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ALTIVAR 56 Fan and Pump Drive User`s Manual

1. DC Bus LED Fault LED ll Caution LED J13 A Power LED GND W T3 VIT2 Outlines 1 amp 2 Outline 3 ATV66U41N4 to D12N4 and ATV66U41M2 to U90M2 ATV66D16N4 to D23N4 and ATV66D12M2 to D16M2 Oo E z HHHH 59555555 655555505 IUE le ee J13 J12 J2 CL24 211919199 0990 SAFA J2 bal um alo o o o oloro O O Ols GND GND 1010 010 0 0 0010109 cu 1 i N GND SND cL2 fed de 2 E W T3 L1 LE bee PB 1 CUT L3 Ji PA L24 L3 7 t 1 Outline 5 Outline 4 ATV66D54N4 to D79N4 ATV66D46M2 ATV66D33N4 to D46N4 ATV66D23M2 to D33M2 Figure 8 Terminal Strip Locations ATV56U41N4 to D79N4 and
2. NOTE Typical Q device shown with options b 1 e e e eg o fol o o um 28 dL H L1 L2 L3 PS pii E o o o Or loj o 5 1 ois ees 50 0 Control 86 Z le m Control Terminale Terminals A T nis 1 15 s 16 33 SW1 Os QW1 QW2 z Se SW2 o e iu GND Fuse Block 4i wj p Figure 78 Terminal Strip Locations for 75 100 hp VT amp 75 hp VTLN 460 V 30 50 hp VT amp 30 40 hp VTLN 208 230 V Power Circuit Y or Z 1996 Square D All Rights Reserved 133 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Bulletin No 50006 519 01B Power Wiring December 1996 POWER WIRING Table 48 Power Terminal Strip Characteristics Terminal Function Characteristic GND 208 VAC 10 560 2 units L1 230 VAC 10 56U G3ee units 3 phase power supply L2 460 VAC 10 56U G4
3. NOTE Typical device shown g with options 90006 11 12 13 25 254 5 DI LL ee f n oeh Fuse Block Oy 295 o lo Control l4 Terminals Control lcs Terminals SW1 1 15 QW1 QW2 T1 T2 T3 SW2 I s 1 GND Figure 75 Terminal Strip Locations for 1 50 hp VT amp 1 40 hp VTLN 460 V 1 25 hp VT amp VTLN 208 230 V Power Circuit Y or Z 1996 Square D All Rights Reserved 151 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Bulletin No 50006 519 01B Terminal Strip Locations De
4. 43 Chapter 4 Diagnostics Preventive Maintenance PREVENTIVE MAINTENANCE LEDS 44 Bulletin No 50006 519 01B December 1996 Before performing preventive maintenance remove all power and check the bus voltage Procedure 1 on page 42 The following preventive maintenance procedures are recommended at regular intervals Check the condition and tightness of the connections Make sure the ventilation is effective and temperature around the drive controller remains at an acceptable level Remove dust and debris from the drive controller if necessary If anything unusual occurs when putting the drive controller into service or during operation be sure all recommendations relating to the environment mounting and connecting the drive controller have been followed The LEDs on the front of the drive controller indicate the following FAULT Red CAUTION Yellow POWER Green DC BUS RED 1 e4 Illuminated Fault exists Illuminated with Fault LED OFF Drive controller is running and in current limit NOTE LED may appear to flash rapidly as drive controller regulates at current limit Slow Flashing with Fault LED OFF This Pre Alarm indicates either a Drive Overtemperature Fault ATV56D16N4 to D79N4 and ATV56D12M2 to D46M2 or a Motor Overload Fault Consult Keypad Display for Motor Ther
5. 128 WIRE ROUTING AND INTERCONNECTION 1 2 129 Wire Classi ick er eee excepi 129 Noise Glas Siei 129 Quiet Wiring 1 1 129 Quiet Wiring 2 2 1 129 Standard Wiring 1 5 1 129 Standard Wiring 2 6 2 129 Standard Wiring 3 129 Pulse Wiring 1 1 1 4 1 129 Voltage Classis zv ue DEicR Go a Al oec duet id reo dev tis 130 TERMINAL STRIP LOCATIONS 1 131 POWER WIBING x cete tir cttm petet ee D lol E eR ER Erbe ee 134 CONTROL WIRING eO Red oe ORE ate 135 SEQUENCE OF OPERATION AND OPTIONS 138 Terminal Command Mode vs Keypad Command 138 POWER CIRCUIT W COMBINATION 139 POWER CIRCUIT Y BYPASS 142 POWER CIRCUIT Z REMOTE STARTER BYPASS 146 PROPER DRIVE ISOLATION METHOD 150 CONTROL
6. 1 52 MENU OVERVIEW 5 725 1 3 peek alate on Mis 53 Selecting the Language 53 Drive Configuration yea ten Oe eee E KH 53 Drive Identifications x meme ante ston wip aa eee ee 53 Display Mode Gee dee eh ee eae eds 53 Maii enii dte 54 DISPLAY MODE d vate iy eee ee DR ut e ea 55 Drive Controller Running 55 Drive Controller in Fault State 55 ACCESS LEVELS oa at Uh ERI NR a E e E RIS ete Neo a 56 Total Eock 5 REVERSE 56 Total UnloGk Be eA 56 MENU SUMMARY USING THIS 57 1 gt SETTING MENU 58 2 J O MAP 5 ex bue dade SE So ed E ee 61 5 ied hn eta ia EUER obo add then 62 4 CONFIGURATION 62 5 gt KEYPAD CONFIGURATION 64 6 gt DRIVE CONFIGURATION 1 4 24 4 66 6 1 Torque me he the SEDE ep Gl a EE un 67 6 2 gt Command Type unsere ree eet Wied ee ee Ae 67
7. 53 Drive Configuration Re pt n Recette on c e KR Ra 53 Drive Identification 1 2 53 Display Mod6 ooi sah ere oes eater Se 53 Main Menu PERSA RUE EE eae 54 DISPLAYMODE 5 21 55 Drive Controller Running 55 Drive Controller Fault 5 55 ACCESS LEVELS REED AERE AP 56 Total Lock ah Ae ga eed Pee eee ty xr 56 Total Wnlock 3 CMS EE 56 MENU SUMMARY USING THIS CHAPTER 57 1 gt SETTING 58 Eow Speed s c een Oa we ele Rt OR ae 58 High Speeds ae ee 59 Acceleration Time oso ERES ETE ke Ae ek Nie Rohe ae pt ees 59 Deceleration 59 2 da Soe Stone ee 59 Profile ot eee eee RIS re 60 Motor Overload 325 css sensi CER a PRA ace 60 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 ALTIVAR 56 Fan and Pump Drive User s Manual Table of Contents 2 O MAP og eee GO E Tui PE 61 3 EAUET HISTORY
8. Customer Supplied Voltage Figure 16 Relay Outputs Contact state is shown with drive controller deenergized Relay contact outputs can be assigned to other functions than those set at the factory Factory settings are listed in Table 16 on page 34 For information on other functions refer to Chapter 5 Maximum recommended fuse type and rating is Bussmann FNQ 2 or equivalent REMOVAL OF CLI Jumpers CL1 and CL2 are factory installed If separate control power is required CL2 JUMPERS these jumpers must be removed To remove jumpers use the following procedure ATV56U41N4 to D12N4 and ATV56U41M2 to U90M2 drive controllers Loosen the CL1 and CL2 screws and the L1 and L2 screws Remove captive jumper wire assembly ATV56D16N4 to D79N4 and ATV56D12M2 to D46M2 drive controllers 1 Loosen the front screws only see Figure 17 Front screws Sleeve Figure 17 CL1 CL2 Jumper Removal 2 Using a pair of needle nose pliers grasp the jumpers and pull straight out The sleeve on the bottom terminal should remain 3 Connect separate control power to the top terminals DO NOT make connections to the bottom terminals which contain the sleeves Leave the bottom terminals open circuited 4 Tighten the front screws to secure the connections 1996 Square D All Rights Reserved 27 Chapter 2 Wi
9. Normal NOLD Low Speed Low Speed High Speed High Speed Acceleration Acceleration Deceleration Deceleration Profile Damping Damping Motor Overload Motor Overload SP Gain 1 Offset 11 KP 1 FLT Ratiol PI Set Pointl2 PI SP Manualls Appears only if Yes Set Point has been selected in the Regulator menu page 88 2lAppears only if Keypad has been selected for setpoint entry in the Set Point menu page 89 2 only if Keypad has been selected for manual setpoint entry in the Setpoint Manual menu page 94 The following sections describe the functions available from the 1 Parameter Setting menu To change the settings of these parameters scroll to the parameter on the menu type in a value and press ENT Low Speed corresponds to the lower limit of the speed reference at or AI2 see Figure 35 and limits the minimum commanded running frequency to a value between 0 and High Speed It does not affect the starting frequency If the drive controller is commanded to run below the programmed Low Speed the output will be limited to the Low Speed value Factory setting is 0 Hz 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 High Speed Acceleration Time Deceleration Time Damping Chapter 5 Configuration 1 Parameter Setting Menu f Hz arnt eee ier Speed Low i Speed Reference 10V OmA 20 mA 4mA 20 mA 20 mA 4mA
10. oe ey E Off Hand Auto TB6 Hi 9 delechae 10 VDC 7 LI2 D ag TB10 Pr uL OQ d LI3 5 KQ d TB11 TB4 Low 24 V CE ee ep N N X 12 AE Jumper BRUT cnp Remote Speed Potentiometer ee ae ap a TB33 sean teeta ege 1 Remote TB4 jx 24 V Auto Start Contact TB8 LI4 Figure 90 Remote Wired Hand Off Auto and Manual Speed Potentiometer MOD E07 provides a Canadian Standards Association CSA certification label when required by local code requirements MOD F07 provides a smoke purge operating mode controlled by a user supplied 120 VAC signal applied between terminals TB26 and TB27 When 120 VAC is supplied to TB26 and TB27 motor operation will be transferred to a user supplied separately mounted starter if not operating in this mode already The jumpers between terminals TB18 and TB19 TB20 and TB21 and TB22 and TB23 must be removed before using this mode 1996 Square D All Rights Reserved 149 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Bulletin No 50006 519 01B Proper Drive Isolation Method December 1996 PROPER DRIVE To properly isola
11. Paleo ER Id 62 Troubleshooting eR RR eS Le ie ERR S 62 4 gt DISPLAY CONFIGURATION 1 62 4 1 gt One Bar Graph 1 63 4 2 gt Two Bar Graphs css a ee ae e TIR REY 64 4 9 SCEOll c eh arent Sed ertt d PU E YO tied ree Riese to Zi 64 55KEYPAD CONFIGURATION 64 Using Keypad Command 65 6 gt DRIVE CONFIGURATION 4 66 6 1 Torque er hide Pee eI wl ek a 67 6 2 gt Command Type wea bean cae eee 67 6 3 gt Motor Power ATV56U41 1 67 2 Wire Command 68 3 ware ee BEGG 68 7 gt GENERAL CONFIGURATION 69 FA gt Diive Parameters rea ee eal RA Rieder m Et 69 4 11 Motor Parameters esee ee es ge oe 69 Nominal Curretitz 2 onem eerte Bo Seti aad ERE 70 Nominal Frequency 70 Nominal Voltage i xc dead cde be eee RADAR GL ee eS be 70 Profil alee that See a et care ee exe SE 71 DAMPI
12. SHUTDOWN BYPASS REGULATOR LOGIC OUTPUTS ANALOG OUTPUTS oe amp ENT to select 7 4 MANAGEMENT FAULT STOP FREEM POWER LOSS NO RUT RESTHRT CATCH ON FLY RAMP 8 amp ENT to modify MOTOR OVERLOAD IN PHASE FAIL YES LOSS FOLLOWER FAULT FOLD BACK FAULT RESET DB FAULT DUT PHASE FLT YES LOGIC QUT FUNCTIONS READY STATE RUNNING STATE AT SPEED TERM KEYPAD oe amp ENT to select AUTO MANUAL CURRENT LIMIT FAULT STATE DRIVE THER AL LOSS FOLLOWER FREG LEY CURRENT LEU ANALOG OUT FUNCTIONS MOT CURRENT MOTOR SPEED THERM STATE ve amp ENT to select VOLTAGE Ne oa es te 1996 Square D All Rights Reserved Appendix B Menu Summary LT 119 0 PARAMETERS NOM CURRENT NOMINAL FREQ NOMINAL VOLT 8 amp ENT to modify PROFILE DAMPING ROTATION NORM CURRENT LIMIT 7 12 CONTROL PARAM MAX FREQUENCY LOW SPEED HIGH SPEED ACCELERATION TECELERATION SKIP FREQUENCY T 13 CONTROL NORMAL MOLD ve amp ENT to modify 167 Appendix Menu Summary Bulletin No 50006 519 01B December 1996 168 _ oei a 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Appendix C Spare Parts List Appendix C
13. 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Table 9 Power Terminal Wire Range Chapter 2 Wiring Power Wiring NOTE All wire entries in AWG or Thousand Circular Mills MCM represent the maximum allowable conductor size for the referenced field wiring terminal All wire entries in square mm represent the recommended size of conductor based on IEC 364 conductor dimensioning criteria Do not use the IEC 364 conductor selections for installations requiring dimensioning per NFPA 70 or CSA C22 Drive Controller 56 U41N4 090 4 D16N4 D33N4 D54N4 Terminals U54N4 D12N4 D23N4 D46N4 064 4 U72N4 U72M2 D12M2 D23M2 D79N4 U41M2 090 2 D16M2 D33M2 D46M2 1 1 1 2 2 Max Wire AWG 10 6 12 12 12 CL1 CL21 Size mm 2 5 10 2 5 2 5 2 5 CL2 CL22 Terminal Ib in 6 73 35 4 6 73 6 73 6 73 Torque Nem 0 76 4 0 76 0 76 0 76 Max Wire AWG 10 6 4 2 0 4 0 L1 Size 2 5 10 10 35 70 12 13 Terminal 6 73 35 4 17 7 26 5 170 Torque Nem 0 76 4 2 3 19 Max Wire AWG 10 6 4 2 0 4 0 Size mm 2 5 10 10 35 70 V T2 W T3 Terminal lb in 6 73 35 4 17 7 26 5 170 Torque Nem 0 76 4 2 3 19 Max Wire AWG 10 6 4 2 0 4 0 E Size mm 2 5 10 10 35 70 Terminal 6 73 35 4 17 7 26 5 170 Torque Nem 0 76 4 2 3 19 Max Wire AWG P Size mm 3 3 3 3 3 Terminal Torque Nem 3 3 3 3 3 Max W
14. LLLI w J Figure 1 Hazard Labeling 1996 Square D All Rights Reserved Bulletin No 50006 519 01B Chapter 1 Receiving and Installation December 1996 Technical Characteristics TECHNICAL Tables 1 and 2 show the power and current ratings for 460 V drive controllers when CHARACTERISTICS set for variable torque Table 1 and variable torque low noise Table 2 Table 1 Variable Torque Drive Controller Ratings 460 V 460 V 15 60 Hz 5 Switching Frequency ATV56U41N4 to D46N4 4 kHz ATV56D54N4 to D79N4 2 kHz Motor Bower Input Line Current M UE Controller 460 V 5 000 AIC or 22 000 Current Current OPE Part No 60 Hz 10 000 AIC 11 AIC 60 s o hp A A A A w 1 2 7 3 2 1 8 5 3 90 ATV56U41N4 2 4 7 5 7 3 4 5 3 110 1 3 6 5 8 4 8 5 3 130 ATV56U54N4 5 9 8 11 9 7 6 8 4 180 ATV56U72N4 7 5 14 17 11 12 1 205 ATV56U90N4 10 17 7 21 4 14 15 4 265 S ATV56D12N4 15 25 1 30 6 21 23 1 350 ATV56D16N4 20 31 8 38 3 27 29 7 480 3 ATV56D23N4 25 38 7 47 34 37 4 560 ATV56D33N4 40 57 1 67 6 52 57 2 800 ATV56D46N4 50 68 6 81 2 65 71 5 910 ATV56D54N4 60 86 4 94 6 77 84 7 960 5 ATV56D64N4 75 106 116 96 105 6 1150 ATV56D79N4 100 138 150 124 136 4 1400 1 10 000 AIC denoted by asterisk Table 2 Variable Torque Low Noise Drive Controller Ratings 460 V 460 V 15 60 Hz 5 Switching Frequency ATV56U41N4 to D46N4 10 kHz ATV56D54N4 to
15. SUM amp ENT to en feso modify 8 28 mH 4 28 28 4 mA a0 mAs w mA i MULTIPLY ERU lt VES Speed Reference allows the assignment of the and AI2 inputs as Speed Reference 1 or Speed Reference 2 Speed Reference also allows you to modify the analog current input 12 for type of signal The adjustment range is 0 20 mA 4 20 mA 20 4 mA or x 20 mA where x can be programmed from 0 to 20 mA in increments of 0 1 mA Factory setting for AI2 is 4 20 mA When Speed Reference is set to x 20 mA the frequency at which the drive controller will run is determined as follows f High Speed Low Speed Input mA 20 mA Low Speed When the value of AI2 is below x mA the drive will run at the Low Speed setting HSP XmA 20mA Figure 48 Speed Reference and Drive Controller Frequency If the switch on the control board is set to voltage AI2 will be a 0 5 V voltage input Refer to Chapter 2 for location of switch AI2 in this case must be set on the keypad display for 0 20 mA The voltage reference input cannot be modified It is fixed as a 0 to 10 VDC input The two inputs and 12 are summed as a factory default limited to High Speed However when Auto Manual is active the inputs function independently and only one is active at a time It is possible to multiply AI2 by 1 by selecting Yes In this case AI2 is subtracted from If Clamp Sum is se
16. USER SUPPLIED nam AUTO START CONTACT 424 4 ALTERNATE USER SUPPLIED OFF n WIRING WHEN MOD HAND AUTO 007 IS USED p LI 10 i 25k rur AA _ AUTO SPEED REFERENCE SHLD 12 4 20 mADC SIGNAL 18 gt INPUT Z 250 COM 14 PROGRAMMABLE ANALOG OUTPUT AO 15 L REFER TO USERS MANUAL FREEZE FIRE STAT INTERLOCK REMOVE JUMPER IF USED gt BYPASS RUN CONTACT CLOSES WHEN BYPASS IS RUNNING gt OPTIONAL SMOKE PURGE RELAY 120 WILL RUN MOTOR AT FULL SPEED gt FAULT CONTACT CLOSES ON FAULT 77 RUNCONTACT CLOSES WHEN AFC RUNS 208V TRANSFORMER CONNECTION H1 208V le 115V 1 2 1 GND DETAILA 24V N C HAND AUTO RIB 28 RIC 29 LOP SIGNAL FAULT 0 2 LH TR R2B R2C R2A 2 MANUAL SPEED POT 2 5K AUTO SPEED REF 4 20 mADC SIGNAL 1 102 a2 c0 Lo SHLD FAULT CONTACT CLOSES ON FAULT RUN CONTACT CLOSES WHEN AFC RUNNING 1 7 11 x 1 RUNNING STATE 1 8 31 1 4 O 44 Teal 5 AUTO START CONTACT SUPPLIED BY OTHERS um 12 IF USED ISOLATION CONTACTOR IC cB 1 N POWER
17. pd TBM T d Low nee oath sho ele J M UNE A 024 V 1 12 QL o x TB32 Jumper 5 _ Remote Speed Potentiometer j TB33 ald Us M Remote HOA TB4 piu 24 V Auto Start Contact 8 4 Figure 86 Remote Wired Hand Off Auto and Manual Speed Potentiometer MOD E07 Provides a Canadian Standards Association CSA certification label when required by local code requirements MOD F07 provides a smoke purge operating mode controlled by a user supplied 120 VAC signal applied between terminals TB26 and TB27 When 120 VAC is supplied to TB26 and TB27 motor operation is transferred to line power if not operating in this mode already The jumpers between terminals TB18 and TB19 TB20 and TB21 and TB22 and TB23 must be removed before using this mode 1996 Square D All Rights Reserved 145 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Bulletin No 50006 519 01B Power Circuit Z Remote Starter Bypass Package December 1996 POWER CIRCUIT Z REMOTE STARTER BYPASS PACKAGE Operator Controls General Arrangement and Operation Adjustable Speed Operation Bypass Operation Freeze Fire Stats Interlocks if used 146 The Remote Starter Bypass Package allows you to run the motor from the power converter or from a user supplied separately
18. 56012 2 D16M2 VZ3 R033W009 100 25W 56023 2 D33M2 VZ3 R010W025 10Q 480W ATV56D46M2 VZ3 R010WA481 Discharge Resistor 5kQ 40W 56033 4 D79N4 VZ3 R5KOW040 5 40 56023 2 to D46M2 VZ3 R5KOW040 Capacitor 15001 450 V ATV56D16N4 D23N4 VY1 ADC152V450 4700uF 450 V ATV56D33N4 D46N4 VY1 ADC472V450 1500uF 450 V ATV56D12M2 D16M2 VY1 ADC152V450 4700uF 450 V ATV56D23M2 D33M2 VY1 ADC472V450 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Spare Parts List Continued Appendix C Spare Parts List Description Rating Drive Controller Reference No Capacitor Sub Assemblies ATV56D54N4 VY1 ADC605 contain 1 capacitor and 1 balancing resistor ATV56D64N4 D79N4 VY1 ADC606 uno ATV56D46M2 VY1 ADC605 6 balancing resistors Current Sensors 2 ATV56D33N4 to D46N4 VY1 A66104 ATV56D54N4 to D79N4 VY1 A66105 ATV56D23M2 VY1 A66104 ATV56D33M2 D46M2 VY1 A66105 1996 Square D All Rights Reserved 171 Appendix Spare Parts List Bulletin No 50006 519 01B December 1996 172 _ 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 A AC line overvoltage 55 ACC 55 62 acceleration 5 34 122 acceleration time 59 75 access levels 56 total lock 56 total unlock 56 access locking switch 52 56 AC LIN OVERVOL 45 additional controllers
19. T832 424 V J TB7 Per TB33 N N S Figure 88 Speed Reference 2 Signal 4 20 mA Only Figure 89 can be used for applications in which the power converter start stop operation is controlled by a user supplied Auto contact and the speed is controlled by a user supplied remote speed potentiometer ix Hi TB9 10 VDC pot TE TB10 Wiper 2 5 kQ _ 1 i 11 se eels T 4 TB12 5 Remote Speed Potentiometer T T mE TB4 Po 24 V Auto Start Contact or Jumper x TB6 lae uias M LI2 Figure 89 Remote Manual Speed Potentiometer Reference Only 1996 Square D All Rights Reserved Bulletin 50006 519 01 December 1996 MOD E07 CSA Certification if used MOD F07 Smoke Purge if used Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Power Circuit Z Remote Starter Bypass Package Figure 90 can be used for applications in which the power converter start stop operation is controlled by a user supplied Hand Off Auto switch and speed is controlled by a user supplied speed potentiometer for Hand mode and a user supplied 4 20 mA DC speed reference signal for Auto mode 2 HP c E
20. Braking to standstill By DC injection Automatic for 0 5 s if frequency drops below 1 Hz Manual by external signal Drive controller protection Motor protection Against short circuits between output phases between output phases and ground on the outputs of internal supplies on the logic and analog outputs Against input line supply under overvoltage Against overheating by thermal sensor Incorporated electronic thermal protection see page 11 and page 36 Keypad display Self diagnostics with full fault messages in seven languages Also refer to Chapter 5 Temperature Operation 32 to 104 F 0 to 40 C Storage 13 to 158 F 25 to 70 C Humidity 95 maximum without condensation or dripping water Altitude lt 3 300 ft 1 000 m above this derate by 1 2 for every 300 ft 100 m max 6 600 ft 2 000 m Enclosure NEMA Type 1 IP30 Pollution Degree Pollution Degree 3 per NEMA ICS 1 and IEC 664 1 Resistance to vibration Conforming to IEC 68 2 6 ATV56U41N4 to D46N4 and 56041 2 to D33M2 1 mm peak to peak from 5 to 22 3 Hz and 2 g peak from 22 3 to 150 Hz ATV56D54N4 to D79N4 and ATV56D46M2 0 15 mm peak to peak from 10 to 58 Hz and 1 g peak from 58 to 150 Hz Resistance to shock Conforming to IEC 68 2 27 15 g peak for 11 ms Codes and standards UL Listed per UL 508C under category NMMS as incorporating electronic over
21. 50006 519 01 December 1996 CONTROL WIRING Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Control Wiring Table 50 Control Terminal Strip Characteristics Power Circuit W Terminal 17121 Function Characteristics 1 LO1 Logic Output 1 24 V 200 mA max 5 2 LO2 Logic Output 2 24 V 200 mA max 5 3 COM Logic Common OV Minimum 12 V Maximum 30 V 4 24 24 V Control Supply Quiescent current 15 mA typical Is 210 mA max 5 24 V 10 mA B State 0 V lt 5 V State 1 V gt 12 V Vmax 30 V 24 V 10 mA State 0 V lt 5 V State 1 V gt 12 V Vmax 30 V 24 V 10 mA Y EIS 9 State 0 V lt 5 V State 1 V gt 12 V Vmax 30 V 24 V 10 mA 8 State 0 V lt 5 V State 1 V gt 12 V Vmax 30 V 9 10 V Reference Supply 10 V Is 10 mA max 10 Analog Input 1 Speed Reference Voltage 0 10 V Z 30 11 COM Speed Reference Common OV 12 GND Ground Shield 13 Al2 Analog Input 2 Speed Reference Current 4 20 mA 6l Z 2500 14 COM Analog Common OV 0 20 mA 12 V max programmable as 4 20 mA 15 1 Analog Output 1 w keypad display 16 Auxiliary Terminal 7 Terminal jumpered to Terminal 4 17 115 V Control Transformer Ul 18 115 V Rated Terminal 7 19 GND Control Transformer 7 A 120 V SPR Relay Coil 21 01 115 120 V 60 Hz supply u
22. Cana Example 2 This example is the same as Example 1 except it uses the keypad as the means for setpoint entry The desired setpoint is 12 5 feet 1 Select YES SET POINT in the PI Regulator menu 2 Select KEYPAD as means for setpoint entry 3 Calculate SP GAIN and OFFSET as illustrated in Example 1 and enter the value Select FEED BACK in the PI Regulator screen Select FB INPUT Select AI2 for feedback input Select MIN FEED BACK Enter 8 for the minimum process level Select MAX FEED BACK 10 Enter 17 for the maximum process level 11 If desired enter optional LOW LEVEL ALM and HIGH LEVEL ALM values 12 Calculate PI SET POINT and enter the value in the 1Parameter Setting menu 00 Is 12 5 8 17 8 SET POINT x 9999 5000 13 Select YES for REV ACTION in PI PARAMETERS menu 14 Adjust KP and KI to achieve the best system response Example 3 In this example the drive controller will be used to regulate the volume of water in a vat The pump will be pumping water into the vat to maintain the level between 100 m and 10 m The feedback signal is 0 to 20 mA At 5 m the feedback signal is 0 mA and at 100 m the feedback signal is 20 mA 0 to 10 V signal is used for the setpoint At 0 V the process level is 100 m and at 10 V the process level is 10 m8 1 Select YES SET POINT in the PI Regulator menu 2 Select SP INPUT 92 1996 Square D All Rig
23. Spare Parts Replacement of spare parts requires the use of special tools and installation procedures not included with the spare parts kits Before replacing any spare part consult the Adjustable Frequency Drive Controller Service and Troubleshooting Manual bulletin no VD0C065701 Spare parts must be removed and installed only by qualified electrical personnel familiar with the Service and Troubleshooting Manual Spare Parts List Description Rating Drive Controller Reference No Adjustable Frequency Drive Controller Service and ATV56 all sizes VD0CO06S701 Troubleshooting Manual Control Kit with control basket M ATV56U41N4 to D79N4 VX4 A56CK1 and keypad ATV56U41M2 to D46M2 VX4 A56CK1 Programming Keypad 56 all sizes Consult factory Removable Control Terminal Strips for J1 J12 J13 ATV56 all sizes VZ3 N006 Power Boards ATV56U41N4 VX5 A56U41N4 ATV56U54N4 VX5 A56U54N4 ATV56U72N4 VX5 A56U72N4 ATV56U90N4 VX5 A56U90N4 ATV56D12N4 VX5 A56D12N4 ATV56D16N4 VX5 A56D16N4 ATV56D23N4 VX5 A56D23N4 ATV56D33N4 VX5 A66D33N4 ATV56D46N4 VX5 A66D46N4 ATV56D54N4 VX5 A66D54N4 ATV56D64N4 VX5 A66D64N4 ATV56D79N4 VX5 A66D79N4 ATV56U41M2 VX5 A56U41M2 ATV56U72M2 VX5 A56U72M2 ATV56U90M2 VX5 A56U90M2 ATV56D12M2 VX5 A56D12M2 ATV56D16M2 VX5 A56D16M2 ATV56D23M2 VX5 A66D23M2 ATV56D33M2 VX5 A66D33M2 ATV56D46M2 VX5 A66D46M2 Gate Driver B
24. 15 SUP amp SUP FRO TRANSISTORS TEST amp EMT to activate ESC to quit Two tests are available from the Autodiagnostic Screen Select either or both of the tests by scrolling with the and W keys and pressing ENT 1 Memory 15 V Supply and Supply Frequency initiates a test on the ROM memory a confirmation of the presence of 15 V and a confirmation of the presence of supply frequency 2 Transistors Tests initiates a test sequence on the drive controller transistor bridge Note that the length of time required for this test varies with product size and the number of transistors in the bridge While the test is in progress the Result display see Figure 67 will report In Process on line 2 Memory Test Transistor Test AUTODTAGNOSTIC ALITODIAGNOSTIC INTERNAL MEMORY 0K CELLS 1 PROCESS 151 SUPPLY Ok T3 K Tat Ok FREQ SUP DETECT or TESTED OF ESC to quit B FAULT ESC to suit Figure 67 Tests Results 1996 Square D All Rights Reserved 109 Chapter 5 Configuration Bulletin No 50006 519 01B 8 Diagnostic Mode December 1996 There are three possible responses for each element of a test OK indicates that the tested element is good e X indicates that the tested element is defective e 2 transistor test only indicates t
25. Input phase failure can be inhibited by selecting No when a line contactor is used with the drive controller and control power is supplied separately to CL1 CL2 or in special applications when a common DC bus tie is used When set to No input phase loss will be ignored however undervoltage will be displayed if the DC bus voltage is less than the undervoltage level but sufficient to maintain the drive controller power supply The Fault State relay R1 will remain energized whenever voltage is present on CL1 and CL2 as long as there are no other faults The undervoltage condition must be cleared prior to the drive controller recognizing a run command LOSS FOLLOWER Ho Go to Hz Fault Loss of follower is used with the AI2 input and occurs when the 4 20 mA or 20 4 reference input is less than mA The drive controller can be programmed to fault to run at a preset speed programmable from Low Speed to High Speed or to ignore the fault condition factory preset when loss of follower is detected When Go to Hz is selected AI2 must be the only assigned speed reference Allother speed references must be de selected see Speed Reference on page 79 The adjustment range of Go to Hz is 0 1 to 72 Hz 1996 Square D All Rights Reserved L 107 Chapter 5 Configuration 7 General Configuration Menu Fold Back Fault Reset Dynamic Brake Fault Output Phase Fault 108 Bulletin No 50006 519 01
26. To restart the drive controller the Run command must be set to low state Then the drive controller will restart on the next command to run For a wiring diagram refer to Chapter 2 The use of 3 wire command requires operator intervention after fault reset or restoration of power to restart the drive controller Li Run Enable 1 0 ui2 1 0 Fwd Speed Ref Speed Ref Figure 40 Timing Diagram for 3 Wire Command If 3 wire command is selected LI1 is Stop normally closed LI1 must be closed for the drive controller to run The forward input must momentarily transition to active to start the drive controller If the drive controller is running and LI1 goes low the drive controller will stop following the normal ramp If the drive controller is running and the keypad STOP key is pressed regardless of whether the drive is in Keypad or Terminal mode the drive controller will stop following the normal ramp To restart the drive controller the Run command must be set to low state Then the drive controller will restart on the next Run command Refer to Chapter 2 for wiring diagram 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 7 gt GENERAL CONFIGURATION MENU 7 1 Drive Parameters 7 11 Motor Parameters Chapter 5 Configuration 7 General Configuration Menu T3GENERRL CONFIG DRIVE PARAMETERS APPLICATION FUNC OU
27. 3 OFF to BYP SW contact A closes energizing the B Bypass contactor Motor overload protection is provided by OL thermal overload relay during running in Bypass SW contact B opens disabling the I contactor control circuit SW contact D opens Since LI3 Sequence Input goes low as a result the drive controller cannot start If the drive controller was still in the process of decelerating the motor when previously in AS the drive controller will initiate a Sequence Time out Fault signalling that an incorrect SW sequence has occurred If incorrect SW sequence indication is not desired the Controlled Stop function can be used along with the Bypass function To use Controlled Stop SW contact D must be connected directly into the LI assigned to Controlled Stop and the I contactor interlock is wired to 24 Use of the Controlled Stop function along with the Bypass function requires the addition of an I O Extension module if a Process Input is used 4 BYP to OFF SW contact A opens de energizing I contactor The motor stops DT CEMF Decay Time Normal Stop STof Sequence Time Out fault Freewheel Stop PTof Process Time Out fault Run forward ni 1 DT DT 1 1 1 DT 1 gt command STof STof 1 1 Sequence input 1 PTof n Reference Frequency Process input 0 i Normal Sequence Incomplete Process Incomplete Sequ
28. 600 V 100A D12 D16 600 V 125A D23 D33 600 V 225A D46 600 V 250A Table 15 Recommended Equipment for all Drive Controllers R1 Potentiometer Push buttons Control station enclosure accepts R1 and two push buttons 32 019965 All Rights Reserved 9001 K2106 9001 KR1UH13 9001 KYAF3 Bulletin No 50006 519 01B December 1996 Chapter 3 Start Up Contents Chapter 3 Start Up INTRODUCTION 21 ETAT eas SU b ae e etel eh are A e 34 FACTORYSSETTINGS V E pote eor eredi Wee COM atn 34 CONTROL TYPES es eel e dk ILE Rma e HR Sea Pena eed 35 Normal 35 NOED 5 keg thd oR UE eo bad 35 MOTOR THERMAL OVERLOAD 36 ADJUSTMENT OF MOTOR OVERLOAD 37 AVAILABLE MOTOR 37 Continuous esc ood the hv pie od ane Ao de 37 Overtorque Capability and Speed 37 Overspeed Operation f2 60 2 38 Driving Torque Production Envelope 38 MOTOR 6 39 Motor Insulation gt ey ed mee e
29. Figure 35 Speed Reference High Speed corresponds to the upper limit of the speed reference at or AI2 see Figure 35 and limits the maximum commanded running frequency to a value between Low Speed and Maximum Frequency set in the 7 12 Control Parameters menu If the drive controller is commanded to run above the programmed High Speed the output will be limited to the High Speed value Factory setting is 60 Hz Acceleration Time is adjustable between 0 1 and 999 9 seconds and represents the time the drive controller will take to accelerate between 0 Hz and Nominal Frequency set in the 7 11 gt Motor Parameters menu Acceleration Time determines the base line slope used by the drive controller to accelerate between frequencies Factory setting is 3 seconds If the acceleration slope is too steep for the motor to accelerate the connected load the acceleration slope will be modified to minimize the possibility of a nuisance trip Deceleration Time is adjustable between 0 1 and 999 9 seconds and represents the time the drive controller will take to decelerate between Nominal Frequency set in the 7 11 Motor Parameters menu and 0 Hz Deceleration Time determines the base line slope used by the drive controller to decelerate between frequencies Factory setting is 3 seconds If the deceleration slope is too steep for the motor to decelerate the connected load the deceleration slope will be modified to minimize the possibility of a nuis
30. L20 Q SUPPLY _ L30 0 2 1 OL O OA 5C on 4 0 T O 1t o OOD COT motor BC 6 5 Of 5 Cos BYPASS CONTACTOR BC FUS FUS 208 1 25 hp VT 460V 5 1 25 hp VTLN H1 H2 7 H4 50 hp VT 75 100 hp VT 40 hp VTLN 75 hp VTLN A AT 30 50 hp VT 30 40 hp VTLN 115 PL CLUSTER FU4 GND L BC 17 e s2 c OPR li teli l2 AFC BYPASS OPTIONAL SMOKE PURGE RELAY SPR REMOVE JUMPERS BETWEEN 18 amp 19 20 amp 21 AND 22 amp 23 IF USED Figure 93 Bypass Package Power Circuit Y with Options 1996 Square D All Rights Reserved IF USED SPR ed bos M FREEZE FIRE STAT INTERLOCKS REMOVE JUMPER BETWEEN TERMINALS 22 amp 23 IF USED OL REF 52010 475 03 153 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Control Circuit Diagrams Bulletin No 50006 519 01B December 1996 154 14 AFC 9 BYPASS PACKAGE W O OPTIONS o TY POWER CIRCUIT Y 15 10 MANUAL gt SPEED AO A POT
31. MODE IS SELECTED SUPPLIED BY OTHERS 27 USER CONNECTIONS TB USER SUPPLIED x AUTO START CONTACT Ll4 Li FREEZE FIRE STAT INTERLOCK REMOVE JUMPER IF USED ALTERNATE USER SUPPLIED OFF 1 WIRING WHEN MOD HAND AUTO ue s 1207S USED L LL RI us AE eni o ol 10 E pro SPEED SUPPLY a0 Eu a 1 21 furnum e COM gt _ AUTO SPEED REFERENCE SHLD 74 20 mADC SIGNAL gt INPUT Z 250 PROGRAMMABLE ANALOG OUTPUT AO1 REFER TO USERS MANUAL FAULT CONTACT s CLOSES ON FAULT RUN CONTACT CLOSES WHEN AFC RUNS AFC MODE STATUS CLOSES WHEN AFC IS IN AUTO MODE USER SUPPLIED WITH D07 MOD Yt vi Bulletin No 50006 519 01B December 1996 AFC COM 10V 9 10 MANUAL AOI Alt SPEED POT 25k AO2 COM COM gt Ny 11 me AC AUTO SPEED REF dg yat 4 20 mADC SIGNAL Log Ale 7O 13 INPUT Z 250 12 101 5 GND R1B 22 fou N C AFC FAULT CONTACT FAULT RiC 23 CLOSES ON FAULT LOP SIGNAL RIA LH R2B LI RUNNING R2C Sevan ee ee RUN CONTACT CLOSES WHEN LIA 2 6 RUNNING 2 W T3 aee gt T2 a MOTOR REF 52010 475 02 Figure 92 Combination Package Power Circuit W without Options 152 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 NOTES BYPASS
32. Scroll Four Tables 64 No No Yes 5 gt Configuration 64 6 Drive Configuration 66 6 1 Torque Type 67 Me Yos Is 6 2 gt Command Type 67 6 3 Motor Power ATV56U41 only 67 7 General Configuration 69 7 1 Drive Parameters 69 No No Yes 7 2 gt Application Functions 77 7 3 Output Assignments 96 7 4 Fault Management 100 No No Yes 8 Diagnostic Mode 109 9 gt Drive Initialization 112 9 1 Total Factory Settings 112 bs 33 9 2 Store User Settings 112 9 3 Recall User Settings 113 Accessible with motor running 1996 Square D All Rights Reserved 57 Chapter 5 Configuration 1 Parameter Setting Menu 1 gt PARAMETER SETTING MENU Low Speed 58 Bulletin No 50006 519 01B December 1996 SETTING LOW SPEED HIGH SPEED ACCELERATION DECELERATION PROFILE Do 205 DAMPING D 33 OVERLOAD 7A SP GAIN 9999 OFFSET D Hf KP 188 KI B FLT RATIO 1885 PI SET POINT B PI SP MANUAL 8 8 Hz The functions accessible from the Parameter Setting menu depend not only on the control type selected page 76 but also on whether or not the drive controller is configured for PI Regulator Factory configuration is Normal control type and no PI Regulator Table 23 on page 58 illustrates the functions available with the various configurations Table 23 Parameter Setting Menu Variable Torque or Variable Torque Low Noise
33. The 6 gt Drive Configuration menu contains three selections Torque Command Type and Motor Motor is a valid selection for the ATV56U41 drive controller only since this drive controller can be used with a 1 2 or 3 hp motor Otherwise selecting Motor calls up a message screen To modify Motor Parameters Please to menu T 11l ENT to continue To access Motor Parameters go to the 7 11 Motor Parameters menu page 69 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 6 1 gt Type 6 2 Command Type 6 35 Motor Power ATV56U41 only Chapter 5 Configuration 6 Drive Configuration Menu 1 0 VARIABLE DRIVE RATING amp ENT to modify Select type of torque according to the application and press ENT A window will appear showing the current and power rating of the drive controller Confirm by pressing ENT Display returns to the 6 gt Drive Configuration menu NOTE Changing Torque Type or Control Type in the 7 13 gt Control Type menu resets the motor parameters in the 7 11 gt Motor Parameters menu to the factory settings 23CDMMBND TYPE 2 WIRE 3 WIRE IMPULSE Cstartstop control amp ENT to modify ESC To uit FlzHele Select 2 wire or 3 wire command The selection affects the operation of LI1 Factory setting is 2 wire command See pages 68 and 68 for detailed descriptions o
34. 120 VAC max 0 10 J operation 80 operations minute R2A contact Programmable 1 0 A 220 VAC max 0 25 J operation 25 operations minute R2B N C contact relay output 2 0 A 24 VDC max 0 10 J operation 80 operations minute R2C Common Arc suppression provided by varistors in parallel with relay contacts Li Logic input 1 24 V 10 mA State 0 V 5 V State 1 V gt 12 V Vmax 30 V Ll2 Logic input 2 24 V 10 mA State 0 V 5 V State 1 V gt 12 V Vmax 30 V LI3 Logic input 3 24 V 10 mA State 0 V 5 V State 1 V gt 12 V Vmax 30 V 4 Logic input 4 24 V 10 mA State 0 V 5 V State 1 V gt 12 V Vmax 30 V J12 2 24 Control supply Is 210 mA max 5 LOP LO supply input Minimum 12 V Maximum 30 V quiescent current typical 15 mA LO1 Logic output 1 24 V 200 mA max 5 LO2 Logic output 2 24 V 200 mA max 5 COM Logic common OV Shield Ground Space for isolation COM Speed ref common oV Input 1 Speed ref voltage 0 10 V Z 30 kQ J13 2 10 Reference supply 10 V Is 10 mA max Al2 Input 2 Speed ref current 4 20 161 Z 2500 AO1 Analog output 1 0 20 mA 12 V max programmable as 4 20 mA w keypad display AO2 Analog output 2 0 20 mA 12 V max programmable as 4 20 mA w keypad display COM Analog common OV 1 See circuit diagrams on page 28 and 29 2 Max wire size for all terminals 14 AWG 2 5 mm Tightening torque 3 5 Ib in 0 4 Relay coil deenergizes on fault
35. 160 5 191 240 Tos 2x 01 14 29 Vey Ao E E JE 2 1 46 37 CN 2 2 3 01 85 47 H1 xls S 8 ES H2 m o E amp N Outline 4 w2 w1 0 REF 3 62_ 5 32_ 6 77_ 8 23 992 13 54 92 135 172 209 252 344 2 01 14 29 c 5 3 gt D 5 2 02 01 51 5 e SSS VA a SS ae SS ier pu gt c5 gt gt 2 52 a 64 c 3 e C 2 s lt I 5 N N 3 gt 9 1 D c T 5 5 3d Dimensions in mm Outline 5 MOUNTING DIMENSIONS Door Drive Drive H1 H2 wi w2 0 J Weight Swing Controller Controller 9 56 4 ATV56 M2 m in mm in mm in mm in mm in mn in Ib kg in mm 4 D33 D46 023 033 23 6 600 22 8 580 9 5 240 8 1 205 0 28 7 319 81 59 5 27 9 5 240 5 054 079 256 650 244 620 13 8 350 11 8 300 0 35 9 3 39 86 882 40 13 8 350 Door hinges on left hand side of drive controller Figure 3 Mounting Information for ATV56D33N4 to D79N4 amp ATV56D33M2 to D46M2 1996 Square D All Rights Reserved Chapter 1 Receiving and Installation Handling Drive Controllers HANDLING DRIVE CONTROLLERS PRELIMINARY INSPECTION Bulletin No 50006 519 01B December 1996 Do not remove drive controller from carton until it is at f
36. 460 V 230 V 208 V Ib kg in mm in mm 500 12 7 30 50 VT 500 127 25 40 VTLN 20 25 VT amp 20 25 VT amp VTLN 170 76 9 750 190 n Figure 71 Mounting Information for 30 50 hp VT amp 25 40 hp VTLN 460 V 20 25 hp VT amp VTLN 208 230 V 126 1996 Square D All Rights Reserved Bulletin No 50006 519 01B Chapter 6 Class 8839 ALTIVAR 56 Combination Devices December 1996 Mounting Dimensions amp Weights MOUNTING 26 00 LIFTING HOLE DETAIL m 660 4 056 14 3 L 12 97 609 4 n 329 5 Lifting Ko gt w Hole 2 50 63 5 i 125 l 31 8 TYP 2 PLACES 63 89 1622 7 p UE 65 00 1650 9 CONDUIT ENTRIES TOP VIEW g B E HeBH CONDUIT ENTRIES BOTTOM VIEW t i 1 8 00 200 0 Y MOUNTING CLEARANCES HP Weight 460 V 230 V 208V Ib kg in mm in mm 1 00 25 4 60 100 VT 30 50 VT 30 50 VT m 158 125 3175 500 12 7 50 75 VTLN 30 40 VTLN 30 40 VTLN 2 00 50 80 750 19 0 2 50 63 50 Figure 72 Mounting Information for 60 100 hp VT
37. 6 3 gt Motor Power ATV56U41 67 2 Wire Command uhr ppp ate dats he pede 68 3 Wire Command s 2243 silere CUERO Jed 68 7 gt GENERAL CONFIGURATION 69 7A gt Diive Parameters 2i kee dea o eae bad DR RR UD ARR P 69 7 11 Motor Parameters 69 7 12 gt Control Parameters 74 7 13 gt Control 76 7 2 gt Application Functions 77 7 3 gt 0utput Assignments 96 7 4 gt Fault Management 100 8 DIAGNOSTIC MODE Siia beste ae pe De a aed E ARRA 109 9 gt DRIVE INITIALIZATION MENU cette rn 112 1996 Square D All Rights Reserved 49 Chapter 5 Configuration Bulletin No 50006 519 01B Keypad Display December 1996 KEY PAD DISPLAY The ALTIVAR 56 drive controller includes a keypad display mounted on front for Identification of the drive controller Display of parameters and faults Recall and adjustment of drive controller parameters Local command of the drive controller LCD Function Key
38. 7 General Configuration Menu This menu displays all functions that can be assigned to the logic outputs and allows reassignment where possible Only the outputs not previously assigned from the 7 2 Application Function menu can be reassigned here An arrow indicates a function that is already assigned Output functions can be assigned to more than one output The R1 relay is assigned to the Fault State function and cannot be reassigned Also the Drive Thermal Alarm function is only available on drive controllers ATV56D16 to ATV56D79 The menus illustrated above show the procedure for reassigning the logic outputs The logic output functions are described in the following sections If drive controller is waiting for a Run command and is not in fault state logic output is high or relay is energized When a Run command is present DC injection is not enabled and there is no fault on the drive controller logic output is high or relay is energized If Bypass is enabled the Sequence Input must also be present for Running State to be high or energized 1 At Speed LOx o Reference Frequency Figure 60 At Speed When drive controller is commanded to run above zero speed and Output Frequency is equal to Frequency Reference input signal logic output is high or relay is energized When drive controller is in Keypad Command logic output is high or relay is energized When in Terminal Command logic output is low or
39. DISPLAY CONFIG KEYPAD CONFIG IRIVE CONFIG GENERAL CONFIG DIAGNOSTIC MODE INIT p Bulletin No 50006 519 01B December 1996 1 SETTING T GENERAL CONFIG LOW SPEED DRIUE PARAMETERS HIGH SPEED APPLICATION FUNC ACCELERATION OUTPUT ASSTGNMENT DECELERRTION FAULT MANAGEMENT DAMPING amp ENT to select PROFILE MOTOR OVERLOAD oan OGNOSTIC MODE AUTODIAGNOSTIC LOGIC INPUT TEST ANALOG INPUT TEST LOGIC OUTPUT TEST ANALOG OUTPUT TEST 2931 0 MAP LOGIC INPUT ANALOG INPUT MAP TOTAL FACTORY SETT LOGIC OUTPUT MAP ANALOG OUTPUT MAP FAULT NAME STB M IN PHASE LOSS AC LIN OWERVOL RUN OVERLOAD ACC ENT to set marker 490 1SPLAY CONFIG ONE GRAPH THO GRAPH SCROLL 4 TABLES oe amp ENT to modify SSKEYPAD CONFIG TERMINAL COMMAND BY LIt__ USER SETTING STORE RECALL USER SETTING amp DRIUE CONFIG TORQUE VARIABLE COMMAND 2 WIRES MOTORS 466 ve amp ENT to modify ESC to awit Fl Hele 1996 Square D All Rights Reserved gt S30UTPUT ASSIGN Bulletin No 50006 519 01B December 1996 T l13DRIUE PARAMETERS MOTOR PARAMETERS CONTROL PARAMETERS CONTROL NORMAL ve amp ENT4 choose T 23BPPLICATION FUNC PRESET SPEEDS SPEED REFERENCE ALTO MANUAL CONTROLLED STOP oe amp ENT to select
40. amp 50 75 hp VTLN 460 V 30 50 hp VT amp 30 40 hp VTLN 208 230 V 1996 Square D All Rights Reserved 127 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Bulletin No 50006 519 01B Handling Drive Controllers December 1996 HANDLING DRIVE Do not remove a drive controller from its packaging until it is at the final CONTROLLERS installation site The packaging protects the drive controller and prevents damage to its exterior Handle the drive controller carefully to avoid damage to the internal components frame or exterior When handling a drive controller balance it carefully to keep it from tipping After removing packaging materials the drive controllers require some type of mechanical lifting Handle drive controllers With a hoist attaching a spreader bar to the two lifting holes on top of the drive controller back panel see Figure 73 Ina horizontal position with back of drive controller resting a pallet WARNING HANDLING AND LIFTING HAZARD Keep area below any equipment being lifted clear of all personnel and property Use lifting method shown in Figure 73 Failure to follow this instruction can result in death serious injury or equipment damage To hoist the drive controller attach a spreader bar to the lifting holes located on top of the drive controller back panel as shown in Figure 73 Handle the drive controller carefully to avoid damage to the internal components frame or
41. amp ENT to modify 3 05 SKIP FREQUENCY aaa The 7 12 Control Parameters menu allows access to basic drive controller parameters The default or previously programmed values for each parameter appear in the right column of the menu Adjustments to control parameters are made either to submenus or directly on the 7 12 Control Parameter menu To select a parameter scroll with the and W keys and press ENT Adjust the parameter to desired setting then press ENT to confirm The Control Parameters are discussed in detail in the following pages Some parameters are also accessible from the 1 gt Parameter Setting menu Any adjustments made to these parameters from the 7 12 Control Parameters menu are also displayed in the 1 Parameter Setting menu A CAUTION MACHINERY OVERSPEED Some motors and or loads may not be suited for operation above nameplate motor speed and frequency Consult motor manufacturer before operating motor above rated speed Under certain steady state and transient conditions the output frequency may reach 12096 of Maximum Frequency setting Adjust Maximum Frequency parameter accordingly Failure to follow this instruction can result in injury or equipment damage Maximum Frequency clamps the High Speed setting Maximum Frequency is fixed at 72 Hz 01996 Square D All Rights Reserved Bulletin 50006 519 01 December 199
42. and 230 V 15 Displacement power factor Approximately 0 96 Input frequency 47 5 to 63 Hz Output voltage Maximum voltage equal to input line voltage 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Chapter 1 Receiving and Installation Technical Characteristics Table 5 Specifications Continued Frequency resolution Drive controller Input Al1 High Speed 1 024 Hz 11 Input Al2 High Speed 512 Hz 111 Keypad display 0 1 Hz increments Processor 0 015 Hz increments With Option Board Option board analog inputs High Speed 4096 Hz 111 Frequency accuracy 0 0075 Hz 0 00005 times High Speed Temperature drift 2 Drive controller Analog inputs 3 x 10 4 times High Speed C typical Keypad display 7 x 10 times High Speed C maximum With option board Option board analog inputs 2 5 x 1075 times High Speed C typical Frequency range ATV56U41N4 to D79N4 0 1 to 72 Hz 56041 2 to D46M2 0 1 to 72 Hz Torque overtorque See page 37 Speed reference 0 10V Al2 4 20 mA 0 5 V with switch on control board 0 20 mA x 20 mA 20 4 mA with keypad display Speed regulation determined by motor slip typically 3 SLFV sensorless flux vector 1 Efficiency Typically greater than 96 Reference sample time 10 ms Ramps Acceleration 0 1 to 999 9 seconds Deceleration 0 1 to 999 9 seconds
43. esy 0 091 C W Calculate minimum useful heat exchange surface area S 300 Pi 0091 3300 in S 12 1996 Square D All Rights Reserved Bulletin No 50006 519 01B Chapter 1 Receiving and Installation December 1996 Mounting in Type 12 IP54 Metal Enclosure Useful heat exchange surface area S of the proposed wall mounted enclosure Height 40 in 1016 mm Width 40 in 1016 mm Depth 20 in 508 mm front area top area side area S 40x40 20 x 40 2 40 x 20 4000 in If the selected enclosure does not provide the required surface area or does not meet application needs consider the following Use a larger enclosure Use one of the recess mounting kits ATV56U41N4 to D23N4 and ATV56U41M2 to D16M2 drive controllers Refer to Table 7 Add a passive heat exchanger to the enclosure Add an air conditioning unit to the enclosure Ventilation When the drive controller is mounted inside a Type 12 or IP54 enclosure observe the following ventilation precautions Observe minimum clearance distances shown in Figure 5 on page 9 Follow the installation precautions on pages 9 and 10 Astirring fan may be necessary to circulate the air inside the enclosure and prevent hot spots in the drive controller and to distribute the heat uniformly to surfaces used for convection cooling If there is a possibility of condensation keep the control supply switched on durin
44. 0 mA and at 20 feet the feedback signal is 20 mA 0 to 10 V signal is used for the setpoint At 0 V the wet well level is 8 feet and at 10 V the wet well level is 17 feet 1 Select YES SET POINT in the PI Regulator menu 2 Select SP INPUT 3 Select for setpoint input 4 Calculate SP GAIN and OFFSET and enter the values Setpoint Signal Input on Corresponding Process Value OV 8 feet Setpoint Min Process value at low speed 10V 17 feet Setpoint Max Process value at high speed Feedback Signal Input on Al2 Corresponding Process Value 5 feet Feedback Min Process value at minimum feedback 20 mA 20 feet Feedback Max Process value at maximum feedback 1996 Square D All Rights Reserved 91 Chapter 5 Configuration Bulletin No 50006 519 01B 7 General Configuration Menu December 1996 17 8 20 5 SP GAIN x 9999 6000 8 5 20 5 OFFSET 9999 2000 Select FEED BACK in the PI Regulator screen Select FB INPUT Select AI2 for feedback input Select MIN FEED BACK Enter 5 for the minimum process level 10 Select MAX FEED BACK 11 Enter 20 for the maximum process level 12 If desired enter optional LOW LEVEL ALM and HIGH LEVEL ALM values 13 Select YES for REV ACTION in PI PARAMETERS menu 14 Adjust KP and KI to achieve the best system response
45. 1 5 mm peak to peak from 2 to 9 Hz Transit test to shock Conforming to National Safe Transit Association and International Safe Transit Association test for packages weighing 100 lbs and over Codes and standards UL Listed per UL 508C under category NMMS as incorporating Class 10 electronic and electromechanical overload protection CSA Certified Label is optional Conforms to applicable NEMA ICS IEC and ISO 9001 standards Resolution limited to processor resolution 2 Drive Controller at operating load and temperature 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Short Circuit Withstand Ratings Controller Part No Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Short Clrcuit Withstand Rating Symmetrical Short Circuit Withstand Ratings Table 46 Short Circuit Withstand Rating of Controller Power Circuits Bypass Path Overcurrent Protective Device 56UCG2VW to 56UPG2VW 8 800 A u 56UCG2LW to 56UNG2LW 56UCG2VY to 56 2 56UCG2LY to 5GUNG2LY 8 800A Motor Circuit Protector 56UCG2VZ to 5eUPG2VZ 8 800 A Dependent upon OCPD by user 56UCG2LZ to 56UNG2LZ supplied bypass starter 11 56UCG3VW to 56UPG3VW 56UCG3LW to 56UNG3LW eee 56UCG3VY to 56 56UCG3LY to 5SUNG3LY 22 000 A Motor Circuit Protector 56UCG3VZ to 56UPG3VZ 22 000 A Dependent upon OCPD by user 56UCG3LZ to 56UNG3LZ i suppl
46. 14 Contact state with drive controller deenergized Total current of 24 V internal supply is 210 mA Available current of the two logic outputs can be calculated as follows each logic input requires 10 mA each analog output requires 20 mA and the typical quiescent current of LOP is 15 mA For example in an application where three logic inputs and one analog output are used the total available current is 210 mA 3 x 10 mA 1 x 20 mA 15 mA 145 mA to drive the logic output loads If more current is required an external supply must be used 6 0 20 mA x 20 mA 20 4 mA programmable with keypad display 0 5 V Z 30 selectable with switch on control board 1996 Square D All Rights Reserved 23 Chapter 2 Wiring Bulletin No 50006 519 01B Using the Logic Inputs J12 December 1996 USING THE LOGIC The logic inputs may be operated from either the internal supply or an external INPUTS J 12 supply Figure 10 shows the connections for operating the logic inputs from the internal power supply Customer supplied Figure 10 Operating the Logic Inputs from Internal Power Supply Figure 11 shows the connections for operating the logic inputs from an external power supply LH LI2 LI3 Ll4 12 30 VDC Supply supplied 1 i 1 1 1 1 1 Fi
47. 18 additional motor 39 AFC off bypass switch 142 146 Al1 Al2 terminals 22 23 26 135 136 Al2 modifying signal type 79 analog input test 110 analog inputs 23 displaying 61 analog output test 111 analog outputs 23 26 assigning functions to 99 displaying 61 1 2 terminals 23 26 application functions menu 77 at speed 97 auto contact 140 143 144 147 148 auto manu 94 auto manual 77 80 97 autodiagnostics 109 automatic restart 102 AUTO TEST FAIL 46 auto test failure 56 B bar graphs displaying 62 64 bele box 117 brake output 99 braking DC injection 34 36 dynamic 47 branch circuit 16 28 BRK 55 62 ALTIVAR 56 Fan and Pump Drive User s Manual bus capacitor voltage 42 bypass 39 77 85 87 142 146 C cable 17 capacitance 17 capacitors charge relay fault 46 DC bus 42 power factor correction 17 Catch on Fly 103 caution LED 11 19 44 circuit diagrams control 28 151 156 logic inputs 24 logic outputs 25 CL1 CL2 terminals 20 21 CL21 CL22 terminals 20 21 class 8839 combination devices 117 bypass 142 144 145 combination 139 140 remote starter bypass 146 148 CLI 55 62 COM terminal 23 25 command type menu 67 selecting 67 component failure locating 109 compression lug kit 21 condensation 10 13 conduit entries 6 entry plate 18 constant torque 38 contactors isolation 29 line 30 31 output 39 continuous duty 37 control board 22 circuit diagrams 28 151 156
48. 1996 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Control Wiring Table 51 Control Terminal Strip Characteristics Power Circuits Y amp Z Terminal 1 2 26 7 27 Function 120 V SPR Relay Coil if used Characteristics 115 120 V 60 Hz supply user supplied 28 3 29 R1 Relay N C Contact Fault Relay Output Minimum 10 mA 24 VDC Maximum inductive load of 2 0 A 120 VAC Max 0 10 J operation 80 operations minute 1 0 A 220 VAC Max 0 25 J operation 25 operations minute 2 0 A 24 VAC Max 0 10 J operation 80 operations minute Arc suppression provided by varistors in parallel w relay contacts 30141 31 R2 Relay Contact Run Relay Output Minimum 10 mA 24 VDC Maximum inductive load of 2 0 A 120 VAC Max 0 10 J operation 80 operations minute 1 0 A 220 VAC Max 0 25 J operation 25 operations minute 2 0 A 24 VAC Max 0 10 J operation 80 operations minute Arc suppression provided by varistors in parallel w relay contacts 3211 33 Auxiliary Contact AFC Mode Status 1 See control circuit diagrams on pages 153 156 2 All terminals are rated 600 V 30 A Class 9080 Type GM6 Maximum wire size for all terminals is 10 AWG 2 5 mm Tightening torque 7 8 Ib in 0 8 0 9 N m 3 Relay coil deenergizes on fault 4 Contact state with drive controller deenergized 5 Total current of 24 V internal supply is 210
49. 4 ATV56U90N4U 56UJG4V_ 15 25 1 30 6 21 23 ATV56D12N4U 56UKG4V_ 20 31 8 38 3 27 30 ATV56D16N4U 56ULG4V_ 25 38 7 47 34 38 ATV56D23N4U 56UMGAV_ 30 44 52 4 40 44 56UNG4V_ 40 57 1 67 6 52 57 56UPG4V_ 50 68 6 81 2 65 72 ATV56D46N4U 56UQGAV_ 60 86 4 94 6 77 98 ATV56D54N4U 56URG4V_ 75 106 116 96 116 ATV56D64N4U 56USG4V_ 100 138 150 124 144 ATV56D79N4U Short circuit current available at controller input 2 10 000 AIC denoted by asterisk For controllers with the Remote Starter Bypass power circuit the short circuit withstand rating depends on the overcurrent protective device in the user supp ied bypass starter It cannot exceed 22 000 A Table 40 Variable Torque Low Noise Class 8839 Enclosed ATV56 Drive Controller Ratings 460 VAC 10 Switching Frequency 56UCG4L_ to 56UNG4L_ 10 kHz 56UPG4L_ to 56URG4L_ 4 kHz Motor Power Input Line Current 11 Max Output transient Power cantar ssov Curent amr Pan hp A A A A 56UCG4L 1 27 32 2 1 2 3 56UDG4L_ 2 47 57 3 4 3 8 ATV56U41N4U 56UEG4L_ 3 6 5 8 4 8 5 3 56UFG4L_ 5 9 8 11 9 76 8 4 ATV56U72N4U 56UGG4L_ 7 5 13 9 16 7 11 12 ATV56U90N4U 56UHG4L_ 10 17 6 21 4 14 15 4 ATV56D12N4U 56UJG4L_ 15 24 8 29 9 21 23 ATV56D16N4U 56UKG4L_ 20 31 9 38 7 27 30 ATV56D23N4U 56ULG4L_ 25 38 7 47 34 38 56UMG4L_ 30 44 52 4 40 44 ied 56UNG4L 40 57 1 67 6 52 57 ATV56D46NA4U 56UPG4L_ 50 68 3
50. 6 10 4 7 5 8 3 ATV56U41M2U 56UEG3L_ 3 13 2 14 3 10 6 11 7 56UFG3L_ 5 20 1 21 8 16 7 18 4 ATV56U72M2U 56UGG3L_ 7 5 28 3 30 6 24 2 26 6 ATV56U90M2U 56UHG3L_ 10 35 9 38 9 31 34 ATV56D12M2U 56UJG3L 15 51 55 1 47 51 ATV56D16M2U 56UKG3L 20 65 2 70 3 60 66 ATV56D23M2U 56ULG3L_ 25 77 4 84 7 75 83 ATV56D33M2U 56UMG3L_ 30 87 5 97 2 88 97 56UNG3L_ 40 111 3 124 2 114 126 ATV56D46M2U Short circuit current available at controller input 2 For controllers with the Remote Starter Bypass power circuit the short circuit withstand rating depends the ied bypass starter It cannot exceed 8 800 A overcurrent protective device in the user supp 1996 Square D All Rights Reserved 121 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Specifications Specifications 122 Input voltage Bulletin No 50006 519 01B December 1996 Table 45 contains specifications for 460 V and 208 230 V drive controllers Table 45 Specifications 460 V 410 or 208 V 10 or 230 V 10 Displacement power factor Approximately 0 96 Input frequency 60 Hz 2 Output voltage Maximum voltage equal to input line voltage Frequency resolution Input 11 High Speed 1 024 Hz 11 Input AI2 High Speed 512 Hz 11 Keypad display 0 1 Hz increments Processor 0 015 Hz increments Option Module Input AI3 High Speed 4 096 Hz Input High Speed 4 096 Hz 11 Frequency accura
51. 80 8 65 72 56054 41 56UQG4L_ 60 86 4 946 77 98 ATV56D64N4U 56URG4L 75 106 116 96 116 ATV56D79N4U Short circuit current available at controller input 2 10 000 AIC denoted by asterisk 3 For controllers with the Remote Starter Bypass power circuit the short circuit withstand rating depends on the overcurrent protective device in the user supp 1996 Square D All Rights Reserved ied bypass starter It cannot exceed 22 000 A 119 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Technical Characteristics Bulletin No 50006 519 01B December 1996 Table 41 Variable Torque Class 8839 Enclosed ATV56 Drive Controller Ratings 230 VAC 10 Switching Frequency 4 kHz Motor Power Input Line Current 11 Max Controller 230 V d utput Transient power 2 Current Part No 60 Hz 5 000 A 22 000 A Current 60 s Converter Part No hp A A A A 56UCG3V_ 1 4 9 5 8 4 2 5 1 56UDG3V 2 8 6 10 2 6 8 8 3 ATV56U41M2U 56UEG3V_ 3 11 8 14 9 6 11 7 56UFG3V_ 5 17 8 21 2 15 2 18 4 ATV56U72M2U 56UGG3V_ 7 5 25 8 30 6 22 26 6 56UHG3V_ 10 32 7 38 8 28 34 ATV56U90M2U 56UJG3V _ 15 46 2 54 8 42 51 ATV56D12M2U 56UKG3V_ 20 58 7 69 4 54 66 ATV56D23M2U 56ULG3V_ 25 71 5 84 4 68 83 56UMG3V _ 30 81 1 97 7 80 97 ATV56D33M2U 56UNG3V _ 40 102 7 125 9 104 126 56UPG3V _ 50 122 6 151 1 130 158 ATV56D46M2U Short circuit current available at controller input 2 For con
52. ANALOG OUTPUTS 13 26 USING THE RELAY OUTPUTS 27 REMOVAL CL1 CL2 JUMPERS 27 CONTROL CIRCUIT DIAGRAMS 28 eh E PUR 28 2 Wire Control with Isolation Contactor on Line Side Coast to 29 Chapter 3 StartUp imere rreri i ani iai ee 33 INTRODUCTION cet ens tole wing BEC 34 FACTORY SETTINGS Een E A A E 34 Pen ie EEE VES 35 Normal e ate Sty ae te A ee odd Be eS Ne re cine d BA en 35 NOLD No Load ie Id RR RE ER P ee ee 35 MOTOR THERMAL OVERLOAD 36 ADJUSTMENT OF MOTOR OVERLOAD 37 1996 Square D All Rights Reserved i ALTIVAR 56 Fan and Pump Drive User s Manual Bulletin No 50006 519 01B Table of Contents December 1996 AVAILABLE MOTOR 4 37 Continuous DUY oor ea i e RE e Ueber t ber ene 37 Overtorque Capability and Speed 37 Overspeed Operation f 2 60 2 38 Driving Torque Production Envelope 38 MOTOR CO
53. CIRCUIT DIAGRAMS 151 1996 Square D All Rights Reserved 115 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Bulletin No 50006 519 01B Contents December 1996 A DANGER HAZARD OF ELECTRIC SHOCK OR BURN This equipment must be installed and serviced only by qualified electrical personnel Turn off power supplying this equipment before working on or inside equipment Always use a properly rated voltage sensing device to confirm power is off Replace all devices doors and covers before turning on power to this equipment DRIVE ISOLATION HAZARD Before servicing the drive controller Disconnect all power Place a Do Not Turn On label on drive controller Lock disconnect in Open position Before servicing basic power converter when Bypass is selected Perform all functions listed above Measure voltages at disconnect output to verify they are zero Wait 1 minute to allow DC bus to discharge verify no voltage is present Remove line fuses labeled FU1 FU2 and FU3 with tool provided Replace cover then close disconnect Failure to observe these precautions will result in death or serious injury 116 0195655 All Rights Reserved Bulletin No 50006 519 01B December 1996 INTRODUCTION Terminology Precautions Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Introduction The Class 8839
54. Consult the factory configuration listing on the applicable control circuit diagram pages 151 to 156 and refer to Chapter 5 before reprogramming logic inputs outputs torque types or control types Changing certain factory settings will adversely affect the performance of the Class 8839 ALTIVAR 56 drive controller A WARNING UNINTENDED EQUIPMENT OPERATION Controller has been factory programmed Alteration of factory programming may create incompatibilities with supplied controller configuration Read and understand Chapter 5 as well as programming information on applicable controller schematics Figures 91 96 f the power converter unit is re initialized using the TOTAL or PARTIAL FACTORY SETTING function the power converter must be re programmed per the programming instructions on applicable controller schematics Figures 91 96 f the power converter unit or the main control board of the power converter is replaced the power converter must be re programmed per the programming instructions on applicable controller schematics Figures 91 96 Failure to observe these instructions can result in death serious injury or equipment damage 138 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 POWER CIRCUIT W COMBINATION PACKAGE Operator Controls General Arrangement and Operation Adjustable Speed Operation Freeze Fire Stats Inter
55. INSERT THE MEMORY CARI INTO THE PCHCIR CONNECTOR ENT when ready The following illustration shows the Store User Settings menu The black boxes correspond to configurations already stored in the card Select an empty box In this example 1 is selected To store press ENT When the configuration has been saved a message will appear indicating whether or not the save operation was successful 1996 Square All Rights Reserved Bulletin 50006 519 01B Chapter 5 Configuration December 1996 9 Drive Initialization Menu 9 535 USER SETT STORE SETTINGS 1 JE LIU j au 71115 automatic SELECT FILE NUME 11 ENT to confirm Recall User Settings To download a configuration from a PCMCIA memory card to the drive controller select Recall User Settings Install the memory card A message will appear 3 43RECRLL USER SETT This oPeration changes 2 13 the ACTUAL SETTINGS 1 to the USER SETTINGS SELECT FILE NUMB 18 RECALL SETTINGS ATU File 56 1 Memory ENT to confirm Select one black box In the example shown above 10 is selected Press ENT to download When the configuration has been downloaded a message will appear indicating whether or not the transfer was successful If an error was made
56. No 50006 519 01B Chapter 5 Configuration December 1996 8 Diagnostic Mode A WARNING UNINTENDED EQUIPMENT ACTION Forcing drive controller logic and analog outputs may cause undesired activation of connected equipment Set the connected equipment to ignore the change of state Failure to follow this instruction can result in death serious injury or equipment damage Analog Output Test ANALOG OUTPUT TEST OUT ASSIGNMENT VALS This menu allows you to change the value of the analog outputs to check for good wiring connections without affecting drive controller operation When the Analog Output Test screen is active all output values are forced to 0 regardless of actual drive controller settings Changes then made to the outputs will alter the setting without affecting the state of the drive controller When you leave the Diagnostic Mode and return to Main menu the analog outputs resume the programmed settings in place before the test sequence 1996 Square D All Rights Reserved a amp amp o 111 Chapter 5 Configuration 9 Drive Initialization Menu 9 gt DRIVE INITIALIZATION MENU Total Factory Settings Store User Settings 112 Bulletin No 50006 519 01B December 1996 9 DRIVE INIT TOTAL FACTORY USER SETTING STORE RECALL USER SETTING This menu is only accessible when the drive controller is stopped It allows the original fa
57. No fault recorded Short circuit or grounding on drive controller output may be internal or external OVERSPEED SEQUENCE T OUT PROCESS TIME OUT Short circuit in transistor ACCESS LEVELS The keypad display can be locked to limit access to drive controller configuration and adjustment parameters Two access levels are available Total Lock factory default and Total Unlock Access levels are selected by positioning the access locking switch on back of the keypad display Figure 30 on page 52 Total Lock When the access locking switch is in locked position the keypad display is in Total Lock mode Total Lock is the factory preset condition of the drive controller In Total Lock mode the choices available from the Main menu are 2 gt I O Map and 3 gt Fault History If Keypad Command is active page 64 the keypad display can be used for local command of the drive controller however all drive controller adjustment and configuration parameters are protected from change MENU BENE Y FAULT HISTORY Figure 34 Main Menu in Total Lock Mode To change access level when in Total Lock mode 1 If Keypad Command is active from any point in the Level 1 amp 2 Software stop the drive controller disconnect the keypad display and set the access locking switch to unlock If Terminal Command is active it is not necessary to stop the drive controller before disconnecting the
58. O Extension module is present Using PI Regulator To activate the PI Regulator function choose YES SET POINT from the PI Regulator menu The SET POINT menu appears SET POINT KEVPRD A Gan SP INPUT All SP GAIN 9999 339 OFFSET 48 ME amp ENT to select Table 32 SETPOINT Menu Items Menu Item Description Range KEYPAD Selects the keypad as the means for entering the setpoint Enter the setpoint with SET POINT in the 1 gt Setting menu SP INPUT Selects an analog input port as the means for entering the Al1 Al2 setpoint Al4 SP GAIN Setpoint scaling adjustment Range corresponds to 9999 to 9999 example 9999 99 99 OFFSET Setpoint offset adjustment Range corresponds to For 9999 to 9999 example 9999 99 99 First select the means for setpoint entry Choose KEYPAD for entering the setpoint through the keypad or SP INPUT for entering the setpoint through an analog input port If KEYPAD is chosen for setpoint entry enter the setpoint value in PI SET POINT under the 1 Parameter Setting menu The setpoint value ranges from 0 to 9999 and is a percentage of the setpoint range where 9999 represents 99 99 0 is setpoint minimum 9999 is setpoint maximum and 5000 is the middle 50 of the setpoint range Calculate the PI SET POINT value percentage as follows B Setpoint Min Process Level P
59. PACKAGE W OPTIONS Chapter 6 Class 883 14 9 ALTIVAR 56 Combination Devices Control Circuit Diagrams A PILOT LIGHT CLUSTER A07 RED PWR ON GREEN AFC RUN GREEN BYP RUN YELLOW AFC FAULT CONFIGURE CONTROLLER FUNCTIONS MENU 7 3 LO1 RUNNING STATE MENU 7 3 LO2 FAULT STATE PILOT LIGHT CLUSTER B07 RED PWR ON GREEN AFC RUN GREEN AUTO MODE YELLOW AFC FAULT PLACE JUMPER BETWEEN TB 4 amp TB 32 POWER CIRCUIT Y 1 2 LO1 CONFIGURE CONTROLLER FUNCTIONS MENU 7 3 LO1 RUNNING STATE MENU 7 3 LO2 FAULT STATE CONTROL TRANSFORMER SHOWN FOR 460V PRIMARY FOR 230V PRIMARY JUMPER H2 H3 IS REMOVED AND JUMPERS H1 H3 amp H2 H4 ARE INSTALLED FOR 208V PRIMARY REFER TO DETAIL A BQ Sar eB DELAY TIMER TR IS CONNECTED ACROSS COIL TERMINALS 1 amp A2 ON IC CONTACTOR FOR ALL CONTACTORS EXCEPT THOSE WITH PART S LC1FXXX FOR THESE TR IS CONNECTED IN SERIES WITH COIL TERMINAL A1 FUSES FU7 amp FU8 SUPPLIED ONLY ON 50 100HP 460 VAC OR 30 50HP 208 230 VAC CONFIGURE CONTROLLER FUNCTIONS AS FOLLOWS MENU 1 DAMPING 100 MENU 6 1 TORQUE TYPE VARIABLE OR VARIABLE LOW NOISE MENU 6 2 COMMAND TYPE 2 WIRE MAINTAINED MENU 7 12 LOW SPEED 3 HZ MENU 7 12 ACCELERATION 10 SEC MENU 7 12 DECELERATION 10 SEC MENU 7 13 CONTROL TYPE NOLD MENU 7 2 AUTO MANUAL LI3 AUTO RUN INPUT Ll4 SPEED REFERENCE 2 Al2 MENU 7 3 R2 RUNNING STATE USER CONNECTIONS
60. V 4 AFC Fault Yellow illuminates whenever LO2 programmed for fault state is high to annunciate a drive fail condition This light is normally not lighted until a controller protective circuit has caused an abnormal shutdown The LED is rated 24 V MOD 07 provides a line isolation contactor factory wired between the line fuses FU1 FU2 and and the power converter L1 L2 and L3 An Open Close switch is provided on the controller door for controlling the contactor The line isolation contactor is energized whenever the Open Close switch is in the closed position 1996 Square D All Rights Reserved 139 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Power Circuit W Combination Package MOD 007 Omit Hand Off Auto Switch and Manual Speed Potentiometer if used 140 Bulletin No 50006 519 01B December 1996 MOD D07 omits the Hand Off Auto selector switch and manual speed potentiometer It is used when the user prefers to supply external control devices There are a number of ways to sequence the operation of the power converter when the Hand Off Auto switch and manual speed potentiometer are not present Figures 79 82 show recommended sequencing diagrams for commonly used control methods Figure 79 can be used for applications in which the power converter start stop operation is controlled b
61. _ primary fuses if used 15 4 AFOR60S 10 Horsepower rating Power line fuse Bussmann 5 45 PR SEC FN 0 R 1 Control transformer e POWER FIELD WIRING 60 75 C CU secondary fuse if used Line terminations LOAD Load terminations bag TORQUE LB IN wire size amp terminal torques ES irs size amp terminal torque REFERENCE INSTRUCTION MANUAL 50006 519 01 ENCLOSURE 1 INUSA 61140 534 12345678A 9646 Date code Factory order no Figure 68 Controller Nameplate 118 1996 Square D All Rights Reserved Bulletin 50006 519 01 December 1996 TECHNICAL CHARACTERISTICS Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Technical Characteristics Table 39 Variable Torque Class 8839 Enclosed ATV56 Drive Controller Ratings 460 VAC 10 Switching Frequency 56UCG4V_ to 56UPG4V_ 4 kHz 56UQG4V_ to 56USG4V_ 2 kHz Motor Power Input Line Current 11 Max Controller 460 V 5 000 A Output Transient Power Part No 60Hz 10 000 a 121 22 000 API Current current 60s Converter Part No hp A A A A 56UCG4V_ 1 2 7 3 2 2 1 2 3 56UDG4V_ 2 47 5 7 3 4 38 ATV56U41N4U 56UEG4V_ 3 6 5 8 4 8 5 3 56UFG4V_ 5 9 8 11 9 7 6 8 4 ATV56U54N4U 56UGG4V_ 75 14 17 11 12 ATV56U72N4U 56UHG4V_ 10 17 7 21 4 14 15
62. bypass 153 154 combination 151 152 remote starter bypass 155 156 external devices 140 141 143 145 147 148 1996 Square D All Rights Reserved Index terminals 23 135 137 three wire 28 two wire 28 29 types 34 35 37 39 voltage supply 20 wiring precaution 17 control parameter menu 74 controlled stop 77 80 by frequency threshold 81 by frequency threshold amp logic input 81 by logic input 81 controllers dimensions 6 7 124 127 disconnect switch 142 146 handling 8 128 inspection 8 128 installation 9 specifications 3 4 122 weight 7 124 127 CSA label 141 145 149 current level 98 limit 72 97 nominal 34 overcurrent 45 ratings 3 4 119 121 CUSTOM FAULT 47 D damping 58 59 71 DB Resistor 47 DC bus LED 19 42 44 DC bus overvoltage 55 DC bus voltage 20 42 DC injection braking 34 36 83 DCB 55 62 DC BUS OVERVOL 45 DEC 55 62 deceleration 5 34 122 deceleration time 59 75 delay time 86 derating 37 diagnostic mode menu 109 dimensions controller 7 124 127 recess mounting 13 disconnect switch 10 142 146 173 ALTIVAR 56 Fan and Pump Drive User s Manual Index display configuration menu 62 display screen 53 55 displaying faults 62 drive configuration 66 downloading 113 menu 53 storing 112 drive controller functions displaying 62 identification menu 53 initialization menu 112 nameplate information 53 118 overtemperature 55 para
63. controller For remote handheld use connect terminal with a 3 meter cable part VW3 A66311 or 2 meter cable part VW3 A66312 For mounting in an enclosure door use kit VW3 A66101 3 meter cable or VW3 A66100 2 meter cable Switch for access locking to prohibit or authorize changes to the configuration e Figure 30 Rear View of Keypad Display E Figure 31 Removing Keypad NOTE Keypad supplied with this drive controller has been matched with the software revision level Do not install keypad on another drive controller Installation of an incompatible keypad may result in non recognition of the keypad by the drive controller at power up Figure 32 Access to RUN and STOP Keys 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Chapter 5 Configuration Menu Overview MENU OVERVIEW Selecting the Language Drive Configuration Drive Identification Display Mode UNINTENDED EQUIPMENT ACTION Unlocking keypad display page 56 gives access to parameters Parameter changes affect drive controller operation Most parameter changes require pressing ENT Some parameter changes such as reference frequency take effect as soon as you press the A or key Read and understand this manual before using the keypad display Failure to follow these instructions can result in death serious injury or equipment
64. e units L3 47 to 63 Hz T1 208 VAC 560 2 units T2 Output Connections to motor 0 to 230 VAC 56U G3 units T3 0 to 460 VAC 560 04 units Table 49 Power Terminal Wire Range Terminals Class 8839 Drive Controller Type L1 L2 L3 Line T1 T2 T3 Load GND Max Max Max Wire Terminal Wire Terminal Wire Terminal Size Torque Size Torque Size Torque 208 230 VAC 460 VAC AWG Ib in AWG 6 AWG 56UCG2 3 W to 56UFG2 3 W 56UCG4 W to 56UHG4 W 4 35 2 0 120 4 35 56UGG2 3 W to 56UHG2 3 W 56UJG4 W to 56UKG4 W 1 0 80 2 0 120 4 35 56UJG2 3 W to 56ULG2 3 W 56ULG4 W to 5eUPG4AVW 1 0 80 2 0 120 1 0 45 56UPGALW 1 0 80 4 0 150 1 0 45 56UMG2 3 W to 56UPG2 3 W 5eUQG4 W to 56USG4 W 350 250 4 0 150 1 0 45 56UCG2 3 Y to 56UFG2 3 Y 56UCG4 Y to 56UHG4 Y 4 35 8 15 4 35 56UCG2 3 Z to 56UFG2 3 Z 56UCG4 Z to 56UHG4 Z 56UGG2 3 Y 56UJG4 Y 56UGG2 3 Z 56UJG4 Z T9 80 8 15 35 56UHG2 3 Y 56UKG4 Y 56UHG2 3 Z 56UKG4 Z YO eee 15 4 92 56UJG2 3 Y to 56ULG2 3 Y 56ULG4 Y to 56UPG4 Y 56UJG2 3 Z to 56ULG2 2 Z 56ULG4 Z to scuPG4 z 10 80 279 56UQG4 Y 56UQG4 Z 350 250 1 0 75 1 0 45 56UMG2 3 Y to 56UNG2 3 Y 56URG4 Y 56UMG2 3 Z to 560 2 3 2 56URG4 Z POM oil Seu ee 56UPG2 3 Y 56USG4 Y 5GUPG2 3 Z 56USG4 Z 350 250 3 0 200 1 0 45 134 1996 Square D All Rights Reserved Bulletin
65. in selecting a box file number a message will indicate an incompatible or empty file NOTE When recalling user settings the physical configuration and power rating of the drive controller must match the physical configuration and power rating of the drive controller from which the settings were copied If the physical configuration and power rating do not match then a message will indicate an incompatible file 1996 Square D All Rights Reserved 113 Chapter 5 Configuration Bulletin No 50006 519 01B Notes December 1996 114 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Contents Chapter 6 Class 8839 ATV56 Combination Devices INTRODUCTION 7m MR eos eed Be Dd ie nA A 117 CONTROLLER PART 118 CONTROLLER NAMEPLATE 118 TECHNICAL CHARACTERISTICS 2 119 Specifications aie acted Bidar PG eaten a 122 Short Circuit Withstand Ratings 123 DIMENSIONS AND WEIGHTS FOR WALL OR PANEL MOUNTING 124 HANDLING DRIVE 5 128 PRELIMINARY INSPECTION
66. in fault state the Display screen shows the fault type If the drive controller has been programmed for Keypad Command the last line of the Display screen indicates the functions of F1 F2 and F3 keys 1996 Square D All Rights Reserved 53 Chapter 5 Configuration Main Menu Main Menu 54 Bulletin No 50006 519 01B December 1996 From the Display screen press ENT to advance to the Main menu Depending on the access level selected page 56 the Main menu contains two Total Lock or nine Total Unlock sub menus Subsequent power up First power up Select language by scrolling with the and V DIBL GUE LRNGURGE keys and pressing ENT Press ENT to advance to English Drive Configuration menu EzPanal Francais amp ENT ENT or20s TORQUE WAR TABLE COMMAND 2 WIRE 441 468 U Powerit z 2kM 3 HP ENT if k Fischanse ESC Displays factory settings of drive controller configuration parameters Motor power displayed only for ATV56U41N4 drive controller Press ENT to advance to Drive Identification screen Unlock access locking switch if ENT F3 necessary for display of the 6 gt Drive or 10s Configuration menu DRIUE IDENTIFICATION Displays drive controller nameplate information ATWS6U4iNd UT 112 1 56041 4 Drive controller catalog
67. is set to Total Unlock DISPLAY MODE FAULT AC LINE OVERVOLTAGE Status code When a fault appears the drive controller trips the motor follows the programmed fault stop page 100 and the Display screen shows the fault type Table 21 lists the faults that the drive controller can display Table 20 Display Mode Status Codes Code Definition Code Definition No Line Power control power supplied separately RDY Drive Ready RUN Drive Running at speed Forward Direction Accelerating NLP CLI Current Limit DCB Injection Braking Run Permissive 1 open BRK Braking FLT Fault DEC Decelerating Table 21 Faults Displayed on Display Mode Screen Fault Designation Description Input Phase Loss loss of power or blown fuses A brief loss of input supply IN PHASE LOSS phase lt 200 ms is not detected Undervoltage input voltage lt 380 V 60 Hz 460 V ATV56 N4 or input voltage lt 170 V ATV56 M2 or temporary voltage loss t 2 200 ms UNDERVOLTAGE AC line overvoltage input voltage to power supply too high AC LIN OVERVOL voltage gt 550 V 60 Hz 460 V ATV56 N4 or input voltage gt 270 V ATV56 M2 DRIVE OVERTEMP Drive overtemperature heatsink temperature too high Motor overload thermal trip because of prolonged overload or running in single phase on the output or motor power rating too low for applic
68. keypad display 2 Reconnect the keypad display 3 Press ENT and display will return to the Drive Configuration menu The drive controller is now in Total Unlock mode Press ENT to advance through the power up screens to the Main menu Total Unlock When the access locking switch is in the unlocked position all drive controller adjustments and configurations are accessible from the Main menu 56 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 MENU SUMMARY USING THIS CHAPTER Chapter 5 Configuration Menu Summary Table 22 is an overview of all sub menus accessible from the Main menu Use the table as a reference for menu index numbers The menu index numbers can be used with the F3 key when it is set to Jump factory setting to go directly to the associated menu Use the table also as a guide to this manual To find a menu description in the manual go to the page number indicated in the table Table 22 Menu Summary Access Level Index Page Menu Total Lock Partial Unlock Total Unlock No No No Yes 1 Yes 1 gt Parameter Setting 58 2 2 1 gt Logic Input Map Yes 1 Yes Yes 2 2 gt Analog Input 61 2 3 Logic Output 2 4 Analog Output Yes 1 Yes Yes I 3 Fault History 62 4 Display Configuration 62 4 1 One Bar Graph 63 i Ne ne 22 4 2 gt Two Bar Graphs 64 4 3
69. lights provided and their functions 1 Power On Red illuminates whenever mains power is applied to the controller The LED is rated 120 V 2 AFC Run Green illuminates whenever LO1 is high programmed for running state to annunciate a drive run condition The LED is rated 24 V 3 Auto Mode Green illuminates whenever the drive is running in Auto mode The LED is sequenced by the Hand Off Auto selector switch and is rated 24 V 4 AFC Fault Yellow illuminates whenever LO2 programmed for fault state is high to annunciate a drive fail condition This light is normally not lighted until a controller protective circuit has caused an abnormal shutdown The LED is rated 24 V MOD C07 provides a line isolation contactor factory wired between the line fuses FU1 FU2 and FU3 and the power converter L1 L2 and L3 The line isolation contactor is energized whenever the AFC OFF Bypass switch is in the AFC position MOD D07 omits the Hand Off Auto selector switch and manual speed potentiometer It is used when the user prefers to supply external control devices There are a number of ways to sequence the operation of the power converter when the Hand Off Auto switch and manual speed potentiometer are not present Figures 83 86 show the recommended sequencing diagrams for commonly used control methods The diagram shown in Figure 83 can be used for applications in which the power converter start stop operation is controlled by a use
70. mA Available current of the two logic outputs can be calculated as follows each input requires 10 mA each analog output requires 20 mA and the typical quiescent current of LOP is 15 mA 6 0 20 mA x 20 mA 20 4 mA programmable with keypad display 0 5 V 7 30 selectable with switch on control board 7 Available only when options are included 8 On when bypass contactor is energized 1996 Square D All Rights Reserved 15 A 125 VAC 10 A 250 VAC 137 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Bulletin No 50006 519 01B Operation Sequence amp Options December 1996 SEQUENCE OF This section describes basic sequences of controller operation for the three pre OPERATION AND engineered power circuit configurations and available options The options are OPTIONS Power Circuit W combination package Power Circuit Y bypass package Power Circuit Z remote starter bypass package Terminal Command Mode In order for factory and or user supplied pilot devices and controls to be vs Keypad Command Mode recognized the Class 8839 ALTIVAR 56 combination drive controller is factory configured to operate in the Terminal Command mode Switching from Terminal Command mode to Keypad Command mode will disable power converter logic inputs Factory and or user provided control devices will be ignored For this reason do not operate the Class 8839 ALTIVAR 56 drive controller in the Keypad Command mode
71. must have a low capacitance phase to phase and to ground Do not use mineral impregnated cable because it has a very high capacitance Immersion of cables in water increases capacitance Cable length the longer the cable the greater the capacitance Cable lengths greater than 100 ft 30 5 m may cause problems Proximity to output cables from other drive controllers because of the high frequency switching and increased capacitance the drive may fault under some conditions Do not use lightning arrestors or power factor correction capacitors on output of drive controller For installation where cable capacitances may be a problem an inductor can be installed between the drive controller and the motor See catalog or consult factory for additional information A CAUTION DRIVE CONTROLLER SWITCH FAILURE For proper drive controller electronic short circuit protection inductance is required in the output power wiring Provide at least 48 in 122 cm of cable at the drive controller output U T1 V T2 W T3 Failure to follow this instruction can result in equipment damage 1996 Square D All Rights Reserved 17 Chapter 2 Wiring Grounding Grounding 18 Bulletin No 50006 519 01B December 1996 For safe dependable operation drive controllers must be grounded according to all national and local c
72. number Variable torque V3 1 Version of drive controller software POWER 2 2kM 3HP 5 8 Imax 1 5In 2 2kw 3 HP Horsepower Nominal drive controller current Maximum drive controller current Press ENT to advance to Display Mode SUPPLY 4601 ENT to continue ENT ESC or10s SPEED REFER 47 2 Hz When drive controller is running reference frequency is displayed factory setting When drive controller is in fault state fault is displayed Press ENT to advance to Main menu Content of Main menu depends on access level selected See page 56 MATH MENU I FAULT HISTORY amp ENT to select Figure 33 Menus Viewed at First Power Up Factory Default Screens 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 DISPLAY MODE Drive Controller Running Drive Controller in Fault State Chapter 5 Configuration Display Mode SPEED REFER C RUNH Status code When the drive controller is running the Display screen can show one bar graph two bar graphs or fourteen items in four tables Factory setting is one bar graph displaying reference frequency Drive controller status is also displayed in the lower right corner of the screen Status codes are defined in Table 20 The type and number of functions shown can be modified in the 4 gt Display Configuration menu page 62 when access level
73. press the STOP key and the drive controller will stop following the deceleration ramp The LI1 input remains active for an override stop in Keypad Command mode SPEED REFER NOTE When running the drive controller in Keypad Command mode after having been in Terminal Command mode the drive controller will run in the same direction in a which it was running in Terminal Command mode The drive controller cannot be 9 Ly commanded to change the direction of the motor once Keypad Command mode is entered Make sure that the motor is rotating in the desired direction before switching from Terminal Command mode to Keypad o Command mode Table 25 Display Mode Screen in Keypad Command Mode In Keypad Command mode the A key is used to increase reference frequency and the key is used to decrease reference frequency Note that pressing the ENT key is not necessary frequency changes automatically upon pressing the A or W keys A reference frequency can also be entered by pressing the decimal point key entering a frequency and pressing the ENT key The assignment of each function key is displayed on the last line of the Display Mode screen above the corresponding function key Table 26 describes the operation of the function keys in keypad command 1996 Square D All Rights Reserved 65 Chapter 5 Co
74. relay is not energized When drive controller is in Auto mode of operation logic output is high or relay is energized When in Manual mode of operation logic output is low or relay is not energized When drive controller reaches current limit value depending on setting in 7 11 Motor Parameters logic output is high or relay is energized If drive controller is in fault state logic output is high or relay is energized The R1 relay already assigned to Fault State deenergizes upon fault When the drive controller has reached the thermal alarm activated a minimum of 60 seconds before a drive controller thermal fault is reached logic output is high or relay is energized Available only on drive controllers ATV56D16 to ATV56D79 If current reference at 2 falls below 3 mA logic output is high or relay is energized Can be used only if AI2 is set for 4 20 mA or 20 4 mA 1996 Square D All Rights Reserved 97 Chapter 5 Configuration 7 General Configuration Menu 98 Frequency Level Current Level Thermal Level FB Limit FB High Alarm FB Low Alarm Bulletin No 50006 519 01B December 1996 Frequency 1 Freq Level LOx 10 Active High Figure 61 Frequency Level When output frequency exceeds the programmed frequency level logic output is high or relay is energized and remains
75. restored when the control logic is no longer active the drive controller will follow a normal power up sequence Restart of the drive controller requires a run command and the absence of faults With power loss set to RAMP the following sequence occurs when power is lost or there is a phase failure while the drive controller is running When the DC bus voltage reaches 80 of its initial value the drive controller is commanded to decelerate following a ramp The deceleration attempts to recover inertial energy stored in the load to enable the drive controller to operate the motor for as long as possible during loss of power The control logic remains active for at least one second by using the power stored on the drive controller DC bus 1996 Square D All Rights Reserved 101 Chapter 5 Configuration 7 General Configuration Menu Automatic Restart 102 Bulletin No 50006 519 01B December 1996 Once the DC bus voltage becomes too low to allow motor operation the drive controller freewheel stops If input power is restored while the control logic is still active the drive controller will automatically restart independent of the Command type in the 6 gt Drive Configuration menu selected If input power is restored when the control logic is no longer active the drive controller will follow a nor
76. set too low and should be increased If the motor speed follows the speed reference ramp sluggishly or tends to vary during steady state operation with constant load Damping is set too high and should be decreased Profile is used only when the drive controller is configured for Normal control type This parameter shapes the V Hz profile of the output Profile can be set toa value between 0 and 100 factory preset to 20 During changes in speed command the V Hz profile becomes linear intersecting the Vn and fn points of Figure 36 As a result there is no reduction in available motor torque during speed changes Vn Shaded area denotes zone within which drive functions when Profile is set between na ima 0 and 100 100 Figure 36 Profile Profile is not available when NOLD control type is selected A CAUTION MOTOR OVERHEATING This drive controller does not provide direct thermal protection for the motor Use of a thermal sensor in the motor may be required for protection at all speeds or loading conditions Consult motor manufacturer for thermal capability of motor when operated over desired speed range Failure to follow this instruction can result in injury or equipment damage Motor Overload enables the drive controller to protect a standard induction motor from overload This function can replace a conventional thermal overload relay for single motor applications however multi motor applications requir
77. speed of the controller Off mode commands the power converter to stop the motor by either following the programmed deceleration ramp factory setting or by freewheel stopping Auto mode is for remote control In Auto mode the power converter is placed in running mode as soon as a user supplied run contact is closed between controller terminals TB5 and TB8 In Auto mode motor speed is varied by adjusting the user supplied auto speed reference signal 4 20 mA supplied to the terminals TB13 TB11 and TB12 Shield in the BELE box Refer to Chapter 5 for scaling of this signal Terminals TB4 and TB5 are dedicated terminals for accepting a user supplied freeze fire stat interlock normally closed The power converter will stop operation if the connection between TB4 and TB5 is opened Remove the factory jumper wire located on these terminals before installing interlock This pilot light cluster provides visual indication of protective functions and circuit status Listed below are the four pilot lights provided and their functions 1 Power On Red illuminates whenever mains power is applied to the controller The LED is rated 120 V 2 AFC Run Green illuminates whenever LOI is high programmed for running state to annunciate a drive run condition The LED is rated 24 V 3 Auto Mode Green illuminates whenever the drive is running in the Auto mode The LED is sequenced by the Hand Off Auto selector switch and is rated 24
78. the control logic is no longer active Green LED on drive controller is out The run command must be activated prior to or during the drive controller power up sequence for this mode to be active The advantage to this control method is that it can resynchronize to command speed in the least amount of time of the three Catch on Fly selections since re acceleration generally occurs with the controller at current limit Also this method which does not require the presence of residual motor voltage is useful when 104 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Motor Overload Chapter 5 Configuration 7 General Configuration Menu regaining control of high inertia loads after extended power outages If the command speed matches the motor speed little if any motor disturbance is seen during restarting This is useful when restarting a single motor on a moving process line This method does have the disadvantage that the motor torque disturbance during resynchronization may be unacceptable to some applications since the motor attempts to accelerate to the commanded speed at the current limit setting of the controller Vm Nm Motor Speed Nsp Commanded i i Speed Vm Motor Voltage Im Motor Current Run Enable LI2 Run Forward Off On Figure 65 Catch On Fly Set to ILIMIT A WARNING MOTOR OVERHEATING This drive controller does not
79. used and the application Control types are described below For information on changing the control type see Chapter 5 The Normal control type is the factory setting Normal is a sensorless flux vector control In order to create high torque at low speeds the drive controller maintains a 90 phase relationship between the rotor and stator electromagnetic fields by continuously calculating the position of the rotor in relation to the electrical position of the stator It is generally applicable on asynchronous motors and provides good torque performance When using Normal control the motor horsepower must be equal to or one horsepower size less than the drive controller horsepower NOLD control maintains a constant volts frequency ratio during acceleration but once the motor is stable voltage to the motor is automatically reduced as a function of load At light load the motor voltage is minimized even at motor base speed This reduces audible motor noise without reducing motor RPM NOLD control should not be used with motors in parallel For more information see Chapter 5 1996 Square D All Rights Reserved 35 Chapter 3 Start Up Motor Thermal Overload Protection MOTOR THERMAL OVERLOAD PROTECTION 36 Bulletin No 50006 519 01B December 1996 A CAUTION LOSS OF MOTOR OVERLOAD PROTECTION When using external overlo
80. user supplied remote speed potentiometer 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 MOD E07 CSA Certification if used MOD F07 Smoke Purge Option if used Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Power Circuit W Combination Package d Hi 9 aan al 10 VDC p 14 TB10 Wiper 2 5kQ 1 11 4 AM 1 tat E INI 12 eos G9 Remote Speed Potentiometer 6 ieee tee 7 12 2 Auto Start Contact or Jumper ym 16 Freezestat 1 x M Jumper 24 V 1 Figure 81 Remote Manual Speed Potentiometer Reference Only Figure 82 can be used for applications in which the power converter start stop operation is controlled by a user supplied Hand Off Auto switch and the speed is controlled by a user supplied speed potentiometer Hand mode and a user supplied 4 20 mA DC speed reference signal Auto mode Hand Auto TB6 Hi 9 x 10 VDC moto 7 Wiper Rel BRL qesseEN EG 1 bg E TBH Wc UM is ___
81. wire and 3 wire command see pages 68 and 68 Catch on Fly is used to regain control of a spinning load after an event such as loss of power or freewheel stop For proper operation of this function the drive controller should be configured for 2 wire control Also the rotation direction of the freewheeling load must be the same as the rotation direction of the drive controller Three possible selections appear for the catch on fly function These selections are Ramp and NO NO is the default setting When commanded to start into a spinning load the drive controller will reset its output frequency to zero and begin to ramp at the set acceleration ramp rate to the commanded speed As the frequency increases the output current increases until the drive controller current limit is reached The torque produced by the motor current will reduce the speed of the spinning motor to a point where the motor rotational speed matches the drive controller output frequency Once this occurs the currents decrease and the drive controller can then accelerate the load to the commanded speed The advantage to this control method is that it does not require any user sequencing of the drive controller power or control In addition it does not require the presence of any residual voltage at the motor for proper operation This method does have the disadvantage that the change in motor speed during resynchronization may be unacceptable to some applicati
82. 00 5 40 50 A 1028 6 EE o B LES oo 18 5 469 9 CONDUIT ENTRIES BOTTOM VIEW t A Y 1 4 00 EA due DUK rd 212 0 100 0 4 B _ 2947 MOUNTING CLEARANCES 232 9 HP D Weight A B 460 V 230 V 208 V in mm Ib kg in mm in mm 1 7 5 VT 178 VT amp VTLN 1 3 VT amp VTLN 660 168 745 337 500 12 7 10 15 VT 5 10 VT 5 10 VT 500 12 7 7 5 10 VTLN 5 7 5 VTLN Esc VTENY 768 195 80 36 2 750 190 F T 20 VT 15 20 10 VTLN 10 VTLN 9 00 229 95 42 9 Figure 69 Mounting Information for 1 20 hp VT amp VTLN 460 V 1 10 hp VT amp VTLN 208 230 V 124 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Mounting Dimensions amp Weights MOUNTING LIFTING HOLE DETAIL 10 11 256 9 1 25 31 8 TYP 2PLACES CONDUIT ENTRIES TOP VIEW M A 629 4 00 100 0 3 B 286 3 MOUNTING CLEARANCES HP W
83. 02 101 COM 2 AO COM R2C R2B PB 1 1 0 0 0 0 0 0 G 0 0O 0 0 0 0 1 Isolation Open Isolation Closed T Add 10 and 11 fuses if tap conductor protection is required The CL1 and CL2 inputs of all ATV56 drive controllers are internally protected and require no external fusing Figure 20 2 Wire Control Circuit Diagram with Isolation Contactor Figure 20 is a 2 wire control circuit diagram with an isolation contactor on the line side It shows how to connect a branch circuit disconnect device and protective fusing to the drive controller Additional sequencing logic may be required Refer to Tables 11 to 15 on pages 30 32 for additional equipment required The maximum number of operations of the 1 contactor should not exceed one per minute for the ATV56U41N4 to ATV56D79N4 and ATV56U41M2 to ATV56D46M2 drive controllers 1996 Square D All Rights Reserved 29 Chapter 2 Wiring Equipment Recommendations Bulletin No 50006 519 01B December 1996 Table 11 Recommended Equipment for 1 to 100 hp 460 V Drive Controllers NOTE The equipment listed in Tables 4 through 8 is valid for all versions of the circuit diagrams A1 F1 F3 Input F10 F11 Control 1 TS Ti F7 F8 Motor Controller Line Power Fuses ATV56 N4 Ratings Fuse Class Cont
84. 0401066 D 8 1 3 4 6 10 600 V 3ea 9080 LC1 9070 FNQ R FNQ R 20 D23 D23 110A T60200 10 2 A amp P 2611 11 6 2 k75D20 4 3 4 6 10 600 V 3 ea 9080 LC1 9070 FNQ R FNQ R FNQ R ee 150A 2006 2 2611 peo1166 0 20 k75D20 4 34 6 10 600 V 3ea 9080 LC1 9070 FNQ R FNQ R FNQ R 20 ae 150A Te0200 1c 2 2611 0801166 2 20 4 34 6 10 600 V 3 ea 9080 LC1 9070 FNQ R FNQ R FNQ R ee 200A T60200 1C 2 F115G6 L9 990 0020 2 1 4 1 6 10 1 6 10 600 V 3 ea 9080 LC1 9070 FNQ R FNQ R FNQ R ud n 250A T60400 1C 2 KTK R 3 F115G6 9980 2 1 4 1 6 10 1 6 10 1 Square D Class CC Fuse Block numbers 2 Bussmann part numbers 7 T1 has been dimensioned to supply 1 coil inrush and sealed VA requirements only Any user control pilot device additions may require re dimensioning of T1 VA capacity 1996 Square D All Rights Reserved 31 Chapter 2 Wiring Equipment Recommendations Bulletin No 50006 519 01B December 1996 Table 14 Maximum Allowable Line Fuse F1 to F3 for 208 230 V Drive Controllers Controller ATV56 M2 Class CC Fast Acting Class T 041 600 V 25 600 V 45A U72 U90
85. 1 2 1 2 1 2 T60030 3CR 2 600 V 600 V 3080 9080 LC1 9070 FNQ R FNQ R FNQ R gt FB3611CC 1 R dj 3 4 FENS ae 15 UA UA 15A KTK R 3 2611 0251066 D G 1 2 1 2 1 2 T60030 3CR 2 600 V 600 V 9080 9070 FNQ R FNQ R FB3611CC 1 R 1 i SEES 2 UH UHA 20A KTK R 3 2611 0251066 1 2 1 2 1 2 T60030 3CR 2 600 V 600 V ee 9080 9070 FNQ R FNQ R gt FB3611CC 1 R 5 RUE UH UH 3A KTK R 3 2611 0251066 D G 1 2 1 2 1 2 T60030 3CR 2 600 V 600 V 081 9080 9070 FNQ R FNQ R FNQ R gt FB3611CC 1 R jos U4 25A KTK R 3 2611 0251066 LA PA2G 1 2 1 2 1 2 T60030 3CR 2 600 V 9080 LC1 9070 FNQ R FNQ R FNQ R 35 160060 3 2 KTK R 3 EE ei 1cc 510 6 4020 2 1 2 1 2 1 2 600 V 9080 LC1 9070 FNQ R FNQ R FNQ R TS eae 45A 760060 30 2 KTK R 3 FB2611CC D2510G6 50020 1 2 1 2 1 2 600 V 9080 LC1 9070 FNQ R FNQ R FNQ R eoa 16006056 2 KTK R 3 1 4 2 1 2 1 2 1 2 600 V 3 ea 9080 LC1 9070 FNQ R FNQ R FNQ R 15 ESO DOM 90A T60100 1C 2 KTK R 3
86. 1 min 10s 0 7 0 8 0 9 1 1 1 Figure 21 Thermal Curves 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 ADJ USTMENT OF MOTOR OVERLOAD AVAILABLE MOTOR TORQUE Continuous Duty Overtorque Capability and Speed Range Chapter 3 Start Up Adjustment of Motor Overload External thermal overload relays are required when more than one motor is connected to the output or when the motor connected to the drive controller is less than half of the drive controller rating The thermal state of the drive controller is not automatically reset when power is removed To adjust Motor Overload first select the type of protection in the 7 4 Fault Management menu Two types of protection are available from the Motor Overload screen Self Cooled Motor No Thermal Protection The drive controller is factory set for a self cooled motor Once the type of protection is selected the Motor Overload current can be set in either the 1 gt Parameter Setting menu or in the 7 4 Fault Management menu Motor Overload can be adjusted from 0 45 to 1 15 times the nominal drive controller current factory preset at 0 9 times the nominal drive controller current Adjust Motor Overload value to nominal motor current For more information on configuring the drive controller refer to Chapter 5 For continuous duty reduced speed applications motor torque derating may be necessary This derating
87. 16 3 415 15 7 400 92 234 82 209 0 22 5 5 30 9 14 9 2 234 Door hinges on left hand side of drive controller Figure 2 Mounting Information for ATV56U41N4 D23N4 amp ATV56U41M2 to D16M2 NOTE When metallic conduit is used with drive controllers of outlines 1 3 install a metal conduit entry plate kit VY1A66201 separately ordered Kit mounts in place of the existing plastic plate and has a conduit hole pattern identical to those shown for outlines 1 through 3 6 _ 1996 Square D All Rights Reserved Chapter 1 Receiving and Installation Bulletin No 50006 519 01B Dimensions amp Weights December 1996 CONDUIT ENTRIES BOTTOM VIEW MOUNTING 212 3 58 4 94 6 32 7 52_ 9 45 p 0 39 10 4xo 54 90 5 125 5
88. 2 s Customer supplied L 4 20 mA Figure 14 Using Speed Reference Inputs The ALTIVAR 56 drive controller has two 0 20 mA analog outputs 1 and 2 They are both 0 20 mA current inputs AOI is factory set as proportional to motor frequency with 20 mA corresponding to High Speed is factory set as proportional to motor current with 20 mA corresponding to twice the rated output current of the drive controller see Tables 1 to 4 on pages 3 4 Maximum driving voltage is 12 V with an internal impedance of 100 The analog outputs can be assigned to other functions than those set at the factory For information on other functions refer to Chapter 5 Customer supplied gt te gt te Figure 15 Analog Outputs 1996 Square D All Rights Reserved Bulletin No 50006 519 01B Chapter 2 Wiring December 1996 Using the Relay Outputs J1 USING THE RELAY The ALTIVAR 56 drive controller has two voltage free Form C relay output OUTPUTS 1 contacts see Figure 16 The contacts have the following characteristics Minimum voltage 24 VDC minimum current 10 mA Maximum voltage 30 VDC maximum current 2 A 120 VAC maximum current 2 A 220 VAC maximum current 1 A is the drive controller fault relay It is not programmable 3 08 Supplied
89. 2 000 Power Part No 60 s o hp A A A Ww 1 5 7 4 9 5 8 4 0 11 7 120 ATV56U41M2 2 10 2 8 6 10 2 7 5 11 7 140 3 14 0 11 8 14 0 10 6 11 7 170 2 ATV56U72M2 7 5 30 6 25 8 30 6 24 2 26 6 302 ATV56U90M2 10 38 8 32 7 38 8 31 34 414 3 ATV56D12M2 15 54 7 46 2 54 8 47 51 559 20 69 3 58 7 69 4 60 65 770 ATV56D23M2 4 25 84 4 71 5 84 4 75 82 831 ATV56D33M2 40 124 9 102 7 125 9 116 126 1260 5 ATV56D46M2 50 149 3 122 6 151 1 143 158 1528 Table 4 Variable Torque Low Noise Drive Controller Ratings 208 230 V 208 V 10 and 230 V 15 60 Hz 5 Switching Frequency ATV56U41M2 to D33M2 10 kHz ATV56D46M2 4 kHz Motor Power Input Line Current Max Total Drive Output Transient 230V Dissipated Controller 208 230V 208V Current Current P 2 PartNo 60Hz 8 800 aic 2000 2 090 60 s AIC AIC o hp A A A A A Ww 1 5 8 5 4 6 4 4 0 11 7 125 1 ATV56U41M2 2 10 4 8 8 10 4 7 5 11 7 150 3 14 3 12 0 14 3 10 6 11 7 181 2 ATV56U72M2 5 21 8 18 3 21 8 16 7 18 4 252 ATV56U90M2 7 5 30 6 25 8 30 7 24 2 26 6 375 3 ATV56D12M2 10 38 9 32 8 39 0 31 34 459 ATV56D16M2 15 55 1 46 5 55 2 47 51 619 7 ATV56D23M2 20 70 3 59 6 70 3 60 66 785 ATV56D33M2 30 97 2 80 8 97 2 88 97 1127 5 ATV56D46M2 40 124 2 102 0 125 4 115 126 1332 Table 5 contains specifications for 460 V and 208 230 V drive controllers Table 5 Specifications Input voltage 460 V 415 or 208 V 10
90. 2 5K NOTES 192 CONTROL TRANSFORMER SHOWN FOR 460V PRIMARY 3 FOR 230V PRIMARY JUMPER H2 H3 IS REMOVED AND JUMPERS H1 H3 amp H2 H4 ARE INSTALLED FOR 208V EOM PRIMARY REFER TO DETAIL A 2 AUTO SPEED REF 4 20 mADC SIGNAL O 102 DELAY TIMER TR IS CONNECTED ACROSS COIL TERMINALS 1 amp A2 ON IC CONTACTOR FOR ALL CONTACTORS EXCEPT 3 THOSE WITH PART S LC1FXXX FOR THESE TR IS CONNECTED IN SERIES WITH COIL TERMINAL A1 0 4 0 5 4 RIB 28 FUSES FU7 amp FU8 SUPPLIED ONLY ON 50 100HP 460 VAC 24 30 50HP 208 230 VAC 2 ane era FAULT RIC 29 CLOSES ON FAULT LOP SIGNAL CONFIGURE CONTROLLER FUNCTIONS AS FOLLOWS Ic Ks RIA MENU 1 DAMPING 100 4 Ln OFF i MENU 6 1 TORQUE TYPE VARIABLE OR VARIABLE LOW NOISE HANDS AUTO 4 PO Get 1 MENU 6 2 COMMAND TYPE 2 WIRE MAINTAINED e x u2 i sae i MENU 7 12 LOW SPEED 3 HZ nn 4 pi adu 1 7 30 MENU 7 12 ACCELERATION 10 SEC RUNNING R2C Tk state O NO AFC MENU 7 12 DECELERATION 10 SEC REA am RUN CONTACT 1 MENU 7 13 CONTROL TYPE NOLD 32 M 8 T R2A 31 AFC MODE STATUS El 0 3 u MENU 7 2 AUTO MANUAL LI3 CLOSES WHEN AUTO o AUTO RUN INPUT L4 AUTO START CONTACT SPEED REFERENCE 2 AI MODE IS SELECTED Q SUPPLIED BY OTHERS MENU 7 3 R2 RUNNING STATE 38 un pon L3 ws USER CONNECTIONS Q9 GND cL2 m 1B 5 4 s L USE
91. 2 L1 Control 1 Control Power CE 0 20 mA NY DNE ENABLE 4 20 mA Equipment 1 F1 F3 R1 A A pp ed cle L3 L2 24 14 12 LH 10 cl2 13 12 1 BE 1 E 1 1 to 1 Keypad 6 1 1 1 Connector 1 WI T3 i 1 ILOP 102 101 COM AO2 AO COM jReC R2A ReB RiC R A RIB PB PA Oo 6 E Add F10 and F11 fuses if tap conductor protection is required The CL1 and CL2 inputs of all ATV56 drive controllers are internally protected and require no external fusing Figure 19 2 Wire Control Circuit Diagram Figure 19 is a 2 wire control circuit diagram It shows how to connect a branch circuit disconnect device and protective fusing to the drive controller Additional sequencing logic may be required See Tables 11 to 15 on pages 30 32 for additional equipment required 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 2 Wire Control with Isolation Contactor on Line Side Coast to Stop Existing user supply shown q4 YYv Chapter 2 Wiring Control Circuit Diagrams Internal L3 12 L Control 1 Power _ _ 1 0 20 420mA KM1 or xd s L4 13 12 LH AP 10 coy 02 CLI L3 L2 Li 1 424 1 ada eo Ga 1 Keypad Connector gt i W T3 1 1 1 1
92. 43 Variable Torque Class 8839 Enclosed ATV56 Drive Controller Ratings 208 VAC 10 Switching Frequency 4 kHz Motor Power Input Line Current 11 Max Controller 208 V S utput Transient 2 urrent Part No 60 Hz 5 000 A 8 800 A Current 60 s Converter Part No hp A A A A 56UCG2V 1 5 8 5 7 4 6 5 1 56UDG2V 2 9 4 10 2 7 5 8 3 ATV56U41M2U 56UEG2V _ 3 12 9 14 10 6 11 7 56UFG2V_ 5 19 5 21 1 16 7 18 4 ATV56U72M2U 56UGG2V_ 7 5 28 2 30 6 24 2 26 6 56UHG2V_ 10 35 8 38 7 31 34 ATV56U90M2U 56UJG2V _ 15 50 6 54 7 47 51 ATV56D12M2U 56UKG2V _ 20 64 2 69 3 60 66 ATV56D23M2U 56ULG2V _ 25 77 9 84 4 75 83 56UMG2V _ 30 88 97 7 88 97 ATV56D33M2U 56UNG2V 40 112 124 9 114 126 56UPG2V _ 50 134 3 149 3 143 158 ATV56D46M2U 1 Short circuit current available at controller input 2 For controllers with the Remote Starter Bypass power circuit the short circuit withstand rating depends on the overcurrent protective device in the user supp ied bypass starter It cannot exceed 22 000 A Table 44 Variable Torque Class 8839 Enclosed ATV56 Drive Controller Ratings 208 10 Switching Frequency 56UCG2L_ to 56UMG2L 10 kHz 56UNG2L_ 4 kHz Motor Power Input Line Current 11 Max Controller 208 V utput _ Transient 2 Current Part No 60 Hz 5 000 8 800 Current 60 Converter Part No hp A A A A 56UCG2L_ 1 5 4 5 8 4 6 5 1 56UDG2L_ 2 9
93. 6 Low Speed High Speed Acceleration Time Deceleration Time Skip Frequencies Chapter 5 Configuration 7 General Configuration Menu Low Speed corresponds to the lower limit of the speed reference at or AI2 see Figure 45 and limits the minimum commanded running frequency to a value between 0 and High Speed It does not affect the starting frequency If the drive controller is commanded to run below the programmed Low Speed the output will be limited to the Low Speed value Factory setting is 0 Hz f Hz Higlis Speed Low Speed Reference 0 mA 20 mA 4 mA 20 mA 20 mA 4 mA Figure 45 Speed Reference High Speed corresponds to the upper limit of the speed reference at AI1 or AI2 see Figure 45 and limits the maximum commanded running frequency to a value between Low Speed and Maximum Frequency If the drive controller is commanded to run above the programmed High Speed the output will be limited to the High Speed value Factory setting is 60 Hz Acceleration Time is adjustable between 0 1 and 999 9 seconds and represents the time the drive controller will take to accelerate between 0 Hz and Nominal Frequency set in the 7 11 gt Motor Parameters menu page 70 Acceleration Time determines the base line slope used by the drive controller to accelerate between frequencies Factory setting is 3 seconds If the acceleration slope is too steep for the motor to accelerate the connected load the accelera
94. 6 519 01B December 1996 Controlled Stop Command Methods By Logic Input By Frequency Threshold By Frequency Threshold Logic Input Chapter 5 Configuration 7 General Configuration Menu CONT STOP BY LI LOGIC INPUT ACTIVE STATE LOW m STOP TYPE FAST ved Fill table ESE suit FREEHHEEL FAST STOP ENT DC INJ 7B DC TIME 25 When Controlled Stop by Logic Input is selected the activation of the assigned logic input causes the drive controller to stop following the selected controlled stop method Freewheel Stop Fast Stop or DC Injection Braking The controlled stop logic input is only active in Terminal Command mode and is disabled in the Keypad Command mode To enable Controlled Stop by Logic Input assign a logic input define its active state as logic low 0 or logic high 1 and choose the stop method ONT STOP BY FREB L LEVEL 8 Hz STOP FAST Enter all values ESC With Controlled Stop by Frequency Threshold enabled if a Stop command is initiated the drive controller follows the active deceleration ramp until the programmed Frequency Threshold is reached At this point the drive controller automatically begins the programmed controlled stop method Controlled Stop by Frequency Threshold is active in both Terminal Command and Keypad Command modes To enable Controlled Stop by Frequency Threshold set Frequency Threshold an
95. 601 300 A 600 V 56046 2 VZ3 IM2300M0601 DB Transistor Modules 20 A 1200 V ATV56D16N4 D23N4 VZ3 IM1025M1001 50 1200 V ATV56D33N4 D46N4 VZ3 IM2050M1201 75 1200 V ATV56D54N4 VZ3 IM2100M1201 150 A 1200 V ATV56D64N4 D79N4 VZ3 IM2150M1201 60A 600V 56012 2 D16M2 VZ3 IM1060M0601 75A 600V 56023 2 VZ3 IM2075M0601 100 A 600 V ATV56D33M2 VZ3 IM2100M0601 150 A 600 V ATV56D46M2 VZ3 IM2150M0601 6 Diode Rectifier 75 A 1600 V ATV56D16N4 D23N4 VZ3 DM6075M1601 75 1600 V ATV56D12M2 D16M2 VZ3 DM6075M1601 2 Diode Rectifier 80 A 1600 V ATV56D33N4 VZ3 DM2080M1606 100 A 1600 V ATV56D46N4 VZ3 DM2100M1601 160 1600 V ATV56D54NA4 to D79N4 VZ3 DM2160M1606 80 A 1600 V 56023 2 VZ3 DM2080M1606 100 1600 V ATV56D33M2 VZ3 DM2100M1601 160 A 1600 V ATV56D46M2 VZ3 DM2160M1606 Fan Sub Assemblies Flow 10 ATV56U41N4 U54N4 VZ3 V661 Flow 20 56072 4 VZ3 V662 Flow 44 ATV56U90N4 D12N4 VZ3 V663 Flow 94 ATV56D16N4 D23N4 VZ3 V664 Flow 200 ATV56D33N4 to D79N4 VZ3 V665 Board Fan ATV56D33N4 to D79N4 VZ3 V6654 Flow 20 CFM ATV56U41M2 VZ3 V662 Flow 44 ATV56U72M2 U90M2 VZ3 V663 Flow 94 CFM ATV56D12M2 D16M2 VZ3 V664 Flow 200 ATV56D23M2 D46M2 VZ3 V665 Board Fan ATV56D23N4 to D46M2 VZ3 V6654 Precharge Resistors 33 0 8 5 ATV56D16N4 D23N4 VZ3 RO33W009 100 25 ATV56D33N4 D46N4 VZ3 R010W025 10Q 480W ATV56D54N4 D79N4 VZ3 R010WA481 330 8 5
96. 66 sensors thermal 11 sequence input 86 time out 56 time out fault 86 service factor 37 setpoint SP automatic 94 gain 89 90 input 89 menu 89 setpoint manual SPM 94 shielding 17 130 shock resistance 5 short circuit 46 56 123 shutdown 77 84 skip frequencies 76 smoke purge option 141 145 149 solenoids 17 spare parts 169 specifications 3 5 122 speed controlling 140 141 143 149 potentiometer manual 139 142 146 omitted 140 143 147 remote 140 144 148 user supplied 141 145 149 range 26 37 reference 77 79 manual 94 inputs 5 23 26 122 start stop command 140 141 143 145 147 148 store user settings 112 supply control 45 frequency testing for 109 input external 24 input line 43 switching between Al1 and Al2 80 T T1 T2 T3 terminals 20 21 134 tachogenerator 47 terminal command 51 selecting 65 terminal keypad 97 terminals 20 21 43 10 23 26 24 24 25 analog outputs 26 control 23 135 137 logic inputs 24 logic outputs 25 power 20 21 134 terminal strips 19 23 131 133 thermal level 1 98 limit 11 overload 36 45 overload fault 107 protection 34 60 105 three wire control 28 timing sequence 39 torque constant 38 driving 38 motor 35 37 overtorque 37 tightening 21 type selecting 67 menu 67 variable 3 4 38 total factory setting 112 transformer fuses 30 transient suppressors 30 31 transistor bridge testing 109 troubleshooting 45 47 tw
97. 9 ALTIVAR 56 LOCATIONS combination devices Tables 48 through 51 list wire size and torque requirements NOTE Typical device shown with options E EE TIT 14 mes L3 dor d X E 5 92971 uou 70 Fuse Block e Control H eI M Terminals Control m ENS g g g TE 17 27 SW1 P SPdITS 0 E 4 Terminals elle a 1 16 piae g 2 QW1 QW2 T1 T2 QE ep 11112113 SW2 T T 1 218 Il GND an ci Figure 74 Terminal Strip Locations for 1 50 hp VT amp 1 40 hp VTLN 460 V 1 25 hp VT amp VTLN 208 230 V Power Circuit W
98. ALTIVAR 56 drives are combination devices composed of drive controller power circuit box with options and wall mountable back pan The Class 8839 ALTIVAR 56 drive controllers are available in combination bypass or remote starter bypass power circuit configurations The following terminology is used throughout this chapter and is specific to the Class 8839 ALTIVAR 56 drive controller family When used as a component of the Class 8839 ALTIVAR 56 drive controller the ATV56U41 through ATV56D79 controllers described in Chapters 1 5 of this in struction bulletin are referred to as Power Converters This distinction is made to minimize confusion when discussing installation and adjustment practices The combination of the power converter enclosure power and control circuits which constitutes the Class 8839 product is referred to as the Drive Controller or Controller The combination of the controller and motor is referred to as the Drive The power circuit box mounted below the power converter is referred to as the BELE box The variable torque rating is referred to as VT The variable torque low noise rating is referred to as VTLN A DANGER HAZARD OF ELECTRIC SHOCK BURN OR EXPLOSION Turn off power supplying this equipment before working inside Failure to follow this instruction will result in death personal injury or electrical shock Follow these precautions unique to the Class 8839 ALTIVAR 56 drive contr
99. ARY JUMPER H2 H3 IS REMOVED AND JUMPERS H1 H3 amp H2 H4 ARE INSTALLED FOR 208V PRIMARY REFER TO DETAIL A DELAY TIMER TR IS CONNECTED ACROSS COIL TERMINALS A 1 amp A2 ON IC CONTACTOR FOR ALL CONTACTORS EXCEPT THOSE WITH PART S LC1FXXX FOR THESE TR IS CONNECTED IN SERIES WITH COIL TERMINAL 1 FUSES FU7 amp FU8 SUPPLIED ONLY ON 50 100HP 460 VAC OR 30 50 208 230 VAC CONFIGURE CONTROLLER FUNCTIONS AS FOLLOWS MENU 1 DAMPING 100 MENU 6 1 TORQUE TYPE VARIABLE OR VARIABLE LOW NOISE MENU 6 2 COMMAND TYPE 2 WIRE MAINTAINED MENU 7 12 LOW SPEED 3 HZ MENU 7 12 ACCELERATION 10 SEC MENU 7 12 DECELERATION 10 SEC MENU 7 13 CONTROL TYPE NOLD MENU 7 2 AUTO MANUAL LI3 AUTO RUN INPUT Ll4 SPEED REFERENCE 2 AI2 MENU 7 3 R2 RUNNING STATE AFC MODE STATUS CLOSES WHEN AUTO MODE IS SELECTED USER CONNECTIONS TB 4 USER SUPPLIED AUTO START CONTACT 1 ALTERNATE USER SUPPLIED OFF WIRING WHEN MOD HAND AUTO 1 i D07 IS USED 1 1 ep SPEED 1 Alto pf OSS 1 SHLD Al2 COM 1 AUTO SPEED REFERENCE t T 4 20 mADC SIGNAL gt Z 250 gt PROGRAMMABLE ANALOG OUTPUT gt REFER TO USERS MANUAL FREEZE FIRE STAT INTERLOCK REMOVE JUMPER IF USED TRANSFER RUN CONTACT CLOSES WHEN TC CONTACTOR IS CLOSED FAULT CONTACT CLOSES ON FAULT RUN CONTACT CLOSES WHEN AFC RUNS AFC MO
100. ATV56U41M2 to D46M2 1996 Square D All Rights Reserved 19 Chapter 2 Wiring Power Wiring Bulletin No 50006 519 01B December 1996 POWER WIRING Table 8 Power Terminal Strip Characteristics H Connector Terminal 21 Function 3 phase power supply Characteristics 460 VAC 15 56 4 units 208 V 410 230 V 15 56 2 units 47 to 63 Hz Filtered DC voltage 620 to 850 VDC ATV56 N4 units 275 to 425 VDC 56 2 units Output connections to motor J2 0 to 460 VAC to 208 VAC 0 to 230 VAC Single phase control supply 460 VAC 15 56 4 units 208 V 10 230 V 15 ATV56 M2 units 47 to 63 Hz Reserved Reserved Do not wire to PA PB terminals Tap for CL1 and CL2 460 VAC 15 ATV56 N4 units 208 V 10 230 V 15 56 2 units 47 to 63 Hz ATV56D16N4 to D79N4 drive controllers only For power terminal strip locations refer to Figure 9 on page 22 2 See circuit diagrams on page 28 and 29 The CL1 and CL2 terminals are connected with jumpers to L1 and L2 terminals When using a line contactor the jumpers must be removed and CL1 and CL2 supplied separately to maintain control power See circuit diagrams on page 28 and page 29 CL1 and CL2 must be connected to the same feeder conductors that supply L1 L2 and L3 of the drive controller 20
101. B December 1996 Percent of preset current limit 100 fn nominal frequency 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 fn Figure 66 Fold Back Fold Back is displayed only if the drive controller is configured for variable torque page 67 Fold Back tapers the current limit curve as shown in Figure 66 Fold Back can be activated or deactivated from the keypad display FAULT RESET NU YES LOGIC se amp ENT to modify ESC to uit Enabling Fault Reset allows the drive controller to be reset when in Terminal Command mode after tripping on certain faults when an assigned logic input is high To enable Fault Reset select Yes and assign a logic input The faults resettable with this function are Overvoltage DC Bus Overvoltage Output Phase Loss Drive Overtemperature Motor Overload Loss of Follower Sequence time out fault and Process time out fault When in Keypad Command mode page 65 a function key can be programmed for Fault Reset DB Fault is available on drive controllers with dynamic braking Enabling the function allows the drive controller to protect the resistor and connection by generating a fault if the DB resistor connection is open Output Phase Fault is used to detect a loss of output phase The fault can be inhibited by setting to No for troubleshooting or when the motor connected to the drive controller is less than 45 of drive controller power Output Phase Fault is au
102. Controlled Stop Command Methods continued Run Forward _ Controlled Stop 1 Active State low 0 i Frequency Output Figure 51 Fast Stop Timing Diagram 2 Wire Command 1 Run Enable 0 1 Run Forward 0 1 1 Controlled Stop 1 1 1 LIx Active 1 1 State low 0 1 1 1 1 Frequency Output Figure 52 Fast Stop Timing Diagram 3 Wire Command With fast stop the drive controller decelerates as quickly as possible without causing a nuisance trip Figure 51 and Figure 52 illustrate timing sequence for Fast Stop DC Injection Braking WARNING NO HOLDING TORQUE DC injection braking does not provide holding torque at zero speed DC injection braking does not function during loss of power or drive controller fault When required use separate brake function for holding torque Failure to follow this instruction can result in death serious injury or equipment damage A CAUTION MOTOR OVERHEATING AND DAMAGE Application of DC injection braking for long periods of time can cause motor overheating and damage Protect motor from extended periods of DC injection braking Failure to follow this instruction can result in injury or equipment damage With DC Injection Braking DC current is injected in the stator creating a stationary magnetic pole which brakes the rotor This method of braking produces maximum torque at low frequencies 1996 Squ
103. D BACK Enter 10 for the minimum process level Select MAX FEED BACK 10 Enter 100 for the maximum process level 11 If desired enter optional LOW LEVEL ALM and HIGH LEVEL ALM values 12 Calculate PI SET POINT and enter the value in the 1 gt Parameter Setting menu 55 10 100 10 PI SET POINT 9999 5000 13 Adjust KP and KI to achieve the best system response 1996 Square D All Rights Reserved 93 Chapter 5 Configuration 7 General Configuration Menu Setpoint Manual 94 Bulletin No 50006 519 01B December 1996 SETPOINT MANUAL KEYPAD lel SPM INPUT AUTOZMANU ___ SPEED ___ amp ENT to select Table 35 SETPOINT MANUAL Menu Items Menu Item Description Range KEYPAD Selects the keypad as the means for entering the manual speed reference Enter speed reference with SP MANUAL in the 1 Parameter Setting menu when KEYPAD is selected SPM INPUT Analog input port used for manual speed reference entry AI1 AI2 AIS AIA AUTO MANU Logic input for switching between automatic setpoint and LI3 to LI8 manual speed reference When the logic input is high Manual is selected When the logic input is low Auto is selected REV SPEED Logic input for switching between forward and reverse speed LI3 to LI8 When the logic input is high the speed ref
104. D79N4 4 kHz Motor M Bower Input Line Current Brom e Controller 460v 5 000 AIC or 22000 Current Current Power 60 Hz 10 000AIC 11 AIC 60 s Ww 1 2 7 3 2 1 8 5 3 90 ATV56U41N4 2 47 5 7 3 4 5 3 110 1 3 6 5 8 48 5 3 130 ATV56U72N4 5 9 8 11 9 7 6 8 4 180 gt 56090 4 75 13 9 16 7 11 12 1 205 ATV56D12N4 10 17 6 21 4 14 15 4 265 ATV56D16N4 15 24 8 29 9 21 23 1 350 3 ATVS6D23NA 20 31 9 38 7 27 29 7 480 4 ATV56D33N4 30 44 52 4 40 44 600 ATV56D46N4 40 57 1 67 6 52 57 2 800 ATV56D54N4 50 68 3 80 8 65 71 5 910 5 ATV56D64N4 60 86 4 94 6 77 84 7 960 ATV56D79N4 75 106 116 96 105 6 1150 11 10 000 AIC denoted by asterisk 1996 Square D All Rights Reserved 3 Chapter 1 Receiving and Installation Technical Characteristics Specifications Bulletin No 50006 519 01B December 1996 Tables 3 and 4 show the power and current ratings for 230 V drive controllers when set for variable torque Table 3 and variable torque low noise Table 4 Table 3 Variable Torque Drive Controller Ratings 208 230 V 208 V 10 and 230 V 15 60 Hz 5 Switching Frequency ATV56U41M2 to D33M2 4 kHz ATV56D46M2 2 kHz Motor Powar Input Line Current Max Total Drive Output Transient Dissipated Controller 208 230 V 208V 230 V Current Current p o 60 Hz 8 800 5 000 2
105. DE STATUS CLOSES WHEN AFC IS IN AUTO MODE USER SUPPLIED WITH 007 MOD Yvvvvv x 1 x E 8 E SUPPLY MANUAL SPEED POT 2 5K AUTO SPEED REF 13 4 20 mADC SIGNAL N C FAULT CONTACT CLOSES ON FAULT LOP SIGNAL OFF HAND AUTO RUNNING N O AFC RUN CONTACT CLOSES WHEN AFC RUNNING 4b AUTO START CONTACT SUPPLIED BY OTHERS ISOLATION CONTACTOR IC OL s 7 0 3 bn eee ae te Co 12 MOTOR STARTER ee ee ee eee E Cro TRANSFER CONTACTOR TC 208 VAC 230 460 VAC TRANSFORMER 1 25 hp VT 1 40 hp VT 1 60 hp VT 1 25 VTLN 1 30hpVTLN 1 60 hp VTLN 50 hp VT 75 100 hp VT 40 hp VTLN 75 hp VTLN 30 50 hp VT 300 VA 30 40 hp VTLN OFF 18 AFC BYPASS FREEZE FIRE STAT INTERLOCKS REMOVE JUMPER BETWEEN TERMINALS 52010 475 06 22 amp 23 IF USED Figure 96 Remote Starter Bypass Package Power Circuit Z without Options 156 1996 Square D All Rights Reserved Bulletin No 50006 519 01B Chapter 6 Class 8839 ALTIVAR 56 Combination Devices December 1996 Notes 1996 Square All Rights Reserved 157 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Bulletin No 50006 519 01B Notes Decembe
106. ECELERATION 10 SEC MENU 7 13 CONTROL TYPE NOLD MENU 7 2 AUTO MANUAL L13 AUTO RUN INPUT L14 SPEED REFERENCE 2 Al2 MENU 7 3 R2 RUNNING STATE USER CONNECTIONS USER SUPPLIED AUTO START CONTACT FREEZE FIRE STAT INTERLOCK REMOVE JUMPER IF USED Ll4 Li 24 WIRING WHEN OFF MOD 007 IS USED HAND AUTO i LI2 LI3 10 SHLD 7 AUTO SPEED REFERENCE 4 20 mADC SIGNAL INPUT 2 250 PROGRAMMABLE ANALOG OUTPUT REFER TO USER S MANUAL OPTIONAL SMOKE PURGE RELAY REMOVE JUMPER IF USED AULT CONTACT CLOSES ON FAULT RUN CONTACT CLOSES WHEN AFC RUNS 208V TRANSFORMER CONNECTION 115 GND leen p i DETAIL A 1T Figure 91 Combination Package Power Circuit W with Options gt gt gt gt gt ye 120 VAC WILL RUN MOTOR AT FULL SPEED gt gt gt gt 1 ME i 1 i 1 RUNNING 1 STATE 1 1 4F AUTO START CONTACT SUPPLIED BY OTHERS 5 LC 6 5 1 8 3 LC 4 O 4r tc 2 O 4t FROM POWER 2 SUPPLY 208 VAC 1 25 hp VT 1 25 hp VTLN 230 VAC 1 40 hp VT 1 80 hp VTLN Control Circuit Diagrams AUTO SPEED REF 4 20 mADC SIGNAL 22 O N C AFC FAULT CONTACT 29 CLOSES ON FAULT a AFC RUN CONTACT 25 CLOSES WHEN AFC RUNNING Ti O gt T2 To O g
107. FAULT STATE R2 RUNNING STATE 2 4BMBLOG OUT QUT ASSIGNMENT VAL 01 MOTOR SPEED R z CURRENT The I O map is a series of display only screens that show the analog and logic input output terminal assignments I O Map is helpful for determining which input output terminals are assigned to which software functions and for displaying the state of the inputs outputs while operating the drive controller The I O Map consists of four three column display only screens The left column of each lists the inputs outputs the middle column shows the input output functions and the right column displays states or values I O states are given as 0 low logic state or 1 high logic state Refer to Chapter 2 for definitions of logic 1 and logic 0 for applicable logic I O Analog I O values are given in percentages See page 99 for base of percentage displayed 1996 Square D All Rights Reserved 61 Chapter 5 Configuration 3 Fault History 3 gt FAULT HISTORY Troubleshooting 4DISPLAY CONFIGURATION MENU 62 Bulletin No 50006 519 01B December 1996 S3FBULT HISTORY FAULT NAME STR M IN PHASE LOSS AC LIN OVERWOL RUM QUERLOAD ACC ENT to set marker The Fault History screen displays the last eight faults stored by the drive controller and run status at time
108. ION 139 Operator Controls General Arrangement and 139 Adjustable Speed Operation 139 Freeze Fire Stats 139 MOD B07 Group 2 Pilot Light Cluster 139 MOD C07 Line Isolation 139 MOD 007 Omit Hand Off Auto Switch amp Manual Speed Potentiometer 140 MOD E07 CSA 141 MOD F07 Smoke Purge 141 POWER CIRCUIT Y BYPASS 142 Operator Controls General Arrangement and Operation 142 Adjustable Speed Operation 142 Bypass 7 142 Freeze Fire Stats 142 MOD 07 Group 1 Pilot Light Cluster 143 MOD 07 Group 2 Pilot Light Cluster 143 MOD C07 Line Isolation 143 MOD 007 Omit Hand Off Auto Switch amp Manual Speed Potentiometer 143 MOD E07 CSA Certification if 145 MOD F07 Smoke Pu
109. Instruction Bulletin 50006 519 01B December 1996 Replaces 50006 519 01A dated 11 96 Price 30 00 ALTIVAR 56 Fan and Pump Drive Adjustable Speed Drive Controllers For Asynchronous Motors User s Manual Variable Torque 1 to 100 hp 460 V and 1 to 50 hp 230 V D SQUARE D A DANGER HAZARDOUS VOLTAGE Read and understand this bulletin in its entirety before installing or operating ALTIVAR 56 drive controllers Installation adjustment repair and maintenance of these drive controllers must be performed by qualified personnel Disconnect all power before servicing drive controller WAIT ONE MINUTE until DC bus capacitors discharge then measure DC bus capacitor voltage between PA and terminals to verify DC voltage is less than 45 V see page 42 The DC bus LED is not an accurate indication of the absence of DC bus voltage DO NOT short across DC bus capacitors or touch unshielded components or terminal strip screw connections with voltage present Install all covers and close door before applying power or starting and stopping the drive controller User is responsible for conforming to all applicable code requirements with respect to grounding all equipment For drive controller grounding points refer to the terminal connection drawings on Figure 9 on page 22 Many parts in this drive controller includin
110. Kit Drive Controller 1 W ATV56U41N4 ATV56U54N4 VW3 A66801T VW3 A66806 ATV56U72N4 ATV56U41M2 56090 4 ATV56D12N4 VW3 A66802T VW3 A66807 ATV56U72M2 75 ATV56U90M2 ATV56D16N4 110 ATV56D23N4 130 VW3 A66803T VW3 A66808 2 110 ATV56D16M2 130 power dissipated in the enclosure by a recess mounted drive controller 14 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Chapter 2 Wiring Contents Chapter 2 Wiring WIRING noc EPI ee OP Ive oae es 16 General Wiring Practices 16 Branch Circuit Connections 16 Control Wiring 5 17 Output Wiring Precautions 17 Grouhdiigiz s etoile t str oer deve wes 18 TERMINAL STRIP LOCATIONS 19 POWER WIRING 2 5 228 25 niet aae VE unie Re iquat quias 20 CONTROL WIRING cer e deme dp Ro eR ed Ke ER RR Re 22 USING THE LOGIC INPUTS 912 24 USING THE LOGIC OUTPUTS 12 25 USING THE SPEED REFERENCE INPUTS J13 26 USING THE ANALOG OUTPUTS 913 26 USING THE RE
111. LAY OUTPUTS 91 27 REMOVAL OF CL1 CL2 6 27 CONTROL CIRCUIT DIAGRAMS 28 3 Wire Control ee ee We a ee Se EI Y DE Bee eee 28 2 Wire Control with Isolation Contactor on Line Side Coast to Stop 29 1996 Square D All Rights Reserved 15 Chapter 2 Wiring General Wiring Practices WIRING General Wiring Practices Branch Circuit Connections 16 Bulletin No 50006 519 01B December 1996 Good wiring practice requires the separation of control circuit wiring from all power line and load wiring Power wiring to the motor must have the maximum possible separation from all other power wiring whether from the same drive or other drives do not run in the same conduit This separation reduces the possibility of coupling electrical noise between circuits When wiring ALTIVAR 56 drive controllers follow the wiring practices required by national and local electrical codes in addition to the following e When metallic conduit is used with ATV56U41N4 to D23N4 and ATV56U41M2 to D16M2 drive controllers a metal conduit entry plate kit VY1A66201 must be used It mounts in place of the existing plastic plate and is held in place with two screws A bond wire is included which must be connected to ground GND on the J2 terminal strip Use metallic conduit for a
112. LC1 9070 FNQ R FNQ R 10 D12 U90 600 V 35 T60060 3CR 2 3 25536 14 n 9080 LC1 9070 FNQ R FNQ R 15 D12 600 V 60 A T60060 3CR 2 KTK R 3 LA4PA2G 4 4 45 9080 LC1 9070 FNQ R FNQ R 15 D16 600 V 60 T60060 3CR 2 3 2 1 m 9080 LC1 9070 FNQ R FNQ R 20 D23 D16 600 V 70 A 60100 3 2 3 1 14 dis 9080 LC1 9070 FNQ R FNQ R 25 D23 600 V 90 T60100 3C 2 3 Lo ed oC 401106 eo 9080 LC1 9070 FNQ R FNQ R 30 D33 600 V 90 T60100 3C 2 KTK R 3 Ebo ed oC 1 40 2 ano eo 3 ea 9080 9070 FNQ R FNQ R 600 V 125 A Teo200 10 oj KTK 2611 0801166 4 29 20 6 10 9080 LC1 9070 FNQ R FNQ R 50 Dod 248 600 V 125 A 1 2 KFS FB2611cc 0801166 A4DA2G K75D20 6 0 3 ea 9080 9070 FNQ R FNQ R i 600 V 175 A 76020915 2 3 2611 11506 A9F98 1 14 1 6 10 3 ea 9080 LC1 9070 FNQ R FNQ R 600 V 2001 0 2 2611 11506 A9F98 1 14 1 610 3 ea 9080 LC1 9070 FNQ R FN
113. LTIVAR 56 Fan and Pump Drive User s Manual logic inputs 23 24 assigning functions to 77 displaying 61 logic output test 110 logic outputs 25 assigning functions to 97 displaying 61 loss of follower 55 97 107 LOSS FOLLOWER 46 low level alarm 91 low speed 58 75 M main menu 54 maintenance 44 max feed back 91 maximum frequency 74 mechanical resonance 76 memory failure 46 56 menus application functions 77 command type 67 control parameters 74 diagnostic mode 109 display configuration 62 display screen 53 55 drive configuration 53 drive Identification 53 drive initialization 112 drive parameters 69 fault history 62 fault management 100 general configuration 69 help 51 Map 61 index number 51 index numbers 57 jump to 51 keypad configuration 64 language 53 main 54 motor parameters 69 motor power 67 one bar graph 63 output assignment 96 overview 57 parameter setting 58 torque type 67 two bar graph 64 1996 Square D All Rights Reserved Index min feed back 91 MOD A07 143 147 07 139 143 147 C07 139 143 147 007 140 143 147 E07 141 145 149 F07 141 145 149 motor current 99 overload 55 58 adjustment 106 MOT OVERLOAD 45 overload protection 60 105 for self cooled motor 106 parameters adjusting 69 menu 69 power selecting 67 speed 99 adjusting 139 142 thermal state 99 types continuous duty 37 multiple 39 noise 35 overload fault 45 overload protection 39 overspe
114. Manual Allows switching between AI2 No No by logic command Al1 is manual Yes Logic input reference AI2 is automatic See Figure A 1 and Figure A 2 Controlled No Stop E E Allows frequency threshold and Logic f 752 Hz y No Input to work together to tailor the By LI Frequency level stopping process 0 1 72 Hz Stopping Methods Freewheel stop Freewheel stop Fast stop DC injection Shutdown Allows drive controller to dwell at low No 4 speed for a time adjustable between 1 185 Ne and 30 seconds before completely Dwell time 0 1 605 15 stopping Bypass No Used to run machine at full speed when Yes Define I O No the drive must be taken off line for Delay time 0 2to10s 2s service or repair Allows for isolation of Sequence Time out 5s the motor by means of a contactor Fault 0 2 to 300 s installed between the drive and the Process Time out Fault 5 s motor with a special command 0 2 s to 300 s Sequence PI Regulator No Yes Set Point Used for controlling level or flow of a Feed Back No process with setpoint and feedback Set Point Manual PI Parameters 1996 Square D All Rights Reserved inputs Bulletin No 50006 519 01B Appendix A Parameter Summary December 1996 7 General Configuration Menu Not Configured 1 0 e O
115. NG s CE 71 Rotation 72 2I ERIS Re Lees 72 Reassigning Analog and Logic Inputs 73 7 12 gt Control 74 Maximum Frequency 74 Low Speeds iis bose bee BORA aod ee ella 75 Speed See SU Var EUR ERE ER 75 Acceleration 75 Deceleration TIME ice ed tet SERE Ra ete Sees 75 Skip Frequencies 75 7413 Gontrol Typen aso o t ru Epis 76 Norral eu ean 76 NOLD No Load ci eatin etna a 76 7 2 Application FUNCHIONS uk hs Beck ee eae als oe ea 77 Preset 5 lt 78 Speed 79 Auto Maniual eorom E e Rep ewpE Vie erts ws 80 Controlled Stop s ze ERROREM RR RR UR th le nn Baye eagle eae 80 By Eogic Input 81 By Frequency Threshold 81 By Frequency Threshold Logic 81 Freewh
116. NSIDERATIONS 1 4 39 Chapter 4 lt lt 41 PRECAUTIONS se alg Absence AR ee ok DE A 42 PROCEDURE 1 BUS VOLTAGE 42 PROCEDURE 2 INPUT LINE VOLTAGE MEASUREMENT 43 PROCEDURE 3 CHECKING PERIPHERAL 43 PREVENTIVE 44 en al A pw eb een ie 44 FAULT MESSAGES eri es eet prep pee eae AD A REDE 45 Chapter 5 49 KEY RAD DIS PEAY 5 s e x tr ERES ER ROLE A Reeds Sans 50 8 6 Fe e Ete DE e Eod eS 50 v iuh critics receta os tese ue 50 seg Cor 50 Arrow W KoyS i tenu Re each MERE gis 50 N meric Keys sole EE Ee death war IE wee ede 50 Function Keys o AERE IRURE E RARE REGRESAR SA 51 iuo li IR Ae eee ee ea ate i 51 STORKO Y en ctu auth prs e del PELA ERA Ee td 51 RUN ec ue e ied vade 52 Keypad Display Connections 52 MENU OVERVIEW 2 Lirik ale cU anu E RUE S ERE RR 53 Selecting the Language
117. NSPECTION 8 INSTALLATION 9 MOUNTING IN GENERAL PURPOSE METAL ENCLOSURE 10 Mure ED 10 MOUNTING TYPE 12 IP54 METAL 12 Calculating Non Ventilated Enclosure 12 Ventilation esien RETIRER eerie ay LE tates oes 13 Recess Mounting aft eee bed tbe bla hte erp epe ey 13 Chapter 2 Wiring 0 15 WIRING ele eek eee 16 General Wiring 16 Branch Circuit 16 Control Wiring 17 Output Wiring 17 GrOUNCING 255 s 18 TERMINAL STRIP LOCATIONS 19 POWER WIRING patna ag Dawes RERUM IE 20 CONTROL WIRING nc Upon la eee woe eet 22 USING THE LOGIC INPUTS 912 24 USING THE LOGIC OUTPUTS 12 25 USING THE SPEED REFERENCE INPUTS 013 26 USING THE
118. NT 1 PRESET SPEED Z PRESET SPEEDS LOGIC INPUT a LOGIC INPUT a SPEED 1 LOGIC INPUT b SPEED it SPEED 2 Enter all amp 5 SPEED 3 15 Hz Enter all values ESC This function allows you to program up to preset speeds If one preset speed is required one logic input must be assigned Two logic inputs must be assigned if three preset speeds are required The preset speeds are adjustable from 0 1 to 72 Hz The actual running speed is limited to the setting of High Speed The programmed values must increase consecutively from speeds 1 2 and 3 If both logic inputs are low the speed will be the speed reference if present or low speed The factory preset value for one Preset Speed is 5 Hz for three Preset Speeds 5 10 and 15 Hz Table 29 gives input states for activation of 3 Preset Speeds If 1 Preset Speed has been selected the speed is active when the assigned input is high 1996 Square D All Rights Reserved Bulletin 50006 519 01 Chapter 5 Configuration December 1996 7 General Configuration Menu Table 29 Logic Input States for 3 Preset Speeds Input a Input b Low Speed or Reference 0 0 Preset Speed 1 1 0 Preset Speed 2 0 1 Preset Speed 3 1 1 Seven preset speeds can be obtained with the I O Extension Module For more information refer to the catalog document number VD0CO065201 Speed Reference SPEED REFERENCE SPEED REF l SPEED REF 2
119. ONTROLLER PART 8 118 CONTROLLER NAMEPLATE IDENTIFICATION 118 TECHNICAL 8 5 119 op alae 122 Short Circuit Withstand 0 123 DIMENSIONS AND WEIGHTS FOR WALL OR PANEL MOUNTING 124 HANDLING DRIVE CONTROLLERS 128 PRELIMINARY 128 WIRE ROUTING AND 14 4 129 Wire Class ed de Secs Ge i 129 Noise Cass c et reti E ER RT 129 Voltage Class we XC EC RR Rn 130 TERMINAL STRIP 6 131 ROWER WIRING RARE RU alee Pape ga he CE 134 CONTROL 1 1 44 135 1996 Square D All Rights Reserved Bulletin No 50006 519 01B ALTIVAR 56 Fan and Pump Drive User s Manual December 1996 Table of Contents SEQUENCE OF OPERATION AND OPTIONS 138 Terminal Command Mode vs Keypad Command 138 POWER CIRCUIT W COMBINAT
120. Q R icol 600 V 225 A 1 2 3 2611 15006 A9F98 k2oop20 1 14 1 610 1 Square D Class CC Fuse Block numbers 2 Bussmann part numbers 7 T1 has been dimensioned to supply KM1 coil inrush and sealed VA requirements only Any user control pilot device additions may require re dimensioning of T1 VA capacity 30 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Chapter 2 Wiring Equipment Recommendations Table 12 Maximum Allowable Line Fuse F1 to F3 for 460 V Drive Controllers Controller 56 4 Class CC Fast Acting Class T Semiconductor U41 U54 U72 600 V 25A 600 V 35A U90 D12 600 V 60A D16 D23 600 V 100A D33 D46 600 V 125A D54 D64 D79 600 V 225 Table 13 Recommended Equipment for 1 to 50 hp 208 230 V Drive Controllers M1 A1 F1 F3 Input F1 F2 Control 1 TS T1 F7 F8 F9 Line Power Motor Controller Fuses ATV56 M2 Ratings Control Sec Fuse Cl Fuse Line Transient Xfmr 2 Xfmr use Class Fuse Carriers Fuses Carriers Contactor 7 Fuses VT CC 2 2 Low VT Fast 208 V 230V Noise Acting 600 V 600 V 9080 9070 FNQ R FNQ R gt FB3611CC 1 R T rts ze ES 1 UH U4 M BETA KTK R 3 2611 0251066 0 26
121. R SUPPLIED o P4 424 Poa zr AUTO START CONTACT FU2 3 Ic 4 ALTERNATE USER SUPPLIED OFF 1 WIRING WHEN MOD HAND AUTO d D07 IS USED i E i ux ees 201 e us 7 F 1 10 Pa ia SiS nen Sec Sie Stet AIO zb cB ISOLATION CONTACTOR IC 1 SPEEDPOT 1 Ai ai Sle be i 1 1 mg ED ma PLA dd 25k u 1 lb SA p _ AUTO SPEED REFERENCE FROM FTN SHLD 12 4 20 mADC SIGNAL POWER 13 799 Z 250 SUPPLY 1 14 PROGRAMMABLE ANALOG OUTPUT 15 REFER TO USERS MANUAL OL FREEZE FIRE STAT INTERLOCK 2 1 REMOVE JUMPER IF USED O O SBC BYPASS RUN CONTACT oL qw CLOSES WHEN BYPASS RUNNING FU7 26 MOTOR 27 6 a Hi Sa 28 FAULT CONTACT O e Cor 29 CLOSES ON FAULT BYPASS CONTACTOR BC 30 7 RUNCONTACT f 31 CLOSES WHEN AFC RUNS F3 F3 a FUS FUG 208 VAC 230 VAC 460 TRANSFORMER VA 32 AFC MODE STATUS CLOSES WHEN AFC IS IN AUTO MODE 125 np VT Veo hp VT USER SUPPLIED WITH 007 MOD 460V 1 25 VTLN 1 30 VTLN 1 60 hp VTLN T H4 50 hp VT 75 100 hp VT HD H2 Hg 40hpVTLN 75 VTLN 30 50 hp VT pac 30 40 hp VTLN 208V TRANSFORMER CONNECTION D 1 H1 208V H2 1 F
122. SHLD 4 M 7 4 20 mADC SIGNAL FROM To 2 gt INPUT 2 250 REMOTE MOTOR gt PROGRAMMABLE ANALOG OUTPUT STARTER AO1 gt REFER TO USERS MANUAL FREEZE FIRE STAT INTERLOCK REMOVE JUMPER IF USED TRANSFER RUN CONTACT CLOSES WHEN TC CONTACTOR IS 1 Yyvvviviivd OPTIONAL SMOKE PURGE RELAY 120VAC WILL RUN MOTOR AT FULL FAULT CONTACT CLOSES ON FAULT RUN CONTACT CLOSES WHEN AFC RUNS r 208V TRANSFORMER CONNECTION 125 i DETAIL A CLOSED 1 25 hp VT 1 40 hp VT 1 60 hp VT 1 25 hp VTLN 1 30 hp VTLN 1 60 hp VTLN H1 50 hp VT 75 100 hp VT SPEED 40 hp VTLN 75 hp eccL FU4 GND PL CLUSTER PLCLUSTER 115v X2 S E AFC BYPASS 18 SPR 19 FREEZE FIE 1 STATE INTERLOCKS REMOVE JUMPER BETWEEN i T TERMINALS 22 amp 23 EET i IF USED 1 OPTIONAL SMOKE PURGE SPH JUMPERS BETWEEN 18 amp 19 1 eem SSS 4 F 7 20 amp 21 AND 22 amp 23 IF USED REF 52010 475 05 Figure 95 Remote Starter Bypass Package Power Circuit Z with Options 1996 Square D All Rights Reserved 155 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Control Circuit Diagrams Bulletin No 50006 519 01B December 1996 REMOTE STARTER BYPASS W O OPTIONS POWER CIRCUIT Z NOTES CONTROL TRANSFORMER SHOWN FOR 460V PRIMARY A FOR 230V PRIM
123. TPUT ASSIGNMENT FAULT MANAGEMENT oe amp ENT to select The 7 gt General Configuration menu allows access to four sub menus 7 1 gt Parameters 7 2 gt Application Functions including input assignments 7 3 gt Output Assignments 7 4 Fault Management These menus can be accessed only if the drive controller is stopped T 1 DRIVE PARAMETERS MOTOR PARAMETERS CONTROL PARAMETERS CONTROL NORMAL amp ENT to modify The 7 1 gt Drive Parameters menu allows access to basic motor and control parameters and control type The menu is accessible only if the drive controller is stopped and in Terminal Command mode page 64 To verify adjustments return to the Display screen by pressing F2 then start the motor To readjust stop the motor and return to the desired menu The parameter choices available on the sub menus vary depending on the torque type selected from the 6 1 gt Type menu and the control type selected from the 7 13Control menu See Table 27 CURRENT A NOMINAL FREB Hz NOMINAL UDLT DAMPING amp ENT to modify ROTATION NORM ABC CURRENT LIMIT naa Use the 7 11 gt Motor Parameters menu to adjust basic motor parameters The functions available from this menu vary depending on the type of control selected page 76 Table 27 shows the functions available from the menu under the various types of control Adjustmen
124. UA oa Lus 1 i 16 9 4 I 1 DETAIL OFF AFC BYPASS 4g 19 80071 Fat P ii 20 22 x Qu cm 1 1 1 FREEZE FIRE STAT INTERLOCKS REF 52010 475 04 REMOVE JUMPER BETWEEN TERMINALS 22 amp 23 IF USED Figure 94 Bypass Package Power Circuit without Options 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 NOTES REMO A PILOT LIGHT OPTION GROUP 1 RED PWR ON GREEN AFC RUN GREEN BYP RUN YELLOW AFC FAULT CONFIGURE CONTROLLER FUNCTIONS MENU 7 3 LO1 RUNNING STATE MENU 7 3 LO2 FAULT STATE A PILOT LIGHT OPTION GROUP 2 RED PWR ON GREEN AFC RUN GREEN AUTO MODE YELLOW AFC FAULT PLACE JUMPER BETWEEN TB 4 amp TB 32 CONFIGURE CONTROLLER FUNCTIONS MENU 7 3 LO1 RUNNING STATE MENU 7 3 LO2 FAULT STATE re SS SS A CONTROL TRANSFORMER SHOWN FOR 460V PRIMARY FOR 230V PRIMARY JUMPER H2 H3 IS REMOVED AND JUMPERS H1 H3 amp H2 H4 ARE INSTALLED FOR 208V PRIMARY REFER TO DETAIL A A DELAY TIMER TR IS CONNECTED ACROSS COIL TERMINALS 1 amp A2 ON IC CONTACTOR FOR ALL CONTACTORS EXCEPT THOSE WITH PART S LC1FXXX FOR THESE TR IS CONNECTED IN SERIES WITH COIL TERMINAL A1 FUSES FU7 amp FU8 SUPPLIED ONLY ON 50 100HP 460 VAC OR 30 50HP 208 230 VAC CONFIGURE CONTROLLER FUNCTIONS AS FOLLOWS MENU 1 DAMPING 100 MENU 6 1 TORQUE TYPE VARIABLE OR
125. Using Regulator on pages 89 to 90 SP GAIN OFFSET KP e PI FLT RATIO PISET POINT present in the 1 gt Setting menu only when KEYPAD is chosen for setpoint entry PI SP MANUAL present in the 1 gt Parameter Setting menu only when KEYPAD is chosen for manual speed reference entry T S0UTPUT ASSIGN LOGIC OUTPUTS ANALOG OUTPUTS amp ENT to select The Output Assignment menu allows Display of the logic and analog output assignments Assignment of functions to available outputs i e outputs not previously assigned from the 7 General Configuration menu LOGIC OUT FUNCTIONS READY STATE RUNNING STATE AT SPEED TERM KEYPAD amp ENT to select AUTO MANUAL CURRENT LIMIT FAULT STATE DRIVE THER AL LOSS FOLLOWER FREQ LEV CURRENT LEU THERMAL LEU THERMAL LEV gt L0 FB LIMIT 80 LEVEL FB HIGH ALARM ENT LOL BT SPEED FB LOW ALARM 102 CURRENT LINIT R2 RUNNING STATE Esc LCLEAR ASSIGNMENT SELECT INPUT amp ENT ENT ESC REASSIGN ENT 101 RT SPEED 101 THERMAL LEU ENT to confirm ESC to abort 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Ready State Running State At Speed Terminal Keypad Auto Manual Current Limit Fault State Drive Thermal Alarm Loss of Follower Chapter 5 Configuration
126. VARIABLE LOW NOISE MENU 6 2 COMMAND TYPE 2 WIRE MAINTAINED MENU 7 12 LOW SPEED 3 HZ MENU 7 12 ACCELERATION 10 SEC MENU 7 12 DECELERATION 10 SEC MENU 7 13 CONTROL TYPE NOLD MENU 7 2 AUTO MANUAL LI3 AUTO RUN INPUT Ll4 SPEED REFERENCE 2 Al2 MENU 7 3 R2 RUNNING STATE Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Control Circuit Diagrams TE STARTER BYPASS W OPTIONS POWER CIRCUIT 2 o MANUAL SPEED POT 2 5K 0 4 Alt 2 PL CLUSTER PL CLUSTER ea eee earls l 3 FAULT e AUTO Y Ka 22 MODE P O Loz MEE l o 1 AUTO SPEED REF _ 4 20 mADC SIGNAL LO1 SHLD 1 OFF AUTO 24V N C AFC FAULT CONTACT HAND CLOSES ON FAULT FAULT LOP SIGNAL ut 1 1 1 Le 1 1 x 1 RUNNING N O AFG T STATE RUN CONTACT 1 CLOSES WHEN 1 4 8 AFC RUNNING AUTO START CONTACT SUPPLIED BY OTHERS LC 8 LC q 1c GONNECTIONS IF USED ISOLATION CONTACTOR IC TB USER SUPPLIED AUTO START CONTACT Y FROM ALTERNATE USER SUPPLIED OFF 1 POWER WIRING WHEN MOD HAND AUTO 007 IS USED 1 SUPPLY ep1sJe22 2 s 10 i i 525 525 T COM Ld AUTO SPEED REFERENCE
127. W LEVEL ALM must be set greater than MIN FEED BACK and HIGH LEVEL ALM must be set less than MAX FEED BACK Select an analog input port for receiving the process feedback signal based on the type of signal used See Table 33 on page 90 for specifications of analog input ports Enter the minimum process value for the process feedback sensor in MIN FEED BACK and enter the maximum process value for the process feedback sensor in MAX FEED BACK LOW LEVEL ALM may be configured in conjunction with FB LOW ALARM to annunciate when the process is below an acceptable level Enter a process value between 9999 and 9999 corresponding to the level in which the feedback low alarm FB LOW ALARM should turn on Configure the logic output which will annunciate the fault minimum with FB LOW ALARM in the PI Parameters menu see page 95 HIGH LEVEL ALM may be configured in conjunction with FB HIGH ALARM to annunciate when the process is above an acceptable level Enter a process value between 9999 and 9999 corresponding to the level in which the feedback high alarm FB HIGH ALARM should turn on Configure the logic output which will annunciate the fault maximum with FB HIGH ALARM in the PI Parameters menu see page 95 The drive controller will be used to regulate the level of water in a wet well The pump will be pumping water out of the wet well to maintain the level between 8 feet and 17 feet The feedback signal is 0 to 20 mA At 5 feet the feedback signal is
128. __0 bow eruere ees r d 24 V l N z 12 ing 5 TB26 i Remote Speed Potentiometer tS oe ee es TBO7 X Freezestat RR Remote HOA TB5 L11 Auto Start Jumper Contact TB8 L14 Figure 82 Remote Wired Hand Off Auto and Manual Speed Potentiometer MOD E07 provides a Canadian Standards Association CSA certification label when required by local code requirements MOD F07 provides a smoke purge operating mode controlled by a user supplied 120 VAC signal applied between terminals TB20 and TB21 When 120 VAC is supplied to TB20 and TB21 the drive controller runs the motor at 60 Hz The jumper between terminals TB4 and TB16 must be removed before using this mode 1996 Square D All Rights Reserved _ _ 141 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Bulletin No 50006 519 01B Power Circuit Y Bypass Package POWER CIRCUIT Y BYPASS PACKAGE Operator Controls General Arrangement and Operation Adjustable Speed Operation Bypass Operation Freeze Fire Stats Interlock if used 142 December 1996 The Bypass Package allows you to run the motor from the power converter or from full voltage line power bypass mode The motor can be run in the bypass mode in the unlikely event the power converter becomes inoperative The Bypass Package consists of IEC ra
129. ad relays connected to drive controller output overload relay must be capable of operation over the expected range of drive controller output frequencies including direct current When DC injection braking is used Overload relay must be suitable for operation with direct current flowing to the motor Do not use overload relays equipped with current transformers for sensing the motor current Failure to follow these instructions can result in equipment damage A CAUTION MOTOR OVERHEATING This drive controller does not provide direct thermal protection for the motor Use of a thermal sensor in the motor may be required for protection at all soeeds and loading conditions Consult motor manufacturer for thermal capability of motor when operated over desired speed range Failure to follow these instructions can result in injury or equipment damage ALTIVAR 56 drive controllers provide indirect motor thermal protection by continuously calculating the theoretical thermal state of the motor The drive controller will trip if this state reaches 109 of nominal current The microprocessor calculates the theoretical thermal state of the motor from Motor thermal time constant based on assumed motor power Operating frequency Current absorbed by the motor Running time Assumed maximum ambient temperature of 40 C around the motor t 6 24 36 60 Hz 1h m 10 min IPod 4 min hot 2 min
130. ailure to follow this instruction can result in injury or equipment damage To avoid equipment damage follow these precautions when installing the drive controller Electrical current through drive controller will result in heat losses that must be dissipated into the ambient air immediately surrounding the drive controller To prevent thermal fault or equipment damage provide sufficient enclosure cooling and or ventilation to limit the ambient temperature around drive controller to a maximum of 40 C For power dissipation refer to Tables 1 through 4 on pages 3 4 Minimum clearances required around the drive controller for unobstructed air flow are shown in Figure 5 For proper thermal dissipation the minimum enclosure size must not be based on clearances alone Refer to section MOUNTING IN GENERAL PURPOSE METAL ENCLOSURE on page 10 for additional information Dimensions in mm Outlines 1 3 Outlines 4 5 ATV56U41N4 to D23N4 and ATV56D33N4 to D79N4 and ATV56U41M2 to D16M2 ATV56D23M2 to D46M2 Figure 5 Clearances for Drive Controllers Mount drive controller vertically Do not locate drive controller near heat radiating elements When installation surface is uneven put a spacer behind the drive controller mounting pads to eliminate gaps The drive controller exterior may be damaged if fastened to an uneven surface Drive controllers are Type 1 enclosed devices and must be installed in a suitab
131. ance trip Damping is available with any drive controller configuration page 67 This parameter adjusts the integral gain of the frequency loop to match the inertial response of the load to the frequency response of the drive controller The adjustable range varies with the drive controller configuration 1 to 100 for NOLD control with either variable torque configuration 1 to 80076 for Normal control with either variable torque configuration When Damping is properly adjusted and the drive controller is not in current limit or ramp modification the motor speed should follow the speed reference ramp without oscillation and with little overshoot During steady state operation with constant load the motor speed should remain constant with no oscillation If the motor load changes the drive controller should correct the motor speed disturbance rapidly with little or no oscillation 1996 Square D All Rights Reserved 59 Chapter 5 Configuration 1 Parameter Setting Menu Profile Motor Overload 60 Bulletin No 50006 519 01B December 1996 The factory preset value of Damping is 20 which corresponds to 1 5 times the factory set motor inertia for the selected motor power rating Most applications do not require Damping adjustment If the motor speed oscillates or overshoots the desired speed during changes in the motor speed reference or during steady state operation with constant load Damping is
132. and factory setting the drive controller takes reference frequency stop and run commands from its terminal strip connections 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Using Keypad Command Mode Chapter 5 Configuration 5 Keypad Configuration Menu Keypad Command allows the drive controller to run and receive its reference frequency from the keypad display If keypad is removed from drive controller while in keypad command mode then the controller will stop and may trip on serial link fault Command mode can be set in one of two ways 1 Select TERMINAL COMMAND from the menu The drive controller will operate in the TERMINAL COMMAND mode 2 Select TER KEY by LI from the menu and assign a logic input LI3 or LI4 This enables switching between command modes by logic input When the assigned logic input is low state 0 Terminal Command will be active When the assigned logic input is high state 1 Keypad Command will be active To reassign a logic input follow the instructions on the screen NOTE Keypad Command is only accessible when in Total Lock if TER KEY by LI has been selected before locking Keypad Command allows the drive controller to run independently of its logic and analog inputs To start the drive controller in Keypad Command momentarily press the RUN key The drive controller will start following the acceleration ramp To stop the drive controller momentarily
133. are D All Rights Reserved 83 Chapter 5 Configuration 7 General Configuration Menu Controlled Stop Command Methods continued Shutdown 84 Bulletin No 50006 519 01B December 1996 Two adjustable parameters DC Injection Level and DC Brake Time control the operation of DC Injection Braking DC Injection Level sets the current level used for injection braking The level is programmable between 50 and 110 of nominal drive controller current Factory setting is 70 Actual braking torque depends on the motor characteristics DC Brake Time can be set between 0 and 30 seconds preset at 2 seconds If 30 1 seconds is selected the drive controller brakes for 30 seconds at the adjusted level and then continuously at 50 of rated current 1 Run Forward 0 Controlled Stop 1 LIx Active 9 State High DC injection Figure 53 DC Injection Timing Sequence 2 Wire Command L1 1 Run Enable 0 Run Forward Controlled Stop 1 Active 0 State High f Frequency output 0 1 Hz DC injection 0 5 s Figure 54 DC Injection Timing Sequence 3 Wire Command SHUTDOWN NO YES el LOGIC OUTPUT DWELL TIME iis amp ENT to modify Shutdown allows the drive controller to dwell at Low Speed for a time period adjustable from 0 1 to 60 seconds before completel
134. atio 95 integrator 95 parameters 95 ref output 95 Regulator 77 regulator 88 application examples 91 93 function compatibility 89 using the function 89 set point 88 89 SP manual 88 94 pilot lights group 1 148 147 group 2 139 143 147 power circuit W 139 140 circuit Y 142 144 145 circuit 7 146 148 control 45 converter 117 fuses 28 input line 43 LED 19 44 loss fault 101 ratings 3 4 119 121 supplies control 20 input line 20 logic inputs 24 logic outputs 25 precharge failure 46 56 1996 Square D All Rights Reserved Bulletin No 50006 519 01B October 1997 preset speeds 77 78 preventive maintenance 44 process input 86 time out 56 time out fault 86 profile 58 60 70 71 programmable relay 23 R R1 R2 terminals 135 137 R1A R1B R1C terminals 23 R2A R2B R2C terminals 23 ramp time 34 ratings 3 208 V 121 230 V 4 120 460 V 3 119 ready state 97 RDY 55 62 recess mounting 13 reference inputs 23 reference signal 10 VDC 140 143 147 4 20 mA 140 141 144 146 149 relays capacitor charge 46 fault 23 27 outputs 27 overload 36 37 programmable 23 terminals 23 reset after fault 100 rev action 95 rev speed 94 reverse direction 99 ROM memory testing 109 rotation normalization 72 RST reset fault 66 RUN 55 62 command 139 142 contact 146 output command 86 running state 97 Bulletin No 50006 519 01B December 1996 S S terminal 23 safety label 2 SCR 66 scroll function
135. ation LOSS FOLLOWER Loss of follower loss of the 4 20 mA or 20 4 mA reference at AI2 input OUT PHASE LOSS _ Loss of an output phase DC BUS OVERVOL DC bus overvoltage overcurrent due to excessive braking or overhauling load MOT OVERLOAD 1996 Square D All Rights Reserved 55 Chapter 5 Configuration Bulletin No 50006 519 01B Access Levels December 1996 Table 21 Faults Displayed on Display Mode Screen Continued Fault Designation Description SHORT CIRCUIT or SHORT CIRCUIT GROUND FAULT Ground fault short circuit to earth on the output of the drive controller PRECHARGE FAIL Precharge failure capacitor precharge relay fault INTERNAL FAULT Internal fault or missing connections on CL1 and CL2 MEMORY FAILURE Error in storing to EEPROM AUTO TEST FAIL Main control board failure Without a tachometer fault occurs when output frequency is 20 above Maximum Frequency parameter setting for 250 mS Sequence time out sequence input not received after Run command within programmed time Used with Bypass function See page 85 Process time out process input not received after Run command within programmed time Used with Bypass function See page 85 DYNAMIC BRAKE Dynamic brake resistor lost or connection open See page 108 TRANS SHORT C or GF OPEN TRANSISTOR Transistor has failed open CONTROL SUPPLY 2 not connected Only recognized upon power up No Fault
136. ation of the motor may result After adjusting Current Limit operate the drive controller throughout its speed range The motor should always start in the correct direction and should rotate even with low 2 3 Hz values of speed reference The steady state motor current should not exceed the motor nameplate current rating For critical loads which cannot be rotated in the reverse direction always uncouple the motor from the load after adjusting Current Limit and check the motor for the proper direction of rotation 1996 Square D All Rights Reserved Bulletin 50006 519 01B Chapter 5 Configuration December 1996 7 General Configuration Menu Set Current Limit to Default Limit or enter a reduced value and select one of the activation methods Frequency Level when the drive controller exceeds the programmed frequency level the reduced Current Limit value is activated To keep the reduced Current Limit value active at all times set frequency level to 0 Logic Input assign a logic input to Current Limit see Figure 44 on page 74 for procedure When the assigned logic input is low state 0 the Current Limit value is the default setting When it is high state 1 the Current Limit is the reduced value Analog Input assign an analog input to Current Limit see Figure 43 on page 73 for procedure The set current limit is ignored and the analog input is scaled so that the adjustment range of current limit is 40 to 110 of
137. ccess cover located on the drive controller BELE box 2 Visually verify that all internal mounting hardware and terminal connection hardware is properly seated securely fastened and undamaged 3 Visually verify that the control board on the power converter is properly seated securely fastened and undamaged Verify that internal wiring connections are tight Inspect all connections for damage 4 Close and secure the drive controller door and replace access cover A CAUTION EQUIPMENT DAMAGE HAZARD Do not operate or install any drive controller that appears damaged Failure to follow this instruction can result in injury or equipment damage The Wire Class describes the compatibility of the field wiring terminal with the conductor material and insulation system When used in conjunction with the required conductor current rating and controller rated ambient temperature the Wire Class forms the basis for the selection of a conductor size which will limit the temperature on the conductor insulation at the field wiring terminal within acceptable limits Conductors with operating temperatures exceeding those given by the Wire Class may be used but the conductor size must be selected based on the Wire Class limits The Noise Class is used to categorize the electromagnetic properties of the voltages and currents present Wiring is classified into six categories for selection of wiring methods and physical segregation purposes Hi
138. cember 1996 NOTE Typical device shown with options 558 L1 L2 L3 swe g Contra i Terminals S 17 27 1 16 d e Swi QW1 QW2 SW1 hee Ex Ez T1 T2 T3 2070 a f SW2 N ale GND Fuse Block f Figure 76 Terminal Strip Locations for 60 100 hp VT amp 50 75 hp VTLN 460 V 30 50 hp VT amp 30 40 hp VTLN 208 230 V Power Circuit W NOTE Typical 0 device shown with options 11 12 13 SW2 T1 T2 T8 Control E SW2 Terminals Control 1 15 Terminals QW1 QW2 16 33 SW1 GND Fuse Block EL Figure 77 Terminal Strip Locations for 60 hp VT amp 50 60 hp VTLN 460 V Power Circuit Y or Z 132 01996 Square D All Rights Reserved Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Bulletin No 50006 519 01B Terminal Strip Locations December 1996
139. circuits are supplied W Combination package Y Bypass package Z Remote starter bypass package 06 08 Power circuit type Defines additional selections to configuration A Pilot light cluster 1 Power On Red Drive Run Green Bypass Run Green Drive Fault Yellow B Pilot light cluster 2 Power On Red Drive Run Green 07 09 Miscellaneous options Auto Mode Green Drive Fault Yellow Line isolation contactor D Omit Hand Off Auto selector and speed potentiometer E CSA certification F Smoke purge option CONTROLLER The nameplate for the Class 8839 ALTIVAR 56 drive controller is located on the left NAMEPLATE hand side of the back panel This nameplate shown in Figure 68 carries the IDENTIFICATION controller class type and MOD options listing When identifying or describing Class 8839 ALTIVAR 56 drive controllers use the data from this nameplate Options MOD code exe Naas CLASS SER CONVERTER ATVS6U90N4U Basic power converter model Controller type code gt S6UHG4VY A07C07E07F07 rz wma C Permissible input voltage 460 10 47 60 6 KA SHORT WITHSTAND RATING Output Frequenc Maximum input current ratings a KA SHORT WITHSTAND RATING y Control transformer OUTPUT Maximum output rated current VOLTS 0 460 PH HZ 0 60 72 AMPS 4 lt
140. compare with operating speed and drive controller motor power rating Check setting of damping and bandwidth if used adjustments Remove all power Check connecting cables and DB resistor with drive controller disconnected Use drive controller self diagnostics See Chapter 5 Check dynamic brake connections Change resistor if necessary LINK FAULT 2 Internal fault Software execution stopped Fault cannot be disabled always causes a freewheel stop 2 Occurs upon power up only 1996 Square D All Rights Reserved Note LED sequence on drive controller FAULT CAUTION POWER all illuminated or CAUTION POWER illuminated Cycle power 3 If fault persists replace keypad or main control board Bulletin No 50006 519 01B December 1996 Fault Message SEQUENCE T OUT Sequence Time out Chapter 4 Diagnostics Fault Messages Figure 27 Fault Messages Continued Probable Cause 1 Sequence input not received after Run command within programmed time Bypass function Troubleshooting Procedure Check connection between user supplied contact and logic input ensuring it is connected to programmed input Verify operation of contact Verify operation of external control sequencing PROCESS TIME OUT 1 Process input not received 1 after Run command within programmed time Bypass function Check connection betwee
141. constant load the motor speed should remain constant with no oscillation If the motor load changes the drive controller should correct the motor speed disturbance rapidly with little or no oscillation The factory preset value of Damping is 20 which corresponds to 1 5 times the factory set motor inertia for the selected motor power rating For most applications no adjustment of Damping should be required If the motor speed oscillates or overshoots the desired speed during changes in the motor speed reference or during steady state operation with constant load Damping is set too low and should be increased If the motor speed follows the speed reference ramp sluggishly or tends to vary during steady state operation with constant load Damping is set too high and should be decreased 1996 Square D All Rights Reserved 71 Chapter 5 Configuration 7 General Configuration Menu Rotation Normalization Current Limit 72 Bulletin No 50006 519 01B December 1996 T 113MOTOR PARAMETER PROFILE DAMPING ROTATION NORM Rewiring the input terminals L1 L2 and L3 will not change the direction of motor shaft rotation therefore with the Rotation Normalization parameter direction of rotation can be inverted from ABC to ACB in order for the motor shaft rotation to agree with the forward and reverse logic inputs Neither the drive controller nor the motor has to be rewired Select desired phase rotation and pres
142. ctory default parameter settings to be restored to the drive controller or the user configuration and adjustment settings to be saved to or recalled from a memory card VW3A66901T This selection returns all of the drive controller adjustment and configuration parameters to the original factory default settings 3 13T T FACTORY Do uou want to change THIS ACTION CLEARS THE ACTUAL CONFIGURATION AND SETTINGS Bre uou sure ENT to eanfirm all the Parameters ENT to factory settings ENT to confirm ESC to abort A WARNING UNINTENDED EQUIPMENT ACTION Factory default settings will be substituted for present settings when Total Factory Settings is selected and confirmed Factory default settings may not be compatible with the application After returning to total factory settings verify that default settings are compatible with application requirements Failure to follow this instruction can result in death serious injury or equipment damage NOTE The PCMCIA Memory Card cannot transfer files between drive controllers of different power ratings or between drive controllers which contain different versions of software See page 54 to determine controller power rating and software version Up to 16 configurations can be saved in a PCMCIA memory card catalog number VW3A66901T After selecting Store User Settings a message will appear prompting you to insert a memory card PLEASE
143. cy 0 0075 Hz 0 00005 times High Speed Temperature drift 2 Analog inputs x 10 4 times High Speed C typical Keypad display 7 x 10 7 times High Speed C maximum Frequency range of power converter ATV56U41N4 to D79N4 0 1 to 72 Hz 56041 2 to D46M2 0 1 to 72 Hz Torque overtorque See Chapter 3 Speed reference 0 10V Al2 4 20 mA 0 5 V with switch on control board 0 20 mA x 20 mA 20 4 mA with keypad display Manual speed potentiometer to Speed regulation determined by motor slip typically 3 SLFV sensorless flux vector 1 Efficiency Typically greater than 96 Reference sample time 10 ms Ramps Acceleration 0 1 to 999 9 seconds Deceleration 0 1 to 999 9 seconds Motor protection Class 10 overload protection with bypass option in addition to controller internal electronic thermal protection Self diagnostics with full fault messages in three languages Keypad display Also refer to Chapter 5 Temperature Operation 32 to 104 F 0 to 40 C Storage 13 to 158 F 25 to 70 C Humidity 95 maximum without condensation or dripping water Altitude lt 3 300 ft 1 000 m above this derate by 1 2 for every 300 ft 100 m max 6 600 ft 2 000 m Enclosure Type 1 Pollution degree Pollution Degree 3 per NEMA ICS 1 and IEC 664 1 Operational test vibration Conforming to IEC 721 3 3 3M3 amplitude
144. d select a stopping method Freewheel Stop Fast Stop or DC Injection Braking CONT STOP LI4FREB L LOGIC INPUT RH ACTIWE STATE STOP TYPE FREB LEVEL Hz STOP TYPE DC To enable Controlled Stop by Frequency Threshold Logic Input assign a logic input and define its active state Set the Frequency Threshold and select stopping methods for both commands If both Logic Input and Frequency Threshold commands are selected and active the stop type for the Logic Input command has priority however both commands can be used in the same stopping sequence 1996 Square D All Rights Reserved 81 Chapter 5 Configuration Bulletin No 50006 519 01B December 1996 7 General Configuration Menu Controlled Stop Command Methods continued Freewheel Stop Fast Stop 82 When Frequency Threshold Logic Input is selected and the drive controller is in Terminal Command mode controlled stopping is active both at the frequency threshold and with the logic input When the drive controller is in Keypad Command mode controlled stopping by frequency threshold is active but controlled stopping by logic input is disabled At the first command to stop the drive controller stops following the selected controlled stop method Freewheel Stop Fast Stop or DC Injection Braking If the other command to stop is given th
145. d STOP keys and local command of drive controller this cover must be removed See Figure 32 on page 52 The key cover can be re installed to cover RUN and STOP keys The STOP key active in Terminal and Keypad Command modes commands normal stop of the motor The motor follows ramp as determined by selected deceleration time A WARNING INABILITY TO INITIATE STOP With the key cover removed the STOP key is enabled and active in both Terminal Command and Keypad Command modes When the key cover is installed the STOP key is not accessible Verify that appropriate system STOP functions are in place when the STOP key is not accessible Failure to follow these instructions can result in death serious injury or equipment damage 1996 Square D All Rights Reserved 51 Chapter 5 Configuration Keypad Display RUN Key Keypad Display Connections 52 Bulletin No 50006 519 01B December 1996 The RUN key commands the motor to run when the drive controller is in Keypad Command mode The motor follows the ramp determined by the selected acceleration time LI1 Run Enable on J12 must be high for the RUN key to command the motor 1 Run Enable 1 0 1 Runkey 0 E LT 1 0 Stop key Motor Speed Figure 29 Run Timing Diagram 9 ub D 9 connector for connection to the drive
146. damage When drive controller is powered up for the first time the Language menu appears allowing you to choose the language used on all menus Scroll through the language choices with the and keys and make a selection by pressing ENT Upon subsequent power ups the display passes directly to the Display screen To display Language menu after first power up press the ESC key twice The Drive Configuration screen shows factory settings of the configuration parameters Voltage is fixed at 460 V for the 460 V units ATV56 4 and is set to 230 V at first power up for 230 V units ATV56 2 This screen is only shown on first power up or after a total return to factory settings Advance to the Drive Configuration screen from the Language menu by pressing ENT The Drive Identification screen is automatically displayed on power up or can be accessed from the Drive Configuration screen by pressing ENT The Drive Identification screen displays the following nameplate information e ATV56 catalog number Software version Motor power Drive nominal current maximum I nominal Voltage From the Drive Identification screen press ENT to advance to the Display screen While the drive controller is running the default display is a bar graph showing reference frequency and drive status The type and number of functions displayed can be modified in the 4 Display Configuration menu page 62 If the drive controller is
147. e ALES dU 39 Motors in Parallel 2 3 gies geen ed a E 39 Output Contactor Between Motor and Drive Controller 39 Additional Motor Connected Downstream of the Drive Controller 39 1996 Square D All Rights Reserved 33 Chapter 3 Start Up Bulletin No 50006 519 01B Introduction December 1996 INTRODUCTION The ALTIVAR 56 drive controller is software driven Reconfiguration of the factory default settings may be required If the factory settings do not match the requirements of your application or if the drive controller must be reconfigured for a new application refer to Chapter 5 Generally at least four key parameters should be checked and adjusted if necessary prior to motor operation Nominal Current Motor Overload Control Type Rotation Normalization Note Changing the wiring of drive controller line terminals L1 L2 and L3 does not affect the motor rotation direction If the ALTIVAR 56 drive controller is supplied as part of a larger system also refer to the documentation supplied with the system for applicable configuration settings Observe the following precautions when using Normal control types The adjustment range of the Nominal Current parameter is 45 to 105 of the drive controller rated output current allowi
148. e alarm is issued at least one minute before the thermal limit is reached Thermal protection of all drive controllers is ensured by a thermal sensor attached to the heat sink When the sensor opens Drive controller trips the fault LED is illuminated and a fault message appears on the keypad display Ventilation system continues operating if control supply is maintained enabling the drive controller to be rapidly cooled down 1996 Square D All Rights Reserved 11 Chapter 1 Receiving and Installation Bulletin No 50006 519 01B Mounting in Type 12 IP54 Metal Enclosure December 1996 MOUNTING IN The ALTIVAR 56 drive controller is a Type 1 IP30 enclosed product however TYPE 12 IP54 certain applications may require Type 12 or IP54 protection The following kits are METAL ENCLOSURE available Recess mounting kits for mounting drive controller with the heat sink outside the enclosure There are two types available see page 13 Calculating Non Ventilated Below is the equation for calculating Rth C W the maximum allowable thermal Enclosure Size resistance of the enclosure T Max internal ambient temp C around drive controller Rth Max external ambient temp C around enclosure P Total power dissipated in enclosure W For the power dissipated by the drive controller
149. e controller will not start and displays a Sequence Time out Fault If the Sequence Input goes low while the drive controller is operating the drive controller will fault and freewheel stop Sequence Input The time period after a run command is received during which the Sequence Input must go high to prevent a sequence time out fault Sequence Time out Fault 0 2 300 s 5s Verifies the occurrence of a user defined event after the acceleration ramp has begun If this input does not go high within the time for which the Process Time out Fault is set the drive controller will trip on Process Time out Fault Process Input The time period after the acceleration ramp has begun during which the Process Input must go high to prevent a 0 2 300s 60s Process Time out fault Process Time out Fault The bypass scheme shown in Figure 58 on page 87 is an example of integrating electromechanical devices with the Bypass function and agrees with the operation described in Table 56 and Figure 57 Depending upon the application modifications to this circuit may be required to achieve the desired performance Command Type must be set in the 6 gt Drive Configuration to 2 wire for our example circuit to operate correctly NOTE When using the Bypass function an external overload relay should be present for motor overload protection The overload relay is required for protection of the motor against overload phase loss when opera
150. e drive controller will only stop following the controlled stop method corresponding to the second command if the method has priority as compared to the first method The order of priority is Freewheel Stop Fast Stop DC Injection Braking 1 Run Forward E 1 1 Controlled Stop 4 1 1 LIx Active 1 State High 0 I 1 1 1 1 f 1 1 Motor Speed i Figure 49 Freewheel Stop Timing Diagram 2 Wire Command uid Run Enable 0 1 1 Run Forward 0 1 1 Controlled Stop 4 LIx Active State High qnss sut 1 1 Motor Speed 1 Figure 50 Freewheel Stop Timing Diagram 3 Wire Command With Freewheel Stop the drive controller output is turned off and the motor coasts to a stop Figure 49 and Figure 50 illustrate the timing sequence for Freewheel Stop A WARNING EXTENDED STOPPING TIME Deceleration time during fast stop may be automatically extended depending on braking ability of drive controller A dynamic brake or mechanical stopping holding brake may be required for consistent stopping times independent of motor load conditions Fast Stop does not function during loss of power or drive controller fault Failure to follow this instruction can result in death serious injury or equipment damage 1996 Square D All Rights Reserved Bulletin 50006 519 01 Chapter 5 Configuration December 1996 7 General Configuration Menu
151. e individual external thermal overload motor protection This function is more effective in protecting a motor operated from a drive controller because it considers motor speed as well as time and current in its protection algorithm This is important since most motors applied on drive controllers are self cooled and their cooling effectiveness declines at lower speeds The drive controller s protection algorithm integrates motor current over time taking into account factors such as stop time and idle time Two types of motor overload protection can be selected from the 7 4 Fault Management menu page 100 for details 1 For Self Cooled Motor factory setting 2 No thermal protection 1996 Square D All Rights Reserved Bulletin No 50006 519 01B Chapter 5 Configuration December 1996 2 1 0 Map Motor Overload can be adjusted from 0 45 to 1 15 times the nominal drive controller current as displayed on the Drive Identification screen Factory preset is 0 9 Adjust Motor Overload value to nominal motor current see page 70 221 0 MAP Return to 4 Main menu ESC LOGIC INPUT MAF ASSIGNMENT 5 ANALOG INPUT LIL RUN PERMISSIVE LOGIC OUTPUT 19 RUN FORWARD ANALOG QUT LIS AUTO MANUAL amp ENT to select LI4 AUTO RUN 27HNALOG INPUT IH ASSIGNMENT VALS All SPEED REF 1 Al2 SPEED REF 2 ASSIGNMENT LOL AT SPEED 102 CURRENT LIMIT R1
152. e need for mechanical switching of the low level analog inputs and allows the Speed References to act independently instead of being summed Manual command is defined as Speed Reference 1 Automatic command as Speed Reference 2 When assigned input is high Auto is active When it is low Manual is active Auto Run Input is optional If assigned it allows the use of a second logic input for an additional 2 wire remote control run command only active when the drive controller is in Auto mode Local control can be used as either 2 wire or 3 wire control See Figure 97 on page 163 and Figure 98 on page 164 for interaction of Auto Manual and Controlled Stop in 2 wire and 3 wire control CONTROLLED STOP ND BY LOGIC INPUT BY FREQ LEVEL BY LI FREQ LEN amp ENT to modify Controlled Stop which customizes the stopping process is commanded by Logic Input Frequency Threshold Frequency Threshold and Logic Input When Controlled Stop is activated the drive controller stops according to one of the following methods Freewheel Stop Fast Stop or DC Injection Braking To enable Controlled Stop select a command and stop method as explained on the following pages Command methods are explained on pages 81 to 85 stop methods on pages 82 85 See Figure 97 and Figure 98 in Appendix A for interaction of Auto Manual and Controlled Stop in 2 wire and 3 wire control 1996 Square D All Rights Reserved Bulletin No 5000
153. e skip frequency bands f Hz Reference Figure 46 Skip Frequency T l33COMTROL TYPE NORMAL HOLT amp ENT to modify NOTE Changing Control Type resets the motor parameters in menu 7 11 to factory settings Normal control is the factory setting Normal is a sensorless flux vector control In order to create high torque at low speeds the drive controller maintains a 90 phase relationship between the rotor and stator electromagnetic fields by continuously calculating the position of the rotor in relation to the electrical position of the stator It is generally applicable on asynchronous motors and provides good torque performance When using Normal control motor horsepower must be equal to or one horsepower size less than drive controller horsepower For the NOLD control type the V Hz profile is linear intersecting the Vn and fn points of Figure 36 on page 60 during changes in speed command or changes in motor load During steady state operation the slope of the V Hz line is automatically adjusted to reduce the voltage on the motor depending on load at any given speed If a motor speed change is commanded or the motor load changes the initial V Hz profile is immediately reestablished The NOLD control type differs from the Normal control type in the following way Motor voltage reduction can occur even at motor nominal frequency for applications where the motor load varies Operation with NOLD contr
154. e to the motor When a thermal overload fault occurs a screen appears which asks Do you want to clear the thermal state If NO is selected the motor overload fault cannot be reset until the thermal state of the motor as calculated by the motor overload algorithm in the drive controller is less than 100 If YES is selected the motor overload fault is restrained The motor overload fault can be reset and the drive controller restarted The restraint of the motor overload trip will last for approximately one minute At the end of one minute the restraint will clear and a motor overload trip will occur This function can be used to allow maintenance personnel to perform an orderly shut down of a process in the event of a motor overload fault Subsequent restraint is possible if required However repeated use of the restraint function can ultimately lead to motor damage Input Phase Failure is used to detect loss of one or all input phases When set to Yes if one input phase is lost the drive controller will trip If the phase is restored and the drive controller is in 2 wire command with the Run Enable and direction inputs high the drive controller will automatically restart the motor regardless of the setting of Automatic Restart If the phase is restored and the drive controller is in 3 wire command the drive controller will be reset but the motor will not start If more than one phase is lost the drive will trip on undervoltage
155. ecember 1996 7 12 gt Control Parameters Appendix A Parameter Summary 7 General Configuration Menu Parameter Range Factory Setting Description Maximum 72 Hz 72 Hz Maximum output frequency Frequency Low Speed 0 to High Speed 0 Hz Low speed setting Low Speed to High Speed Maximum Frequency 60 Hz High speed setting Acceleration 0 1 to 999 9 s Length of time to accelerate from zero speed to nominal frequency Deceleration 0 1 to 999 9 s 35 Length of time to decelerate from nominal frequency to zero Drive controller reference will not stop Skip Low speed to 72 Hz None on the skip frequency which causes Frequencies Skip bands 2 or 5 Hz mechanical resonance Up to 3 can be 7 13 Type Control Variable Torque 1996 Square D All Rights Reserved programmed Factory Setting Normal 161 Appendix Parameter Summary 7 General Configuration Menu 162 7 2 gt Application Functions Bulletin No 50006 519 01B December 1996 Parameter Factory Setting Description Preset No Speeds No When preset Input f Input 2 0 0 Low reference speed 1 Preset speed speeds are 1 0 Preset Speed 1 3 Preset speeds selected factory 0 1 Preset Speed 2 72 Hz settings are 5 10 1 O Preset Speed 3 and 15 Hz Speed 0 20 mA Reference 4 20 mA 20 4 mA 4 20 mA Modification of AI2 for the type of signal x 20 mA Auto
156. ect AOL MOTOR SPEED MOT VOLTAGE aie Se 02 CURRENT CLEAR ASSIGNMENT Select OUTPUT amp ENT em feso REASSIGN 1 SPEED SELECT H z THERM SPEED ENT to confirm ESC to abort Reassigning an Analog Output The Analog Output Functions menu displays all functions that can be assigned to the analog outputs and allows reassignment where possible Only the outputs not previously assigned from the 7 gt General Configuration menu can be reassigned here Arrows indicate previously assigned functions i e functions assigned either by factory default or reassignment The menu illustrated above shows the procedure for reassigning the analog outputs Note that you may change the output signal scaling factor factory default 0 20 mA from the Analog Output Functions menu 20 mA equals 200 of the motor nominal current rating 20 mA equals High Speed 0 mA or 4 mA equals 0 speed Slip compensation does not act on this output 20 mA equals 200 of the nominal motor thermal state 20 mA equals 200 of the motor nameplate power in variable torque low noise configuration 20 mA equals 110 of the nominal motor voltage PI Ref Output PI FB Output PI ERR Output and PI Integral are described in Table 36 on page 95 1996 Square D All Rights Reserved 99 Chapter 5 Configuration 7 G
157. ed 20 Bypass Mode Select Normally jumpered or N C SPR contact when 21 option is supplied 22 Normally jumpered or SPR contact when 23 Freeze Fire Stat Interlocks 17 option is supplied Provision for user supplied N C Freeze Fire state contact Minimum 10 mA 24 VDC Maximum inductive load of 2 0 A 120 VAC Max 0 10 J operation 80 operations minute 24 1 0 A 220 VAC Max 0 25 J operation 7 25 Bypassdiun N O Contact 25 operations minute 1 See control circuit diagrams on pages 153 156 2 All terminals are rated 600 V 30 A Class 9080 Type GM6 Maximum wire size for all terminals is 10 AWG 2 5 mm Tightening torque 7 8 Ib in 0 8 0 9 Nem 3 Relay coil deenergizes on fault 4 Contact state with drive controller deenergized 5 Total current of 24 V internal supply is 210 mA Available current of the two logic outputs can be calculated as follows each input requires 10 mA each analog output requires 20 mA and the typical quiescent current of LOP is 15 mA 6 0 20 mA x 20 mA 20 4 mA programmable with keypad display 0 5 V Z 30 selectable with switch on control board 7 Available only when options are included 8 On when bypass contactor is energized 1996 Square D All Rights Reserved 2 0 A 24 VAC Max 0 10 J operation 80 operations minute Arc suppression provided by varistors in parallel w relay contacts Bulletin No 50006 519 01B December
158. ed 38 overtorque 37 self ventilating 37 speed range 37 timing sequence 39 torque 35 37 mounting dimensions 7 124 127 NEMA Type 1 IP30 10 NEMA Type 12 IP54 12 recess 13 multiple controllers 18 N nameplate 16 118 neg values 95 NLP 55 noise class 129 NOLD control 35 37 38 175 ALTIVAR 56 Fan and Pump Drive User s Manual Index nominal current 34 70 nominal frequency 70 nominal output frequency 34 nominal output voltage 34 nominal voltage 71 normal control 34 35 37 38 76 NRP 55 O offset 89 calculating 90 one bar graph menu 63 open transistor 56 open close switch 139 operator controls AFC off bypass switch 142 146 hand off auto switch 139 142 146 speed potentiometer 139 142 146 options compression lug kit 21 recess mounting kit 13 outputs analog 23 26 assignment menu 96 contactor 39 customer supply 23 logic 23 25 motor 20 phase fault 108 phase loss 47 55 OUT PHASE LOSS 47 power 20 relay 23 27 wiring 17 overcurrent 45 overheating 36 overload fault 45 protection 39 relay 36 37 106 overspeed 38 47 56 overtemperature 45 overtorque 37 overvoltage 45 176 terminals 20 21 parameter setting menu 58 partial factory settings 112 parts list 14 30 32 169 PCMCIA card downloading from 113 storing to 112 phase fault 45 47 loss 47 55 rotation 72 PI proportional integral err output 95 FB output 95 feed back 88 90 FLT r
159. eel Stop ss zipi PRA Ra s deep 82 Fast St0ps cole ek I BAIN oe ped eda 82 DC Injection 0 83 Sh tdown Ier Sa eee Pre we dae 84 oor usd exe reU ewido SUE eee 85 Pl Regulator ei ee 88 1996 Square D All Rights Reserved ALTIVAR 56 Fan and Pump Drive User s Manual Bulletin No 50006 519 01B Table of Contents December 1996 7 3 gt Output 96 Logic Output Functions dere eee ee ee ee eo ies 96 Analog Output 1 99 7 4 gt Fault 100 niei xL REA Te aed Sa ERE RAE os 100 Drive Controller Restart Methods 100 0 58 inlaw RACER GUN RISE 101 Automatic Restart 102 Catch On Ely ed le lioe pene teak en save 103 Motor 2 105 Adjustment of Motor 106 Ty
160. eight A B 460 V 230V 208 V Ib kg in mm in mm 500 127 500 127 25 VT 15 VT amp VTLN 15 VT amp VTLN 138 623 750 19 0 750 19 0 100 254 Figure 70 Mounting Information for 25 hp VT 460 V 15 hp VT amp VTLN 208 230V 1996 Square D All Rights Reserved 125 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Bulletin No 50006 519 01B Mounting Dimensions amp Weights December 1996 LIFTING HOLE DETAIL 31 8 TYP 2 PLACES CONDUIT ENTRIES TOP VIEW CONDUIT ENTRIES BOTTOM VIEW m 16 73 MOUNTING 424 9 gt 14 50 12 21 368 3 310 2 NES O _ Lifting Hole l 1 1 ll i mmm i 1 25 Do a 54 88 1393 8 55 98 1421 9 H 23 49 596 8 Y X 10 45 265 3 200 0 Ll 11 27 286 3 MOUNTING CLEARANCES HP Weight A B
161. el Disable Normal Additional motor Disable Normal Synchronous permanent magnet Not Recommended Synchronous wound field Not Recommended Synchronous reluctance Not Recommended An external thermal overload relay is required if the drive controller protection is disabled 1996 Square D All Rights Reserved 39 Chapter 3 Start Up Bulletin No 50006 519 01B Motor Considerations December 1996 40 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Chapter 4 Diagnostics Contents Chapter 4 Diagnostics nt MT 42 PROCEDURE 1 BUS VOLTAGE 42 PROCEDURE 2 INPUT LINE VOLTAGE 43 PROCEDURE 3 CHECKING PERIPHERAL 43 PREVENTIVE MAINTENANCE 44 Hz MN DEP PU 44 FAULT MESSAGES te Et 45 1996 Square D All Rights Reserved 41 Chapter 4 Diagnostics Bulletin No 50006 519 01B Precautions December 1996 PRECAUTIONS Read the safety statement below before pr
162. emains fixed while the other parameters are displayed successively on the second bar graph DISPLAY MODE OUT FREQUENCY 47 2Hz OUT CURRENT 3 1R RUN Figure 37 Display Screen Configured for Two Bar Graphs The Scroll format displays 11 functions in three tables 12 functions for ATV56D16 to ATV56D79 drive controllers See Figure 38 DISPLAY MODE DISPLAY MODE QUT POWER 3HHHHEEH QUT WOLTAGE U LINE U DC BUS VOLT HHH 1 SPEED REFER 2 OUT FREG iHHHHHHZ QUT CURRENT TORQUE 1st table 2nd table DISPLAY MODE THERMAL 5 DRIUE THER 5 ELAPSED h Hn DISPLAY MODE MOTOR 3rd table 4th table Figure 38 Display Screen Configured for Four Table Scroll NOTE For Motor Thermal State see first line of third table in Figure 38 if Motor Overload is set to No Thermal Overload in the 7 4 Fault Management menu ntH will be displayed instead of a percentage Drive Thermal State second line of third table appears only for ATV56D16 to ATV56D79 drive controllers CONFIG TERMINAL COMMAND TER KEV BY Use the 5 gt Keypad Configuration menu to configure the drive controller for Terminal Command or to configure a logic input for changing control of the drive controller from Terminal Command to Keypad Command In Terminal Comm
163. ence Figure 57 Bypass Timing Diagram L AAA sw OFF o AS BYP 8 o B SS B 0 DRIVE CONTROLLER R2A B ROC 5 76 R2C i 24 RUN PERMISSIVE Goi E 02 FORWARD D SEQUENCE INPUT 4 PROCESS INPUT PS eos Contact AS OFF BYP v x T B m e D x x Pump Figure 58 Bypass Circuit Diagram 1996 Square D All Rights Reserved 87 Chapter 5 Configuration 7 General Configuration Menu Regulator 88 Bulletin No 50006 519 01B December 1996 REGULATOR NOTE Note The drive controller has the capability to run in reverse when the PI Regulator sm SET POINT function is used For fan and pump applications in FEED BACK which reverse operation is not permissible select SET POINT MANUAL NO for NEG VALUES under the PI Parameters PI POROMETERS screen Table 36 on page 95 PI Regulator makes it possible to control a process by adjusting motor speed using a setpoint input and a feedback input For example PI Regulator can be used to control the flow or pressure in a pumping syste
164. eneral Configuration Menu 7 4 gt Fault Management Fault Stop Drive Controller Restart Methods 100 Bulletin No 50006 519 01B December 1996 T 44FAULT MANAGEMENT FAULT STOP FREEH POWER LOSS NO BUTO RESTBRT NO CATCH ON FLY RAMP amp EMT to modify MOTOR OVERLOAD PHASE FAIL YES LENT core LOSS FOLLOWER FRULT RAMP F LDERCK NO FAULT RESET NO DB FAULT NO OUT PHASE FLT VES CATCH pue el LENT I LIMIT NO The 7 4 gt Fault Management menu allows you to program the drive controller for detecting certain fault states and to specify fault stop methods NOTE The user must evaluate the effects of a drive controller fault on the process being controlled and select an appropriate fault management strategy If a drive controller fault occurs applications such as those involving safety critical aspects of a process continuity of service under unusual service conditions emergency braking etc may require additional apparatus or control to achieve an appropriate response or level of redundancy Fault Stop determines how the drive controller will stop upon occurrence of a fault On the ALTIVAR 56 freewheel stop is the fixed method of fault stop See Table 37 on page 101 In freewheel stop the drive controller output is turned off allowing the motor to coast to a stop according to inertia and resistant torque There are t
165. eparating the retaining clips on the cover from the side panel For ATV56D33N4 to D79N4 and ATV56D23M2 to ATV56D46N2 drive controllers the front cover is removed by first opening the cover then lifting it vertically With the front cover removed the ATV56U41N4 to D79N4 and ATV56U41M2 to ATV56D46M2 drive controllers have an IP20 enclosure rating The solid state switches of the drive controller power circuit do not provide complete isolation from the line Leakage currents and voltages may be present at the U T1 V T2 and W 18 terminals of the drive controller whenever power is present MOUNTING IN The ALTIVAR 56 drive controller is a Type 1 IP30 enclosed product However GENERAL PURPOSE certain application considerations may require that the drive controller be installed METAL ENCLOSURE inside a larger enclosure If so observe the following precautions Ventilation Forced air cooling is provided on all drive controllers A fan is located in the bottom of the drive controller see Figure 6 on page 11 and is protected by a perforated cover The fan draws in ambient air from underneath or from the front of the enclosure over the heat sink fins and expels it vertically from the top of the enclosure When mounting the drive controller be sure the air inlets and outlets are not obstructed Follow the installation precautions on pages 9 and 10 Observe minimum clearance distances as indicated in Figure 5 on page 9 If the enclosure does not
166. equency Frequency 60 Hz input 460 V ATV56 N4 units 230 V 56 2 units Nominal Current 0 9 times permanent output current of drive controller Volts Frequency Law Normal linear law Operating Frequency Range 60 Hz input 0 1 to 60 Hz Acceleration 3 s Ramp Times Deceleration 3 s Ramp time automatically adapted in case of overtorque Automatic by DC injection for 0 5 s when frequency drops below 0 1 Hz DC current level 0 7 times the permanent output current of drive controller Braking To Standstill low speed Motor Thermal Protection 0 9 times permanent output current of drive controller see page 36 Control Scheme Two wire control 34 01996 Square D All Rights Reserved Bulletin 50006 519 01 December 1996 CONTROL TYPES Normal NOLD No Load Chapter 3 Start Up Control Types Table 17 Factory Settings Inputs and Outputs Inputs and Outputs Terminal Factory Setting Programmable LH Run Enable No LI2 Run Forward No Logic Inputs Auto Manual Yes Ll4 Auto Run Yes Speed Reference 1 Yes Analog Inputs Al2 Speed Reference 2 Yes LO1 At Speed Yes LO2 Current Limit Yes Logic Outputs R1 Fault No R2 Running State Yes AO1 Motor Speed Yes Analog Outputs AO2 Motor Current Yes The control type affects the amount of available motor torque The control type setting is dependent on the type of motor
167. erence will be reversed When the logic input is low the speed reference will not be reversed Setpoint Manual provides the capability to manually control the controller speed This function is useful for slowly bringing the system up to the desired setpoint and then switching the setpoint to automatic control If KEYPAD is chosen as the means for manual speed reference entry enter the speed reference value in the SP MANUAL menu item in the 1 Parameter Setting menu The PISP MANUAL range expressed as Hz is from low speed to high speed SPM INPUT is the analog input port which will receive the manual setpoint signal Select the SPM INPUT based on the type of signal used See Table 33 on page 90 for specifications on the analog input ports AUTO MANU configures the logic input port which controls whether the manual speed reference or the automatic setpoint is used for setpoint entry If the logic input is low the automatic setpoint will be used If the logic input is high the manual speed reference will be used REVERSE SPEED configures the logic input port which controls the direction in which the drive controller runs in manual If the logic input is high the drive controller will run in the reverse direction from the direction commanded by the manual speed reference 1996 Square D All Rights Reserved Bulletin 50006 519 01 December 1996 P Parameters Chapter 5 Configuration 7 General Configurat
168. etpoint 1 2 OUTPUT output reference proportional to feedback 1 2 PI ERR OUTPUT Analog output reference proportional to error error is the 1 2 percentage difference between desired setpoint and actual feedback compared to the feedback range The analog output is scaled such that 0 or 4 mA is proportional to 5 and 20 mA is proportional to 5 PI INTEGRATOR Analog output reference proportional to integral error 1 2 FB LIMIT Logic output indicating that FLT RATIO has been exceeded See LO1 to LO4 description of PI FLT RATIO RO1 to RO4 FB HIGH ALARM Logic output indicating that HIGH LEVEL ALM has been exceeded See LO1 to LO4 description of HIGH LEVEL ALM on page 91 RO1 to RO4 FB LOW ALARM Logic output indicating that the feedback is less than LOW LEVEL ALM LO1 to LO4 See description of LOW LEVEL ALM on page 91 RO1 to RO4 1996 Square D All Rights Reserved 95 Chapter 5 Configuration 7 General Configuration Menu Regulator Settings Configurable from the 1 Parameter Setting Menu 7 3 gt Assignments Logic Output Functions 96 Bulletin No 50006 519 01B December 1996 The following PI Regulator Settings are also configurable in the 1 gt Parameter Setting menu PI SET POINT and PISP MANUAL are only configurable in the 1 gt Parameter Setting menu See descriptions of these settings in the
169. exterior Place the drive controller in an upright position 1 TiN LIFTING LIFTING FORCE FORCE emm 595 955 aad aan Figure 73 Hoisting Class 8839 ALTIVAR 56 Combination Devices PRELIMINARY The drive controller must be thoroughly inspected before storing or installing INSPECTION Upon receipt 1 Remove the drive controller from its packaging and visually inspect exterior for shipping damage 2 Ensure that the reference number of the drive controller which appears on the nameplate agrees with the packaging slip and corresponding purchase order 3 If you find any shipping damage notify the carrier and your sales representative 4 Ifyou plan to store the drive controller after receipt replace it in original packaging material and observe storage temperature specifications on page 122 128 1996 Square D Rights Reserved Bulletin No 50006 519 01B December 1996 WIRE ROUTING AND INTERCONNECTION Wire Class Noise Class Quiet Wiring 1 QW1 Quiet Wiring 2 QW2 Standard Wiring 1 SW1 Standard Wiring 2 SW2 Standard Wiring 3 SW3 Pulse Wiring 1 PW1 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Wiring Prior to installation 1 Open the power converter door and remove a
170. f 2 wire and 3 wire command J9MO0TOR POWER T3 khe 1 HP 1 3 ki 2 HP 2 2 3 HP vo ENT to modify For the ATV56U41 drive controller with a motor rated less than 3 hp or 4 hp variable torque the 6 3 gt Motor Power screen can be accessed to select the power of the motor This screen is only available on the ATV56U41 drive controller 1996 Square D All Rights Reserved 67 Chapter 5 Configuration 6 Drive Configuration Menu 2 Wire Command 3 Wire Command 68 Bulletin No 50006 519 01B December 1996 The use of 2 wire command will allow the drive controller to restart without operator intervention after fault reset or restoration of power provided that a run command is present For applications where automatic restarting may pose a hazard to personnel the use of 2 wire command is not recommended Li Run Enable 2 Fwd Speed Ref Speed Ref Figure 39 Timing Diagram for 2 Wire Command If 2 wire command is selected LI1 is Run Enable and must always be high for the drive controller to run If drive controller is running and goes low the drive controller will freewheel stop If the drive controller is running and the keypad STOP key is pressed regardless of whether the drive is in Keypad or Terminal mode the drive controller will stop following the normal ramp
171. g compare with operating Speed and drive controller motor power rating 3 Check tachometer connection 4 Check tachometer polarity CUSTOM FAULT 1 User defined 1 Dependent on user setting FEEDBACK LOSS No tachometer feedback signal Check tachometer wiring Other faults may be displayed depending on how the drive controller is programmed For more information on faults and self diagnostics refer to Chapter 5 1996 Square D All Rights Reserved 47 Chapter 4 Diagnostics Bulletin No 50006 519 01B Notes December 1996 48 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Chapter 5 Configuration Contents Chapter 5 Configuration KEYPAD DISPLAY 24 acti bigot otek Ier 50 ECD Display gee xs eee ond ERR VERRE Rede IE une 2 50 ENT K6y zoo vocor IURI MN Hber qa eue ed et 50 ESG ISOV oso CAS te c uude e EP as 50 Arrow AW KEYS 2 58 jad deb Ses qu e qm PIECE 50 Numeric Keys eu eR gence CEREREM ERROR PORE REEL 50 Function Keys e REED Mie ELVAI AER Yrs 51 Key GOVOl oa ce cuits cheer ir cbe des aba 51 STOP Key sane rev eee eua eee Y le Ru ea 51 RUN Key eei AET a uri erue 52 Keypad Display Connections
172. g and Installation INTRODUGTION Ie ei ca eee temen WE 2 SCOPE os des ee an ios ludo 2 Revision bevels wih hha 2 HAZARD LABELING 52 e gored hace Peg ag lai a oed oe Ra tee bs Re he Alea 2 TECHNICAL CHARACTERISTICS 3 Specifications el ase e ey 4 DIMENSIONS amp WEIGHTS FOR WALL OR PANEL MOUNTING 6 HANDLING DRIVE 8 PRELIMINARY INSPECTION 7 8 INSTALLATION 6 1 2 4 9 MOUNTING IN GENERAL PURPOSE METAL ENCLOSURE 10 Ventilation o2 Dey rats ere ecg c ep as 10 MOUNTING IN 12 IP54 METAL 12 Calculating Non Ventilated Enclosure Size 12 MentllatlOD etin E edo 13 Recess Mounting ERG ER 13 1996 Square D All Rights Reserved 1 Chapter 1 Receiving and Installation Introduction INTRODUCTION Scope Revision Level HAZARD LABELING Bulletin No 50006 519 01B December 1996 ALTIVAR 56 is a family of 1 to 100 hp 460 V a
173. g periods when the motor is not running or install thermostatically controlled strip heaters Recess Mounting To reduce power dissipated in an enclosure ATV56U41N4 to D23N4 and ATV56U41M2 to D16M2 drive controllers may be recess mounted in a wall of the enclosure with the heat sink on the outside This requires a cutout in the enclosure and a recess mounting kit for recess mounting When this kit is used the majority of the drive controller heat load is dissipated outside the enclosure The power dissipated in the enclosure P must be dissipated by the available surface area of the enclosure The heat sink assembly which is mounted outside the enclosure is rated for Type 12 IP54 protection when used with this kit There are two types of recess mounting kits the Gasket Kit which contains only the gasket necessary for recess mounting and the Mounting Adaptor Plate Kit which provides mounting plates along with gaskets to allow assembling the drive controller to the plates before bolting the assembly into the enclosure This aids in installation and maintenance of the drive controller 1996 Square D All Rights Reserved 13 Chapter 1 Receiving and Installation Bulletin No 50006 519 01B Mounting in Type 12 IP54 Metal Enclosure December 1996 Table 7 Recess Mounting Kits f Mounting Adaptor 1 Gasket Kit Plate
174. g printed wiring boards operate at line voltage DO NOT TOUCH Use only electrically insulated tools Before servicing drive controller Disconnect all power Place a DO NOT TURN label on drive controller disconnect Lock disconnect in open position Failure to follow these instructions will result in death or serious injury ALTIVAR is a trademark of Telemecanique S A or its successor in interest Schneider Electric S A 1996 Square D All Rights Reserved This document may not be copied in whole or in part or transferred to any other media without the written permission of Square D Electrical equipment should be serviced only by qualified electrical maintenance personnel No responsibility is assumed by Square D for any consequences arising out of the use of this material Bulletin No 50006 519 01B December 1996 ALTIVAR 56 Fan and Pump Drive User s Manual Table of Contents Chapter 1 Receiving and 1 INTRODUCTION eae Bee no ine ee tee ee eres 2 HAZARD LABELING 2 2 eee and ae eens te A e let 2 TECHNICAL CHARACTERISTICS 3 Speciticatioris shad wd EAE does 4 DIMENSIONS amp WEIGHTS FOR WALL OR PANEL 6 HANDLING DRIVE 5 1 8 PRELIMINARY I
175. gh susceptibility analog and digital control signals Signals falling under this classification include digital communication network circuits controller analog I O and analog process signals Medium susceptibility analog and digital control signals Signals falling under this classification include 24 VDC and AC control circuits Low susceptibility control or power circuits rated less than 600 VAC 250 VDC and less than 15 A voltage and current spectra are generally contained within 0 05 9 kHz Signals falling under this classification include 120 VAC control circuits Power circuits rated greater than 15 A voltage and current spectra are generally contained within 0 05 9 kHz Signals falling under this classification include line power to controllers Reserved Control or power circuits whose voltage or current spectra significantly exceed 9 kHz Signals falling under this classification include motor and dynamic braking circuits fed from PWM power converters 1996 Square All Rights Reserved 129 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Bulletin No 50006 519 01B Wiring December 1996 Voltage Class The Voltage Class is used to categorize the voltages present into recognized conductor insulation categories 30 150 300 and 600 V for selection of conductor insulation voltage rating and physical segregation purposes Based upon the Noise Class and Voltage Class of the conductors t
176. gure 11 Operating the Logic Inputs from External Power Supply The logic inputs may be assigned to other functions than those set at the factory Factory settings are listed in Table 16 on page 34 For information on other functions refer to Chapter 5 22 1996 Square D All Rights Reserved Bulletin No 50006 519 01B Chapter 2 Wiring December 1996 Using the Logic Outputs J12 USING THE LOGIC The logic outputs can be operated from either the internal supply or an external OUTPUTS 12 supply An external supply is required if the logic outputs drive a load at a voltage other than 24 V or if the current required is greater than the available current as calculated in Note 5 in Table 10 on page 23 NOTE If the internal supply is used LOP must be connected to 24 Limit 200 mA Customer supplied Figure 12 Operating the Logic Outputs from Internal Power Supply Figure 13 shows the connection of an external supply for operating the logic outputs i Customer 12 30 VDC _ Supply Figure 13 Operating the Logic Outputs from External Power Supply 1996 Square D All Rights Reserved 25 Chapter 2 Wiring Bulletin No 50006 519 01B December 1996 Using the Speed Reference Inputs J13 USING THE SPEED REFERENCE INPUTS 0 13 USING THE ANALOG OUTPUTS J 13 26 The ALTIVAR 56 drive controller has two analog input
177. harge relay closure control fault Check connections in drive controller after following Bus Voltage Measurement Procedure see page 42 INTERNAL FAULT 11 2 LOSS FOLLOWER Internal connection fault Missing connections on CL1 and CL2 Loss of 4 20 mA signal on Al2 input Check internal connections after following Bus Voltage Measurement procedure see page 42 Verify signal connections Check signal GROUND FAULT M1 E MEMORY FAILURE 2 Short circuit of phase to earth or grounding on the output of the drive controller EEPROM memory storage fault Remove all power With drive controller disconnected check connecting cables and motor insulation Use drive controller diagnostics See Chapter 5 Recall factory or customer settings with keypad AUTO TEST FAILI I CONTROL SUPPLY 21 E Main control board failure CL1 CL2 not connected Remove all power Check control board connections with drive controller disconnected Replace main control board Check connection of CL1 and CL2 OVERSPEED DYNAMIC BRAKE Output frequency is 20 above Maximum Frequency parameter setting no tachometer present DB transistor short circuit DB resistor short or open circuited Braking resistor thermal contact tripped 2 Check load base speed and power rating
178. hat the transistor could not be tested Logic Input Test LOGIC INPUT TEST ASSIGNMENTS RUN PERMIT 8 RUN FORWARD 1 AUTO MANUAL 1 B This menu allows you to change the state of the logic inputs to check for good wiring connections When the Logic Input Test screen is active changes made to the inputs will change input bit status without affecting the state of the drive controller Analog Input Test ANALOG INPUT TEST ASSIGNMENT VALS AIL SPEED REF 1 43 BI2 dH Analog Input Test is similar to Logic Input Test When this screen is active you can change the state of the analog inputs to check for good wiring connections without affecting the state of the drive controller Logic Output Test LOGIC OUTPUT TEST OUT ASSIGNMENT 01 READY STATE LOZ SPEED LEVEL 1 Ri FAULT STATE a iri 1 4 To force amp ENT 1 This menu allows you to change the state of the logic outputs to check for good wiring connections without affecting drive controller operation When the Logic Output Test screen is active all outputs are forced to low 0 state regardless of actual drive controller settings Changes then made to the outputs will alter bit status without affecting the state of the drive controller When you leave the Diagnostic Mode and return to Main menu the logic outputs resume the programmed settings in place before the test sequence 110 1996 Square D All Rights Reserved Bulletin
179. he drive controller must be thoroughly inspected before storing or installing Upon receipt 1 Remove the drive controller from its packaging and visually inspect exterior for shipping damage 2 Ensure that the drive controller catalog number agrees with the packing slip and corresponding purchase order The catalog number appears on the drive controller nameplate and shipping package label Refer to page 16 for location of drive controller nameplate 3 If any shipping damage is found notify your carrier and sales representative 4 If drive controller is to be stored after receipt replace it in original packing material and observe storage temperature specifications on page 4 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 INSTALLATION PRECAUTIONS Chapter 1 Receiving and Installation Installation Precautions Prior to installation 1 Open the drive controller door or remove access covers 2 Visually verify that all internal mounting hardware and terminal connection hardware is properly seated securely fastened and undamaged 3 Visually verify that the control board is properly seated securely fastened and undamaged Verify that internal wiring connections are tight Inspect all connections for damage 4 Close and secure the drive controller door or replace access covers A CAUTION EQUIPMENT DAMAGE HAZARD Do not operate or install any drive controller that appears damaged F
180. he wiring methods in Table 47 should be applied to the drive system Table 47 Wire Routing and Interconnection 3 Noise Class of Conductors Wiring Methods and Considerations QW1 QW2 SW1 SW2 PW1 Conductor Grouping in Wireways Conduits 1 All conductors of 1 or 3 phase AC power circuits must be bundled to minimize X X X stray magnetic fields 2 All conductors of a DC power circuit must be bundled to minimize stray magnetic fields X X X When paralleled conductors must be run in separate wireways or conduit bundle conductors into X X groups that minimize stray magnetic fields 4 Maintain conductor runs as short and direct as practical X X X X X Separation of Circuits X X X X X 1 DO NOT run different Noise Class conductors in the same conduit 2 DONOT run different Voltage Class conductors in same conduit unless all conductors are X X X X X insulated for the maximum Voltage Class present 3 All PW conductor groups must be individually segregated using metallic conduit X Segregate all conductors by Noise Class Use the following circuit separation when conductors can run parallel for more than 12 inches Metallic conduit 3 in between QW to SW PW X X X X X Metallic tray 3 in between SW to PW X X X Metallic tray 6 in between QW to SW PW X X X X X Against continuous metal surface 3 in between SW to PW X X X Agai
181. high or energized until output frequency falls below the programmed frequency level Frequency level is adjustable from 0 to 72 Hz To indicate with a low logic level assign a relay output and wire to the correct contacts Current Level Motor Current 1 1 1 Current Level b T Fl Figure 62 Current Level When drive controller exceeds programmed current level adjustable from10 to 110 of nominal drive controller current logic output is high or relay is energized and remains high or energized until drive controller falls below the programmed current level When thermal motor overload value reaches programmed thermal level adjustable from 0 to 200 of nominal motor thermal state logic output is high or relay is energized and remains high or energized until thermal motor overload value falls below thermal level FB Limit FB High Alarm and FB Low Alarm are described in Table 36 on page 95 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Analog Output Functions Motor Current Motor Speed Motor Thermal State Motor Power Motor Voltage Ref Output FB Output ERR Output PI Integral Chapter 5 Configuration 7 General Configuration Menu ANALOG QUT FUNCTIONS MOT CURRENT MOTOR SPEED MOTOR POWER THERMAL STATE ESC PI REF OUTPUT PI FB OUTPUT PI ERR OUTPUT evr STATE gt 00 3 amp ENT to sel
182. hree methods for resetting the drive controller after a fault Automatic restart 2 wire command only See page 102 Manual reset removal of all power for longer than 1 0 second then reapplication of power If input phase failure detection is enabled an input phase failure lasting longer than 1 0 second may also initiate a manual reset Fault reset by logic input or function key see page 108 In all cases fault reset cannot occur unless the cause of the fault is no longer present Certain faults described in Table 37 do not allow an automatic restart 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Power Loss Chapter 5 Configuration 7 General Configuration Menu Table 37 Fault Stop and Restart Methods Resettable Only Fault Reset by LI Non By Manual Reset Function Key or Reset Latching Removal Of Power Manual Reset Faults 11 Can be Automatically Short circuit Ground fault Precharge failure Internal fault Memory failure Dynamic brake fault Dynamic brake resistor fault Auto test failure Transistor short circuit Open transistor Link Fault AC line overvoltage DC bus overvoltage Sequence time out fault Overspeed Output phase loss Drive overtemperature Motor overload Loss of follower Process time out fault Serial link fault AC line overvoltage DC bus overvoltage Sequence time out fault Overspeed Undervoltage Output phase loss input phase Dr
183. hts Reserved Bulletin 50006 519 01B Chapter 5 Configuration December 1996 7 General Configuration Menu 3 Select for setpoint input 4 Calculate SP GAIN and OFFSET and enter the values Setpoint Signal Input on Corresponding Process Value OV 100 Setpoint Min Process value at low speed 10V 10 m8 Setpoint Max Process value at high speed Feedback Signal Input on AI2 Corresponding Process Value 0 mA 5 m3 Feedback Min Process value at minimum feedback 20 mA 10 m3 Feedback Max Process value at maximum feedback 10 100 200 5 SP GAIN 9999 4615 OFFSET 520 3 20 5 x 9999 4871 5 Select FEED BACK in the PI Regulator screen 6 Select FB INPUT 7 Select AI2 for feedback input 8 Select MIN FEED BACK 9 Enter 10 for the minimum process level 10 Select MAX FEED BACK 11 Enter 100 for the maximum process level 12 If desired enter optional LOW LEVEL ALM and HIGH LEVEL ALM values 13 Adjust KP and KI to achieve the best system response Example 4 This example is the same as Example 3 except it uses the keypad as the means for setpoint entry The desired setpoint point is 55 m8 1 Select YES SET POINT in the PI Regulator menu Select KEYPAD as means for setpoint entry Calculate SP GAIN and OFFSET as in Example 3 and enter the value Select FEED BACK in the PI Regulator screen Select FB INPUT Select AI2 for feedback input Select MIN FEE
184. ied bypass starter 11 56UCG4VW to 56UPG4VW 56UCG4LW to 56URG4LW ee 56UCGAVY to 56USG4VY en BGUCGALY to 56URG4LY 22 000 A Motor Circuit Protector 56UCGAVZ to 56USG4VZ 22 000 A Dependent upon OCPD by user 56UCGALZ to 56URG4LZ i supplied bypass starter 11 OCPD Overcurrent Protective Device limited by available short circuit current rating of user supplied bypass starter lt 22 000 A 1996 Square D All Rights Reserved 123 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Bulletin No 50006 519 01B Mounting Dimensions amp Weights December 1996 DIMENSIONS AND WEIGHTS FOR WALL OR PANEL MOUNTING MOUNTING 14 50 LIFTING HOLE DETAIL 368 3 Ba eae Cages T 12 51 je D gt 317 6 38 m i 9 6 H ee CE ery Lifting Hole 2 50 i 63 5 i dy i Vv 1 25 31 8 m TYP 2PLACES PERERA Sot LER EST mn LE CONDUIT ENTRIES TOP VIEW o 39 39 10
185. ight is normally not lighted until a controller protective circuit has caused an abnormal shutdown The LED is rated 24 V This pilot light cluster provides visual indication of protective functions and circuit status Listed below are the four pilot lights provided and their functions 1 Power On Red illuminates whenever mains power is applied to the controller The LED is rated 120 V 2 AFC Run Green illuminates whenever LO1 is high programmed for running state to annunciate a drive run condition The LED is rated 24 V 3 Auto Mode Green illuminates whenever the drive is running in Auto mode The LED is sequenced by the Hand Off Auto selector switch and is rated 24 V 4 AFC Fault Yellow illuminates whenever LO2 programmed for fault state is high to annunciate a drive fail condition This light is normally not lighted until a controller protective circuit has caused an abnormal shutdown The LED is rated 24 V MOD C07 provides a line isolation contactor factory wired between the line fuses FU1 FU2 and FU3 and the power converter L1 L2 and L3 The line isolation contactor is energized whenever the AFC OFF Bypass is in the AFC position MOD D07 omits the Hand Off Auto selector switch and manual speed potentiometer It is used when the user prefers to supply external control devices There are a number of ways to sequence the operation of the power converter when the Hand Off Auto switch and manual speed potentiomete
186. ilable fault current use the maximum input current listed On the ATV56U41N4 to D79N4 and ATV56U41M2 to D46M2 drive controllers the nameplate is located in the bottom right corner of the right side of the drive controller A WARNING OVERCURRENT PROTECTIVE DEVICES MUST BE PROPERLY COORDINATED To achieve published fault withstand current ratings install the specified fuses listed on drive controller nameplate and in Table 11 on page 30 Do not connect drive controller to power feeder whose short circuit capacity exceeds drive controller withstand fault rating listed on drive controller nameplate Failure to follow these instructions can result in death serious injury or equipment damage ALTIVAR 56 drive controllers require fuse protection ATV56U41N4 to D79N4 and ATV56U41M2 to D46M2 drive controllers require user supplied external fuses as indicated on the nameplate and in Table 11 on page 30 and Table 13 on page 31 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Control Wiring Precautions Output Wiring Precautions Chapter 2 Wiring Control Wiring Precautions All control inputs and outputs of the drive controller are isolated from the input lines however certain control wiring precautions must be followed Control wiring conductor runs must be kept short and direct Follow the conduit and circuit separation requirements listed in WIRING on page 16 Control contac
187. inactive during the power outage Green LED on drive controller goes out the restart control method reverts to that described in Catch On Fly Set to NO The advantage to this control method is that it produces the least additional speed disturbance of the three Catch On Fly selections while the motor is synchronizing to the drive controller output This method does have the disadvantage that residual motor voltage must be present for speed estimation to occur Nm Motor Speed Nsp Commanded Speed Vm Motor Voltage H i Im Motor Current 0 LI1 Run Enable LI2 Run Forward Power Power Off On Figure 64 Catch On Fly Set to RAMP Catch On Fly Set to When commanded to start into a spinning load the drive controller output voltage ILIMIT Refer to is reduced and the drive controller output frequency is set to the commanded Figure 65 frequency While the voltage is being reduced the drive controller output voltage is synchronized to the motor If synchronization is not possible the restart control method reverts to that described in Catch On Fly Set to NO If synchronization is possible the drive controller output voltage is then raised causing the motor to rapidly accelerate to commanded speed Acceleration generally occurs with the drive controller at current limit Provided that a run command is present the drive controller will start following an extended power outage where
188. inal installation site The carton protects the drive controller and prevents damage to its exterior Handle drive controller carefully to avoid damage to internal components frame or exterior When handling drive controller balance it carefully to keep it from tipping ATV56U41N4 through D46N4 and ATV56U41M2 through D33M2 drive controllers can be removed from their packing and installed manually After being removed from the carton or shipping wrap ATV56D54N4 through D79N4 and ATV56D46M2 drive controllers require some type of mechanical lifting Handle drive controllers With a hoist attaching a spreader bar to the two lifting rings on top of the drive controller see Figure 4 or For ATV56D54NA through D79N4 and ATV56D46M2 in a horizontal position with back of drive controller resting on a pallet A WARNING HANDLING AND LIFTING HAZARD Keep area below any equipment being lifted clear of all personnel and property Use lifting method shown below in Figure 4 Failure to follow this instruction can result in death serious injury or equipment damage To hoist the drive controller attach a spreader bar to the two lifting rings on top of the drive controller as shown in Figure 4 Handle the drive controller carefully to avoid damage to the internal components frame or exterior Place the drive controller in an upright position LIFTING amp FORCE Figure 4 Hoisting ATV56D54N4 to D79N4 ATV56D46M2 T
189. ion Menu PARAMETERS KP KI NEG VALUES REV ACTION FE LIMIT amp ENT to select FI FLT RATIO FI REF OUTPUT FI FB OUTPUT ERR OUTPUT FI INTEGRATOR ___ FB HIGH ALARM FB LOW ALARM ___ 180 H NO NO 1885 Table 36 describes the various PI adjustment parameters available with PI Regulator Table 36 PI Parameters Menu Items Menu Item Description Range KP Proportional gain Adjusts the speed of the reaction to the feedback loop 0 to 999996 Range corresponds to 96 9999 corresponds to 99 99 KI Integral gain Adjusts the accuracy of PI regulation Range corresponds 0 to 9999 to per second units NEG VALUES Determines if the drive controller will be able to run in both directions or Yes No in only one direction Yes The controller can run in both directions No The controller can run in only one direction REV ACTION Determines the response to error gt between setpoint and feedback Yes No signals Setpoint Feedback Selection gt Speed Response Yes Speed decrease Speed increase No Speed increase Speed decrease PI FLT RATIO User defined error limit between desired setpoint and actual process 0 100 feedback Expressed as a percentage of MAX FEED BACK MIN FEED BACK If the real error exceeds the PI FLT RATIO the FB LIMIT logic output activates REF OUTPUT Analog output reference proportional to s
190. ire AWG 6 6 4 4 2 GND Size mm 6 10 10 16 35 IN Terminal 17 4 35 4 17 7 26 5 26 5 Torque Nem 1 96 4 2 3 3 Max Wire AWG 6 6 4 4 2 GND Size mm 6 10 10 16 35 OUT Terminal 174 35 4 17 7 26 5 26 5 Torque Nem 1 96 4 2 3 3 60 75 C copper 2 75 C copper Reserved Do not wire to PA PB terminals 1996 Square D All Rights Reserved 21 Chapter 2 Wiring Bulletin No 50006 519 01B Control Wiring December 1996 CONTROL WIRING NUES The logic inputs and outputs and analog inputs and outputs are all referenced to Common COM on J12 and J13 This Common is isolated from the input line and from ground S on J13 RMS voltage rating of the isolation barrier between Common and ground is 250 V If Common is elevated with respect to earth by external user connections then all devices connected to Common must be rated for the applied voltage J1 is located on the power board Figure 9 Terminal Strip Connections for Control Board 22 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Chapter 2 Wiring Control Wiring Table 10 Control Terminal Strip Characteristics Connector Terminal 11 Function Characteristics R1A contact Fault relay Minimum 10 mA 24 VDC R1B contact output Maximum inductive load of J1 2 R1C Common 2 0 A
191. is linked to two causes Although the current waveform is similar to a sine wave motor heating is slightly greater than when operating directly from the input line supply The resulting torque derating is approximately 5 For 1 0 service factor motors derating must be considered when choosing the continuous torque production capability of the motor at nameplate speed For 1 15 service factor motors derating of motor continuous torque capability is not required at nameplate rated speed For self ventilating motors ventilation produced by the internal shaft fan decreases as speed is reduced therefore requiring derating of the maximum continuous torque capability of the motor Generally the required derating occurs at approximately 50 of nameplate motor speed Since motor designs vary consult the motor manufacturer for the required derating for a specific motor The driving overtorque capabilities of a given motor are determined by the motor NEMA design category Design B Design D etc no load magnetizing current of the motor at nameplate speed maximum transient output current of the drive controller and the applied V Hz at reduced speed Maximum transient overtorque capability is typically Normal control type ATV56U41N4 to D79N4 and ATV56U41M2 to D46M2 110 over 50 1 speed range NOLD control type ATV56U41N4 to D79N4 and ATV56U41M2 to D46M2 110 over 10 1 speed range With NOLD control the motor overt
192. ive overtemperature failure Motor overload Loss of follower Process time out fault Fault Causing Freewheel Stop When the fault condition is no longer present the drive controller will automatically restart the motor if the Command Type is set for 2 wire and the Run Enable and direction inputs are maintained regardless of the setting of Automatic Restart The following sections describe the faults programmable from the 7 4 Fault Management menu T 43FBULT MANAGEMENT RUT RES pomp CATCH ON amp ENT to modify During loss of input power certain actions are taken by the drive controller to enable recovery once power is restored This is possible since the drive controller logic remains active for a least one second after power is lost The actions taken depend on the settings of Power Loss and Input Phase Failure see page 107 With Power Loss set to FREE factory setting the following sequence occurs when power is lost or there is a phase failure while the drive controller is running The drive controller freewheel stops independent of the setting of Input Phase Failure The control logic remains active for at least one second by using the power stored on the drive controller DC bus If input power is restored while the control logic is still active the drive controller automatically restarts independent of the Command type in the 6 gt Drive Configuration menu selected If input power is
193. j Alt Al4 A AM Keypad 9999 to 9999 OFFSET 9999 to 9999 Feedback HIGH AL M Auto Manual FB LOW ALM 9999 to 9999 LIx 0 Auto Alt Al4 HSP 9Speed ho Reference SPM Input REV SPEED tpoint Manual Setpoint Manual 4 1 15 LIx 1 Kern Manual NOTE An error value of 1 with KP set to 100 and KI set to 0 will result in drive Auto Manual controller output of 61 8 Hz if HSP gt 61 8 Hz error value of 1 with KP set to 1 and KI set to 140 will result in a drive LI3 LIB controller output of 61 8 Hz in one second Figure 59 PI Regulator Block Diagram 1996 Square D All Rights Reserved Bulletin 50006 519 01B Chapter 5 Configuration December 1996 7 General Configuration Menu PI Regulator function can only be used when the drive controller is configured for Function Compatibility 2 wire control Table 31 lists the functions which are incompatible with the PI Regulator function Table 31 Functions Incompatible with PI Regulator Function Menu Number Keypad Configuration Menu 5 Command Type 3 wire 6 2 Preset Speeds 7 2 Speed Reference 7 2 Auto Manual 7 2 Shutdown 7 2 Tach Feedback 7 2 NOTE Tach Feedback shaded is only available when an I
194. le environment The environment around drive controller must not exceed Pollution Degree 3 requirements as defined in NEMA ICS 1 or IEC 664 1996 Square D All Rights Reserved 9 Chapter 1 Receiving and Installation Bulletin No 50006 519 01B Mounting in General Purpose Metal Enclosure December 1996 Verify that the voltage and frequency characteristics of the input line match the drive controller nameplate rating Installation of a disconnect switch between the input line and drive controller is recommended Follow national and local codes Overcurrent protection is required Install line power fuses F1 F3 recommended in Table 11 on page 30 and Table 13 on page 31 Turn off all power before installing the drive controller Place a DO NOT TURN ON label on the drive controller disconnect Before proceeding with installation lock the disconnect in the open position The ATV56U41N4 to ATV56D79N4 and ATV56U41M2 to ATV56D46M2 drive controllers may be mounted inside another enclosure to increase the degree of protection or size of the enclosure See MOUNTING IN GENERAL PURPOSE METAL ENCLOSURE on page 10 and MOUNTING IN TYPE 12 54 METAL ENCLOSURE on page 12 To improve ventilation the front cover may be removed when mounting the drive controller in an enclosure For ATV56U41N4 to D23N4 and ATV56U41M2 to ATV56D16M2 drive controllers the front cover is removed by first opening the cover then s
195. line power 30 power 28 transformer 30 G general configuration menu 69 grounding 18 130 GND terminals 20 21 134 GROUND FAULT 46 56 H handling 8 128 hand off auto switch 139 142 146 omitted 140 143 147 user supplied 141 145 149 heat sink 13 help menu 51 high level alarm 91 high speed 59 75 high torque control 34 hoisting 8 128 extension module 77 79 map 61 index numbers 51 57 inductors 17 IN PHASE LOSS 45 input phase failure 107 input phase loss 55 inputs logic 23 24 phase fault 45 47 speed reference 5 23 26 122 supply 23 inspection 8 128 installation 9 INTERNAL FAULT 46 56 isolation contactor 29 Bulletin No 50006 519 01B December 1996 J J1 terminals 23 27 J12 terminals 22 23 25 J13 terminals 22 23 26 J2 terminal 20 jump to menu 51 K keypad display 50 connection to drive controller 52 locking 56 mounting in enclosure door 52 remote handheld use 52 command 51 56 65 configuration menu 64 keys arrow 50 ENT 50 ESC 50 function F1 F2 F3 51 numeric 50 RUN 52 STOP 51 STOP and RUN key cover 51 selecting 89 94 KI 95 KP 95 L L1 L2 L3 terminals 20 21 134 language selecting 53 LCD 50 LEDs 11 19 42 44 LI1 L12 L13 L14 terminals 23 24 lightning arrestors 17 line contactor 30 31 line fuses removing 150 line isolation contactor 139 143 147 LO1 LO2 LOP terminals 23 25 135 136 local command 56 logic input test 110 A
196. ll drive controller wiring Do not run control and power wiring in the same conduit Metallic conduits carrying power wiring or low level control wiring must be separated by at least 3 in 8 cm Non metallic conduits or cable trays used to carry power wiring must be separated from metallic conduit carrying low level control wiring by at least 12 in 30 5 cm Whenever power and control wiring cross the metallic conduits and non metallic conduits or trays must cross at right angles nsome installations conducted emissions to the line from the drive controller must be attenuated to prevent interference with telecommunication radio and sensitive electronic equipment In these instances attenuating filters may be required Consult catalog for selection and application of these filters Allbranch circuit components and equipment such as transformers feeder cables disconnect devices and protective devices must be rated for the maximum input current of the ALTIVAR 56 drive controller not the motor full load current The drive controller input current is stamped on the nameplate Since maximum input current depends on the impedance of the power system several nameplate values are listed The input current values listed are based on available fault current at the drive input terminals Select the input current corresponding to the available fault current capability If current limiting fuses or circuit breakers are used to reduce the ava
197. load protection CSA certified Conforms to applicable NEMA ICS NFPA IEC amp ISO 9001 standards Resolution limited to processor resolution 2 Drive Controller at operating load and temperature 1996 Square D All Rights Reserved 5 Bulletin 50006 519 01 Chapter 1 Receiving and Installation December 1996 Dimensions amp Weights DIMENSIONS amp WEIGHTS FOR WALL CONDUIT ENTRIES BOTTOM VIEW OR PANEL 1 69 43 5x 01 14 29 2 28 58 MOUNTING 2x 01 14 29 3 x 90 87 22 e sh ag 9 g a 7 2 28 58 2 28 58 4 61 117 Dimensions Outline 3 in mm MOUNTING DIMENSIONS g Drive Drive H1 H2 wi w2 Weight Door Swing Controller Controller 9 Clearance 111 8 56 4 56 2 in in in mm in mm in mm Ib kg in mm 1 U41 U72 U41 11 6 295 10 9 280 7 8 200 6 9 175 0 22 5 5 10 4 47 7 8 200 2 090 012 072 090 12 8 325 12 2 310 92 234 8 2 209 0 22 5 5 161 7 3 9 2 234 3 D16 D23 D12 D16
198. locks if used MOD B07 Group 2 Pilot Light Cluster if used MOD C07 Line Isolation Contactor if used Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Power Circuit W Combination Package The Combination Package is designed for running the motor strictly from the power converter The Combination Package consists of line fuses 120 V fused control transformer when control options are present motor circuit protector disconnect with means for locking in the open position and a Hand Off Auto switch with manual speed potentiometer Operator controls are located on the front of the BELE box cover unless option D07 is included Option D07 omits the Hand Off Auto switch and manual speed potentiometer and no operator controls are present on the BELE box cover If option 07 is included a pilot light cluster is also present on the front of the BELE box cover The Hand Off Auto switch and manual speed potentiometer control the operation of the power converter which is factory configured to operate in terminal command mode To operate the controller the controller disconnect switch located on the front of the BELE box must be in the closed position There are three modes of operation with the Hand Off Auto switch Hand Off and Auto Hand mode is for local control As soon as Hand mode is entered the power converter is placed in running mode In Hand mode the speed potentiometer mounted on the BELE box is used to control the
199. m current that the drive controller can produce i e Current Limit However changing the nominal current parameter can change the value of motor overload current in menu 1 Check and adjust if necessary the value of motor overload if nominal current is changed T 113 PARAMETER CURRENT HOMINAL FREG NOMINAL VOLT DAMPING amp ENT to modifa Nominal Frequency corresponds to the point on the V Hz curve beyond which voltage remains virtually constant and only frequency increases Nominal Frequency often corresponds to the base frequency of the motor which is usually the same as the line frequency of the connected power system Nominal frequency is fixed at 60 Hz 11 0 PARAMETER CURRENT A NOMINAL FREG NOMINAL VOLT DAMPING amp ENT to modify 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Profile Damping Chapter 5 Configuration 7 General Configuration Menu Nominal Voltage corresponds to the point on the V Hz curve beyond which voltage remains virtually constant and only frequency increases Nominal Voltage is used with Nominal Frequency to determine the V Hz baseline Nominal Voltage often corresponds to the base voltage of the motor which is usually the same as the line voltage of the connected power system Nominal voltage is fixed at 460 V for 460 V drive controllers For 230 V drive controllers Nominal Vol
200. m or the liquid level in a reservoir PI Regulator requires at minimum two analog input ports Additional analog and logic input ports are required for other optional PI Regulator functions Table 30 describes the items available from the PI Regulator menu See Figure 59 on page 88 for a block diagram of the PI Regulator function The menus in this section show factory settings Table 30 PI Regulator Menu Items Menu Item Description NO PI Regulator function is off YES SET POINT PI Regulator function is on Selecting this brings up the SET POINT configuration menu The settings under SET POINT must be defined for PI Regulator to operate See page 89 FEED BACK Feedback configuration menu The settings under FEED BACK must be defined for PI Regulator to operate See page 90 SET POINT MANUAL Manual speed reference automatic setpoint configuration menu The settings under SET POINT MANUAL may be configured to allow switching between an automatic setpoint reference and a manual speed reference See page 94 PI PARAMETERS Miscellaneous PI Regulator configuration parameters menu The settings under PI PARAMETERS may be configured to fine tune the operation of PI Regulator or to provide analog and logic reference and status outputs See page 95 0 to 9999 REV ACTION J dt 1 Setpoint 9999 to 9999 y Error 3 GAIN i j SES 0 to 9999
201. mal power up sequence Restart of the drive controller requires a run command and the absence of faults To use the RAMP mode of Power Loss Input Phase Failure must be set to NO Otherwise the drive controller will operate as if Power Loss were set to FREE The selection of FREE or RAMP depends on the amount and type of disturbance that the load can tolerate during a power loss Setting Power Loss to FREE allows a longer deceleration time but requires the drive controller to resynchronize to the motor once power returns FREE is generally best suited for installations which experience long periods of power loss Setting power Loss to RAMP decelerates the motor more rapidly during power loss and does not require the drive controller to resynchronize to the motor If power is restored while the motor is still running recovery to commanded speed occurs rapidly RAMP is generally best suited for installations which experience short periods of power loss RUTO RESTRRT NO VES RESTARTS DELAY TIME 1 5 restartzz time 1 to quit A WARNING UNINTENDED EQUIPMENT ACTION Automatic restart can only be used for machines or installations that present no danger for personnel or equipment in the event of automatic restarting Equipment operation must conform with national and local safety regulations Failure to follow this instruction can result in death serious injury or equipment damage Enabling Au
202. mal State or Drive Thermal State ATV56D16N4 to D79N4 and ATV56D12M2 to D46M2 to determine which condition is causing the Pre Alarm If either of these thermal states exceeds 100 the Caution LED will flash slowly Illuminated with Fault LED ON Drive controller fault exists on either Motor Overload or Drive Overtemperature and the cool down period has not yet expired Consult the fault display on the keypad or the fault history in Menu 3 to determine the most recent fault Illuminated Drive controller is powered DC bus 2 50 V or voltage is present at CL1 CL2 6 Illuminated DC bus gt 50 V Figure 26 Drive Controller LEDs 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 FAULT MESSAGES Chapter 4 Diagnostics Fault Messages The ALTIVAR 56 drive controller can store up to eight faults and display them as messages on the keypad display These fault messages listed in Table 27 allow access to Fault History Screens which display the drive controller run status at the time of each fault For more information on Fault History Screens see Chapter 5 Fault Message Display off or partial 2 display Figure 27 Fault Messages Probable Cause No control supply Control voltage too low Troubleshooting Procedure 1 Check input line voltage Procedure 2 on page 43 Check fuses and circuit breaker Procedure 3 on page 43 Check CL1 CL2 control termi
203. meters 69 74 status codes 55 62 thermal alarm 97 driving torque 38 dynamic brake 46 56 fault 108 E enclosures NEMA Type 1 IP30 10 NEMA Type 12 IP54 12 sizing 12 environment 5 9 13 122 equipment requirements 30 external control devices 140 141 143 145 147 148 F factory default settings restoring 112 fan 10 also see ventilation 10 flow rates 11 fast stop 83 fault descriptions 55 detection programming 100 displaying fault type55 history menu 62 LED 19 44 management menu 100 reset 100 108 174 state 97 stop methods 100 troubleshooting procedure 62 types of control board 46 DB Resistor 47 displaying 62 dynamic braking 46 fault relay 23 ground 46 input phase loss 45 47 internal connection 46 LEDs 11 44 memory failure 46 messages 45 47 overheating 36 overload 45 overspeed 47 overtemperature 45 overvoltage 45 precharge fail 46 relay 23 short circuit 46 signal 46 tachogenerator 47 undervoltage 45 user defined 47 FB high alarm 95 FB input 91 FB limit 95 FB low alarm 95 FEEDBACK LOSS 47 feedback menu 91 FLT 55 62 fold back 108 freewheel stop 82 freeze fire stat interlock 139 142 146 frequency level 1 98 loop gain 59 71 output 34 range 5 122 specifications 4 122 switching 3 4 FU1 FU2 FU3 line fuses 139 143 147 function keys in keypad command 66 1996 Square D All Rights Reserved Bulletin No 50006 519 01B October 1997 fuses control 30 line 150
204. minals ATV56U41N4 D79N4 amp ATV56U41M2 to D46M2 To measure the input line voltage 1 2 3 4 5 Perform Bus Voltage Measurement procedure see page 42 Attach meter leads to L1 and L2 Set voltmeter to the 600 VAC scale Reapply power Check for correct line voltage per drive controller nameplate rating Remove power and repeat procedure for L2 and L3 and L1 and L3 When all phases have been measured remove power Remove meter leads and reinstall covers The following equipment may need to be checked Follow the manufacturer s procedures when checking this equipment 1 2 Aswitching device such as a contactor may not be closing at the correct time 3 4 Connection of cables to the motor or connections to ground may need to be A protective device such as a fuse or circuit breaker may have tripped Conductors may require repair or replacement checked Follow NEMA standard procedure WC 53 Motor insulation may need to be checked Follow NEMA standard procedure MG 1 Do not apply high voltage to drive controller output terminals U T1 V T2 or W T3 Do not connect high potential dielectric test equipment or insulation resistance tester to the drive controller since the test voltages utilized may damage the drive controller Always disconnect the drive controller from the conductors or motor while performing such tests 1996 Square D All Rights Reserved
205. mounted full or reduced voltage starter bypass mode The motor can be run in the bypass mode in the unlikely event the power converter becomes inoperative The Remote Starter Bypass Package consists of IEC rated isolation and transfer contactors with Class 10 overloads line fuses 120 V control transformer motor circuit protector disconnect with means for locking in the open position AFC Off Bypass switch Hand Off Auto switch and a manual speed potentiometer A 7 16 1 2 or 9 16 socket hand tool is included for removing line fuses to isolate the power converter during servicing See PROPER DRIVE ISOLATION METHOD on page 150 Operator controls are located on the front of the BELE box cover unless option D07 is included Option D07 omits the Hand Off Auto switch and manual speed potentiometer and no operator controls are present on the BELE box cover If option A07 or B07 is included a pilot light cluster will also be present on the front of the BELE box cover The AFC Off Bypass switch allows you to select either adjustable speed operation of the motor through the power converter AFC position or to transfer control of the motor to a user supplied remote mounted full or reduced voltage starter Bypass position The Hand Off Auto switch and manual speed potentiometer control operation of the power converter which is factory configured for terminal command mode To control the operation of the motor with the power converter the cont
206. n user supplied contact and logic input ensuring it is connected to programmed input Verify operation of contact Verify operation of process TRANS SHORT C or GF Transistor Short Circuit 1 Transistor is in short circuit 1 Contact local service representative OPEN TRANSISTOR 1 Transistor has failed open Contact local service representative OUT PHASE LOSS 1 Motor power rating too small for controller 2 Output phases 2 disconnected Fault cannot be disabled always causes a freewheel stop 12 Occurs upon power up only Motor power rating must be gt 45 of controller power rating Check output power conductors and connectors for lack of continuity Check output contactor sequencing The additional faults listed in Table 19 may be displayed if an option module is installed and a fault occurs Table 19 Fault Messages from Option Modules Fault Messages OVERSPEED Probable Cause Without tachometer 1 Output frequency is 20 above Maximum Frequency parameter setting With tachometer 1 Incorrect adjustment of tachometer feedback 2 Machine overload 3 No tachometer signal 4 Tachometer polarity incorrect Troubleshooting Procedure E Check load base speed and power rating compare with operating Speed and drive controller motor power rating 1 Check feedback 2 Check load base speed and power ratin
207. nal connections No supply to terminals L1 Check input line voltage Procedure 2 L2 L3 on page 43 2 Power fuses blown Check fuses and circuit breaker IN PHASE LOSS Procedure 3 on page 43 Input phase loss 3 Brief input line failure t Reset drive controller 200 ms 4 Internal connections Check connections 1 Supply too low Check input line voltage Procedure 2 V lt 380 V ATV56 N4 on page 43 Check Nominal Motor V lt 170 V ATV56 M2 Voltage parameter see Chapter 5 UNDERVOLTAGE 11 2 Temporary voltage drop t Reset drive controller 2200 ms 3 Internal connections Check connections AC LIN OVERVOL 11 AC Line Overvoltage 1 Supply too high V gt 550 V 56 4 V gt 270 V 56 2 Check input line voltage Procedure 2 on page 43 Check Nominal Motor Voltage parameter see Chapter 5 DC BUS OVERVOL DC Bus Overvoltage OVERTEMP DRIVE Drive Overtemp Overvoltage or overcurrent due to excessive braking or an overhauling load Heat sink temperature too high gt 203 F 95 Increase deceleration time Add braking option if necessary Reset is possible if line voltage lt 550 V Check motor load fan and ambient temperature around drive controller Wait for drive controller to cool down before resetting MOT OVERLOAD Motor Overload If thermal trip setting is 118 of n
208. nd 1 to 50 hp 208 230 V adjustable frequency AC drive controllers The ALTIVAR 56 family consists of 20 devices in 5 outlines The ALTIVAR 56 drive controllers may function as stand alone drive controllers or as part of complex drive systems The ALTIVAR 56 controller is also available as a combination device drive controller The Class 8839 ALTIVAR 56 is a family of 1 to 100 hp 460 V and 1 to 50 hp 208 230 V combination devices consisting of the drive controller power circuit box with options and back pan The ALTIVAR 56 family also includes optional peripherals Consult catalog for descriptions This manual covers receiving installation start up and configuration of the 460 V 208 V and 230 V lines of ALTIVAR 56 and Class 8839 drive controllers Information on diagnostics is also included Several options are available for the ALTIVAR 56 drive controller Refer to the catalog for a description of these options A manual or instruction sheet is provided with each option This is Revision B It replaces 50006 519 01A dated November 1996 and includes information on the Class 8839 ALTIVAR 56 combination device The ALTIVAR 56 drive controller is shipped with an English safety label applied to the control board If a Spanish German or French label is required affix it to the main control board above the English label see Figure 1 Do not obstruct the English label Spanish German or French English
209. nfiguration 6 Drive Configuration Menu 6 gt DRIVE CONFIGURATION MENU 66 Bulletin No 50006 519 01B December 1996 While in Keypad Command mode 0 Hz reference is treated as a speed Once the RUN key is pressed the drive controller is in a run state After pressing RUN you may select any speed reference including 0 Hz and the drive controller will run at that speed Pressing the STOP key causes the drive controller to ramp to zero output even though the reference remains at a non zero frequency Cycling power resets the reference to zero and causes the drive to be in the stop state Table 26 Operation of Function Keys in Keypad Command Action Achieved by Pressing Associated Label Indication Function Key Reset fault is assigned to associated RST Press function key to reset drive controller after fault function key Scroll function is assigned to Press function key to scroll through display screens SCR 9 and W keys are used for this function in Terminal associated function key Commahdimode The 6 Drive Configuration menu can be accessed only if the drive controller is stopped If the drive controller is running a message appears IMPOSSIBLE TO CONFIGURE THE DRIVE WHILE RUNNING ESC to return to Main menu Press ESC to return to the Main menu amp DRIUE CONFIG TORQUE VARIABLE COMMAND 2 WIRES 66Hz 440 4681 Power 2 2 kWe3 HP ESC to 4uit Fi Hele
210. ng the use of motors with horsepower equal to or one horsepower size less than the drive controller horsepower To adjust the Nominal Current parameter see Chapter 5 Before powering up for the first time compare motor nameplate current rating with output current in Tables 1 through 4 on pages 3 4 depending on drive controller configuration If the motor rating is not within 45 to 105 of the value in the table it is necessary to use a different drive controller For the ATV56U41 use the output current corresponding to motor horsepower and set Motor Power parameter for that value See Chapter 5 The Nominal Current parameter must be set on the drive controller keypad display to match the motor full load current rating If the Nominal Current parameter cannot be adjusted to the motor full load current Normal control types cannot be used for the application For multiple motor applications consult the factory FACTORY SETTINGS The ALTIVAR 56 drive controller is factory set to meet most applications If the values below are compatible with the application the drive controller can be started up If the values listed below do not match the requirements of your application change their settings with the keypad display For detailed use of the keypad display refer to Chapter 5 Table 16 Factory Settings Functions Function Factory Setting Nominal Output Voltage and Automatically set at first power up according to the input fr
211. nst continuous metal surface 6 in between QW to SW PW X X X X X Metallic conduit housing QW 12 in to non metallic conduit SW PW X X X X X Non metallic conduit 3 in between SW to PW X X X Non metallic conduit 24 in between QW to SW PW X X X X X 5 If QW and SW1 wiring must cross SW2 or PW1 wiring the bundles must cross at right angles X X X X X Common Mode Noise Issues X X 1 Provide adjacent signal returns using twisted pair cable 2 Galvanically isolate signal and associated signal return path when possible X X Shielding X X X X X 1 Use metallic conduit for all power and control circuits external to the controller enclosure 2 Shields must be continuous and equipped with a drain wire X X X 3 DO NOT group different Noise Class conductors within the same shield X X X X X 4 Minimize non shielded portion of conductor at the ends of shielded cable X X X X X 5 When shielding AC or DC power conductors group conductors to minimize X X X magnetic field in shield Grounding 1 Ground shields at one end only the controller end x A x x x 2 Use separate ground wire for each shield ground X X X X X 3 Provide a ground wire with all conductor groups whether in tray or conduit X X X 4 When multiple grounds must be made to a shielded power cable the shield must have the same X X X short circuit withstand capability as the ground conductor in the power cable 5 Terminate all power grounds and power shield grounds to the cont
212. nt and PI Feedback first enter the scale factor that multiplies motor rated speed in Hz to determine the application units The scale factor programmable from 1 to 100 is factory preset at 1 NOTE There is only one scaling factor entry available for Machine Speed Reference Machine Speed PI Set Point and PI Feedback The scaling factor chosen for Machine Speed for example will be the same scaling factor fused for PI Set Point Second enter a 4 character label for the application ft s for example in the Units Edition screen Using the A moves up and moves down keys scroll among the alphabetical characters and press ENT to select a character Each selected character will appear in the upper band of the screen Press ESC when you are finished defining the label When the screen displays one bar you may use the and V to display other functions 1996 Square D All Rights Reserved 63 Chapter 5 Configuration 5 Keypad Configuration Menu 4 2 Two Bar Graphs 4 3 Scroll 5 gt CONFIGURATION MENU 64 Bulletin No 50006 519 01B December 1996 The 4 2 gt Two Bar Graphs menu is the same as the 4 1 One Bar Graph menu you can however make two selections Figure 37 on page 64 shows the display screen configured for Two Bar Graphs When the A and W keys are used to scroll the first bar graph r
213. ntactor The bypass contactor and associated power circuit components permit starting running and stopping of the motor directly from line power Bypass operation requires the wiring scheme illustrated in Figure 58 on page 87 To use Bypass assign a logic input LI3 for example to Sequence Input and relay output R2 to Run Output Command Set time values for Delay Time and Sequence Tof Time Out Fault If desired logic input LI4 can be assigned to Process Input and a time value for Process Tof Time out Fault can be set to verify an optional user defined event These parameters are described in Table 56 1996 Square D All Rights Reserved 85 Chapter 5 Configuration 7 General Configuration Menu 86 Example Bypass Circuit Description Bulletin No 50006 519 01B December 1996 Figure 56 Bypass Parameters Parameter Description Range Default Programmable delay time to allow for decay of residual Delay Time motor voltage before restarting the drive controller after operating directly from line power 0 2 10s 2s This output is active if the drive controller receives a Run command and Delay Time has expired Assign relay R2 to Run Output Command Run Output Command Used to initiate the acceleration ramp If this input does not go high within the time for which Sequence Time out Fault is set the driv
214. ntrol As soon as Hand mode is entered the power converter is placed in running mode In Hand mode the speed potentiometer mounted on the BELE box is used to control the speed of the controller Off mode commands the power converter to stop the motor by either following the programmed deceleration ramp factory setting or by freewheel stopping Auto mode is for remote control In Auto mode the power converter is placed in running mode as soon as a user supplied run contact is closed between controller terminals TB4 and TB8 In Auto mode motor speed is varied by adjusting the user supplied auto speed reference signal 4 20 mA supplied to the terminals TB13 TB11 and TB12 Shield in the BELE box Refer to Chapter 5 for scaling of this signal To control the operation of the motor with line power the controller disconnect switch located on the front of the BELE box must be in the closed position and the AFC Off Bypass switch must be in the Bypass position If the AFC Off Bypass selector switch is placed in the Bypass position motor operation is transferred to line power If the selector switch is moved to the Off position the bypass contactor opens and the motor will stop Terminals TB22 and TB23 are dedicated terminals for accepting a user supplied freeze fire stat interlock normally closed The drive output isolation contactor and drive bypass contactor open if the connection between terminals TB22 and TB23 is opened As a
215. ntroller or issue commands Operation of the function keys depends on whether the drive controller is in Terminal Command or Keypad Command mode In Terminal Command drive controller receives its Run Stop and Reference Frequency signals from the drive controller terminal strip the function keys operate as follows F1 calls up the Help menu F2 returns to the Display Mode screen page 53 and page 55 unless set for Terminal Keypad switching in the 5 gt Keypad Configuration menu F3 functions as a jump key To jump directly to a menu press F3 A window will appear Enter the menu s index number and press ENT The display will jump directly to that menu Index numbers are found in the upper left corner of the display for each menu and are also listed in Table 22 on page 57 Throughout this manual menu names are preceded by their index numbers For example in a reference such as 1 gt Parameter Setting 1 is the index number for the Parameter Setting menu In Keypad Command drive controller receives its Run Stop and Reference Frequency signals from the keypad display The functions of the keys are F1 Resets the drive controller after a fault F2 Scrolls through the displays F3 Not assigned No functionality Terminal Command and Keypad Command are described further in the 5 gt Configuration menu section page 64 A plastic cover is factory installed over the RUN and STOP keys For access to RUN an
216. o bar graph menu 64 two wire control 28 29 U U V W terminals 20 21 undervoltage 45 55 1996 Square D All Rights Reserved ALTIVAR 56 Fan and Pump Drive User s Manual Index V V Hz profile 60 71 variable torque 3 4 38 ventilation 10 13 37 vibration resistance 5 voltage 10 V supply 23 26 24 V supply 23 25 bus capacitor 42 class 130 control 20 DC bus 20 input line 4 20 122 logic inputs 24 output 34 reference input 79 setting 53 volts frequency 34 W weight 7 124 127 wiring checking connections 110 class 129 control 17 28 135 137 general practices 16 130 power terminals 21 134 wire size 21 134 Numerics terminals 20 21 43 10 terminal 23 26 24 terminal 23 25 10 VDC reference signal 140 143 147 2 wire command 68 2 wire control 28 29 3 wire command 68 3 wire control 28 4 20 mA reference signal 140 141 144 146 149 177 SQUARE D 50006 519 01B December 1996 Printed in USA FPC Replaces Bulletin No 50006 519 01A dated 11 96 1996 SquareD All Rights Reserved
217. oS 1 or Or Or oro 5 823 2 BE d v oc T S X 98 85 S 25 BS lt 4 o oa 5 955 2 55 3 amp g s Bete 5 lt S eg Y z 3052 2 o 2 lt 5 a cc Figure 97 Auto Manual in 2 Wire Command with Controlled Stop Active High 1996 Square D All Rights Reserved 163 Appendix Parameter Summary Bulletin No 50006 519 01B 7 General Configuration Menu December 1996 Not Configured aes 0 1 0 1 0 1 0 1 0 Run Enable 111 Run Forward T K 1 Keypad Stop 0 Keypad 1 Run 0 Auto Manual Auto Run 0 Controlled 1 Stop 9 Keypad Ref Auto Ref Manual Ref Jog Ref Jog Ref Manual Ref Auto Ref Output Figure 98 Auto Manual in 3 Wire Command with Controlled Stop Active High 164 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Appendix B Menu Summary Appendix B Menu Summary This Appendix contains a summary of Level 1 and 2 Configuration Software menus Use it as a quick reference for menu flow and contents Refer to Chapter 5 for complete explanations of the menus 1996 Square All Rights Reserved 165 Appendix Menu Summary XD cO 1 C E 0 166 MAIN MENU PARAMETER SETTING 1 0 FAULT HISTORY
218. oards ATV56D16N4 VX5 A66103 ATV56D23N4 VX5 A66104 ATV56D33N4 VX5 A56105 ATV56D46N4 VX5 A56106 ATV56D54N4 VX5 A56107 ATV56D64N4 VX5 A56108 ATV56D79N4 VX5 A56109 ATV56D12M2 VX5 A66112 ATV56D16M2 VX5 A66113 ATV56D23M2 VX5 A56107 ATV56D33M2 VX5 A56108 ATV56D46M2 VX5 A56109 Filter Boards ATV56D16N4 D23N4 VX4 A66103 ATV56D33N4 D46N4 VX4 A66104 ATV56D54N4 to D79N4 VX4 A66105 ATV56D12M2 D16M2 VX4 A66103 ATV56D23M2 D33M2 VX4 A66104 ATV56D46M2 VX4 A66105 1996 Square D All Rights Reserved 169 Appendix Spare Parts List 170 Spare Parts List Continued Bulletin No 50006 519 01B December 1996 Description Rating Drive Controller Reference No Control Power Transformer ATV56D33N4 to D79N4 VY1 ADA604 ATV56D23M2 D46M2 VY1 ADA614 Screws for mounting power ATV56D16N4 02334 VY1 ADV603 components ATV56D33N4 04634 VY1 ADV604 ATV56D54N4 to D79N4 VY1 ADV605 2 IGBT Modules 50 A 1200 V ATV56D16N4 VZ3 IM2050M1201 75 1200 V ATV56D23N4 VZ3 IM2075M1201 100 A 1200 V ATV56D33N4 VZ3 IM2100M1201 150 A 1200 V 56046 4 D54N4 VZ3 IM2150M1201 200 A 1200 V ATV56D64N4 VZ3 IM2200M1201 300 A 1200 V ATV56D79N4 VZ3 IM2300M1201 75A 600V ATV56D12M2 VZ3 IM2075M0601 100 A 600 V ATV56D16M2 VZ3 IM2100M0601 150 A 600 V ATV56D23M2 VZ3 IM2150M0601 200 A 600 V ATV56D33M2 VZ3 IM2200M0
219. oceeding with any maintenance or troubleshooting procedures Table 27 on pages 45 48 lists fault messages displayed on the keypad display probable causes or faults and associated corrective action Before taking corrective action remove all power and check the bus voltage Procedure 1 input line voltage Procedure 2 on page 43 and peripheral equipment Procedure 3 on page 43 A DANGER HAZARDOUS VOLTAGE Read and understand these procedures before servicing ALTIVAR 56 drive controllers Installation adjustment repair and maintenance of these drive controllers must be performed by qualified personnel Failure to follow this instruction will result in death or serious injury PROCEDURE 1 BUS ER VOLTAGE A DANG MEASUREMENT HAZARDOUS VOLTAGE This device contains energy storage devices Read and understand Bus Voltage Measurement Procedure before performing procedure Measurement of DC bus capacitor voltage must be performed by qualified personnel DC bus LED is not an accurate indication of absence of DC bus voltage DO NOT short across capacitors or touch unshielded components or terminal strip screw connections with voltage present Many parts in this drive controller including printed wiring boards operate at line voltage DO NOT TOUCH Use only electrically insulated tools Failure to follow these instructions will result in death or serious injury The PA and terminals are located inside the drive contr
220. odes To ground the drive controller Connect a copper wire from the grounding terminal to the power system ground conductor Wire size is determined by the drive controller size and by national and local codes Verify thatresistance to ground is one ohm or less Improper grounding causes intermittent and unreliable operation HAZARDOUS VOLTAGE INADEQUATE GROUNDING Ground equipment using screw provided Drive controller must be properly grounded before applying power Do not use metallic conduits or shields as a ground conductor Failure to follow these instructions will result in death or serious injury Multiple drive controllers must be grounded as shown in Figure 7 Do not loop or series the ground cables Drive Controller Drive Controller Drive Controller Drive Controller Drive Controller Figure 7 Grounding Multiple Drive Controllers When using the metal conduit entry plate kit VY1A66201 with ATV56U41N4 to D23N4 and ATV56U41M2 to D16M2 drive controllers the bond wire must be connected to ground GND as shown in Figure 9 on page 22 1996 Square D All Rights Reserved Bulletin No 50006 519 01 Chapter 2 Wiring December 1996 Terminal Strip Locations TERMINAL STRIP LOCATIONS
221. of fault The most recent fault is displayed first in the list The arrow lt under the M column is used to mark a fault so that it can be followed for future observation Table 24 lists drive controller run status codes Table 21 on page 55 lists the faults that can be displayed on the Fault History Screen Table 24 Fault History Screen Run Status Codes Code ACC Code Definition Accelerating DEC Decelerating RUN Drive controller running at speed BRK Braking dynamic or regenerative RDY Drive controller stopped and ready DCB DC injection braking CLI Current limit active FLT Faulted Refer to Chapter 4 for troubleshooting procedure when a fault is displayed In the case of an internal drive controller fault autodiagnostics can be run to locate the failed component See the 8 gt Diagnostic Mode menu on page 109 By default the Display screen shows reference frequency in bar graph form SPEED REFER 47 2 Hz The type and numbe Configuration menu r of functions shown can be modified from the 4Display Modification is possible while the drive controller is running 4 DISPLAY CONFIG ONE BAR GRAPH THO BAR GRAPH SCROLL 4 TABLES amp EMT to mad ify 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 4 1 gt Bar Graph Chapter 5 Configuration 4 Display Configuration Men
222. ol type generally results in reduced audible motor noise without reducing motor RPM In some cases particularly with motors whose horsepower rating is less than 10 hp improved motor efficiency may result NOLD control should not be used with motors in parallel 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 7 2 gt Application Functions Chapter 5 Configuration 7 General Configuration Menu FUNCTIONS PRESET SPEEDS SPEED REFERENCE MANUAL CONTROLLED STOP amp ENT to select SHUTDOWN N BYPASS Hele F1 ESC to quit This functian is not compatible with Use the 7 2 Application Functions menu to assign functions to the logic inputs and outputs The number of functions assignable is limited by the number of inputs outputs required by a function see Table 28 on page 77 the number of inputs outputs on the drive controller available to be reassigned and by compatibility of the selected functions see Figure 47 on page 78 The selection of a function which is not compatible with one already selected causes the message illustrated above to appear on the terminal screen The drive controller has two logic inputs that can be reassigned If more inputs outputs are required an I O Extension module can be ordered Refer to the catalog document number 0 065201 for more information Table 28 Logic I O Required by Application F
223. oller The controller is suitable for installation in a Pollution Degree 3 environment as defined in NEMA ICS1 and IEC 664 1 The expected environment must be compatible with this rating When attaching wall mountable controllers to their mounting surfaces use fasteners rated for the weight of the apparatus the expected shock and vibra tion of the installation and the expected environment Provide sufficient cooling for expected heat load 1996 Square D All Rights Reserved 117 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Bulletin No 50006 519 01B Controller Part Numbers December 1996 CONTROLLER PART The controller part number located on the nameplate attached to the mounting NUMBERS panel is coded to describe the configuration and options present Use Table 38 to translate the part number into a description of the drive controller Table 38 Controller Part Numbers Field Digit Characteristic Description 01 01 03 Controller style 56U Fan and Pump Drive US only Ct hp 25hp D 2hp 30 hp E 3hp F 5h N 40 hp 02 04 Horsepower n 50 hp 7 5 60 hp 10 hp 75 S 100h K 20 hp 03 05 Enclosure type G Type 1 only 2 200 208 VAC 04 06 Voltage 3 230 240 VAC 4 460 480 VAC V Variable torque rating 05 07 Torque application L Variable torque low noise rating Defines which of 3 pre engineered power
224. oller see Figure 25 on page 43 To measure the bus capacitor voltage 1 Disconnect and verify all power is removed from drive controller 2 Wait 1 minute to allow the DC bus to discharge 3 Open the front cover of the drive controller 4 Setthe voltmeter to the 1000 VDC scale Measure the bus capacitor voltage between the PA and terminals to verify the DC voltage is less than 45 V Do not short across capacitor terminals with voltage present 5 If the bus capacitors are not fully discharged contact your local representative Do not operate the drive controller 42 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 PROCEDURE 2 INPUT LINE VOLTAGE MEASUREMENT PROCEDURE 3 CHECKING PERIPHERAL EQUIPMENT Chapter 4 Diagnostics Input Line Voltage Measurement GS 52525252 622552224 zz wH t ATV56U41N4 to D12N4 ATV56D16N4 to D79N4 and ATV56U41M2 to 090 2 ATV56D12M2 to D46M2 Figure 25 Location of PA and Ter
225. ons since the motor could be forced to near zero speed before re acceleration can occur Vm Nm Motor Speed Nsp Commanded Limit Im Speed Vm Motor Voltage Im Motor Current Run Enable LI2 Run Forward Li Green Pwr i LED for e Power Power Off On Figure 63 Catch On Fly Set to NO 1996 Square All Rights Reserved 103 Chapter 5 Configuration Bulletin No 50006 519 01B 7 General Configuration Menu December 1996 Catch On Fly Set to When commanded to start into a spinning load the drive controller will use the RAMP Refer to residual voltage present at the motor terminals to estimate motor speed If no Figure 64 residual voltage is present then the control method reverts to that described in Catch On Fly Set to NO If residual voltage is present then the drive controller initial output frequency is set to the estimated speed value allowing the motor to rapidly synchronize to the drive controller output frequency The drive controller then increases the motor speed at the set acceleration ramp rate to the commanded speed If a run command is present the drive controller will start in this mode when the input is cycled from logic 1 to logic 0 and back to logic 1 or following a brief power outage for which the control logic remains active Green LED on drive controller remains lit If the control logic becomes
226. ormal thermal state 109 of nominal current thermal trip is due to prolonged overload or output phase failure Motor power rating too low for application 1 Fault cannot be disabled always causes a freewheel stop 2 Occurs upon power up only 1996 Square D All Rights Reserved Check setting of MOT OVERLOAD parameter and compare with motor In Check load and compare with operating speed Check braking conditions possibility of single phase operation Wait approximately 7 minutes before resetting Verify motor and drive controller selection is correct for application For motors with continuous current rating less than 50 of drive controller current rating see Chapter 5 45 Chapter 4 Diagnostics Fault Messages 46 Bulletin No 50006 519 01B December 1996 Figure 27 Fault Messages Continued Fault Message Probable Cause Troubleshooting Procedure SHORT CIRCUIT SHORT CKT_ Desaturation 2 SHORT CKT LIC exceeded Short circuit or grounding on drive controller output Short circuit_ or short Circuit Internal drive fault Short circuit_ Motor improperly applied Short circuit 3 Remove all power With drive controller disconnected check connecting cables and motor insulation Use drive controller self diagnostics See Chapter 5 See MOTOR CONSIDERATIONS on page 39 PRECHARGE Capacitor c
227. orque capability begins to decrease below 50 of motor nameplate speed 1996 Square D All Rights Reserved 37 Chapter 3 Start Up Available Motor Torque Overspeed Operation f gt 60 Hz Driving Torque Production Envelope 38 Bulletin No 50006 519 01B December 1996 With an adjustable frequency drive controller operation at speeds greater than motor nameplate speed may be possible The following must be considered A CAUTION MACHINERY OVERSPEED Some motors and or loads may not be suited for operation above nameplate motor speed and frequency Consult motor manufacturer before operating motor above rated speed Failure to follow this instruction can result in injury or equipment damage The drive controller is incapable of producing additional output voltage when operating above the nominal output frequency 60 Hz When operating above the nominal output frequency the available continuous motor torque will begin to decrease along with the motor maximum overtorque capability Consult the motor manufacturer for continuous and overtorque torque capabilities of the particular motor Figure 22 illustrates a typical continuous torque and overtorque driving capability for a typical NEMA Design B 1 0 service factor motor with variable torque loads For 1 15 service factor motors the continuous torque rating i
228. pes of Protection oil eed 106 Self Cooled 106 No Thermal 1 106 Input Phase 1 107 loss of Foll wer pem eed aoe 107 Fold ale and 108 Fault Reset cse SOR DERE UAR RATER NES 108 Dynamic Brake 108 Output Phase Fault Rec REC 108 82DIAGNOSTIC MODE 109 AutodlaghostlCs emer Iden x pee eed buh cetero Pea 109 Logic lnput Test Ged eee cp UM 110 Analog Input TeSt i id red E DIE GU Soe a Pek ale 110 Logic Output Test e ERU eal Be ens ee obs Woven NS 110 Analog Output See dae ete bed ae ae ee 111 9 gt DRIVE INITIALIZATION 1 112 Total Factory 05 112 store User c boe e mene eth eee es 112 Recall User 0 113 Chapter 6 Class 8839 ATV56 Combination Devices 115 INTRODUCTION 3 3 EREPPLEde e bie Rid 117 C
229. process level depending on the type of application Controller will run at low speed at setpoint minimum Setpoint Max Process value corresponding to the maximum setpoint signal Setpoint Max may either be the maximum process level or the minimum process level depending on the type of application Controller will run at high speed at setpoint maximum Feedback Min Process value at which feedback is minimum Feedback Max Process value at which feedback is maximum 9999 Process resolution factor 9999 corresponds to 99 99 FEED BACK FE INPUT MIN FEED BACK 8 MAX FEED BACK 1680 LOW LEVEL ALM 8 amp ENT to select HIGH LEVEL ALM 8 90 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 PI Regulator Application Examples Example 1 Chapter 5 Configuration 7 General Configuration Menu Table 34 Feedback Menu Items Menu tem Description Pme FB INPUT Selects an analog input port for receiving the Al1 A12 AI3 Al4 feedback signal MIN FEED BACK Minimum process value for the process 9999 to 9999 feedback sensor MAX FEED BACK Maximum process value for the process 9999 to 9999 feedback sensor LOW LEVEL ALM Process value below which the FB LOW 9999 to 9999 ALARM logic output activates HIGH LEVEL ALM Process value above which the FB HIGH 9999 to 9999 ALARM logic output activates NOTE LO
230. provide direct thermal protection for the motor Use of a thermal sensor in the motor may be required for protection at all soeeds or loading conditions Consult motor manufacturer for thermal capability of motor when operated over desired speed range Failure to follow this instruction can result in death serious injury or equipment damage MOTOR OVERLOAD MOT SELF COOLED THERMAL PROT TUNING OWERLD Motor Overload enables the drive controller to protect a standard asynchronous induction motor from overload This function can replace a conventional class 10 thermal overload relay for single motor applications however multi motor applications require individual external thermal overload motor protection 1996 Square All Rights Reserved 105 Chapter 5 Configuration Bulletin No 50006 519 01B December 1996 7 General Configuration Menu Adjustment of Motor Overload Types of Protection Self Cooled Motor No Thermal Protection 106 This function is more effective in protecting a motor operated from a drive controller because it considers motor speed as well as time and current in its protection algorithm This is important since most motors applied on drive controllers are self cooled and their cooling effectiveness declines at lower speeds The drive controller s protection algorithm integrates motor current over time taking into account factor
231. provide sufficient free air flow an enclosure ventilation fan is required to exhaust the heat to the enclosure outside ambient The enclosure fan should have a greater fan flow rate than the drive controller fan flow rate listed in Table 6 on page 11 If there is a possibility of condensation keep the control supply switched on during periods when the motor is not running or install thermostatically controlled strip heaters 10 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Chapter 1 Receiving and Installation Mounting in General Purpose Metal Enclosure Side view shown IER y ATV56U41N4 to D23N4 ATV56D33N4 to D79N4 and U41M2 to D16M2 and D23M2 to D46M2 Figure 6 Ventilation for ATV56U41N4 to D79N4 and ATV56U41M2 to D46M2 Table 6 Flow Rates for ALTIVAR 56 Drive Controller Fans Fan Flow Rate 11 Drive Controller CFM dm3 s ATV56U41N4 ATV56U54N4 10 5 ATV56U72N4 ATV56U41M2 20 10 ATV56U90N4 ATV56D12N4 56072 2 ATV56U90M2 44 22 ATV56D16N4 ATV56D23N4 ATV56D12M2 ATV56D16M2 94 47 ATV56D33N4 ATV56D46N4 ATV56D54N4 ATV56D64N4 200 100 ATV56D79N4 ATV56D23M2 ATV56D33M2 ATV56D46M2 Free air flow rates For ATV56D16N4 to D79N4 and ATV56D12M2 to D46M2 drive controllers the yellow pre alarm LED flashes when the drive controller approaches the thermal limit When the drive controller is running at rated load this pr
232. pting a user supplied freeze fire stat interlock normally closed The drive output isolation contactor and transfer contactor will open if the connection between terminals TB22 and TB23 is opened As a result the motor will stop Remove the factory jumper wire located on these terminals prior to installation of interlock 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 MOD 7 Group 1 Pilot Light Cluster if used MOD B07 Group 2 Pilot Light Cluster if used MOD C07 Line Isolation Contactor if used MOD 007 Omit Hand Off Auto Switch and Manual Speed Potentiometer if used Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Power Circuit Z Remote Starter Bypass Package The pilot light cluster provides visual indication of protective functions and circuit status Listed below are the four pilot lights provided and their functions 1 Power On Red illuminates whenever mains power is applied to the controller The LED is rated 120 V 2 AFC Run Green illuminates whenever LO1 is high programmed for running state to annunciate a drive run condition The LED is rated 24 V 3 Bypass Run Green illuminates whenever the transfer contactor coil is energized and the motor is running from a user supplied separately mounted starter The LED is rated 120 V 4 AFC Fault Yellow illuminates whenever LO2 programmed for fault state is high to annunciate a drive fail condition This l
233. r KP 0 to 9999 100 Proportional gain Regulator Kl 0 to 9999 0 Integral gain Regulator PI FLT RATIO 0 to 100 100 Limitation of error between desired setpoint and actual process feedback PI SET POINT 9999 to 9999 0 Setpoint in Regulator PI SP Manual speed reference with MANUAL 0 to High Speed Regulator 2 1oLogic Input Map Logic Input Factory Setting Reassignable LH Run enable No LI2 Run forward No LI3 Auto manual Yes Ll4 Auto run Yes 2 2 gt Analog Input Map Analog Input Factory Setting Reconfigurable Speed 1 12 Speed reference 2 Yes 1996 Square D All Rights Reserved 159 Appendix Parameter Summary 6 Drive Configuration Menu 6 gt DRIVE CONFIGURATION MENU 7 gt GENERAL CONFIGURATION MENU 160 2 3 Output Map Bulletin No 50006 519 01B December 1996 Logic Input Factory Setting Reassignable LO1 At speed Yes LO2 Current limit Yes R1 Fault No R2 Running state Yes 2 4 5Analog Output Map Analog Output Factory Setting Reassignable AO1 Motor speed Yes AO2 Motor current Yes Parameter Range Factory Setting Description Variable Torque Type Variable Low Noise Variable Type of Torque 2 wire maintained of control circuit which is wired into 3 wire impulse 2 wire the drive controller affecting operation P of the Fo
234. r 1996 158 9 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 1 gt PARAMETER SETTING MENU 221 0 MAP Appendix A Parameter Summary 1 Parameter Setting Menu Appendix A Parameter Summary This Appendix contains a general summary and description of parameters Refer to Chapter 5 for complete explanations of the parameters and applicable precautions Parameter Range Factory Setting Description Low Speed 0 to High Speed 0 Hz Low speed setting Low Speed to 5 High Speed Maximum Frequency 60 Hz High speed setting Length of time to accelerate from zero Acceleration 0 1 to 999 9 s 3s speed to nominal frequency Deceleration 0 1 to 999 9 s 3s Length of time to decelerate from nominal frequency to zero speed Matches the response of the load to the NOLD 1 to 100 5 frequency response of the drive Damping Normal 1 to 800 20 controller by adjusting the integral gain of the frequency loop Shapes the V Hz profile of the output for Profile 0 to 100 20 variable torque applications in normal control type 0 45 to 1 15 times 0 9 times nominal Takes speed time and current into Motor nominal drive controller drive controller account to calculate thermal overload Overload current current state SP Gain 9999 to 9999 9999 System in Regulator Offset 9999 to 9999 0 System offset in Regulato
235. r are not present Figures 87 90 show recommended sequencing diagrams for commonly used control methods Figure 87 can be used for applications in which the power converter start stop operation is controlled by a user supplied Auto contact and the speed is controlled by a user supplied 0 10 VDC speed reference signal 1996 Square D All Rights Reserved 147 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Power Circuit Z Remote Starter Bypass Package 148 Bulletin No 50006 519 01B December 1996 10 i E o Se Alt 0 10 VDC Signal 11 pure ue COM TB12 EDI S E Remote 0 10 V Speed Signal a TB4 7 24 V Auto Start Contact or Jumper SEV etr LI2 Figure 87 Speed Reference 1 Signal 0 10 VDC Only Figure 88 can be used for applications in which the power converter start stop operation is controlled by a user supplied Auto contact and the speed is controlled by a user supplied 4 20 mA DC speed reference signal s ROLLE NES TB13 er I Al2 tt 4 20 2 TB11 ere T 574 GND 12 se 5 i Remote 4 20 mA Speed Signal TB4 ie 24 V Auto Start simpar TB8 R L14 Jumper TB4
236. r supplied Auto contact and the speed is controlled by a user supplied 0 10 VDC speed reference signal 1996 Square All Rights Reserved 143 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Bulletin No 50006 519 01B Power Circuit Y Bypass Package 144 December 1996 I P Oe TB10 n T tr AH 0 10 VDC Signal TB11 11 gt Ee v COM TB12 5 Remote 0 10 V Speed Signal Eur 227 25275 4 UD 24 V Auto Start Contact 1 or Jumper TB6 bee ee L12 Figure 83 Speed Reference 1 Signal 0 10 VDC Only The diagram shown in Figure 84 can be used for applications in which the power converter start stop operation is controlled by a user supplied Auto contact and the speed is controlled by a user supplied 4 20 mA DC speed reference signal TB13 v em 4 4 Al2 tt 4 20 mA n TB11 1 4 41 COM 12 GND o eed G Remote 4 20 mA Speed Signal TB4 TB4 TB32 duca c QE 24 V 24 V 1 Start Auto pl Jumper TB8 Jumper rg TB33 N N L14 LI3 Figure 84 Speed Reference 2 Signal 4 20 mA Only The diagram shown in Figure 85 can be used for applications in which the power conver
237. result the motor will stop Remove the factory jumper wire located on these terminals prior to installation of interlock 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 MOD 7 Group 1 Pilot Light Cluster if used MOD B07 Group 2 Pilot Light Cluster if used MOD C07 Line Isolation Contactor if used MOD 007 Omit Hand Off Auto Switch and Manual Speed Potentiometer if used Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Power Circuit Y Bypass Package This pilot light cluster provides visual indication of protective functions and circuit status Listed below are the four pilot lights provided and their functions 1 Power On Red illuminates whenever mains power is applied to the controller The LED is rated 120 V 2 AFC Run Green illuminates whenever LO1 is high programmed for running state to annunciate a drive run condition The LED is rated 24 V 3 Bypass Run Green illuminates whenever the bypass contactor coil is energized and the motor is running from line power The LED is rated 120 V 4 AFC Fault Yellow illuminates whenever LO2 programmed for fault state is high to annunciate a drive fail condition This light is normally not lighted until a controller protective circuit has caused an abnormal shutdown The LED is rated 24 V This pilot light cluster provides visual indication of protective functions and circuit status Listed below are the four pilot
238. rge Option 145 POWER CIRCUIT Z REMOTE STARTER BYPASS PACKAGE 146 Operator Controls General Arrangement and Operation 146 Adjustable Speed Operation 146 Bypass 146 Freeze Fire Stats 146 MOD 07 Group 1 Pilot Light Cluster 147 MOD 07 Group 2 Pilot Light Cluster 147 MOD C07 Line Isolation 147 MOD 007 Omit Hand Off Auto Switch amp Manual Speed Potentiometer 147 MOD E07 CSA 149 MOD F07 Smoke 149 PROPER DRIVE ISOLATION METHOD 150 CONTROL CIRCUIT DIAGRAMS 151 Appendix A Parameter Summary 159 Appendix B Menu 165 Appendix C Spare lt 169 Index teo dte ot E thm RAS REIR 173 1996 Square D All Rights Reserved Bulletin 50006 519 01 Chapter 1 Receiving and Installation December 1996 Contents Chapter 1 Receivin
239. ring Control Circuit Diagrams CONTROL CIRCUIT DIAGRAMS 3 Wire Control 2 Wire Control 28 Bulletin No 50006 519 01B December 1996 This section contains wiring diagrams for 2 and 3 wire control circuits Operation of 2 and 3 wire control is explained in Chapter 5 External Internal 13 12 Control 7 7 Ep 3 Control oor EE D stor LNN 0 20 mA 1 4 20 mA Equipment 1 i d A 1 Rp m F11 F10 PESEN E CE R cli L2 L1 24 13 12 2 10 1 o A1 Keypad Connector 9 W IT3 Um 102 101 COM AO2 AO COM 2 2 2 R1C R1A R1B V T2 PB PA c Oe Q Q Q 0 0o m Add F10 and F11 fuses if tap conductor protection is required The CL1 and CL2 inputs of all ATV56 drive controllers are internally protected and require no external fusing Figure 18 Recommended 3 Wire Control Circuit Diagram Figure 18 is the recommended 3 wire control circuit diagram It shows how to connect a branch circuit disconnect device and protective fusing to the drive controller Additional sequencing logic may be required Refer to Tables 11 to 15 on pages 30 32 for additional equipment required The drive controller is factory set for 2 wire control To set for 3 wire control refer to Chapter 5 External L2 L1 Internal L
240. rocess Level Min Process 9993 If setpoint is to be entered through an analog input port chose the analog input port based on the type of setpoint signal used see Table 33 1996 Square D All Rights Reserved 89 Chapter 5 Configuration Bulletin No 50006 519 01B 7 General Configuration Menu December 1996 Table 33 Analog Input Port Ranges Analog Input Port Input Range 0to 10V AI2 0 to 20 mA 4 to 20 mA 10 V to 10 V Ul Al4 0 to 20 mA 4 to 20 mA AI3 acts as an absolute value when used for Regulator NOTE The analog inputs shaded are available only when an I O extension module is present Next calculate the system gain and offset values System gain and offset are determined by the setpoint minimum and maximum process values and the feedback minimum and maximum process values Use the following formulas to calculate system gain and offset and then enter the values into the drive controller with the SP GAIN and OFFSET entries on the SET POINT menu _ Setpoint Max Setpoint Min Max Feedback Min 9352 _ Setpoint Min Feedback Min Max Feedback Wi 9999 Setpoint Min Process value corresponding to the minimum setpoint signal Setpoint Min may either be the maximum process level or the minimum
241. rol Line Transient Xfmr Xfmr Xfmr VT Fuse Carriers Fuses CC Fast Carriers Contactor Suppressor 7 Fuses Fuses HP Low VT 2 Acting 2 2 Noise 2090 9080 LC1 9070 FNQ R FNQ R FB3611CC 1 R R 1 U41 041 600 6 600V 6A LA4DA2G 1 4 33 T60060 3CR 2 2000 9080 LC1 9070 FNQ R FNQ R FB3611CC 1 R 5 2 U41 041 600 10 600 10 postoge LA4DA2G 1 4 45 T60060 3CR 2 2090 9080 LC1 9070 FNQ R FNQ R FB3611CC 1 R U41 041 600 V 15A 600 V 15A EAT DAZE 1 4 T60060 3CR 2 5 9080 9070 FNQ R FNQ R FB3611CC 1 R 5 R 4 054 041 600 V 20A 600 V 20A REA LA4DA2G 1 4 2 T60060 3CR 2 oe 9080 9070 FNQ R FB3611CC 1 R 2 gt R Re 5 072 U54 600 V 20A 600 V 20A KTK R 3 e ee postoge 1 4 15 T60060 3CR 2 4 9080 9070 FB3611CC 1 R 3 R 75 972 600 25 600 V 25 A KTK R 3 sae poe oe LA4DA2G 1 4 i5 T60060 3CR 2 9080 LC1 9070 FNQ R FNQ R 75 U90 600 V 30 A T60060 3CR 2 3 2553 2 25 9080
242. roller disconnect switch located on the front of the BELE box must be in the closed position and the AFC Off Bypass switch must be in the AFC position There are three modes of operation with the Hand Off Auto switch Hand Off and Auto Hand mode is for local control As soon as Hand mode is entered the power converter is placed in running mode In Hand mode the speed potentiometer mounted on the BELE box is used to control the speed of the controller Off mode commands the power converter to stop the motor by either following the programmed deceleration ramp factory setting or by freewheel stopping Auto mode is for remote control and places the power converter in a running mode as soon as a user supplied run contact is closed between controller terminals TB4 and TB8 In Auto mode motor speed is varied by adjusting the user supplied auto speed reference signal 4 20 mA supplied to the terminals TB13 TB11 and TB12 Shield in the BELE box Refer to Chapter 5 for scaling of this signal To control the operation of the motor with a user supplied separately mounted starter the AFC Off Bypass switch must be in the Bypass position When the AFC Off Bypass selector switch is placed in the Bypass position motor operation is transferred to the user supplied starter If the selector switch is moved to the Off position the transfer contactor will open and the motor will stop Terminals TB22 and TB23 are dedicated terminals for acce
243. roller grounding point or bar X X X 6 Terminate all signal shield grounds to the terminals provided X X 7 Always supply a separate equipment grounding conductor with the controller power feed DO X X X NOT depend upon metallic conduit for ground connection Resolution limited to processor resolution 130 1996 Square D All Rights Reserved Bulletin No 50006 519 01B Chapter 6 Class 8839 ALTIVAR 56 Combination Devices December 1996 Terminal Strip Locations TERMINAL STRIP Figures 74 through 78 show terminal strip locations for Class 883
244. rve these precautions will result in death or serious injury 150 _ 1996 Square D Rights Reserved Bulletin No 50006 519 01B December 1996 CONTROL CIRCUIT DIAGRAMS COMBINATION PACKAGE W OPTIONS Chapter 6 Class 8839 ALTIVAR 56 Combination Devices POWER CIRCUIT W GROUP 2 By cf een mu E eon NOTES i A PILOT LIGHT OPTION GROUP 2 AUTO RED PWR ON MODE AFC RUN GREEN AFC RUN GREEN AUTO MODE ee l YELLOW AFC FAULT PLACE JUMPER BETWEEN 16 AND 26 CONFIGURE CONTROLLER FUNCTIONS MENU 7 3 LO1 RUNNING STATE MENU 7 3 LO2 FAULT STATE 1 1 1 1 A CONTROL TRANSFORMER SHOWN FOR 460V PRIMARY FOR 230 V PRIMARY JUMPER H2 H3 IS REMOVED 1 AND JUMPERS H1 H3 and H2 H4 ARE INSTALLED 1 FOR 208 V PRIMARY REFER TO DETAIL A USER SUPPLIED FREEZE FIRE STAT INTERLOCK 27 CONTACT REMOVE JUMPER BETWEEN TERMINALS 7 9 FREEZE FIRE be STAT INTERLOCK X 1 1 1 1 1 SIGNAL 1 OFF HAND AUTO 4 8 TB5 IF USED ALTERNATE WIRING FOR SMOKE PURGE RELAY SPR OPTION SHOWN DOTTED REMOVE JUMPER BETWEEN TERMINALS 4 amp 16 IF USED CONFIGURE CONTROLLER FUNCTIONS AS FOLLOWS MENU 1 DAMPING 100 MENU 6 1 TORQUE TYPE VARIABLE OR VARIABLE LOW NOISE MENU 6 2 COMMAND TYPE 2 WIRE MAINTAINED MENU 7 12 LOW SPEED 3 HZ MENU 7 12 ACCELERATION 10 SEC MENU 7 12 D
245. rward and Reverse inputs Bol OW m r INP Used to select motor power for dea ATV56U41 drive only 2 2 kW 3 hp 7 11 gt Motor Parameters Parameter Range Factory Setting Description Nominal 45 to 105 of drive Motor nameplate value for full 90 Current controller current rating load current Point on the V Hz curve beyond Nominal which voltage remains virtually Frequency 6012 constant and only frequency increases 460 V 460 V for ATV56 N4 units ATV56 N4 units FOlntonthe V Hz curve beyond Nominal which voltage remains virtually Voltage 208 230 V 230 V for only frequency 56 2 units 56 2 units Shapes the V Hz profile of the output for variable torque 20 applications in normal control type Matches the response of the NOLD 1 to 100 load to the frequency response Damping 20 of the drive controller by Normal 1 to 800 5 adjusting the integral gain of the frequency loop Rotation ABC ABC Inverts direction of motor Normalization ACB rotation without rewiring Default limit Alternate value 2 2 S 40 110 of nominal drive Default value alternate Curent umit Current Limit value by frequency level logic controller current 110 inp t or analog inp t Current limit by frequency P g input adjustable from 0 1 72 Hz 1996 Square D All Rights Reserved Bulletin No 50006 519 01B D
246. s 1 0 times the motor rated torque value from 50 to 100 of motor nameplate rated speed Normal control type 100 torque typical at 50 of nominal frequency over 2 1 speed range Torque decreases linearly to 50 at 0 1 Hz Transient overtorque typical 10 ATV56U41N4 to D79N4 and ATV56U41M2 to D46M2 110 torque for 60 s NOLD control type 100 torque typical at 50 of nominal frequency over 2 1 speed range Torque decreases linearly to 50 at 10 of nominal frequency Transient overtorque typical 10 ATV56U41N4 to D79N4 and ATV56U41M2 to D46M2 110 torque for 60 s T Tn 1 1 1 1 Continuous useful torque 2 2 Transient overtorque OF 3 Transient overtorque during acceleration 0 5 1 Fn nominal frequency 0 3 0 f 0 1 Fn Fn Fmax Figure 22 Typical Torque Curves 1996 Square D All Rights Reserved Bulletin No 50006 519 01 December 1996 MOTOR CONSIDERATIONS Motor Insulation Motors in Parallel Output Contactor Between Motor and Drive Controller Additional Motor Connected Downstream of the Drive Controller Chapter 3 Start Up Motor Considerations Many factors must be considered when controlling a motor with a drive controller The following sections describe several drive controller characteristics as they relate to motor protection and performance ALTIVAR 56 drive controllers use pulse width modulation Verify that the motor insulation is designed for
247. s ENT Factory setting is ABC corresponding to U T1 V T2 W T3 CURRENT LIMIT __ DEFAULT LIMIT BY FREQ LEW Hz BY LOGIC IN BY ANALOG IN CURR LIMIT A Current Limit can be set to a value between 40 to 110 of drive controller output current Default value is 110 of drive controller output current Note that the Current Limit value is not affected by the Nominal Current parameter set in the 7 11 gt Motor Parameters menu A CAUTION UNINTENDED EQUIPMENT ACTION If Current Limit is set to less than the no load current of the motor unstable operation of the drive controller may result After adjusting Current Limit operate the drive controller throughout its speed range with expected motor load Ensure that The motor rotates in the correct direction Rotation occurs even with small 2 3 Hz values of speed reference The steady state motor current does not exceed the motor nameplate current rating For critical applications that cannot be rotated in the reverse direction such as pumps equipped with anti rotation ratchets uncouple the motor from the load after adjusting Current Limit and check the motor for the proper rotation direction when starting Failure to follow this instruction can result in injury or equipment damage The value of Current Limit can affect the operation of other drive controller functions If Current Limit is set to less than the motor no load current then unstable oper
248. s F1 F2 F3 be Escape Key Enter Key Arrow Keys Bey STOP Key Decimal Key RUN Key Figure 28 Keypad Layout LCD Display The LCD display is a 128 x 64 point graphic screen consisting of six 21 character lines The display can be programmed to show text lines and bar graphs and has reverse video capability for enhancement of text or numbers on the screen ENT Key Use the ENT Enter key to Confirm a menu selection Go to the next menu ESC Key Use the ESC Escape key to Reset an adjustment to its original value Leave the present menu and go back to the previous menu Arrow Keys Use the arrow keys to Scroll through the screens and menus Select an item or function Increase or decrease numeric parameters i e from 12 5 A to 12 6 A The arrow keys adjust the portion of the parameter value highlighted on the display To increase the scrolling speed press and hold the arrow key for two seconds Numeric Keys Use the numeric and decimal point keys to enter numeric values for parameter adjustments The format and limits of values entered are checked by the control software according to the nature of the parameter 50 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Function Keys Key Cover STOP Key Chapter 5 Configuration Keypad Display Use the function keys to program the drive co
249. s at rated load see Tables 1 through 4 on pages 3 4 Useful heat exchange surface area 5 in2 of a wall mounted enclosure generally consists of the sides top and front The minimum surface area required for a drive controller enclosure is calculated as follows K Rth Thermal resistance of the enclosure calculated previously Ses Rth K 300 for painted metal The following points should be considered when sizing the enclosure Use only metallic enclosures since they have good thermal conduction This procedure does not consider radiant or convected heat load from external sources Do not install enclosures where external heat sources such as direct sunlight can add to enclosure heat load If additional devices are present inside the enclosure the heat load of the devices must be considered in the calculation The actual useful area for convection cooling of the enclosure will vary depending upon the method of mounting The method of mounting must allow for free air movement over all surfaces considered for convection cooling Below is a sample calculation of the enclosure size for an ATV56U72N4 5 hp drive controller mounted in a Type 12 enclosure Maximum external temperature T 25 Power dissipated inside enclosure P 165 W Maximum internal temperature T 40 C Area resistivity for painted metal 300 Calculate maximum allowable thermal resistance Rth 40 C 25 s Rth
250. s for the speed reference and AI2 is a 0 10 V voltage input A speed potentiometer between 2 2 and 2 5 can be connected at COM and 10 V as shown in Figure 14 is factory set as a 4 20 mA current input It be programmed to 0 20 mA x 20 mA or 20 4 mA with the keypad display It can also be set for 0 5 V with a switch on the control board The speed reference controls the frequency of applied power to the motor The actual shaft speed remains dependent on the acceleration and deceleration ramps the torque capabilities of the motor drive controller combination the control type selected see page 35 and the number of poles on the motor The speed range is limited by Low Speed and High Speed settings Factory settings are zero and nominal or base frequency The speed reference inputs share the same common and are isolated from the input line and from ground The 10 V internal supply terminals 10 COM has a 10 mA supply capability and is protected against short circuits If signals are present on both inputs the values are summed for the speed reference With the keypad display they can be configured to be independent For more information on configuration of the analog inputs refer to Chapter 5 Figure 14 shows how the speed reference inputs may be connected The speed reference inputs are isolated from the input line 10V 10V Al2 2 2kQ lt R lt 2 5kQ Default setting Al
251. s such as stop time and idle time To adjust Motor Overload first select the type of protection in the 7 4 gt Fault Management menu Two types of protection are available from the Motor Overload screen 1 For Self Cooled Motor 2 No thermal protection Factory setting is Self Cooled Motor Once the type of protection is selected the Motor Overload current can be set in either the 1 Parameter Setting menu or in this screen Motor Overload can be adjusted from 0 45 to 1 15 times the nominal drive controller current see page 54 factory preset is 0 9 times nominal drive controller current see page 70 Adjust Motor Overload value to nominal motor current The types of protection are discussed in the following section With this type of motor overload protection the motor base frequency is assumed to be the same as the nominal rated frequency Enter the motor full load amps for Motor Overload current value The overload time current characteristic is set to allow operation at motor rated current above 50 of motor base speed Below 50 of motor base speed the time current characteristic is linearly tapered so that at zero speed the drive will trip on overload at continuous operation above 25 of the motor overload setting The Pt curve which is used to determine when to trip on a motor overheat condition emulates a class 10 thermal overload curve External thermal overload relays are required when more than one motor is connected
252. ser supplied Minimum 10 mA 24 VDC Maximum inductive load of 2 0 A 120 VAC Max 0 10 J operation 80 operations minute 22 1 0 A 220 VAC Max 0 25 J operation 23 R1 Relay N C Contact Fault Relay Output 25 operations minute 2 0 A 24 VAC Max 0 10 J operation 80 operations minute Arc suppression provided by varistors in parallel w relay contacts Minimum 10 mA 24 VDC Maximum inductive load of 2 0 A 120 VAC Max 0 10 J operation 80 operations minute 24 141 1 0 A 220 VAC Max 0 25 J operation 25 R2 Relay N O Contact Run Relay Output 25 operations minute 2 0 A 24 VAC Max 0 10 J operation 80 operations minute Arc suppression provided by varistors in parallel w relay contacts 26 m 15 A 125 VAC 7 j 27 Auxiliary Contact AFC Mode Status 10 A 250 VAC RON o See control circuit diagrams on pages 151 and 152 All terminals are rated 600 V 30 A Class 9080 Type GM6 Maximum wire size for all terminals is 10 AWG 2 5 mm Relay coil deenergizes on fault Contact state with drive controller deenergized Total current of 24 V internal supply is 210 mA Available current of the two logic outputs can be calculated as follows each input requires 10 mA each analog output requires 20 mA and the typical quiescent current of LOP is 15 mA 0 20 mA x 20 mA 20 4 mA programmable with keypad display 0 5 V Z 30 selectable with switch on control board 7 Available only when op
253. t MOTOR 460 VAC 1 60 hp VT 1 60 hp VTLN TRANSFORMER VA 50 hp VT 40 hp VTLN 75 100 hp VT 75 hp VTLN 30 50 hp VT 30 40 hp VTLN 1 1 1 1 1 i CLOSE OPEN A lt 2 1 1 LINE CONTACTOR OPTION 1 1 IF USED i REF 52010 475 01A SPR 1996 Square D All Rights Reserved 151 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Control Circuit Diagrams COMBINATION PACKAGE W O OPTIONS POWER CIRCUIT W NOTES Le CONTROL TRANSFORMER SHOWN FOR 460V PRIMARY FOR 230V PRIMARY JUMPER H2 H3 IS REMOVED AND JUMPERS H1 H3 amp H2 H4 ARE INSTALLED FOR 208V PRIMARY REFER TO DETAIL A USER SUPPLIED FREEZE FIRE STAT INTERLOCK CONTACT REMOVE JUMPER BETWEEN TERMINALS TB4 amp TB5 IF USED CONFIGURE CONTROLLER FUNCTIONS AS FOLLOWS MENU 1 DAMPING 100 MENU 6 1 TORQUE TYPE VARIABLE OR VARIABLE LOW NOISE MENU 6 2 COMMAND TYPE 2 WIRE MAINTAINED MENU 7 12 LOW SPEED 3 HZ MENU 7 12 ACCELERATION 10 SEC MENU 7 12 DECELERATION 10 SEC MENU 7 13 CONTROL TYPE NOLD MENU 7 2 AUTO MANUAL LI3 AUTO RUN INPUT LI4 ce 16 FREEZE FIRE STAT INTERLOCK SPEED REFERENCE 2 Al2 51 MENU 7 3 R2 RUNNING STATE HAND AUTO 6 Op TET EE TEE ER 1 1 1 1 7 gt 1 1 1 8 1 1 AFC MODE STATUS 0 1 F CLOSES WHEN AUTO AUTO START CONTACT
254. t to Yes factory setting and AI1 AI2 is zero or negative the drive controller will run at Low Speed If Clamp Sum is set to No and 2 is negative the drive controller will change direction See Notes on page 80 1996 Square D All Rights Reserved 79 Chapter 5 Configuration 7 General Configuration Menu Auto Manual Controlled Stop 80 Bulletin No 50006 519 01B December 1996 NOTE The drive controller cannot be commanded to change the direction of the motor once the Keypad Command mode is entered If the direction of motor rotation is reversed with speed reference summing the motor will continue to rotate in this direction if Keypad Command mode is entered Make sure that the motor is rotating in the desired direction before switching from Terminal Command mode to Keypad Command mode NOTE If 20 4 mA is selected user should consider effects of broken wire If broken wire occurs when 20 4 mA is selected drive controller will run at high speed AUTO MANUAL YES L GIC IM AUTO RUM IM amp ENT to modify ESC to uit Auto Manual allows switching between Speed Reference 1 and Speed Reference 2 by using a logic input Speed Reference 1 and Speed Reference 2 can be programmed to or AI2 in the Speed Reference screen see page 79 The Auto Manual function eliminates th
255. tage is set at 230 V upon first power up but configurable as either 208 or 230 V Profile is used only when the drive controller is configured for Normal control type This parameter shapes the V Hz profile of the output Profile can be set toa value between 0 and 100 factory preset to 20 Enter the Profile value directly onto the 7 11 gt Motor Parameters menu During changes in speed command the V Hz profile becomes linear intersecting the Vn and fn points of Figure 41 As a result there is no reduction in available motor torque during speed changes Vn Shaded area denotes zone 100 within which drive functions 0 when Profile is set between 0 uj and 100 fmax Figure 41 Profile Profile is not available when NOLD control type is selected Damping is available with any drive controller configuration page 67 This parameter adjusts the integral gain of the frequency loop to match the inertial response of the load to the frequency response of the drive controller The adjustable range varies with the drive controller configuration 1 to 100 for NOLD control with either variable torque configuration 1 to 800 for Normal control with either variable torque configuration When Damping is properly adjusted and the drive controller is not in current limit or ramp modification the motor speed should follow the speed reference ramp without oscillation and with little overshoot During steady state operation with
256. te the power converter for service or repair and still operate the ISOLATION METHOD controller in Bypass mode it is necessary to remove the line fuses installed in the BELE box This procedure applies to Bypass and Remote Starter Bypass Package units Power Circuits Y and Z 7 16 1 2 or 9 16 socket hand tool is attached in the BELE box and provided for line fuse removal Before performing any maintenance or service on the controller review the following precautions and follow all precautions designated on the controller equipment A DANGER HAZARD OF ELECTRIC SHOCK OR BURN This equipment must be installed and serviced only by qualified electrical personnel Turn off power supplying this equipment before working on or inside equipment Always use a properly rated voltage sensing device to confirm power is off Replace all devices doors and covers before turning on power to this equipment DRIVE ISOLATION HAZARD Before servicing the drive controller Disconnect all power Place a Do Not Turn On label on drive controller Lock disconnect in Open position Before servicing basic power converter when Bypass is selected Perform all functions listed above Measure voltages at disconnect output to verify they are zero Wait 1 minute to allow DC bus to discharge verify no voltage is present Remove line fuses labeled FU1 FU2 and FU3 with tool provided Replace cover then close disconnect Failure to obse
257. ted isolation and bypass contactors with Class 10 overloads line fuses 120 V control transformer motor circuit protector disconnect with means for locking in the open position AFC Off Bypass switch Hand Off Auto switch and a manual speed potentiometer 7 16 1 2 or 9 16 socket hand tool is included for removing line fuses to isolate the power converter during servicing See PROPER DRIVE ISOLATION METHOD on page 150 Operator controls are located on the front of the BELE box cover unless option D07 is included Option D07 omits the Hand Off Auto switch and manual speed potentiometer and no operator controls are present on the BELE box cover If option A07 or B07 is included a pilot light cluster is also present on the front of the BELE box cover The AFC Off Bypass switch allows you to select either adjustable speed operation of the motor through the power converter AFC position or line power operation of the motor Bypass position The Hand Off Auto switch and manual speed potentiometer control the operation of the power converter which is factory configured to operate in terminal command mode To control the operation of the motor with the power converter the controller disconnect switch located on the front of the BELE box must be in the closed position and the AFC Off Bypass switch must be in the AFC position There are three modes of operation with the Hand Off Auto switch Hand Off and Auto Hand mode is for local co
258. ter start stop operation is controlled by a user supplied Auto contact and the speed is controlled by a user supplied remote speed potentiometer IN TBO i Hi pese 10 VDC TB10 Wiper 2 5 PS 1 1 u TBI 1 12 Exe S Remote Speed Potentiometer Mc EE MMC TB4 Qo ey 24 V Auto Start Contact c 786 A 12 Figure 85 Remote Manual Speed Potentiometer Reference Only 1996 Square D All Rights Reserved Bulletin 50006 519 01 December 1996 MOD E07 CSA Certification if used MOD F07 Smoke Purge Option if used Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Power Circuit Y Bypass Package The diagram shown in Figure 86 can be used for applications in which the power converter start stop operation is controlled by a user supplied Hand Off Auto switch and speed is controlled by a user supplied speed potentiometer for Hand mode and a user supplied 4 20 mA DC speed reference signal for Auto mode Gat et 2 ut Off Hand Auto TB6 9 J eue 10 VDC 4 u3 ra aA EE TB10 _ of Jua 2 5kQ
259. the drive controller current This function could be used as a drive current reference for motor torque control Normal Current Limit Reduced Current Limit cole Threshold Motor Frequency Logic Input activation LIx Input Alx Input M Current Limit d E Figure 42 Current Limit Timing Reassigning Analog and To reassign an analog input Logic Input Agie puis CURRENT REASSIGN ent AII SPEED REFER Al SPEED REFERENCE 1 gt Ea ee 4 Clear Assignment CURRENT LIMIT ENT to Confirm Select INPUT amp ENT ESC to Abort ENT Al SIGNAL 2 mH 4 28 mH 2 29 4 nh x zB mA 4mB Figure 43 Reassigning Analog Inputs 1996 Square D All Rights Reserved 73 Chapter 5 Configuration 7 General Configuration Menu 7 12 gt Control Parameters Maximum Frequency 74 Bulletin No 50006 519 01B December 1996 To reassign a logic input AUTO MANUAL LI LI3 BYPASS REASSIGN ENT 14 PRESET SPD Lia SPD Esc Clear Assignment 4 LI4 AUTOZMANUAL ESC ENT to Confirm ESC to Abort Select INPUT amp ENT ENT Figure 44 Reassigning Logic Inputs T 12 CONTROL PARAM MAK FREQUENCY 72 0Hz LOW SPEED B BHz HIGH 5 amp 8 8Hz ACCELERATION 3 85 we
260. this modulation method Drive controller selection Drive controller In gt In1 In2 Inx Drive controller Pn gt Pn1 2 Pnx Protect each motor with a thermal overload relay Inx In rated current Drive Controller Pn rated power Figure 23 Motors in Parallel To operate motors in parallel use the keypad display to set the Control Type to Normal For information on adjusting and disabling parameters see Chapter 5 If three or more motors are to be installed in parallel consult factory When using an output contactor between the drive controller and motor use of the Bypass application function is recommended In order to set the motor parameters for optimum performance the motor must be directly connected to the output of the drive controller at least one time during drive controller power up For more information refer to Chapter 5 When connecting an additional motor comply with the recommendation for Motors in Parallel on page 39 OL1 Drive P c Controller 012 Figure 24 Connecting an Additional Motor If the motor is to be connected to the drive controller while the drive controller is running the sum of the running motor current s plus the expected starting current of the switched motor must not exceed 90 of the drive controller s transient output current rating Table 18 Operating Non Standard Motors Description Overload Motors in parall
261. ting from either the line BYP or drive controller AS Selector switch SW controls the circuit With the switch in the AS Adjustable Speed position the motor is run from the drive controller With the switch in the OFF position no power is applied to the motor With the switch in the BYP Bypass position the motor is run directly from the input line The operation at each transition of SW is as follows 1 OFF to AS SW contact C closes causing 112 Run Forward to go high which starts the Delay Time If the motor had previously been running in Bypass then the delay time allows the residual motor voltage to decay After the Delay Time the R2 relay Run Output Command closes energizing the T Isolation contactor allowing power to the motor The I contactor interlock connected to LI 3 Sequence Input allows the drive controller to start accelerating The I contactor interlock must close within the Sequence ToF time or a Sequence Time out Fault will occur If the pressure switch contactor connected to LI4 Process Input does not close within the Process ToF time a Process Time out Fault will occur 2 AS to OFF SW contact C opens causing LI2 to go low and the drive controller to decelerate and stop the motor Then R2 Run Output Command opens de energizing the I contactor 1996 Square D All Rights Reserved Bulletin 50006 519 01B Chapter 5 Configuration December 1996 7 General Configuration Menu
262. tion slope will be modified to minimize the possibility of a nuisance trip Deceleration Time is adjustable between 0 1 and 999 9 seconds and represents the time the drive controller will take to decelerate between Nominal Frequency set in the 7 11 gt Motor Parameters menu page 70 and 0 Hz Deceleration Time determines the base line slope used by the drive controller to decelerate between frequencies Factory setting is 3 seconds If the deceleration slope is too steep for the motor to decelerate the connected load the deceleration slope will be modified to minimize the possibility of a nuisance trip SKIP FREQUENCY SKIP FREQ 1 Hz SKIP BAND 1 Hz 2 SKIP FREQ 2 5 Hz SKIF BAND 2 Hz SFILSPSHSP Br 2orSHz SKIP FREQ 3 Hz BAND 3 Hz 1996 Square D All Rights Reserved 75 Chapter 5 Configuration 7 General Configuration Menu 7 13 gt Type Normal NOLD No Load 76 Bulletin No 50006 519 01B December 1996 Skip Frequencies 1 2 and 3 are used to avoid mechanical resonance The adjustable range for skip frequencies is from 0 to 72 Hz The three skip points may overlap each other Skip Bands of 2 or 5 Hz can be selected If a reference is set in a skip frequency band the drive controller will not run in that band Ramps are not modified in th
263. tions are included 1996 Square D All Rights Reserved 135 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Control Wiring 136 Bulletin No 50006 519 01B December 1996 Table 51 Control Terminal Strip Characteristics Power Circuits Y amp Z Terminal 1 2 1 Function LO1 Logic Output 1 Characteristics 24 V 200 mA max 5 LO2 Logic Output 2 24 V 200 mA max 5 COM Logic Common 0v Minimum 12 V Maximum 30 V 4 24 24 V Control Supply Quiescent current 15 mAtypical Is 210 mA DI 24 V 10 mA PERI State 0 V lt 5 V State 1 V gt 12 V Vmax 30 V 24 V 10 mA He Logic State 0 V lt 5 V State 1 V gt 12 V Vmax 30 V 24 V 10 mA L13 Eogic Input 3 State 0 V lt 5 V State 1 V gt 12 V Vmax 30 V 24 V 10 mA i LI Logie State 0 V lt 5 V State 1 V gt 12 V Vmax 30 V 9 10 V Reference Supply 10 V Is 10 mA max 10 Al1 Analog Input 1 Speed 0 10V Z 30kQ Reference Voltage 11 COM Speed Reference Common 0V 12 GND S Ground Shield 13 Al2 Analog Input 2 Speed 4 20 mA Bl Z 2500 Reference Current 14 COM Analog Common 0v 0 20 mA 12 V max programmable as 4 20 mA 15 AO1 Analog Output 1 w keypad display 16 115 V Control Transformer 17181 115 V Rated Terminal 18 AFC Mode Select Normally jumpered or N C SPR contact when 19 option is suppli
264. to the output or when the motor connected to the drive controller is less than half the drive controller rating When external overload protection is provided select No Thermal Protection A CAUTION LOSS OF MOTOR OVERLOAD PROTECTION When using external overload relays connected to drive controller output the overload relays must be capable of operation over the expected range of drive controller output frequencies including direct current When DC injection braking is used The overload relay must be suitable for operation with direct current flowing in the motor Do not use overload relays equipped with current transformers for sensing the motor current Failure to follow this instruction can result in equipment damage The thermal state of the drive controller is not automatically reset when power is removed 1996 Square D All Rights Reserved Bulletin No 50006 519 01 December 1996 Input Phase Failure Loss of Follower Chapter 5 Configuration 7 General Configuration Menu A CAUTION MOTOR OVERHEATING Repeated reset of the thermal state after a thermal overload can result in thermal stress to the motor When faults occur promptly inspect motor and driven equipment for problems locked shaft mechanical overload etc prior to restarting Also check power supplied to motor for abnormal conditions phase loss phase imbalance etc Failure to follow this instruction can result in damag
265. tomatic Restart allows up to five restart attempts after the drive controller has tripped on a fault The time between restart attempts is programmable from 1 to 600 seconds The power supply and control commands must be maintained for an Automatic restart To enable Automatic Restart select Yes specify the number of restart attempts 1 5 and set time between restart attempts 1 600 s If the drive controller trips on a fault that is automatically resettable and Automatic Restart is enabled the drive controller is locked for the programmed time period then resets the drive controller if the fault condition has disappeared Then if commanded to run the drive controller restarts the motor If the fault condition remains during the reset attempt the drive controller locks for the programmed period of time and the restart command is repeated at the programmed delay time for the programmed number of restarts maximum of 5 times before the drive controller trips See Table 37 on page 101 for faults that can be automatically reset 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Catch On Fly Catch On Fly Set to NO Refer to Figure 63 Chapter 5 Configuration 7 General Configuration Menu Note that only if the drive controller is configured for 2 wire command will it automatically restart the motor If the drive controller is configured for 3 wire command Automatic Restart is not available For 2
266. tomatically disabled when the Bypass function is used or the drive controller is operated at less than 3376 of nominal frequency NOTE Output Phase Fault should be left enabled except for the reasons stated above If it must be disabled either manually or by the selection of the Bypass function always supply an external motor overload relay Operation with the presence of an Output Phase Fault can affect the calibration of the Motor Overload Protection function of the drive controller 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 8 gt DIAGNOSTIC MODE Autodiagnostics Chapter 5 Configuration 8 Diagnostic Mode AUTODIAGNOSTIC LOGIC INPUT TEST ANALOG INPUT TEST LOGIC OUTPUT TEST amp ENT to activate ANALOG OUTPUT TEST The 8 Diagnostic Mode menu allows access to various tests for locating failed components in case of an internal drive controller fault This menu is accessible only when The drive controller is stopped Supply line power L1 L2 and L3 is disconnected Control power supply CL1 CL2 is connected If any of these conditions are not met an error message appears and access to the Diagnostic Mode is denied Exit the error message screen and return to the Main menu by pressing ESC The motor should be connected when performing tests The following sections cover the functions available from the Diagnostic Mode menu AUITODIAGNOSTIC
267. trollers with the Remote Starter Bypass power circuit the short circuit withstand rating depends on the overcurrent protective device in the user supp ied bypass starter It cannot exceed 22 000 A Table 42 Variable Torque Class 8839 Enclosed ATV56 Drive Controller Ratings 230 10 Switching Frequency 56UCG3L_ to 56UMG3L_ 10 Khz 56UNG3L_ 4 kHz Motor Power Input Line Current 11 Max Controller 230 V a utpul Transient Power 2 Current Part No 60 Hz 5 000A 22 000 Current 60 Converter Part No hp A A A A 56UCG3L_ 1 5 4 6 4 4 2 5 1 56UDG3L_ 2 8 8 10 4 6 8 8 3 ATV56U41M2U 56UEG3L_ 3 12 14 3 9 6 11 7 56UFG3L_ 5 18 3 21 8 15 2 18 4 ATV56U72M2U 56UGG3L_ 7 5 25 8 30 7 22 26 6 ATV56U90M2U 56UHG3L_ 10 32 8 39 28 34 ATV56D12M2U 56UJG3L 15 46 5 55 2 42 51 ATV56D16M2U 56UKG3L 20 59 6 70 3 54 66 ATV56D23M2U 56ULG3L 25 71 7 84 7 68 83 ATV56D33M2U 56UMG3L 30 80 8 97 2 80 97 56UNG3L 40 102 125 4 104 126 ATV56D46M2U Short circuit current available at controller input 2 For controllers with the Remote Starter Bypass power circuit the short circuit withstand rating depends the overcurrent protective device in the user supp 120 1996 Square D All Rights Reserved ied bypass starter It cannot exceed 22 000 A Bulletin No 50006 519 01B December 1996 Chapter 6 Class 8839 ALTIVAR 56 Combination Devices Technical Characteristics Table
268. ts to motor parameters are made either to sub menus or directly on the 7 11 gt Motor Parameters menu itself To select a parameter scroll with the and V keys and press ENT Adjust the parameter value to the desired setting then press ENT to confirm 1996 Square D All Rights Reserved 69 Chapter 5 Configuration 7 General Configuration Menu Nominal Current Nominal Frequency Nominal Voltage 70 Bulletin No 50006 519 01B December 1996 Some motor parameters are also accessible from the 1 gt Setting menu Any adjustments made to these parameters from the 7 11 Motor Parameters menu are also automatically displayed in the Parameter Setting menu Table 27 shows the selections available from the 7 11 Motor Parameters menu under the various drive controller configurations Table 27 7 11 Motor Parameters Menu Variable Torque Nominal Current Nominal Frequency Nominal Voltage Profile Damping Rotation Normalization Current Limit Normal Control Nominal Current Nominal Frequency NOLD Nominal Voltage Control Damping Rotation Normalization Current Limit Nominal Current is the motor nameplate value for full load current Adjustable from 45 to 10576 of the drive controller s current rating the factory preset value is 9076 Set Nominal Current to equal the motor full load current The Nominal Current parameter does not affect the maximu
269. ts used with the drive controller inputs must be rated for operation at open circuit voltages of 24 VDC and closed circuit currents of 10 mADC Twisted cable with a pitch of 1 to 2 inches is required for analog inputs and outputs Use of a cable shield is recommended The shield must be terminated to ground at one end only It is recommended that the shield be terminated at the drive controller Shield connection terminals are provided on the ALTIVAR 56 drive controller for this purpose The coils of all relays and solenoids connected to the output contacts of the drive controller must be equipped with appropriate transient suppressors For proper control wiring conductors must be routed to avoid contact with other voltage potentials in the drive controller Wire insulation must have the appropriate voltage rating for the voltage present WARNING DRIVE CONTROLLER DAMAGE Drive controller will be damaged if input line voltage is applied to output terminals U T1 V T2 W T3 Check power connections before energizing drive controller Failure to follow these instructions can result in death serious injury or equipment damage The drive controller is sensitive to the amount of capacitance either phase to phase or phase to ground present on the output power conductors If excessive capacitance is present the drive controller may trip Follow the guidelines below when selecting output cable Cabletype thecable selected
270. u Three display options are available from the 4Display Configuration screen An arrow indicates the active display option One function displayed in bar graph form Two functions displayed in bar graph form Eleven functions displayed in three tables The One Bar Graph and Two Bar Graph choices have sub menus From a list of nine items in these sub menus you may select the functions to be displayed The list of functions is the same for both display choices and is illustrated in the 4 1 gt Bar Graph menu 4 1 0 BAR GRAPH SPEED REFERENCE ENTER OUTPUT FREQUENCY enr MOTO NOTE Out ENTS put Frequency M Te p Select only 1 item IN OUTPUT POWER OUTPUT VOLTAGE enr ENTER LINE VOLTAGE SCALING ent DC VOLTAGE eM FACTOR UNITS EDITION A MOTOR THERMAL STATE ENT EN d MOTOR SPEED aues MACHINE SPEED REF 7 MACHINE SPEED gt amp ENT to select THERMAL STATE When finished use ESC SET POINT ar FEED BACK pec Use the A and keys to select a function from the 4 1 Bar Graph menu and press ENT Five functions on the menu have associated screens for entering actual values For motor RPM enter the motor rated speed The controller will automatically select the closest standard motor speed 700 900 1200 1800 or 3600 For Machine Speed Reference Machine Speed PI Set Poi
271. unctions Application Function No of LI Inputs No of Al Inputs No of LO or R2 Used 11 Used Outputs Used Preset Speeds 1or2 0 0 Speed Reference 0 1or2 0 Auto Manual 1or2 0 0 Controlled Stop O or 1 0 0 Shutdown 0 0 0 or 1 Bypass 2 0 1 PI Regulator 0 1 or2 0 1 2 or 3 0 1 2 3 1 The only LI inputs which be reprogrammed are and 4 1 is fixed as Run Enable and 142 is fixed as Run Forward If more inputs are required the I O Extension Module can be ordered See catalog document VDOCO06S201 for more information 1996 Square D All Rights Reserved 77 Chapter 5 Configuration 7 General Configuration Menu Preset Speeds 78 Bulletin No 50006 519 01B December 1996 Read up and across from the to identify pairs of incompatible functions Incompatibilities due to the number of I O available for reassignment are not shown PRESET SPEEDS SPEED REFERENCE AUTO MANUAL CONTROLLED STOP SHUTDOWN BYPASS PI REGULATOR 1 Shutdown is incompatible with Controlled Stop by Frequency Threshold and Controlled Stop by Frequency Threshold Logic Input Figure 47 Application Function Incompatibilities PRESET SPEEDS NO 1 PRESET SPEED 3 PRESET SPEED amp ENT to modify E
272. y a user supplied Auto contact and the speed is controlled by a user supplied 0 10 VDC speed reference signal TB10 R e ee 2 10 10 VDC Signal ae TB1 bg rd i Pre COM TB12 aq 9 Remote 0 10 V Speed Signal TB6 12 Auto Start Contact _ _ or Jumper TB16 ede e S Freezestat TB4 oM TB5 NP Jumper 24 V LI Figure 79 Speed Reference 1 Signal 0 10 VDC Only Figure 80 can be used for applications in which the power converter start stop operation is controlled by a user supplied Auto contact and the speed is controlled by a user supplied 4 20 mA DC speed reference signal TB13 E IV ba A12 1 KA 4 20 TB1 4 vy 1 GND TB12 ERE bes S TB7 1 Remote 4 20 mA Speed Signal x LI3 TB8 r n inaa ini Jumpers TB16 Jumper TB26 S v xU que Auto Stat 7 P4 5 LI Jumper TB4 TB27 T s 4 sdumper S 24V Figure 80 Speed Reference 2 Signal 4 20 mA Only Figure 81 can be used for applications in which the power converter start stop operation is controlled by a user supplied Auto contact and the speed is controlled by a
273. y stopping This function is useful in applications such as pumping stations where the dwell time controls the closing of a check valve before the pump is stopped To use Shutdown activate the function by selecting Yes and set dwell time to a value between 0 1 and 60 seconds The timer begins when the drive controller deceleration ramp reaches Low Speed Factory setting of dwell time is 1 second 1996 Square D All Rights Reserved Bulletin No 50006 519 01B December 1996 Bypass Chapter 5 Configuration 7 General Configuration Menu If the application requires it a logic output can be assigned to the Shutdown function When dwell time has expired the drive controller activates the logic output to indicate end of functioning at Low Speed Note that if a Run command is issued during the dwell time it is not taken into account until the end of the dwell time f Hz LSP LI2 0 1 LO10 m Figure 55 Shutdown Timing Diagram 2 Wire Command BYPASS NOTE Do not set Bypass HO function if the drive controller YES DEFINE 140 e is part of a Class 8839 DELAY TIME ALTIVAR 56 combination SEQUENCE i os device PROCESS 106 5 BYPASS 1 0 SEQUENCE INPUT PROCESS INPUT RUN QUT COMMAND Enter all values E50 Bypass is used to sequence an output isolation contactor The output isolation contactor is commonly used in conjunction with a bypass co

ALTIVAR 56 Fan and Pump Drive User`s Manual

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