Rockwell Automation Allen-Bradley ARMORSTART User manual

QUICK START
ARMORSTART®DISTRIBUTED
MOTOR CONTROLLER WITH
ARMORPOINT®BACKPLANE
Getting Started
BULLETIN 284A
Introduction This guide provides the basic information required to start up your
ArmorStart®Distributed Motor Controller. Factory default settings
and information regarding installing, programming, and ArmorPoint®
Communication Protocol, are described here. For detailed
information on specific product features or configurations, refer to the
ArmorStart user manual, Publication 284-UM001*-EN-P.
This guide is intended for qualified service personnel responsible for
setting up and servicing these devices. You must have previous
experience with and a basic understanding of electrical terminology,
configuration procedures, required equipment, and safety precautions.
For Bulletin 284A devices, you should understand Bulletin 1738
ArmorPoint adapter and I/O products.

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Installation The ArmorStart Distributed Motor Controller is convection cooled.
Operating temperature must be kept between –20…40°C (–4…104°F).
Dimensions Dimensions are shown in millimeters (inches). Dimensions are not intended
to be used for manufacturing purposes. All dimensions are subject to
change.
Figure 1 Dimensions for 1 Hp and below @ 230V AC, 2 Hp and below @ 460V AC,
and 2 Hp and below @ 575V AC, IP67/NEMA Type 4 with
Conduit Entrance

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Dimensions are shown in millimeters (inches). Dimensions are not intended
to be used for manufacturing purposes. All dimensions are subject to
change.
Figure 2 Dimensions for 2 Hp @ 230V AC, 3 Hp and above @ 460V AC, and 3 Hp and
above @ 575V AC, IP67/NEMA Type 4 with Conduit Entrance

Publication 284A-QS001C-EN-P - July 2006
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Dimensions are shown in millimeters (inches). Dimensions are not intended
to be used for manufacturing purposes. All dimensions are subject to
change.
Figure 3 Dimensions for 1 Hp and below @ 230V AC, 2 Hp and below @ 460V AC,
and 2 Hp and below @ 575V AC, IP67/NEMA Type 4 with
ArmorConnect™ Connectivity
ArmorStart device with a 10 A short circuit protection rating

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Dimensions are shown in millimeters (inches). Dimensions are not intended
to be used for manufacturing purposes. All dimensions are subject to
change.
Figure 4 Dimensions for 2 Hp @ 230V AC, 3 Hp and above @ 460V AC, and 3 Hp and
above @ 575V AC, IP67/NEMA Type 4 with ArmorConnect Connectivity
ArmorStart device with a 25 A short circuit protection rating

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Wiring Power, Control, Safety Monitor Inputs, and Ground Wiring
Table 1 provides the power, control, safety monitor inputs, ground wire
capacity and the tightening torque requirements. The power, control,
ground, and safety monitor terminals will accept a maximum of two wires
per terminal.
Table 1 Power, Control, Safety Monitor Inputs, Ground Wire Size, and Torque
Specifications
Terminal Designations As shown in Figure 5, the ArmorStart Distributed Motor Controller contains
terminals for power, control, safety monitor inputs and ground wiring.
Access can be gained by removing the terminal access cover plate.
Figure 5 ArmorStart Power, Control, and Safety Monitor Terminals
Terminals Wire Size Torque Wire Strip Length
Power
and
Ground
Primary/Secondary
Terminal:
1.0…4.0 mm2
(#18 …#10 AWG)
Primary Terminal:
10.6…21.6 lb.-in.
(1.2…2.4 N•m)
Secondary Terminal:
5.3…7.3 lb.-in
(0.6…0.8 N•m)
0.35 in. (9 mm)
Control and Safety
Monitor Inputs 0.34mm2…4.0 mm2
(#22…#10 AWG)
5.0…5.6 lb.-in
(0.6 N•m) 0.35 in. (9 mm)
Primaries
Secondaries

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Table 2 Power, Control, and Ground Terminal Designations
➊ Only available with the Safety Monitor option.
Terminal Designations No. of Poles Description
SM1 ➊2 Safety Monitor Input
SM2 ➊2 Safety Monitor Input
A1 (+) 2 Control Power Input
A2 (-) 2 Control Power Common
PE 2 Ground
1/L1 2 Line Power Phase A
3/L3 2 Line Power Phase B
5/L5 2 Line Power Phase C

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ArmorConnect Power Media Description
The ArmorStart Power Media offers both three-phase and control power
cable system of cordsets, patchcords, receptacles, tees, reducers and
accessories to be utilized with the ArmorStart Distributed Motor Controller.
These cable system components allow quick connection of ArmorStart
Distributed Motor Controllers and reduce installation time. They provide
for repeatable, reliable connection of the three-phase and control power to
the ArmorStart Distributed Motor Controller and motor by providing a plug
and play environment that also avoids system mis-wiring. When specifying
power media for use with the ArmorStart Distributed Motor Controllers
(Bulletins 280, 281, 283, and 284) use only the Bulletin 280
ArmorConnect™ power media.
Figure 6 Three-Phase Power System Overview
➊Three-Phase Power Trunk- PatchCord cable with integral female or male connector on each end. (Example Part Number: 280-PWR35A-M*)
➋Three-Phase Drop Cable- PatchCord cable with integral female or male connector on each end. (Example Part Number: 280-PWR22A-M*)
➌Three-Phase Power Tees and Reducer -
Tee connects to a single drop line to trunk with quick change connectors – Part Number: 280-T35
Reducing Tee connects to a single drop line (Mini) to trunk (Quick change) connector – Part Number: 280-RT35
Reducer connects from quick change male connector to mini female connector– Part Number: 280-RA35
➍Three-Phase Power Receptacles -
Female receptacles are a panel mount connector with flying leads – Part Number: 280-M35F-M1
RESET
Bulletin 280/281
ArmorStart
ArmorPoint
Bulletin 284
ArmorStart
Ethernet
PLC
Bulletin 1492FB
Branch Circuit
Protective Device
Enclosure
Bulletin 1606 Bulletin 1606
Bulletin 800F
Emergency Stop
Pushbutton
4
Computer
Terminal

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Figure 7 Control Power Media System Overview
➏Control Power Media Patchcords - PatchCord cable with integral female or male connector on each end
Example Part Number: 889N-F65GFNM-*
➐Control Power Tees - The E-stop In Tee (Part Number: 898N-653ES-NKF) is used to connect to the Bulletin 800F On-Machine E-Stop station using a
control power media patchcord. The E-stop Out tee (Part Number: 898N-653ST-NKF) is used with cordset or patchcord to connect to the ArmorStart
Distributed Motor Controller.
➑Control Power Receptacles - Female receptacles are a panel mount connector with flying leads –
Part Number: 888N-D65AF1-*
RESET
Bulletin 280/281
ArmorStart
ArmorPoint
Bulletin 284
ArmorStart
Ethernet
PLC
Bulletin 1492FB
Branch Circuit
Protective Device
Enclosure
Bulletin 1606 Bulletin 1606
Bulletin 800F
Emergency Stop
Pushbutton
8
6
6
6
67
7
Computer
Terminal

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ArmorStart with ArmorConnect Connectivity
Installing ArmorConnect Power Media using Cord Grips
Control Power Receptacle
Three-Phase Power Receptacle Control Power Receptacle
Three-Phase Power Receptacle
ArmorStart devices with 10 A short
circuit protection rating
ArmorStart devices with 25 A short
circuit protection rating
3/4 in. Lock Nut 1 in. Lock Nut
Thomas & Betts Cord Grip
Part Number: 2931NM
3/4 in. Stain Relief Cord Connector
Cable Range: 0.31…0.56 in.
Used with Control Power Media
Cordset - Example Part Number:
889N-M65GF-M2
Thomas & Betts Cord Grip
Part Number: 2940NM
1 in. Stain Relief Cord Connector
Cable Range: 0.31…0.56 in.
Used with Three-Phase Power
Media Cordset - Example Part
Number: 280-PWR22G-M1
Cord Grips for ArmorStart Devices with 10 A short circuit protection rating
3/4 in. Lock Nut 1 in. Lock Nut
Thomas & Betts Cord Grip
Part Number: 2931NM
3/4 in. Stain Relief Cord Connector
Cable Range: 0.31…0.56 in.
Used with Control Power Media
Cordset - Example Part Number:
889N-M65GF-M2
Thomas & Betts Cord Grip
Part Number: 2942NM
1 in. Stain Relief Cord Connector
Cable Range: 0.70…0.95 in.
Used with Three-Phase Power
Media Cordset - Example Part
Number: 280-PWR35G-M1
Cord Grips for ArmorStart Devices with 25 A short circuit protection rating

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ArmorConnect Cable Ratings
The ArmorConnect Power Media cables are rated per UL Type TC
600V 90 °C Dry 75 °C Wet, Exposed Run (ER) or MTW 600V 90 °C or
STOOW 105 °C 600V - CSA STOOW 600V FT2. For additional
information regarding ArmorConnect Power Media see the ArmorStart
User Manual.
Branch Circuit Protection Requirements for ArmorConnect™
Three-Phase Power Media
When using ArmorConnect Three-Phase Power Media, only fuses can be
used for the motor branch circuit protective device, for the group motor
installations. The recommended fuse types are the following: Class CC, T,
or J type fuses. For additional information, see the ArmorStart User
Manual.
Terminal Designations Description Color Code
A1 (+) Control Power Input Blue
A2 (-) Control Power Common Black
PE Ground Green/Yellow
1/L1 Line Power - Phase A Black
2/L2 Line Power - Phase B White
3/L3 Line Power - Phase C Red

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Group Motor Installations for USA and Canada Markets
The ArmorStart Distributed Motor controllers are listed for use with each
other in group installations per NFPA 79, Electrical Standard for Industrial
Machinery. When applied according to the group motor installation
requirements, two or more motors, of any rating or controller type, are
permitted on a single branch circuit. Group Motor Installation has been
successfully used for many years in the USA and Canada.
Wiring and Workmanship Guidelines
In addition to conduit and seal-tite raceway, it is acceptable to utilize cable
that is dual rated Tray Cable, Type TC-ER and Cord, STOOW, for power
and control wiring on ArmorStart installations. In the USA and Canada
installations, the following guidance is outlined by the NEC and NFPA 79.
In industrial establishments where the conditions of maintenance and
supervision ensure that only qualified persons service the installation, and
where the exposed cable is continuously supported and protected against
physical damage using mechanical protection, such as struts, angles, or
channels, Type TC tray cable that complies with the crush and impact
requirements of Type MC (Metal Clad) cable and is identified for such use
with the marking Type TC-ER (Exposed Run)* shall be permitted between
a cable tray and the utilization equipment or device as open wiring. The
cable shall be secured at intervals not exceeding 1.8 m (6 ft) and installed in
a “good workman-like” manner. Equipment grounding for the utilization
equipment shall be provided by an equipment grounding conductor within
the cable.
*Historically cable meeting these crush and impact requirements were
designated and marked “Open Wiring”. Cable so marked is equivalent to the
present Type TC-ER and can be used.
While the ArmorStart is intended for installation in factory floor
environments of industrial establishments, the following must be taken into
consideration when locating the ArmorStart in the application: Cables,
including those for control voltage including 24V DC and communications,
are not to be exposed to an operator or building traffic on a continuous
basis. Location of the ArmorStart to minimize exposure to continual traffic
is recommended. If location to minimize traffic flow is unavoidable, other
barriers to minimize inadvertent exposure to the cabling should be
considered. Routing cables should be done in such a manner to minimize
inadvertent exposure and/or damage.
Additionally, if conduit or other raceways are not used, it is recommended
that strain relief fittings be utilized when installing the cables for the control
and power wiring through the conduit openings.
The working space around the ArmorStart may be minimized as the
ArmorStart does not require examination, adjustment, servicing or
maintenance while energized. In lieu of this service, the ArmorStart is

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meant to be unplugged and replaced after proper lockout/tag-out procedures
have been employed.
Since the ArmorStart is available with a factory installed HOA keypad
option this may require the ArmorStart to be selected and installed as
follows if the application requires frequent use of the hand operated
interface by the equipment operator:
1. They are not less than 0.6 m (2 ft) above the servicing level and are
within easy reach of the normal working position of the operator.
2. The operator is not placed in a hazardous situation when operating
them.
3. The possibility of inadvertent operation is minimized.
If the operated interface is used in industrial establishments where the
conditions of maintenance and supervision ensure that only qualified
persons operate and service the ArmorStart's operator interface, and the
installation is located so that inadvertent operation is minimized then other
installation locations with acceptable access can be provided.
AC Supply Considerations
Ungrounded Distribution Systems
Disconnecting MOVS
To prevent drive damage, the MOVs connected to ground shall be
disconnected if the drive is installed on an ungrounded distribution system
where the line-to-ground voltages on any phase could exceed 125% of the
nominal line-to-line voltage. To disconnect these devices, remove the
jumper shown in Figure 9, Jumper Removal.
1. Before installing the Bulletin 284, loosen four mounting screws.
2. Unplug control module from the base unit by pulling forward.
ATTENTION
!
The Bulletin 284 contains protective MOVs that are
referenced to ground. These devices should be
disconnected if the Bulletin 284 is installed on an
ungrounded distribution system.

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Figure 8 Removal of Control Module
Figure 9 Jumper Removal
Remove Jumper
ATTENTION
!
Do not remove this jumper if the unit is equipped with an
EMI filter installed.

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LED Status Indication The LED Status Indication provides 4 status LEDs and a Reset button. The
LEDs provide status indication for the following:
• POWER LED
The LED is illuminated solid green when control power is present and
with the proper polarity
•RUNLED
This LED is illuminated solid green when a start command and control
power are present
• NETWORK LED
This bi-color (red/green) LED indicates the status of the
communication link
• FAULT LED
Indicates Controller Fault (trip) condition
The “Reset Button” as a local trip reset.
Figure 10 LED Status Indication and Reset
ArmorStart with ArmorPoint ArmorStart for the ArmorPoint Backplane
The Bulletin 284A ArmorStart Distributed Motor Controller allows
connectivity to the ArmorPoint backplane. The ArmorPoint I/O system can
communicate using DeviceNet™, ControlNet™, or EtherNet
communication protocols. In addition to the other network communication
protocols; the ArmorPoint Distributed I/O products allow the I/O capability
to be expanded beyond the standard two outputs. Two dual-key relay output
connectors are provided standard. The outputs are sourced from control
voltage power (A1, A2). LED status indication is also provided, as standard
with the ArmorPoint. When using ArmorPoint, a maximum of two
ArmorStart Distributed Motor Controllers can be connected to the
ArmorPoint Distributed I/O products.
ArmorStart to ArmorPoint Connectivity
Figure 11 Connectivity Diagram for one ArmorStart Distributed Motor Controller

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When connecting to the Bulletin 1738 ArmorPoint Distributed I/O product,
a network adapter and at least one ArmorPoint Digital Output, Digital Input,
Analog, AC and Relay product, or Specialty product must be selected. The
ArmorPoint Distributed I/O product can accommodate up to 63 modules per
network node. The cable that connects the ArmorPoint Distributed I/O to
the ArmorStart Distributed Motor Controller is the Bulletin 280A-EXT1.
The 280A-EXT1 includes an ArmorPoint bus extension cable and a
network terminating resistor. The network terminating resistor must be
connected to the “ArmorPoint Interface Out” connector.
Figure 12 Connectivity Diagram for two ArmorStart Distributed Motor Controllers
If an additional ArmorStart Distributed Motor Controller is to be connected,
the Bulletin 280A-EXTCABLE will be required. A maximum of two
ArmorStart Distributed Motor Controllers can be connected to the Bulletin
1738 Distributed I/O. The Bulletin 280A-EXTCABLE is connected from
the “ArmorPoint Interface Out” on the first unit, to the “ArmorPoint
Interface In” on the second unit. The network terminating resistor is
connected to the “ArmorPoint Interface Out” on the second unit.
ArmorPoint Backplane Commissioning:
Establishing a Backplane Node Address
Backplane node addresses are established automatically by the ArmorPoint
system on power up. Node addresses for the backplane modules are
allocated from left to right, starting at address 1.
Note: The rotary address switches are ignored on the starter module when
using the ArmorPoint backplane.
Note: When using RSNetWorx for DeviceNet with the 284A ArmorStart
Distributed Motor Controllers, DO NOT use the node
commissioning outlined in Chapter 5 of the User Manual.
ATTENTION
!
Three-phase power must be applied to the Bulletin 284
Distributed Motor Controller to gain access to drive
parameters.

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Details on Using the “ArmorStart Ladder Logic Configurator”
The ArmorStart Ladder Logic Configurator is a ladder logic routine (File
Name: ArmorStart_Configurator.ACD) designed so that under program
control, the entire product family of the ArmorStart Distributed Motor
Controllers can be configured easily from a Logix based controller. The
family of ArmorStart Distributed Motor Controllers includes the following
Bulletin Numbers: 280A, 281A, 283A and 284A. The ArmorStart
Distributed Motor Controllers can be networked over ControlNet or
EtherNetIP, when on the appropriate ArmorPoint backplane. The ladder
logic file is designed to be merged into an existing ladder logic file or it can
be used as the basic program and other logic can be added to it. This
document assumes that the reader has an average knowledge of the use of
RSLogix™5000 and Logix based controllers. Device configuration is done
inside the Controller tag editor under the Monitor Tags tab.
Note: The ArmorStart Ladder Logic Configurator (File Name:
ArmorStart_Configurator.ACD) is provided on the CD shipped with
every ArmorStart product with the ArmorPoint Communications
protocol.

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Theory of Operation
It is possible to connect an ArmorStart product to the Point I/O based subnet
of the ArmorPoint I/O system. This allows the ArmorStart to be connected
to EtherNetIP and ControlNet, along with the original DeviceNet. The
easiest way to program these ArmorStarts is to use RSNetWorx for
DeviceNet software, bridging through the appropriate network. This
ladder logic has been developed as an alternate method of configuration.
Once the appropriate device configuration is done to a User Defined
Structure in the ladder logic file, a bit will need to be turned on in the logic
to trigger a system wide read of the system. This system wide read, goes out
and reads certain attributes of every parameter of every ArmorStart in the
system and stores the information into a large data array. The first attribute
is a flag word that tells the ladder logic if the parameter is read only. If the
read only bit is set, then the ladder logic will skip the additional attribute
reads and will go to the next parameter. If the parameter is writable, then the
logic will read the size, min. allowed value, max. allowed value, the
parameter name, help string and the raw data of each parameter. These
attributes are stored in the data array for use later when the configuration is
written to each ArmorStart. The logic requires that a system wide read
function be completed prior to a system wide write function being
requested.
Note: A system wide read function should be done anytime that a new
ArmorStart is added to the system or an ArmorStart is updated with
a more recent version. This assures that the data array in the logic
matches the total system.
Once a system wide read is done, the raw data of the individual parameters
in the data array can be modified and a system wide write function activated
from a bit in the ladder logic. Only parameters that changed will be written
to the ArmorStart devices, and after a write is done the parameter is read
back and stored in the data array for comparison. If the write and reread
value do not match, an Error Report is generated.
If an error occurs for any reason, during a system wide read or write, an
error report will be logged, containing the device and parameter it occurred
on. Also the status and extended status of the message block is logged in
case the error originated there.

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I/O Tree Overview
In order to transfer I/O information, the ArmorStart needs to be added to the
I/O tree of the Logix processor. The details of doing this are outside of the
scope of these instructions, but screen captures of the completed
configuration are included below for reference. The configuration below
shows the EtherNetIP card in the Logix chassis slot 1. The 1738-AENT
module is always located at slot zero in the subnet and the ArmorStart
device is located in slot 2 on the subnet. These slots are circled below for
you reference.
Figure 13 Logix Processor I/O Tree
The only configuration that the user needs to be concerned with for the
ArmorPoint communication adapter is either the EtherNet IP address or the
ControlNet node address.
Since there currently is no profile for an ArmorStart device in the I\O Tree,
the 1738-MODULE profile needs to be used as a generic profile. The
standard configuration for an ArmorStart 284A, using this profile is shown
below.
Figure 14 ArmorStart Configuration using 1738-MODULE Profile