User Guide FXMP25 Field Controller Part Number: 0476-0009-03 Issue: 3 www.controltechniques.
General Information The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation or adjustment of the optional operating parameters of the equipment or from mismatching the field controller with the motor. The contents of this guide are believed to be correct at the time of printing.
1 Safety information ...............................................................6 Mechanical installation 2 Warnings, cautions and notes .................................................................6 Electrical safety - general warning ..........................................................6 System design and safety of personnel ..................................................6 Environmental limits ................................................................................7 Access ....
7 8 Setting-up ..........................................................................44 Technical data ...................................................................53 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 8.15 8.16 8.17 9 10 Diagnostics ........................................................................60 UL listing information .......................................................64 10.1 10.2 10.3 4 Ratings ........................................................
Declaration of Conformity Control Techniques Ltd, The Gro, Newtown, Powys UK. SY16 3BE FXMP25 Field Controller The field controller product listed above has been designed and manufactured in accordance with the following European harmonized standards: EN 61800-5-1:2007 Adjustable speed electrical power drive systems - safety requirements - electrical, thermal and energy EN 61800-3:2004 Adjustable speed electrical power drive systems.
1 Safety information 1.1 Warnings, cautions and notes A Warning contains information, which is essential for avoiding a safety hazard. WARNING A Caution contains information, which is necessary for avoiding a risk of damage to the product or other equipment. CAUTION NOTE 1.2 A Note contains information which helps to ensure correct operation of the product.
Environmental limits Instructions within the supplied data regarding transport, storage, installation and the use of the field controller must be complied with, including the specified environmental limits. Field controllers must not be subjected to excessive physical force. 1.5 Access Fire protection 1.7 Mechanical installation The field controller enclosure is not classified as a fire enclosure. A separate fire enclosure must be provided. For further information refer to section 3.
1.10 Electrical installation 1.10.1 Electric shock risk The voltages present in the following locations can cause severe electric shock and may be lethal: • • • AC supply cables and connections Output cables and connections Many internal parts of the field controller Unless otherwise indicated, control terminals are single insulated and must not be touched. 1.10.
Product information 2.1 Ratings Safety information 2 Continuous DC output current A 26 25 Mechanical installation 2.2 Continuous AC input current A Product information Maximum continuous input current The value of the maximum continuous input current is given to aid the selection of cables and fuses. The value is stated for worst-case conditions.
2.3 FXMP25 features and options Figure 2-2 FXMP25 features FXMP25 Display M Mode /Reset STORED CHARGE 10 min Mentor MP/ serial port connector AC supply and field output connections Ground connection 2.3.1 Mentor II connector Control terminals Armature voltage feedback connections Options available for FXMP25 Table 2-1 Options Type Cable Serial comms lead Name Further Details CT EIA (RS) -232 (4500-0087) CT Comms cable CT USB (4500-0096) See also section 4.
Mechanical installation Follow the instructions Competence of the installer Mechanical installation WARNING The mechanical and electrical installation instructions must be adhered to. Any questions or doubt should be referred to the supplier of the equipment.
The location and size of the bottom shall cover the area shown in Figure 3-1. Any part of the side which is within the area traced out by the 5 ° angle is also considered to be part of the bottom of the fire enclosure. Figure 3-1 Fire enclosure bottom layout Drive o 5 o 5 The bottom, including the part of the side considered to be part of the bottom, must be designed to prevent escape of burning material - either by having no openings or by having a baffle construction.
Safety information Figure 3-3 Overall dimensions 247mm (9.72in) 123.5mm (4.86in) Product information FXMP25 M Mode /Reset STORED CHARGE 10 min 162mm (6.38in) 176mm (6.93in) 192.38 (7.57in) Mechanical installation 168.5mm (6.63in) Electrical installation Getting started 123.5mm (4.86in) Parameters 90.27 (3.55in) Setting-up Table 3-1 Back-plate information Torque range M6 1.5 N m (1.1 Ib ft) to 2.5 N m (1.
3.2 Electrical terminals Figure 3-4 Location, terminal size and torque setting of power and protective ground terminals FXMP25 M Mode /Reset STORED CHARGE 10 min 3.5mm Torque: 0.4Nm (0.29 Ib ft) Control connections 4.5mm Torque: 0.6Nm (0.44 Ib ft) 4.5mm Torque: 0.6Nm (0.44 Ib ft) Ground connection Power connections 3.3 Routine maintenance The FXMP25 should be installed in a cool, clean, well ventilated location. Contact with moisture and dust should be prevented.
Electrical installation Isolation device The AC supply must be disconnected from the field controller using an approved isolation device before any cover is removed from the field controller or before any servicing work is performed. WARNING Setting-up ELV circuits are single insulated (basic insulation) only. Installer required to provide supplementary insulation of accessible parts.
4.1 Electrical connections When operating in stand alone mode, a relay should be provided to indicate to the controller that the unit has tripped and to protect against an overspeed condition.
Protective ground connections The field controller must be connected to the system protective ground of the AC supply. The protective ground wiring must conform to local regulations and codes of practice. See section 4.3.1 MOV protective ground disconnect on page 17 for possible exceptions. AC supply requirements 4.3.1 MOV protective ground disconnect Line reactors Field output current 400 V 480 V Typical current rating A μH μH A 25 230 290 26 FXMP25 User Guide Issue Number: 3 www.
CAUTION 4.5 Control of current below 250 mA (thyristor holding currents) should be avoided. If control at this level is required then line reactors must be installed to reduce the effect of dv/dt as thyristors turn off. Cable and fuse size ratings The selection of the correct fuse is essential to ensure the safety of the installation.
IEC 60364-5-52[1] UL508C/National Electrical Code[2] 4 mm2 10 AWG Input/Output 4.5.1 Armature connections A1 A2 FXMP25. Cables 0.5 mm2 to 5.26 mm2 (22 AWG to 10 AWG) should be used. 4.5.
Isolate the power before removing the internal semiconductor fuses. WARNING Figure 4-2 Removing the internal semiconductor fuses 1 2 3 4 1. Remove mounting screws (M6 recommended). 2. Apply pressure at the two points shown on the bottom of the FXMP25 to release the terminal cover clips. 3. Open the terminal cover in the direction shown. 4. Remove the internal semiconductor fuses. 20 www.controltechniques.
EMC (Electromagnetic compatibility) The FXMP25 meets immunity requirements (specified in section 8.17 Electromagnetic compatibility (EMC) on page 58) with no special precautions. NOTE Radio frequency noise emission can occur from any of the power connections i.e. AC supply and field output terminals. When radio frequency emission must be limited an input EMC filter can be installed. Shielded cables must be used for the field and the shield must be clamped to grounded metallic parts at both ends.
EN 61800-3:2004 defines the following: • • • 4.6.1 The first environment is one that includes residential premises. It also includes establishments directly connected without intermediate transformers to a lowvoltage power supply network which supplies buildings used for residential purposes. The second environment is one that includes all establishments other than those directly connected to a low-voltage power supply network which supplies buildings used for residential purposes.
Signal from plant Safety information Figure 4-4 Surge suppression for analog and bipolar inputs and outputs Signal to drive 0V Product information 2 x 15 V zener diode e.g. 2xBZW50-15 0V Unipolar TT-UKK5-D/24 DC Bipolar TT-UKK5-D/24 AC 4.7 Mechanical installation Surge suppression devices are available as rail-mounting modules, e.g.
4 5 (+10V) Not used 10V user output Function Supply for Analog input terminal Voltage tolerance 2% Rated output current 5 mA Protection Over 5 mA, the current is limited, but there is no trip (Voltage is less than 10 V if the current is higher than 5 mA) 6 (If) Field current output signal 7 (Va) Armature voltage output signal Type Single-ended voltage Voltage range 0 to 10 V Maximum output current 5 mA Load resistance 2 kΩ min Protection 5 mA short circuit protection Resolution 10
Serial communications 4.8.1 Introduction The drive supports Modbus RTU configured as the default protocol, which is used with the PC-tools commissioning/start-up software as provided on the CD ROM with the product. The communications port applies a 2 unit load to the communications network. 4.8.
Suitable USB to EIA485 and EIA232 to EIA485 isolated converters are available from Control Techniques as follows: • CT USB Comms cable (CT Part No. 4500-0096) • CT EIA232 Comms cable (CT Part No. 4500-0087) When using one of the above converters or any other suitable converter with the FXMP25, it is recommended that no terminating resistors be connected on the network. It may be necessary to 'link out' the terminating resistor within the converter depending on which type is used.
Getting started 5.1 Keypad and display Figure 5-1 Display modes Parameter view mode Status mode Parameter edit mode Parameter value Status Parameter value Parameter value (flashes) FXMP25 M FXMP25 M Mode /Reset M Mode /Reset Mechanical installation FXMP25 Product information The display will show different information depending on the display mode selected. There are three display modes as shown below.
A single up key action when the last parameter is being displayed will cause the parameter number to roll over to the lowest parameter available in the current mode. Similarly holding the down key will cause the parameter number to decrement until the lowest parameter available is reached and a single down key action will cause the parameter number to roll under to Pr 99. Pressing and releasing the M Mode key again will change the display from parameter view mode to parameter edit mode.
Setting the controller back to default values If Pr 00 is set to a non-zero value and edit mode is exited, the field controller is reset when the field controller is inactive (Pr 77= OFF), the selected default parameters will automatically be loaded. After the parameters have been set to default values, they are automatically saved to the field controller’s EEPROM on power down. New values will take effect on subsequent power up.
6 Parameters All parameters are available in default Pr 78 = OFF (0) In the table below the abreviations used in the table have the following meaning: MP - In Mentor MP mode the field controller is being controlled by Mentor MP. MII - In Mentor II mode the field controller is being controlled by Mentor II. ST - In Stand alone mode the field controller is controlled by itself.
Full parameter descriptions Safety information 6.1 Table 6-2 Key to parameter coding Coding Attribute 1 bit parameter FI Filtered: some parameters which can have rapidly changing values are filtered when displayed on the drive keypad for easy viewing. Txt Text: the parameter uses text strings instead of numbers. Variable maximum: the maximum of this parameter can vary. DP Decimal place: indicates the number of decimal places used by this parameter.
02 Coding Armature voltage Bit FI Txt VM DP 1 ND US RW 1 Range 0 to 860 V Update rate Background write BU PS 1 The average measured DC input voltage seen across the field controller A1 and A2 terminals. 03 Coding Flux reference Bit FI Txt VM 1 Range 0.0 to 100.0 % Update rate Background DP ND 1 1 US RW BU PS 1 This parameter displays the level of the analog signal present at the flux reference input, this is a unipolar voltage input where the input range is 0 V to +10 V.
Coding Field flux output scaling Bit FI Txt VM DP ND 3 0.000 to 4.000 Default 1.500 Update rate Background RW BU 1 1 1 PS The default value of 1.500 will produce 10 V output on the analog output (terminal 6) when the feedback is at 100 % (Pr 54 Flux Feedback). Coding Field current feedback scaling Bit FI 0 to 20 Default 10 Update rate Background VM DP ND US RW BU 1 1 1 PS This parameter must be set to the same value as Pr 6.11 on Mentor II when used with Mentor II.
26 Coding FXMP25 OK hysteresis level Bit FI Txt VM DP ND 1 Range 0.0 to 25.0 % Default 0.0 % Update rate 16 ms US RW BU 1 1 1 PS Set the hysteresis from the level set in Pr 25 to eliminate relay bounce when the level is reached. If the value is greater or equal to the threshold Pr 25 plus half the hysteresis band Pr 26 the output becomes active, or if the value is less than the threshold minus half the hysteresis the output becomes inactive.
Safety information flux (%) Linear characteristic (i.e. no saturation) 100% Pr 5.30 Pr 5.29 Product information 75 100 Mechanical installation 50 Field current (%) Electrical installation Getting started Parameters Setting-up Technical data If Pr 29 and Pr 30 have their default values of 50 and 75, the characteristic becomes one line and there will be a linear relationship between the field controller estimate of flux and the field current.
54 Coding Flux feedback Bit FI Txt VM 1 Range ±150.0 % Update rate Background write DP ND 1 1 US RW BU PS Flux feedback after the current to flux converter, see motor saturation breakpoints in Table 6-1 Quick look-up parameter table on page 30. 55 Coding Flux / voltage demand Bit FI Txt VM 1 Range ±120.
Coding Field weakening voltage set point Bit FI Txt 0 to 750 V Default Eur: 400, USA: 480 Update rate Background write DP ND US RW BU 1 1 1 PS The programmable value of the armature back emf or armature voltage (standalone mode), in volts, at which the field begins to weaken. Defined as the voltage at which base speed is reached.
67 Coding Field economy level Bit FI Txt VM DP ND 1 Range 0.0 to 100 % Default 25.0 % Update rate Background read US RW BU 1 1 1 PS In standalone mode, if the field controller is to be used in flux mode Pr 64 = On (1), this parameter would become the external flux reference of the field control loop. When Pr 64 = 0FF (0), this is the reference selected when terminal Ion is open. 68 Coding Maximum flux / voltage limit Bit FI Txt Range 0 to MAX_FIELD_FLUX Default 100.
Coding Flux loop P gain Bit FI Txt VM DP ND 2 0 to 30.00 Default 3.00 Update rate Background read RW BU 1 1 1 PS Increasing this parameter will allow the loop to track the current demand more closely. Setting the value too high will result in instability. Coding Flux loop I gain Bit FI Txt VM DP ND 1 0.00 to 300.0 Default 60.
75 Coding Field voltage mode select Bit FI Txt VM DP ND 1 Range OFF (0) to On (1) Default Eur: OFF (0), USA: On (1) Update rate Background read US RW 1 1 BU PS When this parameter is set to 1 the field controller operates in voltage mode. A fixed voltage is applied to the field rather than the current being regulated.
Enter new mode in Pr 78 Reset Power cycle The new mode will then take effect. NOTE Recommendations Pr 78 can be changed while running between St.H (4) and St.F (5). NOTE When controlling FXMP with Mentor MP, Mentor MP firmware must be V01.05.01 or later (Pr 11.29 = 01.05, Pr 11.34 = 1).
90 Trip 0 91 Trip 1 92 Trip 2 93 Trip 3 Bit Coding FI Txt VM DP 1 Range 0 to 255 Update rate Background write ND US RW 1 BU PS 1 1 PS Indicates the last four field controller trips. 94 Parameter displayed at power-up Bit Coding FI Range 00 to 98 Default 54 Update rate Background read Txt VM DP ND US RW BU 1 1 1 This parameter defines which parameter is displayed at power up. When the field controller enters status mode this parameter is also displayed.
97 Software version FI Txt Range 1.00 to 99.99 Update rate Write at power-up VM DP ND 2 1 US RW BU PS 1 98 User security code FI 0 to 999 Default 0 Update rate Background read VM DP ND US RW BU 1 1 1 1 PS If any number other than 0 is programmed into this parameter, user security is applied so that no parameters can be adjusted. When this parameter is displayed and security is locked it appears as zero. Bit FI Txt Range 1.00 to 99.
7 Setting-up The field current must not be allowed to become zero while the motor is running. WARNING WARNING During the following procedure, you will be required to apply AC power to the FXMP25 controller and to run the motor. Before applying AC power, ensure the following: The controller is correctly connected. The controller cover is securely installed. The motor can be run safely.
Detail If field weakening is required: From European defaults: • Set Pr 59 (Field weakening voltage set point) Setting up for field • Set Pr 69 (minimum flux / voltage limit) weakening From USA defaults: • Set Pr 59 (Field weakening voltage set point) • Set Pr 69 (minimum flux / voltage limit) • Set Pr 70 (Field rated current) Enable the field To enable the field controller: controller • Set Pr 77 (Enable field control) = On (1) Close field Close field economy input (Ion) so that Pr 80 (Economy level econom
Figure 7-1 Standalone mode logic diagram Flux reference input offset External flux reference select 64 04 Flux input Iref Flux reference + + 03 Field weakening voltage set point 59 Voltage error to % error conversion 1 + 59 Field weakeneing voltage set-point _ Armature voltage feedback Armature voltage Flux reference scaling 0 05 1 Compensation factor Flux feedback Field weakening loop P gain 54 62 68 Maximum flux 63 I gain Maximum flux 68 69 Minimum flux 02 06 Armature voltage o
Safety information 67 77 81 Economy level select 1 1 0 80 _ 72 I gain 1 57 78 Field mode Percentage voltage demand 25 26 A1/A2 9 A1/A2 10 5.58 60 Flux feedback 29 30 27 OR 70 A1/A2 74 01 Motor saturation breakpoint 1 Motor saturation breakpoint 2 Rated field current Rated field compensation factor Parameters I Field output voltage Flux calculator 8 L 5.58 58 Getting started 54 Field firing angle Electrical installation 5.
Table 7-2 Quick start commissioning / start up from defaults for Mentor MP mode Action Before power up Detail Ensure: • Motor field is connected. • The MP port on the FXMP25 is connected to the external field controller port on the Mentor MP using a shielded straight through RJ45 to RJ45 lead, maximum length 100 m. • Mentor MP software must be V01.05.01 or later. Ensure: Power up the field • controller • The field controller displays: If the field controller trips, see Chapter 9 Diagnostics on page 60.
Safety information Figure 7-2 Mentor MP mode logic diagram AC supply Field voltage mode select 76 5.75 Flux * demand Field firing angle 5.58 5.73 5.55 1 Flux loop P gain Field flux output scaling If A1/A2 5.71 _ 5.72 I gain 07 5.
Table 7-3 Quick start commissioning / start up from defaults for Mentor II mode Action Before power up Detail Ensure: • Motor field is connected. • The Mentor II port on the FXMP25 is connected to the Mentor II using a 10 way IDC to IDC ribbon. • The supply phases FXMP25 (L1 to L3) are in the same phase as on the Mentor II (E1 to E3). Ensure: Power up the field • controller • The field controller displays: If the field controller trips, see Chapter 9 Diagnostics on page 60.
Drive healthy hysteresis level 25 26 Drive healthy / OK 01 8 27 OR F A I 10 L A1/A2 A1/A2 54 Electrical installation 07 Flux feedback Field flux output scaling Flux calculator Parameters Field flux output Mentor II field feedback setting Getting started 11 56 If A1/A2 Diagnostics When using FXMP 25 with Mentor II, Pr 6.21 must be set in order to avoid field over voltage conditions during fault conditions. (Refer to Pr 6.
FXMP25 Thermal Protection in Mentor 2 Mode. The following parameter setting can be used to provide indication to the Mentor 2 if overtemperature condition is reached. WARNING 52 Pr 9.23 = 1012 - digital output ST5 set to ‘drive OK / healthy’. Pr 8.18 = 613 - digital input to control Pr 6.13 (field enable). Pr 12.03 = 604 - use programmable threshold to detect when firing angle reaches front end-stop. Pr 12.04 = 1000. Pr 9.13 = 806 Pr 9.
Technical data 8.1 Ratings Maximum continuous input current The value of the maximum continuous input current is given to aid the selection of cables and fuses. The value is stated for worst-case conditions. Continuous DC output current A 26 25 Mechanical installation FXMP25 derating for extended ambient operation Electrical installation 8.
8.4 AC supply requirements The FXMP25 is rated for a nominal supply up to 480 Vrms. 8.4.1 Supply types The FXMP25 is suitable for use with any supply type, i.e. TN-S, TN-C-S, TT, IT, with grounding at any potential, i.e. neutral, centre or corner (grounded-delta). 8.4.2 AC supply specification Table 8-2 AC supply Specification Product voltage variant Maximum nominal supply 8.
Temperature and humidity Safety information 8.6 Ambient temperature operating range: 0 °C to 55 °C (32 °F to 131 °F) Field output current derating must be applied at temperature >40 °C (104 °F). Minimum temperature at power-up: Maximum humidity: The FXMP25 can operate in environments up to a maximum relative humidity: 90 % non-condensing at 50 °C. Mechanical installation 8.7 Storage Storage temperature range: -40 to 70 °C. Storage time is 2 years.
Table 8-4 IP rating degrees of protection 8.10 First digit Second digit Protection against contact and ingress of foreign bodies 0 No protection Protection against large foreign bodies φ > 50 mm 1 (large area contact with the hand) Protection against medium 2 size foreign bodies φ > 12 mm (finger) Protection against small 3 foreign bodies φ > 2.
Safety information Bump test Testing in each of three mutually perpendicular axes in turn. Referenced standard:IEC 60068-2-29: Test Eb: Severity: 18 g, 6 ms, half sine No. of Bumps: 600 (100 in each direction of each axis) Product information Random vibration test Testing in each of three mutually perpendicular axes in turn. Referenced standard:IEC 60068-2-64: Test Fh: Severity: 1.0 m2/s3 (0.
8.17 Electromagnetic compatibility (EMC) This is a summary of the EMC performance of the FXMP25. For full details, refer to the FXMP25 EMC data sheet which can be obtained from the supplier of the FXMP25.
Safety information Emission The following standards are met for cable lengths up to 100m. Table 8-6 FXMP25 emission compliance Filter Conformity C4 Schaffner FN3280H-25-33 C2 Product information No filter Filters can be sourced directly from Schaffner. Key (shown in decreasing order of permitted emission level): EN 61800-3:2004 second environment, restricted distribution (Additional measures may be required to prevent interference). C2 Industrial generic standard EN 61000-6-4:2007.
9 Diagnostics The display on the FXMP25 gives various information about the status of the field controller. These fall into three categories: • • • WARNING 9.1 Trip indications Alarm indications Status indications Users must not attempt to repair a faulty FXMP25 or carry out fault diagnosis other than replace internal fuses or through the use of the diagnostic features described in this chapter. Under no circumstances must the casing of the FXMP25 be opened when the AC supply is connected.
Trip EEF Diagnosis Internal EEPROM trip FdL No current in the field supply circuit Check the field circuit. Check the FXMP25 internal fuses. FOC Excess current detected field current feedback Electrical installation Unexpected interrupt Hardware fault - return to supplier HF07 Mechanical installation Maximum field current is present. Check the field rated current (Pr 70) and the field rated voltage (Pr 73) are set correct to the motor nameplate. Check for short circuit on field circuit cabling.
Trip OV Diagnosis Over voltage • • PS Check AC supply is within specification Check that notching on the AC supply is not excessive. Refer to section 8.5 Line reactors on page 54 Internal FXMP25 power supply trip Return to the supplier PS.24 24V comms power supply overload Tune Autotune stopped before completion Check connection to the Mentor MP / serial port connector See Pr 12 (Autotune) 9.2 Trip categories Trips can be grouped into the following categories.
Status indications Safety information 9.4 Table 9-4 Status indications Left hand display Description tr Product information ih Field controller inhibited The field controller is inhibited because the field controller is disabled [Pr 77 = OFF (0)]. Field controller has tripped Mechanical installation The field controller has tripped. The trip code will be displayed in the ‘right hand’ display (see Chapter 9 Diagnostics on page 60). 9.
10 UL listing information FXMP field controller has been assessed to comply with both URus and cUR requirements. Control Techniques UL file number is E171230. Confirmation of UL recognition can be found at website: www.ul.com. 10.1 Conditions of acceptability Conformity: The field controller conforms to UL recognition requirements only when the following are observed. 1. The Device shall be installed in a pollution degree 2. 2. The terminal torques specified in section 3.
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