Parker 590+ series Frame 1, 2, 3, 4, 5, 6 & H. Product Manual (2012) - page 9
4-4 Operating the Drive
Operation in Local Mode
The drive requires the following power terminals to be connected for operation in Local control.
3-phase supply via contactor
Auxiliary supply
3-phase contactor coil
Motor thermistor TH1 & TH2
Motor armature
Motor field
The drive requires the following control terminals to be active for operation in Local control.
Current Limit (jumper A6 to B3)
Program Stop - high (jumper B8 to C9)
Coast Stop - high (jumper B9 to C9)
External Trip - low (jumper C1 to C2)
External Enable - high (jumper C5 to C9)
To run in Local control:
Press the L/R key to enable Local control as detailed above
On the Keypad press the RUN key
to start the unit
Use the UP
and DOWN
keys to control the speed
On the Keypad press the STOP key
to stop the unit
Reading the Status LEDs
These LEDs are used when the blanking cover is fitted to the drive instead of the Keypad.
HEALTH
RUN
Drive State
OFF
Re-Configuration, or corrupted
SHORT FLASH
non-volatile memory at power-up
Tripped
EQUALFLASH
Auto Restarting
LONG FLASH
Stopped
Running with zero reference
ON
HEALTH
RUN
Running
Stopping
Table 4-1 Status indications given by the Health and Run LEDs
Figure 4-4 Blank Cover
showing LEDs
Operating the Drive 4-5
Setting-up the Drive
IMPORTANT You must not exceed the maximum drive and motor ratings. Refer to the Product Code or maximum rating label, and the
motor rating plate.
The following start-up routine assumes that the Keypad is connected and is in default mode, and that the Drive’s control terminals are wired as shown
in the Minimum Connection diagrams in Chapter 3.
The following instructions are written in logical order. Complete each stage successfully before progressing to the next.
Calibrating the Control Board
AUXILIARY POWER ONLY IS CONNECTED AT THIS STAGE
You must first calibrate the Drive for use with the motor.
Connect the auxiliary power supply to auxiliary supply terminals L & N (Frame 3: Terminals L & N = D8 & D7), but
do not connect the main 3-phase power supply at this stage. Check that the correct voltage appears between these
terminals.
The Keypad will now display the Welcome screen, and the Health and Forward LEDs will be illuminated (assuming
that the Drive’s control terminals are
wired as shown in Figure 3-4,
Minimum Connection
Requirements).
NOTE
The CONFIGURE DRIVE menu
at the top of the menu tree
contains many of the important
parameters used during set-up.
Refer to Chapter 6: “The Keypad”
to familiarise yourself with the
keypad’s LED indications, and
how to use the keys and menu
structure.
4-6 Operating the Drive
Set the following parameters:
CONFIGURE ENABLE
Set to TRUE. This allows you to change parameter values, but the drive cannot run.
NOM MOTOR VOLTS - Armature Voltage (VACAL)
If the drive is designed for use on a nominal 3-phase power supply of 500, 600 or 690V, set the Armature Voltage value in the NOM MOTOR VOLTS
parameter.
OR
If the drive is designed for use on a nominal 3-phase power supply of 220V, set DOUBLE the Armature Voltage value in the NOM MOTOR VOLTS
parameter.
NOTE
Refer to the Product Code on the drive's Rating Label to confirm the drive's specification. Also refer to Appendix E: "Technical
Specifications" - Understanding the Product Code.
ARMATURE CURRENT (IA CAL)
Note the maximum armature current from the motor rating plate and set this value in the ARMATURE CURRENT parameter.
FIELD CURRENT (IF CAL)
Note the nominal field current from the motor rating plate and set this value in the FIELD CURRENT parameter.
Frame H: The factory setting of the power board calibration switches allows for a Field Current range of up to 20A. If the Field Current is greater than
20A, refer to Chapter 7: "Trips and Fault Finding" - Power Board Current Calibration Switches (Frames 6 & H). If in doubt, use Ohms Law to
calculate the current i.e. Field Volts/Field Resistance.
FLD.CTRL MODE
Set the field control mode to Field Voltage or Field Current control. Refer to Appendix D: “Programming” - FIELD CONTROL for further
information. By default, the drive is operating in Voltage Control mode.
FLD.VOLTS RATIO
Enter the calculated ratio into the parameter given by the equation:
The maximum value obtainable is 90%, i.e. field output = 0.9 x Vac. Setting this parameter higher than the default 90% will not increase the field
output.
Operating the Drive 4-7
Selecting Speed Feedback
AUXILIARY POWER ONLY IS CONNECTED AT THIS STAGE
Using the Keypad, select the correct speed feedback option. The default is ARM VOLTS FBK.
MMI Menu Map
The selections are ARM VOLTS FBK, ANALOG TACH, ENCODER and ENCODER/ANALOG.
1
CONFIGURE DRIVE
SPEED FBK SELECT
NOTE Refer to Chapter 3: “Installing the Drive” - Speed Feedback and Technology Options for further information.
Speed Feedback Option Boards
Analog Tacho Calibration Option Board
WARNING
Do not fit this Option Board with the drive powered-up.
NOTE This option is not required if armature voltage or encoder feedback is to be used.
The board plugs into the front of the drive. Mount it on the 10-pin connector correctly using
the 4 left-hand pins. This will allow the locating pegs to align with the mounting holes. It
also requires the connecting link wire to the control board. This link is inherent but must be
connected for operation.
The board supports AC and DC analog tachos with a calibration range of 10 to 200V:
• For AC tacho feedback, use terminals G1 and G2 with the selector switch in the AC
position.
• For DC tacho feedback, use terminals G3 and G4 with the selector switch in the DC
position
Calculate the tacho voltage by multiplying the required maximum speed by the tacho
calibration factor, e.g. motor speed 1500 rpm and tacho calibration factor 60V per 1000 rpm
is 90V.
This product may be fitted with a new version of the Analog Tacho Calibration Board:
ORIGINAL - AH385870U001
ORIGINAL: The original option has part number AH385870U001 and the tacho calibration volts are set
using the 2 in-line switches (10-way). The switches set Volts in units and tens. The hundreds
are set by the 1-way switch. The illustration shows a setting of 90V. When setting switches
for AC tachos, calibrate the switches for √2 x voltage feedback required, i.e. √2 x 90V = 127V. This adjusts the rms value received from an AC tacho
into the required peak value.
4-8 Operating the Drive
NEW: The new option has part number AH500935U001 and is mounted in the same manner as the
original. The connecting link wire to the control board is still required and must be connected
for operation.
It is configured by setting its 10-way switch and single 2-position switch.
Calibration of the new AH500935U001 version
On this new version of the option the full-speed tachogenerator voltage is configured by
adding
together the values from any number of the individual selection switches (on the 10-way
switch).
CALIBRATED FULL-SPEED VOLTAGE = 10V + SUM OF SWITCHES SELECTED
NOTE Individual switch values will be included if the switch is set to the right.
In the example AH500935U001 shown above (with three switches selected):
Calibrated full-speed voltage = 10V + (50V + 20V + 10V) = 90V
IMPORTANT
The calibrated full-speed voltage is 10V greater than the sum of switch values selected.
This AH500935U001 board continues to support both AC and DC analog tachos with a calibration range of 10 to 200V.
• For AC tacho feedback, use terminals G1 & G2, with selector switch in the AC position (left). Calibrate the switches for ¥2 x full-
speed voltage required, i.e. ¥2 x 90V = 127V. This adjusts the r.m.s. value received from an AC tacho into the required peak value.
• For DC tacho feedback, use terminals G3 & G4, with selector switch in the DC position (right).
NOTE
Do not set the calibration volts to greater than 200V, the maximum terminal block rating.
Calibration for Voltages Greater than 200V
For full speed tacho voltages greater than 200V, an external resistor, value RE, is required in series with the
1
tachogenerator connection to terminal G3.
0 1 2 3 4 5 6 7 8 9
Set the switches on the Tacho Calibration Option Board to give a value of 200V, as shown opposite.
10
1 2 3 4 5 6 7 8 9 10
RE then is given by the formula:
0
The power dissipation of this resistor is given by the formula
100
W = (tacho volts - 200) x 5 milliwatts
Operating the Drive 4-9
Microtach and Encoder Feedback Option Boards
WARNING!
Do not fit this Option Board with the drive powered-up.
IMPORTANT The Microtach Option Board is fitted with an 11 pin connector. Fit this as shown in the diagram below.
The board plugs into the front of the drive. Mount it on the 10-pin connector correctly. This will allow the
locating pegs to align with the mounting holes.
These option boards assume a 1000 lines per rev encoder is being used. Speed is set directly by the
ENCODER RPM parameter. If you are using an alternative lines per rev encoder, you must set the ENCODER
LINES parameter on the Keypad later in the Operating Instructions.
Save Your Settings
MMI Menu Map
CONFIGURE ENABLE
1
CONFIGURE DRIVE
Set to FALSE.
unused connector
CONFIGURE ENABLE
MMI Menu Map
PARAMETER SAVE
Perform a Parameter Save to save your settings. Press the Ÿ (UP) key,
1
PARAMETER SAVE
as instructed.
PARAMETER SAVE
4-10 Operating the Drive
Initial Start-Up Routine
Complete steps 1 to 18, including steps 16 and 17 as appropriate.
NOTE
This routine assumes that the Drive’s control terminals are wired as shown in the Minimum Connection Requirements drawings in Chapter 3.
The field is “Enabled” and is in Voltage Control (default settings).
IMPORTANT
Do not change any of the previously made calibration settings once the main contactor is energised.
Step 1: Check the Speed Setpoints operate correctly
ANIN1 (terminal A2) : an additional setpoint
MMI Menu Map
ANIN2 (terminal A3) : an additional setpoint
ANIN3 (terminal A4) : this is the normal speed reference source
1
DIAGNOSTICS
ANIN 1 (A2)
Use the Keypad to display the value of the ANIN 3 (A4) (and the additional setpoints if present).
ANIN 2 (A3)
Vary the setpoint potentiometer and observe the input voltage change.
ANIN 3 (A4)
The sum of all the setpoints is given by the value of the SPEED SETPOINT parameter. This is also output at terminal A8.
SPEED SETPOINT
Step 2: Check the External Current Clamps
Use the Keypad to check the operation of the external current clamp settings (refer to Appendix D: “Programming” -
MMI Menu Map
ANALOG INPUTS for setting details).
1
DIAGNOSTICS
• If using a single external clamp (Unipolar), terminal C6 low (0V):
ANIN 4 (A5)
ANIN 5 (A6)
Check that ANIN 5 (A6) is +10V or is adjustable up to +10V
Set to +10V
• If using dual external clamps (Bipolar), terminal C6 high (+24V):
Check the ANIN 5 (A6) is at +10V or is adjustable up to +10V
Set to +10V
Check that ANIN 4 (A5) is at -10V or is adjustable up to -10V
Set to -10V
Setting the current clamps to 10V means that the current demand is controlled by the MAIN CURR. LIMIT parameter for the purposes of this initial
Start routine.
Step 3: Check the Speed Feedback signals
If possible, check the speed feedback by rotating the shaft manually in the forward direction.
MMI Menu Map
1
DIAGNOSTICS
• Analog Tachogenerator:
The Analog Tach Input should go positive.
SPEED FEEDBACK
TACH INPUT
• MICROTACH/Encoder
ENCODER
The ENCODER parameter should give a positive reading.
If there is no feedback signal from the Microtach, verify that both LEDs on the Microtach Option Board are illuminated. If either LED is extinguished,
check that 24V is applied to the Microtach and all ancillary products, and that the fibre optic transmission length is not exceeded.
Operating the Drive 4-11
Step 4: Select the Speed Feedback method
MMI Menu Map
1
SETUP PARAMETERS
Write down the MAIN CURR. LIMIT parameter’s value here:
%
2
CURRENT LOOP
Set the MAIN CURR. LIMIT parameter to 0.00%.
MAIN CURR. LIMIT
MMI Menu Map
Select ARMATURE VOLTAGE initially for the speed feedback method in the SPEED FBK SELECT parameter.
1
CONFIGURE DRIVE
SPEED FBK SELECT
Perform a PARAMETER SAVE. Refer to Chapter 6: “The Keypad” - Saving Your Application.
Step 5: Start the Drive using Auxiliary Power only
With +24V present at terminals B8 and B9 (Program Stop and Coast Stop):
• Apply the "Start/Run" command to C3
MMI Menu Map
The main 3-phase contactor should pull-in and remain energised, (it may de-energise almost immediately due to the
1
DIAGNOSTICS
3-phase fail alarm).
PROGRAM STOP
• Remove the "Start/Run" command from C3
CONTACTOR
CLOSED
The main 3-phase contactor should drop-out and remain de-energised.
If the above sequence does not function, remove the auxiliary power and check start/stop sequencing and contactor wiring.
If the contactor is left energised for an extended time during this check, the controller will detect that 3-phase is not connected and switch off the
contactor, flagging the 3-phase alarm.
IMPORTANT
The main contactor should never be operated by any means other than the drive internal controls, nor should any
additional circuitry be placed around the contactor coil circuit.
WARNING
Do not continue until the stop/start circuits and contactor operate correctly.
Step 6: Power-down the drive and connect the 3-phase supply; power-up the Drive
Switch off all power supplies to the equipment and, when the whole system is totally isolated and safe, re-connect the main 3-phase power supply.
• Switch on the auxiliary supply.
• Switch on the main 3-phase supply.
MAIN & AUXILIARY POWER ARE CONNECTED AT THIS STAGE
4-12 Operating the Drive
MMI Menu Map
Step 7: Set the Speed Setpoint(s) to 5%
1
DIAGNOSTICS
Set the Speed Setpoint(s) to 5% so that the value of the SPEED SETPOINT parameter is 5.0%.
SPEED SETPOINT
This is also output at Terminal A8.
Step 8: Check the MAIN CURR LIMIT is zero
MMI Menu Map
Double-check that the MAIN CURR. LIMIT is set to 0.00%.
1 SETUP PARAMETERS
2 CURRENT LOOP
MAIN CURR.LIMIT
Step 9: Start the Drive and check the field voltage
Apply the Start/Run command and check that 3-phase mains is applied to Power Terminals L1, L2 and L3.
Apply 24V to "Enable" (C5) and immediately check that the correct field voltage appears between the auxiliary supply terminals F+ and F-.
(Note that any external interlocks which affect the Enable input C5 will affect the operation of the drive.)
Caution
This is high voltage DC, proceed with caution. Do not continue if this is incorrect, switch off all supplies and check connections.
Refer to 9.1 or 9.2 on the next page.
If the field voltage is incorrect, make the following checks:
MMI Menu Map
Step 9.1 Internally Supplied Field:
1 SETUP PARAMETERS
• Check that 3-phase is applied to terminals L1, L2 and L3 when the main contactor is closed.
2 FIELD CONTROL
• Check that the coding fuses on the power board or suppression board are healthy.
FIELD ENABLE
• The FIELD ENABLE parameter should be set to ENABLE.
• With the FIELD ENABLE parameter in view, press the ↓ (DOWN) key. The display changes to FLD CTRL
MMI Menu Map
MODE. Press the M key. Is this set to VOLTAGE CONTROL or CURRENT CONTROL?
1
CONFIGURE DRIVE
¾ If set to VOLTAGE CONTROL, check the value of the FLD. VOLTS RATIO parameter. Set this to 65% to
FLD. VOLTS RATIO
obtain 300V fields from 460V supplies.
¾ If set to CURRENT CONTROL, check the field current calibration set-up, refer back to “Calibration”.
If the field volts are at maximum, check the field continuity. (The field current may initially be lower than the rated value
due to a cold field.)
Operating the Drive 4-13
Step 9.2 Externally Supplied Field: (not available on Frame 1 units)
Refer to Chapter 3: “Installing the Drive” - Motor Field Options for conversion details.
MMI Menu Map
1
SETUP PARAMETERS
• Check the voltage applied (externally fused) to terminals FL1 and FL2.
2
FIELD CONTROL
• Check the phasing of voltage applied to FL1 and FL2:
FIELD ENABLE
¾ FL1 must be connected directly or indirectly to the Red phase on main power terminal L1.
¾ FL2 must be connected directly or indirectly to the Yellow phase on main power terminal L2.
• The FIELD ENABLE should be set to ENABLE.
MMI Menu Map
• With the FIELD ENABLE parameter in view, press the ↓ (DOWN) key. The display changes to FLD CTRL
1
SETUP PARAMETERS
MODE. Press the M key. Is this set to VOLTAGE CONTROL or CURRENT CONTROL?
2
FIELD CONTROL
¾ If set to VOLTAGE CONTROL, check the value of the FLD. VOLTS RATIO parameter. Set this to 65% to
obtain 300V fields from 460V supplies.
3
FLD VOLTAGE VARS
¾ If set to CURRENT CONTROL, check the field current calibration set-up, refer back to “Calibration”.
FLD. VOLTS RATIO
Check that 3-phase is applied to terminals L1, L2 and L3.
Step 10: Check the Keypad
Check that the HEALTH and RUN Keypad LEDs are now illuminated, also either the FWD or REV LED.
Step 11: Check the STANDSTILL LOGIC parameter
MMI Menu Map
If the STANDSTILL LOGIC parameter in the STANDSTILL menu at level 2 is ENABLED, temporarily set it to
1
SETUP PARAMETERS
DISABLED.
2
CURRENT LOOP
MAIN CURR.LIMIT
Caution
During the following set-up instructions, be ready to STOP the drive should the motor try to overspeed.
If 5% speed (approximately) is exceeded and the motor continues to accelerate a reversed connection is implied, decrease the MAIN CURR.LIMIT
parameter to zero. Open the main contactor and disconnect all supplies. Reverse the motor connections.
4-14 Operating the Drive
Step 12: Turn the motor and check direction of rotation
Slowly increase the MAIN CURR.LIMIT parameter towards a maximum of 20%. At some point the motor will begin to
MMI Menu Map
rotate as the parameter value is increased. The motor speed will settle at 5% of full speed. If the motor is loaded it may
1 SETUP PARAMETERS
require more than 20% current limit to turn the motor.
2 STANDSTILL
• If the motor does not turn at all when the MAIN CURR.LIMIT is increased to 20%, check the CURRENT
STANDSTILL LOGIC
FEEDBACK parameter to verify that current is flowing into the armature. If no current is flowing, switch off
and check the armature connections.
¾ Is the motor connected to the drive?
¾ Verify that Calibration has been carried out correctly.
Check the direction of rotation is suitable for your process:
• If the direction of rotation is correct, then the armature and field are wired correctly.
• If direction of rotation is incorrect then open the main contactor and disconnect all supplies. Reverse either the armature or field wiring .
WARNING
Do not continue until Step 12 is completed satisfactorily.
Operating the Drive 4-15
Step 13: Check the Speed Feedback sign
MMI Menu Map
With the motor rotating in the correct direction, check the sign of the feedback from the Tachometer or Encoder using the
appropriate Diagnostic menu: TACH INPUT or ENCODER.
1
DIAGNOSTICS
TACH INPUT
• If the diagnostic value is positive (correct), stop the drive. Re-instate your selection for the SPEED FBK
ENCODER
SELECT parameter (if other than ARM VOLTS FBK) and run the drive to check operation. If the test is
MMI Menu Map
successful go to Step 14.
1
CONFIGURE DRIVE
• If the diagnostic value is negative:
ENCODER SIGN
¾ Analog Tach: reverse the connections of the analog tach on terminals G3 and G4
MMI Menu Map
¾ Encoder: change the sign of the encoder feedback parameter.
1
CONFIGURE DRIVE
Re-instate your selection for the SPEED FBK SELECT parameter (if other than ARM VOLTS FBK) and run the
SPEED FBK SELECT
drive to check operation.
When satisfactory operation has been achieved, perform a PARAMETER SAVE. Refer to Chapter 6: “The Keypad” -
Saving Your Application.
Step 14: Adjusting the Speed Setpoint
With the MAIN CURR.LIMIT parameter set to 20% or to the level required to achieve rotation, set the Speed Setpoints so that the value of the
SPEED SETPOINT is about 10%, 1.0V at setpoint input (Terminal A8). The motor will accelerate to this speed setting.
Step 14.1 4 Quadrant Drives which require reverse rotation:
Alter the Speed Setpoints so that the value of the SPEED SETPOINT parameter is about -10% and check that motor
MMI Menu Map
runs in the reverse direction.
1
DIAGNOSTICS
SPEED SETPOINT
Step 14.2 Adjustment of ZERO SPEED OFFSET parameter (Ensure STANDSTILL is DISABLED as in Step 11):
•
4 Quadrant, non-reversing drives
Set the Speed Setpoint potentiometer to zero and adjust the ZERO SPEED OFFSET parameter for minimum
MMI Menu Map
shaft rotation.
1
SETUP PARAMETERS
•
2 Quadrant, non-reversing drives
2
CALIBRATION
Set the Speed Setpoint potentiometer to zero and adjust the ZERO SPEED OFFSET parameter until the shaft is
ZERO SPD.OFFSET
just rotating then reduce level until the shaft stops.
•
4 Quadrant, reversing drives
MMI Menu Map
Set the ZERO SPEED OFFSET parameter to balance maximum speed in forward and reverse directions. You
1
SETUP PARAMETERS
can also set STANDSTILL LOGIC parameter to ENABLE if a stationary shaft is required.
2
STANDSTILL
STANDSTILL LOGIC
4-16 Operating the Drive
Step 15: Fine adjustments for Speed Feedback
Gradually increase the Speed Setpoints so that the value of the SPEED SETPOINT (DIAGNOSTIC menu) is at maximum.
Check the shaft speed is correct.
MMI Menu Map
1 SETUP PARAMETERS
If fine adjustment is required adjust the calibration as appropriate to the speed feedback selection:
2 CALIBRATION
• Armature Voltage feedback has a +2/-10% trim, greater changes outside this range require re-setting of the calibration
ARMATURE V CAL.
switches.
ANALOG TACH CAL.
• Analog Tachogenerator has a +2/-10% trim, greater changes outside this range require re-setting of the calibration
ENCODER RPM
switches.
• The MICROTACH/Encoder should give an absolute rotational speed for which adjustment is unnecessary however the motor speed may not be the
relevant factor thus speed of rotation can be altered by simply adjusting the calibration.
Step 16: Adjustment for Field Weakening
If the drive is to be run with a top speed greater than the base speed then `field weakening’ is used to achieve that top speed.
MMI Menu Map
(Refer to Chapter 5: “Control Loops” - Field Control for a more detailed explanation).
1
CONFIGURE DRIVE
FLD CTRL MODE
NOTE
The drive must be operating in Field Current Control. Select CURRENT CONTROL on the FLD CTRL MODE
parameter. Also, field weakening cannot be used if you have Armature Voltage feedback selected.
IR COMPENSATION (CALIBRATION function block) is also used in field weakening applications to improve dynamic response and speed holding
stability.
To set up IR COMPENSATION:
Set FIELD ENABLE to DISABLED (FIELD CONTROL function block). Start the drive with a 5% speed demand and ensure the ACTUAL
POS I LIMIT is 100% (diagnostic). This should stall the drive at zero speed and cause it to pass 100% current. Monitor the BACK EMF
diagnostic and note the value (typically anything up to 17% is normal). Stop the drive and enter this value into IR COMPENSATION and
repeat the test to ensure that BACK EMF then reads zero.
Run the drive up to base speed and check the motor volts are correct.
In the FLD WEAK VARS menu, verify that field weakening is selected (FIELD WEAK ENABLE) and that the MIN FLD
MMI Menu Map
CURRENT parameter is set appropriately. Adjust the maximum BEMF volts to the required scaled level by setting the MAX
1 SETUP PARAMETERS
VOLTS parameter.
2 FIELD CONTROL
Increase the speed above the base speed, checking that the armature volts remain constant whilst the field current reduces.
3 FLD CURRENT VARS
Gradually increase to maximum speed. Monitor the armature volts at maximum speed and trim the speed using the
4 FLD WEAK VARS
appropriate control as detailed in Step 15. PROCEED WITH CARE - MAKE SMALL ADJUSTMENTS.
FLD. WEAK ENABLE
Trim the MIN FLD CURRENT parameter to the appropriate setting (5% lower than the field current at full speed).
MIN FLD CURRENT
MAX VOLTS
Operating the Drive 4-17
Step17: Adjustment for Reversing Drives
For reversing drives, check the maximum reverse speed.
MMI Menu Map
1 SETUP PARAMETERS
Imbalance in reversing drives can only be corrected by adjusting the ZERO SPD OFFSET parameter, which may be to the
detriment of operation at Zero Setpoint.
2 CALIBRATION
ZERO SPD.OFFSET
Step 18: Re-setting the MAIN CURR. LIMIT parameter
Re-set the MAIN CURR. LIMIT parameter to the original setting that you previously noted in Step 4. If in doubt, set it to
MMI Menu Map
100% to correspond to 100% full load current (FLC).
1 SETUP PARAMETERS
NOTE
The controller cannot achieve 200% current unless the CUR. LIMIT/SCALER parameter is increased to 200% (from
2 CURRENT LOOP
its default setting of 100%). Until this is done, the External Current Clamp will limit the current to 100%, refer to
MAIN CURR.LIMIT
Appendix D: “Programming” - CURRENT LOOP.
• If the current limit is set higher (maximum 200%) and the motor runs into an overload condition, the current is automatically reduced from the
current limit level down to 103% FLC (continual rating).
• If the motor is overloaded, the controller will reduce the current to 103% of the current calibration. (If the motor continues to rotate it may overheat
and thermal protection should be provided).
• If the motor is overloaded and the current provided by the controller is not enough to maintain rotation, i.e. it stalls, the controller will trip out
showing STALL TRIP alarm, if enabled.
Performance Adjustment
Current Loop - The ARMATURE Autotune Feature
Now perform an Autotune to identify and store the following Current Loop parameters:
PROP. GAIN INT. GAIN
DISCONTINUOUS
Initial Conditions
1. Main contactor open, i.e. no Start/Run signal at terminal C3.
2. Set the AUTOTUNE parameter to OFF.
3. Program Stop (terminal B8) and Coast Stop (terminal B9) should be high, i.e. 24V.
4. If the field is being supplied by a third-party controller, remove the field manually. (If the field is internally regulated, Autotune automatically
quenches the field).
IMPORTANT The shaft may require clamping for certain motors to prevent rotation >20% during the Autotune sequence. If the motor is
either a compound motor (series field), has some residual magnetism, or is a permanent magnet motor it WILL rotate and
the shaft must be clamped. If in any doubt, CLAMP OR BE READY TO STOP THE MOTOR.
4-18 Operating the Drive
Performing an Autotune
MMI Menu Map
• Set the AUTOTUNE parameter to ARMATURE.
1
CONFIGURE DRIVE
• Close the main contactor, i.e. Start/Run signal to terminal C3.
AUTOTUNE
• Energise the Enable terminal (C5).
The Autotune sequence is initiated. The Keypad displays “AUTOTUNING” during the process (also the HEALTH led is lit and the RUN led flashes).
When complete (after approximately 10 seconds), the main contactor is opened automatically signalling the end of the sequence and the AUTOTUNE
parameter is reset to OFF.
• Perform a PARAMETER SAVE now. Refer to Chapter 6: “The Keypad - Saving Your Application.
• If necessary, restore field connections and remove the mechanical clamp.
Autotune Failed?
• The Keypad displays the message AUTOTUNE ABORTED
If any one of the Initial Conditions above are removed, or the Autotune sequence times out (after 2 minutes), then the Autotune sequence is aborted
causing the main contactor to drop out.
• The Keypad displays the message AUTOTUNE ERROR
¾ The motor shaft was rotating, or was caused to rotate.
¾ The field current was seen to exceed 6%, when a field-off Autotune had been selected, or the field current stopped during a field-on Autotune.
¾ The drive to armature wiring was open-circuit.
¾ The discontinuous current boundary was found to exceed 200% of either the stack rating or the nominated motor armature current rating
¾ Large imbalance in the three-phase voltages of the supply.
¾ A hardware fault relating to current feedback was detected on the control board.
NOTE
Refer to Chapter 5: “Control Loops” - Current Control for manual tuning instructions.
Speed Loop Adjustment
You will need to adjust the Speed Loop for your particular application although in
Underdamped (oscillatory)
Critically Damped
most cases the default settings are acceptable. The optimum Speed Loop
performance is achieved by adjusting the PROP. GAIN and INT. TIME CONST.
parameters.
OUTPUT
Overdamped
A PI controller is used to control the response of any closed loop system. It is used
specifically in system applications involving the control of drives to provide zero
steady state error between Setpoint and Feedback, together with good transient
performance.
Proportional Gain (PROP. GAIN)
SETPOINT
This is used to adjust the basic response of the closed loop control system. The speed
error is multiplied by the Proportional Gain to produce a motor current demand.
Operating the Drive 4-19
Integral (INT.TIME CONST.)
The Integral term is used to reduce steady state error between the setpoint and feedback values of the controller by accumulating current demand in
proportion to the error input. If the integral is set to zero, then there will always be a steady state error.
A Method for Setting-up the PI Gains
The gains should be set-up so that a critically damped response is achieved for a step change in setpoint. An underdamped or oscillatory system can be
thought of as having too much gain, and an overdamped system has too little.
To set up the P gain, set the I gain to zero. Apply a step change in setpoint that is typical for the System, and observe the speed feedback response on
terminal A7. Increase the gain and repeat the test until the system becomes oscillatory. At this point, reduce the P gain until the oscillations disappear.
This is the maximum value of P gain achievable.
If the steady state error is significant, i.e. the feedback is not sufficiently close to the setpoint value, the I term needs to be used. As before, increase the
I gain and apply the step change. Monitor the output. If the output becomes oscillatory, reduce the P gain slightly. This should reduce the steady state
error. Increasing the I gain further may reduce the time to achieve zero steady state error.
Correct Response
4%
Speed
Time
9
Critically Damped Response with no more than 4% of
maximum speed from first overshoot to first undershoot