Automationdirect.com IronHorse ACN-4020 Manuals

Manuals and User Guides for Automationdirect.com IronHorse ACN-4020. We have 1 Automationdirect.com IronHorse ACN-4020 manual available for free PDF download: User Manual

Automationdirect.com IronHorse ACN-4020 User Manual (453 pages)

AC Drive

Brand: Automationdirect.com | Category: DC Drives | Size: 24 MB

Warnings and Trademarks
2
Marques de Commerce
3
Table of Contents
14
Chapter 1: Getting Started
15
User Manual Overview
15
Overview of this Publication
15
Who Should Read this Manual
15
Supplemental Publications
15
Technical Support
15
Special Symbols
15
Purpose of AC Drives
16
Selecting the Proper Drive Rating
16
Determine Motor Full-Load Amperage (FLA)
16
Determine Motor Overload Requirements
16
Determine Application Type; Constant Torque or Variable Torque
16
Parts Locater
17
Continuous Rated Current Derating
18
Heat Emission
20
Watt Loss and Efficiency
20
Ironhorse ACN Series AC Drive Environmental Information
20
Storage and Transportation
20
Environmental Conditions
21
Installation Orientation
21
Ironhorse ACN Series AC Drive Specifications
22
Class - (Model Specifications)
22
Class - (Model Specifications)
24
Class - (Model Specifications)
25
Specifications Applicable to All ACN Series Models
26
Receiving and Inspection
28
Drive Package Contents
28
Model Number Explanation
29
Nameplate Information
29
Chapter 2: Installation and Wiring
32
Drive Models by Frame Size
32
Installation
32
Basic Configuration Diagram
32
Installation Considerations
33
Minimum Clearances and Air Flow
33
Dimensions
34
Mounting the Drive
35
Removing Front Cover
37
Cable Wiring
38
Floating Ground System
39
Cable Selection
40
Ground Cable and Power Cable Specifications
40
Control (Signal) Cable Specifications
41
Ground Connection
41
Power Terminal Wiring
42
HP (3-Phase)
43
Main Circuit Wiring Diagram (All Frames)
44
Power Terminal Labels and Descriptions
44
Terminals for Connecting DC Reactor, External Brake Resistor, and DC Circuit
44
Wiring Guidelines
45
Motor Operation Precautions
45
Single Phase Input Utility Wiring and Operation
46
Power (HP), Input Current and Output Current
47
Input Frequency and Voltage Tolerance
47
Protection
47
Control Terminal Wiring
48
Control Board Switches
48
Connector
48
Input Terminal Labels and Descriptions
50
Analog Input Configuration
50
Output/Communication Terminal Labels and Descriptions
51
Pre-Insulated Crimp Terminal Connectors (Bootlace Ferrule)
52
PNP/NPN Mode Wiring and Selection
53
PNP Mode (Source)
53
NPN Mode (Sink)
54
Run Command Wiring
54
Digital Output Wiring
55
Analog Wiring
55
AO Wiring
57
System Wiring Diagram
57
Re-Assembling the Cover
57
Post-Installation Checklist
58
Test Run
59
Verifying the Motor Rotation
60
Chapter 3: Keypad Operation and Quick Start
62
Learning to Perform Basic Operations
62
About the Keypad
62
About the Display
63
Operation Keys
64
Control Menu
65
Learning to Use the Keypad
65
Setting Parameter Values
68
Actual Application Examples
70
Frequency Setting (Keypad) and Operation (Via Terminal Input)
73
Wiring Diagram
73
Operation Pattern
73
Frequency Setting (Potentiometer) and Operation (Terminal Input)
74
Frequency Setting (Potentiometer) and Operation (Keypad)
75
Monitoring the Operation
77
Fault Trip Monitoring
77
AC Drive Parameters
81
Bit Selection
81
Parameter Table Format Explanation
81
Operation Parameter Group
83
DRIVE Parameter Group (Dr, DRV)
85
BASIC Parameter Group (Ba, BAS)
90
ADVANCED Parameter Group (Ad, ADV)
95
CONTROL Parameter Group (Cn, CON)
99
INPUT Parameter Group (In, IN)
105
OUTPUT Parameter Group (OU, OUT)
110
COMMUNICATION Parameter Group ( CM, COM)
113
APPLICATION Parameter Group (AP , APP)
119
Extension IO Parameter Group (AO , APO)
122
PROTECTION Parameter Group (Pr, PRT)
125
2Nd MOTOR Parameter Group (M2, M2)
129
USER SEQUENCE Parameter Group (US, USS)
131
USER SEQUENCE FUNCTION Parameter Group (UF , USF)
134
Trip Mode (TRP Last-X)
139
Config Mode (CNF)
140
Ironhorse® ACN Drive Operation and Parameter Details
143
Chart Key
143
Learning Basic Features
144
Setting Frequency Reference
146
Keypad as the Source (Keypad-1 Setting)
146
Keypad as the Source (Keypad-2 Setting)
146
V1 Terminal as the Source
147
Operation
147
Setting a Frequency Reference with Input Voltage (Terminal I2)
152
Setting a Frequency with TI Pulse Input
153
Frequency Hold by Analog Input
154
Changing the Displayed Units (Hz↔Rpm)
155
Setting Multi-Step Frequency
155
Command Source Configuration
157
Communication as a Command Input Device
159
Local/Remote Mode Switching
160
Forward or Reverse Run Prevention
162
Power-On Run
163
Reset and Restart
164
Setting Acceleration and Deceleration Times
165
Acc/Dec Time Based on Maximum Frequency
165
Acc/Dec Time Based on Operation Frequency
166
Multi-Step Acc/Dec Time Configuration
166
Configuring Acc/Dec Time Switch Frequency
167
Acc/Dec Pattern Configuration
169
Stopping the Acc/Dec Operation
170
V/F (Voltage/Frequency) Control
171
Linear V/F Pattern Operation
171
Square Reduction V/F Pattern Operation
172
User V/F Pattern Operation
173
Manual Torque Boost
174
Output Voltage Setting
175
Start Mode Setting
175
Acceleration Start
175
Start after DC Braking
176
Stop Mode Setting
176
Deceleration Stop
176
Stop after DC Braking
177
Free Run Stop
178
Power Braking
178
Frequency Limit
179
Frequency Jump
180
2Nd Operation Mode Setting
181
Multi-Function Input Terminal Control
182
P2P Setting
183
Multi-Keypad Setting
184
User Sequence Setting
185
Programming Rules
189
Execution Rules
189
Communication Address
191
Digital Input
192
Fire Mode Operation
200
Improvement of Output Voltage Drop
201
Learning Advanced Features 4-123
202
Operating with Auxiliary References
203
Jog Operation
206
Jog Operation 1-Forward Jog by Multi-Function Terminal
207
Jog Operation 2-Fwd/Rev Jog by Multi-Function Terminal
208
Jog Operation by Keypad
208
Up-Down Operation
209
3-Wire Operation
211
Safe Operation Mode
212
Dwell Operation
213
Slip Compensation Operation
215
PID Control
216
PID Basic Operation
216
Pre-PID Operation
221
PID Operation Sleep Mode
222
PID Switching (PID Openloop)
222
Auto Tuning
223
Sensorless Vector Control for Induction Motors
225
Sensorless Vector Control Operation Setting for Induction Motors
227
Sensorless Vector Control Operation Guide for Induction Motors
230
Sensorless Vector Control for PM (Permanent-Magnet) Synchronous Motors
231
Detecting the Initial Pole Position
232
Guidelines for Running a PM Synchronous Motor in Sensorless Vector Control Mode
236
Kinetic Energy Buffering Operation
238
Torque Control
240
Automatic Energy Saving Operation
244
Manual Energy Saving Operation
244
Speed Search Operation
245
Auto Restart Settings
248
Operational Noise Settings (Carrier Frequency Settings)
249
2Nd Motor Operation
250
Supply Power Transition
251
Cooling Fan Control
252
Input Power Frequency and Voltage Settings
253
Read, Write, and Save Parameters
253
Parameter Initialization (Reset to Defaults)
253
Parameter View Lock
254
Parameter Lock
255
Changed Parameter Display
256
User Group
256
Easy Start on
257
Config(Cnf) Mode
258
Multi-Function IO Timer Settings
259
Brake Control
260
Multi-Function Output On/Off Control
261
Press Regeneration Prevention
261
Analog Output
262
Analog Pulse Output
264
Digital Output
266
Multi-Function Output Terminal and Relay Settings
266
Multi-Function Output Terminal Delay Time Settings
270
Keypad Language Settings
270
Operation State Monitor
271
Operation Time Monitor
273
Learning Protection Features 4-195
274
Motor Protection
274
Electronic Thermal Motor Overheating Prevention (ETH)
274
Overload Early Warning and Trip
276
Stall Prevention and Flux Braking
277
Drive and Sequence Protection
280
Open-Phase Protection
280
External Trip Signal
281
Drive Overload Protection
281
Speed Command Loss
282
Dynamic Braking
283
Under Load Fault Trip and Warning
285
Fan Fault Detection
285
Low Voltage Fault Trip
286
Output Block by Multi-Function Terminal
286
Operation Mode on Option Card Trip
287
No Motor Trip
287
Fault/Warning List
289
Major Fault
289
Minor Fault
289
Serial Communications
290
Serial RS-485 Communication Features
291
Communication Standards
291
Common Third-Party Modbus RTU Masters
291
Automationdirect Plcs as Modbus Master
292
RS-232C to RS-485 Conversion
293
Setting Communication Parameters
296
Setting Operation Command and Frequency
298
Command Loss Protective Operation
298
Setting Virtual Multi-Function Input
299
Saving Parameters Defined by Communication
300
Total Memory Map for Communication
300
Parameter Group for Data Transmission
301
Communication Protocol
301
Modbus Rtu Protocol
301
Drive Expansion Common Area Parameter
305
Control Area Parameter (Read/ Write)
311
Drive Parameter Modbus Communication Addresses
314
C Hapter T Roubleshooting
325
Chapter 6: Maintenance and Troubleshooting
326
Operations Lockout
326
Maintenance and Inspections
327
Monthly Inspection
327
Annual Inspection
327
Recharge Capacitors (for Drives Not in Service)
327
Recommended Inspection Schedules
328
Ambient Environment
328
Mechanical Parts
329
Main Circuit
329
Storage and Disposal
331
Troubleshooting
332
Trips and Warnings
332
Fault Trips
332
Warning Messages
334
Troubleshooting Fault Trips
335
Troubleshooting Other Faults
337
Fuses/Circuit Breakers
341
High Performance EMI Input Filters
342
EMI Filter Installation
342
General Precaution
342
Recommended Motor Cable Length
344
Line Reactors / Voltage Time Filters
345
Line Reactor
345
Load Reactor/Voltage Time Filter
345
DC Reactor
346
Line/Load Reactors and Output Filters Selection Charts
347
Multiple Motors
349
Single-Phase Applications
350
Recommended Cable Length
350
Dynamic Braking
351
Braking Units
351
Choosing and Installing a Braking Resistor
352
ACN-232C Ironhorse ACN 232 USB to RJ45 Port Cable
353
ACN-LCD Remote LCD Keypad
354
About the Keypad
354
Key Functions
354
Display Items
355
Menu Items
357
Configuration Mode
357
Navigating Modes
358
Navigating Modes and Parameters
361
Navigating through Codes (Function Items
364
Setting Parameters
367
Monitoring Operating Status
369
Monitoring Items
370
Using the Status Display
371
Monitoring Faults
372
Initializing Parameters
375
Parameter Lock (LCD
376
ACN-3MRC LCD Keypad Mount Kit and Cable
377
ACN-LCDKM Remote LCD Keypad NEMA4X Mounting Kit and Cable
378
Installation Procedure
378
Replacement Cooling Fans
382
VFD Suite
383
Connecting to VFD Suite
384
VFD Suite Serial Connection Setup
385
VFD Suite Ethernet Connection Setup
387
Appendix B: Optional I/O Card
390
Basic Information
390
Characteristics
390
Components
390
Specifications
391
Input and Output Specification
391
Installation
392
Installation of ACN I/O Card
392
Control Terminal Wiring
394
Signal (Control) Cable Specifications
396
Parameter Configuration
398
Basic Features
398
Basic Function
398
Setting Frequency Reference
398
Analog Output
405
Digital Output
407
Setting Multi-Step Frequency
411
Multi-Step Acc/Dec Time Configuration
413
Stopping the Acc/Dec Operation
414
Multi-Function Input Terminal Control
415
Appendix C: Ethernet Module ACN-ETH
418
Ethernet/Modbus Card Quick Start
418
Hardware
418
Parameters
419
Introduction
420
ACN-ETH Module
420
Components
420
Ethernet Communication Module Features
421
Common Features
421
Layout of Ethernet Communication Module
421
Installation
422
Terminal Block of Ethernet Communication Specifications
424
Network Cable Specification
425
Protocol Selection
425
LED Information
426
LED Display Feature
426
Ethernet Line LED (Ethernet/Ip and Modbus TCP Are same
426
Modbus TCP LED & Troubleshooting
426
Ethernet/Ip LED & Troubleshooting
427
Keypad Parameter of Ethernet Communication
428
Fbus S/W Ver
428
Fbus Led
428
IP Address, Subnet Mask, Gateway (CM.10~21) Setting
429
Ethernet Speed
429
CIP Input Instance
430
CIP Output Instance
431
Number of Output Parameters
431
Parameter Status
432
Number of Input Parameters
432
Parameter Control
432
Comm Update
432
Modbus TCP
433
Modbus TCP Frame Structure
433
Function Code Description
433
Read Holding Register
433
Read Input Register
433
Write Single Register
434
Write Multiple Register
434
Except Frame
435
Exception Frame Structure
435
Exception Code Type
435
Ethernet/Ip
436
Basic Protocol Configuration
436
Implicit Message
437
Explicit Message
442
Supported Object
443
Lost Command
448
Drive Keypad Parameter
448
Appendix D: Safe Torque off
450
Introduction
450
Terminal Configuration
450
Safe Torque off Terminal Function Description
450
Operation Conditions Description
450
Wiring Diagrams
451
Internal Sto Circuit
451
STO Circuit When Using External 24VDC Power
451
Operating Sequence Description
452
Normal Operation Status
452
Safe Function Failure Rate
453
Safety Requirements Specification
453
Installation Considerations
453
Safe Function Performance
453

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Automationdirect.com IronHorse ACN-4020 User Manual (453 pages)

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