Distributed Power System SA3100 Diagnostics, Troubleshooting, and Start-Up Guidelines Instruction Manual S-3059-1
Throughout this manual, the following notes are used to alert you to safety considerations: ! ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Important: Identifies information that is critical for successful application and understanding of the product.
CONTENTS Chapter 1 Introduction 1.1 Related Publications ........................................................................................ 1-1 1.2 Typographical Conventions ............................................................................. 1-5 Chapter 2 Diagnostics and Troubleshooting 2.1 Definition of Terms Used in Diagnostics and Troubleshooting ........................ 2-1 2.2 Power-up Diagnostics in the UDC Module and PMI Regulator ....................... 2-3 2.3 Interlock Tests ...
.7.8 I/O Verification .....................................................................................4-10 4.7.8.1 Testing UDC/PMI Regulator Communication Status.............4-10 4.7.8.2 Testing Flex I/O Registers .....................................................4-11 4.7.8.3 Testing Feedback Registers and Bits....................................4-14 4.7.8.4 Testing the UDC Module Test Switch Register .....................4-15 4.7.8.5 Testing UDC Module Meter Ports..................................
List of Figures Figure 2.1 – PMI Regulator Operating Modes Overview .......................................... 2-2 Figure 3.1 – PMI Regulator Operating Modes and Diagnostics ............................... 3-2 Figure 3.2 – Internal DC Bus Control Flowchart ....................................................... 3-3 Figure 3.3 – Power Device Test Locations ............................................................... 3-6 Figure I.1 – Terminal Block Locations ................................................
IV Diagnostics, Troubleshooting, and Start-Up Guidelines
List of Tables Table 1.1 – SA3100 Documentation (Binder S-3053) .............................................. 1-1 Table 1.2 – SA3100 Power Structure Service Manual Cross Reference ................. 1-2 Table 3.1 – PMI Regulator Operating Modes ........................................................... 3-1 Table 3.2 – Bridge Test Connections ....................................................................... 3-5 Table 4.1 – UDC/PMI Regulator Communication Status Register Formats ...........
VI Diagnostics, Troubleshooting, and Start-Up Guidelines
CHAPTER 1 Introduction This instruction manual is divided into two sections: 1) a description of SA3100 drive diagnostics and troubleshooting, 2) start-up guidelines. This manual is intended for users of SA3100 drives who have training and experience in AC drive control and who are familiar with all other SA3100 drive documentation.
Power structure replacement parts and service procedures are contained in the instruction manuals listed in table 1.2. Table 1.2 – SA3100 Power Structure Service Manual Cross Reference AC Input Voltage DC Bus Input Voltage Nominal HP Frame Size Use Service Manual 1336 Force- B 6.11 C 6.12 D 6.13 E 6.
Table 1.2 – SA3100 Power Structure Service Manual Cross Reference AC Input Voltage DC Bus Input Voltage Nominal HP Frame Size Use Service Manual 1336 Force- B 6.11 C 6.12 D 6.13 E 6.14 F 6.16 G 6.15 H 6.
Table 1.2 – SA3100 Power Structure Service Manual Cross Reference AC Input Voltage DC Bus Input Voltage Nominal HP Frame Size Use Service Manual 1336 Force- B 6.11 C 6.12 D 6.13 E 6.14 F 6.16 G 6.15 H 6.15 1 3 7.5 10 15 20 25 30 40 50 60 500 VAC 600 VAC [C] 675 VDC 800 VDC [W] 75 100 125 150 200 250 300 350 400 450 500 600 650 800 Other related documents that you should refer to include the following: • AutoMax Programming Executive Instruction Manual Version 3.
1.2 Typographical Conventions The following typographical conventions are used in this manual: • Variable names Variables names are shown in all capital letters followed by the appropriate terminating character. The variable names shown in this manual are suggested names only and may vary from the names used in your application. Example: MCR@ • Register names Register names are shown with the initial letters capitalized followed by the corresponding register number for both drive A and drive B.
1-6 Diagnostics, Troubleshooting, and Start-Up Guidelines
CHAPTER 2 Diagnostics and Troubleshooting The Distributed Power System contains built-in comprehensive diagnostics. In order to diagnose and correct problems quickly, it is important to understand the types of diagnostics that are performed, when they are performed, and how the results are reported. This chapter describes the different types of diagnostics performed by the system’s modules and how the results of these diagnostics are reported.
Run-time diagnostics are those diagnostics performed continuously by the PMI Regulator as a background task after it has received its operating system from the UDC module. Power On Idle Select PMI_RUN@, BRG_TST@, or PMI_TUN@ Interlock Tests PMI Tuning Close MCR Minor Loop Run Bridge Test Bus Missing Open MCR Bus Missing Open MCR Figure 2.
2.2 Power-up Diagnostics in the UDC Module and PMI Regulator Power-up diagnostics execute in the UDC module in the AutoMax© rack and in the PMI Regulator. When power is applied to the AutoMax rack, the UDC module performs a series of self-tests. When all of the tests are successfully completed, the CARD OK LED on the UDC module's faceplate will turn on. When power is applied to the PMI Regulator, the on-board Processor performs a series of self-tests.
2.4 Run-time Diagnostics Run-time diagnostics are performed continuously by the PMI Regulator after its operating system has been downloaded by the UDC module. These diagnostics test the status of the PMI Regulator and the connected hardware and also check the integrity of the communication link between the UDC module and the PMI Regulator. The results of the diagnostics are stored in either the Drive Warning register (203/1203) or the Drive Fault register (202/1202) in the UDC module’s dual port memory.
than 2% of the rated motor current, the PMI Regulator will turn off the MCR output. Note that the PMI Regulator will always turn off the MCR output within 300 msec of the fault occurrence even if the 2% current level has not been reached.
The following conditions will cause the MCR output to turn off: • Absence of the RPI signal • Occurrence of a drive fault • Control algorithm is turned off (PMI_RUN@ = 0) After any of the above conditions occurs, the PMI Regulator will wait for current feedback to be less than 2% of rated motor current multiplied by the motor overload ratio. The PMI Regulator will then turn off the MCR output. If this current level has not been reached within 300 msec, the MCR output will be turned off regardless.
2.5 Internal DC Bus Diagnostics The status of the DC bus is monitored as part of both the interlock and run-time diagnostics. The DC bus is considered “ready” when the PMI Regulator detects that the bus voltage is greater than the undervoltage threshold value stored in local tunable UVT_E0% and has reached a steady state, and the pre-charge contactor has closed. This is checked as an interlock test and is then constantly monitored during run-time diagnostics.
2-8 Diagnostics, Troubleshooting, and Start-Up Guidelines
CHAPTER 3 PMI Regulator Operating Modes The PMI Regulator’s default operating mode is idle. All other operating modes are selected by the programmer in the Drive Control register (100/1100). Table 3.1 shows the available operating modes. Note that the operating modes are mutually exclusive, i.e., only one mode may be enabled at a time (this is checked by the interlock tests). The PMI Regulator’s operating modes are shown in figure 3.1 and are described in the following sections. Table 3.
Power-Up Diagnostics Section 2.2 BUS_ENA@ Reg 100 Bit 4 On Pre-Charge Contactor I/M S-3058 Vdc > UVT_E0% + Steady State Condition and Pre-Charge Contactor Closed Bus Ready Idle Section 3.1 Select PMI_RUN@, BRG_TST@, or PMI_TUN@ Interlock Tests Failed Interlock Tests OK and PMI_TUN@ Reg 100 Bit 1 On PMI Tuning Section 3.3 Tuning Complete Reg 200 Bit 1 On Interlock Tests OK Close MCR Section 2.4.1.
Idle BUS_ENA@ On* Begin 10 Second Timer No Wait for AC Line Hi HP Common Bus or Hi HP Stand-Alone No ? Yes AC Line Status From Power Module = TRUE No More than 10 Seconds Elapsed? Yes Fault Occurs Register 202/1202 ? Yes Hi HP Stand-Alone ? Yes ** Open Pre-Charge Contactor ** Wait for Bus to Charge No Nominal Bus Voltage Reached? No More than 10 Seconds Elapsed? No More than 10 Seconds Elapsed? Yes Yes ** PMI Closes Pre-Charge Contactor Auxiliary Contacts Closed? ** Yes Open Pr
3.1 Idle Mode The PMI Regulator’s default operating mode after passing the power-up diagnostics and completing the DC bus pre-charge sequence is idle. When in idle mode, the PMI Regulator is waiting for a command from the Drive Control register (100/1100) to change operating modes. In order for the PMI Regulator to enter the requested operating mode, the Interlock tests must be passed.
! ATTENTION:The bridge test applies the full DC bus voltage to an output phase for the duration of a test. The motor must not be connected to the Drive while performing the bridge test in order to avoid damage to the drive and motor. Failure to observe this precaution could result in damage to, or destruction of, the equipment. If the Power Module and the motor are connected through one set of leads, disconnect the motor leads from the Power Module.
Left Middle Right Upper + U DC Bus V – W Lower Gate Driver Gate Driver Gate Driver Figure 3.3 – Power Device Test Locations Step 7. Test the bridge by measuring the voltage across the power devices. The bridge test must be enabled and the appropriate value written to the Bridge Test Code register (105/1105) as described below. The value in the Bridge Test Code register specifies which power device pairs to turn on.
d. Enable the internal DC bus by setting the Bus Enable bit (bit 4 in register 100/1100, BUS_ENA@ ). A complete description of the DC bus pre-charge sequence can be found in the SA3100 Power Modules instruction manual, S-3058. e. The drive must pass all the interlock tests and the run permissive input (RPI) must be on. In addition, if it is configured during parameter entry, the MCR output must be turned on by the PMI Regulator to close the M-contactor. f.
3.3 PMI Tuning Mode (Automatic Gain Calculation) The programmer sets the Enable Tuning bit (register 100/1100, bit 1, PMI_TUN@) to request the PMI Regulator to calculate the values for the control algorithm. (Refer to the SA3100 Drive Configuration and Programming instruction manual, S3056, for a complete description of these variables.) Because the calculated values are used in the control algorithms, this procedure must be performed before the run mode is selected.
The minor loop executes until one of the following occurs: • The PMI Run Enable bit (register 100/1100, bit 0) is turned off by the application task. • A drive fault is detected. Refer to Appendix A for a description of the Drive Fault register. • The RPI signal (register 201/1201, bit 0) is removed.
3-10 Diagnostics, Troubleshooting, and Start-Up Guidelines
CHAPTER 4 Installation and Start-Up Guidelines ! ATTENTION:Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
• If a user has Rack access, no other user can make changes in that rack. All other users will be limited to monitoring tasks and variables. • Each user can monitor up to 16 COMMON and/or LOCAL variables. • A maximum of 32 LOCAL variables per UDC module can be monitored, regardless of the number of users. • A maximum of 16 variables per rack can be forced. Appendix G describes the type of access required by the user in order to carry out common Programming Executive operations.
4.3 Installing the Motor The AC motor should be installed in accordance with its own installation instructions. Refer to the instruction manual that was provided for the motor (in the Instruction Book) for specific instructions. 4.4 Installing the Drive The drive is supplied in its own enclosure or in an open-chassis configuration for mounting in a user-supplied enclosure, a motor control center (MCC), or other custom-built control room. 4.4.
Refer to the Elementary Diagram (W/E) (and the Interconnection Diagram (W/I) if provided) supplied with your drive for these interconnections. Be sure that the W/E number corresponds to that on the drive’s nameplate. All interconnecting wiring must be sized and installed in conformance with the National Electrical Code and applicable local or other codes.
Step 2. Turn off and lock out all incoming power. ! ATTENTION:DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge. Then check the voltage across the DC bus test points to ensure the bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life. Step 3.
4.7.3 Physically Inspecting the Drive Before operating the equipment, DISCONNECT AND LOCK OUT ALL INCOMING AC LINE/DC BUS POWER AND CONTROL POWER TO THE DRIVE and perform the following steps: Step 1. Carefully inspect the Power Module and other drive components for physical damage. Verify free operation of all switch relays, auxiliary contacts, and contactors. Step 2. Visually inspect internal buses and wiring for loose or broken connections or damaged wires. Step 3. Visually check for damaged components.
Step 1. If the drive is powered up, disconnect and lock out all incoming AC line/DC bus power and control power to the drive. Refer to section 4.7.1 for additional information on measuring and discharging DC bus voltage. If the drive is not under power, proceed to step 2. ! ATTENTION:After disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge. Then check the voltage across the DC bus to ensure the bus capacitors are discharged before touching any internal components.
4.7.6 Testing AC Input Power Modules with AC Power On ! ATTENTION:Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life. ATTENTION:This procedure is performed with power on.
4.7.7 Testing DC Bus Supplies and DC Input Power Modules ! ATTENTION:Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life. ATTENTION:These procedures are performed with power on.
4.7.8 I/O Verification I/O verification consists of ensuring that all physical I/O is properly connected and functional, and that all critical registers and bits can be accessed in the UDC dual port memory. Before verifying the I/O, ensure that the following have been loaded to the AutoMax rack. Note that the application tasks should not be put into run before you have verified all I/O.
Step 3. Examine registers 82/1082 and 83/1083 (and 86/1086 and 87/1087) for the number of CRC and format errors received on the UDC module (and PMI Regulator). If either of these values is incrementing, it indicates a problem. Step 4. Examine register 88/1088 for the status of the fiber-optic ports on the UDC module. If the operating systems are loaded and no tasks are running, the lower byte should be equal to xx03H (UDC module and PMI Regulator are exchanging data).
Step 1. Test each digital input by initiating the input and verifying that the appropriate bit (displayed on the screen) goes on. Step 2. Test each digital output by forcing the bit on and verifying that the signal is present on the terminal points. Step 3. Test any analog current or voltage output channel being used by writing a value shown in table 4.3 to the channel and verifying with an ammeter or voltmeter that the signal on the terminal points (4-20mA, 0-20mA, +/- 10V, or 0-10V) is proportional.
Analog Data Formats Data is returned from the Flex I/O module’s analog-to-digital converter with 12-bit resolution. The value is left-justified into a 16-bit field, reserving the most significant bit for a sign bit.
4.7.8.3 Testing Feedback Registers and Bits This section describes how to test the feedback registers and bits listed in table 4.4. Fault, warning, and interlock registers are described in Appendices A, B, and C. Use the AutoMax Programming Executive I/O Monitor function to display the registers and bits in the format listed in table 4.4. Table 4.
Step 3. You may want to create a separate monitor screen for registers 206/1206 through 219/1219 and save it. This will allow you to recall the screen later, without having to enter the entire list each time you need to monitor feedback registers. Step 4. Check the User Analog Input (register 214/1214) by applying an input signal to the appropriate pins on the Resolver Feedback connector on the Resolver and Drive I/O board and verifying that register 214/1214 displays an appropriate value.
Step 2. Using the Monitor I/O screen, force a value within the range configured to each UDC register being output on the meters. Step 3. Use a voltmeter to verify that the signal on the terminal points (-10V to +10V) of each meter port is proportional to the value in the corresponding register. Step 4. Unforce the registers being output on the meter ports to zero. 4.7.8.6 Testing PMI Regulator Meter Ports This section describes how to test the PMI Regulator meter ports.
Step 4. The Drive’s AC output phase rotation must match the resolver’s orientation. Output phase rotation (UVW or UWV) is determined by setting the Output Phase Rotation parameter, assuming the motor leads are correctly connected. Resolver orientation is determined by the cosine lead connections. a. Place a value of zero in the Torque Reference register (register 102/1102, TRQ_REF%). Turn on the drive. b. Slowly increase the value in register 102/1102. c.
4.7.11 Updated Drawings and Software Listings (Vector) When start-up is performed by Rockwell personnel, the W/E, W/M, W/P drawings, and all software listings are updated after start-up and are re-issued as revised pages of the Instruction Book. Refer to Installing, Operating and Maintaining Engineered Drive Systems (D2-3115) for more information.
APPENDIX A Drive Fault Register Drive Fault Register 202/1202 The bits in the Drive Fault register indicate the cause of a drive shutdown. The bits in this register are latched until they are reset by setting the Fault Reset bit (bit 8) of the Drive Control register (100/1100, bit 8). After turning the Fault Reset bit on, the drive may be re-started after turning the desired command bit in register 100/1100 off and then back on again.
Ground Current Fault Bit 2 The Ground Current Fault bit is set if ground current exceeds the hardware trip point. Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0004H FLT_GND@ Read only 1021 EXT FLT For models A001/Q001 and A003/Q003 the hardware trip point is 20A @ 10V. For all other models it is 100A @ 10V. Instantaneous Overcurrent Fault Bit 3 The Instantaneous Overcurrent (IOC) Fault bit is set if either of the following conditions is detected: Hex Value: Sug. Var.
Over Temperature Fault The Over Temperature Fault bit is set if the thermistor in the Power Module detects a temperature of 100° C or more. Bit 7 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0080H FLT_OT@ Read only 1016 P.M. FLT Resolver Broken Wire Fault The Resolver Broken Wire Fault bit is set if a sine or cosine signal from the resolver is missing due to a broken wire or if the resolver gain tunable (RES_GAN%) has been set too low. Bit 8 Hex Value: Sug. Var.
UDC Run Fault Bit 14 The UDC Run Fault bit is set if the UDC task stops while the minor loop is running in the PMI Regulator. Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 4000H FLT_RUN@ Read only 1014 N/A Communication Lost Fault Bit 15 The Communication Lost Fault bit is set if the fiber-optic communication between the PMI processor and the UDC module is lost due to two consecutive errors of any type. Hex Value: Sug. Var.
APPENDIX B Drive Warning Register Drive Warning Register 203/1203 The warnings indicated by the Drive Warning register cause no action by themselves. Any resulting action is determined by the application task. The user must ensure that the AutoMax application task monitors register 203/1203 and takes appropriate action if any of these conditions occurs.
Voltage Ripple Warning Bit 3 The Voltage Ripple Warning bit is set if the ripple on the DC bus exceeds the voltage ripple threshold value stored in local tunable VRT_E0%. Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0008H WRN_VR@ Read only N/A N/A This bit is intended to be used to detect an input phase loss if three-phase AC input is used, but it can also be used for a common bus supply.
Bad Gain Data Warning The Bad Gain Data Warning bit is set if any of the following conditions is detected: Bit 8 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0100H WRN_BGD@ Read only N/A N/A • A current minor loop gain variable or a vector algorithm variable has been modified by the user outside of acceptable limits. The invalid value will be ignored by the system and the last acceptable value entered will be used. For a description of the tunable variables, refer to Appendix B.
PMI Communication Warning Bit 15 The PMI Communication Warning bit is set if a fiber-optic communication error is detected between the PMI Processor module and the UDC module. Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 8000H WRN_COM@ Read only N/A N/A Communication errors in two consecutive messages will result in a drive fault.
APPENDIX C Interlock Register Interlock Register 205/1205 Interlock tests are executed whenever bit 0, 1, 2, or 4 of register 100/1100 is set. The first problem detected will be indicated by the corresponding bit in this register. Note that these bits will prevent the torque minor loop from running.
Faults Need Reset Bit 3 The Faults Need Reset bit is set if previous faults (register 202/1202) have not been cleared. Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0008H IC_FLT@ Read only N/A N/A Rising Edge Required Bit 4 The Rising Edge Required bit is set if a rising edge is not detected on a command bit in register 100/1100. Hex Value: Sug. Var.
Incompatible Resolver The Incompatible Resolver bit is set if Resolver & Drive I/O boards B/M 60001 or B/M 60001-1 are detected in the PMI Regulator. Interlock Register Bit 10 Hex Value: Sug. Var.
C-4 Diagnositics, Troubleshooting, and Start-Up Guidelines
APPENDIX D Diagnostic Fault Code Register Diagnostic Fault Code Register The Diagnostic Fault Code register displays an error code to help diagnose the cause of a problem reported in other registers. Note that this register is available for monitoring only. It cannot be referenced in an application task. Diagnostic Fault Code Register 222/1222 Sug. Var.
AC Power Technology Calibration and Power-Up Faults: The following calibration and power-up diagnostic faults indicate an irreparable hardware failure of the AC power technology circuitry on the PMI Regulator motherboard. If any of these faults occurs, replace the PMI Regulator motherboard. Register 202, bit 11 (FLT_PTM@) will be set. Code D-2 Fault Action 1 D/A high voltage error (+3.3V 10% out of tolerance) 2 D/A low voltage error (-3.
Run Time AC Power Technology Hardware Faults Register 202, bit 11 (FLT_PTM@) will be set. Code Fault Description/Action 20 Power supply monitor trip AC power technology power supply level out of tolerance. Replace the PMI Regulator motherboard and/or power supply. 21 AC power technology watchdog time-out AC power technology circuit watchdog timer expired. Replace the PMI Regulator motherboard.
D-4 Diagnostics, Troubleshooting, and Start-Up Guidelines
APPENDIX E Summary of UDC Module Drive Fault Indicators Status/Fault LEDs CARD OK (green) - The CARD OK LED will turn on after the UDC module’s power-up self tests have been successfully completed. The LED will remain on unless there is a watchdog time-out or until power is cycled. OS OK (green) - The OS (operating system) OK LED will turn on after the UDC operating system is loaded into the module. It will remain on until power is cycled.
Drive Fault Error Codes Drive faults are reported in the error log for the task in which the error occurred.
APPENDIX F PMI Regulator LED Summary The following table summarizes the LEDs on the PMI Regulator. Refer to the SA3100 PMI Regulator instruction manual (S-3057) for more information on these LEDs. Refer to the SA3100 Drive Configuration and Programming instruction manual (S-3056) for more information regarding the UDC module’s dual port registers. Name Description LED OK When lit, indicates the PMI Regulator passed its power-up diagnostics and the on-board watchdog timer is being updated.
Name Description LED I/O FLT When lit, indicates communication between a Flex I/O module and the PMI Regulator has been disrupted, or that Flex I/O is configured but is not plugged in. Related Reg/Bit 203/1203 bit 13 WRN_I/O@ Flex I/O Communication Error LED FDBK OK When lit, indicates that the Resolver & Drive I/O board is receiving feedback from the resolver and that no resolver feedback faults have been detected.
APPENDIX G Status of Data in the AutoMax Rack After a STOP_ALL Command or STOP_ALL Fault AutoMax Processor UDC Module PMI Processor LOCAL tunable variables retained retained retained LOCAL variables retained reset to 0 N/A COMMON memory variables non-volatile are retained; others are reset to 0 N/A N/A inputs retained and updated; outputs are reset to 0 inputs retained and updated; outputs are reset to 0 all I/O is reset to 0 retained retained N/A reset to 0 reset to 0 N/A Parameter
G-2 Diagnositics, Troubleshooting, and Start-Up Guidelines
APPENDIX H AutoMax Programming Executive Access Levels Rack Power Supply Keyswitch Position Any Position PROTECT SETUP PROGRAM User’s Access Level Action Force Common None Any Level Data Task Rack Data Task Rack No No No No No Yes Yes Yes Force Local No No No No No No Yes Yes Force I/O No No No No No Yes Yes Yes Set Common No No No No No Yes Yes Yes Set Local No No No No No No Yes Yes Set I/O No No No No No Yes Yes Yes Set/Tune Tunable No N
H-2 Diagnositics, Troubleshooting, and Start-Up Guidelines
APPENDIX I Terminal Block Locations and Test Points TB1 Power Terminal Block TB4 24V DC Auxiliary Input 1 TE Shield Terminals TB4 TB4 TB4 TE TE TE TB1 TB1 TB1 Location TB1 Frames B, C TB1 Location Frame D Frame E R,S,T TB1 Location +,– TB4 TB4 TB4 TE TE TE TB1 Brake Terminals TB1 Location TB1 PE Ground Frame F Frame G TB1 Location TB1 PE Ground Frame H 1.
B1 Frame 200-240V, 5.5 kW (7.5 HP) Terminal Designations 380-480/500-600V, 11 kW (15 HP) Terminal Designations PE PE R DC DC (L1) + Dynamic Brake S (L2) T (L3) U (T1) V (T2) W (T3) To Motor To Motor Required1 Input Fusing 1 Required Branch Circuit Disconnect AC Input Line Common Bus Connection 200-240V, 7.
200-240V, 15-22 kW (20-30 HP) Terminal Designations 380-480V, 30-45 kW (40-60 HP) Terminal Designations 500-600V, 18.
200-240V, 56-75 kW (75-100 HP) Terminal Designations 380-480V, 112-187 kW (150-250 HP) Terminal Designations 500-600V, 112-224 kW (150-300 HP) Terminal Designations EFrame TE +DC -DC BUS PE PE R-L1 S-L2 INPUT T-L3 U-M1 To Motor V-M2 W-M3 OUTPUT To Motor Required1 Input Fusing 1 Required Branch Circuit Disconnect AC Input Line 380-480V, 187-336 kW (250-450 HP) Terminal Designations F Frame R-L1 PE T-L3 S-L2 U-M1 Input Fusing (Supplied) V-M2 W-M3 To Motor 1Required Branch Circuit D
380-480V, 522-597 kW (700-800 HP) Terminal Designations 500-600V, 522-597 kW (700-800 HP) Terminal Designations HFrame DC+ Brake S (L2) T (L3) DCBrake R (L1) Required1 Input Fusing U (M1) 1 Required Branch Circuit Disconnect V (M2) W (M3) AC Input Line To Motor R S T U V typical terminal layout (located at top of drive) (located at bottom of drive) W 1 User supplied. Figure I.
I-6 Diagnositics, Troubleshooting, and Start-Up Guidelines
APPENDIX J PMI Regulator Test Points The following figure illustrates the PMI Regulator test points that may be used for diagnostic purposes. Note that this figure is a basic overview only. Refer to the prints, wiring diagrams (W/Ds), and other documentation shipped with your drive system for specfic information.
Figure J.1 shows the test point arrangement on the PMI regulator mother board. CON18 AGND CON9 CON8 CON7 V-W VOLT V-V VOLT V-U VOLT CON16 CON22 Iq AGND CON14 BUS VOLT CON15 Id CON13 BUS CUR CON12 CON19 Iw FB CON17 AGND CON10 AGND CON11 Iu FBK Iv FBK CON20 DGND CON21 DGND P8 P7 P6 PE PE PE Figure J.
INDEX A Accessing the AutoMax rack, 4-1 to 4-2 AutoMax programming executive access levels, H-1 AutoMax rack status of data, G-1 B Basic drive interconnections, 4-3 to 4-4 Bridge test mode, 3-4 to 3-7 bridge test connections, 3-5 power device test locations, 3-6 I/O verification, 4-10 to 4-16 physically inspecting the drive, 4-6 physically inspecting the motor, 4-6 PMI regulator meter ports, 4-16 recommended start-up sequence, 4-4 testing AC Power Modules with power on, 4-8 testing DC Power Modules with p
Installing the motor, 4-3 Interlock register, C-1 to C-3 Interlock tests, 2-3 Internal DC bus diagnostics, 2-7 Introduction, 1-1 to 1-5 Typographical conventions, 1-5 U LED summary (PMI regulator), F-1 to F-2 UDC module drive fault indicators, E-1 to E-2 UDC module meterports, 4-15 UDC/PMI communication status register, 4-10 Unexpected test results, 4-4 Updating drawings and software listings, 4-18 M V MCR output control, 2-5 to 2-6 Meter ports PMI regulator, 4-16 UDC module, 4-15 Minor loop run mode
Rockwell Automation / 24703 Euclid Avenue / Cleveland, Ohio 44117 / (216) 266-7000 Printed in U.S.A.
