Distributed Power System SA3100 Diagnostics, Troubleshooting, and Start-Up Guidelines

Transcription

1 Distributed Power System SA3100 Diagnostics, Troubleshooting, and Start-Up Guidelines Instruction Manual S

2 Throughout this manual, the following notes are used to alert you to safety considerations:! ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Important: Identifies information that is critical for successful application and understanding of the product.! ATTENTION: Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life. ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life. ATTENTION: Only qualified Rockwell personnel or other trained personnel who understand the potential hazards involved may make modifications to the regulator configuration, variable configuration, and application tasks. Any modifications may result in uncontrolled machine operation. Failure to observe these precautions could result in damage to equipment and bodily injury. ATTENTION: The user must provide an external, hardwired stop circuit outside of the drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled machine operation may result if this procedure is not followed. Failure to observe this precaution could result in bodily injury. ATTENTION: Registers and bits in the UDC module that are described as read only or for system use only must not be written to by the user. Writing to these registers and bits may result in improper system operation. Failure to observe this precaution could result in bodily injury. ATTENTION: Connecting or disconnecting a regulator board may result in unexpected machine motion. Turn off power to the drive before replacing a circuit board or its connecting cables. Failure to observe these precautions could result in bodily injury. ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment. ATTENTION: The circuit boards of the PMI regulator contain static-sensitive components. Do not touch the boards or their connectors. When not installed, circuit boards should be stored in antistatic bags. Failure to observe this precaution could result in damage to, or destruction of, the equipment. The information in this user s manual is subject to change without notice. Ethernet is a trademark of Xerox Corporation. Windows is a trademark of Microsoft Corporation. AutoMax is a trademark of Rockwell Automation Rockwell International Corporation

3 CONTENTS Chapter 1 Chapter 2 Chapter 3 Chapter 4 Introduction 1.1 Related Publications Typographical Conventions Diagnostics and Troubleshooting 2.1 Definition of Terms Used in Diagnostics and Troubleshooting Power-up Diagnostics in the UDC Module and PMI Regulator Interlock Tests Run-time Diagnostics Drive Faults How the System Reacts to Drive Faults MCR Output Control Drive Warnings How to Clear the Drive Fault and Drive Warning Registers Internal DC Bus Diagnostics DC Bus Monitoring During Bridge Test Mode DC Bus Monitoring During Torque Minor Loop Mode PMI Regulator Operating Modes 3.1 Idle Mode Bridge Test Mode PMI Tuning Mode (Automatic Gain Calculation) Run Mode Installation and Start-Up Guidelines 4.1 Using the AutoMax Programming Executive to Access the Rack Environmental Requirements Installing the Motor Installing the Drive Enclosed Drives Open Chassis Drives Wiring the Drive Basic Drive Interconnections Drive Inspection and Start-up Guidelines What To Do After Unexpected Test Results Recommended Test Equipment Physically Inspecting the Drive Physically Inspecting the Motor Checking the Installation with Power Off Testing AC Input Power Modules with AC Power On Testing DC Bus Supplies and DC Input Power Modules Checking the DC Bus Supply Testing DC Input Power Modules with DC Power On Table of Contents I

4 4.7.8 I/O Verification Testing UDC/PMI Regulator Communication Status Testing Flex I/O Registers Testing Feedback Registers and Bits Testing the UDC Module Test Switch Register Testing UDC Module Meter Ports Testing PMI Regulator Meter Ports Performing Uncoupled Motor Tests (Vector) Running Dynamic Motor Tests Updated Drawings and Software Listings (Vector) Appendix A Drive Fault Register... A-1 Appendix B Drive Warning Register... B-1 Appendix C Interlock Register... C-1 Appendix D Diagnostic Fault Code Register... D-1 Appendix E Summary of UDC Module Drive Fault Indicators... E-1 Appendix F PMI Regulator LED Summary... F-1 Appendix G Status of Data in the AutoMax Rack After a STOP_ALL Command or STOP_ALL Fault...G-1 Appendix H AutoMax Programming Executive Access Levels... H-1 Appendix I Appendix J Terminal Block Locations and Test Points...I-1 PMI Regulator Test Points...J-1 II Diagnostics, Troubleshooting, and Start-Up Guidelines

5 List of Figures Figure 2.1 PMI Regulator Operating Modes Overview Figure 3.1 PMI Regulator Operating Modes and Diagnostics Figure 3.2 Internal DC Bus Control Flowchart Figure 3.3 Power Device Test Locations Figure I.1 Terminal Block Locations... I-1 Figure I.2 Terminal Block TB1 (B Frame Drives)... I-2 Figure I.3 Terminal Block TB1 (C and D Frame Drives)... I-3 Figure I.4 Terminal Block TB1 (E, F, and G Frame Drives)... I-4 Figure I.5 Terminal Block TB1 (H Frame Drives)... I-5 Figure J.1 PMI Regulator Mother Board - Test Points... J-2 Table of Contents III

6 IV Diagnostics, Troubleshooting, and Start-Up Guidelines

7 List of Tables Table 1.1 SA3100 Documentation (Binder S-3053) Table 1.2 SA3100 Power Structure Service Manual Cross Reference Table 3.1 PMI Regulator Operating Modes Table 3.2 Bridge Test Connections Table 4.1 UDC/PMI Regulator Communication Status Register Formats Table 4.2 Flex I/O Register Formats Table 4.3 Analog Data Format Table 4.4 Feedback Registers and Bits Table A.1 Effect of a Disconnected Fiber-Optic Cable...A-4 Table of Contents V

8 VI Diagnostics, Troubleshooting, and Start-Up Guidelines

9 CHAPTER 1 Introduction This instruction manual is divided into two sections: 1) a description of SA3100 drive diagnostics and troubleshooting, 2) start-up guidelines. This manual is intended for users of SA3100 drives who have training and experience in AC drive control and who are familiar with all other SA3100 drive documentation. The diagnostics and troubleshooting chapters (chapters 2-3) describe the error checking built into the PMI Regulator operating system and how to use warning and fault registers, LEDs, and the error log to diagnose drive problems. Chapter 4 provides guidelines on starting up SA3100 AC drives. Although initial startup services are usually provided by Rockwell personnel, it is recommended that the user become familiar with the general guidelines in this chapter in order to be better prepared to work with the Rockwell service engineer. 1.1 Related Publications The user must become familiar with the other instruction manuals that describe the SA3100 drive system. The documentation that describes the SA3100 drive is contained in binder S-3053 and is listed in table 1.1. Table 1.1 SA3100 Documentation (Binder S-3053) Document Document Part Number Drive System Overview S-3005 Universal Drive Controller Module S-3007 Fiber Optic Cabling S-3009 SA3100 Drive Configuration & Programming S-3056 SA3100 PMI Regulator S-3057 SA3100 Power Modules S-3058 SA3100 Diagnostics, Troubleshooting, & Start-Up Guidelines S-3059 Information Guide S-3054 Introduction 1-1

10 Power structure replacement parts and service procedures are contained in the instruction manuals listed in table 1.2. Table 1.2 SA3100 Power Structure Service Manual Cross Reference AC Input Voltage 200 VAC VAC [A] DC Bus Input Voltage Nominal HP Frame Size 310 VDC [Q] Use Service Manual 1336 Force- B 6.11 C 6.12 D 6.13 E Diagnostics, Troubleshooting, and Start-Up Guidelines

11 Table 1.2 SA3100 Power Structure Service Manual Cross Reference AC Input Voltage 380 VAC VAC [B] DC Bus Input Voltage Nominal HP Frame Size 513 VDC VDC [R] Use Service Manual 1336 Force- B 6.11 C 6.12 D 6.13 E 6.14 F G H 6.15 Introduction 1-3

12 Table 1.2 SA3100 Power Structure Service Manual Cross Reference AC Input Voltage 500 VAC VAC [C] DC Bus Input Voltage Nominal HP Frame Size 675 VDC VDC [W] Use Service Manual 1336 Force- B 6.11 C 6.12 D 6.13 E 6.14 F G H 6.15 Other related documents that you should refer to include the following: AutoMax Programming Executive Instruction Manual Version 3.5A or later Installing, Operating, and Maintaining Engineered Drive Systems (D2-3115) Additional information about using the SA3100 drive is found in the wiring diagrams, prints, and other documentation shipped with each drive system. Always consult the prints shipped with your drive system for specific information about installing, operating, and maintaining your drive. 1-4 Diagnostics, Troubleshooting, and Start-Up Guidelines

13 1.2 Typographical Conventions The following typographical conventions are used in this manual: Variable names Variables names are shown in all capital letters followed by the appropriate terminating character. The variable names shown in this manual are suggested names only and may vary from the names used in your application. Example: Register names Register names are shown with the initial letters capitalized followed by the corresponding register number for both drive A and drive B. The drive A register number is shown first followed by the drive B register number (A/B). Example: Drive Fault register (202/1202) Bit names Individual bit names are shown with the initial letters capitalized. Also shown, in parentheses, is the bit s register number, bit number, and suggested variable name. Example: Fault Reset bit (register 100/1100, bit 8, FLT_RST@ ) Parameter entry screen titles Parameter entry screen titles and the parameters themselves are shown with the initial letters capitalized. Example: Feedback Data parameter entry screen Introduction 1-5

14 1-6 Diagnostics, Troubleshooting, and Start-Up Guidelines

15 CHAPTER 2 Diagnostics and Troubleshooting The Distributed Power System contains built-in comprehensive diagnostics. In order to diagnose and correct problems quickly, it is important to understand the types of diagnostics that are performed, when they are performed, and how the results are reported. This chapter describes the different types of diagnostics performed by the system s modules and how the results of these diagnostics are reported. This chapter also describes how the system reacts if an error is detected. There are a number of control modes that can be selected by the user for PMI Regulator operation. An overview of these modes is shown in figure 2.1. The Distributed Power System provides diagnostics at each level of operation as shown in figure 3.1. Use these figures as a reference to quickly identify the system's requirements for entering and operating in each mode. These figures also refer to specific sections in the manual that provide additional information. 2.1 Definition of Terms Used in Diagnostics and Troubleshooting For the purpose of describing diagnostics and troubleshooting, this instruction manual will use specific terms to refer to the types of errors that can be detected by the PMI Regulator and the response of the PMI Regulator and UDC module to those errors. A diagnostic is a software routine specifically designed to check for error conditions. There are three types of diagnostics in SA3100 drives: power-up diagnostics, interlock diagnostics, and run-time diagnostics. A drive fault is an error specifically checked for by the PMI Regulator operating system that will shut the drive down. Faults are reported in the Drive Fault register (202/1202) of the UDC module and in the error log for the UDC task in which the fault occurred. A drive shut-down occurs when any fault reported in the Drive register (202/1202) occurs. A drive warning is an error specifically checked for by the PMI Regulator operating system that indicates the drive is not operating in an optimum manner. Drive warnings will not shut the drive down. An error is any condition other than the desired condition. Interlock diagnostics are those diagnostics performed by the PMI Regulator operating system in response to a drive control request from the programmer, e.g., TRQ_RUN@, in register 100/1100 of the UDC module dual port memory. Power-up diagnostics consist of the initial tests for basic functionality performed by all printed circuit board modules. Diagnostics and Troubleshooting 2-1

16 Run-time diagnostics are those diagnostics performed continuously by the PMI Regulator as a background task after it has received its operating system from the UDC module. Power On Idle Select PMI_RUN@, BRG_TST@, or PMI_TUN@ Interlock Tests PMI Tuning Close MCR Minor Loop Run Bridge Test Bus Missing Bus Missing Open MCR Open MCR Figure 2.1 PMI Regulator Operating Modes Overview 2-2 Diagnostics, Troubleshooting, and Start-Up Guidelines

17 2.2 Power-up Diagnostics in the UDC Module and PMI Regulator Power-up diagnostics execute in the UDC module in the AutoMax rack and in the PMI Regulator. When power is applied to the AutoMax rack, the UDC module performs a series of self-tests. When all of the tests are successfully completed, the CARD OK LED on the UDC module's faceplate will turn on. When power is applied to the PMI Regulator, the on-board Processor performs a series of self-tests. When all of the tests are successfully completed, the PMI Regulator s OK LED will turn on. If the PMI Regulator does not pass these tests, it must be replaced. The AC Power Technology circuitry on the PMI Regulator then performs a series of calibration and self-diagnostic tests. When these tests are successfully completed, the DRV RDY LED will turn on. If a failure occurs refer to the description of register 222/1222 in the Drive Configuration and Programming instruction manual (S-3056) for help in identifying the test that failed. After all of the power-up tests are passed, the PMI Regulator requests the appropriate operating system from the UDC module. The UDC module downloads the operating system and the parameter configuration data to the PMI Regulator. The PMI Regulator then runs under the control of its operating system and begins performing the run-time diagnostics. Run-time diagnostics are described in section Interlock Tests Interlock tests are performed by the PMI Regulator whenever one of the PMI Regulator's operating modes is selected by the programmer through the Drive Control register (100/1100). These diagnostics verify that all conditions required for the operating mode selected are satisfied. If the interlock tests are completed successfully, then the operating mode requested by the programmer can be entered. If any of the interlock diagnostics fails, the PMI Regulator will latch a bit in the Interlock register (205/1205) corresponding to the first diagnostic test that failed, and the requested operating mode will not be entered (i.e., the PMI Regulator will remain in the idle mode). If an interlock test failure occurs, follow the procedure below: Step 1. Reset the command bit that is currently set in the Drive Control register (100/1100). Step 2. Correct the condition that caused the test failure. Step 3. Set the desired command bit in the Drive Control register (100/1100). The PMI Regulator will perform the interlock tests each time a rising edge is detected on the command bits. The results of subsequent interlock tests will overwrite the previous test s results. Diagnostics and Troubleshooting 2-3

18 2.4 Run-time Diagnostics Run-time diagnostics are performed continuously by the PMI Regulator after its operating system has been downloaded by the UDC module. These diagnostics test the status of the PMI Regulator and the connected hardware and also check the integrity of the communication link between the UDC module and the PMI Regulator. The results of the diagnostics are stored in either the Drive Warning register (203/1203) or the Drive Fault register (202/1202) in the UDC module s dual port memory. How drive faults and drive warnings are indicated and how they affect the operation of the drive is described in the following sections Drive Faults When the PMI Regulator detects any of the conditions described in the Drive Fault register, it will shut down the drive. To determine the cause of a drive shutdown, the following indicators are provided: Drive Fault register (202/1202) The PMI Regulator will set a bit in the Drive Fault register to indicate the condition that caused the shutdown. The interlock tests check this register for fault conditions that have occurred. Refer to Appendix A for a complete description of the Drive Fault Register. Drive Status Register (200/1200) The PMI Regulator will set the Fault Detected bit (bit 8, FLT@) of the Drive Status register when a drive fault has been detected. LEDs on the UDC module If either DRV FLT A or DRV FLT B is on, a drive fault has been detected for the drive using that communication channel. LEDs on the PMI Regulator The PMI Regulator contains a status/fault LED board. Refer to Appendix E for LED definitions. Error log for the UDC task The error log for the task in which the fault occurred is accessed through the ON LINE menu of the AutoMax Programming Executive. A list of the drive fault error codes can be found in Appendix D. Refer to appropriate AutoMax Programming Executive instruction manual for more information regarding the Programming Executive and the ON LINE menu How the System Reacts to Drive Faults As described in section 2.4.1, if the PMI Regulator detects any of the conditions described in the Drive Fault register, it will shut down the drive. This means that the PMI Regulator responds by disabling the gates of the power devices, causing the motor to begin a coast to stop. When the PMI Regulator detects that current is less 2-4 Diagnostics, Troubleshooting, and Start-Up Guidelines

19 than 2% of the rated motor current, the PMI Regulator will turn off the MCR output. Note that the PMI Regulator will always turn off the MCR output within 300 msec of the fault occurrence even if the 2% current level has not been reached. If any of the following faults are detected by the PMI Regulator, it will disable the gates immediately and set the corresponding bit in the Drive Fault register (202/1202): DC Bus Overvoltage Fault (Bit 0) DC Bus Overcurrent Fault (Bit 1) Ground Current Fault (Bit 2) Instantaneous Overcurrent Fault (Bit 3) Power Supply Fault (Bit 4) Charge Bus Time-Out Fault (Bit 6) Over Temperature Fault (Bit 7) Resolver Broken Wire Fault (Bit 8) Resolver Fault (Bit 9) Overspeed Fault (Bit 10) Power Technology Fault (Bit 11) PMI Regulator Bus Fault (Bit 13) UDC Run Fault (Bit 14) Communications Lost Fault (15) The PMI operating system will then take over turning off the MCR output as described above.! ATTENTION: The UDC task is not stopped automatically when a drive fault occurs. The user must ensure that the application tasks test the Drive Fault register (202/1202) and take the appropriate action if a fault is detected MCR Output Control The MCR output on the PMI Regulator s Resolver & Drive I/O board is used to control an optional M-contactor to turn off power to the motor. This option is selected during UDC module parameter configuration. If the programmer chooses to connect the MCR output to an M-contactor, contacts from this device must be wired to the AUX IN1/MFDBK input as feedback. The PMI operating system will wait for AUX IN1/MFDBK to turn on before executing any operating mode. The Run Permissive input (RPI) on the Resolver & Drive I/O board and the MCR output are interlocked in hardware. The MCR output can be turned on only when the RPI is asserted. The MCR output itself is under the control of the PMI Regulator. Application tasks have no direct control of the MCR output. RPI is controlled by the user. When RPI is off, MCR cannot be activated. Diagnostics and Troubleshooting 2-5

20 The following conditions will cause the MCR output to turn off: Absence of the RPI signal Occurrence of a drive fault Control algorithm is turned off (PMI_RUN@ = 0) After any of the above conditions occurs, the PMI Regulator will wait for current feedback to be less than 2% of rated motor current multiplied by the motor overload ratio. The PMI Regulator will then turn off the MCR output. If this current level has not been reached within 300 msec, the MCR output will be turned off regardless. In addition, if the RPI signal is removed, the MCR output and gate power will be removed under hardware control within approximately 0.5 seconds of the removal of the RPI signal to provide an additional interlock. This is done regardless of the actions taken by the PMI Drive Warnings The PMI Regulator will check for conditions that are not serious enough to shut down the drive, but may affect its performance. If the PMI Regulator detects any of the conditions described in the Drive Warning register, it will set the appropriate bit but will NOT shut down the drive. The user must ensure that the application task tests the Drive Warning register (203/1203) and takes any appropriate action if a warning condition is detected. The PMI Regulator will also set the Warning Detected bit (register 200/1200, bit 9, WRN@) when a drive warning has been detected. Appendix B provides a complete description of the Drive Warning register. Except for I/O faults, drive warnings are not indicated by LEDs (an I/O fault will turn on the I/O FLT LED on the PMI Regulator). Drive warnings are not displayed in the UDC task s error log How to Clear the Drive Fault and Drive Warning Registers After a drive fault has been detected, the programmer must do the following before the drive can be restarted: Step 1. Reset the command bit that is currently set in the Drive Control register (100/1100). Step 2. Correct the fault. Step 3. Set and reset the Fault Reset bit (register 100/1100, bit 8, FLT_RST@) to clear the Drive Fault register (200/1200). (Note that the Fault Reset bit is edge sensitive.) Step 4. Set the desired command bit in the Drive Control register (100/1100). After a drive warning has been detected, the programmer can clear the entire Drive Warning register by setting and resetting the Warning Reset bit (register 100/1100, bit 9, WRN_RST@). (Note that the Warning Reset bit is edge sensitive.) 2-6 Diagnostics, Troubleshooting, and Start-Up Guidelines

21 2.5 Internal DC Bus Diagnostics The status of the DC bus is monitored as part of both the interlock and run-time diagnostics. The DC bus is considered ready when the PMI Regulator detects that the bus voltage is greater than the undervoltage threshold value stored in local tunable UVT_E0% and has reached a steady state, and the pre-charge contactor has closed. This is checked as an interlock test and is then constantly monitored during run-time diagnostics. A complete description of the DC bus pre-charge sequence is provided in the SA3100 Power Modules instruction manual (S-3058). For further details regarding a DC bus fault, see the extended status register 222 (1222) DC Bus Monitoring During Bridge Test Mode If bus voltage drops below the value stored in the undervoltage warning threshold tunable (UVT_E0%) while the PMI Regulator is in bridge test mode, the PMI Regulator will issue a drive warning (203/1203, bit 1, WRN_UV@). If bus voltage continues to drop below the value stored in the power loss fault threshold local tunable (PLT_E0%), the pre-charge contactor will open. While the pre-charge contactor is open, the gates are disabled, and the bridge test is not functional. If bus voltage does not return to the proper level within 10 seconds, a Bus Charge Time-out fault (register 202/1202, bit 6, FLT_CHG@) will occur, and the drive will shut down. If bus voltage returns to the proper level within 10 seconds, the bridge test will return to normal operation DC Bus Monitoring During Torque Minor Loop Mode If bus voltage drops below the value stored in the undervoltage warning threshold tunable (UVT_E0%) while the PMI Regulator is in torque minor loop mode, the PMI Regulator will limit torque in order to avoid further drop in DC bus voltage and issue a drive warning (203/1203, bit 1, WRN_UV@). If bus voltage continues to drop below the value stored in the power loss fault threshold local tunable (PLT_E0%), the pre-charge contactor will open. While the pre-charge contactor is open, the gates of the power devices are disabled, and the motor will begin to coast to stop. If bus voltage returns to the nominal configured value within 10 seconds of the bus voltage dropping to less than the value stored in the power loss fault threshold local tunable, the pre-charge contactor will automatically close and the PMI Regulator will return to using the torque reference currently being requested by the UDC. If bus voltage does not return to the nominal configured value within 10 seconds, a Bus Charge Time-out fault (register 202/1202, bit 6, FLT_CHG@) will occur, and the drive will shut down. Diagnostics and Troubleshooting 2-7

22 2-8 Diagnostics, Troubleshooting, and Start-Up Guidelines

23 CHAPTER 3 PMI Regulator Operating Modes The PMI Regulator s default operating mode is idle. All other operating modes are selected by the programmer in the Drive Control register (100/1100). Table 3.1 shows the available operating modes. Note that the operating modes are mutually exclusive, i.e., only one mode may be enabled at a time (this is checked by the interlock tests). The PMI Regulator s operating modes are shown in figure 3.1 and are described in the following sections. Table 3.1 PMI Regulator Operating Modes Operating Mode Drive Control Register Bit Mode Description Idle The PMI Regulator s default operating mode during which no algorithms are running. Enable PMI Run 0 Executes the control algorithms. Enable Tuning 1 Calculates gain values for the control algorithm. Bridge Test Enable 2 Performs a test to verify gate cable connections and power devices. PMI Regulator Operating Modes 3-1

24 Power-Up Diagnostics Section 2.2 Reg 100 Bit 4 On Pre-Charge Contactor I/M S-3058 Vdc > UVT_E0% + Steady State Condition and Pre-Charge Contactor Closed Bus Ready Idle Section 3.1 Select PMI_RUN@, BRG_TST@, or PMI_TUN@ Interlock Tests Failed Close MCR Section Interlock Tests OK and PMI_TUN@ Reg 100 Bit 1 On Interlock Tests OK PMI Tuning Section 3.3 Tuning Complete Reg 200 Bit 1 On MCR Closed Reg 201 Bit 1 and PMI_RUN@ Reg 100 Bit 0 MCR Closed Reg 201 Bit 1 and BRG_TST@ Reg 100 Bit 2 Minor Loop Run Bridge Test Section 3.4 Section 3.2 Exit if Reg 100 Bit 0 Off or Fault Reg 202 Any Bit or RPI Missing Reg 201 Bit 0 Off Open MCR Section Bus Missing Vdc < PLT_E0% Charge Bus Timeout Fault Reg 202 Bit 6 Bus OK Exit if Reg 100 Bit 1 Off or Fault Reg 202 Any Bit or RPI Missing Reg 201 Bit 0 Off Open MCR Section Bus Missing Vdc < PLT_E0% Charge Bus Timeout Fault Reg 202 Bit 6 Bus OK Figure 3.1 PMI Regulator Operating Modes and Diagnostics 3-2 Diagnostics, Troubleshooting, and Start-Up Guidelines

25 Idle On* Begin 10 Second Timer Wait for AC Line No No Hi HP Common Bus or Hi HP Stand-Alone? Yes AC Line Status From Power Module = TRUE? No More than 10 Seconds Elapsed? Yes Fault Occurs Register 202/1202 Yes Hi HP Stand-Alone? Yes ** Wait for Bus to Charge No Open Pre-Charge Contactor ** Nominal Bus Voltage Reached? No More than 10 Seconds Elapsed? Yes Yes ** PMI Closes Pre-Charge Contactor ** Auxiliary Contacts Closed? No More than 10 Seconds Elapsed? Yes Open Pre-Charge Contactor Yes ** PMI Sets BUS_RDY@ Yes ** Bus Charged Fault Occurs? *BUS_ENA@ must transistion from off to on to start the bus charging process. **BUS_ENA@ must remain on during the drive operation No Figure 3.2 Internal DC Bus Control Flowchart PMI Regulator Operating Modes 3-3

26 3.1 Idle Mode The PMI Regulator s default operating mode after passing the power-up diagnostics and completing the DC bus pre-charge sequence is idle. When in idle mode, the PMI Regulator is waiting for a command from the Drive Control register (100/1100) to change operating modes. In order for the PMI Regulator to enter the requested operating mode, the Interlock tests must be passed. If any of the Interlock tests fails or if any fault is latched in the Drive Fault register (202/1202), the PMI Regulator will remain in the idle mode. The PMI Regulator will return to the idle mode when it exits any of the other operating modes. 3.2 Bridge Test Mode The bridge test mode is used to verify that the power devices in the Power Module work correctly. Enabling this test turns on the power devices one at a time in a user-specified pattern. The operator can then measure the voltages produced across the devices. Note that this test is normally performed at the factory and does not need to be performed by the user unless one or more power devices have been replaced. If required, this test should be performed before enabling any other mode of the PMI Regulator, such as torque minor loop run. Follow the steps below to perform the bridge test: Step 1.! Step 2. Step 3. Step 4. Step 5. Stop the drive if it is running. Turn off and lock out input power. ATTENTION:DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge. Then check the voltage across the DC bus to ensure the bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life. Wait five minutes to allow the DC bus voltage to dissipate. Open the Power Module s cabinet door or chassis cover. Measure the DC bus potential with a voltmeter before working on the drive. Measure the voltage at the DC bus test points as shown in figure 4.1. When the DC bus potential is down to less than 5 volts, touch a 50 ohm, 50 watt or larger resistor between the test points for 20 seconds. This allows any remaining DC bus voltage to dissipate. Remove the resistor and re-measure the DC bus potential, which should now be at 0V. This step and the following steps assume that your installation includes a terminal block between the Power Module and the motor. Disconnect the motor leads from the terminal block to which they are connected. 3-4 Diagnostics, Troubleshooting, and Start-Up Guidelines

27 ! Step 6.! ATTENTION:The bridge test applies the full DC bus voltage to an output phase for the duration of a test. The motor must not be connected to the Drive while performing the bridge test in order to avoid damage to the drive and motor. Failure to observe this precaution could result in damage to, or destruction of, the equipment. If the Power Module and the motor are connected through one set of leads, disconnect the motor leads from the Power Module. You will need to connect the voltmeter directly to the phase U, V, and W outputs of the Power Module. Use table 3.2 to determine the devices to be tested and to identify where to connect the voltmeter. See figure 3.2. Set the voltmeter to the 1000V scale. ATTENTION:The remaining steps are performed with power on. Exercise extreme caution as hazardous voltages exist. Failure to observe this precaution could result in severe bodily injury or loss of life. Power Device Pair Being Tested 1 Table 3.2 Bridge Test Connections Bridge Test Code Register (105/1105) Value 2 Voltmeter Connection for +VDC 3 1. U upper V lower 2. U lower W upper 3. U upper W lower 4. U lower V upper 5. V upper W lower 6. V lower W upper 11H U(+) V( ) 0CH U( ) W(+) 21H U(+) W( ) 0AH U( ) V(+) 22H V(+) W( ) 24H V( ) W(+) 1. It is not necessary to measure all the power device pairs. All possible combinations can be tested by testing either pairs 1 through 4 or 3 through With the bridge test enabled, enter successive values into register 105/1105 to test different device pairs without re-enabling the bridge test. 3. With the bridge test enabled, approximately the nominal bus voltage should be measured across each pair. PMI Regulator Operating Modes 3-5

28 Left Middle Right + Upper DC Bus U V W Lower Gate Driver Gate Driver Gate Driver Figure 3.3 Power Device Test Locations Step 7. Test the bridge by measuring the voltage across the power devices. The bridge test must be enabled and the appropriate value written to the Bridge Test Code register (105/1105) as described below. The value in the Bridge Test Code register specifies which power device pairs to turn on. The value corresponds to a bit pattern, with the bits described as follows: Bit 0: Phase U Upper Power Device Bit 1:Phase V Upper Power Device Bit 2:Phase W Upper Power Device Bit 3:Phase U Lower Power Device Bit 4:Phase V Lower Power Device Bit 5:Phase W Lower Power Device a. Connect the voltmeter to the output terminals U, V, W for the power devices being tested in accordance with table 3.2. b. Turn on power to the drive. c. Clear the Bridge Test Code register (105/1105, TST_CODE%). 3-6 Diagnostics, Troubleshooting, and Start-Up Guidelines

29 Step 8. Step 9. d. Enable the internal DC bus by setting the Bus Enable bit (bit 4 in register 100/1100, BUS_ENA@ ). A complete description of the DC bus pre-charge sequence can be found in the SA3100 Power Modules instruction manual, S e. The drive must pass all the interlock tests and the run permissive input (RPI) must be on. In addition, if it is configured during parameter entry, the MCR output must be turned on by the PMI Regulator to close the M-contactor. f. Set the Bridge Test Enable bit (bit 2 in register 100/100, BRG_TST@ ). The bridge test will remain enabled until the bit is reset by the programmer, a fault is detected, or the RPI input is turned off. g. Enter the proper power device value into register 105/1105, TST_CODE%. The voltmeter should read approximately nominal bus voltage for each power device pair. After testing one pair, turn off power to the drive. Wait five minutes to allow the DC bus voltage to dissipate. Repeat step 4. Select another power device pair and repeat step 7. Test the third power device pair in the same manner. If all the power device pairs have been tested successfully, and no faults have occurred, the test is complete. Reset the Bridge Test Enable bit. If testing a power device pair results in 0 or nearly 0V, both devices have failed. In this case, replace the two power devices. If the test results in more than 0V, but significantly less than nominal bus voltage, one of the two devices in the pair has failed. If testing a power device pair causes an instantaneous overcurrent fault or a bus overcurrent fault (reported in register 202/1202) then a power device has shorted. Note that you must set the Bridge Test Enable bit again to test any other device pairs. If one pair fails the test, you must test a second pair to determine which IGBT module to replace. The second test should include one of the two devices in the pair that failed. If this second pair fails the test, then the IGBT module containing the device that the two pairs have in common should be replaced. If this second pair passes the test, IGBT module containing the device that the two pairs do not have in common should be replaced. For example, if pair 1 in the table (U upper and V lower) fails the test, you could test pair 3 in the table (U upper and W lower) to determine which IGBT module should be replaced. If pair 3 fails, replace the IGBT module switching phase U. If pair 3 passes the test, then the problem is in the IGBT module switching phase V. Refer to the appropriate service manual, as listed in table 1.2, for instructions on replacing an IGBT module. After replacing the IGBT module, repeat this entire procedure beginning at step 1. Step 10. With the test completed, reconnect the motor to the Power Module output. Close and secure the Power Module s cabinet door or chassis cover. PMI Regulator Operating Modes 3-7

30 3.3 PMI Tuning Mode (Automatic Gain Calculation) The programmer sets the Enable Tuning bit (register 100/1100, bit 1, to request the PMI Regulator to calculate the values for the control algorithm. (Refer to the SA3100 Drive Configuration and Programming instruction manual, S3056, for a complete description of these variables.) Because the calculated values are used in the control algorithms, this procedure must be performed before the run mode is selected. In order for the PMI Regulator to perform these calculations, the interlock tests described in section 2.3 must have passed successfully. For the Volts per Hertz regulator, you can tune the characteristic curve by running the motor unloaded and monitoring motor current when going through the frequency range of interest. The curve should be modified to avoid excessive current consumption/transients when going through the frequency range of interest. When the PMI Regulator has completed the calculations (a process that takes less than one second), it will set the Automatic Tuning Complete bit (register 200/1200, bit 1, PMI_ATC@). The PMI Regulator will then return to the idle mode. Turn the Automatic Tuning Complete bit off. 3.4 Run Mode Before executing the run mode, perform the automatic gain calculation procedure (PMI tuning mode) as described in section 3.3. These gain values are used in the control algorithms. If the gain values are not calculated immediately before entering run mode, the motor may not run properly. Note that the Interlock tests do not check the gain values. To execute the run mode, the programmer sets the Enable PMI Loop bit (register 100/1100, bit 0, PMI_RUN@ ). Before the run mode can be executed, all of the following conditions are required: 1. The Interlock tests (described in section 2.3) must be passed successfully. 2. If configured, the M-contactor must be closed (refer to section ). 3. The DC bus must be ready (see section 2.5). 4. The UDC task in the AutoMax rack must be running. The status of the UDC task is indicated by the UDC Task Running bit (register 100/1100, bit 15,UDC_RUN@). If any of these requirements is not met or if a fault is latched in the Drive Fault register (202/1202), the PMI Regulator will remain in the idle mode. If these requirements are met, the PMI Regulator will execute the run command. At this time, the PMI Regulator will set bit 0 in register 200/1200 to indicate the run mode is active. 3-8 Diagnostics, Troubleshooting, and Start-Up Guidelines

31 The minor loop executes until one of the following occurs: The PMI Run Enable bit (register 100/1100, bit 0) is turned off by the application task. A drive fault is detected. Refer to Appendix A for a description of the Drive Fault register. The RPI signal (register 201/1201, bit 0) is removed. PMI Regulator Operating Modes 3-9

32 3-10 Diagnostics, Troubleshooting, and Start-Up Guidelines

33 CHAPTER 4 Installation and Start-Up Guidelines! ATTENTION:Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life. ATTENTION:The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment. This section describes general guidelines that should be followed when verifying the correct installation of the drive hardware and in performing the drive start-up. For more information regarding installation guidelines, refer to instruction manual D (Installing, Operating, and Maintaining Engineered Drive Systems). As part of the start-up procedure, the AutoMax Programming Executive software is used to verify the status of drive I/O and to make drive adjustments. Section 4.1 describes some of the restrictions imposed by the AutoMax Programming Executive software. 4.1 Using the AutoMax Programming Executive to Access the Rack The AutoMax Programming Executive enables four users to access and work in the same rack simultaneously. However, certain restrictions exist when more than one user is working in a rack. The maximum number of users is four (4) per rack (one user connected directly to the rack and three users connected via the DCS/AutoMax Network, or four users connected via the DCS/AutoMax Network). Data access is required for the user to Set/Force COMMON variables. All users must assure that variable values are not written over by other users working in the rack. Task access is required for the user to load a single task and to Set/Tune/Force LOCAL variables in a task. Only one user will be granted Task access for each task in the rack. Rack access is required to load the rack configuration and to load all application tasks (AutoMax tasks and UDC tasks). Installation and Start-Up Guidelines 4-1

34 If a user has Rack access, no other user can make changes in that rack. All other users will be limited to monitoring tasks and variables. Each user can monitor up to 16 COMMON and/or LOCAL variables. A maximum of 32 LOCAL variables per UDC module can be monitored, regardless of the number of users. A maximum of 16 variables per rack can be forced. Appendix G describes the type of access required by the user in order to carry out common Programming Executive operations. Refer to the AutoMax Programming Executive instruction manual for more specific information. 4.2 Environmental Requirements The installation must meet the following requirements: Ambient Temperature Open chassis: 0 to 50 C (32 to 122 F) Enclosed chassis: 0 to 40 C (32 to 104 F) Cooling Air for cooling must be of sufficient quality and flow to avoid recycling the heated exhaust air back into the drive air inlets. Relative humidity 5-95%, non-condensing Altitude 1000 meters (3300 feet) above sea level. Higher altitudes require derating. Air Quality Clean No flammable vapors, chemical fumes, or oil vapor. Clearances Must allow access to the equipment within the cabinets for inspection, maintenance, and replacement. Must provide non-restricted air flow to and from the intake and exhaust openings. See the SA3100 Power Modules instruction manual (S-3058) for more detailed information about installation requirements. 4-2 Diagnostics, Troubleshooting, and Start-Up Guidelines

35 4.3 Installing the Motor The AC motor should be installed in accordance with its own installation instructions. Refer to the instruction manual that was provided for the motor (in the Instruction Book) for specific instructions. 4.4 Installing the Drive The drive is supplied in its own enclosure or in an open-chassis configuration for mounting in a user-supplied enclosure, a motor control center (MCC), or other custom-built control room Enclosed Drives The drive is force ventilated by means of its own internal cooling fan(s). Air is drawn into the enclosure through slots in the cabinet bottom and in the lower portion of the cabinet sides. Air is forced out through internally shielded slots near the top of the cabinet sides. Air intake and exhaust openings are unfiltered Open Chassis Drives Where mounting of an open chassis drive within a user-supplied enclosure is desired, the user is responsible for ensuring that the maximum temperature within the enclosure remains at or below the rated ambient temperature under worst-case operating conditions. Note that the same fan-cooling as described in the previous section will be provided for the drive. 4.5 Wiring the Drive Make certain that the input power to the drive is of the correct voltage and sufficient amperage to support the drive s input current requirements. Note that input power current values must be less than the drive's maximum RMS fault current rating. Refer to the drive chassis and motor nameplates for correct current ratings and input power information. 4.6 Basic Drive Interconnections! ATTENTION:If your drive cabinet is mounted in such a way that the cabinet itself is not grounded, a ground wire must be connected to the drive cabinet to provide safety for personnel. Also the motor frame should be grounded by solidly connecting a ground wire to a screw in the conduit box. Failure to observe these precautions could result in severe bodily injury or loss of life. ATTENTION:The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment. The SA3100 drive requires interconnecting wiring per applicable codes between the drive and the following: input power, the motor, the operator s control station (if used), the resolver, and earth ground. Installation and Start-Up Guidelines 4-3

36 Refer to the Elementary Diagram (W/E) (and the Interconnection Diagram (W/I) if provided) supplied with your drive for these interconnections. Be sure that the W/E number corresponds to that on the drive s nameplate. All interconnecting wiring must be sized and installed in conformance with the National Electrical Code and applicable local or other codes. Unless a standard pre-built fiber-optic cable was included with your system, the fiber-optic cabling that links the UDC module(s) in the AutoMax rack with the PMI Regulator must be installed by someone experienced in installing fiber-optic cables. Unless you have in-house expertise in installing fiber-optic cable, it is recommended that you contact an experienced contractor to perform the installation. Information regarding the selection and installation of fiber-optic cabling is contained in the Distributed Power System Fiber-Optic Cabling instruction manual (S-3009). 4.7 Drive Inspection and Start-up Guidelines! ATTENTION:Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life. ATTENTION:This equipment is at line voltage when AC power is connected to the drive. Whenever power is removed, verify with a voltmeter that the DC bus capacitors are discharged before touching any internal parts of the drive. Failure to observe this precaution could result in severe bodily injury or loss of life. Use the procedures that follow to locate any shipping damage to the drive, to verify proper installation and field wiring, and to start the drive. Recommended Start-Up Sequence 1. Physical inspection of equipment 2. Motor checks 3. Preliminary inspection with power off 4. Inspection with power on 5. I/O verification Before attempting to perform this start-up procedure, you should be familiar with the general arrangement and function of the drive equipment and should verify that it has been installed and wired as described in the following documents, which are included in the Instruction Book provided with your drive system: Wiring Diagrams (W/Ds), Elementary Diagrams (W/Es), Panel Layout Diagrams (W/Ls), Operator's Station Diagrams (W/Os), and Interconnection Diagrams (W/Is) (if supplied) What To Do After Unexpected Test Results Note that if it is not possible to obtain the correct meter reading or proper operation during any of the checks or adjustment procedures described, perform the following steps: Step 1. Stop the drive. 4-4 Diagnostics, Troubleshooting, and Start-Up Guidelines

37 Step 2.! Step 3. Step 4. Step 5. Step 6. Turn off and lock out all incoming power. ATTENTION:DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge. Then check the voltage across the DC bus test points to ensure the bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life. Wait five minutes to allow the DC bus voltage to dissipate. Measure the DC bus potential with a voltmeter before working on the unit. Measure the voltage across the DC + and DC - terminals on terminal block TB1. See Appendix I for terminal block identification. When the DC bus potential is down to less than 5 volts, touch a 50 ohm, 50 W or larger resistor across the DC bus terminals for twenty seconds to allow any remaining voltage to dissipate. Remove the resistor and re-measure the DC bus potential. It should now be 0V. Verify the following: a. All connections are in strict conformance to the wiring diagrams. b. There are no loose or broken connections. c. There are no damaged components. Repeat the original test that failed Recommended Test Equipment Rockwell recommends the following test equipment: Isolated oscilloscope with a current probe and x100 probe for DC bus measurements. An isolation transformer is needed to isolate the oscilloscope and any other equipment. AC and DC clamp-on ammeters Multimeter having a sensitivity of 20KΩ/volt Chart recorder Isolated voltmeter 50 ohm, 50W resistor for discharging bus capacitors A megohmmeter (megger) may be used to reliably verify the absence of inadvertent grounding of the motor. Failure to follow proper procedure when using a megger may cause damage to the drive.! ATTENTION:If a megohmmeter is used, disconnect all leads between the rotating equipment and the drive cabinet. This will prevent damage to electronic circuitry (Power Modules and their associated circuits, etc.) due to the high voltage generated by the megger. Failure to observe this precaution could result in damage to, or destruction of, the equipment. Installation and Start-Up Guidelines 4-5