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Control Techniques COMMANDER S100 - User Manual

Control Techniques COMMANDER S100
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Step By Step Guide
COMMANDER S100
Part number: 0478-0644-01
Issue: 1
MARSHAL
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Summary

Important safety information

Enclosure

Drive must be mounted in an enclosure preventing unauthorized access and contamination.

Lifting and Handling

Use appropriate safeguards when lifting the drive. Refer to STEP 1 for weights.

Terminal Connections and Torque Settings

Loose power connections are a fire risk. Ensure terminals are tightened to specified torques.

General Warning

Unit uses high voltages and currents. Extreme care is necessary. Comply with safety legislation.

Isolation Device

Remove AC supply using an isolation device before servicing. Wait 10 minutes for capacitors to discharge.

Products Connected by Plug and Socket

Hazard exists if plug pins are accessible after unplugging. Implement automatic isolation.

Grounding; Earthing

Drive must be grounded by a conductor sufficient for prospective fault current. Adhere to ground connections.

Fuses

Install suitable overload protection. Integral protection does not provide branch circuit protection.

Over-current Protection

Drive has solid-state overload protection for the motor. Motor rated current must be entered correctly.

Isolation of Control Circuits

Control circuits have basic insulation. Ensure external circuits have adequate insulation or SELV barrier.

Setting Up, Commissioning and Maintenance

Changes to settings require careful consideration. Take precautions against inadvertent changes.

Safety of Machinery and Safety-Critical Applications

Drive control functions are not sufficient for safety-critical applications without additional protection.

Electromagnetic Compatibility (EMC)

Installer must ensure system complies with EMC legislation. Product designed to high EMC standards.

Repairs

Users must not attempt to repair a faulty drive. Return it to the supplier.

Introduction

STEP 1: Mount the drive

STEP 2: Wire the drive

Power Connections

Connect supply and motor using specified cables and fuses/MCBs. Single-phase supply to L1 and L2.

Ground Connections

Use 10 mm² or equivalent conductors for grounding. Ensure proper connection location and size.

Control Connections

Details default configurations for terminal connections including digital and analog I/O.

STEP 3: Run the Motor

Configure Drive Settings

Set minimum/maximum frequency, acceleration/deceleration rates, and motor nameplate details.

Ready to Run (Default Configurations Only)

Enable the drive with terminal 12 and provide a run signal via T13 or T14.

Made a Mistake?

Instructions for restoring factory defaults and troubleshooting drive errors.

Overview

The Commander S100 is a variable speed drive designed for professional integration into industrial equipment and systems. It facilitates precise control of mechanical plant, offering a range of features for mounting, wiring, programming, and motor operation. The drive is compatible with the Marshal mobile app, which provides additional setup, commissioning, diagnostics, and monitoring capabilities.

Function Description:

The Commander S100 serves as a variable speed drive (VSD) or variable frequency drive (VFD), controlling the speed and torque of AC motors by varying the frequency and voltage of the power supplied to them. It is designed to be incorporated into complete equipment or systems, providing efficient and precise motor control. The drive is equipped with both a physical keypad for direct parameter editing and NFC (Near Field Communication) for wireless data transfer, enabling quick setup and commissioning via a mobile app. It supports various input/output configurations for integration into control systems, including analog and digital I/O, as well as EIA 485 communications. The drive includes integral solid-state short circuit protection and thermal memory retention for motor overload protection.

Important Technical Specifications:

The Commander S100 is available in different frame sizes (1, 2, 3) with varying dimensions and weights.

  • Frame Size 1:
    • Overall Dimensions: 156 mm (6.14 in) H x 68 mm (2.70 in) W x 130 mm (5.12 in) D
    • Weight: 0.6 kg (1.2 lb)
    • Mounting Dimensions: 145 mm (5.71 in) H x 45 mm (1.77 in) W x 22 mm (0.89 in) D
    • Maximum Diameter (Ø): 4.8 mm (0.19 in)
  • Frame Size 2:
    • Overall Dimensions: 192 mm (7.56 in) H x 68 mm (2.70 in) W x 132 mm (5.20 in) D
    • Weight: 0.7 kg (1.5 lb)
    • Mounting Dimensions: 180 mm (7.11 in) H x 45 mm (1.77 in) W x 22 mm (0.89 in) D
    • Maximum Diameter (Ø): 4.8 mm (0.19 in)
  • Frame Size 3:
    • Overall Dimensions: 192 mm (7.56 in) H x 90 mm (3.54 in) W x 132 mm (5.20 in) D
    • Weight: 0.7 kg (1.5 lb)
    • Mounting Dimensions: 180 mm (7.11 in) H x 65 mm (2.56 in) W x 37 mm (1.48 in) D
    • Maximum Diameter (Ø): 4.8 mm (0.19 in)

The drive supports various input voltage ratings: 110 V, 230 V, and 400 V, with corresponding fuse/MCB selections and cable sizes (IEC 60364-5-52 mm² and UL 61800-5-1 AWG). For instance, a 110V single-phase S100-01113 model has a max input current of 7.19 A, requiring 10A IEC Class gG fuses or 15A UL Class CC, J or T fuses, and 1.5 mm² (24 AWG) input/output cables. A 400V three-phase S100-02413 model has a max input current of 1.92 A, requiring 4A IEC Class gG fuses or 15A UL Class CC, J or T fuses, and 1.5 mm² (24 AWG) input/output cables. The voltage rating of fuses and MCBs must be greater than or equal to the highest supply voltage of the system.

Terminal connections require specific torque settings: 0.5 Nm for power connections (0.6 Nm for 400V) and 1.5 Nm for ground connections across all voltage ratings. Control circuits are isolated from power circuits by basic insulation, requiring external control circuits to be insulated from human contact.

The operating ambient temperature range is 0 °C to 60 °C (32 °F to 140 °F). Derating is required for reduced clearances or ambient temperatures above 40 °C (104 °F).

Usage Features:

  • Mounting: The drive can be panel mounted with 0 mm space between units. A minimum clearance of 45 mm (1.77 in) is required above and below the drive, except for frame size 1 drives with power rating ≤0.55 kW, which require 100 mm (3.94 in) clearance. A drill template for wall mounting is included in the packaging.
  • Wiring: Power connections are made to L1, L2, L3 (for three-phase) or L1, L2 (for single-phase), and motor connections to U, V, W. Grounding is critical, with conductor sizes of either 10 mm² or two conductors of the same cross-sectional area as the input conductors. Control connections include:
    • +10 V Output (T1)
    • 4-20 mA Input (T2) for remote reference
    • 0 V (T3, T5)
    • 0-10 V Input (T4) for local reference
    • Analog Output (T6) for ramp output
    • +24 V Output (T9)
    • 0 V (T10)
    • No Default Function (T11)
    • Enable (T12)
    • Run Forward (T13)
    • Run Reverse (T14)
    • Reference Select (T15)
    • Relay Normally Open (T41)
    • Relay Common (T42)
    • Relay Normally Closed (T43) A 3 mm (1/8 in) flat-blade screwdriver is recommended for all terminals.
  • Programming and Operation:
    • FastStart via Marshal App: The recommended method for programming. The app allows for quick setup, commissioning, diagnostics, and monitoring.
    • Keypad Programming: Parameters can be edited directly using the drive's keypad. The keypad features:
      • Settings Key: Navigates through parameter settings and rotates displayed parameters when the drive is running.
      • Stop / Reset Key: Resets the drive if an error occurs and stops the drive if enable/run configuration is set appropriately.
      • UP / DOWN Keys: Individually increase or decrease editable values. When pressed together, they provide a latched RUN signal if configured.
      • Press and Hold (1s): Indicates a long press (1 second) for certain functions.
    • Default Workflow:
      1. Power-up: Ensure the drive is not enabled (display shows "inh").
      2. Enter Min/Max Frequency: Set P0.01 (Min Frequency Limit) and P0.02 (Max Frequency Limit).
      3. Acceleration/Deceleration Rates: Define ramp times using P0.03 (Acceleration Rate 1) and P0.04 (Deceleration Rate 1).
      4. Motor Nameplate Details: Input motor rated current (P0.06), speed (P0.07), voltage (P0.08), and power factor (P0.09).
      5. Run: Enable the drive with T12, then provide a run signal with T13 (Run Forward) or T14 (Run Reverse).
      6. Speed Adjustment: Increase/decrease current to Analog Input 1 (T2) or switch reference via Digital Input 5 (T15).
      7. Stopping: Remove T13 or T14 signal to stop the motor. Removing T12 immediately disables the output, causing the motor to coast to a stop.
  • Safety Features: The drive incorporates solid-state overload protection for the motor. Protection levels can be adjusted, and thermal memory retention is included.

Maintenance Features:

  • Troubleshooting: If a fault is detected, the drive displays an error code. All error codes and resolutions are available in the Marshal app or the Commander S100 User Guide.
  • Restore Factory Defaults: If a mistake is made, defaults can be restored by ensuring the drive is not enabled, setting P4.01 to 1 (for 50 Hz defaults) or 2 (for 60 Hz defaults), and then pressing/holding the settings key to exit.
  • Repairs: Users should not attempt to repair a faulty drive; it must be returned to the supplier.
  • Safety Information: Regular inspection and testing of ground connections are required. The equipment should be examined and replaced if damaged. If an overload relay burns out, the complete relay must be replaced.

Safety Considerations:

The Commander S100 operates with high voltages and currents, storing significant electrical energy. Installation, commissioning, and maintenance must be performed by trained and authorized personnel. An approved isolation device must be used to remove AC supply before servicing, and a minimum of 10 minutes must be allowed for capacitors to discharge. For products connected by plug and socket, a means for automatic isolation of the plug from the drive is necessary to prevent electric shock. The drive must be grounded by a conductor sufficient to carry the prospective fault current. Branch circuit protection must be provided in accordance with relevant electrical codes (NEC, Canadian Electrical Code, etc.). The drive is designed for use in an enclosure in an environment classified as pollution degree 2 (dry, non-conducting contamination). The control functions are not sufficient for safety-critical applications without additional independent channels of protection, and a risk assessment is required for such uses. The product complies with EMC legislation (e.g., Electromagnetic Compatibility Directive 2014/30/EU).

Control Techniques COMMANDER S100 Specifications

General IconGeneral
BrandControl Techniques
ModelCOMMANDER S100
CategoryDC Drives
LanguageEnglish

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