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Emerson Affinity User Manual
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Safety
Information
Product
Information
Mechanical
Installation
Electrical
Installation
Getting
Sta
r
t
e
d
Basic
parameters
Running
the motor
Optimization
SMARTCARD
operation
PC tools
Advanced
parameters
T
echnic
al
Data
Diagnostics
UL Listing
Information
172
Affinity User Guide
www.controltechniques.com
Issue Number: 5
Figure 1
1-
13
Men
u 9 logic diagram: Motorized pot
and binary sum
9.30
Binary-sum
logic twos
9.29
Binary-sum
logic ones (LSB)
9.31
Binary-sum
logic fours (MSB)
9.32
Binary-sum
logic output
value
??.??
Any
unprotected
bit
parameter
??.??
9.33
Binary-sum
logic
destination
parameter
Σ
9.24
Motorized
pot.
output scale
9.25
Motorized
pot.
destination
parameter
9.23
Motorized
pot. rate
??.??
Any
unprotected
variable
parameter
??.??
9.27
Motorized pot.
down
9.26
Motorized pot.
up
M
9.03
Motorized pot.
output
indicato
r
9.22
Motorized
pot. bipolar
select
9.21
9.28
Motorized pot.
reset to zero
Motorized pot.
mode
+
+
9.34
Binary-su
m
offset
0.XX
0.XX
Key
Read-write
(RW)
parameter
Read-only (RO
)
parameter
Input
terminals
Output
terminals
The parameters are all shown at
their default settings
Function disabled if set
to a non valid destinatio
n
Function disabled if set
to a non valid destination
171
173
Table of Contents
Default Chapter
3
Table of Contents
3
1 Safety Information
7
Warnings, Cautions and Notes
7
Electrical Safety - General Warning
7
System Design and Safety of Personnel
7
Environmental Limits
7
Access
7
Fire Protection
7
Compliance with Regulations
7
Motor
7
Mechanical Brake Control
7
Electrical Installation
8
2 Product Information
9
Introduction
9
Drive Types
10
Ratings
10
Table 2-1 200V Drive Ratings (200V to 240V ±10%)
11
Table 2-2 400V Drive Ratings (380V to 480V ±10%)
12
Table 2-3 575V Drive Ratings (500V to 575V ±10%)
13
Table 2-4 690V Drive Ratings (500V to 690V ±10%)
13
Model Number
14
Operating Modes
14
Table 2-5 Typical Overload Limits for Size 1 to 6
14
Drive Features
15
Nameplate Description
16
Options
17
Table 2-6 Solutions Module Identification
17
Items Supplied with the Drive
19
Table 2-7 Parts Supplied with the Drive
19
3 Mechanical Installation
20
Safety Information
20
Planning the Installation
20
Terminal Cover Removal
22
Table 3-1 Conduit Box Part Numbers
26
Solutions Module / Keypad Installation / Removal
29
Mounting Methods
31
Table 3-2 Mounting Brackets (Standard)
41
Table 3-3 E12/E54 Mounting Clearances
41
Table 3-4 E12/E54 Mounting Brackets
46
Enclosure for Standard Drives
48
Enclosure Design and Drive Ambient Temperature
49
Enclosing Standard Drive for High Environmental Protection
50
Table 3-5 Description of Fixings
52
Table 3-6 Quantity of Nylon Washers Supplied with the Table 11-7 Drive
52
Table 3-7 Environment Considerations
53
Table 3-8 Power Losses from the Front of the Drive When Through-Panel Mounted
53
External EMC Filter for Standard Drives
54
Table 3-9 Drive EMC Filter Details (Size 1 to 6)
54
Electrical Terminals
62
Table 3-10 Drive Control and Relay Terminal Data
62
Table 3-11 Wall Mounted Drive Power Terminal Data
62
Table 3-12 Plug-In Terminal Block Maximum Cable Sizes
62
Table 3-13 Schaffner External EMC Filter Terminal Data (Size 1 to 6)
62
Table 3-14 Epcos External EMC Filter Terminal Data
62
Routine Maintenance
63
4 Electrical Installation
66
Power Connections
66
AC Supply Requirements
69
Auxiliary Power Supply
70
Table 4-1 Behavior of the Drive in the Event of a Motor Circuit Ground (Earth) Fault with an IT Supply
70
Supplying the Drive with DC / DC Bus Paralleling
71
Fan Connections
71
Control 24Vdc Supply
71
Ratings
71
Table 4-3 Size 1 to 3 Input Current, Fuse and Cable Size Ratings (European)
72
Table 4-5 Size 4 and Larger Input Current, Fuse and Cable Size Ratings
73
Output Circuit and Motor Protection
74
Table 4-6 Maximum Motor Cable Lengths (200V Drives)
74
Table 4-7 Maximum Motor Cable Lengths (400V Drives)
74
Table 4-8 Maximum Motor Cable Lengths (575V Drives)
74
Table 4-9 Maximum Motor Cable Lengths (690V Drives)
74
Braking
76
Table 4-10 Braking Transistor Turn on Voltage
76
Table 4-11 Heatsink Mounted Braking Resistor Data
76
Table
77
Ground Leakage
78
EMC (Electromagnetic Compatibility)
78
Table 4-13 Affinity EMC Filter Cross Reference
79
Table 4-14 IP54 EMC Filter Cross Reference
79
Figure 4-19 Size 4 and 5 Grounding Link Bracket Folded up into Its Through- Panel Mount Position
80
Figure 4-20 Removal of Internal EMC Filter (Size 1 to 3)
81
Figure 4-21 Removal of Internal EMC Filter (Sizes 4 to 6)
81
Figure 4-22 General EMC Enclosure Layout Showing Ground Connections
82
Figure 4-23 Drive Cable Clearances
83
Table 4-15 Second Environment Emission Compliance
83
Figure 4-24 Supply and Ground Cable Clearance (Size 1 to 3)
84
Figure 4-25 Supply and Ground Cable Clearance (Size 4 to 6)
84
Figure 4-26 Sensitive Signal Circuit Clearance
85
Figure 4-27 Grounding the Drive, Motor Cable Shield and Filter
85
Figure 4-28 Grounding the Motor Cable Shield
85
Figure 4-29 Shielding Requirements of Optional External Braking Resistor
85
Figure 4-30 Grounding of Signal Cable Shields Using the Grounding Bracket
86
Figure 4-31 Connecting the Motor Cable to a Terminal Block in the Enclosure
86
Figure 4-32 Connecting the Motor Cable to an Isolator / Disconnect Switch
86
PC Communications Connections
87
Figure 4-33 Surge Suppression for Digital and Unipolar Inputs and Outputs
87
Figure 4-34 Surge Suppression for Analog and Bipolar Inputs and Outputs
87
Figure 4-35 Location of the RJ45 Serial Comms
87
Table 4-16 Connection Details for RJ45 Connector
87
Terminal Connections
88
Figure 4-36 Location of RJ45 Serial Connector
88
Figure 4-37 Connector with Cap Installed
88
Table 4-17 Isolated Serial Comms Lead Details
88
Table 4-18 the Terminal Connections Consist of
88
Figure 4-38 Default Terminal Functions
89
Building Automation Network Connections
92
Heatsink Fan Supply Connections (Size 4 to 6)
92
Figure 4-39 Multi-Drop Connection
92
5 Getting Started
93
Understanding the Display
93
Keypad Operation
93
Figure 5-1 BA-Keypad
93
Menu Structure
94
Figure 5-2 Display Modes
94
Figure 5-3 Mode Examples
94
Figure 5-4 Parameter Navigation
94
Menu 0
95
Advanced Menus
95
Figure 5-5 Menu Structure
95
Figure 5-6 Menu 0 Copying
95
Table 5-2 Menu 40 Parameter Descriptions
95
Table 5-1 Advanced Menu Descriptions
95
Table 5-3 Menu 41 Parameter Descriptions
96
Table 5-4 Alarm Indications
96
Table 5-5 Status Indications
96
Table 5-6 Solutions Module and SMARTCARD Status Indications on Power-Up
96
Changing the Operating Mode
97
Changing the Keypad Mode
97
Saving Parameters
97
Restoring Parameter Defaults
97
Parameter Access Level and Security
97
Displaying Parameters with Non-Default Values Only
99
Displaying Destination Parameters Only
99
Communications
99
Table 5-7 Increased Object Identifier Range Setup
100
6 Basic Parameters
102
Single Line Descriptions
102
Table 6-1 Single Line Descriptions
102
Figure 6-1 Menu 0 Logic Diagram
104
Full Descriptions
106
Figure 6-2 Fixed and Variable V/F Characteristics
107
7 Running the Motor
115
Quick Start Connections
115
Changing the Operating Mode
115
Changing Keypad Mode
115
Table 7-1 Minimum Control Connection Requirements for each Control Mode
115
Figure 7-1 Minimum Connections to Get the Motor Running in any Operating Mode
116
Quick Start Commissioning/Start-Up
118
Motor Map Parameters
121
Current Limits
127
Motor Thermal Protection
127
Figure 8-1 Motor Thermal Protection
127
Switching Frequency
128
High Speed Operation
128
Figure 8-2 Torque and Rated Voltage against Speed
128
Table 8-1 Available Switching Frequencies
128
Table 8-2 Sample Rates for Various Control Tasks at each Switching Frequency
128
9 SMARTCARD Operation
129
Introduction
129
Figure 9-1 Installation of the SMARTCARD
129
Figure 9-2 Basic SMARTCARD Operation
129
Transferring Data
130
Data Block Header Information
131
SMARTCARD Parameters
132
SMARTCARD Trips
133
Ctsoft
135
Onboard PLC and Syptlite
135
Figure 10-1 Onboard PLC Program Scheduling
136
CT Energy Savings Estimator
137
11 Advanced Parameters
139
Menu 1: Frequency / Speed Reference
146
Figure 11-1 Menu 1 Logic Diagram
146
Menu 2: Ramps
150
Figure 11-2 Menu 2 Logic Diagram
150
Menu 3: Speed Feedback and Speed Control
153
Figure 11-3 Menu 3 Open-Loop Logic Diagram
153
Figure 11-4 Menu 3 RFC Logic Diagram
154
Menu 4: Torque and Current Control
156
Figure 11-5 Menu 4 Open Loop Logic Diagram
156
Figure 11-6 Menu 4 RFC Logic Diagram
157
Menu 5: Motor Control
159
Figure 11-7 Menu 5 Open-Loop Logic Diagram
159
Figure 11-8 Menu 5 RFC Logic Diagram
160
Menu 6: Sequencer and Clock
163
Figure 11-9 Menu 6 Logic Diagram
163
Menu 7: Analog I/O
165
Figure 11-10 Menu 7 Logic Diagram
165
Menu 8: Digital I/O
168
Figure 11-11 Menu 8 Logic Diagram
168
Menu 9: Programmable Logic, Motorized Pot, Binary Sum and Timers
171
Figure 11-12 Menu 9 Logic Diagram: Programmable Logic
171
Figure 11-13 Menu 9 Logic Diagram: Motorized Pot and Binary Sum
172
Figure 11-14 Menu 9 Logic Diagram: Timers
173
Menu 10: Status and Trips
175
Menu 11: General Drive Set-Up
177
Menu 12: Threshold Detectors, Variable Selectors and Brake Control Function
178
Figure 11-15 Menu 12 Logic Diagram
178
Figure 11-16 Menu 12 Logic Diagram (Continued)
179
Figure 11-17 Open-Loop Brake Function
180
Figure 11-18 Open-Loop Brake Sequence
181
Figure 11-19 RFC Brake Function
182
Figure 11-20 RFC Brake Sequence
183
Menu 14: User PID Controller
186
Figure 11-21 Menu 14 Logic Diagram - Single Setpoint, Single Feedback
186
Figure 11-22 Menu 14 Logic Diagram - Single Setpoint, Dual Feedback
188
Figure 11-23 Menu 14 Logic Diagram - Dual Setpoint, Dual Feedback
190
Menus 15 and 16: Solutions Module Set-Up
193
Figure 11-24 Location of Solutions Module Slots and Their Corresponding Menu Numbers
193
Figure 11-25 SM-I/O Plus Analog Logic Diagram
194
Figure 11-26 SM-I/O Plus Digital Logic Diagram 1
195
Figure 11-27 SM-I/O Plus Digital Logic Diagram 2
196
Figure 11-28 SM-I/O Lite Digital I/O Logic Diagram
198
Figure 11-29 SM-I/O Lite Analog I/O Logic Diagram
199
Figure 11-30 SM-I/O PELV Digital I/O Logic Diagram
201
Figure 11-31 SM-I/O PELV Digital Input Logic Diagram
202
Figure 11-32 SM-I/O PELV Relay Logic Diagram
202
Figure 11-33 SM-I/O PELV Analog Input Logic Diagram
202
Figure 11-34 SM-I/O PELV Analog Output Logic Diagram
203
Figure 11-35 SM-I/O 24V Protected Digital I/O Logic Diagram
206
Figure 11-36 SM-I/O 24V Protected Digital I/O Logic Diagram
206
Figure 11-37 SM-I/O 24V Protected Relay Logic Diagram
206
Figure 11-38 SM-I/O 24V Protected Analog Output Logic Diagram
207
Figure 11-39 SM-I/O 120V Digital Input Logic Diagram
208
Figure 11-40 SM-I/O 120V Relay Diagram
209
Figure 11-41 SM-I/O 32 Logic Diagram
210
Menu 17: Building Automation Network
212
Menu 18: Application Menu 1
212
Menu 19: Application Menu 2
212
Menu 20: Application Menu 3
212
Menu 21: Second Motor Parameters
213
Menu 22: Additional Menu 0 Set-Up
214
Advanced Features
215
Table 11-10 Power-Up Modes if Pr 1.52 = 3
216
Table 11-11 Increased Object Identifier Range Setup
226
12 Technical Data
228
Drive Technical Data
228
Table 12-10 Losses @ 40°C (104°F) Ambient for Size
235
Table 12-11 Losses @ 50°C (122°F) Ambient for Standard Size 1 to 6, Size 1 to 3 E12/E54 and Size 1 to 3 E12/E66 Drives
236
Table 12-12 Losses @ 35°C (95°F) Ambient for Size 4 to 6 E12/54 Drives
237
Table 12-13 Losses @ 40°C (104°F) Ambient for Size 4 to 6 E12/54 Drives
237
Table 12-14 Losses @ 45°C (113°F) Ambient for Size 4 to 6 E12/54 Drives
238
Table 12-15 Power Losses from the Front of the Drive When Through-Panel Mounted
238
Table 12-16 IP Rating Degrees of Protection
239
Table 12-17 UL / NEMA Enclosure Ratings
239
Table 12-18 Acoustic Noise Data for Wall Mounted Drives
240
Table 12-19 Overall Standard Drive Dimensions
240
Table 12-20 Overall Wall Mounted Standard Drive Dimensions with Conduit Box Installed
240
Table 12-21 Overall E12/E54 and E12/E66 Drive
240
Table 12-22 Overall Drive Weights
241
Table 12-23 Overall E12/E54 Drive Weights
241
Table 12-24 Supply Fault Current Used to Calculate Maximum Input Currents
241
Table 12-25 Size 1 to 3 Input Current, Fuse and Cable
241
Table 12-26 Size 4 and Larger Input Current, Fuse and Cable Size Ratings
242
Table 12-27 Maximum Motor Cable Lengths (200V Drives)
243
Table 12-28 Maximum Motor Cable Lengths (400V Drives)
243
Table 12-29 Maximum Motor Cable Lengths (575V Drives)
243
Table 12-30 Maximum Motor Cable Lengths (690V Drives)
243
Table 12-31 Minimum Resistance Values and Peak Power Rating for the Braking Resistor at 40°C (104°F)
244
Table 12-32 Drive Control and Relay Terminal Data
244
Table 12-33 Drive Power Terminal Data
244
Table 12-34 Wall Mounted Drive Power Terminal Data
244
Table 12-35 Plug-In Terminal Block Maximum Cable Sizes
244
Table 12-36 Immunity Compliance
245
Table 12-37 Size 1 Emission Compliance
245
Table 12-38 Size 2 Emission Compliance
245
Table 12-39 Size 3 Emission Compliance
245
Table 12-40 Size 4 (200V & 400V) Emission Compliance
245
Optional External EMC Filters
246
Table 12-41 Size 4 (690V) Emission Compliance
246
Table 12-42 Size 5 (400V) Emission Compliance
246
Table 12-43 Size 5 (690V) Emission Compliance
246
Table 12-44 Size 6 (400V Only) Emission Compliance
246
Table 12-45 Size 6 (690V Only) Emission Compliance
246
Table 12-46 EMC Filter Cross Reference
246
Table 12-47 IP54 EMC Filter Cross Reference
246
Table 12-48 Optional External EMC Filter Details
247
Trip Indications
250
Figure 13-1 Keypad Status Modes
250
Figure 13-2 Location of the Status LED
250
Table 13-1 Example of Typical Trip Indication
250
Table 13-2 Trip Indications
251
Table 13-3 Serial Communications Look-Up Table
260
Table 13-4 Trip Categories
261
Alarm Indications
262
Status Indications
262
Table 13-5 Alarm Indications
262
Table 13-6 Status Indications
262
Table 13-7 Solutions Module and SMARTCARD Status Indications at Power-Up
262
Displaying the Trip History
263
Behavior of the Drive When Tripped
263
Table 13-8 Trip Log Definition
263
14 UL Listing Information
264
Common UL Information
264
Power Dependant UL Information
264
AC Supply Specification
264
Maximum Continuous Output Current
264
Table 14-1 Maximum Continuous Output Current (200V Drives)
264
Safety Label
265
UL Listed Accessories
265
Table 14-2 Maximum Continuous Output Current (400V Drives)
265
Table 14-3 Maximum Continuous Output Current (575V Drives)
265
Table 14-4 Maximum Continuous Output Current (690V Drives)
265
List of Figures
266
List of Tables
268
4
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Emerson Affinity Specifications
General
Brand
Emerson
Model
Affinity
Category
Controller
Language
English
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