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Pilot Point 480 Volt Switchgear Operations Manual 2008
Operation and Maintenance Manual For 480 Volt Switchgear Project Pilot Point, Alaska Prepared for Alaska Energy Authority Anchorage, Alaska (Contract No. REG-08-026) Prepared by Controlled Power, Inc. 17909 BOTHELL EVERETT HWY. S.E. SUITE #102 BOTHELL, WASHINGTON 98012-6391 USA PHONE: (425)-485-1778, FAX: (425)-485-0658 (Job No. 6474) August 19, 2008 Table of Contents Section 1 Theory of Operation Section 2 Warranty Section 3 Equipment Parts List Section 4 Switchgear and Circuit Breakers Section 5 Enclosures and Panels Section 6 Battery System Section 7 Protective and Sensing Relays Section 8 Meters, Transducers and Power Monitors Section 9 Engine and Generator Synchronizing, Loading, Voltage and Frequency Controls Section 10 Instrumentation and Power Transformers Section 11 Annunciators and Annunciation Lights Section 12 Programmable Logic Controllers (PLC) and Software Section 13 Communications and Network Equipment Section 14 Operator Interface Unit (OIU) Section 15 DC Power Supply System Section 16 Control and Time Relays Section 17 Control Switches and Buttons Section 18 Terminals, Fuses and Miniature Circuit Breakers Section 19 Miscellaneous Section 20 Drawings Section 1 Section 2 Warranty Rev 5-7-07 WARRANTIES Controlled Power, Incorporated warrants the products covered by this agreement to be free from defects in material and workmanship under normal and proper usage for a period of one (1) year from the date of installation, but not to exceed eighteen (18) months from the date of shipment. This express warranty is in lieu of and excludes all other representations made, both expressed and implied. Controlled Power, Incorporated warrants that the goods sold are as described, but no promise, description, affirmation of fact, sample, model, or representation, oral or written , shall be part of any order, unless set forth in these terms and conditions, or are in writing and signed by authorized representative of Controlled Power, Incorporated. This warranty is void if the goods have been misused or abused or if they have been modified, altered or disassembled except according to the seller's express written instruction. PURCHASER'S REMEDIES Controlled Power, Incorporated agrees to correct any defect in workmanship or material, for merchandise manufactured by it, which may develop under normal and proper usage during a period of one (1) year from date of shipment, or by it's option, choose to replace or repair the defective part(s) FOB place of shipment or repay, upon return of the defective part(s) the price paid for such apparatus by the purchaser. Purchaser's remedies shall be limited exclusively to the right of replacement and/or repair or repayment as provided, and do not include any labor cost of replacement. Section 3 MATERIAL LIST PROJECT NAME: PILOT POINT CUSTOMER NAME: ALASKA ENERGY AUTHORITY P.O. NUMBER: REG-08-026 CPI JOB No.: 6474 ISSUE DATE: 12/18/2007 REVISION 1 SUBMITTAL- 1/31/07 REVISION 2 REVISION 3 JMD ITEM SYM QTY DESCRIPTION MFG. PART NO. (Mfg Catalog Number) TAB SECTION 1.0 SWBD 1 DEAD FRONT, NEMA 1A SWBD 480 VOLT, THREE PHASE, FOUR WIRE 1600 AMP COPPER BUS, 35KAIC 5 SECTION (3 GEN, 1 MASTER, 1 DIST.) G.E. 90"H X 150"W X 35"D 4 2.0 52G1 1 CIRCUIT BREAKER: 400AF MOLDED CASE 35 KAIC G.E. SGHA36AT0400 4 2.1 1 RATING PLUG: 200AT G.E. SRPG400A200 4 2.2 1 SHUNT TRIP VOLTAGE: 24 VDC G.E. SAST3 4 ENGINEER: 2.3 1 AUXILIARY CONTACT: 2A/2B G.E. SAUXPAB2 4 2.4 1 BELL ALARM G.E. SABAP1 4 2.5 2 LINE/ LOAD LUGS (3 POLE KIT) G.E. TCLK365 4 3.0 52G2 1 CIRCUIT BREAKER: 400AF MOLDED CASE 35 KAIC G.E. SGHA36AT0400 4 3.1 1 RATING PLUG: 150AT G.E. SRPG400A150 4 3.2 1 SHUNT TRIP VOLTAGE: 24 VDC G.E. SAST3 4 3.3 1 AUXILIARY CONTACT: 2A/2B G.E. SAUXPAB2 4 3.4 1 BELL ALARM G.E. SABAP1 4 3.5 2 LINE/ LOAD LUGS (1 EACH) G.E. TCLK365 4 4.0 52G3 1 CIRCUIT BREAKER: 400AF MOLDED CASE 35 KAIC G.E. SGHA36AT0400 4 4.1 1 RATING PLUG: 150AT G.E. SRPG400A150 4 4.2 1 SHUNT TRIP VOLTAGE: 24 VDC G.E. SAST3 4 4.3 1 AUXILIARY CONTACT: 2A/2B G.E. SAUXPAB2 4 Page 1 MATERIAL LIST ITEM SYM QTY DESCRIPTION MFG. PART NO. (Mfg Catalog Number) TAB SECTION 4.4 1 BELL ALARM G.E. SABAP1 4 4.5 2 LINE/ LOAD LUGS (3 POLE KIT) G.E. TCLK365 4 5.0 52F1 1 CIRCUIT BREAKER PB2: 800AF STATIONARY 65 KAIC G.E. SSF08B208 4 5.1 1 CIRCUIT BREAKER PROGRAMMER G.E. B208LSIG 4 5.2 1 SHUNT TRIP VOLTAGE: 24 VDC G.E. SAST3 4 5.3 1 ELECTRICAL OPERATOR VOLTAGE: 120 VAC G.E. SPE120 4 5.4 1 REMOTE CLOSE SOLENOID VOLTAGE: 120 VAC G.E. SPRCS120 4 5.5 1 RATING PLUG: 800AT G.E. TR8B800 4 5.6 1 SHUNT TRIP VOLTAGE: 24 VDC G.E. SPST024 4 5.7 1 AUXILIARY CONTACT: 4A/4B G.E. SPAS240AB4 4 5.8 1 BELL ALARM W/ LOCKOUT G.E. SPBAL240 4 5.9 1 DOOR INTERLOCK G.E. SPDIL 4 5.10 1 HIDDEN ON BUTTON G.E. SPPBNON 4 5.11 1 LIMITED ACCESS PUSHBUTTON COVER G.E. SPPBCOVER 4 5.12 1 MECHANICAL OPERATIONS COUNTER G.E. SPCOUNTER 4 5.13 1 NEUTRAL CURRENT SENSOR 400/200 AMP G.E. TSVG304A 4 6.0 52SS 1 CIRCUIT BREAKER: 30AF MOLDED CASE 65 KAIC G.E. SELA36AT0030 4 6.1 1 RATING PLUG: 25AT G.E. SRPE30A25 4 6.2 1 AUXILIARY CONTACT: 1A/1B G.E. SAUXPAB1 4 6.3 1 BELL ALARM G.E. SABAP1 4 6.4 6 LINE/LOAD LUGS (1 EACH) G.E. TCAL18 4 6.5 1 BREAKER PADLOCK DEVICE G.E. SEPLD 4 Page 2 MATERIAL LIST ITEM SYM QTY DESCRIPTION MFG. PART NO. (Mfg Catalog Number) TAB SECTION 7.0 CB 12 CIRCUIT BREAKER, 1 POLE, 0.5A, 277V CURVE: D BULLETIN 1489 ALLEN- BRADLEY 1489-A1D005 18 7.1 12 CIRCUIT BREAKER, 1 POLE, 2A, 277V CURVE: C BULLETIN 1489 ALLEN- BRADLEY 1489-A1C020 18 7.2 2 CIRCUIT BREAKER, 1 POLE, 3A, 277V CURVE: D BULLETIN 1489 ALLEN- BRADLEY 1489-A1D030 18 7.3 2 CIRCUIT BREAKER, 1 POLE, 5A, 277V CURVE: C BULLETIN 1489 ALLEN- BRADLEY 1489-A1C050 18 7.4 8 CIRCUIT BREAKER, 1 POLE, 10A, 277V CURVE: C BULLETIN 1489 ALLEN- BRADLEY 1489-A1C100 18 7.5 8 CIRCUIT BREAKER, 1 POLE, 15A, 277V CURVE: C BULLETIN 1489 ALLEN- BRADLEY 1489-A1C150 18 7.6 3 CIRCUIT BREAKER, 1 POLE, 20A, 277V CURVE: C BULLETIN 1489 ALLEN- BRADLEY 1489-A1C200 18 8.0 42G1 1 CONTACTOR, 3 POLE, 400A, 600V, 277 VAC COIL ALLEN- BRADLEY 100D420EA11 4 9.0 42G2 1 CONTACTOR, 3 POLE, 250A, 600V, 277 VAC COIL ALLEN- BRADLEY 100D250EA11 4 10.0 42G3 1 CONTACTOR, 3 POLE, 250A, 600V, 277 VAC COIL ALLEN- BRADLEY 100D250EA11 4 11.0 PT 12 POTENTIAL TRANSFORMER, 277 - 115V, 2.4:1 RATIO, 150VA ITI 460-288 10 12.0 G1CT A,B,C 3 CURRENT TRANSFORMER: FIXED RATIO RATIO: 200:5 CLASS: RELAY, C20 WINDOW: 1.25" ITI 21-201 10 12.1 G2CT A,B,C 3 CURRENT TRANSFORMER:FIXED RATIO RATIO: 100:5 CLASS: RELAY, C20 WINDOW: 1.25" ITI 21-101 10 12.2 G3CT A,B,C 3 CURRENT TRANSFORMER:FIXED RATIO RATIO: 100:5 CLASS: RELAY, C20 WINDOW: 1.25" ITI 21-101 10 Page 3 MATERIAL LIST ITEM SYM QTY DESCRIPTION MFG. PART NO. (Mfg Catalog Number) TAB SECTION 12.3 BCT 3 CURRENT TRANSFORMER: FIXED RATIO RATIO: 200:5 CLASS: RELAY, C20 WINDOW: 5.75" ITI 130-201 10 12.4 SSCT 3 CURRENT TRANSFORMER: 50:5 RATIO CLASS: RELAY, C10 WINDOW: 1.25" ITI 21-500 10 13.0 F-52 CPT 1 CONTROL POWER TRANSFORMER 240/480 - 120/240V, 1000 VA G.E. 9T58K2812 10 14.0 EPM-B 1 SATEC PM172E: BASE UNIT POWER SUPPLY: 19-37 VDC COMM: ETHERNET OUTPUT: 4-20mA SATEC DIN 072E-N-U-60HZ-5- 2DC-AO4-ETH 8 14.1 1 SATEC PM172E REMOVABLE DISPLAY MODULE WITH 10' DB15 CABLE SATEC FMD172E-3L 8 15.0 EPM- SS 1 SATEC PM172E POWER SUPPLY: 19-37 VDC COMM: ETHERNET SATEC DIN 072E-N-U-60HZ-5- 2DC-00-ETH 8 COMM: ETHERNET 15.1 1 SATEC PM172E REMOVABLE DISPLAY MODULE WITH 10' DB15 CABLE SATEC FMD172E-3L 8 16.0 G1-G3 GCP 3 CONTROLLER: GCP-31 CONTROL FUNCTIONS:SYNCHRONIZING, kW, KVAR PT CONFIGURATION: WYE INPUT VOLTAGE: 200/115 VAC, 3 PH-4W, 60 HZ SPEED CONTROL: +/- 3V DC, 0-5V DC VOLTAGE CONTROL: +/- 3 VDC CONTROL ADJUSTMENTS: VIA DISPLAY PANEL OR LEOPC SOFTWARE (INCLUDED) CONTROL VOLTAGE: 24VDC NOMINAL INTERFACE: IKD-1 CAN BUS, ECM WOODWARD 8440-1561 9 17.0 G1-G3 IKD 0 GCP DIGITAL I/O EXPANSION MODULE 16 INPUTS, 8 OUTPUTS MOUNTING: DIN RAIL CONTROL VOLTAGE: 24V DC WOODWARD 8440-1041 9 18.0 F1- 42CS 1 FEEDER CONTACTOR CONTROL SWITCH TRIP, NORM, CLOSE ESCO 2438D 17 19.0 MCS 1 MASTER CONTROL SWITCH AUTO, MAN ESCO 24201C 17 Page 4 MATERIAL LIST ITEM SYM QTY DESCRIPTION MFG. PART NO. (Mfg Catalog Number) TAB SECTION 20.0 M-LTB 1 BLACK PUSHBUTTON OPERATOR CUTLER- HAMMER 10250T101 17 20.1 1 CONTACT BLOCK: N.O. CUTLER- HAMMER 10250T53CP 17 21.0 M-ARB 1 BLACK PUSHBUTTON OPERATOR CUTLER- HAMMER 10250T101 17 21.1 1 CONTACT BLOCK: N.O. CUTLER- HAMMER 10250T53CP 17 22.0 M-ESB 1 EMERGENCY STOP OPERATOR: PUSH- PULL, MAINTAINED ALLEN- BRADLEY 800T-FX6D4 17 22.1 1 PUSH BUTTON GUARD ALLEN- BRADLEY 800T-NX1320 17 22.2 2 CONTACT BLOCK: N.O. FINGER SAFE ALLEN- BRADLEY 800TC-XD1 17 23.0 HTR SW 1 SELECTOR SWITCH, 2 POS HEATER: OFF - ON (LOCATED INSIDE MASTER SECTION) CUTLER- HAMMER 10250T3011 17 (LOCATED INSIDE MASTER SECTION) 23.1 1 CONTACT BLOCK: N.O. CUTLER- HAMMER 10250T53CP 17 24.0 G1-G3 ELS 3 KEY OPERATED SELECTOR SWITCH POSITIONS: 2 ENGINE LOCKOUT: OFF - RUN CUTLER- HAMMER 10250T1511-2 17 24.1 3 CONTACT BLOCK: 2 N.C. CUTLER- HAMMER 10250T3CP 17 25.0 G1-G3 ANNUN 3 ANNUNCIATOR PANEL WINDOW SIZE: 1.575" X 1.575" ROWS: 2 COLUMNS: 12 TYPE: CANDLEABRA VOLTAGE: 24VDC IDEC SLC40N-0212-DE2FB- R(21), A(1), G(2) 11 25.1 63 ANNUNCIATOR LAMP TYPE: LED COLOR: RED VOLTAGE: 24VDC DDP SP071012-R REV. 2 11 25.2 6 ANNUNCIATOR LAMP TYPE: LED COLOR: GREEN VOLTAGE: 24VDC DDP SP071012-G 11 Page 5 MATERIAL LIST ITEM SYM QTY DESCRIPTION MFG. PART NO. (Mfg Catalog Number) TAB SECTION 25.3 3 ANNUNCIATOR LAMP TYPE: LED COLOR: AMBER VOLTAGE: 24VDC DDP SP071012-A 11 26.0 MSTR ANNUN 1 ANNUNCIATOR PANEL WINDOW SIZE: 1.575" X 1.575" ROWS: 2 COLUMNS: 10 TYPE: CANDLEABRA VOLTAGE: 24VDC IDEC SLC40N-0210-DE2FB- R(18), A(2) 11 26.1 18 ANNUNCIATOR LAMP TYPE: LED COLOR: RED VOLTAGE: 24VDC DDP SP071012-R REV. 2 11 26.2 2 ANNUNCIATOR LAMP TYPE: LED COLOR: AMBER VOLTAGE: 24VDC DDP SP071012-A 11 27.0 52 POS ANNUN 4 ANNUNCIATOR PANEL WINDOW SIZE: 1.575" X 1.575" IDEC SLC40N-0102-DE2FB- R(1),G(1) 11 ROWS: 1 COLUMNS: 2 TYPE: CANDLEABRA VOLTAGE: 24VDC (), () 27.1 4 ANNUNCIATOR LAMP TYPE: LED COLOR: RED VOLTAGE: 24VDC DDP SP071012-R REV. 2 11 27.2 4 ANNUNCIATOR LAMP TYPE: LED COLOR: GREEN VOLTAGE: 24VDC DDP SP071012-G 11 28.0 DNCXR 0 RELAY: SEALED TYPE: PLUG-IN, DIN RAIL MOUNT POLES: 4PDT COIL VOLTAGE: 24VDC NAIS HC4E-H-DC24V 16 28.1 0 RELAY BASE POLES: 4PDT IDEC SY4S-05C 16 29.0 CR 42 RELAY: CONTROL TYPE: PLUG-IN, DIN RAIL MOUNT POLES: 2PDT COIL VOLTAGE: 24VDC IDEC RH2BUL-DC24V 16 29.1 42 RELAY BASE POLES: 2PDT IDEC SH2B-05C 16 Page 6 MATERIAL LIST ITEM SYM QTY DESCRIPTION MFG. PART NO. (Mfg Catalog Number) TAB SECTION 30.0 CR 2 RELAY: CONTROL TYPE: PLUG-IN, DIN RAIL MOUNT POLES: 3PDT COIL VOLTAGE: 24VDC IDEC RH3BUL-DC24V 16 30.1 2 RELAY BASE POLES: 3PDT IDEC SH3B-05C 16 31.0 CR 3 RELAY: CONTROL TYPE: PLUG-IN, DIN RAIL MOUNT POLES: 4PDT COIL VOLTAGE: 24VDC IDEC RH4BUL-DC24V 16 31.1 3 RELAY BASE POLES: 4PDT IDEC SH4B-05C 16 32.0 42CR 3 RELAY: CONTACTOR CLOSE AUXILIARY TYPE: POWER RELAY POLES: 2 N.O., 2 N.C. COIL VOLTAGE: 24VDC MOUNTING: DIN RAIL ABB NL22E-81 16 33.0 DBR 1 RELAY: CONTROL TYPE: PLUG-IN, DIN RAIL MOUNT IDEC RR3BUL-AC120V 16 TYPE: PLUG IN, DIN RAIL MOUNT POLES: 3PDT COIL VOLTAGE: 120VAC 33.1 1 RELAY BASE POLES: 3PDT IDEC SR3B-05 16 34.0 PWR PLUG 1 GFCI POWER OUTLET 120V AC, 15A DIN RAIL MOUNTING PHEONIX CONTACT 5600639 19 35.0 PDB 4 POWER DIODE BLOCK, 30 AMPS SEMIKRON SKB30/12A1 19 36.0 M-PS 1 POWER SUPPLY INPUT: 120 VAC OUTPUT: 24 VDC, 20 AMP AUTOMATION DIRECT PS24-500D 15 37.0 MSTR BVC 1 BATTERY VOLTAGE CONVERTER INPUT: 12 VDC OUTPUT: 24 VDC ANALYTIC SYSTEMS VTC605-12-24 15 38.0 HTR 5 STRIP HEATER VOLTAGE: 120V AC POWER: 150 WATTS WATLOW SGA1J7J01 19 38.1 1 THERMOSTAT HOFFMAN A-TEMNC 19 38.2 5 TERMINAL STRIP FOR HEATERS KULKA 600A-2 18 Page 7 MATERIAL LIST ITEM SYM QTY DESCRIPTION MFG. PART NO. (Mfg Catalog Number) TAB SECTION 39.0 PNL ILLUM 5 FLUORESCENT PANEL ILLUMINATION KIT W/ MANUAL SWITCH, 120V AC 12.3"X1.38"X4.59" HOFFMAN ALF16M12R 19 39.1 5 DOOR SWITCH FOR ILLUMINATION KIT HOFFMAN ALFSWD 19 39.2 5 FLUORESCENT LAMP FOR ILLUMINATION SYLVANIA F8T5/CW 19 40.0 CTSB 5 TERMINAL BLOCK: CT SHORTING 4 POLE, 600V, 30A G.E. EB27B04SC 18 41.0 TB 475 TERMINALS, 600V, 30 A, #8 - #24 AWG PHOENIX CONTACT UK-6-N 18 41.1 36 TERMINAL END SECTION PHOENIX CONTACT D-UK-4/10 18 41.2 6 TB MARKING STRIPS, UNPRINTED PACKAGE OF 100 POINTS PHOENIX CONTACT ZB-8/WH-100- UNBEDRUCKT 18 41.3 25 END CLAMPS PHOENIX CONTACT E/NS-35-N 18 42.0 CLMP 90 END CLAMPS IDEC BNL-5 18 43.0 KULKA TB 1 TERMINAL STRIP FOR SS BREAKER KULKA 600A-6 18 44.0 CMP 1 INDUSTRIAL COMPUTER BACK PAN MOUNTED PENTIUM 4, 2.0 GHz PROCESSOR MEMORY: 1 GB RAM, 2- 60 GB HD SCREEN SIZE: 15" NCC BUILT TO SPEC 13 45.0 OIU 1 OPERATOR INTERFACE UNIT PANEL MOUNT AMD PANEL PC 1024 X 768 TFT LCD LX800 500MHz CPU RESISTIVE TOUCH SCREEN INDUSTRIAL IMAGE PMPCS15-C3-RTS 14 45.1 1 1 GB SODIMM SYSTEM MEMORY INDUSTRIAL IMAGE MEM1GB-SODIMM 14 45.2 1 4 GB CF SYSTEM STORAGE HARD DRIVE INDUSTRIAL IMAGE HD4GBCF 14 45.3 1 MICROSOFT WINDOWS XP EMBEDDED INDUSTRIAL IMAGE MSWIN-Xpe-Enbedded 14 46.0 PRIM PLC 1 CHASSIS, 7 SLOT ALLEN- BRADLEY 1746-A7 12 46.1 1 POWER SUPPLY, 24VDC, 90VA ALLEN- BRADLEY 1746-P3 12 46.2 1 CPU, SLC 5/05, 32K MEM, ETHERNET ALLEN- BRADLEY 1747-L552 12 Page 8 MATERIAL LIST ITEM SYM QTY DESCRIPTION MFG. PART NO. (Mfg Catalog Number) TAB SECTION 46.3 1 CPU, MEMORY MODULE ALLEN- BRADLEY 1747-M13 12 46.4 1 DEVICE NET SCANNER ALLEN- BRADLEY 1747-SDN 12 46.5 2 A-B SLC500 MODBUS TCP INTERFACE PROSOFT MVI46-MNET 12 46.6 1 RACK MOUNT I/O MODULE INPUT/ OUTPUT 6PT IN UNIVERSAL/ 6PT OUT SOURCING, 24V DC ALLEN- BRADLEY 1746-IO12DC 12 46.7 3 CARD SLOT FILLER ALLEN- BRADLEY 1746-N2 SERIES B 12 47.0 BKUP PLC 1 CHASSIS, 7 SLOT ALLEN- BRADLEY 1746-A7 12 47.1 1 POWER SUPPLY, 24VDC, 90VA ALLEN- BRADLEY 1746-P3 12 47.2 1 CPU, SLC 5/05, 32K MEM, ETHERNET ALLEN- BRADLEY 1747-L552 12 47.3 1 CPU, MEMORY MODULE ALLEN- BRADLEY 1747-M13 12 47.4 1 DEVICE NET SCANNER ALLEN- BRADLEY 1747-SDN 12 47.5 1 RACK MOUNT I/O MODULE INPUT/ OUTPUT 6PT IN UNIVERSAL/ 6PT OUT SOURCING, 24V DC ALLEN- BRADLEY 1746-IO12DC 12 47.6 3 CARD SLOT FILLER ALLEN- BRADLEY 1746-N2 SERIES B 12 48.0 DNET I/O 2 COMPACT BLOCK LDX I/O INPUT BASE MODULE 16PT, UNIVERSAL, 24V DC ALLEN- BRADLEY 1790D-T16BV0 12 48.1 3 COMPACT BLOCK LDX I/O INPUT EXPANSION MODULE 16PT, UNIVERSAL, 24V DC ALLEN- BRADLEY 1790-T16BV0X 12 48.2 4 COMPACT BLOCK LDX I/O OUTPUT BASE MODULE 16PT, SOURCING, 24V DC ALLEN- BRADLEY 1790D-T0B16 12 48.3 3 COMPACT BLOCK LDX I/O OUTPUT EXPANSION MODULE 16PT, SOURCING, 24V DC ALLEN- BRADLEY 1790-T0B16X 12 Page 9 MATERIAL LIST ITEM SYM QTY DESCRIPTION MFG. PART NO. (Mfg Catalog Number) TAB SECTION 48.4 3 COMPACT BLOCK LDX I/O INPUT/ OUTPUT BASE MODULE 8PT IN UNIVERSAL/ 8PT OUT SOURCING 24V DC ALLEN- BRADLEY 1790D-T8BV8B 12 48.4 2 COMPACT BLOCK LDX I/O INPUT/ OUTPUT EXPANSION MODULE 8PT IN UNIVERSAL/ 8PT OUT SOURCING 24V DC ALLEN- BRADLEY 1790-T8BV8BX 12 48.5 2 COMPACT BLOCK LDX I/O ANALOG INPUT MODULE 4 CHNL, 4-20ma DC ALLEN- BRADLEY 1790D-TN4C0 12 48.6 2 COMPACT BLOCK LDX I/O RTD INPUT MODULE 4 CHNL ALLEN- BRADLEY 1790D-T4R0 12 48.7 13 COMPACT BLOCK LDX I/O DEVICE NET CONNECTOR W/ LOCKING SCREWS PHOENIX CONTACT 1786860 12 49.0 SFTWR 1 AB RSLOGIX SLC500 SOFTWARE ALLEN- BRADLEY 9324RL0300ENF 12 49.1 1 WOODWARD LEO PC GCP SOFTWARE WOODWARD 12 49.2 1 SATEC PAS SOFTWARE SATEC 12 50.0 C0MM 1 INDUSTRIAL ETHERNET SWITCH CHASSIS SLOTS: 3 POWER:24 VDC N-TRON 900B 13 50.1 3 8 PORT 10/100 BASE TX MODULAR INDUSTRIAL ETHERNET SWITCH SLIDE IN MODULE N-TRON 908TX 13 50.2 1 PANEL INTERFACE CONNECTOR (1) RJ-45 (2) RJ-11 (2) USB (2) PS/2 (1) VGA (1) SERIAL GRACEPORT P- P1P3P5P6P11#2Q6#2R2- M3RX 13 50.3 1 UPS TWISTLOCK CONNECTOR W/ COVER 120 VAC (MALE) L520 INLET GRACEPORT P-XX-K3RTT0 13 50.4 2 PLC DF1 PROGRAMMING CABLE LENGTH: 10' ALLEN- BRADLEY 1747-CP3 13 50.5 0 J1939 TO MODBUS/TCP ETHERNET GATEWAY PYRAMID SOLUTIONS AB7645 13 Page 10 MATERIAL LIST ITEM SYM QTY DESCRIPTION MFG. PART NO. (Mfg Catalog Number) TAB SECTION 50.6 0 DB9 M/F CABLE LENGTH: 25' CABLES TO GO 09452 13 50.7 1 GCP CANBUS TO MODBUS/TCP ETHERNET GATEWAY PROCONX GCP-MGATE 13 50.8 1 GCP CANBUS/ USB MODULE IXXAT 1.01.0087.10200 13 51.0 P-TB G1-G3 3POWER TERMINAL BLOCK POLES: 3 RATING: 840A MARATHON 1443614 18 51.1 3 POWER TERMINAL BLOCK COVER MARATHON CC1443 18 52.0 P-TB SS 1POWER TERMINAL BLOCK POLES: 3 RATING: 200A MARATHON 1423122 18 52.1 1 POWER TERMINAL BLOCK COVER MARATHON CC1423 18 53.0 PAN 3 SIDE PANEL HOFFMAN A20P20 1953.0 PAN 3 SIDE PANEL LOCATION: LOWER GEN SECTION HOFFMAN A20P20 19 53.1 PAN 3 SIDE PANEL LOCATION: LOWER MASTER/ DIST SECTION HOFFMAN A12P24 19 54.0 NP 1 SWITCHGEAR PLACARD NAMEPLATES REF. DWG: XXXX-6201-D S.E. 19 54.1 1 SWITCHGEAR SWITCH NAMEPLATES REF. DWG: XXXX-6101-D PRECISION PRODUCTS 19 1.0 52VFD 2 CIRCUIT BREAKER, 3 POLE, 15A, 277V CURVE: D BULLETIN 1489 MOELLER FAZ-D15/3-NA 4 1.1 2 AUXILIARY CONTACT: 1A/1B MOELLER 2-NHK 4 1.2 2 SHUNT TRIP VOLTAGE: 24 VDC MOELLER FAZ-XAA-NA12-110AC 4 2.0 CB 1 CIRCUIT BREAKER, 1 POLE, 1A, 277V CURVE: C BULLETIN 1489 ALLEN- BRADLEY 1489-A1C010 18 2.1 2 CIRCUIT BREAKER, 1 POLE, 10A, 277V CURVE: C BULLETIN 1489 ALLEN- BRADLEY 1489-A1C100 18 VFD COMPONENTS Page 11 MATERIAL LIST ITEM SYM QTY DESCRIPTION MFG. PART NO. (Mfg Catalog Number) TAB SECTION 3.0 VFD 2 ALTIVAR 61 VARIABLE FREQ DRIVE SIZE: 5 HP CONTROL: PID USING 4-20mA INPUT I/O: (4)DIGITAL INPUTS, (1)4-20mA INPUT, (2)DIGITAL OUTPUTS COMM: RS-485 MODBUS RTU SQUARE D ATV61HU40N4 4 3.1 2 ALTIVAR REMOTE KEYPAD DOOR SQUARE D VW3A1102 4 3.2 2 ALTIVAR ETHERNET CARD SQUARE D VW3A3310 4 3.3 1 POWERSUITE VFD SOFTWARE SQUARE D VW3 A8104 12 4.0 42VFD 2 CONTACTOR, 3 POLE, 23A, 600V, 24 VDC COIL CONTACTS: N.O. ALLEN- BRADLEY 100-C23ZJ10 4 4.1 2 ADJUSTABLE SOLID -STATE OVERLOAD RELAY ADJ. RANGE: 3.2- 16 AMPS ALLEN- BRADLEY 193ED1DB 4 4.2 2 DIN RAIL/ PANEL ADAPTER FOR OVERLOAD RELAY ALLEN- BRADLEY 193-EPB 4 5.0 VFD SW 2 DISCONNECT SWITCH 3 POLE, 20A, 600V AUX CONTACTS: 4 N.O. SALZER H216-71322-013V1 4 6.0 VFD ANNUN 2 ANNUNCIATOR PANEL WINDOW SIZE: 1.575" X 1.575" ROWS: 2 COLUMNS: 3 TYPE: CANDLEABRA VOLTAGE: 24VDC IDEC SLC40N-0203-DE2FB- R(2), G(2), A(2) 11 6.1 4 ANNUNCIATOR LAMP TYPE: LED COLOR: RED VOLTAGE: 24VDC DDP SP071012-R REV. 2 11 6.2 4 ANNUNCIATOR LAMP TYPE: LED COLOR: GREEN VOLTAGE: 24VDC DDP SP071012-G 11 6.3 4 ANNUNCIATOR LAMP TYPE: LED COLOR: AMBER VOLTAGE: 24VDC DDP SP071012-A 11 7.0 CR 2 RELAY: CONTROL TYPE: PLUG-IN, DIN RAIL MOUNT POLES: 3PDT COIL VOLTAGE: 24VDC IDEC RH3BUL-DC24V 16 Page 12 MATERIAL LIST ITEM SYM QTY DESCRIPTION MFG. PART NO. (Mfg Catalog Number) TAB SECTION 7.1 2 RELAY BASE POLES: 3PDT IDEC SH3B-05C 16 8.0 VFD TMR 2 TIMER: DELAY ON MAKE TYPE: 8 PIN ROUND POLES: 2PDT COIL VOLTAGE: 24 VDC CROUZET 88 867 215 18 8.1 2 TIMER BASE TYPE: 8 PIN ROUND MOUNTING: DIN RAIL MOUNT FINGER SAFE IDEC SR2P-05C 18 9.0 KULKA TB 0 TERMINAL STRIP FOR VFD BREAKER KULKA 600A-6 18 9.1 2 TERMINAL STRIP FOR DIST. SECTION FAN KULKA 600A-2 18 10.0 FAN 2 VFD SECTION COOLING FAN PACKAGE SIZE: 4", 55 CFM POWER: 120 VAC HOFFMAN TFP41 18 11.0 VFD 1 3 POLE POWER BLOCK, 175 AMP MARATHON 1323580 1811.0 VFD PB 1 3 POLE POWER BLOCK, 175 AMP TOP CONNECTION:(1) 2/O- #14 AWG BOTTOM CONNECTION:(6) #4- #14 AWG MARATHON 1323580 18 11.1 1 1 POLE ADDER POWER BLOCK, 175 AMP TOP CONNECTION:(1) 2/O- #14 AWG BOTTOM CONNECTION:(6) #4- #14 AWG MARATHON 1320580 18 11.2 1 3 POLE POWER BLOCK COVER MARATHON CH1323 18 1.0 CB 0 CIRCUIT BREAKER, 1 POLE, 0.5A, 277V CURVE: D BULLETIN 1489 ALLEN- BRADLEY 1489-A1D005 18 1.1 0 CIRCUIT BREAKER, 1 POLE, 2A, 277V CURVE: C BULLETIN 1489 ALLEN- BRADLEY 1489-A1C020 18 2.0 DELTA PT 0 POTENTIAL TRANSFORMER, 480 - 120V, 4:1 RATIO, 150VA ITI 460-480 10 3.0 F1CT 0 CURRENT TRANSFORMER: FIXED RATIO RATIO: 200:5 CLASS: RELAY, C10 WINDOW: 4" ITI 110-201 10 LS-4 COMPONENTS Page 13 MATERIAL LIST ITEM SYM QTY DESCRIPTION MFG. PART NO. (Mfg Catalog Number) TAB SECTION 4.0 LS-4 0 CONTROLLER: LS4 CONTROL FUNCTIONS: MASTER SYNCHRONIZING, IMPORT/EXPORT CONTROL PT CONFIGURATION: WYE INPUT VOLTAGE: 200 L-L VAC, 3 PH-4W, 60 HZ CONTROL ADJUSTMENTS: VIA DISPLAY PANEL CONTROL VOLTAGE: 24VDC NOMINAL INTERFACE: CAN BUS FLUSH MOUNT WOODWARD 8440-1006 9 5.0 SYNC/ 25M 0 METER: SYNCHROSCOPE PLUS SYNC CHECK TYPE: 4 1/2" SWBD TYPE: 077-14HU SCALE: FAST - SLOW MOVEMENT: 120V, 60 HZ DEAD BUS RELAY CROMPTON 077-14HU-POYY-FQ 9 6.0 SS-F 0 SWITCH: SYNCHRONIZING POSITIONS: 2 DECKS: 2 ESCO 24203B 9 LEGEND: OFF - ON 7.0 DNET I/O 0 COMPACT BLOCK LDX I/O ANALOG OUTPUT MODULE 2 CHNL, 4-20ma DC ALLEN- BRADLEY 1790D-TNOC2 12 Page 14 MATERIAL LIST ITEM SYM QTY DESCRIPTION MFG. PART NO. (Mfg Catalog Number) TAB SECTION 7.1 0 COMPACT BLOCK LDX I/O DEVICE NET CONNECTOR W/ LOCKING SCREWS PHOENIX CONTACT 1786860 12 8.0 CTSB 0 TERMINAL BLOCK: CT SHORTING 4 POLE, 600V, 30A G.E. EB27B04SC 18 1.0 8290 0 ENGINE SPEED CONTROL MODULE, 24V WOODWARD 8290-184 1.0 G1-G3 BVC 3 BATTERY VOLTAGE CONVERTER INPUT: 12 VDC OUTPUT: 24 VDC SOLAR CONVERTERS , INC. EQ12/24-20 15 1.0 RTD 3 RTD SENSOR 3 WIRE, 100 OHM, PLATINUM 3" X .25", 316SS SHEATH 10' TEFLON LEADS W/ OVERBRAID RLB73303E10S 1.0 SPARE ANNUN 3 ANNUNCIATOR LAMP TYPE: LED DDP SP071012-R REV. 2 12VDC GEN COMPONENTS SHIP LOOSE COMPONENTS SPARE COMPONENTS MECHANICAL ENGINE COMPONENTS ANNUN LAMP TYPE: LED COLOR: RED VOLTAGE: 24VDC 1.1 2 ANNUNCIATOR LAMP TYPE: LED COLOR: GREEN VOLTAGE: 24VDC DDP SP071012-G 1.2 1 ANNUNCIATOR LAMP TYPE: LED COLOR: AMBER VOLTAGE: 24VDC DDP SP071012-A 2.0 SPARE CR 1 RELAY: CONTROL TYPE: PLUG-IN, DIN RAIL MOUNT POLES: 2PDT COIL VOLTAGE: 24VDC IDEC RH2BUL-DC24V 3.0 SPARE CR 1 RELAY: CONTROL TYPE: PLUG-IN, DIN RAIL MOUNT POLES: 3PDT COIL VOLTAGE: 24VDC IDEC RH3BUL-DC24V 4.0 SPARE CR 1 RELAY: CONTROL TYPE: PLUG-IN, DIN RAIL MOUNT POLES: 4PDT COIL VOLTAGE: 24VDC IDEC RH4BUL-DC24V Page 15 Section 4 g Power Break® II Circuit Breakers 800–4000 A Frames, 240–600 Vac User’s Guide GEH–6270C Power Break® II Circuit Breakers Getting Started Since this breaker is available in a variety of configurations, please take a moment to compare the catalog number of your purchased breaker with the catalog number key below. Installation of an incorrect breaker could result in misapplication, lack of system coordination, or reduced system selectivity. If you have any questions, call the GE Customer Support Center at 800-843-3742. S H F 16 B2 10 H Code Description Function S Power Break® II Breaker Family S H Standard Hi-Break Frame Type B D F Back-connected Draw-out Front-connected Connection Type 08 16 20 25 30 40 800 A 1600 A 2000 A 2500 A 3000 A 4000 A Frame Rating B2 B3 B4 D2 D3 D4 up to 2000 A CTs 2500–3000 A CTs 4000 A CTs up to 2000 A CTs 2500–3000 A CTs 4000 A CTs MicroVersaTrip Plus™ or MIcroVersaTrip PM™ Trip Unit Power+™ Trip Unit 02 04 08 10 16 20 25 30 40 200 A 400 A 800 A 1000 A 1600 A 2000 A 2500 A 3000 A 4000 A Maximum CT Current Rating H Standard High-range instantaneous➀ CT Type ➀ Available only with B-type Trip Units. Power Break® II insulated-case circuit breaker catalog numbering system. Example – a breaker with catalog number SHF16B210H has the following features: • Power Break® II (S) • Hi-Break® frame (H) • Front-connected (F) • 1600 A frame rating (16) • Trip Unit with up to 2000 A CT(B2) • 1000 A CT rating (10) • High-range instantaneous CT (H) i GEH–6270C WARNINGS, CAUTIONS, AND NOTES AS USED IN THIS PUBLICATION WARNINGS Warning notices are used in this publication to emphasize that hazardous voltages, currents, or other conditions that could cause personal injury are present in this equipment or may be associated with its use. Warning notices are also used for situations in which inattention or lack of equipment knowledge could cause either personal injury or damage to equipment. CAUTIONS Caution notices are used for situations in which equipment might be damaged if care is not taken. NOTES Notes call attention to information that is especially significant to understanding and operating the equipment. This document is based on information available at the time of its publication. While efforts have been made to ensure accuracy, the information contained herein does not cover all details or variations in hardware and software, nor does it provide for every possible contingency in connection with installation, operation, and maintenance. Features may be described herein that are not present in all hardware and software systems. GE Electrical Distribution & Control assumes no obligation of notice t o holders of this document with respect to changes subsequently made. GE Electrical Distribution & Control makes no representation or warranty, expressed, implied, or statutory, with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warrantees of merchantability or fitness for purpose shall apply. The following are trademarks of GE Company: Power Break®, MicroVersaTrip Plus™, MicroVersaTrip PM™, Power+™ © Copyright 1997 GE Company All Rights Reserved Power Break® II Circuit Breakers Table of Contents ii Chapter 1. Introduction 1-1 Overview ........................................................................................................................1 1-2 Receiving the Breaker .....................................................................................................1 Storage....................................................................................................................1 1-3 Preparation for Installation .............................................................................................1 Bolted Electrical Connections...................................................................................1 Panel Cutouts and Clearances..................................................................................1 Accessory Installation ..............................................................................................2 1-4 Breaker Installation ........................................................................................................3 Chapter 2. Operation 2-1 Standard Features...........................................................................................................4 2-2 Operating Instructions....................................................................................................4 Sequence of Operations ...........................................................................................4 Operating Instructions for Manually Operated Breakers ............................................4 Additional Instructions for Motor-Operated Breakers .................................................6 Padlock Operation...................................................................................................6 Periodic Operational Checks....................................................................................6 Wiring Notes ...........................................................................................................6 2-3 Trip Unit Setup..............................................................................................................7 Chapter 3. Accessory Operation 3-1 Lug and Adapter Kits .....................................................................................................8 Lug Kits (800–2000 A Frames).................................................................................8 Lug Kits with Straps (2500–4000 A Frames)..............................................................8 T-Studs ...................................................................................................................8 Adapter Kits............................................................................................................8 3-2 Plug-In Accessory Compartment......................................................................................9 3-3 Bell Alarm–Alarm Only ..................................................................................................9 Operation ...............................................................................................................9 3-4 Bell Alarm with Lockout.................................................................................................10 Operation ..............................................................................................................10 3-5 Shunt Trip ....................................................................................................................10 Operation ..............................................................................................................11 3–6 Shunt Trip with Lockout ...............................................................................................11 Operation ..............................................................................................................11 3-6 Undervoltage Release ....................................................................................................12 Operation ..............................................................................................................12 3-8 Accessory Configuration with MicroVersaTrip Plus™ and MicroVersaTrip PM™ Trip Units ...........................................................................................................................12 Description of Switch Settings ..................................................................................13 3-9 Motor Operator Mechanism ...........................................................................................13 Remote Operation ..................................................................................................14 Power Break® II Circuit Breakers Table of Contents iii Automatic Operation ..............................................................................................14 3-10 Remote Close ..............................................................................................................14 Remote Operation ..................................................................................................14 3-11 Key Interlock Mounting Provision .................................................................................14 Operation ..............................................................................................................14 3-12 Mechanical Counter ....................................................................................................15 3-13 Auxiliary Switch Module...............................................................................................15 Operation ..............................................................................................................15 3-14 Door Interlock .............................................................................................................16 Operation ..............................................................................................................16 3-15 Push Button Cover .......................................................................................................17 Operation ..............................................................................................................17 Chapter 4. Trouble-Shooting Guide ..................................................................................18 Power Break® II Circuit Breakers List of Figures iv 1. Locations of the front-panel escutcheon cutout and mounting holes, 800–2000 A frames...............2 2. Locations of the front-panel escutcheon cutout and monting plate, 2500–4000 A frames................2 3. Locations of the 1/4–20 x 3/8-inch deep screw inserts for mounting the breaker in equipment, 800–2000 A frames....................................................................................................................3 4. Locations of the 3/8–16 x 7/16-inch deep screw inserts for mounting the breaker in equipment, 2500–3000 A back-connected frames...........................................................................................3 5. Locations of the 3/4-inch diameter through holes for mounting the breaker in equipment, 4000 A front-connected frame............................................................................................................3 6. Front of the breaker, showing the locations of standard features....................................................4 7. Front of the breaker, with the Trip Unit and top cover removed....................................................4 8. Side view of the breaker, showing the padlock hasp extended.......................................................6 9. Terminal block mounted on the right side of the breaker.............................................................7 10. Locations of the plug-in accessory modules In the compartment on the front of the breaker..........9 11. Bell Alarm–Alarm Only module.................................................................................................9 12. Bell Alarm–Alarm Only connections on the right terminal block..................................................9 13. Bell Alarm with Lockout module...............................................................................................10 14. Bell Alarm with Lockout connections on the right terminal block................................................10 15. Shunt Trip module...................................................................................................................10 16. Shunt Trip with Lockout module...............................................................................................11 17. Undervoltage Release module...................................................................................................12 18. Accessory configuration switch on the rear of MicroVersaTrip Plus™ and MicroVersaTrip PM™ Trip Units, showing the factory settings......................................................................................13 19. Motor Operator Mechanism......................................................................................................13 20. Remote Close accessory............................................................................................................14 21. Side view of the breaker, showing the padlock tab extended with the Key Interlock installed..........15 22. Mechanical Counter.................................................................................................................15 23. Auxiliary Switch Module with 12 switches...................................................................................15 25. Door Interlock accessory installed on the breaker.......................................................................16 26. Push Button Cover....................................................................................................................17 Power Break® II Circuit Breakers List of Tables v 1. Weights of the various breaker frame sizes, with and without a motor operator...............................1 2. Bolt sizes and mounting torques for bus connections...................................................................1 3. Sequence of operations that may be performed with Power Break II circuit breakers......................5 4. Accessory connections to the right terminal block B.....................................................................7 5. Catalog numbers and wire sizes of Lug Kits for 800–2000 A frames...............................................8 6. Catalog numbers and specifications of Lug Kits with Straps for 2500–4000 A frames......................8 7. Catalog numbers and ratings of T-Studs......................................................................................8 8. Catalog numbers and ratings of Adapter Kits..............................................................................8 9. Bell Alarm–Alarm Only catalog numbers....................................................................................9 10. Bell Alarm with Lockout catalog numbers..................................................................................10 11. Catalog numbers and voltages for the Shunt Trip.......................................................................11 12. Catalog numbers and voltages for the Shunt Trip with Lockout....................................................11 13. Catalog numbers and voltages for the Undervoltage Release........................................................12 14. Accessory configuration switch settings, including the factory defaults.........................................13 15. Catalog numbers and operating voltages for the Motor Operator Mechanism...............................13 16. Catalog numbers and operating voltages for the Remote Close accessory......................................14 17. Catalog numbers of Key Interlock models..................................................................................14 18. Auxiliary Switch Module catalog numbers..................................................................................15 19. Auxiliary switch positions on the terminal board on the left side of the breaker, Block A...............16 Power Break® II Circuit Breakers Chapter 1. Introduction 1 1-1 Overview Power Break® II insulated-case circuit breakers are designed to protect low-voltage power circuits and equipment. They are available with MicroVersaTrip Plus™, MicroVersaTrip PM™, and Power+™ Trip Units for fault detection. 1-2 Receiving the Breaker Unpack the circuit breaker and inspect it for shipping damage. Ensure that the breaker has the proper current, voltage, and interruption ratings for the application by comparing the catalog number with the table in the Getting Started section on the inside front page. The weights of the various frame sizes are listed in Table 1, for reference. FFFFrrrraaaammmmeeee RRRRaaaattttiiii nnnngggg OOOOppppeeeerrrraaaattttiiiioooonnnn TTTTyyyyppppeeee WWWWeeeeiiiigggghhhhtttt ((((llllbbbb)))) 800 A Manual Electrical 71 80 1600 A or 2000 A Manual Electrical 79 88 2500 A Front Connect Manual Electrical 178 187 2500 A Back Connect Manual Electrical 167 176 3000 A Front Connect Manual Electrical 179 188 3000 A Back Connect Manual Electrical 216 225 4000 A Manual Electrical 320 329 Table 1. Weights of the various breaker frame sizes, with and without a motor operator. Storage The breaker should be placed in service immediately in its permanent location. However, if it must be stored for an indefinite period, it should be carefully protected against condensation, preferably by storage in a warm dry room. Circuit breakers for outdoor equipment should be stored in that equipment only when power is available and heaters are in operation, to prevent condensation. The breaker should be stored in a clean location, free from corrosive gases or fumes. In particular, protect the breaker from moisture and cement dust, as that com- bination may be corrosive. If the breaker is stored for any length of time, it should be inspected periodically to ensure good mechanical condition. 1-3 Preparation for Installation Bolted Electrical Connections Using an industry-accepted solvent, remove any foreign material from the line and load strap surfaces and the corresponding surfaces of the connecting bus. Ensure that the mating surfaces are smooth and free of burrs and nicks. Place the bus connections in position and align the mounting holes. Insert and fasten the mounting bolts and washers according to specifications in Table 2. BBBBuuuussss CCCCoooonnnnnnnneeeeccccttttiiiioooonnnn BBBBrrrreeeeaaaakkkkeeeerrrr FFFFrrrraaaammmmeeee BBBBoooolllltttt DDDDiiiiaaaammmm.... TTTToooorrrrqqqquuuueeee ((((iiiinnnn----llllbbbb)))) 800A (1) 1/2 in. 300 1600-2000A (2) 1/2 in. 300 2500 A (4) 3/8 in. 225 3000 A (4) 3/8 in. 225 4000 A (6) 1/2 in. 300 Table 2. Bolt sizes and mounting torques for bus connections. Panel Cutouts and Clearances Use the following information to prepare the equipment and assure proper clearances for installation and operation of the breaker. Figures 1 and 2 show the front-panel escutcheon cutout patterns and the locations of the breaker mounting bolts. The standard door cutout dimensions require a trim plate on the breaker. The optional dimensions are for flush front or non hinged door construction and the trim plate may be omitted. Ventilation cutouts are required for stationary-mounted breakers rated 1600 A and larger and for draw-out breakers rated 2000 A and larger. Ventilation cutouts are not required for draw-out- mounted 800 A or 1600 A frame breakers or for stationary-mounted 800 A frame breakers. Because of arc chamber venting, the minimum through- air distance from the top of the breaker’s molded case to grounded metal for 800–2000 A breakers is 4.50 inches [114 mm] in an area 5.31 inches x 16.00 inches [135 mm x 406 mm], centered over the vent screens. (Refer to outline drawings 10054370, Sheets 1–5, for details.) For 2500–4000 A breakers, the minimum through-air distance from the top of the breaker’s molded case to grounded metal is 8.00 inches [203 mm] in an area 9.00 inches x 16.00 inches [227 mm x 406 mm], over the vent screens. (Refer to outline drawings 10055629, Sheets 1–7, for details.) Power Break® II Circuit Breakers Chapter 1. Introduction 2 Figure 1. Locations of the front-panel escutcheon cutout and mounting holes, 800–2000 A frames. Accessory Installation The following accessories may be installed in the breaker. Refer to Chaper 3 of this publication for catalog numbers and to the instruction sheet supplied with each accessory for installation instructions. • Lugs and Adapters • Motor Operator Mechanism • Remote Close • Undervoltage Release • Shunt Trip • Shunt Trip with Lockout • Bell Alarm–Alarm Only • Bell Alarm with Lockout • Auxiliary Switch Module • Mechanical Counter • Key Interlock Mounting Provision • Push Button Cover • Door Interlock • Mechanical Interlock Figure 2. Locations of the front-panel escutcheon cutout and mounting plate, 2500–4000 A frames. Power Break® II Circuit Breakers Chapter 1. Introduction 3 1-4 Breaker Installation Ensure that all accessory connections are secure. Line up the bolt holes in the enclosure with the attachment points on the breaker, illustrated in Figures 3, 4 and 5, insert the bolts and tighten. Use nonmagnetic material in the area between the line and load terminals to support the breaker. Figure 3. Locations of the 1/4–20 x 3/8-inch deep screw inserts for mounting the breaker in equipment, 800–2000 A frames. Figure 4. Locations of the 3/8–16 x 7/16-inch deep screw inserts for mounting the breaker in equipment, 2500–3000 A back-connected frames. Figure 5. Locations of the 3/4-inch diameter through holes for mounting the breaker in equipment, 4000 A front-connected frame. Power Break® II Circuit Breakers Chapter 2. Operation 4 2-1 Standard Features Power Break II circuit breakers are equipped with the following standard features. The letters are keyed to the breaker photographs in Figures 6 and 7. AAAA Indicator:ON – Red OFF – Green BBBB Indicator:CHARGED – Yellow DISCHARGED – White CCCC ON button DDDD OFF button EEEE Manual charging handle FFFF Integral 36-point terminal block (12 auxiliary switches, A-B type), Block “A” GGGG Integral 36-point terminal block (all other con- nections), Block “B” HHHH Sealable hinged cover IIII Cover mounting screws (4) KKKK Trip Unit interchangeable rating plug LLLL Test set connection port MMMM Standard padlock provision NNNN Dust-resistant ventilation slots Figure 6. Front of the breaker, showing the locations of standard features. Figure 7. Front of the breaker, with the Trip Unit and top cover removed. 2-2 Operating Instructions Sequence of Operations The sequence of operations that may be performed on the circuit breaker are listed in Table 3. Refer to Chapter 3 for information about accessory operation. Operating Instructions for Manually Operated Breakesr Charging the Mechanism Springs Pull the operating handle down about 90° (until it stops). Repeat five more times to fully charge the springs. This will not close the breaker contacts. The charge indicator will show CHARGED on a yellow background. When the springs are fully charged, the handle locks in the stored position. NNNN OOOO TTTT EEEE :::: The breaker cannot be closed unless the springs are fully charged and the handle is stored fully in. NNNN OOOOTTTT EEEE :::: La fermeture du disjoncteur ne peut être réal- isée à moins que les ressorts soient réarmés tout à fait, et le levier est complètement remis à la position d’emmagasinage. Power Break® II Circuit Breakers Chapter 2 – Operation 5 On/Off Indicator Charge Indicator Main Breaker Contacts Condition of Charging Springs Next Permissible Operating Function OFF DISCHARGED Open Discharged Mechanism may be charged OFF CHARGED Open Charged Contacts may be closed ON DISCHARGED Closed Discharged Mechanism may be recharged or Contacts may be opened ON CHARGED Closed Charged Contacts may be opened Table 3. Sequence of operations that may be performed with Power Break II circuit breakers. Closing the Breaker Close the breaker contacts with either of the following methods: • Depress the ON button on the front of the breaker. • Energize the (optional) Remote Close accessory by applying rated voltage to terminals 16 and 34 on terminal block B. CCCC AAAA UUUU TTTT IIII OOOO NNNN :::: The main breaker contacts cannot be closed if the breaker latch is held in the tripped posi- tion by any of the following conditions: • The Bell Alarm with Lockout was not reset after an overcurrent lockout. • The Undervoltage Release is not energized. • The Shunt Trip with Lockout is energized. These conditions must be corrected before the breaker can be closed. AAAA TTTT TTTT EEEE NNNN TTTT IIII OOOO NNNN :::: Les contacts de disjoncteur principal peuvent être fermés où le loquet de disjoncteur est maintenu en position déclenchée à cause de toute des conditions suivantes: • Si la réarmeture du déclencheur n’est pas réalisée après le verrouillage en position “ouvert” provenant du courant de surcharge. • Si le minimum de tension (UVR) n’est pas sous tension. • Le déclenchement shunt avec blocage est actionné. Ces conditions doivent être corrigées avant le disjoncteur peut être fermé. CCCCAAAAUUUUTTTTIIIIOOOONNNN:::: If the breaker latch is held in the tripped position by any of the following conditions and an attempt is made to close the main breaker contacts, the mechanism will “crash” (the closing springs discharge with no motion of the breaker contact arms). The circuit breaker has been designed and tested to withstand more than 100 crash operations, but repeated attempts to close a locked-out breaker will damage the breaker mechanism. • The Key interlock or padlock is in the locked OFF condition. • The draw-out interlock is engaged with the carriage between the TEST and CONNECTED positions. • The walking beam interlock or mechanical interlock is activated. AAAA TTTTTTTT EEEENNNN TTTTIIIIOOOO NNNN:::: Si le cliquet du disjoncteur est tenu en position de déclenchement dans n’importe quelle des conditions suivantes et que l’on tente de fermer les contacts du disjoncteur principal, le mécanisme subira un “crash” (les ressorts de fermeture se détendent sans que les bras des contacts du disjoncteur ne bougent). Le disjoncteur a été conçu et testé pour résister à plus de 100 opérations de type “crash,” cependant des tentatives répétées ayant pour but de fermer un disjoncteur bloqué endommageront le mécanisme du disjoncteur. • Si le verrou de clé ou le cadenas est verrouillé en position OFF. • Si le chariot du verrou débrochable est localisé entre les positions TEST et CONNECTED. • L’enclenchement par support mobile ou enclenchement mécanique est activé. Power Break® II Circuit Breakers Chapter 2. Operation 6 Opening the Breaker Open the breaker contacts with either of the following methods: • Depress the OFF button on the front of the breaker. • Energize the (optional) Shunt Trip or Shunt Trip with Lockout accessory or de-energize the (optional) Undervoltage Release accessory. Additional Instructions for Motor-Operated Breakers Charging the Mechanism Springs The mechanism closing springs may also be charged by the following method: • Short terminals 17 and 35 on the right terminal block, with a push button or similar device, for a minimum of five seconds. • If power is lost during the charge cycle, finish charging the springs by cycling the charging handle until the indicator shows CHARGED on a yellow background. When the springs are fully charged, the handle locks in the stored position. Automatic Operation Connect terminals 17 and 35 on the terminal block on the right side of the breaker with a jumper wire. The Motor Operator will automatically recharge the breaker closing springs whenever the breaker closes. CCCCAAAAUUUUTTTTIIIIOOOONNNN:::: Do not wire breakers for automatic close. AAAATTTT TTTTEEEENNNN TTTTIIII OOOO NNNN :::: Ne pas connecter les disjoncteurs pour la fermeture automatique. Padlock Operation The padlock prevents the breaker from closing by holding the trip latch in the tripped position. To install the padlock, use the following procedure: 1111 ....Trip the breaker (press the OFF button). 2222 ....Grasp the padlock tab (see Figure 6) and pull it out until it is fully extended, as illustrated in Figure 8. Note that if the breaker contacts are closed, the padlock tab will not extend. 3333 ....Insert the padlock; the breaker will not close. As many as three 1/4" to 3/8" padlocks may be attached at one time. Figure 8. Side view of the breaker, showing the padlock tab extended. Periodic Operational Checks Approximately once a year, verify that the breaker is operating correctly by opening and closing the mechanism. Wiring Notes Figure 9 illustrates the terminal block installed on the right side of the breaker. Table 4 lists the device con- nections to the terminal block. Each terminal point will accept the following connections: • Bare stripped wire – one #12 AWG or two #14 AWG. • Ring or spade connectors – two per terminal. The terminal screws should be tightened to 7–9 in-lb torque. The left terminal block is blank unless the optional Auxiliary Switch Module accessory is ordered. See Table 16 for the device connections to the Auxiliary Switch Module terminal block. Power Break® II Circuit Breakers Chapter 2. Operation 7 Figure 9. Terminal block mounted on the right side of the breaker. Terminal Terminal 18 Motor Operator + 36 Motor Operator – 17 Remote Charge 35 Remote Charge 16 Remote Close + 34 Remote Close – 15 Bell Alarm only Com 33 Charge Indicator 14 Bell Alarm only NO 32 Shunt Trip 13 Bell Alarm only NC 31 Shunt Trip 12 Lockout Common 30 Undervoltage Release 11 Lockout NO 29 Undervoltage Release 10 Lockout NC 28 Reserved 9 Reserved 27 Reserved 8 Reserved 26 Zone-Select Input – 7 commnet – 25 Zone-Select Input + 6 commnet + 24 Zone-Select Output – 5 C Phase Volts 23 Zone-Select Output + 4 B Phase Volts 22 Draw-Out Switch 3 A Phase volts 21 Draw-Out Switch 2 24 Vdc – 20 N Tap 1 24 Vdc + 19 N Common Do not apply voltage; see wiring diagram. Not a user connection. Table 4. Accessory connections to the right-side terminal block B. 2-3 Trip Unit Setup See GEH–6273 for detailed instructions on setting u p MicroVersaTrip Plus and MicroVersaTrip PM Trip Units. The procedure for setting up the accessory configuration DIP switch on the rear of the Trip Unit is described in Chapter 3 of this publication. See DEH–049 for detailed instructions on setting u p Power+ Trip Units. Power Break® II Circuit Breakers Chapter 3. Accessory Operation 8 Following are the operation procedures for each of the available breaker accessories. See the user guides sup- plied with the accessories for installation and removal. 3-1 Lug and Adapter Kits Lug Kits (800–2000 A Frames) Direct-mounting lugs bolt directly to the line or load strap of the circuit breaker. Order one Lug Kit per line or load pole. Lug Kit catalog numbers and wire sizes are listed in Table 5. Cat. No. Wires Wire Sizes Amps TPLUG106 1 2 #2–600 kcmil CU/AL 1/0–250 kcmil CU/AL 400 TPLUG206 2 #2–600 kcmil CU/AL 600 TPLUG308 3 300-750 kcmil CU/AL 800 TPLUG408 4 500–800 kcmil CU/AL 1600 Table 5. Catalog numbers and wire sizes of Lug Kits for 800–2000 A frames. Lug Kits with Straps (2500–4000 A Frames) Lug Kits with Straps include copper straps that connect directly to breaker T-studs (must be ordered separately) to provide proper phase clearances for mounting lugs. Order one Lug Kit with Straps per line or load side. Catalog numbers are listed in Table 6. Cat. No. Lugs per Kit Max. Wires per Pole Wire Range Frame Size (A) Max. Amps TSLUG08 9 3 800 TSLUG12 12 4 2500 or 1200 TSLUG16 15 5 3/0- 800 3000 1600 TSLUG20 18 6 kcmil 2000 TSLUG25 21 7 Cu/Al 2500 TSLUG30 27 9 3000 3000 TSLUG40 33 11 4000 4000 Table 6. Catalog numbers and specifications of Lug Kits with Straps for 2500–4000 A frames. T-Studs T-Studs bolt directly to the line or load terminals of the breaker. Order one T-Stud per line or load pole. T-Stud catalog numbers and ratings are listed in Table 7. Cat. No. Material Frame (A) Max. Amps Breaker Connect SP08FCA Al 800 800 Front SP08FCC Cu 800 800 Front SP20FCA Al 1600–2000 2000 Front SP20FCC Cu 1600–2000 2000 Front SPS20FCA Al 2500 2000 Front SPS20BCA Al 2500 2000 Back SPS25FCC Cu 2500 2500 Front SPS25BCC Cu 2500 2500 Back SPS30FCC Cu 3000 3000 Front N/A Cu 3000 3000 Back SPS40FCC Cu 4000 4000 Front SPS40LFCC Cu 4000 4000 Front Integral T-Studs are not removable on 3000 A back-connected breakers. Long studs may be used in place of or alternated with SPS40FCC if desired. Table 7. Catalog numbers and ratings of T-Studs. Adapter Kits Adapter Kits bolt directly to the line or load terminals on the rear of the breaker. They provide proper phase-to- phase clearances for mounting lugs or busbars. Order one Adapter Kit per three-phase line or load side. Lugs must be ordered separately. Adapter Kit catalog numbers and ratings are listed in Table 8. Cat. No. Frame (A) Lug Odering Information (Per Line or Load Side) TPLUGA08 800 9 TPLUG108 Lugs or 9 Crimp Lugs TPLUGA16 1600 18 TPLUG108 Lugs or 18 Crimp Lugs TPLUGA20 1600–2000 18 TPLUG108 Lugs or 18 Crimp Lugs Premounts in equipment, allowing cabling or bussing to be completed before breaker mounting. 3/0–800 kcmil Cu/Al wire range. Anderson No. VCEL-075-12H1 or equivalent. Table 8. Catalog numbers and ratings of Adapter Kits. Power Break® II Circuit Breakers Chapter 3. Accessory Operation 9 3-2 Plug-In Accessory Compartment Several of the accessories are installed in the accessory compartment on the front of the breaker. Figure 10 illustrates this compartment and the locations of each of the plug-in accessory modules. Figure 10. Locations of the plug-in accessory modules in the compartment on the front of the breaker. 3-3 Bell Alarm–Alarm Only The Bell Alarm–Alarm Only module, shown in Figure 11, provides a switch to remotely indicate that the circuit breaker has tripped. It is reset either automatically when the circuit breaker is reclosed or manually when the reset button on the front o f the Bell Alarm–Alarm Only module is pressed. Figure 11. Bell Alarm–Alarm Only module. In addition to activation by protection trips, the Bell Alarm–Alarm Only accessory module can be set up t o interact with other Power Break II accessories, when used with a MicroVersaTrip Plus™ or MicroVersaTrip PM™ Trip Unit. DIP switches on the rear of the MicroVersaTrip Plus or MicroVersaTrip PM Trip Unit can configure the Bell Alarm–Alarm Only accessory t o activate when a Shunt Trip or Undervoltage Release trip occurs. The Power+™ Trip Unit activates the Bell Alarm–Alarm Only for protection trips only. The catalog numbers for the Bell Alarm–Alarm Only are listed in Table 9. For installation instructions see GEH– 6275. Catalog No. Contact Rating SPBAA240 6 A at 240 Vac 0.25 A at 250 Vdc 0.50 A at 125 Vdc SPBAA600 6 A at 600 Vac 0.25 A at 250 Vdc 0.50 A at 125 Vdc 600 V version is not UL listed. Table 9. Bell Alarm–Alarm Only catalog numbers. Operation The Bell Alarm–Alarm Only provides normally open (NO) and normally closed (NC) outputs available at the terminal block on the right side of the breaker, as illustrated in Figure 12. The outputs change state whenever a breaker trip occurs. This trip can be caused by an overcurrent condition detected by the Trip Unit. This trip can also be generated by the Shunt Trip or Undervoltage Release, if installed with a MicroVersaTrip Plus™ or MicroVersaTrip PM™ Trip Unit, and if the appropriate DIP switches have been set on the back of the Trip Unit (see Section 3-8, Accessory Configuration at the Trip Unit). The Bell Alarm–Alarm Only accessory resets auto- matically, returning the outputs to their normal con- figuration, when the breaker is reclosed. The Bell Alarm–Alarm Only can also be reset manually, before the breaker is reclosed, by pressing the reset button on the front of the module. Figure 12. Bell Alarm–Alarm Only connections on the right terminal block. The contacts are shown in the reset state. Power Break® II Circuit Breakers Chapter 3. Accessory Operation 10 3-4 Bell Alarm with Lockout The Bell Alarm with Lockout module, shown in Figure 13, prevents reclosing of the breaker after a trip until the Bell Alarm with Lockout is reset. I t can only be reset by pressing the button on the t op of the module. This module also provides a switch to remotely indicate that the circuit breaker has tripped. Figure 13. Bell Alarm with Lockout module. In addition to activation by protection trips, the Bell Alarm with Lockout accessory module can be set up to interact with other Power Break II accessories when used with a MicroVersaTrip Plus™ or MicroVersaTrip PM™ Trip Unit. DIP switches on the rear of the MicroVersaTrip Plus or MicroVersaTrip PM Trip Unit can configure the Bell Alarm with Lockout accessory t o activate when a Shunt Trip or Undervoltage Release trip occurs. The Power+™ Trip Unit activates the Bell Alarm with Lockout for protection trips only. The catalog numbers for the Bell Alarm with Lockout are listed in Table 10. For installation instructions see GEH– 6278. Catalog No. Contact Rating SPBAL240 6 A at 240 Vac 0.25 A at 250 Vdc 0.50 A at 125 Vdc SPBAL600 6 A at 600 Vac 0.25 A at 250 Vdc 0.50 A at 125 Vdc The 600 V version is not UL listed. Table 10. Bell Alarm with Lockout catalog numbers. Operation The Bell Alarm with Lockout prevents reclosing of the breaker after a trip until the reset button on the front of the module is pressed. This trip can be caused by an overcurrent condition detected by the Trip Unit. This trip can also be generated by the Shunt Trip, Shunt Trip with Lockout, or Undervoltage Release, if installed with a MicroVersaTrip Plus™ or MicroVersaTrip PM™ Trip Unit, and if the appropriate DIP switches have been set on the back of the Trip Unit (see Section 3-8, Accessory Configuration at the Trip Unit). In addition, the Bell Alarm with Lockout provides normally open (NO) and normally closed (NC) alarm outputs available at the terminal block on the right side of the breaker, as illustrated in Figure 14. These outputs are returned to their normal state when the Bell Alarm with Lockout reset button is firmly pressed. Figure 14. Bell Alarm with Lockout connections on the right terminal block. The contacts are shown in the reset state. 3-5 Shunt Trip The Shunt Trip module, shown in Figure 15, allows the breaker to be tripped electrically from a remote location. Figure 15. Shunt Trip module. In addition to providing a trip signal to the breaker, the Shunt Trip accessory module can be set up to interact with other Power Break II accessories, when used with a MicroVersaTrip Plus™ or MicroVersaTrip PM™ Trip Unit. DIP switches on the rear of the Trip Unit can configure the Shunt Trip accessory to activate a Bell Alarm–Alarm Only accessory or a Bell Alarm with Lockout accessory when a Shunt trip occurs. (See Section 3-8, Accessory Configuration at the Trip Unit.) If the breaker is equipped with a Power+™ Trip Unit, it is configured so that only protection trips will activate a Bell Alarm–Alarm Only or Bell Alarm with Lockout. Power Break® II Circuit Breakers Chapter 3. Accessory Operation 11 The catalog numbers for the Shunt Trip for various voltage applications are listed in Table 11. For instal- lation instructions see GEH–6284 or GEH–6519. Catalog Number Voltage Rating Peak Inrush Current, A Nominal RMS Current, mA SPST012 12 Vdc 3.0 200 SPST024 24 Vac 24 Vdc 1.5 140 SPST048 48 Vac 48 Vdc 1.5 110 SPST120 120 Vac 125 Vdc 1.5 85 SPST208 208 Vac 1.5 50 SPST240 240 Vac 250 Vdc 1.5 40 SPST480 480 Vac 0.375 21 SPST600 600 Vac 0.3 17 24–600 Vac devices are rated for 50/60 Hz. Peak inrush current is present for 2–6 ms after activation. This number is provided so that fuses and supplies can be chosen appropriately. Ratings for 480 Vac and 600 Vac devices are at the input of the upstream transformer, included with the accessory and specified in GEH–6519, which powers the device. For voltage and current ratings at the breaker terminal block, see SPST120. Table 11. Catalog numbers and voltages for the Shunt Trip. Operation Apply control voltage to terminals 31 and 32 of the terminal strip on the right side of the breaker to trip the circuit breaker. The Shunt Trip will cause the circuit breaker to trip when the control voltage is greater than 75% of the dc-rated value or 55% of the ac-rated value. 3–6 Shunt Trip with Lockout The Shunt Trip with Lockout module, shown in Figure 16, allows the breaker to be tripped electrically from a remote location and prevents the circuit breaker from closing while the accessory is energized. Figure 16. Shunt Trip with Lockout module. In addition to providing a trip signal to the breaker, the Shunt Trip with Lockout accessory module can be set up to interact with other Power Break II accessories, when used with a MicroVersaTrip Plus™ or MicroVersaTrip PM™ Trip Unit. DIP switches on the rear of the Trip Unit can configure the Shunt Trip with Lockout accessory to activate a Bell Alarm–Alarm Only accessory or a Bell Alarm with Lockout accessory when a Shunt trip occurs. (See Section 3-8, Accessory Configuration at the Trip Unit.) If the breaker is equipped with a Power+™ Trip Unit, it is configured so that only protection trips will activate a Bell Alarm–Alarm Only or Bell Alarm with Lockout. The catalog numbers for the Shunt Trip for various voltage applications are listed in Table 12. For instal- lation instructions see GEH–6284 or GEH–6519. Catalog Number Voltage Rating Peak Inrush Current, A Nominal RMS Current, mA SPSTL012 12 Vdc 19 300 SPSTL024 24 Vac 24 Vdc 15 300 SPSTL048 48 Vac 48 Vdc 7.5 200 SPSTL120 120 Vac 125 Vdc 3.0 80 SPSTL208 208 Vac 1.9 60 SPSTL240 240 Vac 250 Vdc 1.5 45 SPSTL480 480 Vac 0.75 20 SPSTL600 600 Vac 0.60 16 24–600 Vac devices are rated for 50/60 Hz. Peak inrush current is present for 2–6 ms after activation. This number is provided so that fuses and supplies can be chosen appropriately. Ratings for 480 Vac and 600 Vac devices are at the input of the upstream transformer, included with the accessory and specified in GEH–6519, which powers the device. For voltage and current ratings at the breaker terminal block, see SPSTL120. Table 12. Catalog numbers and voltages for the Shunt Trip with Lockout. Operation Apply control voltages to terminals 31 and 32 of the terminal strip on the right side of the breaker to trip the circuit breaker. The Shunt Trip with Lockout will cause the circuit breaker to trip when the control voltage is greater than 75% of the dc-rated value or 55% of the ac- rated value. Power Break® II Circuit Breakers Chapter 3. Accessory Operation 12 3-7 Undervoltage Release The Undervoltage Release (UVR) module, shown in Figure 17, trips the circuit breaker when the input control voltage drops to 35–60% of its rated value and prevents an open breaker from closing until the input control voltage is greater than 80% of the rated value. In addition to providing a trip signal to the breaker, the UVR accessory module can be set up to interact with other Power Break II accessories, when used with a MicroVersaTrip Plus™ or MicroVersaTrip PM™ Trip Unit. DIP switches on the rear of the Trip Unit can configure the UVR accessory to activate a Bell Alarm– Alarm Only accessory or a Bell Alarm with Lockout acces- sory when a UVR trip occurs. (See Section 3-8, Accessory Configuration at the Trip Unit.) If the breaker is equipped with a Power+™ Trip Unit, it is configured so that only protection trips will activate a Bell Alarm– Alarm Only or Bell Alarm with Lockout. Figure 17. Undervoltage Release module. The catalog numbers for the UVR for various voltage applications are listed in Table 13. For installation instructions see GEH-6285 or GEH–6520. Operation Apply control voltage to terminals 29 and 30 of the terminal strip on the right side of the breaker. When the applied control voltage is above 80% of the UVR’s rated value, the breaker can be closed. When the voltage drops to 35–60% of the rated value, the UVR will trip the breaker. Catalog Number Voltage Rating Peak Inrush Current, A Nominal RMS Current, mA SPUV012DC 12 Vdc 19 300 SPUV024DC 24 Vdc 15 140 SPUV048DC 48 Vdc 7.5 70 SPUV125DC 125 Vdc 3 30 SPUV250DC 250 Vdc 1.5 15 SPUV024AC 24 Vac 15 370 SPUV048AC 48 Vac 7.5 210 SPUV120AC 120 Vac 3 80 SPUV208AC 208 Vac 1.9 60 SPUV240AC 240 Vac 1.5 45 SPUV480AC 480 Vac 0.75 20 SPUV600AC 600 Vac 0.60 16 24–600 Vac devices are rated for 50/60 Hz. Peak inrush current is present for 2–6 ms after activation. This number is provided so that fuses and supplies can be chosen appropriately. Ratings for 480 Vac and 600 Vac devices are at the input of the upstream transformer, included with the accessory and specified in GEH–6520, which powers the device. For voltage and current ratings at the breaker terminal block, see SPUV120AC. Table 13. Catalog numbers and voltages for the Undervoltage Release. 3-8 Accessory Configuration with MicroVersaTrip Plus™ and MicroVersaTrip PM™ Trip Units MicroVersaTrip Plus and MicroVersaTrip PM Trip Units have a six-position DIP switch module on the rear of the unit that controls the configuration of the Power Break II integrated accessories. These switches can be set up to define the types of signals (protection trip, Shunt trip, or Undervoltage Release trip) that activate the Bell Alarm– Alarm Only and Bell Alarm with Lockout accessories on the Power Break II breaker. Each of the six switches enables or disables a different path to activate these accessories from the different types of trip signals. The MicroVersaTrip Plus and MicroVersaTrip PM Trip Unit DIP switches are illustrated in Figure 18, with the factory settings shown. Table 14 lists the switch functions. There are no DIP switches on the rear of the Power+™ Trip Unit, which performs according to the default settings in Table 14. Therefore, only protection trips activate Bell Alarm–Alarm Only and Bell Alarm with Lockout accessories when a Power+ Trip Unit is installed in the breaker. Power Break® II Circuit Breakers Chapter 3. Accessory Operation 13 Figure 18. Accessory configuration switch on the rear of MicroVersaTrip Plus™ and MicroVersaTrip PM™ Trip Units, showing the factory settings (solid part indicates that the switch is pushed in on that side). Switch Factory Setting Function 1 Disabled Shunt trip activates Bell Alarm–Alarm Only 2 Disabled UVR trip activates Bell Alarm–Alarm Only 3 Enabled Protection trip activates Bell Alarm– Alarm Only 4 Disabled Shunt trip activates Bell Alarm with Lockout 5 Disabled UVR trip activates Bell Alarm with Lockout 6 Enabled Protection trip activates Bell Alarm with Lockout Table 14. Accessory configuration switch settings, including the factory defaults. Description of Switch Settings Following are descriptions of the effects of each accessory switch when it is enabled: 1111 ....When a Shunt Trip accessory causes the breaker to trip, the contacts of the Bell Alarm–Alarm Only also change state. The factory switch setting is disabled. 2222 ....When an Undervoltage Release accessory causes the breaker to trip, the contacts of the Bell Alarm– Alarm Only also change state. The factory switch setting is disabled. 3333 ....When the protection trip (long-time, short-time, instantaneous, or protective-relay) occurs, the con- tacts of the Bell Alarm–Alarm Only also change state. The factory switch setting is enabled. 4444 ....When the Shunt Trip accessory causes the breaker to trip, the contacts of the Bell Alarm with Lockout also change state. The factory switch setting is dis- abled. 5555 ....When the Undervoltage Release accessory causes the breaker to trip, the contacts of the Bell Alarm with Lockout also change state. The factory switch setting is disabled. 6666 ....When a protection trip (long-time, short-time, instantaneous, or protective-relay) occurs, the con- tacts of the Bell Alarm with Lockout also change state. The factory switch setting is enabled. 3-9 Motor Operator Mechanism The Motor Operator Mechanism, shown in Figure 19, provides a means of remotely or automatically charging the springs that close the breaker. Table 15 lists the catalog numbers for the available Motor Operator Mechanism models. For installation instructions see GEH-6281. Figure 19. Motor Operator Mechanism. Catalog No. Voltage Rating SPE024 24 Vdc SPE048 48 Vdc SPE072 72 Vdc SPE120 120 Vac SPE125 125 Vdc SPE240 240 Vac Table 15. Catalog numbers and operating voltages for the Motor Operator Mechanism. Power Break® II Circuit Breakers Chapter 3. Accessory Operation 14 Remote Operation The circuit breaker closing springs can be charged remotely by shorting terminals 17 and 35 on the terminal block on the right side of the breaker, with a push button or similar device, for a minimum of five seconds. Automatic Operation Connect terminals 17 and 35 on the terminal block on the right side of the breaker with a jumper wire. The Motor Operator will automatically recharge the breaker closing springs whenever the breaker closes. CCCC AAAA UUUU TTTT IIII OOOO NNNN :::: Do not wire breakers for both automatic charge and automatic close. AAAA TTTT TTTT EEEE NNNN TTTT IIII OOOO NNNN :::: Ne pas câbler les disjoncteurs pour tous les deux l’armement automatique et la fermeture automatique. 3-10 Remote Close The Remote Close accessory, shown in Figure 20, pro- vides a means of remotely closing the circuit breaker after the springs have been charged. Table 16 lists the catalog numbers for the available models. For installation instructions see GEH-6283. Remote Operation The circuit breaker can be closed remotely, provided that the springs are charged, by applying the rated voltage to terminals 16 and 34 on the terminal block on the right side of the breaker. The Remote Close accessory is continuously rated and has an anti-pump feature that prevents a motor-operated breaker from repeatedly closing into a fault. Closing control voltage must be removed and reapplied for each breaker closure. Figure 20. Remote Close accessory. Catalog No. Voltage Rating SPRCS024 24 Vdc SPRCS048 48 Vdc SPRCS072 72 Vdc SPRCS120 120 Vac SPRCS125 125 Vdc SPRCS240 240 Vac Table 16. Catalog numbers and operating voltages for the Remote Close accessory. 3-11 Key Interlock Mounting Provision The Key Interlock Mounting Provision provides mounting for one to four key locks. The GE catalog number is SPK4. The key locks must have a zero extension when the bolt is withdrawn with 0.75-inch extension when the bolt is extended. The lock may be up to 1.50 inch wide. Catalog numbers for suitable locks from ABB-Kirk® and Superior Interlock are listed in Table 17. For installation instructions see GEH-6279. # Locks ABB-Kirk® Cat. No. Superior Cat. No. Approx. Lock Length 1 KFN00001_S105827Y 2.38" 2 KFN00002_S105828Y 3.38" 3 KFN00003_S105829Y 4.38" 4 KFN00004_S105827-4Y 5.48" Final digit may be 0, 1, 2, or 3 depending on key removable positions. Table 17. Catalog numbers of Key Interlock models. Operation The Key Interlock prevents the breaker from closing by holding the padlock tab extended, thus keeping the trip latch in the tripped position. A secondary padlock lever is included with the Key Interlock, since the Key Interlock blocks easy access to the standard padlock hasp. To operate, use the following procedure: 1111 ....Trip the breaker (press the OFF button). 2222 ....Grasp the padlock tab and pull it out, as illustrated in Figure 21. Note that if the breaker contacts are closed, the padlock tab will not pull out. 3333 ....Turn the key, securing the padlock tab in the extended position. The breaker cannot be closed until the Key Interlock is disengaged. 4444 ....Rotate the secondary padlock lever out and assem- ble padlocks as desired. Power Break® II Circuit Breakers Chapter 3. Accessory Operation 15 Figure 21. Side view of the breaker, showing the padlock tab extended with the Key Interlock installed. CCCC AAAA UUUU TTTT IIII OOOO NNNN :::: Repeated attempts to close a locked-out circuit breaker will damage the breaker mechanism. AAAATTTTTTTT EEEENNNNTTTTIIIIOOOO NNNN:::: Les tentatives à maintes fermer un dis- joncteur verrouillê en position “ouvert” endommageront le mêcanisme de disjoncteur. 3-12 Mechanical Counter The Mechanical Counter, shown in Figure 22, counts the number of times the breaker is closed. The catalog number of the Mechanical Counter is SPCOUNTER. For installation instructions see GEH-6280. Figure 22. Mechanical Counter. 3-13 Auxiliary Switch Module The Auxiliary Switch Module, shown in Figure 23, provides remote indication of the breaker main contact position through the terminals on the terminal block on the left side of the breaker. Auxiliary Switch Modules are available with 4, 8, and 12 switches with ratings of 6 A at 240 Vac or 600 Vac. Addi- tional ratings of 0.5 A at 125 Vdc and 0.25 A at 250 Vdc apply to all models. Catalog numbers are listed in Table 18. For installation instructions see GEH-6274. Operation Each auxiliary switch provides two outputs that can be used to indicate breaker main contact position. The A output is open or closed the same as the breaker, while the B output is the opposite to the breaker contacts. Fig- ure 24 is a wiring diagram of each auxiliary switch. The connections for the auxiliary switch outputs are found on the terminal block on the left side of the breaker and are listed in Table 19. Figure 23. Auxiliary Switch Module with 12 switches. # Switches 240 Vac 600 Vac 4 SPAS240AB4 SPAS600AB4 8 SPAS240AB8 SPAS600AB8 12 SPAS240AB12 SPAS600AB12 600 Vac devices are not UL listed. Table 18. Auxiliary Switch Module catalog numbers. Power Break® II Circuit Breakers Chapter 3. Accessory Operation 16 Figure 24. Auxiliary switch wiring diagram. Terminal (upper) Terminal (lower) 1 Auxiliary 12 A 19 Auxiliary 11 A 2 Auxiliary 12 B 20 Auxiliary 11 B 3 Auxiliary 12 common 21 Auxiliary 11 common 4 Auxiliary 10 A 22 Auxiliary 9 A 5 Auxiliary 10 B 23 Auxiliary 9 B 6 Auxiliary 10 common 24 Auxiliary 9 common 7 Auxiliary 8 A 25 Auxiliary 7 A 8 Auxiliary 8 B 26 Auxiliary 7 B 9 Auxiliary 8 common 27 Auxiliary 7 common 10 Auxiliary 6 A 28 Auxiliary 5 A 11 Auxiliary 6 B 29 Auxiliary 5 B 12 Auxiliary 6 common 30 Auxiliary 5 common 13 Auxiliary 4 A 31 Auxiliary 3 A 14 Auxiliary 4 B 32 Auxiliary 3 B 15 Auxiliary 4 common 33 Auxiliary 3 common 16 Auxiliary 2 A 34 Auxiliary 1 A 17 Auxiliary 2 B 35 Auxiliary 1 B 18 Auxiliary 2 common 36 Auxiliary 1 common Table 19. Auxiliary switch positions on the terminal board on the left side of the breaker, Block A. 3-14 Door Interlock The Door Interlock, shown in Figure 25, prevents the casual opening of the enclosure door, particularly while the breaker is ON. The catalog number of the Door Interlock is SPDIL. For installation instructions see GEH- 6276. Operation The Door Interlock prevents the opening of the enclosure door unless the locking lever is disengaged. The lever can be disengaged easily with the breaker OFF or with somewhat greater difficulty with the breaker ON, as described below. Opening Door with Breaker Off To open the enclosure door when the breaker is OFF, pull up on the padlock tab and slide the Door Interlock lever counter-clockwise until it no longer obstructs the door. When the door is reclosed, simply slide the lever back into the locking position. Figure 25. Door Interlock accessory installed on the breaker. Opening Door with Breaker On The Door Interlock can be defeated, to allow opening the enclosure door with the breaker ON, even though the padlock tab cannot be lifted. Depress the interlock spring with a screwdriver in the slot on the top of the locking lever and push the lever counter-clockwise to disengage it from the spring. Remove the screwdriver, then continue rotating the locking lever until it clears the door. Power Break® II Circuit Breakers Chapter 3. Accessory Operation 17 3-15 Push Button Cover The Push Button Cover, shown in Figure 26, prevents accidental or unauthorized closing or opening of the circuit breaker with the local push buttons. It consists of two unbreakable, individually sealable Lexan® shields, one over the PUSH ON button and one over the PUSH OFF button. The catalog number is SPPBCOVER. For installation instructions see GEH-6282. Operation Close the cover and put a sealing wire or wire tie in the slot. Each of the covers may be sealed independently. Figure 26. Push Button Cover. Power Break® II Circuit Breakers Chapter 4 – Trouble-Shooting Guide 18 The following guide is provided for trouble-shooting and isolating common problems. It does not cover every possible situation. Contact the ED&C Customer Support Center at 800-843-3742 if any problem is not resolved by these procedures. SSSS yyyy mmmm pppp tttt oooo mmmm PPPP oooo ssss ssss iiii bbbb llll eeee CCCC aaaa uuuu ssss eeee CCCC oooo rrrr rrrr eeee cccc tttt iiii vvvv eeee AAAA cccc tttt iiii oooo nnnn 1111 ....The breaker does not close when the ON button is pressed and there is no sound of the closing spring releasing. The closing spring is not fully charged. The Bell Alarm with Lockout is deployed. The Undervoltage Release is not energized. The Trip Unit is not properly installed. On a manually operated breaker, operate the handle until the indicator shows CHARGED. On an electrically operated breaker, check that the voltage to the motor operator is at least 85% of nominal. See GEH–6281, Motor Operator Mechanism. Correct the condition that initiated the bell alarm, then depress the yellow plunger on the Bell Alarm with Lockout module to reset the lockout. See GEH– 6278, Bell Alarm with Lockout. See GEH–6285, Undervoltage Release, for details on energizing the UVR. See GEH–6273, MicroVersaTrip Plus™ and MicroVersaTrip PM™ Trip Units, or DEH–049, Power+™ Trip Units, for the Trip Unit installation procedure. 2222 ....The breaker does not close when the ON button is pressed, but the closing spring is heard to release. The Trip Unit detected a fault and immediately tripped the breaker. The Shunt Trip is energized. The breaker is locked in the OFF position by a padlock or key interlock. The breaker is interlocked with another breaker with a walking beam. If a draw-out breaker, it is not fully inserted in the substructure (between the TEST and CONNECTED positions. Clear the fault, then recharge the closing spring and close the breaker. For fault diagnostics, see GEH– 6273, MicroVersaTrip Plus™ and MicroVersaTrip PM™ Trip Units, or DEH–049, Power+™ Trip Units. See GEH–6284, Shunt Trip, for instructions on de- energizing the unit. After ensuring that the safety reason for locking the breaker no longer applies, remove the padlock or key interlock. See GEH–-6279, Key Interlock Mounting Provision . See GEH–6286, Walking-Beam Interlock, for the removal procedure. Ensure that the breaker is fully racked in to the substructure. See GEH–6272, Draw-Out Substructure, 800–4000 Amperes. 3333 ....The breaker can be opened locally, but not remotely. There is a problem with the Shunt Trip. There is a problem with the Undervoltage Release. See the trouble-shooting instructions in GEH–6284, Shunt Trip. See the trouble-shooting instructions in GEH–6285, Undervoltage Release. Power Break® II Circuit Breakers Chapter 4 – Trouble-Shooting 19 For any other problems related to Power Break II accessories, consult the corresponding User’s Guide: • GEH–6271, Draw-Out 800–4000 Ampere Frames • GEH–6272, Draw-Out Substructure, 800–4000 Ampere • GEH–6273, MicroVersaTrip Plus™ and MicroVersaTrip PM™ Trip Units • GEH–6274, Auxiliary Switch Module • GEH–6275, Bell Alarm – Alarm Only • GEH–6276, Door Interlock • GEH–4546, Lugs & Adapters for 800–2000 A Frames • GEH–6278, Bell Alarm with Lockout • GEH–6279, Key Interlock Mounting Provision • GEH–6280, Mechanical Counter • GEH–6281, Motor Operator Mechanism • GEH–6282, Push Button Cover • GEH–6283, Remote Close • GEH–6284, Shunt Trip and Shunt Trip with Lockout (except 480 and 600 Vac) • GEH–6519, Shunt Trip and Shunt Trip with Lockout, 480 & 600 Vac • GEH–6285, Undervoltage Release (except 480 and 600 Vac) • GEH–6520, Undervoltage Release, 480 & 600 Vac • GEH–6286, Mechanical Interlock • GEH–6440, Draw-Out Substructure Rail Kit • GEH–6460, Secondary Disconnect • DEH–049, Power+™ Trip Units g GE Industiral Systems General Electric Company 41 Woodford Ave., Plainville, CT 06062 GEH–6270C 0697 © 1997 General Electric Company Bulletin 100-DIEC Contactors 2-84 Visit our website: www.ab.com/catalogs Overview/Product Selection Bulletin 100-D IEC Contactors50…500 kW @ 400V60…600 Hp @ 460V75…700 Hp @ 575VElectronic and Conventional CoilsAC & DC Integrated PLC Interface Low Power Pick-Up & Hold-In Wide Voltage RangesComplete Range of AccessoriesEnvironmentally-FriendlyCompact DimensionsThe Bulletin 100-D/104-D contactor family, along with a wide range ofcommon accessories and Bulletin 193 electronic overload relays,provides the most compact and flexible starter component systemavailable.Standards ComplianceIEC 60947-4-1IEC 60947 Type “2”CoordinationCSA C22.2 No. 14UL 508ApprovalsCE MarkedCSA CertifiedUL ListedTable of ContentsProduct Selection . . .2-85Accessories . . . . . . . . .2-102Specifications . . . . . . .2-139ApproximateDimensions . . . . . . . . .2-146Bulletin_100-D_pg84_87.qxd 26/02/2004 11:28 Page 2-84 Bulletin 100-DIEC Contactors 2-85Visit our website: www.ab.com/catalogs Product SelectionΠροδυχτ Σελεχτιον 100-D180… 100-D420... 100-D860... ⊗Voltage Codes for AC Control Conventional Coil 100-D95...100-D180 100-D95…100-D110 V 50 Hz 60 Hz 50/60 Hz 24 K J — 48 Y X — 100 — — KP 110 D — KN 120 — D — 200 — — KG 208 — H — 220… 230 A — — 230 — — KF 240 T A KA 277 — T — 380… 400 N — — 415 B — — 440 G N — 480 — B — 500 M — — 550 C — — 600 — C — ✶Preferred values according to IEC 60072-1. †Conventional coils. ‡Electronic coils. §Signal voltage of the Cat. No. 100-D… electronic interface: nominal Ue: 24V DC/e: 15 mA Pickup voltage: 13.0V DC...30.2V DC Dropout Voltage: –3.0V DC...+5.0V DC. ♣Not available with 100/104-D300. Electronic Coil w/ EI Interface §V 24 42…64 100 110… 130 200 208… 277 380… 400 380… 415 380… 500 440… 480 500 600 100-D95...100-D300 50/60 Hz EJ♣EY EP ED EG EA EN — 100-D420 50/60 Hz —EY EP ED EG EA EE EN — 100-D630...100-D860 50/60 Hz ——EP ED EG EA EN EB EM EC 3-Pole AC Operated ContactorsConventional and Electronic AC Coils3 Main ContactsNon-Reversing or Reversinge[A]Switching of 3-phase motors — AC-2, AC-3 Auxiliarycontacts Non-ReversingContactorCat. No.ReversingContactorCat. No.60 °C 40 °C kW (50 Hz)✶Hp (60 Hz) N.O N.CAC-3 AC-1 230V 400V 415V 500V 690V 1000V 200V 230V 460V 575V95 160 30 50 55 63 80 45 25 30 60 75 00100-D95⊗00 —11100-D95⊗11 —24 —104-D95⊗24110 160 32 55 63 75 100 55 40 40 75 100 00100-D110⊗00 —11100-D110⊗11 —24 —104-D110⊗24140 250 45 75 80 80†110†75 40 50 100 125 00100-D140⊗00 —11100-D140⊗11 —100‡132‡24 —104-D140⊗24180 250 55 90 100 90†132†90 50 60 150 150 00100-D180⊗00 —11100-D180⊗11 —125‡160‡24 —104-D180⊗24210 350 63 110 125 150 200 110 60 75 150 200 00100-D210⊗00 —11100-D210⊗11 —24 —104-D210⊗24250 350 80 132 150 160 250 132 75 100 200 250 00100-D250⊗00 —11100-D250⊗11 —24 —104-D250⊗24300 450 90 160 160 200 300 160 100 125 250 300 00100-D300⊗00 —11100-D300⊗11 — 24 —104-D300⊗24 420 500 132 220 250 300 425 220 150 175 350 400 00100-D420⊗00 — 11100-D420⊗11 — 24 —104-D420⊗24 630 800 200 355 355 450 500 200 250 500 600 00100-D630⊗00 — 11100-D630⊗11 — 24 —104-D630⊗24 860 1000 250 500 500 560 600 250 300 600 700 00100-D860⊗00 — 11100-D860⊗11 — 24 —104-D860⊗24 Bulletin_100-D_pg84_87.qxd 26/02/2004 11:28 Page 2-85 Bulletin 100-DIEC Contactors 2-86 Visit our website: www.ab.com/catalogs Product Selection, Continued 100-D180… 100-D420... 100-D860... ⊗Voltage Codes for DC Control Conventional Coil V 24 48 110 125 220 100-D95...100-D180†DC ZJ ZY ZD ZS ZA 3-Pole DC-Operated ContactorsConventional and Electronic DC Coils3 Main ContactsNon-Reversing or Reversing Electronic Coil w/ EI Interface ♣V 24 48…72 110…130 200…255 100-D95...100-D300 DC EZJ EZY EZD EZA 100-D420 DC —EZY EZD EZA 100-D630…860 DC ——ED EA ✶Preferred values according to IEC 60072-1. †For conventional DC coils, the pickup winding must be interconnected with the N.C. late-breaking auxiliary contact(s). ‡Conventional coils. §Electronic coils. ♣Signal voltage of the Cat. No. 100-D… electronic interface: nominal Ue: 24V DC/e: 15 mA Pickup voltage: 13.0V DC...30.2V DC , Dropout Voltage: –3.0V DC...+5.0V DC. e [A]Switching of 3-phase motors AC-2, AC-3 Auxiliarycontacts Non-ReversingContactorCat. No.ReversingContactorCat. No.60 °C 40 °C kW (50 Hz)✶Hp (60 Hz) N.O. N.C.AC-3 AC-1 230V 400V 415V 500V 690V 1000V 200V 230V 460V 575V95 160 30 50 55 63 80 45 25 30 60 75 00100-D95⊗00 —11100-D95⊗11 —2 1/1L 100-D95⊗22L†—24 —104-D95⊗242 2/2L —104-D95⊗24L†110 160 32 55 63 75 100 55 40 40 75 100 00100-D110⊗00 —11100-D110⊗11 —2 1/1L 100-D110⊗22L†—24 —104-D110⊗242 2/2L —104-D110⊗24L†140 250 45 75 80 80‡110‡75 40 50 100 125 00100-D140⊗00 —11100-D140⊗11 —100§132§2 1/1L 100-D140⊗22L†—24 —104-D140⊗242 2/2L —104-D140⊗24L†180 250 55 90 100 90‡132‡90 50 60 150 150 00100-D180⊗00 —11100-D180⊗11 —2 1/1L 100-D180⊗22L†—125§160§24 —104-D180⊗242 2/2L —104-D180⊗24L† 210 350 63 110 125 150 200 110 60 75 150 200 00100-D210⊗00 — 11100-D210⊗11 — 24 —104-D210⊗24 250 350 80 132 150 160 250 132 75 100 200 250 00100-D250⊗00 — 11100-D250⊗11 — 24 —104-D250⊗24 300 450 90 160 160 200 300 160 100 125 250 300 00100-D300⊗00 — 11100-D300⊗11 — 24 —104-D300⊗24 420 500 132 220 250 300 425 220 150 175 350 400 00100-D420⊗00 — 11100-D420⊗11 — 24 —104-D420⊗24 630 800 200 355 355 450 500 200 250 500 600 00100-D630⊗00 — 11100-D630⊗11 — 24 —104-D630⊗24 860 1000 250 500 500 560 600 250 300 600 700 00100-D860⊗00 — 11100-D860⊗11 — 24 —104-D860⊗24 Bulletin_100-D_pg84_87.qxd 26/02/2004 11:28 Page 2-86 Bulletin 100-DIEC Contactors 2-87Visit our website: www.ab.com/catalogs Product Selection, ContinuedAuxiliary contacts with sequence numbering.Cat. Nos. 100-D95…D860 — Electronic and Conventional AC Coils, Electronic DC coilsContact Configuration Auxiliary contact configurationsLeft Side Mounting Right Side MountingN.O. N.C. Outside Cat. No. Inside Cat. No.For Use With Inside Cat. No. Outside Cat. No.80100-DS2-20 100-DS1-20 100-D…00 100-DS1-20 100-DS2-20Sequence starts with…7/8 3/4 1/2 5/671100-DS2-20 100-DS1-20 100-D…00 100-DS1-11 100-DS2-20Sequence starts with…7/8 3/4 1/2 5/662100-DS2-20 100-DS1-11 100-D…00 100-DS1-11 100-DS2-20Sequence starts with…7/8 3/4 1/2 5/653100-DS2-20 100-DS1-11 100-D…00 100-DS1-11 100-DS2-11Sequence starts with…7/8 3/4 1/2 5/644100-DS2-11 100-DS1-11 100-D…00 100-DS1-11 100-DS2-11Sequence starts with…7/8 3/4 1/2 5/6Cat. Nos. 100-D95…D860 — Electronic and Conventional AC Coils, Electronic DC CoilsContact Configuration Auxiliary contact configurationsLeft Side Mounting Right Side MountingN.O. N.C. Outside Cat. No. Inside Cat. No.For Use With Inside Cat. No. Outside Cat. No. 80 100-D…11 Sequence starts with… 71100-DS2-20 100-DS1-20 100-D…11 100-DS1-11 100-DS2-20 Sequence starts with…7/8 3/4 1/2 5/6 62100-DS2-20 100-DS1-11 100-D…11 100-DS1-11 100-DS2-20 Sequence starts with…7/8 3/4 1/2 5/6 53100-DS2-20 100-DS1-11 100-D…11 100-DS1-11 100-DS2-11 Sequence starts with…7/8 3/4 1/2 5/6 44100-DS2-11 100-DS1-11 100-D…11 100-DS1-11 100-DS2-11 Sequence starts with…7/8 3/4 1/2 5/6 Contactor cat. nos. 100-D95…D180 — Conventional DC coils Contact Configuration Auxiliary contact configurations Left Side Mounting Right Side Mounting N.O. N.C. Outside Cat. No. Inside Cat. No.For Use With Inside Cat. No. Outside Cat. No. 80 ——100-D…22L —— Sequence starts with…———— 71 ——100-D…22L —— Sequence starts with…———— 62100-DS2-20 100-DS1-11 100-D…22L 100-DS1-L11✶100-DS2-20 Sequence starts with…7/8 3/4 1/2 5/6 53100-DS2-20 100-DS1-11 100-D…22L 100-DS1-L11✶100-DS2-11 Sequence starts with…7/8 3/4 1/2 5/6 44100-DS2-11 100-DS1-11 100-D…22L 100-DS1-L11✶100-DS2-11 Sequence starts with…7/8 3/4 1/2 5/6 ✶With conventional DC control, the pickup winding must be interconnected with the N.C. late-breaking auxiliary contacts. Bulletin_100-D_pg84_87.qxd 26/02/2004 11:28 Page 2-87 Complete IEC Motor Control & Protection Solutions · IEC Contactors 100-D 50…500 kW · IEC Safety Contactors 100S-D 50…500 kW Allen-Bradley 3 Bulletins 100/104-D, 100S-D IEC Contactors Overview/Product Selection Bulletin 100-D IEC Contactors •50…500 kW @400V •60…600 Hp @460V •75…700 Hp @575V •Electronic and Conventional Coils AC & DC Integrated PLC Interface Low Power Pick-Up & Hold-In Wide Voltage Ranges •Complete Range of Accessories •Environmentally-Friendly •Compact Dimensions The Bulletin 100-D/104-D contactor family, along with a wide range of common accessories and Bulletin 193 electronic overload relays, provides the most compact and flexible starter component system available. Ta b le of Contents Product Selection ................. 4 Accessories........................... 9 Specifications ..................... 12 Dimensions ......................... 25 Renewal Parts ..................... 27 Conformity to Standards IEC 60947-4-1 IEC 60947 Type “2” Coordination CSA C22.2 No. 14 UL 508 Approvals CE Marked CSA Certified UL Listed Bulletin 100S-D Safety Contactors •50…500 kW @400V •60…600 Hp @460V •75…700 Hp @575V •Electronic and Conventional Coils AC & DC Integrated PLC Interface Low Power Pick-Up & Hold-In Wide Voltage Ranges •Complete Range of Accessories •Environmentally-Friendly •Compact Dimensions Bulletin 100S-D safety contactors provide mechanically linked, positively guided contacts, which are required in feedback circuits for modern safety applications. The positively guided N.C. auxiliary contacts will not change state when a power contact welds. Ta b le of Contents Product Selection ................. 7 Accessories......................... 10 Specifications ..................... 12 Dimensions ......................... 26 Renewal Parts ..................... 27 Conformity to Standards IEC 60947-4-1 IEC 60947-4 Annex F IEC 60947 Type “2” Coordination CSA C22.2 No. 14 UL 508 Approvals CE Marked CSA Certified UL Listed SUVA Certified Bulletins 100/104-D, 100S-D IEC Contactors 4 Allen-Bradley Product Selection ⊗⊗⊗⊗ Voltage Suffix Codes for AC Control ➊ Preferred values according to IEC 60072-1 ➋ Conventional coils. ➌ Electronic coils. ➍ Signal voltage of the Cat. No. 100-D… electronic interface: Nominal U e : 24V DC/ I e : 15 mA Pick-up Voltage: 13.0V DC…30.2V DC Drop-out Voltage: -3.0V DC…+5.0V DC ➎ Not available for 100-D300 I e [A]Switching of 3-phase motors — AC-2, AC-3 Auxiliary contacts Non-Reversing Contactor Cat. No. Reversing Contactor Cat. No. 60°C 40°C kW (50 Hz) ➊ Hp (60 Hz) N.O. N.C. AC-3 AC-1 230V 400V 415V 500V 690V 1000V 200V 230V 460V 575V 95 160 30 50 55 63 90 45 25 30 60 75 0 0 100-D95 ⊗ 00 — 1 1 100-D95 ⊗ 11 — 2 4 —104-D95 ⊗ 24 110 160 32 55 63 75 100 55 40 40 75 100 0 0 100-D110 ⊗ 00 — 1 1 100-D110 ⊗ 11 — 2 4 —104-D110 ⊗ 24 140 250 45 75 80 80 ➋ 110 ➋ 75 40 50 100 125 0 0 100-D140 ⊗ 00 — 100 ➌ 132 ➌ 1 1 100-D140 ⊗ 11 — 2 4 —104-D140 ⊗ 24 180 250 55 90 100 90 ➋ 132 ➋ 90 50 60 150 150 0 0 100-D180 ⊗ 00 — 125 ➌ 160 ➌ 1 1 100-D180 ⊗ 11 — 2 4 —104-D180 ⊗ 24 210 350 63 110 125 150 200 110 60 75 150 200 0 0 100-D210 ⊗ 00 — 1 1 100-D210 ⊗ 11 — 2 4 —104-D210 ⊗ 24 250 350 80 132 150 160 250 132 75 100 200 250 0 0 100-D250 ⊗ 00 — 1 1 100-D250 ⊗ 11 — 2 4 —104-D250 ⊗ 24 300 450 90 160 160 200 300 160 100 125 250 300 0 0 100-D300 ⊗ 00 — 1 1 100-D300 ⊗ 11 — 2 4 —104-D300 ⊗ 24 420 500 132 220 250 300 425 220 150 175 350 400 0 0 100-D420 ⊗ 00 — 1 1 100-D420 ⊗ 11 — 2 4 —104-D420 ⊗ 24 630 800 200 355 355 450 500 — 200 250 500 600 0 0 100-D630 ⊗ 00 — 1 1 100-D630 ⊗ 11 — 2 4 —104-D630 ⊗ 24 860 1000 250 500 500 560 600 — 250 300 600 700 0 0 100-D860 ⊗ 00 — 1 1 100-D860 ⊗ 11 — 2 4 —104-D860 ⊗ 24 Conventional Coil V 24 48 100 110 120 200 208 220… 230 230 240 277 380… 400 415 440 480 500 550 600 100-D95…100-D180 50 Hz K Y —D ———A —T —N B G —M C — 60 Hz J X ——D —H ——A T ——N B ——C 100-D95…100-D110 50/60 Hz ——KP KN —KG ——KF KA ———————— Electronic Coil w/ EI Interface ➍ V2442… 64 100 110… 130 200 208… 277 380… 400 380… 415 380… 500 440… 480 500 600 100-D95…100-D300 50/60 Hz EJ ➎ EY EP ED EG EA ——EN ——— 100-D420 50/60 Hz —EY EP ED EG EA EE —EN ——— 100-D630…100-D860 50/60 Hz ——EP ED EG EA —EN —EB EM EC 100-D420… 3-pole AC-Operated Contactors •Conventional and Electronic AC Coils •3 Main Contacts •Non-Reversing or Reversing 100-D860…100-D180… Allen-Bradley 5 Bulletins 100/104-D, 100S-D IEC Contactors Product Selection, Continued ⊗⊗⊗⊗Voltage Suffix Codes for DC Control �Preferred value according to IEC 60072-1. �For conventional DC coil only. The pickup winding must be interconnected with the N.C. late-break auxiliary contact(s). �Conventional coils. �Electronic coils. �Signal voltage of the Cat. No. 100-D… electronic interface:Ue: 24V DC/Ie: 15 mA Pick-Up Voltage: 13.0V DC…30.2V DC Drop-Out Voltage: -3.0V DC…+5.0V DC Ie [A]Switching of 3-phase motors — AC-2, AC-3 Auxiliary contacts Non-reversing Contactor Cat. No. Reversing Contactor Cat. No. 60°C 40°C kW (50 Hz) �Hp (60 Hz)N.O. N.C. AC-3 AC-1 230V 400V 415V 500V 690V 1000V 200V 230V 460V 575V 95 160 30 50 55 63 90 45 25 30 60 75 0 0 100-D95⊗00 — 1 1 100-D95⊗11 — 2 1/1L 100-D95⊗22L �— 2 4 —104-D95 ⊗24 2 2/2L —104-D95 ⊗24L � 110 160 32 55 63 75 100 55 40 40 75 100 0 0 100-D110⊗00 — 1 1 100-D110⊗11 — 2 1/1L 100-D110⊗22L �— 2 4 —104-D110 ⊗24 2 2/2L —104-D110 ⊗24L � 140 250 45 75 80 80 �110 � 75 40 50 100 125 0 0 100-D140⊗00 — 1 1 100-D140⊗11 — 100 �132 � 2 1/1L 100-D140⊗22L �— 2 4 —104-D140 ⊗24 2 2/2L —104-D140 ⊗24L � 180 250 55 90 100 90 �132 � 90 50 60 150 150 0 0 100-D180⊗00 — 125 �160 � 1 1 100-D180⊗11 — 2 1/L 100-D180⊗22L �— 2 4 —104-D180 ⊗24 2 2/2L —104-D180 ⊗24L � 210 350 63 110 125 150 200 110 60 75 150 200 0 0 100-D210⊗00 — 1 1 100-D210⊗11 — 2 4 —104-D210 ⊗24 250 350 80 132 150 160 250 132 75 100 200 250 0 0 100-D250⊗00 — 1 1 100-D250⊗11 — 2 4 —104-D250 ⊗24 300 450 90 160 185 220 300 160 100 125 250 300 0 0 100-D300⊗00 — 1 1 100-D300⊗11 — 2 4 —104-D300 ⊗24 420 500 132 220 250 300 425 220 150 175 350 400 0 0 100-D420⊗00 — 1 1 100-D420⊗11 — 2 4 —104-D420 ⊗24 630 800 200 355 355 450 500 — 200 250 500 600 0 0 100-D630⊗00 — 1 1 100-D630⊗11 — 2 4 —104-D630 ⊗24 860 1000 250 500 500 560 600 — 250 300 600 700 0 0 100-D860⊗00 — 1 1 100-D860⊗11 — 2 4 —104-D860 ⊗24 Conventional Coil V 24 48 110 125 220 100-D95…100-D180 �DC ZJ ZY ZD ZS ZA Electronic Coil w/ EI Interface �V 24 48…72 110…130 200…255 100-D95…100-D300 DC EZJ EZY EZD EZA 100-D420 DC —EZY EZD EZA 100-D630…860 DC ——ED EA 3-pole DC-Operated Contactors •Conventional and Electronic DC Coils •3 Main Contacts •Non-Reversing or Reversing 100-D860…100-D420…100-D180… Bulletins 100/104-D, 100S-D IEC Contactors 6 Allen-Bradley Product Selection, Continued Auxiliary contacts with sequence numbering Cat. Nos. 100-D95…D860 — Electronic and Conventional AC Coils, Electronic DC Coils Cat. Nos. 100-D95…D860 — Electronic and Conventional AC Coils, Electronic DC Coils Contactor cat. nos. 100-D95…D180 — Conventional DC coils ➊ With conventional DC control, the pickup winding must be interconnected with the N.C. late-breaking auxiliary contacts. Contact Configuration Auxiliary contact configurations Left-Side Mounting For Use With Right-Side Mounting N.O. N.C.Outside Cat. No.Inside Cat. No.Inside Cat. No.Outside Cat. No. 80 100-DS2-20 100-DS1-20 100-D…00 100-DS1-20 100-DS2-20 Sequence starts with… 7/8 3/4 1/2 5/6 71 100-DS2-20 100-DS1-20 100-D…00 100-DS1-11 100-DS2-20 Sequence starts with… 7/8 3/4 1/2 5/6 62 100-DS2-20 100-DS1-11 100-D…00 100-DS1-11 100-DS2-20 Sequence starts with… 7/8 3/4 1/2 5/6 53 100-DS2-20 100-DS1-11 100-D…00 100-DS1-11 100-DS2-11 Sequence starts with… 7/8 3/4 1/2 5/6 44 100-DS2-11 100-DS1-11 100-D…00 100-DS1-11 100-DS2-11 Sequence starts with… 7/8 3/4 1/2 5/6 Contact Configuration Auxiliary contact configurations Left-Side Mounting For Use With Right-Side Mounting N.O. N.C.Outside Cat. No.Inside Cat. No.Inside Cat. No.Outside Cat. No. 80 ——100-D…11 —— Sequence starts with… — — — — 71 100-DS2-20 100-DS1-20 100-D…11 100-DS1-11 100-DS2-20 Sequence starts with… 7/8 3/4 1/2 5/6 62 100-DS2-20 100-DS1-11 100-D…11 100-DS1-11 100-DS2-20 Sequence starts with… 7/8 3/4 1/2 5/6 53 100-DS2-20 100-DS1-11 100-D…11 100-DS1-11 100-DS2-11 Sequence starts with… 7/8 3/4 1/2 5/6 44 100-DS2-11 100-DS1-11 100-D…11 100-DS1-11 100-DS2-11 Sequence starts with… 7/8 3/4 1/2 5/6 Contact Configuration Auxiliary contact configurations Left-Side Mounting For Use With Right-Side Mounting N.O. N.C.Outside Cat. No.Inside Cat. No.Inside Cat. No.Outside Cat. No. 80 ——100-D…22L —— Sequence starts with… — — — — 71 ——100-D…22L —— Sequence starts with… — — — — 62 100-DS2-20 100-DS1-11 100-D…22L 100-DS1-L11 ➊ 100-DS2-20 Sequence starts with… 7/8 3/4 1/2 5/6 53 100-DS2-20 100-DS1-11 100-D…22L 100-DS1-L11 ➊ 100-DS2-11 Sequence starts with… 7/8 3/4 1/2 5/6 44 100-DS2-11 100-DS1-11 100-D…22L 100-DS1-L11 ➊ 100-DS2-11 Sequence starts with… 7/8 3/4 1/2 5/6 Supplied with Contactor Supplied with Contactor Supplied with Contactor Allen-Bradley 7 Bulletins 100/104-D, 100S-D IEC Safety Contactors Product Selection ⊗⊗⊗⊗ Voltage Suffix Codes for AC Control ➊ Preferred values according to IEC 60072-1. ➋ The N.C. contacts meet IEC 60947-4 Annex F requirements to mirror contact performance. The N.C. mirror contacts are wired in series or parallel and must be used as monitoring contacts with feedback to the safety circuit. ➌ Higher kW rating only applies to contactors with electronic coil. ➍ Signal voltage of the Cat. No. 100S-D… electronic interface:U e : 24V DC/ I e : 15 mA Pick-Up Voltage: 13.0V DC…30.2V DC Drop-Out Voltage: -3.0V DC…+5.0V DC ➎ Not available for 100-D300 I e [A]Switching of 3-phase motors — AC-2, AC-3 Auxiliary contacts Cat. No. 60°C 40°C kW (50 Hz) ➊ Hp (60 Hz) N.O. N.C. ➋ AC-3 AC-1 230V 400V 415V 500V 690V 1000V 200V 230V 460V 575V 95 160 30 50 55 63 90 45 25 30 60 75 2 2 100S-D95 ⊗ 22C 110 160 32 55 63 75 100 55 40 40 75 100 2 2 100S-D110 ⊗ 22C 140 250 45 75 80 80/100 ➌ 110/132 ➌ 75 40 50 100 125 2 2 100S-D140 ⊗ 22C 180 250 55 90 100 90/125 ➌ 132/160 ➌ 90 50 60 150 150 2 2 100S-D180 ⊗ 22C 210 350 63 110 125 150 200 110 60 75 150 200 2 2 100S-D210 ⊗ 22C 250 350 80 132 150 160 250 132 75 100 200 250 2 2 100S-D250 ⊗ 22C 300 450 90 160 160 200 300 160 100 125 250 300 2 2 100S-D300 ⊗ 22C 420 500 132 220 250 300 425 220 150 175 350 400 2 2 100S-D420 ⊗ 22C 630 800 200 355 355 450 500 — 200 250 500 600 2 2 100S-D630 ⊗ 22C 860 1000 250 500 500 560 600 — 250 300 600 700 2 2 100S-D860 ⊗ 22C Conventional Coil V 24 48 100 110 120 200 208 220… 230 230 240 277 380… 400 415 440 480 500 550 600 100S-D95…100S-D180 50 Hz K Y —D ———A —T —N B G —M C — 60 Hz J X ——D —H ——A T ——N B ——C 100S-D95…100S-D110 50/60 Hz ——KP KN —KG ——KF KA ———————— Electronic Coil w/ PLC Interface ➍ V2442… 64 100 110… 130 200 208… 277 380… 400 380… 415 380… 500 440… 480 500 600 100S-D95…100S-D300 50/60 Hz EJ ➎ EY EP ED EG EA ——EN ——— 100S-D420 50/60 Hz —EY EP ED EG EA EE —EN ——— 100S-D630…100S-D860 50/60 Hz ——EP ED EG EA —EN —EB EM EC 100S-D860… 3-pole AC-Operated Contactors •Conventional and Electronic AC Coils •3 Main Contacts •Non-Reversing Bulletins 100/104-D, 100S-D IEC Safety Contactors 8 Allen-Bradley Product Selection, Continued ⊗⊗⊗⊗ Voltage Suffix Codes for DC Control ➊ Preferred values according to IEC 60072-1. ➋ The N.C. contacts meet IEC 60947-4 Annex F requirements to mirror contact performance. The N.C. mirror contacts are wired in series or parallel and must be used as monitoring contacts with feedback to the safety circuit. ➌ For conventional DC coil only. The pickup winding must be interconnected with the N.C. late-breaking auxiliary contacts. ➍ Higher kW rating only applies to contactors with electronic coil. ➎ Signal voltage of the Cat. No. 100S-D… electronic interface: U e : 24V DC/ I e : 15 mA Pick-Up Voltage: 13.0V DC…30.2V DC Drop-Out Voltage: -3.0V DC…+5.0V DC I e [A]Switching of 3-phase motors — AC-2, AC-3 Auxiliary contacts Cat. No. 60°C 40°C kW (50 Hz) ➊ Hp (60 Hz) N.O. N.C. ➋ AC-3 AC-1 230V 400V 415V 500V 690V 1000V 200V 230V 460V 575V 95 160 30 50 55 63 90 45 25 30 60 75 3 2/1L 100S-D95 ⊗ 33LC ➌ 2 2 100S-D95 ⊗ 22C 110 160 32 55 63 75 100 55 40 40 75 100 3 2/1L 100S-D110 ⊗ 33LC ➌ 2 2 100S-D110 ⊗ 22C 140 250 45 75 80 80 110 75 40 50 100 125 3 2/1L 100S-D140 ⊗ 33LC ➌ 100 ➍ 132 ➍ 2 2 100S-D140 ⊗ 22C 180 250 55 90 100 90 132 90 50 60 150 150 3 2/1L 100S-D180 ⊗ 33LC ➌ 125 ➍ 160 ➍ 2 2 100S-D180 ⊗ 22C 210 350 63 110 125 150 200 110 60 75 150 200 2 2 100S-D210 ⊗ 22C 250 350 80 132 150 160 250 132 75 100 200 250 2 2 100S-D250 ⊗ 22C 300 450 90 160 160 200 300 160 100 125 250 300 2 2 100S-D300 ⊗ 22C 420 500 132 220 250 300 425 220 150 175 350 400 2 2 100S-D420 ⊗ 22C 630 800 200 355 355 450 500 — 200 250 500 600 2 2 100S-D630 ⊗ 22C 860 1000 250 500 500 560 600 — 250 300 600 700 2 2 100S-D860 ⊗ 22C Conventional Coil V 24 48 110 125 220 250 100S-D95…100S-D180 ➌ DC ZJ ZY ZD ZS ZA ZT Electronic Coil w/ EI Interface ➎ V24 48…72 110…130 200…255 100S-D95…100S-D300 DC EZJ EZY EZD EZA 100S-D420 DC —EZY EZD EZA 100S-D630…860 DC ——ED EA 100S-D420… 3-pole DC-Operated Contactors •Conventional and Electronic DC Coils •3 Main Contacts •Non-Reversing Allen-Bradley 9 Bulletins 100/104-D, 100S-D IEC Contactors Accessories Auxiliary Contacts Labeling Material Marking Systems (For 100-D95…D860 contactors) ➊ Must be ordered in multiples of package quantities. Description N.O. N.C. Connection Diagram For use with Cat. No. •Side-mounted •With IEC sequence terminal designations 11 100-D Left or right inside mounting 100-DS1-11 11 100-D Left or right outside mounting 100-DS2-11 11L 100-D Left or right inside mounting 100-DS1-L11 20 100-D Left or right inside mounting 100-DS1-20 20 100-D Left or right outside mounting 100-DS2-20 •Electronically compatible auxiliary contacts •Ideal for use when switching low-power control circuits •Contact ratings: AC-12 250V, 0.1 A AC-15, DC-13 3…125V, 1…100 mA 11 100-D Left or right inside mounting 100-DS1-B11 •Uniform labeling materials for contactors, motor protection devices, timing relays, and circuit breakers. Description Pkg. Qty. ➊ Cat. No. Label Sheet •10 sheets with 105 self-adhesive paper labels each, 6 x 17 mm 10 100-FMS Marking Tag Sheet •10 sheets with 160 perforated paper labels each, 6 x 17 mm •To be used with a transparent cover 10 100-FMP Transparent Cover •100 each •To be used with marking tag sheets 100 100-FMC Marking Tag Adapters •100 each •To be used with marking tag: System V4 / V5 System Bul. 1492W 100 100 100-FMA1 100-FMA2 Bulletins 100/104-D, 100S-D IEC Contactors 10 Allen-Bradley Accessories, Continued Suppressor Modules Connecting Components Description Circuit Diagram For use with Cat. No. Suppressor Module for 100-D Contactors •For limiting surge voltage when coil circuits are interrupted •Can be plugged into all 100-D contactors •Supplied as standard on all conventional DC coil contactors and all electronic coil contactors as part of the supply module, or delivered with separate suppressor module RC Module (AC control) for contactors with conventional coil 21…48V 50 Hz/24…55V 60 Hz 95…110V 50 Hz/110…127V 60 Hz 190…240V 50 Hz/220…277V 60 Hz 380…550V 50 Hz/440…575V 60 Hz 100-D95… 100-D180 100-DFSC48 100-DFSC110 100-DFSC240 100-DFSC550 Varistor Module for contactors with conventional coil £ 5 5V AC 56…136V AC 137…277V AC 278…575V AC 100-D95… 100-D180 100-DFSV55 100-DFSV136 100-DFSV277 100-DFSV575 Varistor Module for contactors with electronic coil 208…277V AC (overvoltage category IV) 100-D95… 100-D420 100-DFSV550 Description Output Connection For Use With Terminal Connection Cat. No. 100-D95…180 100-D210…420 100-D630…860 Reversing: Input Connection Wye-Delta: Main-Delta connection 50 mm 2 X Lugs, 100-DL… 100-D180-VL 120 mm 2 X 100-D420-VL 350 mm 2 X 100-D860-VL 50 mm 2 X Te r minal Blocks, 100-DTB… 100-D180-VLTB 120 mm 2 X 100-D420-VLTB Reversing: Output Connection Wye-Delta: Delta-Wye connection 50 mm 2 X Lugs, 100-DL… 100-D180-VT 120 mm 2 X 100-D420-VT 350 mm 2 X 100-D860-VT 50 mm 2 X Te r minal Blocks, 100-DTB… 100-D180-VTTB 120 mm 2 X 100-D420-VTTB Delta-Wye connection if 100-D95…180 is used as a Wye contactor 80 mm 2 —X Te r minal Blocks, 100-DTB…100-D420-VYTB Wye-Delta: Neutral bridge —X —100-D180-VYU —X —100-D420-VYU —X—100-D860-VYU Power Wiring Kits (for contactors using 100-DL lug kits) For 100-D95…100-D180 •Reversing •Tw o-speed, or changeover •Wye-Delta/Star-Delta 100-DPW180 100-D180-VL 100-DPY180 For 100-D210…100-D420 •Reversing •Tw o-speed, or changeover •Wye-Delta/Star-Delta 100-DPW420 100-D420-VL 100-DPY420 For 100-D630…100-D860 •Reversing •Tw o-speed, or changeover 100-DPW860 100-D860-VL Allen-Bradley 11 Bulletins 100/104-D, 100S-D IEC Contactors Accessories, Continued Connecting Components, Continued Interlocks Description Cat. No. Te r minal Blocks •Set of 2 •Protection class IP20 per IEC 60529 and DIN 40 050 For 100-D95,100-D110 For 100-D140,100-D180, 100-D95E…D180E For 100-D210…100-D420 100-DTB110 100-DTB180 100-DTB420 Te r minal Lugs (UL/CSA), Copper Frame •Set of 3 For 100-D95, 100-D110 For 100-D95E, 100-D110E For 100-D140, 100-D180 For 100-D210…100-D420 For 100-D630, 100-D860 For 100-D630, 100-D860 100-DL110 100-DLE110 100-DL180 100-DL420 100-DL630 100-DL860 Te r minal Lugs (UL/CSA), Aluminum Frame •Set of 3 For 100-D95, 100-D110 (conventional coil) For 100-D140, 100-D180, 100-D95E, 100-D110E For 100-D210, 100-D420 100-DLA110 100-DLA180 100-DLA420 Control Circuit Terminal •2 x 2.5 mm 2 For connecting to 100-D95…D180 For connecting to 100-D210…D420 For connecting to 100-D630…D860 100-DAT1 100-DAT2 100-DAT3 Te r minal Shields •Set of 2 •Protection class IP10 per IEC 60529 and DIN 40 050 •For direct-on-line, reversing, two-speed, and wye-delta/ star-delta assemblies For 100-D95,100-D110 For 100-D140,100-D180, 100-D95E…D180E For 100-D210…100-D420 100-DTS110 100-DTS180 100-DTS420 Te r minal Covers •Qty: 1 •Protection class IP20 per IEC 60529 and DIN 40 050 •For direct-on-line, reversing, two-speed, and wye-delta/ star-delta assemblies For 100-D95…100-D180 For 100-D210…100-D420 For 100-D630…100-D860 100-DTC180 100-DTC420 100-DTC860 Phase Barriers •Set of 4 100-D630…D860 100-DPB860 Mountin g Plate •Galvanized steel plate for starter combinations For 100-D95…100-D180 •Direct-on-line •Reversing, two-speed, or changeover •Y- D or Dahlander 100-DMS180 100-DMU180 100-DMY180 For 100-D210…100-D420 •Direct-on-line •Reversing, two-speed, or changeover •Y- D or Dahlander 100-DMS420 100-DMU420 100-DMY420 For 100-D630…100-D860 •Direct-on-line •Reversing, two-speed, or changeover •Y- D or Dahlander 100-DMS860 100-DMU860 100-DMY860 Mounting Plate For interlocking between 100-C60…C85 and 100-D95…D180 contactors •Two-speed or changeover switches 100-DMU85 Description Circuit Diagram For use with Cat. No. Mechanical only •No additional space required 100-D95…100-D860 100-DMA00 Dual electrical/mechanical •No additional space required •2 N.C. auxiliary contacts 100-D95…100-D860 100-DMD02 Mechanical only •No additional space required 100-D95…100-D860 100-DMD00 Mechanical only •Provides interlocking between 100-C and 100-D contactors 100-C60…100-C85 between 100-D95…100-D180 100-DMC00 Dual electrical/mechanical •Provides interlocking between 100-C and 100-D contactors •2 N.C. auxiliary contacts 100-DMC02 22 NC 21 21 NC 22 22 NC 21 21 NC 22 Bulletins 100/104-D, 100S-D Contactors 12 Allen-Bradley S pecifications IEC Specifications ➌ 415 V: Values in ( ) AC-3 and AC-4 lifespan -25 % ➍ To be determined. Coil Type: Conventional Electronic – El 100/104-D, 100S-D 95 110 140 140 180 180 210 250 300 420 630 860 X X X —X ——————— X X —X —X X X X X X X AC-1 Active Power Load (50 Hz); Ambient temperature 40°C I e ≤ 500 V [A] 160 160 250 250 250 250 350 350 450 500 800 1000 690 V [A] 160 160 250 250 250 250 350 350 450 500 800 1000 1000 V [A] 160 160 250 250 250 250 350 350 450 500 ➍➍ 230 V [kW] 64 64 100 100 100 100 139 139 179 199 319 398 240 V [kW] 67 67 104 104 104 104 145 145 187 208 333 416 400 V [kW] 111 111 173 173 173 173 242 242 312 346 554 693 415 V [kW] 115 115 180 180 180 180 252 252 323 359 575 719 500 V [kW] 139 139 217 217 217 217 303 303 390 433 693 866 690 V [kW] 191 191 299 299 299 299 418 418 538 598 956 1195 1000 V [kW] 277 277 433 433 433 433 606 606 779 866 ➍➍ Ambient temperature 60°C I e ≤ 500 V [A] 135 135 210 210 210 210 300 300 380 425 ➍➍ 690 V [A] 135 135 210 210 210 210 300 300 380 425 ➍➍ 1000 V [A] 135 135 210 210 210 210 300 300 380 425 ➍➍ 230 V [kW] 54 54 84 84 84 84 120 120 151 169 ➍➍ 240 V [kW] 56 56 87 87 87 87 125 125 158 177 ➍➍ 400 V [kW] 94 94 145 145 145 145 208 208 263 294 ➍➍ 415 V [kW] 97 97 151 151 151 151 216 216 273 305 ➍➍ 500 V [kW] 117 117 182 182 182 182 260 260 329 368 ➍➍ 690 V [kW] 161 161 251 251 251 251 359 359 454 508 ➍➍ 1000 V [kW] 234 234 364 364 364 364 520 520 658 736 ➍➍ Switching of 3-phase Motors, (50 Hz); Ambient temperature 60°C, AC-2, AC-3 230 V [A] 95 110 140 140 180 180 210 250 300 420 630 860 240 V [A] 95 110 140 140 180 180 210 250 300 420 630 860 400 V [A] 95 110 140 140 180 180 210 250 300 420 630 860 415 V [A] 95 110 (130) ➌ 140 (155) ➌ 140 (155) ➌ 180 (189) ➌ 180 (189) ➌ 210 (227) ➌ 250 (258) ➌ 300 (315) ➌ 420 630 860 500 V [A] 95 110 115 140 140 180 210 250 300 420 630 753 690 V [A] 95 110 115 140 140 180 210 250 300 420 492 ➍ 1000 V [A] 33 40 55 55 65 65 80 95 115 160 ➍➍ 230 V [kW] 30 34 45 45 57 57 67 80 97 135 200 250 240 V [kW] 31 36 47 47 60 60 70 83 101 141 200 250 400 V [kW] 53 61 78 78 101 101 118 140 170 238 355 500 415 V [kW] 55 63 (75) ➌ 82 (90) ➌ 82 (90) ➌ 105 (110) ➌ 105 (110) ➌ 122 (132) ➌ 145 (150) ➌ 176 (185) ➌ 250 355 500 500 V [kW] 66 76 80 98 98 126 147 177 213 298 450 560 690 V [kW] 92 106 111 135 135 176 205 250 293 424 500 ➍ 1000 V [kW] 45 55 75 75 90 90 110 132 160 225 ➍➍ Load Carrying Capacity per UL/CSA (60 Hz) General Purpose Current (enclosed) [A] 160 160 220 220 220 220 300 300 340 420 ➍➍ Rated power (enclosed) 1-phase 115 V [A] 80 100 135 135 — ——————— 230 V [A] 68 110 136 136 176 176 216 — — — — — 115 V [Hp] 7.5 10 15 15 — ——————— 230 V [Hp] 15 25 30 30 40 40 50 — — — — — 3-phase 200 V [A] 78.2 120 120 120 150 150 177 221 285 414 552 692 230 V [A] 80 104 130 130 154 154 192 248 312 420 602 720 460 V [A] 77 96 124 124 180 180 180 240 302 414 590 702 575 V [A] 77 99 125 125 144 144 192 242 289 382 562 651 200 V [Hp] 25 40 40 40 50 50 60 75 100 150 200 250 230 V [Hp] 30 40 50 50 60 60 75 100 125 175 250 300 460 V [Hp] 60 75 100 100 150 150 150 200 250 350 500 600 575 V [Hp] 75 100 125 125 150 150 200 250 300 400 600 700 Allen-Bradley 13 Bulletins 100/104-D, 100S-D Contactors S pecifications ➊ Power ratings at 50 Hz: Preferred values according to IEC 60072-1 ➌ 415 V: Values in ( ) AC-3 and AC-4 lifespan -25 % ➋ Approval pending on 100-D95…D860 ➍ To be determined. Coil Type: Conventional Electronic – El 100/104-D, 100S-D 95 110 140 140 180 180 210 250 300 420 630 860 X X X —X ——————— X X —X —X X X X X X X Switching of 3-phase Motors, (50 Hz); Ambient temperature 60°C, AC-4 230 V [A] 95 110 140 140 180 180 210 250 300 420 ➍➍ 240 V [A] 95 110 140 140 180 180 210 250 300 420 ➍➍ 400 V [A] 95 110 140 140 180 180 210 250 300 420 ➍➍ 415 V [A] 95 110 (130) ➌ 140 (155) ➌ 140 (155) ➌ 180 (189) ➌ 180 (189) ➌ 210 (227) ➌ 250 (258) ➌ 300 (315) ➌ 420 ➍➍ 500 V [A] 85 105 115 140 140 170 210 250 300 360 ➍➍ 690 V [A] 85 105 115 140 140 170 210 250 300 360 ➍➍ 1000 V [A] 33 40 55 55 65 65 80 95 115 160 ➍➍ 230 V [kW] 30 34 45 45 57 57 67 80 97 135 ➍➍ 240 V [kW] 31 36 47 47 60 60 70 83 101 141 ➍➍ 400 V [kW] 53 61 78 78 101 101 118 140 170 238 ➍➍ 415 V [kW] 55 63 (75) ➌ 82 (90) ➌ 82 (90) ➌ 105 (110) ➌ 105 (110) ➌ 122 (132) ➌ 145 (150) ➌ 176 (185) ➌ 250 ➍➍ 500 V [kW] 59 73 80 98 98 119 147 177 213 255 ➍➍ 690 V [kW] 81 102 110 135 135 167 205 250 293 356 ➍➍ 1000 V [kW] 45 55 75 75 90 90 110 132 160 225 ➍➍ AC-4 at approximately 200 000 operations 230 V [A] 43 50 60 60 67 67 85 105 140 170 ➍➍ 240 V [A] 43 50 60 60 67 67 85 105 140 170 ➍➍ 400 / 415 V [A] 43 50 60 60 67 67 85 105 140 170 ➍➍ 500 V [A] 43 50 60 60 67 67 85 105 140 170 ➍➍ 690 V [A] 43 50 60 60 67 67 85 105 140 170 ➍➍ 1000 V [A] 19 23 37 37 43 43 60 72 85 105 ➍➍ 230 V ➊ [kW] 13 15 17 17 20 20 25 32 45 55 ➍➍ 240 V ➊ [kW] 13 15 18.5 18.5 22 22 25 32 45 55 ➍➍ 400 V ➊ [kW] 22 25 32 32 37 37 45 55 75 90 ➍➍ 415 V ➊ [kW] 22 25 32 32 37 37 50 55 80 100 ➍➍ 500 V ➊ [kW] 25 32 40 40 45 45 55 75 100 110 ➍➍ 690 V ➊ [kW] 40 45 55 55 63 63 80 100 132 160 ➍➍ 1000 V ➊ [kW] 22 30 50 50 55 55 80 100 110 150 ➍➍ Max. switching frequency Ops/h 120 120 120 120 100 100 120 100 70 70 ➍➍ Wye-Delta (60 Hz) 200 V [Hp] 40 60 60 60 75 75 100 125 175 250 ➍➍ 230 V [Hp] 50 60 75 75 100 100 125 175 200 250 ➍➍ 460 V [Hp] 100 125 175 175 200 200 250 350 450 600 ➍➍ 575 V [Hp] 125 150 200 200 250 250 300 450 500 650 ➍➍ UL/CSA Elevator Duty ➋ 200 V [A] 62.1 78 92 92 120 120 150 150 177 221 ➍➍ 230 V [A] 68.0 80 104 104 130 130 130 154 192 248 ➍➍ 460 V [A] 65.0 77 96 96 124 124 156 180 180 240 ➍➍ 575 V [A] 62.0 77 77 77 99 99 125 144 192 242 ➍➍ 200 V [Hp] 20 25 30 30 40 40 50 50 60 75 ➍➍ 230 V [Hp] 25 30 40 40 50 50 50 60 75 100 ➍➍ 460 V [Hp] 50 60 75 75 100 100 125 150 150 200 ➍➍ 575 V [Hp] 60 75 75 75 100 100 125 150 200 250 ➍➍ Star-Delta Starting (50 Hz) ≤ 230 V [A] 165 191 242 242 312 312 364 433 520 727 ➍➍ ≤ 240 V [A] 165 191 242 242 312 312 364 433 520 727 ➍➍ 400 V [A] 165 191 242 242 312 312 364 433 520 727 ➍➍ 415 V [A] 165 191 (225) ➌ 242 (268) ➌ 242 (268) ➌ 312 (322) ➌ 312 (322) ➌ 364 (393) ➌ 433 (447) ➌ 520 (546) ➌ 727 ➍➍ 500 V [A] 165 191 199 242 312 312 364 433 520 727 ➍➍ 690 V [A] 165 191 199 242 312 312 364 433 520 727 ➍➍ 1000 V [A] 57 69 95 95 113 113 139 165 200 277 ➍➍ 230 V ➊ [kW] 45 55 75 75 90 90 110 132 160 220 ➍➍ 240 V ➊ [kW] 50 63 80 80 100 100 125 150 160 250 ➍➍ 400 V ➊ [kW] 80 100 132 132 160 160 200 250 300 425 ➍➍ 415 V ➊ [kW] 80 (90) ➌ 100 (132) ➌ 132 (160) ➌ 132 (160) ➌ 160 160 220 250 315 (335) ➌ 425 (450) ➌➍ ➍ 500 V ➊ [kW] 100 132 132 160 200 200 250 315 375 530 ➍➍ 690 V ➊ [kW] 132 160 200 220 300 300 355 425 530 750 ➍➍ 1000 V ➊ [kW] 75 90 132 132 160 160 200 220 280 400 ➍➍ IEC Specifications Bulletins 100/104-D, 100S-D Contactors 14 Allen-Bradley S pecifications IEC Specifications ➊ To be determined. Coil Type: Conventional Electronic – El 100/104-D, 100S-D 95 110 140 140 180 180 210 250 300 420 630 860 X X X —X ——————— X X —X —X X X X X X X Switching of Power Transformers, AC-6a ( 50 Hz) n = 30 ≤ 230 V [A] 53 60 70 70 85 85 105 125 150 210 ➊➊ ≤ 240 V [A] 53 60 70 70 85 85 105 125 150 210 ➊➊ ≤ 400 V [A] 53 60 70 70 85 85 105 125 150 210 ➊➊ 415 V [A] 53 60 70 70 85 85 105 125 150 210 ➊➊ ≤ 500 V [A] 53 60 70 70 85 85 105 125 150 210 ➊➊ ≤ 690 V [A] 53 60 70 70 85 85 105 125 150 210 ➊➊ ≤ 1000 V [A] 53 60 70 70 85 85 105 125 150 210 ➊➊ 230 V [kVA] 21 24 28 28 34 34 42 50 60 84 ➊➊ 240 V [kVA] 22 25 29 29 35 35 44 52 62 87 ➊➊ 400 V [kVA] 37 42 48 48 59 59 73 87 104 145 ➊➊ 415 V [kVA] 38 43 50 50 61 61 75 90 108 151 ➊➊ 500 V [kVA] 46 52 61 61 74 74 91 108 130 182 ➊➊ 690 V [kVA] 64 72 84 84 102 102 125 149 179 251 ➊➊ 1000 V [kVA] 92 104 121 121 147 147 182 217 260 364 ➊➊ n = 20 ≤ 690 V [A] 80 90 105 105 128 128 158 188 225 315 ➊➊ n = 15 ≤ 690 V [A] 107 120 140 140 170 170 210 250 300 420 ➊➊ 60 Hz Peak Inrush/peak rated transformer current n=30 [A] 53 60 70 70 85 85 102 125 150 210 ➊➊ 200 V [kVA] 18.4 20.8 24.2 24.2 29.4 29.4 36.4 43.3 52.0 72.7 ➊➊ 208 V [kVA] 19.1 21.6 25.2 25.2 30.6 30.6 37.8 45.0 54.0 75.7 ➊➊ 240 V [kVA] 22.0 24.9 29.1 29.1 35.3 35.3 43.6 52.0 62.4 87.3 ➊➊ 480 V [kVA] 44.1 49.9 58.2 58.2 70.7 70.7 87.3 104 125 175 ➊➊ 600 V [kVA] 55.1 62.4 72.7 72.7 88.3 88.3 109 130 156 218 ➊➊ 660 V [kVA] 60.6 68.6 80.0 80.0 97.2 97.2 120 143 171 240 ➊➊ 60 Hz Peak Inrush/peak rated transformer current n=20 [A] 80 90 105 105 128 128 158 188 225 315 ➊➊ 200 V [kVA] 27.7 31.2 36.4 36.4 44.3 44.3 54.7 65.1 77.9 109 ➊➊ 208 V [kVA] 28.8 32.4 37.8 37.8 46.1 46.1 51.9 67.7 81.1 113 ➊➊ 240 V [kVA] 33.3 37.4 43.6 43.6 53.2 53.2 65.7 78.2 93.5 131 ➊➊ 480 V [kVA] 66.5 74.8 87.3 87.3 106 106 131 156 187 262 ➊➊ 600 V [kVA] 83.1 93.5 109 109 114 114 141 167 200 281 ➊➊ 660 V [kVA] 91.5 103 120 120 146 146 131 215 257 360 ➊➊ 60 Hz Peak Inrush/peak rated transformer current n=15 [A] 107 120 140 140 170 170 210 250 300 420 ➊➊ 200 V [kVA] 37.1 41.6 48.5 48.5 58.9 58.9 72.7 86.6 104 145 ➊➊ 208 V [kVA] 38.5 43.2 50.4 50.4 61.2 61.2 75.7 90.1 108 151 ➊➊ 240 V [kVA] 44.5 49.9 58.2 58.2 70.7 70.7 87.3 104 125 175 ➊➊ 480 V [kVA] 89.0 99.8 116 116 141 141 175 208 249 349 ➊➊ 600 V [kVA] 111 125 145 145 177 177 218 260 312 436 ➊➊ 660 V [kVA] 122 137 160 160 194 194 240 286 343 480 ➊➊ Rated transformer current Inrush current = n Allen-Bradley 15 Bulletins 100/104-D, 100S-D Contactors S pecifications IEC Specifications ➊ To be determined. Coil Type: Conventional Electronic – El 100/104-D, 100S-D 95 110 140 140 180 180 210 250 300 420 630 860 X X X —X ——————— X X —X —X X X X X X X Switching of 3-phase capacitors, AC-6b (50 Hz); Inductance of leads between capacitors in parallel: min. 6 µH (100-C09…-C30 contactors: min. 30 µH) Single capacitor 40°C 230 V [kVar] 45 45 70 70 70 70 98 98 125 139 ➊➊ 240 V [kVar] 47 47 73 73 73 73 102 102 131 145 ➊➊ 400 V [kVar] 78 78 121 121 121 121 170 170 218 242 ➊➊ 415 V [kVar] 81 81 126 126 126 126 176 176 226 252 ➊➊ 500 V [kVar] 97 97 152 152 152 152 212 212 273 303 ➊➊ 690 V [kVar] 134 134 209 209 209 209 293 293 376 418 ➊➊ 1000 V [kVar] 194 194 303 303 303 303 424 424 546 606 ➊➊ 60°C 230 V [kVar] 38 38 59 59 59 59 84 84 106 119 ➊➊ 240 V [kVar] 39 39 61 61 61 61 87 87 111 124 ➊➊ 400 V [kVar] 65 65 102 102 102 102 145 145 184 206 ➊➊ 415 V [kVar] 68 68 106 106 106 106 151 151 191 214 ➊➊ 500 V [kVar] 82 82 127 127 127 127 182 182 230 258 ➊➊ 690 V [kVar] 113 113 176 176 176 176 251 251 318 356 ➊➊ 1000 V [kVar] 164 164 255 255 255 255 364 364 461 515 ➊➊ Group capacitors 40°C 230 V [kVar] 42 45 70 70 70 70 98 98 125 139 ➊➊ 240 V [kVar] 43 47 73 73 73 73 102 102 131 145 ➊➊ 400 V [kVar] 44 56 76 76 111 111 170 170 218 242 ➊➊ 415 V [kVar] 44 56 76 76 112 112 170 176 226 252 ➊➊ 500 V [kVar] 44 56 76 76 113 113 172 212 273 303 ➊➊ 690 V [kVar] 45 57 78 78 114 114 174 247 356 418 ➊➊ 1000 V [kVar] 46 58 79 79 116 116 177 251 361 606 ➊➊ 60°C 230 V [kVar] 38 38 59 59 59 59 84 84 106 119 ➊➊ 240 V [kVar] 39 39 61 61 61 61 87 87 111 124 ➊➊ 400 V [kVar] 44 56 76 76 102 102 145 145 184 206 ➊➊ 415 V [kVar] 44 56 76 76 106 106 151 151 191 214 ➊➊ 500 V [kVar] 44 56 76 76 113 113 172 182 230 258 ➊➊ 690 V [kVar] 45 57 78 78 114 114 174 247 318 356 ➊➊ 1000 V [kVar] 46 58 79 79 116 116 177 251 361 515 ➊➊ 60 Hz Single Capacitor – 40°C 200 V [kVar] 39 39 61 61 61 61 85 85 109 121 ➊➊ 230 V [kVar] 45 45 70 70 70 70 98 98 125 139 ➊➊ 460 V [kVar] 89 89 139 139 139 139 195 195 251 279 ➊➊ 600 V [kVar] 116 116 182 182 182 182 255 255 327 364 ➊➊ 60 Hz Group Capacitors – 40°C 200 V [kVar] 39 39 61 61 61 61 85 85 109 121 ➊➊ 230 V [kVar] 42 45 70 70 70 70 98 95 125 139 ➊➊ 460 V [kVar] 44 56 76 76 112 112 171 195 251 279 ➊➊ 600 V [kVar] 45 57 77 77 114 114 173 246 327 364 ➊➊ Switching of Lamps Gas discharge lamps AC-5a open [A] 144 144 225 225 225 225 315 315 405 420 ➊➊ closed [A] 122 122 189 189 189 189 270 270 342 383 ➊➊ Individually compendated: Max. capacitance at expected Short-circuit current of 10 kA [µF]—————————— ➊➊ 20 kA [µF]—————————— ➊➊ 50 kA [µF]—————————— ➊➊ Filament AC-b5 230 / 240 V [A] 107 120 140 140 170 170 210 250 300 420 ➊➊ Switching of Low Inductive Loads in Home Appliances and Similar Applications per IEC 61095 (50 Hz) AC-7a 230 V [A]—————————— ➊➊ 400 V [A]—————————— ➊➊ 440 V [A]—————————— ➊➊ Switching of Motor Load for Home Appliances per IEC 61095 (50 Hz) AC-7b 230 V [A]—————————— ➊➊ 400 V [A]—————————— ➊➊ 440 V [A]—————————— ➊➊ Bulletins 100/104-D, 100S-D Contactors 16 Allen-Bradley S pecifications Specifications ➊ Values in brackets refer to electronic coil (EI) version. ➋ To be determined. Coil Type: Conventional Electronic – El 100-D, 100S-D 95 110 140 140 180 180 210 250 300 420 630 860 X X X —X ——————— X X —X —X X X X X X X Switching of Hermetically Sealed Cooling Compressor Motors – manual reset of overload release (50 Hz) AC-8a 400 V [A] — ————————— ➋➋ 500 V [A] — ————————— ➋➋ 690 V [A] — ————————— ➋➋ – automatic reset of overload release AC-8b 400 V [A] — ————————— ➋➋ 500 V [A] — ————————— ➋➋ 690 V [A] — ————————— ➋➋ Switching of DC Loads Non-inductive or slightly inductive loads or resistance furnaces DC-1 at 60°C 1 pole 24 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 48 / 60 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 110 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 220 V [A] 3 3 3.3 3.3 3.3 3.3 4.9 4.9 4.9 5.2 ➋➋ 440 V [A] 0.6 0.6 0.75 0.75 0.75 0.75 1 1 1 1.2 ➋➋ 2 poles in series 24 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 48 / 60 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 110 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 220 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 440 V [A] 3 3 3.3 3.3 3.3 3.3 4.9 4.9 4.9 5.2 ➋➋ 3 poles in series 24 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 48 / 60 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 110 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 220 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 440 V [A] 11 11 11 11 11 11 14 14 14 15 ➋➋ Shunt-wound Motors Starting, reverse current braking, reversing, stepping DC-3, 60°C 3 poles in series 24 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 48 / 60 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 110 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 220 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 440 V [A] 3 3 3.5 3.5 3.5 3.5 4.1 4.1 4.1 5.8 ➋➋ Series-wound Motors Starting, reverse current braking, reversing, stepping DC-5, 60°C 3 poles in series 24 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 48 / 60 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 110 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 220 V [A] 135 135 210 210 210 210 300 300 380 425 ➋➋ 440 V [A] 1.2 1.2 2.1 2.1 2.1 2.1 2.4 2.4 2.4 3 ➋➋ Short Time Withstand Icw, 60°C 10 s [A] 1040 1040 1240 1 360 1 480 1 480 2 360 2 520 2 840 4 700 ➋➋ Resistance and Power Dissipation Main current circuit resistance [mΩ]0.4 0.4 0.42 0.42 0.42 0.42 0.22 0.22 0.18 0.15 0.19 0.14 Power dissipation by all circuits at Ie AC-3 / 400 V [W] 10.8 14.5 24.6 24.6 36.3 36.3 29.4 41.7 48.6 79.5 78.4 103.2 Total power dissipation at Ie AC-3 / 400 V AC control [W] 20.8 (16.8) 24.5 (20.5) 34.5 34.5 46.5 46.5 39.4 51.7 58.6 89.5 105.4 133.2 DC control [W] 18.8 (16.8) 22.5 (20.5) 32.5 32.5 44.5 44.5 37.4 49.7 56.6 87.5 105.4 133.2 Lifespan Mechanical AC control [Mio. operations] 10 10 10 10 10 10 10 10 10 10 2 2 DC control [Mio. operations] 10 10 10 10 10 10 10 10 10 10 2 2 Electrical AC-3 (400 V) [Mio. operations] 1 1 11111111➋➋ Weight AC Non-Reversing kg (lbs.) 3.3 (7.28) [3.8 (8.38)]➊ 3.3 (7.28) [3.8 (8.38)]➊3.3 (7.28) 3.8 (8.38) 3.3 (7.28) 3.8 (8.38) 7.5 (16.53) 7.5 (16.53) 7.5 (16.53) 7.5 (16.53) 28.6 (63) 28.6 (63) Reversing kg (lbs.)➋➋➋➋➋➋➋➋➋➋➋➋ AC Non-Reversing kg (lbs.) 3.3 (7.28) [3.8 (8.38)]➊ 3.3 (7.28) [3.8 (8.38)]➊3.3 (7.28) 3.8 (8.38) 3.3 (7.28) 3.8 (8.38) 7.5 (16.53) 7.5 (16.53) 7.5 (16.53) 7.5 (16.53) 28.6 (63) 28.6 (63) Reversing kg (lbs.)➋➋➋➋➋➋➋➋➋➋➋➋ Allen-Bradley 17 Bulletins 100/104-D, 100S-D Contactors Specifications ➌ Hexagonal socket screw ➍ Hexagonal screw ➎ 25…95 mm2 with sleeve per DIN 46228 Coil Type: Conventional Electronic – El 100-D, 100S-D 95 110 140 140 180 180 210 250 300 420 630 860 X X X —X ——————— X X —X —X X X X X X X Conductor Cross Sections - Main Contacts Te r minal type ➍➍ ➍ ➍ (1) conductor [mm 2] (2) conductors [mm 2] — — — — — — — — — — (1) conductor [mm 2] (2) conductors [mm 2] — — — — — — — — — — b max. [mm] c max. [mm] s max. [mm] Ø min. [mm] 20 25 30 52 52 10 12.5 15 22 22 55 62x8 2x8 6.1 8.3 10.5 13 13 Recommended torque [Nm] 8…10 10…12 16 68 68 Cross section per UL/CSA [AWG] — — — — — Recommended torque [lb-in] 70…90 90…110 130…150 600 600 With terminal lug kit 100-DL110 ➌ 100-DLA110 ➌100-DLE110 ➋100-DL180 ➌ 100-DLA180 ➌ 100-DL420 ➌ 100-DLA420 ➌100-DL630 100-DL860 Cross section per UL/CSA [AWG] 14…2/0 8…20 6…300 MCM (2x) 4…350 MCM 2X 2/0…500MCM 4X 2/0…500MCM Recommended torque [lb-in] 70…90 70…90 90…110 375 400 400 With Frame Terminal Block 100-DTB110 ➌100-DTB180 ➌100-DTB420 ➌—— top opening [mm 2] bottom opening [mm 2] 16…35 16…70 16…35 16…95 25…240 ➎ 25…240 —— top opening [mm 2] bott. opening [mm 2] 16…50 16…95 16…50 16…120 25…300 25…300 —— b max. [mm] s top [mm] s bottom [mm] 16 3…9 3…12 20 3…9 3…14 25 4…20 4…20 —— Recommended torque [Nm] 8…10 10…12 20…25 — — Cross section per UL/CSA top [AWG] 6…1 / 0 AWG 6…1 / 0 AWG 4 AWG…600 MCM — — bottom [AWG] 6…3 / 0 AWG 6 AWG…250 MCM 4 AWG…600 MCM — — Recommended torque [lb-in] 70…90 90…110 180…220 — — b c s c s b b c s b s s b Bulletins 100/104-D, 100S-D Contactors 18 Allen-Bradley Specifications Coil Data ➊Electronic coil drives are controlled for minimizing performance, but this control may shortly require (< 1ms) peak load when energizing.This must be taken into account for the proper sizing of supply devices, all-or-nothing relays and cross-sections of coil supply lines. Please contact your nearest Rockwell Automation distributor for detailed information Coil Type: Conventional Electronic – El 100/104-D, 100S/104S-D 95/110 140/180 95 110 140 180 210 250 300 420 630 860 X X —————————— ——X X X X X X X X X X Operating Limits 50 Hz, 60 Hz, 50/60 Hz pick-up [x Us] 0.85…1.1 0.85…1.1 0.8…1.1 dropout [x Us] 0.3…0.6 0.3…0.5 0.3…0.8 DC control pick-up [x Us] 0.85…1.1 0.85…1.1 0.85…1.1 dropout [x Us] 0.3…0.6 0.3…0.5 0.3…0.8 Coil Consumption 50 Hz, 60 Hz, 50/60 Hz pick-up [VA/W] hold-in [VA/W] 650/310 380/240 ➊490/270 ➊1915/1720 ➊ 50/10 13/6 18/7 33/30 DC control pick-up [W] hold-in [W] 540 265 ➊340 ➊1980 ➊ 86730 Operating Times AC closing delay [ms] opening delay [ms] 20…47 70…45 60…100 6…12 25…110 70…145 With RC module opening delay [ms] 9…18 — — DC closing delay [ms] opening delay [ms] 27…47 25…50 60…100 12…20 35…110 70…145 With integrated diode opening delay [ms] 12…20 — — With external diode opening delay [ms] — — — Allen-Bradley 19 Bulletins 100/104-D, 100S-D Contactors Specifications ➊To be determined. Coil Type: Conventional Electronic – El 100/104-D, 100S/104S-D 95/110 140/180 95 110 140 180 210 250 300 420 630 860 X X —————————— ——X X X X X X X X X X Short Circuit Coordination (Max.Fuse or Circuit Breaker Rating) Per IEC 947-4-1 (contactor and fuses only) DIN Fuses - gG, gL 100 kA Available Fault Current Type "1" (690V) [A] 250 312 250 250 315 355 500 500 630 630 ➋➋ Type "2" (400V) [A] 200 250 200 200 250 315 400 400 500 500 ➋➋ Type "2" (690V) [A] 200 250 200 200 250 315 400 400 500 500 ➋➋ BS88 Fuses 80 kA Available Fault Current Type "1" (690V) [A] 160 250 200 200 250 250 355 355 450 630 ➋➋ Type "2" (690V) [A] 160 250 200 200 250 250 355 355 450 560 ➋➋ Per UL 508 and CSA 22.2 No. 14 (contactor and fuses or circuit breaker only) UL Class K5 and RK5 Fuses 5 kA Available Fault Current UL Listed Combination (600V) [A]———————————— UL Class K5 and RK5 Fuses 10 kA Available Fault Current UL Listed Combination (600V) [A] 225/250 350/450 225 250 350 450 500 ————— UL Class L Fuses 18 kA Available Fault Current UL Listed Combination (600V) [A]———————7007001000 — — UL Class L Fuses 42 kA Available Fault Current UL Listed Combination (600V) [A]——————————2500 2500 UL Class CC and CSA HRCI-MISC Fuses 100 kA Available Fault Current UL Listed Combination (600V) - "Type 2" [A]———————————— UL Class J and CSA HRCI-J Fuses 100 kA Available Fault Current UL Listed Combination (600V) - "Type 2" [A]➋➋➋➋➋➋➋➋➋➋➋➋ UL Inverse-Time Circuit Breaker 5 kA Available Fault Current UL Listed Combination (480V) [A]———————————— UL Listed Combination (600V) [A]———————————— UL Inverse-Time Circuit Breaker 10 kA Available Fault Current UL Listed Combination (600V) [A] 125/150 200/250 125 150 200 250 300 ————— UL Inverse-Time Circuit Breaker 18 kA Available Fault Current UL Listed Combination (600V) [A]———————350400500—— UL Inverse-Time Circuit Breaker 42 kA Available Fault Current UL Listed Combination (600V) [A]——————————1200 1200 Bulletins 100/104-D, 100S-D Contactors 20 Allen-Bradley Specifications Auxiliary Contacts and Auxiliary Contact Blocks ➊Only with 100-DS2-B11 Auxiliary contact for 100-D Conventional Electronically compatible Switching of AC Loads AC-12 Ith at 40 °C [A] 16 0.1 at 60 °C [A] 12 at 250 V AC-15 at rated voltage of (1…100 mA) at 3…125 V 24 V [A] 5.5 42 / 48 V [A] 5.5 120 V [A] 5.5 230 V [A] 5.5 240 V [A] 5 400 V [A] 3 415 V [A] 2.5 500 V [A] 1.6 690 V [A] 1 Switching of DC Loads DC-12 L/R< 1 ms resistive loads at 24 VDC [A] 16 — 48 VDC [A] 9 — 110 VDC [A] 3.5 — 220 VDC [A] 0.55 — 440 VDC [A] 0.2 — DC-14 L/R< 15 ms inductive loads with economy resistor in series at 24 VDC [A] 9 — 48 VDC [A] 5 — 110 VDC [A] 2 — 220 VDC [A] 0.4 — 440 VDC [A] 0.16 — DC-13 switching electromagnets at (1…100 mA) at 3…125 V 24 VDC [A] 5 48 VDC [A] 2 110 VDC [A] 0.7 220 VDC [A] 0.25 440 VDC [A] 0.12 Fuse gG Short-circuit protection with no Welding of contacts per IEC 60947-5-1 [A] 16 — [A] 16 — Protective Separation per IEC 60947-1, Annex N between load and auxiliary circuit 440V Min. switching capacity 17 V IEC 60947-5-4 [mA] 10 1 ➊ Load Carrying Capacity per UL/CSA Rated voltage AC [V] max. 600 max. 250 Continuous rating 40 °C [A] 10 General purpose 0.1 Switching capacity AC [A] Heavy pilot duty (A 600) 0.1 Rated voltage DC [V] max. 600 max. 250 Switching capacity DC [A] Standard pilot duty (P 600) 0.1 Allen-Bradley 21 Bulletins 100/104-D, 100S-D Contactors Specifications General 100-D, 100S-D 95…420 Rated Isolation Voltage Ui IEC [V] 1000 UL, CSA [V] 600 Rated Impulse Voltage Withstand Uimp [kV] 12 Rated Voltage Ue AC 50/60 Hz [V] 230, 240, 400, 415, 500, 690, 1000 DC [V] 24, 48, 110, 220, 440 Insulation Class of the Coil Class «B» per VDE 0660, Tab le 22 Rated coil frequency AC 50 Hz, 50/60 Hz, DC Ambient Temperature Storage [°C] -40…+80 Operation at rated voltage [°C] -25…+60 at 70 °C 15% current reduction against 60°C values Climatic Withstand IEC 68-2 Max. Altitude of Installation Site [m] 2000 NN, per IEC 947-4 Protection Class IP00 IEC 60529 / DIN 40 050 Single contactor cover IP10 IEC 60529 / DIN 40 050 Contactor with frame terminal block IP20 IEC 60529 / DIN 40 050 Auxiliary contact IP20 IEC 60529 / DIN 40 050 Protection against Accidental Contact Finger and back-of-hand proof per VDE 0106, part 100 Resistance to Shock IEC 68-2-27 Resistance to Vibration IEC 68-2-6 Mirror Contacts IEC 60947-4 Annex F SUVA Certified 100-D… + 2 x 100-DS1-11 100S-D5 Standards IEC/EN 60947-1/-4-1/-5-1, UL 508; CSA 22.2. No. 14 Approvals CE, UL, CSA Bulletins 100/104-D, 100S-D IEC Contactors; IEC Safety Contactors 22 Allen-Bradley Specifications, Continued Electrical life in Utilization Category Contact Life for Mixed Utilization Categories AC-3 and AC-4: In many applications, the utilization category cannot be defined as either purely AC-3 or AC-4. In those applications, the electrical life of the contactor can be estimated from the following equation: Lmixed = Lac3/ [1+Pac4*(Lac3/Lac4-1)], where: Lmixed Approximate contact life in operations for a mixed AC-3/AC-4 utilization category application. Lac3 Approximate contact life in operations for a pure AC-3 utlilization category (from the AC-3 life-load curves). Lac4 Approximate contact life in operations for a pure AC-4 utilization category (from the AC-4 life-load curves). Pac4 Percentage of AC-4 operations. I e Rated operational current I Making Current U e Rated voltage I c Breaking Current U r Recovery voltage U Off-load voltage ➊ Plugging is understood as stopping or reversing the motor rapidly by reversing motor primary connections while the motor is running. ➋ Inching (jogging) is understood as energizing a motor once or repeatedly for short periods to obtain small movements of the driven mechanism. Bulletin 100/104 IEC contactors are designed for superior performance in a wide variety of applications. When selecting IEC products, the user must give consideration to the specific load, utilization category and required electrical life of the application. The life-load curves shown here are based on Rockwell Automation tests according to the requirements defined in IEC 60947-4-1. Since contact life in application is dependent on environmental conditions and duty cycle, actual application contact life may vary from that indicated by the curves shown here. To find the contactor’s estimated electrical life, follow these guidelines: 1. Identify the appropriate utilization category from the table below. 2. Choose the graph for the utilization category selected. 3. Locate the intersection of the life-load curve for the appropriate contactor with the application’s operational current ( l e ) found on the horizontal axis. 4. Read the estimated contact life along the vertical axis. Test Conditions Making Breaking I / I e U/U e cos j I c / I e U r /U e cos j AC-1 Resistance Furnaces: Non inductive or slightly inductive loads 110.95 1 1 0.95 AC-2 Slip-ring motors: Starting and reversing 2.5 1 0.65 2.5 1 0.65 AC-3 Squirrel - cage motors: Starting and stopping of running motors I e < 17 A I e > 17 A 6 6 1 1 0.65 0.35 6 6 0.17 0.17 0.65 0.35 AC-4 Squirrel - cage motors: Starting, plugging ➊ , inching ➋ I e < 17 A I e > 17 A 6 6 1 1 0.65 0.35 6 6 1 1 0.65 0.35 AC-15 Solenoids: Contactors, valves and lifting magnets 10 1 0.7 1 1 0.4 Allen-Bradley 23 Bulletins 100/104-D, 100S-D IEC Contactors S pecifications Electrical Life 0.1 1 10 10 100 1000D420D300D250D210D180D140D110D95(AC-1) 100-D Rated operating current Ie AC-3 [A] (Dashed curves ------ AC-1 only, open)Contact life [millions of operations]AC-3 Switching of squirrel-cage motors while starting AC-1 Non- or slightly inductive loads, resistance furnaces; Ue = 400V 0.01 0.1 1 10 1000D420D300D250D210D180D140D110D95100101 100-D Rated operating current Ie AC-4 [A]Contact life [millions of operations]AC-4 Stepping of squirrel-cage motors; Ue = 400V Bulletins 100/104-D, 100S-D IEC Contactors 24 Allen-Bradley S pecifications Electrical Life 0.1 1 10 10 100 1000D420D300D250D210D180D140D110D95100-D Rated operating current Ie AC-3 / AC-4 [A]Contact life [millions of operations]AC-3 90 % & AC-4 10 % Mixed operation of squirrel-cage motors; Ue = 400V Allen-Bradley 25 Bulletins 100/104-D, 100S-D IEC Contactors Approximate Dimensions Bulletin 100-D and 100S-D Contactors and Accessories Dimensions in millimeters. Dimensions are not intended to be used for manufacturing purposes. Mounting Position ➊ Conventional DC coil contactors will only accept 100-DS2… auxiliary contacts. Cat. No. a b c c1 ø dd1d2 ø ee1e2e3e4 100-D95, 100-D110 120 170 156 110.5 5.2 145 100 M6 16 38.5 147 8 100-D95E…100-D180E, 100-D140, 100-D180 120 170 156 110.5 5.2 145 100 M8 20 39 160 10 100-D210E…100-D420E 155 205 180 110.5 6.5 180 130 M10 25 48 193 12.5 100-D630E…100D-860E 255 310 265 110.5 10 230 225 M12 40 70 291 22 Contactor with [mm] Auxiliary contact block ➊ 100-DS1… 100-DS2… a a + 13.5 each Mechanical interlock 100-DM… a + a Frame terminal block 100-DTB110 100-DTB180 100-DTB420 b + 7 each b + 7 each b + 8.5 each Label holder c…+ 5 d2 a c e1 e2 c1 øe ➊bd1e3e4ød 90˚90˚115˚25˚ Bulletins 100/104-D, 100S-D IEC Contactors 26 Allen-Bradley Approximate Dimensions Contactors and Accessories Dimensions in millimeters. Dimensions are not intended to be used for manufacturing purposes. Mounting Position ➊ Conventional DC coil contactors will have an additionial auxiliary contact block that will add 13.5 mm to the “a” dimension on the right-hand side. Cat. No. a b c c1 ø dd1d2 ø ee1e2e3e4 100S-D95, 100S-D110 120 170 156 110.5 5.2 145 100 M6 16 38.5 147 8 100S-D95E…100S-D180E, 100S-D140, 100S-D180 120 170 156 110.5 5.2 145 100 M8 20 39 160 10 100S-D210E…100S-D420E 155 205 180 110.5 6.5 180 130 M10 25 48 193 12.5 100S-D630E…100S-D860E 255 310 265 110.5 10 230 225 M12 40 70 291 22 Contactor with [mm] Auxiliary contact block 100-DS1… 100-DS2… a a + 13.5 each Mechanical interlock 100-DM… a + a Frame terminal block 100-DTB110 100-DTB180 100-DTB420 b + 7 each b + 7 each b + 8.5 each Label holder c…+ 5 d2 a c e1 e2 c1 øe ➊bd1e3e4ød 90˚90˚115˚25˚ Allen-Bradley 27 Bulletins 100/104-D, 100S-D IEC Contactors; IEC Safety Contactors Bulletin 100-D Description Coil For Use With Contactor Cat. No.Cat. No. Arc Chambers for Contactors •For 3-Pole 100-D contactors Conventional 100-D95 100-D110 100-D140 100-D180 100-DA-95 100-DA-110 100-DA-140 100-DA-180 Electronic 100-D95 100-D110 100-D140 100-D180 100-D210 100-D250 100-D300 100-D420 100-D630 100-D860 100-DAE-95 100-DAE-110 100-DAE-140 100-DAE-180 100-DAE-210 100-DAE-250 100-DAE-300 100-DAE-420 100-DAE-630 100-DAE-860 Main Contacts for Contactors •Set for 3-Pole 100-D contactors Conventional 100-D95 100-D110 100-D140 100-D180 100-DC-95 100-DC-110 100-DC-140 100-DC-180 Electronic 100-D95 100-D110 100-D140 100-D180 100-D210 100-D250 100-D300 100-D420 100-D630 100-D860 100-DCE-95 100-DCE-110 100-DCE-140 100-DCE-180 100-DCE-210 100-DCE-250 100-DCE-300 100-DCE-420 100-DCE-630 100-DCE-860 Te r minal Hardware •Set of 6 100-D95…D110 100-D140…D180 100-D210…D420 100-D630…D860 100-DHF110 100-DHF180 100-DHF420 100-DHF860 Bulletins 100/104-D, 100S-D IEC Contactors; IEC Safety Contactors 28 Allen-Bradley Bulletin 100-D Replacement coils for 100-D contactors ➊ Applies to 100-D95…-D110 contactors only. Not available with 100-D140…-D180 contactors. ➋ Not available for 100-D300 AC Standard Control Voltages AC Coil Code 100-D95... 100-D180 100-D210... 100-D420 100-D630... 100-D860 DC Standard Control Voltages DC Coil Code 100-D95... 100-D180 100-D210... 100-D420 100-D630... 100-D860 50 Hz 60 Hz 50/60 Hz Cat. No.Cat. No.Cat. No.Cat. No.Cat. No.Cat. No. Conventional AC Conventional DC 24V — — K TG407 ——12V ZQ TG708 —— —24V — J TG013 ——24V ZJ TG714 —— ——24V ➊ KJ TG855 ——36V ZN TG719 —— 32V 36V — V TG481 ——48V ZY TG724 —— 36V 42V — W TG410 ——60V ZZ TG774 —— 42V — — Y TG414 ——110V ZD TG733 —— 48V 48V — X TG482 ——125V ZS TG737 —— ——100V ➊ KP TG861 ——130V ZF TG738 —— 110V 120V — D TG473 ——220V ZA TG761 —— ——110V ➊ KN TG856 ——240V ZL TG750 —— —208V — H TG049 ——250V ZT TG751 —— ——200V ➊ KG TG862 —— ——220V ➊ KL TG857 —— 220…230V 240V — A TG441 —— 240V 277V — T TG480 —— ——277V ➊ KT TG060 —— ——230V ➊ KF TG851 —— ——240V ➊ KA TG858 —— 380…400V 440V — N TG071 —— 415V 480V — B TG475 —— 440V — —TG___—— 500V — — M TG479 —— 550V 600V — C TG476 —— Electronic AC Electronic DC AC Standard Control Voltages AC Coil Code 100- D95…D300 100-D420 100- D630…D860 DC Standard Control Voltages DC Coil Code 100- D95…D300 100-D420 100- D630…D860 50 Hz 60 Hz 50/60 Hz Cat.-No. Cat.-No. Cat.-No. Cat.-No. Cat.-No. Cat.-No. ——24 V EJ ➋ TGE855 ——24 V EZJ TGE708 —— ——42…64 V EY TGE864 THE864 —48…72 V EZY TGE779 THE779 — ——100 V EJ TGE861 THE861 TJE861 110…130 V EZD TGE780 THE780 — ——110…130 V ED TGE865 THE865 TJE865 ED ——TJE865 ——200 V EG TGE862 THE862 TJE862 200…255 V EZA TGE781 THE781 — ——208…277 V EA TGE866 THE866 TJE866 EA ——TJE866 ——380…400 V EE —THE880 — ——380…500 V EN TGE867 THE867 — ——380…415 V EN ——THJ867 ——440…480 V EB ——TJE868 ——500 V EM ——TJE869 —600 V — EC ——TJE870 Bulletin 100-C/104-C Contactors 21 Product Selection, Continued 3-Pole DC-Operated Contactors •DC Operating Mechanism •3MainContacts ⊗⊗⊗⊗Voltage Suffix Code andTerminalPosition The Cat. No. as listed is incomplete. Select a voltage suffix code from the table below to complete the Cat. No. Example: 24V DC: Cat. No. 100-C09⊗10 becomes Cat. No.100-C09ZJ10. Coil Terminal Position. •All contactors are delivered with the coil terminals located on the line side. •For load side coil terminations, insert a “U”prior to the coil voltage code. Ordering example:Cat. No. 100-C09UZJ10. Ie Ratings for Switching AC Motors - AC-2, AC-3, AC-4 Auxiliary Contacts Cat. No. [A]kW (50 Hz) HP (60 Hz) AC-3 AC-1 230V 380V 415V 400V 500V 690V 1∅3∅ 115V 230V 200V 230V 460V 575V N.O. N.C. 93234441/31 2257-1/2 10100-C09⊗10 01100-C09⊗01 12 32 4 5.5 5.5 5.5 1/2 2 3 3 7-1/2 10 10100-C12⊗10 01100-C12⊗01 16 32 5.5 7.5 7.5 7.5 1 3 5 5 10 10 10100-C16⊗10 01100-C16⊗01 23 32 7.5 11 11 11 2 3 5 7-1/2 15 15 10100-C23⊗10 01100-C23⊗01 30 50 10 15 15 15 2 5 7-1/2 10 20 20 00100-C30⊗00 10100-C30⊗10 01100-C30⊗01 37 50 11 18.5 18.5 18.5 3 5 10 10 25 25 00100-C37⊗00 10100-C37⊗10 01100-C37⊗01 43 85 13 22 22 22 3 7-1/2 10 15 30 30 00100-C43⊗00 10100-C43⊗10 01100-C43⊗01 60 100 18.5 30 30 30 5 10 15 20 40 40 00100-C60⊗00 10100-C60⊗10 01100-C60⊗01 72 100 22 37 37 37 5 15 20 25 50 50 00100-C72⊗00 10100-C72⊗10 01100-C72⊗01 85 100 25 45 45 45 7-1/2 15 25 30 60 60 00100-C85⊗00 10100-C85⊗10 01100-C85⊗01 DC Voltages 9 12 24 36 48 60 64 72 80 110 115 125 220 230 250 100-C09…C43 Standard ZR ZQ ZJ ZW ZY ZZ ZB ZG ZE ZD ZP ZS ZA ZF ZT with Integrated Diode --DJ ------------ 100-C60…C85 with Integrated Diode DR DQ DJ DW DY DZ DB DG DE DD DP DS DA DF DT Cat.No.100-C16ZJ10 Cat.No.100-C23ZJ10 Cat.No.100-C85DJ00Cat.No.100-C43ZJ00 Cat.No. 100-C09Z⊗10 Li ne Side Cat.No. 100-C09UZ⊗10 Load Side Accessories — Page 25 Specifications — Page 31 Approximate Dimensions — Page 46 Prices – Consult Sales Office or price list www.rockwellautomation.com Corporate Headquarters Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, 53202-5302 USA, Tel: (1) 414.212.5200, Fax: (1) 414.212.5201 Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing Solutions Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444 Europe: Rockwell Automation SA/NV, Vorstlaan/Boulevard du Souverain 36-BP 3A/B, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640 Asia Pacific: Rockwell Automation, 27/F Citicorp Centre, 18 Whitfield Road, Causeway Bay, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: (1) 864.297.4800, Fax: (1) 864.281.2433 Europe: Rockwell Automation, Brühlstraße 22, D-74834 Elztal-Dallau, Germany, Tel: (49) 6261 9410, Fax: (49) 6261 1774 Asia Pacific: Rockwell Automation, 55 Newton Road, #11-01/02 Revenue House, Singapore 307987, Tel: (65) 351 6723, Fax: (65) 355 1733 Publication 100D-SG001B-EN-P June Copyright © 2004 Rockwell Automation. All rights reserved. miniature circuit breakers Think future. Switch to green. FAZ branch circuit breakers General Information .................................................................. 2 Selection Tables Trip Characteristic C - Box terminals ...................................... 4 Trip Characteristic D - Box terminals ...................................... 5 Trip Characteristic C - Ring tongue terminals ......................... 6 Trip Characteristic D - Ring tongue terminals......................... 7 Accessories ................................................................................ 8 Technical Data ........................................................................... 10 Dimensions ............................................................................... 15 FAZ supplementary protectors General Information .................................................................. 20 Selection Tables Trip Characteristic B ............................................................. 22 Trip Characteristic C .............................................................. 24 Trip Characteristic D ............................................................. 26 Trip Characteristic K ............................................................. 28 Trip Characteristic Z .............................................................. 30 Trip Characteristic S .............................................................. 31 Accessories ................................................................................ 32 Technical Data ........................................................................... 35 Dimensions ............................................................................... 41 MCB Applications Applying branch circuit breakers and supplementary protectors in North America .............................. 43 Moeller has just expanded its FAZ line of miniature circuit breakers to include de- vices that are listed and certified as molded case circuit breakers per UL 489 and CSA 22.2, No. 5-02. These new branch circuit breakers, called FAZ-NA, are ideal for the protection of power supplies, control power transformers, HVAC, refrigeration equipment, florescent lighting (to 20A) and many other applications requiring a primary protective device. Flexible product range Moeller’s FAZ Branch Circuit Breakers are available in one, two and three pole con- figurations with 20 different current ratings ranging from 0.5A to 40A. All breakers are available in both C and D tripping curves, offering protection from 5 to 10 and 10 to 20 x the continuous rating of the device (In). Two and three pole devices can be used in solidly grounded circuits up to 480V AC. The entire line offers short circuit ratings of 10kA regardless of voltage applied. Many installation options FAZ Branch Circuit Breakers are available in two terminal configu- rations; standard box terminals that accept multiple conductors and ring-tongue terminals, ideally suited to the demanding re- quirements of the semi-conductor industry. All breakers mount on standard 35mm DIN-rail. Bus Connectors and Feeder Termi- nals facilitate mounting and wiring of multiple miniature circuit breaker arrays in control panel assemblies. Power to the circuit breakers can also be fed from the line or load side. Standard features enhance safety As with most products from Moeller, FAZ breaker terminals provide finger and back- of-hand protection to guard against accidental contact with live parts. A color-cod- ed red/green indicator provides immediate visual indication of device status and isolation function (green for OFF, red for ON). All FAZ breakers incorporate a “trip- free” mechanism. This prevents the trip function from being defeated by holding the operator in the ON position. In addition, all FAZ branch circuit breakers are UL listed and CSA certified for fuseless protection of smaller AWG 18 and 16 conductors! Worldwide acceptance FAZ-NA (RT) Molded Case Circuit Breakers are UL Listed for use in the United States in accordance with NFPA 70 (NEC). The devices comply with UL 489 and CSA 22.2 No. 5-02, meeting the requirements for Molded Case Circuit Breakers. These de- vices also comply with IEC 60947-2 and are CE compliant. series FAZ branch circuit breakers Branch circuit protection up to 10kA > Molded case circuit breaker per UL 489 / CSA 22.2 No. 5.1 > Current limiting device > Ring-tongue terminals available > Worldwide approvals (app photo) R See page 43 about… Applying in North America FAZ Tripping characteristics Moeller FAZ-NA(RT) branch circuit breakers are avail- able with “C” and “D” tripping characteristics. C-curve devices are suitable for applications where medium levels of inrush current are expected. Applications in- clude small transformers, lighting, pilot devices, con- trol circuits, and coils. C-curve devices provide a me- dium magnetic trip point. Devices with a “D” curve are suitable for applications where high levels of inrush current are expected. The high magnetic trip point prevents nuisance tripping in high inductive applications such as motors, transform- ers, and power supplies. Even though not required by NEC or CEC for Branch Circuit Breakers, Moeller’s FAZ-NA(RT) devices are cur- rent limiting, which means they interrupt fault currents within one half cycle of the fault. Current limiting de- vices offer superior protection by reducing peak let- through current and energy. This graph shows trip-time versus over- current for Type C and D devices FAZ-NA branch circuit breakers. Available in one, two and three poles with “C” & “D” trip characteristics Arc Chutes quickly extinguish arcs generated by the opening of the contacts under normal or high fault conditions Arc chutes and switching mechanism are kept apart for mechanical reliability Breakers install on standard DIN-rail Bimetal trip assembly provides reliable overload protection through a broad range of ambient temperatures 0.0005Trippingtime t[sec]7200 3600 1200 600 300 120 60 30 10 5 2 1 0.5 0.2 0.1 0.05 0.02 0.005 0.01 0.002 0.001 504030201510987654321 acc.to IEC 60898-1instantaneoustripping 54 54 3 1 2 N N 1 2 t nt N N N N 4 6 N3 I =1.0 I (T=40 °C ) I =1.35 I :t < 1 h (T=25 °C ) 2.0 I :t =12-120 s (T=25 °C ) 10 I :t <0.1 s 20 I :t <0.1 s conventional non-tripping current conventional tripping current type C:5 I :t >0.1 s type D:10 I :t >0.1 s tripping characteristicacc.to UL 489 / CSA 22.2 No. 235 3 DC Multiples of In Short circuit rating to 10kA (@277V AC and 480Y/277V AC for multi-pole) – Choose box terminals (AWA #18 to #4 ) or terminals for ring-tongue connectors Complete bus bar system available for quickly installing breaker arrays Trip-free design; breaker cannot be defeated by holding the handle in the ON position Color coded indicator provides breaker status for easy troubleshooting Breaker information printed on the front of the device for quick identification Discover these advanced features www.moeller.ca www.moellerusa.net FAZ Branch Circuit Breakers Trip Characteristic C FAZ Branch Circuit Breakers Trip Characteristic D > UL Approved (UL489) and CSA Certified (CSA C22.2 No. 5-02) as Branch Circuit Breakers > Interrupting capacity: 10kA UL/CSA; 15kA IEC 60947 > Trip characteristic C: Response time of instantaneous trip: 5 – 10 x In current rating > Current limiting device Trip Characteristic C – Designed for inductive loads Rated Current In(A) 1 pole 2 poles 3 poles Type Price Type Price Type Price 0.5 FAZ-CO,5/1-NA 34 FAZ-C0,5/2-NA 78 FAZ-C0,5/3-NA 120 1 FAZ-C1/1-NA 34 FAZ-C1/2-NA 78 FAZ-C1/3-NA 120 1.5 FAZ-C1,5/1-NA 34 FAZ-C1,5/2-NA 78 FAZ-C1,5/3-NA 120 2 FAZ-C2/1-NA 34 FAZ-C2/2-NA 78 FAZ-C2/3-NA 120 3 FAZ-C3/1-NA 34 FAZ-C3/2-NA 78 FAZ-C3/3-NA 120 4 FAZ-C4/1-NA 34 FAZ-C4/2-NA 78 FAZ-C4/3-NA 120 5 FAZ-C5/1-NA 34 FAZ-C5/2-NA 78 FAZ-C5/3-NA 120 6 FAZ-C6/1-NA 34 FAZ-C6/2-NA 78 FAZ-C6/3-NA 120 7 FAZ-C7/1-NA 34 FAZ-C7/2-NA 78 FAZ-C7/3-NA 120 8 FAZ-C8/1-NA 34 FAZ-C8/2-NA 78 FAZ-C8/3-NA 120 10 FAZ-C10/1-NA 34 FAZ-C10/2-NA 78 FAZ-C10/3-NA 120 13 FAZ-C13/1-NA 34 FAZ-C13/2-NA 78 FAZ-C13/3-NA 120 15 FAZ-C15/1-NA 34 FAZ-C15/2-NA 78 FAZ-C15/3-NA 120 16 FAZ-C16/1-NA 34 FAZ-C16/2-NA 78 FAZ-C16/3-NA 120 20 FAZ-C20/1-NA 34 FAZ-C20/2-NA 78 FAZ-C20/3-NA 120 25 FAZ-C25/1-NA 34 FAZ-C25/2-NA 78 FAZ-C25/3-NA 120 30 FAZ-C30/1-NA 34 FAZ-C30/2-NA 78 FAZ-C30/3-NA 120 32 FAZ-C32/1-NA 34 FAZ-C32/2-NA 78 FAZ-C32/3-NA 120 35 FAZ-C35/1-NA 34 FAZ-C35/2-NA 78 FAZ-C35/3-NA 120 40 FAZ-C40/1-NA 34 FAZ-C40/2-NA 78 FAZ-C40/3-NA 120 Type C Characteristics Suitable for applications where medium levels of inrush current are expected. Instantaneous trip is 5 to 10 x rating of device (In). Ap- plications include small transformers, lighting, pilot devices, control circuits, and coils. Medium magnetic trip point. See Trip Curve chart on page 11 FAZ Branch Circuit Breakers Trip Characteristic C www.moellerusa.net www.moeller.ca FAZ Branch Circuit Breakers Trip Characteristic D > UL Approved (UL489) and CSA Certified (CSA C22.2 No. 5-02) as Branch Circuit Breakers > Interrupting capacity: 10kA UL/CSA; 15kA IEC 60947 > Trip characteristic D: Response time of instantaneous trip: 10 – 20 x In current rating > Current limiting device Trip Characteristic D – Designed for highly inductive loads Rated Current In(A) 1 pole 2 poles 3 poles Type Price Type Price Type Price 0.5 FAZ-D0,5/1-NA 39 FAZ-D0,5/2-NA 90 FAZ-D0,5/3-NA 138 1 FAZ-D1/1-NA 39 FAZ-D1/2-NA 90 FAZ-D1/3-NA 138 1.5 FAZ-D1,5/1-NA 39 FAZ-D1,5/2-NA 90 FAZ-D1,5/3-NA 138 2 FAZ-D2/1-NA 39 FAZ-D2/2-NA 90 FAZ-D2/3-NA 138 3 FAZ-D3/1-NA 39 FAZ-D3/2-NA 90 FAZ-D3/3-NA 138 4 FAZ-D4/1-NA 39 FAZ-D4/2-NA 90 FAZ-D4/3-NA 138 5 FAZ-D5/1-NA 39 FAZ-D5/2-NA 90 FAZ-D5/3-NA 138 6 FAZ-D6/1-NA 39 FAZ-D6/2-NA 90 FAZ-D6/3-NA 138 7 FAZ-D7/1-NA 39 FAZ-D7/2-NA 90 FAZ-D7/3-NA 138 8 FAZ-D8/1-NA 39 FAZ-D8/2-NA 90 FAZ-D8/3-NA 138 10 FAZ-D10/1-NA 39 FAZ-D10/2-NA 90 FAZ-D10/3-NA 138 13 FAZ-D13/1-NA 39 FAZ-D13/2-NA 90 FAZ-D13/3-NA 138 15 FAZ-D15/1-NA 39 FAZ-D15/2-NA 90 FAZ-D15/3-NA 138 16 FAZ-D16/1-NA 39 FAZ-D16/2-NA 90 FAZ-D16/3-NA 138 20 FAZ-D20/1-NA 39 FAZ-D20/2-NA 90 FAZ-D20/3-NA 138 25 FAZ-D25/1-NA 39 FAZ-D25/2-NA 90 FAZ-D25/3-NA 138 30 FAZ-D30/1-NA 39 FAZ-D30/2-NA 90 FAZ-D30/3-NA 138 32 FAZ-D32/1-NA 39 FAZ-D32/2-NA 90 FAZ-D32/3-NA 138 35 FAZ-D35/1-NA 39 FAZ-D35/2-NA 90 FAZ-D35/3-NA 138 40 FAZ-D40/1-NA 39 FAZ-D40/2-NA 90 FAZ-D40/3-NA 138 Type D Characteristics Suitable for applications where high levels of inrush current are expected. Instantaneous trip is 10 to 20 x rating of device (In). The high magnetic trip point prevents nuisance tripping in high inductive applications such as motors, transformers, and power supplies. See Trip Curve chart on page 11 www.moeller.ca www.moellerusa.net FAZ Branch Circuit Breakers - Ring Tongue Trip Characteristic C FAZ Branch Circuit Breakers – Ring Tongue Trip Characteristic D > UL Approved (UL489) and CSA Certified (CSA C22.2 No. 5-02) as Branch Circuit Breakers > Connections for ring-tongue terminals > Trip characteristic C: Response time of instantaneous trip: 5 – 10 x In current rating > Interrupting capacity: 10kA UL/CSA; 15kA IEC 60947 Trip Characteristic C – Designed for inductive loads Rated Current In(A) 1 pole 2 poles 3 poles Type Price Type Price Type Price 0.5 FAZ-CO,5/1-RT 38 FAZ-C0,5/2-RT 86 FAZ-C0,5/3-RT 132 1 FAZ-C1/1-RT 38 FAZ-C1/2-RT 86 FAZ-C1/3-RT 132 1.5 FAZ-C1,5/1-RT 38 FAZ-C1,5/2-RT 86 FAZ-C1,5/3-RT 132 2 FAZ-C2/1-RT 38 FAZ-C2/2-RT 86 FAZ-C2/3-RT 132 3 FAZ-C3/1-RT 38 FAZ-C3/2-RT 86 FAZ-C3/3-RT 132 4 FAZ-C4/1-RT 38 FAZ-C4/2-RT 86 FAZ-C4/3-RT 132 5 FAZ-C5/1-RT 38 FAZ-C5/2-RT 86 FAZ-C5/3-RT 132 6 FAZ-C6/1-RT 38 FAZ-C6/2-RT 86 FAZ-C6/3-RT 132 7 FAZ-C7/1-RT 38 FAZ-C7/2-RT 86 FAZ-C7/3-RT 132 8 FAZ-C8/1-RT 38 FAZ-C8/2-RT 86 FAZ-C8/3-RT 132 10 FAZ-C10/1-RT 38 FAZ-C10/2-RT 86 FAZ-C10/3-RT 132 13 FAZ-C13/1-RT 38 FAZ-C13/2-RT 86 FAZ-C13/3-RT 132 15 FAZ-C15/1-RT 38 FAZ-C15/2-RT 86 FAZ-C15/3-RT 132 16 FAZ-C16/1-RT 38 FAZ-C16/2-RT 86 FAZ-C16/3-RT 132 20 FAZ-C20/1-RT 38 FAZ-C20/2-RT 86 FAZ-C20/3-RT 132 25 FAZ-C25/1-RT 38 FAZ-C25/2-RT 86 FAZ-C25/3-RT 132 30 FAZ-C30/1-RT 38 FAZ-C30/2-RT 86 FAZ-C30/3-RT 132 32 FAZ-C32/1-RT 38 FAZ-C32/2-RT 86 FAZ-C32/3-RT 132 35 FAZ-C35/1-RT 38 FAZ-C35/2-RT 86 FAZ-C35/3-RT 132 40 FAZ-C40/1-RT 38 FAZ-C40/2-RT 86 FAZ-C40/3-RT 132 Type C Characteristics Suitable for applications where medium levels of inrush current are expected. Instantaneous trip is 5 to 10 x rating of device (In). Ap- plications include small transformers, lighting, pilot devices, control circuits, and coils. Medium magnetic trip point. All breakers on this page are equipped with terminals that accommodate ring-tongue connectors. See Trip Curve chart on page 11 FAZ Branch Circuit Breakers - Ring Tongue Trip Characteristic C www.moellerusa.net www.moeller.ca FAZ Branch Circuit Breakers – Ring Tongue Trip Characteristic D > UL Approved (UL489) and CSA Certified (CSA C22.2 No. 5-02) as Branch Circuit Breakers > Connections for ring-tongue terminals > Trip characteristic D: Response time of instantaneous trip: 10 – 20 x In current rating > Interrupting capacity: 10kA UL/CSA; 15kA IEC 60947 Trip Characteristic D – Designed for highly inductive loads Rated Current In(A) 1 pole 2 poles 3 poles Type Price Type Price Type Price 0.5 FAZ-D0,5/1-RT 43 FAZ-D0,5/2-RT 98 FAZ-D0,5/3-RT 150 1 FAZ-D1/1-RT 43 FAZ-D1/2-RT 98 FAZ-D1/3-RT 150 1.5 FAZ-D1,5/1-RT 43 FAZ-D1,5/2-RT 98 FAZ-D1,5/3-RT 150 2 FAZ-D2/1-RT 43 FAZ-D2/2-RT 98 FAZ-D2/3-RT 150 3 FAZ-D3/1-RT 43 FAZ-D3/2-RT 98 FAZ-D3/3-RT 150 4 FAZ-D4/1-RT 43 FAZ-D4/2-RT 98 FAZ-D4/3-RT 150 5 FAZ-D5/1-RT 43 FAZ-D5/2-RT 98 FAZ-D5/3-RT 150 6 FAZ-D6/1-RT 43 FAZ-D6/2-RT 98 FAZ-D6/3-RT 150 7 FAZ-D7/1-RT 43 FAZ-D7/2-RT 98 FAZ-D7/3-RT 150 8 FAZ-D8/1-RT 43 FAZ-D8/2-RT 98 FAZ-D8/3-RT 150 10 FAZ-D10/1-RT 43 FAZ-D10/2-RT 98 FAZ-D10/3-RT 150 13 FAZ-D13/1-RT 43 FAZ-D13/2-RT 98 FAZ-D13/3-RT 150 15 FAZ-D15/1-RT 43 FAZ-D15/2-RT 98 FAZ-D15/3-RT 150 16 FAZ-D16/1-RT 43 FAZ-D16/2-RT 98 FAZ-D16/3-RT 150 20 FAZ-D20/1-RT 43 FAZ-D20/2-RT 98 FAZ-D20/3-RT 150 25 FAZ-D25/1-RT 43 FAZ-D25/2-RT 98 FAZ-D25/3-RT 150 30 FAZ-D30/1-RT 43 FAZ-D30/2-RT 98 FAZ-D30/3-RT 150 32 FAZ-D32/1-RT 43 FAZ-D32/2-RT 98 FAZ-D32/3-RT 150 35 FAZ-D35/1-RT 43 FAZ-D35/2-RT 98 FAZ-D35/3-RT 150 40 FAZ-D40/1-RT 43 FAZ-D40/2-RT 98 FAZ-D40/3-RT 150 Type D Characteristics Suitable for applications where high levels of inrush current are expected. Instantaneous trip is 10 to 20 x rating of device (In). The high magnetic trip point prevents nuisance tripping in high inductive applications such as motors, transformers, and power supplies. All breakers on this page are equipped with terminals that accommodate ring-tongue connectors. See Trip Curve chart on page 11 www.moeller.ca www.moellerusa.net FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Accessories FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Accessories For all FAZ…NA and FAZ…RT Miniature Circuit Breakers Accessories Description Circuit Diagram Rated Operational Voltage Type Price Selectable 2-pole Auxiliary Contact or Auxiliary/Trip-indicating contacts – Small selector screw changes mode – Two Form C (changeover) contacts – Installs on left side of FAZ or Shunt Trip – Aux. contacts switch when FAZ is tripped electrically or manually – Trip indicating contact switches only when FAZ is tripped electrically – Test button for electrical tripping function Two-pole auxiliary mode Trip indicating mode 230V AC Z-NHK 60 Shunt Trip Release – Allows remote trip of FAZ – Installs on left side of FAZ 110-415V AC FAZ-XAA-NA110-415VAC 85 12-110V AC FAZ-XAA-NA12-110VAC 85 Padlock Hasp – Prevents reactivation of the device during maintenance – Holds one padlock IS/SPE-1TE 40 Allowable combinations of accessories NHK FAZ CircuitBreaker XAA ShuntTrip NHK FAZ CircuitBreaker C2 C1 FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Accessories www.moellerusa.net www.moeller.ca FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Accessories Bus Bar System Bus Bar Number of Poles per Device Number of Terminals Rated Operational Current (A)Type Price 1 6 80 A Z-SV/UL-16/1P-1TE/6 12 Z-SV/UL-16/1P-1TE/12 18 Z-SV/UL-16/1P-1TE/18 2 6 80A Z-SV/UL-16/2P-2TE/6 12 Z-SV/UL-16/2P-2TE/12 18 Z-SV/UL-16/2P-2TE/18 3 6 80A Z-SV/UL-16/3P-3TE/6 12 Z-SV/UL-16/3P-3TE/12 18 Z-SV/UL-16/3P-3TE/18 Contact your Moeller representative for availability. Incoming Supply Terminals Terminal Description Type Price Extension Terminal – Accommodates conductors up to 25 mm2 (~ AWG 4) – Finger-safe connection Z-EK-35/UL Bus connector – For conductors up to 50 mm2 (~ AWG 1/0) – Finger-safe connection to Z-SV/UL-16... Z-EK-50/UL Contact your Moeller representative for availability. 10 www.moeller.ca www.moellerusa.net FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Let-through Characteristics FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Technical Data Let-through Energy Characteristic C (0.5-20A), 277V Characteristic D (0.5-20A), 277V Characteristic C (25-40A), 240V Characteristic D (25-40A), 240V500060007000800090001000010001500200030004000500300 400 70000 50000 30000 15000 900 9000 7000 5000 3000 1500 700 500 80000 60000 40000 20000 10000 8000 6000 4000 2000 1000 800 600 C13 C10 C 2 C 1 ,5 C8 C5 C 0 .5 C 1 C3 C4 C6 ,C7C15,C16C20Prospective short-circuit current [A]Let-through energy It [Asec]500060007000800090001000010001500200030004000500300 400 70000 50000 30000 15000 900 9000 7000 5000 3000 1500 700 500 80000 60000 40000 20000 10000 8000 6000 4000 2000 1000 800 600 C30 C35 C40 C32 C25 Prospective short-circuit current [A]Let-through energy It [Asec]500060007000800090001000010001500200030004000500300 400 70000 50000 30000 15000 900 9000 7000 5000 3000 1500 700 500 80000 60000 40000 20000 10000 8000 6000 4000 2000 1000 800 600 D 15,D 16 D 1 3 D10 D8 D 2 D 1 .5 D6,D7 D5 D0.5 D 1 D3 D4 D20 Prospective short-circuit current [A]Let-through energy It [Asec]500060007000800090001000010001500200030004000500300 400 70000 50000 30000 15000 900 9000 7000 5000 3000 1500 700 500 80000 60000 40000 20000 10000 8000 6000 4000 2000 1000 800 600 D30 D35 D40 D32 D25 Prospective short-circuit current [A]Let-through energy It [Asec] FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Let-through Characteristics www.moellerusa.net www.moeller.ca 11 FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Technical Data Tripping Characteristics Influence of ambient temperature T on load carrying capacity 0.0005Trippingtime t[sec]7200 3600 1200 600 300 120 60 30 10 5 2 1 0.5 0.2 0.1 0.05 0.02 0.005 0.01 0.002 0.001 504030201510987654321 acc.to IEC 60898-1instantaneoustripping 54 54 3 1 2 N N 1 2 t nt N N N N 4 6 N3 I =1.0 I (T=40 °C ) I =1.35 I :t < 1 h (T=25 °C ) 2.0 I :t =12-12 0 s (T=25 °C ) 10 I :t <0.1 s 20 I :t <0.1 s conventional non-tripping current conventional tripping current type C:5 I :t >0.1 s type D:10 I :t >0.1 s tripping characteristicacc.to UL 489 / CSA 22.2 No. 235 3 DC Multiples of In 50403020100-10-20 0.90 1.40 1.30 1.20 1.10 1.00 Ambient temperature T [°C ] Maximum load IL at ambient temperature T: IL (T) = In KT (T) Load factor KT [I/In]Power loss at In Characteristic C In [A] 1p P[W] 2p P[W] 3p P[W] 0.5 1.6 3.2 4.7 1 1.1 2.2 3.4 1.5 1.3 2.6 3.9 2 1.4 2.8 4.3 3 1.2 2.4 3.6 4 1.4 2.9 4.3 5 1.9 3.7 5.6 6 1.2 2.3 3.5 7 1.4 2.8 4.3 8 1.4 2.8 4.2 10 1.8 3.6 5.3 13 2.4 4.7 7.1 15 1.9 3.8 5.6 16 2.1 4.3 6.4 20 2.9 5.8 8.7 25 3.1 6.2 9.3 30 3.0 6.0 9.0 32 3.4 6.8 10.2 35 3.7 7.4 11.0 40 4.0 8.1 12.1 Characteristic D In [A] 1p P[W] 2p P[W] 3p P[W] 0.5 1.6 3.2 4.8 1 0.8 1.5 2.3 1.5 1.0 2.1 3.1 2 1.0 2.1 3.1 3 1.2 2.4 3.6 4 1.4 2.9 4.3 5 1.5 2.9 4.4 6 1.2 2.3 3.5 7 1.4 2.8 4.3 8 1.2 2.4 3.7 10 1.5 3.0 4.5 13 2.0 4.1 6.1 15 1.5 3.1 4.6 16 1.7 3.5 5.2 20 1.8 3.7 5.5 25 2.6 5.1 7.7 30 2.7 5.4 8.1 32 3.1 6.2 9.3 35 3.8 7.6 11.3 40 3.9 7.8 11.6 1 www.moeller.ca www.moellerusa.net FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Technical Data FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Technical Data FAZ-NA, FAZ-RT Miniature Circuit Breakers FAZ-NA, FAZ-RT Electrical Design according to Current test marks as printed onto the device UL 489, CSA C22.2 No. 5, IEC 60947-2 Rated voltage UL/CSA 0.5 – 20A UL/CSA 25 – 40A IEC 277/480Y VAC 240 VAC 240/415 VAC Rated frequency Rated breaking capacity UL/CSA IEC 50/60 Hz 10 kA 15 kA Characteristic Endurance Line voltage connection C, D ≥ 20,000 operating cycles operational suitable for reverse feed Mechanical Frame size Device height Device width 45 mm 105 mm 17.7 mm per pole Mounting Upper and lower terminals quick fastening with 2 lock-in positions on DIN rail EN 50022 open mouth/lift terminals Terminal capacity Terminal fastening torque 1 Wire AWG 18-6 2 Wires AWG 18-10 1 Wire 21 lb-in 2 Wires 25 lb-in Mounting Calibration temperature UL 489, CSA C22.2 No. 5 IEC 60947-2 independent of position 40˚C 30˚C FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Technical Data www.moellerusa.net www.moeller.ca 1 FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Technical Data Selectable Aux Contact / Trip Indicating Contact – Z-NHK Z-NHK Electrical Can be mounted from the left onto: Contact function FAZ-NA, FAZ-RT, FAZ-XAA-NA 2 changeover contacts (self cleaning) Rated voltage [V] Rated frequency [Hz] 230 50/60 Rated current [A] Rated thermal current Ith [A] 2 2 Utilization category AC13 Rated operational current Ie [A] Utilization category AC15 Rated operational current Ie [A] Utilization category DC12 Rated operational current Ie [A] Rated insulation voltage Ui [VAC] 3 / 250V AC 2 / 250V AC 0.5 / 110V DC 250 Minimum operational voltage per contact Umin [VDC] Minimum operational current Imin [mA] Rated peak withstand voltage Uimp (1.2/50µ) [kV] 5 10 mA DC 2.5 Conditional short-circuit current Ik with back-up fuse 6A [kA] Max. back-up fuse, overload and short-circuit 1 kA 6A gL Mechanical Tripping indicator “electrical tripping” Frame size blue/white 45 mm Device height Device width 80 mm 8.8 mm (0.5MU) Mounting Degree of protection, built-in Snaps on to side of MCB IP40 Terminal protection Terminals finger and hand-touch safe according to BGV A3, ÖVE-EN 6 lift terminals Terminal capacity Terminal screws 18-14 AWG M3 (Pozidrive Z0) Fastening torque of terminal screws 7 lb-in 1 www.moeller.ca www.moellerusa.net FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Technical Data FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Dimensions Shunt Trip Release FAZ-XAA-NA FAZ-XAA-NA12-110VAC FAZ-XAA-NA110-415VAC Electrical Can be mounted onto FAZ-NA, FAZ-RT FAZ-NA, FAZ-RT Operational voltage range 12-110V AC 12-60V DC 110-415V AC 110-230V DC Frequency Possible standard auxiliary switch 50/60 Hz Z-NHK 50/60 Hz Z-NHK Mechanical Frame size 45 mm 45 mm Device height Device width 105 mm 17.5 mm (1MU) 105 mm 17.5 mm (1MJ) Mounting Degree of protection, built-in quick fastening with 2 lock-in positions on DIN rail EN 50022 IP40 quick fastening with 2 lock-in positions on DIN rail EN 50022 IP40 Terminal protection Terminals Terminal capacity 1 and 2 wires finger and hand-touch safe according to BGV A3, ÖVE-EN 6 box/lift AWG 18-10 finger and hand-touch safe according to BGV A3, ÖVE-EN 6 box/lift AWG 18-10 Bus Bar ➊ Z-SV/UL-16... Electrical Rated voltage Rated current 690V 80A Short-circuit strength Overvoltage category Impulse voltage strength < 25 kA III ≥ 9.5 kV Mechanical Bus bar cross-section Step distance 16 mm2 Cu 17.6 mm Climatic stability Flame class according to UL Pollution degree according to DIN EN 60068 V0/0.4 mm 2 ➊ Contact your Moeller representative for availability. FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Technical Data www.moellerusa.net www.moeller.ca 1 FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Dimensions FAZ-NA, FAZ-RT Z-NHK FAZ-XAA-NA 17.7 1P 3P2P 45105 10 44 60 5 .5 35.4 105 53.1 105 5.5 4580 8.8 44 60 45 10 44 60 5.5 17.7 105 1 www.moeller.ca www.moellerusa.net FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Dimensions FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Dimensions A-A A A 32..54615.5 100.4 1.7 max 1.55 17.6 885x17.6 = Z-SV/UL-16/.P-.TE/6 A-A (1 : 1 ) A A 206 5 17.6 193.611x17.6= 1.5 15.5 32.5461.7 1.5max. Z-SV/UL-16/.P-.TE/12 311.6 5 17.6 299.217x17.6 = 15.5 32.5461.5 Z-SV/UL-16/.P-.TE/18 FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Dimensions www.moellerusa.net www.moeller.ca 1 FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Dimensions Incoming Supply Terminals Z-EK/35/UL Z-EK/50/UL Attention! Z-EK/35/UL supply terminals may only be installed per the illustration below. A-AA A6018.56.8 3 16 2128.5-00.2+A-A 28.829.8Ø13.5 12.4AA 17.75 40 10.5 12.3 45.117.7517.75 ✔ 1 www.moeller.ca www.moellerusa.net FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Dimensions FAZ Branch Circuit Breakers Notes Lockout Attachment .35 -.45 Nm (3 - 4 lb-in) OF F / O LO CK OF F O NL Y 3 m m (1/8") 5.0 -7.0 mm Ø (3/16 " -9/32"Ø) MCB UL 489 FAZ Branch Circuit BreakersFAZ Branch Circuit Breakers Dimensions www.moellerusa.net www.moeller.ca 1 FAZ Branch Circuit Breakers Notes 0 Moeller’s FAZ line of miniature circuit breakers includes a broad range of devices defined as “supplementary protectors.” These breakers comply with UL 1077 and CSA 22.2 No. 235 regulations defining supplementary over-current protection. In these applications, branch circuit protection is not required, or is provided by a separate device like a fuse or molded case circuit breaker. FAZ Supplementary Protectors are typically used for control circuits, lighting, busi- ness equipment, appliances and a range of other applications where “closer” pro- tection is desired than that offered by a branch circuit protection device. Extensive product range Moeller Supplementary Protectors are available in one, two and three pole con- figurations and up to 17 different current ratings from 0.5A to 63A. One pole plus neutral, and three-pole plus neutral devices are also available. Six different trip characteristics including B, C, D, K, S and Z curves give you the ability to configure the exact protection scheme you require. Devices can be used in applications up to 480V AC and 48V DC with short circuit ratings up to 10kA. Straightforward installation All breakers mount on a standard 35mm DIN-rail. Each device has box terminals that accept multiple conductors. Bus Connectors and Feeder Terminals facilitate mounting and wiring of multiple miniature circuit breaker arrays in control panel assemblies. Power to the circuit breakers can also be fed from the line or load side. Standard features enhance safety As with most products from Moeller, FAZ breaker terminals provide finger and back-of-hand protection to guard against accidental contact with live parts. A color-coded red/green indicator provides immediate visual indication of device status (green for OFF, red for ON) and isolation function. All FAZ breakers also incorporate a “trip-free” mechanism. This prevents the trip function from being defeated by holding the operator in the ON position. Worldwide acceptance FAZ Supplementary Protectors are UL Recognized for use in the United States in accordance with NFPA 70 (NEC). The devices comply with UL 1077 and CSA 22.2 No.235, meeting the requirements for supplementary protectors. These devices also comply with IEC 60898 and are CE marked. series FAZ supplementary protectors Supplementary protection up to 10kA > Supplementary protector per UL 1077 / CSA 22.2 No. 235 > Current limiting device > Very broad product range > Worldwide approvals (app photo) See page 43 about… Applying in North America FAZ 1 Six tripping curves to choose Moeller FAZ Supplementary Protectors are available with six different tripping characteristics, including Type B, C, D, K, S and Z. Definitions for each trip curve are con- tained on the ordering pages and can be used to deter- mine the optimal characteristic for your application. For example, low level short-circuit faults in control wiring, such as PLCs, are best protected by devices with Type B trip characteristics (3 to 5 X continuous rating of the de- vice (In). Even though not required by NEC or CEC for Supplemen- tary Protectors, Moeller’s FAZ devices are current limiting, which means they interrupt fault currents within one half cycle. Current limiting devices offer superior protection by reducing peak let-through current and energy. This graph shows trip-time versus over-current for all FAZ Supplementary Protectors. Discover these advanced features Captive posidrive terminal screws with finger and back-of-hand protection (IP20) Available in over 400 configurations including B, C, D, K, S and D trip curves Short circuit rating to 10kA (@277V AC and 480Y/277V AC for multi-pole to 40A) Breakers install on standard DIN-rail Available in one, two and three pole models; one and three pole plus neutral also available Trip-free design; breaker cannot be defeated by holding the handle in the ON position Box terminals accept #16 to #4 wire (1.5 to 25mm2) Color coded indicator provides breaker status for easy troubleshooting Complete bus bar system available for quickly installing breaker arrays in panel assemblies Breaker information printed on the front of the device for quick identification www.moeller.ca www.moellerusa.net FAZ Supplementary Protectors Trip Characteristic B FAZ Supplementary Protectors Trip Characteristic B > Designed for resistive or slightly inductive loads. > Response time of instantaneous trip: 3 – 5 x In current rating > UL Recognized and CSA Certified as Supplementary Protectors > For international and domestic use (conform to IEC / EN60898) Trip Characteristic B – Designed for resistive or slightly inductive loads ➊ Rated Current In(A) 1 pole 2 poles 3 poles 4 poles Type Price Type Price Type Price Type Price 6 FAZ-B6/1 17 FAZ-B6/2 58 FAZ-B6/3 85 FAZ-B6/4 115 8 FAZ-B8/1 17 FAZ-B8/2 58 FAZ-B8/3 85 FAZ-B8/4 115 10 FAZ-B10/1 17 FAZ-B10/2 58 FAZ-B10/3 85 FAZ-B10/4 115 12 FAZ-B12/1 17 FAZ-B12/2 58 FAZ-B12/3 85 FAZ-B12/4 115 13 FAZ-B13/1 17 FAZ-B13/2 58 FAZ-B13/3 85 FAZ-B13/4 115 15 FAZ-B15/1 17 FAZ-B15/2 58 FAZ-B15/3 85 FAZ-B15/4 115 16 FAZ-B16/1 17 FAZ-B16/2 58 FAZ-B16/3 85 FAZ-B16/4 115 20 FAZ-B20/1 17 FAZ-B20/2 58 FAZ-B20/3 85 FAZ-B20/4 115 25 FAZ-B25/1 17 FAZ-B25/2 58 FAZ-B25/3 85 FAZ-B25/4 115 32 FAZ-B32/1 17 FAZ-B32/2 58 FAZ-B32/3 85 FAZ-B32/4 115 40 FAZ-B40/1 24 FAZ-B40/2 75 FAZ-B40/3 100 FAZ-B40/4 135 50 FAZ-B50/1 28 FAZ-B50/2 80 FAZ-B50/3 130 FAZ-B50/4 165 63 FAZ-B63/1 36 FAZ-B63/2 105 FAZ-B63/3 180 FAZ-B63/4 210 ➊ In North America, these switches are UL recognized and CSA certified as Supplementary Protection devices. Per the intent of NEC (National Electrical Code), article 240, and CEC (Canadian Electrical Code), part 1 C22.1, supplementary breakers cannot be used as a substitute for the branch circuit protective device. They can be used to provide over-current protection within an appliance or other electrical equipment where branch circuit over- current protection is already provided, or is not required. See FAZ Branch Circuit Breakers in this catalog. See Trip Curve chart on opposite page Type B Characteristics Suitable for applications where protection against low level short circuit faults in control wiring is desired. Instantaneous trip is 3 to 5 x continu- ous rating of device (In). Applications include PLC wiring, business equip- ment, lighting, appliances and some motors. Low magnetic trip point. FAZ Supplementary Protectors Trip Characteristic B www.moellerusa.net www.moeller.ca FAZ Supplementary Protectors Trip Characteristic B > Designed for resistive or slightly inductive loads. > Response time of instantaneous trip: 3 – 5 x In current rating > UL Recognized and CSA Certified as Supplementary Protectors > For international and domestic use (conform to IEC / EN60898) Trip Characteristic B – Designed for resistive or slightly inductive loads ➊ Rated Current In(A) 1 pole + Neutral 3 poles + Neutral Type Price Type Price 6 FAZ-B6/1N 37 FAZ-B6/3N 105 8 FAZ-B8/1N 37 FAZ-B8/3N 105 10 FAZ-B10/1N 37 FAZ-B10/3N 105 12 FAZ-B12/1N 37 FAZ-B12/3N 105 13 FAZ-B13/1N 37 FAZ-B13/3N 105 15 FAZ-B15/1N 37 FAZ-B15/3N 105 16 FAZ-B16/1N 37 FAZ-B16/3N 105 20 FAZ-B20/1N 37 FAZ-B20/3N 105 25 FAZ-B25/1N 37 FAZ-B25/3N 105 32 FAZ-B32/1N 37 FAZ-B32/3N 105 40 FAZ-B40/1N 45 FAZ-B40/3N 125 50 FAZ-B50/1N 50 FAZ-B50/3N 155 63 FAZ-B63/1N 60 FAZ-B63/3N 205 0.00051 2 3 4 5 6 7 8 9 10 15 20 30 40 50 0.001 0.002 0.005 0.01 0.02 0.05 0.1 0.2 0.5 10t [s]30 60 120 300 600 1200 3600 7200 1.131.45B C D 1 2 5 � � � � � � � � Specied non-tripping cur rent Int = 1.13 X In for t > 1 h Specied tripping cur rent It = 1.45 X In for t < 1 h � 2.55 X In : t = 1 – 60 s (In < 32 A) t = 1 – 120 s (In > 32 A) � Type B: 3 X In : t > 0.1 s � Type B: 5 X In : t < 0.1 s � Type C: 5 X In : t > 0.1 s � Type C: 10 X In : t < 0.1 s � Type D: 10 X In : t > 0.1 s � Type D: 20 X In : t < 0.1 s Multiples of In ➊ In North America, these switches are UL recognized and CSA certified as Supplementary Protection devices. Per the intent of NEC (National Electrical Code), article 240, and CEC (Canadian Electrical Code), part 1 C22.1, supplementary breakers cannot be used as a substitute for the branch circuit protective device. They can be used to provide over-current protection within an appliance or other electrical equipment where branch circuit over- current protection is already provided, or is not required. See FAZ Branch Circuit Breakers in this catalog. Type B Characteristics Suitable for applications where protection against low level short circuit faults in control wiring is desired. Instantaneous trip is 3 to 5 x continu- ous rating of device (In). Applications include PLC wiring, business equip- ment, lighting, appliances and some motors. Low magnetic trip point. www.moeller.ca www.moellerusa.net FAZ Supplementary Protectors Trip Characteristic C FAZ Supplementary Protectors Trip Characteristic C > Designed for inductive loads. > Response time of instantaneous trip: 5 –10 x In current rating > UL Recognized and CSA Certified as Supplementary Protectors > For international and domestic use (conform to IEC / EN60898) Trip Characteristic C – Designed for inductive loads ➊ Rated Current In(A) 1 pole 2 poles 3 poles 4 poles Type Price Type Price Type Price Type Price 0.5 FAZ-C0,5/1 26 FAZ-C0,5/2 59 FAZ-C0,5/3 88 FAZ-C0,5/4 125 1 FAZ-C1/1 26 FAZ-C1/2 59 FAZ-C1/3 88 FAZ-C1/4 125 1.6 FAZ-C1,6/1 26 FAZ-C1,6/2 59 FAZ-C1,6/3 88 FAZ-C1,6/4 125 2 FAZ-C2/1 26 FAZ-C2/2 59 FAZ-C2/3 88 FAZ-C2/4 125 3 FAZ-C3/1 26 FAZ-C3/2 59 FAZ-C3/3 88 FAZ-C3/4 125 4 FAZ-C4/1 26 FAZ-C4/2 59 FAZ-C4/3 88 FAZ-C4/4 125 6 FAZ-C6/1 26 FAZ-C6/2 59 FAZ-C6/3 88 FAZ-C6/4 125 8 FAZ-C8/1 26 FAZ-C8/2 59 FAZ-C8/3 88 FAZ-C8/4 125 10 FAZ-C10/1 26 FAZ-C10/2 59 FAZ-C10/3 88 FAZ-C10/4 125 13 FAZ-C13/1 26 FAZ-C13/2 59 FAZ-C13/3 88 FAZ-C13/4 125 16 FAZ-C16/1 26 FAZ-C16/2 59 FAZ-C16/3 88 FAZ-C16/4 125 20 FAZ-C20/1 26 FAZ-C20/2 59 FAZ-C20/3 88 FAZ-C20/4 125 25 FAZ-C25/1 26 FAZ-C25/2 59 FAZ-C25/3 88 FAZ-C25/4 125 32 FAZ-C32/1 26 FAZ-C32/2 59 FAZ-C32/3 88 FAZ-C32/4 125 40 FAZ-C40/1 26 FAZ-C40/2 65 FAZ-C40/3 98 FAZ-C40/4 130 50 FAZ-C50/1 40 FAZ-C50/2 85 FAZ-C50/3 140 FAZ-C50/4 170 63 FAZ-C63/1 50 FAZ-C63/2 100 FAZ-C63/3 160 FAZ-C63/4 215 ➊ In North America, these switches are UL recognized and CSA certified as Supplementary Protection devices. Per the intent of NEC (National Electrical Code), article 240, and CEC (Canadian Electrical Code), part 1 C22.1, supplementary breakers cannot be used as a substitute for the branch circuit protective device. They can be used to provide over-current protection within an appliance or other electrical equipment where branch circuit over- current protection is already provided, or is not required. See FAZ Branch Circuit Breakers in this catalog. Type C Characteristics Suitable for applications where medium levels of inrush current are expected. Instantaneous trip is 5 to 10 x rating of device (In). Ap- plications include small transformers, lighting, pilot devices, control circuits, and coils. Medium magnetic trip point. See Trip Curve chart on opposite page FAZ Supplementary Protectors Trip Characteristic C www.moellerusa.net www.moeller.ca FAZ Supplementary Protectors Trip Characteristic C > Designed for inductive loads. > Response time of instantaneous trip: 5 –10 x In current rating > UL Recognized and CSA Certified as Supplementary Protectors > For international and domestic use (conform to IEC / EN60898) Trip Characteristic C – Designed for inductive loads ➊ Rated Current In(A) 1 pole + Neutral 3 poles + Neutral Type Price Type Price 0.5 FAZ-C0,5/1N 40 FAZ-C0,5/3N 115 1 FAZ-C1/1N 40 FAZ-C1/3N 115 1.6 FAZ-C1,6/1N 40 FAZ-C1,6/3N 115 2 FAZ-C2/1N 40 FAZ-C2/3N 115 3 FAZ-C3/1N 40 FAZ-C3/3N 115 4 FAZ-C4/1N 40 FAZ-C4/3N 115 6 FAZ-C6/1N 40 FAZ-C6/3N 115 8 FAZ-C8/1N 40 FAZ-C8/3N 115 10 FAZ-C10/1N 40 FAZ-C10/3N 115 13 FAZ-C13/1N 40 FAZ-C13/3N 115 16 FAZ-C16/1N 40 FAZ-C16/3N 115 20 FAZ-C20/1N 40 FAZ-C20/3N 115 25 FAZ-C25/1N 40 FAZ-C25/3N 115 32 FAZ-C32/1N 40 FAZ-C32/3N 115 40 FAZ-C40/1N 45 FAZ-C40/3N 125 50 FAZ-C50/1N 50 FAZ-C50/3N 170 63 FAZ-C63/1N 60 FAZ-C63/3N 195 0.00051 2 3 4 5 6 7 8 9 10 15 20 30 40 50 0.001 0.002 0.005 0.01 0.02 0.05 0.1 0.2 0.5 10t [s]30 60 120 300 600 1200 3600 7200 1.131.45B C D 1 2 5 � � � � � � � � Specied non-tripping cur rent Int = 1.13 X In for t > 1 h Specied tripping cur rent It = 1.45 X In for t < 1 h � 2.55 X In : t = 1 – 60 s (In < 32 A) t = 1 – 120 s (In > 32 A) � Type B: 3 X In : t > 0.1 s � Type B: 5 X In : t < 0.1 s � Type C: 5 X In : t > 0.1 s � Type C: 10 X In : t < 0.1 s � Type D: 10 X In : t > 0.1 s � Type D: 20 X In : t < 0.1 s Multiples of In ➊ In North America, these switches are UL recognized and CSA certified as Supplementary Protection devices. Per the intent of NEC (National Electrical Code), article 240, and CEC (Canadian Electrical Code), part 1 C22.1, supplementary breakers cannot be used as a substitute for the branch circuit protective device. They can be used to provide over-current protection within an appliance or other electrical equipment where branch circuit over- current protection is already provided, or is not required. See FAZ Branch Circuit Breakers in this catalog. Type C Characteristics Suitable for applications where medium levels of inrush current are expected. Instantaneous trip is 5 to 10 x rating of device (In). Ap- plications include small transformers, lighting, pilot devices, control circuits, and coils. Medium magnetic trip point. www.moeller.ca www.moellerusa.net FAZ Supplementary Protectors Trip Characteristic D FAZ Supplementary Protectors Trip Characteristic D > Designed for highly inductive loads. > Response time of instantaneous trip: 10 –20 x In current rating > UL Recognized and CSA Certified as Supplementary Protectors > For international and domestic use (conform to IEC / EN60898) Trip Characteristic D – Designed for highly inductive loads ➊ Rated Current In(A) 1 pole 2 poles 3 poles 4 poles Type Price Type Price Type Price Type Price 6 FAZ-D6/1 28 FAZ-D6/2 63 FAZ-D6/3 102 FAZ-D6/4 140 8 FAZ-D8/1 28 FAZ-D8/2 63 FAZ-D8/3 102 FAZ-D8/4 140 10 FAZ-D10/1 28 FAZ-D10/2 63 FAZ-D10/3 102 FAZ-D10/4 140 13 FAZ-D13/1 28 FAZ-D13/2 63 FAZ-D13/3 102 FAZ-D13/4 140 16 FAZ-D16/1 28 FAZ-D16/2 63 FAZ-D16/3 102 FAZ-D16/4 140 20 FAZ-D20/1 28 FAZ-D20/2 63 FAZ-D20/3 102 FAZ-D20/4 140 25 FAZ-D25/1 28 FAZ-D25/2 63 FAZ-D25/3 102 FAZ-D25/4 140 32 FAZ-D32/1 28 FAZ-D32/2 63 FAZ-D32/3 102 FAZ-D32/4 140 40 FAZ-D40/1 28 FAZ-D40/2 63 FAZ-D40/3 102 FAZ-D40/4 140 ➊ In North America, these switches are UL recognized and CSA certified as Supplementary Protection devices. Per the intent of NEC (National Electrical Code), article 240, and CEC (Canadian Electrical Code), part 1 C22.1, supplementary breakers cannot be used as a substitute for the branch circuit protective device. They can be used to provide over-current protection within an appliance or other electrical equipment where branch circuit over- current protection is already provided, or is not required. See FAZ Branch Circuit Breakers in this catalog. Type D Characteristics Suitable for applications where high levels of inrush current are expected. Instantaneous trip is 10 to 20 x rating of device (In). The high magnetic trip point prevents nuisance tripping in high inductive applications such as motors, transformers, and power supplies. See Trip Curve chart on opposite page FAZ Supplementary Protectors Trip Characteristic D www.moellerusa.net www.moeller.ca FAZ Supplementary Protectors Trip Characteristic D > Designed for highly inductive loads. > Response time of instantaneous trip: 10 –20 x In current rating > UL Recognized and CSA Certified as Supplementary Protectors > For international and domestic use (conform to IEC / EN60898) Trip Characteristic D – Designed for highly inductive loads ➊ Rated Current In(A) 3 poles + Neutral Type Price 6 FAZ-D6/3N 130 8 FAZ-D8/3N 130 10 FAZ-D10/3N 130 13 FAZ-D13/3N 130 16 FAZ-D16/3N 130 20 FAZ-D20/3N 130 25 FAZ-D25/3N 130 32 FAZ-D32/3N 130 40 FAZ-D40/3N 130 0.00051 2 3 4 5 6 7 8 9 10 15 20 30 40 50 0.001 0.002 0.005 0.01 0.02 0.05 0.1 0.2 0.5 10t [s]30 60 120 300 600 1200 3600 7200 1.131.45B C D 1 2 5 � � � � � � � � Specied non-tripping cur rent Int = 1.13 X In for t > 1 h Specied tripping cur rent It = 1.45 X In for t < 1 h � 2.55 X In : t = 1 – 60 s (In < 32 A) t = 1 – 120 s (In > 32 A) � Type B: 3 X In : t > 0.1 s � Type B: 5 X In : t < 0.1 s � Type C: 5 X In : t > 0.1 s � Type C: 10 X In : t < 0.1 s � Type D: 10 X In : t > 0.1 s � Type D: 20 X In : t < 0.1 s Multiples of In ➊ In North America, these switches are UL recognized and CSA certified as Supplementary Protection devices. Per the intent of NEC (National Electrical Code), article 240, and CEC (Canadian Electrical Code), part 1 C22.1, supplementary breakers cannot be used as a substitute for the branch circuit protective device. They can be used to provide over-current protection within an appliance or other electrical equipment where branch circuit over- current protection is already provided, or is not required. See FAZ Branch Circuit Breakers in this catalog. Type D Characteristics Suitable for applications where high levels of inrush current are expected. Instantaneous trip is 10 to 20 x rating of device (In). The high magnetic trip point prevents nuisance tripping in high inductive applications such as motors, transformers, and power supplies. www.moeller.ca www.moellerusa.net FAZ Supplementary Protectors Trip Characteristic K FAZ Supplementary Protectors Trip Characteristic K > Designed for motors, transformers and upstream electronics. > Response time of instantaneous trip: 8 –12 x In current rating > UL Recognized and CSA Certified as Supplementary Protectors > For international and domestic use (conform to IEC / EN60898) Trip Characteristic K – Designed for motors, transformers and upstream electronics ➊ Rated Current In(A) 1 pole 2 poles 3 poles 4 poles Type Price Type Price Type Price Type Price 0.5 FAZ-K0,5/1 26 FAZ-K0,5/2 70 FAZ-K0,5/3 110 FAZ-K0,5/4 140 1 FAZ-K1/1 26 FAZ-K1/2 70 FAZ-K1/3 110 FAZ-K1/4 140 1.6 FAZ-K1,6/1 26 FAZ-K1,6/2 70 FAZ-K1,6/3 110 FAZ-K1,6/4 140 2 FAZ-K2/1 26 FAZ-K2/2 70 FAZ-K2/3 110 FAZ-K2/4 140 3 FAZ-K3/1 26 FAZ-K3/2 70 FAZ-K3/3 110 FAZ-K3/4 140 4 FAZ-K4/1 26 FAZ-K4/2 70 FAZ-K4/3 110 FAZ-K4/4 140 6 FAZ-K6/1 26 FAZ-K6/2 70 FAZ-K6/3 110 FAZ-K6/4 140 8 FAZ-K8/1 26 FAZ-K8/2 70 FAZ-K8/3 110 FAZ-K8/4 140 10 FAZ-K10/1 26 FAZ-K10/2 70 FAZ-K10/3 110 FAZ-K10/4 140 13 FAZ-K13/1 26 FAZ-K13/2 70 FAZ-K13/3 110 FAZ-K13/4 140 16 FAZ-K16/1 26 FAZ-K16/2 70 FAZ-K16/3 110 FAZ-K16/4 140 20 FAZ-K20/1 26 FAZ-K20/2 70 FAZ-K20/3 110 FAZ-K20/4 140 25 FAZ-K25/1 26 FAZ-K25/2 70 FAZ-K25/3 110 FAZ-K25/4 140 32 FAZ-K32/1 26 FAZ-K32/2 70 FAZ-K32/3 110 FAZ-K32/4 140 40 FAZ-K40/1 34 FAZ-K40/2 80 FAZ-K40/3 135 FAZ-K40/4 155 50 FAZ-K50/1 44 FAZ-K50/2 100 FAZ-K50/3 175 FAZ-K50/4 200 63 FAZ-K63/1 55 FAZ-K63/2 120 FAZ-K63/3 205 FAZ-K63/4 250 Special Order These breakers are available by special order only. Contact your Moeller representative for more information. Type K Characteristics Suitable for applications where high levels of inrush current are expected. Instantaneous trip is 8 to 12 x continuous rating of device (In). The high magnetic trip point is ideal for motors and transform- ers. The narrow range (compared with the type D curve) makes it ideal for applications where nuisance tripping is not an issue. ➊ In North America, these switches are UL recognized and CSA certified as Supplementary Protection devices. Per the intent of NEC (National Electrical Code), article 240, and CEC (Canadian Electrical Code), part 1 C22.1, supplementary breakers cannot be used as a substitute for the branch circuit protective device. They can be used to provide over-current protection within an appliance or other electrical equipment where branch circuit over- current protection is already provided, or is not required. See FAZ Branch Circuit Breakers in this catalog. See Trip Curve chart on opposite page FAZ Supplementary Protectors Trip Characteristic K www.moellerusa.net www.moeller.ca FAZ Supplementary Protectors Trip Characteristic K 0.00051 2 3 4 5 6 7 8 9 10 15 20 30 40 50 0.001 0.002 0.005 0.01 0.02 0.05 0.1 0.2 0.5 1 2 5 10t[s]30 60 120 300 600 1200 3600 7200 1.051.30Specied non-tripping current nt = 1.05 u nfor t > 1 h Specied tripping current t = 1.30 u nfor t < 1 h I I I I u rated current > Designed for motors, transformers and upstream electronics. > Response time of instantaneous trip: 8 –12 x In current rating > UL Recognized and CSA Certified as Supplementary Protectors > For international and domestic use (conform to IEC / EN60898) Trip Characteristic K – Designed for motors, transformers and upstream electronics ➊ Rated Current In(A) 3 poles + Neutral Type Price 0.5 FAZ-K0,5/3N 130 1 FAZ-K1/3N 130 1.6 FAZ-K1,6/3N 130 2 FAZ-K2/3N 130 3 FAZ-K3/3N 130 4 FAZ-K4/3N 130 6 FAZ-K6/3N 130 8 FAZ-K8/3N 130 10 FAZ-K10/3N 130 13 FAZ-K13/3N 130 16 FAZ-K16/3N 130 20 FAZ-K20/3N 130 25 FAZ-K25/3N 130 32 FAZ-K32/3N 130 40 FAZ-K40/3N 160 50 FAZ-K50/3N 200 63 FAZ-K63/3N 230 Special Order These breakers are available by special order only. Contact your Moeller representative for more information. Type K Characteristics Suitable for applications where high levels of inrush current are expected. Instantaneous trip is 8 to 12 x continuous rating of device (In). The high magnetic trip point is ideal for motors and transform- ers. The narrow range (compared with the type D curve) makes it ideal for applications where nuisance tripping is not an issue. ➊ In North America, these switches are UL recognized and CSA certified as Supplementary Protection devices. Per the intent of NEC (National Electrical Code), article 240, and CEC (Canadian Electrical Code), part 1 C22.1, supplementary breakers cannot be used as a substitute for the branch circuit protective device. They can be used to provide over-current protection within an appliance or other electrical equipment where branch circuit over- current protection is already provided, or is not required. See FAZ Branch Circuit Breakers in this catalog. 0 www.moeller.ca www.moellerusa.net FAZ Supplementary Protectors Trip Characteristic Z FAZ Supplementary Protectors Trip Characteristic S 0.00051 2 3 4 5 6 7 8 9 10 15 20 30 40 50 0.001 0.002 0.005 0.01 0.02 0.05 0.1 0.2 0.5 1 2 10t[s]30 60 120 300 600 1200 3600 7200 1.051.30Specied non-tripping current nt = 1.05 u nfor t > 1 h Specied tripping current t = 1.30 u nfor t < 1 h I I I I u rated current 5 > Designed for protection of electronic devices. > Response time of instantaneous trip: 2 –3 x In current rating > UL Recognized and CSA Certified as Supplementary Protectors > For international and domestic use (conform to IEC / EN60898) Trip Characteristic Z – Designed for protection of electronic devices ➊ Rated Current In(A) 1 pole 2 poles 3 poles 4 poles Type Price Type Price Type Price Type Price 0.5 FAZ-Z0,5/1 26 FAZ-Z0,5/2 70 FAZ-Z0,5/3 110 FAZ-Z0,5/4 140 1 FAZ-Z1/1 26 FAZ-Z1/2 70 FAZ-Z1/3 110 FAZ-Z1/4 140 1.6 FAZ-Z1,6/1 26 FAZ-Z1,6/2 70 FAZ-Z1,6/3 110 FAZ-Z1,6/4 140 2 FAZ-Z2/1 26 FAZ-Z2/2 70 FAZ-Z2/3 110 FAZ-Z2/4 140 3 FAZ-Z3/1 26 FAZ-Z3/2 70 FAZ-Z3/3 110 FAZ-Z3/4 140 4 FAZ-Z4/1 26 FAZ-Z4/2 70 FAZ-Z4/3 110 FAZ-Z4/4 140 6 FAZ-Z6/1 26 FAZ-Z6/2 70 FAZ-Z6/3 110 FAZ-Z6/4 140 8 FAZ-Z8/1 26 FAZ-Z8/2 70 FAZ-Z8/3 110 FAZ-Z8/4 140 10 FAZ-Z10/1 26 FAZ-Z10/2 70 FAZ-Z10/3 110 FAZ-Z10/4 140 16 FAZ-Z16/1 26 FAZ-Z16/2 70 FAZ-Z16/3 110 FAZ-Z16/4 140 20 FAZ-Z20/1 26 FAZ-Z20/2 70 FAZ-Z20/3 110 FAZ-Z20/4 140 25 FAZ-Z25/1 26 FAZ-Z25/2 70 FAZ-Z25/3 110 FAZ-Z25/4 140 32 FAZ-Z32/1 26 FAZ-Z32/2 70 FAZ-Z32/3 110 FAZ-Z32/4 140 40 FAZ-Z40/1 34 FAZ-Z40/2 80 FAZ-Z40/3 135 FAZ-Z40/4 155 50 FAZ-Z50/1 44 FAZ-Z50/2 100 FAZ-Z50/3 175 FAZ-Z50/4 200 63 FAZ-Z63/1 55 FAZ-Z63/2 120 FAZ-Z63/3 205 FAZ-Z63/4 250 Special Order These breakers are available by special order only. Contact your Moeller representative for more information. Type Z Characteristics Suitable for applications where semiconductors and other compo- nents that fail open are used. Instantaneous trip is 2 to 3 x continu- ous rating of device (In). The short thermal delay and low magnetic trip point are ideal for applications where devices and components have low surge and short circuit tolerances. ➊ In North America, these switches are UL recognized and CSA certified as Supplementary Protection devices. Per the intent of NEC (National Electrical Code), article 240, and CEC (Canadian Electrical Code), part 1 C22.1, supplementary breakers cannot be used as a substitute for the branch circuit protective device. They can be used to provide over-current protection within an appliance or other electrical equipment where branch circuit over- current protection is already provided, or is not required. See FAZ Branch Circuit Breakers in this catalog. FAZ Supplementary Protectors Trip Characteristic Z www.moellerusa.net www.moeller.ca 1 FAZ Supplementary Protectors Trip Characteristic S > Designed for control circuits with high inrush > Response time of instantaneous trip: 13 –17 x In current rating > UL Recognized and CSA Certified as Supplementary Protectors > For international and domestic use (conform to IEC / EN60898) Trip Characteristic S – Designed for control circuits with high inrush ➊ Rated Current In(A) 1 pole 2 poles Type Price Type Price 1 FAZ-S1/1 20 FAZ-S1/2 50 2 FAZ-S2/1 20 FAZ-S2/2 50 3 FAZ-S3/1 20 FAZ-S3/2 50 4 FAZ-S4/1 20 FAZ-S4/2 50 6 FAZ-S6/1 20 FAZ-S6/2 50 10 FAZ-S10/1 20 FAZ-S10/2 50 16 FAZ-S16/1 20 FAZ-S16/2 50 20 FAZ-S20/1 26 FAZ-S20/2 70 25 FAZ-S25/1 28 FAZ-S25/2 75 32 FAZ-S32/1 32 FAZ-S32/2 85 40 FAZ-S40/1 40 FAZ-S40/2 90 Special Order These breakers are available by special order only. Contact your Moeller representative for more information. 0.00051 2 3 4 5 6 7 8 9 10 15 20 30 40 50 0.001 0.002 0.005 0.01 0.02 0.05 0.1 0.2 0.5 1 2 5 10t[s]30 60 120 300 600 1200 3600 7200 1.051.30Specied non-tripping current nt = 1.05 u nfor t > 1 h Specied tripping current t = 1.30 u nfor t < 1 h I I I I u rated current Type S Characteristics Suitable for applications with highly inductive loads, especially in control circuits with coils and light filaments. Instantaneous response between 13 to 17 x rating of device (In). ➊ In North America, these switches are UL recognized and CSA certified as Supplementary Protection devices. Per the intent of NEC (National Electrical Code), article 240, and CEC (Canadian Electrical Code), part 1 C22.1, supplementary breakers cannot be used as a substitute for the branch circuit protective device. They can be used to provide over-current protection within an appliance or other electrical equipment where branch circuit over- current protection is already provided, or is not required. See FAZ Branch Circuit Breakers in this catalog. www.moeller.ca www.moellerusa.net FAZ Supplementary Protectors Accessories FAZ Supplementary Protectors Accessories Auxiliary Contacts and Voltage Trips Module Circuit Diagram Description Rated Operational Voltage Type Price Standard auxiliary contact – 1 NO / 1 NC – Installs on left side of FAZ or Shunt Trip – Max. one per FAZ (1077) device – Switches when FAZ is tripped electrically or manually 230V AC FAZ-XHI11 30 Two-pole auxiliary mode Trip indicating mode Selectable 2-pole Auxiliary Contact or Auxiliary/Trip-indicating contacts – Small selector screw changes mode – Two Form C (changeover) contacts – Installs on left side of FAZ or Shunt Trip – Aux. contacts switch when FAZ is tripped electrically or manually – Trip indicating contact switches only when FAZ is tripped electrically 230V AC FAZ-XAM002 50 D2 U D1 Undervoltage trip – Prevents FAZ from operating unless voltage is present – Installs on left side of FAZ – Includes test button 115V AC FAZ-XUA(115VAC)100 230V AC FAZ-XUA(230VAC)100 400V AC FAZ-XUA(400VAC)100 C2 C1 Shunt trip – Allows remote trip of FAZ – Installs on left side of FAZ 110–415V AC 110–230V DC FAZ-XAA-C-12-110VAC 70 12 – 110V AC 12 – 60V DC FAZ-XAA-C-110-415VAC 70 Allowable combinations of accessories FAZ CircuitBreaker XUA UnderVTrip XAMXHI FAZ CircuitBreaker XAA ShuntTrip or XAMXHI FAZ CircuitBreaker or FAZ Supplementary Protectors Accessories www.moellerusa.net www.moeller.ca FAZ Supplementary Protectors Accessories Bus Bar System ➊ Description Number of Poles per Device Number of Terminals Rated Operational Current (A) ➊Type Price For connecting FAZ Supplemen- tary Protectors without auxiliary contacts. May be fed from line or load side. FAZFAZ FAZ 1 2 80 EVG-16/1PHAS/2MODUL 7 6 EVG-16/1PHAS/6MODUL 13 12 EVG-16/1PHAS/12MODUL 18 2 4 EVG-16/2PHAS/4MODUL 19 6 EVG-16/2PHAS/6MODUL 25 12 EVG-16/2PHAS/12MODUL 40 3 6 EVG-16/3PHAS/6MODUL 32 12 EVG-16/3PHAS/12MODUL 55 4 8 EVG-16/4PHAS/8MODUL 56 12 EVG-16/4PHAS/12MODUL 85 For connecting FAZ Supplemen- tary Protectors with auxiliary contacts. May be fed from line or load side. FAZFAZXHIXAM 1 2 80 EVG-16/1PHAS/2MODUL/HI 11 6 EVG-16/1PHAS/6MODUL/HI 25 9 EVG-16/1PHAS/9MODUL/HI 28 2 4 EVG-16/2PHAS/4MODUL/HI 25 6 EVG-16/2PHAS/6MODUL/HI 32 10 EVG-16/2PHAS/10MODUL/HI 40 3 6 EVG-16/3PHAS/6MODUL/HI 35 12 EVG-16/3PHAS/12MODUL/HI 60 ➊ IEC rated only. www.moeller.ca www.moellerusa.net FAZ Supplementary Protectors Accessories FAZ Supplementary Protectors Let-through Characteristics Incoming Supply Terminals ➊ Accessories Description Installation Type Price Fork connector – Accommodates conductors up to 25 mm2 (~ AWG 4) – Finger-safe connection FAZ-XK35 FAZ-XK25 FAZ-XK25 FAZ FAZ FAZ-XK25 16 Bus connector – For conductors up to 35 mm2 (~ AWG 2) – Finger-safe connection to FAZ-XIS... FAZ-XK35 30 Protective Accessories Accessories Description Type Price Bus Bar Terminal Cover For covering unused terminals FAZ-XBS 17 Bracket for securing the covers Two required per group of supplemen- tary protectors REG-BB 17 Padlock Hasp – Prevents reactivation of the device during maintenance – Holds one padlock FAZ/FIP-XSV 13 ➊ IEC rated only. FAZ Supplementary Protectors Accessories www.moellerusa.net www.moeller.ca FAZ Supplementary Protectors Let-through Characteristics Let-through energy I2t 2 A 1 A 0.5 A 10 A13 A16 A20 A25 A32 A40 A 50 A 63 A 4 A 3 A 6 A 0.5 1.5 15123 4 5 6 7 8 9 10 103 104 105 8 6 4 2 1.5 8 6 4 2 8 6 4 3 1.5 2 .2i dt [A s] FAZ-B FAZ-C FAZ-...-B4HI cc rms [kA]I 10 A 13 A16 A 20 A25 A 32 A40 A 6 A 0.5 1.5 15123 4 5 6 7 8 9 10 104 105 8 6 4 2 1.5 8 6 4 2 1.5 8 6 4 103 2 .2i dt [A s]FAZ-D cc rms [kA]I i2dt [A2s] 103 1.5 0.5 1 1.5 2 3 4 5 2 3 4 6 104 8 1.5 2 3 4 6 8 5 4 3 50 A 63 A FAZ-K 40 A 32 A 25 A20 A 16 A 13 A 10 A 6 A 8 A 4 A3 A 1.6 A 0.5 A 1 A 2 A 6 7 8 9 10 I cc rms [kA] 103 1.5 0.5 1 1.5 2 3 4 5 2 3 4 6 104 8 1.5 2 3 4 6 8 5 i2dt [A2s] 40 A FAZ-S 32 A 25 A 20 A 16 A 10 A 4 A 6 A 3 A2 A 1 A 6 7 8 9 10 I cc rms [kA] www.moeller.ca www.moellerusa.net FAZ Supplementary Protectors Let-through Characteristics FAZ Supplementary Protectors Let-through Characteristics Let-through energy I2t Let-through current ID 103 1.5 0.5 1 1.5 2 3 4 5 2 3 4 6 104 8 1.5 2 3 4 6 8 5 i2dt [A2s] 40 A 50 A 63 AFAZ-Z 32 A 25 A 20 A16 A 8 A 10 A 4 A 6 A 3 A 2 A 1.6 A 1 A 0.5 A 6 7 8 9 10 4 3 I cc rms [kA] FAZ Supplementary Protectors Let-through Characteristics www.moellerusa.net www.moeller.ca FAZ Supplementary Protectors Let-through Characteristics Let-through current ID www.moeller.ca www.moellerusa.net FAZ Supplementary Protectors Technical Data FAZ Supplementary Protectors Technical Data B curve C curve D curve K curve S curve Z curve Electrical Approvals Standards UR (UL 1077), CSA (CSA 22.2 No. 235), CE, VDE IEC/EN 60947-2 Short Circuit Trip Response 3 x 5 In 5 x 10 In 10 x 20 In 8 x 12 In 13 x 17 In 2 x 3 In Supplementary Protectors - UL / CSA Current Range [A]6…63 0.5…63 6…40 0.5…63 0.5…63 1…40 Maximum voltage ratings – UL / CSA 1 pole & 1 pole + neutral 2, 3, 4 pole & 3 pole + neutral [V AC] [V DC] [V AC] 277 48 480Y/277 277 48 480Y/277 277 48 480Y/277 277 48 480Y/277 277 48 480Y/277 277 48 480Y/277 Thermal Tripping Characteristics Single Pole Multi-pole 1.35 x In @ 40°C 1.45 x In @ 40°C Short circuit ratings (at max. voltage) 1 pole 1 pole + neutral 2, 3 & 4 pole 3 pole + neutral 2 poles in series [kA] [kA] [kA] [kA] [kA] 10 (5 for 40A device) 10 (5 for 40A device) 10 (5 for 40A device) 10 (5 for 40A device) 10 @ 125V DC 5 (10 @ 48V DC) 5 (10 @ 48V DC) 5 (10 @ 48V DC) 5 (10 @ 48V DC) 10 @ 125V DC Miniature Circuit Breaker - IEC Current Range [A]6…40 0.5…40 6…25 0.5…40 0.5…40 1…16 Maximum voltage ratings – IEC 1 pole & 1 pole + neutral 2, 3, 4 pole & 3 pole + neutral [V AC] [V DC] [V AC] 240 48 240/415 240 48 240/415 240 48 240/415 240 48 240/415 240 48 240/415 240 48 240/415 Thermal Tripping Characteristics Single Pole Multi-pole >1 hour @ 1.05 x In < 1 hour @ 1.3 x In Interrupt ratings (at max. voltage)[kA]15 15 15 15 10 10 Operational switching capacity [kA]7.5 Max. back-up fuse [A gL/gG]125 Rated impulse withstand - Uimp [V AC]4000 Rated insulation voltage - Ui [V AC]440 Environmental / General Selectivity Class Lifespan [ops.] 3 > 10000 (1 operation = ON/OFF) Shock (IEC 68-2-22)[g]10g - 120ms Operating Temperature Range Shipment & short term storage [°F] [°F] 23…+104 (-5…+40°C) -40…+185 (-40…+85°C) Housing materical Nylon Mechanical Standard front dimension Device height Terminal protection [mm] [mm] 80 Finger- and back-of-hand proof to IEC 536 Mounting width per pole Mounting [mm]17.7 IEC/EN 60715 top-hat rail Degree of protection Terminals top and bottom IP20 Twin-purpose terminals Supply connection Line or load side Terminal capacity [mm2] [mm2] 1 x 25 (AWG 4…18) 2 x 10 (AWG 8…18) Torque [nm]2.4 Thickness of busbar material Mounting position [mm] 0.8 – 2 As required FAZ Supplementary Protectors Technical Data www.moellerusa.net www.moeller.ca FAZ Supplementary Protectors Technical Data Influence of the ambient temperature on the thermal tripping behavior Corrected values of the rated current dependent on the ambient temperature Ambient Temperature T [˚C] In [A]-25 -20 -10 0 10 20 30 35 40 45 50 55 60 0.16 0.20 0.19 0.19 0.18 0.17 0.17 0.16 0.16 0.15 0.15 0.15 0.14 0.14 0.25 0.31 0.30 0.29 0.28 0.27 0.26 0.25 0.25 0.24 0.24 0.23 0.23 0.22 0.5 0.61 0.60 0.58 0.56 0.54 0.52 0.50 0.49 0.48 0.47 0.46 0.45 0.44 0.75 0.92 0.90 0.87 0.84 0.81 0.78 0.75 0.74 0.73 0.71 0.69 0.68 0.66 1 1.2 1.2 1.2 1.1 1.1 1.0 1.0 0.99 0.97 0.95 0.93 0.90 0.89 1.5 1.8 1.8 1.7 1.7 1.6 1.6 1.5 1.5 1.5 1.4 1.4 1.4 1.3 1.6 2.0 1.9 1.9 1.8 1.7 1.7 1.6 1.6 1.5 1.5 1.5 1.4 1.4 2 2.4 2.4 2.3 2.2 2.2 2.1 2.0 2.0 1.9 1.9 1.9 1.8 1.8 2.5 3.1 3.0 2.9 2.8 2.7 2.6 2.5 2.5 2.4 2.4 2.3 2.3 2.2 3 3.7 3.6 3.5 3.4 3.3 3.1 3.0 3.0 2.9 2.8 2.8 2.7 2.7 3.5 4.3 4.2 4.1 3.9 3.8 3.7 3.5 3.4 3.4 3.3 3.2 3.2 3.1 4 4.9 4.8 4.7 4.5 4.3 4.2 4.0 3.9 3.9 3.8 3.7 3.6 3.5 5 6.1 6.0 5.8 5.6 5.4 5.2 5.0 4.9 4.8 4.7 4.6 4.5 4.4 6 7.3 7.2 7.0 6.7 6.5 6.3 6.0 5.9 5.8 5.7 5.6 5.4 5.3 8 9.8 9.6 9.3 9.0 8.7 8.4 8.0 7.9 7.7 7.6 7.4 7.2 7.1 10 12 12 12 11 11 10 10 9.9 9.7 9.5 9.3 9.0 8.9 12 15 14 14 13 13 13 12 12 12 11 11 11 11 13 16 16 15 15 14 14 13 13 13 12 12 12 12 15 18 18 17 17 16 16 15 15 15 14 14 14 13 16 20 19 19 18 17 17 16 16 15 15 15 14 14 20 24 24 23 22 22 21 20 20 19 19 19 18 18 25 31 30 29 28 27 26 25 25 24 24 23 23 22 32 39 38 37 36 35 33 32 32 31 30 30 29 28 40 49 48 47 45 43 42 40 39 39 38 37 36 35 50 61 60 58 56 54 52 50 49 48 47 46 45 44 63 77 76 73 71 68 66 63 62 61 60 58 57 56 Influence of the mains frequency Influence of the mains frequency on the tripping behavior IMA of the instantaneous release Mains frequency f [Hz] 16 2/3 50 60 100 200 300 400 IMA(f)IMA (50 Hz) [%]91 100 101 106 115 134 141 Load carrying capacity of adjoining miniature circuit-breakers 0 www.moeller.ca www.moellerusa.net FAZ Supplementary Protectors Technical Data FAZ Supplementary Protectors Dimensions FAZ-XHI11 Auxiliary FAZ-XAM002 Aux/Trip Indication FAZ-XAA-C…Shunt Trip FAZ-XUA…Undervoltage Trip Electrical Contact function XHI11 XAM002 1M + 1B 2 C/O –– Rated operational voltage Un [V AC]250 –115 230 400 Voltage range [V AC] [V DC] – 12 – 110 110 – 415 110 - 230 12 - 60 – Closing threshhold Tripping threshhold [x Un] [x Un] – – – – 0.8 0.5 Rated frequency ƒ[Hz]50/60 50/60 50/60 General use (UL / CSA) AC DC Pilot Duty 230/240V AC 110/120V DC [A] [A] 2 / 2 0.5 / 0.5 A600 / Q600 – – – – – – Conventional free air thermal current Ith [A]4 Rated operational current AC-13 AC-15 DC-13 Ie Ie Ie [A] [A] [A] 3 (250 V AC) 2 (250 V AC) 0.5 (110 V DC) – – – – – – Rated insulation voltage Minimum operating voltage per contract Rated impulse withstand voltage (1.2/50µ) Ui Umin Uimp [V AC] [V DC] [kV] 250 5 2.5 – – – – – – Rated conditional short-circuit current with 6A back-up fuse Isc [kA]1 –– Max. admissible back-up fuse [A gL]4 –– Mechanical Standard front dimension Device height [mm] [mm] 45 80 45 80 45 80 Mounting width Mounting [mm]8.8 On MCB 17.6 IEC/EN 60715 top-hat rail 17.8 IEC/EN 60715 top-hat rail Degree of protection Enclosed IP40 IP40 IP40 Terminal protection Terminals Protection against electric shock to IEC 536 Lift terminals Protection against electric shock to IEC 536 Twin-purpose terminals Protection against electric shock to IEC 536 Twin-purpose terminals Terminal capacity Solid Flexible [mm2] [mm2] 0.5 – 2.5 0.5 – 2.5 1 – 2.5 1 – 2.5 2 x (1 – 2.5) 2 x (1 – 2.5) Tightening torque of terminal screws [Nm]0.8 – 1.0 2.4 0.8 FAZ Supplementary Protectors Technical Data www.moellerusa.net www.moeller.ca 1 FAZ Supplementary Protectors Dimensions Miniature circuit-breakers FAZ Auxiliary contacts FAZ-XHI11 FAZ-XAM002 Shunt releases Undervoltage release s FAZ-XAA FAZ-XUA 70.8 459.4 60 445.553.135.417.7 80458044 60 5.58.8 458044 60 5.58.8 17.6 8026.2 30.5 105.5 44 60 4517.8 80445.5 60 45 www.moeller.ca www.moellerusa.net FAZ Branch Circuit Breakers Notes FAZ Branch Circuit Breakers Notes Applying branch circuit breakers and supplementary protectors in North America Andre R. Fortin Manager, Codes & Standards Moeller Electric Inc. Applying branch circuit breakers and supplementary protectors in North America Introduction Moeller offers two types of miniature circuit breakers for use in North America. The first version, FAZ- NA(RT), fully complies with the Molded Case Circuit Breaker standard UL 489 and the Canadian equiv- alent CSA 22.2 No. 5-02, which states that devices within that range can be applied legitimately as Feeder and Branch Circuit Protective devices per the US and Canadian electrical Codes. A second version, FAZ, is recognized per UL 1077 and certified per CSA C22.2 No. 235 as a Supplemen- tary Protector and can be fully utilized per the NEC and CEC Codes in that capacity. For international purposes, the entire FAZ family is CE marked and in full conformity with the applicable IEC standards for miniature circuit breakers, EN/IEC 60 898 and EN/IEC 60 947-2. Both FAZ and FAZ-NA(RT) are offered in various ampere ranges and tripping characteristics. This paper will focus on the main technical aspects of the entire line and should assist in the proper selection and application of all versions. Characteristics of IEC-style Miniature Circuit Breakers Because Moeller’s FAZ Miniature Circuit Breakers are IEC-style devices, it is important to understand their inherent characteristics before examining them in the context of UL / CSA requirements. • IEC-style miniature circuit breakers are thermal-magnetic, inverse time protective devices, with both a fixed thermal and a fixed magnetic trip setting. • They are toggle operated, and like all modern circuit breakers, feature a “trip-free” mechanism. This means that the tripping action works independently of the handle position for safety pur- poses. • They all mount on a standard 35mm DIN-rail and share a common single pole width of 17.5 mm. • Most comply with EN/IEC 60898 and EN/IEC 60947-2, which are the relevant international performance and testing standards for low voltage (<1000V) circuit breakers in Europe and the rest of the IEC world. • Outside North America, they can be used in both residential and industrial applications as feeder and branch circuit protective devices. • In North America, most European Miniature Circuit Breakers are only UL recognized and CSA cer- tified as “Supplementary Protectors,” meaning they cannot be utilized as feeder or branch circuit protective devices per the local electrical codes. This commonly restricts their use to applications where “closer” protection is desired than that offered by a branch circuit protection device. • Some variations, like Moeller’s new FAZ-NA(RT) line have been specially designed to meet UL and CSA requirements for Molded Case Circuit Breakers and are marked accordingly. This makes them suitable for feeder and branch circuit protection applications in North America. FAZ-NA(RT)FAZ Supplementary Protectors As mentioned, the standard Moeller FAZ line fulfills all of the criteria per Code of “Supplementary Overcurrent Protective Devices,” or “Supplementary Protectors,” as they are better known. What is the definition of a Supplementary Protector per North American standards? A Supplementary Protector is a manual reset device designed to open the circuit automatically on a pre- determined value of time versus current or voltage within an appliance or other electrical equipment. It may also be provided with manual means for opening or closing the circuit. (Source: UL 1077) In the US (and similarly in Canada) the NEC 2005 further defines supplementary protectors as devices intended to provide limited overcurrent protection for specific applications, such as lighting fixtures and appliances. This limited protection is in addition to the protection provided in the required branch circuit by the branch circuit overcurrent protective device. Clearly, the underlying message in those definitions is that Supplementary Protectors are not Branch Circuit overcurrent protective devices per Code, and neither are they tested that way per UL and CSA standards. They cannot replace the primary protective role performed by listed and certified molded case circuit breakers and fuses. That explains, in part, their status by UL as “recognized only” devices. Supplementary Protectors will never bear a UL listing mark, simply because their suitability as protective devices is dependent on a number of acceptability conditions which can vary from make to make and ultimately define the manner in which they can be properly applied per Code. The manufacturer should be consulted in all cases when evaluating the suitability of “recognized only” components such as UL 1077 Supplemen- tary Protectors. Moeller FAZ protectors are not subject to any specific restrictions in this respect, other than, like all Supplementary Protectors, they must never be used as a substitute for true listed and certified pri- mary overcurrent protective devices. Where can Supplementary Protectors be used effectively per Code standards? Moeller’s FAZ Supplementary Protectors can be used in a number of significant areas. To more clearly illustrate potential applications, however, let’s first present the NEC’s definition of a Branch Circuit: The circuit conductors between the final overcurrent device protecting the circuit and the outlets. (Source: NEC 2005). A branch circuit is that portion of the electrical distribution system which extends beyond the final branch circuit overcurrent protective device and is intended to serve lighting, appliance, motors and/ or other individual loads. Typically, the Branch Circuit Overcurrent Protective Device (BOPD) will be either a listed molded case circuit breaker or fuse. Supplementary Protectors, such as Moeller’s line of FAZ devices, can therefore be added to any of these branch circuits to “supplement” the branch circuit protection. Examples of applications ideally suited for these devices can include: • Any type of OEM electrical equipment which is fed from a service panel board and which often requires additional protection for sensitive internal circuitry and components. (Test and medical equipment, copiers and printers, computers and power supplies etc.) • The need for manual reset devices with optional accessories such as auxiliary contacts and volt- age trips to accomplish fuseless protective circuit designs and enhance operational diagnostics. • Isolation and protection of control cable, coils, contacts and circuit elements of motor control circuits tapped from the load side of the branch circuit protective device. (per NEC 430.72). • Protection of control circuit transformers, especially in the secondary where the manual reset protector can be used to isolate, as well as protect, secondary circuit conductors and loads. “Recognized only” mark from UL All UL 1077 Supplementary Protectors are recognized only devices. They are subject to Conditions of Acceptability in order to be applied properly per the intent of the Electrical Codes. Primary protection, although permissible, is not an ideal application since these protectors, like fuses, have a fixed current setting not ideally matched to the transformer’s primary rated current. A better choice for primary protection of control transformers consists of manual motor controllers additionally evaluated and marked as “Tap Conductor Protectors,” such as Moeller’s PKZM0 device, since these have an adjustable thermal dial which can be set to the exact primary current rating of the transformer. Consult Moeller for additional information on this application. IEC based miniature circuit breakers, such as Moeller’s entire FAZ line, are much more than just conven- tional supplementary protectors from an internal design point of view and can provide an ideal means to enhance the protective capabilities of any circuit. • As mentioned , they are in full compliance with the pertinent EN/IEC standards (EN/IEC 60898, EN/IEC 60947-2) for miniature circuit breakers and can thus be applied, outside of North Ameri- ca, as full-fledged stand-alone overcurrent protective devices in both residential and industrial applications. • As this typical let-through current curve shows, they are highly current limiting devices which appreciably limit the amount of let-through current and destructive energy within their ratings to minimize damage levels to downstream loads and circuits. Circuit breakers that are classified as “current limiting” have the ability to clear dam- aging short circuit currents within the first half cycle of the fault, resulting in better overall protection for all circuit components. • They come in a variety of tripping characteristics, which is ideal when custom- izing protection to match specific load requirements. Moeller FAZ Supplementary Protectors offer a total of six different protection characteristics for this purpose: B, C, D, K, S and Z tripping characteristics. • They feature a number of electrical accessories to enhance the performance and diagnostic capabilities of control panels, as well as a means to facilitate panel mounting and wiring. Tripping characteristics Miniature circuit breakers are thermal-magnetic, inverse time tripping devices. From a thermal point of view, all FAZ protectors are calibrated to trip at the same level, which is 135% of the device’s fixed current rating for single pole and 145% for multi-pole at an ambient reference temperature of 40°C. Note: Higher ambient temperatures, as well as density of mounting groups, can all be accommodated but may be subject to de-rating factors. Please consult Moeller technical data for further information and appropriate curves. It is the response time of the magnetic trip which differentiates each characteristic and for which an identifying letter is assigned. The IEC 898 standard only specifically covers the B, C and D characteris- tics. The rest can vary from brand to brand, but essentially follow a uniform convention. Typical let-through curve profile of a current-limiting device - The X axis shows the prospective short circuit current levels. - The Y axis indicates the actual let-through values (Let-through current in the example shown) at those prospective fault ratings for each FAZ device plotted. As can be interpreted from the bend in the plotted curves, each device acts to limit the damaging let-through energy (and current) at those values of short circuit current. In a conventional circuit breaker, no similar current limiting effect can be denoted and a device takes at least a few cycles to ultimately clear the fault. By design, all Moeller FAZ Supplementary Protectors and Miniature Molded Case circuit breakers are current limiting protective devices. The following magnetic response times apply to each of the characteristic letters referenced in Moeller FAZ part numbers: • B: Instantaneous response between 3..5 x In (In = fixed current rating of each unit) – Ideally suited for resistive loads, such as conductors or heaters. • C: Instantaneous response between 5..10 x In – Ideally suited for inductive loads, such as mo- tors and solenoids. • D: Instantaneous response between 10…20 x In – Ideally suited for highly inductive loads, such as lighting and higher efficiency motors. • K: Instantaneous response between 8..12 x In. – Ideally suited for highly inductive loads, similar to D but with a narrower range. • S: Instantaneous response between 13..17 x In – Ideally suited for highly inductive loads, espe- cially in control circuits with coils and light filaments. • Z: Instantaneous response between 2…3 x In – Very low instantaneous setting to provide tighter protection for loads which are more sensitive to the effects of overcurrents. A typical Tripping Characteristic curve for FAZ miniature circuit breakers can be seen here: FAZ-NA(RT) Miniature Circuit Breakers As previously mentioned, Moeller has expanded its FAZ line of miniature cir- cuit breakers to include a version which is listed and certified as a Molded Case Circuit Breaker (UL 489 and CSA No. 5). This line is rated up to 40A and comes in single, double and triple pole versions with instantaneous trip characteristics C and D. Of course, the line is also in conformity with the IEC standard for molded case circuit breakers, IEC 60947-2, and can therefore be universally applied. The NEC 2005 defines a circuit breaker as follows: A device designed to open and close a circuit by nonautomatic means and to open the circuit automatically on a predetermined overcurrent without damage to itself when properly applied within its rating. Note the text in italics. In the eyes of the Code, that definition sets circuit breakers apart from any other protective device and establishes their role as primary overcurrent protective switches in all types of electrical circuits. UL listing (and CSA Certification) requires additionally that regular testing on circuit breakers be conducted by UL and CSA at the manufacturer’s plant to monitor construction and verify their performance. Moeller’s new miniature Molded Case Circuit Breaker line includes two types: the FAZ-NA with tradi- tional box terminals for multiple wires, and the FAZ-RT which accommodates ring-tongue terminals. Both versions can utilize a bus bar connection system available with the line. 0.00051 2 3 4 5 6 7 8 9 10 15 20 30 40 50 0.001 0.002 0.005 0.01 0.02 0.05 0.1 0.2 0.5 10t [s]30 60 120 300 600 1200 3600 7200 1.131.45B C D 1 2 5 � � � � � � � � Specied non-tripping cur rent Int = 1.13 X In for t > 1 h Specied tripping cur rent It = 1.45 X In for t < 1 h � 2.55 X In : t = 1 – 60 s (In < 32 A) t = 1 – 120 s (In > 32 A) � Type B: 3 X In : t > 0.1 s � Type B: 5 X In : t < 0.1 s � Type C: 5 X In : t > 0.1 s � Type C: 10 X In : t < 0.1 s � Type D: 10 X In : t > 0.1 s � Type D: 20 X In : t < 0.1 s Multiples of In Typical “Inverse Time” tripping characteristic of a miniature circuit breaker - “Inverse Time” refers to the device’s tripping characteristic. As the curve shows, the higher the current, the lower the tripping time. - The trip response on the thermal portion is uniform throughout the line. - The instantaneous response differs, depending on the characteristic selected. (e.g. B, C or D) - Tripping is very quick (less than a half cycle) in the upper range of overcurrents (bottom right) due to the current limiting design of Moeller miniature circuit breakers. The advantages of a current limiting device As already mentioned, all Moeller FAZ devices are current limiting by design. In the case of the UL 489 devices, they are also classified by UL/CSA in that manner and are marked on the label. A circuit breaker that is marked as a current limiting device is one that does not use a fusible element and, when operating within its current limiting range, limits the let-through energy (I2t) to less than the energy of a ½ cycle wave of the available symmetrical current. The label on FAZ-NA(RT) devices lists the actual let-through energy (I2t = 45 kA2 s) and peak let- through current (6.2kA) at the maximum interrupting rating of 10kA. Current limiting circuit breakers substantially reduce the amount of damage sustained by downstream components in the event of a high short circuit fault by clearing the fault in the shortest amount of time possible due to the quick separation of its contacts and ensuing extinction of the arc current. HACR and SWD FAZ-NA(RT) circuit breakers are also marked “HACR” for use in Heating, Air Conditioning and Refrigera- tion applications. In addition, the abbreviation “SWD” on the label indicates the devices are suitable for switching fluorescent lighting loads on a regular basis. Short Circuit markings on FAZ devices Below is tabulated summary of short circuit rating values that apply to the FAZ line of Supplementary Protectors and Molded Case circuit breakers. It is important to keep in mind that short circuit markings on FAZ Supplementary Protectors (UL 1077) and FAZ-NA(RT) Molded Case Circuit breakers (UL 489) must not be interpreted in the same manner. Supplementary Protectors have short circuit markings in association with upstream primary overcur- rent protective devices. Conversely, Molded Case Circuit Breakers are primary overcurrent protective devices and their ratings thus refer to their short circuit Interrupting capability. FAZ Supplementary Protectors (UL 1077) Trip Characteristic Max. Amps Max. Volts Short Circuit Rating Single pole B and C 0.5…35A 277 V AC 10kA 40…63A 277V AC 5kA 0.5…63A 48V DC 10kA D 6…40A 277 V AC 5kA 48V DC 10kA 2, 3, 4 pole B and C 0.5…35A 480Y/277V AC ➊10kA 40…63A 480Y/277V AC ➊5kA 2 poles in series 6…25A 125V DC 10kA 2, 3, 4 pole D 0.5…40A 480Y/277V AC ➊5kA 2 poles in series 125V DC 10kA FAZ-(NA)(RT) Branch Circuit Breakers (UL 489) Trip Characteristic Max. Amps Max. Volts Short Circuit Interrupting Rating Single pole C and D 0.5…20A 277 V AC 10kA 25…40A 240V AC 10kA 2, 3 pole C and D 0.5…20A 480Y/277V AC ➊10kA 20…40A 240V AC 10kA ➊ A circuit breaker with a 480Y/277V AC rating can be applied in a solidly grounded circuit where the nominal voltage of any conductor to ground does not exceed the lower value of the circuit breaker’s rating (e.g. 277V AC) and the nominal voltage between any two conductors does not exceed its higher value (480V AC). These ratings can be typically found on protective devices such as molded case circuit breakers, as well as self-protected “Type E” combination motor controllers. www.moeller.ca Moeller Canadian Head Office 7275 Rapistan Court Mississauga, Ontario CANADA L5N 5Z4 Tel 905.542.2323 Fax 905.542.2321 Moeller Corporate Headquarters 4140 World Houston Parkway, № 100 Houston, Texas USA 77032 Tel 713.933.0999 Fax 832.613.6255 © 2006 by Moeller, Inc. Technical and other changes reserved. Publication: FAZ-CAT-USA-0706 Printed in the USA Article No: 695007 Installation manual Retain for future use Altivar 61 Variable speed drives for asynchronous motors 0.37 (0.5 HP) ... 45 KW (60 HP)/200 - 240V 0.75 (1 HP) ... 75 KW (100 HP)/380 - 480V 3 Contents Before you begin______________________________________________________________________________________________ 4 Steps for setting up the drive ____________________________________________________________________________________ 5 Preliminary recommendations ___________________________________________________________________________________ 6 Drive ratings _________________________________________________________________________________________________ 8 Dimensions and weights_______________________________________________________________________________________ 10 Mounting and temperature conditions ____________________________________________________________________________ 11 Mounting in a wall-mounted or floor-standing enclosure ______________________________________________________________ 13 Installing the graphic display terminal_____________________________________________________________________________ 15 Position of the charging LED ___________________________________________________________________________________ 16 Installing option cards_________________________________________________________________________________________ 17 Installing the EMC plates ______________________________________________________________________________________ 19 Wiring recommendations ______________________________________________________________________________________ 20 Power terminals _____________________________________________________________________________________________ 22 Control terminals_____________________________________________________________________________________________ 24 Option terminals _____________________________________________________________________________________________ 26 Connection diagrams _________________________________________________________________________________________ 31 Operation on an IT system _____________________________________________________________________________________ 40 Electromagnetic compatibility, wiring _____________________________________________________________________________ 41 4 Before you begin Read and understand these instructions before performing any procedure with this drive. DANGER HAZARDOUS VOLTAGE • Read and understand this manual before installing or operating the Altivar 61 drive. Installation, adjustment, repair, and maintenance must be performed by qualified personnel. • The user is responsible for compliance with all international and national electrical standards in force concerning protective grounding of all equipment. • Many parts of this variable speed drive, including the printed circuit boards, operate at the line voltage. DO NOT TOUCH. Use only electrically insulated tools. • DO NOT touch unshielded components or terminal strip screw connections with voltage present. • DO NOT short across terminals PA and PC or across the DC bus capacitors. • Install and close all the covers before applying power or starting and stopping the drive. • Before servicing the variable speed drive: - Disconnect all power. - Place a “DO NOT TURN ON” label on the variable speed drive disconnect. - Lock the disconnect in the open position. • Disconnect all power including external control power that may be present before servicing the drive. WAIT 15 MINUTES to allow the DC bus capacitors to discharge. Then follow the DC bus voltage measurement procedure on page 16 to verify that the DC voltage is less than 45 V. The drive LEDs are not accurate indicators of the absence of DC bus voltage. Electric shock will result in death or serious injury. CAUTION IMPROPER DRIVE OPERATION • If the drive is not turned on for a long period, the performance of its electrolytic capacitors will be reduced. • If it is stopped for a prolonged period, turn the drive on every two years for at least 5 hours to restore the performance of the capacitors, then check its operation. It is recommended that the drive is not connected directly to the line voltage. The voltage should be increased gradually using an adjustable AC source. Failure to follow these instructions can result in equipment damage. 5 Steps for setting up the drive b 1 Take delivery of the drive v Check that the catalog number printed on the label is the same as that on the purchase order v Remove the Altivar from its packaging and check that it has not been damaged in transit Steps 1 to 4 must be performed with the power off b 2 Check the line voltage v Check that the line voltage is compatible with the voltage range of the drive (see pages 8 and 9) b 3 Mount the drive v Mount the drive in accordance with the instructions in this document v Install any internal and external options b 4 Wire the drive v Connect the motor, ensuring that its connections correspond to the voltage v Connect the line supply, after making sure that it is turned off v Connect the control v Connect the speed reference PROGRAMMING v 1 Please refer to the programming manual INSTALLATION 6 Preliminary recommendations Handling/storage To protect the drive prior to installation, handle and store the device in its packaging. Ensure that the ambient conditions are acceptable. Handling on installation ALTIVAR 61 drives up to ratings ATV61HD15M3X and ATV61HD18N4 can be removed from their packaging and installed without a handling device. A hoist must be used for higher ratings; for this reason they are fitted with handling "lugs”. The following recommendations must be observed. WARNING DAMAGED PACKAGING If the packaging appears damaged, it can be dangerous to open it or handle it. Take precautions against all risks when performing this operation. Failure to follow these instructions can result in death or serious injury. WARNING DAMAGED EQUIPMENT Do not operate or install any drive that appears damaged. Failure to follow these instructions can result in death or serious injury. 45° max. 7 Preliminary recommendations Recommendations If the safety of personnel requires the prohibition of unwanted or unintended starts, electronic locking is performed by the Altivar 61's Power Removal function. This function requires the use of connection diagrams conforming to category 3 of standard EN 954-1 and safety integrity level 2 according to IEC/EN 61508. The Power Removal function takes priority over any run command. Read and understand the instructions in the Programming Manual. CAUTION INCOMPATIBLE LINE VOLTAGE Before turning on and configuring the drive, ensure that the line voltage is compatible with the supply voltage range shown on the drive nameplate. The drive may be damaged if the line voltage is not compatible. Failure to follow these instructions can result in equipment damage. DANGER UNINTENDED EQUIPMENT OPERATION • Before turning on and configuring the Altivar 61, check that the PWR (POWER REMOVAL) input is deactivated (at state 0) in order to prevent unintended operation. • Before turning the drive on or on exiting the configuration menus, check that the inputs assigned to the run command are deactivated (at state 0) since they can cause the motor to start immediately. Failure to follow these instructions will result in death or serious injury. 8 Drive ratings Single-phase supply voltage: 200…240 V 50/60 Hz Three-phase motor 200...240 V Three-phase supply voltage: 200…240 V 50/60 Hz Three-phase motor 200...240 V (1)These power ratings and currents are given for an ambient temperature of 50°C (122°F) at the factory-set switching frequency, used in continuous operation (factory-set switching frequency of 4 kHz for ATV61H 075M3 to D15M3X and 2.5 kHz for ATV61H D18M3X to D45M3X). Above this factory setting, the drive will reduce the switching frequency automatically in the event of excessive temperature rise. For continuous operation above the factory setting, derating must be applied to the drive nominal current in accordance with the curves on page 12. (2)Current on a line supply with the "Max. prospective line Isc" indicated and for a drive without any external options. (3)Peak current on power-up for the max. voltage (240 V +10%). (4)ATV61H 075M3 to D15M3X drives are available with or without a graphic display terminal. Catalog numbers for drives without a graphic display terminal have the letter Z added at the end, e.g.: ATV61H075M3Z. This option is not available for drives operating in difficult environmental conditions (5). (5)Drives with the S337 or 337 extension are designed for use in difficult environmental conditions (class 3C2 in accordance with IEC 721-3-3). They are supplied with a graphic display terminal. (6)A line choke must be used (please refer to the catalog). Inhibit the input phase loss fault (IPL) so that ATV61H 075M3 to U75M3 drives can operate on a single-phase supply (see the Programming Manual). If this fault is set to its factory configuration, the drive will stay locked in fault mode. Motor Line supply (input)Drive (output) Altivar 61 Power indicated on plate (1) Max. line current (2) Max. prospective line Isc Apparent power Max. inrush current (3) Max. available nominal current In (1) Max. transient current for 60 s (1) Catalog number (5) at 200 V at 240 V kW HP A A kA kVA A A A 0.37 0.5 6.9 5.8 5 1.4 9.6 3 3.6 ATV61H075M3(4) 0.75 1 12 9.9 5 2.4 9.6 4.8 5.7 ATV61HU15M3(4) 1.5 2 18.2 15.7 5 3.7 9.6 8 9.6 ATV61HU22M3(4) 2.2 3 25.9 22.1 5 5.3 9.6 11.0 13.2 ATV61HU30M3(4) 3 - 25.9 22 5 5.3 9.6 13.7 16.4 ATV61HU40M3(4)(6) 4 5 34.9 29.9 22 7 9.6 17.5 21 ATV61HU55M3(4)(6) 5.5 7.5 47.3 40.1 22 9.5 23.4 27.5 33 ATV61HU75M3(4)(6) Motor Line supply (input)Drive (output) Altivar 61 Power indicated on plate (1) Max. line current (2) Max. prospective line Isc Apparent power Max. inrush current (3) Max. available nominal current In (1) Max. transient current for 60 s (1) Catalog number (5) at 200 V at 240 V kW HP A A kA kVA A A A 0.75 1 6.1 5.3 5 2.2 9.6 4.8 5.7 ATV61H075M3(4) 1.5 2 11.3 9.6 5 4 9.6 8 9.6 ATV61HU15M3(4) 2.2 315 12.8 5 5.3 9.6 11 13.2 ATV61HU22M3(4) 3 - 19.3 16.4 5 6.8 9.6 13.7 16.4 ATV61HU30M3(4) 4 5 25.8 22.9 5 9.2 9.6 17.5 21 ATV61HU40M3(4) 5.5 7.5 35 30.8 22 12.4 23.4 27.5 33 ATV61HU55M3(4) 7.5 10 45 39.4 22 15.9 23.4 33 39.6 ATV61HU75M3(4) 11 15 53.3 45.8 22 18.8 93.6 54 64.8 ATV61HD11M3X(4) 15 20 71.7 61.6 22 25.1 93.6 66 79.2 ATV61HD15M3X(4) 18.5 25 77 69 22 27.7 100 75 90 ATV61HD18M3X 22 30 88 80 22 32 100 88 105.6 ATV61HD22M3X 30 40 124 110 22 42.4 250 120 144 ATV61HD30M3X 37 50 141 127 22 51 250 144 173 ATV61HD37M3X 45 60 167 147 22 65 250 176 211 ATV61HD45M3X 9 Drive ratings Three-phase supply voltage: 380…480 V 50/60 Hz Three-phase motor 380...480 V (1)These power ratings and currents are given for an ambient temperature of 50°C (122°F) at the factory-set switching frequency, used in continuous operation (factory-set switching frequency of 4 kHz for ATV61H 075N4 to D30N4 drives, and 2.5 kHz for ATV61H D37N4 to D75N4). Above this factory setting, the drive will reduce the switching frequency automatically in the event of excessive temperature rise. For continuous operation above the factory setting, derating must be applied to the drive nominal current in accordance with the curves on page 12. (2)Current on a line supply with the "Max. prospective line Isc" indicated and for a drive without any external options. (3)Peak current on power-up for the max. voltage (480 V +10%). (4)ATV61H 075N4 to D15N4 drives are available with or without a graphic display terminal. Catalog numbers for drives without a graphic display terminal have the letter Z added at the end, e.g.: ATV61H075N4Z. This option is not available for drives operating in difficult environmental conditions (5). (5)Drives with the S337 or 337 extension are designed for use in difficult environmental conditions (class 3C2 in accordance with IEC 721-3-3). They are supplied with a graphic display terminal. Motor Line supply (input)Drive (output) Altivar 61 Power indicated on plate (1) Max. line current (2) Max. prospective line Isc Apparent power Max. inrush current (3) Max. available nominal current In (1) Max. transient current for 60 s (1) Catalog number (5) at 380 V at 480 V at 380 V at 460 V kW HP A A kA kVA A A A A 0.75 1 3.7 3 5 2.4 19.2 2.3 2.1 2.7 ATV61H075N4(4) 1.5 2 5.8 5.3 5 4.1 19.2 4.1 3.4 4.9 ATV61HU15N4(4) 2.2 3 8.2 7.1 5 5.6 19.2 5.8 4.8 6.9 ATV61HU22N4(4) 3 - 10.7 9 5 7.2 19.2 7.8 6.2 9.3 ATV61HU30N4(4) 4 5 14.1 11.5 5 9.4 19.2 10.5 7.6 12.6 ATV61HU40N4(4) 5.5 7.5 20.3 17 22 13.7 46.7 14.3 11 17.1 ATV61HU55N4(4) 7.5 10 27 22.2 22 18.1 46.7 17.6 14 21.1 ATV61HU75N4(4) 11 15 36.6 30 22 24.5 93.4 27.7 21 33.2 ATV61HD11N4(4) 15 20 48 39 22 32 93.4 33 27 39.6 ATV61HD15N4(4) 18.5 25 45.5 37.5 22 30.5 93.4 41 34 49.2 ATV61HD18N4 22 30 50 42 22 33 75 48 40 57.6 ATV61HD22N4 30 40 66 56 22 44.7 90 66 52 79.2 ATV61HD30N4 37 50 84 69 22 55.7 90 79 65 94.8 ATV61HD37N4 45 60 104 85 22 62.7 200 94 77 112.8 ATV61HD45N4 55 75 120 101 22 81.8 200 116 96 139 ATV61HD55N4 75 100 167 137 22 110 200 160 124 192 ATV61HD75N4 10 Dimensions and weights With graphic display terminal Without graphic display terminal For a drive without a graphic display terminal, dimensions c, c1 and c2 in the table above are reduced by 26 mm (1.01 in.). The other dimensions are unchanged. (1)For the addition of I/O extension cards, communication cards, or the "Controller Inside" programmable card. ATV61H a mm (in.) b mm (in.) c mm (in.) c1 mm (in.) c2 mm (in.) G mm (in.) H mm (in.) h mm (in.) Ø mm (in.) For screws Weight kg (lb.) 075M3, U15M3, 075N4, U15N4,U22N4 130(5.12)230(9.05)175(6.89)198(7.80)221(8.70)113.5(4.47)220(8.66)5(0.20)5(0.20)M4 3(6.61) U22M3, U30M3, U40M3, U30N4, U40N4 155(6.10)260(10.23)187(7.36)210(8.27)233(9.17)138(5.43)249(9.80)4(0.16)5(0.20)M4 4(8.82) U55M3, U55N4, U75N4 175(6.89)295(11.61)187(7.36)210(8.27)233(9.17)158(6.22)283(11.14)6(0.24)5(0.20)M4 5.5(12.13) U75M3, D11N4 210(8.27)295(11.61)213(8.39)236(9.29)259(10.20)190(7.48)283(11.14)6(0.24)6(0.24)M5 7(15.43) D11M3X, D15M3X, D15N4, D18N4 230(9.05)400(15.75)213(8.39)236(9.29)259(10.20)210(8.26)386(15.20)8(0.31)6(0.24)M5 9(19.84) D18M3X, D22M3X, D22N4 240(9.45)420(16.54)236(9.29)259(10.20)282(11.10)206(8.11)403(15.87)11(0.45)6(0.24)M5 30(66.14) D30N4, D37N4 240(9.45)550(21.65)266(10.47)289(11.38)312(12.28)206(8.11)531.5(20.93)11(0.45)6(0.24)M5 37(81.57) D30M3X, D37M3X, D45M3X 320(12.60)550(21.65)266(10.47)289(11.38)312(12.28)280(11.02)524(20.93)20(0.79)9(0.35)M8 37(81.57) D45N4, D55N4, D75N4 320(12.60)630(24.80)290(11.42)313(12.32)334(13.15)280(11.02)604.5(23.80)15(0.59)9(0.35)M8 45(99.21) 2 option cards (1)1 option card (1)No option card c c1 c2 G a ==Hhb4 x2 option cards (1)1 option card (1)No option card 11 Mounting and temperature conditions Install the drive vertically at ± 10°. Do not place it close to heating elements. Leave sufficient free space to ensure that the air required for cooling purposes can circulate from the bottom to the top of the unit. Free space in front of the drive: 10 mm (0.39 in.) minimum When IP20 protection is adequate, it is recommended that the protective cover on the top of the drive is removed as shown below. Removing the protective cover 2 types of mounting are possible: ATV61H 075M3 to D15M3X and ATV61H 075N4 to D18N4 ATV61H D18M3X to D45M3X and ATV61H D22N4 to D75N4 Type A mounting Free space u 50 mm (u 1.97 in.) on each side, with protective cover fitted Type B mounting Drives mounted side by side, with the protective cover removed (the degree of protection becomes IP20)u 100 mmu 3.94 in.u 100 mmu 3.94 in.u 50 mm u 1.97 in. u 50 mm u 1.97 in. 12 Mounting and temperature conditions Derating curves Derating curves for the drive current In as a function of the temperature, switching frequency and type of mounting. ATV61H 075M3 to D15M3X and ATV61H 075N4 to D18N4 ATV61H D22N4 and ATV61H D30N4 ATV61H D18M3X to D45M3X and ATV61H D37N4 to D75N4 For intermediate temperatures (e.g. 55°C (131°F)), interpolate between 2 curves. In = 100 % 90 % 80 % 70 % 60 % 50 % 4 kHz 8 kHz 12 kHz 16 kHz Switching frequency I/In 40°C (104°F) mounting type A 50°C (122°F) mounting type B 50°C (122 °F) mounting type A 60°C (140°F) mounting types A and B In = 100 % 90 % 80 % 70 % 60 % 50 % 4 kHz 8 kHz 12 kHz 16 kHz Switching frequency I/In 50°C (122°F) 60°C (140°F) 40°C (104°F) In = 100 % 90 % 80 % 70 % 60 % 50 % 4 kHz 8 kHz 12 kHz 16 kHz2,5 kHz Switching frequency I/In 50°C (122°F) 60°C (140°F) 40°C (104°F) 13 Mounting in a wall-mounted or floor-standing enclosure Follow the mounting recommendations on the previous pages. To ensure good air circulation in the drive: - Use ventilation grilles - Ensure that the ventilation is adequate: if not, install forced ventilation with a filter - Use special IP54 filters Dust and damp proof metal wall-mounted or floor-standing enclosure (IP 54 degree of protection) The drive must be mounted in a dust and damp proof enclosure in certain environmental conditions: dust, corrosive gases, high humidity with risk of condensation and dripping water, splashing liquid, etc. To avoid hot spots in the drive, add a fan to circulate the air inside the enclosure, catalog number VW3 A9 4pp (see catalog). Mounting the drive in the enclosure Dissipated power These power ratings are given for operation at nominal load and for the factory-set switching frequency. (1)Add 7W to this value for each option card added Ensure that the flow of air in the enclosure is at least equal to the value given in the table below for each drive. ATV61H Dissipated power (1)ATV61H Dissipated power (1) WW 075M3 66 075N4 44 U15M3 101 U15N4 64 U22M3 122 U22N4 87 U30M3 154 U30N4 114 U40M3 191 U40N4 144 U55M3 293 U55N4 178 U75M3 363 U75N4 217 D11M3X 566 D11N4 320 D15M3X 620 D15N4 392 D18M3X 799 D18N4 486 D22M3X 865 D22N4 717 D30M3X 1134 D30N4 976 D37M3X 1337 D37N4 1174 D45M3X 1567 D45N4 1360 D55N4 1559 D75N4 2326 ATV61H Flow rate m3/hour ft 3/min 075M3, U15M3, 075N4, U15N4, U22N4 17 10 U22M3, U30M3, U40M3, U30N4, U40N4 56 33 U55M3, U55N4, U75N4 112 66 U75M3, D11N4 163 96 D11M3X, D15M3X, D15N4, D18N4 252 148 D18M3X, D22M3X, D22N4 203 119 D30N4, D37N4 203 119 D30M3X, D37M3X, D45M3X 406 239 D45N4, D55N4, D75N4 406 239 14 Mounting in a wall-mounted or floor-standing enclosure Dust and damp proof flange mounting This mounting is used to reduce the power dissipated in the enclosure by locating the power section outside the enclosure. This requires the use of a dust and damp proof flange mounting kit VW3 A9 501...509 (please refer to the catalog). The degree of protection for the drives mounted in this way becomes IP54. To fit the kit to the drive, please refer to the manual supplied with the kit. Power dissipated inside the enclosure for dust and damp proof flange mounting These power ratings are given for operation at nominal load and for the factory-set switching frequency. (1)Add 7W to this value for each option card added ATV61H Dissipated power (1)ATV61H Dissipated power (1) WW 075M3 28 075N4 28 U15M3 35 U15N4 31 U22M3 39 U22N4 35 U30M3 41 U30N4 43 U40M3 48 U40N4 48 U55M3 71 U55N4 54 U75M3 81 U75N4 64 D11M3X 120 D11N4 76 D15M3X 137 D15N4 100 D18M3X 291 D18N4 134 D22M3X 294 D22N4 298 D30M3X 368 D30N4 354 D37M3X 447 D37N4 441 D45M3X 452 D45N4 538 D55N4 592 D75N4 958 Example: ATV61HU55N4 15 Installing the graphic display terminal Installing the graphic display terminal on the drive Drives with catalog numbers ending in the letter Z are supplied without a graphic display terminal (VW3 A1 101). This can be ordered separately. It is installed on the drive as shown below. The graphic display terminal can be connected or disconnected with the power on. Before disconnecting it, drive control via the display terminal must be disabled (refer to the Programming Manual). 16 Position of the charging LED Before working on the drive, turn it off, wait until the red capacitor charging LED has gone out, then measure the DC bus voltage. Position of the capacitor charging LED Procedure for measuring the DC voltage The DC bus voltage can exceed 1,000 V c. Use a properly rated voltage sensing device when performing this procedure. To measure the DC bus voltage: 1 Disconnect the drive power supply. 2 Wait 15 minutes to allow the DC bus capacitors to discharge. 3 Measure the voltage of the DC bus between the PA/+ and PC/- terminals to check whether the voltage is less than 45 V c. See page 23 for the arrangement of the power terminals. 4 If the DC bus capacitors have not discharged completely, contact your local Schneider Electric representative (do not repair or operate the drive). ATV61H 075M3 to D15M3X and ATV61 075N4 to D18N4 ATV61H D18M3 to D45M3X and ATV61H D22N4 to D75N4 Red LED indicating that the DC bus is turned on DANGER HAZARDOUS VOLTAGE Read and understand the instructions on page 4 before performing this procedure. Failure to follow this instruction will result in death or serious injury. 17 Installing option cards These should ideally be installed once the drive is mounted and before wiring it. Check that the red capacitor charging LED has gone out. Measure the DC bus voltage in accordance with the procedure indicated on page 16. The option cards are installed under the drive control front panel. If the drive has a graphic display terminal, remove it, then remove the control front panel as indicated below. Remove the control front panel Installing an encoder interface card There is a special slot on the drive for adding an encoder interface card. 321 • Using a screwdriver, press down on the catch and pull to release the left- hand part of the control front panel • Do the same on the right-hand side • Pivot the control front panel and remove it If an I/O or communication option card or a "Controller Inside" programmable card has already been installed, remove it so you can access the slot for the encoder interface card. 18 Installing option cards Installing an I/O extension card, a communication card or a "Controller Inside" programmable card Install an encoder interface card (if used) (see previous page) Position the option card on the clasps Then pivot it until it clicks into place 4 5 6 Replace the control front panel over the option card (same procedure as for installing the option card, see and ) 7 5 6 6 5 7 , and Remove the control front panel (see previous page) 1 2 3 19 Installing the EMC plates 1 - EMC plate for connecting the power cables 2 - EMC plate for connecting the control cables (only for ATV61H 075M3 to D15M3X and ATV61H 075N4 to D18N4) 3 - EMC plate for connecting the I/O option card cables (supplied with the option cards) 4 - M4 screws (supplied) 5 - M8 screws (supplied) 6 - EMC clamps with captive screws (supplied) ATV61H Δb mm in. 075M3, U15M3,U22M3, U30N4, U40M3, 075N4, U15N4, U22N4, U30N4, U40N4 55 2.17 U55M3, U75M3, D11M3X, D15M3X, U55N4, U75N4, D11N4, D15N4, D18N4 65 2.56 D18M3X, D22M3X, D22N4, D30N4, D37N4D30M3X, D37M3X, D45M3X, D45N4, D55N4, D75N4 120 4.72 3 4 6 1 5 6 3 4 1 4 2 4 ATV61H 075M3 to D15M3X and ATV61H 075N4 to D18N4 ATV61H D18M3X to D45M3X and ATV61H D22N4 to D75N4 6 Installing the EMC clamps Δb 20 Wiring recommendations Power The drive must be connected to the protective ground. To comply with current regulations concerning high leakage currents (above 3.5 mA), use at least a 10 mm² (AWG 6) protective conductor or 2 protective conductors with the same cross-section as the power supply conductors. • Check whether the resistance to the protective ground is one ohm or less. Connect a number of drives to the protective ground, as shown in the diagram (see left). Do not lay protective grounding cables in a loop or in series. When upstream protection by means of a "residual current device" is required by the installation standards, a type A device should be used for single-phase drives and type B for three-phase drives. Choose a suitable model integrating: • HF current filtering • A time delay which prevents tripping caused by the load from stray capacitance on power-up. The time delay is not possible for 30 mA devices. In this case, choose devices with immunity against nuisance tripping, for example "residual current devices" with reinforced immunity from the s.i range (Merlin Gerin brand). If the installation includes several drives, provide one residual current device per drive. WARNING IMPROPER WIRING PRACTICES • The ATV61 drive will be damaged if input line voltage is applied to the output terminals (U/T1,V/T2,W/T3). • Check the power connections before energizing the ATV61 drive. • If replacing another drive, verify that all wiring connections to the ATV61 drive comply with all wiring instructions in this manual. Failure to follow these instructions can result in death or serious injury. WARNING INADEQUATE OVERCURRENT PROTECTION • Overcurrent protective devices must be properly coordinated. • The Canadian Electricity Code and the National Electrical Code require branch circuit protection. Use the fuses recommended on the drive nameplate to achieve published short-circuit current ratings. • Do not connect the drive to a power feeder whose short-circuit capacity exceeds the drive short-circuit current rating listed on the drive nameplate. Failure to follow these instructions can result in death or serious injury. DANGER HAZARDOUS VOLTAGE Ground equipment using the provided ground connecting point as shown in the figure below. The drive panel must be properly grounded before power is applied. Failure to follow these instructions will result in death or serious injury. Drive Drive Drive 21 Wiring recommendations Keep the power cables separate from circuits in the installation with low-level signals (sensors, PLCs, measuring apparatus, video, telephone). The motor cables must be at least 0.5 m (20 in.) long. Do not immerse the motor cables in water. Do not use surge arresters or power factor correction capacitors on the variable speed drive output. Control Keep the control circuits away from the power circuits. For control and speed reference circuits, we recommend using shielded twisted cables with a pitch of between 25 and 50 mm (0.98 and 1.97 in.) and connecting the shielding to ground at each end. If using conduit, do not lay the motor, power supply and control cables in the same conduit. Keep the metal conduit containing the power supply cables at least 8 cm (3 in.) away from the metal conduit containing the control cables. Keep the non-metal conduits or cable ducts containing the power supply cables at least 31 cm (12 in.) away from the metal conduits containing the control cables. If it is necessary for control and power cables to cross each other, be sure they cross at right angles. Length of motor cables Choice of associated components: Please refer to the catalog. CAUTION IMPROPER USE OF A BRAKING RESISTOR • Only use the braking resistors recommended in our catalogs. • Wire the thermal protection contact on the resistor so that the drive power supply is disconnected immediately in the event of a fault (refer to the manual supplied with the resistor). Failure to follow these instructions can result in equipment damage. ATV61H 0 m (0 ft) 50 m (164 ft) 100 m (328 ft) 150 m (492 ft) 300 m (984 ft) 1,000 m (3,280 ft) 075M3 to U75M3 075N4 to D15N4 Shielded cable Unshielded cable D11M3X to D45M3X D18N4 to D75N4 Shielded cable Unshielded cable with dv/dt filters with output filters 22 Power terminals Access to the power terminals ATV61 H075M3 to HD15M3X and ATV61 H075N4 to HD18N4 Unlock the power part access flap and remove it as shown below. ATV61 HD18M3X to HD45M3X and ATV61 HD22N4 and HD75N4 To access the power terminals, remove the front panel as shown below. Characteristics and functions of the power terminals Only remove the link between PO and PA/+ if a DC choke has been added. The screws on the PO and PA/+ terminals must always be fully tightened as there is a high current flowing in the commoning link. Terminal Function t Protective ground connection terminal R/L1 S/L2 T/L3 Power supply PO DC bus + polarity PA/+ Output to braking resistor (+ polarity) PB Output to braking resistor PC/- DC bus - polarity U/T1 V/T2 W/T3 Outputs to the motor Example of ATV61HU22M3 Example of ATV61HD75N4 23 Power terminals Arrangement of the power terminals PO PA/+ PB PC/- U/T1 V/T2 W/T3R/L1 S/L2 T/L3 PO PA/+ PB PC/- U/T1 V/T2 W/T3R/L1 S/L2 T/L3 PO PA/+ PB PC/- U/T1 V/T2 W/T3R/L1 S/L2 T/L3 ATV61H 075M3, U15M3, U22M3, U30M3, U40M3, 075N4, U15N4, U22N4, U30N4, U40N4 ATV61H U55M3, U75M3, D11M3X, D15M3X, U55N4, U75N4, D11N4, D15N4, D18N4 ATV61H D18M3X, D22M3X, D30M3X, D37M3X, D45M3X, D22N4, D30N4, D37N4, D45N4, D55N4, D75N4 ATV61H Maximum wire size Tightening torque mm² AWG Nm (lb.in) 075M3, U15M3, 075N4, U15N4, U22N4 2.5 14 1.2 (10.6) U22M3, U30M3, U40M3, U30N4, U40N4 68 1.2 (10.6) ATV61H Maximum wire size Tightening torque mm² AWG Nm (lb.in) U55M3, U55N4, U75N4 10 6 2 (17.7) U75M3, D11N4 16 4 2.4 (21) D11M3X, D15M3X, D15N4, D18N4 35 1 2.4 (21) ATV61H Maximum wire size Tightening torque mm² AWG Nm (lb.in) D18M3X, D22M3X, D22N4, D30N4, D37N4 50 1/0 6 (53) ATV61H Maximum wire size Tightening torque mm² kcmils Nm (lb.in) D30M3X, D37M3X, D45M3X, D45N4, D55N4, D75N4 120 350 19 (168) 24 Control terminals Access to the control terminals To access the control terminals, open the cover on the control front panel. Removing the terminal card To make it easier to wire the drive control section, the control terminal card can be removed. • Undo the screw until the spring is fully extended • Remove the card by sliding it downwards Arrangement of the control terminals Maximum wire size: 2.5 mm² - AWG 14 Max. tightening torque: 0.6 Nm - 5.3 lb.in Note: The ATV61 is supplied with a link between the PWR and +24 terminals. CAUTION IMPROPERLY SECURED TERMINAL CARD When replacing the control terminal card, it is essential to fully tighten the captive screw. Failure to follow this instruction can result in equipment damage. 1 2 R1BR1AR1CR2AR2CAI1++10AI1-COMAI2COMAO10VP24LI1LI2LI3LI4LI5LI6+24PWRRJ45 SW1 SW2 Ext Source Sink Int PTC LI Logic input switch LI6 input switch RJ45 connector Factory setting: Source Factory setting: LI 25 Control terminals Characteristics and functions of the control terminals Terminal Function Electrical characteristics R1A R1B R1C Common point C/O contact (R1C) of programmable relay R1 • Minimum switching capacity: 3 mA for 24 V c • Maximum switching capacity on resistive load: 5 A for 250 V a or 30 V c • Maximum switching current on inductive load (cos ϕ = 0.4 L/R = 7 ms): 2 A for 250 V a or 30 V c • Reaction time: 7 ms ± 0.5 ms • Service life: 100,000 operations at max. switching power R2A R2C N/O contact of programmable relay R2 +10 + 10 V c power supply for reference potentiometer 1 to 10 kΩ • + 10 V c (10.5 V ± 0.5V) • 10 mA max. AI1+ AI1 - Differential analog input AI1 • -10 to +10 V c (max. safe voltage 24 V) • Reaction time: 2 ms ± 0.5 ms, 11-bit resolution + 1 sign bit • Accuracy ± 0.6% for Δθ = 60°C (140°F), linearity ± 0.15% of max. value COM Analog I/O common 0V AI2 Depending on software configuration: Analog voltage input or Analog current input • Analog input 0 to +10 V c (max. safe voltage 24 V), impedance 30 kΩ or • Analog input X - Y mA, X and Y can be programmed from 0 to 20 mA, impedance 250 Ω • Reaction time: 2 ms ± 0.5 ms • 11-bit resolution, accuracy ± 0.6% for Δθ = 60°C (140°F), linearity ± 0.15% of max. value COM Analog I/O common 0V AO1 Depending on software configuration: Analog voltage output or Analog current output • Analog output 0 to +10 V c, load impedance greater than 50 kΩ or • Analog output X - Y mA, X and Y can be programmed from 0 to 20 mA, max. load impedance 500 Ω • 10-bit resolution, reaction time: 2 ms ± 0.5 ms • Accuracy ± 1% for Δθ = 60°C (140°F), linearity ± 0,2% of max. value P24 Input for external +24V c control power supply •+24 V c (min. 19 V, max. 30 V) • Power 30 Watts 0V Logic input common and 0V of P24 external power supply 0V LI1 LI2 LI3 LI4 LI5 Programmable logic inputs • +24 V c (max. 30 V) • Impedance 3.5 kΩ • Reaction time: 2 ms ± 0.5 ms LI6 Depending on the position of the SW2 switch. - Programmable logic input or - Input for PTC probes SW2 switch on LI (factory setting) • Same characteristics as logic inputs LI1 to LI5 or SW2 switch on PTC • Trip threshold 3 kΩ, reset threshold 1.8 kΩ • Short-circuit detection threshold < 50 Ω +24 Logic input power supply SW1 switch in Source or Sink Int position •+24 V c power supply (min. 21 V, max. 27 V), protected against short-circuits and overloads • Max. current available for customers 200 mA SW1 switch in Sink Ext position • Input for external +24 V c power supply for the logic inputs PWR Power Removal safety function input When PWR is not connected to the 24V, the motor cannot be started (compliance with functional safety standard EN 954-1 and IEC/EN 61508) •24 V c power supply (max. 30 V) • Impedance 1.5 kΩ • State 0 if < 2V, state 1 if > 17V • Reaction time: 10ms SW1 switch State 0 State 1 Source (factory setting) < 5 V c > 11 V c Sink Int or Sink Ext > 16 V c < 10 V c 26 Option terminals Logic I/O option card terminals (VW3 A3 201) Maximum wire size: 1.5 mm² - AWG 16 Max. tightening torque: 0.25 Nm - 2.21 lb.in Characteristics and functions of the terminals Terminal Function Electrical characteristics R3A R3B R3C Common point C/O contact R3C of programmable relay R3 • Minimum switching capacity: 3mA for 24 V c • Maximum switching capacity on resistive load: 5 A for 250 V a or 30 V c • Maximum switching capacity on inductive load (cos ϕ = 0.4 L/R = 7 ms): 2 A for 250 V a or 30 V c • Reaction time: 7 ms ± 0.5 ms • Service life: 100,000 operations -10 -10 V c power supply for reference potentiometer 1 to 10 kΩ •- 10 V c (-10.5 V ± 0.5V) • 10 mA max. +24 Logic input power supply SW3 switch in Source or Sink Int position • +24 V c power supply (min. 21 V, max. 27 V), protected against short-circuits and overloads • Max. current available for customers 200 mA (This current corresponds to the total consumption on the control card +24 and the option cards +24) SW3 switch in Sink Ext position • Input for external +24 V c power supply for the logic inputs LI7 LI8 LI9 LI10 Programmable logic inputs • +24 V c power supply (max. 30 V) • Impedance 3.5 kΩ • Reaction time 2 ms ± 0.5 ms 0 V 0 V 0 V TH1+ PTC probe input • Trip threshold 3 kΩ, reset threshold 1.8 kΩ • Short-circuit detection threshold < 50 ΩTH1- LO1 LO2 Open collector programmable logic outputs • +24 V c (max. 30 V) • Max. current 200 mA for internal power supply and 200 mA for external power supply • Reaction time: 2 ms ± 0.5 ms CLO Logic output common 0V 0 V 0 VR3A TH1+SW3 R3CR3B0V-10+24LI7LI8LI9LI10TH1-L01L02CLO0VExt Source Sink Int Logic input switch SW3 Factory setting: Source Switch SW3 State 0 State 1 Source (factory setting) < 5 V c > 11 V c Sink Int or Sink Ext > 16 V c < 10 V c 27 Option terminals Extended I/O option card terminals (VW3 A3 202) Maximum wire size: 1.5 mm² - AWG 16 Max. tightening torque: 0.25 Nm - 2.21 lb.in Characteristics and functions of the terminals Terminal Function Electrical characteristics R4A R4B R4C Common point C/O contact R4C of programmable relay R4 • Minimum switching capacity: 3mA for 24 V c • Maximum switching capacity on resistive load: 5 A for 250 V a or 30 V c • Maximum switching capacity on inductive load (cos ϕ = 0.4 L/R = 7 ms): 1.5 A for 250 V a or 30 V c • Reaction time 10 ms ± 1ms • Service life: 100,000 operations -10 -10 V c power supply for reference potentiometer 1 to 10 kΩ •- 10 V c (-10.5 V ± 0.5V) • 10 mA max. AI3 + + polarity of the current differential analog input AI3 • Analog input X - Y mA, X and Y can be programmed from 0 to 20 mA, impedance 250 Ω • Reaction time: 5 ms ± 1 ms • 11-bit resolution + 1 sign bit, accuracy ± 0.6% for Δθ = 60°C (140°F) • Linearity ± 0.15% of max. value AI3 - - polarity of the current differential analog input AI3 AI4 Depending on software configuration: Analog current input or Analog voltage input • Analog input 0 to +10 V c (max. safe voltage 24 V), impedance 30 kΩ or • Analog input X - Y mA, X and Y can be programmed from 0 to 20 mA, impedance 250 Ω • Reaction time: 5 ms ± 1 ms • 11-bit resolution, accuracy ± 0.6% for Δθ = 60°C (140°F), linearity ± 0.15% of max. value COM Analog I/O common 0 V AO2 AO3 Depending on software configuration: Analog voltage outputs or Analog current outputs • 0 - 10 V c bipolar analog output or -10/+10 V c depending on software, load impedance greater than 50 kΩ or • Analog current output X-Y mA, X and Y can be programmed from 0 to 20 mA, max. load impedance 500 Ω • 10-bit resolution • Reaction time 5 ms ± 1 ms, accuracy ± 1% for Δθ = 60°C (140°F), linearity ± 0.2%R4A0VSW4 TH2+R4BAO3R4C-10AI3+AI3-AI4COMAO2+24LI11LI12LI13LI14CLO 0V LO4 LO3 RP TH2- Ext Source Sink Int Logic input switch SW4 Factory setting: Source 28 Option terminals Terminal Function Electrical characteristics +24 Logic input power supply SW4 switch in Source or Sink Int position •+24 V c output (min. 21 V, max. 27 V), protected against short-circuits and overloads • Max. current available for customers 200 mA (This current corresponds to the total consumption on the control card +24 and the option cards +24) SW4 switch in Sink Ext position • Input for external +24 V c power supply for the logic inputs LI11 LI12 LI13 LI14 Programmable logic inputs • +24 V c (max. 30 V) • Impedance 3.5 kΩ • Reaction time: 5 ms ± 1 ms 0V Logic input common 0 V TH2 + TH2 - PTC probe input • Trip threshold 3 kΩ, reset threshold 1.8 kΩ • Short-circuit detection threshold < 50 Ω RP Frequency input • Frequency range: 0…30 kHz • Cyclic ratio: 50 % ± 10 % • Maximum sampling time: 5 ms ± 1 ms • Maximum input voltage 30 V, 15 mA • Add a resistor if the input voltage is greater than 5 V (510 Ω for 12 V, 910 Ω for 15 V, 1.3 kΩ for 24 V) • State 0 if < 1.2 V, state 1 if > 3.5 V LO3 LO4 Open collector programmable logic outputs •+24 V c (max. 30 V) • Max. current 20 mA for internal power supply and 200 mA for external power supply • Reaction time 5 ms ± 1ms CLO Logic output common 0V 0 V 0 V SW4 switch State 0 State 1 Source (factory setting) < 5 V c > 11 V c Sink Int or Sink Ext > 16 V c < 10 V c 29 Option terminals Encoder interface card terminals Maximum wire size: 1.5 mm² - AWG 16 Max. tightening torque: 0.25 Nm - 2.21 lb.in Characteristics and functions of the terminals Encoder interface cards with RS422-compatible differential outputs Encoder interface cards with open collector outputs Encoder interface cards with push-pull outputs Terminal Function Electrical characteristics VW3 A3 401 VW3 A3 402 +Vs Encoder power supply •5V c (max. 5.5V) protected against short-circuits and overloads • Max. current 200 mA •15 V c (max. 16 V) protected against short-circuits and overloads • Max. current 175 mA 0Vs A, /A B, /B Incremental logic inputs • Max. resolution: 5,000 points/rev • Max. frequency: 300kHz Terminal Function Electrical characteristics VW3 A3 403 VW3 A3 404 +Vs Encoder power supply • 12 V c (max. 13 V) protected against short-circuits and overloads • Max. current 175 mA •15 V c (max. 16 V) protected against short-circuits and overloads • Max. current 175 mA 0Vs A, /A B, /B Incremental logic inputs • Max. resolution: 5,000 points/rev • Max. frequency: 300kHz Terminal Function Electrical characteristics VW3 A3 405 VW3 A3 406 VW3 A3 407 +Vs Encoder power supply • 12 V c (max. 13 V) protected against short-circuits and overloads • Max. current 175 mA • 15 V c (max. 16 V) protected against short-circuits and overloads • Max. current 175 mA • 24V c (min. 20V, max. 30V) protected against short-circuits and overloads • Max. current 100 mA 0Vs A, /A B, /B Incremental logic inputs • Max. resolution: 5,000 points/rev • Max. frequency: 300kHz VW3 A3 401...407 A A B B 0Vs +Vs 30 Option terminals Selecting the encoder The 7 encoder interface cards available as options with the ATV61 enable three different encoder technologies to be used: • Optical incremental encoder with differential outputs compatible with the RS422 standard • Optical incremental encoder with open collector outputs • Optical incremental encoder with push pull-outputs The encoder must comply with the following two limits: • Maximum encoder frequency 300 kHz • Maximum resolution 5,000 points/revolution Choose the max. standard resolution within these two limits to obtain optimum accuracy. Wiring the encoder Use a shielded cable containing 3 twisted pairs with a pitch of between 25 and 50 mm (0.98 in. and 1.97 in.). Connect the shielding to ground at both ends. The minimum cross-section of the conductors must comply with the table below to limit line voltage drop: Max. encoder cable length VW3 A3 401...402 VW3 A3 403...407 Max. consumption current of encoder Minimum cross-section of conductors Max. consumption current of encoder Minimum cross-section of conductors 10 m 32.8 ft 100 mA 0.2 mm² AWG 24 100 mA 0.2 mm² AWG 24 200 mA 0.2 mm² AWG 24 200 mA 0.2 mm² AWG 24 50 m 164 ft 100 mA 0.5 mm² AWG 20 100 mA 0.5 mm² AWG 20 200 mA 0.75 mm² AWG 18 200 mA 0.75 mm² AWG 18 100 m 328 ft 100 mA 0.75 mm² AWG 18 100 mA 0.75 mm² AWG 18 200 mA 1.5 mm² AWG 15 200 mA 1.5 mm² AWG 16 200 m 656 ft - - - 100 mA 0.5 mm² AWG 20 - - - 200 mA 1.5 mm² AWG 15 300 m 984 ft - - - 100 mA 0.75 mm² AWG 18 - - - 200 mA 1.5 mm² AWG 15 31 Connection diagrams Connection diagrams conforming to standards EN 954-1 category 1 and IEC/EN 61508 capacity SIL1, stopping category 0 in accordance with standard IEC/EN 60204 1 Single-phase power supply (ATV61H 075M3 to U75M3) Diagram with line contactor Diagram with switch disconnect (1)Line choke, if used (compulsory for ATV61H U40M3 to U75M3 drives) (2)Fault relay contacts, for remote signaling of drive status Inhibit the input phase loss fault (IPL) so that ATV61H 075M3 to U75M3 drives can operate on a single-phase supply (see the Programming Manual). If this fault is set to its factory configuration, the drive will stay locked in fault mode. Note: Install interference suppressors on all inductive circuits near the drive or connected to the same circuit (relays, contactors, solenoid valves, etc). Choice of associated components: Please refer to the catalog. ATV61HpppM3 U / T1V / T2W / T3R / L1M 3 aS / L2T / L3A1 R1AR1CR1BR2AR2C(2) (1) - KM1 - KM1 A2A1- S1- S2 R1CR1A - KM1 - T1- Q2 - Q3 - Q2 A1 U1W1V1PWR+24P0PA / +PBPC / - 2 a Braking resistor (if used) ATV61HpppM3 U / T1V / T2W / T3R / L1U1W1V1M 3 aS / L2T / L3A1 R1AR1CR1BR2AR2C(1) (2)P0PA / +PBPC / -Q1 PWR+242 a Braking resistor (if used) 32 Connection diagrams Connection diagrams conforming to standards EN 954-1 category 1 and IEC/EN 61508 capacity SIL1, stopping category 0 in accordance with standard IEC/EN 60204-1 Three-phase power supply Diagram with line contactor Diagram with switch disconnect (1)Line choke (if used) (2)Fault relay contacts, for remote signaling of drive status Note: Fit interference suppressors to all inductive circuits near the drive or coupled to the same circuit (relays, contactors, solenoid valves, etc). Choice of associated components: Please refer to the catalog.U / T1V / T2W / T3R / L1M 3 aS / L2T / L3+24PWRA1 R1AR1CR1BR2AR2C(2) - KM1 - KM1 A2A1- S1- S2 R1CR1A - KM1 - T1- Q2 - Q3 - Q2 A1 U1W1V1(1)P0PA / +PBPC / - 3 a Braking resistor (if used)U / T1V / T2W / T3R / L1U1W1V1M 3 aS / L2T / L3PWR+24A1 R1AR1CR1BR2AR2C(1) (2) Q1 P0PA / +PBPC / - 3 a Braking resistor (if used) 33 Connection diagrams Connection diagrams conforming to standards EN 954-1 category 3 and IEC/EN 61508 capacity SIL2, stopping category 0 in accordance with standard IEC/EN 60204-1 This connection diagram is suitable for use with machines with a short freewheel stop time (machines with low inertia or high resistive torque). When the stop request is activated, the motor power supply is cut immediately and it stops is accordance with category 0 of standard IEC/EN 60204-1. (1)Line choke (if used) (2)It is essential to connect the shielding on the cable connected to the Power Removal input to ground. - Standard EN 954-1 category 3 requires the use of a stop button with double contact (S1). - S1 is used to activate the Power Removal safety function. - S2 is used to initialize the Preventa module when powering up or after an emergency stop. ESC enables the use of other initialization conditions for the module. - One Preventa module can be used for the Power Removal safety function on several ATV61 drives. - A logic input on the Preventa module can be used to indicate safely that the drive is operating in safe conditions. Note: For preventive maintenance, the Power Removal function must be activated at least once a year. The drive power supply must be turned off and then on again before carrying out this preventive maintenance. The drive logic output signals cannot be considered as safety-type signals. Fit interference suppressors to all inductive circuits near the drive or coupled to the same circuit (relays, contactors, solenoid valves, etc). Choice of associated components: Please refer to the catalog.U / T1V / T2W / T3R / L1U1W1V1M 3 aS / L2T / L3+24PWRA1 R1AR1CR1BLI1LI6S2 A1 23 33Y213 A2 PE 14 24 34 Y43 Y44 Y1 K2K148 V, 115 V, 230 V K1 K2 T ESC XPS AC S1 F1 LI2L1(+)N(-)P0PA / +PBPC / -(1) 3 a (2) Braking resistor (if used) Logic 34 Connection diagrams Connection diagrams conforming to standards EN 954-1 category 3 and IEC/EN 61508 capacity SIL2, stopping category 1 in accordance with standard IEC/EN 60204-1 This connection diagram is suitable for use with machines with a long freewheel stop time (machines with high inertia or low resistive torque). When the stop request is activated, deceleration of the motor, controlled by the drive, is requested first. Then, after a time delay corresponding to the deceleration time, the Power Removal safety function is activated. Example: - 2-wire control - LI1 assigned to forward - LI2 assigned to reverse (1)In this example, the logic inputs LIp are wired as "Source" but can be wired as "Sink Int" or "Sink Ext". (2)Line choke (if used) (3)It is essential to connect the shielding on the cable connected to the Power Removal input to ground. - Standard EN 954-1 category 3 requires the use of a stop button with double contact (S1). - S1 is used to activate the Power Removal safety function. - S2 is used to initialize the Preventa module when powering up or after an emergency stop. ESC enables the use of other initialization conditions for the module. - One Preventa module can be used for the Power Removal safety function on several ATV61 drives. In this case the time delay must be set to the longest stopping time. - A logic input on the Preventa module can be used to indicate safely that the drive is operating in safe conditions. Note: For preventive maintenance, the Power Removal function must be activated at least once a year. The drive power supply must be turned off and then on again before carrying out this preventive maintenance. The drive logic output signals cannot be considered as safety-type signals. Fit interference suppressors to all inductive circuits near the drive or coupled to the same circuit (relays, contactors, solenoid valves, etc). Choice of associated components: Please refer to the catalog. S1F1 ESC U / T1V / T2W / T3R / L1U1W1V1M 3 aS / L2T / L3+24PWRA1 R1AR1CR1BLI1LI6LI2S21 S11A1 A2 PE Y1 13 T -+ 115 V230 V 2 K2 K1 K3 K4 K1 K2K3 23 2414 34 42 6858 33 41 57 67B1S12S22 S33 XPS AT Y2 Y3 K4 K1 K2 K2 K1 1 Y4 Y5 K3 K4 S2 N(-)L1(+) (1)P0PA / +PBPC / -(2) (3) 3 a Braking resistor (if used) Logic 35 Connection diagrams Control connection diagrams Control card connection diagram Logic input switch (SW1) The logic input switch (SW1) is used to adapt the operation of the logic inputs to the technology of the programmable controller outputs. • Set the switch to Source (factory setting) if using PLC outputs with PNP transistors. • Set the switch to Sink Int or Sink Ext if using PLC outputs with NPN transistors. • SW1 switch set to "Source" position • SW1 switch set to "Source" position and use of an external power supply for the LIs • SW1 switch set to "Sink Int" position • SW1 switch set to "Sink Ext" position WARNING Unintended Equipment Operation • When the SW1 switch is set to "Sink Int" or "Sink Ext", the common must never be connected to ground or the protective ground, as there is then a risk of unintended equipment operation on the first insulation fault. Failure to follow this instruction can result in death or serious injury.LI1LI5+240VA1 ATV61Hppppp PWR+10AI1+AI2AI1-COMCOMAO1LI3LI2LI6LI4Referencepotentiometer 0 ± 10 VorX-Y mA A1 ATV61Hppppp SW1 Ext Source Sink Int LI1LI5+240VLI3LI2LI6LI4A1 ATV61Hppppp SW1 Ext Source Sink Int LI1LI5+240VLI3LI2LI6LI4+24 V 0 V 24V c source A1 ATV61Hppppp SW1 Ext Source Sink Int LI1LI5+240VLI3LI2LI6LI4A1 ATV61Hppppp SW1 Ext Source Sink Int LI1LI5+240VLI3LI2LI6LI4+24 V 0 V 24V c source 36 Connection diagrams Bipolar speed reference Speed reference using axis control SW2 switch The LI6 logic input switch (SW2) makes it possible to use the LI6 input: - either as a logic input by setting the switch to LI (factory setting) - or for motor protection via PTC probes by setting the switch to PTC Control power supply via an external source The control card can be supplied via an external +24V c source- 10 V+ 10 VCOMAI1+AI1-A1 ATV61Hppppp ±10 V c source +COMAI1+AI1-A1 ATV61Hppppp 0V-Axis control ±10 Vreference 0VLI6A1 ATV61Hppppp PTC LI SW2 Motor A1 ATV61Hppppp P240V +24 V 0 V 24V c source 37 Connection diagrams I/O extension card connection diagrams Connection diagram for extended I/O option card (VW3 A3 202) Connection diagram for logic I/O option card (VW3 A3 201)+24VW3 A3 202 0VRPCLOLO4LO3LI110VTH2+TH2-AO2AO3COMAI4AI3-AI3+R4AR4CR4BA1 0 ± 10 VorX-Y mA Motor Source0-20 mA4-20 mAX-Y mA +24VW3 A3 201 CLOLO2LO1LI70VTH1+TH1-R3AR3CR3BA1 Motor 38 Connection diagrams SW3/SW4 logic I/O switch • Switch in "Source" position • Switch in "Source" position and use of an external +24 V c source • Switch in "Sink Int" position • Switch in "Sink Ext" position WARNING Unintended Equipment Operation • When the SW3 or SW4 switches are set to "Sink Int" or "Sink Ext", the common must never be connected to ground or the protective ground, as there is then a risk of accidental starting on the first insulation fault. Failure to follow this instruction can result in death or serious injury. A1 VW3 A3 20p +24CLOLOpLIp0VExt Source Sink Int SW3 or SW4 +24V 0V +24CLOLOpLIp0VA1 VW3 A3 20p Ext Source Sink Int 24V c source SW3 or SW4 A1 +24CLOLOpLIp0VVW3 A3 20p Ext Source Sink Int SW3 or SW4 +24V 0V +24CLO0VLOpLIpA1 VW3 A3 20p Ext Source Sink Int 24V c source SW3 or SW4 39 Connection diagrams Connection of several drives in parallel on the DC bus Connection in parallel on the DC bus is recommended in applications for which full motor power must be guaranteed. Each drive uses its own charging circuit Drives , and must not be more than one size apart when they are connected in this way. F1, F2, F3: fast-acting semiconductor fuses for protection on the DC bus side. F1 F2 F3 U / T1V / T2W / T3U1W1V1M1 3 a ATV61Hppppp PO PC/-U / T1V / T2W / T3U2W2V2M2 3 a ATV61Hppppp PO PC/-U / T1V / T2W / T3U3W3V3M3 3 a ATV61Hppppp PO PC/- 1 2 3R / L1S / L2T / L3R / L1S / L2T / L3R / L1S / L2T / L3 3 a 1 2 3 40 Operation on an IT system IT system: Isolated or impedance grounded neutral. Use a permanent insulation monitor compatible with non-linear loads, such as a Merlin Gerin type XM200 or equivalent. Altivar 61 drives feature built-in RFI filters. These filters can be isolated from ground for operation on an IT system as follows: Remove the jumper located to the left of the power terminals CAUTION When the filters are disconnected, the drive switching frequency must not exceed 4 kHz. Refer to the programming manual for the corresponding parameter setting. Failure to follow this instruction can result in equipment damage. Normal (filter connected) IT system (filter disconnected) 41 Electromagnetic compatibility, wiring Electromagnetic compatibility Principle • Grounds between thedrive, motor and cable shielding must have "high frequency" equipotentiality. • Use of shielded cables with shielding connected to ground at both ends for the motor cables, braking resistor (if used) and control-signal wiring. Conduits or metal ducting can be used for part of the shielding length provided that there is no break in continuity. • Ensure maximum separation between the power supply cable (line supply) and the motor cable. Installation diagram ATV61H 075M3 to D15M3X and ATV61H 075N4 to D18N4 • Attach and ground the shielding of cables 4 and 5 as close as possible to the drive: - Strip the shielding. - Use stainless steel metal clamps on the parts from which the shielding has been stripped, to attach them to the metal plate 2. The shielding must be clamped tightly enough to the metal plate to ensure correct contact. • Install the control EMC plate 11 on the sheet steel grounded plate 2, as shown in the diagram. • Attach and ground the shielding of cables 7, 12 and 13 as close as possible to the drive: - Strip the shielding. - Use stainless steel metal clamps on the parts from which the shielding has been stripped, to attach them to the control EMC flange 9. The shielding must be clamped tightly enough to the metal plate to ensure correct contact. 1 Altivar 61 2 Sheet steel grounded plate supplied with the drive 3 Tapped holes for installing the control EMC plate. 4 Shielded cable for motor connection with shielding connected to ground at both ends. The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes. 5 Shielded cable for connecting the braking resistor (if used). The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes. 6 Non-shielded wires for relay contact output. 7 Shielded cables for connecting the Power Removal safety function input. The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes. 8 Metal clamps 9 Connection to the protective ground 10 Unshielded power supply wires or cable 11 Control EMC plate 12 Shielded cables for connecting the control-signal cables. For applications requiring several conductors, use cables with a small cross-section (0.5 mm2 - AWG 20). 13 Shielded cables for connecting the encoder. The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes. Note: • If using an additional input filter, it should be mounted under the drive and connected directly to the line supply via an unshielded cable. Link 10 on the drive is then via the filter output cable. • The HF equipotential ground connection between the drive, motor and cable shielding does not remove the need to connect the PE protective conductors (green-yellow) to the appropriate terminals on each unit. 1 2 5 410 3 612 7 11 13 8 9 42 Electromagnetic compatibility, wiring Installation diagram ATV61H D18M3X to D45M3X and ATV61H D22N4 to D75N4 Attach and ground the shielding of cables 4 and 5 as close as possible to the drive: - Strip the shielding. - Use stainless steel metal clamps on the parts from which the shielding has been stripped, to attach them to the metal plate 2. The shielding must be clamped tightly enough to the metal plate to ensure correct contact. • Attach and ground the shielding of cables 6, 7 and 8 as close as possible to the drive: - Strip the shielding. - Use stainless steel metal clamps on the parts from which the shielding has been stripped, to attach them to the drive. The shielding must be clamped tightly enough to the metal plate to ensure correct contact. 1 Altivar 61 2 Sheet steel grounded plate supplied with the drive 3 Metal clamps 4 Shielded cable for motor connection with shielding connected to ground at both ends. The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes. 5 Shielded cable for connecting the braking resistor (if used). The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes. 6 Shielded cables for connecting the control-signal cables. For applications requiring several conductors, use cables with a small cross-section (0.5 mm2 - AWG 20). 7 Shielded cables for connecting the Power Removal safety function input. The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes. 8 Shielded cables for connecting the encoder. The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes. 9 Non-shielded wires for relay contact output. 10 Connection to the protective ground 11 Unshielded power supply wires or cable Note: • If using an additional input filter, it should be mounted under the drive and connected directly to the line supply via an unshielded cable. Link 4 on the drive is then via the filter output cable. • The HF equipotential ground connection between the drive, motor and cable shielding does not remove the need to connect the PE protective conductors (green-yellow) to the appropriate terminals on each unit. 1 2 5 3 4 6 7 8 10 11 9 2005-09 atv61s_installation_manual_en_v2 SWITCHES FROM 10A THROUGH 315A DISCONNECT SWITCHES / ROTARY CAM SWITCHES Product Overview Quality makes the difference! Disconnect Switches Disconnect Switches from Salzer are hand-operated switchgears for main circuits and are offered as ON-OFF Switches (3, 4, 6, and 8 pole) or as Changeover Switches with centre Off (3 and 4 pole). 90° switching angle Forced open Contacts Terminal screws in open position Finger protected (degree of protection up to IP20) Short-circuit rating Fulfills the load break requirements up to 690V or up to 1000V All products are designed, manufactured and tested according to the following standards: UL 508 CSA 22.2, No. 14 IEC 60947 EN 60947 IEC 60204-1 EN 60204-1 Safe Switching and Disconnecting Disconnect Switches offer ideal features for their use as: ON-OFF Switches Main Switches Emergency-Off Switches Maintenance Switches Safety Switches Distribution Switches Motor Switches www.salzerusa.com Design and Function Applications Conformity Front Mounting Four hole mounting Single hole mounting Available as Main/Emergency-Off Switch, Main Switch, ON-OFF Switch or as Changeover Switch. With a broad range of mounting and operator options, Salzer can provide economical, versatile and reliable solutions! Mounting Options Base Mounting DIN Rail mounting Four hole mounting Available as Main/Emergency-Off Switch, Main Switch, ON-OFF Switch or as Changeover Switch. Enclosed Switches Insulated enclosure Powder coated sheet metal enclosure Stainless steel enclosure Available as Main/Emergency-Off Switch, Main Switch, ON-OFF Switch or as Changeover Switch. Disconnect Switches www.salzerusa.com IEC:UL/ CSA: Main/Emergency-Off Switch, Main Switch 20A - 63A 15A - 60A 3 ... 8 pole switching angle 90° ON-OFF Switch 20A - 63A 15A - 60A 3 ... 8 pole switching angle 90° Changeover Switch 20A - 40A 20A - 40A 3 ... 4 pole switching angle 90° Product lines Product line H200 IEC:UL/ CSA: Main/Emergency-Off Switch, Main Switch 63A - 125A 63A - 100A 3 ... 8 pole switching angle 90° ON-OFF Switch 63A - 125A 63A - 100A 3 ... 8 pole switching angle 90° Changeover Switch 63A - 125A 63A - 100A 3 ... 4 pole switching angle 90° Product line H400 IEC:UL/ CSA: Main/Emergency-Off Switch, Main Switch 160A 175A 3 ... 8 pole switching angle 90° ON-OFF Switch 160A 175A 3 ... 8 pole switching angle 90° Changeover Switch 160A 175A 3 ... 4 pole switching angle 90° Product line K600 IEC:UL/ CSA: Main/Emergency-Off Switch, Main Switch 315A 240A 3 ... 8 pole switching angle 90° ON-OFF Switch 315A 240A 3 ... 8 pole switching angle 90° Changeover Switch 315A 240A 3 ... 4 pole switching angle 90° Product line K800 Rotary Cam Switches Rotary Cam Switches from Salzer, are manually operated, independently programmable control switches for main and auxiliary circuits with up to 24 contacts and are offered with switching angles of 30°, 45°, 60° or 90°. A maximum of 12 switching positions can be provided. 30°/ 45°/ 60° or 90° switching angle Forced open Contacts Terminal screws in open position Finger protected (degree of protection up to IP20) Short-circuit rating Fulfills the load break requirements up to 690 Volt Safe Switching and Controlling Rotary Cam Switches offer ideal features for their use as: ON-OFF Switches Changeover Switches Multi-step Switches Code Switches Gang Switches Instrument Switches Motor Switches www.salzerusa.com Design and Function Applications All products are designed, manufactured and tested according to the following standards: UL 508 CSA 22.2, No. 14 IEC 60947 EN 60947 IEC 60204-1 EN 60204-1 Conformity Front Mounting Two hole mounting Single hole mounting Four hole mounting Wall mounting with plaster depth box Available as Control Switch, ON-OFF Switch, Multi-step Switch, Changeover Switch, Motor Switch, Main/Emergency-Off Switch or as Main Switch. Our modular technology allows us to build custom switching solutions for up to 24 poles! Mounting Options Base Mounting DIN Rail mounting Four hole mounting Available as Control Switch, ON-OFF Switch, Multi-step Switch, Changeover Switch, Motor Switch, Main/Emergency-Off Switch or as Main Switch. Enclosed Switches Insulated enclosure Available as Control Switch, ON-OFF Switch, Multi-step Switch, Changeover Switch, Motor Switch, Main/Emergency-Off Switch or as Main Switch. Rotary Cam Switches www.salzerusa.com Product lines Product line P100 Product line P200 Product line M200 Product line T200 Product line S400 Product line S600 Product line S800 IEC:UL/ CSA: connection in mounting direction 10A 10A 1 ... 16 contacts switching angle 30°/45°/60°/90° IEC:UL/ CSA: connection in mounting direction 20A - 25A 20A - 25A 1 ... 24 contacts switching angle 30°/45°/60°/90° IEC:UL/ CSA: lateral connection 20A - 25A 20A - 25A 1 ... 24 contacts switching angle 30°/45°/60°/90° IEC:UL/ CSA: lateral connection 32A 35A 1 ... 24 contacts switching angle 30°/45°/60°/90° IEC:UL/ CSA: lateral connection 50A - 63A 55A - 70A 1 ... 24 contacts switching angle 30°/45°/60°/90° IEC:UL/ CSA: lateral connection 80A - 160A 95A - 175A 1 ... 24 contacts switching angle 30°/45°/60°/90° IEC:UL/ CSA: lateral connection 315A 240A 1 ... 24 contacts switching angle 30°/45°/60°/90° Disconnect Switches www.salzerusa.com General Standards UL 508, CSA 22.2, No. 14, IEC 60947, EN 60947, IEC 60204, EN 60204 Mechanical lifespan >10 5 >105 >105 >105 >105 >105 >105 >105 >105 >105 >106 >106 Max. operating frequency/ h 50 50 50 50 50 50 50 50 50 50 50 50 Climatic resistance damp heat, constant, to DIN IEC 60068-2-3 damp heat, cyclic, to DIN IEC 60068-2-30 Ambient temperature open min / max oC −25 / +50 enclosed min / max oC −25 / +40 Mechanical shock resistance (shock duration 20 ms) g >10 > 25 > 25 > 25 > 25 > 25 > 25 > 25 > 25 > 25 >10 >10 Rated frequency Hz 50 to 60 (other frequencies on request) Rated data Operational voltage Ue V AC 690 690 690 690 690 690 690 1)690 1)690 1)690 1)690 690 Impulse withstand voltage Uimp kV466666888866 Uninterrupted current Iu / Ith / Ithe A 20 20 25 32 40 63 63 80 100 125 160 315 Load carrying capacity in intermittent operation, class 12 AB 60% / 40% / 25% DF=1,3 / 1,6 / 2 × Ie Short-circuit rating Max. fuse gL 20 20 25 35 40 63 63 80 100 125 160 315 Conditional short- circuit current kAeff 15 15 15 15 15 15 25 25 25 25 25 25 Isolating characteristics acc. to EN 60947 up to... V AC 440 690 690 690 690 690 1000 1000 1000 1000 690 690 Switching angle 90° 90° 90° 90° 90° 90° 90° 90° 90° 90° 90° 90° Contacts (current paths) max 4 8 8 884888888 Terminal capacity solid or min mm 2 111114444495 2)185 2) stranded max mm 2 2,5 10 10 10 10 16 50 50 50 50 95 2)185 2) flexible or multiwired min mm 2 1 0,75 0,75 0,75 0,75 2,5 2,5 2,5 2,5 2,5 95 2)185 2) including ferrule max mm 2 2,56 6 6 6 103535353595 2)185 2) American Wire Gauge AWG 14 8 8 8 8 6 1/0 1/0 1/0 1/0 4/0 350MCM Operational current IeAC-21A A 20 20 25 32 40 63 63 80 100 125 160 315 AC-22A 220 – 500 V A 20 20 25 32 40 63 63 80 100 125 160 315 660 – 690 V A 16 16 20 32 40 63 63 80 100 100 125 125 UL / CSA 300 V AC A 15 20 25 30 40 60 63 80 100 100 175 240 General Use 600 V AC A 15 20 25 30 40 60 63 80 100 100 175 240 Operational power at 50 – 60 Hz, 3 pole UL / CSA110 – 120 V ACHP111,523557,510151525 208 V AC HP 2 2 3 5 7,5 15 10 10 15 15 15 30 220 – 240 V AC HP 2 2 3 5 7,5 15 15 20 25 30 15 30 440 – 480 V AC HP 3 3 5 10 15 30 30 30 30 40 40 50 550 – 600 V AC HP 5 5 5 10 15 40 30 30 30 40 50 50 AC-23A 220 – 240 V kW 3 3 4 5,5 7,5 15 15 18,5 22 30 37 75 380 – 440 V kW 5,5 5,5 7,5 11 15 22 22 30 37 45 75 132 500 V kW 5,5 5,5 7,5 11 15 22 22 30 37 45 90 132 660 – 690 V kW 5,5 5,5 7,5 11 15 22 22 30 37 37 55 55 AC-3 220 – 240 V kW 2,2 2,2 3 4 5,5 11 11 15 22 30 22 37 380 – 440 V kW 3,7 3,7 5,5 7,5 11 18,5 18,5 22 30 37 45 55 500 V kW 3,7 3,7 5,5 7,5 11 18,5 18,5 30 37 45 45 55 660 – 690 V kW 3,7 3,7 5,5 7,5 11 18,5 18,5 22 30 37 45 55 Technical data H212 H216 H220 H226 H233 H263 H406 H408 H410 H412 K616 K830 1) 1000 V, AC-20, no load switching 2) with terminal extensions for cable lug connection General Standards UL 508, CSA 22.2, No. 14, IEC 60947, EN 60947, IEC 60204, EN 60204 Mechanical lifespan >10 6 >106 >106 >106 >106 >106 >106 >106 >106 >106 >106 >106 Max. operating frequency /h 50 50 50 50 50 50 50 50 50 50 50 50 Climatic resistance damp heat, constant, to DIN IEC 60068-2-3 damp heat, cyclic, to DIN IEC 60068-2-30 Ambient temperature open min / max oC −25 / +50 enclosed min / max oC −25 / +40 Mechanical shock resistance (shock duration 20 ms) g >10 >10 >10 >10 >10 >10 >10 >10 >10 >10 >10 >10 Rated frequency Hz 50 to 60 (other frequencies on request) Rated data Operational voltage Ue V AC 440 690 690 690 690 690 690 690 690 690 690 690 Impulse withstand voltage Uimp kV466666666666 Uninterrupted current Iu / Ith / Ithe A102020252532506380100160315 Load carrying capacity in intermittent operation, class 12 AB 60% / 40% / 25% DF=1,3 / 1,6 / 2 × Ie Short-circuit rating Max. fuse gL 10 20 20 25 25 32 50 63 80 100 160 315 Conditional short- circuit current kAeff 3 1010101015202025252525 Isolating characteristics acc. to EN 60947 bis ... V AC 440 690 690 690 690 690 690 690 690 690 690 690 Switching angle 30° / 45° / 60° / 90° Contacts (current paths) max 16 24 24 24 24 24 24 24 24 24 24 24 Terminal capacity solid or min mm 2 0,75 1,0 1,0 1,5 1,5 2,5 2,5 4 6 10 10 185 1) stranded max mm 2 1,5 2,5 2,5 4,0 4,0 6,0 10 16 25 35 70 185 1) flexible or multiwired min mm 2 0,75 1,0 1,0 1,5 1,5 1,5 2,5 2,5 6 10 10 185 1) including ferrule max mm 2 1,5 2,5 2,5 2,5 2,5 4,0 6,0 10 16 25 50 185 1) American Wire Gauge AWG 16 12 12 10 10 10 6 4 4 1/0 2/0 350MCM Operational current IeAC-21A A 10 20 20 25 25 32 50 63 80 100 160 315 AC-22A 220 – 500 V A 10 20 20 25 25 32 50 63 80 100 160 315 660 – 690 V A—202025253250638080125125 UL / CSA 300V AC A 10 20 20 25 25 35 55 1)70 1)95 1)110 1)175 1)240 General Use 600V AC A — — 20 — 25 35 55 1)70 1)95 1)110 1)175 1)240 Operational power at 50 – 60 Hz, 3 pole UL / CSA 110 – 120 V AC HP 0,5 1 1 1,5 1,5 3 5 7,5 10 10 15 25 208 V AC HP 0,5 2 2 5 5 7,5 7,5 7,5 10 15 15 30 220 – 240 V AC HP 0,5 2 2 5 5 7,5 10 15 15 15 15 30 440 – 480 V ACHP——5 —1010203030304050 550 – 600 V ACHP——5 —1010254050505050 AC-23A 220 – 240 V kW 1,8 4 4 5,5 5,5 7,5 11 15 30 30 37 75 380 – 440 V kW 3 7,5 7,5 11 11 15 22 30 45 55 75 132 500 V kW — 7,5 7,5 11 11 15 30 45 55 55 90 132 660 – 690 V kW — 7,5 7,5 11 11 15 30 37 45 45 55 55 AC-3 220 – 240 V kW 1,5 3 3 4 4 5,5 11 15 15 22 22 37 380 – 440 V kW 2,2 5,5 5,5 7,5 7,5 11 22 30 30 37 45 55 500 V kW — 5,5 5,5 7,5 7,5 11 22 30 30 37 45 55 660 – 690 V kW — 5,5 5,5 7,5 7,5 11 22 30 30 37 45 55 Technical data Rotary Cam Switches www.salzerusa.com P110 M220 M221* P225 M225 T225 S432 S440 S606 S608 S612 S825 P220 P221* P226* * use this version for 600V AC (UL/CSA) applications 1) with terminal extensions for cable lug connection Switches from Salzer: Solutions for the future! Our product range includes Disconnect Switches and Rotary Cam Switches from 10A through 315A. These are available in a wide variety of voltage ratings and virtually an unlimited number of switching programs. With an extensive selection of mounting forms, operators and accessories, we are able to offer practical solutions in a short time. No matter what switch you are looking for, all common components are systems specific and therefore easy to assemble. No matter what the application, Salzer switches stand for safety and reliability! Special requirements? Call us, we’ll help you find an individual solution for your switching needs. Just in Time with SMD! To insure even greater flexibility and worldwide availability, Salzer has introduced the SMD system (Salzer Modular Design) which guarantees the product ready to ship within 24 hr. SMD modules are individually prefabricated and tested components. Salzer’s extensive inventory of components allows SMD Service to easily assemble standard and custom products for any application. Salzer USA Corporation Phone: 480.325.2690 3047 N Sawyer St. Fax: 480.985.9663 Mesa, AZ 85207 E Mail: info@salzerusa.com www.salzerusa.com IB104/US · © by Sälzer Electric GmbH · changes reserved Section 5 (No Items in this Section) (No Items in this Section) Section 6 Section 7 (No Items in this Section) Section 8 Series PM172 Powermeters Installation and Operation Manual BG0270 Rev. C i LIMITED WARRANTY The manufacturer offers the customer a 24-month functional warranty on the instrument in respect of faulty workmanship or parts from date of dispatch from the distributor. In all cases, this warranty is valid for 36 months from the date of production. This warranty is on a return to factory basis. The manufacturer does not accept liability for any damage caused by instrument malfunction. The manufacturer accepts no responsibility for the suitability of the instrument to the application for which it was purchased. Failure to install, set up or operate the instrument according to the instructions herein will void the warranty. Only a duly authorized representative of the manufacturer may open your instrument. The unit should only be opened in a fully anti-static environment. Failure to do so may damage the electronic components and will void the warranty. NOTE The greatest care has been taken to manufacture and calibrate your instrument. However, these instructions do not cover all possible contingencies that may arise during installation, operation or maintenance, and all details and variations of this equipment are not covered by these instructions. For additional information regarding installation, operation or maintenance of this instrument, contact the manufacturer or your local representative or distributor. IMPORTANT Please read this instruction manual before installing the unit, and take note of the following precautions: 1. Ensure that all incoming AC power and other power sources are turned OFF before performing any work on the instrument. Failure to do so may result in serious or even fatal injury and/or equipment damage. 2. Before connecting the instrument to the power source, check the labels on the side of the instrument to ensure that your instrument is equipped with the appropriate power supply voltage, input voltages, currents, analog output and communication protocol for your application. ii 3. Do not connect the instrument to a power source if it is damaged. 4. Do not expose the instrument to rain or moisture. 5. The secondary of an external current transformer must never be allowed to be an open circuit when the primary is energized. An open circuit can cause high voltages, possibly resulting in equipment damage, fire and even serious or fatal injury. Ensure that the current transformer wiring is made through shorting switches and is secured using an external strain relief to reduce mechanical strain on the screw terminals, if necessary. 6. Setup procedures must be performed only by qualified personnel familiar with the instrument and its associated electrical equipment. 7. DO NOT open the instrument under any circumstances. ) Read this manual thoroughly before connecting the meter to the current carrying circuits. During operation of the meter, hazardous voltages are present on input terminals. Failure to observe precautions can result in serious or even fatal injury or damage to equipment. Modbus is a trademark of Modicon, Inc. iii Table of Contents 4XLFN6WDUW Y &KDSWHU,QWURGXFWLRQ$ERXWWKLV0DQXDO $ERXWWKH30 &KDSWHU,QVWDOODWLRQ 0HFKDQLFDO,QVWDOODWLRQ (OHFWULFDO,QVWDOODWLRQ 3RZHU6RXUFH&RQQHFWLRQ &XUUHQW,QSXWV*URXQG 9ROWDJH,QSXWV 5HOD\V6WDWXV,QSXWV $QDORJ2XWSXW &KDSWHU8VLQJWKH0HQXV &KDSWHU6HWXS0HQXV %DVLF6HWXS0HQX &RPPXQLFDWLRQV3RUW6HWXS0HQXV 'LJLWDO,QSXWV6HWXS0HQX 3XOVH&RXQWHUV6HWXS0HQX $QDORJ2XWSXW6HWXS0HQX $QDORJ([SDQGHU6HWXS0HQX 3XOVLQJ2XWSXW6HWXS0HQX $ODUP(YHQW6HWSRLQWV6HWXS0HQX 7LPHUV6HWXS0HQX 57&6HWXS0HQX 'LVSOD\6HWXS0HQX 8VHU6HOHFWDEOH2SWLRQV0HQX 5HOD\2SHUDWLRQ&RQWURO0HQX $FFHVV&RQWURO0HQX 5HVHW0HQX &KDSWHU'DWD'LVSOD\ 1DYLJDWLQJLQWKH'LVSOD\0RGH 'DWD'LVSOD\)RUPDWV 6HOI7HVW'LDJQRVWLFV'LVSOD\ &KDSWHU9LHZLQJ6WDWXV,QIRUPDWLRQ 7KH6WDWXV,QIRUPDWLRQ0HQX 6WDWXV'LVSOD\)RUPDWV &KDSWHU&RPPXQLFDWLRQV iv &RQQHFWLRQ'LDJUDPV &20&RQQHFWLRQV &203RUW&RQQHFWLRQV 8VLQJD3ULQWHU &RQILJXULQJWKH&203RUWIRU3ULQWHU 3ULQWRXW)RUPDW $SSHQGL[$7HFKQLFDO6SHFLILFDWLRQV $SSHQGL[%8VLQJ6HWSRLQWV $SSHQGL[&&RQILJXULQJ728 $SSHQGL['(YHQWDQG'DWD/RJJLQJ $SSHQGL[(3RZHU4XDOLW\6HWXS v Quick Start TYPICAL INSTALLATION Wiring Mode 4LL3, RS-485 Connection (See Sections 2.2.4 and 7.2 for complete set of diagrams) ANALOG OUTPUT 23 RS-485 PC 1 + - METER RS-485 UP TO 31 DEVICES + POWER---TX+TX-RX +RX 9 678 9 6V 5 4321 RS-422/485N 5 111 RS-232 COM.1 3V 8 V2 5 2 V1 12 + STATUS INPUT -1 1918 2120 22 2A 3(C) N LINE LINE 2(B) LINE 1(A) RS-485 RS-485 00-06011 POWER-METER - PC 2 - + + UP TO 31 DEVICES LINE AC N+ - 10N/- 1713 14 15 16 RS-422/RS-485 +TX-RX-TX 12+RX L/+ COM.2 5A L 3I 9- 7+ N I 6- 2 4+ 3 I - 1 +12-2 1RELAYS+ 2624 25 2827 29 OUTPUT250VAC,5A RELAY Shorting Switches K LOADKL L LK vi SETUP Setups can be performed directly on the front panel or via PAS communication software - see Chapter 4 for full instructions. Performing Basic and Communications Setup Press Press to activate middle window; press ▲▼ to scroll to option. Press to activate lower window; press ▲▼ to scroll to value. Press to save selected value. Basic and Communications Setup: Default Options Code Parameter Default Description ConF Wiring mode 4Ln3 4-wire Wye using 3 PTs Pt PT ratio 1.0 Phase potential transformer primary to secondary ratio Ct CT primary current 5A Primary rating of the phase current transformer d.P Power demand period 15 min Length of demand period for power demand calculations, in minutes. E = external synchronization n.dp Number of power demand periods 1 No. of demand periods to be averaged for sliding window demands. 1 = block interval A.dP Ampere/Volt demand period 900 s Length of demand period for volt/ampere demand calculations, in seconds 0 = measuring peak current buF Buffer size 8 Number of measurements for RMS averaging Freq Nominal frequency 50/60 Hz Nominal power utility frequency LoAd Maximum demand load current 0 Maximum demand load current used in TDD calculations: 0 = CT primary current rSt Reset enabled En Enabled (disable to protect all reset functions) Prot Communications protocol ASCII ASCII protocol rS Interface standard 485 RS-485 interface Addr Address 1 Device address bAud Baud rate 9600 bps Baud rate dAtA Data format 8n Data format (8 bits, no parity) H.Sh Flow control (handshaking) nonE No flow control Ctrl RTS control nonE RTS is not used CPtb ASCII compatibility mode diS Disabled ENTERCHGENTER bASc 4L-n ConF Prt.1 ASCII Prot menu option value menu option value SELECT SELECT ENTER Chapter 1 Introduction 1 Chapter 1 Introduction 1. Chapter 1 Introduction 1.1 About this Manual This manual is intended for the user of the PM172 Powermeter. This Powermeter is a microprocessor-based instrument used for the measurement, monitoring, and management of electrical parameters. This chapter gives an overview of this manual and an introduction to the PM172. Chapter 2, Installation, provides instructions for mechanical and electrical installation. Chapter 3, Using the Menus, presents the structure of menus for setup and status viewing. Chapter 4, Setup Menus, provides instructions for performing parameter setup on the front panel. Chapter 5, Data Display, guides you through the display pages. Chapter 6, Viewing Status Information, tells you how to access additional status information on the instrument. This information may be useful during installation. Chapter 7, Communications, provides drawings for communications connections. Appendix A contains the PM172 Technical Specifications. Appendix B contains instructions on programming setpoints. Appendix C provides information on configuring TOU registers. Appendix D provides detail on Event and Data logging. 1.2 About the PM172 The PM172 is a compact three-phase AC Powermeter, specially designed to meet the requirements of users ranging from electrical panel builders to substation operators. The PM172 is available in two models: the PM172P for basic power measurements, and the PM172E which adds energy measurements and data recording. Both are suitable for 4-inch round and 92x92mm square cutouts. The PM172 is an advanced microprocessor-based digital instrument that incorporates the capabilities of a network analyzer, data recorder and programmable controller. The instrument provides three-phase measurements of electrical quantities in power distribution systems, monitoring external events, operating external equipment via relay contacts, fast and long-term on-board recording of measured quantities and events. 2 Chapter 1 Introduction Features Local Display: The front panel features bright LED displays (three windows, up to 49 pages, 6-digit energy counters) with adjustable update time, a bar graph showing percent load with respect to user-definable nominal load current, and two communications receive/transmit LEDs. Display auto scroll is available on the main screen with a programmable scroll interval of 2 to 15 seconds. Automatic return to the main screen is available after 30 seconds of uninterrupted use. The PM172E also features an energy pulsing LED. AC Inputs: 3 voltage and 3 current galvanically isolated inputs for direct connection to power line or via potential and current transformers. Harmonic Measurements: • Per phase voltage and current total harmonic distortion • Per phase current total demand distortion • Per phase K-Factor Setup is menu driven, with optional password protection. Two communication ports are available for RS-232/RS-485 and RS- 422/RS-485 standards, with ASCII, Modbus RTU and DNP3.0 protocols. In ASCII and Modbus protocols, 120 assignable registers allow the user to re-map any register address accessible in the instrument to the user assignable register area. Changing setups and resetting accumulated data through communications can be secured by the password. Two relays are provided for energy pulsing (KYZ) or alarm and remote control. Two optically isolated status inputs are provided for status monitoring with timestamp, for counting pulses and for external demand interval and time synchronization. Two optically isolated analog outputs with an internal power supply are provided for remote monitoring or control. Current loop options are 0-20mA, 4-20mA, 0-1mA, ± 1mA. Real Time Clock is provided for date and time stamp log and demand interval synchronization. Standard or Daylight Savings Time (DST) with automatic time adjustment is available. DST switch dates can be configured for the use in different time zones. The TOU (Time of Use) system: • 7 configurable TOU energy registers for accumulating kWh (import and export), kvarh (import and export), kVAh and energy from two external meters through 2 pulsing inputs • 3 configurable TOU Maximum Demand registers for recording maximum kW (import and export), and kVA demands • 16 tariffs Chapter 1 Introduction 3 • 16 daily profiles (e.g., 4 seasons, 4 daily profiles per season) • 8 daily tariff start times (tariff changes) • 2-year calendar • automatically configurable daily and monthly TOU profile log for each allocated energy and maximum demand register using season energy tariffs A 0.5 Megabyte onboard non-volatile memory is provided in the PM172E for data and event recording. • Event recorder provides logging resets, device diagnostics and setpoint operation events. The event-driven Data recorder is provided for recording user-selectable data in up to 8 data log files on a periodic basis or on any internal and external trigger. It can be used for load profile and TOU energy profile recording, or to log fault data on alarm conditions or digital input changes. For more detailed information on event and data logging, see Appendix D. User-selectable options are provided (see Section 4.11): • Two power calculation modes • Programmable energy rollover value (PM172E) • Phase energy calculations option (PM172E) 4 Chapter 1 Introduction PM172 Dimensions Figure 1-1 PM172 Dimensions SWITCHBOARD PANEL (127.0)5.000" MAX.(127.0) MAX.(20.0)4.500"5.000"(127.0)5.000" (114.0)(114.0)4.5000.787"99-06020 Chapter 1 Introduction 5 Measured Parameters NOTE: Real-time values are measured over 1 cycle of fundamental frequency; Average values are of 8, 16 or 32 Real-time values. # = setup via panel, $ = setup via PC Parameter Display Comm.Analog Pulse Alarm Average Values Average RMS Voltage per phase 3 3 #$ #$ Average RMS Current per phase 3 3 #$ #$ Average Active Power per phase 3 3 Average Reactive Power per phase 3 3 Average Apparent Power per phase 3 3 Average Power Factor per phase 3 3 Average Total Active Power 3 3 #$ #$ Average Total Reactive Power 3 3 #$ #$ Average Total Apparent Power 3 3 #$ #$ Average Total Power Factor 3 3 #$ #$ Average Frequency 3 3 #$ #$ Average Neutral Current 3 3 #$ #$ Voltage & Current unbalance 3 Amps & Volt Demands Ampere & Volt Demand per phase 3 #$ Maximum Ampere Demand per phase 3 3 Maximum Voltage Demand per phase 3 3 Power Demands Active Power Accumulated Demand Imp & Exp 3 #$ #$ Reactive Power Accumulated Demand Imp & Exp 3 #$ #$ Apparent Power Accumulated Demand 3 #$ #$ Active Power Demand Import & Export 3 #$ Reactive Power Demand Import & Export 3 #$ Apparent Power Demand 3 #$ Active Power Sliding Demand Import & Export 3 #$ Reactive Power Sliding Demand Import & Export 3 #$ Apparent Power Sliding Demand 3 #$ Active Power Predicted Demand Import & Export 3 #$ Reactive Power Predicted Demand Imp & Exp 3 #$ Apparent Power Predicted Demand 3 #$ Maximum Active Power Demand Import 3 3 Maximum Active Power Demand Export 3 Maximum Reactive Power Demand Import 3 Maximum Reactive Power Demand Export 3 Maximum Apparent Power Demand 3 3 Energy per Phase Active Energy Import per phase 3 3 Reactive Energy Import per phase 3 3 Apparent Energy per phase 3 3 Total Energy Total Active Energy Import & Export 3 3 #$ Total Reactive Energy Import & Export 3 3 #$ Total Reactive Energy Net 3 E E E 6 Chapter 1 Introduction Parameter Display Comm.Analog Pulse Alarm Total Apparent Energy 3 3 #$ TOU Registers 7 Energy registers 3 3 3 Maximum demand registers (selectable kW import & export, kvar import & export, kVA demands) 3 16 Tariffs for each TOU register 3 Total Harmonic Measurements Voltage THD per phase 3 3 #$ #$ Current THD per phase 3 3 #$ #$ Current TDD per phase 3 3 #$ #$ K-factor per phase 3 #$ #$ Fundamental Values Voltage and Current per phase 3 kW, PF per phase 3 3 kvar, KVA per phase 3 Total kW, PF 3 3 Total kvar, KVA 3 Real-time (RT) Values RMS Voltage per phase 3 #$ #$ RMS Current per phase 3 #$ #$ Active Power per phase 3 Reactive Power per phase 3 Apparent Power per phase 3 Power Factor per phase 3 Total Active Power 3 #$ Total Reactive Power 3 #$ Total Apparent Power 3 #$ Total Power Factor 3 #$ Frequency 3 #$ #$ Neutral Current 3 Voltage & Current unbalance 3 Min/Max Logging Min/Max A, V, total kW, kvar, kVA, PF 3 3 Min/Max Frequency, Neutral current 3 3 Phase Rotation 3 3 #$ Day and Time 3 3 #$ Pulse Counters 3 3 #$ Remote Relay Control 3 Inputs & Outputs Status Digital Inputs Status 3 3 #$ Alarm Relay Status 3 3 #$ Alarm Trigger/Setpoint Status 3 Self-diagnostic Tests 3 3 - available in the PM172E E E Chapter 2 Installation 7 Chapter 2 Installation 2. Chapter 2 Installation 2.1 Mechanical Installation Figure 2-1 STEP 1 (4” round cut-out): Mount the Display Module on cut-out 3.375"HEX NUT #8-32 LOCK WASHER #8 FLAT WASHER #8 (WIDE)DISPLAY3.375"0.198" 4.0" SWITCHBOARD PANEL STANDARD 4" ROUND 99-05013 Chapter 2 Installation 8 Figure 2-2 STEP 1 (92x92mm Square DIN cut-out): Mount the Display Module on cut-out Figure 2-3 STEP 2: Assemble the 4 Locating Studs SWITCHBOARD PANEL DIN43700 92x92mm 92.0mm 92.0mmLOCK WASHER #8 FLAT WASHER #8 (WIDE) HEX NUT #8-32 DISPLAY99-05014 99-05015 SWITCHBOARD PANEL LONG STUD Chapter 2 Installation 9 99-05016 S L ID IN G D IR E C T IO N Figure 2-4 STEP 3: Slide and Position the Powermeter on Locating Studs 99-05017 THUMB NUT M4 LOCK WASHER M4 Figure 2-5 STEP 4: Affix the Powermeter Using the Thumb Nuts Chapter 2 Installation 10 2.2 Electrical Installation ) Before installation ensure that all incoming power sources are shut OFF. Failure to observe this practice can result in serious or even fatal injury and damage to equipment. Connections to the PM172 are made via terminals located on the rear panel of the instrument as shown in Figure 2-6. 2 RELAYS NOM. VOLT. MEASUREMENT N/- L/+ POWER SUPPLY COMM. PROTOCOL Devices RS-422/485 Static-Safe Workstations Handle Only at 11 V 9N 5 RS-232 COM.1 13 161514 17 -RX RS-422/RS-485 -TX613 1 +TX +RX 16 171514 COM.2 STATUS INPUT ANALOG OUTPUT POWER SUPPLY 10-16VDC 18-36VDC 36-72VDC ATTENTION SW. VER S/N Static-Sensitive (24)5 V V 8 3 (48)2 V 2 1 50/60Hz 85-290VDC (12) 90-264VAC CT.5A I 1A CT. ASCII & DNP3.0 ANALOG OUTPUT ASCII & MODBUS S INPUT N O 120V (OPT. U) 690V STANDARD 10W LOW DC P T O R 12 18 19 20 18 19 20 2523 1+- 2221 -2+ 24 26 1 27 28 26 27 28 10 00-06007 12 6 I -9 3 +7 - 2I +4 -3 1I +1 29 29 Figure 2-6 Terminals - Rear View 2.2.1 Power Source Connection The power source can be dedicated-fused, or from a monitored voltage if it is within the instrument’s power supply range. AC power supply: line to terminal 12; neutral to terminal 10. DC power supply: positive to terminal 12; negative to terminal 10. Chapter 2 Installation 11 2.2.2 Current Inputs To ensure accurate readings, the input current should not exceed 2A RMS and 2.93A amplitude for the 1A CT secondary, or 10A RMS and 14.6A amplitude for the 5A CT secondary. Copper wiring 2.5 – 3.5 mm2 (12 AWG) should be used. 2.2.3 Ground Connect the chassis ground of the PM172 to the switchgear earth ground using dedicated wire greater than 2 mm2/14 AWG. 2.2.4 Voltage Inputs Input of 690V (Standard): To ensure accurate readings, the measured voltage between terminals 2-5, 5-8 and 8-2 should not exceed 790V AC RMS, and the measured voltage between terminals 2-11, 5-11 and 8-11 should not exceed 460V AC RMS and 695V amplitude. Use any of the seven wiring configurations shown in Figures 2-7 through 2-13. Input of 120V (Option U): To ensure accurate readings, the measured voltage between terminals 2-5, 5-8, 8-2, 2-11, 5-11 and 8-11 should not exceed 144V AC RMS and 225V amplitude. 120V input usually implies use of a potential transformer (PT). The PT requires use of any of the four wiring configurations shown in Figures 2-9 through 2-12. Wiring Configuration (See parameter setup instructions in Section 4.2) Setup Code Figure 3-wire direct connection using 2 CTs (2-element) 3dir2 2-7 4-wire WYE direct connection using 3 CTs (3-element) 4Ln3 or 4LL3 2-8 4-wire WYE connection using 3 PTs, 3 CTs (3-element) 4Ln3 or 4LL3 2-9 3-wire open delta connection using 2 PTs, 2 CTs (2- element) 3OP2 2-10 4-wire WYE connection using 2 PTs, 3 CTs (2½ -element) 3Ln3 or 3LL3 2-11 3-wire open delta connection using 2 PTs, 3 CTs (2½ - element) 3OP3 2-12 4-wire delta direct connection using 3 CTs (3-element) 4Ln3 or 4LL3 2-13 Chapter 2 Installation 12 Figure 2-7 Three Wire Direct Connection Using 2 CTs (2-element) Wiring Mode = 3dir2 c99-05030 LINE 1 (A) (C) N (B)K +-+-+K L LOAD -L K L LINE 2 LINE 3 N V 3V V 2 V1 Shorting Switches Voltages 1 7 10 12 + 9 4 6 + + 3 - - - Currents Figure 2-8 Four Wire WYE Direct Connection Using 3 CTs (3- element) Wiring Mode = 4LL3 or 4Ln3 Chapter 2 Installation 13 Figure 2-9 Four Wire WYE Connection Using 3 PTs, 3 CTs (3- element) Wiring Mode = 4LL3 or 4Ln3 Figure 2-10 Three Wire Open Delta Connection Using 2 PTs, 2 CTs (2-element) Wiring Mode = 3OP2 Chapter 2 Installation 14 Figure 2-11 Four Wire Wye Connection Using 2 PTs, 3 CTs (2½-element) Wiring Mode = 3LL3 or 3Ln3 This configuration will provide accurate power measurements only if the voltages are balanced. Figure 2-12 Three Wire Open Delta Connection Using 2 PTs, 3 CTs (2½-element) Wiring Mode = 3OP3 Chapter 2 Installation 15 1. Line to neutral voltages: 120V; 208V; 120V. 2. Line to line voltages: 240V; 240V; 240V. VOLTAGES DISPLAYED: N(A)*1L 120V 2L*(C)120V208V L 3*(B) Grounded delta connection N LINE LINE LINE 208VAC 240VAC 240VAC N L 3 ** ** ** 120VAC N L 3 (C) 120VAC 240VAC 2L L 1 (A) 2L(B) 1L ++- K+K K-L L LOAD - L 11 c99-05031 8 5 2 1(A) 2(B) 3(C) V 1 V 2 V N V 3 ShortingSwitches 1 7 10 12 -9 4 + 6 + 3 - CurrentsVoltages Figure 2-13 Four Wire Delta Direct Connection Using 3 CTs (3-element) Wiring Mode = 4LL3 or 4Ln3 2.2.5 Relays Figure 2-14 Relays Connection 2.2.6 Status Inputs Figure 2-15 Status Inputs Connection Two optically isolated status inputs are provided for status monitoring, counting pulses and for external power demand period and time synchronization. Two relays are provided for energy pulsing, alarms or remote control. Chapter 2 Installation 16 2.2.7 Analog Output The PM172 provides two optically isolated analog outputs with an internal power supply and current output options of 0-20 mA and 4-20 mA (current loop load of up to 500 Ohm), 0-1 mA and ±1 mA (current loop load of 10 kOhm). Figure 2-16 Analog Output Connection Chapter 3 Using the Menus 17 Chapter 3 Using the Menus 3. Chapter 3 Using the Menus Press and release to enter the setup mode. The primary menus will appear: Press again to activate the window of the desired primary menu. Press Select CHG to initialize or modify the instrument setup, or to clear the accumulated values stored in the instrument. Entry to this menu can be protected by a password. Select StA to view extended status information which may be useful during installation and in certain applications. Select OPS for viewing (not editing) the instrument setup options. After selecting either OPS or CHG, the list of setup menus is displayed in the upper window. Figure 3-1 presents a complete menu list. Depending on the model of your instrument, some menus may not appear. Password The Setup Change Menu can be secured by a user-defined password comprised of 4 digits. The instrument is shipped with password protection disabled. To enable password protection, go to the Access Control Menu (see Section 4.14). The Password Menu appears if password protection is enabled. To enter a password: 9 Set the first digit using the up and down arrow keys. 9 Press to advance to the next digit. 9 Set the other password digits in the same manner. 9 Press to continue setup. If your password is incorrect, you will return to the Primary Selection Menu. SELECT ENTER ENTER SELECT Î Î Î Î Î Î SELECT SELECT StA ENTER SELECT CHG ENTER SELECT OPS ENTER StA CHG OPS - Status Information Menu (see Chapter 6) - Setup Options Menu - Setup Change Menu (see Chapter 4) PASS 0000 18 Chapter 3 Using the Menus Figure 3-1 Menu Structure (if ordered) SELECT StA OPS CHG PASS bASc Port dinP Cnt Aout AEPn PulS SetP t-r Status Information Setup Options Setup Change rtc diSP Password Basic Setup rSt OPtS AccS Port Setup Digital Inputs Counters Analog Outputs Analog Expander Pulsing Setpoints Event Setpoints Interval Timers Real Time Clock Display Setup Reset Functions Selectable Options Access Control Ï Ð ENTER ENTER PHAS rEL St.In Cnt.1 Cnt.2 Cnt.3 Cnt.4 ELoG DLG.1 DLG.2 DLG.8 Phase Rotation bAtt Relay Status Status Inputs Counter #1 Counter #2 Counter #3 Counter #4 Event Log Status Data Log #1 Status Data Log #2 Status Data Log #8 Status Battery Status Ï Ð SELECT Selects an active window Enters menu/sub-menu Quits menu/sub-menu Scrolls options forward Scrolls options backward ENTER Ï Ð ESC rELo Relay Operation | | - available in the PM172E E E E E E E E E Chapter 4 Setup Menus 19 Chapter 4 Setup Menus 4. Chapter 4 Setup Menus Instrument setup can be performed directly on the front panel using the setup menus or via communications using PAS communication software, supplied with your instrument. For information on using PAS, refer to the user documentation provided. ++ Recommended method, + Possible, - Not possible Setup Display PAS Basic + ++ Communication port ++ + User selectable options ++ + Analog output, analog expander + ++ Digital inputs + ++ Timer + ++ Alarm/Event setpoints + ++ Pulsing output, pulse counter + ++ Log memory - ++ Data log - ++ Real time clock + ++ TOU system - ++ Assignable registers - + Display ++ - 4.1 Basic Setup Menu Î Î Î Î This menu contains the basic configuration options which define the general operating characteristics of your instrument, such as wiring mode, input scales, the size of the RMS averaging buffer, etc. Table 4-1 lists the basic setup options, their code names and applicable ranges. Activate the middle window to scroll through the list of available options, and then activate the lower window to set the option value. To select and view a setup option: 9 Press to activate the middle window 9 Use the up/down arrow keys to scroll to the desired option. The current value for this option appears in the lower window. To change the value of the selected option: 9 Press to make the lower window active. 9 Press the up/down arrow keys to scroll to the desired value. 9 Press to store the selected value, or press to quit the menu. SELECT bASc 4L-n ConF SELECT CHG ENTER bASc ENTER ENTER ESC SELECT 20 Chapter 4 Setup Menus Table 4-1 Basic Setup Options (∗ default setting) Code Parameter Options Description ConF Wiring mode 3OP2 3-wire open delta using 2 CTs (2 element) 4Ln3∗ 4-wire Wye using 3 PTs (3 element), line to neutral voltage readings 3dir2 3-wire direct connection using 2 CTs (2 element) 4LL3 4-wire Wye using 3 PTs (3 element), line to line voltage readings 3OP3 3-wire open delta using 3 CTs (2½ element) 3Ln3 4-wire Wye using 2 PTs (2½ element), line to neutral voltage readings 3LL3 4-wire Wye using 2 PTs (2½ element), line to line voltage readings Pt PT ratio 1.0∗ - 6,500.0 The potential transformer ratio Ct CT primary current 1-10,000A (5∗) The primary rating of the phase current transformer d.P Demand period 1, 2, 5, 10, 15∗, 20, 30, 60, E min The length of the demand interval (sub- interval for sliding window demand) for power demand calculations, in minutes. E = external synchronization n.dP Number of demand periods 1-15 (1∗) The number of demand sub-intervals to be averaged for sliding window demands. A product of the demand period and the number of demand periods should not exceed 60 min. For block demand, set this value to one. A.dP Ampere/Volt demand period 0-1800 s (900∗) The length of the demand period for volt/ampere demand calculations, in seconds (0 = measuring peak current) buF Averaging buffer size 8∗, 16, 32 The number of measurements for RMS averaging rSt Reset enable/disable diS, En∗ Protects all reset functions, both via the front panel or communications. Freq Nominal frequency 50, 60 Hz1 Nominal line frequency LoAd Maximum demand load current 0-10,000 A (0∗) The maximum demand load current used in TDD calculations (0 = CT primary current) 1 60 Hz default for North America; elsewhere, default is 50Hz. NOTES 1. The maximum value for CT PRIMARY CURRENT × PT RATIO is 10,000,000. If this product is greater, power related values will be zeroed. 2. Always specify WIRING MODE, PT RATIO and CT PRIMARY CURRENT prior to setting up alarm setpoints and analog output channels, otherwise the alarm/event setpoints and analog outputs, which use these parameters, will automatically be disabled. Chapter 4 Setup Menus 21 4.2 Communications Port Setup Menus Î Î Î Î Î Î Î Î These menus allow you to access the communications port options for communication with a master computer. Table 4-2 lists the communications options and their code names. From the main menu, select the menu for the port you want to configure. To select and view a setup option: 9 Press to activate the middle window. 9 Use the up/down arrow keys to scroll to the desired option. The option setting will appear in the lower window. To change the selected option: 9 Press to activate the lower window. 9 Use the up/down arrow keys to scroll to the desired value. 9 Press to store the selected value or press to quit the setup menu. NOTE: An optional analog expander can be connected to Port #2. Prt.1 ASCII Prot SELECT CHG ENTER Prt.1ÏÐ ENTER ENTER ESC SELECT CHG ENTER Prt.2ÏÐ ENTER SELECT SELECT 22 Chapter 4 Setup Menus Table 4-2 Communications Options (∗ default setting) Code Parameter Options Description Prot Communications protocol ASCII∗ rtu dnP3 Prnt ASCII protocol Modbus RTU protocol DNP3.0 protocol Printer mode rS Interface standard 232 1 RS-232 interface 422 RS-422 interface 485∗ RS-485 interface Addr Address 02 - 99 ASCII (1∗) 1∗ - 247 Modbus 0 - 255 DNP3.0 (1*) Device address bAud Baud rate 110 110 baud 300 300 baud 600 600 baud 1200 1200 baud 2400 2400 baud 4800 4800 baud 9600∗ 9600 baud 19.20 19,200 baud dAtA Data format 7E 7 bits, even parity 8n∗ 8 bits, no parity 8E 8 bits, even parity H.Sh 1 Flow control nonE∗ No flow control (handshaking) SOFt Software (XON/XOFF) Hard Hardware (CTS) CtrL 1 RTS control nonE∗ RTS is not used dtr RTS is forced asserted (DTR mode) rtS RTS is controlled by the meter (asserted during the transmission) Prn.P Printout period 1∗, 2, 5, 10, 15, 20, 30, 60 min Time interval between printouts CPtb ASCII compatibility mode diS∗, En Disables/enables ASCII compatibility mode. For more information, see ASCII Communications Protocol Reference Guide 1 COM1 port only 2 Device with address 0 will reply to all incoming addresses. Address 0 must not be used in multi-point RS-422/RS-485 connections. Chapter 4 Setup Menus 23 4.3 Digital Inputs Setup Menu Î Î Î Î This menu is used to set up the two digital inputs provided by the PM172. Each digital input can be allocated as: - a status input to monitor external contact status, or - a pulse input to sense pulses provided by an external source. In the PM172E, one of the inputs can be configured to receive an external synchronization pulse indicating the beginning of a new demand interval for power demand measurements. A pulse input can also be configured to receive time synchronization pulses to provide synchronization of the instrument clock with a precise external time source. Time synchronization pulses can follow in intervals of one minute multiples aligned at 00 seconds. Receipt of the external pulse adjusts the RTC to the nearest round minute. Whenever a precise external demand synchronization source is used, the same input that is allocated for this pulse can be configured as a time synchronization input. An input allocated for the external synchronization pulse will be automatically configured as a pulse input. Status inputs do not have to be explicitly allocated in your instrument. All digital inputs except those you have allocated as pulse inputs are automatically configured as status inputs. Pulse inputs External demand synchronization input Time synchronization input To select and view inputs allocation: 9 Scroll through the inputs allocation sub-menus (shown above) in the upper window using the up/down arrow keys. To change the digital input allocation: 9 Press to activate the middle window. 9 Use the up/down arrow keys to set the input allocation status. 9 Press to store your new inputs allocation. 9 Press to leave the allocation unchanged or to quit the menu. ESC ENTER SELECT CHG dinPÏÐ ENTERENTER P.InP 0.1 E.Snc 0.1 t.Snc 0.1 SELECT 24 Chapter 4 Setup Menus Digital inputs are numbered from the left to right. “0” indicates “not allocated”; “1” indicates “allocated”. Each digital input is set separately. NOTE Digital inputs configured as status inputs can be monitored via the Status Information Menu (see Chapter 6) and communications. The pulses being received via pulse inputs can be directed to one of the four pulse counters (see Section 4.4) and, at the same time, to any of the TOU energy registers. 4.4 Pulse Counters Setup Menu Î Î Î Î This menu is used to configure the instrument’s four pulse counters. Any counter can be connected to one of the two digital inputs, to count incoming pulses (in this event the connected digital input must be allocated as a pulse input as directed in Section 4.3) or to count a wide variety of events via setpoints (see Section 4.8). Each counter can be independently scaled (weighted) by specifying a scale factor in the range of 1 to 9999. This means that each incoming pulse or an event will add to a counter the specified number of units. Counter setup To select and view a counter setup: 9 Press the up/down arrow keys to choose the desired counter. To connect a pulse input to the counter: 9 Press to activate the middle window. 9 Use the up/down arrow keys to select the desired pulse input. Selecting nonE disconnects pulse inputs from the counter. To change the scale factor for the counter: 9 Press to activate the lower window. 9 Use the up/down arrow keys to set the desired scale factor. 9 Press to store your new counter setup. To quit the setup without changes: 9 From the middle or lower window, press . To quit the menu: 9 From the upper window, press or . ENTER ESC ENTERESC SELECT SELECT Cnt.1 1 InP.1 SELECT CHG CntÏÐ ENTERENTER Chapter 4 Setup Menus 25 4.5 Analog Output Setup Menu [This section is relevant to instruments ordered with this option] Î Î Î Î This menu allows you to set up an output value and its zero and full scales for either of the two internal analog output channels. Table 4-3 explains the analog output setup options, and Table 4-4 lists all measurement parameters that can be directed to analog output. Output parameter Zero-scale output Full-scale output To select an analog channel: 9 Use the up/down arrow keys to select the desired analog output channel. To view the setup options for the selected channel: 9 Press to activate the middle window. 9 Use the up/down arrow keys to scroll to the desired option. The value associated with this option is displayed in the lower window. To change the setup options for the selected channel: 9 Press to activate the lower window. 9 Use the up/down arrow keys to scroll to the desired value. 9 Press to store the selected value, or press to leave the value unchanged. 9 Press again to store the setup for the channel. To quit the setup without changes: 9 From the middle or lower window, press . To quit the menu: 9 From the upper window, press or . NOTES 1. Except for the signed power factor, the output scale is linear within the value range. The scale range will be inverted if the full scale specified is less than the zero scale. 2. The output scale for the signed power factor is symmetrical with regard to ±1.000 and is linear from -0 to -1.000, and from 1.000 to +0 (note that -1.000 ≡ +1.000). Negative power factor is output as [-1.000 minus measured value], and non-negative power factor is output as [+1.000 minus measured value]. To define An. 1 828 Hi An. 1 rt U1 Outp An. 1 0 Lo SELECT SELECT ENTER ESC ENTER ESC ESC ENTER SELECT CHG AoutÏÐ ENTERENTER 26 Chapter 4 Setup Menus the entire range for power factor from -0 to +0, the scales would be specified as - 0.000/0.000. 3. For bi-directional analog output (±1 mA), the zero scale corresponds to the center of the scale range (0 mA) and the direction of current matches the sign of the output parameter. For signed (bi-directional) values, such as powers and signed power factor, the scale is always symmetrical with regard to 0 mA, and the full scale corresponds to +1 mA output for positive readings and to -1 mA output for negative readings. For these, the zero scale (0 mA output) is permanently set in the instrument to zero for all parameters except the signed power factor for which it is set to 1.000, and may not change. Unsigned parameters are output within the current range 0 to +1 mA and can be scaled using both zero and full scales as in the case of single-ended analog output. 4. When the analog scale value exceeds the number of places in the window, it is converted to higher units (for instance, kW to MW) and a decimal point is placed in the window to indicate the new measurement range. 5. Each time you select the output parameter for the analog channel, its zero and full scales are set by default to the lower and upper parameter limits, respectively. Table 4-3 Analog Output Setup Options Code Option Description OutP Output parameter The output parameter for the analog output channel Lo Zero scale (0/4 mA) The reading of the parameter corresponding to a zero-scale current output Hi Full scale (1/20 mA) The reading of the parameter corresponding to a full-scale current output Table 4-4 Analog Output Parameters Code Parameter Unit Scale1 nonE Output disabled 0 Real-time Measurements rt U 1 Voltage L1/L12 3 V/kV 0 to Vmax rt U 2 Voltage L2/L23 3 V/kV 0 to Vmax rt U 3 Voltage L3/L31 3 V/kV 0 to Vmax rt C1 Current L1 A 0 to Imax rt C2 Current L2 A 0 to Imax rt C3 Current L3 A 0 to Imax rt P Total kW kW/MW -Pmax to Pmax rt q Total kvar kvar/Mvar -Pmax to Pmax rt S Total kVA kVA/MVA 0 to Pmax rt PF Total PF -0.000 to 0.000 rt PF.LG Total PF lag 0 to 1.000 rt PF.Ld Total PF lead 0 to 1.000 rt Fr Frequency Hz 0 to 100.00 2 Average Measurements Ar U 1 Voltage L1/L12 3 V/kV 0 to Vmax Ar U 2 Voltage L2/L23 3 V/kV 0 to Vmax Ar U 3 Voltage L3/L31 3 V/kV 0 to Vmax Ar C1 Current L1 A 0 to Imax Chapter 4 Setup Menus 27 Code Parameter Unit Scale1 Ar C2 Current L2 A 0 to Imax Ar C3 Current L3 A 0 to Imax Ar P Total kW kW/MW -Pmax to Pmax Ar q Total kvar kvar/Mvar -Pmax to Pmax Ar S Total kVA kVA/MVA 0 to Pmax Ar PF Total PF -0.000 to 0.000 Ar PF.LG Total PF lag 0 to 1.000 Ar PF.Ld Total PF lead 0 to 1.000 Ar neU.C Neutral current A 0 to Imax Ar Fr Frequency Hz 0 to 100.00 2 Present Demands Acd.P.i Accumulated kW import demand kW/MW 0 to Pmax Acd.P.E Accumulated kW export demand kW/MW 0 to Pmax Acd.q.i Accumulated kvar import demand kvar/Mvar 0 to Pmax Acd.q.E Accumulated kvar export demand kvar/Mvar 0 to Pmax Acd.S Accumulated kVA demand kVA/MVA 0 to Pmax - available in the PM172E 1 The value scales are as follows: Imax (×200% over-range) = 2 × CT primary current [A] Direct wiring (PT Ratio = 1): Vmax (690 V input option) = 828.0 V Vmax (120 V input option) = 144.0 V Pmax = (Imax × Vmax × 3) [kW x 0.001] @ wiring modes 4Ln3, 3Ln3 Pmax = (Imax × Vmax × 2) [kW x 0.001] @ wiring modes 4LL3, 3OP2, 3dir2, 3OP3, 3LL3 NOTE: Pmax is rounded to nearest whole kW units. If Pmax is more than 9999.000 kW, it is truncated to 9999.000 kW Wiring via PTs (PT Ratio > 1): Vmax (690 V input option) = 144 × PT Ratio [V] Vmax (120 V input option) = 144 × PT Ratio [V] Pmax = (Imax × Vmax × 3)/1000 [MW x 0.001] @ wiring modes 4Ln3, 3Ln3 Pmax = (Imax × Vmax × 2)/1000 [MW x 0.001] @ wiring modes 4LL3, 3OP2, 3dir2, 3OP3, 3LL3 NOTE: Pmax is rounded to nearest whole kW units. 2 The actual frequency range is 45.00 - 65.00 Hz 3 When the 4LN3 or 3LN3 wiring mode is selected, the voltages will be line-to- neutral; for any other wiring mode they will be line-to-line voltages. E E 28 Chapter 4 Setup Menus 4.6 Analog Expander Setup Menu Î Î Î Î By connecting two optional AX-7 or AX-8 analog expanders (with outputs of 0-20 mA, 4-20 mA, 0-1 mA or ±1mA) to the PM172, an additional 14 (with AX-7) or 16 (with AX-8) external analog output channels can be provided. This menu allows you to select an output value, and its zero and full scales, for these extended channels. Channels A1-1 to A1-8 correspond to the first analog expander, and channels A2-1 to A2-8 correspond to the second one. The setup menu operates in the same way as the Analog Output Setup Menu (see Section 4.5). NOTES 1. The analog expander outputs operate through communications port #2 in RS- 422 and RS-485 mode. In both cases, connections between the instrument and the analog expander should be made using four wires. 2. Settings you made for analog expander outputs will not be in effect until the analog expander output is globally enabled in the instrument. To activate the analog expander output, set the analog expander option in the User Selectable Options setup (see Section 4.12) as it is set in your expander. Do not enable the analog expander output when you do not have the analog expander connected to the instrument, otherwise the computer communications will become garbled. 3. If you have the analog expander connected to your instrument, you will not be able to communicate with the instrument via a PC until you enable the analog expander option in the User Selectable Options setup (see Section 4.12). If this option is enabled, communications will be successful whether or not the analog expander outputs operate. SELECT CHG AEPnÏÐ ENTERENTER Chapter 4 Setup Menus 29 4.7 Pulsing Output Setup Menu Î Î Î Î In the PM172E, this menu allows you to program either of the two relays provided by your instrument to output energy pulses. Available pulsing parameters are listed in Table 4-5. To select a pulse relay: 9 Use the up/down arrow keys to scroll to the desired relay. The pulsing parameter assigned to the relay is displayed in the middle window, and the amount of unit-hours per pulse is displayed in the lower window. To change the pulse relay setup: 9 Press to activate the middle window. 9 Use the up/down arrow keys to scroll to the desired output parameter. Selecting nonE disables pulsing through this relay. 9 Press to activate the lower window. 9 Use the up/down arrow keys to set the amount of unit-hours per pulse. The available range is 1-9999. The pulse rate should not exceed 2 pulses per second. 9 Press to store the new setup, or press to quit the setup without changes. To quit the pulsing setup menu: 9 From the upper window, press or . Table 4-5 Pulsing Output Parameters Code Parameter nonE Output disabled Ac.Ei kWh import (positive) Ac.EE kWh export (negative) rE.Ei kvarh import (inductive) rE.EE kvarh export (capacitive) rE.Et kvarh total (absolute) AP.Et kVAh total NOTES 1. You will not be able to store your setup in the instrument if you assigned a parameter to relay output with a zero number of unit-hours per pulse, or if the parameter you selected has just been assigned to another relay output. 2. If a relay you allocated for pulsing has been manually operated or released, it reverts automatically to normal operation. ENTERESC SELECT SELECT ENTER ESC rEL.1 1 Ac.Ei SELECT CHG PulSÏÐ ENTERENTER 30 Chapter 4 Setup Menus 3. If a relay you allocated for pulsing has been engaged by an alarm/event setpoint, the setpoint is automatically disabled. 4.8 Alarm/Event Setpoints Setup Menu Î Î Î Î This menu is used to specify the events to be monitored by the setpoints, and actions to be triggered by those events. Your instrument provides 16 alarm/event setpoints that can monitor a wide variety of events; in turn, these events can be programmed to trigger specific actions. Each setpoint can contain up to four trigger conditions combined by logical operators OR and AND, up to four setpoint actions, and optional operate and release delays. For more information on using setpoints, see Appendix B Using Setpoints. Table 4-6 explains the setpoint setup parameters. For the entire list of available triggers and setpoint actions, refer to Tables 4-7 and 4-8. Example: First trigger parameter Setpoint 1 is set to monitor the real-time high current on phase 1 (the first trigger parameter). Operate limit for the first trigger Release limit for the first trigger The operate (On) and release (OFF) limits which determine setpoint operation are defined as 1200A and 1100A respectively. First setpoint action The first action to be triggered is operation of relay #1. Operate delay Release delay The delays before operation (On d) and release (OFFd) are set at 5 seconds and 10 seconds respectively. SP 1 RtHi.C1 trG.1 SP 1 5 On d SP 1 10 OFFd SP 1 1200 On.1 SP 1 rEL.1 Act.1 SP 1 1100 OFF.1 SELECT CHG SEtPÏ Ð ENTER ENTER Chapter 4 Setup Menus 31 To select a setpoint: 9 Scroll to the desired setpoint using the up/down arrow keys. To view the setup options for the setpoint: 9 Press to activate the middle window. 9 Use the up/down arrow keys to scroll to the desired setup option. The value associated with this option is displayed in the lower window. To change the selected setup option: 9 Press to activate the lower window. 9 Use the up/down arrow keys to scroll to the desired value. 9 Press to store the new value. 9 Press to leave the value unchanged. To store your new setup for the setpoint: 9 From the middle window, press . To quit the setpoint setup without changes: 9 From the middle window, press . To quit the setpoints setup menu: 9 From the upper window, press or . NOTES 1. When you enter the setpoints setup menu at the protected level, monitoring of setpoints is temporarily suspended until you return to the main setup menu. 2. Each time you select a new trigger parameter, the operate and release limits are set by default to zero. 3. You will not be able to store your setpoint setup to the instrument if a setpoint action is directed to a relay allocated for pulsing. 4. The setpoint action directed to a relay output can be overridden using commands sent via communications. A relay can be operated or released manually. When the relay reverts to normal operation, it returns automatically to setpoint control. 5. By using logical operators [OR/AND], trigger parameters can be mixed in the setpoint in an arbitrary sequence. Logical operations on triggers have no specific priority or precedence, so that the result of the entire logical expression is defined only by the location of the logical operator in the expression. The entire logical expression is evaluated in the direction from the left to right; any logical operator affects all the conditions evaluated before it. To avoid confusion, it is recommended not to alternate different logical operators in one setpoint. Instead, bring all triggers using the same logical operator to one side of the expression, and the others - to the opposite side. SELECT SELECT ENTER ENTER ENTER ESC ESC ESC 32 Chapter 4 Setup Menus Table 4-6 Setpoint Setup Options (middle window) Code Option Description LGC.1 - LGC.4 Logical operator (OR/AND) for the trigger Connects the trigger condition to previous setpoint conditions using specified logical operator trG.1 - trG.4 Trigger parameter The measurement parameter or signal to be monitored by the setpoint. On.1 - On.4 Operate limit for the trigger The threshold at which the setpoint becomes operative. OFF.1 - OFF.4 Release limit for the trigger The threshold at which the setpoint is released (becomes inoperative). Act.1 - Act.4 Setpoint action The action performed when the setpoint is operative. On d Operate delay The time delay (seconds) before operation when the operate condition is fulfilled. OFF d Release delay The time delay (seconds) before release when the release condition is fulfilled. Table 4-7 Setpoint Triggers (lower window, when middle window is trG) Code Parameter Unit Range1 nonE Setpoint disabled Status Inputs 4 St1.On Status input #1 ON St2.On Status input #2 ON St1.OFF Status input #1 OFF St2.OFF Status input #2 OFF Pulse Inputs 4 PlS.In.1 Pulse input #1 PlS.In.2 Pulse input #2 Counters 4 Cnt.1 High counter #1 0 to 999999 Cnt.2 High counter #2 0 to 999999 Cnt.3 High counter #3 0 to 999999 Cnt.4 High counter #4 0 to 999999 Relay Status 4 rL1.On Relay #1 ON rL2.On Relay #2 ON rL1.OFF Relay #1 OFF rL2.OFF Relay #2 OFF Phase Reversal 4 POS.Ph.r Positive phase rotation reversal 2 NEG.Ph.r Negative phase rotation reversal 2 Real-time Values per Phase rt Hi.C1 High current L1 A 0 to Imax rt Hi.C2 High current L2 A 0 to Imax Chapter 4 Setup Menus 33 Code Parameter Unit Range1 rt Hi.C3 High current L3 A 0 to Imax rt Lo.C1 Low current L1 A 0 to Imax rt Lo.C2 Low current L2 A 0 to Imax rt Lo.C3 Low current L3 A 0 to Imax Real-time Values on any Phase rt Hi. U High voltage 5 V/kV 0 to Vmax rt Lo. U Low voltage 5 V/kV 0 to Vmax rt Hi. C High current A 0 to Imax rt Lo. C Low current A 0 to Imax rt thd.U High voltage THD % 0 to 999.9 rt thd.C High current THD % 0 to 999.9 rt HFc.C High K-factor % 1.0 to 999.9 rt tdd.C High current TDD % 0 to 100.0 Real-time Auxiliary Measurements rt Hi.Fr High frequency Hz 0 to 100.00 3 rt Lo.Fr Low frequency Hz 0 to 100.00 3 Average Values per Phase Ar Hi.C1 High current L1 A 0 to Imax Ar Hi.C2 High current L2 A 0 to Imax Ar Hi.C3 High current L3 A 0 to Imax Ar Lo.C1 Low current L1 A 0 to Imax Ar Lo.C2 Low current L2 A 0 to Imax Ar Lo.C3 Low current L3 A 0 to Imax Average Values on any Phase Ar Hi. U High voltage 5 V/kV 0 to Vmax Ar Lo. U Low voltage 5 V/kV 0 to Vmax Ar Hi. C High current A 0 to Imax Ar Lo. C Low current A 0 to Imax Average Total Values Ar Hi.P.i High total kW import (positive) kW/MW 0 to Pmax Ar Hi.P.E High total kW export (negative) kW/MW 0 to Pmax Ar Hi.q.i High total kvar import (positive) kvar/Mvar 0 to Pmax Ar Hi.q.E High total kvar export (negative) kvar/Mvar 0 to Pmax Ar Hi. S High total kVA kVA/MVA 0 to Pmax Ar PF.LG Low total PF Lag 0 to 1.000 Ar PF.Ld Low total PF Lead 0 to 1.000 Average Auxiliary Measurements Ar neU.C High neutral current A 0 to Imax Ar Hi.Fr High frequency Hz 0 to 100.00 3 Ar Lo.Fr Low frequency Hz 0 to 100.00 3 Present Demands (power demands ) Hi d.U1 High volt demand L1 5 V/kV 0 to Vmax Hi d.U2 High volt demand L2 5 V/kV 0 to Vmax Hi d.U3 High volt demand L3 5 V/kV 0 to Vmax Hi d.C1 High ampere demand L1 A 0 to Imax Hi d.C2 High ampere demand L2 A 0 to Imax Hi d.C3 High ampere demand L3 A 0 to Imax Hi d.P.i High block interval kW import demand kW/MW 0 to Pmax E 34 Chapter 4 Setup Menus Code Parameter Unit Range1 Hi d.P.E High block interval kW export demand kW/MW 0 to Pmax Hi d.q.i High block interval kvar import demand kvar/Mvar 0 to Pmax Hi d.q.E High block interval kvar export demand kvar/Mvar 0 to Pmax Hi d.S High block interval kVA demand kVA/MVA 0 to Pmax Hi Sd.P.i High sliding window kW import demand kW/MW 0 to Pmax Hi Sd.P.E High sliding window kW export demand kW/MW 0 to Pmax Hi Sd.q.i High sliding window kvar import demand kvar/Mvar 0 to Pmax Hi Sd.q.E High sliding window kvar export demand kvar/Mvar 0 to Pmax Hi Sd.S High sliding window kVA demand kVA/MVA 0 to Pmax Hi Ad.P.i High accumulated kW import demand kW/MW 0 to Pmax Hi Ad.P.E High accumulated kW export demand kW/MW 0 to Pmax Hi Ad.q.i High accumulated kvar import demand kvar/Mvar 0 to Pmax Hi Ad.q.E High accumulated kvar export demand kvar/Mvar 0 to Pmax Hi Ad.S High accumulated kVA demand kVA/MVA 0 to Pmax Hi Pd.P.i High predicted sliding window kW import demand kW/MW 0 to Pmax Hi Pd.P.E High predicted sliding window kW export demand kW/MW 0 to Pmax Hi Pd.q.i High predicted sliding window kvar import demand kvar/Mvar 0 to Pmax Hi Pd.q.E High predicted sliding window kvar export demand kvar/Mvar 0 to Pmax Hi Pd.S High predicted sliding window kVA demand kVA/MVA 0 to Pmax Internal Events 4 (energy and power demand events ) PlS.Ac.i kWh import pulse PlS.Ac.E kWh export pulse PlS.rE.i kvarh import pulse PlS.rE.E kvarh export pulse PlS.rE.t kvarh total (absolute) pulse PlS.AP.t kVAh total pulse PlS.P.dn Start power demand interval PlS.S.dn Start sliding window demand interval PlS.A.dn Start volt/ampere demand interval PlS.trF Start new tariff interval Timers 4 t-r.1 Timer #1 sec 0 to 9999 t-r.2 Timer #2 sec 0 to 9999 TOU Parameters 4 trF Active tariff trF.1- trF.16 PrF Active profile PrF.1- PrF.16 Time/Date Parameters 4 U.dAY Day of week Sun, Πon, tuE, Ued, thu, Fri, Sat YEAr Year 0-99 Πon Month 1-12 Π.dAY Day of month 1-31 hour Hour 0-23 E E E E Chapter 4 Setup Menus 35 Code Parameter Unit Range1 Πin Minutes 0-59 SEC Seconds 0-59 - available in the PM172E 1 For parameter limits, see notes to Table 4-4. 2 The setpoint is operated when the actual phase sequence does not match the indicated normal phase rotation. 3 The actual frequency range is 45.00 to 65.00 Hz. 4 For this trigger, release limit is not used. 5 When the 4LN3 or 3LN3 wiring mode is selected, the voltages will be line-to- neutral; for any other wiring mode they will be line-to-line voltages. Table 4-8 Setpoint Actions (lower window, when middle window is Act) Code Action none No action 1 rEL.1 Operate relay #1 2 rEL.2 Operate relay #2 2 Inc.Cn.1 Increment counter #1 Inc.Cn.2 Increment counter #2 Inc.Cn.3 Increment counter #3 Inc.Cn.4 Increment counter #4 Clr.Cn.1 Clear counter #1 Clr.Cn.2 Clear counter #2 Clr.Cn.3 Clear counter #3 Clr.Cn.4 Clear counter #4 Clr.Cnt Clear all counters ELoG Event log 3 dLoG.1 Data log #1 dLoG.2 Data log #2 dLoG.3 Data log #3 dLoG.4 Data log #4 dLoG.5 Data log #5 dLoG.6 Data log #6 dLoG.7 Data log #7 dLoG.8 Data log #8 Clr.Enr Reset total energy Clr.dnd Reset all total maximum demands Clr.P.dn Reset power maximum demands Clr.A.dn Reset volt/ampere maximum demands Clr.tEn Reset TOU energy Clr.tdn Reset TOU maximum demands Clr.LHi Clear Min/Max registers - available in the PM172E 1 When a setpoint is operated, its status is always stored to the alarm status register even if no action is assigned to the setpoint. The alarm status register can be polled and cleared through communications. E E E E E E E E E E E E E E E 36 Chapter 4 Setup Menus 2 In the PM172E, operate/release actions via relays are automatically recorded to the event log whenever an electrical quantity, status input or phase reversal trigger is used. 3 Setpoint operation and release are recorded to the event log. 4.9 Timers Setup Menu Î Î Î Î This menu allows you to access the two interval timers provided by the PM172E which can trigger setpoints on a user-defined time interval basis. This is useful for continuous data logging at specified time intervals in order to produce trend and load profile graphs. Each timer has a time interval range up to 9999 seconds at a one-second resolution and runs independently. The timer accuracy is about ±0.05 sec. To use a timer as the trigger for a setpoint, simply select one of the timers as a trigger when defining the setpoint, and then specify for the selected timer a non-zero time interval at which you want the periodic action (for example, a data log) to be made. To stop a timer, set the time interval to zero. Each timer can be used to trigger multiple setpoints, for example, if you need multiple data logs at the same time. Timer setup To select a timer: 9 Press to activate the middle window, and then use the up/down arrow keys to scroll to the desired timer. The time interval associated with the timer is displayed in the lower window. To change the timer interval: 9 Press to activate the lower window. 9 Use the up/down arrow keys to set the desired time interval. The available range is 0-9999 (seconds). Setting the interval to zero stops the timer. 9 Press to store your new setting. 9 Press to leave the timer setup unchanged. To quit the timer setup menu: 9 Press . SELECTt-r 1 t-r.1 ENTER ESC ESC SELECT CHG t-rÏÐ ENTERENTER Chapter 4 Setup Menus 37 4.10 RTC Setup Menu Î Î Î Î This menu allows you to view and set the time, date and day of week in the onboard Real Time Clock (RTC), and to modify the Daylight Savings Time (DST) settings for your time zone. The time is displayed as HH.MM.SS, where the hour and minute are shown in the middle window separated by a dot, and the seconds - in the lower window. The date is displayed as per the user definition (YY.MM.DD, MM.DD.YY, or DD.MM.YY), where the first two items are shown in the middle window, and the last one - in the lower window. For instructions on how to select the date format, see Section 4.11. The day of the week is displayed in the lower window, as follows: Sun Sunday thu Thursday Πon Monday Fri Friday tuE Tuesday Sat Saturday UEd Wednesday The day of the week can only be viewed. It is set automatically when you change the date. The DST option can be disabled or enabled. When DST is disabled, the RTC will operate in standard time only. When enabled, the instrument will automatically update the time at 2:00 AM at the pre-defined DST switch dates. The DST switch points are specified by the month, week of the month and weekday. Select the appropriate weekday in the month by specifying the 1st, 2nd, 3rd, 4th or the last (abbreviated as LSt) weekday in the month. This entry specifies the DST start date when Daylight Savings Time begins. Press to select the date parameter you wish to change. By default, DST starts at 2:00 AM on the first Sunday in April of each year. This entry specifies the DST end date when Daylight Savings Time ends. Press to select the date parameter you wish to change. By default, DST ends at 2:00 AM on the last Sunday in October of each year. dAtE 99 25.07. hour 45 11.52 dAY Sun SELECT CHG rtcÏÐ ENTER ENTER dSt diS dSt.S 1St.Sun APr SELECT dSt.E LSt.Sun Oct SELECT 38 Chapter 4 Setup Menus To select an option sub-menu: 9 From the upper window, use the up/down arrow keys to scroll to the desired sub-menu (time, date, weekday, or DST). To change time, date, day of week (not seconds) or DST setting: 9 Press to activate the desired item. When in the time setup sub-menu, the hour and minutes indications are now frozen to allow you to adjust them. 9 Use the up/down arrow keys to set the value. 9 Set the other items in the same manner. To update the RTC with your new setting (and to reset seconds): 9 From the middle or lower window, press . 9 If you want to reset seconds, press to activate the seconds window, and then press while the seconds window is flashing. To quit the sub-menu without changes: 9 From the middle or lower window, press . To quit the RTC menu: 9 Press . 4.11 Display Setup Menu Î Î Î Î This menu allows you to view and change display properties. Table 4-9 lists available options with their code names and applicable ranges. To select a display option: 9 Press to activate the middle window, and then use the up/down arrow keys to scroll to the desired option. To change the display option: 9 Press to activate the lower window. 9 Use the up/down arrow keys to set the desired option. 9 Press to store your new setting or press to leave your previous setting unchanged. To quit the display setup menu: 9 From the middle window, press or . ENTERESC SELECT SELECT ENTER ENTER ESC ESC SELECT CHG diSPÏÐ ENTER ENTER SELECT SELECT ESC ENTER diSP UPdt 0.5 Chapter 4 Setup Menus 39 Table 4-9 Display Options (∗ default setting) Code Parameter Options Description UPdt Display update time 0.1 - 10.0 s (0.5)* Defines interval between display updates ScrL Auto scroll nonE* 2-15 s Disables/enables auto scroll on common measurements display (main screen) and defines scroll interval rEtn Auto return to the main screen diS*, En Disables/enables auto return to the main screen after 30 seconds of uninterrupted use bAr Nominal load current for LED bar graph 0-10,000A (0*) Defines the nominal load (100%) level for the bar graph display (0 = CT primary current) UoLt Voltage display Pri*, Sec Defines type of voltage displayed, primary or secondary. Secondary voltage is always displayed in Volt units (V) Ph.P Phase powers display diS*, En Disables/enables display of phase powers in common measurements (main screen) Fund Fundamental values display diS*, En Disables/enables display of fundamental values in common measurements (main screen) dAtE Date format n.d.Y* d.n.Y Y.n.d Defines the date format in the RTC display: d=day, n=month, Y=year Each date format character is set separately. rSt Simple reset PASS*, En PASS – the reset buttons are blocked if password checking is programmed En – enables the reset buttons regardless of a password 40 Chapter 4 Setup Menus 4.12 User Selectable Options Menu Î CHG Î Î Î This menu allows you to change options which relate to the instrument features and functionality. Table 4-10 lists all available options with their code names and applicable ranges. To select an option: 9 Press to activate the middle window, and then use the up/down arrow keys to scroll to the desired option. To change the selected option: 9 Press to activate the lower window. 9 Use the up/down arrow keys to set the desired value. 9 Press to store your new setting or to leave the previous setting unchanged. To quit the display setup menu: 9 From the middle window, press or Table 4-10 User Selectable Options (∗ default settings) Code Parameter Option Description P.cAL Power calculation mode 1 rEAc∗ nAct Using reactive power Using non-active power roLL Energy roll value 2 10.E4 10.E5 10.E6 10.E7 10.E8 10.E9∗ 10,000 kWh 100,000 kWh 1,000,000 kWh 10,000,000 kWh 100,000,000 kWh 1,000,000,000 kWh Ph.En Phase energy measurements diS∗, En Enables/disables measurements of energies per phase An.Ou Analog output option (see Section 4.5) nonE∗ 0-20 4-20 0-1 -1-1 Disables analog output 0-20 mA 4-20 mA 0-1 mA ±1 mA An.EP Analog expander option (see Section 4.6) nonE∗ 0-20 4-20 0-1 -1-1 Disables analog expander 0-20mA 4-20mA 0-1mA ±1 mA Ï ÐENTER SELECT ENTERSELECT ESC ENTER SELECT SELECT OPtS rEAc P.cAL ENTER E E ESC Chapter 4 Setup Menus 41 bAtt Battery mode OFF∗, On Switches the backup battery OFF/ON tESt LED energy pulse test mode 3 OFF∗ Ac.Ei rE.Ei Disables energy pulse test mode Runs Wh energy pulse test Runs varh energy pulse test - available in the PM172E 1 Power calculation mode (P.cAL): Mode 1: Reactive power calculation (rEAc) Active power P and reactive power Q are measured directly and apparent power: 22QPS+= Mode 2: Non-active power calculation (nAct) Active power is measured directly, apparent power S = V × I (where V, I = RMS voltage and currents) and non-active power: 22PSN−= Mode 1 is recommended for electrical networks with low harmonic distortion (voltage THD < 5%, current THD < 10%); Mode 2 is recommended for all other cases. 2 Energy roll value example: If roll value = 10.E4, the energy counter contains 4 digits, i.e., energy is displayed up to 9.999 MWh (Mvarh, MVAh) with resolution 0.001 MWh. E E E 42 Chapter 4 Setup Menus Rollover Value Maximum Energy kWh (kvarh, kVAh) Maximum Display Reading MWh (Mvarh, MVAh) Display Resolution MWh (Mvarh, MVAh) 10.E4 9,999 9.999 0.001 10.E5 99,999 99.999 0.001 10.E6 999,999 999.999 0.001 10.E7 9,999,999 9,999.99 0.01 10.E8 99,999,999 99,999.9 0.1 10.E9 999,999,999 999,999 1 The roll value may be changed in accordance with the average load of the power line. For example, if average power is 400 kW and the counter must be reset every 3 months (2160 hours), then energy during this period equals 864000 kWh (6 digits) and the roll value = 10.E6. 3 Energy pulse test mode is used for testing the device’s energy measurement accuracy. When the meter is put into the test mode, the energy pulse LED flashes at a rate of 0.1 Wh/pulse (10,000 pulses/kWh) in secondary readings as the meter measures imported (consumed) active or inductive reactive energy. When the meter is in the test mode, the common energy accumulators are not affected. Chapter 4 Setup Menus 43 4.13 Relay Operation Control Menu Î Î Î Î This menu allows you to set the relay operation mode: non-failsafe or failsafe. Failsafe relay operation is the opposite of normal operation where relay contacts are closed when a relay is operated (activated), and are open when a relay is released (de-activated). In failsafe mode, an alarm is activated by a non-energized relay which will open in all cases when an alarm condition is present or an alarm setpoint is not operational either due to a loss of control power or due to corruption of the setpoint setup configuration. A failsafe relay is closed only if it is under setpoint control and no alarm conditions exist, or if it is manually operated via communications. To select a relay: 9 Press to activate the middle window, and then use the up/down arrow keys to scroll to the desired relay. To change the relay operation mode: 9 Press to activate the lower window. 9 Use the up/down arrow keys to set the desired option. Select nor for normal (non-failsafe) relay operation, or select FSAFE for failsafe relay operation. 9 Press to store your new setting or press to leave your previous setting unchanged. To quit the setup menu: 9 From the middle window, press or NOTES 1. You will not be able to change the relay operation mode if a relay has been allocated for pulsing. 2. When a failsafe relay is allocated for pulsing, it automatically reverts to normal operation. rELo nor rEL.1 SELECT CHG rELoÏÐ ENTERENTER SELECT ENTER ENTER ESC ESC SELECT 44 Chapter 4 Setup Menus 4.14 Access Control Menu Î Î Î Î This menu can only be accessed via the Setup Change Menu (CHG). It is used in order to: • change the user password • enable or disable password check from the front panel keypad • enable or disable password protection for downloading setups and resetting data through communications To view an option setting: 9 Press to activate the middle window. 9 Use the up/down arrow keys to scroll to the desired option (PASS, CtrL, Port). Password Setting Password Protection Password Protection for the keypad for communications To change the password: 9 Press to activate the lower window. 9 Use the up/down arrow keys to modify the password. The password can be up to four digits long. 9 Press to store your new password, or to leave the password unchanged. To enable/disable password checking: 9 Press to activate the middle window, and then use the up/down arrow keys to move to the CtrL or Port entry. 9 Press to activate the lower window. 9 Use the up/down arrow keys to change the password checking status: select OFF to disable password protection, or select On to enable password protection. 9 Press to store your new option, or to leave the option unchanged. To quit the setup menu: 9 From the middle window, press or . ESC SELECT SELECT CHG AccSÏÐ ENTERENTER SELECT SELECT SELECT ENTER ESC ESC ENTER AccS 8780 PASS AccS OFF CtrL AccS OFF Port ENTER Chapter 4 Setup Menus 45 Store your password in a safe place. If you cannot provide the correct password, contact your local distributor for the super-user password to override password protection. 4.15 Reset Menu Î Î Î Î This menu allows you to reset to zero the accumulators and Min/Max registers in your instrument. The menu can only be accessed via the Setup Change Menu (CHG). If the reset is disabled from the Basic Setup Menu (see Section 4.1), you will not be able to enter this menu. The following designations are used in the menu to specify a data location to be reset: Lo.Hi Resets Min/Max registers (does not affect maximum demands) A.dnd Resets volt/ampere maximum demands P.dnd Resets total power maximum demands dnd Resets all total maximum demands EnrG Resets total and phase energies tOU.E Resets the TOU energy registers tOU.d Resets the TOU maximum demand registers Cnt Resets all pulse counters Cnt.1 Resets counter # 1 Cnt.2 Resets counter # 2 Cnt.3 Resets counter # 3 Cnt.4 Resets counter # 4 - available in the PM172E To reset the desired locations: 9 Press to activate the middle window, and then use the up/down arrow keys to scroll to the desired data location entry 9 Press to activate the lower window. 9 Press and hold for about 5 seconds until the do label is replaced with done, and then release the key. You will return to the middle window. To quit the reset menu: 9 Press . ENTER SELECT CHG rStÏÐ ENTERENTER SELECT ESC rSt do EnrG E E E E E E SELECT 46 Chapter 4 Setup Menus NOTE The meter allows the simple “two-button” reset of the Min/Max registers, maximum demands and total energies from the data display (see Section 5.1) and counters from the Status Information Menu (see Section 6.1) without entering the reset menu. This feature is active if changing data in the meter is not secured by a password, or it is enabled regardless of a password from the Display Setup menu. Chapter 5 Data Display 47 Chapter 5 Data Display 5. Chapter 5 Data Display 5.1 Navigating in the Display Mode The front panel has a simple interface that allows you to display numerous measurement parameters in a total of 49 display pages. For easier reading, the parameters are divided into four groups, each accessible by a designated key. These are: y Common measurements - no selection key y Min/Max measurements - selected by the key y Total Harmonic measurements - selected by the key y Energy measurements - selected by the key The up/down arrow keys are used as follows in the Display Mode: Scrolls through the pages downward (forward) Scrolls through the pages upward (backward) Returns to the first page within current measurement group TDDMIN./MAX. T HD PULSE ENERGY MAX.ESC /TDDMIN.THD 00-06009 Hz 3-13V /V kW 3A kvar MVAh MWhMvarh COM.1 ENTERSELECTENERGY COM.2 COMMUNICATION 8 0 %LOAD50% 60% 4 0 % 70 %100%90%110%PM172E 1V /V 1-2 1A A neut. 2A 2 PF V /V 2-3 kVA The front panel display is updated approximately twice per second; you can adjust the display update rate via the Display Setup Menu (see Section 4.11). Table 5-1 lists all displayed parameters and their LED indicators. Ï Ï Ð Ð Small LEDs - indicate current measurement group and parameter Load bar graph - indicates % of the current load MIN/MAX THD/TDD ENERGY 03-12008 48 Chapter 5 Data Display Load Bar Graph The load bar graph displays the amount, in percent, of the current load with respect to user-defined nominal load current. The highest current measured by the PM172 is divided by the nominal load current as defined in the Display Setup Menu (see Section 4.11) and expressed as a percent by the LEDs (40% to 110%) which are lit. For example, if all LEDs up to and including 90% are lit, this means that the load is 90% of the nominal load current. If the nominal load current is set to 0, it is taken from the CT primary current setup. Auto Scroll If display Auto Scroll option is enabled (see Section 4.11), the common measurements display (main screen) will scroll automatically after 30 seconds of uninterrupted use. 9 To stop auto scrolling at the current page, press either arrow key. Auto Return to the Main Screen If display Auto Return option is enabled (see Section 4.11), the display will automatically return to the main screen from any other measurement screen after 30 seconds of uninterrupted use. Simple Reset Buttons The PM172 allows the simple “two-button” reset of the Min/Max registers, maximum demands and total energies via the front panel without entering the reset menu (see “Simple Reset of Accumulated Data” below). Selecting a Display Page 9 Press the down/up arrow keys to scroll through display pages. NOTES 1. The common measurements display (main screen) does not have a designated indicator LED. If no arrow LED is lit up below the display, this means that the common measurement parameters are being displayed at this time. To return to the common measurements from another group, just press the same key that you used to display this group (the key pointed to by an illuminated arrow LED) until the illuminated LED goes out. 2. When you move to another measurement group, the instrument stores your last location; when you return to the previous group, the instrument restores the last page. At power up, the instrument always returns to the common measurements group and shows you the last page that was displayed prior to loss of power. Chapter 5 Data Display 49 Selecting Common Measurements (Main Screen) 9 Press the key pointed to by the illuminated arrow LED below the front panel display. If no LED is lit up, this means that the front panel displays the common measurements parameters. Selecting Total Harmonic Measurements 9 Press the key. Use the up/down arrow keys to scroll through harmonic measurements. Selecting Energy Measurements 9 Press the key. Use the up/down arrow keys to scroll through the different energy readings. Selecting TOU Energy Registers 9 Press the key until the REG.1 label appears in the upper window. Use the key to scroll through all TOU registers. Use the up/down arrow keys to scroll through the different tariff readings for the selected register. Note that only registers you have allocated will be displayed. Simple Reset of Accumulated Data The reset buttons are active if changing data via the front panel is not secured by a password, or this feature is enabled regardless of a password from the Display Setup menu (see Section 4.11) . 9 Select a display page where the data you want to reset is displayed. To reset: • Min/Max log registers: select a Min/Max page from the Min/Max measurements display (where Lo or Hi is displayed at the left in the lower window). • Ampere and volt maximum demands: select the ampere or volt maximum demand page from the Min/Max measurements display (where Hd is displayed at the left in the lower window, and volts or amps arrow LEDs at the right are lit). • Power maximum demands: select the power maximum demand page from the Min/Max measurements display (where Hd is displayed at the left in the lower window, and kVA/MVA and kW/MW arrow LEDs at the right are lit). • Total and phase energies: select the energy measurements display (not a TOU register). 9 While holding the key, press and hold for about 5 seconds. The displayed data is reset to zero. ENTER ENERGY THD/TDD ENERGY ENERGY SELECT 50 Chapter 5 Data Display 5.2 Data Display Formats Table 5-1 specifies all front panel local displays available in the display mode. The display windows are labeled in the table as follows: 1 = upper window, 2 = middle window, 3 = lower window. Table 5-1 Displayed Parameters Page Window Arrow LED Parameter1 Digits Unit 2 Common Measurements 1 1 V1/V1-2 Voltage L12 4 V/kV 1 2 V2/V2-3 Voltage L23 4 V/kV 1 3 V3/V3-1 L. Voltage L31 4 V/kV 2 1 V1/V1-2 Voltage L18 4 V/kV 2 2 V2/V2-3 Voltage L28 4 V/kV 2 3 V3/V3-1 P. Voltage L38 4 V/kV 3 1 A1 Current L1 4 A 3 2 A2 Current L2 4 A 3 3 A3 Current L3 4 A 4 1 kVA Total kVA 4 kVA/MVA 4 2 PF Total power factor 4 4 3 kW Total kW 4 kW/MW 5 1 A NEUT Neutral current 4 A 5 2 Hz Frequency 4 Hz 5 3 kvar Total kvar 4 kvar/Mvar 6 1 Ph.L15 Label 6 2 PF Power factor L1 4 6 3 kW kW L1 4 kW/MW 7 1 kVA kVA L1 4 kVA/MVA 7 2 Ph.L15 Label 7 3 kvar kvar L1 4 kvar/Mvar 8 1 Ph.L25 Label 8 2 PF Power factor L2 4 8 3 kW kW L2 4 kW/MW 9 1 kVA kVA L2 4 kVA/MVA 9 2 Ph.L25 Label 9 3 kvar kvar L2 4 kvar/Mvar 10 1 Ph.L35 Label 10 2 PF Power factor L3 4 10 3 kW kW L3 4 kW/MW Chapter 5 Data Display 51 11 1 kVA kVA L3 4 kVA/MVA 11 2 Ph.L35 Label 11 3 kvar kvar L3 4 kvar/Mvar 12 1 H014 (Fundamental) Label 12 2 PF H01 total power factor 4 12 3 kW H01 total kW 4 kW/MW 13 1 H1.L14,5 (Fundamental) Label 13 2 PF H01 power factor L1 4 13 3 kW H01 kW L1 4 kW/MW 14 1 H1.L24,5 (Fundamental) Label 14 2 PF H01 power factor L2 4 14 3 kW H01 kW L2 4 kW/MW 15 1 H1.L34,5 (Fundamental) Label 15 2 PF H01 power factor L3 4 15 3 kW H01 kW L3 4 kW/MW MIN/MAX Min/Max Measurements 3 Lo Label 1 1 V1/V1-2 Minimum voltage L1/L127 4 V/kV 1 2 V2/V2-3 Minimum voltage L2/L237 4 V/kV 1 3 V3/V3-1 Minimum voltage L3/L317 4 V/kV 2 1 A1 Minimum current L1 4 A 2 2 A2 Minimum current L2 4 A 2 3 A3 Minimum current L3 4 A 3 1 kVA Minimum total kVA 4 kVA/MVA 3 2 PF Minimum total power factor 4 3 3 kW Minimum total kW 4 kW/MW 4 1 A NEUT Minimum neutral current 4 A 4 2 Hz Minimum frequency 4 Hz 4 3 kvar Minimum total kvar 4 kvar/Mvar 3 Hi Label 5 1 V1/V1-2 Maximum voltage L1/L127 4 V/kV 5 2 V2/V2-3 Maximum voltage L2/L237 4 V/kV 5 3 V3/V3-1 Maximum voltage L3/L317 4 V/kV 6 1 A1 Maximum current L1 4 A 6 2 A2 Maximum current L2 4 A 6 3 A3 Maximum current L3 4 A 52 Chapter 5 Data Display 7 1 kVA Maximum total kVA 4 kVA/MVA 7 2 PF Maximum total power factor 4 7 3 kW Maximum total kW 4 kW/MW 8 1 A NEUT Maximum neutral current 4 A 8 2 Hz Maximum frequency 4 Hz 8 3 kvar Maximum total kvar 4 kvar/Mvar 3 Hd Label 9 1 V1 Maximum volt demand L1/L127 4 V/kV 9 2 V2 Maximum volt demand L2/L237 4 V/kV 9 3 V3 Maximum volt demand L3/L317 4 V/kV 10 1 A1 Maximum ampere demand L1 4 A/kA 10 2 A2 Maximum ampere demand L2 4 A/kA 10 3 A3 Maximum ampere demand L3 4 A/kA 11 1 kVA Maximum sliding window kVA demand 4 kVA/MVA 11 2 PF Power factor (import) at maximum kVA demand 4 11 3 kW Maximum sliding window kW import demand 4 kW/MW Total Harmonics THD 1 1 V1/V1-2 Voltage THD L1/L12 3 % 1 2 V2/V2-3 Voltage THD L2/L23 3 % 1 3 V3/V3-1 Voltage THD L3 3 % 2 1 A1 Current THD L1 3 % 2 2 A2 Current THD L2 3 % 2 3 A3 Current THD L3 3 % TDD 3 1 A1 Current TDD L1 3 % 3 2 A2 Current TDD L2 3 % 3 3 A3 Current TDD L3 3 % Chapter 5 Data Display 53 Total Energies 1 1 MWh Ac.En. Label 1 2 IP. Label 1 3 MWh import 6 MWh 2 1 Mvarh rE.En. Label 2 2 IP. Label 2 3 Mvarh import 6 Mvarh 3 1 MVAh AP.En. Label 3 3 MVAh 6 MVAh 4 1 MWh Ac.En. Label 4 2 EP. Label 4 3 MWh export 6 MWh 5 1 Mvarh rE.En. Label 5 2 EP. Label 5 3 Mvarh export 6 Mvarh Phase Energies6 6 1 MWh Ac.En. Label 6 2 IP.L1 Label 6 3 MWh import L1 6 MWh 7 1 Mvarh rE.En. Label 7 2 IP.L1 Label 7 3 Mvarh import L1 6 Mvarh 8 1 MVAh AP.En. Label 8 2 L1 Label 8 3 MVAh L1 6 MVAh 9 1 MWh Ac.En. Label 9 2 IP.L2 Label 9 3 MWh import L2 6 MWh 10 1 Mvarh rE.En. Label 10 2 IP.L2 Label 10 3 Mvarh import L2 6 Mvarh 11 1 MVAh AP.En. Label 11 2 L2 Label 11 3 MVAh L2 6 MVAh 12 1 MWh Ac.En. Label 12 2 IP.L3 Label 12 3 MWh import L3 6 MWh 13 1 Mvarh rE.En. Label 13 2 IP.L3 Label 13 3 Mvarh import L3 6 Mvarh 14 1 MVAh AP.En. Label 14 2 L3 Label 14 3 MVAh L3 6 MVAh E E 54 Chapter 5 Data Display TOU Energy Registers6 1-7 1 MWh/ rEG.1 - rEG.7 Label 1-16 2 Mvarh/ trF.1 - tF.16 Label 1-16 3 MVAh Tariff register reading9 6 - available in the PM172E 1 Display readings for all electrical quantities except Min/Max log and energies are sliding average values. 2 When using direct wiring (PT Ratio = 1), voltages are displayed in 0.1 V units, currents in 0.01 A units, and powers in 0.001 kW/kvar/kVA units. For wiring via PTs (PT Ratio > 1), voltages are displayed in 0.001 kV units, currents in 0.01 A units, and powers in 0.001 MW/Mvar/MVA units. When the value width is over the window resolution, the right most digits are truncated 3 By default, the maximum range for energy readings is 999,999,999 MWh/Mvarh/MVAh. Beyond this value, the reading will roll over to zero. When the energy reading exceeds the window resolution, the right-most digits are truncated. To avoid truncation, you can change the energy roll value to a lower limit via the User Selectable Options menu (see Section 4.12). Negative (exported) energy readings are displayed without a sign. 4 Fundamental values are displayed if they are enabled in the Display Setup menu (see Section 4.11). 5 Per phase power and power factor readings are displayed only in 4LN3/4LL3 and 3LN3/3LL3 wiring modes (see Section 4.1) if the phase power display is enabled in the Display Setup menu (see Section 4.11). 6 Phase energy readings are displayed only in 4LN3/4LL3 and 3LN3/3LL3 wiring modes (see Section 4.1) if they are enabled in the User Selectable Options menu (see Section 4.12). 7 When the 4LN3 or 3LN3 wiring mode is selected, the voltages will be line-to- neutral; for any other wiring mode, they will be line-to-line voltages. 8 Displayed only in the 4LN3 or 3LN3 wiring mode. 9 TOU energy readings are displayed in MWh/Mvarh/MVAh according to the energy input assigned to the register. A corresponding arrow LED will be lit showing energy units when a register reading is displayed. If a TOU register counts external pulses, the MWh LED will be lit. E E Chapter 5 Data Display 55 5.3 Self-Test Diagnostics Display The PM172 periodically performs self-test diagnostics during operation. If the instrument fails the test, it discards the last measurement results, and an error code is displayed for one second on all LEDs. Error codes are listed in Table 5-2. Frequent failures may be the result of excessive electrical noise in the region of the instrument. If the instrument resets itself continuously, contact your local distributor. Table 5-2 Self-Test Diagnostic Codes Code Meaning Code Meaning 1 ROM error 5 Out of control trap 2 RAM error 7 Timing failure 3 Watch dog timer reset 8 Normal power up 4 Sampling failure 9 External reset (warm restart) NOTE The PM172 provides a self-check alarm register accessible through communications that indicates possible problems with instrument hardware or setup configuration. The hardware problems are indicated by the appropriate bits, which are set whenever the instrument fails self-test diagnostics, or in the event of loss of power. The setup configuration problems are indicated by the dedicated bit which is set when either configuration register is corrupted. In this event, your instrument will use the default configuration. For more information on the self- check alarm register, refer to the communications reference guides shipped with your instrument. 56 Chapter 6 Viewing Status Information Chapter 6 Viewing Status Information 6. Chapter 6 Viewing Status Information The Status Information Menu (STA) is used to view the status of various instrument features. 6.1 The Status Information Menu Î Î To enter the Status Information Menu: 9 From the display mode, press to enter the Primary Selection Menu. 9 Press to activate the StA window. 9 Press . To select a display page: 9 Press the up/down arrow keys to scroll through the display pages. To quit the menu and return to the display mode: 9 Press or . Front Panel Display When you are in the Status Information Menu, the front panel display is updated approximately four times per second and shows you a wide variety of status information that you can review by scrolling through display pages. The status parameters are designated by the abbreviated labels in the upper and/or middle window. The upper window flashes, indicating that you are in the menu display. Simple Reset of Counters If the reset buttons are enabled in the meter (see “Simple Reset of Accumulated Data” in Section 5.1), you can reset the counters from the Status Information Menu display without entering the reset menu: 9 Select a display page where the counter you want to reset is displayed. 9 While holding the key, press and hold or about 5 seconds. The displayed data is reset to zero. ENTER SELECT SELECT StA ENTER SELECT ENTER ENTERESC SELECT Chapter 6 Viewing Status Information 57 6.2 Status Display Formats Table 6-1 lists all the displays available from the Status Information Menu. The display windows are labeled in the table as follows: 1=upper window, 2=middle window, 3=lower window. Table 6-1 Status Information Page Window Parameter Digits Unit 1 1 PHAS. Label 1 2 rOt. Label 1 3 Phase rotation (POS/NEG/ERR) 4 2 1 rEL. Label 2 2 1.2. Label 2 3 Relay status #1-#2 2 3 1 St.In Label 3 2 1.2. Label 3 3 Status inputs #1-#2 2 4 1 Cnt.1 Label 4 3 Counter #1 6 5 1 Cnt.2 Label 5 3 Counter #2 6 6 1 Cnt.3 Label 6 3 Counter #3 6 7 1 Cnt.4 Label 7 3 Counter #4 6 8 1 ELoG Label 8 2 Number of records in the Event log 4 8 3 Event log percent full 3 9 1 DLG.1 Label 9 2 Number of records in Data log #1 4 9 3 Data log #1 percent full 3 10 1 DLG.2 Label 10 2 Number of records in Data log #2 4 10 3 Data log #2 percent full 3 11 1 DLG.3 Label 11 2 Number of records in Data log #3 4 11 3 Data log #3 percent full 3 12 1 DLG.4 Label 12 2 Number of records in Data log #4 4 12 3 Data log #4 percent full 3 13 1 DLG.5 Label 13 2 Number of records in Data log #5 4 13 3 Data log #5 percent full 3 14 1 DLG.6 Label 14 2 Number of records in Data log #6 4 14 3 Data log #6 percent full 3 E E E E E E E 58 Chapter 6 Viewing Status Information Page Window Parameter Digits Unit 15 1 DLG.7 Label 15 2 Number of records in Data log #7 4 15 3 Data log #7 percent full 3 16 1 DLG.8 Label 16 2 Number of records in Data log #8 4 16 3 Data log #8 percent full 3 17 1 bAtt Label 17 3 The battery status (NORMAL/LOW) - available in the PM172E E E E E Chapter 7 Communications 59 Chapter 7 Communications 7. Chapter 7 Communications A full description of the communications protocols is found in the PM172 ASCII, Modbus and DNP 3.0 Communications Manuals provided on electronic media 7.1 Connection Diagrams COM1 COM2 Figure 7-1 RS-232/RS-422/RS-485 and RS-422/RS-485 Terminal Blocks RS-232 - up to 15 meters distance, one PC/PLC to one PM172, by flat or twisted pair cable of 0.33mm2/22AWG RS-422, RS-485 - up to 1200 meters distance, up to 32 instruments on one multi-drop line. 7.1.1 COM1 Connections Computer Connections COM1 - RS-232 Figure 7-2 RS-232 Simple 3- Wire Connection, 25- pin Figure 7-3 RS-232 Simple 3-Wire Connection, 9-pin +TX Transmit Data Plus +RX Receive Data Plus -TX Transmit Data Minus -RX Receive Data Minus Chassis Ground 60 Chapter 7 Communications Figure 7-4 RS-232 Hardware Handshaking Connection, 25-pin Figure 7-5 RS-232 Hardware Handshaking Connection, 9-pin Modem Connections COM1 - RS-232 Figure 7-6 Connection for 25-pin Modem Connector Figure 7-7 Connection for 9-pin Modem Connector Computer Connections COM1 - RS-422/RS-485 RS-422 TO SATEC CONVERTER TO PM172 COM1 +T +R -R -T 8 1 6 2 7 3 9 4 5 (MALE) DB9 +T +R -T -R RS-422 CABLE 5 4 3 2 1 Figure 7-8 COM1 RS-422/RS-485 Connections Chapter 7 Communications 61 7.1.2 COM2 Port Connections Computer Connections COM2 - RS-422/RS-485 R1, R2 ≅ 200-500 Ohm, 0.5 W Figure 7-9 RS-422 Multidrop Connection, 25-Pin PC Port R1, R2 ≅ 200-500 Ohm, 0.5 W Figure 7-10 RS-422 Multidrop Connection, 9-Pin PC Port R1, R2 ≅ 200-500 Ohm, 0.5 W Figure 7-11 RS-485 Multidrop Connection, 25-Pin PC Port c98-10007/4 R1, R2 ≅ 200-500 Ohm, 0.5 W Figure 7-12 RS-485 Multidrop Connection, 9-Pin PC Port NOTE: Where an RS-232/RS-422 converter is used, R1 is not applicable since it is built in to the converter. 62 Chapter 7 Communications 7.2 Using a Printer 7.2.1 Configuring the COM1 Port for Printer Set the printer mode and desired printout period in the communications port setup (see Section 4.2). The baud rate and data format should be configured as those on the printer. Cable connections to the serial printer are shown in Figures 7-13 through 7-16. Printer Connections COM1 - RS-232 Figure 7-13 Connection for 25-pin DCE Printer Connector Figure 7-14 Connection for 9-pin DCE Printer Connector Figure 7-15 Connection for 25-pin DTE Printer Connector Figure 7-16 Connection for 9-pin DTE Printer Connector Most serial printers provide a few bytes of buffer storage where characters can queue for printing. If the buffer size is sufficient to accept full print report, i.e., when a printer has at least 256 bytes of input buffer, flow control is not needed. If the buffer size is less than 256 bytes, you should provide hardware handshaking, otherwise the printer output will become garbled. Use the CTS signal to provide hardware flow control. Chapter 7 Communications 63 Set the handshaking parameter to HArd in the communications port setup. It is possible to use a parallel printer as well with a serial-to-parallel converter. When a converter is used, hardware handshaking is required. 7.2.2 Printout Format The PM172 prints a fixed format report at user-defined intervals. After resetting the instrument or completing the current page, the record heading is printed on the top of the new page. On each page, 14 data records are printed provided with date and time stamps. The record format is shown in the following illustration and detailed in Table 7-1. The date format is user-selectable (see Section 4.12). Table 7-1 Printout Format Line Pos Heading Parameter Digits Unit 1 1 V1/kV1 Voltage L1/L12 5 V/kV 1 2 V2/kV2 Voltage L2/L23 5 V/kV 1 3 V2/kV3 Voltage L3/L31 5 V/kV 1 4 A1 Current L1 5 A 1 5 A2 Current L2 5 A 1 6 A3 Current L3 5 A 1 7 kW/MW Total kW 6 kW/MW 1 8 kvar/Mvar Total kvar 6 kvar/Mvar 1 9 kVA/MVA Total kVA 6 kVA/MVA 1 10 PF Total power factor 6 2 1 THDU1 Voltage THD L1/L12 5 % 2 2 THDU2 Voltage THD L2/L23 5 % 2 3 THDU3 Voltage THD L3 5 % 2 4 THDI1 Current THD L1 5 % 2 5 THDI2 Current THD L2 5 % 2 6 THDI3 Current THD L3 5 % 2 7 Hz Frequency 5 Hz 2 8 A_NEU Neutral current 5 A 2 9 U_UNB Voltage unbalance 5 % 2 10 I_UNB Current unbalance 5 % 3 1 A1_MD Maximum Ampere demand L1 5 A 3 2 A2_MD Maximum Ampere demand L2 5 A 3 3 A3_MD Maximum Ampere demand L3 5 A 3 4 kW_MD/ MW_MD Maximum sliding window kW import demand 6 kW/MW 3 5 kVA_MD/ MVA_MD Maximum sliding window kVA demand 6 kVA/MVA 3 6 +MWh MWh import 7 MWh 3 7 -MWh MWh export 7 MWh 3 8 +Mvarh Mvarh import 7 Mvarh 3 9 -Mvarh Mvarh export 7 Mvarh 3 10 MVAh MVAh 7 MVAh 64 Appendix A Technical Specifications Appendix A Technical Specifications 8. Appendix A Technical Specifications Input and Output Ratings 3 Galvanically Isolated Voltage inputs: 120V option Input using PT (up to 120V+20% line-to- line voltage) Burden: <0.15 VA 690V option Direct input (up to 690V +15% line-to-line voltage) Burden: <0.5 VA Input using PT Burden: <0.15 VA 3 Galvanically Isolated Current inputs: 1A option Input via CT with 1A secondary output Burden: <0.02 VA Overload withstand: 6A RMS continuous, 80A RMS for 1 second 5A option Input via CT with 5A secondary output Burden: <0.1 VA Overload withstand: 15A RMS continuous, 300A RMS for 1 second Voltage and Current Input terminals UL recognized E101708 Maximum wire section: 3.5 mm2 (12 AWG) 2 Optically Isolated Communication Ports EIA RS-232/RS-422/RS-485 and RS-422/RS- 485 standards Maximum wire section: 2.5 mm2 (12 AWG) 2 Relay Outputs Relay rated at 5A, 250VAC/5A, 30VDC 2 contacts (SPST Form A) 4 Optically Isolated Digital Inputs Dry Contact Optically Isolated Analog Output Accuracy 0.5%, Non-linearity 0.2% Maximum wire section: 1.5 mm2 (14 AWG) 4-20 mA (default) 0-20 mA (option) Load up to 510 Ohm for 20 mA ± 1 mA (option) Load up to 10 kOhm for 1 mA Appendix A Technical Specifications 65 Display Indication 3 high-brightness seven-segment digital LEDs Power Supply (factory set) Galvanically isolated 120&230 V AC and 110&220 V DC 85-265VAC 50/60 Hz and 88-290VDC Burden 10 W Option 12 V DC Option 24 V DC Option 48 V DC 9.6 - 19 VDC 19 - 37 VDC 37 - 72 VDC Environmental Conditions Operating temperature -20°C to +60°C (-4°F to +140°F) Storage temperature -25°C to +80°C (-13°F to +176°F) Humidity 0 to 95% non-condensing Construction Instrument body Case enclosure: Plastic PC/ABS blend Dimensions: 127 x 127 x 127 mm (5.0 x 5.0 x 5.0 “) Mounting: 4-inch round or 92x92mm square panel mount Instrument weight 1.23 kg (2.7 lb.) Display body Display body: plastic PC/ABS blend Front Panel: plastic PC Dimensions: 114.0x114.0x20.0 mm (4.5x4.5x.787”) 66 Appendix A Technical Specifications Standard Compliance Standards UL File # E129258 (PENDING) Directive Complied With: EMC: 89/336/EEC as amended by 92/31/EEC and 93/68/EEC LVD: 72/23/EEC as amended by 93/68/EEC and 93/465/EEC Harmonized Standards to which Conformity is Declared: EN55011:1991; EN50082-1:1992; EN61010-1:1993; A2/1995 ANSI C37.90.1 1989 Surge Withstand Capability (SWC) EN50081-2 Generic Emission Standard - Industrial Environment EN50082-2 Generic Immunity Standard - Industrial Environment EN55022: 1994 Class A EN61000-4-2 ENV50140: 1983 ENV50204: 1995 (900MHz) ENV50141: 1993 EN61000-4-4:1995 EN61000-4-8: 1993 Appendix A Technical Specifications 67 Measurement Specifications Accuracy, % Parameter Full scale Rdg FS Conditions Range Display resolution (%Rdg) @ Range 2 Voltage 120V×PT @ 120V 400V×PT @ 690V 0.2 0.1 10% to 120% FS 0 to 999,000 V Direct wiring (PT=1): 0.1 V @ 0.1V to 999.9 V Wiring via PTs (PT>1): 0.001 kV @ 0.001kV to 9.999 kV ≤0.1% @ 10.00 kV to 999.0 kV Starting voltage 1.5% FS Line current CT PRIMARY CURRENT 0.3 0.02 1% to 200% FS 0 to 9999 A 0.01 A @ 0.01A to 99.99 A ≤0.1% @ 100.0 A to 9999 A Starting current 0.2% FS Active power 0.36×PT×CT @ 120V input 1.2×PT×CT @ 690V input 0.4 0.5 0.02 0.02 PF = 1 |PF| ≥ 0.5 1 -2,000,000 to 2,000,000 kW Direct wiring (PT=1): 0.001 kW @ 0.001kW to 9.999 kW Wiring via PTs (PT>1): 0.001 MW @ 0.001MW to 9.999 MW ≤0.1% @ 10.00 MW to 2000 MW Reactive power 0.36×PT×CT @ 120V input 1.2×PT×CT @ 690V input 0.6 0.02 |PF| ≤ 0.9 1 -2,000,000 to 2,000,000 kvar Direct wiring (PT=1): 0.001 kvar @ 0.001kvar to 9.999 kvar Wiring via PTs (PT>1): 0.001 Mvar @ 0.001Mvar to 9.999 Mvar ≤0.1% @ 10.00 Mvar to 2000 Mvar 68 Appendix A Technical Specifications Accuracy, % Parameter Full scale Rdg FS Conditions Range Display resolution (%Rdg) @ Range 2 Apparent power 0.36×PT×CT @ 120V input 1.2×PT×CT @ 690V input 0.5 0.02 1 0 to 2,000,000 kVA Direct wiring (PT=1): 0.001 kVA @ 0.001kVA to 9.999 kVA Wiring via PTs (PT>1): 0.001 MVA @ 0.001MVA to 9.999 MVA ≤0.1% @ 10.00 MVA to 2000 MVA Power factor 1 0.6 |PF| ≥ 0.5, I ≥ 10% FSI -0.999 to 1.000 0.001 Frequency 0.02 45.00 to 65.00 Hz 0.01 Hz Neutral (unbalanced) current CT PRIMARY CURRENT 0.5 2% to 200% FS 0 to 9999 A 0.01 A @ 0.01A to 99.99 A ≤0.1% @ 100.0 A to 9999 A Starting current 0.5% FS Ampere demand Same as for current KW demand (block & sliding) Same as for kW KVA demand (block & sliding) Same as for kVA Total Harmonic Distortion THD V (I), %V1(I1) 999.9 1.5 0.2 THD ≥ 2% FS, V (I) ≥10% FSV (FSI) 0 to 999.9 0.1 Total Demand Distortion TDD, % 100 1.5 TDD ≥ 2% FS, I ≥ 10% FSI 0 to 100 0.1 Appendix A Technical Specifications 69 Accuracy, % Parameter Full scale Rdg FS Conditions Range Display resolution (%Rdg) @ Range 2 Active energy Import & Export Class 0.5S (IEC 687-1992-6) 0 to 999,999 MWh 1 kWh @ 1 to 999,999 kWh 10 kWh @ 1000 to 9,999.99 MWh 100 kWh @ 10,000 to 99,999.9 MWh 1MWh @ 100,000 to 999,999 MWh Reactive energy Import & Export Under conditions of Class 1.0 (IEC 1036) |PF| ≤ 0.9 1 0 to 999,999 Mvarh 1 kvarh @ 1 to 999,999 kvarh 10 kvarh @ 1000 to 9,999.99 Mvarh 100 kvarh @ 10,000 to 99,999.9 Mvarh 1Mvarh @ 100,000 to 999,999 Mvarh Apparent energy Under conditions of Class 0.5S (IEC 687-1992-6) 1 0 to 999,999 MVAh 1 kVAh @ 1 to 999,999 kVAh 10 kVAh @ 1000 to 9,999.99 MVAh 100 kVAh @ 10,000 to 99,999.9 MVAh 1MVAh @ 100,000 to 999,999 MVAh PT = external potential transformer ratio CT, CT Primary Current = primary current rating of external current transformer FSV = voltage full scale FSI = current full scale V1 = voltage fundamental I1 = current fundamental 1 Voltage 70% to 120% FS and current 2% to 120% FS 2 Higher resolution is achievable via communications Additional Notes 1. Accuracy is expressed as ± (percentage of reading + percentage of full scale) ± 1 digit. This does not include inaccuracies introduced by the user's potential and current transformers. 2. Specifications assume: voltage and current waveforms with THD ≤ 5% for kvar, kVA and PF; reference operating temperature: 20-26°C. 3. Ordinary measurement error is considerably less than the specified accuracy which indicates maximum error. 4. Harmonic real time values assume errors averaged over 10-20 readings. 70 Appendix B Using Setpoints Appendix B Using Setpoints 9. Appendix B Using Setpoints The PM172 has an embedded logical controller that can run different actions in response to user-defined internal and external events. Unlike a PLC, the PM172 uses a simplified setpoint programming technique that allows the user to define a logical expression based on measured analog and digital values that will produce a required action. The PM172 provides 16 setpoints with programmable operate and release delays. Each setpoint can evaluate a logical expression with up to four arguments using OR/AND logic. Whenever an expression is evaluated as “true”, the setpoint performs up to four consequent actions that can send a command to the output relays, increment or decrement a counter, or trigger a recorder. The scan time for all setpoints is 50 ms. Using Logical Expressions Logical operators OR/AND are treated in a simplified manner. They have no specific priority or precedence rules. Any trigger condition bound to the logical expression by the OR operator and evaluated as “true” will override any preceding condition evaluated as “false”. Similarly, any trigger condition evaluated as “false” and bound by the AND operator will override any condition evaluated before it as “true”. To avoid confusion, it is recommended not to alternate different logical operators in one expression. Instead, bring all conditions that use the same logical operator together to one side of the expression, and the others - to the opposite side. To explicitly override all other conditions with the critical trigger, put it at the end of the expression using the OR operator if you want the setpoint to be operated anyway when the trigger condition is asserted, and with the AND operator, if the setpoint should not be operated while the critical trigger is not asserted. Using Numeric Triggers For numeric (analog) triggers, a setpoint allows you to specify two thresholds for each trigger to provide hysteresis (dead band) for setpoint operations. The operate limit defines the operating threshold, and the second release limit defines the release threshold for the trigger. The trigger thresholds are specified in primary units. If you do not want to use hysteresis for the trigger, set the release limit to the same as the operate limit. Appendix B Using Setpoints 71 Using Binary Triggers Binary (digital) triggers, like digital inputs, relays, or internal static and pulsed events, are tested for ON (closed/set) or OFF (open/cleared) status. The binary events are divided into two types: static events and pulsed events. Static events are level-sensitive events. A static event is asserted all the time while the corresponding condition exists. Examples are digital inputs and relays. Pulsed events are edge-sensitive events with auto-reset. A pulsed event is generated for a trigger only once when a positive transition edge is detected on the trigger input. The examples of pulsed events are pulse inputs (transition pulses on the digital inputs), internal pulsed events (energy pulses and time interval pulses), and events generated by the interval timers. The logical controller automatically clears pulsed events at the end of each scan, so that triggers that used pulsed events are prevented from being triggered by the same event once again. Using Interval Timers The PM172E has 2 interval timers that can be programmed to generate periodic events at user-defined intervals. They are commonly used for periodic recording of interval data at the time of the fault or in the presence of other events detected by setpoints. Interval timers are not synchronized with the clock. When you run a timer, it generates a pulsed timer event that can trigger a setpoint if you have put the timer into a list of the setpoint triggers. When the setpoint event is asserted, the timer is restarted, and then generates the next timer event when the timer interval expires. If you want to record interval data at predefined intervals without linking to other events, just select a timer as a setpoint trigger and specify in the setpoint actions list a data log file you want to use for recording. If you want the periodic data to be recorded in the presence of a specific event, select triggers that will identify your event, and then add the timer at the end of the trigger list using the AND operator. Using Time Triggers If you want the setpoint actions to be synchronized with the clock, for example, to provide synchronous recording interval data every 15 minutes or each hour, or to output time pulses through relay contacts, use the time triggers that generate static events synchronized to the device clock. You can exercise the default setting for Setpoint #1 in your device as an example of using time triggers. The setpoint is pre-programmed for data profiling at 15-minute intervals using data logs #1 and #2. Delaying Setpoint Operations Two optional delays can be added to each setpoint to extend monitoring setpoint triggers for a longer time before making a decision on whether 72 Appendix B Using Setpoints the expected event occurred or not. When a delay is specified, the logical controller will change the setpoint status only if all conditions are asserted for a period at least as long as the delay time. You cannot use delays with pulsed events since they are cleared immediately and will no longer exist on the next setpoint scan. Using Setpoint Events and Actions When a setpoint status changes, i.e., a setpoint event is either asserted or de-asserted, the following happens in your device: 1. The new setpoint status is logged to the setpoint status register that can be monitored through communications from the SCADA system or from a programmable controller in order to give an indication on the expected event. 2. The operated setpoint status is latched to the setpoint alarm latch register accessible through communications. The register holds the last setpoint alarm status until it is explicitly cleared via communications. 3. Up to four programmable actions can be performed in sequence on setpoint status transition when a setpoint event is asserted. Generally, setpoint actions are performed independently for each setpoint and can be repeated a number of times for the same target. The exceptions are relay operations and data logging that are shared for each separate target between all setpoints using an OR scheme. A relay output is operated when one of the setpoints linked to the relay is activated and will stay in the operated state until all of these setpoints are released. Data logging directed to the same file are done once for the first setpoint among those that specify the same action, guaranteeing that there will not be repeated records related to the same time. Recording Setpoint Events In the PM172E, time-tagged setpoint events will be recorded to the Event Log if you put a corresponding action into the setpoint action list. The Event Recorder will log into a log file a separate record for each active trigger caused a setpoint status transition, and a separate record for each action done on the setpoint activation (except for logging actions that are not recorded to the Event Log). Appendix C Configuring TOU 73 Appendix C Configuring TOU 10. Appendix C Configuring TOU The PM172E provides 7 TOU energy and 3 TOU maximum demand registers that can be linked to any internal energy source or to any external pulse source that delivers energy pulses through the device digital inputs. The device supports 16 different tariffs using an arbitrary tariff structure. The PM172E TOU system technique is based on the currently active TOU annual calendar that assigns the user-selectable daily profile to each day of the year. The TOU daily profiles specify daily tariff change points. The PM172E memory can store calendars for 2 years. A total of 16 types of days are supported with up to eight tariff changes per day. By default, the TOU registers in your device are not linked to energy sources and are not operational. To activate a TOU energy register, you should link it to the energy source. To configure the TOU, you should use the PAS software package supplied with your meter To activate TOU system: 1. Configure the TOU daily profiles for different types of days. 2. Configure the TOU calendars by assigning a corresponding day profile to each day of the year. 3. Link the TOU registers to the corresponding energy or maximum demand registers that are used as source registers for TOU system. Configuring TOU Registers To configure TOU registers: 1. Select Energy/TOU from the Meter Setup menu and click on the TOU Registers tab. 2. In the Register Input box, select energy or maximum demand source input for each register you want to activate. For external pulse sources, type in the multiplier (pulse weight) in kWh per pulse. Configuring TOU Daily Profiles To configure the TOU daily profiles: 1. Select Energy/TOU from the Meter Setup menu, and then click on the TOU Daily Profiles tab. 2. In the Profile No. box, select a profile number for this type of day. 74 Appendix C Configuring TOU 3. Select the start time for each tariff change point and the corresponding active tariff number. 4. Repeat the setup for all types of days that have a different tariff schedule. The first tariff change point is fixed at 00:00 hours, and the last tariff change you specified will be in use until 00:00 hours on the next day. Configuring TOU Calendars To configure the TOU calendars: 1. Select Energy/TOU from the Meter Setup menu, and then click on the TOU Calendars tab. 2. In the Calendar No. box, select the calendar number for the calendar you want to set up. 3. Select the calendar year for your calendar and set the month to January. 4. In the Daily Profiles box, click on the first daily profile that will be active in this month. Click on day cells when this profile will be active. The cells will be colored in the selected profile’s color and the assigned profile number will be printed in the cells. Repeat these steps for all daily profiles that will be active in this month. 5. Repeat the setup for all months of the year. 6. Select the next calendar and configure it for the following year in the same manner. Appendix D Event and Data Logging 75 Appendix D Event and Data Logging 11. Appendix D Event and Data Logging The PM172E has a 0.5-Megabyte onboard non-volatile memory for data and event recording. Before using event and data recorders, the PM172E memory should be partitioned between log files. The device memory is fully configurable. The user defines how much memory to allocate for each log file. At the factory, the memory is pre-configured for use with most applications. If you want to change the factory settings, follow the guidelines in the section below. You will need to use the PAS software package supplied with your meter to configure the device memory. Configuring Device Memory The PM172E memory can be partitioned for a total of 9 log files: • Event Log • 8 Data Logs To view the present device memory settings, select Memory/Log from the Meter Setup menu, and then click on the Log Memory tab. The available file options are described in the following table. Option Range Description Type Wrap around, Non-wrap Monthly profile Daily profile Defines the file behavior when it is filled up. WRAP AROUND: recording continues over the oldest records. NON-WRAP: recording is stopped until the file is cleared. MONTHLY PRF: monthly TOU profile data log (only for data log #7). DAILY PRF: daily TOU profile data log (only for data log #8). Size Shows the size of the memory allocated to the file. It is set automatically depending on the size of a file record and the number of records in the file. Sections/Channels 0-10 Shows the numbers of sections (registers) in a multi-section TOU profile data log file Num. of Records 0-65535 Allocates the file memory for predefined number of records Num. of Events 0-65535 Shows the total number of events that can be stored in the file Record size Shows the size of the file record for a single section. It is set automatically depending on the file and on the number of parameters in the data record 76 Appendix D Event and Data Logging Option Range Description Parameters Defines the number of parameters in a single data record for data log files. Memory is allocated for each file statically when you set up the files and will not change unless you re-organize your files. The following table shows how to calculate a file size for different log files. File Record Size, Bytes File Size, Bytes Event Log 14 Record size x Number of events Data Log 8 + 4 x Number of parameters in a record Record size x Number of events TOU Profile Data Log (#7, #8) 8 + 4 x Number of season tariffs Record size x Number of TOU registers x Number of events The default memory configuration preset at the factory is shown in the following table. No. File Size, Bytes Number of Events Description 1 Event log 5600 400 2 Data log #1 241520 3360 Configured for periodic 15-min data recording for 35 days 3 Data log #2 241520 3360 Configured for periodic 15-min data recording for 35 days Event Recording By default, the meter stores to the Event Log file all events related to resets and device diagnostics. In addition, the meter can record to the Event Log events related to setpoint operations. To record setpoint operations to the Event Log, add the “Event log” action to the setpoint actions list. When a setpoint event happens, the meter records all setpoint conditions that caused the event and all setpoint actions performed in response to the event. Data Recording The data recorder is event-driven and can be triggered by any event through the programmable setpoints. The data recorder can record up to 16 data parameters per record in each of 8 data log files. The list of parameters is configured individually for each data log file. Before configuring data log parameters in your device, you should allocate memory for the data log and specify how many parameters each record will contain. Parameters that are not included into the record will be designated as not available. Appendix D Event and Data Logging 77 To configure the data log parameters, select Memory/Log from the Meter Setup menu, click on the Data Recorder tab, and then select a data log you want to configure. To specify parameters for the data log: 1. Click on the “Group” box for the first parameter and select a data group that contains the desired parameter. 2. Click on the “Parameter” box for the first parameter and select a parameter from the list. 3. Select the other parameters in the same manner. For your convenience, when you open the “Group” box for the next parameter, PAS highlights the same group as in your previous selection. If you select this group again, PAS will automatically update the “Parameter” box with the next parameter in the group. Data logs #1 and #2 are preset at the factory for periodic recording of the standard power quantities. Their default data log configuration is shown in the following table. Data Log #1 No. Parameter No. Parameter 1 V1 9 Total kVA 2 V2 10 Total PF 3 V3 11 V1 THD 4 I1 12 V2 THD 5 I2 13 V3 THD 6 I3 14 I1 THD 7 Total kW 15 I2 THD 8 Total kvar 16 I3 THD Data Log #2 No. Parameter No. Parameter 1 V1 Demand 9 kVA sliding demand 2 V2 Demand 10 kWh Import 3 V3 Demand 11 kWh Export 4 I1 Demand 12 kvarh Import 5 I2 Demand 13 kvarh Export 6 I3 Demand 14 In 7 kW import sliding demand 15 Frequency 8 kvar import sliding demand 16 Digital input #1 Setpoint #1 is preset at the factory to trigger Data Logs #1 and #2 in 15 min intervals. TOU Energy/Demand Profile Recording Data Log #7 and Data Log #8 can be configured to store a TOU monthly profile log and a TOU daily profile log respectively. A TOU profile log file is organized as a multi-section file that has a separate section for each TOU energy and maximum demand register. The number of sections is 78 Appendix D Event and Data Logging taken automatically from the Energy/TOU setup. In order to correctly allocate the memory space for TOU profile log files, you should activate TOU registers before you set up your TOU profile log files. See Appendix C for information on how to configure the TOU registers in your meter. Appendix E Power Quality Setup 79 Appendix E Power Quality Setup 12. Appendix D Event and Data Logging The PM172E can provide detection and registration of power quality events such as: • Voltage dips and interruptions • Voltage swells and overvoltages • Frequency variations The following table gives an example of programming setpoints for detection and recording power quality events. Limits Delay SP No Trigger Parameter Operate Release Action Operate Release 2 Low RT Voltage 0.9 Vn 0.92 Vn Event Log Data Log #3 0 0.2 s 3 High RT Voltage 1.1 Vn 1.08 Vn Event Log Data Log #3 0 0.2 s 4 High RT Frequency 1.01 Fn 1.008 Fn Event Log Data Log #3 0 0.2 s 5 Low RT Frequency 0.99 Fn 0.992 Fn Event Log Data Log #3 0 0.2 s 6 High RT Voltage THD 5.0% 4.5% Event Log Data Log #3 30 s 0.2 s Vn – nominal system voltage Fn – nominal system frequency (50/60 Hz) Each power quality event will force the meter to record the time and fault magnitude of the power quality parameter to the Event Log both at the start and the end of the event, and to record all power quality parameters together at the time of the event to Data Log #3. The following table shows an example for selecting parameters for Data Log #3. See Appendix D for information on how to allocate memory for your power quality Data Log. Data Log #3 No. Group Parameter No. Group Parameter 1 RT PHASE V1 9 2 RT PHASE V2 10 3 RT PHASE V3 11 4 RT PHASE V1 THD 12 5 RT PHASE I2 THD 13 6 RT PHASE I3 THD 14 7 RT AUX FREQ 15 8 16 Take into consideration that in the 4LN3 and 3LN3 wiring modes, the high and low voltage triggers will represent line-to-neutral voltages; in all other wiring modes they will be line-to-line voltages (see Note 6 to Table 4-7 in Section 4.8). 80 Appendix E Power Quality Setup The characteristics of the power quality events, such as a category, phase, magnitude and duration, can be obtained by analyzing the Event Log and Data Log files. The duration of a power quality event can be calculated by taking the difference between time stamps of the pair of records in the Event Log recorded when a setpoint corresponding to the power quality trigger was operated at the beginning of the event and was released at the end of the event. The phase, category and magnitude of a voltage and harmonic fault can be obtained from the power quality Data Log record corresponding to the event, i.e., having the same setpoint ID and the time stamp close to that was recorded to the Event Log at the beginning of the event. The phase and category of a voltage fault can be identified by comparing phase magnitudes with thresholds recognized for different categories of voltage faults. Use the following table to classify your voltage faults. Voltage Fault Category Magnitude Typical Duration Voltage interruption < 0.01 Vn on all phases Voltage dip (sag) < 0.9 Vn 0.5 cycles – 1 min Undervoltage < 0.9 Vn > 1 min Voltage swell > 1.1 Vn 0.5 cycles – 1 min Overvoltage > 1.1 Vn > 1 min Index 81 INDEX accuracy, 36, 65 active energy, 64, 65 active power, 40, 63, 64 ampere demand, vi, 20, 33, 34, 49, 60 analog output, i, 2, 20, 25, 26, 28, 40 analog outputs, 20 basic setup, 19 burden, 61, 62 communications, 65 connections, 1, 59 CT, vi, 11, 20, 27, 39, 46, 61, 63, 64, 65 CT PRIMARY CURRENT, 20, 63, 64, 65 current inputs, 61 current transformers, 65 demand, vi, 2, 3, 6, 20, 23, 27, 33, 34, 43, 47, 49, 60, 64 demand period, vi, 20 diagnostic, 6 digital inputs, 23, 24 display, 1, 38, 39, 41, 44, 45, 46, 47, 51, 53, 54 display mode, 39, 44, 46, 47, 53 energy, 1, 2, 3, 24, 29, 35, 40, 41, 43, 47, 51, 64, 65 external synchronization, vi, 2, 20, 23 frequency, vi, 5, 20, 27, 33, 35, 49, 64 inputs, 6, 23, 24, 54, 61 Load bar graph, 46 measurement, 65 menu, 17, 19, 21, 23, 24, 25, 28, 29, 30, 31, 36, 37, 38, 39, 41, 42, 43, 44, 51, 53 Modbus, ii, 21, 56 mounting, 1, 7, 8 open delta, 11, 20 options, 16 overload withstand, 61 PAS, vi, 19, 69, 71 password, 2, 17, 42, 43, 44, 53 power, i, vi, 1, 2, 10, 20, 23, 25, 26, 34, 35, 40, 41, 43, 46, 47, 48, 49, 51, 52, 60, 63, 64 power demand, vi, 20, 23, 34 power factor, 64 power source, i, 10 PT, vi, 11, 20, 27, 51, 61, 63, 64, 65 PT RATIO, 20 pulsing, 2, 29, 30, 31, 42 reactive energy, 65 reactive power, 40, 63 relays, 2, 29, 36 reset, vi, 20, 38, 41, 43, 44, 46, 47, 52, 53 self tests, 52 setpoints, 20, 24, 30, 31, 36 setup menus, 17, 19 setup mode, 17 standards, 2, 61 status, 1, 2, 17, 23, 24, 35, 36, 42, 53, 54, 55 terminals, ii, 10, 11, 61 voltage inputs, 61 wiring configuration, 11 Wye, vi, 20 Section 9 37364A GCP-30 Packages Genset Control Installation Software Version from V4.3046 Manual 37364A Manual 37364A GCP-30 Packages - Genset Control WARNING Read this entire manual and all other publications pertaining to the work to be performed before install- ing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage. The engine, turbine, or other type of prime mover should be equipped with an overspeed (overtempera- ture, or overpressure, where applicable) shutdown device(s), that operates totally independently of the prime mover control device(s) to protect against runaway or damage to the engine, turbine, or other type of prime mover with possible personal injury or loss of life should the mechanical-hydraulic gov- ernor(s) or electric control(s), the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s), or the controlled device(s) fail. Any unauthorized modifications to or use of this equipment outside its specified mechanical, electrical, or other operating limits may cause personal injury and/or property damage, including damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product certifications or listings. CAUTION To prevent damage to a control system that uses an alternator or battery-charging device, make sure the charging device is turned off before disconnecting the battery from the system. Electronic controls contain static-sensitive parts. Observe the following precautions to prevent dam- age to these parts. • Discharge body static before handling the control (with power to the control turned off, contact a grounded surface and maintain contact while handling the control). • Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit boards. • Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. OUT-OF-DATE PUBLICATION This publication may have been revised or updated since this copy was produced. To verify that you have the latest revision, be sure to check the Woodward website: http://www.woodward.com/pubs/current.pdf The revision level is shown at the bottom of the front cover after the publication number. The latest version of most publications is available at: http://www.woodward.com/publications If your publication is not there, please contact your customer service representative to get the latest copy. Important definitions WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. CAUTION Indicates a potentially hazardous situation that, if not avoided, could result in damage to equipment. NOTE Provides other helpful information that does not fall under the warning or caution categories. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, Woodward assumes no responsibility unless otherwise expressly undertaken. © Woodward All Rights Reserved. Page 2/46 © Woodward Manual 37364A GCP-30 Packages - Genset Control Revision History Rev. Date Editor Changes NEW 06-01-11 TP Release A 07-02-07 TP Technical Data and CAN bus section updated; minor corrections Contents NOTE The functions described in this manual are included in all GCP-30 series controls (all packages). Func- tionality that is specific to particular models of GCP-30 controls will be differentiated by having the model number at the beginning of the text for the function. [GCP-32] Functionality for 2 circuit breaker applications (GCP-32 control types). [GCP-31] Functionality for single circuit breaker applications (GCP-31 control types). BPQ Functionality for all units with the BPQ Package (unit types GCP-31/BPQ and GCP-32/BPQ). XPD Functionality for all units with the XPD Package (unit types GCP-31/XPD and GCP-32/XPD). XPQ Functionality for all units with the XPQ Package (unit types GCP-31/XPQ and GCP-32/XPQ). SB03 Functionality for all units with the SB03 Option (unit types GCP-31/XPQ+SB03 and GCP- 32/XPQ+SB03). SC10 Functionality for all units with the SC10 Option (unit types GCP-31/XPQ+SC10 and GCP- 32/XPQ+SC10). CHAPTER 1. GENERAL INFORMATION..........................................................................................7 CHAPTER 2. ELECTROSTATIC DISCHARGE AWARENESS ..............................................................8 CHAPTER 3. HOUSING ................................................................................................................9 Dimensions .............................................................................................................................................9 Panel Cut-Out .......................................................................................................................................10 Side view...............................................................................................................................................11 Installation.............................................................................................................................................12 CHAPTER 4. WIRING DIAGRAMS - OVERVIEW ............................................................................13 GCP-31/BPQ Package .........................................................................................................................14 GCP-31/XPD Package ..........................................................................................................................15 GCP-31/XPQ Package .........................................................................................................................16 GCP-31/XPQ+SB03 Package ..............................................................................................................17 GCP-31/XPQ+SC10 Package ..............................................................................................................18 GCP-32/BPQ Package .........................................................................................................................19 GCP-32/XPD Package ..........................................................................................................................20 GCP-32/XPQ Package .........................................................................................................................21 GCP-32/XPQ+SB03 Package ..............................................................................................................22 GCP-32/XPQ+SC10 Package ..............................................................................................................23 © Woodward Page 3/46 Manual 37364A GCP-30 Packages - Genset Control Page 4/46 © Woodward CHAPTER 5. CONNECTORS - DETAILS ...................................................................................... 24 Power Supply........................................................................................................................................ 24 Measuring Inputs.................................................................................................................................. 25 Voltage ....................................................................................................................................... 25 Current........................................................................................................................................ 27 Discrete Inputs...................................................................................................................................... 29 Control Inputs............................................................................................................................. 29 Alarm Inputs ............................................................................................................................... 30 Operation Mode Selection Via DI (XPD, XPQ) .......................................................................... 32 Analog Inputs (XPD, XPQ) ................................................................................................................... 33 MPU...................................................................................................................................................... 34 Relay Outputs....................................................................................................................................... 35 Controller Outputs...................................................................................................................... 35 Relay Manager ........................................................................................................................... 35 Analog Outputs (XPD, XPQ) ................................................................................................................ 36 Controller Outputs ................................................................................................................................ 36 Three-Position Controller (XPD) ................................................................................................ 36 Multi Functional Controller Outputs (BPQ, XPQ)....................................................................... 37 Interface................................................................................................................................................ 39 Interface Wiring .......................................................................................................................... 39 CAN Bus Shielding..................................................................................................................... 39 CAN Bus Topology..................................................................................................................... 40 DPC - Direct Configuration Interface.......................................................................................... 41 CHAPTER 6. TECHNICAL DATA ................................................................................................. 42 CHAPTER 7. ACCURACY .......................................................................................................... 45 Manual 37364A GCP-30 Packages - Genset Control Illustrations and Tables Illustrations Figure 3-1: Housing - Dimensions .............................................................................................................................................9 Figure 3-2: Housing - Control panel cut-out ............................................................................................................................10 Figure 3-3: Side view - without clamps ...................................................................................................................................11 Figure 3-4: Side view - with clamps ........................................................................................................................................11 Figure 4-1: Wiring diagram GCP-31/BPQ Package ................................................................................................................14 Figure 4-2: Wiring diagram GCP-31/XPD Package ................................................................................................................15 Figure 4-3: Wiring diagram GCP-31/XPQ Package ................................................................................................................16 Figure 4-4: Wiring diagram GCP-31/XPQ+SB03 Package .....................................................................................................17 Figure 4-5: Wiring diagram GCP-31/XPQ+SC10 Package .....................................................................................................18 Figure 4-6: Wiring diagram GCP-32/BPQ Package ................................................................................................................19 Figure 4-7: Wiring diagram GCP-32/XPD Package ................................................................................................................20 Figure 4-8: Wiring diagram GCP-32/XPQ Package ................................................................................................................21 Figure 4-9: Wiring diagram GCP-32/XPQ+SB03 Package .....................................................................................................22 Figure 4-10: Wiring diagram GCP-32/XPQ+SC10 Package ...................................................................................................23 Figure 5-1: Power supply .........................................................................................................................................................24 Figure 5-2: Measuring inputs - Voltage - Generator ................................................................................................................25 Figure 5-3: Measuring inputs - Voltage - Busbar.....................................................................................................................26 Figure 5-4: Measuring inputs - Voltage - Mains ......................................................................................................................26 Figure 5-5: Measuring inputs - Current - Generator ................................................................................................................27 Figure 5-6: Measuring inputs - Current - Mains - via transformer ...........................................................................................28 Figure 5-7: Measuring inputs - Real power - Mains - via measuring transducer .....................................................................28 Figure 5-8: Discrete inputs - Control inputs.............................................................................................................................29 Figure 5-9: Discrete inputs - Alarm inputs - positive logic ......................................................................................................30 Figure 5-10: Discrete inputs - Alarm inputs - negative logic (Example).................................................................................31 Figure 5-11: Analog inputs ......................................................................................................................................................33 Figure 5-12: MPU ....................................................................................................................................................................34 Figure 5-13: MPU - Typical behavior of the input voltage sensitivity ....................................................................................34 Figure 5-14: Relay outputs - Controller outputs - CB activation .............................................................................................35 Figure 5-15: Relay outputs - Relay manager ...........................................................................................................................35 Figure 5-16: Analog outputs ....................................................................................................................................................36 Figure 5-17: Controller - Three-position controller .................................................................................................................36 Figure 5-18: Three-position controller .....................................................................................................................................37 Figure 5-19: Analog controller output n/f/P - Wiring and external jumper setting ..................................................................38 Figure 5-20: Analog controller output V/Q - Wiring and jumper setting.................................................................................38 Figure 5-21: Interface - Terminals ...........................................................................................................................................39 Figure 5-22: Interface - CAN bus shielding .............................................................................................................................39 Figure 5-23: Interfaces - CAN bus topology ............................................................................................................................40 © Woodward Page 5/46 Manual 37364A GCP-30 Packages - Genset Control Page 6/46 © Woodward Tables Table 1-1: Manual - Overview...................................................................................................................................................7 Table 3-1: Housing - panel cut-out ..........................................................................................................................................10 Table 5-1: Conversion chart - wire size ...................................................................................................................................24 Table 5-2: Terminal assignment - power supply......................................................................................................................24 Table 5-3: Terminal assignment - generator voltage measuring ..............................................................................................25 Table 5-4: Terminal assignment - busbar voltage measuring ..................................................................................................26 Table 5-5: Terminal assignment - mains voltage measuring....................................................................................................26 Table 5-6: Terminal assignment - generator current measuring ..............................................................................................27 Table 5-7: Terminal assignment - mains current measuring ....................................................................................................28 Table 5-8: Terminal assignment - mains real power measuring ..............................................................................................28 Table 5-9: Terminal assignment - control inputs .....................................................................................................................29 Table 5-10: Terminal assignment - alarm inputs positive logic ...............................................................................................30 Table 5-11: Terminal assignment - alarm inputs negative logic ..............................................................................................31 Table 5-12: Discrete inputs - operation mode selection ...........................................................................................................32 Table 5-13: Analog inputs - terminal assignment ....................................................................................................................33 Table 5-14: MPU - terminal assignment ..................................................................................................................................34 Table 5-15: MPU - input voltage .............................................................................................................................................34 Table 5-16: Relay outputs - terminal assignment ....................................................................................................................35 Table 5-17: Relay manager - terminal assignment...................................................................................................................35 Table 5-18: Analog outputs - terminal assignment ..................................................................................................................36 Table 5-19: Controller outputs - terminal assignment..............................................................................................................36 Table 5-20: Controller outputs - three-position .......................................................................................................................37 Table 5-21: Controller outputs - analog or PWM ....................................................................................................................38 Table 5-22: Controller outputs - analog ...................................................................................................................................38 Table 5-23: Interface - terminal assignment ............................................................................................................................39 Table 5-24: Maximum CAN bus length...................................................................................................................................40 Manual 37364A GCP-30 Packages - Genset Control Chapter 1. General Information Type English German GCP-31/32 Series GCP-31/32 Packages - Installation this manual Ö 37364 GR37364 GCP-31/32 Packages - Configuration 37365 GR37365 GCP-31/32 - Function/Operation 37238 GR37238 GCP-31/32 - Application 37240 GR37240 GCP-31/RPQ - Installation 37366 GR37366 GCP-31/RPQ - Configuration 37367 GR37367 Option SB - Caterpillar CCM coupling 37200 GR37200 Option SC09/SC10 - CAN bus coupling 37382 GR37382 Additional Manuals IKD 1 - Manual 37135 GR37135 Discrete expansion board with 8 discrete inputs and 8 relay outputs that can be coupled via the CAN bus to the control unit. As- sessment of the discrete inputs as well as control of the relay outputs is done via the control unit. LeoPC1 - Manual 37146 GR37146 PC program for visualization, configuration, remote control, data logging, language upload, alarm and user management and man- agement of the event recorder. This manual describes the use of the program. LeoPC1 - Manual 37164 GR37164 PC program for visualization, configuration, remote control, data logging, language upload, alarm and user management and man- agement of the event recorder. This manual describes the programming of the program. GW 4 - Manual 37133 GR37133 Gateway for transferring the CAN bus to any other interface or bus. ST 3 - Manual 37112 GR37112 Control to govern the air fuel ratio of a gas engine. The ratio will be directly measured though a Lambda probe and controlled to a configured value. Table 1-1: Manual - Overview Intended Use: This control is intended to be operated according to the guidelines described in this manual. The prerequisite for a proper and safe operation of the product is correct transportation, storage, and installation as well as careful operation and maintenance. NOTE This manual has been developed for a control fitted with all available options. Inputs/outputs, func- tions, configuration screens and other details described, which do not exist on your control may be ig- nored. The present manual has been prepared to enable the installation and commissioning of the control. Due to the large variety of parameter settings, it is not possible to cover every combination. The man- ual is therefore only a guide. In case of incorrect entries or a total loss of functions, the default settings can be taken from the list of parameters located in the appendix of the Configuration manual. © Woodward Page 7/46 Manual 37364A GCP-30 Packages - Genset Control Chapter 2. Electrostatic Discharge Awareness All electronic equipment is static-sensitive, some components more than others. To protect these components from static damage, you must take special precautions to minimize or eliminate electrostatic discharges. Follow these precautions when working with or near the control. 1. Before doing maintenance on the electronic control, discharge the static electricity on your body to ground by touching and holding a grounded metal object (pipes, cabinets, equipment, etc.). 2. Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic materials. Wear cotton or cotton-blend materials as much as possible because these do not store static electric charges as much as synthetics. 3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or folders, plastic bottles, and plastic ash trays) away from the control, the modules, and the work area as much as possible. 4. Opening the Control unit will void the warranty! Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary. If you must remove the PCB from the control cabinet, follow these precautions: • Make sure that the unit is completely de-energized (all connectors have to be pulled off). • Do not touch any part of the PCB except the edges. • Do not touch the electrical conductors, connectors, or components with conductive devices or with bare hands. • When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in until you are ready to install it. Immediately after removing the old PCB from the control unit, place it in the antistatic protective bag. WARNING To prevent damage to electronic components caused by improper handling, read and observe the pre- cautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules. Page 8/46 © Woodward Manual 37364A GCP-30 Packages - Genset Control Chapter 3. Housing Dimensions ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Configuration port 136.0 mm 1 50 90 83 Y1 Y5 48 X5X1 120 8.0 mm 111.0 mm136.0 mm54 24 60 25 144.0 mm32.0 mm 42.0 mm144.0 mm12.0 mm 2004-10-04 | GCP30 Dimensions g2ww-4504-ab.skf 128 0 10493 105 113 Figure 3-1: Housing - Dimensions © Woodward Page 9/46 Manual 37364A GCP-30 Packages - Genset Control Panel Cut-Out ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ h' h H b B b' Figure 3-2: Housing - Control panel cut-out Measure Description Tolerance H Height Total 144 mm --- h Panel cut-out 138 mm + 1.0 mm h' Housing dimension 136 mm B Width Total 144 mm --- b Panel cut-out 138 mm + 1.0 mm b' Housing dimension 136 mm Depth Total 118 --- Table 3-1: Housing - panel cut-out Page 10/46 © Woodward Manual 37364A GCP-30 Packages - Genset Control Side view ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ CabinetFront frameHousingMounting cones Figure 3-3: Side view - without clamps CabinetFront frameHousingMounting conesMounting clamp Figure 3-4: Side view - with clamps © Woodward Page 11/46 Manual 37364A GCP-30 Packages - Genset Control Installation ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ For installation into a door panel proceed as follows: 1. Panel cut-out Cut out the panel according to the dimensions in Figure 3-1. b h H B 2. Insert control into cut-out Insert the control into the panel cut-out. Verify that the control fits cor- rectly in the cut-out. If the panel cut-out is not big enough, enlarge it accordingly. Move housing into panel a) Attach clamp here3. Attach mounting clamps Rotate clamps according to the picture on the right until they snap into the mounting cones. b) Rotate clamp until frontnut of the clamp locks intofront cone 4. Screw clamps Tighten the screw clamps until the housing is pressed and fixed against the panel. Be careful not to over tighten the clamps, which can unsnap the front frame from the housing. If this happens remove the control from the panel and reattach the frame by pressing firmly against the housing. Screw down until thehousing fits into the panel Note: Using the gasket kit (P/N 8923-1043) increases the IP protection from IP42 to IP54 from front. Mounting of the gasket is described in the manual supplied with the gasket kit. Page 12/46 © Woodward Manual 37364A GCP-30 Packages - Genset Control Chapter 4. Wiring Diagrams - Overview WARNING A circuit breaker must be located near to the control and in a position easily accessible to the operator. This must also bear a sign identifying it as an isolating switch for the control. NOTE Connected inductances (e.g. operating current coils, undervoltage tripping devices, auxiliary contac- tors, and/or power contactors) must be wired with an appropriate interference protection. © Woodward Page 13/46 Manual 37364A GCP-30 Packages - Genset Control Page 14/46 © Woodward GCP-31/BPQ Package Mains current L1 CAN-L G5 0 Vdc 2006-02-08 | GCP30 Wiring Diagram g2ww-0606-ap.skf 2 1 4 3 9 6 7 8 A B C D E F G 5051522728535423244114154252642293031322021221112138910X1X2X3X4X5012356733343536606162636465666768697071727318194344454674757677787980818283909192s2 (l) s1 (k) L1 L2 s2 (l) s1 (k) s2 (l) s1 (k) s2 (l) s1 (k) 12/24 Vdc MPU input(Magnetic Pickup Unit)up to 13 additionalgensets (each viaone GCP-30)GATEWAYGW 4Control roomSPSPCDriveSubject to technical mocifications. Mains voltage L1 Mains voltage L3 Mains voltage L2GCBReply: GCB is open Automatic 1 Ready for operation Automatic 2 Multi function terminal Common (terminal 3/4/5/6/53/54) Common Alarm input 1(at sprinkler: emergency stop) Alarm input 2 Alarm input 3 Common Alarm input 4 Alarm input 5 orFiring speed detected by term. 62 Alarm input 6 or Mode selection locked Alarm input 7 orBreaker logic Alarm input 8 Alarm input 9 Alarm input 10 or'GCB close' without 'eng.mon.' Alarm input 11 or block emergency operation Alarm input 12 Alarm input 13 or'Idle mode' Alarm input 14 Alarm input 15 Alarm input 16 Start relay / Gas valve Starter Relay 1 Relay 2 Relay 3 Relay 4 Relay 5 Command: open GCB Generator current L1 Generator current L2 Generator current L3 Generator voltage L1 Generator voltage L2 Generator voltage L3 Command: close GCB The socket for the PC configuration is situated on theside of the unit. This is where the DPC has to be plugged in.CAN bus interfaceGuidance level GND - switching/inductive + GND CAN-H Termination Relay 6 3837Relay 7 4847Standard =Ignition / preglow Standard =Centralized alarm configurable during setup (NO/NC)#1#1 Battery or another power supply; terminal 7/33/60 is pos. or neg. signal#2NO/NC Isolated operation Meaning Terminal 54 Terminal 53 Isolated operation YES (e.g. 24 Vdc)NO (e.g. 0 Vdc) Mains parallel operation NO (e.g. 0 Vdc)YES (e.g. 24 Vdc)4039Busbar voltage Battery#2 #2Battery Battery#2 #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC starting firmware version 4.2xxx3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l) s1 (K) s2 (L)s2 (l) s1 (K)s1 (k) s2 (L)s2 (l) s1 (k) L2 L1 L3 3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l)L1 2 GCP-31/BPQPWMquasi-continuous controllerwith analog outputs (three-positioncontroller via relay manager;ext. R/C connection!)DCcurrentDCvoltagePWMSPEED / POWER(analog controller output) VOLTAGE / POW. FAC.(analog controller output)GNDGNDGNDPWMUAN/CIAGNDUAGNDN/CIACommon =terminal 7Common = terminal 7 Aim at mains paralleloperation with MCB "EXTERNAL" See funct. table above on the left Functional table for terminals 53/54: Command: open external CB YES (e.g. 24 Vdc)YES (e.g. 24 Vdc)17Command: close external CB 16Neutral / chassis ground +- Figure 4-1: Wiring diagram GCP-31/BPQ Package Manual 37364A GCP-30 Packages - Genset Control © Woodward Page 15/46 GCP-31/XPD Package Mains current L1 CAN-L G5 0 Vdc 2006-02-08 | GCP30 Wiring Diagram g2ww-0606-ap.skf 2 1 4 3 9 6 7 8 A B C D E F G 5051522728535423244114154252642293031322021221112138910X1X2X3X4X5012356733343536606162636465666768697071727318194344454674757677787980818283909192s2 (l) s1 (k) L1 L2 s2 (l) s1 (k) s2 (l) s1 (k) s2 (l) s1 (k) 12/24 Vdc MPU input(Magnetic Pickup Unit)up to 13 additionalgensets (each viaone GCP-30)GATEWAYGW 4Control roomSPSPCDriveSubject to technical mocifications. Mains voltage L1 Mains voltage L3 Mains voltage L2GCBReply: GCB is open Automatic 1 Ready for operation Automatic 2 Multi function terminal Common (terminal 3/4/5/6/53/54) Common Alarm input 1(at sprinkler: emergency stop) Alarm input 2 Alarm input 3 Common Alarm input 4 Alarm input 5 orFiring speed detected by term. 62 Alarm input 6 or Mode selection locked Alarm input 7 orBreaker logic Alarm input 8 Alarm input 9 Alarm input 10 or'GCB close' without 'eng.mon.' Alarm input 11 or block emergency operation Alarm input 12 Alarm input 13 or'Idle mode' Alarm input 14 Alarm input 15 Alarm input 16 Start relay / Gas valve Starter Relay 1 Relay 2 Relay 3 Relay 4 Relay 5 Command: open GCB Generator current L1 Generator current L2 Generator current L3 Generator voltage L1 Generator voltage L2 Generator voltage L3 Command: close GCB The socket for the PC configuration is situated on theside of the unit. This is where the DPC has to be plugged in.CAN bus interfaceGuidance level GND - switching/inductive + GND CAN-H Termination Relay 6 3837Relay 7 4847Standard =Ignition / preglow Standard =Centralized alarm configurable during setup (NO/NC)#1#1 Battery or another power supply; terminal 7/33/60 is pos. or neg. signal#2NO/NC Isolated operation Meaning Terminal 54 Terminal 53 Isolated operation YES (e.g. 24 Vdc)NO (e.g. 0 Vdc) Mains parallel operation NO (e.g. 0 Vdc)YES (e.g. 24 Vdc)4039Busbar voltage Battery#2 #2Battery Battery#2 #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC starting firmware version 4.2xxxGCP-31/XPD3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l) s1 (K) s2 (L)s2 (l) s1 (K)s1 (k) s2 (L)s2 (l) s1 (k) L2 L1 L3 3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l)L1 2 VOLTAGE / POW. FAC.(three-position controller) raise lower raise lower SPEED / POWER(three-position controller)10510610710810911011111211312012112212393949596979899100101102103104GND GND AI AI Analog outputmanagerAnalog output0/4 to 20 mA Analog input 1 [T1]0/4 to 20 mA Analog input 2 [T2]0/4 to 20 mA Analog input 3 [T3]0/4 to 20 mA Analog input 4 [T4]Pt100 Analog input 5 [T5]Pt100 Analog input 7 [T7]VDO Temperature 30 to 120 °C (0 to 380 Ohm) or 86 to 248 °F (0 to 380 Ohm) Analog input 6 [T6]VDO Pressure 0 to 5/10 bar (0 to 180 Ohm)or 0 to 72.5/145 psi (0 to 180 Ohm)max. 8xLS 4Common =terminal 7Common = terminal 7 Aim at mains paralleloperation with MCB "EXTERNAL"124127128Common Operation mode STOP Operation mode AUTOMATIC #1NO/NC #1NO/NC Battery#2 See funct. table above on the left Functional table for terminals 53/54: Command: open external CB YES (e.g. 24 Vdc)YES (e.g. 24 Vdc)17Command: close external CB 16Neutral / chassis ground +- Figure 4-2: Wiring diagram GCP-31/XPD Package Manual 37364A GCP-30 Packages - Genset Control Page 16/46 © Woodward GCP-31/XPQ Package Mains current L1 CAN-L G5 0 Vdc 2006-02-08 | GCP30 Wiring Diagram g2ww-0606-ap.skf 2 1 4 3 9 6 7 8 A B C D E F G 5051522728535423244114154252642293031322021221112138910X1X2X3X4X5012356733343536606162636465666768697071727318194344454674757677787980818283909192s2 (l) s1 (k) L1 L2 s2 (l) s1 (k) s2 (l) s1 (k) s2 (l) s1 (k) 12/24 Vdc MPU input(Magnetic Pickup Unit)up to 13 additionalgensets (each viaone GCP-30)GATEWAYGW 4Control roomSPSPCDriveSubject to technical mocifications. Mains voltage L1 Mains voltage L3 Mains voltage L2GCBReply: GCB is open Automatic 1 Ready for operation Automatic 2 Multi function terminal Common (terminal 3/4/5/6/53/54) Common Alarm input 1(at sprinkler: emergency stop) Alarm input 2 Alarm input 3 Common Alarm input 4 Alarm input 5 orFiring speed detected by term. 62 Alarm input 6 or Mode selection locked Alarm input 7 orBreaker logic Alarm input 8 Alarm input 9 Alarm input 10 or'GCB close' without 'eng.mon.' Alarm input 11 or block emergency operation Alarm input 12 Alarm input 13 or'Idle mode' Alarm input 14 Alarm input 15 Alarm input 16 Start relay / Gas valve Starter Relay 1 Relay 2 Relay 3 Relay 4 Relay 5 Command: open GCB Generator current L1 Generator current L2 Generator current L3 Generator voltage L1 Generator voltage L2 Generator voltage L3 Command: close GCB The socket for the PC configuration is situated on theside of the unit. This is where the DPC has to be plugged in.CAN bus interfaceGuidance level GND - switching/inductive + GND CAN-H Termination Relay 6 3837Relay 7 4847Standard =Ignition / preglow Standard =Centralized alarm configurable during setup (NO/NC)#1#1 Battery or another power supply; terminal 7/33/60 is pos. or neg. signal#2NO/NC Isolated operation Meaning Terminal 54 Terminal 53 Isolated operation YES (e.g. 24 Vdc)NO (e.g. 0 Vdc) Mains parallel operation NO (e.g. 0 Vdc)YES (e.g. 24 Vdc)4039Busbar voltage Battery#2 #2Battery Battery#2 #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC starting firmware version 4.2xxxGCP-31/XPQ3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l) s1 (K) s2 (L)s2 (l) s1 (K)s1 (k) s2 (L)s2 (l) s1 (k) L2 L1 L3 3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l)L1 2 PWMquasi-continuous controllerwith analog outputs (three-positioncontroller via relay manager;ext. R/C connection!)DCcurrentDCvoltagePWMSPEED / POWER(analog controller output) VOLTAGE / POW. FAC.(analog controller output)GNDGNDGNDPWMUAN/CIAGNDUAGNDN/CIAmax. 8xLS 410510610710810911011111211312012112212393949596979899100101102103104GND GND AI AI Analog outputmanagerAnalog output0/4 to 20 mA Analog input 1 [T1]0/4 to 20 mA Analog input 2 [T2]0/4 to 20 mA Analog input 3 [T3]0/4 to 20 mA Analog input 4 [T4]Pt100 Analog input 5 [T5]Pt100 Analog input 7 [T7]VDO Temperature 30 to 120 °C (0 to 380 Ohm) or 86 to 248 °F (0 to 380 Ohm) Analog input 6 [T6]VDO Pressure 0 to 5/10 bar (0 to 180 Ohm)or 0 to 72.5/145 psi (0 to 180 Ohm)Common =terminal 7Common = terminal 7 Aim at mains paralleloperation with MCB "EXTERNAL"124127128#1NO/NC #1NO/NC #2Common Operation mode STOP Operation mode AUTOMATIC Battery See funct. table above on the left Functional table for terminals 53/54: Command: open external CB YES (e.g. 24 Vdc)YES (e.g. 24 Vdc)17Command: close external CB 16Neutral / chassis ground +- Figure 4-3: Wiring diagram GCP-31/XPQ Package Manual 37364A GCP-30 Packages - Genset Control © Woodward Page 17/46 GCP-31/XPQ+SB03 Package Mains current L1 CAN-L G5 0 Vdc 2006-02-08 | GCP30 Wiring Diagram g2ww-0606-ap.skf 2 1 4 3 9 6 7 8 A B C D E F G 5051522728535423244114154252642293031322021221112138910X1X2X3X4X5012356733343536606162636465666768697071727318194344454674757677787980818283909192s2 (l) s1 (k) L1 L2 s2 (l) s1 (k) s2 (l) s1 (k) s2 (l) s1 (k) 12/24 Vdc MPU input(Magnetic Pickup Unit)up to 13 additionalgensets (each viaone GCP-30)GATEWAYGW 4Control roomSPSPCDriveSubject to technical mocifications. Mains voltage L1 Mains voltage L3 Mains voltage L2GCBReply: GCB is open Automatic 1 Ready for operation Automatic 2 Multi function terminal Common (terminal 3/4/5/6/53/54) Common Alarm input 1(at sprinkler: emergency stop) Alarm input 2 Alarm input 3 Common Alarm input 4 Alarm input 5 orFiring speed detected by term. 62 Alarm input 6 or Mode selection locked Alarm input 7 orBreaker logic Alarm input 8 Alarm input 9 Alarm input 10 or'GCB close' without 'eng.mon.' Alarm input 11 or block emergency operation Alarm input 12 Alarm input 13 or'Idle mode' Alarm input 14 Alarm input 15 Alarm input 16 Start relay / Gas valve Starter Relay 1 Relay 2 Relay 3 Relay 4 Relay 5 Command: open GCB Generator current L1 Generator current L2 Generator current L3 Generator voltage L1 Generator voltage L2 Generator voltage L3 Command: close GCB The socket for the PC configuration is situated on theside of the unit. This is where the DPC has to be plugged in.CAN bus interfaceGuidance level GND - switching/inductive + GND CAN-H Termination Relay 6 3837Relay 7 4847Standard =Ignition / preglow Standard =Centralized alarm configurable during setup (NO/NC)#1#1 Battery or another power supply; terminal 7/33/60 is pos. or neg. signal#2NO/NC Isolated operation Meaning Terminal 54 Terminal 53 Isolated operation YES (e.g. 24 Vdc)NO (e.g. 0 Vdc) Mains parallel operation NO (e.g. 0 Vdc)YES (e.g. 24 Vdc)4039Busbar voltage Battery#2 #2Battery Battery#2 #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC starting firmware version 4.2xxx3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l) s1 (K) s2 (L)s2 (l) s1 (K)s1 (k) s2 (L)s2 (l) s1 (k) L2 L1 L3 3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l)L1 2max. 8xLS 4GCP-31/XPQ+SB03PWMquasi-continuous controllerwith analog outputs (three-positioncontroller via relay manager;ext. R/C connection!)DCcurrentDCvoltagePWMSPEED / POWER(analog controller output) VOLTAGE / POW. FAC.(analog controller output)GNDGNDGNDPWMUAN/CIAGNDUAGNDN/CIA105106107108109110111112113Y1Y2Y3Y4Y512012112212393949596979899100101102103104GND GND AI AI Analog outputmanagerRS232 interfaceEngine level Analog output0/4 to 20 mA GND CTS TxDCCM Analog input 1 [T1]0/4 to 20 mA Analog input 2 [T2]0/4 to 20 mA Analog input 3 [T3]0/4 to 20 mA Analog input 4 [T4]Pt100 Analog input 5 [T5]Pt100 Analog input 7 [T7]VDO Temperature 30 to 120 °C (0 to 380 Ohm) or 86 to 248 °F (0 to 380 Ohm) Analog input 6 [T6]VDO Pressure 0 to 5/10 bar (0 to 180 Ohm)or 0 to 72.5/145 psi (0 to 180 Ohm) RTS RxD Common =terminal 7Common = terminal 7 Aim at mains paralleloperation with MCB "EXTERNAL"124127128#1NO/NC #1NO/NC #2Common Operation mode STOP Operation mode AUTOMATIC Battery See funct. table above on the left Functional table for terminals 53/54: Command: open external CB YES (e.g. 24 Vdc)YES (e.g. 24 Vdc)17Command: close external CB 16Neutral / chassis ground +- Figure 4-4: Wiring diagram GCP-31/XPQ+SB03 Package Manual 37364A GCP-30 Packages - Genset Control Page 18/46 © Woodward GCP-31/XPQ+SC10 Package max. 8xLS 4Mains current L1 CAN-L G5 0 Vdc 2007-01-18 | GCP30 Wiring Diagram g2ww-0307-ap.skf 2 1 4 3 9 6 7 8 A B C D E F G 5051522728535423244114154252642293031322021221112138910X1X2X3X4X5012356733343536606162636465666768697071727318194344454674757677787980818283909192s2 (l) s1 (k) L1 L2 s2 (l) s1 (k) s2 (l) s1 (k) s2 (l) s1 (k) 12/24 Vdc MPU input(Magnetic Pickup Unit)up to 13 additionalgensets (each viaone GCP-30)GATEWAYGW 4Control roomSPSPCDriveSubject to technical mocifications. Mains voltage L1 Mains voltage L3 Mains voltage L2GCBReply: GCB is open Automatic 1 Ready for operation Automatic 2 Multi function terminal Common (terminal 3/4/5/6/53/54) Common Alarm input 1 (at sprinkler: emergency stop) Alarm input 2 Alarm input 3 Common Alarm input 4 Alarm input 5 orFiring speed detected by term. 62 Alarm input 6 orMode selection locked Alarm input 7 orBreaker logic Alarm input 8 Alarm input 9 Alarm input 10 or'GCB close' without 'eng.mon.' Alarm input 11 orblock emergency operation Alarm input 12 Alarm input 13 or'Idle mode' Alarm input 14 Alarm input 15 Alarm input 16 Start relay / Gas valve Starter Relay 1 Relay 2 Relay 3 Relay 4 Relay 5 Command: open GCB Generator current L1 Generator current L2 Generator current L3 Generator voltage L1 Generator voltage L2 Generator voltage L3 Command: close GCB The socket for the PC configuration is situated on theside of the unit. This is where the DPC has to be plugged in.CAN bus interfaceGuidance level GND - switching/inductive + GND CAN-H Termination Relay 6 3837Relay 7 4847Standard =Ignition / preglow Standard =Centralized alarm configurable during setup (NO/NC)#1#1 Battery or another power supply; terminal 7/33/60 is pos. or neg. signal#2NO/NC Isolated operation Meaning Terminal 54 Terminal 53 Isolated operation YES (e.g. 24 Vdc)NO (e.g. 0 Vdc) Mains parallel operation NO (e.g. 0 Vdc)YES (e.g. 24 Vdc)4039Busbar voltage Battery#2 #2Battery Battery#2 #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC starting firmware version 4.2xxxGCP-31/XPQ+SC103/(4)3 s1 (K)s1 (k) s2 (L)s2 (l) s1 (K) s2 (L)s2 (l) s1 (K)s1 (k) s2 (L)s2 (l) s1 (k) L2 L1 L3 3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l)L1 2 PWMquasi-continuous controllerwith analog outputs (three-positioncontroller via relay manager;ext. R/C connection!)DCcurrentDCvoltagePWMSPEED / POWER(analog controller output) VOLTAGE / POW. FAC.(analog controller output)GNDGNDGNDPWMUAN/CIAGNDUAGNDN/CIA105106107108109110111112113Y1Y2Y3Y4Y512012112212393949596979899100101102103104GND GND AI AI Analog outputmanagerCAN bus interfaceEngine level Analog output0/4 to 20 mA GND CAN-H CAN-L Terminationexternalextension Analog input 1 [T1]0/4 to 20 mA Analog input 2 [T2]0/4 to 20 mA Analog input 3 [T3]0/4 to 20 mA Analog input 4 [T4]Pt100 Analog input 5 [T5]Pt100 Analog input 7 [T7]VDO Temperature 30 to 120 °C (0 to 380 Ohm)or 86 to 248 °F (0 to 380 Ohm) Analog input 6 [T6]VDO Pressure 0 to 5/10 bar (0 to 180 Ohm)or 0 to 72.5/145 psi (0 to 180 Ohm)Common =terminal 7Common = terminal 7 Aim at mains paralleloperation with MCB "EXTERNAL"124127128#1NO/NC #1NO/NC #2Common Operation mode STOP Operation mode AUTOMATIC Battery See funct. table above on the left Functional table for terminals 53/54: Command: open external CB YES (e.g. 24 Vdc)YES (e.g. 24 Vdc)17Command: close external CB 16Neutral / chassis ground +- Figure 4-5: Wiring diagram GCP-31/XPQ+SC10 Package Manual 37364A GCP-30 Packages - Genset Control © Woodward Page 19/46 GCP-32/BPQ Package 17Mains current L1 CAN-L G5 0 Vdc 2006-02-08 | GCP30 Wiring Diagram g2ww-0606-ap.skf 2 1 4 3 9 6 7 8 A B C D E F G 5051522728535423244114154252642293031322021221112138910X1X2X3X4X5012356733343536606162636465666768697071727318194344454674757677787980818283909192s2 (l) s1 (k) L1 L2 s2 (l) s1 (k) s2 (l) s1 (k) s2 (l) s1 (k) 12/24 Vdc MPU input(Magnetic Pickup Unit)up to 13 additionalgensets (each viaone GCP-30)GATEWAYGW 4Control roomSPSPCDriveSubject to technical mocifications. Mains voltage L1 Mains voltage L3 Mains voltage L2GCBReply: GCB is open Automatic 1 Ready for operation Automatic 2 Multi function terminal Common (terminal 3/4/5/6/53/54) Common Alarm input 1(at sprinkler: emergency stop) Alarm input 2 Alarm input 3 Common Alarm input 4 Alarm input 5 orFiring speed detected by term. 62 Alarm input 6 or Mode selection locked Alarm input 7 orBreaker logic Alarm input 8 Alarm input 9 Alarm input 10 or'GCB close' without 'eng.mon.' Alarm input 11 or block emergency operation Alarm input 12 Alarm input 13 or'Idle mode' Alarm input 14 Alarm input 15 Alarm input 16 Start relay / Gas valve Starter Relay 1 Relay 2 Relay 3 Relay 4 Relay 5 Command: open GCB Generator current L1 Generator current L2 Generator current L3 Generator voltage L1 Generator voltage L2 Generator voltage L3 Command: close GCB The socket for the PC configuration is situated on theside of the unit. This is where the DPC has to be plugged in.CAN bus interfaceGuidance level GND - switching/inductive + GND CAN-H Termination Relay 6 3837Relay 7 4847Standard =Ignition / preglow Standard =Centralized alarm configurable during setup (NO/NC)#1#1 Battery or another power supply; terminal 7/33/60 is pos. or neg. signal#2NO/NC 401639MCBReply: MCB is open Command: close MCB Enable MCB Command: open MCB Busbar voltage Battery#2 #2Battery Battery#2 #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC starting firmware version 4.2xxx3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l) s1 (K) s2 (L)s2 (l) s1 (K)s1 (k) s2 (L)s2 (l) s1 (k) L2 L1 L3 3/(4)3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l)L1 2 GCP-32/BPQPWMquasi-continuous controllerwith analog outputs (three-positioncontroller via relay manager;ext. R/C connection!)DCcurrentDCvoltagePWMSPEED / POWER(analog controller output) VOLTAGE / POW. FAC.(analog controller output)GNDGNDGNDPWMUAN/CIAGNDUAGNDN/CIACommon =terminal 7Common = terminal 7 1716Neutral / chassis ground +- Figure 4-6: Wiring diagram GCP-32/BPQ Package Manual 37364A GCP-30 Packages - Genset Control Page 20/46 © Woodward GCP-32/XPD Package 17Mains current L1 CAN-L G5 0 Vdc 2006-02-08 | GCP30 Wiring Diagram g2ww-0606-ap.skf 2 1 4 3 9 6 7 8 A B C D E F G 5051522728535423244114154252642293031322021221112138910X1X2X3X4X5012356733343536606162636465666768697071727318194344454674757677787980818283909192s2 (l) s1 (k) L1 L2 s2 (l) s1 (k) s2 (l) s1 (k) s2 (l) s1 (k) 12/24 Vdc MPU input(Magnetic Pickup Unit)up to 13 additionalgensets (each viaone GCP-30)GATEWAYGW 4Control roomSPSPCDriveSubject to technical mocifications. Mains voltage L1 Mains voltage L3 Mains voltage L2GCBReply: GCB is open Automatic 1 Ready for operation Automatic 2 Multi function terminal Common (terminal 3/4/5/6/53/54) Common Alarm input 1(at sprinkler: emergency stop) Alarm input 2 Alarm input 3 Common Alarm input 4 Alarm input 5 orFiring speed detected by term. 62 Alarm input 6 or Mode selection locked Alarm input 7 orBreaker logic Alarm input 8 Alarm input 9 Alarm input 10 or'GCB close' without 'eng.mon.' Alarm input 11 or block emergency operation Alarm input 12 Alarm input 13 or'Idle mode' Alarm input 14 Alarm input 15 Alarm input 16 Start relay / Gas valve Starter Relay 1 Relay 2 Relay 3 Relay 4 Relay 5 Command: open GCB Generator current L1 Generator current L2 Generator current L3 Generator voltage L1 Generator voltage L2 Generator voltage L3 Command: close GCB The socket for the PC configuration is situated on theside of the unit. This is where the DPC has to be plugged in.CAN bus interfaceGuidance level GND - switching/inductive + GND CAN-H Termination Relay 6 3837Relay 7 4847Standard =Ignition / preglow Standard =Centralized alarm configurable during setup (NO/NC)#1#1 Battery or another power supply; terminal 7/33/60 is pos. or neg. signal#2NO/NC 401639MCBReply: MCB is open Command: close MCB Enable MCB Command: open MCB Busbar voltage Battery#2 #2Battery Battery#2 #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC starting firmware version 4.2xxxGCP-32/XPD3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l) s1 (K) s2 (L)s2 (l) s1 (K)s1 (k) s2 (L)s2 (l) s1 (k) L2 L1 L3 3/(4)3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l)L1 2 VOLTAGE / POW. FAC.(three-position controller) raise lower raise lower SPEED / POWER(three-position controller)10510610710810911011111211312012112212393949596979899100101102103104GND GND AI AI Analog outputmanagerAnalog output0/4 to 20 mA Analog input 1 [T1]0/4 to 20 mA Analog input 2 [T2]0/4 to 20 mA Analog input 3 [T3]0/4 to 20 mA Analog input 4 [T4]Pt100 Analog input 5 [T5]Pt100 Analog input 7 [T7]VDO Temperature 30 to 120 °C (0 to 380 Ohm)or 86 to 248 °F (0 to 380 Ohm) Analog input 6 [T6]VDO Pressure 0 to 5/10 bar (0 to 180 Ohm)or 0 to 72.5/145 psi (0 to 180 Ohm)Common =terminal 7Common = terminal 7 124127128#1NO/NC #1NO/NC #2Common Operation mode STOP Operation mode AUTOMATIC Battery 1716Neutral / chassis ground +- Figure 4-7: Wiring diagram GCP-32/XPD Package Manual 37364A GCP-30 Packages - Genset Control © Woodward Page 21/46 GCP-32/XPQ Package 12017Mains current L1 CAN-L G5 0 Vdc 2006-02-08 | GCP30 Wiring Diagram g2ww-0606-ap.skf 2 1 4 3 9 6 7 8 A B C D E F G 5051522728535423244114154252642293031322021221112138910X1X2X3X4X5012356733343536606162636465666768697071727318194344454674757677787980818283909192s2 (l) s1 (k) L1 L2 s2 (l) s1 (k) s2 (l) s1 (k) s2 (l) s1 (k) 12/24 Vdc MPU input(Magnetic Pickup Unit)up to 13 additionalgensets (each viaone GCP-30)GATEWAYGW 4Control roomSPSPCDriveSubject to technical mocifications. Mains voltage L1 Mains voltage L3 Mains voltage L2GCBReply: GCB is open Automatic 1 Ready for operation Automatic 2 Multi function terminal Common (terminal 3/4/5/6/53/54) Common Alarm input 1(at sprinkler: emergency stop) Alarm input 2 Alarm input 3 Common Alarm input 4 Alarm input 5 orFiring speed detected by term. 62 Alarm input 6 or Mode selection locked Alarm input 7 orBreaker logic Alarm input 8 Alarm input 9 Alarm input 10 or'GCB close' without 'eng.mon.' Alarm input 11 or block emergency operation Alarm input 12 Alarm input 13 or'Idle mode' Alarm input 14 Alarm input 15 Alarm input 16 Start relay / Gas valve Starter Relay 1 Relay 2 Relay 3 Relay 4 Relay 5 Command: open GCB Generator current L1 Generator current L2 Generator current L3 Generator voltage L1 Generator voltage L2 Generator voltage L3 Command: close GCB The socket for the PC configuration is situated on theside of the unit. This is where the DPC has to be plugged in.CAN bus interfaceGuidance level GND - switching/inductive + GND CAN-H Termination Relay 6 3837Relay 7 4847Standard =Ignition / preglow Standard =Centralized alarm configurable during setup (NO/NC)#1#1 Battery or another power supply; terminal 7/33/60 is pos. or neg. signal#2NO/NC 401639MCBReply: MCB is open Command: close MCB Enable MCB Command: open MCB Busbar voltage Battery#2 #2Battery Battery#2 #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC starting firmware version 4.2xxxGCP-32/XPQ3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l) s1 (K) s2 (L)s2 (l) s1 (K)s1 (k) s2 (L)s2 (l) s1 (k) L2 L1 L3 3/(4)3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l)L1 2 PWMquasi-continuous controllerwith analog outputs (three-positioncontroller via relay manager;ext. R/C connection!)DCcurrentDCvoltagePWMSPEED / POWER(analog controller output) VOLTAGE / POW. FAC.(analog controller output)GNDGNDGNDPWMUAN/CIAGNDUAGNDN/CIA10510610710810911011111211312112212393949596979899100101102103104GND GND AI AI Analog outputmanagerAnalog output0/4 to 20 mA Analog input 1 [T1]0/4 to 20 mA Analog input 2 [T2]0/4 to 20 mA Analog input 3 [T3]0/4 to 20 mA Analog input 4 [T4]Pt100 Analog input 5 [T5]Pt100 Analog input 7 [T7]VDO Temperature 30 to 120 °C (0 to 380 Ohm)or 86 to 248 °F (0 to 380 Ohm) Analog input 6 [T6]VDO Pressure 0 to 5/10 bar (0 to 180 Ohm)or 0 to 72.5/145 psi (0 to 180 Ohm)Common =terminal 7Common = terminal 7 124127128#1NO/NC #1NO/NC #2Common Operation mode STOP Operation mode AUTOMATIC Battery 1716Neutral / chassis ground +- Figure 4-8: Wiring diagram GCP-32/XPQ Package Manual 37364A GCP-30 Packages - Genset Control Page 22/46 © Woodward GCP-32/XPQ+SB03 Package 17Mains current L1 CAN-L G5 0 Vdc 2006-02-08 | GCP30 Wiring Diagram g2ww-0606-ap.skf 2 1 4 3 9 6 7 8 A B C D E F G 5051522728535423244114154252642293031322021221112138910X1X2X3X4X5012356733343536606162636465666768697071727318194344454674757677787980818283909192s2 (l) s1 (k) L1 L2 s2 (l) s1 (k) s2 (l) s1 (k) s2 (l) s1 (k) 12/24 Vdc MPU input(Magnetic Pickup Unit)up to 13 additionalgensets (each viaone GCP-30)GATEWAYGW 4Control roomSPSPCDriveSubject to technical mocifications. Mains voltage L1 Mains voltage L3 Mains voltage L2GCBReply: GCB is open Automatic 1 Ready for operation Automatic 2 Multi function terminal Common (terminal 3/4/5/6/53/54) Common Alarm input 1(at sprinkler: emergency stop) Alarm input 2 Alarm input 3 Common Alarm input 4 Alarm input 5 orFiring speed detected by term. 62 Alarm input 6 or Mode selection locked Alarm input 7 orBreaker logic Alarm input 8 Alarm input 9 Alarm input 10 or'GCB close' without 'eng.mon.' Alarm input 11 or block emergency operation Alarm input 12 Alarm input 13 or'Idle mode' Alarm input 14 Alarm input 15 Alarm input 16 Start relay / Gas valve Starter Relay 1 Relay 2 Relay 3 Relay 4 Relay 5 Command: open GCB Generator current L1 Generator current L2 Generator current L3 Generator voltage L1 Generator voltage L2 Generator voltage L3 Command: close GCB The socket for the PC configuration is situated on theside of the unit. This is where the DPC has to be plugged in.CAN bus interfaceGuidance level GND - switching/inductive + GND CAN-H Termination Relay 6 3837Relay 7 4847Standard =Ignition / preglow Standard =Centralized alarm configurable during setup (NO/NC)#1#1 Battery or another power supply; terminal 7/33/60 is pos. or neg. signal#2NO/NC 401639MCBReply: MCB is open Command: close MCB Enable MCB Command: open MCB Busbar voltage Battery#2 #2Battery Battery#2 #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC starting firmware version 4.2xxx3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l) s1 (K) s2 (L)s2 (l) s1 (K)s1 (k) s2 (L)s2 (l) s1 (k) L2 L1 L3 3/(4)3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l)L1 2 105106107108109110111112113Y1Y2Y3Y4Y512012112212393949596979899100101102103104GND GND AI AI Analog outputmanagerRS232 interfaceEngine level Analog output0/4 to 20 mA GND CTS TxDCCM PWMAnalog input 1 [T1]0/4 to 20 mA Analog input 2 [T2]0/4 to 20 mA Analog input 3 [T3]0/4 to 20 mA Analog input 4 [T4]Pt100 Analog input 5 [T5]Pt100 Analog input 7 [T7]VDO Temperature 30 to 120 °C (0 to 380 Ohm)or 86 to 248 °F (0 to 380 Ohm) Analog input 6 [T6]VDO Pressure 0 to 5/10 bar (0 to 180 Ohm)or 0 to 72.5/145 psi (0 to 180 Ohm)quasi-continuous controllerwith analog outputs (three-positioncontroller via relay manager;ext. R/C connection!)DCcurrentDCvoltagePWMSPEED / POWER(analog controller output) VOLTAGE / POW. FAC.(analog controller output)GNDGNDGNDPWMUAN/CIAGCP-32/XPQ+SB03GNDUAGNDN/CIARTS RxD Common =terminal 7Common = terminal 7 124127128#1NO/NC #1NO/NC #2Common Operation mode STOP Operation mode AUTOMATIC Battery 1716Neutral / chassis ground +- Figure 4-9: Wiring diagram GCP-32/XPQ+SB03 Package Manual 37364A GCP-30 Packages - Genset Control © Woodward Page 23/46 GCP-32/XPQ+SC10 Package 17Mains current L1 CAN-L G5 0 Vdc 2007-01-18 | GCP30 Wiring Diagram g2ww-0307-ap.skf 2 1 4 3 9 6 7 8 A B C D E F G 5051522728535423244114154252642293031322021221112138910105106107108109110111112113X1X2X3X4X5Y1Y2Y3Y4Y512012112212301235673334353660616263646566676869707172731819434445467475767778798081828390919293949596979899100101102103104GND s2 (l) s1 (k) L1 L2 s2 (l) s1 (k) s2 (l) s1 (k) s2 (l) s1 (k) GND AI AI 12/24 Vdc MPU input(Magnetic Pickup Unit)up to 13 additionalgensets (each viaone GCP-30)Analog outputmanagerGATEWAYGW 4Control roomSPSPCDriveSubject to technical mocifications. Mains voltage L1 Mains voltage L3 Mains voltage L2GCBReply: GCB is open Automatic 1 Ready for operation Automatic 2 Multi function terminal Common (terminal 3/4/5/6/53/54) Common Alarm input 1 (at sprinkler: emergency stop) Alarm input 2 Alarm input 3 Common Alarm input 4 Alarm input 5 orFiring speed detected by term. 62 Alarm input 6 orMode selection locked Alarm input 7 orBreaker logic Alarm input 8 Alarm input 9 Alarm input 10 or'GCB close' without 'eng.mon.' Alarm input 11 orblock emergency operation Alarm input 12 Alarm input 13 or'Idle mode' Alarm input 14 Alarm input 15 Alarm input 16 Start relay / Gas valve Starter Relay 1 Relay 2 Relay 3 Relay 4 Relay 5 Command: open GCB Generator current L1 Generator current L2 Generator current L3 Generator voltage L1 Generator voltage L2 Generator voltage L3 CAN bus interfaceEngine level Analog output0/4 to 20 mA Command: close GCB The socket for the PC configuration is situated on theside of the unit. This is where the DPC has to be plugged in.CAN bus interfaceGuidance level GND - switching/inductive + GND CAN-H Termination GND CAN-H CAN-L Termination Relay 6 3837Relay 7 4847Standard =Ignition / preglow Standard =Centralized alarmexternalextension PWMconfigurable during setup (NO/NC)#1#1 Battery or another power supply; terminal 7/33/60 is pos. or neg. signal#2NO/NC 401639MCBReply: MCB is open Command: close MCB Enable MCB Command: open MCB Busbar voltage Analog input 1 [T1]0/4 to 20 mA Analog input 2 [T2]0/4 to 20 mA Analog input 3 [T3]0/4 to 20 mA Analog input 4 [T4]Pt100 Analog input 5 [T5]Pt100 Analog input 7 [T7]VDO Temperature 30 to 120 °C (0 to 380 Ohm)or 86 to 248 °F (0 to 380 Ohm) Analog input 6 [T6]VDO Pressure 0 to 5/10 bar (0 to 180 Ohm)or 0 to 72.5/145 psi (0 to 80 Ohm)quasi-continuous controllerwith analog outputs (three-positioncontroller via relay manager;ext. R/C connection!)DCcurrentDCvoltagePWMSPEED / POWER(analog controller output) VOLTAGE / POW. FAC.(analog controller output) Battery#2 #2Battery Battery#2 #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC #1NO/NC starting firmware version 4.2xxxGNDGNDGNDPWMUAN/CIAGCP-32/XPQ+SC10GNDUAGNDN/CIA3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l) s1 (K) s2 (L)s2 (l) s1 (K)s1 (k) s2 (L)s2 (l) s1 (k) L2 L1 L3 3/(4)3/(4)3 s1 (K)s1 (k) s2 (L)s2 (l)L1 2 Common =terminal 7Common = terminal 7 124127128#1NO/NC #1NO/NC #2Common Operation mode STOP Operation mode AUTOMATIC Battery 1716Neutral / chassis ground +- Figure 4-10: Wiring diagram GCP-32/XPQ+SC10 Package Manual 37364A GCP-30 Packages - Genset Control Chapter 5. Connectors - Details WARNING All technical data and ratings indicated in this chapter are not definite! Only the values indicated in Technical Data on page 42 are valid! The following chart may be used to convert square millimeters [mm²] to AWG and vice versa: AWG mm² AWG mm² AWG mm² AWG mm² AWG mm² AWG mm² 30 0.05 21 0.38 14 2.5 4 25 3/0 95 600MCM 300 28 0.08 20 0.5 12 4 2 35 4/0 120 750MCM 400 26 0.14 18 0.75 10 6 1 50 300MCM 150 1000MCM 500 24 0.25 17 1.0 8 10 1/0 55 350MCM 185 22 0.34 16 1.5 6 16 2/0 70 500MCM 240 Table 5-1: Conversion chart - wire size Power Supply ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ 012N 0 Vdc D1 C1 C1 = 47,000 uF / 40 V D1 = P600M for 12 V DC systems Power supply 9.5 to 32 V DC (in normal operation)(min. 12 V DC to start) 9.5 to 32 Vdc 9.5 to 32 Vdc Figure 5-1: Power supply Terminal Description Amax 0 Neutral point of the three-phase wye system or neutral terminal of the voltage transformer (Measuring reference point) 2.5 mm² 1 9.5 to 32 Vdc, 15 W 2.5 mm² 2 0 Vdc reference point 2.5 mm² Table 5-2: Terminal assignment - power supply NOTE Please note the above description in an application with 12 Vdc power supply. Page 24/46 © Woodward Manual 37364A GCP-30 Packages - Genset Control Measuring Inputs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Voltage Generator L1 L2 L3 N Generator voltage MCB GCB 0N202122L3 L2 L1 G Figure 5-2: Measuring inputs - Voltage - Generator Terminal Measurement Description Amax 20 Generator voltage L1 2.5 mm² 21 Generator voltage L2 2.5 mm² 22 Generator voltage L3 2.5 mm² 0 400 Vac or ../100 Vac Neutral point of the 3-phase wye system/transformer 2.5 mm² Table 5-3: Terminal assignment - generator voltage measuring NOTE A GCP-30 controller with 400V PT inputs and potential transformers with 100V secondary outputs must be used for 480V delta applications. The GCP-30 will not properly protect the generator or system from overvoltage fault conditions if a GCP-30 with 100V PT inputs is used with 100V potential transformers or a 400V PT input unit is directly connected to a 480V system. The 100V model inputs are limited to measuring voltage up to 125V and an overvoltage fault would exceed this range. The 400V model of the GCP-30 is also unable to monitor for overvoltage faults if potential transformers are not utilized due to the overvoltage fault exceeding the voltage monitoring range of maximum 500V as well. NOTE If a three-wire system is connected, terminal 0 must remain disconnected. If terminal 0 is connected, the control may monitor a voltage that exceeds the permissible limits. © Woodward Page 25/46 Manual 37364A GCP-30 Packages - Genset Control Busbar 2324L2 L1 MCB GCB N L1 L2 L3 Busbar voltage G Figure 5-3: Measuring inputs - Voltage - Busbar Terminal Measurement Description Amax 23 Busbar voltage L1 2.5 mm² 24 400 Vac or ../100 Vac Busbar voltage L2 2.5 mm² Table 5-4: Terminal assignment - busbar voltage measuring Mains L3 L2 L1 N Mains voltage MCB 52L3 5150L2 L1 GCB G Figure 5-4: Measuring inputs - Voltage - Mains Terminal Measurement Description Amax 50 Mains voltage L1 2.5 mm² 51 Mains voltage L2 2.5 mm² 52 Mains voltage L3 2.5 mm² 0 400 Vac or ../100 Vac Neutral point of the 3-phase system / transformer 2.5 mm² Table 5-5: Terminal assignment - mains voltage measuring NOTE The mains voltage measuring inputs must be connected if a GCP-31 is used in mains parallel opera- tion. Page 26/46 © Woodward Manual 37364A GCP-30 Packages - Genset Control Current WARNING Before disconnecting the secondary terminals of the current transformer or the connections of the cur- rent transformer at the control, ensure that the transformer is short-circuited. NOTE Current transformers are generally to be grounded on one side of the secondary. Generator N L2 L3 L1 Detail: Connection of the transformers S2 s2 L.. Generator current ../1 A or ../5 A s1 (k)..L..s2 (l)..MCB GS1 s1 L332s1 (k)31s2 (l)30292625s1 (k) s2 (l) s2 (l) s1 (k)L2 L1 GCB G Figure 5-5: Measuring inputs - Current - Generator Terminal Measurement Description Amax 25 Generator current L1, transformer terminal s2 (l) 2.5 mm² 26 Generator current L1, transformer terminal s1 (k) 2.5 mm² 29 Generator current L2, transformer terminal s2 (l) 2.5 mm² 30 Generator current L2, transformer terminal s1 (k) 2.5 mm² 31 Generator current L3, transformer terminal s2 (l) 2.5 mm² 32 Transformer ../1 A or ../5 A Generator current L3, transformer terminal s1 (k) 2.5 mm² Table 5-6: Terminal assignment - generator current measuring © Woodward Page 27/46 Manual 37364A GCP-30 Packages - Genset Control Mains (Mains Current Measuring Via Transformer) L2 L3 L1 N GCBS1 s1 S2 s2 MCB G Mains current ../1A or ../5 A s1 (k)2728s2 (l)L1 Figure 5-6: Measuring inputs - Current - Mains - via transformer Terminal Measurement Description Amax 27 Mains current L1, transformer terminal s2 (l) 2.5 mm² 28 Transformer ../1A or ../5A Mains current L1, transformer terminal s1 (k) 2.5 mm² Table 5-7: Terminal assignment - mains current measuring Mains (Mains Interchange Import/Export Real Power Actual Value Via Measuring Transducer [XPD and XPQ]) NOTE During configuration the free configurable 20 mA inputs can be enabled with the following functions: • Mains interchange (import/export) real power actual value • Real power set point value • Alarm input Please note the details in the configuration manual 37365. NOTE If several controls are interconnected, the 20 mA measuring signal must not be looped through all con- trols. At each control, a 0/4 to 20 mA buffer amplifier must be connected to the mains interchange (im- port/export) real power measurement output signal. When selecting the external measuring transducer, please note that this must transmit both positive and negative ranges when transmitting the supply and reference power values. Measuring transducer MCB GCB Mains active power0/4 to 20 mA GL2 L3 L1 N +- Figure 5-7: Measuring inputs - Real power - Mains - via measuring transducer Terminal Measurement Description Amax configurable see page 33 0/4 to 20 mA Mains interchange (import/export) real power meas- ured value via 0/4 to 20 mA signal of an external measuring transducer (e.g. UMT 1) 1.5 mm² Table 5-8: Terminal assignment - mains real power measuring Page 28/46 © Woodward Manual 37364A GCP-30 Packages - Genset Control Discrete Inputs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ CAUTION Please note that the operating voltages recommended for the discrete inputs range from 4 to 40Vdc. The voltage potential may be applied with either a positive or negative polarity without causing damage. Voltages higher than the recommended range may result in damage or destruction of the hardware! Control Inputs Signal device +/-4 to 40 Vdc Reply DCB 3 BACDiscrete input Discrete input Figure 5-8: Discrete inputs - Control inputs Terminal Associated Common Description (according to DIN 40 719 Part 3, 5.8.3) Amax A B NO contact 3 Automatic 1 2.5 mm² 5 Automatic 2 2.5 mm² 6 Multi function (selectable in configuration): • Sprinkler operation • Engine enable • External acknowledgement • Engine stop • Operating mode STOP • Start without CB 2.5 mm² 53 7 [GCP-31] Enable externally [GCP-32] Enable MCB 2.5 mm² C D NC contact 4 Reply: GCB is open 2.5 mm² 54 7 [GCP-31] Status: Isolated operation [GCP-32] Reply: MCB is open 2.5 mm² Table 5-9: Terminal assignment - control inputs © Woodward Page 29/46 Manual 37364A GCP-30 Packages - Genset Control Alarm Inputs The discrete inputs can be connected in positive or negative logic: • positive logic The DI is connected to +4 to 40Vdc and common is connected to chassis ground/batt. negative. • negative logic The DI is connected to chassis ground/batt. negative and common is connected to +4 to 40Vdc. Positive Logic Signal device Discrete inputAB+/-4 to 40 Vdc Figure 5-9: Discrete inputs - Alarm inputs - positive logic Terminal Associated Common Amax A B Description (according to DIN 40 719 Part 3, 5.8.3) 34 Discrete input [D01] - Alarm input - In Sprinkler operation: EMERGENCY STOP 2.5 mm² 35 Discrete input [D02] - Alarm input 2.5 mm² 36 33 Discrete input [D03] - Alarm input 2.5 mm² 61 Discrete input [D04] - Alarm input - If discrete input terminal 34 is not available in Sprinkler operation: EMERGENCY STOP 2.5 mm² 62 Discrete input [D05] - Alarm input or - Firing speed reached ("Generator") 2.5 mm² 63 Discrete input [D06] - Alarm input or - Operation mode selector blocked 2.5 mm² 64 Discrete input [D07] - Alarm input or - Change breaker logic 2.5 mm² 65 Discrete input [D08] - Alarm input 2.5 mm² 66 Discrete input [D09] - Alarm input 2.5 mm² 67 Discrete input [D10] - Alarm input or - 'Close GCB' before expiration of delayed engine monitoring 2.5 mm² 68 Discrete input [D11] - Alarm input or - Inhibition emergency power (from software version 4.3010 or higher) 2.5 mm² 69 Discrete input [D12] - Alarm input 2.5 mm² 70 Discrete input [D13] - Alarm input or - No-load operation mode 2.5 mm² 71 Discrete input [D14] - Alarm input 2.5 mm² 72 Discrete input [D15] - Alarm input 2.5 mm² 73 60 Discrete input [D16] - Alarm input 2.5 mm² Page 30/46 © Woodward Table 5-10: Terminal assignment - alarm inputs positive logic Manual 37364A GCP-30 Packages - Genset Control Negative Logic Discrete inputAB Signal device +/-4 to 40 Vdc Figure 5-10: Discrete inputs - Alarm inputs - negative logic (Example) Associated Common Terminal Amax A B Description (according to DIN 40 719 Part 3, 5.8.3) 34 Discrete input [D01] - Alarm input - In Sprinkler operation: EMERGENCY STOP 2.5 mm² 35 Discrete input [D02] - Alarm input 2.5 mm² 33 36 Discrete input [D03] - Alarm input 2.5 mm² 61 Discrete input [D04] - Alarm input - If discrete input terminal 34 is not available in Sprinkler operation: EMERGENCY STOP 2.5 mm² 62 Discrete input [D05] - Alarm input or - Firing speed reached ("Generator") 2.5 mm² 63 Discrete input [D06] - Alarm input or - Operation mode selector blocked 2.5 mm² 64 Discrete input [D07] - Alarm input or - Change breaker logic 2.5 mm² 65 Discrete input [D08] - Alarm input 2.5 mm² 66 Discrete input [D09] - Alarm input 2.5 mm² 67 Discrete input [D10] - Alarm input or - 'Close GCB' before expiration of delayed engine monitoring 2.5 mm² 68 Discrete input [D11] - Alarm input or - Inhibition emergency power (from software version 4.3010 or higher) 2.5 mm² 69 Discrete input [D12] - Alarm input 2.5 mm² 70 Discrete input [D13] - Alarm input or - No-load operation mode 2.5 mm² 71 Discrete input [D14] - Alarm input 2.5 mm² 72 Discrete input [D15] - Alarm input 2.5 mm² 60 73 Discrete input [D16] - Alarm input 2.5 mm² Table 5-11: Terminal assignment - alarm inputs negative logic © Woodward Page 31/46 Manual 37364A GCP-30 Packages - Genset Control Operation Mode Selection Via DI (XPD, XPQ) This functionality enables external selection of the operation mode using terminals 127 and 128. The discrete in- puts can be connected using positive or negative logic as described above. Terminal Associated common Description (according to DIN 40 719 Part 3, 5.8.3) Amax 127 Control input [terminal 127] - Operation mode STOP 2.5 mm² 128 124 Control input [terminal 128] - Operation mode AUTOMATIC 2.5 mm² Table 5-12: Discrete inputs - operation mode selection NOTE The selection of the operation mode via discrete inputs 127/128 is only possible if the discrete input on terminal 63 (Operation mode selector blocked) is energized. More detailed information may be found in the configuration manual (37365) under 'Block operation mode selector switch via terminal 63'. Page 32/46 © Woodward Manual 37364A GCP-30 Packages - Genset Control Analog Inputs (XPD, XPQ) ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ WARNING The analog inputs of the GCP are not isolated. When utilizing an isolation monitor, use of two-pole, iso- lated transmitters is recommended. The analog inputs for active transmitters (0 to 20 mA, 0 to 10V) should only be operated with two-pole, isolated transmitters. GND CCABCAaI BABAnalog input VDO 0 to 180/380 Ohm Analog input 0/4 to 20 mA Analog input Pt100 Figure 5-11: Analog inputs Terminal Amax A B C Description (according to DIN 40 719 Part 3, 5.8.3) 93 94 95 Analog input 1 [T1] 0/4 to 20 mA, configurable function: - Alarm input / Set value input / Actual value input 1.5 mm² 96 97 98 Analog input 2 [T2] 0/4 to 20 mA, configurable function: - Alarm input / Set value input / Actual value input 1.5 mm² 99 100 101 Analog input 3 [T3] 0/4 to 20 mA, configurable function: - Alarm input / Set value input / Actual value input 1.5 mm² 102 103 104 Analog input 4 [T4] Pt100, configurable function: - Alarm input / Actual value input 1.5 mm² 105 106 107 Analog input 5 [T5] Pt100, configurable function: - Alarm input / Actual value input 1.5 mm² 108 109 - Analog input 6 [T6] VDO pressure 0 to 180 Ω (0 to 5/10 bar or 0 to 72.5/145 psi), configurable function: - Alarm input / Actual value input 1.5 mm² 111 112 - Analog input 7 [T7] VDO temperature 0 to 380 Ω (30 to 120°C or 86 to 248°F), configurable function: - Alarm input / Actual value input 1.5 mm² Table 5-13: Analog inputs - terminal assignment © Woodward Page 33/46 Manual 37364A GCP-30 Packages - Genset Control MPU ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ 24 V MPU swiching/inductive< 1.0 V 9091GND92sw./ind. Figure 5-12: MPU Terminal Description Amax 90 switching/inductive 2.5 mm² 91 2.5 mm² 92 MPU (Magnetic Pickup Unit) GND 2.5 mm² Table 5-14: MPU - terminal assignment Specification of the input circuit for inductive speed sensors Ambient temperature: 25 °C Signal shape Sinusoidal Minimum input voltage in the range of 200 to 10,000 Hz < 0.5 Veff Minimum input voltage in the range of 300 to 5,000 Hz < 0.3 Veff Maximum input voltage in the range of 0 to 1,500 Hz 30 Veff Maximum input voltage in the range of 1,500 to 10,000 Hz 30 to 60 Veff (linear increasing) Table 5-15: MPU - input voltage Note: As the ambient temperature increases, the minimum input voltage increases at a rate of approxi- mately 0.3 V/°C. Minimum effective voltages relative to the frequency Veff 0 0,5 1 1,5 2 2,5 3 100 1000 10000 100000 Frequency [Hz]Minimum effective input voltage [V] Figure 5-13: MPU - Typical behavior of the input voltage sensitivity Page 34/46 © Woodward Manual 37364A GCP-30 Packages - Genset Control Relay Outputs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Controller Outputs Enable GCB max. 250 V AC Command: close GCB Command: close MCB Command: open MCB GCB MCB MCB GCB 4142141740391615 Figure 5-14: Relay outputs - Controller outputs - CB activation Make cont. Description Amax 14/15 Command: close GCB 2.5 mm² 16/17 [GCP-32] Command: close MCB; [GCP-31] Comm.: close ext. CB 2.5 mm² 39/40 [GCP-32] Command: open MCB; [GCP-32] Comm.: open ext. CB 2.5 mm² 41/42 Command: open GCB 2.5 mm² Table 5-16: Relay outputs - terminal assignment Relay Manager ABRelay outputexternal device max. 250 V AC Figure 5-15: Relay outputs - Relay manager Make cont. Description Amax 18/19 Ready for operation 2.5 mm² 43/44 Fuel solenoid relay/gas valve 2.5 mm² 45/46 Starter 2.5 mm² 74/75 Relay [R1] (Relay manager) 2.5 mm² 76/77 Relay [R2] (Relay manager) 2.5 mm² 78/79 Relay [R3] (Relay manager) 2.5 mm² 80/81 Relay [R4] (Relay manager) 2.5 mm² 82/83 Relay [R5] (Relay manager) 2.5 mm² 37/38 Relay [R6] (Relay manager; pre-assigned: Preheat/Ignition ON) 2.5 mm² 47/48 Relay [R7] (Relay manager; pre-assigned: Centralized alarm horn) 2.5 mm² Table 5-17: Relay manager - terminal assignment © Woodward Page 35/46 Manual 37364A GCP-30 Packages - Genset Control Analog Outputs (XPD, XPQ) ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Analog output0 V A BAI Figure 5-16: Analog outputs Ia GND Description Amax A B 120 121 Analog output [A1] - 0/4 to 20 mA 1.5 mm² 122 123 Analog output [A2] - 0/4 to 20 mA 1.5 mm² Table 5-18: Analog outputs - terminal assignment Controller Outputs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ The voltage and speed controller outputs in the XPD Package are three-position contacts [made up of a change- over contact and a normally open contact]. The voltage and speed controller outputs in the BPQ and XPQ Packages are configurable as voltage, current, or PWM output signals. Three-Position Controller (XPD) The three-position controller is only included in the XPD Package. 111213Voltage / power factor controller Common Raise Lower Voltage / power factor controller8Common Speed / power controller Speed / power controller max. 250 V AC 910Lower Raise Figure 5-17: Controller - Three-position controller Terminal Description Amax 8 common 2.5 mm² 9 raise 2.5 mm² 10 lower Speed controller (n/f) / Power controller (P) 2.5 mm² 11 common 2.5 mm² 12 raise 2.5 mm² 13 lower Voltage controller (V) / Reactive power controller (Q) 2.5 mm² Table 5-19: Controller outputs - terminal assignment Page 36/46 © Woodward Manual 37364A GCP-30 Packages - Genset Control Multi Functional Controller Outputs (BPQ, XPQ) Configuration and an external jumper can change the multifunction controller outputs. Versions - Three-position controller via relay manager - Control of n/f/P: Parameter "F/P contr.type" = THREESTEP n+/f+/P+ = relay manger parameter 114 n-/f-/P- = relay manager parameter 115 - Control of V/Q: Parameter "V/Q contr.output" = THREESTEP V+/Q+ = relay manager parameter 116 V-/Q- = relay manager parameter 117 - Analog controller output - Control of n/f/P: Parameter "F/P contr.type" = ANALOG Current output (mA) = no jumpers necessary Voltage output (V) = jumpers between 8/9 Connect speed control to terminals 9/10 - Control of V/Q: Parameter "V/Q contr.output" = ANALOG Current output (mA) = no jumpers necessary Voltage output (V) = jumpers between 11/12 Connect voltage regulator to terminals 12/13 - PWM controller output - Control of n/f/P: Parameter "F/P contr.type" = PWM PWM output = jumpers between 8/9 Connect speed control to terminals 9/10 Wiring Of Controller - Setting: THREE-POSITION (Three-position controller) A/C B/D Relay output max. 250 Vac Figure 5-18: Three-position controller Terminal Description Amax A 2.5 mm² B raise 2.5 mm² C 2.5 mm² D lower Speed / Frequency / Real power (RelayManager: "raise" = 114, "lower" = 115) or Voltage / Reactive power (RelayManager: "raise" = 116, "lower" = 117) 2.5 mm² The selection and programming occurs via the relay manager (RM). Table 5-20: Controller outputs - three-position CAUTION Refer to Technical Data on page 42 for information about current limits. Use an interposing relay if nec- essary. Currents higher than those specified destroy the hardware! © Woodward Page 37/46 Manual 37364A GCP-30 Packages - Genset Control - Setting: ANALOG or PWM (Analog controller) - Frequency-/Power controller Page 38/46 © Woodward GND Speed / power controller 8109GND PWMSpeedGovernorGND PWM PWM Speed / power controller 8109A VoltageSpeedGovernorAU GND Speed / power controller 8AI109GNDCurrentSpeedGovernorAI GND N/C V Figure 5-19: Analog controller output n/f/P - Wiring and external jumper setting Type Terminal Description Amax 8 IA 2.5 mm² 9 2.5 mm² I Current 10 GND 2.5 mm² 8 2.5 mm² 9 VA 2.5 mm² V Voltage 10 GND 2.5 mm² 8 2.5 mm² 9 PWM 2.5 mm² PWM 10 GND Speed controller / Frequency controller / Real power controller 2.5 mm² Table 5-21: Controller outputs - analog or PWM - Setting: ANALOG (Analog controller) - Voltage-/Reactive power controller Voltage / re-active power controller 11AI1312GNDCurrentAVRAI GND N/C Voltage / re-active power controller 111312A VoltageAU GND GND AVRV Figure 5-20: Analog controller output V/Q - Wiring and jumper setting Type Terminal Description Amax 11 IA 2.5 mm² 12 2.5 mm² I Current 13 GND 2.5 mm² 11 2.5 mm² 12 VA 2.5 mm² V Voltage 13 GND Voltage controller / Reactive power controller 2.5 mm² Table 5-22: Controller outputs - analog Manual 37364A GCP-30 Packages - Genset Control Interface ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Interface Wiring CAB D E GNDCAN-HCAN-LCAN-LCAN-HInterfaceCAN bus Figure 5-21: Interface - Terminals Terminal Description A B C D E X1* CAN-H X2* CAN-L X3 GND X4* CAN-H X5* CAN-L CAN bus guidance level * may be used to connect to the CAN bus and/or to connect the termination resistor. Table 5-23: Interface - terminal assignment NOTE Refer to the respective manuals for a description of the Engine Control Unit interface (terminals Y1 to Y5): • Option SB03 (37200) • Option SC10 (37382) CAN Bus Shielding Interface CAN bus CAN-L CAN-H GND Shield 1 MOhm0.01 µF 400 Vac Figure 5-22: Interface - CAN bus shielding © Woodward Page 39/46 Manual 37364A GCP-30 Packages - Genset Control CAN Bus Topology NOTE Please note that the CAN bus must be terminated with an impedance which corresponds to the wave impedance of the cable (e.g. 120 Ω). The CAN bus is terminated between CAN-H and CAN-L. The two CAN-H and CAN-L terminals in the unit are hard-wired internally and can be used to feed the CAN bus through. However, if you want to avoid a break of the bus when a unit is unplugged, you may connect the incoming and outgoing bus line in the same terminal. GNDCAN-LCAN-HGNDGNDCAN-LCAN-HCAN-LCAN-HCAN-LCAN-HCAN bus Terminationresistor Note:The termination has to be performed with a resisitance, which corresponds to the impedance of the used cable (e.g 120 Ohms) CAN bus CAN bus Terminationresistor CAN-LCAN-HCAN-LCAN-H Figure 5-23: Interfaces - CAN bus topology Possible CAN Bus Problems If no data is transmitted on the CAN bus, check the following for common CAN bus communication problems: - T structure bus is utilized (stub-end feeders or branch lines are not recommended) - CAN-L and CAN-H are interchanged - Not all devices on the bus are using identical Baud rates - Correct terminating resistor(s) is/are missing - Incorrect baud rate (too high) for length of CAN bus - The CAN bus cable is co-routed with power cables Woodward recommends the use of twisted-pair cables for the CAN bus (i.e.: Lappkabel Unitronic LIYCY (TP) 2×2×0.25, UNITRONIC-Bus LD 2×2×0.22). Maximum CAN Bus Length The maximum length of the communication bus wiring is dependent on the configured Baud rate. Refer to Table 5-24 for the maximum bus length (Source: CANopen; Holger Zeltwanger (Hrsg.); 2001 VDE VERLAG GMBH, Berlin und Offenbach; ISBN 3-8007-2448-0). Baud rate Max. length 1000 kbit/s 25 m 800 kbit/s 50 m 500 kbit/s 100 m 125 kbit/s 250 m 50 kbits/s 1000 m 20 kbit/s 2500 m Table 5-24: Maximum CAN bus length The maximum specified length for the communication bus wiring might not be achieved if poor quality wire is utilized, there is high contact resistance, or other conditions exist. Reducing the baud rate may overcome these is- sues. Page 40/46 © Woodward Manual 37364A GCP-30 Packages - Genset Control DPC - Direct Configuration Interface NOTE To configure via the configuration interface (direct configuration), you need the configuration cable (part number 5417-557), the program LeoPC1 (delivered with the cable), and the corresponding con- figuration files. Please consult the online help installed when the program is installed for a description of the LeoPC1 program and its setup. If the parameter "Direct para." is enabled on the control, communication via the CAN bus interface on terminals X1/X5 is disabled. If the control unit detects that the engine is running (ignition speed exceeded), the direct configuration port is disabled. © Woodward Page 41/46 Manual 37364A GCP-30 Packages - Genset Control Chapter 6. Technical Data Nameplate ------------------------------------------------------------------------------------------------------ 1 S/N Serial number (numerical) 2 S/N Date of production (YYMM) 3 S/N Serial number (Barcode) 4 P/N Item number 5 REV Item revision number 6 Details Technical data 7 Type Description (long) 8 Type Description (short) 9 UL UL sign Measuring values, voltages ---------------------------------------------------------------------------------- - Measuring voltage Rated value (Vrated) /Δ ...........................[1] 66/115 Vac [4] 230/400 Vac Maximum value VPh-Ph (UL/cUL)....... [1] max. 150 Vac [4] max. 300 Vac Rated voltage VPh-ground ................................[1] 150 Vac [4] 300 Vac Rated surge voltage ........................................[1] 2.5 kV [4] 4.0 kV - Setting range (prim)............................................................................0.050 to 65.000 kVac - Linear measuring range........................................................................................1.3 × Vrated - Measuring frequency .................................................................50/60 Hz (40.0 to 70.0 Hz) - Accuracy ................................................................................................................... Class 1 - Input resistance per path ...................................................................................[1] 0.21 MΩ [4] 0.7 MΩ - Maximum power consumption per path ................................................................< 0.15 W Measuring values, currents -----------------------------------------------------------------------isolated Measuring current Rated value (Irated)................................................. ../5 A - Accuracy ................................................................................................................... Class 1 - Linear measuring range Generator.........................................................3.0 × Irated Mains/ground current ......................................1.5 × Irated - Maximum power consumption per path ..............................................................< 0.15 VA Rated short-time current (1 s) ..... .......................................................................10.0 × Irated Ambient variables --------------------------------------------------------------------------------------------- - Power supply............................................................................12/24 Vdc (9.5 to 32.0 Vdc) - Intrinsic consumption.......................................................................................... max. 20 W - Ambient temperature Storage..................................-30 to 80 °C / -22 to 176 °F Operation...............................-20 to 70 °C / -4 to 158 °F - Ambient humidity.............................................................................95 %, non-condensing Page 42/46 © Woodward Anleitung 37364A GCP-30 Packages - Genset Control © Woodward Seite 43/46 Discrete inputs ---------------------------------------------------------------------------------------isolated - Input range (VCont, digital input) .....................................Rated voltage 12/24 Vdc (6 to 32 Vdc) - Input resistance............................................................................................. approx. 6.8 kΩ Relay outputs ---------------------------------------------------------------------------------potential free - Contact material........................................................................................................AgCdO - General purpose (GP) (VCont, relay output) AC.............................................2.00 Aac@250 Vac DC...............................................2.00 Adc@24 Vdc 0.36 Adc@125 Vdc 0.18 Adc@250 Vdc - Pilot duty (PD) (VCont, relay output) DC...............................................1.00 Adc@24 Vdc 0.22 Adc@125 Vdc 0.10 Adc@250 Vdc Analog inputs (XPD, XPQ) -------------------------------------------------------------- freely scaleable - Resolution....................................................................................................................10 Bit - 0/4 to 20 mA input..................................................... Difference measurement, load 150 Ω - 0 to 5/10 Vdc input.................. Difference measurement, input resistance approx. 16.5 kΩ - Pt100/Pt1000 input....................................for measuring resistances according to IEC 751 [Pt100]............2/3-conductor measurement, 0 to 200 °C [Pt1000]............2-conductor measurement, -30 to 200 °C - 0 to 180/380 Ω input................................difference measurement, sensor current ≤1.9 mA Analog outputs (XPD, XPQ) ----------------------------------------------------------------------isolated - at rated output...............................................................................................freely scalable, - Insulation voltage.................................................................................................3,000 Vdc - Versions........................................................0 to 5 Vdc, +/-5 Vdc, 0 to 10 Vdc, 0 to 20 mA - Resolution PWM................................................................. 8/12 Bit (depending on model) - 0/4 to 20 mA output............................................................................maximum load 500 Ω - 0 to 10 V/+/-5 V output.................................................................internal resistance ≤1 kΩ MPU input---------------------------------------------------------------------------------------------isolated - Input impedance ....................................................................................min. approx. 17 kΩ - Input voltage............................................................ (see Table 5-15: MPU - input voltage) Anleitung 37364A GCP-30 Packages - Genset Control Seite 44/46 © Woodward Interface -------------------------------------------------------------------------------------------------------- Service interface - Version......................................................................................................................RS-232 - Signal level......................................................................................................................5 V Level conversion and insulation by using DPC (P/N 5417-557) CAN bus interface isolated - Insulation voltage................................................................................................. 1,500 Vdc - Version...................................................................................................................CAN bus - Internal line termination...................................................................................Not available Battery (XPD, XPQ) ------------------------------------------------------------------------------------------ - Type............................................................................................................................. NiCd - Durability (at operation without power supply)............................................approx. 5 years - Battery field replacement...................................................................................not possible Housing ---------------------------------------------------------------------------------------------------------- - Type........................................................................................... APRANORM DIN 43 700 - Dimensions (W × H × D).................................................................... 144 × 144 × 118 mm - Front cutout (W × H)...............................................................138 [+1.0] × 138 [+1.0] mm - Wiring................................................................ screw-plug-terminals 1.5 mm² or 2.5 mm² - Recommended tightening torque ..............................................................................0.5 Nm use 60/75 °C copper wire only use class 1 wire only or equivalent - Weight..........................................................................................................approx. 1,000 g Protection ------------------------------------------------------------------------------------------------------- - Protection system.....................................................IP42 from front for proper installation IP54 from front with gasket (gasket: P/N 8923-1043) IP21 from back - Front folio.................................................................................................insulating surface - EMC test (CE)................................................tested according to applicable EN guidelines - Listings.........................................................CE marking; UL listing for ordinary locations - Type approval..................................UL/cUL listed, Ordinary Locations, File No.: 231544 Anleitung 37364A GCP-30 Packages - Genset Control Chapter 7. Accuracy Measuring values Display and ranges Accuracy Notes Frequency Generator fL1N, fL2N, fL3N 15.0 to 85.0 Hz 1 % - Busbar fL12 15.0 to 85.0 Hz 1 % - Mains fL1N, fL2N, fL3N 40.0 to 85.0 Hz 1 % - Voltage Generator VL1N, VL2N, VL3N 0 to 400 V 1 % Transformer ratio adjustable VL12, VL23, VL31 0 to 400 V 1 % Busbar VL12 0 to 400 V 1 % Transformer ratio adjustable Mains VL1N, VL2N, VL3N 0 to 400 V 1 % Transformer ratio adjustable VL12, VL23, VL31 0 to 400 V 1 % Current Generator IL1, IL2, IL3 0 to 9,999 A 1 % - Max. value IL1, IL2, IL3 0 to 9,999 A 1 % Slave pointer Mains IL1 0 to 9,999 A 1 % - Real power Current total real power value -32.0 to 32.0 MW 2 % - Reactive power Current value in L1, L2, L3 -32.0 to 32.0 Mvar 2 % - Power Factor (cos φ) Current value power factor (cos φ) L1 i0.00 to 1.00 to c0.00 2 % - Miscellaneous Real energy 0 to 4,200 GWh 2 % not calibrated Operating hours 0 to 65,000 h - Maintenance call 0 to 9,999 h - Start counter 0 to 32,750 - Battery voltage 10 to 30 V 1 % - Pickup speed fN +/- 40 % - Analog inputs (XPD, XPQ) 0/4 to 20 mA freely scaleable - Pt100 0 to 250 °C not calibrated 0 to 180 Ω freely scaleable for VDO sensors 0 to 360 Ω freely scaleable for VDO sensors Reference conditions (to measure the accuracy): • Input voltage.............................sinusoidal rated voltage • Input current.............................sinusoidal rated current • Frequency.................................rated frequency +/- 2 % • Power supply............................rated voltage +/- 2 % • Power factor (cos φ).................1.00 • Ambient temperature................23 °C +/- 2 K • Warm-up period .......................20 minutes © Woodward Seite 45/46 We appreciate your comments about the content of our publications. Please send comments to: stgt-documentation@woodward.com Please include the manual number from the front cover of this publication. Woodward Governor Company Leonhard-Reglerbau GmbH Handwerkstrasse 29 - 70565 Stuttgart - Germany Phone +49 (0) 711 789 54-0 • Fax +49 (0) 711 789 54-100 sales-stuttgart@woodward.com Homepage http://www.woodward.com/power Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address/phone/fax/e-mail information for all locations is available on our website (www.woodward.com). 2007/2/Stuttgart 37365A Configuration Software version starting from 4.3046 Manual 37365A GCP-30 Series Packages Genset Control Manual 37365A GCP-30 Series Packages - Genset Control Page 2/179 © Woodward WARNING Read this entire manual and all other publications pertaining to the work to be performed before install- ing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage. The engine, turbine, or other type of prime mover should be equipped with an overspeed (overtempera- ture, or overpressure, where applicable) shutdown device(s), that operates totally independently of the prime mover control device(s) to protect against runaway or damage to the engine, turbine, or other type of prime mover with possible personal injury or loss of life should the mechanical-hydraulic gov- ernor(s) or electric control(s), the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s), or the controlled device(s) fail. Any unauthorized modifications to or use of this equipment outside its specified mechanical, electrical, or other operating limits may cause personal injury and/or property damage, including damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product certifications or listings. CAUTION To prevent damage to a control system that uses an alternator or battery-charging device, make sure the charging device is turned off before disconnecting the battery from the system. Electronic controls contain static-sensitive parts. Observe the following precautions to prevent dam- age to these parts. • Discharge body static before handling the control (with power to the control turned off, contact a grounded surface and maintain contact while handling the control). • Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit boards. • Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. OUT-OF-DATE PUBLICATION This publication may have been revised or updated since this copy was produced. To verify that you have the latest revision, be sure to check the Woodward website: http://www.woodward.com/pubs/current.pdf The revision level is shown at the bottom of the front cover after the publication number. The latest version of most publications is available at: http://www.woodward.com/publications If your publication is not there, please contact your customer service representative to get the latest copy. Important definitions WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. CAUTION Indicates a potentially hazardous situation that, if not avoided, could result in damage to equipment. NOTE Provides other helpful information that does not fall under the warning or caution categories. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, Woodward assumes no responsibility unless otherwise expressly undertaken. © Woodward All Rights Reserved. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 3/179 Revision History Rev. Date Editor Changes NEW 06-01-11 TP Release A 07-02-07 TP Minor corrections; linguistic review Contents NOTE The functions described in this manual are included in the different packages of the GCP-30 series. Some functions are only available in specific packages. Specific model numbers at the beginning of the parameter/function text will indicate package specific parameters/functionality. [GCP-32] This function is only found in GCP-32 controllers. [GCP-31] This function is only found in GCP-31 controllers. BPQ This function is only found in controllers with the BPQ Package (GCP-31/BPQ and GCP- 32/BPQ). XPD This function is only found in controllers with the XPD Package (GCP-31/XPD and GCP- 32/XPD). XPQ This function is only found in controllers with the XPQ Package (GCP-31/XPQ and GCP- 32/XPQ). SB03 This function is only found in controllers with the SB03 Option (GCP-31/XPQ+SB03 and GCP-32/XPQ+SB03). SC10 This function is only found in controllers with the SC10 Option (GCP-31/XPQ+SC10 and GCP-32/XPQ+SC10). CHAPTER 1. GENERAL INFORMATION.........................................................................................7 Functional Overview................................................................................................................................8 CHAPTER 2. FUNCTION .............................................................................................................9 Considerations To Be Taken: .................................................................................................................9 Different Options...........................................................................................................................9 Systems Without a Mains Circuit Breaker....................................................................................9 Signals...................................................................................................................................................10 Discrete Inputs............................................................................................................................10 Control Outputs...........................................................................................................................12 CHAPTER 3. CONFIGURATION ..................................................................................................14 Basic Data.............................................................................................................................................15 Version Number (Software Version)...........................................................................................15 Password....................................................................................................................................15 Direct Configuration....................................................................................................................16 Generator Number......................................................................................................................17 Language Manager (XPD, XPQ)................................................................................................17 Service Display...........................................................................................................................20 Event Logger (XPD, XPQ) ....................................................................................................................21 Possible Event Logger Entries....................................................................................................21 Analog Inputs..............................................................................................................................23 Manual 37365A GCP-30 Series Packages - Genset Control Page 4/179 © Woodward Measuring.............................................................................................................................................24 Rated Frequency ........................................................................................................................24 Potential Transformers (Voltage Transformers).........................................................................24 Rated Voltage.............................................................................................................................26 Generator Current......................................................................................................................27 Mains Current/Mains Power Measurement................................................................................28 LS 4 Mode (GCP-31: XPD, XPQ)..............................................................................................31 Measurement Units....................................................................................................................31 Password Configuration.............................................................................................................32 Controller..............................................................................................................................................33 Analog Controller Outputs (BPQ, XPQ).....................................................................................34 Real Power Controller, Set Point Values ...................................................................................37 Table Of Set Point Values..........................................................................................................38 Frequency Controller..................................................................................................................39 Voltage Controller.......................................................................................................................43 Power Factor Controller .............................................................................................................47 Real Power Controller................................................................................................................49 Load and/or var Sharing.............................................................................................................53 Automatic..............................................................................................................................................57 Load Management .....................................................................................................................57 Stop Of The Engine At Mains Failure [GCP-31]........................................................................66 Interface......................................................................................................................................67 Breaker .................................................................................................................................................68 Functional Description................................................................................................................68 Breaker Logic .............................................................................................................................74 Start/Stop Ramp, Open GCB With F2 Alarm.............................................................................81 GCB/MCB Pulse/Continuous Pulse...........................................................................................82 Open/Close GCB........................................................................................................................84 Synchronization..........................................................................................................................85 Synchronization Time Monitoring...............................................................................................86 Dead Bus Start...........................................................................................................................87 Breaker Monitoring.....................................................................................................................88 Mains Decoupling.......................................................................................................................89 Emergency Power (AMF) (GCP-32; GCP-31: XPD, XPQ) ..................................................................91 Emergency Power With Breaker Logic "PARALLEL" ................................................................92 Emergency Power With Breaker Logic "OPEN TRANSIT.".......................................................92 Emergency Power With Breaker Logic "CLOSED TRANSIT." ..................................................93 Emergency Power With Breaker Logic "INTERCHANGE" ........................................................93 Emergency Power With Breaker Logic "EXTERNAL"................................................................93 Emergency power With MCB Malfunction..................................................................................94 Emergency Power Operation; Parameters ................................................................................94 Protection..............................................................................................................................................95 Generator Power Monitoring......................................................................................................95 Mains Power Monitoring.............................................................................................................97 Generator Overload Monitoring..................................................................................................98 Generator Reverse/Reduced Power Monitoring........................................................................99 Unbalanced Load Monitoring...................................................................................................100 Independent Time-Overcurrent Monitoring..............................................................................101 Generator Frequency Monitoring.............................................................................................103 Engine Overspeed Monitoring..................................................................................................103 Generator Voltage Monitoring..................................................................................................104 Mains Frequency Monitoring....................................................................................................105 Mains Voltage Monitoring.........................................................................................................106 Phase/Vector Shift Monitoring dϕ/dt ........................................................................................107 Mains Settling Time..................................................................................................................108 Battery Voltage Monitoring.......................................................................................................109 Time Of Active Horn .................................................................................................................109 Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 5/179 Discrete Inputs....................................................................................................................................110 Alarm Inputs..............................................................................................................................111 Configuring The Text For The Discrete Inputs .........................................................................112 Control Inputs............................................................................................................................113 Terminal 6 Function..................................................................................................................116 Analog Inputs (XPD, XPQ)..................................................................................................................119 Setting The Analog Inputs ........................................................................................................119 Outputs................................................................................................................................................127 Analog Outputs (XPD, XPQ).....................................................................................................127 Relay Manager..........................................................................................................................128 Engine.................................................................................................................................................129 Start/Stop Sequence 'Gas Engine' ...........................................................................................130 Start/Stop Sequence 'Diesel Engine'........................................................................................133 Cool Down ................................................................................................................................135 Delayed Engine Monitoring And Firing Speed..........................................................................136 Magnetic Pick-Up Input.............................................................................................................138 Counter / Real Time Clock..................................................................................................................139 Maintenance Call......................................................................................................................139 Operating Hours Counter..........................................................................................................140 Start Counter.............................................................................................................................140 kWh Counter.............................................................................................................................141 Real Time Clock (XPD, XPQ)...................................................................................................142 Current Slave Pointer ...............................................................................................................143 CHAPTER 4. COMMISSIONING ................................................................................................144 APPENDIX A. ANALOG OUTPUT MANAGER (XPD, XPQ)..........................................................146 APPENDIX B. RELAY MANAGER .............................................................................................149 APPENDIX C. INTERFACE PROTOCOL .....................................................................................153 Transmission Telegram ......................................................................................................................153 Receiving Telegram............................................................................................................................162 CAN Bus Structure..............................................................................................................................163 Transmission Telegram............................................................................................................163 Current Direction Message.......................................................................................................163 Power Set Point Value Message..............................................................................................164 CAN Bus Address Requirements .............................................................................................164 APPENDIX D. LIST OF PARAMETERS ......................................................................................165 APPENDIX E. SERVICE OPTIONS ............................................................................................174 Product Service Options .....................................................................................................................174 Returning Equipment For Repair........................................................................................................174 Packing A Control.....................................................................................................................175 Return Authorization Number RAN ..........................................................................................175 Replacement Parts..............................................................................................................................175 How To Contact Woodward................................................................................................................176 Engineering Services..........................................................................................................................177 Technical Assistance ..........................................................................................................................178 Manual 37365A GCP-30 Series Packages - Genset Control Page 6/179 © Woodward Illustrations And Tables Illustrations Figure 3-1: Control loop..........................................................................................................................................................34 Figure 3-2: Step response (Example).......................................................................................................................................34 Figure 3-3: Step responds - governor configuration ................................................................................................................36 Figure 3-4: CAN bus load/var sharing, diagram......................................................................................................................55 Figure 3-5: Breaker control logic 'Impulse' for MCB..............................................................................................................82 Figure 3-6: Breaker control logic 'Impulse' for GCB...............................................................................................................83 Figure 3-7: Breaker control logic 'Continuous'........................................................................................................................83 Figure 3-8: Characteristic of the time-overcurrent monitoring..............................................................................................101 Figure 3-11: Sprinkler operation............................................................................................................................................118 Figure 3-12: VDO transmitter 323.425 (slope)......................................................................................................................124 Figure 3-13: Start-Stop sequence: Gas engine.......................................................................................................................130 Figure 3-14: Wiring diagram for opening gas valves with the GCP-30 from V4.1001 .........................................................131 Figure 3-15: Start-stop sequence: Diesel engine....................................................................................................................133 Figure 3-16: Delayed engine monitoring...............................................................................................................................136 Figure 4-1: Analog outputs - power factor scaling ................................................................................................................148 Tables Table 1-1: Manual - Overview...................................................................................................................................................7 Table 1-2: Functional overview.................................................................................................................................................8 Table 3-1: Event recorder - Messages, part 1 ..........................................................................................................................22 Table 3-2: Event recorder – Messages, part 2..........................................................................................................................23 Table 3-3: Set point value table...............................................................................................................................................38 Table 3-4: Limit values, permissible limits..............................................................................................................................68 Table 3-5: Limit values generator, dead bus start....................................................................................................................71 Table 3-6: Limit values mains, dead bus start..........................................................................................................................72 Table 3-7: Limit values, Emergency power.............................................................................................................................91 Table 3-9: Discrete alarm inputs - delay stages.....................................................................................................................111 Table 3-10: Function - external operation mode selection.....................................................................................................113 Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 7/179 Chapter 1. General Information Type English German GCP-31/32 Series GCP-31/32 Packages - Installation 37364 GR37364 GCP-31/32 Packages - Configuration this manual Ö 37365 GR37365 GCP-31/32 - Function/Operation 37238 GR37238 GCP-31/32 - Application 37240 GR37240 GCP-31/RPQ - Installation 37366 GR37366 GCP-31/RPQ - Configuration 37367 GR37367 Option SB - Caterpillar CCM coupling 37200 GR37200 Option SC09/SC10 - CAN bus coupling 37382 GR37382 Additional Manuals IKD 1 - Manual 37135 GR37135 Discrete expansion board with 8 discrete inputs and 8 relay outputs that can be coupled via the CAN bus to the control unit. As- sessment of the discrete inputs as well as control of the relay outputs is done via the control unit. LeoPC1 - Manual 37146 GR37146 PC program for visualization, configuration, remote control, data logging, language upload, alarm and user management and man- agement of the event recorder. This manual describes the use of the program. LeoPC1 - Manual 37164 GR37164 PC program for visualization, configuration, remote control, data logging, language upload, alarm and user management and man- agement of the event recorder. This manual describes the programming of the program. GW 4 - Manual 37133 GR37133 Gateway for transferring the CAN bus to any other interface or bus. ST 3 - Manual 37112 GR37112 Control to govern the air fuel ratio of a gas engine. The ratio will be directly measured though a Lambda probe and controlled to a configured value. Table 1-1: Manual - Overview Manual 37365A GCP-30 Series Packages - Genset Control Page 8/179 © Woodward Functional Overview ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Function Package GCP-31 GCP-32 BPQ XPD XPQ XPQ+SB03 XPQ+SC10 BPQ XPD XPQ XPQ+SB03 XPQ+SC10 Common Functions 1× readiness for operation relay 9 9 9 9 9 9 9 9 9 9 4/6× control relay (form A, make contact) 9 9 9 9 9 9 9 9 9 9 7× freely configurable relay outputs (form A, make contact) 9 9 9 9 9 9 9 9 9 9 2× three-position controller for n/f/V/P, power factor * -- 9 -- -- -- -- 9 -- -- -- 2× three position controller for n/f/V/P, power factor via relay manager * 9 -- 9 9 9 9 -- 9 9 9 2× analog controller outputs for n/f/V/P/Q and PWM output * 9 -- 9 9 9 9 -- 9 9 9 up to 8× discrete control inputs 6 8 8 8 8 6 8 8 8 8 16× discrete alarm inputs 16 16 16 16 16 16 16 16 16 16 CAN bus interface 'guidance level' 9 9 9 9 9 9 9 9 9 9 CAN bus interface to 2× IKD 1 and ST 3 -- -- -- -- 9 -- -- -- -- 9 CAN bus communications with mtu MDEC and Scania EMS/S6 -- -- -- -- 9 -- -- -- -- 9 CAN bus communications with SAE J1939 -- -- -- -- 9 -- -- -- -- 9 RS-232 communications via Caterpillar CCM with ECM & EMCP-II -- -- -- 9 -- -- -- -- 9 -- 7× analog inputs -- 9 9 9 9 -- 9 9 9 9 1× Magnetic Pick-Up input 9 9 9 9 9 9 9 9 9 9 2× analog outputs + external operation mode selection by term. 127/128 -- 9 9 9 9 -- 9 9 9 9 Password system 9 9 9 9 9 9 9 9 9 9 Configuration via DPC possible (direct configuration) 9 9 9 9 9 9 9 9 9 9 Event recorder with real-time clock -- 9 9 9 9 -- 9 9 9 9 Language manager for LCD texts 9 9 9 9 9 9 9 9 9 9 Running hours, maintenance, start, and kWh counter 9 9 9 9 9 9 9 9 9 9 Control/Synchronization Synchronization of 1 breaker with V and f correction * 9 9 9 9 9 9 9 9 9 9 Synchronization of 2 breakers with V and f correction * -- -- -- -- -- 9 9 9 9 9 Closing to a dead/voltage free busbar (dead bus start) 9 9 9 9 9 9 9 9 9 9 Voltage control 9 9 9 9 9 9 9 9 9 9 Power factor control 9 9 9 9 9 9 9 9 9 9 Speed/frequency control 9 9 9 9 9 9 9 9 9 9 Generator real power control & import/export real power control 9 9 9 9 9 9 9 9 9 9 Real power & var sharing 9 9 9 9 9 9 9 9 9 9 Analog set point value for real power -- 9 9 9 9 -- 9 9 9 9 Analog mains interchange (import/export) real power measuring -- 9 9 9 9 -- 9 9 9 9 "Open transition" & "closed transition" breaker logic -- -- -- -- -- 9 9 9 9 9 "Soft loading "breaker logic -- -- -- -- -- 9 9 9 9 9 "Parallel operation" breaker logic 9 9 9 9 9 9 9 9 9 9 "External" breaker logic 9 9 9 9 9 9 9 9 9 9 Remote control via CAN bus interface 9 9 9 9 9 9 9 9 9 9 Protective Functions Over-/undervoltage monitoring, generator VGen>/< 9 9 9 9 9 9 9 9 9 9 Over-/undervoltage monitoring, mains VMains>/< 9 9 9 9 9 9 9 9 9 9 Over-/underfrequency monitoring f>/< 9 9 9 9 9 9 9 9 9 9 dϕ/dt vector/phase jump monitoring dϕ/dt 9 9 9 9 9 9 9 9 9 9 Reverse/reduce power monitoring +/-PGen< 9 9 9 9 9 9 9 9 9 9 Overload monitoring PGen> 9 9 9 9 9 9 9 9 9 9 Unbalanced load monitoring ΔPGen> 9 9 9 9 9 9 9 9 9 9 Independent time-overcurrent monitoring I> / I>> 9 9 9 9 9 9 9 9 9 9 Battery voltage monitoring VBat< 9 9 9 9 9 9 9 9 9 9 * n = speed / f = frequency / V = voltage / P = real power / Q = reactive power Table 1-2: Functional overview Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 9/179 Chapter 2. Function Considerations To Be Taken: ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Different Options Depending how a control unit is configured, different parameters will be displayed and only the relevant parame- ters will be able to be accessed: • Various inputs and outputs will be present or deleted, corresponding to the control configuration (depending on the ordered package). Please refer to the wiring diagram and the notes regarding the packages contained in these. The control inputs and outputs will vary by the specific package ordered. Refer to the wiring diagram and notes that correspond to them. • Specific display screens correspond to specific types of interfaces. Systems Without a Mains Circuit Breaker If a control with 2-circuit-breaker logic [GCP-32] or 1-circuit-breaker logic [GCP-31] is installed for use with one circuit breaker, the following shall apply: • If the control unit is to be operated in an isolated or an isolated parallel application (the MCB is opened), the following terminals must be energized/de-energized: - "Reply: MCB is open" / "Isolated operation" (terminal 54): energized (logical "1") - "Enable MCB" (terminal 53): de-energized (logical "0") - Condition: Parameter 137 "Emergency power" must be configured as "OFF". • If the control unit is to be operated in a mains parallel application (the MCB always is closed if the generator operates in mains parallel), the following terminals must be energized/de-energized: - "Reply: MCB is open" / "Isolated operation" (terminal 54): de-energized (logical "0") - "Enable MCB" (terminal 53): energized (logical "1") • If the control unit is to be operated in an isolated parallel as well as a mains parallel application (the MCB can be opened or closed), the following terminals must be energized/de-energized: - "Reply: GCB is open" (terminal 4): de-energized (logical "0") - "Reply: MCB is open" (terminal 54): de-energized (logical "0") - "Enable MCB" (terminal 53): energized (logical "1") Case A - The MCB must remain closed (except during an emergency power operation): Terminal 53 must be energized. Case B - The MCB can be opened (except during an emergency power operation): If a mains parallel opera- tion is to be initiated, terminal 53 must be energized to initiate synchronization of the MCB. During the syn- chronization of the MCB (GCP-31: This is performed by an LS-4 or external control) the generator frequency is increased to a level slightly higher than the mains frequency (df max/2). A message is shown in the LC dis- play that the unit is synchronizing. If the system is to be disconnected from the mains and operated in an is- land mode, terminal 53 must be de-energized. Manual 37365A GCP-30 Series Packages - Genset Control Page 10/179 © Woodward Signals ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Discrete Inputs NOTE Emergency power and critical operation modes will be carried out while the GCP-30 is in TEST or AUTOMATIC mode regardless if the discrete inputs for "Automatic 1" and/or "Automatic 2" are enabled. This is dependent upon if Parameter 137 (Emergency power) has been configured as ON and if Para- meter 211 (Terminal 6) is configured for a critical/sprinkler mode. NOTE If terminals 3 and 5 are enabled simultaneously, terminal 3 has precedence over terminal 5 and the generator will operate in accordance with how "Automatic 1" is configured. Automatic 1 (Start/Stop the engine) Terminals 3/7 Enabling this input while the control is in the AUTOMATIC operation mode will result in the GCP- 30 controlling the real power in accordance with how "P controller: set point 1" is configured and may be used to initiate the engine start/stop sequence. Energize........ If the AUTOMATIC operation mode has been enabled the real power is controlled in the manner configured in "P controller: set point 1" (Parameter 35) while in parallel with the mains. If "P controller: set point 1" is configured for baseload (C), import (I), or export (E) the engine will start when terminal 3 is energized and a mains parallel operation will be performed following the synchronization of the GCB. If the genera- tor is not connected to the mains, the generator will start, perform a dead bus closure, and assume the load. Additional generators will synchronize and share the load propor- tionally. If the controller is in the AUTOMATIC operation mode and "P controller: set point 1" (Parameter 35) is configured for 000kW and "Loadd.start/stop at ter.3" (Parameter 95) is configured OFF, the engine will start and the GCB will synchronize. The load may be increased or decreased by raising or lowering the load set point manually. The load for the control is changed by pressing the SETPOINT button until the "P set 1" screen is displayed and increasing or decreasing the load set point to the desired value by pressing either the Setpoint raise or lower buttons. De-energize .. The generator will unload, the GCB will open, and the engine will perform a cool down and stop unless an emergency power or critical/sprinkler mode operation is ac- tive. The generator will shutdown after the emergency power or critical/sprinkler mode operation has terminated. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 11/179 Automatic 2 (Start/Stop the engine) Terminals 5/7 Enabling this input while the control is in the AUTOMATIC operation mode will result in the GCP- 30 controlling the real power in accordance with how " P controller: set point 2" is configured and may be used to initiate the engine start/stop sequence. Energize ........If the AUTOMATIC operation mode has been enabled the real power is controlled in the manner configured in "P controller: set point 2" (Parameter 36) while in parallel with the mains. If "P controller: set point 2" is configured for baseload (C), import (I), or export (E) the engine will start when terminal 5 is energized and a mains parallel operation will be performed following the synchronization of the GCB. If the genera- tor is not connected to the mains, the generator will start, perform a dead bus closure, and assume the load. Additional generators will synchronize and share the load propor- tionally. If the controller is in the AUTOMATIC operation mode and "P controller: set point 2" (Parameter 36) is configured for 000kW and "Loadd.start/stop at ter.5" (Parameter 96) is configured OFF, the engine will start and the GCB will synchronize. The load may be increased or decreased by raising or lowering the load set point manually. The load for the control is changed by pressing the SETPOINT button until the "P set 2" screen is displayed and increasing or decreasing the load set point to the desired value by pressing either the Setpoint raise or lower buttons. De-energize ...The generator will unload, the GCB will open, and the engine will perform a cool down and stop unless an emergency power or critical/sprinkler mode operation is ac- tive. The generator will shutdown after the emergency power or critical/sprinkler mode operation has terminated. If a set point value is specified externally (e.g. via an 0/4 to 20 mA analog input or a bi-directional in- terface), the external set point value is the discrete input enabled by energizing terminal 5 (refer to Table 3-3: Set point value table). Multifunction Terminals 6/7 Terminal 6 may be configured to perform one of several functions. Parameter 211 lists the available functions. Note: When the Critical (Sprinkler) mode is configured, the input operates on negative logic. The Critical (Sprinkler) mode is disabled when terminal 6 is energized and enabled when terminal 6 is de- energized. Reply: GCB is open Terminals 4/7 When this input is energized, the controller recognizes that the GCB is open (the "GCB ON" LED is not illuminated). [GCP-32] Reply: MCB is open Terminals 54/7 When this input is energized, the controller recognizes that the MCB is open (the "MCB ON" LED is not illuminated). [GCP-31] Isolated operating / reply external breaker Terminals 54/7 When this input is energized, the controller recognizes that the genset is operating isolated from the mains (the "Mains parallel" LED is not illuminated). This discrete input determines if the controller performs frequency control (terminal 54 = energized) or real power control (terminal 54 = de- energized) after the GCB has been closed. Enable MCB Terminals 53/7 Energized ......The MCB has been enabled and a mains parallel operation will be performed. The GCP-31 uses the LS-4 or an external controller to operate the MCB. De-energized .The MCB is disabled and cannot be closed. The controller will operate as an isolated or mains parallel operation dependent upon the state of the input "Reply MCB is open". Manual 37365A GCP-30 Series Packages - Genset Control Page 12/179 © Woodward Discrete inputs Terminals 34 to 36/33 and 61 to 73/60 These freely programmable alarm inputs may be configured with user defined text, alarm classes, time delays, whether alarm monitoring should be delayed by the engine speed, and if the contacts are N.O. or N.C. contacts. Control Outputs Ready for operation Terminals 18/19 This relay output is used to ensure that the internal functions of the controller are operating properly. If this relay is bypassed or disabled, proper functionality of the control cannot be guaranteed. This re- lay should be used in conjunction with an alarm that ensures proper actions are initiated upon activa- tion of this relay output (i.e. GCB opening, engine shutdown). It is recommended that this contact be put in series with an emergency stop function. Preheating (Diesel engine) pre-assigned to terminals 37/38 When this relay is enabled, the diesel engine's glow plugs are energized (refer to the "Diesel Engine" section). This function only occurs if the control has been configured for diesel engine start/stop logic. Ignition "ON" (Gas engine) pre-assigned to terminals 37/38 When this relay is enabled, the ignition of the gas engine is energized (refer to the "Gas Engine" sec- tion). This function only occurs if the control has been configured for gas engine start/stop logic. Fuel relay / gas valve Terminals 43/44 a) Diesel engine: fuel relay (Parameter 269) a.1) Open to stop A start/run command will initiate the start sequence for the diesel engine and close the contacts for this relay energizing the fuel solenoid relay. This relay will disable (contacts open) when a stop command is issued or the engine speed drops below the configured firing speed (Parameter 272). Refer to the "Diesel Engine" section. a.2) Close to stop A start/run command will initiate the start sequence for the diesel engine and open the contacts for this relay. This relay will enable (contacts close) when a stop command is issued or the engine speed drops below the configured firing speed (Parameter 272). Refer to the "Diesel Engine" sec- tion. b) Gas engine: gas valve A start/run command will initiate the start sequence for the gas engine and close the contacts for this relay energizing the gas valve relay. This relay will disable (contacts open) when a stop com- mand is issued or the engine speed drops below the configured firing speed (Parameter 272). Refer to the "Gas Engine" section. Starter Terminals 45/46 The starter relay is enabled when a start command is issued. The starter relay output is de-energized when firing speed (Parameter 272) has been achieved, the configured crank time (Parameter 259 or Parameter 265) has expired, or the STOP mode is enabled. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 13/179 Centralized alarm pre-assigned to terminals 47/48 This relay is enabled when a centralized alarm is issued. An external horn, buzzer, or beacon may be operated by this relay output during a fault condition. Pressing the "RESET" button will reset the re- lay. The relay will re-energize if another alarm condition is detected. The centralized alarm is issued for fault classes F1 through F3. Command: close GCB Terminals 14/15 The "Command: close GCB" relay issues the signal for the GCB to close. This relay may be config- ured for a momentary pulse to operate an external holding coil for the GCB or for a continuous cur- rent (Parameter 114). If the relay is configured for a momentary pulse, the relay will energize for the time configured in "Synchronize time pulse" (Parameter 119). If the relay is configured for a constant current, the relay will energize and remain energized when the discrete input "Reply: GCB is open" de-energizes and the generator and busbar voltages are identical. If an F2 alarm condition is detected, the generator load is reduced and the GCB is opened when the measured power is less than 3% of rated or the time configured for "Add on/off max. time" (Para- meter 112) expires, which ever occurs first. If an F3 alarm condition is detected, this relay de- energizes immediately. Command: open GCB Terminals 41/42 The "Command: open GCB" relay issues the signal to open the GCB. After the open command has been issued this relay is de-energized. [GCP-32] Command: close MCB Terminals 16/17 The "Command: close MCB" relay issues the signal for the MCB to close. This relay is a momentary pulse and must be used with an external holding coil for the MCB. [GCP-32] Command: open MCB Terminals 39/40 The "Command: open MCB" relay issues the signal to open the MCB. After the open command has been issued this relay is de-energized. Relay Manager Terminals 74 to 83, 37/38, 47/48 The "Relay Manager" (Parameter 250) permits specific logical functions to be assigned to specific re- lay outputs. Default values: •·Relay 1 to 5 = relay number (e.g. relay 1 = alarm class F1, relay 2 = alarm class F2, etc.) •·Relay 6 = Ignition / preheating •·Relay 7 = Centralized alarm Refer to Appendix B for a description of the Relay Manager functions. Manual 37365A GCP-30 Series Packages - Genset Control Page 14/179 © Woodward Chapter 3. Configuration Configuration may be performed via the front panel keys or using a PC and the LeoPC1 program via the serial interface. LeoPC1 version 3.1 or higher is required to perform this. Configuration via a CAN bus converter is also possible. The following communication protocols require the following baud rates: • Direct configuration (RS-232) = 9,600 Baud (8 Bit, no parity, 1 Stop bit) • CAN bus (CiA) (RS-485) = 125 kBaud CAUTION A PC with configuration software with the following revision number or higher is required to configure this control (applies to firmware versions 4.3xxx or higher): LeoPC1 from 3.1 GCP controllers with Option SC10 cannot be completely configured through the face panel. Therefore, it is recommended to have LeoPC1 and the correct configuration files available when commissioning. Due to functional enhancements of the GCP-30 control series, it is necessary (beginning with firmware version 4.3xxx) to use a newer version of the configuration software LeoPC1. This requires that LeoPC1 version 3.1 or higher be used. If your current LeoPC1 software is an earlier version, the latest version can be ordered from our technical sales or can be downloaded from our homepage at http://www.woodward.com/software. Older project files may still be used with the updated version of LeoPC1 after installation has been completed. These files should be transferred to the appropriate file locations within the updated version of LeoPC1. WARNING Please note that configuration only should be performed while the system is not operating. NOTE Prior to configuring a control unit, familiarize yourself with the parameters listed in this manual. You can advance through the individual parameter screens if you are in configuration mode (simultaneously pressing of "Digit↑" and "Cursor→" push buttons permits access to the configuration mode) by using the "Se- lect" button. If you press and hold the "Select" push button, the scroll function will be activated, allowing for the parameter screens to be advanced through more rapidly. The control unit will permit the operator to reverse up to four previous screens (exception: it is not possible to reverse from the first parameter to the last parameter or to backup through the service screens). To perform the reverse function through the parameter screens, the "Select" and "Cursor→" push buttons must be pressed and released simultaneously. The control unit will revert to auto- matic mode if an entry isn’t performed, a change made, or any other action performed for 90 seconds. NOTE Two hardware versions are described in this manual. The differences between these versions are 120 Vac and 480 Vac voltage-measuring inputs. Configuration screens and permissible limits of these units will differ as well. These models are differentiated by numerals in the applicable text. The 120 Vac model is identified by a [1] and the 480 Vac is identified by a [4] in front of the text that applies to the unit. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 15/179 Basic Data ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Version Number (Software Version) Parameter 1 Software version Vx.xxxx Software version This screen displays the software version loaded into the control (the last two xx are for software revisions which do not affect the function of the unit). Password The unit is equipped with a three-level code and configuration hierarchy, which allows different user access to the control. A distinction is made between: Code level CS0 (User Level) Factory password = none This code level allows for monitoring of the system and does not permit access to the parameters. Configuration is blocked. Code level CS1 (Basis Service Level) Factory password = "0 0 0 1" This code level entitles the user to change selected parameters, like setting Bar/PSI, °C/°F, and clock adjustment. Changing a password is not permitted at this level. This password expires two hours after entering the password and the user is returned to the CS0 level. Code level CS2 (Commissioning Level) Factory password = "0 0 0 2" Allows direct access to all parameters (displaying and changing). In addition, the user may also set the password for levels CS1 and CS2. This password expires two hours after entering the password and the user is returned to the CS0 level. NOTE Once the code level is entered, access to the configuration menus will be allowed for two hours or until another password is entered into the control. If a user needs to exit a code level, then code level CS0 should be entered. This will block any configuration of the control. Specific code levels may also be accessed using the LeoPC1 program. Parameter 2 Enter code 0000 Enter code number 0000 to 9999 Upon enabling the configuration mode, the user is required to enter an access code number, which identifies the various users. The displayed number 0000 is a ran- domly generated number. If the random number is confirmed by pressing the "Se- lect" button without being changed, the current level of access maintained. Upon entering either a level 1 or level 2 access code, the corresponding level of access is granted. If an incorrect access code is entered the control unit changes to code level 0 and all access is blocked until a code level 1 or 2 access code is entered. Manual 37365A GCP-30 Series Packages - Genset Control Page 16/179 © Woodward Direct Configuration NOTE A direct configuration cable DPC (P/N 5417-557), the LeoPC1 program (supplied with the cable), and the corresponding configuration files are required to perform direct configuration. After the program has been installed, consult the online help for a description of the PC program and its setup. Configuration files may be downloaded from the Woodward homepage at: http://www.woodward.com/software/ConfigFiles/ The unit part number and revision number will be required to locate the appropriate configuration files. Remote configuration: For remote configuration, the level CS2 password of must be entered via the parameter "Enter code", otherwise, the values can only be read but not written. Configuring via the communication bus has no effect on the unit display screen. This means that the control unit remains in code level 0and configuration is only permitted via the communication bus. The control may remain idle for 2 hours before configuration via the communication bus is disabled. The password must be re-entered to re-enable configuration via the communica- tion bus again. The password must also be entered prior to loading a language file. If the code for level 2 is en- tered on the unit itself, configuration via the communication bus is automatically enabled. WARNING If Parameter 3 "Direct para." is configured to "YES", communication via the interface terminals X1 to X5 is disabled. If the interface communication is to be re-established after the unit is configured, Para- meter 3 must be configured to "NO"! The GCP-30 will automatically disable the direct configuration port (Parameter 3 is automatically switched from YES to NO) when the unit detects that firing speed has been achieved (Parameter 272). Additional configuration may be performed while the generator is running through the display panel or via a CAN bus converter (i.e. IXXAT USB to CAN 1 converter). The direct configuration port is disabled and the communication interface is re-enabled upon detection firing speed as a safety precaution. This is done to prevent a simultaneous closing of GCBs to the de-energized bus bar in the event conditions for a multiple unit start-up (i.e. emergency power situation) are detected. Parameter 3 Direct para. YES Direct configuration YES/NO YES ..............The direct configuration port is enabled, and CAN bus communica- tions via X1 to X5 terminals are disabled. The following conditions must be met in order to carry out configuration via the configuration port: - A connection must be established via the direct configuration cable between the control and the PC - The baud rate of the LeoPC1 program must be set to 9,600 Baud - The corresponding configuration file for the controller must be used (file name: "xxxx-xxxx-yyy-zz.asm"). NO ................The direct configuration port is disabled and CAN bus communica- tions via X1 to X5 terminals are enabled. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 17/179 Generator Number Parameter 4 Generator number 0 Generator number (controller CAN bus address) 1 to 14 If a power plant is composed of multiple generators with controllers, the controllers must be coupled via a CAN bus. Each controller must be assigned a unique CAN bus address to differentiate the units. Generator address number 1 should be as- signed even if the power plant is composed of only a single generator and control- ler. The address assigned in this parameter corresponds to the control number used in the LeoPC1 program. Language Manager (XPD, XPQ) The following steps must be accomplished in order to load a different language into the control: 1.) A communication link between your PC and the control unit must be established via the direct configura- tion cable (DPC). To do this insert the serial cable into the COM port of your PC and the RJ45 plug into the communication port of the control unit (communication via the CAN bus or a GW 4 is also possible). 2.) Enter the CS 2 level password into the control (Parameter 2). 3.) If the direct configuration cable (DPC) is to be utilized, Parameter 3 "Direct para." must be configured as "YES". If a GW 4 or the CAN bus is to be utilized for configuration, Parameter 3 "Direct para." must be configured as "NO". 4.) If a language is to be loaded via the CAN bus, enter the desired CAN bus address (1 to 14) into the "Gen- erator number" screen (Parameter 4), so that LeoPC1 is able to communicate with the correct control unit. 5.) Scroll the configuration screen on the controller to "Language" (Parameter 5) and select either the primary language for the control unit by selecting "first" or the secondary language by selecting "second". 6.) Start the program LeoPC1, and log into the program by selecting "System" from the tool bar and "User login…" from the drop down menu or clicking on the key icon. 7.) Enter the user name and password and click the "OK" button. The default user ID is "system" and the de- fault password is "system". Manual 37365A GCP-30 Series Packages - Genset Control Page 18/179 © Woodward 8.) Open the applicable *.cfg file for the application by selecting "File" from the tool bar and "open" from the drop down menu. Select the proper *.cfg file from the window that appears. 9.) To start communication between the control unit and LeoPC1 select "Communication" from the tool bar and "Connect" from the drop down menu or click on the up and down arrow icon. 10.) Select "Devices" from the tool bar and "Parameterize…" from the drop down menu or click on the letter P icon. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 19/179 11.) A window will appear with all the tunable parameters in it. Move the cursor over the numbers for the pass- word and double click. 12.) Enter the password for code level CS 2 (Parameter 2). 13.) Close the parameterization window. 14.) Select "Devices" from the tool bar and "Load language…" from the drop down menu or click on the letter L icon. Manual 37365A GCP-30 Series Packages - Genset Control Page 20/179 © Woodward 15.) Load the desired language file using the button "Load LNG file ..." 16.) Select the desired language and click the "Transfer language" button. 17.) If an additional language is to be loaded into the control unit, return to step 5 and change the language se- lection from the currently active language to the inactive language and acknowledge the change with the "Select" button. This is cannot be accomplished via LeoPC1. Repeat the sequence of step use to load the previous language. Parameter 5 Language ----- Language first / second first ...............All texts are displayed in the primary language. second...........All texts are displayed in the secondary language. Service Display Refer to manual 37238 for a description of these screens. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 21/179 Event Logger (XPD, XPQ) ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ NOTE Displaying and clearing of events depends on access authorization: • Displaying of events ..................... Access authorization CS# 1 und CS# 2 • Clearing of events......................... Access authorization CS# 2 # CS = Code level (see chapter "Password" on page 15. When an event listed on Table 3-1 or Table 3-2 occurs, it is stored in the event logger. The following information is recorded: • Event • Date of occurrence • Time of occurrence Up to 50 events can be stored in the event logger. The stored events are listed in chronological order starting with the most recent event. The oldest event entries are automatically deleted when the event log reaches 50 entries and a new event is recorded. Pressing the "RESET" button while an event is displayed will clear the event from the event log. The events are displayed on two lines. The top line indicates the date and time of the event that has occurred; the lower line shows the type of event. Parameter 6 check event list YES Event logging YES/NO YES ..............Events can be viewed and acknowledged. NO................Events cannot be viewed and acknowledged. NOTE Starting from version 4.3010, the event logger can also be read via CAN. This makes it possible for the event logger to be read via a GW4/modem for example. If the event logger is to be read via CAN, the respective connection protocol (i.e. Gateway-RS232, IX- XAT VCI2-CAN, etc.), must be selected in LeoPC1. Reading the event logger is then performed in the same manner as for direct configuration. Possible Event Logger Entries YY-MM-DD ss:mm xxxxxxxxxxxxxxxx 50 × alarm log YY-MM-DD ss:mm ........Display of date and time of the event. xxxxxxxxxxxxxxxx ...Refer to Table 3-1 or Table 3-2 for event text. Manual 37365A GCP-30 Series Packages - Genset Control Page 22/179 © Woodward Event type xxxxxxxxxxxxxxxx German English Internal events Engine overspeed (Pickup) Überdrehzahl Over speed Generator overfrequency Überfrequenz Overfrequency Generator underfrequency Unterfrequenz Underfrequency Generator overvoltage Gen.-Überspg. Gen.overvolt. Generator undervoltage Gen.-Unterspg. Gen.undervolt. Generator overcurrent, level 1 Gen.-Überstrom 1 Gen.overcurr. 1 Generator overcurrent, level 2 Gen.-Überstrom 2 Gen.overcurr. 2 Reverse/reduced power Rück/Minderleist Revers/min.power Overload Gen.-Überlast Gen.overload Unbalanced(asymmetrical load Schieflast Load unbalance Mains overvoltage Netz-Überspg. Mains-overvolt. Mains undervoltage Netz-Unterspg. Mains-undervolt. Mains overfrequency Netz-Überfreq. Mains-underfreq. Mains underfrequency Netz-Unterfreq. Mains-overfreq. Mains phase/vector jump Phasensprung Phase shift Battery undervoltage Batt.-Unterspg. Batt.undervolt. GCB synchronization time monitoring expired Synch.Zeit GLS GCB syn.failure MCB synchronization time monitoring expired Synch.Zeit NLS MCB syn.failure CB closure to dead busbar time monitoring expired Stör. df/dU-max. Failure df/dVmax The unload ramp rate timer has expired and the breaker was opened prior to the load reaching the minimum load R-Rampe:GLS auf P-ramp:open GCB GCB closing malfunction Störung GLS ZU GCBclose failure MCB closing malfunction Störung NLS ZU MCBclose failure GCB opening malfunction Störung GLS AUF GCB open failure MCB opening malfunction Störung NLS AUF MCB open failure Zero power transfer control failure at GCB interchange synchronization Bezugsleist. <>0 Power not zero Maintenance call timer expired Wartung Service Control unit CAN bus (X1 to X5) interface monitoring failure Fehl.Schnit.X1X5 Interf.err. X1X5 ECU CAN bus (Y1 to Y5) interface monitoring failure Fehl.Schnit.Y1Y5 Interf.err. Y1Y5 Magnetic Pickup/generator frequency mismatch Pickup/Gen.Freq. Pickup/Gen.freq. Engine failed to stop Abstellstörung Stop failure Engine failed to start Fehlstart Start failure Engine stopped unintentionally ungewollter Stop unintended stop GCP Discrete Inputs Discrete input [D01] Discrete input [D02] Discrete input [D03] Discrete input [D04] Discrete input [D05] Discrete input [D06] Discrete input [D07] Discrete input [D08] Discrete input [D09] Discrete input [D10] Discrete input [D11] Discrete input [D12] Discrete input [D13] Discrete input [D14] Discrete input [D15] Discrete input [D16] frei parametrierbar freely configurable Table 3-1: Event recorder - Messages, part 1 Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 23/179 External expansions Discrete input [D1.01] of IKD1.1 Option SC10 + IKD1 Discrete input [D1.02] of IKD1.1 Option SC10 + IKD1 Discrete input [D1.03] of IKD1.1 Option SC10 + IKD1 Discrete input [D1.04] of IKD1.1 Option SC10 + IKD1 Discrete input [D1.05] of IKD1.1 Option SC10 + IKD1 Discrete input [D1.06] of IKD1.1 Option SC10 + IKD1 Discrete input [D1.07] of IKD1.1 Option SC10 + IKD1 Discrete input [D1.08] of IKD1.1 Option SC10 + IKD1 Discrete input [D2.01] of IKD1.2 Option SC10 + IKD1 Discrete input [D2.02] of IKD1.2 Option SC10 + IKD1 Discrete input [D2.03] of IKD1.2 Option SC10 + IKD1 Discrete input [D2.04] of IKD1.2 Option SC10 + IKD1 Discrete input [D2.05] of IKD1.2 Option SC10 + IKD1 Discrete input [D2.06] of IKD1.2 Option SC10 + IKD1 Discrete input [D2.07] of IKD1.2 Option SC10 + IKD1 Discrete input [D2.08] of IKD1.2 Option SC10 + IKD1 frei parametrierbar freely configurable Air-fuel-ratio sender alarm from ST 3 Option SC10 + ST 3 Lambdasonde Lambda probe Other Events MANUAL operation mode enabled BAW Hand Manual mode AUTOMATIC operation mode enabled BAW Automatik Automatic mode STOP operation mode enabled BAW Stop Stop mode TEST operation mode enabled BAW Probe Test mode Load TEST operation mode enabled BAW Lastprobe Loadtest mode "MCB OFF" button pressed (in MANUAL MODE) Taste NLS AUS Button MCB OFF "GCB OFF" button pressed (in MANUAL MODE) Taste GLS AUS Button GCB OFF "GCB ON" button pressed (in MANUAL MODE) Taste GLS EIN Button GCB ON "MCB ON" button pressed (in MANUAL MODE) Taste NLS EIN Button MCB ON "START" button pressed (in MANUAL MODE) Taste Hand START Button START "STOP" button pressed (in MANUAL MODE) Taste Hand STOP Button STOP Remote start initiated Fernstart Remote start Remote stop initiated Fernstop Remote stop Remote acknowledgment via interface Fernquittierung Remote acknowl. Remote acknowledgment via terminal 6 Quittierung Kl.6 Acknowledg-ter 6 Acknowledgment via "RESET" button Quittierg. Taste Ackn.button QUIT Mains failure (AMF) Netzausfall Mains failure Mains settling time has expired Netzwiederkehr Mains o.k. Emergency power (AMF) started Notstrom Anfang Emerg. run start Emergency power (AMF) ended Notstrom Ende Emerg. run stop Engine successfully started (engine enabled, firing speed exceeded) Aggr. gestartet Start of engine Engine intentionally stopped Aggregatestop Stop of engine Table 3-2: Event recorder – Messages, part 2 Analog Inputs The display of the control unit is the analog alarm texts. Six digits on the left side of the screen are reserved for the monitored analog values. If the texts for these alarms are expanded to the complete message, the monitored values will be overwritten and not displayed. The text below is displayed when the controller detects the listed fault conditions. WIRE__.......Wire break (Analog input wire broken) ALARM_.......Limit 1 value exceeded STOP__.......Limit 2 value exceeded YY-MM-DD ss:mm STOP Analog inpu Example Limit 2 value (STOP) of analog input 1 was exceeded. The text for the analog input shifts 6 digits to the right. This results in the measured value not being displayed. Ensure you take the text displacement into account when configuring the analog input! Manual 37365A GCP-30 Series Packages - Genset Control Page 24/179 © Woodward Measuring ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ WARNING It is absolutely necessary for correct rated values to be entered in the following parameters, as numer- ous measurements and monitoring functions refer to these values. Failure to do so may lead to incor- rect measuring of parameters resulting in damage to or destruction of the generator and/or personal in- jury or death. NOTE The parameters for this control are grouped together in blocks to permit navigation through the large number of configuration screens more rapidly. Selecting "YES" or "NO" has no effect whether or not control or monitoring is carried out for the parameters located in that block. Selecting "YES" or "NO" only determines if the individual parameters may be accessed and changed or are bypassed. Parameter 7 Configure measuring YES Configuration of the measuring values YES/NO The basic generator measuring values are configured in this block of parameters. This parameter has the following effect: YES ..............The parameters in this block are displayed and can either be viewed ("Select" button), or modifications can be made to the parameters ("Cursor→", "Digit↑" or "Select" buttons). NO ................The parameters in this block are not displayed, cannot be modified, and are skipped. Rated Frequency Parameter 8 Generator freq. f set 00.0Hz Generator frequency set point 40.0 to 70.0 Hz The generator frequency set point is configured here. This is the reference fre- quency that the generator will control at when operating in an isolated and/or no- load applications.. In most cases, the value entered into this screen will be 50 Hz or 60 Hz. It is possible to configure a value other than 50 Hz or 60 Hz into this pa- rameter. Parameter 9 Rated system frequency 00.0Hz System rated frequency 50/60 Hz The frequency of the system that the generator is going to connect to must be con- figured in this parameter. This parameter is dependent on the individual country or individual system. Potential Transformers (Voltage Transformers) WARNING The values of the following parameters must be verified to ensure that they are compatible with the configured values for the potential transformers: • Generator rated voltage (Parameter 16) • Voltage controller dead band (Parameter 58) • Maximum voltage differential (dV max) for synchronization (Parameter 118) • Maximum voltage differential (dV max) for a GCB dead bus closure (Parameter 127) • Generator overvoltage threshold (Parameter 175) • Generator undervoltage threshold (Parameter 177) Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 25/179 Parameter 10 Gen.volt.transf. secondary 000V Generator potential transformer secondary [1] 50 to 125 V; [4] 50 to 480 V L This value corresponds to the rated voltage on the secondary side of the PTs, which are directly connected to the control. The potential transformer secondary voltage is set here in V. This parameter is util- ized to calculate the generator voltage in the display. For voltages of 400 V meas- ured without a potential transformer, 400 V must be entered here. Parameter 11 Gen.volt.transf. primary 00.000kV Generator potential transformer primary 0.050 to 65.000 kV L This value corresponds to the rated voltage on the primary side of the PTs. The potential transformer primary voltage is entered here in kV. This entry is used to show the generator voltage in the display. For voltages measured without a po- tential transformer such as 400V, the value must be entered as 00.400 kV. Parameter 12 Bus.volt.transf. secondary 000V Busbar potential transformer secondary [1] 50 to 125 V; [4] 50 to 480 V L This value corresponds to the rated voltage on the secondary side of the PTs, which are directly connected to the control. The potential transformer secondary voltage is set here in V. This parameter is util- ized to calculate the busbar voltage in the display. For voltages of 400 V measured without a potential transformer, 400 V must be entered here. Parameter 13 Bus.volt.transf. primary 00.000kV Busbar potential transformer primary 0.050 to 65.000 kV L This value corresponds to the rated voltage on the primary side of the PTs. The potential transformer primary voltage is entered here in kV. This entry is used to show the busbar voltage in the display. For voltages measured without a poten- tial transformer such as 400V, the value must be entered as 00.400 kV. WARNING The values of the following parameters must be verified to ensure that they are compatible with the configured values for the potential transformers: • Mains overvoltage threshold (Parameter 185) • Mains undervoltage threshold (Parameter 187) Parameter 14 mains volt.trans secondary 000V Mains potential transformer secondary [1] 50 to 125 V; [4] 50 to 480 V L This value corresponds to the rated voltage on the secondary side of the PTs, which are directly connected to the control. The potential transformer secondary voltage is set here in V. This parameter is util- ized to calculate the mains voltage in the display. For voltages of 400 V measured without a potential transformer, 400 V must be entered here. Parameter 15 mains volt.trans primary 00.000kV Mains potential transformer primary 0.050 to 65.000 kV L This value corresponds to the rated voltage on the primary side of the PTs. The potential transformer primary voltage is entered here in kV. This entry is used to show the mains voltage in the display. For voltages measured without a potential transformer such as 400V, the value must be entered as 00.400 kV. Manual 37365A GCP-30 Series Packages - Genset Control Page 26/179 © Woodward Rated Voltage Parameter 16 Gen.voltage V set 000V Generator voltage set point [1] 50 to 125 V; [4] 50 to 530 V L This value corresponds to the rated voltage on the secondary side of the PTs, which are directly connected to the control. The generator voltage set point is configured here. This is the reference voltage that the generator will control at when operating in an isolated and/or no-load applica- tions. The voltage controller enable set point (Parameter 55) refers to the value con- figured in this parameter. Parameter 17 Rated voltage in system 000V Rated system voltage [1] 50 to 125 V; [4] 50 to 480 V The system rated voltage (VL-L) is defined in this parameter. The following parameters use the value configured here as a protection and control reference point: - Generator voltage monitoring - Mains voltage monitoring - Voltage controller dead band - Maximum voltage differential (dV max) for synchronization - Maximum voltage differential (dV max) for a GCB dead bus closure Parameter 18 Volt.meas./mon. ---------------- This parameter affects the display. Voltage measuring/voltage monitoring Ph-neut./Ph-Ph The control can monitor either the phase-neutral voltages (four-wire system) or the phase-phase voltages (three-wire system). Generally, low-voltage systems are con- figured to monitor the phase-neutral voltages, while medium- and high-voltage sys- tems are configured to monitor the phase-phase voltages only. The monitoring of the phase-phase voltages is recommended to avoid a phase-earth fault in a compensated or isolated mains resulting in the voltage protection tripping. Ph-neut/Ph-neut System voltage measurement is performed phase-neutral (WYE connected system). The phase voltages and the neutral must be connected for proper calculation. This requires that the neutral terminal (terminal 0) be connected to the ground reference. The voltage measurement and protection functions are performed in accordance with WYE connected systems. The phase-phase and phase-neutral voltages are displayed. Ph-neut/Ph-Ph System voltage measurement is performed phase-neutral (WYE connected system). The phase voltages and the neutral must be connected for proper calculation. This requires that the neutral terminal (terminal 0) be connected to the ground reference. The phase-phase and phase-neutral voltages are displayed. The volt- age protection is performed phase-phase only. Ph-Ph/Ph-Ph System voltage measurement is performed phase-phase (Delta connected system). Phase voltages must be connected for proper calculation. This does not require the neutral terminal (terminal 0) be connected to the ground reference. The voltage measurement and protection functions performed in accordance with Delta con- nected systems. Only the phase-phase voltages are displayed. Note: Ph-neut = Four-wire system (3ph 4w)/Wye Ph-Ph = Three-wire system (3ph 3w)/Delta Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 27/179 NOTE If a three-wire system is connected, terminal 0 must remain disconnected. If terminal 0 is connected, the control may monitor a voltage that exceeds the permissible limits. Generator Current Parameter 19 Current transf. generator 0000/x Generator CTs 10 to 7,000/{x} A The input of the current transformer ratio is necessary for the indication and control of the actual monitored value. The current transformers ratio should be selected so at least 60% of the secondary current rating can be measured when the monitored system is at 100% of operating capacity (i.e. at 100% of system capacity a 5A CT should output 3A). If the current transformers are sized so that the percentage of the output is lower, the loss of resolution may cause inaccuracies in the monitoring and control functions and may affect the functionality of the control. The control may be ordered with either ../1 A or ../5 A current transformer inputs. The CT inputs will dictate how this parameter is displayed on the control. Informa- tion about the current transformers inputs may be found on the unit data plate. {x} = 1 A ......GCP30x1B/xxx = Current transformer inputs rated for ../1 A {x} = 5 A ......GCP30x5B/xxx = Current transformer inputs rated for ../5 A Parameter 20 Power measuring gen.------------ Generator power measurement singlephase / threephase This controller may be configured to measure generator power single-phase or three-phase. If "single-phase power measurement" is selected, only the voltage and current from L1 phase will be used to calculate power. If "three-phase power meas- urement" is selected, the voltage and current from all three phases will be used to calculate power. • single-phase power measurement: P = √3 × VL12 × IL1 × power factor • three-phase power measurement: P = (VL1N × IL1 × power factor) + (VL2N × IL2 × power factor) + (VL3N × IL3 × power factor). NOTE When the generator is supplying positive real power to a load, the current should flow from the genera- tor to the load through the CT in the "S1 to S2" direction. When positive real power is being supplied, the inductive reactive (lagging) power flows in the same direction through the CT. If the S1 termi- nal/polarity dot is facing the generator and the s1 terminal of the CT is connected to the s1 terminal of the GCP-30, the control will display that positive real power is being supplied. If a CT is installed back- wards, that phase will display negative real power for that phase. Parameter 21 Rated power generator 0000kW Generator rated power 5 to 9,999 kW The generator rated power is configured here. It is crucial to ensure that the correct generator power rating is entered. Multiple measuring, control, and protective func- tions refer to the value configured in this parameter (i.e. the percentage configured for generator overload). Parameter 22 Rated current generator 0000A Generator rated current 10 to 7,000 A The generator rated current is configured here. The percentages configured for the protective function refer to the value input in this parameter. Manual 37365A GCP-30 Series Packages - Genset Control Page 28/179 © Woodward Mains Current/Mains Power Measurement Mains current measurement via mains CT Parameter 23 Current transf. mains 0000/x Mains current transformer 5 to 7,000/{x} A The input of the current transformer ratio is necessary for the indication and control of the actual monitored value. The current transformers ratio should be selected so at least 60% of the secondary current rating can be measured when the monitored system is at 100% of operating capacity (i.e. at 100% of system capacity a 5A CT should output 3A). If the current transformers are sized so that the percentage of the output is lower, the loss of resolution may cause inaccuracies in the monitoring and control functions and may affect the functionality of the control. The control may be ordered with either ../1 A or ../5 A current transformer inputs. The CT inputs will dictate how this parameter is displayed on the control. Informa- tion about the current transformers inputs may be found on the unit data plate. {x} = 1 A .......GCP30x1B/xxx = Current transformer inputs rated for ../1 A {x} = 5 A .......GCP30x5B/xxx = Current transformer inputs rated for ../5 A Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 29/179 Mains power actual value measurement via analog input (XPD, XPQ) The actual value measurement of the mains power via an analog input T{x} [x = 1 to 7] is possible if at least one of the analog inputs T{x} [x = 1 to 7] is a 0/4 to 20 input. Selection of the analog input is performed with the following parameters. Parameter 24 Analog in Pmains OFF Analog input P-mains: Selection OFF / T{x} OFF..............The mains power analog input functionality is not used. The actual value for the mains interchange (import/export) real power is calcu- lated from the measured mains current and the measured mains volt- age. The analog inputs can either be used as real power set point in- puts or as freely configurable alarm inputs. The following screens of this function are not displayed. T{x}..............The mains interchange (import/export) real power actual value can be transmitted as a 0/4 to 20 mA signal to the control from a measur- ing transducer and measured via the configured scalable 0/4 to 20 mA input T{x} ({x} = 1 to 7). The controller will not accept other types of analog signals for this function (i.e. 0 to 5 Vdc). The follow- ing screens of this function are displayed. Note The analog input used (T{x}) for the mains power analog input must be configured as follows: • "Generator external power set point" (Parameter 78) must be configured as OFF. • "Analog input {x} scalable" (Parameter 215) must be configured as OFF (refer to the "Analog inputs" section in this manual). • The GCP-30 may be purchased with various types of analog inputs. If the con- troller being configured has analog inputs, only a 0/4 to 20 mA input may be used for this input. • Due to the fact that LeoPC1 is not a dynamic program, the graphic display of the generator/plant does not automatically update to reflect any changes made during reconfiguration. To update the program’s graphical display, LeoPC1 must be shutdown and restarted. Priority of the functions of the analog inputs If more than one function has been assigned to a analog input, the following is the priority that the control assigns to functions: • Highest priority: Mains interchange (import/export) real power actual value • Middle priority: Generator real power set point value • Lowest priority: Measuring input as common analog value Manual 37365A GCP-30 Series Packages - Genset Control Page 30/179 © Woodward Parameter 25 Analog in Pmains 0-00mA Analog input P mains: Range 0 to 20 mA / 4 to 20 mA The mains power analog input measuring range is defined here. 0 to 20 mA or 4 to 20 mA may be selected for this parameter. If the 4 to 20 mA range is selected and the current for the input drops below 2 mA, a broken wire alarm is issued. Note The text and number of significant digits to be displayed for the mains interchange analog input are defined in "name and unit" (Parameter 216). Refer to the "Analog Inputs (XPD, XPQ)" section starting on page 119. NOTE When determining the measuring range for an import/export real power control application, ensure that the the measuring range is in the middle of the of the selected set point values. This will utilize the unit control dynamics to the fullest extent. Parameter 26 Analog in Pmains 0% 0000kW Mains real power 0/4 mA [1] -9,990 to 9,990 kW; [4] -6,900 to 6,900 kW The scaleable analog input is assigned a numerical value, which corresponds to the lowest input value Æ (0 % (0 or 4 mA) corresponds to -500 kW or 500kW im- ported from the mains). Parameter 27 Analog in Pmains 100% 0000kW Mains real power 20 mA [1] -9,990 to 9,990 kW; [4] -6,900 to 6,900 kW The scaleable analog input is assigned a numerical value, which corresponds to the highest input value Æ (100 % (20 mA) corresponds to 500 kW or 500kW exported to the mains). Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 31/179 LS 4 Mode (GCP-31: XPD, XPQ) Parameter 28 LS 4 mode ON [GCP-31] LS 4 mode ON/OFF ON................The GCP has been enabled to operate with LS 4 breaker controllers. The GCP controller monitors the CAN bus for messages from an LS 4 and reacts accordingly. Additionally the GCP controller trans- mits messages to the LS 4. OFF..............The control GCP operates as a genset control without LS 4 function- ality. Parameter 29 Rated power in system 00000kW [GCP-31] Rated power in the system 0 to 16,000 kW The GCP-31 uses the value configured in this parameter to display the real power at the mains interchange. The LS 4 transmits the measured real power at the mains interchange as a percentage to the GCP-31. The GCP-31 calculates that percentage with the value configured here and displays the power level as a kW reading. Note This parameter is only utilized if the LS 4 mode has been enabled. IMPORTANT! Since the LS 4 only transmits a percentage value related to the rated system power, it is absolutely necessary that this parameter and the system rated power parameter in the LS 4 be configured identically. Measurement Units NOTE LeoPC1 is not a dynamic program. Changes made to a controller during configuration will not be automatically updated in the graphic display of LeoPC1. LeoPC1 must be shutdown and restarted for any changes to be reflected in the graphic display. Parameter 31 Pressure in ---------------- Analog inputs; pressure measurement in ... bar / psi The analog input for pressure measurement may be configured to display in bar or phi. The configured engineering unit is displayed in the LC display or transmitted via the CAN bus to other HMIs communicating with the GCP-30. bar Ö psi psi Ö bar P [psi] = P [bar] x 14.5 P [bar] = P [psi] / 14.5 Parameter 30 Temperature in ---------------- Analog inputs; temperature measurement in ... Celsius / Fahrenheit The analog input for temperature measurement may be configured to display in °C or °F. The configured engineering unit is displayed in the LC display or transmitted via the CAN bus to other HMIs communicating with the GCP-30. °C Ö °F °F Ö °C T [°F] = (T [°C] x 1.8) + 32 T [°C] = (T [°F] – 32) / 1.8 Manual 37365A GCP-30 Series Packages - Genset Control Page 32/179 © Woodward Password Configuration NOTE Once the code level is entered, access to the configuration menus will be allowed for two hours or until another password is entered into the control. If a user needs to exit a code level, then the control should have the CS0 code level enabled. This will block access to all of the control’s parameters. A user may re-enable the CS0 code level by changing any one digit of the randomly generated number on the password screen and entering it into the unit. The control unit automatically reverts to code level CS0 two hours after the entry of a password, or if the power supply is disconnected from the control unit. By entering the correct password, the corre- sponding level may again be accessed. Parameter 32 Define level 1 code 0000 Code level 1 (Customer) 0000 to 9999 Access to this parameter is only enabled when the CS2 access code has been en- tered into the controller. Personnel assigned the CS1 password will be permitted access only to select parameters. The default access code for this code level (CS) is CS1 = 0 0 0 1 Parameter 33 Define level 2 code 0000 Code level 2 (Commissioner) 0000 to 9999 Access to this parameter is only enabled when the CS2 access code has been en- tered into the controller. Personnel assigned the CS2 password will be permitted access to all parameters. The default access code for this code level (CS) is CS2 = 0 0 0 2 Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 33/179 Controller ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ WARNING The following parameters dictate how the GCP-30 controls voltage, frequency, load, and power factor. It is vital that the correct setting be entered in these parameters. Failure to do so may lead to incorrect measurements and failures within the control unit resulting in damage to or destruction of the genera- tor and/or personal injury or death. NOTE The parameters for this control are grouped together in blocks to permit navigation through the large number of configuration screens more rapidly. Selecting "YES" or "NO" has no effect whether or not control or monitoring is carried out for the parameters located in that block. Selecting "YES" or "NO" only determines if the individual parameters may be accessed and changed or are bypassed. Parameter 34 Configure controller YES Configuration of the controller YES/NO The basic generator control functions are configured in this block of parameters. This parameter has the following effects: YES ..............The parameters in this block are displayed and can either be viewed ("Select" button), or modifications can be made to the parameters ("Cursor→", "Digit↑" or "Select" buttons). NO................The parameters in this block are not displayed, cannot be modified, and are skipped. Manual 37365A GCP-30 Series Packages - Genset Control Page 34/179 © Woodward Analog Controller Outputs (BPQ, XPQ) Some controls may be purchased with the BPQ or XPQ packages. These packages offers an alternative to a three-position controller output to a voltage regulator or speed control. If this option is selected, additional con- figuration screens are displayed for tuning. The analog PID controller is a closed-loop control loop with the con- trolled system (usually a first-order lag element). The PID loop parameters (gain KPR, reset TN, and derivative TV) can each be modified individually. Kp T1 Controlled system (PT1)PID controller Kpr Tn Tv Lag element (Tt) Influenciny quantity Tt Figure 3-1: Control loop If an abrupt disturbance variable is applied to the control loop, the reaction of the controlled system can be re- corded at the output as a function of time (step response). 0 t/s x T T T x x d m x d x m T Rise time Overshoot System deviation rise rise Tolerance band Settling timesett settdisturbance variable Figure 3-2: Step response (Example) The step response consists of multiple values; these are required for adjusting the controller to its optimum set- ting: Rise time Trise: The period of time it takes for a control variable to re-enter a predefined tolerance range after a disturbance has been applied or the reference input has been changed. The time starts when the control variable leaves the predefined tolerance range and ends when the control variable first re-enters the predefined tolerance range. Settling time Tsett: The period of time it takes for a control variable to permanently re-enter a predefined toler- ance range after a disturbance has been applied or the reference input has been changed. The time starts when the control variable leaves the predefined tolerance range and ends when the control variable permanently re-enters the predefined tolerance range. Overshoot xm: The greatest deviation passed the defined set point value when the system is transitioning from one steady-state condition to a new steady-state condition following the application of a disturbance to the sys- tem or reference input variable (xm Optimal ≤ 10 %). System deviation xd: Permanent deviation from the final value (PID controller: xd = 0). Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 35/179 CAUTION The following must be ensured when tuning a controller: • Ensure that the emergency shutdown system is operational • While determining the critical frequency, pay attention to the amplitude and frequency • If the two values change uncontrollably, initiate Î EMERGENCY SHUTDOWN Initial state: The start position of the speed or voltage controller is determined using the initial state of the con- troller. If the controller output is disabled, the basic setting can be used to output a fixed controller position. If the MANUAL operation mode has been selected, the initial state signal is output only after the engine "START" button has been pressed. Even when the analog controller output is disabled, the initial state can be freely ad- justed (e.g. the speed controller can be controlled in a linear manner). When the "STOP" button is been pressed, the analog controller is turned off. Controller outp. Init.state= 000% Initial state of the actuator 0 to 100 % The value entered for the initial state is the start reference point for a speed or volt- age controller. If the output to that particular controller has been disabled, the out- put will act as a control position reference point. General settings: The setting rule described below only serves as an example. It cannot be assumed that this is the proper method of control for your system since every system behaves uniquely. There are various methods of setting a controller. The setting rules of Ziegler and Nichols are explained below (determination for abrupt disturbances on the system input); this setting method assumes a pure lag element con- nected in series with a first-order lag system. 1. The controller is operated as a P-loop only controller (where Tn = ∞ [screen setting: Tn =0], TV = 0). 2. Increase gain KPR (P-gain) until KP = KPcrit and the control loop starts to oscillates continuously. ATTENTION If the engine starts to oscillate uncontrollably, carry out an emergency shutdown and alter the screen set- ting accordingly. 3. At the same time, measure the critical cycle duration Tcrit 4. Set the parameters: Manual 37365A GCP-30 Series Packages - Genset Control Page 36/179 © Woodward PID-controller PI-controller KPR = 0.6 × KPcrit KPR = 0.45 × KPcrit Tn = 0.5 × Tcrit Tn = 0.83 × Tcrit TV = 0.125 × Tcrit Step response Controller setting Optimal (xm ≤ 10 %) Controller setting Tcrit Controller setting Incorrect 0 1 x 0 t/s 0 0 1 x t/s 0 1 x 0 t/s Figure 3-3: Step responds - governor configuration P-gain Kpr = 000 P-gain (KPR) Proportional-action coefficient 1 to 240 The proportional-action coefficient KPR indicates the closed-loop control system gain. By increasing the gain, the response is increased to permit larger corrections to the variable to be controlled. The farther out of tolerance the process is the larger the response action is to return the process to the tolerance band. If the gain is con- figured too high, the result is excessive overshoot/undershoot of the desired value. Reset time Tn = 00.0s Reset time (Tn) 0.2 to 60.0 s The reset time Tn represents the I-component of the PID controller. The reset time corrects for any offset (between set point and process variable) automatically over time by shifting the proportioning band. Reset automatically changes the output re- quirements until the process variable and the set point are the same. This parameter permits the user to adjust how quickly the reset attempts to correct for any offset. The reset time constant must be greater than the derivative time constant. If the re- set time constant is too small, the engine will continually oscillate. If the reset time constant is too large, the engine will take an excessive amount of time to settle at a steady state. Derivative time Tv=0.00s Derivative-action time (TV) 0.00 to 6.00 s The derivative-action time TV represents the D-component of the PID controller. By increasing this parameter, the stability of the system is increased. The controller will attempt to slow down the action of the actuator in an attempt to prevent exces- sive overshoot or undershoot. Essentially this is the brake for the process. This por- tion of the PID loop operates anywhere within the range of the process unlike reset. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 37/179 Real Power Controller, Set Point Values These screens appear only if the generator real power controller (Parameter 74) has been configured to "ON". NOTE The fixed-value power controller does not monitor the mains interchange point. If excess power for the load requirements is generated, the excess power is exported to the mains. If insufficient power for the load requirements is generated, remaining power required is imported from the mains. Engine starting depends on whether an automatic start/stop operation has been enabled or disabled (Parameter 95 or Parameter 96). If it has been disabled, the engine will always start. Parameter 35 Power controller Pset1 I0000kW Power controller: set point 1 C/I/E 0 to 9,999 kW Set point 1 is enabled when Automatic 1 (terminal 3) is energized. The mains in- terchange (import/export) real power is then controlled to the configured value. Generator real power control C...................The letter C stands for constant power set point (= base load). The generator shall always supply the value entered for the constant power level. All load swings are absorbed by the utility. The genera- tor will always start when a constant power (base load) operation is enabled. Mains interchange (import/export) real power control I ....................The letter I stands for import power (power supplied by the mains). The value entered for the import level shall always be supplied by the utility. All load swings are absorbed by the generator(s) provided the load rating for the generator(s) is not exceeded. The generator will start when the power imported from the utility exceeds the level con- figured in this parameter. E ...................The letter E stands for export power (power supplied to the mains). The value entered for the export level shall always be supplied to the utility. All load swings are absorbed by the generator(s) provided the load rating for the generator(s) is not exceeded. The generator will always start when an export power operation is enabled. Manual 37365A GCP-30 Series Packages - Genset Control Page 38/179 © Woodward Parameter 36 Power controller Pset2 I0000kW Power controller: set point 2 C/I/E 0 to 9,999 kW Set point 2 is enabled when Automatic 2 (terminal 5) is energized and the external set point value (0/4 to 20 mA or interface) has not been enabled. If set point 1 and set point 2 are enabled at the same time, the power will be controlled in the manner specified by set point 1. The mains interchange (import/export) real power is con- trolled to the configured value. Generator real power control C ...................The letter C stands for constant power set point (= base load). The generator shall always supply the value entered for the constant power level. All load swings are absorbed by the utility. The genera- tor will always start when a constant power (base load) operation is enabled. Mains interchange (import/export) real power control I ....................The letter I stands for import power (power supplied by the mains). The value entered for the import level shall always be supplied by the utility. All load swings are absorbed by the generator(s) provided the load rating for the generator(s) is not exceeded. The generator will start when the power imported from the utility exceeds the level con- figured in this parameter. E ...................The letter E stands for export power (power supplied to the mains). The value entered for the export level shall always be supplied to the utility. All load swings are absorbed by the generator(s) provided the load rating for the generator(s) is not exceeded. The generator will always start when an export power operation is enabled. Table Of Set Point Values Automatic 1 (terminal 3) Automatic 2 (terminal 5) Control via interface External set point value Specification of the set point value through energized insignificant insignificant insignificant Set point 1 (Parameter 35) de-energized energized OFF OFF Set point 2 (Parameter 36) de-energized energized insignificant ON Externally via 0/4-20 mA input (XPD, XPQ; Parameter 78) de-energized energized ON OFF Externally via interface de-energized de-energized OFF OFF Standby only: Emergency power (AMF) Table 3-3: Set point value table Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 39/179 Frequency Controller Parameter 37 Initial state Frequency 000% BPQ, XPQ Frequency controller: initial state of the actuator 0 to 100 % The value entered for this parameter is the start reference point for the analog out- put to the speed controller. If the output to the speed control has been disabled, the output will act as a control position reference point. The percentage value config- ured here refers to the range of the analog signal configured by "Stepper sign.frq (min.)" (Parameter 48) and "Stepper sign.frq (max)" (Parameter 49). Example: If a 0 to 10 V signal is configured with a min. limit of 10% and a max. limit of 90%, the reference range is 1 to 9 V. A setting of 25% would result a start reference point of 3 V. Refer to the Special Applications chapter of the Application Manual 37240 for more detailed information about this setting. Parameter 38 Freq.controller ON Frequency controller: enable ON/OFF ON................The generator frequency is controlled by the GCP-30. The method of generator frequency is determined by the application (isolated opera- tion / synchronization). The subsequent screens of this function are displayed. OFF..............The generator frequency is not controlled by the GCP-30 The subse- quent screens of this function are not displayed. Parameter 39 f-contr. active at: 00.0Hz Frequency controller: activation frequency 0.0 to 70.0 Hz The frequency controller is activated when the monitored generator frequency has exceeded the value configured in this parameter. This prevents the GCP-30 from attempting to control the frequency while the engine is completing its start se- quence. Parameter 40 Delay time for f-contr. 000s Frequency controller: activation delay 0 to 999 s The frequency controller is enabled after the configured time for this parameter ex- pires. Parameter 41 Freq.controller ramp 00Hz/s Frequency controller: set point ramp 1 to 50 Hz/s Different sized generators and applications require different ramp rates for the speed control when starting. The rate at which theGCP-30 changes the speed refer- ence point is defined by this parameter. A more rapid change to the speed reference requires a larger value to be configured here. NOTE The parameters for the speed/frequency controller influence the generator real power controller. Manual 37365A GCP-30 Series Packages - Genset Control Page 40/179 © Woodward Parameter 42 F/P contr.type ---------------- BPQ, XPQ Frequency controller: type THREESTEP / ANALOG / PWM THREESTEP The signal to the speed control to increase/decrease the speed/frequency/real power is output via the relay manager to any two configurable relays. The following relay functions must be as- signed to the individual relays. • function 114 = increase RPM (n+) / frequency (f+) / power (P+) • function 115 = decrease RPM (n-) / frequency (f-) / power (P-) Refer to the Controller Outputs section of manual 37364 for wiring an external Resistive/Capacitive protection circuit. ANALOG.....Speed control is performed via the analog outputs (terminals 8/9/10). The control of speed/frequency/real power is performed via either a voltage or current signal. The amplitude and signal type (mA or V) to be utilized is configured in "F/P contr.output" (Parameter 46). If a voltage signal is used, a jumper must be installed between terminals 8/9 (refer to the wiring diagram in manual 37364). PWM ............Speed control is performed via the analog outputs (terminals 8/9/10). The control of speed/frequency/real power is performed via a PWM signal. The amplitude of the PWM signal to be utilized is configured in "Level PWM" (Parameter 47). If a PWM signal is used, a jumper must be installed between terminals 8/9 (refer to the wiring diagram in manual 37364). Three-Position Controller (XPD; BPQ, XPQ: Setting 'THREESTEP') Parameter 43 Freq.controller deadband 0.00Hz Frequency controller: dead band 0.02 to 1.00 Hz Isolated operation The generator frequency is controlled in such a manner that the measured frequency does not deviate from the configured set point by more than the value configured in this parameter without the con- troller issuing a frequency raise/lower signal to the frequency control. This prevents unneeded wear on the frequency bias output control or the raise/lower relay contacts. Synchronization The generator frequency is controlled in such a manner that the measured frequency does not deviate from the monitored reference (mains or busbar) frequency by more than the value configured in this parameter without the controller issuing a frequency raise/lower signal to the frequency control. This prevents unneeded wear on the frequency bias output control or the raise/lower relay contacts. The value configured for this parameter must be less than the value con- figured for the df max (maximum frequency differential) for syn- chronization. Parameter 44 Freq.controller time pulse>000ms Frequency controller: three-step minimum pulse 10 to 250 ms When "F/P contr.type" (Parameter 42) has been configured as THREESTEP, a minimum pulse on time must be configured. The shortest possible pulse time should be configured to limit overshoot of the desired speed reference point. Parameter 45 Freq.controller gain Kp 00.0 Frequency controller: gain 0.1 to 99.9 The gain factor Kp influences the the operating time of the relays. By increasing the number configured in this parameter, the operating time of the relay will be in- creased in response to a deviation from the power factor reference. By increasing the gain, the response is increased to permit larger corrections to the variable to be controlled. The farther out of tolerance the process is the larger the response action is to return the process to the tolerance band. If the gain is configured too high, the result is excessive overshoot/undershoot of the desired value. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 41/179 Analog Controller Output (BPQ, XPQ: Setting 'ANALOG/PWM') Parameter 46 F/P contr.output ---------------- BPQ, XPQ Frequency controller: output range see below If "F/P contr.type" (Parameter 42) has been configured as "ANALOG", this pa- rameter must be configured to the appropriate type of analog controller signal. The range of the analog output is configured here. To switch from a current to a voltage or PWM signal output a jumper must be installed between terminals 8/9. The avail- able ranges are listed below Type Setting in above configuration screen Jumper between term. 8/9 Range Lower level Upper level Current +/-20mA (+/-10V) no +/-20mA -20 mA +20 mA +/-10mA (+/-5V) +/-10mA -10 mA +20 mA 0 to 10mA (0 to 5V) 0-10mA 0 mA 10 mA 0 to 20mA (0 to 10V) 0-20mA 0 mA 20 mA 4 to 20mA 4-20mA 4 mA 20 mA 10 to 0mA (5 to 0V) 10-0mA 10 mA 0 mA 20 to 0mA (10 to 0V) 20-0mA 20 mA 0 mA 20 to 4mA 20-4mA 20 mA 4 mA Voltage +/-20mA (+/-10V) yes +/-10V -10 Vdc +10 Vdc +/-10mA (+/-5V) +/-5V -5 Vdc +5 Vdc +/-3V +/-3V -3 Vdc +3 Vdc +/-2.5V +/-2.5V -2.5Vdc +2.5 Vdc +/-1V +/-1V -1 Vdc +1 Vdc 0 to 10mA (0 to 5V) 0 to 5V 0 Vdc 5 Vdc 0.5V to 4.5V 0.5 to 4,5V 0.5 Vdc 4.5 Vdc 0 to 20mA (0 to 10V) 0 to 10V 0 Vdc 10 Vdc 10 to 0mA (5 to 0V) 5 to 0V 5 Vdc 0 Vdc 4.5V to 0.5V 4.5 to 0,5V 4.5 Vdc 0.5 Vdc 20 to 0mA (10 to 0V) 10 to 0V 10 Vdc 0 Vdc NOTE The control logic of the PWM signal can be inverted by following steps: - Configure "F/P contr.type" (Parameter 42) as ANALOG. - Configure "F/P contr.output" (Parameter 46 "F/P contr.output") with any of above inverted control outputs (i.e. "10 to 0mA (5 to 0V)", "4.5V to 0.5V", "20 to 0mA (10 to 0V)" or "20 to 4mA"). - Return to "F/P contr.type" (Parameter 42) by pressing "Select" and "Cursor→" simultaneously. - Configure "F/P contr.type" (Parameter 42) as PWM. The PWM signal is now inverted. Parameter 47 Level PWM ---------------- BPQ, XPQ Frequency controller: PWM level 3.0 to 10.0 V If PWM has been selected in Parameter 42 the amplitude of the PWM signal can be adjusted here. Parameter 48 Stepper sign.frq (min.) 000% BPQ, XPQ Frequency controller: minimum value 0 to 100% This parameter permits the operator to clamp or limit the lower limit of the analog output signal. Example: A 1 to 4V analog output is needed for the voltage controller to operate properly. A jumper is installed on terminals 8/9 as described above and the analog output signal of 0 to 5V is selected. The number to be configured as the minimum output signal in this parameter is determined by dividing the desired lower limit by the range of the signal (1V/5V = 0.20 or 20%). 20% is the value to be configured in this parameter. Manual 37365A GCP-30 Series Packages - Genset Control Page 42/179 © Woodward Parameter 49 Stepper sign.frq (max.) 000% BPQ, XPQ Frequency controller: maximum value 0 to 100% This parameter permits the operator to clamp or limit the upper limit of the analog output signal. Example: A 1 to 4V analog output is needed for the voltage controller to operate properly. A jumper is installed on terminals 8/9 as described above and the analog output signal of 0 to 5V is selected. The number to be configured as the maximum output signal in this parameter is determined by dividing the desired upper limit by the range of the signal (4V/5V = 0.80 or 80%). 80% is the value to be configured in this parameter. Parameter 50 Freq.controller gain Kpr 000 BPQ, XPQ Frequency controller: P gain 1 to 240 The gain coefficient Kpr specifies the Proportional portion of the PID control loop. By increasing the gain, the response is increased to permit larger corrections to the variable to be controlled. The farther out of tolerance the process is the larger the response action is to return the process to the tolerance band. If the gain is config- ured too high, the result is excessive overshoot/undershoot of the desired value. Parameter 51 Freq.controller reset Tn 00.0s BPQ, XPQ Frequency controller: reset time (integration) 0.0 to 60.0 s The reset time Tn identifies the Integral portion of the PID control loop. The reset time corrects for any offset (between set point and process variable) automatically over time by shifting the proportioning band. Reset automatically changes the out- put requirements until the process variable and the set point are the same. This pa- rameter permits the user to adjust how quickly the reset attempts to correct for any offset. The reset time constant must be greater than the derivative time constant. If the reset time constant is too small, the engine will continually oscillate. If the reset time constant is too large, the engine will take an excessive amount of time to settle at a steady state. Parameter 52 Freq.controller derivat.Tv 0.00s BPQ, XPQ Frequency controller: derivative-action time 0.00 to 6.00 s The derivative-action time TV identifies the Derivative portion of the PID control loop. By increasing this parameter, the stability of the system is increased. The con- troller will attempt to slow down the action of the actuator in an attempt to prevent excessive overshoot or undershoot. Essentially this is the brake for the process. This portion of the PID loop operates anywhere within the range of the process unlike reset. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 43/179 Voltage Controller Parameter 53 Initial state voltage 000% BPQ, XPQ Voltage controller: initial state of the actuator 0 to 100 % The value entered for this parameter is the start reference point for the analog out- put to the voltage controller. If the output to the voltage control has been disabled, the output will act as a control position reference point. The percentage value con- figured here refers to the range of the analog signal configured by "Stepper sign.vol (min.)" (Parameter 62) and "Stepper sign.vol (max.)" (Parameter 63). Example: If a 0 to 10 V signal is configured with a min. limit of 10% and a max. limit of 90%, the reference range is 1 to 9 V. A setting of 25% would result a start reference point of 3 V. Refer to the Special Applications chapter of the Application Manual 37240 for more detailed information about this setting. Parameter 54 Volt.controller ON Voltage controller: activation ON/OFF ON................Generator voltage control is performed by the GCP-30. The subse- quent screens of this function are displayed. OFF..............Generator voltage control is not performed by the GCP-30. The sub- sequent screens of this function are not displayed. Parameter 55 Start voltage V control. 000V Voltage controller: start voltage 12.0 to 100.0 % L This value refers to the generator voltage set point (Parameter 16). The voltage controller is activated when the monitored generator voltage has ex- ceeded the value configured in this parameter. This prevents the GCP-30 from at- tempting to control the voltage while the engine is completing its start sequence. Parameter 56 Delayed. Start V contr. 000s Voltage controller: delayed start 0 to 999 s The voltage controller is enabled after the configured time for this parameter ex- pires. NOTE The following parameters for the voltage controller influence the power factor is controlled. Parameter 57 V/Q contr.type ---------------- BPQ, XPQ Voltage controller: type THREESTEP / ANALOG THREESTEP The signal to the voltage control to increase/decrease the volt- age/power factor is output via the relay manager to any two config- urable relays. The following relay functions must be assigned to the individual relays. • function 116 = increase voltage (V+) / power factor (Q+) • function 117 = decrease voltage (V-) / power factor (Q-) Refer to the Controller Outputs section of manual 37364 for wiring an external Resistive/Capacitive protection circuit. ANALOG ....Voltage control is performed via the analog outputs (terminals 11/12/13). The control of voltage/reactive power is performed via ei- ther a voltage or current signal. The amplitude and signal type (mA or V) to be utilized is configured in "V/Q contr.output" (Para- meter 61). If a voltage signal is use, a jumper must be installed be- tween terminals 11/12 (refer to the wiring diagram in manual 37364). Manual 37365A GCP-30 Series Packages - Genset Control Page 44/179 © Woodward Three-Position Controller (XPD; BPQ, XPQ: Setting 'THREESTEP') Parameter 58 Volt.controller dead band 00.0% Voltage controller: dead band 00.1 to 15.0 % L This value refers to the rated system voltage (Parameter 17). Isolated operation The generator voltage is controlled in such a manner that the measured voltage does not deviate from the configured set point by more than the value configured in this parameter without the control- ler issuing a voltage raise/lower signal to the voltage regulator. This prevents unneeded wear on the voltage bias output control or the raise/lower relay contacts. Synchronization The generator voltage is controlled in such a manner that the measured voltage does not deviate from the monitored reference (mains or busbar) voltage by more than the value configured in this parameter without the controller issuing a voltage raise/lower signal to the voltage regulator. This prevents unneeded wear on the voltage bias output control or the raise/lower relay contacts. The value con- figured for this parameter must be less than the value configured for the dV max (maximum voltage differential) for synchronization. Parameter 59 Volt.controller time pulse>000ms Voltage controller: minimum voltage 20 to 250 ms When "V/Q contr.type" (Parameter 57) has been configured as THREESTEP, a minimum pulse on time must be configured. The shortest possible pulse time should be configured to limit overshoot of the desired speed reference point. Parameter 60 Volt.controller gain Kp 00.0 Voltage controller: gain 0.1 to 99.9 The gain factor Kp influences the operating time of the relays. By increasing the number configured in this parameter, the operating time of the relay will be in- creased in response to a deviation from the power factor reference. By increasing the gain, the response is increased to permit larger corrections to the variable to be controlled. The farther out of tolerance the process is the larger the response action is to return the process to the tolerance band. If the gain is configured too high, the result is excessive overshoot/undershoot of the desired value. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 45/179 Analog Controller (BPQ, XPQ: Setting 'ANALOG') Parameter 61 V/Q contr.output ---------------- BPQ, XPQ Voltage controller: range see below If "V/Q contr.type" (Parameter 57) has been configured as "ANALOG", this pa- rameter must be configured to the appropriate type of analog controller signal. The range of the analog output is configured here. To switch from a current to a voltage signal output, a jumper must be installed between terminals 11/12. The available ranges are listed below. Type Setting in above configuration screen Jumper between term. 11/12 Range Lower level Upper level Current +/-20mA (+/-10V) no +/-20mA -20 mA +20 mA +/-10mA (+/-5V) +/-10mA -10 mA +20 mA 0 to 10mA (0 to 5V) 0-10mA 0 mA 10 mA 0 to 20mA (0 to 10V) 0-20mA 0 mA 20 mA 4 to 20mA 4-20mA 4 mA 20 mA 10 to 0mA (5 to 0V) 10-0mA 10 mA 0 mA 20 to 0mA (10 to 0V) 20-0mA 20 mA 0 mA 20 to 4mA 20-4mA 20 mA 4 mA Voltage +/-20mA (+/-10V) yes +/-10V -10 Vdc +10 Vdc +/-10mA (+/-5V) +/-5V -5 Vdc +5 Vdc +/-3V +/-3V -3 Vdc +3 Vdc +/-2.5V +/-2.5V -2.5Vdc +2.5 Vdc +/-1V +/-1V -1 Vdc +1 Vdc 0 to 10mA (0 to 5V) 0 to 5V 0 Vdc 5 Vdc 0.5V to 4.5V 0.5 to 4.5V 0.5 Vdc 4.5 Vdc 0 to 20mA (0 to 10V) 0 to 10V 0 Vdc 10 Vdc 10 to 0mA (5 to 0V) 5 to 0V 5 Vdc 0 Vdc 4.5V to 0.5V 4.5 to 0.5V 4.5 Vdc 0.5 Vdc 20 to 0mA (10 to 0V) 10 to 0V 10 Vdc 0 Vdc Parameter 62 Stepper sign.vol (min.) 000% BPQ, XPQ Voltage controller: minimum value 0 to 100% This parameter permits the operator to clamp or limit the lower limit of the analog output signal. Example: A 1 to 4V analog output is needed for the voltage controller to operate properly. A jumper is installed on terminals 8/9 as described above and the analog output signal of 0 to 5V is selected. The number to be configured as the minimum output signal in this parameter is determined by dividing the desired lower limit by the range of the signal (1V/5V = 0.20 or 20%). 20% is the value to be configured in this parameter. Parameter 63 Stepper sign.vol (max.) 000% BPQ, XPQ Voltage controller: maximum value 0 to 100% This parameter permits the operator to clamp or limit the upper limit of the analog output signal. Example: A 1 to 4V analog output is needed for the voltage controller to operate properly. A jumper is installed on terminals 8/9 as described above and the analog output signal of 0 to 5V is selected. The number to be configured as the maximum output signal in this parameter is determined by dividing the desired upper limit by the range of the signal (4V/5V = 0.80 or 80%). 80% is the value to be configured in this parameter. Manual 37365A GCP-30 Series Packages - Genset Control Page 46/179 © Woodward Parameter 64 Volt.controller gain Kpr 000 BPQ, XPQ Voltage controller: P-gain 1 to 240 The gain coefficient Kpr specifies the Proportional portion of the PID control loop. By increasing the gain, the response is increased to permit larger corrections to the variable to be controlled. The farther out of tolerance the process is the larger the response action is to return the process to the tolerance band. If the gain is config- ured too high, the result is excessive overshoot/undershoot of the desired value. Parameter 65 Volt.controller reset Tn 00.0s BPQ, XPQ Voltage controller: reset time (integration) 0.0 to 60.0 s The reset time Tn identifies the Integral portion of the PID control loop. The reset time corrects for any offset (between set point and process variable) automatically over time by shifting the proportioning band. Reset automatically changes the out- put requirements until the process variable and the set point are the same. This pa- rameter permits the user to adjust how quickly the reset attempts to correct for any offset. The reset time constant must be greater than the derivative time constant. If the reset time constant is too small, the engine will continually oscillate. If the reset time constant is too large, the engine will take an excessive amount of time to settle at a steady state. Parameter 66 Volt.controller derivat.Tv 0.00s BPQ, XPQ Voltage controller: derivative-action time 0.00 to 6.00 s The derivative-action time TV identifies the Derivative portion of the PID control loop. By increasing this parameter, the stability of the system is increased. The con- troller will attempt to slow down the action of the actuator in an attempt to prevent excessive overshoot or undershoot. Essentially this is the brake for the process. This portion of the PID loop operates anywhere within the range of the process unlike reset. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 47/179 Power Factor Controller Parameter 67 Pow.fact.contr. ON Power factor controller: enable ON/OFF ON................Power factor control is automatically performed by the GCP-30 when in a mains parallel operation. The power factor cannot be accurately measured if the monitored current is excessively low (secondary cur- rent less than 5 % Irated). The GCP-30 will lock the power factor at the value configured in Parameter 68 if the monitored secondary cur- rent is less than 5% of the input rating. The subsequent screens of this function are displayed. OFF..............Power factor is not controlled by the GCP-30 The subsequent screens of this function are not displayed. Parameter 68 Pow.fact.contr. setpoint 0.00 Power factor controller: set point i0.70 to 1.00 to c0.70 The GCP-30 is capable of producing power at a specified power factor when in parallel with the mains. The desired power factor is configured here so that the re- active power is regulated in the system. The designations "i" and "c" stand for in- ductive/lagging (generator overexcited) and capacitive/leading (generator under excited) reactive power. The power factor is only controlled to the value configured here when the generator is in a mains parallel operation. NOTE Please note the settings for the voltage controller will also influence the power factor controller. Refer to the "Voltage Controller" section on page 43. Three-Position Controller (XPD; BPQ, XPQ: Setting 'THREESTEP') Parameter 69 Pow.fact.contr. dead band 00.0% Power factor controller: dead band 0.5 to 25.0 % The generator reactive power is controlled in such a manner, when paralleled with the mains, so that the monitored power factor does not deviate from the configured power factor set point by more than the value configured in this parameter without the controller issuing a voltage raise/lower signal to the voltage regulator. This pre- vents unneeded wear on the raise/lower relay contacts. The configured percentage for the dead band refers to the generator rated power (Parameter 21). Parameter 70 Pow.fact.contr. gain Kp 00.0 Power factor controller: gain 0.1 to 99.9 The gain factor Kp influences the operating time of the relays. By increasing the number configured in this parameter, the operating time of the relay will be in- creased in response to a deviation from the power factor reference. By increasing the gain, the response is increased to permit larger corrections to the variable to be controlled. The farther out of tolerance the process is the larger the response action is to return the process to the tolerance band. If the gain is configured too high, the result is excessive overshoot/undershoot of the desired value. Manual 37365A GCP-30 Series Packages - Genset Control Page 48/179 © Woodward Analog Controller (BPQ, XPQ: Setting 'ANALOG') Parameter 71 Pow.fact.contr. gain Kpr 000 BPQ, XPQ Power factor controller: P-gain 1 to 240 The gain coefficient Kpr specifies the Proportional portion of the PID control loop. By increasing the gain, the response is increased to permit larger corrections to the variable to be controlled. The farther out of tolerance the process is the larger the response action is to return the process to the tolerance band. If the gain is config- ured too high, the result is excessive overshoot/undershoot of the desired value. Parameter 72 Pow.fact.contr. reset Tn 00.0s BPQ, XPQ Power factor controller: reset time (integration) 0.0 to 60.0 s The reset time Tn identifies the Integral portion of the PID control loop. The reset time corrects for any offset (between set point and process variable) automatically over time by shifting the proportioning band. Reset automatically changes the out- put requirements until the process variable and the set point are the same. This pa- rameter permits the user to adjust how quickly the reset attempts to correct for any offset. The reset time constant must be greater than the derivative time constant. If the reset time constant is too small, the engine will continually oscillate. If the reset time constant is too large, the engine will take an excessive amount of time to settle at a steady state. Parameter 73 Pow.fact.contr. derivat.Tv 0.00s BPQ, XPQ Power factor controller: derivative-action time 0.00 to 6.00 s The derivative-action time TV identifies the Derivative portion of the PID control loop. By increasing this parameter, the stability of the system is increased. The con- troller will attempt to slow down the action of the actuator in an attempt to prevent excessive overshoot or undershoot. Essentially this is the brake for the process. This portion of the PID loop operates anywhere within the range of the process unlike reset. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 49/179 Real Power Controller Parameter 74 Power controller ON Power controller: enable ON/OFF ON................Real power control is enabled. The generator will automatically load with real power to the level configured in Pset1 (Parameter 35) or Pset2 (Parameter 36) when the corresponding inputs (terminal 3 or 5) are energized and the system is in parallel with the mains. The subse- quent screens of this function are displayed. OFF..............Real power control is not performed, and the subsequent screens of this function are not displayed. Parameter 75 power controller ramp 000.0%/s Power controller: set point ramp %/s 0.1 to 100.0 %/s The GCP-30 controller has the ability to softly load and unload when paralleled. The load reference point is changed by the control at the rate of a configured per- cent per second. This percentage refers to the generator rated power (Para- meter 21). A smaller configured percentage for the ramp rate will result in a slower ramp rate. Conversely a larger configured percentage will result in a faster ramp rate. Power Limitation Parameter 76 Power limit P max. 000% Power controller: maximum power limitation 10 to 120 % If the maximum generator real load is to be limited, a percentage based on the gen- erator rated power (Parameter 21) is entered here. The GCP-30 will not permit the load to exceed the configured power limitation value. This parameter is only func- tional when the generator is in a mains parallel operation. Parameter 77 Power limit P min. 00% Power controller: minimum power limitation 0 to 50 % If the generator minimum real load is to be limited, a percentage based on the gen- erator rated power (Parameter 21) is entered here. The GCP-30 will not permit the load to drop below the configured power limitation value. This parameter is only functional when the generator is in a mains parallel operation. Manual 37365A GCP-30 Series Packages - Genset Control Page 50/179 © Woodward External Generator Power Set Point Value (XPD, XPQ) The generator real power set point value may be regulated via an analog input T{x} [x = 1 to 7] if one of the analog inputs T{x} [x = 1 to 7] is a 0/4 to 20 mA input. The selection of the analog input is done using the fol- lowing parameters. Parameter 78 Power setpoint external OFF XPD, XPQ Power set point value: external input OFF / T{x} OFF ..............External regulation of the generator real power set point value via the 0/4 to 20 mA input is disabled. If this parameter is configured to "OFF" a generator real power set point value is not monitored via the 0/4 to 20 mA input to the control. The analog inputs can be used either as a mains interchange (import/export) real power actual value or as freely configurable alarm inputs. If terminal 5 is utilized, the in- ternal set point value 2 "Pset2" (Parameter 36) is used as set point value. The subsequent screens of this function are not displayed. T{x}..............External regulation of the generator real power set point value via the 0/4 to 20 mA input is enabled. If terminal 5 is utilized, the inter- nal set point value 2 "Pset2" (Parameter 36) is used as the set point value. The subsequent screens of this function are displayed. Note Please note the following if analog input T{x} has been selected: • "Analog in Pmains" (Parameter 24) in the "Measuring" section must be config- ured as OFF. • "Analog input {x} scalable" (Parameter 215) in the "Analog inputs" section must be configured as OFF. • The GCP-30 is may be purchased with various types of analog inputs. If the con- troller being configured has analog inputs, only a 0/4 to 20 mA input may be used for this input. • Due to the fact that LeoPC1 is not a dynamic program, the graphic display of the generator/plant does not automatically update to reflect any changes made during reconfiguration. To update the program’s graphical display, LeoPC1 must be shutdown and restarted. Priority of the functions of the analog inputs If more than one function has been assigned to an analog input, the following is the priority that the control assigns to functions: • Highest priority: Mains interchange real power actual value measurement • Middle priority: Real power set point value • Lowest priority: Measuring input as common analog value Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 51/179 Parameter 79 Analog input 0-00mA XPD, XPQ Power set point value: range 0 to 20 / 4 to 20 mA The analog input measurement range is selected in this parameter. The user may se- lect from 0 to 20 mA or 4 to 20 mA to match the source of the input. 0 to 20 mA ...Minimum set point value corresponds to 0 mA; maximum set point value corresponds to 20 mA. 4 to 20 mA ...Minimum set point value corresponds to 4 mA; maximum set point value corresponds to 20 mA. CAUTION It is possible to scale the real power interchange set point. Do not configure a base load operation (C) with an import (I) or export (E) operation. The chart below shows permissible combinations of the ana- log input current levels and import, export, and base load power operations. External set point 0/4 mA C I E I E External set point 20 mA C I E E I Parameter 80 Ext.setpoint 0mA 0000kW XPD, XPQ Power set point value: scaling-minimum value C/I/E 0 to 9,999 kW The minimum value of the generator real power that corresponds to 0/4 mA is de- fined here (e. g. 0 kW). Parameter 81 Ext.setpoint 20mA 0000kW XPD, XPQ Power set point value: scaling-maximum value C/I/E 0 to 9,999 kW The maximum value of the generator real power that corresponds to 20 mA is de- fined here (e. g. 100 kW). Three-Position Controller (XPD; BPQ, XPQ: Setting 'THREESTEP') Parameter 82 Power controller dead band 00.0% Power controller: dead band 0.1 to 25.0 % The generator real power is controlled in such a manner, when paralleled with the mains, so that the monitored real power does not deviate from the configured real power set point by more than the value configured in this parameter without the controller issuing a frequency raise/lower signal to the speed control. This prevents unneeded wear on the raise/lower relay contacts. The configured percentage for the dead band refers to the generator rated power (Parameter 21). Parameter 83 Power controller gain Kp 00.0 Power controller: gain factor 0.1 to 99.9 The gain factor Kp influences the operating time of the relays. By increasing the gain, the response is increased to permit larger corrections to the variable to be con- trolled. The farther out of tolerance the process is the larger the response action is to return the process to the tolerance band. If the gain is configured too high, the result is excessive overshoot/undershoot of the desired value. Parameter 84 Powercontr. dead band ratio *0.0 Power controller: dead band factor 1.0 to 9.9 The GCP-30 has the capability to increase the power controller dead band. This function may be desired as a method of reducing wear on the voltage regulator as a result of frequent actuation due to minor fluctuation of the load. If adjusting pulses have not been output for at least 5 seconds, the dead band is increased by this fac- tor. Example: A dead band of 2.5 % and a factor of 2.0 have been configured and the GCP-30 has not issued an adjustment pulse in the last 5 seconds. The dead band is increased to 5.0 % of the rated power. If the monitored power deviates from the 5% dead band, the controller automatically returns to the original dead band (2.5 %) and controls the power at that level. Manual 37365A GCP-30 Series Packages - Genset Control Page 52/179 © Woodward Analog Controller (BPQ, XPQ: Setting 'ANALOG') Parameter 85 Power controller gain Kpr 000 BPQ, XPQ Power controller: P gain 1 to 240 The gain coefficient Kpr specifies the Proportional portion of the PID control loop. By increasing the gain, the response is increased to permit larger corrections to the variable to be controlled. The farther out of tolerance the process is the larger the response action is to return the process to the tolerance band. If the gain is config- ured too high, the result is excessive overshoot/undershoot of the desired value. Parameter 86 Power controller reset Tn 00.0s BPQ, XPQ Power controller: reset time (integration) 0.0 to 60.0 s The reset time Tn identifies the Integral portion of the PID control loop. The reset time corrects for any offset (between set point and process variable) automatically over time by shifting the proportioning band. Reset automatically changes the out- put requirements until the process variable and the set point are the same. This pa- rameter permits the user to adjust how quickly the reset attempts to correct for any offset. The reset time constant must be greater than the derivative time constant. If the reset time constant is too small, the engine will continually oscillate. If the reset time constant is too large, the engine will take an excessive amount of time to settle at a steady state. Parameter 87 Power controller derivat.Tv 0.00s BPQ, XPQ Power controller: derivative-action time 0.00 to 6.00 s The derivative action time TV identifies the Derivative portion of the PID control loop. By increasing this parameter, the stability of the system is increased. The con- troller will attempt to slow down the action of the actuator in an attempt to prevent excessive overshoot or undershoot. Essentially this is the brake for the process. This portion of the PID loop operates anywhere within the range of the process unlike reset. Partial Load Lead Parameter 88 Warm up load limit value 000% Power controller: partial-load limit 5 to 110 % The GCP-30 is capable of partially loading the generator to a specified limit for a designated time period to permit warming up of the prime mover prior assuming service loads. The partial load level is specified as a percentage in this parameter. The configured percentage for the partial load limit refers to the generator rated power (Parameter 21). Parameter 89 Warm up load time 000s Power controller: partial-load limit 0 to 600 s The GCP-30 is capable of partially loading the generator to a specified limit for a designated time period so the prime mover may be warmed up prior assuming ser- vice loads. The length of the warm-up period with partial load following the initial closure of the GCB in mains parallel operation is configured here. If an engine warm-up period is not desired, this parameter must be set to zero. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 53/179 Load and/or var Sharing The GCP-30 performs proportional load and/or var sharing. This means each generator will share the load at the same percentage level of the generator rated power when paralleled against the mains, in an isolated operation with multiple generators paralleled, or when re-synchronizing the common bus to the mains. Proportional load/var sharing will not be performed when the GCP-30 has the GCB closed and is in the constant power/base load mode. The GCP-30 is capable of controlling up to 14 generators. The GCP-30 is also capable of controlling any generator rated up to 10 MW. The total rated system power for all generators may not exceed 32 MW. Mains parallel operation with mains interchange real power control (import/export): The GCP-30 control- lers maintain the real load level on the individually controlled generators at a level so that the real power set point at the mains interchange remains at the configured set point. The real power set point for the mains interchange must be configured identically for each GCP. The GCP-30 controller communicates with other controls in the system via a CAN bus. This enables the control- lers to adjust the real power generated by the generator while remaining within the rated power of the generator. A smaller generator will contribute less real power as compared to a large generator, but they will both be util- ized to the same capacity factor. An example of this would be a 100 kW generator with a configured 1000 kW generator and a mains interchange of 825 kW. The 100 kW generator would contribute 75 kW and the 1000 kW generator would contribute 750 kW or both generators would be at 75% of their rated capacity. Reactive load sharing is not performed when operating in parallel with the mains. The reactive power control will be defined by the configured power factor set point of the individual controllers. If "Pow.fact.contr. setpoint" (Parameter 68) is configured as i0.95, the GCP will proportionally share the real load with all generators in paral- lel with the mains while controlling the reactive power at a 0.95 lagging power factor regardless of the what power factor the mains is operating at. The parameter "kW/kvar sharing: reference variable kW" (Parameter 91) can be used now to define the priority of the real power sharing reference variable (real power at interchange). A higher configured percentage influ- ences the control more towards maintaining the real power set point for the interchange. A lower configured per- centage influences the control more towards maintaining real power sharing between units. The parameter "kW/kvar sharing: reference variable kvar" (Parameter 93) has no influence here. Isolated operation in parallel: The GCP-30 controllers maintain the voltage and frequency of the individually controlled generators at a constant level. This makes it imperative that the voltage and frequency set points are configured identically for each GCP. The GCP-30 controller communicates with other controls in the system via a CAN bus. This enables the control- lers to adjust the real power generated by the generator while remaining within the rated power of the generator. A smaller generator will contribute less real power as compared to a large generator, but they will both be util- ized to the same capacity factor. An example of this would be a 100 kW generator and a 1000 kW generator with an 825 kW load. The 100 kW generator would contribute 75 kW and the 1000 kW generator would contribute 750 kW or both generators would be at 75% of their rated capacity. The reactive power will be shared proportionally among all generators involved. The parameter "kW/kvar sharing: reference variable kW" (Parameter 91) can be used to define the priority of the reference variable for real power sharing. A higher configured percentage influences the control more towards frequency control. A lower configured percentage influences the control more towards real power sharing. The parameter "kW/kvar sharing: reference variable kvar" (Parameter 93) can be used now to define the priority of the reference variable for reactive power sharing. A higher configured percentage influences the control more towards voltage control. A lower configured percentage influences the control more towards reactive power shar- ing. Manual 37365A GCP-30 Series Packages - Genset Control Page 54/179 © Woodward Re-synchronization of the busbar to the mains: The system is operating as an isolated system, for synchroni- zation to be performed the voltage and frequency differentials of the mains and bus must be within the config- ured windows. The bus frequency reference point is dictated by the monitored mains frequency and the configured frequency differential (+ dfmax/2). Example: If +dfmax = 0.2 Hz, the GCP-30 will calculate the bus frequency reference point as: [monitored mains frequency] + [dfmax/2] = bus frequency reference point A practical example of this would be: The monitored mains frequency is 60 Hz Configured + dfmax = 0.2 Hz [60 Hz] + [0.2Hz/2] = 60.1 Hz bus frequency reference point The differential voltage is configured as a window. The monitored voltage from the potential transformers sec- ondary for the mains and the bus must be within the configured voltage differential limit. This means that if the secondary voltage inputs have been configured for 120 V and a dV of 2 V is configured, then synchronization will be permitted when the monitored voltage on the secondary of the main and bus are within 2 V of each other. When the monitored bus frequency and voltage are within the configured differential limits, the "Command: close MCB" relay will enable, closing the MCB, and the system will be paralleled to the mains. Prerequisites: All GCP-30 controllers connected to the system must have rated system frequencies and breaker logic configured identically and the parameter "Active power load-share" (Parameter 90) must be enabled. Description of the load-share interface: The GCP-30 utilizes a peer relationship between units to control the system. This permits for parallel applications of up to 14 generators. NOTE Refer to the Interface section of the Installation Manual 37364 for information about the CAN bus con- nection. Diagram of load/var sharing via the CAN bus (refer to Figure 3-4 on page 36): The parameter "Active load sharing factor" determines if and how a generator performs real power or frequency control when paralleled with other generators in an isolated operation. This parameter is defined as a percentage. In the figure below 10 % means increased real power control and 99 % increased frequency control. This parameter must be configured individually for each generator. In the illustrated control system, it must be noted that each control calculates the mean utilization factor of all controls from the data transmitted via the CAN bus and then compares this with its own utilization factor. The utilization factor is compared with the reference variable and results in a new reference variable set point. Fre- quency and real power control are carried out simultaneously in these controls (corresponding to the reference variable). Frequency control is carried out via the measured voltage/frequency of the voltage system. The Pickup is used merely for monitoring functions, or is available as a control value to the secondary controller. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 55/179 Figure 3-4: CAN bus load/var sharing, diagram Manual 37365A GCP-30 Series Packages - Genset Control Page 56/179 © Woodward Parameter 90 Active power load-share ON kW sharing: load sharing ON/OFF ON ................Real power sharing is enabled. When multiple generators are operat- ing in parallel, the real power is shared proportionally. The subse- quent screens of this function are displayed. OFF ..............Real power sharing is disabled. The subsequent screens of this func- tion are not displayed. Parameter 91 Act. load share factor 00% kW sharing: reference variable kW 10 to 99 % It is possible to change the emphasis placed on maintaining control variables. By increasing or decreasing the percentage value in this parameter, the control places a higher priority on maintaining the primary or secondary control reference variable. If the value for this parameter is configured higher, maintaining the primary control variable has more priority. If the value for this parameter is configured lower, maintaining the secondary control variable has a greater priority. Primary control variable • Isolated operation = frequency maintained • Mains parallel operation = real power level at the mains interchange point main- tained Secondary control variable • Isolated operation = real power sharing with other generators maintained • Mains parallel operation = real power sharing with other generators maintained The smaller this factor the higher the priority to equally share the load among all generators. Parameter 92 Reactive power load share ON kvar sharing: var sharing ON/OFF ON ................Reactive power sharing is enabled. When multiple generators are op- erating in parallel, the reactive power is shared proportionally. The subsequent screens of this function are displayed. OFF ..............Reactive power sharing is disabled. The subsequent screens of this function are not displayed. Parameter 93 React.load share factor 00% kvar sharing: reference variable kvar 10 to 99 % It is possible to change the emphasis placed on maintaining control variables. By increasing or decreasing the percentage value in this parameter, the control places a higher priority on maintaining the primary or secondary control reference variable. If the value for this parameter is configured higher, maintaining the primary control variable has a greater priority. If the value for this parameter is configured lower, maintaining the secondary control variable has a greater priority. Primary control variable • Isolated operation = voltage maintained • Mains parallel operation = power factor maintained Secondary control variable • Isolated operation = reactive power sharing with other generators maintained •Mains parallel operation = power factor maintained Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 57/179 Automatic ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Parameter 94 Configure automatic YES Configuration of automatic YES/NO The automatic control functions are configured in this block of parameters. This parameter has the following effects: YES ..............The parameters in this block are displayed and can either be viewed ("Select" button), or modifications can be made to the parameters ("Cursor→", "Digit↑" or "Select" buttons). NO................The parameters in this block are not displayed, cannot be modified, and are skipped. Load Management NOTE To enable the automatic start/stop function, "Active power load-share" (Parameter 90) must be config- ured to “ON”, regardless if additional generators are available for load sharing. NOTE The automatic start/stop functionality of the engine, requires that identical rated power (Parameter 21) be configured in all participating controls. Load-Dependent Start/Stop in Mains Parallel Operation Parameter 95 Loadd.start/stop at ter.3 ON Load dependent start/stop: enable via terminal 3 ON/OFF ON................The automatic start/stop functionality is enabled. When the discrete input "Automatic 1" (terminal 3) is energized, the GCP-30 will automatically start/stop dependent upon the measured load in accor- dance with how generator real power set point 1 (Parameter 35) is configured. If terminal 5 is energized simultaneously, terminal 3 has priority and will override terminal 5. The subsequent screens of this function are displayed. OFF..............The automatic start/stop functionality is disabled. The generator will start only when terminal 3 is energized and stop when de-energized. The generator is loaded in accordance with how generator real power set point 1 (Parameter 35) is configured. The subsequent screens of this function are not displayed. Parameter 96 Loadd.start/stop at ter.5 ON Load dependent start/stop: enable via terminal 5 ON/OFF ON................The automatic start/stop functionality is enabled. When the discrete input "Automatic 2" (terminal 5) is energized, the GCP-30 will auto- matically start/stop dependent upon the measured load in accordance with how generator real power set point 2 (Parameter 36) is config- ured. If terminal 3 is energized simultaneously, terminal 3 has prior- ity and will override terminal 5. The subsequent screens of this func- tion are displayed. OFF..............The automatic start/stop functionality is disabled. The generator will start only when terminal 3 is energized and stop when de-energized. The generator is loaded in accordance with how generator real power set point 1 (Parameter 35) is configured. The subsequent screens of this function are not displayed. Manual 37365A GCP-30 Series Packages - Genset Control Page 58/179 © Woodward Single generator in mains parallel operation The load-dependent start/stop function is enabled when all of the following conditions have been met: • The control has been placed in the AUTOMATIC operation mode • The mains interchange power control (import/export power) has been enabled by either the "Automatic 1" or "Automatic 2" discrete inputs (terminals 3 or 5) and are configured for import or export operations • One or both parameters "Load-dependent start/stop on terminal 3/5" (Parameter 95 or Parameter 96) has been configured to "ON". Parameter 97 Minimum load generator 0000kW Load dependent start/stop: generator minimum power start set point 0 to 6,900 kW For the mains interchange (import/export) real power control to function, a mini- mum generator power set point value is required. In many cases, it is desirable that the engine is prevented from starting unless the generator will operate at a specific kW level or higher to ensure a reasonable degree of efficiency. Example: The mains interchange must reach a level that will permit an 80kW gen- erator to operate at a minimum load of 40kW prior to the engine starting. Parameter 98 Add-on delay mains oper. 000s Load dependent start/stop: start delay 0 to 999 s Load swings may exceed the "Minimum load generator" (Parameter 97) set point momentarily. In order to prevent the engine from starting due to short-term load swings, a delay time may be configured. The load must remain above the minimum load set point without interruption for the delay time, configured in seconds, prior to a start command being issued. If the load falls below the minimum load set point before the delay time expires, the delay time is reset and a start command is not is- sued. Parameter 99 Shed-off delay mains oper. 000s Load dependent start/stop: stop delay 0 to 999 s Load swings may fall below the "Hysteresis add on/off op." (Parameter 100) set point momentarily. In order to prevent the engine from stopping due to short-term load swings, a delay time may be configured. The load must remain below the hys- teresis set point without interruption for the delay time, configured in seconds, prior to a stop command being issued. If the load exceeds the hysteresis set point before the delay time expires, the delay time is reset and a stop command is not issued. Stopping hysteresis NOTE Parameter 100 is used to determine the stopping hysteresis for a single generator in a mains parallel operation and multiple paralleled generators in an isolated operation. Parameter 100 Hysteresis add-. on/off op.0000kW Load dependent start/stop: stopping hysteresis 0 to 9,999 kW The shutdown power limit of the generator is determined via a hysteresis. The hys- teresis is used to prevent the engine continuously starting and shutting down due to minor load swings. The hysteresis should be configured so that the system has time to bring an additional generator online during the largest possible load swing that the plant may experience. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 59/179 Single generator mains parallel operation (mains interchange (import/export) real power control) NOTE The "desired mains interchange power level" will equal 0 in the formulas below if the breaker logic is configured as Open Transition, Closed Transition, Interchange, or External. The desired mains inter- change power level is utilized for import and export power operations. General Formula A: Determining the start set point An engine start command is issued when: Desired mains interchange power level – Minimum load generator = Mains power level when generator started Formula B: Stop of the engine An engine stop command is issued when: Desired mains interchange power level + Monitored mains power + Minimum load generator – Generator hys- teresis = Mains power level when generator stopped Example Situation: A customer wants to import only 50kW from the utility. The minimum efficient load to start the gen- erator is 30kW. The generator should be shut down when the generator load drops below 20kW. Desired mains interchange power level = the power to be imported or exported to the mains Imported power is always calculated as a negative number since the generator does not produce it. Ex- ported power is always calculated as a positive number since the generator produces it. The desired im- port level should be entered as "I0050kW" for Pset1 or Pset2 (Parameter 35 or Parameter 36). Desired mains interchange power level = -50 kW Minimum load generator = the minimum efficient load that a start request will be issued "Minimum load generator" (Parameter 97) should be configured as "0030kW". Minimum load generator = 30 kW Generator hysteresis = the power level that a stop command will be issued This value is calculated by subtracting the minimum generator load for a shut down command from the minimum load that a start command is issued. In this example the calculation would be [30kW – 20kW = 10kW]. "Hysteresis add on / off op." (Parameter 100) should be configured as "10kW". Generator hysteresis = 10 kW Monitored mains power = the monitored power level and direction at the mains breaker The situation above will be calculated as follows: Case 1: An engine start command is issued when the monitored mains power reaches a specified level. Formula A is used as follows: Desired mains interchange power level – minimum load generator = mains power level when generator starts - 50 kW - 30 kW = -80 kW The power supplied by the mains must be equal to or greater than 80 kW in order for the GCP-30 to issue a start command. After the engine starts and the GCB closes, the generator will assume load until the mains interchange is importing 50kW. Case 2: An engine stop command is issued when the monitored mains power falls to a specified level. Formula B is used as follows: Desired mains interchange power level + monitored mains power + minimum load generator – generator hystere- sis = generator power level when generator stops - 50 kW + 50 kW + 30 kW - 10 kW = 20 kW The power supplied by the generator must be equal to or less than 20 kW for the delay time without interruption prior to the GCP-30 issuing a stop command. After the GCP-30 issues the stop command, the generator will transfer the remaining load to the mains (increasing the mains import level to 70kW), open the GCB, and shut- down the engine. Manual 37365A GCP-30 Series Packages - Genset Control Page 60/179 © Woodward Load sharing with multiple generators in a mains parallel operation The load-dependent start/stop functionality is enabled when the following conditions have been met for all con- trols: • The control has been placed in the AUTOMATIC operation mode • The mains interchange power control (import/export power) has been enabled by energizing either the "Auto- matic 1" or "Automatic 2" discrete inputs (terminals 3 or 5) and are these discrete inputs are configured for import or export operations • All parameters, such as start power (Parameter 97), stop power (Parameter 100), start delay (Parameter 98), stop delay (Parameter 99), and the frequency set point value (Parameter 8) are configured identically for all generators that will be load sharing • One or both parameters "Load-dependent stop/start on terminal 3/5" (Parameter 95 and/or Parameter 96) has been configured "ON" • The parameters "Load sharing" (Parameter 90) and/or "var sharing" (Parameter 92) have been configured "ON" • All generators are configured for the same rated power (Parameter 21) NOTE "Reserve power mains op." (Parameter 101) is only utilized when multiple generators are to be paral- leled with the mains. The first engine will be started as described in the section: Single generator mains parallel operation (mains interchange (import/export) real power control) on page 59. Parameter 101 Reserve power mains op. 0000kW Load dependent start/stop: reserve power 0 to 9,999 kW The value configured for the reserve power determines when an additional genera- tor will be started. The reserve power is the desired spinning reserve of a generator or generators. The reserve power is usually configured as the largest load swing that a power plant may encounter during the time it takes to bring an additional generator online. The available generator power is calculated by multiplying the number of generators with closed GCBs by the generator real power rating of a generator. The reserve generator power is calculated by subtracting the power cur- rently being produced by all generators with closed GCBs from the total available generator power. If the actual reserve power of the generators is less than the value configured in this parameter, the next generator will be started. Currently available total generator rated real power - Currently available total generator actual real power = Reserve power Parameter 102 Priority of generators 0 Load dependent start/stop: priority of generators 0 to 14 This parameter specifies the sequence in which the individual generators are started. The control with the lowest configured number has the highest priority. This generator will be the first started and the last stopped. In the event two or more generators have been assigned identical priorities, the starting sequence is de- termined by the operating hours. In this case, the generator with the lowest operat- ing hours will be started first. In the event the generators have the same number of operating hours, the generator with the lowest generator number (CAN bus address, Parameter 4) is started. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 61/179 Mains parallel operation(mains interchange (import/export) real power control with multiple generators) NOTE The "desired mains interchange power level" will equal 0 in the formulas below if the breaker logic is configured as Open Transition, Closed Transition, Interchange, or External. The desired mains inter- change power level is utilized for import and export power operations. General Formula C: Start of the first generator All GCBs are open. The first engine is started when: desired mains interchange power level – minimum load generator = mains power level when generator starts Formula D: Starting of additional generators At least one GCB in the group is closed. The next engine is started when: [(generator rating)(number of closed GCBs) – parallel reserve power] / number of closed GCBs = individual gen- erator power level at next start Formula E: Stopping a generator At least two GCBs in the group are closed. An engine is stopped when: (number of generators needed for load – 1)(generator rating) – parallel reserve power – generator hysteresis = power level next generator stopped Formula F: Stopping of the last generator Only one GCB in the group is closed. The last engine is stopped when: [desired mains interchange power level + monitored mains power + minimum load generator – generator hys- teresis = mains power level when generator stops Example When the generators are running the customer wishes to remain paralleled with the mains but does not want the mains to supply any power to the system. This value has been configured as "I0000kW" (refer to "Real Power Controller, Set Point Values on page 37"). The same functionality may be achieved by configuring the main in- terchange power as "E0000kW". The largest load swing the system will encounter is 40 kW. The customer wants a 20 kW buffer to prevent restarting of generators due to load swings. A reserve power for the system of 40 kW and a generator hysteresis of 20 kW is desired for this application. The power plant consists of three generators capable of paralleling. Each generator is rated for 200 kW of real power. It is not economical to start a generator unless it will carry 30 kW of load. Manual 37365A GCP-30 Series Packages - Genset Control Page 62/179 © Woodward Variables Generator rating = the power rating for an individual generator (all generators used in this application must be of the same power rating). "Rated power generator" (Parameter 21) should be configured as "200 kW". Generator rating = 200 kW Number of closed GCBs = all generator that are used to calculate available generation power must have their cir- cuit breaker closed. Number of closed GCBs = varies Desired mains interchange power level = the power to be imported or exported to the mains Imported power is always calculated as a negative number since the generator does not produce it. Exported power always calculated as a positive number since the generator produces it. The desired import level should be entered as "I0000 kW" for Automatic 1 or 2 (Parameter 35 or Parameter 36). Desired mains interchange power level = 0 kW Minimum load generator = the minimum load that the first start request will be issued "Minimum load generator" (Parameter 97) should be configured as "0030kW". Minimum load generator = 30 kW Generator hysteresis = the power level that a stop command will be issued This value is calculated by subtracting the minimum generator load for a shut down command to be issued from the minimum load that a start command is issued. In this example the calculation would be [30 kW – 10 kW = 20 kW]. "Hysteresis add on / off op." (Parameter 100) should be configured as "20 kW". Generator hysteresis = 20 kW Parallel reserve power = the real load that a generator or generators are able to absorb while the next generator is started. The reserve power is usually configured as the largest load swing that a power plant may encounter dur- ing the time it takes to bring an additional generator online. "Reserve power mains op." (Parameter 101) should be configured as "40 kW". Reserve power = 40 kW Monitored mains power = the monitored power level and direction at the mains breaker Case 3: An engine start command is issued when the monitored mains power reaches a specified level. Formula C is used as follows: Desired mains interchange power level – Minimum load generator = Mains power level when generator starts 0 kW - 30 kW = -30 kW The power supplied by the mains must be at equal to or greater than 30 kW in order for the GCP-30 to issue a start command. After the engine starts and the GCB closes, the generator will assume load until the mains inter- change is importing 0 kW. Case 4: An engine start command is issued to the second generator when the monitored mains power reaches a specified level. Formula D is used as follows: [(generator rating)(number of closed GCBs) – parallel reserve power] / number of closed GCBs = generator power level at next start [(200 kW)(1) – 40 kW] / 1 = 160 kW The single generator that is providing power has a total load rating of 200 kW (200 kW x 1). This generator has an available load of 160 kW (200 kW – 40 kW). When the individual generator load exceeds 160 kW, the next generator will be started and brought online to share the load. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 63/179 Case 5: An engine start command is issued to the second generator when the monitored mains power reaches a specified level. Formula D is used as follows: [(generator rating)(number of closed GCBs) – parallel reserve power] / number of closed GCBs = generator power level at next start [(200 kW)(2) – 40 kW] / 2 = 180 kW. The two generators that are providing power have a total load rating of 400 kW (200 kW x 2). Both generators combined have an available load of 360 kW (400 kW – 40 kW). The reserve power limit is split equally between the two generators giving each generator an effective load of 180 kW each. When the individual generator loads exceed 180 kW, the next generator will be started and brought online to share the load. Case 6: An engine stop command is issued to the first generator when the monitored system power falls to a specified level. Formula E is used as follows: (number of generators needed for load – 1 generator)(generator rating) – reserve power – generator hysteresis = Power level next generator stopped (3 – 1)(200 kW) – 40 kW – 20 kW = 340 kW(3 – 1)(200 kW) – 40 kW – 20 kW = 340 kW System power level / number of closed GCBs = individual generator load level 340 kW / 3 = 113.3 kW The three generators that are providing power have a total load rating of 600 kW (200 kW x 3). Before a genera- tor can be shut down as the load decreases, the two generators that will remain online must be able to sustain the remaining load. This requires that the above formula be used to determine the load level that a shutdown com- mand is issued. According to the calculations above that level is 340 kW. This load is shared equally among the online generators. To determine the individual generator load levels the shut down power level must be divided by the number of generators online (340 / 3 = 113.3 kW). When the individual loads for the generators drop be- low 113.3 kW, a stop command will be issued and a generator will shed its load to the remaining generators, open its GCB, and shut down. Case 7: An engine stop command is issued to the second generator when the monitored system power falls to a specified level. Formula E is used as follows: (number of generators needed for load – 1 generator)(generator rating) – parallel reserve power – generator hys- teresis = system power level next generator stopped (2 – 1)(200 kW) – 40 kW – 20 kW = 140 kW. System power level / number of closed GCBs = individual generator load level 140 kW / 2 = 70 kW The two generators that are providing power have a total load rating of 400 kW (200 kW x 2). Before a generator can be shut down as the load decreases, the generator that will remain online must be able to sustain the remain- ing load. This requires that the above formula be used to determine the load level that a shutdown command is is- sued. According to the calculations above that level is 140 kW. This load is shared equally among the online generators. To determine the individual generator load levels the shut down power level must be divided by the number of generators online (140 / 2 = 70 kW). When the individual loads for the generators drop below 70 kW, a stop command will be issued and a generator will shed its load to the remaining generator, open its GCB, and shut down. Case 8: An engine stop command is issued to the last generator when the monitored system power falls to a specified level. Formula F is used as follows: desired mains interchange power level + monitored mains power + minimum load generator – generator hystere- sis = mains power level when generator stops 0 kW + 0 kW + 30 kW - 20 kW = 10 kW The final remaining generator will be taken offline after the load supplied by the generator drops below the con- figured mains interchange level plus the monitored power at the mains interchange minus the minimum config- ured load for the generator minus the generator hysteresis or 10 kW in this case. When the load drops to 10 kW, the load is shed from the generator to the mains, the GCB is opened, and the generator is shut down. The mains will now import 10 kW. If the load increases again, the previous steps are repeated. Manual 37365A GCP-30 Series Packages - Genset Control Page 64/179 © Woodward Isolated operation in parallel with other generators The load-dependent start/stop functionality is enabled when the following conditions have been met for all con- trols: • The control has been placed in the AUTOMATIC operation mode • The mains interchange power control (import/export power) has been enabled by either the "Automatic 1" or "Automatic 2" discrete inputs (terminals 3 or 5) and are configured for import or export operations • All parameters, such as start power (Parameter 97), stop power (Parameter 100), start delay (Parameter 98), stop delay (Parameter 99), and the frequency set point value (Parameter 8) are configured identically for all generators that will be load sharing • One or both parameters "Load-dependent stop/start on terminal 3/5" (Parameter 95 and/or Parameter 96) has been configured to "ON" • The parameters "Load sharing" (Parameter 90) and/or "var sharing" (Parameter 92) have been configured to "ON" • All generators are configured for the same rated power (Parameter 21) NOTE In order to prevent a generator from becoming overloaded, ensure that the value configured for the re- serve power (Parameter 103) is larger than the largest load swing any one generator might endure while an additional generator is brought online. Parameter 103 Reserve power isol.op. 0000kW Load dependent start/stop: reserve power (isolated operation) 0 to 9,999 kW The value configured for the reserve power determines when an additional genera- tor will be started. The reserve power is the desired spinning reserve of a generator or generators. The reserve power is usually estimated as the largest load swing that a power plant may encounter during the time it takes to bring an additional genera- tor online. The available generator power is calculated by multiplying the number of generators with closed GCBs by the generator real power rating of a generator. The reserve generator power is calculated by subtracting the power currently being produced by all generators with closed GCBs from the total available generator power. If the actual reserve power of the generators is less than the value config- ured in this parameter, the next generator will be started. Currently available total generator rated real power - Currently available total generator actual real power = Reserve power Parameter 104 Add-on delay isol.op. 000s Load dependent start/stop: start delay (isolated operation) 0 to 999 s Load swings may exceed the "Reserve power isol. op." (Parameter 97) set point momentarily. In order to prevent the engine from starting due to short-term load swings, a delay time may be configured. The load must remain above the reserve power set point without interruption for the delay time, configured in seconds, prior to a start command being issued. If the load falls below the reserve power set point before the delay time expires, the delay time is reset and a start command is not is- sued. Parameter 105 Shed-off delay isol.op. 000s Load dependent start/stop: stop delay (isolated operation) 0 to 999 s Load swings may fall below the "Hysteresis add on/off op." (Parameter 100) set point momentarily. In order to prevent the engine from stopping due to short-term load swings, a delay time may be configured. The load must remain below the hys- teresis set point without interruption for the delay time, configured in seconds, prior to a stop command being issued. If the load exceeds the hysteresis set point before the delay time expires, the delay time is reset and a stop command is not issued. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 65/179 General Formula G: Start of the engine [(generator rated power)(number of closed GCBs) – isolated reserve power] / number of closed GCBs = generator power level that a generator is started Formula H: Stop of the engine (number of generators needed for load – 1 generator)(generator rating) – isolated reserve power – genera- tor hysteresis = generator power level that a generator is stopped Example Two generators are in an isolated parallel operation application. One generator will always be in operation. The second generator is used to share large loads. Generator rating = the power rating for an individual generator (all generators used in this application must be of the same power rating). "Rated power generator" (Parameter 21) should be configured as "200 kW". Generator rating = 200 kW Number of closed GCBs = all generator that are used to calculate available generation power must have their cir- cuit breaker closed. Number of closed GCBs = varies Isolated reserve power = the real load that a generator or generators are able to absorb while the next generator is started. The reserve power is usually configured as the largest load swing that a power plant may encounter dur- ing the time it takes to bring an additional generator online. "Reserve power isol.op." (Parameter 103) should be configured as "60 kW". Isolated reserve power = 60 kW Generator hysteresis = the power level that a stop command will be issued This value is calculated by subtracting the minimum generator load for a shut down command to be issued from the minimum load that a start command is issued. In this example the calculation would be [60 kW – 30 kW = 30 kW]. "Hysteresis add on / off op." (Parameter 100) should be configured as "30 kW". Generator hysteresis = 30 kW Case 11: An engine start command is issued to the second generator when the monitored system power reaches a specified level. Formula G is used as follows: [(generator rating)(number of closed GCBs) – isolated reserve power] / number of closed GCBs = generator power level that a generator is started (200 kW)(1) - 60 kW/1 = 140 kW The generator that is providing power has a total load rating of 20 0kW (20 0kW x 1). The online generator has an available load of 140 kW (200 kW – 60 kW). When the online generator load exceeds 140 kW, the second generator will be started and brought online to share the load. Case 12: An engine stop command is issued to a generator when the monitored system power falls to a specified level. Formula H is used as follows: (Number of generators needed for load – 1 generator)(generator rating) – isolated reserve power – generator hys- teresis = system power level next generator stopped 400 kW - 60 kW - 200 kW - 30 kW = 110 kW system power level / number of closed GCBs = individual generator load level 110 kW / 2 = 55 kW The two generators providing power have a total load rating of 400 kW (200 kW x 2). Before a generator can be shut down as the load decreases, the generator that will remain online must be able to sustain the remaining load. This requires that the above formula be used to determine the load level that a shutdown command is issued. Ac- cording to the calculations above that level is 110 kW. This load is shared equally among the online generators. To determine the individual generator load levels the shut down power level must be divided by the number of generators online (110 / 2 = 55 kW). When the individual loads for the generators drop below 55 kW, a stop command will be issued and a generator will shed its load to the remaining generator, open its GCB, and shut down. Manual 37365A GCP-30 Series Packages - Genset Control Page 66/179 © Woodward Stop Of The Engine At Mains Failure [GCP-31] Parameter 106 Mains error - stop eng. ON Engine stop at mains failure ON/OFF ON ................The GCB will open and the engine will shut down if a mains failure is detected for at least the time configured for "Emergency power start delay" (Parameter 138) and the discrete input "Isolated opera- tion" (terminal 54) is de-energized (mains parallel operation en- abled). When the mains return and the mains settling time (Para- meter 194) has expired, the engine will start and the GCB will synchronize. OFF ..............The GCB will open and the engine will continue running at rated speed with no load if a mains failure is detected for at least the time configured for "Emergency power start delay" (Parameter 138) and the discrete input "Isolated operation" (terminal 54) is de-energized (mains parallel operation enabled). When the mains returns and the mains settling time (Parameter 194) has expired, the GCB is syn- chronized. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 67/179 Interface NOTE For remote acknowledgement of alarms, a remote stop while in idle mode must be performed. If the control is in an isolated operation, an acknowledgement combined with a remote start must be per- formed. Parameter 107 Control via COM X1X5 ON Control via interface COM X1-X5 ON/OFF ON................The remote control interface via the CAN bus (X1X5 terminals) is enabled. This parameter requires that "Direct configuration" (Para- meter 3) be configured "OFF", the AUTOMATIC operation mode must be enabled, and the discrete input "Automatic 2" (terminal 5) has been energized. When remote control of a unit has been enabled, it is possible to start and stop the engine, acknowledge alarms, and change the real power and power factor set points via CAN bus communication. The meas- ured values and states of the controller may be monitored as well. OFF..............The remote control interface via the CAN bus (X1X5 terminals) is disabled. The generator real power is controlled in the accordance with how "Automatic 2" (Parameter 36) and the "Power factor con- trol set point" (Parameter 68) are configured when the "Automatic 2" discrete input is energized. Parameter 108 Supervision COMX1X5 ON if COMX1X5 = ON only Remote monitoring of the interface ON/OFF ON................Monitoring of the remote control interface is enabled. The controller monitors to ensure the control signal (CAN ID 503) is received every 90 seconds. If the control signal is not received every 90 seconds, a class 1 (warning) alarm is issued. OFF..............Monitoring of the interface is disabled. Parameter 109 Ackn. F2,F3 via COM interf ON if COMX1X5 = ON only Remote acknowledgment of F2/F3 alarms via the interface ON/OFF ON................Acknowledgement of class F2/F3 alarms via the remote control inter- face is enabled. OFF..............Acknowledgement of class F2/F3 alarms via the remote control inter- face is disabled. Acknowledgment of alarms is performed by energiz- ing the "Acknowledgment" discrete input (terminal 6) or by pressing the "RESET" push button. NOTE For the description of the second interface (Option SB03 and Option SC10) refer to the following manu- als: • Option SB03 = manual 37200 • Option SC10 = manual 37382 Manual 37365A GCP-30 Series Packages - Genset Control Page 68/179 © Woodward Breaker ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ NOTE The parameters for this control are grouped together in blocks to permit navigation through the large number of configuration screens more rapidly. Selecting "YES" or "NO" has no effect whether or not control or monitoring is carried out for the parameters located in that block. Selecting "YES" or "NO" only determines if the individual parameters may be accessed and changed or are bypassed. Parameter 110 Configure breaker YES Configuration of the breakers YES/NO The breaker control functions are configured in this block of parameters. This pa- rameter has the following effects: YES ..............The parameters in this block are displayed and can either be viewed ("Select" button), or modifications can be made to the parameters ("Cursor→", "Digit↑" or "Select" buttons). NO………… The parameters in this block are not displayed, cannot be modified, and are skipped. Functional Description Permissible Limits If the generator or mains monitoring for over-/undervoltage (Parameter 174) or over-/underfrequency (Para- meter 168) is disabled, the CB logic (Parameter 111), the control uses internally defined default limits for genera- tor and mains monitoring. The internally defined default limits always are used to monitor the busbar. Voltage Frequency Generator VGen: 75 to 115 % VRated fGen: 80 to 110 % fRated Busbar VBusbar: 85 to 112.5 % VRated fBusbar: 90 to 110 % fRated Mains VMains: 85 to 112.5 % VRated fMains: 90 to 110 % fRated Table 3-4: Limit values, permissible limits The permissible limits refer to the respective rated values in the system, such as the system rated voltage (Para- meter 17) and the system rated frequency (Parameter 9). Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 69/179 Synchronization Synchronization of the GCB GCB synchronization will be performed with frequency and voltage correction when the following conditions have been met: NOTE The GCP-30series controller does not have maximum phase angle limit for synchronization. The GCP- 30 uses the parameters "Closing time GCB" (Parameter 120) and/or "Closing time MCB" (Para- meter 121) to calculates the optimum time for a breaker closure signal to be issued with the measured frequency differential. The typical maximum tolerances are 1.5° to 3.5° with a frequency differential ranging of 0.2 Hertz to 0.49 hertz. If the parameters "Closing time GCB" and/or "Closing time MCB" are not configured accurately, these tolerances will increase due to inaccurate information being provided for the close command calculation resulting in a larger phase angle at closing. Automatic mode • The control has been placed in the AUTOMATIC operation mode • The circuit breaker logic (Parameter 111) is configured as "PARALLEL" (mains parallel operation), "IN- TERCHANGE" (mains interchange (import/export) real power control), or "CLOSED TRANSIT." (make- before-break/overlap synchronization) • An F2 or F3 class alarm has not been detected • The "Automatic 1" (terminal 3) or "Automatic 2" (terminal 5) discrete input has been energized, a remote starting signal has be activated via the interface, or an emergency power operation has been initiated resulting in additional engines being started • The busbar is energized (the control measures voltage on the bus) • The engine is running and the generator voltage and frequency are within the permissible limits • The delayed engine monitoring (Parameter 271) has expired (this does not apply in the case of emergency power) • The rotating field of the generator and the mains voltages are identical and no alarms are displayed Manual mode • The control has been placed in the MANUAL operation mode • The circuit breaker logic (Parameter 111) is configured as "PARALLEL" (mains parallel operation), "IN- TERCHANGE" (mains interchange (import/export) real power control), or "CLOSED TRANSIT." (make- before-break/overlap synchronization) • An F2 or F3 class alarm has not been detected • The busbar is energized (the control measures voltage on the bus) • The engine is running and the generator voltage and frequency are within the permissible limits • The "GCB ON" push-button has been pressed • The rotating field of the generator and the mains voltages are identical and no alarms are displayed Load test mode • The control has been placed in the MANUAL operation mode • The circuit breaker logic (Parameter 111) is configured as "PARALLEL" (mains parallel operation), "IN- TERCHANGE" (mains interchange (import/export) real power control), or "CLOSED TRANSIT." (make- before-break/overlap synchronization) • An F2 or F3 class alarm has not been detected • The busbar is energized (the control measures voltage on the bus) • The engine is running and the generator voltage and frequency are within the permissible limits • The "GCB ON" push-button has been pressed • The rotating field of the generator and the mains voltages are identical and no alarms are displayed Manual 37365A GCP-30 Series Packages - Genset Control Page 70/179 © Woodward Synchronization of the MCB [GCP-32] MCB synchronization will be performed with frequency and voltage correction when the following conditions have been met: Automatic mode • The control has been placed in the AUTOMATIC operation mode • The circuit breaker logic (Parameter 111) is configured as "PARALLEL" (mains parallel operation), "IN- TERCHANGE" (mains interchange (import/export) real power control), or "CLOSED TRANSIT." (make- before-break/overlap synchronization) • An F2 or F3 class alarm has not been detected • The busbar is energized (the control measures voltage on the bus) • The mains voltage is present and within the permissible limits • The engine is running and the generator voltage and frequency are within the permissible limits • The discrete input "Reply: GCB is open" is not energized (the GCB is closed) • The discrete input "Enable MCB" is energized • The rotating field of the generator and the mains voltages are identical and no alarms are displayed Manual operation • The control has been placed in the MANUAL operation mode • The circuit breaker logic (Parameter 111) is configured as "PARALLEL" (mains parallel operation), "IN- TERCHANGE" (mains interchange (import/export) real power control), or "CLOSED TRANSIT." (make- before-break/overlap synchronization) • An F2 or F3 class alarm has not been detected • The busbar is energized (the control measures voltage on the bus) • The mains voltage is present and within the permissible limits • The engine is running and the generator voltage and frequency are within the permissible limits • The discrete input "Reply: GCB is open" is not energized (the GCB is closed) • The discrete input "Enable MCB" is energized • The "MCB ON" push-button has been pressed • Load test: The GCB is opened in accordance with the configured breaker logic (INTERCHANGE, or CLOSED TRANSIT.) after the load test has been terminated • The rotating field of the generator and the mains voltages are identical and no alarms are displayed Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 71/179 Dead Bus Start Dead bus start of the GCB The GCB will close without synchronization when the following conditions have been met: Automatic mode • The control has been placed in the AUTOMATIC operation mode • An F2 or F3 class alarm has not been detected • "GCB dead bus start" (Parameter 125) has been configured as "ON" • The busbar is de-energized (the control does not measure voltage on the bus) • The engine is running and the generator voltage and frequency are within the permissible limits • The discrete input "Reply: MCB is open" is energized (the MCB is open) • If load sharing is performed via the CAN bus - All GCBs must be open if the system has multiple generators in an isolated parallel application - The generator with the lowest CAN bus address/generator number (Parameter 4) will be the first to close its GCB Manual mode • The control has been placed in the MANUAL operation mode • An F2 or F3 class alarm has not been detected • The busbar is de-energized (the control does not measure voltage on the bus) • The engine is running and the generator voltage and frequency are within the permissible limits • The discrete input "Reply: MCB is open" is energized (the MCB is open) • If load sharing is performed via the CAN bus - All GCBs must be open if the system has multiple generators in an isolated parallel application - The generator with the lowest CAN bus address/generator number (Parameter 4) will be the first to close its GCB • The "GCB ON" push-button has been pressed Disabled generator monitoring: If the generator monitoring for over-/undervoltage (Parameter 174) or over-/underfrequency (Parameter 168) is disabled, the control uses internally defined default limits for generator monitoring. Generator monitors Voltage Frequency ON Monitor values Monitor values OFF VGen > 75 % VRated VGen < 115 % VRated fGen > 80 % fRated fGen < 110 % fRated Table 3-5: Limit values generator, dead bus start The permissible limits refer to the respective rated values in the system, such as the system rated voltage (Para- meter 17) and the system rated frequency (Parameter 9). Manual 37365A GCP-30 Series Packages - Genset Control Page 72/179 © Woodward Dead bus start of the MCB [GCP-32] The MCB will close without synchronization when the following conditions are met: Automatic mode • The control has been placed in the AUTOMATIC operation mode • "MCB dead bus start" (Parameter 129) has been configured as "ON" • The busbar is de-energized (the control does not measure voltage on the bus) • The mains voltage is present and within the permissible limits • The discrete input "Reply: GCB is open" is energized (the GCB is open) • The discrete input "Enable MCB" is energized Manual mode • The control has been placed in the MANUAL operation mode • The busbar is de-energized (the control does not measure voltage on the bus) • The mains voltage is present and within the permissible limits • The discrete input "Reply: GCB is open" is energized (the GCB is open) • The discrete input "Enable MCB" is energized • The "MCB ON" push button has been pressed Operation mode STOP • If "Enable MCB" (terminal 53) is energized and "Switch MCB in stop mode" (Parameter 135) is configured as "YES", the MCB will close when all generators are in STOP mode Disabled mains monitoring: If the mains monitoring for over-/undervoltage (Parameter 184) or over-/underfrequency (Parameter 179) is dis- abled, the control uses internally defined default limits for generator monitoring. Mains monitors Voltage Frequency ON Monitor values Monitor values OFF VMains > 85 % VRated VMains < 112.5 % VRated fMains > 90 % fRated fMains < 110 % fRated Table 3-6: Limit values mains, dead bus start The permissible limits refer to the respective rated values in the system, such as the system rated voltage (Para- meter 17) and the system rated frequency (Parameter 9). Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 73/179 Open Breaker Open GCB The GCB will be opened though one of two methods that is dependent upon how the breaker closure signal is configured. If the breaker closure signal is configured as a "continuous pulse" (Parameter 115), the "Command: GCB close" relay output will be de-energized. If the breaker closure signal is configured as a "momentary pulse" (Parameter 115), the GCB will open when the "Command: GCB open" relay is energized. The GCB will be opened under the following circumstances: • If a mains failure is detected and the mains decoupling is configured to occur at the GCB (Parameter 132 or Parameter 133 depending on control unit) • In the STOP operation mode • If a F2 or F3 class alarm is detected • Upon pressing the "GCB OFF" or [GCP-32] "MCB ON" push-button (dependent upon the configured breaker logic) in the MANUAL operation mode • Upon pressing the "STOP" push-button in the MANUAL operation mode • Upon pressing the "GCB OFF" or [GCP-32] "MCB ON" push-button (dependent upon the configured breaker logic) in the LOAD TEST operation mode • In the event of an automatic shutdown in the AUTOMATIC operation mode • [GCP-32] After the MCB has closed when the breaker logic is configured as "CLOSED TRANSIT." (make- before-break/overlap synchronization) • [GCP-32] Prior to closing the MCB to the dead busbar when the breaker logic is configured as "OPEN TRANSIT." (break-before-make/changeover) • In a critical mode/sprinkler operation, provided that an emergency power operation is not enabled • [GCP-32] Following the load transfer from the generator(s) to the mains so that a zero power transfer occurs at the GCB when the breaker logic is configured for "INTERCHANGE" (mains interchange (import/export) real power control) Open MCB [GCP-32] The MCB will be opened when the "Command: GCB open" relay is energized (configuration of "continuous pulse" is not possible for the MCB). The MCB will be opened under the following circumstances: • If a mains fault is detected and the mains decoupling is configured to EXT (Parameter 133) • If emergency power (AMF) is enabled (mains failure) • After the GCB has closed when the breaker logic is configured as "CLOSED TRANSIT." (make-before- break/overlap synchronization) • Before the GCB is closed to the dead busbar when the breaker logic is configured as "OPEN TRANSIT." (break-before-make/changeover) • Upon pressing the "MCB OFF" or "GCB ON" push-button (dependent upon the configured breaker logic) in the MANUAL operation mode • Upon pressing the "MCB OFF" or "GCB ON" push-button (dependent upon the configured breaker logic) in the LOAD TEST operation mode • Following the load transfer from the mains to the generator(s) so that a zero power transfer occurs at the MCB when the breaker logic is configured for "INTERCHANGE" (mains interchange (import/export) real power control) Manual 37365A GCP-30 Series Packages - Genset Control Page 74/179 © Woodward Breaker Logic NOTE Using the discrete input "Change breaker logic via terminal 64" (Parameter 207), the breaker logic may be switched between two different breaker logics (description on page 113). The primary breaker logic is configured in Parameter 111. If Parameter 206 is configured as "ON", the discrete input terminal 64 is used as a control input. When terminal 64 is energized, the secondary breaker logic configured in Para- meter 207 is enabled. When terminal 64 is de-energized, the primary breaker logic configured in Para- meter 111 is enabled. Therefore it is possible during operation to change between the breaker logic "PARALLEL" (automatic synchronizing) and "EXTERNAL" (manual synchronizing) with the flip of a switch. Parameter 111 Breaker logic: ---------------- only accessible via LeoPC1 Breaker logic see below The GCP may be configured to utilized two different breaker logics. Depending on the unit, there are up to five breaker logic modes to select from. The available breaker logic modes are: GCP-31 GCP-32 EXTERNAL EXTERNAL PARALLEL PARALLEL --- OPEN TRANSIT. --- CLOSED TRANSIT. --- INTERCHANGE A detailed explanation for each mode may be found in the following text. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 75/179 "PARALLEL" Breaker Logic Configuring Parameter 111 to "PARALLEL" enables parallel operation. NOTE Parallel breaker logic must be selected for the following operation modes: • Isolated operation • Isolated operation with multiple generators in parallel • Mains parallel operation In the event of an add-on request, the following occurs: • The GCB is synchronized and closed • The necessary generator assumes load and real power and/or reactive power is controlled Following the add-off request, the following occurs: • The generator sheds load and the generator power factor is controlled to "1.00" (unity) • The GCB is opened • The engine is shut down following the configured cool down period [GCP-32] The MCB is synchronized with the energized common bus and closed if: • Terminal 53 "Enable MCB" is energized • The GCB is closed [GCP-32] The MCB is closed onto the de energized common bus and closed if: • The GCB is open • The MCB is open • The busbar is dead (de-energized) • Terminal 53 "Enable MCB" is energized NOTE Soft unloading (power reduction) is carried out prior to opening the GCB when a stop command is is- sued to the engine unless an F3 class alarm has been detected. Manual 37365A GCP-30 Series Packages - Genset Control Page 76/179 © Woodward "INTERCHANGE" Breaker Logic [GCP-32] Configuring Parameter 111 to "INTERCHANGE" enables real power control (import/export) through a mains in- terchange operation. NOTE For this breaker logic to function correctly, the mains power measurement must be connected prop- erly. The power controller must also be assigned the properly process identifier (C, I, or E). In the event of an add-on request, a change is made from mains to generator supply, the following occurs: • The GCB is synchronized and closed • The generator assumes load until the mains interchange (import/export) real power is "zero" • The MCB is opened When an add-off request has been issued, the load is transferred from the generator to the mains supply. The fol- lowing occurs: • The MCB is synchronized and closed • The generator sheds load until a "zero" power transfer is measured across the GCB • The GCB is opened "CLOSED TRANSIT." Breaker Logic [GCP-32] Configuring Parameter 111 to "CLOSED TRANSIT." enables the MCB and GCB to perform a closed transition (make-before-break/overlap synchronization) when transferring from the mains to the generator and back. NOTE The GCP does not perform a "zero" power transfer when opening or closing the MCB or GCB. The cir- cuit breakers will be opened regardless of the monitored power. In the event of an add-on request, the load is transferred from mains to the generator. The following occurs: • The GCB is synchronized and closed • The MCB is opened and the generator assumes all loads After the engine shed-off request has been issued, the load is transferred from the generator to mains. The fol- lowing occurs: • The MCB is synchronized and closed • The GCB is opened and the mains assume all load NOTE When the GCP is configured for a closed transition, the maximum time of the transition between the MCB and the GCB is 500ms. This time is measured from the moment that the breaker closure reply is received until the moment that the CB open command is issued. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 77/179 "OPEN TRANSIT." Breaker Logic [GCP-32] Configuring Parameter 111 to " OPEN TRANSIT." enables the MCB and GCB to perform an open transition (break-before-make/change over logic) when transferring from the mains to the generator and back. In the event of an add-on request, the load is transferred from mains to generator supply. The following occurs: • The MCB is opened • The GCB is closed After the add-off request has been issued, the load is transferred from generator to mains supply. The following occurs: • The GCB is opened • The MCB is closed "EXTERNAL" Breaker Logic Configuring Parameter 111 to "EXTERNAL" enables the MCB and GCB breaker logic to be controlled from an external source. All breaker control must be carried out via a master controller such as a PLC. The GCP will only issue opening and closing pulses to the MCB and GCB when in the MANUAL operating mode. The GCP will always issue a breaker open command under fault conditions. Manual 37365A GCP-30 Series Packages - Genset Control Page 78/179 © Woodward Overview GCP-32 STOP TEST MANUAL AUTOMATIC Breaker logic: EXTERNAL (External breaker control) The MCB and the GCB are primarily operated by an external control such as a PLC. The breakers may be operated through the GCP only if the MANUAL operation mode has been enabled when this breaker logic is used. In a mains parallel opera- tion, decoupling from the mains is carried out via the MCB or the GCB in the event of a mains failure. The GCP will not automatically close the breakers in an emergency power operation. Emergency power operations are not possible when this circuit breaker logic is utilized in accordance with European Community Specification DIN VDE 0108. The GCB is ope- ned. The GCB and the MCB are not operated. Exception: The breakers are opened to decouple from the mains. The MCB and the GCB may be manually opened and closed without synchronization. The cir- cuit breakers are opened to de- couple from the mains. The GCB is opened if the genset is stopped or if decoupling from the mains but will not close if the engine is started unless given a close command from an external controller. The MCB is opened only if decoupling from the mains and is never closed unless given a close command from an external controller. Breaker logic: PARALLEL: (Mains parallel operation) The MCB and GCB are synchronized to permit continuous mains parallel operation in this breaker logic mode. The GCB is ope- ned; the MCB is not operated. The GCB and the MCB are not operated. Exception: Pressing the "GCB ON" push-button enables load tests. Pressing the "GCB OFF" push-button terminates the load test. Emergency power: If a mains failure occurs while in the TEST mode, the control initiates an emergency power operation. The respective breaker enable discrete inputs must be energized. Synchronization of either the generator or the mains can be ini- tiated by pressing the "GCB ON" or "MCB ON" push-button. The GCB is synchronized via an add-on request and a mains paral- lel operation is performed. When an add-off request is issued, the generator sheds load and opens the GCB and the engine is shut down following completion of the configured cool down period. Emergency power: The emer- gency power operation is termi- nated after mains voltage is de- tected without interruption for the entire mains settling time. The MCB is synchronized and closed, returning the system to a mains parallel operation. Breaker logic: OPEN TRANSIT.: (Open transition / change-over / brake-before-make) The MCB and GCB are never synchronized in this breaker logic mode. The GCB is ope- ned; the MCB is not operated. The GCB and the MCB are not operated. Exception: Pressing the "GCB ON" push-button enables load tests. Pressing the "GCB OFF" or the "MCB ON" push-button ter- minates the load test. Emergency power: If a mains failure occurs while in the TEST mode, the control initiates an emergency power operation. The respective breaker enable discrete inputs must be energized. Pressing the "GCB ON" push- button will open the MCB and close the GCB. Pressing the "MCB ON" push-button will open the GCB and close the MCB. Pressing the "STOP" push- button will open the GCB and shut the engine down. A generator is started and brought online through an add-on command. When an add-off command is initiated, the load is returned to the mains. If the bust bar is de-energized and an add-on command has not been issued, the MCB will be closed. Emergency power: The emer- gency power operation is termi- nated after mains voltage is de- tected without interruption for the entire mains settling time. The GCB is opened and the MCB closed, returning the load back to then mains. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 79/179 STOP TEST MANUAL AUTOMATIC Breaker logic: CLOSED TRANSIT.: (Closed transition / make-before-brake / overlap synchronization) The MCB and the GCB are synchronized; preventing the busbar from being de-energized while the load is transferred. Im- mediately after the synchronization of one breaker, the other is opened. Continuous mains parallel operation is not possible. The GCB is ope- ned; the MCB is not operated. The GCB and the MCB are not operated. Exception: Pressing the "GCB ON" push-button enables load tests. Pressing the "GCB OFF" or "MCB ON" push-button termi- nates the load test. Emergency power: If a mains failure occurs while in the TEST mode, the control initiates an emergency power operation. The respective breaker enable discrete inputs must be energized. Synchronization of either the generator or the mains can be ini- tiated by pressing the "GCB ON" or "MCB ON" push-button. The GCB is synchronized via an add-on request. After the GCB closes the MCB is opened, trans- ferring the load to the generator. Following the add-off request be- ing issued, the MCB is synchro- nized and closed. The GCB is opened immediately after the MCB closure, returning the load to the mains. Emergency power: The emer- gency power operation is termi- nated after mains voltage is de- tected without interruption for the entire mains settling time. The MCB is synchronized to the gen- erator and the MCB is closed. The GCB is opened immediately after the MCB closure, returning the load to the mains. Breaker logic: INTERCHANGE: (Soft loading / interchange synchronization) The MCB and the GCB are synchronized; preventing the busbar from being de-energized while the load is transferred. The operation of a breaker under load is avoided by utilizing the ability to softly transfer the load from one source to the other. Continuous mains parallel operation is not possible with this breaker logic. Following the add-off request, the MCB synchro- nizes and closes, the generator soft unloads to the mains and the GCB opens. After the GCB is open the engine is stopped fol- lowing the expiration of the configured cool down period. The GCB is ope- ned; the MCB is not operated. The GCB and the MCB are not operated. Exception: Pressing the "GCB ON" push-button enables load tests. Pressing the "GCB OFF" or "MCB ON" push-button termi- nates the load test. Emergency power: If a mains failure occurs while in the TEST mode, the control initiates an emergency power operation. The respective breaker enable discrete inputs must be energized. Synchronization of either the generator or the mains can be ini- tiated by pressing the "GCB ON" or "MCB ON" push-button. The GCB is synchronized via an add-on request. The MCB is opened after the load has been softly transferred from the mains to the generator and a "zero" power condition has been achieved at the MCB. Following the add-off request being issued, the MCB is synchronized to the generator and the MCB is closed. The GCB is opened after the load has been softly transferred to the mains and a "zero" power condi- tion has been achieved at the GCB. Emergency power: The emer- gency power operation is termi- nated after mains voltage is de- tected without interruption for the entire mains settling time. The MCB is synchronized to the gen- erator and the MCB is closed. The GCB is opened after the load has been softly transferred to the mains and a "zero" power condi- tion has been achieved at the GCB. Manual 37365A GCP-30 Series Packages - Genset Control Page 80/179 © Woodward Overview GCP-31 STOP TEST MANUAL AUTOMATIC Breaker logic: EXTERNAL: (External) GCB is primarily operated by an external control such as a PLC. The GCB may be operated through the GCP only if the MANUAL operation mode has been enabled when this breaker logic is used. In a mains parallel operation, decoupling from the mains is carried out via the GCB in the event of a mains failure. The GCB will not automatically close in an emergency power operation. The GCB is ope- ned. The GCB is not operated. Exception: The GCB is opened to decouple from the mains. The GCB can be manually opened and closed without syn- chronization. The GCB is opened to decouple from the mains. The GCB is opened if the genset is stopped or if decoupling from the mains but will not close if the engine is started unless given a close command from an external controller. The GCB is opened only if decoupling from the mains and is never closed unless given a close command from an external controller. Breaker logic: PARALLEL: (Mains parallel) The GCB is synchronized to permit continuous mains parallel operation or paralleling multiple generators in an isolated ap- plication. This mode may also be used to operate a single isolated generator. The GCB is opened. The GCB is not operated. Exception: Pressing the "GCB ON" push-button enables load tests. Pressing the "GCB OFF" push-button terminates the load test. Emergency power: If a mains failure occurs while in the TEST mode, the control can be config- ured to open the GCB to de- couple from the mains. Synchronization of either the generator can be initiated by pressing the "GCB ON" or push- button. This will enable a mains parallel operation. The GCB is synchronized via an add-on request and a mains paral- lel operation is performed. When an add-off request is issued, the generator sheds load and opens the GCB and the engine is shut down following completion of the configured cool down period. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 81/179 Start/Stop Ramp, Open GCB With F2 Alarm Parameter 112 Add-on/off ramp max.time 000s Start/stop ramp 0 to 999 s The add-on/add-off timer can be used to influence two functions: Stopping: The maximum amount of time generator should take to shed all load is configured here. If the generator load fails to drop below 3 % of the generator rated power (Parameter 21) within the amount of time configured, the GCB is opened re- gardless of the load. Start with soft loading: If the mains interchange (import/export) real power value fails to reach 0 kW while in the "INTERCHANGE" breaker logic within the time configured here, an F1 class alarm and alarm message are issued. Concurrently the relay, which is programmed with relay manager function 78 (Appendix B), is en- abled and the MCB is prevented from opening. Parameter 113 Open GCB with F2 max.time 000s Max. permissible time with F2 alarms for starting an additional engine 0 to 999 s Prerequisite: Load sharing (Parameter 90) and automatic start/stop (Parameter 95 or Parameter 96) are configured to "ON". The generator is operating in an isolated par- allel application and at least one additional generator is connected to a busbar. If an F2 class alarm occurs, the engine shutdown may be delayed by the time config- ured here. This delay time should be configured so that an additional engine may be started and brought online to assume the load from the generator with the F2 alarm. After the configured delay time expires the engine with the F2 alarm condition will shutdown regardless if an additional engine was able to start and assume the load. Manual 37365A GCP-30 Series Packages - Genset Control Page 82/179 © Woodward GCB/MCB Pulse/Continuous Pulse The closing and opening processes of the GCB and the MCB are described in Figure 3-5 and Figure 3-7. Chang- ing of the generator breaker control logic to either a momentary pulse or a continuous signal is configured using Parameter 114 (the MCB can only be configured for a momentary pulse). If "Automatic breaker deblocking" (Parameter 122) is configured to "ON", an open pulse is issued prior issuing a close pulse. Energizing the dis- crete input "Enable MCB" (terminal 54) enables/disables closing the MCB. De-energizing terminal 54 will not result in a closed MCB being opened. • Breaker logic: 'Impulse' for MCB 'Enable MCB' 'Command: open .. .. MCB' (39/40) 'Command: close MCB' (16/17) 'Reply: .. .. MCB is open' (54/7) Time/s Time/s Time/s Time/s 21 8 4 7 9 12 11 10 65 13 0.8 s Figure 3-5: Breaker control logic 'Impulse' for MCB 'Impulse' logic (MCB): • Enable MCB: 1 Terminal 53 (Enable MCB) energized; 2 Systems synchronizing; 8 Terminal 53 (Enable MCB) de-energized • Close MCB: 4 Closing pulse for MCB issued; 5 Inherent breaker closure delay; 6 Reply MCB closed re- ceived; 7 Closing pulse terminated • Open MCB: 9 Opening pulse MCB issued; 10 Inherent breaker opening delay; 11 Reply MCB open re- ceived; 12 Time delay (MCB: 0.8 s); 13 Opening pulse terminated Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 83/179 • Breaker logic: 'Impulse' for GCB 'Enable GCB' 'Command: open .. .. GCB' (41/42) 'Command: close GCB' (14/15) 'Reply: .. .. GCB is open' (4/7) Time/s Time/s Time/s Time/s 21 8 4 7 9 12 11 10 65 13 2 s Figure 3-6: Breaker control logic 'Impulse' for GCB 'Impulse' logic (GCB): • Enable GCB: 1 GCB enabled internally; 2 Systems synchronizing • Close GCB: 4 Closing pulse for GCB issued; 5 Inherent breaker closure delay; 6 Reply GCB closed re- ceived; 7 Closing pulse terminated • Open GCB: 9 Opening pulse GCB issued; 10 Inherent breaker opening delay; 11 Reply GCB open re- ceived; 12 Time delay (GCB: 2 s); 13 Opening pulse terminated • Beaker logic: 'Continuous' 'Enable GCB' 'Command: open .. .. GCB' (41/42) 'Command: close GCB' (14/15) 'Reply: .. .. GCB is open' (4/7) Time/s Time/s Time/s Time/s 21 8 4 9 12 11 10 65 13 2 s 7 Figure 3-7: Breaker control logic 'Continuous' 'Continuous' logic (GCB only): • GCB enabled: 1 GCB enabled internally; 2 Systems synchronizing • Close GCB: 4 Continuous GCB close pulse issued; 5 Inherent breaker closure delay; 6 Reply GCB closed received; 7 Closing pulse terminated • Open GCB: 9 Continuous GCB pulse disabled and GCB open pulse issued; 10 Inherent breaker opening de- lay; 11 Reply GCB open received; 12 Time delay (GCB: 2 s); 13 Opening pulse terminated Manual 37365A GCP-30 Series Packages - Genset Control Page 84/179 © Woodward Parameter 114 GCB close.relay ---------------- Signal logic for the GCB Impulse/Constant Constant ......The "Command: close GCB" relay can be utilized as part of the hold- ing circuit of the breaker. The "Command: close GCB" relay remains energized after the connect impulse has been issued and the circuit breaker closed reply has been received provided the following condi- tions are met: • The "Reply: GCB is open" discrete input (terminal 4) is de- energized when the GCB is closed • The phase angle between generator voltage and busbar voltage does not exceed +/-14°. • The "Command: close GCB" relay de-energizes if the GCB must be opened Impulse ........The "Command: close GCB" relay issues a momentary pulse. An ex- ternal holding circuit keeps the GCB closed. The "Reply: GCB is open" discrete input (terminal 4) is de-energized when the GCB is closed to signal that the GCB is closed. The "Command: open GCB" relay (terminals 41/42) is energized to open the GCB regardless of how the breaker closing logic is configured. Open/Close GCB Parameter 115 GCB open relay ---------------- Opening the GCB (terminal 41/42) NO-contact/NC-contact NC-contact...The "Command: open GCB" relay (terminals 41/42) energizes when the GCB is to be opened. Following the "Reply: GCB is open" the re- lay de-energizes. NO-contact .The "Command: open GCB" relay (terminals 41/42) de-energizes when the GCB is to be opened. Following the "Reply: GCB is open" the relay energizes again. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 85/179 Synchronization Parameter 116 Synchronize df max 0.00Hz Max. permissible synchronization frequency differential (positive slip) 0.02 to 0.49 Hz The prerequisite for a breaker closure command being issued is that the monitored frequency differential of the two systems being synchronized is less than the con- figured frequency differential. The value configured in this parameter specifies the upper limit of the frequency differential. A positive value corresponds to positive slip Æ the generator frequency is greater than the busbar frequency in the case of GCB synchronization; busbar frequency is higher than the mains frequency in the case of MCB synchronization. Parameter 117 Synchronize df min -0.00Hz Max. permissible synchronization frequency differential (negative slip) 0.00 to -0.49 Hz The prerequisite for a breaker closure command being issued is that the monitored frequency differential of the two systems being synchronized is greater than the configured frequency differential. The value configured in this parameter specifies the lower limit of the frequency differential. A negative value corresponds to negative slip Æ the generator frequency is less than the busbar frequency in the case of GCB synchronization; busbar frequency is less than the mains frequency for MCB synchronization. Parameter 118 Synchronize dV max 00.0% Max. permissible synchronization voltage differential 01.0 to 20.0 % L This value refers to the parameter "Rated volt. in system" (Parameter 17). A breaker closure command will only be issued when the measured voltage differ- ential of the systems being synchronized falls below the configured voltage differ- ential. Parameter 119 Synchronize time pulse>0.00s Min. pulse duration of connect relay for synchronization 0.02 to 0.26 s The duration of the close pulse can be adjusted to the breaker (valid for synchroni- zation and dead bus start). Parameter 120 Closing time GCB 000ms Inherent closing delay of GCB for synchronization 40 to 300 ms The inherent closing time of the GCB corresponds to the lead-time of the close command being issued. The GCP uses the frequency differential to calculate when the breaker closure command should be issued. The value configured in this pa- rameter dictates how many milliseconds at the measure frequency differential that the breaker closure command is issued prior to the two systems reaching the syn- chronous point. Parameter 121 Closing time MCB 000ms [GCP-32] Inherent closing delay of MCB for synchronization 40 to 300 ms The inherent closing time of the MCB corresponds to the lead-time of the close command being issued. The GCP uses the frequency differential to calculate when the breaker closure command should be issued. The value configured in this pa- rameter dictates how many milliseconds at the measure frequency differential that the breaker closure command is issued prior to the two systems reaching the syn- chronous point. Manual 37365A GCP-30 Series Packages - Genset Control Page 86/179 © Woodward Parameter 122 Automat.breaker deblocking ON Automatic circuit breaker deblocking ON/OFF ON ................Depending if the MCB or the GCB is being closed, a breaker open command is issued for 1 second prior to the breaker closure com- mand being issued. The breaker close command is then enabled until the breaker is closed. OFF ..............A breaker open command is not issued prior to issuing the breaker closure command. The GCP will only issue a breaker closure com- mand. Synchronization Time Monitoring If Parameter 123) is configured to "ON", synchronization time monitoring is enabled: The synchronization time monitoring will be activated after the delayed engine monitoring has terminated. The synchronization time moni- toring will start when synchronization of the GCB or MCB [GCP-32] is initiated. If the time configured for the synchronization time monitoring expires prior to the breaker closing, an F1 alarm is issued. NOTE If "MCB monitoring" (Parameter 131) is enabled and an alarm is detected while closing the MCB, an emergency power operation will be performed if "Emergency power" (Parameter 137) has been config- ured as ON. Parameter 123 Sync.time contr. ON Monitoring of synchronization time ON/OFF ON ................Synchronization time monitoring is enabled. The subsequent screens of this function are displayed. OFF ..............Synchronization time monitoring is disabled. Synchronization will be attempted until the breaker closes. The subsequent screens of this function are not displayed. Parameter 124 Sync.time contr. delay 000s Maximum synchronization time 10 to 999 s When synchronization of the GCB or MCB is initiated, the synchronization timer is started following the termination of the delayed engine monitoring. If the breaker cannot be closed prior to the expiration of this time, an alarm message is issued and the control continues to attempt to close the breaker. The relay assigned relay man- ager function 16 (GCB) and/or 70 (MCB) is energized. Issuing of F1 class alarm Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 87/179 Dead Bus Start If the busbar is de-energized, a dead bus start of the GCB or the MCB is performed. If closing commands for the MCB and the GCB are issued simultaneously, priority is given to the MCB provided the discrete input "Enable MCB" (terminal 54) has been energized. Parameter 125 GCB dead bus op. ON GCB dead bus start ON/OFF ON................A dead bus start is performed in the event of a de-energized busbar and an open MCB. The subsequent screens of this function are dis- played. OFF..............A dead bus start will not be performed. The subsequent screens of this function are not displayed. Parameter 126 GCB dead bus op. df max 0.00Hz Maximum frequency differential for GCB dead bus start 0.05 to 5.00 Hz Prior to issuing a breaker close command, the frequency differential between the monitored generator frequency and the rated generator frequency must be less than the value configured here. The higher the frequency differential is configured, the more rapidly a generator may be permitted to close to a dead bus. Parameter 127 GCB dead bus op. dV max. 00.0% Maximum voltage differential for GCB dead bus start 01.0 to 15.0 % L This value refers to the parameter "rated voltage in system" (Parameter 19). Prior to issuing a breaker close command, the voltage differential between the monitored generator voltage and the rated generator voltage must be less than the value configured here. The higher the voltage differential is configured, the more rapidly a generator may be permitted to close to a dead bus. Parameter 128 GCB dead bus op max.time 000s Maximum time for closing the GCB 0 to 999 s This timer is initiated at the start of the breaker closing sequence when the GCB is to be closed to a dead busbar. If the breaker fails to close prior to the configured time expiring, an F1 class alarm is issued. Issuing of F1 class alarm Parameter 129 MCB dead bus op. ON [GCP-32] Dead bus closing of the MCB ON/OFF ON................A dead bus closing of the MCB is performed in the event of a de- energized busbar and an open GCB. The subsequent screens of this function are displayed. OFF..............A dead bus closing of the MCB will not be performed. The subse- quent screens of this function are not displayed. Manual 37365A GCP-30 Series Packages - Genset Control Page 88/179 © Woodward Breaker Monitoring Upon CLOSING - The GCP monitors the GCB and/or the MCB to ensure that the respective breaker has closed if "GCB monitoring" (Parameter 130) and/or "MCB monitoring" (Parameter 131) have been configured "ON" unless the breaker logic is configured "EXTERNAL" (Parameter 111). If the breaker has not closed after five at- tempts, a class F1 alarm is issued. If a relay has been assigned relay manager functions 74 or 75, it will be ener- gized. A breaker is considered as closed, if the reply is present for 5s. This resets the internal counter. Upon OPENING - The GCP-30 monitors the GCB and/or the MCB to ensure that the respective breaker has opened if "GCB monitoring" (Parameter 130) and/or "MCB monitoring" (Parameter 131) have been configured "ON". If the GCP-30 does not receive a reply that the respective breaker has opened within 2 seconds of the open command being issued, an F1 class alarm is issued. If a relay has been assigned relay manager functions 76 or 77, it will be energized. Parameter 130 Supervision GCB ON GCB monitoring ON/OFF ON ................Monitoring of the GCB is performed except when the breaker logic is configured as "EXTERNAL". If the breaker cannot be closed after five attempts, an alarm message is issued and the relay assigned relay manager function 75 is energized. The GCP will continue to attempt to close the GCB after the alarm has been issued unless load sharing (Parameter 90) has been enabled. If load sharing has been enabled (Parameter 90) and several GCPs are connected to the CAN bus, the breaker close command is cancelled upon issuing of the alarm so that another GCP may start up and close its breaker. If a "Reply: GCB is open" message is not detected 2 seconds after a "Command: open GCB" pulse is issued, an alarm message is issued and the relay as- signed relay manager function 77 is energized. Issuing of F1 class alarm OFF ..............No GCB monitoring is performed. Parameter 131 Supervision MCB ON [GCP-32] MCB monitoring ON/OFF ON ................Monitoring of the MCB is performed except when the breaker logic is configured as "EXTERNAL". If the breaker cannot be closed after five attempts, an alarm message is issued and the relay assigned relay manager function 74 is energized. The GCP will continue to attempt to close the MCB after the alarm has been issued unless load sharing (Parameter 90) has been enabled. If load sharing has been enabled (Parameter 90) and several GCPs are connected to the CAN bus, the closing command to the breaker is cancelled if an alarm is issued so that another GCP may close its breaker. If a "Reply: MCB is open" message is not detected 2 seconds after a "Command: open MCB" pulse is issued, an alarm message is issued and the relay assigned re- lay manager function 76 is energized. Issuing of F1 class alarm OFF ..............No MCB monitoring is performed. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 89/179 Mains Decoupling NOTE If the mains monitoring (frequency and voltage) is disabled, decoupling from the mains is not per- formed. Parameter 132 Mains decoupling via ------ [GCP-31] Decoupling from the mains via ... GCB; GCBÆEXT; EXTERNAL; EXTÆGCB GCB .............If a mains failure (Parameter 179 through Parameter 193) occurs the GCB will be opened. A mains failure is detected by means of the mains voltage (terminals 50/51/52). GCBÆEXT .If a mains failure (Parameter 179 through Parameter 193) occurs the GCB will be opened. A mains failure is detected by means of the mains voltage (terminals 50/51/52). If the GCP does not receive the reply that the GCB has opened (terminal 4 energizes) prior to the time configured in Parameter 134 expiring, an F1 alarm will be is- sued and the relay assigned relay manager function 76 will be ener- gized. The "Command: open GCB" relay (terminal 41/42) will de- energize and the "Command: Open external CB" relay (termi- nals 39/40) will energize. Issuing of F1 class alarm EXTERNAL If a mains failure (Parameter 179 through Parameter 193) occurs the "Command: Open external CB" relay (terminals 39/40) will be ener- gized. A mains failure is detected by means of the mains voltage (terminals 50/51/52). EXTÆGCB .If a mains failure (Parameter 179 through Parameter 193) occurs the "Command: Open external CB" relay (terminals 39/40) will be ener- gized. A mains failure is detected by means of the mains voltage (terminals 50/51/52). If the GCP does not receive the reply that the external CB has opened (terminal 54 energizes) prior to the time con- figured in Parameter 134 expiring, an F1 alarm will be issued and the relay assigned relay manager function 77 will be energized. The "Command: Open external CB" relay (terminals 39/40) will de- energize and the "Command: open GCB" relay (terminals 41/42) will energize. Issuing of F1 class alarm Manual 37365A GCP-30 Series Packages - Genset Control Page 90/179 © Woodward NOTE If the mains monitoring (frequency and voltage) is disabled, decoupling from the mains is not per- formed. Parameter 133 Mains decoupling via ------ [GCP-32] Decoupling from the mains via ... GCB; GCBÆMCB; MCB; MCBÆGCB GCB .............If a mains failure (Parameter 179 through Parameter 193) occurs the GCB will be opened. A mains failure is detected by means of the mains voltage (terminals 50/51/52). GCBÆMCB If a mains failure (Parameter 179 through Parameter 193) occurs the "Command: Open GCB " relay (terminals 41/42) will be energized. A mains failure is detected by means of the mains voltage (terminals 50/51/52). If the GCP does not receive the reply that the GCB has opened (terminal 4 energizes) prior to the time configured in Para- meter 134 expiring, an F1 alarm will be issued and the relay assigned relay manager function 76 will be energized. The "Command: Open GCB " relay (terminals 41/42) will de-energize and the "Command: open MCB" relay (terminals 39/40) will energize. Issuing of F1 class alarm MCB .............If a mains failure (Parameter 179 through Parameter 193) occurs the MCB will be opened. A mains failure is detected by means of the mains voltage (terminals 50/51/52). MCBÆGCB If a mains failure (Parameter 179 through Parameter 193) occurs the "Command: Open MCB " relay (terminals 39/40) will be energized. A mains failure is detected by means of the mains voltage (terminals 50/51/52). If the GCP does not receive the reply that the MCB has opened (terminal 54 energizes) prior to the time configured in Para- meter 134 expiring, an F1 alarm will be issued and the relay assigned relay manager function 77 will be energized. The "Command: Open MCB " relay (terminals 39/40) will de-energize and the "Command: open GCB" relay (terminals 41/42) will energize. Issuing of F1 class alarm Parameter 134 Mains decoupling -> after 0.00s only accessible via LeoPC1 Mains decoupling after 0.10 to 5.00 s The maximum amount of time that the mains decoupling should be completed in. WARNING It is possible for the MCB to close after the mains settling time (Parameter 194) expires, causing the busbar to energize, while maintenance is being performed on the busbar if Parameter 135 is configured as "YES". Closing of the MCB can be disabled by configuring Parameter 1355 as "NO" or by blocking the MCB through other methods. Parameter 135 Switch MCB in STOP mode NO [GCP-32] Close MCB in STOP operation mode YES/NO YES ..............The MCB will be closed by the GCP when the STOP mode is en- abled. The breaker will not close unless the "Enable MCB" discrete input (terminal 54) is energized as well. NO ................The GCP will not change the state of the MCB when the STOP mode is enabled The breaker will remain open or closed depending upon its state when the operation mode is changed to STOP. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 91/179 Emergency Power (AMF) (GCP-32; GCP-31: XPD, XPQ) ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ NOTE The parameters for this control are grouped together in blocks to permit navigation through the large number of configuration screens more rapidly. Selecting "YES" or "NO" has no effect whether or not control or monitoring is carried out for the parameters located in that block. Selecting "YES" or "NO" only determines if the individual parameters may be accessed and changed or are bypassed. Parameter 136 Configure emergency YES Configuration of the emergency power (AMF) YES/NO The emergency power control functions are configured in this block of parameters. This parameter has the following effects: YES ..............The parameters in this block are displayed and can either be viewed ("Select" button), or modifications can be made to the parameters ("Cursor→", "Digit↑" or "Select" buttons). NO................The parameters in this block are not displayed, cannot be modified, and are skipped. NOTE Emergency power functionality is only possible with synchronous generators utilizing a minimum of a mains circuit breaker and a generator circuit breaker (i.e. GCP-32 or GCP-31 with LS 4 coupling). Prerequisite: The emergency power function (AMF) may only be enabled with synchronous generators by con- figuring "Emergency power" (Parameter 136) as "ON". Emergency power operations are only performed in the AUTOMATIC or TEST operation modes regardless of the status of the "Automatic 1" and "Automatic 2" dis- crete inputs. NOTE If the "Engine enable" or "Engine block" function is assigned to terminal 6 (Parameter 212), emergency power operations can be prevented or interrupted from an external source through a discrete input. Re- fer to "Terminal 6" on page 116. If Parameter 209 is configured ON and discrete input 11 (terminal 68) is energized, emergency power operation will also be prevented or interrupted (refer to Enable 'Emergency OFF' via terminal 68 on page 114). Activation of emergency power: If a mains voltage fault (over-/undervoltage, -frequency or phase/vector jump) is detected on any single phase of terminals 50/51/52 continuously for the duration of the emergency power start delay time (Parameter 138), an emergency power operation is activated. A mains voltage fault is defined as fol- lows: If the mains voltage and frequency monitoring (Parameter 179 and/or Parameter 184) are enabled and the configured limit has been exceeded. If either or both the mains voltage and frequency monitoring are not en- abled, the internal default limits will be used for protective limits. The internal protective limits are defined as follows: Mains watchdogs Voltage Frequency ON Monitoring values (see Parameter 179) Monitoring values (see Parameter 184) OFF Vmains < 85 % Vrated Vmains > 112 % Vrated fmains < 90 % frated fmains > 110 % frated Table 3-7: Limit values, Emergency power An emergency power operation (AMF) may also be initiated through the detection of a breaker fault when the MCB is closed. This protection will only occur if "Emergency power" (Parameter 137) and "MCB monitoring" (Parameter 131) are configured as "ON". Manual 37365A GCP-30 Series Packages - Genset Control Page 92/179 © Woodward The following actions occur in an emergency power operation: • If emergency power operation is initiated, the engine is started provided the sequence is not interrupted by an alarm or the operation mode is not changed • If the mains are restored during the start cycle, the MCB remains closed. The engine starts and continues run- ning until the mains settling time (Parameter 194) expires. If another mains fault occurs during this time, the MCB is opened and the GCB is closed to the dead busbar. The engine shuts down following restoration of the main and the expiration of the mains settling time (Parameter 194) provided no additional mains faults occur. • The GCB will be closed regardless of the engine delay time once the dead bus limits have been reached. • If the mains are restored while an emergency power operation is being performed and the GCP will wait for the mains settling time (Parameter 194) to expire. After the mains settling time has expired, the MCB will be synchronized and closed. Emergency power: In the event an emergency power operation is being performed, the message "Emergency power" is displayed on the screen of the GCP. Emergency Power With Breaker Logic "PARALLEL" Emergency power: After detecting a mains fault, the GCP-30 will wait until the "emergency power start delay" (Parameter 138) has expired before starting an engine. Once the engine has started and the monitored generator voltage and frequency have exceeded the dead bus start limits (Parameter 126 and Parameter 127), the MCB is opened and the GCB is closed to the dead busbar. The generator is now supplying power to the load. Return of the mains: Following the termination of the mains fault, the GCP will continue the emergency power operation until the mains settling time has expired (Parameter 194) before synchronization of the MCB is initi- ated. After closing the MCB, the control returns to its original operation mode. If the engine is to be shut down after the emergency power operation has terminate, a power reduction (soft unloading) is carried out provided the real power controller (Parameter 74) is configured as "ON". If the GCP has initiated the start cycle and the mains are restored, the GCP completes the start cycle but the MCB is not opened. The engine remains in idle mode during the mains settling time (Parameter 194). The engine re- mains running while the mains settling time expires so the GCB can be closed and the MCB opened immediately in the event of another mains failure. Emergency Power With Breaker Logic "OPEN TRANSIT." Emergency power: After detecting a mains fault, the GCP will wait until the "emergency power start delay" (Parameter 138) has expired before starting an engine. Once the engine has started and the monitored generator voltage and frequency have exceeded the dead bus start limits (Parameter 126 and Parameter 127), the MCB is opened and the GCB is closed to the dead busbar. The generator is now supplying power to the load. Return of the mains: Following the termination of the mains fault, the GCP will continue the emergency power operation until the mains settling time has expired (Parameter 194) before the open transition back to main sup- ply is performed. If an engine request is present following the expiration of the mains settling time (Para- meter 194), the generator will maintain the isolated operation. If the GCP has initiated the start cycle and the mains are restored, the GCP completes the start cycle but the MCB is not opened. The engine remains in idle mode during the mains settling time (Parameter 194). The engine re- mains running while the mains settling time expires so the GCB can be closed and the MCB opened immediately in the event of another mains failure. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 93/179 Emergency Power With Breaker Logic "CLOSED TRANSIT." Emergency power: After detecting a mains fault, the GCP will wait until the "emergency power start delay" (Parameter 138) has expired before starting an engine. Once the engine has started and the monitored generator voltage and frequency have exceeded the dead bus start limits (Parameter 126 and Parameter 127), the MCB is opened and the GCB is closed to the dead busbar. The generator is now supplying power to the load. Return of the mains: Following the termination of the mains fault, the GCP will continue the emergency power operation until the mains settling time has expired (Parameter 194) before synchronization of the MCB is initi- ated. After closing the MCB, a power reduction (soft unloading) is carried out provided the real power controller (Parameter 74) is configured as "ON", and the GCB is opened. After opening the GCB the engine continues to run for the amount of time configured in "Cool down time" (Parameter 270) and is then shut down. If an engine request is present following the expiration of the mains settling time (Parameter 194), the generator will maintain the isolated operation. If the GCP has initiated the start cycle and the mains are restored, the GCP completes the start cycle but the MCB is not opened. The engine remains in idle mode during the mains settling time (Parameter 194). The engine re- mains running while the mains settling time expires so the GCB can be closed and the MCB opened immediately in the event of another mains failure. Emergency Power With Breaker Logic "INTERCHANGE" Emergency power: After detecting a mains fault, the GCP will wait until the "emergency power start delay" (Parameter 138) has expired before starting an engine. Once the engine has started and the monitored generator voltage and frequency have exceeded the dead bus start limits (Parameter 126 and Parameter 127), the MCB is opened and the GCB is closed to the dead busbar. The generator is now supplying power to the load. Return of the mains: Following the termination of the mains fault, the GCP will continue the emergency power operation until the mains settling time has expired (Parameter 194) before synchronization of the MCB is initi- ated. After closing the MCB, a power reduction (soft unloading) is carried out provided the real power controller (Parameter 74) is configured as "ON", and the GCB is opened. After opening the GCB the engine continues to run for the amount of time configured in "Cool down time" (Parameter 270) and is then shut down. If an engine request is present following the expiration of the mains settling time (Parameter 194), the generator will maintain the isolated operation. If the GCP has initiated the start cycle and the mains are restored, the GCP completes the start cycle but the MCB is not opened. The engine remains in idle mode during the mains settling time (Parameter 194). The engine re- mains running while the mains settling time expires so the GCB can be closed and the MCB opened immediately in the event of another mains failure. Emergency Power With Breaker Logic "EXTERNAL" ATTENTION This breaker logic will not permit emergency power in accordance with DIN VDE 0108! Emergency power: After detecting a mains fault, the GCP will wait until the "emergency power start delay" (Parameter 138) has expired before starting an engine. Once the engine has started and the monitored generator voltage and frequency have exceeded the dead bus start limits (Parameter 126 and Parameter 127), the MCB is opened and the GCB is closed to the dead busbar. The generator is now supplying power to the load. Further op- erations of the GCB and the MCB are not operated performed regardless if the mains are restored. Manual 37365A GCP-30 Series Packages - Genset Control Page 94/179 © Woodward Emergency power With MCB Malfunction MCB malfunction: If the MCB opens without an open command from the GCP while in the AUTOMATIC mode and the control is configured for emergency power standby, the GCP will attempt to reclose the breaker. If the MCB cannot be reclosed due to an MCB failure and "Emergency power" (Parameter 136 ) and "Supervision MCB" (Parameter 131 ) are configured "ON", the engine is started and the alarm message "MCB malfunction" is displayed. Once the engine has started and the monitored generator voltage and frequency have exceeded the dead bus start limits (Parameter 126 and Parameter 127), the GCB is closed to the dead busbar. After the condi- tion that caused the MCB fault has been corrected and the "MCB malfunction" alarm has been acknowledged, the emergency power operation is terminated and the load is transferred to the mains in the manner prescribe by the configured circuit breaker logic detailed above. Emergency Power Operation; Parameters Parameter 137 Emergency power ON Emergency power ON/OFF ON ................If the control is in AUTOMATIC or TEST mode and a mains failure occurs, the engine is started and an emergency power operation is performed. The subsequent parameters of this function are displayed. Emergency power operations may also be initiated by the detection of a breaker failure when the MCB is to be closed. In order to enable this, the Parameter 131 ("Supervision MCB") must be configured to "ON". OFF ..............Emergency power operation is not enabled and the subsequent pa- rameters of this function are not displayed. Parameter 138 Emergency power start del. 00.0s Start delay for emergency power 0.5 to 99.9 s In order to start the engine and to carry out an emergency power operation, the mains must fail for at least this delay time. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 95/179 Protection ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ NOTE The parameters for this control are grouped together in blocks to permit navigation through the large number of configuration screens more rapidly. Selecting "YES" or "NO" has no effect whether or not control or monitoring is carried out for the parameters located in that block. Selecting "YES" or "NO" only determines if the individual parameters may be accessed and changed or are bypassed. Parameter 139 Configure monitoring YES Configuration of the protection YES/NO The generator and system protective functions are configured in this block of pa- rameters. This parameter has the following effects: YES ..............The parameters in this block are displayed and can either be viewed ("Select" button), or modifications can be made to the parameters ("Cursor→", "Digit↑" or "Select" buttons). NO................The parameters in this block are not displayed, cannot be modified, and are skipped. Generator Power Monitoring It is possible for the GCP to monitor two independently configured generator power limits. If one of these con- figured limits is surpassed, it is possible to energize a relay output by assigning a relay manager function (relay manager function 56 and 80) to one of the freely configurable relays. This functionality makes it possible to initi- ate external load shedding. NOTE This functionality does not initiate a centralized alarm or issue a message to be displayed. An external device must evaluate the relay output. WARNING This function does not provide generator protection. Parameter 151 and Parameter 156 or an external protection device must be used if generator protection is required. Parameter 140 Gen.power monit. ON Generator power monitoring ON/OFF ON................Generator power monitoring is enabled. Relay manager function 56 must be assigned to one relay and relay manager function 80 must be assigned to a second relay. The subsequent screens of this function are displayed. OFF..............Generator power monitoring is disabled. The subsequent screens of this function are not displayed. Manual 37365A GCP-30 Series Packages - Genset Control Page 96/179 © Woodward Parameter 141 Gen.power monit. resp.val1 0000kW Power monitoring threshold value, level 1 0 to 9,999 kW If this threshold value has been exceeded for at least the delay time (Para- meter 143), the relay assigned relay manager function 56 energizes. Parameter 142 Gen.power monit. hyst.lv1 000kW Power monitoring hysteresis, level 1 0 to 999 kW To prevent the relay assigned relay manager function 56 from energizing and de- energizing continuously due to minor load swings, a hysteresis is configured in this parameter. The value configured here is the amount the monitored power must drop below the configured threshold in Parameter 141 before the corresponding relay output will de-energize. Parameter 143 Gen.power monit. delay lv1 000s Power monitoring delay, level 1 0 to 650 s For the control unit to recognize that the level 1 power monitoring threshold has been exceed, the threshold value configured in Parameter 141 must be exceeded without interruption for this period of time. Parameter 144 Gen.power monit. resp.val2 0000kW Power monitoring threshold value, level 2 0 to 9,999 kW If this threshold value has been exceeded for at least the delay time (Para- meter 146), the relay assigned relay manager function 80 energizes. Parameter 145 Gen.power monit. hyst.lv2 000kW Power monitoring hysteresis, level 2 0 to 999 kW To prevent the relay assigned relay manager function 80 from energizing and de- energizing continuously due to minor load swings, a hysteresis is configured in this parameter. The value configured here is the amount the monitored power must drop below the configured threshold in Parameter 144 before the corresponding relay output will de-energize. Parameter 146 Gen.power monit. delay lv2 000s Power monitoring delay, level 2 0 to 650 s For the control unit to recognize that the level 2 power monitoring threshold has been exceedn, the threshold value configured in Parameter 144 must be exceeded without interruption for this period of time. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 97/179 Mains Power Monitoring It is possible for the GCP-30 to monitor a configured mains power limit. If this configured limit is surpassed, it is possible to energize a relay output by assigning a relay manager function (relay manager function 67) to one of the freely configurable relays. This functionality makes it possible to initiate external load shedding. NOTE This functionality does not initiate a centralized alarm or issue a message to be displayed. An external device must evaluate the relay output. WARNING This function does not provide mains protection. Parameter 151 and Parameter 156 or an external protection device must be used if mains protection is required. Parameter 147 Mains power mon. ON Mains power monitoring ON/OFF ON................Mains power monitoring is enabled. Relay manager function 67 must be assigned to a relay. The subsequent screens of this function are displayed. OFF..............Mains power monitoring is disabled. The subsequent screens of this function are not displayed. Parameter 148 Mains power mon. res.val. I0000kW Power monitoring threshold value I/E 0 to 9,999 kW If this threshold value has been exceeded for at least the delay time (Para- meter 150), the relay assigned relay manager function 67 energizes. Imported power is entered with a " - " before the value, exported power is entered with a " + " before the value. If the value is confirmed, the " - " becomes an " I " and the " + " becomes an " E ". Parameter 149 Mains power mon. hysteresis 000kW Power monitoring hysteresis 0 to 999 kW To prevent the relay assigned relay manager function 67 from energizing and de- energizing continuously due to minor load swings, a hysteresis is configured in this parameter. The value configured here is the amount the monitored power must drop below the configured threshold in Parameter 148 before the corresponding relay output will de-energize. Parameter 150 Mains power mon. delay 000s Power monitoring delay 0 to 650 s For the control unit to recognize that the mains power monitoring threshold has been exceed, the threshold value configured in Parameter 148 must be exceeded without interruption for this period of time. Manual 37365A GCP-30 Series Packages - Genset Control Page 98/179 © Woodward Generator Overload Monitoring NOTE All percentage values refer to a percentage of the generator rated power (Parameter 21; page 27). Function: "Positive real power not within the permissible limits" - The single-phase or three-phase measured generator real power is above the configured limit value of the real power. Parameter 151 Overload monit. ON Generator overload monitoring ON/OFF ON ................Monitoring of the generator real power is enabled. The subsequent screens of this function are displayed. OFF ..............Monitoring of the generator real power is disabled. The subsequent screens of this function are not displayed. Parameter 152 Gen.overload MOP resp.value 000% Generator overload monitoring threshold value MOP 80 to 150 % For the control unit to recognize that a generator overload fault while in a mains parallel operation (MOP) has occurred, the monitored generator power must exceed the configured percentage of the rated generator power without interruption for the delay time configured in Parameter 153. An F2 class alarm is issued when the delay time expires. Issuing of F2 class alarm without power reduction Parameter 153 Gen.overload MOP delay 00s Generator overload monitoring delay MOP 0 to 99 s For the control unit to recognize that a generator overload fault has occurred while in a mains parallel operation (MOP) has occurred, the threshold value configured in Parameter 152 must be exceeded without interruption for this period of time. Parameter 154 Gen.overload IOP resp.value 000% Generator overload monitoring threshold value IOP 80 to 150 % For the control unit to recognize that a generator overload fault has occurred while in an isolated parallel operation (IOP), the monitored generator power must exceed the configured percentage of the rated generator power without interruption for the delay time configured in Parameter 155. An F2 class alarm is issued when the delay time expires. Issuing of F2 class alarm without power reduction Parameter 155 Gen.overload IOP delay 00s Generator overload monitoring delay 0 to 99 s For the control unit to recognize that a generator overload fault has occurred while in a mains parallel operation, the threshold value configured in Parameter 154 must be exceeded without interruption for this period of time. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 99/179 Generator Reverse/Reduced Power Monitoring NOTE All percentage values refer to a percentage of the generator rated power (Parameter 21; page 27). Function: "Real power not within the permissible limits" - The real power measured in a single-phase or in a three-phase system is below the configured limit value for the minimum load or below the configured value for reverse power. By setting positive threshold values (minimum load monitoring), a shutdown can be performed before the generator ends up in reverse power. Parameter 156 Rev./red.power monitoring ON Reverse/reduced power monitoring ON/OFF ON................Monitoring of the generator reverse/reduced power is enabled. The subsequent screens of this function are displayed. OFF..............Monitoring of the generator reverse/reduced power is disabled. The subsequent screens of this function are not displayed. Parameter 157 Rev./red.power resp.value -00% Reverse/reduced power monitoring threshold value -99 to 99 % Reverse power monitoring: If a negative threshold value is configured and the monitored power falls below the threshold value for at least the delay time (Parameter 158), an F3 class alarm is issued. Reduced power monitoring: If a positive threshold value is configured and the monitored power falls below the threshold value for at least the delay time (Parameter 158), an F3 class alarm is issued Issuing of F3 class alarm Parameter 158 Rev./red.power delay 0.0s Reverse power monitoring delay 0.0 to 9.9 s For the control unit to recognize that a reverse or reduced power fault has occurred, the threshold value configured in Parameter 157 must be exceeded without inter- ruption for this period of time. Manual 37365A GCP-30 Series Packages - Genset Control Page 100/179 © Woodward Unbalanced Load Monitoring NOTE All percentage values refer to a percentage of the generator rated power (Parameter 22; page 27). Function: "Generator load imbalance not within the permissible limits" - The percentage threshold value speci- fies the permissible deviation of any single phase current to the arithmetic mean value of all three phase currents. Parameter 159 Load unbalanced monitoring ON Unbalanced load monitoring ON/OFF ON ................Monitoring for unbalanced load of the generator real power is en- abled. The subsequent screens of this function are displayed. OFF ..............Monitoring for unbalanced load of the generator real power is dis- abled. The subsequent screens of this function are not displayed. Parameter 160 Load unbalanced max. 000% Maximum permissible unbalanced load 0 to 100 % For the control unit to recognize that an unbalanced load fault has occurred, the monitored phase load must exceed the configured load differential percentage with- out interruption for the delay time configured in Parameter 161. An F3 class alarm is issued when the delay time expires. Issuing of F3 class alarm Parameter 161 Load unbalanced delay 00.00s Unbalanced load monitoring delay 0.02 to 9.98 s For the control unit to recognize that an unbalanced load fault has occurred, the threshold value configured in Parameter 160 must be exceeded without interruption for this period of time. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 101/179 Independent Time-Overcurrent Monitoring NOTE All percentage values refer to a percentage of the generator rated power (Parameter 22; page 27). Function: The GCP utilizes a two tier independent time-overcurrent monitoring with separate adjustable time delays. The threshold values and delays can be selected so that the monitored current level is independent from the tripping time. The level 2 overcurrent is used as a fast-triggering high-current stage for protection against short circuits. The level 1 overcurrent reacts to overcurrent below level 2 but above permissible limits that are present over a longer period of time. I >> (I ) I > (I ) t2 t1 t [s] I [%] 1 2 Figure 3-8: Characteristic of the time-overcurrent monitoring Parameter 162 Gen.overcurrent monitoring ON Independent time-overcurrent monitoring ON/OFF ON................Independent time-overcurrent monitoring of the generator is enabled. The subsequent screens of this function are displayed. OFF..............Independent time-overcurrent monitoring of the generator is dis- abled. The subsequent screens of this function are not displayed. Parameter 163 Gen.overcurrent limit 1 000% Threshold value independent time-overcurrent limit 1 0 to 300 % If the monitored generator current exceeds the configured percentage of the rated generator current for at least the delay time configured in Parameter 164, an F3 class alarm is issued. Issuing of F3 class alarm Parameter 164 Gen.overcurrent delay 1 00.00s Independent time-overcurrent, delay, limit 1 0.02 to 9.98 s For the control unit to recognize that a time-overcurrent fault has occurred, the threshold value configured in Parameter 163 must be exceeded without interruption for this period of time. Manual 37365A GCP-30 Series Packages - Genset Control Page 102/179 © Woodward Parameter 165 Gen.overcurrent limit 2 000% Independent time-overcurrent, threshold value, limit 2 0 to 300 % If the monitored generator current exceeds the configured percentage of the rated generator current for at least the delay time configured in Parameter 166, an F3 class alarm is issued. Issuing of F3 class alarm Parameter 166 Gen.overcurrent delay 2 00.00s Independent time-overcurrent, delay, limit 2 0.02 to 9.98 s For the control unit to recognize that a time-overcurrent fault has occurred, the threshold value configured in Parameter 165) must be exceeded without interrup- tion for this period of time. Parameter 167 Gen.overcurrent Cool down ON Open GCB with engine cool down due to overcurrent ON/OFF ON ................If the GCB is opened due to an overcurrent fault condition, an engine cool-down is performed prior to engine stop. OFF ..............The engine is stopped without a cool-down. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 103/179 Generator Frequency Monitoring Function: "Generator frequency not within the permissible limits" - The generator frequency is outside of the limit values set for overfrequency or underfrequency. The engine is shut down immediately (class F3 alarm), and an alarm message is displayed. The activation of generator underfrequency monitoring is delayed by means of "Delayed engine monitoring" (Parameter 271) in order to enable correct generator start-up. Parameter 168 Gen.frequency- monitoring ON Generator frequency monitoring ON/OFF ON................Monitoring of the generator frequency is enabled. The subsequent screens of this function are displayed. OFF..............Monitoring of the generator frequency is disabled. The subsequent screens of this function are not displayed. Parameter 169 Gen.overfreq. f > 000.0% Threshold value: generator overfrequency 50.0 to 140.0 % L This value refers to the parameter "Rated freq. in system" (Parameter 9). If the monitored generator frequency exceeds the configured percentage of the rated generator frequency for at least the delay time configured in Parameter 170, an F3 class alarm is issued. Issuing of F3 class alarm Parameter 170 Gen.overfreq. delay 0.00s Generator overfrequency delay 0.02 to 9.98 s For the control unit to recognize that a generator overfrequency fault has occurred, the threshold value configured in Parameter 169 must be exceeded without inter- ruption for this period of time. Parameter 171 Gen.underfreq. f < 000.0% Generator underfrequency threshold value 50.0 to 140.0 % L This value refers to the parameter "Rated freq. in system" (Parameter 9). If the monitored generator frequency falls below the configured percentage of the rated generator frequency for at least the delay time configured in Parameter 172, an F3 class alarm is issued. Issuing of F3 class alarm Parameter 172 Gen.underfreq. delay 0.00s Generator underfrequency delay 0.02 to 9.98 s For the control unit to recognize that a generator underfrequency fault has oc- curred, the threshold value configured in Parameter 171 must be exceeded without interruption for this period of time. Engine Overspeed Monitoring Parameter 173 Engine overspeed > 0000 rpm Engine overspeed monitoring 0 to 9,999 rpm If the monitored engine speed exceeds the generator rated speed (Parameter 276) for at 0.1 s, an F3 class alarm is issued. The engine overspeed monitoring is per- formed in addition to and independent of the generator frequency. The Magnetic Pickup Unit (MPU) must be enabled (Parameter 274) for engine speed monitoring to be performed. If the MPU input is disabled, engine speed monitoring is disabled. If the monitored engine speed exceeds the rated speed, an F3 class alarm is issued. Issuing of F3 class alarm Manual 37365A GCP-30 Series Packages - Genset Control Page 104/179 © Woodward Generator Voltage Monitoring The line-to-line (wye) voltage is monitored. Function: "Generator voltage not within the permissible limits" - If one or more phases of the generator voltage exceeds the limit values set for overvoltage or undervoltage, the engine is shut down immediately (F3 class alarm) and an alarm message is displayed. Monitoring of generator undervoltage is delayed by means of "De- layed engine monitoring" (Parameter 271) in order to enable generator start-up. Parameter 174 Gen.voltage monitoring ON Generator voltage monitoring ON/OFF ON ................Monitoring of the generator voltage is enabled. The subsequent screens of this function are displayed. OFF ..............Monitoring of the generator voltage is disabled. The subsequent screens of this function are not displayed. Parameter 175 Gen.overvoltage V > 000.0% Generator overvoltage threshold value 020,0 to 150,0 % L This value refers to the parameter "Rated volt. in system" (Parameter 17). If the monitored generator voltage exceeds the configured percentage of the rated generator frequency for at least the delay time configured in Parameter 176, an F3 class alarm is issued. Issuing of F3 class alarm NOTE The threshold value for generator overvoltage may not exceed 149 V [1] or 495 V [4] for delta connec- tions, because higher voltages cannot be detected. Parameter 176 Gen.overvoltage delay 0.00s Generator overvoltage delay 0.02 to 9.98 s For the control unit to recognize that a generator overvoltage fault has occurred, the threshold value configured in Parameter 175 must be exceeded without interruption for this period of time. Parameter 177 Gen.undervoltage V < 000.0% Generator undervoltage threshold value 020,0 to 150,0 % L This value refers to the parameter "Rated volt. in system" (Parameter 17). If the monitored generator voltage falls below the configured percentage of the rated generator frequency for at least the delay time configured in Parameter 178, an F3 class alarm is issued. Issuing of F3 class alarm Parameter 178 Gen.undervoltage delay 0.00s Generator undervoltage delay 0.02 to 9.98 s For the control unit to recognize that a generator undervoltage fault has occurred, the threshold value configured in Parameter 177 must be exceeded without inter- ruption for this period of time. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 105/179 Mains Frequency Monitoring Monitoring the mains frequency is absolutely vital if a generator is operated in parallel with the infinite grid. In the event of a mains failure (e.g. utility power outage) the generator that is operating in parallel with the utility must be automatically disconnected from the mains. Decoupling from the mains only occurs when the MCB and GCB are closed. If the following parameters are enabled, the limit values are used to assess if an emergency power operation should be initiated. The parameters below define if the mains are or aren’t present. The breaker opening times do not affect these parameters. Function: "Mains frequency not within the permissible limits" - If the mains frequency exceeds the limit values configured for overfrequency or underfrequency a mains failure is recognized. The circuit breaker configured to disconnect from the mains is immediately opened. The prerequisite of mains frequency monitoring is that the generator is operating in parallel with the mains (the MCB and GCB are both closed). Parameter 179 Mains frequency monitoring ON Mains frequency monitoring ON/OFF ON................Monitoring of the mains frequency is enabled. The subsequent screens of this function are displayed. OFF..............Monitoring of the mains frequency is disabled. The subsequent screens of this function are not displayed. Parameter 180 Mains overfreq. f > 000.0% Mains overfrequency threshold value 80.0 to 140.0 % L This value refers to the parameter "Rated freq. in system" ((Parameter 9). If the monitored mains frequency exceeds the configured percentage of the rated system frequency for at least the delay time configured in Parameter 181, an F0 class alarm is issued. The MCB, GCB, or an external CB is opened depending on how the GCP is configured to decouple from the mains. Issuing of F0 class alarm Parameter 181 Mains overfreq. delay 0.00s Mains overfrequency delay 0.02 to 9.98 s For the control unit to recognize that a mains overfrequency fault has occurred, the threshold value configured in Parameter 180 must be exceeded without interruption for this period of time. Parameter 182 Mains underfreq. f < 000.0% Mains underfrequency threshold value 80.0 to 140.0 % L This value refers to the parameter "Rated freq. in system" ((Parameter 9). If the monitored mains frequency falls below the configured percentage of the rated system frequency for at least the delay time configured in Parameter 183, an F0 class alarm is issued. The MCB, GCB, or an external CB is opened depending on how the GCP is configured to decouple from the mains. Issuing of F0 class alarm Parameter 183 Mains underfreq. delay 0.00s Mains underfrequency delay 0.02 to 9.98 s For the control unit to recognize that a mains underfrequency fault has occurred, the threshold value configured in Parameter 182 must be exceeded without inter- ruption for this period of time. Manual 37365A GCP-30 Series Packages - Genset Control Page 106/179 © Woodward Mains Voltage Monitoring Monitoring the mains voltage is absolutely vital if a generator is operated in parallel with the infinite grid. In the event of mains failure (e.g. utility power outage) the generator that is operating in parallel with the utility must be automatically disconnected from the mains. Decoupling from the mains only occurs when the MCB and GCB are closed. The phase-to-neutral (wye) voltage is always monitored. If the following parameters are enabled, the limit values are used to assess if an emergency power operation should be initiated. The parameters below define if the mains are or aren't present. The breaker opening times do not affect these parameters. Function: "Mains voltage not within the permissible limits" - If one or more phases of the generator voltage ex- ceeds the limit values set for overvoltage or undervoltage, a mains failure is recognized. The circuit breaker con- figured to disconnect from the mains is immediately opened. The prerequisite of mains voltage monitoring is that the generator is operating in parallel with the mains (the MCB and GCB are both closed). Parameter 184 Mains voltage monitoring ON Mains voltage monitoring ON/OFF ON ................Monitoring of the mains voltage is enabled. The subsequent screens of this function are displayed. OFF ..............Monitoring of the mains voltage is disabled. The subsequent screens of this function are not displayed. Parameter 185 Mains overvolt. V > 000.0% Mains overvoltage threshold value 20.0 to 150.0 % L This value refers to the parameter "Rated volt. in system" (Parameter 17). If the monitored mains voltage exceeds the configured percentage of the rated sys- tem frequency for at least the delay time configured in Parameter 186, an F0 class alarm is issued. The MCB, GCB, or an external CB is opened depending on how the GCP is configured to decouple from the mains. Issuing of F0 class alarm Parameter 186 Mains overvolt. delay 0.00s Mains overvoltage delay 0.02 to 9.98 s For the control unit to recognize that a mains overvoltage fault has occurred, the threshold value configured in Parameter 185 must be exceeded without interruption for this period of time. Parameter 187 Mains undervolt. V < 000.0% Mains undervoltage threshold value 20.0 to 150.0 % L This value refers to the parameter "Rated volt. in system" (Parameter 17). If the monitored mains voltage falls below the configured percentage of the rated system frequency for at least the delay time configured in Parameter 189, an F0 class alarm is issued. The MCB, GCB, or an external CB is opened depending on how the GCP is configured to decouple from the mains. Issuing of F0 class alarm Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 107/179 Parameter 188 Mains undervolt. Hysteresis 00.0% Mains undervoltage hysteresis 0.0 to 50.0 % The value configured here is the amount the monitored voltage must exceed the configured threshold in Parameter 187 before the corresponding relay output will de-energize. Parameter 189 Mains undervolt. delay 0.00s Mains undervoltage delay 0.02 to 9.98 s For the control unit to recognize that a mains undervoltage fault has occurred, the threshold value configured in Parameter 187 must be exceeded without interruption for this period of time. Phase/Vector Shift Monitoring dϕ/dt A phase/vector shift is a sudden change in the voltage curve that is caused by a large generator load change. The measuring circuit detects a change in a single sine wave. This sine wave is compared with a calculated mean value from previous measurements. Monitoring encompasses all three phases. The threshold value in degrees specifies the difference in time between the mean and the measured value in reference to a full cycle. Monitoring can be set in various manners. The phase/vector shift watchdog may be used as an additional means for decoup- ling from the mains. The minimum voltage that the phase shift is activated is 70 % of the rated secondary volt- age. Function: "Voltage cycle duration not within the permissible limits" - A fault is recognized if one or more phases of the generator voltage cycle duration exceeds the configured limit value for the phase/vector shift. The circuit breaker configured to disconnect from the mains is opened and an alarm message is displayed. The pre- requisite for phase/vector shift monitoring is that the generator is operating in parallel with the mains operation (the MCB and GCB are both closed). Parameter 190 Phase shift monitoring ON Phase/vector shift monitoring ON/OFF ON................Monitoring of the mains frequency for a phase/vector shift is en- abled. The subsequent screens of this function are displayed. OFF..............Monitoring of the mains frequency for a phase/vector shift is dis- abled. The subsequent screens of this function are not displayed. Parameter 191 Monitoring ---------------- Phase/vector shift monitoring one-/threephase / only threephase one-/threephase..During single-phase voltage phase/vector shift monitoring, trip- ping occurs if the phase/vector shift exceeds the configured threshold value (Parameter 192) in at least one of the three phases. Note: If a phase/vector shift occurs in one or two phases, the single-phase threshold value (Parameter 192) is taken into consideration; if a phase/vector shift occurs in all three phases, the three-phase thresh- old value (Parameter 193) is taken into consideration. Single phase monitoring is very sensitive and may lead to nuisance tripping if the selected phase angle settings are too small. only threephase..During three-phase voltage phase/vector shift monitoring, trip- ping occurs only if the phase/vector shift exceeds the specified thres- hold value (Parameter 193) in all three phases within 2 cycles. Issuing of F0 class alarm Manual 37365A GCP-30 Series Packages - Genset Control Page 108/179 © Woodward NOTE If monitoring is configured to "threephase", only Parameter 192 is displayed; if monitoring is config- ured to "one-/threephase", Parameter 192 and Parameter 193 are dispalyed. Parameter 192 Phase shift one-phase 00° This screen is visible only if monitoring is configured to "one/three-phase". Phase/vector shift monitoring threshold value single-phase 3 to 30 ° If the monitored electrical angle of the mains voltage shifts more than this config- ured value in any single phase, an F0 class alarm is initiated. The MCB, GCB, or an external CB is opened depending on how the GCP is configured to decouple from the mains. Parameter 193 Phase shift three-phase 00° Phase/vector shift monitoring threshold value three-phase 3 to 30 ° If the monitored electrical angle of the mains voltage shifts more than this config- ured value in all three phases, an F0 class alarm is initiated. The MCB, GCB, or an external CB is opened depending on how the GCP is configured to decouple from the mains. Mains Settling Time Parameter 194 Mains settling time 000s Mains settling time 0 to 999 s It is possible to delay the synchronization of the generator to the mains for the pe- riod of time configured here. This will permit the user to ensure that the mains volt- age is stable while the generator continues to operate in an isolated (parallel) mode or idle offline. Note For devices with one circuit breaker, refer to Parameter 106. If a GCP-32 has both the MCB and GCB open and the mains return, the mains set- tling time is reduced to 2 seconds when the mains return if the mains settling time is configured for longer. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 109/179 Battery Voltage Monitoring Parameter 195 Batt.undervolt. V < 00.0V Battery voltage monitoring: Threshold value 9.5 to 30.0 V If the monitored battery voltage falls below the configured percentage of the con- figured threshold for at least the delay time configured in Parameter 196, an F1 class alarm is issued. Issuing of F1 class alarm Parameter 196 Batt.undervolt. delay 00s Battery undervoltage delay 0 to 99 s For the control unit to recognize a battery undervoltage fault condition, the thresh- old value configured in Parameter 195 must be exceeded without interruption for this period of time. Note: Regardless of the configured battery voltage monitoring threshold, readiness for operation is withdrawn and an alarm message is issued if the power supply volt- age falls below 9 Vdc during normal operation or if the power supply voltage falls below 11 Vdc during the start sequence. Time Of Active Horn Parameter 197 Horn self reset 0000s Horn acknowledgment after 1 to 9.999 s The horn (centralized alarm) will remain active for the time configured and then deactivate (acknowledged) automatically. Manual 37365A GCP-30 Series Packages - Genset Control Page 110/179 © Woodward Discrete Inputs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ NOTE The parameters for this control are grouped together in blocks to permit navigation through the large number of configuration screens more rapidly. Selecting "YES" or "NO" has no effect whether or not control or monitoring is carried out for the parameters located in that block. Selecting "YES" or "NO" only determines if the individual parameters may be accessed and changed or are bypassed. Parameter 198 Configure dig.inputs YES Configuration of discrete inputs YES/NO The discrete inputs functionality and logic are configured in this block of parame- ters. This parameter has the following effects: YES ..............The parameters in this block are displayed and can either be viewed ("Select" button), or modifications can be made to the parameters ("Cursor→", "Digit↑" or "Select" buttons). NO ................The parameters in this block are not displayed, cannot be modified, and are skipped. NOTE The discrete inputs can be used as alarm inputs or control inputs. If they were configured as alarm in- puts (Parameter 204 to Parameter 210 are configured to "OFF") the parameters in "Alarm Inputs" (page 111) are valid. If they have been configured as control inputs (Parameter 204 to Parameter 210 are configured to "ON") the parameters in "Control Inputs" (page 113) are valid. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 111/179 Alarm Inputs Discrete input 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Name 1 2 3 4 5 6 7 8 9 A B C D E F G Terminal 34 35 36 61 62 63 64 65 66 67 68 69 70 71 72 73 Function A A A A A/C A/C A/C A A A/C A A A/C A A A A..Alarm input; A/C..Alarm or control input (dependent on the configuration) NOTE Normally Open (N.O.): Energizing the discrete input will enable the relay. This does not provide wire break monitoring! Normally Closed (N.C.): De-energizing the discrete input will enable the relay. This may provide wire break monitoring. Example: Discrete inputs 1 through 4 (use the same procedure for inputs 5 to 16) Parameter 199 Dig.input 1234 function EEEE Function of the discrete alarm inputs 1 to 4 E/D The discrete inputs may be operated by a normally open contact or a normally closed contact. The normally closed contact input may be used to monitor for a wire break. A positive or negative voltage polarity may be utilized. E ...................The discrete input is analyzed as "enabled" by energizing the input (N.O.; E = energize to operate). D...................The discrete input is analyzed as "enabled" by de-energizing the in- put (N.C.; D = de-energize to operate). Parameter 200 Dig.input 1234 delay 0000 Delay time of the discrete alarm inputs 1 to 4 0 to 9 A delay time can be assigned to each alarm input. The delay times are configured as stages. The individual stages are listed below. The discrete input must be ener- gized/de-energized, depending on how it is configured, without interruption throughout the delay time in order to be "enabled". Delay stage Delay stage 0 100 ms 1 200 ms 2 500 ms 3 1 s 4 2 s 5 5 s 6 10 s 7 20 s 8 50 s 9 100 s Table 3-9: Discrete alarm inputs - delay stages Parameter 201 Delayed by 1234 eng.speed YYYY Delayed by firing speed of the discrete alarm inputs 1 to 4 Y/N It is possible to configure the GCP to ignore discrete inputs until the engine has achieved firing speed. This parameter defines if the discrete input, which is being used as an alarm input, is only to be monitored after the engine is running ("firing speed reached"). Y...................The discrete input is only monitored after the engine firing speed has been achieved and monitoring of the engine protections have been enabled. N...................The discrete input is always monitored. Manual 37365A GCP-30 Series Packages - Genset Control Page 112/179 © Woodward Parameter 202 Dig.input 1234 error class 0000 Alarm class of the discrete alarm inputs 1 to 4 F0 to F3 The discrete inputs, which have been designated as alarm inputs, may be assigned an alarm class. This parameter defines what action is to be taken by the GCP when an alarm discrete input is enabled. The alarm classes are listed below. The monitoring functions are divided into four alarm classes: F0 - Warning alarm - This alarm does not lead to an interruption of the operation. An alarm message is dis- played without a centralized alarm (horn) Æ Alarm text. F1 - Warning alarm - This alarm does not lead to an interruption of the operation. A centralized alarm is issued. Æ Alarm text + flashing "alarm" LED + group alarm relay (horn). F2 – Triggering alarm - This alarm leads to the shutdown of the engine. A power reduction is performed prior to the GCB being opened. An engine cool down is performed. Æ Alarm text + flashing "alarm" LED + group alarm relay (horn) + soft shutdown. F3 – Triggering alarm - This alarm leads to the immediate opening of the GCB and shutdown of the engine. Æ Alarm text + flashing "alarm" LED + group alarm relay (horn) + hard shutdown. Configuring The Text For The Discrete Inputs NOTE If terminal 6 is configured to "Sprinkler operation" (override or critical mode; Parameter 211) or if a gas engine is selected (Parameter 254), the EMERGENCY STOP function must be assigned to terminal 34. If terminal 34 is not used as a discrete input, the EMERGENCY STOP function is assigned to the discrete input with the lowest terminal number (terminal 61). NOTE Special characters, numbers, upper and lower case letters may be configured for the alarm text. NOTE If the unit is equipped with a second communication interface (Option SB03 and Option SC10), the alarm texts can only be configured via LeoPC1. Parameter 203 Errortxt.term.34 EMERGENCY STOP Setting the alarm texts These parameters are used to enter the alarm texts (in this example for terminal 34 the alarm text "EMERGENCY STOP"). The text for these parameters is user de- fined. Terminal 34 is the recommended terminal to assign EMERGENCY STOP functions to. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 113/179 Control Inputs Acknowledge firing speed via terminal 62 Parameter 204 Firing speed by Term. 62 ON only accessible via LeoPC1 Firing speed reached via terminal 62 ON/OFF OFF..............This terminal is used as an alarm input. ON................Configuring the starting sequence logic: If Parameter 199 is configured to "E", the discrete input utilizes “N.O.” contacts and the starter disengages when this discrete input becomes TRUE/energized. Once the delayed engine monitoring time has expired, the discrete input changes to "N.C." logic internally even though "N.O." logic is still programmed. This permits the controller to generate an alarm condition in the event of a voltage loss (includ- ing a configured time delay). This input will operate on the inverse of this principle as well. If Parameter 199 is configured to "D", the discrete input utilizes "N.C." logic to disengage the starter in the event of a voltage loss. Once the delayed engine monitoring has expired, the discrete input changes to "N.O." logic internally even though "N.C." logic is still programmed and will initiate an alarm as soon as voltage is applied. Block operation mode selector switch via terminal 63 Parameter 205 Op.mode blocked by Ter.63 ON only accessible via LeoPC1 Disabling the change of the mode using terminal 63 ON/OFF OFF..............This terminal is used as an alarm input. ON................Terminal 63 is used as control input. If terminal 63 is energized, the operation mode buttons of the face of the control are disabled and cannot be used to operating mode. If this input is configured as control input and energized, it is possible for units with XPD or XPQ Packages from version 4.3010 to change the operation mode externally using terminals 127 and 128 as control inputs. The functionality is described in the following table: Operation mode blocked (terminal 63) Input STOP (terminal 127) Input AUTOMATIC (terminal 128) Function de-energized not applicable not applicable The operation mode can be selected using the buttons on the face of the GCP. (The terminals 127/128 have no effect.) energized energized de-energized The STOP operation mode is activated. After connecting the supply voltage, the unit is in STOP operation mode. The operation mode se- lection buttons on the face of the GCP are disabled. energized de-energized energized The AUTOMATIC operation mode is activated. After connecting the supply voltage, the unit changes to AUTOMATIC operation mode via STOP. The operation mode selection buttons on the face of the GCP are disabled. energized energized energized The STOP operation mode is activated. After connecting the supply voltage, the unit is in STOP operation mode. The operation mode se- lection buttons on the face of the GCP are disabled. Table 3-10: Function - external operation mode selection Manual 37365A GCP-30 Series Packages - Genset Control Page 114/179 © Woodward Change breaker logic via terminal 64 Parameter 206 Breaker logic by Term64 ON only accessible via LeoPC1 Breaker logic via terminal 64 ON/OFF OFF ..............This terminal is used as an alarm input. ON ................This terminal is used as control input. • Energized When this terminal is energized, the breaker logic of Parameter 207 is used. • De-energized When this terminal is de-energized, the breaker logic of Parameter 111 is used. Parameter 207 Breaker logic: ---------------- Visible only if breaker logic via terminal 64 is configured to "ON". Breaker logic via terminal 64 see page 74 Selection of the breaker logic that is to be used when terminal 64 is energized. This parameter is only displayed if Parameter 206 has been configured to ON (for the description of the breaker logic refer to the "Breaker logic" section on page 74). Enable 'Close GCB without engine delay' via terminal 67 Parameter 208 Close GCB asap by Ter.67 ON Close GCB before the delayed engine monitoring expires via terminal 67 ON/OFF OFF ..............This terminal is used as an alarm input. ON ................This terminal is used as control input. • Energized When this terminal is energized, the GCB closes be- fore the delayed engine monitoring expires. • De-energized When this terminal is de-energized, the GCB closes after the delayed engine monitoring has expired. Enable 'Emergency OFF' via terminal 68 Parameter 209 Emergency OFF by Ter.68 OFF only version 4.3010 or later only accessible via LeoPC1 Prevent an emergency power operation via terminal 68 ON/OFF OFF ..............This terminal is used as an alarm input. ON ................This terminal is used as control input. • Energized When this terminal is energized, an emergency power operation is prevented or terminated. The unit oper- ates as if Parameter 137 "Emergency power" is dis- abled. • De-energized When this terminal is de-energized, an emergency power operation may be performed. The unit oper- ates in the manner prescribed by Parameter 137 "Emergency power". Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 115/179 Enable 'Idle mode' via terminal 70 Parameter 210 Idle Mode by term.70 ON only accessible via LeoPC1 Enable idle mode via terminal 70 ON/OFF OFF..............This terminal is used as an alarm input. ON................This terminal is used as control input. The discrete output pro- grammed with the relay manager function 133 ("idle mode active") enables/disables in accordance with the logical status of terminal 70 according to the configured NO/NC logic. Generally this discrete output from the GCP must be wired to the "idle input" of the speed governor normally. • Energized Energizing the terminal 70 discrete input enables the idle mode. The message "Idle Mode" is displayed in all operational modes (except STOP mode) when a start request is initiated and during the post-run time so long as there are no other message with a higher display priority (i.e. pre-glow). The generator under- voltage and underfrequency protections are disabled and the warning limit value for the oil pressure input is suppressed while in the idle mode. These protec- tions are enabled after terminal 70 is de-energized and the monitored frequency is measured within 1 Hz of the rated generator frequency or after 60 seconds, which ever occurs first. • De-energized The idle mode is disabled and the protections are en- abled again (refer to the description above). Manual 37365A GCP-30 Series Packages - Genset Control Page 116/179 © Woodward Terminal 6 Function ATTENTION Specific terminal 6 functionality require different input signals! Parameter 211 Function term.6 ---------------- Function of terminal 6 This parameter is used to assign a function to the terminal 6 discrete input. The fol- lowing functions may be selected for the discrete input: • Sprinkler operation By de-energizing terminal 6, the sprinkler operation (critical mode) is enabled in accordance with the functional description. Energizing terminal 6 terminates the sprinkler operation. For a description of the sprinkler operation function refer to "Sprinkler (Critical) Operation" on page 117). Note: Load-dependent starting and stopping is not possible in sprinkler operation. Attention: This is a negative logic function! • Engine enabled Terminal 6 has the same function as the STOP button: De-energizing terminal 6 prevents the engine from starting and stops the engine if it is already running. Energizing terminal 6 en- ables the starting of the engine Attention: Use of this function makes it possible to abort or prevent an emergency power operation. An emergency power operation is not possible without enabling this function! The enable engine function only operates when the GCP is in the AUTOMATIC operation mode. • Engine blocked Energizing terminal 6 can prevent starting of the engine. If the engine is running due to an active emergency power operation, energizing this discrete input will stop it. The engine- blocked functionality is only possible when the GCP is in the AUTOMATIC operation mode. The function of this mode is the opposite of the function of the "Engine enabled" mode. • Ext. acknowledgment Alarms can be acknowledged externally by momentarily energizing terminal 6 in the STOP and AUTOMATIC operation modes. In order to achieve additional acknowledgements, ter- minal 6 must first be de-energized and then energized again. If terminal 6 is continuously re- energized, any alarm messages generated after terminal 6 was energized will not be ac- knowledged. • STOP mode By energizing terminal 6 the STOP mode is activated. If terminal 6 is de-energized, the op- eration mode will revert back to the mode that was active prior to terminal 6 being ener- gized. • Start without CB If the terminal 6 is energized, the engine starts. Synchronization is not performed and the GCB is not closed (no closing to dead busbar). The GCB will only close if an emergency power operation is enabled. After the mains return, the load is transferred back to the mains according to the configured breaker logic. An engine start command from terminal 6 has a higher priority than a start command from terminals 3/5. If terminal 6 is energized, termi- nals 3/5 are ignored. If the generator is in a mains parallel operation mode with "Parallel" breaker logic and terminal 6 is energized, the GCB will be opened following a power reduc- tion. The generator will continue to run without load and the GCB open. Note: Load-dependent starting and stopping is not possible in sprinkler operation. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 117/179 Starting Without Closing GCB Parameter 212 Start without CB cool down ON Only if terminal 6 has been con- figured to "start without CB". Perform engine cool down if starting without CB has been selected ON/OFF ON................After removing the start request (terminal 6 has been de-energized), an engine cool down is performed for the time configured in Para- meter 270. OFF..............After removing the start request (terminal 6 has been de-energized), the engine is stopped immediately without an engine cool down. Alarm Classes Enabled During Sprinkler Coasting Parameter 213 Sprinkler shutd. F1 active ON Only if terminal 6 has been configured to "Sprinkler operation". Sprinkler alarm classes only active if terminal 6 is energized ON/OFF ON................If terminal 6 is configured as "Sprinkler operation", the alarm classes will be enabled after the sprinkler demand has been terminated and the coasting has expired (terminal 6 is energized and sprinkler coast- ing 10 minutes). OFF..............If terminal 6 is configured as "Sprinkler operation", the alarm classes will be enabled after the sprinkler demand has been terminated (ter- minal 6 is energized). Sprinkler (Critical) Operation NOTE Terminal 6 must be configured for the "Sprinkler operation" functionality. ATTENTION The sprinkler operation function is a negative logic function. Terminal 6 must remain energized to pre- vent a Sprinkler (critical) operation from being performed. De-energizing terminal 6 will initiate a Sprin- kler (critical) operation. Sprinkler "ON": If terminal 6 de-energizes, the Sprinkler (critical) operation ON command is initiated. The message "Sprinkler operation" is shown on the display. Up to 6 attempts are made to start the engine if it is not already in operation. All fault conditions or discrete inputs, which result in shutdown, become messages with the exceptions of terminals 34 or 61 and overspeed. The alarm input for terminal 34 will still shut the engine down. Terminal 61 is used for this if terminal 34 is not present on the control. It is recommended that EMER- GENCY STOP be assigned to one of these terminals. Manual 37365A GCP-30 Series Packages - Genset Control Page 118/179 © Woodward NOTE If a "Sprinkler operation" (terminal 6) has been activated, F2 and F3 class alarms are converted to F1 class alarms (exception: terminal 34 or 61 and overspeed). F2 and F3 class alarms Ö F1 class alarm "Sprinkler shutdown F1 active": Parameter 213 permits the user to select if the F2 and F3 class alarms are en- abled after the Sprinkler coasting has concluded or if the F2 and F3 alarm class will be enabled as soon as the Sprinkler (critical) mode request has terminated (terminal 6 energized). A distinction is made between three operating conditions: 1.) MCB is closed (Ö mains voltage available) a) The engine is stopped: The engine will be started and the GCB will not be closed b) The engine runs with the GCB open 2.) MCB is opened (Ö mains voltage not available and the Parameter 137 "Emergency power" is ON) a) The GCB will be closed or remains closed b) In the event of a generator overload, the GCB will open c) Following the alarm acknowledgement the GCB will be closed again Figure 3-11: Sprinkler operation 3.) MCB is open (Ö mains voltage available) a) The MCB will be synchronized b) Following the synchronization of the MCB, the GCB will be opened Sprinkler "OFF": Energizing terminal 6 terminates the Sprinkler (critical) mode and the Sprinkler ON com- mand. The message "Sprinkler coasting" appears on the display screen. The Sprinkler (critical mode) operation concludes after a 10-minute coasting period. Changing the GCP operation mode to STOP will result in the coast- ing period terminating immediately. When the Sprinkler (critical) mode operation has concluded, fault conditions that result in shutdowns are enabled again. G M Sprinkler pump GCB MCB Mains Busbar Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 119/179 Analog Inputs (XPD, XPQ) ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ NOTE The parameters for this control are grouped together in blocks to permit navigation through the large number of configuration screens more rapidly. Selecting "YES" or "NO" has no effect whether or not control or monitoring is carried out for the parameters located in that block. Selecting "YES" or "NO" only determines if the individual parameters may be accessed and changed or are bypassed. Parameter 214 Configure analg.inp. YES Configuration of analog inputs YES/NO The analog inputs functionality and logic are configured in this block of parame- ters. This parameter has the following effects: YES ..............The parameters in this block are displayed and can either be viewed ("Select" button), or modifications can be made to the parameters ("Cursor→", "Digit↑" or "Select" buttons). NO................The parameters in this block are not displayed, cannot be modified, and are skipped. Setting The Analog Inputs The analog inputs [T1] to [T7] are only available in the XPD and XPQ packages. The analog input types and specification are as follows: • Scaleable analog input 0/4 to 20 mA (page 120) • Pt100 input (page 119) • VDO input (temperature, page 122 or pressure, page 123) Analog input 1 2 3 4 5 6 7 Assignment 0/4 to 20 mA Pt100 VDO #1 VDO #2 Terminal 93/94/95 96/97/98 99/100/101 101/102/103 104/105/106 107/108/109 110/111/112 VDO #1 = 0 to 180 Ohm, VDO #2 = 0 to 380 Ohm NOTE If you want to visualize the analog inputs via the PC program LeoPC1 (Firmware Version 4.0.xxx or higher) the following must occur: 1. Establish a connection between LeoPC1 and the GCP. 2. Select in the menu "Devices" the topic "Refresh Configuration". 3. Restart LeoPC1 according to the requests. Manual 37365A GCP-30 Series Packages - Genset Control Page 120/179 © Woodward Scaleable analog input 0/4 to 20 mA (analog input [T1] - [T3]) NOTE The scalable analog inputs 0/4 to 20 mA can be configured alternatively for the following functions: • Mains interchange (import/export) real power actual value (Parameter 24) • Real power set point value (Parameter 78) If one of the both functions is assigned to an available 0/4 to 20 mA input T{x} (refer to Parameter 24 and Parameter 78), that analog input T{x} must be configured to OFF. The analog input can no longer be used as an alarm input. Priority of the analog input functions The following priority is valid if more than one function has been assigned to a analog input: • Highest priority: Mains interchange (import/export) real power actual value measurement • Middle priority: Real power set point value • Lowest priority: Measuring input as common analog value 0/4 to 20 mA sensors may be measured here. A description and the engineering unit may be assigned to the in- put. The analog input is displayed with its description. Two limit levels can be monitored. The first limit level initiates a class F1 alarm, the second limit level initiates a class F3 alarm. Parameter 215 Analog input x scalable ON [x = 1 to 3] 0/4 to 20 mA input; enable/disable ON/OFF ON ................The value of this input appears in the display and monitoring is en- abled. The subsequent parameters of this function are displayed. OFF ..............The value of this input does not appear in the display and monitoring is disabled. The subsequent parameters of this function are not dis- played. NOTE If the unit is equipped with a second communication interface (Option SB03 and Option SC10), this parameter can only be configured via LeoPC1. Parameter 216 Name and unit ---------------- 0/4 to 20 mA input; description User defined text The description of the analog input may be programmed using this parameter. A maximum of four zeros may be used as placeholders for the numerical measuring values. Characters may divide the placeholders (i.e. a comma). The measured val- ues subsequently appear wherever the zeros are placed. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 121/179 Parameter 217 Analog input x 0-00mA [x = 1 to 3] 0/4 to 20 mA input; measuring range 0 to 20 mA / 4 to 20mA The measuring range 0 to 20 mA or 4 to 20 mA is selected via this parameter. If 4 to 20 mA is configured and a current of less than 2 mA is measured, the controller assumes a wire break has occurred (see below). Parameter 218 Value at 0% 0000 0/4 to 20 mA input; smallest input value -9,999 to 9,999 The user must assign a numeric value to the scaleable analog input that corresponds to the smallest input value Æ Definition of the lower value (i.e. 0 % equals 0 kW, 0 V, etc.) at the minimum analog input value of 0 mA or 4 mA. Parameter 219 Value at 100% 0000 0/4 to 20 mA input; largest input value -9,999 to 9,999 The user must assign a numeric value to the scaleable analog input that corresponds to the largest input value Æ Definition of the upper value (i.e. 100 % equals 500 kW, 400 V, etc.) at the maximum analog input value of 20 mA. Parameter 220 Limit warning value -0000 0/4 to 20 mA input; limit value for class F1 alarm -9,999 to 9,999 If the measured value exceeds or falls below this configured threshold value (de- pendent upon Parameter 223) for at least the delay time (Parameter 222), the fol- lowing alarm class is initiated. Issuing of F1 class alarm Parameter 221 Limit shutdown value -0000 0/4 to 20 mA input; limit value for class F3 alarm -9,999 to 9,999 If the measured value exceeds or falls below this configured threshold value (de- pendent upon Parameter 223) for at least the delay time (Parameter 222), the fol- lowing alarm class is initiated. Issuing of F3 class alarm Parameter 222 Delay limit 1/2 000s 0/4 to 20 mA input; delay time for limit values of class F1 and F3 alarm 0 to 650 s In order to initiate an alarm, the measured value must be over or under (dependent upon Parameter 223) the configured threshold value (Parameter 220 or Para- meter 221) without interruption for at least this time. Parameter 223 Monitoring for ---------------- 0/4 to 20 mA input; monitoring for ... high limit mon. / low limit mon. A fault condition is recognized when the measured value has exceeded or fallen be- low the threshold value (Parameter 220 or Parameter 221). high limit mon.: The measured value must exceed the threshold value. low limit mon.: The measured value must fall below the threshold value. Manual 37365A GCP-30 Series Packages - Genset Control Page 122/179 © Woodward Pt100 Input (Analog Input [T4] to [T5]) Pt100 inputs may be measured here. The analog input is displayed with its description. Two threshold limits can be monitored. The first level initiates a class F1 alarm, the second level initiates a class F3 alarm. Parameter 224 Temperature x Pt100 ON [x = 4 to 5] Pt100 input; enable/disable ON/OFF ON ................The value of this input appears in the display and monitoring is en- abled. The subsequent parameters of this function are displayed. OFF ..............The value of this input does not appear in the display and monitoring is disabled. The subsequent parameters of this function are not dis- played. NOTE If the unit is equipped with a second communication interface (Option SB03 and Option SC10), the alarm texts can only be configured via LeoPC1. Parameter 225 ***name**** -----------000°C Pt100 input; description User defined text The description of the analog input may be programmed using this parameter. A maximum of eleven characters may be used to describe the measured value. In the event of an alarm, the description and the monitored value are displayed with an exclamation mark before the temperature. Parameter 226 Limit warning 000°C Pt100 input; limit value for class F1 alarm 0 to 200 °C If the measured value exceeds or falls below this configured threshold value (de- pendent upon Parameter 229) for at least the delay time (Parameter 228), the fol- lowing alarm class is initiated. Issuing of F1 class alarm Parameter 227 Limit shutdown 000°C Pt100 input; limit value for class F3 alarm 0 to 200 °C If the measured value exceeds or falls below this configured threshold value (de- pendent upon Parameter 229) for at least the delay time (Parameter 228), the fol- lowing alarm class is initiated. Issuing of F3 class alarm Parameter 228 Delay limit 1/2 000s Pt100 input; delay time for limit values of class F1 and F3 alarm 0 to 650 s In order to initiate an alarm, the measured value must exceed or fall below (de- pendent upon Parameter 229) the configured threshold value (Parameter 226 or Parameter 227) without interruption for at least this time. Parameter 229 Monitoring for ---------------- Pt100 input; monitoring for ... high limit mon. / low limit mon. A fault condition is recognized when the measured value has exceeded or fallen be- low the threshold value (Parameter 226 or Parameter 227). high limit mon.: The measured value must exceed the threshold value. low limit mon.: The measured value must fall below the threshold value. NOTE If temperature limit monitoring is not required, a threshold value, which is higher than the expected monitored temperature, must be configured to the corresponding parameter (e.g. the ambient tempera- ture is 100 °C). Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 123/179 VDO Input 'Pressure' (Analog Input [T6]) NOTE The default threshold values are configured in "bar". If the engineering unit "psi" is configured (Para- meter 144), the display of the measured values as well as the transmission via the interface appears in "psi". VDO inputs for pressure may be monitored here. The analog input is displayed with its description. Two thresh- old levels can be monitored. The first level initiates a class F1 alarm, the second level initiates a class F3 alarm. Parameter 230 Analog input 6 VDO ON VDO input, pressure; enable/disable ON/OFF ON................The value of this input appears in the display and monitoring is en- abled. The subsequent parameters of this function are displayed. OFF..............The value of this input does not appears in the display and monitor- ing is disabled. The subsequent parameters of this function are not displayed. NOTE If the unit is equipped with a second communication interface (Option SB03 and Option SC10), the alarm texts can only be configured via LeoPC1. Parameter 231 Name and unit ---------------- VDO input, pressure; description User defined text The description of the analog input may be programmed using this parameter. A maximum of four zeros may be used as placeholders for the numerical measured values. Characters may divide the placeholders (i.e. a comma). The measured val- ues subsequently appear wherever the zeros are placed. The measured value will always be displayed and transmitted via the interface in bar [× 0.1] or psi [× 0.1]. Parameter 232 Analog input 6 VDO 0-00bar VDO input, pressure; measuring range 0 to 5 / 0 to 10 bar The measuring range of the analog input can be selected. 0 to 5 bar .....Measuring range 0 to 180 Ohm 0 to 10 bar ...Measuring range 0 to 180 Ohm Parameter 233 Limit warning value 00.0bar VDO input, pressure; limit value for class F1 alarm 0.0 to 10.0 bar If the measured value exceeds or falls below this configured threshold value (de- pendent upon Parameter 236) for at least the delay time (Parameter 235), the fol- lowing alarm class is initiated. Issuing of F1 class alarm Parameter 234 Limit shutdown value 00.0bar VDO input, pressure; limit value for class F3 alarm 0.0 to 10.0 bar If the measured value exceeds or falls below this configured threshold value (de- pendent upon Parameter 236) for at least the delay time (Parameter 235), the fol- lowing alarm class is initiated. Issuing of F3 class alarm Manual 37365A GCP-30 Series Packages - Genset Control Page 124/179 © Woodward Parameter 235 Delay limit 1/2 000s VDO input, pressure; delay time for limit values of class F1 and F3 alarm 0 to 650 s In order to initiate an alarm, the measured value must exceed or fall below (de- pendent upon Parameter 236) the threshold value (Parameter 233 or Parameter 235) without interruption for at least this time. Parameter 236 Monitoring for ---------------- VDO input, pressure; monitoring for ... high limit mon. / low limit mon. A fault condition is recognized when the measured value has exceeded or fallen be- low the threshold value (Parameter 233 or Parameter 235). high limit mon.: The measured value must exceed threshold. low limit mon.: The measured actual value must fall below the threshold value. VDO Input 'Temperature' (Analog Input [T7]) VDO inputs may be measured here (the input has been calibrated to the VDO sender 323.425 or 323.478 (0 to 380 ohm, 40 to 120 °C). The analog input is displayed with its description. Two threshold levels can be moni- tored. The first level initiates a F1 class alarm, the second level initiates a class F3 alarm. NOTE Prior to ordering any VDO sender, ensure that the proper thread (metric or SAE) is ordered for your application. Figure 3-12: VDO transmitter 323.425 (slope) Parameter 237 Analog input 7 VDO ON VDO input, temperature; enable/disable ON/OFF ON ................The value of this input appears in the display and monitoring is en- abled. The subsequent parameters of this function are displayed. OFF ..............The value of this input does not appear in the display and monitoring is disabled. The subsequent parameters of this function are not dis- played. NOTE If the unit is equipped with a second communication interface (Option SB03 and Option SC10), the alarm texts can only be configured via LeoPC1. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 125/179 Parameter 238 Name and unit ---------------- VDO input, temperature; description User defined text The description of the analog input may be programmed using this parameter. A maximum of four zeros may be used as placeholders for the numerical measured values. Characters may divide the placeholders (i.e. a comma). The measured val- ues subsequently appear wherever the zeros are placed. The measured values sub- sequently appear wherever the zeros are placed. Parameter 239 Limit warning value 000°C VDO input, temperature; limit value for class F1 alarm 40 to 120 °C If the measured value exceeds or falls below this configured threshold value (de- pendent upon Parameter 242) for at least the delay time (Parameter 241), the fol- lowing alarm class is issued. Issuing of F1 class alarm Parameter 240 Limit shutdown 000°C VDO input, temperature; limit value for class F3 alarm 40 to 120 °C If the measured value exceeds or falls below this configured threshold value (de- pendent upon Parameter 242) for at least the delay time (Parameter 241), the fol- lowing alarm class is issued. Issuing of F3 class alarm Parameter 241 Delay limit 1/2 000s VDO input, temperature; delay time for limit values of class F1 and F3 alarm 0 to 650 s In order to initiate an alarm, the measured value must exceed or fall below (de- pendent upon Parameter 242) the threshold value (Parameter 239 or Parameter 240) without interruption for at least this time. Parameter 242 Monitoring for ---------------- VDO input, temperature; monitoring for ... high limit mon. / low limit mon. A fault condition is recognized when the measured value has exceeded or fallen be- low the threshold value (Parameter 239 or Parameter 240). high limit mon.: The measured value must exceed threshold value. low limit mon.: The measured value must fall below the threshold value. Monitoring Of The Measuring Range (All Analog Inputs) Ana.input --.- Analog inputs; monitoring of the measuring range This message appears when the measured value exceeds or falls below the measur- ing range occurs. A fault condition is initiated depending on the values specified below. NOTE The GCP has the ability to monitor for possible wire break conditions if the measuring range has been exceeded. If the configured measuring range is exceeded, an alarm will be issued and the affected ana- log input will be deactivated. Fault conditions are recognized when the measuring range exceeds the following values for each type of input: 4 to 20 mA 2 mA and below Pt100 216 °C and above 180 Ω VDO, 0 to 5 Bar 305 Ω and above 180 Ω VDO, 0 to 10 Bar 305 Ω and above Manual 37365A GCP-30 Series Packages - Genset Control Page 126/179 © Woodward Engine Delayed Monitoring Of The Analog Inputs Parameter 243 Ana.in 12345678 SV.del. NNNNNYNN Analog inputs; engine delayed monitoring Y/N The analog inputs may be disabled until the engine has reached the configured fir- ing speed (Parameter 272). This parameter specifies which analog inputs are to be constantly enabled or disabled until firing speed has been achieved by configuring a "Y" or an "N" below the input number. Y ...................Monitoring of the analog input is enabled after firing speed has been reached (the green LED "Protection" illuminates). N ...................The analog input is always monitored. Note: If the controller is equipped with 5 or more analog inputs, the screen for this parameter will display 8 inputs. If the control is equipped with 4 or less analog in- puts this parameter screen will display 4 inputs. If the control is equipped with fewer inputs than are displayed on the screen, only changes made to the valid in- puts will have any effect on the control. Analog Inputs Selectable as Control Inputs Parameter 244 Ana.in 12345678 control NNNNNNNN Analog input as control input J/N This parameter defines if specific analog inputs operate as control inputs or not. Y ...................The analog input operates as control input: The analog value is dis- played and the configured relays are enabled when the configured limits has been reached. However, an alarm will not be issued and a message will not be transmitted on the CAN bus. (A wire break will not effect the behavior of the control) N ...................The analog input operates as described for the above settings. Note: If the controller is equipped with 5 or more analog inputs, the screen for this parameter will display 8 inputs. If the control is equipped with 4 or less analog in- puts this parameter screen will display 4 inputs. If the control is equipped with fewer inputs than are displayed on the screen, only changes made to the valid in- puts will have any effect on the control. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 127/179 Outputs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ NOTE The parameters for this control are grouped together in blocks to permit navigation through the large number of configuration screens more rapidly. Selecting "YES" or "NO" has no effect whether or not control or monitoring is carried out for the parameters located in that block. Selecting "YES" or "NO" only determines if the individual parameters may be accessed and changed or are bypassed. Parameter 245 Configure outputs YES Configuration of the outputs YES/NO The discrete outputs functionality and logic are configured in this block of parame- ters. This parameter has the following effects: YES ..............The parameters in this block are displayed and can either be viewed ("Select" button), or modifications can be made to the parameters ("Cursor→", "Digit↑" or "Select" buttons). NO................The parameters in this block are not displayed, cannot be modified, and are skipped. Analog Outputs (XPD, XPQ) The analog output manager can be used to apply a specific measurement variable to the available analog outputs. The output may be carried out as a 0 to 20 mA or as a 4 to 20 mA value. A list of the possible functions is con- tained in Appendix A. Each variable is assigned a unique number. The variable may be scaled via an upper and a lower output value. The outputs may also be assigned with prefixes (for further details, see "Analog output man- ager" in Appendix A). NOTE The list of values and limits for the analog output manager is contained in Appendix A: "Analog Output Manager" starting on page 146. Possible outputs: Analog outputs terminals 120/121 and 122/123 Example: Analog output terminals 120/121 Parameter 246 Analg.out.12O121 Parameter 00 Function for analog output 0 to 22 The analog output function number of the desired function is configured here. A list of all selectable functions, together with output and limit value ranges, is con- tained in Appendix A. Parameter 247 Analg.out.12O121 0-00mA Analog output range OFF / 0 to 20 / 4 to 20 mA The output range 0 to 20 mA or 4 to 20 mA is selected using this parameter. Parameter 248 Analg.out.12O121 0% 0000 Scaling the lower output value 0 to 9,990 The configurable limit for the 0% value is contained in Appendix A. Parameter 249 Analg.out.12O121 100% 0000 Scaling the upper output value 0 to 9,990 The configurable limit for the 100% value is contained in Appendix A. Manual 37365A GCP-30 Series Packages - Genset Control Page 128/179 © Woodward Relay Manager The relay manager enables the assignment of a logical combination of functions to each relay. Each function has been assigned a number. The numbers for these functions are entered into the configuration screen and are com- bined to create a logical condition that energizes the assigned relay. Up to three function numbers may be com- bined in this link. The length of the text for the logical condition must not exceed 16 characters. The control can detect incorrect function numbers or formula constructions and will not accept these. NOTE The relay manager functions are listed in Appendix B: Relay Manager starting on page 149. Permissible text/symbols for logic functions and their meaning include: +....................OR operator (logic function) *....................AND operator (logic function) -.....................NOT operator (logic function) 1, 2, 3, ..........Function numbers +/*.................the following applies "*" has precedence over "+" Function Programmed text Relay is enabled, if ... ... function 22 is true. 22 ... function 22 is not true. - 22 ... both function 2 is true and function 27 is true. 2 * 27 ... function 2 is true or function 27 is true. 2 + 27 ... function 3 is true or function 5 is not true or function 13 is true. 3 + -5 + 13 ... function 4 or 7 or 11 is true. 4 + 7 + 11 ... function 4 is not true and function 7 is not true and function 11 is not true. - 4 * -7 * -11 ... function 4 and 7 and 11 are true. 4 * 7 * 11 ... function 7 and 11 are true or function 4 is true. 4 + 7 * 11 Example of logical conditions and relevant texts ... function 4 is not true or function 7 is not true or function 11 is not true. -4 + -7 + -11 NOTE Entering an illegal logical combination will delete the equation. Parameter 250 Assignm.relay x 3+-8+13 [x = 1 to 7] Programming relay outputs The relay x [x = 1 to 7] energizes, if the logical equation is met. Example: 3 + -8 + 13 (OR link) 3 a class F3 alarm has occurred -8 operation mode MANUAL has not been selected 13 "Generator underspeed" alarm is present Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 129/179 Engine ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ NOTE The parameters for this control are grouped together in blocks to permit navigation through the large number of configuration screens more rapidly. Selecting "YES" or "NO" has no effect whether or not control or monitoring is carried out for the parameters located in that block. Selecting "YES" or "NO" only determines if the individual parameters may be accessed and changed or are bypassed. Parameter 251 Configure engine YES Configuration of the engine YES/NO The engine functionality and protection are configured in this block of parameters. This parameter has the following effects: YES ..............The parameters in this block are displayed and can either be viewed ("Select" button), or modifications can be made to the parameters ("Cursor→", "Digit↑" or "Select" buttons). NO................The parameters in this block are not displayed, cannot be modified, and are skipped. Parameter 252 Aux.services prerun 000s Engine; auxiliary prerun (start preparation) 0 to 999 s Prior to each starting sequence, a relay output (relay manager function 52) can be enabled (i.e. pre-lube pumps run) for the time configured in this parameter. A mes- sage is displayed when the relay output is enabled. This relay output is automati- cally enabled in MANUAL operation mode. The relay output will remain enabled until the operation mode is changed from MANUAL. CAUTION This delay is ignored in the event of emergency power operation. The engine is started immediately. Parameter 253 Aux.services postrun 000s Engine; auxiliary postrun 0 to 999 s The relay output (relay manager function 52) can be enabled for this time following each engine cool down (i.e. operate a coolant pump). If the operation mode is changed from MANUAL to STOP or AUTOMATIC without an engine start re- quest, the relay output remains enabled for the configured time and a message is displayed. Parameter 254 Start-stop-logic ---------------- Engine; start/stop sequence for ... DIESEL/GAS/EXTERNAL DIESEL .......Start/stop logic is performed for a diesel engine. GAS .............Start/stop logic is performed for a gas engine. EXTERNAL Start/stop logic is performed externally (the start/stop sequence is disabled). Manual 37365A GCP-30 Series Packages - Genset Control Page 130/179 © Woodward Start/Stop Sequence 'Gas Engine' NOTE The configured number of start attempts (Parameter 258) will be performed. t/s tZVtSt SPZt tZV GVt tZN 1500 1/min ZD (1) (1)(2) MVt tN Ignition Starter Speed governor Gas valve Start request Engine monitoring activated Delayed enginemonitoring 00s Time jump Speed curve with Pickup Speed curve without Pickup Start Stop Approach idle gas position Switching-on of the ignitionDisengaging of the starter Ignition and gas ON Start attempt unsuccessful Start attempt successful Ignition speed reached min. speed starter (Pickup ON) [1/min] (2) min. speed starter is not reached Start frequency f-contr. + time without Pickup active: < 15 Hz [1/min] Figure 3-13: Start-Stop sequence: Gas engine The signs and indices mean: tSta............Approach idle gas position [s] tZV ...........Firing delay [s] tGV ...........Gas valve delay [s] tSPZ ..........Time between two start attempts [s] tMV ...........Delayed engine monitoring [s] tZN ...........Ignition coasting [s]; pre-specified: 5 s tN .............Engine cool down time [s] (1) ...........Disengagement of the starter; Ignition and gas also ON (2) ...........Switching ON the ignition Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 131/179 Starting Sequence If the control is equipped with a three-position frequency controller, a continuous "Frequency lower prior to start" signal (time adjustable via Parameter 262) is output before starting the engine. The starter is enabled after the time configured in parameter 262 expires. The ignition is enabled following the expiration of the ignition de- lay time (Parameter 256) and if the engine is rotating with at least the configured "minimum speed for ignit." (Parameter 255). Following the expiration of the gas valve delay (Parameter 257), the gas valve is enabled. If the starting sequence finishes successfully (the firing speed (Parameter 272) was exceeded) the starter is disengaged. The gas valve and the ignition remain enabled by means of the firing speed. After reaching the "f-controller: starting frequency" (Parameter 39) and the delayed engine monitoring has expired (Parameter 271), the speed controller is enabled. Stopping Sequence When the start request is terminated, a power reduction is performed (if the real power controller is enabled, Parameter 74). After the GCB has opened, an engine cool down is performed (Parameter 270). When the engine cool down period expires, the gas valve is closed, and the engine is stopped. When the engine speed falls below the firing speed (Parameter 272), the engine starting sequence is disabled for 10 seconds. If the engine fails to stop after 30 seconds, an alarm message is issued and a F3 class alarm is initiated. After the engine speed has fallen below the firing speed, the ignition will remain enabled for an additional 5 seconds so that any gas remaining in the cylinders is able to combust. Safety Instructions To Control Gas Valves In order to ensure a safe shutdown of the gas valves, a separate shutdown circuit must be utilized. The following is recommended to prevent the gas valve from failing to close due to stuck relays. Controlling gas valves with the GCP The GCP relay manager from V4.1001 and on contains function 131 ("fuel valve ON"). This function exists in the GCP so that a relay configured with this function behaves like the "Gas valve" relay. The wiring diagram shown below is an example of a recommended gas valve control system in the gas line. Emergency stop K1 K2 GCP-30 Gas valve Relay manager param. 131 K1 K2 Gas valve 1 Gas valve 2 GCP-3044 43 Figure 3-14: Wiring diagram for opening gas valves with the GCP-30 from V4.1001 Manual 37365A GCP-30 Series Packages - Genset Control Page 132/179 © Woodward Parameter Parameter 255 Min.speed for ignit. 000 rpm This screen is only visible if the parameter "Pickup" is set "ON". Gas engine; minimum start speed 0 to 999 rpm L The minimum starter speed can only be detected if the magnetic pick-up has been enabled (Parameter 280). Once the ignition delay (Parameter 256) has expired, the engine must exceed the speed configured with this parameter in order to enable the ignition relay (relay manager function 84). Parameter 256 Ignition delay 00s Gas engine; ignition delay 0 to 99 s In gas engine applications a purging operation is frequently desired prior to start- ing. The ignition delay is initiated when the starter is engaged. If this time has ex- pired and the "Minimum speed for ignition" (Parameter 255) has been exceeded, the ignition is enabled. Parameter 257 Gasvalve delay 00s Gas engine; gas valve delay 0 to 99 s This timer is initiated once the ignition is enabled. Once this timer has expired and the engine speed is at least 150 rpm, the gas valve is opened. Upon reaching the fir- ing speed (Parameter 272) the relay remains energized until the engine stops. Parameter 258 Max. attempts to start 0 Gas engine; maximum number of start attempts 1 to 6 The control will initiate up to this number of start attempts. If the engine cannot be started within this number of start attempts, an alarm message is issued. Parameter 259 Starter time 00s Gas engine; engagement time of the starter 2 to 99 s The maximum amount of time the starter will crank the engine during a start se- quence. Parameter 260 Start pause time 00s Gas engine; time between two start attempts 1 to 99 s The delay time between the individual start attempts. Parameter 261 f lower before start ON with three-step controllers only only accessible via LeoPC1 Gas engine; frequency lower prior to start ON/OFF If this function is enabled and the control is equipped with a three-step frequency controller, the command "lower engine speed" is issued for the time configured in Parameter 262 before the starter is engaged. The low-idle position must either be equipped with a limit switch or the engine potentiometer must be equipped with a slipping clutch to protect the device once the lowest possible setting has been achieved. A message is displayed while this function is active. CAUTION The engine starting is delay by means of the low-idle position in the event of emer- gency power operation. Parameter 262 time f lower bef.start 000s with three-step controllers only only accessible via LeoPC1 Gas engine; frequency lower prior to start (time) 0 to 999 s The duration that the "lower engine speed" signal (Parameter 261) is output. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 133/179 Start/Stop Sequence 'Diesel Engine' NOTE The configured number of start attempts (Parameter 264) will be performed. t/s tSta VGt tEin SPZt 1500 1/min ZD MVt 0,5 s VGt tEin 0,5 s Nt Speed governor Pre-glow Starter Start relay Start request Engine monitoring activated Delayed enginemonitoring 00s Start Stop Approach idle gas position Start attempt unsuccessful Start attempt successful Ignition speed reached Start frequency f-contr. + time Figure 3-15: Start-stop sequence: Diesel engine The signs and indices mean: tSta ........... Approach idle fuel position [s] tVG ........... Pre-glow time [s] tEin ........... Crank time [s] tSPZ .......... Time between two start attempts [s] tMV .......... Delayed engine monitoring [s] tN............. Engine cool down time [s] Manual 37365A GCP-30 Series Packages - Genset Control Page 134/179 © Woodward Starting Sequence If the control is equipped with a three-position frequency controller, a continuous "Frequency lower prior to start" signal (time adjustable via Parameter 268) is output before starting the engine. The "Pre-glow" relay is en- abled for the time configured in Parameter 263 after the frequency lower signal terminates. After the pre-glow cycle terminates, the fuel relay is enabled (Parameter 269), followed by the crank relay. Once the firing speed (Parameter 272) has been exceeded, the starter disengages, and the fuel relay remains enabled by means of the firing speed. After reaching the "f-controller: starting frequency" (Parameter 39) and the delayed engine monitor- ing has expired (Parameter 271), the speed controller is enabled. Stopping Sequence When the start request is terminated, a power reduction is performed (if the real power controller is enabled, Parameter 74). Once the GCB has opened, an engine cool down is performed (Parameter 270). When the engine cool down period expires, the fuel relay is de-energized and the engine is stopped. When the engine speed falls below the firing speed (Parameter 272), the engine starting sequence is disabled for 10 seconds. If the engine fails to stop after 30 seconds, an alarm message is issued and a F3 class alarm is initiated. Parameter Parameter 263 Preglow time 00s Diesel engine; pre-glow time 0 to 99 s Prior to each starting sequence, the engine glow plugs are energized for this time period. Parameter 264 Max. attempts to Start 0 Diesel engine; maximum number of start attempts 1 to 6 The control will initiate up to this number of start attempts. If the engine cannot be started within this number of start attempts, an alarm message is issued. Parameter 265 Starter time 00s Diesel engine; crank time 2 to 99 s The maximum amount of time the starter will crank the engine during a start se- quence. Parameter 266 Start pause time 00s Diesel engine; time between two start attempts 1 to 99 s The delay time between the individual start attempts. Parameter 267 f lower before start OFF with three-step controllers only only accessible via LeoPC1 Diesel engine; frequency lower prior to start ON/OFF If this function is enabled and the control is equipped with a three-step frequency controller, the command "lower engine speed" is issued for the time configured in Parameter 268 before the starter is engaged. The low-idle position must either be equipped with a limiting switch, or the engine potentiometer must be equipped with a slipping clutch to protect the devices. A message is displayed. CAUTION The engine starting is delay by means of the low-idle position in the event of emer- gency power operation. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 135/179 Parameter 268 time f lower bef.start 000s with three- step controllers only only accessible via LeoPC1 Diesel engine; frequency lower prior to start (time) 0 to 999 s The duration that the "lower engine speed" signal (see Parameter 267) is output. Parameter 269 Fuel relay logic ---------------- Diesel engine; fuel solenoid logic open to stop / close to stop open to stop .The fuel solenoid is energized prior to each start sequence. In order to stop the engine, the fuel solenoid is de-energized. close to stop In order to stop the engine, the fuel shutdown solenoid is energized. The fuel shutdown solenoid remains energized for an additional 30 seconds once the engine speed drops below firing speed (Para- meter 272) and the generator voltage is less than 20 V. Cool Down Parameter 270 Cool down time 000s Engine; cool down time 0 to 999 s If the engine performs a normal shutdown (i.e. STOP mode initiated) or an F2 class alarm has been initiated, an engine cool down period with frequency control is per- formed for the time configured here after the GCB opens. The engine will shut- down following the conclusion of the engine cool down period. If the engine cool down has terminated (cool down time has been expired) and engine speed (Para- meter 272) is still detected after 30 seconds, an engine failure to stop message is displayed. Note The GCP will not perform a cool down period unless the GCB reply (terminal 4) has been de-energized for at least 5 seconds, indicating that the breaker has been closed. Manual 37365A GCP-30 Series Packages - Genset Control Page 136/179 © Woodward Delayed Engine Monitoring And Firing Speed Firing Speed - Engine Monitoring Delay 2003-09-05.cdrt [s]t [s]t [s]t [s]tMVDelayed enginemonitoringStart requestRated speed[RPM]Ignition speedreached [ZD]Firingspeed [ZD][1/min; RPM] Figure 3-16: Delayed engine monitoring Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 137/179 Parameter 271 Delayed engine monitoring 00s Engine; delayed engine monitoring 1 to 99 s A delay may be configured to prevent the GCP from monitoring for selected alarms (e.g. oil pressure, generator underfrequency, etc.) for a specific time period after the engine has reached the firing speed. Parameter 272 Firing speed reached f >00Hz Engine; firing speed reached 5 to 70 Hz Once the engine has achieved this configured firing speed, the starter is disengaged (switched off) and the frequency controller is enabled. Note The GCP may be configured to monitor for firing speed via the MPU input or the frequency of the generated voltage. If the MPU input has been enabled, the GCP is able to monitor frequencies as low as 5Hz accurately. If the MPU input has not been enabled, the GCP will monitor that firing speed has been achieved when the monitored frequency has achieved 15Hz or greater depending upon the configured value. Parameter 273 Speed detected V L1-L2 > 00.0% Engine; speed detected from 5.0 to 25.0 % When the monitored voltage surpasses the value configured for this parameter, the GCP will recognize that engine has achieved firing speed. The configured value for this parameter is a percentage of the voltage rating con- figured for the voltage inputs (Parameter 17). Speed will only be detected when the monitored voltage between L1 and L2 (terminals 20/21) exceeds this configured percentage of the rated system voltage. If the configured threshold value for this parameter is to low, EMI induced voltages from other sources may cause the con- trol to incorrectly detect speed and issue a nuisance fault condition resulting in a shutdown alarm. Note Regardless of the value configured for this parameter, speed will only be detected if the monitored voltage between L1 and L2 (terminals 20/21) is more than 5% of the configured rated voltage of the generator potential transformer secondary (Para- meter 10). Attention The GCP may fail to detect speed or frequency on applications without an MPU if the threshold for this parameter is configured to high. Manual 37365A GCP-30 Series Packages - Genset Control Page 138/179 © Woodward Magnetic Pick-Up Input Measuring the engine speed may be performed by means of a Magnetic Pickup. The use of an alternator or a ta- cho generator to detect engine speed are alternate methods of monitoring if the engine has achieved firing speed. If an alternate means of detecting engine speed is utilized, then the GCP must receive a signal via terminal 62 (refer to Acknowledge firing speed via terminal 62 on page 113). Refer to the Installation Manual 37364 for the wiring diagram that pertains to your specific controller. Parameter 274 Pickup input ON Magnetic pickup; measurement ON/OFF ON ................The Magnetic Pickup input is enabled to monitor engine speed. The GCP utilizes the signal from the MPU to detect when firing speed has been achieved. The engine speed signal monitored via the MPU is used to disengage the starter. OFF ..............The MPU input is disabled. All speed and frequency monitor- ing/control is performed via generator frequency. The GCP utilizes the frequency of the monitored generator voltage to detect when fir- ing speed has been achieved. The starter will disengage when the GCP detects that the frequency has exceeded 15Hz or higher (de- pendent upon how "Firing speed reached f> 00Hz" (Parameter 272) is configured). Parameter 275 Number of pickup teeth 000 only accessible via LeoPC1 Magnetic pickup; number of teeth on flywheel 30 to 280 Number of pulses per revolution. Plausibility monitoring: The GCP performs plausibility checks to ensure that the frequency of the voltage and engine speed match. This is performed by comparing the frequency of the gen- erated voltage and the mechanical speed of the engine as determined by the MPU signal. If the two frequencies are not identical, a F1 class alarm is issued. Plausibil- ity monitoring is enabled after the delayed engine monitoring (Parameter 271) ex- pires and is performed continuously while the generator is operating. Parameter 276 Gen.rated speed 0000 rpm only accessible via LeoPC1 Magnetic pickup; rated speed at rated frequency 0 to 3,000 rpm The number of revolutions per minute that the engine will turn at while the genera- tor is producing voltage at the rated frequency. Note In normal direct drive applications the following are typical settings. These values will vary if a transmission is used. 60Hz = 1800 RPM 50Hz = 1500 RPM Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 139/179 Counter / Real Time Clock ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ NOTE The parameters for this control are grouped together in blocks to permit navigation through the large number of configuration screens more rapidly. Selecting "YES" or "NO" has no effect whether or not control or monitoring is carried out for the parameters located in that block. Selecting "YES" or "NO" only determines if the individual parameters may be accessed and changed or are bypassed. Parameter 277 Configure counters YES Configuration of the counters YES/NO The counters are configured in this block of parameters. This parameter has the fol- lowing effects: YES ..............The parameters in this block are displayed and can either be viewed ("Select" button), or modifications can be made to the parameters ("Cursor→", "Digit↑" or "Select" buttons). NO................The parameters in this block are not displayed, cannot be modified, and are skipped. Maintenance Call Parameter 278 Service interval in 0000h Counter; maintenance call 0 to 9,999 h A maintenance counter may be desired to alert the operator that the generator has run for a specified number of hours and preventive maintenance should be per- formed. This parameter defines the length of the time period for the maintenance call. This timer functions as a count down timer. When this time expires, a message is issued (F1 class alarm) to alert the operator. Note The maintenance call counter may be disabled, preventing the maintenance alarm from being issued, by configuring the time for 0000h. Proceed as follows to acknowledge the maintenance call: • After the maintenance interval has expired, the message "Service" is displayed, the alarm LED is flashing, and the horn (if present) is enabled. • The horn may be silenced by pressing the RESET button. The maintenance call may not be acknowl- edged at this point in time. • The maintenance will be performed now. • After successful maintenance, acknowledge the message by navigating to the display screen "Service in 000h" using the "Select" button. • Press and hold the "Digit" button for 10 seconds. • The time remaining in the new maintenance interval is displayed, but the message "Service" remains active. • Acknowledge the message by pressing the RESET button. NOTE If a maintenance is to be performed before the maintenance interval expires, the new maintenance in- terval may also be reset as described bove. Manual 37365A GCP-30 Series Packages - Genset Control Page 140/179 © Woodward Operating Hours Counter NOTE If the unit is equipped with Option SC10, and the MDEC or J1939 coupling is enabled as well, the oper- ating hours will be taken over from the engine control unit. Please refer to manual 37382 for further in- formation. Parameter 279 Set oper.hours counter 00000h Counter; operating hours counter 0 to 65,000 h This parameter can be used to specify the number of hours an engine has been in operation. This permits the user to display the correct number of engine hours if the controller is retrofitted to an older engine or the controller is replacing an older controller. NOTE If the operating hours counter is to be changed from the factory default value, the controller must be in code level CS2 before the change can be made. For safety reasons, the counter is set in a 2-step se- quence. The following sequence applies: Step 1: Configure new value -- Set and store the desired operating hours Step 2: Integrate the new operating hours -- Terminate the configuration mode and switch to AUTOMATIC mode -- Display the operating hours -- Press and hold the "Digit" button for at least 5 seconds. Start Counter Parameter 280 Set start counter 00000 Counter; number of engine starts 0 to 32,000 The start counter is used to display how many starts of the engine have been at- tempted. Following each starting attempt (successful or not) the start counter is in- creased by one. This parameter permits the user to display the correct number of starts if this controller is retrofitted to an older engine, a starter is replaced, or this controller is replacing an older controller. Only maintenance personnel should configure the start counter! NOTE If the engine start counter is to be changed from the factory default value, the controller must be in code level CS2 before the change can be made. For safety reasons, the counter is set in a 2-step se- quence. The following sequence applies: Step 1: Configure new value -- Set and store the desired number of starts Step 2: Integrate the new number of starts -- Terminate the configuration mode and switch to AUTOMATIC mode -- Display the number of engine starts -- Press and hold the "Digit" button for at least 5 seconds Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 141/179 kWh Counter Parameter 281 kWh counter set in --- Counter; power measurement scaling kWh/MWh The power produced may be measured in kWh or MWh. The user defined which scale is desired for the controller with this parameter. Parameter 282 kWh counter set 00000--- Counter; kWh 0 to 65,500 kWh/MWh The kWh/MWh counter (depending on Parameter 281) is used to display how much power the generator has produced. This parameter permits the user to display the correct kWh/MWh if this controller retrofitted to an older generator or this con- troller is replacing an older controller. NOTE If the kWh counter is to be changed from the factory default value, the controller must be in code level CS2 before the change can be made. The counter is set in a two-step procedure due to safety reasons. The following proceeding is valid: Step 1: Configure new value -- Set and store the desired counter values for the parameters 293 and 294 Step 2: Integrate the new value -- Terminate the configuration mode and change to AUTOMATIC mode -- Display the kWh counter -- Press and hold the "Digit" button for at least 5 seconds Manual 37365A GCP-30 Series Packages - Genset Control Page 142/179 © Woodward Real Time Clock (XPD, XPQ) NOTE If multiple GCP control units are on a common CAN bus, all clocks are synchronized daily at 12:00 o'clock (noon) to the time of the control with the lowest CAN bus ID/generator number (Parameter 4). This makes it essential that each GCP has a different control number. Parameter 283 Time 00:00 Real time clock; time Setting of the hours and minutes of the internal real time clock. Hour 00 0th hour of the day (midnight) 01 1st hour of the day ... ... 23 23rd hour of the day Minute 00 0th minute of the hour 01 1st minute of the hour ... ... 59 59th minute of the hour Parameter 284 Year,month 00,01 Real time clock; year/month Setting the year and month of the internal real time clock. Year 99 Year 1999 00 Year 2000 01 Year 2001 ... ... Month 01 January 02 February ... ... 12 December Parameter 285 Day/weekday 01/1 Real time clock; day/day of week Setting of the day and weekday of the internal real time clock. Day 01 1st of the month 02 2nd of the month ... ... 31 31st of the month, if available Weekday 1 Monday 2 Tuesday ... ... 7 Sunday Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 143/179 Current Slave Pointer A current slave pointer, which records and stores the maximum generator current, is implemented in the control. The display of the maximum generator current can be selected in the Automatic mode by pressing the "Mes- sage" button. The following screen appears in the display: Parameter 286 000 000 000 000 max. Gen.current Current slave pointer; display of the maximum generator current The maximum generator current in each phase is displayed. Reset: Pressing and holding the "reset" button for 3 seconds while the current slave pointer screen is being displayed will reset the memory. Manual 37365A GCP-30 Series Packages - Genset Control Page 144/179 © Woodward Chapter 4. Commissioning DANGER - HIGH VOLTAGE When commissioning the control, please observe all safety rules that apply to the handling of live equipment. Ensure that you know how to provide first aid in the event of an uncontrolled release of en- ergy and that you know where the first aid kit and the nearest telephone are. Never touch any live com- ponents of the system or on the back of the system: L I F E T H R E A T E N I N G WARNING Only a qualified technician may commission the unit. The "EMERGENCY-STOP" function must be op- erational prior to commissioning of the system and must not depend on the unit for its operation. WARNING A discrete Input assigned to an "Emergency Stop" function is only a signaling input. This input may only be used to signal that an external emergency stop button has been actuated. According to EN 60204, this input is not approved to be used as the emergency stop function. The emergency stop func- tion must be implemented external to the control and cannot rely on the control to function properly. CAUTION Prior to commissioning ensure that all measuring devices are connected in correct phase sequence. The connect command for the unit circuit breaker must be disconnected at the unit circuit breaker. The field rotation must be monitored for proper rotation. Any absence of or incorrect connection of voltage measuring devices or other signals may lead to malfunctions and damage the unit, the engine, and/or components connected to the unit! Commissioning Procedure: 1. After wiring the unit and ensuring all voltage-measuring devices are phased correctly, apply the control system voltage (i.e. 12/24 Vdc). The "Operation" LED will illuminate. 2. Simultaneously pressing the "Digit↑" and "Cursor→" buttons will enable the configuration mode. After entering the proper access code number, the unit may be configured according to the application require- ments (refer to the parameters section). 3. After applying the measuring variables, the unit will display the measured values. These values should be confirmed with a calibrated measuring instrument. 4. The initial start of the engine should be performed in the MANUAL operation mode (press the "MAN- UAL" button). Start the engine ("START" button) and then stop it ("STOP" button). All generator- measured values must be checked. Any alarm messages should be investigated as well. 5. Check the automatic start sequence by means of the TEST operation mode (press the "TEST" push- button). Test the protections that result in alarms with shutdowns. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 145/179 6. "AUTO" operation mode (press the "AUTO" button): Applying the automatic control inputs and the en- gine start request can now carry out automatic starting with subsequent synchronization. Check synchronization: Disable the GCB from being able to close onto the two systems. Check the gen- erator and the generator busbar rotating fields. Check the connect command with a zero voltmeter (deter- mination of the phase angle) at the generator power circuit breaker (GCB). If several correct synchroniz- ing pulses have been output, switch the operation mode to "STOP" and re-enable the GCB closing circuit ("Command: close GCB") with the engine in "STOP" mode. 7. If steps 1 through 6 have been carried out successfully, parallel operations may be commenced. It is rec- ommended to start with a constant power/baseload operation (approx. 25 % of the generator rated power) initially. While this operation is being carried out, the displayed measured values must be verified. Test the GCB shutdown. Check the real power controller and if necessary the power factor controller for proper operation. Enter various set point values and verify proper operation. 8. If the mains parallel operation performs in a satisfactory manner, the synchronization of the mains power circuit breaker (MCB) must be checked: A power failure in the system must be simulated or observed by the controller. During a mains parallel operation, change the operation mode from AUTOMATIC to MANUAL. Open the MCB ("MCB ON" LED will turn off). Press the AUTOMATIC mode button to return the controller back to the AUTO- MATIC operation mode. Check the generator busbar and the mains rotating field. Disable the MCB from being able to close onto the two systems. Check the connect command with a zero voltmeter (determination of the phase angle) at the MCB. If several correct synchronizing pulses have been output, switch the operation mode to "STOP" and re-enable the GCB closing circuit ("Command: close MCB") with the engine in "STOP" mode. 9. Test the emergency power operation functions NOTE The MCB and GCB reply messages are processed as negative logic. When the breaker is open, the breaker reply (terminal 4/54) input should be energized (12/24Vdc). When the breaker is closed, the cor- responding breaker reply input is de-energized (0Vdc). The circuit breaker auxiliary contacts should be configured as normally closed! The CB aux contacts should be configured as normally closed! Refer to the description of the auxiliary and control inputs starting on page 10. It is vital that these replies be connected! Electrical insulation between voltage supply and discrete control and feedback inputs: By the use of corre- sponding external wiring, the common reference point of the discrete inputs can be electrically isolated from the supply voltage (0 V, terminal 2). This is necessary if the discrete inputs are not to be triggered with 24 Vdc and electrical isolation of the control voltage (e. g. 220 Vdc, 220 Vac) from the supply voltage must be insured. Manual 37365A GCP-30 Series Packages - Genset Control Page 146/179 © Woodward Appendix A. Analog output manager (XPD, XPQ) NOTE The functions listed below can only be output correctly if the existing version of the control permits this. Func- tion Output Value Input of the two limit values 0 The analog output is disabled. N/A N/A 1 Actual generator real power [dimen- sionless] 0% Lower power limit (can also be negative) e.g. -0050 kW 100% Upper power limit (can also be negative) e.g. 0200 kW 2 Actual generator power factor ϕ [e.g. (-070 to +080) /100] (Definition at end of Table) [dimen- sionless] 0% Lower interval to power factor ϕ=1 e.g. -0030 corresponds to c0.70 100% Upper interval to power factor ϕ=1 e.g. 0030 corresponds to i0.70 3 Actual generator frequency [Hz∗100] 0% Lower frequency e.g. 0000 corresponds to 00.00 Hz. 100% Upper frequency e.g. 7000 corresponds to 70.00 Hz. 4 Actual generator reactive power [kvar] 0% capacitive reactive power (negative) e.g -0100 kvar 100% inductive reactive power (positive) e.g. +0100 kvar 5 Rated power of all generators connected to generator busbar minus nominal actual power [kW] 6 Total actual power of all genera- tors connected to generator bus- bar [kW] 0% Lower power (can also be negative) e.g.-0050 kW 100% Upper power (can also be negative) e.g. 0200 kW 7 Generator apparent current in L1 [A] 8 Generator apparent current in L2 [A] 9 Generator apparent current in L3 [A] 0% Lower current output e.g. 0000 A 100% Upper current output e.g. 500 A 10 Speed via MPU [min-1] 0% Lower speed e.g. 0000 rpm 100% Upper speed e.g. 3000 rpm Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 147/179 Func- tion Output Value Input of the two limit values 11 Analog input [T1] [°C] or [°F] or freely scaleable 12 Analog input [T2] [°C] or [°F] or freely scaleable 13 Analog input [T3] [°C] or [°F] or freely scaleable 14 Analog input [T4] [°C] or [°F] or freely scaleable 15 Analog input [T5] [°C] or [°F] or freely scaleable 16 Analog input [T6] [Bar] or [PSI] or freely scaleable 17 Analog input [T7] [Bar] or [PSI] or freely scaleable 18 --free-- [°C] or [°F] or freely scaleable 0% Lower measured value e.g. 0000 corresponds to 000 °C at temperature input 100% Upper measuring value e.g. 0255 corresponds to 255 °C at temperature input 0% Lower measured value e.g. 0000 corresponds to 00.0 bar oil pressure 100% Upper measured value e.g. 0100 corresponds to 10.0 bar oil pressure 19 Actual mains interchange (im- port/export) real power [kW] 0% lower power e.g. -0800 kW 100% upper power e.g. 0800 kW 20 Mains apparent current in L1 [A] 0% Lower current output e.g. 0000 A 100% Upper current output e.g. 500 A 21 Mains power factor ϕ [e. g. (-070 to +080) /100] (Definition at end of Table) [dimen- sionless] 0% Lower interval to power factor ϕ=1 e.g. -0030 corresponds to k0,70 100% Upper interval to power factor ϕ=1 e.g. 0030 corresponds to i0,70 22 Actual mains reactive power [kvar] 0% capacitive reactive power (negative) e.g. -0100 kvar 100% inductive reactive power (positive) e.g. +0100 kvar 23 --free-- 24 Generator real power set point, which is currently issued by the ramp of the real power controller (Parameter 75) The actual value of the generator real power is issued in isolated operation [kW] 0% lower set point e.g. 0000 kW 100% higher set point e.g. 0800 kW Manual 37365A GCP-30 Series Packages - Genset Control Page 148/179 © Woodward The designation 0 % stands for either 4 mA or 0 mA; the designation 100 % stands for 20 mA. The values may also be assigned with prefixes (see relay manager function 1). Definition of power factor cos ϕ scaling: According to the scaling of the analog output, the power factor can be output within the range from capacitive values ranging from c0.00 via power factor ϕ = 1 to inductive values up to i0.00. Scalable range (0..20 mA) eg. k0.70..1.00..i0.70 Power factor = 1,00 k 0.00 Capacitive Lower distance eg. 0030 Higher distance eg. 0030 i 0.00 Inductive Figure 4-1: Analog outputs - power factor scaling Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 149/179 Appendix B. Relay Manager No. Output Explanation 1 Alarm class 1 2 Alarm class 2 3 Alarm class 3 4 Firing speed reached (engine running) 5 Mains failure; undelayed The function reacts according to the status of the breakers. The condi- tions described in chapter "Emer- gency power" apply. 6 Battery undervoltage 7 AUTOMATIC operation mode 8 MANUAL operation mode 9 TEST operation mode 10 STOP operation mode 11 Generator undervoltage 12 Generator overvoltage 13 Generator underfrequency 14 Generator overfrequency 15 Generator overcurrent level 1 16 "Synchronization GCB" or "Connect GCB" time monitoring alarm 17 Engine start failure 18 Generator unbalanced load 19 Generator overload 20 Generator reverse/reduced power 21 Readiness for operation Output via relay manager 22#1 Analog input [T1], level 1 23#1 Analog input [T1], level 2 24#1 Analog input [T2], level 1 25#1 Analog input [T2], level 2 26#1 Analog input [T3], level 1 27#1 Analog input [T3], level 2 28#1 Analog input [T4], level 1 29#1 Analog input [T4], level 2 30#1 Analog input [T5], level 1 33#1 Analog input [T5], level 2 32#1 Analog input [T6], level 1 33#1 Analog input [T6], level 2 34#1 Analog input [T7], level 1 35#1 Analog input [T7], level 2 36 Discrete input [D01] 37 Discrete input [D02] 38 Discrete input [D03] 39 Discrete input [D04] 40 Discrete input [D05] 41 Discrete input [D06] 42 Discrete input [D07] 43 Discrete input [D08] 44 Discrete input [D09] 45 Discrete input [D10] 46 Discrete input [D11] 47 Discrete input [D12] 48 Discrete input [D13] 49 Discrete input [D14] 50 Discrete input [D15] #1 (XPD, XPQ Packages only) Manual 37365A GCP-30 Series Packages - Genset Control Page 150/179 © Woodward No. Output Explanation 51 Discrete input [D16] 52 Auxiliary services i.e. prelube/cooling pumps 53#1 --Internal-- 54 Centralized alarm (class F1, F2, or F3 alarm; enabled until acknowledge- ment) 55 TEST or AUTOMATIC operation mode selected 56 Generator power watchdog, level 1 57 MCB is closed 58 GCB is closed 59#2 Interface fault Y1/Y5 60 Mains parallel operation is desired: disable interlock of GCB <> MCB 61 Overcurrent I/t or generator overcurrent, level 2 62 Introduce load-shedding: Connection / synchronization of GCB is carried out or circuit breaker is closed Signal is enabled prior to connection / synchronization and remains en- abled after circuit breaker is closed. 63 MCB connected / synchronization carried out or circuit breaker is closed Signal is enabled prior to connection / synchronization and remains en- abled after circuit breaker is closed. 64 Overspeed via Magnetic Pickup 65 Emergency power is active 66 Shutdown malfunction 67 Power watchdog for power supplied by the mains 68 Maintenance call 69 MPU speed/generator frequency mismatch The monitored generator frequency and the engine speed from the MPU are different 70 "Synchronization MCB" or. "Connect MCB" time monitoring alarm. 71 GCB synchronization will be performed 72 MCB synchronization will be performed 73 Lamp test active 74 Malfunction "Reply: GCB is open" - fault on closing The GCB cannot be closed after 5 at- tempts. 75 Malfunction "Reply: MCB is open" - fault on closing The MCB cannot be closed after 5 attempts. 76 Malfunction "Reply: GCB is open" - fault on opening 2 s following the "Command: open GCB" a reply continues to be de- tected. 77 Malfunction "Reply: MCB is open" - fault on opening 2 s following the "Command: open MCB" a reply continues to be de- tected. 78 Power supplied by the mains not able to achieve zero power (P>0<P) In the event of interchange synchro- nization, the zero incoming power cannot be attained. The MCB is pre- vented from opening as a result of this. Reset via acknowledgment. 79 Connect time for dead bus start exceeded 80 Generator power watchdog, level 2 #1 special versions only #2 (Option SC10) Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 151/179 No. Output Explanation 81 CCW mains rotating field 82 Engine enable Set engine enable As long as there is a start request for the engine and during cool down, the operation of the engine is enabled (i.e. AUTOMATIC operation mode and discrete input 3/5, emergency power, start via interface, manual start, etc. are energized/enabled). Reset engine enable The engine enable will be reset if a start request is no longer present due to a manual stop, an F3 alarm class, or during the engine stop time, and if "zero" speed is detected and a start request is not present or coasting is not taking place. 83 "RESET" button pressed 84 Preheating/firing ON (pre-assigned to relay [7]) pre-assigned default value 85 Group alarm of class F1, F2, or F3 alarm (pre-assigned to relay [8]) pre-assigned default value Horn: after 2 min independent shut- off 86#1 --Internal-- 87#1 --Internal-- 88 Generator voltage and/or frequency are not in range (undelayed) 89 Busbar voltage and/or frequency are not in range (undelayed) 90#1 --Internal-- 91 MPU detects nominal speed (+/-6 %) 92 Mains voltage fault via protection device 93 Mains frequency fault via protection device 94 Phase/vector shift fault via protection device 95#1 --Internal-- 96 Delayed engine monitoring time exceeded 97 Sprinkler mode is active (included Sprinkler coasting) 98#2 IKD1 discrete input 1 99#2 IKD1 discrete input 2 100#2 IKD1 discrete input 3 101#2 IKD1 discrete input 4 102#2 IKD1 discrete input 5 103#2 IKD1 discrete input 6 104#2 IKD1 discrete input 7 105#2 IKD1 discrete input 8 106#2 IKD2 discrete input 1 107#2 IKD2 discrete input 2 108#2 IKD2 discrete input 3 109#2 IKD2 discrete input 4 110#2 IKD2 discrete input 5 111#2 IKD2 discrete input 6 112#2 IKD2 discrete input 7 113#2 IKD2 discrete input 8 #1 special versions only #2 (Option SC10) Manual 37365A GCP-30 Series Packages - Genset Control Page 152/179 © Woodward No. Output Explanation 114#1 Three-position controller: n+ / f+ / P+ 115#1 Three-position controller: n- / f- / P- 116#1 Three-position controller: V+ / Q+ 117#1 Three-position controller: V- / Q- (use an external Resistive/Capacitive protection circuit) 118#2 --Internal-- 119#3 Wire break Analog input [T1] 120#3 Wire break Analog input [T2] 121#3 Wire break Analog input [T3] 122#3 Wire break Analog input [T4] 123#3 Wire break Analog input [T5] 124#3 Wire break Analog input [T6] 125#3 Wire break Analog input [T7] 126#2 --Internal-- 127#2 --Internal-- 128#2 --Internal-- 129#4 Failure lambda probe 130#4 Lambda controller ON 131 Fuel relay is ON / stop relay is ON / gas valve is ON 132#2 --Internal-- 133 Idle mode active 134#4 IKD1 communication OK 135#4 IKD2 communication OK 136#4 ST3 communication OK 137#4 MDEC communication OK 138#4 J1939 communication OK 139 Phase rotation generator and mains mismatch 140 Direction of rotation, mains voltage: CW 141 Direction of rotation, generator voltage: CCW 142 Direction of rotation, generator voltage: CW 143 Starter engaged (cranking) 144 GCB is to be opened 145#2 --Internal-- 146 Parallel operation CB from V4.3010 147#2 --Internal-- 148 Unintended stop from V4.3010 149 Interface error X1/X5 from V4.3010 150#4 ECU yellow alarm from V4.3030 151#4 ECU red alarm from V4.3030 152#2 --Internal-- 153#2 --Internal-- 154#2 --Internal-- 155#2 --Internal-- 156#2 --Internal-- 157 Engine cool down from V4.3046 158 Mains settling time is running from V4.3046 #1 (BPQ, XPQ Package) #2 special versions only #3 (XPD, XPQ Package) #4 (Option SC10) NOTE Relay Manager functions with a number above 128 may only be configured with LeoPC1 Version 3.0.015 or later. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 153/179 Appendix C. Interface Protocol NOTE Only selected parameters are transmitted via the interface depending on the Package configuration. Transmission Telegram ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ MUX No. Contents (words) Unit Note 0/1 1 Generator voltage delta V12 V × 10UGNEXPO 0/2 2 Generator frequency f Hz × 100 0/3 3 Actual generator real power P W × 10PGNEXPO 1/1 4 Exponents High Byte: PGNEXPO Generator power Low Byte: UGNEXPO Generator voltage 1/2 5 Real power set point value see note PGNEXPO10800.2 PGNWDW ×× 1/3 6 Conversion factor Steps Æ kW PGNWD (internal) 2/1 7 Busbar voltage delta V12 V × 10UGSSEXPO 2/2 8 Mains voltage delta V12 V × 10UNTEXPO 2/3 9 Currently present alarm class Bit 15 = 1 --Internal-- Bit 14 = 1 --Internal-- Bit 13 = 1 \ Bit 12 = 1 / Alarm class F2 or alarm class F3 Bit 11 = 1 \ Bit 10 = 1 / LED "Alarm" flashes Bit 9 = 1 --Internal-- Bit 8 = 1 --Internal-- Bit 7 = 1 \ Bit 6 = 1 / Alarm class F3 Bit 5 = 1 \ Bit 4 = 1 / Alarm class F2 Bit 3 = 1 \ Bit 2 = 1 / Alarm class F1 Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 1 = 1 \ Bit 0 = 1 / Alarm class F0 3/1 10 Control register 2 Bit 15 = 1 \ Bit 14 = 1 / Terminal 3 is energized Bit 13 = 1 \ Bit 12 = 1 / Terminal 5 is energized Bit 11 = 1 \ Bit 10 = 1 / --Internal-- Bit 9 = 1 \ Bit 8 = 1 / Terminal 53 is energized DI "Enable MCB" Bit 7 = 1 \ Bit 6 = 1 / Terminal 4, reply: GCB is closed Bit 5 = 1 \ Bit 4 = 1 / Terminal 54, reply: MCB is closed Bit 3 = 1 \ Bit 2 = 1 / Terminal 6 is energized Bit 1 = 1 \ Bit 0 = 0 / Shutdown power reached Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 1 = 0 \ Bit 0 = 1 / Shutdown power not reached Manual 37365A GCP-30 Series Packages - Genset Control Page 154/179 © Woodward MUX No. Contents (words) Unit Note 3/2 11 Actual mains interchange (import/export) real power W × 10PNTEXPO 3/3 12 Control register 1 Bit 15 = 1 \ Bit 14 = 1 / Starting enabled (in isolated operation or mains parallel operation) Bit 13 = 1 \ Bit 12 = 1 /--Internal-- Bit 11 = 1 \ Bit 10 = 1 / Execution of acknowledgment of a class F2/F3 alarm Bit 9 = 1 \ Bit 8 = 1 / Execution of acknowledgment of a class F1 alarm Bit 7 = 1 \ Bit 6 = 1 /--Internal-- Bit 5 = 1 \ State of generator busbar 1 = OK Bit 4 = 1 /--Internal-- Bit 3 = 1 \ Bit 2 = 1 /--Internal-- Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 1 = 1 \ Bit 0 = 0 /--Internal-- 4/1 13 Alarm message IKD (SC10) Bit 15 = 1 Failure DI8 of the IKD1.1 Bit 14 = 1 Failure DI7 of the IKD1.1 Bit 13 = 1 Failure DI6 of the IKD1.1 Bit 12 = 1 Failure DI5 of the IKD1.1 Bit 11 = 1 Failure DI4 of the IKD1.1 Bit 10 = 1 Failure DI3 of the IKD1.1 Bit 9 = 1 Failure DI2 of the IKD1.1 Bit 8 = 1 Failure DI1 of the IKD1.1 Bit 7 = 1 --Internal-- Bit 6 = 1 --Internal-- Bit 5 = 1 --Internal-- Bit 4 = 1 --Internal-- Bit 3 = 1 --Internal-- Bit 2 = 1 --Internal-- Bit 1 = 1 --Internal-- Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 0 = 1 --Internal-- 4/2 14 Internal alarm 6 Bit 15 = 1 MPU plausibility fault Bit 14 = 1 Engine shutdown malfunction Bit 13 = 1 Time overrun, GCB dead bus switching Bit 12 = 1 --Internal-- Bit 11 = 1 MCB open switch malfunction Bit 10 = 1 GCB open switch malfunction Bit 9 = 1 MCB synchronization time monitoring Bit 8 = 1 GCB synchronization time monitoring Bit 7 = 1 Range alarm analog input [T8] Bit 6 = 1 Range alarm analog input [T7] Bit 5 = 1 Range alarm analog input [T6] Bit 4 = 1 Range alarm analog input [T5] Bit 3 = 1 Range alarm analog input [T4] Bit 2 = 1 Range alarm analog input [T3] Bit 1 = 1 Range alarm analog input [T2] Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 0 = 1 Range alarm analog input [T1] 4/3 15 Generator voltage delta V23 V × 10UGNEXPO 5/1 16 Generator voltage delta V31 V × 10UGNEXPO 5/2 17 Generator voltage wye V1N V × 10UGNEXPO 5/3 18 Generator voltage wye V2N V × 10UGNEXPO 6/1 19 Generator voltage wye V3N V × 10UGNEXPO Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 155/179 MUX No. Contents (words) Unit Note 6/2 20 Configuration [T1]-[T4] Display in ... #1# °C °F bar/10 psi/10 % no unit Analog input [T4] Bit 15 = 0 0 0 1 1 1 0 Bit 14 = 0 1 1 0 0 1 0 Bit 13 = 0 0 1 0 1 0 1 Bit 12 = 0 1 0 1 0 0 1 Analog input [T3] Bit 11 = 0 0 0 1 1 1 0 Bit 10 = 0 1 1 0 0 1 0 Bit 9 = 0 0 1 0 1 0 1 Bit 8 = 0 1 0 1 0 0 1 Analog input [T2] Bit 7 = 0 0 0 1 1 1 0 Bit 6 = 0 1 1 0 0 1 0 Bit 5 = 0 0 1 0 1 0 1 Bit 4 = 0 1 0 1 0 0 1 Analog input [T1] Bit 3 = 0 0 0 1 1 1 0 Bit 2 = 0 1 1 0 0 1 0 Bit 1 = 0 0 1 0 1 0 1 #1#: The analog input is not available or he has been configured either as real power set point value or as mains (import/export) real power value. Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 0 = 0 1 0 1 0 0 1 6/3 21 Engine speed measured via the Pickup min-1 7/1 22 Generator current in L1 A × 10IGNEXPO 7/2 23 Generator current in L2 A × 10IGNEXPO 7/3 24 Generator current in L3 A × 10IGNEXPO 8/1 25 Actual generator reactive power var × 10PGNEXPO positive = inductive 8/2 26 Generator power factor cos ϕ Example: FF9EH cos ϕ = c 0.98 (capacitive/lagging) FF9DH cos ϕ = c 0.99 (capacitive/lagging) 0064H cos ϕ = 1.00 0063H cos ϕ = i 0.99 (inductive/leading) 0062H cos ϕ = i 0.98 (inductive/leading) 8/3 27 Current reserve power in the system kW 9/1 28 Current actual real power in the system kW 9/2 29 Number of participants on the CAN bus 9/3 30 H.B. Mains status L.B. Generator status FFH Voltage and frequency available 00H Voltage and frequency not available 10/1 31 Exponents High Byte: IGNEXPO Generator current Low Byte: --- free 10/2 32 Busbar frequency Hz × 100 Manual 37365A GCP-30 Series Packages - Genset Control Page 156/179 © Woodward MUX No. Contents (words) Unit Note 10/3 33 Configuration [T5]-[T8] Display in ... #1# °C °F bar/10 psi/10 % no unit Analog input [T8] Bit 15 = 0 0 0 1 1 1 0 Bit 14 = 0 1 1 0 0 1 0 Bit 13 = 0 0 1 0 1 0 1 Bit 12 = 0 1 0 1 0 0 1 Analog input [T7] Bit 11 = 0 0 0 1 1 1 0 Bit 10 = 0 1 1 0 0 1 0 Bit 9 = 0 0 1 0 1 0 1 Bit 8 = 0 1 0 1 0 0 1 Analog input [T6] Bit 7 = 0 0 0 1 1 1 0 Bit 6 = 0 1 1 0 0 1 0 Bit 5 = 0 0 1 0 1 0 1 Bit 4 = 0 1 0 1 0 0 1 Analog input [T5] Bit 3 = 0 0 0 1 1 1 0 Bit 2 = 0 1 1 0 0 1 0 Bit 1 = 0 0 1 0 1 0 1 #1#: The analog input is not available or he has been configured either as real power se tpoint value or as mains (import/export) real power value. Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 0 = 0 1 0 1 0 0 1 11/1 34 Mains voltage delta V23 V × 10UNTEXPO 11/2 35 Mains voltage delta V31 V × 10UNTEXPO 11/3 36 Mains voltage wye V1N V × 10UNTEXPO 12/1 37 Mains voltage wye V2N V × 10UNTEXPO 12/2 38 Mains voltage wye V3N V × 10UNTEXPO 12/3 39 Mains frequency out off VN12/VN23/VN31 Hz × 100 13/1 40 Mains current in L1 A × 10INTEXPO 13/2 41 Mains reactive power var × 10PNTEXPO 13/3 42 Mains power factor ϕ Example: FF9EH cos ϕ = c 0.98 (capacitive/lagging) FF9DH cos ϕ = c 0.99 (capacitive/lagging) 0064H cos ϕ = 1.00 0063H cos ϕ = i 0.99 (inductive/leading) 0062H cos ϕ = i 0.98 (inductive/leading) 14/1 43 Exponents High Byte: PNTEXPO Mains power Low Byte: UNTEXPO Mains voltage 14/2 44 Exponents High Byte: INTEXPO Mains current Low Byte: USSEXPO Busbar voltage 14/3 45 Engine operating hours ( H.W.) h × 216 Double word 15/1 46 Engine operating hours ( L.W.) h 15/3 47 Hours until next maintenance h 15/3 48 Engine start number Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 157/179 MUX No. Contents (words) Unit Note 16/1 49 Operation mode Bit 15 = 1 LOAD TEST operation mode Bit 14 = 1 STOP operation mode Bit 13 = 1 TEST operation mode Bit 12 = 1 MANUAL operation mode Bit 11 = 1 AUTOMATIC operation mode Bit 10 = 1 --Internal-- Bit 9 = 1 --Internal-- Bit 8 = 1 --Internal-- Bit 7 = 1 Bit 6 = 0 Emergency power is ON Bit 7 = 0 Bit 6 = 1 Emergency power is OFF Bit 5 = 1 Bit 4 = 1 Delayed engine monitoring is ON Bit 3 = 1 Bit 2 = 1 Cool down expired Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 1 = 1 Bit 0 = 1 --Internal-- 16/2 50 Generator active energy ( H.W.) kWh × 216 Double word 16/3 51 Generator active energy (L.W.) kWh 17/1 52 Battery voltage V × 10 17/2 53 Internal alarm 1 Bit 15 = 1 \ Bit 14 = 1 /F3: Generator overfrequency 1 Bit 13 = 1 \ Bit 12 = 1 /F3: Generator underfrequency 1 Bit 11 = 1 \ Bit 10 = 1 /F3: Generator overvoltage 1 Bit 9 = 1 \ Bit 8 = 1 /F3: Generator undervoltage 1 Bit 7 = 1 \ Bit 6 = 1 /--Internal-- Bit 5 = 1 \ Bit 4 = 1 /F1: Battery undervoltage Bit 3 = 1 \ Bit 2 = 1 /F3: Generator overload Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 1 = 1 \ Bit 0 = 1 /F3: Generator reverse power 17/3 54 Internal alarm 2 Bit 15 = 1 \ Bit 14 = 1 /F0: Mains overfrequency Bit 13 = 1 \ Bit 12 = 1 /F0: Mains underfrequency Bit 11 = 1 \ Bit 10 = 1 /F0: Mains overvoltage Bit 9 = 1 \ Bit 8 = 1 /F0: Mains undervoltage Bit 7 = 1 \ Bit 6 = 1 /Interface fault X1-X5 Bit 5 = 1 GCB opened; "Time add-on ramp" ex- pired Bit 4 = 1 --Internal-- Bit 3 = 1 \ Bit 2 = 1 /--Internal-- Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 1 = 1 \ Bit 0 = 1 /F0: Mains phase/vector jump Manual 37365A GCP-30 Series Packages - Genset Control Page 158/179 © Woodward MUX No. Contents (words) Unit Note 18/1 55 Internal alarm 3 Bit 15 = 1 \ Bit 14 = 1 / F3: Time-overcurrent, level 2 or inverse time-overcurrent, IEC255 Bit 13 = 1 \ Bit 12 = 1 /F3: Generator overspeed (Pickup) Bit 11 = 1 \ Bit 10 = 1 /Import power 0 kW not reached Bit 9 = 1 \ Bit 8 = 1 /F3: Generator unbalanced load Bit 7 = 1 \ Bit 6 = 1 /F3: Time-overcurrent, level 1 Bit 5 = 1 \ Bit 4 = 1 /Interface fault Y1-Y5 Bit 3 = 1 \ Bit 2 = 1 /F1: Maintenance call Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 1 = 1 \ Bit 0 = 1 /Start failure 18/2 56 Internal alarm 4 Bit 15 = 1 \ Bit 14 = 1 /F1: Analog input [T1], level 1 Bit 13 = 1 \ Bit 12 = 1 /F3: Analog input [T1], level 2 Bit 11 = 1 \ Bit 10 = 1 /F1: Analog input [T2], level 1 Bit 9 = 1 \ Bit 8 = 1 /F3: Analog input [T2], level 2 Bit 7 = 1 \ Bit 6 = 1 /F1: Analog input [T3], level 1 Bit 5 = 1 \ Bit 4 = 1 /F3: Analog input [T3], level 2 Bit 3 = 1 \ Bit 2 = 1 /F1: Analog input [T4], level 1 Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 1 = 1 \ Bit 0 = 1 /F3: Analog input [T4], level 2 18/3 57 Internal alarm 5 Bit 15 = 1 \ Bit 14 = 1 /F1: Analog input [T5], level 1 Bit 13 = 1 \ Bit 12 = 1 /F3: Analog input [T5], level 2 Bit 11 = 1 \ Bit 10 = 1 /F1: Analog input [T6], level 1 Bit 9 = 1 \ Bit 8 = 1 /F3: Analog input [T6], level 2 Bit 7 = 1 \ Bit 6 = 1 /F1: Analog input [T7], level 1 Bit 5 = 1 \ Bit 4 = 1 /F3: Analog input [T7], level 2 Bit 3 = 1 \ Bit 2 = 1 /--Internal-- Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 1 = 1 \ Bit 0 = 1 /--Internal-- Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 159/179 MUX No. Contents (words) Unit Note 19/1 58 External alarm 1 Bit 15 = 1 \ Bit 14 = 1 /Discrete input [D01] Bit 13 = 1 \ Bit 12 = 1 /Discrete input [D02] Bit 11 = 1 \ Bit 10 = 1 /Discrete input [D03] Bit 9 = 1 \ Bit 8 = 1 /Discrete input [D04] Bit 7 = 1 \ Bit 6 = 1 /Discrete input [D05] Bit 5 = 1 \ Bit 4 = 1 /Discrete input [D06] Bit 3 = 1 \ Bit 2 = 1 /Discrete input [D07] Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 1 = 1 \ Bit 0 = 1 /Discrete input [D08] 19/2 59 External alarm 2 Bit 15 = 1 \ Bit 14 = 1 /Discrete input [D09] Bit 13 = 1 \ Bit 12 = 1 /Discrete input [D10] Bit 11 = 1 \ Bit 10 = 1 /Discrete input [D11] Bit 9 = 1 \ Bit 8 = 1 /Discrete input [D12] Bit 7 = 1 \ Bit 6 = 1 /Discrete input [D13] Bit 5 = 1 \ Bit 4 = 1 /Discrete input [D14] Bit 3 = 1 \ Bit 2 = 1 /Discrete input [D15] Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 1 = 1 \ Bit 0 = 1 /Discrete input [D16] 19/3 60 Internal alarm 7 Bit 15 = 1 --Internal-- Bit 14 = 1 --Internal-- Bit 13 = 1 --Internal-- Bit 12 = 1 --Internal-- Bit 11 = 1 --Internal-- Bit 10 = 1 --Internal-- Bit 9 = 1 --Internal-- Bit 8 = 1 --Internal-- Bit 7 = 1 MCB close malfunction Bit 6 = 1 GCB close malfunction Bit 5 = 1 --Internal-- Bit 4 = 1 --Internal-- Bit 3 = 1 --Internal-- Bit 2 = 1 --Internal-- Bit 1 = 1 --Internal-- Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 0 = 1 Immediate stop 20/1 61 Analog input [T1] The measured value is transmitted. 20/2 62 Analog input [T2] The measured value is transmitted. 20/3 63 Analog input [T3] The measured value is transmitted. 21/1 64 Analog input [T4] The measured value is transmitted. 21/2 65 Analog input [T5] The measured value is transmitted. 21/3 66 Analog input [T6] The measured value is transmitted. 22/1 67 Analog input [T7] The measured value is transmitted. Manual 37365A GCP-30 Series Packages - Genset Control Page 160/179 © Woodward MUX No. Contents (words) Unit Note 22/2 68 Alarm messages IKD2 (SC10) Bit 15 = 1 Failure DI8 of the IKD1.2 Bit 14 = 1 Failure DI7 of the IKD1.2 Bit 13 = 1 Failure DI6 of the IKD1.2 Bit 12 = 1 Failure DI5 of the IKD1.2 Bit 11 = 1 Failure DI4 of the IKD1.2 Bit 10 = 1 Failure DI3 of the IKD1.2 Bit 9 = 1 Failure DI2 of the IKD1.2 Bit 8 = 1 Failure DI1 of the IKD1.2 Bit 7 = 1 --Internal-- Bit 6 = 1 --Internal-- Bit 5 = 1 --Internal-- Bit 4 = 1 --Internal-- Bit 3 = 1 --Internal-- Bit 2 = 1 --Internal-- Bit 1 = 1 --Internal-- Note – On double /fourfold bits the follow- ing is valid: If the indicated bit combination is fulfilled (high byte and low byte) ,the message is active (otherwise inactive). Bit 0 = 1 --Internal-- 22/3 69 LCD-display / Pickup Currently active display message Bit 15 = x Bit 14 = x Bit 13 = x Bit 12 = x Bit 11 = x Bit 10 = x Bit 9 = x Bit 8 = x A number is transmitted, please consult the table for the meaning of the num- ber 69 of the telegram "Monitoring of the active display". Pickup Bit 7 = 1 Bit 6 = 1 Bit 5 = 1 Bit 4 = 1 Firing speed reached f > parameter Bit 3 = 1 Bit 2 = 1 Bit 1 = 1 Bit 0 = 1 Speed existing without pickup (pickup = OFF): f > 15 Hz with pickup (pickup = ON): f > 5 Hz UGNEXPO Exponent Generator voltage USSEXPO Exponent Busbar voltage IGNEXPO Exponent Generator current UNTEXPO Exponent Mains voltage PGNEXPO Exponent Generator power PNTEXPO Exponent Mains power PGNWD Step conversion factor Æ kW Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 161/179 Meaning of the number 69 of the telegram " Currently active display message": Number Meaning 0 GCB synchronization 1 MCB synchronization 2 GCB dead bus start 3 MCB dead bus start 4 Crank 5 Start pause 6 Cool down 000s (000s: the remaining time is displayed) 7 Engine stop! 8 Pre-glow 9 Purging operation 10 Initial state 11 Auxiliary prerun 12 Auxiliary post-run 13 Mains settling 000s (000s: the remaining time is displayed) 14 Lambda initial state 15 Sprinkler coasting 16 Ignition 17 --Internal-- 18 --Internal-- 19 --Internal-- 20 --Internal-- 21 --Internal-- 22 --Internal-- 23 --Internal-- 24 Phase rotation incorrect! 25 Start without closing GCB and simultaneous emergency power 26 Start without closing GCB 27 Sprinkler operation (critical mode) and simultaneous emergency power 28 Sprinkler operation (critical mode) 29 Emergency power 30 TEST 31 Load TEST 32 --Internal-- 33 --Internal-- 34 --Internal-- 35 --Internal-- 36 --Internal-- 37 --Internal-- 38 --Internal-- 39 --Internal-- 40 --Internal-- 41 --Internal-- 42 --Internal-- 43 --Internal-- 44 Idle run 45 --Internal-- 46 --Internal-- 47 Power reduction ... 255 No message on the display (basic screen) Manual 37365A GCP-30 Series Packages - Genset Control Page 162/179 © Woodward Receiving Telegram ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ A Gateway GW 4 may be used for remote starting the GCP. The following three data words can be received by the GCP. Refer to the GW 4 manual on how to control several GCP control units. MUX No. Contents (words) Unit Note 1/1 1 Set point value for the generator real power kW with control argument; see below 1/2 2 Set point value for the generator power fac- tor cos ϕ Example: FF9EH cos ϕ = c 0.98 (capacitive/lagging) FF9DH cos ϕ = c 0.99 (capacitive/lagging) 0064H cos ϕ = 1.00 0063H cos ϕ = i 0.99 (inductive/leading) 0062H cos ϕ = i 0.98 (inductive/leading) 1/3 3 Control word Bit 15 = 1 --Internal-- Bit 14 = 1 --Internal-- Bit 13 = 1 --Internal-- Bit 12 = 1 --Internal-- Bit 11 = 1 --Internal-- Bit 10 = 1 --Internal-- Bit 9 = 1 --Internal-- Bit 8 = 1 --Internal-- Bit 7 = 1 --Internal-- Bit 6 = 1 --Internal-- Bit 5 = 1 --Internal-- Bit 4 = 1 Remote acknowledgement Bit 3 = 1 Always "0" Bit 2 = 1 Always "0" Bit 1 = 1 Remote stop (high priority) Bit 0 = 1 Remote start Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 163/179 CAN Bus Structure ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Transmission Telegram The data of the following table can be handled by a Gateway GW 4 or a PLC and can be transferred to other communication busses. A GCP is sending the data via circular CAN messages. The transmitting rate of this communication is 125 kBaud. The CAN ID, on which the GCP is sending, is calculated as follows: CAN ID = 800 + item/generator number (or 320 + ID/generator number) (The ID number, Parameter 4, is adjustable and influences the CAN ID directly on which the item sends the visualization message). A visualization message, which is sent out of a GCP, has 8 Bytes and is assembled as follows: Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 H‘DD MUX num- ber data word 1 High-Byte data word 1 Low Byte data word 2 High-Byte data word 2 Low Byte data word 3 High-Byte data word 3 Low Byte In a visualization message the byte 0 is always used to show the hexadecimal value DD. This one defines the message as a visualization message. As the complete transmission telegram of the GCP includes more than three words byte 1 sends an additional MUX number starting with 0. Therefore it is theoretically possible to send (256 × 3 = 768) words via the CAN ID. The whole telegram is built up as follows: Line 1: MUX number 0, word 1 Line 2: MUX number 0, word 2 Line 3: MUX number 0, word 3 Line 4: MUX number 1, word 1 Line 5: MUX number 1, word 2 Line 6: MUX number 1, word 3 . . Line (n): MUX number (n-1/3), word 1 Line (n+1): MUX number (n-1/2), word 2 Line (n+2): MUX number (n-1/1), word 3 n depends on the total length of the item special telegram and cannot be larger than H’FF. Current Direction Message The current direction can be recognized via the prefix of the power. A positive transmitted value indicates ex- ported power (power supplied to the mains, supply) and a negative transmitted value indicates imported power (power supplied by the mains, consumption). Manual 37365A GCP-30 Series Packages - Genset Control Page 164/179 © Woodward Power Set Point Value Message The following power values may be pre-specified: constant/baseload power (C power), outgoing/export power (E power) and incoming/import power (I power). The real power set point value is transmitted in binary form using bits 0-13. The control argument must be transmitted in the basis of bits 14 and 15. In this case, the following cod- ing applies: Control argument Bit 15 Bit 14 C power 0 1 E power 0 0 I power 1 1 Example: C power of 150 kW is to be compensated. The value transmitted is then: 01/00 0000 1001 0110 B Ö 4096 H E power of 300 kW is to be compensated. The value transmitted is then: 00/00 0001 0010 1100 B Ö 012C H I power of 600 kW is to be compensated. Negative power is transmitted. The value transmitted is then: 11/11 1101 1010 1000 B Ö FDA8 H CAN Bus Address Requirements The IDs given in the following are reserved for the data exchange between GCPs and LS4s. If third-party devices are connected to the bus, third-party device addresses must not conflicts with these addresses. CAN-ID in [hex] [decimal] GCP sends Distribution message to other GCPs 180 + GENNO 384 + GENNO Control message to LS4 (the GCP with the lowest ID) 311 785 Visualization 320 + GENNO 800 + GENNO GCP receives Distribution message from other GCP 180 + GENNO 384 + GENNO Control message from an LS4 300 + GENNO 768 + GENNO Configuration messages from a higher control 33F 831 LS4 sends Logic message to other LS4s 180 + LS4NO 384 + LS4NO Control message to GCP (the LS4 with the lowest ID) 300 + GENNO 768 + GENNO LS4 receives Logic message from other LS4 180 + LS4NO 384 + LS4NO Control message from a GCP 311 785 Configuration messages and Configuration messages from a higher control 33F 831 [hex] [decimal] GENNO = 1 to E 1 to 14 GENNO = Generator number LS4NO = 11 to 1E 17 to 30 LS4NO = LS4 number Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 165/179 Appendix D. List of Parameters Unit number P/N _____________________________ Rev _______________________________ Version GCP-30_______________________________________________________________ Project _____________________________________________________________________ Serial number S/N _______________ Date ______________________________ Access Parameter Setting range Default value Customer setting Software version - V x.xxxx - - Enter code 0 to 9.999 XXXX Direct para. YES/NO NO Y N Y N Generator number 1 to 14 1 Language first/second first f s f s Check event list YES/NO NO Y N Y N GENERATOR AND MAINS ENVIRONMENT CONFIGURATION Configure measuring YES/NO NO Y N Y N Generator freq. f set 40.0 to 70.0 Hz 50.0 Hz Gen.volt.transf. secondary 50 to 125/50 to 480 V 400 V Gen.volt.transf. primary 0.05 to 65.0 kV 0.4 kV Bus.volt.transf. secondary 50 to 125/50 to 480 V 400 V Bus.volt.transf. primary 0.05 to 65.0 kV 0.4 kV mains volt.trans. secondary 50 to 125/50 to 480 V 400 V mains volt.trans primary 0.05 to 65.0 kV 0.4 kV Gen.voltage U set 50 to 125/50 to 530 V 100/400 V Rated voltage in system 50 to 125/50 to 480 V 100/400 V Volt.meas./mon. Ph-neut/Ph-Ph [4/3] Ph-Ph/Ph-Ph [3/3] Ph-neut/Ph-neut [4/4] Ph-neut/Ph-Ph 4/3 3/3 4/4 4/3 3/3 4/4 Current transf. generator 10 to 7,000/{X} A 500/{X} A Power measuring gen.singlephase [1] threephase [3] threephase 1 3 1 3 Rated power generator 5 to 9,999 kW 200 kW Rated current generator 10 to 7,000 A 300 A Current transf. mains 5 to 7,000/{X} A 500 {X} A XPD, XPQ Analog in Pmains OFF/T{x} OFF XPD, XPQ Analog in Pmains 0 to 20 mA 4 to 20 mA 4 to 20 mA 0-20 mA 4-20 mA 0-20 mA 4-20 mA XPD, XPQ Analog in Pmains 0%0 to +/-9,990/0 to +/-6,900 kW -200 kW XPD, XPQ Analog in Pmains 100%0 to +/-9,990/0 to +/-6,900 kW 200 kW GCP-31 XPD, XPQ LS 4 mode ON/OFF OFF on off on off GCP-31 XPD, XPQ Rated power in system 0 to 16,000 kW 1,600 kW Temperature in Celsius [°C] Fahrenheit [°F] Celsius [°C] °C °F °C °F Pressure in bar psi bar bar psi bar psi Define level 1 code 0 to 9999 0001 Define level 2 code 0 to 9999 0002 Manual 37365A GCP-30 Series Packages - Genset Control Page 166/179 © Woodward Access Parameter Setting range Default value Customer setting CONTROLLER CONFIGURATION Configure controller YES/NO NO Y N Y N Power controller Pset1 C/I/E 0 to 9,999 kW C 50 kW Power controller Pset2 C/I/E 0 to 9,999 kW C 80 kW BPQ, XPQ Initial state Frequency 0 to 100 % 50 % Freq.controller ON/OFF ON on off on off f-contr. active at: 0.0 to 70.0 Hz 40.0 Hz Delay time for f-contr. 0 to 999 s 5 s Freq.controller ramp 1 to 50 Hz/s 10 Hz/s BPQ, XPQ F/P contr.type Three-step Analog PWM Analog Three-st. Analog PWM Three-st. Analog PWM Freq.controller deadband 0.02 to 1.00 Hz 0.03 Hz Freq.controller time pulse> 10 to 250 ms 80 ms Freq.controller gain Kp 0.1 to 99.9 20.0 BPQ, XPQ F/P contr.output Refer to Parameter 46 +/-10 V BPQ, XPQ Level PWM 3.0 to 10.0 V 3.0 V BPQ, XPQ Stepper sign.frq (min.) 0 to 100 % 0 % BPQ, XPQ Stepper sign.frq (max.) 0 to 100 % 100 % BPQ, XPQ Freq.controller gain Kpr 1 to 240 20 BPQ, XPQ Freq.controller reset Tn 0.0 to 60.0 s 1.0 s BPQ, XPQ Freq.controller derivat.Tv 0.00 to 6.00 s 0.00 s BPQ, XPQ Starting point voltage 0 to 100 % 50 % Volt.controller ON/OFF ON on off on off Initial state U control. 12.0 to 100.0 % 75 % Delayed. Start U contr. 0 to 999 s 3 s BPQ, XPQ V/Q contr.type Three-step Analog Analog Three-st. Analog Three-st. Analog Volt.controller dead band 0.1 to 15.0 % 0.9 % Volt.controller time pulse> 20 to 250 ms 80 ms Volt.controller gain Kp 0.1 to 99.9 20.0 BPQ, XPQ V/Q contr.output Refer to Parameter 61 +/-10 V BPQ, XPQ Stepper sign.vol (min.) 0 to 100 % 0 % BPQ, XPQ Stepper sign.vol (max.) 0 to 100 % 100 % BPQ, XPQ Volt.controller gain Kpr 1 to 240 20 BPQ, XPQ Volt.controller reset Tn 0.0 to 60.0 s 1.0 s BPQ, XPQ Volt.controller derivat.Tv 0.00 to 6.00 s 0.00 s Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 167/179 Access Parameter Setting range Default value Customer setting CONTROLLER CONFIGURATION Pow.fact.contr. ON/OFF OFF on off on off Pow.fact.contr. setpoint i0.70 to 1.00 to k0.70 1.00 Pow.fact.contr. dead band 0.5 to 25.0 % 0.5 % Pow.fact.contr. gain Kp 0.1 to 99.9 20.0 BPQ, XPQ Pow.fact.contr. gain Kpr 1 to 240 20 BPQ, XPQ Pow.fact.contr. reset Tn 0.0 to 60.0 s 1.0 s BPQ, XPQ Pow.fact.contr. derivat.Tv 0.0 to 6.0 s 0.0 s Power controller ON/OFF ON on off on off power controller ramp 0.1 to 100.0 %/s 20 %/s Power limit P max.10 to 120 % 100 % Power limit P min.0 to 50 % 0 % XPD, XPQ Power setpoint external OFF/ T1 / T2 / T3 OFF OFF T1 T2 T3 OFF T1 T2 T3 XPD, XPQ Analog input 0 to 20 mA 4 to 20 mA 4 to 20 mA 0-20 mA 4-20 mA 0-20 mA 4-20 mA XPD, XPQ Ext.setpoint 0mA C/I/E 0 to 9,999 kW C 0 kW XPD, XPQ Ext.setpoint 20mA C/I/E 0 to 9,999 kW C 200 kW Power controller dead band 0.1 to 25.0 % 0.5 % Power controller gain Kp 0.1 to 99.9 20.0 Powercontr. dead band ratio 1.0 to 9.9 2.0 XPD, XPQ Power controller gain Kpr 1 to 240 20 XPD, XPQ Power controller reset Tn 0.0 to 60.0 s 1.0 s XPD, XPQ Power controller derivat.Tv 0.0 to 6.0 s 0.0 s Warm up load derivat.Tv 5 to 110 % 15 % Warm up load time 0 to 600 s 0 s Active power load-share ON/OFF ON on off on off Act. load share factor 10 to 99 % 50 % Reactive power load share ON/OFF OFF on off on off React.load share factor 10 to 99% 50 % LOAD MANAGEMENT CONFIGURATION Configure automatic YES/NO NO Y N Y N Loadd.start/stop at ter.3 ON/OFF OFF on off on off Loadd.start/stop at ter.5 ON/OFF OFF on off on off Minimum load generator 0 to 6,900 kW 15 kW Add-on delay mains oper.0 to 999 s 1 s Shed-off delay mains oper.0 to 999 s 3 s Hysteresis add-. on/off op.0 to 9,999 kW 5 kW Reserve power mains op.0 to 9,999 kW 10 kW Priority of generators 0 to 14 0 Reserve power isol.op.0 to 9,999 kW 20 kW Add-on delay isol.op.0 to 999 s 1 s Shed-off delay isol.op.0 to 999 s 4 s GCP-31 Mains error - stop eng.ON/OFF OFF on off on off Control via COM X1X5 ON/OFF OFF on off on off Supervision COM X1X5 ON/OFF OFF on off on off Ackn. F2,F3 via COM interf ON/OFF OFF on off on off Manual 37365A GCP-30 Series Packages - Genset Control Page 168/179 © Woodward Access Parameter Setting range Default value Customer setting BREAKER CONFIGURATION Configure breaker YES/NO NO Y N Y N L Breaker logic: EXTERNAL [EXT] PARALLEL [PAR] OPEN TRANSIT [OPEN] CLOSED TRANSIT [CLOSE] INTERCHANGE [CHANG] PARALLEL EXT PAR OPEN CLOSE CHANG EXT PAR OPEN CLOSE CHANG Add-on/off ramp max.time 0 to 999 s 20 s Open GCB with F2 max.time 0 to 999 s 10 s GCB close.relay Impulse [I] Constant [C] Constant I C I D GCB open relay NO-contact [NO] NC-contact [NC] NO-contact NO NC NO NC Synchronize df max 0.02 to 0.49 Hz 0.20 Hz Synchronize df min 0.0 to 0,49 Hz -0.10 Hz Synchronize dV max 1.0 to 20.0 % 2.0 % Synchronize time pulse> 0.02 to 0.26 s 0.24 s Closing time GCB 40 to 300 ms 80 ms GCP-32 Closing time MCB 40 to 300 ms 80 ms Automat.breaker deblocking ON/OFF OFF on off on off Sync.time contr. ON/OFF ON on off on off Sync.time contr. delay 10 to 999 s 180 s GCB dead bus op. ON/OFF ON on off on off GCB dead bus op. df max 0.05 to 5.00 Hz 2.0 Hz GCB dead bus op. dV max. 1.0 to 15.0 % 10.0 % GCB dead bus op max.time 0 to 999 s 30 s GCP-32 MCB dead bus op. ON/OFF ON on off on off Supervision GCB ON/OFF ON on off on off GCP-32 Supervision MCB ON/OFF ON on off on off GCP-31 Mains decoupling via GCB [GCB] GCB->EXT [GCB>EX] EXT [EXT] EXT->GCB [EX>GCB] GCB GCB GCB>EX EXT EX>GCB GCB GCB>EX EXT EX>GCB GCP-32 Mains decoupling via GCB [GCB] GCB->MCB [GCB>MC] MCB [MCB] MCB->GCB [MC>GCB] GCB GCB GCB>MC MCB MC>GCB GCB GCB>MC MCB MC>GCB GCP-32 L Mains decoupling -> after 0.10 to 5.00 s 0.14 s GCP-32 Switch MCB in STOP mode YES/NO NO Y N Y N EMERGENCY POWER CONFIGURATION GCP-32 GCP-31: XPD, XPQ Configure emergency YES/NO NO Y N Y N GCP-32 GCP-31: XPD, XPQ Emergency power ON/OFF ON on off on off GCP-32 GCP-31: XPD, XPQ Emergency power start del. 0.5 to 99.9 s 3.0 s Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 169/179 Access Parameter Setting range Default value Customer setting MONITORING CONFIGURATION Configure monitoring YES/NO NO Y N Y N Gen.power monit. ON/OFF OFF on off on off Gen.power monit. resp.val1 0 to 9,999 kW 100 kW Gen.power monit. hyst.lv1 0 to 999 kW 10 kW Gen.power monit. delay lv1 0 to 650 s 1 s Gen.power monit. resp.val2 0 to 9,999 kW 120 kW Gen.power monit. hyst.lv2 0 to 999 kW 10 kW Gen.power monit. delay lv2 0 to 650 s 1 s Mains power mon. ON/OFF OFF on off on off Mains power mon. res.val.I/E 0 to 9,999 kW E100 kW Mains power mon. hysteresis 0 to 999 kW 10 kW Mains power mon. delay 0 to 650 s 1 s Overload monit. ON/OFF OFF on off on off Gen.overload MOP resp.value 80 to 150 % 120 % Gen.overload MOP delay 0 to 99 s 1 s Gen.overload IOP resp.value 80 to 150 % 105 % Gen.overload IOP delay 0 to 99 s 1 s Rev./red.power monitoring ON/OFF OFF on off on off Rev./red.power resp.value -99 to +99 % -10 % Rev./red.power delay 0.0 to 9.9 s 1.0 s Load unbalanced ON/OFF OFF on off on off Load unbalanced max.0 to 100 % 30 % Load unbalanced delay 0.02 to 9.98 s 1.00 s Gen.overcurrent monitoring ON/OFF OFF on off on off Gen.overcurrent limit 1 0 to 300 % 110 % Gen.overcurrent delay 1 0.02 to 9.98 s 1.00 s Gen.overcurrent limit 2 0 to 300 % 120 % Gen.overcurrent delay 2 0.02 to 9.98 s 0.04 s Gen.overcurrent Cool down ON/OFF OFF on off on off Gen.frequency- monitoring ON/OFF ON on off on off Gen.overfreq. f >50.0 to 140.0 % 110.0 % Gen.overfreq. delay 0.02 to 9.98 s 0.30 s Gen.underfreq. f <50.0 to 140.0 % 90.0 % Gen.underfreq. delay 0.02 to 9.98 s 0.30 s Engine overspeed >0 to 9,999 rpm 1,900 rpm Gen.voltage monitoring ON/OFF ON on off on off Gen.overvoltage U >20.0 to 150.0 % 110.0 % Gen.overvoltage delay 0.02 to 9.98 s 0.30 s Gen.undervoltage U <20.0 to 150.0 % 90.0 % Gen.undervoltage delay 0.2 to 9.98 s 0.30 s Mains frequency monitoring ON/OFF ON on off on off Mains overfreq. f >80.0 to 140.0 % 110.0 % Mains overfreq. delay 0.02 to 9.98 s 0.06 s Mains underfreq. f <80.0 to 140.0 % 90.0 % Mains underfreq. delay 0.02 to 9.98 s 0.06 s Mains voltage monitoring ON/OFF ON on off on off Mains overvolt. U >20.0 to 150.0 % 110.0 % Mains overvolt. delay 0.02 to 9.98 s 0.06 s Mains undervolt. U <20.0 to 150.0 % 90.0 % Mains undervolt. Hysteresis 0.0 to 50.0 % 0.8 % Mains undervolt. delay 0.02 to 9.98 s 0.06 s Phase shift monitoring ON/OFF ON on off on off Monitoring one-phase [1] three-phase [3] three-phase 1 3 1 3 Phase shift one-phase 3 to 30 ° 12 ° Phase shift three-phase 3 to 30 ° 8 ° Mains settling time 0- to 999 s 10 s Batt.undervolt. U <9.5 to 30.0 V 10.0 V Batt.undervolt. delay 0 to 99 s 10 s Horn self reset 1 to 9,999 s 180 s Manual 37365A GCP-30 Series Packages - Genset Control Page 170/179 © Woodward Access Parameter Setting range Default value Customer setting DISCRETE INPUTS CONFIGURATION Configure dig.inputs YES/NO NO Y N Y N Dig.input 1234 function E/D DDDD Dig.input 1234 delay 0 to 9 0000 Delayed by 1234 eng.speed Y/N NNNN Dig.input 1234 error class 0 to 3 3210 Dig.input 5678 function E/D DDDD Dig.input 5678 delay 0 to 9 0000 Delayed by 5678 eng.speed Y/N NNNN Dig.input 5678 error class 0 to 3 3111 Dig.input 9ABC function E/D DDDD Dig.input 9ABC delay 0 to 9 0000 Delayed by 9ABC eng.speed Y/N NNNN Dig.input 9ABC error class 0 to 3 1111 Dig.input DEFG function E/D DDDD Dig.input DEFG delay 0 to 9 0000 Delayed by DEFG eng.speed Y/N NNNN Dig.input DEFG error class 0 to 3 1111 L Errortxt.term.34 freely configurable EMERGENCY OFF L Errortxt.term.35 freely configurable terminal 35 L Errortxt.term.36 freely configurable terminal 36 L Errortxt.term.61 freely configurable terminal 61 L Errortxt.term.62 freely configurable terminal 62 L Firing speed by Term. 62 ON/OFF OFF on off on off L Errortxt.term.63 freely configurable terminal 63 L Op.mode blocked by Ter.63 ON/OFF OFF on off on off L Errortxt.term.64 freely configurable terminal 64 L Breaker logic by Term64 ON/OFF OFF on off on off Breaker logic: EXTERNAL [EXT] PARALLEL [PAR] OPEN TRANSIT [OPEN] CLOSED TRANSIT [CLOSE] INTERCHANGE [INCHG] EXTERNAL EXT PAR OPEN CLOSE INCHG EXT PAR OPEN CLOSE INCHG L Errortxt.term.65 freely configurable terminal 65 L Errortxt.term.66 freely configurable terminal 66 L Errortxt.term.67 freely configurable terminal 67 Close GCB asap by Ter.67 ON/OFF OFF on off on off L Errortxt.term.68 freely configurable terminal 68 GCP-32 GCP-31: XPD, XPQ L Emergency OFF by Ter.68 ON/OFF OFF on off on off L Errortxt.term.69 freely configurable terminal 69 L Errortxt.term.70 freely configurable terminal 70 L Idle mode by Term.70 ON/OFF OFF on off on off L Errortxt.term.71 freely configurable terminal 71 L Errortxt.term.72 freely configurable terminal 72 L Errortxt.term.73 freely configurable terminal 73 Function term.6 Sprinkler operation [SO] Engine enabled [EE] ext.acknowledgment [ExA] STOP mode [SM] Engine blocked [EB] Start without CB [SwB] ExA SO EE ExA SM EB SwB SO EE ExA SM EB SwB Start withno GCB cool down ON/OFF OFF on off on off Sprinkler shutd. F1 active ON/OFF OFF on off on off Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 171/179 Access Parameter Setting range Default value Customer setting ANALOG INPUTS CONFIGURATION Configure analg.inp.YES/NO NO Y N Y N Analog input 1 scalable ON/OFF ON on off on off L Name and unit freely configurable Analog 1 Analog input 1 0 to 20 mA 4-20 mA 4 to 20 mA 0-20 mA 4-20 mA 0-20 mA 4-20 mA Value at 0%-9999 to +9999 0 Value at 100%-9999 to +9999 100 Limit warning value -9999 to +9999 80 Limit shutdown value -9999 to +9999 90 Delay limit 1/2 0 to 650 s 1 s Monitoring for High limit mon. [high] low limit mon. [low] High limit mon. high low high low Analog input 2 scalable ON/OFF ON on off on off L Name and unit freely configurable Analog 2 Analog input 2 0 to 20 mA 4 to 20 mA 4 to 20 mA 0-20 mA 4-20 mA 0-20 mA 4-20 mA Value at 0%-9999 to +9999 0 Value at 100%-9999 to +9999 100 Limit warning value -9999 to +9999 80 Limit shutdown value -9999 to +9999 90 Delay limit 1/2 0 to 650 s 1 s Monitoring for High limit mon. [high] low limit mon. [low] High limit mon. high low high low Analog input 3 scalable ON/OFF ON on off on off L Name and unit freely configurable Analog 3 Analog input 3 0 to 20 mA 4 to 20 mA 4 to 20 mA 0-20 mA 4-20 mA 0-20 mA 4-20 mA Value at 0%-9999 to +9999 0 Value at 100%-9999 to +9999 100 Limit warning value -9999 to +9999 80 Limit shutdown value -9999 to +9999 90 Delay limit 1/2 0 to 650 s 1 s Monitoring for High limit mon. [high] low limit mon. [low] High limit mon. high low high low Temperature 4 Pt100 ON/OFF ON on off on off L ***name**** 000°C freely configurable Analog 4 Limit warning 0 to 200 °C 80 °C Limit shutdown 0 to 200 °C 90 °C Delay limit 1/2 0 to 650 s 1 s Monitoring for High limit mon. [high] low limit mon. [low] High limit mon. high low high low Temperature 5 Pt100 ON/OFF ON on off on off L ***name**** 000°C freely configurable Analog 5 Limit warning 0 to 200 °C 80 °C Limit shutdown 0 to 200 °C 90 °C Delay limit 1/2 0 to 650 s 1 s Monitoring for High limit mon. [high] low limit mon. [low] High limit mon. high low high low Manual 37365A GCP-30 Series Packages - Genset Control Page 172/179 © Woodward Access Parameter Setting range Default value Customer setting ANALOG INPUTS CONFIGURATION Analog input 6 VDO ON/OFF ON on off on off L Name and unit freely configurable Analog 6 Analog input 6 VDO 0 to 5 bar 0 to 10 bar 0 to 5 bar 0-5 bar 0-10 bar 0-5 bar 0-10 bar Limit warning value 0.0 to 10.0 bar 2.0 bar Limit shutdown value 0.0 to 10.0 bar 1.0 bar Delay limit 1/2 0 to 650 s 1 s Monitoring for High limit mon. [high] low limit mon. [low] low limit mon. high low high low Analog input 7 VDO ON/OFF ON on off on off L Name and unit freely configurable Analog 7 Limit warning value 40 to 120 °C 80 °C Limit shutdown 40 to 120 °C 90 °C Delay limit 1/2 0 to 650 s 1 s Monitoring for High limit mon. [high] low limit mon. [low] High limit mon. high low high low Ana.in 12345678 SV.del. Y/N NNNNNYNN Ana.in 12345678 control Y/N NNNNNNNN OUTPUT CONFIGURATION Configure outputs YES/NO NO Y N Y N Analg.out.12O121 Parameter 0 to 22 1 Analg.out.12O121 0-00 mA OFF 0 to 20 mA 4 to 20 mA 0 to 20 mA OFF 0-20mA 4-20 mA OFF 0-20mA 4-20 mA Analg.out.12O121 0% 0 to 9,990 0 Analg.out.12O121 100% 0 to 9,990 200 Analg.out.122123 Parameter 0 to 22 1 Analg.out.122123 0-00 mA OFF 0 to 20 mA 4 to 20 mA 0 to 20 mA OFF 0-20mA 4-20 mA OFF 0-20mA 4-20 mA Analg.out.122123 0% 0 to 9,990 0 Analg.out.122123 100% 0 to 9,990 200 Assignm.relay 1 refer to page 128 for more info 1 Assignm.relay 2 refer to page 128 for more info 2 Assignm.relay 3 refer to page 128 for more info 3 Assignm.relay 4 refer to page 128 for more info 4 Assignm.relay 5 refer to page 128 for more info 5 Assignm.relay 6 refer to page 128 for more info 84 Assignm.relay 7 refer to page 128 for more info 85 Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 173/179 Access Parameter Setting range Default value Customer setting ENGINE CONFIGURATION Configure engine YES/NO NO Y N Y N Aux.services prerun 0 to 999 s 0 s Aux.services postrun 0 to 999 s 0 s Start-stop-logic for DIESEL GAS EXTERNAL [EXT] DIESEL DIESEL GAS EXT DIESEL GAS EXT Min.speed for ignit.0 to 999 rpm 100 rpm Ignition delay 0 to 99 s 3 s Preglow time 0 to 99 s 3 s Gasvalve delay 0 to 99 s 5 s Max. attempts to start 1 to 6 3 Starter time 2 to 99 s 10 s Start pause time 1 to 99 s 8 s L f lower before start ON/OFF OFF on off on off L time f lower bef.start 0 to 999 s 5 s L f lower before start ON/OFF OFF on off on off L time f lower bef.start 0 to 999 s 5 s Fuel relay logic Open to stop [OPEN] Close to stop [STOP] Open to stop OPEN STOP OPEN STOP Cool down time 0 to 999 s 15 s Delayed engine monitoring 1 to 99 s 8 s Firing speed reached f>5 to 70 Hz 15 Hz Speed detected V L1-L2 > 00.0%5.0 to 25.0 % 5.0 % Pickup input ON/OFF ON on off on off L Number of pickup teeth 30 to 280 160 L Gen.rated speed 0 to 3,000 rpm 1,500 rpm COUNTER CONFIGURATION Configure counters YES/NO NO Y N Y N Service interval in 0 to 9,999 h 300 h Set oper.hours counter 0 to 65,000 h 0 h Set start counter 0 to 32,000 0 kWh counter set in kWh MWh kWh kWh MWH kWh MWH kWh counter set 0 to 65,500 kWh/MWh 0 kWh XPD, XPQ Time 00:00 to 23:59 00:00 XPD, XPQ Year,month 00 to 99,01 to 12 00.00 XPD, XPQ Day/weekday 01 to 31/1 to 7 00.0 BPQ This parameter is only available in the BPQ Package XPD This parameter is only available in the XPD Package XPQ This parameter is only available in the XPQ Package L This parameter may only be accessed via LeoPC1 depending on the unit GCP-31 This parameter is only available in the GCP-31 Packages GCP-32 This parameter is only available in the GCP-32 Packages Manual 37365A GCP-30 Series Packages - Genset Control Page 174/179 © Woodward Appendix E. Service Options Product Service Options ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ The following factory options are available for servicing Woodward equipment, based on the standard Wood- ward Product and Service Warranty (5-01-1205) that is in effect at the time the product is purchased from Woodward or the service is performed. If you are experiencing problems with installation or unsatisfactory per- formance of an installed system, the following options are available: • Consult the troubleshooting guide in the manual. • Contact Woodward technical assistance (see "How to Contact Woodward" later in this chapter) and discuss your problem. In most cases, your problem can be resolved over the phone. If not, you can select which course of action you wish to pursue based on the available services listed in this section. Returning Equipment For Repair ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ If a control (or any part of an electronic control) is to be returned to Woodward for repair, please contact Wood- ward in advance to obtain a Return Authorization Number. When shipping the unit(s), attach a tag with the fol- lowing information: • Name and location where the control is installed • Name and phone number of contact person • Complete Woodward part numbers (P/N) and serial number (S/N) • Description of the problem • Instructions describing the desired repair CAUTION To prevent damage to electronic components caused by improper handling, read and observe the pre- cautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules. Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 175/179 Packing A Control Use the following materials when returning a complete control: • Protective caps on any connectors • Antistatic protective bags on all electronic modules • Packing materials that will not damage the surface of the unit • At least 100 mm (4 inches) of tightly packed, industry-approved packing material • A packing carton with double walls • A strong tape around the outside of the carton for increased strength Return Authorization Number RAN When returning equipment to Woodward, please telephone and ask for the Customer Service Department in Stuttgart, Germany [+49 (0) 711 789 54-0]. They will help expedite the processing of your order through our dis- tributors or local service facility. To expedite the repair process, contact Woodward in advance to obtain a Re- turn Authorization Number, and arrange for issue of a purchase order for the unit(s) to be repaired. No work will be started until a purchase order is received. NOTE We highly recommend that you make arrangement in advance for return shipments. Contact a Woodward customer service representative at +49 (0) 711 789 54-0 for instructions and for a Re- turn Authorization Number. Replacement Parts ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ When ordering replacement parts for controls, include the following information: • The part numbers P/N (XXXX-XXX) that is on the enclosure nameplate • The unit serial number S/N, which is also on the nameplate Manual 37365A GCP-30 Series Packages - Genset Control Page 176/179 © Woodward How To Contact Woodward ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Please contact following address if you have questions or if you want to send a product for repair: Woodward GmbH Handwerkstrasse 29 70565 Stuttgart - Germany Phone: +49 (0) 711 789 54-0 (8.00 - 16.30 German time) Fax: +49 (0) 711 789 54-100 e-Mail: sales-stuttgart@woodward.com For assistance outside Germany, call one of the following international Woodward facilities to obtain the address and phone number of the facility nearest your location where you will be able to get information and service. Facility Phone number USA +1 (970) 482 5811 India +91 (129) 409 7100 Brazil +55 (19) 3708 4800 Japan +81 (476) 93 4661 The Netherlands +31 (23) 566 1111 You can also contact the Woodward Customer Service Department or consult our worldwide directory on Woodward’s website (www.woodward.com) for the name of your nearest Woodward distributor or service fa- cility. [For worldwide directory information, go to www.woodward.com/ic/locations.] Manual 37365A GCP-30 Series Packages - Genset Control © Woodward Page 177/179 Engineering Services ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Woodward Industrial Controls Engineering Services offers the following after-sales support for Woodward prod- ucts. For these services, you can contact us by telephone, by e-mail, or through the Woodward website. • Technical support • Product training • Field service during commissioning Technical Support is available through our many worldwide locations, through our authorized distributors, or through GE Global Controls Services, depending on the product. This service can assist you with technical ques- tions or problem solving during normal business hours. Emergency assistance is also available during non- business hours by phoning our toll-free number and stating the urgency of your problem. For technical engineer- ing support, please contact us via our toll-free or local phone numbers, e-mail us, or use our website and refer- ence technical support. Product Training is available on-site from several of our worldwide facilities, at your location, or from GE Global Controls Services, depending on the product. This training, conducted by experienced personnel, will as- sure that you will be able to maintain system reliability and availability. For information concerning training, please contact us via our toll-free or local phone numbers, e-mail us, or use our website and reference customer training. Field Service engineering on-site support is available, depending on the product and location, from our facility in Colorado, or from one of many worldwide Woodward offices or authorized distributors. Field engineers are experienced on both Woodward products as well as on much of the non-Woodward equipment with which our products interface. For field service engineering assistance, please contact us via our toll-free or local phone numbers, e-mail us, or use our website and reference field service. Manual 37365A GCP-30 Series Packages - Genset Control Page 178/179 © Woodward Technical Assistance ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ If you need to telephone for technical assistance, you will need to provide the following information. Please write it down here before phoning: Contact Your company____________________________________________________ Your name_______________________________________________________ Phone number____________________________________________________ Fax number______________________________________________________ Control (see name plate) Unit no. and revision: P/N:____________________ REV: ____________ Unit type GCP-______________________________________ Serial number S/N _______________________________________ Description of your problem _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ Please be sure you have a list of all parameters available. You can print this using LeoPC1. Additionally you can save the complete set of parameters (standard values) and send them to our Service department via e-mail. We appreciate your comments about the content of our publications. Please send comments to: stgt-documentation@woodward.com Please include the manual number from the front cover of this publication. Woodward Handwerkstrasse 29 - 70565 Stuttgart - Germany Phone +49 (0) 711 789 54-0 • Fax +49 (0) 711 789 54-100 sales-stuttgart@woodward.com Homepage http://www.woodward.com/power Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address/phone/fax/e-mail information for all locations is available on our website (www.woodward.com). 2007/2/Stuttgart 37238D Function/Operation Software version 4.3xxx Manual 37238D GCP-30 Series Genset Control Manual 37238D GCP-30 Series - Genset Control Page 2/39 © Woodward WARNING Read this entire manual and all other publications pertaining to the work to be performed before install- ing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage. The engine, turbine, or other type of prime mover should be equipped with an overspeed (overtempera- ture, or overpressure, where applicable) shutdown device(s), that operates totally independently of the prime mover control device(s) to protect against runaway or damage to the engine, turbine, or other type of prime mover with possible personal injury or loss of life should the mechanical-hydraulic gov- ernor(s) or electric control(s), the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s), or the controlled device(s) fail. Any unauthorized modifications to or use of this equipment outside its specified mechanical, electrical, or other operating limits may cause personal injury and/or property damage, including damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product certifications or listings. CAUTION To prevent damage to a control system that uses an alternator or battery-charging device, make sure the charging device is turned off before disconnecting the battery from the system. Electronic controls contain static-sensitive parts. Observe the following precautions to prevent dam- age to these parts. • Discharge body static before handling the control (with power to the control turned off, contact a grounded surface and maintain contact while handling the control). • Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit boards. • Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. OUT-OF-DATE PUBLICATION This publication may have been revised or updated since this copy was produced. To verify that you have the latest revision, be sure to check the Woodward website: http://www.woodward.com/pubs/current.pdf The revision level is shown at the bottom of the front cover after the publication number. The latest version of most publications is available at: http://www.woodward.com/publications If your publication is not there, please contact your customer service representative to get the latest copy. Important definitions WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. CAUTION Indicates a potentially hazardous situation that, if not avoided, could result in damage to equipment. NOTE Provides other helpful information that does not fall under the warning or caution categories. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, Woodward assumes no responsibility unless otherwise expressly undertaken. © Woodward All Rights Reserved. Manual 37238D GCP-30 Series - Genset Control © Woodward Page 3/39 Revision History Rev. Date Editor Changes NEW 04-06-02 Tr Release A 04-09-23 TP Minor corrections, functionality from V4.3xxx updated B 05-06-15 TP Appendix Parameters and Set Points added, various minor corrections Description GCP-31 RPQ-SC08 (Rental Package) added C 06-01-11 TP Various minor corrections D 07-02-07 TP Various minor corrections; linguistic review Contents CHAPTER 1. GENERAL INFORMATION.........................................................................................5 CHAPTER 2. DISPLAY AND OPERATING ELEMENTS ....................................................................8 Brief Explanation Of The LEDs and Buttons...........................................................................................9 LEDs .............................................................................................................................................9 Buttons..........................................................................................................................................9 Others ...........................................................................................................................................9 Functional Overview..............................................................................................................................10 LEDs......................................................................................................................................................11 Buttons..................................................................................................................................................13 General / Configuration...............................................................................................................13 Circuit Breaker Operation...........................................................................................................14 Operating Mode Selection..........................................................................................................15 LC Display.............................................................................................................................................18 CHAPTER 3. DISPLAY ..............................................................................................................19 Measured Values..................................................................................................................................19 Top Display Line.........................................................................................................................19 Bottom Display Line....................................................................................................................20 Direction Of Power......................................................................................................................22 Power Factor Definition ..............................................................................................................22 Service Display .....................................................................................................................................24 Control Function Messages ..................................................................................................................25 Counters................................................................................................................................................28 Reset Maintenance Call..............................................................................................................28 CHAPTER 4. ALARM MESSAGES ..............................................................................................29 Alarm Classes.......................................................................................................................................29 Acknowledge Alarm Messages .............................................................................................................30 Short Acknowledgement (< 2,5 s) ..............................................................................................31 Long Acknowledgement (> 2,5 s)...............................................................................................31 Alarm Messages .........................................................................................................................32 APPENDIX A. CODE LEVEL ACCESS PERMISSIONS ...................................................................38 Code Level 0 or No Code Level .................................................................................................38 Code Level 1...............................................................................................................................38 Code Level 2...............................................................................................................................38 Manual 37238D GCP-30 Series - Genset Control Page 4/39 © Woodward Illustrations And Tables Illustrations Figure 2-1: Front panel GCP-31................................................................................................................................................8 Figure 2-2: Front panel GCP-32................................................................................................................................................8 Figure 3-1: Direction of power................................................................................................................................................22 Tables Table 1-1: Manual - Overview...................................................................................................................................................5 Table 2-1: Functional overview...............................................................................................................................................10 Table 2-2: Function – external operation mode selection........................................................................................................17 Table 4-1: Alarms – Short acknowledgement..........................................................................................................................31 Table 4-2: Alarms – Long acknowledgement - Table for warning alarms...............................................................................31 Table 4-3: Alarms – Long acknowledgement - Table for alarms causing a shutdown............................................................31 Table 4-4: Alarms – Text messages.........................................................................................................................................32 Manual 37238D GCP-30 Series - Genset Control © Woodward Page 5/39 Chapter 1. General Information Type English German GCP-31/32 Series GCP-31/32 Packages - Installation 37364 GR37364 GCP-31/32 Packages - Configuration 37365 GR37365 GCP-31/32 - Function/Operation this manual Ö 37238 GR37238 GCP-31/32 - Application 37240 GR37240 Option SB - Caterpillar CCM coupling 37200 GR37200 Option SC06/SC07/SC08 - CAN bus coupling 37313 GR37313 Option SC09/SC10 - CAN bus coupling 37382 GR37382 Additional Manuals IKD 1 - Manual 37135 GR37135 Discrete expansion board with 8 discrete inputs and 8 relay outputs that can be coupled via the CAN bus to the control unit. Evalua- tion of the discrete inputs as well as control of the relay outputs is done via the control unit. LeoPC1 - Manual 37146 GR37146 PC program for visualization, for configuration, for remote control, for data logging, for language upload, for alarm and user man- agement and for management of the event recorder. This manual describes the use of the program. LeoPC1 - Manual 37164 GR37164 PC program for visualization, for configuration, for remote control, for data logging, for language upload, for alarm and user man- agement and for management of the event recorder. This manual describes the programming of the program. GW 4 - Manual 37133 GR37133 Gateway for transferring the CAN bus to any other interface or bus. ST 3 - Manual 37112 GR37112 Control to govern the air fuel ratio of a gas engine. The ratio will be directly measured though a Lambda probe and controlled to a configured value. Table 1-1: Manual - Overview Manual 37238D GCP-30 Series - Genset Control Page 6/39 © Woodward The GCP-30 series generator set controllers provide the following functions: • Engine and generator protection • Engine data measurement - ○ including oil pressure and temperature, coolant temperature, battery voltage, speed, service hours, etc. • Generator data measurement - ○ including. voltage, current, power, kvar, kW, kWh, etc. • Engine start/stop logic • Alarm display with breaker trip and engine shutdown • Emergency operation for mains failure recognition and automatic engine start incl. transfer logic • Control of voltage, frequency, real power and reactive power • Real power and reactive power load sharing including load management with automatic start/stop of addi- tional generators. • Synchronization of one or two circuit breakers • CAN bus communications to engine controllers and plant management systems Type designation is as follows: GCP- 32 4 5 -h0018 B/ BPD +ABDEF..Z Options. A description of the options on the unit may be found in the man- ual corresponding to the listed options. The chapter heading indi- cates whether a described option is standard in every device or only available as an option. Package A description of the unit packages may be found in the manual corresponding to the listed control. The chapter heading indicates whether a described function is available in a package. Assembly type [B]..Installs in cabinet panel door Hardware variation derivative types; e.g. green display, additional relays Current transformer, secondary [5] = ../5 A Potential transformer, maximum secondary voltage [1] = 100 Vac [4] = 400 Vac Model [-31] = Model with 1 circuit breaker [-32] = Model with 2 circuit breakers Type Examples: • GCP-3245B/XPQ+SC10 (GCP-32 with 400 Vac PT inputs and ../5 A CT inputs, Package XPQ with Option SC10) • GCP-3115B/BPQ (GCP-31 with 100 Vac PT inputs and ../5 A CT inputs, Package BPQ without options) Manual 37238D GCP-30 Series - Genset Control © Woodward Page 7/39 Intended Use The unit must only be operated according to the guidelines described in this manual. The prerequi- site for a proper and safe operation of the product is correct transportation, storage, and installation as well as careful operation and maintenance. NOTE This manual has been developed for a unit fitted with all available options. Inputs/outputs, functions, configuration screens and other details described, which do not exist on your unit may be ignored. The present manual has been prepared to enable the installation and commissioning of the unit. On account of the large variety of parameter settings, it is not possible to cover every possible combina- tion. The manual is therefore only a guide. In case of incorrect entries or a total loss of functions, the default settings can be taken from the enclosed list of parameters. Manual 37238D GCP-30 Series - Genset Control Page 8/39 © Woodward Chapter 2. Display And Operating Elements The pressure-sensitive membrane of the front panel consists of a plastic coating. All keys have been designed as touch-sensitive membrane switch elements. The display is an LC display, comprised of two rows with 16 charac- ters in each row that are indirectly illuminated in red. The contrast of the display can be infinitely adjusted via a rotary potentiometer positioned on the left side of the control. The direct configuration port is located on the left side of the unit. The direct configuration cable (DPC) will connect there. V / kV A (L1) A (L2) A (L3) Operating and Alarm Messages AUTO MAN TEST STOP RESET Setpoint ON Mains Parallel Automatic Manual Protection Alarm V1 V2 V3 Stop Genset Control Package GCP-30 ON OFF STOP 2726252423212218171615 11 1 2 3 4 5 10 29 6 7 8 9 28 13 12 14 30 Figure 2-1: Front panel GCP-31 V / kV A (L1) A (L2) A (L3) Operating and Alarm Messages AUTO MAN TEST STOP RESET Setpoint ON ON Automatic Manual Protection V1 V2 V3 Stop Genset Control Package GCP-30 ONON OFF OFF STOP 27262524232021221819171615 11 1 2 3 4 5 10 29 6 7 8 9 28 13 12 14 30 Figure 2-2: Front panel GCP-32 Manual 37238D GCP-30 Series - Genset Control © Woodward Page 9/39 Brief Explanation Of The LEDs and Buttons ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ LEDs No Description Function 1 V1 Voltage L1 2 V2 Voltage L2 3 V3 Voltage L3 4 Stop "STOP" mode selected 5 -10%..fn..+10% Synchroscope 6 Automatic "AUTOMATIC" mode selected 7 Manual "MANUAL" mode selected 8 Protection Fault monitoring is enabled 9 Alarm Alarm message present 10 ON (GCB ON) Reply: GCB is closed 11 ON (MCB ON) [GCP-32] Reply: MCB is closed [GCP-31] Status message: unit is operating in "Mains parallel" Buttons No Description Function 12 Message↓ Advance to next message/screen 12 Select Confirm selection 13 Display↓ Switch display 13 Digit↑ Increase digit 14 Setpoint Display set point value 14 Cursor→ Move cursor one position to the right 15 Setpoint↑ Increase displayed set point value 16 Setpoint↓ Reduce displayed set point value 17 ON (GCB ON) Close GCB manually 18 OFF (GCB OFF) Open GCB manually 19 ON (MCB ON) [GCP-32] Close MCB manually 20 OFF (MCB OFF) [GCP-32] Open MCB manually 21 AUTO Enable "AUTOMATIC" mode 22 MAN Enable "MANUAL" mode 23 START Start engine manually 24 STOP Stop engine manually 25 TEST Activate "TEST" mode 26 STOP Stop engine automatically 27 RESET Acknowledge alarm messages Others No Description Function 28 LC-Display LC-Display 29 DPC plug Configuration plug 30 Potentiometer Adjust LCD contrast Manual 37238D GCP-30 Series - Genset Control Page 10/39 © Woodward Functional Overview ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Mode functions RESET STOP MAN AUTO TEST STOP ON OFF ON OFF Engine GCB MCB Setpoint Message Display Set point Acknowledge STOP MANUAL AUTOMATIC TEST Start Stop Close Open Close Open Raise Lower MANUAL Mode Start engine n o Stop engine X n o Close GCB n o Open GCB n o [GCP-32] Close MCB n o [GCP-32] Open MCB n o Raise set point value o n p Lower set point value o n p AUTOMATIC Mode **) Start engine n **) Stop engine X n **) Close GCB n **) Open GCB n [GCP-32] **) Close MCB n [GCP-32] **) Open MCB n Raise set point value o n p Lower set point value o n p TEST Mode Start engine n Start load test n o End load test n [GCP-32] *) End load test n* n* Raise set point value o n p Lower set point value o n p Mode STOP n LED test n n Configuration Select Digit Cursor Enable configuration mode n n Confirm and advance to next screen n Return to previous screen n n Next position/change text n Increase digit n End configuration mode n n *) Depending on configured breaker transfer logic **) A discrete input must be energized or the operational mode will dictate a logical condition for the required action n o p Press the buttons in the order indicated by the bullets n n Press the buttons simultaneously X: Pressing the STOP button changes the operating mode and stops the generator Table 2-1: Functional overview Manual 37238D GCP-30 Series - Genset Control © Woodward Page 11/39 LEDs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ NOTE The LEDs can be checked via a lamp test. In order to achieve this, the "Setpoint↑" and "Setpoint↓" but- tons must be pressed simultaneously. 1 2 3 V1 - V2 - V3 Color: green Voltage control The LEDs "V1", "V2" and "V3" indicate which voltage (VL1N, VL2N, VL3N, VL12, VL23 or VL31) is currently being displayed. This applies both to the gen- erator and the mains voltage display. 4 Stop Color: red "STOP" operating mode If the "STOP" LED is illuminated, the "STOP" mode has been enabled. If this LED is flashing, engine speed has been detected while the control is in the "STOP" mode. 5 -10%..fN..+10% Color: red/yellow/green Phase angle / synchroscope Normal operation: The LEDs between -10 % and +10 % display the gen- erator frequency differential relative to the frequency of the system that the generator is synchronizing with. If the fre- quency differential is greater than +10 % or less than -10 % the corresponding outer LED will flash. Configuration: If the control is in the configuration mode and the service display is configured "ON", the LEDs show the phase angle between the systems being synchronized when the double voltage/double frequency screen is displayed. The green LED in the center of the 15 LEDs indicates that the measured phase angle between the voltage systems displayed is less than 12 ° electrical. The phase angle is only displayed if the frequencies of the two voltages are within the following permissible lim- its: Generator 88 to 112 % of rated frequency (fN) Mains 96 to 104 % of rated frequency (fN) A distinction is made between two directions of rotation: -10 % → +10 % = If the LEDs illuminate from left to right, the generator frequency is greater than the synchronizing frequency (i.e. the generator is synchronizing in the fast direction). +10 % → -10 % = If the LEDs illuminate from right to left, the generator frequency is lower than the synchronizing frequency (i.e. the generator is synchronizing in the slow direction). 6 Automatic Color: yellow "AUTOMATIC" operating mode If the "AUTOMATIC" LED is illuminated, the "AUTOMATIC" operating mode is enabled. The "Setpoint↑", "Setpoint↓", "GCB ON", "GCB OFF", "MCB ON", "MCB OFF", "START", and "STOP" buttons are disabled. Manual 37238D GCP-30 Series - Genset Control Page 12/39 © Woodward 7 Manual Color: yellow "MANUAL" operating mode If the "Manual" LED is illuminated, the "MANUAL" operating mode has been enabled. The circuit breaker control, "START", and "STOP" buttons are enabled. 8 Protection Color: green Engine monitoring If the "Monitoring" LED is illuminated, the engine delayed protective moni- toring (protective functions configured to be ignored during start up) is ac- tively monitored by the control. Generator underspeed, underfrequency, un- dervoltage and reverse power are also monitored. The protective monitoring (i.e. overcurrent) that cannot be delayed by engine speed will always be monitored. 9 Alarm Color: red Alarm If the "Alarm" LED illuminates, the control has detected a fault condition. The control will respond according to the assigned alarm class of the fault. If the "RESET" button is pressed and released, the alarm is acknowledged, the centralized alarm (horn) is discontinued, and the "Alarm" LED becomes continuously illuminated. An alarm message is shown in the LC display as well. Table 4-4 lists all standard alarm messages for this control. 10 GCB on Color: green Reply: GCB is closed The GCB is closed when the "GCB ON" LED is illuminated. 11 [GCP-32] MCB on [GCP-31] Mains parallel Color: green Reply: MCB is closed / Mains parallel [GCP-32] Units that control two power circuit breakers: The MCB is closed when the "MCB ON" LED is illuminated. [GCP-31] Units that control only one circuit breaker may be used with sys- tem breaker control units (LS 4). These breaker control units use the load sharing CAN bus to communicate the status of circuit breakers and disconnectors to the GCP-31. When the MCB is closed, the LS 4 transmits this status and The "Mains parallel" LED is illuminated when the MCB and the GCB are closed simultaneously. Manual 37238D GCP-30 Series - Genset Control © Woodward Page 13/39 Buttons ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ In order to facilitate configuring the control parameters, the buttons are equipped with a "AUTOROLL" function. This permits the user to rapidly advance the display to the next setting, configuration screen, digit, or cursor posi- tion. The "AUTOROLL" function is only enabled when the user presses and holds the corresponding button. General / Configuration 12 Message↓ / Select Color: blue Message↓ / Select Normal operation: Message↓ - By pressing this button, the user will ad- vance to the next display screen of measured values and alarm messages. Configuration: Select - By pressing this button, the user will advance to the next configuration screen. If the original displayed value has been changed by pressing either the "Digit↑" or "Cursor→" buttons, the new value is saved by pressing the "Select" button once. Pressing this button again will advance the display to the next configuration screen. 13 Display V↓ / Digit↑ Color: blue Display V↓ / Digit↑ Normal operation: Display V↓ - By pressing this button, the user will ad- vance to the next generator and mains voltage display screen. Note: Pressing and holding this button for at least 5 seconds while a counter (kWh, start, running hours) is being displayed will result in that counter being reset. Configuration: Digit↑ - By pressing this button, the user will increase the number over the cursor by one digit. The numbers in the display may only be increased to the maximum permissible limit (refer to the list of parameters located in the Appendix of manual 37365). If a number has been increased to the maximum permissible limit, the number automati- cally reverts to the lowest permissible limit. 14 Setpoint / Cursor → Color: blue Setpoint / Cursor → Normal operation Setpoint - By pressing this button, the user will be able to display individual set point values. The displayed set point values may be adjusted by pressing the "Setpoint↑" or "Setpoint↓" buttons. Certain set point values, which are entered into the unit from external sources, can only be viewed. The set points that may be viewed in each code level can be found in Appendix A on page 38. Configuration Cursor→ - By pressing this button, the user will move the cursor one position to the right. The cursor automatically returns to the extreme left position when the "Cursor→" button is pressed while the cursor is in the extreme right position. 15 16 Setpoint↑ / Setpoint↓ Color: blue Setpoint↑ / Setpoint↓ By pressing the "Setpoint↑" or "Setpoint↓" buttons, the displayed set point will be changed accordingly. Only values that have been enabled during configuration and are accessible in the current operating mode may be changed. If the set point raise and lower buttons are pressed and held simul- taneously, the lamp test function is activated. Manual 37238D GCP-30 Series - Genset Control Page 14/39 © Woodward Circuit Breaker Operation 17 18 GCB ON / GCB OFF Color: green/red Close GCG / open GCB Note: These buttons function only if either the MANUAL or TEST operat- ing mode has been enabled. GCB ON ......This function is dependent upon the configured breaker logic. Pressing the "GCB ON" button will result in the mains circuit breaker closing. The breaker closure process will be aborted if the either "GCB OFF" or "MCB ON" button is pressed or the operating mode is changed. GCB OFF ....This function is dependent upon the configured breaker logic. Pressing the "GCB OFF" button will result in the generator circuit breaker opening. The breaker synchronization and closing process can be aborted by pressing this button as well. 19 20 [GCP-32] MCB ON / MCB OFF Color: green/red Close MCB / open MCB (only available in [GCP-32]) Note: These buttons function only if either the MANUAL or TEST operat- ing mode has been enabled. MCB ON......This function is dependent upon the configured breaker logic. Pressing the "MCB ON" button will result in the mains circuit breaker closing. The breaker closure process will be aborted if the either "MCB OFF" or "GCB ON" button is pressed or the operating mode is changed. MCB OFF....This function is dependent upon the configured breaker logic. Pressing the "MCB OFF" button will result in the mains cir- cuit breaker opening. The breaker synchronization and closing process can be aborted by pressing this button as well. Manual 37238D GCP-30 Series - Genset Control © Woodward Page 15/39 Operating Mode Selection 21 AUTO Color: blue AUTOMATIC operating mode The engine is automatically started/stopped and the circuit breakers are automatically actuated. The control inputs "Automatic 1" and "Automatic 2" are used to control the generator output to a configured level while in the "AUTOMATIC" operating mode (refer to the description of the discrete in- puts in the configuration manual). The control monitors for conditions re- quiring an emergency power and/or sprinkler operation to be initiated re- gardless of the status of the "Automatic 1" and "Automatic 2"discrete inputs. Discrete input "Automatic 1" energized: The generator is loaded with real power to the level configured for set point 1. Discrete input "Automatic 2" energized: The generator is loaded with real power to the level configured for set point 2 or to the level that corresponds to the external set point via the ana- log input (0/4 to 20 mA, 0 to 5/10 Vdc) or interface. NOTE Energizing discrete input 2 (terminal 63) will prohibit the operating mode from being changed from the mode currently enabled. 22 MAN Color: blue MANUAL operating mode The "MANUAL" operating mode enables the buttons on the control to be used for manual operations of the unit. The automatic operation functional- ity of the generator and the breakers is disabled. The protective functions (i.e. low oil pressure, underfrequency, overvoltage, etc.) of the control re- main enabled. The control does not monitor for conditions requiring an emergency power and sprinkler operation to be initiated. If an emergency power and sprinkler operation was initiated prior to changing the operation mode to "MANUAL", the emergency power or sprinkler operation will con- tinue. 23 24 START / STOP Color: green/red Engine start/stop START ........Pushing this button while the control is in the MANUAL op- eration mode will start the engine. The starter and fuel sole- noid/gas valve are enabled when the START button is pressed. The fuel solenoid/gas valve remains energized and the starter disengages after the engine reaches the configured firing speed. STOP ...........Pressing this button stops the engine by de-energizing the fuel solenoid/gas valve relay output. Manual 37238D GCP-30 Series - Genset Control Page 16/39 © Woodward 25 TEST Color: blue TEST operating mode Pressing the "TEST" button will start the engine and enable engine protec- tive functions. The circuit breakers may be operated manually to conduct load tests. If a mains failure occurs while in the TEST mode, the controller will initiate an emergency and/or sprinkler operation depending on how the control is configured. Initiate a load test After the "TEST" mode has been enabled, a load test may be initiated by pressing the "GCB ON" button. The GCB will synchronize or the MCB will open in accordance with how the circuit breaker logic is configured. Once the genera- tor is synchronized or the bus is dead, the GCB will close. The generator load can be increased or decreased by changing the load reference point with the "SETPOINT" buttons. Terminate a load test The load test will be terminated immediately when the "GCB OFF" or "MCB ON" button is pressed (depending upon the configured circuit breaker logic). A power reduction will not be performed when the load test is terminated in this manner. The generator will perform a power reduction if the "STOP" or "AUTOMATIC" mode buttons are pressed and the controller is not receiving a run request signal. 26 STOP Color: blue STOP operating mode Pressing the "STOP" button will shut the generator down. The following se- quence is performed when the STOP mode is enabled: Stopping process: • The "STOP" button is pressed once • The generator load is reduced • The GCB is opened once the measured load reaches 5 % of the rated gen- erator real power • A cool down period is carried out according to the configured engine cool down Shutdown process: • The "STOP" button is pressed twice • The GCB is opened immediately without performing a power reduction • The generator shuts down immediately without performing a cool down If discrete input 6 (terminal 63) is energized and configured as a control input by setting parameter "Op.mode blocked by Ter.63" as YES, it is possible for XPD and XPQ Package units with version 4.3010 software or higher to select the operation mode via an external source. Energizing and/or de-energizing terminals 127 and 128 in accordance with Table 2-2 will change the operating mode of the unit. It is assumed that the controller has supply power applied. Manual 37238D GCP-30 Series - Genset Control © Woodward Page 17/39 Operation mode blocked (terminal 63) Input STOP (terminal 127) Input AUTOMATIC (terminal 128) Function de-energized nonfunctional nonfunctional The operation mode selection buttons at the front of the GCP are en- abled and are used to change the operational mode (terminals 127/128 have no effect). energized de-energized de-energized The controller is locked into the operation mode that the unit is in at the moment terminal 63 is energized. The operation mode selection buttons at the front of the GCP are disabled and cannot be used to change the operational mode. energized energized de-energized The STOP operation mode is activated. The operation mode selection buttons at the front of the GCP are disabled and cannot be used to change the operational mode. energized de-energized energized The AUTOMATIC operation mode is activated. The operation mode selection buttons at the front of the GCP are disabled and cannot be used to change the operational mode. energized energized energized The STOP operation mode is activated. The operation mode selection buttons at the front of the GCP are disabled and cannot be used to change the operational mode. Table 2-2: Function – external operation mode selection WARNING Acknowledging an alarm, which has shut the engine down, while the control is still enabled (i.e. a run signal is still enabled) before to discovering the cause of the fault condition may result in an uninten- tional restart of the engine. Prior to acknowledging the alarm, verify the fault condition has cleared in order to protect against injury of personnel in the vicinity and damage or destruction effected equip- ment. ⇒ If the cause of the alarm is unknown or unclear, NEVER press the RESET button! The result may be destruction of the engine or equipment! 27 RESET Color: blue Acknowledgement Pressing this button acknowledges alarm messages. The alarm text in the display is cleared and the "Alarm" LED is turned off. The control display is returned to the basic operating screen. F2 and F3 class alarms may only be acknowledged in either the "STOP" or "MANUAL" operating modes. Manual 37238D GCP-30 Series - Genset Control Page 18/39 © Woodward LC Display ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ 28 LC-Display Liquid Crystal Display The LC display shows messages and measured values, depending on the mode or function currently enabled. In the configuration mode, individual parameters are displayed and may be changed. In the AUTOMATIC mode the measured operating values (e.g. voltage and current values) may be dis- played. Manual 37238D GCP-30 Series - Genset Control © Woodward Page 19/39 Chapter 3. Display Measured Values ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Top Display Line NOTE By using the "Display V" button will display the different measured voltages. xxxx yyy yyy yyy ---------------- Display in automatic mode, top line: measured values The following measured values are displayed (LEDs V1/V2/V3 indicate the meas- ured conductor(s)): • "xxxx" - generator voltage depending of the LEDs V1/V2/V3: V1 illuminates line-to-neutral voltage VL1-N V2 illuminates line-to-neutral voltage VL2-N V3 illuminates line-to-neutral voltage VL3-N V1+V2 illum. line-to-line voltage VL1-L2 V2+V3 illum. line-to-line voltage VL2-L3 V3+V1 illum. line-to-line voltage VL3-L1 • "yyy" - generator currents (line currents IL1, IL2 and IL3). Manual 37238D GCP-30 Series - Genset Control Page 20/39 © Woodward Bottom Display Line NOTE Pressing the "Message↓" button will advance the bottom line of the display. Pressing the "Message↓" button will also advance through any alarm text that may be present. The following screens may be viewed in succession by pressing the "Message↓" button. When the last display screen has been reached, the display returns to the basic screen. If alarms have occurred, the message texts are displayed in the sequence of occurrence in the display screens before the basic screen. If control functions are ac- tive (i.e. synchronization of the GCB), the basic screen is superimposed with the corresponding message (i.e. " synchronization"). Following the termination of the control function, the basic screen is displayed again. ---------------- xxxxxxxxxxxxxxxx Display in automatic mode, bottom line: measured values Instead of "xxxxxxxxxx" the following measuring values are displayed: • The maximum generator current (slave pointer) • The first four alarm messages that occurred • The time and date (XPD and XPQ Packages only) • The energy counter (kWh) Succession Display Description 0 (basic screen) --- --- --- --- Gen 0.00 0000kW Generator power factor Generator actual real power 1 --- --- --- --- max. Gen.current Slave pointer (maximum generator current [the measured values are displayed above the text]) 2 --- --- --- --- Time Date and time (XPD and XPQ Packages only) 3 (MPU = ON) --- --- --- --- Gen. 0000 rpm Engine speed (Pickup input is configured YES) 4.1 (alternative to 4.2/4.3) --- --- --- --- Ma E0000kW Mains measured real power (measured via analog input; E = Export, I = Import) 4.2 (alternative to 4.1/4.3) --- --- --- --- Ma 0.00 E0000kW Mains power factor Mains measured real power (calculated; E = Export, I = Import) 4.3 (alternative to 4.1/4.2) --- --- --- --- Ma LS4: 00000kW Mains measured real power (measured by LS 4; GCP-31/XPD and XPQ Packages only) 5 --- --- --- --- Mainscurr.0000 A Mains measured current L1 6.1 (alternative to 6.2) --- --- --- --- Mainsvolt.0000 V Mains measured voltage (pressing the "Display V↓" button will change the mains phase displayed) 6.2 (alternative to 6.1) --- --- --- --- M-decoupl:0000 V Mains voltage after the mains decoupling (measured by LS 4; GCP- 31/XPD and XPQ Packages only) Manual 37238D GCP-30 Series - Genset Control © Woodward Page 21/39 Succession Display Description 7 --- --- --- --- xxxxxxxxxxxxxxxx Measured value of the analog inputs (this display depends on the con- figuration of the analog input; XPD and XPQ Packages only) 8 --- --- --- --- Gen. = 0000kvar Generator reactive power (is calculated via the current of phase L1; even if power measurement is selected "three-phase"), 9 --- --- --- --- Energy=000000kWh Generator real energy counter 10.1 --- --- --- --- L: So0.00 Is0.00 Set and actual Lambda values (Option SC07/SC10) 10.2 --- --- --- --- P.actu: 000.00% Position of the actuator in % (Option SC07/SC10) 11 --- --- --- --- running: 000000h Operating hours 12 --- --- --- --- Rent.TM:0000:00h Rental duty time (RPQ Package only) 13 --- --- --- --- Service in 0000h Time remaining until the next maintenance call 14 --- --- --- --- Startno. 00000 Engine start counter 15 --- --- --- --- Battery: 00.0 V Battery voltage (supply voltage) 16 --- --- --- --- Comunicators: 00 CAN bus participants (load share line) 17 --- --- --- --- xxxxxxxxxxxxxxx MDEC and J1939 text/messages (Option SC07/SC08/SC09/SC10) 18 --- --- --- --- xxxxxxxxxxxxxxx CCM text/messages (Option SB03) 19 --- --- --- --- xxxxxxxxxxxxxxx IKD 1 text/messages (Option SC07/SC08/SC09/SC108) 20 --- --- --- --- xxxxxxxxxxxxxxx Alarm messages (maximum of 4 displayed). Alarms are display se- quentially from first to occur to last. Additional messages will be dis- played as alarm messages are acknowledged. 21 --- --- --- --- xxxxxxxxxxxxxxxx Active control functions (i.e. synchronization) or current alarm. Refer to the description on page 32. Manual 37238D GCP-30 Series - Genset Control Page 22/39 © Woodward Direction Of Power If the current transformers for the controller are wired according to the pin diagram shown, the following values are displayed: • Positive generator real power.........The generator supplied real power. • Inductive gen. power factor ϕ ........The generator supplied inductive re-active power. • Positive mains real power..............Real power supplied to the mains. • Inductive mains power factor ϕ .....The inductive re-active power supplied to the mains. S1 (K) S2 (L) S2 (L) S1 (K) Active power Dispaly positive Reactive power Display inductive Active power Display positive Reactive power Display capacitive GCB generator circuit breaker MCB mains circuit breaker GCP 26 25 s1 (k) G s2 (l) 28 27 s1 (k) s2 (l) pospos GENERATOR indindQQ PP pospos indindQQ PP BUSBAR MAINS Figure 3-1: Direction of power Power Factor Definition The phasor diagram is used from the generator's view. This defines the following definitions. Power Factor is defined as a ratio of the real power to apparent power. In a purely resistive circuit, the voltage and current waveforms are instep resulting in a ratio or power factor of 1.00 (often referred to as unity). In an in- ductive circuit the current lags behind the voltage waveform resulting in usable power (real power) and unusable power (reactive power). This results in a positive ratio or lagging power factor (i.e. 0.85lagging). In a capacitive circuit the current waveform leads the voltage waveform resulting in usable power (real power) and unusable power (reactive power). This results in a negative ratio or a leading power factor (i.e. 0.85leading). Manual 37238D GCP-30 Series - Genset Control © Woodward Page 23/39 Inductive: Electrical load whose current waveform lags the voltage waveform thus having a lagging power fac- tor. Some inductive loads such as electric motors have a large startup current requirement resulting in lagging power factors. Capacitive: Electrical load whose current waveform leads the voltage waveform thus having a leading power factor. Some capacitive loads such as capacitor banks or buried cable result in leading power factors. Different power factor displays at the unit: i0.91 (inductive) lg.91 (lagging) c0.93 (capacitive) ld.93 (leading) Reactive power display at the unit: 70 kvar (positive) -60 kvar (negative) Output at the interface: + (positive) - (negative) In relation to the voltage, the current is lagging leading The generator is over excited under excited Control: If the control unit is equipped with a power factor controller A voltage lower "-" signal is output as long as the measured value is "more inductive" than the reference set point Example: measured = i0.91; set point = i0.95 A voltage raise "+" signal is output as long as the measured value is "more capacitive" than the reference set point Example: measured = c0.91; set point = c0.95 Phasor diagram: inductive capacitive Manual 37238D GCP-30 Series - Genset Control Page 24/39 © Woodward Service Display ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Service display ON only visible while configuration mode is active Service display ON/OFF ON ................The service display is enabled and the following three screens are displayed. The voltages displayed in the screens will differ depend- ing how the controller is configured and if potential transformers are utilized. OFF ..............The service screens are disabled and the following screen are not displayed. B 00.0kV 00.00Hz G 00.0kV 00.00Hz only visible while configuration mode is active Double voltage and double frequency display The generator and busbar voltage and frequency are displayed. The phase angle be- tween the generator and busbar is displayed by the synchroscope (LED strip): B ...................Busbar voltage and frequency. G ...................Generator voltage and frequency. M 00.0kV 00.00Hz B 00.0kV 00.00Hz only visible while configuration mode is active Double voltage and double frequency display The mains and busbar voltage and frequency are displayed. The phase angle be- tween the mains and busbar is displayed by the synchroscope (LED strip): M ..................Mains voltage and frequency. B ...................Busbar voltage and frequency. Relay: MCB f V GCB only visible while configuration mode is active Status of circuit breakers and controller output relays The display shows the relay states of the controller outputs and the signals to the circuit breakers during synchronization. f .....................+ Frequency controller RAISE Terminal 8/9 ......................- Frequency controller LOWER Terminal 8/10 V ...................+ Voltage controller RAISE Terminal 11/12 ......................- Voltage controller LOWER Terminal 11/13 MCB .............On Connect pulse to the MCB Terminal 16/17 ......................Off Disconnect pulse to the MCB Terminal 39/40 GCB .............On Connect pulse to the GCB Terminal 14/15 ......................Off Disconnect pulse to the GCB Terminal 41/42 Manual 37238D GCP-30 Series - Genset Control © Woodward Page 25/39 Control Function Messages ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ EN Synchron. GCB DE Synchron. GLS Control function: GCB is synchronizing The GCB is synchronizing and will be closed when the synchronous condi- tions are met. Synchronization will be carried out, if generator and busbar voltages are measured. EN Synchron. MCB DE Synchron. NLS [GCP-32] Control function: MCB is synchronizing The MCB is synchronizing and will be closed when the synchronous condi- tions are met. Synchronization will be carried out, if generator and busbar voltages are measured. EN Synchron. Extern DE Synchron. Extern [GCP-31] Control function: MCB is synchronizing In order to enable the synchronization of an external circuit breaker, the bus- bar frequency will be controlled at a slightly higher frequency (df max/2) than the measured mains frequency. EN Dead bus st.GCB DE Schwarzst. GLS Control function: Close GCB to a de-energized bus The GCB is closed to the de-energized bus when voltage is measured from the generator but not measured from the bus. EN Dead bus st.MCB DE Schwarzst. NLS [GCP-32] Control function: Close MCB to a de-energized bus The MCB is closed to the de-energized bus when voltage is measured from the mains but not measured from the bus. EN Start DE Anlassen Control function: Start engine The GCP has received a start command while in AUTOMATIC (mains fail- ure, terminal 6 "Start engine" is energize, etc.) or MANUAL modes (engine start button was pressed). EN Preglow DE Vorglühen Control function: Preheating (Diesel engine) The diesel engine is preheated for the specified time. Relay output 6 con- tacts are closed for the designated time. EN Turning DE Spülvorgang Control function: Purging operation (Gas engine) The starter is engaged to rotate the engine prior to enabling the ignition and completely purge any remaining gas in the engine (and to prevent a backfir- ing or deflagration when switching on the ignition). Manual 37238D GCP-30 Series - Genset Control Page 26/39 © Woodward EN Ignition DE Zündung Control function: Ignition ON (Gas engine) The ignition is enabled. EN Governor down DE Grundstellung Control function: Drive governor down (Diesel engine) The GCP issues a speed lower signal to the speed controller prior to starting the engine. This ensures that the speed controller is at the start speed refer- ence point and prevents the engine from following a steep start speed ramp rate and shutting down for overspeed. EN Aux.serv.prerun DE Vorl.Hilfsbetr. Control function: Auxiliary operation pre-run Prior to starting the engine (excluding emergency operation starts) the con- figured relay output remains enabled for the configured time. This message is displayed for the configured time as well. This function permits external pre-start operations to be performed (i.e. open louvers, enable pre-lube oil pump, etc.). EN Aux.serv.postrun DE Nachl.Hilfsbetr. Control function: Auxiliary operation post-run After the engine has stopped, the configured relay output remains enabled for the configured time. his message is displayed for the configured time as well. This function permits external post-run operations to be performed (i.e. close louvers, enable external cooling pump, etc.). EN Start-Pause DE Start-Pause Control function: Time delay between start attempts In order to protect the starting circuit from overheating, a delay time be- tween start attempts may be configured. This message will be displayed for the configured delay time. EN Testmode DE Probebetrieb Control function: TEST The operating mode TEST has been enabled and this message is displayed appears intermittently with other control functions that are being performed. EN Load test DE Lastprobebetrieb Control function: Load test This message will be displayed when the GCP is in the TEST mode and the GCB button has been pressed and the GCB has closed. This function is per- formed when the generator is to be load tested. EN Emergency run DE Notstrom Control function: Emergency run operation The conditions for an "emergency run" operation have been met (i.e. the mains have failed while the unit is in AUTOMATIC). EN Mains settl.000s DE Netzber. 000s Control function: Mains settling time The GCP will wait for the configured time after the mains are restored fol- lowing a mains failure. The time remaining in the mains settling time is dis- played in this screen. EN Sprinkler DE Sprinklerbetrieb Control function: Sprinkler operation This message is displayed if the GCP has been configured for sprinkler op- erations and the conditions for a sprinkler operation have been met. Manual 37238D GCP-30 Series - Genset Control © Woodward Page 27/39 EN Sprinkler shutd. DE Sprinkler Nachl. Control function: Sprinkler coasting The engine will operate without load for 10 minutes following the conclu- sion of a sprinkler operation and the GCP will display this message. EN Cool down 000s DE Nachlauf 000s Control function: Engine coasting A no-load (cool down) operation may be configured prior to the engine stopping. The time remaining in the cool down period is displayed in this message. EN Stop engine! DE Motor Stop! Control function: Engine stop! This message is displayed while the engine is being shutdown. When the engine speed drops below the configured firing speed set point, the starting functions are disabled for 10 seconds. EN Unloading DE Leistungsred. Control function: Power reduction A power reduction is generally performed when a generator is being taken off line. The load on the generator is reduced according to the configured ramp rate. This message is displayed while the load is being reduced. NOTE The texts "Sprinkler operation", "Emergency power", "Test", "Load test" and "Sprinkler+Emergency power" are intermittently displayed with the basic display screen. If one of these texts is active, press- ing the "Select" button will change the display so that only the basic display screen is shown. The "Sprinkler operation", "Emergency power", "Test", "Load test" and "Sprinkler+Emergency power" texts may be displayed again by pressing the "RESET" button. EN Sprinkler+Emerg. DE Sprinkler+Notstr Control function: Sprinkler operation and emergency operation Both the sprinkler operation and the emergency power functions are active. Both functions are initiated according to the parameters specific to each op- eration. EN Start without CB DE Start ohne GLS Control function: Start engine without closing GCB The engine is started without closing the GCB when terminal 6 is energized (normally after the period of delayed engine monitoring the GCB will be closed either after synchronizing or with a dead bus start). Manual 37238D GCP-30 Series - Genset Control Page 28/39 © Woodward Counters ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Reset Maintenance Call ---------------- SERVICE Reset maintenance call The alarm message to the left is displayed when the configured maintenance inter- val has expired. The maintenance interval is configured when the unit is commis- sioned. In addition to the alarm message being displayed, the "Alarm" LED will flash and the "Centralized alarm" relay (horn) is energized. To acknowledge this alarm message and to reset the service counter back to the configured time, utilize the following procedure: 1.) Acknowledge the alarm by pressing (short acknowledgement) the "RESET" button This will de-energize the "Centralized alarm" relay. At this point it is not possible to acknowledge/clear the "Maintenance" alarm. It will be possible to accomplish this after the maintenance counter has been reset. 2.) Perform the scheduled generator maintenance. 3.) Acknowledge the maintenance call as follows: - Using the "Message↓" button, advance the bottom line of the display to the "Service in 000h" screen. - Press and hold the "Digit" button for 10 seconds. - The indicated maintenance interval should revert to the configured mainte- nance interval. - Press the "RESET" button and the alarm should clear. Notes: • The maintenance counter may be reset according to the procedure described above if the generator maintenance is performed prior to the maintenance interval counter expiring (the Service message does not appear). • If the number of hours until the next maintenance call shall be changed, please contact the service staff (and notice the configuration manual). If the maintenance interval counter must be changed, code level 2 access rights are required to access the configuration menus. • The maintenance interval counter may be disabled by configuring 0 hours for the maintenance interval. • If the unit is equipped with Option SC07/SC08/SC09/SC10 and the MDEC or J1939 communication is enabled, the operating hours will be taken from the en- gine control unit. Please refer to manual 37313 or 37382 for further information. Manual 37238D GCP-30 Series - Genset Control © Woodward Page 29/39 Chapter 4. Alarm Messages Alarm Classes ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ NOTE If terminal 6 is energized and configured for "Sprinkler operation", alarm classes F2 and F3 are con- verted to alarm class F1. The exception to this is if terminal 34 is energized (terminal 61 if terminal 34 is not available) and overspeed faults. Alarm class F2 and alarm class F3 ⇒ Alarm class F1 The monitoring functions are divided into four alarm classes: F0 - Warning alarm - When faults of this alarm class are monitored an alarm message is displayed without issu- ing a centralized alarm. This alarm class does not lead to an interruption of the generator operation. Æ Alarm text. F1 - Warning alarm - When faults of this alarm class are monitored an alarm message is displayed and a cen- tralized alarm is issued. This alarm class does not lead to an interruption of the generator operation. Æ Alarm text + flashing "alarm" LED + centralized alarm relay (horn). F2 - Triggering alarm - When faults of this alarm class are monitored an alarm message is displayed, a central- ized alarm is issued, the generator load is shed prior to opening the GCB, and the engine is shutdown after the cool down period expires. Operations are interrupted. Æ Alarm text + flashing "alarm" LED + centralized alarm relay (horn) + soft shutdown. F3 - Triggering alarm - When faults of this alarm class are monitored the GCB is immediately opened and the engine shutdown. Load reduction is not performed. Operations are interrupted. Æ Alarm text + flashing "alarm" LED + centralized alarm relay (horn) + hard shutdown. Manual 37238D GCP-30 Series - Genset Control Page 30/39 © Woodward Acknowledge Alarm Messages ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ WARNING Acknowledging an alarm, which has shut the engine down, while the control is still enabled (i.e. a run signal is still enabled) before to discovering the cause of the fault condition may result in an uninten- tional restart of the engine. Prior to acknowledging the alarm, verify the fault condition has cleared in order to protect against injury of personnel in the vicinity and damage or destruction effected equip- ment. ⇒ If the cause of the alarm is unknown or unclear, NEVER press the RESET button! The result may be destruction of the engine or equipment! By pressing the "RESET" push-button, the output of the centralized alarm and the alarm messages on the LC dis- play are acknowledged according to the following logic: Horn: After 2 minutes the horn is reset regardless of the acknowledgement of an alarm. Interface: All internal errors are conveyed via the interface. NOTE In order to acknowledge alarm messages via terminal 6, the "acknowledgement" function must be con- figured for this terminal. Refer to the description in manual 37365. An alarm cannot be acknowledged until the cause of the fault condition has been corrected. NOTE When alarms are acknowledging via the CAN bus interface, no differentiation is made between a "short acknowledge" and "long acknowledge". All input signals over 0.1 seconds are recognized as a "long acknowledge". Manual 37238D GCP-30 Series - Genset Control © Woodward Page 31/39 Short Acknowledgement (< 2,5 s) Methods to perform a short acknowledgement • The "RESET"button is pressed for more than 0.5 seconds but less than 2.5 seconds • Terminal 6 is energized more than 0.5 s seconds but less than 2.5 seconds Result • The "Alarm" LED changes from flashing to continuous illumination Acknowledgement via Operating mode Button "RESET" Terminal 6 STOP AUTO TEST MANUAL 1 x 1 1 1 1 0 1 1 1 0 0 1 = energized/pressed, 0 = de-energized/not pressed, x = 0 or 1 irrelevant Table 4-1: Alarms – Short acknowledgement Long Acknowledgement (> 2,5 s) Methods to perform a long acknowledgement • The "RESET" button is pressed for more than 2.5 seconds • Terminal 6 is energized more than 2.5 seconds • The acknowledgement bit is received via the CAN bus interface. Result • The LED "Alarm" turns off (alarm classes F1 through F3) • The group alarm relays F1 and F3 are reset • The displayed alarm messages are acknowledged if the corresponding fault condition is no longer present. Alarm messages cannot be acknowledged if the fault condition that initiated the alarm is still present. Table for warning alarms (alarm class F0 and F1) provided no F2 or F3 class alarms are present Acknowledgement via Operating mode Button "RESET" Terminal 6 Interface STOP AUTO TEST MANUAL 1 x x 1 1 1 1 0 1 x 1 1 0 0 0 0 1 0 1 0 0 1 = energized/pressed, 0 = de-energized/not pressed, x = 0 or 1 irrelevant Table 4-2: Alarms – Long acknowledgement - Table for warning alarms Table for alarms causing a shutdown (alarm class F2 and F3) Acknowledgement via Operating mode Button "RESET" Terminal 6 Interface STOP AUTO TEST MANUAL 1 x x 1 0 1 1 0 1 x 1 1 0 0 0 0 1 *) 0 1 0 0 1 = energized/pressed, 0 = de-energized/not pressed, x = 0 or 1 irrelevant Table 4-3: Alarms – Long acknowledgement - Table for alarms causing a shutdown *) Only if the parameter "Ackn. F2, F3 via interf." is enabled Manual 37238D GCP-30 Series - Genset Control Page 32/39 © Woodward Alarm Messages NOTE Pressing the "Message↓" button will advance the bottom line of the display to the next alarm message. ---------------- yyyyyyyyyyyyyyyy Display in automatic mode, second line: Alarms When an alarm is initiated, the corresponding alarm message is displayed in the bottom line of the LC display according to the following list: Type of alarm Alarm class Alarm text Relay output (Terminal) Engine overspeed (Pickup) F3 Over speed Generator overfrequency F3 Over frequency Generator underfrequency F3 Low frequency Generator overvoltage F3 Gen.overvolt. Generator undervoltage F3 Gen.undervolt. Generator overcurrent level 1 F3 Gen.overcurr. 1 Generator overcurrent level 2 F3 Gen.overcurr. 2 Reverse/reduced load F3 Revers/min.power Overload F2 Gen.overload Unbalanced load F3 Load unbalanced Mains overvoltage F0 Mains-overvolt Mains undervoltage F0 Mains-undervolt. Mains overfrequency F0 Mains-overfreq. Mains underfrequency F0 Mains-underfreq. Mains phase shift F0 Phase shift Battery undervoltage F1 Batt.undervolt. GCB synchronization time monitoring expired F1 GCB syn.failure MCB synchronization time monitoring expired F1 MCB syn.failure Switching to de-energized busbar time monitoring expired F1 Failure df/dVmax. GCB closing malfunction F1 GCB close failure MCB closing malfunction F1 MCB close failure GCB opening malfunction F1 GCB open failure MCB opening malfunction F1 MCB open failure MCB opened before zero power transfer occurred w/ GCB synch interch. F1 Import power <> 0 Maintenance call timer expired F1 Service Interface monitoring error X1/X5 F1 Interf.err.X1X5 Interface monitoring error Y1/Y5 F1 Interf.err.Y1Y5 Engine speed/generator frequency mismatch F3 Pickup/Gen.freq. Engine shutdown malfunction F3 Stop failure Engine start failure F3 Start failure Unintended stop of engine F3 Unintended stop [GCP-31] External mains decoupling failure via terms. 39/40 F1 EXT open failure Power ramp did not reach set point prior to the breaker open timer expired F1 P-ramp: open GCB Refer to the Relay Out- puts Section in the Con- figuration Manual for detailed info Group alarm via the Relay manager with the parameter 85 Table 4-4: Alarms – Text messages Manual 37238D GCP-30 Series - Genset Control © Woodward Page 33/39 NOTE Discrete input – If a discrete input has been configured as alarm input, the alarm and configured text will be displayed when the input is enabled. Analog input – An "!" and the text configured for the analog input screen is displayed as the alarm message when a fault is detected (i.e. !Coolant). If the control detects a broken wire for the analog input, the measured value is overwritten with "- -". An alarm is issued in accordance with the con- figured alarm class at the same time. EN Gen.undervoltage DE Gen.-Unterspg. Alarm message: Generator undervoltage Alarm class: F3 The monitored generator voltage has fallen below the undervoltage limit for the configured delay time. EN Gen.overvoltage DE Gen.-Überspg. Alarm message: Generator overvoltage Alarm class: F3 The monitored generator voltage has exceeded the overvoltage limit for the configured delay time. EN Low frequency DE Gen.-Unterfreq. Alarm message: Generator underfrequency Alarm class: F3 The monitored generator frequency has fallen below the underfrequency limit for the configured delay time. EN Over frequency DE Gen.-Überfreq. Alarm message: Generator overfrequency Alarm class: F3 The monitored generator frequency has exceeded the overfrequency limit for the configured delay time. EN Mains-undervolt. DE Netz-Unterspg. Alarm message: Mains undervoltage Alarm class: F0 The monitored mains voltage has fallen below the undervoltage limit for the configured delay time. EN Mains-overvolt. DE Netz-Überspg. Alarm message: Mains overvoltage Alarm class: F0 The monitored mains voltage has exceeded the overvoltage limit for the configured delay time. EN Mains-underfreq. DE Netz-Unterfreq. Alarm message: Mains underfrequency Alarm class: F0 The mains frequency has been measured below the underfrequency limit for the configured delay time. EN Mains-overfreq. DE Netz-Überfreq. Alarm message: Mains overfrequency Alarm class: F0 The monitored mains frequency has exceeded the overfrequency limit for the configured delay time. Manual 37238D GCP-30 Series - Genset Control Page 34/39 © Woodward EN Phase shift DE Phasensprung Alarm message: Phase shift Alarm class: F0 The monitored measured phase shift has exceeded the limit for the config- ured delay time. EN Over speed DE Überdrehzahl Alarm message: Engine overspeed Alarm class: F3 The monitored engine speed has exceeded the engine overspeed limit for the configured delay time. EN Gen.overload DE Gen.-Überlast Alarm message: Generator overload Alarm class: F3 The monitored generator load has exceeded the generator overload limit for the configured delay time. EN Revers/min.power DE Rück/Minderleist Alarm message: Generator reverse-/-reduced load Alarm class: F3 The monitored generator reverse power / reduced load has exceeded / fallen below the generator reverse power / reduced load limit for the configured delay time. EN Load unbalanced DE Schieflast Alarm message: Load unbalanced Alarm class: F1 The monitored generator load has exceeded the asymmetric load limit for the configured delay time. EN Gen.overcurr. 1 DE Gen.-Überstrom 1 Alarm message: Generator overcurrent, limit value 1 Alarm class: F3 The monitored generator current has exceeded the generator overcurrent limit 1 for the configured delay time. EN Gen.overcurr. 2 DE Gen.-Überstrom 2 Alarm message: Generator overcurrent, limit value 2 Alarm class: F3 The monitored generator current has exceeded the generator overcurrent limit 2 for the configured delay time. EN Batt.undervolt. DE Batt.-Unterspg. Alarm message: Battery undervoltage Alarm class: F1 The monitored battery voltage has fallen below the battery undervoltage limit for the configured delay time. Manual 37238D GCP-30 Series - Genset Control © Woodward Page 35/39 EN Pickup/Gen.Freq DE Pickup/Gen.Freq Alarm message: Engine speed/frequency mismatch Alarm class: F3 The monitored engine speed (MPU) has deviated by more than 10 Hz from the monitored generator frequency. EN Interf.err. X1X5 DE Fehl.Schnit.X1X5 Alarm message: Interface fault X1-X5 Alarm class: F1 The load share CAN bus interface (terminals X1-X5) has malfunctioned. External control signals cannot be received. EN Interf.err. Y1Y5 DE Fehl.Schnit.Y1Y5 Alarm message: Interface fault Y1-Y5 Alarm class: F1 The ECU CAN bus interface (terminals Y1-Y5) has malfunction. ECU mes- sages cannot be received. EN GCB syn.failure DE Synch.Zeit GLS Alarm message: GCB synchronization time exceeded Alarm class: F1 The configured time for synchronization of the GCB has expired. EN MCB syn.failure DE Synch.Zeit NLS Alarm message: MCB synchronization time exceeded Alarm class: F1 The configured time for synchronization of the MCB has expired. EN EXT open failure DE Störung EXT AUF Alarm message: Malfunction when opening an external breaker Alarm class: F1 GCP-31 only: The external circuit breaker reply has failed to signal that the breaker opened after the GCP-31 (terminals 39/40) issued an open com- mand. Manual 37238D GCP-30 Series - Genset Control Page 36/39 © Woodward EN GCBclose failure DE Störung GLS ZU Alarm message: Malfunction when closing GCB Alarm class: F1 The GCB has attempted to close 5 times and the circuit breaker reply fails to signal that the breaker has closed. EN GCB open failure DE Störung GLS AUF Alarm message: Malfunction when opening GCB Alarm class: F1 The GCP has issued a GCB open command and the circuit breaker reply fails to signal that the breaker has open within 2 seconds following the open command was issued. EN MCBclose failure DE Störung NLS ZU Alarm message: Malfunction when closing MCB Alarm class: F1 The MCB has attempted to close 5 times and the circuit breaker reply fails to signal that the breaker has closed. EN MCB open failure DE Störung NLS AUF Alarm message: Malfunction when opening MCB Alarm class: F1 The GCP has issued a MCB open command and the circuit breaker reply fails to signal that the breaker has open within 2 seconds following the open command was issued. EN Import power<>0 DE Bezugsleist.<>0 Alarm message: Incoming power "Zero" not reached Alarm class: F1 The GCP has opened the MCB prior to a zero power transfer being achieved when "CLOSED TRANSITION" circuit breaker logic has been configured and the time configured for "Max. start/stop ramp time" has expired. EN Failure df/dVmax DE Stör. df/dU-max. Alarm message: Time for dead bus start exceeded Alarm class: F1 The generator voltage or frequency has failed to reach the configured win- dow for a dead bus closure and the configured time for "GCB dead bus op. max. time" has expired. EN Start failure DE Fehlstart Alarm message: Start fail Alarm class: F3 The GCP has unsuccessfully attempted to start the engine three times. The GCP does not initiate further start attempts. EN Stop failure DE Abstellstörung Alarm message: Stop failure Alarm class: F3 The GCP has detected speed via generator frequency, the MPU input, or dis- crete input 5 (terminal 62/firing speed detected) 30 seconds after issuing a stop command. Manual 37238D GCP-30 Series - Genset Control © Woodward Page 37/39 EN Service DE Wartung Alarm message: Maintenance call Alarm class: F1 The configured maintenance interval time has expired. ⇒ Also refer to "Reset Maintenance Call" on page 28. EN Unintended stop DE ungewollter Stop Alarm message: Unintended stop Alarm class: F3 The engine has ceased running without being issued a stop running com- mand from the GCP. Note: The engine may cease running due to mechanical damage, overload- ing, running out of fuel and the engine R.P.M. fall below the configured fir- ing speed. This alarm will not be issued if delayed by engine speed monitor- ing is enabled. EN P-ramp: open GCB DE P-Rampe: GLS auf Alarm message: Shutdown failure Alarm class: F3 The GCP has issued a stop command but the GCB has not opened prior to the configured time expiring for "add/stop ramp max. time". NOTE The following message is not an alarm message. It is displayed for information purposes only. Due to the fact it an informative message and not an alarm message, it does not require the operator to ac- knowledge the message and will not result in a shutdown of the generator set. The message will auto- matically clear when the rotating fields match. EN Phase sequence! DE Drehfeld falsch! Alarm message: generator/mains rotating field mismatch display only The generator and the mains have counter rotating fields. Closing GCB/MCB is blocked. Manual 37238D GCP-30 Series - Genset Control Page 38/39 © Woodward Appendix A. Code Level Access Permissions Code Level 0 or No Code Level Configuration screen - Software version - Enter code - Language first/second - Service display Set point in display mode - Psetmanual only in "Manual" or "Test" operation mode Code Level 1 Configuration screen - Software version - Enter code - Language first/second - Service display - View event logger - Real power controller Pset1 - Real power controller Pset 2 - Power factor controller set point Cset - Horn reset after - Maintenance call remaining time - Time - Year, Moth - Day/weekday Set point in display mode - Psetmanual only in "Manual" or "Test" operation mode - Pset1 only in "Automatic" or "Stop" operation mode - Pset2 only in "Automatic" or "Stop" operation mode - Cset Code Level 2 Configuration screen - complete access Set point in display mode - Psetmanual only in "Manual" or "Test" operation mode - Pset1 only in "Automatic" or "Stop" operation mode - Pset2 only in "Automatic" or "Stop" operation mode - Cset - Fset - Uset Set points are only visible when the respective controller is enabled! We appreciate your comments about the content of our publications. Please send comments to: stgt-documentation@woodward.com Please include the manual number from the front cover of this publication. Woodward Handwerkstrasse 29 - 70565 Stuttgart - Germany Phone +49 (0) 711 789 54-0 • Fax +49 (0) 711 789 54-100 sales-stuttgart@woodward.com Homepage http://www.woodward.com/power Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address/phone/fax/e-mail information for all locations is available on our website (www.woodward.com). 2007/2/Stuttgart Section 10 Type IP Core and Coil Transformers 1 Choosing a brand of dry type core and coil transformer for your electrical equipment is an important decision. You need one that will perform to your customer’s expectations. One that will last longer than the equipment itself. Since 1928, original equipment manufacturers have chosen GE transformers for those very reasons. All GE Type IP core and coil transformers are made with high quality, grain- oriented electrical steel and magnetic wire using GE proprietary processes. Coils are automatically wound by numerically controlled machines. Products are assembled by a skilled work force that utilizes Six Sigma quality procedures. Each unit is 100% tested per NEMA, UL and ANSI standards using a custom-made automated test equipment system. Units that pass all electrical tests and meet stringent inspection criteria are proudly tagged with the tester’s name. It’s no wonder that, in survey after survey, people equate the GE name with quality. World-class quality and systems integration An increasingly competitive global market demands equipment that meets world-class quality and systems integration requirements. The standard line of Type IP transformers is UL and C-UL listed. Additionally, a series of “CE” compliant transformers is now available that satisfies the low voltage directive EN60742 (European norm). Because system compatibility is so important in today’s complex control schemes, Type IP appearance and performance characteristics form a per fect link in an integrated control system that utilizes GE world-class circuit breakers and controls. GE Type IP Transformers for Performance, Reliability and Service Life 2 GE Type IP Core and Coil Transformers Type IP transformers are core and coil units designed for machine tool, industrial control, panelboard, and general purpose applications. Several types of terminations are available to simplify installation. These include primary and secondary leads out, integral fuse holder assemblies and the standard terminal block finished into the epoxy encapsulation. Consult your local GE Electrical Distribution & Control sales office for complete technical applications data. Standards:Type IP units conform to ANSI C89.2. They are UL and C-UL listed under UL-506, file E2739. Insulation classes:Generally, 150 VA and below are 105°C insulation class, 55°C rise. 200 VA and above are 185°C (NEMA), 180°C (UL) insulation class, 115°C rise. Maximum sur face temperature is 65°C. Frequency:60 Hertz is standard; 50 Hertz is available as an option. Voltage regulation:All designs 2.0 kVA and below are compensated for voltage drop. Generally, this compensation ranges from 10% in the smallest rating to 3% for the largest. All machine tool designs meet or exceed NMTBA regulation requirements. Series-multiple secondary connections:Transformers with 120/240V secondaries (series-multiple) may be connected for 120V, 240V or 240/120V three-wire. Jumpers are provided. Overcurrent protection:Type IP transformers are low impedance transformers that require overcurrent protection for most applications. They provide for optional integral primary and/or secondary fusing. Mounting dimensions:Type IP transformers are lightweight, small and designed for minimum mounting dimensions. Many units will fit competitors' mounting footprints. Application Guide 3 Step-by-step Selection of Core and Coil Transformers 1.Determine the input voltage, output voltage and frequency. 2.Determine the continuous power (VA) drawn by each load device. Calculate the maximum continuous power of all load devices that could be energized at the same time. 3.Determine if any of the load devices are voltage sensitive. NEMA stan- dards require electromagnetic components to operate reliably at 85% of rated voltage. This includes devices such as contactors, relays and solenoids. For applications with voltage sensitive devices, determine the inrush current of each load device. Inrush is the power (VA) drawn by a device the instant it is energized. Electromechanical devices have an inrush from 3 to 10 times their continuous power rating. The inrush of resistive devices is the same as their continuous power rating. Calculate the maximum inrush power. This is the inrush of all devices being energized at a given instant, plus the continuous power of all devices already energized. A number of load device combinations may have to be examined to determine which produces the maximum inrush current. 4.Use the transformer selection tables to determine the correct catalog number. Select a unit capable of carrying the maximum continuous power. If any load devices are voltage sensitive, select a transformer capa- ble of carrying both the maximum continuous power and the maximum inrush power. Inrush VA listed in selection tables is for .20 PF loads and 95% secondary voltage output. This assures 85% voltage will be supplied to loads on the secondary even if voltage from the primary source is reduced as much as 10%. If you cannot find the exact unit you need, have your GE distributor contact our Customer Service Center. Continuous Frame Inrush VA Catalog Number kVA Size at .20 PF, Terminal Board 95% sec. volt 220/440, 230/460, 240/480 Volts Primary — 110, 115, 120 Volts Secondary — 60 Hertz .050 611 193 9T58K0042 .075 612 303 9T58K0043 .100 811 396 9T58K0044 .150 813 724 9T58K0045 .200 814 821 9T58K0046 .250 815 1034 9T58K0047 .300 817 1307 9T58K0048 .375 817 1441 9T58K0049 .500 1016 2027 9T58K0050 .750 12225 3092 9T58K0051 1.0 12300 4494 9T58K0052 1.5 14225 5156 9T58K0053 2.0 14300 9193 9T58K0054 3.0 14475 14513 9T58K0056 230/460/575 Volts Primary — 115/95 Volts Secondary — 50/60 Hertz .050 613 196 9T58K0062 .075 811 278 9T58K0063 .100 813 445 9T58K0064 .150 815 663 9T58K0065 .200 815 864 9T58K0066 .250 817 1137 9T58K0067 .300 1016 1412 9T58K0068 .375 1016 1670 9T58K0069 .500 1016 1822 9T58K0070 .750 12300 3524 9T58K0071 1.0 14225 4392 9T58K0072 1.5 14300 6753 9T58K0073 2.0 14475 11563 9T58K0074 208/277/380 Volts Primary — 115/95 Volts Secondary — 50/60 Hertz .050 613 217 9T58K0082 .075 811 322 9T58K0083 .100 813 464 9T58K0084 .150 815 761 9T58K0085 .200 815 837 9T58K0086 .250 817 1198 9T58K0087 .300 1016 1409 9T58K0088 .375 1016 1674 9T58K0089 .500 1016 1821 9T58K0090 .750 12300 3771 9T58K0091 1.0 14225 4234 9T58K0092 1.5 14300 7091 9T58K0093 2.0 14475 11729 9T58K0094 4 GE Type IP Core and Coil Transformers GE Type IP transformers are now encapsulated designs to provide the highest quality electrical per formance. The transformer coil is completely surrounded by epoxy, making the unit impervious to external elements. Terminations are made of a new, rugged, high-impact plastic terminal strip. Full head #8 brass screws assure quick, easy terminations with maximum connection integrity. The encapsulated design retains dimensions and footprint similar to our previous style core and coil units for easy exchange. Options Secondary fusing:Factory or field installed secondary fuse clips are available. They are restricted to units with terminal strips and a single secondary voltage or secondary with one tap. Dual primary and secondary fusing:Factory or field installed dual primary and secondary fusing is avail- able on all units, including leads out and multiple sec- ondary voltages. Leads out:Terminal strip is replaced by rugged prima- ry and secondary leads emanating from the top of the encapsulated coil. (Note: Refer to page 9 for CE compliant transformers) 50-3000VA, Encapsulated Open Core and Coils Machine Tool Applications Single-Phase Continuous Frame Catalog Number kVA Size Terminal With Primary and Board Secondary Leads Out1 240/480 Volts Primary — 120/240 Volts Secondary — 60 Hertz .050 611 9T58K2802 9T58K1802 .075 612 9T58K2803 9T58K1803 .100 811 9T58K2804 9T58K1804 .150 813 9T58K2805 9T58K1805 .200 814 9T58K2806 9T58K1806 .250 815 9T58K2807 9T58K1807 .300 815 9T58K2808 9T58K1808 .375 817 9T58K2809 9T58K1809 .500 1016 9T58K2810 9T58K1810 .750 12225 9T58K2811 9T58K1811 1.0 12300 9T58K2812 9T58K1812 1.5 14225 9T58K2813 9T58K1813 2.0 14300 9T58K2814 9T58K1814 3.0 14475 9T58K2815 9T58K1815 600 Volts Primary — 120/240 Volts Secondary —60 Hertz .100 811 9T58K2824 9T58K1824 .200 814 9T58K2826 9T58K1826 .300 815 9T58K2828 9T58K1828 .500 1016 9T58K2830 9T58K1830 1.0 12300 9T58K2832 9T58K1832 2.0 14300 9T58K2834 9T58K1834 3.0 14475 9T58K2835 9T58K1835 120/240 Volts Primary — 120/240 Volts Secondary —60 Hertz .100 811 9T58K2907 — .200 814 9T58K2909 — .300 815 9T58K2911 — .500 1016 9T58K2913 — .750 12225 9T58K2914 — 1.0 12300 9T58K2915 — 2.0 14300 9T58K2917 — 3.0 14475 9T58K2918 — Control Power Applications 1Secondary fusing not available. 1Secondary fusing not available. Single-Phase 5 50-3000VA Encapsulated Open Core and Coils Continuous Frame Catalog Number kVA Size Terminal With Primary and Board Secondary Leads Out1 120/240 Volts Primary — 12/24 Volts Secondary — 60 Hertz .050 611 9T58K2873 9T58K1873 .075 612 9T58K2874 9T58K1874 .100 811 9T58K2875 9T58K1875 .150 813 9T58K2876 9T58K1876 .200 814 9T58K2877 9T58K1877 .250 815 9T58K2878 9T58K1878 .300 815 9T58K2879 9T58K1879 .500 1016 —9T58K1881 240/480 Volts Primary — 120/240 Volts Secondary — 50/60 Hertz .500 1016 9T58K2930 9T58K1930 .750 12300 9T58K2931 9T58K1931 1.0 14225 9T58K2932 9T58K1932 1.5 14300 9T58K2933 9T58K1933 2.0 14475 9T58K2934 9T58K1934 3.0 14475 9T58K2935 9T58K1935 380/400/416 Volts Primary — 115/230 Volts Secondary — 50/60 Hertz .500 1016 9T58K2978 — .750 12300 9T58K2979 9T58K1979 1.0 14225 9T58K2980 9T58K1980 1.5 14300 9T58K2981 9T58K1981 2.0 14475 9T58K2982 9T58K1982 3.0 14475 9T58K2983 — 240/480 Volts Primary — 12/24 Volts Secondary — 60 Hertz .050 611 9T58K3164 — .100 811 9T58K4132 — .150 813 9T58K4133 — .250 815 9T58K3024 — 208/240 Volts Primary — 12/24 Volts Secondary — 60 Hertz .050 611 9T58K4050 — .100 811 9T58K4051 — .150 813 9T58K4052 — .250 815 9T58K4053 — 6 GE Type IP Core and Coil Transformers Encapsulated Transformer Continuous Power Rating (VA) Secondary 750 1000 1500 2000 3000 Voltage Fuse Rating (amperes) 95 12 15 20 25 – 110 10 12 20 25 30 115 10 12 20 20 30 120 10 12 15 20 30 208 6 8 12 15 20 220 5 7 10 12 20 230 5 7 10 12 20 240 5 6 10 12 15 Glass fuse H-K fuse Options and Fusing Guide 1 For motor control circuits fusing, refer to NEC 430-72. Fuse Clips Mounted On Fuse Blocks Mounted On Top Of Transformer Terminals Dual Dual Dual Terminal Terminal 13/32” x 1 1/2”13/32” x 1 1/2”13/32” x 1 1/2”Links Block Single Single Single Single Dual Class CC Class CC Class CC Covers 1/4” x 1 1/4”1/4” x 1 1/4”13/32” x 1 1/2”9/16” x 2”9/16” x 2”Fuses with Fuses with Fuses with (Standard (Standard Glass Fuse1 Glass Fuse Midget Fuse H/K Fuses H/K Fuses Single Single Single Terminal Terminal 1/4” x 1 1/4”13/32” x 1 1/2”9/16” x 2”Blocks)Blocks) 2 Glass Fuse Midget Fuse H/K Fuse 9T58K0000 9T58E0000 -G09 -G24 -G42 -G10 -G05 -G48 -G38 -G18 -G01 -G35 Encapsulated Transfor mer Options 1 Use G24 when the transformer is a series multiple or multi-tapped winding with no open terminals. 2 Terminal block cover is standard on “CE” marked designs. Prefix for this catalog number is 9T58E. Encapsulated Transformer Continuous Power Rating (VA) Primary 50 75 100 150 200 250 300 375 500 Voltage Fuse Rating (amperes) 100 1.50 2.00 3.00 4.00 3.00 4.00 5.00 6.00 8.00 110 1.25 2.00 2.50 4.00 5.00 3.00 4.00 5.00 7.00 120 1.25 1.60 2.50 3.00 5.00 3.00 4.00 5.00 6.00 200 0.75 1.00 1.50 2.00 3.00 3.00 4.00 5.00 4.00 208 0.60 1.00 1.25 2.00 2.50 3.00 4.00 5.00 4.00 220 0.60 1.00 1.25 2.00 2.50 3.00 4.00 5.00 3.00 230 0.60 0.80 1.25 1.60 2.50 3.00 3.00 4.00 3.00 240 0.60 0.80 1.25 1.60 2.50 3.00 3.00 4.00 3.00 277 0.50 0.80 1.00 1.60 2.00 2.50 3.00 4.00 5.00 380 0.30 0.50 0.75 1.00 1.50 1.60 2.00 2.50 3.00 400 0.30 0.50 0.75 1.00 1.50 1.60 2.00 2.50 3.00 416 0.30 0.50 0.60 1.00 1.25 1.60 2.00 2.50 3.00 440 0.30 0.50 0.60 1.00 1.25 1.60 2.00 2.50 3.00 460 0.30 0.40 0.60 0.80 1.25 1.60 1.60 2.00 3.00 480 0.30 0.40 0.60 0.80 1.25 1.50 1.60 2.00 3.00 550 0.25 0.40 0.50 0.80 1.00 1.25 1.60 2.00 2.50 575 0.25 0.30 0.50 0.75 1.00 1.25 1.50 1.60 2.50 600 0.25 0.30 0.50 0.75 1.00 1.25 1.50 1.60 2.50 Fuse Guide1 Midget Class CC Rejection Fuse Secondar y Fuse Selection Glass Fuse Encapsulated Transformer Continuous Power Rating (VA) Secondary 50 75 100 150 200 250 300 375 500 Voltage Fuse Rating (amperes) 12 6.00 10.00 12.00 15.00 20.00 25.00 30.00 —— 24 3.00 5.00 6.00 10.00 12.00 12.00 15.00 —25.00 36 2.00 3.00 4.00 6.00 8.00 10.00 12.00 12.00 15.00 48 1.60 2.50 3.00 5.00 6.00 8.00 10.00 12.00 12.00 95 0.80 1.25 1.60 2.50 3.00 4.00 5.00 6.00 8.00 110 0.75 1.00 1.50 2.00 3.00 3.00 4.00 5.00 7.00 115 0.60 1.00 1.25 2.00 2.50 3.00 4.00 5.00 7.00 120 0.60 1.00 1.25 2.00 2.50 3.00 4.00 5.00 6.00 208 0.40 0.60 0.80 1.00 1.60 2.00 2.00 3.00 4.00 220 0.30 0.50 0.75 1.00 1.50 1.60 2.00 2.50 3.00 230 0.30 0.50 0.60 1.00 1.25 1.60 2.00 2.50 3.00 240 0.30 0.50 0.60 1.00 1.25 1.60 2.00 2.50 3.00 7 Dimensions (inches) Approx Maximum Envelope Mounting Frame Ref 60Hz Weight Depth Width Height Depth Width Slot kVA (lbs)A1 A2 B1 B2 C1 C2 E F G 611 .050 2.6 3.97 3.18 3.29 3.29 2.79 2.64 2.16 2.50 .219 x .750 612 .075 3.0 4.22 3.43 3.29 3.29 2.79 2.64 2.41 2.50 .219 x .750 613 .087 3.4 4.47 3.68 3.29 3.29 2.79 2.64 2.66 2.50 .219 x .750 811 .100 3.9 4.17 3.18 4.04 4.04 3.29 3.29 2.16 3.12 .219 x .750 813 .150 5.5 4.67 3.68 4.04 4.04 3.29 3.29 2.66 3.12 .219 x .750 814 .200 6.3 4.92 3.93 4.04 4.04 3.29 3.29 2.91 3.12 .219 x .750 815 .250 7.0 5.17 4.18 4.04 4.04 3.29 3.29 3.16 3.12 .219 x .750 817 .375 8.3 5.67 4.68 4.04 4.04 3.29 3.29 3.66 3.12 .219 x .750 1016 .500 11.6 5.82 5.82 4.79 4.79 3.92 3.92 3.31 3.79 .297 x .5901 6, 8 and 10 Frame Encapsulated Transfor mer Dimensions and Weights TOP TOP A1 A2 C1 B1 FRONT C2 B2 FRONT SIDE SIDE MOUNTING Ter minal block Leads out (SLOT) F E G MOUNTING F G E (SLOT) 1The mounting slots on the 1016 frame run side-to-side (parallel to the "F" dimension) rather than front-to-rear (parallel to the "E" dimension) as shown. A2 dimension is less than A1 on units built on 6 and 8 frame core sizes. 8 GE Type IP Core and Coil Transformers SIDE FRONT TOP TOP MOUNTING Ter minal block A B FRONT B C F E G (MTG. SLOT) Leads out Dimensions (inches) Ref Approx Maximum Envelope Mounting Frame 60 hz Weight Depth Width Height Depth Width Slot KVA (lbs)A B C E F G 12225 .75 13.0 5.81 5.31 4.62 3.38 4.0 .297x.580 12300 1.00 17.5 6.56 5.31 4.62 4.12 4.0 .297x.580 14225 1.50 29.0 6.31 6.81 5.88 3.38 5.5 .297x.580 14300 2.00 35.5 7.06 6.81 5.88 4.12 5.5 .297x.580 14475 3.00 51.5 8.81 6.81 5.88 5.88 5.5 .297x.580 12 and 14 Frame Encapsulated Transfor mer Dimensions and Weights SIDE MOUNTING F E G (MTG. SLOT) A C 9 CE Compliant Transformers The CE compliant transformer offering developed by GE is of the highest quality. This product is designed to be incorporated into equipment manufactured for sale in the European Community. This product is in conformity with the European Standard: EN 60 742, 1995 per the provisions of the Low Voltage (LV) Directive 73/23/EEC in 1973 as amended by 93/68/EEC in 1995. The Type IP CE offering utilizes all copper windings, which are encapsulated in a hardened epoxy, making the winding impervious to the elements. These designs are rated at 550 C rise with a 400 C ambient. Standard on these designs are terminal board covers. These provide protection from current carrying terminals for personnel working on the equipment. These designs incorporate customer friendly connection on rugged high-impact molded terminal boards. Besides being CE rated, these designs are both UL and C-UL Listed. Available as an option are two fuse blocks that have fuse covers that provide the touch safety like the terminal covers. These can be ordered factory installed or as kits. In kit form order: Fuse block for 2 class CC fuses is 9T58E0000G46, Fuse block for 2 class CC and 1 Midget fuse is 9T58E0000G47. For factory installation add the G46 or G47 suffix to the transformer catalog number (example 9T58E0020G47). Catalog VA Frame Number Size Safety Isolation, 230/400 volts primary 12/24 volts secondary, 50/60 Hz 9T58E0020 25 611 9T58E0021 50 613 9T58E0023 75 811 9T58E0024 100 813 9T58E0025 150 815 9T58E0026 200 1016 9T58E0027 250 1016 9T58E0028 300 1016 9T58E0029 375 12200 Isolation, 230/400 Volts Primary 24/48 volts secondary, 50/60 Hz 9T58E0060 25 611 9T48E0061 50 613 9T58E0063 75 811 9T58E0064 100 813 9T58E0065 150 815 9T58E0066 200 1016 9T58E0067 250 1016 9T58E0068 300 1016 9T58E0069 375 12200 9T58E0071 500 12275 9T58E0073 750 14200 Isolation (TRIPLE RATED) 220/380, 230/400, 240/415 Volts Primary 110/220, 115/230, 120/400 Volts Secondary, 50/60 Hz 9T58E0150 25 611 9T58E0151 50 613 9T58E0153 75 811 9T58E0154 100 813 9T58E0155 150 815 9T58E0156 200 1016 9T58E0157 250 1016 9T58E0158 300 1016 9T58E0159 375 12200 9T58E0161 500 12275 9T58E0163 750 14200 9T58E0164 1000 14300 9T58E0165 1500 14400 Single-Phase GE Type IP Core and Coil Transformers CE Compliant Transformers Dimensions (inches) Approx Maximum Envelope Mounting Style Frame Weight Depth Width Height Depth Width Slot (lbs)A B C E F G 611 2.6 3.97 3.29 3.08 2.16 2.50 .219 x .750 612 3.0 4.22 3.29 3.08 2.41 2.50 .219 x .750 613 3.4 4.47 3.29 3.08 2.66 2.50 .219 x .750 811 3.9 4.17 4.04 3.60 2.16 3.12 .219 x .750 AA 813 5.5 4.67 4.04 3.60 2.66 3.12 .219 x .750 814 6.3 4.92 4.04 3.60 2.91 3.12 .219 x .750 815 7.0 5.17 4.04 3.60 3.16 3.12 .219 x .750 817 8.3 5.67 4.04 3.60 3.66 3.12 .219 x .750 1016 11.6 5.82 4.79 4.17 3.31 3.79 .297 x .590 12200 11.5 5.56 5.31 4.62 3.12 4.00 .297 x .580 12225 13.0 5.81 5.31 4.62 3.38 4.00 .297 x .580 12275 16.0 6.31 5.31 4.62 3.88 4.00 .297 x .580 12300 17.5 6.56 5.31 4.62 4.12 4.00 .297 x .580 BA 14200 26.8 6.06 6.81 5.88 3.12 5.50 .297 x .580 14225 29.0 6.31 6.81 5.88 3.38 5.50 .297 x .580 14250 31.2 6.56 6.81 5.88 3.62 5.50 .297 x .580 14300 35.5 7.06 6.81 5.88 4.12 5.50 .297 x .580 14350 40.2 7.56 6.81 5.88 4.62 5.50 .297 x .580 14400 44.8 8.06 6.81 5.88 5.12 5.50 .297 x .580 14475 51.5 8.81 6.81 5.88 5.88 5.50 .297 x .580 Fuse Block Option Dimensions (inches) Frame H H Series 2 Pole 3 Pole Fuse Block Fuse Block 600 5.05 N/A 800 5.67 5.67 1000 6.30 6.30 12000 6.97 6.97 14000 8.26 8.26 Style AA Style BA Fuse Block Option Note: Fuse Block option may include 2 or 3 pole fuse block 10 GEA-10548D 1098 GE Industrial Systems General Electric Company 41 Woodford Avenue, Plainville, CT 06062 www.ge.com/edc © 1998 General Electric Company Section 11 SLC40 Series: 1.57" (40mm)Display Lights C-26 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C Display LightsSLC40 Series Annunciators SLC series panel mounted annunciators are an ideal alternative to mounting multiple pilot devices. Cluster mounting simplifies panel cutouts and offers a variety of window combination sizes. Available with incandescent or Superbright LED illumination. SLC40 Series — Panel Mounted Annunciators Key features of the SLC40 series include: •Custom configuration up to 105 windows •Four window sizes based on a 40mm grid •Non-reflective clear lenses that can be extended (angled) for better visibility when mounted in higher locations •Incandescent or Superbright LED illumination •Wide variety of input voltage Cert. No. B970213332375 CSA Certified File No. LR48366-24 UL Recognized File No. E69861 ABS AmericanBureau ofShipping Style F Style H Style L Style V Staggered Terminals: and serviceability increased safetyExtended Windows Display Lights SLC40 Series: 1.57" (40mm) www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C-27 C Display LightsSpecificationsLight Source LED Incandescent Voltages Full Voltage 6, 12, 24V AC/DC 6.3, 12, 18, 24, 30V AC/DC Transformer 120, 240V AC 120, 240V AC DC-DC Converter 110V DC — Colors Full voltage:Amber, Green, Red, Yellow, Blue (24V), White, dual color Red/Green (24V only)Amber, Green, Red, Yellow, Blue, White Lamp Type Surface (chip type) LED cluster (40mA approximately) E12/15 (2W) screw base Available Window Sizes Insulation Resistance 100MΩ minimum (with 500V DC megger), between live and dead parts Degree of Protection IP20 (for indoor use only), NEMA 1 Dielectric. Strength Full voltage: 2,000V AC direct Adaptor/transformer 2,500V AC (1 minute) Operating Temperature – 20˚ to +40˚C; (45-85% relative humidity) Material of Marking Plate and Color Screen Polycarbonate Termination X1 and X2 terminals: M3.5 screw with a captive wire clamp washer(Check terminal: M3 screw, or applicable models) Maximum Size Full voltage: 7 rows, 15 columns (105 windows)Others: 50 windows maximum Recommended Wire Size 22-14 AWG x2 (2mm2 x 2) Approvals 40x40mm 40x120mm40x80mm 80x40mm “F”“H” “L” “V” Cert. No. B970213332375 CSA Certified File No. LR48366-24 UL Recognized File No. E69861 ABS AmericanBureau ofShipping SLC40 Series: 1.57" (40mm)Display Lights C-28 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C Display LightsPart Number Guide Part Numbers: Assembled Parts Description Code Remark ➀ Number of Rows 01, 02, 03, 04, 05, 06, 07 7 row maximum (number of base unit “F-Style” windows) ➁ Number of Columns 01, 02, 03, 04, 05, 06, 07, 08, 09, 1011, 12, 13, 14, 15 15 column maximum(number of base unit “F-Style” windows) ➂ Type LED Full voltage DD 6V, 12V, 24V Full voltage with check terminal DHM 24V only Full voltage2 color (Red/Green)DW 24V only Transformer TD 120V, 240V AC DC-DC converter CD 110V DC only Incandescent Full voltage DE 6V, 12V, 18V, 24V, 30V Full voltage with check terminal DEM 6V, 18V, 24V, 30V Transformer TE 120V, 240V ➃ Voltage 6.3V (6V) AC/DC 6 Type DD, DE, or DEM 12V AC/DC 1 With Type DD or DE 18V AC/DC 8 Type DE or DEM 24V DC 2 Type DD, DHM, DW, DE, or DEM 30V AC/DC 3 Type DE or DEM 120V AC/DC 12 Type TD or TE 240V AC/DC 24 Type TD or TE 110V DC 1 With Type CD No lamp 99 Type DE or DEM ➄ Style Square F Horizontal rectangle H Large horizontal rectangle L Vertical rectangle V Combination M Fill out the order form on the next page ➅ Color and Number of Windows Amber A After each color, specify the number of windows Example... A(3), G(2), R(1) Green G Red R Blue S (LED version: 24V only) White W Yellow Y Part Numbers (assembled) SLC40N 01 03 DD 2 F A(3)–– ➀➁➂➃➄➅ Number of Rows Number of Columns Type Voltage – Style Color and Number of Windows B 40x40mm 40x80mm 40x120mm 80x40mm 1.Secondary voltage on AC adaptors and DC-DC converters is 24V. 2. To specify the arrangement of varying window sizes and colors, use the order form on the next page. 3. Drawings are required for any units ordered with engraving. 4. Incandescents use color screen and marking plate, LEDs use two marking plates (no color screen) Display Lights SLC40 Series: 1.57" (40mm) www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C-29 C Display LightsSheetofDatePurchase Order No.THIS SIDE UPFill in Part Number Below:BasicUnitSize(style F)First Window(upper, left-handcorner of panel)SLC40NAGRSWYNumber of AmberNumber of GreenNumber of RedNumber of BlueNumber of WhiteNumber of YellowNumber ofRowsNumber ofColumnsOperatingVoltageBlackFrameBTypeCodeWindowCodeNote: Convert all window stylesto the style F (basic unit size).THIS SIDE UPCOLUMNSROWSQuantityNote: All units ordered on one order form must be identical.F = One WindowH = Two Windows WideL = Three Windows WideV = Two Windows HighM = Multiple CombinationStyle1. The part number guide is on the previous page.2. Engraving information is on the next page. (Separate drawing required.) 3. Panel cutout dimensions are on pageC–31. Order Form Remarks:ContactCompanyCity/State/ZIPPhone #Ship to SLC40 Series: 1.57" (40mm)Display Lights C-30 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C Display LightsPart Numbers: Engraving Plates Engraving Template Window Type Part No.Character Size Maximum Characters per Line Maximum Lines F SLC-4PF 5/16 5 2 7/32 8 4 5/32 11 5 H SLC-4PH 5/16 12 2 7/32 17 4 5/32 22 5 L SLC-4PL 5/16 18 2 7/32 26 4 5/32 34 5 V SLC-4PV 5/16 5 6 7/32 8 7 5/32 11 12 Engraving Size Samples 5/16" size 7/32" size 5/32" size Engraving Information 40x40mm 40x80mm 40x120mm 80x40mm L V H F Display Lights SLC40 Series: 1.57" (40mm) www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C-31 C Display LightsPanel Cut-Out Dimensions No. of Columns →1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ← No. of RowsOverall Panel Width Dimension →2.205"(56mm)3.780" (96mm)5.354" (136mm)6.929" (176mm)8.504" (216mm)10.079" (256mm)11.654" (296mm)13.228" (336mm)14.804" (376mm)16.378" (416mm)17.953" (456mm)19.528" (496mm)21.102" (536mm)22.677" (576mm)24.252" (616mm)Overall Height ↓ Cut- out Ht ↓ Cut- out Wd →1.772"(45mm)3.346" (85mm)4.921" (125mm)6.496" (165mm)8.071" (205mm)9.646" (245mm)11.220" (285mm)12.795" (325mm)14.370" (365mm)15.945" (405mm)17.520" (445mm)19.094" (485mm)20.669" (525mm)22.244" (565mm)23.819" (605mm)1 2.205" (56mm)1.772" (45mm)123456789101112131415 2 3.780" (96mm)3.346" (85mm)24681012141618202224262830 3 5.354" (136mm)4.921" (125mm)369121518212427303336394245 4 6.929" (176mm)6.496" (165mm)4812162024283236404448525660 5 8.504" (216mm)8.071" (205mm)51015202530354045505560657075 6 10.079" (256mm)9.646" (245mm)61218243036424854606672788490 7 11.654" (296mm)11.220" (285mm)714212835424956637077849198105 Total Number of Windows (equivalent to style F—basic unit size) Window Style Style F Style H Style L Style V Appearance Widow Size Illumination Face (H x W)1.575" x 1.575" (40 x 40mm) 1.575" x 3.150" (40 x 80mm) 1.575" x 4.724" (40 x 120mm) 3.150" x 1.575" (80 x 40mm) Lens (H x W) 1.457" x 1.457" (37 x 37mm) 1.457" x 3.031" (37 x 77mm) 1.457" x 4.606" (37 x 117mm) 3.031" x 1.457" (77 x 37mm) Marking Plate(H x W x t)1.409" x 1.409" x 0.04" (35.8 x 35.8 x 1.0mm)1.409" x 2.984" x 0.04" (35.8 x 75.8 x 1.0mm)1.409" x 4.559" x 0.04" (35.8 x 115.8 x 1.0mm)2.984" x 1.409" x 0.04" (75.8 x 35.8 x 1.0mm) Color Screen(H x W x t)1.409" x 1.409" x 0.04" (35.8 x 35.8 x 1.0mm)1.409" x 2.984" x 0.04" (35.8 x 75.8 x 1.0mm)1.409" x 4.559" x 0.04" (35.8 x 115.8 x 1.0mm)2.984" x 1.409" x 0.04" (75.8 x 35.8 x 1.0mm) Engraving Area 1.339" x 1.339" (34 x 34mm)1.339" x 2.913" (34 x 55mm)1.339" x 4.488" (34 x 85mm)2.913" x 1.339" (55 x 34mm) Dimensions 1. The number of rows and columns refers to styles equivalent to style F (basic unit size). For styles H, L, and V, convert into style F (basic unit size) equivalents. Style H: 1 window high (1 row) x 2 windows wide (2 columns) Style V: 2 windows high (2 rows) x 1 window wide (1 column) Style L: 1 window high (1 row) x 3 windows wide (3 columns) Example: 18 windows = 3 windows high (3 rows) x 6 windows wide (6 columns) → Overall dimension (H x W): 5.354" x 10.079" (136 x 256mm) Panel cut-out (H x W): 4.921" x 9.646" (125 x 245mm) To lerance: +0.039" (1mm), –0 2. See pageC–28 for part numbering information. SLC40 Series: 1.57" (40mm)Display Lights C-32 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C Display LightsStyles F, H, L, V: Single Window (right) Multiple Windows (below) Description LED Incandescent A Full voltage 2.618" (66.5mm)2.539" (64.5mm) B Full voltage LED2-color alternate 2.874" (73mm)— C AC adaptor 3.327" (84.5mm)— DC-DC converter 3.327"(84.5mm)— Transformer — 2.854" (72.5mm) Terminals (X1, X2) M3.5 screw Check terminal (C) M3 screw Same terminals, adjacent windows 1.575" (40mm) centers ❑ 1.575" (40mm) ❑ 2.205" (56mm) 1.575" (40mm) 1.102" (28mm) ❑ 1.575" (40mm) 0.433" (11mm) 0.217" (5.5mm) 0.327" (8.3mm) 0.433" (11mm) 0.031" to 0.236" (0.8 to 6mm) 0.236" (6mm) Panel Thickness using mounting clips (typical for all styles) 0.748" (19mm) 0.748" (19mm) 0.787" (20mm) A B C Single Window Multiple Windows Style F (basic Style V 1.102" (28mm) 1.575" (40mm) 2.205" (42mm) 1.575" (40mm) 3.780" (96mm) 3.150" (80mm) 1.102" (28mm) 1.890" (48mm) 1.575" (40mm) 1.575" (40mm) 3.150" (80mm) unit size) Styles H and L H: 3.780" (96mm) 2.205" (42mm) 1.575" (40mm) L: 5.354" (136mm) H: 3.150" (80mm) L: 4.724" (120mm) H: 1.890" (48mm) L: 2.677" (68mm) 1.102" (28mm) Single Window Multiple Windows 1.575" (40mm) H: 3.150" (80mm) L: 4.724" (120mm) H: 3.150" (80mm) L: 4.724" (120mm) A B C 0.236" (6mm) (typical for all styles) 0.031" to 0.236" (0.8 to 6mm) Panel Thickness using mounting clips 0.433" (11mm) 0.787" (20mm) 0.217" (5.5mm) 0.327" (8.3mm) 0.748 (19mm 0.433" (11mm) 0.748" (19mm) Dimensions, continued Display Lights SLC40 Series: 1.57" (40mm) www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C-33 C Display LightsEstimating Weights Example: SLC40N-0304-DD2FB Total weight = A (rows + columns) + B (rows x columns) + C (rows x columns) Total weight = 0.93 (3+4) + 0.93 (3x4) + 0.93 (3x4) = 28.83 oz Full Voltage Transformer (incandescent) AC Adapter (LED)DC-DC Converter (LED only) A Frame Weight B Housing Weight C Lamp/LED Weight (Includes Lamp/LED) 0.93oz (30g) 0.93oz (30g) 0.93oz (30g) 2.98oz (96g) 1.92oz (62g) Dimensions, continued Instructions A x B x Rows + Columns Rows Total Weight of Display Panelx Columns C x Rows x Columns Make sure that the panel thickness is sufficient to support the total weight of the display panel(s). 2.Weights are approximate. Centers Centers Centers 0.236" (6mm) 0.429" (10.9mm) 0.303" (7.7mm) 1.890" (48mm) 0.118" (3mm) 1.496" (38mm) SLC30 SLC40 1.890" (48mm) 1.496" (38mm) SLC30 SLC40 1.850" (47mm) 1.457" (37mm) SLC30 SLC40 JUMPERS Thickness = 0.020" (0.5mm) Centers:SLC30 = 1.181" (30mm)SLC40 = 1.575" (40mm) ± 0.004" (0.1mm) SLC Series: Accessories Display Lights C-34 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C Display LightsDescription Application Part No.Remarks Lenses SLC30 incandescent, LED F SLC-3LF-(UL) A lens is included with each window on assembled units H and V SLC-3LH-(UL) L SLC-3LL-(UL) G SLC-3LG-(UL) SLC40incandescent, LED F SLC-4LF-(UL) H and V SLC-4LH-(UL) Color Screens SLC30incandescent F SLC-3PF-*-(UL)Specify color code in place of asterisk ( * ):A = AmberC = TransparentG = Green (incandescent)R = RedS = BlueW = WhiteY = Yellow A color screen and marking plate are included with each window of assembled incandescent units Two marking plates are included with each window of assembled LED units; LED units do not use color screens H and V SLC-3PH-*-(UL) L SLC-3PL-*-(UL) G SLC-3PG-*-(UL) SLC40incandescent F SLC-4PF-*-(UL) H and V SLC-4PH-*-(UL) Marking Plates SLC30 incandescent, LED F SLC-3PF-■-(UL) Specify color code in place of square ( ■ ):C = Transparent (LED)W = White (incandescent)WL = White (LED) H and V SLC-3PH-■-(UL) L SLC-3PL-■-(UL) G SLC-3PG-■-(UL) SLC40incandescent, LED F SLC-4PF-■-(UL) H and V SLC-4PH-■-(UL) Lens Frames SLC30incandescent only F SLC-3WF-B A lens frame is included with each window on assembled units H SLC-3WH-B V SLC-3WV-B L SLC-3WL-B G SLC-3WG-B SLC30LED only F SLC-3WF-BL H SLC-3WH-BL V SLC-3WV-BL L SLC-3WL-BL G SLC-3WG-BL SLC40incandescent only F SLC-4WF-B H SLC-4WH-B V SLC-4WV-B SLC40LED only F SLC-4WF-BL H SLC-4WH-BL SLC Series Accessories Lens Frame Color Screen Marking Plate Lens Display Lights SLC Series: Accessories www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C-35 C Display LightsReplacement Parts Description Application Part No.Remarks Incan- descent Lamps SLC30incandescent only BA9S/13lamp base IS-6 6.3V, 1W; operating voltage: 5 to 6V AC/DC Unless “no lamp” (99) is specified, a lamp is included with each style F win-dow equivalent One part number is specified for one replacement bulb IS-12 12V, 1W; operating voltage: 9 to 12V AC/DC IS-24 24V, 1W; operating voltage: 18 to 24V AC/DC IS-30 30V, 1W; operating voltage: 24 to 30V AC /DC SLC40incandescent only 2WE12/15lamp base LE-6 6.3V, 2W; operating voltage: 5 to 6V AC/DC LE-8 18V, 2W; operating voltage: 12 to 18V AC/DC LE-2 24V, 2W; operating voltage: 18 to 24V AC/DC LE-3 30V, 2W; operating voltage: 24 to 30V AC/DC LED Lamps SLC30LED only1-color 6V AC/DC SLC-6SP* Specify color code in place of asterisk (*):A = AmberG = Green R = RedS = Blue (available in 24V version only)W = WhiteY = Yellow 12V AC/DC SLC-1SP* 24V AC/DC SLC-2SP* SLC30LED only2-color: Red/Green 24V AC/DC SLC-2SP-R/G SLC40LED only1-color 6V AC/DC SLC-6EP* 12V AC/DC SLC-1EP* 24V AC/DC SLC-2EP* SLC40LED only2-color: Red/Green 24V AC/DC SLC-2EP-R/G Full Voltage Models Description Type Part Number SLC30 LED Incandescent DS SLC-3DS Standard LED DD SLC-3DH LED w/ Check Terminal DHM SLC-3DHM Dual Color LED DW SLC-3DHW SLC 40 Incandescent Incandescent DE SLC-4DE Incandescent w/ Check Terminal DEM SLC-4DEM Standard LED DD SLC-4DH LED w/ Check Terminal DHM SLC-4DHM Dual Color LED DW SLC-4DHW Step Down Models Description Type Part Number SLC30 LED Incandescent xfrmr, 120V AC TS12 SLC-3TS120 Incandescent xfrmr, 240V AC TS24 SLC-3TS240 LED xfrmr, 120V AC TD12 SLC-3TP120 LED xfrmr, 240V AC TD24 SLC-3TP240 LED DC-DC converter, 110V DC CD1 SLC-3CP1 SLC40 Incandescent Incandescent xfrmr, 120V AC TE12 SLC-4TE12 Incandescent xfrmr, 240V AC TE24 SLC-4TE240 LED xfrmr, 120V AC TD12 SLC-4TP120 LED xfrmr, 240V AC TD24 SLC-4TP240 LED DC-DC converter, 110V DC CD1 SLC-4CP1 BA9S/13(1W) E12/15(2W) SLC Series: Accessories Display Lights C-36 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C Display LightsDescription Application Part No.Remarks Lamp Holder Tool SLC30 and SLC40 incandescent OR-55 Rubber tool eases the removal of incandescent lamps Tab Terminal Adaptors Used for wiring quick-connect terminals TW-FA1 #250 tab terminal (W x H): 0.250" x 0.031" (6.35 x 0.8mm) single tab Jumpers SLC30 X1 terminal (spade) SLC-JP30 Total number of jumpers equals total number of style F window equivalents X2 terminal (ring) SLC-JP33 C terminal (ring) SLC-JP32 SLC40 X1 terminal (spade) SLC-JP40 X2 terminal (ring) SLC-JP41 C terminal (ring) SLC-JP42 Mounting Clip All SLCs SLC-3K1 Mounting clips are included with the panel (see page B–40 for details about quantity and placement). Marking Strip BNM2 White glossy paper with adhesive back (the dimensions are given below); the marking strip can be stuck to the terminal transformer or directly to the units for identification of the unit or circuit number; Sticker dimension (W x L): 0.197" x 393.701" (5 x 10,000mm) Finger-Safe Terminal Covers Use with SLC30 types DD, TD, CD, DS and TS SLC30-VL3 Use with all SLC30 types DHM and DW SLC30-VL6 Use with SLC40 types DD, TD, CD, DE and TE HW-VL3 Use with SLC40 types DHM, DW, and DEM SLC40-VL6 Incandescent BA9S/13 Base (1W) LampsLED Amber Green Red *White Yellow Housing Mounting Clip (included with unit) F H V G L F F Lens Frame Black SLC30 Series Clear, Non-Reflective Cover Frame Black Color ScreenAmber Blue Green Red White Yellow Marking Plate Standard: Transparent Special: White (white LED only) Blue Display Lights SLC Series: Accessories www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C-37 C Display LightsGeneral Information: Ordering SLC Display Lights When ordering a custom-built combination of SLC display lights for a multiple panel, copy the order form provided. This is the only order form accepted. Using the Order Form Part No.: Enter the part number using the part numbering guides. Quantity: Enter the number of identicalcompletely assembled panels required. Window Count: Convert all window stylesto style F (basic unit size) equivalents: Style F = 1 window Style H = 2 windows (1 row high x 2 columns wide) Style L = 3 windows(1 row high x 3 columns wide) Style V = 2 windows(2 rows high x 1 column wide) *Style G = 4 windows(2 rows high x 2 columns wide) Maximum Windows for Multiple Combination Panels For style code “M,” it is necessary to use the order form. Do not exceedmaximum panel sizes: SLC30: 200 windows (full voltage)50 windows (other type codes) SLC40: 105 windows (full voltage)50 windows (other type codes) Series: SLC30 1.181" (30mm) or SLC40 1.575" (40mm) Window style(s):Style F, H, L, or V for SLC30 or SLC40Style G for SLC30 onlyStyle M for a multiple combination panel Row count: Convert all windows to style F (basic unit size using infor-mation in the left column of this page. Column count: Convert windows to style F (basic unit size) using infor-mation in the left column of this page. Illumination type: LED or incandescent. Input mode: Full voltage, AC adaptor, or DC-DC conversion for LED; full volt-age or transformer for incandescent. Operating voltage: See preceding page to select voltages compatible with the input mode required. Window colors: Specify the number of windows in each color. Engraving: Clearly mark the engravings for each window desired on the grid of the order form clearly. If there is not enough space, number each window and use a separate sheet to write the engravings for each win-dow number. Also note “no engraving.” Using the grid on the order form (following page), show the actual size and placement of all desired windows. To Specify a Multiple Combination • Draw a heavy outline on corresponding gray lines to show the over- all panel size. • Darken the appropriate gray lines to show the outlines of the various window style(s) required. • For each window, specify color and clearly identify the engraving desired. Determining SLC Pricing 1. The initial, 2-window price is determined based on series, type, and style. This 2-window price includes framing and assembly. When ordering a single window, the 2-window price is also the mini-mum price, including window, framing, and assembly. 2. Convert all window styles required into style F (basic unit size) equiva-lents using the information in the left column of this page. 3. Subtract “2” from the total number of style F equivalent windows determined in step 2. The result is the number of additional windows. 4. Multiply the number of additional windows determined in step 3 by the additional window price. 5. Determine the quantity of windows with engravings. Do not use the style F equivalents; use the actual window style(s) required. 1. Style G is available for the SLC30 series only. 2. If there is not enough space on the grid to show the engrav- ing clearly, number every required window, and write the engraving on a separate sheet of paper. Make sure to write the window number which corresponds to the engraving, and also make sure to note “no engraving” as required. 3.The pricing referred to above can be obtained from any autho- rized IDEC representative or distributor. 4.When determining window pricing, always convert every win- dow size required to the style F equivalent (basic unit size). SLC Series: Accessories Display Lights C-38 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C Display LightsSLC Series Installation Instructions Installation Notes 1. Since lamps generate heat, it is recommended that ventilation be pro-vided for cooling when more than ten lamps are lit continuously. 2. A lower number of windows is specified for multiple transformer, ACadapter, and DC-DC converter units (50 maximum, instead of 200 as forfull voltage only). This is done to avoid damage which may result fromexcessive heat generation when all lamps are lit simultaneously. 3. When multiple units are panel mounted, determine panel thickness sothat the combined weight of all units and connecting wires can be sup-ported. 4. Multiple units are not designed for continuous, simultaneous lighting ofall lamps. However, it is possible to conduct a lamp test with all lampslit simultaneously for a period of up to 40 minutes. 5.Before removing the LED unit, turn the power supply off. 6. DC-rated voltages for LED units are complete direct current voltages.Make sure to check the measuring instruments and compensate for anyerror in the measured, full-wave rectified or pulsating voltages. 7. To ensure brightness and long life of LED units, keep the DC power volt-age within the operating voltage range. LED Operating Voltage Range: 24V DC ± 10% Terminal Arrangements (LED units) For full voltage (1- and 2-color) and DC-DC converter LED units, terminalX1 is positive and terminal X2 is negative. Make sure to observe polaritywhen wiring. For 2-color alternate units, terminal X1 is positive, and terminals X2 and C(check terminal) are negative. X1 X2 C D1 D2 X1 X2 C RED GREEN X1 RED GREEN C X2 X1 X2 C X1 X2 X1 X2 C X1 X2 SLC30Full VoltageDC-DC Converter SLC40Full VoltageDC-DC Converter SLC30AC AdaptorTransformer SLC30/402-Color LED(alternating) SLC30 SLC40 Display Lights SLC Series: Accessories www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C-39 C Display LightsInstallation Instructions, continued Removing Windows SLC30: To remove a window, insert the tip of a small screwdriver into the slot under the lens frame and gently press down on the screwdriver. SLC40: To remove an extended window, pull on the top as if to extend the unit; then continue pulling until the unit comes out of the housing. All units are shipped with windows retracted. When transporting units, make sure windows are pushed in fully. After windows are installed, they can be extended as shown in Figure 1. Removing Lens, Color Screen, and Marking Plate The lens has two retaining projections on the right and two on the left. To remove the lens, color screen, and marking plate from the lens frame, push open the lens frame with both hands as shown in Figure 2. The lens can also be removed by inserting a screwdriver into one of the sides with recesses. Since the lens has an orientation, be sure to insert the screw-driver in the direction shown in Figures 3 and 4. Installing Lens, Color Screen, and Marking Plate First, install the marking plate and color screen into the lens frame. To install the lens, insert its retaining projections into the recesses inside the lens frame, and press the lens into the lens frame as shown in Figure 5. Replacing the LED Unit To remove: Insert the tip of a screwdriver into one of the two slots inside the LED unit. Pull the LED unit straight out without pressing on the LED termi-nals, as shown in Figure 6. To install: Make sure that the junction inside the LED unit is aligned in the same direction as the junction of the LED housing. Push the LED unit into the LED housing as shown in Figure 7. Installing Units into a Panel Single units: With leaf springs installed, push the SLC housing from the front of the panel. Secure the SLC housing with two mounting clips. Tighten the mounting clip screws to a torque of 4 to 5 kgf-cm as shown in Figure 8. Multiple combination units: Insert the units into the panel cut-out from the front. Install the attached mounting clips into the openings on the frame, and tighten the screws as shown in Figure 9. After tightening, use Loctite to prevent loosening. The number of mounting clips included with each multiple unit varies with the number of windows as shown in the table below. Figure 1: SLC40 Figure 2: SLC30 and SLC40 Figure 3: SLC30 Figure 4: SLC40 Figure 5: SLC30 and SLC40 Lens Frame Marking Plate Color Screen Lens Figure 6: Remove LED Figure 7: Install LED Figure 8: Single Unit Figure 9: Multiple Combination SLC Series: Accessories Display Lights C-40 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C Display LightsNumber of Mounting Clips Included Recommended Mounting Clip Positions Assembly Order for Lamp On/Lamp Off Colors Columns 1 or 2 3 to 8 9 to 15 16 to 20 * Rows Full Voltage Others Full Voltage Others All Types All Types 1 or 2 2 4 6 8 3 to 6 4668 8 10 7 to 10 (SLC30 only)68 8 10 12 Columns 1 or 2 3 to 8 9 to 15 16 to 20* Rows Full Voltage Others Full Voltage Others All Types All Types 1 or 2 2 Clips 4 Clips 6 Clips 8 Clips 3 to 6 4 Clips 6 Clips 6 Clips 8 Clips 8 Clips 10 Clips 7 to 10(SLC30 only) 6 Clips 8 Clips 8 Clips 10 Clips 12 Clips Lamp On: Amber, Blue, Green, Red, Yellow Lamp On: White Lamp On: Red/Green Lamp Off: Desired Color Lamp Off: White Lamp Off: White Lamp Off: White SLC Series Installation Instructions, continued * SLC30 series only. Lens ColorScreen:Any Color Matte Surface Light Source (non-shiny) MarkingPlate:White Lens MarkingPlate:White Matte Surface Light Source (non-shiny) ColorScreen:Any Color Lens Matte Surface Light Source (non-shiny) MarkingPlate:White ColorScreen:White Lens Matte Surface Light Source (non-shiny) (LED only) MarkingPlate:White ColorScreen:White SLC40 Series: 1.57" (40mm)Display Lights C-26 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C Display LightsSLC40 Series Annunciators SLC series panel mounted annunciators are an ideal alternative to mounting multiple pilot devices. Cluster mounting simplifies panel cutouts and offers a variety of window combination sizes. Available with incandescent or Superbright LED illumination. SLC40 Series — Panel Mounted Annunciators Key features of the SLC40 series include: •Custom configuration up to 105 windows •Four window sizes based on a 40mm grid •Non-reflective clear lenses that can be extended (angled) for better visibility when mounted in higher locations •Incandescent or Superbright LED illumination •Wide variety of input voltage Cert. No. B970213332375 CSA Certified File No. LR48366-24 UL Recognized File No. E69861 ABS AmericanBureau ofShipping Style F Style H Style L Style V Staggered Terminals: and serviceability increased safetyExtended Windows Display Lights SLC40 Series: 1.57" (40mm) www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C-27 C Display LightsSpecificationsLight Source LED Incandescent Voltages Full Voltage 6, 12, 24V AC/DC 6.3, 12, 18, 24, 30V AC/DC Transformer 120, 240V AC 120, 240V AC DC-DC Converter 110V DC — Colors Full voltage:Amber, Green, Red, Yellow, Blue (24V), White, dual color Red/Green (24V only)Amber, Green, Red, Yellow, Blue, White Lamp Type Surface (chip type) LED cluster (40mA approximately) E12/15 (2W) screw base Available Window Sizes Insulation Resistance 100MΩ minimum (with 500V DC megger), between live and dead parts Degree of Protection IP20 (for indoor use only), NEMA 1 Dielectric. Strength Full voltage: 2,000V AC direct Adaptor/transformer 2,500V AC (1 minute) Operating Temperature – 20˚ to +40˚C; (45-85% relative humidity) Material of Marking Plate and Color Screen Polycarbonate Termination X1 and X2 terminals: M3.5 screw with a captive wire clamp washer(Check terminal: M3 screw, or applicable models) Maximum Size Full voltage: 7 rows, 15 columns (105 windows)Others: 50 windows maximum Recommended Wire Size 22-14 AWG x2 (2mm2 x 2) Approvals 40x40mm 40x120mm40x80mm 80x40mm “F”“H” “L” “V” Cert. No. B970213332375 CSA Certified File No. LR48366-24 UL Recognized File No. E69861 ABS AmericanBureau ofShipping SLC40 Series: 1.57" (40mm)Display Lights C-28 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada (888) 317-IDEC C Display LightsPart Number Guide Part Numbers: Assembled Parts Description Code Remark Number of Rows 01, 02, 03, 04, 05, 06, 07 7 row maximum (number of base unit “F-Style” windows) Number of Columns 01, 02, 03, 04, 05, 06, 07, 08, 09, 1011, 12, 13, 14, 15 15 column maximum(number of base unit “F-Style” windows) Type LED Full voltage DD 6V, 12V, 24V Full voltage with check terminal DHM 24V only Full voltage2 color (Red/Green)DW 24V only Transformer TD 120V, 240V AC DC-DC converter CD 110V DC only Incandescent Full voltage DE 6V, 12V, 18V, 24V, 30V Full voltage with check terminal DEM 6V, 18V, 24V, 30V Transformer TE 120V, 240V Voltage 6.3V (6V) AC/DC 6 Type DD, DE, or DEM 12V AC/DC 1 With Type DD or DE 18V AC/DC 8 Type DE or DEM 24V DC 2 Type DD, DHM, DW, DE, or DEM 30V AC/DC 3 Type DE or DEM 120V AC/DC 12 Type TD or TE 240V AC/DC 24 Type TD or TE 110V DC 1 With Type CD No lamp 99 Type DE or DEM Style Square F Horizontal rectangle H Large horizontal rectangle L Vertical rectangle V Combination M Fill out the order form on the next page Color and Number of Windows Amber A After each color, specify the number of windows Example... A(3), G(2), R(1) Green G Red R Blue S (LED version: 24V only) White W Yellow Y Part Numbers (assembled) SLC40N 01 03 DD 2 F A(3)–– Number of Rows Number of Columns Type Voltage – Style Color and Number of Windows B 40x40mm 40x80mm 40x120mm 80x40mm 1.Secondary voltage on AC adaptors and DC-DC converters is 24V. 2. To specify the arrangement of varying window sizes and colors, use the order form on the next page. 3. Drawings are required for any units ordered with engraving. 4. Incandescents use color screen and marking plate, LEDs use two marking plates (no color screen) (This Page Intentionally Left Blank) Section 12 (This Page Intentionally Left Blank) Publication 1746-IN016A-MU-P Installation Instructions SLC 500™ Modular Chassis (Catalog Numbers 1746-A4, -A7, -A10, and -A13 Series B) English Section What’s in this Publication Use this publication as a guide when installing an SLC 500 modular chassis. Installation To...............................................................................................See page prepare for installation.............................................................................5 allow sufficient mounting space..............................................................6 install your chassis ...................................................................................7 ground your chassis..................................................................................9 install the chassis interconnect cable (optional)....................................12 install your I/O modules and attach your power supply.........................12 Reference For this information................................................................See page specifications..........................................................................................13 CSA hazardous location approval...........................................................14 mounting dimensions..............................................................................75 For additional installation information, see the SLC 500 Modular Style Installation and Operation Manual, publication 1747-6.2. 4 SLC 500™ Modular Chassis Publication 1746-IN016A-MU-P Important User InformationBecause 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, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication. Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation, and Maintenance of Solid-State Control (available from your local Allen-Bradley 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 in part, without written permission of Allen-Bradley Company, Inc., is prohibited. Throughout these installation instructions we use notes to make you aware of safety considerations: Attention statements help you to: •identify a hazard •avoid the hazard • recognize the consequences !!!! 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. SLC 500™ Modular Chassis 5 Publication 1746-IN016A-MU-P Prepare for InstallationMake sure you have these items. M4 or M5 (#10 or #12) Hardware • phillips screw and star washer (or SEM screw — phillips screw with attached star washer) for chassis mounting tabs • phillips screwdriver •drill Documentation For your: • processor or I/O adapter module •power supply • communication modules and/or I/O modules This chassis: Has: 1746-A4 4 mounting tabs 1746-A7 4 mounting tabs 1746-A10 6 mounting tabs 1746-A13 8 mounting tabs 6 SLC 500™ Modular Chassis Publication 1746-IN016A-MU-P Allow Sufficient Mounting SpaceIMPORTANTMake sure you meet these minimum spacing requirements. Up to three SLC chassis can be connected (for a maximum of 30 I/O slots). IMPORTANT When vertically connecting two 1746-A13 chassis with a 1746-C9 cable, the space cannot be greater than 15.3 cm (6.0 in) for the cable to reach from chassis to chassis. For dimensions of: See page: left side of all chassis 75 1746-A4, -A7 75 1746-A10, -A13 76 15.3 to 20 cm (6.0 to 8.0 in) 1746-C9 7.7 to 10.2 cm (3.0 to 4.0 in)1746-C7Enclosure >15.3 cm (6.0 in) >15.3 cm (6.0 in) >10.2 cm (4.0 in) >10.2 cm (4.0 in) SLC 500™ Modular Chassis 7 Publication 1746-IN016A-MU-P Install Your Chassis1 !!!! ATTENTION Be careful of metal chips when drilling mounting holes for the SLC chassis. Do not drill holes above an SLC chassis if a processor and I/O modules are installed. Drill holes in the back panel of the enclosure for chassis mounting tabs. 2 Install the hardware for the top mounting tabs. M4 or M5 (#10 or #12) phillips screw and star washer (or SEM screw) NOTE Scrape paint off the back panel for an electrical connection between the chassis and back panel. 8 SLC 500™ Modular Chassis Publication 1746-IN016A-MU-P 3 !!!! ATTENTION If the chassis mounting tabs do not lay flat before the screws are tightened, use additional washers as shims so that the chassis will not be warped by tightening the screws. Warping a chassis could damage the backplane and cause poor connections. Slide the chassis over the installed hardware and tighten the screws. 4 Leaving far-left and far-right tabs open for grounding, install the remaining tab hardware (for a four-slot chassis, leave both tabs open). SLC 500™ Modular Chassis 9 Publication 1746-IN016A-MU-P Ground Your Chassis Verify Grounding Configuration This figure shows you how to run ground connections from the chassis to the ground bus. Two acceptable grounding methods are shown; we recommend using a ground bus because it reduces the electrical resistance at the connection. To properly ground your I/O chassis: See page: verify grounding configuration 9 install a central ground bus 10 connect equipment grounding conductor 10 connect equipment grounding conductor to ground bus 11 connect ground bus to grounding-electrode system 11 2 mm2 (14 AWG) Earth Ground 5.2 mm2 (10 AWG) Preferred Grounding Method. NOTE Keep wire length as short as possible. 2 mm2 (14 AWG) 2 mm2 (14 AWG) 10 AWG 10 SLC 500™ Modular Chassis Publication 1746-IN016A-MU-P Install a Central Ground Bus Each enclosure must contain a central ground bus. The ground bus is the common connection for each chassis within the enclosure and the enclosure itself. If you have not already installed a central ground bus, see the Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1. Connect Equipment Grounding Conductor IMPORTANT Use the following information, along with the installation manual for your programmable controller, to ground the chassis and your I/O modules. chassis mounting tab ground lug with 5.2mm2 (10 AWG) wire 4M or 5M (#10 or #12) phillips screw and star washer (or SEM screw) 4M or 5M (#10 or #12) star washer NOTE Keep wire length as short as possible. SLC 500™ Modular Chassis 11 Publication 1746-IN016A-MU-P Connect Equipment Grounding Conductor to Ground BusConnect an equipment grounding conductor directly from each chassis to an individual bolt on the ground bus. • use 2.54 cm (1in) copper braid or 5.2 mm2 (10 AWG) copper wire to connect each chassis, the enclosure, and a central ground bus mounted on the back-panel • use a steel enclosure to guard against electromagnetic interference (EMI) • make sure the enclosure door viewing window is a laminated screen or a conductive optical substrate (to block EMI) • install a bonding wire for electrical contact between the door and the enclosure; do not rely on the hinge Connect Ground Bus to Grounding-Electrode System The grounding-electrode system is at earth-ground potential and is the central ground for all electrical equipment and ac power within any facility. Use a grounding-electrode conductor to connect the ground bus to the grounding-electrode system. Use at minimum 8.3 mmminimum 8.3 mmminimum 8.3 mmminimum 8.3 mm2222 (8 AWG) (8 AWG) (8 AWG) (8 AWG) copper wire for the grounding-electrode conductor to guard against EMI. The National Electrical Code specifies safety requirements for the grounding-electrode conductor. IMPORTANT Do not lay one ground lug directly on top of the other; this type of connection can become loose due to compressiondue to compressiondue to compressiondue to compression of the metal lugs. Place the first lug between a star washer and a nut with a captive star washer. After tightening the nut, place the second lug between the first nut and a second nut with a captive star washer. bolt equipment grounding conductors ground lug star washer Grounding-electrode conductor to grounding-electrode system tapped hole ground bus ground bus mounting 12 SLC 500™ Modular Chassis Publication 1746-IN016A-MU-P Install the Chassis Interconnect Cable (optional)To connect up to three chassis together (for a maximum of 30 I/O slots), install the chassis interconnect cable before attaching your power supply. Install Your I/O Modules and Attach Your Power Supply Use the installation instructions/user manuals for your modules to install them into the chassis. Use the installation instructions for your power supply to attach it to your chassis. !!!! ATTENTION • Keep the connector plug on the left side-connector of the chassis if you are not connecting chassis together. • Remove the protective label from the top of the power supply before applying power. IMPORTANT Series B chassis have a 1M W resistor between logic ground and chassis ground. When using a 1746-P3 power supply, follow the grounding instructions provided with the power supply to avoid unwanted potentials across the logic ground of the SLC processor. SLC chassis where processor will be installed SLC 500™ Modular Chassis 13 Publication 1746-IN016A-MU-P Specifications SLC Chassis, Series B 1746-A4 1746-A7 1746-A10 1746-A13 dimensions (with tabs) -W x H x D 17.7 x 17.1 x 14.5 cm (7.1 x 6.8 x 5.8 in) 28.2 x 17.1 x 14.5 cm (11.3 x 6.8 x 5.8 in) 39.7 x 17.1 x 14.5 cm (15.9 x 6.8 x 5.8 in) 50.2 x 17.1 x 14.5 cm (20.1 x 6.8 x 5.8 in) approximate weight (without modules) 0.75 kg (1.7 lbs) 1.1 kg (2.4 lbs) 1.45 kg (3.2 lbs) 1.9 kg (4.2 lbs) maximum backplane current 5.1V dc @ 10A; 24V dc @ 2.88A 5.1V dc @ 10A; 24V dc @ 2.88A 5.1V dc @ 10A; 24V dc @ 2.88A 5.1V dc @ 10A; 24V dc @ 2.88A module slots 471013 type of mount panel mount panel mount panel mount panel mount operating conditions operating temperature: 0°C to +60°C (+32°F to +140°F) storage temperature: -40°C to +85°C (-40°F to +185°F) relative humidity: 5 to 95% (without condensation) certification Internal Connection Controller Logic Ground Chassis Ground Earth Ground SLC Chassis, Series B 1746-P3 +24V DC DC NEUT CHASSIS GROUND LISTED IND. CONT. EQ. FOR HAZ. LOC A196 CLASS I GROUPS A, B, C, AND D DIV. 2 OPERATING TEMPERATURE CODE T3C CE compliant for all applicable directives 14 SLC 500™ Modular Chassis Publication 1746-IN016A-MU-P CSA Hazardous Location ApprovalCSA certifies products for general use as well as for use in hazardous locations. Actual CSA certification is indicated by the CSA certification product label, and not by any statements in any user documentation. To comply with CSA certification for use in hazardous locations, the following information becomes a part of the product literature for this CSA-certified industrial control product: • This equipment is suitable for use in Class I, Division 2, Groups A, B, C, D, or non-hazardous locations only. • The products having the appropriate CSA markings (that is, Class I, Division 2, Groups A, B, C, D) are certified for use in other equipment where the suitability of combination (that is, application or use) is determined by the CSA or the location inspection office having jurisdiction. IMPORTANT Due to the modular nature of a programmable control system, the product with the highest temperature rating determines the overall temperature code rating of a programmable control system in a Class I, Division 2 location. The temperature code rating is marked on the product label. !!!! WARNING EXPLOSION HAZARD • Substitution of components may impair suitability for Class I, Division 2. • Do not replace components or disconnect equipment unless power has been switched off or the area is known to be non-hazardous. • Do not connect or disconnect components unless power has been switched off or the area is known to be non-hazardous. • All wiring must comply with N.E.C. article 501-4(b). 75 Publication 1746-IN016A-MU-P Mounting DimensionsDimensions de montage Einbauabmessungen Dimensioni per il montaggio Dimensiones de montaje Dimensoes de montagem 1746-A4 (1) 1746-P1 (2) 1746-P2, 1746-P3, 1746-P5, 1746-P6, 1746-P7 (3) 1746-P4 1.1 cm Dia. (0.433 in) 0.55 cm Dia. (0.217 in) 7.0 cm (2.76 in) 21.5 cm (8.46 in)23.5 cm (9.25 in)26.1 cm (10.28 in) 15.8 cm (6.22 in) 14.0 cm (5.51 in) 17.1 cm (6.73 in) 0.55 Dia. (0.217 in) 4.5 cm (1.77 in) 1.4 cm (0.55 in) (1)(2)(3) 0.1 cm (0.04 in) 17.1 cm (6.73 in) 14.0 cm (5.51 in) 14.5 cm (5.71 in) 1746-A4 1746-A7 1747-A10 1746-A13 76 Publication 1746-IN016A-MU-P 1746-A7 1746-A10 (1) 1746-P1 (2) 1746-P2, 1746-P3, 1746-P5, 1746-P6, 1746-P7 (3) 1746-P4 1.1 cm Dia. (0.433 in) 0.55 cm Dia. (0.217 in) 17.5 cm (6.89 in) 32.0 cm (12.60 in)34.0 cm (13.39 in)36.6 cm (14.41 in) 15.8 cm (6.22 in)14.0 cm (5.51 in) 17.1 cm (6.73 in) 0.55 Dia. (0.217 in) 4.5 cm (1.77 in) 1.4 cm (0.55 in) (1)(2)(3) 1.1 cm Dia. (0.433 in) 0.55 cm Dia. (0.217 in) 14.0 cm (5.51 in) 5.5 cm (2.17 in) 43.5 cm (17.13 in)45.5 cm (17.91 in)48.1 cm (18.94 in) 15.8 cm (6.22 in) 14.0 cm (5.51 in) 17.1 cm (6.73 in) 0.55 Dia. (0.217 in) 14.0 cm (5.51 in)1.4 cm (0.55 in) (1)(2)(3) 15.8 cm (6.22 in) 77 Publication 1746-IN016A-MU-P 1746-A13 (1) 1746-P1 (2) 1746-P2, 1746-P3, 1746-P5, 1746-P6, 1746-P7 (3) 1746-P4 1.1 cm Dia. (0.433 in) 0.55 cm Dia. (0.217 in) 10.5 cm (4.13 in) 14.0 cm (5.51 in) 54.0 cm (21.26 in)56.0 cm (22.05 in)58.6 cm (23.07 in) 15.8 cm (6.22 in) 14.0 cm (5.51 in) 17.1 cm (6.73 in) 0.55 Dia. (0.217 in) 14.0 cm (5.51 in) 1.4 cm (0.55 in) (1)(2)(3) 15.8 cm (6.22 in) 5.5 cm (2.17 in) Publication 1746-IN016A-MU-P - September 2000 PN 957345-42A Supersedes 1746-5.8 - November 1996 © 2000 Rockwell International Corporation. All rights reserved. Printed in the U.S.A. SLC 500 is a trademark of Rockwell Automation. SLC 500 est une marque déposée de Rockwell Automation. SLC 500 ist ein Warenzeichen der Rockwell Automation. SLC 500 è un marchio di fabbrica della Rockwell Automation. SLC 500 es una marca comercial de Rockwell Automation. SLC 500 é uma marca registrada da Rockwell Automation. Publication 1746-IN004C-MU-P - September 2002 Installation InstructionsSLC 500™ Power Supplies (Catalog Numbers 1746-P1, 1746-P2, 1746-P3, 1746-P4, 1746-P5, 1746-P6, and 1746-P7) Inside… . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page Installation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Notice d’installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Installationsanleitung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Istruzioni per l'installazione. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Instrucciones de instalación. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 取付説明書 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 2 SLC 500™ Power Supplies Publication 1746-IN004C-MU-P - September 2002 Important User InformationBecause 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. In no event will Allen-Bradley be responsible or liable for indirect or consequential damage resulting from the use or application of these products. Any 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, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication. Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation, and Maintenance of Solid-State Control (available from your local Allen-Bradley 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 in part, without written permission of Rockwell Automation, is prohibited. Throughout this publication, notes may be used to make you aware of safety considerations. The following annotations and their accompanying statements help you to identify a potential hazard, avoid a potential hazard, and recognize the consequences of a potential hazard: WARNING ! Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. 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. SLC 500™ Power Supplies 3 Publication 1746-IN004C-MU-P - September 2002 ATTENTION ! Environment and Enclosure This equipment is intended for use in a Pollution Degree 2 industrial environment, in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as “open type” equipment. It must be mounted within an enclosure that is suitably designed for those specific environmental conditions that will be present and appropriately designed to prevent personal injury resulting from accessibility to live parts. The interior of the enclosure must be accessible only by the use of a tool. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings that are required to comply with certain product safety certifications. NOTE: See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the Allen-Bradley publication 1770-4.1, Industrial Automation Wiring and Grounding Guidelines, for additional installation requirements pertaining to this equipment. 4 SLC 500™ Power Supplies Publication 1746-IN004C-MU-P - September 2002 Publication 1746-IN004C-MU-P - September 2002 Installation InstructionsSLC 500™ Power Supplies (Catalog Numbers 1746-P1, 1746-P2, 1746-P3, 1746-P4, 1746-P5, 1746-P6, and 1746-P7) Overview Install your power supply using these installation instructions. The only tools you require are Flat head (1/8”) and Phillips head (1/4”, #2) screwdrivers. ATTENTION ! Electrostatic discharge can damage integrated circuits or semiconductors if you touch backplane connector pins. Follow these guidelines when you handle the power supplies. •Touch a grounded object to discharge static potential. •Do not touch the backplane connector or connector pins. •Do not touch circuit components inside the power supply. •If available, use a static-safe work station. •When not in use, keep the power supplies in their static-shield packaging. IMPORTANT If the equipment is not installed and used as described in this manual, the protection provided by the equipment may be impaired. 6 SLC 500™ Power Supplies Publication 1746-IN004C-MU-P - September 2002 Hazardous Location ConsiderationsProducts marked CL1, DIV 2, GP A, B, C, D are suitable for use in Class I, Division 2, Groups A, B, C, D or non-hazardous locations only. Each product is supplied with markings on the rating nameplate indicating the hazardous location temperature code. When combining products within a system, the most adverse temperature code (lowest “T” number) may be used to help determine the overall temperature code of the system. Combinations of equipment in your system are subject to investigation by the local Authority Having Jurisdiction at the time of installation. Install the Chassis Interconnect Cable (Optional) To connect up to three SLC 500™ chassis together, install the chassis interconnect cable before installing the power supply. . WARNING ! EXPLOSION HAZARD •Do not disconnect equipment unless power has been removed or the area is known to be non-hazardous. •Do not disconnect connections to this equipment unless power has been removed or the area is known to be non-hazardous. Secure any external connections that mate to this equipment using screws, sliding latches, threaded connectors, or other means provided with this product. •Substitution of components may impair suitability for Class I, Division 2. •All wiring must comply with N.E.C. article 501-4(b). SLC 500 chassis/A For more information, see the SLC 500 Modular Hardware Style User Manual (publication 1747-UM011). SLC 500™ Power Supplies 7 Publication 1746-IN004C-MU-P - September 2002 Power Supply Installation1.Align the circuit board of the power supply with the card guides on the left side of the chassis. 2.Slide the power supply in until it is flush with the chassis. Then fasten the power supply to the chassis. Power Supply Wiring TIP For more information on wiring, see Allen-Bradley Programmable Controller Grounding and Wiring Guidelines, publication number 1770-4.1. Refer to publication 1746-IN016 for chassis installation and grounding requirements. Use these screws to fasten the power supply to the chassis. 1.2 Nm (11 in-lbs.) max. torque. 8 SLC 500™ Power Supplies Publication 1746-IN004C-MU-P - September 2002 1.Place the input voltage jumper to match the input voltage. (This does not apply to the 1746-P3, -P5, -P6, and -P7 power supplies, which do not have a jumper.) ATTENTION ! Set the input jumper before applying power. Hazardous voltage is present on exposed pins when power is applied; contact with the pin may cause injury to personnel. WARNING ! If you connect or disconnect the wiring to the terminal blocks or if you insert or remove the power supply while power is on, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding. Catalog Number 1746-P1 & -P2 Catalog Number 1746-P4 Fuse Jumper Selection Jumper Selection 100/120 Volts 200/240 Volts 85-132V ac 170-250V ac SLC 500™ Power Supplies 9 Publication 1746-IN004C-MU-P - September 2002 2.Connect the ground screw of the power supply to the nearest ground or ground bus. Use a #14 AWG 75 Deg. Copper wire (Category 1 per publication 1770-4.1, Industrial Automation Wiring and Grounding Guidelines) and keep the leads as short as possible. The 1746-P4 is shown below. Refer to page 11 for special wiring considerations for the 1746-P3. 3.Connect incoming power. See illustration on page 10. ATTENTION ! Turn off incoming power before connecting wires; failure to do so could cause injury to personnel and/or equipment. Use 14 AWG Copper wire. Tighten terminal screws to 0.8 Nm (7 in-lb.). CHASSIS GROUND Nearest Ground Bus Tighten terminal screws to 0.8 Nm (7 in-lbs.) 10 SLC 500™ Power Supplies Publication 1746-IN004C-MU-P - September 2002 ATTENTION ! Your SLC 500 power supply can be damaged by voltage surges when switching inductive loads such as motors, motor starters, solenoids, and relays. To avoid damage to your SLC 500 power supply in these applications, use an isolation transformer to isolate the power supply from harmful voltage surges. 120/240V ac VAC NEUT DC NEUT + 24V dc JUMPER 170–250 V ac L2 NEUTRAL L1 85–132/170–250 85–132V ac +125V dc DC NEUT CHASSIS GROUND CHASSIS GROUNDCHASSIS GROUND CHASSIS GROUND CHASSIS GROUND +48V dc DC NEUT CHASSIS GROUNDCHASSIS GROUND DC NEUT + 12/24V dc CHASSIS GROUND Catalog Number 1746-P3 Catalog Number 1746-P4 Catalog Number 1746-P5 Catalog Number 1746-P6 Catalog Number 1746-P7 Catalog Number 1746-P1 & P2 Incoming Power Incoming Power Incoming Power Incoming Power P4 Incoming Power P4 Jumper Selection Incoming Power SLC 500™ Power Supplies 11 Publication 1746-IN004C-MU-P - September 2002 1746-P3 Wiring ConsiderationsThe information below describes special wiring considerations for the 1746-P3. ATTENTION ! Any voltage applied to the 1746-P3 DC NEUT terminal will be present at the SLC logic ground and the processor DH-485 port. To prevent unwanted potentials across the logic ground of the controller and/or damage to the SLC chassis, the DC NEUTRAL of the external DC power source must be either isolated from the SLC chassis ground or connected to earth ground as shown in the following illustration. IMPORTANT SLC 500 Series A chassis (1746-A4, -A7, -A10, and -A13) manufactured before November 1992 have a resistor between the logic ground and chassis ground as the drawing on the following page illustrates. This resistor could be damaged if the wiring recommendation described within the attention box above is not followed. See the figure on the following page for the location of the resistor. SLC 500 Series A chassis (1746-A4, -A7, -A10, and -A13) with a manufacture date of November 1992 or later do not have this resistor. SLC 500 Series B chassis have a 1MΩ resistor that limits the current between logic ground and chassis ground. +24V dc DC Neut +24V dc DC Neut DH-485 Port • External DC Power Source Door 1746-P3 Processor SLC 500 Chassis SLC Logic Ground Chassis Ground Earth Ground Earth Ground A jumper wire is recommended between the DC NEUT and Chassis Ground of the external power source. 12 SLC 500™ Power Supplies Publication 1746-IN004C-MU-P - September 2002 4. (Optional) For the 1746-P1, -P2,-P4, -P5 and -P6 power supplies, use PWR OUT +24V dc and PWR OUT COM terminals to power 24V dc sensors and loads. The terminals on the 1746-P1, 1746-P2, 1746-P5 and 1746-P6 provide an isolated, nonfused 200 mA, 24V dc power supply. The terminals on the 1746-P4 provide an isolated, nonfused 1A, 24V dc power supply. (The 1746-P3 and -P7 power supplies do not provide for an external power source.) +24V dc DC Neut Not Used Not Used Chassis Ground DH-485 Port • • Door 1746-P3 Processor SLC 500 Chassis SLC Logic Ground Chassis Ground Resistor Earth Ground PWR OUT +24V dc PWR OUT COM PWR OUT +24V dc PWR OUT COMMON Catalog Number 1746-P1, P2, P5 & P6 Catalog Number 1746-P4 User PowerUser Power SLC 500™ Power Supplies 13 Publication 1746-IN004C-MU-P - September 2002 SLC 500 Operation with 24V dc User Power Overcurrent Condition 5.Remove the protective label. Catalog No. SLC Operation Recovery Procedure 1746-P1 Series A (made in Japan) P/S shutdown, CPU Fault Reload user program 1746-P1 Series A (made in Malaysia- current production) 24V dc user shutdown, CPU continues Correct overcurrent condition 1746-P2 Series A, B P/S shutdown, CPU Fault Reload user program 1746-P2 Series C 24V dc user shutdown, CPU continues Correct overcurrent condition 1746-P4 Series A P/S shutdown, CPU Fault Reload user program 1746-P5 Series A 24V dc user shutdown, CPU continues Correct overcurrent condition 1746-P6 Series A 24V dc user shutdown, CPU continues Correct overcurrent condition ATTENTION ! For 1746-P1 (made in Malaysia), 1746-P2 Series C, 1746-P5 Series A, and 1746-P6 Series A to avoid unexpected operation due to 24V dc user power shutdown, monitor the 24V dc user output with a 24V dc input channel. 14 SLC 500™ Power Supplies Publication 1746-IN004C-MU-P - September 2002 Power Supply Undervoltage OperationSLC 500 controllers continue to operate (hold-up) for a short period of time if the input voltage to the power supply drops below the recommended operating voltage range. The controller continues to scan the user program and control I/O during this time. CPU hold-up for each power supply is shown on pages 14 and 16. SLC 500 controllers turn OFF (stop scanning and disable outputs) if input voltage to the power supply is removed or drops below the recommended operating range for a period exceeding the CPU hold-up time. The controller resumes operation automatically when the input voltage is restored to normal. If the input voltage to the 1746-P7 power supply falls into a range of 4 to 9V for a period exceeding the CPU hold-up time, the controller turns OFF and will not turn back ON until: •input voltage is increased to 11V dc. General Specifications (Power Supplies 1746-P1, -P2, -P3, and -P4) Description: Specification: 1746- P1 P2 P3 P4 Line Voltage 85-132/170-265V ac 47-63 Hz 19.2-28.8V dc 85-132/170-250V ac 47-63 Hz Typical Line Power Requirement 135 VA 180 VA 90 VA 150 VA Maximum Inrush Current 20A 45A Internal Current Capacity 2A at 5V dc 0.46A at 24V dc 5A at 5V dc 0.96A at 24V dc 3.6A at 5V dc 0.87A at 24V dc 10.0A at 5V dc 2.88A at 24V dc(1) Fuse Protection(2)1746-F1 or equivalent(3) (4) 1746-F2 or equivalent(3) (5) 1746-F3 or equivalent(3) (6) Fuse is soldered in place. 24V dc User Power Current Capacity 200 mA Not Applicable 1A(1) 24V dc User Power Volt. Range 18-30V dc 20.4-27.6V dc Max. User-supplied overcurrent protection(7) 15A Not Applicable 15A Ambient Operating Temperature 0°C to +60°C (+32°F to +140°F) Current capacity is derated 5% above +55°C. 0°C to +60°C (+32°F to +140°F) no derating Isolation(8)1800V ac RMS for 1 s None(9)2600V dc for 1 s CPU Hold-up Time(10)20 ms (full load) 3000 ms (no load) 5 ms (full load) 1000 ms (no load) 20 ms (full load) 3000 ms (no load) SLC 500™ Power Supplies 15 Publication 1746-IN004C-MU-P - September 2002 Certification (when product is marked) UL Listed Industrial Control Equipment for Class 1, Division 2, Groups A, B, C, D Hazardous Locations UL Listed Industrial Control Equipment UL Listed Industrial Control Equipment for Class 1, Division 2, Groups A, B, C, D Hazardous Locations CSA Certified Process Control Equipment for Class 1, Div 2, Groups A, B, C, D Hazardous Locations CE(11) European Union 89/336/EEC EMC Directive, compliant with: EN 50082-2 Industrial Immunity EN50081-2 Industrial Emissions European Union 73/23/EEC LVD Directive, compliant with: EN61131-2 Programmable Controllers C-Tick Australian Radiocommunications Act, compliant with: AS/NZS 2064 Industrial Emmissions (1) The combination of all output power (5 volt backplane, 24 volt backplane, and 24 volt user source) cannot exceed 70 watts. (2) Power supply fuse is intended to guard against fire hazard due to short-circuit conditions. This fuse may not protect the supply from miswiring or excessive transient in the power line. (3) Fuse sizes specified are for end-devices only. Fuse size may need to be reduced depending on the size of circuit wiring. (4) Equivalent fuses: 250V-3A fuse, nagasawa ULCS-61ML-3, or BUSSMAN AGC 3 (5) Equivalent fuse: 250V-3A fuse, SANO SOC SD4, or BUSSMAN AGC 3 (6) Equivalent fuse: 125V-3A fuse, Nagasawa ULCS-61ML-5, or BUSSMAN AGC 5 (7) Use time-delay type overcurrent protection in all ungrounded conductors. (8) Isolation is between input terminals and backplane. (9) No isolation between input terminals and backplane. However, dielectric withstand between input terminals and chassis ground terminal is 600V ac RMS for 1 s. (10) CPU hold-up time is for 0V unless specified. Hold-up time is dependent on power supply loading. (11) See the Product Certification link at www.ab.com for Declarations of Conformity, Certificates, and other certification details. Description: Specification: 1746-P1 P2 P3 P4 16 SLC 500™ Power Supplies Publication 1746-IN004C-MU-P - September 2002 General Specifications (Power Supplies 1746-P5, -P6 and -P7) Description: Specification: 1746- P5 P6 P7 Line Voltage 90-146V dc 30-60V dc 10-30V dc(1) (1) See page 14 for information on power supply under voltage operation. Typical Line Power Requirement 85 VA 100 VA 12V dc input: 50 VA 24V dc input: 75 VA Maximum Inrush Current 20A 20A (required for turn-on) Internal Current Capacity 5A at 5V dc 0.96A at 24V dc 12V dc input: 2.0A at 5V dc 0.46A at 24V dc 24V dc input: 3.6A at 5V dc 0.87A at 24V dc See P7 current capacity chart on page 17. Fuse Protection(2) (2) Power supply fuse is intended to guard against fire hazard due to short-circuit conditions. This fuse may not protect the supply from miswiring or excessive transient in the power line. Fuse is soldered in place. 24V dc User Power Current Capacity 200 mA Not Applicable 24V dc User Power Voltage Range 18-30V dc Ambient Operating Temp. 0°C to +60°C (+32°F to +140°F) Current capacity is derated 5% above +55°C. Isolation(3) (3) Isolation is between input terminals and backplane. 1800V ac RMS for 1 s 600V ac RMS for 1 s CPU Hold-up Time(4) (4) CPU hold-up time is for 0V unless specified. Hold-up time is dependent on power supply loading. 20 ms (full load) 3000 ms (no load) 5 ms (full load) 1500 ms (no load) 12V dc input: 1.37 ms at 0V dc (full load) 895 ms at 0V dc (no load) 10 ms at 9V dc (full load) continuous at 9V dc (no load) 24V dc input: 40 ms at 0V dc (full load) 1860 ms at 0V dc (no load) 790 ms at 11V dc (full load) continuous at 11V dc (no load) Certification (when product is marked) UL Listed Industrial Control Equipment for Class 1, Division 2, Groups A, B, C, D Hazardous Locations UL Listed Industrial Control Equipment for Class 1, Division 2, Groups A, B, C, D Hazardous Locations CE(5) European Union 89/336/EEC EMC Directive, compliant with: EN 50082-2 Industrial Immunity EN50081-2 Industrial Emissions European Union 73/23/EEC LVD Directive, compliant with: EN61131-2 Programmable Controllers (5) See the Product Certification link at www.ab.com for Declarations of Conformity, Certificates, and other certification details. C-Tick Australian Radiocommunications Act, compliant with: AS/NZS 2064 Industrial Emmissions SLC 500™ Power Supplies 17 Publication 1746-IN004C-MU-P - September 2002 1746-P7 Current Capacity Physical Dimensions Controller: 1746- Length: mm (in.) Depth: mm (in.) Height: mm (in.) P1 65 (2.56) 140 (5.70) 140 (5.51) P2 85 (3.35) P3 P4 110 (4.33) 145 (5.70) P5 85 (3.35) 140 (5.70) P6 P7 3.6A 2.64A 2.0A .87A 0.625A 0.46A 10V dc 12.2V dc 15Vdc 19.2Vdc 30V dc Input Voltage 5V dc Output Current 24V dc Output Current Publication 1746-IN004C-MU-P - September 2002 PN 40072-083-01(3) Supersedes Publication 1746-IN004B-MU-P - October 2001 Copyright © 2002 Rockwell Automation. All rights reserved. Printed in the U.S.A. Publication 1747-2.39 SLC 500™ Chassis–Based Processors (Catalog Numbers 1747–L511, –L514, – L524, –L531, –L532, –L541, –L542, –L543, – L551, –L552, –L553) Product Data The SLC 500 product line allows you to build just the right control system to meet your needs. We offer four chassis sizes, five power supplies, eleven processors, and a wide variety of I/O modules. Additionally, we offer flexible communication options and programming and operator interface options. The SLC 500 family of programmable controllers have expanded to meet a broader range of applications. From high–speed packaging and material handling applications to advanced process control applications, Allen–Bradley offers the right processor for your job. The SLC 5/03™ , SLC 5/04™ and SLC 5/05™ processors offer features previously found only on high–level Plus. The SLC 500 processors provide a broad range of communication options, including DH–485, RS–232, DH+ä, and Ethernetä . Increased instruction support with ASCII, floating point math, and indirect addressing allows you to expand your application’s capabilities. 2 SLC 500™ Chassis–Based Processors Publication 1747-2.39 Features and Benefits Supports user memory sizes from 1K to 64K. By offering a wide range of user memory, SLC 500 modular processors can be used in a wide variety of applications. Supports a variety of input and output modules. The 1746 modular I/O system offers over 60 types of modules, allowing you to customize your control solution to meet your application needs. Supports I/O configurations of up to 3 chassis (30 local I/O slots). Provides you with the flexibility to expand I/O capacity as required. Supports remote I/O and DeviceNet. The SLC 5/02 and above processors support up to 4096 discrete inputs and 4096 discrete outputs which may be a mix of local or remote I/O as well as I/O on DeviceNet. Provides superior system throughput. SLC 500 modular processors deliver fast overall system throughput times, providing fast response in high–speed applications. Supports Ethernet communication. The SLC 5/05 processors support 10 Mbps Ethernet communication and use the TCP/IP protocol. The 10Base–T Ethernet channel provides an economical connection to your Ethernet network. Supports Data Highway Plus™ (DH+) communication. The SLC 5/04 processor provides communication and seamless integration into the larger Allen–Bradley PLC–5® network. Supports DH–485 communication. Communication via the DH–485 network is available in every processor we ship, reducing your system cost for processor communication. Provides a second channel for RS–232 communication for the SLC 5/ 03, SLC 5/04, and SLC 5/05 processors. This allows: • dial up for remote monitoring and programming • networking over modems for SCADA master/slave RTU applications • an alternate connection for operator interfaces freeing up peer–to–peer network • direct communication to ASCII devices such as bar code decoders and serial printers via a complete set of ASCII ladder instructions which simplify programming. Provides user–selectable program security. The wide range of system protection capabilities allow you to secure user data and program files from changes. SLC 500™ Chassis–Based Processors 3 Publication 1747-2.39 Supports a host of third–party products through the Allen–Bradley Encompass Program. The Encompass Program provides access to products and services that increase your application capabilities. Overview of the Processors The SLC 500 processor product line offers five types of chassis– based processors. SLC 5/01™Processor (Catalog # 1747–L511 or 1747–L514) The SLC 5/01 processor offers the instruction set of the SLC 500 fixed controller in a modular hardware configuration. The SLC 5/ 01 processor provides: • two choices of program memory size - 1K or 4K instructions • control of up to 3840 input and output points • powerful ladder logic programming instruction set • subroutines • a DH–485 communication channel (peer–to–peer communication response to message commands only) • capacitor backup for the –L511; battery backup for the – L514 SLC 5/02™ Processor (Catalog # 1747–L524) The SLC 5/02 processor offers additional instructions, increased diagnostics, faster throughput, and additional peer–to–peer communication options; building on what the SLC 5/01 processors offer. The SLC 5/02 processor provides: • program memory size of 4K instructions • control of up to 4096 input and output points • PID - used to provide closed loop process control • indexed addressing • interrupt capability • user fault routines • ability to handle 32–bit signed math functions • built–in DH–485 communication channel (initiation of peer– to–peer communication) • battery–backed RAM 4 SLC 500™ Chassis–Based Processors Publication 1747-2.39 SLC 5/03™ Processor (Catalog # 1747–L531 and 1747–L532) The SLC 5/03 processor significantly increases performance by supplying system throughput times of 1 ms for a typical 1K user program. Now applications such as high–speed packaging, sorting, and material handling become more affordable. With the addition of online editing, the SLC 5/03 processor presents a positive solution for your continuous process application. A built–in RS–232 channel gives you the flexibility to connect to external intelligent devices without the need for additional modules. The SLC 5/03 processor provides: • program memory size of 8K or 16K •control of up to 4096 input and output points • online programming (includes runtime editing) • built–in DH–485 channel • built–in RS–232 channel, supporting: — DF1 Full–Duplex for point–to–point communication; remotely via a modem, or direct connection to program- ming or operator interface devices. (Use a 1747–CP3 cable for direct connection.) — DF1 Half–Duplex Master/Slave for SCADA type (point–to–multipoint) communication — DH–485 (Serves as a second DH–485 channel. Use a 1761–NET–AIC with a 1747–CP3 cable to connect to the DH–485 network.) — ASCII I/O for connection to other ASCII devices, such as bar code readers, serial printers, and weigh scales • remote I/O passthru • built–in real–time clock/calendar • 2 ms Selectable Timed Interrupt (STI) • 0.50 ms Discrete Input Interrupt (DII) • advanced math features - trigonometric, PID, exponential, floating point, and the compute instruction • indirect addressing • flash PROM provides firmware upgrades without physically changing EPROMS • optional flash EPROM memory module available • keyswitch - RUN, REMote, PROGram (clear faults) • battery–backed RAM SLC 500™ Chassis–Based Processors 5 Publication 1747-2.39 SLC 5/04™ Processor (Catalog # 1747–L541, –L542, or –L543) The SLC 5/04 processor provides the baseline functionality of the SLC 5/03 processor plus DH+ communication. Communication via DH+ takes place 3 to 12 times faster than DH–485, providing you with increased performance levels. In addition, the SLC 5/04 processor runs approximately 15% faster than the SLC 5/03 processor. The SLC 5/04 processor provides: •program memory sizes of 16K, 32K, or 64K • high–speed performance - 0.90 ms/K typical •control of up to 4096 input and output points • online programming (includes runtime editing) • built–in DH+ channel, supporting: — high–speed communication (57.6K, 115.2K, and 230.4K baud) — messaging capabilities with SLC 500, PLC–2 ®, PLC– 5®, and PLC–5/250 processors • built–in RS–232 channel, supporting: — DF1 Full–Duplex for point–to–point communication; remotely via a modem, or direct connection to program- ming or operator interface devices. (Use a 1747–CP3 cable for direct connection.) — DF1 Half–Duplex Master/Slave for SCADA type (point–to–multipoint) communication — DH–485 (Use a 1761–NET–AIC with a 1747–CP3 cable to connect to the DH–485 network.) — ASCII I/O for connection to other ASCII devices, such as bar code readers, serial printers, and weigh scales • channel–to–channel (DH+ to DH–485) passthru capability to operator interface devices • channel–to–channel (DF1 Full–Duplex to DH+) passthru (OS401 and later only) • remote I/O passthru • built–in real–time clock/calendar • 1 ms Selectable Timed Interrupt (STI) • 0.50 ms Discrete Input Interrupt (DII) • advanced math features - trigonometric, PID, exponential, floating point, and the compute instruction • indirect addressing • flash PROM provides firmware upgrades without physically changing EPROMS • optional flash EPROM memory module available • keyswitch - RUN, REMote, PROGram (clear faults) • battery–backed RAM 6 SLC 500™ Chassis–Based Processors Publication 1747-2.39 SLC 5/05™ Processor (Catalog # 1747–L551, –L552, or –L553) The SLC 5/05 processor provides identical functionality as the SLC 5/04 processor using standard Ethernet communications. Ethernet communication takes place at 10 Mbps, providing you with a high performance network for program upload/download, on–line editing, and peer–to–peer messaging. The variety of memory sizes allows you to closely match your application needs. The SLC 5/05 provides: • program memory sizes of 16K, 32K, or 64K • high–speed performance - 0.90 ms/K typical • control of up to 4096 input and output points • online programming (includes runtime editing) • built–in 10Base–T Ethernet channel, supporting: — high–speed computer communication using TCP/IP — messaging capabilities with SLC 5/05, PLC–5, and PLC–5/250 processors, 1785–ENET Ethernet interface module, and 1756–ENET Ethernet bridge — SNMP for standard Ethernet network management — BOOTP for optional dynamic IP address assignment • built–in RS–232 channel, supporting: — DF1 Full–Duplex for point–to–point communication; remotely via a modem, or direct connection to program- ming or operator interface devices. (Use a 1747–CP3 cable for direct connection.) — DF1 Half–Duplex Master/Slave for SCADA type (point–to–multipoint) communication — DH–485 (Use a 1761–NET–AIC with a 1747–CP3 cable to connect to the DH–485 network.) — ASCII I/O for connection to other ASCII devices, such as bar code readers, serial printers, and weigh scales • remote I/O passthru • built–in real–time clock/calendar • 1 ms Selectable Timed Interrupt (STI) • 0.50 ms Discrete Input Interrupt (DII) • advanced math features - trigonometric, PID, exponential, floating point, and the compute instruction •indirect addressing • logical ASCII addressing • flash PROM provides firmware upgrades without physically changing EPROMS • optional flash EPROM memory module available • keyswitch - RUN, REMote, PROGram (clear faults) • battery–backed RAM SLC 500™ Chassis–Based Processors 7 Publication 1747-2.39 System Throughput When your application requires high–speed processing it requires more than just fast instruction or program scan times. It requires speed from the time an input is read until the time an output is turned on. The SLC 500 processors improve performance in every phase of system throughput, from input and output scans, to program scans and housekeeping functions. 8 SLC 500™ Chassis–Based Processors Publication 1747-2.39 Interrupt Subroutines The following interrupt subroutines allow you to provide predetermined responses to special events in an application. Selectable Timed Interrupt This function allows you to interrupt the scan of the processor automatically, on a periodic basis, in order to scan a specified subroutine file. When using an SLC 5/02 processor, the Selectable Timed Interrupt (STI) timebase can be adjusted in 10 ms increments. The timebase for the SLC 5/03, SLC 5/04, and SLC 5/05 processors can be adjusted in 1 ms increments. The SLC 5/03 processor begins at 2 ms STI, and the SLC 5/04 and SLC 5/05 processors begin at 1 ms STI. Discrete Input Interrupt Use the Discrete Input Interrupt (DII) for high–speed processing applications or any application that needs to respond to an event quickly. This function allows the processor to execute a ladder subroutine when the input bit pattern of a discrete I/O card matches a compare value that you programmed. The discrete input interrupt is examined every 100 µs asynchronous to the ladder program scan. You may also specify the number of counts (matches) to occur before subroutine execution. I/O Event Interrupt This function allows the 1746–BAS (BASIC) module to interrupt the normal processor operating cycle in order to scan a specified subroutine file. Use this interrupt with SLC 5/02, SLC 5/03, SLC 5/04, and SLC 5/05 processors. SLC 500™ Chassis–Based Processors 9 Publication 1747-2.39 Communication Options The SLC 500 processors support different types of communication options. The following sections describe the physical connections and protocol options used by the processors. Physical Connection Options Ethernet (10Base–T) channel offers: • 10 Mbps communication rate • ISO/IEC 8802–3STD 802.3 (RJ45) connector for 10Base–T media • TCP/IP communication protocol • built–in isolation Data Highway Plus (DH+) channel offers: • communication rates of 57.6K, 115.2K, and 230.4K baud • maximum network length of 3,048 m (10,000 ft.) at 57.6K baud • Belden 9463 (blue hose) cable connection between nodes (daisy chain connection) • built–in isolation DH–485 channel offers: • configurable communication rates up to 19.2K baud • electrical isolation via the 1747–AIC or 1761–NET–AIC • maximum network length of 1219m (4,000 ft.) • RS–485 electrical specifications • Belden 9842 or Belden 3106A cable connection between nodes (daisy chain connection) RS–232 channel offers: • communication rates up to 19.2K baud (38.4K baud SLC 5/ 05) • maximum distance between devices is 15.24 m (50 ft.) • RS–232C (EIA–232) electrical specifications • modem support • built–in isolation 10 SLC 500™ Chassis–Based Processors Publication 1747-2.39 The table below summarizes the SLC 500 processor channel connections. Protocol Options Ethernet TCP/IP Protocol Standard Ethernet, utilizing the TCP/IP protocol, is used as the backbone network in many office and industrial buildings. Ethernet is a local area network that provides communication between various devices at 10 Mbps. This network provides the same capabilities as DH+ or DH–485 networks, plus: • SNMP support for Ethernet network management • optional dynamic configuration of IP addresses using a BOOTP utility • SLC 5/05 Ethernet data rate up to 40 times faster than SLC 5/04 DH+ messaging • ability to message entire SLC 5/05 data files • much greater number of nodes on a single network possible compared to DH–485 (32) and DH+ (64) Processor Physical Communication Channel DH-485 RS-232a DH+ Ethernet SLC 5/01 DH-485 protocol SLC 5/02 DH-485 protocol SLC 5/03 Channel 0 DH-485, DF1 Full-Duplex, DF1 Half-Duplex Master/ Slave, and ASCII protocols Channel 1 DH-485 protocol SLC 5/04 Channel 0 DH-485, DF1 Full-Duplex, DF1 Half-Duplex Master/ Slave, and ASCII protocols Channel 1 DH+ protocol SLC 5/05 Channel 0 DH-485, DF1 Full-Duplex, DF1 Half-Duplex Master/ Slave, and ASCII protocols Channel 1 Ethernet TCP/IP protocol a.A 1761-NET-AIC (or 1747-AIC) is required when connecting to a DH-485 network. SLC 500™ Chassis–Based Processors 11 Publication 1747-2.39 Data Highway Plus (DH+) Protocol The Data Highway Plus protocol is used by the PLC–5 family of processors and the SLC 5/04 processor. This protocol is similar to DH–485, except that it can support up to 64 devices (nodes) and runs at faster communication (baud) rates. DH–485 Protocol The SLC 500 processors have a DH–485 channel that supports the DH–485 communication network. This network is a multi– master, token–passing network protocol capable of supporting up to 32 devices (nodes). This protocol allows: • monitoring of data and processor status, along with program uploading and downloading of any device on the network from one location • SLC processors to pass data to each other (peer–to–peer communication) • operator interface devices on the network to access data from any SLC processor on the network DF1 Full–Duplex Protocol DF1 Full–Duplex protocol (also referred to as DF1 point–to– point protocol) allows two devices to communicate with each other at the same time. This protocol allows: • transmission of information across modems (dial–up, leased line, radio, or direct cable connections) • communication to occur between Allen–Bradley products and third–party products DF1 Half–Duplex Protocol (Master and Slave) DF1 Half–Duplex protocol provides a multi–drop single master/ multiple slave network capable of supporting up to 255 devices (nodes). This protocol also provides modem support and is ideal for SCADA (Supervisory Control and Data Acquisition) applications because of the network capability. ASCII Protocol The ASCII protocol provides connection to other ASCII devices, such as bar code readers, weigh scales, serial printers, and other intelligent devices. 12 SLC 500™ Chassis–Based Processors Publication 1747-2.39 System Protection Options The SLC 500 family of processors offer a number of hardware and software security features that allow you to protect your system from unauthorized changes to program or data files. The different types of protection are: Types of Protection SLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 Password ••• Future Access (OEM Lock) • • • Program Owner • • • Program Files • Data Table Files • • • Memory Module Data File Overwrite • Memory Module Program Compare • Memory Module Write Protection • Force Protection • Keyswitch • Communication Channel Protection SLC 500™ Chassis–Based Processors 13 Publication 1747-2.39 I/O Usages The SLC 500 family of processors support a variety of I/O modules, allowing you to exactly match your application. The following table lists the various types of I/O modules and their compatibility with the SLC 500 processors. I/O Module SLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 1746–Discrete Input/Output AC/DC • • • 1746sc–Isolated Discrete Input/Output AC/DCa ••• 1746–Analog Modules • • • 1746sc–Isolated Analog Modules • • • 1746–NT4 and 1746–INT4 Thermocouple Modules and 1746sc–NT8 Isolated Thermocouple Module ••• 1746–NR4 RTD Input Module • • • 1747–SN Remote I/O Scanner Module • • 1746–SDN DeviceNet Scanner Module • • 1746–BAS Basic Module • • • 1747–KE DH–485/RS232 KE Module • • • 1746–HSCE High–Speed Counter Encoder Module •• 1746–HSTP1 Stepper Controller Module • • 1746–HS IMC 110 Servo Controller Module • • • 1746–HSRV Servo Control Module • 1746–QV Open–Loop Velocity Control Module • • 1746–BTM Barrel Temperature Module • • 1746–QS Synchronized Axes Module • • a.Sold and supported by Spectrum Controls, Inc., Bellevue, WA. For additional information, contact Spectrum at (206) 746-9481. 14 SLC 500™ Chassis–Based Processors Publication 1747-2.39 Programming Instructions The following programming instructions are used with the SLC 500 processors. Included are instruction execution times (µs) for the processors when the instruction is True and when floating point math is used and the instruction is True. Basic Instructions Instruction Mnemonic and Name Execution Times (µs)Function - Conditional Instructions Input or OutputSLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 XIC Examine if Closed 4 2.4 0.44 0.37 Conditional instruction. True when bit is on (1). XIO Examine if Open 4 2.4 0.44 0.37 Conditional instruction. True when bit is off (0). OTE Output Energize 18 11 0.63 0.56 Output instruction. True (1) when conditions preceding it are true. False when conditions preceding it go false. OTL Output Latch 19 11 0.63 0.56 Output instruction. Addressed bit goes true (1) when conditions preceding the OTL instruction are true. When conditions go false, OTL remains true until the rung containing an OTU instruction with the same address goes true. OTU Output Unlatch 19 11 0.63 0.56 Output instruction. Addressed bit goes false (0) when conditions preceding the OTU instruction are true. Remains false until the rung containing an OTL instruction with the same address goes true. OSR One-Shot Rising 34 20 10.80 9.10 Conditional instruction. Makes rung true for one scan upon each false–to–true transition of conditions preceding it in the rung. TON Timer On-Delay 135 83 1.40 1.31 Counts time intervals when conditions preceding it in the rung are true. Produces an output when accumulated value (count) reaches preset value. TOF Timer Off-Delay 140 86 1.40 1.31 Counts time intervals when conditions preceding it in the rung are false. Produces an output when accumulated value (count) reaches preset value. RTO Retentive Timer 140 86 1.40 1.31 This is an On–Delay timer that retains its accumulated value when: • Rung conditions go false. • The mode changes to program from run or test. • The processor loses power. • A fault occurs. CTU Count Up 111 69 1.40 1.31 Counts up for each false–to–true transition of conditions preceding it in the rung. Produces an output when accumulated value (count) reaches the preset value. CTD Count Down 111 69 1.40 1.31 Counts down for each false–to–true transition of conditions preceding it in the rung. Produces an output when accumulated value (count) reaches preset value. RES Reset 40 26 1.40 1.31 Used with timers and counters. When conditions preceding it in the rung are true, the RES instruction resets the accumulated value and control bits of the timer or counter. SLC 500™ Chassis–Based Processors 15 Publication 1747-2.39 Comparison Instructions Instruction Mnemonic and Name Execution Times (µs) Floating Point (µs) a b Function - Conditional (Input) Instructions SLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 EQU Equal 60 38 1.25/12.94 1.12 / 12.5 Instruction is true when source A = source B. NEQ Not Equal 60 38 1.25 / 13.25 1.12 / 12.18 Instruction is true when source A =/ source B. LES Less Than 60 38 1.25 / 13.19 1.12 / 13.94 Instruction is true when source A < source B. LEQ Less Than or Equal 60 38 1.25 / 13.19 1.12 / 13.93 Instruction is true when source A < source B. GRT Greater Than 60 38 1.25 / 14.82 1.12 / 12.62 Instruction is true when source A > source B. GEQ Greater Than or Equal 60 38 1.25 / 14.81 1.12 / 14.31 Instruction is true when source A > source B. MEQ Masked Comparison for Equal 75 47 38 22.75 Compares 16–bit data of a source address to 16–bit data at a reference address through a mask. If the values match, the instruction is true. LIM Limit Test - 45 1.95 / 22.81 1.68 / 20.19 True/false status of the instruction depends on how a test value compares to specified low and high limits. a.Floating point times do not apply to SLC 5/03 OS300 processors. b.When only one Execution Time is listed for an instruction, Floating Point does not apply. 16 SLC 500™ Chassis–Based Processors Publication 1747-2.39 Math Instructions Instruction Mnemonic and Namea Execution Times (µs) Floating Point (µs) b c Function - Output Instructions SLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 Add Add 122 76 1.70 / 38.44 1.50 / 18.22 When rung conditions are true, the ADD instruction adds source A to source B and stores the result in the destination. SUB Subtract 125 77 1.70 / 38.19 1.50 / 19.50 When rung conditions are true, the SUB instruction subtracts source B from source A and stores the result in the destination. MUL Multiply 230 140 20 / 39.05 17.75 / 21.94 When rung conditions are true, the MUL instruction multiplies source A by source B and stores the result in the destination. DIV Divide 400 242 23 / 57.56 25.9 / 23.27 When rung conditions are true, the DIV instruction divides source A by source B and stores the result in the destination and the math register. DDV Double Divide 650 392 33 29.6 When rung conditions are true, the DDV instruction divides the contents of the math register by the source and stores the result in the destination and the math register. NEG Negate 110 68 1.70 / 12.38 1.5 / 11.87 When rung conditions are true, the NEG instruction changes the sign of the source and places it in the destination. CLR Clear 40 26 1.70 / 6.62 1.5 / 5.94 When rung conditions are true, the CLR instruction clears the destination to zero. SQR Square Root — 162 32.00 / 70.00 28.8 / 18.87 When rung conditions are true, the SQR instruction calculates the square root of the source and places the result in the destination. SCL Scale — 480 d / 32.00 d / 33.06 When rung conditions are true, the SCL instruction multiplies the source by a specified rate. The result is added to an offset value and placed in the destination. SCP Scale with Parameters ——33.10 / 196.10 29.85 / 94.15 Produces a scaled output value that has a linear relationship between the input and scaled values. CPT Compute — — d / 8.8 d / 7.7 Evaluates an expression and stores the result in the destination. To get the total execution time for a CPT instruction, take the CPT execution time plus each additional math instruction execution time, plus the number of math instructions times 3.01. For example if an SLC 5/03 CPT instruction calls one ADD and one SUB instruction, the calculation is: 8.8 + 1.70 + 1.70 + 2(3.01) = 18.22 SLC 500™ Chassis–Based Processors 17 Publication 1747-2.39 SWP Swap ——24 + 13.09 per word 22.6 + 12.13 per word Swaps the low and high bytes of a specified number of words in a bit integer, ASCII, or string file. ABS Absolute Value — — 9.95 / 5.20 8.60 / 4.35 Calculates the absolute value of the source and places the result in the destination. XPY X to the Power of Y Register/Data ——d / 699.30 d /335.10 Raises a value to a power and stores the result in the destination. LOG Log to the Base 10 ——d / 390.80 d / 54.55 Takes the log base 10 of the value in the source and stores the result in the destination. LN Natural Log — — d / 392.00 d / 51.35 Takes the natural log of the value in the source and stores it in the destination. SIN Sine — — d / 311.95 d / 38.05 Takes the sine of a number and stores the result in the destination. COS Cosine — — d / 310.90 d / 37.20 Takes the cosine of a number and stores the result in the destination. TAN Tangent — — d / 406.35 d / 43.00 Takes the tangent of a number and stores the result in the destination. ASN Arc Sine — — d / 483.05 d / 41.45 Takes the arc sine of a number and stores the result (in radians) in the destination. ACS Arc Cosine — — d / 510.85 d / 51.90 Takes the arc cosine of a number and stores the result (in radians) in the destination. ATN Arc Tangent — — d / 387.05 d / 40.15 Takes the arc tangent of a number and stores the result (in radians) in the destination. a.Applies to SLC 5/03 OS302, SLC 5/04 OS401 and SLC 5/05 OS500 processors. b.Floating point times do not apply to SLC 5/03 OS300 processors. c.When only one Execution time is listed for an instruction, Floating Point does not apply. d.The execution times assum floating point data. If signed interger data is used, add 15 microseconds per instruction execution time. 18 SLC 500™ Chassis–Based Processors Publication 1747-2.39 Data Handling Instructions Instruction Mnemonic and Name Execution Times (µs) Floating Point (µs) b c Function - Output InstructionsSLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 TOD Convert to BCD 200 122 38 34.06 When rung conditions are true, the TOD instruction converts the source value to BCD and stores it in the math register or the destination. FRD Convert from BCD 223 136 31 23.88 When rung conditions are true, the FRD instruction converts a BCD value in the math register or the source to an integer and stores it in the destination. RAD Degrees to Radiansa ——d / 31.80 d / 24.65 When rung conditions are true, RAD converts degrees (source) to radians and stores the result in the destination. DEG Radians to Degrees a ——d / 32.80 d / 24.70 When rung conditions are true, DEG converts radians (source) to degrees and stores the result in the destination. DCD Decode 80 50 10 8.88 When rung conditions are true, the DCD instruction decodes 4–bit value (0 to 16), turning on the corresponding bit in 16–bit destination. COP File Copy 45 + 21 per word 29 + 13 per word 30 + 2.20 per word 20.2 + 2.0 per word When rung conditions are true, the COP instruction copies a user–defined source file to the destination file. FLL File Fill 37 + 14 per word 25 + 8 per word 28 + 2 per word 21.9 + 2.5 per word When rung conditions are true, the FLL instruction loads a source value into specified elements in a user–defined file. MOV Move 20 14 1.25 / 12.19 1.12 / 11.44 When rung conditions are true, the MOV instruction moves a copy of the source to the destination. MVM Masked Move 115 71 19 17.40 When rung conditions are true, the MVM instruction moves a copy of the source through a mask to the destination. AND And 87 55 1.70 1.5 When rung conditions are true, sources A and B of the AND instruction are ANDed and stored in the destination. OR Inclusive Or 87 55 1.70 1.5 When rung conditions are true, sources A and B of the OR instruction are ORed bit by bit and stored in the destination. XOR Exclusive Or 87 55 1.70 1.5 When rung conditions are true, sources A and B of the XOR instruction are Exclusive ORed and stored in destination. NOT Not 66 42 1.70 1.5 When rung conditions are true, the source of the NOT instruction is NOTed bit by bit and stored in the destination. FFL Load — 150 58 40.75 First In First Out (FIFO). The FFL instruction loads a word into a FIFO stack on successive false–to–true transitions. The FFU unloads a word from the stack on successive false–to–true transitions. The first word loaded is the first to be unloaded. FFU Unload — 150 + 11 per word 79 + 2.20 per word 60 + 2 per word LFL Load — 150 58 40.70 Last In First Out (LIFO). The LFL instruction loads a word into a LIFO stack on successive false–to–true transitions. The LFU unloads a word from the stack on successive false–to–true transitions. The last word loaded is the first to be unloaded. LFU Unload — 180 66 34.70 a.Applies to SLC 5/03 OS302 and SLC 5/04 OS401 processors. b.Floating point times do not apply to SLC 5/03 OS300 processors. c.When only one Execution Time is listed for an instruction, Floating Point does not apply. d.The execution times assum floating point data. If signed integer data is used, add 15 microseconds per instruction execution time. SLC 500™ Chassis–Based Processors 19 Publication 1747-2.39 Program Flow Instructions Instruction Mnemonic and Name Execution Times (µs) Function - Conditional or Output InstructionsSLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 JMP Jump to Label 38 23 44.45 37.44 Output instruction. When rung conditions are true, the JMP instruction causes the program scan to jump forward or backward to the corresponding LBL instruction. LBL Label 2 4 0.25 0.18 This is the target of the correspondingly numbered JMP instruction. JSR Jump to Subroutine 46 28 131.0 112.0 Output instruction. When rung conditions are true, the JSR instruction causes the processor to jump to the targeted subroutine file. SBR Subroutine 2 4 0.25 0.18 Placed as first instruction in a subroutine file. Identifies the subroutine file. RET Return from Subroutine 34 20 23 20.0 Output instruction, placed in subroutine. When rung conditions are true, the RET instruction causes the processor to resume program execution in the main program file or the previous subroutine file. MCR Master Control Reset 10 6 4 3.0 Output instruction. Used in pairs to inhibit or enable a zone within a ladder program. TND Temporary End 32 22 12 13.05 Output instruction. When rung conditions are true, the TND instruction stops the program scan, updates I/O, and resumes scanning at rung 0 of the main program file. SUS Suspend 12 7 12 10.31 Output instruction, used for troubleshooting. When rung conditions are true, the SUS instruction places the controller in the Suspend Idle mode. The suspend ID number is placed in word S:7 and the program file number is placed in S:8. IIM Immediate Input with Mask 372 340 51.85 51.0 When conditions preceding it in the rung are true, the IIM instruction is enabled and interrupts the program scan to write a word of masked external input data to input data file. IOM Immediate Output with Mask 475 465 70.90 75.74 When conditions preceding it in the rung are true, the IOM instruction is enabled and interrupts the program scan to read a word of data from the output data file and transfer the data through a mask to the corresponding external outputs. 20 SLC 500™ Chassis–Based Processors Publication 1747-2.39 Application Specific Instructions Communication Instructions Proportional Integral Derivative Instruction Instruction Mnemonic and Name Execution Times (µs) Function - Output InstructionsSLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 BSL Bit Shift Left BSR Bit Shift Right 144 + 24 per word 89 + 14 per word 50 + 2.30 per word 31.5 + 2.31 per word On each false–to–true transition, these instructions load a data bit into a bit array, shift the pattern of data through the array, and unload the end bit of data. The BSL shifts data to the left and the BSR shifts data to the right. SQO Sequencer Output 225 137 70 44.1 On each false–to–true transition, these instructions load a data bit into a bit array, shift the pattern of data through the array, and unload the end bit of data. The BSL shifts data to the left and the BSR shifts data to the right. SQC Sequencer Compare 225 137 60 33.2 On successive false–to–true transitions, the SQC moves a step through the programmed sequencer file, comparing the data through a mask to a source word or file for equality. SQL Sequencer Load — 135 56 33.2 On successive false–to–true transitions, the SQL moves a step through the sequencer file, loading a word of source data into the current element of the sequencer file. Instruction Mnemonic and Name Execution Times (µs) Function - Output InstructionsSLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 MSG Message Read/ Write — 180 203 183 This instruction transfers data from one node to another on the communication network. When the instruction is enabled, message transfer is pending. Actual data transfer takes place at the end of the scan. SVC Service Communications — 240 240 200 When conditions preceding it in the rung are true, the SVC instruction interrupts the program scan to execute the service communication portion of the operating cycle. Instruction Mnemonic and Name Execution Times (µs) Function - Output InstructionsSLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 PID Proportional Integral Derivative — 3600 272 169.82 This instruction is used to control physical properties such as temperature, pressure, liquid level, or flow rate of process loops. SLC 500™ Chassis–Based Processors 21 Publication 1747-2.39 ASCII Instructions Instruction Mnemonic and Namea Execution Times (µs) Function - Output InstructionsSLC 5/03 SLC 5/04 SLC 5/05 ABL Test Buffer for Line 129.9 156.0 Determines the number of characters in the buffer, up to and including the end–of–line characters (termination). ACB Number of Characters in Buffer 140.7 131.0 Determines the total characters in the buffer. ACI String to Integer 86.62 56.0 Converts an ACSII string to an integer value. ACL ASCII Clear Receive and/or Send Buffer 367.5 332.8 Clears the ASCII buffer. ACN String Concantenate 69.4 + 2.1 per character 56 + 2.5 per character Combines two strings using ACSII strings as operands. AEX String Extract 56.2 + 4.7 per character 43.4 + 4.0 per character Creates a new string by taking a portion of an existing string and linking it to a new string. AHL ASCII Handshake Lines 138.7 115.1 Sets or resets the RS-232 Data Terminal REady and Request to Sender handshake control lines for the modem. AIC Integer to String 103.4 110.0 Converts an integer value to an ASCII string. ARD ASCII Read Characters 181.8 151.0 Reads characters from the buffer and stores them in a string. ARL ASCII Read Line 190.0 156.0 Reads characters from the buffer up to and including the end-of-line characters and stores them in a string. ASC String Search 53.4 + 1.8 per character 43.5 + 2.5 per character Searches an existing string for an occurrence of the source string. ASR ASCII String Compare 49.69 43.5 Compares two ASCII strings. AWA ASCII Write with Append 365.5 307.8 Adds the two appended characters set from the ASCII configuration menu. AWT ASCII Write 263.8 217.3 Writes characters from a source string to a display device. a.Only SLC 5/03 (OS301, OS302), SLC 5/04 and SLC 5/05 processors use these instructions. 22 SLC 500™ Chassis–Based Processors Publication 1747-2.39 Interrupt Routine Instructions Indirect Addressing The following sections describe how indirect addressing affects the execution time of instructions in the SLC 5/03 OS302, SLC 5/ 04 OS401, and SLC 5/05 processors. The timing for an indirect address is affected by: • the form of the indirect address • if the indirect address is a source or destination parameter • whether indirect addressing is used in either a COP, FLL, FFL/FFU, LFL/LFU, BSR, BSL, or MVM instruction • whether indirect addressing is used in either an XIC, XIO, OTU, OTL, OTE, or OSR instruction For the address forms in the table on the next page, you can substitute the following file types: Instruction Mnemonic and Name Execution Times (µs) Function - Output InstructionsSLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 STD Selectable Timed Disable —9 4 3.56 Associated with the Selectable Timed Interrupt function. STD and STE are used to prevent an STI from occurring during a portion of the program; STS initiates an STI. STE Selectable Timed Enable —9 5 5.0 STS Selectable Timed Start — 72 58 44.38 IIE I/O Interrupt Enable — 42 16 10.44 The IIE, IID and RPI instructions are used with specialty I/O modules capable of generating an I/O interrupt. IID I/O Interrupt Disable — 39 6 5.81 RPI Reset Pending I/O Interrupt — 240 78 + 60 per added slot 91 + 56 per added slot REF I/O Refresh — 240 240 200 When conditions preceding it in the rung are true, the REF instruction interrupts the program scan to execute the I/O scan (write outputs-service comms-read inputs). The program scan then resumes. INT Interrupt Subroutine — 0 0.25 0.18 Associated with STI interrupts and I/O event- driven interrupts. For an Integer (N) For a String (ST) Input (I) Control (R) Output (O) Counter (C) Bit (B) Timer (T) Floating Point (F) ASCII (A) SLC 500™ Chassis–Based Processors 23 Publication 1747-2.39 Execution Times for Word–Level Indirect Addresses For most types of instructions that contain an indirect address(es), look up the form of the indirect address in the table below and add that time to the execution time of the instruction. Address Forma Source Operand (µs)Destination Operand (µs) If used in a file type instruction SLC 5/03 SLC 5/04 SLC 5/05 SLC 5/03 SLC 5/04 SLC 5/05 SLC 5/03 SLC 5/04 SLC 5/05 N7:[*] 65.1 56.15 63.10 54.20 76.35 66.75 ST12:[*].[*] 69.45 60.00 67.45 58.05 80.70 70.60 ST12:[*].0 74.65 59.60 72.65 57.65 85.90 70.20 ST12:0.[*] 74.65 59.60 72.65 57.65 85.90 70.20 N[*]:[]:[ 105.90 89.40 131.50 112.55 138.75 118.70 N[*]:0 111.10 89.00 136.70 112.15 143.95 118.30 N[*]:0 111.10 89.00 136.70 112.15 143.95 118.30 ST[*]:[*].[*] 110.25 93.25 135.85 116.40 143.10 122.55 ST[*]:[*].0 115.45 92.85 141.05 116.00 148.30 122.15 ST[*]:0.[*] 115.45 92.85 141.05 116.00 148.30 122.15 ST[*]:0.0 120.65 92.45 146.25 115.60 153.50 121.75 #N7:[*] 73.05 59.35 64.65 57.30 86.80 69.80 #ST12:[*].[*] 77.40 63.20 69.00 61.15 91.15 73.65 #ST12:[*].0 82.60 62.80 74.20 60.75 96.35 73.25 #ST12:0.[*] 82.60 62.80 74.20 60.75 96.35 73.25 #N[*]:[*] 110.95 92.95 133.40 114.40 146.65 121.35 #N[*]:0 116.15 92.55 138.60 114.00 151.85 120.95 #ST[*]:[*].[*] 115.30 96.80 137.75 118.25 151.00 125.20 #ST[*]:[*].0 120.50 96.40 142.95 117.85 156.20 124.80 #ST[*]:0.[*] 120.50 96.40 142.95 117.85 156.20 124.80 #ST[*]:0.0 125.70 96.00 148.15 117.45 161.40 124.40 a.[*] indicates that an indirect reference is substituted. 24 SLC 500™ Chassis–Based Processors Publication 1747-2.39 Execution Times for Bit–Level Indirect Addresses Indirect bit addresses are based on the form of the indirect address and the type of bit instruction. Use the following two tables to calculate the execution time of a bit instruction. Execution Time Examples - Word Level and Bit Level Indirect Address Address Form Additional Time (µs) SLC 5/03 SLC 5/04 SLC 5/05 B3/[*] 96.70 77.80 B3:1/[*] 96.70 77.80 B3:[*=/]:[ 91.50 72.80 ST12:[*].[*=/]:[ 100.65 76.65 ST12:[*].[*]/0 100.85 76.25 ST12:[*].0/[*] 100.85 76.25 ST12:[*].0/0 105.85 75.85 ST12:0.[*] /0 105.85 75.85 ST12:0.0/[*] 105.85 75.85 B[*=/]:[ 171.50 141.40 B[*]:1/[*] 171.50 141.40 B[*]:[*=/]:[ 166.30 141.80 ST[*]:[*].[*=/]:[ 170.65 145.65 ST[*]:[*].[*]/0 175.85 145.25 ST[*]:[*].0/[*] 175.85 145.25 ST[*]:[*].0/0 181.05 144.85 ST[*]:0.[*=/]:[ 175.85 145.25 ST[*]:0.[*]/0 181.05 144.85 ST[*]:0.0/[*] 181.05 144.85 ST[*]:0.0/0 186.25 144.45 SLC 500™ Chassis–Based Processors 25 Publication 1747-2.39 Instruction Execution Times Execution Time Example - Bit Instruction Using an Indirect Address To calculate the execution time of an XIC at B3/[N7:0] using an SLC 5/03 processor add the following: Execution Time for Bit–Level Indirect Address + Instruction Execution Time =10.20 + 96.70 = 106.90 Specifications The following table summarizes the detailed specifications for the SLC 500 processor family: Instruction Execution Time (µs) SLC 5/03 SLC 5/04 SLC 5/05 XIC 10.20 8.72 XIO 14.65 12.76 OTU 6.30 5.45 OTL 9.35 5.40 OTE 6.25 5.50 OSR 10.50 8.10 Specification SLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 1747–L511 1747–L514 1747–L524 1747–L531 1747–L532 1747–L541 1747–L542 1747–L543 1747–L551 1747–L552 1747–L553 Memory Size (words) 1K (1747–L511) 4K (1747–L514)4K 8K (1747–L531) 16K (1747–L532) 16K (1747–L541) 32K (1747–L542) 64K (1747–L543) 16K (1747–L551) 32K (1747–L552) 64K (1747–L553) Max. I/O Capacity 3940 Discrete 4096 Discrete 4096 Discrete 4096 Discrete 4096 Discrete Max. Local Chassis/Slots 3/30 3/30 3/30 3/30 3/30 Programming •RSLogix 500 (V1.00 or later), SLC–500 A.I. Series •APS Programming Software •HHT 1747–L531: •RSLogix 500 (V1.26.03 or later) •SLC 500 A.I. Series (V8.15 or later) 1747–L532: •RSLogix 500 (V1.24.04 or later) •SLC 500 A.I. Series (V8.10 or later) •APS (V6.0 or later) •RSLogix 500 (V1.24.04 or later) •SLC 500 A.I. Series (V8.10 or later) •APS ( V6.0 or later) •RSLogix 500 (V2.10 or later) Programming Instructions 52 71 99 99 99 Typical Scan Timea 8 ms/K 4.8 ms/K 1 ms/K 0.9 ms/K 0.9 ms/K Bit Execution (XIC)4 µs2.4 µs 0.44 µs 0.37 µs0.37 µs a.The scan times are typical for a 1K ladder logic program consisting of simple ladder logic and communication servicing. Actual scan times depend onyour program size, instructions used and the communication protocol. 26 SLC 500™ Chassis–Based Processors Publication 1747-2.39 The following table summarizes the communication options for the SLC 500 processor family. Communications Protocol Processor SLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 DH485 peer–to– peer receive only receive and initiate receive and initiate DH485 via RS232 port receive and initiatec receive and initiatec receive and initiatec DF1 via RS232 port (full–duplex or half–duplex master or slave) receive onlya receive onlya receive and initiate receive and initiate receive and initiate ASCII via RS232 port receive and initiate receive and initiate receive and initiate Data Highway Plus (DH+)receive onlyb receive onlyb receive and initiated receive and initiate receive and initiate Ethernet receive and initiate a.A 1747-KE or 1770-KF3 is required to bridge from DF1 (full-duplex or half-duplex slave only) to DH485. b.A 1785-KA5 is required to bridge from HD+ to DH485. c.If using 1747-AIC for isolation, connect to DH-485 network using 1747-PIC; if using 1761-NET-AIC for isolation, directly connect to DH-485 network with 1747-CP3 serial cable (or equivalent RS-232 null-modem cable). d.Either a 1785-KA5 is required to bridge from DH+ to DH485 or the SLC 5/04’s channel-to-channel passthru feature may be used to bridge between DH+ and DH485 or between DH+ and DF1 Full-Duplex (DH+ to DF1 Full-Duplex passthru available starting with OS401). Another option is to use the 1785-KE to bridge between DH+ and DF1 Full-Duplex or DH+ and a DF1 Half-Duplex Master/Slave network. Note:The 1785-KA5 and 1785-KE modules require use of a 1771-series chassis and power supply. SLC 500™ Chassis–Based Processors 27 Publication 1747-2.39 The following table summarizes the general specifications for the SLC 500 processor family: The following table summarizes the available memory back up options for the SLC 500 processors. EEPROM and UVPROM memory modules provide non-volatile memory backup. Flash EPROMs (Flash Erasable Programmable Read-Only Memory) combine the versatility of EEPROMs with the security of UVPROMs. Description Specification Power Supply Loading SLC 5/01 and SLC 5/02 350mA at 5V dc. 105 mA at 24V dc SLC 5/03 500 mA at 5V dc. 175 mA at 24V dc SLC 5/04 and SLC 5/05 1.0 A at 5V dc 200 mA at 24V dc Program Scan Hold-up time after Loss of Power 20 ms to 3 s (dependent on power supply loading) Clock/Calendar Accuracy (Applicable only to SLC 5/03, SLC 5/04, and SLC 5/05 processors) ±54 sec/month at +25° C (77° F) ±81 sec/month @ +60° C (+140°F) Noise Immunity NEMA Standard ICS 2-230 Vibration Displacement 0.015 inch, peak-to-peak at 5-57 Hz Acceleration 2.5Gs at 57-2000 Hz Shock (operating)30Gs Ambient Temperature Rating Operating Temperature 0 to +60°C (+32°F to +140°F) Storage Temperature -40°C to +85°C (-40°F to 185°F) Humidity 5 to 95% without condensation Certification UL listed CSA approved Class 1, Groups A, B, C or D, Division 2 CE compliant for all applicable directives Specification SLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 1747-L511 1747-L514 1747-L524 1747-L531 1747-L532 1747-L541 1747-L542 1747-L543 1747-L551 1747-L552 1747-L553 EEPROM 1747-M1 1747-M2 1747-M2 UVPROM 1747-M3 1747-M4 1747-M4 Flash 1747-M11 1747-M12 (OS302 or later) 1747-M11 1747-M12 (OS401 or later) 1747-M11 1747-M12 Publication 1747-2.39 - December 1997 Supersedes Publication 1747-2.39 - December 1995 Ó 1998 Rockwell International. All Rights Reserved. Printed in USA Allen-Bradley Support In today’s competitive environment, when you buy any product, you expect that product to meet your needs. You also expect the manufacturer of that product to back it up with the kind of customer service and product support that will prove you made a wise purchase. As the people who design, engineer and manufacture your Industrial Automation Control equipment, Allen-Bradley has a vested interest in your complete satisfaction with our products and services. Allen-Bradley offers support services worldwide, with 75 Sales/ Support offices, 512 authorized Distributors and 260 authorized Systems Integrators located throughout the United States, plus Allen-Bradley representatives in every major country in the world. Contact your local Allen-Bradley representative for: • sales and order support • product technical training • warranty support • support service agreements PLC, PLC-2, PLC-3 and PLC-5 are registered trademarks of Rockwell Automation. SLC, SLC 500, SLC 5/01, SLC 5/02, SLC 5/03, SLC 5/04, SLC 5/05, Data Highway Plus and PanelView are trademarks of Rockwell Automation. A.I. Series and RSLogix are trademarks of Rockwell Software, Inc. 1 Publication 1747-IN010C-MU-P Installation Instructions SLC 500™ Memory Modules for Fixed and Modular Controllers (Cat. No. 1747-M1, 1747-M2, 1747-M13) Inside ... English Section ........................................................................................... 2 Section en français ..................................................................................... 4 Deutscher Abschnitt ................................................................................... 6 Sezione italiana .......................................................................................... 8 Sección en español ................................................................................... 10 Publication 1747-IN010C-MU-P 2 English Section Installation Instructions English Section SLC 500™ Memory Modules for Fixed and Modular Controllers (Cat. No. 1747-M1, 1747-M2, 1747-M13) Memory Module Compatibility ATTENTION ! If you are using a 1747-M15 memory module adaptor to program a 1747-M13 memory module, you must use the Series B 1747-M15 memory module adaptor. If you use the Series A 1747-M15 memory module adaptor, you may damage the memory module, the PROM programming equipment, or both. Specification Fixed SLC SLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 1747-L511 1747-L514 1747-L524 1747-L531 1747-L532 1747-L541 1747-L542 1747-L543 1747-L551 1747-L552 1747-L553 M1 •••• M2 •••• M13 • • • Firmware Version Series C OS302 or higher Series C OS401 or higher Series C OS501 or higher Publication 1747-IN010C-MU-P SLC 500™ Memory Modules for Fixed and Modular Controllers 3 Memory Module Installation Always turn off power to the controller before removing the processor and inserting the memory module. This guards against possible damage to the module and undesired processor faults. Memory modules have connectors that are “keyed” to guard against improper installation. When product or packaging is marked, the product is CE compliant for all applicable directives. ATTENTION ! To avoid potential damage to the memory modules, handle them by the ends of the carrier or edges of the plastic housing. Skin oil and dirt can corrode metallic surfaces, inhibiting electrical contact. Also, do not expose memory modules to surfaces or areas that may typically hold an electrostatic charge. Electrostatic charges can alter or destroy memory. Modular Controller Side View of SLC Processor 1747-L511, -L514, and -L524 Series B Side View of SLC Processor 1747-L524 Series C Jumper J1 setting for M1 and M2 memory module. Invalid J1 jumper settings. Memory Module Socket Jumper J1, (Note: Jumper J1 is not on 1747-L511.) Memory Module Socket Jumper J1 Memory Module Socket Memory Module Connector Side View of SLC Processor 1747-L531, 1747-L532, 1747-L541, 1747-L542, 1747-L542P, 1747-L543, 1747-L543P, 1747-L551, 1747-L552, 1747-L553, and 1747-L553P 1.If the processor module is installed in the chassis, turn off power to the controller. 2.Remove the module by pressing the retainer clips at both the top and bottom of the module and sliding it out. 3.Locate the socket on the 1747-L511, -L514, and -L524 processor boards or the connector on the 1747-L531, -L532, -L541, -L542, -L542P, -L543, -L543P, -L551, -L552, -L553, and -L553P processor boards. Place the memory module onto the socket or connector and press firmly in place. 4.Place jumper J1 as shown above on the -L514 and -L524 processors. 5.Install the processor module into the chassis. 6.Restore power to the controller. Fixed Controller Front View of 20 I/O Fixed Controller 1.Turn off power to the controller. 2.Remove the processor compartment cover. 3.Locate the socket on the PC board. 4.Position the module correctly over the socket and press the module firmly into place. (The memory module is keyed for proper installation.) 5.Replace the processor compartment cover. 6.Restore power to the controller. Publication 1747-IN010C-MU-P - June 2002 12 PN 40072-106-01(2) Supersedes Publication 1747-IN010B-MU-P - July 2001 © 2002 Rockwell International Corporation. Printed in the U.S.A. Publication 1747-IN058D-EN-P - January 2007 Installation Instructions1747-SDN DeviceNet Scanner Module Catalog Number 1747-SDN, Series C Topic Page Important User Information 2 Safety Guidelines 3 About DeviceNet Scanner Module 4 Before You Begin 6 Install DeviceNet Scanner Module 8 Interpret the LED Indicators 11 Numeric Codes and Descriptions 12 Specifications 15 Additional Resources 17 2 Publication 1747-IN058D-EN-P - January 2007 Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://literature.rockwellautomation.com) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited. Throughout this manual, when necessary, we use notes to make you aware of safety considerations. WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may 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. ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you to identify a hazard, avoid a hazard, and recognize the consequences. SHOCK HAZARD Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present. BURN HAZARD Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures. 3 Publication 1747-IN058D-EN-P - January 2007 Safety GuidelinesFollow these guidelines for environment and enclosure information for this equipment. Follow these guidelines when you handle this equipment. ATTENTION This equipment is intended for use in a Pollution Degree 2 industrial environment, in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 m (6562 ft) without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as open type equipment. It must be mounted within an enclosure that is suitably designed for those specific environmental conditions that will be present and appropriately designed to prevent personal injury resulting from accessibility to live parts. The interior of the enclosure must be accessible only by the use of a tool. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings that are required to comply with certain product safety certifications. See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1, for additional installation requirements pertaining to this equipment. ATTENTION This equipment is sensitive to electrostatic discharge that can cause internal damage and affect normal operation. •Touch a grounded object to discharge potential static. •Wear an approved grounding wrist strap. •Do not touch connectors or pins on component boards. •Do not touch circuit components inside the equipment. •Use a static-safe workstation if available. •Store the equipment in appropriate static-safe packaging when not in use. 4 Publication 1747-IN058D-EN-P - January 2007 About DeviceNet Scanner ModuleThe 1747-SDN DeviceNet scanner module acts as an interface between DeviceNet devices and the SLC 500 processor. The module has the following software and hardware features. Software Features The module has these software features. Slave Mode Slave mode allows processor-to-processor communication and enables the scanner to perform as a slave device to another master on the network. When the scanner module is in slave mode, it exchanges data with only one master. You control what information is exchanged through scan list configuration and associated mapping functions of RSNetWorx for DeviceNet software. This feature has the following variations. Poll A poll message is a point-to-point transfer of data (0…255 bytes) sent by the scanner module that solicits a response from a single device. The device responds with its input data (0…255 bytes). Strobe A strobe message is a multicast transfer of data (64 bits in length) sent by the scanner module that solicits a response from each strobed slave device. There is one bit for each of the possible 64 node addresses. The devices respond with their data, which can be as much as 8 bytes. Module Mode Module Action Null Contains an empty or disabled scan list (default) Master Serves as a master to one or more slaves but is not simultaneously serving as a slave to another master Slave Serves as a slave to another master Dual Serves as both a master to one or more slaves and as a slave to another master simultaneously 5 Publication 1747-IN058D-EN-P - January 2007 Change of StateChange of state enables the scanner module to perform a scan: •whenever a network data change occurs. •at a user-configurable heartbeat rate. Because data is only sent on an as-needed basis, this feature increases system performance by reducing network traffic. Cyclic I/O Cyclic I/O allows you to instruct the scanner module to perform a scan at a specific send rate. Because data is only sent at a periodic rate, this feature increases system performance by reducing network traffic. Pass-through The SLC 500 pass-through feature allows communication with the DeviceNet network from another network. This feature can be used to adjust and fine tune the nodes on your network. The pass-through feature is not intended to replace a 1770-KFD, 1784-PCD, 1784-PCID, or 1784-PCIDS connection to the network. To use the pass-through feature you must meet the following hardware, software and firmware requirements. Pass-through Requirements SLC 500 Processor 1747-SDN Firmware RSLinx Software M0 and M1 Files SLC 5/03 or later 4.015…5.001 2.10 or later Configured for 361 words SLC 5/03 or later 6.001 or later 2.31 or later Configured for 395 words 6 Publication 1747-IN058D-EN-P - January 2007 Hardware FeaturesUse this illustration to identify the external features of the scanner module. Before You Begin Before you install your module you need the following items. •Personal computer with Microsoft Windows 2000 or later operating system •RSNetWorx for DeviceNet software, version 2.22 or later •RSLogix 500 software •SLC 1746 chassis with SLC 5/02, SLC 5/03, SLC 5/04, or SLC 5/05 processor DeviceNet STATUS MODULE NET ADDRESS/ERROR Module Status indicator indicates module status Node address and status displays numeric codes and indicates scanner node address or error Network Status indicator indicates status of DeviceNet channel communication link Access door Wiring color codes 10-pin linear plug inserted into DeviceNet port 7 Publication 1747-IN058D-EN-P - January 2007 For network communication, you have two options.•Use the pass-through feature to communicate with the DeviceNet network from another network. This method is intended for fine tuning and adjustment of network devices. •Use a 1770-KFD RS-232 DeviceNet adapter or 1784-PCD, 1784-PCID, or 1784-PCIDS DeviceNet PC card. This method is necessary for a complete network configuration and real time monitoring of your network devices. Before you install your module you must know how to: •program and operate an Allen-Bradley SLC 500 programmable controller. •install and configure the devices on your DeviceNet network. Electronic Data Sheet Requirement This release of the scanner module requires the latest EDS file for RSLinx Classic and RSNetWorx for DeviceNet software. If the software displays the device as an Unrecognized Device, the EDS file must be installed. You can download the latest EDS file online at: http://www.ab.com/networks/eds For FRN 8.002 and later, you can upload the embedded EDS file from the scanner module itself. 1.Open RSLinx Classic or RSNetWorx for DeviceNet software and right click on the Unrecognized Device. 2.Select Upload EDS file from device for RSLinx Classic software or Register Device for RSNetWorx for DeviceNet software. 3.Follow the instructions in the EDS wizard to complete the installation. Perform a ControlFLASH Update If you want to upgrade the scanner module to a newer firmware release, you must perform a ControlFLASH update. To get the kit, contact Rockwell Automation Technical Support at 440.646.5800. To install the kit, refer to the ControlFLASH Firmware Upgrade Kit User Manual, publication 1756-QS105. IMPORTANT You can flash update Series A and B scanner modules up to FRN 7.006. Only Series C scanner modules support FRN 8.002 and later. 8 Publication 1747-IN058D-EN-P - January 2007 Confirm Processor and Adapter CompatibilityMake sure that your processor and adapter are compatible. You can use the 1747-SDN scanner module in any slot in an I/O chassis except for the leftmost, which is reserved for the SLC 500 processor. Install DeviceNet Scanner Module Follow these steps to install the module. 1.Turn off the chassis power supply. 2.Select a slot for the module in the chassis. You may use any slot except the leftmost slot, which is reserved for the SLC 500 processor. IMPORTANT You cannot use the scanner module in a remote I/O chassis with a 1747-ASB adapter module. The adapter module does not support M-file transfer. WARNING If you insert or remove the scanner module with power applied to this module or any device on the network, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding. 9 Publication 1747-IN058D-EN-P - January 2007 3.Insert the module into the slot you have selected.4.Apply firm, even pressure to seat the module in the I/O chassis backplane connectors. Connect the Module to the DeviceNet Network Follow these steps to connect the module to the DeviceNet network. 1.Turn off the network power supply. 2.Connect the DeviceNet drop line to the 10-pin linear plug by matching the wire insulation colors to the colors shown on the label. 3.Locate the DeviceNet port connector on the front of the module. WARNING If you connect the scanner module with power applied to this module or any device on the network, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding. +24V Red Can_H White Drain/Shield Can_L Blue +24V Return Black Front of Module 10-pin linear plug Red White Shield Blue Black 10 Publication 1747-IN058D-EN-P - January 2007 4.Insert the 10-pin linear plug into the DeviceNet port connector. You have installed and wired your module. To operate the module you must apply power and then configure and program the SLC processor to communicate with it. Apply Chassis Power When you apply chassis power, the module numeric indicators cycle through the following displays. •Seven-segment lamp test (88) •Firmware major revision (01 through 7F hexadecimal) •Firmware minor revision (01 through FF hexadecimal) •Communication rate (indicates 00 for the default of 125, 01 for 250, or 02 for 500 Kbps) •Node address (00…63 with 63 as the default) Use the RSNetWorx for DeviceNet software to change the communication rate and node address. 10-pin Linear Plug DeviceNet Drop Line DeviceNet Port Connector DeviceNet STATUS MODULE NET ADDRESS/ERROR Module Numeric Indicators 11 Publication 1747-IN058D-EN-P - January 2007 Refer to the Numeric Code Display Summary table on page 14 for a complete listing of numeric displays. Interpret the LED Indicators The bicolor (green/red) module status indicator (MODULE) on the front of your module displays module status. It indicates whether the module has power and is functioning properly. The DeviceNet channel has a bicolor (green/red) network status indicator (NET). The following table provides troubleshooting information about the DeviceNet channel communication link. Module Status LED Indicator Indicator Color Description Corrective Action Off There is no power applied to the module. Verify power connections and apply power. Green The module is operating normally. No action required. Flashing Green The module is not configured. Configure the module. Flashing Red There is an invalid configuration. Check configuration setup. Red The module has an unrecoverable fault. Replace the module. DeviceNet Channel Communication Indicator Color Description Device Operation Corrective Action Off The channel is disabled for DeviceNet communication. The device has no power or the channel is disabled for communication due to bus off condition, loss of network power, or has been intentionally disabled. Power-up the module, provide network power to the channel, and be sure the channel is enabled in both the module configuration table and the module command word. Green All slave devices in the scan list table are communicating normally with the module. Normal operation. None. 12 Publication 1747-IN058D-EN-P - January 2007 Numeric Codes and Descriptions Your module uses numeric displays to indicate diagnostic information about the status of your module. The display flashes at 1 second intervals. The following table summarizes the meanings of the numeric codes. Flashing Green The channel is enabled but no communication is occurring. The two-digit numeric display for the channel indicates an error code that provides more information about the condition of the channel. Configure the scan list table for the channel to add devices. Flashing Red At least one of the slave devices in the module’s scan list table has failed to communicate with the module. The two-digit numeric display for the channel displays an error code that provides more information about the condition of the channel. Examine the failed device and the scan list table for accuracy. Red The module may be defective. The communications channel has failed. The two-digit numeric display for the channel displays an error code that provides more information about the condition of the channel. Reset module. If failures continue, replace module. Numeric Code Description Corrective Action 0…63 Normal operation. The numeric display indicates the 1747-SDN’s node address on the DeviceNet network. None. 70 Module failed Duplicate Node Address check. Change the module channel address to another available one. The node address you selected is already in use on that channel. 71 Illegal data in scan list table (node number alternately flashes). Reconfigure the scan list table and remove any illegal data. 72 Slave device stopped communicating (node number alternately flashes). Inspect the field devices and verify connections. DeviceNet Channel CommunicationIndicator Color Description Device Operation Corrective Action 13 Publication 1747-IN058D-EN-P - January 2007 73 Device’s identity information does not match electronic key in scan list table entry. Verify that the correct device is at this node number. Make sure that the device at the scrolling node address matches the desired electronic key (vendor, product code, product type). 74 Data overrun on port detected. Modify your configuration and check for invalid data. Check network communication traffic. 75 No traffic from other modules detected on the network. Check the network configuration. (Scanlist may be empty.) 76 No direct network traffic for module detected. None. The module hears other network communication. 77 Data size expected by the device does not match scan list entry. Reconfigure your module for the correct transmit and receive data sizes. 78 Slave device in scan list table does not exist. Add the device to the network, or delete the scan list entry for that device. 79 Module has failed to transmit a message. Make sure that your module is connected to a valid network. Check for disconnected cables. 80 Module is in Idle mode. Put controller in Run mode. Enable Run bit in module command register. 81 Module is in Fault mode. Check Module Command Register for fault bit set. 82 Error detected in sequence of fragmented I/O messages from device. Check scan list table entry for slave device to make sure that input and output data lengths are correct. Check slave device configuration. 83 Slave device is returning error responses when module attempts to communicate with it. Check accuracy of scan list table entry. Check slave device configuration. Slave device may be in another master’s scan list. Reboot slave device. 84 Module is initializing the DeviceNet network. None. This code clears itself once module attempts to initialize all slave devices on the network. 85 Data size was incorrect for this device at runtime. Slave device is transmitting incorrect length data. Verify device is not configured for variable poll connection size. Try replacing the device. 86 Device is producing zero length data (idle state) while module is in Run mode. Check device configuration and slave node status. Numeric Code Description Corrective Action 14 Publication 1747-IN058D-EN-P - January 2007 87 The primary owner has not allocated the slave. Put the primary owner online. 88 The connection choices (polled, strobed) between the primary connection and the shared input only connection do not match. Reconfigure the shared input-only connection's choices to be the same as, or a subset of, the primary connection's choices. 89 Slave device initialization using Auto Device Replacement parameters failed. Put the slave device into configurable mode. Check the slave's EDS file, if the slave is configured offline. Check to see if the slave device has been replaced with an incompatible device. 90 User has disabled communication port. Check Module Command Register for DISABLE bit set. 91 Bus-off condition detected on comm port. Module is detecting communication errors. Check DeviceNet connections and physical media integrity. Check system for failed slave devices or other possible sources of network interference. 92 No network power detected on communication port. Provide network power. Make sure that module drop cable is providing network power to module comm port. 95 Application FLASH update in progress. None. Do not disconnect the module while application FLASH is in progress. You will lose any existing data in the module’s memory. 97 Module operation halted by user command. Check Module Command Register for HALT bit set. 98 Unrecoverable firmware failure. Service or replace your module. 99 Unrecoverable hardware failure. Service or replace your module. E2 RAM Test Failure Service or replace your module. E4 Lost power during FLASH upgrade Service or replace your module. E5 No boot or main code Service or replace your module. E9 Module memory has been flushed for factory default settings. Cycle module power to recover. Numeric Code Description Corrective Action 15 Publication 1747-IN058D-EN-P - January 2007 SpecificationsSLC DeviceNet Scanner - 1747-SDN Attribute Value Module Location SLC 5/02 or later chassis Module Defaults Node Address – 63 Baud Rate – 125 Kbits/s Power Consumption - Backplane Current - DeviceNet(1) 5V dc, 500 mA 24V dc, 90mA Class 2 Isolation Voltage Optical Isolation between backplane and DeviceNet channel, tested to withstand 500V ac for 60 s 1 MΩ resistor from DeviceNet channel to chassis Temperature, Operating IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock): 0…60 oC (32…140 oF) Temperature, Storage IEC 60068-2-1 (Test Ab, Unpackaged Nonoperating Cold), IEC 60068-2-2 (Test Bc, Unpackaged Nonoperating Dry Heat), IEC 60068-2-14 (Test Na, Unpackaged Nonoperating Thermal Shock): –40…85 oC (–40…185 oF) Relative Humidity IEC 60068-2-30 (Test Db, Unpackaged Nonoperating Damp Heat): 5…95% noncondensing Vibration IEC60068-2-6 (Test Fc, Operating): 2 g @10…500 Hz Shock IEC60068-2-27:1987, Test Ea (Unpackaged shock, ES#002) Operating - 30 g Nonoperating - 50 g Emissions CISPR 11: Group 1, Class A (with appropriate enclosure) ESD Immunity IEC 61000-4-2: 4 kV contact discharges Radiated RF Immunity IEC 61000-4-3: 10 V/m with 1 kHz sine-wave 80% AM from 30 MHz…1000 Mhz EFT/B Immunity IEC 61000-4-4: +2 kV at 5 kHz on communication ports Surge Transient Immunity IEC 61000-4-5: +2 kV line-earth(CM) on signal ports Conducted RF Immunity IEC 61000-4-6: 10 Vrms with 1 kHz sine-wave 80% AM from 150 kHz…30 MHz 16 Publication 1747-IN058D-EN-P - January 2007 Enclosure Type Rating None (open style) Wiring - Type - Category(2) 1771-CD 2 10-pin Linear Plug - Torque - Catalog Number 5…7 lb-in 1787-PLUG10R (1)To remain compliant with UL/CSA certification, the DeviceNet power supply must meet NEC Class 2 requirements. (2)Use this conductor category information for planning conductor routing as described in Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1. Certifications - 1747-SDN Certification Value UL UL Listed Industrial Control Equipment CSA CSA Certified Process Control Equipment CSA CSA Certified Process Control Equipment for Class I, Division 2, Group A,B,C,D Hazardous Locations CE(1)European Union 89/336/EEC EMC Directive, compliant with: EN 50081-2; Industrial Emissions EN 50082-2; Industrial Immunity European Union 73/23/EEC LVD Directive, compliant with: EN 61131-2; Programmable Controllers C-Tick(2)Australian Radiocommunications Act, compliant with: AS/NZS 2064; Industrial Emissions ODVA ODVA conformance tested to ODVA DeviceNet specifications (1)To remain compliant with UL/CSA certification, the DeviceNet power supply must meet NEC Class 2 requirements. (2)See the Product Certification link at http://www.ab.com for Declaration of Conformity, Certificates, and other certification details. SLC DeviceNet Scanner - 1747-SDNAttribute Value 17 Publication 1747-IN058D-EN-P - January 2007 Additional Resources You can view or download publications at http://literature.rockwellautomation.com. To order paper copies of technical documentation, contact your local Rockwell Automation distributor or sales representative. Resource Description SLC 500 DeviceNet Scanner Module User Manual, publication 1747-UM655 Provides application examples for the DeviceNet scanner module. ControlFlash Firmware Upgrade Kit User Manual, publication 1756-QS105 Provides instructions on using ControlFlash to upgrade the firmware. Getting Results with RSLogix 500, publication LG500-GR002 Provides information on RSLogix 500 software. Getting Results with RSLinx, publication LINX-GR001 Provides information on RSLinx software. DeviceNet Media Design and Installation Guide, DNET-UM072 Provides information on using DeviceNet communication network. Getting Results with RSNetWorx for DeviceNet, publication DNET-GR001 Provides information on using RSNetWorx for DeviceNet software. 18 Publication 1747-IN058D-EN-P - January 2007 19 Publication 1747-IN058D-EN-P - January 2007 Publication 1747-IN058D-EN-P - January 2007 PN 953030-67 Supersedes Publication 1747-IN058C-EN-P - May 2002 Copyright © 2007 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A. Rockwell Automation SupportRockwell Automation provides technical information on the Web to assist you in using its products. At http://support.rockwellautomation.com, you can find technical manuals, a knowledge base of FAQs, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer TechConnect Support programs. For more information, contact your local distributor or Rockwell Automation representative, or visit http://support.rockwellautomation.com. Installation Assistance If you experience a problem with a hardware module within the first 24 hours of installation, please review the information that's contained in this manual. You can also contact a special Customer Support number for initial help in getting your module up and running. New Product Satisfaction Return Rockwell tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning, it may need to be returned. Rockwell Auotmation, Allen-Bradley, TechConnect, SLC, SLC 500, SLC 5/02, SLC 5/03, SLC 5/04, SLC 5/05, RSLinx, RSLogix 500, and RSNetWorx are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. United States 1.440.646.3223 Monday – Friday, 8am – 5pm EST Outside United States Please contact your local Rockwell Automation representative for any technical support issues. United States Contact your distributor. You must provide a Customer Support case number (see phone number above to obtain one) to your distributor in order to complete the return process. Outside United States Please contact your local Rockwell Automation representative for return procedure. Class 1, Division 2, Groups A, B, C, and D Hazardous Locations. Modbus TCP/IP Client Server Communication Module MVI46-MNET With the growing trend of Ethernet technology in the industrial marketplace, this product has a wide variety of application uses. • Food processing • Petrochemical • Pulp and paper • Automobile manufacturing • Water and Wastewater • Oil and Gas • Power and Electric How to Contact Us: Sales and Support All ProSoft Technology products are backed with unlimited technical support. Contact our worldwide Technical Support team directly by phone or email: Asia Pacific +603.7724.2080, asiapc@prosoft-technology.com Languages spoken include: Chinese, Japanese, English Europe – Middle East – Africa +33 (0) 5.34.36.87.20, support.EMEA@prosoft- technology.com Languages spoken include: French, English North America +1.661.716.5100, support@prosoft-technology.com Languages spoken include: English, Spanish Latin America (Sales only) +1.281.298.9109, latinam@prosoft-technology.com Languages spoken include: Spanish, English Brasil +55-11.5084.5178, eduardo@prosoft-technology.com Languages spoken include: Portuguese, English Modbus TCP/IP Client/Server Communication Module MVI46-MNET The MVI46 Modbus TCP/IP Communication Module is designed to allow SLC processors to interface easily with other Modbus TCP/IP protocol-compatible devices using client and server functionality. Compatible devices include not only Modicon processors (which support the Modbus TCP/IP protocol) but also a wide assortment of other clients and server devices. Features and Benefits The MVI46-MNET module is a single slot solution that provides a powerful connection between Rockwell Automation's SLC processor and Modbus TCP/IP network applications. The TCP/IP Modbus network applications include those networks hosted by Modicon Quantum processors, networks controlled by operator interface software packages, and the growing number of manufactured devices that support this protocol. The module acts as an input/output module between the Modbus TCP/IP network and the Rockwell Automation backplane. The data transfer from the processor is asynchronous from the actions on the Modbus TCP/IP network. A 5000- word register space in the module exchanges data between the processor and the Modbus TCP/IP network. • Support for the storage and transfer of up to 5000 registers to/from the SLC processor using M0/M1 data file transfer • User-definable module memory usage • 10/100 MB Ethernet compatible interface • Configurable parameters for the client and server applications and floating point support General Specifications • Single Slot – 1746 backplane compatible (Local or extended I/O rack only. Remote rack not supported) • The module is recognized as an Input/Output module and has access to processor memory for data transfer between processor and module using M0/M1 files • Ladder Logic is used for data transfer between module and processor. Sample ladder file included • Configuration data obtained from configuration text file downloaded to module. Sample configuration file included Hardware Specifications Specification Description Backplane Current Load 800 ma @ 5V (from backplane) Operating Temperature 0 to 60°C (32 to 140°F) Storage Temperature –40 to 85°C (–40 to 185°F) Relative Humidity 5 to 95% (non-condensing) Shock 30g operational, 50g non- operational Vibration 5 g from 10150 Hz LED indicators Module status, Backplane transfer status, Application status, Serial activity (debug port), Ethernet link and activity, and error LED status Debug/Configuration port (CFG) CFG Port (CFG) RJ45 (DB-9M with supplied cable) RS-232 only No hardware handshaking Configuration Connector RJ45 RS-232 Connector (RJ45 to DB-9 cable shipped with unit) Application Ports Ethernet Port (Ethernet Modules) RJ45 Connector Link and activity LED indicators Functional Specifications General Protocol specifications Type Specifications Floating Point Data Floating point data movement supported, including configurable support for Enron implementation Modbus Server Protocol Specifications The server driver supports connections to Modbus TCP/IP clients supporting Service Port 502 using the standard MBAP protocol, and clients supporting Modbus on Service Port 2000. Modbus Server Protocol Specifications The server driver supports connections to Modbus TCP/IP clients supporting Service Port 502 using the standard MBAP protocol, and clients supporting Modbus on Service Port 2000. General • Supports five independent server connections for Service Port 502 • Supports five independent server connections for Service Port 2000 • All data mapping begins at Modbus register 40001. Status Data Error codes, counters, and port status available Modbus Function Codes Code Description 1: Read Output Status 2: Read Input Status 3: Read Multiple Data Registers 4: Read Input Registers 5: Write Single Bit 6: Write Single Data Register 15: Write Multiple Bits 16: Write Multiple Data Register Modbus TCP/IP Client The client driver supports the active reading and writing of data with Modbus TCP/IP compatible devices. One client connection available (connect up to 100 servers/devices using the available 100 master commands) Additional Products ProSoft Technology offers a full complement of hardware and software solutions for a wide variety of industrial communication platforms. Compatible products in the inRAx product line also include: Modbus Master/Slave Communication Module for SLC (MVI46-MCM) Modbus Plus Communication Module for SLC (MVI46-MBP) Modbus TCP/IP Client Communication Module for SLC (MVI46-MNETC) Visit our web site at http://www.prosoft-technology.com for a complete list of products. Ordering Information To order this product, please use the following: MVI46-MNET Modbus TCP/IP Client Server Communication Module To place an order, please contact your local ProSoft Technology distributor. For a list of ProSoft distributors near you, go to http://www.prosoft-technology.com Distributors: Place your order by email or fax to: North American / Latin American / Asia Pacific orders@prosoft-technology.com, fax to +1 661.716.5101 Europe europe@prosoft-technology.com, fax to +33 (0) 5.61.78.40.52 Copyright © ProSoft Technology, Inc. 2000 - 2007. All Rights Reserved. February 12, 2007 Publication 1746-IN005B-EN-P - September 2002 Installation Instructions Digital I/O Modules (Catalog Number 1746 Series) Input Module Catalog Numbers: 1746-IA4, -IA8, -IA16, -IB8, -IB16, -IC16, -IG16, -IH16, -IM4, -IM8, -IM16, -IN16, -ITB16, -ITV16, -IV8, -IV16 Output Module Catalog Numbers: 1746-OA8, -OA16, -OAP12, -OB8, -OB6EI, -OB16, -OB16E, -OBP8, -OBP16, -OG16, -OV8, -OV16, -OVP16, -OW4, -OW8, -OW16, -OX8 Combination Input/Output Module Catalog Numbers: 1746-IO4, -IO8, -IO12, -IO12DC 2 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Important User InformationBecause 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, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication. Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation, and Maintenance of Solid-State Control (available from your local Allen-Bradley 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 in part, without written permission of Allen-Bradley Company, Inc., is prohibited. Throughout these installation instructions we use notes to make you aware of safety considerations: Attention statements help you to: ·identify a hazard ·avoid the hazard ·recognize the consequences 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. Digital I/O Modules 3 Publication 1746-IN005B-EN-P - September 2002 Table of ContentsOverview............................................................................................................................................4 Hazardous Location Considerations ..................................................................................................4 Environnements Dangereux...............................................................................................................4 Installation.........................................................................................................................................5 Specifications ....................................................................................................................................6 General I/O................................................................................................................................6 Heat Dissipation.......................................................................................................................6 Input Modules - ac....................................................................................................................8 Input Modules - dc....................................................................................................................9 Output Modules - ac...............................................................................................................12 Output Modules - dc...............................................................................................................13 Relay Contact Output Modules...............................................................................................18 Relay Contact Ratings.............................................................................................................19 Input/Output Combination Modules.......................................................................................20 Octal Label Kit Installation (for PLC Processors Only).....................................................................21 Applying the Octal Filter Label ...............................................................................................21 Applying the Octal Door Label................................................................................................21 Removable Terminal Blocks....................................................................................................21 Fuse Protection and Blown Fuse Diagnostics..................................................................................22 Fuse Protection (1746-OBP16 and 1746-OVP16) ....................................................................23 Fuse Protection (1746-OAP12)................................................................................................23 Blown Fuse Diagnostics..........................................................................................................23 Processor Operation in Case of Blown Fuse - Processor Continues......................................26 Processor Operation in Case of Blown Fuse - Processor Faults.............................................26 Recovery From Blown Fuse/Processor Fault/Processor Shutdown........................................28 Replacement Fuse Recommendations....................................................................................28 Fuse Replacement Procedure .................................................................................................29 Electronically Protected Modules (1746-OB6EI and -OB16E)..........................................................30 Electronic Protection...............................................................................................................30 Auto Reset Operation.............................................................................................................31 Short Circuit/Overload Current Diagnostics...........................................................................31 Recovery From Channel Shutdown.........................................................................................31 Wiring Diagrams..............................................................................................................................32 Labeling for SLC/PLC® Systems............................................................................................32 Input Modules - ac..................................................................................................................33 Input Modules - dc..................................................................................................................35 Output Modules - ac...............................................................................................................37 Output Modules - dc...............................................................................................................38 Relay Contact Output Modules...............................................................................................41 Input/Output Combination Modules.......................................................................................42 4 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 OverviewIn addition to providing the module’s electrical specifications, this document tells you how to: ·install the module into a chassis ·wire the module’s terminal block ·install the Octal Filter Label Hazardous Location Considerations This equipment is suitable for use in Class I, Division 2, Groups A, B, C, D or non-hazardous locations only. The following WARNING statement applies to use in hazardous locations. Environnements Dangereux Cet équipement est conçu pour être utilisé dans des environnements de Classe I, Division 2, Groupes A, B, C, D ou non dangereux. La mise en garde suivante s’applique à une utilisation dans des environnements dangereux. WARNING ! EXPLOSION HAZARD ·Substitution of components may impair suitability for Class I, Division 2. ·Do not replace components or disconnect equipment unless power has been switched off or the area is known to be non-hazardous. ·Do not connect or disconnect components unless power has been switched off or the area is known to be non-hazardous. ·All wiring must comply with N.E.C. article 501-4(b). AVERTISSEMENT ! DANGER D’EXPLOSION ·La substitution de composants peut rendre cet équipement impropre à une utilisation en environnement de Classe I, Division 2. ·Ne pas remplacer de composants ou déconnecter l'équipement sans s'être assuré que l'alimentation est coupée. ·Ne pas connecter ou déconnecter des composants sans s'être assuré que l'alimentation est coupée. Digital I/O Modules 5 Publication 1746-IN005B-EN-P - September 2002 Installation ATTENTION ! Never install, remove, or wire modules with power applied to chassis. IMPORTANT The first slot of the chassis is reserved for the processor or the 1747-ASB module. Slot 1 A B D C max. #14 AWG (2 mm2) max. 2 wires per terminal max. torque: 0.9 Nm (8 in-lbs) 1.Disconnect power. 2.Align circuit board of module with chassis card guide. (A) 3.Slide the module into the chassis until the bottom tabs lock into place. (B) 4.Route the wires down and away from the module, securing them with the wire tie. (C) 5.To keep the chassis free from debris, cover all unused slots with Card Slot Filler, catalog number 1746-N2. To remove the module, press and hold the module release located on each self-locking tab, and slide the module out of the chassis slot. (D) Figure 1 Module Installation 6 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Specifications General I/O Heat Dissipation The following tables contain values for the heat dissipated by each I/O module. Use them to calculate the total amount of heat dissipated by your SLC 500™ control system. For details on how to calculate total heat dissipation, refer to the SLC 500 Modular Hardware Style User Manual, publication 1747-UM011. Please note the following definitions: ·Watts per Point - the heat dissipation that can occur in each field wiring point when energized at nominal voltage. ·Minimum Watts - the amount of heat dissipation that can occur when there is no field power present. ·Total Watts - the watts per point multiplied by the number of points, plus the minimum watts (with all points energized). Table 1 Specifications for All Digital Modules Operating Temperature 0°C to 60°C (32°F to 140°F)(3) (3) Exceptions are indicated with certain modules. Storage Temperature -40°C to 85°C (-40°F to 185°F) Operating Humidity 5% to 95% (noncondensing) Noise Immunity NEMA standard ICS 2-230 Vibration (Operating)Displacement 0.015 in peak at 5 to 57 Hz Acceleration 2.5Gs at 57 to 2000 Hz Shock (Operating)30Gs (all modules except relay contact) 10Gs (relay contact modules: -OW, -OX, and combination I/O modules) Isolation(1) (1) Electro-optical isolation between I/O terminals and control logic. 1500V Agency Certification ·UL listed ·CSA certified or C-UL approved as indicated by product marking ·CE compliant for all applicable directives when product or packaging is marked ·C-Tick marked for all applicable acts Hazardous Environment Class(2) (2) Some modules are classified Class 1, Division 2 by CSA only or C-UL only as shown in the specification table for the respective module. Class I, Division 2 Hazardous Environment UL-A196, CSA, C-UL Digital I/O Modules 7 Publication 1746-IN005B-EN-P - September 2002 Table 2 Input Module Heat DissipationCatalog Numbers Watts per Point Minimum Watts Total Watts 1747-IA4 0.27 0.175 1.30 1746-IA8 0.27 0.250 2.40 1746-IA16 0.27 0.425 4.80 1746-IB8 0.20 0.250 1.90 1746-IB16 0.20 0.425 3.60 1746-IC16 0.22 0.425 3.95 1746-IG16 0.02 0.700 1.00 1746-IH16 0.32 0.217 5.17 1746-IM4 0.35 0.175 1.60 1746-IM8 0.35 0.250 3.10 1746-IM16 0.35 0.425 6.00 1746-IN16 0.35 0.425 6.00 1746-ITB16 0.20 0.425 3.60 1746-ITV16 0.20 0.425 3.60 1746-IV8 0.20 0.250 1.90 1746-IV16 0.20 0.425 3.60 Table 3 Output Module Heat Dissipation Catalog Numbers Watts per Point Minimum Watts Total Watts 1746-OA8 1.000 0.925 9.00 1746-OA16 0.462 1.850 9.30 1746-OAP12 1.000 1.850 10.85 1746-OB6EI 0.440 0.230 2.90 1746-OB8 0.775 0.675 6.90 1746-OB16 0.388 1.400 7.60 1746-OB16E 0.150 0.675 3.07 1746-OBP8 0.300 0.675 3.08 1746-OBP16 0.310 1.250 6.26 1746-OG16 0.033 0.900 1.50 1746-OV8 0.775 0.675 6.90 1746-OV16 0.388 1.400 7.60 1746-OVP16 0.310 1.250 6.26 1746-OW4 0.133 1.310 1.90 1746-OW8 0.138 2.590 3.70 1746-OW16 0.033 5.170 5.70 1746-OX8 0.825 2.590 8.60 8 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Input Modules - ac Table 4 Combination Input/Output Module Heat DissipationCatalog Numbers Watts per Point Minimum Watts Total Watts 1746-IO4 0.27 per input point 0.133 per output point 0.75 1.60 1746-IO8 0.27 per input point 0.133 per output point 1.38 3.00 1746-IO12 0.27 per input point 0.133 per output point 2.13 4.60 1746-IO12DC 0.20 per input point 0.133 per output point 1.84 3.90 Table 5 Specifications for Input Modules 1746-IA4, -IA8, and -IA16 Specification Catalog Number 1746- IA4 IA8 IA16(1) (1) Removable Terminal Block. Voltage Category 100/120V ac Signal Input Number of Inputs 4816 Points per Common 4816 Operating Voltage 85 to 132V ac at 47 to 63 Hz Backplane Current Consumption 5V dc 0.035A 0.050A 0.085A 24V dc 0.0A Signal Delay (max.)on = 35 ms off = 45 ms Off State Voltage (max.)30V ac Off State Current (max.)2 mA Nominal Input Current at 120V ac 12 mA Inrush Current (max.)(2) (2) An ac input device must be compatible with SLC 500 input circuit inrush current. A current limiting resistor can be used to limit inrush current; however, the operating characteristics of the ac input circuit will be affected. 0.8A Inrush Current Time Duration (max.)0.5 ms Digital I/O Modules 9 Publication 1746-IN005B-EN-P - September 2002 Input Modules - dc Table 6 Specifications for Input Modules 1746-IM4, -IM8, and -IM16Specification Catalog Number 1746- IM4 IM8 IM16(1) (1) Removable Terminal Block. Voltage Category 200/240V ac Signal Input Number of Inputs 4816 Points per Common 4816 Operating Voltage 170 to 265V ac at 47 to 63 Hz Backplane Current Consumption 5V dc 0.035A 0.050A 0.085A 24V dc 0.0A Signal Delay (max.)on = 35 ms off = 45 ms Off State Voltage (max.)50V ac Off State Current (max.)2 mA Nominal Input Current at 240V ac 12 mA Inrush Current (max.)(2) (2) An ac input device must be compatible with SLC 500 input circuit inrush current. A current limiting resistor can be used to limit inrush current; however, the operating characteristics of the ac input circuit will be affected. 1.6A Inrush Current Time Duration (max.)0.5 ms Table 7 Specifications for Input Modules 1746-IB8, -IB16, -ITB16, and -IC16 Specification Catalog Number 1746- IB8 IB16(1) (1) Removable Terminal Block. ITB16(1)IC16(1)(2) (2) Use ID Code 0509 when configuring your system with programming software or the HHT. Voltage Category 24V dc Signal Input (sinking) 48V dc Signal Input (sinking) Number of Inputs 8161616 Points per Common 8161616 Operating Voltage 10 to 30V dc (sinking) 30 to 60V dc at 55°C (sinking) 30 to 55V dc at 60°C (sinking) Backplane Current Consumption 5V dc 0.050A 24V dc 0.0A Signal Delay (max.)on = 8 ms off = 8 ms on = 8 ms off = 8 ms on = 0.3 ms off = 0.5 ms(3) (3) Typical signal delay for these modules: ON = 0.1 ms, OFF = 0.25 ms at 24V dc. on = 4 ms off = 4 ms Off State Voltage (max.)5.0V dc 10.0V dc Off State Current (max.)1 mA 1 mA 1.5 mA 1.5 mA Nominal Input Current 8 mA at 24V dc 4.1 mA at 48V dc 10 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Table 8 Specifications for Input Modules 1746-IV8, -IV16, and -ITV16Specification Catalog Number 1746- IV8 IV16(1) (1) Removable Terminal Block. ITV16(1) Voltage Category 24V dc Signal Input (sourcing) Number of Inputs 81616 Points per Common 81616 Operating Voltage 10 to 30V dc (sourcing) Backplane Current Consumption 5V dc 0.050A 0.085A 0.085A 24V dc 0.0A Signal Delay (max.)on = 8 ms off = 8 ms on = 8 ms off = 8 ms on = 0.3 ms off = 0.5 ms(2) (2) Typical signal delay for these modules: ON = 0.1 ms, OFF = 0.25 ms at 24V dc. Off State Voltage (max.)5.0V dc Off State Current (max.)1 mA 1 mA 1.5 mA Nominal Input Current at 24V dc 8 mA Table 9 Specifications for Input Module 1746-IG16 Specification 1746-IG16(1) (1) Removable Terminal Block. Voltage Category 5V dc TTL Signal Input (sourcing) Number of Inputs 16 Points per Common 16 Operating Voltage +5 V to DC COM 4.5 to 5.5V dc (sourcing) 50 mV peak to peak ripple (max.) Backplane Current Consumption 5V dc 0.140A 24V dc 0.0A Signal Delay (max.)on = 0.25 ms off = 0.50 ms Off State Voltage (max.)2 to 5.5 V dc (2) (2) TTL inputs are inverted (-0.2 to +0.8V dc = low voltage = True = ON). Use a NOT instruction in your ladder program to convert to traditional True = High logic. Off State Current (max.)4.1 mA Nominal Input Current at 5V dc 3.7 mA ATTENTION ! To avoid potential damage to TTL modules, handle them by the ends of the module, not metallic surfaces. Electrostatic discharges can damage the module. Care should be taken to prevent exposure of terminals or components to electrostatic charges. Digital I/O Modules 11 Publication 1746-IN005B-EN-P - September 2002 Careful wire routing within the enclosure helps cut down electrical noise between I/O lines. Refer to the SLC 500 Modular Hardware Style User Manual, publication 1747-UM011, for recommended wiring procedures for TTL modules. Cable Length - Limit cable length to 15 meters (50 feet) per point for inputs in standard environments. Refer to Allen-Bradley Programmable Controller Wiring and Grounding Guidelines, publication 1770-4.1, for complete information. Table 10 Specifications for Input Module 1746-IN16 Specification 1746-IN16(1) (1) Removable Terminal Block. Voltage Category 24V ac/dc Signal Input Number of Inputs 16 Points per Common 16 Operating Voltage dc 10 to 30V dc (sinking) ac 10 to 30V ac Backplane Current Consumption 5V dc 0.085A 24V dc 0.0A Signal Delay (max.) dc on = 15 ms off = 15 ms ac on = 25 ms off = 25 ms Off State Voltage (max.) dc 3.0V dc ac 3.0V ac Off State Current (max.) dc 1 mA ac 1 mA Nominal Input Current dc 8 mA at 24V dc ac 8 mA at 24V ac Inrush Current (max.)0.02A (ac only) Table 11 Specifications for Input Module 1746-IH16 Specification 1746-IH16(1)(2)(3) Voltage Category 125V dc Signal Input (sinking Number of Inputs 16 Points per common 16 Operating Voltage Range: ·90 to 146V dc Max. Points ON Simultaneously: ·16 at 146V dc and 30°C ·12 at 146V dc and 50°C ·14 at 132V dc and 55°C ·16 at 125V dc and 60°C Backplane Current Consumption 5V dc 0.085A 24V dc 0.0A 12 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Output Modules - ac Signal Delay (max.)on = 9 ms off = 9 ms Off State Voltage (max.)20.0V dc Off State Current (max.)0.8mA Nominal Input Current 2.15 mA at 125V dc 2.25 mA at 132V dc (1) Removable Terminal Block. (2) Use ID Code 0507 when configuring your system with programming software or the HHT. (3) If the input module is connected in parallel with an inductive load, use surge suppression across the load to protect the input module from damage caused by reverse voltage. Refer to the SLC 500 Modular Hardware Style User Manual, publication 1747UM011, for more information on surge suppression. Table 12 Specifications for Output Modules 1746-OA8, -OA16, and -OAP12 Specification Catalog Number 1746- OA8 OA16(1) (1) Removable Terminal Block. OAP12(1)(2)(3)(4) (2) A fused common and blown fuse LED are provided on this module. See “Fuse Protection and Blown Fuse Diagnostics” on page 22. (3) Use ID Code 2803 when configuring your system with programming software or the HHT. Voltage Category 120/240V ac Signal Input Number of Outputs 81612 Points per Common 486 Operating Voltage 85 to 265V ac at 47 to 63 Hz Backplane Current Consumption 5V dc 0.185A 0.370A 0.370A 24V dc 0.0A Max. Signal Delay, Resistive Load(5)on = 1 ms, off = 11.0 ms Off State Leakage (max.)(6)2 mA Load Current (min.)10 mA Continuous Current per Point(7)1.0A at 30°C 0.50A at 60°C 0.50A at 30°C 0.25A at 60°C 2.0A at 30°C 1.25A at 55°C 1.0A at 60°C Continuous Current per Module (max.) 8.0A at 30°C 4.0A at 60°C 8.0A at 30°C 4.0A at 60°C 9.0A at 30°C 6.0A at 60°C On State Voltage Drop (max.)1.50V at 1.0A 1.50V at 0.50A 1.2V at 2.0A Surge Current per Point(8) (max.)10.0A for 25 ms 10.0A for 25 ms 17.0A for 25 ms(9) Table 11 Specifications for Input Module 1746-IH16Specification1746-IH16(1)(2)(3) Digital I/O Modules 13 Publication 1746-IN005B-EN-P - September 2002 Output Modules - dc (4) Certified for Class 1, Division 2 hazardous location by CSA. (5) Triac outputs turn on at any point in the ac line cycle, and turn off at ac line zero cross. (6) To limit the effects of leakage current through solid state outputs, a loading resistor can be connected in parallel with your load. For 120V ac operation, use a 15K W, 2W resistor. For 240V ac operation, use a 15K W, 5W resistor. (7) Recommended surge suppression: For triac outputs when switching 120V ac inductive loads, use Harris Metal-Oxide Varistor, model number V220MA2A. Refer to the SLC 500 Modular Hardware Style User Manual, publication 1747-UM011, for more information on surge suppression. (8) Repeatability is once every 1s at 30°C. Repeatability is once every 2s at 60°C. (9) Surge current = 35A per common for 10 ms. Table 13 Specifications for Output Modules 1746-OB8, -OB16, and -OB16E Specification Catalog Number 1746- OB8 OB16(1) (1) Removable Terminal Block. OB16E(1)(2) (2) Use the following ID Code when configuring your system with programming software or the HHT: 1746-OB16E = 2920. Number of Outputs 81616 Points per Common 81616 Voltage Category 24V dc Signal Output Operating Voltage (V dc)10 to 50 (source) 10 to 30 (source) Backplane Current Consumption 5V dc 0.135A 0.280A 0.135A 24V dc 0.0A Signal Delay (max.). Resistive Load.on = 0.1 ms off = 1.0 ms on = 0.1 ms off = 1.0 ms on = 1.0 ms(3) off = 1.0 ms (3) Fast turn-off modules (1746-OB6EI, -OBP8 Series B and later, -OB16E Series B and later, -OBP16, and -OVP16) provide fast OFF delay for inductive loads. Comparative OFF delay times for 1746-OB8/-OV8 and fast turn-off modules, when switching Bulletin 100-B110 (24W sealed) contactor, are: 1746-OB8/-OV8 OFF delay = 152 ms; fast turn-off modules OFF delay = 47 ms. Off State Leakage (max.)(4) (4) To limit the effects of leakage current through solid state outputs, a loading resistor can be connected in parallel with your load. For transistor outputs, 24V dc operation, use a 5K W, 1/2W resistor. 1 mA Load Current (min.)1 mA Continuous Current per Point(5)1.0A at 30°C 0.50A at 60°C 0.50A at 30°C 0.25A at 60°C 1.0A at 30°C(6) 0.50A at 60°C Continuous Current per Module 8.0A at 30°C 4.0A at 60°C 8.0A at 30°C 4.0A at 60°C 8.0A at 0 to 60°C On State Voltage Drop (max.)1.2V at 1.0A 1.2V at 0.50A 1.0V at 0.50A Surge Current per Point(7)3.0A for 10 ms 3.0A for 10 ms 2.0A for 10 ms(8) 14 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 (5) Recommended surge suppression: For transistor outputs when switching 24V dc inductive loads, use a 1N4004 diode reverse-wired across the load. Refer to the SLC 500 Modular Hardware Style User Manual, publication 1747-UM011, for more information on surge suppression. (6) Fast off delay for inductive loads is accomplished with surge suppressors on the 1746-OB6EI, -OBP8 Series B and later, -OB16E Series B and later, -OBP16, and -OVP16 modules. A suppressor at the load is not needed unless another contact is connected in series. If this is the case, a 1N4004 diode should be reverse wired across the load. This defeats the fast turn-off feature. (7) Repeatability is once every 1s at 30°C. Repeatability is once every 2s at 60°C. (8) Surge current = 32A per module for 10 ms. ATTENTION ! A transient pulse occurs in transistor outputs when the external dc supply voltage is applied to the output common terminals (e.g., via the master control relay). This can occur regardless of the processor having power or not. For most applications, the energy of this pulse is not sufficient to energize the load. Refer to the SLC 500 Modular Hardware Style User Manual, publication 1747-UM011, for more information on transient pulses and guidelines to reduce inadvertent processor operation. Table 14 Specifications for Output Modules 1746-OB6EI, -OBP8, and -OBP16 Specification Catalog Number 1746- OB6EI(1)(2)OBP8(1)(2)(3)OBP16(1)(2)(4)(5) Number of Outputs 6816 Points per Common Individually Isolated 4 16 Voltage Category 24V dc Signal Output Operating Voltage (V dc)10 to 30 (source) 20.4 to 26.4 (source) Backplane Current Consumption 5V dc 0.046A 0.135A 0.250A 24V dc 0.0A Signal Delay (max.). Resistive Load.on = 1.0 ms(6) off = 2.0 ms on = 1.0 ms(6) off = 2.0 ms on = 0.1 ms(6) off = 1.0 ms Off State Leakage (max.)(7)1 mA Load Current (min.)1 mA Continuous Current per Point(8)(9)2.0A at 0 to 60°C 2.0A at 0 to 60°C 1.5A at 30°C 1.0A at 60°C Continuous Current per Module 12.0A at 0 to 60°C 8.0A at 0 to 60°C 6.4A at 0 to 60°C On State Voltage Drop (max.)1.0V at 2.0A 1.0V at 2.0A 1.0V at 1.0A Surge Current per Point(10)4.0A for 10 ms 4.0A for 10 ms 4.0A for 10 ms Surge Current per Module(10)24.0A for 10 ms 32.0A for 10 ms 32.0A for 10 ms Digital I/O Modules 15 Publication 1746-IN005B-EN-P - September 2002 Electronic Protection yes no no (1) Removable Terminal Block. (2) Use the following ID Code when configuring your system with programming software or the HHT: 1746-OB6EI = 2619, 1746-OBP8 = 2721 and 1746-OBP12 = 2921. (3) An external fuse can be used to protect this module from short circuits. Recommended fuse is SANO MQ4-3.15A, 5x20 mm. (4) A fused common and blown fuse LED are provided on this module. See “Fuse Protection and Blown Fuse Diagnostics” on page 22. (5) Certified for Class 1, Division 2 hazardous location by CSA. (6) Fast turn-off modules (1746-OB6EI, -OBP8 Series B and later, -OB16E Series B and later, -OBP16, and -OVP16) provide fast OFF delay for inductive loads. Comparative OFF delay times for 1746-OB8/-OV8 and fast turn-off modules; when switching Bulletin 100-B110 (24W sealed) contactor, are: 1746-OB8/-OV8 OFF delay = 152 ms; fast turn-off modules OFF delay = 47 ms. (7) To limit the effects of leakage current through solid state outputs, a loading resistor can be connected in parallel with your load. For transistor outputs, 24V dc operation, use a 5.6K W, 1/2W resistor. (8) Recommended surge suppression: For transistor outputs when switching 24V dc inductive loads, use a 1N4004 diode reverse-wired across the load (also see footnote 9). Refer to the SLC 500 Modular Hardware Style User Manual, publication 1747-UM011, for more information on surge suppression. (9) Fast off delay for inductive loads is accomplished with surge suppressors on the 1746-OB6EI, -OBP8 Series B and later, -OB16E Series B and later, -OBP16, and -OVP16 modules. A suppressor at the load is not needed unless another contact is connected in series. If this is the case, a 1N4004 diode should be reverse wired across the load. This defeats the fast turn-off feature. (10) Repeatability is once every 1s at 30°C. Repeatability is once every 2s at 60°C. ATTENTION ! A transient pulse occurs in transistor outputs when the external dc supply voltage is applied to the output common terminals (e.g., via the master control relay). This can occur regardless of the processor having power or not. For most applications, the energy of this pulse is not sufficient to energize the load. Refer to the SLC 500 Modular Hardware Style User Manual, publication 1747-UM011, for more information on transient pulses and guidelines to reduce inadvertent processor operation. Table 14 Specifications for Output Modules 1746-OB6EI, -OBP8, and -OBP16Specification Catalog Number 1746- OB6EI(1)(2)OBP8(1)(2)(3)OBP16(1)(2)(4)(5) 16 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Table 15 Specifications for Output Modules 1746-OV8, -OV16, and -OVP16 Specification Catalog Number 1746- OV8 OV16(1) (1) Removable Terminal Block. OVP16(1)(2)(3)(4) (2) A fused common and blown fuse LED are provided on this module. See “Fuse Protection and Blown Fuse Diagnostics” on page 22. (3) Use the following ID Code when configuring your system with programming software or the HHT: 1746-OVP16 = 2922. (4) Certified for Class 1, Division 2 hazardous location by CSA. Number of Outputs 81616 Points per Common 81616 Voltage Category 24V dc Signal Output Operating Voltage (V dc)10 to 50 (sink) 20.4 to 26.4 (sink) Backplane Current Consumption 5V dc 0.135A 0.270A 0.250A 24V dc 0.0A Signal Delay (max.). Resistive Load.on = 0.1 ms off = 1.0 ms on = 0.1 ms(5) off = 1.0 ms (5) Fast turn-off modules (1746-OB6EI, -OBP8 Series B and later, -OB16E Series B and later, -OBP16, and -OVP16) provide fast OFF delay for inductive loads. Comparative OFF delay times for 1746-OB8/-OV8 and fast turn-off modules; when switching Bulletin 100-B110 (24Ws sealed) contactor, are: 1746-OB8/-OV8 OFF delay = 152 ms; fast turn-off modules OFF delay = 47 ms. Off State Leakage (max.)(6) (6) To limit the effects of leakage current through solid state outputs, a loading resistor can be connected in parallel with your load. For transistor outputs, 24V dc operation, use a 5.6K W, 1/2W resistor. 1 mA Load Current (min.)1 mA Continuous Current per Point(7) (7) Recommended surge suppression: For transistor outputs when switching 24V dc inductive loads, use a 1N4004 diode reverse-wired across the load (also see footnote 9). Refer to the SLC 500 Modular Hardware Style User Manual, publication 1747UM011 for more information on surge suppression. 1.0A at 30°C 0.50A at 60°C 0.50A at 30°C 0.25A at 60°C 1.5A at 30°C(8) 1.0A at 60°C (8) Fast off delay for inductive loads is accomplished with surge suppressors on the 1746-OB6EI, -OBP8 Series B and later, -OB16E Series B and later, -OBP16, and -OVP16 modules. A suppressor at the load is not needed unless another contact is connected in series. If this is the case, a 1N4004 diode should be reverse wired across the load. This defeats the fast turn-off feature. Continuous Current per Module 8.0A at 30°C 4.0A at 60°C 6.4A at 0 to 60°C On State Voltage Drop (max.)1.2V at 1.0A 1.2V at 0.5A 1.0V at 1.0A Surge Current per Point(9) (9) Repeatability is once every 1s at 30°C. Repeatability is once every 2s at 60°C. 3.0A for 10 ms 4.0A for 10 ms(10) (10) Surge current = 32A per module for 10 ms. Digital I/O Modules 17 Publication 1746-IN005B-EN-P - September 2002 Careful wire routing within the enclosure helps cut down electrical noise between I/O lines. Refer to the SLC 500 Modular Hardware Style User Manual, publication 1747-UM011, for recommended wiring procedures for TTL modules. ATTENTION ! A transient pulse occurs in transistor outputs when the external dc supply voltage is applied to the output common terminals (e.g., via the master control relay). This can occur regardless of the processor having power or not. For most applications, the energy of this pulse is not sufficient to energize the load. Refer to the SLC 500 Modular Hardware Style User Manual, publication 1747-UM011, for more information on transient pulses and guidelines to reduce inadvertent processor operation. Table 16 Specifications for Output Module 1746-OG16 Specification 1746-OG16(1) (1) Removable Terminal Block. Number of Outputs 16 Points per Common 16 Voltage Category 5V dc TTL Signal Input (sinking) Operating Voltage VDC to DC COM 4.5 to 5.5V dc(2) 50mV peak to peak ripple (max.) (2) TTL outputs are inverted (0 to 0.4V dc = low voltage = True = ON). Use a NOT instruction in your ladder program to convert to traditional True = High logic. Backplane Current Consumption 5V dc 0.180A 24V dc 0.0A Signal Delay (max.). Resistive Load.on = 0.25 mA off = 0.50 mA Offstate Voltage 4.5 to 5.5V dc(2) Off State Leakage (max.)0.1 mA Load Current (min.)0.15 mA Continuous Current per Point 24 mA ATTENTION ! To avoid potential damage to TTL modules, handle them by the ends of the module, not metallic surfaces. Electrostatic discharges can damage the module. Care should be taken to prevent exposure of terminals or components to electrostatic charges. 18 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Cable Length - Limit cable length to 3 meters (10 feet) per point for outputs in standard environments. Refer to Allen-Bradley Programmable Controller Wiring and Grounding Guidelines, publication 1770-4.1, for complete information. Relay Contact Output Modules Table 17 Specifications for Output Modules 1746-OW4, -OW8, -OW16, and -OX8 Specification Catalog Number 1746- OW4(1) (1) Certified for Class 1, Division 2 hazardous location by CSA. OW8(1)OW16(1)(2) (2) Removable Terminal Block. OX8(1)(2) Number of Outputs 48168 Points per Common 4 4 8 Individually Isolated Voltage Category ac/dc Relay Operating Voltage 5V dc 5 to 125 24V ac 5 to 265 Backplane Current Consumption 5V dc 0.045A 0.085A 0.170A 0.085A 24V dc 0.045A 0.090A 0.180A 0.090A Signal Delay (max.). Resistive Load. on = 10.0 ms off = 10.0 ms Off State Leakage (max.)0 mA Load Current (min.)10mA at 5V dc Continuous Current per Point(3) (3) Recommended surge suppression: For relay contact outputs, refer to the SLC 500 Modular Hardware User Manual publication 1747-UM011. Connecting surge suppressors across your external inductive load will extend the life of SLC 500 relay contacts. See relay contact ratings. (Table 18 and Table 19 on page 19) Continuous Current per Module 8.0A ac 8.0A /Common 16.0A ac 8.0A /Common 16.0A ac 8.0A /Common (4) (4) The continuous current per module must be limited so the module power does not exceed 1440 VA. Digital I/O Modules 19 Publication 1746-IN005B-EN-P - September 2002 Relay Contact RatingsTable 18 Relay Contact Rating Table for Output Modules 1746-OW4, -OW8, and -OW16 Voltages:Amperes(2)Amperes(2) Continuous Volt-Amperes Make Break Make Break Maximum Volts (ac) 120 15 1.5 2.5 1800 180 240 7.5 0.75 Maximum Volts (dc) 125 0.22(3)1.0 28 24 1.2(3)2.0 28 Table 19 Relay Contact Rating Table for Output Module 1746-OX8 Voltages:Amperes(1) (1) Recommended surge suppression: For relay contact outputs, refer to the SLC 500 Modular Hardware User Manual, publication 1747-UM011. Connecting surge suppressors across your external inductive load will extend the life of SLC 500 relay contacts. Amperes Continuous(2) (2) The continuous current per module must be limited so the module power does not exceed 1440 VA. Volt-Amperes Make Break Make Break Maximum Volts (ac) 120 30 3.0 5.0 3600 360 240 15 1.5 Maximum Volts (dc) 125 0.22(3) (3) For dc voltage applications, the make/break ampere rating for relay contacts can be determined by dividing 28 VA by the applied dc voltage. For example, 28 VA/48V dc = 0.58A. For dc voltage applications less than 14V, the make/break ratings for relay contacts cannot exceed 2A. 1.0 28 24 1.2(3)2.0 28 20 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Input/Output Combination Modules Table 20 Specifications for Combination Modules 1746-IO4, -IO8, -IO12, and -IO12DC Specification Catalog Number 1746- IO4(1)(2) (1) Certified for Class 1, Division 2 hazardous location by CSA. (2) See specifications for catalog numbers 1746-IA4 and 1746-OW4. Continuous Current per 1746-IO4 Module is 4.0A. Continuous Current per 1746-IO8 Module is 8.0A. IO8(1)(2)IO12(1)(3)(4) (3) Removable Terminal Block. (4) See specifications for catalog numbers 1746-IA16 and 1746-OW16. Continuous Current per 1746-IO12 Module is 8.0A. IO12DC(3)(5)(6)(7) (5) See specification for catalog numbers 1746-IB16 and 1746-OW16. Continuous Current per 1746-IO12DC Module is 8.0A. (6) Certified for Class 1, Division 2 hazardous location by C-UL. (7) Use the following ID Code when configuring your system with programming software or the HHT: 1746-IO12DC = 1512. Points per Module 2 inputs 2 outputs 4 inputs 4 outputs 6 inputs 6 outputs 6 inputs 6 outputs Points per Common 2466 Voltage Category (Inputs)120V ac 24V dc Operating Voltage (Inputs)85 to 132V ac 10 to 30V dc Voltage Category (Outputs)100/120V ac Relay contact output Operating Voltage (Outputs)5 to 265V ac 5 to 125V dc Backplane Current Consumption 5V dc 0.030A 0.060A 0.090A 0.080 24V dc 0.025A 0.045A 0.070A 0.060 TIP Combination I/O modules (Catalog Numbers 1746-IO4, 1746-IO8, 1746-IO12 and 1746-IO12DC: For the first several seconds of any power-up or when power is applied to a rack that is not under processor control, the output LEDs of the combination IO modules in the rack will be illuminated. Racks are not under processor control if one of the following conditions exist: Modular Hardware Style (only): Processor is absent from the rack or the rack interconnect cable is not properly connected. Modular Hardware Style and Fixed Hardware Style: The processor does not have the firmware PROM installed or the processor is not functioning properly. Digital I/O Modules 21 Publication 1746-IN005B-EN-P - September 2002 Octal Label Kit Installation (for PLC Processors Only)The octal label kit consists of an octal filter label and a door label. Use these octal labels to replace the decimal labels that are attached to the I/O modules. The octal label kit is included with the I/O modules and can also be obtained through your Allen-Bradley distributor. Applying the Octal Filter Label 1.Remove the octal filter label from its paper carrier. 2.Align the octal filter label numbers horizontally to the module color bar and over the decimal filter numbers. 3.Apply the octal label to the filter. 4.Press firmly to ensure proper adhesion of the label. Applying the Octal Door Label 1.Remove the octal door label from its paper carrier. 2.Align the octal label directly over the decimal door label on the inside of the door. 3.Press firmly to ensure proper adhesion of the label. Removable Terminal Blocks Colored terminal blocks are removable by loosening the upper and lower retaining screws. Black terminal blocks are not removable. ATTENTION ! Do not touch or remove the terminal block when the SLC 500 system is powered. Contact with ac line potential may cause injury to personnel. 22 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Figure 2 Installing Octal Labels Fuse Protection and Blown Fuse Diagnostics This section describes fusing characteristics for the following modules: ·Catalog 1746-OBP16 ·Catalog 1746-OVP16 ·Catalog 1746-OAP12 Beveled Edge Removable Terminal Block Terminal Wiring max. #14 AWG (2mm2) max. 2 wires per terminal max. torque: 0.9Nm (8 in-lbs) Upper Retaining Screw Maximum Torque = 0.6 Nm (5.3 in-lbs) Module Color Bar Lower Retaining Screw Maximum Torque = 0.6 Nm (5.3 in-lbs) Octal Door Label 1746-XXXX 1746-XXXX(OCTAL) Octal Filter Label OCTAL Digital I/O Modules 23 Publication 1746-IN005B-EN-P - September 2002 Fuse Protection (1746-OBP16 and 1746-OVP16)The fuse on the 1746-OBP16 and 1746-OVP16 modules (shown on page 24) has been designed to provide short-circuit protection for wiring only (16 AWG or larger) to external loads. In the event of a short circuit on an output channel, it is likely that the transistor associated with that channel will be damaged and the module should be replaced or a spare output channel used for the load. The fuse does not provide overload protection. In the event of an overload on an output channel, it is likely that the fuse will not blow and the transistor associated with that channel will be damaged. To provide overload protection for your application, user-supplied fuses should be installed externally and properly sized to match your individual load characteristics. Fuse Protection (1746-OAP12) A fuse is provided on each common of the 1746-OAP12 module (shown on page 25) for a total of 2 fuses. The fuses are designed to protect the module from short-circuit conditions. The fuse does not provide overload protection. In the event of an overload on an output channel, it is likely that the fuse will not blow and the output device associated with that channel will be damaged. To provide overload protection for your application, user-supplied fuses should be installed externally. Recommended fuse for overload protection is SAN-O HT. Select the fuse rating according to your load. Do not use HT fuses rated higher than 2.0A. Blown Fuse Diagnostics If the fuse blows on the 1746-OBP16, -OVP16 or -OAP12, the following occurs: 1.The blown fuse LED will illuminate provided power (5V dc via backplane and load power via external supply) is applied to the module. 2.A processor error will occur if JP1 connects pins 2 and 3. (See figures on page 24 and page 25.) 24 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Figure 3 Location of Jumpers and Fuses for 1746-OBP16 and -OVP16 12 23 OUTPUT Front View 1 2 3 JP 1 JP1F U S E Location for 1746-OBP16 Fuse (F1) Jumper for processor notification (JP1)Left Side View Location for 1746-OVP16 Fuse (F1) WHEN FUSE OPENS PROCESSOR CONTINUES PROCESSOR FAULTS REPLACEMENT FUSE: LITTELFUSE 322010 A-B CAT. NO. 1746-F8 Blown Fuse LED Jumper Settings and Fuse Replacement Information Digital I/O Modules 25 Publication 1746-IN005B-EN-P - September 2002 Figure 4 Location of Jumpers and Fuses for 1746-OAP12 1 WHEN FUSE OPENS 2 23 OUTPUT 1JP123JP1F U S E F1 Left Side View Jumper for processor notification (JP1) F2 PROCESSOR CONTINUES PROCESSOR FAULTS REPLACEMENT FUSE: SAN-O HQ 6.3A A-B CAT. NO. 1746-F9 Jumper Settings and Fuse Replacement Information Blown Fuse LED Front View 26 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Processor Operation in Case of Blown Fuse - Processor ContinuesThe factory set position for JP1 is shown in Figure 5. For this JP1 configuration, the processor operation will continue if the module fuse blows. Figure 5 JP1 Factory Set Position (No Processor Notification) Processor Operation in Case of Blown Fuse - Processor Faults The Processor Fault position for JP1 is shown in Figure 6 on the following page. For this JP1 configuration, the processor generates a non-recoverable error for all SLC 500 processors. For a non-recoverable error, note the following: ·Processor operation halts and the processor fault light flashes. ·All outputs are reset to OFF. ·The processor major fault bit S:1/13 is set. ·Monitor processor status file word S:6 for error code xx58 for SLC 500 and 5/01™ processors, and error code xx60 for SLC 5/02™ and higher processors. JP1 is in Factory Set position. There is no processor notification for blown fuse. JP1 32 1 JP1 1 2 3 1746-OAP12 1746-OBP16 and -OVP16 Digital I/O Modules 27 Publication 1746-IN005B-EN-P - September 2002 Figure 6 JP1 in Processor Fault Notification Position For additional information on processor fault codes and user fault routines refer to the following user manuals: ·Your programming device’s reference manual ·HHT User Manual, publication 1747-NP002: Chapter 28, Troubleshooting Faults Chapter 29, Understanding the Fault Routine Table 21 defines operation of all SLC 500 processors in the case of a blown fuse in a 1746-OBP16, -OVP16 and -OAP12: IMPORTANT When using SLC 5/02 and higher processors, a User Fault Routine cannot be used to clear the major fault bit. ATTENTION ! For 1746-OBP16/-OVP16, all outputs on the module are OFF if the fuse blows. For 1746-OAP12, all outputs on the same common as the blown fuse are OFF. If processor operation is allowed to continue after a blown fuse, extreme care should be taken to ensure the safety of personnel and guard against equipment damage. JP1 is in processor Fault Position. Processor is notified when fuse is blown JP1 23 JP1 1 1 2 3 1746-OBP16 and -OVP16 1746-OAP12 28 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 . Recovery From Blown Fuse/Processor Fault/Processor Shutdown Processor operation will stop under the following conditions: ·The output module fuse blows due to a short circuit. ·JP1 is set to the Processor Faults position (pins 2 and 3 connected). If the above conditions occur, the following procedures should be used for recovery: 1.Follow fuse replacement procedures shown on page 29. 2.Clear the processor major fault bit S:1/13. 3.Clear processor status file S:6 major error code (optional). 4.Return processor to Run Mode. For additional information on processor fault codes and clearing processor fault bits, refer to the following user manuals: ·Your programming device’s reference manual ·HHT User Manual, publication 1747-NP002 Chapter 28, Troubleshooting Fault Chapter 29, Understanding the Fault Routine Replacement Fuse Recommendations Use the following replacement fuses: ·1746-OBP16/-OVP16 -Littelfuse #322010,10A. This fuse is required to maintain UL/CSA rating. Replacement Fuse Kit is catalog number 1746-F8. (5 fuses per kit). ·1746-OAP12 -Use SAN-O HQ 6.3A for replacement. This fuse is required to maintain UL/CSA rating. Replacement Fuse Kit is catalog number 1746-F9 (5 fuses per kit). Table 21 Processor Operation After A Blown Fuse (1746-OBP16, -OVP16 and -OAP12) JP1 Set to Processor Continues JP1 Set to Processor Faults No error. Processor continues with 1746-OBP16/-OVP16 outputs de-energized. 1746-OAP12 outputs, on the same common as the blown fuse, are de-energized. Non-recoverable error. Processor operations stop and all outputs reset to OFF. Digital I/O Modules 29 Publication 1746-IN005B-EN-P - September 2002 Fuse Replacement ProcedureTo replace a blown fuse: 1.Remove SLC 500 system power and correct the conditions causing the short circuit. 2.Remove the output module from the chassis. 3.Remove the fuse. ·1746-OBP16/-OVP16: Use a wide tipped, slotted head screw driver to remove the blown fuse. Slide the screw driver tip under the fuse and use a twisting motion to pry the fuse from the fuse clip. Use care so that the printed circuit board and surrounding electronics are not damaged. ·1746-OAP12: A fuse holder is provided with each fuse. Simply grasp the fuse holder with needle-nose pliers, or your fingers, and pull it out. 4.Replace the fuse. ·1746-OBP16/OVP16: Center the replacement fuse over the fuse clip and press down. If a tool is used to press the fuse in place, apply pressure to the metal end caps only, not the center of the fuse. ·1746-OAP12: Insert a new fuse into the fuse holder, align fuse holder on fuse clips and press down. 5.Replace the output module in the chassis. 6.Restore SLC 500 system power. Clear processor fault bits as indicated in the steps provided on page 28. ATTENTION ! Never install, remove, or wire modules with power applied to chassis. 30 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Electronically Protected Modules (1746-OB6EI and -OB16E) Electronic Protection The electronic protection of the 1746-OB6EI and -OB16E has been designed to provide protection for the modules from short circuit and overload current conditions. The protection is based on a thermal cut-out principle. In the event of a short circuit or overload current condition on an output channel, that channel will limit current within milliseconds after its thermal cut-out temperature has been reached. All other channels continue to operate as directed by the CPU (processor) module. Figure 7 EFUSE LED IMPORTANT The modules do not provide protection against reverse polarity wiring or wiring to AC power sources. Electronic protection is not intended to replace fuses, circuit breakers, or other code-required wiring protection devices. OUTPUT E F U S E OUTPUT E F U S E EFUSE LED There is no jumper setting on this module Front View Digital I/O Modules 31 Publication 1746-IN005B-EN-P - September 2002 Auto Reset Operation Short Circuit/Overload Current Diagnostics If a short circuit or overload current condition occurs on an output channel: 1.The E-Fuse LED will illuminate provided that power is applied to the module. Power required: 5V dc via backplane and load power via an external supply. 2.All other channels continue to operate as directed by the CPU (processor) module. Recovery From Channel Shutdown 1.Remove the SLC 500 system power and correct the conditions causing the short circuit or overload current condition. 2.Restore the SLC 500 system power. The module automatically resets and resumes control of the output channel and associated load. IMPORTANT The 1746-OB6EI and -OB16E perform auto-reset under overload conditions. When an output channel overload occurs as described on page 30, that channel will limit current within milliseconds after its thermal cut-out temperature has been reached. While in current limit, the output channel can cool below the thermal cut-out temperature allowing the module to auto-reset and resume control of the output channel as directed by the processor until the thermal cut-out temperature is again reached. Removing power from an overloaded output channel would also allow the output channel to cool below the thermal cut-out temperature, allowing auto-reset to occur when power is restored. The output channel would operate as directed by the processor until the thermal cut-out temperature is again reached. To avoid auto-reset of an output channel under overload conditions, an external mechanical fuse can be used to open the circuit when overloaded. 32 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Wiring DiagramsThe wiring diagrams in these installation instructions are examples only. It is not necessary to connect an I/O device to each and every I/O module terminal. Labeling for SLC/PLC® Systems In this document, 16-point I/O module wiring diagrams include both decimal and octal numbers for I/O addressing and wire identification (see figure below). To wire your 16-point I/O module when used in a SLC system, use the decimal numbers in the upper left portion of each box. When used in a PLC system, use the octal numbers in the lower right portion of the box. As shipped from the factory, the I/O module has a decimal address label on the inside of its door. An octal label kit should be included with your 16-point I/O modules, or a separate octal conversion kit can be ordered, to allow you to convert your module to the octal system. Figure 8 Decimal and Octal Labeling for 16-Point I/O Modules IMPORTANT Ensure the octal labels are used with your PLC system. Directions on how to install the labels are included with the kit and on page 21 of this document. IN 14 16 IN 1 IN 0 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 9 IN 10 IN 11 IN 12 IN 13 IN 14 IN 15 AC COM AC COM 0 1 2 4 6 IN 8 10 12 14 16 11 13 15 17 3 5 7 L1 L2 PLC SLC 100/120V ac 1746-IA16 100/120V ac COMMONS CONNECTED INTERNALLY For PLC (octal) For SLC (decimal) Digital I/O Modules 33 Publication 1746-IN005B-EN-P - September 2002 Input Modules - acFigure 9 Wiring Diagrams (1746-IA4, -IA8, -IA16) PLC SLC IN 1 IN 0 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 9 IN 10 IN 11 IN 12 IN 13 IN 14 IN 15 AC COM AC COM 0 1 2 4 6 IN 8 10 12 14 16 11 13 15 17 3 5 7 L1 L2 100/120V ac L1 L2 100/120V ac IN 0 IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 AC COM AC COM L1 100/120V ac NOT USED NOT USED NOT USED NOT USED IN 0 IN 1 IN 2 IN 3 AC COML2 1746-IA4 100/120V ac 1746-IA8 100/120V ac COMMONS CONNECTED INTERNALLY 1746-IA16 100/120V ac COMMONS CONNECTED INTERNALLY 34 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Figure 10 Wiring Diagrams (1746-IM4, -IM8, -IM16) IN 0 IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 AC COM L1 L2 AC COM 200/240V ac NOT USED NOT USED NOT USED NOT USED IN 0 IN 1 IN 2 IN 3 AC COM L1 L2 200/240V ac PLC L1 L2 200/240V ac IN 0 IN 2 IN 4 IN 6 IN 10 IN 12 IN 14 AC COM 0 2 4 6 IN 8 10 12 14 16 SLC 3 IN 5 IN 7 IN 9 IN 11 IN 13 IN 15 AC COM 11 13 15 17 5 7 IN 1 1 IN 3 1746IM4 200/240V ac 1746-IM8 200/240V ac COMMONS CONNECTED INTERNALLY 1746-IM16 200/240V ac COMMONS CONNECTED INTERNALLY Digital I/O Modules 35 Publication 1746-IN005B-EN-P - September 2002 Input Modules - dcFigure 11 Wiring Diagram (1746-IN16) Figure 12 Wiring Diagram (1746-IB8, -IB16, -ITB16, -IC16, -IH16) PLC SLC L1 or +DC L2 or -DC IN 1 IN 0 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 9 IN 10 IN 11 IN 12 IN 13 IN 14 IN 15 AC/DC COM AC/DC COM 0 1 2 4 6 IN 8 10 12 14 16 11 13 15 17 3 5 7 V ac/dc 1746-IN16 24V ac/dc Sinking COMMONS CONNECTED INTERNALLY -DC IN 0 IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 +DC -DC DC COM DC COM 24V dc PLC SLC +DC IN 1 IN 0 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 9 IN 11 IN 12 IN 13 IN 14 IN 15 DC COM DC COM 0 1 2 4 6IN 8 10 14 11 13 15 17 3 5 7 24V dc (IB16, ITB16) 48V dc (IC16) 125V dc (IH16) 6 IN 10 12 16 1746-IB8 24V dc Sinking COMMONS CONNECTED INTERNALLY 1746-IB16, -ITB16 24V dc Sinking 1746-IC16 48V dc Sinking 1746-IH16 125V dc Sinking COMMONS CONNECTED INTERNALLY 36 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Figure 13 Wiring Diagram (1746-IV8, -IV16, -ITV16) Figure 14 Wiring Diagram (1746-IG16) PLC SLC -DC +DC IN 1 IN 0 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 9 IN 10 IN 11 IN 12 IN 13 IN 14 IN 15 VDC VDC 0 1 2 4 6 IN 8 10 12 14 16 11 13 15 17 3 5 7 24V dc IN 0 IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 VDC -DC +DC VDC 24V dc 1746-IV8 24V dc Sourcing VDC CONNECTED INTERNALLY VDC CONNECTED INTERNALLY 1746-IV16, -ITV16 24V dc Sourcing PLC IN 0 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 9 IN 10 IN 11 IN 12 IN 13 IN 14 DC COM 0 1 2 4 6 10 12 14 16 11 13 15 IN 15 17 3 5 7 +DC -DC SLC +5V dc IN 8 IN 1 +5 DC 1746-IG16 TTL Input (Low = True) Digital I/O Modules 37 Publication 1746-IN005B-EN-P - September 2002 Output Modules - acFigure 15 Wiring Diagrams (1746-OA8, -OA16) Figure 16 Wiring Diagram (1746-OAP12) 100-240V ac 100-240V ac CR CR VAC 1 OUT 0 OUT 1 OUT 2 OUT 3 VAC 2 OUT 4 OUT 5 OUT 6 OUT 7 CR CR L2 L1 L2 L1 OUT0 OUT 2 OUT 3 OUT 4 OUT 5 OUT 6 OUT 9 OUT 8 OUT 11 OUT 10 OUT 14 OUT 12 0 2 4 6 11 13 16 10 12 14 3 5 L1 PLC SLC CR CR L2 CR CR CR CR L2 CR CR 100-240V ac OUT 7 7 OUT 1 1 VAC 1 100-240V ac L1 OUT 15 17 OUT 13 15 VAC 2 1746-OA8 100 to 240V ac Triac Output 1746-OA16 100 to 240V ac Triac Output 11 7 OUT 7 OUT 2 OUT 3 OUT 4 OUT 5 2 4 3 5 L1 PLC SLC CR L2 CR CR L2 CR 100-240V ac OUT 1 1 VAC 1 100-240V ac NOT USED VAC 2 L1 CR CR NOT USED OUT 0 0 VAC 2 VAC 1 OUT 10 OUT 11 12 13 OUT 9 OUT 8 10 OUT 6 6 1746-OAP12 100 to 240V ac High Current Triac Output COMMONS CONNECTED INTERNALLY COMMONS CONNECTED INTERNALLY 38 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Output Modules - dcFigure 17 Wiring Diagrams (1746-OB6EI) VDC 0 OUT 0 DC COM 0 VDC 2 OUT 2 DC COM 2 VDC 4 OUT 4 DC COM 4 VDC 1+DC -DC +DC -DC +DC -DC +DC -DC +DC -DC +DC -DC 10-30V dc 10-30V dc 10-30V dc 10-30V dc 10-30V dc 10-30V dc OUT 1 DC COM 1 VDC 3 OUT 3 DC COM 3 VDC 5 OUT 5 DC COM 5 CR CR CR 1746-OB6EI 10 to 30V dc Transistor Output-Sourcing Channel-to-Channel Isolated Digital I/O Modules 39 Publication 1746-IN005B-EN-P - September 2002 Figure 18 Wiring Diagrams (1746-OB8, -OBP8, -OB16, -OB16E, -OBP16) VDC1 OUT 1 OUT 3 NC NC CR CR OUT 0 OUT 2 NC DC COM1 -DC +DC 20.4-26.4V dc -DC +DC 10-50V dc -DC +DC 20.4-26.4V dc -DC +DC 10-50V dc (OB16) 10-30V dc (OB16E) 20.4-26.4V dc (OBP16) VDC2 OUT 7 OUT 5 NC CR CR OUT 6 OUT 4 NC DC COM2 NC VDC OUT 0 OUT 1 OUT 2 OUT 3 OUT 4 OUT 5 OUT 6 OUT 7 DC COM CR CR CR CR OUT 3 OUT 5 OUT 9 OUT 11 11 13 3 5 PLC SLC CR CR CR CR OUT 7 7 OUT 1 1 VDC OUT 15 17 OUT 13 15 CR CR CR CR OUT 0 OUT 2 OUT 4 OUT 6 OUT 8 OUT 10 OUT 14 OUT 12 0 2 4 6 16 10 12 14 DC COM 1746-OB8 10 to 50V dc Transistor Output-Sourcing 1746-OBP8 20.4 to 26.4V dc Transistor Output-Sourcing 1746-OB16, 1746-OB16E, -OBP16 10 to 50V dc, 10 to 30V dc, 20.4 to 26.4V dc Transistor Output-Sourcing 40 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Figure 19 Wiring Diagrams (1746-OV8, -OV16, -OVP16) Figure 20 Wiring Diagrams (1746 -OG16) VDC OUT 0 OUT 1 OUT 2 OUT 3 OUT 4 OUT 5 OUT 6 OUT 7 DC COM -DC +DC CR CR CR CR 10-50V dc PLC SLC 10-50V dc (OV16) 20.4-26.5V dc (OVP16) OUT 0 OUT 2 OUT 4 OUT 6 OUT 9 OUT 8 OUT 14 OUT 12 0 2 4 6 16 10 12 14 CR CR CR CR CR CR CR CR DC COM +DC -DC OUT 3 OUT 5 OUT 11 13 3 5 OUT 7 7 OUT 1 1 VDC OUT 15 17 OUT 13 15 11 OUT 10 1746-OV8 10 to 50V dc Transistor Output Sinking 1746-OV16, -OVP16 10 to 50V dc OR 20.4 to 26.4V dc Transistor Output Sinking 16 OUT 0 OUT 2 OUT 3 OUT 4 OUT 5 OUT 6 OUT 9 OUT 8 OUT 11 OUT 10 OUT 14 OUT 12 0 2 4 6 11 13 10 12 14 3 5 PLC SLC L L L L +5V dc OUT 7 7 OUT 1 1 VDC OUT 15 17 OUT 13 15 L L L L DC COM +DC -DC L L L L L L L L 1746-OG16 TTL Output (Low = True) Digital I/O Modules 41 Publication 1746-IN005B-EN-P - September 2002 Relay Contact Output ModulesFigure 21 Wiring Diagrams (1746 -OW4, -OW8, -OW16) V ac/dc CR CR VAC-VDC OUT 0 OUT 1 OUT 2 OUT 3 OUT 7 L2 or -DC L1 or +DC CR CR OUT 0 OUT 1 OUT 2 OUT 3 OUT 4 OUT 5 OUT 6 OUT 7 CR CR NOT USED NOT USED NOT USED NOT USED NOT USED OUT0 OUT 2 OUT 3 OUT 4 OUT 5 OUT 6 OUT 9 OUT 8 OUT 11 OUT 10 OUT 14 OUT 12 0 2 4 6 11 13 16 10 12 14 3 5 PLC SLC CR CR CR CR CR CR CR CR OUT 7 7 OUT 1 1 OUT 15 17 OUT 13 15 VAC-VDC 1 VAC-VDC 2 VAC-VDC 1 VAC-VDC 2 V ac/dc L2 or -DC L1 or +DC V ac/dc L2 or -DC L1 or +DC V ac/dc L2 or -DC L1 or +DC V ac/dc L2 or -DC L1 or +DC 1746-OW4 Relay Output 1746-OW8 Relay Output 1746-OW16 Relay Output 42 Digital I/O Modules Publication 1746-IN005B-EN-P - September 2002 Figure 22 Wiring Diagram (1746-OX8) Input/Output Combination Modules Figure 23 Wiring Diagram (1746-IO4, -IO8) VAC-VDC 0 OUT 0 OUT 1 OUT 2 OUT 3 NOT USED VAC-VDC 1 VAC-VDC 2 VAC±VDC 3 NOT USED VAC-VDC 4 VAC-VDC 5 VAC-VDC 6 VAC-VDC 7 VS0 L1 VS1 L1 VS2 VDC VS3 VDC VS4 L1 VS5 L1 VS6 VDC VS7 VDC VS0 L2 VS1 L2 VS2 DC COM VS3 DC COM VS4 L2 VS5 L2 VS6 DC COM VS7 DC COM CR CR OUT 4 OUT 5 OUT 6 OUT 7 CR CR 1746-OX8 Channel-to-Channel Isolated Relay Output CR VAC-VDC OUT 0 OUT 1 NOT USED NOT USED OUT 7 IN 0 IN 1 NOT USED NOT USED AC COM L1 L2 CR CR OUT 0 OUT 1 OUT 2 OUT 3 OUT 7 L2 or -DC L1 or +DC IN 0 IN 1 IN 2 IN 3 AC COM L1 L2 100/120V ac VAC-VDC V ac/dcL2 or -DC L1 or +DC V ac/dc 100/120V ac 1746-IO4 100/120V ac Input - Relay Output 1746-IO8 100/120V ac Input - Relay Output Digital I/O Modules 43 Publication 1746-IN005B-EN-P - September 2002 Figure 24 Wiring Diagram (1746-IO12) Figure 25 Wiring Diagram (1746-IO12DC) OUT 0 OUT 2 OUT 3 OUT 4 OUT 5 NOT USED IN 1 IN 2 IN 3 IN 4 AC COM NOT USED CR CR NOT USED OUT 1 NOT USED IN 5 VAC-VDC IN 0 100/120V ac L1 L2 L2 or -DC L1 or +DC V ac/dc 1746-IO12 100/120V ac INPUT - RELAY OUTPUT OUT 0 OUT 2 OUT 3 OUT 4 OUT 5 NOT USED IN 1 IN 2 IN 3 IN 4 DC COM NOT USED CR CR NOT USED OUT 1 NOT USED IN 5 VAC-VDC IN 0 -DC 10-30V dc +DC L2 or -DC L1 or +DC V ac/dc 1746-IO12DC 24V dc INPUT - RELAY OUTPUT Publication 1746-IN005B-EN-P - September 2002 PN 40071-079-01 (2) Supersedes Publication 1746-IN005A-US-P - January 2000 Copyright © 2002 Rockwell Automation. All rights reserved. Printed in the U.S.A. ·H’*o!¶2˘¤ For More Information If you would like a manual, you can: ·download a free electronic version from the internet: www.theautomationbookstore.com ·purchase a printed manual by: –contacting your local distributor or Rockwell Automation representative –visiting www.theautomationbookstore.com and placing your order –calling 1.800.963.9548 (USA/Canada) or 001.330.725.1574 (Outside USA/Canada) PLC is a registered trademark of Rockwell Automation. SLC 500, SLC 5/01, SLC 5/02, SLC 5/03, SLC 5/04, and SLC 5/05 are trademarks of Rockwell Automation. For Refer to this Document Pub. No. A more detailed description on how to install and use your modular SLC 500 system. SLC 500 Modular Hardware Style User Manual 1747-UM011 A reference manual that contains status file data, instruction set, and troubleshooting information. SLC 500 Instruction Set Reference Manual 1747-RM001 In-depth information on grounding and wiring Allen-Bradley programmable controllers Allen-Bradley Programmable Controller Grounding and Wiring Guidelines 1770-4.1 Compact Block LDX I/O for DeviceNet 1790D, 1790 Technical Data The CompactBlockTM I/O product family now offers you a new, more cost-effective I/O product line for light industrial and commercial automation environments. CompactBlock LDX I/O utilizes the leading, lowest-cost, device-level communication network, DeviceNetTM, to translate simple messages from the controller to the plant floor. It is especially suitable where low cost and confined space is coupled with reduced envrionmental requirements. Publication 1790D-TD001B-EP - February 2002 2 Overview CompactBlock LDX I/O The following CompactBlock LDX I/O for DeviceNet base and expansion blocks are available with either D-shell connectors or screw terminations (terminal blocks): D-Shell Blocks Description 1790D-16BV0 24VDC, 16 universal input base block 1790D-8BV8B 24VDC, 8 universal input/8 sourcing output base block 1790D-8BV8V 24VDC, 8 universal input/8 sinking output base block 1790D-0B16 24VDC, 16 sourcing output base block 1790D-0V16 24VDC, 16 sinking output base block 1790D-0W6 6 relay output base block 1790-16BV0X 24VDC, 16 universal input expansion block 1790-8BV8BX 24VDC, 8 universal input/8 sourcing output expansion block 1790-8BV8VX 24VDC, 8 universal input/8 sinking output expansion block 1790-0B16X 24VDC, 16 sourcing output expansion block 1790-0V16X 24VDC, 16 sinking output expansion block 1790-0W8X 8 relay output expansion block 1790D-N4C0 4 channel analog current input block 1790D-N0C2 2 channel analog current output block 1790D-N4V0 4 channel analog voltage input block 1790D-N0V2 2 channel analog voltage output block 1790D-4R0 4 channel input RTD base block 1790D-4T0 4 channel input Thermocouple base block Terminal Blocks Description 1790D-T16BV0 24VDC, 16 universal input base block 1790D-T8BV8B 24VDC, 8 universal input/8 sourcing output base block 1790D-T8BV8V 24VDC, 8 universal input/8 sinking output base block 1790D-T0B16 24VDC, 16 sourcing output base block 1790D-T0V16 24VDC, 16 sinking output base block 1790D-T0W6 6 relay output base block 1790D-T8A0 120VAC, 8 input base block 1790D-T0A6 120VAC, 6 output base block 1790-T16BV0X 24VDC, 16 universal input expansion block 1790-T8BV8BX 24VDC, 8 universal input/8 sourcing output expansion block 1790-T8BV8VX 24VDC, 8 universal input/8 sinking output expansion block 1790-T0B16X 24VDC, 16 sourcing output expansion block 1790-T0V16X 24VDC,16 sinking output expansion block 1790-T0W8X 8 relay output expansion block 1790-T8A0X 120VAC, 8 input expansion block 1790-T0A8X 120VAC, 8 output expansion block 1790D-TN4C0 4 channel analog current input block 1790D-TN0C2 2 channel analog current output block 1790D-TN4V0 4 channel analog voltage input block 1790D-TN0V2 2 channel analog voltage output block 1790D-T4R0 4 channel input RTD base block 1790D-T4T0 4 channel input Thermocouple base block Publication 1790D-TD001B-EP - February 2002 CompactBlock LDX I/O Overview 3 Overview CompactBlock LDX I/O for DeviceNet blocks are compatible with PLC®, SLC™, SoftLogix™ or Logix programmable controllers using DeviceNet scanners. All CompactBlock LDX I/O block values are accessible through the data tables of the PLC or SLC programmable controller. Set node addresses on the blocks using rotary switches, located on the base block, RSNetWorx for DeviceNet™ software or a similar configuration tool. Set baud rate using a similar configuration tool. Benefits •Wide breadth of I/O types that can handle diverse commercial applications •Expands up to 4 digital blocks for flexibility of node size (6-64 points) •Base blocks have a built-in DeviceNet adapter –Digital base blocks (24Vdc, 120Vac and relay) can support up to 3 digital expansion blocks –Analog base blocks (current and voltage) can support up to 2 digital expansion blocks –RTD and Thermocouple base blocks do not support expansion blocks •Universal sink/source inputs reduces the number of components to stock and allows flexibility of input types •Compatible with a broad range of sensors: –NEMA/IEC Type 3 compliance for DC blocks –NEMA/IEC Type 1 compliance for AC blocks •Very compact, can fit into confined areas (104mm x 52mm x 42mm) •Selectable termination types - removable D-shell and fixed screw termination •Easy to connect and configure using modular EDS files •Installation and configuration costs are minimized •ODVA conformance tested means high level of interoperability with other DeviceNet products •RTD and thermocouple blocks support a wide range of sensors and have on-board scaling •Cyclic and change-of-state messaging increases network throughput, increases productivity •Auto baud rate detection •Mounts horizontally or vertically on DIN rail •UL/cUL Listed, CE certified CompactBlock LDX I/O Blocks Base block with screw terminations Base block with D-shell connector Expansion block with D-shell connector Expansion block with screw terminations Publication 1790D-TD001B-EP - February 2002 4 Overview CompactBlock LDX I/O Typical Configuration This illustration shows how CompactBlock LDX I/O fits into a typical DeviceNet system. System Compatibility CompactBlock LDX I/O blocks are compatible with PLC, SLC or SoftLogix programmable controllers when used with DeviceNet scanners. CompactBlock LDX I/O Family Block Communication The CompactBlock LDX I/O blocks act as slaves in a master/slave environment. Their I/O data is exchanged with the master through a polled, cyclic, or change-of-state connection. This selection is made in the DeviceNet scanner module’s configuration. Polled When configured as a polled device, a master initiates communication by sending its polled I/O message to the CompactBlock LDX I/O block. In response, the I/O block returns its input data. Cyclic When using cyclic operation, the master only sends data to the CompactBlock LDX I/O block and only receives data from the block at a preconfigured time interval. EXPANSION UNIT CompactCompactBlock LDX PULLPULL PULLPULL EXPANSION UNITANSION UNIT CompactCompactBlock LDX PULLPULL PULLPULL EXPANSION UNITANSION UNIT CompactCompactBlock LDXBlock LDX PULLPULL PULLPULLPULLPULL 1790 CompactBlock LDX I/O 20455-M 1784-PCD PCMCIA card Personal Computer with Configuration software PLC-5 controller 1771-SDN scanner 1747-SDN scanner SLC controller Series 9000 Photoelectric Sensors RediSTATION Interface DTAMTM 1336 PLUSTM Drive 1305 Drive 1336 FORCE Drive GV3000 drive Ezlink bearing monitor FlexPac 3000 drive SSCTM Bulletin 160 motor starter with SMP-3TM overload relay SMCTM Dialog Plus DeviceLinkTM I/O with limit switch FLEX I/O ArmorBlockTM I/O DeviceViewTM hand-held computer TM TM Micro or plus Publication 1790D-TD001B-EP - February 2002 CompactBlock LDX I/O Overview 5 Change-of-State When the CompactBlock LDX I/O blocks are configured for change-of-state, the master sends output data only when: •the user’s control program wants to update the block’s output •the time period for communication has expired The CompactBlock LDX I/O block’s input data is sent to the master only when: •an input changes •the time period for communication has expired With change-of-state, the master does not have to request input data from the slave, it is sent automatically when data changes. In addition, an adjustable "heartbeat" is produced periodically by the CompactBlock LDX I/O block to let the consuming device know that the block connection is alive and ready to communicate. Software and EDS File Requirements CompactBlock LDX I/O block require RSNetWorx for DeviceNet software, version 3.0 or later. Additionally, current functionality of CompactBlock LDX I/O blocks require current modular EDS files for RSNetWorx for DeviceNet software. These files are easy to install and are available on-line at: www.ab.com/networks/eds/ EDS files for blocks with matching catalog numbers (for D-Shell and terminal block versions) are the same. Thus on the website or in RSNetWorx for DeviceNet, there may be only one catalog number listed for both versions. Status Indicators Each CompactBlock I/O block has indicators to provide a diagnostic readout. Module and Network Status I/O Status Base Block I/O Status Expansion Block Publication 1790D-TD001B-EP - February 2002 6 Overview CompactBlock LDX I/O Module/Network Status Indicators - All Base Blocks I/O Status Indicators - Digital Base and Expansion Blocks I/O Status Indicators - Analog Base Blocks Mod/Net Status Indicator LED Indicator:Status:Description: Module Status Solid Red Unrecoverable fault in base block Flashing Red Recoverable fault Solid Green Normal operation - OK Flashing Green Standby Off No power LED Indicator:Status:Description: Network Status Solid Red Unrecoverable communication fault Flashing Red Recoverable communication fault Solid Green Communication path complete - OK Flashing Green Communication path incomplete Off Device not online or not powered I/O Status Indicators Function:LED Color:Module Illumination:Condition: Outputs Each output: Green None Green Output not energized Output energized Inputs Each Input: Green None Green No valid input Valid input 1790D-N4V0, -TN4V0 Analog Voltage Input Block 1790D-N4C0, -TN4C0 Analog Current Input Block Status:Description:Status:Description: Flashing Green/ Red Power up Flashing Green/ Red Power up Off Off line Off Off line Red On line and no field power Red On line and no field power Red DeviceNet connection and no field power Red DeviceNet connection and no field power Green Field power and open wire Flashing Red1 Field power and open wire (4-20mA range only)2 Green Field power and valid input Green Field power and valid input Green Input over range Green Input over range Green Input under range Flashing Red1 Input under range <3mA (4-20ma range only)2 Flashing Red Recoverable fault Flashing Red Recoverable fault 1 Green for 0-20mA range. 2 Can be determined from the data table. Publication 1790D-TD001B-EP - February 2002 CompactBlock LDX I/O Overview 7 I/O Status Indicators - Analog Base Blocks I/O Status Indicators - RTD and Thermocouple Base Blocks Power Supply Requirements The DeviceNet network supplies power to the CompactBlock I/O base and expansion blocks. Inputs and outputs are powered by an external 24V dc source which is independent of the network. Mounting You can mount the CompactBlock I/O base and expansion blocks directly to a panel or on a DIN rail. 1790D-N0V2, -TN0V2 Analog Voltage Output Block 1790D-N0C2, -TN0C2 Analog Current Output Block Status:Description:Status:Description: Flashing Green/ Red Power up Flashing Green/ Red Power up Off Off line Off Off line Off On line and no field power Off On line and no field power Green DeviceNet connection and no field power Green DeviceNet connection and no field power Green Field power and open wire Green Field power and open wire Green Field power and valid output Green Field power and valid output Flashing Red Field power and output out of range Flashing Red Field power and output out of range Flashing Green Output idle Flashing Green Output idle Flashing Red Recoverable fault Flashing Red Recoverable fault 1790D-4R0, -4T0 Status:Description: Flashing Green/Red Power up Off Off line Red On line and no field power Red DeviceNet connection and no field power Flashing Red Field power and open wire Green Field power and valid input Flashing Red Input over range Flashing Red Input under range Flashing Red Recoverable fault Publication 1790D-TD001B-EP - February 2002 8 Overview CompactBlock LDX I/O The following illustration shows the base and expansion blocks mounting dimensions. Remember to consider the length of the expansion ribbon cable when installing a base block with an expansion. The expansion block must be close enough for the expansion cable to reach from the base block to the expansion block. Beginning with the base block, you can mount the blocks either horizontally or vertically as shown below: Base block Expansion block 41mm 1.6 in 41mm 1.6 in 25mm 1 in 95 mm 3.74 in 95 mm 3.74 in To install plug, gently pull and swing expansion cover inward Red strip must be on bottom of expansion cable EXPANSION UNIT CompactCompactBlock LDX PULLPULL PULLPULL RIGHT SIDE UP EXPANSION UNIT CompactCompactBlock LDX PULLPULL PULLPULL RIGHT SIDE UP EXPANSION UNIT CompactCompactBlock LDX PULLPULL PULLPULL RIGHT SIDE UP EXPANSION UNIT CompactCompactBlock LDX PULLPULL PULLPULL RIGHT SIDE UP EXPANSION UNIT CompactCompactBlock LDX PULLPULL PULLPULL RIGHT SIDE UP EXPANSION UNITCompactCompactBlock LDXPULLPULLPULLPULLUPSIDE DOWN EXPANSION UNIT CompactCompactBlock LDX PULLPULL PULLPULL RIGHT SIDE UP The longer expansion cable (1790-15CMCBL) will allow up to 7cm of space between blocks Publication 1790D-TD001B-EP - February 2002 CompactBlock LDX I/O Overview 9 CompactBlock LDX I/O Accessories and DeviceNet Cables CompactBlock LDX I/O Accessories DeviceNet Cables Detailed Block Information The remainder of this publication describes detailed informaton for each CompactBlock LDX I/O block, such as: •schematic diagrams •connection sizes •word/bit definitions •connection wiring diagrams •specifications Description Part Number 5-position open style plug for DeviceNet 1799-DNETCON 5-position open style plug for DeviceNet (with locking screws) 1799-DNETSCON 5-position plug adapter to 12mm male connector, straight 1799-DNC5MMS 7cm LDX I/O replacement ribbon cable (included with expansion module) 1790-7CMCBL 15cm optional LDX I/O ribbon cable (required for vertical mounting) 1790-15CMCBL Description Length m Part Number (aluminum): Part Number (stainless steel): Application: Mini male to conductor (unshielded) 1 1485-P1M5-C 1485RS-P1M5-C DeviceNet drop cable (flat media)6 1485R-P6M5-C 1485RS-P6M5-C Mini male to conductor (shielded) 1 1485R-P1M5-C 1485P-1M5-C DeviceNet drop cable (round media)2 1485R-P2M5-C 1485RS-P2M5-C 3 1485RS-P3M5-C 1485RS-P3M5-C Publication 1790D-TD001B-EP - February 2002 10 Overview CompactBlock LDX I/O Refer to the table below to find information about a specific block. Related Publications Refer to the following list of publications for more information about CompactBlock LDX I/O blocks as well as the DeviceNet network and its products. For information about: See page: DeviceNet Digital and Analog Base and Expansion D-Shell Blocks 11 24VDC, 16 universal input (1790D-16BV0 and 1790-16BV0X) 12 24VDC, 8 universal input/8 sinking output1790D-8BV8V and 1790-8BV8VX) 13 24VDC, 8 universal input/8 sourcing output (1790D-8BV8B and 1790-8BV8BX) 14 24VDC, 16 sourcing output (1790D-0B16 and 1790-0B16X) 14 24VDC, 16 sinking output (1790D-0V16 and 1790-0V16X) 16 6 relay output (1790D-0W6) and 8 relay output (1790-0W8X) 17, 18 4 channel analog current input (1790D-N4C0) 19 4 channel analog voltage input (1790D-N4V0) 20 2 channel analog current output (1790D-N0C2) 21 2 channel analog voltage output (1790D-N0V2) 22 4 channel input RTD base block (1790D-4R0) 23 4 channel input Thermocouple base block (1790D-4T0) 24 DeviceNet Digital and Analog Base and Expansion Terminal Blocks 25 24VDC, 16 universal input (1790D-T16BV0 and 1790-T16BV0X) 26 24VDC, 8 universal input/8 sinking output (1790D-T8BV8V and 1790-T8BV8VX) 27 24VDC, 8 universal input/8 sourcing output (1790D-T8BV8B and 1790-T8BV8BX) 28 24VDC, 16 sourcing output (1790D-T0B16 and 1790-T0B16X) 29 24VDC, 16 sinking output (1790D-T0V16 and 1790-T0V16X) 30 6 relay output (1790D-T0W6 and1790-T0W8X) 31, 32 120VAC, 8 input (1790D-T8A0 and 1790-T8A0X) 33 120VAC, 6 output (1790D-T0A6) and 8 output (1790-T0A8X) 34, 35 4 channel analog current input (1790D-TN4C0) 36 4 channel analog voltage input (1790D-TN4V0) 37 2 channel analog current output (1790D-TN0C2) 38 2 channel analog voltage output (1790D-TN0V2) 39 4 channel input RTD base block (1790D-T4R0) 40 4 channel input Thermocouple base block (1790D-T4T0) 41 Title: Publication Number: CompactBlock LDX I/O Product Profile 1790-PP002B-EN-P DeviceNet Analog Base Terminal Block CompactBlock LDX I/O Installation Instructions 1790-IN002A-EN-P Digital Expansion D-shell Block CompactBlock LDX I/O Installation Instructions 1790-IN003A-EN-P DeviceNet Analog Base D-shell CompactBlock LDX I/O Installation Instructions 1790-IN004A-EN-P Digital Expansion Terminal Block CompactBlock LDX /O Installation Instructions 1790-IN005A-EN-P DeviceNet Digital Base Terminal Block CompactBlock LDX I/O Installation Instructions 1790-IN006A-EN-P DeviceNet Digital Base D-shell Block CompactBlock LDX I/O Installation Instructions 1790-IN007A-EN-P DeviceNet Digital Base RTD and Thermocouple D-shell and Terminal Block CompactBlock LDX I/O Installation Instructions 1790-IN011A-EN-P DeviceNet Selection Guide DNET-SG001A-EN-P DeviceNet Product Overview DN-2.5 DeviceNet Cable System Planning and Installation Manual DN-6.7.2 CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog D-Shell Blocks 11 DeviceNet Digital and Analog D-Shell Blocks The DeviceNet digital and analog D-shell block I/O is exchanged with the master through a poll, change-of-state, or cyclic connection. Polled - a master initiates communication by sending its polled I/O message to the block. The block consumes the message, updates any outputs, and produces a response. If any inputs are present, the response will contain the input data. Change-of-state - productions occur when an input changes. If no input change occurs within the expected packet rate, a heartbeat production occurs. This heartbeat production tells the scanner module that the block is alive and ready to communicate. Consumption occurs when data changes and the master produces new output data to the block. Cyclic - allows configuration of the block as an I/O client. The block will produce and consume its I/O cyclically at the rate configured. The DeviceNet Network uses advanced network technology, producer/consumer communication, to increase network functionality and throughput. Visit our Web site at http://www.ab.com/networks for producer/ consumer technology information and updates. General Specifications The following table contains specifications that are common to all of the DeviceNet base and expansion blocks in this section. Individual block connection sizes, word/bit definitions, schematics, wiring diagrams and specifications are detailed after this table. 1 Refer to publication 1770-4.1, Programmable Controller Wiring and Grounding Guidelines. 1 Refer to publication 1770-4.1, Programmable Controller Wiring and Grounding Guidelines. 2 See the Product Certification link at www.ab.com for Declarations of Conformity, Certificates, and other certification details. Environmental Specifications Operating Temperature 0 to 55°C (32 to 131°F) IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock) Storage Temperature -40 to 85°C (-40 to 185°F) IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bb, Un-packaged Non-operating Dry Heat), IEC 60068-2-14 (Test Na, Un-packaged Non-operating Thermal Shock) Relative Humidity 5-90% non-condensing IEC 60068-2-30 (Test Db, Un-packaged Non-operating) Operating Altitude 2000m Vibration I2g @ 10-500Hz EC60068-2-6 (Test Fc, Operating) Environmental Specifications Shock: Operating Non-operating I0g 30g IEC60068-2-27 Test Ea, (Unpackaged Shock) Emissions Group 1, Class A CISPR 11 ESD Immunity 8kV air discharges IEC 61000-4-2 Radiated RF Immunity 10V/m with 1kHz sine-wave 80%AM from 80MHz to 1000MHz 10V/m with 200Hz 50% Pulse 100%AM @ 900Mhz IEC 61000-4-3 EFT/B Immunity +1kV @ 5kHz on power ports +2kV @ 5kHz on signal ports +2kV @ 5kHz on communications ports IEC 61000-4-4 Surge Transient Immunity +1kV line-line(DM) and +2kV line-earth(CM) on power ports +1kV line-line(DM) and +2kV line-earth(CM) on signal ports +2kV line-earth(CM) on shielded ports IEC 61000-4-5 Conducted RF Immunity 10Vrms with 1kHz sine-wave 80%AM from 150kHzto 80MHz IEC 61000-4-6 Enclosure Type Rating None (open style) Mounting DIN rail or screw Dimensions 52x104x42mm (2.03x4.07x1.64in) Weight 0.3lb (0.1kg) DeviceNet Specifications Network protocol I/O Slave messaging: - Poll command - Bit Strobe command - Cyclic command - COS command Network length 500 meters maximum @ 125Kbps 100 meters maximum @ 500Kbps Indicators 1 red/green module status 1 red/green network status Number of nodes 64 maximum - rotary switch type node address setting Communication rate 125Kbps, 250Kbps, 500Kbps - auto baud rate selection Isolation Type test 1250Vac rms for 60 seconds between field power and DeviceNet (I/O to logic) Wiring Refer to publication DN-6.7.2 General Specifications Wiring Category 21 Product Certifications (when product or packaging is marked) c-UL-us UL Listed for Class I, Division 2 Group A,B,C,D Hazardous Locations, certified for U.S. and Canada CE2 European Union 89/336/EEC EMC Directive, compliant with: EN 50081-2; Industrial Emissions EN 50082-2; Industrial Immunity EN61326; Meas./Control/Lab., Industrial Requirements EN 61000-6-2; Industrial Immunity C-Tick2 Australian Radiocommunications Act, compliant with: AS/NZS 2064; Industrial Emissions ODVA ODVA conformance tested to ODVA DeviceNet specifications Publication 1790D-TD001B-EN-P - February 2002 12 DeviceNet Digital and Analog D-Shell Blocks CompactBlock LDX I/O 24VDC 16 Universal Input Base and Expansion Block - 1790D-16BV0 and 1790-16BV0X Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for D-Shell Connector •For inputs 0-7: Sinking inputs - wire Com 1 to Field Power (+) 24V dc, wire Com 0 to Field Power (-) GND Sourcing inputs - wire Com 1 to Field Power (-) GND, wire Com 0 to Field Power (+) 24V dc •For inputs 8-15: Sinking inputs - wire Com 3 to Field Power (+) 24V dc, wire Com 2 to Field Power (-) GND Sourcing inputs - wire Com 3 to Field Power (-) GND, wire Com 2 to Field Power (+) 24V dc Note: All Com 1 and Com 3 are internally connected - Com 1 is used for inputs 0-7, Com 3 is used for inputs 8-15. Block Specifications Blocks I/O Points Produce (input bytes) Consume (output bytes) 1790D-16BV0, 1790-16BV0X 16 input 2 0 Bit 0706050403020100 Produces 0 I7 I6 I5 I4 I3 I2 I1 I0 Produces 1 I15 I14 I13 I12 I11 I10 I9 I8 Word Bit Description Produces 0 00-07 Input Status bits - when the bit is set (1), the input is on. Bit 00 corresponds to input I0, bit 01 corresponds to input I1, bit 02 corresponds to input I2, bit 03 corresponds to input I3, etc. Produces 1 08-15 Input Status bits - when the bit is set (1), the input is on. Bit 00 corresponds to input I8, bit 01 corresponds to input I9, bit 02 corresponds to input I10, bit 03 corresponds to input I11, etc. Input 24Vdc Opto Isolation +/- -/+ System Circuitry Input Indication LED (logic) COM 1790D-16BVO and 1790-BV0X Inputs per block 16 points, sinking or sourcing On-state voltage 9.6V dc minimum 24V dc nominal 28.8V dc maximum Off-state voltage 5.0V dc maximum On-state current 8mA maximum per channel @ 28.8V dc Nominal input impedance 4.8KΩ Indicators 16 green input status Common type 8 points/8COM (non-polarity) General Specifications DeviceNet Power - base block Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms DeviceNet to logic: non-isolated DeviceNet power: non-isolated Wiring 37-pin D-Shell connector 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 COM0 I0 I1 I2 I3 I4 I5 I6 I7 COM2 I8 I9 I10 I11 I12 I13 I14 I15 COM1 COM1 COM1 COM1 COM1 COM3 COM3 COM3 COM3 COM1 COM1 COM1 COM1 COM3 COM3 COM3 COM3 COM3 CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog D-Shell Blocks 13 24VDC 8 Universal Input/8 Sinking Output Base and Expansion Blocks - 1790D-8BV8V and 1790-8BV8VX Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for D-Shell Connector •Sinking inputs - wire Com 1 to Field Power (+) 24V dc, wire Com 0 to Field Power (-) GND Sourcing inputs - wire Com1 to Field Power (-) GND, wire Com 0 to Field Power (+) 24V dc Note: all Com 1 are internally connected. •Sinking outputs -wire Com 2 to Field Power (+) 24Vdc, wire Com 3 to Field Power (-) GND Note: all Com 2 are internally connected. Block Specifications Blocks I/O Points Produce (input bytes) Consume (output bytes) 1790D-8BV8V and 1790-8BV8VX 8 input / 8 output 11 Bit 0706050403020100 Produces I7 I6 I5 I4 I3 I2 I1 I0 Consumes O7 O6 O5 O4 O3 O2 O1 O0 Word Bit Description Produces 00-07 Input Status bits - when the bit is set (1), the input is on. Bit 00 corresponds to input I0, bit 01 corresponds to input I1, bit 02 corresponds to input I2, bit 03 corresponds to input I3, etc. Consumes 00-07 Output bits - when the bit is set (1), the output is on. Bit 00 corresponds to output O0, bit 01 corresponds to output 01, bit 02 to output 02, bit 03 to output 03, etc. Input Output Input 24Vdc +/- -/+ COM Opto Isolation System Circuitry Input Indication LED (logic) Output Indication LED (logic) System Circuitry Opto Isolation Protected Output Device Vdc Output 24Vdc GND 1790D-8BV8V and 1790-8BV8VX INPUT SPECIFICATIONS Inputs per block 8 points non-isolated, sinking or sourcing On-state voltage 9.6V dc minimum 24V dc nominal 28.8V dc maximum On-state current 8mA maximum per point @ 28.8V dc Off-state voltage 5V dc maximum Nominal input impedance 4.8KΩ Indicators 8 green status Common type 8 points/8COM (non-polarity) OUTPUT SPECIFICATIONS Outputs per block 8 points non-isolated, sinking On-state voltage 10V dc minimum 24V dc nominal 28.8V dc maximum On-state voltage drop 0.5V dc maximum On-state current 1mA minimum per channel Off-state leakage 0.5mA maximum Output signal delay Off to On: 0.5ms maximum On to Off: 1.0ms maximum Indicators 8 green status Output current rating Maximum 0.5A per output 4.0A maximum per common Common type 8 points/8COM General Specifications DeviceNet Power - base block Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply voltage - 24V dc nominal Voltage range - 10-28.8V dc Power dissipation - 6mA @ 28.8V dc per point Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms DeviceNet to logic: non-isolated DeviceNet power: non-isolated Wiring 37-pin D-Shell connector 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 COM0 I0 I1 I2 I3 I4 I5 I6 I7 COM2 O0 O1 O2 O3 O4 O5 O6 O7 COM1 COM1 COM1 COM1 COM1 COM2 COM2 COM2 COM2 COM1 COM1 COM1 COM1 COM3 COM2 COM2 COM2 COM2 Publication 1790D-TD001B-EN-P - February 2002 14 DeviceNet Digital and Analog D-Shell Blocks CompactBlock LDX I/O 24VDC 8 Universal Input/8 Sourcing Output Base and Expansion Blocks - 1790D-8BV8B and 1790-8BV8BX Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for D-Shell Connector •Sinking inputs - wire Com 1 to Field Power (+) 24V dc, wire Com 0 to Field Power (-) GND Sourcing inputs - wire Com1 to Field Power (-) GND, wire Com 0 to Field (+) 24V dc Note: all Com 1 are internally connected. •Sourcing outputs -wire Com 2 to Field Power (+) 24Vdc, wire Com 3 to Field Power (-) GND Note: all Com 3 are internally connected. Block Specifications Blocks I/O Points Produce (input bytes) Consume (output bytes) 1790D-8BV8B, 1790-8BV8BX 8 input / 8 output 11 Bit 0706050403020100 Produces I7 I6 I5 I4 I3 I2 I1 I0 Consumes O7 O6 O5 O4 O3 O2 O1 O0 Word Bit Description Produces 00-07 Input Status bits - when the bit is set (1), the input is on. Bit 00 corresponds to input I0, bit 01 corresponds to input I1, bit 02 corresponds to input I2, bit 03 corresponds to input I3, etc. Consumes 00-07 Output bits - when the bit is set (1), the output is on. Bit 00 corresponds to output O0, bit 01 corresponds to output 01, bit 02 to output 02, bit 03 to output 03, etc. Input Output Input 24Vdc +/- -/+ COM Opto Isolation System Circuitry Input Indication LED (logic) Output Indication LED (logic) System Circuitry Opto Isolation Protected Output Device Vdc Output 24Vdc GND 1790D-8BV8B, 1790-8BV8BX INPUT SPECIFICATIONS Inputs per block 8 points non-isolated, sinking or sourcing On-state voltage 9.6V dc minimum 24V dc nominal 28.8V dc maximum On-state current 8mA maximum per point @ 28.8V dc Off-state voltage 5V dc maximum Nominal input impedance 4.8KΩ Indicators 8 green status Common type 8 points/8COM (non-polarity) OUTPUT SPECIFICATIONS Outputs per block 8 points non-isolated, sourcing On-state voltage 10V dc minimum 24V dc nominal 28.8V dc maximum On-state voltage drop 0.5V dc maximum On-state current 1mA minimum per channel Off-state leakage 0.5mA maximum Output signal delay Off to On: 0.5ms maximum On to Off: 1.0ms maximum Indicators 8 green status Output current rating Maximum 0.5A per output 4.0A maximum per common Common type 8 points/8COM - 1790D-8BV8B General Specifications DeviceNet Power - base block Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply voltage - 24V dc nominal Voltage range - 10-28.8V dc Power dissipation - 6mA @ 28.8V dc per point Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms DeviceNet to logic: non-isolated DeviceNet power: non-isolated Wiring 37-pin D-Shell connector 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 COM0 I0 I1 I2 I3 I4 I5 I6 I7 COM2 O0 O1 O2 O3 O4 O5 O6 O7 COM1 COM1 COM1 COM1 COM1 COM3 COM3 COM3 COM3 COM1 COM1 COM1 COM1 COM3 COM3 COM3 COM3 COM3 CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog D-Shell Blocks 15 24VDC 16 Sourcing Output Base and Expansion Blocks - 1790D-0B16 and 1790-0B16X Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for D-Shell Connector •Sourcing outputs - wire Com 0 and Com 2 to Field Power (+) 24V dc, wire Com 1 and Com 3 to Field Power (-) GND Note: all Com 1 and Com 3 are internally connected. Block Specifications Blocks I/O Points Produce (input bytes) Consume (output bytes) 1790D-0B16 and 1790-OB16X 16 outputs 0 2 Bit 0706050403020100 Consumes 0 O7 O6 O5 O4 O3 O2 O1 O0 Consumes 1 O15 O14 O13 O12 O11 O10 O9 O8 Word Bit Description Consumes 0 00-07 Output bits - when the bit is set (1), the output will be turned on. Bit 00 corresponds to output O0, bit 01 corresponds to output 01, bit 02 to output 02, bit 03 to output 03, etc. Consumes 1 08-15 Output bits - when the bit is set (1), the output will be turned on. Bit 00 corresponds to output O8, bit 01 corresponds to output O9, bit 02 to output O10, bit 03 to output O11, etc. Vdc Output GND 24Vdc 1790D-OB16 and 1790-OB16X Outputs per block 16 points non-isolated, sourcing On-state voltage 10V dc minimum 24V dc nominal 28.8V dc maximum On-state voltage drop 0.5V dc maximum On-state current 1mA minimum per channel Off-state voltage 28.8V dc maximum Off-state leakage 0.5mA maximum Output signal delay Off to On: 0.5ms maximum On to Off: 1.0ms maximum Indicators 16 green status Output current rating Maximum 0.5A per output 4.0A maximum per common Common type 8 points/8COM for 1790D-0B16 General Specifications DeviceNet Power - base block Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply voltage - 24V dc nominal Voltage range - 10-28.8V dc Power dissipation - 6mA @ 28.8V dc per point Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms Wiring 37-pin D-Shell connector 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 COM0 O0 O1 O2 O3 O4 O5 O6 O7 COM2 O8 O9 O10 O11 O12 O13 O14 O15 COM1 COM1 COM1 COM1 COM1 COM3 COM3 COM3 COM3 COM1 COM1 COM1 COM1 COM3 COM3 COM3 COM3 COM3 Output Indication LED (logic) System Circuitry Opto Isolation Protected Output Device Publication 1790D-TD001B-EN-P - February 2002 16 DeviceNet Digital and Analog D-Shell Blocks CompactBlock LDX I/O 24VDC 16 Sinking Output Base and Expansion Blocks - 1790D-0V16 and 1790-0V16X Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for D-Shell Connector •Sinking outputs - wire Com 0 and Com 2 to Field Power (+) 24V dc, wire Com 1 and Com 3 to Field Power (-) GND Note: all Com 0 and Com 2 are internally connected. Block Specifications Blocks I/O Points Produce (input bytes) Consume (output bytes) 1790D-0V16 and 1790-0V16X 16 output 0 2 Bit 0706050403020100 Consumes 0 O7 O6 O5 O4 O3 O2 O1 O0 Consumes 1 O15 O14 O13 O12 O11 O10 O9 O8 Word Bit Description Consumes 0 00-07 Output bits - when the bit is set (1), the output will be turned on. Bit 00 corresponds to output O0, bit 01 corresponds to output 01, bit 02 to output 02, bit 03 to output 03, etc. Consumes 1 08-15 Output bits - when the bit is set (1), the output will be turned on. Bit 00 corresponds to output O8, bit 01 corresponds to output O9, bit 02 to output O10, bit 03 to output O11, etc. Output Indication LED (logic) System Circuitry Opto Isolation Protected Output Device Vdc Output 24Vdc GND 1790D-OV16 and 1790-OV16X Outputs per block 16 points non-isolated, sinking On-state voltage 10V dc minimum 24V dc nominal 28.8V dc maximum On-state voltage drop 0.5V dc maximum On-state current 1mA minimum per channel Off-state voltage 28.8V dc maximum Off-state leakage 0.5mA maximum Output signal delay Off to On: 0.5ms maximum On to Off: 1.0ms maximum Indicators 16 green status Output current rating Maximum 0.5A per output 4.0A maximum per common Common type 8 points/2COM for 1790D-OV16 General Specifications DeviceNet Power - base block Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply voltage - 24V dc nominal Voltage range - 10-28.8V dc Power dissipation - 6mA @ 28.8V dc per point Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms Wiring 37-pin D-Shell connector 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 COM0 O0 O1 O2 O3 O4 O5 O6 O7 COM2 O8 O9 O10 O11 O12 O13 O14 O15 COM1 COM0 COM0 COM0 COM0 COM2 COM2 COM2 COM2 COM0 COM0 COM0 COM0 COM3 COM2 COM2 COM2 COM2 CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog D-Shell Blocks 17 6 Relay Output Base Block - 1790D-0W6 Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for D-Shell Connector •Wire pins 18 and 19 to Field Power (+) 24Vdc Wire pins 36 and 37 to Field Power (-) GND Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790D-0W6 6 outputs 0 1 Bit 050403020100 Consumes 0 O5 O4 O3 O2 O1 O0 Word Bit Description Consumes 0 00-06 Output bits - when the bit is set (1), the output will be turned on. Bit 00 corresponds to output O0, bit 01 corresponds to output 01, bit 02 to output 02, bit 03 to output 03, etc. Output Indication LED (logic) System Circuitry Opto Isolation Vdc Output 24Vdc GND Relay Power Source COM Load + -1790D-OW6 Relay type Form A, normally open Single pole, single throw Output voltage range (load dependent) 5-24V dc @ 2.0A resistive 30V ac @ 2.0A resistive Output current rating (at rated power) 2.0A @ 5-24V dc resistive 2.0A @ 30V dc resistive Minimum load 100µA, 100mV dc per input Maximum on-state voltage drop 0.5V @ 2.0A, resistive load, 24V dc Initial Contact Resistance 30m ohm Expected contact life 300K cycles resistive 100K cycles inductive Maximum off-state leakage 1.5mA maximum Output delay time 10ms maximum on to off or off to on Indicators 6 green status Common type 1 point/1COM General Specifications DeviceNet Power Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply voltage - 24V dc nominal Voltage range - 19.2-28.8V dc Power dissipation - 10mA @ 28.8V dc per channel Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms Wiring 37-pin D-Shell connector 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 +24V CH0 COM0 CH1 COM1 CH2 COM2 CH3 COM3 CH4 COM4 CH5 COM5 NC NC NC NC GND GND +24V Publication 1790D-TD001B-EN-P - February 2002 18 DeviceNet Digital and Analog D-Shell Blocks CompactBlock LDX I/O 8 Relay Output Expansion Block - 1790-0W8X Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for D-Shell Connector •Wire pins 18 and 19 to Field Power (+) 24Vdc Wire pins 36 and 37 to Field Power (-) GND Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790-0W8X 8 outputs 0 1 Bit 0706050403020100 Consumes 0 O7 O6 O5 O4 O3 O2 O1 O0 Word Bit Description Consumes 0 00-08 Output bits - when the bit is set (1), the output will be turned on. Bit 00 corresponds to output O0, bit 01 corresponds to output 01, bit 02 to output 02, bit 03 to output 03, etc. Output Indication LED (logic) System Circuitry Opto Isolation Vdc Output 24Vdc GND Relay Power Source COM Load + -1790-OW8X Relay type Form A, normally open Single pole, single throw Output voltage range (load dependent) 5-24V dc @ 2.0A resistive 30V ac @ 2.0A resistive Output current rating (at rated power) 2.0A @ 5-24V dc resistive 2.0A @ 30V dc resistive Minimum load 100µA, 100mV dc per input Maximum on-state voltage drop 0.5V @ 2.0A, resistive load, 24V dc Initial Contact Resistance 30m ohm Expected contact life 300K cycles resistive 100K cycles inductive Maximum off-state leakage 1.5mA maximum Output delay time 10ms maximum on to off or off to on Indicators 8 green status Common type 1 point/1COM General Specifications Field Power Supply voltage - 24V dc nominal Voltage range - 19.2-28.8V dc Power dissipation - 10mA @ 28.8V dc per channel Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms Wiring 37-pin D-Shell connector 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 +24V CH0 COM0 CH1 COM1 CH2 COM2 CH3 COM3 CH4 COM4 CH5 COM5 CH6 COM6 CH7 COM7 GND GND +24V CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog D-Shell Blocks 19 4 Channel Analog Current Input Block - 1790D-N4C0 Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for D-Shell Connector •Wire pins 17, 18 and 19 to Field Power (+) 24Vdc Wire pins 35, 36 and 37 to Field Power (-) GND Input Data File Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790D-N4C0 4 channel 10 0 Word Decimal Bit Description Read Word 0 Bits 00-11 Channel 0 input data Bits 12-15 Not used: Set to 0 Read Word 1 Bits 00-11 Channel 1 input data Bits 12-15 Not used: Set to 0 Read Word 2 Bits 00-11 Channel 2 input data Bits 12-15 Not used: Set to 0 Read Word 3 Bits 00-11 Channel 3 input data Bits 12-15 Not used: Set to 0 Read Word 4 Bits 00-03 Status bits for individual channels - Bit 00 corresponds to input channel 0, bit 01 corresponds to input channel 1 and so on. When set (1) indicates: •No field power •Open wire (4-20mA current input only) •Under range (4-20mA current input only) •Recoverable module fault (whole channel to be set) •Unrecoverable module fault (whole channel to be set) Bits 04-15 Not used: Set to 0 Analog Input 0 Analog Input 1 Analog Input 2 Analog Input 3 Input 0 Input 1 Input 2 Input 3 Signal Multi- plexer Isolation A/D Signal Control Select Micro controller Xcur Network Optocouplers Indicator LEDs Analog Power Supply Analog Power24VDC Field Power Power Supply Vcc GND System 24VDC Power Isolation Word Bit Position 1514131211109876543210 0 Not Used Analog Input Data Channel 0 1 Not Used Analog Input Data Channel 1 2 Not Used Analog Input Data Channel 2 3 Not Used Analog Input Data Channel 3 4 Not Used S 3 S 2 S 1 S 0 1790D-N4C0 Inputs per module 4 channel single-ended, non-isolated Input Current (software configurable) 4-20mA (default) 0-20mA Resolution 12 bits-unipolar 1/4096 maximum 3.90µA/bit (4-20mA) 4.88µA/bit (0-20mA) Converted Data Binary data 0000 to 0fff (max scale) Conversion Time 10ms/channel Overall accuracy 0.2% Full scale @0°-55°C Calibration None required Input Impedance 249Ω Insulation Resistance 20MΩ minimum @ 250V dc (between insulated circuits) General Specifications DeviceNet Power Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply Voltage - 24Vdc nominal Voltage Range - 21.6-26.4V dc (+10%) Power Dissipation - 1.5W maximum @26.4V dc Isolation I/O to logic: photocoupler isolation Isolation voltage: Type Test 1250V ac rms for 60 seconds DeviceNet to logic: non-isolated Field power: non-isolated Indicators 4 red/green I/O status Wiring 37-pin D-Shell connector IMPORTANT: This analog base module can accommodate a maximum of two discrete expansion modules. 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 +24V +24V CH0 CH1 CH2 CH3 GND GND GND COM COM COM COM +24V Publication 1790D-TD001B-EN-P - February 2002 20 DeviceNet Digital and Analog D-Shell Blocks CompactBlock LDX I/O 4 Channel Analog Voltage Input Block - 1790D-N4V0 Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for D-Shell Connector •Wire pins 17, 18 and 19 to Field Power (+) 24Vdc Wire pins 35, 36 and 37 to Field Power (-) GND Input Data File Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790D-N4V0 4 channel 10 0 Word Decimal Bit Description Read Word 0 Bits 00-11 Channel 0 input data Bits 12-15 Not used: Set to 0 Read Word 1 Bits 00-11 Channel 1 input data Bits 12-15 Not used: Set to 0 Read Word 2 Bits 00-11 Channel 2 input data Bits 12-15 Not used: Set to 0 Read Word 3 Bits 00-11 Channel 3 input data Bits 12-15 Not used: Set to 0 Read Word 4 Bits 00-03 Status bits for individual channels - Bit 00 corresponds to input channel 0, bit 01 corresponds to input channel 1 and so on. When set (1) indicates: •No field power •Open wire (4-20mA current input only) •Under range (4-20mA current input only) •Recoverable module fault (whole channel to be set) •Unrecoverable module fault (whole channel to be set) Bits 04-15 Not used: Set to 0 Analog Input 0 Analog Input 1 Analog Input 2 Analog Input 3 Input 0 Input 1 Input 2 Input 3 Signal Multi- plexer Isolation A/D Signal Control Select Micro controller Xcur Network Optocouplers Indicator LEDs Analog Power Supply Analog Power24VDC Field Power Power Supply Vcc GND System 24VDC Power Isolation Word Bit Position 1514131211109876543210 0 Not Used Analog Input Data Channel 0 1 Not Used Analog Input Data Channel 1 2 Not Used Analog Input Data Channel 2 3 Not Used Analog Input Data Channel 3 4 Not Used S 3 S 2 S 1 S 0 1790D-N4V0 Inputs per module 4 channel single-ended, non-isolated Input Voltage 0-10V Resolution 12 bits-unipolar 1/4096 maximum 2.44mV/bit Converted Data Binary data 0000 to 0fff (max scale) Conversion Time 10ms/channel Overall accuracy 0.2% Full scale @0°-55°C Calibration None required Input Impedance 500KΩ minimum Insulation Resistance 20MΩ minimum @ 250V dc (between insulated circuits) General Specifications DeviceNet Power Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply Voltage - 24Vdc nominal Voltage Range - 21.6-26.4V dc (+10%) Power Dissipation - 1.5W maximum @26.4V dc Isolation I/O to logic: photocoupler isolation Isolation voltage: Type Test 1250V ac rms for 60 seconds DeviceNet to logic: non-isolated Field power: non-isolated Indicators 4 red/green I/O status Wiring 37-pin D-Shell connector IMPORTANT: This analog base module can accommodate a maximum of two discrete expansion modules. 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 +24V +24V CH0 CH1 CH2 CH3 GND GND GND COM COM COM COM +24V CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog D-Shell Blocks 21 2 Channel Analog Current Output Block - 1790D-N0C2 Simplified Schematic Connection Sizes Word/Bit Definitions Output Data File Wiring Diagram for D-Shell Connector •Wire pins 17, 18 and 19 to Field Power (+) 24Vdc Wire pins 35, 36 and 37 to Field Power (-) GND Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790D-N0C2 2 channel 0 4 Word Decimal Bit Description Write Word 0 Bits 00-11 Channel 0 output data Bits 12-15 Not used: Set to 0 Write Word 1 Bits 00-11 Channel 1 output data Bits 12-15 Not used: Set to 0 Word Bit Position 1514131211109876543210 0 Not Used Analog Output Data Channel 0 1 Not Used Analog Output Data Channel 1 Analog Output 0 Analog Output 1 Output 0 Output 1 Isolation D/A Data Control Micro controller Xcur Network Optocouplers Indicator LEDs Analog Power Supply Analog Power24VDC Field Power Power Supply Vcc GND System 24VDC Power Isolation 1790D-N0C2 Outputs per module 2 channel single-ended, non-isolated Output Current 0-20mA Resolution 12 bits 1/4096 maximum 4.88µA/bit Converted Data Binary data 0000 to 0fff (max scale) Conversion Time 2ms/channel Overall accuracy 0.2% Full scale @0°-55°C Calibration None required Allowable external output load resistance 600Ω maximum Insulation Resistance 20MΩ minimum @ 250V dc (between insulated circuits) General Specifications DeviceNet Power Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply Voltage - 24Vdc nominal Voltage Range - 21.6-26.4V dc (+10%) Power Dissipation - 1.5W maximum @26.4V dc Isolation I/O to logic: photocoupler isolation Isolation voltage: Type Test 1250V ac rms for 60 seconds DeviceNet to logic: non-isolated Field power: non-isolated Indicators 2 red/green I/O status Wiring 37-pin D-Shell connector IMPORTANT: This analog base module can accommodate a maximum of two discrete expansion modules. 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 +24V +24V CH0 CH1 GND GND GND COM COM +24V Publication 1790D-TD001B-EN-P - February 2002 22 DeviceNet Digital and Analog D-Shell Blocks CompactBlock LDX I/O 2 Channel Analog Voltage Output Block - 1790D-N0V2 Simplified Schematic Connection Sizes Word/Bit Definitions Output Data File Wiring Diagram for D-Shell Connector •Wire pins 17, 18 and 19 to Field Power (+) 24Vdc Wire pins 35, 36 and 37 to Field Power (-) GND Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790D-N0V2 2 channel 0 4 Word Decimal Bit Description Write Word 0 Bits 00-11 Channel 0 output data Bits 12-15 Not used: Set to 0 Write Word 1 Bits 00-11 Channel 1 output data Bits 12-15 Not used: Set to 0 Word Bit Position 1514131211109876543210 0 Not Used Analog Output Data Channel 0 1 Not Used Analog Output Data Channel 1 Analog Output 0 Analog Output 1 Output 0 Output 1 Isolation D/A Data Control Micro controller Xcur Network Optocouplers Indicator LEDs Analog Power Supply Analog Power24VDC Field Power Power Supply Vcc GND System 24VDC Power Isolation 1790D-N0V2 Outputs per module 2 channel single-ended, non-isolated Output Voltage 0-10V Resolution 12 bits 1/4096 maximum 2.44mV/bit Converted Data Binary data 0000 to 0fff (max scale) Conversion Time 2ms/channel Overall accuracy 0.2% Full scale @0°-55°C Calibration None required Allowable external output load resistance 1KΩ minimum Output Impedance 0.5Ω maximum Insulation Resistance 20MΩ minimum @ 250V dc (between insulated circuits) General Specifications DeviceNet Power Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply Voltage - 24Vdc nominal Voltage Range - 21.6-26.4V dc (+10%) Power Dissipation - 1.5W maximum @26.4V dc Isolation I/O to logic: photocoupler isolation Isolation voltage: Type Test 1250V ac rms for 60 seconds DeviceNet to logic: non-isolated Field power: non-isolated Indicators 2 red/green I/O status Wiring 37-pin D-Shell connector IMPORTANT: This analog base module can accommodate a maximum of two discrete expansion modules. 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 +24V +24V CH0 CH1 GND GND GND COM COM +24V CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog D-Shell Blocks 23 4 Channel Input RTD Base Block - 1790D-4R0 Simplified Schematic Connection Sizes Word/Bit Definitions Input Data File Wiring Diagram for D-Shell Connector •Wire pins 17, 18 and 19 to Field Power (+) 24Vdc Wire pins 35, 36 and 37 to Field Power (-) GND Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790D-4R0 4 channel 10 0 Word Decimal Bit Description Read Word 0 Bits 00-15 Channel 0 input data Read Word 1 Bits 00-15 Channel 1 input data Read Word 2 Bits 00-15 Channel 2 input data Read Word 3 Bits 00-15 Channel 3 input data Read Word 4 Bits 00-03 Underrange for individual channels - Bit 00 corresponds to input channel 0, bit 01 corresponds to input channel 1 and so on. When set (1) the input signal is below the input channel’s minimum range. Bits 04-07 Not used: Set to 0 Bits 08-11 Overrange for individual channels - Bit 08 corresponds to input channel 0, bit 09 corresponds to input channel 1 and so on. When set (1) the input signal is above the input channel’s maximum range, or open RTD is detected. Bits 12-15 Not used: Set to 0 Word Bit Position 1514131211109876543210 0 RTD Input Data Channel 0 1 RTD Input Data Channel 1 2 RTD Input Data Channel 2 3 RTD Input Data Channel 3 4 Not Used S 11 S 10 S 9 S 8 Not Used S 3 S 2 S 1 S 0 Isolation A/D Micro controller Network Vcc Indicator LEDs Analog Power Supply Auxiliary 24VDC Field Power Power Supply Vcc GND System 24VDC Power Isolation Transmit Transceiver GND A-GND Multiplexer A B Com CH0 SENSE0 RTN0 EXC0 Input VA2 VA3 VA1 EXC Current VA1 Vref Vref AIN- AIN+2 AIN+1 Channel Select Recieve UA1 UA2 UA3 A-GND VDC GND 1790D-4R0 Inputs per module 4 channel, RTD/Resistance Input Input Range 1-625 ohm Sensors Supported Sensor Type Degree Counts Resolution Resistance 100mΩ1 to 625Ω10 to 6250 100mΩ Resistance 10mΩ1 to 327Ω100 to 32700 10mΩ 100ohm Pt/α =0.00385 -200 to +850°C -2000 to +8500 0.1°C 200ohm Pt/α =0.00385 -200 to +850°C -2000 to +8500 0.1°C 500ohm Pt/α =0.00385 -200 to +650°C -2000 to +6500 0.1°C 100ohm Pt/α =0.003916 -200 to +640°C -2000 to +6400 0.1°C 200ohm Pt/α =0.003916 -200 to +640°C -2000 to +6400 0.1°C 500ohm Pt/α =0.003916 -200 to +640°C -2000 to +6400 0.1°C 100ohm Nickel -60 to 250°C -600 to 2500 0.1°C 120ohm Nickel -80 to 260°C -800 to 2600 0.1°C 200ohm Nickel -60 to 250°C -600 to 2500 0.1°C 500ohm Nickel -60 to 250°C -600 to 2500 0.1°C Resolution 16 bits across 625ohms, 0.1°C/bit or 0.1°F/bit (RTD Sensors) 20bit Sigma-Delta modulation converter Data Format 16 bit Integer (2’s compliment) Module Scan Time 8ms/channel @ Notch Filter = 60Hz Overall accuracy 0.2% Full scale @0°C-55°C Settable Notch Filter 10Hz (default), 25Hz, 50Hz, 60Hz, 100Hz, 250Hz, 500Hz Open Wire Detection Out of range, open wiring Excitation Current 1mA Input Impedance 5M ohm DeviceNet Power Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply Voltage - 24Vdc nominal Voltage Range - 21.6-26.4V dc (+10%) Power Dissipation - 1.5W maximum @26.4V dc Isolation I/O to logic: photocoupler isolation Isolation voltage: Type Test 1250V ac rms for 60 seconds DeviceNet to logic: non-isolated Field power: non-isolated Indicators 4 red/green I/O status Wiring 37-pin D-Shell connector IMPORTANT: This module does not support any expansion modules. 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 +24V +24V NC NC NC CH0_A CH0_B CH1_A CH1_B NC NC CH2_A CH2_B CH3_A CH3_B NC NC NC GND GND NC COM COM COM COM COM COM GND NC NC COM COM COM COM COM COM +24V Publication 1790D-TD001B-EN-P - February 2002 24 DeviceNet Digital and Analog D-Shell Blocks CompactBlock LDX I/O 4 Channel Input Thermocouple Base Block - 1790D-4T0 Simplified Schematic Connection Sizes Word/Bit Definitions Input Data File Wiring Diagram for D-Shell Connector •Wire pins 17, 18 and 19 to Field Power (+) 24Vdc Wire pins 35, 36 and 37 to Field Power (-) GND Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790D-4T0 4 channel 10 0 Word Decimal Bit Description Read Word 0 Bits 00-15 Channel 0 input data Read Word 1 Bits 00-15 Channel 1 input data Read Word 2 Bits 00-15 Channel 2 input data Read Word 3 Bits 00-15 Channel 3 input data Read Word 4 Bits 00-03 Underrange for individual channels - Bit 00 corresponds to input channel 0, bit 01 corresponds to input channel 1 and so on. When set (1) the input signal is below the input channel’s minimum range. Bits 04-07 Not used: Set to 0 Bits 08-11 Overrange for individual channels - Bit 08 corresponds to input channel 0, bit 09 corresponds to input channel 1 and so on. When set (1) the input signal is above the input channel’s maximum range, or open RTD is detected. Bits 12-15 Not used: Set to 0 Word Bit Position 1514131211109876543210 0 Thermocouple Input Data Channel 0 1 Thermocouple Input Data Channel 1 2 Thermocouple Input Data Channel 2 3 Thermocouple Input Data Channel 3 4 Not Used S 11 S 10 S 9 S 8 Not Used S 3 S 2 S 1 S 0 Isolation A/D Micro controller Network Vcc Indicator LEDs Analog Power Supply Auxiliary 24VDC Field Power Power Supply Vcc GND System 24VDC Power Isolation Transmit Transceiver GND A-GND Multiplexer A B CH0 Input VA2 VA3 VA1 Vref Vref AIN- AIN+ Channel Select Recieve UA1 UA2 UA3 A-GND VDC GND + _ 1790D-4T0 Inputs per module 4 channel, Thermocouple/mV Input Input Range +76.50mV Sensors Supported Sensor Type Range Scaling Voltage 10µV -76.50 to +76.50mV -7650 to +7650 Type B 300 to 1800°C 3000 to 18000 Type E -270 to 1000°C -2700 to 10000 Type J -210 to 1200°C -2100 to 12000 Type K -270 to 1370°C -2700 to 13700 Type R -50 to 1768°C -500 to 17680 Type S -50 to 1768°C -500 to 17680 Type T -270 to 400°C -2700 to 4000 Type N -270 to 1300°C -2700 to 13000 Resolution 16 bits, 0.1°C/bit or 0.1°F/bit (Thermocouple Sensors) 20bit Sigma-Delta modulation converter Data Format 16 bit Integer (2’s compliment) Module Scan Time 140ms/channel @ Notch Filter = 60Hz Overall accuracy 0.2% Full scale @0°C-55°C Settable Notch Filter 10Hz (default), 25Hz, 50Hz, 60Hz, 100Hz, 250Hz, 500Hz Open Wire Detection Out of range, open wiring Cold Junction Compensation Range 0 to 70°C Input Impedance 5M ohm General Specifications DeviceNet Power Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply Voltage - 24Vdc nominal Voltage Range - 21.6-26.4V dc (+10%) Power Dissipation - 1.5W maximum @26.4V dc Isolation I/O to logic: photocoupler isolation Isolation voltage: Type Test 1250V ac rms for 60 seconds DeviceNet to logic: non-isolated Field power: non-isolated Indicators 4 red/green I/O status Wiring 37-pin D-Shell connector IMPORTANT: This module does not support any expansion modules. 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 +24V +24V NC NC NC CH0_A CH0_B CH1_A CH1_B NC NC CH2_A CH2_B CH3_A CH3_B NC NC NC GND GND NC NC NC NC NC NC NC GND NC NC NC NC NC NC NC NC +24V CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog Terminal Blocks 25 DeviceNet Digital and Analog Terminal Blocks The DeviceNet digital and analog terminal block I/O is exchanged with the master through a poll, change-of-state, or cyclic connection. Polled - a master initiates communication by sending its polled I/O message to the block. The block consumes the message, updates any outputs, and produces a response. If any inputs are present, the response will contain the input data. Change-of-state - productions occur when an input changes. If no input change occurs within the expected packet rate, a heartbeat production occurs. This heartbeat production tells the scanner module that the block is alive and ready to communicate. Consumption occurs when data changes and the master produces new output data to the block. Cyclic - allows configuration of the block as an I/O client. The block will produce and consume its I/O cyclically at the rate configured. The DeviceNet Network uses advanced network technology, producer/consumer communication, to increase network functionality and throughput. Visit our Web site at http://www.ab.com/networks for producer/ consumer technology information and updates. General Specifications The following table contains specifications that are common to all of the DeviceNet base and expansion blocks in this section. Individual block connection sizes, word/bit definitions, schematics, wiring diagrams and specifications are detailed after this table. 1 Refer to publication 1770-4.1, Programmable Controller Wiring and Grounding Guidelines. 1 Refer to publication 1770-4.1, Programmable Controller Wiring and Grounding Guidelines. 2 See the Product Certification link at www.ab.com for Declarations of Conformity, Certificates, and other certification details. Environmental Specifications Operating Temperature 0 to 55°C (32 to 131°F) IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock) Storage Temperature -40 to 85°C (-40 to 185°F) IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bb, Un-packaged Non-operating Dry Heat), IEC 60068-2-14 (Test Na, Un-packaged Non-operating Thermal Shock) Relative Humidity 5-90% non-condensing IEC 60068-2-30 (Test Db, Un-packaged Non-operating) Operating Altitude 2000m Vibration I2g @ 10-500Hz EC60068-2-6 (Test Fc, Operating) Environmental Specifications Shock: Operating Non-operating I0g 30g IEC60068-2-27 Test Ea, (Unpackaged Shock) Emissions Group 1, Class A CISPR 11 ESD Immunity 8kV air discharges IEC 61000-4-2 Radiated RF Immunity 10V/m with 1kHz sine-wave 80%AM from 80MHz to 1000MHz 10V/m with 200Hz 50% Pulse 100%AM @ 900Mhz IEC 61000-4-3 EFT/B Immunity +1kV @ 5kHz on power ports +2kV @ 5kHz on signal ports +2kV @ 5kHz on communications ports IEC 61000-4-4 Surge Transient Immunity +1kV line-line(DM) and +2kV line-earth(CM) on power ports +1kV line-line(DM) and +2kV line-earth(CM) on signal ports +2kV line-earth(CM) on shielded ports IEC 61000-4-5 Conducted RF Immunity 10Vrms with 1kHz sine-wave 80%AM from 150kHzto 80MHz IEC 61000-4-6 Enclosure Type Rating None (open style) Mounting DIN rail or screw Dimensions 52x104x42mm (2.03x4.07x1.64in) Weight 0.3lb (0.1kg) DeviceNet Specifications Network protocol I/O Slave messaging: - Poll command - Bit Strobe command - Cyclic command - COS command Network length 500 meters maximum @ 125Kbps 100 meters maximum @ 500Kbps Indicators 1 red/green module status 1 red/green network status Number of nodes 64 maximum - rotary switch type node address setting Communication rate 125Kbps, 250Kbps, 500Kbps - auto baud rate selection Isolation Type test 1250Vac rms for 60 seconds between field power and DeviceNet (I/O to logic) Wiring Refer to publication DN-6.7.2 General Specifications Wiring Category 21 Product Certifications (when product or packaging is marked) c-UL-us UL Listed for Class I, Division 2 Group A,B,C,D Hazardous Locations, certified for U.S. and Canada CE2 European Union 89/336/EEC EMC Directive, compliant with: EN 50081-2; Industrial Emissions EN 50082-2; Industrial Immunity EN61326; Meas./Control/Lab., Industrial Requirements EN 61000-6-2; Industrial Immunity C-Tick2 Australian Radiocommunications Act, compliant with: AS/NZS 2064; Industrial Emissions ODVA ODVA conformance tested to ODVA DeviceNet specifications Publication 1790D-TD001B-EN-P - February 2002 26 DeviceNet Digital and Analog Terminal Blocks CompactBlock LDX I/O 24VDC 16 Universal Input Base and Expansion Blocks - 1790D-T16BV0 and 1790-T16BV0X Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for Terminal Block •For inputs 0-7: Sinking inputs - wire COM 0 (pin 9) to Field Power (-) GND Sourcing inputs - wire COM 0 (pin 9) to Field Power (+) 24V dc •For inputs 8-15: Sinking inputs - wire COM 1 (pin 11) to Field Power (-) GND Sourcing inputs - wire COM 1 (pin 11) to Field Power (+) 24V dc Note: both COM 0 are internally connected - COM 0 is used for inputs 0-7, COM 1 is used for inputs 8-15. Both COM 1 are internally connected. Block Specifications Blocks I/O Points Produce (input bytes) Consume (output bytes) 1790D-T16BV0, 1790-T16BV0X 16 input 2 0 Bit 0706050403020100 Produces 0 I7 I6 I5 I4 I3 I2 I1 I0 Produces 1 I15 I14 I13 I12 I11 I10 I9 I8 Word Bit Description Produces 0 00-07 Input Status bits - when the bit is set (1), the input is on. Bit 00 corresponds to input I0, bit 01 corresponds to input I1, bit 02 corresponds to input I2, bit 03 corresponds to input I3, etc. Produces 1 08-15 Input Status bits - when the bit is set (1), the input is on. Bit 00 corresponds to input I8, bit 01 corresponds to input I9, bit 02 corresponds to input I10, bit 03 corresponds to input I11, etc. Input 24Vdc Opto Isolation +/- -/+ System Circuitry Input Indication LED (logic) COM 1790D-T16BVO and 1790-TBV0X Inputs per block 16 points, sinking or sourcing On-state voltage 9.6V dc minimum 24V dc nominal 28.8V dc maximum Off-state voltage 5.0V dc maximum On-state current 8mA maximum per channel @ 28.8V dc Nominal input impedance 4.8KΩ Indicators 16 green input status Common type 8 points/8COM (non-polarity) General Specifications DeviceNet Power - base block Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms DeviceNet to logic: non-isolated DeviceNet power: non-isolated Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors 2018161412108642 191715131197531 IN15IN11COM1IN7IN3 IN13IN9COM0IN5IN1 IN12IN8COM0IN4IN0 IN14IN10COM1IN6IN2 CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog Terminal Blocks 27 24VDC 8 Universal Input/8 Sinking Output Base and Expansion Blocks - 1790D-T8BV8V and 1790-T8BV8VX Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for Terminal Block •Sinking inputs - wire COM (pin 9) to Field Power (-) GND Sourcing inputs - wire COM (pin 9) to Field Power (+) 24V dc Note: both COM (pins 9 and 10) are internally connected. •Sinking outputs -wire VDC (pin 11) to Field Power (+) 24Vdc, wire GND (pin 12) to Field Power (-) GND Block Specifications Blocks I/O Points Produce (input bytes) Consume (output bytes) 1790D-T8BV8V and 1790-T8BV8VX 8 input / 8 output 11 Bit 0706050403020100 Produces I7 I6 I5 I4 I3 I2 I1 I0 Consumes O7 O6 O5 O4 O3 O2 O1 O0 Word Bit Description Produces 00-07 Input Status bits - when the bit is set (1), the input is on. Bit 00 corresponds to input I0, bit 01 corresponds to input I1, bit 02 corresponds to input I2, bit 03 corresponds to input I3, etc. Consumes 00-07 Output bits - when the bit is set (1), the output is on. Bit 00 corresponds to output O0, bit 01 corresponds to output 01, bit 02 to output 02, bit 03 to output 03, etc. Input Output Input 24Vdc +/- -/+ COM Opto Isolation System Circuitry Input Indication LED (logic) Output Indication LED (logic) System Circuitry Opto Isolation Protected Output Device Vdc Output 24Vdc GND 1790D-T8BV8V and 1790-T8BV8VX INPUT SPECIFICATIONS Inputs per block 8 points non-isolated, sinking or sourcing On-state voltage 9.6V dc minimum 24V dc nominal 28.8V dc maximum On-state current 8mA maximum per point @ 28.8V dc Off-state voltage 5V dc maximum Nominal input impedance 4.8KΩ Indicators 8 green status Common type 8 points/8COM (non-polarity) OUTPUT SPECIFICATIONS Outputs per block 8 points non-isolated, sinking On-state voltage 10V dc minimum 24V dc nominal 28.8V dc maximum On-state voltage drop 0.5V dc maximum On-state current 1mA minimum per channel Off-state leakage 0.5mA maximum Output signal delay Off to On: 0.5ms maximum On to Off: 1.0ms maximum Indicators 8 green status Output current rating Maximum 0.5A per output 4.0A maximum per common Common type 8 points/8COM General Specifications DeviceNet Power - base block Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply voltage - 24V dc nominal Voltage range - 10-28.8V dc Power dissipation - 6mA @ 28.8V dc per point Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms DeviceNet to logic: non-isolated DeviceNet power: non-isolated Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors 2018161412108642 191715131197531 OUT7OUT3GNDIN7IN3 OUT5OUT1COMIN5IN1 OUT4OUT0COMIN4IN0 OUT6OUT2VDCIN6IN2 Publication 1790D-TD001B-EN-P - February 2002 28 DeviceNet Digital and Analog Terminal Blocks CompactBlock LDX I/O 24VDC 8 Universal Input/8 Sourcing Output Base and Expansion Blocks - 1790D-T8BV8B and 1790-T8BV8BX Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for Terminal Block •Sinking inputs - wire COM (pin 9) to Field Power (-) GND Sourcing inputs - wire COM (pin 9) to Field Power (+) 24Vdc Note: both COM (pins 9 and 10) are internally connected. •Sourcing outputs -wire VDC (pin 11) to Field Power (+) 24Vdc, wire GND (pin 12) to Field Power (-) GND Block Specifications Blocks I/O Points Produce (input bytes) Consume (output bytes) 1790D-T8BV8B, 1790-T8BV8BX 8 input / 8 output 11 Bit 0706050403020100 Produces I7 I6 I5 I4 I3 I2 I1 I0 Consumes O7 O6 O5 O4 O3 O2 O1 O0 Word Bit Description Produces 00-07 Input Status bits - when the bit is set (1), the input is on. Bit 00 corresponds to input I0, bit 01 corresponds to input I1, bit 02 corresponds to input I2, bit 03 corresponds to input I3, etc. Consumes 00-07 Output bits - when the bit is set (1), the output is on. Bit 00 corresponds to output O0, bit 01 corresponds to output 01, bit 02 to output 02, bit 03 to output 03, etc. Input Output Input 24Vdc +/- -/+ COM Opto Isolation System Circuitry Input Indication LED (logic) Output Indication LED (logic) System Circuitry Opto Isolation Protected Output Device Vdc Output 24Vdc GND 1790D-T8BV8B, 1790-T8BV8BX INPUT SPECIFICATIONS Inputs per block 8 points non-isolated, sinking or sourcing On-state voltage 9.6V dc minimum 24V dc nominal 28.8V dc maximum On-state current 8mA maximum per point @ 28.8V dc Off-state voltage 5V dc maximum Nominal input impedance 4.8KΩ Indicators 8 green status Common type 8 points/8COM (non-polarity) OUTPUT SPECIFICATIONS Outputs per block 8 points non-isolated, sourcing On-state voltage 10V dc minimum 24V dc nominal 28.8V dc maximum On-state voltage drop 0.5V dc maximum On-state current 1mA minimum per channel Off-state leakage 0.5mA maximum Output signal delay Off to On: 0.5ms maximum On to Off: 1.0ms maximum Indicators 8 green status Output current rating Maximum 0.5A per output 4.0A maximum per common Common type 8 points/8COM - 1790D-8BV8B General Specifications DeviceNet Power - base block Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply voltage - 24V dc nominal Voltage range - 10-28.8V dc Power dissipation - 6mA @ 28.8V dc per point Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms DeviceNet to logic: non-isolated DeviceNet power: non-isolated Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors 2018161412108642 191715131197531 OUT7OUT3GNDIN7IN3 OUT5OUT1COMIN5IN1 OUT4OUT0COMIN4IN0 OUT6OUT2VDCIN6IN2 CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog Terminal Blocks 29 24VDC 16 Sourcing Output Base and Expanxion Blocks - 1790D-T0B16 and 1790-T0B16X Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for Terminal Block •Sourcing outputs - wire VDC0 (pin 9) and VDC1 (pin 11) to Field Power (+) 24V dc, wire GND0 (pin 10) and GND1 (pin 12) to Field Power (-) GND Block Specifications Blocks I/O Points Produce (input bytes) Consume (output bytes) 1790D-T0B16 and 1790-TOB16X 16 outputs 0 2 Bit 0706050403020100 Consumes 0 O7 O6 O5 O4 O3 O2 O1 O0 Consumes 1 O15 O14 O13 O12 O11 O10 O9 O8 Word Bit Description Consumes 0 00-07 Output bits - when the bit is set (1), the output will be turned on. Bit 00 corresponds to output O0, bit 01 corresponds to output 01, bit 02 to output 02, bit 03 to output 03, etc. Consumes 1 08-15 Output bits - when the bit is set (1), the output will be turned on. Bit 00 corresponds to output O8, bit 01 corresponds to output O9, bit 02 to output O10, bit 03 to output O11, etc. Vdc Output GND 24VdcOutput 1790D-TOB16 and 1790-TOB16X Outputs per block 16 points non-isolated, sourcing On-state voltage 10V dc minimum 24V dc nominal 28.8V dc maximum On-state voltage drop 0.5V dc maximum On-state current 1mA minimum per channel Off-state voltage 28.8V dc maximum Off-state leakage 0.5mA maximum Output signal delay Off to On: 0.5ms maximum On to Off: 1.0ms maximum Indicators 16 green status Output current rating Maximum 0.5A per output 4.0A maximum per common Common type 8 points/8COM General Specifications DeviceNet Power - base block Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply voltage - 24V dc nominal Voltage range - 10-28.8V dc Power dissipation - 6mA @ 28.8V dc per point Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors 2018161412108642 191715131197531 OUT15OUT11GND1OUT7OUT3 OUT13OUT9GND0OUT5OUT1 OUT12OUT8VDC0OUT4OUT0 OUT14OUT10VDC1OUT6OUT2 Output Indication LED (logic) System Circuitry Opto Isolation Protected Device Publication 1790D-TD001B-EN-P - February 2002 30 DeviceNet Digital and Analog Terminal Blocks CompactBlock LDX I/O 24VDC 16 Sinking Output Base and Expansion Blocks - 1790D-T0V16 and 1790-T0V16X Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for Terminal Block •Sinking outputs - wire VDC0 (pin 9) and VDC1 (pin 11) to Field Power (+) 24V dc, wire GND0 (pin 10) and GND1 (pin 12) to Field Power (-) GND Block Specifications Blocks I/O Points Produce (input bytes) Consume (output bytes) 1790D-T0V16 and 1790-T0V16X 16 output 0 2 Bit 0706050403020100 Consumes 0 O7 O6 O5 O4 O3 O2 O1 O0 Consumes 1 O15 O14 O13 O12 O11 O10 O9 O8 Word Bit Description Consumes 0 00-07 Output bits - when the bit is set (1), the output will be turned on. Bit 00 corresponds to output O0, bit 01 corresponds to output 01, bit 02 to output 02, bit 03 to output 03, etc. Consumes 1 08-15 Output bits - when the bit is set (1), the output will be turned on. Bit 00 corresponds to output O8, bit 01 corresponds to output O9, bit 02 to output O10, bit 03 to output O11, etc. Output Indication LED (logic) System Circuitry Opto Isolation Protected Output Device Vdc Output 24Vdc GND 1790D-TOV16 and 1790-TOV16X Outputs per block 16 points non-isolated, sinking On-state voltage 10V dc minimum 24V dc nominal 28.8V dc maximum On-state voltage drop 0.5V dc maximum On-state current 1mA minimum per channel Off-state voltage 28.8V dc maximum Off-state leakage 0.5mA maximum Output signal delay Off to On: 0.5ms maximum On to Off: 1.0ms maximum Indicators 16 green status Output current rating Maximum 0.5A per output 4.0A maximum per common Common type 8 points/2COM General Specifications DeviceNet Power - base block Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply voltage - 24V dc nominal Voltage range - 10-28.8V dc Power dissipation - 6mA @ 28.8V dc per point Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors 2018161412108642 191715131197531 OUT15OUT11GND1OUT7OUT3 OUT13OUT9GND0OUT5OUT1 OUT12OUT8VDC0OUT4OUT0 OUT14OUT10VDC1OUT6OUT2 CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog Terminal Blocks 31 6 Relay Output Base Block - 1790D-T0W6 Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for Terminal Block •Wire VDC (pin 1) to Field Power (+) 24Vdc Wire GND (pin 2) to Field Power (-) GND Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790D-T0W6 6 outputs 0 1 Bit 050403020100 Consumes 0 O5 O4 O3 O2 O1 O0 Word Bit Description Consumes 0 00-06 Output bits - when the bit is set (1), the output will be turned on. Bit 00 corresponds to output O0, bit 01 corresponds to output 01, bit 02 to output 02, bit 03 to output 03, etc. Output Indication LED (logic) System Circuitry Opto Isolation Vdc Output 24Vdc GND Relay Power Source COM Load + -1790D-TOW6 Relay type Form A, normally open Single pole, single throw Output voltage range (load dependent) 5-24V dc @ 2.0A resistive 30V ac @ 2.0A resistive 125V ac @ 2.0A resistive 250V ac @ 2.0A resistive Output current rating (at rated power) 2.0A @ 5-24V dc resistive 2.0A @ 30V dc resistive Minimum load 100µA, 100mV dc per input Maximum on-state voltage drop 0.5V @ 2.0A, resistive load, 24V dc Initial Contact Resistance 30m ohm Expected contact life 300K cycles resistive 100K cycles inductive Maximum off-state leakage 1.5mA maximum Output delay time 10ms maximum on to off or off to on Indicators 6 green status Common type 1 point/1COM General Specifications DeviceNet Power Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply voltage - 24V dc nominal Voltage range - 19.2-28.8V dc Power dissipation - 10mA @ 28.8V dc per channel Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors 2018161412108642 191715131197531 NCCOM5COM3COM1NC NCCOM4COM2COM0GND NCOUT4OUT2OUT0VDC NCOUT5OUT3OUT1NC Publication 1790D-TD001B-EN-P - February 2002 32 DeviceNet Digital and Analog Terminal Blocks CompactBlock LDX I/O 8 Relay Output Expansion Block - 1790-T0W8X Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for Terminal Block •Wire VDC (pin 1) to Field Power (+) 24Vdc Wire GND (pin 2) to Field Power (-) GND Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790-T0W8X 8 outputs 0 1 Bit 0706050403020100 Consumes 0 O7 O6 O5 O4 O3 O2 O1 O0 Word Bit Description Consumes 0 00-08 Output bits - when the bit is set (1), the output will be turned on. Bit 00 corresponds to output O0, bit 01 corresponds to output 01, bit 02 to output 02, bit 03 to output 03, etc. Output Indication LED (logic) System Circuitry Opto Isolation Vdc Output 24Vdc GND Relay Power Source COM Load + -1790-TOW8X Relay type Form A, normally open Single pole, single throw Output voltage range (load dependent) 5-24V dc @ 2.0A resistive 30V ac @ 2.0A resistive 125V ac @ 2.0A resistive 250V ac @ 2.0A resistive Output current rating (at rated power) 2.0A @ 5-24V dc resistive 2.0A @ 30V dc resistive Minimum load 100µA, 100mV dc per input Maximum on-state voltage drop 0.5V @ 2.0A, resistive load, 24V dc Initial Contact Resistance 30m ohm Expected contact life 300K cycles resistive 100K cycles inductive Maximum off-state leakage 1.5mA maximum Output delay time 10ms maximum on to off or off to on Indicators 8 green status Common type 1 point/1COM General Specifications Field Power Supply voltage - 24V dc nominal Voltage range - 19.2-28.8V dc Power dissipation - 10mA @ 28.8V dc per channel Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors 2018161412108642 191715131197531 NCCOM6COM4COM2COM0 COM7COM5COM3COM1GND OUT7OUT5OUT3OUT1VDC NCOUT6OUT4OUT2OUT0 CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog Terminal Blocks 33 120VAC 8 Input Base and Expansion Blocks - 1790D-T8A0 and 1790-T8A0X Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for Terminal Block •Wire 120Vac Field Power to VAC (pin 1) and COM (pin 2) Note: all VAC are internally connected. All COM are internally connected. Block Specifications Blocks I/O Points Produce (input bytes) Consume (output bytes) 1790D-T8A0 and 1790-T8A0X 8 inputs 1 0 Bit 0706050403020100 Consumes 0 O7 O6 O5 O4 O3 O2 O1 O0 Word Bit Description Consumes 0 00-08 Input bits - when the bit is set (1), the input will be turned on. Bit 00 corresponds to input O0, bit 01 corresponds to input 01, bit 02 to input 02, bit 03 to input 03, etc. Input Indication LED (logic) System Circuitry Opto Isolation COM COM Input Vac 120Vac Power Input Device 1790D-T8AO and 1790-T8A0X Inputs per block 8 points non-isolated On-state voltage range 79V ac minimum 110V ac nominal 132V ac maximum Input impedance 18K ohm On-state current 9mA maximum @132V ac Off-state voltage 45V ac maximum Input signal delay 10ms off to on 30ms maximum on to off Indicators 8 green input status Common type 8 points/8COM General Specifications DeviceNet Power - base block Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc External AC power supply Supply voltage - 110V rms, 60Hz Voltage range - 85-132Vrms, 47-63Hz Power dissipation - 3W @ 132Vac Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms/V ac Field power: non-isolation Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors Recommended Fusing 1A, 250V, Normal Blow 2018161412108642 191715131197531 COMCOMCOMCOMCOM COMCOMCOMCOMCOM IN6IN4IN2IN0VAC IN7IN5IN3IN1VAC Publication 1790D-TD001B-EN-P - February 2002 34 DeviceNet Digital and Analog Terminal Blocks CompactBlock LDX I/O 120VAC, 6 Output Base Block - 1790D-T0A6 Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for Terminal Block •Wire 120Vac Field Power to VAC (pin 1) and COM (pin 2) Note: all VAC are internally connected. All COM are internally connected. Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790D-T0A6 6 outputs 0 1 Bit 050403020100 Consumes 0 O5 O4 O3 O2 O1 O0 Word Bit Description Consumes 0 00-06 Output bits - when the bit is set (1), the output will be turned on. Bit 00 corresponds to output O0, bit 01 corresponds to output 01, bit 02 to output 02, bit 03 to output 03, etc. Output Indication LED (logic) System Circuitry Opto Isolation OutputOutput Device Vac External Fuse* Load COM COM 120Vac Power *1A, 250V, Normal Blow 1790D-T0A6 Outputs per expansion block 6 points non-isolated Load voltage range 15-132Vrms Maximum load current 0.5Arms Minimum load current 10mArms Max off-state leakage current 1.0mArms @ 100Vrms 60Hz Max on-state voltage drop 1.3Vrms @ max load Maximum operate time 1mS Maximum release 1/2 cycle + 1mS Insulation resistance Minimum 1,000MΩ (for input-output) Dielectric strength 2500 Vrms 1 minute (for input-output) Input signal delay 10ms off to on 30ms maximum on to off Indicators 6 green input status Common type 6 points/6COM General Specifications DeviceNet Power Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc External AC power supply Supply voltage - 110V rms, 60Hz Voltage range - 15-132Vrms, 60Hz Power dissipation - 3.9W @ rated current Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms/V ac Field power: non-isolation Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors Recommended Fusing 1A, 250V, Normal Blow 2018161412108642 191715131197531 NCCOMCOMCOMCOM NCCOMCOMCOMCOM NC0UT40UT20UT0VAC NC0UT50UT30UT1VAC CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog Terminal Blocks 35 120VAC, 8 Output Base Block - 1790-T0A8X Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for Terminal Block •Wire 120Vac Field Power to VAC (pin 1) and COM (pin 2) Note: all VAC are internally connected. All COM are internally connected. Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790-T0A8X 8 outputs 0 1 Bit 0706050403020100 Consumes 0 O7 O6 O5 O4 O3 O2 O1 O0 Word Bit Description Consumes 0 00-08 Output bits - when the bit is set (1), the output will be turned on. Bit 00 corresponds to output O0, bit 01 corresponds to output 01, bit 02 to output 02, bit 03 to output 03, etc. Output Indication LED (logic) System Circuitry Opto Isolation OutputOutput Device Vac External Fuse* Load COM COM 120Vac Power *1A, 250V, Normal Blow 1790-T0A8X Outputs per expansion block 8 points non-isolated Load voltage range 15-132Vrms Maximum load current 0.5Arms Minimum load current 10mArms Max off-state leakage current 1.0mArms @ 100Vrms 60Hz Max on-state voltage drop 1.3Vrms @ max load Maximum operate time 1mS Maximum release 1/2 cycle + 1mS Insulation resistance Minimum 1,000MΩ (for input-output) Dielectric strength 2500 Vrms 1 minute (for input-output) Input signal delay 10ms off to on 30ms maximum on to off Indicators 8 green input status Common type 8 points/8COM General Specifications External AC power supply Supply voltage - 110V rms, 60Hz Voltage range - 15-132Vrms, 60Hz Power dissipation - 5.2W @ rated current Isolation I/O to logic: photocoupler isolation Isolation voltage: 1250V ac rms/V ac Field power: non-isolation Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors 2018161412108642 191715131197531 COMCOMCOMCOMCOM COMCOMCOMCOMCOM OUT60UT40UT20UT0VAC OUT70UT50UT30UT1VAC Publication 1790D-TD001B-EN-P - February 2002 36 DeviceNet Digital and Analog Terminal Blocks CompactBlock LDX I/O 4 Channel Analog Current Input Block - 1790D-TN4C0 Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for Terminal Block •Wire pin 1 to Field Power (+) 24Vdc Wire pin 2 to Field Power (-) GND Input Data File Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790D-TN4C0 4 channel 10 0 Word Decimal Bit Description Read Word 0 Bits 00-11 Channel 0 input data Bits 12-15 Not used: Set to 0 Read Word 1 Bits 00-11 Channel 1 input data Bits 12-15 Not used: Set to 0 Read Word 2 Bits 00-11 Channel 2 input data Bits 12-15 Not used: Set to 0 Read Word 3 Bits 00-11 Channel 3 input data Bits 12-15 Not used: Set to 0 Read Word 4 Bits 00-03 Status bits for individual channels - Bit 00 corresponds to input channel 0, bit 01 corresponds to input channel 1 and so on. When set (1) indicates: •No field power •Open wire (4-20mA current input only) •Under range (4-20mA current input only) •Recoverable module fault (whole channel to be set) •Unrecoverable module fault (whole channel to be set) Bits 04-15 Not used: Set to 0 Analog Input 0 Analog Input 1 Analog Input 2 Analog Input 3 Input 0 Input 1 Input 2 Input 3 Signal Multi- plexer Isolation A/D Signal Control Select Micro controller Xcur Network Optocouplers Indicator LEDs Analog Power Supply Analog Power24VDC Field Power Power Supply Vcc GND System 24VDC Power Isolation Word Bit Position 1514131211109876543210 0 Not Used Analog Input Data Channel 0 1 Not Used Analog Input Data Channel 1 2 Not Used Analog Input Data Channel 2 3 Not Used Analog Input Data Channel 3 4 Not Used S 3 S 2 S 1 S 0 1790D-TN4C0 Inputs per module 4 channel single-ended, non-isolated Input Current (software configurable) 4-20mA (default) 0-20mA Resolution 12 bits-unipolar 1/4096 maximum 3.90µA/bit (4-20mA) 4.88µA/bit (0-20mA) Converted Data Binary data 0000 to 0fff (max scale) Conversion Time 10ms/channel Overall accuracy 0.2% Full scale @0°-55°C Calibration None required Input Impedance 249Ω Insulation Resistance 20MΩ minimum @ 250V dc (between insulated circuits) General Specifications DeviceNet Power Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply Voltage - 24Vdc nominal Voltage Range - 21.6-26.4V dc (+10%) Power Dissipation - 1.5W maximum @26.4V dc Isolation I/O to logic: photocoupler isolation Isolation voltage: Type Test 1250V ac rms for 60 seconds DeviceNet to logic: non-isolated Field power: non-isolated Indicators 4 red/green I/O status Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors IMPORTANT: This analog base module can accommodate a maximum of two discrete expansion modules. 2018161412108642 191715131197531 NCNCNCCOM2COM0 NCNCCOM3COM1GND NCNCCH3CH1+24V NCNCNCCH2CH0 CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog Terminal Blocks 37 4 Channel Analog Voltage Input Block - 1790D-TN4V0 Simplified Schematic Connection Sizes Word/Bit Definitions Wiring Diagram for Terminal Block • Wire pin 1 to Field Power (+) 24Vdc Wire pin 2 to Field Power (-) GND Input Data File Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790D-TN4V0 4 channel 10 0 Word Decimal Bit Description Read Word 0 Bits 00-11 Channel 0 input data Bits 12-15 Not used: Set to 0 Read Word 1 Bits 00-11 Channel 1 input data Bits 12-15 Not used: Set to 0 Read Word 2 Bits 00-11 Channel 2 input data Bits 12-15 Not used: Set to 0 Read Word 3 Bits 00-11 Channel 3 input data Bits 12-15 Not used: Set to 0 Read Word 4 Bits 00-03 Status bits for individual channels - Bit 00 corresponds to input channel 0, bit 01 corresponds to input channel 1 and so on. When set (1) indicates: •No field power •Open wire (4-20mA current input only) •Under range (4-20mA current input only) •Recoverable module fault (whole channel to be set) •Unrecoverable module fault (whole channel to be set) Bits 04-15 Not used: Set to 0 Analog Input 0 Analog Input 1 Analog Input 2 Analog Input 3 Input 0 Input 1 Input 2 Input 3 Signal Multi- plexer Isolation A/D Signal Control Select Micro controller Xcur Network Optocouplers Indicator LEDs Analog Power Supply Analog Power24VDC Field Power Power Supply Vcc GND System 24VDC Power Isolation Word Bit Position 1514131211109876543210 0 Not Used Analog Input Data Channel 0 1 Not Used Analog Input Data Channel 1 2 Not Used Analog Input Data Channel 2 3 Not Used Analog Input Data Channel 3 4 Not Used S 3 S 2 S 1 S 0 1790D-TN4V0 Inputs per module 4 channel single-ended, non-isolated Input Voltage 0-10V Resolution 12 bits-unipolar 1/4096 maximum 2.44mV/bit Converted Data Binary data 0000 to 0fff (max scale) Conversion Time 10ms/channel Overall accuracy 0.2% Full scale @0°-55°C Calibration None required Input Impedance 500KΩ minimum Insulation Resistance 20MΩ minimum @ 250V dc (between insulated circuits) General Specifications DeviceNet Power Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply Voltage - 24Vdc nominal Voltage Range - 21.6-26.4V dc (+10%) Power Dissipation - 1.5W maximum @26.4V dc Isolation I/O to logic: photocoupler isolation Isolation voltage: Type Test 1250V ac rms for 60 seconds DeviceNet to logic: non-isolated Field power: non-isolated Indicators 4 red/green I/O status Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors IMPORTANT: This analog base module can accommodate a maximum of two discrete expansion modules. 2018161412108642 191715131197531 NCNCNCCOM2COM0 NCNCCOM3COM1GND NCNCCH3CH1+24V NCNCNCCH2CH0 Publication 1790D-TD001B-EN-P - February 2002 38 DeviceNet Digital and Analog Terminal Blocks CompactBlock LDX I/O 2 Channel Analog Current Output Block - 1790D-TN0C2 Simplified Schematic Connection Sizes Word/Bit Definitions Output Data File Wiring Diagram for Terminal Block •Wire pin 1 to Field Power (+) 24Vdc Wire pin 2 to Field Power (-) GND Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790D-TN0C2 2 channel 0 4 Word Decimal Bit Description Write Word 0 Bits 00-11 Channel 0 output data Bits 12-15 Not used: Set to 0 Write Word 1 Bits 00-11 Channel 1 output data Bits 12-15 Not used: Set to 0 Word Bit Position 1514131211109876543210 0 Not Used Analog Output Data Channel 0 1 Not Used Analog Output Data Channel 1 Analog Output 0 Analog Output 1 Output 0 Output 1 Isolation D/A Data Control Micro controller Xcur Network Optocouplers Indicator LEDs Analog Power Supply Analog Power24VDC Field Power Power Supply Vcc GND System 24VDC Power Isolation 1790D-TN0C2 Outputs per module 2 channel single-ended, non-isolated Output Current 0-20mA Resolution 12 bits 1/4096 maximum 4.88µA/bit Converted Data Binary data 0000 to 0fff (max scale) Conversion Time 2ms/channel Overall accuracy 0.2% Full scale @0°-55°C Calibration None required Allowable external output load resistance 600Ω maximum Insulation Resistance 20MΩ minimum @ 250V dc (between insulated circuits) General Specifications DeviceNet Power Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply Voltage - 24Vdc nominal Voltage Range - 21.6-26.4V dc (+10%) Power Dissipation - 1.5W maximum @26.4V dc Isolation I/O to logic: photocoupler isolation Isolation voltage: Type Test 1250V ac rms for 60 seconds DeviceNet to logic: non-isolated Field power: non-isolated Indicators 2 red/green I/O status Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors IMPORTANT: This analog base module can accommodate a maximum of two discrete expansion modules. 2018161412108642 191715131197531 NCNCNCNCCOM0 NCNCNCCOM1GND NCNCNCCH1+24V NCNCNCNCCH0 CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog Terminal Blocks 39 2 Channel Analog Voltage Output Block - 1790D-TN0V2 Simplified Schematic Connection Sizes Word/Bit Definitions Output Data File Wiring Diagram for Terminal Block •Wire pin 1 to Field Power (+) 24Vdc Wire pin 2 to Field Power (-) GND Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790D-TN0V2 2 channel 0 4 Word Decimal Bit Description Write Word 0 Bits 00-11 Channel 0 output data Bits 12-15 Not used: Set to 0 Write Word 1 Bits 00-11 Channel 1 output data Bits 12-15 Not used: Set to 0 Word Bit Position 1514131211109876543210 0 Not Used Analog Output Data Channel 0 1 Not Used Analog Output Data Channel 1 Analog Output 0 Analog Output 1 Output 0 Output 1 Isolation D/A Data Control Micro controller Xcur Network Optocouplers Indicator LEDs Analog Power Supply Analog Power24VDC Field Power Power Supply Vcc GND System 24VDC Power Isolation 1790D-TN0V2 Outputs per module 2 channel single-ended, non-isolated Output Voltage 0-10V Resolution 12 bits 1/4096 maximum 2.44mV/bit Converted Data Binary data 0000 to 0fff (max scale) Conversion Time 2ms/channel Overall accuracy 0.2% Full scale @0°-55°C Calibration None required Allowable external output load resistance 1KΩ minimum Output Impedance 0.5Ω maximum Insulation Resistance 20MΩ minimum @ 250V dc (between insulated circuits) General Specifications DeviceNet Power Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply Voltage - 24Vdc nominal Voltage Range - 21.6-26.4V dc (+10%) Power Dissipation - 1.5W maximum @26.4V dc Isolation I/O to logic: photocoupler isolation Isolation voltage: Type Test 1250V ac rms for 60 seconds DeviceNet to logic: non-isolated Field power: non-isolated Indicators 2 red/green I/O status Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors IMPORTANT: This analog base module can accommodate a maximum of two discrete expansion modules. 2018161412108642 191715131197531 NCNCNCNCCOM0 NCNCNCCOM1GND NCNCNCCH1+24V NCNCNCNCCH0 Publication 1790D-TD001B-EN-P - February 2002 40 DeviceNet Digital and Analog Terminal Blocks CompactBlock LDX I/O 4 Channel Input RTD Base Block - 1790D-T4R0 Simplified Schematic Connection Sizes Word/Bit Definitions Input Data File Wiring Diagram for Terminal Block •Wire pin 1 to Field Power (+) 24Vdc Wire pin 2 to Field Power (-) GND Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790D-T4R0 4 channel 10 0 Word Decimal Bit Description Read Word 0 Bits 00-15 Channel 0 input data Read Word 1 Bits 00-15 Channel 1 input data Read Word 2 Bits 00-15 Channel 2 input data Read Word 3 Bits 00-15 Channel 3 input data Read Word 4 Bits 00-03 Underrange for individual channels - Bit 00 corresponds to input channel 0, bit 01 corresponds to input channel 1 and so on. When set (1) the input signal is below the input channel’s minimum range. Bits 04-07 Not used: Set to 0 Bits 08-11 Overrange for individual channels - Bit 08 corresponds to input channel 0, bit 09 corresponds to input channel 1 and so on. When set (1) the input signal is above the input channel’s maximum range, or open RTD is detected. Bits 12-15 Not used: Set to 0 Word Bit Position 1514131211109876543210 0 RTD Input Data Channel 0 1 RTD Input Data Channel 1 2 RTD Input Data Channel 2 3 RTD Input Data Channel 3 4 Not Used S 11 S 10 S 9 S 8 Not Used S 3 S 2 S 1 S 0 Isolation A/D Micro controller Network Vcc Indicator LEDs Analog Power Supply Auxiliary 24VDC Field Power Power Supply Vcc GND System 24VDC Power Isolation Transmit Transceiver GND A-GND Multiplexer A B Com CH0 SENSE0 RTN0 EXC0 Input VA2 VA3 VA1 EXC Current VA1 Vref Vref AIN- AIN+2 AIN+1 Channel Select Recieve UA1 UA2 UA3 A-GND VDC GND 1790D-T4R0 Inputs per module 4 channel, RTD/Resistance Input Input Range 1-625 ohm Sensors Supported Sensor Type Degree Counts Resolution Resistance 100mΩ1 to 625Ω10 to 6250 100mΩ Resistance 10mΩ1 to 327Ω100 to 32700 10mΩ 100ohm Pt/α =0.00385 -200 to +850°C -2000 to +8500 0.1°C 200ohm Pt/α =0.00385 -200 to +850°C -2000 to +8500 0.1°C 500ohm Pt/α =0.00385 -200 to +650°C -2000 to +6500 0.1°C 100ohm Pt/α =0.003916 -200 to +640°C -2000 to +6400 0.1°C 200ohm Pt/α =0.003916 -200 to +640°C -2000 to +6400 0.1°C 500ohm Pt/α =0.003916 -200 to +640°C -2000 to +6400 0.1°C 100ohm Nickel -60 to 250°C -600 to 2500 0.1°C 120ohm Nickel -80 to 260°C -800 to 2600 0.1°C 200ohm Nickel -60 to 250°C -600 to 2500 0.1°C 500ohm Nickel -60 to 250°C -600 to 2500 0.1°C Resolution 16 bits across 625ohms, 0.1°C/bit or 0.1°F/bit (RTD Sensors) 20bit Sigma-Delta modulation converter Data Format 16 bit Integer (2’s compliment) Module Scan Time 8ms/channel @ Notch Filter = 60Hz Overall accuracy 0.2% Full scale @0°C-55°C Settable Notch Filter 10Hz (default), 25Hz, 50Hz, 60Hz, 100Hz, 250Hz, 500Hz Open Wire Detection Out of range, open wiring Excitation Current 1mA Input Impedance 5M ohm DeviceNet Power Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply Voltage - 24Vdc nominal Voltage Range - 21.6-26.4V dc (+10%) Power Dissipation - 1.5W maximum @26.4V dc Isolation I/O to logic: photocoupler isolation Isolation voltage: Type Test 1250V ac rms for 60 seconds DeviceNet to logic: non-isolated Field power: non-isolated Indicators 4 red/green I/O status Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors IMPORTANT: This module does not support any expansion modules. 2018161412108642 191715131197531 NCNCCH3_BCOMCH0_B NCCOMCH2_BCH1_BGND NCCOMCH2_ACH1_A+24V NCNCCH3_ACOMCH0_A CompactBlock LDX I/O Publication 1790D-TD001B-EN-P - February 2002 DeviceNet Digital and Analog Terminal Blocks 41 4 Channel Input Thermocouple Base Block - 1790D-T4T0 Simplified Schematic Connection Sizes Word/Bit Definitions Input Data File Wiring Diagram for Terminal Block •Wire pin 1 to Field Power (+) 24Vdc Wire pin 2 to Field Power (-) GND Block Specifications Block I/O Points Produce (input bytes) Consume (output bytes) 1790D-T4T0 4 channel 10 0 Word Decimal Bit Description Read Word 0 Bits 00-15 Channel 0 input data Read Word 1 Bits 00-15 Channel 1 input data Read Word 2 Bits 00-15 Channel 2 input data Read Word 3 Bits 00-15 Channel 3 input data Read Word 4 Bits 00-03 Underrange for individual channels - Bit 00 corresponds to input channel 0, bit 01 corresponds to input channel 1 and so on. When set (1) the input signal is below the input channel’s minimum range. Bits 04-07 Not used: Set to 0 Bits 08-11 Overrange for individual channels - Bit 08 corresponds to input channel 0, bit 09 corresponds to input channel 1 and so on. When set (1) the input signal is above the input channel’s maximum range, or open RTD is detected. Bits 12-15 Not used: Set to 0 Word Bit Position 1514131211109876543210 0 Thermocouple Input Data Channel 0 1 Thermocouple Input Data Channel 1 2 Thermocouple Input Data Channel 2 3 Thermocouple Input Data Channel 3 4 Not Used S 11 S 10 S 9 S 8 Not Used S 3 S 2 S 1 S 0 Isolation A/D Micro controller Network Vcc Indicator LEDs Analog Power Supply Auxiliary 24VDC Field Power Power Supply Vcc GND System 24VDC Power Isolation Transmit Transceiver GND A-GND Multiplexer A B CH0 Input VA2 VA3 VA1 Vref Vref AIN- AIN+ Channel Select Recieve UA1 UA2 UA3 A-GND VDC GND + _ 1790D-T4T0 Inputs per module 4 channel, Thermocouple/mV Input Input Range +76.50mV Sensors Supported Sensor Type Range Scaling Voltage 10µV -76.50 to +76.50mV -7650 to +7650 Type B 300 to 1800°C 3000 to 18000 Type E -270 to 1000°C -2700 to 10000 Type J -210 to 1200°C -2100 to 12000 Type K -270 to 1370°C -2700 to 13700 Type R -50 to 1768°C -500 to 17680 Type S -50 to 1768°C -500 to 17680 Type T -270 to 400°C -2700 to 4000 Type N -270 to 1300°C -2700 to 13000 Resolution 16 bits, 0.1°C/bit or 0.1°F/bit (Thermocouple Sensors) 20bit Sigma-Delta modulation converter Data Format 16 bit Integer (2’s compliment) Module Scan Time 140ms/channel @ Notch Filter = 60Hz Overall accuracy 0.2% Full scale @0°C-55°C Settable Notch Filter 10Hz (default), 25Hz, 50Hz, 60Hz, 100Hz, 250Hz, 500Hz Open Wire Detection Out of range, open wiring Cold Junction Compensation Range 0 to 70°C Input Impedance 5M ohm General Specifications DeviceNet Power Supply voltage - 24V dc nominal Voltage range - 11-28.8V dc Power dissipation - 1.2W maximum @ 28.8V dc Field Power Supply Voltage - 24Vdc nominal Voltage Range - 21.6-26.4V dc (+10%) Power Dissipation - 1.5W maximum @26.4V dc Isolation I/O to logic: photocoupler isolation Isolation voltage: Type Test 1250V ac rms for 60 seconds DeviceNet to logic: non-isolated Field power: non-isolated Indicators 4 red/green I/O status Wiring Terminal block (M3.0) - screw torque: 7 inch-pounds maximum (use copper or copper-clad aluminum conductors IMPORTANT: This module does not support any expansion modules. 2018161412108642 191715131197531 NCNCCH3_BNCCH0_B NCNCCH2_BCH1_BGND NCNCCH2_ACH1_A+24V NCNCCH3_ANCCH0_A Notes Notes Publication 1790D-TD001B-EN-P - February 2002 44 PN 957678-44 Supersedes Publication 1790-TD001A-EN-P - September 2001 Copyright © 2002 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A. Allen-Bradley, PLC, PLC-5 and SLC are registered trademarks of Rockwell Automation, Inc. 1336 PLUS, ArmorBlock, CompactBlock I/O, DeviceLink, DeviceView, DTAM, Ezlink, FLEX I/O, RSNetWorx for DeviceNet, SMC Dialog Plus, SoftLogix, SMP-3 and SSC are trademarks of Rockwell Automation, Inc. DeviceNet is a trademark of Open DeviceNet Vendor Association. Extract from the online catalog Plug component, nominal current: 12 A, rated voltage: 250 V, pitch: 5.0 mm, no. of positions: 5, type of connection: Screw connection Order No.1786860 Ord designation MSTB 2,5/ 5-STF EAN 4017918042820 Pack 50 Pcs. Customs tariff 85366990 Weight/Piece 0,0096 KG Catalog page information Page 175 (CC-2007) Product notes WEEE/RoHS-compliant since:01/01/2003 IMPORTANT : This date is valid for Customers in Germany only. Date Format is MM/DD/YYYY.Please contact your local in-country Phoenix Contact location or designated business partner for a Logistics Compliant date in your area.In order to guarantee delivery of RoHS-Compliant product, please purchase Phoenix Contact parts from authorized Phoenix Contact representatives and distributors. MSTB 2,5/ 5-STF Please note that the data given here has been taken from the online catalog. For comprehensive information and data, please refer to the user documentation at http://www.download.phoenixcontact.com. The General Terms and Conditions of Use apply to Internet downloads. PHOENIX CONTACT GmbH & Co. KG http://www.phoenixcontact.com May 11, 2007 Page 1/10 Technical data MSTB 2,5/ 5-STF PHOENIX CONTACT GmbH & Co. KG http://www.phoenixcontact.com May 11, 2007 Page 2/10 Dimensions / positions Pitch 5 mm Dimension a 20 mm Number of positions 5 Screw thread M 3 Tightening torque, min 0.5 Nm Technical data Insulating material group I Rated surge voltage (III/3) 4 kV Rated surge voltage (III/2) 4 kV Rated surge voltage (II/2) 4 kV Rated voltage (III/2) 320 V Rated voltage (II/2) 630 V Connection in acc. with standard EN-VDE Nominal current IN 12 A Nominal voltage UN 250 V Nominal cross section 2.5 mm2 Maximum load current 12 A (with 2.5 mm2 conductor cross section) Insulating material PA Inflammability class acc. to UL 94 V0 Internal cylindrical gage A3 Stripping length 7 mm Connection data Conductor cross section solid min. 0.2 mm2 Conductor cross section solid max. 2.5 mm2 Conductor cross section stranded min. 0.2 mm2 Conductor cross section stranded max. 2.5 mm2 Conductor cross section stranded, with ferrule without plastic sleeve min. 0.25 mm2 Conductor cross section stranded, with ferrule without plastic sleeve max. 2.5 mm2 Conductor cross section stranded, with ferrule with plastic sleeve min. 0.25 mm2 Conductor cross section stranded, with ferrule with plastic sleeve max. 2.5 mm2 Conductor cross section AWG/kcmil min. 24 Conductor cross section AWG/kcmil max 12 2 conductors with same cross section, solid min. 0.2 mm2 2 conductors with same cross section, solid max. 1 mm2 2 conductors with same cross section, stranded min. 0.2 mm2 2 conductors with same cross section, stranded max. 1.5 mm2 2 conductors with same cross section, stranded, ferrules without plastic sleeve, min. 0.25 mm2 2 conductors with same cross section, stranded, ferrules without plastic sleeve, max. 1 mm2 2 conductors with same cross section, stranded, TWIN ferrules with plastic sleeve, min. 0.5 mm2 2 conductors with same cross section, stranded, TWIN ferrules with plastic sleeve, max. 1.5 mm2 MSTB 2,5/ 5-STF PHOENIX CONTACT GmbH & Co. KG http://www.phoenixcontact.com May 11, 2007 Page 3/10 Certificates / Approvals Certificate logos CSA Nominal voltage UN 300 V Nominal current I N 10 A AWG/kcmil 28-12 CUL Nominal voltage UN 300 V Nominal current IN 12 A AWG/kcmil 30-12 UL Nominal voltage U N 300 V Nominal current I N 12 A AWG/kcmil 30-12 MSTB 2,5/ 5-STF PHOENIX CONTACT GmbH & Co. KG http://www.phoenixcontact.com May 11, 2007 Page 6/10 Drawings Diagram Dimensioned drawing MSTB 2,5/ 5-STF PHOENIX CONTACT GmbH & Co. KG http://www.phoenixcontact.com May 11, 2007 Page 7/10 Accessories Item Designation Description General 1733169 EBP 2- 5 Insertion bridge, fully insulated, for plug connectors with 5.0 or 5.08 mm pitch, no. of positions: 2 Marking 0804183 SK 5/3,8:FORTL.ZAHLEN Marker card, printed horizontally, self-adhesive, 12 identical decades marked 1-10, 11-20 etc. up to 91-(99)100, sufficient for 120 terminal blocks Plug/Adapter 1734634 CP-MSTB Coding section, is inserted into the slot on the plug or inverted header, red insulating material Tools 1205053 SZS 0,6X3,5 Screwdriver, bladed, matches all screw terminal blocks up to 4.0 mm² connection cross section, blade: 0.6 x 3.5 mm, without VDE approval MSTB 2,5/ 5-STF PHOENIX CONTACT GmbH & Co. KG http://www.phoenixcontact.com May 11, 2007 Page 8/10 Additional products Item Designation Description General 0710057 DFK-MSTB 2,5/ 5-GF Header, nominal current: 12 A, rated voltage: 320 V, pitch: 5.0 mm, no. of positions: 5, mounting: Direct mounting 1900109 EMSTB 2,5/ 5-GF Header, nominal current: 12 A, rated voltage: 250 V, pitch: 5.0 mm, no. of positions: 5, mounting: press in 1914084 EMSTBV 2,5/ 5-GF Header, nominal current: 12 A, rated voltage: 200 V, pitch: 5.0 mm, no. of positions: 5, mounting: press in 1846726 MDSTB 2,5/ 5-GF Header, nominal current: 10 A, rated voltage: 250 V, pitch: 5.0 mm, number of positions: 5, mounting type: soldering 1846111 MDSTBV 2,5/ 5-GF Header, nominal current: 10 A, rated voltage: 250 V, pitch: 5.0 mm, number of positions: 5, mounting type: soldering 1776728 MSTB 2,5/ 5-GF Header, nominal current: 12 A, rated voltage: 250 V, pitch: 5.0 mm, no. of positions: 5, mounting: Soldering 1776919 MSTBV 2,5/ 5-GF Header, nominal current: 12 A, rated voltage: 250 V, pitch: 5.0 mm, no. of positions: 5, mounting: Soldering MSTB 2,5/ 5-STF PHOENIX CONTACT GmbH & Co. KG http://www.phoenixcontact.com May 11, 2007 Page 9/10 Address PHOENIX CONTACT GmbH & Co. KG Flachsmarktstr. 8 32825 Blomberg Germany Phone +49 5235 3 00 Fax +49 5235 3 41200 http://www.phoenixcontact.com Phoenix Contact Technical modifications reserved; MSTB 2,5/ 5-STF PHOENIX CONTACT GmbH & Co. KG http://www.phoenixcontact.com May 11, 2007 Page 10/10 Rockwell Software 3 For more information visit: www.software.rockwell.com RSLogix Programming for Allen-Bradley PLC-5, SLC 500, MicroLogix, and Logix5000 FamiliesProgramming for Allen-Bradley PLC-5, SLC 500, MicroLogix, and Logix5000 Families he RSLogix™family of ladder logic programming packages helps you maximize performance, save project development time, and improve productivity. This family of products has been developed to operate on Microsoft’s Windows®operating systems. Supporting the Allen-Bradley SLC 500™and MicroLogix™families of processors, RSLogix 500™ was the first PLC®programming software to offer unbeatable productivity with an industry-leading user interface. RSLogix 5™supports the Allen- Bradley PLC-5®family of programmable controllers. RSLogix 5000™provides support for the Logix5000’s Highly Integrated Motion functionality. RSLogix offers reliable communications, powerful functionality, and superior diagnostics. These RSLogix products share: • Flexible, easy-to-use editors • Common look-and-feel • Diagnostics and troubleshooting tools • Powerful, time-saving features & functionality RSLogix programming packages are compatible with programs created with Rockwell Software’s DOS- based programming packages for the PLC-5 or SLC 500 and MicroLogix families of processors, making program maintenance across hardware platforms convenient and easy. Interoperability Rockwell Software provides you with the most powerful and complete programming products available today in the RSLogix family. The interoperability between RSLogix and Rockwell Software’s HMI package, RSView32™, and communication package, RSLinx™, positions RSLogix as the ultimate programming solution. With the Rockwell Software family of products, you have the ability to share your database with RSView32. You can create schematic drawings of your system directly from your RSLogix project using RSWire™, automatically tune PID loops with RSTune™, trend critical application parameters with RSTrend™, or test and debug your ladder logic programs using RSLogix Emulate 5™or RSLogix Emulate 500™. T RSLogix 9324-RL5300ENE RSLogix 5 Programming for the PLC-5®Family 9324-RL0300ENE RSLogix 500 Programming for the SLC 500 and MicroLogix Families 9324-RLD300ENE RSLogix 5000 Programming for the Logix5000 Family 9324-RL5300NXENE RSLogix 5 with RSNetWorx for ControlNet 9324-RLC300ENE RSLogix 5/RSLogix 500 Programming for the PLC-5 Family and Programming for the SLC 500 and MicroLogix Families Bundle 9324-RL5700NXENE RSLogix 5 Professional 9324-RL0700NXENE RSLogix 500 Professional 9324-RL0100ENE RSLogix 500 Starter 9324-RLD700ENE RSLogix 5000 Professional, ENU 1 PRODUCT OVERVIEW PowerSuite Software Version 2.0 takes the programming and monitoring of Altivar AC drive controllers, Altistart soft start controllers, and TeSys U-line motor starters to a new level. The features of PowerSuite Software V2.0 are described in this data bulletin. For descriptions of Altivar (ATV) drive controllers, Altistart (ATS) soft start controllers, and TeSys U-line motor starters, visit the Motor Control products pages at www.us.SquareD.com, or contact your local Schneider Electric field office. DESCRIPTION PowerSuite Software V2.0 is a Windows®-compatible program providing an intuitive configuration environment for ATV11, ATV28, ATV31, ATV58 TRX, and ATV58 Type FVC drive controllers, ATS48 soft start controllers, and TeSys U-line motor starters. The software is designed to run on •Any PC using Microsoft® Windows 95, Windows 98, Windows 2000, Windows NT® 4.0, or Windows XP® operating systems •A Pocket PC (PPC) with an Intel® Xscale® processor and Windows 2003 for PPC. Compaq® iPAQ™ 2210, iPAQ 3970, and HP® Jornada® 565 PPCs have been tested and approved for use with PowerSuite Software V2.0. Contact Drives Product Support for updates on PPC product compatibility. FEATURES OF POWERSUITE SOFTWARE V2.0 PowerSuite Software V2.0 allows you to •Commission the device •Create and modify configuration files and store them on a PC •Transfer data to and from the device and the PC •Print a hard copy of the device configuration for reference •Start, stop, and run the device \PowerSuite Software V2.0 uses the same familiar interface as PowerSuite Software V1.5 for ATV28, ATV58 TRX, and ATV58 Type FVC drive controllers, ATS48 soft start controllers, and TeSys U-line motor starters. Start, Stop, and Run Devices from the User Interface Data Bulletin 8806DB0001R5/04 05/2004 Raleigh, NC, USA Replaces 8806DB0001R4/03 dated 4/03 PowerSuite™ Software Version 2.0 For Altivar® AC Drive Controllers, Altistart® 48 Soft Start Controllers, and TeSys™ U-Line Motor Starters PowerSuite™ Software Version 2.0 8806DB0001R5/04 New Features of PowerSuite Software V2.0 05/2004 © 2000–2004 Schneider Electric All Rights Reserved2 NEW FEATURES OF POWERSUITE SOFTWARE V2.0 With Version 2.0, PowerSuite Software now allows you to •Configure all of the supported devices in your plant at once with the explorer-type user interface •Assign meaningful names to the devices that relate them to their functions in the process •Move among all of the configured devices without closing programs by double clicking on the device icon •Define a generic product configuration and use the same configuration for similar devices •Include a drawing or photograph of each device when it is created •Manage multiple projects, large projects, or multiple plant locations from individual directories In addition: •New explorer-type interfaces for the ATV11 and ATV31 drive controllers allow easy navigation among the parameters. •A 4-pen strip chart recorder is available for ATV31 controllers. Each pen can be configured and scaled for a particular parameter. Data can be captured for later display, for comparison to other data, or for analysis in a database spreadsheet. Explorer-Type User Interface Apply One Configuration to Several Devices New Interface for ATV11 and ATV31 Drives Eases Navigation Among Parameters 4-Pin Strip Chart Recorder Available for ATV31 Drives 8806DB0001R5/04 PowerSuite™ Software Version 2.0 05/2004 PowerSuite Software Compatibility and Product List © 2000–2004 Schneider Electric All Rights Reserved 3 POWERSUITE SOFTWARE COMPATIBILITY AND PRODUCT LIST 1 Contact Drives Product Support for additional information about Ethernet to Modbus bridges. Table 1: PowerSuite Software Version Compatibility with AC Drives, Soft Starters, and Motor Starters PowerSuite Software compatibility with AC drives, soft starters, and motor starters Motor Starter Soft Starter AC Drives TeSys U-line ATS48 ATV11 ATV28 ATV31 ATV58 TRX and ATV58 Type FVC PowerSuite Software with serial link for PC Kit and CD-ROM VW3A8104 VW3A8105 PowerSuite Software Version ≥ V1.40 PowerSuite Software Version ≥ V1.30 PowerSuite Software Version ≥ V1.40 PowerSuite Software Version ≥ V1.00 PowerSuite Software Version ≥ V2.00 PowerSuite Software Version ≥ V1.00 PowerSuite Software with Ethernet link for PC Kit and CD-ROM VW3A8104 VW3A8105 PowerSuite Software Version ≥ V1.50 and Ethernet Modbus Bridge1 PowerSuite Software Version ≥ V1.50 and Ethernet Modbus Bridge1 PowerSuite Software Version ≥ V2.00 and Ethernet Modbus Bridge1 PowerSuite Software Version ≥ V1.50 and Ethernet Option Card PowerSuite Software for Pocket PC Kit and CD-ROM VW3A8104 VW3A8105 PowerSuite Software Version ≥ V1.50 PowerSuite Software Version ≥ V1.30 PowerSuite Software Version ≥ V1.40 PowerSuite Software Version ≥ V1.20 PowerSuite Software Version ≥ V2.00 PowerSuite Software Version ≥ V1.20 Compatible products and software Non compatible products Table 2: PowerSuite Software Version Compatibility with Pocket PCs Operating System: Performance tested on models: PowerSuite Software V1.30 PowerSuite Software V1.40 PowerSuite Software V1.50 PowerSuite Software V2.00 Windows for Pocket PC 2003 Compaq iPAQ series 2210 no no no yes Windows for Pocket PC 2002 Compaq iPAQ series 3800, 3900 no no yes yes HP Jornada series 560 no yes yes yes Windows for Pocket PC 2000 HP Jornada series 525 yes yes yes no Windows CE HP Jornada series 420 yes no no no Table 3: PowerSuite Products Available from Schneider Electric Catalog No. Description VW3A8104 PowerSuite commissioning software on CD VW3A8105 PowerSuite upgrade CD • Software for PC and PPC • Technical documentation and ABC Configurator Program VW3A8106 PC connection kit. Includes the following to connect a PC to an ATV11, ATV28, ATV31, ATV58, ATS48, or TeSys U-line controller: • 1 m cable with RJ45 connectors • RS-232 to RS-485 adapter with RJ45 and DB9 female connectors • RJ45 to DB9 male adapter for use with an ATV58 controller • Cable adapter for use with an ATV11 controller, VW3A11301 VW3A8111 Pocket PC connection kit. Includes the following to connect a JORNADA or iPAQ PPC to an ATV11, ATV28, ATV31, ATV58, ATS48, or TeSys U-line controller: • 1/2 m cable with RJ45 connectors • RS-232 to RS-485 adapter with RJ45 and DB9 male connectors • RJ45 to DB9 male adapter for use with an ATV58 controller • Cable adapter for use with an ATV11 controller, VW3A11301 VW3A11301 RS-485 cable adapter for use with the ATV11 controller PowerSuite™ Software Version 2.0 8806DB0001R5/04 Data Bulletin 05/2004 Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material. © 2000–2004 Schneider Electric All Rights Reserved Schneider Electric USA 8001 Highway 64 East Knightdale, NC 27545 1-888-SquareD (1-888-778-2733) www.us.SquareD.com CONNECTIONS ATV28 Controller ATV31 Controller ATS48 ControllerLUCMATV11 Controller Cable Adapter (Attaches to RJ45 Connector) (Base Unit Attaches to RJ45 Connector) ATV58 Controller DB9 Male RJ45 PC Connections Using Kit VW3A8106 (See Table 1 for Kit Contents) PPC Connections Using Kit VW3A8111 (See Table 1 for Kit Contents) RS-232/RS-485 PC Adapter PC RJ45 DB9 Female RS-232/RS-485 PC Adapter Serial Connection Cable (2) JORNADA or iPAQ Pocket PC (1) Pocket PC RJ45 DB9 Female OR RJ45 Ethernet Cable 1 Contact Drives Product Support for the current PPC compatibility list. 2 Contact the Pocket PC manufacturer for information on serial communication cables. 37146 User Manual Software version 3.1 Manual 37146 LeoPC1 User Manual LeoPC1 User Manual © Woodward Governor Company Page 2/2 37146 WARNING Read this entire manual and all other publications pertaining to the work to be performed before install- ing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage. Important Definitions WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. Appropriate precautions have to be taken. CAUTION Indicates important notes for setting and defining parameters. Please pay attention in configuration of the software. NOTE References to other notes and supplements as well as tables and lists are identified by means of the "i" symbol. Most of the referenced sections are included in the Annex. Woodward Governor Company reserves the right to update any portion of this publication at any time. Information provided by Wood- ward Governor Company is believed to be correct and reliable. However, Woodward Governor Company assumes no responsibility unless otherwise expressly undertaken. © Woodward Governor Company All Rights Reserved Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 3/3 Contents CHAPTER 1. GENERAL INFORMATION.........................................................................................7 General Points ........................................................................................................................................7 Helpful Information about the Manual.....................................................................................................8 CHAPTER 2. COMMISSIONING ....................................................................................................9 Installation...............................................................................................................................................9 Components of the Installation.....................................................................................................9 Procedure for Installation............................................................................................................10 Procedure for De-installing.........................................................................................................16 Loading a Plant Configuration...............................................................................................................17 General Configuration...........................................................................................................................22 Components of the General Configuration.................................................................................22 Procedure for General Configuration..........................................................................................23 Dynamic Configuration..........................................................................................................................33 Components of the Dynamic Configuration................................................................................33 Procedure for Dynamic Configuration ........................................................................................33 CHAPTER 3. PROPERTIES OF LEOPC1 ....................................................................................35 Displays.................................................................................................................................................35 Components of the Display.........................................................................................................35 Procedure for Displays ...............................................................................................................36 Configuration.........................................................................................................................................38 Components of the Configuration...............................................................................................38 Procedure for Configuration........................................................................................................39 Inputs (Configuration and Standard Values).........................................................................................41 Standard Values....................................................................................................................................45 Components of the Standard Values..........................................................................................45 Procedure for the Standard Values............................................................................................45 Remote Control.....................................................................................................................................48 Components of the Remote Control...........................................................................................48 Procedure for the Remote Control..............................................................................................49 Data Logging.........................................................................................................................................51 Procedure for Data Logging........................................................................................................52 Short-term Storage................................................................................................................................56 Components of the Short-term Storage......................................................................................56 Procedure for Short-term Storage ..............................................................................................57 Alarm Management...............................................................................................................................60 Components of the Alarm Management.....................................................................................60 Procedure for Alarm Management .............................................................................................61 Loading Languages ..............................................................................................................................64 Components of Loading Languages...........................................................................................64 Procedure for Load Language....................................................................................................65 Event Recorder.....................................................................................................................................67 Components of the Event Recorder...........................................................................................67 Procedure for the Event Recorder..............................................................................................67 LeoPC1 User Manual © Woodward Governor Company Page 4/4 37146 CHAPTER 4. COMMUNICATION AND CONNECTION .................................................................... 69 General Information.............................................................................................................................. 69 Communication with Devices ............................................................................................................... 69 Drivers for Serial Interfaces........................................................................................................ 69 Components of the Drivers for Serial Interfaces........................................................................ 70 Procedure for Serial Drivers....................................................................................................... 70 Drivers for Network Cards.......................................................................................................... 76 Components of the Network Card Drivers ................................................................................. 76 Procedure for Network Card Drivers.......................................................................................... 76 Communication with Other Applications............................................................................................... 81 CSV Interface............................................................................................................................. 81 Components of the CSV Interface ............................................................................................. 81 Procedure for the CSV Interface................................................................................................81 CHAPTER 5. ANNEX ................................................................................................................ 83 Content of the Software Package......................................................................................................... 83 Directories and Designation of the Installed Component Files.................................................. 83 Registration Data Base .............................................................................................................. 84 FAQ....................................................................................................................................................... 86 Listing of Selected Error Messages ........................................................................................... 86 No faults are logged in an Error File. .........................................................................................86 The Data for Data Logging is stored in the Swap File and not in a Normal File........................ 86 The PC has crashed. Is my Logging Data now lost?................................................................. 86 Driver Settings are reset again and again.................................................................................. 86 Why is the Logo of the LeoPC1 not printed out? ....................................................................... 86 Starting the Configuration the Message appears: "File not found *.opt".................................... 86 Is Communication possible via COM Interface (direct, Gateway RS-232), if the Laptop/PC doesn’t have a (free) COM Port? ............................................................................................... 87 You cannot configure! ................................................................................................................ 87 How to Contact Woodward................................................................................................................... 89 Internet Download of the Software....................................................................................................... 89 Engineering Services............................................................................................................................ 90 Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 5/5 Illustrations and Tables Illustrations Figure 2.1 Start installation......................................................................................................................................................11 Figure 2.2 Select components..................................................................................................................................................12 Figure 2.3 Select language.......................................................................................................................................................12 Figure 2.4 Finish installation ...................................................................................................................................................13 Figure 2.5 Open User Login ....................................................................................................................................................14 Figure 2.6 User Login..............................................................................................................................................................14 Figure 2.7 Open User Management.........................................................................................................................................14 Figure 2.8 User Management...................................................................................................................................................15 Figure 2.9 Open Tools menu....................................................................................................................................................18 Figure 2.10 Search directory....................................................................................................................................................18 Figure 2.11 Open Device Settings ...........................................................................................................................................19 Figure 2.12 Enable Program Modules......................................................................................................................................20 Figure 2.13 Open Device Settings ...........................................................................................................................................20 Figure 2.14 General Options....................................................................................................................................................20 Figure 2.15 Open User Login ..................................................................................................................................................23 Figure 2.16 User Login............................................................................................................................................................23 Figure 2.17 Open User Management.......................................................................................................................................23 Figure 2.18 User Management.................................................................................................................................................24 Figure 2.19 Open System Settings...........................................................................................................................................25 Figure 2.20 System Settings.....................................................................................................................................................25 Figure 2.21 Open System Settings...........................................................................................................................................26 Figure 2.22 Path variables for CFG files..................................................................................................................................27 Figure 2.23 Open Device Settings ...........................................................................................................................................28 Figure 2.24 General Options....................................................................................................................................................28 Figure 2.25 Drivers..................................................................................................................................................................29 Figure 2.26 Remote control and Displays................................................................................................................................29 Figure 2.27 Open Device Settings ...........................................................................................................................................30 Figure 2.28 Service Configuration...........................................................................................................................................30 Figure 2.29 Open Device Settings ...........................................................................................................................................31 Figure 2.30 Enable Program Modules......................................................................................................................................32 Figure 2.31 Open Refresh Configuration.................................................................................................................................33 Figure 2.32 Refresh Configuration - Start................................................................................................................................33 Figure 2.33 Refresh Configuration - End.................................................................................................................................34 Figure 2.34 Re-load configuration...........................................................................................................................................34 Figure 3.1 Open Device Settings .............................................................................................................................................36 Figure 3.2 General Options......................................................................................................................................................36 Figure 3.3 Open View menu....................................................................................................................................................37 Figure 3.4 Select View Levels.................................................................................................................................................37 Figure 3.5 Open Parameterize..................................................................................................................................................39 Figure 3.6 Parameterize...........................................................................................................................................................39 Figure 3.7 Enter Password.......................................................................................................................................................40 Figure 3.8 Enter A Number......................................................................................................................................................41 Figure 3.9 Set Flags.................................................................................................................................................................41 Figure 3.10 Set a Connector Group..........................................................................................................................................42 Figure 3.11 Insert Yes/No........................................................................................................................................................42 Figure 3.12 Select Text............................................................................................................................................................42 Figure 3.13 Insert Text.............................................................................................................................................................43 Figure 3.14 Input Relay ...........................................................................................................................................................43 Figure 3.15 Logics Manager....................................................................................................................................................44 Figure 3.16 Open Standard Values ..........................................................................................................................................46 Figure 3.17 Standard Values....................................................................................................................................................46 Figure 3.18 Enter Password.....................................................................................................................................................47 Figure 3.19 Open Device Settings ...........................................................................................................................................49 Figure 3.20 General Options....................................................................................................................................................49 Figure 3.21 Open Remote Control...........................................................................................................................................50 Figure 3.22 Remote Control.....................................................................................................................................................50 LeoPC1 User Manual © Woodward Governor Company Page 6/6 37146 Figure 3.23 Open System Settings...........................................................................................................................................52 Figure 3.24 System Settings ....................................................................................................................................................52 Figure 3.25 Open Data Logging ..............................................................................................................................................53 Figure 3.26 Data Logging........................................................................................................................................................53 Figure 3.27 Data Logging - Parameter.....................................................................................................................................54 Figure 3.28 Data Logging - Scaling.........................................................................................................................................54 Figure 3.29 Open Short-term Storage......................................................................................................................................57 Figure 3.30 Short-term Storage................................................................................................................................................57 Figure 3.31 Short-term Storage - Settings................................................................................................................................58 Figure 3.32 Short-term Storage - Protocol...............................................................................................................................60 Figure 3.33 Open Device Settings...........................................................................................................................................61 Figure 3.34 General Options....................................................................................................................................................61 Figure 3.35 Open Alarm Management.....................................................................................................................................62 Figure 3.36 Alarm Management..............................................................................................................................................62 Figure 3.37 Manual Input Into Error List.................................................................................................................................62 Figure 3.38 Open Current Alarms............................................................................................................................................63 Figure 3.39 Current Alarms.....................................................................................................................................................63 Figure 3.40 Open Parameterize................................................................................................................................................65 Figure 3.41 Enter Password.....................................................................................................................................................65 Figure 3.42 Open Load Language............................................................................................................................................65 Figure 3.43 Load Language.....................................................................................................................................................66 Figure 3.44 Open Event Recorder............................................................................................................................................67 Figure 3.45 Event Recorder.....................................................................................................................................................68 Figure 4.1 Direct interface.......................................................................................................................................................70 Figure 4.2 Gateway RS-232 interface......................................................................................................................................70 Figure 4.3 Modem interface.....................................................................................................................................................70 Figure 4.4 Open Device Settings.............................................................................................................................................71 Figure 4.5 General Options......................................................................................................................................................71 Figure 4.6 Settings for Serial Drivers ......................................................................................................................................71 Figure 4.7 Driver Timeouts Handling......................................................................................................................................72 Figure 4.8 Settings for Modem................................................................................................................................................74 Figure 4.9 Open Device Settings.............................................................................................................................................74 Figure 4.10 General Options....................................................................................................................................................75 Figure 4.11 CAN bus interface................................................................................................................................................76 Figure 4.12 Open Device Settings...........................................................................................................................................77 Figure 4.13 General Options....................................................................................................................................................77 Figure 4.14 CAN Settings........................................................................................................................................................78 Figure 4.15 CAN-Hardware.....................................................................................................................................................78 Figure 4.16 CAN Settings - Options........................................................................................................................................79 Figure 4.18 Settings – Demo Version......................................................................................................................................80 Figure 4.19 Open System Settings...........................................................................................................................................81 Figure 4.20 System Settings ....................................................................................................................................................81 Figure 4.21 Open Data Logging ..............................................................................................................................................82 Figure 4.22 Save Export ..........................................................................................................................................................82 Tables Table 4.1 Driver settings - Serial.............................................................................................................................................72 Table 4.2 Driver settings - Modem..........................................................................................................................................73 Table 5.1 Component files – Installation.................................................................................................................................83 Table 5.2 Registration Software keys – Main..........................................................................................................................84 Table 5.3 Registration Software keys – Language and Help...................................................................................................84 Table 5.4 Registration Software keys – Environment and DL.................................................................................................85 Table 5.5 Registration Software keys – Drivers ......................................................................................................................85 Table 5.6 FAQ – Error descriptions.........................................................................................................................................86 Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 7/7 Chapter 1. General Information General Points ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ LeoPC1 provides you with a Windows-based program for your PC or laptop, that offers support for the handling of selected measuring instruments as well as open-loop and closed-loop control devices. The following functions are supported they are installed on the device as well: Display of measured variables or the logical statuses of your plant Configuration of the configurable devices used in your plant Standard values of your devices can be stored for reloading or transferring Remote control of the controllable devices used in your plant Logging of selected data and measured values or events of your plant Events of the corresponding devices can be read out and printed Language management and loading for the display of your adaptable devices Alarm logging, management and preparation for your plant The devices differ in level of support: Full support of all functions Limited support of the functionality No device not supported The degree of support depends on the product the year of manufacture, and what external devices are to be used with the product. NOTE Please refer to the corresponding documentation for the specific devices to see what support utilities your devices permits in terms of operator control with the LeoPC1. LeoPC1 utilizes permits management of access rights. These access rights are graduated in the degree of access to the programming. It is differentiated between: Administrative access to all functions and settings is permitted Level 2 authorized access to all functions permitted Level 1 authorized access to data logging functions only Access denied access to all functions and settings are blocked Should a component described in this manual not be available, please contact your system administrator. The system administrator will be able to provide you with the advice you require. The LeoPC1 is obtainable in the following version: Full version LeoPC1 with full functionality: • CAN bus driver (allows all functions via a CAN card connection) • Gateway RS-232 driver (allows all functions via a Gateway connection) • Modem driver (allows all functions via a modem connection) • Direct driver (only for configuration via the direct connection) • Demo driver (for demonstration purposes without a connected device) LeoPC1 User Manual © Woodward Governor Company Page 8/8 37146 Helpful Information about the Manual ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ This manual provides for a first-time users explanatory introductions to: Commissioning: Installation, uninstalling, and general configuration Properties: of all functions and their application Communication Connection: Drivers and communication utilities of the LeoPC1. The individual sections are structured so that you are provided with each of the following for each program seg- ment: Introduction to specific functions and their significance Explanation of the individual components in terms of their functionality Description of the procedure, broken down into by individual steps. Provided in addition with the descriptions of the procedure are: Illustrations that permit cross-referencing to the relevant screens and menus of the LeoPC1. NOTE Information captions contain general, important items of information, additional specifications and/or references to more extensive sources of information. Comments additional explanatory comments are printed in “( )” Should you have more detailed questions regarding the LeoPC1 that have not been answered in this reference manual, please contact our support team. Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 9/9 Chapter 2. Commissioning The following version of the LeoPC1 is available: The full version comprises the following components: Application (minimum requirement) Demo driver Direct driver IXXAT VCI2 – CAN bus-driver Modem driver Gateway RS-232 driver LeoPC1 can be easily installed from your CD-ROM drive. Follow the instructions and prompts given during in- stallation. Some customization to individual installations is possible during the installation process. A detailed explanation of the installation and configuration process is located in the following section. Installation ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ During installation numerous components are installed in your PC due to the multiple versions of LeoPC1 with differing functionalities. The differences in the functionality of the LeoPC1 program are dependent upon the ver- sion of the program that has been selected for installation. If there are controllers that have been configured with LeoPC1 v2.x, they cannot be reconfigured with later versions of LeoPC1. STD files created by LeoPC1 v2.x are not compatible with LeoPC1 v3.x and higher. This version will be installed in a different directory by default and can be launched by a different entry in the start menu than version 3.0 or any older version of LeoPC1. Versions 2.x can not be run after setting up a new version. Due to this it is recommended to uninstall any version 2.x of LeoPC1 before setting up this new version. If an IXXAT VCI driver version lower than 2.16 is installed on your PC/laptop, e.g. it was installed with LeoPC1 version 2.x or 3.0, you are recommended to follow the instructions given from IXXAT.de to remove the old VCI version with their tool vciclean.exe You do not need to install the IXXAT VCI driver, it will be done with the LeoPC1 installation. Components of the Installation The full version enables you to perform data transfers for the purpose of display, configuration and control via a special CAN bus, modem, RS-232, or a direct connection. NOTE Locate the version of LeoPC1 being installed. This information can be obtained from the title page of the CD-ROM or during the installation process. For detailed information on the relevant files to be installed and in which directory they are to be found is located in the annex of this manual. LeoPC1 User Manual © Woodward Governor Company Page 10/10 37146 The following files and sub directories will be found in the main program menu directory: Files System files “*.*”, configuration files “*.cfg”, event memory files “*.dat”, and files for external tools. ALARMS\For daily alarm protocols “01.alm” to “31.alm” DL\For temporary data-logging files “DLx.tmp”, where x stands for the device number LNG\For the load language files “*.lng” PICTURES\For the bit map layout files “*.bmp” STD\For the standard value files “*.std” TOOLS\For the assembler “*.asm” and option files “*.opt” used with the configura- tion files NOTE Temporary files are created for each connected, device that are used to display the configured values after exiting or in the event of an application crash for restarting the LeoPC1. These files are lost when a new configuration is started. LeoPC1 can be installed on all Microsoft Windows©-systems. When installing LeoPC1 the following require- ments must be followed: WinNT/2000/XP Administration rights for the computer to have the program installed. The operator for the program will require main user rights to the computer at a minimum. Win95 If installation is aborted by the system, repeat installation with Win95 in safe mode. The required hard drive space for installing LeoPC1 is dependent on the application modules of the version to be installed: The program will require between 20 and 60 MB of storage space. NOTE These specifications are minimum specifications and relate to the LeoPC1 itself. This specification does not account for storage space that will be required by the configuration, data logging, alarm management files and all other files created for the use of this software tool. Procedure for Installation NOTE The beginning of the software installation is dependent upon the source for the LeoPC1 program. If a dialog window does not initiate from the installation program, follow the instructions below. Ensure that all setup files are in one directory prior to starting installation. The number of files that must be located depends on the version of LeoPC1. The following files must be located: • LeoPC1.exe or: • Install.ini, ReadMe.txt • Setup.exe and other Setup.W0n (‚n’ stands for numbers from 2 to 4) • Package1.exe and may be other package files • Vci2.xx.exe (‚xx’ stands for the current version of the IXXAT driver). Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 11/11 To start installation: Insert the CD-ROM into the CD-Rom drive Locate and (double) click on: Setup.exe or Click on the Start button for Windows Move the cursor up to Run and click on it (the Run dialog is opened) and Enter “PATH\Setup.exe” (“PATH” stands for the drive to be used) Figure 2.1 Start installation or Search... (Setup.exe in the corresponding installation directory) OK NOTE The installation is initiated by setup.exe or LeoPC1.exe depending on the version of the software. Continue with the installation by following the prompts and instructions given in the dialog windows. There may be differences in the dialog windows that are dependent upon the software version being installed. The following dialog windows will guide you through the setup procedure. By clicking on the “Next” button, the program will advance to the next dialog window. It is strongly recommended to read all of the dialog windows when performing the installation. If any it is desired to make changes to the setup, it is possible to return to all previously displayed screen by clicking on the “Back” button. - Welcome (greeting and notices) - ReadMe file (important installation information) - Choose destination location (please select your directory here) To select a directory: C:\Program File\Woodward\LeoPC1 (represents the standard setting, where the main directory of the LeoPC1 will be installed) or Select your desired path or directory NOTE You may install LeoPC1 to any desired location in your computer with the “Choose Destination Loca- tion” dialog window. It is recommended to utilize the default location. All sub-directories of LeoPC1 will be installed in the directory selected during this step. After LeoPC1 has been installed on the computer do not alter or move individual software tool compo- nents or entire directories. Doing so may result in errors or the program failing to operate properly. Select components (uncheck the non-required components) LeoPC1 User Manual © Woodward Governor Company Page 12/12 37146 Figure 2.2 Select components NOTE If required, any components that were not installed in the initial installation may be installed at a later date by simply repeating the installation procedure and selecting the desired components to be in- stalled. If another CAN driver is installed on your system, a notice will be displayed. It is possible to continue the setup and use the old driver version with limited compatibility for the latest CAN-Interfaces. The recommended to de-install the old configuration and driver of your CAN bus Interfaces according to the instructions of IXXAT http://www.ixxat.de before starting the setup program. New CAN bus driv- ers will be installed by the setup. After LeoPC1 has completed its installation procedure, the option to install the IXXAT-VCI-driver on the PC/laptop will be given. Select language (Select the language with which the LeoPC1 is to be started initially after the installation) Figure 2.3 Select language Start installation To start installation, click the “Next” button. File installing A progress bar will be displayed while the file is installing Plant configuration Please wait... (interim information) Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 13/13 Setup – IXXAT VCI V2.16 for Windows ... The VCI driver for IXXAT CAN-Interfaces may now be installed. If this message is not displayed, the appropriate drivers are already installed or the VCI version 1 is already installed. Finish installation Click the button to complete the installation. Figure 2.4 Finish installation NOTE It is necessary to restart the PC/laptop after the completion of the installation to ensure the operating software is stored and all functions and links are properly enabled. After rebooting the PC/laptop, LeoPC1 may be started by following the log on procedure below: To start the application: Click on: Start..Programs..Woodward.. LeoPC1.. LeoPC1 or Via Windows-Explorer start the “main.exe” in the selected main directory or Start a “*.cfg” file in the selected main directory LeoPC1 User Manual © Woodward Governor Company Page 14/14 37146 To log on:Click on: System...User Login or click the icon. Figure 2.5 Open User Login In the “Name” box type the user name as “system”. In the “Password” box type in the password as “system” (to protect the password letters are displayed as ****). Figure 2.6 User Login Click to gain access. NOTE It is recommended that the system administrator change the password immediately after logging on the first time. Make note of the password issued to you, as most functions of LeoPC1 require this password for access. If you attempt to utilize LeoPC1 prior to logging on, you will be prompted that logging on is required. By clicking on the “Yes” button the User Login dialog window will be displayed. Defining the system administrator: After logging in to LeoPC1, click on: System...User management... (the Users Management dialog window will appear) Figure 2.7 Open User Management Editing boxes At the bottom of the dialog window is the “New user” box. Type in the de- sired user ID and Type the desired password into the “Password” box and Type the desired password again into the “Repeat” box To enable the new user ID and password click on . Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 15/15 Option: Setting the level of access for users: by clicking and highlighting a user ID the level of access may be changed. The default level of access is Level 1 authorized. Click on the desired access level and enable it by clicking . Deleting a user ID: By clicking on a user ID and highlighting it then click- ing the “Delete” button a user ID is deleted from the Users Manager. Before deleting the default user ID and password system, it is strongly recom- mended that the new system administrator log off and back on to verify that the new ID and password function properly. After this has been verified, de- lete the default user ID “system” and password for security purposes. It is required to click to enable any changes made in this dialog window. Figure 2.8 User Management LeoPC1 User Manual © Woodward Governor Company Page 16/16 37146 Procedure for De-installing During installation of the LeoPC1, a tool is also set up for de-installing this program. If you wish to remove LeoPC1 version on your PC, please use this tool only. To start uninstalling:The pathway to unwise.exe if the default installation was utilized is typically C:\Program Files\Woodward\LeoPC1\unwise.exe. (Double) click on: Unwise.exe or Start\Run\unwise.exe or Search\unwise.exe NOTE Please continue to follow the directions of the de-installer program, which will guide you through the Unwise dialogs, if you confirm with . When the de-installer program, Unwise.exe, has been started, you will be prompted to make decisions on the de-installation process. Confirm your choices by clicking on the “Next” button. For easy and quick uninstalling, use the option “Automatic” and confirm by clicking on “Next”. The option “Custom” requires extensive administrative knowledge and is not covered by this manual. If the application is to be de-installed and the configuration files (*.cfg and *.asm) or other files gener- ated during use of the application need to be kept, the configuration files will need to be copied to an- other directory prior to uninstalling the application. If the application is uninstalled prior to transferring these files, they may no longer be available after de-installing. Generally the file folder for LeoPC1 and individual files stored in it are not affected by the de- installation. The file folder may be deleted by following the directions below if the default installation was chosen. To delete main directory:Click on: My Computer... Program Files... Woodward... and Highlight the LeoPC1 file folder and Delete the file folder Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 17/17 Loading a Plant Configuration ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ NOTE Open your plant configuration from the actual application. A plant configuration must be opened from the correct application file (**.asm). LeoPC1 must be started and the correct application file opened to begin configuring a plant. Various plant configurations can be loaded with LeoPC1. The plant configuration functions and layout are de- pendent on the following:: Version of the LeoPC1 being used Devices that are to be communicated with Tasks that to be assigned to devices Requirements that the plant must meet Basically it can be differentiated between: • Demo configuration • Direct parametric configuration • Display configuration • Configuration and display configuration NOTE Due to the numerous control units and possible combinations of these units, it is impossible to cover every plant configuration. Operator control will be discussed only in general terms because of this. For further information on and examples of configurations, please refer to the following sections: Fehler! Verweisquelle konnte nicht gefunden werden.“General Configuration” after page 22 ”Communication and Connection” after page 69 and the corresponding sections of the manuals for your specific control unit Some prerequisites have to be met before you can load your plant configuration (provided that it has not been done already by installation) To copy files: Use, for example, Windows-Explorer for this step: Copy the corresponding CFG configuration file (*.cfg) to the main menu in the LeoPC1 file folder Pathway C:\Program Files\Woodward\LeoPC1 and Copy the pertinent ASM configuration file (*.asm, if necessary *.opt) to the sub-directory TOOLS in the LeoPC1 file folder Pathway C:\Program\Woodward\LeoPC1\Tools Copy and paste. NOTE In some versions of LeoPC1 (e.g. LeoPC1.cfg), it is possible to copy and paste configuration files from a floppy disk or a CD-ROM. If too many sub-directories are transferred at one time by this method, the possibility of errors occurring in the files is greatly increased. LeoPC1 User Manual © Woodward Governor Company Page 18/18 37146 To use copy tools:Click on Tool...Get Config Figure 2.9 Open Tools menu and Follow the directions in the dialog window that opens up and Select the desired configuration files from the disk, CD ROM, or file folder where they are located. Figure 2.10 Search directory and Start the copy operation. A dialog window will open displaying the status of the files that were transferred. This may be acknowledged by clicking . To connect devices For communication with the desired connection type (Depending on your device and plant configuration): Demo connection Connection to a device is necessary Direct connection COM port of the PC > Direct configuration cable > RJ45 port of the device Gateway connection COM port of the PC <> Gateway RS-232 <> Device. Modem connection COM port of the PC <> modem <> Telephone network <> Gateway <> Device CAN bus connection CAN card COM port of the PC <> Adapter cable <> Device NOTE Ensure that the COM port to be used for configuration has not been assigned to more than one func- tion. Read the documentation of the device to be configured prior to beginning the configuration of that unit. All control units will require individual tuning to gain optimum performance within the plant. Some older control units require the configuration interface to be activated before configuration can be performed. Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 19/19 To activate devices: Configuration method Turn power on to all devices to be configured. Direct connection On devices with a display set the direct configuration screen to “ON” Gateway and modem connection On devices with display set the direct configuration screen to “OFF” (the CAN bus interface is disabled when the direct configuration mode is enabled) CAN bus connection On devices with displays set the direct configuration screen to “OFF” (the CAN bus interface is disabled when the direct configuration mode is enabled) To load a configuration: Click on: Start...Program...Woodward...LeoPC1...LeoPC1 (application is started) File...Open…(the “Open” file dialog window is opened) Or click the icon. and Select the *.cfg file that has been copied to the main directory or Configuration method Start the *.cfg file directly from the selected mains directory Direct connection Only used for configuration of the device. Display of the measured data may not be possible. Gateway, modem or CAN bus connection The device may be configured while measured data from the generator/ plant is displayed. Extreme caution must be exercised when configuring through this method. To log on: Click on: System...User Login...(Only personnel with system administrator privileges may configure control units) Or click the icon. NOTE If no changes have been made to the user/password settings, the user ID and password for the system administrator will still be set as the default: Name = “system” Password = “system” To select application modules: Click on: Devices...Settings... (Settings to parameterize system dialog window will open) Figure 2.11 Open Device Settings Select Enable Program Modules (changes the available configuration mod- ules) LeoPC1 User Manual © Woodward Governor Company Page 20/20 37146 Figure 2.12 Enable Program Modules and Enable the modules that will be required for the connection and tasks: Direct configuration The modules “Parameterize” and “standard values” are sufficient to config- ure most control units generally. Gateway, modem or CAN bus connection All modules may be used for configuring control units. Select the modules that will be needed according to your requirements Click on to save settings. To select the communication type: Click on: Devices...Settings... (The “Settings to parameterize system” dialog window will open) Figure 2.13 Open Device Settings Select General Options Figure 2.14 General Options Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 21/21 and Select the method of configuration to be used in the Data communication Driver box from the following: Direct configuration Driver: “Direct” Gateway connection Driver: “Gateway RS-232” modem connection Driver: “Modem” CAN bus connection Driver: “IXXAT VCI2 – CAN” Remote control Displays Set the remaining dialog boxes as follows: “Not active” “Deactivate while parameterizing/load language” or Set according to requirements NOTE Refer to the product manual when selecting the baud rate for communications. To connect: Click on: Communication...Connect (The communication link between the PC/laptop and the device is established) Or click the icon. LeoPC1 User Manual © Woodward Governor Company Page 22/22 37146 General Configuration ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ LeoPC1 may be configured in several different ways. For this purpose it is differentiated between: General configuration Adaptation of the system settings and the device settings to your plant Special configuration Creation of the *.cfg files and *.asm configuration files NOTE Special configuration is generally not necessary. Your supplier should have already performed all nec- essary adaptations to your plant and devices. This special configuration is described in more detail in a separate manual 37164. Components of the General Configuration NOTE Ensure that the general configuration described below can only be accessed/performed by experi- enced personnel through the use of the System administrator. Failure to do so may result in these set- tings will interfering with your PC operating system, the hardware configurations, and/or the plant con- figuration. The components of the general configuration are subdivided into three areas: System Configurations Log on /log off user Dialog window for logging on/off User management List of the user names, passwords, and access rights System settings Language settings and logging parameters Path variables for CFG-files Plant Configurations General options Definition of the alarm path and of the alarm help file and definition of the data communication and connection settings Service Configuration Definition of parameters for the data buffer etc. Enable program modules Definition of the enable/disabled application modules View Configurations Symbol bars and settings Definition of the LeoPC1 window layout Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 23/23 Procedure for General Configuration System Configurations User To log on: Click on: System...User Login or click the icon. Figure 2.15 Open User Login Editing boxes Name: “system” (visible as system), if the factory default has not been changed or “User ID” (with administrative rights) and Password: “system” (visible as ******), if the factory default has not been changed or “User password” Figure 2.16 User Login Click To open user management Click on: System...User management... (The user management dialog window will open) Figure 2.17 Open User Management To set up a user Open user management and click on: Editing boxes: “New user” and enter the desired user ID and “Password” and enter the desired user password and “Repeat” and verify the desired user password Click and the new user will appear in the Users List Option: Highlight the desired user ID and click on ”System admin.” to assign full access rights to this user or the appropriate level of access at this time. Confirm all changes made to users and access rights by clicking on LeoPC1 User Manual © Woodward Governor Company Page 24/24 37146 Figure 2.18 User Management NOTE A user ID can only be assigned one password and level of access at a time. A user ID should be assigned the appropriate level of access when it is created. Only the highlighted user ID can have any changes made to the level of access or status. It is not possible to edit a pass- word for an active user ID. A user ID that has been deleted cannot be edited or logged onto the system. User ID’s that have been deleted can be re-entered as a new user ID if it is desired to use again. To manage a user:Open Users manager and click on: Desired user name (scroll menu with all defined users) Desired options:“Access denied” (denies access to a user) “System admin.” (Permits full access to system functions and settings) or “Level 2 authoriz.” (Permits access to system functions only) or “Level 1 authoriz.” (Permits access to data logging only) Verify all changes by clicking the “OK” button. To delete a user Open user management and click on: Desired user name (scroll menu with all defined users) (The user is removed from the scroll menu) NOTE Only one user can be logged onto LeoPC1 at any one time. If a user is logged on, he/she must log off to permit another user to log on to the application. The user ID of the signed on user is displayed at the bottom right corner of the LeoPC1 window. The user may be logged off by clicking on the icon or using the “System” button in the tool bar and clicking on “Log off user” Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 25/25 System To open system settings Select “System” from the Command menu, “System Settings…” from the drop down menu (the “System settings” dialog window will open), and click on: Figure 2.19 Open System Settings Settings tab (changes the displayed tab) Figure 2.20 System Settings To define the language Select “System” from the Command menu, “System Settings…” from the drop down menu (the “System settings” dialog window will open), and click on: Language: (pull down menu displays all available languages) NOTE The language defined in this parameter has no effect on a control unit that may be configured in a dif- ferent language. Example: If a control unit is configured in English and German is the language selected for this pa- rameter, the control unit will continue to display all parameters in English while the same parameters will be displayed in the LeoPC1 program in German. LeoPC1 User Manual © Woodward Governor Company Page 26/26 37146 To define data logging:Select “System” from the Command menu, “System Settings…” from the drop down menu (the “System settings” dialog window will open), and click on: Start data logging automatically upon loading the plant configuration Save data logging automatically upon closing the plant configuration activate Enter a check mark in the box next to the desired data logging option deactivate Remove the check mark in the box next to the data logging option to be de- activated Saving data Click on the icon to open the “Save As“ dialog window, type in the name of the file for the data, and select the file to save the data in. After a file name has been selected the Save button has been clicked, the pathway for the file will be displayed in text box. The OK at the bottom of the Sys- tem settings dialog window must be clicked to accept any changes made to these settings. NOTE When saving data logging files, they must end in ".llo". All data logging files must use the "LLO" for- mat. To define data export:Select “System” from the Command menu, “System Settings…” from the drop down menu (the “System settings” dialog window will open), and click on: Under “setting for export data logging files” enter a check mark in the box next to “Output header line?” Enter separator character (it is recommended that a semicolon “;” be used). To open system settings Select “System” from the Command menu, “System Settings…” from the drop down menu (the “System settings” dialog window will open), and click on: Figure 2.21 Open System Settings Paths tab (changes the displayed tab) Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 27/27 Figure 2.22 Path variables for CFG files NOTE As newly defined variables require an equivalent in the configuration file, it is not recommended add- ing or removing any path variables, but merely adapting the directories. Example: If the configuration files were stored in a common file on a network so that they may be ac- cessed from multiple computers instead of being stored on an individual computer, the pathway to the necessary CFG files would be modified here for the computer that will require access to these files. To define paths: Open the System settings dialog window and click on: Paths (changes the displayed page) Desired path variable for CFG file (selected variable is entered into the text box for editing) Editing box In the “Path:” text box enter desired path or Click on the icon to open the “'Select Path” dialog window and modify the pathway to the desired path and Click to enable the new path (the path is relocated to the path variable) To define the path variable Click on: Editing boxes: Click in the “Variable:” text box and enter the appropriate designation of the CFG file Click in the “Path:” text box and enter desired path or Click on the icon to open the “Select Path” dialog window and enter the desired path and Click to enter the new path variable (the path variable is set and appears in the list box) LeoPC1 User Manual © Woodward Governor Company Page 28/28 37146 Plant Configurations General settings NOTE Any changes made to the General Options will take effect immediately after the dialog window is closed. To open general settings Select “Devices” from the Command menu, “Settings…” from the drop down menu (the “Settings to parameterize system” widow will open): Figure 2.23 Open Device Settings Figure 2.24 General Options Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 29/29 To define communication: Select “Devices” from the Command menu, “Settings…” from the drop down menu (the “Settings to parameterize system” dialog window will open), the “General Options” tab, and click on: Driver pull down menu: in Data communication and select the applicable driver for your configuration method (all installed drivers will be displayed) Figure 2.25 Drivers Next click on the button and the corresponding settings for the selected driver are displayed. Requisite options: The tunable parameters are dependent on the driver If the button is clicked, another dialog window with more tunable parameters that are specific to the selected driver are displayed. NOTE If required, any components that were not installed in the initial installation may be installed at a later date by simply repeating the installation procedure and selecting the desired components to be in- stalled. For further information on the exact settings, please refer to page 10. Communication option “Start communication automatically upon loading the plant configuration” NOTE Placing a check mark in the box next to the text enables this option. If this has been enabled, LeoPC1 will attempt to establish communication with the control unit immediately after the plant configuration has been loaded. If this option is disabled communication with the control unit must be started manu- ally. Remote control and Displays Select a mode from the list below: Mode activated or deactivate while parameterizing/loading language or not activated Figure 2.26 Remote control and Displays To define the alarm directory Select “Devices” from the Command menu, “Settings…” from the drop down menu, the “General Options” tab, and click on: Editing box: “Path for alarm files:”: text box and enter the desired directory or Click on the icon for “Path for alarm files:” and click on the appropri- ate file folders in the ”Select Path” dialog window. NOTE Faults that occur on your plant are logged in files that are stored in the directory specified here. This directory is always relative to the position of the corresponding plant configuration file (CFG file) and not relative to the position of the application file “Main.exe”. This means that if the CFG file is not stored in the main directory, the path must be completely specified for the directory “ALARMS\” or a corresponding directory must be created in the directory in which the CFG file is located. Ensure that the new pathway ends with ”\” or it may not function correctly. LeoPC1 User Manual © Woodward Governor Company Page 30/30 37146 To define the alarm help file Select “Devices” from the Command menu, “Settings…” from the drop down menu, the “General Options” tab, and click on: Editing box “Help file for alarms:”: and enter data path or Click on the icon for “Help file for alarms:” and click on the appropri- ate file folders in the ”Open” dialog window. Service Configuration NOTE The settings on this tab page should only be changed by experienced users or by your support team. Under certain circumstances the application will no longer process all data if the wrong parameters are entered here. Any changes made to this tab page do not become active until the application has been restarted or the plant configuration has been reloaded. To open device settings Select “Devices” from the Command menu, “Settings…” from the drop down menu (the “Settings to parameterize system” dialog window will open) and click on: Figure 2.27 Open Device Settings Service Configuration tab (changes the displayed tab page) Figure 2.28 Service Configuration Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 31/31 To define the data buffer: Open Service Configuration tab page and click on: Editing boxes: “Size of the data buffer” text box (The entered value must be greater than the highest parameter-ID and greater than the “ID of the first entry for re- mote monitoring” plus the ”Size of the data buffer for remote monitoring”) and ”ID of the first entry for remote monitoring” (The entry is dependent on the device and must be larger than the highest parameterization ID, all higher values will be ignored). and “Size of the data buffer for remote monitoring” (Entry is the number of dis- play data words plus 1). NOTE Some older control units may have different default values than newer control units of the same model in the text field “Size of the buffer for remote monitoring”. If an incorrect value has been entered, some or all of the monitored values will not be displayed or logged! Option: “Test mode” (if enabled, default values are read and saved) Editing boxes: ”ID for remote control word” (default is 503) and “Break for data transfer” (default is 200 ms) To define Windows title: Open Service setting tab page and click on: Editing box: ”Text within title row” (your desired title can be edited here) Option: ”Show name of program as title?” (Enables the display of the custom title by checking the block) Enable program modules NOTE The Enable Program Modules tab page specifies which modules are available for the user. Only mod- ules with check marks in the box next to it are enabled and displayed in black text. All Modules that have been disabled are displayed in grey text. To select application modules: Select “Devices” from the Command Menu, “Settings…” from the drop down menu, the “Enable Program Modules” tab, and click on: (the “Settings to parameterize system” dialog window will open) Figure 2.29 Open Device Settings Enable Program Modules tab (changes the displayed tab page) LeoPC1 User Manual © Woodward Governor Company Page 32/32 37146 Figure 2.30 Enable Program Modules to activate Insert a check mark inside the box next to the Module to deactivate Remove the check mark from the box next to the Module View Configurations To select view:Select View from the Command Menu and enable the desired selection by placing a check mark next to the desired View tool: On possible bars:View...Tool Bar (enables quick operator control via screen buttons) View...Status Listing (supplies information to the operator) View...Levels (enables fast changing between monitoring levels (i.e. power plant, engine, or sensors/actuators) Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 33/33 Dynamic Configuration ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Using the dynamic configuration module, LeoPC1 creates the parameter lists and display levels according to the options selected. Components of the Dynamic Configuration The components of the dynamic configuration are not immediately recognizable. If this type of configuration is utilized, the components of the dynamic configuration are hidden in the device and relevant files (*.cfg, *.opt and *.asm) for the configuration of the plant .The components can be subdivided as follows: Device parameters: The corresponding values are tunable for the individual control unit and de- termine the parameter list for the individual application modules. Language parameters: The corresponding values from the system data of the application determine the language for the display of your measured values. Button: Performed via: Devices...Refresh Configuration Files: OPT files contain definitions for the dynamic configuration. ASM files contain options for the specific control unit and are the tool files required for the CFG file to communicate with the LeoPC1 program. CFG files contain options for the specific control unit and reflect any changes that have been made to parameters in the control unit. Procedure for Dynamic Configuration NOTE Devices with the option of dynamic configuration usually only require this once during the setup of the control unit. Dynamic configuration will not work if the control unit is not connected to the PC/laptop running LeoPC1. To connect: Click on: Communication...Connect or icon (connection to the selected device is made) To configure dynamically: Click on: Devices...Refresh configuration (starts the dynamic configuration) Figure 2.31 Open Refresh Configuration Question dialog "Are you certain that you want to refresh dynamic configuration?" Figure 2.32 Refresh Configuration - Start and Click the “Yes” button (a status dialog window "Parameter data for dyn. configuration" appears briefly) LeoPC1 User Manual © Woodward Governor Company Page 34/34 37146 Question dialog You are requested to load the new plant configuration. Figure 2.33 Refresh Configuration - End and Click the “OK” button (the updating is not completed until you have re- loaded) Select File...New or click on the icon (closes the configuration) and File...1 Name of the configuration.cfg (Re-opens and updates the configuration) Figure 2.34 Re-load configuration Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 35/35 Chapter 3. Properties of LeoPC1 Depending on the type and configuration of the devices, LeoPC1 puts the components explained in detail below at your disposal. Displays ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ LeoPC1 can display the current values of the connected devices. This permits for a complete overview of the status of your plant, machines, and devices. Components of the Display There are two primary formats to display the measured values and different statuses of your plant • In a bit map format • In a tabular format In turn these formats may be configured in various ways and differ in quantity of displayed information (depend- ing on you’re the user and plant requirements). The measured values can be displayed separately according to their significance, on plant-related, machine- related and device-related levels: Power plant level: This displays the most important monitored values of the plant. Machine level: This displays the most important monitored machine values. Sensors/actors: These represent all values of monitored devices. Within these levels it is possible to change randomly between the various displays in compliance with the user’s needs and thus obtain a complete overview of your plant status. If LeoPC1 is used for configuration only, only a simple background image is displayed of the plant. The Plant overview dialog window is composed of the following elements for displays in compliance with your configuration: Text boxes: Information and comments Parameter boxes: Display of monitored parameter, value, and engineering unit Buttons: Navigation via: Buttons for alarm display Buttons to change between different levels Bitmap: Makes up the background design, integrating title, plant component descriptors, circuit diagrams, and open/closed breaker positions of the generator(s) etc. Table: Tabular display of monitored values LeoPC1 User Manual © Woodward Governor Company Page 36/36 37146 Procedure for Displays To load configuration:Click on: File...Open... or the icon and Select the appropriate *.cfg file from the ”Open” file dialog window NOTE It is possible to open a *.cfg file by locating it through Windows-Explorer and double clicking on the desired file. The control unit cannot be configured or updated unless communication between the control unit and the PC/laptop has been established. If a *.cfg file is opened without a having an automatic connection established, the default values are displayed. If the connection is interrupted after a data transfer, the last values displayed will remain on the screen. To set displays:Click on: Devices...Settings... (The “Settings to parameterize system” dialog window will open) Figure 3.1 Open Device Settings General Options tab (changes the tab page displayed) Figure 3.2 General Options Put a check mark in the box next to “Start communication automatically upon loading the system configuration ” to enable automatic communica- tion. Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 37/37 Displays From the Displays pull down menu select either ”Deactivate while configuration/load language” or '”active” Enable all changes by clicking on . NOTE The next time this configuration is opened the communication is established automatically. If a con- nection to the control unit currently exists, all the configured values are immediately displayed. To select view: Click on: View...Next View View...Next Engine View...Next Device Figure 3.3 Open View menu or Pull down menu of plant level Pull down menu of engine level Pull down menu of device level (sensors/actors) Figure 3.4 Select View Levels and Select the desired level To close a configuration: Click on: File...Close or click the icon (terminates your application) File...Open...or click the icon and select the appropriate *.cfg file from the ”Open” file dialog window or File...1 **.cfg or File...2 **.cfg or File...3 **.cfg Opens the selected configuration and simultaneously closes the previously opened configuration file LeoPC1 User Manual © Woodward Governor Company Page 38/38 37146 Configuration ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ LeoPC1 can provide user support for the configuration of a control unit. This program permits a control unit to be set up for a new application or adapted for new requirements to an existing system within the control unit’s individual parameters. NOTE In some cases it may be necessary to see the parameter list without displaying any configured values of a control unit. This can be accomplished by selecting “Devices” from the Command Menu and “Set- tings...” from the drop down menu. Click on the “Service Configuration” tab to display the tab page. In- sert a check mark in the box to the right of the text “Test modus (set data with default values)”. Verify any changes made to the tab page by clicking the “OK” button. This function enables the user to configure, print, and/or save parameter lists without affecting any se- lected drivers or connected devices. Do not use STD files that have been created in the Test modus to configure any control units. Some pa- rameters will not load correctly unless the control unit is running and communicating with LeoPC1 when the change to the parameter is made. Ensure that the “Test modus” is disabled after it is no longer required. Failure to do so will result in the user not being able to configure control units until this function is disabled. Components of the Configuration For online configuration LeoPC1 provides a configuration dialog window with the following functions: Device to be parameterized:Selection via the pull down menu with all corresponding devices Relevant parameter:Display of: Name (designation of the parameter) Value (value last read of the parameter) and Rights (read = 'R' and/or write = 'W') Buttons:Handling via: (By this means you change and transfer the parameters) (Reads one or more current values from the device) (Aborts reading of values) (Reads all current values from the device) (Prints out the current parameter list) (Saves the current parameter list as an STD file) (Calls corresponding help file) (Closes the configuration dialog) NOTE It is possible to parameterize multiple units by saving the control unit configuration as an STD file. If the user desires to transfer the same configuration settings to a second control unit, this is accom- plished by utilizing the “Standard Values” dialog window (see "Standard Values" after page 45). Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 39/39 Procedure for Configuration NOTE Communication between the control unit and LeoPC1 must exist for online configuration. If this con- nection does not exist, you will be asked whether you wish to start this connection. To connect: Click on: Communication...Connect or the icon (connection to the selected de- vice is made) To open configuration: Click on: Devices...Configuration...or the icon (Configuration dialog is opened) Figure 3.5 Open Parameterize Select the desired control unit using the pull down menu with all available devices listed Figure 3.6 Parameterize NOTE Before the parameters for a control unit may be changed, it may be necessary to enter a password in the Parameterize dialog window. If this is required follow the operating instructions that pertain to the device being configured. LeoPC1 User Manual © Woodward Governor Company Page 40/40 37146 To unlock the device protection: To enable configuration, double click on: Parameter ”password level 2” in the Parameterize dialog window (the pass- word dialog window will open) Figure 3.7 Enter Password and Enter the password specific to the device NOTE After the password has been accepted, the user may change all parameters with write rights ("W" in the column Rights). A parameter that has only a read right ("R" in the column Rights) cannot be changed. Parameterization:Open Parameterization and click on: (Only if all current parameters are to be read) or Highlight one or more parameter that should be read and Click (the marked line values are read from the device) or Double click on the desired parameter (scroll in parameterization dialog window to the desired parameter) and Click (an input dialog window for the parameter open) NOTE For the input dialog window, a range of values that conform to the parameter type may be entered. The possible inputs can be found in chapter "Inputs (Configuration and Standard Values)" beginning on page 41. In contrast to the standard values dialog, the parameters entered via the input dialog windows are transferred immediately to the device when the user confirms the input dialog with the ”Ok” button. Prior to making any changes, ensure that values being transferred are the required values. All parameters that failed to read when prompted are highlighted in blue. The user may attempt to re- read these parameters by clicking on the “Marked Rows” button. To stop:Click on: (Aborts reading of values) To print:Click on: and Select the desired options in the print dialog window To save:Click on: and Create or update file in the “Save As” dialog window Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 41/41 NOTE The file name must end with ".std" and the file must have the STD format. The current settings will be saved in STD format in the file specified by the user. The STD file may be modified offline without an existing connection or for archiving as standard values that may be transferred to a control unit through the Standard Values procedure. To disconnect: Click on: Communication...Interrupt or click on the icon (terminates the connec- tion) Inputs (Configuration and Standard Values) ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Enter A Number Enter the numerical value for a parameter in the input range. The first line of text for the window is the parameter description. The second line is a ge- neric screen definition for the control unit. The third line is the input field in that the user can change the value. The last line is the input range. Verify any changes made by clicking on . Figure 3.8 Enter A Number Real power set value Outgoing power Fixed value power Reference power Input E0000 to 6900 C0000 to 6900 I0000 to 6900 Cosine-Phi Capacitive/Lagging Inductive/Leading Input k0.01 to 0.99 1.00 i0.01 to 0.99 Flags The first line of text is the parameter description. The input field contains up to a maximum of 16 discrete inputs, which may be enabled (E) or disabled (D). In order to change the state, check marks must be added or removed from the boxes to the left of the discrete input. Verify any changes made by clicking on . Figure 3.9 Set Flags LeoPC1 User Manual © Woodward Governor Company Page 42/42 37146 Connector Group The first line of text is the parameter description. Below the parameter de- scription are four buttons that display the current status of the button. To change a status, press the desired button. The button will change the dis- played status to the next value. Verify any changes by clicking on . Figure 3.10 Set a Connector Group Insert YES/NO Set value of the parameter on YES or NO. The first line of text is the pa- rameter description. Below the parameter description is the option field. The option may be changed by clicking on the desired field and verified by clicking on . Figure 3.11 Insert Yes/No Select A Text The first line of text is the parameter description. Below the parameter de- scription is the input field that contains a pull down menu to select the de- sired text. The top line is the current displayed text. The text messages listed below are the messages that may be configured to the input. Verify any changes by clicking on . Figure 3.12 Select Text Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 43/43 Insert A Text The first line of text is the parameter description. Below the parameter de- scription is the input field. The user may define the text of a parameter up to 16 digits in the input field. Verify any changes by clicking on . Figure 3.13 Insert Text Input Relay The first line of text is the parameter description. Below the parameter de- scription is the input field. The relay manager function linking is configured here. The numeric codes for the desired functions are linked with the logic symbols listed below. Up to three functions may be linked. The links are transmitted in three sequential words. The numeric codes for the relay man- ager functions may be found in the product manual that is being configured. Verify any changes by clicking on . Figure 3.14 Input Relay Type of links OR AND NOT End coding Input + * - LeoPC1 User Manual © Woodward Governor Company Page 44/44 37146 Logic manager The LogicsManager is configurable with up to two time delays, three input fields, two unary sign inputs, and two Boolean sign inputs. Verify any changes by clicking on . The configuration will be transmit- ted in seven sequential words. Figure 3.15 Logics Manager Sign, unary NOT value Value always “1“ always “0“ Description The value is inverted The value is looped 1:1 The value is inde- pendent of the ac- tual state pass over as “TRUE“. The value is inde- pendent of the ac- tual state pass over “FALSE”. Input Linkage, binary AND NAND OR NOR XOR NXOR Description Logical AND Negative Logical AND Logical OR Negative Logical OR Exclusive OR Negative Exclusive OR Input Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 45/45 Standard Values ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ LeoPC1 permits the user to archive plant-specific parameter settings as standard value files. These files can be stored and modified offline. The user may later transfer these files to the appropriate device. This function per- mits the user to quickly configure multiple control units of the same design to the same configuration of a pre- existing control unit. Components of the Standard Values For configuration with standard values a standard value dialog window is available to the user with the follow- ing functions: Devices to be parameterized: Selection via pull down menu with all corresponding devices Device of the open file: Selection via pull down menu with all corresponding devices Relevant parameters: Display of: Name (designation of the parameter) Value (value last read of the parameter) and Rights (read = 'R' and/or write = 'W') Buttons: Handling via: Load (loads the desired file in STD format) Input (the user may change the parameters without transferring the file) Marked rows (transfers one or more selected values to the device) All rows (transfers all displayed values to the device) Stop (aborts transfer of values) Print (prints out the current parameter list) Save (saves the current parameter list as an STD file) Help (opens the Help window) Close (closes the standard values dialog window) Procedure for the Standard Values NOTE Only one path of communication should exist with a device that is going to be parameterized with standard values. The path of communication should be initiated prior to opening the “Standard Val- ues” dialog window if any parameters are going to be transferred. If parameter values are just going to be modified and not transferred, it is not necessary to establish communication with the control unit. If only one control unit needs to have the parameters modified, it is better to perform these modifica- tions online with the “Parameterization” dialog window.. (see "General Configuration” starting on page 22). When configuring with the “Standard Values” dialog window, only load files that have been taken from identical control units. Do Not use empty STD files (i.e. STD files from the demo). If empty STD files are used, errors in the configuration may occur under certain circumstances. To connect: Click on: Communication...Connect or the icon (connection to the selected de- vice is made) LeoPC1 User Manual © Woodward Governor Company Page 46/46 37146 To open standard values:Click on: Devices...Standard values...or the icon Figure 3.16 Open Standard Values Click and Select the desired *.std file from the “Open” file dialog window. Figure 3.17 Standard Values NOTE The file name must end with ".std" and the file must have the format STD. Select the control unit to be configured from the pull down menu at the bot- tom of the “Standard Values” dialog window. NOTE Prior to changing any parameters in a control unit, the level 2 password must be entered into the de- vice. Follow the procedure for entering a password that applies to the individual control unit. Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 47/47 To unlock the device protection Open standard values and click on: Parameter “password level 2” in the list box Next click on or Double click on the text line for the password (the “Input” dialog window will open) Figure 3.18 Enter Password and Enter the correct password for the control unit and Click on (this will transmit the password) NOTE After the password has been accepted, all parameters with write rights ("W" in the column Rights) may be changed. A parameter that has only read rights ("R" in the column Rights) cannot be changed. To parameterize: Open the ”Standard Values” dialog window and click on: Desired parameter (scroll in parameter list to the corresponding position) Click on (an input dialog window appropriate for the pa- rameter is opened) NOTE There are various input dialog windows for entering parameter values. The input dialog windows vary according to the type of parameter. The possible inputs may be found in the "Inputs (Configuration and Standard Values)” chapter starting on page 41. Unlike the configuration dialog window, the values modified here are not transferred immediately to the control unit. These values must be transferred separately. If parameter cannot be written an error message is displayed. To transfer: Open the “Standard Values” dialog window and click on: One or more lines that should be transferred to the device (to highlight mul- tiple line hold the “Ctrl” button on the keyboard while highlighting the pa- rameters) and (Values of the marked lines are transferred to the device) or (All values are transferred to the device) To stop: Click on: (Only if necessary to abort transfer of values) To print: Click on: and Select the desired options in the print dialog window LeoPC1 User Manual © Woodward Governor Company Page 48/48 37146 To save:Click on: and The desired file via the “Save as” dialog window NOTE When saving a file, the file name must end with ".std" and the file must have the STD format. After a file has been saved in this format, it is available for modification or archiving as standard values that can be loaded and transferred at a future date. Saving the file again is only required if the values of the pre- viously loaded file been changed. To disconnect:Click on: Communication...Interrupt or the icon (terminates the connection) Remote Control ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ LeoPC1 can provide the user with support for the control of your control unit from a remote location. This per- mits the user to start and stop the plant, machines, and devices or modify selected parameters right from your of- fice or residence. Components of the Remote Control For control a remote control dialog window with the following functions is available: Device to be controlled:Selection via pull down menu with all available devices Remote control parameters:Editable values: Set point of active power Generator Cosphi (power factor) Control words:Enable/disable: Acknowledgement (resets the alarm memory of the device) Remote stop (stops your controlled machine) Remote start (starts your controlled machine) Buttons:Handling via: (Transfers the selected commands to the device) (Opens Help window) (Closes the remote control dialog window) NOTE The Control Word “Acknowledgement” is automatically reset after a specific time period if the existing communication link does not permit the message to transmit constantly. The Command Word “Remote Stop” has priority over “Remote Stop” if there is an existing communica- tion link to the control unit. Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 49/49 Procedure for the Remote Control NOTE If the user desires to use the remote control feature, this must be set when starting the configuration. The remote control feature must be enabled individually for each unit that will utilize this. The control unit must be configured for remote control and not controlled by another component of the system. Read the operation instructions for the control unit prior to enabling the remote control function. To define communication: Click on: Devices...Settings... (Settings to parameterize system dialog is opened) Figure 3.19 Open Device Settings General Options tab (changes the displayed dialog window) Figure 3.20 General Options Remote control Select “activated” (standard) or “Deactivate while paramerterzing/load language” Verify changes by clicking on To connect: Click on: Communication...Connect or the icon (the connection to the selected device is created...) LeoPC1 User Manual © Woodward Governor Company Page 50/50 37146 To open remote control:Click on: Devices...Remote control... or the icon Figure 3.21 Open Remote Control To select:Open remote control and click on: The control unit to be controlled (pull down menu with all available de- vices) Figure 3.22 Remote Control To control:Open remote control and click on: Desired editing box:Active power set point (set process and Kw level) and/or Generator Cosphi (set power factor) and Input the requisite value Desired option/s:Acknowledgement (resets the alarm bits in the device) and/or Remote stop (overrides remote start if it is selected simultaneously) and/or Remote start and Click (sets your selection for transfer) To disconnect:Click on: Communication...Interrupt or the icon (terminates the connection) Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 51/51 Data Logging ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ LeoPC1 has the capability to perform data logging of selected parameters of the user’s plant for the purpose of control. Device to be controlled: Selection via pull down menu with all available devices Measured values to be logged: Selection via pull down menu with the specific measured values Selected values: Display on data diagram with time and value axis Logging parameters: Display of sampling rate and logging time period Display individual line: Option that displays only the selected measured value Display several lines: Option that displays all measured values defined in a maximum of 8 buttons Parameter dialog: with the following options: Logging time period in minutes Sampling rate in seconds Display of the storage space requirement to be expected Scaling dialog: With the following options: Logging time period axis X with selection facility of: Complete logging time period Individual setting (time from... to...) Measured value, axis Y, with facility for selecting: Complete value range Individual setting (measured value from... to...) Buttons: Handling via: (Selected values for 8 parameters that can be individually formatted and scaled) (Allows the insertion, removal and setting of the selected measured val- ues) (Starts the desired logging) (Stops the desired logging) (Loads the desired file in LLO format onto the display) (Closes the current file in LLO format on the display) (Prints out the current logging diagram) (Saves the current logging as an LLO file) (Opens the Help window) (Closes the data logging dialog) LeoPC1 User Manual © Woodward Governor Company Page 52/52 37146 Procedure for Data Logging NOTE It is possible to set data logging when the configuration is started. To define data logging:Click on: System...System settings... (The” System settings” dialog window will open) Figure 3.23 Open System Settings Settings tab (changes the displayed tab page) Figure 3.24 System Settings Start data logging automatically while loading your system. Save data logging automatically while closing your system. activate Insert a check mark in the box to the left the option desired deactivate Remove the check mark Click the icon to right of the “in file:” text box and create or select the file to store the data in from the “Save as” dialog window. NOTE File name must end in ".llo" and the file must have the format LLO. To log:Click on: Communication...connect or the icon (the connection to the selected device is established...) Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 53/53 To open data logging: Click on: Devices...Data Logging... or the icon (Data Logging dialog is opened) Figure 3.25 Open Data Logging Figure 3.26 Data Logging To load: Click on: and Select the file to be loaded from the “Open” file dialog window NOTE Set the tick desired by you to activate the option. To select: Open data logging and click on: Desired device (pull down menu with all available devices) Desired measured value (pull down menu with all corresponding measured values) Desired options: Display single line (the selected measure value is displayed) or Display several lines (the selected and inserted measured values are dis- played with their individually definable scaling and formatting) and Click on (allows you an assignment of the selected measured value) Click the button (select the appropriate action from the drop down menu) Append: adds the selected parameter to be monitored to the selected button. Delete: removes the selected parameter from the selected button. or Properties... opens the “Line Setting Definition” dialog window and If necessary assign its scaling individually by clicking on LeoPC1 User Manual © Woodward Governor Company Page 54/54 37146 To log:Open data logging and click on: (The “Data logging –parameter” dialog window will open) Figure 3.27 Data Logging - Parameter Desired editing box:Sampling rate (enter value between 2 and 120 seconds) and/or Logging time period (value between 1 and 32,767 minutes possible) (Parameter dialog is closed) NOTE Prior to starting data logging ensure that there is enough storage space for the file that is created. When smaller sampling rates for longer periods of time are utilized, the larger the file size becomes. If adequate storage space is not available for the data-logging file, the data logging will not occur. Files of several megabytes can be produced quickly with long periods of data logging. The file for the data logging session is create prior to the session starting, preventing the hard drive space being utilized for other applications. (A dialog window for changing the scaling range is opened) Figure 3.28 Data Logging - Scaling Select desired options:Complete logging time period (according to the specified time) or Individual setting and Enter time range from... to... Select desired options:Complete value range (according to the specified parameters) or Individual setting and Enter measured value range from... to... Verify changes by clicking on (scaling dialog is closed) Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 55/55 NOTE A change in the scaling results in an enlargement of the extracted data that is retained after the logging window is closed. If the option “Display several lines” is selected, the individual lines may be defined and activated by selecting the desired parameter button and editing the scaling for that parameter. Click (the selected recording will be started) To zoom: Place the cursor at the start of the area that is to be examined and highlight the desired area by pressing and holding the left mouse key. Release the mouse key when the desired area is completely highlighted. It is possible to perform this process multiple times. Reset the zoom by clicking the right-hand mouse key (if necessary, by click- ing it several times). The user may zoom out by pressing and releasing the right mouse button. This may be performed multiple times or until the origi- nal scale is displayed. To stop: Click on: (Only if it is necessary to terminate the procedure prema- turely) To print: Click on: And Select the desired options in the print dialog To save: Click on: And Select via the Save as dialog NOTE File name must end in ".llo" and the file must have the format LLO. To unload: Click on: (Only if you would like to close the file currently loaded) Disconnect: Click on: Communication...disconnect or the icon (terminates the connection) LeoPC1 User Manual © Woodward Governor Company Page 56/56 37146 Short-term Storage ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ LeoPC1 can log specific criteria of selected events from the available control units. The monitored parameters for this selective logging are displayed as a guide value. Components of the Short-term Storage The LeoPC1 provides a Short-term storage dialog for logging appropriate defined events or limiting values. Functions are as follows: General dialog:with the following options: Current settings Selected device: Activation by: <selected parameter/alarm/value> Start Short-term storage automatically while loading system Buttons: (Opens the Settings dialog) (Starts the desired monitoring) (Stops the current monitoring) Protocol dialog:with the following options: Events that occurred No., Date, File, Start, End, Event (Deletes all events from the display) Buttons:Handling via: (Confirms changes without closing the dialog window) (Opens Help window) (Closes the Short-term storage dialog window) (Confirms changes and closes the dialog window) Settings dialog:Tunable: • Device (pull down menu with all available devices) Value for activating Short-term storage • Alarm (pull down menu with all possible alarms) • Exceeding a limit value (pull down menu for parameter, box for limit value) • Edited value (selection of the Displayed ID, the operator, box for event value) Recording parameter • At issue time in seconds • Saving interval in seconds • Hold-back time in seconds • Follow-up time in seconds File name (file name the event is saved as in the DL directory) Display of the expected storage space requirement per event Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 57/57 Procedure for Short-term Storage NOTE Only one event can be monitored at a time. If the monitored fault condition occurs during the follow-up time, the event is not logged. The short-term storage is still processing the data from the previous fault occurrence and is not reset for monitoring. The parameter settings described in the following text are dependent upon the configured settings and the configuration of the plant to be monitored. If a low save interval setting is configured and a large data base must be processed or a low Hold-back time is configured, the result may be that the time in- terval that is save is larger than the time interval that was configured. To open short-time storage: Click on: Devices...Short-term storage...or the icon (the Short-term storage dia- log window will open) Figure 3.29 Open Short-term Storage Figure 3.30 Short-term Storage LeoPC1 User Manual © Woodward Governor Company Page 58/58 37146 To set:Open short-term storage and click on: General tab page (changes the dialog level) (Opens the Settings dialog) Figure 3.31 Short-term Storage - Settings Desired event source:Desired device (pull down menu with all available devices) Desired event:Activation of: Error/Alarm Enable by clicking on text (activates as soon as the defined alarm has oc- curred) and Selection of the error/alarm message of the pull down list with all defined events. NOTE If an event that is controlled by an alarm message, only select the activating message. Exceeding a limit value Enable by clicking on text (activates as soon as a limit value has been ex- ceeded) and Selection of the desired measured parameter from the pull down list and Input of the desired upper limit value NOTE If you wish to utilize the option "Exceeding a limit value", select the parameter to be measured and en- ter the corresponding limit value. Edited value Activates as soon as the condition is fulfilled and Selection of the desired display ID from pull down menu (list of protocol) and Selection of the appropriate operator NOTE The option "Edited value" offers the user more complex configurations. This does also require detailed knowledge of operands. The input of the value occurs unformatted (i.e. a battery voltage of 24.8 volts (formatted) is input as 248 (unformatted)). Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 59/59 Operand AND Less than Less equal Greater than Greater equal Equal Description Logic AND, for interpreta- tion binary values Less than the specified value Less than or equal tithe specified value Greater than the specified value Greater than or equal tithe specified value Equal to the specified value Input AND < <= > >= = Desired parameters: Input of: At issue time Minimum time for which the event must occur to activate monitoring Saving interval Minimum time that should lie between two data samplings Hold-back time Time that is logged before and after the event occurs to show system status prior to and during the fault condition Follow-up time Time required for the data logging to process the collected data NOTE The Holdback time and the Follow-up time added together make up the entire logging time period. and File name (designation of the file in which the event period is saved) Example Event-on_2001-07-13_at_12-12_hrs.llo NOTE When assigning the file name, it is possible to use a time stamp: Permitted formatting Year Month Day Weekday / Week Hours / Minutes / Seconds Input %Y / %y %m / %b / %B %d / %a / %A %w / %W %H / %M / %S Format (example) 2004 / 04 06 / Jun / June 30 / Mo / Monday 3 / 27 10 / 55 / 45 To monitor: Open short-term storage and click on: (in the status line "STS" appears) Start Short-term storage automatically upon loading the configuration and If a defined event occurs, logging is activated To stop: Open short-time storage and click on: and Monitoring of the event is terminated NOTE It is possible to graphically display the generated files via the data logging module and, if required, se- lect and export the measured values as described there. LeoPC1 User Manual © Woodward Governor Company Page 60/60 37146 To monitor:Open short-time storage and click on: Protocol tab (changes the displayed tab page) Figure 3.32 Short-term Storage - Protocol and The events that have already occurred are displayed with: No., Date, File, Start, End, Event (Deletes all displayed events from the dialog window) NOTE The “Events that occurred” list does not automatically update. To update the list the dialog window must be closed and re-opened. When a new event occurs the previous events are deleted from the dis- play. Alarm Management ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ LeoPC1 can log and display all events and alarms that occur in the connected devices. Components of the Alarm Management The following components are available for alarm management: Alarm Management Dialog with the Following Functions: Desired alarm file:Selection via scroll menu of the possible devices Buttons:Handling via: Corresponding alarm list:Display of alarm time (Time... until...) (Opens Help window) (For manual entries in the alarm list) (Currently not functional) (Closes the alarm management dialog window) Current Alarm Dialogs with the Following Functions: Current alarms:Display of the current or device specific alarms Buttons:Handling via: (Opens help window if available) (Closes the current alarm dialog window) Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 61/61 Procedure for Alarm Management NOTE If configured as follows, a new file is created for each day. The file name is assigned as the date. Communication to the control unit must exist for these files to be created. To define system settings: Click on: Devices...Settings... (Settings to parameterize system dialog window will open) Figure 3.33 Open Device Settings Figure 3.34 General Options Editing box: Click on the text box for ”Path for alarm files”: and enter directory or Click on the icon and select from the “Select Path” directory dialog window (”ALARMS\” is the default) NOTE This directory is always relative to where the corresponding plant configuration file (CFG file) is stored and is not relative to where the applications file "Main.exe" is located. If the CFG file is not stored in the main directory, the user must specify the path completely for the directory ”ALARMS\“ or in the di- rectory where the CFG file is located an alarms directory must be created. Ensure that the pathway input into the settings ends with '\'. Editing box: 'Help file for alarms': and enter file path or Click on the icon and select file path from the “Open” file dialog win- dow LeoPC1 User Manual © Woodward Governor Company Page 62/62 37146 Managing Alarms To open alarm management:Click on: Alarms...Management... (“Alarm Management” dialog window will open) Figure 3.35 Open Alarm Management Figure 3.36 Alarm Management To select:Open alarm management and click on: Desired file in the scroll menu alarm files To print:Open alarm management and click on: and Select the desired options in the print dialog window To comment:Open alarm management and click on: (Manual input in the alarm list dialog window will open) Figure 3.37 Manual Input Into Error List and Manually enter the desired text (line break with Ctrl +Enter) Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 63/63 Show Current Alarms To open current alarms: Click on: Alarms...Show current ... (“Current Alarms” dialog window will open) Figure 3.38 Open Current Alarms or (Indicates only device-specific current alarms) Figure 3.39 Current Alarms (Shows you an explanation for the highlighted alarm) LeoPC1 User Manual © Woodward Governor Company Page 64/64 37146 Loading Languages ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ LeoPC1 can transfer to connected devices a different language. The corresponding operating instructions provide you with Information about the facilities of your devices. The following instructions provide the procedures for facilitating this function. Components of Loading Languages LeoPC1 provides a Load language dialog window for transferring a language to a control unit with the follow- ing functions: Device to be controlled:Selection via pull down menu with the available devices Relevant parameters:Display of: INFO lines (displays comment lines) xxxx lines (xxxx stands for the number code of the device parameters) Texts to be transferred:Selection options for: All texts (marks all texts for transfer) Transfer language (user specified lines are transferred) Buttons:Handling via: (Closes the load language dialog) (Calls corresponding Help) (Opens the desired language file) (Prints out the loaded language list) (Stops the transfer, if required) (Transfers your selection to the device) Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 65/65 Procedure for Load Language NOTE To transfer languages to your device a connection to your plant must exist. Please ensure that no other device is connected at the same time. To connect: Click on: Communication...Connector the icon (connection to the selected de- vice will be established) To switch clear the device: Click on: Devices...Configuration... or the icon (the “Parameterization” dialog window is opened) Figure 3.40 Open Parameterize Highlight parameter "password level 2" in the list box or Double click on parameter "password level 2" (input dialog window will open) Figure 3.41 Enter Password and Enter the password. Verify the password by clicking on . NOTE After the password has been accepted, the language can be loaded into the control unit. Refer the to the product manual prior to attempting to transfer the language texts to ensure that all set- tings are correct. To call: Click on: Devices...Load language... or the icon Figure 3.42 Open Load Language and Select the desired file from the “Open” file dialog window NOTE The file name must end with ".lng" and the file must have the LNG format. LeoPC1 User Manual © Woodward Governor Company Page 66/66 37146 Figure 3.43 Load Language Select the desired device (pull down menu with all available devices) The suitable language lines are displayed on the scroll menu To transfer:Click on: texts to be transferred All texts (all language texts are selected) or Texts from ... to ... (enter code number range) (Your desired selection is transferred) NOTE Depending on the selection and options the language transfer can take awhile. To stop:Click on: (Please only if it is necessary to terminate the procedure prematurely) To print:Click on: and Select the desired options in the print dialog OK (language texts are printed out) To disconnect:Click on: Communication...Interrupt or the icon (terminates the connection) Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 67/67 Event Recorder ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ LeoPC1 can read the event recorder from the available devices. If this function is integrated, the appropriately defined events can be called up and printed out. Components of the Event Recorder LeoPC1 makes available to the user the reading of events or errors an event recorder dialog window with the following functions: Device: Selection via the pull down menu with the possible devices Read date: All or already read events as of the date ... Relevant parameters: Display of: Date on which read (only for 'Date read: All displayed) Event/error number, date, description, value (if defined) Buttons: Handling via: (Closes the event memory dialog window) (Opens Help window) (Prints out the read event lists) (Deletes all previously read events) (Starts reading of the event from the device) (Resets the event memory, if this function is defined) Procedure for the Event Recorder NOTE To read events out of your device a connection to your plant must exist. To connect: Click on: Communication...Connect or the icon (connection to selected device will be initiated) To open event recorder: Click on: Devices...Event recorder... or the icon (event recorder dialog is opened) Figure 3.44 Open Event Recorder LeoPC1 User Manual © Woodward Governor Company Page 68/68 37146 Figure 3.45 Event Recorder Open event recorder and click on pull down menu of: Device: (device desired to be read) and/or Date read: (date of event desired to be read) and Selection of the list of all events already read. Read events:Open event recorder and click on: (If you want to delete the displayed earlier read values) (The process is started) and Wait until the list is displayed or a prompt opens with instructions NOTE The read out of the event recorder can take some time depending on the device and the selected con- nection. The displayed events can be filtered by using “Read Date” as long as the events have been read previ- ously and not deleted. To print:Open event recorder and click on: and Select the desired options in the print dialog window (Event list is printed out) To disconnect:Open event recorder and click on: Communication...Interrupt or the icon (terminates the connection) Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 69/69 Chapter 4. Communication and Connection LeoPC1 can communicate with other software and hardware. It has to be differentiated between the following communication types: Devices Hardware that is compatible to the LeoPC1. Applications Software compatible to CSV format such as EXCEL or ACCESS Various drivers and a data export are available to the user for these communications and are explained in further detail below. General Information ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Hardware and software interfaces are at the center of the data communication. Correct connection, settings, and operator control are required to ensure that the communication functions correctly. Take the following informa- tion into consideration where it relates to your requirements. If there are any questions or problems, refer to the supplied documentation or contact the manufacturer of the product (e.g. modem, CAN card, cables, etc.). Communication with Devices ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ LeoPC1 supplies at your disposal the drivers listed below. Drivers for Serial Interfaces Direct Interface The direct driver of LeoPC1 provides permits the user to directly configure the control unit through a serial con- nection to the computer and an RJ45 connection on the control unit. The RS-232 standard for communications is utilized with this function. The device will dictate the number of functions that may be performed through this method of communication. Gateway RS-232 Interface LeoPC1 provides the user with the ability to utilize the Gateway RS-232 driver. This permits the user to config- ure the control unit with the RS-232 standard without using an RJ45 connection. This does require the user to drive an Gateway RS-232 in the system. This method of communication assumes that all devices in the system are communicating via a CAN bus. This method of interfacing permits the user to utilize most of the properties of LeoPC1. Modem Interface LeoPC1 provides the user with the ability to utilize a modem driver. This permits the user to configure the con- trol units via an analog modem through the RS-232 standard without using an RJ45 connection. This does re- quire the user to drive an analog modem in the system. This method of communication assumes that all devices in the system are communicating via a CAN bus. This method of interfacing permits the user to utilize most of the properties of LeoPC1. LeoPC1 User Manual © Woodward Governor Company Page 70/70 37146 Components of the Drivers for Serial Interfaces Direct Interface Figure 4.1 Direct interface Gateway RS-232 interface Figure 4.2 Gateway RS-232 interface Modem Interface Figure 4.3 Modem interface NOTE These wiring diagrams are only examples. Depending on the devices, other connections may be re- quired. Refer to the manual for the specific requirements of your device. Procedure for Serial Drivers NOTE Before the drivers can be utilized, the hardware configuration of the control units must conform to the relevant circuit diagram or according to the unit documentation. Furthermore, you should check the software configuration with the aid of the steps described and, if necessary, adapt it to suit your re- quirements. In addition to the hardware requirements. If the required driver is not installed on the computer to be utilized, the LeoPC1 installation program must be re-initiated and the required drivers installed. If only the demo version of LeoPC1 is available, contact your support team for assistance with obtaining the required drivers. Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 71/71 To set driver: Click on: Devices...Settings... (The “Settings to parameterize system” dialog window will open) Figure 4.4 Open Device Settings General settings tab (changes the displayed tab page) Figure 4.5 General Options Select the desired driver (pull down menu with all installed drivers) (Settings for driver name dialog window will open) Figure 4.6 Settings for Serial Drivers LeoPC1 User Manual © Woodward Governor Company Page 72/72 37146 Possible parameters:Port (please allocate your corresponding COM port) Port Select COM1, COM2 or according to PC configuration Baud Set the permissible transfer speed in accordance with the specifications of the hardware being utilized Parity Set ”None” for asynchronous transfer Data Bits Set ”8” for asynchronous transfer Stop Bits Set ”1” for asynchronous transfer NOTE Information about COM port assignment can be obtained via: - Start...Settings… Control Panel...System and corresponding selection of the options. Information about the permissible baud rate can be obtained from the device’s documentation. For ex- ample, the Gateway operates at 9,600 baud. If any problems occur, the selected driver can still be indi- vidually configured by clicking on ”” and adapted to the plant. Most configuration files are have default values for the communication methods that do not required the user to modify these parameters. Only modem connections may require that the user to modify the settings according to the individual system conditions. Depending on the driver, the user can modify the following settings in this dialog window: Computer-related settings Guide values: The settings specified here are guideline values that should be adapted to special situations as necessary. The values found in the parenthesis may be used for many units and are safer for use when doubt ex- ists for what value should be entered. Description Direct Gateway RS- 232 Modem Number of repetitions to send a command 3 (5) 3 (5) 0 (10) Timeout after writing a command 0 (50) 0 (100) 500 Delay between writing a command 10 (150) 10 (150) - Timeout after reading an incorrect answer (CAN error) 0 0 (500) 0 (1000) Number of repetitions to read the answer 3 (5) 3 (5) 3 (10) Timeout for reading the answer 300 (500) 300 (500) 300 (700) Timeout if no answer was received 100 200 200 (500) Table 4.1 Driver settings - Serial Flow chart: This flow chart shows you the steps LeoPC1 takes when attempting to establish communication with a device. This chart can be helpful determining what values may need to be adapted to your individual re- quirements. Figure 4.7 Driver Timeouts Handling Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 73/73 Description of the flow chart: 1. When a command is written/sent, the time for "timeout after writing a command" and "timeout for read- ing the answer" is started. If a valid answer is received before the time expires, the next command starts or the procedure ends. 2. If an invalid answer is received, the "timeout after reading an invalid answer" is started. If this time ex- pires without receiving a valid answer, the "number of repetitions while reading the answer" is activated and begins its cycle at "timeout for reading the answer". 3. If a valid answer is not received see step #6. 4. If no answer is received, the time for "timeout if no answer has been received" is started. If this time ex- pires without receiving an answer, the "number of repetitions while reading the answer" is activated and begins its cycle at "timeout for reading the answer". 5. If an answer is not received see step #6. 6. If the "number of repetitions while reading the answer" has elapsed without a valid answer being re- ceived, the "number of repetitions for send command" is initiated and the procedure begins again at step #1. 7. If the "number of repetitions for send command" is run through without a valid answer, the procedure is aborted. Plant-related settings Modem Strings Description Initializing Attention command ATH (external) ATH&F0 (internal) Connect (P/D#) Attention command ATDP (pulse dialing process) ATDT (tone dialing process) ATX1DT or P (internal) Disconnect Attention command +++~~~~ ATH ^M Handicap for telephone number Enter here your standard connection (if dialing via an outside line, enter '0W' as prefix) Allow user to change telephone number? Allows you to input telephone numbers other than the stan- dard connection ID for connection Attention command CONNECT Timeouts Initialization Timeout At least '40' seconds Dialing process Timeout At least '40' seconds Table 4.2 Driver settings - Modem NOTE If you would like to establish a connection to a foreign country, it is recommended that each timeout be increased to 60 seconds or more so that the connection can be established. If problems still occur with the connection, please refer to the operating instructions for the modem or contact its manufacturer. LeoPC1 User Manual © Woodward Governor Company Page 74/74 37146 Figure 4.8 Settings for Modem NOTE A connection to the device or devices must exist in order to use the drivers for communication. The exception to this is the demo driver. The demo driver is designed to demonstrate within certain limits the properties of LeoPC1 with requiring a connection to a control device. When the configuration buttons are clicked on, LeoPC1 will prompt the user to initiate communication with the control unit if communications have not already been established. Communications can be specified to start auto- matically when the plant configuration loaded. The procedures for this are shown in the following text. NOTE The status for communication is displayed on the level bar by the appearance of the following icons: + A connection does not exist. + A connection exists (display data are received). + Display data is not being received or the communication is not correct. To set auto-connection:Click on: Devices...Settings... (The “Settings to parameterize system” dialog window will open) Figure 4.9 Open Device Settings General settings tab page (changes the displayed dialog window) Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 75/75 Figure 4.10 General Options Place a check mark in the box to the left of ”Start communication automati- cally while loading system configuration” NOTE If this option is selected, LeoPC1 will attempt to establish a connection with the control unit immedi- ately after the plant configuration is loaded. If this option is not selected, the user must start the com- munication. To connect: Click on: Communication...Connect or the icon (starts the connection to the de- vice) To disconnect: To open event recorder and click on: Communication...Interrupt or the icon (terminates the connection) NOTE Take note of the communication parameters required or desired by the individual plant. Prior to termi- nating the connection ensure whether or not the connection is to be used for remote configuration or control. LeoPC1 User Manual © Woodward Governor Company Page 76/76 37146 Drivers for Network Cards NOTE LeoPC1 currently supports IXXAT products with VCI driver version 1.17 or 2.xx. For example: • iPC-I 320, iPC-I 165 (ISA-PC cards) • iPC-I 320 PCI, iPC-I 165 PCI (PCI-PC cards) • tinCAN (PCMCIA-Interface, full support only with 'IXXAT VCI2 CAN' - driver) • USB-to-CAN compact Interface (support only with 'IXXAT VCI2 CAN' - driver) Not all CAN-interfaces are supported by all operation systems where LeoPC1 can be installed. It is not possible to use more than one IXXAT driver version at a time. If the IXXAT driver version 1.xx is currently installed on the PC/laptop, the user will be prompted to completely delete this file. If VCI 1.xx has never been installed or after the files have been deleted, driver version VCI 2.xx can be in- stalled by using the LeoPC1 software installation utility. CAN Bus Interface By means of the CAN bus driver LeoPC1 provides the user the ability to connect the control units via the CAN bus to a PC/laptop, provided that the PC is compatible with one of the listed CAN cards. This interface permits the user’s PC/laptop to be automatically connected to the plant, machines, and devices. The user can set parame- ters, control remotely, display, and load languages if necessary. Components of the Network Card Drivers You will find the circuit diagrams for the individual network card drivers here: CAN Bus Interface Figure 4.11 CAN bus interface Procedure for Network Card Drivers NOTE Before the drivers can be utilized, the hardware configuration of the control units must conform to the relevant circuit diagram or according to the unit documentation. Furthermore, you should check the software configuration with the aid of the steps described and, if necessary, adapt it to suit your re- quirements. In addition to the hardware requirements If the required driver is not installed on the computer to be utilized, the LeoPC1 installation program must be re-initiated and the required drivers installed. If only the demo version of LeoPC1 is available, contact your support team for assistance with obtaining the required drivers. Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 77/77 CAN Bus Interface To set: Click on: Devices...Settings... (The “Settings to parameterize system” dialog window will open) Figure 4.12 Open Device Settings General settings tab page (changes the displayed tab page) Figure 4.13 General Options Select the CAN bus driver (pull down menu with all installed drivers) (CAN Settings dialog window will open) LeoPC1 User Manual © Woodward Governor Company Page 78/78 37146 Figure 4.14 CAN Settings NOTE You can obtain information about the following parameters among others via: - Start...Settings… Control Panel...System and corresponding selection of the options The documentation for the hardware being used can provide the necessary information as well. Setting parameters:Select, if not already automatically assigned, for: Board Click the button and the card type available for use will be displayed Figure 4.15 CAN-Hardware Segment (only VCI1)The basic address of your CAN card (VCI1-CAN driver only) IRQ (only VCI1)An interrupt used by the CAN card (VCI1-CAN driver only) Protocol The protocol that is used for communication ('Std.' is standard) Chip The chip that is to be used Baud rate The baud rate of the CAN bus If necessary: LPT (only VCI1)The printer port used by the CAN card PCMCIA (only VCI1)The slot in which your PCMCIA CAN card is inserted Download A download of the VCI firmware can be effected Card test A card test can be performed with each communication setup Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 79/79 NOTE If any problems occur, the driver can still be individually configured for your CAN card and adapted to your plant. To adapt: Click on: (“Options” dialog window will open) Figure 4.16 CAN Settings - Options Timeout The amount of time LeoPC1 will wait for an answer to a sent command Number of repetitions How many times a command is re-sent to the CAN bus card after a timeout. NOTE The following entries require detailed knowledge of the device and protocol that is used. CAN ID while sending ID to be used for sending commands Offset CAN buffer Offset of the data sent by the CAN bus to the internal buffer NOTE Select the button to change the allocation table between device no. and CAN ID no. The “Allocate device No. To CAN-ID” dialog window is opened for the purpose of managing the device no. and CAN ID allocation table. This dialog window permits the user to change or delete existing entries and add new entries by marking the desired lines, changing the required inputs, and/or clicking on the corresponding button. All connected CAN bus device numbers must be assigned here with LeoPC1. If no entry appears in this list box, communication via the CAN driver is not possible. CAN-IDs should not be assigned to more than one device. The CAN-ID for sending a command should not be assigned a device number. LeoPC1 User Manual © Woodward Governor Company Page 80/80 37146 Figure 4.17 Allocate Device No. To CAN- ID For demonstration purposes LeoPC1 displays a driver without devices being connected. Only the time delay for saving for this demo driver can be configured. No other configurations can be achieved. To set:Click on: Devices...Settings... (The “Settings to parameterize system” dialog window will open) General Options tab page (changes the displayed tab page) Select the Demo driver (pull down menu with all installed drivers) (Settings - demo version dialog window will open) Figure 4.18 Settings – Demo Version Editing box:”Delay at saving” and Input desired time in milliseconds (ms) (Settings - demo version dialog window will close) Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 81/81 Communication with Other Applications ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ CSV Interface LeoPC1 provides for further processing of the logging data from the "Data Logging" utility of the plant, ma- chines, or devices for use with other applications such as EXCEL or a database like ACCESS. This is the func- tion of the CSV interface. Only the data from one device may be stored in a file that limits the interface to only being able to display the data from on device. Components of the CSV Interface The CSV interface consists of a normal ASCII file in CSV format. A corresponding character separates the indi- vidual entries. This allows the files to be read and processed for use in spreadsheet programs and databases with a corresponding software interface. Procedure for the CSV Interface NOTE The user can adapt the system settings according to the plant requirements if required. To prepare export: Click on: System...System settings... (The “System settings” dialog window will open) Figure 4.19 Open System Settings Settings tab page (changes the displayed tab page) Figure 4.20 System Settings Desired option Select or edit the following two parameters. Output heading line? Enable by placing a check mark in the box to the left of the text. Input Separator (a semi-colon “;” is the preferred character) LeoPC1 User Manual © Woodward Governor Company Page 82/82 37146 To perform export:Click on: Devices...Data logging... or click the icon (The “Data Logging” window will open) Figure 4.21 Open Data Logging NOTE If no data exists, refer to “Procedure for Data Logging” on page 52 and follow the user instructions in order to log and save the required data your plant. (The "Save As" dialog window will open) Figure 4.22 Save Export and Select from: Editing box:"File name" (please enter the desired designation) or Selection from the directory menu and file list EXCEL compatible file (*.csv) Click on the button (the data will be exported under the se- lected name) NOTE The exported data must be in CSV format. If the file name does not end in “.csv”, the data will not be able to be utilized in the spreadsheet program EXCEL or the database program ACCESS. By following the previous steps the user will ensure the data functions properly with these applications. Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 83/83 Chapter 5. Annex Content of the Software Package ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ The software package consists of the following file groups: Applications Main.exe / Unwise.exe Language resources LngGer.dll (German), LngEng.dll (English), LngPrt.dll (Portuguese) System files System.dat (user management), Install.log/.ini (information), *.hlp/.cnt (help) Communication drive DrvModem.dll, DrvGW4.dll (RS-232), DrvCAN2.dll, DrvDiAc.dll (direct) Configuration files *.cfg (definitions), *.asm (objects), *.opt (options), *bmp (pictures) Plant files *.std (standard values), *.llo (loggings), *.csv (export), *.alm (alarms), *.dat (event recorder), *.lng (load language) NOTE The list below may have some missing information or information duplicated in it. Directories and Designation of the Installed Component Files Application %Main directory% Main.exe Unwise.exe Alarms\*.alm Install.ini Unwise.ini Dl\*.llo und *.csv MainUtil.ocx System.dat Lng\*.lng LngGer.dll LngEng.dll PICTURES\*.bmp LngPrt.dll ReadMe.txt Std\*.std HelpGer.hlp HelpGer.cnt TOOLS\*.asm und *.opt HelpEng.hlp HelpEng.cnt Bckgrnd.bmp prnLogo.bmp Demo/Direct DrvDemo.dll DrvDiAc.dll Gateway RS-232/Modem DrvGW4.dll DrvModem.dll CAN-Bus (VCI1/VCI2)DrvCAN1.dll DrvCAN2.dll CAN components %System% (C:\WINDOWS\SYSTEM or YSTEM32) General Cci14c26.dll Xacdyapi.dll Uci20cci.dll Xatisahw.dll Cci14t26.dll Drvrapi.dll Cci31dp6.dll Xat11reg.dll Cci14dp6.dll Cci31usb.dll Xat12c16.dll Cci14i46.dll Cci16dp6.dll Xat24dp6.dll Tca_32.dll Cci16c26.dll Vci11unb.dll Pciacc32.dll Axhost.dll Vci_w32.dll Vci_w32.dll Xatinst.cpl Drivers\ WinNT Xatpcikl.sys Cndy.reg Xat12c1.sys Xatcdykl.sys Tincanv2.reg Xat24dp.sys Mpmi2e.sys Xatpcikl.reg Xat10d25.sys Win9x and Xatcdy.vxd Mpmi2e.vxd Inf\ xat20u23.sys Win2000/XP (VCI2 only)xat10c16.dll xat11dp6.dll Xatusb.inf Xat10u23.sys xat12pc6.dll xat11c1.vxd Xat_pci.inf Xat10d24.vxd xat40t16.dll Xat22dp.vxd Xat_pcm.inf Xat24dp.vxd vci11un6.dll Xat_isa.inf Xat12c1.vxd System components Msvcp60.dll Asycfilt.dll Comctl32.ocx Msvcrt.dll atl.dll Comdlg32.ocx Msvcirt.dll Dao350.dll Comcat.dll Msvbvm60.dll mfc42.dll Olepro32.dll Msstkprp.dll Stdole2.tlb Oleaut32.dll Table 5.1 Component files – Installation LeoPC1 User Manual © Woodward Governor Company Page 84/84 37146 NOTE The graphs and pictures (*.bmp) supplied can be altered with a standard image-editing program (CorelDraw, Microsoft® Paint, etc.). The configuration files (*.cfg and *.asm) can be edited with a standard text editor (such as Micro- soft®WordPad, Microsoft® NotePad, MultiEdit, etc.) Registration Data Base Settings in the registration database can be computer-dependent or user-dependent. The following two segments list entries that are present in the registration database. The specified values are installed as default values, which, if necessary, may be changed during the application. Other entries may be changed, if necessary, during use of the application. Computer-dependent [HKEY_LOCAL_MACHINE\Software\] NOTE The export, data logging, and system modules are comprised of code that can be configured through LeoPC1. Application %Main key% Default background "LogoBitmapFile"="Bckgrnd.bmp" Display of splash in ms "SplashTime"=dword:00000bb8 Aktive language "Language"="Deutsch" Output of export header "ExportHeader"=dword:00000001 Active separator symbol ExportSeperatorKey"=";" Autostart Short-term storage "STSAutostart"=dword:00000000 Autostart data logging "DataLoggingAutostart"=dword:00000000 Autosaving of data logging "DataLoggingAutosave"=dword:00000000 Active backup file "DataLoggingAutosaveFile"="" Time period parameter X "DataLoggingXSetting"=dword:00000001 Start time "DataLoggingXStart"=dword:00000000 End time "DataLoggingXEnd"=dword:0000012c Measured value parameter Y "DataLoggingYSetting"=dword:00000000 Minimum value "DataLoggingYStart"=dword:00000000 Maximum value "DataLoggingYEnd"=dword:00000320 Sampling rate "DataLoggingRate"=dword:00000002 Logging time period "DataLoggingTime"=dword:0000012c 0=zero, 1=file, 2=window "CfgSyntaxCheck"=dword:00000000 File name "CfgSyntaxcheckFile"="syntax.log" Table 5.2 Registration Software keys – Main NOTE Code comprises all installed languages, their dynamic configuration value, and the relevant assigned help file. The user can select the desired language from the “Load Language” dialog window in LeoPC1 from all available languages. Application %Sub key% Languages\"Deutsch"="LngGer.dll,0" "English"="LngEng.dll,1" "Portuguese"="LngPrt.dll,2" \Helps "Deutsch"="HelpGer.hlp" "English"="HelpEng.hlp" "Portuguese"="HelpEng.hlp" Table 5.3 Registration Software keys – Language and Help Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 85/85 NOTE The directory variables are comprised of code. These variables can be used in the CFG files when the bit maps or configuration files are specified. The settings can be edited through LeoPC1 under System Settings...Paths tab page. Application %Sub key% \Environment "ASM_PATH"="main directory\Tools" "BITMAP_PATH"="main directory\Pictures" "LNG_PATH"="main directory\LNG" "STD_PATH"="main directory\STD" "DL_PATH"="main directory\DL" \DL \Value0 \... \Value7 Table 5.4 Registration Software keys – Environment and DL NOTE The individual communication drivers are comprised of code. The driver list contains all configured in- terface drivers. New interface drivers are automatically entered in this list when installed. Additional plant-specific files may be found in the CFG files. Application %Sub key% \Drivers "Demo"="main directory\DrvDemo.dll" "Direkt"="main directory\DrvDiAc.dll " "Modem"=" main directory\DrvModem.dll " "Gateway RS-232"="main directory\DrvGW4.dll " "IXXAT VCI2–CAN"="main directory\DrvCAN2.dll " \DrvDemo "Timeout"=dword:000007d0 \DrvDiAc "Port"=dword:00000001 \DrvGW4 "Port"=dword:00000001 \DrvModem "Port"=dword:00000001 \DrvRS-232 "Port"=dword:00000001 \DrvCAN Entries are dependent on the driver version and the hard- ware that is installed. Table 5.5 Registration Software keys – Drivers NOTE Further entries are achieved under [HKEY_CLASSES_ROOT], [HKEY_USERS\Software\], and [HKEY_USERS\.DEFAULT\Software\]. These are used for internal application functions. If necessary, they can refer to other codes. LeoPC1 User Manual © Woodward Governor Company Page 86/86 37146 FAQ ≡≡≡≡≡≡≡≡≡≡≡≡ Listing of Selected Error Messages Error number Description -1 Unknown error -13 COM-Port is not connected/available -15 Error while modem initialization -16 Error while connecting (modem) -123 Wrong device/communication-ID -232 Access to device was refused: wrong module was selected, Password is missing/wrong, etc. -1009 VCI (CAN) was canceled -1011 VCI (CAN) was disconnected -1012 CAN bus buffer overflow -1013 CAN bus did not answer Table 5.6 FAQ – Error descriptions No faults are logged in an Error File. If new files are not created, the user can check this by adding a manual entry. If this is not possible, check whether the directory that is entered in the device settings actually exists. The Data for Data Logging is stored in the Swap File and not in a Normal File. Please check whether there is a subfolder named DL in your folder containing the configuration file. If not, cre- ate this folder, as the data logging files are stored here. If this folder does not exist, the data logging files will be stored in the swap file. The PC has crashed. Is my Logging Data now lost? A special logging procedure ensures that the data is not lost, even if the computer crashes. Start up the PC and restart LeoPC1. The data will be available until data logging is restarted. Driver Settings are reset again and again. Ensure that the CFG file is not write-protected. If the CFG file is write protected, disable the write protection since some of the settings are managed in the CFG. Why is the Logo of the LeoPC1 not printed out? Check if the cfg file was loaded from the mains directory. If it was opened from another directory, then the suited logo file ("prnLogo.bmp") must be stored there. The file is in bmp format and has the following size: width: 308 pixel, height: 86 pixel. Starting the Configuration the Message appears: "File not found *.opt" The required *.opt file is expected to be located in the sub directory ”Tools”. It must be in the same directory as the cfg file, which has to be opened. For example the *.cfg file is located in: " C:\Program Files\Woodward\LeoPC1\cfg ", then the *.opt file is expected to be located in: " C:\Program Files\Woodward\LeoPC1\TOOLS ". Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 87/87 Is Communication possible via COM Interface (direct, Gateway RS-232), if the Laptop/PC doesn’t have a (free) COM Port? It is possible to configure a COM port over a USB interface with compatible hardware and software that can be utilized by LeoPC1. You cannot configure! Problem 1: Neither reading nor writing is possible Problem A: Error sources on the devices side: Question 1 Is the parameter "Direct para" in the device configured "ON" for direct drivers or "OFF" for all other communication drivers? (Modem, Gateway RS-232, and IXXAT VCI2 – CAN)? Question 2 Are the connections for the PC, direct parameterization (DPC) cable, and the device good? If necessary test with a different DPC cable! Question 3 Is an extension cable being used? Check the polarity to ensure the input pins are connected to the correct out- put pins. Problem B: Error sources on the software side: Question 1 Have you selected the correct driver for your configuration? If it's INCORRECT, select the correct driver. Question 2 Is the correct COM port configured in the driver settings? Ensure the correct COM port being utilized is the same as the COM port configured in the driver settings. Question 3 Is any other software using the COM port? Close the software application that is using the COM port so LeoPC1 may start communications. The COM port can only be utilized by one application at a time. Question 4 Are the communication timeouts configured correctly? Use the guide values in the driver settings (it is better to set higher values if doubt exists whether the configured time is too short). NOTE Modem connections from LeoPC1 must comply with the operating instructions for the modem being utilized. Other AT commands may result from this pre-specified as defaults. Problem 2: Reading is possible, but writing not. Problem B: Error sources on the software side: Question 5 Has the correct password been input via LeoPC1? If not, input the level 2 code in the device. Question 6 Are the expected password and the input data correct? If not, input the correct password and/or data. LeoPC1 User Manual © Woodward Governor Company Page 88/88 37146 Problem 3: Reading and writing of individual parameter values possible via input, but parame- ters are not being read when “Read All” is used. Problem B:Error sources on the software side: Question 7 Are the formatted values readable? If not, the problem most likely is with the device. NOTE It is recommended to establish communication with a control device via the “Parameterization” dialog window to perform a readout of the parameters and storage of the STD file rather than producing an STD file offline that will be loaded into a control unit at a later date. Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 89/89 How to Contact Woodward ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Please contact following address if you have questions or if you want to send a product for repair: Woodward Governor Company Leonhard-Reglerbau GmbH Handwerkstrasse 29 70565 Stuttgart - Germany Phone: +49 (0) 711 789 54-0 (8:00 - 16:30 German time) Fax: +49 (0) 711 789 54-100 e-mail: sales-stuttgart@woodward.com For assistance outside Germany, call one of the following international Woodward facilities to obtain the address and phone number of the facility nearest your location where you will be able to get information and service. Facility Phone number USA +1 (970) 482 5881 India +91 (129) 230 7111 Brazil +55 (19) 3708 4800 Japan +81 (476) 93 4661 The Netherlands +31 (23) 566 1111 You can also contact the Woodward Customer Service Department or consult our worldwide directory on Woodward’s website (www.woodward.com) for the name of your nearest Woodward distributor or service fa- cility. [For worldwide directory information, go to www.woodward.com/ic/locations.] Internet Download of the Software ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ The latest version of the LeoPC1 you can download from the following internet page www.woodward.com/software/Software.cfm and select LeoPC1 from the list right there. LeoPC1 User Manual © Woodward Governor Company Page 90/90 37146 Engineering Services ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Woodward Industrial Controls Engineering Services offers the following after-sales support for Woodward prod- ucts. For these services, you can contact us by telephone, by e-mail, or through the Woodward website. • Technical support • Product training • Field service during commissioning Technical Support is available through our many worldwide locations, through our authorized distributors, or through GE Global Controls Services, depending on the product. This service can assist you with technical ques- tions or problem solving during normal business hours. Emergency assistance is also available during non- business hours by phoning our toll-free number and stating the urgency of your problem. For technical engineer- ing support, please contact us via our toll-free or local phone numbers, e-mail us, or use our website and refer- ence technical support. Product Training is available on-site from several of our worldwide facilities, at your location, or from GE Global Controls Services, depending on the product. This training, conducted by experienced personnel, will as- sure that you will be able to maintain system reliability and availability. For information concerning training, please contact us via our toll-free or local phone numbers, e-mail us, or use our website and reference customer training. Field Service engineering on-site support is available, depending on the product and location, from our facility in Colorado, or from one of many worldwide Woodward offices or authorized distributors. Field engineers are experienced on both Woodward products as well as on much of the non-Woodward equipment with which our products interface. For field service engineering assistance, please contact us via our toll-free or local phone numbers, e-mail us, or use our website and reference field service. Manual 37146 LeoPC1 - User Manual © Woodward Governor Company LeoPC1 User Manual 37146 Page 91/91 We appreciate your comments about the content of our publications. Please send comments to: icinfo@woodward.com Please include the manual number from the front cover of this publication. Woodward Governor Company Leonhard-Reglerbau GmbH Handwerkstrasse 29 - 70565 Stuttgart - Germany Telefon +49 (0) 711-789 54-0 • Fax +49 (0) 711-789 54-100 sales-stuttgart@woodward.com Homepage http://www.woodward.com/smart-power Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address/phone/fax/e-mail information for all locations is available on our website (www.woodward.com). 04/9/S PAS Power Analysis Software for Windows Version 1.2.5 Getting Started SATEC Ltd. BG0337 Rev. A1 Table of Contents Introduction 1 Installation 1 File Formats 1 Automatic Data Retrieving 1 Embedded Communication Test 1 Preprogrammed Data Sets 1 Creating a New Site 2 Setting up Communications 3 Selecting a Protocol for a Serial Port/Modem 3 Communicating through a Serial Port 4 Communicating through a Modem 5 Communicating through Internet 5 Creating Setups for Your Meters Off-Line 6 Downloading Setups to Your Meters 7 Uploading Setups from Your Meters 7 Viewing Real-time Data 8 Changing the Data View 9 Adjusting the Number of Rows in a Multi- Record View 9 Saving Data to a File 9 Printing Data to a Printer 10 Copying Data to Another Application 10 Real-time Data Logging 10 Viewing Real-time Min/Max Log 11 Viewing Real-time Waveforms 11 Updating the Clock in Your Meters 12 Remote Relay Operations on Your Meters 12 Uploading Historical Data on Demand 13 Using the Upload Scheduler 13 Adding a New Site to the Schedule 14 Configuring a Schedule for the Meter 14 Activating a Schedule for the Meter 14 Suspending the Scheduler 15 Running the Scheduler on Demand 15 Recording Upload Problems 15 Viewing Historical Data On-line 15 Opening a Log File 16 Exporting Data to Another Application 16 Saving Data to a File 16 Printing Data to a Printer 17 Viewing the Event Log 17 Sorting Events 17 Filtering Events 17 Viewing the Data Log 18 Viewing the Waveform Log 18 Selecting Waveform Channels 18 Customizing Line Colors and Styles 19 Viewing Phasor Diagrams 20 Viewing Symmetrical Components 20 Selecting Primary and Secondary Units 20 Using the Marker Lines 21 Using a Zoom 21 Viewing Waveforms 21 Viewing an RMS Plot 22 Viewing a Spectrum Chart 23 Viewing a Spectrum Table 24 Customizing Date Order 25 Customizing Timestamp 25 Selecting Voltage Disturbance Units 25 1 Introduction The following paragraphs outline some of the differences between this version of PAS in comparison to previous versions you may have used. Installation If you install the new PAS into the same directory where your current version of PAS is installed, it is recommended that you do not uninstall your old PAS before installing this version; otherwise, your present PAS configuration database will be destroyed. Your current configuration database and all data files you have are still functional in the new PAS. File Formats Although PAS allows you to open ASCII log files created by previous PAS versions, and even to store data from the screen to ASCII files, most new features will only use the Microsoft Access .mdb database format. This format allows you to store different types of logs to a single database as separate tables, and makes it easy to transport your databases onto other PCs. Automatic Data Retrieving PAS allows you to retrieve all data logs from your meters at once and store them to a database, either on demand or on a time basis (e.g., daily or weekly) using a predefined schedule. Embedded Communication Test PAS incorporates the test features that were previously included in the DOS-based PComTest program, allowing you to test communication with your meters. Preprogrammed Data Sets Any data sets you have prepared for the RT Data Monitor and RT Min/Max Log are still functional in the new PAS, although they need to undergo a simple procedure before you can use them: open the Data Set dialog and scroll through all active data sets, and then save them. Perform this procedure for both the RT Data Monitor and RT Min/Max Log. 2 Communicating with Your Meters Creating a New Site In order to communicate with your meters, you should create a separate site database for each one where all meter settings are stored. PAS keeps all site settings in a file with a name you give it and the extension .mdb. When you install PAS on your computer, a directory named "Sites" is created in the PAS installation directory. It is advised to keep all your site databases in this directory. o create a new database for your meter, select 'Configuration' from the Tools menu, and then click 'Sites' at right on the 'Instrument Setup' tab. From the 'Look in' box, select the directory where a new database will be stored. Type a site name for your meter in the 'File name' box, click 'New', and then click 'OK'. You will see the selected site's name in the 'Site' box. As you create new databases, their names are added to the site list that you can browse from this box. In the 'Model' box, select your meter model type, and in the 'Instrument Options' group boxes, specify the voltage and current input and analog output (if any) Chapter 1 T COMMUNICATING WITH YOUR METERS 3 options for your meter. If the meter has an onboard logging memory, select the correct memory module size for your meter. You can add any comments to the 'Comments' box, such as meter location or any other data concerning this particular site. You cannot change the site properties or communication settings when the 'On-line' button on the toolbar is checked. Uncheck it before entering the 'Configuration' dialogs. Setting up Communications Your meters can be connected to a PC through serial communications (directly to your PC RS-232 port, via the RS-485 to RS-232 converter, or through a modem), the Internet (using the SATEC ETC-2002 Network Communicator), or the USB port. To provide PAS with information on your meter location, select 'Configuration' from the Tools menu. In the 'Communication' group on the 'Instrument Setup' tab, select the type of a connection for your meter, and set the device communication address you assigned to the meter. The 'Sampling Rate' box defines a rate at which PAS will update data on your screen when you continuously poll the meter in the PAS Data Monitor. If you selected 'Serial Port/Modem Site', click on the 'Connection' tab to select a port on the PC through which PAS will communicate to your meter. Selecting a Protocol for a Serial Port/Modem On the 'Connection' tab, click on 'Protocol' and select the communications protocol as you have selected in your meter. Note COMMUNICATING WITH YOUR METERS 4 The remaining settings in this dialog do not normally need to be changed. The 'Response Time-out' box defines the maximum time in milliseconds that PAS will wait for the meter response before announcing a failure. When communicating through a modem, especially over long distances, this time may require some adjustment. The 'Break Time-out' box defines the maximum idle time that PAS will wait after receiving the last message character to close a connection. This setting is important only when PAS is running the Modbus RTU or DNP3 protocol. It does not affect ASCII communications. The default value of 10 ms is usually sufficient for reliable communications, but it can be affected by the load on your PC. If there are many applications running on your PC, PAS might be prevented from responding to received characters fast enough, so it might close the communication while the meter is still transmitting its response message. If you frequently receive the message 'Communication failed', this could mean that 'Break Time-out' should be increased. Note that this time is added to the message transfer time, and increasing it excessively will slow communications. The 'Retries' box defines the number of attempts that PAS will use to receive a response from the meter in the event the communication fails before announcing a communication failure. Communicating through a Serial Port On the 'Connection' tab, select from the 'Device' box a COM port and click on 'Configure' to specify the baud rate and data format for the port. Choose the same baud rate and data format as you have set in the meter, and then click 'OK'. COMMUNICATING WITH YOUR METERS 5 Communicating through a Modem On the 'Connection' tab, select in the 'Device' box a local modem installed on your PC through which you will communicate to your meter. Click on 'Phones' to add the phone number of the remote modem to the phone list. Type the phone number in the 'Phone number' box, add comments if you desire, click 'Add', and then click 'OK'. In the 'Phone number' box on the 'Connection' pane, select the phone number from the list. Click 'OK'. Communicating through Internet Click on the 'Connection' tab. Click on the 'IP address' and type in the IP address of the ETC-2002 Network Communicator to which your meter is connected. In the 'Protocol' box, select communications protocol that you set in the meter. Type the TCP port number for your protocol in the 'Host Port' box. Use the following table to correctly select the TCP port for your protocol: Modbus RTU - 502 DNP3 - 20000 SATEC ASCII - 5002 If you wish, adjust the time that PAS waits for a connection before announcing an error and the number of retries PAS will use to receive a response from the meter if communications fail. 6 Programming Your Meters Creating Setups for Your Meters Off-Line PAS allows you to prepare setup data for your meters off-line without the need to have the meter connected to your PC. You can save these data in the meter's site database, and then recall and download it to the meter when you have the meter on-line. o prepare a setup for your meter, select a meter site from the list box on the toolbar, and then select the desired setup group from the 'Meter Setup' menu. Click on the tab with the name of the setup you want to create and fill in the boxes with the desired configuration data for your meter. After you have completed the setup, click on the 'Save as...' button. The name of the selected site database appears in the 'File name' box by default. If you want to save your setup into another site database, select it from the file pane. Click on 'OK'. Chapter 2 T PROGRAMMING YOUR METERS 7 PAS uses the Basic Setup data as a reference in all setup dialogs. Create the Basic Setup configuration for your meter first and save it to the site database before preparing other meter setups. If you want to reuse setups from another site, you can simply copy setups from that site to your present site database. Click 'Open', select the desired site database, and then click 'OK'. The opened setup will be copied to your site database. You can also copy all setups from one site database into another site's database. Select a meter site from the list box on the toolbar from which you want to reproduce setups, and then select 'Copy to...' from the 'Meter Setup' menu. Select the site database to which to copy setups from the present database, and then click 'OK'. Downloading Setups to Your Meters PAS allows you to update each setup in your meter one at time or to download all setups together from the site database. o update a particular setup in your meter, check the 'On-line' button on the toolbar, select a meter site from the list box on the toolbar, and then select the desired setup group from the 'Meter Setup' menu. Click on the pane with the name of the setup you want to download to the meter, and then click 'Send'. To download all setups to your meter at once, check the 'On-line' button on the toolbar, select a meter site from the list box on the toolbar, and then select 'Download Setups' from the 'Meter Setup' menu. Reply 'Yes' to the PAS warning message. Uploading Setups from Your Meters PAS allows you to update the site databases with the setups currently presented in your meters. o upload the setups from the meter to the site database, check the 'On- line' button on the toolbar, select a meter site from the list box on the toolbar, and then select 'Upload Setups' from the 'Meter Setup' menu. Reply 'Yes' to the PAS warning message. Note T T 8 Monitoring Your Meters Viewing Real-time Data Real-time data can be continuously retrieved from your meters and updated on the screen at a rate you defined in the Instrument Setup. o poll your instrument, select a meter site from the list box on the toolbar, select 'RT Data Monitor' from the 'Monitor' menu, and then select a data set you want to view. PAS supports 33 programmable data sets each consisting of up to 40 data parameters. Set 0 is intended for old SATEC meters, such as PM170, PM270, PM290, which have a limited number of parameters. To re-organize data sets, select 'Data Set' from the 'Monitor' menu or click on the button on the toolbar. You will see some predefined data sets and others which are empty. You can freely modify both to organize data in sets that will be convenient for you to use. Chapter 3 T MONITORING YOUR METERS 9 To run data polling, check the 'On-line' button on the toolbar, and then click on either the 'Single poll' button or 'Continuous poll' button . When in continuous poll, you can stop it by clicking on the 'Stop' button . You can open as many data monitor windows as you want, either for different sites, or for the same site using different data sets. When you open a data monitor window, it is linked both to the current site and to the selected data set. If you select another site from the site list, this does not affect the open data monitor windows. They are still linked to the sites for which they were created. Changing the Data View PAS can display data in either a single record or multi-record view. To change the view, click with the right mouse button on the Data Monitor window and select either 'Wrap' to see a single record, or 'UnWrap' to go to the multi-record view. Adjusting the Number of Rows in a Multi-Record View Click with the right mouse button on the Data Monitor window and select 'Options'. Adjust the number of records you want to see in the window, and then click 'OK'. When the number of retrieved records exceeds the number of rows in the window, the window will scroll up so that older records will be erased. Saving Data to a File You can save retrieved data to a file for later analysis. Click on the 'Save' button . Select the type of a file in which you want to keep the data. The choices are the ASCII *.dtl file and the *.mdb database. The ASCII files can hold only data of one type, while the .mdb file can hold all types of data in a single database, both real-time and historical data. Note MONITORING YOUR METERS 10 Select a directory where you want your log files to be kept. To avoid confusion, do not store data files into the 'Sites' directory where site databases are located. Select an existing file or type the name for a new file, and then click 'Save'. Printing Data to a Printer To print retrieved data to a printer, click the print button on the toolbar, select a printer and click 'OK'. If you want to check how your document appears on the printed page, select 'Print Preview' from the 'File' menu. Copying Data to Another Application You can copy the entire data table or a part of a table into the Clipboard or into another application such as Microsoft Excel or Word in order to prepare your report. Click with the right mouse button on the Data Monitor window and choose 'Select All', or click on the upper-left corner of the data table (where the 'No.' label is displayed). Click with the right mouse button on the Data Monitor window again and choose 'Copy' or click the 'Copy' button on the toolbar. Run an application to where you want to copy data, position cursor at the correct place, and then click the 'Paste' button on the application's toolbar or select 'Paste' from the 'Edit' menu. If you want only a part of data to be copied, select with the mouse cursor while holding the left mouse button the rows or columns in the table you want to copy, and then click the 'Copy' button on the toolbar. Real-time Data Logging PAS allows you to log polled data records to a database automatically at the time it updates the Data Monitor window on the screen. To setup the real-time logging options: 1. Open the Data Monitor window. 2. Click on the 'RT Logging On/Off' button on the toolbar, or select 'RT Logging Options' from the 'Tools' menu. 3. Select an existing database, or type the name for a new database and select a directory where you want to save it. 4. Select the number of tables, and the number of records in each table you want recorded. 5. Adjust the file update rate for automatic recording. It must be a multiple of the sampling rate that you defined in the Instrument Setup dialog. 6. Click Save. When you run real-time data polling, PAS automatically saves retrieved records to the database at the rate you specified. The 'RT Logging On/Off' button on the toolbar should be checked all the time to allow PAS to perform logging. You can MONITORING YOUR METERS 11 suspend logging by un-checking this button, and then resume logging by checking it again. Viewing Real-time Min/Max Log o retrieve the real-time Min/Max log data from the meter, select a meter site from the list box on the toolbar, select 'RT Min/Max Log' from the 'Monitor' menu, and then select a data set you want to view. PAS supports nine programmable data sets each consisting of up to 40 data parameters. To re-organize data sets, select 'Data Set' from the 'Monitor' menu or click the button on the toolbar. You will see some predefined data sets and others being empty. You can freely modify both to organize data in sets that will be convenient for you to use. To retrieve the selected Min/Max log data, check the 'On-line' button on the toolbar, and then click on the 'Single poll' button . You can save retrieved data to a file or print it in the same manner as described in the previous section. Viewing Real-time Waveforms o retrieve the real-time waveforms from the meter, select a meter site from the list box on the toolbar, and then select 'RT Waveform Monitor' from the 'Monitor' menu. To run polling waveforms, check the 'On-line' button on the toolbar, and then click on either the 'Single poll' button or 'Continuous poll' button . When in continuous poll, you can stop it by clicking on the 'Stop' button . By default, PAS retrieves six 4-cycle waveforms (V1-V3 and I1-I3) sampled at a rate of 128 samples per cycle. If you want to retrieve waveforms only for selected phases, select 'Customize' from the 'Tools' menu, click on the 'Preferences' tab, check phases you want polled, and then click 'OK'. Retrieved waveforms can be viewed in different windows as overlapped or non- overlapped waveforms, as RMS cycle-by-cycle plot, or as a harmonic spectrum chart or table. For information on using different waveform views, see Chapter 5. T T MONITORING YOUR METERS 12 Updating the Clock in Your Meters o update clock (RTC) in the meter, select a meter site from the list box on the toolbar, check the 'On-line' button on the toolbar, and then select 'RTC ' from the 'Monitor' menu. The RTC dialog displays the current PC time and the time in the meter. To synchronize the meter clock with the PC time, click 'Set'. Remote Relay Operations on Your Meters o perform remote control operations on the relays, or to check their present status, select a meter site from the list box on the toolbar, check the 'On-line' button on the toolbar, and then select 'Remote Control' from the 'Monitor' menu. The dialog shows you present forced relay status. To force a relay to operate or release, select a command for the relay and click 'Send'. T T 13 Retrieving Historical Data from Your Meters If your meter has on-board logging capabilities, you can retrieve the historical logs from the meter and save them to the database for later analysis. This can be done in two ways. The first is uploading historical data on demand at any time you need them. The second is using the upload scheduler that runs at predefined intervals on your schedule, for example, daily, weekly or monthly. Historical logs are stored as separate tables to the .mdb databases. Uploading Historical Data on Demand o retrieve the historical logs from your meter, select a meter site from the list box on the toolbar, check the 'On-line' button on the toolbar, and then select 'Upload Logs' from the 'Logs' menu. Click the 'Select logs' button, check boxes for logs you want to upload from the meter, and then click 'OK'. If you leave the box named 'Do not scan entire file' checked with the PM171 or PM295 meters, PAS will retrieve only new records that have not yet been read. In the event the historical files have been read from another PC, PAS might skip the last read records and you will miss data. Check this box with caution only if you are sure that your meter may not be accessed from another PC. Select an existing database, or type the name for a new database and select a directory where you want to save it, and then click 'OK'. Using the Upload Scheduler o setup the Upload Scheduler, select 'Upload Scheduler' from the 'Logs' menu. Chapter 4 T Note T RETRIEVING HISTORICAL DATA 14 Adding a New Site to the Schedule Click 'Add Site', select the site database for which you want to organize the schedule, and then click 'OK'. Configuring a Schedule for the Meter Click 'Configure' or double click with the left mouse button on the site row. Click on the 'Select logs' button, check boxes for logs you want to upload on a schedule from the meter, and then click 'OK'. Pay attention to the Note in the previous section. Select a daily, weekly or monthly schedule, and adjust the start time for uploading. Select the number of attempts to upload data in the event of temporary communication problems or unavailability of your meter, and the delay between attempts in minutes and seconds. If you want to use this schedule to synchronize the clock in the meter with the PC time, check the 'RTC Synchronization Enable' box. If your meter is secured by the communications password, type in the password you set in the meter to allow PAS to update the clock. After you have configured a schedule for the site, click 'OK'. Click 'Browse' at right and select an existing database for storing retrieved data, or type the name for a new database and select a directory where you want to save it, and then click 'OK'. Activating a Schedule for the Meter To activate a schedule for the meter, check the 'Enabled' box at left on the meter site row. RETRIEVING HISTORICAL DATA 15 To keep the Upload Scheduler running, the 'On-line' button on the toolbar must be checked all the time. If you uncheck it, the scheduler will stop operations. This will not cause loss of data, since the scheduler will resume operations when you check this button again. Suspending the Scheduler To suspend the Upload Scheduler, check the 'Suspend Scheduler' box at right. To activate the Upload Scheduler, leave this box unchecked. Running the Scheduler on Demand You can run the scheduler at any time outside the schedule by checking the 'Start Now' box at right. This is a one-time action. After uploading is completed, the Upload Scheduler will uncheck this box automatically. Recording Upload Problems When the Upload Scheduler fails to retrieve data from the meter, or some data is missing, or another problem occurs, it records an error message to the log file. To review this file, select 'Log Window' from the 'View' menu. Viewing Historical Data On-line ometimes, it is useful to review a particular historical data on-line at the time you expect the new events to appear in the log. PAS allows you to retrieve historical data from a particular log without storing it to a file. The data appears only in the window on your screen. If you want, you can save it manually to the database. To view a historical log on-line, select from the 'Logs' menu the log you want to retrieve, check the 'On-line' button on the toolbar, and then click on the 'Single poll' button . Only new log records will be retrieved from the meter. If you want to review the log from the beginning, click on the 'Restore Log' button on the toolbar, and then click on the 'Single poll' button . There is a difference between retrieving waveform logs on-line and viewing waveforms from a file. The waveforms are read one record a time, so that a multi- record waveform series may not be viewed in this mode as a single waveform. For information on using different log views, see Chapter 5, 'Viewing Log Files'. If you decide to view historical data on-line, make sure you leave unchecked the box 'Do not scan entire file' in the 'Select Logs' dialog when configuring the automatic uploading (see Note in section 'Uploading Historical Data on Demand'); otherwise, you may discover that the last logs are missing from your log files. Keeping it running S Note 16 Viewing Log Files Data stored into data files can be viewed on the screen in different formats. You can see how they look on your screen and check different options by opening sample files you received with PAS. They are located on your disk in the 'Samples' directory under the PAS installation directory. Opening a Log File o open a log file, click on the 'Open' button at left of the toolbar, or select 'Open...' from the 'File' menu. In the 'Files of type' box, select the type of files you want to view, enter the directory where your files are located and select a file you want to open. If this is an .mdb database, click once on the file name with the mouse to receive the database contents on the right pane, select a desired table from this pane, and then click 'Open' The following operations are available in all log views regardless of the particular log you are viewing. Exporting Data to Another Application You can copy the entire data table or graph, or part of the data into the Clipboard or into another application such as Microsoft Excel or Word in order to expand your report. Click with the right mouse button on the data window and choose 'Select All'. If your current view represents a table, click on the upper-left corner of the table (where the 'No.' label is commonly displayed). Click with the right mouse button on the window again and choose 'Copy' or click the 'Copy' button on the toolbar. Run the application to which you want to copy data, position the cursor at the correct place, and then click the 'Paste' button on the application's toolbar or select 'Paste' from the 'Edit' menu. Saving Data to a File To save data to a file, click on the 'Save' button . Select the type of a file in which you want to keep the data. The choices are commonly the ASCII file with a log-specific extension and the *.mdb database. Select a directory where you want your log file to be stored. To avoid confusion, do not store data files into the 'Sites' directory where site databases are located. Chapter 5 T VIEWING LOG FILES 17 Select an existing file or type the name for a new file, and then click 'Save'. Printing Data to a Printer To print data to a printer, click the print button on the toolbar, select a printer and click 'OK'. If you want to check how your document appears on the printed page, select 'Print Preview' from the 'File' menu. Viewing the Event Log vent log files are displayed in a tabular view, one event per row. PAS loads the entire log file (or database table) to a window, so that you can scroll through the entire log to view its contents. Sorting Events Normally, event records are shown in the order based on the date and time of the event appearance. PAS can rearrange records in the order based on a cause of the event, and then sort records within each group according to the event time. To change the sorting order, click with the right mouse button on the Event Log window, select 'Sort...', check a desired sort order, and then click 'OK'. Filtering Events The event log usually contains a large amount of records that concern events caused by different sources. You can use filtering to find and work with a subset of events that meet the criteria you specify. PAS will temporary hide rows you do not want displayed. You can use a filter along with sorting to rearrange filtered records in the desired order. To filter events, click with the right mouse button on the Event Log window, select 'Filter...', check the causes of events you want to display, and then click 'OK'. E VIEWING LOG FILES 18 Viewing the Data Log ata log files are displayed in a tabular view, one data record per row. PAS loads the entire data log file (or database table) to a window. There are no any specific controls available for data log views. Viewing the Waveform Log aveform log data can be displayed in five different views. When you open a new file, PAS shows you a waveform graph with overlapped waveforms. Each waveform window has a local toolbar from where you can open another window for these waveforms to examine data in a different view. You can open all five views together to analyze different properties of the waveforms such as wave shape, disturbances, unbalance, or spectrum. When you move to another waveform record, all views are updated simultaneously to reflect the changes in the waveforms. The status bar at the bottom of the waveform window shows you how many records the log file contains and the record number for the record currently displayed in the window. Use green arrowheads on the PAS toolbar to move from a record to record. Selecting Waveform Channels A single waveform record can contain up to 25 waveforms including up to 8 AC channels (V1-V4, I1-I4 or I5-I8), one VDC channel and up to 16 digital channels, which you can see all together in a non-overlapped waveform view. Other waveform views may offer you fewer channels, or sometimes only a single channel. D W VIEWING LOG FILES 19 If you do not want to view all waveforms together on one screen, you can use filtering to work with a subset of waveforms that meet your criteria. PAS will temporary hide waveforms you do not want displayed. To select desired waveform channels, click with the right mouse button on the waveform window, select 'Options...', check the channels you want displayed on the 'Channels' tab, and then click 'OK'. Waveforms recorded by the PM295 and PM296 to the Waveform Log 2 at a rate of 128 samples per cycle may not be displayed all together in one waveform view. Only two waveforms related to the selected phase will be shown. Customizing Line Colors and Styles Waveforms for different channels can be shown in different colors using different line styles. To change the colors or line styles, click with the right mouse button on the waveform window, select 'Options...', click on the 'Display' tab, adjust colors and styles for channels, and then click 'OK'. You can also change the colors for the waveform background and gridlines. Note VIEWING LOG FILES 20 Viewing Phasor Diagrams Waveform views have an additional pane at the lower right, where PAS draws phasor diagrams for displayed waveforms. The phasor diagrams show you the relative magnitude and angle of the fundamental harmonic for the selected voltage and current channels. All angles are taken relative to the reference voltage channel. To change the reference channel, click with the right mouse button on the waveform window, select 'Options...', click on the 'Phasor' tab, check the channel you want to make a reference channel, and then click 'OK'. If you leave the 'Triangle' box checked, PAS will connect the ends of the voltage and current vectors by lines showing you tree-phase voltage and current triangles. This may be useful when analyzing voltage and current unbalances. Phasor diagrams are calculated for one waveform cycle pointed to by the left marker line. As you move the marker, the phasor diagrams are updated reflecting the new marker position. Viewing Symmetrical Components Waveform views have an additional pane at the right where PAS can display the symmetrical components for voltages and currents, which are calculated for the point indicated by the left marker line. To enable or disable the symmetrical components, click with the right mouse button on the waveform window, select 'Options...', check or uncheck the symmetrical components on the 'Channels' tab, and then click 'OK'. Selecting Primary and Secondary Units Voltages and currents can be displayed in primary (default) or secondary units. To select primary or secondary units for your waveforms, click with the right mouse button on the waveform window, select 'Options...', select the desired units for voltages and currents on the 'Channels' tab, and then click 'OK'. ASCII waveform files logged by previous releases of PAS do not contain information on the secondary voltage or current set in the waveform recorder. These waveforms will always shown in primary units. Note VIEWING LOG FILES 21 Using the Marker Lines Waveform and RMS panes have two blue dashed marker lines. The left marker indicates the position from where data will be taken to calculate the harmonics spectrum and phasor diagrams, and also the starting position for calculating the RMS, average and peak values. The right marker indicates the end position for calculating the RMS, average and peak values. The minimum distance between the two markers is exactly one cycle. To change the marker position, click with the right mouse button on the waveform window, select 'Set Marker', and then click with left mouse button on the point where you want to put the marker. You can also drag both markers with the mouse, or use the right and left arrow keys on your keyboard to change the marker position. Before using the keyboard, click on the waveform pane with the mouse, to allow the keyboard to get your input. Using a Zoom You can use a horizontal and a vertical zoom to change size of your waveforms. Use the buttons on you local toolbar representing green arrowheads to zoom in or out of the waveform graph. Every click on these buttons gives you a 100-percent horizontal or 50-percent vertical zoom. Two buttons representing a magnifying glass give you a proportional zoom in both directions. When in the overlapped waveform view, you can zoom in on a selected waveform region. Click with the right mouse button on the waveform window, click 'Zoom', point onto one of the corners of the region you want to zoom in, press and hold the left mouse button, then point to another corner of the selected region and release the mouse button. Viewing Waveforms Waveforms can be displayed in two views: overlapped and non-overlapped. To select the first view, click on the button representing a single waveform on the VIEWING LOG FILES 22 local toolbar; to select a non-overlapped view, click on the button showing two waveforms. Waveform data are recorded to files in series that may contain many cycles of the sampled waveforms. A waveform window can display up to 64 waveform cycles. If the waveform contains more than 64 cycles, the scroll bar appears under the waveform pane allowing you to scroll through the entire waveform. Viewing an RMS Plot PAS can show you the cycle-by-cycle RMS plot of the sampled AC waveforms. To open the RMS view, click on the button representing two curves above horizontal axes. The RMS view displays the RMS measured over one cycle and updated each half cycle of the sampled waveforms as per IEC 61000-4. VIEWING LOG FILES 23 Viewing a Spectrum Chart To view the spectrum chart for the selected waveform channel, click on the button representing a spectrum graph. The spectrum is calculated over four cycles of the selected waveform beginning from the point where the left marker line is located in the open waveform view. If both waveform views are open, PAS gives the priority to the overlapped waveform view. The highest number of the spectrum harmonic that will be calculated is equal to the half sampling rate at which the waveforms were sampled minus one. For example, if the sampling made at a rate of 128 samples per cycle, 63 harmonics are available. With 32 samples per cycle, only 15 harmonics will be calculated, while others will be zeros. VIEWING LOG FILES 24 Viewing a Spectrum Table To view the harmonics spectrum in a table view, click on the button on the local toolbar. PAS allows you to view either a spectrum table for the selected channel, or all channels (V1-V3 and I1-I3) in a single table. Refer to section 'Selecting Waveform Channels' above for instructions on how to select waveform channels. 25 Customizing Your Views Customizing Date Format o change the way PAS displays the date, select 'Customize' from the 'Tools' menu, click on the 'Preferences' tab, select the preferred date order, and then click 'OK'. Customizing Timestamp he timestamp is normally recorded in the data log files and displayed on the screen at a 1-ms resolution. If you have an application that does not support this format, you can instruct PAS to drop the milliseconds. To change the way PAS records and displays the timestamp, select 'Customize' from the 'Tools' menu, click on the 'Preferences' tab, select the preferred timestamp format, and then click 'OK'. Selecting Voltage Disturbance Units hen programming a voltage disturbance trigger in your meter, the operate limit for the trigger can be set as a percent of the nominal voltage, in RMS units or in amplitude units. To change the disturbance units, select 'Customize' from the 'Tools' menu, click on the 'Preferences' tab, select the preferred units, and then click 'OK'. Chapter 6 T T W (This Page Intentionally Left Blank) Section 13 (This Page Intentionally Left Blank) 1 900 Series Industrial Ethernet Switch Installation Guide 2 Industrial Ethernet Switch Installation Guide 900B/900N 908TX 904FX 904FXE 902FX 902FXE 3 Copyright, © N-TRON Corp., 2005 N-TRON Corp. 820 S. University Blvd. Suite 4E Mobile, AL 36609 All rights reserved. Reproduction, adaptation, or translation without prior written permission from N-TRON Corp. is prohibited, except as allowed under copyright laws. Ethernet is a registered trademark of Xerox Corporation. All other product names, company names, logos or other designations mentioned herein are trademarks of their respective owners. The information contained in this document is subject to change without notice. N-TRON Corp. makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability or fitness for a particular purpose. In no event shall N-TRON Corp. be liable for any incidental, special, indirect, or consequential damages whatsoever included but not limited to lost profits arising out of errors or omissions in this manual or the information contained herein. Warning Do not perform any services on the unit unless qualified to do so. Do not substitute unauthorized parts or make unauthorized modifications to the unit. Do not operate the unit with the top cover removed, as this could create a shock or fire hazard. Do not block the air vents on the sides or the top of the unit. Do not operate the equipment in the presence of flammable gasses or fumes. Operating electrical equipment in such an environment constitutes a definite safety hazard. 4 Safety Warnings ELECTRICAL SAFETY WARNING: Disconnect the power cable before removing the enclosure top. WARNING: Do not operate the unit with the top cover removed. WARNING: Do not work on equipment or cables during periods of lightning activity. WARNING: Do not perform any services on the unit unless qualified to do so. WARNING: Do not block the air vents. WARNING: Observe proper DC Voltage polarity when installing power input cables. Reversing voltage polarity can cause permanent damage to the unit and void the warranty. LASER SAFETY (904FXE and 902FXEOnly) WARNING: CLASS 1 Laser Product. WARNING: Do not stare into the Laser Beam. 5 900 Series Hazardous Location Installation Requirements 1. WARNING: EXPLOSION HAZARD. DO NOT DISCONNECT UNIT WHILE CIRCUIT IS LIVE, UNLESS KNOWN TO BE NON- HAZARDOUS. 2. AVERTISEMENT: RISQUE D’EXPLOSION. NEPAS DE’BRANCHER TANT QUE LE CIRCUIT EST SOUS TENSION, A’MOINS QU’IL S’ A GISSE D’UN EMPLACEMENT NON DANGEREUX. 3. WARNING: Install only in accordance with Local & National Codes of Authorities Having Jurisdiction. 4. Power must be supplied by an isolating source, and a 3.3A max rated UL recognized fuse must be installed immediately before the unit. 5. Class I, Div 2 installations require that all devices connected to this product must be UL approved for the area in which it is installed. 6. Only UL approved wiring with temperature ratings greater than 90OC permitted for Class I, Div 2 installations operating at temperatures up to 70OC ambient. 7. Limited Operating Voltage: 12-30V for Class I, Div 2 installations. 6 900 Series Industrial Ethernet Switches The 900 Series Modular Industrial Ethernet Switches support high speed layer 2 switching between ports. The 900B and 900N enclosures contain a three slot backplane that supports up to three modules. The 908TX, 902FX and 904FX modules are the available modules. The N-TRON Corp. 900B is housed in a ruggedized steel enclosure, and can withstand industrial temperatures, as well as extreme shock & vibration. The 908TX is an 8 port module that is capable of auto negotiating 10/100 Mb and half/full duplex communications. The N-TRON 908TX also supports MDIX auto sensing (for auto connecto of straight through or crossover cables) and provides 8 Category 5 compliant 10/100-BaseT connections for high performance network design, and hub/repeater upgrades. The 902FX is a two port 100Mb module, that supports multimode fiber. ST and SC connectors are available. The 902FXE is a single mode (laser) version of the 902FX, and can support distances of up to 80km. The 904FX and 904FXE are four port versions of the 902FX and 902FXE respectively. All 900 Series Units operate on 10-30VDC (1A @ 24V, 2A Surge) Key Features • Full IEEE 802.3 & 100BASE-FX Compliance • Extended Environmental Specifications • Support for Full/Half Duplex Operation • LED Link/Activity Status Indication • Auto Sensing Speed and Flow Control • Auto MDIX (908TX only) • Up to 4.8 Gb/s Maximum Throughput • Industry Standard DIN-Rail Enclosure 7 PACKAGE CONTENTS Please make sure the Ethernet Switch package contains the following items: 1. 900 Series Ethernet Switch 2. Installed Modules 3. This Installation Guide Contact your carrier if any items are damaged. INSTALLATION Read the following warning before beginning the installation: WARNING The 902FXE and 904FXE unit contain a class 1 laser. Do not stare into the laser beam (fiber optic connector) when installing or operating the product. Never install or work on electrical equipment or cabling during periods of lightning activity. Disconnect the power cable before removing the enclosure top. Do not operate the unit with the top cover removed UNPACKING Remove all the equipment from the packaging, and store the packaging in a safe place. File any damage claims with the carrier. 8 902FX/FXE & 904FX /FXE HALF DUPLEX SETUP (Rev. B modules Only) Rev. B 900 series fiber modules are factory configured for full duplex operation. The setting is controlled by jumper JP1 on the backplane. Note: Most 100Mbit fiber systems will be compatible with this Full Duplex setting. If Half Duplex operation is desired, then follow these steps using proper wrist strap grounding techniques: 1. Remove the power & power plugs from the unit. 2. Loosen all thumbscrews & remove all modules. 3. Remove the six screws holding the backplane 4. Remove the backplane. 5. Move the jumper JP1 from position 1-2 to 3-4 6. Re-install the backplane & modules & power plugs. Rev. C & D boards are hard wired for Port 1 HDPLX, Port 2-4 FDPLX Rev. E boards are hard wired for ports 1-4 FDPLX DIN-Rail Mounting Install the unit in a standard Din-Rail. Recess the unit to allow at least 3” of horizontal clearance for fiber optic cable bend radius and for TX models. The Din-Rail mount is reversible to allow pressure up or pressure down for Din-Rail insertion/removal, and it is removable for panel mounting. 19” Rack Mounting 19” Rack mount kits are available. Please consult the factory for price & availability. JP1 9 908TX Module From Left to Right: RJ45 Ports Ports 1-8 Auto sensing 10/100 BaseT Ports Upper Left LED Port Link Status Upper Right LED Port Activity Status Green LED lights when Power is connected Note: At power cycle, all LED’s flash on for approximately two seconds, and then return to proper state. LED’s: The table below describes the operating modes: LED Color Description GREEN Power is Applied OFF Power is OFF LNK GREEN Link between ports established OFF No Link between ports ACT GREEN Data is active between ports OFF Data is inactive between ports 908 Module Jumpers Settings JP1 install jumper in location 1-2 when 1 or 2 modules installed install jumper in location 3-4 when 3 modules installed JP2 install jumper in location 1-2 when 1 module installed install jumper in location 3-4 when 2 or 3 modules installed 10 902/904 FX & FXE Module From Left to Right: TX Fiber Optic Transmit Port RX Fiber Optic Receive Port LNK Link LED (top LED) for Fiber Optic Port ACT Activity LED (bottom LED) for Fiber Optic Port Green LED lights when Power is connected Note: At power cycle, only the LED’s on the first port flash on to indicate the reset condition, and then return to their proper state. All other reports remain off during reset. This is normal behavior. LED’s: The table below describes the operating modes: LED Color Description GREEN Power is Applied OFF Power is OFF LNK GREEN Link between ports established OFF No Link between ports ACT GREEN Data is active between ports OFF Data is inactive between ports 902/904 Module Jumpers Settings JP1 install jumper in location 1-2 when 1 or 2 modules are installed install jumper in location 3-4 when 3 modules are installed JP2 install jumper in location 1-2 when 1 module are installed install jumper in location 3-4 when 2 or 3 modules are installed 11 MODULE LOCATION Modules must be installed in slot order. In a single module system, the module must be installed in the top slot. In a two module system, modules must be installed in the top two slots. Empty (unused) slots must be covered with blank 900B front panels to meet emission standards. APPLYING POWER 1. Unscrew the flange & Remove the DC Voltage Input Plug(s) from the side headers. 2. Install the DC Power Cables into the Plug(s) (observing polarity). 3. Plug the Voltage Input Plug(s) back into the side header. All 10/100 BaseT LED’s will flash ON Momentarily. For fiber optic ports, only port 1 will flash momentarily. 4. Verify the Power LED stays ON (GREEN). Note: Only 1 plug must be connected to power for minimal operation. For redundant power operation, V1 and V2 plugs must be connected to separate DC Voltage sources. Use wire sizes 16-28 guage. Recommended 24V DC Power Supplies, similar to 120/240VAC: Puls Engineering ML70.100 24VDC at 3 A 0-70C CONNECTING THE UNIT For 902 & 904 FX & FXE units, remove the dust cap from the fiber optic connectors and connect the fiber optic cables. The TX port on the 902 and/or 904 units should be connected to the RX port of the far end station. The RX port on the 902 and/or 904 units should be connected to the TX port of the far end station. For 10/100 Base-TX ports, plug a Category 5 twisted pair cable into the RJ45 connector. Connect the other end to the far end station. Verify that the LNK LED’s are ON once the connection has been completed. For Switch to Switch or Switch to Repeater connections, since the 908TX supports the advanced MDIX function, there is no need to use crossover cables. The 908TX will sense & adapt accordingly. 12 TROUBLESHOOTING 1. Make sure the (Power LED) is ON. 2. Make sure the ! (Error LED) remains OFF 3 seconds after initial power up. 3. Verify that Link LED’s are ON for connected ports. 4. Verify straight through cabling used between stations. 5. Verify cabling (pin-outs & integrity). 6. Verify that cabling is Category 5 (or higher) for 100Mbit Operation. 7. Verify TX is connected to far end RX and vise versa (902 and 904 FX/FXE only). SUPPORT Contact N-TRON Corp. at: TEL: 251-342-2164 FAX: 251-342-6353 www.n-tron.com FCC STATEMENT This product complies with Part 15 of the FCC-A Rules. Operation is subject to the following conditions: (1) This device may not cause harmful Interference (2) This device must accept any interference received, including interference that may cause undesired operation. 13 Key Specifications Physical Height: 3.2" (8.13 cm) Width: 7.1" (18.03 cm) Depth: 4.1" (10.41 cm) Weight: ~3.0 lbs (2.3 kg) (note: can be mounted horizontally or vertically) Electrical Input Voltage: 10-30 VDC (Redundant Inputs) Input/Inrush Current: 200/400mA@24V per backplane Input/Inrush Current: 250/500 mA@24V per 908TX module Input/Inrush Current: 400/800mA@24V per 902/904FX module Environmental Operating Temperature: 0oC to 70oC (32oF to 158oF) Storage Temperature: -20oC to 85oC (-4oF to 185oF) Operating Humidity: 10% to 90% (Non Condensing) Operating Altitude: 0 to 10,000 ft. Shock and Vibration (Bulkhead Mounting) Shock: 200g @ 10ms Vibration: 1g, 10-500Hz, 3 axis Seismic: 20g, 5-200Hz, 15s Reliability MTBF: >1M Hours (measured) Network Media 10BaseT: Category 3,4,5 Cable 100BaseT: Category 5 or higher Cable 100BaseFX: 62.5/125µm Fiber @ 1300nm or 50/125µm Fiber @ 1300nm Fiber Transceiver Characteristics (multimode/singlemode - 15km) Transmit Power: -17/-3dBm (typical) Receiver Sensitivity: -33/-35dBm (typical) 14 Recommended Wiring Clearance: Front: 2" (5.08 cm) Side: 1" (2.54 cm) Key Specifications (Cont.) Emissions and Safety Approvals: FCC Part 15 Class A, CE Note: Shielded cables must be used to meet emission standards. Ordering Information PN Description 900B Industrial Ethernet switch chassis with 3 slots for optional expansion modules 900-RM 19" Rackmount Kit 908TX Eight ports 10/100BaseTX (RJ45) 902FX-XX Two ports 100BaseFX multimode fiber 902FXE-XX-YY Two ports 100BaseFX singlemode fiber 904FX-XX Four ports 100BaseFX multimode fiber 904FXE-XX-YY Four ports 100BaseFX singlemode fiber Where "XX" is: ST for ST style fiber connector SC for SC style fiber connector Where "YY" is: 15 for 15km max. fiber segment length 40 for 40km max. fiber segment length 80 for 80km max. fiber segment length Warranty One Year Parts & Labor Contact/Support Information N-TRON Corp. 820 S. University Blvd. Suite 4E Mobile, AL 36609 TEL (251) 342-2164 FAX (251) 342-6353 Website: www.n-tron.com 15 N-TRON Limited Warranty N-TRON, Corp. warrants to the end user that this hardware product will be free from defects in workmanship and materials, under normal use and service, for the applicable warranty period from the date of purchase from N-TRON or its authorized reseller. If a product does not operate as warranted during the applicable warranty period, N-TRON shall, at its option and expense, repair the defective product or part, deliver to customer an equivalent product or part to replace the defective item, or refund to customer the purchase price paid for the defective product. All products that are replaced will become the property of N-TRON. Replacement products may be new or reconditioned. Any replaced or repaired product or part has a ninety (90) day warranty or the remainder of the initial warranty period, whichever is longer. N-TRON shall not be responsible for any custom software or firmware, configuration information, or memory data of customer contained in, stored on, or integrated with any products returned to N- TRON pursuant to any warranty. OBTAINING WARRANTY SERVICE: Customer must contact N-TRON within the applicable warranty period to obtain warranty service authorization. Dated proof of purchase from N-TRON or its authorized reseller may be required. Products returned to N-TRON must be pre-authorized by N-TRON with a Return Material Authorization (RMA) number marked on the outside of the package, and sent prepaid and packaged appropriately for safe shipment. Responsibility for loss or damage does not transfer to N-TRON until the returned item is received by N- TRON. The repaired or replaced item will be shipped to the customer, at N- TRON’s expense, not later than thirty (30) days after N-TRON receives the product. N-TRON shall not be responsible for any software, firmware, information, or memory data of customer contained in, stored on, or integrated with any products returned to N-TRON for repair, whether under warranty or not. ADVANCE REPLACEMENT OPTION: Upon registration, this product qualifies for advance replacement. A replacement product will be shipped within three (3) days after verification by N-TRON that the product is considered defective. The shipment of advance replacement products is subject to local legal requirements and may not be available in all locations. When an advance replacement is provided and customer fails to return the original product to N-TRON within fifteen (15) days after shipment of the replacement, N-TRON will charge customer for the replacement product, at list price. WARRANTIES EXCLUSIVE: IF AN N-TRON PRODUCT DOES NOT OPERATE AS WARRANTED ABOVE, CUSTOMER'S SOLE REMEDY FOR BREACH OF THAT WARRANTY SHALL BE REPAIR, REPLACEMENT, OR REFUND OF THE PURCHASE PRICE PAID, AT N-TRON'S OPTION. TO THE FULL EXTENT ALLOWED BY LAW, THE FOREGOING WARRANTIES AND REMEDIES ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER WARRANTIES, TERMS, OR CONDITIONS, EXPRESS OR IMPLIED, EITHER IN FACT OR BY OPERATION OF LAW, STATUTORY OR OTHERWISE, INCLUDING WARRANTIES, TERMS, OR CONDITIONS OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, SATISFACTORY QUALITY, CORRESPONDENCE WITH DESCRIPTION, 16 AND NON-INFRINGEMENT, ALL OF WHICH ARE EXPRESSLY DISCLAIMED. N-TRON NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR IT ANY OTHER LIABILITY IN CONNECTION WITH THE SALE, INSTALLATION, MAINTENANCE OR USE OF ITS PRODUCTS. N-TRON SHALL NOT BE LIABLE UNDER THIS WARRANTY IF ITS TESTING AND EXAMINATION DISCLOSE THAT THE ALLEGED DEFECT OR MALFUNCTION IN THE PRODUCT DOES NOT EXIST OR WAS CAUSED BY CUSTOMER'S OR ANY THIRD PERSON'S MISUSE, NEGLECT, IMPROPER INSTALLATION OR TESTING, UNAUTHORIZED ATTEMPTS TO OPEN, REPAIR OR MODIFY THE PRODUCT, OR ANY OTHER CAUSE BEYOND THE RANGE OF THE INTENDED USE, OR BY ACCIDENT, FIRE, LIGHTNING, POWER CUTS OR OUTAGES, OTHER HAZARDS, OR ACTS OF GOD. LIMITATION OF LIABILITY: TO THE FULL EXTENT ALLOWED BY LAW, N-TRON ALSO EXCLUDES FOR ITSELF AND ITS SUPPLIERS ANY LIABILITY, WHETHER BASED IN CONTRACT OR TORT (INCLUDING NEGLIGENCE), FOR INCIDENTAL, CONSEQUENTIAL, INDIRECT, SPECIAL, OR PUNITIVE DAMAGES OF ANY KIND, OR FOR LOSS OF REVENUE OR PROFITS, LOSS OF BUSINESS, LOSS OF INFORMATION OR DATA, OR OTHER FINANCIAL LOSS ARISING OUT OF OR IN CONNECTION WITH THE SALE, INSTALLATION, MAINTENANCE, USE, PERFORMANCE, FAILURE, OR INTERRUPTION OF ITS PRODUCTS, EVEN IF N-TRON OR ITS AUTHORIZED RESELLER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES, AND LIMITS ITS LIABILITY TO REPAIR, REPLACEMENT, OR REFUND OF THE PURCHASE PRICE PAID, AT N-TRON'S OPTION. THIS DISCLAIMER OF LIABILITY FOR DAMAGES WILL NOT BE AFFECTED IF ANY REMEDY PROVIDED HEREIN SHALL FAIL OF ITS ESSENTIAL PURPOSE. DISCLAIMER: Some countries, states, or provinces do not allow the exclusion or limitation of implied warranties or the limitation of incidental or consequential damages for certain products supplied to consumers, or the limitation of liability for personal injury, so the above limitations and exclusions may be limited in their application to you. When the implied warranties are not allowed to be excluded in their entirety, they will be limited to the duration of the applicable written warranty. This warranty gives you specific legal rights which may vary depending on local law. GOVERNING LAW: This Limited Warranty shall be governed by the laws of the State of Alabama, U.S.A. Computer InterfacesComputer Interfaces Keyboard, Mouse, & Monitor P3 Keyboard (PS/2)Extn 6MDINF 6MDINM P28 Keyboard (USB)Extn USBAF USBAM P5 Mouse (PS/2)Extn 6MDINF 6MDINM P29 USB Mouse Extn USBAF USBAM P6 VGA Monitor Extn HDDB15F HDDB15M Q102 DVI F/F (DVI-I, D, A) Bulkhd F F P7 Modem Bulkhd RJ12F RJ12F Other Parallel Pin-to-Pin Extension Cables R3 DB9 F/M Extn DB9F DB9M P1 DB9 M/F Extn DB9M DB9F P2 DB25 F/M Extn DB25F DB25M R9 DB25 M/F Extn DB25M DB25F R6 DB37 M/F Extn DB37M DB37F R7 DB37 F/M Extn DB37F DB37M R10 DB15 M/F Extn DB15M DB15F R11 DB15 F/M Extn DB15F DB15M R44 DB15HDM M/F Extn M F R45 DB15HDM F/M Extn F M R8 8 Pin MiniDIN Extn 8MDINF 8MDINM R28 8 Pin MiniDin Locking Extn 8MDINF 8MDINM (Not for VGA) Data Switch Interfaces R38 DB9F 2:1 Custom F F R39 DB9F 4:1 Custom F F R36 8MDin 2:1 Custom F F R37 8MDin 4:1 Custom F F R47 DB15 2:1 Custom F F R48 DB15 4:1 Custom F F R101 50 OHM BNC 2:1 Custom F F R102 VGA 2:1 Custom F F R103 RJ11/12 2:1 Custom F F R104 RJ11/12 4:1 Custom F F Network Taps B2 A-B DH+ (DB9F PCB)Term DB9F Terminal Block B3 A-B DH+ (8MDIN PCB)Term 8MDINF Terminal Block B6 A-B DH+ / Remote I/O Term 3RTBM Terminal Block B9 A-B DH+ Combo (DB9/8MDIN)Term 8 MDIN/DB9F Terminal Block D3 Profi-Bus Term DB9F Terminal Block D4 DeviceNet (8A Max)Term 5RTBM Terminal Block M4 Modicon ModBus Plus Tap Term RJ-45 Terminal Block M9 Schneider Automation -FIPWay Term DB9F Terminal Block PLC CONNECTOR CODESPLC CONNECTOR CODES PLC NETWORK TAPSPLC NETWORK TAPS Ethernet & Network Interfaces R2 Category 5e Ethernet Bulkhd RJ45F RJ45F R33 Category 5e Shielded Bulkhd RJ45F RJ45F R62 Category 6 Ethernet Bulkhd RJ45F RJ45F BNC Connectors Q79 75 Ohm BNC F/F-Auto-Terminating Bulkhd F F Q93 75 Ohm BNC F/F (RJ58)Bulkhd F F Q42 50 Ohm BNC F/F (RJ58)Bulkhd F F Generic Bulkhead Interfaces Q3 DB-9 F/F Bulkhd F F Q7 DB-9 F/M Bulkhd F M Q9 DB-9 M/F Bulkhd M F Q15 DB-9 M/M Bulkhd M M Q4 DB-25 F/F Bulkhd F F Q8 DB-25 F/M Bulkhd F M Q10 DB-25 M/F Bulkhd M F Q16 DB-25 M/M Bulkhd M M Q35 DB-15 F/F Bulkhd F F Q36 DB-15 M/M Bulkhd M M Q37 DB-15 F/M Bulkhd F M Q38 DB-15 M/F Bulkhd M F Q11 DB-15HD F/M Bulkhd F M Q12 DB-15HD M/F Bulkhd M F Q18 DB-15HD F/F Bulkhd F F Q19 DB-15HD M/M Bulkhd M M Q22 DB-15HDVGA F/F Bulkhd F F Q23 DB-15HDVGA M/F Bulkhd M F Q24 DB-15HDVGA F/M Bulkhd F M Q25 DB-15HDVGA M/M Bulkhd M M Q6 RJ-11/12 F/F Bulkhd F F Q17 RJ-45 F/F Bulkhd F F Q26 4 MDIN F/F Bulkhd F F Q28 6MDIN F/F Bulkhd F F Q29 8MDIN F/F Bulkhd F F Q26 S-Video F/F Bulkhd F F P24 S-Video F/M Bulkhd F M P25 S-Video M/F Bulkhd M F P26 S-Video M/M Bulkhd M M Connector to Terminal Block PCB R1 DB9F (PCB Pins 1-9 to TB)Term DB9F TB R12 DB9M (PCB Pins 1-9 to TB)Term DB9M TB R15 RJ-45 (PCB Pins 1-8 to TB)Term RJ45F TB Allen-Bradley (Rockwell Automation) A5 PanelView (Serial)Extn DB9M DB9F A8 ControlLogix Extn DB9M DB9F A10 SCANport Extn 8MDINF 8MDINM-lock A11 PLC-5 Channel 0 (DB-25)Extn DB25F DB25M A12 SLC-500 Channel 0 Extn DB9M DB9F A13A13 AIC+ Port 2AIC+ Port 2 ExtnExtn 8 MDIN-F8 MDIN-F 8 MDIN-M8 MDIN-M A14A14 MicroLogix (Series C)MicroLogix (Series C)ExtnExtn 8 MDIN-F8 MDIN-F 8 MDIN-M8 MDIN-M A16 CompactLogix Extn DB9M DB9F A17 A-B FlexLogix Extn DB9M DB9F A18 MicroLogix 1500-LRP (DB-9)Extn DB9M DB9F A19 PowerFlex Extn 8MDINF 8MDINM-lock A20 PowerFlex 40,400 B/H-cable RJ45F RJ45M B1 SLC 500 DH-485 (20' Cable)Term RJ45F RJ45M B14 A-B SLC 500 DH-485 Bulkhd RJ45F RJ45F Data Highway B2 DH+ (DB9F PCB)Term DB9F Terminal Block B3 DH+ (8MDIN PCB)Term 8MDINF Terminal Block B6 DH+ / Remote I/O Term 3RTBM Terminal Block B9 DH+ Combo(DB9/8MDIN) Term 8 MDIN/DB9F Terminal Block ControlNet B4 ControlNet RJ-45 (20' Cable)Term RJ45F RJ45M B7 ControlNet (75 Ohm BNC tap)Term BNCF BNCF B10 A-B ControlNet (20' cable)B/H-Cable RJ45F RJ45M ©2005 Grace Engineered Products Inc. GracePort® is a registered trademark of Grace Engineered Products Inc. Serial, Parallel XXXX Null Connector code Connector Codes Description Type Gender Outside Gender Inside Bulkhd:Standard bulkhead connectors B-H/cable:Standard bulkhead connector with cable. Printed circuit board pin-pin to terminal block OR Network Tap Extn: Male-Female pin-pin extension cables. Term: Network Taps are designed for specific networks. Examples above: Modbus+, Data Highway+, DeviceNet, and more. GENERIC CONNECTOR CODESGENERIC CONNECTOR CODES -P -P -MM 5D4B2R2 -- (Special text, logos, cable lengths, MORE!) POWER OPTIONS CODES HOUSING & NEMA CODES EXCEPTION CODES M 3 C5--R O Uxx CALL 800-280-9517 for + Connector Codes (not shown) + Configuration Assistance CALL 800-280-9517 for Connector Codes (not shown) Configuration Assistance + + www.grace-eng.com DS-Config 2005-02 Alpha/Numeric Codes ordered Alphabetically and used in name of data sheet (i.e. D4.PDF) UA TLOLEM AWTKI OCNORMPASSNOC Universal Serial Bus P11 USB Type A-A Cable Extn USB-AF USB-AM P22 USB Type A-A F/F Bulkhd USB-AF USB-AF Q50 USB Type A/B F/F Bulkhd USB-AF USB-BF Q51 USB Type B/A F/F Bulkhd USB-BF USB-AF P27 USB Type B/B F/F Bulkhd USB-BF USB-BF P31 USB Type B/B M/M Bulkhd USB-BM USB-BM ra ce o rt ® G P E xc lu s ve i sraceort® G P E xc lu s vei s P1 DB9 Serial Extn DB9M DB9F P9 DB25 Serial Extn DB25M DB25F P2 DB25 Parallel Extn DB25F DB25M Connector Codes Description Gender Outside Gender Inside GracePort® Interface Products Part Number Guide Of Ordering The A Of Ordering The B C ‘s Note: CALL for other power options not shown (other outlets, DC jacks, & customs) POWER OPTION CODES DESCRIPTION VAC AMPS R US, Canada, Mexico (also used in Japan & Taiwan)120 15 RD Duplex Outlet 120 20 RF GFCI Outlet 120 20 RG Isolated Ground (Duplex)120 15 RM IEC 320 Female Power Entry Module 250 10 RN IEC 320 Male Power Entry Module 250 10 FOREIGN OUTLETS RA Australia, New Zealand, & Peoples Republic of China 250 10 RB United Kingdom, Hong Kong, Ireland, Singapore, & Malaysia 250 13 RE Continental Europe "Schuko" (Germany, Finland, Netherlands, Norway, Sweden, Portugal, Spain, Greece, Soviet Republic, & Eastern Bloc)250 16 RF France & Belgian 250 16 RI Italy 250 10 RU India 250 15 Cat.5 Ethernet Computer Serial Port Computer Parallel Port 120VAC Outlet, No Circuit Breaker NEMA 12/4 Panel Mount Housing Add Value! YOUR LOGO* Here!!! (Two) Universal Serial Bus PS/2 Keyboard & Mouse P2 P1 R2 P3 P5 P11 #2 P6 Uxx M 3 R -O VGA Monitor--P - (Special text, logos, cable lengths, MORE!) POWER OPTIONS CODES HOUSING & NEMA CODES EXCEPTION CODES P --P1 P2 P3 P5 P6 P11 #2 R2 M 3 C5--R O INTERFACE CODES Uxx 0 No Breaker 3 3 Amp 250V 5 5 Amp 250V Call for other sizes CIRCUIT BREAKER CODES H M M5 M6 B F G L L5 A E Type 304 Stainless Type 316 Stainless L6 Type 304 Stainless 6 16 24 48 48 48 PANEL MOUNT HOUSING CODES HOUSING SIZE SURFACE MOUNT HOUSING CODES M7 Hazardous LocationN/A K 32 N/A GracePort® Part GuideHousings Crossover Switch (See Data Sheets) R49 Crossover -Generic DB9F Custom Qty (2) DB9 R53 MicroLogix 1000, 1200, 150LSP to PanelView 300 Micro Custom Qty (2) DB9 R54 MicroLogix 1500 LRP, SLC,PLC5, Control Logix, Compact Logix,Flex Logix to PanelView 300 Micro Custom Qty (2) DB9 R55 MicroLogix 1500 LRP, SLC,PLC5, Control Logix, Compact Logix,Flex Logix to PanelView(+) 300-1500 Custom Qty (2) DB9 Modicon M4 ModBus Plus Industrial Tap Term RJ-45 Terminal Block M6 ModBus Plus Extn DB9F BLUNT M7 Micro, E284-258/265/275/285 P/O DB9F RJ-45 M8 ModBus (Serial -Extension Cable Version)Extn DB9F DB9M M16 Momentum (Peripheral Port)Extn RJ-45F/F RJ-45M M17 Momentum Extn DB9F RJ-45M Other PLC's G1 GE Fanuc Genius Extn DB9M DB9F G2 GE Fanuc (340 SNP, 9/30)Extn DB15F DB15M H5 Siemens Simatic 545-(1103,1104,1105,1106), 555- (1103,1104,1105,1106), 575-2104,2105,2106) Extn DB9F DB9M H6 Siemens Micro-Master Extn DB15F DB15M M5 Telemechanique UniTelway 8MDIN locking cable Extn 8MDINF 8MDINM M9 Schneider Automation -FIPWay Term DB9F M10 Mitsubishi FX Series PLC Extn 8MDIN-F 8MDIN-M M11 Mitsubishi A Series PLC Extn DB25F DB25M M13 Mitsubishi Q-Series PLC Extn 6MDINF 6MDINM M14 Omron Serial (DB9)Extn DB9M DB9F M15 Omron CS/CJ/CQ Peripheral Port (Use Omron Programming Cable) Bulkhd DB9F DB9M PLC Direct M20 (DL340/CPU Ports)B/H Cable RJ-11F/F M M21 (DL05,06,105,205,D3-350,D4-450 CPU Ports)B/H Cable RJ-12F/F M M22 (DL06, D2-250 Bottom Port)Extn DB15HD-F M M23 (DL405 Port CPU, DL405 SLICE I/O)M M24 (DL405 CPU/Bottom/DCM, DL305 w/DCU RS232)M Extn Extn DB15-F DB25-F PLC CONNECTOR CODES (cont)PLC CONNECTOR CODES (cont) ©2005 Grace Engineered Products Inc. GracePort® is a registered trademark of Grace Engineered Products Inc. Every Enclosure Type!Every Enclosure Type! www.grace-eng.com www.grace-eng.com5000 Tremont Ave Suite 203, Davenport, IA 52807 FAX: 563-386-9639 anitah@grace-eng.com AU TLOLME AW TKI OCNORMPASSNOC ©2005 Grace Engineered Products Inc. GracePort® is a registered trademark of Grace Engineered Products Inc. DS-Config 2005-02 GracePort® Thru-Door Interfaces Combination - 1000’s & 1000’s!! Connector - USB, Serial, PS2, EtherNet, DeviceNet, DH/+... Enclosure Type - Nema 12/4, 4X, 7/9, & Stainless Steel 4X - 2-3 Days Typical CSA & CE (Foreign Power Outlets) > > > > > EVERY EVERY EVERY VERY UL TYPE 4 & 4X (1) Quick Delivery! Ratings - EVERY VERY UL TYPE 4 & 4X EVERY EVERY Connector - USB, Serial, PS2, EtherNet, DeviceNet, DH/+... Quick Delivery! - 2-3 Days Typical 800-280-9517Type Note (1) UL Type 4X Recognition Pending NEMA RATING CODES NOTES 1 NEMA 1 (Panel mount no housing)ADD "-G" TO THE END OF THE PART NUMBER FOR GASKETING 2 NEMA 4X 3 NEMA 12/4 & IP-65 5 NEMA 4X TYPE 304 STAINLESS STEEL 6 NEMA 4X TYPE 316 STAINLESS STEEL 7 NEMA 7&9 EXPLOSION PROOF NO POWER OPTIONS C US Type 4X C US Type 4 C US Type 4X C US Type 4X C US * (1) CE: EN61010/EN60950 (Foreign Power Outlets) PC to SLC-5/4 Communications Figure 1 Full Duplex Point-To-Point Communications Point-to-point communication between PC and SLC-5/4 is a DTE to DTE communication link. As shown in Figure 1 either two DTE to DCE cables with interceding modems may be used or one DTE to DTE (null modem) cable may be used. The DTE-to-DTE cable is connect to one of the DB-9P connectors on the PC and to the DB-9P (Channel-0) connector on the SLC as illustrated in Figure 2. Figure 2 DTE to DTE Connection To use a DTE-to-DTE cable, you should do the following: • Configure PC to use DF-1 drivers. • Use 1747-CP3 or compatible cable with circuit shown Figure 3. • Set default communication speed to 1200 bps. • Use Channel-0 (DB-9P) connector on SLC-5/4 • Use Com1, Com2, Com3, or Com4 (DB-9P) on PC 1747-CP3 The 1747-CP3 is a form of a null modem cable. Read the notes on Figure 3 and pay attention to note two. Note that pin 2 and pin 3 are interchange on the cable and pin 5 is feed straight through. The other line are only used if hardware handshaking is not or cannot be turn off. Figure 3 1747-CP3 Baud Rate Selection To set the baud rate can take up to three steps. The first step is to synchronize the baud rate of the SLC 500 and the PC. If the SLC and PC are already communicating you may skip this step. Step 1: • Load RSLinx communication package • Start application and select communications • Then select configure driver • Choose the RS-232 driver DF-1 device • Click on add new if DF-1 driver is not present • Select autoconfig and the PC and SLC-5/4 will connect at 1200 bps (default) or the current baud rate. Then select OK. The next step is to set the baud rate of the UART in the SLC 500. To perform this operation use the RSLogix 500 software and follow the steps in STEP 2. Step 2: • Load RSLogix 500 • Open an existing project (RSS) file or create a new project file by selecting New under File. • In the project Tree double click on Channel Configuration under Controller • Select the Chan-0 System tab • Select the new baud rate and then apply. At this point you most likely have lost communication between the SLC 500 and the PC. This is because the SLC UART is now at the new baud rate and the PC is at the old baud rate. To change the PC’s Baud rate follow the steps in Step 3. Step 3 • Start RSLinx application or transfer focus if it is currently running. • Select communications • Then select configure driver • Choose the RS-232 driver DF-1 device if another is highlighted • Under channel configuration select a higher baud rate such as 9.6 kbps and then apply. • If communications is lost between the SLC500 and PC, then remove from Who Active window and then refresh. The SLC 5/04 should reappear in the Who Active window. Note only one RSLinx driver can be configured per hardware device. GCP-MG GCP Modbus Gateway User Manual Edition 1.0 May 2007 GCP-MG User Manual Support We provide electronic support and feedback for the proconX products. Please use the Support web page at: http :// www.proconx.com /support Contact For further information about this product or this document please contact us at: Website: http :// www.proconx.com/info Email: mail@proconx.com Document Revision History 2007-05-14, 1.0, Initial Release for hardware version J367-S3-PB and firmware version 1.0 Notice Copyright © 2007 FOCUS Software Engineering Pty Ltd. All rights reserved. No part of this material may be reproduced or transmitted in any form or by any means or used to make any derivative work without express written consent from the copyright holders. proconX is a trademarks of FOCUS Software Engineering Pty Ltd. All other product and brand names mentioned in this document may be trademarks or registered trademarks of their respective owners. Disclaimer FOCUS Software Engineering makes no warranty for the use of its products, other than those expressly contained in the Company’s standard warranty which is detailed in FOCUS Software Engineering’s Terms and Conditions located on the Company’s web site. The Company assumes no responsibility for any errors which may appear in this document, reserves the right to change devices or specifications detailed herein at any time without notice, and does not make any commitment to update the information contained herein. No licenses to patents or other intellectual property of FOCUS Software Engineering are granted by the Company in connection with the sale of FOCUS Software Engineering's products, expressly or by implication. FOCUS Software Engineering’s products are not authorized for use in life support devices or systems. 2 Table of Contents 1 Introduction........................................................................................................5 1.1 Features.......................................................................................................6 2 Description..........................................................................................................7 3 Installation..........................................................................................................8 3.1 Safety Precautions......................................................................................9 3.2 Regulatory Notes......................................................................................10 3.3 General Instructions................................................................................11 3.4 DIN Rail Mounting and Removal..........................................................12 3.5 Powering the GCP-MG...........................................................................13 3.6 Wiring the CAN Interface.......................................................................14 3.7 Wiring the Modbus RS-485 Interface.....................................................15 3.8 Wiring the RS232-MODBUS Interface...................................................16 3.9 Ethernet.....................................................................................................17 3.10 Connecting to the Diagnostic Port.......................................................18 4 Ethernet & IP Configuration...........................................................................19 4.1 IP Setup Using a Web Browser and a Cross-Over Network Cable...20 4.2 IP Setup Using HyperTerminal..............................................................21 4.3 Temporarily changing the IP settings on your PC..............................22 5 Web Browser Based Management.................................................................24 5.1 Connecting to the GCP-MG....................................................................24 5.2 Monitoring and Diagnostic.....................................................................26 5.2.1 Devic e Status.....................................................................................26 5.2.2 Modbus Conne ction Status.............................................................28 5.2.3 CAN Communicat ion Status..........................................................29 5.2.4 Finding the Firmware Version and Serial Number.....................30 5.3 Configuring and Commissioning..........................................................32 5.3.1 Configuring Ethernet and IP..........................................................33 5.3.2 Configuring GCP-30 and LS 4 Modbus Access............................34 5.3.3 Configuring Serial Line Modbus....................................................35 5.3.4 Remote Restarting the Device........................................................36 6 Gateway Operation..........................................................................................38 7 Modbus Data Organization............................................................................40 7.1 GCP-30 Mux Data Table 3:0001..............................................................43 7.1.1 Allocatio n with Options SB03 and SB06........................................46 7.2 GCP-30 Remote Control Data Table 4:0001..........................................47 7.3 GCP-30 Floating Point Table 3:1001.......................................................48 3 GCP-MG User Manual 7.4 LS 4 Mux Data Table 3:0001....................................................................50 7.5 LS 4 Remote Control Data Table 4:0001................................................52 7.6 LS 4 Floating Point Data Table 3:1001...................................................53 8 Specifications....................................................................................................54 8.1 Dimensions...............................................................................................56 4 1 Introduction 1 Introduction The GCP-MG is a next-generation Modbus/CAN gateway specifically designed to interface Woodward's GCP-30 Series Genset Controls and LS 4 Circuit Breaker Controls with Modbus networks. The GCP-MG GCP Modbus Gateway has been developed in cooperation with Woodward to ensure the highest possible degree of interoperability with Woodward equipment. The gateway features CAN, serial RS-232 and RS-485 ports as well as an Ethernet port and can be mounted on a DIN rail. On the CAN side it implements the Woodward CAL protocol to connect to the GCP-30 series controls. On the serial ports and on Ethernet it implements a Modbus server (Modbus RTU and Modbus/TCP) and accepts connections from Modbus master devices like PLCs and SCADA systems. Usage and configuration of the gateway is simple and conveniently performed using a web browser which connects to the embedded web server. Possible areas of application are: ❑PLC connection ❑Operator panel interfacing ❑HMIs ❑SCADA integration ❑Power station automation ❑Gen set control ❑Remote control & monitoring ❑Data logging 5 GCP-MG User Manual 1.1 Features The GCP-MG GCP Modbus Gateway provides the following key features: ❑Modbus/TCP protocol (Ethernet) ❑Modbus RTU protocol (RS-232 or RS-485, software configurable) ❑Interfaces with up to 16 GCP-30 controls and up to 8 LS 4 controls ❑Full support of Option SB03 (Cat CCM) and Option SC06 (MTU MDEC) ❑GW4 backward compatible Modbus register layout ❑Dedicated Modbus Slave ID for each GCP-30 and LS 4 control ❑Complete data set of one GCP-30 unit can be read with a single Modbus transaction ❑Integer/Exponent value pairs for voltages, power and currents are additionally represented as 32-bit floating point registers ❑Serial baud rate up to 115200 bps ❑Support of Modbus function codes 03, 04, 06 and 16 ❑Concurrent Modbus serial line and Modbus/TCP connections ❑Embedded web server for easy configuration and commissioning using a web browser ❑Firmware upgradeable via Ethernet ❑DIN rail mountable ❑24 V DC (10-30 V) power supply ❑Status LEDs for Power, Ethernet Link, Device Status and Modbus/CAN status 6 2 Description 2 Description 1 Power terminal block socket 2 Modbus RS-485 terminal block socket 3 CAN connector 4 Clear front cover 5 Primary RS-232 (Modbus) connector 6 Secondary RS-232 (Diagnostic) connector 7 Ethernet connector 8 DIN rail clip 9 Power LED 10 Ethernet Link LED 11 Device Status LED 12 Modbus/CAN Status LED 7 TOP VIEW 2 31 4 10 11 12 9 FRONT VIEW BOTTOM VIEWBOTTOM VIEW 5 7 8 6 4 GCP-MG User Manual 3 Installation 3.1 Safety Precautions DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH •Only qualified workers should install this equipment. Such work should be performed only after reading this entire set of instructions. •NEVER work alone. •Before performing visual inspections, tests, or maintenance on this equipment, disconnect all sources of electric power. Assume that all circuits are live until they have been completely de-energized, tested, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of backfeeding. •Apply appropriate personal protective equipment and follow safe electrical practices. •Turn off all power supplying the equipment in which the GCP-MG is to be installed before installing and wiring the GCP-MG. •Always use a properly rated voltage sensing device to confirm that power is off. •Beware of potential hazards, wear personal protective equipment, and carefully inspect the work area for tools and objects that may have been left inside the equipment. •The successful operation of this equipment depends upon proper handling, installation, and operation. Neglecting fundamental installation requirements may lead to personal injury as well as damage to electrical equipment or other property. Failure to follow these instructions will result in death or serious injury! 3.2 Regulatory Notes 1.The GCP-MG module is suitable for use in non-hazardous locations only. 2.The GCP-MG module is not authorized for use in life support devices or systems. 3.Wiring and installation must be in accordance with applicable electrical codes in accordance with the authority having jurisdiction. 4.The GCP-MG module is designed for installation into an electrical switchboard or cubical as part of a fixed installation. 3.3 General Instructions 1.Before installing or removing the module or any connector, ensure that the system power and external supplies have been turned off. 2.Check the system supply voltage with a multimeter for correct voltage range and polarity. 3.Connect the power supply cable and switch on the system power. Check if the Power LED is lit. 8 3.3 General Instructions 4.Turn off system power. 5.Connect all I/O cables. 6.Once you are certain that all connections have been made properly, restore the power. 3.4 DIN Rail Mounting and Removal You can mount the module on a DIN rail. To mount the module on a DIN rail, slot the top part of the GCP-MG into the upper guide of the rail and lower the enclosure until the bottom of the red hook clicks into place. To remove the GCP-MG from the DIN rail, use a screw driver as a lever by inserting it in the small slot of the red hook and push the red hook downwards. Then remove the module from the rail by raising the bottom front edge of the enclosure. 9 2 1 Click DIN rail Slide down 2 1 GCP-MG User Manual 3.5 Powering the GCP-MG Power is supplied via a 3.81 mm 2-pin pluggable terminal block (Phoenix Contact Mini Combicon type MC1,5/2-ST-3.81) located at the top side of the mounted module (refer to illustration on page 7). The following table and picture shows the power terminal socket pinout: Pin Signal Function 1 V+Positive voltage supply (10 – 30 V DC) 2 V-Negative voltage supply, ground Warning: Make sure that the polarity of the supply voltage is correct before connecting any device to the serial and CAN ports! A wrong polarity can cause high currents on the ground plane between the V- power supply pin and the CAN port and serial port GND pins, which can cause damage to the module. 3.6 Wiring the CAN Interface The CAN interface connects to the GCP-30 and LS 4 devices. The connector is a male 9-pin D-sub type located at the top side of the mounted module (refer to illustration on page 7). It has industry standard CiA DS-102 pin-out as shown in the following table and picture: Pin Signal Description 1 (not connected) 2 CAN_L CAN_L bus line 3 GND CAN Ground 4 (not connected) 5 (not connected) 6 GND Optional CAN Ground 7 CAN_H CAN_H bus line 8 (not connected) 9 (not connected) FG Connector shell is internally connected to ground 10 CANCAN_LGNDCAN_HGND 3.6 Wiring the CAN Interface ❑The bus must be terminated at both ends with its characteristic impedance, typically a 120 Ohm resistor. ❑The cable must be a twisted pair (for CAN_H/CAN_L) and a third wire (for the ground). ❑Maximum number of CAN nodes is 64 ❑Maximum cable length is 250 m (820 ft). ❑Stub connections off the main line should be avoided if possible or at least be kept as short as possible. ❑The cable must be shielded and the shield must be connected to a protective ground at a single point to assure a high degree of electromagnetic compatibility and surge protection. ❑The shield must not be connected to the GND pins or the connector shell. 3.7 Wiring the Modbus RS-485 Interface The Modbus RS-485 port is used for integrating the GCP-MG into a two- wire Modbus over Serial Line network. The GCP-MG is a Modbus Slave device. The RS-485 signals are located at the 3.81 mm 6-pin pluggable terminal block (Phoenix Contact Mini Combicon type MC1,5/2-ST-3.81) on the top side of the mounted module (refer to illustration on page 7). The following table and picture shows the pinout: Pin EIA-485 Name Modbus Name Function 1 C/C’Common Signal Common (GND) 2 B/B’D1 Non-inverting Transceiver terminal 1 (RX/TX+) 3 A/A’D0 Inverting Transceiver Terminal 0 (RX/TX-) 4 (unused, must be left unconnected) 5 (unused, must be left unconnected) 6 (unused, must be left unconnected) ❑The bus must be terminated at both ends with its characteristic impedance, typically a 120 Ohm resistor. ❑The bus lines are to be biased (polarized) at one point, typically at the master connection 11 GCP-MG User Manual ❑The cable must be a twisted pair (for B+/A-) and a third wire (for the common). ❑Maximum number of nodes without repeater is 32 ❑Maximum cable length to 1200 m (4000 ft). ❑Stub connections off the main line should be avoided if possible or at least be kept as short as possible. ❑To assure a high degree of electromagnetic compatibility and surge protection, the RS-485 cable must be shielded and the shield must be connected to a protective ground at a single point. The shield must not be connected to the GND pin. 3.8 Wiring the RS232-MODBUS Interface The module's primary RS-232 port is used for serial communication to a Modbus Master device. The GCP-MG is a Modbus Slave device. The connector is a male 9-pin D-sub type located at the bottom side of the mounted module (refer to illustration on page 7). It has industry standard EIA-574 data terminal equipment (DTE) pinout as shown in the following table and picture: Pin Signal Function 1 (unused, must be left unconnected) 2 RXD Received Data 3 TXD Transmitted Data 4 (unused, must be left unconnected) 5 GND Signal Ground 6 (unused, must be left unconnected) 7 RTS Request to Send 8 CTS Clear to Send 9 (unused, must be left unconnected) ❑Maximum cable length is 15 m (50 ft) or a length equal to a line capacitance of 2500 pF, both at the maximum standard bit rate of 20 kbps. If operating at higher bit rates the maximum cable length drops to 3 m (10 ft) at a bit rat e of 57.6 kbps. 12 RS232 MODBUSGNDTDXCTSRXDRTS 3.8 Wiring the RS232-MODBUS Interface ❑The cable must be shielded and the shield must be connected to a protective ground at a single point to assure a high degree of electromagnetic compatibility and surge protection. ❑The shield must not be connected to the GND pin or the connector shell. Note: To connect to a PC (Personal Computer) or any other device with data terminal equipment (DTE) pinout you need a null-modem or cross- over cable. 3.9 Ethernet The following table describes the 10BASE-T Ethernet RJ-45 connector pinout: Pin Signal Function 1 TX+Transmit 2 TX-Transmit 3 RX+Receive 4 5 (connected together)Termination network 6 RX-Receive 7 8 (connected together)Termination network FG Connector frame/shell is connected to ground ❑We recommend to use Category 5 shielded twisted pair network cable. ❑Maximum cable length is 100 m (3000 ft). ❑The network cable must be shielded and the shield must be connected to a protective ground at a single point to assure a high degree of electromagnetic compatibility and surge protection. ❑The shield must not be connected to the connector frame. 13 ETHERNET GCP-MG User Manual 3.10 Connecting to the Diagnostic Port The module's secondary RS-232 port is used as Diagnostic port and only active power-up of the device. It allows configuration of the IP settings and reset of the settings to factory defaults via a terminal program. The connector is a male 9-pin D-sub type located at the bottom side of the mounted module. It has industry standard EIA-574 data terminal equipment (DTE) pinout as shown in the following table and picture: Pin Signal Function 1 (unused, must be left unconnected) 2 RXD Received Data 3 TXD Transmitted Data 4 (unused, must be left unconnected) 5 GND Signal Ground 6 (unused, must be left unconnected) 7 (unused, must be left unconnected) 8 (unused, must be left unconnected) 9 (unused, must be left unconnected) Note: To connect to a PC (Personal Computer) or any other device with data terminal equipment (DTE) pinout you need a null-modem or cross- over cable. 14 RS232 DIAGNOSTICRXDGNDTDX 4 Ethernet & IP Configuration 4 Ethernet & IP Configuration Before configuring the GCP-MG, obtain a unique static IP address, subnet mask, and default gateway address from your network administrator. The factory default IP Address of the GCP-MG is 169.254.0.10 which is in the Automatic Private IP Addressing (APIPA) address range. There a several methods of configuring the gateway’s IP address: ❑Removing your PC from your corporate network and using a cross- over network cable (see page 15). ❑Via the secondary serial port and a terminal program like HyperTerminal (see page 16). ❑Leaving your PC connected to your corporate network and temporarily changing the IP settings on your PC to match the subnet of the GCP- MG (see page 17). Note: In order to connect to the GCP-MG via TCP/IP, your PC must be on same IP subnet as the gateway. In most situations this means that the first three numbers of the IP address have to be identical. 4.1 IP Setup Using a Web Browser and a Cross-Over Network Cable This method applies only to operating systems like Windows, which support APIPA (Automatic Private IP Addressing). It also requires your PC to be configured for DHCP. If your computer is configured with a static IP address, follow the procedure “Temporaril y changing the IP settings on your PC” on page 17. 1.Disconnect your PC from your corporate network. If your computer is configured for DHCP it should now automatically fall back to use a default IP address from the APIPA range 169.254.x.x. 2.Connect an Ethernet crossover cable from the GCP-MG to the computer. 3.Start Internet Explorer. 4.In the address box, type 169.254.0.10 and then press Enter. 5.Click Configuration... and then Ethernet & IP in the menu on the left side of the page. 15 GCP-MG User Manual 6.Enter the IP address, subnet mask, and gateway address assigned to your GCP-MG, then click Save. 7.Reconnect your computer to your corporate network. 4.2 IP Setup Using HyperTerminal 1.Connect a null modem RS-232 cable between your PC and the GCP- MG’s Diagnostic port. 2.In Windows XP, click Start, point to All Programs, point to Accessories , point to Communications, and then click HyperTerminal. 3.When HyperTerminal starts, it opens a dialog box and asks for a name for the new connection. Enter a name (for example, deviceconfig) then click OK. 4.The Connect to dialog opens. Select the COM port you will be using in the Connect using drop-down list box, then click OK. 5.Select 9600, 8, None, 1, None in the COM Properties dialog, then click OK. 6.HyperTerminal is now connected to the serial line. 7.Keep the space bar pressed in HyperTerminal and power-cycle your device at the same time. 8.A menu should appear after one or two seconds showing device information, the current IP configuration and a “>” prompt. 9.Type SETIP, then press Enter within 10 seconds after the prompt is shown. 10.The device will show current values and prompt for new values for IP Address, Net mask and Gateway Address. Enter the new values and press Enter. A key press must be received at least every 10 seconds otherwise the device will go back to RUN MODE and resume normal operation. 16 4.2 IP Setup Using HyperTerminal 11.The gateway will return to the main prompt. Type X and press Enter to leave DIAG MODE and resume normal operation indicated with RUN MODE. 4.3 Temporarily changing the IP settings on your PC This method involves manually assigning an IP address to your PC in the same subnet as the gateway. The default subnet of the gateway is 169.254.0.0/16. 1.Connect the GCP-MG to your Ethernet network. 2.On a Windows PC, open the Control Panel and double-click on Network Connections. Right-click on the Network Connection associated with your network adapter and select Properties. This will show the Local Area Connection Properties Dialog: 17 Right-Click Properties GCP-MG User Manual 3.Write down your current settings so they can be restored later. 4.Configure a static IP Address in the same subnet as the device, for example 169.254.0.1 and the subnet mask 255.255.0.0. 5. 18 Right-Click Properties Click Internet Protocol (TCP/IP) 4.3 Temporarily changing the IP settings on your PC 6.Start Internet Explorer. 7.In the address box, type 169.254.0.10 and then press Enter. 8.Click Configuration... and then Ethernet & IP in the menu on the left side of the page. 9.Enter the IP address, subnet mask, and gateway address assigned to your GCP-MG, then click Save. 10.Restore your computer’s original settings. 19 IP address: 169.254.0.1 Subnet mask: 255.255.0.0 Select Use the following IP address Click OK to save the changes GCP-MG User Manual 5 Web Browse r Based Management The GCP-MG incorporates an embedded web server. This allows you to connect to the device and monitor and configure it using a web browser. Most browsers should work, provided they support JavaScript. We recommend Internet Explorer 6.0 or higher. 5.1 Connecting to the GCP-MG Once you made sure that your PC is configured to be on the same subnet as the GCP-MG, start your web browser. In the address box, type the IP address of your device (169.254.0.10 is the default), and then press Enter. (See page 15 on how to configure Ethernet & IP) The web browser will establish communication with the embedded web server and an overview page similar to the following picture will appear: Use the menu bar shown on the left side to navigate the different pages. 20 Gateway IP Address Configuration Sub-menu Information Area Main Menu 5.1 Connecting to the GCP-MG Note: In order to connect to the GCP-MG via TCP/IP, your PC must be on same IP subnet as the gateway. In most situations this means that the first three numbers of the IP address have to be identical. 5.2 Monitoring and Diagnostic The GCP-MG offers several web pages which allow monitoring of the status of the different communication networks and the device performance. 5.2.1 Device Status The Overview Page shows the principal device status as shown in the following picture: The value shown in the Device row represents the device status register which keeps track of run-time faults. All run-time faults are latched and must be reset by the user. The following faults can be listed here: OK – The device is fault free. Watchdog reset – This warning indicates that the device was reset by it's internal watchdog supervision circuit. Brown out reset – This warning indicates that the device was reset by it's internal supply voltage monitoring circuit. This fault occurs when the supply voltage drops below the lower limit. Device out of memory – This warning indicates that the internal dynamic memory has been exhausted and due to this a certain function could not be completed. Device configuration data write failure – This alarm indicates that the configuration data could not be written to the non-volatile memory. 21 GCP-MG User Manual Configuration data changes will be lost once the device is power- cycled or reset. Reset to factory defaults – This alarm indicates that the device' configuration data was reset to factory defaults. The device requires re-commissioning. The CAN Controller status indicates the status of the CAN interface and can be in one of the following states: ACTIVE – The CAN bus is fault free. PASSIVE – CAN's built in fault confinement mechanism (refer to ISO 11898–1) has set the node to “error passive state” due to a large number of errors on the CAN bus. This warning indicates a wiring error. BUS-OFF – CAN's built in fault confinement mechanism (refer to ISO 11898–1) has set the node to “bus-off” state due to excessive errors on the CAN bus. This alarm indicates a wiring error. The GCP-MG will not transmit or receive any message on the CAN bus once entered this state. The device needs to be manually restarted on order to recover from this fault. 5.2.2 Modbus Connection Status The Modbus Status page shows status and statistics about the Modbus traffic. These values provide valuable information used to troubleshoot Modbus network problems. This page is automatically updated every 5 seconds. 22 5.2 Monitoring and Diagnostic Note: This page shows accumulated readings since the GCP-MG was last activated or reset. If power to the GCP-MG is lost, all cumulative values are reset to zero. The following statistics are maintained: TCP Status – Status of the TCP/IP connection as per TCP finite state machine (refer to RFC 793). If no client is connected the status indicates LISTEN. If a client is connected, it's IP address is shown. Accumulative Connections – A counter that increments each time a client opens a Modbus/TCP connection. Requests – A counter that increments each time an inbound request message is successfully received. Replies – A counter that is incremented each time a reply message is sent back to the master. This includes exception replies. CRC Errors – A counter that increments each time a message is received that has a CRC that does not match what is calculated. Typically the result of wiring issues. Messages with CRC errors are discarded and not replied to. Invalid Frames – A counter that increments each time a malformed Modbus frame is detected. Malformed frames are for example messages larger than the allowed maximum PDU size defined in the Modbus standards. This can be caused by non-Modbus traffic on the network. Rx Time-outs (Modbus Serial Line) – A counter that increments each time an inter-character time-out occurred during the reception of an inbound message. Rx Time-outs (Modbus/TCP) – A counter that increments if the master connection has timed out. Subsequently the connection is terminated by the GCP-MG. A time-out occurs if no Modbus request is received from a connected client within a 10 second period. Tx Time-outs – Number time-outs occurred when attempting to send a reply message. The cumulative diagnostic data is reset when the device is power cycled or reset. The data is also reset by pressing the Clear Counter button. 23 GCP-MG User Manual 5.2.3 CAN Communication Status The CAN Status page shows status and statistics about the CAN bus traffic. These values provide valuable information used to troubleshoot CAN problems. This page is automatically updated every 5 seconds. Note: This page shows accumulated readings since the GCP-MG was last activated or reset. If power to the GCP-MG is lost, all cumulative values are reset to zero. The CAN communication channel between a GCP-30 or LS 4 unit and the GCP-MG can be in one of the following states: OK – The CAN communication channel with the GCP-30 or LS 4 unit has been established. The GCP-30 or LS 4 control is cyclically updating data. WAIT – The presence of a GCP-30 or LS 4 unit has been detected however the GCP-MG is currently waiting to receive a complete data set. It takes approximately between 2.3 and 3 seconds to receive a full data set from the GCP-30 and approximately 10 seconds from the LS 4. TIME-OUT – No CAN message was received for a period of 1 second. A GCP-30 control is supposed to send a CAN message every 100 ms, a LS 4 every 200 ms. 24 5.2 Monitoring and Diagnostic The following statistics are maintained: Messages Received – A counter that increments each time an inbound CAN message matching the shown CAN Id is successfull y received. Messages Sent – A counter that is incremented each time a CAN message is sent. CAN messages are only sent if Remote Control is enabled for this GCP-30 or LS 4. The cumulative diagnostic data is reset when the device is power cycled or reset. The data is also reset by pressing the Clear Counter button. 5.2.4 Finding the Firmwar e Version and Serial Number Click on the About menu entry on the menu bar to show the About page as shown below: This product information is important for service and support inquiries. The following product information is provided: Product Name – The name of the product. Hardware Version – GCP-MG hardware version. Firmware Version – The firmware version that is installed on the GCP- MG. Serial Number – The serial number of the GCP-MG. The serial number is specific to your device. 5.3 Configuring and Commissioning The configuration pages are accessed by clicking on the Configuration... menu entry on the menu bar which then expands a configuration sub- menu. All configuration settings are kept in the device' non-volatile memory. 25 GCP-MGATE GCP-MG User Manual Note: If you make changes to any settings, remember to save each page before changing to a different page! 5.3.1 Configuring Ethernet and IP Select the Configuration→Ethernet & IP sub-menu from the menu bar to open the Ethernet & IP Settings page which is shown below: The following Ethernet parameters are shown: MAC Address – The device’ unique MAC address. This number is hard coded and cannot be changed. The following Internet Protocol (IP) settings can be entered: IP Address – The IP Address assigned to this device. Subnet Mask (also known as network mask) – If you have a router, enter the subnet mask for the segment to which this device is attached. Gateway Address – If your network segment has a router, enter its IP address here. Otherwise leave the address as 0.0.0.0. Once you click Save the new settings are stored and applied instantly. The new settings are confirmed with the following page: Note: Please write down the new IP address so you are able to communicate with the device in the future! 26 5.3 Configuring and Commissioning 5.3.2 Configuring GCP-30 and LS 4 Modbus Access Access from the Modbus to a GCP-30 and LS 4 unit can be configured on a per unit basis. You have the option of completely disabling a gen set control for Modbus access, have read-only access or enabling remote control either unsupervised or time-out supervised. To configure the Modbus Access, enter the Configuration sub-menu and click on either the GCP-30 or LS 4 menu entry. This opens the GCP-30 Settings or LS 4 Settings page similar to the one shown below: The CAN Ids and Modbus Slave Ids are preassigned and cannot be changed. The following Modbus Access options can be selected: Disabled – Modbus access to this unit is completely disabled. The gateway does not respond to a Modbus master query and ignores messages for the associated Modbus Slave ID. The associated slave ID can be used by another Modbus device connected to the Modbus network. Read-only – Modbus access is enabled for read-only data. No remote control is possible, access to the Remote Control Data Table 4:0001 will result in Modbus exception code 03 “Illegal Value” being returned. Control – Modbus access is enabled for reading and for remote control. No supervision of Modbus master activity takes place (See Monitored Control). Before being able to use Remote Control, please check that 27 GCP-MG User Manual the GCP-30 unit has been parameterized accordingly, otherwise the messages sent by the GCP-MG are ignored by the GCP-30. Refer to chapter “Interface ” in your “GCP-30 Series Genset Control” manual. For Remote Control to work, GCP-30 parameter 120 “Control via COM X1X5” must be turned on and discrete input “Automatic 2” (terminal 5) must be asserted. If remote alarm acknowledgment is required, GCP-30 parameter 122 “Ackn. F2,F3 via COM interf” must be turned on in addition. Monitored Control – Similar to Control but in addition the remote control is monitored and a Modbus muster must cyclically update the remote control words by writing to the Remote Control Data Table. If a Modbus master fails to do this within a certain time limit, the GCP- MG will trigger an “Interface error X1X5” alarm on the GCP-30. For Monitored Control to be effective, GCP–30 Parameter 121 “Supervision X1X5” must be turned on. Once you click Save the new settings are stored and applied instantly. A confirmation message is shown. 5.3.3 Configuring Serial Line Modbus The Modbus settings for serial line can be configured to match the network configuration of your Modbus master device. Select the Configuration→Modbus sub-menu from the menu bar to open the Modbus Settings page which is shown below: The following Modbus settings can be entered: Physical Layer – Can be set to two-wire TIA/EIA-485 (RS-485) or TIA/EIA-232-E (RS-232) mode. RS-485 is the default. Depending on this setting either the D-sub (RS-232) connector or the terminal block connector (RS-485) of the GCP-MG is utilized. 28 5.3 Configuring and Commissioning Transmission Mode – Only RTU (Remote Terminal Unit) mode can be selected here. Baud rate – 9600 and 19200 are the most common baud rates for Modbus. 19200 is the default setting. Data bits – Only 8 data bits can be selected here which is a requirement for RTU. Stop bits – Can be configured to be 1 or 2. The Modbus standard mandates that 2 stop bits are configured when using no parity. Parity – Changes parity mode to either none, even or odd. The default parity mode for Modbus is eve n parity. Once you click Save the new settings are stored and applied instantly. A confirmation message is shown. 5.3.4 Remote Restarting the Device You can perform a remote restart of the device from the web interface. A remote restart is similar to power cycling the device. Possibly connected clients are disconnected and communication is interrupted until the device has rebooted. To perform a Remote Restart, click on the Configuration sub-menu and then click on the Restart menu entry. This will open the Restart Device page as shown below: Click on the Restart button to perform a restart of the device. The restart is confirmed with the following notification page. 29 GCP-MG User Manual Please allow a few seconds before continuing working with the device as it has to fully start-up first, before being able to respond to further web browser requests. Note: After a remote restart a “Watchdog reset” alarm is shown on the device' home page. This is a side-effect of the remote restart procedure and the alarm shall be ignored and cleared. 30 6 Gateway Operation 6 Gateway Operation This chapter describes the principal operation of the gateway. The GCP-MG establishes a communication channel to each GCP-30 and LS 4 unit connected to the CAN bus. All GCP-30 and LS 4 units transmit multiplexed data values which the GCP-MG stores in its internal data tables. A GCP-30 for example sends a new value every 100 ms, a LS 4 every 200 ms. The GCP-MG acts as a Modbus server on Ethernet and the serial interface. It accepts connections and Modbus queries from Modbus master devices. The Modbus registers are then served from the GCP-MG's internal data tables. Because of the data table buffering, the Modbus can be polled significantly faster than the update rate on the CAN bus. However faster poll rates would not offer higher update cycles of the data values. Multiplexed CAN messages Round-robin scheduled CAN control words GCP-MGAT E Read Input Registe rs Read Data Table Write Data Table Modbus CAN Read Input Registers Modbus PLC For remote control, a Modbus master writes control words to a dedicated internal data table which is then cyclically sent to the corresponding GCP- 30 or LS 4 unit. One remote control data table is processed every 100 ms. This makes the remote control update cycles depend on the number of units enabled for remote control. For example if 3 GCP-30s are enabled for remote control, it takes 300 ms to send all control words to all GCP-30s, if all 16 GCP-30 and all 8 LS 4 units are enabled for remote control it takes 2.4 s ((16 + 8) x 0.1 s) to transmit all control words to the connected units. 31 GCP-MG User Manual 7 Modbus Data Organization This chapter describes how GCP-30 and LS 4 data values are organized in logical blocks and accesse d via Modbus. The GCP-MG supports the Modbus function codes 03, 04, 06 and 16. A maximum of 100 16-bit words can be requested with Modbus command 04. This makes it possible to read the complete data set of a GCP-30 or LS4 unit with a single Modbus transaction. Modbus Function Code Function Name Access Max. Number of 16-bit words per transaction Data Table/ Block 04 Read Input Registers read 100 3:0000 03 Read Holding Registers write 3 4:0000 06 Write Single Register write 1 4:0000 16 Write Multiple Registers write 3 4:0000 The GCP-MG emulates a virtual Modbus Slave device for each GCP-30 and LS 4 unit connected to the CAN bus. This simplifies management of PLC and SCADA variable tag tables, as the Modbus start address is identical for all GCP-30 and LS 4 units. The following tables show the relation of an individual unit with the Modbus Slave ID and the Modbus Register range: Unit Modbus Slave ID Modbus Read Address Range Modbus Write Address Range Modbus Floating Point Address Range CAN ID GCP-301 1 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 801 2 2 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 802 3 3 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 803 4 4 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 804 5 5 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 805 6 6 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 806 7 7 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 807 8 8 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 808 9 9 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 809 10 10 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 810 11 11 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 811 12 12 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 812 13 13 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 813 32 7 Modbus Data Organization Unit Modbus Slave ID Modbus Read Address Range Modbus Write Address Range Modbus Floating Point Address Range CAN ID 14 14 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 814 15 15 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 815 16 16 3:0001-3:0100 4:0001-4:0003 3:1001-3:1076 816 LS 41 17 3:0001-3:0100 4:0003 3:1001-3:1034 817 2 18 3:0001-3:0100 4:0003 3:1001-3:1034 818 3 19 3:0001-3:0100 4:0003 3:1001-3:1034 819 4 20 3:0001-3:0100 4:0003 3:1001-3:1034 820 5 21 3:0001-3:0100 4:0003 3:1001-3:1034 821 6 22 3:0001-3:0100 4:0003 3:1001-3:1034 822 7 23 3:0001-3:0100 4:0003 3:1001-3:1034 823 8 24 3:0001-3:0100 4:0003 3:1001-3:1034 824 A standard LS 4 occupies only the range from 3:0001 to 3:0029. The remaining range is reserved for future expansion of the LS 4 or custom versions. Note: If no response was obtained from the target GCP-30 unit, Modbus exception code 0B “Gateway Target Device failed to respond” is returned. The following table lists the Modbus exception responses sent by the gateway instead of a normal response message in case of an error: Modbus Exception Code Exception Name Reason 01 Illegal Function A Modbus master sent a Modbus function which is not supported by the gateway. Please refer to the documentation of the individual Data Tables for valid function codes. 02 Illegal Data Address A Modbus master queried a non-existing Modbus address or the queried range points outside of a Data Table. Please refer to the documentation of the individual Data Tables for valid address ranges. 03 Illegal Value A Modbus master sent a Modbus message which’s structure or implied length is invalid. Also returned if a Modbus master tries to access remote control functions for a unit configured as read-only. 0B Gateway Target Device failed to respond A Modbus master tries to access data which is unavailable because no response was obtained from the target GCP-30 or LS 4 unit. Usually means that the unit is not present on the CAN bus. 33 GCP-MG User Manual 7.1 GCP-30 Mux Data Table 3:0001 The GCP-30 Mux Data Table contains all data values a GCP-30 is transmitting cyclically on the CAN bus. A GCP-30 sends a value every 100 ms. Therefore it takes approximately between 2.3 and 3 s for a complete update of the data table with new values from the CAN bus. The data table can be polled much faster by a Modbus master, however faster poll rates would not offer higher update cycles. The GCP-30 Mux Data Table is located in the so called Input Register address block, which sometimes is also identified with offset 3:0000. The block is accessed using Modbus function code 04 “Read Input Registers”. Only Modbus address 0001 can be access ed at all times. All other Modbus addresses can only be accessed if the CAN communication between GCP- MG and GCP-30 has been established. If this is not the case, Modbus exception code 0B “Gateway Target Device failed to respond” is returned indicating the GCP-30 is not present on the CAN bus. For the GCP-30 Mux Data Table , the GCP-MG acts as a transparent gateway between the GCP-30 unit and the Modbus. Except for the Device Status Register at Modbus address 0001, it does not perform any modification to the representation of the data values. The Woodward “GCP-30 Series Genset Control ” manual is the ultimate reference for the encoding and representation of the data values. Please refer to the “Transmission Telegram ” table in Appendix C “Interface Control” of your Woodward “GCP-30 Series Genset Control ” manual for further details. The following table shows the relationship between Modbus addresses and the so called MUX identifiers or Word Numbers the “GCP-30 Series Genset Control” manual is referring to: Block Modbus Address GCP-30 MUX GCP-30 Word No.GCP-30 Manual Designator 3 0001 n/a n/a CAN Device Status Register Bit 1: 1 = CAN communication between GCP-MG and GCP-30 OK Bit 2-16: reserved for future use 3 0002 0/1 1 Generator voltage delta V12 3 0003 0/2 2 Generator frequency f 3 0004 0/3 3 Actual generator real power P 34 7.1 GCP-30 Mux Data Table 3:0001 Block Modbus Address GCP-30 MUX GCP-30 Word No.GCP-30 Manual Designator 3 0005 1/1 4 Exponents 3 0006 1/2 5 Real power set point value 3 0007 1/3 6 Conversion factor steps to kW 3 0008 2/1 7 Bus bar voltage delta V12 3 0009 2/2 8 Mains voltage delta V12 3 0010 2/3 9 Currently present alarm class 3 0011 3/1 10 Control register 2 3 0012 3/2 11 Actual mains interchange (import/export) real power 3 0013 3/3 12 Control register 1 3 0014 4/1 13 Alarm message IKD (SC06) 3 0015 4/2 14 Internal alarm 6 3 0016 4/3 15 Generator voltage delta V23 3 0017 5/1 16 Generator voltage delta V31 3 0018 5/2 17 Generator voltage delta V1N 3 0019 5/3 18 Generator voltage delta V2N 3 0020 6/1 19 Generator voltage delta V3N 3 0021 6/2 20 Configuration [T1]-[T4] 3 0022 6/3 21 Engine speed measured via the Pickup 3 0023 7/1 22 Generator current in L1 3 0024 7/2 23 Generator current in L2 3 0025 7/3 24 Generator current in L3 3 0026 8/1 25 Actual generator reactive power 3 0027 8/2 26 Generator cos phi 3 0028 8/3 27 Current reserve power in the system in kW 3 0029 9/1 28 Current actual real power in the system 3 0030 9/2 29 Number of participants on the CAN bus 3 0031 9/3 30 High byte: Mains status, Low byte: Generator status 3 0032 10/1 31 Exponents 3 0033 10/2 32 Bus bar frequency 3 0034 10/3 33 Configuration [T5]-[T8] 3 0035 11/1 34 Mains voltage delta V23 3 0036 11/2 35 Mains voltage delta V31 3 0037 11/3 36 Mains voltage delta V1N 3 0038 12/1 37 Mains voltage delta V2N 3 0039 12/2 38 Mains voltage delta V3N 3 0040 12/3 39 Mains frequency out off VN12/VN23/VN31 3 0041 13/1 40 Mains current in L1 3 0042 13/2 41 Mains reactive power 35 GCP-MG User Manual Block Modbus Address GCP-30 MUX GCP-30 Word No.GCP-30 Manual Designator 3 0043 13/3 42 Mains power factor 3 0044 14/1 43 Exponents 3 0045 14/2 44 Exponents 3 0046 14/3 45 Engine operating hours, high word 3 0047 15/1 46 Engine operating hours, low word 3 0048 15/2 47 Hours until next maintenance 3 0049 15/3 48 Engine start number 3 0050 16/1 49 Operation mode 3 0051 16/2 50 Generator active energy, high word 3 0052 16/3 51 Generator active energy, low word 3 0053 17/1 52 Battery voltage 3 0054 17/2 53 Internal alarm 1 3 0055 17/3 54 Internal alarm 2 3 0056 18/1 55 Internal alarm 3 3 0057 18/2 56 Internal alarm 4 3 0058 18/3 57 Internal alarm 5 3 0059 19/1 58 External alarm 1 3 0060 19/2 59 External alarm 2 3 0061 19/3 60 Internal alarm 7 3 0062 20/1 61 Analogue input T1 3 0063 20/2 62 Analogue input T2 3 0064 20/3 63 Analogue input T3 3 0065 21/1 64 Analogue input T4 3 0066 21/2 65 Analogue input T5 3 0067 21/3 66 Analogue input T6 3 0068 22/1 67 Analogue input T7 3 0069 22/2 68 Alarm messages IKD2 (SC06) 3 0070 22/3 69 LCD-display / Pickup 3 0071 - 0100 Not used by a standard GCP-30, reserved for options, future expansion or custom versions. See below for allocation by option SB03 and SB06. Note: If no response was obtained from the target GCP-30 unit, Modbus exception code 0B “Gateway Target Device failed to respond” is returned. 36 7.1 GCP-30 Mux Data Table 3:0001 7.1.1 Allocation with Options SB03 and SB06 Block Modbus Address GCP-30 MUX GCP-30 Word No. SB03 Option Cat CCM Designator SC06 Option MTU MDEC Designator 3 0071 23/1 70 Coolant temperature Woodward ST-3 control Lambda Setpoint 3 0072 23/2 71 Oil pressure Woodward ST-3 control Lambda Reading 3 0073 23/3 72 Raw water temperature Woodward ST-3 control Actuator Position 3 0074 24/1 73 Turbo charger intake temperature Engine Speed 3 0075 24/2 74 Oil temperature Oil Pressure 3 0076 24/3 75 Intake manifold temperature Alarm Code 3 0077 25/1 76 Throttle Position Operating Hours 3 0078 25/2 77 Engine Speed Coolant Temperature 3 0079 25/3 78 Multiplexed ECU alarms 1 Oil Temperature 3 0080 26/1 79 Multiplexed ECU alarms 2 Fuel Temperature 3 0081 26/2 80 Multiplexed ECU alarms 3 Speed Reply 3 0082 26/3 81 Multiplexed ECU alarms 4 Multiplexed ECU Alarm Group 1 3 0083 27/1 82 Multiplexed ECU Alarm Group 2 3 0084 27/2 83 Reserved MDEC bit 11 3 0085 27/3 84 Reserved MDEC bit 12 3 0086 28/1 85 Reserved MDEC bit 13 3 0087 28/2 86 Reserved MDEC bit 14 3 0088 28/3 87 Reserved MDEC bit 15 3 0089 29/1 88 Reserved MDEC bit 16 3 0090 29/2 89 Reserved MDEC bit 17 3 0091 29/3 90 Reserved MDEC bit 18 7.2 GCP-30 Remote Control Data Table 4:0001 The GCP-30 Remote Control Data Table is located in the so called Holding Register address block, which sometimes is also identified with offset 4:0000. This block can be written to using Modbus function code 16 “Write Multiple Registers” or function code 06 “Write Single Register”. 37 GCP-MG User Manual If Remote Control is enabled, the three remote control words are sent cyclically to the respective GCP-30. They are also stored in the GCP-MG's memory and can be read back using Modbus function code 03 “Read Holding Registers”. Note: Remote Control is disabled by default and Modbus exception code 03 “Illegal Value” is returned if a Modbus master tries to access remote control functions for a unit configured as read-only. Remote Control can be enabled on a per unit basis through the GCP-30 Settings page of the GCP-MG (see page 27). Block Modbus Address GCP-30 Word No.GCP-30 Manual Designator Encoding 4 0001 501 Generator real power set-point kW with control argument 4 0002 502 Generator power factor set-point cos phi x 100 4 0003 503 Control Word Bit 1: 1 = Remote Start Bit 2: 1 = Remote Stop (high priority) Bit 3: write always 0 Bit 4: write always 0 Bit 5: 1 = Alarm Acknowledgment Bit 6-16: internal use Note: If no response was obtained from the target GCP-30 unit, Modbus exception code 0B “Gateway Target Device failed to respond” is returned. 7.3 GCP-30 Floating Point Table 3:1001 The GCP-30 Floating Point Data Table is located in the so called Input Register address block, which is sometime s also identified with offset 3:0000. This block is accessed using Modbus function code 04 “Read Input Registers”. The floating point values are encoded in industry standard single- precision (32-bit) IEEE 754 format. The 32-bit floating point values are transmitted as pairs of two consecutive 16-bit registers in little-endian word order. 38 7.3 GCP-30 Floating Point Table 3:1001 Block Modbus Address GCP-30 MUX GCP-30 Word No.GCP-30 Manual Designator Unit 3 1001 0/1 1 Generator voltage delta V12 V 3 1003 0/2 2 Generator frequency f Hz 3 1005 0/3 3 Actual generator real power P kW 3 1007 1/2 5 Real power set point value kW 3 1009 2/1 7 Busbar voltage delta V12 V 3 1011 2/2 8 Mains voltage delta V12 V 3 1013 3/2 11 Actual mains interchange (import/export) real power kW 3 1015 4/3 15 Generator voltage delta V23 V 3 1017 5/1 16 Generator voltage delta V31 V 3 1019 5/2 17 Generator voltage delta V1N V 3 1021 5/3 18 Generator voltage delta V2N V 3 1023 6/1 19 Generator voltage delta V3N V 3 1025 6/3 21 Engine speed measured via the Pickup rpm 3 1027 7/1 22 Generator current in L1 A 3 1029 7/2 23 Generator current in L2 A 3 1031 7/3 24 Generator current in L3 A 3 1033 8/1 25 Actual generator reactive power kW 3 1035 8/2 26 Generator cos phi 3 1037 8/3 27 Current reserve power in the system in kW kW 3 1039 9/1 28 Current actual real power in the system kW 3 1041 10/2 32 Busbar frequency Hz 3 1043 11/1 34 Mains voltage delta V23 V 3 1045 11/2 35 Mains voltage delta V31 V 3 1047 11/3 36 Mains voltage delta V1N V 3 1049 12/1 37 Mains voltage delta V2N V 3 1051 12/2 38 Mains voltage delta V3N V 3 1053 12/3 39 Mains frequency out off VN12/VN23/VN31 V 3 1055 13/1 40 Mains current in L1 A 3 1057 13/2 41 Mains reactive power kVAR 3 1059 13/3 42 Mains power factor 3 1061 17/1 52 Battery voltage V 3 1063 20/1 61 Analogue input T1 3 1065 20/2 62 Analogue input T2 3 1067 20/3 63 Analogue input T3 3 1069 21/1 64 Analogue input T4 3 1071 21/2 65 Analogue input T5 3 1073 21/3 66 Analogue input T6 39 GCP-MG User Manual Block Modbus Address GCP-30 MUX GCP-30 Word No.GCP-30 Manual Designator Unit 3 1075 22/1 67 Analogue input T7 Note: If no response was obtained from the target GCP-30 unit, Modbus exception code 0B “Gateway Target Device failed to respond” is returned. 7.4 LS 4 Mux Data Table 3:0001 The LS 4 Mux Data Table contains all data values a LS 4 is transmitting cyclically on the CAN bus. A LS 4 sends a value every 200 ms. Therefore it takes approximately 10 s for a complete update of the data table with new values from the CAN bus. The data table can be polled much faster by a Modbus master, however faster poll rates would not offer higher update cycles. The LS 4 Mux Data Table is located in the so called Input Register address block, which sometimes is also identified with offset 3:0000. The block is accessed using Modbus function code 04 “Read Input Registers”. Only Modbus address 0001 can be access ed at all times. All other Modbus addresses can only be accessed if the CAN communication between GCP- MG and LS 4 has been established. If this is not the case, a Modbus exception code 0B “Gateway Target Device failed to respond” is returned, indicating the LS 4 unit is not present on the CAN bus. For the LS 4 Mux Data Table, the GCP-MG acts as a transparent gateway between the LS 4 unit and the Modbus. Except for the Device Status Register at Modbus address 0001, it does not perform any modification to the representation of the data values. The Woodward “LS 4 Circuit Break Control” manual is the ultimate reference for the encoding and representation of the data values. Please refer to the “Transmissi on telegra m” table in Appendix E “Interface” of your Woodward “LS 4 Circuit Break Control ” manual for further details. The following table shows the relationship between Modbus addresses and the so called MUX identifiers or Word Numbers the “LS 4 Circuit Break Control” manual is referring to. 40 7.4 LS 4 Mux Data Table 3:0001 Block Modbus Address GCP-30 MUX GCP-30 Word No.GCP-30 Manual Designator 3 0001 n/a n/a CAN Device Status Register Bit 1: 1 = CAN communication between GCP-MG and LS 4 OK Bit 2-16: reserved for future use 3 0002 0/1 1 Protocol number “1600” 3 0003 0/2 2 Voltage L12 system A 3 0004 0/3 3 Voltage L23 system A 3 0005 1/1 4 Voltage L31 system A 3 0006 1/2 5 Voltage L1N system A 3 0007 1/3 6 Voltage L2N system A 3 0008 2/1 7 Voltage L3N system A 3 0009 2/2 8 Frequency system A 3 0010 2/3 9 Current L1 system A 3 0011 3/1 10 Current L2 system A 3 0012 3/2 11 Current L3 system A 3 0013 3/3 12 Power factor 3 0014 4/1 13 Real power system A 3 0015 4/2 14 Reactive power system A 3 0016 4/3 15 Voltage L12 system B 3 0017 5/1 16 Voltage L23 system B 3 0018 5/2 17 Voltage L31 system B 3 0019 5/3 18 Frequency system B 3 0020 6/1 19 Exponent 3 0021 6/2 20 Exponent 3 0022 6/3 21 Internal Alarms 1 3 0023 7/1 22 Internal Alarms 2 3 0024 7/2 23 Internal Alarms 3 3 0025 7/3 24 Internal Alarms 4 3 0026 8/1 25 Internal Alarms 5 3 0027 8/2 26 Internal Alarms 6 3 0028 8/3 27 Internal Alarms 7 3 0029 9/1 28 Internal Diagnosis 3 0030 - 0100 Not used by a standard LS 4, reserved for future expansion or custom versions. Note: If no response was obtained from the target LS 4 unit, Modbus exception code 0B “Gateway Target Device failed to respond” is returned. 41 GCP-MG User Manual 7.5 LS 4 Remote Control Data Table 4:0001 The LS 4 Remote Control Data Table is located in the so called Holding Register address block, which sometimes is also identified with offset 4:0000. The block can be written to using Modbus function code 16 “Write Multiple Registers” or function code 06 “Write Single Register”. If Remote Control is enabled, the three remote control words are sent cyclically to the respective LS 4. They are also stored in the GCP-MG's memory and can be read back using Modbus function code 03 “Read Holding Registers”. Note: Remote Control is disabled by default and Modbus exception code 03 “Illegal Value” is returned if a Modbus master tries to access remote control functions for a unit configured as read-only Remote Control can be enabled on a per unit basis through the LS 4 Settings page of the GCP-MG (see page 27). Block Modbus Address LS 4 Word No. LS 4 Documentation Designator Encoding 4 0001 501 (not used for LS-4) 4 0002 502 (not used for LS-4) 4 0003 503 Control Word Bit 1: 1 = Open CB (high priority) Bit 2: 1 = Close CB Bit 3: write always 0 Bit 4: write always 0 Bit 5: 1 = Alarm Acknowledgment Bit 6-16: internal use Note: If no response was obtained from the target LS 4 unit, Modbus exception code 0B “Gateway Target Device failed to respond” is returned. 7.6 LS 4 Floating Point Data Table 3:1001 The LS 4 Floating Point Data Table is located in the so called Input Register address block, which is sometimes also identified with offset 3:0000. This block is accesse d using Modbus Function Code 04 “Read Input Registers ”. 42 7.6 LS 4 Floating Point Data Table 3:1001 The floating point values are encoded in industry standard single- precision (32-bit) IEEE 754 format. The 32-bit floating point values are transmitted as pairs of two consecutive 16-bit registers in little-endian word order. Block Modbus Address LS 4 MUX LS 4 Word No.LS 4 Manual Designator Units 3 1001 0/2 2 Voltage L12 system A V 3 1003 0/3 3 Voltage L23 system A V 3 1005 1/1 4 Voltage L31 system A V 3 1007 1/2 5 Voltage L1N system A V 3 1009 1/3 6 Voltage L2N system A V 3 1011 2/1 7 Voltage L3N system A V 3 1013 2/2 8 Frequency system A Hz 3 1015 2/3 9 Current L1 system A A 3 1017 3/1 10 Current L2 system A A 3 1019 3/2 11 Current L3 system A A 3 1021 3/3 12 Power factor 3 1023 4/1 13 Real power system A kW 3 1025 4/2 14 Reactive power system A kVAR 3 1027 4/3 15 Voltage L12 system B V 3 1029 5/1 16 Voltage L23 system B V 3 1031 5/2 17 Voltage L31 system B V 3 1033 5/3 18 Frequency system B Hz Note: If no response was obtained from the target LS 4 unit, Modbus exception code 0B “Gateway Target Device failed to respond” is returned. 43 GCP-MG User Manual 8 Specifications Modbus Gateway for GCP-30 (GCP-MG) Interfaces Ethernet 1 Serial Ports 2 1 RS-232 or RS-485, software configurable 1 RS-232 CAN 1 User Interface LED Indicators Power (green), Ethernet link (green), 2 status (bi-color red/green) Monitoring & Configuration Web browser based Diagnostic High Availability Features Wat chdog supervision, Brown-out detection CAN Port Connector male 9-pin D-sub, CiA DS-102 pin-out Physical Layer ISO 11898 Speed 10 kBit/s – 1 MBit/s Max. number of nodes 64 Protocols CAL Isolation non-isolated ESD Protection 6 kV RS-485 Modbus Port Connector 3.81 mm 6-pin pluggable terminal block header (Mini Combicon) Physical Layer EIA-485-A, 2-wire Speed 300-115200 bps Max. number of nodes 32 Protocols Modbus RTU Isolation non-isolated ESD Protection 8 kV RS-232 Modbus Port Connector male 9-pin D-sub, DTE, EIA-574 pin-out Physical Layer EIA–232-F Signals RXD, TXD, RTS, CTS Speed 300-115200 bps Protocols Modbus RTU Isolation non-isolated ESD Protection 10 kV RS-232 Diagnostic Port 44 8 Specifications Connector male 9-pin D-sub, DTE, EIA-574 pin-out Physical Layer EIA–232-F Signals RXD, TXD Speed 9600 bps Isolation n/a Protocols ASCII Terminal ESD Protection 10 kV Ethernet Port Connector RJ-45 socket for Cat 5 shielded twisted pair Physical & Data Link Layer Layer IEEE 802.3i 10BASE-T Speed 10 MBit/s Max. Cable Length 100 m (328 ft) Ethernet Frame Types 802.3 Protocols IP, TCP, HTTP, ARP, TFTP, Modbus/TCP Isolation 1.5 kV galvanic Enclosure Material Self-extinguishing PC/ABS blend (UL 94-V0) Mounting 35 mm DIN Rail (EN 60715) Protection Rating IP 20 / NEMA Type 1 Power Supply Connector 3.81 mm 2-pin pluggable terminal block header (Mini Combicon) Voltage 10-30 V DC Current 30 mA typical @ 24 V DC Intrinsic Consumption 750 mW Environmental Operating Temperature 0 to 60° C / 32 to 140 °F Storage Temperature -25 to 85° C / -13 to 185 °F Humidity 10 to 95% (without condensation) Operating Ambience Free from corrosive gas, minimal dust Physical Dimensions 101 x 22.5 x 120 mm / 3.98” x 0.886 “ x 4.72” Weight 0.12 kg / 0.265 lbs 45 GCP-MG User Manual 8.1 Dimensions 101.0 mm101.0 mm120.0 mm 3.98 in3.98 in4.72 in 0.89 in 22.5 mm 46 25 Intelligent low-cost CAN interface for the USB-Port The USB-to-CAN compact is a low-cost,active CAN module for connection to the USB bus.The 16-bit microcontroller system en- ables reliable,loss-free transmission and reception of messages in CAN networks with both a high transmission rate and a high bus load.In addition,messages are provided with a time-stamp and can be filtered and buffered directly in the USB-to-CAN compact.The module can also be used as a master assembly,e.g.for CANopen systems.Together with the universal CAN driver VCI supplied with the delivery,the USB-to-CAN compact allows the simple integration of PC-supported applications into CAN systems. Combining an extremely attractive price with compact construc- tion,the USB-to-CAN compact is ideal for use in series products and in conjunction with the canAnalyser for development,service and maintenance work. T E C H N I C A L D ATA PC bus interface USB,Version 2.0 (full speed) PC address range Plug &Play Interrupts Plug &Play Microcontroller Infineon C161U,24 MHz Memory extension 128 kByte RAM,512 kByte Flash CAN controller Philips SJA 1000,10 kBit/s to 1 MBit/s CAN bus interface ISO/IS 11898-2,Sub D9 connector or RJ45 con- nector according to DS 102,galvanically decou- pled as an option Power supply Provided by USB port,250 mA typ Temperature range 0 ºC to +50 ºC Certification CE,FCC,CSA/UL Size Approx.80 x 45 x 20 mm O R D ER O P T I O N S Galvanic decoupled V E R S I O N S With Sub D9 plug according to DS102 With RJ45 plug according to DS102 C O N T E N T S O F D E L I V E R Y CAN interface,user’s manual CAN driver VCI for Windows 2000,XP Simple CAN monitor "miniMon" O R D ER N U M B E R 1.01.0087.10100 USB-to-CAN compact (with SUB-D9 plug) 1.01.0087.10200 USB-to-CAN compact,with galvanic isolation (with SUB-D9 plug) 1.01.0088.10100 USB-to-CAN compact (with RJ45 plug) 1.01.0088.10200 USB-to-CAN compact,with galvanic isolation (with RJ45 plug) USB-to-CAN compact Section 14 (This Page Intentionally Left Blank) (No Items in this Section) (This Page Intentionally Left Blank) Section 15 (This Page Intentionally Left Blank) Power Products 1-800-633-040526–16 PS Series 12 VDC and 24 VDC Power Supplies Switching power supplies at linear supply prices AUTOMATIONDIRECT offers the most practical industrial control power supplies available. The PS Series power supplies give you consistent, reliable, switched DC power at linear power supply prices. These power supplies use efficient switching technology to produce the most power in the smallest space, while generating a minimum amount of heat. The constant-current short circuit protection limits the output current as the voltage is reduced to safely protect your control components from direct shorts and device failures. Once the short is corrected, the PS Series power supplies automatically resume supplying full-voltage power. Precisely regulated output power is suitable for battery charging applications. Extra- sturdy DIN rail mounts and removable plug connections make installation a breeze. Meeting UL/cUL 60950, 508 and 1604* (Class I, Div. 2), our PS-D (DIN-rail mounted) power supplies meet the standards required for practi- cally any industrial control application. Features • 2A - 24A at 24 VDC, 3.5A at 12 VDC • Regulated switch mode type • Easy DIN-rail mounting • Constant-current short circuit protection • Low ripple and noise • Selectable input voltage (115/230 VAC) • High EMC immunity • EMI meets EN 55011-B and FCC Part 15, Level B • Worldwide safety approvals: UL/cUL508, 60950 and 1604* (Class I,Div. 2) CE (see Note on following page about IEC 61000-3-2) • Low profile case Sturdy DIN-rail mounting: • Easy to mount and remove, but still secure Power ON LED: • Quick visual check for troubleshooting Efficient switching technology: • Smaller size and less heat generated results in less wasted space and energy Durable metal case: • A reliable industrial duty package Constant current protection with auto-recovery: • No current spikes to damage powered devices due to improper wiring or a powered device failure Removable plug terminals: • Easy to install and disconnect wiring PS12-050D D: DIN-Rail Mounting Output Watts Output Volts PS: Series Name Part numbering system Note: All specifications are valid at nominal input voltage, full load and +25°C after warm up time, unless otherwise stated. * PS12-050D, PS24-050D and PS24-500D do not meet UL 1604 Class I Div 2. Power Products 26–17w w w . a u t o m a t i o n d i r e c t . c o m / p o w e r a n d a c c e s s o r i e s PS Series Power Supplies Specifications General Specifications Temperature Operating (ambient) -25°C to + 70°C max Derating above 50°C 2%/C Storage (non-operating) -25°C to + 85°C maxTemperature drift 0.02%/C Humidity 95% (non-condensing) relative humidity max Switching Frequency 80 kHz typical (PWM) Isolation According to IEC/EN 60950, UL 60950, UL 508 Output Regulation Input variation: ± 0.2% max Load variation:50 W, 75 W, 150 W models: ± 1% max300 W, 500 W, 600 W models: ± 0.3% max Output Voltage Ripple < 50 mV peak-peak (20 MHz bandwidth) Output Protection Current limit: 110% maximum output rating Voltage limit: 140% Vout nom Vibration 1gn 20 sweeps each axis Shock 15gn, 11mS each axis Enclosure Rating IP 20 Enclosure Material Aluminum (chassis) / stainless steel (cover) Mounting Snap-on with self-locking spring for 35mm DIN rails Connection Removable screw terminals for 22-10 AWG Agency* Approvals UL/cUL 60950 recognized UL/cUL 508 listed UL/cUL 1604 listed (Class I, Div 2, groupsA,B,C, and D hazardous locations), exceptPSxx-050 and PS24-500D, which are notUL/cUL1604 listed.CE (See IEC 61000-3-2 Note below) Note: All specifications are valid at nominal input volt- age, full load and +25°C after warm-up time, unless otherwise stated. Input Specifications Part Number Input Voltage Range Input Frequency Range Input Current (Typical) Inrush Current (<2mS)Effi- ciency (Typ.)115 VAC 230 VAC 115 VAC 230 VAC PS12-050D 93-264 VAC 47-63 Hz 1.2 A 0.7 A <15 A <30 A 84% PS24-050D 93-264 VAC 1.2 A 0.7 A 87% PS12-075D 93-132 VAC187-264 VAC (switch selectable) 1.7 A 0.9 A <16.5 A <33 A 83% PS24-075D 1.7A 0.9 A 85% PS24-150D 3.0 A 1.7 A <35 A <70 A 84% PS24-300D 5.4 A 3.3 A 87% PS24-500D 93-132 VAC 9.5 A N/A <50 A N/A 87% PS24-600D 93-132 VAC 187-264 VAC(switch selectable)10.5 A 6.4 A <70 A <80 A 88% Output Specifications Part Number Price Output Voltage Output Voltage Adj. Range Output Current (Max.) Output Power (Max.) Output Voltage Regulation* Hold-Up Time MTBF (IEC 1709 @ 25°C)115 VAC 230 VAC PS12-050D <--->12 VDC 12-14 VDC 3.5 A 50 W 1%25 mS 30 mS 2,992,000 hoursPS24-050D <--->24 VDC 24-28 VDC 2.0 A 50 W PS12-075D <--->12 VDC 12-14 VDC 6.0 A 75 W 1,800,000 hoursPS24-075D <---> 24 VDC 24-28 VDC 3.0 A 75 W PS24-150D <--->6.0 A 150 W 1,939,000 hours PS24-300D <--->12.0 A 300 W 0.3% 1,913,000 hours PS24-500D <--->20.0 A 500 W 20 mS N/A 1,467,000 hours PS24-600D <--->24.0 A 600 W 15 mS 25 mS 1,434,000 hours *Load variation (10-90%)Notes: Output current characteristic suitable for battery charging applica- tions. Not recommended for redundancy or parallel operation. PS12-050D / PS24-050D PS12-075D / PS24-075D PS24-150D PS24-600DPS24-300D PS24-500D Replacement terminal blocks are available. See price list. * PS12-050D, PS24-050D and PS24-500D do not meet UL 1604 (Class I,Div. 2). Note: IEC 61000-3-2 Power Factor Correction The IEC 61000-3-2 standard is intended to reduce the amount of disturbance a device feeds back into its power source. AutomationDirect power supplies all carry the CE mark. Normally, 61000-3-2 is met or does not apply. Only our PS24-150D and PS24-300D could potentially be used in a manner not compliant with the 61000-3-2 standard. PLCOverview DL05/06PLC DL105PLC DL205PLC DL305PLC DL405PLC Field I/O Software C-more HMIs Other HMI AC Drives Motors Steppers/Servos MotorControls ProximitySensors PhotoSensors LimitSwitches Encoders Pushbuttons/Lights Process Relays/Timers Comm. TB’s & Wiring Power Enclosures Appendix Part Index Power Products 1-800-633-040526–18 PS Series Power Supplies Dimensions 100.0 (3.94)75 (2.95) 37.5 (1.48)74.0(2.91)56.7 (2.23)26(1.02)5 (0.2)31.5(1.24)10(0.39)114.6 (4.51)90 (3.54) 45 (1.77)10(0.39)56.7 (2.23)86.5(3.4)34(1.34)5 (0.2)39.5(1.56)PS12-050D, PS24-050D PS12-075D, PS24-075D PS24-150D PS24-600D PS24-300D PS24-500D 6.8(0.27)177.2 (6.98)82.8 (3.26)32 (1.26)120.2 (4.73)82.6 (3.25) 179 (7.05) 243 (9.57) Note: All dimensions are in millimeters (inches). Tolerances ±0.5mm (This Page Intentionally Left Blank) • Ultra-Quiet • Power sensitive electronics without interference • Rugged & Reliable • Ensure years of safe and trouble free operation • Marine Electronics Displays • Mobile Offices (TV and Radio Vans) • Automotive / RV • Electric Utilities and Substations • Base Station Power (Radio & Telecommunications) • Industrial Controls (OEM Applications) • Field Work / Construction Sites • Solar / Alternative Power Systems • Any 12 or 24V Equipment DC/DC Converters VTC605 Series Step-Up Converter Step up a 12 VDC battery to between 13.5 and 17.0 or 24.0 and 27.5 VDC in 0.5 VDC increments (via 3 position DIP switch), or stabilize a 12 or 24 VDC power system. Safety features include reverse input protection, low input voltage alarm, low output voltage alarm, over temperature shutdown and alarm, a dry contact alarm relay output and output overvoltage crowbar. If the input voltage exceeds the regulated output voltage, the unit simply passes the voltage through with full LC filtering and a single schottky diode drop (0.5 VDC or less). Optional features include remote panel monitoring with On/Off control. Applications include temporarily brightening 12 volt headlights or work lights, increasing voltage into an automotive or marine ignition system for hotter spark and/or prevention of failures due to voltage drop during engine start, stabilizing 12V and 24 VDC power systems in marine, automotive or aeronautical environments and more. • Vibration proof output voltage adjustment by 3 position DIP switch • Audible & visual indicators for constant current, low input voltage, low output voltage & over-temperature • Extremely rugged and well suited for marine and other demanding environments • High tolerance for shock and vibration • Ultra-quiet low EMI operation • Current limiting protection • Reverse input protection • Output over-voltage crowbar • Dry contact output fail relay • Remote control option • Wide-Temperature operation available • Parallel output diodes available • Conformal Coating and/or Harsh Environment Ruggedization Available • 3 year parts and labour warranty Description Benefits App lications Features VTC605 Series Step-Up Voltage Converter Specifications ♦ The actual output current capability depends upon the input/output voltage ratio. To obtain Quality since 1976 the actual output current capability at any given input voltage, use the following formula: #207 12448 82nd Ave. Surrey, BC V3W 3E9 CANADA Output Amps = Input Volts/Output Volts x 45 +1 (604) 543-7378 phone For example, at 10.5 VDC in and 13.6 VDC out, the output current = 10.5/13.6 x 45 = 34.7 amps 1-800-668-3884 toll free +1-604-543-7354 fax Available From: www.analyticsystems.com ' 2002 Analytic Systems Ware Ltd. (1993) Specifications Subject to Change Without Notice Operating Temp. Range -25 - +40C @ maximum output Derate Linearly 2.5% per C from 40C (Optional -40C extra wide temp. operation avail.) Humidity 0 - 95C Relative Humidity (non-condensing) with optional conformal coating Audible Noise NONE db @ 3 ft Typical Service Life > 10 yrs. (87,600 hrs) Isolation Any Input or Output to Case 500 VDC Input to Output Common Negative Input Volts (DC) 10.5-18 10.5-28 Input Amps (max) 50 Input Fuse (AGC) 30 x 2 Amp Noise on Input < 50 mV Low Input Voltage Alarm 10.5 VDC Current Limit 50 Amps in Output Nominal (op) 12 24 Output Volts (DC) Input - 1V or 13.5 to 17.0 Input - 1V or 24.0 to 27.5 Whichever is greater Whichever is greater Output Amps ♦ 45 Output Crowbar Programmed Output Volts x 1.2 Output Ripple & Noise < 50 mV Low Output Voltage Alarm Programmed Output Voltage minus 2.5 VDC Transient Response < 1V for 50% Surge Regulation Line/Load < +/- 0.5% Duty Cycle Continuous 100% for 24 hrs per day Efficiency > 90% @ Maximum Output Length 9.1 in / 23.1 cm Width 7.8 in / 19.8 cm Height 4.3 in / 10.8 cm Material Marine Grade Aluminium Finish Black Anodize / Powder Epoxy Coat Fastenings All 18-8 Stainless Steel Weight 6.0 lb / 2.7 kg Connections Four contact output terminals Warranty 3 years Mechanical Diagram Electrical (Input) Environmental Specifications Electrical (Output) Mechanical Specifications 12 / 24 V @ 20 Amps Battery Equalizer and DC Autotransformer Application This rugged and versatile unit is used to power a small load at 12 V from a 24 V battery, or to power a small 24 V load from a 12 V battery. It functions both ways, producing 12 V @ 20 Amps from a 24 V input or can be connected backwards to produce 24 V @ 10 Amps from a 12 V input. When connected as a battery equalizer, it allows large transient 12 V loads to be taken off the centre tap of a 24 V battery (made of 2 X 12 V batteries) without fear of upsetting the voltage balance of the battery and destroying the 24 V battery system that would otherwise occur. Model: EQ 12/24-20 Features • >95 % efficiency, typically 96 % over 20 % load • Simple to use • Bi-directional power flow • Weatherproof, NEMA 4 enclosure Electrical Specifications Input low side Input high side Input Voltage (nominal battery) V 12V 24V Output Voltage 24V 12V Output Current 10A Current Limited 20A Current Limited Ripple at load 30mV rms 30mV rms Efficiency >96% >96% Voltage Regulation Mode Proportional: This standard unit regulates the output voltage proportional to 1/2 the input when connected 24 V input and regulates the output to 2 X input when connected 12 V input. This characteristic, when connected across 2 X 12 V batteries in a 24 V configuration, will keep the batteries at equal voltages. Fixed: Special units are available for example EQ 12/24-20 RXX where XX is the voltage on the 12 V side that the voltage is to be regulated to. For example, EQ 12/24-20 R13.6 will output 13.6 V @ 20 amps to either power a 12 V load or charge a 12 V battery to 13.6 V. Note: For units that require a fixed voltage at the higher voltage output, for example, to charge a 24 V battery from a 12 V battery, use one of the Constant Voltage Regulators Mechanical Specifications Enclosure: • Weatherproof, NEMA 4 enclosure Dimensions: • 4.5" X 2.5" X 2" nominal, resembling a junction box with feet Temperature Range: • -40 deg C to 60 deg C • It is recommended, as with all electronics, that the unit not be placed in direct sunshine Terminations: • 6" Flying Leads • Red= High Input + • Black= Common Neg. - for input and output voltage • White= Low Input + Wire Size: • Red, Black, White: Power leads #12 AWG Humidity: • N/A weatherproof Mechanical Drawing: Click here for picture Note: In the interest of continuous product improvement, specifications subject to change without notice. Order Model No: EQ 12/24-20 EQ 12/24-20 RXX where XX is the specified regulated voltage on the 12 V side March 2002 dwg# i-8005 Page 1 MANUAL Model: EQ 12/24 -20 Solar Converters Inc. - Rev. E IMPORTANT NOTE: Unit is bi-directional in its operation. Please take a moment to ensure the input and output voltage required and the direction of the power flow. Misconnection or backwards connection of the unit may provide either half the voltage or twice the voltage to the load, with potential damage to the load and/or unit. Warning: This unit may operate from multiple hazardous energy sources. Ensure that all power sources are inactive before making any connections to this unit. Ensure proper procedures and the appropriate electrical codes are followed. To be serviced only by qualified personnel. Warning: Ensure the battery is disconnected and/or safe operating procedures are followed when making battery connections. Extreme care must be taken to ensure the battery is not shorted. Make sure all strands are inside their respective terminals. Qualified personnel only to connect and service this unit. START HERE Section 1: Please determine if a step down, step up or battery equalization function is required. - If the load voltage is 1/2 the input voltage = step down. Go to Section 2 - If the load voltage is twice the input voltage = step up. Go to Section 3 - If used to equalize battery voltage to account for battery voltage mismatch, used as both step up and step down. Go to Section 4. Section 2: Step Down Transformer Input Voltage: 10.5 - 32 DC volts Current: 0 - 10 amps nominal Output Voltage: 5.5 - 16 DC volts = 1/2 input voltage Current: 0 - 20 amps continuous 2.1 Common Connection Using wire of sufficient amperage for the load connection (#12 AWG or better) connect the negative of the battery to the BLACK #12 AWG flying lead and the negative connection of the load. 2.2 Load Power Connection Using a wire of sufficient amperage for the load power (#12 AWG or better) connect the positive of the load to the WHITE #12 AWG flying lead. 2.3 Input Power Connection Using wire of sufficient amperage for the input connection (#12 AWG or better) connect the positive of the battery to the RED #12 AWG flying lead. Section 3: Ste p Up Transformer Input Voltage: 10.5 - 16 DC volts Current: 0 - 20 amps nominal dwg# i-8005 Page 2 Output Voltage: 21 - 32 DC volts = twice input voltage Current: 0 - 10 amps continuous 3.1 Common Connection Using wire of sufficient amperage for the load connection (#12 AWG or better) connect the negative of the battery to the BLACK #12 AWG flying lead and the negative connection of the load. 3.2 Load Power Connection Using a wire of sufficient amperage for the load power (#12 AWG or better) connect the positive of the load to the RED #12 AWG flying lead. 3.3 Input Power Connection Using wire of sufficient amperage for the input connection (#12 AWG or better) connect the positive of the battery to the WHITE #12 AWG flying lead. Section 4: Step Up and Step Down Transformer or Battery Voltage Equalization Input/Output Voltage High: 12 - 32 DC volts Current: 0 - 10 amps nominal This is the voltage off the top of your battery string nominally 24 V Input/Output Voltage Low: 6 - 16 DC volts Current: 0 - 20 amps continuous This is the midpoint voltage off your battery string nominally 12 V Unit uses its bi-directional capability to take power from the higher voltage battery and transfer the excess charge to the lower voltage battery. The net effect is to bring the battery voltages to be exactly equal. As well, as load current is taken off the battery, the stronger battery will support the weaker battery, making your battery power last longer. 4.1 Common Connection Using wire of sufficient amperage for the load connection (#12 AWG or better) connect the negative of the battery string to the BLACK #12 AWG flying lead. Nominally this is the negative connection of the 24 V battery. 4.2 Low Voltage Connection Using a wire of sufficient amperage for the load power (#12 AWG or better) connect the midpoint of the battery set to the WHITE #12 AWG flying lead. Nominally this is the 12 V point in your 24 V battery string. 4.3 High Voltage Connection Using wire of sufficient amperage for the input connection (#12 AWG or better) connect the positive of the battery to the RED #12 AWG. Nominally this is the 24 V positive connection of the 24 V battery. Note: It may take a while for the unit to equalize the voltages of the batteries as a considerable amount of charge movement between batteries may be required depending upon the state of charge and quality of the respective batteries. ***** dwg# i-8005 Page 3 WARRANTY The product is warranted to be free from defects in material and workmanship for a period of one (1) year from the date of purchase by a retail customer. The purchase date must be evidenced by a valid and original sales receipt. In lieu of sales receipt, factory will use code date on its label. Removal of the Solar Converters Inc. label or serial number will void the warranty. Product liability, except where mandated by law, is limited to repair or replacement at the manufacturer's discretion. No specific claim of merchantability or use shall be assumed or implied beyond what is printed on the manufacturers printed literature. No liability shall exist from circumstances arising from the inability to use the product, or its inappropriateness for any specific purpose or actual use, or consequences thereof for any purpose. It is the user's responsibility to determine the suitability of the product for any particular use . Solar Converters Inc. shall not be liable for any damages or any kind including without limitatio n, special, incidental or consequential obligations and liabilities of Solar Converters Inc. and the remedies of Buyer set forth herein shall be Solar Converters Inc. sole and exclusive liability. Failure to provide a safe and correct installation, safe operation, or care for the product will void the warranty. Personal safety, and compatibility with any other equipment is the ultimate responsibility of the end user. Any returned product that shows significant evidence of abuse may not be covered by this warranty. Installation must be preformed by a person with qualification to insure safe and effective operation and the installation thereof certifies that the installer has the technical qualifications to do so. Solar Converters Inc. cannot guarantee the compatibility of its products with other components used in conjunction with Solar Converters Inc. products, including, but not limited to, solar modules, batteries, and system interconnects, and such loads as inverters, transmitters and other loads which produce “noise” or electromagnetic interference, in excess of the levels to which Solar Converters Inc. products are compatible. Solar Converters Inc. shall not assume responsibility for any damages to any system components used in conjunction with Solar Converters Inc. products nor for claims for personal injury or property damage resulting from the use of Solar Converters Inc. products or the improper operation thereof or consequential damages arising from the products or use of the products. The warranties set forth herein are Solar Converters Inc. sole and exclusive warranties for or relating to the goods. Seller neither makes nor assumes any warranty or merchantability, any warranty fitness for any particular purpose, or any other warranty of any kind, express, implied or statutory. Solar Converters Inc. neither assumes nor authorizes any person or entity to assume for it any other liability or obligation in connection with the sale or use of the goods, and there are no oral agreements or warranties collateral to or affecting the sale of the goods. WARRANTY CLAIM PROCEDURE In the event of product failure, follow this warranty claim procedure. 1. Make sure the problem you are having is actually due to the suspected product and not some other part of the system. You may call technical support for advanced troubleshooting assistance. 2. If you determine that a Solar Converters Inc. product is actually defective, describe on paper, in detail the exact nature of the failure. 3. The product must be accompanied by proof of the date of purchase satisfactory to Solar Converters Inc. 4. Return the product and description to the business office address, along with your address and a daytime phone number. Purchasers must prepay all delivery costs or shipping charges as well as any other charges encountered, in shipping any defective Solar Converters Inc. product under this warranty policy. No shipment will be accepted Freight Collect. 5. Any return shipment from Solar Converters Inc. will be via Canada Post. Foreign shipments will ship best way. Special shipping arrangements are available at the customer's expense. Section 16 (This Page Intentionally Left Blank) 395 HC-RELAYS MINIATURE RELAY FOR WIDER APPLICATIONS VDE 1c, 2c, 4c HCE Amber Relays mm inch 27.2 1.071 35.2 1.386 20.8 .819 27.2 1.071 35.2 1.386 20.8 .819 FEATURES • Extra long life — Min. 10 8 mechanical operations (DC type) • 4 contact arrangements 4 Form C (for 5 A 250 V AC), 3 Form C (for 7 A 250 V AC), 2 Form C (for 7 A 250 V AC), 1 Form C (for 10 A 250 V AC) • Applicable to low to high level loads (100 m A to 10A) • Amber sealed types available • Bifurcated contact types available as HC4D SPECIFICATIONS Contacts Coil Remarks * Specifications will vary with foreign standards certification ratings. * 1 Detection current: 10 mA * 2 Excluding contact bounce time * 3 Half-wave pulse of sine wave: 11ms; detection time: 10 m s * 4 Half-wave pulse of sine wave: 6ms * 5 Detection time: 10 m s * 6 Refer to 5. Conditions for operation, transport and storage mentioned in AMBIENT ENVIRONMENT (Page 61). Characteristics Arrangement 1 Form C 2 Form C 3 Form C 4 Form C Initial current resistance, max. (By voltage drop 6 V DC 1 A)30 m W Contact material Gold-flashed silver alloy Gold-clad silver nickel Rating (resistive) Nominal switching capacity 10 A 250 V AC 7 A 250 V AC 7 A 250 V AC 5 A 250 V AC Max. switching power 2,500 VA 1,750 VA 1,750 VA 1,250 VA Max. switching voltage 250 V AC Max. switching current 10 A 7 A 7 A 5 A Nominal operating power AC (50Hz): 1.3VA, AC (60Hz): 1.2 VA DC:0.9 to 1.1W Max. operating speed 20 cpm (at max. rating) Initial insulation resistance Min. 1,000 MW at 500 V DC Initial breakdown voltage* 1 Between open contacts 700 Vrms for 1 min. Between contact sets 700 Vrms for 1 min. Between contact and coil 2,000 Vrms for 1 min. Operate time* 2 (at nominal voltage) (at 20°C) Approx. 10 ms (DC, AC type) Release time (without diode)* 2 (at nominal voltage) (at 20°C) Approx. 5 ms (DC type) Approx. 10 ms (AC type) Temperature rise, max. (at 70 ° C) (at nominal voltage)80 ° C Shock resistance Functional* 3 Min. 196 m/s 2 {20 G} Destructive* 4 Min. 980 m/s 2 {100 G} Vibration resistance Functional* 5 10 to 55 Hz at double amplitude of 1 mm Destructive 10 to 55 Hz at double amplitude of 2 mm Conditions for operation, transport and storage* 6 (Not freezing and condens- ing at low temperature) Ambient temp. –50 ° C to +70 ° C –58 ° F to +158 ° F Humidity 5 to 85% R.H. Unit weight Approx. 30g 1.06 oz Expected life (min. operations) Electrical (at 20 cpm) Voltage 125 V AC 250 V AC 30 V DC Expected lifeLoadResistive (cos j = 1) Inductive (cos j ] 0.4) Resistive (cos j = 1) Inductive (cos j ] 0.4)Resistive Inductive HC1 (1 Form C)Current 10A 5A 10A 3A — — 2 ´ 10 5 7A 3A 7A 2.5A 3A 1A 5 ´ 10 5 5A 2A 5A 1.5A — — 1 ´ 10 6 HC2 (2 Form C)Current 7A 3.5A 7A 2A — — 2 ´ 10 5 5A 2.5A 5A 1.5A 3A 0.6A 5 ´ 10 5 3A 1.5A 3A 1A — — 1 ´ 10 6 HC3 (3 Form C)Current 7A—7A———1 ´ 10 5 — 3.5A — 2A — — 2 ´ 10 5 5A — 5A — 3A 0.4A 5 ´ 10 5 HC4 (4 Form C)Current 5A 2A 5A 1A — — 2 ´ 10 5 3A 1A 3A 0.8A 3A 0.4A 5 ´ 10 5 2A 0.5A 2A 0.4A — — 1 ´ 10 6 Mechanical life (at 180 cpm) DC type: 10 8 , AC type: 5 ´ 10 7 HC 396 TYPICAL APPLICATIONS Transportation, power station control equipment, refrigerators, building control equipment, office machines, coin operat- ed machines, amusement devices, medi- cal equipment, etc. ORDERING INFORMATION EX. HC 4 D H AC 240V Contact arrangement 1: 1 Form C 2: 2 Form C 3: 3 Form C 4: 4 Form C Nil: Standard type D: Bifurcated contact type (HC4D only. See Page 400.) K: Latching relay type (HC2K only. See Page 401.) H: Plug-in HP: PC board terminal HTM: Top mounting HL: Light emitting diode wired, plug-in HPL: Light emitting diode wired, PC board AC 6, 12, 24, 48, 120/240 V DC 6, 12, 24, 48, 110 V Type classifications Terminal arrangement Coil voltage Notes: 1. When ordering VDE recognized types, add suffix VDE. 2. HC3 (3 Form C) series are not approved by VDE. 3. AC 48 V type is not available for LED wiring. 4. Standard packing Carton: 20 pcs.; Case: 200 pcs. 5. UL/CSA approved type is standard. COIL DATA (Common for Standard, Amber sealed and Bifurcated contact types) DC Type at 20 ° C 68 ° F AC Types (50/60 Hz) at 60 Hz, 20 ° C 68 ° F Coil voltage, V DC Pick-up voltage, V DC (max.) Drop-out voltage, V DC (min.) Max. allowable voltage, V DC Coil resistance, W ( ± 10%) Nominal coil current, mA ( ± 10%) Operating power, W Nominal Minimum 6 4.8 0.6 6.6 40 150 0.9 0.58 12 9.6 1.2 13.2 160 75 0.9 0.58 24 19.2 2.4 26.4 650 37 0.9 0.58 48 38.4 4.8 52.8 2,600 18.5 0.9 0.58 110 88.0 11.0 121.0 10,000 10 1.0 0.64 Coil voltage, V AC Pick-up voltage, V AC (max.) Drop-out voltage, V AC (min.) Max. allowable voltage, V AC Nominal coil current, mA ( ± 20%) Operating power, VA Nominal Minimum 6 4.8 1.8 6.6 200 1.20 0.77 12 9.6 3.6 13.2 100 24 19.2 7.2 26.4 50 48 38.4 14.4 52.8 25 110/120 96 36 132 10.9/11.9 220/240 176.0 66.0 264.0 6.0/6.5 NOTES: 1. The range of coil current is ± 15% for AC (60 Hz), and ± 10% for DC, at 20 ° C. 2. The relay is applicable to the range of 80 % to 110% of the nominal coil voltage. However, it is recommended that the relay be used in the range of 85% to 110% to take temporary voltage variations into consideration. 3. The coil resistance of DC types is the measured value at a coil temperature of 20 ° C. Please compensate coil resistance by ± 0.4% for each degree centigrade coil temperature change. 4. All AC 240 V types are rated for double coil voltages, both AC 220 V and AC 240 V. 5. For use with 220 V or 240 V DC, con- nect a resistor as suggested in the chart below, in series with the 110 V DC relay. Voltage 1 Form C, 2 Form C, 3 Form C, 4 Form C 220 V DC 11 k W (5 W) 240 V DC 13 k W (5 W) HC 397 DIMENSIONS (Common for standard, Amber sealed and Bifurcated contact (4C only) types) Plug-in type HC1-H (1 Form C) HC2-H (2 Form C) HC3-H (3 Form C) HC4-H (4 Form C) General tolerance: ± 0.2 ± .008 20.8 .819 0.6 .024 6.4 .252 0.5 .020 4.41 .174 4.06 .160 6.35 .250 6.35 .250 4.45 .175 13.35 .526 2.54 .100 1 .039 27.2 1.071 35.2 1.386 1.7 .067 1.7 .067 20.8 .819 0.6 .024 6.4 .252 0.5 .0204.41 .174 4.06 .160 6.35 .250 6.35 .250 13.35 .526 2.54 .100 1 .039 27.2 1.071 35.2 1.386 1.7 .067 1.7 .067 20.8 .819 0.6 .024 6.4 .252 0.5 .0204.41 .174 4.06 .160 6.35 .250 6.35 .250 13.35 .526 2.54 .100 1 .039 27.2 1.071 35.2 1.386 1.7 .067 1.7 .067 20.8 .819 0.6 .024 6.4 .252 0.5 .0204.41 .174 4.06 .160 6.35 .250 6.35 .250 4.45 .175 13.35 .526 2.54 .100 1 .039 27.2 1.071 35.2 1.386 1.7 .067 1.7 .067 mm inch PC board type HC4-H (4 Form C) General tolerance: ± 0.2 ± .008 20.8 .819 0.6 .024 3.5 .138 0.5 .020 4.41 .174 4.06 .160 6.35 .250 6.35 .250 4.45 .175 13.35 .526 1.5 .059 1.5 .059 1 .039 27.2 1.071 35.2 1.386 1.7 .067 1.7 .067 Dimensions of HC1-HP, HC2-HP, HC3-HP are the same as those of plug-in type except shapes of terminals. PC board pattern (Copper-side view) 1c 2c 4.1 .161 16.8 .661 10.4 .409 8.9 .350 4.45 .175 13.35 .526 5-2 dia. 5-.079 dia. 4.1 .161 16.8 .661 10.4 .409 13.35 .526 8-2 dia. 8-.079 dia. 3c 4c Tolerance: ± 0.1 ± .004 4.1 .161 16.8 .661 10.4 .409 13.35 .526 11-2 dia. 11-.079 dia. 4.1 .161 16.8 .661 10.4 .409 8.9 .350 4.45 .175 13.35 .526 14-2 dia. 14-.079 dia. Note: Special PC terminal with 0.9 mm (.035 inch) width available with suffix "-31". Schematic (bottom view) HC1-H, HC1-HP (1 Form C) LED AC type LED DC type HC2-H, HC2-HP (2 Form C) LED AC type LED DC type HC3-H, HC3-HP (3 Form C) LED AC type LED DC type HC4-H, HC4-HP (4 Form C) LED AC type LED DC type 2 7 12 1413 7 12 14 2 13 (~)(~) 2 7 12 1413 (-)(+) 14 8 12 14 5 9 13 14 13 (~)(~) 14 8 12 5 9 1413 (-)(+) 14 8 12 5 9 1 14 4 7 2 5 8 3 6 9 13 1413 (~)(~) 1 4 7 2 5 8 3 6 9 1413 (-)(+) 1 4 7 2 5 8 3 6 9 1 14 5 9 2 6 10 3 7 11 4 8 12 13 1413 (~)(~) 1 5 9 2 6 10 3 7 11 4 8 12 14 13 (-)(+) 1 5 9 2 6 10 3 7 11 4 8 12 HC 398 REFERENCE DATA 1. Life curve Load: 250 V AC resistive load 2. Switching capacity range 3. H2S gas test 246810 100 200 300 400 500 5,000 10,000 1c 2c 3c 4c Load current, ALife, ´104 timesMechanical life (DC type) Mechanical life (AC type) (250 V AC cosj = 1) 10mA 100 10 250 1A1mA 7A 5A 10A HC1c HC4c HC2c, 3c AC currentAC voltage, V101 10mW 100mW 1W 10W 100W 20 50 100 Exposure time, Hrs. 200 500 1000 2000 5000 Standard HC relay HCE Amber relay Gas density: 2 to 5 ppm Temperature: 40°C Humidity: 90% RH Contact resistance4. Coil temperature rise Measured portion: Inside the coil Note: When the nominal voltage is applied to AC 120 or 240 V coil types respectively, the figures of coil tem- perature rise increase by approx. 10 degrees to the ones shown on each graph. HC1 AC coil Ambient temperature: 25°C 77°F HC2 AC coil Ambient temperature: 30°C 86°F 80 90 100 110 120 0 10 20 30 40 50 60 70 80 90 100 10A 7A 0A 2A 5A Coil applied voltage, %VTemperature rise, °C80 90 100 110 120 0 10 20 30 40 50 60 70 80 90 100 7A 5A 0A Coil applied voltage, %VTemperature rise, °CHC3 AC coil Ambient temperature: 18°C 64°F HC4 AC coil Ambient temperature: 15 to 21°C 59 to 70°F HC1 DC coil Ambient temperature: 29°C 84°F 80 90 100 110 120 0 10 20 30 40 50 60 70 80 90 100 5A 7A 0A Coil applied voltage, %VTemperature rise, °C80 90 100 110 120 0 20 40 60 80 100 120 140 160 180 5A 3A 1A Coil applied voltage, %VTemperature rise, °C80 90 100 110 120 0 10 20 30 40 50 60 70 80 90 100 10A 5A 0A Coil applied voltage, %VTemperature rise, °CHC2 DC coil Ambient temperature: 29°C 84°F HC3 DC coil Ambient temperature: 29°C 84°F HC4 DC coil Ambient temperature: 17 to 18°C 62 to 64°F 80 90 100 110 120 0 10 20 30 40 50 60 70 80 90 100 7A 5A 0A Coil applied voltage, %VTemperature rise, °C80 90 100 110 120 0 10 20 30 40 50 60 70 80 90 100 7A 5A 0A Coil applied voltage, %VTemperature rise, °C80 90 100 110 120 0 10 20 30 40 50 60 70 80 90 100 5A 3A 1A Coil applied voltage, %VTemperature rise, °C HC 399 Amber Relays HCE HC sealed relays are version of the HC relays and are recommended for use in switching medium loads under adverse ambient conditions. They show highly sta- ble contact resistance even after long use, due to their sealed construction and reli- able gold plated contacts. Amber relays also make the combined process of auto- matic wave soldering and cleaning pro- cess possible with their resultant savings in cost and labor. Contact arrangements of 1 Form C, 2C, and 4C are available for plug-in, PC board and top-mount. Construction The diagram at right shows a cross-sec- tion of the plastic sealed relay. All the plastic parts are annealed and out- gassed to ensure fully the stability of both chemical and physical characteristics. Sealed construction SPECIFICATIONS Contacts Contact arrangement 1 Form C 2 Form C 4 Form C Rating (resistive) Nominal switching capacity 5 A 250 V AC 3 A 250 V AC 2 A 250 V AC Max. switching power 1,250 VA 700 VA 500 VA Max. switching voltage 250 V AC Max. switching current 5 A 3 A 2 A Conditions for operation, transport and storage (Not freezing and condensing at low temperature) Ambient temp.–40oC to +60oC –40oF to +140oF Humidity 5 to 85% R.H. Ambient air pressure 760 mmHg +20% (1.013 mb +20%) Expected life (min. operations) Electrical (at 20 cpm) Voltage 125 V AC 250 V AC 30 V DC Expected lifeLoadResistive (cos J = 1) Resistive (cos J = 1)Resistive Inductive HC1E (1 Form C)Current 5 A 5 A 3 A 1 A 2s 105HC2E (2 Form C)Current 3 A 3 A 2 A 1.7 A HC4E (4 Form C)Current 2 A 2 A 2 A 0.6 A Mechanical life (at 180 cpm)DC type: 108 , AC type: 5s 107 Characteristics Operate time Approx. 10 ms (DC, AC type) Release time Approx. 5 ms (DC type) Approx. 10 ms (AC type) ORDERING INFORMATION EX. HC 4 E D HP AC 240V Contact arrangement 1: 1 Form C 2: 2 Form C 4: 4 Form C Nil: Standard type D: Bifurcated contact type (HC4D only. See Page 400.) H: Plug-in HP: PC board terminal HTM: Top mounting L: Light emitting diode wired, plug-in PL:Light emitting diode wired, PC board AC 6, 12, 24, 48, 120, 240 V DC 6, 12, 24, 48, 110 V Type classifications Terminal arrangement Coil voltage UL/CSA approved type is standard. REFERENCE DATA (HC Amber Relays) 1. Switching capacity range 2.-(1) Coil temperature rise (1c AC type) Measured portion: Inside the coil Ambient temperature 30oC 86oF 2.-(2) Coil temperature rise (2c AC type) Measured portion: Inside the coil Ambient temperature: 30oC 86oF 10mA 250V 100V 10V 1A 3A2A 5A 10A HC1E HC4E HC2E AC currentAC voltage, V80 90 100 110 120 0 10 20 30 40 50 60 70 80 90 100 5A Voltage applied to coil, %VTemperature rise, oC80 90 100 110 120 0 10 20 30 40 50 60 70 80 90 100 3A Voltage applied to coil, %VTemperature rise, oC HC 400 2.-(3) Coil temperature rise (4c AC type) Measured portion: Inside the coil Ambient temperature: 30°C 86°F 2.-(4) Coil temperature rise (1c DC type) Measured portion: Inside the coil Ambient temperature: 30°C 86°F 2.-(5) Coil temperature rise (2c DC type) Measured portion: Inside the coil Ambient temperature: 30°C 86°F 80 90 100 110 120 0 10 20 30 40 50 60 70 80 90 100 2A Voltage applied to coil, %VTemperature rise, °C80 90 100 110 120 0 10 20 30 40 50 60 70 80 90 100 5A 0A Voltage applied to coil, %VTemperature rise, °C80 90 100 110 120 0 10 20 30 40 50 60 70 80 90 100 5A Voltage applied to coil, %VTemperature rise, °CBifurcated contact types HC4D Extremely high contact reliability has been made possible by adoption of gold- clad bifurcated contacts for both movable and stationary contacts. HC4D type can be used from the dry cir- cuit 100 mA at 10 V DC to the power circuit 3 A at 250 V AC resistive load. Therefore, with HC4D type such a usage is possible that one contact switches 100 mA and another contact switches 3 A load. Also Amber sealed types are available as HC4ED relays. SPECIFICATIONS Contacts Contact arrangement 4 Form C only Contact material Gold-clad silver nickel Rating (resistive) Nominal switching capacity 3 A 250 V AC Max. switching power 750 VA Max. switching current 3A Characteristics Operate time (Approx.)DC, AC: 10 ms Release time (Approx.) DC: 5 ms AC: 10 ms Expected life (min. operations) Electrical (at 20 cpm) Voltage 125 V AC 250 V AC 30 V DC Expected lifeLoadResistive (cos j = 1) Inductive (cos j ] 0.4) Resistive (cos j = 1) Inductive (cos j ] 0.4)Resistive HC4DE 3 A 1 A 3 A 0.8 A 3 A 2´105 HC4ED 1 A — 1 A — — REFERENCE DATA 1. Switching capacity range Standard type Amber type 100mA 100mV 100 250 1A 3A 10A AC currentAC voltage, V100mA 100mV 100 250 1A 3A 10A AC currentAC voltage, V Sockets SY Series: DIN Rail Snap-Mount www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC F-19 F SocketsSY4S Sockets M3 Screw 5.9max. ø3.2min.(TOP VIEW) 1 13 9 14 12 11 10 5678 4 3 2 26 18.5 25 4max.4.8min. 6 30 26 4.26230.74518 2-ø4.2 Mounting Hole (M4 screw hole) Terminal Arrangement 28.5 whenusing BAA DIN Rail (BAA) SY4S-05 Style 14-blade, snap-mount/surface mount Terminal/Torque M3 screw with captive wire clamp (5.5 - 9 in•lbs) Wire Size Maximum up to 2–#14AWG Electrical Rating 300V, 7A Compatible Relay RY4S, RY42S, RU4S, RU42S, RM2S, *RY2KS, (*latching relay) Compatible Timer GT5Y Hold-Down Spring SY4S-51F1 for all relays; SY4S-51F3 for RY2KS only Hold-Down Clip SFA-101 (top notch), SFA-202 (side notch) for all relays and timers 9 11 12 13 A1 10 21 5 12 1 14 42 4 8 44 A2 23 14 31 6 11 24 32 34 41 22 7 M3 Screw ø 5.5 18 25 2.030 6 6426 461.64.22918.2 (TOP VIEW) 1 13 9 14 12 11 10 5678 4 3 2 26 (cannot use ring terminal) 2-ø4.2 Mounting Hole (M4 screw hole) Terminal Arrangement 32.5 when using BAA DIN Rail (BAA)SY4S-05C Fingersafe Style 14-blade, snap-mount/surface mount Terminal/Torque M3 screw with captive wire clamp, fingersafe (5.5 - 9 in•lbs) Wire Size Maximum up to 2–#14AWG Electrical Rating 300V, 7A Compatible Relay RY4S, RY42S, RM2S, RU4S, RU42S, *RY2KS, (*latching relay) Compatible Timer GT5Y Hold-Down Spring SY4S-51F1 for all relays; SY4S-51F3 for RY2KS only Hold-Down Clip SFA-101 (top notch), SFA-202 (side notch) for GT5Y timer and relays All dimensions are in mm. 1. For socket mounting accessories, see page F-29. 2. For hold-down clip/spring selections, see page F-4. (This Page Intentionally Left Blank) RH Series Relays E-12 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC E RelaysKey features of the RH series include: •Compact midget size saves space •High switching capacity (10A) •Choice of blade or PCB style terminals •Relay options include indicator light, check button, and top mounting bracket •DIN rail, surface, panel, and PCB type sockets available for a wide range of mounting applications SpecificationsContact Material Silver cadmium oxide Contact Resistance 50mΩ maximum (initial value) Minimum Applicable Load 24V DC/30mA, 5V DC/100mA (reference value) Operating Time SPDT (RH1), DPDT (RH2): 20ms maximum3PDT (RH3), 4PDT (RH4): 25ms maximum Release Time SPDT (RH1), DPDT (RH2): 20ms maximum3PDT (RH3), 4PDT (RH4): 25ms maximum Maximum Continuous Applied Voltage (AC/DC) at 20°C 110% of the rated voltage Minimum Operating Voltage (AC/DC) at 20°C 80% of the rated voltage Drop-Out Voltage (AC)30% or more of the rated voltage Drop-Out Voltage (DC)10% or more of the rated voltage Power Consumption SPDT (RH1): DC: 0.8WAC: 1.1VA (50Hz), 1VA (60Hz)DPDT (RH2): DC: 0.9WAC: 1.4VA (50Hz), 1.2VA (60Hz)3PDT (RH3): DC: 1.5WAC: 2VA (50Hz), 1.7VA (60Hz)4PDT (RH4): DC: 1.5WAC: 2.5VA (50Hz), 2VA (60Hz) Insulation Resistance 100MΩ min (measured with a 500V DC megger) Dielectric Strength SPDT (RH1)Between live and dead parts: 2,000V AC, 1 minute; Between contact circuit and oper-ating coil: 2,000V AC, 1 minute; Between contacts of the same pole: 1,000V AC, 1 minute DPDT (RH2), 3PDT (RH3), 4PDT (RH4)Between live and dead parts: 2,000V AC, 1 minute; Between contact circuit and oper-ating coil: 2,000V AC, 1 minute; Between contact circuits: 2,000V AC, 1 minute; Between contacts of the same pole: 1,000V AC, 1 minute Frequency Response 1,800 operations/hour Temperature Rise Coil: 85°C maximumContact: 65°C maximum Vibration Resistance 0 to 6G (55Hz maximum) Shock Resistance SPDT/DPDT: 200N (approximately 20G)3PDT/4PDT: 100N (approximately 10G) Life Expectancy Electrical: over 500,000 operations at 120V AC, 10A; (over 200,000 operations at 120V AC, 10A for SPDT [RH1], 3PDT [RH3], 4PDT [RH4])Mechanical: 50,000,000 operations Operating Temperature –30 to +70°C Weight SPDT: 24g, DPDT: 37g (approximately)3PDT: 50g, 4PDT: 74g (approximately) RH Series — General Purpose Midget Relays Order standard voltages for fastest delivery. Allow extra delivery time fornon-standard voltages. UL Recognized Files No. RH1 = E66043 RH2 = E66043 RH3 = E66043 RH4 = E55996 CSA Certified File No.LR35144 File No. B020813332452 Ordering Information RH2B-U AC110-120V Basic Part No. Coil Voltage: Relays RH Series www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC E-13 E RelaysPart Numbers: RH Series with Options Coil Ratings Termination Contact Configuration Basic Part No.Indicator Light Check Button Indicator Light and Check Button Top Bracket B(blade) SPDT RH1B-U RH1B-UL RH1B-UC RH1B-ULC RH1B-UT DPDT RH2B-U RH2B-UL RH2B-UC RH2B-ULC RH2B-UT 3PDT RH3B-U RH3B-UL RH3B-UC RH3B-ULC RH3B-UT 4PDT RH4B-U RH4B-UL RH4B-UC RH4B-ULC RH4B-UT V2(PCB 0.078" [2mm] wide) SPDT RH1V2-U RH1V2-UL RH1V2-UC RH1V2-ULC — DPDT RH2V2-U RH2V2-UL RH2V2-UC RH2V2-ULC — 3PDT RH3V2-U RH3V2-UL RH3V2-UC RH3V2-ULC — 4PDT RH4V2-U RH4V2-UL RH4V2-UC RH4V2-ULC — Rated Voltage Rated Current ±15% at 20°C Coil Resistance ±15% at 20°C60Hz50Hz SPDT DPDT 3PDT 4PDT SPDT DPDT 3PDT 4PDT SPDT DPDT 3PDT 4PDT AC 6V 150mA 200mA 280mA 330mA 170mA 238mA 330mA 387mA 18.87 9.47 6.07 5.47 12V 75mA 100mA 140mA 165mA 86mA 118mA 165mA 196mA 76.87 39.37 25.37 21.27 24V 37mA 50mA 70mA 83mA 42mA 59.7mA 81mA 98mA 3007 1537 1037 84.57 120V* 7.5mA 11mA 14.2mA 16.5mA 8.6mA 12.9mA 16.4mA 19.5mA 7,6807 4,1707 27707 22207 240V† 3.2mA 5.5mA 7.1mA 8.3mA 3.7mA 6.5mA 8.2mA 9.8mA 3,12007 15,2107 12,1007 91207 SPDT DPDT 3PDT 4PDT SPDT DPDT 3PDT 4PDT DC 6V 128mA 150mA 240mA 250mA 477 407 257 247 12V 64mA 75mA 120mA 125mA 1887 1607 1007 967 24V 32mA 36.9mA 60mA 62mA 7507 6507 4007 3887 48V 18mA 18.5mA 30mA 31mA 2,6607 2,6007 1,6007 15507 110V‡8mA 9.1mA 12.8mA 15mA 13,8007 12,1007 8,6007 7,3407 Rated Voltage Coil Inrush Coil Inductance Energizing De-Energizing SPDT DPDT 3PDT 4PDT SPDT DPDT 3PDT 4PDT SPDT DPDT 3PDT 4PDT AC 6V 250mA 340mA 520mA 620mA 0.09H 0.08H 0.05H 0.05H 0.06H 0.04H 0.03H 0.02H 12V 120mA 170mA 260mA 310mA 0.037H 0.30H 0.22H 0.18H 0.22H 0.16H 0.12H 0.10H 24V 56mA 85mA 130mA 165mA 1.5H 1.2H 0.9H 0.73H 0.9H 0.63H 0.5H 0.36H 120V* 12mA 16mA 26mA 33mA 37H 33H 21H 18H 22H 15H 12H 9H 240V† 7mA 8mA 12mA 16mA 130H 130H 84H 73H 77H 62H 47H 36H SPDT DPDT 3PDT 4PDT SPDT DPDT 3PDT 4PDT DC 6V N/A N/A N/A N/A N/A N/A N/A N/A 12V 24V 48V 110V Part Numbers Ratings * For RH2 relays = 110/120V AC. † For RH2 relays = 220/240V AC. ‡ For RH2 relays = 100/110V DC. * For RH2 relays = 110/120V AC. † For RH2 relays = 220/240V AC. RH Series Relays E-14 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC E RelaysContact Ratings CSA Ratings Part Numbers: Sockets # of Poles Max Contact Power General Ratings Resistive Inductive Voltage Resistive Inductive* RH1 AC1540VADC300W AC990VADC210W AC110 10A 7A AC220 7A 4.5A DC30 10A 7A RH2RH3RH4 AC1650VADC300W AC1100VADC225W AC110 10A 7.5A AC220 7.5A 5A DC30 10A 7.5A Voltage Resistive General Use HP Rating RH1 RH2 RH3 RH4 RH1 RH2 RH3 RH4 RH1, 2, 3 AC240V 10A 10A — 7.5A 7A 7A 7A 5A 1/3HP AC120V 10A 10A 10A 10A 7.5A 7.5A — 7.5A 1/6HP DC30V 10A 10A 10A 10A 7A 7.5A — — — Relay Standard DIN Rail Mount Finger-Safe DIN Rail Mount Surface Mount Panel Mount PCB Mount Spring & Clips (optional) Part Number Use With RH1B SH1B-05 SH1B-05C —SH1B-51 SH1B-62 SY2S-02F1SFA-101 SFA-202 SH1B-05, 05C SY4S-51F1 SFA-301 SFA-302 SH1B-51, 62 RH2B SH2B-05 SH2B-05C SH2B-02 SH2B-51 SH2B-62 SY4S-02F1 SFA-101 SFA-202 SH2B-05, 05C SY4S-51F1 SFA-301 SFA-302 SH2B-51, 62 RH3B SH3B-05 SH3B-05C — SH3B-51 SH3B-62 SH3B-05F1 SFA-101 , -202 SH3B-05, 05C SY4S-51F1 SFA-301 SFA-302 SH3B-51, 62 RH4B SH4B-05 SH4B-05C SH4B-51 SH4B-62 SH4B-02F1 SFA-101 , -202 SH4B-05, 05C SY4S-51F1SFA-301 SFA-302 SH4B-51, 62 UL Ratings TUV Ratings Voltage Resistive General Use Horse Power Rating RH1, RH2 RH3 RH4 RH1, RH2 RH3 RH4 RH1, RH2 RH3 AC240V 10A 7.5A 7.5A 7A 6.5A 5A 1/3HP AC120V 10A 10A 10A 7A 7.5A 7.5A 1/6HP DC30V 10A 10A — 7A — — — — DC28V 10A 10A 10A 7A — — — — Voltage RH1 RH2 RH3 RH4 AC240V 10A 10A 7.5A 7.5A DC30V 10A 10A 10A 10A ¨ *cosø = 0.3 L/R - 7ms Applicable Sockets Ratings con’t See Section F for details on sockets. All DIN rail mount sockets shown above can be mounted using DIN rail BNDN1000. Top latch Side latch Pullover spring Relays RH Series www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC E-15 E RelaysRH1 RH2 RH3 RH4 Internal Circuits 85 1 9 1413 (-) (+)RH1 5 1 9 1413 (-)(+)RH2 4 12 65 1 9 1413 (-)(+)RH3 2 10 8 4 12 65 1 9 1413 (-)(+)RH4 2 10 7 3 11 8 4 12 Image as viewed from bottom of relay. Refer to socket for exact wiring layout (Section F). Electrical Life Curves 13579246810 50 20 10 100 500 1000 AC 110V Resistive AC 220V Inductive AC 220V ResistiveAC 110V Inductive Load Current (A)Life (x 10,000) Operations1 3579246810 50 20 10 100 500 1000 DC 30V Resistive DC 30V Inductive DC 100V Resistive AC 220V ResistiveDC 100V Inductive Load Current (A)Life (x 10,000) Operations13579246810 50 20 10 100 500 1000 AC 110V Resistive AC 220V Inductive AC 220V Resistive AC 110V Inductive Load Current (A)Life (x 10,000) Operations13579246810 50 20 10 100 500 1000 DC 30V Resistive DC 30V InductiveDC 100V Resistive DC 100V Inductive Load Current (A)Life (x 10,000) Operations13579246810 50 20 10 100 500 1000 AC 110V Resistive AC 220V Inductive AC 220V Resistive AC 110V Inductive Load Current (A)Life (x 10,000) Operations13579246810 50 20 10 100 500 1000 DC 30V Resistive DC 30V Inductive DC 100V Resistive DC 100V Inductive Load Current (A)Life (x 10,000) Operations RH Series Relays E-16 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC E RelaysRH1 RH2/RH3/RH4 Maximum Switching Capacity 15 0.5 1.0 5.0 10.0 10 100 200 30050 0.1 DC inductive DC resistive AC resistive AC inductive Load Voltage (V)Load Current (A)(RH2/RH3/RH4) 15 0.5 1.0 5.0 10.0 10 100 200 30050 0.1 Load Voltage (V)Load Current (A)DC inductive DC resistive AC inductive AC resistive (RH1) Dimensions Top Bracket Mounting Blade Terminal RH1B-UT RH2B-UT ø2.6 hole 13 1 5 9 14 3.5 14.5 35.6 max. 6.4 5.423843.227.56.65.94.70.54.7ø2.6 hole 14 58 912 13 14 3.5 21.5 2 35.6 max. 6.43843.227.54.75.97.250.54.710Plug-in Blade Terminal RH2BRH1B 13 1 5 9 144.70.56.4 5.4 14 27.5SH1B-05A: 61.5 (63.5) max., SH1B-51: 39.6 (41.6) max. 35.6 max. Total length from panel surface including relay socket Dimensions in the ( ) include a hold-down spring. ø2.6 hole 14 58 912 13 14 6.4 21 27.54.70.5SH2B-05A: 61.5 (63.5) max., SH2B-51: 39.6 (41.6) max. 35.6 max. Total length from panel surface including relay socket Dimensions in the ( ) include a hold-down spring. ø2.6 hole All dimensions in mm. Relays RH Series www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC E-17 E RelaysPlug-in Blade Terminal RH4BRH3B 13 14 1 2 4 865 9 10 114.70.527.56.4 31 SH3B-05A: 61.5 (63.5) max., SH3B-51: 39.6 (41.6) max. 35.6 max. Total length from panel surface including relay socket Dimensions in the ( ) include a hold-down spring. ø2.6 hole 1234 7865 9101112 13 14 6.4 414.70.527.5SH4B-05A: 61.5 (63.5) max., SH4B-51: 39.6 (41.6) max. 35.6 max. Total length from panel surface including relay socket Dimensions in the ( ) include a hold-down spring. ø2.6 hole Dimensions con’t RH2V2 RH4V2 PCB Terminal RH1V2 RH3V2 RH3B-UT RH4B-UT 13 1 5 9 14 35.6 max.4.60.527.514 3-ø2.4 holes 2-ø2 holes 4.47.156.612.54.70.5 1.528-ø2.4 holes 10 14.27.87.2513.15 4.7 1413 14 58 9 12 35.6 max.4.6 27.5520.50.520.5 21 13 14 124 865 91011 35.6 max. 4.6 310.50.5 227.511-ø2.4 holes 10 10 7.87.2513.154.71234 7865 9101112 13 1420.535.6 max. 4.6 0.5 41 27.514-ø2.4 holes 7.87.2513.154.710 30 ø2.6 hole 13 14 124 865 91012 21.5 31.5 35.6 max. 6.4 3.5 3843.22810104.72 4.75.97.250.5ø2.6 hole 1010104.72 35.6 max. 6.4 42 max. 13 12 14 1234 7865 91011 28 41.5 283.5 38444.75.97.250.5All dimensions in mm. Sockets SH Series: DIN Rail Snap-Mount www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC F-15 F SocketsSH2B Sockets SH2B-05 Style 8-blade, snap-mount/surface mount Terminal/Torque M3.5 screws with captive wire clamp (9 - 11.5 in•lbs) Wire Size Maximum up to 2–#12AWG Electrical Rating 300V, 10A Compatible Relay RH2B Hold-Down Spring SY4S-02F1 Hold-Down Clip SFA-101 (top notch), SFA-202 (side notch) 22 4.2672.58 26 254718 14.526 30 M3.5 Terminal Screw When using BAA/BAP: 28.5 DIN Rail (BAA/BAP) 8 4 5 1 12 14 9 13 Terminal Arrangement 2-ø4.2 Mounting Holes (or M4 Tapped Holes) 7.9 max. 4.4 max.5.5 min. ø3.6 min. (Top View) SH2B-05C Fingersafe Style 8-blade, snap-mount/surface mount Terminal/Torque M3.5 screws with captive wire clamp, finger- safe (9 - 11.5 in•lbs) Wire Size Maximum up to 2–#12AWG Electrical Rating 300V, 10A Compatible Relay RH2B Hold-Down Spring SY4S-02F1 Hold-Down Clip SFA-101 (top notch), SFA-202 (side notch) ø 5 1.7694.222 7 30 26 M3.5 Terminal Screw 8 4 5 1 12 14 9 13 Terminal Arrangement25 29.5 18.749 DIN Rail (BAA/BAP) When using BAA/BAP: 33 26 2-ø4.2 Mounting Holes (or M4 Tapped Holes) Ring type crimping terminals cannot be used. (Top View) 1. For socket mounting accessories, see page F-29. 2. For hold-down clip/spring selections, see page F-4.All dimensions are in mm. SH Series: DIN Rail Snap-Mount Sockets F-16 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC F SocketsSH3B Sockets (TOP VIEW) M3.5 Screw ø3.6min.7.9max. 5 1 12 14 10 13 8 4 6 2 9 36 25 32 4.2672.54718 14.5 8 4.4max.5.5min. 36 40 2-ø4.2 Mounting Hole (M4 screw hole) Terminal Arrangement 28.5 when using BAA DIN Rail (BAA) SH3B-05 Style 11-blade, snap-mount/surface mount Terminal/Torque M3.5 screws with captive wire clamp (9 - 11.5 in•lbs) Wire Size Maximum up to 2–#12AWG Electrical Rating 300V, 10A Compatible Relay RH3B, RH2LB Hold-Down Spring SH3B-05F1 Hold-Down Clip SFA-101 (top notch), SFA-202 (side notch) 14 5 1 12 12 41 910 14 13 1121 A2 A1 2242 44 24 4 2 8 6 M3.5 Screw 25 1.729.5 18.7 32 494.27 40 36 ø 5 (TOP VIEW) 5 1 12 14 10 13 8 4 6 2 9 36 (cannot use ring terminal) 2-ø4.2 Mounting Hole (M4 screw hole) Terminal Arrangement 33 when using BAA DIN Rail (BAA)SH3B-05C Fingersafe Style 11-blade, snap-mount/surface mount Terminal/Torque M3.5 screws with captive wire clamp, fingersafe (9 - 11.5 in•lbs) Wire Size Maximum up to 2–#12AWG Electrical Rating 300V, 10A Compatible Relay RH3B, RH2LB Hold-Down Spring SH3B-05F1 Hold-Down Clip SFA-101 (top notch), SFA-202 (side notch) 1. For socket mounting accessories, see page F-29. 2. For hold-down clip/spring selections, see page F-4.All dimensions are in mm. Sockets SH Series: DIN Rail Snap-Mount www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC F-17 F SocketsSH4B Sockets (TOP VIEW) M3.5 Screw ø3.6min. 7.9max. 5 1 9 13 10 14 8 4 7 3 6 2 12 11 46 25 42 4.2672.54718 14.5 8 4.4max.5.5min. 46 50 2-ø4.2 Mounting Hole (M4 screw hole) Terminal Arrangement 28.5 when using BAA DIN Rail (BAA) SH4B-05 Style 14-blade, snap-mount/surface mount Terminal/Torque M3.5 screws with captive wire clamp (9 - 11.5 in•lbs) Wire Size Maximum up to 2–#12AWG Electrical Rating 300V, 10A Compatible Relay RH4B Hold-Down Spring SH4B-02F1 Hold-Down Clip SFA-101 (top notch), SFA-202 (side notch) 4 3 2 1 8 67 5 32 31 22 41 A2 A1 12 142434 12 11 10 9 14 44 21 11 42 13 ø5 25 4.21.76946 42 7 18.7 29.5 50 49(TOP VIEW) 5 1 9 13 10 14 8 4 7 3 6 2 12 11 46 (cannot use ring terminal) 2-ø4.2 Mounting Hole (M4 screw hole) Terminal Arrangement 33 when using BAA DIN Rail (BAA) SH4B-05C Fingersafe Style 14-blade, snap-mount/surface mount Terminal/Torque M3.5 screws with captive wire clamp, fingersafe (9 - 11.5 in•lbs) Wire Size Maximum up to 2–#12AWG Electrical Rating 300V, 10A Compatible Relay RH4B Hold-Down Spring SH4B-02F1 Hold-Down Clip SFA-101 (top notch), SFA-202 (side notch) 1. For socket mounting accessories, see page F-29. 2. For hold-down clip/spring selections, see page F-4. All dimensions are in mm. (This Page Intentionally Left Blank) RR Series Relays E-18 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC E Relays Key features of the RR series include: •High reliability and long service life •Available in octal (8- and 11-pin) or square (11-blade) base •Options include check button for test operation, indicator light, and side flange (contact IDEC for diodes) •DIN rail, surface and panel type sockets available for a wide range of mounting applications Specifications Contact Material Silver Contact Resistance 30m Ω maximum (initial value) Minimum Applicable Load 24V DC/10mA, 5V DC/20mA (reference value) Operating Time 25ms maximum Release Time 25ms maximum Maximum Continuous Applied Voltage (AC/ DC) at 20°C 110% of the rated voltage Minimum Operating Voltage (AC/DC) at 20°C 80% of the rated voltage Drop-Out Voltage (AC) at 20°C 30% of the rated voltage Drop-Out Voltage (DC) at 20°C 15% of the rated voltage Power Consumption AC: approximately 3VA (50Hz), 2.5VA (60Hz)DC: approximately 1.5W Insulation Resistance 100M Ω minimum (measured with 500V DC megger) Dielectric Strength Pin (RR2P, RR3PA)Between live and dead parts: 1,500V AC, 1 minuteBetween contact circuit and operating coil: 1,500V AC, 1 minuteBetween contact circuits: 1,500V AC,1 minute (1,000V AC between NO-NC contacts) Blade (RR1BA, RR2BA, RR3B)Between live and dead parts: 2,000V AC, 1 minuteBetween contact circuit and operating coil: 2,000V AC, 1 minuteBetween contact circuits: 2,000V AC, 1 minuteBetween contacts of same polarity: 1,000V AC, 1 minute Frequency Response 1,800 operations/hour Temperature Rise Coil: 85°C maximumContact: 65°C maximum Vibration Resistance 0 to 6G (55Hz maximum) Shock Resistance 100N (approximately 10G) Life Expectancy Electrical: over 500,000 operations (120V, 50/60Hz, 10A)Mechanical: over 10,000,000 operations Operating Temperature –30 to +70°C Weight RR2P: 90g, RR3PA: 96g (approximately)RR1BA/RR2BA/RR3B: 82g (approximately) RR Series — General Purpose Power Relays Order standard voltages for fastest delivery. Allow extra delivery time fornon-standard voltages. UL Recognized File No. E66043 CSA Certified File No. LR35144 * Pin Style Only File No. B020813332452* * Pin Style Only (does not apply to blade style) * Ordering Information RR3PA-U AC120V Basic Part No. Coil Voltage: Relays RR Series www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC E-19 E RelaysPart Numbers: RR Series with Options Coil Ratings Contact Ratings Part Numbers: Sockets Termination Contact Configuration Basic Part No.Indicator Light Check Button Light and Check Button Side Flange P, PA (pin) DPDT RR2P-U RR2P-UL RR2P-UC RR2P-ULC — 3PDT RR3PA-U RR3PA-UL RR3PA-UC RR3PA-ULC — B, BA(blade) SPDT RR1BA-U RR1BA-UL RR1BA-UC RR1BA-ULC RR1BA-US DPDT RR2BA-U RR2BA-UL RR2BA-UC RR2BA-ULC RR2BA-US 3PDT RR3B-U RR3B-UL RR3B-UC RR3B-ULC RR3B-US Rated Voltage Rated Current ±15% at 20°C Coil Resistance ±10% at 20°C Inrush Current Inductance 60Hz 50Hz Energizing De-Energizing AC 6V 420mA 490mA 4.97 720mA 0.04H 0.02H 12V 210mA 245mA 187 365mA 0.15H 0.08H 24V 105mA 121mA 797 182mA 0.57H 0.32H 120V 20.5mA 24mA 2100 7 35mA 15H 8.2H 240V 10.5mA 12.1mA 83307 18mA 57H 32H DC 6V 240mA 257 N/A 12V 120mA 1007 24V 60mA 4007 48V 30mA 16007 110V 13mA 84607 Resistive Inductive Motor Load Voltage Nominal UL CSA Nominal UL CSA UL 30V DC 10A 10A 10A 7.5A 7A 7.5A — 110V DC 0.5A — — 0.3A — 0.5A — 120V AC 10A 10A 10A 7.5A 7.5A 7.5A 1/4 hp 240V AC 7.5A 10A 10A 5A 7A 7A 1/3 hp Relays Standard DIN Rail Mount Finger-Safe DIN Rail Mount Panel Mount Springs & Clips (optional) Part Numbers Use With Socket RR2P SR2P-05SR2P-06 SR2P-05C SR2P-51 SR2B-02F1 SR2P-05, -05C, -06 SR3P-01F1 SR2P-51, SR3P-51 RR3PA SR3P-05SR3P-06 SR3P-05C SR3P-51 SR3B-02F1 SR3P-05, -05C, -06SR3B-05, -51 SR3P-01F1 SR3P-51 RR1BARR2BARR3B SR3B-05 —SR3B-51 SR3B-02F1 SR3B-05SR3B-51 Part Numbers 1.RR1BA, RR2BA, and RR3PA are U.S. standard terminal arrangements. 2. For diode option on DC coils please consult factory. Ratings Inductive load: cos ø = 0.3, L/R = 7ms. Applicable Sockets See Section F for details on sockets. All DIN rail mount sockets listed can be mounted using DIN rail BNDN1000. RR Series Relays E-20 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC E RelaysInternal Circuits 5 2 7 BA (-)(+) 1 2 6 5 7 8 4 3 (+)(-) 1 2 657 84 3 (+)(-) 9 10 11 RR2P RR3PA RR1BA 4 1 7 BA (-)(+) RR2BA 6 3 9 4 1 7 BA (-)(+) RR3B 6 3 9 5 2 8 Image as viewed from bottom of relay. Refer to socket for exact wiring layout (Section F). Electrical Life Curves 012345678910 10 50 100 500 1000 AC 110V Resistive AC 220V Inductive AC 220V Resistive AC 110V Inductive Load Current (A)Life (x 10,000) Operations012345678910 10 50 100 500 1000 DC 30V Resistive DC 100V Inductive DC 100V Resistive DC 30V Inductive Load Current (A)Life (x 10,000) OperationsMaximum Switching Capacity 10.0 5.0 1.0 0.5 151050 100 200 300Load Current (A)Load Voltage (V) DC resistive DC inductive AC resistive AC inductive Relays RR Series www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC E-21 E RelaysDimensions 8-Pin RR2P 11-Pin RR3PA Note: Dimensions in [ ] include hold-down spring. Blade RR1BA, RR2BA, RR3B Side Flange RR1BA-US, RR2BA-US, RR3B-US 5 123 64 789 AB 47.5 max.0.57.3 Dimensions in the ( ) include a hold-down spring. 36 36SR3B-05: 73 (76) max., SR3B-51: 56 (60) max. Total length from panel surface including relay socket4.73.0 × ø2.0 oblong hole 4.216.073.5 47.5 max.16.1 4.711.111.163.5 7.3 63.5 36 363.0 × ø2.0 oblong hole 2-ø4.5 Mounting Holes 5 123 64 789 AB0.5Dimensions in the ( ) include a hold-down spring. 55.5 max. 9.9 13 35.6 35.6SR3P-05: 84.5 (87.5) max., SR3P-51: 63 (68) max. To tal length from panel surface including relay socket 11 10 9 8 7 6 5 4 3 2 1 55.5 max. SR2P-05: 84.5 (87.5) max., SR2P-51: 63 (68) max. Total length from panel surface including relay socket Dimensions in the ( ) include a hold-down spring. 9.9 13 28.6 35.61 2 3 45 6 7 8 All dimensions in mm. Sockets SR Series: DIN Rail Snap-Mount www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC F-13 F SocketsSR3B Sockets SR3B-05 Style 11-blade, snap-mount/surface mount Terminal/Torque M3.5 screws with captive wire clamp (9 - 11.5 in•lbs) Wire Size Maximum up to 2–#12AWG Electrical Rating 300V, 15A (10A)* (*denotes CSA rating) Compatible Relay RR1BA, RR2BA, RR3B Compatible Timer RTE-B Hold-Down Spring SR3B-02F1 (relays) Hold-Down Clip SFA-202 (relays and timers)7637 432 25 14.556When using BAA/BAP: 28.5 DIN Rail (BAA/BAP) 37 ø3.6 min. 7.9 max. 4.4 max.5.5 min. 4 1 9 B 8 A 6 3 5 2 7 Terminal Arrangement 2-ø4.2 Mounting Holes (or M4 Tapped Holes) 36 8 M3.5 Terminal Screw 4.2(Top View) All dimensions are in mm. 1. For socket mounting accessories, see page F-29. 2. For hold-down clip/spring selections, see page F-4. (This Page Intentionally Left Blank) 1 1/22 Multi-function or mono-function Multi-range (7 ranges,available options) Multi-voltage Relay output 1 or 2: 8 A - 250 V (10 A UL) Plug-in 1 LED status indicators Option of connecting an external power supply to the control input 3-wire sensor control option Chronos 2 electronic timers - Plug-in 8-pin (35 mm) Relay output 1 or 2 change over relays Types Part numbers and voltage 24V c / 24 • 240V a 12 V a / c 12 • 240 V a / c Functions Nominal current Accessories 8-pin connector base (for the whole range)25 622 128 Timing ranges (7 ranges) 1s - 10 s - 1 min - 10 min - 1 h - 10 h - 100 h Timing ± 0.5 % (CEI 1812-1) ± 0.05 % / °C ± 0.2 % / V ±10 % / 25 °C 30 ms 100 ms 100 ms >10 ms depending on version, see page 1/21 50/60 Hz 85 to 110 % Un (85 to 120 % Un for 12V AC/DC) 100 % 0.6 W 24V AC/DC 1.5 W 230V AC 32 VA 230V AC 2000 VA / 80 W 2000 V A / 80W 8 A AC 8 A DC 10 mA / 5 VDC 250V AC/VDC 105 operations 8 A 250V resistive 5 x 106 operations 2.5 kV / 1min / 1 mA /50Hz 5 kV, wave 1.2 / 50 µs 0.4 V -20 °C + 60 °C -30 °C + 60 °C Voltage surge category 4 kV / 3 IP 20 IP 40 IP 50 f = 10 • 55 Hz A = 0.35 mm 93 % Level III (Air 8 K / Contact 6 KV) Level III 10V/m: 80 MHz to 1 GHz) Level III (direct 2kV/ Capacitive coupling clamp 1 KV) Level III (common mode 2 KV / residual current mode 1KV) Level III (10V rms: 0.15 MHz to 80 MHz) 30 % / 10 ms 60 % / 100 ms > 95 % / 5 s Class B 8-pin Self-extinguishing 80 g General specifications Conforming to standards IEC 1812-1, EN 50081-1/2, EN 50082-1/2, LV directives (73/23/EEC + 93/68/EEC (CE marking) + EMC (89/336/EEC + IEC 669- 2-3 (17.5 mm) Approvals UL - CSA - cUL pending Temperatures limits - use - stored Installation category (acc. to IEC 664-1) Creepage distance and clearance acc. to IEC 664-1 Degree of protection acc. to IEC 529 - terminal block - casing - front face (except Tk2R1) Vibration resistance acc. to IEC 68-2-6 Relative humidity acc. to IEC 68-2-3 without condensation Electromagnetic compatibility - Immunity to electrostatic discharges acc. to IEC 1000-42 - Immunity to electrostatic fields acc. to ENV 50140/204 (IEC 1000-4-3) - Immunity to rapid transient bursts acc. to IEC 1000-4-4 - Immunity to shock waves on power supply acc. to IEC 1000-4-5 - Immunity to radiofrequency in common mode acc. to ENV - Immunity to voltage dips and breaks acc. to IEC 1000-4-11 - Mains-borne and radiated emissions acc. to EN 55022 (EN 55011 Group 1) Fixing: plug-in bases Casing material Weight: plug-in casing Other information Timing Repetition accuracy (with constant parameters) Drift - Temperature - Voltage Display precision according to IEC 1812-1 Minimum pulse duration - Typically - Typically under load Maximum reset time by de-energisation - Typically Immunity to breaks in supply voltage: typically Power supply Multi-voltage power supply Frequency Operating range Load factor Maximum power consumption Output elements relay output 1 or 2 changeover relays, AgNi (cadmium-free) Rated power Maximum breaking current Minimum breaking current Voltage breaking capacity Electrical life Mechanical life Breakdown voltage acc. to IEC 1812-1 Impulse voltage acc. to IEC 664-1 IEC 1812-1 Display State displayed by 1 LED - Flashing green when on Green LED operation indicator Pulsing: - timer on, no timing in progress (except functions Di-D and Li-L) Flashing: - timing in progress Permanently lit: - Relay waiting, no timing in progress Input type - Volt-free contact - 3-wire PNP output control option maximum residual voltage: 0.4 V whatever the timer power supply Technical specifications Non stocked, minimum order quantity 100 units. 1 1/23 88 867 155 - - Bifunction Li - L 8 A 1 timer 88 867 135 - - Mono-function C 8 A 1 timer 88 867 215 - - Mono-function A 8 A 2 timers 88 867 105 - - Multi-function A - At - B - C - H - Ht - Di - D - Ac - Bw 8 A 1 timer 0.1s • 100h OUR1 0.1s • 100h OA2R1 0.1s • 100h OCR1 0.1s • 100h OLR1 - 88 867 100 - Multi-function A - At - B - C - H - Ht - Di - D - Ac - Bw 8 A 1 timer 0.1s • 100h OUR4 - - 88 867 103 Multi-function A - At - B - C - H - Ht - Di - D - Ac - Bw 8 A 1 timer 0.1s • 100h OUR3 2 3 1 Functions : A - At / H - Ht / B / C Li A Di - D / Ac / BW L : Connections:8-pin 1 relay 8-pin 2 relay U 4 R Y1+ – 5 6 7 81 2 3 U 4 R1 R2 + – 5 6 7 81 2 3 U 4 R + – 5 6 7 81 2 3 Function diagrams Function A Delay on energisation 1 relay Function C Timing after impulse 1 timer Function H Timing on energisation 1 relay 2 timers U R1/R2 T U R T U C R t1 t2 T = t1+t2 U C R ∞T U C R ∞T T R U Function Ht Delay on energisation with memory 1 relay t1R C U t2 T = t1+t2 Function D Flip-flop 1 relay Pause start U T T R Function Di Flip-flop 1 relay Pulse start U R T T Function Ac Timing after closing and opening of control contact 1 relay U C R T T Function Bw Pulse output (adjustable) 1 relay U C R T T Dimensions 453,5 12,5 74,5 35 Function L Asymmetrical recycler 1 relay Pause start T1 R T2 U Function Li Asymmetrical recycler 1 relay Pulse start T1 R U T2 Type Part number Part number Example: Chronos 2 Timers OUR1 88 867 105 8-pin connector base 25 622 128 321Standard products To order, specify: H 2 6 Accessorie 8-pin connector base 25 622 128 Function At Timing on energisation with memory 1 relay Function B Timing on impulse one shot 1 relay 1 1/10 Function C:Timing after impulse Delay OFF (with constant supply After energisation, once the control contact is closed the output state changes. Timing will only begin on the re-opening of this control contact (one shot). Relay R returns to its initial position at the end of the timing period. Function D or Di:Flip-flop Repetitive cycle which switches the output alternately between the rest and operating position for equal time bases. T1 + T2 = T total Function D: the cycle begins with the output in rest position. Pause start. Function Di: the cycle begins with the output in the operating position. Pulse start. Function H:Timing on energisation Interval timer - one shot On energisation, the output changes state, remains in that state for the duration of timing and resets at the end of the single cycle. N.B.This is complementary to function A. Function B:Timing on impulse one shot On pulse (with constant supply) After energisation; a pulse (≥50 ms) or a maintained control contact will cause the output to change state which reverts to the rest position at the end of timing. N.B. :this process enables shortening or lengthening of a signal. Function Bw:Pulse output (adjustable) AOutput relay R (or the load) changes state, and remains in the changed-over state for the timing period, both when control contact C (Y1) closes and when it opens. U : Supply C (Y1) : Control contact R : Output or load relay T :Timing : indefinite Function A:Delay on energisation Single timing cycle which begins on energisation. The output changes state after timing. Function Ab:One-shot cycle The output changes states at the end of the set time T1, for a period T2. Both T1 and T2 independently adjustable. Function Ac:Timing after closing and opening of control contact After energisation, closure of the control contact causes the timing period T to commence and output relay R (or the load) changes state at the end of this interval. When contact C (Y1) opens, relay R resets after a second timing period T. . Function Ad :Delay on energisation by switch (not resettable) After power-up, pressing or holding down the switch starts timing. At the end of timing, the output is energised.The output will be reset the next time the switch is pressed or held down. Function Ah :Flashing single cycle by switch (not resettable) After power-up, pressing or holding down the switch starts timing. At the end of timing, the output is energised. At the end of this second timing, the output falls back to its initial value. Function At:Timing on energisation with memory Provides a cumulative time for contact opening. The output changes states at the end of the set time. U R1/R2 R2 INST T U R T U R T1 T2 U C R TT U C R t1 t2 T = t1+t2 U C R1/R2 t1 t2 T = t1+t2 R2 Inst. U C R T U C R1/R2 T R2 Inst. U C R TT U C R TT U C R T U C R1/R2 T R2 inst. Functions U C R1/R2 TT R2 Inst. U C R TT 1 relay 2 relays timed or 1 relay timed and 1 instantaneous 1 relay 2 relays timed or 1 relay timed and 1 instantaneous 1 relay 1 relay U C R1/R2 R2 Inst. T T T T 2 relays timed or 1 relay timed and 1 instantaneous 1 relay 2 relays timed or 1 relay timed and 1 instantaneous 1 relay 2 relays timed or 1 relay timed and 1 instantaneous 1 relay 2 relays timed or 1 relay timed and 1 instantaneous U TT R U TT R1/R2 R2 Inst. U R TT U R1/R2 TT 2 Inst. 1 relay 1 relay 2 relays timed or 1 relay timed and 1 instantaneous 2 relays timed or 1 relay timed and 1 instantaneous T R U T R1/R2 U R2 Inst. 1 relay 2 relays timed or 1 relay timed and 1 instantaneous 1 1/11 Function P :Delayed fixed-length pulse Timing begins on energisation. At the end of the timing period output relay R (or the load) changes state for a period of approx. 500 milliseconds. Function Pt :Impulse counter (delay on) Calculates the total opening time of a contact. At the end of timing, the output is energised for approximately 500 ms. Function Q :Star-delta" At the end of timing, the output is not energised. It remains "open" (not conducting) and will only change state after the fixed time of Ti has elapsed. Dwell time selectable Function T :Timing on energisation with memory a - energisation by control signal The timer sums the times for which the control contact is closed (C1). Reset is by the reset signal (C2) only. b - energisation by supply voltage The timer sums the times for which the supply voltage (U) is on. Reset is by the reset signal (C2) only Function T :Impulse relay After power-up, pressing or holding down the switch closes the relay. Pressing the switch a second time opens the relay. Function Tt :Timed impulse relay After power-up, pressing or holding down the switch closes the relay and starts timing.The relay opens at the end of timing or when the switch is pressed a second time. Function W :Timing after pulse on control contact After energisation, if the control contact opens it causes output relay R (or the load) to change state and timing to start. At the end of the timing period, relay R resets to its original state. Function L :Cyclic timing - Asymmetrical recycler Repetitive cycle comprising 2 independent adjustable time bases. Each time base corresponds alternately to a different output state. N.B. :The cycle starts with the output in the rest position. Function Li :Cyclic timing - Asymmetrical recycler Repetitive cycle comprising 2 independent adjustable time bases. Each time base corresponds alternately to a different output state. N.B.:The cycle starts with the output in the operating position. Function N :"Safe-guard" At the first control pulse the output is energised. To complete the timing the interval between the two control pulses must be greater than the timing set. Function O :"Delayed safe-guard". On energisation, a first timing sequence occurs and the output changes state. With the closing of the control contact, the output resets and the timing starts, with the output being activated after timing. For the timing to be completed, the interval between the closing of two control contacts must be greater than the timing set. T1 R T2 U T1 R U T2 T R C U TT U R TP P = 500 ms T R U Ti U C R t1 t2 P T= t1+t2 T R C U U C R Tt888U C R T R C U T1 R1/R2 T2 U T1 R1/R2 U T2 1 relay 2 relays timed or 1 relay timed and 1 instantaneous 1 relay 2 relays timed or 1 relay timed and 1 instantaneous Function Ht :Delay on energisation with memory Provides a cumulative time for contact opening. On energisation, the output changes state, remains in that state for the duration of timing and resets at the end of the single cycle. Function K:Delay on de-energisation - True delay OFF On energisation, the output changes state. On de-energisation timing commences and the output only returns to the reset condition after timing. T R U t1 R C U t2 T = t1+t2 t1 R1/R2 C U t2 T = t1+t2 R2 Inst. 1 relay 2 relays timed or 1 relay timed and 1 instantaneous 1 relay 2 relays timed or 1 relay timed and 1 instantaneous T R2 U R1 Sockets SR Series: DIN Rail Snap-Mount www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC F-11 F SocketsSR Series: DIN Rail Snap-Mount Sockets SR2P Sockets 2-ø4.2 Mounting Hole (M4 screw hole) 7.9max. ø3.6min. M3.5 ø4.2 Terminal Arrangement (TOP VIEW) 6 5 4 3 7 8 2 1 16.5 20 28.533 523ø2529 4.4max.5min. 8 52336 29 Mounting Hole Screw 32 when using BAA DIN Rail (BAA)SR2P-05 Style 8-pin octal, snap-mount/surface mount Terminal/Torque M3.5 screws with captive wire clamp(9 - 11.5 in•lbs) Wire Size Maximum up to 2–#12AWG Electrical Rating 300V, 10A Compatible Relay RR2P Compatible Timer RTE-P1, GT3 (8-pin), GT5P, GE1A Hold-Down Spring SR2B-02F1 (for RR2P) Hold-Down Clip SFA-203 (for timers only, except GE1A) 8 7 6 5 4 3 2 1 521.5 4. 2 2.25830 29 7 36 (TOP VIEW) 6 5 4 3 7 8 2 1 29 Terminal ArrangementDIN Rail (BAA) 2-ø4.2 Mounting Hole (M4 screw hole) 33.5 when using BAA (cannot use ring terminal) SR2P-05C Fingersafe Style 8-pin octal, snap-mount/surface mount Terminal/Torque M3.5 screws with captive wire clamp, fingersafe (9 - 11.5 in•lbs) Wire Size Maximum up to 2–#12AWG Electrical Rating 300V, 10A Compatible Relay RR2P Compatible Timer RTE-P1, GT3 (8-pin), GT5P, GE1A Hold-Down Spring SR2B-02F1 (for RR2P) Hold-Down Clip SFA-203 (for timers only, except GE1A) ø3.6min. 7.9max. ø4.2 (TOP VIEW) 6 5 4 3 2187 8 40 16033 18 22 33 4.9max.5min.ø25M3.5 Screw Mounting Hole 25.5 when using BAA DIN Rail (BAA) 2-ø4.2 Mounting Hole (M4 screw hole) Terminal Arrangement SR2P-06 Style 8-pin octal, snap-mount/surface mount Terminal/Torque M3.5 screws with captive wire clamp(9 - 11.5 in•lbs) Wire Size Maximum up to 2–#12AWG Electrical Rating 300V, 10A Compatible Relay RR2P Compatible Timer RTE-P1, GT3 (8-pin), GT5P, GE1A Hold-Down Spring SR2B-02F1 (for RR2P) Hold-Down Clip SFA-202 (for timers only, except GE1A) 1. For socket mounting accessories, see page F-29. 2. For hold-down clip/spring selections, see page F-4. All dimensions are in mm. 7 7C o n t r o l r e l a y s Low Voltage Products & Systems 7.1 ABB Inc. • 888-385-1221 • www.abb-control.com AC 1000 - 11/03 Control relays Type N, NE, NL & TNL Positive safety AC/DC operated Positive safety relays There are many applications where safety is very critical and it is important to use electrical equipment which ensures that dangerous machine movement cannot occur when a fault is detected with the moving contacts during the cycle which the fault is indicated. Regulations and standards have been written to ensure that safety is maintained: • United States ANSI B11.19-1990 ANSI B11.20-1991 • Germany SÜVA ZH1/457 • France INRS • United Kingdom BIA • Switzerland SA The ABB Type N & NL 4 and 8 pole relays are designed with “Positive Guided” contacts and fulfi ll the regulations or standards shown. The relays can provide positive safety for the N.O. and N.C. contacts which assure that the N.O. contacts will not close before any N.C. contact opens. Therefore, if one of the contacts weld due to abnormal conditions in the control circuit, the other contacts will also remain in the same position as when the welding occurred. This means that the open contacts must maintain an air distance 0.5mm when the coil is energized at 110% Vc or when it is de-energized. UL File No: E39231 (N & NL) 7 7Contr ol r el a y s 7.2 Low Voltage Products & Systems AC 1000 - 11/03 ABB Inc. • 888-385-1221 • www.abb-control.com N40E 14NO 24NO 34NO 44NO 13NO 23NO 33NO 43NO 5-6-7-8- 5-6-7-8- A1 A 2 22 0-230 V 50 H z 230-240 V 60 Hz R 80 General information Type N, AC operated Description • AC operated with laminated magnetic circuit. • 2 versions: 4 pole or 8 pole. The width of 8 pole devices is identical to that of 4 pole devices; only the depth is increased. • Side by side mounting possible. • Self cleaning auxiliary contacts. • Alone or by itself or with a 4 pole CA5 auxiliary contact block, these devices offer “positive safety” between their auxiliary contacts. Application Type N control relays are used for switching auxiliary circuits and control circuits. N 40E–84 Catalog number explanation Frame type Coil voltage (see coil voltage chart below) Contact confi guration Hz Relay Volts type 12 24 48 110 120 125 208 220 240 277 380 415 440 480 500 600 60 N 81 83 84 84 34 36 80 42 86 86 51 53 55 50 N 81 83 84 80 85 86 55 DC NE, NL 80 81 83 86 87 88 89 Coil voltage selection chart Clear marking of coil voltages and frequencies. Holes for screw mounting (screws not supplied). Distances between holes according to EN50 002. Location of side mounted accessories: mounting on right or left hand side. Terminal marking according to IEC947-5-1 and EN50 011. Location of function marker. Stops for attaching front mounted accessories. All terminal screws: Posidrive (+, -) N° 2 Location of surge suppressors Quick mounting on 35 x 7.5mm DIN mounting rail according to IEC715 and EN50 022. Terminals delivered in open position with captive screws (screws of unused terminals should be tightened). Screwdriver guidance for all screws makes it possible to use motorized screwdrivers. All terminals provide protection against accidental direct contact with live parts according to VDE0106 – Part. 100 and offer IP 20 degree of protection according to IEC947-1. NE12E 14NO 22NC 32NC 86NC 13NO 21NC 31NC 85NC 4-5-6-7- 4-5-6-7- A1 A 2 22 0-230 V 50 H z 230-240 V 60 Hz R 80 7 7C o n t r o l r e l a y s Low Voltage Products & Systems 7.3 ABB Inc. • 888-385-1221 • www.abb-control.com AC 1000 - 11/03 General information Type NE, DC operated Description • Contactor relays with laminated magnet circuit and double-winding coil fed from a DC supply via a built-in N.C. lagging auxiliary contact. • 1-stack version with three built-in auxiliary contacts. • Self-cleaning auxiliary contacts • Alone or fi tted with a 4-pole CA5 auxiliry contact block, these devices offer mechanically linked contacts. • Side by side mounting possible. Application NE... contactor relays are used for switching auxiliary circuits and control circuits. Catalog number explanation NE 12E–84 Frame type Coil voltage (see coil voltage chart below) Contact confi guration Electrical connection between the coil and the N.C. lagging auxiliary contact. Clear marking of the coil voltage Location of side mounted accessories: mounting on right or left hand side. Terminal marking according to IEC947-5-1 and EN50 011. N.C. lagging auxiliary contact path. Stops for attaching front- mounted accessories. All terminal screws: Posidrive (+, -) N° 2 Location of surge suppressor. Hole for screw mounting (screws not supplied). Distances between holes according to EN50 002. Terminals delivered in open position with captive screws (screws of unused terminals should be tightened). Screwdriver guidance for all screws makes it possible to use motorized screwdrivers. All terminals provide protection against accidental direct contact with live parts according to VDE0106 – Part. 100 and offer IP 20 degree of protection according to IEC947-1. Quick mounting on 35 x 7.5mm mounting rail according to IEC 715 and EN 50 022. Location of function marker. Hz Relay Volts type 12 24 48 110 120 125 208 220 240 277 380 415 440 480 500 600 60 N 81 83 84 84 34 36 80 42 86 86 51 53 55 50 N 81 83 84 80 85 86 55 DC NE, NL 80 81 83 86 87 88 89 Coil voltage selection chart 7 7Contr ol r el a y s 7.4 Low Voltage Products & Systems AC 1000 - 11/03 ABB Inc. • 888-385-1221 • www.abb-control.com 13 A1 23 33 43 5- V D C 24 6-7-8- 14 24 34 44 5-6-7-8- KC 4 0 E General information Type NL & TNL, DC operated Type NL Description • Magnetic circuit variants: NL types: d.c. operated with solid magnetic circuits. • 2 versions: 4 pole or 8 pole The width of 8 pole devices is identical to that of 4 pole devices; only the depth is increased. • Bifurcated auxiliary contacts. • Alone or mounted with a 4 pole CA5 auxiliary contact block, these devices offer “positive safety” between their auxiliary contacts. Application Type NL control relays are used for switching auxiliary circuits and control circuits. Type TNL Description • Magnetic circuit variants – NL types: D.C. operated with solid magnetic circuits. – TNL types: D.C. operated with solid magnetic circuit and large coil voltage range. • 2 versions – 4-pole/1-stack or 8-pole/2-stack – The width of 8-pole devices is identical to that of 4 pole devices; only the depth is increased. • Double sharp auxiliary contacts. • Alone or mounted with a 4-pole CA 5 auxiliary contact block, these devices offer "positive safety" between their auxiliary contacts. Application Type NL and TNL control relays are used for switching auxiliary circuits and control circuits. Catalog number explanation (T)NL 44E–84 Frame type Coil voltage (see coil voltage chart below.) Contact confi guration Location of surge suppressors. Quick mounting on 35 x 7.5mm or 35 x 15mm DIN mounting rail according to IE715 and EN50022. Holes for screw mounting (screws not supplied). Distances between holes according to EN50002. Clear marking of coil voltages. Terminals delivered in open position with captive screws (screws of unused terminal should be tightened). Screwdriver guidance for all screws makes it possible to use motorized screwdrivers. All terminals provide protection against accidental direct contact with live parts according to VDE0106 – Part. 100. Terminal marking according to IEC947-5-1 and EN50 011. All terminal screws: M 3.5, posidrive (+,-) N° 2 Location of function marker and surge suppressor. Stops for attaching front mounted accessories. Hz Relay Volts type 12 24 48 110 120 125 208 220 240 277 380 415 440 480 500 600 60 N 81 83 84 84 34 36 80 42 86 86 51 53 55 50 N 81 83 84 80 85 86 55 DC NE, NL 80 81 83 86 87 88 89 Coil voltage selection chart Uc (DC) A1 A2 B2 - Holding B1 - Pull-in A3 Coil supply Uc <110 VDC Coil supply via built-in varistor UC ≤110 VDC B1 - Pull-in B2 - Holding Uc (DC) A1 A2 Varistor A3 U 7 7C o n t r o l r e l a y s Low Voltage Products & Systems 7.5 ABB Inc. • 888-385-1221 • www.abb-control.com AC 1000 - 11/03 N40E-1 NE12E-1 A.C. operated Type N & NL AC & DC operated Contact confi guration Catalog List N.O. N.C. number price 4 0 N40E-84 3 1 N31E-84 $ 60 2 2 N22E-84 4 4 N44E-84 5 3 N53E-84 6 2 N62E-84 120 7 1 N71E-84 8 0 N80E-84 D.C. operated Contact confi guration Catalog List N.O. N.C. number price 4 0 NL40E-86 3 1 NL31E-86 $ 72 2 2 NL22E-86 4 4 NL44E-86 1 5 3 NL53E-86 6 2 NL62E-86 144 7 1 NL71E-86 8 0 NL80E-86 1 2 NE12E-86 2 1 NE21E-86 72 3 0 NE30E-86 4 3 NE43E-86 1 5 2 NE52E-86 6 1 NE61E-86 144 7 0 NE70E-86 Discount schedule KCN Coil voltage selection All AC operated catalog numbers include a 120VAC coil. All DC operated catalog numbers include a 110VDC coil. To select other coil voltages, substitute the code from the Coil Voltage Selection Chart for the fi rst digit after the last dash in the catalog number. Ex.: A 240V coil is required for an N80 control relay: N80E-80 Block diagrams for NE... contactor relay coil supply 1 NE43 – NE70 and NL44 – NL62 control relays cannot accept any front mounted auxiliary contact blocks. Hz Relay Volts type 12 24 48 110 120 125 208 220 240 277 380 415 440 480 500 600 60 N 81 83 84 84 34 36 80 42 86 86 51 53 55 50 N 81 83 84 80 85 86 55 DC NE, NL 80 81 83 86 87 88 89 Coil voltage selection chart 7 7Contr ol r el a y s 7.6 Low Voltage Products & Systems AC 1000 - 11/03 ABB Inc. • 888-385-1221 • www.abb-control.com Type NL and TNL AC & DC operated 4 Pole, 1 stack 4 – – 4 0.600 TNL44E-★ $ 180 4 – 2 2 0.600 TNL62E-★ ★ - Substitute the ★ for the coil voltage code. See the Type TNL Coil voltage Selection chart beneath the photos. Number of contacts Catalog List 1st stack 2nd stack Weight number price N.O. N.C. N.O. N.C. 8 Pole, 2 stack 2 2 – – 0.540 TNL22E-★ 3 1 – – 0.540 TNL31E-★ $ 121 4 – – – 0.540 TNL40E-★ Number of contacts Catalog List 1st stack 2nd stack Weight number price N.O. N.C. N.O. N.C. Coil characteristics No extra tolerances applicable to the Uc min. ... max. values quoted in the Coil voltage selection table • Coil consumption at Uc max. q = 20 °C: 9 W pull-in/holding • Replacement coils: consult us (standard coils used on NL control relays are not suitable for TNL control relays). Pos.1 A B Pos. 3, 4 ABB ABB ABB ABB A B Ambient temp. Max. switching frequency mm mm °C Operating cycles/h 2 20 < 20 1200 5 20 < 55 1200 Mounting distance – for coil operating limits Uc min. … Uc max.ABBABBABB Mounting positions Pos. 1, 3 or 4 TNL 40-E 4 2 1 1 1 – – VBC 30 BA 5-50 Pos. 1, 3 or 4 TNL 31-E 4 1 1 1 – – – VBC 30 BA 5-50 Pos. 1, 3 or 4 TNL 22-E 4 – 1 – – – – VBC 30 BA 5-50 Pos. 1 ±30° TNL - all types – – – – – – – VBC 30 BA 5-50 Control Max. number of auxiliary contact blocks Timer Mechanical Label relays CA5-10 CA5-01 CA5-40 CA5-31 CA5-22 CA5-04 TP interlock marker Add-on accessories Discount schedule KCN TNL22E Coil voltage selection Min. UC Max Voltage 17 – 32 51 24 – 45 52 36 – 65 54 42 – 78 58 50 – 90 55 77 – 143 62 90 – 150 66 152 – 264 68 7 7C o n t r o l r e l a y s Low Voltage Products & Systems 7.7 ABB Inc. • 888-385-1221 • www.abb-control.com AC 1000 - 11/03 TP40DA VE5-1 Accessories Type N, NL & TNL Feature Contacts Catalog List N.O. N.C. number price Timing Contacts Catalog List range N.O. N.C. number price Pneumatic timers Interlocks On delay 0.1 – 40s 1 1 TP40DA N, NL On delay 10 – 180s 1 1 TP180DA $ 108 NE, TNL Off delay 0.1 – 40s 1 1 TP40IA Off delay 10 – 180s 1 1 TP180IA N, NE, NL, TNL Mechanical/electrical — 2 VE5-1 $ 45 N, NE, NL, TNL Mechanical — — VM5-1 21 CAL5-11 CA5-10 RV5/50 RC5-1/50 ZA16-84 BA5-50 Discount schedule ABA Auxiliary contact blocks Positioning Contacts Catalog List N.O. N.C. number price N, NE, NL, TNL (front mount) 1 — CA5-10 $ 15 — 1 CA5-01 4 — CA5-40N N, NL, NE, TNL (4 pole) 2 2 CA5-22N 30 — 4 CA5-04N N, NE, NL, TNL (side mount) 1 1 CAL5-11 Feature Catalog List number price Mechanical latches N, NL (4 pole only) WB75A-★ $ 84 Coil voltage selection chart — mechanical latches 50 Hz 60 Hz Voltage code 24 24 – 28 01 42 42 – 48 02 48 48 – 55 03 110 110 – 127 04 220 – 230 220 – 255 06 230 – 240 230 – 277 05 380 – 415 380 – 440 07 415 – 440 440 – 480 08 Feature Catalog List number price Identifi cation markers Pack of 50 BA5-50 $ 15 7 7Contr ol r el a y s 7.8 Low Voltage Products & Systems AC 1000 - 11/03 ABB Inc. • 888-385-1221 • www.abb-control.com Accessories Type N, NL, NE & TNL ZA16-84 Feature Type Voltage Catalog List range number price Surge suppressors — for Type N control relays 24 – 50 VAC/DC RV5/50 Varistor N, NE 50 – 133 VAC/DC RV5/133 NL, TNL 110 – 250 VAC/DC RV5/250 250 – 440 VAC/DC RV5/440 $ 30 24 – 50 VAC RC5-1/50 RC N 50 – 133 VAC RC5-1/133 110 – 250 VAC RC5-1/250 250 – 440 VAC RC5-1/440 Technical data Type Control Opening time Residual overvoltage Remarks circuit growth factor or clipping voltage RV5/... Advantages • Good energy absorption & damping 50 AC/DC 1.1 to 1.5 132V • Unpolarized system 133 AC/DC 1.1 to 1.5 270V Disadvantages • Clipping from Uvdr thus voltage 250 AC/DC 1.1 to 1.5 480V front up to this point 440 AC/DC 1.1 to 1.5 825V RC5-1/... or RC5-2/... AC 1.2 to 3 2 to 3 x Uc Advantages • Very fast clipping RC-EH300/... • Attenuation of steep fronts and therefore, high frequencies • No operating delays Discount schedule ABA Coils Relay Catalog List type number price N ZA16-★ $ 24 NE ZAE16-★ 24 ★ Select the coil voltage from the Control Relay Coil Voltage Selection chart and substitute the letter code for the ★ as the last digit in the catalog number. Hz Relay Volts type 12 24 48 110 120 125 208 220 240 277 380 415 440 480 500 600 60 N 81 83 84 84 34 36 80 42 86 86 51 53 55 50 N 81 83 84 80 85 86 55 DC NE, NL 80 81 83 86 87 88 89 Coil voltage selection chart 02 NC NC 01 NC 02 01 NC RV5 RC5-1 Surge suppressor VM5-1 VE5-1 Interlock unit CAL5-11 Side-mounted 2-pole auxiliary contact block CAL5-11 Side-mounted 2-pole auxiliary contact block N22E N31E N40E Control Relay N22E N31E N40E Control Relay CA5-10 and CA5-01 Front-mounted 1-pole auxiliary contact blocks CA5... Front-mounted 4-pole auxiliary contact block TP40DA TP180DA TP40IA TP180IA Pneumatic timer 02 NC NC 01 NC 02 01 NC VM5-1 RV5 RC5-1 Surge suppressor VM5-1 VE5-1 Interlock unit CAL5-11 Side-mounted 2-pole auxiliary contact block N44E N53E N62E N71E N80E Control Relay N44E N53E N62E N71E N80E Control Relay CAL5-11 Side-mounted 2-pole auxiliary contact block 7 7C o n t r o l r e l a y s Low Voltage Products & Systems 7.9 ABB Inc. • 888-385-1221 • www.abb-control.com AC 1000 - 11/03 Accessory mounting information Type N, NE, NL & TNL 4 Pole, N control relays 8 Pole, N contactor relays 7 7Contr ol r el a y s 7.10 Low Voltage Products & Systems AC 1000 - 11/03 ABB Inc. • 888-385-1221 • www.abb-control.com Possible accessory combinations Type N, NE, NL, TNL Confi gurations of accessories are different depending on whether front or side mounted. Accessories — Front mounting Accessories — Side mounting Auxiliary contact blocks TP - A Pneumatic Auxiliary contact Blocks Interlock units 1-pole CA5- 4-pole CA5- timer block 2-pole CAL5-11 Type Main Built-in poles auxiliary contacts N ............................... 1 2 2 E 1 to 4 CA5- 1 CA5- 1 to 2 1 VM/E5-1 block N ............................... 1 3 1 E 1-pole blocks or 4-pole block or 1 TP - A block + CAL5-11 blocks or N ................................... 4 0 E + 1 CAL5-11 block N ................................... 4 4 E N ................................... 5 3 E 1 to 2 1 VM/E5-1 block N ................................... 6 2 E — — — + CAL5-11 blocks or + 1 CAL5-11 blockN ................................... 7 1 E N ................................... 8 0 E NE ............................... 1 2 2 E 1 to 4 CA5- 1 CA5- 1 to 2 1 VM/E5-1 block NE ............................... 1 3 1 E 1-pole blocks or 4-pole block or 1 TP - A block + CAL5-11 blocks or + 1 CAL5-11 block NE ................................... 4 0 E NE ................................... 4 4 E NE ................................... 5 3 E 1 to 2 1 VM/E5-1 block NE ................................... 6 2 E — — — + CAL5-11 blocks or + 1 CAL5-11 blockNE ................................... 7 1 E NE ................................... 8 0 E NL ............................... 1 2 2 E 1 to 4 CA5- 1 CA5- 1 to 2 1 VM/E5-1 block NL ............................... 1 3 1 E 1-pole blocks or 4-pole block or 1 TP - A block + CAL5-11 blocks or + 1 CAL5-11 block NL ................................... 4 0 E NL ................................... 4 4 E NL ................................... 5 3 E 1 to 2 1 VM/E5-1 block NL ................................... 6 2 E — — — + CAL5-11 blocks or + 1 CAL5-11 blockNL ................................... 7 1 E NL ................................... 8 0 E TNL ..............................1 2 2 E 1 to 4 CA5- 1 CA5- 1 to 2 1 VM/E5-1 block TNL ..............................1 3 1 E 1-pole blocks or 4-pole block or 1 TP - A block + CAL5-11 blocks or + 1 CAL5-11 block TNL .................................. 4 0 E TNL .................................. 4 4 E TNL .................................. 5 3 E 1 to 2 1 VM/E5-1 block TNL .................................. 6 2 E — — — + CAL5-11 blocks or + 1 CAL5-11 blockTNL .................................. 7 1 E TNL .................................. 8 0 E NL22E TNL22E 13 21 31 43 NO NC NC NO NO NC NC NO 14 22 32 44 A1 A2 NL40E TNL40E 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 A1 A2 A1 A2 43 NO NO 44 33 NO NO 34 23 NO NO 24 13 NO NO 14 NL40E TNL40E 43 NO NO 44 31 NC NC 32 21 NC NC 22 13 NO NO 14 A1 A2 NL22E TNL22E 33 NO NO 34 21 NC NC 22 13 NO NO 14 A1 A2 43 NO NO 44 NL31E TNL31E NL44E TNL44E 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 A1 A2 NCNCNC NC 51 61 71 81 52 62 72 82 NL62E TNL62E 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 A1 A2 NCNCNO NO 53 61 71 83 54 62 72 84 A1 A2 43 NO NO 44 33 NO NO 34 23 NO NO 24 13 NO NO 14 81 NC NC 82 71 NC NC 72 61 NC NC 62 51 NC NC 52 NL44E TNL44E A1 A2 43 NO NO 44 33 NO NO 34 23 NO NO 24 13 NO NO 14 83 NO NO 84 71 NC NC 72 61 NC NC 62 53 NO NO 54 E0491DNL62E TNL62E NL31E TNL31E 13 21 33 43 NO NC NO NO NO NC NO NO 14 22 34 44 A1 A2 33 NO NO 34 21 NC NC 22 13 NO NO 14 A1 A2 43 NO NO 44 43 NO NO 44 43 NO NO 44 43 NO NO 44 53 NO NC 54 Combination 41 E A1 A2 43 NO NO 44 33 NO NO 34 23 NO NO 24 13 NO NO 14 61 NC NC 62 51 NC NC 52 Combination 42 ECombination 41E 13 21 33 43 NO NC NO NO NO NC NO NO 14 22 34 44 A1 A2 = = + + + 53 54 NO NL31E TNL31E CA5-10 CA5-10 13 21 33 43 NO NC NO NO NO NC NO NO 14 22 34 44 A1 A2 5- 5- -3 -4 NO Combination 50E 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 A1 A2 = = + + + 53 54 NO NL40E TNL40E CA5-10 CA5-10 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 A1 A2 5- 5- -3 -4 NO A1 A2 43 NO NO 44 53 NO NO 54 33 NO NO 34 23 NO NO 24 13 NO NO 14 Combination 50 E A1 A2 43 NO NO 44 53 NO NO 54 63 NO NO 64 33 NO NO 34 23 NO NO 24 13 NO NO 14 Combination 60 E Combination 80E 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 A1 A2 NONONO NO 53 63 73 83 54 64 74 84 NONONO NO 53 63 73 83 54 64 74 84 NL40E TNL40E CA5-40E CA5-40E 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 A1 A2 5-6- 7- 8- 5-6- 7- 8- = = + + + A1 A2 43 NO NO 44 33 NO NO 34 23 NO NO 24 13 NO NO 14 83 NO NO 84 73 NO NO 74 63 NO NO 64 53 NO NO 54 Combination 80 E A1 A2 Combination 42 E NL40E TNL40E = = + + ++ + + CA5-01 CA5-01 CA5-01 CA5-01 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 13 23 33 43 NO NO NO NONO NO NO 51 52 NC 61 62 NC -1 -2 5- 5- 6- 6- NC NO NO NO NO 14 24 34 44 A1 A2 -1 -2 NC A1 A2 Combination 60 E NL40E TNL40E = = + + + + ++ CA5-10 CA5-10 CA5-10 CA5-10 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 13 23 33 43 NO NO NO NONO NO NO 53 54 NO 63 64 NO -3 -4 5- 5- 6- 6- NO NO NO NO NO 14 24 34 44 A1 A2 -3 -4 NO 7 7Contr ol r el a y s 7.14 Low Voltage Products & Systems AC 1000 - 11/03 ABB Inc. • 888-385-1221 • www.abb-control.com Technical data Terminal marking and positioning Type NL & TNL Standard devices without addition of auxiliary contacts Other possible contact combinations with auxiliary contacts added by the user 2.91 74 1.73 44 1.972.36 60 50 1.38 35 0.18 4.5 2.91 74 2.68 68 0.22 5.5 2.91 74 1.73 44 1.972.36 60 50 1.38 35 0.18 4.5 2.91 74 2.68 68 0.22 5.5 7 7C o n t r o l r e l a y s Low Voltage Products & Systems 7.17 ABB Inc. • 888-385-1221 • www.abb-control.com AC 1000 - 11/03 Type N, 4 Pole, AC operated Approximate dimensions Type N, NE, NL, & TNL AC & DC operated00.00 00.00 Inches [Millimeters] Type NE, 4 Pole, DC operated Type NL, TNL 7 7C o n t r o l r e l a y s Low Voltage Products & Systems 7.11 ABB Inc. • 888-385-1221 • www.abb-control.com AC 1000 - 11/03 Technical data UL & CSA Voltage Continuous Maximum Maximum current make break AC inductive ratings — NEMA A600 120V 240V 10 7200VA 720VA 480V 600V AC mechanical endurance 30 million operations 80VA 8VA In rush Sealed AC coil consumption 10 – 20ms 10 – 20ms Pickup Dropout AC operating time Voltage Continuous Maximum Maximum current make break DC inductive ratings — NEMA P300 120V 250V 5 138VA 138VA 300-600V DC mechanical endurance 30 million operations 7.0W 7.0W In rush Sealed DC coil consumption 30 – 90ms 10 – 20ms Pickup Dropout DC operating time N22E 13 21 31 43 NO NC NC NO NO NC NC NO 14 22 32 44 A1 A2 A2 N31E 13 21 33 43 NO NC NO NO NO NC NO NO 14 22 34 44 A1 A2 A2 N44E 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 A1 A2 A2 NCNCNC NC 51 61 71 81 52 62 72 82 N53E 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 A1 A2 A2 NCNCNO NC 53 61 71 81 54 62 72 82 N62E 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 A1 A2 A2 NCNCNO NO 53 61 71 83 54 62 72 84 N80E 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 A1 A2 A2 NONONO NO 53 63 73 83 54 64 74 84 N40E 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 A1 A2 A2 N71E 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 A1 A2 A2 NONCNO NO 53 61 73 83 54 62 74 84 43 NO NO 44 31 NC NC 32 21 NC NC 22 13 NO NO 14 A1 A2 N22E 33 NO NO 34 21 NC NC 22 13 NO NO 14 A1 A2 43 NO NO 44 N31E A1 A2 43 NO NO 44 33 NO NO 34 23 NO NO 24 13 NO NO 14 N40E A1 A2 43 NO NO 44 33 NO NO 34 23 NO NO 24 13 NO NO 14 83 NO NO 84 73 NO NO 74 61 NC NC 62 53 NO NO 54 N71E A1 A2 43 NO NO 44 33 NO NO 34 23 NO NO 24 13 NO NO 14 83 NO NO 84 71 NC NC 72 61 NC NC 62 53 NO NO 54 N62E A1 A2 43 NO NO 44 33 NO NO 34 23 NO NO 24 13 NO NO 14 81 NC NC 82 71 NC NC 72 61 NC NC 62 53 NO NO 54 N53E A1 A2 43 NO NO 44 33 NO NO 34 23 NO NO 24 13 NO NO 14 81 NC NC 82 71 NC NC 72 61 NC NC 62 51 NC NC 52 N44E A1 A2 43 NO NO 44 33 NO NO 34 23 NO NO 24 13 NO NO 14 83 NO NO 84 73 NO NO 74 63 NO NO 64 53 NO NO 54 N80E N33/11 13 23 33 41 NO NO NO NC NO NO NO NC 14 24 34 42 A1 A2 A2 NCNCNC NO 51 61 75 87 52 62 76 88 N51/11 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 A1 A2 A2 NCNCNO NO 53 61 75 87 54 62 76 88 A1 A2 33 NO NO 34 23 NO NO 24 13 NO NO 14 87 NO NO 88 75 NC NC 76 61 NC NC 62 N31/11 41 NC NC 42 51 NC NC 52 A1 A2 43 NO NO 44 33 NO NO 34 23 NO NO 24 13 NO NO 14 87 NO NO 88 75 NC NC 76 61 NC NC 62 53 NO NO 54 N51/11 33 NO NO 34 21 NC NC 22 13 NO NO 14 A1 A2 43 NO NO 44 53 NO NO 54 Combination 41 E Combination 41 E N31E= = + + CA5-10 A1 A2 13 21 33 43 NO NC NO NO 13 21 33 43 NO NC NO NO 53 54 NO 53 NO NO NC NO NO 14 22 34 44 NO NC NO NO 14 22 34 44 A2 13 21 33 43 NO NC NO NO NO NC NO NO 14 22 34 44 13 21 33 43 NO NC NO NO NO 5- 5- NC NO NO 14 22 34 44 A1 A2 A2 -3 -4 NONO A1 A2 43 NO NO 44 53 NO NO 54 33 NO NO 34 23 NO NO 24 13 NO NO 14 Combination 50 E A1 A2 43 NO NO 44 53 NO NO 54 63 NO NO 64 33 NO NO 34 23 NO NO 24 13 NO NO 14 Combination 60 E A1 A2 43 NO NO 44 33 NO NO 34 23 NO NO 24 13 NO NO 14 61 NC NC 62 51 NC NC 52 Combination 42 E Combination 42 E N40E= = ++ ++ CA5-01 CA5-01 -1 -2 NC A1 A2 13 23 33 43 NO NO NO NONO NO NO 51 52 NC 61 62 NC NO NO NO NO 14 24 34 44 A2 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 5- 5- 6- 6- A1 A2 A2 -1 -2 NC Combination 60 E N40E= = + ++ +CA5-10 CA5-10 A1 A2 13 23 33 43 NO NO NO NONO NO NO 53 54 NO 63 64 NO NO NO NO NO 14 24 34 44 A2 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 5- 5- 6- 6- A1 A2 A2 -3 -4 NO -3 -4 NO Combination 50 E N 40 E CA5-10= = + + -3 -4 NO A1 A2 13 23 33 43 NO NO NO NONO NO NO 53 54 NO NO NO NO NO 14 24 34 44 A2 13 23 33 43 NO NO NO NO NO NO NO NO 14 24 34 44 5- 5- A1 A2 A2 7 7Contr ol r el a y s 7.12 Low Voltage Products & Systems AC 1000 - 11/03 ABB Inc. • 888-385-1221 • www.abb-control.com Technical data Terminal marking and positioning Type N N control relays Pole confi guration schematics Other possible contact combinations with auxiliary contacts added by the user 4 Pole control relay with 4 pole adder deck 4 Pole control relay NE12E 13 21 31 85 NO NC NC NC NO NC NC NC 14 22 32 86 A1 A2 A3 NE21E 13 21 33 85 NO NC NO NC NO NC NO NC 14 22 34 86 A1 A2 A3 NE30E 13 23 33 85 NO NO NO NC NO NO NO NC 14 24 34 86 A1 A2 A3 31 NC NC 32 21 NC NC 22 13 NO NO 14 A1 A2 NE12E A3 86 85 33 NO NO 34 21 NC NC 22 13 NO NO 14 A1 A2 NE21E A3 86 85 33 NO NO 34 23 NO NO 24 13 NO NO 14 A1 A2 NE30E A3 86 85 7 7C o n t r o l r e l a y s Low Voltage Products & Systems 7.13 ABB Inc. • 888-385-1221 • www.abb-control.com AC 1000 - 11/03 Technical data Terminal marking and positioning Type NE NE control relays Pole confi guration schematics Breaking current (A)Million ops CA5, CAL 5 0.02 0.05 0.1 0.2 0.3 0.5 1 2 3 5 10 0.1 0.2 0.3 0.5 1 2 3 5 10 20 30 46 4and 8 -pole N Lt yp e s 4a nd 8-p o le N & N E t y p e s 7 7C o n t r o l r e l a y s Low Voltage Products & Systems 7.15 ABB Inc. • 888-385-1221 • www.abb-control.com AC 1000 - 11/03 ABB Pos. 4 Pos. 2 Pos. 6 Pos. 1 Pos. 5 Pos. 5 Pos. 1±30° 30°30 ° A A B1 B2 C2 C1 ABB Technical data IEC Mounting positions Electrical durability of contacts utilization category AC – 15 according to IEC947-5-1 making current: 10 x Ie with cos ϕ = 0.7 and Ue breaking current: Ie with cos ϕ = 0.4 and Ue The curves op po site show the electrical du ra bil i ty of the control re lays as well as the add-on aux il ia ry con tact blocks in re la tion to the breaking current Ic. These curves have been drawn for re sis tive and in- duc tive loads up to 690V, 40 – 60Hz. Type NE12, NE 21, NE 30 N22, N31, N40 N44, N53, N62, N71, N80 NL22, NL31, NL40 NL44, NL62 Number of poles 3 4 8 4 8 Insulation characteristics Rated insulation voltage Ui acc. to IEC947-5-1 and VDE0110 (Gr. C) V 690 acc. to UL/CSA V 600 Rated impulse withstand voltage Uimp acc. to IEC947-5-1 kV 8 General technical data Standards Devices complying with international standards IEC947-5-1/947-4-1 and European standards EN60 947-5-1/60 947-4-1 Electromagnetic compatibility (EMC) according to amendment A11 to IEC947-1; EN60 947-1 and amendment 2 to IEC947-4-1 Air temperature near contactor — for operation in free air: °C -40 to +55 (0.85 – 1.1 Uc) / +55 to +70 (Uc) — for storage: °C -60 to +80 Climatic withstand according to IEC68-2-30 and 68-2-11 – UTE C63-100, Specifi cation II Mounting positions Positions 1 to 5 - θ < 55°C : 0.85 – 1.1 Uc - θ = 55 - 70°C : — Uc Position 6 - θ < 55°C : 0.95 – 1.1 Uc (see diagrams below) - θ > 55°C : not acceptable Operating altitude m < 3000 Shock withstand according to 1/2 sinusoidal shock, 11ms: no change in contact position IEC 68-2-27 and EN 60068-2-27 Shock direction: A, C1, C2 : 20 g Mounting pos. 1 B1 : 5 g (see below) B2 : 15 g Mounting — on mounting rail 35mm according to IEC715 and EN50022 — with screws (not supplied) 2 x M4 Connection terminals (delivered in open position, M 3.5 (+,-) posidrive 2 screw with cable clamp screws of unused terminals must be tightened) Connection capacity Rigid solid 1 x AWG 16 – 12 2 x AWG 16 – 12 Degree of protection according to IEC529, IEC947-1 and EN60529 — Pole terminals IP20 IP10 — Coil terminals IP20 IP20 7 7Contr ol r el a y s 7.16 Low Voltage Products & Systems AC 1000 - 11/03 ABB Inc. • 888-385-1221 • www.abb-control.com Technical data IEC 1 50/60 Hz coils: voltage codes 80 to 88, see page 7.5. 2 Using surge sup pres sors increases the opening time on a scale/ratio of 1.1 to 1.5 for a varistor suppressor and by 4 to 8 for a diode suppressor. Type NE12, NE21, NE30 N22, N31, N40 N44, N53, N62, N71, N80 NL22, NL31, NL40 NL44, NL62 Number of poles 3 4 8 4 8 Pole utilization characteristics Rated operational voltage Ue V 690 Conventional thermal current in free air Ith according to IEC947-5-1 θ ≤ 40°C A 16 10 Rated operating current Ie in AC-15 according to IEC947-5-1 24 – 127 V 50/60 Hz A 6 6 230 – 240 V 50/60 Hz A 4 4 400 – 415 V 50/60 Hz A 3 3 500 V 50/60 Hz A 2 2 690 V 50/60 Hz A 2 2 in DC-13 according to IEC947-5-1 24VDC A/W 6/144 6/144 48VDC A/W 2.8/134 2.8/134 72VDC A/W 1/72 1/72 125VDC A/W 0.55/69 0.55/69 250VDC A/W 0.3/75 0.3/75 Field of rated frequencies Hz 25 – 400 Mechanical durability in operating cycles 10 million > 20 million 30 million Max. switching frequency cycles/h 3000 6000 6000 Electrical durability in operating cycles Max. switching frequency cycles/h 1200 Rated making capacity according to IEC947-5-1 10 x Ie /AC-15 Rated breaking capacity according to IEC947-5-1 10 x Ie /AC-15 gG (gl) protection fuse A 10 Rated short time withstand current at ambient temp. of 40 °C, 1.0 s 100A 50A in free air, from cold state 0.1 s 140A 100A Insulation resistance at 500 VDC after durability test: 5 MΩ Min. switching capacity with failure rate below 10-6 17V / 5mA 24V / 5mA Non overlapping time between N.O. and N.C. contacts ms ≥ 2 Power loss per pole at 6A W 0.10 0.15 Magnet system characteristics Coil operating limits θ ≤ 40°C according to IEC 947-5-1 : 0.85 - 1.1 Uc Drop out voltage in % of Uc 10 – 30% roughly 40 – 65% roughly 10 – 30% Coil consumption (average value) — a.c. operation: 50 Hz pull in VA — 70 — 60 Hz pull in VA — 80 — 50/60 Hz1 pull in VA/VA — 74/70 — 50/60Hz holding VA/W — 8/2 — — d.c. operation: cold pull in W 90 — 7 warm holding W 2 — 7 Rated control voltage Uc — AC operation: 50/60 Hz V — 20 – 690 — — DC operation: VDC 12 – 250 — 24 – 240 Max. permissible short supply interruption without opening of contacts ms 2 2 2 Operating time between coil energization and: — closing of N.O. contact ms 10 – 16 10 – 26 50 – 75 — opening of N.C. contact ms 8 — 12 7 – 21 45 – 70 between coil de energization and: — opening of N.O. contact ms 5 — 14 4 – 11 15 – 30 2 — closing of N.C. contact ms 11 — 17 9 – 16 17 – 32 2 MECH INTERLOCK D.C. OPERATED SIDE MOUNTED AUXILIARY A SINGLE POLE TOP MOUNTED AUXILIARY B C FOUR POLE TOP MOUNTED AUXILIARY ON-POSITION LATCH ED PNEUMATIC TIMER F7 7Contr ol r el a y s 7.18 Low Voltage Products & Systems AC 1000 - 11/03 ABB Inc. • 888-385-1221 • www.abb-control.com Approximate dimensions Accessories for Type N & NE N & NE Type A B C D E F N IN 2.20 3.96 4.21 5.71 5.00 — MM 56 100.5 107 145 127 — NE IN 2.20 3.96 4.21 5.71 5.00 — MM 56 100.5 107 145 127 — Section 17 (This Page Intentionally Left Blank) (This Page Intentionally Left Blank) Accessories — page 10-79 Legend Plates — page 10-91 Bulletin 800T/800H30.5 mm Push Buttons 10-53Visit our website: www.ab.com/catalogs Emergency Stop Operators2-Position Push-Pull and Push-Pull/Twist Release, Non-IlluminatedNote:A jumbo or large legend plate is recommended, if space allows.2-Position Push-PullCat. No. 800T-FX6D4 2-Position Push-Pull/TwistCat. No. 800T-FXT6D4 2-Position Push-Pull/TwistCat. No. 800H-FRXT6D4 Approximate Dimensions — page 10-97 Contact Type Operator Position ButtonColor Type 4/13 Type 4/4X/13Push-Pull Push-Pull/TwistRelease Push-Pull/TwistReleaseOutInCat. No.Cat. No.Cat. No.N.C.L.B.�X O Red 800T-FX6D4 800T-FXT6D4 800H-FRXT6D4N.O. -N.C.L.B.�OX XO Red 800T-FX6A1 800T-FXT6A1 800H-FRXT6A1N.C.L.B. -N.C.L.B.�XX OO Red 800T-FX6A5 800T-FXT6A5 800H-FRXT6A5S.M.C.B.�†X O Red 800TC-FX6D4S 800TC-FXT6D4S 800HC-FRXT6D4SN.O. -S.M.C.B.�†OX XO Red 800TC-FX6A1S 800TC-FXT6A1S 800HC-FRXT6A1SS.M.C.B. -S.M.C.B�†XX OO Red 800TC-FX6A5S 800TC-FXT6A5S 800HC-FRXT6A5SNote:X = Closed/O = OpenNote:Emergency stop push buttons are compliant with EN 418 and EN/IEC 60947-5-5 Standards when using N.C.L.B. contact blocks. �Normally closed late break contact. When button is pushed from the OUT to IN position, the mechanical detent action of the operator occurs before electrical contacts change state. When the button is pulled from the IN to the OUT position, the electrical contacts change state before the mechanical detent occurs. †The Self Monitoring Contact Block (S.M.C.B.) is composed of a N.C.L.B. contact wired in series with a N.O. monitoring contact. The N.O. monitoring contact automatically closes when the S.M.C.B. is properly installed onto the E-stop operator. If the S.M.C.B. is separated from the E-stop operator, the N.O. monitoring contact will automatically open. Bulletin 800T/800H30.5 mm Push Buttons 10-88 Visit our website: www.ab.com/catalogs Accessories, ContinuedGuards Description Type Cat. No.800TPush Button GuardsMomentary push button guards to reduce the risk ofaccidental operation.1 in Guard for Non-Illuminated 800T-N131/2 in Guard for Non-Illuminated 800T-N1431-1/2 in Guard for Illuminated 800T-N93Push Button Unit with Cat. No. 800T-N131 in (25.4 mm) Extra Long Guard 1-1/2 in Guard for Non-Illuminatedwith Locking Attachment 800T-N39800HIlluminated Push Button GuardThis guard provides additional protection against accidental operation of the push button unit.1-1/2 in (38.1 mm) guard for illumination units.800H-N152Illuminated Push Button Unit withCat. No. 800H-N152 Guard 800HStainless Steel GuardUsed on non-illuminated push buttons that have protective boots as shown on page 10-83.800H-N153Stainless Steel GuardCat. No. 800H-N153 800TMushroom Push Button GuardsMomentary mushroom guards for standard and jumbomushroom push buttons. Reduces the risk of accidentaloperation.Standard Guard 800T-N129Standard Guard with Set Screw 800T-N165Jumbo Size Guard 800T-N151Standard Mushroom Push Button Unit withCat. No. 800T-N129 Guard Jumbo Size Guard with Set Screw 800T-N154 Description Type of Finish Cat. No. 800T/H Protective Guard Protective ring for 800T 2-position push-pull operators. Illuminated or non-illuminated. Often used to avoid unintentional tripping of E-stop operators. This guard is used with standard size button (40 mm dia.). Stainless Steel 800T-N310 Protective Ring for 2-Position Push-Pull Cat. No. 800T-N310 and 800T-NX1320 Black 800T-NX1320 Description Cat. No. 800T/H Jumbo Protective Guard Protective ring for 800T 2-position push-pull operators. Illuminated or non-illuminated. Often used to avoid unintentional tripping of E-stop operators. This guard is used with jumbo size button (60 mm dia.). 800T-N310J Protective Ring for 2-Position Push-Pull Cat. No. 800T-N310J 800T/H Ramp Guard For Bulletin 800T/800H 2- and 3-position illuminated and non-illuminated push-pull units. Standard size button only (40 mm dia.). 800T-N339 Ramp Guard Cat. No. 800T-N339 Bulletin 800T/800H30.5 mm Push Buttons 10-79Visit our website: www.ab.com/catalogs AccessoriesΑχχεσσοριεσContact BlocksPackaged in kit form for field installation. All necessary mounting hardware is provided with each contact block kit.Contact ratings arelisted on page 10-52.Note:It is not recommended to mount more than four contact blocks on any one non-illuminated operator, (maximum two blocks deep).Contact blocks cannot be stacked onto power modules, so illuminated operators are limited to two contact blocks. Sealed switchcontact blocks are not stackable, and are limited to two blocks per operator. Time delay contacts are only available as one circuit peroperator.PenTUFF (Low Voltage)Contact Block Logic Reed Block Sealed Switch Block Stackable Sealed SwitchBlockShallow Block Mini Block Time Delay BlockSelf Monitoring Contact Block Shallow Contact Block Hardware Contact Type Shallow Block�†PenTUFF(Low Voltage) Block�†Logic ReedBlock‡SealedSwitch Block‡Stackable SealedSwitch Block‡Cat. No.Cat. No.Cat. No.Cat. No.Cat. No.1 N.O.800T-XD1 800T-XD1V 800T-XD1R 800T-XD1P 800T-XD1Y1 N.C.800T-XD2 800T-XD2V 800T-XD2R 800T-XD2P 800T-XD2Y1 N.O.E.M.800T-XD3 800T-XD3V ———1 N.C.L.B.800T-XD4 800T-XD4V ———1 N.O. - N.C.800T-XA 800T-XAV 800T-XAR 800T-XAP 800T-XAY2 N.O.800T-XA2§—800T-XA2R§—800T-XA2Y2 N.C.800T-XA4 —800T-XA4R —800T-XA4Y1 N.C.L.B. - 1 N.O.800T-XA1 ————1 N.C.L.B. - 1 N.C.800T-XA7 ———— Contact Type S.M.C.B.�� Cat. No. 1 N.C.L.B. (wired in series with 1 N.O. monitoring contact)800TC-XD4S Contact Type Mini Block� Time Delay Block♣MaxDuty Block Cat. No.Cat. No.Cat. No. 1 N.O.800T-XD5 800T-XT 800T-XD1M 1 N.C.800T-XD6 800T-XS 800T-XD2M 1 N.C.L.B.——800T-XD4M MaxDuty Block �Contact blocks with normally closed contacts meet direct drive positive opening standard requirements when properly fused to IEC 269-1 and 269-2. Shallow/mini contacts: 10 A gl or N type cartridge fuse. PenTUFF contacts: 6 A gl or N type cartridge fuse. †Specify Bulletin 800TC for finger-safe contact blocks. Example:Cat. No. 800T-XA becomes Cat. No. 800TC-XA. ‡800T operator using sealed switch and logic reed contact blocks and installed in a suitable enclosure are UL Listed as suitable for use in Class I, Division 2/Zone 2 hazardous locations. §Additional contacts cannot be stacked on XA2 and XA2R contact blocks. ♣For contact ratings, see page 10-51. �For use with 2-position push-pull or push-pull/twist operators only. Must be mounted on the first level of the operator. The N.O. monitoring contact automatically closes when the S.M.C.B. is properly installed onto the operator. If the S.M.C.B. is separated from the operator, the N.O. monitoring contact automatically opens. Description Cat. No. Contact Block Mounting Screw 800T-N335 Screw Retainer 800T-N336 Actuator Extender 800T-N337 (This Page Intentionally Left Blank) Section 18 (This Page Intentionally Left Blank) BULLETIN 1489 CIRCUIT BREAKERSSELECTION GUIDE Bulletin 1489Circuit Breakers 3Visit our website: www.ab.com/catalogs DescriptionBulletin 1489 Circuit BreakersIndustrial Circuit Breakers for North American ApplicationsThe Bulletin 1489 line includes:FeaturesyDesigned Manufactured and Listed to UL489 (CSA 22.2 no. 5.1)y Thermal-Magnetic protection y All ratings are HACR rated y 10 kA Interrupting rating y Finger –Safe Design (front) y DIN Rail Mounting y Wire Connections line and load y Optional Ring Terminal Connections (convertible) ApprovalsTable of ContentsSpecifications.............. 11Description................... 3Product Selection ...... 81489 ApproximateDimensions................... 12 Description Bulletin 1489 Circuit Breakers for Branch Circuit protection are available in one (1)-, two (2)-, and three (3)-pole construction and are rated 0.5 to 40 A at 240V AC and 0.5 to 20 A at 480Y/277V AC for North American applications (UL 489 and CSA 22.2 No. 5.1). For IEC applications the products are rated 415V AC 0.5 to 40 A. Thermal Magnetic Circuit Breakers The Bulletin 1489 Thermal Magnetic Circuit Breakers are general-purpose devices suitable for the majority of industrial, inverse time circuit breaker applications. They combine thermal and magnetic trip actions and provide accurate overload and short-circuit protection for conductors and connected equipment. Circuit Breaker Application Information Selection of a Bulletin 1489 circuit breaker with appropriate circuit protection includes consideration of: y Circuit Voltage y Circuit Frequency y Available Short Circuit Current y Continuous Current Rating y Application Considerations y Special Operating Conditions The following discussion is based upon National Electric Code and UL requirements. Similar considerations are appropriate for Canadian applications. Circuit Voltage The Bulletin 1489 circuit breakers are rated by voltage class. Applications should not exceed the listed voltage and current range (see Table 1). Circuit Frequency The Bulletin 1489 circuit breakers may be applied to frequencies of 50 Hz and 60 Hz without derating. For applications above 60 Hz, contact Rockwell Automation with specific application information for the derating of the circuit breakers. Available Short Circuit Current The Bulletin 1489 circuit breakers should only be applied in those applications in which the available short-circuit (or fault) current is less than or equal to 10,000 A. Table 1. Voltage and Current Ranges Region Max. Voltage Current Range IEC Regions 415V AC 0.5...40 A North America (UL 489 & CSA 22.2 No. 5.1) 240V AC 0.5...40 A 480Y/277V AC 0.5...20 A y UL 489, CSA 22.2 No. 5.1y240V AC 0.5...40 Ay480V/277V AC 0.5...20 AyMiniature Circuit Breaker for IEC ApplicationsEN 60 947-2y415V AC 0.5...40 A y CE markedyUL 489yCSA 22.2 No. 5.1 y HACR y SWD (0.5...20 A) Switching Duty for flourescent lighting applications y IEC 60 947-2 1489-SG001A.qxd 10/11/2005 3:31 PM Page 3 Bulletin 1489Circuit Breakers 4 Visit our website: www.ab.com/catalogs Description, ContinuedContinuous Current Rating Application Considerations Standard current ratings are: 0.5 A, 1 A, 1.5 A, 2 A, 3 A, 4 A, 5 A, 6 A, 7 A, 8 A, 10 A, 15 A, 16 A, 20 A, 25 A, 30 A, 32 A, 35A, and 40 A.The Bulletin 1489 circuit breakers are rated in RMS amperes at a 40°C (104°F) ambient temperature per the UL 489 (CSA 22.2 No. 5.1)standard. This temperature is generally used as the average temperature within an industrial enclosure. If a circuit breaker is applied in atemperature that exceeds the 40°C (104°F) ambient, then the circuit breaker should be derated. For IEC 60 947-2 standard the productscarry an ambient rating of 30°C. Follow standard IEC application considerations for temperature rating in different ambient temperatures.The characteristic trip curves are shown on page 6 . The trip bands shown for each breaker represent current tripping limits for a circuitbreaker and are within the limits established by UL. For a specific current at 40°C (104°F), a circuit breaker will open ("clear the circuit")automatically at some total time that will be within the "Minimum" and "Maximum" time shown on the curves. For example, figure 1 shows that a one-pole, 15 A, Bulletin 1489 circuit breaker trips in not less than 10 sec. and not more than 120 sec. on a 30 A current. Because the UL standard defines this time spread, users should not specify exact tripping time. The lower current portion of the curves (upper left) depict the time to trip due to thermal action and reflect overload protection of the wire and connect load. The higher current portion of the curves (lower right) depicts the trip due to magnetic action of the circuit breaker and reflects protection due to short circuit level currents. The following is a discussion of application considerations related to North American applications. When applying product to IEC regional requirements, follow IEC practices and guidelines. The selection of a specific ampere rating for a specific application is dependent on the type of load and duty cycle and is governed by the National Electric Code (Canadian Electric Code) and UL/CSA. In general, the codes require that overcurrent protection is at the current supply and at points where wire sizes are reduced. In addition, the codes state that conductors be protected according to their current carrying capacity. There are specific situations that require application consideration, such as motor circuit, and guidelines for the selection for transformer protection. The Bulletin 1489 circuit breakers are “non 100 percent rated” as defined by UL 489, para 7.1.4.2. As such, the circuit breaker's rating should be loaded to no more than 80% if used with continuous loads. Branch Circuits: Bulletin 1489 circuit breakers may be used to protect branch circuits. A branch circuit is the wiring portion of a system extending beyond the final overcurrent device protecting the circuit. Guidelines established in NEC, CEC, UL, and CSA should be used to determine the specific device. For example: 1) Motor Branch Circuit Bulletin 1489 circuit breakers are not horsepower rated because they are able to safely interrupt currents far in excess of the locked rotor value for a selected motor. This ability is recognized in the codes and standards and is also established by the UL and CSA tests described in UL 489 and CSA 22.2 No. 5.1 standards. The size of a Bulletin 1489 circuit breaker should be determined following the guidelines for an Inverse Time Circuit Breaker. References: NEC 430.51 and UL 489. Also see CEC and appropriate Canadian Standards. 2) Transformer Protection Bulletin 1489 circuit breakers may be used for transformer protection following the guidelines established. References: NEC 450 and UL 489. Also see CEC and appropriate Canadian Standards. 3) Heater Load, Lighting, and Other Load Protection Bulletin 1489 circuit breakers may be used for protection of heater loads, lighting loads, and other loads following the guidelines established. References: NEC Article 31 and UL 508A. Also see CEC and appropriate Canadian Standards. Coordinated Overcurrent Protection Where an orderly shutdown is required to minimize the hazards to personnel and equipment, a system of coordination based upon the faulted or overloaded circuit is isolated by selective operation of only the overcurrent protective device closest to the overcurrent condition. The user should select devices that meet this requirement. References: NEC 240.12. Also see CEC. 1489-SG001A.qxd 10/11/2005 3:31 PM Page 4 Bulletin 1489Circuit Breakers 5Visit our website: www.ab.com/catalogs Determining Ratings Description, Continued Ambient Temperature Graph 1.40 1.30 1.20 1.10 1.00 0.90 -20 -10 0 10 20 30 50 50 Ambient Temperature T [°C] Maximum load I at Ambient Temperature T:L LI (T) = I K (T) TnLoad Factor K [I/I ]TnInfluence of Ambient Temperature (T) on Load-Carrying Capacity The standard tripping characteristic for Bulletin 1489 is Type C. Type C has a magnetic trip activated at 5…10 times the rated current of thecircuit breaker. The reference temperature for the thermal tripping characteristics is 40° C. The Type C characteristic will suit mostapplications. In rare occurrences when the Type C characteristic does not fully meet the application, the following additional magnetic trip characteristic isavailable:Type D allows for transients approximately twice as high as the standard Type C. Use the following table and graph to determine the current rating for the breaker if the ambient is significantly different than 40°C.Device MarkedCurrent Rating in (A) @ 40° C In (A) at higher Ambient Temperature 15° C 20° C 25° C 30° C 40° C 50° C 55° C 0.5 0.6 0.5 0.5 0.5 0.5 0.5 0.5 1.0 1.1 1.1 1.1 1.0 1 1.0 0.9 1.5 1.7 1.6 1.6 1.6 1.5 1.4 1.4 2.0 2.2 2.2 2.1 2.1 2 1.9 1.9 3.0 3.3 3.2 3.2 3.1 3 2.9 2.8 4.0 4.4 4.3 4.2 4.2 4 3.8 3.8 5.0 5.5 5.4 5.3 5.2 5 4.8 4.7 6.0 6.6 6.5 6.4 6.2 6 5.8 5.6 7.0 7.7 7.6 7.4 7.3 7 6.7 6.6 8.0 8.8 8.6 8.5 8.3 8 7.7 7.5 10.0 11.0 10.8 10.6 10.4 10 9.6 9.4 13.0 14.3 14.0 13.8 13.5 13 12.5 12.2 15.0 16.5 16.2 15.9 15.6 15 14.4 14.1 16.0 17.6 17.3 17.0 16.6 16 15.4 15.0 20.0 22.0 21.6 21.2 20.8 20 19.2 18.8 25.0 27.5 27.0 26.5 26.0 25 24.0 23.5 30.0 33.0 32.4 31.8 31.2 30 28.8 28.2 32.0 35.2 34.6 33.9 33.3 32 30.7 30.1 40.0 44.0 43.2 42.4 41.6 40 38.4 37.6 Note:The table shows the corrected values of the rated current dependent on the ambient temperature. 1489-SG001A.qxd 10/11/2005 3:32 PM Page 5 Bulletin 1489Circuit Breakers 6 Visit our website: www.ab.com/catalogs Time Current Curve – 1-, 2-, and 3-Pole Circuit BreakerTime-Current Characteristic Bulletin 1489Type C and DAmbient Temperature 40°C C D 3 acc. to UL 489 tripping characteristic type D: 10 I : t > 0.1 s type C: 5 I : t > 0.1 s conventional tripping current conventional non-tripping current 20 I : t < 0.1 s 10 I : t < 0.1 s 2.0 I : t = 12- 120 s (T=25°C) I = 1.35 I : t < 1 h (T=25°C) I = 1.0 I (T=40°C) 3 N 6 4 N N N N nt t 2 1 N N 2 1 3 4 5 4 5 instantaneous tripping acc. to IEC 60898-1 1 2345678910 15 20 30 40 50 0.001 0.002 0.01 0.005 0.02 0.05 0.1 0.2 0.5 1 2 5 10 30 60 120 300 600 1200 36007200 I / I Nt [sec]0.0005 1489-SG001A.qxd 10/11/2005 3:32 PM Page 6 Bulletin 1489Circuit Breakers 7Visit our website: www.ab.com/catalogs Catalog Number ExplanationBulletin 1489 Cat. No. ExplanationExamples given in this section are for reference purposes. This basic explanation should not be used for product selection; not allcombinations will produce a valid catalog number.bPolesCode Description1 1-Pole 2 2-Pole 3 3-Pole cTrip CurveCode Trip Curve C Trip Curve C D Trip Curve D e Factory Modifications Code Description (empty) Standard Terminal R Ring Terminal (Check for availability) aBody StyleCode Description A Standard configuration, 10 000 A interrupting 1489 -A 1 C 005 Rabcde dRated Current (In)Code Voltage (V) 005 0.5 010 1 015 1.5 020 2 030 3 040 4 050 5 060 6 070 7 080 8 100 10 130 13 150 15 160 16 200 20 250 25 300 30 320 32 350 35 400 40 1489-SG001A.qxd 10/11/2005 3:32 PM Page 7 Bulletin 1489Circuit Breakers 8 Visit our website: www.ab.com/catalogs Product SelectionBulletin 1489 1-Pole Miniature Circuit Breakers Standard WireConfiguration Cat. No.1489-A1C0051489-A1C0101489-A1C0151489-A1C0201489-A1C0301489-A1C0401489-A1C0501489-A1C060 1489-A1C070 1489-A1C080 1489-A1C100 1489-A1C130 1489-A1C150 1489-A1C160 1489-A1C200 1489-A1C250 1489-A1C300 1489-A1C320 1489-A1C350 1489-A1C400 1489-A1D005 1489-A1D010 1489-A1D015 1489-A1D020 1489-A1D030 1489-A1D040 1489-A1D050 1489-A1D060 1489-A1D070 1489-A1D080 1489-A1D100 1489-A1D130 1489-A1D150 1489-A1D160 1489-A1D200 1489-A1D250 1489-A1D300 1489-A1D320 1489-A1D350 1489-A1D400 Ring TerminalConfiguration Cat. No.1489-A1C005R1489-A1C010R1489-A1C015R1489-A1C020R1489-A1C030R1489-A1C040R1489-A1C050R1489-A1C060R 1489-A1C070R 1489-A1C080R 1489-A1C100R 1489-A1C130R 1489-A1C150R 1489-A1C160R 1489-A1C200R 1489-A1C250R 1489-A1C300R 1489-A1C320R 1489-A1C350R 1489-A1C400R 1489-A1D005R 1489-A1D010R 1489-A1D015R 1489-A1D020R 1489-A1D030R 1489-A1D040R 1489-A1D050R 1489-A1D060R 1489-A1D070R 1489-A1D080R 1489-A1D100R 1489-A1D130R 1489-A1D150R 1489-A1D160R 1489-A1D200R 1489-A1D250R 1489-A1D300R 1489-A1D320R 1489-A1D350R 1489-A1D400R No. of Poles IEC Maximum Voltage V AC Trip Curve UL/CSA Max. Volt. Rated Current 1 415 C 480Y/277 0.511.523456 7 8 10 13 15 16 20 240 25 30 32 35 40 D 480Y/277 0.5 1 1.5 2 3 4 5 6 7 8 10 13 15 16 20 240 25 30 32 35 40 1489-SG001A.qxd 10/11/2005 3:32 PM Page 8 Bulletin 1489Circuit Breakers 9Visit our website: www.ab.com/catalogs Product Selection, ContinuedBulletin 1489 2-Pole Miniature Circuit BreakersNo. of Poles IEC Maximum VoltageV AC Trip Class UL/CSA Max. Volt. Rated Current Standard Wire TerminalCat. No.Ring Terminal ConfigurationCat. No. 2 415 C 480Y/277 0.5 1489-A2C005 1489-A2C005R11489-A2C010 1489-A2C010R1.5 1489-A2C015 1489-A2C015R21489-A2C020 1489-A2C020R31489-A2C030 1489-A2C030R41489-A2C040 1489-A2C040R51489-A2C050 1489-A2C050R61489-A2C060 1489-A2C060R 7 1489-A2C070 1489-A2C070R 8 1489-A2C080 1489-A2C080R 10 1489-A2C100 1489-A2C100R 13 1489-A2C130 1489-A2C130R 15 1489-A2C150 1489-A2C150R 16 1489-A2C160 1489-A2C160R 20 1489-A2C200 1489-A2C200R 240 25 1489-A2C250 1489-A2C250R 30 1489-A2C300 1489-A2C300R 32 1489-A2C320 1489-A2C320R 35 1489-A2C350 1489-A2C350R 40 1489-A2C400 1489-A2C400R D 480Y/277 0.5 1489-A2D005 1489-A2D005R 1 1489-A2D010 1489-A2D010R 1.5 1489-A2D015 1489-A2D015R 2 1489-A2D020 1489-A2D020R 3 1489-A2D030 1489-A2D030R 4 1489-A2D040 1489-A2D040R 5 1489-A2D050 1489-A2D050R 6 1489-A2D060 1489-A2D060R 7 1489-A2D070 1489-A2D070R 8 1489-A2D080 1489-A2D080R 10 1489-A2D100 1489-A2D100R 13 1489-A2D130 1489-A2D130R 15 1489-A2D150 1489-A2D150R 16 1489-A2D160 1489-A2D160R 20 1489-A2D200 1489-A2D200R 240 25 1489-A2D250 1489-A2D250R 30 1489-A2D300 1489-A2D300R 32 1489-A2D320 1489-A2D320R 35 1489-A2D350 1489-A2D350R 40 1489-A2D400 1489-A2D400R 1489-SG001A.qxd 10/11/2005 3:32 PM Page 9 Bulletin 1489 3-Pole Miniature Circuit BreakersBulletin 1489Circuit Breakers 10 Visit our website: www.ab.com/catalogs Product Selection, ContinuedNo. of Poles IEC Maximum VoltageV AC Trip Class UL/CSA Max. Volt. Rated Current Standard Wire TerminalCat. No.Ring TerminalConfigurations Cat. No. 3 415 C 480Y/277 0.5 1489-A3C005 1489-A3C005R11489-A3C010 1489-A3C010R1.5 1489-A3C015 1489-A3C015R21489-A3C020 1489-A3C020R31489-A3C030 1489-A3C030R41489-A3C040 1489-A3C040R51489-A3C050 1489-A3C050R61489-A3C060 1489-A3C060R 7 1489-A3C070 1489-A3C070R 8 1489-A3C080 1489-A3C080R 10 1489-A3C100 1489-A3C100R 13 1489-A3C130 1489-A3C130R 15 1489-A3C150 1489-A3C150R 16 1489-A3C160 1489-A3C160R 20 1489-A3C200 1489-A3C200R 240 25 1489-A3C250 1489-A3C250R 30 1489-A3C300 1489-A3C300R 32 1489-A3C320 1489-A3C320R 35 1489-A3C350 1489-A3C350R 40 1489-A3C400 1489-A3C400R D 480Y/277 0.5 1489-A3D005 1489-A3D005R 1 1489-A3D010 1489-A3D010R 1.5 1489-A3D015 1489-A3D015R 2 1489-A3D020 1489-A3D020R 3 1489-A3D030 1489-A3D030R 4 1489-A3D040 1489-A3D040R 5 1489-A3D050 1489-A3D050R 6 1489-A3D060 1489-A3D060R 7 1489-A3D070 1489-A3D070R 8 1489-A3D080 1489-A3D080R 10 1489-A3D100 1489-A3D100R 13 1489-A3D130 1489-A3D130R 15 1489-A3D150 1489-A3D150R 16 1489-A3D160 1489-A3D160R 20 1489-A3D200 1489-A3D200R 240 25 1489-A3D250 1489-A3D250R 30 1489-A3D300 1489-A3D300R 32 1489-A3D320 1489-A3D320R 35 1489-A3D350 1489-A3D350R 40 1489-A3D400 1489-A3D400R 1489-SG001A.qxd 10/11/2005 3:32 PM Page 10 Bulletin 1489Circuit Breakers 11Visit our website: www.ab.com/catalogs Accessories/Specifications Specifications Number of Poles 1, 2, and 3 Standards UL 489 CSA 22.2 No. 5.1 IEC 60 947-2 Certifications UL Listed Circuit Breaker (File Number E197878) CSA Certified, VDE Approved MCB, CE HACR Rating (USA/Canada) Yes SWD Rating (USA/Canada) Yes (0.5...20 A) Calibration Temperature 40°C Rated Interrupting Capacity UL/CSA: 10 000 AIC IEC - Icu: 10 000 A Rated Tripping Current UL/CSA: 0.5...20 A, 480Y/277V AC 0.5...40 A, 240V AC IEC: 0.5...40 A, 415V AC Degree of Protection Finger-safe from front: -IP20 per IEC 529 from front -IP00 at wire terminals Normal Operating Environment -25…55°C (23...104°F) (non-condensing) Trip Curves C curve (Inductive) 5...10 IN D curve (Highly Inductive) 10...20 IN Shipment and Short-Term Storage Limits -40...85°C (-40...185°F) Wire Size 1 wire: #18...6 AWG 2 wire: #18...10 AWG Terminal Torque #18...12 AWG: 21 lb-in. #10...8 AWG: 25 lb-in. #6 AWG: 36 lb-in. Recommended Wire Strip Length 0.5 in. Description CSA/UL Certifications IEC 60 947-2Compliance CE IEC Max. Volt. UL/CSA Max. Volt. Connection Cat. No.Auxillary Contact, 2sets, each are FormC, 1 NO & 1 NC Yes Yes Yes 250V AC 240V AC9 Cable 1489-AAHH3Auxillary/SignalContact, each areForm C, 1 NO & 1NC Yes Yes Yes 250V AC 240V AC9 Cable 1489-AAHS3Shunt Trip Module Yes Yes Yes 110...415V AC 110...415V AC Cable 1489-AASTA1Shunt Trip Module Yes Yes Yes 12...110V AC 12...110V AC Cable 1489-AASTA2 9 Use of auxilliary or signal contact limits the circuit breaker to a maximum voltage of 240V AC for UL/CSA applications. Miniature Circuit Breaker Accessories1489-SG001A.qxd 10/11/2005 3:32 PM Page 11 Bulletin 1489 Circuit Breaker Approximate DimensionsBulletin 1489Circuit Breakers 12 Visit our website: www.ab.com/catalogs Approximate Dimensions 1492-A1C005 1492-A2C005 1492-A3C005 Note: Dimensions are in millimeters (mm). Note:Dimensions are not intended for manufacturing purposes.1489-SG001A.qxd 10/11/2005 3:32 PM Page 12 Bulletin 1489Circuit Breakers 13Visit our website: www.ab.com/catalogs Notes1489-SG001A.qxd 10/11/2005 3:32 PM Page 13 Bulletin 1489Circuit Breakers 14 Visit our website: www.ab.com/catalogs Notes1489-SG001A.qxd 10/11/2005 3:32 PM Page 14 Publication 1489-SG001A-EN-P – October 2005 Copyright ©2005 Rockwell Automation, Inc. All Rights Reserved. Printed in USA. Kulka®600A GP Series 300 Volts 76 Double Row Terminal Blocks Single/Double Row Terminal BlocksSpecifications: •Base, Phenolic, 150° C •3/8” Centers •JJ (GDI-30F) Material Available •Wire Range With Wire Binding Screw •Open Back Design (Insulator Strip Required for #12-#22 AWG – 15 Amps for Voltage Rating)•UL Recognized File No. E47811 •Screws, #6-32 Binder Head, Phil-Slot •CSA Certified File No. LR19766 •Te r minals, Plated Brass • •1-22 Poles •The Suitability Of These Devices For Greater Currents Shall Be Determined In The End-Use Application Hardware Options: (Hardware options may affect ratings - consult factory) KT 19 = Full Quick Connect (0° flat) See Page 88 KT 20 = Full Quick Connect (45° Bend) See Page 88 KT 21 = Full Quick Connect (90° Bend) See Page 88 ST = Full Solder See Page 89 LL(J 600) = Line to Line Jumper See Page 91 3/4 ST = Half Solder See Page 89 KT 25 = Half Quick Connect (0° Flat) See Page 88 KT 26 = Half Quick Connect (45° Bend) See Page 88 KT 27 = Half Quick Connect (90° Bend) See Page 88 3865 = Wire Clamp Screw See Page 91 Y = Feed Thru Solder (.312) YSY = Feed Thru Solder (.500) Z=Lug Over the Side (.625) 2002 = Stud See Page 93 600A GP 01 1 1.03 0.75 600A GP 02 2 1.41 1.13 600A GP 03 3 1.78 1.50 600A GP 04 4 2.16 1.88 600A GP 05 5 2.53 2.25 600A GP 06 6 2.91 2.63 600A GP 07 7 3.28 3.00 600A GP 08 8 3.66 3.38 600A GP 09 9 4.03 3.75 600A GP 10 10 4.41 4.13 600A GP 11 11 4.78 4.50 Catalog # # of poles A B Dimensions 600A GP 12 12 5.16 4.88 600A GP 13 13 5.53 5.25 600A GP 14 14 5.91 5.63 600A GP 15 15 6.28 6.00 600A GP 16 16 6.66 6.38 600A GP 17 17 7.03 6.75 600A GP 18 18 7.41 7.13 600A GP 19 19 7.78 7.50 600A GP 20 20 8.16 7.88 600A GP 21 21 8.53 8.25 600A GP 22 22 8.91 8.63 Catalog # # of poles A B Dimensions Top Mounted Hardware is .187” Wide MM = Dim X 25.4 Catalog # # of poles A B Dimensions Catalog # # of poles A B Dimensions MULTILIN GE Power Management 1 EB-25/26/27 Terminal Blocks APPLICATION The EB-25, -26, and -27 line of terminal blocks are used where any permanent or temporary wiring connections are required especially if many wires are involved. DESCRIPTION The EB-25, -26, and -27 terminal blocks are molded one piece design available in 4, 6, and 12 points. They are furnished with washer-less head binding screws (#10-32) for circuit wire connections. The blocks are supplied with a black marking strip with white numbers on one side, and white unmarkod on the reverse side for circuit identification. To mount the terminal block, drill for a No. 10 screw. The board will accomodate No. 18 to No. 10 inclusive wire sizes. The EB-26 is of the same construction and dimensions as the type EB-25, except the claim type connections are furnished for circuit wire connections. The board will accept wire sizes No.18 to No.10 inclusive. The EB-27 terminal block is the same as the type EB-25, except that short circuit strips are supplied in lieu of a marking strip. On the EB-25, EB-26, and EB-27 terminal blocks, the mini- mum spacing between the barrier separation is 11/32 inches. The distance between adjacent connection screws is 5/8 inches. ¥ UL Listed 5171-EB-25 2/25/98 3:03 PM Page 1 PHOENIX CONTACT Inc., USA Page 1 / 7 http://www.phoenixcon.com Apr 30, 2008 Extract from the online catalog UK 6 N Order No.: 3004524 http://eshop.phoenixcontact.de/phoenix/treeViewClick.do?UID=3004524 Universal terminal block with screw connection, cross section: 0.2 - 6 mm², AWG: 24 - 8, width: 8.2 mm, color: gray Commercial data EAN 4017918090821 Pack 50 Pcs. Customs tariff 85369010 Weight/Piece 0.01384 KG Catalog page information Page 278 (CL-2007) Product notes WEEE/RoHS-compliant since: 01/01/2003 http:// www.download.phoenixcontact.com Please note that the data given here has been taken from the online catalog. For comprehensive information and data, please refer to the user documentation. The General Terms and Conditions of Use apply to Internet downloads. Technical data General Number of levels 1 Number of connections 2 Color gray UK 6 N Order No.: 3004524 http://eshop.phoenixcontact.de/phoenix/treeViewClick.do?UID=3004524 PHOENIX CONTACT Inc., USA Page 2 / 7 http://www.phoenixcon.com Apr 30, 2008 Insulating material PA Inflammability class acc. to UL 94 V0 Dimensions Width 8.2 mm Length 42.5 mm Height NS 35/7,5 47 mm Height NS 35/15 54.5 mm Height NS 32 52 mm Technical data Maximum load current 57 A (with 10 mm2 conductor cross section) Rated surge voltage 8 kV Pollution degree 3 Surge voltage category III Insulating material group I Connection in acc. with standard IEC 60947-7-1 Nominal current IN 57 A Nominal voltage UN 800 V Open side panel ja Connection data Conductor cross section solid min.0.2 mm2 Conductor cross section solid max.10 mm2 Conductor cross section stranded min.0.2 mm2 Conductor cross section stranded max.6 mm2 Conductor cross section AWG/kcmil min.24 Conductor cross section AWG/kcmil max 8 Conductor cross section stranded, with ferrule without plastic sleeve min.0.25 mm2 Conductor cross section stranded, with ferrule without plastic sleeve max.6 mm2 Conductor cross section stranded, with ferrule with plastic sleeve min.0.25 mm2 Conductor cross section stranded, with ferrule with plastic sleeve max.6 mm2 2 conductors with same cross section, solid min.0.2 mm2 2 conductors with same cross section, solid max.2.5 mm2 UK 6 N Order No.: 3004524 http://eshop.phoenixcontact.de/phoenix/treeViewClick.do?UID=3004524 PHOENIX CONTACT Inc., USA Page 3 / 7 http://www.phoenixcon.com Apr 30, 2008 2 conductors with same cross section, stranded min.0.2 mm2 2 conductors with same cross section, stranded max.2.5 mm2 2 conductors with same cross section, stranded, TWIN ferrules with plastic sleeve, min.0.5 mm2 2 conductors with same cross section, stranded, TWIN ferrules with plastic sleeve, max.4 mm2 2 conductors with same cross section, stranded, ferrules without plastic sleeve, min.0.25 mm2 2 conductors with same cross section, stranded, ferrules without plastic sleeve, max.1.5 mm2 Cross-section with insertion bridge, solid max.4 mm2 Cross-section with insertion bridge, stranded max.4 mm2 Type of connection Screw connection Stripping length 10 mm Internal cylindrical gage A5 Screw thread M 4 Tightening torque, min 1.5 Nm Tightening torque max 1.8 Nm Certificates / Approvals CSA Nominal voltage UN 600 V Nominal current IN 50 A AWG/kcmil 26-8 CUL Nominal voltage UN 600 V Nominal current IN 50 A AWG/kcmil 26-8 UL Nominal voltage UN 600 V Nominal current IN 50 A UK 6 N Order No.: 3004524 http://eshop.phoenixcontact.de/phoenix/treeViewClick.do?UID=3004524 PHOENIX CONTACT Inc., USA Page 4 / 7 http://www.phoenixcon.com Apr 30, 2008 AWG/kcmil 26-8 Certification ABS, BV, CCA, CSA, CUL, DNV, GL, GOST, KEMA, KR, LR, NK, PRS, RS, UL requested approbations Certification Ex:CUL-EX, FM, GL-EX, IECEx, KEMA-EX, UL-EX Accessories Item Designation Description Assembly 3003224 ATP-UK Separating plate, for visual and electrical separation of terminal groups, width: 1.5 mm, color: Gray 3022218 CLIPFIX 35 Snap-on end bracket, for 35 mm NS 35/7.5 or NS 35/15 mounting rail, can be fitted with Zack strip ZB 8 and ZB 8/27, terminal strip marker KLM 2 and KLM, width: 9.5 mm, color: gray 3003020 D-UK 4/10 Cover, width: 1.8 mm, color: gray 1201442 E/UK End clamp, for supporting the electronic base. If mounted vertically, 2 end clamps are required in each case 1024014 EA 5 Single covers, color: transparent 1024085 EA 5-WS Single covers, for covering one terminal block, with black symbol (lightning flash) snap fit, color: transparent/yellow 1201028 NS 32 AL UNPERF 2000MM G rail 32 mm (NS 32) 1201280 NS 32 CU/120QMM UNPERF 2000MM G-profile DIN rail, deep-drawn, material: Copper, unperforated, height 15 mm, width 32 mm, length 2 m 1201358 NS 32 CU/35QMM UNPERF 2000MM G-profile DIN rail, material: Copper, unperforated, height 15 mm, width 32 mm, length 2 m 1201002 NS 32 PERF 2000MM G-profile DIN rail, material: Steel, perforated, height 15 mm, width 32 mm, length 2 m 1201015 NS 32 UNPERF 2000MM G-profile DIN rail, material: Steel, unperforated, height 15 mm, width 32 mm, length 2 m 0801762 NS 35/ 7,5 CU UNPERF 2000MM DIN rail, material: Copper, unperforated, height 7.5 mm, width 35 mm, length: 2 m 0801733 NS 35/ 7,5 PERF 2000MM DIN rail, material: Steel, perforated, height 7.5 mm, width 35 mm, length: 2 m 0801681 NS 35/ 7,5 UNPERF 2000MM DIN rail, material: Steel, unperforated, height 7.5 mm, width 35 mm, length: 2 m 1201756 NS 35/15 AL UNPERF 2000MM DIN rail, deep-drawn, high profile, unperforated, 1.5 mm thick, material: Aluminum, height 15 mm, width 35 mm, length 2 m 1201895 NS 35/15 CU UNPERF 2000MM DIN rail, material: Copper, unperforated, 1.5 mm thick, height 15 mm, width 35 mm, length: 2 m UK 6 N Order No.: 3004524 http://eshop.phoenixcontact.de/phoenix/treeViewClick.do?UID=3004524 PHOENIX CONTACT Inc., USA Page 5 / 7 http://www.phoenixcon.com Apr 30, 2008 1201730 NS 35/15 PERF 2000MM DIN rail, material: Steel, perforated, height 15 mm, width 35 mm, length: 2 m 1201714 NS 35/15 UNPERF 2000MM DIN rail, material: Steel, unperforated, height 15 mm, width 35 mm, length: 2 m 1201798 NS 35/15-2,3 UNPERF 2000MM DIN rail, material: Steel, unperforated, 2.3 mm thick, height 15 mm, width 35 mm, length: 2 m 1302215 TS-K Separating plate, for electrical separation of neighboring bridges, can be fitted later, no loss of pitch, color: Gray Bridges 0202154 EB 2- 8 Insertion bridge, 2-pos., fully insulated 0202141 EB 3- 8 Insertion bridge, 3-pos., fully insulated 0202138 EB 10- 8 Insertion bridge, 10-pos., divisible, fully insulated 3029224 FB 2- 8-EX Fixed bridge, for cross connections, with screws, screw heads without insulation, 2-pos. 0202167 FB 3- 8 Fixed bridge, for cross connections, with screws, screw heads without insulation, 3-pos. 0202183 FB 4- 8 Fixed bridge, for cross connections, with screws, screw heads without insulation, 4-pos. 0202170 FB 10- 8 Fixed bridge, for cross connections, with screws, screw heads without insulation, 10-pos. 3003185 FB 10- 8-EX Fixed bridge, for cross connections, with screws, screw heads without insulation, 10-pos. 0200020 FBI 2- 8 Fixed bridge, for cross connections, with screws, screw heads without insulation, 2-pos. 0200059 FBI 3- 8 Fixed bridge, for cross connections, with screws, screw heads without insulation, 3-pos. 0200046 FBI 4- 8 Fixed bridge, for cross connections, with screws, screw heads without insulation, 4-pos. 0203263 FBI 10- 8 Fixed bridge, 10-pos., screw heads with insulating collar, divisible, with screws 1303337 IS-K 10 Bridge bar isolator, as distance piece 0301534 ISSBI 10- 8 Isolator bridge bar, 10-position, divisible, with screws, for switchable branches 0200062 SB 2- 8/13 N Switching bridge, 2-pos. Marking 1007235 SBS 8:UNBEDRUCKT Marker cards for modular terminal blocks, color: white 1004128 WS 3- 8 Warning plate, with 2 plastic screws, across 3 terminal blocks, pitch 8 mm 1004212 WS 4- 8 Warning plate, with 2 plastic screws, across 4 terminal blocks, pitch 8 mm UK 6 N Order No.: 3004524 http://eshop.phoenixcontact.de/phoenix/treeViewClick.do?UID=3004524 PHOENIX CONTACT Inc., USA Page 6 / 7 http://www.phoenixcon.com Apr 30, 2008 1004416 WS 5- 8 Warning plate, with 2 plastic screws, across 5 terminal blocks, pitch 8 mm 1050512 ZB 8:SO/CMS Zack strip, 10-section, divisible, special printing, marking according to customer requirements Plug/Adapter 0311540 KSS 8 Short circuit connector, for short circuiting neighboring terminal blocks, can only be used with PSB or PSBJ, 2-pos., pitch: 8.2 mm, color: Black 0311647 PS-MT Test plug, consisting of: metal part for 4 mm diameter socket hole and insulating sleeve for PS metal part 0303299 PSB 4/7/6 Test plug socket, not insulated, length: 7 mm, screw thread width: 4 mm, socket width: 6 mm 0303406 PSBJ 4/15/6 BK Test plug socket, insulated, length: 15 mm, screw thread width: 4 mm, socket width: 6 mm, insulation material in black 0303354 PSBJ 4/15/6 BU Test plug socket, insulated, length: 15 mm, screw thread width: 4 mm, socket width: 6 mm, insulation material in blue 0303419 PSBJ 4/15/6 FARBLOS Test plug socket, insulated, length: 15 mm, screw thread width: 4 mm, socket width: 6 mm, insulation material transparent 0303370 PSBJ 4/15/6 GN Test plug socket, insulated, length: 15 mm, screw thread width: 4 mm, socket width: 6 mm, insulation material in green 0303396 PSBJ 4/15/6 GY Test plug socket, insulated, length: 15 mm, screw thread width: 4 mm, socket width: 6 mm, insulation material in gray 0303325 PSBJ 4/15/6 RD Test plug socket, insulated, length: 15 mm, screw thread width: 4 mm, socket width: 6 mm, insulation material in red 0303383 PSBJ 4/15/6 VT Test plug socket, insulated, length: 15 mm, screw thread width: 4 mm, socket width: 6 mm, insulation material in violet 0303312 PSBJ 4/15/6 WH Test plug socket, insulated, length: 15 mm, screw thread width: 4 mm, socket width: 6 mm, insulation material in white 0303367 PSBJ 4/15/6 YE Test plug socket, insulated, length: 15 mm, screw thread width: 4 mm, socket width: 6 mm, insulation material in yellow UK 6 N Order No.: 3004524 http://eshop.phoenixcontact.de/phoenix/treeViewClick.do?UID=3004524 PHOENIX CONTACT Inc., USA Page 7 / 7 http://www.phoenixcon.com Apr 30, 2008 Address PHOENIX CONTACT Inc., USA 586 Fulling Mill Road Middletown, PA 17057,USA Phone (800) 888-7388 Fax (717) 944-1625 http://www.phoenixcon.com © 2008 Phoenix Contact Technical modifications reserved; Accessories Terminal Blocks P-12 www.idec.com USA: (800) 262-IDEC or (408) 747-0550, Canada: (888) 317-IDEC P Terminal BlocksPart Numbers: End Plates, DIN Rail Stops, Stand-Offs, DIN Rail and Dust Covers Description Appearance Use with Part No.Remarks End Plates BNH10WBNH15MWBNH15LW BNE15W BNH30W BNE30W BNF10SWBNF10NWBNF10DW BNE20 BNH50W BNE50W BN75W BNE75W BN150W BNE150W BNDH15W BNDE15W DIN Rail Stops BNH10WBNH15MWBNH15LWBNH30WBNH50WBNF10SWBNF10NWBNF10DWBA111TBA211TBA311TBA411SBAF111SUBAF111SDU BNL5(small) 1. DIN rail stops prevent side-to-side movement. 2. The BNL-5 width is 0.375" (9.5mm). BN75WBN150W BNL6(medium) 1. DIN rail stops prevent side-to-side movement. 2. The BNL-6 width is 0.375" (9.5mm). 3. To firmly stabilize these higher profile terminal blocks, the BNL-6 has a higher profile than the BNL-5. BNDH15WBN200NW#BN400NW# BNL8(large) 1. DIN rail stops prevent side-to-side movement. 2. The BNL-8 width is 0.571" (14.5mm). 3. # = number of poles. DIN Rail Stand-Offs All series BNS3 1.46" (37mm) height BNS4 3.03" (77mm) height DIN Rail All series BNDN1000(length 39.37" (1m)) 1. For calculating the rail lengths required, see the instructions on page P-18. 2. The DIN rail material is aluminum. Dust Covers BNDH15WBNH10WBNH15MWBNH15LW BNH30W BNC230 The overall length is 39.37" (1,000mm). The material is polycarbonate. BNH50W BNC320 BN75W BNC420 BN150W BNC520 BN200 BAC820 BN400 BNC1000 Accessories BNC230 BNC320 BNC420 BNC520 BNC820 BNC1000 Power Stud Blocks 600 Volts 42Power BlocksLine Openings Load Openings Catalog# Poles Amps Wire Range Per Pole Wire Range Per Pole 1421123 1 1422123 2 200 1/4-20 Screw 1 1/4-20 Screw 1423123 3 1 1421122 1 1422122 2 200 1/4-20 X 9/16 Stud 1 1/4-20 X 9/16 Stud 1 1423122 3 1431563 1 1432563 2 230 3/8-16 X1 3/16 Stud 1 3/8-16 X1 3/16 Stud 1 1433563 3 1431561 1 1432561 2 230 3/8-16 X1 3/16 Stud 1 1/4-20 X1 3/16 Stud 1 1433561 3 1441122 1 1442122 2 260 3/8-16 X1 7/16 Stud 1 1/4-20 X 9/16 Stud 2 1443122 3 1441553 1 1442553 2 230 3/8-16 X1 7/16 Stud 1 3/8-16 X1 7/16 Stud 1 1443553 3 1451606 1 1452606 2 410 1/2-13 X1 7/16 Stud 1 1/2-13 X1 7/16 Stud 1 1453606 3 1451573 1 1452573 2 360 3/8-16 X1 7/16 Stud 1 3/8-16 X1 7/16 Stud 2 1453573 3 1451583 1 1452583 2 360 3/8-16 X1 7/16 Stud 1 1/4-20 X1 7/16 Stud 2 1453583 3 1441614 1 1442614 2 840 3/8-16 X 1 Stud 1 3/8-16 X 1 Stud 1 1443614 3 Specifications: •Connector, High Conductive Copper, Tin Plated •Stud, Brass, Tin Plated •Amp Rating Based on NEC Table 310-16 Using 75° C Copper Wire •UL Recognized File No. E62806 •CSA Certified File No. LR19766 • Connector Configuration Connector Configuration 38-50.power blocks 7/10/03 2:57 PM Page 42 9.32 Data subject to change without notice ☎763 422 2211 FAX 763 422 2600 ©2003 Hoffman Enclosures Inc. Cooling Fan and Exhaust Packages Cooling Fan and Exhaust Packages Finish Fan housing, composite plenum, and grille are RAL 7035 light gray. Stainless steel grilles have brushed finish. ABS composite grille is black. Filters Standard and Hi-Density Type 12 air filters are washable foam. Industry Standards UL 508 Component Recognized, File Number SA61997 CSA certified (fan only) CE Accessories Temperature Control Switch Grille Options: Stainless Steel Grille Black Grille Aluminum and Hi-Density Type 12 Filters EMC Upgrade Kit Installation Fan and exhaust packages can be installed on any surface of an enclosure.They are most effective when the fan assembly is located on a lower panel of the enclosure and the exhaust grille is positioned near the top on the opposite side.This installation assists heat transfer by causing slightly more turbulence and also prolongs the working life of the fan since it is located in the path of the cooler air entering the enclosure. Cooling fans and exhaust grilles can be turned 90° for mounting on narrow enclosures.Allow adequate clearance for servicing the fan when equipment is installed inside the enclosure and for replacing filters on both the fan and the exhaust. Cutout dimensions for both the fan and the exhaust are shown in the order table. The fan and exhaust packages must be ordered separately (see page 2). Application Designed for use in enclosures where space is limited and reliable filtered airflow is required.The Cooling Fan Package is the air inlet of a cooling system. It requires at least one Exhaust Package of the same size and type rating to provide the outlet.Where positive air flow through the enclosure is not required, Exhaust Packages can be used on both the inlet and outlet. Note:Fan and Exhaust Packages must be ordered separately. The Cooling Fan Package is available for both Type 1 and Type 12 enclosures.Type 1 is recommended in UL Type 1 environments where the ambient air is cool and clean.Type 12 is recommended in UL Type 12 environments where the ambient air is cool and may contain small amounts of dust, foreign bodies, and splashing water. For both Type 1 and Type 12 systems a monthly maintenance schedule is recommended to ensure optimal cooling performance. The cooling fan and exhaust packages come with RAL 7035 composite or brushed stainless steel grilles; replacement black ABS composite and brushed stainless steel grilles are available separately. The optional EMC Upgrade Kit prepares the fan and exhaust packages for use where EMC protection is required. Construction • Cooling Fan Package includes fan, air filter, composite air plenum, finger guard, and grille • Exhaust Package includes air filter, filter retainer with integral finger guard, and grille • EMC Upgrade Kit includes a grille standoff collar and a special EMC shielding grille. It can be used with either the Fan or the Exhaust Package • Optional grille, available in both brushed stainless steel and black ABS plastic, can be used with either the fan or exhaust package • Washable foam (Type 1) or disposable (Type 12) filter in both fan and exhaust packages provides good arrestment of airborne dirt with minimal pressure drop. Optional washable aluminum air filter is also available for Type 1 applications. • Durable composite air plenum and grille takes up minimal enclosure space. Plenum permits even airflow through the filter for maximum filtering efficiency. An integral and removable finger guard on either side of the plenum adds safety and convenience. • Air filters can be accessed for cleaning from outside the enclosure • Rigid fan housing eliminates breakage and grounding problems • Dynamically balanced fan impellers molded from polycarbonate material • 4 inch fan is thermally protected and uses permanently lubricated ball bearings • 6 and 10 inch fans have ball bearing construction and split capacitor motors that are thermally protected to avoid premature failure • Engineered for 50,000 hours of continuous operation without lubrication or service • Fans have leadwires for power connection with ends stripped 1/2 inch (12 millimeters) • All mounting hardware and installation instructions are furnished Catalog Fits Fan and Exhaust Number Nominal Size T4EMC 4 in. T6EMC 6 in. T10EMC 10 in. EMC Upgrade Kit With the addition of this kit, the cooling fan and exhaust packages are upgraded to provide EMC (electromagnetic compatibility) protection. Consult Hoffman for shielding effectiveness (dB attenuation vs. frequency). Note:Separate kits must be installed on both the inlet and outlet.Cooling fan and exhaust package must be ordered separately. See Accessories, Chapter 12, for more information. 9.33Data subject to change without notice ☎763 422 2211 FAX 763 422 2600 ©2003 Hoffman Enclosures Inc.Fans, Blowers, Louvers, and VentsCooling Fan and Exhaust Packages9 Bulletin D85 Standard Sizes and Cutout Dimensions Cooling Fan and Exhaust Packages Catalog Number Composite Grille Stainless Grille Composite Grille Nominal UL 508 Type 1 UL 508 Type 1 UL 508 Type 12 Fan A B C F H T W Fan* Exhaust Fan* Exhaust Fan* Exhaust Size in. mm in. mm in. mm in. mm in. mm in. mm in. mm TFP41 TEP4 TFP41SS TEP4SS TFP41UL12 TEP4UL12 4 inch 6.29 160 7.37 187 2.65 67 5.66 144 0.77 20 4.12 105 6.39 162 TFP42 TEP4 TFP42SS TEP4SS TFP42UL12 TEP4UL12 4 inch 6.29 160 7.37 187 2.65 67 5.66 144 0.77 20 4.12 105 6.39 162 TFP61 TEP6 TFP61SS TEP6SS TFP61UL12 TEP6UL12 6 inch 7.80 198 8.87 225 3.75 95 7.16 182 1.33 34 4.50 114 7.89 200 TFP62 TEP6 TFP62SS TEP6SS TFP62UL12 TEP6UL12 6 inch 7.80 198 8.87 225 3.75 95 7.16 182 1.33 34 4.50 114 7.89 200 TFP101 TEP10 TFP101SS TEP10SS TFP101UL12 TEP10UL12 10 inch 11.81 300 12.99 330 5.25 133 11.16 283 2.14 54 6.88 175 11.89 302 TFP102 TEP10 TFP102SS TEP10SS TFP102UL12 TEP10UL12 10 inch 11.81 300 12.99 330 5.25 133 11.16 283 2.14 54 6.88 175 11.89 302 Catalog Number Composite Stainless Composite Maximum Operating Grille Grille *CFM Grille *CFM Watts Amps Temperature Noise Weight UL Type 1 UL Type 1 50/60Hz UL Type 12 50/60 Hz 50/60 Hz Voltage Hz 50/60 Hz °F (°C) SIL (dB) lb (kg) TFP41 TFP41SS 46/55 TFP41UL12 21/25 17/15 115 50/60 .26/.21 156 (70) 37/41 4.2 (1.90) TFP42 TFP42SS 46/55 TFP42UL12 21/25 16/14 230 50/60 .14/.11 158 (70) 37/41 4.3 (1.95) TFP61 TFP61SS 117/140 TFP61UL12 50/60 36/32 115 50/60 .45/.36 158 (70) 50/56 5.3 (2.40) TFP62 TFP62SS 117/140 TFP62UL12 50/60 39/35 230 50/60 .23/.18 158 (70) 50/56 5.4 (2.45) TFP101 TFP101SS 180/215 TFP101UL12 63/75 64/80 115 50/60 .58/.70 167 (75) 54/61 12.0 (5.45) TFP102 TFP102SS 180/215 TFP102UL12 63/75 64/80 230 50/60 .29/.35 167 (75) 54/61 11.4 (5.17) * An intake grille and filter are included with each Cooling Fan Package.At least one Exhaust Package is normally required for each installation. Must be ordered separately. Optional grilles and replacement filters are also available. Technical Performance Data for Cooling Fan Packages * CFM with single exhaust grille installed. ■Performance Curve for a 4" Cooling Fan Package @ 60 Hz ■Performance Curve for a 6" Cooling Fan Package @ 60 Hz ■Performance Curve for a 10" Cooling Fan Package @ 60 Hz Static Pressure Inches of WaterAirflow (CFM)Static Pressure Inches of WaterAirflow (CFM)Static Pressure Inches of WaterAirflow (CFM) 4" Fan (Fan Mounted to Back of Plenum) 6" and 10" Fan (Box Style Plenum) Fan and Exhaust Grille Fan and Exhaust Package Mounting Cutout Rev.A September 2003 Section 19 (This Page Intentionally Left Blank) Power Outlets by Phoenix Contact Auxiliary Dual Utility Outlet EM-DUO/120/15/GFI/AUX Order No: 56 00 63 9 Features • DIN-rail mount dual utility outlet • Vertical mounting • Fits on 35 mm wide DIN-rail • Ground fault protection circuit • Auxiliary ground fault protected connections Description The EM-DUO 120/15/GFI/AUX is a fully enclosed DIN-rail mounted utility outlet that offers two 120 V/15 A receptacles with GFCI (Ground Fault Circuit Interruption). A special feature of this dual outlet is the addition of auxiliary GFCI connections. This feature adds versatility and safety by allowing additional GFCI protected, 120 V powered items to be connected downstream of the GFCI and still be protected. The dual outlet is packaged in a touch safe enclosure to eliminate the possibility of shock caused by accidental contact with live connections. The innovative spring clip mounting bracket on the EM-DUO saves assembly time and space by allowing easy vertical installation. VDFK 4 self-locking screw terminal blocks provide reliable input power connections. This utility outlet can be used for connecting test equipment, diagnostic equipment, power tools, soldering irons, displays, lighting, fans or anything that needs a 120 V power source. This part is manufactured in the United States and is a stock item in Harrisburg as well as at our stocking distributor locations. The device is UL listed under file #E123528. ©2007 PHOENIX CONTACT Phone:(800) 888-7388 Email: info@phoenixcon.com Page 1 of 1PHOENIX CONTACT | Products | Interface Products | EM-DUO 12/6/2007http://www.phoenixcon.com/products/interface/em-duo/moreinfo.asp?partnumber=5600639 (This Page Intentionally Left Blank) © by SEMIKRON B 11 – 310895 Power Bridge Rectifiers SKB 30 SKD 30 SKB SKD Features ·Isolated metal case with screw terminals ·Blocking voltage to 1600 V ·High surge currents ·SKB = single phase bridge rectifier SKD = three phase bridge rectifier ·Easy chassis mounting ·UL recognized, file no. E 63 532 Typical Applications ·Single and three phase rectifiers for power supplies ·Input rectifiers for variable frequency drives ·Rectifiers for DC motor field supplies ·Battery charger rectifiers VRSM ID (Tcase = . . .) VRRM 30 A (94 °C) 30 A (98 °C) Types Rmin Types Rmin V WW 200 SKB 30/02 A1 0,15 SKD 30/02 A1 0,15 400 SKB 30/04 A1 0,3 SKD 30/04 A1 0,3 800 SKB 30/08 A1 0,5 SKD 30/08 A1 0,5 1200 SKB 30/12 A1 0,75 SKD 30/12 A1 0,75 1400 SKB 30/14 A1 0,9 SKD 30/14 A1 0,9 1600 SKB 30/16 A1 1 SKD 30/16 A1 1 Symbol Conditions SKB 30 SKD 30 Units ID Tamb = 45 °C;isolated1)6,5 6,5 A chassis2)15 15 A P5A/100 21 21 A R4A/120 23 23 A P1A/120 29 31 A Tamb = 35 °C;P1A/120 F 38 A IDCL Tamb = 45 °C;isolated1) 66,5A chassis2)13 15 A P5A/100 17 21 A P1A/120 24 31 A Tamb = 35 °C;P1A/120 F 32 A IFSM Tvj = 25 °C, 10 ms 370 A Tvj = 150 °C, 10 ms 320 A i2tTvj = 25 °C, 8,3...10 ms 680 A 2s Tvj = 150 °C, 8,3...10 ms 500 A 2s VF Tvj = 25 °C; IF = 150 A 2,2 V V(TO)Tvj = 150 °C0,85V rT Tvj = 150 °C12mW IRD Tvj = 25 °C; VRD = VRRM 0,3 mA Tvj = 150 °C; VRD = VRRM 5mA trr Tvj = 25 °C typ. 25 ms fG 2000 Hz Rthjc total 0,7 °C/W Rthch total 0,1 °C/W Rthja isolated1)8,5 °C/W chassis2)3,3 °C/W P5A/100 2,2 °C/W P1A/120 1,4 °C/W Tvj – 40...+ 150 °C Tstg – 55...+ 150 °C Visol a.c. 50...60 Hz; r.m.s.; 1 s / 1 min 3000 / 2500 V~ RC PR = 1 W 50 W 0,1 mF Fu 25 A M1 to heatsink SI units 5 ± 15 % Nm US units 44 ± 15 % lb. in. M2 to terminals SI units 1,5 ± 15 % Nm US units 13 ± 15 % lb.in. w125g Case G 12 G 13 1) Freely suspended or mounted on an insulator 2) Mounted on a painted metal sheet of min. 250 x 250 x 1 mm © by SEMIKRONB 11 – 32 © by SEMIKRON B 11 – 330896 © by SEMIKRONB 11 – 34 W A T L O W 241 Strip HeatersWelded 10-24 Threaded Post Terminals Strip Heaters375 Strip Aptly named for its 0.375 inch (9.5 mm) thickness, the Watlow 375 strip is a rugged heater capableof both high temperatures and high watt densities. Its ruggedness comes from thedesign and use of choice materials.Watlow begins construction byaccurately placing a coiled, nickel-chrome element wire in the center of the heater. The element wire is then embedded in MgO-basedinsulation ... compacted into a solidmass that results in excellent heatconductivity and high dielectricstrength. Finally, the heater isenclosed in aluminized steel sheathing. Performance Capabilities• Aluminized steel sheath temperatures to 1100°F (595°C) • Stainless steel sheath temperatures to 1200°F (650°C) • Watt densities to 130 W/in 2 (20.2 W/cm2) •UL®approved to 240VÅ(ac) (File No. E52951) • CSA approved to 600VÅ(ac) (File No. LR7392) Features and Benefits •Nickel-chrome element wire is centered in the heater to uniformly heat the strip. •Aluminized steel sheath operates at higher temperatures and resists corrosion better than iron-sheathed heaters. •Optional 430 stainless steel sheath is available for applica- tions where temperatures reach 1200°F (650°C). •Post terminals, welded to the element wire, produce strong, trouble-free connections. •Rigid 3⁄8 inch (9.5 mm) thick design enables the 375 strip heater to fit into many existing applications. •Available dimensions are 11⁄2 inches (38 mm) wide, and 51⁄2 (140 mm) to 48 inches (1220 mm) long. •Next day shipment is available on106 in-stock models in popular sizes and ratings. Applications • Food warming • Freeze and moisture protection • Tank and platen heating • Packaging • Dies and mold heating • Autoclaves • Ovens Aluminized Steel Sheath Mineral Insulation Nickel Chromium Resistance Wire Mounting Slots • Next day shipment on all stock units. UL®is a registered trademark of Underwriter’s Laboratories, Inc. 375 Strip 11/28/00 8:16 AM Page 241 242 Strip Heaters375 StripApplications and Technical DataCalculating Watt DensityUse the Maximum Allowable WattDensitygraphs and formulas toensure that the allowable watt density for the heater will not beexceeded in your application. Watt density is calculated for oneside of the heater only.Watt Density =Heated Area (Offset Terminals) = [Overall Length (A) x 1.5 in] - 6 in2= [Overall Length (A) x 38.1 mm] - 38.7 cm2Heated Area (Parallel Terminals) = [Overall Length (A) x 1.5 in] - 4.7 in2= [Overall Length (A) x 38.1 mm] - 30.3 cm2Heated Area (One-on-One Terminals) = [Overall Length (A) x 1.5 in] - 6.4 in2= [Overall Length (A) x 38.1 mm] - 41.3 cm2Formulas:WattageHeated AreaMaximum Allowable Watt Density Clamped 1200 1000 800 600 400 200 600 Sheath Temperature—°F20 40 60 80 100 Watt Density—W/in2 Sheath Temperature—°C500 400 300 200 100 246810 Watt Density—W/cm2 Sheath Temperature (Aluminized Steel) 70°F (21°C) ambient operating in still air Sheath Temperature (Stainless Steel) Maximum Allowable Watt Density in Air 1200 1000 800 600 400 200 600 Part Temperature—°F20 40 60 80 100 Watt Density—W/in2 Part Temperature—°C500 400 300 200 100 375 Strip < 24" O.A.L.; bar clamped,operating in 70°F (21°C) ambient air 375 Strip < 24" O.A.L.; bar clamped operating in insulated or enclosed environments 2 4 6 8 10 12Watt Density—W/cm2 Units 24" and longer Consult Factory 375 Strip 11/28/00 8:16 AM Page 242 W A T L O W 243 Strip HeatersParallel Terminals*Two 10-24 threaded post terminalsare used; both terminals on one end.Strip Heaters375 StripTermination Options 1 1/4"(31.8 mm)Typ.5/16" x 1/2" (7.9 x 12.7 mm)Mounting Slots11/2"(38.1 mm)A 1/2"(12.7 mm)10-24 Threaded Terminals 7/8"(22.2 mm)3/8"(9.5 mm)2 3/4"(69.9 mm)1.18"(30 mm)7/8"(22.2 mm)Heated Length11/2"(38.1 mm)3/4"(19.1 mm)3/8"(9.5 mm)10-24 Threaded TerminalsA 1 7/8" (47.6 mm) 7/8"(22.2 mm)1/2"(12.7 mm)5/16" x 1/2" (7.9 x 12.7 mm)Mounting Slots11/2"(38.1 mm)3/8"(9.5 mm)1.18"(30 mm)11/2"(38.1 mm)3/4"(19.1 mm) Heated Length 1 1/4" (31.8 mm) Typ. 3/8"(9.5 mm) 10-24 Threaded Terminals A 3/8" (9.5 mm)1/2" (12.7 mm) 5/16" x 1/2" (7.9 x 12.7 mm) Mounting Slots11/2" (38.1 mm) 1/2" (12.7 mm) 7/8" (22.2 mm) 0.950" (24.1 mm) Heated Length 1.18" (30 mm) 11/2" (38.1 mm) C B 3/8" (9.5 mm) Offset Terminals*Two 10-24 threaded post terminalsare offset from each other on thesame end. One-on-One Terminals* Two 10-24 threaded post terminals are placed one on each end. * Tab removal available fromstock or manufactured. 1 1/4" (31.8 mm) Typ. 5/16" x 1/2" (7.9 x 12.7 mm) Mounting Slots 11/2" (38.1 mm) A 1/2" (12.7 mm) 10-24 Threaded Terminals 7/8" (22.2 mm) 3/8" (9.5 mm) 2 3/4" (69.9 mm) 1.18" (30 mm) 7/8" (22.2 mm) Heated Length 11/2" (38.1 mm) 3/8" (9.5 mm) 3/4" (19.0 mm) In-Line Terminals* Two 10-24 threaded post terminals are in-line with each other on the same end. 375 Strip 11/28/00 8:16 AM Page 243 How to Order To order your stock 375 strip heater, specify: •Quantity •Watlow code number •Removal of mounting tabs, if desired If stock units do not meet application needs, Watlow can manufacture 375 strip heaters to special requirements. For made-to-order units, please specify, in addition to above information: •Width •Heater length, including mounting tabs •Terminal type (offset, parallel or one-on-one) Availability Stock:Next day shipment Made-to-Order:Please consult your Watlow sales engineer or authorized distributor. Note:5⁄16 inch (7.9 mm) x 1⁄2 inch (12.7 mm) mounting slots are supplied on all 375 strip heaters. Tabs can be removed upon request. Also, note Watlow code number specifies that the 375 strip heater comes with an aluminized steel sheath. If you require a special sheath material, such as stainless steel, please consult your sales engineer or authorized distributor for material availability. ➀Chromalox®and Wellman®part numbers are used as a cross reference to help you select the equivalent Watlow code number. Chromalox®sizes 27 inches and longer, and all Wellman®sizes, will have mounting slot center to center distances 1⁄8 inch less than Watlow spacing. 244 Strip Heaters375 StripTermination OptionsContinued 2"21/2"21/2"2"2"11/2"Variations Metallic Terminal BoxesAvailable in in-line terminals only.Metallic terminal boxes are availableon offset terminals from stock.Terminal boxes act as a safety feature by covering the terminals.Ceramic Terminal Covers A convenient and economic way to insulate post terminals. Sized for standard length posts. 10-24 screw thread size. These are supplied as an accessory item and shipped separately. Specify Z-4918 and quantity. Conduit may be attached to the boxthrough 7⁄8 inch (22 mm) diameterholes in the ends of the box. Toorder, specify terminal box.Available on offset terminals from stock and manufactured.Accessories375 Strip 11/28/00 8:16 AM Page 244 W A T L O W 245 Strip HeatersF.O.B.: St. Louis, MissouriStrip Heaters375 Strip CONTINUED Width Length Term. Volts Power Watt Approx. Avail. Code No. Chromolox®Code No.➀Wellman®Code No.➀in (mm) in (mm) (Watts)Density Net Wt. Rust Resist. Chrome Stl. Aluminized Chrome Stl.W/in2 (W/cm2) lbs (kg)Iron Sheath Sheath Steel Sheath Sheath Wellman®is a registered tradename of Wellman Thermal Systems Corp. Chromolox®is a registered tradename of Chromolox Industrial Heaters Products. 11⁄2 (38.1) 51⁄2 (139.7) Parallel 120 125 35 (5.4) 0.4 (0.18) Stk SGA1J5JP1 PT-512 —— —51⁄2 (139.7) Parallel 120 250 70 (10.8) 0.4 (0.18) Stk SGA1J5JP2 —PT-502 ——61⁄2 (153.0) Parallel 120 150 35 (5.4) 0.4 (0.18) Stk SGA1J6AP2 PT-615 —— —61⁄2 (153.0) Parallel 240 150 35 (5.4) 0.4 (0.18) Stk SGA1J6AP3 PT-615 —— —61⁄2 (153.0) Parallel 120 300 70 (10.8) 0.4 (0.18) Stk SGA1J6AP4 —PT-603 ——61⁄2 (153.0) Parallel 240 300 70 (10.8) 0.4 (0.18) Stk SGA1J6AP5 —PT-603 ——71⁄2 (190.5) Offset 120 150 29 (4.5) 0.5 (0.23) Stk SGA1J7J01 OT-715 —SS1041 —71⁄2 (190.5) Offset 240 150 29 (4.5) 0.5 (0.23) Stk SGA1J7J02 OT-715 —SS1052 —71⁄2 (190.5) Offset 240 200 38 (5.9) 0.5 (0.23) Stk SGA1J7J03 —OT-702 —SS205281⁄2 (203.2) Offset 120 150 25 (3.9) 0.5 (0.23) Stk SGA1J8A01 OT-815 —SS1061 —81⁄2 (203.2) Offset 240 150 25 (3.9) 0.5 (0.23) Stk SGA1J8A05 OT-815 —SS1072 —81⁄2 (203.2) Offset 120 175 29 (4.5) 0.5 (0.23) Stk SGA1J8A06 OT-817 —SS1081 —81⁄2 (203.2) Offset 240 175 29 (4.5) 0.5 (0.23) Stk SGA1J8A07 OT-817 —SS1092 —81⁄2 (203.2) Offset 120 250 42 (6.5) 0.5 (0.23) Stk SGA1J8A02 —OT-802 —SS206181⁄2 (203.2) Offset 240 250 42 (6.5) 0.5 (0.23) Stk SGA1J8A08 —OT-802 —SS207281⁄2 (203.2) Offset 120 400 67 (10.4) 0.5 (0.23) Stk SGA1J8A09 —OT-804 —SS208181⁄2 (203.2) Offset 240 400 67 (10.4) 0.5 (0.23) Stk SGA1J8A010 —OT-804 —SS209281⁄2 (203.2) Offset 120 500 83 (12.9) 0.5 (0.23) Stk SGA1J8A03 ——— —81⁄2 (203.2) Offset 240 500 83 (12.9) 0.5 (0.23) Stk SGA1J8A04 ——— —81⁄2 (203.2) 1-on-1 120 150 24 (3.7) 0.5 (0.23) Stk SGA1J8AT1 S-815 —SD1021 —81⁄2 (203.2) 1-on-1 240 150 24 (3.7) 0.5 (0.23) Stk SGA1J8AT2 S-815 —SD1032 —91⁄2 (241.3) 1-on-1 120 200 23 (3.6) 0.6 (0.27) Stk SGA1J9JT1 S-920 —SD1041 — 101⁄2 (266.7) Offset 120 250 26 (4.0) 0.7 (0.32) Stk SGA1J10J01 OT-1025 —SS1101 — 101⁄2 (266.7) Offset 240 250 26 (4.0) 0.7 (0.32) Stk SGA1J10J02 OT-1025 —SS1102 — 101⁄2 (266.7) Offset 120 350 36 (5.6) 0.7 (0.32) Stk SGA1J10J08 —OT-1003 —SS2101 101⁄2 (266.7) Offset 240 350 36 (5.6) 0.7 (0.32) Stk SGA1J10J05 —OT-1003 —SS2112 101⁄2 (266.7) Offset 120 400 41 (6.4) 0.7 (0.32) Stk SGA1J10J06 —OT-1004 —SS2131 101⁄2 (266.7) Offset 240 400 41 (6.4) 0.7 (0.32) Stk SGA1J10J07 —OT-1004 —SS2132 121⁄2 (304.8) Offset 120 250 21 (3.3) 0.8 (0.32) Stk SGA1J12A01 OT-1225 OT-1202 SS1141 — 121⁄2 (304.8) Offset 240 250 21 (3.3) 0.8 (0.32) Stk SGA1J12A02 OT-1225 OT-1202 SS1152 — 121⁄2 (304.8) Offset 120 350 29 (4.5) 0.8 (0.36) Stk SGA1J12A05 —OT-1203 —SS2141 121⁄2 (304.8) Offset 240 350 29 (4.5) 0.8 (0.36) Stk SGA1J12A06 —OT-1203 —SS2152 121⁄2 (304.8) Offset 120 500 42 (6.5) 0.8 (0.36) Stk SGA1J12A03 —OT-1205 —SS2161 121⁄2 (304.8) Offset 240 500 42 (6.5) 0.8 (0.36) Stk SGA1J12A04 —OT-1205 —SS2172 121⁄2 (304.8) 1-on-1 120 250 20 (3.1) 0.8 (0.36) Stk SGA1J12AT1 S-1225 S-1202 SD1061 SD2071 121⁄2 (304.8) 1-on-1 240 250 20 (3.1) 0.8 (0.36) Stk SGA1J12AT2 S-1225 S-1202 SD1072 SD2082 121⁄2 (304.8) 1-on-1 240 500 40 (6.2) 0.8 (0.36) Stk SGA1J12AT3 —S-1205 —SD2122 141⁄2 (355.6) Offset 120 300 20 (3.1) 0.9 (0.41) Stk SGA1J14A02 OT-1430 —SS1181 — 141⁄2 (355.6) Offset 240 300 20 (3.1) 0.9 (0.41) Stk SGA1J14A01 OT-1430 —SS1192 — 141⁄2 (355.6) Offset 120 500 33 (5.1) 0.9 (0.41) Stk SGA1J14A03 —OT-1405 —SS2181 141⁄2 (355.6) Offset 240 500 33 (5.1) 0.9 (0.41) Stk SGA1J14A04 —OT-1405 —SS2192 141⁄2 (355.6) 1-on-1 120 300 20 (3.1) 0.9 (0.41) Stk SGA1J14AT1 S-1430 —SD1131 — 151⁄4 (387.4) Offset 120 325 19 (2.9) 1.0 (0.45) Stk SGA1J15E02 OT-1532 —SS1201 — 151⁄4 (387.4) Offset 240 325 19 (2.9) 1.0 (0.45) Stk SGA1J15E03 OT-1532 —SS1212 — 151⁄4 (387.4) Offset 240 500 30 (4.6) 1.0 (0.45) Stk SGA1J15E04 —OT-1505 —SS2212 177⁄8 (454.0) Offset 120 350 17 (2.6) 1.2 (0.54) Stk SGA1J17R04 OT-1835 —SS1221 SS2221 177⁄8 (454.0) Offset 240 350 17 (2.6) 1.2 (0.54) Stk SGA1J17R05 OT-1835 —SS1232 SS2232 177⁄8 (454.0) Offset 120 375 18 (2.8) 1.2 (0.54) Stk SGA1J17R06 OT-1837 —SS1241 — 177⁄8 (454.0) Offset 240 375 18 (2.8) 1.2 (0.54) Stk SGA1J17R07 OT-1837 —SS1252 — 177⁄8 (454.0) Offset 120 500 24 (3.7) 1.2 (0.54) Stk SGA1J17R01 OT-1850 —SS1261 SS2241 177⁄8 (454.0) Offset 240 500 24 (3.7) 1.2 (0.54) Stk SGA1J17R02 OT-1850 —SS1272 SS2252 375 Strip 11/28/00 8:16 AM Page 245 246 Strip Heaters375 StripWidth Length Term. Volts Power Watt Approx. Avail. Code No. Chromolox®Code No.➀Wellman®Code No.➀in (mm) in (mm) (Watts)Density Net Wt. Rust Resist. Chrome Stl. Aluminized Chrome Stl.W/in2 (W/cm2) lbs (kg)Iron Sheath Sheath Steel Sheath Sheath11⁄2 (38.1) 177⁄8 (454.0) Offset 120 750 36 (5.6) 1.2 (0.54) Stk SGA1J17R09 —OT-1807 —SS2261177⁄8 (454.0) Offset 240 750 36 (5.6) 1.2 (0.54) Stk SGA1J17R08 —OT-1807 —SS2272177⁄8 (454.0) Offset 120 1000 48 (7.4) 1.2 (0.54) Stk SGA1J17R010 —OT-1801 —SS2281177⁄8 (454.0) Offset 240 1000 48 (7.4) 1.2 (0.54) Stk SGA1J17R03 —OT-1801 —SS2292177⁄8 (454.0) 1-on-1 120 500 24 (3.7) 1.2 (0.54) Stk SGA1J17RT1 S-1850 S-1805 SD1211 SD2171177⁄8 (454.0) 1-on-1 240 500 24 (3.7) 1.2 (0.54) Stk SGA1J17RT2 S-1850 S-1805 SD1222 SD2182177⁄8 (454.0) 1-on-1 240 750 35 (5.4) 1.2 (0.54) Stk SGA1J17RT3 —S-1807 —SD2202177⁄8 (454.0) 1-on-1 120 1000 47 (7.3) 1.2 (0.54) Stk SGA1J17RT4 —S-1801 —SD2211177⁄8 (454.0) 1-on-1 240 1000 47 (7.3) 1.2 (0.54) Stk SGA1J17RT5 —S-1801 —SD2222191⁄2 (495.3) Offset 240 350 15 (2.3) 1.3 (0.59) Stk SGA1J19J06 OT-1935 —SS1301 —191⁄2 (495.3) Offset 120 500 22 (3.4) 1.3 (0.59) Stk SGA1J19J07 OT-1950 OT-1905 —SS2301191⁄2 (495.3) Offset 240 500 22 (3.4) 1.3 (0.59) Stk SGA1J19J04 OT-1950 OT-1905 —SS2312191⁄2 (495.3) Offset 240 750 32 (5.0) 1.3 (0.59) Stk SGA1J19J08 —OT-1907 ——191⁄2 (495.3) Offset 240 1000 43 (6.7) 1.3 (0.59) Stk SGA1J19J01 —OT-1901 —SS2332191⁄2 (495.3) 1-on-1 240 750 32 (5.0) 1.3 (0.59) Stk SGA1J19JT1 —S-1907 —SD2262211⁄2 (533.4) Offset 120 500 20 (3.1) 1.4 (0.64) Stk SGA1J21A01 OT-2150 —SS1341 —211⁄2 (533.4) Offset 240 500 20 (3.1) 1.4 (0.64) Stk SGA1J21A02 OT-2150 —SS1352 —211⁄2 (533.4) Offset 120 750 29 (4.5) 1.4 (0.64) Stk SGA1J21A03 —OT-2107 —SS2341211⁄2 (533.4) Offset 240 750 29 (4.5) 1.4 (0.64) Stk SGA1J21A04 —OT-2107 —SS2352211⁄2 (533.4) 1-on-1 120 500 19 (2.9) 1.4 (0.64) Stk SGA1J21AT1 S-2050 S-2005 SD1291 SD2291233⁄4 (603.3) Offset 120 500 17 (2.6) 1.5 (0.68) Stk SGA1J23N05 OT-2450 OT-2405 SS1361 SS2361233⁄4 (603.3) Offset 240 500 17 (2.6) 1.5 (0.68) Stk SGA1J23N06 OT-2450 OT-2405 SS1372 SS2372 233⁄4 (603.3) Offset 120 750 25 (3.9) 1.5 (0.68) Stk SGA1J23N01 OT-2475 OT-2407 SS1391 SS2381 233⁄4 (603.3) Offset 240 750 25 (3.9) 1.5 (0.68) Stk SGA1J23N02 OT-2475 OT-2407 SS1402 SS2392 233⁄4 (603.3) Offset 120 1000 34 (5.3) 1.5 (0.68) Stk SGA1J23N07 —OT-2401 —SS2401 233⁄4 (603.3) Offset 240 1000 34 (5.3) 1.5 (0.68) Stk SGA1J23N03 —OT-2401 —SS2412 233⁄4 (603.3) Offset 240 1500 51 (7.9) 1.5 (0.68) Stk SGA1J23N04 —OT-2415 —— 233⁄4 (603.3) 1-on-1 240 250 8 (1.2) 1.5 (0.68) Stk SGA1J23NT1 S-2425 —SD1322 — 233⁄4 (603.3) 1-on-1 240 500 17 (2.6) 1.5 (0.68) Stk SGA1J23NT3 S-2450 S-2404 SD1342 SD2322 233⁄4 (603.3) 1-on-1 240 750 25 (3.9) 1.5 (0.68) Stk SGA1J23NT5 —S-2407 —SD2352 233⁄4 (603.3) 1-on-1 120 1000 33 (5.1) 1.5 (0.68) Stk SGA1J23NT6 —S-2401 —SD2361 233⁄4 (603.3) 1-on-1 240 1000 33 (5.1) 1.5 (0.68) Stk SGA1J23NT7 —S-2401 —SD2372 233⁄4 (603.3) 1-on-1 240 1500 50 (7.7) 1.5 (0.68) Stk SGA1J23NT8 —S-2415 —— 251⁄2 (647.7) Offset 120 500 16 (2.5) 1.7 (0.77) Stk SGA1J25J01 OT-2550 —SS1421 — 251⁄2 (647.7) Offset 240 500 16 (2.5) 1.7 (0.77) Stk SGA1J25J02 OT-2550 —SS1432 — 251⁄2 (647.7) Offset 120 750 23 (3.6) 1.7 (0.77) Stk SGA1J25J03 OT-2575 OT-2507 SS1441 SS2421 251⁄2 (647.7) Offset 240 750 23 (3.6) 1.7 (0.77) Stk SGA1J25J04 OT-2575 OT-2507 SS1452 SS2432 251⁄2 (647.7) Offset 240 1000 31 (4.8) 1.7 (0.77) Stk SGA1J25J05 —OT-2501 —SS2452 263⁄4 (679.5) Offset 240 700 21 (3.3) 1.7 (0.77) Stk SGA1J26N01 OT-2670 —SS1472 — 263⁄4 (679.5) Offset 240 1000 29 (4.5) 1.7 (0.77) Stk SGA1J26N02 —OT-2601 —SS2472 301⁄2 (774.7) Offset 120 750 19 (2.9) 2.0 (0.91) Stk SGA1J30J02 OT-3075 OT-3007 SS1481 — 301⁄2 (774.7) Offset 240 750 19 (2.9) 2.0 (0.91) Stk SGA1J30J03 OT-3075 OT-3007 SS1492 SS2482 301⁄2 (774.7) 1-on-1 240 750 19 (2.9) 2.0 (0.91) Stk SGA1J30JT1 S-3075 S-3007 SD1452 — 331⁄2 (850.9) Offset 240 750 17 (2.6) 2.2 (1.0) Stk SGA1J33J01 OT-3375 OT-3307 SS1522 SS2522 331⁄2 (850.9) 1-on-1 240 1000 22 (3.4) 2.2 (1.0) Stk SGA1J33JT1 —S-3301 —SD2472 357⁄8 (911.2) Offset 120 1000 21 (3.3) 2.3 (1.0) Stk SGA1J35R04 OT-3610 SS1531 SS1531 — 357⁄8 (911.2) Offset 240 1000 21 (3.3) 2.3 (1.0) Stk SGA1J35R03 OT-3610 —SS1542 SS2532 357⁄8 (911.2) Offset 240 1500 31 (4.8) 2.3 (1.0) Stk SGA1J35R01 —OT-3601 SS2552 — 357⁄8 (911.2) 1-on-1 240 1000 21 (3.3) 2.3 (1.0) Stk SGA1J35RT1 S-3610 S-3601 SD1492 SD2492 381⁄2 (977.9) Offset 120 1000 19 (2.9) 2.5 (1.1) Stk SGA1J38J02 OT-3810 OT-3801 SS1581 SS2561 381⁄2 (977.9) Offset 240 1500 29 (4.5) 2.5 (1.1) Stk SGA1J38J03 —OT-3815 —— 421⁄2(1079.5) Offset 240 1500 26 (4.0) 2.8 (1.3) Stk SGA1J42J01 —OT-4315 SS1632 SS2632 477⁄8(1216.0) Offset 240 2250 34 (5.3) 3.1 (1.4) Stk SGA1J47R01 —OT-4822 —— F.O.B.: St. Louis, Missouri375 Strip 11/28/00 8:16 AM Page 246 9.40 Data subject to change without notice 763 422 2211 FAX 763 422 2600 ©2003 Hoffman Enclosures Inc. Thermal Management Accessories When the enclosure reaches the pre- determined set point, temperature contacts in the thermostat are activated and the fan or heater automatically begins to operate. Thermostats prolong the life expectancy of heaters and fans by curtailing their operating hours and also increase the working efficiency of electrical components by exposing them to fewer contaminants from the surrounding environment. Connections consist of tubular screw terminals for AWG 14 (0.04 in2). Provision for both panel mounting and DIN rail mounting. Housing is plastic Industry Standards UL94-VO Protection rating IEC IP30 UL/cUL Component Recognized CE These easy to install thermostats are designed to regulate and monitor air temperature in switch-gear enclosures that are set up to operate with heaters, fans, filter ventilators, heat exchangers, and/or signal transmitters. Thermostat A-TEMNC is specifically designed for use with heaters (contacts close on temperature drop), while thermostat A-TEMNO is designed to control fans, filter ventilators, or for switching signal transmitters in the event of overheating (contacts close on temperature rise). Both thermostats have a bi- metallic adjustable set point range of 30 to 140° F.An additional label is provided to convert set point range to degrees Celsius.A preset label is also provided to cover the set point range label after the thermostat is put at desired temperature. Catalog Number Contact Type ATEMNC NC (normally closed), quickacting ATEMNO NO (normally open), quickacting Switching Capacity Amp Volts Load 15 120 AC Resistive 16 250 AC Resistive 1 120-250 AC Inductive 10 12-24 DC Resistive 1 12-24 DC Inductive Temperature Control Switches (Thermostats) Front View Side View Bottom View UL File Number E164102 9.41Data subject to change without notice 763 422 2211 FAX 763 422 2600 ©2003 Hoffman Enclosures Inc.Fans, Blowers, Louvers, and VentsThermal Management Accessories9 Bulletin D85 Industrial Corrosion Inhibitors Hoffman corrosion inhibitors protect • Interior components of electrical enclosures, boxes, consoles, and wireways • Interior components of electronic enclosures • Electrical and electronic equipment and controls • Parts and components that are packaged in crates during shipping and storage • Switch gear and relay cabinets • Interiors of pipes, conduits, and fuse boxes • Process control computers, instruments, and recording devices • Tool chest interiors and contents • Equipment stored at construction sites Chief Advantages • Protects against salt and high humidity • Eliminates the need of oiling, plating, or dipping metal • Puts protected equipment to use immediately without degreasing or coating removal • Provides durable protection for up to 12 months How They Work Each inhibitor contains a special chemical combination that vaporizes and condenses on all surfaces in an enclosed area.Vapors will redeposit as needed in the event of condensation of moisture on surfaces.These vapors reach every part of an enclosure, protecting all interior components. Spraying, wiping, or greasing are not required.This eliminates precoating, special wraps, and drying agents. Protection is effective even in salt water atmospheres.The AHCI5E and AHCI10E emitters have additional red metal inhibitors for further protection. Enclosures containing corrosion inhibitors must be reasonably sealed. Life Expectancy and Usage The normal useful life-span of Hoffman corrosion inhibitors is in excess of one year. However, inhibitor life expectancy is shortened by approximately 25% when exposed to temperatures above 104° F (40°C).This product is not recommended for use where temperature exceeds 199°F. Ventilated enclosures or enclosures not sealed properly as well as frequent door openings also shorten the product life. Additional inhibitors should be used if these conditions exist. Since Hoffman corrosion inhibitors are vapor phase protective, all surfaces to be protected should be accessible to the vapors.The maximum distance the vapors can travel is approximately 1.50 feet (.46 meters). Protection of long narrow enclosures can be achieved with tape or multiple inhibitors. Storage and Handling Each Hoffman corrosion inhibitor is individually packaged in a resealable bag for maximum effectiveness at time of usage. Corrosion inhibitors should be stored at temperatures not exceeding 120°F (45°C ). Recommended shelf life under normal conditions is one year. Hoffman corrosion inhibitors are not returnable. When determining the proper corrosion inhibitor for your application, assume that the enclosure volume to be protected is greater than calculated if (1) cabinet doors are opened frequently, (2) cabinet is located in an extremely corrosive area, and/or (3) cabinet length divided by depth is greater than four. AHCI1DV Foam device protects one cubic foot (28 liters) of enclosure volume for approximately one year. Size: .25" x 1.25" x 3.00" (6mm x 32mm x 76mm) AHCI60R Tape protects sixty cubic feet of enclosure volume per roll. Use approximately 2.50" (6.3cm) of tape per cubic foot (28 liters) of enclosure volume to be protected. Each roll of tape is packaged individually in a resealable bag. Size: .25" x .75" x 12.00' (6mm x 19mm x 3.6m) AHCI240R Tape protects 240 cubic feet of enclosure volume per roll. Use approximately 1.00" (2.5cm) of tape per cubic foot (28 liters) of enclosure volume to be protected. Each roll of tape is packaged individually in a resealable bag. Size: .25" x 2.00" x 20.00' (6mm x 51mm x 6.1m) AHCI5E Emitter protects five cubic feet (142 liters) of enclosure volume for approximately one year. Emitters contain additional red metal (non-ferrous) inhibitors. Size: 2.50" (diameter) x 1.50" (high) (63mm x 38mm) AHCI10E Emitter protects ten cubic feet (283 liters) of enclosure volume for approximately one year. Emitters contain additional red metal (non-ferrous) inhibitors. Size: 2.50" (diameter) x 2.00" (high) (63mm x 51mm) AHCI236S Spray is a non-conductive, non- flammable, vapor phase film and is non-toxic. It has essentially neutral pH value.Application provides instant protection against corrosion. Spray is water soluble and can be easily flushed away with water if desired.This product should be kept from freezing, and has a shelf life of 2+ years in normal warehouse conditions. Metal Protected by Chemical Unprotected by Chemical Aluminum Marked reduction of surface attack; no pitting Severe surface attack; tarnish; pitting * Brass Decreased tarnish; very minor surface attack Surface discoloration; pitting Steel, Iron No change Severe corrosion * Copper Slight staining Heavy corrosive attack Zinc Plate Slight discoloration Severe corrosion Tin Plate Slight discoloration Moderate corrosive attack Catalog Number Enclosure Volume Protected AHCI1DV 1 cu. ft. (28.32 liters) AHCI5E 5 cu. ft. (141.6 liters) AHCI10E 10 cu. ft. (283.2 liters) AHCI60R 60 cu. ft. pr. roll (1699 liters) AHCI240R 240 cu. ft. pr. roll (6797 liters) AHCI238S (Corrosion Inhibitor Spray) * AHCI5E and AHCI1OE emitters are recommended for these materials. Data subject to change without notice 763 422 2211 FAX 763 422 2600 ©2003 Hoffman Enclosures Inc.12.16 General Accessories Lighting Packages Fluorescent Lighting Package Light packages are designed to illuminate the interior of medium to large size electrical enclosures and cabinets.These low profile light packages are available with either a manual switch or a door activated switch with plunger, integrally mounted. On door-activated switches, the circuit is closed (activates the light) when the enclosure door is opened. Each light comes with a pre-wired terminal block for easy connection to electric supply, in either 115 volt or 230 volt models.An easy to remove, non-yellowing white plastic lens cover provides protection against bulb breakage (fluorescent bulb not included).All 115 volt models come standard with a 9 amp convenience outlet. Optional accessories include a mounting bracket kit designed specifically for Hoffman PROLINE®disconnect enclosure applications and easy to mount "remote" manual and door activated switches with mounting bracket. Construction • Low profile design • Painted steel body • Integrally mounted switch (manual or door depending on model) • Terminal block for easy wiring • Standard mounting hardware and brackets included (can be panel mounted) • Non-yellowing lens cover • Convenience outlet on 120 volt models • Accept the following standard bulbs, which are not included with light package: F8T5, F15T8, F18T8, or F40T12 Finish Light gray RAL 7035 polyester powder paint on body. Industry Standards UL 508A, 508 Listed File No. E229434 cUL C22.2 No. 14 File No. E229434 Maintains UL/cUL Type 4 and Type 12 when properly installed in a Hoffman enclosure Standard Sizes Fluorescent Light Packages Convenience L M N Catalog Number Description VAC Hz Amps Outlet in. mm in. mm in. mm ALF16D12R Door switch 115 60 0.16 Yes 12.30 (312) 1.38 42 4.59 140 ALF16M12R Manual switch 115 60 0.16 Yes 12.30 (312) 1.38 42 4.59 140 ALF16D18R Door switch 115 60 0.35 Yes 18.10 (460) 1.38 42 4.59 140 ALF16M18R Manual switch 115 60 0.35 Yes 18.10 (460) 1.38 42 4.59 140 ALF16M18RCa Manual switch, 115 60 0.35 Yes 18.10 (460) 1.38 42 4.59 140 6 ft power cord ALF25D18R Door switch 230 50 0.30 No 18.10 (460) 1.84 56 5.25 160 ALF25M18R Manual switch 230 50 0.30 No 18.10 (460) 1.84 56 5.25 160 ALF16D24R Door switch 115 60 0.35 Yes 24.10 (612) 1.38 42 4.59 140 ALF16M24R Manual switch 115 60 0.35 Yes 24.10 (612) 1.38 42 4.59 140 ALF16M48R Manual switch 115 60 0.65 Yes 48.00 (1219) 1.84 56 5.25 160 Millimeter dimensions ( ) are for reference only; do not convert metric dimensions to inch. a Corded light is listed to UL/cUL 153 standard. See Page 12.18 for Disconnect Mounting Bracket and Remote Switch kits. 12 General AccessoriesData subject to change without notice 763 422 2211 FAX 763 422 2600 ©2003 Hoffman Enclosures Inc.12.17 Bulletin A80 Incandescent Lighting Package Designed to illuminate the interior of an electrical enclosure. Models are available with a door-activated switch or a manually operated switch.A terminal block is provided for connection to the electrical supply circuit. A convenience outlet is also provided for ease of servicing components mounted within the enclosure. Lighting package mounts at the top of the enclosure door opening and protrudes into the opening less than one inch (25mm). A removable wire guard protects the bulb from damage. Maintains UL/CSA Type 4 when properly installed on a Hoffman enclosure. Catalog Number Description VAC Hz Amps ALTMB1 Manual switch with terminal block 120 50/60 15 ALTDB1 Door switch with terminal block 120 50/60 15 Construction • 60 watt incandescent T-10 style bulb included • Terminal block has three 6-32 screw terminals with barriers labeled for power and ground connections • Operates on 120 volts, 50/60 Hz • 120 volt convenience outlet with ground, 12 amp maximum rating • 20 gauge sheetmetal construction • Stainless steel wire guard snaps in place for easy bulb replacement • Includes two self-sealing installation screws Industry Standards UL Component Recognized Certified by Canadian Standards Association Finish Lighting Package is white.Wire guard is stainless steel. Installation Designed to be mounted in most Hoffman Type 4, 12, 13, 3, and 3R enclosures. Front mounting holes are used on most applications. Two .173-inch (4mm) holes must be drilled in the enclosure. Lighting Package should be installed with two sealing screws which are included. Data subject to change without notice 763 422 2211 FAX 763 422 2600 ©2003 Hoffman Enclosures Inc.12.18 General Accessories Lighting; Epoxy Patch Kit; Corrosion Inhibitors Epoxy Patch Kit Applications include sealing rivets, bolts, metal joints, seams and welds, cement cracks, pipe couplings, joints, and tees. Each kit has two tubes of material, application instructions, and a mixing stick.When the resin and hardener are mixed, a gray epoxy is formed which cures at room temperature, has high adhesion, and will not sag. It is resistant to oils, acids, and chemicals. Catalog Number A307 C2597-3 Manual Switch Mounting Bracket Kit for Fluorescent Light Package Kit simplifies mounting light package in Hoffman PROLINE®disconnect enclosures. Includes brackets, all mounting hardware, and complete instructions. Catalog Number Description PDLFBRKT Mounting Bracket Kit Remote Switches for Fluorescent Light Package Remote switches for these light packages. Catalog Number Description ALFSWM Manual switch ALFSWD Door-activated switch C2597-2 Door-Activated Switch (This Page Intentionally Left Blank) Section 20 (This Page Intentionally Left Blank)