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Emerson Affinity User Manual
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Safety
Information
Product
Information
Mechanical
Installation
Electrical
Installation
Getting
Sta
r
t
e
d
Basic
parameters
Running
the motor
Optimization
SMARTCARD
operation
PC tools
Advanced
parameters
T
echnic
al
Data
Diagnostics
UL Listing
Information
144
Affinity User Guide
www.controltechniques.com
Issue Number: 5
T
able
1
1-5
Maximum motor rated curren
t
Model
K
C
Maximum Normal Duty current
rating
A
BA1201
4.3
5.2
BA1202
5.8
6.8
BA1203
7.5
9.6
BA1204
10.6
1
1
BA2201
12.6
15.5
BA2202
17.0
22.0
BA2203
25.0
28.0
BA3201
31.0
42.0
BA3202
42.0
54.0
BA4201
56.0
68.0
BA4202
68.0
80.0
BA4203
80.0
104.0
BA5201
105.0
130.0
BA5202
130.0
154.0
BA1401
2.1
2.8
BA1402
3.0
3.8
BA1403
4.2
5.0
BA1404
5.8
6.9
BA1405
7.6
8.8
BA1406
9.5
1
1.0
BA2401
13.0
15.3
BA2402
16.5
21.0
BA2403
23.0
29.0
BA3401
32.0
35.0
BA3402
40.0
43.0
BA3403
46.0
56.0
BA4401
60.0
68.0
BA4402
74.0
83.0
BA4403
96.0
104.0
BA5401
124.0
138.0
BA5402
156.0
168.0
BA6401
154.2
202.0
BA6402
180.0
236.0
BA3501
4.1
5.4
BA3502
5.4
6.1
BA3503
6.1
8.4
BA3504
9.5
1
1.0
BA3505
12.0
16.0
BA3506
18.0
22.0
BA3507
22.0
27.0
BA4601
19.0
22.0
BA4602
22.0
27.0
BA4603
27.0
36.0
BA4604
36.0
43.0
BA4605
43.0
52.0
BA4606
52.0
62.0
BA5601
63.0
84.0
BA5602
85.0
99.0
BA6601
85.7
125.0
BA6602
107.1
144.0
143
145
Table of Contents
Default Chapter
3
Table of Contents
3
1 Safety Information
7
Warnings, Cautions and Notes
7
Electrical Safety - General Warning
7
System Design and Safety of Personnel
7
Environmental Limits
7
Access
7
Fire Protection
7
Compliance with Regulations
7
Motor
7
Mechanical Brake Control
7
Electrical Installation
8
2 Product Information
9
Introduction
9
Drive Types
10
Ratings
10
Table 2-1 200V Drive Ratings (200V to 240V ±10%)
11
Table 2-2 400V Drive Ratings (380V to 480V ±10%)
12
Table 2-3 575V Drive Ratings (500V to 575V ±10%)
13
Table 2-4 690V Drive Ratings (500V to 690V ±10%)
13
Model Number
14
Operating Modes
14
Table 2-5 Typical Overload Limits for Size 1 to 6
14
Drive Features
15
Nameplate Description
16
Options
17
Table 2-6 Solutions Module Identification
17
Items Supplied with the Drive
19
Table 2-7 Parts Supplied with the Drive
19
3 Mechanical Installation
20
Safety Information
20
Planning the Installation
20
Terminal Cover Removal
22
Table 3-1 Conduit Box Part Numbers
26
Solutions Module / Keypad Installation / Removal
29
Mounting Methods
31
Table 3-2 Mounting Brackets (Standard)
41
Table 3-3 E12/E54 Mounting Clearances
41
Table 3-4 E12/E54 Mounting Brackets
46
Enclosure for Standard Drives
48
Enclosure Design and Drive Ambient Temperature
49
Enclosing Standard Drive for High Environmental Protection
50
Table 3-5 Description of Fixings
52
Table 3-6 Quantity of Nylon Washers Supplied with the Table 11-7 Drive
52
Table 3-7 Environment Considerations
53
Table 3-8 Power Losses from the Front of the Drive When Through-Panel Mounted
53
External EMC Filter for Standard Drives
54
Table 3-9 Drive EMC Filter Details (Size 1 to 6)
54
Electrical Terminals
62
Table 3-10 Drive Control and Relay Terminal Data
62
Table 3-11 Wall Mounted Drive Power Terminal Data
62
Table 3-12 Plug-In Terminal Block Maximum Cable Sizes
62
Table 3-13 Schaffner External EMC Filter Terminal Data (Size 1 to 6)
62
Table 3-14 Epcos External EMC Filter Terminal Data
62
Routine Maintenance
63
4 Electrical Installation
66
Power Connections
66
AC Supply Requirements
69
Auxiliary Power Supply
70
Table 4-1 Behavior of the Drive in the Event of a Motor Circuit Ground (Earth) Fault with an IT Supply
70
Supplying the Drive with DC / DC Bus Paralleling
71
Fan Connections
71
Control 24Vdc Supply
71
Ratings
71
Table 4-3 Size 1 to 3 Input Current, Fuse and Cable Size Ratings (European)
72
Table 4-5 Size 4 and Larger Input Current, Fuse and Cable Size Ratings
73
Output Circuit and Motor Protection
74
Table 4-6 Maximum Motor Cable Lengths (200V Drives)
74
Table 4-7 Maximum Motor Cable Lengths (400V Drives)
74
Table 4-8 Maximum Motor Cable Lengths (575V Drives)
74
Table 4-9 Maximum Motor Cable Lengths (690V Drives)
74
Braking
76
Table 4-10 Braking Transistor Turn on Voltage
76
Table 4-11 Heatsink Mounted Braking Resistor Data
76
Table
77
Ground Leakage
78
EMC (Electromagnetic Compatibility)
78
Table 4-13 Affinity EMC Filter Cross Reference
79
Table 4-14 IP54 EMC Filter Cross Reference
79
Figure 4-19 Size 4 and 5 Grounding Link Bracket Folded up into Its Through- Panel Mount Position
80
Figure 4-20 Removal of Internal EMC Filter (Size 1 to 3)
81
Figure 4-21 Removal of Internal EMC Filter (Sizes 4 to 6)
81
Figure 4-22 General EMC Enclosure Layout Showing Ground Connections
82
Figure 4-23 Drive Cable Clearances
83
Table 4-15 Second Environment Emission Compliance
83
Figure 4-24 Supply and Ground Cable Clearance (Size 1 to 3)
84
Figure 4-25 Supply and Ground Cable Clearance (Size 4 to 6)
84
Figure 4-26 Sensitive Signal Circuit Clearance
85
Figure 4-27 Grounding the Drive, Motor Cable Shield and Filter
85
Figure 4-28 Grounding the Motor Cable Shield
85
Figure 4-29 Shielding Requirements of Optional External Braking Resistor
85
Figure 4-30 Grounding of Signal Cable Shields Using the Grounding Bracket
86
Figure 4-31 Connecting the Motor Cable to a Terminal Block in the Enclosure
86
Figure 4-32 Connecting the Motor Cable to an Isolator / Disconnect Switch
86
PC Communications Connections
87
Figure 4-33 Surge Suppression for Digital and Unipolar Inputs and Outputs
87
Figure 4-34 Surge Suppression for Analog and Bipolar Inputs and Outputs
87
Figure 4-35 Location of the RJ45 Serial Comms
87
Table 4-16 Connection Details for RJ45 Connector
87
Terminal Connections
88
Figure 4-36 Location of RJ45 Serial Connector
88
Figure 4-37 Connector with Cap Installed
88
Table 4-17 Isolated Serial Comms Lead Details
88
Table 4-18 the Terminal Connections Consist of
88
Figure 4-38 Default Terminal Functions
89
Building Automation Network Connections
92
Heatsink Fan Supply Connections (Size 4 to 6)
92
Figure 4-39 Multi-Drop Connection
92
5 Getting Started
93
Understanding the Display
93
Keypad Operation
93
Figure 5-1 BA-Keypad
93
Menu Structure
94
Figure 5-2 Display Modes
94
Figure 5-3 Mode Examples
94
Figure 5-4 Parameter Navigation
94
Menu 0
95
Advanced Menus
95
Figure 5-5 Menu Structure
95
Figure 5-6 Menu 0 Copying
95
Table 5-2 Menu 40 Parameter Descriptions
95
Table 5-1 Advanced Menu Descriptions
95
Table 5-3 Menu 41 Parameter Descriptions
96
Table 5-4 Alarm Indications
96
Table 5-5 Status Indications
96
Table 5-6 Solutions Module and SMARTCARD Status Indications on Power-Up
96
Changing the Operating Mode
97
Changing the Keypad Mode
97
Saving Parameters
97
Restoring Parameter Defaults
97
Parameter Access Level and Security
97
Displaying Parameters with Non-Default Values Only
99
Displaying Destination Parameters Only
99
Communications
99
Table 5-7 Increased Object Identifier Range Setup
100
6 Basic Parameters
102
Single Line Descriptions
102
Table 6-1 Single Line Descriptions
102
Figure 6-1 Menu 0 Logic Diagram
104
Full Descriptions
106
Figure 6-2 Fixed and Variable V/F Characteristics
107
7 Running the Motor
115
Quick Start Connections
115
Changing the Operating Mode
115
Changing Keypad Mode
115
Table 7-1 Minimum Control Connection Requirements for each Control Mode
115
Figure 7-1 Minimum Connections to Get the Motor Running in any Operating Mode
116
Quick Start Commissioning/Start-Up
118
Motor Map Parameters
121
Current Limits
127
Motor Thermal Protection
127
Figure 8-1 Motor Thermal Protection
127
Switching Frequency
128
High Speed Operation
128
Figure 8-2 Torque and Rated Voltage against Speed
128
Table 8-1 Available Switching Frequencies
128
Table 8-2 Sample Rates for Various Control Tasks at each Switching Frequency
128
9 SMARTCARD Operation
129
Introduction
129
Figure 9-1 Installation of the SMARTCARD
129
Figure 9-2 Basic SMARTCARD Operation
129
Transferring Data
130
Data Block Header Information
131
SMARTCARD Parameters
132
SMARTCARD Trips
133
Ctsoft
135
Onboard PLC and Syptlite
135
Figure 10-1 Onboard PLC Program Scheduling
136
CT Energy Savings Estimator
137
11 Advanced Parameters
139
Menu 1: Frequency / Speed Reference
146
Figure 11-1 Menu 1 Logic Diagram
146
Menu 2: Ramps
150
Figure 11-2 Menu 2 Logic Diagram
150
Menu 3: Speed Feedback and Speed Control
153
Figure 11-3 Menu 3 Open-Loop Logic Diagram
153
Figure 11-4 Menu 3 RFC Logic Diagram
154
Menu 4: Torque and Current Control
156
Figure 11-5 Menu 4 Open Loop Logic Diagram
156
Figure 11-6 Menu 4 RFC Logic Diagram
157
Menu 5: Motor Control
159
Figure 11-7 Menu 5 Open-Loop Logic Diagram
159
Figure 11-8 Menu 5 RFC Logic Diagram
160
Menu 6: Sequencer and Clock
163
Figure 11-9 Menu 6 Logic Diagram
163
Menu 7: Analog I/O
165
Figure 11-10 Menu 7 Logic Diagram
165
Menu 8: Digital I/O
168
Figure 11-11 Menu 8 Logic Diagram
168
Menu 9: Programmable Logic, Motorized Pot, Binary Sum and Timers
171
Figure 11-12 Menu 9 Logic Diagram: Programmable Logic
171
Figure 11-13 Menu 9 Logic Diagram: Motorized Pot and Binary Sum
172
Figure 11-14 Menu 9 Logic Diagram: Timers
173
Menu 10: Status and Trips
175
Menu 11: General Drive Set-Up
177
Menu 12: Threshold Detectors, Variable Selectors and Brake Control Function
178
Figure 11-15 Menu 12 Logic Diagram
178
Figure 11-16 Menu 12 Logic Diagram (Continued)
179
Figure 11-17 Open-Loop Brake Function
180
Figure 11-18 Open-Loop Brake Sequence
181
Figure 11-19 RFC Brake Function
182
Figure 11-20 RFC Brake Sequence
183
Menu 14: User PID Controller
186
Figure 11-21 Menu 14 Logic Diagram - Single Setpoint, Single Feedback
186
Figure 11-22 Menu 14 Logic Diagram - Single Setpoint, Dual Feedback
188
Figure 11-23 Menu 14 Logic Diagram - Dual Setpoint, Dual Feedback
190
Menus 15 and 16: Solutions Module Set-Up
193
Figure 11-24 Location of Solutions Module Slots and Their Corresponding Menu Numbers
193
Figure 11-25 SM-I/O Plus Analog Logic Diagram
194
Figure 11-26 SM-I/O Plus Digital Logic Diagram 1
195
Figure 11-27 SM-I/O Plus Digital Logic Diagram 2
196
Figure 11-28 SM-I/O Lite Digital I/O Logic Diagram
198
Figure 11-29 SM-I/O Lite Analog I/O Logic Diagram
199
Figure 11-30 SM-I/O PELV Digital I/O Logic Diagram
201
Figure 11-31 SM-I/O PELV Digital Input Logic Diagram
202
Figure 11-32 SM-I/O PELV Relay Logic Diagram
202
Figure 11-33 SM-I/O PELV Analog Input Logic Diagram
202
Figure 11-34 SM-I/O PELV Analog Output Logic Diagram
203
Figure 11-35 SM-I/O 24V Protected Digital I/O Logic Diagram
206
Figure 11-36 SM-I/O 24V Protected Digital I/O Logic Diagram
206
Figure 11-37 SM-I/O 24V Protected Relay Logic Diagram
206
Figure 11-38 SM-I/O 24V Protected Analog Output Logic Diagram
207
Figure 11-39 SM-I/O 120V Digital Input Logic Diagram
208
Figure 11-40 SM-I/O 120V Relay Diagram
209
Figure 11-41 SM-I/O 32 Logic Diagram
210
Menu 17: Building Automation Network
212
Menu 18: Application Menu 1
212
Menu 19: Application Menu 2
212
Menu 20: Application Menu 3
212
Menu 21: Second Motor Parameters
213
Menu 22: Additional Menu 0 Set-Up
214
Advanced Features
215
Table 11-10 Power-Up Modes if Pr 1.52 = 3
216
Table 11-11 Increased Object Identifier Range Setup
226
12 Technical Data
228
Drive Technical Data
228
Table 12-10 Losses @ 40°C (104°F) Ambient for Size
235
Table 12-11 Losses @ 50°C (122°F) Ambient for Standard Size 1 to 6, Size 1 to 3 E12/E54 and Size 1 to 3 E12/E66 Drives
236
Table 12-12 Losses @ 35°C (95°F) Ambient for Size 4 to 6 E12/54 Drives
237
Table 12-13 Losses @ 40°C (104°F) Ambient for Size 4 to 6 E12/54 Drives
237
Table 12-14 Losses @ 45°C (113°F) Ambient for Size 4 to 6 E12/54 Drives
238
Table 12-15 Power Losses from the Front of the Drive When Through-Panel Mounted
238
Table 12-16 IP Rating Degrees of Protection
239
Table 12-17 UL / NEMA Enclosure Ratings
239
Table 12-18 Acoustic Noise Data for Wall Mounted Drives
240
Table 12-19 Overall Standard Drive Dimensions
240
Table 12-20 Overall Wall Mounted Standard Drive Dimensions with Conduit Box Installed
240
Table 12-21 Overall E12/E54 and E12/E66 Drive
240
Table 12-22 Overall Drive Weights
241
Table 12-23 Overall E12/E54 Drive Weights
241
Table 12-24 Supply Fault Current Used to Calculate Maximum Input Currents
241
Table 12-25 Size 1 to 3 Input Current, Fuse and Cable
241
Table 12-26 Size 4 and Larger Input Current, Fuse and Cable Size Ratings
242
Table 12-27 Maximum Motor Cable Lengths (200V Drives)
243
Table 12-28 Maximum Motor Cable Lengths (400V Drives)
243
Table 12-29 Maximum Motor Cable Lengths (575V Drives)
243
Table 12-30 Maximum Motor Cable Lengths (690V Drives)
243
Table 12-31 Minimum Resistance Values and Peak Power Rating for the Braking Resistor at 40°C (104°F)
244
Table 12-32 Drive Control and Relay Terminal Data
244
Table 12-33 Drive Power Terminal Data
244
Table 12-34 Wall Mounted Drive Power Terminal Data
244
Table 12-35 Plug-In Terminal Block Maximum Cable Sizes
244
Table 12-36 Immunity Compliance
245
Table 12-37 Size 1 Emission Compliance
245
Table 12-38 Size 2 Emission Compliance
245
Table 12-39 Size 3 Emission Compliance
245
Table 12-40 Size 4 (200V & 400V) Emission Compliance
245
Optional External EMC Filters
246
Table 12-41 Size 4 (690V) Emission Compliance
246
Table 12-42 Size 5 (400V) Emission Compliance
246
Table 12-43 Size 5 (690V) Emission Compliance
246
Table 12-44 Size 6 (400V Only) Emission Compliance
246
Table 12-45 Size 6 (690V Only) Emission Compliance
246
Table 12-46 EMC Filter Cross Reference
246
Table 12-47 IP54 EMC Filter Cross Reference
246
Table 12-48 Optional External EMC Filter Details
247
Trip Indications
250
Figure 13-1 Keypad Status Modes
250
Figure 13-2 Location of the Status LED
250
Table 13-1 Example of Typical Trip Indication
250
Table 13-2 Trip Indications
251
Table 13-3 Serial Communications Look-Up Table
260
Table 13-4 Trip Categories
261
Alarm Indications
262
Status Indications
262
Table 13-5 Alarm Indications
262
Table 13-6 Status Indications
262
Table 13-7 Solutions Module and SMARTCARD Status Indications at Power-Up
262
Displaying the Trip History
263
Behavior of the Drive When Tripped
263
Table 13-8 Trip Log Definition
263
14 UL Listing Information
264
Common UL Information
264
Power Dependant UL Information
264
AC Supply Specification
264
Maximum Continuous Output Current
264
Table 14-1 Maximum Continuous Output Current (200V Drives)
264
Safety Label
265
UL Listed Accessories
265
Table 14-2 Maximum Continuous Output Current (400V Drives)
265
Table 14-3 Maximum Continuous Output Current (575V Drives)
265
Table 14-4 Maximum Continuous Output Current (690V Drives)
265
List of Figures
266
List of Tables
268
4
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Emerson Affinity Specifications
General
Brand
Emerson
Model
Affinity
Category
Controller
Language
English
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