Rockwell Automation ArmorStart Bulletin 280G User manual

USER MANUAL
Bulletin 280G/281G, 284G
ArmorStart® Distributed Motor
Controller

3
Important User Information
Because of the variety of uses for the products described in this publication,
those responsible for the application and use of this control equipment must
satisfy themselves that all necessary steps have been taken to assure that
each application and use meets all performance and safety requirements,
including any applicable laws, regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown in
this guide are intended solely for purposes of example. Since there are many
variables and requirements associated with any particular installation,
Rockwell Automation does not assume responsibility or liability (to include
intellectual property liability) for actual use based upon the examples shown
in this publication.
Rockwell Automation publication SGI-1.1, Safety Guidelines for the
Application, Installation and Maintenance of Solid-State Control (available
from your local Allen-Bradley sales office), describes some important
differences between solid-state equipment and electromechanical devices
that should be taken into consideration when applying products such as
those described in this publication.
Reproduction of the contents of this copyrighted publication, in whole or
part, without written permission of Rockwell Automation, is prohibited.
Throughout this manual we use notes to make you aware of safety
considerations:
Attention statements help you to:
•identify a hazard
•avoid a hazard
•recognize the consequences
Trademark List
ArmorStart and ControlLogix are registered trademarks of Rockwell Automation, Inc.
ArmorConnect, DeviceLogix, PLC, RSNetWorx, RSLogix 5000, and SLC are trademarks of Rockwell Automation,
Inc. DeviceNet and the DeviceNet logo are trademarks of the Open Device Vendors Association (ODVA). ControlNet
is a trademark of ControlNet International, LTD.
ATTENTION
!
Identifies information about practices or circumstances
that can lead to personal injury or death, property damage
or economic loss
IMPORTANT
Identifies information that is critical for successful
application and understanding of the product.

4
European Communities (EC)
Directive Compliance
If this product has the CE mark it is approved for installation within the
European Union and EEA regions. It has been designed and tested to meet
the following directives.
Low Voltage and EMC Directives
This product is tested to meet Council Directive 73/23/EEC Low Voltage
and 89/336/EEC and Council Directive 89/336/EC Electromagnetic
Compatibility (EMC) by applying the following standard(s):
•Bulletin 280/281: EN 60947-4-1 — Low-voltage switchgear and
controlgear — Part 4-1:Contactors and motor-starters —
Electromechanical contactors and motor-starters.
•Bulletin 283: EN 60947-4-2 — Low-voltage switchgear and
controlgear — Part 4-2: AC semiconductor motor controllers and
starters.
•Bulletin 284: EN 61800-3 — Adjustable speed electronic power drive
systems — Part 3: EMC product standard including specific test
methods.
This product is intended for use in an industrial environment.

Table of Contents i
Table of Contents
Chapter 1
Product Overview
Introduction ....................................................................................1-1
Description .....................................................................................1-1
Safety ArmorStart............................................................................1-1
Operation .......................................................................................1-2
Mode of Operation ..........................................................................1-2
Bulletin 280G/281G — Full-Voltage Start ................................1-2
Bulletin 284G — Sensorless Vector Control..............................1-2
Description of Features ..................................................................1-3
Overload Protection .................................................................1-3
LED Status Indication ..............................................................1-5
Fault Diagnostics .....................................................................1-5
Inputs ......................................................................................1-6
Gland Plate Entrance ...............................................................1-6
ArmorStart with DeviceNet Network Capabilities ......................1-6
DeviceLogix™ ........................................................................1-6
Peer to Peer Communications (ZIP) ..........................................1-6
EMI Filter..................................................................................1-6
Dynamic Brake Resistor ...........................................................1-7
Control Brake Contactor ..........................................................1-7
Chapter 2
Installation and Wiring
Receiving .......................................................................................2-1
Unpacking ......................................................................................2-1
Inspecting ......................................................................................2-1
Storing ...........................................................................................2-1
General Precautions .......................................................................2-2
Precautions for Bulletin 280G/281G Applications.............................2-2
Precautions for Bulletin 284G Applications ......................................2-2
Dimensions ....................................................................................2-4
Bulletin 280G/281G..................................................................2-4
Bulletin 284G ...........................................................................2-6
Bulletin 1000............................................................................2-8
Wiring ..........................................................................................2-13
Power, Control, Safety Monitor Inputs, and
Ground Wiring ......................................................................2-13
Terminal Designations ..................................................................2-14
Dimensions for Safety Products.....................................................2-15
Bulletin 280G Safety Product..................................................2-15
Bulletin 281G Safety Product..................................................2-16
Bulletin 284G Safety Product..................................................2-17
Bulletin 1000 Safety Product ..................................................2-19
Safety Terminal Designations .......................................................2-26
ArmorConnect Power Media .........................................................2-29
Description ............................................................................2-29
ArmorStart with ArmorConnect Connectivity ..........................2-30
Terminal Designations............................................................2-30
ArmorStart Safety with ArmorConnect Connectivity ...............2-31
Terminal Designations............................................................2-31
ArmorConnect Cable Ratings .................................................2-31
Branch Circuit Protection Requirements for
ArmorConnect Three-Phase Power Media .............................2-32
Group Motor Installations for USA and Canada Markets ................2-32

ii Table of Contents
Wiring and Workmanship Guidelines ............................................2-32
DeviceNet Network Installation .....................................................2-33
Other DeviceNet System Design Considerations ....................2-34
Electromagnetic Compatibility (EMC) ............................................2-35
General Notes (Bulletin 284G only) ........................................2-35
Grounding .............................................................................2-35
Wiring ...................................................................................2-35
Chapter 3
Bulletin 280G/281G
Programmable Parameters
Introduction ....................................................................................3-1
Parameter Programming .........................................................3-1
Parameter Group Listing .................................................................3-2
DeviceLogix™ Group .....................................................................3-2
DeviceNet Group ............................................................................3-7
Starter Protection Group ...............................................................3-10
User I/O ........................................................................................3-14
Misc. Group .................................................................................3-14
ZIP Parameters ............................................................................3-16
Starter Display .............................................................................3-23
Starter Setup ................................................................................3-24
Chapter 4
Bulletin 284G Programmable Parameters
for Sensorless Vector Controllers Introduction ....................................................................................4-1
Parameter Programming .........................................................4-1
Parameter Group Listing .................................................................4-2
DeviceLogix™ Group .....................................................................4-3
DeviceNet Group ............................................................................4-8
Starter Protection Group ...............................................................4-12
User I/O ........................................................................................4-15
Miscellaneous Group ....................................................................4-16
Drive DeviceNet Group ..................................................................4-18
Display Group................................................................................4-20
Basic Program Group ....................................................................4-25
Advanced Program Group..............................................................4-28
Clear Type 1 Fault and Restart ......................................................4-42
Clear an Overvoltage, Undervoltage, or Heatsink OvrTmp Fault
without Restarting the Drive..........................................................4-42
How Step Logic Works .................................................................4-55
Step Logic Settings .......................................................................4-55
Chapter 5
DeviceNet™ Commissioning
Establishing a DeviceNet Node Address ..........................................5-1
Node Commissioning using Hardware ............................................5-1
Node Commissioning using Software .............................................5-2
Building and Registering an EDS File ..............................................5-3

Table of Contents iii
Using the Node Commissioning Tool Inside RSNetWorx
for DeviceNet ................................................................................. 5-5
System Configuration ................................................................... 5-6
Using Automap feature with default Input and Output (I/O)
Assemblies (Bulletin 280G/281G).................................................... 5-7
Default Input and Output (I/O) Assembly Formats
(Bulletin 280G/281G) ...................................................................... 5-7
Setting the Motor FLA and Overload Trip Class
(Bulletin 280G/281G) ...................................................................... 5-8
Using Automap feature with default Input and Output (I/O)
Assemblies (Bulletin 284G)............................................................. 5-9
Default Input and Output (I/O) Assembly Formats (Bulletin 284G) .... 5-9
Setting the Motor FLA (Bulletin 284G) ........................................... 5-10
193-DCNT Product Overview ........................................................ 5-11
User Manual .......................................................................... 5-11
Bill of Material ....................................................................... 5-11
Accessories ........................................................................... 5-11
Tools Menu............................................................................ 5-12
Node Comissioning................................................................ 5-12
Chapter 6
Explicit Messaging on DeviceNet™
Logic Controller Application Example with Explicit
Messaging ..................................................................................... 6-1
Programming the 1747-SLC .......................................................... 6-2
I/O Mapping ............................................................................ 6-2
Explicit Messaging with SLC .......................................................... 6-3
Setting up the Data File ................................................................. 6-4
Sequence of Events ....................................................................... 6-5
Programming the 1756-ControlLogix ............................................. 6-8
I/O Mapping ............................................................................ 6-8
Explicit Messaging with ControlLogix ............................................. 6-9
Setting Up the MSG Instruction ...................................................... 6-9
Chapter 7
Using DeviceLogix™
DeviceLogix Programming ............................................................. 7-1
DeviceLogix Programming Example ............................................... 7-2
ArmorStart Fault Bit, Status Bit, Outputs and Produced Network Bits in
the DeviceLogix Ladder Editor ....................................................... 7-5
Chapter 8
ArmorStart® ZIP Configuration
Overview ....................................................................................... 8-1
ZIP Parameter Overview ................................................................ 8-1
Data Production ............................................................................. 8-3
Data Consumption ......................................................................... 8-3
Mapping Consumed Data to the DeviceLogix Data Table. ............... 8-3
Finding ZIP bits in Device Logix Editor........................................... 8-12

iv Table of Contents
Chapter 9
Diagnostics
Overview ........................................................................................9-1
Protection Programming ..........................................................9-1
Fault Display ..................................................................................9-1
Clear Fault .....................................................................................9-2
Fault Codes ....................................................................................9-2
Fault Definitions .............................................................................9-3
Short Circuit ............................................................................9-3
Overload Trip ...........................................................................9-3
Phase Loss ..............................................................................9-3
Phase Short..............................................................................9-3
Ground Fault ............................................................................9-3
Stall .........................................................................................9-3
Control Power ..........................................................................9-3
I/O Fault ..................................................................................9-3
Over Temperature ...................................................................9-3
Phase Imbalance .....................................................................9-3
Over Current.............................................................................9-4
DeviceNet™ Power Loss .........................................................9-4
Internal Communication Fault...................................................9-4
DC Bus Fault ............................................................................9-4
EEPROM Fault .........................................................................9-4
Hardware Fault ........................................................................9-4
Restart Retries .........................................................................9-4
Miscellaneous Faults................................................................9-4
Chapter 10
Troubleshooting
Introduction ..................................................................................10-1
Bulletin 280G/281G Troubleshooting .............................................10-2
Bulletin 284G Troubleshooting.......................................................10-5
Fault Definitions .....................................................................10-5
Operation and Troubleshooting of the DB1- Dynamic Brake....10-7
Internal Drive Faults .............................................................10-10
DeviceNet Troubleshooting Procedures ......................................10-14
Control Module Replacement (Bulletin 280G/281G) .....................10-15
Control Module Replacement (Bulletin 284G)...............................10-16
Base Module Replacement (Bulletin 280G/281G).........................10-17
Base Module Replacement (Bulletin 284G) ..................................10-19
Appendix A
Specifications
Bulletin 280G/281G Specifications ..................................................A-1
Bulletin 284G Specifications............................................................A-6
ArmorConnect™ Three-Phase Power Media ................................A-11
Patchcords ............................................................................A-11
Power Tees & Reducer ..........................................................A-12
Power Receptacles ................................................................A-13
Appendix B
Bulletin 280G/281G CIP Information
Electronic Data Sheets ...................................................................B-1
DOL Type Product Codes and Name Strings ...................................B-1
DOL Reversing Type Product Codes and Name String .....................B-2
DeviceNet Objects ..........................................................................B-2

Table of Contents v
Identity Object — CLASS CODE 0x0001 .........................................B-3
Identity Objects ..............................................................................B-3
Message Router — CLASS CODE 0x0002 ......................................B-3
DeviceNet Object — CLASS CODE 0x0003 .....................................B-4
Assembly Object — CLASS CODE 0x0004 .....................................B-5
Custom Parameter Based
“Word-wise” I/O Assemblies ..........................................................B-5
“Word-wise” Bit-Packed Assemblies ..............................................B-6
Standard Distributed Motor Controller I/O Assemblies .....................B-7
Standard Distributed Motor Controller Output
(Consumed) Assemblies ..........................................................B-7
Standard Distributed Motor Controller Input
(Produced) Assemblies ............................................................B-8
Connection Object — CLASS CODE 0x0005 .................................B-10
Discrete Input Point Object — CLASS CODE 0x0008 ...................B-14
Discrete Output Point Object — CLASS CODE 0x0009 ..................B-15
Discrete Output Point Object Special Requirements ......................B-16
DOP Instances 1 and 2 Special Behavior ...............................B-16
Parameter Object — CLASS CODE 0x000F ..................................B-18
Parameter Group Object — CLASS CODE 0x0010 ........................B-19
Discrete Input Group Object — CLASS CODE 0x001D ..................B-20
Discrete Output Group Object — CLASS CODE 0x001E ................B-21
Control Supervisor Object -CLASS CODE 0x0029 ..........................B-22
Acknowledge Handler Object — CLASS CODE 0x002b .................B-23
Overload Object — CLASS CODE 0x002c .....................................B-24
DeviceNet Interface Object -CLASS CODE 0x00B4 ........................B-25
Appendix C
Bulletin 284G CIP Information
Electronic Data Sheets ...................................................................C-1
VFD Type Product Codes and Name Strings ....................................C-1
DeviceNet Objects ..........................................................................C-2
Identity Object — CLASS CODE 0x0001 .........................................C-2
Identity Objects ..............................................................................C-3
Message Router — CLASS CODE 0x0002 ......................................C-3
DeviceNet Object — CLASS CODE 0x0003 .....................................C-4
Assembly Object — CLASS CODE 0x0004 .....................................C-5
Custom Parameter Based
“Word-wise” I/O Assemblies ..........................................................C-6
“Word-wise” Bit-Packed Assemblies ..............................................C-6
Standard Distributed Motor Controller I/O Assemblies .....................C-8
Standard Distributed Motor Controller Output
(Consumed) Assemblies ..........................................................C-8
Standard Distributed Motor Controller Input
(Produced) Assemblies ............................................................C-9
Inverter Type Distributed Motor Controller Input
(Produced) Assemblies ...........................................................C-10
PowerFlex Native Assemblies .................................................C-11
Connection Object — CLASS CODE 0x0005 .................................C-13
Discrete Input Point Object — CLASS CODE 0x0008 ...................C-18
Discrete Output Point Object — CLASS CODE 0x0009 ..................C-19

vi Table of Contents
Discrete Output Point Object Special Requirements ......................C-20
DOP Instances 3 and 4 Special Behavior ...............................C-20
DOP Instances 1, 2, 9, and 10 Special Behavior ....................C-22
Parameter Object — CLASS CODE 0x000F ..................................C-24
Parameter Group Object — CLASS CODE 0x0010 ........................C-25
Discrete Input Group Object — CLASS CODE 0x001D ..................C-26
Discrete Output Group Object — CLASS CODE 0x001E ................C-27
Control Supervisor Object -CLASS CODE 0x0029 ..........................C-28
Acknowledge Handler Object — CLASS CODE 0x002b .................C-29
DeviceNet Interface Object -CLASS CODE 0x00B4 ........................C-30
Appendix D
Group Motor Installations
Application of ArmorStart® Controllers in Group Installation ...........D-1
Appendix E
Accessories
IP67 Dynamic Brake Resistor ..........................................................E-3
Appendix F
Safety I/O Module and TÜV
Requirements
ArmorStart Safety-Related Parts......................................................F-1
ArmorBlock Guard I/O Modules .......................................................F-2
Specifications ..........................................................................F-2
ArmorBlock Guard I/O Recommended Compatible
Cables and Connectors....................................................................F-3
Safety-Related Specifications..........................................................F-6
Maintenance and Internal Part Replacement....................................F-6
Troubleshooting ..............................................................................F-7
Appendix G
Renewal Parts
Renewal Parts.................................................................................G-1
Appendix H
PID Setup
Exclusive Control.............................................................................H-1
Trim Control....................................................................................H-2
PID Reference and Feedback...........................................................H-3
PID Deadband .................................................................................H-3
PID Preload .....................................................................................H-4
PID Limits .......................................................................................H-4
PID Gains ........................................................................................H-4
Guidelines For Adjusting PID Gains..................................................H-5
Appendix I
Step Logic, Basic Logic and Timer/
Counter Functions
Step Logic Using Timed Steps..........................................................I-2
Step Logic Using Basic Logic Functions............................................I-3
Timer Function.................................................................................I-4
Counter Function..............................................................................I-4
Step Logic Parameters .....................................................................I-5