Magnetek IMPULSE G+/VG+ Series 4 S4IO AC Owner's Manual

AC Digital Input/Output Installation

Manual

September 2011

Part Number: 144-23967

© Copyright 2011 Magnetek

1. Preface and Safety

Magnetek manufactures products used as components in a wide variety of industrial systems and equipment. The selection and application of Magnetek products remain the responsibility of the equipment manufacturer or end user. Magnetek accepts no responsibility for the way its products are incorporated into the final system design. Under no circumstances should any Magnetek product be incorporated into any product or design as the exclusive or sole safety control. Without exception, all controls should be designed to detect faults dynamically and fail safely under all circumstances. All systems or equipment designed to incorporate a product manufactured by Magnetek must be supplied to the end user with appropriate warnings and instructions as to the safe use and operation of that part. Any warnings provided by Magnetek must be promptly provided to the end user.

Magnetek offers an express warranty only as to the quality of its products in conforming to standards and specifications published in the Magnetek manual. NO OTHER WARRANTY, EXPRESS OR

IMPLIED, IS OFFERED. Magnetek assumes no liability for any personal injury, property damage, losses, or claims arising from misapplication of its products.

Applicable Documentation

The following manuals are available for the option:

Digital Input S4IO Option

IMPULSE

®

•

G+/VG+ Series 4

Digital Input S4IO Installation

Manual

Manual No: 144-23967

Read this manual first.

The installation manual is packaged with the option and contains information required to install the option and set up related drive parameters.

MPULSE•G+/VG+ Series 4 Drive

IMPULSE

®

•

G+/VG+ Series 4

Quick Start Guide

The drive manuals cover basic installation, wiring, operation procedures, functions, troubleshooting, and maintenance information. The manuals also include important information about parameter settings and drive tuning.

IMPULSE

®

•

G+/VG+ Series 4

Instruction Manual

Access http://www.magnetekmh.com to obtain Magnetek instruction manuals.

IMPULSE®•G+/VG+ Series 4 AC Digital Input/Output Installation Manual - September 2011

1-2

Terms

Drive :

IMPULSE

®

•G+/VG+ Series 4

Option:

IMPULSE

®

•G+/VG+ Series 4 Option Digital Input S4IO

DIO:

Digital Input Option

MFDI:

Multi-Function Digital Input

MFDO:

Multi-Function Digital Output

Registered Trademarks

Trademarks are the property of their respective owners.

Supplemental Safety Instructions

Read and understand this manual before installing, operating, or servicing this option. Install the option according to this manual and local codes.

The following conventions indicate safety messages in this manual. Failure to heed these messages could cause fatal injury or damage products and related equipment and systems.

D A N G E R

DANGER

indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.

WA R N I N G

WARNING

indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

C A U T I O N

CAUTION

indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices.

N O T I C E

NOTICE

indicates an equipment damage message.

NOTE: A NOTE statement is used to notify installation, operation, programming, or maintenance information that is important, but not hazard-related.


1-3

General Safety

General Precautions

• The diagrams in this book may include options and drives without covers or safety shields to illustrate details. Be sure to reinstall covers or shields before operating any devices. Use the option according to the instructions described in this manual.

• Any illustrations, photographs, or examples used in this manual are provided as examples only and may not apply to all products to which this manual is applicable.

• The products and specifications described in this manual or the content and presentation of the manual may be changed without notice to improve the product and/or the manual.

• When ordering new copies of the manual, contact a Magnetek representative and provide the manual number shown on the front cover.

D A N G E R

Heed the safety messages in this manual.

Failure to comply may result in death or serious injury

.

The operating company is responsible for any injuries or equipment damage resulting from failure to heed the warnings in this manual.

N O T I C E

Do not modify the drive or option circuitry.

Failure to comply could result in damage to the drive or option and will void warranty.

Magnetek is not responsible for any modification of the product made by the user. This product must not be modified.

Do not expose the drive or option to halogen group disinfectants.

Failure to comply may cause damage to the electrical components in the drive or option.

Do not pack the drive in wooden materials that have been fumigated or sterilized.

Do not sterilize the entire package after the product is packed.


1-4

2. Product Overview

About This Product

The Digital Input/Output Option S4IO allows the user to expand the number of drive multi-function digital inputs and digital outputs. The S4IO option board has four photocoupler digital input signals, each requiring a typical input signal of 120 VAC 8mA (24 VAC and 48 VAC are optional). The S4IO option board also has four relay outputs. Each relay output signal is capable of loads up to 250 VAC

1A or 30 VDC 1A.

S4IO Model

S4IO-120A60

S4IO-48A60

S4IO-24A60

Voltage

120 VAC

48 VAC

24 VAC

I1-I4

Frequency

60 Hz

60 Hz

60 Hz

Voltage

120 VAC

120 VAC

120 VAC

O1-O6

Current

1.0 A

1.0 A

1.0 A


1-5

3. Receiving

Please perform the following tasks upon receiving the option:

• Inspect the option for damage. Contact the shipper immediately if the option appears damaged upon receipt.

• Verify receipt of the correct model by checking the model number printed on the option nameplate (refer to Figure 1 on page 7 for more information).

• Contact your supplier if you have received the wrong model or the option does not function properly.

Option Package Contents

Description: Option Screws (M3)

Installation

Manual

--

Quantity 1 3 1

Tools Required for Installation

• A Phillips screwdriver (M3 metric / #1, #2 U.S. standard size) is required to install the option.

• A straight-edge screwdriver (blade depth: 0.015” [0.4 mm], width: 0.098” [2.5 mm]) is required to wire the option terminal block.

• A pair of diagonal cutting pliers.

• A small file or medium-grit sandpaper.

NOTE: Tools required to prepare option cables for wiring are not listed in this manual.


1-6

4. Option Components

AC Digital Input S4IO Option

Terminal Blocks

Figure 1: Digital Input/Output Option

Figure 2: Terminal Blocks

Refer to Table 3 on page 18 for details on terminal functions and signal levels.


1-7

5. Installation Procedure

Section Safety

D A N G E R

Electric Shock Hazard

Do not connect or disconnect wiring while the power is on.

Failure to comply will result in death or serious injury.

Disconnect all power to the drive and wait at least the amount of time specified on the drive front cover safety label. After all indicators are off, measure the DC bus voltage to confirm safe level, and check for unsafe voltages. The internal capacitor remains charged after the power supply is turned off.

WA R N I N G

Electrical Shock Hazard

Do not remove the front cover of the drive while the power is on.

Failure to comply could result in death or serious injury.

The diagrams in this section may include options and drives without covers or safety shields to show details. Be sure to reinstall covers or shields before operating any devices. Use the option according to the instructions described in this manual.

Do not allow unqualified personnel to use equipment.


Maintenance, inspection, and replacement of parts must be performed only by authorized personnel familiar with installation, adjustment, and maintenance of this product.

Do not touch circuit boards while the power to the drive is on.


Do not use damaged wires, place excessive stress on wiring, or damage the wire insulation.


Fire Hazard

Tighten all terminal screws to the specified tightening torque.

Loose electrical connections could result in death or serious injury by fire due to overheating of electrical connections.


1-8

N O T I C E

Damage to Equipment

Observe proper electrostatic discharge (ESD) procedures when handling the option, drive, and circuit boards.

Failure to comply may result in ESD damage to circuitry.

Never shut the power off while the drive is running or outputting voltage.

Failure to comply may cause the application to operate incorrectly or damage the drive.

Do not operate damaged equipment.

Failure to comply may cause further damage to the equipment.

Do not connect or operate any equipment with visible damage or missing parts.

Do not use unshielded cable for control wiring.

Failure to comply may cause electrical interference resulting in poor system performance.

Use shielded twisted-pair wires and ground the shield to the ground terminal of the drive.

Properly connect all pins and connectors.

Failure to comply may prevent proper operation and possibly damage equipment.

Check wiring to ensure that all connections are correct after installing the option and connecting any other devices.

Failure to comply may result in damage to the option.


1-9

Prior to Installing the Option

Prior to installing the option, wire the drive, make the necessary connections to the drive terminals, and verify that the drive functions normally. Refer to the Quick Start Guide packaged with the drive for information on wiring and connecting the drive.

Figure 3 shows an exploded view of the drive with the option and related components for reference.

Figure 3: Drive Components with Option


1-10

Installing the Option

Refer to the instructions below to install the option.

1.

Shut off power to the drive, wait the appropriate amount of time for voltage to dissipate, then remove the digital operator (D) and front covers (C, E). Refer to the Quick Start Guide packaged with the drive for directions on removing the covers. Cover removal varies depending on drive size.

D A N G E R

Electrical Shock Hazard.

Disconnect all power to the drive and wait at least the amount of time specified on the drive front cover safety label. After all indicators are off, measure the DC bus voltage to confirm safe level, and check for unsafe voltages before servicing to prevent electric shock. The internal capacitor remains charged even after the power supply is turned off.

N O T I C E

Damage to Equipment

Observe proper electrostatic discharge procedures (ESD) when handling the option, drive, and circuit boards. Failure to comply may result in ESD damage to circuitry.

Figure 4: Remove the Front Covers and Digital Operator


1-11

2.

Insert the option card (B) into the CN5-A (I), CN5-B (J), or CN5-C (K) connector located on the drive and fasten it into place using two of the included screws (G).

NOTE: Install the option to ports CN5-B and CN5-C on the drive for monitoring purposes only and input levels will be displayed in monitor U1-17. The option will not set the frequency reference or replace the drive analog input with higher resolution inputs when connected to ports CN5-B or CN5-C.

Figure 5: Insert the Option Card


1-12

3.

Prepare and connect the wire ends as shown in Figure 6 and Figure 7. Refer to Wire Gauges,

Tightening Torques, and Crimp Terminals on page 17 to confirm that the proper tightening torque is applied to each terminal. Take particular precaution to ensure that each wire is properly connected and wire insulation is not accidentally pinched into electrical terminals.

WA R N I N G

Fire Hazard.

Tighten terminal screws to the specified tightening torque. Loose electrical connections could result in death or serious injury by fire due to overheating. Tightening screws beyond the specified tightening torque may cause erroneous operation, damage the terminal block, or cause a fire.

N O T I C E

Heat shrink tubing or electrical tape may be required to ensure that cable shielding does not contact other wiring. Insufficient insulation may cause a short circuit and damage the option or drive.

Figure 6: Preparing Ends of Shielded Cable

Figure 7: Preparing and Connecting Cable Wiring


1-13

4.

Wire the customer-supplied digital input signal to the terminal blocks on the option. Refer to Figure

8 for wiring instructions.

Connection Diagram

Refer to Table 3 on page 18 for a detailed description of the option board terminal functions. To ensure accurate control, use a stable power supply for the voltage reference source.

Figure 8: Option Connection Diagram


1-14

5.

Route the option wiring.

Depending on the drive model, some drives may require routing the wiring through the side of the front cover to the outside. In these cases, cut out the perforated openings on the left side of the drive front cover as shown in Figure 9-A and leave no sharp edges to damage wiring.

Route the wiring inside the enclosure as shown in Figure 9-B for drives that do not require routing through the front cover.

Refer to the IMPULSE

®

•G+/VG+ Series 4 Instruction Manual for more information.

<1> The drive will not meet NEMA Type 1 requirements if wiring is exposed outside the enclosure.

Figure 9: Wire Routing Examples


1-15

6.

Replace and secure the front covers of the drive (C, E) and replace the digital operator (D).

Figure 10: Replace the Front Covers and Digital Operator

NOTE: Take proper precautions when wiring the option so that the front covers will easily fit back onto the drive. Make sure cables are not pinched between the front covers and the drive when replacing the covers.

7.

Set drive parameters in Table 4 for proper option performance.


1-16

Wire Gauges, Tightening Torques, and Crimp Terminals

Wire Gauges and Tightening Torques

Wire gauge and torque specifications are listed in Table 1.

Terminal

Size

X2

I1 to I4

O1 to O6

Screw

Size

M2

M3

Table 1: Wire Gauges and Tightening Torques

Tightening

Torque

N-m (in-lb)

0.22 to 0.25

(1.95 to 2.21)

0.5 to 0.6

(4.43 to 5.31)

Bare Cable

Applicable

Gauges mm

2

Stranded wire:

0.25 to 1.0

(24 to 17 AWG)

Solid wire:

0.25 to 1.5

(24 to 16 AWG)

Stranded wire:

0.14 to 1.5

(26 to 16 AWG)

Solid wire:

0.14 to 1.5

(26 to 16 AWG)

Recomm.

Gauge mm

2

0.75

(18 AWG)

Crimp Terminals

Applicable

Gauges mm

2

Recomm.

Gauge mm

2

0.25 to 0.5

(24 to 20 AWG)

0.25 to 1.5

(24 to 16 AWG)

0.5

(20 AWG)

Wire

Type

Shielded twisted pair, etc.

Crimp Terminals

Magnetek recommends using CRIMPFOX 6 by Phoenix Contact or equivalent crimp terminals with the specifications listed in Table 2 for wiring to ensure proper connections.

Wire Gauge mm

2

Table 2: Crimp Terminal Sizes

Phoenix

Contact

Model

L mm (in) d1 mm (in)

0.25 (24 AWG) AI 0.25 - 6YE 10.5 (13/32) 0.8 (1/32)

0.34 (22 AWG) AI 0.34 - 6TQ 10.5 (13/32) 0.8 (1/32)

0.5 (20 AWG)

1.0 (16 AWG)

AI 0.5 - 6WH

AI 1-6RD

14 (9/16)

12 (15/32)

1.1 (3/64)

1.5 (1/16)

d2 mm (in)

2 (5/64)

2 (5/64)

2.5 (3/32)

3.0 (1/8)


1-17

Terminal Functions

Terminal

Block

Terminal

TB1

TB2

I3

I4

O1

O2

X2

I1

I2

O3

O4

O5

O6

Table 3: Option Terminal Functions

Description

MFDI Common

DIO MFDI Terminal 1

DIO MDFI Terminal 2

DIO MDFI Terminal 3

DIO MDFI Terminal 4

Relay output 1

Relay 1 and 2 common

Relay output 2

Relay output 3

Relay 3 and 4 common

Relay output 4


1-18

6. Related Parameters

The parameters outlined in the following sections are used to set up the drive for operation with the option. Set parameters as needed. Parameter setting methods can be found in the drive Quick Start

Guide or Instruction Manual.

C9-02

C9-03

C9-04

C9-05

1 Enabled DI-A3

3 Serial

DIO Terminal 1

DIO Terminal 2

DIO Terminal 3

DIO Terminal 4

Table 4: Input Related Parameters

Parameter

Code

C9-01

Display

Digital In Sel

0 Disabled

1 Enabled S4IO

Function

Provides additional programmable

MFDI

No additional MFDI are being used.

Additional MFDI from S4I using

C9-02 ~ C9-05

Additional MFDI from DI-A3 using

C9-02 ~ C9-19

Additional MFDI from MB RTU using C9-02 ~ C9-19

MFDI by S4IO.

See H1-0x settings in the

IMPULSE

®

•

G+/VG+ Series 4

Instruction Manual for MFDI selections.

Range

0 - 2

0–FF

0–FF

0–FF

0–FF

Initial

Value

0

0F

0F

0F

0F

Table 5: Output Related Parameters

Parameter

Code

F5-01

F5-02

F5-03

F5-04

F5-09

Display

DO Ch1 Select

DO Ch2 Select

DO Ch3 Select

DO Ch4 Select

DO Function Sel

Function

MFDO by S4IO

Refer to drive instruction manual for more informatioin on setting the

F5 parameters.

Digital output mode selection. This value cannot be changed when the S4IO board is installed.

Range

0–140

0–140

0–140

0–140

2

0F

0F

2

Initial

Value

0F

0F


1-19

Parameter F5-09

Set parameter F5-09 to select the option output mode.

Table 6 shows the changes in the output terminal contents according to the output mode set in F5-

09.

Table 6: Output Terminal

Terminal

Block

TB2

Terminal

O1-O2

O3-O2

O4-O5

O6-O5

F5-09 = 2

Multi-Function Output

Determined by F5-01

Determined by F5-02

Determined by F5-03

Determined by F5-04


1-20

7. Troubleshooting

Drive-Side Error Codes

Table 7 lists the various fault codes related to the option. Refer to the drive’s Instruction Manual for further details on fault codes.

Check the following items first when an error code occurs on the drive:

• Cable connections.

• Make sure the option is properly installed to the drive.

• Did a momentary power loss interrupt communications?

Table 7: Fault Displays, Causes, and Possible Solutions

Digital Operator Display Fault Name

Option Fault (CN5-A) oFA01

Option is not properly connected

Cause

Option at drive port CN5-A was changed during run.

Digital Operator Display

oFb01

Cause

Option at drive port CN5-B was changed during run.


Possible Solution

Turn the power off and check the connectors between the drive and option.

Fault Name

Option Fault (CN5-B)

Option is not properly connected



Fault Name

Option Fault (CN5-B) oFb02

Two of the same options are connected simultaneously

Cause

DI-A3 option connected to CN5-B port while another option was connected to

CN5-A port.



Only one of the options, DI-A3, AI-A3, or SI-XX can be connected to the drive at the same time.

Fault Name

oFC01 Option connection error at drive port CN5-C

Cause

Option at drive port CN5-C was changed during run.




1-21

Digital Operator Display Fault Name

Option Fault (CN5-C) oFC02

Two of the same options are connected simultaneously

Cause

DI-A3 option connected to CN5-C port while another option was connected to

CN5-A port.



Only one of these options, DI-A3, AI-A3, or SI-XX can be connected to the drive at the same time.

Fault Name

Cause

oPE05

Run command/frequency reference source selection error


Frequency reference is assigned to an option (b1-01 = 3) but an option is not connected.

Reconnect the option to the drive.

Preventing Noise Interference

Take the following steps to prevent erroneous operation caused by noise interference:

• Use shielded wire for the signal lines.

• Limit the length of wiring under 50 m (164 ft.).

• Separate the control wiring to the option, main circuit wiring, and power lines.


1-22

8. Specifications

Table 8: Option Specifications

Items

Model

Input Terminals

Input Signal Type

(Parameter Settings)

Input Signal

Output Terminals

Output Signal

Ambient

Temperature

Humidity

Storage

Temperature

Area of Use

Altitude

Specifications

S4IO

4 terminals

Binary 16-bit,4-digit BCD

Binary 12-bit, 3-digit BCD

Binary 8-bit, 2-digit BCD

120 VAC/60 Hz

4 outputs

Max. allowable voltage/current: 250 VAC/1A, 30 VDC/1A

-10 °C to +60 °C (14 °F to 140 °F)

95% RH or lower with no condensation

-20 °C to +70 °C (-4 °F to 158 °F) allowed for short-term transport of the product

Indoor (free of corrosive gas, airborne particles, etc.)

1000 m (3280 ft.) or lower


1-23


1-24

Magnetek IMPULSE G+/VG+ Series 4 S4IO AC Owner's Manual

Assistant Bot

AC Digital Input/Output Installation

Manual

September 2011

Part Number: 144-23967

© Copyright 2011 Magnetek

1. Preface and Safety

Digital Input S4IO Option

MPULSE•G+/VG+ Series 4 Drive

General Precautions

2. Product Overview

3. Receiving

4. Option Components

Figure 1: Digital Input/Output Option

Figure 2: Terminal Blocks

5. Installation Procedure

Figure 3: Drive Components with Option

Figure 4: Remove the Front Covers and Digital Operator

Figure 5: Insert the Option Card

Figure 6: Preparing Ends of Shielded Cable

Figure 7: Preparing and Connecting Cable Wiring

Figure 8: Option Connection Diagram

Figure 9: Wire Routing Examples

Figure 10: Replace the Front Covers and Digital Operator

Wire Gauges and Tightening Torques

Table 1: Wire Gauges and Tightening Torques

Crimp Terminals

Table 2: Crimp Terminal Sizes

Table 3: Option Terminal Functions

6. Related Parameters

Table 4: Input Related Parameters

Table 5: Output Related Parameters

Table 6: Output Terminal

7. Troubleshooting

Table 7: Fault Displays, Causes, and Possible Solutions

8. Specifications

Table 8: Option Specifications

Key Features

Frequently Answers and Questions

What does this option do?

What are the types of input signals that this option can accept?

What types of loads can the relay outputs drive?

What is the purpose of the MFDI and MFDO terminals on the option?

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