Yaskawa SmartTrac AC1 User Manual
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SMART TRAC AC1
Table of Contents
List of Figures..................................................................................................................................iv
List of Tables ...................................................................................................................................iv
Warranty............................................................................................................................................v
Limitation of Liability .......................................................................................................................v
Important Safety and Warranty Information 1-1
Warnings, Cautions and Notes.................................................................................................................1-1
General Safety Precautions - Warnings .................................................................................................. 1-2
Important Warranty Information............................................................................................................ 1-2
Smart Trac AC1 2-1
Overview..................................................................................................................................................... 2-1
General Capabilities......................................................................................................................2-1
Specifications................................................................................................................................ 2-2
Assembling a Smart Trac AC1 3-1
The Contents of Your Shipment............................................................................................................... 3-1
Assembly Procedure.................................................................................................................................. 3-1
Option Cards.............................................................................................................................................. 3-5
Smart Trac PG Card...................................................................................................................... 3-6
Smart Trac PS Card....................................................................................................................... 3-6
Smart Trac Ethernet Card.............................................................................................................. 3-6
Optional PC-104 Compliant Cards................................................................................................ 3-6
Smart Trac AC1 Installation 4-1
Installing Your Smart Trac AC1 ............................................................................................................. 4-2
Storage .......................................................................................................................................... 4-2
Unpacking..................................................................................................................................... 4-2
Locating Your Smart Trac AC1.................................................................................................... 4-2
Making Electrical Connections..................................................................................................... 4-4
Smart Trac Grounding................................................................................................................. 4-10
Connecting Auxiliary Input and Output Power Option Devices................................................. 4-12
Connecting the Control Circuit................................................................................................... 4-12
Terminating Shielded Cable........................................................................................................ 4-16
Connecting Optional Cards......................................................................................................... 4-16
Pre-Power Checklist................................................................................................................................ 4-17
Booting and Power-Up Self-Test............................................................................................................ 4-17
The Boot Menu ........................................................................................................................................ 4-17
TCP/IP Address........................................................................................................................... 4-19
Inverter Type............................................................................................................................... 4-19
COM1 Config ............................................................................................................................. 4-19
Serial Download?........................................................................................................................ 4-20
Firmware Version........................................................................................................................ 4-20
Technical Manual TM 3554-000 •• 0-i
SMART TRAC AC1
Flash Access................................................................................................................................ 4-20
Start System?............................................................................................................................... 4-20
Setting the System Time ............................................................................................................. 4-20
Connecting the Vector Controlled Motor.............................................................................................. 4-20
Tune Your Smart Trac AC1................................................................................................................... 4-21
Power On and Preliminary Checks ............................................................................................. 4-21
Tachometer and Motor Rotation Check................................................................................................ 4-24
Recording Settings Using the Programming Menu.............................................................................. 4-27
Auto-Tuning Faults and Corrective Actions......................................................................................... 4-29
Networking the Smart Trac AC1 5-1
Types of Networks for Your Smart Trac AC1........................................................................................ 5-1
PC-based Operation ...................................................................................................................... 5-1
Self-Contained, Control Networks................................................................................................ 5-1
Using Ethernet for PC-based Operation........................................................................................ 5-2
Ethernet Network Architecture ............................................................................................................... 5-4
Linear Bus using 10Base-T.......................................................................................................... 5-4
Star network using 10Base-2 or 10Base-T.................................................................................... 5-5
Ethernet Network Configuration............................................................................................................. 5-7
Addresses and subnet mask........................................................................................................... 5-7
Configuration for PC-Based Operation......................................................................................... 5-7
Configuration for an enterprise-wide LAN................................................................................... 5-8
Verifying Your TCP/IP Configuration........................................................................................ 5-10
Troubleshooting Your Smart Trac AC1 6-1
Reporting of Faults and Errors................................................................................................................ 6-1
Fault Histories............................................................................................................................... 6-1
Resetting Faults............................................................................................................................. 6-2
Clearing Faults.............................................................................................................................. 6-2
Troubleshooting Motor Symptoms.......................................................................................................... 6-2
If the drive/motor will not operate ................................................................................................ 6-3
Troubleshooting For Fault Conditions.................................................................................................... 6-3
Smart Trac AC1 Maintenance 7-1
Preventive Maintenance............................................................................................................................ 7-1
Corrective Maintenance............................................................................................................................ 7-3
Replacing Parts.............................................................................................................................. 7-3
Ordering Parts ............................................................................................................................... 7-6
Appendix A – Dimensions 8-1
Smart Trac AC1 Dimensions.................................................................................................................... 8-1
Mounting Hardware and Hole Dimensions............................................................................................. 8-3
Appendix B – Detailed Specifications 8-5
AC1 Specifications..................................................................................................................................... 8-5
Appendix C - Wiring, Grounding and Installation Practices for Noise Immunity 8-9
Wiring, Grounding and Installation Practices........................................................................................ 8-9
Wiring Requirements for Panel Design/Layout:........................................................................... 8-9
Wire separation groups – STANDARD PRACTICE:................................................................. 8-10
Wiring Requirements for Shop Wiring....................................................................................... 8-11
0-ii •• Technical Manual TM 3554-000
SMART TRAC AC1
Wiring Requirements and Recommendations for Field Installation: .......................................... 8-12
Appendix D - Application Parameters 8-15
Application Parameter Form ................................................................................................................. 8-15
Appendix E – Installing System Software 8-21
Installing Boot, Monitor or Operating System Software and Recovery from CPU Failure............. 8-21
Kernel Download........................................................................................................................ 8-21
Appendix F – Technical Support 8-25
Getting Help............................................................................................................................................. 8-25
Problem Report ....................................................................................................................................... 8-26
Training.................................................................................................................................................... 8-27
References ................................................................................................................................................ 8-29
Appendix G – Replaceable Parts 8-33
Replaceable Parts Listing ....................................................................................................................... 8-33
Glossary of Terms 8-35
Index 8-39
Technical Manual TM 3554-000 •• 0-iii
SMART TRAC AC1
List of Figures
List of Tables
Figure 1. Smart Trac card assembly showing option cards. ............................. 3-6
Figure 2. Grounding of Three Smart Trac AC1s (top) and Grounding of Smart
Trac AC1 with Vector Controlled Motor (VCM) (bottom).................... 4-11
Figure 3. Simplified Customer Connection Diagram ..................................... 4-14
Figure 4. Shielded Termination...................................................................... 4-16
Figure 5. The Smart Trac AC1 Boot Process. ................................................4-19
Figure 6. A typical local area network used for PC-based operation of Smart
Trac AC1s................................................................................................. 5-4
Figure 7. A Linear Bus topology using 10Base-T............................................ 5-5
Figure 8. A Star topolgy using 10Base-T......................................................... 5-6
Figure 9. The Command Prompt from Windows NT..................................... 5-10
Figure 10. IPCONFIG results......................................................................... 5-10
Figure 11. A successful PING of the computer you are using........................ 5-11
Figure 12. Using thePC/104 card extraction tool..............................................7-4
Figure 13. Removing the Smart Trac Card Stack............................................. 7-5
Figure 14. The Kernel Download – Download Operations dialog box. .........8-22
Figure 15. The Kernel Download – Communications Setup dialog box........8-23
Table 1. Smart Trac AC1 Specifications.......................................................... 2-2
Table 2. Terminal screws, connectors and clamping torque by wire size......... 4-5
Table 3. Wire Sizing for Main Circuit, 230 Volt..............................................4-6
Table 4. Wire Sizing for Main Circuit, 460 Volt..............................................4-7
Table 5. Wire Sizing for Main Circuit 600V (575V)........................................ 4-9
Table 6.Terminal Definitions of the Inverter Control Card............................ 4-15
Table 7. Motor Setup Parameters ................................................................... 4-23
Table 8. Troubleshooting Faults....................................................................... 6-3
Table 9. Smart Trac AC1 Replaceable Parts List............................................. 7-7
0-iv •• Technical Manual TM 3554-000
SMART TRAC AC1
Warranty
Standard products manufactured by MagneTek are warranted to be free from
defects in workmanship and material for a period of one year from date of
shipment and any products which are defective in workmanship or material will
be repaired or replaced, at MagneTek’s option, at no charge to the Buyer. Final
determination as to whether a product is actually defective rests with MagneTek.
The obligation of MagneTek hereunder shall be limited solely to repair or
replace, at MagneTek’s discretion, products that fall within the foregoing
limitations, and shall be conditioned upon receipt by MagneTek of written
notice of any alleged defects or deficiency promptly after discovery and within
the warranty period, and in the case of components or units purchased by
MagneTek, the obligations of MagneTek shall not exceed the settlement that
MagneTek is able to obtain from the supplier thereof. No products shall be
returned to MagneTek without its prior consent. Products which MagneTek
consents to have returned shall be shipped prepaid f.o.b. MagneTek’s factory.
MagneTek cannot assume responsibility or accept invoices for unauthorized
repairs to its components, even though defective. The life of the products of
MagneTek depends, to a large extent, upon the usage thereof, and MAGNETEK
MAKES NO WARRANTY AS TO FITNESS OF ITS PRODUCTS FOR THE
SPECIFIC APPLICATIONS BY THE BUYER NOR AS TO PERIOD OF
SERVICE UNLESS MAGNETEK SPECIFICALLY AGREES OTHERWISE
IN WRITING AFTER THE PROPOSED USAGE HAS BEEN MADE
KNOWN TO IT.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL
OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, BUT
NOT LIMITED TO, ANY WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR A PARTICULAR PURPOSE AND BUYER HEREBY
WAIVES ANY AND ALL CLAIMS THEREFORE.
Limitation of Liability
IN NO EVENT SHALL MAGNETEK BE LIABLE FOR LOSS OF PROFIT,
INDIRECT, CONSEQUENTIAL, OR INCIDENTAL DAMAGES WHETHER
ARISING OUT OF WARRANTY, BREACH OF CONTRACT OR TORT.
Technical Manual TM 3554-000 •• 0-v
SMART TRAC AC1
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0-vi •• Technical Manual TM 3554-000
SMART TRAC AC1
Important Safety and Warranty
Information
This Chapter will enable you to:
q Be aware of warnings, cautions and notes as they appear
in the documentation.
q Learn about important warranty information.
Warnings, Cautions and Notes
WARNING
A statement of conditions which MUST BE OBSERVED to
prevent personal injury or death.
WARNING - ESD
A statement of conditions which must be observed to prevent
damage to components due to ESD (ElectroStatic Discharge) and
to prevent personal injury or death.
CAUTION
A statement of conditions which must be observed to prevent
undesired equipment faults, Smart Trac AC1 system degradation
and damage to equipment.
IMPORTANT
A statement of conditions which should be observed during Smart Trac AC
setup or operation to ensure dependable service.
Technical Manual TM 3554-000 Important Safety and Warranty Information •• 1-1
SMART TRAC AC1
NOTE: Notes indicate information that is in addition to a discussion of the topic
in adjoining text. Alternatively, it may limit or restrict the paragraph(s) that
follow(s) to specific models or conditions.
TIP - Tips indicate information that should make a procedure easier or more
efficient.
General Safety Precautions Warnings
Important safety information follows. Please read and understand all
precautions listed below before proceeding with the specification, installation,
set-up or operation of your Smart Trac AC1. Failure to follow any of the
following precautions may result in personal injury or death, or damage to the
equipment.
WARNING - ESD
The Control Printed Circuit Board (PCB) employs CMOS
Integrated Circuits that are easily damaged by static electricity.
Use proper ElectroStatic Discharge (ESD) procedures when
handling the Control PCB. See Smart Trac AC1 Technical Manual
for details. Failure to comply may result in damage to equipment
and/or personal injury.
Important Warranty Information.
Do not modify your Smart Trac AC1, its components, or any of the procedures
contained in the technical documentation supplied by MagneTek. Any
modification of this product by the user is not the responsibility of MagneTek
and will void the warranty.
1-2 •• Important Safety and Warranty Information Technical Manual TM 3554-000
SMART TRAC AC1
WARNINGWARNING
Verify that the rated voltage of the Smart Trac AC1 matches the
voltage of the incoming power.
Always ground the Smart Trac AC1 using ground terminal G. See the
detailed instructions provided in the Smart Trac Technical Manual.
Wiring must be performed only by qualified personnel.
Do not perform a "HIPOT" or withstand voltage test on any part of
the Smart Trac AC1. The AC1 uses semi-conductors and is vulnerable
to high voltage.
Never connect the main circuit output terminals T1, T2 and T3 to the
AC main circuit power supply.
All parameters have been factory set to values commonly used. Do
not change their settings without good reason.
Failure to comply with this warning may result in damage to the
Smart Trac AC1 and connected equipment along with personal injury
and/or death.
WARNING WARNING -- ESD ESD
The Control Printed Circuit Board (PCB) employs CMOS Integrated
Circuits that are easily damaged by static electricity. Use proper
Electrostatic Discharge (ESD) procedures when handling the Control
PCB. Failure to comply may result in damage to equipment and/or
personal injury.
CAUTIONCAUTION
All parameters have been factory set to values commonly used. Do not
change their settings without a full understanding of their impact on
Smart Trac AC1 and machine operation. Failure to comply may result
in damage to equipment and/or personal injury.
Technical Manual TM 3554-000 Important Safety and Warranty Information •• 1-3
SMART TRAC AC1
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1-4 •• Important Safety and Warranty Information Technical Manual TM 3554-000
Smart Trac AC1
This Chapter will enable you to:
q Describe the capabilities of the Smart Trac AC1
q Become familiar with the ratings and specifications of the
Smart Trac AC1
SMART TRAC AC1
General Capabilities
Overview
The Smart Trac AC1 is a high performance, programmable AC motor drive that
eliminates the need for an external PLC or PC to control a machine or process.
Utilizing the Windows® environment, Smart Trac Workstation™ software allows
the Smart Trac AC1 to be programmed efficiently and easily. Each Smart Trac
AC1 can be programmed to fulfill a specific function and purpose using any of
the five IEC-61131-3 programming languages. IEC-61131-3 programming
languages include Relay Ladder Logic (RLL), Structured Text (ST), Sequential
Function Charts (SFC), Function Blocks (FB) or Instruction Lists (IL).
Commonly used function blocks may be obtained from MagneTek's Program
Library. Consult your local MagneTek representative for details.
Smart Trac AC1 offers many means of communications with other control
devices using either the built-in RS-232 port or any of the optional add-on
communication cards. A MagneTek ARCNET card may be used to
communicate with MicroTrac® LAN systems, providing backward
compatibility with existing MagneTek systems. In addition, the Smart Trac AC1
system supports off-the-shelf Ethernet, DeviceNet, Profibus, SDS, Interbus-S,
Fiber Optic and local I/O cards conforming to PC/104 specifications for form
and fit.
The Smart Trac AC1 provides a sine-coded and pulse width modulated threephase output with adjustable voltage and frequency. This provides for complete
speed and/or torque control of any conventional squirrel cage induction motor.
Automatic stall prevention and voltage boost prevents nuisance tripping during
load or line side transient conditions. The Smart Trac AC1 will not induce any
voltage line notching distortion back to the utility line and will maintain a
displacement power factor of not less than 0.98 throughout its speed range.
Technical Manual TM 3554-000 Smart Trac AC1 •• 2-1
SMART TRAC AC1
Specifications
Table 1. Smart Trac AC1 Specifications
Characteristic Specification
Ratings: 0.75 to 100 HP at 230 VAC
1.0 to 1600 HP at 460 VAC
2.0 to 200 HP at 600 VAC
Amperes 3.2 to 1,600 amps, depending on model
Input Power – 208/230V
Class
Output Power-208/230V
Class
Input Power –
380/415/460V Class
Output Power–
380/415/460V Class
Input Power –
575 / 600 V Class
Output Power–
575 / 600 V Class
Overload Capacity 150% for 1 minute
Enclosure Types NEMA 1 Protected Chassis, NEMA 4 , or NEMA 12
Ambient Operating
Temp.
Storage Temperature -20° C to 60° C
Humidity 95% RH non-condensing
Vibration 1G<20Hz, 0.2G 20 to 50 Hz
Location Indoor, protected from corrosive gases and dust
Elevation 3300 ft (1000 M) or less
Voltage: 3 Phase 200/208/220/230 VAC +10%, -15%
Frequency: 50/60 Hz ± 5%
Voltage: 0-230V (proportional to input voltage)
Frequency: 0-400 Hz (V/Hz pattern selectable)
Voltage: 3 Phase 380/400/415/440/460 VAC +10%, -15%
Frequency: 50/60 Hz ± 5%
Voltage: 0-460V (proportional to input voltage)
Frequency: 0-400 Hz (V/Hz pattern selectable)
Voltage: 3 Phase 500/ 575/ 600 VAC ±10%
Frequency: 50/60 Hz ± 5%
Voltage: 0-575V (proportional to input voltage)
Frequency: 0-400 Hz (V/Hz pattern selectable)
0°C to 40° C
2-2 •• Smart Trac AC1 Technical Manual TM 3554-000
SMART TRAC AC1
Assembling a Smart Trac AC1
This Chapter will enable you to:
q Understand what is contained within your Smart Trac
AC1
q Learn how to assemble your Smart Trac AC1 from the
components you received.
q Recognize each of the Option cards in your Smart Trac
AC1
The Contents of Your Shipment
Because Smart Trac AC1s are shipped to your specifications, there is wide
variation in the types and numbers of component parts shipped to you. While
some of your components may already be assembled, the assembly procedures
in this chapter assume that you've received the following components :
• Smart Trac AC1 Chassis, Drive and Inverter Card (assembled)
• Cover and Adapter Ring
• Smart Trac CPU Card
• Smart Trac Option Cards (as specified for your configuration)
Assembly Procedure
Use the following procedure for first time installation of your Smart Trac AC1
only!
WARNING WARNING -- ESD ESD
The Smart Trac AC1 electronics are electrostatic sensitive devices.
Follow Electrostatic Discharge (ESD) procedures when handling to
protect components. Failure to follow ESD procedures may result in
damage to the Smart Trac AC1 or its components.
1. Ensure wiring harness at connector 7CN, located at the top of the Smart
Trac Inverter card, is connected to the 7CN connector on the primary
power supply printed circuit board (1PCB). The power supply board is
either a Power PCB (units B034 or less) or a Gate Drive PCB (A064 or
higher number).
Technical Manual TM 3554-000 Assembling a Smart Trac AC1 •• 3-1
SMART TRAC AC1
While rotating the Smart Trac CPU card about 45 degrees from its base
should be oriented so the standoff screw hole is on the left and the plate
2. Ensure ground strap E, located at bottom of inverter card, is connected
to the Smart Trac case ground terminal (indicated by the printed ground
symbol .
NOTE: The case ground terminals are the two screw terminals in the lower left
of smaller cases, or placed one on the lower left and one on the lower right sides
of larger cases. You can use either or both terminals to connect ground straps,
depending on the length of the strap or your preference.
3. Connect and tighten all electrical leads to terminal blocks on the Smart
Trac Inverter card to their proper termination, as shown on the specific
connection diagram for your Smart Trac AC1 installation.
4. Remove the Smart Trac CPU card (marked "ST") from its anti-static
bag.
5. Familiarize yourself with the location of the 2CN connector on the
Inverter card. The female half of the black 2CN connector is located on
the Smart Trac Inverter card. The male half is located on the Smart
Trac CPU card.
NOTE: Standoffs used
between the Smart Trac CPU
and Inverter cards are
shorter than other standoffs
6.
position, set the Smart Trac CPU card locking plate into the plastic
locking tab on the Inverter card. Align the holes in the locking plate
with the special, short black plastic standoffs. The metal locking plate
used between all other cards.
is below the plane of the black plastic standoffs. Rotate the card
downward to lock in place.
7. Insert four metal standoffs through four outside holes in the Smart Trac
Inverter card and screw into the four standoffs on the underside of the
card. Tighten standoffs with fingers (torque to about 10 in-lbs).
8. Locate the three plastic standoffs and spring-loaded clips that secure
the Smart Trac CPU card to the Smart Trac Inverter card through holes
in the card.
9. Orient the Smart Trac CPU card with the PC/104 connector at the
bottom. The MagneTek logo, printed on the card, should be at the top.
Slip the Smart Trac CPU card under the wiring harness connector (the
harness is connected to 1CN on the inverter card). Rotate slightly
upward from the left.
10. Align the male and female halves of the 2CN connector and, being
careful not to bend the pins of the 2CN connector, press the Smart Trac
CPU card firmly into place on the Smart Trac Inverter card (1PCB).
You should see and hear the plastic standoffs and spring-loaded clips
snap into place.
NOTE: Depending on the
drive and case size, make
encoder connections before
installing the Smart Trac PG
Card.
11. Install four metal standoffs through four outside holes in the Smart
Trac CPU card and screw into the four standoffs on the underside of
the card. One standoff may be a different color thatn the other three.
This standoff is inserted through the CPU card and into the trhreaded
hole in the metal locking plate. Tighten standoffs with fingers (torque
to about 10 in-lbs).
12. If you purchased the Smart Trac PG card option, install it at as follows.
Otherwise, proceed immediately to step 12.
3-2 •• Assembling a Smart Trac AC1 Technical Manual TM 3554-000
SMART TRAC AC1
a. Locate two block pin positions on the female PC/104 connector.
Using a pin or other sharp object, carefully remove two black plugs
from the two blocked pin positions.
b. Orient the Smart Trac PG card so that the PC/104 connector and
the J2 connector (on the solder side of the card) align with the
PC/104 connector on the Smart Trac CPU card and the 4CN
connector on the Inverter Control card. The standoff hole above J6
must slip over the plastic standoff. Be careful to align the PC/104
connector pins with the receptacle on the Smart Trac CPU card so
the pins don't bend when the card is pushed into place.
c. Gently but firmly push the Smart Trac PG card onto the Smart
Trac CPU card. Make sure connecting pins are in alignment and J2
mates with 4CN before pushing the two boards tightly together.
Secure the card using four (4) metal standoffs and one (1) plastic
standoff. Tighten metal standoffs with fingers (torque to about 10
lb-ft).
13. Position the Adapter Ring over the drive chassis, aligning two tabs on
the right side of the ring with slots in the chassis.
14. Secure the Adapter Ring to the chassis using two or four Phillips head
screws, depending on drive case size.
15. Connect the 9-pin RS-232 cable at connector J5 on the Smart Trac CPU
card.
16. If your unit includes a Smart Trac PG card, connect the ground strap
from J11 on the Smart Trac PG card, to the left inside and top inside of
the Adapter Ring.
17. Connect the 12-pin wiring harness from the Digital Operator to
connector J4 on the Smart Trac PS card.
18. Install other option cards per instructions included with each card. See
"Option Cards" below for general information.
19. Close the cover and tighten the screws or single captive screw to secure
the cover.
20. Your Smart Trac AC1 should not be assembled and ready for
connection to a 110V power supply.
Technical Manual TM 3554-000 Assembling a Smart Trac AC1 •• 3-3
SMART TRAC AC1
PS Card
Smart Trac
Option Cards
The Smart Trac Inverter Control Card is the first card of the stack. It is the card
on which all others are stacked. The Smart Trac CPU card is mounted on top of
the Smart Trac Inverter and communicates with it via the connector labeled
2CN.
Optional
PC/104
Card
Optional
PC/104
Card
Ethernet
Card
Smart Trac
4CN
Connector
Smart Trac
PG Card
2CN
Connector
Smart Trac
CPU Card
Figure 1. Smart Trac card assembly showing option cards.
Inverter Control
Card
Adapter
Ring
Main Chassis
3-4 •• Assembling a Smart Trac AC1 Technical Manual TM 3554-000
SMART TRAC AC1
Smart Trac PG Card
Smart Trac PS Card
Smart Trac Ethernet
Card
Optional PC-104
Compliant Cards
The Smart Trac PG (Pulse Generator) card is installed on top of the Smart Trac
CPU card. It communicates with the Smart Trac Inverter control card via
connector 4CN and the Smart Trac CPU card's PC/104 connector. The Smart
Trac PG card accumulates pulses (A, B and Z) from both master and follower
encoders. It has two analog inputs and can accept two proximity switches. It
includes its own +5V power supply rated at 50 ma. This 50 ma power is
typically ample for applications requiring a load cell.
The Smart Trac PS (Power Supply) card is connected to the Smart Trac PG card
via the PC/104 connector and supplies all the voltages and power to support the
Smart Trac CPU, Smart Trac PG, and all other option cards. If the Smart Trac
PG card is not installed, the Smart Trac PS connects to the Smart Trac CPU.
The Smart Trac Ethernet Card is a PC/104 compliant card included in all Smart
Trac AC1s, providing quick program downloads and uploads and fast, reliable
networking capabilities.
Several additional PC/104 compliant option cards may be stacked on top of the
Smart Trac PG card. Optional cards might include local I/O, ARCNET, Genius,
DeviceNet, Profibus or fiber optic cards for communications and/or additional
system I/O. The Smart Trac ARCNET card allows the Smart Trac AC1 to
communicate with MagneTek Micro Trac drives, making it fully backward
compatible with MagneTek's earlier drive systems. DeviceNet, Profibus and
Fiber Optic cards will support master/slave and peer-to-peer communications.
See the documentation on the individual option cards for further information
Technical Manual TM 3554-000 Assembling a Smart Trac AC1 •• 3-5
SMART TRAC AC1
Smart Trac AC1 Installation
This Chapter will enable you to:
q Prepare your Smart Trac AC1 for installation
q Determine a physical location for your Smart Trac AC1.
q Make required electrical connections.
q Recommend the proper grounding and shielding for your
Smart Trac AC1.
q Run adequate conduit for the wiring to and from your
Smart Trac AC1.
q Audit your Smart Trac AC1 system using the Pre-power
checklist.
q Become familiar with the Digital Operator
q Start your Smart Trac AC1 for the first time.
q Connect one or more vector-controlled motors.
q Perform an integrated Smart Trac AC1 and motor test.
Technical Manual TM 3554-000 Smart Trac AC1 Installation •• 4-1
SMART TRAC AC1
Installing Your Smart Trac AC1
WARNING WARNING -- ESD ESD
Keep electronic circuit boards in Electrostatic Discharge (ESD)
protective bags when not being handled. Use proper ESD
procedures (including an ESD wrist strap) when handling circuit
boards. Failure to comply may result in damage to equipment.
When working with an Electrostatic Discharge (ESD) device, you should be
grounded at all times. The easiest and most common way to provide this ground
is to use an approved ESD wrist strap. The strap is secured to your wrist with a
wire attached to the strap and clipped or taped to the chassis of the unit being
worked on. Any static is dissipated through the wire to ground, greatly reducing
the possibility of damage to the device.
It is a good idea to touch the chassis with your finger before handling any
electrostatic sensitive device. Any static electricity will be discharged to chassis
ground and will not be transferred to the device.
Always store devices (cards, other electronic components) in ESD protective
bags when not being handled.
Storage
Unpacking
Contents Checklist
Locating Your Smart
Trac AC1
If the Smart Trac AC-1 will be stored for a while after receipt, keep the Smart
Trac AC1 in its original packaging material. Store the Smart Trac AC1 in a
controlled environment that meets the following:
q temperature range within –20° C to 60° C
q humidity of less than 95% (no condensation)
Remove the protective shipping and packing material from the equipment.
Ensure contact wedges and other shipping devices have been removed.
You should have received the following with your Smart Trac AC1:
q Smart Trac AC1
q Option card(s) and accessories, if purchased, and option card technical
manuals
q Smart Trac Technical Manual
q Applicable Smart Trac AC-1 Bulletins and Application Notes
To achieve proper performance and normal operating life, your Smart Trac AC1
must be installed in an area where it is protected:
q Excessive heat, direct sunlight, rain or moisture.
q Corrosive gases or liquids.
q Vibration, airborne dust or metallic particles.
4-2 •• Smart Trac AC1 Installation Technical Manual TM 3554-000
SMART TRAC AC1
Consider the following when planning the installation and installing your Smart
Trac AC1:
• Always lift your Smart Trac AC1 by its base, never by the front cover.
• Install the Smart Trac AC1 on a flat, non-flammable vertical surface
(wall or panel) using mounting screws specified (See "Smart Trac AC1
Dimensions" for screw specifications).
• Provide a minimum 4.7" (26.1cm) clearance above and below the
Smart Trac AC1. This allows for proper air circulation over the heat
sink fins.
• Provide a minimum 1.2" (3.05cm) clearance on each side of the Smart
Trac AC1.
• Mount your Smart Trac AC1 in a freestanding floor-mount cabinet.
Sufficient clearance must be obtained to permit the door to be opened.
• Add a fan or cooling device as necessary to ensure air entering the
Smart Trac AC1 is below 113° F. (45° C) for protected chassis or
below 104° F. (40° C) for NEMA 1. See "Table 1. Smart Trac AC1
Specifications".
Making Electrical
Connections
Complete wire interconnections per information Table 2 and Table 3, Table 4 or
Table 5 , depending on the voltage of your Smart Trac AC1. Always adhere to
the following:
WARNINGWARNING
Wiring should be performed only by qualified personnel.
Disconnect all power to Smart Trac AC1. Do not remove the front
cover while input power is ON.
Never connect the main circuit output terminals T1, T2 and T3 to
the AC main circuit power supply.
Failure to comply with this warning may result in damage to the
Smart Trac AC1 and connected equipment along with personal
injury and/or death.
• Use 600V vinyl-sheathed wire or equivalent.
• Determine wire size to consider voltage drop of leads.
• Wire size must be suitable for NEC Class I Circuits.
• Use UL approved closed loop connectors or CSA certified ring
connectors sized for the selected wire gauge. Install connectors using
only the connector manufacturer's recommended crimp tool. See Table
2.
• Motor lead length should not exceed 164 feet (50 meters). Motor
wiring should be run in a separate conduit from the power wiring. If
lead length must exceed this distance, reduce the carrier frequency and
consult the motor manufacturer for proper installation procedures.
• Never connect AC main power to drive output terminals T1(U), T2(V),
T3(W).
Technical Manual TM 3554-000 Smart Trac AC1 Installation •• 4-3
SMART TRAC AC1
• Never allow wire leads to contact metal surfaces. Short-circuit may
result.
• Never connect power factor correction capacitors or noise filters to
Smart Trac AC1 output.
Table 2. Terminal screws, connectors and clamping torque by wire size
Wire
Size
(AWG)
20 0.50 M3.5 1.25-3.5 7.8 0.9 7.0 0.8
18 0.75 M4 1.25-4 13.0 1.5 10.4 1.2
16 1.25 M4 1.25-4 13.0 1.5 10.4 1.2
14 2
12 3.5
10 5.5
8 8
6 14 M6 14-6 40.9 34.8 4.8 4.1
4 22 M8 22-8 100.0 82.6 11.7 10.7
2 38
1/0 60 M10 60-10 182.6 156.5 21.4 18.4
3/0 80 M10 80-10 182.6 156.5 21.4 18.4
4/0 100
MCM300 150 M12 150-12 313.0 191.3 36.7 23.1
MCM400 200 M12 200-12 313.0 191.3 36.7 23.1
MCM650 325 M12 325-12 313.0 191.3 36.7 23.1
M16 325-16 313.0 191.3 36.7 23.1
Wire
Size
(mm2)
ClosedTerminal
Screw
M4 2-4 13.0 1.5 10.4 1.2
M5 2-5 26.1 20.9 3.1 2.4
M4 3.5-4 13.0 1.5 10.4 1.2
M5 3.5-5 26.1 20.9 3.1 2.4
M4 5.5-4 13.0 1.5 10.4 1.2
M5 5.5-5 26.1 20.9 3.1 2.4
M5 8-5 26.1 20.9 3.1 2.4
M6 8-6 40.9 34.8 4.8 4.1
M8 38-8 100.0 82.6 11.7 10.7
M10 38-10 182.6 156.5 21.4 18.4
M10 100-10 182.6 156.5 21.4 18.4
M12 100-12 313.0 191.3 36.7 23.1
Loop
Connector
Clamping
Torque
Steel,
lb-in
Clamping
Torque
Steel, N-m
Clamping
Torque
Copper,
lb-in
Clamping
Torque
Copper,
lb-in
4-4 •• Smart Trac AC1 Installation Technical Manual TM 3554-000
Table 3. Wire Sizing for Main Circuit, 230 Volt
SMART TRAC AC1
Smart Trac AC1 Model No. Terminal Symbol
STAC*A003
STAC*A006
STAC*A011
STAC*A017
STAC*A080
STAC*A130
STAC*A160
STAC*A224
STAC*A300
Wire Sizing for Main Circuit, 230 Volt
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W), GND
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W), GND
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W)
GND
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W), GND
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W), GND
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W)
GND
L1(R), L2(S), L3(T), , 1, 2, 3, T1(U),
T2(V), T3(W)
GND
L1(R), L2(S), L3(T), , 1, 2, 3, T1(U),
T2(V), T3(W)
GND
L1(R), L2(S), L3(T), , 1, 2, 3, T1(U),
T2(V), T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), ,3, T1(U), T2(V), T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), ,3, T1(U), T2(V), T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), , 3, T1(U), T2(V),
T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), , 3, T1(U), T2(V),
T3(W)
GND
1(r), 2(s)
Terminal
Screw
Wire
Size
(AWG)
Wire
Size
(mm2)
M4 14-10 2-5.5
M4 14-10 2-5.5
M4 14-10 2-5.5 STAC*A008
M4 12-10 3.5-5.5
M4 12-10 3.5-5.5
M4 10 5.5
M5 8 8 STAC*A025, STAC*A033
M5 10-8 5.5-8
M6 4 22 STAC*A049
M6 8 8
M8 3 30 STAC*A064
M6 8 8
M8 3 30
M8 6 14
M4 20-10 0.5-5.5
M10 4/0 100
M8 4 22
M4 20-10 0.5-5.5
M10 1/0 XP 60 X 2P
M8 4 22
M4 20-10 0.5-5.5
M10 1/0 XP 60 X 2P
M8 3 30
M4 20-10 0.5-5.5
M12 4/0 X 2P 100 X
2P
M8 1 50
M4 20-10 0.5-5.5
Technical Manual TM 3554-000 Smart Trac AC1 Installation •• 4-5
SMART TRAC AC1
Table 4. Wire Sizing for Main Circuit, 460 Volt
Smart Trac AC1 Model No. Terminal Symbol
STAC*B001
STAC*B011, STAC*B014
STAC*B041
STAC*B052
STAC*B065
STAC*B080
STAC*B096
STAC*B128
Wire Sizing for Main Circuit, 460 Volt
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W), GND
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W)
GND
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W), GND
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W)
GND
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W)
GND
L1(R), L2(S), L3(T), , 1, 2, 3, T1(U),
T2(V), T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), , 1, 2, 3, T1(U),
T2(V), T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), , 1, 2, 3, T1(U),
T2(V), T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), , 1, 2, 3, T1(U),
T2(V), T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), , 1, 2, 3, T1(U),
T2(V), T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), , 3, T1(U), T2(V),
T3(W)
GND
1(r), 2 200 (s200), 2 400 (s400)
L1(R), L2(S), L3(T), , 3, T1(U), T2(V),
T3(W)
GND
Terminal
Screw
Wire
Size
(AWG)
Wire
Size
(mm2)
M4 14-10 2-5.5
M4 14-10 2-5.5 STAC*B003, STAC*B004, STAC*B008
M4 12-10 3.5-5.5
M4 12-10 3.5-5.5
M4 8-6 8-14 STAC*B021
M4 8-6 8-14
M5 8-6 8-14 STAC*B027, STAC*B034
M6 8 8
M6 6 14
M8 8 8
M4 20-10 0.5-5.5
M6 4 22
M8 8 8
M4 20-10 0.5-5.5
M8 4 22
M8 8 8
M4 20-10 0.5-5.5
M8 3 30
M8 6 14
M4 20-10 0.5-5.5
M8 1 50
M8 6 14
M4 20-10 0.5-5.5
M10 4/0 100
M8 4 22
M4 20-10 0.5-5.5
M10 1/0 60 x 2P STAC*B165
M8 4 22
4-6 •• Smart Trac AC1 Installation Technical Manual TM 3554-000
Wire Sizing for Main Circuit, 460 Volt
SMART TRAC AC1
Wire
Terminal
Smart Trac AC1 Model No. Terminal Symbol
STAC*B224
STAC*B302
STAC*B302
STAC*B450, STAC*B605
1(r), 2 200 (s200), 2 400 (s400)
L1(R), L2(S), L3(T), , 3, T1(U), T2(V),
T3(W)
GND
1(r), 2 200 (s200), 2 400 (s400)
L1(R), L2(S), L3(T), , 3, T1(U), T2(V),
T3(W)
GND
1(r), 2 200 (s200), 2 400 (s400)
L1(R), L2(S), L3(T), , 3, T1(U), T2(V),
T3(W)
GND
1(r), 2 200 (s200), 2 400 (s400)
L1(R), L2(S), L3(T), , 1, 3, T1(U), T2(V),
T3(W)
GND
1(r), 2 20 0 (s200), 2 400 (s400)
Screw
M4 20-10 0.5-5.5
M10 1/0 x 2P 60 x 2P
M8 3 30
M4 20-10 0.5-5.5
M10 1/0 x 2P 60 x 2P
M8 3 30
M4 20-10 0.5-5.5
M12 4/0 x 2P 100 x 2P
M8 1 50
M4 20-10 0.5-5.5
M16 MCM65
M8 1/0 60
M4 20-10 0.5-5.5
Size
(AWG)
0 x 2P
Wire
Size
(mm2)
325 x 2P
Technical Manual TM 3554-000 Smart Trac AC1 Installation •• 4-7
SMART TRAC AC1
Table 5. Wire Sizing for Main Circuit 600V (575V).
Smart Trac AC1 Model No. Terminal Symbol
STAC*C010
STAC*C027, STAC*C032
STAC*C041
STAC*C052
STAC*C062
STAC*C077
STAC*C099
Wire Sizing for Main Circuit, 600 Volt
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W)
GND
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W)
GND
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W)
GND
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W)
GND
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W),
GND
L1(R), L2(S), L3(T), , 1, 2, B1, B2, T1(U),
T2(V), T3(W)
GND
L1(R), L2(S), L3(T), , 1, B1, B2, T1(U),
T2(V), T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), , 1, T1(U), T2(V),
T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), , 1, T1(U), T2(V),
T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), , 1, T1(U), T2(V),
T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), , 1, T1(U), T2(V),
T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), , 1, T1(U), T2(V),
T3(W)
Terminal
Screw
M4
Wire
Size
(AWG)
14-10 2-5.5 STAC*C003, STAC*C004
Wire
Size
(mm2)
12-10 3.5-5.5
M4
14-10 2-5.5 STAC*C006
12-10 3.5-5.5
M4 12-10 3.5-5.5
M4
10 5.5 STAC*C012
12-10 3.5-5.5
M5 STAC*C017
10-6 5.5-14
M6
M5 8-6 8-14 STAC*C022
M6 10-6 5.5-14
M6 8-6 8-14
Ä
10-6 5.5-14
M4 14-10 2-5.5
M8 6-1/0 14-50
* 8-2 8-30
M4 14-10 2-5.5
M8 4-1/0 22-50
* 8-2 8-30
M4 14-10 2-5.5
M8 3-1/0 30-50
* 8-2 8-30
M4 14-10 2-5.5
M8 2-1/0 30-50
* 6-2 22-30
M4 14-10 2-5.5
M8 2/0-1/0 50-60
4-8 •• Smart Trac AC1 Installation Technical Manual TM 3554-000
Wire Sizing for Main Circuit, 600 Volt
SMART TRAC AC1
Wire
Terminal
Smart Trac AC1 Model No. Terminal Symbol
STAC*C130
STAC*C172
STAC*C200
* Indicates terminal uses a pressure lug.
GND
1(r), 2(s)
L1(R), L2(S), L3(T), , 1, T1(U), T2(V),
T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), , 1, T1(U), T2(V),
T3(W)
GND
1(r), 2(s)
L1(R), L2(S), L3(T), , 1, T1(U), T2(V),
T3(W)
GND
1(r), 2 (s)
Screw
* 4-2 22-30
M4 14-10 2-5.5
M10 3/0=300 80-150
* 4-2/0 22-60
M4 14-10 2-5.5
M12 300-400 150-200
* 4-2/0 22-60
M4 14-10 2-5.5
M12 350-400 180-200
* 3-2/0 30-60
M4 14-10 2-5.5
Size
(AWG)
Wire
Size
(mm2)
Smart Trac
Grounding
Your Smart Trac AC1 must be solidly grounded using main circuit ground
terminal GND. Refer to the latest edition of the National Electrical Code (NEC),
Article 250, Grounding, for proper grounding methods, especially ground rod
requirements. Select lead size suitable for size of terminal screw. Make the
length as short as possible.
Never ground the Smart Trac AC1 with the same common as welding machines,
motors, or other large-current electrical equipment. Where several Smart Trac
AC1s are used, ground each directly or daisy chain each to the machine ground
bar or ground rod. Refer to Figure 2. Do not form a loop with the ground
leads.
Technical Manual TM 3554-000 Smart Trac AC1 Installation •• 4-9
SMART TRAC AC1
Star
washer
between
cabinet
and bus
wire
Electrical
Cabinet
Copper
Bus
Electrical
Cabinet
Copper
Bus
GROUND
NOT
ACCEPTABLE
ACCEPTABLE
GROUND
NOT
ACCEPTABLE
POLE
Electrical
Cabinet
GROUND
POLES
NOT
ACCEPTABLE
ACCEPTABLE
Figure 2. Grounding of Three Smart Trac AC1s (top) and Grounding of Smart
Trac AC1 with Vector Controlled Motor (VCM) (bottom)
POLE
Connecting Auxiliary
Input and Output
Power Option
Devices
Connecting the
Control Circuit
Proper wiring practices and relative locations within the electrical path, from
line to load, are shown in ." Your application may use some or all of the devices
shown. Disregard items depicted which do not match those in your Smart Trac
AC1 configuration.
WARNINGWARNING
Disconnect all power to Smart Trac AC1. Do not remove the front
cover while input power is ON. Failure to comply may result in
personal injury or death.
Mount all power option devices as close to the Smart Trac AC1 as possible.
Keep electrical connections as short as possible. For Models with base
designations of STAC-A003 through STAC-A064, STACWA003 through
STACWA064, STAC-B001 through STAC-B034, and STACWB001 through
STACWB034, an input or DC reactor should be used.
Basic control circuit (signal) terminations on the Smart Trac AC1 are shown in
the "Simplified Customer Connection Diagram."The use of these terminals,
however, is dependent on the needs of the the application program. Terminal
numbers and their function are listed in the table "Terminal Definitions of the
Inverter Control Card."
4-10 •• Smart Trac AC1 Installation Technical Manual TM 3554-000
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