armorstart distributed motor controller
Contents
1. Publication 284D 0S001D EN P July 2006 DETAIL A System Configuration Information The following information is provided to identify the default method for setting up communication to the ArmorStart Additional configuration information and advanced settings help can be found in the ArmorStart User Manual Publication 284 UM001 EN P Using Automap Feature with Default Input and Output 1 0 Assemblies The Automap feature available in all Rockwell Automation scanners will automatically map the information as shown below If manual mapping is required the information below can be used to map a device based on the default configuration Table 3 Default 1 0 Messaging Data Default Message type Polled Consumed data size 4 byte Rx Produced data size 4 bytes Tx 23 Default Input and Output 1 0 Assembly Formats2. 1 CONDUIT OPENING 0 75 CONDUIT OPENING Publication 284D QS001D EN P July 2006 Dimensions are shown in millimeters inches Dimensions are not intended to be used for manufacturing purposes All dimensions are subject to change Figure 4 Dimensions for 2 Hp 230V AC 3 Hp and above 460V AC and 3 Hp and above 575V AC IP67 NEMA Type 4 with ArmorConnect Connectivity ArmorStart device with a 25 A short circuit protection rating Publication 284D 0S001D EN P July 2006 Dimensions are shown in millimeters inches Dimensions are not intended to be used for manufacturing purposes All dimensions are subject to change Figure 5 Dimensions for 1 Hp and below 230V AC 2 Hp and below 460V AC and 2 Hp and below 575V AC NEMA Type 4X with Conduit Entrance 420 38 16 551 236 9 q Wd T h ul tL _ H fig MOTOR CONNECTION 266 9 10 51 t 12 373 114
3. Parameter Parameter Display Min Defaults Number Description Options Max Settings Based on 131 Motor NP Volts 1 VAC 20 Drive Rated Driving Volts Rating 1320 Motor NP Hz 1 Hz 15 400 Hz 60 Hz Motor OL 0 0 Drive Rated Based on 133 0 1A Driving Current Amps x 2 i Rating 134 Minimum Freq 0 1 Hz 0 0 400 Hz 0 0 Hz Maximum 1350 Freq 0 1 Hz 0 0 400 Hz 60 Hz 0 Keypad 1 3 Wire 2 2 Wire 136 Start Source 3 2 W Lvl Sens 0 5 5 4 2 W Hi Speed 5 Comm Port 0 Ramp CF 1 Coast CF 2 DC Brake CF 3 DCBrkAuto CF 4 Ramp 137 Stop Mode 5 Coast 0 9 9 6 DC Brake 7 DC BrakeAuto 8 Ramp EM B CF 9 Ramp EM Brk 0 Drive Pot 1 InternalFreq 2 0 10V Input Speed 3 4 20 mA Input 138 Reference 4 Preset Freq ae 3 5 Comm Port 6 Stp Logic 7 Anlg in Mult 139 Accel Time 1 0 1 Secs 0 0 600 0 Secs 10 0 Secs 140 Decel Time 1 0 1 Secs 0 0 600 0 Secs 10 0 Secs Reset to 0 Ready ldle 1o Default 1 FactoryRset an Stop drive before changing this parameter See Important below Available with the A10 factory installed option IMPORTANT become disabled These drive parameters options will cause the Bulletin 284 ArmorStart Distributed Motor Controller to Publication 284D 0S001D EN P July 2006 Quick Reference Troubleshooting Network Status LED Off 27 There are four LEDs on the front of the ArmorStart that can provide an indicat
4. See Publication M116 CA001A EN P for complete cable selection information Replace symbol with desired length in meters Example 889D F4ACDM 1 for a 1 m cable Standard cable lengths 1 m 2 m 5 m and 10 m NOTE Stainless steel versions may be ordered by adding an S to the cat no Example 889DS F4ACDM 1 Table 15 Sealing Caps Description Used on 1 0 Connection Cat No Plastic Sealing Cap M12 Input 1485A M12 Aluminum Sealing Cap Output 889A RMCAP To achieve IP67 rating sealing caps must be installed on all unused 1 0 connections Publication 284D 0S001D EN P July 2006 Registered Trademark List ArmorPoint and ArmorStart are registered trademarks of Rockwell Automation Inc Trademark List ArmorConnect RSLogix5000 PLC RSNetWorx and SLC are trademarks of Rockwell Automation Inc ControlNet is a trademark of ControlNet International LTD DeviceNet and the DeviceNet logo are trademarks of the Open Device Vendors Association ODVA www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 288
5. 60 Hz Comm Port Ramp CF Comm Port 10 0 Sec 10 0 Sec Ready Idle 0 v b Bulletin 284 Pararmeters Table 6 Basic Program Group for Sensorless Vector Performance 25 Parameter Parameter Display Min Defaults Number Description Options Max Settings A Based on 1310 Motor NP Volts 1 VAC 20 Drive Rated Driving Volts Rating 1320 Motor NP Hz 1 Hz 10 240 Hz 60 Hz Based on 133 Motor OL 01A 0 0 Drive Rated Driving Current Amps x 2 Rating 134 Minimum Freq 0 1 Hz 0 0 240 Hz 0 0 Hz 1350 Maximum 0 1 Hz 0 0 240 Hz 60 Hz Freq 0 Keypad 1 3 Wire 2 2 Wire 136 Start Source 3 2 W Lvl Sens 0 5 5 4 2 W Hi Speed 5 Comm Port 0 Ramp CF 1 Coast CF 2 DC Brake CF 3 DCBrkAuto CF 137 Stop Mode 4 Ramp 0 7 0 5 Coast 6 DC Brake 7 DC BrakeAuto 0 Drive Pot 1 InternalFreq Speed 2 0 10V Input 138 Reference 3 4 20 mA Input 3 A 4 Preset Freq 5 Comm Port 139 Accel Time 1 0 1 Secs 0 0 600 0 Secs 10 0 Secs 140 Decel Time 1 0 1 Secs 0 0 600 0 Secs 10 0 Secs Reset to 0 Ready ldle ve Default 1 FactoryRset oa 0 Stop drive before changing this parameter See Important below IMPORTANT These drive parameters options will cause the Bulletin 284 ArmorStart Distributed Motor Controller to become disabled Publication 284D 0S001D EN P July 2006 26 Table 7 Basic Program Group for Sensorless Vector Control
6. The I O assembly formats for the ArmorStart are identified by the value in Parameter 11 Consumed IO Assy and Parameter 12 Produced IO Assy These values determine the amount and arrangement of the information communicated to the master scanner The tables below identify the default information produced and consumed by Bulletin 284 devices For additional formats and advance configurations please reference the user manual Defaults for Bulletin 284 Distributed Motor Controllers Table 4 Instance 164 Default Consumed Inverter Type Distributed Starter 4 bytes Byte Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit 1 BitO User User Jog 0 OutB outa Rev Jog Fwd Fault Reset Run Rev Run Fwd 1 Drive Drive Drive Drive DecelRate2 DecelRate1 Accel Rate 2 Accel Rate 1 In4 In3 In2 ini Enable Enable Enable Enable 2 Comm Frequency Command Low xxx x Hz 3 Comm Frequency Command High xxx x Hz Table5 Instance 165 Default Produced Inverter Type Distributed Starter 4 bytes Byte Bit 7 Bit6 Bit5 Bit4 Bit 3 Bit 2 Bit 1 Bit O At Net Ref NetCtl Running Running s 0 Reference Status Status Ready Rev Fwd sul Tripped Contactor2 Contactor 140M HOA 1 o On Status Input 3 Input 2 Input 1 Input 0 2 Output Frequency Low xxx x Hz 3 Output Frequency High xxx x Hz Refers to output contactor status Refers to source brake contactor status
7. 691 Re Ota 2 l Tm N S HE S j T ENN 13 YAY aar A ig 1 CONDUIT OPENING i 38 972 41 1 931 1 851 0 75 CONDUIT OPENING Publication 284D 0S001D EN P July 2006 Dimensions are shown in millimeters inches Dimensions are not intended to be used for manufacturing purposes All dimensions are subject to change Figure 6 Dimensions for 1 Hp and below 230V AC 2 Hp and below 460V AC and 2 Hp and below 575V AC NEMA Type 4X with ArmorConnect Connectivity SS SS a S Q Publication 284D 0S001D EN P July 2006 Dimensions are shown in millimeters inches Dimensions are not intended to be used for manufacturing purposes All di
8. Current Trip has been exceeded F64 Drive 2 Drive rating of 150 for 1 min or Reduce load or extend Accel Time Overload 200 for 3 sec has been exceeded F70 Power Unit 2 Failure has been detected in the 1 Cycle power drive power section 2 Replace starter module if fault cannot be cleared F80 SVC Autotune The autotune function was either Restart procedure cancelled by the user or failed F81 Comm Loss 2 RS485 DSI port stopped 1 Turn off using Parameter 205 Comm Loss Action communicating 2 Replace starter module if fault cannot be cleared F100 Parameter 2 The checksum read from the board Set Parameter 141 Reset To Defaults to option 1 Reset Defaults Checksum does not match the checksum calculated F122 1 0 Board Fail 2 Failure has been detected in the 1 Cycle power drive control and 1 0 section See Table 11 for in 2 Replace starter module if fault cannot be cleared ernal drive fault types Publication 284D 0S001D EN P July 2006 32 Figure 17 Bulletin 284 ArmorStart Local Disconnect L L A N N H i LED Status Indication aa m 4 Allen Bradley 2 Outputs m on ar or Micro M12 4 Inputs Micro M12 Lt Sourc
9. Publication 284D 0S001D EN P July 2006 24 Setting the Motor OL Current The product should now be configured and communicating on the network The last step is to program the proper motor OL current setting Parameter 133 This can be accomplished by using software such as RSNetWorx for DeviceNet or a handheld DeviceNet tool Use the software to access the device parameters screen By default the motor OL current is set to the minimum motor OL current setting for the device Set this parameter to the desired value and download to the device Select Motor OL Current Parameter 133 and enter a value that corresponds to the FLA of the motor connected to the ArmorStart Make sure the Single radio button is selected and then select Download to Device The proper motor protection is now in place Figure 16 RSNetWorx Parameter Screen ArmorStart 284D PF4 240 0 5HP 2 x General Device Parameters 1 0 Defaults EDS File DeviceLogix Groups 0 n Line All parameters lt 1 Singe Restore Default Values Cc All Upload From Device Download To Device Start Monitor Parameter Help Parameter Motor NP Volts Motor NP Hertz Motor OL Current Minimum Freq Maximum Freq Start Source Stop Mode Speed Reference Accel Time 1 Decel Time 1 Reset To Defalts Reserved Publication 284D 0S001D EN P July 2006 Cancel Apply Help Current Value 230 60 Hz 2 34 0 0 Hz
10. examination adjustment servicing or maintenance while energized In lieu of this service the ArmorStart is meant to be unplugged and replaced after proper lockout tag out procedures have been employed Since the ArmorStart is available with a factory installed HOA keypad option this may require the ArmorStart to be selected and installed as follows if the application requires frequent use of the hand operated interface by the equipment operator 1 They are not less than 0 6 m 2 ft above the servicing level and are within easy reach of the normal working position of the operator 2 The operator is not placed in a hazardous situation when operating them 3 The possibility of inadvertent operation is minimized If the operated interface is used in industrial establishments where the conditions of maintenance and supervision ensure that only qualified persons operate and service the ArmorStart s operator interface and the installation is located so that inadvertent operation is minimized then other installation locations with acceptable access can be provided DeviceNet Network Installation The ArmorStart Distributed Motor Controller contains the equivalent of 30 in 0 76 m of Device Net drop cable s electrical characteristics and therefore 30 in of drop cable must be included in the DeviceNet drop cable budget for each ArmorStart in addition to actual drop cable required for the installation Other DeviceNet System Design Con
11. fuses For additional information see the ArmorStart User Manual 17 Group Motor Installations for USA and Canada Markets The ArmorStart Distributed Motor controllers are listed for use with each other in group installations per NFPA 79 Electrical Standard for Industrial Machinery When applied according to the group motor installation requirements two or more motors of any rating or controller type are permitted on a single branch circuit Group Motor Installation has been successfully used for many years in the USA and Canada Wiring and Workmanship Guidelines In addition to conduit and seal tite raceway it is acceptable to utilize cable that is dual rated Tray Cable Type TC ER and Cord STOOW for power and control wiring on ArmorStart installations In the USA and Canada installations the following guidance is outlined by the NEC and NFPA 79 In industrial establishments where the conditions of maintenance and supervision ensure that only qualified persons service the installation and where the exposed cable is continuously supported and protected against physical damage using mechanical protection such as struts angles or channels Type TC tray cable that complies with the crush and impact requirements of Type MC Metal Clad cable and is identified for such use with the marking Type TC ER Exposed Run shall be permitted between a cable tray and the utilization equipment or device as open wiring The cable shall be secu
12. o IU o e of 1 CONDUIT OPENING Zee as A Do mee 0 75 CONDUIT OPENING Publication 284D QS001D EN P July 2006 Publication 284D 0S001D EN P July 2006 Dimensions are shown in millimeters inches Dimensions are not intended to be used for manufacturing purposes All dimensions are subject to change Figure 2 Dimensions for 1 Hp and below 230V AC 2 Hp and below 460V AC and 2 Hp and below 575V AC IP67 NEMA Type 4 with ArmorConnect Connectivity L q 68 2 68 Dimensions are shown in millimeters inches Dimensions are not intended to be used for manufacturing purposes All dimensions are subject to change Figure 3 Dimensions for 2 Hp 230V AC 3 Hp and above 460V AC and 3 Hp and above 575V AC IP67 NEMA Type 4 with Conduit Entrance 444 38 117 501 236 19 290 Ct a2i e SST ji JA ah 5 58 1 12 He MOTOR CONNECTION 266 9 10 51
13. operating in a normal condition is on line but with no connection to another device This is the typical state for new devices The device may need to be mapped to a master scanner placed in a scanlist or have another device communicate to it Flashing Red Recoverable fault has occurred Check to make sure the PLC and scanner are operating correctly and that there are no media cabling issues Check to see if other networked devices are in a similar state Solid Red The device has detected a major error that has Troubleshooting should be done to ensure that the network is correct rendered it incapable of communicating on the terminators lengths etc and there is not a duplicate node problem network Duplicate MAC ID Bus off media issue If other devices on the network appear to be operating fine and power cycling the device does not work contact Technical Support Flashing Red and The device is in a communication faulted state Power cycling the device may resolve the problem however if the Green problem continues it may be necessary to contact Technical Support Fault Definitions Some of the Bulletin 284 ArmorStart Distributed Motor Controller faults are detected by the internal hardware of the ArmorStart while others are detected by the internal drive For internal drive faults the internal hardware of the ArmorStart simply polls the drive for the existence of faults and reports the fault state No fault lat
14. w5 Z5 Mini Straight Female Mini Straight Male 1485C P N5 M5 Mini Straight Female Mini Right Angle Male 1485C P ws N5 Thick Cable ary Mini Right Angle Female Mini Straight Male 1485C P m5 25 Mini Right Angle Female Mini Straight Male See Publication M116 CA001A EN P for complete cable selection information 1485C P W5 Z5 Replace symbol with desired length in meters Example 1485G P1N5 M5 for a 1 m cable Standard cable lengths 1 m 2 m 3 m 4 m 5 m and 6 m Replace symbol with desired length in meters Example 1485C P1N5 M5 for a 1 m cable Standard cable lengths 1 m 2 m 3 m 4 m 5 m 6 m 8 m 10 m 12 m 18 m 24 m and 30 m NOTE Stainless steel versions may be ordered by adding an S to the cat no Example 1485CS P1N5 M5 Publication 284D 0S001D EN P July 2006 34 Table 14 Sensor Media Description Armorstart ue Pin Count Connector Cat No Connection gt Straight Female Straight Male 889D F4ACDM KC Input 5 Pin Sy Straight Female 2 paG Right Angle Male 889D F4AACDE DC Micro Patchcord LAL gt Straight Female 879D F4ACDM 2 Ge E Input 5 pin j Right Angle Male 879D R4ACM 2 DC Micro V Cable ve Straight Female o Input 5 pin Right Angle Male 879D F4ACTE DC Micro Y Cable Straight Female Straight Male 889R F3AERM Ge Output 3 pin o Straight Female Right Angle Male 899R F3AERE AC Micro Patchcord
15. 7 4788 Fax 852 2508 1846 41053 384 02 Publication 284D QS001D EN P July 2006 Copyright 2006 Rockwell Automation Inc All Rights Reserved Printed in USA Superecedes Publication 284D QS001C EN P September 2005
16. Dimensions for 2 Hp 230V AC 3 Hp and above 460V AC and 3 Hp and above 575V AC NEMA Type 4X with ArmorConnect Connectivity ArmorStart device with a 25 A short circuit protection rating 29 68 ii 2 68 Publication 284D 0S001D EN P July 2006 11 Wiring Power Control Safety Monitor Inputs and Ground Wiring Table 1 provides the power control safety monitor inputs ground wire capacity and the tightening torque requirements The power control ground and safety monitor terminals will accept a maximum of two wires per terminal Table 1 Power Control Safety Monitor Inputs Ground Wire Size and Torque Specifications Terminals Wire Size Torque Wire Strip Length Primary Terminal p Primary Secondary 10 6 21 6 Ib in ower Terminal 1 2 2 4 Nem and 2 s dary Terminal 0 35 in 9 mm Ground 1 0 4 0 mm econdary ermina 18 10 AWG 5 3 7 3 Ib in 0 6 0 8 Nem Control and Safety 0 34mm2 4 0 mm 5 0 5 6 Ib in Monitor Inputs 22 10 AWG 0 6 Nem soit i Terminal Designations for As shown in Figure 9 the ArmorStart Distributed Motor Controller contains Conduit Entrance terminals f
17. UTEN QUICK START ARMORSTART DISTRIBUTED MOTOR CONTROLLER Getting Started BULLETIN 284D Introduction This guide provides the basic information required to start up your ArmorStart Distributed Motor Controller Factory default settings and information regarding installing programming and DeviceNet Node Commissioning are described here For detailed information on specific product features or configurations refer to the ArmorStart user manual Publication 284 UM001 EN P This guide is intended for qualified service personnel responsible for setting up and servicing these devices You must have previous experience with and a basic understanding of electrical terminology configuration procedures required equipment and safety precautions You should understand DeviceNet network operations including how slave devices operate on a network and communicate with a DeviceNet master You should also be familiar with RSNetWorx for DeviceNet You must use RSNetWorx for DeviceNet revision 3 21 service pack 2 or later This software package is referred to often in this manual Rockwell Automation product EDS files are available on the internet at http www ab com networks eds Rockwell Allen Bradley Rockwell Software Automation Installation Dimensions The ArmorStart Distributed Motor Controller is convection cooled Operating temperature must be kept between 20 40 C 4 104 F Dimensions are shown i
18. cations F3 Power Loss 2 DC bus voltage remained below 1 Monitor the incoming AC line for low voltage or line power interruption 85 of nominal 2 Check input fuses F4 UnderVoltage 1 DC bus voltage fell below the Monitor the incoming AC line for low voltage or line power interruption minimum value F5 OverVoltage 1 DC bus voltage exceeded Monitor the AC line for high line voltage or transient conditions Bus maximum value overvoltage can also be caused by motor regeneration Extend the decel time or install dynamic brake option F6 Motor Stalled 1 Drive is unable to accelerate motor Increase Parameter 139 167 Accel Time x or reduce load so drive output current does not exceed the current set by Parameter 189 Current Limit 1 F7 Motor Overload 1 Internal electronic overload trip 1 An excessive motor load exists Reduce load so drive output current does not exceed the current set by Parameter 133 Motor OL Current 2 Verify Parameter 184 Boost Select setting F8 Heatsink 1 Heatsink temperature exceeds a 1 Check for blocked or dirty heat sink fins Verify that ambient OvrTmp predefined value temperature has not exceeded 40 C 2 Replace internal fan F12 HW OverCurrent 2 The drive output current has Check programming Check for excess load improper programming of exceeded the hardware current Parameter 184 Boost Select DC brake volts set too high or other causes of limit excess current F13 Ground Fault 2 A c
19. ching is done by the internal hardware of the ArmorStart for these faults The Pr FltReset Mode parameter Parameter 23 determines the Auto Resettability of only the faults that are detected on the main control board These faults are listed as param 23 autoresettable in Table 10 The Auto Resettability of the faults that are detected in the internal drive is controlled by internal drive parameters These faults are listed as drive controlled in Table 10 Publication 284D 0S001D EN P July 2006 28 Fault LED Indications for Bulletin 284D ArmorStart Distributed Motor Controllers Table 10 Controller Fault LED Definitions Blink Fault Definitions Possible Causes or Remedies Pattern armorStart Drive Controlled 1 Short 140M The circuit breaker has tripped Try to reset the breaker If the condition continues check the power wiring This fault cannot be disabled 2 Overload Fault An excessive motor load exists Reduce load so drive output current does not exceed the current Drive Error Codes 7 and 64 set by Parameter 133 Motor OL Current and verify Parameter 184 Boost Select setting Reduce load or extend Accel Time This fault cannot be disabled 3 Phase Short Drive Error Codes The ArmorStart has detected a phase short Excessive current has been detected between two 41 43 of the output terminals Check the motor for a shorted condition Replace starter modul
20. e Brake Connector Motor DeviceNet Connector Connection 5 0 10V ini ynamic Ground MINU MB Brake Connector Analog Input Terminal Available only with the Bulletin 284 with sensorless vector control Figure 18 Bulletin 284 ArmorStart with ArmorConnect Al ME la APAR AAT LO H ORE l S 5 U Ground Ground Terminal Terminal Control Three Phase Power Control Power Three Phase Power Power Publication 284D QS001D EN P July 2006 Accessories Table 13 DeviceNet Media Description Length m ft Cat No Sealed 33 KwikLink pigtail drops are Insulation 1485P P1E4 B1 N5 Displacement Connector IDC with integral Class 1 round cables for interfacing devices or power 1485P P1E4 B2 N5 supplies to flat cable 1485P P1E4 B3 N5 Right Keyway DeviceNet Mini T Port Tap Left Keyway Connector 1485P P1E4 B6 N5 1485P P1N5 MNSNF 1485P P1N5 MNSKM Cat No Mini Straight Female Mini Straight Male 1485G P N5 M5 Mini Straight Female Gray PVC Thin Cable Mini Right Angle Male 1485G P W5 N5 Mini Right Angle Female Mini Straight Male 1485G P M5 Z5 Mini Right Angle Female Mini Straight Male 1485G P
21. e if fault cannot be cleared This fault cannot be disabled 4 Ground Fault Drive Error Codes A current path to earth has been detected at or more of the drive output terminals or a phase to 13 38 40 ground fault has been detected between the drive and motor in this phase Check the motor for a grounded condition Replace starter module if fault cannot be cleared This fault cannot be disabled 5 Motor Stalled Drive is unable to accelerate motor Increase Parameter 139 and or 167 Accel Time x or reduce Drive Error Code 6 load so drive output current does not exceed the current by Parameter 189 This fault cannot be disabled 6 Control The ArmorStart has detected a loss of the control power voltage Check control voltage wiring Power and proper polarity Also check and replace control voltage fuse if necessary This fault can be disabled and js disabled by default 7 1 0 Fault Depending on the types of modules in the configuration this error could be generated by a shorted sensor shorted input device wiring mistakes or a blown output fuse If this fault occurs the offending problem should be isolated or removed prior to restarting the system This fault can be disabled and s disabled by default 8 Heatsink Overtemperature Heatsink temperature exceeds a predefined value Verify that ambient temperature has not Drive Error Code 8 exceeded This fault cannot be disabled Replace internal fan 9 Over Current T
22. edia offers both three phase and control power cable system of cordsets patchcords receptacles tees reducers and accessories to be utilized with the ArmorStart Distributed Motor Controller These cable system components allow quick connection of ArmorStart Distributed Motor Controllers and reduce installation time They provide for repeatable reliable connection of the three phase and control power to the ArmorStart Distributed Motor Controller and motor by providing a plug and play environment that also avoids system mis wiring When specifying power media for use with the ArmorStart Distributed Motor Controllers Bulletins 280 281 283 and 284 use only Bulletin 280 ArmorConnect power media Figure 10 Three Phase Power System Overview Enclosure PLC i f 7 7 0 Bulletin 1492FB 1606 XLSDNET4 I Branch Circuit peun 1606 DeviceNet 9 Protective Device PPly Power Supply I l I I I I I I I E AEE igre a ee EAEE SE EENE REE EEEE ATE Bulletin 280 281 Bulletin 283 Bulletin 284 ArmorStart ArmorStart ArmorStart Bulletin 800F h Emergency Stop Pushbutton e HEE 2 Three Phase Power Trunk PatchCord cable with integral female or male connector on each end Examp
23. he ArmorStart has detected a voltage imbalance Check the power system and correct if Drive Error Codes 12 and 63 necessary This fault cannot be disabled 10 DNet Power DeviceNet power has been lost or has dropped below the 12V threshold Check the state of the Loss network power supply and look for DeviceNet media problems This fault can be disabled and is disabled by default 11 Internal This fault occurs when communications between the main board the drive is lost This fault Comm cannot be disabled 12 DC Bus Fault DC bus voltage remained below 85 of nominal DC bus voltage fell below the minimum value Drive Error Codes 3 4 and 5 DC bus voltage exceeded maximum value Monitor the incoming AC line for low voltage or line power interruption Check input fuses Monitor the AC line for high line voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the decel time or install a starter module with the dynamic brake option This fault cannot be disabled 13 EEPROM Fault Internal Comm This is a major fault which renders the ArmorStart inoperable Possible causes of this fault are Fit transients induced during EEprom storage routines If the fault was initiated by a transient Drive Error Codes 81 and 100 power cycling should clear the problem Otherwise replacement of the starter module may be required This fault cannot be disabled 14 Hardware Fault This fault indicates that a ser
24. ion as to the health of the device The following is a brief explanation of the operation of each LED Table 8 LED Status Indication LED Definition This LED will be illuminated solid green when control power is present and with Power the proper polarity Run This LED will be illuminated solid green when a start command and control power are present Network This bi color LED is used to indicate the status of the DeviceNet network See the Network Status LED table below for additional information This LED is used to indicate the fault status of the ArmorStart When the unit is Fault faulted the unit will respond with a specific blink pattern to identify the fault See the Fault LED table below for additional information Table 9 Network LED Status Indication Definition The device has not completed the initialization is Possible Causes Check to make sure the product is properly wired and configured on not on an active network or may not be powered up the network Flashes green red off While waiting to detect the network baud rate the LED will flash this pattern about every 3 seconds If the product stays in this state it means that there is no set baud rate Insure that at least one device on the network has a set baud rate Solid Green The device is operating in a normal condition and is communicating to another device on the network No action required Flashing Green The device is
25. ious hardware problem exists Check for a base starter module Drive Error Codes 2 70 and mismatch Auxiliary input interlock is open Failure has been detected in the drive power 122 section Failure has been detected in the Drive control and 1 0 section Cycle power and replace drive if fault cannot be cleared This fault cannot be disabled 15 Auto Restart Tries Drive unsuccessfully attempted to reset a fault and resume running for the programmed number Drive Error Code 33 of Parameter 192 Auto RstrtTries Correct the cause of the fault This fault cannot be disabled 16 Miscellaneous Fault This fault is actually the logical OR of the drive s Auxiliary Input fault Fault Code 2 Heatsink Publication 284D 0S001D EN P July 2006 Overtemperature fault Fault Code 8 Parameter Defaulted fault Fault Code 48 and SVC Autotune fault Fault Code 80 This fault cannot be disabled 29 Internal Drive Faults A fault is a condition that stops the drive There are two fault types Table 11 Internal Drive Fault Types Type Description Auto Reset Run When this type of fault occurs and Parameter 192 Auto Rstrt Tries Related Parameter s 155 158 161 193 is set to a value greater than 0 a user configurable timer Parameter 193 AutoRstrt Delay Related Parameter s 192 begins When the timer reaches zero the drive attempts to automatically reset the fault If the condition that caused the fault is no longer p
26. le Part Number 280 PWR35A M Three Phase Drop Cable PatchCord cable with integral female or male connector on each end Example Part Number 280 PWR22A M Three Phase Power Tees and Reducer Tee connects to a single drop line to trunk with quick change connectors Part Number 280 135 Reducing Tee connects to a single drop line Mini to trunk Quick change connector Part Number 280 RT35 Reducer connects from quick change male connector to mini female connector Part Number 280 RA35 Three Phase Power Receptacles Female receptacles are a panel mount connector with flying leads Part Number 280 M35F M1 Publication 284D 0S001D EN P July 2006 14 Figure 11 Control Power Media System Overview Enclosure id 1606 XLSDNET4 Bulletin 1492FB Bulletin 1606 l l nl I I I I I Branch Circuit DeviceNet I I Protective Device Power Supply Power Supply l I I I I I l l l l l l I I eh f eee eee Bulletin 280 281 Bulletin 283 Bulletin 284 ArmorStart ArmorStart ArmorStart Bulletin 800F Emergency Stop Pushbutton Control Power Media Patchcords PatchCord cable with integral female or male co
27. mensions are subject to change Figure 7 Dimensions for 2 Hp 230V AC 3 Hp and above 460V AC and 3 Hp and above 575V AC NEMA Type 4X with Conduit Entrance 444 38 17501 290 11 42 P A g of 268 10 55 287 5 11 321 min Hill il il j 67 9 31 1 CONDUIT OPENING 38 972 1 531 0 75 CONDUIT OPENING of 236 9 e eH al e HILO 3 02 C121 le NOTOR CONNECTION 266 9 10 51 s 313 14 69 LASI H S s Or H e o0 Q j o f s L o o at 0 o AL HO 2 SS SSS SS Tr Publication 284D 0S001D EN P July 2006 Dimensions are shown in millimeters inches Dimensions are not intended to be used for manufacturing purposes All dimensions are subject to change Figure 8
28. n millimeters inches Dimensions are not intended to be used for manufacturing purposes All dimensions are subject to change Figure 1 Dimensions for 1 Hp and below 230V AC 2 Hp and below 460V AC and 2 Hp and below 575V AC IP67 NEMA Type 4 with Conduit al Entrance 236 191 o qT qT q i D 287 5 im 1 32 F eL UU le H f j 3 02 12 He MOTOR CONNECTION 266 9 10 51 Qe Tia e RA A i 17 68 47 1 851 er 2 P ETIT e e
29. nnector on each end Example Part Number 889N F65GFNM Control Power Tees The E stop In Tee Part Number 898N 653ES NKF is used to connect to the Bulletin 800F On Machine E Stop station using a control power media patchcord The E stop Out tee Part Number 898N 653ST NKF is used with cordset or patchcord to connect to the ArmorStart Distributed Motor Controller Control Power Receptacles Female receptacles are a panel mount connector with flying leads Part Number 888N D65AF1 Publication 284D 0S001D EN P July 2006 15 ArmorStart with ArmorConnect Connectivity ArmorStart devices with 10 A short ArmorStart devices with 25 A short circuit protection rating circuit protection rating Control Power Receptacle Control Power Receptacle Three Phase Power Receptacle Three Phase Power Receptacle Installing ArmorConnect Power Media using Cord Grids Cord Grips for ArmorStart Devices with 10 A short circuit protection rating 3 4 in Lock Nut gt if lt q 44 1in Lock Nut A Thomas amp Betts Cord Grip Pr aaber JAIN Thomas amp Betts Cord Grip art Number 29 Part Number 2940NM 3 4 in Stain Relief Cord Connector 1 in Stain Relief Cord Connector Cable Range 0 31 0 56 in _ Cable Range 0 31 0 56 in Used with Control Power Media Used with Three Phase Power Cordset Example Part Number Media Cordset Example Part 889N M65GF M2 Number 280 PWR22G M1 Cord Gri
30. on for the following POWER LED The LED is illuminated solid green when control power is present and with the proper polarity RUN LED This LED is illuminated solid green when a start command and control power are present NETWORK LED This bi color red green LED indicates the status of the communication link FAULT LED Indicates Controller Fault trip condition The Reset Button as a local trip reset DeviceNet Node Commissioning 21 Figure 14 LED Status Indication and Reset POWER RUN mm RESET a NETWORK FAULT ATTENTION Three phase power must be applied to the Bulletin 284 Distributed Motor Controller to gain access to drive parameters Establishing a DeviceNet Node Address The ArmorStart is shipped with a default node address of 63 and Autobaud enabled Each device on a DeviceNet network must have a unique node address or MAC ID which can be set to a value from 0 63 Keep in mind that most DeviceNet systems use address 0 for the master device Scanner and node address 63 should be left vacant for introduction of new slave devices The ArmorStart offers two methods for node commissioning as shown in the following pages Node Commissioning using Software To set the node address of the ArmorStart using software or other handheld tools leave the hardware rotary switches in their default position 99 or insure that they are set to something greater then 63 With the hardware switches set u
31. or power control safety monitor inputs and ground wiring Access can be gained by removing the terminal access cover plate Figure 9 ArmorStart Power Control and Safety Monitor Terminals Secondaries Primaries AA 2 6 NE BR O Da DETAIL B Q b SCALE 2 000 oe u Publication 284D QS001D EN P July 2006 Table 2 Power Control Safety Monitor and Ground Terminal Designations Terminal Designations No of Poles Description SM1 2 Safety Monitor Input SM2 0 2 Safety Monitor Input A1 2 Control Power Input A2 2 Control Power Common PE 2 Ground 1 L1 2 Line Power Phase A 3 L3 2 Line Power Phase B 5 L5 2 Line Power Phase C Only available with the Safety Monitor option Operation of NEMA Type 4X To Open Disconnect Handle Disconnect Handle 1 Rotate locking ring 45 until it stops 2 To open push the tab on the left hand side and lift the access cover Note The access door can not be closed when 140 black handle is in the OFF position To Close Disconnect Handle for Lockout Tag out With disconnect handle in the ON position rotate lockout tag out ring counterclockwise until the disconnect handle is in the OFF position 7 wt oa z Note The disconnect hanlde is designed to be used with a 1 4 in lockout tag out padlock Publication 284D 0S001D EN P July 2006 13 ArmorConnect Power Media Description The ArmorStart Power M
32. ps for ArmorStart Devices with 25 A short circuit protection rating 3 4 in Lock Nut gt q d lt q 1in Lock Nut v Th Betts Cord Gri ie oa an i Thomas amp Betts Cord Grip 3 4 in Stain Relief Cord Connector Part Number 2942NM Cable Range 0 31 0 56 in _ 4 1 in Stain Relief Cord Connector Used with Control Power Media Cable Range 0 70 0 95 in Cordset Example Part Number Used with Three Phase Power 889N M65GF M2 Media Cordset Example Part Number 280 PWR35G M1 Publication 284D QS001D EN P July 2006 Publication 284D 0S001D EN P July 2006 Terminal Designations Description J ColorCode A1 Control Power Input Blue A2 Control Power Common Black PE Ground Green Yellow 1 L1 Line Power Phase A Black 2 L2 Line Power Phase B White 3 L3 Line Power Phase C Red ArmorConnect Cable Ratings The ArmorConnect Power Media cables are rated per UL Type TC 600V 90 C Dry 75 C Wet Exposed Run ER or MTW 600V 90 C or STOOW 105 C 600V CSA STOOW 600V FT2 For additional information regarding ArmorConnect Power Media see the ArmorStart User Manual Branch Circuit Protection Requirements for ArmorConnect Three Phase Power Media When using ArmorConnect Three Phase Power Media only fuses can be used for the motor branch circuit protective device for the group motor installations The recommended fuse types are the following Class CC T or J type
33. red at intervals not exceeding 1 8 m 6 ft and installed in a good workman like manner Equipment grounding for the utilization equipment shall be provided by an equipment grounding conductor within the cable Historically cable meeting these crush and impact requirements were designated and marked Open Wiring Cable so marked is equivalent to the present Type TC ER and can be used While the ArmorStart is intended for installation in factory floor environments of industrial establishments the following must be taken into consideration when locating the ArmorStart in the application Cables including those for control voltage including 24V DC and communications are not to be exposed to an operator or building traffic on a continuous basis Location of the ArmorStart to minimize exposure to continual traffic is recommended If location to minimize traffic flow is unavoidable other barriers to minimize inadvertent exposure to the cabling should be considered Routing cables should be done in such a manner to minimize inadvertent exposure and or damage Additionally if conduit or other raceways are not used it is recommended that strain relief fittings be utilized when installing the cables for the control and power wiring through the conduit openings Publication 284D 0S001D EN P July 2006 Publication 284D 0S001D EN P July 2006 The working space around the ArmorStart may be minimized as the ArmorStart does not require
34. resent the fault will be reset and the drive will be restarted Non Resettable This type of fault may require drive or motor repair or is caused by wiring or programming errors The cause of the fault must be corrected before the fault can be Cleared Automatically Clearing Faults Option Step Clear a Type 1 fault and restart the drive 1 Set Parameter 192 Auto Rstrt Tries to a value other than 0 2 Set Parameter 193 Auto Rstrt Delay to a value other than 0 Clear an OverVoltage UnderVoltage or Heatsink OvrTmp fault without restarting the drive 1 Set 192 Auto Rstrt Tries to a value other than 0 2 Set 193 Auto Rstrt Delay to 0 Auto Restart Reset Run The Auto Restart feature provides the ability of the drive to automatically perform a fault reset followed by a start attempt without user or application intervention This allows remote or unattended operation Only certain faults are allowed to be reset Certain faults Type 2 that indicate possible drive component malfunction are not resettable Caution should be used when enabling this feature since the drive will attempt to issue its own start command based on user selected programming Publication 284D 0S001D EN P July 2006 30 Table 12 Fault Types Descriptions and Actions No Fault pig Description Action F2 Auxiliary Input 1 Auxiliary input interlock is open 1 Check remote wiring 2 Verify communi
35. se the software or handheld tool to change the address When using software to node commission a device it may be necessary to have the EDS file stored on the computer The EDS file defines how the software such as RSNetWorx for DeviceNet will communicate to the ArmorStart Rockwell Automation product EDS files are available on the internet at http www ab com networks eds You must use RSNetWorx for DeviceNet Revision 3 21 Service Pack 2 or later Node Commissioning using Hardware The ArmorStart is shipped with the hardware rotary switches set to a value of 99 If the switches are set to a value of 64 or above the device will automatically configure itself to the software node address If the switches are set to a value of 63 or less the device will be at the node address designated by the switch configuration Publication 284D 0S001D EN P July 2006 22 To set an address using the hardware rotary switches simply set the switches to the desired node address To access the node address rotary switches three phase and control power should be turned off Then remove the starter module from the base unit The rotary node address switches are located on the back side of the starter module Change the switches to the desired node address Re install the starter module to the base unit Reapply power and the device will re start at the new address Figure 15 Rotary Node Address Configuration
36. siderations The separation of the control power and DeviceNet power is recommended as a good design practice This minimizes the load on the DeviceNet supply and prevents transients which may be present on the control power system from influencing the communication controls 19 AC Supply Considerations Ungrounded Distribution Systems ATTENTION The Bulletin 284 contains protective MOVs that are referenced to ground These devices should be disconnected if the Bulletin 284 is installed on an ungrounded distribution system Disconnecting MOVS To prevent drive damage the MOVs connected to ground shall be disconnected if the drive is installed on an ungrounded distribution system where the line to ground voltages on any phase could exceed 125 of the nominal line to line voltage To disconnect these devices remove the jumper shown in Figure 13 Jumper Removal 1 Before installing the Bulletin 284 loosen four mounting screws 2 Unplug control module from the base unit by pulling forward Figure 12 Removal of Control Module as s gt e ilis Publication 284D 0S001D EN P July 2006 20 LED Status Indication Publication 284D 0S001D EN P July 2006 Figure 13 Jumper Removal Remove Jumper ATTENTION Do not remove this jumper if the unit is equipped with an EMI filter installed The LED Status Indication provides 4 status LEDs and a Reset button The LEDs provide status indicati
37. urrent path to earth ground has Check the motor and external wiring to the drive output terminals for a been detected at one or more of the grounded condition drive output terminals F33 Auto Rstrt Tries Drive unsuccessfully attempted to Correct the cause of the fault and manually clear reset a fault and resume running for the programmed number of Parameter 192 Auto Rstrt Tries F38 Phase U to Gnd 2 A phase to ground fault has been 1 Check the wiring between the drive and motor F39 Phase V to Gnd detected between the drive and 2 Check motor for grounded phase F40 Phase W to Gnd motor in this phase 3 Replace starter module if fault cannot be cleared F41 Phase UV Short 2 Excessive current has been 1 Check the motor and drive output terminal wiring for a shorted F42 Phase UW Short detected between these two output condition F43 Phase VW Short terminals 2 Replace starter module if fault cannot be cleared See Table 11 for in Publication 284D 0S001D EN P July 2006 ernal drive fault types 31 Table 12 Fault Types Descriptions and Actions Continued No Fault bs Description Action F48 Params 2 The drive was commanded to write 1 Clear the fault or cycle power to the drive Defaulted default values to EEPROM 2 Program the drive parameters as needed F63 SW 2 Programmed Parameter 198 SW Check load requirements and Parameter 198 SW Current Trip setting OverCurrent
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