AF-1200 Adjustable Frequency AC Drive Instruction Manual
Contents
1. OF 4 FEF EEE amp e En 48 np e E pp x 8 48 8 4 do amp 11 12 12 16 1 17 15 23 25 26 28 Cutler Hammer reserves the right to discontinue or make modifications to the design ot its products without prior notice and holds no obligation to make modifications to products sold previously Cutier Hammer also holds no liability for losses of any kind which may result from this action Cutler Hammer warrants the AF1200 series AC motor control to be free of defects in material and workmanship for a period of 1 year from the date of sale to ihe user or eighteen from the date of manufacture which ever occurs first Any control component which under normal use becomes defective within the stated warranty time period shall be returned 0 Cutler Hammer freight prepaid for examination Cutler Hammer reserves the right to make the final determination as to the validity of a warranty claim and sole obligation is to repair or replace only components which have been rendered defective due to faulty material or workmanship No warranty claim will be accepted for components which have been2. fr er FREQUENCY CUT MAXIMUM 1 00 360 00 MZ LOAD OUT MAXIMUM 10 200 7 MINIMUM FREQUENOY 0 10 120 00 R 0 50 we MAXIMUM FREQUENCY 0 10 120 00 HZ 6000 HZ 2 IR COMPENSATION 0 0 20 0 0 00 64 STABILITY NORMAL LOW COMP NORMAL 2 HIGH COMP 65 COAST TO STOP ENABLED DISABLED DISABLED 2 66 FORWARD REVERSE FWD ONLY REV ONLY FWD ONLY 2 FWO REV 57 AUTO MANUAL SEL ENABLED DISABLED ENABLED 2 7 RESTART ON FAULT ENABLED DISABLED DISABLED 2 RESTART LIMIT 3 TIMES ninni ir kri ceri Pe RESTART DELAY 1 0 150 0 SEC CA ae rr RESTART DECEL CARIATI 1 0 959 9 SEC 10 0 SEC ser 29 194 105 121 122 LOAD MULTIPLIE AUTO V BOOST MANUAL V BOOST TER VALUE LIM 8 NAME MENU CHOICE DEFAULT PASSWORD SETTING LEVEL RESTART CURRENT LIMIT DC BRAKE DISABLED TIMED CONTINUOUS DO BRAKE LOAD 1 180 6 DC BRAKE ame 1 0 1 SEC 7 SPEED UNITS HZ RPM Aen SPEED MULTIPIER 0 10 10000 LOAD UNITS AMPS LOAD
3. AF12 AF1200 SERIES NPUT VOLTAGE 1 120 6 SPECIAL 4 460 VAC 2 208 230 VAC 5 575 VAG 3 380 VAC 6 346 380 VAC 01 1HP 15 15HP 60 HP 02 2HP 20 20HP 75HP 03 3HP 28 25 HP 100 HP 05 5HP 30 30 HP 125 HP 07 76 40 40HP 10 10HP 50 50 HP T THREE PHASE INPUT ON DRIVE MODEL WHICH USUALLY HAS SINGLE PHASE INPUT ONLY 1 HP CHASSIS NONE OPEN FRAME TYPE 1 VENTED COVER TYPE4 ENCLOSED WATER TIGHT TYPE 2 ENCLOSED DUST TIGHT NON STANDARD SPECIAL MODELS HAVE A THREE DIGIT SUFFIX 1200 SERIES LOW HP CHASSIS AND TYPE 1 ENCLOSED CHASSIS TYPE 1 Frei Y 0 i KE SES z E HE E LE E 8 E 2 d I gud PG S e EL E f OR d ees e Hun HIHI i LALLA gt 2 AAM LAA 78 4 MOUNTING HOLES 25 DIA CENTER CONDUIT HOLE 1 13 DIA OUTER CONDUIT HOLES Tu B DIA BEA 4 63 2 80 HP VOLT CHASSIS TYPE 1 D L M 8 Y 1 230 VAG AF12201A AF12201AB 14 00 10 60 660 7 13 2 50 7 88 1 13 N A AGO VAC AF12401A 12401 5 14 00 10 00 6 60 1 13 2 50 7 88 1 15 N A 575 VAC 12501 AF12501AB 14 00 10 00 6 60 1 13 2 50 7 58 1 13 N A 2 230 VAC AF12202A 12202 8 14 00 10 50 660 143 250 788 113 N A 460 VAC AF12402A AF12402AB 14 00 10
4. RATED HP 575 VAC 1 AF12201_ AF12301_ AF12401 AF12501_ 2 AF12202_ AF12302_ 12402 AF12502_ 3 AF12203 AF12303 AF12403 AF12503 5 AF12205 AF12305 AF12405 AF12505 7 5 AF12207_ AF12307_ AF12407_ AF12507_ 10 AF12210_ AF12310_ AF12410_ AF12510_ 15 AF12215_ AF12315_ AF12415 AF12515_ 20 AF12220 AF12320 AF12420 AF12520 25 AF12225 AF12325 AF12425 AF12525 _ 30 AF12230_ AF12330_ AF12430_ AF12530_ 40 AF12240_ AF12340_ AF12440_ AF12540_ 50 AF12250_ AF12350 AF12450_ 12550 6 AF12260_ AF12360_ AF12460_ AF12560_ 78 12375 AF12475 AF12575_ 108 1 en AF123100_ AF124100_ AF125100_ 1286 n 124125 le of CO GENERAL Js PRODUCT CHANGES WARRANTY RECEIVING CUSTOMER MODIFICATION e 38 2 Fk J KM 9 2 4 FF 8 51 3 5 5 ve 4 5 A F AF1200 SERIES MODEL DESIGNATION CODE DIMENSION DATA DRIVE 65 DESIGN SPECIFICATIONS 0 8 8
5. A 9 8 E 7 4 4 4 a 8 5 3 4 48 4 8 DESCRIPTION OF AC MOTOR OPERATION DRIVE FUNCTION DESCRIPTION VOLTAGE SELECTION INSTALLATION 2 00 0 008 WIRING POWER WIRING e 4 4 E 4 RM a 8 FE 8 E 4 E 4 y 48 4 4 a 38 a AF1200 SERIES POWER WIRING DIAGRAM CONTROL WIRING INITIAL POWER UP OPERATING BY KEYPAD CONTROL DIAGNOSTIC DISPLAY PROGRAMMING 0u PROGRAMMABLE PARAMETER MENU DESCRIPTION OF PARAMETERS OPTIONS sss DYNAMIC BRAKING SERIAL COMMUNICATIONS PORT a mM 81 E wk Ern E 5 4 4 8 8 4 E a 5 a 8 E f
6. BASE 8889899988 360 00 HZ CURVE TYPE LINEAR 1 0 VAR TORQUE 1 3 VAR TORQUE 1 6 VAR TORQUE 0 AT SPEED ABOVE SET SPEED CURRENT LIMIT FOLLOWER RELAY 1 FUNCTION RUN FAULT FAULT LOCKOUT PRESENT NO FUNCTION i i i ii HHL RELAY 2 FUNCTION RUN FAULT FAULT LOCKOUT AT SPEED ABOVE SET SPEED CURRENT LIMIT FOLLOWER PRESENT NO FUNCTION FAULT 30 VALUE LIMIT OR DEFAULT PASSWORD NAM MENU CHOICE SETTING LEVEL 123 RELAY SET SPEED 0 00 120 00 HZ 50 HZ 2 124 TB 14 FUNCTION AT SPEED ABOVE SET SPEED CURRENT LIMIT FOLLOWER RUN FAULT FAULT LOCKOUT NO FUNCTION 2 PRESENT NO FUNCTION 130 DRIVE os HP 2 132 MAINTENANCE TARGET 0 6 HR 0 HR 2 142 CLEA HISTORY ENABLED DISABLED DISABLED 2 lm 144 SOFTWARE VERSION 213 012X 213 012X 2 VT 1 145 SERIAL COMMUNICATIONS PROGRAM CONTROL PROG PROGRAM 2 AND CONTROL DISABLED DETECT MONITOR ONLY 148 SERIAL ME OUT 5 600 SEG 0 2 147 SERIAL ADDRESS 2 148 ENABLE PASSWORDS 2 149 LEVEL 1 PASSWORD 2 i 150 LEVEL 2 PASSWORD a 200 PREVIOUS FAULT THIS PARAMETER iS FOR N A Gg VIEWING ONLY e 31 The current limit setting determines the maximum value of the output current This is usually don
7. 2 OR T3 THIS WILL An input power disconnect switch or contactor MUST be wired in series with terminals L L2 and LS 1 and L2 if input is single phase This may be supplied by Cutler Hammer as an option If one has not been supplied by Cutier Hammer a disconnect means must be wired during installation This disconnect must be used to power down the crive when servicing or when drive is not to be operated for a long period of time but should not be used to start and stop the motor Start and stop the motor with the drive run stop circuit Repetitive cycling of an input contactor mare than once every two minutes may cause severe damage to the drive lf the drive is nameplated for single phase input wire to terminals L1 and L2 If the drive is nameplated for single or three phase input wire to terminals Li and L2 for single phase input or L1 L2 and L3 for three phase input If the drive is namepiated for three phase input wire to terminals Li L2 and 1 3 All three power output wires from terminals T1 T2 and 3 to the motor must be kept tighily bundied and run in a separate conduit away from other wiring Do not install contactors between drive and motor without consulting Cutler Hammer for more information 17 WIRE INPUT VOLTAGE TO Dm 7 BASE DRIVER BOARD 7 TERMINALS LI L2 L3 ON MODELS Ti T7273 GNDL3 Sch LU
8. 36 The RESTART LIMIT determines the number of times the drive will attempt to restart after a Zeien unable to restart fault condition persists within the set number of attempts the drive will display FAULT LOCKOUT and cease attempting to restart The drive wil not attempt to restart in the event of an E stop trip or into a shorted motor without first being reset 73 HESTART DELAY The RESTART DELAY is the time delay in between restart attempts During this time delay the operator screen will be over written with a warning display WARNING START PEND ING This parameter also determines the time period which must pass after a fault before the drive can be reset 75 RESTART DECEL The RESTART DECEL sets rate at which the drive lowers the output frequency during a restari speed search This parameter and the RESTART CURRENT LIMIT are set for a particular system by trial ART CURRENT LIMIT The RESTART CURRENT LIMIT determines the current limit value used during the auto restart on trip sequence Er Pues Pass Ae SE Rete EDI 3 a DC injection braking provides shaft stopping holding torque by supplying low level DC voltage to the motor s stator coils DC braking can provide up to the motor s full rated torque for short periods of time from 10 Hz down to very low speeds This parameter sets the DC braking function to be either DISABLED or operational in a TIMED rode or CONTINU
9. LAC 20 NE GEL This parameter sets the acceleration rate when the speed is commanded from the keypad a potentiometer 4 20 MA 0 5 VDC or 0 10VDC It also determines the acceleration for the preset speeds if the PRESET ACC DEC is DISABLED The NORMAL ACCEL does not have any effect when the speed is commanded by JOG The ability to accelerate a given load at a particular rate will be limited by the output power capabilities of the drive motor combination NOTE All acceleration and deceleration times are based on the time to increase or decrease speed from 0 HZ to the BASE FREQUENCY value 33 These parameters sei each individual acceleration rate when the speed is commanded the corresponding preset speed 1 7 and PRESET ACC DEC is set to ENABLED This parameter sets the acceleration rate for the Jog speed This parameter sets the deceleration rate when the speed is commanded by the Keypad potentiometer 4 20 mA 0 5 VDC 10 VDC or speed presets when PRESET ACC DEC is inthe DISABLED mode Dynamic braking may be needed to provide enough decelerating capacity to slow large inertia loads from higher speeds See OPTIONS DYNAMIC BRAKING Parameters 41 through 44 are used to prevent continued operation at critical speeds Critical Speeds are speeds which cause mechanical resonance usually causing excessive vibration in the driven equipment The SKIP SPEEDS parameters 41 43 and SKIP BANDWIDTH pa
10. 8 00 8 00 8 00 se ern woh Oo cS Cm DI DIA OOO N SOM SOS ow gt DO O00 000 Meo wa VPN NNN NN E gt OOD OOO COOP OOO 222 men CO 8100 MO OC word wend NN BBN BRB DNN Co m DI Y 0 00 0 00 0 00 0 00 0 00 0 00 0 0 0 00 vana Co NNO sins DO GA ARQO MUT DO N NN 2 o A LE fap se sero pere pa peg SILE ae an d 4 MOUNTING HOLES 28 DIA KNOCKOUTS CONDIT HOLES 1 13 DIA EDS4 A 40 50 75 100 125 AF1200 SERIES HIGH HP TYPE 4 AND TYPE 12 ENCLOSED Ww A A 7 AL 78 Wie ete mn 0 5 00 Dio VOLTAGE TYPE4 TYPE 12 VAC AF12220C AF122200 230 VAC 88122250 AF122250 230 VAC AF12425C AF12425D 460 VAC AF12230C 122300 230 VAC 12430 AF124300 460 VAC AF12530C 125300 575 VAC AF12240C AF122400 230 VAG AF12440C AF124400 460 VAC AF125400 AF12540D 575 VAC AF12250C AF122800 230 VAC AF124500 AF12450D 460 VAC AF12550C AF12
11. fo enter ENABLED will clear the fault history log and return the parameter value to DISABLED This parameter displays the version number of the drives s software This information is useful if referring to the factory for programming or trouble snooting assistance Since this value is a view only parameter it s value cannot be changed WARA This parameter used with the serial communications option If the serial communications option is not installed leave this parameter set to the default setting of PROGRAM if the serial communications option is installed see the Serial Communications Software User s Guide for more Information This parameter is used with the serial communications option If the serial communications option is not installed leave this parameter set to the default setting of 8 If the serial communications option is installed see the Serial Communications Software User s Guide for more information This parameter is used with the serial communications option I the serial communications option is not installed leave this parameter set to the default setting of 1 If the serial communications option is installed see the Serial Communications Software User s Guide for more information This parameter seis the programming mode to be password protected when set to the ENABLED mode Password protection is based on a two level System See the PARAMETER MENU for a listing of the pass
12. 38 1 38 1 38 1 38 m 53 ni CO Oo a ARE 11 DIA ARE DIA B EDL1 A 15 20 25 AF1200 SERIES LOW HP TYPE 4 AND TYPE 12 ENCLOSED TYPE 4 aj Ltd 13 d Se d d T ER D 4 MOUNTING HOLES VOLT 230 VAC 460 VAC 575 VAC 230 VAC 460 VAC 575 VAC 230 VAC 575 VAC 230 VAC 460 VAC 575 VAC 230 VAC 460 VAC 575 VAC 230 VAC 460 VAC 575 VAC 230 VAC 575 VAC 460 VAC 575 VAC 575 VAC TYPE 4 AF12201C AF12401C AF12501C AF12202G AF12402C AF12502C AF12203C AF12403C AF12803C AF12205C AF12405C AF12505C AF12207C AF12407C AF12507C AF12210C AF12410C AF12510C AF12215C AF12415C AF12515C AF12420C AF12520C AF12525C 28 DIA TYPE 12 110 10 AF125010 Ar 122020 AF12402D AF12502D AF12203D AF12403D AF125030 AF122050 AF12405D AF12505D AF12207D AF12407D AF 1250706 AF122100 AF124100 8 AF12215D AF12415D AFi2515D AF 124200 AF 12520D AF125250 nah asih OOD BAD ABR BAR ABA mung Dom OOO O00 OOO wants weih wc i NNN PRR DOR WOW Wwe WOM sini minisito age MOT OOO GUA AMK AKN sa ere seria wend meio D 8 00 8 00 8 00 8 00 8 00 5 00
13. 50 6 60 2 50 7 88 1 13 N A 575 VAC AF12502A AF12502AB 14 00 10 50 6 60 1 13 2 50 7 88 1 13 N A 3 230 VAG AF12203A 12203 5 1400 11 00 6 60 1 13 2 50 7 88 1 13 N A 460 VAC AF12408A AF12403AB 14 00 11 00 6 60 1 13 2 50 7 88 1 18 N A 575 VAC AF12503A 12503 5 1400 11 00 6 60 1 13 2 50 7 88 1 13 N A 5 230 VAC 12205 AF12205AB8 16 50 11 25 8 50 13 3 50 7 58 1 13 N A 460 VAC 12405 AF12405AB 1400 11 00 5 60 13 2 50 7 88 1 19 N A 575 VAC AF12505A AF12505AB 14 00 11 00 6 60 13 2 80 7 88 1 13 N A 7 5 230 VAC AP12207A 12207 5 16 50 11 25 8 90 AS 3 50 7 88 1 13 N A 460 VAC AF12407A AFI12407AB 16 50 11 25 8 90 13 3 50 7 88 1 13 N A 575 VAC AF12507A 12507 5 16 50 11 25 8 90 1 3 3 50 1 88 1 13 N A 10 230 VAC 12210 12210 5 2400 13 00 6 90 2 18 3 50 9 75 1 38 1 75 460 VAG AF12410FA AF12410AB 24 00 13 00 8 30 2 15 3 3 9 75 1 38 1 75 575 VAC AF12510FA AF12510AB 24 00 13 00 8 80 2 13 3 50 275 1 38 1 75 15 AF12415FA AF12415AB 24 00 13 00 50 2 13 3 56 9 75 1 38 1 75 AF12515FA AF12515AB 2400 13 00 6 90 2 13 3 50 9 75 138 1 5 EDS1 A MOUNTING HOLES 31 DIA IF LESS THAN OR EQUAL TO 29 25 40 60 75 125 AF1200 SERIES HIGH HP FAN COOLED CHASSIS 37 DIA IF GREATER THAN 29 230 VAC 230 VAC 460 VAC 575 VAC 230 VAC 460 VAC 575 VAC 230 VAC 460 VAC 575 VAC 230 VAC 460 VAC 575 VAC 230 VAC 460 VAC
14. 575VAC 230 VAC 460 VAC 575 VAC 460 VAC 575 VAC 460 VAC 575 VAC 460 VAC AF12215A AF12220A AF12520A AF12225A AF12425A AF12525A AF12230A AF12430A AF12530A AF12240A AF12440A AF12540A AF12250A AF12450A AF12550A AF12260A AF12460A AF 12560A 12475 AF12575A AF124100A AF125100A AF124125A AF12215A8 AF12220AB 48 AF12520AB AF12225AB 8 AF12525AB AF12230AB AF12430AB AF12530AB AF12240AB AF12440AB AF12540AB AF12250AB AF12450AB AF12550AB AF12260AB AF12460AB AF12560AB AF12475AB AF12575AB 1215 78 8 29 00 29 00 21 00 21 00 29 00 29 00 21 00 35 00 29 00 35 00 29 00 35 00 35 00 35 00 47 00 35 00 35 00 35 00 35 00 47 00 47 00 47 00 18 50 18 50 18 50 18 50 18 50 18 50 18 50 19 00 18 50 18 50 19 00 18 50 18 50 18 00 19 00 19 00 20 28 19 00 19 00 19 00 19 00 20 25 20 25 0 25 CHASSIS AND TYPE 1 ENCLOSED TYPE D 10 50 10 50 10 50 10 50 10 50 10 50 10 50 11 75 10 50 10 50 11 75 10 50 1050 11 75 11 75 11 75 13 00 11 75 11 75 11 75 11 75 13 00 13 00 13 00 24 00 24 00 16 00 16 00 24 00 24 00 16 00 30 00 24 00 24 00 30 00 24 00 24 00 30 00 30 00 30 00 40 25 30 00 30 00 30 00 30 00 40 25 40 25 40 25 CENTER CONDUIT HOLES OUTER CONDUIT HOLES 1
15. AF12201A AF12207D 9 AF12321A AF123070 T 5 2401 5 7 NOTE 1 i NOTE 1 AFI2501A AF12507D DO NOT CYLCLE INPUT NOTE 3 TT DISCONNECT POWER MORE THAN SWITCH ON A ICE EVERY TWO 1 REQUIRED MINUTES d FREQUENT CYCLING MAY L H DAMAGE CHARGE CIR CUIT THREE PHASE INPUT VOLTAGE DISCONNECT SWITCH WIRE INPUT VOLTAGE TO REQUIRED FUSE BLOCK TERMINALS Li L2 13 ON MODELS NOTE 2 AF12210A AF12260D AF12310A AF123100D AF12410A AF124125D AF12510A AF128100D A INPUT TERMINAL BLOCK du 4 i ge E U OR INPUT FUSE BLOCK THREE PHASE AC MOTOR NOTES AND NCO epee NG AC POWER Wi RES 2 USE TERMINALS Li AND L2 FOR DRIVES RATED FOR SINGLE PHASE INPUT 3 DO NOT INSTALL CONTACTORS BETWEEN DRIVE AND MOTOR WITHOUT FI RST CONSULTI ING GUTLER HAMMER FOR MORE INFC 6 7 ION OPERATING CONTACTORS BETWEEN DRIVE AND MOTOR MAY RESULT IN SEVERE DAMAGE The AF1200 can be controlled by the keypad or by operators wired to the control terminal strip To run the drive from the keypad wire the control per the instruction in the OPERATING BY KEYPAD CONTROL section Control wiring when run external to the drive MUST be in a separate conduit and away from all input and output power wiring Use twisted wires or shielded cable grounded at drive panei ONLY Terminais marked 2 are the digital circuit common used for the start stop jog fwa rev input se
16. THE DRIVE TO RUN AT THE SPEED DETERMINED BY THE JOG SPEED PARAMETER KEYPAD FUNCTIONS IN LOCAL OPERATING MODE START STOP Note STOP key is always active SPEED CONTROL To change the speed via the keypad press the UP ARROW and DOWN ARROW keys to scroll to the desired speed or input tne desired speed with the numerical keys and press ENTER JOGGING To enter the keypad jog mode press the JOG key while holding down the STOP Key anc then release both keys JOG will appear in the speed reference portion of the display The drive will now jog whenever the JOG button is pressed Press any key other than JOG to exit the jog mode 23 ARD REVERSE To change the direction of rotation press the EV ke then press the ENTER key Note Parameter 66 must be REV for this key to be active AUTO MIAN key and then press ENTER To acti vate a speed refe rence 6 type other than keypad control the corresponding terminal 12E 12F 12G 13A 38 or 5 36 on the control strip must be connected to terminal 2 See the contro wiring section Note Parameter 67 must be set to ENABLE for this key to be active CLEARING MISS KEYED INPUTS Use the CLEAR key to clear errors made while enter ing data VIEWING A FAULT To view the present fault condition press ENTER while in the operat ing mode To view previous faults press Prog Run and then ENTER Previous faults are stored in parameter 200 see the DESCRIPTION OF PARA
17. between 0 360 Hz ACC DEC This parameter is used to ENABLE or DISABLE the individual acceleration and deceleration rates for each of the seven speed presets When disabled the NORMAL ACCEL and NORMAL tral tis ta Impel ri m all ia sn na m ata DECEL control the rate of acceleration and deceleration of ali ins 8 5886 PRESETS 1 7 Speed presets are pre programmed speeds which are activated via contact closures De tween terminal 2 and terminal 13A 13B or 13C The presets can be set to any value between the MINIMUM FREQUENCY and MAXIMUM FREQUENCY The speed presets are activated by the multiplex scheme shown in the following tabie 32 PRESET NUMBER TISA TO 2 CLOSED OPEN cima AAA CLOSED OPEN CLOSED ramarri pp CLOSED CLOSED OPEN CLOSED OPEN CLOSED CLOSED ert a n CLOSED CLOSED CLOSED The JOG SPEED controis the speed whether JOG is called for from the keypad local JOG mode or from a contact between terminais 2 and 120 remote Jog mode The JOG SPEED can be set to any value between the MINIMUM FREQUENCY and the MAXIMUM FREQUEN CY JOG SPEED is usually set to a low value 5 10 HZ For information on activating the JOG function see the OPERATING FROM THE KEYPAD and CONTROL WIRING sections
18. continuous 180 for one minute 0 120 Hz 11 Three phase AC motors are comprised of two major components the stator and the rotor The stator a set of three electrical windings held stationary in the motor housing The rotor is a metal cylinder fixed to the motor drive shaft which rotates within the stator The arrangement oi the stator colis and the presence of three phase AC voltage give rise to a rotating magnetic field which drives the rotor The speed at which the magnetic field rotates is known as the synchronous speed of the motor Synchronous speed is a function of the frequency at which the voltage Is alternating and the number of poles in the stator windings The following equation gives the relation between synchronous speed frequency and the number of poles a Ss 120 f p Where Ss Synchronous speed rpm f frequency Hz number of poles in three phase induction motors the actual shaft speed differs from the synchronous speed as load is applied This difference is known as slip Slip is commonly expressed as a percentage of synchronous speed and common values are about three percent The strength of the magnetic field in the gap between the rotor and stator is proportional to the amplitude of the voltage at a given frequency The output torque capability of the motor is therefore a function of the applied voltage amplitude at a given frequency When operated below base rated spe
19. damaged due to mis handling improper installation unauthorized repair and or alteration of the product operation in excess of design specifications or other misuse or improper maintenance Cutier Hammer makes no warranty that its products are compatible with any other equipment or to any specific application to which they may be applied and shall not be held liable for any other consequential damage or injury arising from the use of its products Inspect all cartons for damage which may have occurred during shipping Carefully unpack equipment and inspect thoroughly for damage or shortage Report any darnage to carrier and or shortages to supplier All major components and connections should be examined for damage and tightness with special attention given to PC boards plugs knobs and switches Cutter Hammer its sales representatives and distributors welcome the opportunity to assist our customers in applying our products Many customizing options are available to aid in this function Cutler Hammer cannot assume responsibility for any modifications not authorized by its engineering department The model number of a AF1200 Series drive gives a full descripition of the basic drive unit see example below Options such as dynamic braking additional door mounted operator controls remote operator stations door interlocked disconnects etc are listed separately AF12505AB 575 VAC 5 HP TYPE 1 ENCLOSURE AF125 05
20. to operate the drive when in the local mode terminal 7 is closed to terminal 2 An LED to the right of the LCD display indicates ihe presence of power to the contral board THE Ar i200 SERIES KEYPAD When the AF 1200 Series is first powered up it will be in the operating mode in standby The display will appear as follows To program the AF1200 Serles drive first access the program mode by pressing the PROG RUN button This will result in either direct entry into the program mode if password proctection is disabied or the ENTER PASSWORD prompt will be displayed if password protection is enabled If the ENTER PASSWORD prompt is displayed see diagram below 26 input the appropriate password and press the ENTER key if an asterisk is showing in the upper right hand corner of the display li is not necessary to input the password before pressing ENTER Upon entering the program mode the first item in the parameter list will be displayed see below To change the displayed parameter scroll inrough the menu using the UP and DOWN keys or move directly to the desired point by keying in a new parameter number with the numerical Keys and then pressing ENTER To change the parameter value press ENTER to move the cursor highlighted character irom the parameter number inthe above example to the parameter value 180 in the value by scrolling to the desired value using the UP and DOWN keys and press
21. 5500 575 VAC AF12260G AF122600 230 VAC AF124606 AF124600 460 VAC AF125600 12580 575 80 VAC AF12475C 460 VAG AF12575C AF12575D 575 VAC AF124100C 1241000 460 VAC 125100 AF125100D 575 VAC AF124125C AF124125D 460 LSA 9 9999950 868 1919 t 8 CENTER CONDUIT HOLE 1 13 DIA OUTER CONDUIT HOLES 5 DIA DRIVES SHIPPED WITH CAPLUGS IN CONDUIT HOLES W 27 00 32 00 27 00 32 00 27 00 27 00 32 00 32 00 32 00 32 00 34 00 32 00 32 00 32 00 32 00 32 00 32 00 32 00 32 00 32 00 D 14 00 16 00 14 00 16 00 14 00 14 00 16 00 16 00 16 00 16 00 16 00 16 00 20 00 16 00 16 00 20 00 20 00 20 00 20 00 20 00 2 50 3 00 2 50 3 00 2 50 2 50 3 00 3 00 3 00 3 00 3 00 3 00 4 50 3 00 3 00 4 50 4 50 4 50 4 50 4 50 1 38 1 75 1 38 1 75 1 38 1 38 1 75 1 75 1 75 2 00 1 75 1 75 2 00 2 00 2 00 2 00 2 00 EDL4 A AF12230 AF12240 AF12250 er ma 41 AF12302 AFT 230 ER 12205 E 12310 2315 AF12328 AF12325 AF12330 AF12375 AF123100_ pr OUTPUT 460 VAC 86 HZ 0 460 VA
22. 80 208 VAC or 230 VAC operation can be Operation of ihe Sp on 230 VAC input while the drive is set for 208 VAC amace the Contro Tra nsiorn ier Driver 415 VOLT INPUT ON AF12300 SERIES DRIVES AF12300 DRIVES 380 VAC MODELS Model AF12300 is normally snipped set to operate on 380 VAC Models AF12301 AF12307 can be operated on 415 VAC by moving piug PL3 on the driver board to the 415 V position For operation on 380 VAC plug PL3 MUST be in the 380 V position On models AF 12310 AF 123100 380 VAC or 415 VAC operation can be set with switch 8 91 on the Line Voltage Board Moving this switch selects the proper primary winding in the Contro Transformer Operation of the drive on 4 3 ta G input while ine drive is set for 380 VAC input will damag All models of the AF1200 drive should be mounted on a smooth vertical surface canabie of safely supporting the unit without vibrating The LCD display has an optimum field of view this should be considered when determining the mounting position Chassis models must be installed in an electrical enclosure which will provide complete mechanical protection and maintain uniform internal temperature below 55 C Drives MUST be mounted in a vertical position for proper heatsink cooling Maintain a minimum of three to four inches above and below the drive and a minimum of two inches on either side of of Units rated below 20 HP Maintain a minimum of six to eight inches above an
23. C PHASE KVA AF12407_ AF12410_ R AF12415 15 2420 20 AF12425 AFI2460_ AF12475_ AF124100 AF124125 90771 ero KA i a i dnp a 125005 QUTPUT 6 575 VAC AF12502_ Per ni he AF12503_ o w AF12507 _ mm 12510 hi AP12515_ AF12520_ rpm eeh d AF12525 AF12520_ AP1254 0 AF12550_ reer ae eee rr rpg anal h i NW AF12575 0 5 Storage Temperature Ambient Operating Temp Models Ambient Maximum Altitude Inout voltage Tolerance Reference Voltage Control Voltage Wave Form Output Signals Proportional to frequency Proportional to 1080 Frequency Stability Service Factor Overicad Capacity Output 7 20 to 70 C Chassis 0 55 C Type 1 Enclosed 0 50 C Type 4 and 12 Enclosed 0 40 C Less than 93 non condensing 3300 feet above sea level 12 0 5 VDC 0 10 VDC 4 20 mADC fisolated common to control voltage 20 VDC isolated common to reference voltage Sine Coded Pulse Width Modulated 4 20 mA 0 5 10 VDC 12 VDC pulse train 0 1 mA 0 00006 C 1 15 115
24. Dy calling for a stop lf restart is ENABLED and the drive ti ips the drive will attempt to restart after a 6 delay set by RESTART DELAY if the drive is unable to restart ihe drive will attempt additional restarts each after a time delay The number of attempted restarts is determined by the RESTART LIMIT The RESTART ON TRIP function is designed 16 restart into a coasting motor by conducting a speed search to catch the motor while it is stili spinning and then accelerate to the commanded speed The speed search is conducted by first restarting the drive at MAXIMUM FREQUENCY ai a educed voltage The voltage is then increased and the motor current rises to a high leve causing the drive to go into current limit based on the RESTART CURRENT LIMIT setting The motor current rises to a high level the current limit level because of the differential between the output frequency of the drive and the speed at which the moior is coasting The drive output frequency then decelerates at the RESTART DECEL rate until the motor current drops below the current limit level this occurs when the drive output frequency is matched to the motor speed Once output frequency and motor speed are matched the drive output frequency is accelerated returning the motor to the commanded speed NOTE The drive output frequency will ramp up from zero in the event of restart after a power outage no speed search will be conducted If this parameter 70 AUTO START is enabled
25. METERS section THE AF1200 DISPLAY IN THE OPERATING MODE RUN COMMANDED STATUS SPEED LOAD LOAD DIRECTION LOCAL OR REFERENCE UNITS REMOTE 24 The diagnostic dispiay is an eight segment LED located to the left of the keypad on the AF1200 Series control board This LED acts as a complement to the 2X20 LCD screen on the keypad to indicate the status of the drive by displaying one of the symbols in the table below Fault trip conditions are also displayed on the LCD keypad display and stored under PREVIOUS FAULTS parameter 200 ae ROTATING O RUN MODE A ee eR HA a oe FE ee bt ch 2 OUTPUT AMBIENT HIGH TEMPERATURE TRIP 75 DRIVE OPERATING IN CURRENT LIMIT nn Croci SOLI L PL a CURRENT OUTPUT FAULT TRIP HIGH VOLTAGE TRIP LOW VOLTAGE TRIP PROTECT MOTOR OVERLOAD PROTECTION TRIP OVER RIDE OPERATING IN DECEL OVER DE MODE ERROR START AROR START CLOSED AT POWER UP stor EMERGENCY STOP TRIP CIRCUIT OPEN TERM 22 LOGIC ERROR LOGIC RESET ERROR 0 25 The AF1200 is programmed by using the keypad to enter the program parameter list menu and change parameter values The keypad is also used
26. OUS mode inthe TIMED mode DC braking energizes either when the output frequency reaches the DC BRAKE SPEED COAST TO STOP 65 is DISABLED or immediately when a stop command is given COAST TO STOP 65 is ENABLED and remains energized until a time period equal to the DC BRAKE TIME elapses in the CONTIUOUS mode DC braking energizes either when the output frequency reaches the DC BRAKE SPEED COAST TO STOP 65 is DISABLED or imediately when a stop command is given COAST TO STOP 65 is ENABLED and remains energized until a start command is given 37 This parameter sets the magnitude of the current applie ed to the motor by the DC braking circuit This parameter is based on the drive s name plate current rating DC BRAKE LOAD should be set to the lowest possible value which gives satisfactory operation in order to minimize motor heating TIME should be set to the lowest value which gives sati isfactory operati on in order to minimize motor heating SPEED UNITS sets the units of the output speed indication on the keypad display 91 SPEED MULTIPLIER The SPEED MULTIPLIER is a calibration constant for the output speed indication on the keypad display The speed multiplier is the constant which when multiplied by the frequency in Hertz will give tne desired displayed value LOAD UNITS sets the units of the output load indication on the keypad display The LOAD MULTIPLIER is a calibration const
27. REQUENCY AUTO V BOOST supercedes the V HZ setting determined by the BASE FREQUENCY and VHZ CURVE TYPE to increase output voltage during acceleration In order to boost motor torque the output voltage is increased in the amount of the AUTO V BOOST setting whenever the drive is accelerating AUTO V BOOST is usually used in applications with high inertia loads where quick accelerations are desired 105 BOOST The MANUAL V BOOST supercedes the V HZ setting determined by the BASE FREQUENCY and V FIZ CURVE TYPE and maintains a minimum voltage at lower frequency leveis MANUAL BOOST 15 used in applications which require high starting torque 6 9 conveyors lifts and other loads which have high static friction or high inertia RELAY 1 FUNCTION RELA Y 2 FUNCTION There are two auxilary relays which can be programmed for a variety of funciions RUN FAULT FAULT LOCKOUT AT SPEED and ABOVE SET SPEED CURRENT LIMIT FOL LOWER PRESENT NO FUNCTION Each relay has a set of FORM 0 contacts rated 2 amps 5 amps resistive ai 28 VDC or 120 VAG Control wiring diagrams show relays in the rest colis NOT energized state 123 gt REL T SPEED This value is the speed setting at which an auxiliary set for the ABOVE SET SPEED function will change states The relay will energize as the output frequency rises to the RELAY SET SPEED value and de energize as the output frequency falls below the RELAY SET SPEED Value T
28. aining the drive and a protective ventilated cover for the resisior assembly Resistor banks and covers are usually shipped loose when ordered with a drive but can be factory mounted by Cutier riammer to the top of NEMA 12 enclosures upon request Ventilated resistor bank covers are NEMA 1 rated and sulted for use only In clean dry environments When used in severe environments HDB resistor banks must be enclosed in an appropriate electrical enclosure Circuit boards are mounted to the drive panel with two 8 32x3 8 thread forming chip ires screws and the resistor assembly and ventilated cover are mounted using 10 32x3 8 thread forming chip free screws lockwashers and nuts When field mounting the heavy duty dynamic brake option note the accompanying installation and wiring instructions Continuous braking hold back of 100 of motor rated torque at output frequencies up to 15 Hz 25 of motor base speed 50 at output frequencies up to 30 Hz 50 of motor base speed and 25 at output frequencies up to 60 Hz 100 of motor base speed is possibie Intermittent once per minute braking hold back at 180 of motor rated torque is possible for thirty seconds at output frequencies up to 15 Hz 25 of motor base speed fifteen seconds ai output frequencies up to 30 Hz 50 of motor base speed and seven seconds at output frequencies up to 80 Hz 100 of motor base speed Heavy duty dynamic braking 15 not recommended for continuous cycl
29. ant for the output load indication on the keypad display Setting this value to 1 while the LOAD UNITS are set to LOAD configures the 1080 indication to be a load percentage meter this is the factory default Setting the LOAD UNITS to AMPS and the LOAD MULTIPLIER to the nameplate amp rating of the drive configures the oad indicator as an ammeter The BASE FREQUENCY is the frequency at which the drive output reaches full voitage ror most applications the base frequency should be set to the motor s rated frequency When the drive is set for constant torque output V HZ CURVE TYPE set to LINEAR 1 0 the BASE FREQUENCY is the determinent of the volts to heriz ratio For example if the drive is rated for 460 VAC and the BASE FREQUENCY is set to 60 HZ the drive will maintain a constant of ratio 7 66 V HZ except when AUTO V BOOST or MANUAL V BOOST supercede 191 This parameter is used to change the relationship between the output voltage and frequency Choices are LINEAR 0 VARS TORQUE 1 3 38 LINEAR 1 0 gives a linear relationship between voltage and frequency V FIZ is a constant yielding constant motor torque capability The three VARIABLE TORQUE values 1 3 1 6 2 0 are used to gain optimum energy savings and reduce accousticai noise in variable torque applications such as pumps and fans An infinite array of V HZ patterns are available by adjusting the BASE FREQUENCY V HZ CURVE TYPE MINIMUM FREQUENCY and MAXI MUM F
30. d 120 are use to select direction of motor rotation in the remote mode Terminal 128 must be closed to terminal 2 to select forward or terminal 12C must be closed to terminai 2 to select reverse in order for the drive to start when in the remote mode JOG Closing the remote jog circuit terminal 2 to terminai 12D will cause the drive to enter the remote jog mode When jogging the drive will start if not already in the run mode ramp to the jog speed at the jog accel or decel rate and run at the jog speed until ine jog cicuit is SPEED REFERENCE SELECTION A speed reference is selected by closing one of the terminals 12E through 13C to terminal 2 Closing terminal 12E to 2 activates a pot wired to terminals 2A 5A and 6 Closing terminal 12 to 2 activates a 4 20 mA speed reference wired to terminals 2 and SB Closing terminal 12G to 2 activates a 0 5 VDC or 0 10 VDC speed reference wired to terminals 2 and SC or SD Closing different combinations of terminals 13 138 and or 13C to terminal 2 will activate one of the seven speed presets See PARAMETERS 11 17 PRESET SPEEDS in the DESCRIPTIONS OF PARAMETERS section 20 JCA YE UNdLNO 86123550 0 ET Ta 51 4 3 3 13 612365 AP e T 124 12323 1 6 ONILVOIGNI VA LO Aficdino ONILYOIGNI 03225 VIN G 1118 1860 DNILVOIGNI 03365 038 7014 JGA T Ind
31. d below the arive and a minimum of four inches on either side of of units rated above 20 HP Fans or blowers should be used to insure proper cooling in tight quarters Do not mount drives above other drives or heat producing equipment Upper limits of the ambient operating temperature for each of the enclosure types are as follows Chassis models A or FA style 55 G 130 F Ventilated Type 1 models AB and FAB style 50 C 122 F Type 4 and Type 12 models C and D style 40 C 104 PF If it is necessary to delli or cut the drive enclosure or pane extreme care must be taken to avoid damaging drive components or contaminating the drive with metal fragments which cause shorting of electrical circuits Cover drive components with a clean cloth to keep out metal chips and other debris Use a vacuum cleaner to clean drive components after drilling even H chips do not appear to be present Do not aiternpt to use positive air pressure to biow chips out of drive since this will lodge debris under electronic components Contaminating the drive with metai chips will void the warranty Note drive input and output current ratings and check applicable electrical codes for required wire type and size grounding requirements over current protection and incoming power disconnect before wiring the AF1200 drive Input and output wire should have insulation rated to a minimum of 105 221 F Size conservatively to minimize the voltage drop
32. de when operated above base speed where drive output voltage is limited by the input line voltage This operating range 15 known 85 the constant horsepower range The typical maximum range for constant horsepower is about 2 3 to 1 60 to 140 Hz The diagram below depicts the operating characteristics of a typical AC Induction motor WARNING Consult motor mautacturer before operating above base speed AC MOTOR OPERATING RANGES 100 CONSTANT TORQUE RANGE KNEE TORQUE BELOW KNEE ABOVE THIS POINT OUTPUT CAPABILITY VOLTAGE REMAINS CONSTANT 7 7 I CONSTANT HORSEPOWER RANGE OUTPUT VOLTAGE INCREASING WITH 1 1 100 FREQUENCY DRIVE FUNCTION DESCRIPTION The AF1200 is a 16 bit microprocessor based keypad programmabie variable speed AC motor drive The AF1200 has four major sections an input diode bridge and filter a driver board a control board and an output transistor bridge DRIVE OPERATION incoming AC line voltage is converted to a pulsating DC voltage by the input diode briage The DC voltage is supplied to the BUS filter capacitors through a charge circuit which limits inrush current to the capacitors during power up and discharges the capacitors alter power is removed The pulsating DC voltage is filtered by tne BUS capacitors which reduces tne ripple level The filtered DC voltage enters t
33. e 16 limit motor torque capability For most applications the current limit is maintained at the maximum setting a THEI as an inverse squared t function This circuit emulates the function of a mechanical thermal overload relay commonly refered to as heaters Set the THERMAL OVERLOAD to a value which is equai to the ratio of the motor amp rating to the drive amp rating X 150 This will restult in a trip at 150 of motor rating in one minute and allow for continuous operation ai a 1 15 service factor SLIP COMPENSATION is used to compensate for changes in motor speed slip which occur due to changes in load in a standard AC induction motor as the load on the motor increases the motor current increases and the motor shaft spsed decreases By increasing the output frequency in response to the increased motor current the reduction in the motor speed due to increased load is greatly reduced Speed regulation with no load to full load fluctuations of less than 1 of base speed are attainable in most applications SLIP COMPENSATION is often set to 3 since that is the standard slip rating of most motors D 20M A OV These two parameters determine the gain in the 4 20 MA or 20 4 MA and 0 10 VDC for 100 VDC follower circuit The follower circuit is set to be either proportional 4 20 or inversely proportional 20 4 depending on which value is larger The speed follower extremes can be set to any value at or
34. e and against continuous ex cessive output current Activation of any of these circults will cause the drive to shut down in a protection trip OUTPUT SIGNALS The AF 4200 has terminals for three output signals which are proportional to output frequen cy a 4 20 mA signal between terminals 2 and 10D a 0 5 VDC signal between terminals 2 and 108 and a 12 VDC pulse train at 6 times the output frequency between terminals 2 and 10G A 0 1 mA output signal which is proportional to motor current is available between terminais 2 and 11 for icad indication AURZILLARY RELAY CONTACTS The AF1200 series contro board has two sets of FORM contacts at terminals 16 through 21 Contacts are rated 2 amps at 28 VDC or 120 VAC Each set of contacts can be programmed for several different functions see the DESCRIPTION OF PARAMETERS section 144 The AF12200 Series can operate on input voltages of 230 VAC 12 or 208 VAC 12 and the AF12300 Series can operate on input voltages of 380 VAC 12 or 415 VAG 12 by setting the control transformer for the proper voltage 208 VOLT INPUT ON 12200 SERIES DRIVES AF12200 DRI VES 250 VAG MODELS Model AF12200 is normally shipped set to operate on 230 VAC Models AF12201 AF12207 can be operated on 208 VAC oy moving plug PL3 on tne driver board to the 208 V position For operation on 230 VAC plug PL3 MUST be in the 230 V position On models AF 12216 1 22
35. ed AC motors are commonly run in a mode known as constant torque Constant torque output is obtained by maintaining a constant ratio between voltage 60 and 575 volt motors common values for this volts to heriz ratio are 3 83 7 66 and 9 58 respectively Operating with these values of the volts to hertz ratio generally yields optimum torque capability Operating at lower ratio values lowers torque and power capability Operating at higher ratio values wil cause the motor to over heat Most standard motors are capable of providing full torque output from 3 to 60 hertz However at lower speeds where motor cooling fans become less effective supplemental cooling may be needed to operate at full torque output continuously A typical motor derating curve is depicted below amplitude volts and frequency hertz For 60 hertz lf the motor s applied frequency is increased while voltage remains constant its torque capability will decrease as speed increases This will cause horsepower capability of the TYPICAL DERATING CURVE FOR CONTINUOUS LOW SPEED 200 A iai is ebe He n Amaia 150 INTERMITENT REQUIRED OPERATION TORQUE 100 CONTINUOUS 50 OPERATION CONTINUOUS TORQUE 50 100 PERCENTAGE OF MOTOR BASE SPEED 12 motor to remain approximately constant Motors are commonly run in this mo
36. he inverter section of the drive composed of six output transistors which make up the three output legs of the drive Each leg nas one transistor connected to the positive voltage and one connected to the negative voltage Alternately switching on each leg transistor produces an alternating voltage on each of the corresponding motor windings By switching each output transistor at a very high frequency known as the carrier frequency for varying time intervals the inverter is able to produce a smooth three phase sinusoidal current wave which optimizes motor performance CIRCUIT DESCRIPTION The control section of the AF1200 Series consists of a control board with a 16 bit microprocessor and keypad interface board with an 8 bit microprocessor Drive programing is accomplished via the kepad or an optional serial communications port During operation the drive can be controlled via the keypad by control devices wired to the contro terminal strip or by the optional serial communications port The Base Driver Board of the AF 1200 incorporates six amplifiers and protection circuits which supply power to the six output BUS filter capacitors an isolated motor current feedback circuit a voltage feedback circuit and a fault signal circuit The AF 1200 has many built in protection circuits These include phase to phase and phase to ground short circuit protection high and tow line voltage 13 protection protection against excessive ambient temperatur
37. his parameter determines the function of an open collector output This circuit is used when an additional status indicating relay is needed The following functions ae available RUN PAULT FAULT LOCKOUT AT SPEED and ABOVE SET SPEED CURRENT LIMIT FOL LOWER PRESENT NO FUNCTION Consult the factory before attempting to utilize this circuit 130 DRIVE KO This parameter is used to scale the kilowatt hour meter display Enter the horsepower rating of the drive not the motor horsepower as it appears on the drive data plate The kilowatt hour display is accessed by pressing ENTER while in the run mode The kilowatt nour display is disabled if the drive horsepower parameter value is set to 0 0 3g This parameter sets the time pericd in hours for the maintenance target alarm The maintenance target alarm alerts the operator that a given amount of accumulated run time has passed This can be used to indicate the need for maintenance on the driven equioment After the time period set by this parameter has elapsed a message displayed indicating that the maintenance target has been reached The message can be cleared oy pressing any key on the keypad but will be re displayed each hour until a new maintenance target is set 142 CLE This parameter is used to clear the fault history log which is stored in parameter 200 To clear ine list of ten previous faults set this parameter to ENABLED Pressing the ENTER key
38. ing applications which require stopping inertial loads greater than twice that of the motor from 1800 rom more than eight times from 2500 rom more than four times or from 3500 rom more than two times during a one minute period Consult Cutier Hammer if assistance is needed when selecting or sizing a dynamic brake option Please have available information concerning the number of stops per minute required stopping time motor operating speed inertia of the driven load and the motor frame size See manual supplement 43 Eaton Yale Ltd Westinghouse amp Cutier Hammer Products 3228 South Service Road P O Box 5040 Station A Burlington Ontario L7R 3Y8 905 333 6442 Pub No 94 001
39. ing the ENTER Key Numeric parameter values may also be changed by keying in the desired value via the numerical keys and then pressing ENTER See the PARAMETER MENU and PARAMETER DESCRIPTION sections for more information on programming 27 DEFAULT PASSWORD SETTING LEVEL VALUE LIMIT OR CURRENT LIMIT THERMAL OVERLOAD SLIP COMPENSATION SPEED 4 MA VDC m yr P P SPEED 20 MA 10 VDC pe PRESET ACC DEC ENABLED DISABLED SPEED PRESETS 1 7 0 50 120 00 HZ JOG SPEED 0 50 120 00 HZ 30 0 SEC NORMAL ACCEL 0 1 3600 0 SEC PRESET 1 7 ACCEL 0 1 36000 SEC 30 0 SEC JOG ACCEL 30 0 SEC NORMAL DECEL 0 1 3600 0 SEC BARA TT imi PRESET 1 7 DECEL 0 1 3600 0 SEC 38 JOG DECEL 0 1 3600 0 SEC 41 SKIP SPEED 1 0 00 120 00 HZ SKIP SPEED 2 0 00 120 00 HZ 0 00 He 2 pp ALTER 0 00 120 00 7 0 00 HZ 2 28 SKIP SPEED 3 PASSWORD LEVEL DEFAULT SETTING VALUE LIMIT OR MENU CHOICE eee 0 00 10 00 HZ FREQUENCY OUTPUT TYPE 0 10 0 20 MA 0 10 0 20 MA 2 2 10 4 20 MA
40. io ONILYSIGNI 03348 230 SO 238 033098 SGA 9 0 40 54 CEES VV 33 li Before attempting to operate drive motor and driven equipment be sure all procedures pertaining to installation and wiring have been properly followed Before powering up the Grive for the first time wire the drive for operation via the keypad see OPERATING BY KEYPAD CONTROL then follow the procedures below Disconnect the driven load from the motor Verify that the drive input terminals L1 L2 and L3 L1 and L2 for single phase input are wired to the proper input voltage per the nameplate rating of the drive For AF12200 and AF12300 series drives verify the control transformer voltage has been properly selected as noted in the VOLTAGE SELECTION section Energize the incoming power line The LCD display should light and indicate the standby mode ifthe display does not appear remove the incoming power wait three minutes check to be sure the bus capacitors have discharged and verify correct installation of wiring I wiring is correct re apply incoming power note display for drive status Next follow the procedures in the PROGRAMMING section to properly configure the parameter values Power down the drive and wait for the bus capacitors to discharge then wire the proper correct voltage leads of the motor to T1 T2 and T3 Press start Ifthe motor rotates in the wrong d
41. ional to output frequency speed and current load These signals can be used to Interface with other equipment or to operate speed and load meters Three signals proportional to frequency are available A 4 20 mA DC current signal between terminais 10D and 2A capable of sourcing 9 VDC 1 mA a 0 10 VDC voltage signal between terminals 108 and 2A capable of sourcing 5 mA 10 VDC and a frequency output 50 duty cycle pulse train between terminals 107 and 2 2 VDC open circuit 2200 ohm source impedance The frequency is six times the drive output frequency Note The output type must be selected in the case of the analog outputs see the PARAMETER DESCRIPTION section 0 1 mA DC current signal between terminais 11 and 2A is proportional to output current and can be used to indicate the motor load This signal is capable of sourcing up to 10 VDC G 1 MA AUXILLIARY OUTPUT CONTACTS The AF1200 control board has two auxilllary relays with form C contacts which can be used to indicate several different drive functions see the PARAMETER DESCRIPTION section The terminais for relay number one are 16 17 and 18 The terminals for relay number two are 19 20 and 21 Terminals 17 and 20 are the respective commons Contacts between 16 and 17 and 19 and 20 are normally open N O Contacts between 17 and 18 and 20 and 21 are normally closed N C Contacts are rated 2 amps at 28 VDC or 120 VAC FORWARD REVERSE Terminals 125 an
42. irection remove the incoming power wait three minutes check to be sure the bus capacitors have discharged and swap motor wires connected to Tiand T2 Rewire control wiring per directions in the CONTROL WIRING section H required 22 CONTROL The 1200 Series drive can be operated by the keypad local mode by control devices wired to the contro terminal strip remote mode or by a combination of the two For simplicity E is recommended that units be run in the keypad control mode during initial start up For information on wiring remote operators see the CONTROL WIRING section and the DESCRI PTION OF PROGRAMMABLE PARAMETERS sections SETTING UP FOR CONTROL BY THE KEYPAD To operate by keypad control first wire the AF1200 Series drive per the diagram depicted below WIRING THE AF1200 FOR BASIC KEYPAD CONTROL 1 2 to 1 de activates remote start stop 2 2 to 7 to activates local keypad mode 3 2 to 22 to de activates E stop 2 6 5 50 6 7 08100100 i 1112 22 27 4 paang EE 1718119120 21 22 L 51952 L dA LLJ T Note To Run in the remote mode in addition to opening terminals 2 to 7 several terminal closures must be made A direction must be selected by closing 125 or 126 to 2 A speed reference type must be selected by closing 12E 12F 12G 13A 13B or 130 to terminai 2 Terminai 120 JOG activates the jog function THIS CIRCUIT OVERRIDES THE START STOP FUNCTION AND CAUSES
43. lect locai remote and E stop functions Terminal 2A is the circuit common for analog speed reference inputs and analog speed and load indicating outputs H necessary terminal 2 and ZA may both be connected to ground RUN COMMAND Start stop control of the AF 1200 Series can be accomplished by either a two wire or a three wire circuit For two wire control terminal 2 is connected to terminai 12A ana the run contact is wired to terminals 1 and 2 For three wire control a normally closed switch is wired to terminals 1 and 2 stop signal and a normaily open switch is wired to terminals 2 and 12 start signal SPEED REFERENCE SIGNAL The AF 1200 allows for four speed reference signal types a speed potentiometer 0 5 volt 4 20 mA 0 5 VDC or 0 10 VDC signals For control by a speed pot the wiper lead is connected to terminal 5A and the high and low end leads are connected to terminals 6 and 2A respectively For 4 20 mA control wire the positive to terminal 5B and the negative to terminal 2A For 0 5 VDC contro or 0 10 VDC control wire the positive to terminal 5C or 5D respectively and the negative to terminal 2A The input impedance of the speed control potentiometer and 0 5VDC inputs is 100 K ohms the 0 10 VDC input is 200 K chms and the 4 20 mA input is 100 onms 0 4 to 2 0 VDC Terminal 2A is circuit common and the minus connection OUTPUT FREQUENCY AND LOAD SIGNALS The AF1209 is equipped with output signals that are proport
44. lly 396 of full speed This means a standard motor will not produce full rated torque below 2 Hz Note units are always in HERTZ The minimum frequency range is 6 Hz up to the MAXIMUM FREQUENCY The Maximum frequency deterrnines the highest output frequency in Hertz at which tne the drive will operate continuously IR COMPENSATION is used to compensate for decreased torque capability cue to the increasing effects resistance in the motor windings as current increases As tne motor load and therefore current increases the drive will Increase the output voltage to the motor to increase the torque capability The STABILITY adjustment alters the drive output to compensate for differences in motor inductance capacitance and impedance Certain motors may operate erratically under lightly loaded conditions lf motor operation is erratic at low load levels adjusting the STABILITY setting to LOW COMP or HIGH COMP may give smoother operation This parameter sets the drive to either coast to a stop or ramp to a stop When the COAST TO STOP is in the ENABLED mode and a stop command 5 given the motor will benave as though the drive was instantaneously disconnected When the COAST TO STOP is in the DISABLED mode and a stop command is given the drive output frequency will ramp down at a rate determined by the prevailing decel rate Note Dynamic braking may be needed to provide enough decelerating capacity to slow large inertia loads fr
45. om higher speeds See OPTIONS DYNAMIC BRAKING This parameter is used to the set motor direction and or the function of the FWD REV key on the keypad it only has effect when the drive is in the local LOC mode The parameter can bs set to one of three values FW PV ONLY disable the FWD REV key and sot the motor di rection to forward or only reverse FWD REV enables the FWD REV key allowing the motor direction to be changed from tne keypad When FWD REV is selected and the FWD REV key is depressed to change the motor direction the frequency will ramp down to zero speed at the decel rate and then ramp up to the set speed at the accel rate 87 AUTO MANUAL SELECT This parameter is used to ENABLE or DISABLE the AUTO MAN key on the keypad When the AUTO MAN key is disabled the drive s speed reference will default to a speed reference activated by the terminal strip if no other speed reference is activated on the terminal strip the speed reference will default to the keypad This parameter is used to automatically start the drive upon application input power The drive must be wired for two wire start stop control win a maintained start contact which is in the closed position NOTE The drive output requency will E Up from zero no speed search will be conducted ONNELI This parameter sets the drive to either restart after a fault or to remain tripped until it is reset
46. rameter 44 are used to define up to three speed ranges which correspond to critical speeds speed avoidance ranges The SKIP SPEEDS are the mid points of each of the speed avoidance ranges The SKIP BANDWITH is the width of the speed avoidance ranges the commanded speed lies within the speed avoidance range the drive output speed will not enter the range I the commanded speed lies on the opposite side of the speed avoidance range the output frequency will ramp to the value of the commanded frequency This parameter selects the analog speed indicating output signals at terminals 108 and 10D to be either 0 10VDC on terminal 108 and 0 20 mA on terminal 10D or 2 10VDC on terminal 105 and 4 20 mA on terminal 10D This parameter scales the the analog speed indicating output signals at terminals 105 and 10D Set the parameter value to the drive output frequency which is to correspond to maximum output level of the speed indicating signal 10VDC or 20 mA 34 This parameter scales the the analog load indicating output signal at terminal 11 Set the parameter value to the drive output current which is to correspond to the maximum output level of the load Indicating signal 1 mA The Minimum frequency determines the lowest output frequency in Hertz at which the the drive will operate continuously Note that the lowest speed at which a standard AC induction motor can produce torque is limited by the slip range usua
47. ture available when the parameter memory is not activated asterisk not showing in the when the ENTER PASSWORD is displayed 42 STANDARD DUTY DYNAMIC BRAKING The standard duty dynamic braking option consisis of a circuit board only braking resistors are board mounted on one through three horsepower models and a circuit board and separate resistor assembiy on five through one hundred and twenty five horsepower models Circuit boards are mounted to the drive panel with two 8 32x3 8 thread forming chip free screws and the resistor assembly when required is mounted to the inside of the enclosure using 10 32x3 8 thread forming chip free screws lockwashers and nuts When field mounting the standard dynamic brake option note the accompanying installation and wiring instructions Standard duty dynamic brakes are not recommended for continuous cycling applications which require stopping inertial loads greater than twice that of the motor from 1800rpm more than eight times from 2500 rpm more than four times or from 3600 rpm more than two times during a five minute period HEAVY DUTY DYNAMIC BRAKING The neavy duty dynamic braking option is capable of providing more frequent stopping and stopping higher inertia loads than the standard duty dynamic braking option by using externaliy mounted resistors Al heavy duty dynamic braking options consist of a circuit board a separate resistor assembly mounted external to the enclosure cont
48. word level for each parameter Level one allows access to low end parameters which are changed more frequently Level two allows access to all parameters which are user adjustable AQ Factory default value 9100 PASSWORD Factory default value 0079 4 This parameter stores a fault history of ten previous fault conditions If any fault trips nave occured ihe fault number and name will be stored here View the previous faults Dy pressing ENTER and then scrolling through the previous faults with the UP and DOWN arrow Keys Possible values are shown in the table below INPUT POWER APPLIED WITH START CIRCUIT CLOSED OR AUTO RESTART OR RESTART ON FAULT IS ENABLED WHILE DRIVE IS NOT SET FOR TWO WIRE CONTROL TERMINAL 2 TO 12A NOT CLOSED HIGH CONTROL HIGH AMBIENT TEMPERATURE OR HIGH HEATSINK TEMPERATURE i TEMPERATURE OUTPUT TRANSISTOR FAULT FAULT DETECTED AT OUTPUT TRANSISTOR PHASE TO PHASE OR PHASE TO GROUND SHORT HIGH DC BUS HIGH INPUT LINE VOLTAGE OR REGENERATING MOTOR 0 VOLTAGE LOW DC BUS LOW INPUT LINE VOLTAGE VOLTAGE MOTOR OVERLOAD HIGH MOTOR AMPERAGE DRAW OVERLOADED MOTOR 0 PROTECTION EMERGENCY STOP E STOP CONNECTION TERMINAL 2 TO TERMINAL 22 OPEN LOGIC RESET FAULT FAILURE TO PROPERLY RE INITIALIZE DRIVE MEMORY CONSULT FACTORY IF UNABLE TO RESET 0 Direct access is available to this parameter by pressing the PROG RUN key and pressing ENTER fea
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