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T ransition manual Altivar 61 Migration from A TV38 V A TV61.
This document ha s been designed to assis t you when replacing an Altivar 38 with an Altivar 6 1 version V1.1 ie01 or lat er. Scope of applicatio n: - Variable-torque app lications - Replacement of Al.
3 T able of content s Determining catal og numbers ____________________ _____________________________ ______________________________ _____ 6 Choosing the Alt ivar 61 catalog number __________________ .
4 Implement ation procedure b 1 Identifying the existing ATV 38 v Make an inventory of your Altivar 38 installation. Steps 3 and 4 must be performed wit h the power off. b 2 Selecting the ATV 61 v Determine the Altivar 61 catalog number. v Choose the various options required.
5 Altivar 38 hardware identification Before selecting the Altivar 61, the Altivar 38 hardware configuration needs to be determined carefully. 1 Measure the line voltage and ind icate the type of po we.
6 1. Determining cat alog numbers 1. 1. Choosing the Alti var 61 catalog number Required information (re fer to page 5 ): type of use, l ine voltage, Altivar 3 8 catalog number 1.
7 1. Determining cat alog numbers 1. 2. Selecting the power circuit options 1. 2. 1. Radio interference filters (VW3A684x ) The filters previously ins talled on the ATV38 are not com patible with the ATV 61 and must, therefore, be replaced. No kit for substit ution (mounting) between the 2 filter ranges.
8 1. Determining cat alog numbers 1. 3. Mounting accessories 1. 3. 1. Removable power terminal kit (VW3A5881x) There is no equivalent to this k it for the Altivar 61. 1. 3. 2. Air exchanger kit (VW3A5880x) There is no equivalent to this k it for the Altivar 61.
9 1. Determining cat alog numbers 1. 4. Control circuit options 1. 4. 1. Control card fan kit (VW3A5882x) Required informati on: Altivar 61 catalog number At an ambient temperatu re between 50°C and 60°C, the Altivar 61 has a higher operating capa city than the Altivar 38.
10 1. Determining cat alog numbers 1. 5. Selecting I/O extension cards (VW 3A58201, VW3A58202) 1. 5. 1. ATV38 and I/O option cards (VW3A58201, VW3A58202) Required information: Connect ion diagram, presence of an I/O extension card As standard the ATV 61 has more I/O than t he ATV38.
11 1. Determining cat alog numbers PI feedback or summed reference: Th ree different opti ons Tachometer: Totally incompatible . Alternative solution: u se an in cremental encoder.
12 1. Determining cat alog numbers 1. 6. Selecting communication channels 1. 6. 1. Communication via Modbus ne twork With this t ype of communication, t here are several possible sc enarios: 1) The Al.
13 1. Determining cat alog numbers 1. 6. 5. Communication with Metasys N2 bus VW3A58354U Card catalog number 1. 6. 6. Communication with INTERBUS bus (VW3A58304(E)) Card catalog number Installation and connection For the Altivar 61, keep the exi sting connections.
14 2. Drive implement ation 2. 1. Installation 2. 1. 1. Using catalog numbers sta rting with ATV38H The dimensions g iven in th e following secti ons can be used to compare those of an Altivar 3 8 equipped with an option c ard and i ts operator terminal wit h an Altivar 61 also equipped with an option card an d operator terminal.
15 2. Drive implement ation 2. 1. 1. 1. Three-phase supply 380…480 V (f or catalog numbers starting with ATV38H) Comparison of dimen sions (1) No problem if space is left between 2 drives . Width incompatible if the ATV38 drives are mount ed side by side.
16 2. Drive implement ation 2. 1. 1. 2. Three-phase supply 380…480 V for catalog numbers s tarting with ATV38H. Comparison of dimen sions (1) No problem if space is left between 2 drives . Width incompatible if the ATV38 drives are mount ed side by side.
17 2. Drive implement ation 2. 2. Comparison of dimensions 2. 2. 1. Dimensions ATV38H ppp product on heatsink ATV 61H ppp y 15 kW without graphic dis play termi nal, with and without option cards ATV-38H a b c G H Ø U18N4, U29N4, U41N4 150 23 0 184 133 210 5 U54N4, U72N4, U90N4 175 286 184 155 270 5.
18 2. Drive implement ation ATV 61H ppp y 15 kW with graphic display termi nal, with and witho ut option cards ATV 61H ppp y 75 kW with graphic display termi nal, with and witho ut option cards ATV 61H a mm (in.) b mm (in.) c mm (in.) c1 mm (in.) c2 mm (in.
19 2. Drive implement ation ATV 38H ppp > 75 kW and y 315 kW - Product on heatsink ATV 61H ppp > 75 kW and y 315 kW with graphic display terminal , with and without op ti on cards ATV 61H a mm (in.) b mm (in.) c mm (in.) G mm (in.) H mm (in.) Ø mm (in.
20 2. Drive implement ation 2. 3. Mounting the RFI filter The dimensions gi ven in the following se ctions can be used to compa re the dimensions of the Altivar 38 RFI filters wit h those u sed on the Altivar 61.
21 2. Drive implement ation 2. 3. 0. 2. Three-phase supply 400…460 V for catalog numbers s tarting with ATV38H Drive Filter Width Height Depth Mounting a b c G H ATV38HC10N4 (X) VW3A68415 260 386 11.
22 2. Drive implement ation 2. 3. 1. Comparison of dimensions 2. 3. 1. 1. RFI filters VW3 a (mm) b (mm) c (mm) G (mm) H (mm) H1 (mm) Ø (mm) A4 401 130 290 40 105 275 – 4.5 A4 402 155 324 50 130 309 – 4.5 A4 403 175 370 60 150 355 – 5.5 A4 404 210 380 60 190 365 – 5.
23 2. Drive implement ation Mounting under the drive Side mounting against t he ATV 61 4 x ATV 38 ATV 61 Filter Drive Filter - Drive connection Power connection.
24 2. Drive implement ation 2. 4. NEMA mounting kits Dimensions, in inches and (mm) Kit cata log number Prod uct size Drive catalog number ATV38H ppppp a (in.) b (in.) c (in.) G (in.) H (in.) Ø (in.) d (lb.) VW3A58852 2 U18N4, U29N4, U41N4 5.9 1 (150) 9.
25 2. Drive implement ation Kit for UL NEMA Type 1 conformity or IP 21 protec tion VW3 A9 ppp VW3 a (in.) b (in.) VW3 a (in.) b (in.) A9 101, 201 130 (5.12) 113 (4.45) A9 106, 206 240 (9.45) 185 (7.28) A9 102, 202 155 (6.10) 103 (4.06) A9 107, 207 240 (9.
26 2. Drive implement ation 2. 5. Separate cont rol card power supply 2. 6. Remote display terminal Used to connect the programming te rminal remotely on the front of the enclosure. Fixings: As the dimensions are not th e s ame, the fixing holes must be modified.
27 2. Drive implement ation 2. 7. Power cables The layout and type of power termi nal s have changed: Ring terminals must be used rathe r than ferrules for the ground termin als, although for the power termina ls the ferrules used p reviously can be retained if they are in good condition (a flattened ferrule wil l not make a good connection).
28 2. Drive implement ation Characteristics of the ATV38 power ter minals Layout of the ATV 61 power termin als and tightening torque For ATV 61 pppppp drives For ATV 61 pppppp drives For ATV 61 pppppp drives ATV 38 E rati ng Maximum wire si ze Tighteni ng torque in Nm AWG mm 2 D05N4, D07N4, D09N4, AWG 8 6 0.
29 2. Drive implement ation Layout of the ATV 61 power termin als and tightening torque ATV61H D55M3X, D75M3X, D90N4, C11N4 Maximum terminal wire size/tightening torque Drive terminals L1/R , L2/S, L3/T, U /T1, V/T2, W/T3 PC/-, PO, PA/+ PA, PB 2 x 100 mm 2 /24 Nm 2 x 100 mm 2 /41Nm 60 mm 2 /12 Nm 2 x 250 MCM/212 lb.
30 2. Drive implement ation ATV61H D90M3X, C13N4 Maximum terminal wire size/tightening torque (1) Power s upply for th e fans, comp ulsory if the drive is on ly powered by the DC bus. Do not use i f the drive is powered with a 3-phase supply by L1/R, L2/S, L3/T.
31 2. Drive implement ation ATV61HC16N4 Maximum terminal wire size/tightening torque (1) Power s upply for th e fans, comp ulsory if the drive is on ly powered by the DC bus. Do not use i f the drive is powered with a 3-phase supply by L1/R, L2/S, L3/T.
32 2. Drive implement ation ATV61HC22N4 Maximum terminal wire size/tightening torque Power supply for the f ans, co mpul sory if t he d rive is only po we red b y t he DC bu s. Do no t use if t he d rive is powered with a 3-p h a se s upply by L1/R, L2/S, L3/T.
33 2. Drive implement ation ATV61H C25N4, C31N4 Maximum terminal wire size/tightening torque (1) Power s upply for th e fans, comp ulsory if the drive is on ly powered by the DC bus. Do not use i f the drive is powered with a 3-phase supply by L1/R, L2/S, L3/T.
34 2. Drive implement ation Control wiring and I/O characteristics (Warning: Check the I/O assignment made by PowerSuite) In order to ensure that the Altivar 6 1 works correctly, the following rules m.
35 2. Drive implement ation Connection diagram for logi c I/O option card (VW3 A3 201) Connection diagram for exten ded I/O option card (VW3 A3 202) AI1 input on the ATV 61 wired as non differential 0.
36 2. Drive implement ation Wiring the VW3 A3 401 option card encoder input when replacing an ATV38 On the Altivar 38, encoder signals A A- or B B- had to be reversed in order to avoid t he motor rotating in th e wrong direction. This anomaly has been corrected on the Alti var 61 and , therefore, the wiring conforms to the si gnal order A A- B B-.
37 3. Implement ation of the Alti var 61 communication option cards 3. 1. General Acceptance Check that the card catalog number mark ed on the label is the same as that on the delivery no te corresponding to the purchase o rder. Remove the option card from its pack aging and check that it has not been damaged in tra nsit.
38 3. Implement ation of th e communication option cards Option card fault The [internal com. link ] ( ILF- ) fault appears when the following seri ous problems occur: - Hardware fault on the option c.
39 3. Implement ation of th e communication option cards 3. 2. Communication via Modbus network 3. 2. 1. Calculating the polarization resisto rs Mixed schematic Slaves with 4.7 k Ω polarization can be int egrated into a standard schematic. Su itable polarizat ion resistance (Rp) must be c alculated.
40 3. Implement ation of th e communication option cards 3. 2. 2. Reminder of the va rious connection methods: ATV 61 RJ45 connector on TSXSCA50 or other screw terminals : Use cable VW3 A8 306 D30 (RJ45 to stripped end, 3 meters) ATV 61 RJ45 connector on TSXSCA62: Use cabl e VW3 A8 306 (RJ45 to 15-way Sub-D) 3.
41 3. Implement ation of th e communication option cards Configuring communication monitoring Since the Altivar 38’ s communication monitoring ti me out is the same as the default valu e of the Altivar 61’s [Mod bus time out] ( tt O ) field (10 s), there is no poi nt in modifying the value of this fi eld.
42 3. Implement ation of th e communication option cards 3. 3. Communication via Unitelway/Modbus network a nd VW3 A3 303 option card 3. 3. 1. Reminder of possible conn ection methods If the chosen co.
43 3. Implement ation of th e communication option cards 3. 3. 3. Configuring polarity on the drive RS 485 bus The card is equipped with 2 line polarity conf iguration switches but the orientation is not the same f or the Altivar 38 and the Altivar 61.
44 3. Implement ation of th e communication option cards 3. 4. 3. Configuring the drive On the Altivar 38 ’s CANopen communication opt ion card, both addresses a nd the bus speed coul d be set via switches.
45 3. Implement ation of th e communication option cards 3. 5. Communication vi a Profibus DP network 3. 5. 1. Reminder of the possible c onnection methods: Same as existing 3.
46 3. Implement ation of th e communication option cards 3. 5. 3. Configuring the drive in "ATV38 Interc hangeability" mode The Profibus protocol operat es according to the principle of exchanging periodic data.
47 3. Implement ation of th e communication option cards 3. 6. Communication via Fipio network - VW3 A3 311 option card 3. 6. 1. Reminder of the possible c onnection methods: Same as existing 3.
48 3. Implement ation of th e communication option cards 3. 6. 5. Configuring the drive in "ATV38 Interc hangeability" mode In order to use the Alt ivar 38’s periodic input /output variable s rather than those of the Altivar 61, you need to set switch 1 to t he ON position and restart the dri ve.
49 3. Implement ation of th e communication option cards 3. 7. Communication via Interbus network 3. 7. 1. Reminder of the possible c onnection methods: Same as existing The profile used by the Altivar 61 in the CMD Tool bus configurato r is compatible with that of the Altivar 38, i.
50 3. Implement ation of th e communication option cards 3. 8. Communication vi a Modbus Plus network 3. 8. 1. Reminder of the possible c onnection methods: Same as existing 3.
51 3. Implement ation of th e communication option cards 3. 8. 4. Configuring the drive in "ATV38 Interc hangeability" mode The followi ng bus management para meters: Time out, Peer Cop node, Control st ation, Number of regist ers are transferred by the PowerSuite software wo rkshop wit h the same values as they had in the Altivar 38.
52 3. Implement ation of th e communication option cards 3. 9. Communication via DeviceNet network 3. 9. 1. Reminder of the possible c onnection methods: Same as existing 3.
53 3. Implement ation of th e communication option cards PLC configuration and application Only activate the Device Type opt io n in the "Electronic Key" zone, so that there is no control over th e node type when the bus starts.
54 3. Implement ation of th e communication option cards 3. 9. 4. Drive implementation on the DeviceNet n etwork Before attempting t o replace an Altivar 38 wi th an Altivar 61, its co nfiguration must b e backed up using the RSNe tWorx software work shop.
55 3. Implement ation of th e communication option cards 3 "Upload" the Altivar 38 configuration: Once the network has been i dentified correctly, the whole configuration can be retrieved from a slave. Double-click with the lef t mouse button on the relevant Altivar 38.
56 3. Implement ation of th e communication option cards 4 Click on the "Device Parameter" tab; a window appears a sking whether you want to "Upload " or "Download". Choose Upload in order to retrieve the Altiva r 38 configuration.
57 3. Implement ation of th e communication option cards 5 Once uploading is complet e, a window appears; click on the "Device Parameters" tab to display all the Altivar 38 parameters. The whole Altivar 38 configuration has now been retrie ved.
58 3. Implement ation of th e communication option cards Backing up the configu ration before transfer to the Alti var 61 in 8 serie mode: Select "Save As…" in the File menu to retain this.
59 3. Implement ation of th e communication option cards 6 Preparation of the Alti var 61: It is vita l to perform a speci al setting on the Alt ivar 61 so that it c an accept the old Alt ivar 38 configuration, which will b e transmitted by th e DeviceNet network.
60 3. Implement ation of th e communication option cards 3. 9. 5. Communication fault DeviceNet communication faults are indicated by the red RD LED on th e card. Parameter [Network fault] ( CnF- ) can be use d to obtain more detailed information about the origin of the fault.
61 3. Implement ation of th e communication option cards 3. 10. Communication via Ethernet network 3. 10. 1. Reminder of the possible connect ion methods: Same as existing Warning Because of certain minor incompa tibilities, described below, the repl acement of an Altivar 38 by an Al tivar 61 on an Ethernet b us is supposed to be definitive.
62 3. Implement ation of th e communication option cards 3. 10. 5. Using the DHCP-FDR protocol The DHCP-FDR protocol is only supported by vers ion 2.1 of the VW3 A58310 Ethernet opti on card. This section, ther efore, only applies to replacement of an Al tivar 38 equipped with this type of card .
63 3. Implement ation of th e communication option cards 3. 10. 7. Programming the Altivar 38 Ethernet pa rameters Apart from the drive DHCP name ("DeviceName" parameter), all the pa ra meters that can be accessed usin g the Altivar 38’ s program ming terminal are present on an Alt ivar 61 equipped with a VW3 A3 310 Ethern et card.
64 3. Implement ation of th e communication option cards Ethernet card access to t he Modbus server With the VW3 A3 310 Ethernet card, access to address fields W40 ppp (values tran smitted by the IO S.
65 3. Implement ation of th e communication option cards 3. 10. 10. Communication fault Ethernet communic ation faults are indi cated by the red FLT LED on the card. Parameter [Network fault] ( CnF- ) can be use d to obtain more detailed information about the origin of the fault.
66 3. Implement ation of th e communication option cards Configuring the "IO Scanner" page from the HTTP server Click the " Setup " button.
67 3. Implement ation of th e communication option cards Click the " PassWord " button, enter USER i n the Password field; press the Ent er key on your keyboard, then De activate t he IO scanner by setting IoScanne r to No.
68 3. Implement ation of th e communication option cards Configuring the "IO Scanner" page using TCP/Modbus mess aging Using TCP/Modbus serv ices and calling on the Ethernet card’ s Modbus server, assign the same drive parameter as for the Altivar 38 register to each peri odi c register.
69 3. Implement ation of th e communication option cards Standard HTTP server The storage capaci ty of the VW3 A3 310 Ethernet card fo r Web server files has been increased: 1.536 kb , as against 196 kb for the VW3 A58310 Etherne t card. The maximum number of URL files ha s changed from 50 to 150.
70 3. Implement ation of th e communication option cards 3. 11. AS-i The bus configuration must be modified in the PLC because the profi le used by the 4I/4O (S.7.0.F.E) module is di fferent from th at of a drive (7E). 4I/4O module wiring: ASI20MT4I4OR 3.
71 3. Implement ation of th e communication option cards 3. 11. 1. 1. +/- speed mode Assignment of the Inputs/Outputs 4 logic inputs used on the termina ls, 2-wire control LI1: Forward LI2: Reverse LI3: + speed LI4: - speed 3.
72 3. Implement ation of th e communication option cards 3. 11. 2. 4-speed mode, 2 dire ctions of operation Assignment of inputs/outp uts 4 logic inputs used on the termina ls, 2-wire control LI1: Forward LI2: Reverse LI3: 2 preset speeds LI4: 4 preset speeds 3.
73 3. Implement ation of th e communication option cards 3. 12. Application-s pecific option cards Please refer to the Altiva r 61 Programming Guide for information abou t how to us e these different functions. Pump card VW3A58210 This card is con tinued on the Altivar 61 and its catalog number is VW3A3502.
2006-04 atv61_migration_en_v 1.
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