Altivar® 31 S-Flex Combination Bypass Package for Adjustable Speed Drive Controllers Class 8839 1 to 20 hp, 460 V

Instruction Bulletin Retain for future use.

Altivar® 31 S-Flex Combination Bypass Package Hazard Categories and Special Symbols

HAZARD CATEGORIES AND SPECIAL SYMBOLS

30072-450-90A 08/2005

Read these instructions carefully and look at the equipment to become familiar with the device before trying to install, operate, service or maintain it. The following special messages may appear throughout this bulletin or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure. The addition of either symbol to a “Danger” or “Warning” safety label indicates that an electrical hazard exists which will result in personal injury if the instructions are not followed. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING WARNING indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury.

CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury.

CAUTION CAUTION, used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, can result in property damage.

PLEASE NOTE

Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material.

PRODUCT SUPPORT

For support and assistance, contact the Product Support Group. The Product Support Group is staffed from 8:00 am until 6:00 pm Eastern time to assist with product selection, start-up, and diagnosis of product or application problems. Emergency phone support is available 24 hours a day, 365 days a year.

2

Toll Free

1-888-Square D (1-888-778-2733)

E-mail

[email protected]

Fax

919-217-6508

© 2005 Schneider Electric All Rights Reserved

Altivar® 31 S-Flex Combination Bypass Package Table of Contents

30072-450-90A 08/2005

SECTION 1:

INTRODUCTION AND TECHNICAL CHARACTERISTICS

Product Overview ........................................................................................ 5 Related Documentation .............................................................................. 5 Terminology ........................................................................................... 5 Part Number Description ............................................................................. 6 Nameplate Identification ............................................................................. 6 Technical Characteristics ............................................................................ 7 Short Circuit Ratings ............................................................................. 7 Input Current Ratings ............................................................................ 8 Specifications ........................................................................................ 8

SECTION 2:

RECEIVING, HANDLING, AND STORAGE

Receiving and Preliminary Inspection ......................................................... 9 Storing the Equipment ........................................................................... 9 Unpacking the S-Flex .......................................................................... 10 Before Installing the S-Flex ................................................................. 10 Handling the Controller ........................................................................ 11

SECTION 3:

INSTALLATION

Precautions ............................................................................................... 12 Shipping Weights ...................................................................................... 13 Watts Loss/Heat Dissipation Data ............................................................ 13 Dimensions and Weights for Wall or Panel Mounting ............................... 14 Wire Routing and Interconnection ............................................................. 16 Wire Class ........................................................................................... 16 Noise Class ......................................................................................... 16 Voltage Class ...................................................................................... 16 Wiring Methods ................................................................................... 17 Terminal Block Location ............................................................................ 18 Power Wiring ............................................................................................. 19 Control Wiring ........................................................................................... 20

SECTION 4:

OPERATION

Sequence of Operation and Configuration ................................................ 21 Command Mode .................................................................................. 21 Programming the Power Converter ..................................................... 22 Power Circuit Y Full Voltage Bypass ........................................................ 22 Operator Controls—General Arrangement and Operation .................. 23 Adjustable Speed Operation ............................................................... 23 Bypass Operation ................................................................................ 23 Freeze/Firestat Interlocks (if used) ...................................................... 23 Pilot Lights ........................................................................................... 23 Line Reactor ........................................................................................ 24 Smoke Purge Function (Selectable) .................................................... 24 Auxiliary Drive Run Contact ................................................................ 24 Auxiliary Bypass Run Contact ............................................................. 24 Auxiliary Fault Contact ........................................................................ 24 Power and Control Circuit Elementary Diagram ....................................... 25

SECTION 5:

MAINTENANCE

Technical Support ..................................................................................... 26 S-Flex Troubleshooting Sheet .................................................................. 27 Renewal Parts ........................................................................................... 28

© 2005 Schneider Electric All Rights Reserved

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Altivar® 31 S-Flex Combination Bypass Package Table of Contents

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30072-450-90A 08/2005

© 2005 Schneider Electric All Rights Reserved

Altivar® 31 S-Flex Combination Bypass Package Introduction and Technical Characteristics

30072-450-90A 08/2005

SECTION 1— INTRODUCTION AND TECHNICAL CHARACTERISTICS PRODUCT OVERVIEW

This bulletin provides installation and maintenance information for the Altivar® 31 (ATV31) S-Flex combination bypass package. The Class 8839 ATV31 S-Flex is a combination device composed of a power circuit box with options, and a wall-mountable back pan used with a power converter. The S-Flex is configured with a full voltage bypass power circuit configuration for customer installation and commissioning.

RELATED DOCUMENTATION

In addition to this bulletin, refer to the following documentation, supplied with the S-Flex:

•

Instruction Bulletin VVDED303043US, Altivar 31 Start-Up Guide, describes the installation, operation, and characteristics of the ATV31 Drive Controller when used as a component of the ATV31 S-Flex.

•

Instruction Bulletin 30072-200-50, Safe Handling, Installation, Operation, and Maintenance of Electrical Equipment.

NOTE: To replace missing documents, contact your local Schneider Electric field office, or download them from the Technical Library at www.us.SquareD.com.

Terminology

© 2005 Schneider Electric All Rights Reserved

This instruction bulletin uses the following terminology. The terminology distinctions minimize confusion when discussing installation and adjustment practices.

•

S-Flex, drive controller or controller refers to the combination of the power converter, enclosure, and the power and control circuits that constitute the ATV31 S-Flex product.

•

Power converter refers to the ATV31HO75N4A through ATV31HD15N4A controllers (described in instruction bulletin VVDED303041NA, Altivar 31 Installation Manual), when used as a component of the ATV31 S-Flex.

•

Drive refers to the combination of the controller and motor.

5

Altivar® 31 S-Flex Combination Bypass Package Introduction and Technical Characteristics

30072-450-90A 08/2005

PART NUMBER DESCRIPTION

The part number, located on the nameplate attached to the S-Flex, is coded to describe the configuration and options present. Use Table 1 to translate the part number into a description of the drive controller. Table 1:

Part Number Description

Field

Digit

Characteristic

Description

01

01-03

Controller Style

SFD = Altivar 31 S-Flex Drive Controller C = 1 hp D = 2 hp E = 3 hp F = 5 hp G = 7.5 hp H = 10 hp J = 15 hp K = 20 hp

02

04

Horsepower

03

05

Enclosure Type

G = Type 1 General Purpose

04

06

Voltage

4 = 460/480 Vac

05

07

Power Circuit

Y = Combination Full Voltage Bypass Each configuration includes:

–

NAMEPLATE IDENTIFICATION

Figure 1:

• • • • • • • •

Standard Features: Control and Pilot Devices

–

Circuit breaker disconnect 3% minimum rated line reactor HAND-AUTO selector switch AFC-OFF-BYPASS selector switch Pilot lights: power on (red), bypass run (yellow) Freeze/firestat interlock Smoke purge (selectable) Auxiliary contacts for drive run, bypass run, and fault

The nameplate for the S-Flex is located on the inside right wall of the S-Flex. This nameplate, shown in Figure 1, carries the controller Class, Type, and Mod (option) listings. When identifying or describing the S-Flex product, use the data from this nameplate.

S-Flex Nameplate

CLASS 8839 S-FLEX

SQUARE D

ENCLOSED INDUSTRIAL CONTROL PANEL CLASS Part Number (S-Flex)

TYPE

8839

A

SER

SFDCG4Y

Basic ATV31 Converter Model

ATV31H075N4A

POWER CONVERTER

MOD

INPUT

Permissible Input Voltage

VOLTS

OUTPUT AT VOLTS

Overcurrent Protective Device (OCPD) Identification

PANEL 460

PH 3

1.3 AMPS AT 100 KA

Hz 60

SC RATING

Input Current and Coordinated Short Circuit Rating

KHz SWITCHING FREQUENCY

4

0-460

± 10 %

PH 3

2.3

OVERLOAD CAPACITY

Hz 0-60

AMPS FOR 60 S

2.1

AMPS HP / KW

CIRCUIT BREAKER

TRANSFORMER FUSES

FHL3600712M8041

PRIMA RY ENCLOSURE

CC

Line Terminations (wire size and terminal torques)

± 10 %

6

200

POWER WIRING

TYPE LINE

AWG

TORQUE lb-in

#14 - #4

35

1

Product Bar Code Here

Horsepower/ Kilowatt Rating

1 / 0.75

CLASS CC, 600 V, TIME-DELAY

1-1/2

SECONDA RY

OVERLOAD RELAY CLASS

2

WIRE TYPE / TEMPERATURE

10

75° C

CU

LOAD AWG

TORQUE lb-in

#14 - #8

15

Enclosure Environmental Rating Load Terminations (wire size and terminal torques)

REFERENCE MANUALS 30072-450-90: S-Flex Manual

Plant Code (Seneca, SC)

6

FIELD WIRING DIAGRAM 52017-685 MADE IN USA

VVDED303043US: ATV31 Startup Guide

30072-200-50: Equipment Bulletin

FO NUMBER / Q2C CODE

46

68331

Factory Order Number (Q2C) and Item Number

52017 - 677 - 01

© 2005 Schneider Electric All Rights Reserved

Altivar® 31 S-Flex Combination Bypass Package Introduction and Technical Characteristics

30072-450-90A 08/2005

TECHNICAL CHARACTERISTICS

The power ratings given in Table 2 are for a switching frequency between 2 and 16 kHz, variable torque (VT). Above 4 kHz, the drive controller reduces the switching frequency in the event of excessive temperature rise. The temperature rise is controlled by a PTC probe in the power module. Table 2: S-Flex Catalog Number

Short Circuit Ratings

© 2005 Schneider Electric All Rights Reserved

Variable Torque Ratings—460 Vac ±10% Motor Power1 460 V 60 Hz (hp)

Input Current (A)

Output Current (A)

Max. Transient Output Current Power Converter Part Number2 60 s (A)

SFDCG4Y

1

1.3

2.1

3.1

ATV31HO75N4A

SFDDG4Y

2

2.4

3.4

5.1

ATV31HU15N4A ATV31HU22N4A

SFDEG4Y

3

3.6

4.8

7.2

SFDFG4Y

5

5.8

7.6

11.4

ATV31HU40N4A

SFDGG4Y

7.5

8.5

11

16.5

ATV31HU55N4A

SFDHG4Y

10

11.2

14

21.0

ATV31HU75N4A

SFDJG4Y

15

16.4

21

31.5

ATV31HD11N4A

SFDKG4Y

20

21.8

27

40.5

ATV31HD15N4A

1

These power ratings and currents are for a maximum ambient temperature of 50 °C and a switching frequency of 4 kHz in continuous operation. The switching frequency is adjustable from 2 to 16 kHz. Derate the nominal current if continuous operation above 4 kHz is required. For details, refer to “Derating Curves” in the ATV31 Start-Up Guide, bulletin VVDED303043US.

2

The drive controller includes a control potentiometer and RUN/STOP buttons.

All S-Flex devices include a Mag-Gard® circuit breaker as the overcurrent protective device (OCPD). All configurations have a short circuit current rating of 100,000 A (symmetrical).

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Altivar® 31 S-Flex Combination Bypass Package Introduction and Technical Characteristics

Input Current Ratings

Specifications

30072-450-90A 08/2005

All branch circuit components and equipment—such as transformers, feeder cables, disconnect devices, and protective devices—must be rated for the input current of the drive controller or the motor full load current, whichever is greater. The input current is stamped on the nameplate (see Figure 1 for location). Branch circuit feeder protection must be sized according to NEC Article 430. Table 3:

Specifications

Input voltage

460 V ±10%

Displacement power factor

Approximately 0.96

Input frequency

60 Hz ± 5%

Output voltage

Three-phase output, maximum voltage equal to input voltage

Galvanic isolation

Galvanic isolation between power and control (inputs, outputs, and power supplies)

Frequency range of the power converter

0.1 to 500 Hz (factory setting of 60 Hz maximum)

Current limit

150% of nominal drive full load amperage (FLA) for 60 s

Switching frequency

Selectable from 2 to 16 kHz [1]

Speed reference

AI1: 0 to +10 V, Impedance = 30 kΩ AI3: 4 to 20 mA, Impedance = 250 Ω 0 to 20 mA (reassignable, X–Y range with keypad display) Through-cover speed potentiometer

Frequency resolution in 0.1 for 100 Hz (10 bits) analog reference Speed regulation

V/f: determined by motor slip, typically 3% SLFV (sensorless flux vector): 1%

Efficiency

Typically greater than 95%

Reference sample time

5 ms

Acceleration and deceleration ramps

0.1 to 999.9 seconds (adjustable in 0.1 s increments)

Motor protection

Class 10 overload protection with bypass option in addition to controller internal electronic thermal protection

Keypad display

Self-diagnostics with fault messages in three languages Also refer to the setup guide, VVDED303043US

Storage temperature

–13 to +158 °F (–25 to +70 °C) with vent cover removed and without derating

Operating temperature

+14 to +122 °F (–10 to +50 °C)

Humidity

96% with no condensation or dripping water, conforming to IEC 60068-2-3

Altitude

3,300 ft (1000 m) maximum without derating; derate the current by 1% for each additional 330 ft (100 m)

Enclosure

Type 1

Pollution degree

Pollution degree 2 per NEMA ICS-1 and IEC 60664-1 According to IEC 60068-2-6:

Resistance to vibrations (Power converter only) • 1.5 mm zero to peak from 3 to 13 Hz • 1 gn from 13 to 150 Hz Resistance to shocks (Power converter only)

• 15 g, 11 ms

Transit test to shock

Conforming to National Safe Transit Association and International Safe Transit Association test for packages weighing 100 lbs or less

Codes and standards

UL Listed per UL508A as incorporating Class 10 electronic and electromechanical overload protection. Conforms to applicable NEMA ICS, NFPA, IEC, and ISO 9001 standards.

[1]

8

According to IEC 60068-2-27:

Above 4 kHz, the drive controller reduces the switching frequency in the event of excessive temperature rise. The temperature rise is controlled by a PTC probe in the power module. Derate the nominal current if continuous operation above 4 kHz is required. For details, refer to “Derating Curves” in the ATV31 Start-Up Guide, bulletin VVDED303043US.

© 2005 Schneider Electric All Rights Reserved

Altivar® 31 S-Flex Combination Bypass Package Receiving, Handling, and Storage

30072-450-90A 08/2005

SECTION 2— RECEIVING, HANDLING, AND STORAGE

CAUTION DAMAGED EQUIPMENT Do not operate any S-Flex controller that appears damaged. Failure to follow this instruction can result in injury or equipment damage.

RECEIVING AND PRELIMINARY INSPECTION

The S-Flex controller must be thoroughly inspected before it is stored or installed. Upon receipt: 1. Remove the S-Flex from its packaging and visually inspect the exterior for shipping damage. 2. Ensure that the catalog number of the S-Flex, which appears on the nameplate, agrees with the packing slip and corresponding purchase order. 3. If you find any shipping damage, notify the carrier and your sales representative.

Storing the Equipment

CAUTION STACKING DURING STORAGE OR SHIPPING • Do not stack S-Flex controllers on top of each other. • Do not place any material on top of the S-Flex. • Store or ship the equipment in the original packaging. Failure to follow this instruction can result in equipment damage. If you plan to store the S-Flex controller after receipt, replace it in its original packaging and observe the storage temperature and humidity specifications in Table 3 on page 8. NOTE: Storing the equipment in its original packaging until it reaches its final installation site protects the equipment and prevents damage to its exterior.

© 2005 Schneider Electric All Rights Reserved

9

Altivar® 31 S-Flex Combination Bypass Package Receiving, Handling, and Storage

30072-450-90A 08/2005

Unpacking the S-Flex

WARNING HEAVY EQUIPMENT • Lifting this S-Flex Controller requires the use of a lifting apparatus or two people. • Always use safe lifting procedures. Failure to follow these instructions can result in serious injury or equipment damage. Handle the S-Flex controller carefully to avoid damage to the internal components, frame, and exterior. Lift the S-Flex out of its shipping carton, lifting with two people or a suitable lifting apparatus, and place it on a flat surface.

Before Installing the S-Flex

Before installing the S-Flex, visually verify that all components are properly seated, securely fastened, and undamaged. 1. Loosen the thumbscrews on the S-Flex cover, then remove the cover. 2. Visually verify that: — all internal mounting hardware and terminal connection hardware is properly seated — the control transformer fuses are in place in the fuse block 3. Replace and secure the cover.

10

© 2005 Schneider Electric All Rights Reserved

Altivar® 31 S-Flex Combination Bypass Package Receiving, Handling, and Storage

30072-450-90A 08/2005

Handling the Controller

When handling, moving, or lifting the controller, do not allow it to tip or drop. After removing the product from the packaging, the controller will require some type of mechanical lifting. (This is true whether the power converter is installed or not.) Handle the controller:

•

With a hoist, attaching a spreader bar to the two lifting holes on the S-Flex panel (on either side of the power converter). See Figure 2.

•

In a horizontal position, with the back of the controller resting on a flat surface.

WARNING HEAVY EQUIPMENT • Keep the area below any equipment being lifted clear of all personnel and property. • Before lifting the controller: — Inspect the lifting plates, holes, slots, or eyebolts for any damage. — Attach a spreader bar. — Keep the lifting force vertical. — Limit the sling angle to less than 45°. Failure to follow these instructions can result in death, serious injury, or equipment damage.

Figure 2:

Hoisting the S-Flex

Max. 45°

Spreader Bar Lifting Force Enclosure with Lifting Plates

To hoist the controller, attach a spreader bar to the lifting slots located on top of the back panel. Refer to Figure 2. Handle the controller carefully to avoid damage to the internal components, frame, and exterior. Place the controller in an upright position.

© 2005 Schneider Electric All Rights Reserved

11

Altivar® 31 S-Flex Combination Bypass Package Installation

30072-450-90A 08/2005

SECTION 3— INSTALLATION PRECAUTIONS

DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E. • This equipment must only be installed and serviced by qualified electrical personnel. • Turn off all power supplying this equipment before working on or inside equipment. • Always use a properly rated voltage sensing device to confirm that power is off. • Before servicing the equipment, remove all power, then wait three minutes. Verify that no voltage is present. • Replace all devices, doors, and covers before turning on power to this equipment. Failure to follow these instructions will result in death or serious injury. Follow these precautions when installing the S-Flex:

•

The controller is suitable for installation in a pollution degree 2 environment, as defined in NEMA ICS1 and IEC 60664-1.

•

When attaching wall-mountable controllers to their mounting surfaces, use fasteners rated for the weight of the apparatus (see Table 4 on page 13), the expected shock and vibration of the installation, and the expected environment.

•

Provide sufficient cooling (see Table 5 on page 13) for the expected heat load.

•

Do not mount the controller in direct sunlight or on hot surfaces. Mount it on a solid, flat surface only.

WARNING IMPROPER MOUNTING Before removing the lifting mechanism: • Ensure that all hardware is of sufficient size and type for the controller weight. • Secure and tighten all hardware. Failure to follow these instructions can result in death, serious injury, or equipment damage.

12

© 2005 Schneider Electric All Rights Reserved

Altivar® 31 S-Flex Combination Bypass Package Installation

30072-450-90A 08/2005

SHIPPING WEIGHTS

Table 4:

Shipping Weight Weight 460 Volts

hp

WATTS LOSS/HEAT DISSIPATION DATA

S-Flex lb (kg)

Power Converter lb (kg)

Total lb (kg)

1

48.61 (22.05)

2.92 (1.32)

51.53 (23.37)

2

48.61 (22.05)

2.92 (1.32)

51.53 (23.37)

3

48.61 (22.05)

5.19 (2.35)

53.80 (24.40)

5

48.61 (22.05)

5.19 (2.35)

53.80 (24.40)

7.5

48.61 (22.05)

10.39 (4.71)

59.00 (26.76)

10

48.61 (22.05)

10.39 (4.71)

59.00 (26.76)

15

59.61 (27.04)

19.89 (9.02)

79.50 (36.06)

20

59.61 (27.04)

19.89 (9.02)

79.50 (36.06)

The total dissipated watts loss is provided strictly for sizing the environmental HVAC cooling requirements, based on worst-case operating conditions. Table 5:

Total Watts Loss 460 Volts hp

Total Watts Loss (W)

1

78

2

104

3

125

5

207

7.5

297

10

341

15

494

20

617

NOTE: For BTU/hr, multiply values by 3.413.

© 2005 Schneider Electric All Rights Reserved

13

Altivar® 31 S-Flex Combination Bypass Package Installation

30072-450-90A 08/2005

DIMENSIONS AND WEIGHTS FOR WALL OR PANEL MOUNTING Figure 3:

Mounting Information for 1–10 hp @ 460 Vac Top View

12.05 (306) R

0.95 (24) 13.03 (331) 6.69 (170)

1.88 (47)

8.00 [203]

8.75 (222) 5.00 (127)

Four Slots, Radius 0.188 (8)

0.40 (10)

7.09 (180) 9.00 (229)

34.12 (867) 33.48 (850) 21.82 (554) 20.17 (512)

Left Side View

R

1.57 (40)

R

5.00 (127)

0 [0.00]

Front View 1.89 (48)

Mounting Clearance

3 x 1.82 (46)

Dimensions: in. (mm)

9.10 (231) Bottom View

Four Knockouts, Concentric for Conduit Hubs: 0.50 (13), 0.75 (19), and 1.00 (25)

1.81 (46)

14

R

© 2005 Schneider Electric All Rights Reserved

Altivar® 31 S-Flex Combination Bypass Package Installation

30072-450-90A 08/2005

Figure 4:

Mounting Information for 15–20 hp @ 460 Vac Top View

12.05 (306)

R

0.93 (24)

9.65 (245) 11.50 (292) 11.25 (286)

1.63 (41) 8.00 (203)

0.40 (10)

7.51 (191)

Four Slots, Radius 0.188 (8)

13.03 (331)

8.00 (203)

39.70 (1009) 39.06 (992)

23.62 (600) 21.97 (558)

R

Left Side View

1.32 (34)

8.00 (203)

0.00 (0)

Front View 1.87 (48)

R

R

Mounting Clearance

3 x 1.94 (49)

Dimensions: in. (mm)

11.66 (296)

Five Knockouts, Concentric for Conduit Hubs: 0.50 (13), 0.75 (19), and 1.00 (25)

1.81 (46)

Bottom View

© 2005 Schneider Electric All Rights Reserved

15

Altivar® 31 S-Flex Combination Bypass Package Installation

30072-450-90A 08/2005

WIRE ROUTING AND INTERCONNECTION Wire Class

The wire class describes the compatibility of the field wiring terminal with the conductor material and insulation system. When used in conjunction with the required conductor current rating and the controller ambient temperature rating, the wire class forms the basis for selecting a conductor size that limits the temperature on the conductor insulation at the field wiring terminal to acceptable limits. Conductors with operating temperatures exceeding those given by the wire class can be used, but the conductor size must be selected based on the wire class limits.

Noise Class

The noise class categorizes the electromagnetic properties of the voltages and currents present. The six noise class categories determine proper wiring methods and physical segregation.

Quiet Wiring 1 (QW1)

High-susceptibility analog and digital control signals. Signals falling under this classification include digital communication/network circuits, controller analog I/O, and analog process signals.

Quiet Wiring 2 (QW2)

Medium-susceptibility analog and digital control signals. Signals falling under this classification include 24 Vdc and 24 Vac control circuits.

Standard Wiring 1 (SW1)

Low-susceptibility control or power circuits rated less than 600 Vac (250 Vdc) and less than 15 A (voltage and current spectra are generally contained within 0.05–9 kHz). Signals falling under this classification include 120 Vac control circuits.

Standard Wiring 2 (SW2)

Power circuits rated greater than 15 A (voltage and current spectra are generally contained within 0.05–9 kHz). Signals falling under this classification include line power to controllers.

Standard Wiring 3 (SW3)

Reserved.

Pulse Wiring 1 (PW1)

Control or power circuits whose voltage or current spectra significantly exceed 9 kHz. Signals falling under this classification include motor and dynamic braking circuits fed from PWM (pulse width modulation) power converters.

Voltage Class

The voltage class groups the voltages present into recognized conductor insulation categories (30, 150, 300, and 600 V) for selection of conductor insulation voltage rating and physical segregation purposes.

16

© 2005 Schneider Electric All Rights Reserved

Altivar® 31 S-Flex Combination Bypass Package Installation

30072-450-90A 08/2005

Wiring Methods Table 6:

Based on the Noise Class and Voltage Class of the conductors, apply the wiring methods in Table 6 to the drive system.

Wire Routing and Interconnection Noise Class of Conductors [1]

Wiring Methods and Considerations QW1 QW2 Conductor Grouping in Wireways and Conduits 1. Bundle all conductors of 1- or 3-phase AC power circuits to minimize stray magnetic fields. 2. Bundle all conductors of a DC power circuit to minimize stray magnetic fields.

SW1

SW2

PW1

X

X

X

X

X

X

X

X

3. When parallel conductors must be run in separate wireways or conduit, bundle the conductors into groups that minimize stray magnetic fields. 4. Maintain conductor runs that are as short and direct as is practical. Separation of Circuits 1. Do not run different noise class conductors in the same conduit. 2. Do not run different voltage class conductors in the same conduit unless all conductors are insulated for the maximum voltage class present.

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

3. Separate all conductors by Noise Class. Use the following circuit separation when conductors can run parallel for more than 12 inches.

4.

•

Metallic conduit: 3 in. from QW to SW or PW

•

Metallic tray: 3 in. from SW to PW

•

Metallic tray: 6 in. from QW to SW or PW

•

Against continuous metal surface: 3 in. from SW to PW

•

Against continuous metal surface: 6 in. from QW to SW or PW

X

X

•

Metallic conduit housing QW: 12 in. to non-metallic conduit SW or PW

X

X

•

Non-metallic conduit: 3 in. from SW to PW

•

Non-metallic conduit: 24 in. from QW to SW or PW

X

X

X

X

X

X

X

X

X

X

All PW conductor groups must be individually separated using metallic conduit.

5. If QW and SW1 wiring must cross SW2 or PW1 wiring, cross the bundles at right angles. Common Mode Noise Issues 1. Provide adjacent signal returns using twisted pair cable. 2. Galvanically isolate the signal and the associated signal return path when possible. Shielding 1. Use metallic conduit for all power and control circuits external to the controller enclosure. 2. Use shields that are continuous and equipped with a drain wire.

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

3. Do not group different noise class conductors within the same shield.

X

X

X

X

X

4. Minimize the non-shielded portion of the conductor at the ends of the shielded cable.

X

X

X

X

X

X

X

X

5. When shielding AC or DC power conductors, group the conductors to minimize the magnetic field in the shield. Grounding

X

X

X

X

X

X

X

X

X

X

3. Provide a ground wire with all conductor groups, whether in tray or conduit.

X

X

X

4. When multiple grounds must be made to a shielded power cable, the shield must have the same short circuit withstand capability as the ground conductor in the power cable.

X

X

X

X

X

X

X

X

X

1. Ground shields only at the controller end. 2. Use separate ground wire for each shield ground.

5. Terminate all power grounds and power shield grounds to the controller grounding point or bar. 6. Terminate all signal shield grounds to the terminals provided. 7. Always supply a separate equipment grounding conductor with the controller power feed. Do not depend on metallic conduit for the ground connection. [1]

X

X

“X” indicates applicability to the specified Noise Class.

© 2005 Schneider Electric All Rights Reserved

17

Altivar® 31 S-Flex Combination Bypass Package Installation

TERMINAL BLOCK LOCATION

30072-450-90A 08/2005

Figure 5 shows the customer terminal block location for S-Flex controllers. Table 8 on page 19 lists the wire size and terminal torque requirements. Figure 5:

Customer Terminal Block Location

Adjustable Speed Drive Controller

Smoke Purge Relay (SPR) Control Power Transformer (CPT)

Customer Terminal Block (TB1) Isolation Contactor (IC)

Secondary Fuse (FU1) Primary Fuses (FU2 and FU3)

Bypass Contactor (BC)

Circuit Breaker (CB)

Overload Relay (OLR) Line Reactor (LR) Ground Lugs Ground Bar

18

© 2005 Schneider Electric All Rights Reserved

Altivar® 31 S-Flex Combination Bypass Package Installation

30072-450-90A 08/2005

POWER WIRING

Table 7:

Power Terminal Characteristics

Terminal

Function

Characteristics

GND

Ground (to ground lug on panel)

460 Vac ±15% (SFD•G4Y units)

L1 L2 L3

Three-phase power supply (to top of circuit breaker)

460 Vac ±15% (SFD•G4Y units)

T1 T2 T3

Output connections to motor (from overload relay)

0 to 460 Vac (SFD•G4Y units)

DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E. • Some terminals have voltage on them when both disconnects are open. • Turn off all power supplying this equipment before working on or inside equipment. • Always use a properly rated voltage sensing device to confirm that power is off. • Replace all covers before turning on power to equipment. Failure to follow these instructions will result in death or serious injury. Table 8:

Power Terminal Wire Range and Torque Requirements Terminals

Class 8839 Circuit Breaker SFD_ L1, L2, L3 Horsepower (Line) @460 V

© 2005 Schneider Electric All Rights Reserved

Overload Relay T1, T2, T3 (Load)

GND Bar

GND Lug

AWG

lb-in (N•m)

AWG

lb-in (N•m)

AWG

lb-in (N•m)

AWG

lb-in (N•m)

1–15

#14–#1/0

50 (5.65)

#18–#10

15 (1.69)

14–4

35 (3.95)

14–1/0

110 (12.43)

20

#14–#1/0

50 (5.65)

#14–#6

15 (1.69)

14–4

35 (3.95)

14–1/0

110 (12.43)

19

Altivar® 31 S-Flex Combination Bypass Package Installation

CONTROL WIRING

30072-450-90A 08/2005

Connect the control wiring to the top portion of the terminal block. See Figure 6. Each terminal is rated for one wire, 26–12 AWG (0.4 to 2.5 mm2); or two wires, 26–16 AWG (0.4–1.0 mm2), same gauge. Torque the terminal screws to 5.3–7.1 lb-in (0.6–0.8 N•m). The customer terminal block is designated TB1 on the wiring diagrams shipped with the S-Flex. Figure 6:

Customer Terminal Block (TB1)

Table 9:

TB1 Customer Terminal Connections

Function

Customer Terminals

SPR Disable

(Add jumper to disable)

1

Freeze/Firestat

(Remove jumper/add interlock)

2

2 4

SPR Disable

(Remove jumper to disable)

9

10

AFC Run Aux. Contact

(Closes with AFC running motor)

12

13

Bypass Run Aux. Contact

(Closes with bypass running motor)

14

15

Fault Aux. Contact

(Contact closes on AFC fault)

16

17

SPR Coil

(120 Vac to energize SPR)

18

19

0–10 Vdc Input

(Auto Speed Reference)

AI1

COM

4–20 mA Input

(Auto Speed Reference)

AI3

COM

Auto Start Contact

(Auto Mode Run Input)

+24

LI1

SPR = Smoke purge relay

Refer to the power and control circuit elementary diagram in Figure 7 on page 25.

20

© 2005 Schneider Electric All Rights Reserved

30072-450-90A 08/2005

Altivar® 31 S-Flex Combination Bypass Package Operation

SECTION 4— OPERATION

WARNING UNINTENDED EQUIPMENT OPERATION • Changes to programming other than the settings shown in Table 10 on page 22 can create incompatibilities with the supplied controller configuration. • Read and understand instruction bulletin VVDED303043US, as well as the programming information found in Table 10 on page 22. • If the power converter is re-initialized using the TOTAL or PARTIAL FACTORY SETTING function, the power converter must be reprogrammed according to the programming instructions found in Table 10 on page 22. • If the power converter or the main control board of the power converter is replaced, the power converter must be reprogrammed according to the programming instructions found in Table 10 on page 22. Failure to follow these instructions can result in death, serious injury, or equipment damage.

SEQUENCE OF OPERATION AND CONFIGURATION

This section describes the basic sequence of operation for the full voltage bypass power circuit configuration and available options.

Command Mode

The ATV31 controller is configured to operate in keypad command mode while in the Hand position and in terminal command mode while in the Auto position. Before reprogramming logic inputs, outputs, torque types, or control types, consult the factory configuration listing on the power and control circuit elementary diagram in Figure 7 on page 25 and in Table 10 on page 22. Changing certain factory settings adversely affects the performance of the ATV31 drive controller.

© 2005 Schneider Electric All Rights Reserved

21

Altivar® 31 S-Flex Combination Bypass Package Operation

Programming the Power Converter

30072-450-90A 08/2005

The ATV31 power converter is factory configured as shown in Table 10. Configure the power converter with the motor full-load current as shown on the motor nameplate. For additional programming information, refer to bulletin VVDED303043US, Altivar 31 Start-Up Guide, supplied with the S-Flex controller. Table 10:

1

POWER CIRCUIT Y FULL VOLTAGE BYPASS

Power Converter Factory Configuration

Menu

Code

Setting Description

Ctl

LAC

L3

Level 3 access

Ctl

Fr1

AIP

Reference 1 via the ATV31 keypad potentiometer

Ctl

Fr2

AI3

Reference 2 via analog input AI3 (4–20 mA)

Ctl

rFC

LI3

Ctl

CHCF

SEP

Separate control and reference channels

Ctl

Cd1

LOC

Control channel 1 = drive keypad display control

Ctl

Cd2

tEr

Control channel 2 = terminal block control

Ctl

CCS

LI3

Control channel switching via logic input LI3

drC

UFt

nLd

Energy savings (variable torque applications)

drC

bFr

60

Motor frequency = 60 Hz

drC

SCS

Str 1

Save the configuration (for backup)

Flt

Atr

Yes

Automatic restart

Flt

FLr

Yes

Catch on the fly

Flt

OPL

OAC

Motor phase loss fault is not triggered

FUn1

nSt

LI2

Freewheel stop via logic input LI2

I-O

tCC

2W

Two-wire control

I-O

tCt

LEL

Two-wire control, maintained

I-O

dO

rFr

Analog/logic output AOC/AOV = motor frequency

I-O

r1

FLt

Relay R1 = drive fault

I-O

r2

rUn

Relay R2 = drive running

I-O

rrS

nO

Reverse operation not assigned

SEt

ACC

60

Acceleration ramp time, in seconds

SEt

dEC

60

Deceleration ramp time, in seconds

SEt

LSP

15

Low speed, in Hz

SEt

HSP

60

High speed, in Hz

Reference switching via logic input LI3

In the StC sub-menu.

The full voltage bypass package operates the motor either from the power converter or at full-speed, full-voltage line power (bypass mode). You can run the motor in bypass mode in the unlikely event that the power converter becomes inoperative. The bypass package consists of:

•

An IEC-rated isolation and bypass contactor with Class 10 overload relay

• •

A 120 V control power transformer (CPT) A Mag-Gard® circuit breaker disconnect with means for locking in the open position

•

A bimetallic Class 10 overload relay with remote through-cover push button reset

•

An AFC-OFF-BYPASS switch

Always set and/or verify that the overload relay is set to the motor full load current. 22

© 2005 Schneider Electric All Rights Reserved

Altivar® 31 S-Flex Combination Bypass Package Operation

30072-450-90A 08/2005

Operator Controls—General Arrangement and Operation

Operator controls are located on the front of the ATV31 power converter and the control rail of the S-Flex. Use the AFC-OFF-BYPASS switch to select either adjustable speed operation of the motor through the power converter (AFC position) or line power operation of the motor (bypass position).

Adjustable Speed Operation

To control the operation of the motor with the power converter, close the controller disconnect switch located on the front of the S-Flex and place the AFC-OFF-BYPASS switch in the AFC position. There are two modes of operation with the HAND-AUTO switch:

•

Hand mode is for local control via the ATV31 power converter keypad. In Hand mode, pressing the start push button issues a run command, and the speed potentiometer controls the speed reference.

•

Auto mode is for remote control. In Auto mode, closing a user-supplied run contact between controller terminals TB1/+24 and TB1/LI1 immediately places the power converter in running mode. To vary motor speed, adjust one of the following user-supplied auto speed reference signals in the S-Flex: — 0–10 Vdc supplied to terminals TB1/AI1 (+) and TB1/COM (–) — 4–20 mA supplied to terminals TB1/AI3 (+), TB1/COM (–), and GND (Shield) Refer to instruction bulletin VVDED303043US for scaling of this signal.

Bypass Operation

To control the operation of the motor with line power, close the controller disconnect switch located on the front of the S-Flex and place the AFC-OFF-BYPASS switch in the bypass position. This transfers motor operation to line power, full speed operation. Moving the selector switch to the off position opens the bypass contactor and stops the motor.

Freeze/Firestat Interlocks (if used)

Terminals TB1-2 and TB1-4 are dedicated for accepting a user-supplied, normally closed, freeze/firestat interlock. If the connection between terminals TB1-2 and TB1-4 is opened, the drive output isolation contactor and the drive bypass contactor open, stopping the motor. Remove the factory-installed jumper from these terminals before installing the interlock.

Pilot Lights

Pilot lights visually indicate protective functions and circuit status. The bulb rating is 120 V. The functions of the two pilot lights are: 1. Power on (red): illuminates while mains power is applied to the controller. 2. Bypass run (yellow): illuminates while the bypass contactor coil is energized and the motor is running from line power.

© 2005 Schneider Electric All Rights Reserved

23

Altivar® 31 S-Flex Combination Bypass Package Operation

Line Reactor

30072-450-90A 08/2005

A 3% minimum rated AC line reactor is provided for harmonic mitigation and other power quality benefits. Table 11:

Line Reactors

Horsepower @ 460 V

Catalog number

% Z (Actual impedance)

1

RL00201

3.58

2

RL00402

3.14

3

RL00402

4.43

5

RL00802

3.24

7.5

RL00802

4.69

10

RL01202

4.97

15

RL01802

4.47

20

RL01802

5.75

Smoke Purge Function (Selectable)

Provides a smoke purge operating mode, controlled by a user-supplied 120 Vac signal applied between terminals TB1-18 and TB1-19. Supplying 120 Vac to TB1-18 and TB1-19 transfers motor operation to line power (if not operating in this mode already). Remove the jumper between terminals TB1-9 and TB1-10, and install it on terminals TB1-1 and TB1-2 to disable the smoke purge function.

Auxiliary Drive Run Contact

Provides a normally open (N.O.) contact between terminals TB1-12 and TB1-13 that closes when the bypass contactor is closed and the motor is running in drive mode.

Auxiliary Bypass Run Contact

Provides a normally open (N.O.) contact between terminals TB1-14 and TB1-15 that closes when the bypass contactor is closed and the motor is running in bypass mode.

Auxiliary Fault Contact

Provides a normally closed (N.C.) fail safe contact between terminals TB1-16 and TB1-17 that closes when the drive faults.

24

© 2005 Schneider Electric All Rights Reserved

© 2005 Schneider Electric All Rights Reserved

(14) (13)

10

(21) SPR

SPR

2

1

1

(22)

1

9

BC 6

(13) (14)

(A1)

8 (A1)

(21) (22)

9

IC

5

BYP

BYP

(21) (22)

AFC

(13) (14)

4

AFC

R (X2)

Bypass Run

(X1)

Power On

TS

7

OL

2 Fire/freezestat interlocks: remove jumper.

(C2)

(C1)

(13) (14)

Auto

Drive Run

12

LI3

LI1

LI2

15

AOC

AOV

CL1

LI6

LI5

LI4

LI3

LI1

LI2

+24

L2

Bypass Run

14

U

GND

AI3

COM

AI1

+10

R2C

R2A

R1B

R1C

Drive Fault

16

17

Fault (R1C) (R1B)

Run

Fault

R1A

AFC V ATV31 Adjustable Speed L3 W Drive

L1

BC (53) (54)

AOC

A

13

Run (R2A) (R2C)

H

IC (13) (14) Auto Start +24 LI1

(B2)

(B1)

+24

(A2)

LR (A1)

Isolation Contactor (IC)

50

(A2) Bypass Contactor (BC)

(A2) (95) (96)

BC

IC

TS

3 Y (X2) 14 (X1)

BC 13

(XF)

120 V

(X2)

(H3) (H1)

FU2

1 Remove jumper 9–10 and add jumper 1–2 to disable smoke purge.

1

2

OFF

FU1

(X1)

(H1)

460 V

(H4) (H2)

FU3

(HF)

IC

IC

19

(A2)

SPR 120 Vac

18

SPR

AI3

COM

4–20 mA Input

0–10 Vdc Input

NOTE: Fr2 (frequency reference 2) is programmed as AI3. For a 0–10 V input, program Fr2 to AI1.

I/O programmed as follows: LI1 = Run forward LI2 = Freewheel stop LI3 = Keypad/reference switching

AI1

(2)

(4)

(6)

(A1)

13

12

17

16

(1)

(3)

IC

T3

BC (6)

(5)

(5)

T2

BC (4)

T1

(3)

OLR

BC (2)

(1)

Figure 7:

L3

L2

L1

CB

30072-450-90A 08/2005 Altivar® 31 S-Flex Combination Bypass Package Operation

POWER AND CONTROL CIRCUIT ELEMENTARY DIAGRAM Full Voltage Bypass Package, Power Circuit Y

25

Altivar® 31 S-Flex Combination Bypass Package Maintenance

30072-450-90A 08/2005

SECTION 5— MAINTENANCE Before replacing any parts in the S-Flex, read and observe the following safety message and all other safety messages provided in this bulletin.

DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E • This equipment must be installed and serviced only by qualified electrical personnel. • Turn off all power supplying this equipment, open the disconnect, and lock it in the open position before working on or inside the equipment. • Always use a properly rated voltage-sensing device to confirm that the power is off. • Wait fifteen minutes to allow the DC bus to discharge, then verify that the voltage is less than 45 V. • Replace the cover before energizing the controller. Failure to follow these instructions will result in death or serious injury.

TECHNICAL SUPPORT

When troubleshooting the S-Flex, discuss with operating personnel the symptoms of the reported problems. Ask them to describe the problem, to identify when they first observed the problem, and where the problem was seen. Observe directly the drive system and process. Record the drive controller, motor, and peripheral equipment nameplate data on the S-Flex Troubleshooting Sheet. A sample of the Troubleshooting Sheet is shown on page 27. Copy this form as needed. For support and assistance, contact the Product Support Group. The Product Support Group is staffed from 8:00 am until 6:00 pm Eastern time to assist with product selection, start-up, and diagnosis of product or application problems. Emergency phone support is available 24 hours a day, 365 days a year.

26

Toll Free

1-888-Square D (1-888-778-2733)

E-mail

[email protected]

Fax

919-217-6508

© 2005 Schneider Electric All Rights Reserved

Altivar® 31 S-Flex Combination Bypass Package Maintenance

30072-450-90A 08/2005

S-FLEX TROUBLESHOOTING SHEET When requesting after-sales service, it is important to disclose all conditions under which the equipment currently operates. This will help in diagnosing the system quickly. Call the Product Support Group at 1-888-SquareD (1-888-778-2733). DATE: CONTACT NAME: COMPANY: ADDRESS: CITY: STATE: PHONE: FAX:

DRIVE CONTROLLER CONFIGURATION CATALOG NUMBER: CLASS 8839 TYPE SFD: APPLICATION/EQUIPMENT DESIGNATION:

MOTOR NAMEPLATE DATA HORSEPOWER:__________ VOLTAGE (3 PHASE):__________

FREQUENCY:_________

SERVICE FACTOR:________________________________________ MOTOR INSULATION:

POLES:__________ NEW OR

FLA:___________

EXISTING

MOTOR CABLE TYPE:______________________________________ LENGTH IN FEET:________________________________ IS MOTOR DESIGNED TO COMPLY WITH NEMA MG-1 PART 31 GUIDELINES?

YES

NO

POWER SOURCE AND ENVIRONMENT VOLTAGE BETWEEN:

L1 AND L2:____________

L2 AND L3:____________

L3 AND L1:____________

SERVICE TRANSFORMER RATING: ________________KVA

________________% Z FREQUENCY:

AMBIENT TEMPERATURES:

MAX °C (°F)___________

MIN °C (°F)___________

60 HZ OR

50 HZ

HUMIDITY:________________________

ALTITUDE IF GREATER THAN 3300 FEET ABOVE SEA LEVEL, SPECIFY:________________FT

DRIVE FAULT CODES PHF INPUT PHASE FAILURE OLF MOTOR OVERLOAD OCF OVERCURRENT EPF EXTERNAL FAULT CFI COMM NETWORK FAULT

USF UNDERVOLTAGE OBF OVERBRAKING SCF MOTOR SHORT CIRCUIT INF INTERNAL FAULT COF SERIAL CANOPEN

OSF OVERVOLTAGE OPF MOTOR PHASE FAILURE CRF PRECHARGE CIRCUIT BLF BRAKE SEQUENCE CFF CONFIGURATION (APPLICATION)

OHF DRIVE OVERLOAD LFF LOSS OF 4–20 mA SLF SERIAL MODBUS SOF OVERSPEED TNF AUTO-TUNING

DETAILED DESCRIPTION OF PROBLEM

© 2005 Schneider Electric All Rights Reserved

27

Instruction Bulletin Altivar® 31 S-Flex Combination Bypass Package

RENEWAL PARTS

Schneider Electric provides a limited number of renewal parts for the ATV31 S-Flex combination devices. Before replacing any parts, consult your local field sales representative. Renewal parts must be installed by qualified personnel. Table 12:

Renewal Parts

Renewal Part

460 V Rating

Power Converter

Schneider Electric USA 8001 Highway 64 East Knightdale, NC 27545 1-888-SquareD (1-888-778-2733) www.us.SquareD.com

1 hp

ATV31HO75N4A

2 hp

ATV31HU15N4A

3 hp

ATV31HU22N4A

5 hp

ATV31HU40N4A

7.5 hp

ATV31HU55N4A

10 hp

ATV31HU75N4A

15 hp

ATV31HD11N4A

20 hp

ATV31HD15N4A

120 V Incandescent Bulb

DL1CE130

FU2, FU3 Control Power Transformer (Primary Fuse)

25430-20150

FU1 Control Power Transformer (Secondary Fuse)

25430-20200

Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material. 30072-450-90A © 2005 Schneider Electric All Rights Reserved 08/2005