Circuit Operation and Options
Precautions
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HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Read and understand the precautions in bulletin NHA60269,
Drives Systems Installation and Maintenance, before performing any
procedures in this bulletin.
Failure to follow these instructions will result in death or serious injury.
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hazard of electric shock, explosion, or arc flash
Before operating the ATV960 process drive:
Failure to follow these instructions will result in death or serious injury.
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Voltage Supply and Auxiliary Voltage
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All drive systems are equipped with a control transformer matching the mains voltage and the required power.
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When equipped, the DC supply units generate 48 Vdc for the internal power fans, the fans in the drive enclosure doors, and a 24 Vdc auxiliary voltage.
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By default all control components are supplied by the 115 Vac control transformer.
Control Terminals
Control Terminal Specifications
Maximum Cable Length
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AI•, AQ•, DI•, DQ•: 50 m shielded
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STOA, STOB: 30 m
Wiring Characteristics
Wire Sizes and Tightening Torque
Control Terminals | Relay Output Wire Cross Section | Other Wire Cross Section | Tightening
Torque lb-in. (N•m) |
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Minimum* AWG (mm2) |
Maximum AWG (mm2) |
Minimum* AWG (mm2) |
Maximum AWG (mm2) |
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All terminals | 18 (0.75) | 16 (1.5) | 20 (0.5) | 16 (1.5) | 4.4 (0.5) |
Consider the protective separation (PELV) when preparing the signal wires and coupling relay. A PELV system is an electrical system in which voltage cannot exceed 50 volts RMS for alternating current, or ripple-free 120 volts for direct current, under dry conditions and which can have a ground connection.
Control Terminal Electrical Characteristics
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For a description of the terminal arrangement, refer to Control Block Ports.
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For factory setting I/O assignments, refer to the Programming Manual or the documentation supplied with your enclosed drive.
Electrical Characteristics
Terminal | Description | I/O Type | Electrical characteristics |
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R1A | NO contact of relay R1 | O |
Output Relay 1
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R1B | NC contact of relay R1 | O | |
R1C | Common point contact of relay R1 | O | |
R2A | NO contact of relay R2 | O |
Output Relay 2
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R2C | Common point contact of relay R2 | O | |
R3A | NO contact of relay R3 | O |
Output Relay 3
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R3C | Common point contact of relay R3 | O | |
STOA, STOB | STO inputs | I | Safety Function STO Inputs Refer to the Safety Functions Manual (NHA80947) available on www.se.com.* |
24V | Output power supply for digital inputs and safety function STO inputs* | O |
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10V | Output supply for Analog input | O |
Internal supply for the analog inputs
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AI1, AI3 | Analog inputs and sensor inputs | I |
Software-configurable V/A: voltage or current analog input
Software-configurable thermal sensors or water level sensor
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COM | Analog I/O common | I/O | 0 V for Analog outputs |
AI2 | Analog input | I |
Voltage bipolar analog input –10 to +10 Vdc, impedance 31.5 kΩ
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AQ1 | Analog output | O |
AQ: Analog output software-configurable for voltage or current
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AQ2 | Analog output | O | |
COM | Digital and analog output Common | I/O | 0 V for analog outputs and logic output |
DQ– | Digital output | O |
Digital output configurable by switch
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DQ+ | Digital output | O | |
DQ+ | Pulse output | O |
Pulse-train output (configurable by switch)
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P24 | External input supply | I |
+24 Vdc external input supply
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0V | 0 V | I/O | 0 V of P24 |
DI1-DI8 | Digital inputs | I |
8 programmable logic inputs 24 Vdc, comply with IEC/EN 61131-2 logic type 1
Multiple assignment makes it possible to configure several functions on one input (example: DI1 assigned to forward and preset speed 2, DI3 assigned to reverse and preset speed 3). |
DI7-DI8 | Pulse inputs | I |
Programmable Pulse input
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Control Block Ports
Control Block Terminal Ports
Marking | Description |
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RJ45 port for Graphic display terminal | |
RJ45 ports for Ethernet embedded | |
Sink-Ext-Source switch PTO-DQ switch (see Configuration of the Sink/Source Selector Switch) |
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RJ45 port for Modbus embedded | |
Slot B, for encoder interface, and I/O relay module | |
Slot A, for communication and I/O relay modules |
RJ45 Communication Ports
The control block includes four RJ45 ports. They allow you to connect:
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A PC for using a commissioning software (such as SoMove™ or SoMachine™ software) to configure and monitor the drive and to access the drive webserver
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A SCADA system
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A PLC system
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A Graphic display terminal, using Modbus protocol
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A Modbus fieldbus
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Verify that the RJ45 cable is not damaged before connecting it to the drive, otherwise there could be interruptions in control power or loss of communication.
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Do not plug an Ethernet cable into the Modbus port or vice versa.
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hazard of electric shock, explosion, or arc flash
Failure to follow these instructions will result in death or serious injury.
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MISOPERATION DUE TO INTERFERENCES
Failure to follow these instructions can result in injury or equipment damage.
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Configuration of the Sink/Source Selector Switch
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UNANTICIPATED EQUIPMENT OPERATION
Failure to follow these instructions can result in death, serious injury, or equipment
damage.
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The switch is used to adapt the operation of the digital inputs to the technology of the signal control. The switch is located below the control terminals (see Control Block Ports).
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Set the selector switch to SRC (Source) when using PLC outputs with PNP transistors (factory setting).
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Set the switch to Ext (external) when using PLC outputs with NPN transistors.
Programming the Power Converter
The ATV960 process drive system is factory configured as shown in Drive System without Full-Voltage Bypass. Be sure to configure the drive’s motor full-load current as shown on the motor nameplate. For additional programming information, see the ATV900 Programming manual available online at www.se.com.
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Loss of Control
Changes to the factory set parameters must be completed
in the sequence given in Drive System without Full-Voltage Bypass.
Failure to follow these instructions can result in death, serious injury, or equipment
damage.
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Changes to parameter factory settings must be completed in the order in which the parameters appear in Drive System without Full-Voltage Bypass. Space is provided in the table for noting changes to the factory settings for your records.
Drive System without Full-Voltage Bypass
Menu | Parameter | Description | Factory Setting | Custom Setting |
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1 | bFr | Basic Frequency | 60 | |
1 | tFr | Max Frequency | 60 | |
1 | LSP | Low Speed | 3 | |
5.2 | SFr | Switching frequency | 2.5 | |
5.4 | Fr1 | REF FREQ 1 Config | AI3 | |
5.4 | rFC | Freq Switch Assign | DI3 | |
5.4 | tCt | 2-wire type | LEL | |
5.4 | Fr2 | REF. FREQ 2 CONFIG | AI1 | |
5.4 | CHCF | Control Mode | IO | |
5.4 | CCS | Command Switching | DI3 | |
5.4 | Cd1 | CMD Channel 1 | tEr | |
5.4 | Cd2 | CMD Channel 2 | tEr | |
5.14 | AI3T | AI3 TYPE | 0A | |
5.14 | CrL3 | AI3 min value | 4 | |
5.14 | AO1 | AQ1 ASSIGNMENT | oFr | |
5.14 | AOL1 | AQ1 min output | 4 | |
5.14 | r1 | R1 ASSIGNMENT | FLt | |
5.14 | r2 | R2 ASSIGNMENT | run | |
5.16 | FLr | Catch on the fly | YES | |
5.16 | rSF | Trip Reset | DI4 |
Adjust the parameters shown in Drive System with Integral Full-Voltage Bypass (Y10), Drive System with Integral Passive Harmonic Filter (M09)Drive System with Integral Passive Harmonic Filter (M09), Drive System Configured For Heavy Duty (H06), and Drive System Configured for 0-10 V Speed Reference (E14)if these optional features are included with the equipment.
Drive System with Integral Full-Voltage Bypass (Y10)
Menu | Parameter | Description | Factory Setting | Custom Setting |
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5.2 | nSt | DI2 (Low Level) | DI2 |
Drive System with Integral Passive Harmonic Filter (M09)
Menu | Parameter | Description | Factory Setting | Custom Setting |
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5.12 | Ftd | Motor Freq Thd | 1 | |
5.14 | FtA | R3 Assignment | Motor frequency high threshold | |
5.14 | rld | R3 Delay time | 2000 | |
5.16 | EtF | Ext Error assign | DI6 (low level) |
Drive System Configured For Heavy Duty (H06)
Menu | Parameter | Description | Factory Setting | Custom Setting |
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5.2 | Drt | Dual rating | HIGH |
Drive System Configured for 0-10 V Speed Reference (E14)
Menu | Parameter | Description | Factory Setting | Custom Setting |
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5.14 | AI3T | AI3 TYPE | 10u |
Electromagnetic Compatibility
This product meets the EMC requirements according to the standard IEC 61800-3 if the measures described in this manual are implemented during installation. If the selected composition (the product itself, the mains filter, or other accessories and measures) does not meet the requirements of category C1, the following information applies as it appears in IEC 61800-3:
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RADIO INTERFERENCE
In a domestic environment this product may cause radio
interference in which case supplementary mitigation measures may be
required.
Failure to follow these instructions can result in death, serious injury, or equipment
damage.
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Operation on an IT or Corner-Grounded System
Definition
An IT system is one with an isolated or impedance grounded neutral. Use a permanent insulation monitoring device compatible with nonlinear loads, such as an XM200 type or equivalent.
A corner-grounded system has one phase grounded, for example corner-grounded delta.
Operation
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Hazard of Electric Shock, explosion, or arc flash
Read and understand the precautions beginning with Installation
and Maintenance Precautions before performing any procedure in this
section.
Failure to follow these instructions will result in death or serious injury.
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The enclosed drives have a built-in EMC filter. As a result they exhibit leakage current to ground. If the leakage current creates compatibility problems with your installation, you can reduce the leakage current by removing the screws as shown in the following section. In this configuration the product does not meet the EMC requirements according to the standard IEC 61800-3.
Configuration
For all 208/230 V enclosed drives and for enclosed drives rated 1–100 hp HD, 1–125 hp ND, @ 460 V, refer to Altivar Process Variable Speed Drives ATV930, ATV950 Installation Manual (NHA80932) for instructions on configuring the equipment for operation on an IT or corner-grounded system.
For 125–700 hp HD, 150–900 hp ND, 460 V enclosed drives, follow these steps:
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Remove all power from the enclosed drive.
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Turn the circuit breaker and handle assembly to the Off position and open the enclosure door.
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Test for the absence of voltage.
NOTE: Verify that the voltage tester is functioning properly before and after testing for the absence of voltage. -
Locate the EMC filter board. It is typically located in the lower right corner. See Settings for 125–700 hp HD, 150–900 hp ND, 460 V Enclosed Drives.
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Remove two nuts and remove the clear plastic cover. See Settings for 125–700 hp HD, 150–900 hp ND, 460 V Enclosed Drives.
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For operation on a system that is not IT or corner-grounded
, position the bolt and washer as shown in Settings for 125–700 hp HD, 150–900 hp ND, 460 V Enclosed Drives, detail 1. Torque the bolt to 49 lb-in. (5.5 N•m).
NOTE: Take care when you remove the bolt, as the EMC board can shift. -
For operation on an IT or corner-grounded system
, position the bolt and washer as shown in Settings for 125–700 hp HD, 150–900 hp ND, 460 V Enclosed Drives, detail 2. Torque the bolt to 49 lb-in. (5.5 N•m).
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Replace the clear plastic cover. Torque the nuts to 49 lb-in. (5.5 N•m).
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Close all doors and restore power to the enclosed drive.
Power Circuit W: Without Bypass
The non-bypass power circuit provides a coordinated drive and circuit breaker package. It includes a number of possible power circuit additions including selection of harmonic and transient mitigation methods. Additional space is provided for engineered to order options and field installable equipment.
Power Circuit Y: With Integral Full-Voltage Bypass
The bypass power circuit provides a coordinated drive and circuit breaker package and the flexibility and security of a full-voltage bypass motor drive that is available at any time. The Zelio Smart Relay coordinates the power converter's output contactor and bypass contactor. See Appendix A for more information. A number of possible power circuit additions, including selection of harmonic and transient mitigation methods and options like the field service disconnect and line isolation contactor, are available in this power circuit configuration allowing for even greater reliability and serviceability. Additional space is provided for engineered to order options and field installable equipment.
The integral full-voltage bypass starter includes a Class 10 bimetallic or solid-state overload relay.
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UNINTENDED EQUIPMENT OPERATION
Switching between Drive mode and Bypass mode without allowing
the motor to come to a complete stop is not recommended.
Failure to follow these instructions can result in equipment damage.
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Power Circuit S: With ATS22/ATS480 Softstart Bypass
This power circuit option provides additional flexibility and reliability to the bypass configuration with the option of selection between ATS22 and ATS480 softstarts.
Mod A09: 5% Impedance
This option provides a total of 5% equivalent line impedance.
Mod M09: Passive Harmonic Filter
This option includes a integrally-mounted harmonic filter, factory installed and wired between the circuit breaker disconnect means and the power converter for harmonic mitigation.
UL® Type 3R Operation
To prevent condensation on the inside of the cabinet, leave the process drive energized even when the motor is not running.
The enclosed drive has a UL 869A approved insulated ground neutral lug assembly and mounting bracket with a bonded enclosure ground wire suitable for use as service entrance rated equipment. Service Entrance Rating is not available when cUL is required.
Control Options
Mod A11: Hand-Off-Auto Selector Switch
Mod A11 provides a door-mounted Hand-Off-Auto selector switch for operating the drive system (two-wire control scheme).
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Hand mode is for local control. When Hand mode is selected, the drive starts the motor and speed command reference is provided by the door mounted speed potentiometer.
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Off mode commands the drive to stop the motor by deceleration ramp.
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Auto mode is for remote control. In Auto mode, the drive starts the motor when the user-supplied Start contact is closed between drive terminals 3 and 4. The drive stops the motor when the user-supplied Start contact is opened.
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The speed command reference is provided by the speed control reference signal supplied to AI3 (factory set for 4-20 mA input).
Mod B11: Hand-Auto Selector Switch and Start-Stop Push Buttons
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INABILITY TO Initiate A STOP
The Stop push button is only active in the Hand mode.
Failure to follow these instructions can result in death, serious injury, or equipment
damage.
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Mod B11 provides a door-mounted, Hand-Off-Auto selector switch, a Start push button, and a Stop push button (mixed mode control scheme).
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Hand mode is for local control. In Hand mode:
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The Start push button commands the drive to start the motor.
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The Stop push button commands the drive to stop the motor by deceleration ramp.
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The speed command reference is provided by the door-mounted speed potentiometer.
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Off mode commands the drive to stop the motor by deceleration ramp.
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Auto mode is for remote control. In Auto mode, the drive starts the motor when the user-supplied Start contact is closed between drive terminals 3 and 4. The drive stops the motor when the user-supplied Start contact is opened. In Auto mode:
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The Start push button does not command the drive to start the motor locally.
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The Stop push button does not command the drive to stop the motor locally.
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The speed command reference is provided by the speed control reference signal supplied to AI3 (factory set for 4-20 mA input).
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Mod N11: No Control Operators
No door-mounted control operators are provided. Omit a control option selection when ordering to receive no operators. A run command 120 Vac relay, connected to the customer terminal blocks, is provided.
Pilot Light Cluster Options
Mod A12: Pilot Light Cluster 1
Mod A12 provides red Run (On), green Run, and yellow Trip and Auto pilot lights for status enunciation.
Mod B12: Pilot Light Cluster 2
Mod B12 provides red Run (On), green Run, and yellow Trip pilot lights for status enunciation.
Mod N12: No Pilot Lights
No door-mounted lights are provided. Omit a pilot light option selection when ordering to receive no lights.
Miscellaneous Options
Mod A14: Door Mounted Ethernet Port
Provides a port on the door of the enclosed drive for making an Ethernet connection.
Mod B14: Line Contactor
This option is only available for Power Circuit Y (Bypass). It provides a factory-wired line contactor between the circuit breaker disconnect (or line reactor or harmonic filter when provided) and the power converter. When the line contactor is open, the 24 V power supply keeps serial communication enabled.
Mod E14: 0–10 V Auto Speed Reference
This option provides a 0–10 V user-supplied auto speed reference signal into the AI3 input, terminals 12 and 13 on terminal block TB1. The 0–10 V analog input is not optically isolated.
Mod F14: 1 N.O. (Form A) Auxiliary Auto Mode Contact
Mod F14 provides one Form A, normally open (N.O.) contact, rated 5 A at 120 Vac, wired to the terminal blocks. The contact(s) change state when the controller is placed in Auto (Remote) mode. This option is included with 125–700 hp HD and 150–900 hp ND enclosed drives.
Mod G14: Type 1 Surge Protective Device
Mod G14 provides an integrated Type 1 supplementary voltage surge protective device to protect equipment in the event of transient voltage surges associated with some electrical power distribution systems. The SPD is suitable for peak surge currents up to 40 kA.
Mod H14: Type 2 Surge Protective Device
Mod H14 provides an integrated Type 2 supplementary voltage surge protective device (SPD) to protect equipment in the event of transient voltage surges associated with some electrical power distribution systems. The SPD is suitable for peak surge currents up to 80 kA.
Mod K14: 150 VA Control Power
Mod K14 provides additional VA capacity of the control power transformer to power field installable equipment and control circuits.
Mod L14: Push-to-Test Pilot Lights
This option provides a push-to-test feature on all pilot lights except Power On.
Mod P14: Permanent Wire Markers
Mod P14 provides permanent wire markers for control wires for use in identification and troubleshooting of control circuits.
Mod Q14: Trip Reset
Provides a push button signal to reset a drive trip or bypass overload trip. Mod Y10 Bypass must also be selected.
Mod S14: 50°C Operation
Mod S14 provides a high ambient equipment rating above 40°C (104°F) to a maximum of 50°C (122°F). This modification requires derating to the current ratings shown in Input and Output Current Ratings and Dissipated Heat.
Mod T14: Drive Input Disconnect Switch
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HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Do not operate the switch with the door open.
Failure to follow these instructions will result in death or serious injury.
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This option provides an input line power disconnect switch between the mains power disconnect and the power converter. The Drive Input Disconnect Switch will disconnect line power to the power converter. The motor can run in bypass mode in the unlikely event the power converter becomes inoperative.
Mod U14: Top Entry Cubicle
Mod U14 provides additional wireway space for floor-mounted equipment, especially where mains or motor conductors are feed from the top of the equipment. Available for 150–900 hp ND and 125–700 hp HD @ 460 Vac.
Mod X14: dv/dt Filter
Provides a factory mounted and wired dv/dt filter on the drive output for long motor lead lengths in excess of published guidelines.
Maximum Cable Lengths
Type of Cable | Maximum Cable Length |
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Shielded | 984 ft (300 m) |
Unshielded | 1640 ft (500 m) |
Mod Y14: Seismic Certificate
Supplies a certification label and hardware qualification to seismic rating ICC ES AC156.
Drive Communications and Expansion Cards
ATV960 process drives come factory configured with integral Modbus and Ethernet communications for the drive. The optional expansion cards described in this section are available for additional communication systems and feature configurations.
Mod A13: Profibus DP V1
Mod A13 provides a factory installed plug-in Profibus DP V1 card (VW3A3607). Connect to the Profibus DP card with one nine-pin female SUB-D connector.
Mod B13: CANopen Daisy Chain
Mod B13 provides a factory installed plug-in CANopen daisy chain card (VW3A3608). Connect to the CANopen daisy chain card with two RJ-45 ports.
Mod C13: DeviceNet
Mod C13 provides a factory installed plug-in DeviceNet card (VW3A3609). Connect to the DeviceNet card with one five-point terminal block.
Mod D13: CANopen SUB-D
Mod D13 provides a factory installed plug-in CANopen Sub-D9 card (VW3A3618). Connect to the CANopen Sub-D9 card with one nine-pin male SUB-D connector.
Mod E13: CANopen Open Style
Mod E13 provides a factory installed plug-in CANopen open style card (VW3A3628). Connect to the CANopen open style card with one five-point terminal block.
Mod F13: ProfiNet
Mod F13 provides a factory installed plug-in ProfiNet card (VW3A3627). Connect to the ProfiNet card with two RJ-45 ports.
Mod C14: I/O Extension Card
Mod C14 provides a factory installed I/O expansion card (VW3A3203). The card expands the available I/O with an additional six logic inputs, two logic outputs, and two analog inputs.
Mod D14: Relay Output Card
Mod D14 provides a factory installed relay output card (VW3A3204). The card adds three normally open contacts that may be assigned within drive logic.
Mod H13: EtherCat
Provides a factory installed VW3A3601 card.
Mod B13: Bacnet MS/TP
Provides a factory installed Bacnet MS/TP (VW3A3725) card.
Engineered to Order Options
Along with the options listed in Configured to Order list described before- there are additional Engineered to Order options available as EPMOD. If any additional feature is needed to be ordered, other than the ones listed below, please get in touch with local Drives Representative.
Other Engineered to Order Options include:
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Emergency Stop
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Options for customized pilot light colors and sizes
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Additional factory wired contacts for customer use
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Additional customer supplied or PM5000 series meters
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Control circuit updates to including- Power On Delay, Smoke Purge/End Damper circuit, High/Low Pressure alarms, High/ Low Basin level alarms, Motor Overtemperature alarm, Additional control power for customer use, Provision for motor heater circuits etc.
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Additional relays, current transformers, potential transformers etc.
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Softstart bypass options with ATS22 and ATS480