Magnetek IMPULSE G+/VG+ Series 4 DO A3 Owner's Manual

Digital Output Installation Manual

August 2011

Part Number: 144-23920

© 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

T he following manuals are available for the option:

Digital Output DO-A3 Option

IMPULSE

®

•

G+/VG+ Series 4

Digital Output Installation

Manual

Manual No: 144-23920

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.

IMPULSE

®

•G+/VG+ Series 4 Drive

IMPULSE

®

•

G+/VG+ Series 4

Quick Start Guide

IMPULSE

®

•

G+/VG+ Series 4

Instruction Manual

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.

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

IMPULSE®•G+/VG+ Series 4 Digital Output Installation Manual

August 2011

1-2

Terms

Drive :

IMPULSE

®

•G+/VG+ Series 4

Option: IMPULSE

®

•G+/VG+ Series 4 Option Digital Output DO-A3

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.


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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 will 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 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.


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2. Product Overview

About This Product

The Digital Output Option DO-A3 allows the user to expand the number of available digital outputs to monitor drive run status.

The option has the following features:

• Six photocoupler outputs (48 V, 50 mA or less)

• Two relay outputs (250 Vac, 1 A or less; 30 Vdc, 1 A or less)


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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 Ground Wires Screws (M3)

Installation

Manual

--

Quantity 1 2 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.


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4. Option Components

DO-A3 Option

<1> The ground wires provided in the option shipping package must be connected during installation.

Figure 1: Digital Output DO-A3 Option Components

Terminal Blocks TB1 and TB2

Figure 2: Terminal Blocks

Refer to Table 3 on page 19 for details on TB1 and TB2 terminal functions and signal levels.


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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 covers 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, stress the 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.


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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.


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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 Options


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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 front 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


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1-11

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

Figure 5: Insert the Option Card


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1-12

3. Connect one end of the ground wire (H) to the ground terminal (I) using one of the remaining screws (G). Connect the other end of the ground wire (H) to the remaining ground terminal and installation hole on the option (B) using the last remaining provided screw (G).

Figure 6: Connect the Ground Wire

NOTE: 1. The option package includes three ground wires. Use the longest wire when plugging the option into connector CN5-C on the drive side. Use the next longest wire when plugging the option into connector CN5-B. Use the shortest wire when plugging the option into connector CN5-A. Refer to Option Package Contents on page 6 for more information.

2. There are two screw holes on the drive for use as ground terminals (I).


August 2011

1-13

4. Prepare and connect the wire ends as shown in Figure 7 and Figure 8. Refer to Wire Gauges,

Tightening Torques, and Crimp Terminals on page 18 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 7: Preparing Ends of Shielded Cable

Figure 8: Preparing and Connecting Cable Wiring


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1-14

5. Wire the customer-supplied circuit to the terminal blocks on the option. Refer to Figure 9 for wiring instructions.

Connection Diagram

Refer to Table 3 on page 19 for a detailed description of the option board terminal functions. To ensure accurate control, use stable power supply for the voltage reference source

<1> Double-check the polarity on the diode when connecting a DC relay.

<2> Install a surge absorber (SA ) when using an AC relay.

Figure 9: Option Connection Diagram


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1-15

6. 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 10-A and leave no sharp edges to damage wiring.

Route the wiring inside the enclosure as shown in Figure 10-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 10: Wire Routing Examples


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1-16

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

Figure 11: 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.

8. Set drive parameters in Table 6 for proper option performance.


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1-17

Wire Gauges, Tightening Torques, and Crimp Terminals

Wire Gauges and Tightening Torques

Wire gauge and torque specifications are listed in Table 1.

Terminal

Size

P1 to P6,

PC

M1 to M4

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:

0.25 to 1.5

(24 to 16 AWG)

Solid wire:

0.25 to 2.5

(24 to 13 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 1.0

(24 to 17 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. Properly trim wire ends so loose wire ends do not extend from the crimp terminals.

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)


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1-18

Terminal Functions

Terminal

Block

Terminal

TB1

TB2

M1

M2

M3

M4

P1

P2

P3

P4

P5

P6

PC

Table 3: Option Terminal Functions

Output <1>

Contact relay output 1

Contact relay output 2

Photocoupler output 1






Photocoupler output common

Output Type

N.O. Output

Output Level

Max voltage and current:

250 VAC, 1 A

30 VDC, 1 A

Open-collector output

Max voltage and current:

48 VDC, 50 mA

Emitter common

<1> Set drive parameters to determine the function assigned to each output.


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1-19

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.

Parameter F5-09

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

Table 4 shows the changes in the output terminal contents according to the output mode set in F5-

09.

Table 4: Related Parameters

Terminal

Block

TB1

TB2

Terminal

F5-09 = 0

Individual Output

(default)

M1-M2 Zero Speed

M3-M4 Speed Agree

P1-PC

P2-PC oC, GF (Overcurrent) ov (Overvoltage)

P3-PC

P4-PC

P5-PC

P6-PC oH2 (Drive overheat) or oL2 (Overload)

Not used oS (Overspeed) oH, oH1 (Drive overheat) or oL1 (Overload)

F5-09 = 1

Binary Code Output

During run

Alarm (excluding bb)

Binary code output (refer to Table 6)

Zero speed

Speed agree

F5-09 = 2

Multi-Function

Output

Determined by F5-07

Determined by F5-08

Determined by F5-01

Determined by F5-02

Determined by F5-03

Determined by F5-04

Determined by F5-05

Determined by F5-06

9

D

E

F

A

B

C

Coded

Output

6

7

4

5

8

2

3

0

1

Table 5: Binary Coded Output (F5-09 = 1)

TB2

Description

Normal operation (no fault) oC, GF (Overcurrent) ov (Overvoltage) oL2 (Drive overload) oH, oH1 (Drive over heat) oS (Overspeed)

Not used rr, rH (Braking resistor overheat)

EF1 to EF12 (External fault)

CPFXX, oFAXX, oFbXX, oFCXX

(Drive hardware fault) oL1 (Motor overload)

Not used

Uv1, Uv2, Uv3 (Undervoltage) dEv (Speed deviation)

PGo (PG disconnect)

Not used

1

1

0

1

0

1

0

P1-PC

0

1

0

1

0

0

1

0

1

0

1

1

1

1

0

P2-PC

1

1

0

0

0

1

1

0

0

0

P3-PC

1

1

1

1

0

0

0

0

0

0

1

1

1

0

0

1

1

1

1

1

1

1

1

P4-PC

0

0

0

0

1

0

0

0

0


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Parameter Table

No. (Addr.

Hex)

F5-01 (399)

F5-02 (39A)

F5-03 (39B)

F5-04 (39C)

F5-05 (39D)

F5-06 (39E)

F5-07 (39F)

F5-08 (3A0)

Name

Terminal P1-PC Output

Selection


Selection


Selection


Selection


Selection


Selection

Terminal M1-M2 Output

Selection

Terminal M3-M4 Output

Selection

F5-09 (3A1)

Table 6: Related Parameters

DO-A3 Output Mode

Selection

Description Values

Sets the function for contact output terminals M1-M2, M3-M4, and photocoupler output terminals P1 through P6. <1>

Default: 0

Range: 0 to 148

Default: 1

Range: 0 to 148

Default: 2

Range: 0 to 148

Default: 4

Range: 0 to 148

Default: 6

Range: 0 to 148

Default: 37

Range: 0 to 148

Default: F

Range: 0 to 148

Default: F

Range: 0 to 148

0: Output terminals are each assigned separate output functions.

1: Binary code output.

2: Multi-function output (set functions in parameters F5-01 through F5-08)

Default: 0

Range: 0 to 2

<1> Refer to the drive Instructionl Manual for more information on setting the F5 parameters.


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7. Troubleshooting

Drive-Side Error Codes

Table 8 lists the various fault codes related to the option. Refer to the drive Instruction Manual for further details on fault codes.

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

• Are the cables connected properly and securely?

• Is the option properly installed to the drive?

• Did a momentary power loss occur?

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

Possible Solution

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

Fault Name

Option Fault (CN5-B)

Cause

changed during run.

oFb01

Option at drive port CN5-B was


Option is not properly connected.


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

Fault Name

Option Fault (CN5-B) oFb02

Two of the same options are connected simultaneously.

Cause

Same type of option connected to ports

CN5-A and CN5-B.



Use only compatible options.

Fault Name

oFC01 Option connection error at drive port CN5-C

Cause

Option at drive port CN5-C was changed during run


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


August 2011

1-22


oFC02

Fault Name

Option Fault (CN5-C)

Two of the same options are connected simultaneously.

Cause

Same type of option connected to drive ports CN5-A, CN5-B, and CN5-C.


Use only compatible options.

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.

Interface Circuit

Figure 12: Output Interface Circuit


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1-23

8. Specifications

Table 8: Option Specifications

Model

Items

Photocoupler Output

Specifications

DO-A3

6 outputs (common emitter)

Maximum allowable voltage/current: 48 Vdc / 50 mA

2 outputs (independent)

Maximum allowable voltage/current: 250 Vac / 1 A, 30 Vdc / 1 A

Contact Relay

Output

Ambient

Temperature

Humidity

Storage

Temperature

Area of Use

Altitude

-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


August 2011

1-24

Magnetek IMPULSE G+/VG+ Series 4 DO A3 Owner's Manual

Digital Output Installation Manual

August 2011

Part Number: 144-23920

© Copyright 2011 Magnetek

1. Preface and Safety

Digital Output DO-A3 Option

IMPULSE

•G+/VG+ Series 4 Drive

General Precautions

2. Product Overview

3. Receiving

4. Option Components

Figure 1: Digital Output DO-A3 Option Components

Figure 2: Terminal Blocks

5. Installation Procedure

Figure 3: Drive Components with Options

Figure 4: Remove the Front Covers and Digital Operator

Figure 5: Insert the Option Card

Figure 6: Connect the Ground Wire

Figure 7: Preparing Ends of Shielded Cable

Figure 8: Preparing and Connecting Cable Wiring

Figure 9: Option Connection Diagram

Figure 10: Wire Routing Examples

Figure 11: 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: Related Parameters

Table 5: Binary Coded Output (F5-09 = 1)

Table 6: Related Parameters

7. Troubleshooting

Table 7: Fault Displays, Causes, and Possible Solutions

Interface Circuit

Figure 12: Output Interface Circuit

8. Specifications

Table 8: Option Specifications

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