Emerson Affinity User manual

User Guide
Affinity
Model sizes 1 to 6
Building Automation HVAC/R
drive
Part Number: 0474-0000-05
Issue: 5
www.controltechniques.com

General Information
The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect
installation or adjustment of the optional operating parameters of the equipment or from mismatching the variable speed
drive with the motor.
The contents of this guide are believed to be correct at the time of printing. In the interests of a commitment to a policy
of continuous development and improvement, the manufacturer reserves the right to change the specification of the
product or its performance, or the contents of the guide, without notice.
All rights reserved. No parts of this guide may be reproduced or transmitted in any form or by any means, electrical or
mechanical including photocopying, recording or by an information storage or retrieval system, without permission in
writing from the publisher.
Drive software version
This product is supplied with the latest software version. If this drive is to be connected to an existing system or machine,
all drive software versions should be verified to confirm the same functionality as drives of the same model already
present. This may also apply to drives returned from a Control Techniques Service Centre or Repair Centre. If there is
any doubt please contact the supplier of the product.
The software version of the drive can be checked by looking at Pr 11.29 and Pr 11.34. This takes the form of xx.yy.zz
where Pr 11.29 displays xx.yy and Pr 11.34 displays zz. (e.g. for software version 01.01.00, Pr 11.29 = 1.01 and Pr 11.34
displays 0).
The software version of the Building Automation interface can be checked by looking at Pr 17.02 and Pr 17.51. The
software version takes the form of xx.yy.zz, where Pr 17.02 displays xx.yy and Pr 17.51 displays zz.
Environmental statement
Control Techniques is committed to minimising the environmental impacts of its manufacturing operations and of its
products throughout their life cycle. To this end, we operate an Environmental Management System (EMS) which is
certified to the International Standard ISO 14001. Further information on the EMS, our Environmental Policy and other
relevant information is available on request, or can be found at www.greendrives.com.
The electronic variable-speed drives manufactured by Control Techniques have the potential to save energy and
(through increased machine/process efficiency) reduce raw material consumption and scrap throughout their long
working lifetime. In typical applications, these positive environmental effects far outweigh the negative impacts of product
manufacture and end-of-life disposal.
Nevertheless, when the products eventually reach the end of their useful life, they must not be discarded but should
instead be recycled by a specialist recycler of electronic equipment. Recyclers will find the products easy to dismantle
into their major component parts for efficient recycling. Many parts snap together and can be separated without the use
of tools, whilst other parts are secured with conventional fasteners. Virtually all parts of the product are suitable for
recycling.
Product packaging is of good quality and can be re-used. Large products are packed in wooden crates, while smaller
products come in strong cardboard cartons which themselves have a high recycled fibre content. If not re-used, these
containers can be recycled. Polythene, used on the protective film and bags for wrapping product, can be recycled in the
same way. Control Techniques' packaging strategy prefers easily-recyclable materials of low environmental impact, and
regular reviews identify opportunities for improvement.
When preparing to recycle or dispose of any product or packaging, please observe local legislation and best practice.
REACH legislation
EC Regulation 1907/2006 on the Registration, Evaluation, Authorisation and restriction of Chemicals (REACH) requires
the supplier of an article to inform the recipient if it contains more than a specified proportion of any substance which is
considered by the European Chemicals Agency (ECHA) to be a Substance of Very High Concern (SVHC) and is
therefore listed by them as a candidate for compulsory authorisation.
For current information on how this requirement applies in relation to specific Control Techniques products, please
approach your usual contact in the first instance. Control Techniques position statement can be viewed at:
http://www.controltechniques.com/REACH
Copyright © May 2011 Control Techniques Ltd.
Issue Number: 5
Software: 01.06.00 onwards

Affinity User Guide 3
Issue Number: 5 www.controltechniques.com
Contents
1 Safety information .................................7
1.1 Warnings, cautions and notes ...............................7
1.2 Electrical safety - general warning ........................7
1.3 System design and safety of personnel ................7
1.4 Environmental limits ..............................................7
1.5 Access ..................................................................7
1.6 Fire protection .......................................................7
1.7 Compliance with regulations .................................7
1.8 Motor .....................................................................7
1.9 Mechanical brake control ......................................7
1.10 Adjusting parameters ............................................7
1.11 Electrical installation .............................................8
2 Product information ..............................9
2.1 Introduction ...........................................................9
2.2 Drive types ..........................................................10
2.3 Ratings ................................................................10
2.4 Model number .....................................................14
2.5 Operating modes ................................................14
2.6 Drive features ......................................................15
2.7 Nameplate description ........................................16
2.8 Options ................................................................17
2.9 Items supplied with the drive ...............................19
3 Mechanical installation .......................20
3.1 Safety information ...............................................20
3.2 Planning the installation ......................................20
3.3 Terminal cover removal ......................................22
3.4 Solutions Module / keypad installation /
removal ...............................................................29
3.5 Mounting methods ..............................................31
3.6 Enclosure for standard drives .............................48
3.7 Enclosure design and drive ambient
temperature..........................................................49
3.8 Enclosing standard drive for high environmental
protection ............................................................50
3.9 External EMC filter for standard drives ..............54
3.10 Electrical terminals ..............................................62
3.11 Routine maintenance ..........................................63
4 Electrical installation ..........................66
4.1 Power connections ..............................................66
4.2 AC supply requirements ......................................69
4.3 Auxiliary power supply ........................................70
4.4 Supplying the drive with DC / DC bus
paralleling ............................................................71
4.5 Fan connections ..................................................71
4.6 Control 24Vdc supply ..........................................71
4.7 Ratings ................................................................71
4.8 Output circuit and motor protection .....................74
4.9 Braking ................................................................76
4.10 Ground leakage ..................................................78
4.11 EMC (Electromagnetic compatibility) ..................78
4.12 PC communications connections ........................87
4.13 Terminal connections ..........................................88
4.14 Building automation network connections ...........92
4.15 Heatsink fan supply connections (size 4 to 6) .....92
5 Getting started..................................... 93
5.1 Understanding the display ..................................93
5.2 Keypad operation ................................................93
5.3 Menu structure ....................................................94
5.4 Menu 0 ................................................................95
5.5 Advanced menus ................................................95
5.6 Changing the operating mode .............................97
5.7 Changing the keypad mode ................................97
5.8 Saving parameters ..............................................97
5.9 Restoring parameter defaults ..............................97
5.10 Parameter access level and security ..................97
5.11 Displaying parameters with non-default
values only ..........................................................99
5.12 Displaying destination parameters only ..............99
5.13 Communications .................................................99
6 Basic parameters ..............................102
6.1 Single line descriptions .....................................102
6.2 Full descriptions ................................................106
7 Running the motor ............................115
7.1 Quick start Connections ....................................115
7.2 Changing the operating mode ...........................115
7.3 Changing keypad mode ....................................115
7.4 Quick Start commissioning/start-up ..................118
8 Optimization .......................................121
8.1 Motor map parameters ......................................121
8.2 Current limits .....................................................127
8.3 Motor thermal protection ...................................127
8.4 Switching frequency ..........................................128
8.5 High speed operation ........................................128

4Affinity User Guide
www.controltechniques.com Issue Number: 5
9 SMARTCARD operation ....................129
9.1 Introduction .......................................................129
9.2 Transferring data ...............................................130
9.3 Data block header information ..........................131
9.4 SMARTCARD parameters ................................132
9.5 SMARTCARD trips ............................................133
10 PC tools ..............................................135
10.1 CTSoft ...............................................................135
10.2 Onboard PLC and SYPTLite .............................135
10.3 CT Energy Savings Estimator ...........................137
11 Advanced parameters .......................139
11.1 Menu 1: Frequency / speed reference ..............146
11.2 Menu 2: Ramps .................................................150
11.3 Menu 3: Speed feedback and speed control .....153
11.4 Menu 4: Torque and current control ..................156
11.5 Menu 5: Motor control .......................................159
11.6 Menu 6: Sequencer and clock ...........................163
11.7 Menu 7: Analog I/O ...........................................165
11.8 Menu 8: Digital I/O ............................................168
11.9 Menu 9: Programmable logic, motorized pot,
binary sum and timers .......................................171
11.10 Menu 10: Status and trips .................................175
11.11 Menu 11: General drive set-up ..........................177
11.12 Menu 12: Threshold detectors, variable
selectors and brake control function .................178
11.13 Menu 14: User PID controller ............................186
11.14 Menus 15 and 16: Solutions Module set-up ......193
11.15 Menu 17: Building Automation Network ............212
11.16 Menu 18: Application menu 1 ............................212
11.17 Menu 19: Application menu 2 ............................212
11.18 Menu 20: Application menu 3 ............................212
11.19 Menu 21: Second motor parameters .................213
11.20 Menu 22: Additional Menu 0 set-up ..................214
11.21 Advanced features ............................................215
12 Technical data ....................................228
12.1 Drive technical data ...........................................228
12.2 Optional external EMC filters ............................246
13 Diagnostics ........................................250
13.1 Trip indications ..................................................250
13.2 Alarm indications ...............................................262
13.3 Status indications ..............................................262
13.4 Displaying the trip history ..................................263
13.5 Behavior of the drive when tripped ....................263
14 UL listing information .......................264
14.1 Common UL information ...................................264
14.2 Power dependant UL information ......................264
14.3 AC supply specification .....................................264
14.4 Maximum continuous output current .................264
14.5 Safety label .......................................................265
14.6 UL listed accessories ........................................265
List of figures .................................... 266
List of tables ..................................... 268
Index .................................................. 270

Affinity User Guide 5
Issue Number: 5 www.controltechniques.com
Declaration of Conformity (Size 1 to 5)
Control Techniques Ltd
The Gro
Newtown
Powys
UK
SY16 3BE
The AC variable speed drive products listed above have been designed
and manufactured in accordance with the following European
harmonized standards:
These products comply with the Low Voltage Directive 2006/95/EC and
the Electromagnetic Compatibility Directive 2004/108/EC.
T.Alexander
Vice President, Technology
Newtown
Date: 14th July 2009
These electronic drive products are intended to be used with
appropriate motors, controllers, electrical protection components
and other equipment to form complete end products or systems.
Compliance with safety and EMC regulations depends upon
installing and configuring drives correctly, including using the
specified input filters. The drives must be installed only by
professional assemblers who are familiar with requirements for
safety and EMC. The assembler is responsible for ensuring that the
end product or system complies with all the relevant laws in the
country where it is to be used. Refer to the User Guide. An EMC
Data Sheet is also available giving detailed EMC information.
BA1201 BA1202 BA1203 BA1204
BA2201 BA2202 BA2203
BA3201 BA3202
BA4201 BA4202 BA4203
BA5201 BA5202
BA1401 BA1402 BA1403 BA1404 BA1405 BA1406
BA2401 BA2402 BA2403
BA3401 BA3402 BA3403
BA4401 BA4402 BA4403
BA5401 BA5402
BA3501 BA3502 BA3503 BA3504 BA3505 BA3506
BA3507
BA4601 BA4602 BA4603 BA4604 BA4605 BA4606
BA5601 BA5602
EN 61800-5-1:2007
Adjustable speed electrical power drive
systems - safety requirements - electrical,
thermal and energy
EN 61800-3:2004
Adjustable speed electrical power drive
systems. EMC product standard including
specific test methods
EN 61000-6-2:2005
Electromagnetic compatibility (EMC).
Generic standards. Immunity standard for
industrial environments
EN 61000-6-4:2007
Electromagnetic compatibility (EMC).
Generic standards. Emission standard for
industrial environments

Safety
Information
Product
Information
Mechanical
Installation
Electrical
Installation
Getting
Started
Basic
parameters
Running
the motor Optimization SMARTCARD operation PC tools Advanced parameters
Technical
Data Diagnostics UL Listing Information
6Affinity User Guide
www.controltechniques.com Issue Number: 5
Declaration of Conformity (Size 6)
Control Techniques Ltd
The Gro
Newtown
Powys
UK
SY16 3BE
The AC variable speed drive products listed above have been designed
and manufactured in accordance with the following European
harmonized standards:
These products comply with the Low Voltage Directive 2006/95/EC and
the Electromagnetic Compatibility Directive 2004/108/EC.
T.Alexander
Vice President, Technology
Newtown
Date: 14th July 2009
These electronic drive products are intended to be used with
appropriate motors, controllers, electrical protection components
and other equipment to form complete end products or systems.
Compliance with safety and EMC regulations depends upon
installing and configuring drives correctly, including using the
specified input filters. The drives must be installed only by
professional assemblers who are familiar with requirements for
safety and EMC. The assembler is responsible for ensuring that the
end product or system complies with all the relevant laws in the
country where it is to be used. Refer to the User Guide. An EMC
Data Sheet is also available giving detailed EMC information.
BA6401 BA6402
BA6601 BA6602
EN 61800-5-1:2007
Adjustable speed electrical power drive
systems - safety requirements - electrical,
thermal and energy
EN 61800-3:2004
Adjustable speed electrical power drive
systems. EMC product standard including
specific test methods
EN 61000-6-2:2005
Electromagnetic compatibility (EMC). Generic
standards. Immunity standard for industrial
environments

Safety
Information
Product
Information
Mechanical
Installation
Electrical
Installation
Getting
Started
Basic
parameters
Running
the motor Optimization SMARTCARD operation PC tools Advanced parameters
Technical
Data Diagnostics UL Listing Information
Affinity User Guide 7
Issue Number: 5 www.controltechniques.com
1 Safety information
1.1 Warnings, cautions and notes
A Note contains information which helps to ensure correct operation of
the product.
1.2 Electrical safety - general warning
The voltages used in the drive can cause severe electrical shock and/or
burns, and could be lethal. Extreme care is necessary at all times when
working with or adjacent to the drive.
Specific warnings are given at the relevant places in this User Guide.
1.3 System design and safety of
personnel
The drive is intended as a component for professional incorporation into
complete equipment or a system. If installed incorrectly, the drive may
present a safety hazard.
The drive uses high voltages and currents, carries a high level of stored
electrical energy, and is used to control equipment which can cause
injury.
Close attention is required to the electrical installation and the system
design to avoid hazards either in normal operation or in the event of
equipment malfunction. System design, installation, commissioning/
start-up and maintenance must be carried out by personnel who have
the necessary training and experience. They must read this safety
information and this User Guide carefully.
The STOP function of the drive do not isolate dangerous voltages from
the output of the drive or from any external option unit. The supply must
be disconnected by an approved electrical isolation device before
gaining access to the electrical connections.
None of the drive functions must be used to ensure safety of
personnel, i.e. they must not be used for safety-related functions.
Careful consideration must be given to the functions of the drive which
might result in a hazard, either through their intended behavior or
through incorrect operation due to a fault. In any application where a
malfunction of the drive or its control system could lead to or allow
damage, loss or injury, a risk analysis must be carried out, and where
necessary, further measures taken to reduce the risk - for example, an
over-speed protection device in case of failure of the speed control, or a
fail-safe mechanical brake in case of loss of motor braking.
1.4 Environmental limits
Instructions in this User Guide regarding transport, storage, installation
and use of the drive must be complied with, including the specified
environmental limits. Drives must not be subjected to excessive physical
force.
1.5 Access
Access must be restricted to authorized personnel only. Safety
regulations which apply at the place of use must be complied with.
1.6 Fire protection
The drive enclosure is not classified as a fire enclosure. A separate fire
enclosure must be provided. See section 3.2.6 Fire protection on
page 20 for more information.
1.7 Compliance with regulations
The installer is responsible for complying with all relevant regulations,
such as national wiring regulations, accident prevention regulations and
electromagnetic compatibility (EMC) regulations. Particular attention
must be given to the cross-sectional areas of conductors, the selection
of fuses or other protection, and protective earth (ground) connections.
This User Guide contains instruction for achieving compliance with
specific EMC standards.
Within the European Union, all machinery in which this product is used
must comply with the following directives:
2006/42/EC: Safety of machinery.
2004/108/EC: Electromagnetic Compatibility.
1.8 Motor
Ensure the motor is installed in accordance with the manufacturer’s
recommendations. Ensure the motor shaft is not exposed.
Standard squirrel cage induction motors are designed for single speed
operation. If it is intended to use the capability of the drive to run a motor
at speeds above its designed maximum, it is strongly recommended that
the manufacturer is consulted first.
Low speeds may cause the motor to overheat because the cooling fan
becomes less effective. The motor should be installed with a protection
thermistor. If necessary, an electric forced vent fan should be used.
The values of the motor parameters set in the drive affect the protection
of the motor. The default values in the drive should not be relied upon.
It is essential that the correct value is entered in parameter 0.46 motor
rated current. This affects the thermal protection of the motor.
1.9 Mechanical brake control
The brake control functions are provided to allow well co-ordinated
operation of an external brake with the drive. While both hardware and
software are designed to high standards of quality and robustness, they
are not intended for use as safety functions, i.e. where a fault or failure
would result in a risk of injury. In any application where the incorrect
operation of the brake release mechanism could result in injury,
independent protection devices of proven integrity must also be
incorporated.
1.10 Adjusting parameters
Some parameters have a profound effect on the operation of the drive.
They must not be altered without careful consideration of the impact on
the controlled system. Measures must be taken to prevent unwanted
changes due to error or tampering.
A Warning contains information which is essential for
avoiding a safety hazard.
A Caution contains information which is necessary for
avoiding a risk of damage to the product or other equipment.
WARNING
CAUTION
NOTE

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1.11 Electrical installation
1.11.1 Electric shock risk
The voltages present in the following locations can cause severe electric
shock and may be lethal:
• AC supply cables and connections
• Output cables and connections
• Many internal parts of the drive, and external option units
Unless otherwise indicated, control terminals are single insulated and
must not be touched.
1.11.2 Stored charge
The drive contains capacitors that remain charged to a potentially lethal
voltage after the AC supply has been disconnected. If the drive has been
energized, the AC supply must be isolated at least ten minutes before
work may continue.

Safety
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Technical
Data Diagnostics UL Listing Information
Affinity User Guide 9
Issue Number: 5 www.controltechniques.com
2 Product information
2.1 Introduction
The Affinity is a high performance open loop AC drive specifically designed for use in building automation HVAC/R applications. Figure 2-1 below
indicates the key product features including built in connectivity to building automation systems. Each drive is equipped with two identical option slots
for I/O and communications expansion
Figure 2-1 Features
The Affinity drive can be used as a standalone motor controller or integrated into a building automation system using analog and digital I/O or serial
communications. The base drive incorporates a RS-485 serial communications port that is selectable between BACnet, Metasys N2 or Modbus RTU.
LonWorks, Ethernet, Profibus and Devicenet connectivity is achieved with the addition of plug-in Solutions Modules.
Key features:
Fire Mode
Fire Mode is a configurable override function that is used to alter the operation of the drive based upon external inputs, typically a discrete digital
input from a Building Management Fire Protection system (refer to section 11.21.3 Fire mode on page 216).
Real time Clock
An internal real time clock is available which is used for the timer functions and trip log
Timer functions
Two timers are available to switch an output on a routine basis
Sleep/Wake Mode
Sleep/wake mode stops and starts the motor during periods of low demand to improve system efficiency
Advanced Process PID
Two PIDs are available which can operate independently or combine to provide more complex functionality
SM-I/O Plus
SM-I/O Lite
SM-I/O 120V
SM-I/O 24V Protected
SM-I/O PELV
SM-I/O 32
I/O Expansion
Fieldbus options
SM-LON
SM-Ethernet
SM-DeviceNet
SM-PROFIBUS-DP-V1
SM-EtherCAT
SM-LON
SM-INTERBUS
SM-CAN
SM-CANopen
Modbus
Standard Fieldbus
(Selectable between)
BACnet
Modbus RTU
Metasys N2
Standard Fieldbus
Building Automation System
Fire Mode - Important Warning
When Fire Mode is active the motor overload and thermal protection are disabled, as well as a number of drive protection functions. Fire
Mode is provided for use only in emergency situations where the safety risk from disabling protection is less than the risk from the drive
tripping - typically in smoke extraction operation to permit evacuation of a building. The use of Fire Mode itself causes a risk of fire from
overloading of the motor or drive, so it must only be used after careful consideration of the balance of risks.
Care must be taken to prevent inadvertent activation or de-activation of Fire Mode. Fire Mode is indicated by a flashing display text
warning "Fire mode active".
Care must be taken to ensure that parameters Pr 1.53 or Pr 1.54 are not inadvertently re-allocated to different inputs or variables. It should
be noted that, by default, Pr 1.54 is controlled from digital input 4 and changing Pr 6.04 or Pr 8.24 can re-allocate this digital input to another
parameter. These parameters are at access level 2 in order to minimize the risk of inadvertent or unauthorized changes. It is recommended
that User Security be applied to further reduce the risk (see section 5.10 Parameter access level and security on page 97). These
parameters may also be changed via serial communications so adequate precautions should be taken if this functionality is utilized.
WARNING

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10 Affinity User Guide
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2.2 Drive types
There are three versions of Affinity drive available:
• Standard
• IP54 (NEMA12)
• IP66 (NEMA12)
The IP54 and IP66 drives are identified by additional characters at the end of the model number, i.e. E12/E54 or E12/E66. The standard drive has no
additional characters.
The standard drives are rated to IP20/NEMA1. Drive sizes 1 and 3 conform to UL Type 1 and sizes 4 to 6 are Open Class. If the optional conduit box
(refer to section 3.5 Mounting methods on page 31) is installed, then drive sizes 4 to 6 conform to UL Type 1.
The E12/E54 and E12/E66 drives have an additional cover installed. They are rated to IP54/NEMA12 and IP66/NEMA12 respectively and both
conform to UL Type 12. E12/E54 and E12/E66 drive sizes 1 to 3 have an internal fan installed to re-circulate the air. The larger drive sizes have fans
installed to the cover to provide forced ventilation using filtered air.
2.3 Ratings
Self ventilated (TENV/TEFC) induction motors require increased protection against overload due to the reduced cooling effect of the fan at low speed.
To provide the correct level of protection the I2t software operates at a level which is speed dependent. This is illustrated in the graph below.
The protection starts when the motor speed is below 50% of base speed.
NOTE
Operation of motor I2t protection (It.AC trip)
Motor I2t protection is fixed as shown below and is compatible with:
• Self ventilated (TENV/TEFC) induction motors
Motor total
current (Pr 4.01)
as a percentage
of motor rated
current
Motor speed as a
percentage of base speed
100%
Max. permissible
continuous
current
100%
I t protection operates in this region
2
70%
50%15%