QUICK START
ARMORSTART® DISTRIBUTED
MOTOR CONTROLLER WITH
ARMORPOINT® BACKPLANE
Getting Started
BULLETIN 283A
Introduction This guide provides the basic information required to start up your
ArmorStart
and information regarding installing, programming, and ArmorPoint
Communication Backplane, are described here. For detailed
information on specific product features or configurations, refer to the
ArmorStart user manual, Publication 283-UM001*-EN-P.
This guide is intended for qualified service personnel responsible for
setting up and servicing these devices. You must have previous
experience with and a basic understanding of electrical terminology,
configuration procedures, required equipment, and safety precautions.
For Bulletin 283A devices, you should understand Bulletin 1738
ArmorPoint adapter and I/O products.
®
Distributed Motor Controller. Factory default settings
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Installation The ArmorStart Distributed Motor Controller is convection cooled.
Operating temperature must be kept between -20…40°C (-4…104°F).
Dimensions Dimensions are shown in millimeters (inches). Dimensions are not intended
to be used for manufacturing purposes. All dimensions are subject to
change.
Figure 1 Dimensions for IP67/NEMA Type 4 with Conduit Entrance
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ArmorStart device with a 10 A short circuit protection rating ArmorStart device with a 25 A short circuit protection rating
Dimensions are shown in millimeters (inches). Dimensions are not intended
to be used for manufacturing purposes. All dimensions are subject to
change.
Figure 2 Dimensions for IP67/NEMA Type 4 with ArmorConnect™ Connectivity
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Primaries
Secondaries
Wiring Power, Control, Safety Monitor Inputs, and Ground Wiring
Table 1 provides the power, control, safety monitor inputs, ground wire
capacity and the tightening torque requirements. The power, control,
ground, and safety monitor terminals will accept a maximum of two wires
per terminal.
Table 1 Power, Control, Safety Monitor Inputs, Ground Wire Size, and Torque
Specifications
Terminals Wire Size Torque Wire Strip Length
Primary Terminal:
10.6…21.6 lb.-in.
(1.2…2.4 N•m)
Secondary Terminal:
5.3…7.3 lb.-in
(0.6…0.8 N•m)
5.0…5.6 lb.-in
(0.6 N•m)
0.35 in. (9 mm)
0.35 in. (9 mm)
Power
and
Ground
Control and Safety
Monitor Inputs
Primary/Secondary
Terminal:
1.0…4.0 mm
(#18 …#10 AWG)
2
0.34mm
…4.0 mm2
(#22…#10 AWG)
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Terminal Designations As shown in Figure 3, the ArmorStart Distributed Motor Controller contains
terminals for power, control, safety monitor inputs, and ground wiring.
Access can be gained by removing the terminal access cover plate.
Figure 3 ArmorStart Power, Control, and Safety Monitor Terminals
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Table 2 Power, Control, and Ground Terminal Designations
Terminal Designations No. of Poles Description
SM1 ➊ 2 Safety Monitor Input
SM2 ➊ 2 Safety Monitor Input
A1 (+) 2 Control Power Input
A2 (-) 2 Control Power Common
PE 2 Ground
1/L1 2 Line Power Phase A
3/L3 2 Line Power Phase B
5/L5 2 Line Power Phase C
➊ Only available with the Safety Monitor option.
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ArmorConnect Power Media Description
The ArmorStart Power Media offers both three-phase and control power
cable system of cordsets, patchcords, receptacles, tees, reducers and
accessories to be utilized with the ArmorStart Distributed Motor Controller.
These cable system components allow quick connection of ArmorStart
Distributed Motor Controllers and reduce installation time. They provide
for repeatable, reliable connection of the three-phase and control power to
the ArmorStart Distributed Motor Controller and motor by providing a plug
and play environment that also avoids system mis-wiring. When specifying
power media for use with the ArmorStart Distributed Motor Controllers
(Bulletins 280, 281, 283, and 284) use only Bulletin 280 ArmorConnect™
power media.
Figure 4 Three-Phase Power System Overview
Enclosure
Bulletin 1492FB
Branch Circuit
Protective Device
Bulletin 1606
Bulletin 1606
PLC
Ethernet
Computer
Terminal
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Bulletin 283
ArmorStart
ArmorPoint
➊ Three-Phase Power Trunk- PatchCord cable with integral female or male connector on each end
Example Part Number: 280-PWR35A-M*
➋ Three-Phase Drop Cable- PatchCord cable with integral female or male connector on each end
Example Part Number: 280-PWR22A-M*
➌ Three-Phase Power Tees and Reducer -
Tee connects to a single drop line to trunk with quick change connectors – Part Number: 280-T35
Reducing Tee connects to a single drop line (Mini) to trunk (Quick change) connector – Part Number: 280-RT35
Reducer connects from quick change male connector to mini female connector– Part Number: 280-RA35
➍ Three-Phase Power Receptacles -
Female receptacles are a panel mount connector with flying leads – Part Number: 280-M35F-M1
Bulletin 284
ArmorStart
Bulletin 800F
Emergency Stop
Pushbutton
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Figure 5 Control Power Media System Overview
Bulletin 283
ArmorStart
ArmorPoint
Bulletin 284
ArmorStart
Ethernet
PLC
Bulletin 1492FB
Branch Circuit
Protective Device
Enclosure
Bulletin 1606
Bulletin 1606
Bulletin 800F
Emergency Stop
Pushbutton
8
6
6
6
6
7
7
Computer
Terminal
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➏ Control Power Media Patchcords - PatchCord cable with integral female or male connector on each end
Example Part Number: 889N-F65GFNM-*
➐ Control Power Tees - The E-stop In Tee (Part Number: 898N-653ES-NKF) is used to connect to the Bulletin 800F On-Machine E-Stop station using a
control power media patchcord. The E-stop Out tee (Part Number: 898N-653ST-NKF) is used with cordset or patchcord to connect to the ArmorStart
Distributed Motor Controller.
➑ Control Power Receptacles - Female receptacles are a panel mount connector with flying leads –
Part Number: 888N-D65AF1-*
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Control Power Receptacle
Three-Phase Power Receptacle
Control Power Receptacle
Three-Phase Power Receptacle
ArmorStart devices with 10 A short
circuit protection rating
ArmorStart devices with 25 A short
circuit protection rating
3/4 in. Lock Nut 1 in. Lock Nut
Thomas & Betts Cord Grip
Part Number: 2931NM
3/4 in. Stain Relief Cord Connector
Cable Range: 0.31…0.56 in.
Used with Control Power Media
Cordset - Example Part Number:
889N-M65GF-M2
Thomas & Betts Cord Grip
Part Number: 2940NM
1 in. Stain Relief Cord Connector
Cable Range: 0.31…0.56 in.
Used with Three-Phase Power
Media Cordset - Example Part
Number: 280-PWR22G-M1
Cord Grips for ArmorStart Devices with 10 A short circuit protection rating
3/4 in. Lock Nut 1 in. Lock Nut
Thomas & Betts Cord Grip
Part Number: 2931NM
3/4 in. Stain Relief Cord Connector
Cable Range: 0.31…0.56 in.
Used with Control Power Media
Cordset - Example Part Number:
889N-M65GF-M2
Thomas & Betts Cord Grip
Part Number: 2942NM
1 in. Stain Relief Cord Connector
Cable Range: 0.70…0.95 in.
Used with Three-Phase Power
Media Cordset - Example Part
Number: 280-PWR35G-M1
Cord Grips for ArmorStart Devices with 25 A short circuit protection rating
ArmorStart with ArmorConnect Connectivity
Installing ArmorConnect Power Media using Cord Grips
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Terminal Designations Description Color Code
A1 (+) Control Power Input Blue
A2 (-) Control Power Common Black
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PE Ground Green/Yellow
1/L1 Line Power - Phase A Black
2/L2 Line Power - Phase B White
3/L3 Line Power - Phase C Red
ArmorConnect Cable Ratings
The ArmorConnect Power Media cables are rated per UL Type TC
600V 90 °C Dry 75 °C Wet, Exposed Run (ER) or MTW 600V 90 °C or
STOOW 105 °C 600V - CSA STOOW 600V FT2. For additional
information regarding ArmorConnect Power Media see the ArmorStart
User Manual.
Branch Circuit Protection Requirements for ArmorConnect™
Three-Phase Power Media
When using ArmorConnect Three-Phase Power Media, only fuses can be
used for the motor branch circuit protective device, for the group motor
installations. The recommended fuse types are the following: Class CC, T,
or J type fuses. For additional information, see the ArmorStart User
Manual.
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Group Motor Installations for USA and Canada Markets
The ArmorStart Distributed Motor controllers are listed for use with each
other in group installations per NFPA 79, Electrical Standard for Industrial
Machinery. When applied according to the group motor installation
requirements, two or more motors, of any rating or controller type, are
permitted on a single branch circuit. Group Motor Installation has been
successfully used for many years in the USA and Canada.
Wiring and Workmanship Guidelines
In addition to conduit and seal-tite raceway, it is acceptable to utilize cable
that is dual rated Tray Cable, Type TC-ER and Cord, STOOW, for power
and control wiring on ArmorStart installations. In the USA and Canada
installations, the following guidance is outlined by the NEC and NFPA 79.
In industrial establishments where the conditions of maintenance and
supervision ensure that only qualified persons service the installation, and
where the exposed cable is continuously supported and protected against
physical damage using mechanical protection, such as struts, angles, or
channels, Type TC tray cable that complies with the crush and impact
requirements of Type MC (Metal Clad) cable and is identified for such use
with the marking Type TC-ER (Exposed Run)* shall be permitted between
a cable tray and the utilization equipment or device as open wiring. The
cable shall be secured at intervals not exceeding 1.8 m (6 ft) and installed in
a “good workman-like” manner. Equipment grounding for the utilization
equipment shall be provided by an equipment grounding conductor within
the cable.
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*Historically cable meeting these crush and impact requirements were
designated and marked “Open Wiring”. Cable so marked is equivalent to the
present Type TC-ER and can be used.
While the ArmorStart is intended for installation in factory floor
environments of industrial establishments, the following must be taken into
consideration when locating the ArmorStart in the application: Cables,
including those for control voltage including 24V DC and communications,
are not to be exposed to an operator or building traffic on a continuous
basis. Location of the ArmorStart to minimize exposure to continual traffic
is recommended. If location to minimize traffic flow is unavoidable, other
barriers to minimize inadvertent exposure to the cabling should be
considered. Routing cables should be done in such a manner to minimize
inadvertent exposure and/or damage.
Additionally, if conduit or other raceways are not used, it is recommended
that strain relief fittings be utilized when installing the cables for the control
and power wiring through the conduit openings.
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The working space around the ArmorStart may be minimized as the
ArmorStart does not require examination, adjustment, servicing or
maintenance while energized. In lieu of this service, the ArmorStart is
meant to be unplugged and replaced after proper lockout/tag-out procedures
have been employed.
Since the ArmorStart is available with a factory installed HOA keypad
option this may require the ArmorStart to be selected and installed as
follows if the application requires frequent use of the hand operated
interface by the equipment operator:
1. They are not less than 0.6 m (2 ft) above the servicing level and are
within easy reach of the normal working position of the operator.
2. The operator is not placed in a hazardous situation when operating
them.
3. The possibility of inadvertent operation is minimized.
If the operated interface is used in industrial establishments where the
conditions of maintenance and supervision ensure that only qualified
persons operate and service the ArmorStart's operator interface, and the
installation is located so that inadvertent operation is minimized then other
installation locations with acceptable access can be provided.
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LED Status Indication The LED Status Indication provides 4 status LEDs and a Reset button. The
LEDs provide status indication for the following:
• POWER LED
The LED is illuminated solid green when control power is present and
with the proper polarity
•RUN LED
This LED is illuminated solid green when a start command and control
power are present
• NETWORK LED
This bi-color (red/green) LED indicates the status of the
communication link
• FAULT LED
Indicates Controller Fault (trip) condition
The “Reset Button” as a local trip reset.
Figure 6 LED Status Indication and Reset
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ArmorStart with ArmorPoint ArmorStart for the ArmorPoint Backplane
The Bulletin 283A ArmorStart Distributed Motor Controller allows
connectivity to the ArmorPoint backplane. The ArmorPoint I/O system can
communicate using DeviceNet™, ControlNet™, or EtherNet
communication protocols. In addition to the other network communication
protocols; the ArmorPoint Distributed I/O products allow the I/O capability
to be expanded beyond the standard two outputs. Two dual-key output
connectors are provided standard. The outputs are sourced from control
voltage power (A1, A2). LED status indication is also provided, as standard
with the ArmorPoint. When using ArmorPoint, a maximum of two
ArmorStart Distributed Motor Controllers can be connected to the
ArmorPoint Distributed I/O products.
ArmorStart to ArmorPoint Connectivity
Figure 7 Connectivity Diagram for one ArmorStart Distributed Motor Controller
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When connecting to the Bulletin 1738 ArmorPoint Distributed I/O product,
a network adapter and at least one ArmorPoint Digital Output, Digital Input,
Analog, AC and Relay product, or Specialty product must be selected. The
ArmorPoint Distributed I/O product can accommodate up to 63 modules per
network node. The cable that connects the ArmorPoint Distributed I/O to
the ArmorStart Distributed Motor Controller is the Bulletin 280A-EXT1.
The 280A-EXT1 includes an ArmorPoint bus extension cable and a
network terminating resistor. The network terminating resistor must be
connected to the “ArmorPoint Interface Out” connector.
Figure 8 Connectivity Diagram for two ArmorStart Distributed Motor Controllers
If an additional ArmorStart Distributed Motor Controller is to be connected,
the Bulletin 280A-EXTCABLE will be required. A maximum of two
ArmorStart Distributed Motor Controllers can be connected to the Bulletin
1738 Distributed I/O. The Bulletin 280A-EXTCABLE is connected from
the “ArmorPoint Interface Out” on the first unit, to the “ArmorPoint
Interface In” on the second unit. The network terminating resistor is
connected to the “ArmorPoint Interface Out” on the second unit.
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ArmorPoint Backplane Commissioning
Establishing a Backplane Node Address
Backplane node addresses are established automatically by the ArmorPoint
system on power up. Node addresses for the backplane modules are
allocated from left to right, starting at address 1.
Note: The rotary address switches on the starter module are ignored
when using the ArmorPoint backplane.
Note: When using RSNetWorx for DeviceNet with the 283A
ArmorStart Distributed Motor Controllers, DO NOT use the
node commissioning outlined in Chapter 5 of the User Manual.
Details on Using the “ArmorStart Ladder Logic Configurator”
The ArmorStart Ladder Logic Configurator is a ladder logic routine (File
Name: ArmorStart_Configurator.ACD) designed so that under program
control, the entire product family of the ArmorStart Distributed Motor
Controllers can be configured easily from a Logix based controller. The
family of ArmorStart Distributed Motor Controllers includes the following
Bulletin Numbers: 280A, 281A, 283A and 284A. The ArmorStart
Distributed Motor Controllers can be networked over ControlNet or
EtherNetIP, when on the appropriate ArmorPoint backplane. The ladder
logic file is designed to be merged into an existing ladder logic file or it can
be used as the basic program and other logic can be added to it. This
document assumes that the reader has an average knowledge of the use of
RSLogix™5000 and Logix based controllers. Device configuration is done
inside the Controller tag editor under the Monitor Tags tab.
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Note: The ArmorStart Ladder Logic Configurator (File Name:
ArmorStart_Configurator.ACD) is provided on the CD shipped
with every ArmorStart product with the ArmorPoint
Communications protocol.
Theory of Operation
It is possible to connect an ArmorStart product to the Point I/O based subnet
of the ArmorPoint I/O system. This allows the ArmorStart to be connected
to EtherNetIP and ControlNet, along with the original DeviceNet. The
easiest way to program these ArmorStarts, is to use RSNetWorx for
DeviceNet software, bridging through the appropriate network. This
ladder logic has been developed as an alternate method of configuration.
Once the appropriate device configuration is done to a User Defined
Structure in the ladder logic file, a bit will need to be turned on in the logic
to trigger a system wide read of the system. This system wide read, goes out
and reads certain attributes of every parameter of every ArmorStart in the
system and stores the information into a large data array. The first attribute
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is a flag word that tells the ladder logic if the parameter is read only. If the
read only bit is set, then the ladder logic will skip the additional attribute
reads and will go to the next parameter. If the parameter is writable, then the
logic will read the size, min. allowed value, max. allowed value, the
parameter name, help string and the raw data of each parameter. These
attributes are stored in the data array for use later when the configuration is
written to each ArmorStart. The logic requires that a system wide read
function be completed prior to a system wide write function being
requested.
Note: A system wide read function should be done anytime that a new
ArmorStart is added to the system or an ArmorStart is updated
with a more recent version. This assures that the data array in
the logic matches the total system.
Once a system wide read is done, the raw data of the individual parameters
in the data array can be modified and a system wide write function activated
from a bit in the ladder logic. Only parameters that changed will be written
to the ArmorStart devices, and after a write is done the parameter is read
back and stored in the data array for comparison. If the write and reread
value do not match, an Error Report is generated.
If an error occurs for any reason, during a system wide read or write, an
error report will be logged, containing the device and parameter it occurred
on. Also the status and extended status of the message block is logged in
case the error originated there.
I/O Tree Overview
In order to transfer I/O information, the ArmorStart needs to be added to the
I/O tree of the Logix processor. The details of doing this are outside of the
scope of these instructions, but screen captures of the completed
configuration are included below for reference. The configuration below
shows the EtherNetIP card in the Logix chassis slot 1. The 1738-AENT
module is always located at slot zero in the subnet and the ArmorStart
device is located in slot 2 on the subnet. These slots are circled below for
you reference.
Figure 9 Logix Processor I/O Tree
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The only configuration that the user needs to be concerned with for the
ArmorPoint communication adapter is either the EtherNet IP address or the
ControlNet node address.
Since there currently is no profile for an ArmorStart device in the I\O Tree,
the 1738-MODULE profile needs to be used as a generic profile. The
standard configuration for an ArmorStart 283A, using this profile is shown
below.
Figure 10 ArmorStart Configuration using 1738-MODULE Profile
Logic Configuration Details
Inside the Configurator file is a large User Defined structure called
Armor_Start_System, which contains all of the data for both the
configuration of the routine, and also storage space for all of the ArmorStart
parameters. With 20 devices, the total memory needed to hold this structure
in the Logix controller is 195K bytes. The diagram below shows the upper
part of the structure and 3 important elements.
Figure 11 Configurator File — Armor_Start_System
Armor_Start_System.Max_Devices defaults to 20; because the total
number of devices that the structure is designed to hold initially, is 20. This
amount can be easily changed, but doing so will also necessitate a
change to the size of the System Array structure to match exactly.
Note: The Logix memory that contains the structure will also change
size proportionally.
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Shown below is the array size that will also need to be changed to match the
Armor_Start_System.Max_Devices value.
Figure 12 System Array Size
Armor_Start_System.Max_Parameters defaults to 262, because the
maximum number of parameters in any existing ArmorStart product is 262
or less. This amount can be easily be changed, and doing so will also
proportionally change the size of the System Array structure and the Logix
memory that holds it. Shown below is the array size that will also need to
be changed to be 1 greater than the
Armor_Start_System.Max_Parameters value. This is because the
parameters are stored by parameter number, and since there is no parameter
0, that storage location is unused.
Figure 13 Array Size Parameter
Armor_Start_System.Num_Devices defaults to zero and is defined as the
total number of ArmorStart products connected to the control system that
need to be configured. It is important that this value be set before the
configuration routine is executed.
It is to the users best advantage to trim the structures down to the minimum
values that match their system because this will save a considerable amount
of Logix processor memory. However, some room should be left in the
structures to handle any future additions of ArmorStart devices to the
system.
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Adding Devices to the Configuration Structure
Once the three major System level parameters are entered, it is up to the
user to enter in, each of the ArmorStart devices configuration information.
These parameters are defined by the slot in the Logix chassis where the
EtherNetIP or ControlNet communication card resides. The next parameter
is the EtherNetIP IP or ControlNet node address of the 1738 communication
adapter containing the ArmorStart. Lastly, the slot number on the
ArmorPoint subnet where the ArmorStart is connected also needs to be
entered. An optional parameter is a string that can be entered with a
description of the function of the ArmorStart device. Each device will be
configured by entering its data into a different block of the
Armor_Start_System.Device[] array.
The Following shows the configuration for a communication card in the
Logix chassis 2, AENT IP address 192.168.1.10 and Point I/O slot 3. The
logic determines whether the network is EtherNetIP or ControlNet
depending on whether the ENET_IP_Addr field is blank or the
CNET_Address is zero. One of these two fields must be filled out for the
logic to work correctly. The Armor_Descriptor field is optional and is used
to more easily identify the ArmorStart as to its function in the system.
Figure 14 Communication Card Configuration
Note: To easily edit an ASCII string, click on the string value field and
a small icon with three dots appears.
Figure 15 String Browser Box
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Click on the three dots icon and a String Browser box appears. Modify the
text to what is desired and click on Apply, then click on OK. This works for
ALL strings throughout the entire data array.
Figure 16 String Browser Box
Modifying Parameter Data for an ArmorStart
The last configuration that will need to be done eventually, is the writing of
a parameter configuration change for an ArmorStart. This is done by first
equating a particular ArmorStart to a device number in the data array.
Again, this device number is determined by the Logix slot of the
communication card, ETherNetIP or CNet address of the communication
adapter and subnet slot of ArmorStart. The optional, Armor_Descriptor
field is extremely handy for doing a functional lookup of the device number.
Once the device number is determined, the parameter number to be
modified, must be obtained. The best way to do this, is to go to the
ArmorStart user manual and get the parameter number of the value to be
modified. The parameter numbers all start with 1 and are numbered
sequentially to the last parameter number. The user manual is important
because it will thoroughly describe each parameter, for example, whether or
not a parameter is writable and what the parameter limits/interpretation are.
Once the device and parameter number is obtained, the next step is to
modify the configuration data for that parameter. The following screen
capture shows the data array and particularly, the parameter 8 for Device 0.
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Figure 17 Data Array
The value to be modified is the .data element of the structure. For reference,
the Min_value, Max_value, and Name_String for the parameter is also in
the structure, so that the user knows what the minimum and maximum
allowable values are for the data. It is important to realize that the data is in
a raw format. In other words, this data could be considered a Boolean, a bit
mask, an ASCII string, an integer, a byte, etc., depending on the definition
of the parameter in the ArmorStart. Also, there could be an implied decimal
point, scaling, and different units involved. It is important that the user
fully understand and verify the raw data value being modified with the
user manual, so that it is correctly interpreted by the ArmorStart or
undesired operation in the ArmorStart may occur.
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Once the data is written, during a System Wide Write function, the ladder
logic will read it back and put into the .Last_Read_Value of the structure.
This will be a handy visual verification that the data was written correctly.
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Triggering a System Wide Read
Once the system configuration has been done, a System Wide Read must be
initiated. The logic to trigger both a System Wide Read and Write is
contained in a subroutine called Handle_All_Armor. The rungs are shown
below for reference.
Figure 18 Handle_All_Armor Rungs
To trigger the system wide read, the contact Read_All_Condition_Here
needs to be energized in the ladder logic. This can be done through
additional logic or simply by energizing the bit, on-line, in the
RSLogix™5000 software, Controller Tag monitor screen. The
Read_All_Condition_Here is handled as a one shot inside the logic, but
should be de-energized at a later time. This is so a system wide read is not
triggered after every Logix power cycle or for each transition from Program
to RUN mode. When the read finishes successfully, the
Read_All_System_Done_Flag bit energizes in the logic. However, if an
error occurs during the read, the Read_All_System_Error_Flag bit
energizes and the error will be logged into the structure called
Error_Report.
Triggering a System Wide Write
Once a successful System Wide Read has been initiated and the
Read_All_System_Done_Flag bit is energized, a System Wide Write can
be triggered. To trigger the system wide write, the contact
Write_All_Condition_Here needs to be energized in the ladder logic. This
can be done through additional logic or simply by energizing the bit on-line,
in the RSLogix5000 software, Controller Tag monitor screen. The
Write_All_Condition_Here is handled as a one shot inside the logic, but
should be de-energized at a later time. This is so a System Wide Write is not
triggered after every Logix power cycle or for each transition from Program
to RUN mode. When the write finishes successfully, the
Write_All_System_Done_Flag bit energizes in the logic. If an error occurs
during the write, the Write_All_System_Error_Flag bit energizes and the
error will be logged into the structure called Error_Report.
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Interpreting the Error Report
If an error occurs during the operation of the ladder logic, either the
Write_All_System_Error_Flag or Read_All_System_Error_Flag bits will
energize depending on which function was being triggered. Information will
be logged inside the data structure Error_Report, that will aid in
troubleshooting the problem. The format of this structure is shown below.
Figure 19 Error Report
The first element of this structure is .Local_Error and will contain a
number corresponding to an error interpretation. The error numbers are
described in the next table.
Table 3 Error Definitions
Error
No.
0 Success. Function completed successfully.
1 Read Number Parameter Error. Num_Devices element in the configuration is either 0 or
greater than the Max_Devices element.
2 Read Message Block Error. The Message block doing the data reads returned back an
error. Look at the Msg_Error and Msg_Ext_Error fields for the errors reported by the
message.
3 Write Data out of Limits. The value of the data to be written is either less than the
Min_value or greater than the Max_value.
4 Write Message Block Error. The Message block doing the data writes returned back an
error. Look at the Msg_Error and Msg_Ext_Error fields for the errors reported by the
message.
5 Write Disallowed. The System Wide Write attempted without a successful System Wide
Read done first.
6 Data Write Error. The data read back after a parameter write, does not match.
7 Number of Parameters Error. The number of parameters read from an ArmorStart is
greater than the Max_Devices element in the structure.
Error Description
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Quick Reference
Troubleshooting
There are four LEDs on the front of the ArmorStart that can provide an
indication as to the health of the device. The following is a brief explanation
of the operation of each LED.
Table 4 LED Status Indication
LED Definition
Power
Run
Network
Fault
Table 5 Network LED Status Indication
Network Status LED Definition Possible Causes
Off The device has not completed the initialization, is not on an
active network, or may not be powered up.
Flashes green-red-off While waiting to detect the network baud rate, the LED will
flash this pattern about every 3 seconds.
Solid Green The device is operating in a normal condition, and is
communicating to another device on the network.
Flashing Green The ArmorPoint module cannot successfully establish a
connection on the backplane.
Flashing Red The ArmorPoint module has stopped communicating over
the backplane with ArmorStart.
Solid Red Backplane media issue. Check backplane media and ArmorStart backplane cable
Flashing Red and Green The device is in a communication faulted state. Power cycling the device may resolve the problem;
This LED will be illuminated solid green when control power is present and
with the correct polarity.
This LED will be illuminated solid green when a start command and control
power are present.
This bi-color LED is used to indicate the status of the communications
network. See the Network Status LED table below for additional information.
This LED is used to indicate the fault status of the ArmorStart. When the unit is
faulted, the unit will respond with a specific blink pattern to identify the fault.
See the Fault LED table below for additional information.
Check to make sure the product is properly wired and
configured on the network.
If the product stays in this state it means that there is no set
baud rate. Insure that at least one device on the network
has a set baud rate.
No action required.
The wrong connection parameter for the ArmorStart was
entered in the “Module Properties” page in RSLogix5000 or
the I/O Tree was not properly configured.
Check control power connections to the ArmorPoint Module
and ArmorStart.
connections.
however, if the problem continues, it may be necessary to
contact Technical Support.
Publication 283A-QS001C-EN-P - July 2006
24
Fault LED indications for
Bulletin 283A ArmorStart
Distributed Motor Controllers
Table 6 Controller Fault LED Definitions
Blink
Pattern
1
2
3
4
5
6
7 I/O Fault This error indicates a blown output fuse.
8 Over Temperature This fault is generated when the operating temperature has been exceeded. This fault cannot be disabled.
9
10 Reserved Not Used
11
12
13
Definitions Possible Causes or Remedies
Short Circuit The motor circuit protector has tripped, or the internal wiring protection algorithm has detected an unsafe
current range. Try to reset the protector if tripped. If the condition continues, check the power wiring. This
fault cannot be disabled.
Overload trip The load has drawn excessive current and based on the trip class selected, the device has tripped. Verify
that the load is operating correctly and the ArmorStart is properly set-up. This fault cannot be disabled.
Phase Loss The ArmorStart has detected a missing phase. Verify that three-phase voltage is present at the line side
connections. This fault can be disabled and is disabled by default.
Shorted SCR Prior to every start, the unit will check all SCRs for shorts and unit load connections to the motor. If there is
a shorted SCR in the SMC-3 and/or open load, the start will be aborted and a shorted SCR/open load fault
will be indicated. This prevents damage from phase imbalance. This fault cannot be disabled.
Phase Rotation When enabled, 3-phase input power will be verified before starting. If input power phasing is detected to
be incorrect, the start will be aborted and a fault indicated. This fault can be disabled and is disabled by
default.
Control Power The ArmorStart has detected a loss of the control power voltage. Check control voltage, wiring, and proper
polarity. Also check and replace the control voltage fuse, if necessary. This fault can be disabled and is
disabled by default.
Phase Imbalance The ArmorStart has detected a voltage imbalance. Check the power system and correct if necessary. This
fault can be disabled and is disabled by default.
Internal Communication This fault occurs when communication between the main board and the SMC-3 is lost. This fault cannot be
disabled.
Heatsink Over
temperature/JAM
EEPROM Fault This is a major fault, which renders the ArmorStart inoperable. Possible causes of this fault are transients
This fault indicates either an over temperature fault or a JAM fault. The heatsink is monitored by
thermistors and the SCR temperature is tracked by an algorithm. When a maximum temperature is reached
by either, the microcomputer switches off the SMC and indicates a fault code of 12. A fault code of 12
could also indicate a JAM fault. This fault cannot be disabled.
induced during EEprom storage routines. If the fault was, initiated by a transient, power cycling should
clear the problem otherwise replacement of the ArmorStart may be required. This fault cannot be disabled.
Hardware Fault This fault indicates that a serious hardware problem exists. Check for a base/starter module mismatch. If
14
16 Miscellaneous Fault This fault cannot be disabled.
Publication 283A-QS001C-EN-P - July 2006
no mismatch exists, the ArmorStart may need to be replaced. (Hdw Flt is the factory-enabled default
setting.) This fault cannot be disabled.
Bulletin 283 Parameters
Table 7 Starter Display and Parameter Settings
Parameter Name String Path (hex) Min Max Dflt Type Value
SMC Display
101 Phase A Current 002C – 01 – 08 0 32767 — INT xxx.x Amps
102 Phase B Current 002C – 01 – 09 0 32767 — INT xxx.x Amps
103 Phase C Current 002C – 01 – 0A 0 32767 — INT xxx.x Amps
104 Average Current 002C – 01 – 05 0 32767 — INT xxx.x Amps
105 % Therm Utilized 002C – 01 – 07 0 100 — USINT xxx %
SMC Settings
106 FLA Setting 002C – 01 – 03 See Table 8 below Min I INT xxx.x Amps
107 OL Trip Class 002C – 01 – 04 0 3 1 BYTE 1 = 10
108 OL Reset Level 0029 – 01 – 131 0 100 75 BYTE xxx %
109 Start Time 000F - 06D - 01 1 45 10 USINT sec
110 Start Mode 000F - 06E - 01 0 1 0 BOOL
111 Current Limit 000F - 06 - 01 150 600 350 UINT
112 Initial Torque 000F - 070 - 01 0 90 60 USINT % LRT
113 Soft Stop Time 000F - 071 - 01 0 90 0 USINT sec
114 Kick Start 000F - 072 - 01 0.0 1.5 0.0 USINT sec
115 SCR Temp Reset Mode 000F - 073 - 01 0 1 0 BOOL
116 Phase Rotation 000F - 074 - 01 0 1 0 BOOL
0 = Current Limit
1 = Soft Start
Display multiplier of 10.
SMC is looking for values
between 15 and 60.
0 = Manual
1 = Auto Reset
0 = Disable
25
xxx % FLA
1 = Enable
Table 8 FLA Setting Ranges and Default Values (with indicated setting precision)
FLA Current Range (A)
Minimum Value Maximum Value
1.1 3.0 1.1
3.0 5.5 3.0
5.3 7.6 5.3
6.3 16.0 6.3
Default Value
Publication 283A-QS001C-EN-P - July 2006
26
LED Status
Indication
Motor
Connection
ArmorPoint
Local Disconnect
2 Outputs
(Micro/M12)
ArmorPoint
Source Brake
Connector
Interface
(IN)
Interface
(OUT)
Ground Terminal
Control Power
Control Power
Three-Phase Power
Three-Phase Power
Ground Terminal
Ground Terminal
Figure 20 Bulletin 283 ArmorStart
Figure 21 Bulletin 283 ArmorStart with ArmorConnect
Publication 283A-QS001C-EN-P - July 2006
27
Table 9 DeviceNet Media
➊
Description Length m (ft) Cat. No.
Sealed
KwikLink pigtail drops are Insulation
Displacement Connector (IDC) with integral Class
1 round cables for interfacing devices or power
supplies to flat cable
1 m (3.3) 1485P-P1E4-B1-N5
2 m (6.5) 1485P-P1E4-B2-N5
3 m (9.8)
1485P-P1E4-B3-N5
6 m (19.8) 1485P-P1E4-B6-N5
DeviceNet Mini- T-Port Tap
Right Keyway
Left Keyway
1485P-P1N5-MN5NF
1485P-P1N5-MN5KM
Connector Cat. No.
Gray PVC Thin Cable
Thick Cable
Mini Straight Female
Mini Straight Male
Mini Straight Female
Mini Right Angle Male
Mini Right Angle Female
Mini Straight Male
Mini Right Angle Female
Mini Straight Male
Mini Straight Female
Mini Straight Male
Mini Straight Female
Mini Right Angle Male
Mini Right Angle Female
Mini Straight Male
Mini Right Angle Female
Mini Straight Male
1485G-P➋N5-M5
1485G-P➋W5-N5
1485G-P➋M5-Z5
1485G-P➋W5-Z5
1485C-P➌N5-M5
1485C-P➌W5-N5
1485C-P➌M5-Z5
1485C-P➌W5-Z5
➊
See publication M116-CA001A-EN-P for complete cable selection information.
➋
Replace symbol with desired length in meters (Example: 1485G-P1N5-M5 for a 1 m cable). Standard cable lengths: 1 m, 2 m, 3 m, 4 m, 5 m, and 6 m.
➌
Replace symbol with desired length in meters (Example: 1485C-P1N5-M5 for a 1 m cable). Standard cable lengths: 1 m, 2 m, 3 m, 4 m, 5 m, 6 m, 8 m, 10 m, 12 m,
18 m, 24 m, and 30 m.
NOTE: Stainless steel versions may be ordered by adding an “S” to the cat. no. (Example: 1485CS-P1N5-M5)
Publication 283A-QS001C-EN-P - July 2006
28
DC Micro Patchcord
DC Micro V-Cable
DC Micro Y-Cable
AC Micro Patchcord
Table 10 Sensor Media
Description
0
ArmorStart I/O
Connection
➊
Pin Count Connector Cat. No.
Straight Female
Straight Male
889D-F4ACDM-
➋
Input 5-Pin
Straight Female
0
0
Right Angle Male
Straight Female
889D-F4AACDE-
879D-F4ACDM-
➋
➋
Input 5-pin
0
Right Angle Male
0
Input 5-pin
0
Straight Female
Right Angle Male
879D-R4ACM-
879D-F4ACTE-
➋
➋
Straight Female
Straight Male
Output 3-pin
Straight Female
Right Angle Male
See Publication M116-CA001A-EN-P for complete cable selection information.
➊
Replace symbol with desired length in meters (Example: 889D-F4ACDM-1 for a 1 m cable). Standard cable lengths: 1 m, 2 m, 5 m, and 10 m.
➋
NOTE: Stainless steel versions may be ordered by adding an “S” to the cat. no. (Example: 889DS-F4ACDM-1)
Table 11 Sealing Caps
➌
Description Used on I/O Connection Catalog Number
Plastic Sealing Cap (M12) Input
Aluminum Sealing Cap Output
➌
To achieve IP67 rating, sealing caps must be installed on all unused I/O connections.
Table 12 ArmorPoint Media
Description Length m (ft) Cat. No.
0
ArmorPoint Bus Extension Cable including
Terminating Resistor
Extension Cable to connect two ArmorStart
Distributed Motor Controllers to ArmorPoint
communication protocol
1 (3.3)
1 (3.3)
889R-F3AERM-
899R-F3AERE-
1485A-M12
889A-RMCAP
280A-EXT1
280A-EXTCABLE
➋
➋
Publication 283A-QS001C-EN-P - July 2006
Bulletin 1738 ArmorPoint Distributed I/O Products
Table 13 Digital I/O Products
Description Cat. No.
0
Table 14 Digital Input Products
24V DC 8 Source Output w/ 8 M12 connectors 1738-OB8EM12
24V DC 8 Source Output w/ 8 M8 connectors 1738-OB8EM8
24V DC 4 Source Output w/ 4 M12 connectors 1738-OB4EM12
24V DC 4 Source Output w/ 4 M8 connectors
24V DC 2 Source Output w/ 2 M12 connectors 1738-OB2EM12
24V DC 2 Source Output - 2 A Prot. w/ 2 M12
connectors
24V DC 4 Sink Output w/ 4 M12 connectors
29
1738-OB4EM8
1738-OB2EPM12
1738-OV4EM12
0
Table 15 Analog Products
0
24V DC Analog Current Input w/ 2 M12 connectors 1738-IE2CM12
24V DC Analog Voltage Input w/ 2 M12 connectors
24V DC Analog Current Output w/ 2 M12 connectors
24V DC Analog Voltage Output w/ 2 M12 connectors
Description
24V DC 8 Sink Input w/ 4 M12 connectors,
2 points per connector
24V DC 8 Sink Input w/ 8 M8 connectors
24V DC 8 Sink Input w/ 1 M23 connector
Cat. No.
1738-IB8M12
1738-IB8M8
1738-IB8M23
24V DC 4 Sink Input w/ 4 M12 connectors 1738-IB4M12
24V DC 4 Sink Input w/ 4 M8 connectors 1738-IB4M8
24V DC 2 Sink Input w/ 2 M12 connectors
1738-IB2M12
24V DC 4 Source Input w/ 4 M12 connectors 1738-IV4M12
Description
Cat. No.
1738-IE2VM12
1738-OE2CM12
1738-OE2VM12
24V DC 2 Thermocouple Input
24V DC 2 RTD Input
1738-IT2IM12
1738-IR2M12
Table 16 Power Supply Products
Description
0
POINT I/O Field Potential Distributor Module 1738-FPD
24V DC Expansion Power Supply
Cat. No.
1738-EP24DC
Publication 283A-QS001C-EN-P - July 2006
30
Table 17 AC and Relay Products
Description Cat. No.
0
24V DC Coil N.O. DPST Relay w/ 2 M12 connectors 1738-OW4M12
24V DC Coil N.O. DPST Relay w/ 2 AC M12
120V AC 2 Input w/ 2 AC 4 pin M12 connectors
120V AC 2 Input w/ 2 AC 3 pin M12 connectors
120/230V AC 2 Output w/ 2 AC 3 pin M12
Table 18 Specialty Products
connectors
connectors
1738-OW4M12AC4
1738-IA2M12AC4
1738-IA2M12AC3
1738-OA2M12AC3
0
ArmorPoint I/O RS-232 ASCII Serial Interface
ArmorPoint I/O RS-485 ASCII Serial Interface
ArmorPoint Synchronous Serial Interface Module
Table 19 Adapter Products
0
ArmorPoint DeviceNet Adapter Module, Drop or
ArmorPoint DeviceNet Adapter Module, Drop only,
ArmorPoint DeviceNet Adapter Module, Drop or
ArmorPoint DeviceNet 24V DC Adapter Module with
ArmorPoint Redundant ControlNet Adapter Module
ArmorPoint Ethernet/IP 10/100 Mbps Adapter
Description
Module
Module
24V DC Very High Speed Counter Module
Cat. No.
1738-232ASCM12
1738-485ASCM12
1738-VHSC24M23
ArmorPoint 5V Encoder/Counter Module 1738-IJM23
with Absolute Encoder
1738-SSIM23
Description Cat. No.
Pass-through, with male and female M12
1738-ADN12
connectors
with male M18 connector
Pass-through, with male and female M18
1738-ADN18
1738-ADN18P
connectors
subnet expansion
1738-ADNX
1738-ACNR
Module
1738-AENT
Publication 283A-QS001C-EN-P - July 2006
Notes:
31
Publication 283A-QS001C-EN-P - July 2006
Registered Trademark List
ArmorPoint and ArmorStart are registered trademarks of Rockwell Automation, Inc.
Tr ademark List
ArmorConnect, RSLogix5000, PLC, RSNetWorx, and SLC are trademarks of Rockwell Automation, Inc. ControlNet is a trademark of ControlNet
International, LTD. DeviceNet and the DeviceNet logo are trademarks of the Open Device Vendors Association (ODVA).
Publication 283A-QS001C-EN-P — July 2006 41053-384-06
Superecedes Publication 283A-QS001B-EN-P — September 2005 Copyright ©2006 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
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