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VersaPoint I/O System Motor Starter Modules Manual

1. Enable Manual mode 1 Module IC220STR002 Disabling Minimum Current Checking output bit 4 For Motor Starter Module IC220STRO002 3 7KW ONLY bit 4 of the output byte can be used to control whether or not the module will monitor the current level to make sure it is above 160mA Bits 7 6 5 4 3 2 1 0 a Module IC220SRT002 only Check for minimum current level 0 check current 1 do not check current no minimum level If the Current Check bit 4 is 0 the module monitors the current level If it is below 160mA the module switches off the motor The module notifies the system host by returning the message Power level cannot be controlled in its input data byte Use of the input data byte is described later in this section If the Current Check bit 4 is 1 the module does not monitor for minimum current CAUTION If this bit is set to 0 the module cannot detect two phase operation so complete motor protection is not possible GFK 2134 Chapter 3 Data Exchanged by the Motor Starter Module and the System Host 3 9 Acknowledging a Reset After an Error output bit 5 The host should use the Reset output bit to acknowledge an error after the cause of the error has been corrected sfr e s 4 feje Reset Acknowledge error 1 reset If the error condition has shut down the motor the cause of the error must be removed to restart the motor After co
2. Therefore the actual motor current is 0 93 Amp in this example VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Checking for Manual Mode Active input bit 4 Bit 4 of the input data shows whether Manual Mode is active 1 or not active 0 Bits 7 6 5 4 3 2 1 0 Manual Mode active not active When Manual Mode is activated bit 4 is set immediately When switching from Manual Mode back to system control the module maintains a 1 second delay time If bit 4 is NOT set and there are no pre existing error conditions the motor can be started by the host immediately If bit 4 is set the module ignores all commands from the system host When Manual Mode is active the motor MUST be controlled locally If bit 4 is set AND a Motor Starter Pendent or similar switching device is connected to the Enable input on the Motor Starter Module the motor protection functions normally provided by the Motor Starter module are NOT present errors that occur are NOT reported in the input data byte If Manual Mode is set while an error is present that error no longer appears in the input byte Switching to Manual Mode serves as an error acknowledgement that is equivalent to a Reset command However any error conditions that still exist upon exiting Manual Mode are again reported in the input data If bit 4 is set but the Enable input is controlled by the system host the motor pr
3. 75 on average 85 occasionally no condensation Degree of protection IP 20 according to IEC 60529 Class of protection Class 1 according to EN 51078 Control voltage Motor Starter Brake Module 24VDC from the Motor Starter Module Control current 17mA Current limit Using dropping resistor Contact spacing Brake to be Connected 7 62mm 0 30 in Cable diameter Up to 2 5mm 14 AWG Maximum continuous current 300mA Protective current IC220ACC100 Diode against polarity protection and TAZ diode 1C220ACC101 Diode against polarity protection and 460V _varistor Degree or protection Protection against direct touch Contact type Polarized solid state contact Connection voltage no tolerances permitted IC220ACC100 5VDC minimum to 31VDC maximum IC220ACC101 12VDC minimum to 440VDC maximum 20VAC minimum to 400VAC maximum Residual voltage IC220ACC100 0 4VDC maximum IC220ACC101 3 4VDC maximum Chapter 5 Motor Starter Brake Modules 5 5 5 6 Power Dissipation Power dissipation of the electronics can be calculated using the following formulas For IC220ACC100 Prot 0 1 W 0 4 V x IL For IC220ACC101 Prot 0 1 W 3 4 V x IL Prot is the total power dissipation of the brake module IL is the load current Safety Devices Overvoltage IC220ACC100 TAZ diode IC220ACC101 460
4. None Control voltage for the Motor Starter Module 24V segment voltage when the segment voltage is switched off the Motor Starter Module cannot be switched on and the motor is off External short circuit fuse Type 2 contactor still functions after a short circuit 20A gG Contact wiring None Power Consumption for Module IC220STR002 Communications power UL 7 5V Current consumption at UL 50mA maximum Power consumption at UL 0 375W maximum Segment supply voltage Us 24VDC nominal Nominal current consumption at Us 160mA Total internal power consumption 4 2W maximum Permissible voltage range for segment voltage Us 19 2VDC to 28 8VDC including ripple Chapter 1 VersaPoint Motor Starter Modules Line Connection for Module IC220STR002 Connection method Power connector or power bridge Terminal strip X11 and X12 Number of pins on 5 L1 L2 L3 N PE not leading Permissible cable cross section Up to 2 5mm 14 AWG Nominal operating voltage 400VAC Voltage range 187VAC minimum up to 519VAC with safe isolation between line and SELV up to BOOVAC with basic insulation between line and SELV Frequency 50Hz 60Hz Current load incoming line 20A maximum Supplying the line voltage through a frequency inverter is NOT permitted Current load incoming line 20A ma
5. Controls motors with two directions of rotation 1 2 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Additional Equipment for Motor Starter Applications The additional equipment described below can be used in a Motor Starter Module installation Motor Starter Power Connector A Motor Starter Power Connector IC220ACC103 can be used to connect the power source for the motor to the Motor Starter module Motor Starter Power Bridge A Motor Starter Power Bridge IC220ACC104 can be used to connect a second Motor Starter module to the first The Motor Starter Bridge passes power from the first Motor Starter module to the second GFK 2134 Chapter 1 VersaPoint Motor Starter Modules 1 3 1 4 Motor Starter Pendent An optional Motor Starter Pendent IC220ACC102 can be connected to a Motor Starter Module and used to turn the motor on or off locally When use of a Motor Starter Pendent is enabled inputs from the Pendent override control commands from the system host See chapter 4 for information about using a Motor Starter Pendent Motor Starter Brake Module The optional Motor Starter Brake module is a passive electronic brake switch that can interface a brake to a Motor Starter module Two VersaPoint Motor Starter Brake modules are available C220ACC100 and IC220ACC101 See chapter 5 for more information about using Motor Starter Brake modules Motor Starter Brake Module Feat
6. voltage Alternatively an external switch can be wired to the module via these terminals and used to control the 24V segment voltage If an external switch is installed the power level of the module is enabled only when the switch is closed WARNING Be sure the motor is switched off before supplying control power to the module 2 6 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Connection for a Thermistor Module Switching Output If the switching output of a VersaPoint Thermistor Module will directly control 24V power to the Motor Starter Module the switching output can be connected to the Motor Starter Module as shown below right side of the diagram See chapter 6 for more information about using a Thermistor Module CAUTION Only connect pin 1 1 on the Thermistor Module to the Motor Starter Module DO NOT connect the ground terminal of the switching output pin 2 1 on the Thermistor Module The ground of the switching output is internally connected via the voltage jumper In some applications the system host will shut down the motor if it receives an error message from the Thermistor Module In that type of system the Motor Starter Module should not be connected to the switching output of the Thermistor Module See chapter 6 for details GFK 2134 Chapter 2 Installing VersaPoint Motor Starter Modules 2
7. 1 5kW fpr AC 3 operation 4 position synchronous motor Usage category According to AC 3 Switch on time 1 second minimum Switch off time 1 second minimum Phase angle cos gt 0 3 Motor starting time 0 5 second maximum The minimum permissible motor current of 0 1A per phase must be maintained during operation or the error message Power level cannot be controlled will be generated Internal Protection Fuse 6 3 x 32 10 AT in the switched phases Control voltage for the Motor Starter 24V segment voltage when the Module segment voltage is switched off the Motor Starter Module cannot be switched on and the motor is off WARNING When the segment voltage is switched off the motor is not disconnected WARNING If thermal damage occurs to the module it is not able to switch off the motor This error state is indicated by the error code 10 in the module input data It is important to provide an alternative means of switching off the motor with a mechanical switch WARNING Do not attempt to repair or perform other work on the Motor Starter Module The fuses inside the module protect both personnel and system equipment If these fuses blow for example in the event of a short circuit at the motor output the module must be replaced Chapter 1 VersaPoint Motor Starter Modules Power Consumption for Module IC220STR003 Communications power 7 5V Current consumption from the local bus 45mA max
8. 5 x In 7 2 X In Release Tp lt 120s 2s lt Tp lt 10s Time If the current is disconnected due to an overcurrent wait at least 60 seconds to ensure successful acknowledgement of the error Chapter 1 VersaPoint Motor Starter Modules Current Monitoring Monitored phase T1 Measuring range 0 to 25 Amps Resolution 14mA Supply of the current detection from the 7 5V communications power Number 1 Terminal Strip X32 Number of pins on X32 4 Conductor cross section 1 5mm 16AWG maximum Input current Approximately 5mA at Us 24V Filter time 0 2ms typical Potential Potential of the supply voltage Us Module error after error in self test Message to the controller Overcurrent Error message in diagnostic code and Power level cannot be controlled displeyadion ERR LED ommodule VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Specifications for Motor Starter Module IC220STRO03 GFK 2134 Motor Starter Module IC220STR003 Switches Electronic hybrid switches two phase switching Connection disconnection and reversing is carried out using thyristors that are jumpered by relays in the conductive state Operating voltage conductor voltage 187VAC to 440VAC 0 minimum Power frequency 50Hz or 60Hz Nominal current range 0 2A to 3 6A Minimum current 100mA Power
9. Button 1C220STRO02 For Module IC220STR003 Motor on off F1 Motor on off direction of rotation 1 Motor on off p2 Not used direction of rotation 2 Motor Starter Pendent Specifications Motor Starter Pendent Voltage 24VDC nominal 32VDC maximum Operating temperature 40 deg C 40 deg F to 60 deg C 140 deg F Storage temperature 20 deg C 4 deg F to 60 deg C 140 deg F LEDs Local F1 F2 GFK 2134 Chapter 4 Local Motor Control 4 7 Controlling Manual Mode from the System Host The Motor Starter Module s Motor Control input s are not used unless Manual Mode is also enabled A Motor Starter Pendent or similar switching device controls Manual Mode by connecting to both the Enable input and the Motor Control input s It is also possible to control Manual Mode by connecting only the Motor Control input s as shown below A shielded cable must be used for the Motor Control inputs to minimize potential effects from interference CPina pias oe Motor Control shielded cable Ci 3 IC220STR002 CPin 1 Pin 4 Crins For Module Wie Motor Control in Direction of Rotation 1 Ces IC220STRO03 as Motor Control in Direction of Rotation 2 rin i Pi 4 Because the Enable input is not controlled by the switching device Manual Mode must be enabled or disabled from the system host by setting bit 3 of the module s out
10. Starter Brake Module and Brake The optional Motor Starter Brake module IC220ACC100 or ACC101 and brake cable should be connected as shown below Be sure the brake is connected with the correct polarity otherwise it may not operate correctly GFK 2134 Chapter 2 Installing VersaPoint Motor Starter Modules 2 11 Wiring Two Motor Starter Modules IC220STRO02 for Reversing Reversing applications can only be set up using Motor Starter Module IC220STR103 Reversing 1 5KW 400W or two Motor Starter Modules IC220SRT002 Direct 3 7KW 400W CAUTION DO NOT ATTEMPT to implement a reversing application using Motor Starter Modules IC220STRO01 Connecting Two Modules IC220STR002 To set up a reversing application using two Motor Starter Modules IC220STRO02 connect the motor as shown below A Motor Starter Power Bridge IC220ACC104 can be used to transfer motor power from the first module to the second Module 1 Module 2 IC220STRO02 1C220STRO02 T1 T273 T1 T2736 OOG Seog 2 12 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Application Software Required for a Reversing Application In this application it is not possible to interlock the IC220STR002 modules using the hardware they must be interlocked using the application software in the system host Because interlocking is controlled by the system host it is not possible in Manual Mode WARN
11. below 0 1A for module IC220STRO01 or 0 16A for module IC220STRO002 the module shuts down the motor The module s ERR LED lights and it sends a diagnostic message to the system host The module also generates an error message if The control signal for the module is NOT present but the measured motor current is greater than the minimum current The control signal for the module is present but the motor current is below the permissible minimum current for that module type For module IC220STRO02 minimum current monitoring can be disabled as described in chapter 3 1 6 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 General Specifications for Motor Starter Modules Specifications for all three Motor Starter Modules are given below Additional specifications for each module type are listed on the following pages Specifications for the VersaPoint Motor Starter Pendent Motor Starter Brake Module and Thermistor Module are listed in their individual chapters Programming Data for All Motor Starter Modules ID code BF hex 191 decimal Length code 81 hex 129 decimal Process data length 8 bits Input data length 1 byte Output data length 1 byte Parameter channel PCP 0 bytes Register length 1 byte General Data for All Motor Starter Modules Housing dimensions width x height x depth 63mm x 224mm x 109mm 2 48in x 8 82in x 4 29in Amb
12. consumption from the local bus 0 45W Segment supply voltage Us 24VDC nominal Nominal current consumption of Us 0 5A maximum Total power consumption 0 15W maximum Number Thermistor Input 1 Connection type 2 wire Thermistor current 1 2A maximum No load voltage Under 8VDC Filter time 10ms typical Cable length to thermistor 30 meters 95 ft maximum Operating range total resistance Switching Thresholds 50 Ohms to 2 25k Ohms Tripping range total resistance 4k Ohms or more Tripping value total resistance 2 7k Ohms to 3 5k Ohms Release value 1 4k Ohms to 1 5k Ohms Warning response temperature minus 5 K 1 6k Ohms to 1 8k Ohms Short circuit Under 50 Ohms Output signal high Switching Output Total resistance less than 2 7k Ohms Output signal low Total resistance more than 3 5k Ohms Output voltage Segment voltage 1V Output current 50mA short circuit proof Chapter 6 Motor Protection with a Thermistor Module 6 7 s 6 8 Power Dissipation Power dissipation of the electronics can be calculated using the following formula Pe 0 45 W 3 V x IL Prot is the total power dissipation of the module IL is the load current Power dissipation of the housing is 0 6W Safety Devices Overvoltage Protective circuits of the power terminal Polarity reversal
13. for Manual Mode are made to the upper left corner of the Motor Starter Module Typically this connector is used to attach a Motor Starter Pendent IC220STRO02 GFK 2134 Chapter 4 Local Motor Control 4 3 Manual Mode Input Assignments The module s connector pins for Manual Mode have the following assignments For Modules For Module Pin Function IC220STR001 and 1C220STRO02 IC220STROO3 Motor on off 1 Input E9 Not used direction of rotation 1 Motor on off 2 InBULES Motoronior direction of rotation 2 3 Input E10 Enable Manual Mode 4 Us 24V segment voltage The 24V segment voltage pin 4 is not protected against short circuit or overloads inside the module The installation should include short circuit protection for the segment voltage at the VersaPoint Power Terminal or Segment Terminal module that supplies the 24V segment voltage for the Motor Starter Module 4 4 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Manual Mode Input Diagrams GFK 2134 A Motor Starter Pendent or similar switching device connects to the module inputs as indicated below It is also possible to control the motor inputs by connecting a switching device to the motor control input s only and controlling the Enable signal from the system host Enable _ _ _ ioi Pirs For Modules 7 Motor Control f IC220STR001 and X r IC220STR002 C
14. host controls thermistor protection it monitors the input data sent by the Thermistor Module If an error occurs the application program can command the Motor Starter Module to shut down the motor Input Data Sent by the Thermistor Module The Thermistor Module sends 4 bits of input data to the system host It does not have any output data The group of 4 bits can be in any position within the byte Bits 3 2 E o Error Conditions 1 0 1 Overtemperature thermistor Thermistor response temperature reached 0 1 0 Short circuit of thermistor or connecting cable not used 1 0 0 Alarm Thermistor temperature approximately 5K below response temperature If an overtemperature error occurs the Thermistor Module sets bit 0 of its input data to 1 At the same time the Thermistor module turns OFF its switching output Note that the Thermistor Module sees motors with thermostatic switches as short circuits Thermistor Module Switching Output Shuts Down the Motor GFK 2134 The switching output of the Thermistor Module can be directly connected to the Motor Starter Module as shown on the next page If thermistor resistance is 4k Ohms or more the Thermistor Module turns off its switching output That in turn interrupts the 24V power to the Motor Starter Module The Motor Starter Module then turns off the motor Chapter 6 Motor Protection with a Thermistor Module 6 3 s Thermistor Module Connections Thermisto
15. the Motor Starter Module The fuses inside the module protect both personnel and system equipment If these fuses blow for example in the event of a short circuit at the motor output the module must be replaced GFK 2134 Chapter 2 Installing VersaPoint Motor Starter Modules 2 3 Module Installation A VersaPoint Motor Starter module must be panel mounted on a horizontal DIN rail as shown below As the illustration shows a Motor Starter Module is larger than other types of VersaPoint modules Its dimensions are 63mm x 224mm x 109mm 2 48in x 8 82in x 4 29in At least 50mm 2 inches of space is required above and below the Motor Starter module to assure adequate module ventilation 2 4 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Connectors and Connection Points The lefthand diagram below shows the connection points on a Motor Starter Module The righthand diagram shows the devices that may be connected to them Motor Starter Pendent 2 x0 Item Description Item Description 1 Data jumper for the I O Station Connects to previous module 2 Voltage jumper for the low level signals Um Us Uana UL GND FE Connects to previous module X8 Connection for optional Motor 4 Motor Starter Brake Module IC220ACC100 Starter Brake Module including 5 Connector to optional brake on X9 brake switch and connection for brake X9 X10 Connecti
16. 0 46 2E 238 EE 0 45 5 05 197 C5 1 90 27 1B 219 DB 4 80 47 2F 239 EF 0 50 6 06 198 C6 2 00 28 1C 220 DC 5 00 48 30 240 F0 0 55 7 07 199 C7 2 10 29 1D 221 DD 5 20 49 31 241 F1 0 60 8 08 200 C8 2 20 30 1E 222 DE 5 40 50 32 242 F2 0 65 9 09 201 C9 2 30 31 1F 223 DF 5 60 51 33 243 F3 0 70 10 0A 202 CA 2 40 32 20 224 E0 5 80 52 34 244 F4 0 75 11 0B 203 CB 2 50 33 21 225 E1 6 00 53 35 245 F5 0 80 12 OC 204 CC 2 60 34 22 226 E2 6 20 54 36 246 F6 0 85 13 OD 205 CD 2 70 35 23 227 E3 6 40 55 37 247 F7 0 90 14 0E 206 CE 2 80 36 24 228 E4 6 60 56 38 248 F8 0 95 15 OF 207 CF 2 90 37 25 229 E5 6 80 57 39 249 F9 1 00 16 10 208 D0 3 00 38 26 230 E6 7 00 58 3A 250 FA 1 05 17 11 209 D1 3 20 39 27 231 E7 7 20 59 3B 251 FB 1 10 18 12 210 D2 3 40 40 28 232 E8 7 40 60 3C 252 FC 1 15 19 13 211 D3 3 60 41 29 233 E9 7 60 61 3D 253 FD 1 20 20 14 212 D4 7 80 62 3E 254 FE 1 30 21 15 213 D5 8 00 63 3F 255 FF VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Calculating the Nominal Current It is also possible to calculate nominal current using one of the following equations Nominal Current from 0 2A to 1 2A N
17. 00 from 12VDC to 400VDC 20VAC to 400VAC IC220ACC101 from 5VDC to 31VDC Protection against polarity reversal 5 2 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Brake Module Connections Connector 1 above on the brake module connects to the Motor Starter Module Connector 2 is for the brake The brake must be connected with the correct polarity or it will not operate properly During operation the brake module switches a rectified voltage from the brake rectifier of the motor to the brake Internal Circuit Diagram of a Brake Module z E Pa Optocoupler Diode 2 pos connector i 3 pos connector S Isolated area Protective earth ground GFK 2134 Chapter 5 Motor Starter Brake Modules 5 3 5 4 Controlling the Operation of the Brake Ordinarily the Motor Starter Module controls the operation of the brake automatically based on the motor control commands it receives from the system host When the Motor Starter Module is being controlled by a Motor Starter Pendent or similar switching device or if the Reset Acknowledge bit 5 is set the module always controls the brake automatically When the host is controlling module operation the host can enable independent control of the brake as described below Enabling Brake Control Independent brake operation is enabled or disabled using the Enable Brake command o
18. 4 5 Manual Mode inputs 4 4 Minimum current checking for module IC220STRO02 output bit to enable or disable 3 9 Module dimensions 2 4 Module features 1 2 Module position 2 4 Module spacing 2 4 Motor control bits 3 11 Motor current calculating as a percent 3 14 calculating in Amps 3 14 monitoring 3 13 possible values returned 3 13 Motor power connections 2 8 Motor protection disabled with Motor Starter Pendent 4 5 Motor running monitoring from host 3 16 Motor Starter Brake Module connectors 5 2 features 5 2 Index 1 Index internal circuit diagram 5 2 specifications 5 4 Motor Starter Brake Modules overview 1 4 Motor Starter Brake Modules IC220ACC 100 101 1 4 Motor Starter Pendent 4 5 functions and LEDs 4 6 overview 1 4 Mounting distances 1 7 Mounting position 1 7 N Nominal Motor Current 1 6 configuring using output command 3 4 equations for calculating 3 5 possible values 3 4 O Operation overview 1 6 Ordering information 1 20 Output data control command output bits 3 7 format of output bits 3 4 how it is received from host 3 2 Output data length 1 7 P Part numbers 1 20 Power Bridge IC220ACC104 1 3 Power Connector IC220ACC103 1 3 R Repairing the module 2 3 Reset acknowledgement 3 10 Reversing 1 2 2 2 Reversing 2 12 S Safety requirements 2 2 Segment voltage 2 3 Segment voltage jumper 2 6 Specifications general 1 7 Motor Starter Brake Mod
19. 6 4 A a 081 15 2 3 4 6 8 10 Multiples of the nominal current Minutes Seconds Current Monitoring for Module IC220STRO001 Monitored phase T1 Measuring range 0 to 25A Resolution 14mA Supply of the current detection From the 7 5V communications power Diagnostic Messages for Module IC220STRO01 Module error after error in self test Message to the controller Overcurrent Error message in diagnostic code and displayed on ERR LED on module Power level cannot be controlled 1 12 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Specifications for Motor Starter Module IC220STRO02 Motor Starter Module IC220STR002 GFK 2134 Switch Mechanical contactor Operating voltage conductor 187VAC to 600VAC voltage Power frequency 50Hz or 60Hz Nominal current range 0 2A to 8 0A up to 40 degrees C 104F Derating on 6A at 55 degrees C 131F Minimum current gt 5mA switching element Power 3 7kW fpr AC 3 operation 4 position synchronous motor Usage category According to AC 3 Service life 1 5 million cycles nom current 8 0A to 10 million cycles nom current up to 3 0A Switching frequency 5 switching operations per minute maximum Phase angle cos gt 0 3 Motor starting time 1 second maximum Internal Protection
20. 7 Connecting the Power Source for the Motor Power for the motor can be connected to the Motor Starter Module using Power Connector IC220ACC103 When another Motor Starter module is connected to the first for example when two IC220STRO002 modules are used together to implement a reversing application power can be passed to the second module using a Motor Starter Power Bridge C220ACC104 Installing the Power Connector Inserting a Power Bridge The pins on the power terminals have the following assignments X11 Line In X12 Line Out L1 L1 L2 L2 L3 L3 N N PE D VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Connecting Power from the Module to the Motor Attach the cable for the motor to the connector on the lower left corner of the module Pin Assignment 1 Motor T1 2 Motor T2 3 Motor T3 a Motor GFK 2134 Chapter 2 Installing VersaPoint Motor Starter Modules Protecting the Motor The motor does not shut down automatically under every type of error condition CAUTION If an error occurs it is important to be able to switch off the 400V operating voltage of the Motor Starter Module as shown in the example below to prevent damage to the motor Line ee K1 2 10 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Connecting a Motor
21. ACC103 Motor Starter Power Bridge IC220ACC104 Motor Circuit Connector quantity 10 IC220ACC105 Thermistor Module 1 Point IC220MDD850 I O Terminal Strip quantity 10 for Thermistor Module IC220TBK081 1 20 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Chapter Installing VersaPoint Motor Starter Modules Z This chapter provides specific installation information for the VersaPoint Motor Starter Modules including Safety Requirements Module Installation Connectors and Connection Points Connecting 24V Module Power Connecting the Power Source for the Motor Connecting Power from the Module to the Motor Protecting the Motor Connecting a Motor Starter Brake Module and Brake Wiring Two Motor Starter Modules IC220STR002 for Reversing Module LEDs Internal Circuit Diagram To complete the installation you will also need to refer to the general system installation instructions in the Network Interface Unit User Manual for your system Configuring the Nominal Current During system operation the module monitors motor current by comparing it to a configured nominal motor current If the actual motor current is too high the module interprets it as an overcurrent error and shuts down the motor At startup and after a reset the nominal current defaults to 0 2 Amp If a higher nominal current is preferred for the application it can be changed by the system ho
22. Brake 3 8 Switch Brake 3 8 Brake connection 2 11 Brake control 5 3 Brake control overview 1 6 C Connectors and connection points 2 5 Current monitoring overview 1 6 D Diagnostics overview 1 6 Dimensions 1 7 E EMC Conformance 1 8 Error and status messages 3 16 Error messages 10 Power level cannot be controlled 3 17 11 overcurrent 3 17 F Features of Motor Starter Modules 1 2 G General specifications 1 7 IC220ACC100 101 Motor Starter Brake Modules 1 4 IC220ACC102 Motor Starter Pendent 1 4 IC220ACC 103 Power Connector 1 3 IC220ACC104 Power Bridge 1 3 IC220MDD850 Thermistor Module 1 5 IC220STRO01 Motor Starter Module features 1 2 specifications 1 9 IC220STRO02 Motor Starter Module features 1 2 specifications 1 13 IC220STROO3 Motor Starter Module Index features 1 2 specifications 1 17 ID code 1 7 Input data format of input byte 3 12 how it is received by host 3 3 Input data length 1 7 Interference 2 3 Internal module diagram 2 14 L LEDs Motor Starter Module 2 13 Motor Starter Pendent 4 6 Thermistor Module 6 6 Length code 1 7 Local control overview 1 6 Loss of communications 3 2 Manual mode brake control during 4 2 checking for status of 3 15 connector on module 4 3 enabling from host 4 7 errors during 4 5 Motor Starter Pendent 4 3 operation 4 2 output bit 3 9 reported in input data 4 2 shutdown delay 4 2 switching when errors are present
23. GE Intelligent Platforms Programmable Control Products VersaPoint I O System Motor Starter Modules User s Manual GFK 2134 March 2010 GFL 002 Warnings Cautions and Notes as Used in this Publication Warning notices are used in this publication to emphasize that hazardous voltages currents temperatures or other conditions that could cause personal injury exist in this equipment or may be associated with its use In situations where inattention could cause either personal injury or damage to equipment a Warning notice is used Caution notices are used where equipment might be damaged if care is not taken Note Notes merely call attention to information that is especially significant to understanding and operating the equipment This document is based on information available at the time of its publication While efforts have been made to be accurate the information contained herein does not purport to cover all details or variations in hardware or software nor to provide for every possible contingency in connection with installation operation or maintenance Features may be described herein which are not present in all hardware and software systems GE Intelligent Platforms assumes no obligation of notice to holders of this document with respect to changes subsequently made GE Intelligent Platforms makes no representation or warranty expressed implied or statutory with respect to and assumes no responsibility for t
24. ING A phase to phase short circuit can occur if this type of reversing application is switched too fast For example the arc of the contactor switching off has not extinguished yet and the contacts of the contactor switching on have already been closed To avoid this risk both Motor Starter Modules contactor coils must be switched off during reversing for at least 100ms GFK 2134 Chapter 2 Installing VersaPoint Motor Starter Modules 2 13 2 14 Module LEDs During operation the module LEDs provide local diagnostics showing the state of the module the motor and whether or not the module is currently being controlled locally for example by a Motor Starter Pendent The LEDs present depend on the module type IC220STRO01 IC220STRO02 IC220STRO03 ERR ERR Om Rt R2 Loc Loc For the two direct type Motor Starter Modules IC220STRO01 and STROO2 the M1 LED shows the status of the motor For reversing type module IC220STRO03 LEDs R1 and R2 show the status of the motor in each of its two directions LED 0707 0 g Meaning D Green LED Diagnostics ON 1 0 Station communications are active Flashing 0 5 Hz Communications power is present but I O Station communications slow not active 4Hz fast Communications power is present but local connection to the module has failed modules to the right of the module are also affected OFF Communica
25. Pin 1 Cin 4 or Enable Cri 3 in For Module Ka Motor Control in Direction of Rotation 1 pin 5 IC220STRO03 a Motor Control in Direction of Rotation 2 pint Oo Pin Cin 4 If a Motor Starter Pendent or other switching device that controls the Enable input is used the motor protection functions of the Motor Starter Module are NOT available However if the system host controls the Enable input and an external device controls only the Motor Control input s the motor protection functions of the module ARE available Chapter 4 Local Motor Control 4 5 Using a Motor Starter Pendent Connecting the Motor Starter Pendent or similar device to the module s Enable input and Motor Control input s automatically enables Manual Mode When Manual Mode is enabled the Local LED on the Motor Starter Pendent lights and the LOC LED on the Motor Starter Module lights After Manual Mode has been activated the Motor Starter Module automatically indicates that it is in Manual Mode in its input data Bits 7 6 5 4 3 2 1 0 Manual Mode active 1 Note that the Motor Starter Pendent cannot be used with two Motor Starter Modules IC220STRO02 that are connected in a reversing application Motor Protection Disabled with a Motor Starter Pendent When the module s Enable input is connected via a Motor Starter Pendent or similar switching device the motor protection functions of the module overcurrent maximum current are NOT available This
26. Protective circuits of the power terminal Overload in segment circuit Yes thermal protection Electrical Isolation Isolation of the Voltage Range CAUTION To provide electrical isolation between the logic level and the I O area you must supply the VersaMax I O Station NIU and the thermistor module using separate power supplies Do not interconnect the 24V power supplies The connection terminals of the thermistor are isolated to the 7 5V supply the 24V supply and the functional earth ground with a basic insulation for a 300VAC rated voltage Common potentials the 24V segment voltage and GND have the same potential Functional earth ground is a separate potential area Separate System Potentials Consisting of NIU Power Terminal and I O Terminal 5V supply incoming remote bus 7 5V supply bus logic _ 500 VAC 50 Hz 1 min 5V supply outgoing remote bus 7 5V supply bus logic 500 VAC 50 Hz 1 min 7 5V supply bus logic 24V supply I O 500 VAC 50 Hz 1 min 24V supply I O functional earth ground 500 VAC 50 Hz 1 min Thermistor all other areas 1200 VAC 50 Hz 1 min ID code BE hex 190 dec Length code 4 hex Input length 4 bits Output length 0 Parameter channel 0 bits Register length 4 bits VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 GFK 2134 A Acknowledge Reset bit 3 10 B Brake commands Enable
27. V varistor Polarity reversal of the brake Diode against polarity protection Electrical Isolation Isolation of the Voltage Range CAUTION To provide electrical isolation between the logic level and the I O area you must supply the VersaMax I O Station NIU and the brake module using separate power supplies Do not interconnect the 24V power supplies Common potentials the 24V segment voltage GND and brake control have the same potential The protective earth ground PE and the brake each have their own isolated area Isolated Voltages in the System Consisting of a Motor Starter Module Brake Module and Brake 24V supply US GND brake control protective earth 500 VAC 50 Hz 1 min ground PE For Brake Module IC220ACC100 24V supply US GND brake control brake output 500 VAC 50 Hz 1 min Brake output protective earth ground PE 500 VAC 50 Hz 1 min For Brake Module IC220ACC101 24V supply US GND brake control brake output 1200 VAC 50 Hz 1 min Brake output protective earth ground PE 1200 VAC 50 Hz 1 min VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Chapter Motor Protection with a Thermistor Module 6 This chapter describes the use of an optional VersaPoint Thermistor Module to provide thermal protection for motors with built in thermistors Description of the Thermistor Module Thermistor Module Features Thermi
28. ains how to use Manual Mode for local control of the motor Operation of the Motor Starter Module in Manual Mode Enabling Disabling Manual Mode Manual Mode Input Connections Manual Mode Input Assignments Manual Mode Input Diagrams Using a Motor Starter Pendent Motor Protection Disabled with a Motor Starter Pendent Controlling the Motor with a Motor Starter Pendent Motor Starter Pendent Specifications Controlling Manual Mode from the System Host Motor Protection Functions in System Controlled Manual Mode 4 1 Operation of the Motor Starter Module in Manual Mode When Manual Mode is active the motor must be controlled locally The shutdown delay time is approximately 200ms If the system host has set up independent brake control using an optional Motor Starter Brake Module the brake is automatically controlled by the manual motor input s Independent brake control is restored on exiting Manual Mode Enabling Disabling Manual Mode When Manual Mode is being enabled or disabled there is a delay time of 1 second During this time the Motor Starter Module switches the motor off If a brake switch is connected it opens When switched to Manual Mode the module immediately indicates Manual Mode operation in its input data byte Bits Manual Mode active 0 4 2 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Manual Mode Input Connections Connections
29. arter Module are commanded by the system host Configuring the Nominal Motor Current By default the nominal motor current is set to 0 2 Amp At startup or following a reset the system host can change the nominal motor current to higher value as appropriate for the motor For details of configuring the nominal motor current see chapter 3 Controlling the Motor and Optional Brake During system operation the system host controls the operation of the motor The host also controls reset of the Motor Starter Module after an error has caused a shutdown If an optional Motor Starter Brake Module and brake are connected to the Motor Starter Module the brake is also controlled by the system host By default brake control occurs automatically when the motor is switched on and off However the system host can also switch the brake independently of the motor operation See chapter 3 for more information Optional Local Control Connecting a Motor Starter Pendent or similar switching device to the Motor Starter Module s enable and motor control inputs automatically enables local control of the motor Local control can also be set up by connecting only the motor control inputs and enabling Manual mode from the system host See chapter 4 for information Diagnostics The Motor Starter Module automatically monitors the current level of the motor If the actual current level exceeds the nominal or configured current level or if the current falls
30. cannot guarantee the suitability of the procedures described or the circuit suggestions for the relevant application Correct Usage WARNINGS The Motor Starter Module is only to be used as specified in this manual GE Intelligent Platforms accepts no liability if the device is used for anything other than its designated application Notes for Reversing Applications Do not implement a reversing application by combining two Motor Starter Modules IC220STRO001 Do not use Motor Starter Module IC220STT001 to control pole reversing motors dual speed Motor Starter Module IC220STRO03 is intended for reversing applications Alternatively two Motor Starter Modules IC220STRO02 can be combined for reversing applications as shown later in this chapter For module IC220STRO03 the motor must have come to a stop before the direction of rotation can be changed VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Installation Safety Instructions WARNINGS Do not replace modules while power is connected Before removing or installing a VersaPoint module disconnect power to the entire I O Station Be sure the entire I O Station is reassembled before switching the power back on Dangerous Voltage Carry out all work on the Motor Starter Module and the connectors when the power is not connected Before working with the Motor Starter Module or system disconnect the AC line voltag
31. ccecesceceeeeecceeeeeeneceeseecceeeeeneacecensaecenteseeeenteseaaeneees 4 5 Controlling Manual Mode from the System Host ecceceeeeeeeeeeeeeeeeeneeeeesnneeeeesneeeee 4 7 Motor Starter Brake Modules ssssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 5 1 Description of the Brake Modules cccccceeeeeeeceeceeeeeeeeeceneaeceeeeeeeseceaaeeeeeeeeeeeesnnaeees 5 2 Controlling the Operation of the Brake ccccceceeseeeeeeeneeeseeeeeeeseeeeeeeseeeeeeeteeaeerseeaees 5 3 Specifications for Motor Starter Brake Modules IC220ACC100 and IC220ACC101 5 4 Contents Chapter 6 Motor Protection with a Thermistor Module 0 5 vi Description of the Thermistor Module 2 ececceceeeeeeeeeeteeeeteeeettees Thermistor Module Operation ccccceecseceeceeeeeeeeeenaeceeeeeeeseestnaeeeeees Thermistor Module Connections 0 cccccecceeeeceeeeeeeeeeeecaeeeeeeeeeeeesnaees Internal Circuit Diagram of the Thermistor Module n Thermistor Module LEDS c cccccceceeeeeeeeeeeeeceeeeeeeseseneaeceeeeeeeeeesnnaeess Specifications for the Thermistor Module IC220MDD850 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Chapter VersaPoint Motor Starter Modules l This manual contains the instructions and reference information needed to install and use a VersaPoint Motor Starter module There ar
32. ce for the MOtor ccccccceeceeeeseeneeeeseeeeeeeseeeeeeseeeeeeeseenaees 2 8 Connecting Power from the Module to the Motor ccccccceeceeeeeeeeeeeseeeeeeteeeeeeeseeaeees 2 9 Protecting the Motore sirar irea T AA AE ER 2 10 Connecting a Motor Starter Brake Module and Brake ccccccceeeeeeeeeeeeeeeeeneeeeeenaees 2 11 Wiring Two Motor Starter Modules IC220STRO02 for Reversing csecceeeeseeeeeeees 2 12 ModulesEED sss aisre a een e sare ct eee te aetna see ee a heat ee 2 13 Internal Circuit Diagrami meie cece n ee erent ee a E E RE a i taS RAA 2 14 Data Exchanged by the Motor Starter Module and the System Host 3 1 Exchanging Data with a Motor Starter Module ee eececeeeeeeeeeeeneeeeeeeneeeeetnaeeeeseaneeeeeaaes 3 2 Output Data Configuring the Nominal Motor Current ccccceeeeeceeeeeeeeeeeeenteeeeeeaeees 3 4 Output Data Sending Control Commands 0 ececcecececeeeeeeeececeeeeeeeeeeeeceeeeeeeeeeeetenaees 3 7 Input Data Monitoring the Motor Starter Module cccccceeeeeeceeeeeeeeeeteetteeeeeeeeteees 3 12 Local Motor COMtrol siiccisssaiscssstejesiessadeceassadesassnsdecasasadecsnataiasaassaguceaceheree 4 1 Operation of the Motor Starter Module in Manual Mode ccceecseseceeceeeeeeeteeteaeees 4 2 Manual Mode Input Connections c ccccceceeeeeeeeececeeeeeeeeeceaeaeeeeeeesesecnaeaeeeeeeesesnnaeeeeees 4 3 Using a Motor Starter Pendent ccccc
33. differs from an installation where the system host enables and disables Manual Mode and only the Motor Control input s are switched manually When the system host controls the Enable function motor protection functions ARE available Control of Manual Mode by the system host is described later in this chapter Switching to Manual Mode when Errors are Present Switching to Manual Mode acts as an error acknowledgement that is equivalent to a Reset Acknowledgement command If Manual Mode is set while an error is present that error no longer appears in the module s input data However if the error condition still exists upon exiting Manual Mode it is again reported in the input data If Manual Mode is entered during the 60 second waiting time following an overcurrent error the 60 second wait starts again when exiting Manual Mode The overcurrent error cannot be acknowledged during this time Errors During Manual Mode If an error occurs while the Motor Starter Module is in Manual Mode the error is not reported in the input data byte When Manual Mode is exited errors are no longer displayed if the cause has been removed Any errors that are still present are displayed again 4 6 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Controlling the Motor with a Motor Starter Pendent The Motor Starter Pendent has two function buttons F1 and F2 each with its own LED For Modules IC220STRO001 and
34. e and make sure it cannot be switched on again If this precaution is not followed personal injury or death may result The semiconductors in the module disconnect the motor without electrical isolation even when switched off Due to the leakage currents of the semiconductors an exposed dangerous voltage may be present at the motor connection even when the power levels are disconnected Be sure that phase T1 is not connected and is always present at the motor connection Take Measures to Suppress Interference Switching three phase induction motors when they are not at zero current generates electromagnetic disturbance that can adversely affect the function of the system In order to limit this type of interference appropriate measures must be taken in accordance with standard EN 60204 1 1998 Electrical Equipment of Machines to attenuate the interference at its source the motor In practice RC interference suppression elements have proven to be effective Segment Voltage 24V Switched Off Does NOT Disconnect Motor When the segment voltage is switched off the motor is not disconnected Provide an External Switch to Control the Motor If thermal damage occurs to the module it is not able to switch off the motor This error state is indicated by the error code 10 in the module input data It is important to provide an alternative means of switching off the motor with a mechanical switch Do not attempt to repair or perform other work on
35. e three module versions Motor Starter Direct 1 5KW 400VAC Module IC220STR001 Motor Starter Direct 3 7KW 400VAC Module IC220STRO02 Motor Starter Reversing 1 5KW 400VAC Module IC220STRO03 This manual also describes optional equipment that can be used with a Motor Starter Module for local motor control brake operation and thermal protection of the motor Chapter 1 VersaPoint Motor Starter Modules describes each module and lists its technical specifications This chapter also gives an overview of optional equipment and a list of ordering information for the Motor Starter Modules and optional equipment Chapter 2 Installation Instructions This chapter provides specific installation information for the VersaPoint Motor Starter Modules Chapter 3 Data Exchanged by the Module and the System Host describes the data formats used to configure control and monitor a Motor Starter Module Chapter 4 Local Motor Control explains how to use Manual Mode for optional local control of the motor This is usually done with a Motor Starter Pendent which is also described in this chapter Chapter 5 Motor Starter Brake Modules describes the use of an optional Motor Starter Brake Module Chapter 6 Thermistor Module for Motor Protection describes the use of an optional Thermistor Module for thermal protection of motors with built in thermistors Additional Documentation Needed For additional installation instructions and co
36. f EN 55011 Class A housing Do not operate the Motor Starter Module close to strong or medium range electromagnetic fields Portable radio transmission systems with transmission power above 2 Watts at a distance of 2 meters or less or the use of strong radio transmitters and ISM devices close to the Motor Starter Module may adversely effect its operation Electrical Isolation for All Motor Starter Modules Safe isolation between line and SELV according to EN 50178 1998 For module IC220STR002 Up to a line voltage of 519VAC 0 safe isolation Up to a line voltage of 600VAC 0 basic insulation Supply voltage Us 400V level 1 2kVAC 50 Hz 1 min Supply voltage Us brake switch 1 2kVAC 50 Hz 1 min Supply voltage UL 400V level 1 2kVAC 50 Hz 1 min Supply voltage U brake switch 1 2kVAC 50 Hz 1 min Remote bus 400V level 1 2kVAC 50 Hz 1 min Remote bus brake switch 1 2kVAC 50 Hz 1 min Mechanical Capability for All Motor Starter Modules Shock test according to IEC 60068 2 27 EN 60068 2 27 10g Criterion 1 Vibration operation according to IEC 60068 2 6 EN 60068 2 6 IC220STRO01 IC220STROO3 2g Criterion 1 IC220STROO2 1g Criterion 1 1 8 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Specifications for Motor Starter Module IC220STROO1 Motor Starter Module I1C220STR001 GFK 2134 Swi
37. ge from the host contains all of the output data for the I O Station The system host must sequence the output data to reflect the data type and module order Fieldbus Protocol NIU Bats System Host Message 4 Module Output Data for all Modules The NIU places the data in its own memory then regularly sends the output data to the modules in its I O Station The content of the data itself is not meaningful to the NIU A Motor Starter module receives one byte of output data from the host via the NIU NIU Motor Starter Module l Output Data A A Motor Starter module interprets the one byte of output data it receives from the NIU as one of the configuration or control commands described in this chapter Loss of Communications with the Host If the I O Station is reset or if system communications stop for 640ms the Motor Starter Module immediately begins decelerating the motor shaft If an optional Motor Starter Brake Module is installed on the Motor Starter Module the brake is automatically activated It is still possible to control the motor locally using an optional Motor Starter Pendent or similar switching device even during a system reset or if system communications are lost VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 The Module Provides Input Data After receiving commands in the output data the Motor Starter Module performs the commanded funct
38. he accuracy completeness sufficiency or usefulness of the information contained herein No warranties of merchantability or fitness for purpose shall apply indicates a trademark of GE Intelligent Platforms Inc and or its affiliates All other trademarks are the property of their respective owners Copyright 2010 GE Intelligent Platforms Inc All Rights Reserved Contact Information If you purchased this product through an Authorized Channel Partner please contact the seller directly General Contact Information Online technical support and http www ge ip com support GlobalCare Additional information http www ge ip com Solution Provider solutionprovider ip ge com Technical Support If you have technical problems that cannot be resolved with the information in this guide please contact us by telephone or email or on the web at www ge ip com support Americas Technical Support Email a Europe the Middle East and Africa Online Technical Support www ge ip com support dialing from a mobile telephone Asia Pacific Online Technical Support www ge ip com support Phone 86 400 820 8208 86 21 3217 4826 India Indonesia and Pakistan Technical Support Email support cn ip ge com China support jp ipn ge com Japan support in ip ge com remaining Asia customers Customer Care Email customercare apo i e com customercare cn ip ge com China Chapter 1 Chapter 2 Chapter 3 Cha
39. he input byte 3 If bit 6 gets 0 or bit 7 gets 1 write zero to the output byte to finalize parameterization If you want to automatically reconfigure the Motor Starter after a VersaPoint station reset e g power cycle execute the above steps again when input byte bit 6 is 1 and bit 7 is 0 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Output Data Sending Control Commands After configuring the nominal motor current the system host sends control commands to the Motor Starter Module The three types of Motor Starter Modules have different features which are reflected in the use of the output control bits as shown below Use of these control bits is described on the following pages af 7 oe fs s fs lefa 0 Brake 0 brake switch open motor decelerated 1 brake switch closed motor enabled Enable Brake 0 brake controlled by Motor bit bit 6 1 brake controllable separately reserved must be 0 Direct mode 0 no direct mode 1 enable direct mode Module IC220SRT002 only Check for minimum current level 0 check current 1 do not check current no minimum level Reset Acknowledge error 1 Acknowledge Modules IC220STROO1 and IC220STRO02 only 0 motor off brake switch open 1 motor on brake switch closed Module IC220STR003 only For motor in direction of rotation 1 0 off brake switch open 1 motor
40. hes the motor on bit 6 1 or off bit 6 0 For the reversing type Motor Starter Module IC220STRO003 output bit 6 switches the motor on bit 6 1 or off bit 6 0 in direction of rotation 1 If an optional Motor Starter Brake module is connected AND its use is not currently being controlled by bit 1 as described above bit 6 also opens bit 6 0 or closes bit 6 1 the brake switch If output bit 6 is zero the motor is turned off If the brake is present and being controlled the brake switch is opened and the motor is decelerated If bit 6 is 1 the motor is switched on If the brake is present and being controlled the brake switch is closed and the brake is released Controlling the Motor in Direction 2 Reversing type Module output bit 7 For the reversing type Motor Starter Module IC220STRO003 output bit 6 switches the motor on bit 7 1 or off bit 7 0 in direction of rotation 2 If an optional Motor Starter Brake module is connected AND its use is not currently being controlled by bit 1 as described above bit 7 either opens bit 7 0 or closes bit 6 1 the brake switch as described above For the direct type Motor Starter Modules IC220STRO01 and IC220STRO02 output bit 6 is not used and must be set to 0 Modules IC220STRO01 and IC220STRO02 only 0 motor off brake switch open 1 motor on brake switch closed Module IC220STR003 only For motor in direction of rotation 1 0 off b
41. ient temperature operation 25 C to 55 C 13 F to 131 F Ambient temperature storage transport 25 C to 85 C 13 F to 185 F Humidity 75 on average 85 occasionally Degree of protection IP 20 according to IEC 60529 Class of protection Class 1 according to VDE 0106 IEC 60536 Line protection of the voltage feeder 20A maximum Required mounting position Panel mounting on horizontal DIN rail mounting as shown in installation instructions Mounting distances At least 50mm 2 in of space is required above and below the module to assure adequate module ventilation GFK 2134 Chapter 1 VersaPoint Motor Starter Modules 1 7 Conformance With EMC Directive 89 336 EEC Noise Immunity Test According to EN 50082 2 Electrostatic discharge EN 61000 4 2 6kV contact discharge Criterion B ESD IEC 61000 4 2 8kV air discharge Criterion B Electromagnetic fields EN 61000 4 3 Criterion A IEC 61000 4 3 Field strength 3V m Fast transients burst EN 61000 4 4 Criterion B IEC 61000 4 4 Supply lines 2kV Signal data lines 2kV Surge voltage EN 61000 4 5 Criterion B IEC 61000 4 5 DC supply lines 0 5kV 0 5kV symmetrical asymmetrical Criterion B AC supply lines 2kV 4kV symmetrical asymmetrical Conducted interference EN 61000 4 6 Criterion A IEC 61000 4 6 Test voltage 10 V Noise Emission Test According to EN 50081 2 Noise emission o
42. imum Power consumption from the local bus 0 34W maximum Segment supply voltage Us 24VDC nominal Nominal current consumption at Us 50mA maximum Total internal power consumption 1 2W maximum Motor Output for Module IC220STR003 WARNING Dangerous voltage Switch off the line voltage before working with the Motor Starter module or the motor CAUTION Avoid a motor output short circuit which may damage the module electronics Number of motor outputs One 3 phases short circuit protected with external fuse of 16A total range protection for semiconductor type gR Terminal strip X10 Number of pins 4 T1 T2 T3 D Conductor cross section 1mm 18AWG minimum to 2 5mm 14 AWG maximum Degree of protection Protection against direct touch Wiring Varistor 460VAC Nominal load Three phase asynchronous motors Note The minimum motor current of 0 1A must be maintained in the operating state or the error message Power level cannot be controlled will be generated Motor power ranges Motor voltage 400V Number of motor poles 4 Motor power 0 18kW to 1 5kW The selection of an appropriate motor depends on the nominal motor current which ranges from 0 2A to 3 6A 1 18 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 GFK 2134 Motor Protection for Module IC220STR003 A motor protection relay is inserted using a
43. inal motor current has been configured It is set at startup and following a restart as mentioned below When an error occurs the module sets input bit 7 to 1 and shuts down the motor immediately The module s ERR LED lights The system should also monitor the motor control output bit s which are used to turn the motor on or off Bit 7 l Description Status Informational Message 0 0 No status message 0 1 Nominal motor current not yet configured This bit is set after the operating voltage UL is switched on and also after a restart voltage reset This message does NOT cause the motor to shut down and does not need to be acknowledged Error Messages 1 0 Power level cannot be controlled 1 1 Overcurrent condition has triggered overcurrent protection VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Error Code 1 0 Power Level Cannot be Controlled The module generates error message 1 0 if either of the following conditions exists for more than 1 second The control signal for the module is NOT present but the measured motor current is greater than the minimum current The control signal for the module is present but the motor current is below the permissible minimum current for that module type Note that for module IC220STRO02 minimum current monitoring can be disabled as mentioned below and described earlier in this chapter The minimum curre
44. ion It then sets the content of its one input data byte accordingly The input data byte provides information about the operation of the motor about error conditions and about the motor current Input data is described later in this chapter The NIU regularly reads the input data from the module and stores it in memory Again the content of the input data is not meaningful to the NIU NIU Motor Starter Module A Input Data The system host must read the input data from the NIU according to its specific communications protocol Fieldbus Protocol NIU Motor System Host Message Starter Module Input Data from all Modules The Output Input Data Cycle Because of the asynchronous processing times of the host the network and the NIU if the host sends commands too rapidly the output data in the NIU can be overwritten by the host before the NIU sends it to the module After sending a command to a Motor Starter Module in the output data the system host should evaluate the input data from the module before sending its next command GFK 2134 Chapter 3 Data Exchanged by the Motor Starter Module and the System Host 3 3 3 4 Output Data Configuring the Nominal Motor Current The configured nominal motor current provides protection against overcurrent If the default of 0 2 Amp is satisfactory it does not need to be changed The host can reconfigure the n
45. mmunications information you will also need the Network Interface User s Manual for your system GFK 2134 1 1 VersaPoint Motor Starter Modules VersaPoint Motor Starter modules provide switching protection and monitoring of three phase asynchronous motors These modules are installed in the 24V area of a VersaPoint I O Station Features of all VersaPoint Motor Starter Modules Integrated electronic motor protection according to IEC 60947 4 1990 System control of the motor through the module s output data Optional local motor control Connection for optional external passive brake module Safe isolation between line voltage and 24V supply voltage according to EN 50178 1997 Diagnostic and status indicators Motor current monitoring and integrated protection Features of Motor Starter Direct 1 5KW 400VAC IC220STR001 Nominal voltage is 400VAC Nominal Motor current is configurable from 0 2 Amps to 3 6 Amps This module must NOT be used for a reversing application Features of Motor Starter Direct 3 7KW 400VAC IC220STR002 Nominal voltage is 400VAC or 500VAC Nominal Motor current is configurable from 0 2 Amps to 8 0 Amps Two IC220STRO002 modules can be used to control two motors that are set up for a reversing application Features of Motor Starter Reversing 1 5KW 400VAC IC220STR003 Nominal voltage is 400VAC Nominal Motor current is configurable from 0 2 Amps to 3 6 Amps
46. nt levels for the VersaPoint Motor Starter Modules are Module Type Minimum Current IC220STROO1 ae IC220STRO03 Sone IC220STRO02 0 16 Amp For module IC220STRO02 only the system host can disable monitoring for minimum current level If output bit 4 is set for this module there is no minimum current level If this error occurs it can be acknowledged after 0 3 second Protecting the Motor The motor does not shut down automatically under every circumstance that may cause the Motor Starter module to generate status code 1 0 CAUTION It is important to be able to switch off the 400V operating voltage of the Motor Starter Module if an error occurs to prevent damage to the motor An example shutdown system is shown in chapter 2 These errors can be caused by defective power levels the interruption of a phase in the main supply or certain hardware faults The application program can evaluate the error type and the present contents of the output control byte and make appropriate corrections Error Code 1 1 Overcurrent If the Motor Starter Module detects an overcurrent condition it sets the bits 7 and 6 to 1 1 and turns off the motor The ERR LED lights An overcurrent error can only be acknowledged after a recovery time of at least 60 seconds GFK 2134 Chapter 3 Data Exchanged by the Motor Starter Module and the System Host 3 17 Chapter 4 GFK 2134 Local Motor Control This chapter expl
47. om current value bits 5 to 0 Nom current in Amps 0 2A 0 05A Nominal Current from 1 3A to 3 0A Nom current value bits 5 to 0 Nom current in Amps 0 8A 0 1A Nominal Current from 3 2A to 3 6A or 3 2A to 8 0A for Module IC220STR002 3 7KW ONLY Nom current value bits 5 to 0 Nom current in Amps 4 6A 0 2A Configuration Example In this example the nominal motor current for the Motor Starter module will be configured to be 2 5 Amps Step 1 Find the correct nominal current value in the table For 2 5 Amps the table shows Bits Byte dec hex dec hex 2 50 33 21 225 E1 Step 2 Enter the appropriate value in the output data to be sent to the module Output Byte Bits 7 6 5 4 3 2 1 0 binary 1 1 1 0 0 0 1 1 hex E 1 Step 3 Wait until the module s input data indicates successful configuration Input bits 7 and 6 will both be 0 Input Byte Bits 7 6 5 4 3 2 1 0 Error Code 0 0 Nostatus message 0 1 Nominal motor current not configured Step 4 after successful configuration the output byte is used for module control as described next in this section GFK 2134 Chapter 3 Data Exchanged by the Motor Starter Module and the System Host 3 5 3 6 To configure the nominal motor current follow these steps 1 Write the parameter of the above table to the output byte 2 Check Bits 6 and 7 of t
48. ominal motor current using the module s output data byte The motor is automatically switched off during configuration Note that the configured nominal input current level is not stored through loss of power If the 7 5V power supply U fails the host needs to reconfigure the nominal current Configuring the Nominal Motor Corrent Value For configuration output bits 7 and 6 of the module s output byte are set to 1 The additional bits specify the nominal current value Bits 7 6 5 4 3 2 1 0 1 1 Nominal Motor Current Set to 1 for Configuration mode The table below shows all nominal current values For each nominal current it lists equivalent decimal and hex values for bytes 0 5 and for the entire byte with bits 7 and 6 set to 1 All modules can use the values shown in the first two sections of the table Only module IC220STRO02 can use the values in the righthand section All Modules All Modules Module IC220STRO02 ONLY Amps Bits 0 5 Byte Amps Bits Byte Amps Byte dec hex dec hex dec hex dec hex dec hex dec hex 0 20 0 00 192 C0 1 40 22 16 214 D6 3 80 42 2A 234 EA 0 25 1 01 193 C1 1 50 23 17 215 D7 4 00 43 2B 235 EB 0 30 2 02 194 C2 1 60 24 18 216 D8 4 20 44 2C 236 EC 0 35 3 03 195 C3 1 70 25 19 217 D9 4 40 45 2D 237 ED 0 40 4 04 196 C4 1 80 26 1A 218 DA 4 6
49. on brake switch closed t Modules IC220STROO1 and IC220STROO2 only reserved must be 0 Module IC220STRO03 only For motor in direction of rotation 2 0 off brake switch open 1 motor on brake switch closed GFK 2134 Chapter 3 Data Exchanged by the Motor Starter Module and the System Host 3 7 Using the Brake Commands Bits 0 and 1 If an optional Motor Starter Brake module and brake are connected to the Motor Starter Module the system host ordinarily controls the brake automatically using the motor control command bit s However the brake can also be controlled independently using output bits 0 and 1 aml 7 e fs a fa e i 0 IES Control Brake 0 brake switch open motor decelerated 1 brake switch closed motor enabled Enable Brake 0 brake automatically controlled by Motor bit bit 6 1 brake must be controlled separately For more information about the Motor Starter Brake modules see chapter 5 Enabling Brake Control output bit 1 To be able to switch the brake independently brake control must first be enabled using the Enable Brake command If the Enable Brake bit 1 is set to 0 the brake cannot be freely controlled it is automatically controlled by tbe bit s controlling the motor When the Enable Brake bit 1 is set to 1 the brake must be explicitly controlled using bit 0 even if an error occurs If the Enable Brake bit 1 is reset to 0 after being set to 1
50. on for the motor output 3 Motor Output Connector T1 T2 T3 X11 Connection for the incoming line 1 Incoming line here Motor Starter Power L1 L2 L3 N Connector IC220ACC103 X12 Connection for the outgoing line 2 Optional outgoing line Motor Starter Power L1 L2 L3 N Bridge IC220ACC104 X18 Enabling the power 7 Jumper for 24V segment power A switch to level connection for 24V control 24V power can be substituted for this isolation jumper X32 Connection for manual mode 6 Optional Motor Starter Pendent IC220ACC102 GFK 2134 Chapter 2 Installing VersaPoint Motor Starter Modules Connecting 24V Module Power Power for module operation comes from the NIU module or separate power supply as described in the NIU User s Manual Connecting the modules on the DIN rail automatically creates jumpers between modules for I O Station power Enabling the Power Level 24V Isolation The two pins shown below control the 24V segment voltage for the Power Monitor Module When this 24V control voltage is not present the contacts are always open and the brake is always applied the motor is decelerated Pin Description 1 1 24 V segment voltage US 2 2 enable power level The Motor Starter Module is supplied with a jumper inserted between these pins If no switch is connected to these pins the jumper can remain inserted In that case the Motor Starter Module will be enabled by the directly available 24V segment
51. onics WARNING Dangerous voltage Switch off the line voltage before working with the Motor Starter module or the motor CAUTION Avoid a motor output short circuit which may damage the module Number of motor outputs One 3 phases short circuit protected with external fuse of 16A total range protection for semiconductor type gR Number of pins on output terminal strip X10 Four T1 T2 T3 Conductor cross section 1mm 18AWG minimum to 2 5mm 14 AWG maximum Degree of protection Protection against direct touch Wiring Varistor 460VAC Note The minimum motor current of 0 1A must be maintained in the operating state or the error message Power level cannot be controlled will be generated Motor power ranges Motor voltage Number of motor poles Motor power 400V 4 0 18kW to 1 5kW ranges from 0 2A to 3 6A The selection of an appropriate motor depends on the nominal motor current which Chapter 1 VersaPoint Motor Starter Modules Motor Protection for Module 1C220STR001 Trip class According to Class 10A of IEC 60947 4 Quick Shutdown gt 20 3A after 300ms Configurable range 0 2A to 3 6A Typical Response Behavior Current 1 5 x In 7 2 X In 10 Release Time Tp lt 120s 2s lt Tp lt 10s 6 If the current is disconnected due to an A overcurrent wait at least 60 seconds to ensure successful acknowledgement of 7 the error a 40 20 10
52. ot be switched on and the motor is off WARNING When the segment voltage is switched off the motor is not disconnected WARNING If thermal damage occurs to the module it may not be able to switch off the motor It is important to provide an external switch so that the motor can be turned off in case the Motor Starter module is damaged Chapter 1 VersaPoint Motor Starter Modules 1 9 Power Consumption for Module IC220STR001 Communications power UL 7 5V Current consumption at UL 45mA maximum Power consumption at UL 0 34W maximum Segment supply voltage Us 24VDC nominal Nominal current consumption at Us 50mA maximum Total internal power consumption 1 2W maximum Connection method Power connector or power bridge Terminal strip X11 and X12 Number of pins 5 L1 L2 L3 N PE not leading Permissible cable cross section Up to 2 5mm 14 AWG Nominal operating voltage 400VAC Voltage range 187VAC to 440V AC 0 minimum with safe isolation between line and SELV Tolerances outside the voltage range are not permitted Frequency 50Hz or 60Hz The supply of the line voltage through a frequency inverter is not permitted Current load incoming line 20A maximum Wiring TSE wiring Varistor 460VAC 1 10 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 GFK 2134 Motor Output for Module IC220STRO001 electr
53. otection functions remain available status messages described later in this section are still reported in the input byte If Manual Mode was entered during the 60 second waiting time following an overcurrent error the 60 second wait starts again when exiting Manual Mode The overcurrent error cannot be acknowledged during this time GFK 2134 Chapter 3 Data Exchanged by the Motor Starter Module and the System Host 3 15 3 16 Monitoring the Motor s On Off State input bit 5 Bit 5 of the input byte shows whether the motor is currently running Bits 7 6 5 4 3 2 1 0 Motor running not running Reading Status and Error Messages Bits 6 and 7 of the input byte contain status and error information Bits 7 6 5 4 3 2 1 0 Error Code 0 0 Nostatus message 0 Nominal motor current not configured 1 Overcurrent protection triggered 1 Power level cannot be controlled on During normal operation the control system only needs to monitor bit 7 If bit 7 is 1 the control program can evaluate the entire diagnostic code and begin an appropriate response The first error that occurred is indicated in the input data until it is removed and acknowledged by setting the Reset Acknowledgement bit or by connecting a Motor Starter Pendent The message is deleted once it has been acknowledged Then the motor can be restarted If bit 7 is O the state of bit 6 indicates whether the nom
54. pter 3 Data Exchanged by the Motor Starter Module and the System Host 3 13 3 14 Calculating the Actual Motor Current as a Percent The system host can use the input data value to automatically calculate the actual current as a percentage of the nominal current This will produce the same percent values shown on the previous page To get the actual current in Amps instead see below To calculate the actual motor current as a percent the application should substitute the decimal value from the input date into the following equation Decimal value Actual Current as ete a Percentage of Nominal Current in bits 0 to 3 0 75 X 100 32 Calculating the Actual Motor Current in Amps If the application needs to calculate the actual motor current in Amps use the equation below For this calculation the application must substitute both the decimal value from the input byte and the nominal current The nominal current cannot be read from the module it must already be known If the nominal input current has not been reconfigured for the module as described previously in this chapter the default is 0 2 Amp Decimal value 1 15 in bits 0 to 3 Nominal Current Actual Current 0 75 X in Amps 32 Example the decimal value presently in bits 0 to 3 is 3 decimal the configured nominal current is 1 1 Amp substituting those two values gives the following equation 3 Actual Current 0 75 X 1 1 Amps 32
55. pter 4 Chapter 5 GFK 2134 Contents VersaPoint Motor Starter Modules cccceeeeee eee eee e eee e eee eeeeeeeeeeeeeneenes 1 1 VersaPoint Motor Starter Modules ccccccceceecceceeeeeeeeeeeaeeeeeeeeeeseceaeaeceeeeesesecsisaeeeees 1 2 Additional Equipment for Motor Starter Applications ccccccceeeseceeceeeeeeeeeeneeeeeeeees 1 3 Overview of Motor Starter Module Operation ccccceceeeeeeceeceeeeeseeeeceeeaeeeeeeesetennaees 1 6 General Specifications for Motor Starter Modules cccccccceceeeeeeeeeeeeeeeeeeeeeeeeeteenaees 1 7 Specifications for Motor Starter Module IC220STRO01 ccccceeeeeeeeeeeceeeeeeeteesenaeees 1 9 Specifications for Motor Starter Module IC220STROO2 ccceceeeeeeeeeecteeeeeeeeeteees 1 13 Specifications for Motor Starter Module IC220STROOS ccceceeeeeseeetceeeeeeeteeteees 1 17 Ordering Ional ein aia dec eeakar e E A E E GG eee eared eve etd 1 20 Installing VersaPoint Motor Starter Modules esssseeeeeeeeeeeeeee 2 1 Safety Requirements ns anian ieee tee eettom raaa e iar r a Naa e AAE A A 2 2 Modulet Installation a T eaa aa e a ae a aaaea a A aE 2 4 Connectors and Connection Points cccccceeeeeeeeeeceeeeeeeeeceaeeeeeeeeesetecnaeeeeeeretseesnnaeees 2 5 Connecting 24V Module POWE ccccceecceceseeeeeeeeceeeeeeeeeneeeeeseneeeeeceeeaeeeeeeeaeeetenaeeeseeaeees 2 6 Connecting the Power Sour
56. put data word Enable Manual mode 1 Motor Protection Functions in System Controlled Manual Mode When the system host enables and disables Manual Mode as described above the motor protection functions of the Motor Starter Module overcurrent maximum current remain available This differs from the other Manual Mode options When the module s Enable input is connected via a Motor Starter Pendent or similar switching device the motor protection functions of the module are NOT available 4 8 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Chapter 5 GFK 2134 This chapter describes the use of an optional Motor Starter Brake Module Motor Starter Brake Modules Description of the Brake Modules Motor Starter Brake Module Features Internal Circuit Diagram of a Brake Module System Host Controls the Operation of the Brake Enabling Brake Control Switching the Brake Specifications for the Motor Starter Brake modules 5 1 Description of the Brake Modules A Motor Starter Brake module is a passive electronic brake switch that can be used to connect a brake to a VersaPoint Motor Starter module Two VersaPoint Motor Starter Brake modules are available C220ACC100 and IC220ACC101 Both types can be used with any VersaPoint Motor Starter Module Motor Starter Brake Module Features Electronic brake switch solid state switch Nominal voltage ranges IC220ACC1
57. r Module IC220MDD850 requires one 1 I O Terminal Strip IC220TBK081 ordered separately The pin assignments are 1 1 Switching output 4 2 1 Ground for Switching Output 3 P3 1 2 2 2 Thermistor Connection Ba 1 3 2 3 not used 1 4 2 4 Functional Earth Ground Connecting the Thermistor Module to the Motor Starter Module If the Thermistor Module s switching output is used to control the Motor Starter Module then point 1 1 on the Thermistor Module should be connected to the 24V Enable Input at the upper left of the Motor Starter Module as described in chapter 2 The switching output ground pin 2 1 may not be connected because it is internally connected via the voltage jumper 6 4 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Ls A Thermistor Module can also provide thermal protection for a motor without using the Motor Starter Module to turn off the motor in case of error This type of installation requires an extra VersaPoint power terminal that supplies power to a VersaPoint discrete output module The discrete output module controls the operation of the motor Controlling the Motor without Using the Motor Starter Module The Thermistor Module is connected to the thermistor and to the power terminal If the switching output on the Thermistor module becomes inactive power is no longer supplied to the power te
58. rake switch open 1 motor on brake switch closed Modules IC220STRO01 and IC220STRO02 only reserved must be 0 Module IC220STR003 only For motor in direction of rotation 2 0 off brake switch open 1 motor on brake switch closed GFK 2134 Chapter 3 Data Exchanged by the Motor Starter Module and the System Host 3 11 Input Data Monitoring the Motor Starter Module The Motor Starter Module provides one byte of status data to the control system The system host can use this data to monitor the motor current and to determine whether the motor is running It can also check for error conditions and for status of Manual Mode Bits 7 6 5 4 3 2 1 0 Motor Current monitoring Possible values are listed in this section Manual Mode active 1 Manual mode is activated Motor Running 1 motor output is controlled Error Code 0 0 No status message Nominal motor current not configured Overcurrent protection triggered Power level cannot be controlled A300 ono The system host should evaluate this input data before sending commands to the Motor Starter Module 3 12 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Monitoring the Motor Current input bits 0 3 The value in input bits O 3 indicates the relationship between the actual current and the configured nominal current This value is based on the actual cu
59. rminal and the motor is switched off This type of installation is wired as shown below GFK 2134 Chapter 6 Motor Protection with a Thermistor Module 6 5 s Internal Circuit Diagram of the Thermistor Module Bus logic and voltage conditioning LED Converter Optocoupler Threshold value switch maS ag Amplifier Isolater area 24 V Ug 24 V Uy Thermistor Module LEDS LED Color Meaning E D D Green Bus diagnostics sc A E Red Error overtemperature thermistor SC Red Short circuit of the thermistor or connecting cable A Yello Alarm message thermistor temperature is w approximately 5K below response temperature 6 6 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Ls Specifications for the Thermistor Module IC220MDD850 GFK 2134 General Data Housing dimensions width x height x depth 12 2mm x 120mm x 71 5mm 0 48in x 4 72in x 2 82in Ambient temperature operation 25 C to 55 C 13 F to 131 F Ambient temperature storage transport 25 C to 85 C 13 F to 185 F Humidity 75 on average 85 occasionally no condensation Degree of protection IP 20 according to IEC 60529 Power Consumption Communications voltage 7 5V Current consumption from the local bus 60mA maximum Power
60. rrecting the error condition the control system should set the Reset Acknowledge output bit The error can also be acknowledged in manual mode by inserting the Motor Starter Pendent which places the module into manual mode If the underlying cause of the error is not removed the error message will continue to be reported in the input data CAUTION Following a critical error do NOT issue repeated Reset commands before correcting the fault Resetting the module before fully correcting the error can cause damage to the equipment or personal injury If the Motor Starter Module accepts the Reset Acknowledgement the error codes are removed from the input data The Reset bit must remain set until the error code is reset Timing for Reset Acknowledgement If an Overcurrent error error code 11 occurs an acknowledgement will not be accepted until recovery time of at least 60 seconds has passed A Power Level error error code 10 can be acknowledged after 0 3 second The module s built in timer is not immediately reset after receiving a Reset Acknowledgement command Depending on the reason for the shutdown the counter is not reset until approximately 2 to 3 minutes after the motor is switched off 3 10 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Controlling the Motor output bit 6 For the direct type Motor Starter Modules IC220STRO01 and IC220STRO02 output bit 6 switc
61. rrent of phase T1 which corresponds to the output on pin 1 of the Motor Starter Module s motor output connector X8 Bits 7 6 5 4 3 2 1 0 Motor Current monitoring Possible values are listed below he input data value is updated every 120ms Each binary decimal value that may be represented in bits 0 to 3 corresponds to a specific relationship between the current values The resolution of the motor current ratio lact Inom is 1 32 The table below shows each possible value as both a ratio and a percentage For example if the value in bits 0 to 3 is equal to decimal 5 the actual input current is 91 of the configured nominal motor current As the table shows the actual current can range from less than 75 to more than 122 of the configured nominal current Nom Current Nom Current ae Sy 0 0 00 lt 0 75 lt 75 0 0 0 0 0 8 1 00 100 0 0 0 1 1 0 78 78 0 0 0 1 9 1 03 103 0 10 10 2 0 81 81 0 0 1 0 10 1 06 106 0 0 1 1 3 0 84 84 0 0 1 1 11 1 09 109 0 1 0 0 4 0 88 88 0 1 0 0 12 1 13 113 0 1 0 1 5 0 91 91 0 1 0 1 13 1 16 116 0 1 10 6 0 94 94 O 1 1 0 14 1 19 119 O 1 1 1 7 0 97 97 O 1 1 1 15 21 22 122 Using the values read in bits 0 to 3 the application can calculate both the percentage values shown in the table above and the actual motor current by following the steps described on the next page GFK 2134 Cha
62. single phase current measurement in unconnected phase T1 The motor current is measured in the T1 phase Trip class According to Class 10A of IEC 60947 4 1990 Quick Shutdown gt 20 3A after 300ms Configurable range Typical Response Behavior Minutes Seconds 0 81 15 2 3 4 6 810 Multiples of the nominal current 0 2A to 3 6A Current 1 5 x N 7 2 X In Release Tp lt 120s 2s lt Tp lt 10s Time If the current is disconnected due to an overcurrent wait at least 60 seconds to ensure successful acknowledgement of the error Current Monitoring for Module IC220STR003 Monitored phase T1 Measuring range 0 to 25A Resolution 14mA Supply of the current detection From the 7 5V communications power Diagnostic Messages for Module IC220STR003 Error message in diagnostic code and Overcurrent Power level cannot be controlled displayed on ERR LED on module Chapter 1 VersaPoint Motor Starter Modules Ordering Information Product Type Catalog Number Motor Starter Module Direct 1 5 KW 400 VAC IC220STROO1 Motor Starter Module Direct 3 7 KW 400 VAC IC220STRO02 Motor Starter Module Reversing 1 5 KW 400 VAC IC220STRO03 Motor Starter Brake Module 5 VDC to 31 VDC IC220ACC100 Motor Starter Brake Module 12 VDC to 400 VDC 20VAC to 400VAC IC220ACC101 Motor Starter Power Connector IC220
63. st as explained in chapter 3 If the actual motor current is less than 0 1 Amp during operation the module also shuts down the motor See chapter 3 for more information GFK 2134 2 1 2 2 Safety Requirements The Motor Starter Module and connected machines are used in high power industrial plants During operation this equipment has dangerous live moving or rotating parts It can pose considerable risk of personal injury or death and of damage to equipment WARNINGS Only qualified personnel may work on the Motor Starter Module or system Unqualified personnel may not work on the Motor Starter Module on the machines or in their vicinity Qualified personnel are people who because of their education experience and instruction and their knowledge of relevant standards regulations accident prevention and service conditions have been authorized by those responsible for the safety of the plant to carry out any required operations and who are able to recognize and avoid any possible dangers Definitions for skilled workers according to EN50110 1 When work is being carried out on the Motor Starter Module or system the relevant product documentation must always be kept at hand and referred to The instructions given on this document must be followed during installation and startup The additional information presented on this document should be understood and applied in an appropriate manner GE Intelligent Platforms
64. stor Module Operation System Host Shuts Down the Motor Thermistor Module Switching Output Shuts Down the Motor Thermistor Module Connections Connecting the Thermistor Module to the Motor Starter Module Controlling the Motor without Using the Motor Starter Module Internal Circuit Diagram of the Thermistor Module Thermistor Module LEDs Specifications for the Thermistor Module GFK 2134 6 1 Description of the Thermistor Module Motors with integrated thermistors can be thermally protected with an optional VersaPoint Thermistor Module IC220MDD850 Thermistor Module Features The Thermistor Module monitors motor thermistors for Operating range resistance between 50 Ohms and 2 25kOhms Tripping range resistance of 4k Ohms or more Motor temperature below the tripping temperature generates warning Short circuit resistance is 50 Ohms or less It also evaluates the optional PTC resistors incorporated in three phase induction motors 6 2 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Thermistor Module Operation If an error occurs the Thermistor Module can cause the Motor Starter Module to shut down the motor in either of two ways by triggering a command from the system host to the Motor Starter Module by using its switching output to control the 24V segment voltage to the Motor Starter Module System Host Shuts Down the Motor When the system
65. tarter Module and the System Host This chapter explains how a system host exchanges information with a Motor Starter module in a VersaPoint I O Station GFK 2134 Exchanging Data with a Motor Starter Module The Host Sends Output Data The Module Provides Input Data The Output Input Data Cycle Output Data Configuring the Nominal Motor Current Entering the Nominal Motor Current Configuration Example Output Data Sending Control Commands Using the Brake Commands Enabling Manual Mode Module IC220STRO02 Disabling Minimum Current Checking Acknowledging a Reset Controlling the Motor Input Data Monitoring the Motor Starter Module Monitoring the Motor Current Calculating the Actual Motor Current as a Percent Calculating the Actual Motor Current in Amps Checking for Manual Mode Active Monitoring the Motor s On Off State Reading Status and Error Messages Error Code 1 0 Power Level Cannot be Controlled Error Code 1 1 Overcurrent 3 1 3 2 Exchanging Data with a Motor Starter Module A system host exchanges data with the Network Interface Unit in a VersaPoint I O Station using the appropriate bus protocol for example Profibus or DeviceNet Protocol details are described in the each Network Interface Unit User s Manual For all bus protocols the content of the actual module data exchanged between the host and the NIU is the same The Host Sends Output Data Each output messa
66. tches Electronic hybrid switches two phase switching Connection and disconnection is carried out using thyristors that are jumpered by relays in the conductive state Operating voltage conductor voltage 187VAC to 440VAC 0 minimum Power frequency 50Hz or 60Hz Nominal current range 0 2A to 3 6A Minimum current 100mA Minimum current of 0 1A per phase must be maintained in the operating state Otherwise module generates error message 10 Power level cannot be controlled Power 1 5kW for AC 3 operation 4 position synchronous motor Usage category According to AC 3 Switching frequency 30 switching operations per minute maximum depending on the nominal motor current and ambient temperature Chart shows maximum preted switching a frequencies at ambient temperatures of 25C 200 77F and 55C 131F s9 10 0 25 0 5 0 0 0 07 10 15 20 26 30 36 40 Nominal motor current A Switch on time 1 second minimum Switch off time 1 second minimum Phase angle cos gt 0 3 Motor starting time 0 5s maximum Internal Protection Fuse 6 3 x 32 10 AT in the switched phases Internal fuses are not user replaceable Do not attempt to repair the module If the fuses blow the module MUST BE REPLACED Control voltage for the Motor Starter Module 24V segment voltage when the segment voltage is switched off the Motor Starter Module cann
67. the brake is set according to the present state of the motor If the motor is on the brake is released If the motor is off the brake is enabled Controlling the Brake output bit 0 If independent control has been enabled using bit 1 then bit O can be used to control the operation of the brake When the Brake bit 0 is set to 0 the brake switch is opened the brake takes effect and the motor is decelerated When the Brake bit 0 is set to 1 the brake switch is closed the brake is released and the motor is enabled 3 8 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Enabling Manual Mode output bit 3 If a Motor Starter Pendent or similar switching device is connected to the module s Enable and Motor Control inputs Manual mode is enabled automatically See chapter 4 for more information about using Manual Mode Manual Mode can be used WITHOUT a Motor Starter Pendent or similar switching device connected to the Motor Starter Module s Enable input In that case a switching device is connected only to the Motor Control input s and the Enable input is not connected The system host must enable Manual Mode using bit 3 If output bit 3 is 0 Manual Mode is disabled If output bit 3 is set to 1 the motor is switched directly by the Motor Control input s on the Motor Starter Module In Manual mode the motor cannot be controlled from the system host Bits 7 6 5 4 3 2 1 0
68. tions power is not present no local communications ERR Red LED Group error message motor protection ON Operational fault motor protection has been triggered power level cannot be controlled OFF No error M1 Yellow LED M1 Motor Status R1 or R2 R1 Motor Status in Direction of Rotation 1 R2 Motor Status in Direction of Rotation 2 ON Motor is switched on OFF Motor is not switched on LOC Yellow LED Manual mode local usually controlled by a Motor Starter Pendent ON Manual mode is active OFF Manual mode is not active VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Internal Circuit Diagram The same basic circuitry and connectors of an electronic Motor Starter Module are shown below X32 connector for manual mode X18 connector for enabling 24V isolation Amplifier Ee E Ge Gel pagg Optocoupler Protocol chip bus logic incl Voltage conditioning Line connection Current transformer 24 V Us Fuse co Relay WV Thyristor diode ale Capacitor 7 Isolated area X10 connector for motor output X8 connector for external brake module Ground Functional earth ground u Voltage jumper GFK 2134 Chapter 2 Installing VersaPoint Motor Starter Modules 2 15 Chapter 3 Data Exchanged by the Motor S
69. ule 5 4 Motor Starter IC220STR001 1 9 Motor Starter IC220STR003 1 17 Motor Starter Module IC220STR002 1 13 Thermistor Module 6 7 Status and error messages 3 16 Switch for operating voltage 2 10 Switch for segment voltage 2 6 T Thermistor Module connections 6 4 description 6 2 features 6 2 internal circuit diagram 6 6 LEDs 6 6 operation 6 3 specifications 6 7 Thermistor module connection 2 7 Thermistor Module overview 1 5 Timing for Reset Acknowledgement 3 10 of commands exchanged with host 3 3 Index 2 VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134
70. ures Electronic brake switch solid state switch Nominal voltage ranges IC220ACC100 from 12VDC to 400VDC 20VAC to 400VAC IC220ACC101 from 5VDC to 31VDC Protection against polarity reversal VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Thermistor Module GFK 2134 Motors having integrated thermistors can be thermally protected by wiring an optional VersaPoint Thermistor module IC220MDD850 to the motor With the Thermistor Module s input connected to the motor thermistor the module can check for Operating range resistance between 50 Ohms and 2 25k Ohms Tripping range resistance of 4k Ohms or more Short circuit resistance of 50 Ohms or less Motor temperature below the tripping temperature generates warning If an error is detected the Thermistor Module can turn off the motor either directly or indirectly Direct control the Thermistor Module s switching output turns off the 24V segment power to the Motor Starter Module which will shut off the motor Indirect control the module reports the error condition to the system host which can then turn off the motor by sending a command to the Motor Starter Module See chapter 6 for more information about using a Thermistor Module in a Motor Starter Module application Chapter 1 VersaPoint Motor Starter Modules 1 5 Overview of Motor Starter Module Operation Control and configuration of a Motor St
71. utput bit 1 Bits 7 6 s jalz Control Brake 0 brake switch open motor decelerated 1 brake switch closed motor enabled Enable Brake 0 brake automatically controlled by Motor bit 1 brake must be controlled separately When the Enable Brake bit 1 is set to 0 the brake cannot be freely controlled it is automatically controlled by the bit s controlling the motor If the Enable Brake bit 1 is set to 1 the brake must be explicitly controlled using bit 0 even if an error occurs When the Brake bit 0 is set to 0 the brake switch is opened the brake takes effect and the motor is decelerated When the Brake bit 0 is set to 1 the brake switch is closed the brake is released and the motor is enabled If the Enable Brake bit 1 is reset to 0 after being set to 1 the brake is set according to the present state of the motor If the motor is on the brake is released If the motor is off the brake is enabled VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 Specifications for Motor Starter Brake Modules IC220ACC100 and IC220ACC101 GFK 2134 General Data depth Housing dimensions width x height x 57mm x 55mm x 16mm 2 24in x 2 17in x 0 63in Ambient temperature operation 25 C to 55 C 13 F to 131 F Ambient temperature storage transport 25 C to 85 C 13 F to 185 F Humidity
72. ximum Wiring Y capacitors Varistor 625V Motor Output for Module IC220STR002 Motor Starter module or the motor electronics WARNING Dangerous voltage Switch off the line voltage before working with the CAUTION Avoid a motor output short circuit which may damage the module Number of motor outputs One 3 phases Short circuit protection with external 16A fuse total range protection for semiconductor type gR Number of pins on output terminal strip X10 Four T1 T2 T3 Conductor cross section 1mm 18AWG minimum to 2 5mm 14 AWG maximum Degree of protection Protection against direct touch Motor power Wiring Varistor 460VAC Motor power ranges Motor voltage 400V Number of motor poles 4 0 18kW to 3 7kW 0 241 hp to 4 958 hp The selection of appropriate motors from 0 2A to 8 0A depends on the nominal motor current ranging VersaPoint I O System Motor Starter Modules User s Manual September 2005 GFK 2134 GFK 2134 Current range 0 2 Amp to 8 0 Amps The motor current is measured in the T1 phase Motor protection relay Inserted using a single phase current measurement in unconnected phase T1 Trip class According to Class 10A of IEC 60947 1990 Quick Shutdown Minutes Seconds 081 152 3 4 6 8 10 Multiples of the nominal current gt 20 3A after 300ms Typical Response Behavior Current 1

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