Alliance Laundry Systems 160 User Manual

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Washer/Extractor

AC Adjustable Frequency

Drive Information

For Allen-BradleyModel Numbers:

160

1305

1336

PowerFlex 40

PowerFlex 400

U072M

PHM1396C

TMB1396C

U074M

FAULT

READY

 

U071M U071

U073M

Supplement

Part No. F232120R6

January 2010

 

 

Supplement

 

General Information...........................................................................

3

Table of

Nameplate Location..............................................................................

4

Contents

Storage ..................................................................................................

5

 

General Inspection ................................................................................

5

 

PowerFlex 40 and 400 Drive Control Logic .....................................

6

 

Installation/Wiring................................................................................

6

 

Input Power Conditioning................................................................

6

 

Electrical Interference......................................................................

7

 

Terminal Block Access ....................................................................

8

 

Power Terminal Block Description .................................................

9

 

Control Terminal Blocks Description and Control Logic................

10

 

AC Drive Diagnostics/Parameter Viewing...........................................

28

 

PowerFlex Integrated Keypad..........................................................

28

 

Fault Display and Troubleshooting Information ..................................

32

 

Allen-Bradley Drive Fault Codes ....................................................

33

 

Troubleshooting Suggestions...........................................................

35

 

Allen-Bradley 160-Series AC Drives.................................................

36

 

Installation/Wiring................................................................................

36

 

Input Power Conditioning................................................................

36

 

Electrical Interference......................................................................

37

 

Terminal Block Access ....................................................................

39

 

Power Terminal Block Description .................................................

40

 

Control Terminal Blocks Description and Control Logic................

41

 

160 Series Drive Control Logic Chart .............................................

42

 

AC Drive Diagnostics/Parameter Viewing...........................................

51

 

160 Program Keypad Module (PKM or Parameter Unit)................

51

 

CopyCat Keypad..............................................................................

54

 

Fault Display and Troubleshooting Information ..................................

58

 

Fault Code Identification .................................................................

58

 

Allen-Bradley Drive Fault Codes ....................................................

59

 

Troubleshooting Suggestions...........................................................

61

 

Allen-Bradley 1305-Series AC Drives...............................................

62

 

Installation/Wiring................................................................................

62

 

Input Power Conditioning................................................................

62

 

Electrical Interference......................................................................

63

 

Terminal Block Access ....................................................................

64

 

Power Terminal Block Description .................................................

65

 

Control Terminal Blocks Description and Control Logic................

65

 

AC Drive Diagnostics/Parameter Viewing...........................................

73

 

Human Interface Module (HIM or Parameter Unit) ........................

73

 

HIM Structure Chart – Series A 3.00, Series B 1.01

 

 

or Later Versions................................................................................

75

 

HIM Structure Chart – Earlier Versions...............................................

76

 

Fault Display and Troubleshooting Information ..................................

80

 

Fault Code Identification .................................................................

80

 

Allen-Bradley Drive Fault Codes ....................................................

81

 

Troubleshooting Suggestions...........................................................

83

© Copyright 2010, Alliance Laundry Systems LLC

All rights reserved. No part of the contents of this book may be reproduced or transmitted in any form or by any means without the expressed written consent of the publisher.

F232120

© Copyright 2006, Alliance Laundry Systems LLC – DO NOT COPY or TRANSMIT

1

Supplement

Allen-Bradley 1336-Series AC Drives...............................................

84

Installation/Wiring................................................................................

84

Input Power Conditioning................................................................

84

Electrical Interference......................................................................

85

Terminal Block Access ....................................................................

86

Power Terminal Block Description .................................................

87

Control Terminal Blocks Description and Control Logic................

88

AC Drive Diagnostics/Parameter Viewing...........................................

98

Human Interface Module (HIM or Parameter Unit) ........................

98

HIM Structure Chart – Series A 3.00, Series B 1.01

 

or Later Versions ............................................................................

100

HIM Structure Chart – Earlier Versions ..........................................

101

Fault Display and Troubleshooting Information ..................................

105

Fault Code Identification ......................................................................

105

Allen-Bradley Drive Fault Codes ....................................................

107

Troubleshooting Suggestions...........................................................

109

2

© Published by permission of the copyright owner – DO NOT COPY or TRANSMIT

F232120

General Information

General Information

This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, or servicing this assembly. Component damage may result if ESD control procedures are not followed.

An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring or application errors, such as incorrect or inadequate AC supply or excessive ambient temperatures, may result in malfunction of the system.

This drive contains power storage devices that retain their charge for a time after the removal of main power. Extreme caution should be used when working in and around the drive. It is recommended that main disconnect power to the drive remain off for three minutes prior to approaching connections.

Warnings specific to a particular subject will appear in the manual with the discussion of that subject.

CAUTION

Only personnel familiar with the drive and associated machinery should plan or implement the installation, start-up,and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.

W659

F232120

© Copyright, Alliance Laundry Systems LLC – DO NOT COPY or TRANSMIT

3

General Information

Nameplate Location

Pertinent drive information used in obtaining information on drive operation or replacement is located on the nameplate shown in Figures 1 through4.

FAULT

Nameplate Located on

 

READY

Exterior of Enclosure

 

160 NAMEPLATE LOCATION

U146ME3A

Figure 1

Nameplate Located on

Exterior of Enclosure

1305 NAMEPLATE LOCATION

U072ME3A

 

 

U072ME3A

Figure 2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Nameplate Located

 

on Bottom Portion of

Nameplate Located

Chassis Behind Cover

on Mounting Plate of

 

 

 

 

 

 

 

 

 

 

Main Control Board

FRAMES A1, A2, A3, A4

FRAMES B-G

 

U147ME3A

1336 PLUS NAMEPLATE LOCATION

U147ME3A

Figure 3

Nameplate Located on

Exterior of Enclosure.

TMB1396C

POWERFLEX NAMEPLATE LOCATION

PHM1396C

Figure 4

4

© Copyright, Alliance Laundry Systems LLC – DO NOT COPY or TRANSMIT

F232120

General Inspection

Upon delivery, verify the item’s nameplate catalog number against the purchase order.

Before the installation and start-upof the drive, a general inspection of the mechanical integrity (i.e., loose parts, wires, connections, etc.) should be made.

General Information

Storage

The drive should remain in its shipping container prior to installation. If the equipment is not to be used for a period of time, it must be stored according to the following instructions in order to maintain warranty coverage:

Store in a clean, dry location.

Store within an ambient temperature range of -40to 70 degrees C.

Store within a relative humidity range of 0 to 95 percent.

Do not store equipment where it could be exposed to a corrosive atmosphere.

Do not store equipment in a construction area.

F232120

© Copyright, Alliance Laundry Systems LLC – DO NOT COPY or TRANSMIT

5

PowerFlex 40 and 400 Drive Control Logic

PowerFlex 40 and 400 Drive Control Logic

Installation/Wiring

CAUTION

An incorrectly installed system can result in component damage or reduction in product life. The most common causes are:

1.Wiring AC line to drive output or control terminals.

2.EXTERNAL voltage application to control terminals.

3.Incorrect or inadequate AC supply.

Contact factory for assistance with application or wiring.

W660

Input Power Conditioning

The drive is suitable for direct connection to input power within the rated voltage of the drive. Listed in

Table 1 are certain input power conditions which may cause component damage or reduction in product life. If any of the conditions exist, as described inTable 1, install one of the devices listed under the headingCorrective Action on the line side of the drive.

IMPORTANT: Only one device per branch circuit is required. It should be mounted closest to the branch and sized to handle the total current of the branch circuit.

Input Power Condition

 

Corrective Action

 

 

 

Low Line impedance (less than 1% line reactance)

Install Line Reactor

 

or Isolation Transformer

Greater than 120 kVA supply transformer

or Bus Inductor – 5.5 & 11kW (7.5 & 15 HP) drives

 

 

 

only

 

 

 

Line has power factor correction capacitors

Install Line Reactor

 

or Isolation Transformer

Line has frequent power interruptions

 

 

 

 

 

Line has intermittent noise spikes in excess of 6000V

 

 

(lightning)

 

 

 

 

 

Phase to ground voltage exceeds 125% of normal line to line

Remove MOV jumper to ground.

voltage

or Install Isolation Transformer with grounded

 

 

secondary

Ungrounded distribution system

 

 

if necessary

 

 

 

 

 

240V open delta configuration (stinger leg) (1)

Install Line Reactor

(1) For drives applied on an open delta with a middle phase grounded neutral system, the phase opposite the phase that is tapped in the middle to the neutral or earth is referred to as the “stinger leg,” “high leg,” “red leg,” etc. This leg should be identified throughout the system with red or orange tape on the wire at each connection point. The stinger leg should be connected to the center Phase B on the reactor.

Table 1

6

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F232120

Electrical Interference

EMI

Careful attention must be given to the arrangement of power and ground connections to the drive to avoid interference with nearby sensitive equipment. Be sure to replace all ground connections to their appropriate locations.

RFI

Drives can be installed with an RFI filter, which controls high-frequencyconducted emissions into the main supply lines.

Where it is essential that very low emission levels must be achieved or if conformity with standards is required, the optional RFI filter may be present. Figure 5 displays an electrical schematic for various RFI configurations.Table 2 shows associated RFI filter part numbers.

CAUTION

ELECTRIC SHOCK HAZARD! Service and

maintenance to be performed only by an authorized technician. Disconnect power before opening any access panels.

W661

PowerFlex 40 and 400 Drive Control Logic

SINGLE PHASE MACHINES

1

2

 

 

 

 

INPUT

L1

LINE

ALLEN-BRADLEY

LOAD

POWER

L2

RFI

 

 

 

 

 

 

FILTER

 

 

 

 

 

2

3

 

3

PROVEN EARTH GROUND

 

TO AC DRIVE UNIT Ð

 

 

 

 

GREEN-YELLOWWIRE MUST CONNECT TO

 

 

 

 

AC DRIVE GROUND TERMINAL.

WASHING

BLACK WIRES WILL CONNECT TO AC DRIVE

INPUT TERMINALS "R", "S" & "T".

MACHINE

BLACK WIRES ARE NOT LABELED AND THEIR

GROUNDING

RESPECTIVE TERMINATION IN AC DRIVE IS

TERMINAL

NOT OF IMPORTANCE.

 

THREE PHASE MACHINES

1

2

 

 

 

 

INPUT

L1

LINE

ALLEN-BRADLEY

 

L2

 

LOAD

POWER

RFI

 

 

L3

 

 

 

 

 

FILTER

 

 

 

 

 

 

 

 

 

 

2

3

 

3

PROVEN EARTH GROUND

 

TO AC DRIVE UNIT Ð

 

 

 

 

GREEN-YELLOWWIRE MUST CONNECT TO

 

 

 

 

AC DRIVE GROUND TERMINAL.

WASHING

BLACK WIRES WILL CONNECT TO AC DRIVE

INPUT TERMINALS "R", "S" & "T".

MACHINE

BLACK WIRES ARE NOT LABELED AND THEIR

GROUNDING

RESPECTIVE TERMINATION IN AC DRIVE IS

TERMINAL

NOT OF IMPORTANCE.

 

 

U166ME3A

U166ME3A

Figure 5

RFI Filter Part Number Information

Drive P/N

Drive Catalog

 

Machine Voltage

Filter P/N

F8044301 and F8168603

22B-B017N104xx

 

200-240V50-60Hz3 phase

F8053901

F8044401 and F8168604

22B-D010N104xx

 

380-480V50-60Hz3 phase

F8053902

 

 

 

 

 

F8044701 and F8168601

22B-B012N104xx

 

200-240V50-60Hz 3 Phase

F8053901

 

 

 

 

 

F8044901 and F8168602

22B-D6P0N104xx

 

380-480V50-60Hz 3 Phase

F8053902

C002501 and F8168701

22B-B024N104xx

 

200-240V50-60Hz 3 Phase

F8054001

 

 

 

 

 

C002502 and F8168702

22B-D012N104xx

 

380-480V50-60Hz 3 Phase

F8054002

 

 

 

 

 

C002507 and F8168705

22B-D024N104xx

 

380-480V50-60Hz 3 Phase

C002569

C002502, F200309300

22B-B033N104Axx

 

200-240V50-60Hz3 phase

F8054001

and F8168703

 

 

 

 

C002506, F200309400

22B-D017N104Axx

 

380-480V50-60Hz3 phase

F8054002

and F8168704

 

 

 

 

 

 

Table 2

 

F232120

© Copyright, Alliance Laundry Systems LLC – DO NOT COPY or TRANSMIT

7

PowerFlex 40 and 400 Drive Control Logic

Terminal Block Access

WARNING

To reduce risk of electric shock, severe injury or death, allow machine power to remain off for three minutes minimum prior to working in and around AC drive. Proceed with caution.

W662

The following information illustrates the terminal block designations for each of the drive models.

Opening the Cover

1.Press and hold in the tabs on each side of the cover. Refer to Figure 6.

2.Pull the cover out and up to release.

COVER

PHM636N

Figure 6

Power Terminal Block

The drive utilizes a finger guard over the power wiring terminals. To remove:

1. Press in and hold the locking tab.

2.Slide finger guard down and out. Refer to

Figure 7.

3.Replace the finger guard when wiring is complete.

POWER TERMINAL BLOCK (TYPICAL)

PHM637N

Figure 7

8

© Copyright, Alliance Laundry Systems LLC – DO NOT COPY or TRANSMIT

F232120