AF93-IS903

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Cutler-Hammer STOP RUN FAULT SETUP UP DOWN Scroll START F/R OPERATE SELECT Change Settings Keypad Remote Forward Reverse 93 93 ETN-COVER-3 Cutler-Hammer

Cutler-Hammer

Instruction Manual

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2. Press the SELECT button until Keypad Indicator is lit.

3. Verify the Operate Indicator is lit. If not, press the OPERATE button.

4. Press the START button.

5. Press the UP or DOWN button and verify SPEED SETPOINT appears on the top line of the LCD and speed in RPMs appears on the bottom line.

6. Use the UP or DOWN button to set the drive at 1200 RPM.

7. If reversal of rotation is required, press the F/R button.

Press the STOP button to stop the drive.

Quick Start

RUN FAULT SETUP UP DOWN Scroll ETN-10.A START STOP F/R OPERATE SELECT Change Settings Keypad Remote Forward Reverse

Cutler-Hammer

Before applying power to the unit, make sure it is properly wired. The input line should be

connected to terminals L1, L2, and L3, and the motor should be connected to terminals T1, T2, and T3. The unit should also be properly

grounded in accordance with the connection drawings in the AF93/IS903 Instruction Manual. To run the drive in KEYPAD mode, make sure a jumper or customer permissive circuit is

connected between terminal 7 and 8, and terminal 7 and 15. See the connection drawings in the AF93/IS903 Instruction Manual.

To Start Drive and Set Speed

Complete the following procedure to start the drive and set the speed (to 1200 RPM for example). 1. Apply power and verify both lines of LCD

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Safety

Cutler-Hammer has made every effort to provide you with the safest motor drives on the market but wishes to point out how to safely operate and troubleshoot your drive.

After you review this section you will:

¥ Understand the meaning of the Safety Alert Symbol, Danger, Warning, Caution, and Notice safety statements.

¥ Know what safety statements you should be aware of when you operate and troubleshoot Cutler-Hammer motor drives.

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The Meaning of Safety Statements

You will find various types of safety information on the following pages and on the labels

attached to the equipment. This section explains their meaning.

Notice

- means that failure to follow these instructions could cause damage to the equipment or cause it to operate improperly.

AF93/IS903 Safety Statements

The following safety statements relate to the installation, operation and troubleshooting of Cutler-Hammer Adjustable Frequency Drives.

Notice

- Make sure you read and understand the installation procedures in this manual

before

you attempt to operate or troubleshoot the equipment.

Danger

means that failure to follow this safety statement

will

result in serious personal injury or death.

Safety

Danger

Warning

could

result in serious personal injury or death.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Caution

may

result in minor or moderate personal injury or property damage.

Warning

Caution

Motor control equipment and electronic controllers are connected to hazardous line voltage. When you install or service Adjustable Frequency Drives and electronic controllers, there may be exposed components with their cases and protrusions at or above line potential. Take extreme care to protect yourself and others against shock:

¥ Observe all shock hazard labels that may be located inside the drive.

¥ Stand on an insulating pad and make it a habit to use only one hand when installing or checking components.

¥ Always work with another person in case an emergency occurs.

¥ Always disconnect power before you install or check controllers or perform maintenance. ¥ Be sure equipment is properly grounded. ¥ Make sure that all electrical work conforms

with the National Electrical Codes and local regulations.

¥ Installation should only be performed by qualified personnel.

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Safety

AF93/IS903 Adjustable Frequency Drives are not suitable for use in an explosive atmosphere or in a ÒHazardous (Classified) Location.Ó See Article 500 of the National Electric Code.

Danger

Carefully consider the application when you select AF93/IS903 Adjustable Frequency Drive components and options and associated drive motor. You must ensure that your application meets the restrictions stated in this manual and the nameplate of your drive.

Failure to observe these restrictions can cause personal injury or damage to personal property and could void your warranty:

¥ Make sure selected equipment meets the requirements of the NEC, NEMA, UL, CSA, IEC, IEEE, and local codes.

¥ Pay particular attention to the requirements for motor and power disconnect devices, emergency stop pushbuttons, pre-start alarms and guards on mechanical power transmission apparatus.

¥ Make sure motor selected is appropriately sized for the application. Follow the recommendations in Section 2 of this manual, Pre-Installation.

¥ If you configure the drive to operate above 60 Hz, the motor may operate above its nameplate speed. Personal injury or equipment damage may exist when you operate the motor and driven machines above their rated speed. Make certain that all guards and shields are in place before operating at any speed. Refer to the motor manufacturer to verify safe motor speed. Before operating the equipment, make sure that appropriate guards and safety devices are in place.

Warning

A hazard of potential damage to your drive, due to overheating, exists if your drive is operated at a line impedance below 1%.

You must ensure that the input line power has an impedance of at least 1%, and less than or equal to 5% for proper drive operation. Damage may occur if the source impedance is less than 1%. If the source impedance is more than 5%, the drive may not provide rated output voltage. Install a AF93/IS903 1% input line reactor if your line impedance measures below 1%.

Caution

Internal parts of the drive are at line voltage when AC power is connected to input terminals. This voltage is extremely dangerous and can cause death or serious injury. When the supply is disconnected from the input terminal block, it will take up to 10 minutes before the DC bus capacitors are discharged to a safe voltage. To ensure the voltage is safe, monitor the capacitor discharge with a digital voltmeter connected between the ÒAÓ and ÒBÓ terminals on the capacitor assembly as described in

Section 5, Troubleshooting. Do not work on the drive until the capacitors have completely discharged. Do not attempt to discharge the capacitors by short circuiting the bus.

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Safety

Rotating mechanical equipment can cause serious personal injury and property damage unless you handle them carefully, especially when the equipment is operating:

¥ Never wear loose fitting clothing, such as ties and scarves, when you operate rotating mechanical equipment.

¥ Always wear safety glasses when you operate rotating mechanical equipment. ¥ Stand clear, and make sure all hands and

feet are clear, of rotating mechanical equipment before you start the Adjustable Frequency Drive.

¥ Refer to OSHA rules and regulations,

paragraph 1910.219 for the use of guards on mechanical power transmission devices.

Warning

AF93/IS903 Adjustable Frequency Drives contain components and sub-assemblies that are sensitive to electrostatic discharge. Static control precautions are required when installing, testing, servicing, or repairing your Adjustable Frequency Drive. Component damage may result if you ignore electrostatic discharge control procedures. Observe the following precautions when you are working with electrical subassemblies:

¥ Before opening the enclosure, discharge static electricity from your body by touching a grounded metal object.

¥ When installing the equipment, connect the equipment ground conductor as soon as possible.

¥ Keep your hands and tools away from the electronic circuitry as much as possible. Non-conductive materials such as paper, plastic and Styrofoam must be kept away from the electronic circuitry. Do not use tape in the equipment enclosure. Pulling tape from a roll generates a high static charge.

¥ Printed circuit boards must be repaired by Cutler-Hammer technicians. Field service of printed circuit boards inside your AF93/IS903 is not possible without the proper software or diagnostic tools.

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SECTION 1

Introduction

Congratulations! You have purchased one of the most

sophisticated Adjustable Frequency Drives in the industry. Your drive is part of a family of drives that provide AC motor speed control in a wide variety of industrial and commercial applications. Models are available for 2 to 25 Hp applications.

This manual provides a check list, drawings, specifications and pre-installation information to help you select the right equipment and properly install your AF93/IS903 Adjustable Frequency Drive. To assure successful installation, thoroughly read and understand the material presented in each section before you attempt to install the drive. If this is your first installation, we suggest that you read each section in the sequence they are presented since they assume you know the material presented previously. Once you are an experienced installer, you can use the manual as a source of reference and look up the information you need using the index as a guide.

AF93/IS903 Adjustable Frequency Drives are designed to provide adjustable speed control of three phase motors. The

microprocessor based pulse width modulated (PWM) drives have standard features which can be programmed to tailor your driveÕs performance to suit your needs.

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About This Manual

SECTION 1

Note that throughout the manual, titles of sections and other AF93/IS903 manuals are shown in italics. Items in

bold italics

are important. Items

in

bold without italics

are parameters or commands that appear on

the LCD of the keypad on your AF93/IS903 Adjustable Frequency Drive. If you have any questions or comments, please feel free to contact us. We at Cutler-Hammer are proud to have you as a customer and can assure you that you will have many productive years from your new AF93/IS903 Adjustable Frequency Drive.

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SECTION 2

Installation

This section of the AF93/IS903 Instruction manual provides pre-installation information, an pre-installation check list, drawings, and specifications to help you select the right equipment and properly install your AF93/IS903 Adjustable Frequency Drive.

To ensure successful installation, thoroughly read and understand the material presented in this section before you attempt to install the drive. If this is your first installation, we suggest that you read this section in the sequence it is presented. Once you are an experienced installer, you can use this section as a source of reference and look up the information you need using the index as a guide.

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This part of the Installation section of this Instruction Manual provides guidelines to consider

before you install your drive

:

¥ Handling of Drive After Delivery. ¥ Where to Locate Drive.

¥ Application Considerations. ¥ Input Line Considerations. ¥ Output Power Considerations

¥ Analog and Digital Signal Considerations.

Pre-Installation

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Pre-Installation

INSTALLATION

Handling of Drive After Delivery

Although every precaution is taken to ensure

that the unit is delivered in good condition, take a moment to inspect your drive after it arrives at your plant:

1. Inspect the shipping container for evidence of rough handling immediately after the unit arrives. Report all damage to the freight carrier and your nearest Cutler-Hammer customer support center and your Cutler-Hammer sales representative.

2. Carefully unpack the drive, taking care to save the shipping container and any packing material should you need to return the unit at a later date. Verify that the items on the packing list or bill of lading agree with your order.

3. If you are not installing the drive right away, store the drive in a clean, dry, area where the ambient temperature is between -4 to 158¡F (-20 to 70¡C) and less than or equal to 95% humidity (non condensing).

Make sure the drive is not subject to a corrosive atmosphere (such as H2S).

Large frame AF93/IS903 Adjustable Frequency Drives may require more than one person to move from one location to another. Observe proper lifting techniques to avoid injury when handling heavy electrical equipment.

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Pre-Installation

INSTALLATION

Where to Locate Drive

Consider the following:

1. Locate the drive in an area consistent with the environment specifications listed in the

Specifications section of this manual.

Mount enclosures away from heavy and overhead construction.

2. Select the type of enclosure that meets your application.

Note: Standard AF93/IS903 NEMA 1 drives can withstand an ambient temperature of 122¡F (50¡C) up to 3,300 feet (1000 meters) above sea level. Standard AF93/IS903 NEMA 12 drives can withstand an ambient temperature of 104¡F (40¡C) up to 3,300 feet (1000 meters) above sea level. If you install the drive in an optional enclosure, the maximum temperature is derated.

If you install an enclosure at temperatures exceeding these values, you must derate the unit as follows:

For every 9¡F (5¡C) over the rated temperature you must derate the AF93/IS903 current ratings by 10%. However, do not exceed a maximum of 131¡F (55¡C) under any circumstances. In addition for every 1000 feet (300 meters) above the rated altitude, you must derate the AF93/IS903 current ratings by 2%.

3. Refer to the illustrations in the Drawings section of this manual for the mounting dimensions of each enclosure.

4. Make sure there is plenty of ventilating space surrounding the drive. Refer to the illustrations in the Drawings section of this manual for ventilation clearances.

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Pre-Installation

INSTALLATION

Application Considerations

When you plan your AF93/IS903 Adjustable Frequency Drive installation, consider its application. Different applications, such as industrial process control and HVAC system control, require different drive options, motors and software configuration.

The following is a list of items you should keep in mind when you plan the installation and order the materials. It is important to note that some of the options available for your drive must be installed at the factory.

AF93/IS903 Options

1. Remember you must have an input line

impedance of at least 1% and not over 5% for proper drive operation. You should

calculate the input line impedance to determine whether a 1% input reactor is required. Refer to the discussion on Input

Line Considerations later in this section for

more details on determining input line impedance.

2. Order a 3% or 5% input line reactor to correct input line harmonic distortions as required. Refer to the discussion on Input

Line Characteristics on later in this section

for more details for more details on harmonic distortions.

3. An AF93/IS903 circuit breaker is a lockable means for disconnecting the motor from the power source. The circuit breaker is

mounted in an optional NEMA 1 or 12 enclosure or MCC.

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Pre-Installation

INSTALLATION

Application Considerations

Motor Selection

Careful consideration of the proper motor is essential to obtain optimum performance from your drive. Contact your Cutler-Hammer sales representative or distributor for additional assistance and/or literature regarding motor selection and other aspects of drive applications. 1. Your AF93/IS903 drive is designed to be

connected directly to a single, NEMA design B, three phase AC motor. The motor must be selected and applied so that the average operating motor current and horsepower do not exceed the continuous current and horsepower ratings of the drive. The intermittent operating current must not exceed the intermittent current rating of the drive.

2. Consider the effect of speed on the cooling capacity of the motor. As you slow down some types of motors (such as a Totally Enclosed Fan Cooled [TEFC]), its internal fan turns slower which reduces air flow through the motor. Typically, these types of motors may overheat if you operate them for extended periods of time at their rated torque and a reduced speed (less than 50% of full speed). Choose a motor that matches the expected duty, torque range and speed.

3. Multiple motors may be operated by an AF93/IS903 drive if:

¥ Total current from all motors does not

exceed the current rating of the AF93/IS903. ¥ Individual motor overload protection is

supplied.

¥ All motors must start and change speed together.

If you configure the drive to operate above 60 Hz, the motor may operate above its nameplate speed. Personal injury or equipment damage may exist when you operate the motor and driven machines above their rated speed. Make certain that all guards and shields are in place before operating at any speed. Refer to the motor manufacturer to verify safe motor speed.

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Pre-Installation

INSTALLATION

All wiring must comply with the requirements of the National Electric Code (NEC) and/or other codes as required by the authority having jurisdiction over the installation. The installer must ensure that the electrical connections at the site conform with the connection diagrams shipped with the drive.

Note: Make sure you use the most recent version of the codes when you install your AF93/IS903 drive.

Input Line Conductor and Branch Circuit

Overload Protection Selection

Use a combination of the following guidelines to choose the correct input line conductors and proper branch circuit overload protection: Note: Select the input line conductor size and

branch circuit overload protection in accordance with applicable code requirements.

¥ The input line and branch circuit overload protection must be rated for the input voltage and current stated on the nameplate of the drive.

¥ For runs over 300 feet, consider the recommended minimum wire size listed in Table 2-1.

¥ In addition, consider the wire size capacity of the input line terminals:

2 to 10 Hp Maximum wire size is #10 AWG 15 to 25 Hp Maximum wire size is #4 AWG ¥ The input line conductors must be made of

copper with a temperature rating of at least

167¡F (75¡C).

¥ The power terminal tightening torque range is 16-18 in. lbs. on terminals L1, L2, L3, T1, T2, T3, and the ground lugs.

Grounding Connections

For personal safety and reliable equipment operation, firmly connect each chassis to earth ground as shown in the connection diagrams in the Drawings section of this manual.

The AF93/IS903 chassis ground conductor should be the same size as the input line conductors or sized according to electrical code requirements. Use a copper or aluminum conductor.

Connection to a grounded conduit does not provide an adequate equipment ground.

Make sure that all operatorÕs control stations and motor frames are adequately grounded.

Input Line Impedance

You must ensure that the input line power has an impedance of at least 1% and less than or equal to 5% equated to drive size for proper operation. Damage to the drive may occur if the source impedance is less than 1%. If the source impedance is more than 5%, the drive may not provide rated output voltage.

Actual input current varies considerably in response to the efficiency and power factor of the motor connected to your drive and the impedance of the power source.

Since power source impedance has an effect on the harmonic content of the input current, the amount of impedance affects the value of the input line current.

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Pre-Installation

INSTALLATION

Input Line Considerations

The value of source impedance is expressed as a percent of the effective impedance of the drive.

To determine the source impedance as a percent of the effective impedance of the drive, you must know:

¥ The short circuit capacity of the power source at the driveÕs input power terminals. ¥ The full load (output) current rating of the

drive (found on the nameplate).

The following calculation provides the source impedance as a percent of the effective impedance of the drive:

The short circuit capacity must be at least 20 times the full load current rating (5%

impedance) and no more than 100 times the full load current rating (1% impedance).

For example, if the full load (output) current of an AF93/IS903 drive is 22 amps and the short circuit current capacity of the power source is 2200 amps, the source impedance is:

Since the design of a power distribution system often includes a short circuit capacity study, power distribution system drawings or other distribution system documentation may show the short circuit capacity at various points. If this data is not available, contact your

Cutler-Hammer sales representative or distributor for help on estimating or calculating short circuit current capacity.

Short Circuit Capacity

Full Load Current _{= Source}

Impedance

* 100

2200 22 = 1.00%

* 100

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Pre-Installation

INSTALLATION

Recommended Minimum Input Line and Output Power Wire Size

Table 2-1

Input Line Considerations

Hp 2 3 5 7.5 10 15 20 25 Typical Current per NEC in Amps. 230V [460V] 6.8 [3.4] 9.6 [4.8] 15.2 [7.6] 22 [11] 28 [14] 42 [21] 54 [27] 68 [34] 300 Ft. 14 [14] 14 [14] 12 [14] 10 [14] 8 [12] 8 [10] 6 [8] 6 [8] 500 Ft. 12 [14] 12 [14] 10 [12] 8 [12] 8 [10] 6 [8] 4 [8] 4 [8] 700 Ft. 12 [14] 10 [14] 8 [12] 6 [10] 6 [8] 4 [6] 4 [6] 4 [6] 1,000 Ft. 10 [14] 8 [12] 6 [10] 6 [8] 4 [6] 2 [6] 1 [4] 1 [4] 1,500 Ft. 8 [12] 6 [10] 6 [8] 4 [6] 2 [6] 1/0 [4] 2/0 [2] 2/0 [2] 2,000 Ft. 6 [10] 4 [8] 4 [6] 2 [4] 1 [4] 2/0 [2] 4/0 [1] 4/0 [1]

Note 1: Make sure that the wireway conforms with the applicable electrical codes and is designed to support the wire size indicated in this table. Note 2: Refer to Input and Output Considerations for

terminal block limitations.

Recommended Minimum Wire Size (AWG and MCM) To Prevent Excessive Voltage Drop (For Various Wire Run Distances in Feet). 230V [460V]

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Pre-Installation

INSTALLATION

Input Line Considerations

Harmonic Distortion

As stated in the discussion on Input Line

Impedance, source impedance can affect the

harmonic content of the input line current. As source impedance increases, line current harmonic content decreases.

The relationship between input line impedance and harmonic voltage distortion is just the opposite of the relationship between impedance and current distortion. As source impedance increases, so does harmonic voltage distortion.

For example, if the source impedance (expressed as a percent of the effective impedance of the drive) is 1%, you will cause less than 5% harmonic voltage distortion when you connect a single AF93/IS903 to an

undistorted power source. If the source impedance increases to 5%, the resulting harmonic distortion is less than 10%. Contact your Cutler-Hammer sales

representative or distributor for assistance in estimating harmonic distortion in multiple drive installations. They can also provide assistance in selecting a means of harmonic reduction such as line reactors.

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Pre-Installation

INSTALLATION

Input Line Considerations

Input Line Routing

For 7.5 to 25 Hp AF93/IS903:

¥ If you use conduit - Use a separate conduit for input line conductors and output power conductors. Never route analog and

digital wiring from any equipment in the same conduit as input or output power wiring.

¥ If you use cable trays - Use a separate cable tray for input line conductors and output line conductors. Never route analog

and digital wiring from any equipment in the same cable tray as input or output power wiring.

For 2 to 5 Hp AF93/IS903:

If you use conduit, use separate conduit for

input and output power and AF93/IS903 control wiring, up to the AF93/IS903 drive. At the drive use a T-coupling to combine the input power and output power wiring and attach to conduit entry point.

Multiple Conductor Wiring

If multiconductor wiring is used, a separate multiconductor cable must be used for the input line wiring for each drive.

Line Fuses

Line fuses are intended to remove input line voltage from the drive in the event of internal component and drive failure. Line fuses must

not be used in place of branch circuit overload protection.

CT (Current Transformer)

On 2 Hp, 3 Hp, and 5 Hp units manufactured prior to May 2, 1996 and 7.5 and 10 Hp units manufactured prior to July 1, 1996, a CT was supplied internal to the drive for ground fault protection. On units manufactured after these dates, the ground fault protection is built into the transistor module. If your drive contains a CT to provide ground fault protection, input lines L1,

L2, and L3 must pass through the CT when you are installing the input lines (See 5 and 10 Hp connection drawings):

1. Remove the foam packing.

2. Pass L1, L2, and L3 through the knockout and current transformer and then connect them to terminals L1, L2, and L3,

respectively.

3. DO NOT pass any ground lines through the current transformer.

4. The current transformer is connected to the logic board at the factory.

AF93/IS903 Circuit Breaker

This option is used as a mechanical means of disconnecting output power to the motor.

AF93/IS903 circuit breakers must not be used in place of branch circuit overload

protection.

Isolation Transformers

Isolation transformers can be used with AF93/IS903 Adjustable Frequency Drives. Remember that the input line impedance must be at least 1% and not over 5% with the drive running. See the previous discussion on Input

Line Impedance.

Power Factor Correction

The displacement power factor at the input terminals of an AF93/IS903 drive is

approximately 0.95 at all operating speeds and loads. Therefore, power factor correction capacitors are not required and should not be installed. If capacitors for correcting the power factor of other equipment are installed too close to the drive, there may be an undesirable

interaction between the capacitors and the drive.

Standby Power Generation

Three phase standby power generators can be used with AF93/IS903 Adjustable Frequency Drives as long as the input line impedance is within the 1% to 5% range.

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To comply with local and nationally recognized codes, such as the NEC, you must consider proper output power wiring when you plan your Adjustable Frequency Drive installation.

Note: Make sure you use the most recent version of the codes when you install your AF93/IS903 drive.

Output Power Conductor and Ground

Conductor Sizing

Use a combination of the following guidelines to choose the correct output line conductors and proper branch circuit overload protection:

Note: Select the output power conductor size in accordance with applicable code

requirements.

¥ The output power conductors must be rated for the output voltage and current stated on the nameplate of the drive.

¥ For runs over 300 feet, consider the recommended minimum wire size listed in Table 2-1.

¥ In addition, consider the wire size capacity of the output line terminals:

2 to 10 Hp Maximum wire size is #10 AWG 15 to 25 Hp Maximum wire size is #4 AWG ¥ The input line conductors must be made of

copper with a temperature rating of at least

167¡F (75¡C).

¥ The power terminal tightening torque range is 16-18 in. lbs. on terminals L1, L2, L3, T1, T2, T3, and the ground lugs.

¥ The AF93/IS903 chassis ground conductor should be the same size as the output line conductors or sized according to electrical code requirements. Use a copper or aluminum conductor.

¥ Connection to a grounded conduit does not provide an adequate equipment ground. ¥ Make sure that all operatorÕs control stations

Pre-Installation

INSTALLATION

Output Power Considerations

Output Power Conductor Routing

For 7.5 to 25 Hp AF93/IS903:

¥ If you use conduit - Use a separate conduit for input line conductors and output power conductors. Never route analog and digital

wiring from any equipment in the same conduit as input or output power wiring.

¥ If you use cable trays - Use a separate cable tray for input line conductors and output line conductors. Never route analog

and digital wiring from any equipment in the same cable tray as input or output power wiring.

For 2 to 5 Hp AF93/IS903:

Overcurrent Protection

AF93/IS903 Adjustable Frequency Drives are designed to automatically provide overcurrent protection for the output power circuit only if one motor is connected to the drive and sized to match the drive.

If more than one motor is connected to the drive, each motor must have its own overcurrent protection. In addition, the combined input current rating on the nameplate of each motor must not exceed the output current rating of the drive.

Power Factor Correction

Power factor correction capacitors must

never

be connected to the output of the drive. They may damage the drive and would not serve any useful purpose.

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Pre-Installation

INSTALLATION

Analog and Digital Signal Considerations

To comply with the design of the drive and local

and nationally recognized codes, consider proper analog and digital signal wiring when you plan your Adjustable Frequency Drive installation. Note: Make sure you use the most recent

version of the codes when you install your AF93/IS903 drive.

External Fault Signal

Some configurations, such as an optional

overload interlock relay, provide an external fault signal to the drive so the drive will not start if the relay has tripped and has not been reset. If this or other option that requires an external fault signal is installed by the factory, the signal is factory wired. See the connection diagrams in the Drawings section of this manual for details.

Analog and Digital Signal Wiring

¥ 18 AWG wire size is recommended. Minimum wire size is 20 AWG. Maximum wire size is 16 AWG.

¥ One conductor per terminal for 16 AWG conductors. Two conductors per terminal at 18 AWG. Three conductors per terminal at 20 AWG.

¥ Maximum length is 500 feet; call your Cutler-Hammer sales representative or distributor for longer runs.

¥ Use shielded cable for the analog signal conductors where indicated on the terminal block connection diagram. Typically,

shielding is required for all analog input and output runs.

All digital signal runs over 75 feet long should be shielded.

¥ Only ground the shield conductor of shielded cable at the terminal block of the drive for input signals only. Output signals should not be grounded at the drive end of the cable but should be grounded at the device.

¥ The analog and digital signal conductors must be made of copper with a temperature rating of at least 167¡F (75¡C).

Analog and Digital Conductor Routing

For 7.5 to 25 Hp AF93/IS903:

¥ If you use conduit:

Never route analog and digital wiring from any equipment in the same conduit as input or output power wiring.

Do not run AF93/IS903 Adjustable

Frequency Drive analog and digital signal conductors in the same conduit that has control wiring for other equipment.

For 2 to 5 Hp AF93/IS903:

¥ If you use cable trays:

Never route analog and digital wiring from any equipment in the same cable tray as input or output power wiring.

Separate analog and digital wiring for your AF93/IS903 drive from other control

equipment wiring using a metal tray divider or keeping the conductors at least 2 inches apart.

Trays containing analog and digital wiring should be separated from trays containing low voltage (up to 30 volts) power wiring by at least 9 inches.

Trays containing analog and digital wiring should be separated from trays containing medium voltage (between 30 and 150 volts) power wiring by at least 18 inches.

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Installation Check List

To help assure a safe and reliable drive installation, make sure that the following tasks have been properly completed. You can find complete information on the task by referring to the Section(s) listed in the right column:

Installation Tasks

❐

Pre-Installation

Handling of Drive After Delivery Where to Locate Drive

Application Considerations Input Line Considerations Output Power Considerations

Analog and Digital Signal Considerations

Page

2-3 2-4 2-5 2-6 to 2-7 2-8 to 2-12 2-13 2-14

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Installation Check List

INSTALLATION

Installation Tasks

❐

Rough-In Enclosures

¥ Install options, if necessary, using the instructions packed with each option. ¥ Mount enclosures, in location selected,

when job site is clear of heavy and overhead construction.

¥ Use mounting dimensions shown in the applicable enclosure illustration.

❐

Rough-In Wiring

¥ Refer to the pre-installation section and gather wiring and materials necessary to install input line, output power, and terminal block wiring.

¥ Route all wiring through conduit or cable trays as described.

Page

AF93/IS903 Options Manual 2-5 2-22 to 2-24 2-12 to 2-14 To avoid an electrical shock, which can cause

serious personal injury or death, make sure branch circuit AC power is disconnected before you rough-in and connect the wiring.

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Installation Check List

INSTALLATION

Installation Tasks

❐

Connect Wiring

¥ Connect input line and output power conductors to locations shown in applicable connection diagram. ¥ Connect input and output ground

conductors to the chassis where shown on the applicable connection diagram.

¥ Connect the analog and digital signal wiring to locations shown on the applicable connection diagram.

¥ Connect all shielded cables to terminal block ground terminals where shown on the applicable connection diagram. Ground the cable at the drive end for inputs only.

¥ Check all wiring connections against all

connection diagrams shown at the end of this section, and those that came packed with the drive.

Page

2-29 and 2-30 2-29 and 2-30 2-29 to 2-32 2-31 and 2-32 AF93/IS903 Adjustable Frequency Drives

contain components and sub-assemblies that are sensitive to electrostatic discharge. Static control precautions are required when installing, testing, servicing, or repairing your Adjustable Frequency Drive. Component damage may result if you ignore electrostatic discharge control procedures.

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Installation Check List

INSTALLATION

Installation Tasks

❐

Install Motor and Related Equipment

¥ Mount motor and related equipment

according to manufacturerÕs instructions. Care should be taken to assure that the motor is properly aligned with the driven machinery to minimize motor loading. ¥ Connect output wiring to motor

according to the motor manufacturerÕs instructions. Make sure all phases are properly connected and the motor frame is grounded. Then connect the motor, applying the proper voltage, according to the diagram provided on the motor nameplate.

¥ Check wiring connections to the motor. To avoid an electrical shock , which can cause serious personal injury or death, make sure AC power is disconnected from drive before you connect the output power to the motor.

!

Warning

Read and heed all danger, warning, and caution statements contained in the motor manual and attached to the equipment. Refer to OSHA rules and regulations, paragraph 1910.219 for guards on mechanical power transmission apparatus.

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Installation Tasks

❐

Initial Startup

1. Before applying power to the drive, perform a safety check to assure the motor can rotate freely and that all necessary guards and shields are in place.

2. Apply AC power to the drive.

If the required jumpers or customer control circuitry is connected between terminals 7 and 8, and terminals 7 and 15 (see Figures 2-8 and 2-9), the drive is ready to operate as shipped using the keypad operator controls. 3. Use the operator keypad to enter the motor nameplate

parameters. Follow the instructions for entering parameters in the Using Your Keypad and Using the

Parameters sections.

If the motor is designed for a non-standard voltage or frequency, or if there are other unusual operating requirements, we recommend that you contact the Cutler-Hammer Solid State Motor Control Service Department for startup assistance.

4. Set a low operating speed.

5. If Reverse indicator is illuminated, press

F/R

button,

Forward indicator will light.

6. Press the

Start

button.

Check to see that the motor is rotating in the correct direction. Be prepared to stop the drive if the direction of rotation is not correct. If the direction is not correct, reverse the connection of any two motor leads.

7. Check operation throughout the normal operating speed range.

8. If you observe abnormal operation, refer to the

Troubleshooting section of this Instruction Manual.

9. Check operation with external control circuitry.

Installation Check List

INSTALLATION

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(31)

This part of the Installation section of this Instruction Manual presents the following series of drawings:

¥ Outline dimensions and options for mounting each chassis. ¥ Component identification drawings.

¥ Connection diagrams.

Drawings

(32)

Drawings

INSTALLATION

Mounting Dimensions for 2, 3, and 5 hp Frame Size

Figure 2-1

5.6" [142.00 mm] 8.3" [210.50 mm] 7.875" [200.02 mm] 5.157" [131.00 mm] ¿.207" (5.25 mm) (Two Places) ¿ .217" [5.50 mm] (Two Places) 6.5" [165.00] .28" [7.00 mm] 2 Airflow 1

Mounting hardware M5 or 8-32 UNC fasteners Recommended mounting torques:

Wood Screw - 20 in. lbs. (± 5 in. lbs.) Machine Screw - 15 in. lbs. (± 2 in. lbs.) Molly Bolt - 15 in. lbs. (± 2 in. lbs.)

Mount to flat, vertical surface (wall) for proper cooling 2

1 Note: 0 inch clearance required between

left and right sides and abutting surfaces when units are mounted horizontally in a row. If multiple rows will be stacked, 6 inches clearance is required between the sides - see Fig. 2-4.

4" Ventilation Space Required

AF93-5DIMEN

Approximate weight is 5 lbs. 3

(33)

Drawings

INSTALLATION

Mounting Dimensions for 7.5 and 10 hp Frame Size

Figure 2-2

¿.281" [7.14 mm] (Two Places) Airflow 5.957" [151.30 mm] 10.016" [254.41 mm] ¿.281" [7.14 mm] (Two Places) 6.535" [166.00 mm] 6.89" [175.00 mm] .394" [10.00 mm] 10.595" [269.11 mm] 2 1

AF93-10DIMEN

Note: 0 inch clearance required between left and right sides and abutting surfaces when units are mounted horizontally in a row. If multiple rows will be stacked, 6 inches clearance is required between the sides - see Fig. 2-4.

Mounting hardware M6 or 1/4-20 UNC fasteners Recommended mounting torques:

Mount to flat, vertical surface (wall) for proper cooling 2

1

Approximate weight is 9 lbs. 3

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Drawings

INSTALLATION

7.25" [184.15 mm] 16.50" [419.1 mm] 15.50" [393.00 mm] 8.40" [213.36 mm] 7.42" [188.61 mm] 1 2 Airflow

6" Ventilation Space Required 4" Ventilation Space Required

Mounting hardware M5 or 10-32 UNF or 10-24 UNC fasteners Recommended mounting torques:

Mount to flat, vertical surface (wall) for proper cooling 2 1 Approximate weight is 20 lbs. 3 Fan Fan AF93-20DIMEN ¿.25" [6.35 mm] (Two Places)

Mounting Dimensions for 15, 20 and 25 hp Frame Size

Figure 2-3

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Drawings

INSTALLATION

Air Flow Air Flow

Air Flow Air Flow Baffle

8" or 10" Ventilation Space

Required (Depending on Frame Size - See

Figs. 2-1 to 2-3) 6" Ventilation

Space Required

45° 45° Note: Install baffle at approx.

45° when mounting units in vertical alignment. Note: Multiple units can be staggered to provide adequate ventilation. AF93-MOUNT 6" Ventilation Space Required Baffle

OPTION 2

OPTION 1

Mounting Options for Adequate Ventilation

Figure 2-4

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Drawings

INSTALLATION

STOP RUN FAULT SETUP UP DOWN Scroll START F/R OPERATE SELECT Change Settings Keypad Remote Forward Reverse ETN-93-5HP Drive Platform (Not Field Serviceable)

Capacitor Assembly Cover

Fan

Keypad

Component Identification for 2, 3, and 5 hp Frame Size

Figure 2-5

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Drawings

INSTALLATION

Component Identification for 7.5 and 10 hp Frame Size

Figure 2-6

STOP RUN FAULT SETUP UP DOWN Scroll START F/R OPERATE SELECT Change Settings Keypad Remote Forward Reverse ETN-93-10HP Drive Platform (Not Field Serviceable)

Capacitor Assembly Cover

Fan

(38)

Drawings

INSTALLATION

Cover Heat Sink Fan Conduit Holes Rear Cover ETN-93-20HP STOP RUN FAULT SETUP UP DOWN Scroll START F/R OPERATE SELECT Change Settings Keypad Remote Forward Reverse Keypad Front Panel

Component Identification for 15, 20, and 25 hp Frame Size

Figure 2-7

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Drawings

INSTALLATION

Connection Drawing for 2, 3, and 5 hp Frame Size

Figure 2-8

AF93-5HpConn 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 FLTNO FLTCOM FLTNC RLY2B RLY2A RLY1B RLY1A EXTFLT PRST3 PRST2 PRST1 ACC2/JOG FWD/REV START STOP DIGCOM AOUT2 AOUT1 POT_HI POT_WPR Optional Dynamic Brake Module Service Entrance L1 L2 L3 Service GND Motor GND T3 T2 T1 NEMA-B Motor Wiring Box AGND ILOOP DB1 +BUS L1 L2 L3 T1 T2 T3 To Logic Board -Factory Wired Current Transformer (see Input Line

Considerations

in Pre-Installation instructions)

Note 1 : Customer supplied jumpers (7 and 8, 7 and 15) are required for running drive in KEYPAD mode.

See table 2-2 on page 2-37. Note 2 : Power terminal tightening

torque range is 16-18 in. lbs. on terminals L1, L2, L3, T1, T2, T3, and ground lugs. See Note 1 See Note 2 115V, 1¿, 60Hz L L Customer Supplied Fused Disconnect or Circuit Breaker Panel

(40)

Drawings

INSTALLATION

Connection Drawing for 7.5 (240 volt), 10, 15, 20, and 25 hp Frame Size

Figure 2-9

AF93-10HpConn 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 FLTNO FLTCOM FLTNC RLY2B RLY2A RLY1B RLY1A EXTFLT PRST3 PRST2 PRST1 ACC2/JOG FWD/REV START STOP DIGCOM AOUT2 AOUT1 POT_HI POT_WPR Optional Dynamic Brake Module Service Entrance L1 L2 L3 Service GND Motor GND T3 T2 T1 NEMA-B Motor Wiring Box AGND ILOOP IND- BR+ L1 L2 L3 Customer Supplied Fused Disconnect or Circuit Breaker Panel

To Logic Board -Factory Wired

Current Transformer (see Input Line

Considerations in Pre-Installation instructions) DB1 +BUS T1 T2 T3 115V, 1¿, 60Hz L L

torque range is 16-18 in. lbs. on terminals L1, L2, L3, T1, T2, T3, and ground lugs. Note 3 : Do not remove jumper. See Note 1

See Note 2

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Drawings

INSTALLATION

Connection Drawing for 7.5, 480 volt Frame Size

Figure 2-10

AF93-7.5HpConn 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 FLTNO FLTCOM FLTNC RLY2B RLY2A RLY1B RLY1A EXTFLT PRST3 PRST2 PRST1 ACC2/JOG FWD/REV START STOP DIGCOM AOUT2 AOUT1 POT_HI POT_WPR Optional Dynamic Brake Module Service Entrance L1 L2 L3 Service GND Motor GND T3 T2 T1 NEMA-B Motor Wiring Box AGND ILOOP L1 L2 L3 Customer Supplied Fused Disconnect or Circuit Breaker Panel

To Logic Board -Factory Wired

Current Transformer (see Input Line

Considerations in Pre-Installation instructions) DB1 +BUS T1 T2 T3 115V, 1¿, 60Hz L L

torque range is 16-18 in. lbs. on terminals L1, L2, L3, T1, T2, T3, and ground lugs. See Note 1

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Drawings

INSTALLATION

1 2 3 4 5 6 7 8 9 ₁₀ ₁₁ ₁₂ ₁₃ ₁₄ ₁₅ ₁₆ ₁₇ ₁₈ ₁₉ ₂₀ ₂₁ ₂₂

Speed Pot

STOP START _REV

FWD

ACCEL2/JOG

AF93-I/O Conn

Set two of relay output

Form C contacts for customer use

Note 2: To operate drive in KEYPAD mode, a jumper or customer permissive circuit must be installed between terminal 7 and terminal 15. See table 2-2 on page 2-37.

Note 3: Terminate the shield for ILOOP at the transducer end, not at the drive. Terminate the shield for speed pot and analog outputs at the AF93/IS903 chassis ground terminals located below the power terminal block. Note 1: To operate drive in KEYPAD mode,

a jumper must be installed between terminal 7 and terminal 8. See table 2-2 on page 2-37.

Set one of relay output

See Note 2

See Note 1

See Note 3

(Ð)

(+)

Analog Signal Input-(4-20 mA)

CH 2

Analog Signal Output to Ground (0-10 V)

Digital Preset Speed Inputs

CH 1

ILOOP AGND POT WPR POT HI AOUT1 AOUT2 DIGCOM STOP START FWD/REV ACC2/JOG PRST1 PRST2 PRST3 EXTFLT RLY1A RLY1B RLY2A RLY2B FLTNC FLTCOM FLTNO

Chassis Gound Screw

See Note 3

Input/Output Terminal Block Connections for 3-Wire Start/Stop Control

Figure 2-11

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Drawings

INSTALLATION

1 2 3 4 5 6 7 8 9 ₁₀ ₁₁ ₁₂ ₁₃ ₁₄ ₁₅ ₁₆ ₁₇ ₁₈ ₁₉ ₂₀ ₂₁ ₂₂ REV FWD ACCEL2/JOG AF93-I/O Conn2

Note 2: To operate drive in KEYPAD mode, a jumper or customer permissive circuit must be installed between terminal 7 and terminal 15. See table 2-2 on page 2-37.

Note 1: To operate drive in KEYPAD mode, a jumper must be installed between terminal 7 and terminal 8. See table 2-2 on page 2-37.

Set two of relay output programmed as "KEYPAD" Set one of relay output programmed as "RUN"

See Note 2

See Note 1

(Ð)

(+)

Analog Signal Input-(4-20 mA)

CH 2

Analog Signal Output to Ground (0-10 V)

Digital Preset Speed Inputs

CH 1

STOP

START

ILOOP AGND POT WPR POT HI AOUT1 AOUT2 DIGCOM STOP START FWD/REV ACC2/JOG PRST1 PRST2 PRST3 EXTFLT RLY1A RLY1B RLY2A RLY2B FLTNC FLTCOM FLTNO

Note 3: Terminate the shield for ILOOP at the transducer end, not at the drive. Terminate the shield for speed pot and analog outputs at the AF93/IS903 chassis ground terminals located below the power terminal block.

Form C contacts for customer use

See Note 3

Chassis Gound Screw

See Note 3

Speed Pot

Input/Output Terminal Block Connections for 2-Wire Start/Stop Control

Figure 2-12

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This part of the Installation section of this Instruction Manual provides the following specifications:

¥ Nameplate Identification ¥ General Specifications

Specifications

(45)

Specifications

INSTALLATION

Nameplate Identification

Adjustable Frequency AC Drive

Cat No: Input: Output:

150% Load Rating for 1 Minute Nominal HP:

Enclosure Type: Grounding Required

Cutler Hammer Corporation Solid State Motor Control Oldsmar, Florida USA 34677

V 3PH HZ A RMS V 3PH HZ A RMS Max Ambient ¡C @ Volts ETN-AF93NAME 1 2 5 3 6 4 7 8 14 9 10 11 12 13

Typical AF93/IS903 Nameplate

Figure 2-13

Legend:

1. Cat. No: - AF93/IS903 drives are available in various

models with different ratings, specifications and features as required for different applications. Figure 2-11 summarizes the information coded into the catalog number.

2. Input V 3PH: - Rated input line voltage; 3 phase.

3. Hz: - Rated input line frequency.

4. A RMS: - Rated input line current.

5. Output V 3PH: - Rated output line voltage; 3 phase.

6. Hz: - Rated output line frequency.

7. A RMS: - Rated output line current.

8. 150% or 110% Load Rating for 1 Minute - This

statement refers to the fact that the drive is rated to run for either one minute at 150% or one minute at 110% of its output current rating (see item7).

9. Max. Ambient: - Maximum allowable ambient

temperature for continuous operation at rated operating conditions.

10. Nominal HP: - Maximum brake horsepower load subject to the output voltage limitation (see item 11). 11. Volts: - The voltage limitation used when the Nominal

HP is measured (see item 10).

12. Enclosure Type: - The specific type of enclosure provided by the factory (see catalog for complete listing).

13. Bar Code: - All of the ordering and drive specific information is encoded at the factory.

14. Independent Testing Laboratory Logo: - Only certified or listed products are marked with a testing laboratory logo.

The equipment warranty covers only the original nameplate rating. If the equipment is applied contrary to the nameplate rating, or if unauthorized equipment modifications are made, the warranty becomes invalid.

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Specifications

INSTALLATION

General Specifications

Frequency Range

1.7 to 180 Hz

You must make certain that the motor and associated equipment are capable of

operating safely, and that protective guards are in place, before you operate your drive above 60 Hz.

Input Line Conditions

¥ Three phase 240 VAC, three phase 480 VAC, or single phase 240 VAC (±10 %). ¥ Input line impedance - 1% to 5%. You must

purchase a 1% input line reactor if you calculate or measure input line

impedance less than 1%.

¥ Line Distortion - The harmonic voltage distortion of the input power line should be limited to 10% or less including distortion caused by the drive(s). (See IEEE Standard 519.)

¥ Input phase voltage unbalance less than 3% (per IEEE Standard 446).

¥ Single phase input protection - drive will safely run on single phase until input current rating of the drive is exceeded. The output

current rating must be derated by 50% for all drives except the 2 Hp, 240 VAC unit (AF93AG0B002D) when single phase 240 V power is supplied. The 2 Hp, 240 VAC unit is fully rated for single phase or

¥ Drive insensitive to line phase sequence. ¥ Suitable for use on a circuit capable of

delivering not more than 65K RMS

symmetrical amperes, 480 volts maximum.

Input Line Transients

¥ Drive protected and operational for line

transients to ANSI C62.41 (formerly IEEE 587) and IEC 801.

¥ Drive protected (but may trip) for severe or prolonged transients per IEEE 446.

Operator Interface

The AF93/IS903 operator interface consists of: ¥ An LCD display (two rows of 16 characters per

row) and keypad.

¥ Operator can display operating conditions, parameter settings, or English language diagnostic messages on the LCD.

¥ Operator can change the settings of a pre-defined list of parameters.

¥ Operator can issue Start, Stop, Forward, and Reverse commands and change speeds using the keypad. Keypad can also be set for

remote Start and speed change. It is your responsibility to check your installation

to make sure it meets the conditions stated in these specifications

before

you install your Adjustable Frequency Drive. Operation of the drive outside of these specifications will void your warranty.

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Specifications

INSTALLATION

Terminal Block

The AF93/IS903 terminal block description is summarized in table 2-2 below:

AF93/IS903 Terminal Block Descriptions

Table 2-2

Terminal Name Terminal Description

1 LOOP Analog input speed reference from a 4-20mA current loop. Zin²250½. If SPEED FOLLOWER, PI REGULATOR, or ANALOG LOAD LIM (parameter 21) is enabled: Then if Iloop<1 mA, this input is ignored and speed reference is taken from terminal 3; If Iloop>1 mA, terminal 3 is ignored and speed reference is taken from this input. Active in REMOTE mode only.

2 AGND Analog signal common and shield tie point.

3 POT WPR 0-10V Analog input speed command. May be attached to the wiper of a potentiometer or the output of a remote control circuit. Zin > 100 k½. Active if SPEED FOLLOWER, PI REGULATOR, or ANALOG LOAD LIM (parameter 23) is enabled.

4 POT HI Analog input reference for external potentiometer. Requires a remote potentiometer of 1 k½ or greater. 5 AOUT1 Programmable analog output 1. 0-10V signal represents 0 to full scale of the selected parameter. 6 AOUT2 Programmable analog output 2. 0-10V signal represents 0 to full scale of the selected parameter. 7 DIGCOM Digital Input Common. This is local digital ground.

8 STOP Digital Input Stop/Run Enable Command. Must be LO (or connected to terminal 7) for drive to start or run; acts as a Run Enable. Momentary HI (or opening) stops the drive. Active in both KEYPAD and REMOTE modes. To run the drive in KEYPAD

mode, a customer supplied jumper must be placed between terminals 7 and 8, and terminals 7 and 15. Attempting to start

in KEYPAD mode without the jumper installation will yield a RUN DISABLED message. If drive is in AUTO RESTART mode, LO-HI (closed-open) transition exits the auto restart sequence and enters STOP mode without asserting a fault. If drive is in FAULT mode, LO- HI (closed-open) transition resets the fault and stops the drive.

9 START Digital Start Input. In 3-wire control, a momentary contact between terminals 9 and 7 sends a RUN command to the drive. In 2-wire control, a jumper is installed between terminals 9 and 7. Active when REMOTE mode is enabled. If drive is in AUTO RESTART mode, START is ignored. If drive is in FAULT mode, HI-LO (open-closed) transition while Run Enable is true resets the fault and starts the drive.

10 FWD/REV Digital Fwd/Rev Input. HI (open) = Forward (clockwise rotation viewed from the motor shaft end); LO (closed to terminal 7) = Reverse (counter-clockwise rotation viewed from the motor shaft end). Active when REMOTE mode is enabled.

11 ACC2/JOG Digital Accel/Decel2 Input / Jog Input. LO (closed to terminal 7) and RUN enable present (terminal 7 closed to terminal 8) selects second set of Accel/Decel presets in ACCEL2 mode; LO (closed to terminal 7) and RUN enable is present causes a jog motion in JOG mode. Active when REMOTE mode is selected.

12 PRST1 Digital Preset Speed Input 1. Least Significant Bit (LSB) of a 3-bit binary coded speed preset select. HI (open) = 0 (OFF), LO (closed to terminal 7) =1 (ON). Active when REMOTE mode is selected.

13 PRST2 Digital Preset Speed Input 2. Binary number selects one of seven internal presets entered from the setup menu. Code 0 (all inputs HI (open), OFF)) directs speed pot. or 4-20 mA current loop speed setting as command input. Active when REMOTE mode is selected.

14 PRST3 Digital Preset Speed Input 3. MSB of a 3-bit binary coded speed preset select. Active when REMOTE mode is selected. 15 EXTFLT Digital External Fault Trip Input. HI (opened to terminal 7) triggers an External Fault event and places the drive in FAULT mode,

shutting it down. To run the drive in KEYPAD mode, customer supplied jumpers must be placed between terminals 7 and

8 and terminals 7 and 15. Always active in both KEYPAD and REMOTE modes. Drive will coast to a stop.

16 RLY1A Programmable Relay 1 NO contact 17 RLY1B Programmable Relay 1 NO contact 18 RLY2A Programmable Relay 2 NO contact 19 RLY2B Programmable Relay 2 NO contact 20 FLTNC Fault Relay NC contact

21 FLTCOM Fault Relay Common 22 FLTNO Fault Relay NO contact

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Specifications

INSTALLATION

Digital Inputs

Dry contact closure. Protected from steady state overload of up to +25V/-5VDC. No isolation from internal logic supply is provided.

Digital Outputs

Two relay contact closure outputs are provided. The contacts are rated at 125 VAC, 1 amp resistive load (24 VDC, 1 amp).

Analog Inputs

0-10 VDC or 4-20 mA DC current loop. Input impedance greater than 100 k½ for voltage inputs; less than or equal to 250 ½ for current loop input. Protected from steady state overload of up to +25 V / -5 VDC. No isolation from internal logic supply is provided.

Analog Outputs

0-10 VDC. Output impedance less than 50 ½. Protected from externally applied steady state overload of up to +25 V / -5 VDC. No isolation from internal logic supply is provided. Output scaling is set from 0 to 10V, with no offset. If set to speed, 0 V = 0 rpm / 10 V = Max Speed. Minimum load impedance should be 1000 ½; 10,000 ½ is recommended.

Analog and Digital Input and Output

Signal Transient Protection

Inputs and outputs protected to IEC 801 transients.

Operating Environment

¥ Ambient Operating Conditions NEMA 1: 32 to 122ûF (0 to 50ûC). NEMA 4/12: 32 to 104ûF (0 to 40ûC). Less than or equal to 95% humidity (non-condensing and non-corrosive).

¥ Cooling Air

The cooling air must be free of conductive dust, oil mist and condensation. If the cooling air contains dust and oil, clean the heat sink surface of the unit regularly. If it is not cleaned, the unit will not be able to dissipate as much heat. The AF93/IS903 drive includes over-temperature protection, which will cause a fault and stop the drive. ¥ Storage Conditions

-4 to 158¡F (-20 to 70¡C). Less than or equal to 95% humidity (condensing and non-corrosive).

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Specifications

INSTALLATION

Dissipation Into Heatsink(2)

Drive Hp (240 VAC) Rated I(1) _{At Rated Current} _{At Half Rated Current}

3 9.6 Amps 84 Watts 40 Watts

7.5 22.0 Amps 184 Watts 85 Watts

Drive Hp (480 VAC) Rated I(1) _{At Rated Current} _{At Half Rated Current}

7.5 11.0 Amps 165 Watts 91 Watts

¥ Hazardous Environment

Must not be subject to explosive atmosphere or ÒHazardous (Classified) LocationÓ per National Electrical Code Article 500. ¥ Corrosive Environment

Must not be exposed to corrosive atmosphere, such as H2S. ¥ Solvent Withstand

Keypad will withstand common industrial solvents, such as alcohols and acids, per ASTM-896.

Shock and Vibration

Drive will withstand shock and vibration encountered during shipping, installation and operation per ASTM D999 and MIL-STD 202E.

EMI Radiation

Drive complies with FCC part 15B of federal regulation #47 as a class A digital device when operated in a specially designed optional enclosure.

EMI Susceptibility

Drive complies with IEC 801 (Performance Criteria 1) without fault or disturbance.

Agency Standards

In addition to standards previously listed, AF93/IS903 drives comply with the following agency standards: ¥ UL - Standard 508C and 840 ¥ cUL ¥ NEMA - ICS 3.1 ¥ IEC - 22G ¥ Heat Dissipation

(50)

Specifications

INSTALLATION

Catalog Number Codes

Voltage

Modification Codes (See AF93/IS903 Catalog) Application Rating

Special

*Horsepower

Base Catalog Number Series Enclosure A B C D E F G H A B C D E F G H -Legend Enclosure Style G - NEMA 1 J - NEMA 12 Voltage B - 200-240 V; 50/60 Hz C - 380-480 V, 50/60 Hz *Horsepower (Examples) 005 - 5 Horsepower Application Rating D - Dual Rated V - Variable Torque

Catalog Number Decoding for Drives Operating on 3-Phase Input Power

Figure 2-14

* Horsepower must be derated by 0.5 if single phase input power is used with 240 VAC units.

(51)

This section of your Instruction Manual identifies each keypad indicator and button and describes their function. After you review this section you will understand how to:

¥ Select which parameters will be displayed on your keypad LCD display.

¥ Change the settings of selected parameters using the keypad. ¥ Issue selected commands from the keypad.

SECTION 3

Using Your Keypad

Make sure you read, understand and follow all of the Safety Statements in the Safety section of this guide and all of the operation instructions in this manual

AF93-IS903

Cutler-Hammer

Instruction Manual

Quick Start

Cutler-Hammer

To Start Drive and Set Speed

Table of Contents

Page

Safety . . . S-1

The Meaning of Safety Statements . . . S-2

AF93/IS903 Safety Statements . . . S-2

Introduction . . . 1-1

Installation. . . 2-1

Pre-Installation . . . 2-3

Installation Check List . . . 2-15

Drawings. . . 2-21

Specifications . . . 2-33

Using Your Keypad . . . 3-1

About Your Keypad . . . 3-2

Keypad Tips and Modes . . . 3-5

Using the Start Button . . . 3-6

Using the Stop Button . . . 3-7

Using the Forward/Reverse Button. . . 3-8

Changing Parameter Settings. . . 3-10

Table of Contents

Page

Using the Parameters . . . 4-1

AF93/IS903 Parameter List . . . 4-2

AF93/IS903 Parameter Descriptions . . . 4-13

Troubleshooting Your Drive . . . 5-1

Displaying Fault Messages . . . 5-2

Solutions To Drive Problems . . . 5-3

Checking DC Bus Voltage . . . 5-6

Appendix . . . A-1

AF93/IS903 Parameter List - Numerical Order . . . A-2

AF93/IS903 Parameter List - Alphabetical Order . . . A-4

AF93/IS903 Keypad Template . . . A-7

Index . . . I-1

Safety

The Meaning of Safety Statements

Notice

AF93/IS903 Safety Statements

Notice

before

Danger

will

Safety

Danger

Warning

could

Caution

may

Warning

Caution

Safety

Danger

Warning

Caution

Safety

Warning

SECTION 1

Introduction

About This Manual

SECTION 1

bold italics

bold without italics

SECTION 2

Installation

before you install your drive

Pre-Installation

Pre-Installation

INSTALLATION

Handling of Drive After Delivery

Pre-Installation

INSTALLATION

Where to Locate Drive

Pre-Installation

INSTALLATION

Application Considerations

AF93/IS903 Options