Zener MSC-3 User Manual

MSC-3
Instruction Manual
INVENTIVE TECHNOLOGY
DSP-II

Zener MSC-3 Specifications

General

Brand	Zener
Model	MSC-3
Category	Controller
Language	English

Summary

Safety Information

Zener Technology and Quality Assurance

Details Zener's history, experience, and quality assurance for MSC-3 drives.

General Safety Guidelines

Emphasizes safe application, installation, and operation, highlighting user responsibility and skilled personnel.

Zener Drive Applications and Enclosures

Drive Applications

Describes suitability for Variable and Constant Torque Loads, highlighting key drive features.

Enclosure Options

Presents different enclosure types (IP30, IP54, IP66) for various environmental conditions.

MSC-3 Options and Accessories

Supply Voltage Options

Details available supply voltage and phase configurations for the MSC-3 series.

DC Bus Choke

Explains benefits of DC Bus Choke for reducing harmonics and improving power factor.

Remote Display Panel

Describes the remote display kit for accessing programming and controls.

Option Boards

Introduces expansion slots for option boards like Power Supply Card and Extended Features.

Understanding Symbols and Warnings

Explanation of Symbols

Explains the meaning of various warning, caution, and informational symbols used throughout the manual.

Critical Warnings

Provides safety warnings regarding mounting, electrical noise, emergency stops, and automatic restart.

Installation Procedures

Mounting Location and Precautions

Discusses mounting considerations, environmental factors, and installation cautions.

DC Bus Choke Installation

Explains the benefits and installation of the optional DC bus choke.

Mechanical Installation Details

Chassis A Mechanical Information

Provides diagrams and dimensions for mechanical installation of MSC-3 Chassis A models.

Chassis B Mechanical Installation

Chassis B Dimensions and Weights

Shows mechanical dimensions and weights for MSC-3 Chassis B, with and without choke.

Chassis C Mechanical Installation

Chassis C Dimensions and Weights

Lists mechanical dimensions and weights for MSC-3 Chassis C, with and without choke.

Chassis D Mechanical Installation

Chassis D Dimensions and Weights

Shows mechanical dimensions and weights for MSC-3 Chassis D models.

3-Phase Power Wiring

Basic Power Wiring Diagram

Illustrates the fundamental power wiring connections for a 3-phase supply.

Supply Circuit Protection

Details requirements for fuses, circuit breakers, and switchgear for proper supply circuit protection.

Cable Size Selection

Provides guidance on selecting appropriate cable sizes based on local rules and terminal types.

Electrical Isolation Requirements

Explains the necessity of electrical isolation and proper marking for dual supply arrangements.

Fuse and Motor Protection

Fuse/Breaker Ratings

Lists recommended fuse or circuit breaker ratings and UL class fuses for MSC-3 models.

Motor Thermal Protection

Describes the electronic thermal overload function and need for external motor protection.

Single-Phase Power Wiring

Single-Phase Supply Diagram

Shows the power wiring diagram for single-phase operation of the MSC-3.

Single-Phase Operation Constraints

Details voltage limits, motor type, fuses, DC choke, and current rating for single-phase use.

MSC-3 with DC Supply

DC Supply Considerations

Discusses considerations for using MSC-3 with DC supply, advising factory consultation.

EMC Compliance Practices

EMC Installation Practices

Details requirements for EMC compliant installation, including screened cable and termination.

Wiring Materials for EMC

Categorizes wiring materials by EMC properties, emphasizing reputable manufacturers.

EMC Installation Diagrams

Chassis A (3-11Amp) IP30 EMC

Shows wiring diagram for EMC compliant installation of Chassis A (3-11Amp) IP30.

Chassis A IP66 EMC Installation

EMC Wiring for Chassis A IP66

Shows the wiring diagram for EMC compliant installation of Chassis A (3-11Amp) IP66.

Chassis B EMC Installation

EMC Wiring for Chassis B

Shows the wiring diagram for EMC compliant installation of Chassis B (15-14Amp).

Chassis C EMC Installation

EMC Wiring for Chassis C

Shows the wiring diagram for EMC compliant installation of Chassis C (55 - 170Amp).

Chassis D EMC Installation

EMC Wiring for Chassis D

Shows the wiring diagram for EMC compliant installation of Chassis D (175 - 490Amps).

Control Connections and Configuration

General Configuration Overview

Explains parameter selection for application-specific functions.

Factory Default Settings

Describes the factory default terminal configuration and parameter settings.

Application-Specific Settings

Details how analogue inputs, digital inputs, and relays can be individually assigned.

Quick Setup Guides

Guides users to application-specific setup pages for quick configuration.

Terminal Configuration Examples

Terminal Config 1: Industrial Applications

Shows factory default configuration for single direction control and local/remote operation.

Quick Setup for Terminal Config 1

Control Methods

Illustrates wiring for push button or switch control, and power-up start.

Local/Remote Selection

Explains wiring for local/remote selection and console override.

Speed Reference Configuration

External Potentiometer Control

Explains using an external potentiometer for manual speed control.

External Signal Control

Details configuring analogue inputs for external speed signals (mA or voltage).

Preset Speed Setting

Describes how to set a single fixed speed using presets.

Console Speed Control

Explains using the console's up/down buttons for speed control.

Application: Water Pumping Pressure Control

Procedure Steps

Outlines steps for setup: power wiring, control wiring, and transducer signal connection.

Quick Setup for Terminal Config 4

Configuration Features

Describes forward/reverse operation, pushbuttons, and local/remote selection.

Setup Procedure

Outlines the steps for setting up Terminal Config 4.

Local/Remote Selection Wiring

Explains wiring for local/remote selection and console override.

Speed Reference Selection

External Potentiometer Speed Control

Details using an external potentiometer for manual speed control.

External Signal Speed Control

Explains configuring analogue inputs for external speed signals.

Preset Speed Configuration

Describes setting a single fixed speed using presets.

Console Speed Control

Explains using console buttons for speed control.

Application: Machine Drive Jog Control

Setup Procedure

Outlines steps for setting up machine drive with jog control and local/remote selection.

REMOTE Mode Note

Clarifies that the I11 REMOTE function forces operation into REMOTE mode.

HVAC Terminal Configuration (Config 3)

General HVAC Setup

Explains configuration for HVAC pump/fan drives controlled by BMS.

Essential Services Override (ESO)

Explains the Essential Services Override feature and its use in HVAC applications.

Local vs. Remote Control

Describes local control via console and remote control via terminal strip.

Quick Setup for Config 3: HVAC Fans

Configuration Features

Lists features for Config 3: forward operation, local/remote, and ESO.

Setup Procedure

Outlines the steps for setting up Config 3.

Essential Services Override (ESO) Details

Provides details on the Essential Services Override feature.

Local/Remote Selection Wiring

Explains wiring for local/remote selection and console override.

Application: HVAC Supply Air/Smoke Spill Fan

Procedure Steps

Outlines steps for setup: power wiring, control wiring, and parameter configuration.

Application: HVAC Return Air Fan

Procedure Steps

Outlines steps for setup: power wiring, control/signal wiring, and parameter configuration.

Application: Stair Pressurisation Fan (Internal PID)

Procedure Steps

Outlines steps for setup: power wiring, control wiring, and transducer signal wiring.

Essential Services Override (ESO)

Provides details on the Essential Services Override feature.

Application: Stair Pressurisation Fan (External PID)

Procedure Steps

Outlines steps for setup: power wiring, control wiring, and PID controller signal wiring.

Essential Services Override (ESO)

Provides details on the Essential Services Override feature.

Application: Cooling Tower Fan (Internal PID)

Procedure Steps

Outlines steps for setup: power wiring, control wiring, and transducer signal wiring.

Communications Wiring

EIA/RS-485 Best Practices

Details recommended practices for EIA/RS-485 wiring, emphasizing 3 conductors and a shield.

Terminating Resistors

Explains the use and value of terminating resistors for EIA/RS-485 networks.

EIA/RS-485 Network Setup

Typical Wiring Arrangement

Illustrates a typical wiring arrangement for EIA/RS-485 networks.

General Wiring Guidelines

Provides general guidelines for EIA/RS-485 cabling and network setup.

Extended Features Option Wiring

Analogue Output Configuration

Details the single analogue output feature on extended cards for feedback signals.

MSC-3 Start Up Procedure

Initial Power Up Steps

Provides initial steps for starting up the MSC-3, including wiring and basic parameter checks.

Drive Displays and Navigation

Run Display Information

Explains the Run Display, showing speed reference and drive status.

Meter Display Functions

Describes the Meter Display, showing output values like current, power, and speed.

Menu System Navigation

Explains how to access and navigate the MSC-3 menu system.

Key MSC-3 Features

Motor Speed Ramp Configuration

Details the programmable motor speed ramp with acceleration, deceleration, and S-curve rates.

Dual Ramps Feature

Explains the dual rate acceleration and deceleration for minimum speed applications.

Essential Services Override (ESO)

Details the ESO mode for disabling protective features during critical operations.

Operational Modes and Controls

Essential Services Override Warnings

Warns about the 'run to destruction' nature of ESO and potential hazards.

Minimum Speed Idle Function

Describes function stopping operation if minimum speed is held for a set interval.

Line Contactor Start Control

Explains configuring MSC-3 to control an external line contactor for mains power.

Reference Selection Configuration

Reference Selector Function

Explains multiplexor using digital inputs to select reference sources.

User Reference Inputs

Details customisable inputs (User REF 1 & 2) for the reference selector.

Analogue Input Configuration

Analogue Inputs and Spanning

Describes configurable voltage/current analogue inputs and spanning features.

Extended Features Option Cards

Analogue Output Functionality

Details the single analogue output feature on extended cards for feedback signals.

PID Controller Setup and Tuning

PID Controller Overview

Explains PID controller function, parameters, and application examples.

PID Setup Checklist

Provides a checklist for PID setup, wiring, and tuning.

PID Tuning Steps

Details PID tuning steps, including PV verification and loop closing.

PID Application Examples

Stair Pressurisation Fan (Internal PID)

Details setup for stair pressurisation fans using internal PID and ESO mode.

Cooling Tower Fan (Reverse PID)

Details setup for cooling tower fans using reverse acting PID.

Water Pumping (Pressure Control)

Details setup for centrifugal pump applications using PID control.

Communication Interfaces

EIA/RS-485 Communication Indicators

Explains the visual indicators for EIA/RS-485 communication status.

BACnet MS/TP Protocol

Details the MSC-3 BACnet interface, supported services, and data link layer.

MAC ID and Device Object Instance

Explains setting the MAC ID and Device Object Instance for BACnet.

BACnet Setup and Operation

Local and Remote Modes

Explains control modes and reference selection for BACnet operation.

Essential Services Operation (ESO)

Explains ESO mode selection from all sources is honoured.

BACnet Quick Setup Guide

Provides a quick setup guide for BACnet configuration.

MODBUS Protocol Setup

MODBUS Setup and Operation

Details Modbus setup and operation, including local/remote modes and network settings.

MODBUS Quick Setup Guide

Provides a quick setup guide for Modbus configuration.

Parameter Defaults and Menu Lock

A00 Defaults Menu Options

Allows saving/loading parameters, defaults, and uploading/downloading configurations.

A01 Menu Lock Configuration

Protects menu mode and settings with a code entry system.

Display Configuration

A02 Default Display Selection

Allows selection of the default display mode (SPEED-REF, METER, PID, etc.).

Meter Display Details

Describes the Meter Display, showing output values like current, power, and speed.

A03 Run Display Settings

Menu for configuring Run Display format, scaling, and units.

Run Display Formatting

A030 Run Display Format

Sets the numerical format for the run display.

A031 Run Display Scale

Sets the scale for the run display values.

A032 Run Display Units

Allows selection of units to be displayed for the run display.

Parameter Default Management

Loading Factory Defaults

Restores factory default parameters, requiring LOCAL mode and stopped motor.

Loading Custom Defaults

Allows reinstalling custom default parameters, requiring LOCAL mode and stopped motor.

Configuration Management

Saving Custom Defaults

Saves current parameters as 'Custom Defaults' for future reference.

Upload/Download Connection

Facilitates configuration and software updates via computer connection.

B00 MOTOR Menu

Menu for entering motor nameplate information (volts, amps, Hz, RPM).

Motor Performance Parameters

C00 Performance Menu

Menu for setting motor characteristics: speed, ramps, compensation.

Minimum Frequency (C01)

Sets minimum output frequency, including minimum speed idle function.

Speed and Ramp Configuration

Minimum and Maximum Frequency

Sets minimum (C010 MIN Hz) and maximum (C02 MAX Hz) operating frequencies.

Idle Delay and Resume Speed

Sets idle delay (C011) and resume speed (C012) for minimum speed idle function.

Ramp and Flux Control

Ramp Time Settings (C03)

Configures acceleration (C030), deceleration (C031), and S-curve (C032) times.

Flux Plus Control (C04)

Utilizes flux vector control to enhance motor torque and performance.

Protection Features Menu

Slip Compensation (C05)

Compensates for motor slip to maintain constant shaft speed under varying loads.

Audible Frequency (C06)

Sets PWM frequency, affecting motor noise and switching losses.

D00 Protection Menu Overview

Contains parameters for motor and system protective features.

Current Limit and I2t Protection

Current Limit (D01)

Sets the maximum output current to prevent motor overload.

I2t Thermal Overload (D02)

Estimates motor heating based on load, tripping on I2t setting.

Motor Operation Settings

Reverse Operation (D03)

Enables or disables reverse motor operation.

DC Input Operation (D04)

Allows operation from a DC input supply, requiring specific voltage levels.

Single-Phase Input (D05)

Allows operation from a single-phase electrical supply.

Skip Speed Function (D06)

Allows drive to avoid operation within specific speed ranges causing instability.

Stop/Start Modes

Stopping Modes

Sets motor stopping modes: Coast Stop (E01) and Dynamic Brake (E02).

Auto Restart Function (E03)

Allows automatic restart attempts after a trip occurs.

Reference Selection Menu

F01 Remote Reference

Selects speed reference source for remote operation.

F02 Local Reference

Selects speed reference source for local operation.

F03 ESO Reference

Selects speed reference for Essential Services Override (ESO) mode.

F04 Jog Forward & F05 Jog Reverse

Selects speed reference for Jog Forward and Jog Reverse modes.

Console Configuration

F08 Console Configuration

Configures console reference operation modes (power-on reset, stop reset, persistent).

Preset Speed and Communication Settings

F09 Comms Preset

Sets power-on value for COMMS REF reference, used when communications are lost.

F10 Presets

Defines 8 preset speed references, often used with the Reference Selector.

Input/Output Configuration

G00 Input/Output Menu

Main menu for configuring all terminal strip inputs and outputs.

G01 Input Function Configuration

Maps physical digital inputs to internal input functions with selectable logic levels.

Digital Input Functions

Forward and Latch (I00)

Configures digital input for forward start and latching operation.

Reverse and Latch (I01)

Configures digital input for reverse start and latching operation.

Stop Input (I02)

Configures digital input for stopping the motor and clearing latched inputs.

Forward Run Input (I03)

Configures digital input for non-latching forward motor run.

Additional Digital Input Functions

Reverse Run Input (I04)

Configures digital input for non-latching reverse motor run.

Up/Down Speed Inputs (I05/I06)

Configures digital inputs to adjust console reference speed.

Reset Input (I07)

Configures digital input to reset trip conditions.

Specialized Digital Inputs

Essential Services Override (I08)

Configures digital input to enable Essential Services Override (ESO) mode.

Jog Inputs (I09/I10)

Configures digital inputs for Jog Forward and Jog Reverse operations.

Remote Mode Input (I11)

Configures digital input for selecting Remote mode operation.

External Signal Inputs

External Alarm Input (I12)

Configures digital input for external alarm, registering a trip.

External Warning Input (I13)

Configures digital input for external warning, displaying a status message.

Timer Control Inputs (I14/I15)

Configures digital inputs to activate or deactivate timers.

Analogue Input Configuration (G02)

Selector Inputs (I16-I18)

Digital inputs used in combination for the reference selector function.

Analogue Input Type Selection

Selects the input type for the analogue input (Volts or mAmps).

Minimum Input Value (G021)

Sets the minimum input value for analogue input spanning.

Analogue Input Spanning Settings

Maximum Input Value (G022)

Sets the maximum input value for analogue input spanning.

Reference Min/Max Settings (G023/G024)

Defines minimum and maximum references for input spanning.

Analogue Input Compare Levels

High Compare Level (G025)

Sets the high level threshold for analogue input compare output.

Low Compare Level (G026)

Sets the low level threshold for analogue input compare output.

Relay Output Configuration (G03)

Relay Output Functions

Lists available functions that can be assigned to relay outputs.

Relay 1 Signal Selection (G030)

Selects the output function for Relay #1.

Relay 1 Timing and Sense

Relay 1 Sense (G031)

Selects direct or inverted operation for Relay #1.

Relay 1 On-Delay (G032)

Sets the on-delay for Relay #1.

Relay 1 Off-Delay (G033)

Sets the off-delay for Relay #1.

Relay Output Configuration (G04)

Relay 2 Signal Selection (G040)

Selects the output function for Relay #2.

Relay 2 Sense (G041)

Selects direct or inverted operation for Relay #2.

Relay 2 On-Delay (G042)

Sets the on-delay for Relay #2.

Relay Function Configurations

Relay 2 Off-Delay (G043)

Sets the off-delay for Relay #2.

Relay Configuration Settings (G05)

Configures relay functions, including under/over speed thresholds.

Under Speed Threshold (G050)

Sets the motor frequency threshold for the UNDER SPEED relay function.

Over Speed Threshold (G051)

Sets the motor frequency threshold for the OVER SPEED relay function.

Load Warning and Remote Override

% Load Warning Calibration (G052)

Calibrates %load vs. speed characteristic for warning of potential failures.

Remote Override Enable (G06)

Enables or disables remote override operation via the console button.

Timer Configuration

Timer Intervals (G070/G072)

Sets the timing intervals for Timer 1 and Timer 2.

Timer Modes (G071/G073)

Sets the mode (Delay ON/OFF) for Timer 1 and Timer 2.

Digital and Analogue Outputs

Digital Output Configuration (G08)

Configures extra digital outputs available with extended features cards.

Analogue Output Configuration (G11/G15)

Configures extra analogue outputs (0-5V, 0-10V, 0-20mA) for scaling and translation.

Analogue Output Settings

Analogue Output Type (G110)

Selects the output type for extra analogue outputs (Volts or mAmps).

Analogue Output Signal Source (G111)

Selects the signal source for analogue outputs.

Analogue Output Signal Span (G112/G113)

Sets the minimum and maximum signal values for analogue output spanning.

EIA/RS-485 Communication Protocols

G160 Protocol Selection

Selects the communication protocol (BACnet or Modbus).

Communication Settings

G161 Bit Rate Selection

Selects the communication bit rate (baud rate) for the chosen protocol.

G162 Parity Selection

Selects the communication parity (no parity, even, odd).

Network Addressing and Parameters

G163 MAC/Dev ID Configuration

Sets the unique Media Access Control (MAC) ID for network identification.

G164 Device Instance

Sets the Device Instance Number, unique across the BACnet system.

G165 Max Masters Setting

Specifies the highest allowable MAC ID for master devices in BACnet MS/TP.

Run Signal Source and Termination

G166 Run Signals Source

Determines the source of run command signals (terminals or network).

G167 Terminator Setting

Enables or disables communication network termination.

G168 Comms Lost Time

Sets the interval for detecting loss of communications.

PID Controller Parameters

Proportion Band (H01 PB %)

Sets the Proportion Band, affecting gain and system response.

Integrator Gain (H02 Ti sec/r)

Sets the integrator gain, affecting regulation speed and overshoot.

PID Tuning and Response Adjustment

Derivative Gain (H03 Td sec)

Sets the derivative gain, affecting system response to step inputs.

Output Clamping (H04/H05)

Sets upper and lower limit thresholds for PID output saturation.

Setpoint (SV) Selection (H06)

Selects the reference value (Setpoint) for the PID controller.

Process Variable and Display Scaling

Process Variable (PV) Selection (H07)

Selects the analogue input for measuring the process variable.

PID Units Display (H08)

Sets the units displayed for PID values on the run display.

PID Scale for Display (H09)

Scales SV and PV values for PID run display, not affecting control loop.

Service and Status Displays

S00 Service Menu

Accesses service-specific displays and menus.

Fan Override Control (S04)

Enables or disables internal cooling fans based on parameter setting.

System Status Displays

Temperature Sensor Display

Shows readings from internal temperature sensors.

Digital Input Status

Displays the state (active/deactivated) of digital input terminals.

Analogue Input Status

Displays the state of analogue inputs (mA or V).

Relay Status Display

Displays the state (energised/de-energised) of relays.

Extended Features Display Information

Extended Features Digital Inputs

Shows the state of digital inputs on Extended Features cards.

Extended Features Analogue Inputs

Shows the state of analogue and thermistor inputs on Extended Features cards.

Extended Features Outputs

Shows the state of analogue and digital outputs on Extended Features cards.

Date, Time, and Usage Meters

M02 Date and Time Display

Displays the MSC-3's internal date and time.

kWhr and Hours Run Meters

Menu for accessing cumulative kWhrs and Hours Run meters.

Appendix A: BACnet Protocol

BACnet Objects and Properties

Lists supported BACnet objects and their properties.

Appendix B: MODBUS Protocol

MODBUS Memory Model

Describes the MODBUS memory model structure for the MSC-3.

Discrete Inputs (Read-Only)

Lists read-only discrete inputs for Modbus communication.

Coils (Read/Write)

Lists read/write coils for Modbus communication.

MODBUS Register and Function Code Details

Input Registers (Read-Only)

Lists read-only input registers for Modbus communication.

Holding Registers (Read/Write)

Lists read/write holding registers for Modbus communication.

Supported Modbus Function Codes

Lists and briefly describes supported Modbus function codes.

Modbus Function Code Details

Function Code 01: Read Coils

Details request, response, and error structure for Modbus Function Code 01.

Function Code 02: Read Discrete Inputs

Details request, response, and error structure for Modbus Function Code 02.

Function Code 03: Read Holding Registers

Details request, response, and error structure for Modbus Function Code 03.

Modbus Function Code Details (Continued)

Function Code 04: Read Input Registers

Details request, response, and error structure for Modbus Function Code 04.

Function Code 05: Write Single Coil

Details request, response, and error structure for Modbus Function Code 05.

Function Code 06: Write Single Register

Details request, response, and error structure for Modbus Function Code 06.

Modbus Function Code Details (Advanced)

Function Code 07: Read Exception Status

Details request, response, and error structure for Modbus Function Code 07.

Function Code 08: Diagnostics

Details request, response, and error structure for Modbus Function Code 08.

Modbus Function Code Details (Write Operations)

Function Code 15: Write Multiple Coils

Details request, response, and error structure for Modbus Function Code 15.

Function Code 16: Write Multiple Holding Registers

Details request, response, and error structure for Modbus Function Code 16.

Function Code 43: Read Device Identification

Details request, response, and error structure for Modbus Function Code 43.

Modbus Exceptions

Supported Modbus Exception Codes

Lists the Modbus exception codes supported by the MSC-3.

Display Messages and Troubleshooting

Trip Messages Explained

Lists and describes trip messages indicating fault conditions.

Run Messages Explained

Lists and describes run messages indicating drive status.

MSC-3 Specifications

Electrical Specifications

Details input/output voltage, frequency, and enclosure ratings.

Environmental and Compliance Ratings

Lists environmental conditions and compliance standards.

Terminal Strip Connections

Details terminal strip connections for digital inputs, analogue inputs, and relay outputs.

User Configurable Parameters

Lists configurable user parameters like motor voltage, current, frequency, and references.

Output Current Specifications

MSC-3 Output Current Ratings

Provides continuous and overload current ratings for different MSC-3 models.

Troubleshooting Guide

Common Symptoms and Causes

Lists common symptoms encountered with the MSC-3.

Troubleshooting Remedies

Provides solutions and corrective actions for diagnosed issues.

Transportation and Weights

MSC-3 Model Dimensions and Weights

Lists approximate dimensions and weights for MSC-3 models in standard packaging.

Glossary of Terms