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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?