Rockwell Automation 284 User Manual

ArmorStart® Distributed Motor Controller

USER MANUAL

Bulletin 280/281,283,284

ATTENTION

IMPORTANT

Important User Information

Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Rockwell Automation does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication.

Rockwell Automation publication SGI-1.1, Safety Guidelines for the Application, Installation and Maintenance of Solid-State Control (available from your local Allen-Bradley sales office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication.

Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation, is prohibited.

Throughout this manual we use notes to make you aware of safety considerations:

Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss

Attention statements help you to:

• identify a hazard

• avoid a hazard

• recognize the consequences

Identifies information that is critical for successful application and understanding of the product.

Trademark List ArmorStart, ArmorPoint, and ControlLogix are registered trademarks of Rockwell Automation, Inc.

ArmorConnect, DeviceLogix, PLC, RSNetWorx, RSLogix 5000, and SLC are trademarks of Rockwell Automation, Inc. DeviceNet and the DeviceNet logo are trademarks of the Open Device Vendors Association (ODVA). ControlNet is a trademark of ControlNet International, LTD.

European Communities (EC) Directive Compliance

If this product has the CE mark it is approved for installation within the European Union and EEA regions. It has been designed and tested to meet the following directives.

Low Voltage and EMC Directives

This product is tested to meet Council Directive 73/23/EEC Low Voltage and 89/336/EEC and Council Directive 89/336/EC Electromagnetic Compatibility (EMC) by applying the following standard(s):

• Bulletin 280/281: EN 60947-4-1 — Low-voltage switchgear and

controlgear — Part 4-1:Contactors and motor-starters — Electromechanical contactors and motor-starters.

• Bulletin 283: EN 60947-4-2 — Low-voltage switchgear and

controlgear — Part 4-2: AC semiconductor motor controllers and starters.

• Bulletin 284: EN 61800-3 — Adjustable speed electronic power drive

systems — Part 3: EMC product standard including specific test methods.

This product is intended for use in an industrial environment.

Table of Contents

Table of Contents i

Chapter 1 Product Overview

Introduction ....................................................................................1-1

Description .....................................................................................1-1

Operation .......................................................................................1-2

Mode of Operation ..........................................................................1-2

Bulletin 280/281 — Full-Voltage Start .....................................1-2

Bulletin 283 — Soft Start.........................................................1-2

Bulletin 283 — Current Limit Start...........................................1-3

Bulletin 283 — Selectable Kick Start........................................1-3

Bulletin 283 — Soft Stop .........................................................1-3

Bulletin 284 — Sensorless Vector Performance .......................1-4

Bulletin 284 — Sensorless Vector Control................................1-4

Description of Features ..................................................................1-5

Overload Protection .................................................................1-5

LED Status Indication ..............................................................1-7

Fault Diagnostics .....................................................................1-7

Inputs ......................................................................................1-8

Outputs ...................................................................................1-8

Gland Plate Entrance ...............................................................1-8

Motor Cable .............................................................................1-8

ArmorStart with DeviceNet Network Capabilities ......................1-8

ArmorStart with ArmorPoint® I/O ............................................1-8

DeviceLogix™ ........................................................................1-9

Peer to Peer Communications (ZIP) ..........................................1-9

Factory Installed Options ................................................................1-9

Safety Monitor Option ..............................................................1-9

Optional HOA Keypad Configuration .........................................1-9

HOA Selector Keypad with Jog Function .................................1-10

Source Brake Contactor..........................................................1-10

EMI Filter................................................................................1-10

Dynamic Brake.......................................................................1-10

Dynamic Brake Resistor .........................................................1-11

Control Brake Contactor ........................................................1-11

Output Contactor....................................................................1-11

Shielded Motor Cable .............................................................1-11

0…10V Analog Input..............................................................1-11

Chapter 2 Installation and Wiring

Receiving .......................................................................................2-1

Unpacking ......................................................................................2-1

Inspecting ......................................................................................2-1

Storing ...........................................................................................2-1

General Precautions .......................................................................2-2

Dimensions ....................................................................................2-3

Bulletin 280/281 ......................................................................2-3

Bulletin 283..............................................................................2-9

Bulletin 284............................................................................2-14

Wiring ...................................................................................2-24

Power, Control, Safety Monitor Inputs, and

Ground Wiring ......................................................................2-24

Terminal Designations ..................................................................2-25

ii Table of Contents

Optional Locking Clip ...................................................................2-27

Operation of NEMA Type 4X Disconnect Handle ............................2-28

To Open Disconnect Handle ...................................................2-28

To Close Disconnect Handle for Lockout/Tag out ...................2-28

ArmorConnect Power Media .........................................................2-29

Description ............................................................................2-29

ArmorStart with ArmorConnect Connectivity ..........................2-31

Installing ArmorConnect Power Media using CordSets ...........2-31

ArmorConnect Cable Ratings .................................................2-32

Branch Circuit Protection Requirements for

ArmorConnect Three-Phase Power Media .............................2-32

Undergrounded and High Resistive Distribution Systems ........2-33

Disconnecting MOVs ..............................................................2-33

Group Motor Installations for USA and Canada Markets ................2-35

Wiring and Workmanship Guidelines ............................................2-35

DeviceNet Network Installation .....................................................2-37

Other DeviceNet System Design Considerations ....................2-37

Electromagnetic Compatibility (EMC) ............................................2-37

Grounding .............................................................................2-37

Wiring ...................................................................................2-37

Chapter 3 Bulletin 280/281 Programmable Parameters

Chapter 4 Bulletin 283 Programmable Parameters

Introduction ....................................................................................3-1

Parameter Programming .........................................................3-1

Parameter Group Listing .................................................................3-2

DeviceLogix™ Group .....................................................................3-2

DeviceNet Group ............................................................................3-7

Starter Protection Group ...............................................................3-10

User I/O ........................................................................................3-14

Misc. Group .................................................................................3-17

ZIP Parameters ............................................................................3-18

Starter Display .............................................................................3-26

Starter Setup ................................................................................3-27

Introduction ....................................................................................4-1

Parameter Programming .........................................................4-1

Parameter Group Listing .................................................................4-2

DeviceLogix™ Group .....................................................................4-3

DeviceNet Group ............................................................................4-9

Starter Protection Group ...............................................................4-12

User I/O ........................................................................................4-16

Misc. Group .................................................................................4-20

ZIP Parameters ............................................................................4-22

Soft Start Display .........................................................................4-28

Soft Start Setup ............................................................................4-29

Chapter 5 Bulletin 284 Programmable Parameters for Volts per Hertz Controllers

Table of Contents iii

Introduction ................................................................................... 5-1

Parameter Programming ......................................................... 5-1

Parameter Group Listing ................................................................ 5-1

DeviceLogix™ Group .................................................................... 5-3

DeviceNet Group ............................................................................ 5-9

Starter Protection Group .............................................................. 5-13

User I/O ....................................................................................... 5-16

Misc. Group ................................................................................. 5-20

Drive DeviceNet Group.................................................................. 5-22

ZIP Parameters ............................................................................ 5-24

Display Group............................................................................... 5-31

Basic Program Group.................................................................... 5-35

Advanced Program Group............................................................. 5-38

Clear an Overvoltage, Undervoltage, or Heatsink OvrTmp

Fault without Restarting the Drive................................................. 5-47

Chapter 6 Bulletin 284 Programmable Parameters for Sensorless Vector Controllers

Chapter 7 HOA Keypad Operation

Introduction ................................................................................... 6-1

Parameter Programming ......................................................... 6-1

Parameter Group Listing ................................................................ 6-2

DeviceLogix™ Group .................................................................... 6-3

Starter Protection Group .............................................................. 6-12

User I/O ....................................................................................... 6-15

Drive DeviceNet Group.................................................................. 6-20

Display Group............................................................................... 6-22

Clear Type 1 Fault and Restart...................................................... 6-45

Clear an Overvoltage, Undervoltage, or Heatsink OvrTmp Fault

without Restarting the Drive ......................................................... 6-45

Step Logic.................................................................................... 6-58

Introduction ................................................................................... 7-1

Keypad Description ........................................................................ 7-1

Keypad Disable and HOA ............................................................... 7-5

iv Table of Contents

Chapter 8 DeviceNet™ Commissioning

Chapter 9 Explicit Messaging on DeviceNet™

Establishing a DeviceNet Node Address ..........................................8-1

Node Commissioning using Hardware ............................................8-1

Node Commissioning using Software .............................................8-2

Building and Registering an EDS File ..............................................8-3

Using the Node Commissioning Tool Inside RSNetWorx

for DeviceNet .................................................................................8-5

System Configuration ....................................................................8-6

Using Automap feature with default Input and Output (I/O)

Assemblies ....................................................................................8-7

Default Input and Output (I/O) Assembly Formats ............................8-7

Setting the Motor FLA and Overload Trip Class (Bulletin 280/281) ...8-8

Setting the Motor FLA (Bulletin 283)................................................8-9

Setting the Morot FLA (Bulletin 284)..............................................8-10

Logic Controller Application Example with Explicit

Messaging .....................................................................................9-1

Programming the 1747-SLC ...........................................................9-1

I/O Mapping ............................................................................9-1

Explicit Messaging with SLC ...........................................................9-2

Setting up the Data File ..................................................................9-4

Sequence of Events ........................................................................9-4

Programming the 1756-ControlLogix ..............................................9-7

I/O Mapping ............................................................................9-7

Explicit Messaging with ControlLogix ..............................................9-8

Setting Up the MSG Instruction .......................................................9-8

Chapter 10 Using DeviceLogix™

Chapter 11 ArmorStart® to ArmorPoint® Connectivity

Chapter 12 ArmorStart® ZIP Configuration

DeviceLogix Programming ............................................................10-1

DeviceLogix Programming Example .............................................10-2

ArmorStart with ArmorPoint ..........................................................11-1

ArmorStart for the ArmorPoint Backplane ..............................11-1

ArmorStart to ArmorPoint Connectivity ...................................11-1

ArmorPoint Backplane Commissioning ..................................11-3

Details on Using the “ArmorStart Ladder Logic

Configurator” ........................................................................11-3

Theory of Operation ...............................................................11-3

I/O Tree Overview ..................................................................11-4

Logic Configuration Details ....................................................11-5

Adding Devices to the Configuration Structure .......................11-7

Modifying Parameter Data for an ArmorStart .........................11-8

Triggering a System Wide Read .............................................11-9

Triggering a System Wide Write ...........................................11-10

Interpreting the Error Report ................................................11-10

Overview ......................................................................................12-1

ZIP Parameter Overview ...............................................................12-1

Data Production ...........................................................................12-3

Data Consumption ........................................................................12-3

Table of Contents v

Mapping Consumed Data to the DeviceLogix Data Table. .............12-3

Finding ZIP bits in Device Logix Editor .........................................12-12

Chapter 13 Diagnostics

Overview ......................................................................................13-1

Protection Programming ........................................................13-1

Fault Display ................................................................................13-1

Clear Fault ...................................................................................13-2

Fault Codes ..................................................................................13-2

Fault Definitions ...........................................................................13-3

Short Circuit ..........................................................................13-3

Overload Trip .........................................................................13-3

Phase Loss ............................................................................13-3

Phase Short............................................................................13-3

Shorted SCR...........................................................................13-3

Ground Fault ..........................................................................13-3

Stall .......................................................................................13-3

Control Power ........................................................................13-3

I/O Fault ................................................................................13-3

Over Temperature .................................................................13-4

Phase Imbalance ...................................................................13-4

Over Current...........................................................................13-4

DeviceNet™ Power Loss .......................................................13-4

Internal Communication Fault.................................................13-4

DC Bus Fault ..........................................................................13-4

EEPROM Fault .......................................................................13-4

Hardware Fault ......................................................................13-4

Restart Retries .......................................................................13-4

Miscellaneous Faults..............................................................13-4

Chapter 14 Troubleshooting

Appendix A Specifications

Introduction ..................................................................................14-1

Bulletin 280/281 Troubleshooting..................................................14-2

Bulletin 283 Troubleshooting.........................................................14-4

Bulletin 284 Troubleshooting.........................................................14-8

DeviceNet Troubleshooting Procedures ......................................14-14

ArmorPoint Backplane Troubleshooting Procedures ....................14-15

Control Module Replacement ......................................................14-16

Base Module Replacement..........................................................14-19

Bulletin 280/281 Specifications.......................................................A-1

Bulletin 283 Specifications..............................................................A-4

Bulletin 284 Specifications..............................................................A-9

ArmorConnect™ Three-Phase Power Media ................................A-14

Trunk Cables .........................................................................A-14

Drop Cables ..........................................................................A-15

Power Tees & Reducer ..........................................................A-16

Power Receptacles ................................................................A-18

ArmorConnect Control Power Media .............................................A-20

Trunk & Drop Cables .............................................................A-20

T-Ports ..................................................................................A-21

vi Table of Contents

Receptacles ..........................................................................A-22

Shorting Plugs .......................................................................A-23

Appendix B Bulletin 280/281 CIP Information

Electronic Data Sheets ...................................................................B-1

DOL Type Product Codes and Name Strings ...................................B-1

DOL Reversing Type Product Codes and Name String .....................B-2

DeviceNet Objects ..........................................................................B-2

Identity Object — CLASS CODE 0x0001 .........................................B-3

Identity Objects ..............................................................................B-3

Message Router — CLASS CODE 0x0002 ......................................B-3

DeviceNet Object — CLASS CODE 0x0003 .....................................B-4

Assembly Object — CLASS CODE 0x0004 .....................................B-5

Custom Parameter Based

“Word-wise” I/O Assemblies ..........................................................B-5

“Word-wise” Bit-Packed Assemblies ..............................................B-6

Standard Distributed Motor Controller I/O Assemblies .....................B-7

Standard Distributed Motor Controller Output

(Consumed) Assemblies ..........................................................B-7

Standard Distributed Motor Controller Input

(Produced) Assemblies ............................................................B-8

Connection Object — CLASS CODE 0x0005 .................................B-10

Discrete Input Point Object — CLASS CODE 0x0008 ...................B-14

Discrete Output Point Object — CLASS CODE 0x0009 ..................B-15

Discrete Output Point Object Special Requirements ......................B-16

DOP Instances 3 and 4 Special Behavior ...............................B-17

DOP Instances 1 and 2 Special Behavior ...............................B-17

Parameter Object — CLASS CODE 0x000F ..................................B-21

Parameter Group Object — CLASS CODE 0x0010 ........................B-22

Discrete Input Group Object — CLASS CODE 0x001D ..................B-23

Discrete Output Group Object — CLASS CODE 0x001E ................B-24

Control Supervisor Object -CLASS CODE 0x0029 ..........................B-25

Acknowledge Handler Object — CLASS CODE 0x002b .................B-26

Overload Object — CLASS CODE 0x002c .....................................B-27

DeviceNet Interface Object -CLASS CODE 0x00B4 ........................B-28

Appendix C Bulletin 283 CIP Information

Electronic Data Sheets ...................................................................C-1

Soft Starter Type Product Codes and Name Strings ........................C-1

DeviceNet Objects ..........................................................................C-3

Identity Object — CLASS CODE 0x0001 .........................................C-3

Identity Objects ..............................................................................C-4

Message Router — CLASS CODE 0x0002 ......................................C-4

DeviceNet Object — CLASS CODE 0x0003 .....................................C-4

Assembly Object — CLASS CODE 0x0004 .....................................C-5

Custom Parameter Based

“Word-wise” I/O Assemblies ..........................................................C-6

“Word-wise” Bit-Packed Assemblies ..............................................C-6

Standard Distributed Motor Controller I/O Assemblies .....................C-8

Standard Distributed Motor Controller Output

Table of Contents vii

(Consumed) Assemblies ..........................................................C-9

Standard Distributed Motor Controller Input

(Produced) Assemblies ............................................................C-9

SMC Dialog Plus Native Assemblies........................................C-10

Connection Object — CLASS CODE 0x0005 .................................C-11

Discrete Input Point Object — CLASS CODE 0x0008 ...................C-16

Discrete Output Point Object — CLASS CODE 0x0009 ..................C-16

Discrete Output Point Object Special Requirements ......................C-18

DOP Instances 3 and 4 Special Behavior ...............................C-18

DOP Instances 1 and 2 Special Behavior ...............................C-19

Parameter Object — CLASS CODE 0x000F ..................................C-21

Parameter Group Object — CLASS CODE 0x0010 ........................C-22

Discrete Input Group Object — CLASS CODE 0x001D ..................C-23

Discrete Output Group Object — CLASS CODE 0x001E ................C-24

Control Supervisor Object -CLASS CODE 0x0029 ..........................C-25

Acknowledge Handler Object — CLASS CODE 0x002b .................C-26

Overload Object — CLASS CODE 0x002c .....................................C-27

DeviceNet Interface Object -CLASS CODE 0x00B4 ........................C-28

Appendix D Bulletin 284 CIP Information

Electronic Data Sheets ...................................................................D-1

Soft Starter Type Product Codes and Name Strings ........................D-1

DeviceNet Objects ..........................................................................D-2

Identity Object — CLASS CODE 0x0001 .........................................D-2

Identity Objects ..............................................................................D-3

Message Router — CLASS CODE 0x0002 ......................................D-3

DeviceNet Object — CLASS CODE 0x0003 .....................................D-4

Assembly Object — CLASS CODE 0x0004 .....................................D-5

Custom Parameter Based

“Word-wise” I/O Assemblies ..........................................................D-6

“Word-wise” Bit-Packed Assemblies ..............................................D-6

Standard Distributed Motor Controller I/O Assemblies .....................D-8

Standard Distributed Motor Controller Output

(Consumed) Assemblies ..........................................................D-8

Standard Distributed Motor Controller Input

(Produced) Assemblies ............................................................D-9

Inverter Type Distributed Motor Controller Input

(Produced) Assemblies...........................................................D-10

PowerFlex Native Assemblies.................................................D-11

Connection Object — CLASS CODE 0x0005 .................................D-13

Discrete Input Point Object — CLASS CODE 0x0008 ...................D-18

Discrete Output Point Object — CLASS CODE 0x0009 ..................D-19

Discrete Output Point Object Special Requirements ......................D-20

DOP Instances 3 and 4 Special Behavior ...............................D-20

DOP Instances 1, 2, 9, and 10 Special Behavior ....................D-22

Parameter Object — CLASS CODE 0x000F ..................................D-24

Parameter Group Object — CLASS CODE 0x0010 ........................D-27

Discrete Input Group Object — CLASS CODE 0x001D ..................D-28

Discrete Output Group Object — CLASS CODE 0x001E ................D-29

Control Supervisor Object -CLASS CODE 0x0029 ..........................D-30

Acknowledge Handler Object — CLASS CODE 0x002b .................D-31

viii Table of Contents

DeviceNet Interface Object -CLASS CODE 0x00B4 ........................D-32

Appendix E Group Motor Installations

Appendix F 24V DC Control Design Considerations

Appendix G Accessories

Appendix H Renewal Parts

Appendix I PID Setup

Application of ArmorStart® Controllers in Group Installation ........... E-1

ArmorStart® DC Control Voltage Application Information ................F-1

System Design Considerations When Using 16 AWG

Control Wiring ................................................................................F-4

Other System Design Considerations ..............................................F-4

Bulletin 1738 ArmorPoint Distributed I/O Products ..........................G-3

Renewal Parts.................................................................................H-1

Exclusive Control.............................................................................. I-1

Trim Control..................................................................................... I-2

PID Reference and Feedback............................................................I-3

PID Deadband ..................................................................................I-3

PID Preload ......................................................................................I-4

PID Limits ........................................................................................I-4

PID Gains .........................................................................................I-4

Guidelines For Adjusting PID Gains................................................... I-5

Appendix J Step Logic, Basic Logic and Timer/ Counter Functions

Step Logic Using Timed Steps......................................................... J-2

Step Logic Using Basic Logic Functions........................................... J-3

Timer Function................................................................................J-4

Counter Function............................................................................. J-5

Chapter 1

Product Overview

Introduction This chapter provides a brief overview of the features and

functionality of the Bulletin 280/281, 283, and 284 ArmorStart® Distributed Motor Controllers.

Description The ArmorStart Distributed Motor Controllers are integrated, pre-

engineered, starters with Bulletin 280/281 for full-voltage and reversing applications, Bulletin 283 for solid-state motor control, and Bulletin 284 for variable frequency AC drives applications. The ArmorStart offers a robust IP67/NEMA Type 4 enclosure design, which is suitable for water wash down environments. The ArmorStart products are also offered with NEMA Type 4X rating suitable for environment wash down with caustic chemical used in the food and beverage industry. The wash down rating is 1000 psi for the NEMA Type 4X rated devices.

The modular “plug and play” design offers simplicity in wiring the installation. The quick disconnects for the I/O, communications, and motor connections reduce the wiring time and eliminate wiring errors. The ArmorStart offers, as standard, four DC inputs and two relay outputs, to be used with sensors and actuators respectively, for monitoring and controlling the application process. The ArmorStart’s LED status indication and built-in diagnostics capabilities allow ease of maintenance and troubleshooting. The optional Hand/Off/Auto (HOA) keypad configuration allows local start/stop control at the ArmorStart

Distributed Motor Controller.

The ArmorStart Distributed Motor Controller offers short circuit protection per UL508 and IEC 60947. The ArmorStart is rated for local-disconnect service by incorporating the Bulletin 140 Motor Protector as the local-disconnect, eliminating the need for additional components. The ArmorStart Distributed Motor Controllers are suitable for group motor installations.

1-2 Product Overview

00%

)

Operation The ArmorStart Distributed Motor Controllers can operate three-

phase squirrel-cage induction motors as follows:

Bulletin 280/281: 0.24…16 A; 200VAC, 230VAC, 460VAC, 575V AC; 50/60 Hz. Bulletin 283: 1.1…16 A; 200VAC, 230VAC, 460VAC, or 575V AC; 50/60 Hz. Bulletin 284: up to 2.0 Hp (1.5 kW) @ 240V AC, up to 5 Hp (3.0 kW) @ 480V AC, and up to 5 Hp (4.0 kW) @ 575V AC; 50/60 Hz.

Depending on the catalog number ordered, the ArmorStart Distributed Motor Controller will accept a control power input of 120VAC, 240VAC or 24V DC.

Mode of Operation Bulletin 280/281

Full-Voltage Start

This method is used in applications requiring across-the-line starting, in which full inrush current and locked-rotor torque are realized. The ArmorStart Bulletin 280 offers full-voltage starting and the Bulletin 281 offers full-voltage starting for reversing applications.

Percent

Volta

Time (seconds

Bulletin 283

Soft Start

This method has the most general application. The motor is raised from an initial torque value to full voltage. The initial torque is adjustable to 15%, 25%, 35%, or 65% of locked rotor torque. The motor voltage is gradually increased during the acceleration ramp time, which can be adjusted from 1 to 45 seconds.

Product Overview 1-3

Current Limit Start

This starting mode is used when it is necessary to limit the maximum starting current. It can be adjusted for 150...600% of full load amps. Start times are selectable from 1...45 seconds.

Selectable Kick Start

A kickstart, or boost, at the beginning of the start mode is intended to provide a current pulse of 450% of full load current. The kickstart time is adjustable from 0.5...1.5 seconds. This allows the motor to develop additional torque at start for loads which may need a boost to get started.

Soft Stop

The Soft Stop function can be used with applications that require an extended coast to rest. When enabled, the voltage ramp down time can be selected from 1...90 seconds. The motor will stop when the motor voltage drops to a point where the load torque is greater than the motor torque.

1-4 Product Overview

Bulletin 284

Sensorless Vector Performance (Volts per Hertz)

• Drive automatically provides auto boost (IR compensation) and

slip compensation

• Provides excellent speed regulation and high levels of torque

across the entire speed range of the drive and improved speed

regulation even as load increases.

• Most cost-effective performance when sensorless vector control

is not required.

• To select this method of operation, select H for the Mode of

Operation listed in the catalog structure. See

Publication 280-SG001_-EN-P.

Sensorless Vector Control

• Sensorless Vector Control provides exceptional speed regulation

and very high levels of torque across the entire speed range of the

drive

• The Autotune feature allows the Bulletin 284 ArmorStart

Distributed Motor Controller to adapt to individual motor

characteristics.

• To select this method of operation, select V for the Mode of

Operation listed in the catalog structure. See

Publication 280-SG001_-EN-P.

Description of Features Overload Protection

Class 15 Overload Curves

100

10000

0 100 200 300 400 500 600 700

Multiples for Full Load Current

Approximate Trip Time (sec)

Cold

Hot

Class 10 Ove rload Curv es

100

1000

10000

0 100 200 300 400 500 600 700

Multiples of Full Load Current

Approximate Trip Time (sec)

Cold

Hot

Class 20 Ove rload Curv es

100

10000

0 100 200 300 400 500 600 700

Multiples of Full Load Current

Approximate Trip Time (sec)

Cold

Hot

Class 10

Class 15

Class 20

The ArmorStart Distributed Motor Controller incorporates, as standard, electronic motor overload protection. This overload

protection is accomplished electronically with an I ArmorStart’s overload protection is programmable via the communication network, providing the user with flexibility.

The Bulletin 280/281 overload trip class can be selected for class 10, 15, 20 protection. Ambient insensitivity is inherent in the electronic design of the overload.

Figure 1.1 Overload Trip Curves

Product Overview 1-5

t algorithm. The

1-6 Product Overview

Class 10 Overload Curv es

100

1000

10000

0 100 200 300 400 500 600 700

Multiples of Full Load Curre nt

Approximate Trip Time (sec)

Cold

Hot

Class 10

% of P132 (Motor NP Hertz) % of P132 (Motor NP Hertz)

% of P132 (Motor NP Hertz)

% of P133 (Motor OL Current)

The Bulletin 283 overload trip class allows for class 10 protection. Ambient insensitivity is inherent in the electronic design of the overload.

Figure 1.2 Overload Trip Curve

The Bulletin 284 ArmorStart Distributed Motor Controller incorporates, as standard, electronic motor overload protection. This

overload protection is accomplished electronically with an I

t algorithm. The ArmorStart’s overload protection is programmable via the communication network providing the user with flexibility. Programming the Motor OL Current parameter provides class 10 overload protection for the Bulletin 284 Distributed Motor Controller. Ambient insensitivity is inherent in the electronic design of the overload.

Figure 1.3 Overload Trip Curves

Product Overview 1-7

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” acts as a local trip reset.

Figure 1.4 Status Indication and Reset

Fault Diagnostics

Fault diagnostics capabilities built in the ArmorStart Distributed Motor Controller help you pinpoint a problem for easy

troubleshooting and quick re-starting.

Fault Indication

• Short Circuit X X X • Miscellaneous Fault X X

• Overload X X X • Brake Fuse Detection X X

• Phase Loss X X X • Internal Comm. Fault X X

• Control Power Loss X X X • Shorted SCR X

• Control Power Fuse Detection X X X • Phase Rotation X

• Output Power Fuse Detection X X X • Heatsink Temperature Fault X

•I/O Fault X X X •DC Bus Fault X

• Over Temperature X X X • Ground Fault X

• DeviceNet™ Power Loss ➊ X X X • Overcurrent X

• EEprom Fault X X X • Restart Retries X

• Hardware Fault X X X • Stall X

• Phase Imbalance X X • Phase Short X

Available on Bulletin:

Fault Indication

280/281 283 284 280/281 283 284

➊ Not available on the Bulletin 280A/281A., 283A, or 284A.

Available on Bulletin:

1-8 Product Overview

Inputs

The inputs are single-keyed (2 inputs per connector), which are sourced from DeviceNet power (24V DC), with LED status indication

- Not available with on the Bulletin 280A/281A, 283A, or 284A.

Outputs

Two dual-key relay output connectors are supplied as standard. The outputs are sourced from control power (A1 and A2). LED status indication is also provided as standard for each output.

Gland Plate Entrance

The ArmorStart product offers two different methods of connecting incoming three-phase and control power to the device. One method offered is the traditional conduit entrance with a ¾ in. and 1 in. conduit hole opening for wiring three-phase and control power. The second method offers connectivity to the ArmorConnect™ power media. Factory-installed receptacles are provided for connectivity to both three-phase and control power media.

Motor Cable

With every ArmorStart Distributed Motor Controller, a 3-meter unshielded 4-conductor cordset is provided with each unit as standard. If the optional EMI filter is selected for Bulletin 284 units, a shielded 4-conductor cordset is provided with each unit as standard.

ArmorStart with DeviceNet Network Capabilities

The ArmorStart Distributed Motor Controller delivers advanced capabilities to access parameter settings and provides fault diagnostics, and remote start-stop control. DeviceNet is the communication protocol, provided with the ArmorStart Bulletin 280D/281D, 283D, or 284D Distributed Motor Controller.

ArmorStart with ArmorPoint® I/O

The Bulletin 280A/281A, 283A, and 284A 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 different network protocols, the ArmorPoint Distributed I/O products allow the I/O capability to be expanded beyond the standard two outputs. Two dual-key relay output connectors are supplied as standard. The outputs are sourced from control power (A1 and A2). LED status indication is also provided as standard for each output. When using the ArmorPoint backplane, a maximum of two ArmorStart Distributed Motor Controllers can be connected to the ArmorPoint Distributed I/O product.

Product Overview 1-9

If the I/O capability of the Bulletin 280D/281D, 283D, or 284D ArmorStart Distributed Motor Controller needs to be expanded beyond the standard four inputs and two outputs, the ArmorStart Distributed Motor Controller with the DeviceNet communication protocol can be configured to the ADNX Architecture, in which the ArmorStart is part of the DeviceNet subnet, using the Bulletin 1738ADNX ArmorPoint Distributed I/O product.

DeviceLogix™

DeviceLogix is a stand-alone Boolean program that resides within the ArmorStart Distributed Motor Controller. DeviceLogix is programmed using Boolean math operations, such as, AND, OR, NOT, Timers, Counters, and Latches. DeviceLogix can run as a standalone application, independent of the network. However, 24V DC must be supplied at the DeviceNet connector to power the inputs.

Peer to Peer Communications (ZIP)

The zone control capabilities of ArmorStart Distributed Motor Controllers is ideal for large horsepower (0.5…10 Hp) motored conveyors. The ArmorStart Distributed Motor Controllers have builtin DeviceNet communications, DeviceLogix technology, and the added Zone Interlocking Parameters (ZIP) which allow one ArmorStart to receive data directly, from up to four other DeviceNet nodes, without going through a network scanner. These direct communications between conveyor zones are beneficial in a merge, diverter, or accumulation conveyor application.

Factory Installed Options Safety Monitor Option (Bulletins 280/281, 283, and 284)

The Safety Monitor Option allows for independent monitoring of the output status of the device. The function is implemented using a normally closed contact which complies with EN/IEC 60947-5-1 for mechanically linked contacts. Two terminal blocks are provided as the inputs which may be used with an external safety circuit. The external safety circuit monitors the status of the contactor.

Optional HOA Keypad Configuration (Bulletin 280/281 only)

The ArmorStart offers two optional factory-installed Hand/Off/Auto (HOA) configurations: Standard and Forward/Reverse HOA.

Figure 1.5 Optional HOA Configuration

1-10 Product Overview

Optional HOA Keypad Configuration (Bulletin 283 only)

The ArmorStart offers an optional factory-installed Hand/Off/Auto (HOA) configuration:

Figure 1.6 Optional HOA Configuration

Optional HOA Selector Keypad with Jog Function (Bulletin 284 only)

The HOA Selector Keypad with Jog Function allows for local start/ stop control with capabilities to jog in forward/reverse motor directions.

Figure 1.7 Optional HOA with Jog Function Configuration

Source Brake Contactor (Bulletins 283 and 284 only)

An internal contactor is used to switch the electromechanical motor brake on/off. The motor brake is powered from the main power circuit. A customer-accessible 3.0 A fuse is provided to protect the brake cable. A 3 meter, 3-pin cable for connection to the motor brake is provided as standard when the option is selected.

EMI Filter (Bulletin 284 only)

The EMI Filter option is required if the Bulletin 284 ArmorStart Distributed Motor Controller must be CE-compliant. If the EMI Filter is selected, a 3 meter shielded 4-conductor cordset is provided as standard. This option is only available with sensorless vector control.

Dynamic Brake (Bulletin 284 only)

A 3 meter 3-pin cable for connection to a dynamic brake module is provided as standard when this option is selected. Accessories for available dynamic brake modules.

See Appendix G,

Product Overview 1-11

Dynamic Brake Resistor (Bulletin 284 only)

The IP67 Dynamic Brake Resistor plug and play design offers simplicity in writing and installation. The factory installed option of DB1 must be selected in order to have the quick disconnect connectivity. The cable length of the IP67 Dynamic Brake Resistor is available in two lengths, 0.5 meter and 1 meter. See Appendix G, Accessories, for available IP67 Dynamic Brake Resistors.

Control Brake Contactor (Bulletin 284 only)

An internal contactor is used to switch the electromechanical motor brake On/Off. The motor brake is powered from the control voltage circuit. A customer accessible 3.0 A fuse is provided to protect the brake cable. One 3-meter 3-pin cable for connection to the motor brake is provided as standard when this option is selected.

Output Contactor (Bulletin 284 only)

An internal contactor will be sourced from control voltage to isolate the load side of the Bulletin 284 ArmorStart Distributed Motor Controller. When control power is applied, the output contactor is closed, and when control power is removed, the output contact opens. There is no switching element, such as a relay, in the system. If control power is lost then the output contactor will open, since its coil power is lost. A sequenced stop involving the output contactor cannot be performed.

Shielded Motor Cable (Bulletin 284 only)

A 3 meter shielded 4-conductor cordset is provided instead of the 3 meter unshielded 4-conductor cordset. If the EMI Filter is selected, a 3 meter shielded 4-conductor cordset is provided as standard.

0…10V Analog Input (Bulletin 284 only)

The Bulletin 284 Distributed Motor Controller with Sensorless Vector Control provides a 0…10V analog input. The 0…10V Analog Input is a factory installed option that provides a 0…10V external frequency command from the 0…10V or +/-10V analog input or remote potentiometer. A 5-pin micro receptacle is provided for connectivity for customer connection. A shielded 5-conductor cordset or patch cord is recommended.

1-12 Product Overview

Notes:

Chapter 2

Installation and Wiring

Receiving It is the responsibility of the user to thoroughly inspect the equipment

before accepting the shipment from the freight company. Check the item(s) received against the purchase order. If any items are damaged, it is the responsibility of the user not to accept delivery until the freight agent has noted the damage on the freight bill. Should any concealed damage be found during unpacking, it is again the responsibility of the user to notify the freight agent. The shipping container must be left intact and the freight agent should be requested to make a visual inspection of the equipment.

Unpacking Remove all packing material, wedges, or braces from within and

around the starter. Remove all packing material from device(s).

Inspecting After unpacking, check the nameplate catalog number(s) against the

purchase order.

Storing The controller 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 –25°C…+85°C

(–13°F…+185°F).

• Store within a relative humidity range of 0…95%,

noncondensing.

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

atmosphere.

• Do not store equipment in a construction area.

2-2 Installation and Wiring

ATTENTION

General Precautions In addition to the precautions listed throughout this manual, the

following statements, which are general to the system, must be read and understood.

The controller contains ESD (electrostatic discharge)-sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing, or repairing the assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, refer to Publication 8000-4.5.2, Guarding against Electrostatic Discharge, or any other applicable ESD protection handbooks.

An incorrectly applied or installed controller can damage components or reduce product life. Wiring or application errors, such as undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures, may result in malfunction of the system.

Precautions for Bulletin 284 Applications

Only personnel familiar with the controller and associated machinery should plan or implement the installation, startup, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage.

The drive contains high voltage capacitors which take time to discharge after removal of mains supply. Before working on drive, ensure isolation of mains supply from line inputs (R, S, T [L1, L2, L3]). Wait three minutes for capacitors to discharge to safe voltage levels. Failure to do so may result in personal injury or death. Darkened display LEDs are not an indication that capacitors have discharged to safe voltage levels.

Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, startup, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage.

Installation and Wiring 2-3

Dimensions for Bulletin 280/281 Dimensions are shown in millimeters (inches). Dimensions are not

intended to be used for manufacturing purposes. All dimensions are subject to change.

Figure 2.1 Dimensions for IP67/NEMA Type 4 with Conduit Entrance

2-4 Installation and Wiring

ArmorStart® with a 10 A

Short-Circuit Protection Rating

ArmorStart® with a 25 A

Short-Circuit Protection Rating

Dimensions for Bulletin 280/281, Continued

Dimensions are shown in millimeters (inches). Dimensions are not intended to be used for manufacturing purposes. All dimensions are subject to change.

Figure 2.2 Dimensions for IP67/NEMA Type 4 with ArmorConnect™

Connectivity

Installation and Wiring 2-5

Dimensions for Bulletin 280/281, Continued

Dimensions are shown in millimeters (inches). Dimensions are not intended to be used for manufacturing purposes. All dimensions are subject to change.

Figure 2.3 Dimensions for NEMA Type 4X with Conduit Entrance

2-6 Installation and Wiring

Dimensions for Bulletin 280/281, Continued

Dimensions are shown in millimeters (inches). Dimensions are not intended to be used for manufacturing purposes. All dimensions are subject to change.

Figure 2.4 Dimensions for Type 4X with ArmorConnect Connectivity

+ 450 hidden pages