Bulletin 1395 Digital DC Drive USER MANUAL Firmware Versions 5.xx to 10.10/9.
Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at http:// www.rockwellautomation.com/literature) describes some important differences between solid state equipment and hard-wired electromechanical devices.
Summary of Changes The information below summarizes the changes to the Bulletin 1395 User Manual, publication 1395-5.40 since the last release (February, 2004). Change Added control power spec Updated Figure 2.5 Updated Figure 2.7 Updated Figure 2.9 & Removed Control Voltage Common description Updated Figure 3.1 Updated Figure 3.12 Removed Control Common description Updated Figure 3.13 Updated Figure 4.1 Updated Figure 4.12 & Removed Control Common description Updated Figure 5.5 Updated Figure 6.
Summary of Changes Notes SOC-2
Summary of Changes Firmware Revision History The following is a brief description of the MCB Firmware Revision History: 1.00: First Release. 2.30: Enhanced noise immunity. 3.01: Released Trending and VP and CP Autotune. 4.01: Enhanced EEprom fault reporting for SP-83 and SP30 SEEG device, VP indirects added, check for Ia with contactor open. 4.02: Consolidate 1396 and 1395 board assemblies. 4.
Summary of Changes b. Increase wait time for each flux table measurement from 5 seconds to 15 seconds. c. Change test for up to speed (during field flux autotune) to use a constant 5% instead of being tied to the speed tolerance parameter, to reduce the occurrence of “Motor not up to speed” faults. SP: 1. Slave percent 2 (P670) — Enhanced EEprom Save and Recall function for this parameter. 2.
Table of Contents Introduction, Inspection & Storage, and Publication References Chapter 1 Manual Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Drive Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Options . . . . . . . . . . . . . . . . . . . . .
Table of Contents Hardware Description 40 – 100 HP, 230VAC Series A 75 – 200 HP, 460VAC Series A Chapter 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hardware Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Armature Bridge Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Functional Description Chapter 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto-tuning . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Start-Up Chapter 8 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Required Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter Introduction, Inspection and Storage, and Publication References Manual Objectives The purpose of this manual is to provide the user with the necessary information to install, program, start up and maintain the1395 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, and Publication References Standard Drive Features The 1395 is a microprocessor Digital DC Drive available in; • Four quadrant, armature regenerative, two quadrant field: – 1 – 300 HP @ 230VAC in standard 1395 enclosures – 400 – 700 HP @ 230VAC in Bulletin 2100 CENTERLINE motor control centers (MCCs) – 2 – 600 HP @ 460VAC in standard 1395 enclosures – 700 to 1750 HP @ 460VAC in MCCs – 750 to 2250 HP @ 575VAC in MCCs – 750 to 2500 HP @ 660VAC in MCCs • Non–reg
Chapter 1 Introduction, Inspection & Storage, and Publication References • • • • • Accessories • • Node Adapter Board Provides an interface between external (push buttons, pots) devices and the Bulletin 1395. The board allows the Bulletin 1395 to be controlled using an Allen-Bradley PLC Programmable Controller from the PLC3 or PLC5 family. Multi-Communications Adapter Board Contains the hardware necessary to connect the 1395 to Allen-Bradley’s RIO or Data Highway Plus communication links.
Chapter 1 Introduction, Inspection & Storage, and Publication References Specifications Type Drive: Electrical: Input Voltages – Input Power – Input Frequency – Max Rate of Change of 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 – 1-4 Full Wave Regen, 12 SCR w/Full
Chapter 1 Introduction, Inspection & Storage, and Publication References Feedback Devices: DC Tachometer – 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 5 PY, BC42 or equal Incremental, dual channel; 12 volts, 500mA, isolated with differential transmitter, 102.5 kHz max.
Chapter 1 Introduction, Inspection & Storage, and Publication References Digital Reference Board; Digital Reference Input (1) – Digital Inputs (10) – Discrete Outputs (5) – Analog Inputs (2) – Analog Outputs (2) – Current source and sink input for high common mode noise immunity. Nominal 5VDC or 12VDC interface (internal hardware configurable), + 10mA nominal current source/sink requirements. 24VDC Nominal; 18VDC minimum, 28VDC maximum; 10 mA nominal. -25%, +16.
Chapter 1 Introduction, Inspection & Storage, and Publication References ControlNet Adapter Board; Rev Requirement – Requires Main Control Board Revision 8.10 or greater. Communication Channel – One ControlNet channel with a redundant connector to allow for backup connection in case one fiber optic cable fails. Port – One Network Access Port Catalog Number Explanation 230 Volt AC Input (1–100HP) 1395 First Position Second Position Bulletin No.
Chapter 1 Introduction, Inspection & Storage, and Publication References 460 Volt AC Input (2–200HP) 1395 First Position Bulletin No. 1395 Second Position Horsepower P10 – X1 Third Position Fourth Position Contactor Type Options* Letter Letter Non–Regenerative Letter HP B63N B64N B65N B66N B67N B68N B69N B70N B71N B72N B73N B74N – 2HP – 3HP – 5HP – 7.
Chapter 1 Introduction, Inspection & Storage, and Publication References 230 Volt AC Input (125 –300HP) 1395 E1 A77 P30 – P50 – X2 First Position Second Position Third Position Bulletin No.
Chapter 1 Introduction, Inspection & Storage, and Publication References Publication References This update provides you with a list of user manuals for 1395 and 2361 drives and their current status. If a firmware version or date is not shown with a publication, it indicates that the publication is the current version, which will be updated until the firmware version changes.
Chapter 1 Introduction, Inspection & Storage, and Publication References List of User Manuals for 1395 and 2361 Drives PUB NO. PUB DATE DESCRIPTION F/W VER STATUS 1395 – 5.6 1395 – 5.11 1395 – 5.11 DU1 1395 – 5.40 Feb. 1989 Aug. 1989 Oct. 1991 Oct. 2002 User Manual, Current Rated Drives User Manual, Current Rated Drives User Manual Supplement, HP Rated Drives User Manual, HP Rated Drives OBSOLETE FIRMWARE OBSOLETE FIRMWARE OBSOLETE FIRMWARE CURRENT 1395 – 5.70 Nov. 1995 2361–5.01 Jul.
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Chapter Hardware Description 1 – 30 HP; 230VAC 2 – 60 HP; 460VAC (3.6 – 110 A) Series B Introduction Chapter 2 contains both a general description of the major hardware components of the1395 Series B 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 1 – 30HP, 230VAC and 2 – 60HP, 460VAC Series B Drive.
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC Figure 2.
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC 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 protect the power bridge from rapid rate of current changes (di/dt). When an isolation transformer matched to the unit rating is used, an AC line reactor is not required.
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC Surge Suppression – Surge suppressor MOV1 to MOV4 on the Power Board protects the armature power bridge from line voltage spikes and line surges. Line Reactor – A reactor mounted outside the drive is used to protect the power bridge SCRs from rapid rate of current changes (di/dt). SCR Packaging – SCR packaging in the 1395 in bridge ratings 3.6 – 110A (1 – 60 HP) consists of 2 SCRs per module.
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC Field Bridge Components A general description of the components in the field bridge (Fig. 2.4) and their operation is covered here: Supply Voltage – Two of the three supply voltage phases are routed to the input of the field supply power bridge (TB1-1 and TB1-2). Field Current Feedback – Current at transformer FCT provides field current feedback information to the PSI/Switcher board.
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC Power Board The operation of the Power Board components (Figures 2.5 and 2.6) is detailed here: Gate Firing Pulses – The function of the Power Board is to provide the gate firing pulses for the armature and field bridges. Transient Voltage Protection – The Power Board provides protection against line voltage spikes and transients (dv/dt) for the armature and field SCRs.
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC Figure 2.
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC PSI/Switcher Board The primary function of the board (Figure 2.7) is to provide interface between the Main Control Board, and the Power Board. The PSI/Switcher board also provides the following: • Distribution of DC logic power to the Main Control Board. • Three-Phase line synchronization signals to the Main Control Board. • Contactor and other logic control interface with the Main Control Board.
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC Table 2.A PSI/Switcher Board Jumper Settings Jumper Function Position 1–2 Position 2–3 J11 MotorTemp 24VDC 120VAC J12 Reset 24VDC 120VAC Table 2.B Field Current Range Jumper Selections (see Table 8.J) J1 Jumper Position 1–30HP 240VDC; 2–60HP 500VDC Field Current Range 1 4.5 – 10.6A 2 2.0 – 4.6A 3 0.5 – 2.1A 4 0.15 – .6A Note: See Table 8.
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC Main Control Board The Main Control Board (Figure 2.8) performs all control functions of the 1395 drive. Hardware located on the board is used to support operation of the microprocessor firmware. The primary functions performed include: • • • • Microbus interface. Control Firmware Analog signal interface Develop gate firing signals sent to the PSI/Switcher Board Figure 2.
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC Power Distribution 115VAC Control Voltage – Figure 2.9 illustrates the distribution of 115VAC control voltage within the Bulletin 1395. Single phase 115VAC control voltage, provided from an external source by the user enters the drive at TB2-2 and 3. Fuse F3 provides protection against short circuits on the 115VAC input to the drive. Figure 2.
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC Relay Logic (1 – 30 HP 230VAC) (2 – 60 HP 460VAC) Main Contactor (M1) Control – Figure 2.10 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 115 VAC source at TB2-1. The source voltage may be interrupted before being input to the drive at TB2-1 by the use of externally controlled contacts.
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC The control voltage being applied to K2 may be monitored on the Power Stage Interface at TP21. If K3 is being commanded to energize, the voltage at TP21 will be 0VDC. If K3 is to be de-energized, the voltage at TP21 will be +24VDC. Figure 2.10 Relay Logic M1 CHASSIS PE 5 Optional External Control Contacts 115 VAC HST2 J3 J4 J2 TE PE 24V DC or 115 VAC Common NOTE: An explanation of terminals 1, 2 and 3 is provided on pg 6.22.
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC Options Programming Terminal Interface – The Programming Terminal (shown in Figure 2.11) is used to access information in the firmware of the 1395.
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC 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 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC 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 and is available in 120VAC or 24VDC versions.
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC The inputs are preconfigured for the following signals: RUN REFERENCE SELECT A,B,C, RAMP DISABLE, JOG 2, 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 the bits of the state of the output (on or off).
Chapter 2 Hardware Description 1 – 30 HP, 230VAC 2 – 60 HP, 460VAC ControlNet Adapter Board 2-18 The CNA board provides a sophisticated interface to Allen-Bradley PLC controllers and other equipment capable of communicating over ControlNet. This adapter has the following features: • One ControlNet channel, with a redundant connector to allow for backup connection in case one cable fails.
Chapter Hardware Description 40 – 100 HP; 230VAC 75 – 200 HP; 460VAC (111 – 345 A) Series A Introduction Chapter 3 contains both a general description of the major hardware components of the Series A 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 40 – 100HP, 230VAC and 75 – 200HP, 460VAC Series A Drives.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC Figure 3.1 Hardware Overview 3 Phase AC L1 L2 Fuses 1 Phase AC Unit Power Supply A6 J2 Feedback Board A1 J2 J7 J7 J2 J6 J5 Main Control Board J2 A8 J4 J1 L3 ACT-1 J1 J3 Arm P.T. & Snubber A4 J8 Power Stage Interface J9 A7 TB-1 ACT-2 J1 J4 3 Phase SCR Bridge Arm P.T. & Snubber A3 J1 J6 J2 J5 Arm P.T. & Snubber A2 TB–1 J2 Feed Back Board A1 Programming Terminal DHT/DMT TB3 TD M1 FCT Fld P.T.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC Armature Bridge Components 75 – 200 HP, 460VAC A general description of the components in the armature bridge (Figures 3.2 and 3.3) 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 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC Surge Suppression – Surge suppressor 1 MOV (Fig. 3.2) protects the armature power bridge from high voltage line spikes and line surges. Line Chokes – Line Chokes CH2 through CH7 are used to protect the power bridge SCRs in each of the six legs of the power bridge from rapid rate of current changes (di/dt). SCR Packaging – SCR packaging in the 1395 in bridge ratings 111 – 345 consists of 2 SCRs per module.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC Field Bridge Components 75 – 200 HP, 460VAC A general description of the components in the field bridge (Fig. 3.4) and their operation is covered here: Supply Voltage – In addition to being used for synchronization, the three-phase voltage from fuses F4, F5 and F6 is sent to TB1 where two of the three phases are routed to the input of the field supply power bridge (labeled Field L1 and Field L3 on Figure 3.4).
Chapter 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC Figure 3.4 Field Bridge Components See Fig 6.9 TB-1 1 L1 From Fig. 3.2 L2 L3 PM7 TB-2 1 2 L1 3 L2 4 L3 5 PM8 Field L1 2 3 CH8 Field L3 2MOV 4 5 6 3MOV FCT 7 8 Note: Phase Sensitive 9 10 L3 G2 G1 F2 L1 G1 G2 F1 Field Pulse Transformer and Snubber Board A5 8 Feedback Board A1 3-6 F+ To Motor F– Field Leads 9 TB-1 See Fig. 3.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC Control Boards 75 – 200 HP, 460VAC Feedback Board – Figure 3.5 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 3.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC Figure 3.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC Power Stage Interface (A7) – The primary function of the 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 include: • Distribution of DC Control power to Main Control Board.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC Figure 3.7 Power Stage Interface Hardware Location See Page 6-19 Power Stage Interface Board 34 34 MFG ASSEMBLY # TB1 1 1 J9 J8 SPARE PART KIT NO.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC Main Control Board (A8) – The Main Control Board (Figure 3.8) 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 3.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC Armature Pulse Transformer and Snubber Board (A2, A3, A4) – The primary functions of the Armature Pulse Transformer and Snubber Board (Figure 3.9) include: • Isolate power bridge circuitry from control circuitry. • Provide dv/dt protection across SCRs. There are 3 Armature Pulse Transformer and Snubber Boards. Each board is associated with a single phase of the incoming AC line.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC Figure 3.10 Field Pulse Transformer and Snubber Board Hardware Location MFG Revision No. Connection to Power Stage Interface (SCR Gate Pulses) R1 L3 Spare Part Kit No.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC Power Distribution 115VAC Control Voltage – Figure 3.12 illustrates the distribution of 115VAC control voltage within the Bulletin 1395. Single phase 115VAC control voltage, provided from an external source by the user enters the drive at TB2-4 and 5. Fuse F8 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 3.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC DC Control Voltage Distribution – The Unit Power Supply converts 115VAC (supplied as shown in Figure 3.13) to +5VDC and the +/–12VDC control voltages. In addition to the voltages supplied by the Unit Power Supply, the Power Stage Interface converts the 20VAC coming from the control transformer 1 PT to 24VDC which is used for relay logic, including the ECoast, Pilot Relay, and Fault/No Fault Logic.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC Figure 3.13 DC Power Distribution and Control Common TP22 +5VDC J7 J1 J8 TP51 +5VDC J5 +5V J6 TP52 DGND c26 A6 UNIT POWER SUPPLY c25 D GND A GND c24 5 TE TP1 –12VDC TB2 115 VAC J2 J2 10 4 TP53 ISO GND FEEDBACK BOARD I 10 13 Power Supply (+12VDC) 14 17 18 Port A TP41 24V Sense (approx.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC Relay Logic 75 – 200 HP, 460VAC Main Contactor (M1) Control – Figure 3.14 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 TB2-3 by the use of externally controlled contacts.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC If K3 is being commanded to energize, the voltage at TP21 will be 0VDC. If K3 is to be de-energized, the voltage at TP21 will be +24VDC. Figure 3.14 Relay Logic M1 A1 Armature Bridge 3 Phase AC To DC Motor A2 PE Optional External Control Contacts 115 VAC Common NOTE: To provide DC Contactor energization, a jumper or other external circuitry must be connected between TB2–8 and TB2–9.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC Options 75 – 200 HP, 460VAC Programming Terminal Interface – The handheld Programming Terminal 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 3.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC 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 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC 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.
Chapter 3 Hardware Description 40 – 100 HP, 230VAC 75 – 200 HP, 460VAC 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 Hardware Description 40 – 100 HP, 230VAC ControlNet Adapter Board 75 – 200 HP, 460VAC The CNA board provides a sophisticated interface to Allen-Bradley PLC controllers and other equipment capable of communicating over ControlNet. This adapter has the following features: • One ControlNet channel, with a redundant connector to allow for backup connection in case one cable fails.
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Chapter Hardware Description 125 – 300 HP; 230VAC 250 – 600 HP; 460VAC Medium KVA (MKVA) Introduction Chapter 4 contains both a general description of the major hardware components of the Series B 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 125 – 300HP, 230VAC and 250 – 600HP, 460VAC Series B Drives.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC Hardware Overview Figure 4.1 provides an overview of the hardware components associated with the 1395 drive. Hardware can be divided into one of three categories: • Control Boards • Control/Power Interface hardware • Power Hardware This chapter describes in general all of the major hardware components for a 125 – 600HP (346 – 980A) drives. Figure 4.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600HP, 460VAC Armature Bridge Components A general description of the components in the armature bridge (Figures 4.2 and 4.3) and their operation is detailed here: Incoming Device – Either a line choke or an isolation transformer is required. Fuses – Fast acting semiconductor fuses are standard on all ratings. Synchronization – The three-phase input to the drive is tapped and fused using fuses F1, F2 and F3 (Fig. 4.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC Surge Suppression – Surge Suppressor 1 MOV (Fig. 4.2) protects the armature power bridge from high voltage line spikes and line surges. SCR Packaging – In 346 – 980A bridges (125 – 600HP) SCRs are packaged as individual hockey-puck type SCRs. Two SCRs connected in antiparallel in one of six legs of the bridge is referred to as an SCR cell. There are 6 SCR cells per bridge for armature regenerative construction.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600HP, 460VAC SCR Cell Fuses – Each SCR cell is protected from high currents by a cell fuse, located in each leg. DC Contactor – Output of the armature bridge is connected to the DC motor through the main DC contactor M1. Coil voltage to M1 is controlled by contacts from the pilot relay PR (an external 115VAC control input entering at TB5). Bridge Output Connections – Bridge output connections labeled A1 and A2 (Fig. 4.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC Figure 4.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600HP, 460VAC Control Boards Feedback 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 4.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC Power Stage Interface (A7) – The primary function of the Power Stage Interface board (Fig. 4.6) is to provide interface between the Main Control Board, and the Power Bridge boards such as the Pulse Transformer and Snubber boards and the Feedback Board. The primary functions performed include: • • • • 4-8 Distribution of DC Control power to Main Control Board. Provide 3 phase line synchronization signals to Main Control Board.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600HP, 460VAC Figure 4.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC Main Control Board – Figure 4.7 illustrates the major hardware points on the board. The board performs all control functions of the Bulletin 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 control signals sent to the Power Stage Interface. Figure 4.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC Armature Pulse Transformer Boards (A2, A3, A4) – Figure 4.8 illustrates the major hardware points on the board. The primary functions performed include: • Isolate power bridge circuitry from control circuitry • Provides Gate Pulses to the SCRs There are three Armature Pulse Transformer Boards. Each board is associated with a single phase of the incoming AC line.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC Field Pulse Transformer Boards (A5) – Figure 4.9 illustrates the major hardware points on the board. The primary functions performed include: • Isolate power bridge circuitry from control circuitry • Provide dv/dt protection for 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 the DC bus. Figure 4.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC Peripheral Devices Unit Power Supply (A6) – The Unit Power Supply 115VAC input comes from the user external 115VAC power supply. 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 4.10 shows the location of the Unit Power Supply. Figure 4.
Chapter 4 Hardware Description 125 - 300 HP, 230VAC 250 - 600 HP, 460VAC 115VAC Control Voltage - Figure 4.11 illustrates the distribution of 115VAC control voltage within the Bulletin 1395. Single phase 115VAC control voltage, provided from an external source by the user enters the drive at TB5-4 and 5. Fuse F4 provides protection against short circuits on the 115VAC input to the drive terminal block TB6 (an internal terminal block). Power Distribution Figure 4.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC DC Control Voltage Distribution – The Unit Power Supply converts 115VAC (supplied as shown in Figure 4.12) to +5VDC and +/– 12VDC control voltages.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC Relay Logic Main Contactor (M1) Control – Figure 4.13 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 TB5-6 by the use of externally controlled contacts.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC Figure 4.13 Relay Logic TB5 NOTE: A jumper 115 VAC must be used if external cotacts Com aren’t used at TB5 6&7. External Contacts NOTE: To provide DC Contactor energization, a jumper or other external circuitry must be connected to TB5–8 and 9 M1 F4 4 5 6 7 8 9 10 11 12 D1 TE PR See Fig 4.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC Options Programming Terminal Interface – Both versions of the handheld Programming Terminal are 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 4.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC 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 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC 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 (Fig. 4.15). Digital Inputs – The Discrete Adapter Board contains four discrete inputs for either 120VAC signals or 24VDC signals.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC The inputs are preconfigured for the following signals: RUN REFERENCE SELECT A,B,C, RAMP DISABLE, JOG 2, 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 are LED indicated for high input level visibility.
Chapter 4 Hardware Description 125 – 300 HP, 230VAC 250 – 600 HP, 460VAC ControlNet Adapter Board 4-22 The CNA board provides a sophisticated interface to Allen-Bradley PLC controllers and other equipment capable of communicating over ControlNet. This adapter has the following features: • One ControlNet channel, with a redundant connector to allow for backup connection in case one cable fails.
Chapter Functional Description Introduction Chapter 5 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 5 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 5.1 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 5 Functional Description Figure 5.1 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 5 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 5 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 5 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 5.2 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 5 Functional Description Figure 5.2 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 5 Functional Description Table 5.
Chapter 5 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 5.2, 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 5 Functional Description Table 5.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 5 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 5.3 Linking Sources to Sinks Programming Terminal Interface 1395 Drive Control Logic Programming Terminal Sources Sinks 200 - 249 150 Logic Cmd 1 Programming Terminal Sinks 151 Logic Cmd 2 152 250 - 299 Logic Cmd 3 154 Velocity Ref.
Chapter 5 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 5.3, 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 5 Functional Description Figure 5.4 Discrete Adapter Board Configuration Example Programming Terminal Programming Interface Terminal 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 5 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 5.4.
Chapter 5 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 5 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 5 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 5 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 5 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 5 Functional Description Table 5.C Trending Parameters Description Trend #1 Parm. Num. Trend #2 Parm. Num. Trend #3 Parm. Num. Trend #4 Parm. Num.
Chapter 5 Functional Description Programming a Trend Buffer Determining What to Trend – The first step to programming a Trend Buffer is to determine which parameter you want to monitor or trend. The parameter you select to trend must be a fast parameter because you will establish a configuration link to that parameter. This link will be made between the parameter to be trended and the Trend Input Parameter (Parameters. 50 through 53).
Chapter 5 Functional Description 5. AND (.AND.) – Compares the bits(s) of a 16 bit value for the parameter specified by Operand X to the bit(s) for the parameter specified by Operand Y. If ALL of the same bit(s) are set to “1” in both parameters, the trend is triggered Generally Operand Y is set up to use one of the Bit Trend Constant parameters (Parameters 904 through 907). 6. Negated AND (.NAND.
Chapter 5 Functional Description Setting the Trend Buffer Type – Each trend buffer can be set up as a “one-shot” or “continuous trigger” buffer. When a buffer is set up as a “one-shot” it is turned off after all post samples have been taken. At this time, the trend enable parameter value is changed to OFF effectively disabling that trend buffer. The buffer will retain the data from the most recent trigger until it is manually activated or turned ON.
Chapter 5 Functional Description Trend Setup Determining What to Trend: 1. While in the program terminal Drive setup configuration mode. 2. Link the Trend Input Parameter associated with the trend buffer to be setup to the Drive parameter you want to trend. 3. Link the Trend output parameter if trend data is to be output to an external device. NOTE: Refer to the tables at the end of Chapter 9 for a listing of the parameter numbers for each trend buffer. 1.
Chapter 5 Functional Description Activating a Trend Buffer: 1. Select the Trend Enable parameter for the trend buffer you are setting up. 2. Set this parameter “ON” to activate the buffer or “OFF” to deactivate the buffer. Setting the Output Data Rate: 1. Select the Trend Output Rate parameter for the trend buffer you are setting up. 2. Enter the desired sample rate. NOTE: The Drive will round the desired sample time to the nearest 4ms.
Chapter 5 Functional Description The selected speed reference then enters a speed limit block. The maximum and minimum limit of the speed reference are adjustable by changing the values of Forward Speed Limit (Parameter 608) and Reverse Speed Limit (Parameter 607). Forward Speed Limit sets the maximum speed reference for the forward direction, and Reverse Speed Limit sets the maximum speed reference for the reverse direction.
Chapter 5 Functional Description Velocity Pl Control (Circle 5) Compares the speed reference value from the Velocity Reference Control to the actual motor speed, from the Velocity Feedback Control. The Final Velocity Reference (Parameter 104), is modified by KF Velocity (Parameter 661). This parameter controls the amount of velocity reference that will be summed with velocity feedback. This is filtered and modified through a Proportional/Integral (PI) Control function.
Chapter 5 Functional Description Torque Select (Circle 8) Selects the reference input to the Current Control, based on the value of Torque Mode (Parameter 625). Torque Mode is a number coded parameter which allows operation under several different torque modes. There are two possible reference inputs to choose from. The output of the Velocity PI Control, which has been converted to a torque reference, is used as an internal torque reference.
Chapter 5 Functional Description When enabled, the Tach Loss feature operates as follows: Velocity feedback from an encoder or tach is compared against velocity feedback derived from armature voltage. When the magnitude (absolute value) of the difference between the two feedbacks exceeds the Tach Loss Window (Parameter #688), for a period of time in excess of 40 msec., an automatic switchover to Armature Volts Feedback will occur. NOTE: This statement is true for version 5.01 Firmware.
Chapter 5 Functional Description Current Reference Control (Circle 9) The output of the Torque Reference Select block is applied to a limiting function block. Forward Bridge Current Limit (Parameter 663) and Reverse Bridge Current Limit (Parameter 664), specify the largest allowable positive and negative motor armature current that can be commanded. The limited current is then applied to a Torque Taper function block.
Chapter 5 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 5 Functional Description Figure 5.5 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 5 Functional Description LOGIC CMD 150, 151, 152 3 1,2,5,9,10 RAMP CONTROL 1 FWD SPEED LIMIT 608 RPM LOGIC CMD 150, 151, 152 11 2 5 626 Jog Ramp Enable Pre–Ramp Vel Ref 102 9 DESIRED CONTOUR 653 % 10 RAMP BYPASS Ramp Vel Ref 103 RPM LINEAR ACCEL/DECEL RAMP S CONTOUR FILTER RPM 0 STOP COMMAND RPM ACCEL TIME 651 SEC DECEL TIME 652 SEC 607 REV SPEED LIMIT To Sheet 2 4096 = Motor Base Speed PROCESS TRIM SELECT 628 =3 FINAL VEL REF 104 From Sheet 2 STOP LOGIC 15 AUTO TUNE PA
Chapter 5 Functional Description Figure 5.5 (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 657 = 0 0 4096 e .
Chapter 5 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 123 KI VELOCITY LOOP 659 0 + T S KI GAIN – 8.
Chapter 5 Functional Description Figure 5.
Chapter 5 Functional Description 10 ARM CUR I PI OUT 2048 = 1PU VOLTS 113 CURRENT PI CONTROL PI V 735 KP/4096 ARM CURRENT FIRE ANG 2048 = 90 DEG.
Chapter 5 Functional Description This Page Intentionally Left Blank 5-38
Chapter Installation Chapter Objectives The following data will guide you in planning the installation of Bulletin 1395 drives rated at 1–300HP @ 230VAC and 2–600HP @ 460VAC. For 1395 drives rated at or above 700HP @ 460 VAC, or 750HP @ 575VAC/660VAC, refer to publication 2361–5.01 for installation instructions. 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.
Chapter 6 Installation ! CAUTION: The installation of the drive must be planned such that all cutting, drilling, tapping and welding can be accomplished with the drive removed from the enclosure. The drive is of the open type construction and any metal debris must be kept from falling into the drive. Metal debris or other foreign matter may become lodged in the drive circuitry resulting in component damage. Figure 6.
Chapter 6 Installation Figure 6.2 Nominal Dimensions Series A 40 – 100 HP 230V 75 – 200 HP 460V Dimensions are in inches and (mm) TOP VIEW 1.5 (38) Clearance for Service 11.05 (281) 1355 Door Swing Front 23.30 (592) Maximum Dimension for Service ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ ÇÇÇÇÇÇÇÇ Exhaust Air 10° C Rise 5.0 (127) B Max. 0.38 (9.7) Dia. Mtg. Holes & Slots – 4 Plcs. For Mounting with 0.312 (7.9) Hardware C Max. E SIDE 1395 REAR A Max. D ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉ 3.
Chapter 6 Installation Figure 6.3 Nominal Dimensions MKVA Series B 125 – 300 HP 230V 250 – 600 HP 460V Dimensions are in inches and (mm) B C Max. 6.0 (152) E Exhaust Air 10° C Rise 2.00 (50.8) SIDE REAR 1395 A 6.0 (152) 6-4 6.25 (158.8) (A2) Bussbar Intake Air 55° C Maximum D 230V Drive 460V Drive Weight lbs. (kg) A B C D E 125-300 HP 250-600 HP 515 (234) 46 (1168) 32.00 (813) 18.50 (470) 44.00 (1118) 28.
Chapter 6 Installation Cooling Airflow In order to maintain proper cooling, the drive must be mounted in a vertical position (fuses in the upper right hand corner). Refer to Figures 6.1 through 6.3 for the recommended minimum clearance of each drive. 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 55°C (131°F).
Chapter 6 Installation ! WARNING: Hazard of electric shock or equipment damage exist if drive is not installed correctly. The National Electrical Code (NEC) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.
Chapter 6 Installation Table 6.B Cable and Wiring Recommendations Category Wiring Class Signal Definition Power 1 AC Power (600V or greater) 2.3kV 3/Ph AC Lines per NEC & Local Codes 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 4 DC Power Reg.
Chapter 6 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 6.4 and explained below. Ground (PE) – Is the safety ground required by code.
Chapter 6 Installation Figure 6.
Chapter 6 Installation As previously explained, two different types of grounds are used in the 1395 drive. They are defined as follows: Ground (PE) - A Safety Ground is normally required by the electrical code and is defined externally as PE ground. Main PE is located at the ground stud next to the contactor. On MKVA: The PE ground stud is located on the back panel between L2 & L3 ACT's and bus bars. TB-X connections are for jumpering TE to PE for stand alone only.
Chapter 6 Installation configured as a stand alone unit, the TE and PE grounds may be run individually to the drive, or a jumper can be placed as shown in Table 6.C and one ground lead run as indicated in Table 6.D. Table 6.C Safety/Signal Ground Rating Wiring Connection 1 – 30HP 230VAC 2 – 60 HP 460VAC TB2 – 4 & 5 60 – 100HP 230VAC 75 – 200 HP 460VAC TB2 – 6 & 7 125 – 300HP 230VAC 250 – 600 HP 460VAC TB5 – 10 & 11 Table 6.
Chapter 6 Installation Figure 6.
Chapter 6 Installation Power Wiring It is recommended that an Allen-Bradley DC Loop Contactor Lug Kit be ordered for proper wire terminations. Table 6.E provides a listing and description of the available lug kits. Table 6.E Allen-Bradley Armature DC Loop Contactor Lug Kits Rated Motor Arm. Current1 A DC DC Contactor Rating A DC Armature Conductor Size2 AWG DB Conductor Size3 AWG Arm.
Chapter 6 Installation Power Wiring Procedure The following procedure provides the steps needed to properly perform the power wiring connections to the 1395 drive. Using Table 6.F, verify that the motor field is compatible with the DC field voltage output of the drive. Table 6.F Standard Field Voltage Output AC Incoming Voltage to Drive DC Supply Output Voltage to Field 230VAC 120-150VDC 380VAC 200-250VDC 415VAC 220-270VDC 460VAC 240-300VDC 1.
Chapter 6 Installation Connect incoming three-phase AC line power to the AC line fuses or to the bus bar on the 125-600 HP drive. The fuses supplied are designed to provide protection against short circuits for the drive semiconductors and associated output wiring. They are not to be considered a substitute for the user supplied motor branch circuit protective devices that are required by the National Electrical Code. Refer to Tables 6.R and 6.S for proper sizing of the AC power and branch fuses.
Chapter 6 Installation 3. If the DC motor field is not compatible with the field DC output of the drive, an external field control transformer must be used. Refer to the following example for transformer selection information. EXAMPLE: 10 HP, 240 Volt Armature, 17.2A, 240 Volt Field, 2.0A a) The Field Control Transformer will have 230V primary, 460V secondary, single-phase 60 Hz. b) kVA = 2A x 460VAC x 1.5 = 1.38 kVA (1.
Chapter 6 Installation ATTENTION: The motor field supply is phase sensitive. To guard against possible drive/motor damage, ensure that the connections are properly made according to Figure 6.10. ! Figure 6.
Chapter 6 Installation ATTENTION: The motor field supply is phase sensitive. To guard against possible drive/motor damage, ensure that the connections are properly made according to Figure 6.8, 6.9, 6.11 and 6.12. ! Figure 6.
Chapter 6 Installation Table 6.H Field Current Jumper Setting Field Current Range J1 Jumper on PSI /Switcher Field Current Range 1-30 HP, 240VDC 2-60 HP, 500VDC J1 Jumper on Fdbk Bd 40-100 HP, 240VDC 75-200 HP, 500VDC 125-300 HP, 240VDC 250-600 HP, 500VDC 1 4.5 to 10.6A DC 1 9.1 to 21.2A DC 18.3 to 42.4A DC 2 2.0 to 4.6A DC 2 4.1 to 9.2A DC 8.6 to 18.4A DC 3 0.5 to 2.1A DC 3 1.1 to 4.2A DC 2.3 to 8.7A DC 4 0.15 to 0.6A DC 4 0.4 to 1.2A DC 1.0 to 2.4A DC 2.
Chapter 6 Installation ! ATTENTION: Jumpers J8 through J10 must all be in the same position. To guard against possible damage to the Main Control Board, ensure that jumpers are positioned correctly for your application. Table 6.
Chapter 6 Installation Additional individual terminal blocks can be attached to the mounting rail to meet application requirements. These additional terminal blocks are supplied when using an adapter board, to allow for I/O to and from the drive. Control Wiring Procedure 1. Wire Encoder to TB3. If an encoder is used, 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.
Chapter 6 Installation Figure 6.12 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 ENCPWR +12V ENCGND 12V –24V OUT 12 +24V OUT 11 24V DC E-Coast Refer to Table 6.M –24V ECOAST 10 +24V ECOAST 9 FLT 2 8 Closed When Drive is not Faulted Drive FLT Output FLT 1 7 115V AC Common 115V COMMON OUT 6 115V ECOAST2 5 Refer to Table 6.
Chapter 6 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 6.13 and Table 6.M for connection information. If a 24VDC ECOAST is desired, the contacts of the ECOAST device must be wired between terminals 9 & 11 of TB3.
Chapter 6 Installation The voltage used must be the same as the voltage supplied for the motor thermostat input. IMPORTANT: The 24VDC provided at TB3-11 and 12 must only be used for the 24VDC ECOAST circuit. Figure 6.
Chapter 6 Installation Table 6.N 115VAC Connections Drive Rating 115VAC Input Connection 1 – 30 HP 230VAC 2 – 60 HP 460VAC TB2 – 2 and 3 (see Fig. 6.13) 40 – 100 HP 230VAC 75 – 200 HP 460VAC TB2 – 4 and 5 (see Fig. 6.14) 125 – 300 HP 230VAC 250 – 600 HP 460VAC TB5 – 4 and 5 (see Fig. 6.15) Figure 6.
Chapter 6 Installation Terminal TB5–6&7 125–300HP 230VAC 250–600HP 460VAC The 115VAC control voltage enters the drive and is controlled by the pilot relay (PR). If it is desired to control the Ml coil voltage using contacts external to the drive (in addition to the pilot relay), the external contacts must be wired in series with the 115VAC supply voltage before entering the drive at either TB2-1, TB2-3 or TB5-4 .
Chapter 6 Installation Figure 6.15 115VAC Input and Contactor Control Connections – 125 to 300 HP, 230 VAC; 250 to 600HP, 460 VAC M1 Line Reactor or Isolation Transformer AC Supply L1 L2 L3 Armature Bridge M A2 TB5 230 or 460VAC Fuse 115V AC 4 F4 1 M1-X K K PR 3 6 7 8 See Step Step 8 Power Stage Interface Board A2 TB6 5 External Contacts A1 A1 + 6 10 9 Common 10 11 12 c o m m o n AC 12 15 – 1395 8.
Chapter 6 Installation Table 6.O External Contactor Bypass Jumpers Drive Rating 115VAC Input Connection 1 – 30 HP 230VAC 2 – 60 HP 460VAC TB2 – 6 and 7 60 – 100 HP 230VAC 75 – 200 HP 460VAC TB2 – 8 and 9 125 – 300 HP 230VAC 250 – 600 HP 460VAC TB5 – 8 and 9 9. 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.
Chapter 6 Installation 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. The drive is shipped pre-configured, meaning that all of the inputs and outputs are linked to a predefined signal. Figure 6.17 shows the 1395 standard configuration for the Discrete Adapter Board. The user has the flexibility to configure the drive for a particular application.
Chapter 6 Installation Figure 6.
Chapter 6 Installation 24VDC Connection/Digital Input – Sizing of the power supply is based on the number of input and output selections. Figure 6.18 shows the typical connection of the digital input using the external power supply. 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.6.19 ). Figure 6.
Chapter 6 Installation Tach Velocity – The analog tachometer device generates a DC voltage that is direction sensitive and proportional to speed. The tach output must be connected to an analog input channel on the Discrete Adapter Board or Digital Reference Board. Most industrial tachs have an output greater than the ±10V range of the analog inputs.
Chapter 6 Installation 3. The analog input channel on the adapter board must now be scaled to represent an accurate velocity feedback signal. First determine the analog input signal for base speed. Parameter numbers are given in ( ) where applicable. Base Motor Speed (606) x 9V Max Speed = Base Speed Input 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.
Chapter 6 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. Figure 6.23 shows the 1395 standard configuration for the Digital Reference Adapter Board. The drive has the flexibility to be reconfigured for the application or as required.
Chapter 6 Installation Figure 6.
Chapter 6 Installation Figure 6.24 Typical Analog Input Connections TB3 TB3 Forward 28 IMPORTANT: Connect to either terminal 28 or 29, Not Both 29 Reverse R * +10V DC P.S. 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 + – Reference * 2.5k Ohm Minimum P.S. COMMON IMPORTANT: Connect shield to drive end only.
Chapter 6 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 6 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 6 Installation Analog/Digital Output Figure 6.27 shows typical analog and digital output connections. Figure 6.27 Typical Output Connections TB3 TB3 + 0 to +10VDC, 1mA Maximum IMPORTANT: Connect shield to drive end only. Other end is to be insulated and left floating. 41 ARM. CURRENT FDBK. – 61 +24V DC HIGH External 24VDC Power Supply 62 0 VOLTS COMMON 42 ARM. CURRENT FDBK.
Chapter 6 Installation Node Adapter Board The Node Adapter Board is connected to Microbus Port B and is not preconfigured. Refer to the Node Adapter manual for configuration and installation information. Multi-Communication Adapter Board The Multi-Communication Board is not preconfigured. Refer to the Multi-Communication Adapter manual for configuration and installation information. Table 6.P Terminal Torque Values Terminals L1 – L3 AC Input Amps Wire Range Torque In. – Lbs. L1 – L3 2.9 – 45.
Chapter 6 Installation Table 6.R 230VAC Input –Armature Current Ratings Power Output ARMATURE DC Output AC Input Volts Max A Volts Max A FIELD AC Input DC Output Volts Max A Volts Max A .75KW/1HP 1.2KW/1.5HP 1.5KW/2HP 2.2KW/3HP 3.7KW/5HP 5.6KW/7.5HP 7.5KW/10HP 11.2KW/15HP 15KW/20HP 18.7KW/25HP 22.4KW/30HP 29.9KW/40HP 37.3KW/50HP 44.8KW/60HP 56KW/75HP 74.6KW/100HP 93.3KW/125HP 112KW/150HP 149.2KW/200HP 186.5KW/250HP 223.
Chapter 6 Installation Table 6.S 460VAC Input –Armature Current Ratings 6-42 ARMATURE DC Output AC Input Volts Max A Max A Power Output Volts 1.5KW/2HP 2.24KW/3HP 3.75KW5HP 5.6KW/7.5HP 7.5KW/10HP 11.2KW/15HP 15KW/20HP 18.7KW25HP 22.4KW/30HP 29.9KW/40HP 37.3KW/50HP 44.8KW/60HP 56KW/75HP 74.6KW/100HP 93.3KW/125HP 112KW/150HP 149.2KW/200HP 186.5KW/250HP 223.8KW/300HP 298.
Chapter 7 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 7 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 7 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 7.1. Figure 7.1 Parameter Entry Parameter Number Hex Units Name Init.
Chapter 7 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 7 Programming Parameters Table 7.
Chapter 7 Programming Parameters Table 7.A Cont.
Chapter 7 Programming Parameters Table 7.A Cont.
Chapter 7 Programming Parameters Table 7.A Cont.
Chapter 7 Programming Parameters Table 7.A Cont.
Chapter 7 Programming Parameters Table 7.A Cont.
Chapter 7 Programming Parameters Table 7.A Cont.
Chapter 7 Programming Parameters Table 7.A Cont. INIT MIN MAX EE FUNCTION/CLASSIFICATION/PORT Slave Percent 2 0 –200 200 EE Torque Control/Setup 2A0H KI Flux 1638 0 32767 EE Field Weak Control/Set-Up 673 2A1H KP Flux 4096 0 32767 EE Field Weak Control/Set-Up 674 2A2H Fld Economy Ref % 50 0 100 EE Field Flux Control/Set-Up 675 2A3H Fld Economy Ref Sec 30 0 6553.5 EE Field Flux Control/Set-Up 676 2A4H Fld Flux Ref % 100 0.
Chapter 7 Programming Parameters Table 7.A Cont. INIT MIN MAX EE FUNCTION/CLASSIFICATION/PORT Proc Trim KP 4096 0 32767 EE Process Trim Control/Set-Up Proc Tri Lo Lim –4096 –32767 32767 EE Process Trim Control/Set-Up 2CEH Proc Trim Hi Lim 4096 –32767 32767 EE Process Trim Control/Set-Up 719 2CFH Proce Trim Out K 1.000 –16.0 +16.0 EE Process Trim Control/Set-Up 720 2D0H Ovld Pend Level % 115 0.0244 260 EE Fault Detection/Set-Up 721 2D1H Proc Trim Lo Sum RPM –6xB.
Chapter 7 Programming Parameters Table 7.A Cont. HEX NAME INIT MIN MAX EE FUNCTION/CLASSIFICATION/PORT 904 388H Trend Logic Value 0 0 See Descrip EE Trend Function 905 389H Trend Logic Value 0 0 See Descrip EE Trend Function 906 38AH Trend Logic Val 0 0 32767 EE Trend Function 907 38BH Trend Logic Val 0 0 32767 EE Trend Function +16.
Chapter 7 Programming Parameters Parameter Descriptions This section provides a brief description of the parameters in the Bulletin 1395. The programming terminal for the 1395 is also used for other products. Parameters not used by the 1395 will appear as follows “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 7 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 # DHT REF.
Chapter 7 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 7 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 7 Programming Parameters IF VELOCITY CONTROL FAULTS ARE SELECTED: (630 = 1) Bit # DHT REF.
Chapter 7 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 7 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 7 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 7 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 7 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 7 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 7 Programming Parameters Table 7.B Logic Command Word Bits 0,1,2 2 1 0 Definition 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 Selected Parameters 154 633 634 635 636 637 MOP MOP External speed reference indicates Parameters 153 and 154 will be the velocity reference.
Chapter 7 Programming Parameters Table 7.C Logic Command Word Bits 6, 7 Bit 7 Bit 6 0 0 0 1 0 1 0 1 Definition Selected Parameters 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 7.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 7 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 7 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 7 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 7 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 an 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 (Parameter 627).
Chapter 7 Programming Parameters Parameter 166 – Velocity Indirect 4 [Vel Indirect 4] Internal units : Programming Terminal units : Description : This is the Fast Sink, with its pointer in Parameter 603, Velocity Parameter Select 4.
Chapter 7 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 7 Programming Parameters Parameter 610 – Rated Motor Voltage [Rated Motor Volt] Internal units : volts x 10 Programming Terminal units: VOLTS Minimum Value: 75 Maximum Value: 850 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. Note: This parameter WILL NOT limit motor voltage to the value entered.
Chapter 7 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 7 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 7 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 7 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 and regen to a stop.
Chapter 7 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 7 Programming Parameters Bit 4 – CEMF Hold: When set, this bit holds the integral term and output of the CEMF regulator to the last value before the bit was set. When clear, the CEMF regulator is not affected. Bit 5 – CEMF Reset: When set, this bit will cause the integral term and out put of the CEMF regulator to be preset to the value found in CEMF Preload Parameter (#687). When clear, the CEMF regulator is not affected.
Chapter 7 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 (Parameter 101).
Chapter 7 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 7 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 7 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 7 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 7 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 selected. 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 7 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 7 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 7 Programming Parameters Parameter 667 – Minimum Tapered 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 7 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 (Parameter 627).
Chapter 7 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 7 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 7 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 7 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 7 Programming Parameters Only Available in Firmware Version 5.01 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: (5.01 firmware only) This parameter establishes the window for detection of tach loss when the Tach Loss Recovery feature is selected.
Chapter 7 Programming Parameters Available in Version 5.01 and Later Firmware 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.
Chapter 7 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 7 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 7 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 7 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 7 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 7 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 7 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 7 Programming Parameters Parameter 726– SCR Overtemperature Delay [SCR Overtemp Delay] 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 heatsink overtemperature discrete input must be low before an SCR overtemperature fault will be indicated.
Chapter 7 Programming Parameters Parameter 730– Field Failure Delay [Fld Failure Dly] Internal units : Seconds x 10 Programming Terminal units: Seconds Minimum Value: 0.1 Maximum Value: 5.0 Default Value: 1.0 Description: This parameter indicates the length of time that the field current feedback value can deviate by more than 50% of field current reference before a field loss condition is indicated.
Chapter 7 Programming Parameters Parameter 734 – K Discontinuous [K Discontinuous] Internal units : 1024 = 400h = Full load current Programming Terminal units: None Minimum Value: 4 Maximum Value: 2048 Default Value: 288 Description: Represents the average value of current feedback at the cross over point between discontinuous and continuous armature current. Used to linearize the armature current loop and calculate the armature current loop gains.
Chapter 7 Programming Parameters Parameter 739 – K Armature Volts [K Arm Volts] Internal units : 10 x armature volts@ maximum A/D input Programming Terminal units: None Minimum Value: 3000 Maximum Value: 25000 Default Value: 12500 Description: A parameter which scales the analog armature voltage (± 2.5 volt = ± 512 a/d value) into ten times the actual armature voltage. K ARM VOLT should be equal to ten times the armature voltage required to produce 5 volts on TP 27.
Chapter 7 Programming Parameters Parameter 741– Desired Current Loop Bandwidth [Cur Desired BW] Internal units : None Programming Terminal units: RAD/Sec. Minimum Value: 40 Maximum Value: 1000 Default Value: 500 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. The desired bandwidth is limited to the maximum achievable bandwidth which is calculated by the current processor (CP).
Chapter 7 Programming Parameters Added in Firmware Version 9.20 Parameter 744 - Bridge Switch Delay Internal units : None Minimum Value: 0 Maximum Value: 75 Default Value: 2 Description: This parameter allows the user to set up a programmable delay which would begin after the drive's Zero Current Detector tells the drive to switch between bridges. A load with higher than normal inductance could mean that an undesirable level of current still exists when the drive attempts to change bridges.
Chapter 7 Programming Parameters Added in Firmware Version 10.10 Parameter 745 – K Discontinuous Fraction [K Disc Fraction] Internal units : 10240 = 2800h = Full Load Current Programming Terminal units: None Minimum Value: 0 Maximum Value: 0.9 Default Value: 0 Description: Represents the fractional part of Parameter 734 – K Discontinuous and together represent the average value of current feedback at the cross over point between discontinuous and continuous armature current.
Chapter 7 Programming Parameters Parameter 841 – SP Indirect 2 [SP Indirect 2] 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 11, and can be linked to a Sink Parameter. ATTENTION: For system indirect inputs, proper values, Min/ Max limits and polarities must be observed.
Chapter 7 Programming Parameters Parameter 843 – SP Indirect 4 [SP Indirect 4] 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 13 and can be linked to a Sink Parameter. ATTENTION: For system indirect inputs, proper values, Min/ Max limits and polarities must be observed.
Chapter 7 Programming Parameters Parameter 902 – Trend Constant Signed Value [Trend Sign Val] Internal units : None Programming Terminal units: None Minimum Value: – 32767 Maximum Value: + 32767 Default Value: 0 Description: This parameter specifies a signed constant value used for trend trigger evaluation. This parameter number is entered when programming Trend Operand Parameter X or Y.
Chapter 7 Programming Parameters Parameter 906 – 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 7 Programming Parameters Parameter 910 – Trend 1 Operand Parameter X [Tr 1 Opnd X Param] Internal units : None Programming Terminal units: None Minimum Value: 1 Maximum Value: 947 Default Value: 100 Description: This parameter specifies the first of two parameter numbers for the trend trigger evaluation. The data value for the entered parameter number is used in the trigger evaluation.
Chapter 7 Programming Parameters Parameter 913 – Trend 1 Sampling Rate [Tr 1 Sample Rate] Internal units : 1 = 0.001 secs. Programming Terminal units: Secs Minimum Value: 0.004 Maximum Value: 30.0 Default Value: 0.020 Description: This parameter specifies the interval at which the data for the fast source parameter, linked with the Trend fast sink parameter, is sampled. It is programmable in increments of 4ms. All values are rounded down to the nearest 4ms.
Chapter 7 Programming Parameters Parameter 916 – Trend 1 Enable Trend [Tr 1 Enable] Internal units : None Programming Terminal units: None Minimum Value: 0 Maximum Value: 1 Default Value: 0 Description: This parameter is a switch that enables (activates) or disables (de-activates) the trend. The choices are: Disable, 0 = Immediately terminates the trend (if it is activated). Enable, 1 = Starts the trend provided a link has been established with the corresponding Trend 1 Input source fast parameter.
Chapter 7 Programming Parameters This Page Intentionally Left Blank 7-78
Chapter 8 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. ! WARNING: Servicing energized industrial control equipment can be hazardous.
Chapter 8 Start–Up ! Terminology CAUTION: 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 8 Start–Up Figure 8.1 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 6 Installation, have been properly completed. 2.
Chapter 8 Start–Up Table 8.
Chapter 8 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 8.E – 8.G: • Three phase source voltages L1 to L2, L2 to L3 and L3 to L1.
Chapter 8 Start–Up 4. Record the following DC voltage measurements in Tables 8.E to 8.G. If any voltage measurement is incorrect, refer to the Troubleshooting manual for guidelines. • +5 +/– 0.15VDC measured at TP 51 (+) with respect to TP 52 (–) on the Main Control Board. • +12 +/–0.48VDC measured at TP 55 (+) with respect to TP57 (–) on the Main Control Board. • –12 +/– 0.48VDC measured at TP56 (+) with respect to TP57 (–) on the Main Control Board. • +5 +/– 0.
Chapter 8 Start–Up Table 8.F Voltage Measurements, 40-100HP 230V and 75-200HP 460V Series A Test Points Expected Voltage AC VOLTAGES: L1 to L2 L2 to L3 L3 to L1 TB1-1 to TB1-5 TB2-4 to TB2-5 Rated AC Input Rated AC Input Rated AC Input Rated AC Field Input 115VAC +/–10% MAIN CONTROL BOARD: TP51 to TP52 TP55 to TP57 TP56 to TP57 TP58 to TP53 TP54 to TP53 +5 +/– 0.15 VDC +12 +/– 0.48 VDC –12 +/– 0.48 VDC +5 +/– 0.15 VDC +12 +/– 0.48 VDC PSI BOARD: TP5 to TP23 +24 +/– 6 VDC Measured Voltage Table 8.
Chapter 8 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 24VDC ECOAST stop circuit is used, measure the voltage from TB3 – 11 to 9 with the ECOAST stop contact open and closed.
Chapter 8 Start–Up Table 8.
Chapter 8 Start–Up Line/Armature Current Burden Resistors Table 8.I Rated Arm Brdg Current (I) (Parm 615) Also refer to Publication 1395-5.70, Chapter 6 and 2361-5.01, Chapters 2, 3, and 4. Line Cur Burden Resistor Ser B Ser A Ser B (MKVA) HKVA Arm Cur Burden Resistor TB1 TB2 TB2 TB2 TB3 TB3 TB3 TB3 Ser A Current HP 230VAC HP 460VAC Rated Drives Cat No. HP Cat No. HP Part # Ohms DC Output Amps Part # Ohms 3.6 – 5 A 6.0 – 10 A 6.0 – 10 A 11 – 19 A A61 A62 A63 A64 1 1.
Chapter 8 Start–Up Series B J1 Jumper Table 8.J Rated Fld Brdg I Settings (Parameter 616) Series A 1 – 30 HP, 240VDC 2 – 60 HP, 500VDC 1 2 3 4 40 – 100 HP, 240VDC 75 – 200 HP, 500VDC 10.6 4.6 2.1 0.6 Series B MKVA 125 – 300 HP, 240VDC 250 – 600 HP, 500VDC 21.2 9.2 4.2 1.2 42.2 18.4 8.7 2.4 Table 8.K Basic Parameters — Feedback Scaling Parm Parameter Name Description 739 K Arm Volts Numerical value used to scale the armature voltage feedback.
Chapter 8 Start–Up Table 8.
Chapter 8 Start–Up Table 8.M Speed Reference Parameters Parm 633 634 635 636 637 638 639 Parameter Name Classification Preset Speed 1 Preset Speed 2 Preset Speed 3 Preset Speed 4 Preset Speed 5 Jog Speed 1 Jog Speed 2 Application Application Application Application Application Application Application Value Table 8.
Chapter 8 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 8.O and 8.P.
Chapter 8 Start–Up Table 8.
Chapter 8 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 5 of this manual lists all of the allowable Source and Sink parameters associated with the Drive control.
Chapter 8 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 50VDC to start with, and then work down until a reading can be obtained.
Chapter 8 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 8 Start–Up Drive Tuning(Drive Setup/Autotune/ Current) PARM 661 676 698 699 702 733 743 The following parameters should be set-up prior to using the Auto-Tuning features: DESCRIPTION PRESENT VALUE 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 8 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 8 Start–Up 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. If a stop command is issued anytime during the test, the motor will stop and the test will be aborted. Check Parameter 624 (maintain start) to determine if the start command is latched or momentary.
Chapter 8 Start–Up 3. Set KI, KP for the CEMF regulator (Parameters 672, 673), to their default value. 4. Set Parameter 612, the rated motor field current to the actual value, referring to the motor nameplate data. IMPORTANT: The Drive start command must be true for the entire time the test is being performed. If a stop command is issued anytime during the test, the motor will stop and the test will be aborted. Check Parameter 624 (maintain start) to determine if the start command is latched or momentary.
Chapter 9 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 9.
Chapter 9 Reference Materials Table 9.A Fast Source Parameters cont.
Chapter 9 Reference Materials Table 9.B Fast Sink Parameters cont.
Chapter 9 Reference Materials Parameter Value List Record all parameter values or PLC references as finalized during start-up in the following tables: Table 9.
Chapter 9 Reference Materials Table 9.C Parameter Values cont.
Chapter 9 Reference Materials Table 9.C Parameter Values cont.
Chapter 9 Reference Materials Table 9.C Parameter Values cont.
Chapter 9 Reference Materials Table 9.D Internal Configuration Parameters Param # 840 841 842 843 844 Description Internal Param SP INDIRECT 1 SP INDIRECT 2 SP INDIRECT 3 SP INDIRECT 4 SP INDIRECT 5 Linked to Fast Sink Param Description 10 11 12 13 14 Table 9.
Chapter 9 Reference Materials Table 9.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 Param # 920 921 922 923 924 925 926 927 Parameter Range Param. Value 1 through 947 1 through 947 GT, LT,EQ, AND, NAND, OR, NOR 0.
Chapter 9 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 Fdbk Arm Resistance Arm Voltage Fdbk Arm Voltage Offset At Speed 1 – 5 Auto Tune I Lim Auto Tune Speed Base Motor Speed Bridge Switch Delay 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 Driv
Chapter 9 Reference Materials Parameter Reference Listing (Alphabetical) PARAMETER NAME Fld Failure Delay Fld Flux Ref 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 9 Reference Materials Parameter Reference Listing (Alphabetical) PARAMETER NAME Maintain Start Minimum Tapered Current MOP Accel 1 – 4 Mtr Overload Sel MOP Decel 1 – 4 MOP Max Speed MOP Min Speed Motor Arm FLA Motor Inertia 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
Chapter 9 Reference Materials Parameter Reference Listing (Alphabetical) PARAMETER NAME PARAMETER NO.
Chapter 9 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 9 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.
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Chapter 10 Renewal Parts Introduction 1 – 30HP, 230VAC 2 – 60HP, 460VAC SERIES B Chapter 10 provides renewal parts information for the 1395 Drive. The chapter is divided into three sections based on horsepower rating. Included in each section is a listing of the renewal parts available. In addition, figures are provided to show the approximate component locations. For part number and pricing information, refer to the 1395 Renewal Parts publication (1395-6.0). NOTE: Refer to publication 2361–5.
Chapter 10 Renewal Parts 10 or 11 13 9 12 20 4 , 4A or 5 AB0668A 1 or 2 10-2
Chapter 10 Renewal Parts 16 15 6 7 6 17 3 21 (located below on heat sink) 7 (located behind #6) 23 18 22 (below bus bar) AB0669A 10-3
Chapter 10 Renewal Parts 19 8 (back of drive) AB0670A 14 (bottom of drive) 10-4
Chapter 10 Renewal Parts 40 – 100HP, 230VAC 75 – 200HP, 460VAC SERIES A 1 Reference Number Description Quantity 1 Armature Pulse Board 3 2 Digital Reference Adapter Board 1 3 Discrete Adapter Board 1 4 Feedback Board 1 5 Field Pulse Board 1 6 Main Control Board 1 7 Multi Communication Board 1 7A ControlNet Adapter Board 1 8 Node Adapter Board 1 9 Power Stage Interface Board 1 10 Power Supply Board 1 11 Auxiliary Contact, N.O.
Chapter 10 Renewal Parts 25 23 29 17 18 19 20 22 (behind fuse plate) 11, 12 or 13, 14, 15 7, 7A or 8 2 or 3 4 5 16 (bottom of drive) 10-6 6 (back of first swing-down panel) AB0673A
Chapter 10 Renewal Parts 27 28 24 26 27 1 9 10 AB0674A 10-7
Chapter 10 Renewal Parts 125 – 300HP, 230VAC 250 – 600HP, 460VAC SERIES B Reference Number Description Quantity 2 Armature Pulse Board1 3 3 Digital Reference Adapter Board 1 4 Discrete Adapter Board 1 5 Feedback Board 1 6 Field Pulse Board 1 7 Main Control Board 1 8 Multi Communication Adapter Board 1 7A Control Net Adapter Board 1 9 Node Adapter Board 1 9 Power Stage Interface Board 1 10 Power Supply Board 1 11 Contactor 1 12 Fans 3 13 Fan Switch 3 14 15 16 1
Chapter 10 Renewal Parts 9 10 6 (back of swing-down panel) 7, 7A or 8 2 or 3 AB0675A 5 14 25 22 21, 23 17 20 16 24 ÂÂ ÂÂ Â Â Â ÂÂ Â Â ÂÂ Â Â Â ÂÂ ÂÂ Â Â Â Â 15 18 1 11 19 12, 13 AB0676A 4 10-9
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Appendix Understanding EEPROM Functions And how they relate to Main Control and Adapter Board Replacement For detailed programming information, refer to the Bulletin 1300 Programming Terminal User Manual, publication 1300-5.5. Initialize The Initialize function sets all parameters and links to default values. It also identifies what adapter boards are installed and allows them to be programmed.
Appendix Notes A-2
Index Numbers 1–30 HP/2–60 HP Drives 115VAC Control Voltage, 2-11 115VAC Control Voltage – Illustration, 2-11 AC Current Feedback, 2-3 AC Line Reactor, 2-3 Adapter Board, 2-1, 2-15 Adapter Board – Illustration, 2-15 Analog Inputs, 2-16, 2-17 Analog Output, 2-16 Analog Outputs, 2-17 Armature Bridge Components, 2-3 Armature Bridge Components – Illustration, 2-3, 2-4 Bridge Output Connections, 2-4, 2-5 Bus Bar, 2-6 Control Voltage Common, 2-11 ControlNet Adapter Board, 2-18 DC Bus Snubbers, 2-4 DC Contactor,
Index Digital Outputs, 4-20, 4-21 Digital Reference Adapter Board, 4-20 Digital Reference Input, 4-20 Discrete Adapter Board, 4-20 ECOAST Stop, 4-16 Feedback Board, 4-7 Feedback Board – Illustration, 4-7 Feedback Board Jumpers, 4-7 Field Bridge Components, 4-5 Field Bridge Components – Illustration, 4-6 Field Current Feedback, 4-5 Field Pulse Transformer, 4-12 Field Pulse Transformer – Illustration, 4-12 Fuses, 4-3 Hardware Description, 4-1 Hardware Overview, 4-2 Hardware Overview – Illustration, 4-2 Incom
Index Field Current Feedback, 3-5 Field Pulse Transformer and Snubber Board, 3-5 Field Pulse Transformer and Snubber Board (A5), 3-12 Field Pulse Transformer and Snubber Board – Illustration, 3-13 Hardware Description, 3-1 Hardware Overview, 3-1 Hardware Overview – Illustration, 3-2 Interface, 3-1 Line Choke, 3-4, 3-5 Main Contactor (M1) Control, 3-17 Main Control Board (A8), 3-11 Main Control Board Hardware – Illustration, 3-11 Main Control Relay, 3-17 Microbus, 3-1 Multi-Communication Adapter Board, 3-22
Index Armature DC Loop Contactor Lug Kits, 6-13 Bypass Jumpers, External Contactor, 6-28 Armature Firing, 1-4 Armature Pulse Transformer and Snubber Board 40–100 HP/75–200 HP Drives, 3-12 40–100 HP/75–200 HP Drives – Illustration, 3-12 Armature Pulse Transformer Boards 125–300 HP/250–600 HP Drives, 4-11 125–300 HP/250–600 HP Drives – Illustration, 4-11 Armature Regenerative Bridge Components, 125–300 HP/250–600 HP Drives – Illustration, 4-4 C Cable and Wiring Recommendations, 6-7 Cable Shielding Recomme
Index ECoast Connections, 6-23 External Contactor Bypass Jumpers, 6-28 Procedure, 6-21 TB3 Terminal Descriptions, 6-22 Controller Current Output, 1-4 ControlNet Adapter Board 1–30 HP/2–60 HP Drives, 2-18 125–300 HP/250–600 HP Drives, 4-22 40–100 HP/75–200 HP Drives, 3-23 Specifications, 1-7 Cooling Airflow, 6-5 Current Damping Factor, 743, 7-68 Current Loop Test, 5-14 Current Loop Tune, 5-14 Current Test, 5-15 Current Tune, 5-16 Description, 5-15 Current PI Control, Block Diagram, 5-37 Current Reference Co
Index Inspection, 1-3 Publication References, 1-10 Receiving Information, 1-3 Specifications, 1-4 Standard Features, 1-2 Storage, 1-3 Unpacking, 1-3 External Inputs Specifications, 1-5 External Outputs Specifications, 1-5 External Overtemperature Delay, 725, 7-63 F Drive Calibration, Verification, 8-17 Fast Parameter, Definition, 5-1, 7-1 Drive Configuration, 5-6 Fast Sink Parameters, Configuration and Linking, 9-2 Drive Fault, 101, 7-18 Fast Source Parameters, Configuration and Linking, 9-1 Drive
Index Field Current at 7/8 Flux, 684, 7-53 Field Current Feedback 1–30 HP/2–60 HP Drives, 2-5 125–300 HP/250–600 HP Drives, 4-5 40–100 HP/75–200 HP Drives, 3-5 Field Current Feedback, 118, 7-23 Field Current Range Jumper Selections, 1–30 HP/2–60 HP Drives, 2-9 Field Current Reference, 117, 7-22 Field Economy, 1-4 Field Economy Delay, 675, 7-50 Field Economy Reference, 674, 7-50 Field Failure Delay, 730, 7-65 Functional Description, 5-1 Terminology, 5-1 Fuses, 125–300 HP/250–600 HP Drives, 4-3 G Gate Firi
Index J Logic Description, 5-25 Logic Status, 100, 7-16 Jog 1 Speed, 638, 7-42 Jog 2 Speed, 639, 7-43 Jog Dwell, 711, 7-60 Jog Ramp Enable, 626, 7-39 Jog Speeds, 1-5 Jumper Connections, Circuit Board, 6-18 Jumper Settings Field Current, 6-19 Main Control Board, 6-19, 6-20 Power Stage Interface Board, 6-19 K K AC Volts, 740, 7-67 M Main Contactor (M1) Control 1–30 HP/2–60 HP Drives, 2-12 125–300 HP/250–600 HP Drives, 4-16 40–100 HP/75–200 HP Drives, 3-17 Main Control Board 1–30 HP/2–60 HP Drives, 2-10 1
Index Motor Connection, 6-8 for CCW Rotation, 6-14 Motor Inertia, 613, 7-34 Motor Operated Pot, 1-5 Motor Overload Select, 629, 7-40 Motor Thermostat, 1-5 Mounting, 6-1 Multi-Communication Adapter Board, 6-40 1–30 HP/2–60 HP Drives, 2-17 125–300 HP/250–600 HP Drives, 4-21 40–100 HP/75–200 HP Drives, 3-22 Specifications, 1-6 N NEMA Type 12 Enclosures, 6-5 Node Adapter Board, 6-40 1–30 HP/2–60 HP Drives, 2-17 125–300 HP/250–600 HP Drives, 4-21 40–100 HP/75–200 HP Drives, 3-22 Non-Volatile Memory, Definition
Index External Overtemperature Delay, 725, 7-63 Fault Report, 630, 7-41 Fault Select, 623, 7-37 Feedback Device Type, 621, 7-36 Field Current at 0/8 Flux, 677, 7-51 Field Current at 1.
Index SP Output 5, 14, 7-15 Stall Delay, 727, 7-64 Start Taper Speed, 665, 7-48 System Inertia, 703, 7-58 System Reset Select, 620, 7-36 Tach Loss CEMF, 731, 7-65 Tach Loss Velocity, 732, 7-65 Tach Switch Ki, 689, 7-55 Tach Switch Kp, 690, 7-55 Tach Switch Select, 691, 7-56 Tach Switch Tolerance, 688, 7-55 Tach Velocity, 156, 7-30 Torque Command, 110, 7-21 Torque Mode, 625, 7-38 Torque Reference 2, 167, 7-32 Torque Reference, 157, 7-30 Trend 1 Contiguous Trigger Switch, 915, 7-76 Trend 1 Enable Trend, 916,
Index Process Trim, 5-27 Process Trim Control, Block Diagram, 5-34 Process Trim Feedback, 162, 7-31 R Ramp Control, Block Diagram, 5-33 Ramp Velocity Reference, 103, 7-20 Process Trim Filter Constant, 713, 7-61 Rated AC Line Voltage, 617, 7-35 Process Trim High Limit, 718, 7-62 Rated Armature Bridge Current, 8-10 Process Trim High Sum, 722, 7-63 Rated Armature Bridge Current, 615, 7-35 Process Trim KI Gain, 715, 7-61 Rated Field Bridge Current, Settings, 8-11 Process Trim KP, 716, 7-61 Rated Fie
Index 125–300 HP/250–600 HP Drives, 4-4 40–100 HP/75–200 HP Drives, 3-4 SCR Snubbers, 125–300 HP/250–600 HP Drives, 4-5 Set Up Parameter, Definition, 7-2 Setting Trend Buffer Output Rate, 5-23 Setting Trend Buffer Type, 5-23 Set-Up Parameters, 8-12 Sink Definition, 5-2 Parameters, 5-6 Slave Percent 2, 670, 7-49 Slave Percent, 669, 7-49 Source Definition, 5-2 Parameters, 5-9 Source and Sink Parameters Partial Illustration, 5-7 Table, 5-8 SP Indirect 1, 840, 7-70 SP Indirect 2, 841, 7-71 SP Indirect 3, 842,
Index Tach Switch Tolerance, 688, 7-55 Trend Buffer, 5-18 Activating, 5-23, 5-25 Continuous Trigger, 5-23 Data Sample Rate, 5-22, 5-24 Example, 5-19 One-shot, 5-23 Output Data Rate, 5-25 Output Rate, 5-23 Parameters, 5-20 Post Samples, 5-22 Post Samples Rate, 5-24 Programming, 5-21 Sample Worksheet, 5-20 Setting the Type, 5-23 Setup, 5-24 Setup Description, 5-19 Trend Constant Parameters, 5-21 Trend Trigger, 5-21 Trigger Equation, 5-21 Troubleshooting Aid, 5-25 Type, 5-24 Tach Velocity, 6-32 Trend Const
Index Velocity Desired Bandwidth, 700, 7-57 Velocity PI Output, 123, 7-24 Velocity Error, 124, 7-24 Velocity Reference Control, 5-25 Block Diagram, 5-32 Velocity Feed Forward, 108, 7-21 Velocity Feedback Control, 5-26 Block Diagram, 5-34 Velocity Feedback Filter Select, 631, 7-41 Velocity Feedback Select, Definition, 5-4 Velocity Feedback, 106, 7-20 Velocity Indirect 1, 163, 7-31 Velocity Indirect 2, 164, 7-31 Velocity Indirect 3, 165, 7-31 Velocity Indirect 4, 166, 7-32 Velocity Loop Motor Test, 5-14
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U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives www.rockwellautomation.com Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA,Tel: (1) 414.382.2000, Fax: (1) 414.382.