Bulletin 1395 Digital DC Drive 1350A & 2250A Installation Manual
Important User Information ! ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss. Attentions help you: • Identify a hazard. • Avoid the hazard. • Recognize the consequences. IMPORTANT: Identifies information that is especially important for successful application and understanding of the product. DANGER labels may be located on or inside the drive to alert people that dangerous voltage may be present.
1395 Digital DC Drive 1350A & 2250A 1395 Digital DC Drive 1350A & 2250A Installation Manual Publication 1395-5.70 – November, 1995 Installation Manual Publication 1395-5.
Table of Contents Introduction, Inspection & Storage Chapter 1 Manual Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Drive Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Options . . . . . . . . . . . .
Table of Contents Functional Description Chapter 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communication Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Logic Control . . . .
Table of Contents Programming Parameters Chapter 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameter Table Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Chapter Introduction, Inspection and Storage Manual Objectives The purpose of this manual is to provide the user with the necessary information to install, program, start up and maintain the 1350A and 2250A version of the 1395 DC Drive. This manual should be read in its entirety before operating, servicing or initializing the 1395 Drive. This manual must be consulted first, as it will reference other 1395 manuals for troubleshooting or option initialization.
Chapter 1 Introduction, Inspection & Storage Standard Drive Features The 1395 is a microprocessor Digital DC Drive available in: • • • • • • • • • Options • • • 1-2 400 – 2000 HP, four quadrant, armature regenerative two quadrant field 400 – 2000 HP, non-regenerative AC Input Circuit Breaker DC Contactor Field regulation over a 6 to 1 speed range.
Chapter 1 Introduction, Inspection & Storage • Node Adapter Board The board allows the Bulletin 1395 to be controlled using an Allen-Bradley PLC Programmable Controller from the PLC3 or PLC5 family. This board connects directly to the RIO scanner • Multi-Communications Adapter Board Contains the hardware necessary to connect the 1395 to Allen-Bradley’s RIO or Data Highway Plus communication links. • • Isolation Transformers, AC Line Reactors. Program Terminals.
Chapter 1 Introduction, Inspection & Storage Specifications Electrical: Input Voltages – Input Power – Input Frequency – Output Voltage – Output Horsepower (Continuous) – Output Current– Field Voltage– Field Current– Field Control– Field Economy– Armature Firing– Output Waveform– Controller Current Output – Armature Control – Speed Regulation: Encoder – DC Tachometer – Armature Voltage – 230 – 660VAC +/– 10%, 3 phase 912kVA @460VAC, 1308 kVA @ 660VAC 50/60Hz +/– 3 Hz.
Chapter 1 Introduction, Inspection & Storage Feedback Devices: Cont. Encoder – External Inputs: Enable/Contingency Coast Stop – System Reset – Motor Thermostat – Communication Port – External Outputs: Drive Ready/Faulted– Environmental Ambient Operating Temperature Relative Humidity Altitude Incremental, dual channel; 12 volts, 500mA, isolated with differential transmitter, 102.5 kHz max. Quadrature : 90° ± 27° @ 25°C, Duty Cycle: 50% ± 10% Source/ Sink capable, A–B 845H or equal.
Chapter 1 Introduction, Inspection & Storage Digital Reference Board; Digital Reference Input (1) – Digital Inputs (10) – Discrete Outputs (5) – Analog Inputs (2) – Analog Outputs (2) – Power Supply – (for external use) +10VDC, 4mA maximum, –10VDC, 4mA maximum. Node Adapter Board; This board allows the Bulletin 1395 to be controlled using an Allen-Bradley PLC controller from either the PLC3 or PLC5 family. The board connects directly to the RIO scanner.
Chapter 2 Hardware Description 400 – 600 HP; 230VAC 700 – 1250 HP; 460VAC 1000 – 2000 HP; 660 VAC Introduction Chapter 2 contains both a general description of the major hardware components of the 1395 drive and background information to support the procedures detailed in other chapters of this manual. You should use this chapter in conjunction with the Installation chapter when installing 400 – 600 HP, 230VAC, and 700 – 1250 HP, 460VAC and 1000 – 2000 HP, 660 VAC Series A Drives.
Chapter 2 Hardware Description Figure 2.1 Hardware Overview 3 Phase AC Aux 460V 3∅ AC 6F CB1 J2 Unit Power Supply A6 7F 8F CT Feedback Board A1 CT CT J7 J2 J6 J5 Main Control Board A8 J4 J2 J1 Arm P.T. & Snubber 24 3B J1 Arm P.T. & Snubber 24A 3C J1 Arm P.T. & Snubber 25 3D J1 Arm P.T. & Snubber 25A J8 J9 J1 J6 Programming Terminal DHT/DMT 3A Power Stage Interface A7 J2 3 Phase SCR Bridge Fld P.T.
Chapter 2 Hardware Description Armature Bridge Components A general description of the components in the armature bridge (Figures 2.2 and 2.3) and their operation is detailed here: AC Line Reactor – When connecting the drive directly to the main distribution system an AC line reactor must be used to guard against system disturbance. When an isolation transformer matched to the unit rating is used, an AC line reactor is not required.
Chapter 2 Hardware Description DC Current Sensing – DC overcurrent sensing is provided using a DC transducer. Figure 2.
Chapter 2 Hardware Description SCR Packaging – SCR packaging in the 1395 consists of 1 hockey puck type SCR. Pulse Transformer/Snubber Boards – All four boards are identical and are mounted directly to the armature bridge bus bars. R-C networks contained on the board are used to protect the SCRs against voltage transients (dv/dt). DC Contactor – Output of the armature bridge is connected to the DC motor through the main DC contactor M1 (Fig. 2.3).
Chapter 2 Hardware Description Figure 2.
Chapter 2 Hardware Description Control Boards Feedback Board – Figure 2.5 illustrates the major hardware points on the board. The primary function of the board is to provide scaling and transfer of feedback signals coming from power bridge devices being sent to the Power Stage Interface and eventually to the Main Control Board. Figure 2.
Chapter 2 Hardware Description Power Stage Interface (A7) – The primary function of this board is to provide interface between the Main Control Board, and the Power Bridge boards such as the Pulse Transformer and Snubber boards, and the Power Bridge boards such as the Pulse Transformer and Snubber boards and the Feedback Board. The primary functions performed by the Power Stage Interface (Figure 2.6) include: • Distribution of DC Control power to Main Control Board.
Chapter 2 Hardware Description Main Control Board (A8) – The Main Control Board (Figure 2.7) performs all control functions of the 1395 drive. Hardware located on the board is used to support operation of the microprocessor program. The primary functions performed include: • • • • Microbus interface. Control Firmware Analog signal interface Develop gate signals sent to the Power Stage Interface Figure 2.
Chapter 2 Hardware Description Armature Pulse Transformer (A24, A24A, A25, A25A) – The primary functions of the Armature Pulse Transformer Board (Figure 2.8) include: • Isolate power bridge circuitry from control circuitry. There are 4 Armature Pulse Transformer Boards. Each board is associated with each of 4 commutation groups. There are four boards for the Regen and two for the Non-Regen.
Chapter 2 Hardware Description Field Pulse Transformer and Snubber Board (A5) – The primary functions of the Field Pulse Transformer and Snubber Board (Figure 2.9) include: • Isolate field bridge circuitry from control circuitry. • Provide dv/dt protection across SCRs. The board is physically mounted on the field power bridge buswork, with the screw terminals used to mount the board also being used as the connections to the incoming AC line and DC bus. Figure 2.
Chapter 2 Hardware Description Peripheral Devices Unit Power Supply (A6) – The Unit Power Supply 115VAC input comes from the 115VAC power supply on the 6PT transformer. The AC voltage is rectified and regulated to produce +5VDC and + 12VDC control voltages which are distributed to the 1395 control boards through the Power Stage Interface. Figure 2.10 shows the location of the Unit Power Supply components. Figure 2.
Chapter 2 Hardware Description Power Distribution 115VAC Control Voltage – Figure 2.11 illustrates the distribution of 115VAC control voltage within the Bulletin 1395. Single phase 115VAC control voltage, is provided by the 6PT transformer at TB5-14 and -15. Fuse 4F provides protection against short circuits on the 115VAC input to the drive. TB5 (an internal terminal block) distributes control voltage to components within the 1395. Figure 2.
Chapter 2 Hardware Description DC Control Voltage Distribution – The Unit Power Supply converts 115VAC (supplied as shown in Figure 2.12) to +5VDC and the +/–12VDC control voltages. In addition to the voltages supplied by the Unit Power Supply, the Power Stage Interface converts 115VAC to 24VDC which is used for relay logic and provides the supply voltage to the SCR Pulse Transformer and Snubber boards to produce SCR gate signals for the armature and field.
Chapter 2 Hardware Description Relay Logic Main Contactor (M1) Control – Figure 2.13 illustrates the hardware associated with the control of the coil voltage applied to the Main DC contactor M1. The coil voltage originates at an external 115VAC source. The source voltage may be interrupted before being input to the drive at TB5-9 and -10 by the use of externally controlled contacts. These external contacts may include an external master coast stop, PLC controlled contacts, permissive contacts, etc.
Chapter 2 Hardware Description Figure 2.
Chapter 2 Hardware Description Options Programming Terminal Interface – The Handheld Programming Terminal (HHT) is used to access information in the firmware of the 1395. Keypads on both the handheld programming terminal and the door-mounted terminal (shown in Figure 2.
Chapter 2 Hardware Description Adapter Boards – External control devices such as a PLC, discrete operators devices, etc., are interfaced with the Main Control Board through one of the two microbus ports, labeled PORT A (J7) and PORT B (J6) on the Main Control Board. The microbus is a 60 line bus designed specifically for the transfer of data between microprocessors. The microbus is used on the Main Control Board to transfer data between devices on the board.
Chapter 2 Hardware Description Discrete Adapter Board The Discrete Adapter Board connects directly to the Main Control Board using Port A of the Microbus interface. All user connections to the board are made at Terminal Block TB-3 located at the bottom of the 1395 Drive. Digital Inputs – The Discrete Adapter Board contains four discrete inputs for either 120VAC signals or 24VDC signals. These optically coupled inputs provide a means for external control of the 1395 via pushbuttons, relays, switches, etc.
Chapter 2 Hardware Description The inputs are preconfigured for the following signals: RUN REFERENCE SELECT A,B,C, RAMP DISABLE, JOG2, JOG1, NORMAL STOP, START, CLOSE CONTACTOR, CLEAR FAULT. Digital Outputs – Five programmable solid state outputs are provided. These 24VDC outputs, can be connected to any source parameter such as the logic status word. All five outputs have LEDs indicating when the signal is on.
Chapter 3 Functional Description Introduction Chapter 3 contains a general description of the functionality of the 1395 drive. This description is intended to provide sufficient background information to support other procedures in this manual and to enable the reader to: • Configure the parameters of the drive. • Interface the drive with peripheral devices such as an Allen-Bradley PLC, discrete operators I/O and the Programming Terminal.
Chapter 3 Functional Description Functional Overview Parameter Table Table of parameter entries for all Configuration and Setup parameters used in the drive. Source Fast parameter used as a source of data. Sink Fast parameter used to receive data input. General Figure 3.1 provides an overview of the major blocks associated with the control functions of the Bulletin 1395. All control functions in the 1395 are performed through the use of parameters which can be changed with a Programming Terminal.
Chapter 3 Functional Description Figure 3.1 Functional Overview Port A Programming Adapter Board Terminal Three-Phase Line Port B Adapter Board L1 L2 L3 Three-Phase Disconnect To Field Bridge Drive Logic Control Communication Control Armature Current Feedback Interface with Parameter Table Three-Phase AC Voltage Feedback 3-Ph.
Chapter 3 Functional Description Communication Control The Communication Control block controls all of the data transfer. The Programming Terminal communicates with the drive through an RS-422 serial communication link. Internal communication in the drive is accomplished using a Microbus which is a specialized microprocessor bus designed by Allen-Bradley. In addition to internal communication, transfer of data between the drive and up to two Adapter Boards is provided through the Microbus.
Chapter 3 Functional Description Velocity Control The Velocity Control compares the velocity reference to the velocity feedback to determine the velocity error. Torque Reference Select The 1395 can operate as either a speed regulated or a torque regulated drive, and therefore has the capability to accept either a velocity reference or a torque reference input.
Chapter 3 Functional Description Field Sync and Firing Logic The Phase Angle output from the Field Current Control is converted to a time reference which is synchronized to the Line Sync signal from the Armature Sync and Firing Logic to produce the gate firing pulses for the SCRs. Configuration Figure 3.2 shows an overview of the parameters associated with configuration of the drive. The 1395 has been designed to accept control input through the use of Adapter Boards.
Chapter 3 Functional Description Figure 3.2 Source and Sink Parameters (Partial) Programming Terminal Interface Programming Terminal Sources 200 - 204 1395 Drive Control Logic Sinks 150 Logic Cmd 1 Programming Terminal Sinks 151 Logic Cmd 2 152 250 - 254 Logic Cmd 3 154 Velocity Ref. Whole Port A Interface Port A Sources 156 400 157 Tach Velocity Torque Reference 409 Sources 100 Logic Status Port A Sinks 101 Drive Fault 450 106 Velocity Feedback 459 112 Arm. Current Fdbk.
Chapter 3 Functional Description Table 3.
Chapter 3 Functional Description Source Parameters Information input to a Sink parameter must originate from a Source parameter which transmits the information through the Microbus Ports. As shown in Figure 3.2, there are 10 Source parameters associated with each of the ports. The specific hardware devices associated with the Source parameters are determined by the Adapter Board which has been physically connected to the port.
Chapter 3 Functional Description Table 3.B Control Logic Source Parameters Number Name Function 100 Logic Status 16 bit word used to indicate the present operating condition of the drive. 101 Drive Fault 16 bit word used to indicate fault conditions in the drive. 102 Pre Ramp Vel Ref Velocity reference output from the Velocity Reference Control 103 Ramp Vel Ref Velocity reference output from the Ramp Control.
Chapter 3 Functional Description noted that the 1395 drive is shipped from the factory pre-configured. The user has the capability of reconfiguring the drive as required. Figure 3.3 Linking Sources to Sinks Programming Terminal Interface Programming Terminal Sources Sinks 200 - 249 150 1395 Drive Control Logic Logic Cmd 1 Programming Terminal Sinks 151 Logic Cmd 2 152 250 - 299 Logic Cmd 3 154 Velocity Ref.
Chapter 3 Functional Description The specific function and data requirements for each source parameter associated with the ports is defined by the Sink parameter from the control firmware to which it is linked. For example, in Figure 3.3, Parameter 400 is linked to Parameter 151 (Logic Cmd 2). Because Logic Cmd 2 has been pre-defined as a 16 bit control word, Parameter 400 must be handled by the Adapter Board, and in turn by the external control devices, as the 16 bit control word Logic Cmd 2 (i.e.
Chapter 3 Functional Description Figure 3.4 Discrete Adapter Board Configuration Example Programming Terminal Programming Terminal Interface Sources 200 - 249 1395 Drive Control Logic Sinks 150 Logic Cmd 1 Programming Terminal Sinks 151 Logic Cmd 2 152 250 - 299 Logic Cmd 3 154 Discrete Adapter Port A Interface Bit Sel Velocity Ref.
Chapter 3 Functional Description In this example, the speed feedback is being provided by a DC tachometer. The standard drive control is set up to use a digital Encoder for speed feedback, therefore, the standard hardware of the drive does not have an input for DC tach feedback. In this case, the DC tach feedback must be provided through the Discrete Board as an analog input as shown in Figure 3.4.
Chapter 3 Functional Description Current Loop Tuning As previously explained, the current loop tuning function performs two separate functions. First, it checks the armature bridge of the drive to assure that it is functional. Second, it tests and tunes the current loop gains of the drive. The current loop function can affect the following parameters: Parameter No.
Chapter 3 Functional Description Current Tune The Autotune Current Tune calculates the maximum current loop bandwidth and current loop gains. The KP and KI Armature Loop gains (Parameters 735 and 736) are based on the maximum discontinuous current (Parameter 734), desired Current Loop Bandwidth (Parameter 741) and Damping Factor (Parameter 743). Parameter 734 is used by autotuning to calculate the current loop gains because Parameter 734 is inversely proportional to the armature inductance.
Chapter 3 Functional Description In addition, the parameters listed below are used by the velocity loop function during test and tune. These parameters must be set up properly for the tuning function to work properly. Parameter No. Description 698 Auto Tune I Lim 699 Auto Tune Speed 702 Velocity Loop Damping Factor Velocity Loop Motor Test The motor test calculates the motor inertia (Parameter 613) by running the drive through a defined velocity profile.
Chapter 3 Functional Description Field Flux Tuning The Field Flux Tuning function calculates the field current values required to obtain specific field flux levels and calibrates the flux parameters accordingly. Field Flux Tuning is not performed if Armature Voltage Feedback is used as the feedback device type (Parameter 621). It also calculates the rated field current and adjusts the Rated Field Current (Parameter 612) as required. The field flux tuning function does not control the motor speed directly.
Chapter 3 Functional Description • Once a trend buffer is activated, it continuously samples the selected parameter. When it is triggered, each buffer will take an additional number of samples as specified by the Post Sample Parameter. When finished sampling, the data is transferred to an output buffer where it can be displayed or sent to an external device.
Chapter 3 Functional Description General Logic Description A general block diagram (software overview) of the 1395 logic is shown in Figure 3.5. Each of the major functions has a circled reference number assigned to it, which corresponds to the general software functional description given in this section. All diagrams used for the logic description in this manual use a function block representation of the actual software function being performed.
Chapter 3 Functional Description been provided. Desired Contour (Parameter 653), specifies the rounding of the edges of the velocity profile or “S” filtering. These functions can be bypassed by setting bit 5 in Logic Command. Ramp Velocity Reference (Parameter 103), is the output of the Ramp and Contour function blocks. The value of this parameter is conditionally offset by the Droop function (if used), to become the Final Velocity Reference (Parameter 104).
Chapter 3 Functional Description Process Trim (Circle 7) Process Trim Reference (Parameter 161), and Process Trim Feedback (Parameter 162), are summed to provide the error signal into the filter block. Process Trim Filter Constant (Parameter 713), determines the gain of a single pole filter used in the process trim. The output of the filter is used as the input to the process trim P/I regulator.
Chapter 3 Functional Description Feedback Control (Circle 14) Two current transformers (CT’s) sense armature current flow. The current feedback is scaled using Motor Armature Full Load Amps (Parameter 611) and Rated Armature Bridge Current (Parameter 615). Parameter 112 is the average armature current feedback value. The field current transducer (FCT) provides field current feedback to the control which is scaled by Rated Field Motor Current (Parameter 612) and Rated Field Bridge Current (Parameter 616).
Chapter 3 Functional Description functional again, it would be possible to switch back to it through one of two methods: 1. Change the value of the feedback device parameter (Parameter 621) to the original feedback type. NOTE: If the drive is running while this change is made, the drive will check to make certain the feedback from the primary feedback device is within the tach loss window. If it is, the switch will be honored and the parameter values will be restored to their previous values.
Chapter 3 Functional Description – Field Economy Reference (Parameter 674) specifies the field flux flux reference to the motor. The flux value specified by this parameter will be in use when the motor has been stopped for the time specified in the Field Economy Delay (Parameter 675). – Minimum Field Regulate Speed (Parameter 686), and velocity Fdbk, (Parameter 106), are required for Field Weakening.
Chapter 3 Functional Description Figure 3.5 1395 Block Diagram 1 VELOCITY REFERENCE CONTROL SPEED REFERENCE SELECT LOGIC CMD BITS 2 0 0 0 0 1 1 1 1 1 0 0 1 1 0 0 1 1 0 0 1 0 1 0 1 0 1 SPEED REF.
Chapter 3 Functional Description LOGIC CMD 150, 151, 152 1,2,5,9,10 3 RAMP CONTROL 1 FWD SPEED LIMIT 608 RPM LOGIC CMD 150, 151, 152 11 2 5 DESIRED CONTOUR 653 % 10 626 Jog Ramp Enable Pre–Ramp Vel Ref 102 RPM 9 RAMP BYPASS LINEAR ACCEL/DECEL RAMP 0 STOP COMMAND Ramp Vel Ref 103 RPM To Sheet 2 4096 = Motor Base Speed S CONTOUR FILTER ACCEL TIME 651 SEC DECEL TIME 652 SEC RPM 607 REV SPEED LIMIT PROCESS TRIM SELECT 628 FINAL VEL REF 104 =3 From Sheet 2 STOP LOGIC 15 AUTO TUNE VELOCITY I
Chapter 3 Functional Description Figure 3.5 (Sheet 2 of 3) 1395 Block Diagram PROC TRIM HI SUM 4096 = BASE MTR. SPD. 722 RPM Ramp Vel Ref 103 From Sheet 1 4096 = Base Motor Speed + + – + RPM DROOP FILTER 4096 = 100% 658 DROOP PERCENT 657 % % RPM 6 721 PROC TRIM LOW SUM % DROOP DROOP CONTROL 100 T(S) = W/S+W DROOP GAIN 657 = 0 0 4096 e .
Chapter 3 Functional Description 5 VELOCITY PI CONTROL KF VELOCITY LOOP 661 Final Vel Ref 104 KP VELOCITY LOOP 660 Velocity Feed Forward 108 TACH SWITCH KP 690 RPM RPM KF GAIN + 65536 – FEED FORWARD 8 8 TORQUE SELECT PROPORTIONAL GAIN FUNCTION H FWD TORQUE LIMIT From Sht 3 AUTO TUNE GAIN 124 + KP GAIN FWD TORQUE LIMIT From Sht 3 B – 0 + T S KI GAIN – 8.
Chapter 3 Functional Description Figure 3.
Chapter 3 Functional Description 10 CURRENT PI CONTROL ARM CURRENT FIRE ANG 2048 = 90 DEG.
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Chapter 4 Installation Chapter Objectives The following data will guide you in planning the installation of the Bulletin 1395. Since most start-up difficulties are the result of incorrect wiring, every precaution must be taken to assure that the wiring is done as instructed. IMPORTANT: The end user is responsible for completing the installation, wiring and grounding of the 1395 drive and for complying with all National and Local Electrical Codes.
Chapter 4 Installation Figure 4.1 Nominal Dimensions 400 – 600 HP 230V 700 – 1250 HP 460V 1000 – 2000 HP 660V ÇÇÇÇÇ ÇÇÇÇÇÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇÇÇ Top Entry Cable Housing Exhaust Air 10° C Rise Dimensions are in inches and (mm) P B . . . . . . . . . . . . . . . . . . . . . . . A . . . . .. .. . . .. .. . SIDE . . . . . PE . .
Chapter 4 Installation Cooling Airflow In order to maintain proper cooling, the drive must be mounted in a vertical position (fuses in the upper left hand corner). The recommended minimum clearance for the drive is 12 inches top, 6 inches sides and 9 inches front as shown in Figure 4.1. The drive design produces up to a 10°C or 18°F air temperature rise when the drive is operated at full capacity. Precautions should be taken not to exceed the maximum inlet ambient air temperature of 40°C (104°F).
Chapter 4 Installation Figure 4.
Chapter 4 Installation Table 4.A Cable and Wiring Recommendations Cable Type Minimum Spacing in Inches between Classes – Steel Conduit/Tray Spacing 2/3/4 5/6 1 7/8 9/10/11 Notes AC Power (600V or greater) 2.3kV 3/Ph AC Lines per NEC & Local Codes 0 3/9 3/9 3/18 Note6 1/2/5 2 AC Power (less than 600V) 460V 3/Ph AC Lines per NEC & Local Codes 3 DC Power DC Motor Armature per NEC & Local Codes 3/9 0 3/6 3/12 Note 6 1/2/5 4 DC Power Reg.
Chapter 4 Installation Grounding Procedures The purpose of grounding is to: • Limit dangerous voltages on exposed parts to ground potential in the event of an electrical fault. • To facilitate proper overcurrent device operation when ground fault conditions are incurred. • To provide for electrical interference suppression. The general grounding concept for the 1395 is shown in Figure 4.3 and explained below. Safety Ground (PE) – is the safety ground required by code.
Chapter 4 Installation Figure 4.
Chapter 4 Installation As previously explained, two different types of grounds are used in the 1395 drive. They are defined as follows: Safety Ground (PE) – A Safety Ground is normally required by the electrical code and is defined externally as PE ground. Main PE is located on the bottom of the cabinet on the left side . Signal Ground (TE) – The Signal Ground point is used for all control signals internal to the drive.
Chapter 4 Installation Power Wiring Procedure The following procedure provides the steps needed to properly perform the power wiring connections to the 1395 drive. Using Table 4.D, verify that the motor field is compatible with the DC field voltage output of the drive. Table 4.D Standard Field Voltage Output AC Incoming Voltage to Drive DC Supply Output Voltage to Field 230VAC 150VDC 460VAC 300VDC 660VAC 300VDC 1.
Chapter 4 Installation Figure 4.4 Power Connections – Standard Field Voltage Line Reactor Isolation Transformer L1 L2 Aux 3PH 460V L3 CB1 FRONT VIEW OF DRIVE DC Contactor M1 A1 A2 6F 7F 8F DC Field Output TB5 1 – 15 TB7 see Fig. 4.
Chapter 4 Installation Circuit Board Jumper Connections There are several jumpers located on different boards in the 1395 that are used to configure the drive for a specific application. 1. Verify that the motor field current jumper, is in the proper location per Table 4.F. Obtain the motor full field current data from the motor nameplate. The position of the jumper is determined by both the drive current rating and DC shunt field current rating.
Chapter 4 Installation 3. Verify that the encoder voltage selection is correct. If an encoder is used, the drive can provide +12VDC (500 mA) to power the encoder. Check the encoder documentation to determine which voltage is to be used, then verify that jumpers J8 through J10 on the Main Control Board are in the proper position. See Table 4.H for jumper settings. Table 4.
Chapter 4 Installation Control Wiring Procedure 1. If an encoder is used, wire it to TB3. Refer to the encoder instruction manual for proper wiring to the drive. a) Terminals 19 and 20 connect to differential encoder output A (NOT) and A. b) Terminals 17 and 18 connect to differential encoder output B (NOT) and B. c) Terminals 15 and 16 are reserved for future use and are not to be used. d) Terminal 14 provides + 12VDC (500 mA max.) power to the encoder.
Chapter 4 Installation Figure 4.5 TB3 Terminal Descriptions Encoder TB3 Channel A 20 Channel A 19 Channel B 18 Channel B 17 ENCA1 ENCA1 Main Control Board ENCB1 ENCB1 16 15 + Supply Voltage 14 – Supply Voltage 13 12 11 24V DC E-Coast Refer to Table 4.J 10 9 8 Drive Ready Output 7 115V AC Common 6 5 Refer to Table 6.
Chapter 4 Installation 2. Wire Emergency Coast Stop Circuit (ECOAST). The drive has the capability to accept an ECOAST input from either a 24VDC or 115VAC contact. The contact must be normally closed and will typically be a Stop pushbutton. Refer to the following paragraphs, Figure 4.5 and Table 4.J for connection information. If a 24VDC ECOAST is desired, the contacts of the ECOAST device must be wired between terminals 9 and 11 of TB3.
Chapter 4 Installation 5. Connect Programming Terminal. Connect the 9 pin D-style connector of the Programming Terminal to the D-style connector (labeled DHT) mounted on the TB3 mounting rail. Refer to the Programming Terminal Installation and Operation Manual for further details. Adapter Boards Discrete Adapter Board The Discrete Adapter Board is connected to Microbus Port A with wiring to external devices being accomplished at TB3, terminals 23 to 52.
Chapter 4 Installation Figure 4.
Chapter 4 Installation Analog Input – Velocity and Trim Reference. Connections for the velocity and trim reference inputs can be for uni- or bi-directional operation, using the internal drive ±10VDC power supply (see Fig. 4.8). Figure 4.8 Typical Analog Input Connections TB3 IMPORTANT: Connect to either terminal 31 or 32, Not Both TB3 Forward * 31 –10V DC P.S. 32 +10V DC P.S. Reverse R* R 31 –10V DC P.S. 32 +10V DC P.S. R Reverse Relay + + ANALOG INPUT Reference* 2.
Chapter 4 Installation Many problems relate to the scaling of the tach signals. Below is a procedure for checking the scaling of the analog tach feedback for proper drive operation. 1. Determine the Volts/RPM rating of the tach (refer to tach name plate). Multiply this rating times the absolute maximum speed the motor will be commanded to accelerate to. This value should also be programmed in Parameter 607 “Rev Speed Lim” and 608 “Fwd Speed Lim” to assure that the velocity command will be properly clamped.
Chapter 4 Installation 5. The Raw Adapter Units are then used to determine the correct scaling parameter value according to the equation below. 4096 Raw Adapter Units = Scaling Parameter Value 6. The Scaling Parameter Value should then be entered into the associated analog input scaling set-up parameter. This procedure will be correct to within 5%. Verify that the scaling is correct by measuring the actual motor velocity with a hand tachometer.
Chapter 4 Installation Digital Reference Adapter Board The Digital Reference Adapter Board is connected to Microbus Port A with wiring to external devices at terminals 23 to 62 of TB3. The drive is shipped pre-configured, meaning that all of the inputs and outputs are linked to a predefined signal. To change the configuration refer to the Digital Reference Adapter Manual. Figure 4.10 shows the 1395 standard configuration for the Digital Reference Adapter Board.
Chapter 4 Installation Figure 4.
Chapter 4 Installation Figure 4.13 Typical Analog Input Connections TB3 TB3 Forward 28 IMPORTANT: Connect to either terminal 28 or 29, Not Both 29 +10V DC P.S. Reverse R * R* 28 +10V DC P.S. 29 –10V DC P.S. 31 EXT. VELOCITY REF. 32 EXT. VELOCITY REF. 30 P.S. COMMON R –10V DC P.S. Reverse Relay – Reference* 2.5k Ohm Minimum + 31 EXT. VELOCITY REF. 32 EXT. VELOCITY REF. 30 P.S. COMMON – Reference * 2.5k Ohm Minimum + IMPORTANT: Connect shield to drive end only.
Chapter 4 Installation The tach signal then must be scaled in the adapter board to determine the proper relationship of output voltage/motor velocity to base speed in Drive Units. This scaled configuration data must then be linked to Parameter 156 “Tach Velocity.” Many problems relate to the scaling of the tach signals. Below is a procedure for checking the scaling of the analog tach feedback for proper drive operation. 1. Determine the Volts/RPM rating of the tach (refer to tach name plate).
Chapter 4 Installation 4. The input voltage at base speed is then converted to Raw Adapter Units according to the following equation. Base Speed Input x 2048 10 = Raw Adapter Units 5. The Raw Adapter Units are then used to determine the correct scaling parameter value according to the equation below. 4096 Raw Adapter Units = Scaling Parameter Value 6. The Scaling Parameter Value should then be entered into the associated analog input scaling set-up parameter.
Chapter 4 Installation Analog/Digital Output Figure 4.16 shows typical analog and digital output connections. Figure 4.16 Typical Output Connections TB3 TB3 + 0 to +10VDC, 1mA Maximum 41 ARM. CURRENT FDBK. – 61 +24V DC HIGH External 24VDC Power Supply 62 0 VOLTS COMMON 42 ARM. CURRENT FDBK. PL* IMPORTANT: Connect shield to drive end only. Other end is to be insulated and left floating.
Chapter 5 Programming Parameters Introduction This chapter contains the information required to assist the user in programming the drive for a specific application after initial start-up. Drives are shipped programmed with default values and are preconfigured for the options installed. The drive parameters can be divided into the following categories: Basic – The Basic parameters that must be programmed at the time of start-up.
Chapter 5 Programming Parameters Non-Volatile Memory – Data memory in the drive which retains the values of all data even when power is disconnected from the drive control. EEPROM (Electrically Erasable Programmable Read Only Memory) chips are used for the 1395 non-volatile memory to store some of the drive parameters. Parameter Table – Table of parameter entries for all configuration and setup parameters used in the drive.
Chapter 5 Programming Parameters Parameter Table Structure All data used by the 1395 control to perform the drive functions is stored in the Parameter Table. Each parameter entry in the parameter table contains the information illustrated in Figure 5.1. Figure 5.1 Parameter Entry Parameter Number Hex Units Name Init.
Chapter 5 Programming Parameters 1 Bit Field Select – A single bit used to enable/disable a specific drive function. For 1 bit field select type data, the entire 16 bit word is stored in the parameter entry, but only the first bit (bit 0) is used. Parameter Table Storage Whenever power is applied to the drive control, the entire parameter table is copied from EEPROM to RAM (Random Access Memory). All information stored in RAM is lost when power is disconnected.
Chapter 5 Programming Parameters Table 5.
Chapter 5 Programming Parameters Table 5.A Cont.
Chapter 5 Programming Parameters Table 5.A Cont.
Chapter 5 Programming Parameters Table 5.A Cont.
Chapter 5 Programming Parameters Table 5.A Cont.
Chapter 5 Programming Parameters Table 5.A Cont.
Chapter 5 Programming Parameters Table 5.A Cont.
Chapter 5 Programming Parameters Table 5.A Cont. PARM HEX NAME INIT MIN MAX EE FUNCTION/CLASSIFICATION/PORT 670 2A6H Slave Percent 2 0 –200 200 EE Torque Control/Setup 672 2A8H KI Flux 1638 0 32767 EE Field Weak Control/Set-Up 673 2A9H KP Flux 4096 0 32767 EE Field Weak Control/Set-Up 674 2AAH Fld Economy Ref % 50 0 100 EE Field Flux Control/Set-Up 675 2ABH Fld Economy Ref Sec 30 0 6553.5 EE Field Flux Control/Set-Up 676 2ACH Fld Flux Ref % 100 0.
Chapter 5 Programming Parameters Table 5.A Cont. INIT MIN MAX EE FUNCTION/CLASSIFICATION/PORT Proc Tri Lo Lim –4096 –32767 32767 EE Process Trim Control/Set-Up Proc Trim Hi Lim 4096 –32767 32767 EE Process Trim Control/Set-Up 2D6H Proce Trim Out K 1.000 –16.0 +16.0 EE Process Trim Control/Set-Up 720 2D7H Ovld Pend Level % 115 0.0244 260 EE Fault Detection/Set-Up 721 2D8H Proc Trim Lo Sum RPM –6xB.S. –6xB.S.
Chapter 5 Programming Parameters Table 5.A Cont. PARM HEX NAME UNITS INIT MIN MAX EE FUNCTION/CLASSIFICATION/PORT 906 Trend Logic Val 0 0 32767 EE Trend Function 907 Trend Logic Val 0 0 32767 EE Trend Function +16.0 EE Trend Function 908 Trend Unsign Val 0 0 909 Trend Unsign Val 0 0 260 EE Trend Function 910 Tr1 Opnd Parm X 100 1 947 EE Trend Function 911 Tr1 Opnd Parm Y 904 1 947 EE Trend Function .AND .GT .NOR EE Trend Function 0.02 0.
Chapter 5 Programming Parameters Parameter Descriptions This section provides a brief description of the parameters in Bulletin 1395. The programming terminal for the 1395 is also used for other products. Parameters not used by the 1395 will appear as “NOT USED, NOT CHANGEABLE”. Information is provided in the following format: Parameter Number – Parameter Name [Parameter Name as it appears on the Programming Terminal].
Chapter 5 Programming Parameters Parameter 100 – Logic Status [Logic Status] Internal Units : None Programming Terminal units : Bit Field Description : This is a word of status data that indicates conditions within the Drive in boolean logic. Where a bit is set to 1, the corresponding condition in the drive is true, otherwise the condition is false. The bits in the Logic Status word are defined as: Bit # 15 14 13 DHT REF.
Chapter 5 Programming Parameters Contactor closed (Bit 4) : A 1-bit field indicating the status of the contactor. 1 denotes contactor closed and 0 denotes open. Drive running (Bit 5) : A 1-bit field, when set to 1, indicates the drive has acknowledged the start or jog inputs in the logic command and is regulating speed. 1 denotes Drive is running and zero not running. Running reverse (Bit 6) : A 1-bit field, indicating the motor is moving at a non-zero velocity in the reverse direction.
Chapter 5 Programming Parameters At speed 3 (Bit 13) : A 1-bit field that is set to 1 when the actual velocity of the motor is greater than the at speed 3 setpoint. Otherwise, set to 0. Internally in the drive, if the feedback velocity (Parameter 106) is greater than or equal to at speed 3 (Parameter 706), the at speed 3 bit is set to 1. At speed 4 (Bit 14) : A 1-bit field that is set to 1 when the actual velocity of the motor is greater than the at speed 4 setpoint. Otherwise, set to 0.
Chapter 5 Programming Parameters IF VELOCITY CONTROL FAULTS ARE SELECTED: (630 = 1) Bit # 15 14 13 DHT REF.
Chapter 5 Programming Parameters Parameter 102 – Pre Ramp Velocity Reference [Pre Ramp Vel Ref] Internal Units : 4096 = 1000h = 1 pu = base motor speed Programming Terminal units : RPM Description : This parameter indicates the value of the velocity reference that has been currently selected by the reference control. When a 32 bit velocity reference is used, this will be the most significant 16 bits or upper word. This data is input to the velocity reference ramp software.
Chapter 5 Programming Parameters Parameter 107 – Position Feedback [Position Fdbk] Internal Units : 4096 = 1000h = 1 PU = 1 pu position Programming Terminal units : None Description : Position Feedback indicates the latest measured angular motor position. This information could originate from a digital encoder, analog tachometer, or armature voltage feedback, depending upon the selected feedback device (Parameter 621).
Chapter 5 Programming Parameters Parameter 112 – Armature Current Feedback [Arm Current Fdbk] Internal Units : 4096 = 1000h = 1 PU = 100% rated arm. current Programming Terminal units : Amps Description : This parameter indicates the latest armature current feedback value.
Chapter 5 Programming Parameters Parameter 118 – Field Current Feedback [Fld Current Fdbk] Internal units : 4096 = 1000h = 1 pu = 100% rated motor field current Programming Terminal units: Amps Description : This parameter indicates the latest field current feedback value as measured by the drive.
Chapter 5 Programming Parameters Parameter 122 – Encoder Velocity [Encoder Velocity] Internal units : 4096 = base motor speed Programming Terminal units: RPM Minimum Value: N/A Maximum Value: N/A Default Value: N/A Function: Software Test Point Description : This is the measured velocity feedback from the encoder feedback Parameter 123 – Velocity PI Output [Velocity PI Out] Internal units : 4096 = 100% rated motor torque Programming Terminal units: % Minimum Value: N/A Maximum Value: N/A Default Value: N/A
Chapter 5 Programming Parameters Parameter 150 – Logic Command 1 [Logic Cmd 1] Internal units : None Programming Terminal units: Bit Field Description : This is a word of fast data used to control drive logic operation. The information is contained in binary (boolean) form. If a bit is set, the associated function is enabled, otherwise the function is disabled (inactive). The functions contained in Logic Command 1 are similar to those in Logic Command 2 and 3.
Chapter 5 Programming Parameters Table 5.B Logic Command Word Bits 0,1,2 2 1 0 Definition Selected Parms 0 0 0 0 1 1 1 1 0 0 1 1 0 0 1 1 0 1 0 1 0 1 0 1 External Speed Reference Preset Speed 1 Preset Speed 2 Preset Speed 3 Preset Speed 4 Preset Speed 5 MOP Forward Speed MOP Reverse Speed 154 633 634 635 636 637 MOP MOP External speed reference indicates Parameters 153 and 154 will be the velocity reference.
Chapter 5 Programming Parameters Table 5.C Logic Command Word Bits 6, 7 Bit 7 Bit 6 0 0 0 1 0 1 0 1 Definition Selected Parms MOP 1 accel, decel MOP 2 accel, decel MOP 3 accel, decel MOP 4 accel, decel 641, 645 642, 646 643, 647 644, 648 Command Enable (Bit 8) : A 1-bit field used to select one of the three logic commands in the Drive. For details see Table 5.D. If the command enable bit is set to 1 in Logic Command 3, then Logic Command 3 is the active logic command accepted by the Drive.
Chapter 5 Programming Parameters The drive will continue to run using the Jog 1 speed reference until this bit is set to 0. At this time, velocity reference will be set to zero and the drive regenerate to a stop. Once the motor has stopped, velocity regulation will stop. The contactor will remain closed for the time specified by Jog Dwell (Parameter 711). For jogging, the ramp function may be using the Jog Ramp Enable (Parameter 626).
Chapter 5 Programming Parameters Parameter 152 – Logic Command 3 [Logic Cmd 3] Internal units : None Programming Terminal units: Bit Field Description : This controls Drive logic operation when the Programming Terminal is in control of the Drive. All functions present in Logic Command 3 are identical to Logic Command 1. The Command/Enable bit in logic command 3 will select Drive control with logic command 3 (if set) regardless of the state of the Command/Enable bit in other logic words.
Chapter 5 Programming Parameters Parameter 156 – Tach Velocity [Tach Velocity] Internal units : 4096 = 1000h = 1 pu = base motor speed Programming Terminal units: RPM Description : This word supplies a motor velocity feedback signal when an analog tachometer is used. This input will typically be linked to an analog input parameter from the Discrete Adapter Board. The analog scaling for the adapter should be set up so that a value of 4096 in this parameter represents base motor speed.
Chapter 5 Programming Parameters Parameter 160 – CEMF Reference [CEMF Reference] Internal units : 4096 = 1000h = 100% motor CEMF Programming Terminal units: Percent of full motor CEMF. Description : This word supplies a n external CEMF reference to the flux control. This input would be used when it is desired to operate the field flux control in the CEMF mode of operation. The Drive will use this input when the CEMF Control Enable bit is set in Flux Mode Select (Parm 627).
Chapter 5 Programming Parameters Parameter 166 – Velocity Indirect 4 [Vel Indirect 4]Veloc Internal units : Programming Terminal units : Description : This is the Fast Sink, with its pointer in Parameter 603, Velocity Parameter Select 4.
Chapter 5 Programming Parameters Parameter 606 – Base Motor Speed [Base Motor Speed] Internal units : RPM Programming Terminal units: RPM Minimum Value: 1 Maximum Value: 6000 Default Value: 1750 Description : Nameplate base motor speed in RPM.
Chapter 5 Programming Parameters Parameter 610 – Rated Motor Voltage [Rated Motor Volt] Internal units : volts x 10 Programming Terminal units: VOLTS Minimum Value: 75 Maximum Value: 700 Default Value: 240 Function: Torque Control Description : Nameplate rated motor voltage. This should be the measured armature voltage when the motor is running at base speed with rated field current.
Chapter 5 Programming Parameters Parameter 614 – Armature Resistance [Arm Resistance] Internal units : 4096 = 1000h = 1 per unit = 100% of rated armature voltage. Programming Terminal units: Percent of rated armature voltage Minimum Value: 0% Maximum Value: 100.0% Default Value: 5.
Chapter 5 Programming Parameters Parameter 620 – System Reset Select [Sys Reset Select] Internal units : None Programming Terminal units: None Minimum Value: 0 Maximum Value: 1 Default Value: 0 Description: This parameter determines whether terminal TB3-3 provides the System Reset function or the Logic Command Stop function. The choices are: 0 = System Reset 1 = Normal Stop The System Reset function requires a Normally Open operator device which closes to cause a reset.
Chapter 5 Programming Parameters Parameter 622 – Contactor Type [ContactorType] Internal units : None Programming Terminal units: None Minimum Value: 0 Maximum Value: 1 Default Value: 1 Description: Parameter 622 selects the location of the contactor in the circuit. The choices are: AC Contactor Mode, 0 = Contactor interrupts AC supply. Contactor will not automatically close/open with Drive Start/Stop operation. DC Contactor Mode, 1 = Contactor interrupts DC armature circuit.
Chapter 5 Programming Parameters Parameter 624 – Maintained Start [Maintain Start] Internal units : None Programming Terminal units: 0/1 selection Minimum Value: 0 Maximum Value: 3 Default Value: 2 Description: Parameter 624 selects the type of Start signal required in the logic command word. Choices are: 0 = Start signal treated as a momentary input. The drive will latch the start input. A Stop bit will be required to unlatch the start function. 1 = Start signal treated as a maintained input.
Chapter 5 Programming Parameters Parameter 626 – Jog Ramp Enable [Jog Ramp Enable] Internal units : None Programming Terminal units: 0/1 selection Minimum Value: 0 Maximum Value: 1 Default Value: 0 Description: Parameter 626 selects the use of velocity reference ramp while jogging.
Chapter 5 Programming Parameters Bit 6 – Disable Field Loss Detection: When set, this bit will disable the check for field loss. This feature could be used in applications where external field supplies or permanent magnet motors are used. When clear, field loss detection is active. Caution should be used when disabling the Field Loss Detection feature. Damage to equipment or injury to personnel could occur during an undetected field loss with non-permanent magnet type motors.
Chapter 5 Programming Parameters Parameter 630 – Fault Report [Fault Report] Internal units : None Programming Terminal units: None Minimum Value: 0 Maximum Value: 1 Default Value: 1 Description: This parameter selects whether Velocity or Current Control fault status will be written to the FAULT WORD (Parm 101).
Chapter 5 Programming Parameters Parameter 634 – Preset Speed 2 [Preset Speed 2] Internal units : 4096 = 1000h = 1 PU = base motor speed Programming Terminal units: RPM Minimum Value: –6 x base speed Maximum Value: +6 x base speed Default Value: 0 Description: This will be the velocity reference used by the drive when preset 2 has been selected in the logic command word.
Chapter 5 Programming Parameters Parameter 639 – Jog 2 Speed [Jog 2 Speed] Internal units : 4096 = 1000h = 1 PU = base motor speed Programming Terminal units: RPM Minimum Value: –6 x base speed Maximum Value: +6 x base speed Default Value: 0 Description: This will be the velocity reference used by the Drive when Jog 2 has been selected in the logic command word. Parameter 641 – Mop Accel 1 [Mop Accel 1] Internal units : Seconds x 10 Programming Terminal units: Seconds Minimum Value: 0.
Chapter 5 Programming Parameters Parameter 644 – Mop Accel 4 [Mop Accel 4] Internal units : Seconds x 10 Programming Terminal units: Seconds Minimum Value: 0.1 Maximum Value: 6553.5 Default Value: 0.1 Description: This parameter determines the acceleration rate of the MOP generated velocity reference when Mop rate 4 has been selected in the logic command word. The units are in seconds to accelerate from 0 to base speed.
Chapter 5 Programming Parameters Parameter 648 – Mop Decel 4 [Mop Decel 4] Internal units : Seconds x 10 Programming Terminal units: Seconds Minimum Value: 0.1 Maximum Value: 6553.5 Default Value: 0.1 Description: This parameter determines the deceleration rate of the MOP generated velocity reference when Mop rate 4 has been selected in the logic command word. The units are in seconds to decelerate from base speed to zero speed.
Chapter 5 Programming Parameters Parameter 652 – Decel Time [Decel Time] Internal units : seconds x 10 Programming Terminal units: Seconds Minimum Value: 0.1 Maximum Value: 6553.5 Default Value: 10.0 Description: This parameter determines the deceleration rate of the velocity reference for all references. Units are measured in seconds taken to decelerate from base speed to 0 speed. The deceleration ramp applies to speed changes toward zero speed in either the forward or reverse direction.
Chapter 5 Programming Parameters Parameter 658 – Droop Filter (Gain) [Droop Filter] Internal units : 4096 = 1000h = 100% droop filtering Programming Terminal units: Percent of maximum Droop filtering Minimum Value: 0% Maximum Value: 100.0% Default Value: 93% Description: This parameter determines the gain of a single pole filter used in the droop. A filter is used to correct for stability problems caused by subtracting a function of velocity error from the velocity reference.
Chapter 5 Programming Parameters Parameter 663 – Forward Bridge Current Limit [Fwd Brdg Cur Lim] Internal units : 4096 = 1000h = 100% rated motor current Programming Terminal units: Percent of rated motor current Minimum Value: 0.024% Maximum Value: 260% Default Value: 50% Description: This parameter specifies the largest allowable positive motor armature current that will be commanded. Attempts by the speed regulator to exceed this level will be limited to this value.
Chapter 5 Programming Parameters Parameter 667 – Minimum Taper Current [Min Taper Cur] Internal units : 4096 = 1000h = 100% rated motor current Programming Terminal units: percent of rated motor current Minimum Value: 0.024% Maximum Value: 260% Default Value: 100% Description: This is the armature current limit value that will be used for motor speeds above the End Taper Speed value. The final armature current reference value will be limited to a number less than or equal to this number.
Chapter 5 Programming Parameters Parameter 672 – KI Flux [KI Flux] Internal units : gain / 3277 Programming Terminal units: None Minimum Value: 0 Maximum Value: 32767 Default Value: 1638 Description: This parameter controls the integral gain of the CEMF Regulator. For example; If KI flux is equal to 32767, then 1 pu CEMF error will produce 1 pu flux command in 1 second. The CEMF Regulator is a classical PI regulator that is activated by setting an enable bit in Flux Mode Select (Parm 627).
Chapter 5 Programming Parameters Parameter 676 – Field Flux Reference [Fld Flux Ref] Internal units : 4096 = 1000h = 100% full motor flux. Programming Terminal units: percent of full motor field flux. Minimum Value: 0.024% Maximum Value: 125% Default Value: 100% Description: This parameter specifies the full flux reference value for the motor. This value is the highest flux reference value that can be applied to the motor field.
Chapter 5 Programming Parameters Parameter 679 – Field Current at 2/8 Flux [Fld I @ 2/8 FLUX] Internal units : 4096 = 1000h = 100% rated field current Programming Terminal units: None Minimum Value: 0% Maximum Value: 100% Default Value: 14.3% Description: This is the third entry in a 9 element lookup table for converting flux reference commands to field current reference. The lookup conversion is used to linearize the field current reference with respect to flux.
Chapter 5 Programming Parameters Parameter 682 – Field Current at 5/8 Flux [Fld I @ 5/8 FLUX] Internal units : 4096 = 1000h = 100% rated field current Programming Terminal units: Percent rated field current Minimum Value: 0% Maximum Value: 100% Default Value: 45.5% Description: This is the sixth entry in a 9 element lookup table for converting flux reference commands to field current reference. The lookup conversion is used to linearize the field current reference with respect to flux.
Chapter 5 Programming Parameters Parameter 685 – Field Current at 1.0 Flux [Fld I @ 1/0 FLUX] Internal units : 4096 = 1000h = 100% rated field current Programming Terminal units: Percent rated field current Minimum Value: 0% Maximum Value: 100% Default Value: 100% Description: This is the eighth entry in a 9 element lookup table for converting flux reference commands to field current reference. The lookup conversion is used to linearize the field current reference with respect to flux.
Chapter 5 Programming Parameters Parameter 688 – Tach Switch Tolerance [Tach Switch TOL] Internal units : 4096 = base motor speed Programming Terminal units: RPM Minimum Value: 0 Maximum Value: base speed Default Value: 10% base speed Function: Tach Loss Recovery Description: This parameter establishes the window for detection of tach loss when the Tach Loss Recovery feature is selected.
Chapter 5 Programming Parameters Parameter 691 – Tach Switch Select [Tach Switch SEL] Internal units : None Programming Terminal units: None Minimum Value: 0 Maximum Value: 1 Default Value: 0 Function: Tach Loss Recovery Description: This parameter selects the automatic Tach Switchover to Armature Voltage Feedback feature. When set to a one, a malfunction of the selected velocity feedback device will cause a warning to be reported and the drive will continue to run using Armature Voltage feedback.
Chapter 5 Programming Parameters Parameter 699 – Auto Tune Speed [Auto Tune Speed] Internal units : 4096 = 1000H = 1 pu = Base motor speed Programming Terminal units: RPM Minimum Value: –Base Speed Maximum Value: +Base Speed Default Value: +Base Speed Description: This parameter is the top speed of the motor during an auto tune velocity motor test, velocity system test, and field flux tune. For a field flux tune, the motor must be at the auto tune speed before performing the field flux tune.
Chapter 5 Programming Parameters Parameter 702 – Velocity Damping Factor [Vel Damp Factor] Internal units : None Programming Terminal units: None Minimum Value: 0.5 Maximum Value: 3.0 Default Value: 1.0 Description: This parameter (along with Parameter 700) determines the dynamic behavior of the velocity loop. The damping factor influences the amount of overshoot the velocity loop will exhibit during a transient.
Chapter 5 Programming Parameters Parameter 705 – At Speed 2 [At Speed 2] Internal units : 4096 = 1000h = 1 pu = base motor speed Programming Terminal units: RPM Minimum Value: –6 x base speed Maximum Value: +6 x base speed Default Value: base speed/8 rpm Description: This parameter specifies a setpoint for determining when the motor has reached a given speed.
Chapter 5 Programming Parameters Parameter 708 – At Speed 5 [At Speed 5] Internal units : 4096 = 1000h = 1 pu = base motor speed Programming Terminal units: RPM Minimum Value: –6 x base speed Maximum Value: +6 x base speed Default Value: base speed rpm Description: This parameter is used to specify the at speed 5 setpoint in the logic status ( parameter 100, bit 15). This 1 bit field is set to 1 when the actual velocity of the motor is greater than the at speed 5 setpoint. Otherwise, set to 0.
Chapter 5 Programming Parameters Parameter 713 – Process Trim Filter Constant [Proc Trim Fltr K] Internal units : 4096 = 1000h = 100% process trim filtering Programming Terminal units: percent of maximum process trim filtering Minimum Value: 0% Maximum Value: 100% Default Value: 0% Description: This parameter determines the gain of a single pole filter used in the Process Trim.
Chapter 5 Programming Parameters Parameter 717 – Process Trim Low Limit [Proc Trim Lo Lim] Internal units : 1000h = 4096 = 1 PU Programming Terminal units: None Minimum Value: –32767 Maximum Value: +32767 Default Value: –4096 Description: The output of the process trim regulator is limited by adjustable high and low limits. This parameter specifies the low limit of the Process Trim output value .
Chapter 5 Programming Parameters Parameter 721 – Process Trim Low Sum [Proc Trim Low Sum] Internal units : 4096 = 1000H = 1 PU = base motor speed Programming Terminal units: RPM Minimum Value: –6 x BS RPM Maximum Value: 0 RPM Default Value: –6 x Base Speed RPM Description: This parameter is associated with the Speed trim option of the Process Trim Select Parameter (#628 = 1). Parameter 721 will be in use when the speed trim option is enabled and the Process Trim Regulator has been enabled.
Chapter 5 Programming Parameters Parameter 725 – External Overtemperature Delay [Ext Overtemp Dly] Internal units : Seconds x 10 Programming Terminal units: Seconds Minimum Value: 0.1 Maximum Value: 3276.7 Default Value: 1.0 Description: This parameter specifies the length of time that the motor overtemperature discrete input must be low before a motor overtemperature fault will be indicated.
Chapter 5 Programming Parameters Parameter 729 – Field Fault Threshold [Fld Flt Thresh] Internal units : 4096 = 1000h = 1 PU = 100% rated motor field current Programming Terminal units: Per cent rated field current Minimum Value: 0% Maximum Value: 100% Default Value: 30% Description: This parameter is used to set the threshold for activating the motor loss fault in the CP fault word (parameter 101, bit 6).
Chapter 5 Programming Parameters Parameter 733 – Armature Bridge Type [Arm Bridge Type] Internal units : None Programming Terminal units: None Minimum Value: 0 Maximum Value: 1 Default Value: 1 Description: Selects the type of armature bridge (regenerative or nonregenerative). The choices are: 0 = Nonregenerative Drive. The armature bridge has 6 SCRs. 1 = Regenerative Drive. The armature bridge consists of 12 SCRs.
Chapter 5 Programming Parameters Parameter 738 – KI Field Loop [KI Field Loop] Internal units : None Programming Terminal units: None Minimum Value: 0 Maximum Value: 32767 Default Value: 168 Description: The integral gain for the PI regulator in the field current loop.
Chapter 5 Programming Parameters Parameter 741 – Desired Current Loop Bandwidth [Cur Desired BW] Internal units : None Programming Terminal units: RAD/Sec. Minimum Value: 100 Maximum Value: 1000 Default Value: 402 Description: This parameter specifies the armature current loop bandwidth requested by the user and determines (along with Parameter 743) the dynamic behavior of the current loop.
Chapter 5 Programming Parameters Parameter 780 – 1395 Version Number [1395 Version No] Internal units : None Programming Terminal units: None Description: This non-changeable parameter specifies the current firmware version number on the Main Control Board, comprising the VP, SP and CP.
Chapter 5 Programming Parameters Parameter 844 – SP Indirect 5 [SP Indirect 5] Internal units : None Programming Terminal units: None Minimum Value: –32767 Maximum Value: +32767 Default Value: 0 Description: When programmed, appears as a constant Source parameter value at parameter 14 and can be linked to a Sink parameter.
Chapter 5 Programming Parameters Parameter 904 – Trend Constant Logic Value [Trend Logic Val] Internal units : None Programming Terminal units: None Minimum Value: 0000 0000 0000 0000 Maximum Value: 1111 1111 1111 1111 Default Value: 0000 0000 0000 0000 Description: This parameter specifies a bit(s) value used for trend trigger evaluation. This parameter number is entered when programming Trend Operand Parameter X or Y. The default value is zero.
Chapter 5 Programming Parameters Parameter 908 – Trend Constant Unsigned Value [Trend Unsign Val] Internal units : None Programming Terminal units: None Minimum Value: 0 Maximum Value: 65535 Default Value: 0 Description: This parameter specifies an unsigned constant value used for trend trigger evaluation. This parameter number is entered when programming Trend Operand Parameter X or Y.
Chapter 5 Programming Parameters Parameter 912 – Trend 1 Operator [Tr 1 Operator] Internal units : None Programming Terminal units: None Minimum Value: 1 Maximum Value: 8 Default Value: 5 Description: This parameter specifies the operator used in Parameters 910 and 911 for the trend trigger evaluation. The available operators are: 1 – Greater Than 2 – Less Than 3 – Equals 4 – Not Equals 5 – Logical AND 6 – Logical NAND 7 – Logical OR 8 – Logical NOR (.GT.) (.LT.) (.EQ.) (.NE.) (.AND.) (.NAND.) (.OR.) (.
Chapter 5 Programming Parameters Parameter 915 – Trend 1 Contiguous Trigger Switch [Tr 1 Cont Trigger] Internal units : None Programming Terminal units: None Minimum Value: 0 Maximum Value: 1 Default Value: 1 Description: This parameter specifies the type of trend. The choices are One Shot Trend, 0 = Once the trigger condition is true, and the number of samples after the trigger is taken (as programmed in 914) are gathered, the trend will halt.
Chapter 6 Start-Up Introduction This chapter is a detailed step-by-step procedure for the proper start up and tuning of the 1395 drive. Among the procedures to be performed in this chapter are the following: • Basic drive tuning procedures. • Verification of proper supply voltages. • Calibrate drive set-up parameters. • Configure drive I/O The Start Up checklist must be used to record all data. ATTENTION: Servicing energized industrial control equipment can be hazardous.
Chapter 6 Start–Up ATTENTION: The CMOS devices used on the control circuit boards can be destroyed or damaged by static charges. If personnel will be working near static sensitive devices, they must be appropriately grounded. If you are not familiar with static control procedures, before servicing, reference Allen-Bradley Publication 8000-4.5.2, Guarding against Electrostatic Damage or any other applicable ESD protection handbook.
Chapter 6 Start–Up Figure 6.1 Bulletin 1395 Start-Up Sequence PRE-POWER CHECKS External Connection Checks Internal Connection Checks Feedback Board Jumper Check LIVE-POWER CHECKS Incoming Voltage Checks Logic Level Checks Polarity Checks Monitor Armature Voltage PARAMETER PROGRAMMING START-UP With Node Adapter With Discrete Adapter TUNING Pre-Power Checks 1. Verify all procedures listed in Chapter 4 Installation, have been properly completed. 2.
Chapter 6 Start–Up Table 6.
Chapter 6 Start–Up Voltage Measurement 1. Before applying power to the Drive ensure that the ECOAST input to TB3-4 and 5 is locked in the open state. The DC contactor must remain in the open state while the following measurements are being made. 2. Apply the main power source to the drive. 3. Record the following AC voltage measurements in Tables 6.E – 6.G. • Three-phase source voltages L1 to L2, L2 to L3 and L3 to L1.
Chapter 6 Start–Up • +5 +/– 0.15 VDC measured at TP58 (+) with respect to TP53 (–) on the Main Control Board. • +12 +/– 0.48 VDC measured at TP54 (+) with respect to TP53 (–) on the Main Control Board. • +24 +/– 6 VDC is measured at the Power Stage Interface (PSI) as outlined in Table 6.D. Table 6.
Chapter 6 Start–Up Standard Control I/O Checks The ECOAST Stop and Reset/Normal Stop inputs are supplied as basic drive inputs. Verify the proper operation of these inputs using the following steps. If an input does not produce the expected results, verify correct operation of the appropriate power supply. 1. Apply power to the Drive. 2. If a 24 VDC ECOAST stop circuit is used, measure the voltage from TB3-11 to -9 with the ECOAST stop contact open and closed.
Chapter 6 Start–Up Table 6.
Chapter 6 Start–Up Table 6.I Basic Parameters — Feedback Scaling Parm Parameter Name 739 K Arm Volts 740 K AC Volts Description Numerical value used to scale the armature voltage feedback. Values to be entered at this time are: 6414 = for 150 – 300 rated arm voltage 12321 = for 300 – 575 rated arm voltage 16017 = for 575 – 700 rated arm voltage Numerical value used to scale the incoming AC line voltage feedback.
Chapter 6 Start–Up Table 6.J Set-Up Parameters (cont.) Parm 718 721 722 724 727 729 730 731 732 737 738 Parameter Name Classification Process Trim High Lim Process Trim Low Sum Process Trim High Sum Absolute Overspeed Stall Delay Field Fault Threshold Field Failure Delay Tach Loss CEMF Tach Loss Velocity KP Field Loop KI Field Loop Value Application Application Application Application Application Application Application Application Application Application Application Table 6.
Chapter 6 Start–Up Adapter Parameters In order to operate the drive from external control devices it first must be configured by linking Source Parameters to Sink Parameters as described in the Configuration section of Chapter 5. The drive can be controlled by either discrete I/O devices using the Discrete or Digital Reference Adapter Board, or an Allen-Bradley PLC3 or 5 using the Node Adapter Board or the Multi-Communication Adapter. The 1395 is factory preconfigured as shown in Tables 6.M and 6.N.
Chapter 6 Start–Up Table 6.
Chapter 6 Start–Up Up to 18 links of Source to Sink parameters may be made using the programming Terminal Drive Set-Up mode. Two of the potential twenty links are permanently linked in order to maintain critical communications paths between the programming terminal and the 1395 Drive. This leaves 18 programmable source to sink parameters. The configuration section in Chapter 3 of this manual lists all of the allowable Source and Sink parameters associated with the Drive control.
Chapter 6 Start–Up 4. Connect DC Voltmeter to Terminal A1 (+) and A2 (–) at the output of the main contactor. 5. Apply power to the Drive. 6. Rotate motor shaft in CCW (counter clockwise) direction as viewed from the commutator end, using an externally applied mechanical force to the motor shaft. 7. Measure the voltage at A1 (+) and A2 (–). Set the meter range to 50 VDC to start with, and then work down until a reading can be obtained.
Chapter 6 Start–Up 6. Verify correct scaling of Armature voltage feedback. Measure the armature voltage at A1 and A2 output connections of the Drive. Verify that the voltage measured is the same as the value shown in Parm 105 (Arm Voltage Fdbk). If the value of Parm 105 is incorrect, change the value of Parm 739 (K ARM Volts) until the measured voltage agrees with Parm 105. Increasing Parm 739 increases Parm 105. 7. Verify correct scaling of speed feedback.
Chapter 6 Start–Up Drive Tuning (Drive Setup/Autotune/ Current) The following parameters should be set-up prior to using the Auto-Tuning features: PARM 661 676 698 699 702 733 743 PRESENT VALUE DESCRIPTION KF Velocity Loop Field Flux Reference Auto Tune I Limit Auto Tune Speed Velocity Loop Damping Factor Armature Bridge Type Current Loop Damping Factor SET TO 45875 100% See Note Base Speed if Possible Default Value Recommended refer to cat. no.
Chapter 6 Start–Up Current Loop Tune – This procedure calibrates the current loop gain based on the information generated by the current loop test. 1. Select the current tune option (Drive Setup/Autotune/Current Tune) on the program terminal. 2. Follow the instructions given by the Program Terminal. 3. The Program Terminal will indicate when the tuning has been completed. The test just performed writes the value of parameters 735 and 736 when option to save in EEPROM is executed.
Chapter 6 Start–Up Velocity Loop System Test – This procedure calculates the system inertia (param. 703), maximum bandwidth (param. 701). If these values are known they can be entered directly and you can proceed to the Field Flux Tuning procedure. 1. Connect the motor to the machine. 2. Select the Velocity System Test (Drive Setup/Autotune/Vel Sys Test) option on the program terminal. IMPORTANT: The Drive start command must be true for the entire time the test is being performed.
Chapter 6 Start–Up Field Flux Tuning – This procedure will setup the field flux table (parameters 677 through 684) and the rated motor field current (parameter 612) based on the actual motor characteristics. 1. Record the value of the field flux reference (Parm. 676). 2. Set the field flux reference and the field economy reference to 100%. 3. Set KI, KP for the CEMF regulator (Params 672, 673), to their default value. 4.
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Chapter 7 Reference Materials Introduction This chapter contains reference materials intended to provide additional information pertaining to the 1395 such as: • Configuration Parameter lists • Start-up Parameter Tables • An alphabetical listing of all parameters. • Glossary Configuration Parameter List Record all configuration and linking as finalized during start-up in the following tables: Table 7.
Chapter 7 Reference Materials Table 7.A Fast Source Parameters cont.
Chapter 7 Reference Materials Table 7.B Fast Sink Parameters cont.
Chapter 7 Reference Materials Parameter Value List Record all parameter values or PLC references as finalized during start-up in the following tables: Table 7.
Chapter 7 Reference Materials Table 7.C Parameter Values cont.
Chapter 7 Reference Materials Table 7.C Parameter Values cont.
Chapter 7 Reference Materials Table 7.C Parameter Values cont.
Chapter 7 Reference Materials Table 7.D Internal Configuration Parameters Parameter 840 841 842 843 844 Description Internal Parameter SP INDIRECT 1 SP INDIRECT 2 SP INDIRECT 3 SP INDIRECT 4 SP INDIRECT 5 10 11 12 13 14 Linked to Fast Sink Parameter Description Table 7.
Chapter 7 Reference Materials Table 7.F Trend Buffer Parameters (cont.) Trend Buffer #2 is linked to parameter: The output of Trend Buffer #2 is linked to parameter: Description TREND 2 Operand Parameter X TREND 2 Operand Parameter Y TREND 2 Operator TREND 2 sample rate TREND 2 post samples TREND 2 multiple trigger TREND 2 enable TREND 2 output rate Parameter 920 921 922 923 924 925 926 927 Parameter Range Parameter Value 1 through 947 1 through 947 GT, LT,EQ, AND, NAND, OR, NOR 0.
Chapter 7 Reference Materials Alphabetical Parameter Reference Listing PARAMETER NAME ABS Overspeed AC Line Voltage Accel Time Arm Bridge Type Arm Current Firing Angle Arm Current PI Output Arm Current Reference Arm Current Reference Arm Resistance Arm Voltage Fdbk At Speed 1 – 5 Auto Tune I Lim Auto Tune Speed Base Motor Speed CEMF Feedback CEMF Reference CEMF Reg Preload Contactor Type Cur Damp Factor Cur Desired BW Cur Max BW Decel Time Desired Contour DI/DT Limit Drive Fault Droop Filter Droop Percent
Chapter 7 Reference Materials Parameter Reference Listing (Alphabetical) PARAMETER NAME Fld I @ 0/8 Flux Fld I @ 1/8 Flux Fld I @ 2/8 Flux Fld I @ 3/8 Flux Fld I @ 4/8 Flux Fld I @ 5/8 Flux Fld I @ 6/8 Flux Fld I @ 7/8 Flux Fld I @ 1.
Chapter 7 Reference Materials Parameter Reference Listing (Alphabetical) PARAMETER NAME MOP Accel 1 – 4 MOP Decel 1 – 4 MOP Max Speed MOP Min Speed Motor Arm FLA Motor Inertia Mtr Overload Sel Overload Pending Position Error Position Feedback Preramp Preset Speed 1 – 5 Process Trim Feedback Process Trim Filter Process Trim Hi Sum Process Trim Select Process Trim Hi Lim Process Trim KI Gain Process Trim Lo Lim Process Trim Lo Sum Process Trim Output Gain Process Trim Preload Process Trim PI Input Process T
Chapter 7 Reference Materials Parameter Reference Listing (Alphabetical) PARAMETER NAME PARAMETER NO.
Chapter 7 Reference Materials Glossary Adapter Board – A circuit board required to convert information to and from an external device to the format required by the Main Control Board microbus. Analog – A control system with continuously adjustable voltage or current level. Binary – A numbering system using the base 2 Radix. The value can be 0 or 1. Bit – One binary digit of data consisting of 0 or 1. Default – Value provided for a parameter as part of the program when the Drive is initially started.
Chapter 7 Reference Materials Parameter – A memory address that is used to store data for use by the program. The data stored in the parameter can be either variable or constant. Port – Hardware located on the Main Control Board which allows for connection of one Adapter Board to the microbus. Reset – A signal used to return a function to its initial state. Scaling – A number used as a multiplier, so chosen that it will cause a set quantity to fall within a given range of values.
Chapter 7 Reference Materials This Page Intentionally Left Blank.
Chapter 8 Renewal Parts Introduction 400 – 600HP, 230VAC 700 – 1250HP, 460VAC 1000 – 2000HP, 660VAC Chapter 8 provides an overview of the 1395 High Horsepower components that are available as renewal parts and the required quantity of each item. Figure 8.1 is provided to show the approximate component locations. For part number and pricing information, refer to the 1395 Renewal Parts publication.
Chapter 8 Renewal Parts Figure 8.
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