Instruction Bulletin
VVDED397046US R7/00
July 2000
Raleigh, NC, USA
ALTIVAR
®
58 Adjustable Speed
Drive Controllers
Analog I/O Extension Card
VW3A58201U
Retain for future use.
DANGER
HAZARDOUS VOLTAGE
• Read and understand this bulletin in its entirety before installing or operating the ALTIVAR 58 drive controllers. Installation, adjustment, repair, and maintenance of these drive controllers must be performed by qualified personnel.
• Disconnect all power (including external control power that may be present) before servicing the drive controller. Wait three minutes for the DC bus capacitors to discharge. Follow the DC
Bus Voltage Measurement procedure on page 3 to verify that the
DC voltage is less than 45 V. The drive controller LEDs are not accurate indicators of the absence of DC bus voltage.
• DO NOT short across DC bus capacitors or touch unshielded components or terminal strip screw connections with voltage present.
• Install and close all doors and covers before applying power or starting and stopping the drive controller.
• User is responsible for conforming to applicable code requirements with respect to grounding all equipment. For drive controller grounding points, refer to the terminal connection drawing in the installation guide delivered with the drive controller being serviced.
• Many parts in this drive controller, including printed wiring boards, operate at line voltage. DO NOT TOUCH. Use only electrically insulated tools.
Before servicing drive controller:
• Disconnect all power.
• Place a “DO NOT TURN ON” label on the drive controller disconnect.
• Lock the disconnect in the open position.
Electrical shock will result in death or serious injury.
Bulletin No. VVDED397046US R7/00
July 2000
ALTIVAR
58 Analog I/O Extension Card
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
REVISION LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PRELIMINARY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BUS VOLTAGE MEASUREMENT PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
I/O Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
I/O ASSIGNMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
© 1998-2000 Schneider Electric All Rights Reserved i
ALTIVAR
58 Analog I/O Extension Card Bulletin No. VVDED397046US R7/00
July 2000 ii © 1998-2000 Schneider Electric All Rights Reserved
Bulletin No. VVDED397046US R7/00
July 2000
ALTIVAR
58 Analog I/O Extension Card
Introduction
INTRODUCTION
ALTIVAR 58 is a family of adjustable frequency AC drive controllers. They range from:
• 1 to 75 hp (CT) / 100 hp (VT), 460 V, three-phase input
• 0.5 to 7.5 hp, 230 V, single-phase input
• 2 to 40 hp (CT) / 50 hp (VT), 230 V, three-phase input
REVISION LEVEL
All ALTIVAR 58 drive controllers are designed for three-phase motors.
Use this bulletin to install, wire, and become familiar with the analog I/O extension card, part number VW3A58201U.
Where to go for further information on using the drive controller:
• For information on using the keypad display and on programming all of the functions available in the drive controller, refer to the
ALTIVAR 58 Keypad Display Programming Guide,
VVDED397047US.
• For information on installation, start-up, wiring, and maintenance of the drive controller, refer to the Installation Guide shipped with your type of ALTIVAR 58 drive controller.
This document replaces VVDED397046US dated April 1999.
PRELIMINARY INSPECTION
Thoroughly inspect the analog I/O extension card upon receipt, before installing or storing.
1.
Remove the analog I/O extension card from its packaging and visually inspect the exterior for shipping damage.
2.
Ensure that the catalog number agrees with the packing slip and corresponding purchase order.
3.
If you find any shipping damage, notify the carrier and your sales representative.
4.
If storing the card after receipt, replace it in its original packing material, re-seal the antistatic bag, and store it at a temperature between –13 °F and +149 °F (–25 °C and +65 °C).
© 1998-2000 Schneider Electric All Rights Reserved 1
ALTIVAR
58 Analog I/O Extension Card
Installation
INSTALLATION
Bulletin No. VVDED397046US R7/00
July 2000
To install the analog I/O extension card:
1.
Perform the Bus Voltage Measurement Procedure on page 3 to be certain that hazardous voltage is not present in the controller.
2.
With the hinged cover open, fold the flexible shield installed over the control board to the left. Note that the flexible shield is not shown in
Figure 1.
3.
Mount the option card by aligning it with the locating pins on either side of the connector on the control board. Gently press the card onto the connector pins.
4.
Visually verify that the card is properly seated, then tighten the three mounting screws.
Keypad Port
Locating Pins
2
Main Control Board
Figure 1: Installing an Analog I/O Extension Card
(Model ATV58HU09M2 Shown)
© 1998-2000 Schneider Electric All Rights Reserved
Bulletin No. VVDED397046US R7/00
July 2000
ALTIVAR
58 Analog I/O Extension Card
Bus Voltage Measurement Procedure
BUS VOLTAGE MEASUREMENT PROCEDURE
DANGER
HAZARDOUS VOLTAGE
• Read and understand the Bus Voltage Measurement Procedure before performing this procedure. Measurement of bus capacitor voltage must be performed by qualified personnel.
• DO NOT short across DC bus capacitors or touch unshielded components or terminal strip screw connections with voltage present.
• Many parts in this drive controller, including printed wiring boards, operate at line voltage. DO NOT TOUCH. Use only electrically insulated tools.
Electrical shock will result in death or serious injury.
The DC bus voltage level is determined by monitoring the + and – measurement points. The location of the measurement points varies by drive controller model; Table 1 below and Figure 2 on page 4 show the measurement locations for each drive controller model. The model number of the drive controller is listed on the controller’s nameplate.
Table 1: DC Bus Measurement Points for Different ATV58 Models
Model Number of
Drive Controller
ATV58•
+ Measurement Point
Terminal
Block or
Connector
Terminal
Designation
– Measurement Point
Terminal
Block or
Connector
Terminal
Designation
U09M2• and U18M2•
D16M2• to D46M2•
D28N4• to D79N4•
U29M2• to D12M2•
U18N4• to D23N4•
J2
J2
+
PA
J2
J18
—
7
© 1998-2000 Schneider Electric All Rights Reserved 3
4
ALTIVAR
58 Analog I/O Extension Card
Bus Voltage Measurement Procedure
Bulletin No. VVDED397046US R7/00
July 2000
The J18 connector is in the upper left corner of the main control board, behind the flexible shield.
Use a thin probe to access the connector pins.
J18
Flexible
Shield
Main Control Board
J18-7
–
+
} ATV58•U29M2–D12M2
ATV58•U18N4–D23N4
L1 L2 L3 PA PB U V W
+
–
}
ATV58•U09M2–U18M2
L1 L2 + – U V W
+
–
} ATV58•D16M2–D46M2
ATV58•D28N4–D79N4
L1 L2 L3 + – PA PB U V W
J2-Power
Terminal
Block
Figure 2: DC Bus Voltage Measurement Point Locations
(Model ATV58HU09M2 Shown)
To measure the bus capacitor voltage:
1.
Disconnect all power from the drive controller including external control power that may be present on the control board and option board terminals.
2.
Wait three minutes for the DC bus capacitors to discharge.
3.
Obtain the model number from the drive controller nameplate.
4.
Using the model number and the information shown in Table 1 on page 3 and Figure 2, identify the + and – measurement points.
5.
Open the hinged cover.
6.
Set the voltmeter to the 1000 Vdc scale. Measure the voltage between the + and – measurement points identified in step 4.
© 1998-2000 Schneider Electric All Rights Reserved
Bulletin No. VVDED397046US R7/00
July 2000
ALTIVAR
58 Analog I/O Extension Card
Wiring
7.
Verify that the DC voltage has discharged below 45 V before servicing the drive controller.
If the bus capacitors do not discharge below 45 V, contact your local
Square D representative. Do not operate the drive controller.
8.
Replace all covers after servicing the drive controller.
WIRING
Good wiring practice requires the separation of control circuit wiring from all power wiring. This separation reduces the possibility of coupling electrical noise from power circuits or from the motor into control circuits.
When wiring the analog I/O extension card, follow the wiring practices required by national and local electrical codes as well as those listed in the installation guide shipped with your ALTIVAR 58 drive controller.
Terminate the multiple conductor cable shield wires at the drive controller terminal designated for this purpose. Refer to the installation guide for your type of ALTIVAR 58 drive controller for the location of this terminal.
For information concerning electromagnetic compatibility, refer to your installation guide.
I/O Characteristics
The analog I/O extension card includes:
• Two 24 Vdc logic inputs
• One ±10 Vdc bipolar differential analog input
• One 24 Vdc open collector logic output
• One 0–20 mA analog output (output range adjustable)
• DC power supplies (24 V, +10 V, –10 V) for I/O
• A removable terminal strip for easy wiring
© 1998-2000 Schneider Electric All Rights Reserved 5
ALTIVAR
58 Analog I/O Extension Card
Wiring
Bulletin No. VVDED397046US R7/00
July 2000
Terminal Locations
Figure 3 shows the location of the terminals on the analog I/O extension card.
6
Figure 3: Location of Terminals
Table 2 lists the functions and characteristics of each terminal. The environmental characteristics of the analog I/O extension card are the same as those for your type of ALTIVAR 58 drive controller. See the installation guide shipped with your drive controller.
Table 2: Functions and Characteristics of Terminals [1]
Function Characteristics
For information on assigning inputs and outputs, see the
ALTIVAR 58 Keypad
Display Programming
Guide,
VVDED397047US.
Available DC power supplies
(+10 V, –10 V, +24 V)
Logic inputs
LI5, LI6
Protected against short circuits and overloads
1 output, +10 V ± 1%, maximum current = 10 mA
1 output, -10 V ±1%, maximum current = 10 mA
1 output, +24 V (20 V min., 30 V max.), maximum current = 200 mA
[2]
2 reassignable logic inputs. Impedance = 3.5 k
Ω
. Compatible with
Level 1 PLCs according to IEC 65A-68. Maximum shielded cable length: 330 ft (100 m).
Supply: +24 V (11 V min., 30 V max.)
State 0 if < 5 V, state 1 if > 11 V.
The logic inputs are sampled every 2 ms, maximum.
Logic output
LO
1 reassignable open collector logic output, compatible with Level 1
PLCs according to IEC 65A-68.
Supply: +24 V (12 V min., 30 V max.), maximum current = 20 mA with internal source or
200 mA with external source.
The logic output is updated every 2 ms, maximum.
[1]
The maximum wiring size for all terminals is 14 AWG (1.5 mm
2
). Terminal screw tightening torque is 3.5 lb-in (0.4 N•m).
[2]
The 200 mA is the sum of the current supplied by the +24 V supply on the control board and the +24 V supply on the I/O extension card.
© 1998-2000 Schneider Electric All Rights Reserved
Bulletin No. VVDED397046US R7/00
July 2000
ALTIVAR
58 Analog I/O Extension Card
Wiring
Table 2: Functions and Characteristics of Terminals [1] (Cont.)
Function Characteristics
Analog output
AO
Analog Input
AI3
1 reassignable 0–20 mA analog output (with range adjustment on drive software versions V2.4 or later).
Maximum load impedance = 500
Ω
.
Resolution: 0.04 mA (9 bits).
Linearity: ± 0.1 mA.
Accuracy: ± 0.2 mA.
The analog output is updated every 2 ms, maximum.
1 reassignable, ±10 V bipolar differential input.
Input Impedance: AI3A to AI3B > 300 k
Ω
.
AI3A to COM
≅
30 k
Ω
AI3B to COM > 600 k
Ω
Adjustable gain (dtS): Tachometer scaling factor
Maximum allowable voltage: ± 30 V.
Frequency reference resolution: 0.1 Hz for 100 Hz (0.1% of maximum frequency), 10 bits plus sign.
Accuracy: ± 0.5%.
Linearity: ± 0.2% of the maximum output frequency.
The analog input is sampled every 2 ms, maximum.
Maximum length of shielded cable: 66 ft (20 m).
If configured for thermal sensors, use 750
Ω
maximum at 20 °C
(three 250
Ω
sensors in series).
External power
LO+
(DC supply input for logic output)
Input: +24 Vdc nominal (12 Vdc min., 30 Vdc max.).
Maximum current = 200 mA per logic output.
Common (for inputs, outputs, and external power)
COM
0 Vdc—same potential as COM on main control board.
[1]
The maximum wiring size for all terminals is 14 AWG (1.5 mm
2
). Terminal screw tightening torque is 3.5 lb-in (0.4 N•m).
[2]
The 200 mA is the sum of the current supplied by the +24 V supply on the control board and the +24 V supply on the I/O extension card.
© 1998-2000 Schneider Electric All Rights Reserved 7
ALTIVAR
58 Analog I/O Extension Card
Wiring
Bulletin No. VVDED397046US R7/00
July 2000
Typical Wiring Diagrams
Figure 4 shows a wiring diagram for the analog I/O extension card.
Figures 5 to 10 show examples of how the inputs and outputs are wired depending on their use.
8
±10 V
Meter
Figure 4: Wiring Diagram
+
KA
-
Relay
Coil
The Meter and Relay Coil shown are examples of devices that can be attached.
A bipolar speed reference wired to the
COM, AI3A, AI3B, +10, and –10 terminals.
R = 2–10 K Ω .
R
Figure 5: Bipolar Speed Reference Using Internal Supply
A unipolar speed reference wired to only the COM, AI3A, AI3B, and +10 terminals.
R = 1–10 K
Ω
.
R
Figure 6: Unipolar Speed Reference Using Internal Supply
© 1998-2000 Schneider Electric All Rights Reserved
Bulletin No. VVDED397046US R7/00
July 2000
ALTIVAR
58 Analog I/O Extension Card
Wiring
A bipolar speed reference or
PI regulator feedback using an external ±10 Vdc source.
± 10 Vdc
Figure 7: Bipolar Speed Reference (External Supply) or PI Feedback
A tachometer feedback with resistor divider network wired to AI3A and AI3B (see the next page for calculation of resistor values).
± 5 to ±9 Vdc
R1
R2 T
Figure 8: Speed Regulation With Tachometer Feedback
When using tachometer feedback, the voltage at the analog input must be between 5 and 9 Vdc when running at high speed (HSP).
Example:
• Tachometer of 0.05 volts/rpm
• Maximum drive controller frequency of 80 Hz
• Motor rated speed at 60 Hz of 1800 rpm
• Maximum tachometer current = 10 mA
The following equation is used to determine the maximum tachometer voltage:
Max. tach. voltage = Tach. Vdc/rpm
×
Motor rated frequency (Hz)
×
Max. application frequency (Hz)
= 0.05 Vdc/rpm
×
60 Hz
× (
80Hz
)
= 120 Vdc
© 1998-2000 Schneider Electric All Rights Reserved 9
ALTIVAR
58 Analog I/O Extension Card
Wiring
Bulletin No. VVDED397046US R7/00
July 2000
To calculate the total value of R1 + R2, use the maximum current of the tachometer, which equals 10 mA.
Total resistance = maximum tach. current
=
120 Vdc
12 k
Ω
0.01A
=
To calculate each resistance, use the average voltage at the inputs,
7 Vdc.
Value of R1 =
Maximum voltage
=
12 k
Ω ×
7 Vdc
120 Vdc
= 700
Ω
The closest standard value is 680
Ω
.
Value of R2 = Total resistance – R1 = 12 k
Ω
– 0.680 k
Ω
= 11.32 k
Ω
The closest standard value is 11 k
Ω
.
Therefore, the exact voltage at AI3 is:
120 Vdc
×
R1 / (R1 + R2) = 120 Vdc
×
-----------------------
11.68k
Ω
= 6.99 Vdc
Use 2 W power resistors. To scale speed feedback precisely, adjust the tachometer scaling factor (dtS) at the time of installation.
10 © 1998-2000 Schneider Electric All Rights Reserved
Bulletin No. VVDED397046US R7/00
July 2000
ALTIVAR
58 Analog I/O Extension Card
Wiring
Relay
Coil
+
KA
-
An external + 24 Vdc supply can be used to power the logic inputs and/or the logic output. In this case, the +24 terminal on the analog I/O extension card is not used.
The Relay Coil shown is an example of devices than can be attached.
24 Vdc Supply
Figure 9: Using an External 24 Vdc Supply
R = 10 K
Ω
± 5% R
Thermal sensors used for motor thermal protection, wired to AI3A and AI3B.
2 W, 750
Ω
maximum.
Motor Heat Sensors
(three 250
Ω probes in series)
Figure 10: Connection of Motor Thermal Sensors
© 1998-2000 Schneider Electric All Rights Reserved 11
ALTIVAR
58 Analog I/O Extension Card
I/O Assignments
Bulletin No. VVDED397046US R7/00
July 2000
I/O ASSIGNMENTS
Table 3 shows the factory assignments of the inputs and outputs on the analog I/O extension card as they appear upon installation of the option card.
The analog I/O extension card inputs and outputs can be reassigned with one of the following tools:
• Keypad Display, VW3A58101U
• Hand-Held Programmer, VW3A58102L1U or VW3A58102L2U
• PC Software, VW3A58104
Refer to the instruction bulletins shipped with each of these products and with the drive controller for information concerning starting up the drive controller and assigning inputs and outputs.
NOTE: The installer must ensure that these functions are compatible with the control scheme used.
Table 3: Analog I/O Extension Card Factory Presets
(MACRO-CONFIG = Hdg:Handling)
I/O Assigned
Logic Input LI5
Logic Input LI6
Analog Input AI3
Logic Output LO
Analog Output AO
Parameter Label
PS8: 8 presetSP
RST: Fault Reset
SAI: Summed Ref.
CTA: I Attained
OFR: Motor Freq
Description
Provides the ability to obtain eight preset speeds when used in conjunction with two additional logic inputs. Uses threebit binary coding.
Activate input to High to reset faults.
See the ALTIVAR 58 Keypad Display
Programming Guide,
VVDED397047US, for more information.
Frequency setpoints entering the analog input can be added to or subtracted from frequency setpoints appearing on AI1 and/or AI2. AI1 ± AI2 ± AI3.
Output is activated to a High state when the output current to the motor is greater than or equal to the programmed current threshold.
A current output proportional to the motor frequency, where 0 mA = zero frequency and 20 mA = programmed
Max. Freq. parameter (tFr).
12 © 1998-2000 Schneider Electric All Rights Reserved
Bulletin No. VVDED397046US R7/00
July 2000
NOTES
ALTIVAR
58 Analog I/O Extension Card
Startup
© 1998-2000 Schneider Electric All Rights Reserved 13
ALTIVAR
58 Analog I/O Extension Card
Startup
NOTES
Bulletin No. VVDED397046US R7/00
July 2000
14 © 1998-2000 Schneider Electric All Rights Reserved
W915980990111A02
91598099011102
