Download Document 3397631

OmniPulse™ DDC
Magnetek Training
OmniPulse™ DDC
Training
• The objective of this training is to familiarize service and
maintenance personnel with
– The many resources available to assist in
• Start up
• Maintenance
• Troubleshooting
– The training course is designed to provide knowledge on:
• The basics of DC motors and DCCP control
• The User Manual layout and information
OmniPulse™ DDC
Training
• The basic operating theory of the technology
• Hardware layout, circuit board layout, and circuit board jumper and
switch settings
• Navigating the display and software menus
• Understanding each parameter function and how they interrelate
and effect drive performance
• Trouble analysis using drive fault messages and trouble flow charts
• Loading control and display software
OmniPulse™ DDC
Session One
Basic DC Background
Quadrants of Operation
Quadrants of
Operation
In this quadrant the
motor must
provide the
braking Torque to
slow the Hoist or
plugging in travel
motion. The
energy is a result
from the rotating
inertia reflected at
the motor shaft.
In this quadrant the
motor must
provide the
physical torque to
overcome
frictional forces,
such as lowering in
open hook.
In this quadrant the
motor must
provide the
physical torque to
raise the load or
move the Trolley
or Bridge.
In this quadrant the
motor must
provide the
braking torque to
counter act gravity
effect when
lowering a load at
a controlled speed.
DC Motors
Performance Curves
Hoist Control DCCP Panel
DC Motor Construction
Brush Rigging even number of
brushes in pairs
(Pos and Neg)
Series Field
Armature
Commutator
DC Motor Connections
Basic Performance Curves
Typical DCCP Hoisting
Performance Curves
Series Resistor Hoist
•
•
•
•
Hoist connection
High speeds light loads
High torque low speeds
Effect of increasing resistor
– Reduced torque
– Poorer speed regulation
Variable Shunted Armature
• Hoist connection
• Good speed regulation @
reduced speeds
• Increased current in series
field
• Slow down torque available
• Decreasing Resistance
–
–
–
–
Reduces starting torque
Improves speed regulation
Increases slowdown torque
Increase the current in the
series field
Fixed Shunted Armature
• Hoist connection
• Increasing resistance
–
–
–
–
Decreases starting torque
Reduces speed regulation
Decreases slowdown torque
Decreases current in the
series field
Shunted Field Var Res
•
•
Lowering connection
Increasing series field
resistance
– Increases starting torque
– Increases dynamic lowering
speed
– Reduces speed regulation
Shunted Field Var Arm Res
•
•
Lowering connection
Increasing resistance
– Reduces starting torque
– Reduces speed regulation
– Increases dynamic lowering
speed
Off Position DB
• Self excited no power
required
• No starting torque developed
• Increasing resistance
– Increases speed
– Reduces speed regulation
– Reduces deceleration
torque
Typical One Line Electrical
DCCP Typical Crane
Single Wiring Diagram
DCCP Typical Panel &
Resistor
DCCP Hoist Diagram
Hoist Steps
Lowering Steps 1 and 2
Lower Steps 3, 4, and 5
DB Step
End of Session One
Note:
All reference to Figures, Page Numbers and Tables are
to be found in the
OmniPulse DDC Technical
Manual
Session Two
OmniPulse™ DDC Changing The Rules
Operating Principles Pages12-15
Hoist Power Circuit
MCB
M
F1
L1+
Q1P
L11
K
PR
RT
Q2P
D1P
Q3P
D3P
D2P
CT2
CT1
Q1N
Q2N
Q3N
CT3
C
MCB
D2N
D1N
D3N
LL2
L2Ð
T1
T2
A1
A2
T4
R6
R8
DB
Collector
Rails
T3
B1
B2
LS
Q2
Resistor
Q6
Q1
A2
A1 Q5
S2
Series
Field
Arm
Q4
S1
Q3
B1
B2
Series
Brake
Simplified Motor Circuit
Series Field Hoist Motion
T1, T2, T3 Voltages Referenced to L2(-)
T1
T2
T3
PWM Power Hoisting
T1
Drive
Terminal
Voltage
T2
T3
Motor Armature
Terminals
T1-T2
Voltage
+V
0
-V
Q1 P
+V
0
-V
Q2 P
+V
0
-V
Q3 P
Q1 N
Q2 N
Q3 N
+V
0
-V
Current
0
Series Field
Terminals
T2-T3
Voltage
+V
0
-V
Current
0
t1
t2
t3
t4
t1 - t2 Current Path Power
Hoisting
MCB
M
F1
L1+
Q1P
L11
K
PR
RT
Q2P
D1P
Q3P
D3P
D2P
CT2
CT1
Q1N
Q2N
Q3N
CT3
C
D2N
D1N
MCB
D3N
LL2
L2Ð
T1
T2
A1
A2
T4
Time Period t1 - t2
+V
0
-V
R6
R8
DB
Collector
Rails
T3
B1
B2
LS
Q2
Resistor
0
Q6
+V
0
-V
Q1
A2
Series
Field
Arm
Q4
0
t1
t2
t3
t4
A1 Q5
S1
Q3
S2
B1
B2
Series
Brake
t2 - t3 Current Path Power
Hoisting
MCB
M
F1
L1+
Q1P
L11
K
PR
RT
Q2P
D1P
Q3P
D3P
D2P
CT2
CT1
Q1N
Q2N
Q3N
CT3
C
D2N
D1N
MCB
D3N
LL2
L2Ð
T1
T2
A1
A2
T4
Time Period t2-t3
+V
R6
R8
DB
Collector
Rails
T3
B1
0
B2
LS
Q2
-V
Resistor
0
Q6
+V
Q1
A2
0
-V
Q4
t1
t2
t3
t4
A1 Q5
S2
Series
Field
Arm
0
S1
Q3
B1
B2
Series
Brake
t3 - t4 Current Path Power Hoisting
MCB
M
F1
L1+
Q1P
L11
K PR
RT
Q2P
D1P
Q3P
D3P
D2P
CT2
CT1
Q1N
Q2N
Q3N
CT3
C
D2N
D1N
MCB
D3N
LL2
L2Ð
Time Period t3-t4
+V
0
-V
T1
T2
A1
A2
T4
R6
R8 DB
Collector
Rails
T3
B1
B2
LS
Q2
Resistor
0
Q6
+V
0
-V
Q1
A2
Q4
t1
t2
t3
t4
A1 Q5
S2
Series
Field
Arm
0
S1
Q3
B1
B2
Series
Brake
PWM Power Lowering
T1
Drive
Terminal
Voltage
T2
T3
+V
0
Q 1P
-V
Q 1N
+V
Q 2P
0
-V
Q 2N
+V
Q 3P
0
-V
Q 3N
+V
Motor Armature
Terminals
T1-T2
Series Field
Terminals
T2-T3
Voltage
0
-V
Current
0
Voltage
+V
0
-V
Current
0
t9
t 10
t 11
t10 - t11 Current Path
Power Lower
MCB
M
F1
L1+
Q1P
L11
K
PR
RT
Q2P
D1P
Q3P
D3P
D2P
CT2
CT1
Q1N
Q2N
Q3N
CT3
C
D2N
D1N
MCB
D3N
LL2
L2Ð
Time Period t10-t11
+V
0
-V
T1
T2
A1
A2
T4
R6
R8
DB
Collector
Rails
T3
B1
B2
LS
Q2
Resistor
0
Q6
A2
+V
0
-V
t9
t 10
t 11
A1 Q5
S1
S2
Series
Field
Arm
Q4
0
Q1
Q3
B1
B2
Series
Brake
Power Hoisting
10% RPM
151V
125V
T1
122V
T2
+26V
T3
+3V
Deceleration Braking
10% RPM
99V
125V
T1
122V
T2
-26V
T3
+3V
Power Lowering
10% RPM
106V
125V
T1
122V
T2
-19V
T3
+3V
Dynamic Lowering
10% RPM
144V
125V
T1
122V
T2
+19V
T3
+3V
Travel Power Circuit
Simplified Travel Motor
Circuit
T1, T2, T3, T4 Voltages
T1
T2
4
T4
T3
PWM Travel Motoring
T1
Drive
Terminal
Voltage
T2
T3
Motor Armature
Terminals
T1-T2
+V
0
-V
Q1 P
+V
0
-V
Q2 P
+V
0
-V
Q3 P
T4
+V
Voltage
+V
0
-V
Q1 N
Q2 N
Q3 N
Current
0
Series Field
Terminals
T4-T3
Voltage
+V
0
-V
Current
0
t1
t2
t3
t4
t1 - t2 Current Path Travel
Motoring
D3P
T1 - T2 =0
T4 - T3 =0
t2 - t3 Current Path Travel
Motoring
D3
P
T1 - T2 =0
T4 - T3 =+V
t3 – t4 Current Path Tr
avel Motoring
D3P
T1 - T2 =+V
T4 - T3 =0
Travel Plugging / Braking
D3P
T1 - T2 =-V
T4 - T3 =+V
End of Session Two Questions?
OmniPulse™ DDC
Session Three
Hardware
Modular Drive Design
NEMA 3
Complete
(133A)
144-45004
* Interface
144-45062
Display
144-45063
NEMA 4
Complete
(200A)
Control
144-45060
Driver
144-45058
133A Stack
144-45042
* Interface
144-45062
Display
144-45063
*NOTE:
Interface Card 144-45062 mounted
separately from module enclosure
Control
144-45060
Driver
144-45059
200A Stack
Modular Drive Design
144-45005
NEMA 5
Complete
(400A)
* Interface
144-45062
Display
144-45063
Control
144-45060
Driver
144-45059
400A Stack
144-45005
NEMA 6
Complete
(800A)
* Interface
144-45062
Display
144-45063
Control
144-45060
Driver
144-45059
400A Stack
144-45006
*NOTE:
Interface Card 144-45062 mounted
separately from module enclosure
400A Follower
Driver
144-45059
400A Stack
Modular Drive Design
NEMA 7
Complete
(1200A)
144-45005
* Interface
144-45062
Display
144-45063
Control
144-45060
Driver
144-45059
144-45006
400A Follower
Driver
144-45059
*NOTE:
Interface Card 144-45062 mounted
separately from module enclosure
400A Stack
400A Stack
144-45006
400A Follower
Driver
144-45059
400A Stack
Modular Drive Design
144-45005
NEMA 8S
Complete
(1600A)
* Interface
144-45062
Display
144-45-063
Control
144-45060
400A
Follower
*NOTE:
Interface Card 144-45062 mounted
separately from module enclosure
400A
Follower
400A
Follower
Driver
144-45059
400A Stack
144-45006
Driver
144-45059
400A Stack
144-45006
Driver
144-45059
400A Stack
144-45006
Driver
144-45059
400A Stack
Modular Drive Design
144-45005
NEMA 8L
Complete
(2000A)
97-3619-4
* Interface
144-45062
Display
144-45-063
*NOTE:
Interface Card 144-45062 mounted
separately from module enclosure
Control
144-45060
Driver
144-45059
400A Stack
400A
Follower
144-45006
Driver
144-45059
400A Stack
400A
Follower
144-45006
Driver
144-45059
400A Stack
400A
Follower
144-45006
Driver
144-45059
400A Stack
400A
Follower
144-45006
Driver
144-45059
400A Stack
Trolley Panel Size 3 133
Amps
Interface
Bd
M
Contactor
SB Contactor
Hoist Panel Size 5 400
Amps
M Contactor
DB Contactor
Drive
Interface Bd
Travel Panel Size 6 800
Amps
SB Contactor
M Contactor
Follower
Master
Interface Bd
Hoist Panel Size 7 1200
Amps
M Contactor
Follower 2
Follower 1
Master
SB Contactor
Hoist Panel Size 8S 1600
Amps
CCB
DB Contactors
MCB
Follower
3
Follower
2
Follower
1
Master
Drive
M Contactor
Interface Card 144-45007
Interface Card 144-45062
Figure 24 User Manual
Green LED
230VDC
Output
Status
indicators
S1 Reset
Switch
144-45062
Green LED
230VDC
Input Status
indicators
Interface Card 144-45062
Picture
144-45062
L1+
L2COM+
SB 230VDC Output
DB 230VDC Output
M 230VDC Output
230 VDC Conn.
5 Amp
Fuses
Reset
Stop
Enable
Lower
Hoist
2nd Speed
3rd Speed
4th Speed
5th Speed
Prog Input
Output Status
Ind.
Input Status
Ind.
144-45062 Parameter
Reference
133 Amp Drive 144-45004
Incoming Terminals
Fuse 144-45065
Display Assembly 144-45063
Power Supply LED’s
Control Card 144-45060
Load Terminals
Driver Card 144-45058
400 Amp Master Drive
144-45005
Incoming
Terminals
Fuse 144-45066
Display Assembly
144-45063
Control Card
144-45060
Discharge
Resistor Card
144-45064
Driver Card
144-45059
Load
Terminals
Master to Follower
Conversion
Incoming
Terminals
Fuse 144-450XX
Control Card
144-45060
Display Assembly
Discharge
144-45063
Resistor Card
144-450XX
Disconnect
these cables
from the
control board
J 9 connector
needs all pins
open.
Driver Card
144-45059
Load
Terminals
Follower Driver Board J9
Jumper Positions
Shift large J9 jumpers to
the left keeping top row
of pins open
Remove Jumper from
LK2 and place on pins 11
and 12 of J9
DDC Demo Power Up
Demo power connection will allow
you to power the drive up to load a
different control program, change
parameters, or practice navigation
of the menu groups from your shop
supply.
144-45060 Control Card
Picture Rev 2
Flash
SW2
Interface Card Con
LK1
Driver Card Con
LK2
Fault
Display Con
PWR On
SW1
144-45060 Control Card
Rev 3, 4, & 5
Display Con
Flash boot load link
1 -- 2 -- 3
Figure 25 User Manual
1& 2 Flash boot load
2 & 3 Normal
LK2
485 Terminator
1&2 120 OHM Connected
2&3 120 Ohm not connected
LK4
LK3
1 & 2 RESET input resets CPU
2 & 3 RESET input used as logic input
LK3
Configuration Switch
SW1
Power LED
SC Fault
Lockout LED
Interface Card Con
SW2
Driver Card Con
Analog Input Switch
144-45060 Parameter
Reference
144-45060 Switch Settings
Table 27 SW2 DIP Switch Settings
SW POS
OFF
ON
A
AN1
-10/+10V
AN1
Diff
AN1
X1
AN2
-10/+10V
AN1
4/20 mA
AN1
Non Diff
AN1
X2
AN2
4/20 mA
B
C
D
Table 28 SW1 DIP Switch Settings
SW1 positions 1 and 2 are used to select the current rating:
Current Class
DIP switch setting
NEMA2 67A maximum
SW1-1 OFF
SW1-2 OFF
NEMA3 133A maximum
SW1-1 ON
SW1-2 OFF
NEMA4 200A maximum
SW1-1 OFF
SW1-2 ON
NEMA5 400A maximum
SW1-1 ON
SW1-2 ON
SW1 position 3 determines hoist or the travel configuration:
Configuration
DIP switch setting
HOIST
SW1-3 OFF
TRAVEL
SW1-3 ON
SW1 position 4 are used to select the voltage rating:
Voltage Class
DIP switch setting
200/360V
SW1-4 OFF
400/720V
SW1-4 ON
Main Hoist
SW1 Settings
1
2
3
4
5
6
7
8
On
On
Off
Off
Off
Off
Off
Off
144-45060 Rev 5 Control
Board
• New revision 5 control board
– Being phased into production July 2006
– Can be used with all existing installed drives
• Improves noise immunity of the drive I/O
• Component location same as revision 3 and 4 boards
Control Board Software
Capability
• Software compatibility
– Version 1 control software requires 1.19 Display EPROM in
144-45063 display
– Version 2&3 software requires 2.00 Display EPROM in 14445063 display
• EPROM Display software version
– Determines control software load for 144-45060 control
board
– Control software can be loaded into all revisions of control
board 144-45060
Rev 1 & 2 144-45058
Driver Board
Internal
Fan
Supply
LED
+5V
+24V
-15V
+15V
LK1 LK2 Lk3 Link
Location
144-45058 Rev 3 Driver
Board
Precharge
250 VDC
Conn
Charge
LED
Q
1
Gate
Driver
Module
Q
2
Supply
LED
Q
3
+5V
+24V
-15V
+15V
Control Card
Conn
HS
Fan
Thermistor
CT1 CT2
CT3
Links
Driver Card 144-45059
NEMA 4/5
Control Card Conn
Q1
Gate
Driver
Q1
Q2
Gate
Driver
Q2
-15V +5V +15V +24V
Supply LED
250 VDC
Conn
Precharge
LK 5
Gate
Driver
Q3
Q3
Thermistor
LK 2
Bus Connector Follower Units
CT1
CT2
CT3
LK 1
HS Fan
Driver Card 144-45059
Test Points
Test Point
Description
TP1
DCCT 3 Signal: 4.0 VDC = 600 Amps
TP2
0 Volts Ground (Signal Common)
TP3
DCCT 1 Signal : 4.0 VDC = 600 Amps
TP4
DCCT 2 Signal (Signal Common)
TP5
Volts DC+
TP6
+ 24 volt Power Supply
TP7
- 15 volt Power Supply
TP8
CEMF Average volts
TP9
+ 5 volt Power Supply
TP10
+ 15 volt Power Supply
TP11
0 Volts Ground (Signal Common)
Driver Card 144-45059
Test Points
TP11
TP10
TP8
TP9
TP7
TP6
TP4
TP3
TP1
TP5
TP2
Current Feedback Scaling
Table 29 Gate Drive Board Link Settings
The current feedback scaling is determined by SIP jumpers LK1, LK2 and LK3 or LK5:
Current Class
Current Feedback Scaling
NEMA2 67A maximum
LK1, LK2, LK3 IN
NEMA3 133A maximum
LK1, LK2, LK3 OUT
NEMA4 200A maximum
LK1, LK2, LK5 IN
NEMA5 400A maximum
LK1, LK2, LK5 OUT
If ground fault detection is enabled, SIP jumper LK10 must be correctly positioned:
Configuration
DIP switch setting
HOIST
LK10 IN
TRAVEL
LK10 OUT
Earlier Printed Circuit Board Revisions
144-45058 rev1 and 2 (used on 200/360V NEMA 2 and NEMA3):
LK10 does not exist. In the TRAVEL or HOIST configuration set Parameter D07 ‘Ground
Fault’ to ‘Disabled’
144-45059 Rev 1 and 2 (used on 200/360V NEMA 4 and NEMA5):
LK10 does not exist. In the TRAVEL or HOIST configuration set D07 ‘Ground Fault’ to
‘Disabled’
144-45058 NEMA 2/3
Scaling Links
LK 3
LK 2
LK 1
Scaling Link Position
Closed For NEMA 2
Open For NEMA 3
144-45059 Scaling Links
NEMA 4/5
LK 5
Buss Link Connector Position
LK 2
Closed For Master Drive
Open For Follower Drive
400A Driver Link Position
Bus Connector
LK 1
LK1
LK2
LK5
Out
Out
Out
200A Driver Link Position
LK1
LK2
LK5
Closed
Closed
Closed
400 Amp RPM 144-45061
144-45061 400 Amp RPM
Schematic
Common buss RPM
400 Amp diagram
Stand alone RPM 400 Amp diagram
Common buss RPM
800 Amp diagram
144 –45039
144 –45039
RPM and Resistor
Required
• For crane mounted DC rectifier or MG set
• When Regeneration current exceeds 500 Amps
– Generally simultaneous motions above 150 HP
• Scheme shown requires RPM Unit to be connected
behind the M contactor (connected to the DC drive
Caps L1+ and L2- drive terminals)
• RPM designed for 20% duty @ 400 Amps
RPM Sizing
• Tabulate all motion FLA
– ½ hour FLA for hoist motion
– 1 hour FLA for travel motions
• Calculate Regen Current for simultaneous motion
operation I
REGEN   FLAHOIST *.8   FLATRAVEL *.3

 
• Size RPM as close as possible to calculated value

Line Reactor Required
• For crane mounted DC rectifier or MG set
– Provide a line reactor for all motion panels
• For large Bus rectifiers (>500KW)
– Generally large DC Bus Rectifiers have a large AC Ripple
content that impact the control performance
– Provide a line reactor for all panels
Questions?
End Session Three
Session Four
Version 3.10 Software
OmniPulse™ DDC
Main Menu Screen
• Power Up screen
• Title Screen:
MAGNETEK
OMNIPULSE DDC
Pressing the Down Key
• Title Screen:
MAGNETEK
OMNIPULSE DDC
Display Software Version 2.00
Pressing RIGHT MENU Key
•
•
•
•
•
•
•
•
•
Group A Monitoring
Group B Access
Group C Controller Set Up
Group D Protection
Group E Drive Control Set Up
Group F Speed and Torque Settings
Group G I/O Configuration
Group H Fault History
Main Menu Screen
Hoist motion current loop
flowchart
Hoist motion speed loop
flowchart
Travel motion current loop
flowchart
Travel motion speed loop
flowchart
Group A Monitoring (Up Key)
• Tables list are in OmniPulse DDC manual.
• Table 13 Motor Current and Voltage
–
–
–
–
Armature Current
Field Current
Armature Voltage
DC Bus Voltage
• Table 14 Motor Speed and Torque
–
–
–
–
–
Motor CEMF
Flux calculation % of rated value
Motor RPM calculation
Motor Torque calculation % of rated value
Hook Load measurement % of rated value
Group A Monitoring Continued
• Table 15 Power, Energy, and Operation Cycles
–
–
–
–
Input Power instantaneous power main DC supply
Energy Used: accumulated energy consumption
No of operations or cycles commanded
Elapsed Hours: Accumulated power on time
• Table 16 Analog Input Status
– Analog Input 1: % of full scale input 1
– Analog Input 2: % of full scale input 2
Group A Monitoring Continued
• Table 17 Current and Speed (Advanced Tools)
–
–
–
–
–
Arm Current Ref: calculated Ref % of rated value
Fld Current Ref: calculated Ref % of rated value
Speed Ref: Calculated Ref % of rated value
Upper Control Limit: Fwd current limit applied
Lower Control Limit: Rev current limit applied
• Table 18 Logic I/O Status
– Logic Inputs: Eight total binary representation
– Logic Outputs: Five total binary representation
Group A Monitoring Continued
• Table 19 Controller Status (Advanced Tool)
–
–
–
–
–
–
–
–
–
Heatsink Temp: Semiconductor Heatsink
Ambient Temp: Temp of electronic control card
Overload Level: Accumulated ovld calculation
T1 Duty Cycle: T1 PWM duty
T2 Duty Cycle: T2 PWM duty
T3 Duty Cycle: T3 PWM duty
Control Status flags: Eight binary representation
Fault Status
Sequence Status
Group B Access
• Table 20 Access
– Password: two levels of access for changes
• User
• Engineer (2004)
– Access Level: current active level
• Monitor
• User
• Engineer
– Control Firmware
– Modbus AN1
Monitor transmitted analog reference on
– Modbus AN2
communication bus
– Tach Coefficient
Group C Control Set Up
• Table 21 Controller Rating Setup
–
–
–
–
–
–
–
–
Configuration
Voltage Class
Current Class
Parallel Stacks
Armature Set Up: Internal or External CT
Input Bus Voltage: Sets UV and OV trip points
Field Set Up : Internal or External CT
Default Values: store user settings; restore user settings;
restore factory default settings
Group D Protection
• Table 22 Protection
–
–
–
–
–
–
–
–
Motor rated current
Motor rated voltage
Motor rated speed
Motor field current: Motor FLA for series motors
Current limit forward (Hoist)
Current limit reverse (Hoist)
Arm/Field ratio: Defines motor commutation limit
Ground Fault
Field Weakening
Armature to Filed Ratio
Armature to Field Ratio
300%
250%
200%
A/F=1.5
150%
A/F=2
100%
A/F=3
50%
% FIELD CURRENT
0%
10
%
90
%
80
%
70
%
60
%
50
%
40
%
30
%
20
10
%
0%
0%
% ARMATURE CURRENT
FIELD WEAKENING ARMATURE FIELD RATIO
Group D Protection Continued
• Table 22 Protection Continued
– OH alarm level: Cuts back current to 150%
– OH trip level: HS Temperature trip level
– LS detection Sets limit switch mode detection
• Disabled
• Hook Sense (Software Detection)
• HLS (software detection) no fault registered
• LS Relay (Hardware Detection)
• ELS (external hardware detection) no fault registered
Group D Protection Continued
• Table 22 Protection Continued
–
–
–
–
–
LS lower detection level: 2 to 50% of measured motor volts
LS hoist detection level: 2 to 50% of measured motor volts
LS back out time : timed back out of limit switch
Slack cable: Disabled or enabled
Slack cable torque: Detection level .1 to 25% torque
Group E Drive Setup
• Table 23 Drive Control Setup
–
–
–
–
–
–
Accel Time: set in seconds
Decel Time: set in seconds
Current gain*
Speed P Gain*
Speed I Gain*
IR Comp Gain*
*(It is recommended to use the default values for the
parameters highlighted for crane applications)
Group E Drive Setup
Continued
• Table 23 Drive Control Setup Continued
– Start Delay: time to allow M to close*
*(too low a setting can cause UV faults recommend 300 ms
setting)
– Bypass Speed: acceleration time ramp not applied to reach
this speed - drive will go to this speed immediately *
*(Normally not used on crane applications)
– Stop Speed: speed at which the stop sequence is initiated
Group E Drive Setup
Continued
• Table 23 Drive Control Setup Continued
– DB Delay: time to allow DB to open
– DB Time: time for DB braking at end of run request
– Lower Minimum Field: sets maximum lowering speed with
empty hook (Hoist Mode Only 200% maximum)
– Hoist Minimum Field: sets maximum hoisting speed with
empty hook (Hoist Mode Only 300% maximum)
OmniPulse DDC Version
3.10 Hoist Speed
Stop sequence begins
when speed reference
equals stop speed
value
OmniPulse DDC Version 3.10
Hoist Speed Below 15%
When speed reference is at
or below 15% in the hoist
direction the stop sequence
is executed immediately
without delays.
OmniPulse DDC Version
3.10 Travel Motion
Stop sequence begins
when speed reference
equals stop speed
value
Group E Drive Setup
Continued
• Table 23 Drive Control Setup Continued
– Economy Field: starting field current level for empty hook or
free run travel*
*(For economy filed to function properly Minimum field
values E15, E16, or E18 must be equal or set at a lower
value than E17)
– Minimum Field: sets maximum travel speed (300%
maximum)
– Field Rate Change: Limits rate per second change of field
current in field weakening operation
Minimum Field Settings
• Acts like an electronic governor limiting the maximum
allowable speed of an unloaded DC Series Motors
– Upper limit is 300% of rated motor RPM
– Lower limit is 100% of rated motor RPM
– Limit is adjustable within 100 - 300% range
• Modifies the basic DC Series Motor speed / torque
curve to a flatter profile
• This ability to change the basic speed / torque
characteristic of the DC series motors is an exclusive
feature of the OmniPulse DDC technology
Parameter Interaction
• The Minimum Field parameter (E15 and E16 for hoist
applications, or E18 for travel applications) acts as
the “governor” and limits the top speed of an
unloaded motor
• Parameter Group F sets the speeds available for
operator commands, however
• Commanded speeds cannot exceed the maximum
speed limit set by Parameter Group E
• Speeds above natural motor curve not available
Examples of “Flattened”
Curves
450
400
Min Field set at 25%
350
% Speed
300
Min Field set at 90%
250
Min Field set at 100%
200
150
100
50
0
2
10
20
30
% Torque
50
100
150
Group E Drive Setup
Continued
• Table 23 Drive Control Setup Continued
– Timer Type defines type of timer function for programmable
outputs
• On Delay TC or TO
• Off Delay TC or TO
– Timer Time sets the timer length
– Micro Speed Factor
• Input function
• Reduces programmed or analog speed reference by a
set factor
Group E Drive Setup
Continued
• Table 23 Drive Control Setup Continued
– Shunt Brake Release Point: Mimics series brake release
based on field current
– Shunt Brake Release Time:
• Provides additional adjustment to release of shunt brake
• Time begins when SB Rel Pt value is reached
– Shunt Brake Time: time for shunt brake to set
– Stall Protection Time
• Defines time period to report a fault if armature current is
present while CEMF < 25%
• A setting of 0 turns the monitoring function off
Group F Speed & Torque
• Table 24 Speed and Torque Settings.
–
–
–
–
Reference Source Selection.
Preset Hoist Speeds: Not visible in travel config.
Preset Travel Speeds: Not visible in hoist config.
Preset Travel Torque: Not visible in hoist config.
Group F Speed & Torque
Continued
• Table 24 Speed and Torque Settings Continued
– Speed Reference source
– Torque Reference Source
• Source Selection:
–
–
–
–
–
Cntr Switch (Master Switch)
Analog Reference 1
Analog Reference 2
Serial Analog Reference 1
Serial Analog Reference 2
Group F Speed & Torque
Continued
• Table 24 Speed and Torque Settings Continued
– Five independent hoist speeds
– Five independent lower speeds
• Speeds adjustable from 0 to 300% rated value Hoist and
0 to 200% rated value Lower
• Sub Menu not visible when travel configuration is active
• Proprietary constant HP software design maximizes
productivity and safety by controlling the motor speed
based on motor loading
Group F Speed & Torque
Continued
• Table 24 Speed and Torque Settings Continued
– Five travel speeds
• Speeds same in forward or reverse
• Adjustable from 0 to 300% rated value
Group F Speed & Torque
Continued
• Table 24 Speed and Torque Settings Continued
– Five Torque (current limit) settings for adjustable torque
when plugging and accelerating from one direction to
another
• Adjustable from 0% to 200% rated current
• Neutral or OFF Position current setting adjustable from
0% to 200%
– 0% setting will stop the drive in coast mode
– Settings other than 0% will stop on deceleration ramp or current
limit
• Sub Menu not visible in hoist configuration mode
Group G I/O Configuration
• Table 25 I/O Configuration
–
–
–
–
–
–
–
Analog IP1 Type: volts or ma
Analog IP1 Gain
Analog IP1 Bias
Tacho FS RPM: Tach Rated RPM at full scale volts
Analog IP2 Type: volts or ma
Analog IP2 Gain
Analog IP2 Bias
Group G I/O Configuration
Continued
• Table 25 I/O Configuration
– Analog Output Gain
– Analog Output Bias
– Analog Output Func: Programmable
• Motor speed
• Motor torque
• Hook Load (Field Current)
• Line Voltage
Group G I/O Configuration
Continued
• Table 25 I/O Configuration
– Prog IP Func: Programmable input 230 VDC or 24VDC
• Not Used
• External limit switch
• Travel slowdown
• External Fault
• Micro Speed
Group G I/O Configuration
Continued
• Table 25 I/O Configuration
– Prog OP1 Func: Programmable 230 VDC
(OP1 control of Remote I/O 144-45062 DB terminal
is not programmable in Hoist configuration)
– Prog OP2 Func: Programmable 24 VDC
(X1-2 terminal 144-45060)
– Prog OP3 Func: Programmable 24 VDC
(X1-3 terminal 144-45060)
– Prog OP4 Func: Programmable 24 VDC
(X1-4 terminal 144-45060)
And 230 VDC (SB terminal on 144-45062)
Group G I/O Configuration
Continued
• Table 25 I/O Configuration
– Program Functions
• DB contactor (OP1 Default)
• Controller fault: Coil energized when fault occurs (OP2
Default)
• Controller ready (OP3 Default)
• Shunt brake (OP4 Default)
• Timer
Group G I/O Configuration
Continued
• Table 25 I/O Configuration
– Serial Baud Rate: 2400 to 19200 baud
– RS232/RS485 Select
– Serial Format
• 8 bit even or odd parity checking
• 1 or 2 stop bits
• Modbus RTU 1 enabled
– Modbus address: 1 to 247
– Drive Control: Hardware I/O or serial communication
Group H Fault History
• Table 26 Fault History
– Record of last 15 faults with elapsed time stamp
– Push down stack
– Engineer level can reset or clear the fault history
• A value of 1 in H30 clears fault history log
– CUV, UV1, and MS faults are not recorded in the fault history
Questions?
End of Session Four
Session Five
OmniPulse™ DDC
Start UP And Trouble Analysis
Service Tools
• Start Up procedures Pages 82-93
• Fault code explanation and corrective actions Pages
94-95
• Transistor Diode Check Page 95
• Trouble charts Pages 96-109
• Drive exploded view Pages 117-118
• Renewal part component lists Pages 119-124
CUV Fault Control Power
Loss
• User Manual Figure 30
– 24 V supply has fallen below 19 V
– Control input power interrupted for more than 1 second
• Center master switch or controller to neutral (off)
position to reset
• Trouble Charts Pages 96 - 97
• Active fault not recorded in fault history
UV1 Fault Under Voltage
Main Bus
• User Manual Figure 31
– Main DC supply voltage below 50% of CO5 Value or below
125 V
– M contactor did not close properly
• Center master switch or controller to neutral (off)
position to reset
• Trouble Charts Pages 98-99
• Active fault not recorded in fault history
OT1 Fault Heat Sink Over
Temp
• User Manual Figure 32
– Heat sink thermistor has reached parameter D09 trip value
• Heat sink temperature must cool down to below 90°C
to reset
• Master switch or controller must be set to neutral (off)
position to reset
• Trouble Charts Pages 100 - 101
SC Fault Short IGBT
Circuit
• User Manual Figure 33
– Internal IGBT power supplies fell below 13 VDC
– Disable all IGBT devices
• 10 SC faults in 5 minute window will lock drive from
service
– Power down of the drive or Reset of the drive required to
clear the lock out
• Master switch or controller must be set to neutral (off)
position to reset
• Trouble Chart Page 102
OV Fault Over Voltage
• User Manual Figure 34
– Main DC bus voltage exceeds over voltage trip point set by
parameter C05 (See page 45 for explanation)
– Main DC volts exceed 400 V maximum hardware trip
• Master switch or controller must be set to neutral (off)
position to reset
• Trouble Chart Page 103
OC Fault Over Current
• User Manual Figure 35
– Current loops failed to maintain current inside limits
– Disable all IGBT devices
• Master switch or controller must be set to neutral (off)
position to reset
• Trouble Chart Page 104
OA Ambient Over
Temperature
• User Manual Figure 36
– Thermistor hardware trip from the control board 75°C
– Finishes current movement before faulting
• Reset cannot occur until thermistor falls below 65°C
• Master switch or controller must be set to neutral (off)
position to reset
• Trouble Chart Page 105
AOC Armature Open
Circuit
• User Manual Figure 37
– Motor armature circuit is open
– IGBT Q1 or Q2 are not conducting
• Master switch or controller must be set to neutral (off)
position to reset
• Trouble Chart Page 106
FL Field Loss
• User Manual Figure 38
– Motor field circuit is open
– IGBT Q2 or Q3 are not conducting
• Master switch or controller must be set to neutral (off)
position to reset
• Trouble Chart Page 107
LS Limit Switch
• User Manual Figure 39
– Software detected tripped power limit switch
• Master switch or controller must be set to neutral (off)
position to reset
• Jogging out of Limit switch is required in back out
mode
• Trouble Chart Page 108
MOL Fault Motor Over
Load
• User Manual Figure 40
– Current exceeded one minute rating of 150%
– Current exceeded 3 second rating of 200%
– Integrator increases above 110% current and decrements
below
• Master switch or controller must be set to neutral (off)
position to reset
• Trouble Chart Page 109
Motor Stall
• User Manual Table 33
– Armature Current > 0
– Armature %CEMF < 25%
– For Stall Protection Time Period (E26)
• Drive shuts down and records fault
• Master switch or controller must be set to neutral (off)
position to clear fault
• A value of 0 turns this function off
MOS
• User Manual Table 33
– MOS Module Out of Service
– Error message occurs when one of the follower follower
units loses its power supply
PER
• User Manual table 33
– Parameter Exceeds Rating
• Parameter value entered exceeds min max value for
the parameter input
EXT
• User Manual Table 33
– External limit switch trip detected
• Disables hoist position and enters limit switch back
out mode
• Master switch or controller must be set to neutral (off)
position to reset
• Jogging out of Limit switch is required in back out
mode
SLC
• User Manual Table 33
– Slack Cable
– Software detected a slack cable condition
– Lowering is disabled until condition clears
• Master switch or controller must be set to neutral (off)
position to reset
MS
• User Manual Table 33
– Master Switch
• Software detected the controller inputs are not in the
off or neutral position upon start up
– Drive disabled until inputs are in neutral position
• Master switch or controller must be set to neutral (off)
position to reset
• Active fault not recorded in fault history
COC
• User Manual Table 33
– Change of Configuration
• Error message received when DIP switch settings on
the control board are changed when the drive is in a
ready state
• Requires power down or Reset of the drive to clear
the fault
• Fault is not logged
External Fault
• User Manual Table 33
– External fault input activated
• External fault must be removed
• Master switch or controller must be set to neutral (off)
position to clear fault
Ground Fault
• Occurs if ground fault is enabled and current CT’s
see 50% drive rating current differential
• In Hoist configuration
– CT1-CT2 (armature)
– CT2-CT3 (Field)
• In Travel configuration CT1-CT2 (armature)
Driver Card 144-45059
Test Points
Test Point
Description
TP1
DCCT 3 Signal
TP2
0 Volts Ground
TP3
DCCT 1 Signal
TP4
DCCT 2 Signal
TP5
Volts DC+
TP6
+ 24 volt Power Supply
TP7
- 15 volt Power Supply
TP8
CEMF Average volts
TP9
+ 5 volt Power Supply
TP10
+ 15 volt Power Supply
TP11
0 Volts Ground
Driver Card 144-45059
Test Points
TP11
TP10
TP8
TP9
TP7
TP6
TP4
TP3
TP1
TP5
TP2
Transistor & Diode Check
Transistor & Diode Check
Diode Check
Positive Probe
Negative Probe
Reading
D1P
T1
L1
.312
D2P
T2
L1
.312
D3P
T3
L1
.312
D1N
L2
T1
.312
D2N
L2
T2
.312
D3N
L2
T3
.312
IGBT Check
Positive Probe
Negative Probe
Reading
Q1P
L1
T1
>.6
Q2P
L1
T2
>.6
Q3P
L1
T3
>.6
Q1N
T1
L2
>.6
Q2N
T2
L2
>.6
Q3N
T3
L2
>.6
Table 35 User Manual
L1 is connected to the
drive bus through an
internal power fuse.
Before taking readings
check the power fuse and
make sure it is good
RPM Transistor / Diode
Check
End of Session Five Questions?
Session Six
OmniPulse™ DDC Loading Software
Software Updates
•
The OmniPulse™ DDC has two software programs.
– Display software current version 2.0.0.
• Display software is loaded into a removable EPROM
located in the back of the display unit.
• To update display software the EPROM must be
changed.
– Control software current version 3.12
• Control software is loaded into a non volatile FLASH
memory.
• Updates are loaded through HEX files using a RS232
port, a laptop, and the Flasher Program supplied by
Magnetek.
Display EPROM
144-45063 Rev 1 or higher
required for Display software 2.00
Removable EPROM
Display Software
Control Software Update
• You can make the cable yourself very easily
– User manual Figure 23 shows the connections
– Requires a D connector, three wires twisted or shielded
cable, and one of the removable terminals from the control
board
• There is no part number for the RS485 connector
– Hardware is present for RS485
– Software support for RS485 is enabled in version 3 control
software release
Software Update
Procedure
• Start Flasher Program
– Select Com 1, 57600 Baud Rate, and AMD Flash
– Press the Select button and select appropriate DDC HEX file
to load
• On the drive control Card set either LK1 (original
board closed) or LK4 on latest board to the boot
position (position 1 & 2)
• Reset power to the drive either by the reset button on
the interface card or cycle drive power off then on
(wait 15 seconds before restart)
DDC Flasher Program
Original 144-45060 Control
Board
Flash
SW2
Interface Card Con
LK1
Driver Card Con
LK2
Fault
Display Con
PWR On
SW1
Revised 144-45060
Control Card
Display Con
Flash boot load link
1 -- 2 -- 3
LK2
485 Terminator
1&2 120 OHM Connected
2&3 120 Ohm not connected
1& 2 Flash boot
load
2 & 3 Normal
LK4
LK3
1 & 2 RESET input resets CPU
2 & 3 RESET input used as logic input
SW1
Configuration Switch
Interface Card Con
Driver Card Con
SW2
Analog Input Switch
Software Update
Procedure
• Wait for the drive to power back up
– In boot mode the drive fan will run constantly
– Check for air flow or listen for fan operation
• Click the Update button in the Flasher window
– Bar at bottom will begin to increase as the program loads
– When loading is complete an upload complete message will
be visible
Software Update
Procedure
• Move the LK1 or LK4 links back to original position
– LK1 open
– LK4 position 2 & 3
•
•
•
•
•
Reset the drive or cycle power to drive
Set parameter (B00) password to 2004
Restore factory defaults via parameter (C07)
Reset the drive or cycle power to drive
Check the Control Software version in the display to
verify the loading process
End of Session Six
Questions?