VersaPoint I/O System Motor Starter Modules Manual

VersaPoint I/O System Motor Starter Modules Manual
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
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
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 the 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
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Contents
Chapter 1
VersaPoint Motor Starter Modules ....................................................... 1-1
VersaPoint Motor Starter Modules .................................................................................... 1-2
Additional Equipment for Motor Starter Applications ........................................................ 1-3
Overview of Motor Starter Module Operation ................................................................... 1-6
General Specifications for Motor Starter Modules ............................................................ 1-7
Specifications for Motor Starter Module IC220STR001 .................................................... 1-9
Specifications for Motor Starter Module IC220STR002 .................................................. 1-13
Specifications for Motor Starter Module IC220STR003 .................................................. 1-17
Ordering Information ....................................................................................................... 1-20
Chapter 2
Installing VersaPoint Motor Starter Modules ...................................... 2-1
Safety Requirements......................................................................................................... 2-2
Module Installation ............................................................................................................ 2-4
Connectors and Connection Points .................................................................................. 2-5
Connecting 24V Module Power......................................................................................... 2-6
Connecting the Power Source for the Motor..................................................................... 2-8
Connecting Power from the Module to the Motor ............................................................. 2-9
Protecting the Motor ........................................................................................................ 2-10
Connecting a Motor Starter Brake Module and Brake .................................................... 2-11
Wiring Two Motor Starter Modules IC220STR002 for Reversing ................................... 2-12
Module LEDs................................................................................................................... 2-13
Internal Circuit Diagram .................................................................................................. 2-14
Chapter 3
Data Exchanged by the Motor Starter Module and the System Host 3-1
Exchanging Data with a Motor Starter Module ................................................................. 3-2
Output Data: Configuring the Nominal Motor Current....................................................... 3-4
Output Data: Sending Control Commands ....................................................................... 3-7
Input Data: Monitoring the Motor Starter Module............................................................ 3-12
Chapter 4
Local Motor Control............................................................................... 4-1
Operation of the Motor Starter Module in Manual Mode................................................... 4-2
Manual Mode Input Connections ...................................................................................... 4-3
Using a Motor Starter Pendent.......................................................................................... 4-5
Controlling Manual Mode from the System Host .............................................................. 4-7
Chapter 5
Motor Starter Brake Modules................................................................ 5-1
Description of the Brake Modules ..................................................................................... 5-2
Controlling the Operation of the Brake.............................................................................. 5-3
Specifications for Motor Starter Brake Modules: IC220ACC100 and IC220ACC101...... 5-4
GFK-2134
v
Contents
Chapter 6
Motor Protection with a Thermistor Module........................................ 6-1
Description of the Thermistor Module ............................................................................... 6-2
Thermistor Module Operation ........................................................................................... 6-3
Thermistor Module Connections ....................................................................................... 6-4
Internal Circuit Diagram of the Thermistor Module ........................................................... 6-6
Thermistor Module LEDS.................................................................................................. 6-6
Specifications for the Thermistor Module: IC220MDD850............................................... 6-7
vi
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
VersaPoint Motor Starter Modules
Chapter
1
This manual contains the instructions and reference information needed to
install and use a VersaPoint Motor Starter module. There are three module
versions:
▪
▪
▪
Motor Starter Direct, 1.5KW/400VAC Module (IC220STR001)
Motor Starter Direct, 3.7KW/400VAC Module (IC220STR002)
Motor Starter Reversing, 1.5KW/400VAC Module (IC220STR003)
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 communications information, you
will also need the Network Interface User's Manual for your system.
GFK-2134
1-1
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
▪
Safe isolation between line voltage and 24V supply voltage according to
EN 50178:1997
▪
▪
Diagnostic and status indicators
Connection for optional external passive brake
module
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 IC220STR002 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)
▪
▪
▪
1-2
Nominal voltage is 400VAC
Nominal Motor current is configurable from 0.2 Amps to 3.6 Amps
Controls motors with two directions of rotation.
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
1
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
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: IC220ACC100
and IC220ACC101. See chapter 5 for more information about using Motor
Starter Brake modules.
Motor Starter Brake Module Features
▪
▪
▪
1-4
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
1
Thermistor Module
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.
GFK-2134
Chapter 1 VersaPoint Motor Starter Modules
1-5
1
Overview of Motor Starter Module Operation
Control and configuration of a Motor Starter 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 below 0.1A for module IC220STR001 or 0.16A for
module IC220STR002, 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:
1-6
▪
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 IC220STR002, minimum current monitoring can be disabled as
described in chapter 3.
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
1
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
GFK-2134
Housing dimensions
(width x height x depth)
63mm x 224mm x 109mm
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
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.
(2.48in x 8.82in x 4.29in)
Chapter 1 VersaPoint Motor Starter Modules
1-7
1
Conformance With EMC Directive 89/336/EEC
Noise Immunity Test According to EN 50082-2
Electrostatic discharge
(ESD)
EN 61000-4-2
IEC 61000-4-2
6kV contact discharge, Criterion B
8kV air discharge , Criterion B
Electromagnetic fields
EN 61000-4-3
IEC 61000-4-3
Criterion A
Field strength: 3V/m
Fast transients (burst)
EN 61000-4-4
IEC 61000-4-4
Criterion B
Supply lines: 2kV
Signal/data lines: 2kV
Surge voltage
EN 61000-4-5
IEC 61000-4-5
Criterion B
DC supply lines: 0.5kV/0.5kV
(symmetrical/asymmetrical)
Criterion B
AC supply lines: 2kV / 4kV
(symmetrical/asymmetrical)
Conducted interference
EN 61000-4-6
IEC 61000-4-6
Criterion A
Test voltage 10 V
Noise Emission Test According to EN 50081-2
Noise emission of
housing
EN 55011
Class A
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 UL / 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
IC220STR001, IC220STR003: 2g, Criterion 1
IC220STR002: 1g, Criterion 1
1-8
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
1
Specifications for Motor Starter Module IC220STR001
Motor Starter Module IC220STR001
Switches
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
switching
frequencies at
ambient
temperatures of 25C
(77F) and 55C
(131F).
Switch-on time
1 second minimum
Switch-off time
1 second minimum
Phase angle
cos φ = >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 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 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.
GFK-2134
Chapter 1 VersaPoint Motor Starter Modules
1-9
1
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
Line Connection for Module IC220STR001
Connection method
1-10
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
2
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
1
Motor Output for Module IC220STR001
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).
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
2
2
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
The selection of an appropriate motor depends on the nominal motor current, which
ranges from 0.2A to 3.6A.
GFK-2134
Chapter 1 VersaPoint Motor Starter Modules
1-11
1
Motor Protection for Module IC220STR001
Trip class
According to Class 10A of IEC 60947-4
Quick Shutdown
> 20.3A after 300ms
Configurable range
0.2A to 3.6A
Typical Response Behavior
Current
1.5 x IN
Release Time TP < 120s
7.2 x IN
2s < TP < 10s
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 IC220STR001
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 IC220STR001
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
1
Specifications for Motor Starter Module IC220STR002
Motor Starter Module IC220STR002
Switch
Mechanical contactor
Operating voltage (conductor
voltage)
187VAC to 600VAC
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
>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 φ = >0.3
Motor starting time
1 second maximum
Internal Protection
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 shortcircuit): 20A gG
Contact wiring
None
Power Consumption for Module IC220STR002
GFK-2134
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
1-13
1
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
2
- up to 519VAC with safe isolation between line
and SELV
- up to 600VAC 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 maximum
Wiring
Y capacitors, Varistor 625V
Motor Output for Module IC220STR002
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 protection with
external 16A fuse (total range protection for
semiconductor type gR).
Number of pins on output terminal Four: T1, T2, T3,
strip X10
2
2
Conductor cross-section
1mm (18AWG) minimum, to 2.5mm (14 AWG)
maximum
Degree of protection
Protection against direct touch
Wiring
Varistor 460VAC
Motor power ranges
Motor voltage
Number of motor poles
Motor power
400V
4
0.18kW to 3.7kW (0.241 hp to 4.958 hp)
The selection of appropriate motors depends on the nominal motor current ranging
from 0.2A to 8.0A
1-14
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
1
Motor Protection for Module IC220STR002
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
>20.3A after 300ms
Typical Response Behavior
Current
1.5 x IN
7.2 x IN
Release
Time
TP < 120s
2s < TP < 10s
If the current is disconnected due to an
overcurrent, wait at least 60 seconds to
ensure successful acknowledgement of the
error.
GFK-2134
Chapter 1 VersaPoint Motor Starter Modules
1-15
1
Current Monitoring
Monitored phase
T1
Measuring range
0 to 25 Amps
Resolution
14mA
Supply of the current detection
from the 7.5V communications power
Manual Mode Input
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
2
Diagnostic Messages for Module IC220STR002
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
1-16
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
1
Specifications for Motor Starter Module IC220STR003
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
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 φ = >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
Module
24V segment voltage (when the
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.
GFK-2134
Chapter 1 VersaPoint Motor Starter Modules
1-17
1
Power Consumption for Module IC220STR003
Communications power
7.5V
Current consumption from the local bus
45mA, maximum
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,
Conductor cross-section
1mm (18AWG) minimum, to 2.5mm (14
AWG) maximum
Degree of protection
Protection against direct touch
2
Wiring
Varistor 460VAC
Nominal load
Three-phase asynchronous motors
2
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
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
1
Motor Protection for Module IC220STR003
A motor-protection relay is inserted using a 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
> 20.3A after 300ms
Configurable range
0.2A to 3.6A
Typical Response Behavior
Current
1.5 x IN
7.2 x IN
Release
Time
TP < 120s
2s < TP < 10s
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
Overcurrent
Power level cannot be controlled
GFK-2134
Error message in diagnostic code and
displayed on ERR LED on module.
Chapter 1 VersaPoint Motor Starter Modules
1-19
1
Ordering Information
Product Type
Catalog Number
Motor Starter Module, Direct, 1.5 KW /400 VAC
IC220STR001
Motor Starter Module, Direct, 3.7 KW / 400 VAC
IC220STR002
Motor Starter Module, Reversing, 1.5 KW / 400 VAC
IC220STR003
Motor Starter Brake Module, 5 VDC to 31 VDC
IC220ACC100
Motor Starter Brake Module, 12 VDC to 400 VDC, 20VAC to 400VAC IC220ACC101
1-20
Motor Starter Power Connector
IC220ACC103
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
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
Installing VersaPoint Motor Starter Modules
Chapter
2
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 host 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
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 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 (IC220STR001). Do not use Motor Starter Module IC220STT001 to
control pole-reversing motors (dual speed) !
Motor Starter Module IC220STR003 is intended for reversing applications.
Alternatively, two Motor Starter Modules IC220STR002 can be combined for
reversing applications as shown later in this chapter.
For module IC220STR003, the motor must have come to a stop before the
direction of rotation can be changed.
2-2
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
2
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 voltage 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 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
2
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
2
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.
X9
Item
Description
Description
Item
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
X10
Connection for optional Motor
Starter Brake Module including
brake switch and connection for
brake (X9)
4
Motor Starter Brake Module, IC220ACC100
5
Connector to optional brake (on X9)
Connection for the motor output:
3
Motor Output Connector
1
Incoming line, here: Motor Starter Power
Connector IC220ACC103
2
Optional outgoing line, Motor Starter Power
Bridge IC220ACC104
T1, T2, T3,
X11
Connection for the incoming line
L1, L2, L3, N,
X12
Connection for the outgoing line.
X18
Enabling the power
level/connection for 24V
isolation
7
Jumper for 24V segment power. A switch to
control 24V power can be substituted for this
jumper
X32
Connection for manual mode /
Motor Starter Pendent
6
Optional Motor Starter Pendent,
IC220ACC102
L1, L2, L3, N,
GFK-2134
Chapter 2 Installing VersaPoint Motor Starter Modules
2-5
2
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
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
2
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
2
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 IC220STR002 modules are used together to
implement a reversing application), power can be passed to the second module
using a Motor Starter Power Bridge, IC220ACC104.
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
2-8
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
2
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 assignments for this cable are shown below:
Pin
Assignment
1
Motor:T1
2
Motor: T2
3
Motor: T3
4
GFK-2134
Motor:
Chapter 2 Installing VersaPoint Motor Starter Modules
2-9
2
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.
2-10
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
2
Connecting a Motor 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.
X9
X8
X10
GFK-2134
Chapter 2 Installing VersaPoint Motor Starter Modules
2-11
2
Wiring Two Motor Starter Modules IC220STR002 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 IC220STR001!
Connecting Two Modules IC220STR002
To set up a reversing application using two Motor Starter Modules IC220STR002,
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,
IC220STR002
2-12
Module #2,
IC220STR002
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
2
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.
WARNING
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
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.
IC220STR001, IC220STR002
IC220STR003
For the two direct-type Motor Starter Modules, IC220STR001 and STR002, the M1
LED shows the status of the motor. For reversing-type module IC220STR003,
LEDs R1 and R2 show the status of the motor in each of its two directions.
LED
D
Color
Meaning
Green LED Diagnostics
ON:
I/O Station communications are active
Flashing:
ERR
0.5 Hz:
(slow)
Communications power is present, but I/O Station communications
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:
Communications power is not present, no local communications
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
LOC
2-14
ON:
Motor is switched on.
OFF:
Motor is not switched on
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
2
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
Optocoupler
Protocol chip (bus logic
incl. Voltage conditioning)
Line connection
Current transformer
Fuse
Relay
Thyristor diode
Capacitor
Isolated area
X10 connector for motor
output
X8 connector for external
brake module
Ground
Functional earth ground
Voltage jumper
GFK-2134
Chapter 2 Installing VersaPoint Motor Starter Modules
2-15
Data Exchanged by the Motor Starter Module and
the System Host
Chapter
3
This chapter explains how a system host exchanges information with a Motor
Starter module in a VersaPoint I/O Station.
▪
Exchanging Data with a Motor Starter Module
▪
▪
▪
▪
The Output / Input Data Cycle
Entering the Nominal Motor Current
Configuration Example
Output Data: Sending Control Commands
▪
▪
▪
▪
▪
▪
The Module Provides Input Data
Output Data: Configuring the Nominal Motor Current
▪
▪
▪
The Host Sends Output Data
Using the Brake Commands
Enabling Manual Mode
Module IC220STR002: 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 in Amps
Checking for Manual Mode Active
Monitoring the Motor's On/Off State
Reading Status and Error Messages
▪
▪
GFK-2134
Calculating the Actual Motor Current as a Percent
Error Code 1 0 : Power Level Cannot be Controlled
Error Code 1 1 : Overcurrent
3-1
3
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 message 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.
System Host
Fieldbus Protocol
Message
NIU
Output Data
for all
Modules
Motor
Starter
Module
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.
Motor
Starter
Module
NIU
Output Data
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.
3-2
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
3
The Module Provides Input Data
After receiving commands in the output data, the Motor Starter Module performs
the commanded function. 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
Input Data
The system host must read the input data from the NIU according to its specific
communications protocol.
System Host
Fieldbus Protocol
Message
Input Data
from all
Modules
NIU
Motor
Starter
Module
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
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 nominal 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 UL 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
1
1
5
4
3
2
1
0
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 IC220STR002 can use the values in the righthand section.
All Modules
Amps
0.20
0.25
0.30
0.35
0.40
0.45
0.50
0.55
0.60
0.65
0.70
0.75
0.80
0.85
0.90
0.95
1.00
1.05
1.10
1.15
1.20
1.30
3-4
Bits 0-5
dec (hex)
0 (00)
1 (01)
2 (02)
3 (03)
4 (04)
5 (05)
6 (06)
7 (07)
8 (08)
9 (09)
10 (0A)
11 (0B)
12 (0C)
13 (0D)
14 (0E)
15 (0F)
16 (10)
17 (11)
18 (12)
19 (13)
20 (14)
21 (15)
Byte
dec (hex)
192 (C0)
193 (C1)
194 (C2)
195 (C3)
196 (C4)
197 (C5)
198 (C6)
199 (C7)
200 (C8)
201 (C9)
202 (CA)
203 (CB)
204 (CC)
205 (CD)
206 (CE)
207 (CF)
208 (D0)
209 (D1)
210 (D2)
211 (D3)
212 (D4)
213 (D5)
Amps
1.40
1.50
1.60
1.70
1.80
1.90
2.00
2.10
2.20
2.30
2.40
2.50
2.60
2.70
2.80
2.90
3.00
3.20
3.40
3.60
All Modules
Module IC220STR002 ONLY
Bits
dec (hex)
22 (16)
23 (17)
24 (18)
25 (19)
26 (1A)
27 (1B)
28 (1C)
29 (1D)
30 (1E)
31 (1F)
32 (20)
33 (21)
34 (22)
35 (23)
36 (24)
37 (25)
38 (26)
39 (27)
40 (28)
41 (29)
Amps
Byte
dec (hex)
214 (D6)
215 (D7)
216 (D8)
217 (D9)
218 (DA)
219 (DB)
220 (DC)
221 (DD)
222 (DE)
223 (DF)
224 (E0)
225 (E1)
226 (E2)
227 (E3)
228 (E4)
229 (E5)
230 (E6)
231 (E7)
232 (E8)
233 (E9)
3.80
4.00
4.20
4.40
4.60
4.80
5.00
5.20
5.40
5.60
5.80
6.00
6.20
6.40
6.60
6.80
7.00
7.20
7.40
7.60
7.80
8.00
Bits
dec (hex)
42 (2A)
43 (2B)
44 (2C)
45 (2D)
46 (2E)
47 (2F)
48 (30)
49 (31)
50 (32)
51 (33)
52 (34)
53 (35)
54 (36)
55 (37)
56 (38)
57 (39)
58 (3A)
59 (3B)
60 (3C)
61 (3D)
62 (3E)
63 (3F)
Byte
dec (hex)
234 (EA)
235 (EB)
236 (EC)
237 (ED)
238 (EE)
239 (EF)
240 (F0)
241 (F1)
242 (F2)
243 (F3)
244 (F4)
245 (F5)
246 (F6)
247 (F7)
248 (F8)
249 (F9)
250 (FA)
251 (FB)
252 (FC)
253 (FD)
254 (FE)
255 (FF)
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
3
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:
Nom. 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:
Amps
Bits
dec (hex)
Byte
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
(binary)
1
1
(hex)
5
4
3
2
1
0
0
0
E
1
0
1
1
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 No status 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
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 the 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.
3-6
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
3
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.
Bits:
7
6
5
4
3
2
1
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 IC220STR001 and IC220STR002 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 on / brake switch closed
Modules IC220STR001 and IC220STR002 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
3-7
3
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.
Bits:
7
6
5
4
3
2
1
0
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, 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 0 can be used to
control the operation of the brake.
3-8
▪
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.
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
3
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
Enable Manual mode = 1
Module IC220STR002: Disabling Minimum Current Checking
(output bit 4)
For Motor Starter Module IC220STR002 (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
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
3
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.
Bits:
7
6
5
4
3
2
1
0
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 correcting 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
3
Controlling the Motor (output bit 6)
For the direct-type Motor Starter Modules, IC220STR001 and IC220STR002,
output bit 6 switches the motor on (bit 6 = 1) or off (bit 6 = 0).
For the reversing-type Motor Starter Module, IC220STR003, 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, IC220STR003, 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, IC220STR001 and IC220STR002,
output bit 6 is not used and must be set to 0.
Bits:
7
6
5
4
3
2
1
0
Modules IC220STR001 and IC220STR002 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 on / brake switch closed
Modules IC220STR001 and IC220STR002 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
3
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
0 1
1 1
1 0
No status message
Nominal motor current not configured
Overcurrent protection triggered
Power level cannot be controlled
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
3
Monitoring the Motor Current (input bits 0-3)
The value in input bits 0 - 3 indicates the relationship between the actual current
and the configured nominal current. This value is based on the actual current 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
T
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 IACT / 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.
Bits
Dec
3
2
1
0
0
0
0
0
0
0
0
0
0
0
Actual Current /
Nom. Current
Bits
Dec Actual Current /
Nom. Current
Ratio
%
3
2
1
0
Ratio
%
0
<0.75
<75
0
0
0
0
8
1.00
100
1
1
0.78
78
0
0
0
1
9
1.03
103
1
0
2
0.81
81
0
0
1
0
10
1.06
106
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
1
0
6
0.94
94
0
1
1
0
14
1.19
119
0
1
1
1
7
0.97
97
0
1
1
1
15
>1.22
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
Chapter 3 Data Exchanged by the Motor Starter Module and the System Host
3-13
3
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:
Actual Current as
a Percentage of
Nominal Current
Decimal value
1 - 15
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.
Actual Current =
Decimal value
1 - 15
in bits 0 to 3
X
+ 0.75
Nominal Current
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
Therefore, the actual motor current is 0.93 Amp in this example.
3-14
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
3
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:
▪
▪
▪
GFK-2134
the motor protection 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.
Chapter 3 Data Exchanged by the Motor Starter Module and the System Host
3-15
3
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
0 1
1 1
1 0
No status message
Nominal motor current not configured
Overcurrent protection triggered
Power level cannot be controlled
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 0, the state of bit 6 indicates whether the nominal 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
Bit 6
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
3-16
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
3
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
IC220STR002, minimum current monitoring can be disabled as mentioned
below and described earlier in this chapter.
The minimum current levels for the VersaPoint Motor Starter Modules are:
Module Type
Minimum Current
IC220STR001
IC220STR003
0.1 Amp
IC220STR002
0.16 Amp*
*For module IC220STR002 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
Local Motor Control
Chapter
4
This chapter explains how to use Manual Mode for local control of the
motor:
▪
Operation of the Motor Starter Module in Manual Mode
▪
▪
Manual Mode Input Connections
▪
▪
▪
Manual Mode Input Diagrams
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
▪
GFK-2134
Manual Mode Input Assignments
Using a Motor Starter Pendent
▪
▪
▪
▪
Enabling / Disabling Manual Mode
Motor Protection Functions in System-Controlled Manual Mode
4-1
4
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:
7
6
5
4
3
2
1
0
Manual Mode active = 0
4-2
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
4
Manual Mode Input Connections
Connections 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
(IC220STR002).
GFK-2134
Chapter 4 Local Motor Control
4-3
4
Manual Mode Input Assignments
The module's connector pins for Manual Mode have the following
assignments:
Pin
Function
For Modules
IC220STR001 and
IC220STR002
For Module
IC220STR003
1
Input E9
Not used
Motor on/off,
direction of rotation 1
2
Input E8
Motor on/off
Motor on/off,
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
4
Manual Mode Input Diagrams
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
For Modules
IC220STR001 and
IC220STR002
Motor Control
Pin3
Pin 2
Pin 1
Pin 4
Enable
For Module
IC220STR003
Motor Control in Direction of Rotation 1
Motor Control in Direction of Rotation 2
Pin3
Pin 2
Pin 1
Pin 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.
GFK-2134
Chapter 4 Local Motor Control
4-5
4
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 IC220STR002 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 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
4
Controlling the Motor with a Motor Starter Pendent
The Motor Starter Pendent has two function buttons, F1 and F2, each with
its own LED.
Button
For Modules IC220STR001 and
IC220STR002
For Module IC220STR003
F1
Motor on/off
Motor on/off,
direction of rotation 1
F2
Not used
Motor on/off,
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
4
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.
Pin3
For Modules
IC220STR001 and
IC220STR002
Motor Control (shielded cable)
Pin 2
Pin 1
Pin 4
Pin3
Motor Control in Direction of Rotation 1
For Module
IC220STR003
Motor Control in Direction of Rotation 2
Pin 2
Pin 1
Pin 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 output data word:
Bits:
7
6
5
4
3
2
1
0
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
Motor Starter Brake Modules
Chapter
5
This chapter describes the use of an optional Motor Starter Brake Module:
▪
Description of the Brake Modules
▪
▪
▪
GFK-2134
Internal Circuit Diagram of a Brake Module
System Host Controls the Operation of the Brake
▪
▪
▪
Motor Starter Brake Module Features
Enabling Brake Control
Switching the Brake
Specifications for the Motor Starter Brake modules
5-1
5
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: IC220ACC100
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:
▪
▪
▪
5-2
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
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5
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
Optocoupler
Diode
2-pos connector
3-pos. connector
Isolated area
Protective earth ground
GFK-2134
Chapter 5 Motor Starter Brake Modules
5-3
5
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 (output bit 1).
Bits:
7
6
5
4
3
2
1
0
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.
▪
5-4
▪
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
5
Specifications for Motor Starter Brake Modules:
IC220ACC100 and IC220ACC101
General Data
Housing dimensions (width x height x
depth)
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
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
Motor Starter Brake Module
Control voltage
Control current
Current limit
Brake to be Connected
Contact spacing
Cable diameter
Maximum continuous current
Protective current
Degree or protection
Contact type
Connection voltage
(no tolerances permitted)
Residual voltage
GFK-2134
24VDC from the Motor Starter Module
17mA
Using dropping resistor
7.62mm (0.30 in)
2
Up to 2.5mm (14 AWG)
300mA
IC220ACC100: Diode against polarity protection and
TAZ diode
IC220ACC101: Diode against polarity protection and
460V varistor
Protection against direct touch
Polarized solid-state contact
IC220ACC100: 5VDC minimum to 31VDC maximum
IC220ACC101: 12VDC minimum to 440VDC
maximum, 20VAC minimum to 400VAC maximum
IC220ACC100: 0.4VDC maximum
IC220ACC101: 3.4VDC maximum
Chapter 5 Motor Starter Brake Modules
5-5
5
Power Dissipation
Power dissipation of the electronics can be calculated using the following formulas:
For IC220ACC100: PTOT= 0.1 W + (0.4 V x IL)
For IC220ACC101: PTOT= 0.1 W + (3.4 V x IL)
PTOT is the total power dissipation of the brake module
IL is the load current
Safety Devices
Overvoltage
Polarity reversal of the brake
IC220ACC100: TAZ diode
IC220ACC101: 460V varistor
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
5-6
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
Motor Protection with a Thermistor Module
Chapter
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 Operation
▪
▪
▪
GFK-2134
System Host Shuts Down the Motor
Thermistor Module Switching Output Shuts Down the Motor
Thermistor Module Connections
▪
▪
▪
▪
▪
Thermistor Module Features
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
6-1
6
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
6
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 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
1
0
Error Conditions:
1 0 1 = Overtemperature thermistor
(Thermistor response temperature reached)
not used
0 1 0 = Short circuit of thermistor or
connecting cable
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
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.
GFK-2134
Chapter 6 Motor Protection with a Thermistor Module
6-3
6
Thermistor Module Connections
Thermistor Module IC220MDD850 requires one (1) I/O Terminal Strip,
IC220TBK081, ordered separately. The pin assignments are:
Terminal Point
Assignment
1.1
Switching output
2.1
Ground for Switching Output
1.2, 2.2
Thermistor Connection
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
6
Controlling the Motor without Using the Motor Starter Module
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.
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 terminal 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
6
Internal Circuit Diagram of the Thermistor Module
Bus logic and voltage conditioning
LED
Converter
Optocoupler
Threshold value switch
Amplifier
Isolater area
Thermistor Module LEDS
6-6
LED
Color
Meaning
D
Green
Bus diagnostics
E
Red
Error (overtemperature thermistor)
SC
Red
Short circuit of the thermistor or connecting
cable
A
Yello
w
Alarm message (thermistor temperature is
approximately 5K below response temperature)
VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
6
Specifications for the Thermistor Module: IC220MDD850
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
Current consumption from the local bus
Power consumption from the local bus
Segment supply voltage US
Nominal current consumption of US
Total power consumption
GFK-2134
7.5V
60mA, maximum
0.45W
24VDC nominal
0.5A maximum
0.15W maximum
Thermistor Input
Number
Connection type
Thermistor current
No-load voltage
Filter time
Cable length to thermistor
1
2-wire
1.2A maximum
Under 8VDC
10ms typical
30 meters (95 ft) maximum
Switching Thresholds
Operating range (total resistance)
Tripping range (total resistance)
Tripping value (total resistance)
Release value
Warning (response temperature minus 5 K)
Short circuit
50 Ohms to 2.25k Ohms
4k Ohms or more
2.7k Ohms to 3.5k Ohms
1.4k Ohms to 1.5k Ohms
1.6k Ohms to 1.8k Ohms
Under 50 Ohms
Switching Output
Output signal high
Output signal low
Output voltage
Output current
Total resistance less than 2.7k Ohms
Total resistance more than 3.5k Ohms
Segment voltage - 1V
50mA, short-circuit-proof
Chapter 6 Motor Protection with a Thermistor Module
6-7
6
Power Dissipation
Power dissipation of the electronics can be calculated using the following formula:
PEL = 0.45 W + (3 V x IL)
PTOT is the total power dissipation of the module
IL is the load current
Power dissipation of the housing is 0.6W
Safety Devices
Overvoltage
Polarity reversal
Protective circuits of the power terminal
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
Programming Data
6-8
ID code
Length code
BE hex (190dec)
41hex
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
Index
A
Acknowledge Reset bit, 3-10
B
Brake commands
Enable 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
I
IC220ACC100/101 Motor Starter Brake
Modules, 1-4
IC220ACC102 Motor Starter Pendent, 1-4
IC220ACC103 Power Connector, 1-3
IC220ACC104 Power Bridge, 1-3
IC220MDD850 Thermistor Module, 1-5
IC220STR001 Motor Starter Module
features, 1-2
specifications, 1-9
IC220STR002 Motor Starter Module
features, 1-2
specifications, 1-13
IC220STR003 Motor Starter Module
GFK-2134
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
M
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, 4-5
Manual Mode
inputs, 4-4
Minimum current checking for module
IC220STR002
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
IC220ACC100/101, 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
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
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 Module, 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
Index-2 VersaPoint™ I/O System Motor Starter Modules User's Manual – September 2005
GFK-2134
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