Distributed Power System SA500 Drive Diagnostics, Troubleshooting, and Start-Up Guidelines Instruction Manual S-3022-1
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. The thick black bar shown on the outside margin of this page will be used throughout this instruction manual to signify new or revised text or figures.
CONTENTS Chapter 1 Introduction 1.1 Related Publications ........................................................................................ 1-1 1.2 Typographical Conventions ............................................................................. 1-2 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 ........................................ 2-3 2.
Appendix A Drive Fault Register ................................................................................................. A-1 Appendix B Drive Warning Register ............................................................................................ B-1 Appendix C Interlock Register ..................................................................................................... C-1 Appendix D Summary of UDC Module Drive Fault Indicators .....................................................
List of Figures Figure 2.1 – PMI Operating Modes Overview........................................................... 2-2 Figure 3.1 – PMI Operating Modes and Diagnostics ................................................ 3-3 Figure 4.1 – POS and NEG Terminals on the DC Bus Supply .................................
IV SA500 Diagnostics, Troubleshooting, and Start-Up Guidelines
List of Tables Table 1.1 – SA500 Documentation (Binder S-3002) ................................................ 1-1 Table 3.1 – PMI Operating Modes............................................................................ 3-1 Table 4.1 – UDC/PMI Communication Status Register Formats............................ 4-10 Table 4.2 – Rail I/O Register Formats .................................................................... 4-11 Table 4.3 – Feedback Registers and Bits..........................................
VI SA500 Diagnostics, Troubleshooting, and Start-Up Guidelines
CHAPTER 1 Introduction This instruction manual is divided into two sections: 1) a description of SA500 drive diagnostics and troubleshooting, 2) start-up guidelines. This manual is intended for users of SA500 drives who have training and experience in AC drive control and who are familiar with all other SA500 drive documentation.
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.
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.
POWER-UP DIAGNOSTICS IDLE SELECT PMI_RUN@ OR ALN_TST@ CLOSE MCR ALIGN RESOLVER PMI RUN OPEN MCR Figure 2.
2.2 Power-up Diagnostics in the UDC Module and PMI Power-up diagnostics execute in the UDC module in the AutoMax™ rack and in the PMI in the Power Module. 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. If a failure occurs, the OS OK LED will flash rapidly. When power is applied to the Power Module, the PMI performs a series of self-tests.
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. How drive faults and drive warnings are indicated and how they affect the operation of the drive is described in the following sections. 2.4.1 Drive Faults When the PMI detects any of the conditions identified in the Drive Fault register, it will shut down the drive as described below.
2.4.1.2 MCR Output Control The MCR output on the Power Module is used to control an output contactor. This output contactor, sometimes referred to as an M-contactor, disconnects power from the motor. This option is selected during UDC module parameter configuration. If the programmer selects to connect the MCR output to an output contactor, auxiliary contacts from this device must be wired to the AUX IN1/MFDBK input as feedback.
2.4.3 How to Clear the Drive Fault and Drive Warning Registers After a drive fault has been detected, the programmer must do the following before the drive can be restarted: Step 1. Reset the command bit that is currently set in the Drive Control register (100/1100). Step 2. Correct the fault. Step 3. Set and reset the Fault Reset bit (register 100/1100, bit 8, FLT_RST@) to clear the Drive Fault register (200/1200). (Note that the Fault Reset bit is edge sensitive.) Step 4.
CHAPTER 3 PMI Operating Modes The PMI'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's operating modes are shown in figure 3.1 and are described in the following sections. Table 3.
Before the control algorithm(s) can be executed, all of the following conditions must be met: • The interlock tests, register 205/1205, must be passed successfully. See section 2.3. • The M-contactor must be closed, if configured. See section 2.4.1.2. • The UDC task in the AutoMax rack must be running. The status of the UDC task is indicated by the UDC Task Running bit (register 100/1100, bit 15, UDC_RUN@).
• 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. POWER-UP DIAGNOSTICS SECTION 2.2 IDLE SECTION 3.1 SELECT PMI_RUN@ or ALN_TST@ INTERLOCK TESTS OK and PMI_RUN@ OR ALN_TST@ INTERLOCK TESTS FAILED CLOSE MCR SECTION 2.4.1.2 MCR DID NOT CLOSE MCR CLOSED or NOT USED and ALN_TST@ REG 100 BIT 2 and CONFIGURED FOR BRUSHLESS DC MCR CLOSED or NOT USED and PMI_RUN@ REG 100 BIT 0 PMI RUN SECTION 3.
3.3 Alignment Test Mode For SA500 drives controlling brushless DC motors, the resolver shaft and the rotor shaft must be aligned in order to ensure that maximum torque is generated. Therefore, an alignment procedure must be performed before the torque, speed, and position minor loops are executed. The alignment procedure automatically determines the offset required to bring the rotor and the stator fields 90° apart.
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• 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. Refer to the AutoMax Programming Executive instruction manual for more specific information. 4.
4.3 Installing the Motor The 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 most often supplied in its own NEMA 1 enclosure.
4.
Use the procedures that follow to locate any shipping damage to the drive, to verify proper installation and field wiring, and to start the drive. Recommended Start-Up Sequence 1. Physical inspection of equipment 2. Motor checks 3. Preliminary inspection with power off 4. Inspection with power on 5.
Figure 4.
Step 5. Verify the following: a. All connections are in strict conformance to the wiring diagrams. b. There are no loose or broken connections. c. There are no damaged components. Step 6. Repeat the original test that failed. 4.7.2 Recommended Test Equipment Rockwell recommends the following test equipment: • Isolated oscilloscope with a current probe and x100 probe for DC bus measurements. An isolation transformer is needed to isolate the oscilloscope and any other equipment.
4.7.4 Physically Inspecting the Motor Carefully read and understand the instruction manual that describes your motor. Then make the following motor inspection. Refer to section 4.7.1, What to Do After Unexpected Test Results, for more information.: Step 1. Disconnect and lockout all incoming line power and control power to the drive. Step 2. Check that the motor is installed according to the motor’s instruction manual. Step 3. If possible, uncouple the motor from the driven machinery. Step 4.
Step 3. Verify that all drive components have been properly installed and interwired per the instructions provided in the wiring diagrams (W/Ds, W/Es, W/Ls, W/Os, and W/Is). Step 4. Rotate the 1/4 turn cover fasteners securing the Power Module cover. Remove the cover. Inspect the Power Module for cables that may have come loose during shipping. Replace and re-secure the Power Module cover. Step 5. Check for grounds in the magnetic control circuits.
4.7.7 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 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 are exchanging data). The upper byte should be equal to 02xxH (communication between the UDC module and PMI is unsynchronized). Note that “xx” in the byte descriptions indicates “not used.” Step 5. Examine register 89/1089 for the number of messages transmitted by the UDC module.
4.7.7.3 Testing Feedback Registers and Bits This section describes how to test the feedback registers and bits. Feedback information provided by the fault, warning, and interlock registers is described in Appendices A, B, and C. Use the AutoMax Programming Executive software I/O Monitor function to display the registers and bits in the format listed in table 4.3. Table 4.
Step 3. You may want to create a separate monitor screen for registers 206/1206 through 221/1221 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. (Note that registers 210/1210 and 212/1212 are not used.) Step 4.
4.7.7.5 Testing UDC Module Meter Ports This section describes how to test the UDC module meter ports. Use the AutoMax Programming Executive software Monitor Setup UDC/PMI screen. Check each UDC Meter Port being used as follows: Step 1. Map registers that you want to display to UDC meter ports 1, 2, 3, and 4. Set the desired maximum and minimum values. 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.
If the motor does not turn, place a value of zero in register 102/1102 and turn off the drive. Change the Output Rotation parameter. Regenerate the parameter object file and reload it to the rack. Restart the drive. Slowly increase the value in register 102/1102 and verify that the motor is turning. d. If the motor shaft is turning in a counter-clockwise direction and the application requires that a clockwise shaft rotation be identified as “forward” (i.e.
4.7.10 Updated Drawings and Software Listings 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.
Vcc Power Supply Undervoltage Fault The Vcc Power Supply Undervoltage Fault bit is set if the input to the +5V supply on the PMI drops below the necessary voltage to maintain regulation. Bit 3 +H[ 9DOXH + 6XJ 9DU 1DPH )/7B9&&# $FFHVV 5HDG RQO\ 8'& (UURU &RGH /(' 3 0 )/7 Position Error Fault Bit 4 The Position Error Fault bit is set if the position error exceeds the value set in the PMI Tach Loss Maximum Position Error register (register 166/1166).
PMI Bus Fault The PMI Bus Fault bit is set if a problem is detected with the address and data bus on the PMI regulator board in the Power Module Bit 13 +H[ 9DOXH + 6XJ 9DU 1DPH )/7B%86# $FFHVV 5HDG RQO\ 8'& (UURU &RGH /(' 1 $ UDC Run Fault The UDC Run Fault bit is set if the UDC task stops while the minor loop is running in the PMI.
A-4 SA500 Diagnostics, Troubleshooting, and Start-Up Guidelines
APPENDIX B Drive Warning Register 'ULYH :DUQLQJ 5HJLVWHU 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.
Rail Communication Warning Bit 13 The Rail Communication Warning bit is set if a rail communication problem is detected and logged in registers 4, 10, 16, or 22. +H[ 9DOXH + 6XJ 9DU 1DPH :51B5$/# $FFHVV 5HDG RQO\ 8'& (UURU &RGH 1 $ /(' , 2 )/7 CCLK Not Synchronized Warning The CCLK Not Synchronized Warning bit is set if the CCLK counters in the PMI Regulator and the UDC module are momentarily not synchronized. Bit 14 +H[ 9DOXH + 6XJ 9DU 1DPH :51B&/.
APPENDIX C Interlock Register ,QWHUORFN 5HJLVWHU Interlock tests are executed whenever bit 0 or 1 of register 100/1100 is set. The first problem detected will be indicated by the identifying bit in this register. Note that these bits will prevent the vector or brushless minor loop from running.
Rising Edge Required Bit 4 The Rising Edge Required bit is set if a rising edge is required on any command bit in register 100/1100. +H[ 9DOXH + 6XJ 9DU 1DPH ,&B5,6(# $FFHVV 5HDG RQO\ 8'& (UURU &RGH 1 $ /(' 1 $ This bit will be set if the application task has set the Fault Reset bit (register 100/1100, bit 8) but has not cleared and then re-set any command bits.
APPENDIX D 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 E Power Module LED Summary The following table summarizes the LEDs on the SA500 Power Module. Refer to the SA500 Power Modules instruction manual (S-3018) for more information regarding the Power Module. Refer to the SA500 Drive Configuration and Programming instruction manual (S-3044) for more information regarding the UDC module’s dual port registers. Name Description LED PWR OK When lit, all power supply voltages for the PMI are at acceptable operating levels.
Name Description LED RPI When lit, indicates the run permissive input signal has been detected. Related Reg/Bit 201/1201 bit 0 RPI@ RPI Input Status LED MCR When lit, indicates that the MCR output signal is being driven on. LED AUX IN1 When lit, indicates the presence of a 115V signal on this input.
APPENDIX F Status of Data in the AutoMax Rack After a STOP_ALL Command or STOP_ALL Fault AutoMax Processor PMI Processor UDC Module 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 I/O variables (including UDC dual port memory) inputs retained and updated; outputs are reset to 0 see below? all I/O is reset to 0 Input values, including: Feedback registers UDC/PMI commu
F-2 SA500 Diagnostics, Troubleshooting, and Start-Up Guidelines
APPENDIX G 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
G-2 SA500 Diagnostics, Troubleshooting, and Start-Up Guidelines
INDEX A Accessing the AutoMax rack, 4-1 to 4-2 Alignment test mode, 3-4 AutoMax programming executive access levels, G-1 AutoMax rack status of data, F-1 D DC bus supply POS and NEG terminals, 4-6 Definition of terms, 2-1 Diagnostics and troubleshooting, 2-1 to 2-6 Documentation, 1-1 Drive fault register, A-1 to A-3 Drive inspection and start-up guidelines, 4-4 to 4-16 checking installation with power off, 4-8 to 4-9 dynamic motor tests, 4-15 I/O verification, 4-10 physically inspecting the drive, 4-7 phys
U W UDC module drive fault indicators, D-1 to D-2 meterports, 4-14 UDC/PMI communication status register, 4-10 Updating drawings and software listings, 4-16 Warnings, 2-5 to 2-6, B-1 to B-2 clearing drive warnings, 2-6 Wiring the Power Module, 4-3 Index-2 SA500 Diagnostics, Troubleshooting, and Startup Guidelines
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