Distributed Power System SA3100 Diagnostics ......Distributed Power System SA3100 Diagnostics,...

Distributed Power SystemSA3100 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:

Important: Identifies information that is critical for successful application and understanding of the product.

!ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.

!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: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 and then check the voltage with a voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:Only qualified Rockwell personnel or other trained personnel who understand the potential hazards involved may make modifications to the regulator configuration, variable configuration, and application tasks. Any modifications may result in uncontrolled machine operation. Failure to observe these precautions could result in damage to equipment and bodily injury.

ATTENTION:The user must provide an external, hardwired stop circuit outside of the drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled machine operation may result if this procedure is not followed. Failure to observe this precaution could result in bodily injury.

ATTENTION:Registers and bits in the UDC module that are described as “read only” or for “system use only” must not be written to by the user. Writing to these registers and bits may result in improper system operation. Failure to observe this precaution could result in bodily injury.

ATTENTION:Connecting or disconnecting a regulator board may result in unexpected machine motion. Turn off power to the drive before replacing a circuit board or its connecting cables. Failure to observe these precautions could result in bodily injury.

ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION:The circuit boards of the PMI regulator contain static-sensitive components. Do not touch the boards or their connectors. When not installed, circuit boards should be stored in anti-static bags. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

The information in this user’s manual is subject to change without notice.

Ethernet™ is a trademark of Xerox Corporation.Windows™ is a trademark of Microsoft Corporation.AutoMax™ is a trademark of Rockwell Automation.

©1998 Rockwell International Corporation

CONTENTS

Chapter 1 Introduction1.1 Related Publications........................................................................................ 1-11.2 Typographical Conventions ............................................................................. 1-5

Chapter 2 Diagnostics and Troubleshooting2.1 Definition of Terms Used in Diagnostics and Troubleshooting........................ 2-12.2 Power-up Diagnostics in the UDC Module and PMI Regulator ....................... 2-32.3 Interlock Tests ................................................................................................. 2-32.4 Run-time Diagnostics ...................................................................................... 2-4

2.4.1 Drive Faults ........................................................................................... 2-42.4.1.1 How the System Reacts to Drive Faults ................................. 2-42.4.1.2 MCR Output Control ............................................................... 2-5

2.4.2 Drive Warnings...................................................................................... 2-62.4.3 How to Clear the Drive Fault and Drive Warning Registers .................. 2-6

2.5 Internal DC Bus Diagnostics............................................................................ 2-72.5.1 DC Bus Monitoring During Bridge Test Mode ....................................... 2-72.5.2 DC Bus Monitoring During Torque Minor Loop Mode ........................... 2-7

Chapter 3 PMI Regulator Operating Modes3.1 Idle Mode......................................................................................................... 3-43.2 Bridge Test Mode ............................................................................................ 3-43.3 PMI Tuning Mode (Automatic Gain Calculation) ............................................. 3-83.4 Run Mode ........................................................................................................ 3-8

Chapter 4 Installation and Start-Up Guidelines4.1 Using the AutoMax Programming Executive to Access the Rack ................... 4-14.2 Environmental Requirements .......................................................................... 4-24.3 Installing the Motor .......................................................................................... 4-34.4 Installing the Drive ........................................................................................... 4-3

4.4.1 Enclosed Drives ................................................................................... 4-34.4.2 Open Chassis Drives............................................................................. 4-3

4.5 Wiring the Drive ............................................................................................... 4-34.6 Basic Drive Interconnections ........................................................................... 4-34.7 Drive Inspection and Start-up Guidelines ........................................................ 4-4

4.7.1 What To Do After Unexpected Test Results ......................................... 4-44.7.2 Recommended Test Equipment............................................................ 4-54.7.3 Physically Inspecting the Drive.............................................................. 4-64.7.4 Physically Inspecting the Motor............................................................. 4-64.7.5 Checking the Installation with Power Off............................................... 4-64.7.6 Testing AC Input Power Modules with AC Power On ........................... 4-84.7.7 Testing DC Bus Supplies and DC Input Power Modules ...................... 4-9

4.7.7.1 Checking the DC Bus Supply.................................................. 4-94.7.7.2 Testing DC Input Power Modules with DC Power On............. 4-9

Table of Contents I

4.7.8 I/O Verification .....................................................................................4-104.7.8.1 Testing UDC/PMI Regulator Communication Status.............4-104.7.8.2 Testing Flex I/O Registers .....................................................4-114.7.8.3 Testing Feedback Registers and Bits....................................4-144.7.8.4 Testing the UDC Module Test Switch Register .....................4-154.7.8.5 Testing UDC Module Meter Ports..........................................4-154.7.8.6 Testing PMI Regulator Meter Ports .......................................4-16

4.7.9 Performing Uncoupled Motor Tests (Vector) .......................................4-164.7.10Running Dynamic Motor Tests ............................................................4-174.7.11Updated Drawings and Software Listings (Vector) ..............................4-18

Appendix A Drive Fault Register ............................................................................................... A-1

Appendix B Drive Warning Register ......................................................................................... B-1

Appendix C Interlock Register ................................................................................................... C-1

Appendix D Diagnostic Fault Code Register ............................................................................ D-1

Appendix E Summary of UDC Module Drive Fault Indicators ................................................ E-1

Appendix F PMI Regulator LED Summary ............................................................................... F-1

Appendix G Status of Data in the AutoMax Rack After a STOP_ALL Command or STOP_ALL Fault ................................................................................................G-1

Appendix H AutoMax Programming Executive Access Levels .............................................. H-1

Appendix I Terminal Block Locations and Test Points............................................................I-1

Appendix J PMI Regulator Test Points......................................................................................J-1

II Diagnostics, Troubleshooting, and Start-Up Guidelines

List of Figures

Figure 2.1 – PMI Regulator Operating Modes Overview.......................................... 2-2Figure 3.1 – PMI Regulator Operating Modes and Diagnostics ............................... 3-2Figure 3.2 – Internal DC Bus Control Flowchart ....................................................... 3-3Figure 3.3 – Power Device Test Locations ............................................................... 3-6Figure I.1 – Terminal Block Locations ....................................................................... I-1Figure I.2 – Terminal Block TB1 (B Frame Drives).................................................... I-2Figure I.3 – Terminal Block TB1 (C and D Frame Drives) ......................................... I-3Figure I.4 – Terminal Block TB1 (E, F, and G Frame Drives).................................... I-4Figure I.5 – Terminal Block TB1 (H Frame Drives).................................................... I-5Figure J.1 – PMI Regulator Mother Board - Test Points........................................... J-2

Table of Contents III

IV Diagnostics, Troubleshooting, and Start-Up Guidelines

List of Tables

Table 1.1 – SA3100 Documentation (Binder S-3053) .............................................. 1-1Table 1.2 – SA3100 Power Structure Service Manual Cross Reference ................. 1-2Table 3.1 – PMI Regulator Operating Modes ........................................................... 3-1Table 3.2 – Bridge Test Connections ....................................................................... 3-5Table 4.1 – UDC/PMI Regulator Communication Status Register Formats ........... 4-10Table 4.2 – Flex I/O Register Formats.................................................................... 4-11Table 4.3 – Analog Data Format............................................................................. 4-13Table 4.4 – Feedback Registers and Bits............................................................... 4-14Table A.1 – Effect of a Disconnected Fiber-Optic Cable ..........................................A-4

Table of Contents V

VI Diagnostics, Troubleshooting, and Start-Up Guidelines

CHAPTER 1Introduction

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.

The diagnostics and troubleshooting chapters (chapters 2-3) describe the error checking built into the PMI Regulator operating system and how to use warning and fault registers, LEDs, and the error log to diagnose drive problems.

Chapter 4 provides guidelines on starting up SA3100 AC drives. Although initial start-up services are usually provided by Rockwell personnel, it is recommended that the user become familiar with the general guidelines in this chapter in order to be better prepared to work with the Rockwell service engineer.

1.1 Related PublicationsThe user must become familiar with the other instruction manuals that describe the SA3100 drive system. The documentation that describes the SA3100 drive is contained in binder S-3053 and is listed in table 1.1.

Table 1.1 – SA3100 Documentation (Binder S-3053)

Document Document Part Number

Drive System Overview S-3005

Universal Drive Controller Module S-3007

Fiber Optic Cabling S-3009

SA3100 Drive Configuration & Programming S-3056

SA3100 PMI Regulator S-3057

SA3100 Power Modules S-3058

SA3100 Diagnostics, Troubleshooting, & Start-Up Guidelines

S-3059

Information Guide S-3054

Introduction 1-1

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 BusInput Voltage Nominal HP Frame Size

Use Service Manual

1336 Force-

200 VAC -

240 VAC[A]

310 VDC[Q]

001

B 6.11

003

007

010

015

020

C 6.12025

030

040

D 6.13050

060

075

E 6.14100

125

1-2 Diagnostics, Troubleshooting, and Start-Up Guidelines

380 VAC -

480 VAC[B]

513 VDC-

620 VDC[R]

001

B 6.11

003

007

010

015

020

025

030

040C 6.12

050

060

D 6.13075

100

125

150

E 6.14200

250

300

F 6.16350

400

450

G 6.15500

600

800 H 6.15


AC Input Voltage


Use Service Manual

1336 Force-

Introduction 1-3

Other related documents that you should refer to include the following:

• AutoMax Programming Executive Instruction Manual Version 3.5A or later

• Installing, Operating, and Maintaining Engineered Drive Systems (D2-3115)

Additional information about using the SA3100 drive is found in the wiring diagrams, prints, and other documentation shipped with each drive system. Always consult the prints shipped with your drive system for specific information about installing, operating, and maintaining your drive.

500 VAC -

600 VAC[C]

675 VDC-

800 VDC[W]

1

B 6.11

3

7.5

10

15

20

25

C 6.1230

40

50

60

75

D 6.13100

125

150

E 6.14200

250

300

350F 6.16

400

450

G 6.15500

600

650

800 H 6.15


AC Input Voltage


Use Service Manual

1336 Force-


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. The drive A register number is shown first followed by the drive B register number (A/B).

Example: Drive Fault register (202/1202)

• Bit names

Individual bit names are shown with the initial letters capitalized. Also shown, in parentheses, is the bit’s register number, bit number, and suggested variable name.

Example: Fault Reset bit (register 100/1100, bit 8, FLT_RST@ )

• Parameter entry screen titles

Parameter entry screen titles and the parameters themselves are shown with the initial letters capitalized.

Example: Feedback Data parameter entry screen

Introduction 1-5


CHAPTER 2Diagnostics andTroubleshooting

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. This chapter also describes how the system reacts if an error is detected.

There are a number of control modes that can be selected by the user for PMI Regulator operation. An overview of these modes is shown in figure 2.1. The Distributed Power System provides diagnostics at each level of operation as shown in figure 3.1.

Use these figures as a reference to quickly identify the system's requirements for entering and operating in each mode. These figures also refer to specific sections in the manual that provide additional information.

2.1 Definition of Terms Used in Diagnostics and TroubleshootingFor the purpose of describing diagnostics and troubleshooting, this instruction manual will use specific terms to refer to the types of errors that can be detected by the PMI Regulator and the response of the PMI Regulator and UDC module to those errors.

A diagnostic is a software routine specifically designed to check for error conditions. There are three types of diagnostics in SA3100 drives: power-up diagnostics, interlock diagnostics, and run-time diagnostics.

A drive fault is an error specifically checked for by the PMI Regulator operating system that will shut the drive down. Faults are reported in the Drive Fault register (202/1202) of the UDC module and in the error log for the UDC task in which the fault occurred.

A drive shut-down occurs when any fault reported in the Drive register (202/1202) occurs.

A drive warning is an error specifically checked for by the PMI Regulator operating system that indicates the drive is not operating in an optimum manner. Drive warnings will not shut the drive down.

An error is any condition other than the desired condition.

Interlock diagnostics are those diagnostics performed by the PMI Regulator operating system in response to a drive control request from the programmer, e.g., TRQ_RUN@, in register 100/1100 of the UDC module dual port memory.

Power-up diagnostics consist of the initial tests for basic functionality performed by all printed circuit board modules.

Diagnostics and Troubleshooting 2-1

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.

Figure 2.1 – PMI Regulator Operating Modes Overview

Power On

Idle

Select PMI_RUN@,BRG_TST@,or PMI_TUN@

Close MCR

PMI Tuning

Minor Loop Run Bridge Test

Bus Missing Bus Missing

Open MCR Open MCR

Interlock Tests


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. When all of the tests are successfully completed, the PMI Regulator’s OK LED will turn on. If the PMI Regulator does not pass these tests, it must be replaced.

The AC Power Technology circuitry on the PMI Regulator then performs a series of calibration and self-diagnostic tests. When these tests are successfully completed, the DRV RDY LED will turn on. If a failure occurs refer to the description of register 222/1222 in the Drive Configuration and Programming instruction manual (S-3056) for help in identifying the test that failed.

After all of the power-up tests are passed, the PMI Regulator requests the appropriate operating system from the UDC module. The UDC module downloads the operating system and the parameter configuration data to the PMI Regulator. The PMI Regulator then runs under the control of its operating system and begins performing the run-time diagnostics. Run-time diagnostics are described in section 2.4.

2.3 Interlock Tests

Interlock tests are performed by the PMI Regulator whenever one of the PMI Regulator's operating modes is selected by the programmer through the Drive Control register (100/1100). These diagnostics verify that all conditions required for the operating mode selected are satisfied. If the interlock tests are completed successfully, then the operating mode requested by the programmer can be entered. If any of the interlock diagnostics fails, the PMI Regulator will latch a bit in the Interlock register (205/1205) corresponding to the first diagnostic test that failed, and the requested operating mode will not be entered (i.e., the PMI Regulator will remain in the idle mode).

If an interlock test failure occurs, follow the procedure below:

Step 1. Reset the command bit that is currently set in the Drive Control register (100/1100).

Step 2. Correct the condition that caused the test failure.

Step 3. Set the desired command bit in the Drive Control register (100/1100).

The PMI Regulator will perform the interlock tests each time a rising edge is detected on the command bits. The results of subsequent interlock tests will overwrite the previous test’s results.


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. 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 Regulator detects any of the conditions described in the Drive Fault register, it will shut down the drive. To determine the cause of a drive shutdown, the following indicators are provided:

• Drive Fault register (202/1202)

The PMI Regulator will set a bit in the Drive Fault register to indicate the condition that caused the shutdown. The interlock tests check this register for fault conditions that have occurred. Refer to Appendix A for a complete description of the Drive Fault Register.

• Drive Status Register (200/1200)

The PMI Regulator will set the Fault Detected bit (bit 8, FLT@) of the Drive Status register when a drive fault has been detected.

• LEDs on the UDC module

If either DRV FLT A or DRV FLT B is on, a drive fault has been detected for the drive using that communication channel.

• LEDs on the PMI Regulator

The PMI Regulator contains a status/fault LED board. Refer to Appendix E for LED definitions.

• Error log for the UDC task

The error log for the task in which the fault occurred is accessed through the ON LINE menu of the AutoMax Programming Executive. A list of the drive fault error codes can be found in Appendix D. Refer to appropriate AutoMax Programming Executive instruction manual for more information regarding the Programming Executive and the ON LINE menu.

2.4.1.1 How the System Reacts to Drive Faults

As described in section 2.4.1, if the PMI Regulator detects any of the conditions described in the Drive Fault register, it will shut down the drive. This means that the PMI Regulator responds by disabling the gates of the power devices, causing the motor to begin a coast to stop. When the PMI Regulator detects that current is less


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.

If any of the following faults are detected by the PMI Regulator, it will disable the gates immediately and set the corresponding bit in the Drive Fault register (202/1202):

• DC Bus Overvoltage Fault (Bit 0)

• DC Bus Overcurrent Fault (Bit 1)

• Ground Current Fault (Bit 2)

• Instantaneous Overcurrent Fault (Bit 3)

• Power Supply Fault (Bit 4)

• Charge Bus Time-Out Fault (Bit 6)

• Over Temperature Fault (Bit 7)

• Resolver Broken Wire Fault (Bit 8)

• Resolver Fault (Bit 9)

• Overspeed Fault (Bit 10)

• Power Technology Fault (Bit 11)

• PMI Regulator Bus Fault (Bit 13)

• UDC Run Fault (Bit 14)

• Communications Lost Fault (15)

The PMI operating system will then take over turning off the MCR output as described above.

2.4.1.2 MCR Output Control

The MCR output on the PMI Regulator’s Resolver & Drive I/O board is used to control an optional M-contactor to turn off power to the motor. This option is selected during UDC module parameter configuration. If the programmer chooses to connect the MCR output to an M-contactor, contacts from this device must be wired to the AUX IN1/MFDBK input as feedback. The PMI operating system will wait for AUX IN1/MFDBK to turn on before executing any operating mode.

The Run Permissive input (RPI) on the Resolver & Drive I/O board and the MCR output are interlocked in hardware. The MCR output can be turned on only when the RPI is asserted. The MCR output itself is under the control of the PMI Regulator. Application tasks have no direct control of the MCR output. RPI is controlled by the user. When RPI is off, MCR cannot be activated.

!ATTENTION:The UDC task is not stopped automatically when a drive fault occurs. The user must ensure that the application tasks test the Drive Fault register (202/1202) and take the appropriate action if a fault is detected.


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.

In addition, if the RPI signal is removed, the MCR output and gate power will be removed under hardware control within approximately 0.5 seconds of the removal of the RPI signal to provide an additional interlock. This is done regardless of the actions taken by the PMI.

2.4.2 Drive Warnings

The PMI Regulator will check for conditions that are not serious enough to shut down the drive, but may affect its performance. If the PMI Regulator detects any of the conditions described in the Drive Warning register, it will set the appropriate bit but will NOT shut down the drive. The user must ensure that the application task tests the Drive Warning register (203/1203) and takes any appropriate action if a warning condition is detected.

The PMI Regulator will also set the Warning Detected bit (register 200/1200, bit 9, WRN@) when a drive warning has been detected.

Appendix B provides a complete description of the Drive Warning register. Except for I/O faults, drive warnings are not indicated by LEDs (an I/O fault will turn on the I/O FLT LED on the PMI Regulator). Drive warnings are not displayed in the UDC task’s error log.

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. Set the desired command bit in the Drive Control register (100/1100).

After a drive warning has been detected, the programmer can clear the entire Drive Warning register by setting and resetting the Warning Reset bit (register 100/1100, bit 9, WRN_RST@). (Note that the Warning Reset bit is edge sensitive.)


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. A complete description of the DC bus pre-charge sequence is provided in the SA3100 Power Modules instruction manual (S-3058). For further details regarding a DC bus fault, see the extended status register 222 (1222).

2.5.1 DC Bus Monitoring During Bridge Test Mode

If bus voltage drops below the value stored in the undervoltage warning threshold tunable (UVT_E0%) while the PMI Regulator is in bridge test mode, the PMI Regulator will issue a drive warning (203/1203, bit 1, WRN_UV@). If bus voltage continues to drop below the value stored in the power loss fault threshold local tunable (PLT_E0%), the pre-charge contactor will open. While the pre-charge contactor is open, the gates are disabled, and the bridge test is not functional.

If bus voltage does not return to the proper level within 10 seconds, a Bus Charge Time-out fault (register 202/1202, bit 6, FLT_CHG@) will occur, and the drive will shut down. If bus voltage returns to the proper level within 10 seconds, the bridge test will return to normal operation.

2.5.2 DC Bus Monitoring During Torque Minor Loop Mode

If bus voltage drops below the value stored in the undervoltage warning threshold tunable (UVT_E0%) while the PMI Regulator is in torque minor loop mode, the PMI Regulator will limit torque in order to avoid further drop in DC bus voltage and issue a drive warning (203/1203, bit 1, WRN_UV@). If bus voltage continues to drop below the value stored in the power loss fault threshold local tunable (PLT_E0%), the pre-charge contactor will open. While the pre-charge contactor is open, the gates of the power devices are disabled, and the motor will begin to coast to stop.

If bus voltage returns to the nominal configured value within 10 seconds of the bus voltage dropping to less than the value stored in the power loss fault threshold local tunable, the pre-charge contactor will automatically close and the PMI Regulator will return to using the torque reference currently being requested by the UDC. If bus voltage does not return to the nominal configured value within 10 seconds, a Bus Charge Time-out fault (register 202/1202, bit 6, FLT_CHG@) will occur, and the drive will shut down.



CHAPTER 3PMI 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 3.1 – PMI Regulator Operating Modes

OperatingMode

Drive ControlRegister Bit Mode Description

Idle N/A The PMI Regulator’s default operating mode during which no algorithms are running.

Enable PMI Run 0 Executes the control algorithms.

Enable Tuning 1 Calculates gain values for the control algorithm.

Bridge Test Enable

2 Performs a test to verify gate cable connections and power devices.

PMI Regulator Operating Modes 3-1

Figure 3.1 – PMI Regulator Operating Modes and Diagnostics

Bus Ready

Idle

Select PMI_RUN@,BRG_TST@, or PMI_TUN@

Close MCR

PMI Tuning

Minor Loop Run Bridge Test

Bus Missing

Interlock Tests Failed

Pre-Charge Contactor

Power-Up Diagnostics

Section 2.2

BUS_ENA@ Reg 100 Bit 4 On

I/M S-3058

Vdc > UVT_E0% + Steady State Conditionand

Section 3.1

Section 3.3

Interlock Tests OKandPMI_TUN@ Reg 100 Bit 1 On Tuning Complete Reg 200 Bit 1 On

Section 2.4.1.2

Interlock Tests OK

MCR Closed Reg 201 Bit 1andPMI_RUN@ Reg 100 Bit 0

MCR Closed Reg 201 Bit 1andBRG_TST@ Reg 100 Bit 2

Section 3.4 Section 3.2

Vdc < PLT_E0%

Charge Bus TimeoutFault Reg 202 Bit 6

Bus OK

Open MCRSection 2.4.1.2

Open MCRSection 2.4.1.2

Bus OK

Charge Bus TimeoutFault Reg 202 Bit 6

Exit if Reg 100 Bit 1 OfforFault Reg 202 Any BitorRPI Missing Reg 201 Bit 0 Off

Exit if Reg 100 Bit 0 OfforFault Reg 202 Any BitorRPI Missing Reg 201 Bit 0 Off

Pre-Charge Contactor Closed

Bus MissingVdc < PLT_E0%


Figure 3.2 – Internal DC Bus Control Flowchart

Idle

Wait for Bus toCharge

Nominal BusVoltage

Reached?

Open Pre-ChargeContactor

AuxiliaryContactsClosed?

PMI SetsBUS_RDY@

Bus Charged

PMI ClosesPre-ChargeContactor

More than 10SecondsElapsed?

Fault OccursRegister 202/1202


Open Pre-ChargeContactor

FaultOccurs?

No

Wait for AC Line

AC Line StatusFrom Power Module

= TRUE


Yes

No

CommonBus or Hi HPStand-Alone

?

Yes

Hi HPStand-Alone

?

BUS_ENA@ On*Begin 10 SecondTimer

**

**

**

**

**

**

*BUS_ENA@ must transistion from off to on to start the buscharging process.

**BUS_ENA@ must remain on during the drive operation

NoHi HP

?

No

No

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

No


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. If any of the Interlock tests fails or if any fault is latched in the Drive Fault register (202/1202), the PMI Regulator will remain in the idle mode.

The PMI Regulator will return to the idle mode when it exits any of the other operating modes.

3.2 Bridge Test Mode

The bridge test mode is used to verify that the power devices in the Power Module work correctly. Enabling this test turns on the power devices one at a time in a user-specified pattern. The operator can then measure the voltages produced across the devices. Note that this test is normally performed at the factory and does not need to be performed by the user unless one or more power devices have been replaced. If required, this test should be performed before enabling any other mode of the PMI Regulator, such as torque minor loop run.

Follow the steps below to perform the bridge test:

Step 1. Stop the drive if it is running. Turn off and lock out input power.

Step 2. Wait five minutes to allow the DC bus voltage to dissipate.

Step 3. Open the Power Module’s cabinet door or chassis cover.

Step 4. Measure the DC bus potential with a voltmeter before working on the drive.

Measure the voltage at the DC bus test points as shown in figure 4.1. When the DC bus potential is down to less than 5 volts, touch a 50 ohm, 50 watt or larger resistor between the test points for 20 seconds. This allows any remaining DC bus voltage to dissipate.

Remove the resistor and re-measure the DC bus potential, which should now be at 0V.

Step 5. This step and the following steps assume that your installation includes a terminal block between the Power Module and the motor. Disconnect the motor leads from the terminal block to which they are connected.

!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 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.


If the Power Module and the motor are connected through one set of leads, disconnect the motor leads from the Power Module. You will need to connect the voltmeter directly to the phase U, V, and W outputs of the Power Module.

Step 6. Use table 3.2 to determine the devices to be tested and to identify where to connect the voltmeter. See figure 3.2. Set the voltmeter to the 1000V scale.

!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.

!ATTENTION:The remaining steps are performed with power on. Exercise extreme caution as hazardous voltages exist. Failure to observe this precaution could result in severe bodily injury or loss of life.

Table 3.2 – Bridge Test Connections

Power Device PairBeing Tested1

1. It is not necessary to measure all the power device pairs. All possible combinations can be tested by testing either pairs 1 through 4 or 3 through 6.

Bridge Test Code Register (105/1105)

Value2

2. With the bridge test enabled, enter successive values into register 105/1105 to test different device pairs without re-enabling the bridge test.

Voltmeter Connectionfor +VDC3

3. With the bridge test enabled, approximately the nominal bus voltage should be measured across each pair.

1. U upperV lower

11H U(+)V(–)

2. U lowerW upper

0CH U(–)W(+)

3. U upperW lower

21H U(+)W(–)

4. U lowerV upper

0AH U(–)V(+)

5. V upperW lower

22H V(+)W(–)

6. V lowerW upper

24H V(–)W(+)


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. The value corresponds to a bit pattern, with the bits described as follows:

• Bit 0: Phase U Upper Power Device

• Bit 1:Phase V Upper Power Device

• Bit 2:Phase W Upper Power Device

• Bit 3:Phase U Lower Power Device

• Bit 4:Phase V Lower Power Device

• Bit 5:Phase W Lower Power Device

a. Connect the voltmeter to the output terminals U, V, W for the power devices being tested in accordance with table 3.2.

b. Turn on power to the drive.

c. Clear the Bridge Test Code register (105/1105, TST_CODE%).

Figure 3.3 – Power Device Test Locations

Left Middle Right

U

V

W

Upper

Lower

DCBus

+

–

GateDriver

GateDriver

GateDriver


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. Set the Bridge Test Enable bit (bit 2 in register 100/100, BRG_TST@ ). The bridge test will remain enabled until the bit is reset by the programmer, a fault is detected, or the RPI input is turned off.

g. Enter the proper power device value into register 105/1105, TST_CODE%.

Step 8. The voltmeter should read approximately nominal bus voltage for each power device pair. After testing one pair, turn off power to the drive. Wait five minutes to allow the DC bus voltage to dissipate. Repeat step 4. Select another power device pair and repeat step 7. Test the third power device pair in the same manner.

Step 9. If all the power device pairs have been tested successfully, and no faults have occurred, the test is complete. Reset the Bridge Test Enable bit.

If testing a power device pair results in 0 or nearly 0V, both devices have failed. In this case, replace the two power devices.

If the test results in more than 0V, but significantly less than nominal bus voltage, one of the two devices in the pair has failed. If testing a power device pair causes an instantaneous overcurrent fault or a bus overcurrent fault (reported in register 202/1202) then a power device has shorted. Note that you must set the Bridge Test Enable bit again to test any other device pairs.

If one pair fails the test, you must test a second pair to determine which IGBT module to replace. The second test should include one of the two devices in the pair that failed. If this second pair fails the test, then the IGBT module containing the device that the two pairs have in common should be replaced. If this second pair passes the test, IGBT module containing the device that the two pairs do not have in common should be replaced.

For example, if pair 1 in the table (U upper and V lower) fails the test, you could test pair 3 in the table (U upper and W lower) to determine which IGBT module should be replaced. If pair 3 fails, replace the IGBT module switching phase U. If pair 3 passes the test, then the problem is in the IGBT module switching phase V.

Refer to the appropriate service manual, as listed in table 1.2, for instructions on replacing an IGBT module. After replacing the IGBT module, repeat this entire procedure beginning at step 1.

Step 10. With the test completed, reconnect the motor to the Power Module output. Close and secure the Power Module’s cabinet door or chassis cover.


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.

In order for the PMI Regulator to perform these calculations, the interlock tests described in section 2.3 must have passed successfully.

For the Volts per Hertz regulator, you can tune the characteristic curve by running the motor unloaded and monitoring motor current when going through the frequency range of interest. The curve should be modified to avoid excessive current consumption/transients when going through the frequency range of interest.

When the PMI Regulator has completed the calculations (a process that takes less than one second), it will set the Automatic Tuning Complete bit (register 200/1200, bit 1, PMI_ATC@). The PMI Regulator will then return to the idle mode. Turn the Automatic Tuning Complete bit off.

3.4 Run Mode

Before executing the run mode, perform the automatic gain calculation procedure (PMI tuning mode) as described in section 3.3. These gain values are used in the control algorithms. If the gain values are not calculated immediately before entering run mode, the motor may not run properly. Note that the Interlock tests do not check the gain values.

To execute the run mode, the programmer sets the Enable PMI Loop bit (register 100/1100, bit 0, PMI_RUN@ ). Before the run mode can be executed, all of the following conditions are required:

1. The Interlock tests (described in section 2.3) must be passed successfully.

2. If configured, the M-contactor must be closed (refer to section 2.4.1.2).

3. The DC bus must be ready (see section 2.5).

4. 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@).

If any of these requirements is not met or if a fault is latched in the Drive Fault register (202/1202), the PMI Regulator will remain in the idle mode.

If these requirements are met, the PMI Regulator will execute the run command. At this time, the PMI Regulator will set bit 0 in register 200/1200 to indicate the run mode is active.


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.



CHAPTER 4Installation and Start-Up

Guidelines

This section describes general guidelines that should be followed when verifying the correct installation of the drive hardware and in performing the drive start-up. For more information regarding installation guidelines, refer to instruction manual D2-3115 (Installing, Operating, and Maintaining Engineered Drive Systems).

As part of the start-up procedure, the AutoMax Programming Executive software is used to verify the status of drive I/O and to make drive adjustments. Section 4.1 describes some of the restrictions imposed by the AutoMax Programming Executive software.

4.1 Using the AutoMax Programming Executive to Access the Rack

The AutoMax Programming Executive enables four users to access and work in the same rack simultaneously. However, certain restrictions exist when more than one user is working in a rack.

• The maximum number of users is four (4) per rack (one user connected directly to the rack and three users connected via the DCS/AutoMax Network, or four users connected via the DCS/AutoMax Network).

• Data access is required for the user to Set/Force COMMON variables. All users must assure that variable values are not written over by other users working in the rack.

• Task access is required for the user to load a single task and to Set/Tune/Force LOCAL variables in a task. Only one user will be granted Task access for each task in the rack.

• Rack access is required to load the rack configuration and to load all application tasks (AutoMax tasks and UDC tasks).


ATTENTION:The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

Installation and Start-Up Guidelines 4-1

• 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. Refer to the AutoMax Programming Executive instruction manual for more specific information.

4.2 Environmental Requirements

The installation must meet the following requirements:

Ambient Temperature

• Open chassis: 0 to 50° C (32 to 122° F)Enclosed chassis: 0 to 40° C (32 to 104° F)

Cooling

• Air for cooling must be of sufficient quality and flow to avoid recycling the heated exhaust air back into the drive air inlets.

Relative humidity

• 5 - 95%, non-condensing

Altitude

• 1000 meters (3300 feet) above sea level.Higher altitudes require derating.

Air Quality

• CleanNo flammable vapors, chemical fumes, or oil vapor.

Clearances

• Must allow access to the equipment within the cabinets for inspection, maintenance, and replacement.

• Must provide non-restricted air flow to and from the intake and exhaust openings.

See the SA3100 Power Modules instruction manual (S-3058) for more detailed information about installation requirements.


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.

4.4.1 Enclosed Drives

The drive is force ventilated by means of its own internal cooling fan(s). Air is drawn into the enclosure through slots in the cabinet bottom and in the lower portion of the cabinet sides. Air is forced out through internally shielded slots near the top of the cabinet sides. Air intake and exhaust openings are unfiltered.

4.4.2 Open Chassis Drives

Where mounting of an open chassis drive within a user-supplied enclosure is desired, the user is responsible for ensuring that the maximum temperature within the enclosure remains at or below the rated ambient temperature under worst-case operating conditions. Note that the same fan-cooling as described in the previous section will be provided for the drive.

4.5 Wiring the Drive

Make certain that the input power to the drive is of the correct voltage and sufficient amperage to support the drive’s input current requirements. Note that input power current values must be less than the drive's maximum RMS fault current rating. Refer to the drive chassis and motor nameplates for correct current ratings and input power information.

4.6 Basic Drive Interconnections

The SA3100 drive requires interconnecting wiring per applicable codes between the drive and the following: input power, the motor, the operator’s control station (if used), the resolver, and earth ground.

!ATTENTION:If your drive cabinet is mounted in such a way that the cabinet itself is not grounded, a ground wire must be connected to the drive cabinet to provide safety for personnel. Also the motor frame should be grounded by solidly connecting a ground wire to a screw in the conduit box. Failure to observe these precautions could result in severe bodily injury or loss of life.

ATTENTION:The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.


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.

Unless a standard pre-built fiber-optic cable was included with your system, the fiber-optic cabling that links the UDC module(s) in the AutoMax rack with the PMI Regulator must be installed by someone experienced in installing fiber-optic cables. Unless you have in-house expertise in installing fiber-optic cable, it is recommended that you contact an experienced contractor to perform the installation. Information regarding the selection and installation of fiber-optic cabling is contained in the Distributed Power System Fiber-Optic Cabling instruction manual (S-3009).

4.7 Drive Inspection and Start-up Guidelines

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. I/O verification

Before attempting to perform this start-up procedure, you should be familiar with the general arrangement and function of the drive equipment and should verify that it has been installed and wired as described in the following documents, which are included in the Instruction Book provided with your drive system: Wiring Diagrams (W/Ds), Elementary Diagrams (W/Es), Panel Layout Diagrams (W/Ls), Operator's Station Diagrams (W/Os), and Interconnection Diagrams (W/Is) (if supplied).

4.7.1 What To Do After Unexpected Test Results

Note that if it is not possible to obtain the correct meter reading or proper operation during any of the checks or adjustment procedures described, perform the following steps:

Step 1. Stop the drive.


ATTENTION:This equipment is at line voltage when AC power is connected to the drive. Whenever power is removed, verify with a voltmeter that the DC bus capacitors are discharged before touching any internal parts of the drive. Failure to observe this precaution could result in severe bodily injury or loss of life.


Step 2. Turn off and lock out all incoming power.

Step 3. Wait five minutes to allow the DC bus voltage to dissipate.

Step 4. Measure the DC bus potential with a voltmeter before working on the unit.

Measure the voltage across the DC + and DC - terminals on terminal block TB1. See Appendix I for terminal block identification. When the DC bus potential is down to less than 5 volts, touch a 50 ohm, 50 W or larger resistor across the DC bus terminals for twenty seconds to allow any remaining voltage to dissipate.

Remove the resistor and re-measure the DC bus potential. It should now be 0V.

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.

• AC and DC clamp-on ammeters

• Multimeter having a sensitivity of 20KΩ/volt

• Chart recorder

• Isolated voltmeter

• 50 ohm, 50W resistor for discharging bus capacitors

A megohmmeter (megger) may be used to reliably verify the absence of inadvertent grounding of the motor. Failure to follow proper procedure when using a megger may cause damage to the drive.

!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.

!ATTENTION:If a megohmmeter is used, disconnect all leads between the rotating equipment and the drive cabinet. This will prevent damage to electronic circuitry (Power Modules and their associated circuits, etc.) due to the high voltage generated by the megger. Failure to observe this precaution could result in damage to, or destruction of, the equipment.


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 4. Check fuses.

Step 5. Verify that all shutdown interlocks around the machine are operational.

4.7.4 Physically Inspecting the Motor

Carefully read and understand the instruction manual that describes your AC motor. Then make the following motor inspection:

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 instruction manual.

Step 3. If possible, uncouple the motor from the driven machinery.

Step 4. Rotate the motor shaft by hand to check that the motor is free from any binding or mechanical load problem.

Step 5. Check that no loose items such as shaft keys, couplings, etc., are present.

Step 6. Check all connections for tightness and proper insulation.

Step 7. Check that the interior of the motor is clean and dry.

4.7.5 Checking the Installation with Power Off

Perform the following tests to verify that:

• Correct power is being supplied to the drive

• Wiring has been done properly

• There are no grounds in the magnetic control circuits or rotating equipment

• All safety devices are in place and functional.

!ATTENTION:Before starting the motor, remove all unused shaft keys and loose rotating parts to prevent them from flying off. Replace all covers and protective devices. Failure to observe these precautions could result in damage to equipment and bodily injury.


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.

Step 2. Visually check that the AC line supply or DC bus supply to the drive is of the correct voltage, frequency, and polarity, and that the plant supply branch from which the drive is to be operated is of sufficient ampacity to supply drive input current requirements.

Step 3. Check that the AC line transformer (if used) is connected to provide the correct phases and voltages to the inputs of the drive.

Step 4. 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 5. Open the drive’s cover or enclosure door. Inspect the interior of the drive for cables that may have come loose during shipping. Re-secure the cover or enclosure door.

Step 6. Check for grounds in the magnetic control circuits. Always use an ohmmeter to check for grounds in resolver circuits.

Step 7. Check rotating equipment for grounds.

Step 8. Check for tight connections on all wiring.

Step 9. Check circuit breaker trip settings.

Step 10. Verify that all safety devices are in place. Test the mechanical door interlocks on the power cubicles to ensure they are operational.

!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. Failure to observe this precaution could result in severe bodily injury or loss of life.


4.7.6 Testing AC Input Power Modules with AC Power On

All input voltages should be checked prior to applying any voltage to the drive. Check all line-to-line voltages (VLL) and line-to-ground voltages (VLN). All line-to-line voltages should be equal within +/-5%.

Note:

The following steps are required to test AC Input Power Modules before they can be put into service.

Step 1. Check AC power levels.

a. Verify that AC input power to the drive is off.

b. Connect a voltmeter to terminals R (L1) and S (L2) on the Power Module. See Appendix I for terminal identification.

c. Apply power to the drive and verify the AC voltage level.

d. Repeat the previous steps with the voltmeter connected to terminals R (L1) and T (L3) and then to terminals S (L2) and T (L3).

e. Repeat the checks with the voltmeter connected to terminals R (L1) and ground, S (L2) and ground, and T (L3) and ground.

Step 2. If the motor uses 3-phase AC to power its blower motor, verify proper blower motor rotation. Check to see that air is being forced into the motor. If air flow is reversed (air is being pulled out of the motor), remove AC input power from the blower motor and interchange any two AC line power wires feeding the blower motor. Note that the blower motor must be wired to a fixed AC power source and not to the drive.


ATTENTION:This procedure is performed with power on. Exercise extreme caution as hazardous voltage exists. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:Before proceeding, make sure that you can quickly stop the drive if necessary. If the input power disconnect and/or stop push-button are out of your reach, have an associate stationed to operate them in the event of drive malfunction during these initial power checks and drive adjustment. Failure to observe this precaution could result in damage to equipment and bodily injury.

VLN 3 V•

LL =


4.7.7 Testing DC Bus Supplies and DC Input Power Modules

DC bus power may be supplied to DC input Power Modules by a diode rectifier, a phase controlled rectifier, a synchronous rectifier, or a more complex combination of rectifiers that supply unregulated or regulated DC power to the Power Module’s DC bus. In addition, the DC bus supply may also include snubber dissipation or regenerative capability.

4.7.7.1 Checking the DC Bus Supply

Prior to applying power to any Power Module, operation of the DC bus supply should be checked for proper connections, proper operation, correct voltage levels, and correct polarity at termination points. Refer to the appropriate installation and setup instructions for your system’s specific equipment.

Step 1. Check DC bus voltage and polarity prior to applying power to the Power Module. The DC bus voltage should be approximately equal to 1.43 times the maximum output voltage required from the Power Module.

4.7.7.2 Testing DC Input Power Modules with DC Power On

The following steps are required to test DC input Power Modules before they can be put into service.

Step 1. Check DC power levels.

a. Verify that DC input power to the Power Module is off.

b. Connect a DC voltmeter to the DC+ and DC– terminals on terminal block TB1. See Appendix I for terminal identification.

c. Apply power to the drive and verify the DC voltage level and polarity.

Step 2. If the motor uses 3-phase AC to power its blower motor, verify proper blower motor rotation. Check to see that air is being forced into the motor. If air flow is reversed (air is being pulled out of the motor), remove AC input power from the blower motor and interchange any two AC line power wires feeding the blower motor. Note that the blower motor must be wired to a fixed AC power source and not to the drive.


ATTENTION:These procedures are performed with power on. Exercise extreme caution as hazardous voltage exists. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:Before proceeding, make sure that you can quickly stop the drive if necessary. If the input power disconnect and/or stop push-button are out of your reach, have an associate stationed to operate them in the event of drive malfunction during these initial power checks and drive adjustment. Failure to observe this precaution could result in damage to equipment and bodily injury.


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.

• AutoMax Processor and UDC operating systems

• Rack configuration

• Drive parameters

• All application tasks

The procedures described in the following sections are performed using the Monitor I/O function in the AutoMax Programming Executive software.

4.7.8.1 Testing UDC/PMI Regulator Communication Status

This section describes how to test the UDC/PMI Regulator communication status registers. Use the AutoMax Programming Executive software I/O Monitor function to display the UDC/PMI Regulator Communication Status registers in the format listed in table 4.1.

Step 1. Examine registers 80/1080 and 84/1084 for any errors reported to the UDC module (and PMI Regulator) related to UDC/PMI Regulator communication. If any bits in these registers are on, try to determine what caused the error.

Step 2. Examine registers 81/1081 and 85/1085 for the number of messages received by the UDC module (and PMI Regulator). Over time, this 16-bit value should increase to its maximum value (32767) and then roll over.

Table 4.1 – UDC/PMI Regulator Communication Status Register Formats

DriveA / B Register Name (format)

80 / 1080 UDC Module Ports A/B Status (binary)

81 / 1081 UDC Module Ports A/B Receive Count (decimal)

82 / 1082 UDC Module Ports A/B CRC Error Count (decimal)

83 / 1083 UDC Module Ports A/B Format Error Count (decimal)

84 / 1084 PMI A/B Status (binary)

85 / 1085 PMI A/B Receive Count (decimal)

86 / 1086 PMI A/B CRC Error Count (decimal)

87 / 1087 PMI A/B Format Error Count (decimal)

88 / 1088 UDC Module Ports A/B Fiber-Optic Link Status (hexadecimal)

89 / 1089 UDC Module Ports A/B Transmitted Message Count (decimal)


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). The upper byte should be equal to 02xxH (communication between the UDC module and PMI Regulator 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. Over time, this 16-bit value should increase to its maximum value (32767) and then roll over.

4.7.8.2 Testing Flex I/O Registers

This section describes how to test the Flex I/O registers if used in your system. Use the AutoMax Programming Executive software I/O Monitor function to display the Flex I/O registers in the format listed in table 4.2.

Display these registers in decimal format if they are used for analog I/O. Display them in binary format if they are used for digital I/O.

Table 4.2 – Flex I/O Register Formats

DriveA / B Register Name

0 / 12 Flex I/O Module 0 (Digital I/O)

1 / 13 Flex I/O Module 1 (Digital I/O)

2 / 14 Flex I/O Module 2 (Digital I/O or Analog I/O Channel 0 )

3 / 15 Flex I/O Module 2 (Analog I/O Channel 1)




7 / 19 Flex I/O Module 2 (Analog I/O channel 5)

8 / 20 Flex I/O Module 2 (Analog Input Channel 6)

9 / 21 Flex I/O Module 2 (Analog Input Channel 7)

10 / 22 Flex System Faults; I/O Modules 0 and 1 Faults

11 / 23 Flex I/O Module 2 Faults


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.

Step 4. Test any analog current or voltage input channel being used by verifying that the input signal in that channel (4-20mA, 0-20mA, +/- 10V, or 0-10V) is proportional to the value displayed in appropriate register.

Digital Data Formats

Some digital I/O modules are only 8 bits and do not require the full 16 bits of the assigned UDC register. If the module is only 8 bits, then bits 8 through 15 are not used. Bit 0 is defined as Digital I/O channel 0, bit 1 is channel 1, etc.

Flex I/O module IB10X0B6 (10 input/6 output digital combo module) is mapped to UDC memory as shown below, with the lower ten bits configured as inputs and the upper 6 bits as outputs.

0 = Output

I = Input

Data Format: 8-bit Digital I/O

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Data - - - - - - - - I/O I/O I/O I/O I/O I/O I/O I/O

Data Format: Module IB10X0B6 - 10 Input / 6 Output Digital Combo

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Data O O O O O O I I I I I I I I I I


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.

A/D Unipolar Data 11 10 09 08 07 06 05 04 03 02 01 00

⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓Analog Value 0* 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

Input * = Always positive

A/D Bipolar Data S 10 09 08 07 06 05 04 03 02 01 00

⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓Analog Value S 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

D/A Data S 11 10 09 08 07 06 05 04 03 02 01 00

Output ⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓ ⇓Analog Value S 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00

Table 4.3 – Analog Data Format1

1. The value returned from the A/D converter is 12-bits long, left-justified in a 16-bit field. The most significant bit is reserved for a sign bit.

Current (mA)

4-20 mA Mode

0-20 mA Mode Voltage (V)

+/- 10 Volt Mode 0-10 Volt ModeInput Output

-10.5 -32768 -32768

0 0 -10.0 -31200 -31208

1 1560 -9.0 -28080 -28088

2 3120 -8.0 -24960 -24968

3 4680 -7.0 -21840 -21848

4 0 6240 -6.0 -18720 -18728

5 1927 7800 -5.0 -15600 -15608

6 3854 9360 -4.0 -12480 -12488

7 5782 10920 -3.0 -9360 -9368

8 7710 12480 -2.0 -6240 -6248

9 9637 14040 -1.0 -3120 -3128

10 11565 15600 0 0 0 0

11 13492 17160 1.0 3120 3120 3120

12 15420 18720 2.0 6240 6240 6240

13 17347 20280 3.0 9360 9360 9360

14 19275 21840 4.0 12480 12480 12480

15 21202 23400 5.0 15600 15600 15600

16 23130 24960 6.0 18720 18728 18728

17 25057 26520 7.0 21840 21848 21848

18 26985 28080 8.0 24960 24968 24968

19 28912 29640 9.0 28080 28088 28088

20 30840 31200 10.0 31200 31208 31208

21 32767 32760 10.5 32752 32760 32760


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.

Step 1. Verify that register 200/1200, bit 15 is on. This bit is on when PMI operating system has been successfully downloaded from the UDC module to the PMI Regulator.

Step 2. Check each of the inputs identified by bits 1 through 5 of register 201/1201 by applying 115V to the appropriate pins on the Drive I/O connector on the Resolver and Drive I/O board and verifying that the appropriate bit is on. Refer to instruction manual S-3057, PMI Regulator, for the pinout description.

Table 4.4 – Feedback Registers and Bits

Drive A/B Variable Name Description

200 / 1200Bit 15 (PMI_OK@)

Drive Status RegisterPMI Operating System Loaded

201 / 1201 I/O Status Register

Bit 0 (RPI@) Run Permissive Input

Bit 1 (M_FDBK@) M-Contactor Feedback Input or

(AUX_IN1@) 115VAC Auxiliary Input 1

Bit 2 (AUX_IN2@) 115VAC Auxiliary Input 2




Bit 8 (STR_DET@) External Strobe Detected

203 / 1203 Drive Warning Register

Bit 13 (WRN_I/O@) Flex I/O Communication Error

206 / 1206 (BUS_VDC%) DC Bus Voltage Feedback (1=1V)

207 / 1207 (BUS_IDC%) DC Bus Current Feedback (10=1A)

208 / 1208 (GI_FB%) Ground Current Feedback (10=1A)

209 / 1209 (V_FB%) Voltage Feedback (1=1V RMS)

210 / 1210 (I_FB%) Current Feedback (10=1A RMS)

211 / 1211 (I_FBN%) Current Feedback (normalized)

212 / 1212 (ID_FBN%) Id Feedback (normalized)

213 / 1213 (IQ_FBN%) Iq Feedback (normalized)

214 / 1214 (ANA_IN%) User Analog Input (-2048 =-10V to +2047 = +10V)

215 / 1215 (RES_SCN_POS%) Resolver Scan Position (-32768 to 32767)

216 / 1216 (RES_STR_POS%) Resolver Strobe Position (-32768 to 32767)

217 / 1217 (RPM%) Revolutions Per Minute

218 / 1218 (SLIP_FB%) Slip Feedback (100 = 1 Hz)

219 / 1219 (SEL_VAR%) Selected Variable

222 / 1222 (DIAG_FLT%) Diagnostic Fault Code


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. Refer to instruction manual S-3056 for additional information.

Step 5. Test the resolver. Be sure the resolver’s sine/cosine wires are connected per the W/E diagrams. Monitor the value displayed in the Resolver Scan Position register (215/1215). The value in this register can range from -32768 to 32767. Rotate the resolver by hand, first in one direction, then in the other direction. The value in the register should steadily increase in one direction and steadily decrease in the other direction. If the value in the register does not change at all or if the value does not increase/decrease smoothly, a problem may exist with the resolver and/or its wiring.

Step 6. Test the external strobe, if used, as follows. Note that the resolver and external strobe must be connected. Force register 101, bit 8 (STR_ENA@, Enable External Strobe) on. Verify that register 201/1201, bit 8 (STR_DET@, External Strobe Detected) is on. Check the values displayed for registers 215/1215 (RES_SCN_POS%) and 216/1216 (RES_STR_POS%). The values displayed for these two registers should be very close, if not identical, if the resolver has not turned. After you have finished, unforce register 101, bit 8.

4.7.8.4 Testing the UDC Module Test Switch Register

This section describes how to test the UDC module test switch register. Use the AutoMax Programming Executive software I/O Monitor function to display register 1000 in binary format.

Register 1000 reflects the status of the test switches and LED indicators on the UDC module.

Step 1. Verify the function of the UDC push-button. When the push-button is pressed, register 1000, bit 0 should be on. When the push-button is released, this bit should be off.

Step 2. Verify the function of the UDC Test Switch. When the switch is in the up-position, register 1000, bit 1 should be on. When the switch is in the down-position, register 1000, bit 2 should be on. When the switch is in the center position, both of these bits should be off.

4.7.8.5 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. 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. Use the AutoMax Programming Executive software Monitor Setup UDC/PMI screen.

Step 1. Select parameter 19 (Application Data) for all of the PMI Regulator ports being used. Set the minimum and maximum values to -2048 and +2047, respectively.

Step 2. Return to the I/O Monitor screen. Display register 106/1106 (PMI_DA%).

Step 3. Check each PMI Regulator meter port being used as follows:

a. Write a value between -2047 to +2047 to register 106/1106.

b. Use a voltmeter to verify that the signal (-10V to +10V) on each set of Meter Port terminal points is proportional to the value written in step b above.

4.7.9 Performing Uncoupled Motor Tests (Vector)

The following tests are performed with the motor uncoupled from the load. Ensure that the limit values entered through the parameter entry screens are correct.

Step 1. Verify that the parameter screen information (Power Module data, motor data, speed feedback data, and meter port setup) is correct.

Step 2. Calculate the values for local tunables STATOR_R_E4% (stator resistance), STATOR_T_E4% (stator time constant), and STATOR_IZ_E1% (no load stator current) by setting the Enable Tuning bit (register 100/1100, bit 1, PMI_TUN@). The Automatic Tuning Complete bit (register 200/1200, bit 1, PMI_ATC@) will be on to indicate the values have been calculated. Reset the PMI_TUN@ bit after the test is complete.

Note that if you are using a high slip motor, the value calculated for the tunable STATOR_IZ_E1% may not be correct. Appendix G in the SA3100 Drive Configuration and Programming manual (S-3056) provides the procedure to verify the value in this tunable if you are using a high slip motor.

Step 3. Perform the resolver gain calibration procedure. This procedure is described in the PMI Regulator instruction manual (S-3057). The Resolver Gain Calibration Completed bit (register 201/1201, bit 6, RES_GAN@) will be set to indicate the procedure is complete. Check the value in the local tunable RES_GAN%. Large gain values (close to 255) may indicate a problem with the resolver wiring or connections. Refer to the SA3100 Drive Configuration and Programming instruction manual (S-3056) for a list of the resolvers that may be used with SA3100 drives.


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. If the motor begins turning, verify that the motor shaft is turning in a clockwise direction. Examine the contents of the Resolver Scan Position register (register 215/1215, RES_SCN_POS%). The value in the register should be increasing.

If the motor does not turn, place a value of zero in register 102/1102 and turn off the drive. Change the Output Phase 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., the value in register 215/1215 is increasing), perform the following:

Turn the drive off and switch the resolver’s cosine wires. Change the Output Phase Rotation parameter. Regenerate the parameter object file and reload it to the rack.

e. Verify the motor shaft rotation is in the desired direction by repeating steps a and b.

Step 5. Verify that the motor speed can be regulated. The method used to verify speed regulation will depend upon your application.

Step 6. Perform the resolver balance calibration procedure. This procedure is also described in the PMI Regulator instruction manual (S-3057). The Resolver Balance Calibration Completed bit (register 201/1201, bit 7, RES_BAL@) will be on when the procedure is complete.

If the Tuning Aborted Warning bit (register 203/1203, bit 5, WRN_TUN@) is also on, it indicates that the procedure was unsuccessful (caused by leaving the resolver uncoupled during the procedure or using longer than recommended cable runs) or yielded unusual results (sine/cosine magnitudes are not within 5% of each other). The result of this procedure is stored in local tunable RES_BAL%.

4.7.10 Running Dynamic Motor Tests

The dynamic motor tests complete the drive start-up. The drive is tuned by running the complete system without material in order to adjust motor tracking, maximum speeds, vernier adjustments, and machine section speed adjustments.

The driven machine is then run under actual operating conditions with a load in order to adjust gain values, feedback devices, limit switches, etc., as required, to obtain the specified performance.


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 ADrive 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. If the fault condition still exists, the identifying bit in this register will immediately set again.

The fault conditions reported in this register result in turning off the drive. The UDC task is not stopped automatically if a drive fault occurs unless it is specifically instructed to do so in the application task. The user must ensure that the AutoMax application task tests register 202/1202 and takes appropriate action if a fault occurs.

Note that the status of this register is also reported in the error log for the task in which the error occurred. Most faults reported in this register are also indicated by the EXT FLT or P.M. FLT LEDs on the drive’s PMI Regulator.

DC Bus Overvoltage Fault Bit 0

The DC Bus Overvoltage Fault bit is set if DC bus voltage exceeds:

• 400 volts for 230 VAC Power Modules



Hex Value: 0001HSug. Var. Name: FLT_OV@Access: Read onlyUDC Error Code: 1018LED: EXT FLT

DC Bus Overcurrent Fault Bit 1

The DC Bus Overcurrent Fault bit is set if DC bus current exceeds 125% of the rated Power Module current.

Hex Value: 0002HSug. Var. Name: FLT_DCI@Access: Read onlyUDC Error Code: 1020LED: P.M. FLT

Drive Fault Register A-1

Ground Current Fault Bit 2

The Ground Current Fault bit is set if ground current exceeds the hardware trip point.

Hex Value: 0004HSug. Var. Name: FLT_GND@Access: Read onlyUDC Error Code: 1021LED: 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: 0008HSug. Var. Name: FLT_IOC@Access: Read onlyUDC Error Code: 1017LED: P.M. FLT

• Output current is greater than 200% of the peak RMS current. Bits 0 to 5 in register 204/1204 indicate which power device detected the overcurrent.

• An inverter power device fault is detected. Bit 6 in register 204/1204 will be set if the IOC fault is due to a power device overcurrent.

Power Supply Fault Bit 4

The Power Supply Fault bit is set if the output of the isolated +12V supply, or the output of the external power supply for a G or H frame drive, falls below the configured low voltage threshold.

Hex Value: 0010HSug. Var. Name: FLT_12V@Access: Read onlyUDC Error Code: 1022LED: P.M. FLT

Register 222/1222 provides additional diagnostics if this fault occurs.

Charge Bus Time-Out Fault Bit 6

The Charge Bus Time-out Fault bit is set to indicate any of the conditions listed below. Register 222/1222 provides additional diagnostics if this fault occurs.

Hex Value: 0040HSug. Var. Name: FLT_CHG@Access: Read onlyUDC Error Code: 1024LED: EXT FLT and

P.M. FLT

• The DC bus is not fully charged within 10 seconds after the bus enable bit (register 100/1100, bit 4) is set.

• The drive is on and feedback indicates that the pre-charge contactor has opened.

• DC bus voltage is less than the value stored in the Power Los Fault Threshold (PLT_E0%) tunable variable.

If the Charge Bus Time-Out Fault bit is set, verify that incoming power is at the appropriate level. If the power level is correct, the problem is in the Power Module.

A-2 Diagnositics, Troubleshooting, and Start-Up Guidelines

Over Temperature Fault Bit 7

The Over Temperature Fault bit is set if the thermistor in the Power Module detects a temperature of 100° C or more.

Hex Value: 0080HSug. Var. Name: FLT_OT@Access: Read onlyUDC Error Code: 1016LED: P.M. FLT

Resolver Broken Wire Fault Bit 8

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.

Hex Value: 0100HSug. Var. Name: FLT_TBW@Access: Read onlyUDC Error Code: 1008LED: FDBK OK

Resolver Fault Bit 9

The Resolver Fault bit is set if the fuse blows on the Resolver & Drive I/O board. This indicates the board has failed and must be replaced.

Hex Value: 0200HSug. Var. Name: FLT_RES@Access: Read onlyUDC Error Code: 1009LED: N/A

Overspeed Fault Bit 10

The Over Speed Fault bit is set if the motor’s velocity exceeds the value entered as the Over Speed Trip (RPM) configuration parameter.

Hex Value: 0400HSug. Var. Name: FLT_OSP@Access: Read onlyUDC Error Code: 1010LED: EXT FLT

Power Technology Fault Bit 11

The Power Technology Fault bit is set to indicate a problem with the AC power technology circuit on the PMI Regulator motherboard.

Hex Value: 0800HSug. Var. Name: FLT_PTM@Access: Read onlyUDC Error Code: 1011LED: OK

Register 222/1222 provides additional diagnostics if this fault occurs.

PMI Regulator Bus Fault Bit 13

The PMI Regulator Bus Fault bit is set if the Resolver & Drive I/O board or the AC power technology circuit does not respond to requests from the PMI Processor. This indicates a hardware problem in the PMI Regulator.

Hex Value: 2000HSug. Var. Name: FLT_BUS@Access: Read onlyUDC Error Code: 1013LED: N/A

Drive Fault Register A-3

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: 4000HSug. Var. Name: FLT_RUN@Access: Read onlyUDC Error Code: 1014LED: 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: 8000HSug. Var. Name: FLT_COM@Access: Read onlyUDC Error Code: 1015LED: N/A

This bit is set only after communication between the PMI Regulator and UDC module has been established. This bit should be used in the run permissive logic for the drive. Also refer to the description of the CCLK Synchronized bit (register 200/1200, bit 14) in S-3056.

The following table shows how the operation of the digital I/O and Flex I/O is affected when one or both of the fiber-optic cables is disconnected:

Table A.1 – Effect of a Disconnected Fiber-Optic Cable

Resolver & Drive I/O Analog & Digital

Cable Disconnected MCR AUX OUT Digital Inputs Flex Inputs Flex Outputs

UDC XMT/PMI RCV Turn Off1 Update Last Value2 Held Reset3

PMI XMT/UDC RCV Turn Off1 Last Value2 Last Value2 UDC Control

1. Outputs will remain off until the Fault Reset bit (register 100/1100, bit 8, FLT_RST@) is turned on. At that time, they will be under the control of the application tasks.

2. The application task(s) in the AutoMax rack must monitor the CCLK Synchronized bit (register 200/1200, bit 14, CCLK_OK@) to determine if the digital input data is valid.

3. As soon as communication is re-established, outputs become active again; the Warning Reset bit (register 100/1100, bit 9, WRN_RST@) does not need to be set.

A-4 Diagnositics, Troubleshooting, and Start-Up Guidelines

APPENDIX BDrive 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. If a warning condition is detected, the corresponding bit is latched until the Warning Reset bit (bit 9) of the Drive Control register (register 100/1100) is set.

DC Bus Overvoltage Warning Bit 0

The DC Bus Overvoltage Warning bit is set if the DC bus voltage rises above the overvoltage threshold value stored in local tunable OVT_E0%.

Hex Value: 0001HSug. Var. Name: WRN_OV@Access: Read onlyUDC Error Code: N/ALED: N/A

The torque is automatically limited to avoid an overvoltage fault. Bit 4 of the Drive Warning register will also be set to indicate the torque is being limited by the system. Refer to the SA3100 Power Modules instruction manual (S-3058) for more information about internal DC bus control.

DC Bus Undervoltage Warning Bit 1

The DC Bus Undervoltage Warning bit is set if the DC bus voltage drops below the undervoltage threshold stored in local tunable UVT_E0%.

Hex Value: 0002HSug. Var. Name: WRN_UV@Access: Read onlyUDC Error Code: N/ALED: N/A

The torque is automatically limited to avoid an undervoltage fault. Bit 4 of the Drive Warning register will also be set to indicate the torque is being limited by the system. Refer to the SA3100 Power Modules instruction manual (S-3058) for more information about internal DC bus control.

Ground Current Warning Bit 2

The Ground Current Warning bit is set if ground current exceeds the ground current level stored in local tunable GIT_E1%.

Hex Value: 0004HSug. Var. Name: WRN_GND@Access: Read onlyUDC Error Code: N/ALED: N/A

Drive Warning Register B-1

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: 0008HSug. Var. Name: WRN_VR@Access: Read onlyUDC Error Code: N/ALED: 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.

Reference In Limit Warning Bit 4

In Vector mode, the Reference in Limit Warning bit is set if the reference to the regulator exceeds the maximum value permitted (+/- 4095) or is being limited by the system in response to an overvoltage or undervoltage warning.

Hex Value: 0010HSug. Var. Name: WRN_RIL@Access: Read onlyUDC Error Code: N/ALED: N/A

In Volts per Hertz mode, this bit is set if current limit is selected and the regulator has detected a specified current output within a specified time limit. The regulator will begin adjusting output frequency to limit current.

This bit is also used by the bridge test to indicate an illegal test code. Refer to the SA3100 Drive Configuration and Programming instruction manual (S-3056) for additional information on the bridge test.

Tuning Aborted Warning Bit 5

The Tuning Aborted Warning bit is set if any of the automatic tuning procedures (e.g., resolver balance and gain calibration) is not successful.

Hex Value: 0020HSug. Var. Name: WRN_TUN@Access: Read onlyUDC Error Code: N/ALED: N/A

Over Temperature Warning Bit 7

The Over Temperature Warning bit is set if the Power Module’s heatsink reaches a temperature of 90° C.

Hex Value: 0080HSug. Var. Name: WRN_OT@Access: Read onlyUDC Error Code: N/ALED: N/A

B-2 Diagnositics, Troubleshooting, and Start-Up Guidelines

Bad Gain Data Warning Bit 8

The Bad Gain Data Warning bit is set if any of the following conditions is detected:

Hex Value: 0100HSug. Var. Name: WRN_BGD@Access: Read onlyUDC Error Code: N/ALED: 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.

• Drive parameter(s) have been loaded that are outside of acceptable limits. This is also part of an interlock test that will prevent the drive from entering the run mode. See register 205/1205, bit 0.

• The following relationship between the power loss fault threshold (PLT_E0%), the overvoltage warning threshold (OVT_E0%), and the undervoltage warning threshold (UVT_E0%) is not true: PLT_E0% < UVT_E0% < OVT_E0%.

• OVT_E0% > 975V for 575 VAC Power Modules,> 800V for 460 VAC Power Modules,> 400V for 230 VAC Power Modules.

Thermistor Open Circuit Warning Bit 9

The Thermistor Open Circuit Warning bit is set if an open is detected in the Power Module’s thermistor circuit.

Hex Value: 0200HSug. Var. Name: WRN_TOC@Access: Read onlyUDC Error Code: N/ALED: N/A

Flex I/O Communication Warning Bit 13

The Flex I/O Communication Warning bit is set if a Flex I/O communication problem is detected and logged in registers 10, 11, 22, or 23.

Hex Value: 2000HSug. Var. Name: WRN_FLX@Access: Read onlyUDC Error Code: N/ALED: I/O FLT

Refer to the SA3100 Drive Configuration and Programming instruction manual (S-3056) for further information.

CCLK Not Synchronized Warning Bit 14

The CCLK Not Synchronized Warning bit is set if the CCLK counters in the PMI Regulator and the UDC module are momentarily not synchronized.

Hex Value: 4000HSug. Var. Name: WRN_CLK@Access: Read onlyUDC Error Code: N/ALED: N/A

Drive Warning Register B-3

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: 8000HSug. Var. Name: WRN_COM@Access: Read onlyUDC Error Code: N/ALED: N/A

Communication errors in two consecutive messages will result in a drive fault.

B-4 Diagnositics, Troubleshooting, and Start-Up Guidelines

APPENDIX CInterlock 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.

Configuration Parameters Not Loaded Bit 0

The Configuration Parameters Not Loaded bit is set if the configuration parameters have not been downloaded into the UDC module from the Programming Executive or if the parameters are outside of acceptable limits.

Hex Value: 0001HSug. Var. Name: IC_CNF@Access: Read onlyUDC Error Code: N/ALED: N/A

Valid Gains Not Loaded Bit 1

The Valid Gains Not Loaded bit is set if the following pre-defined local tunables are zero or if a UDC task containing these variables has not been loaded to the PMI:

Hex Value: 0002HSug. Var. Name: IC_GAIN@Access: Read onlyUDC Error Code: N/ALED: N/A

CML_WC0% FLUX_WCO% GIT_E1% IST_E1%

OVT_E0% PLT_E0% SLIP_ADJ_E3%1 STATOR_IZ_E1%STATOR_T_E4% STATOR_R_E4% UVT_E0%

1. Vector with Constant Power mode only

RPI Missing Bit 2

The RPI Missing bit is set if the Run Permissive input on the Resolver & Drive I/O board is not on.

Hex Value: 0004HSug. Var. Name: I_RPI@Access: Read onlyUDC Error Code: N/ALED: N/A

Interlock Register C-1

Faults Need Reset Bit 3

The Faults Need Reset bit is set if previous faults (register 202/1202) have not been cleared.

Hex Value: 0008HSug. Var. Name: IC_FLT@Access: Read onlyUDC Error Code: N/ALED: 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: 0010HSug. Var. Name: IC_RISE@Access: Read onlyUDC Error Code: N/ALED: N/A

This interlock 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-enabled any command bits.

More Than One Request Bit 5

The More Than One Request bit is set if more than one operating mode is requested at a time in register 100/1100 (bits 0, 1, 2).

Hex Value: 0020HSug. Var. Name: IC_MORE@Access: Read onlyUDC Error Code: N/ALED: N/A

Refer to the SA3100 Drive Configuration and Programming instruction manual (S-3056) for more information.

Bus Not Ready Bit 6

The Bus Not Ready bit is set when turning on the drive if the DC bus is not ready.

Hex Value: 0040HSug. Var. Name: IC_BUS@Access: Read onlyUDC Error Code: N/ALED: N/A

The bus is ready when the DC bus voltage is greater than the undervoltage threshold value stored in local tunable UVT_E0% and has reached a steady state, and feedback indicates that the pre-charge contactor has closed.

This interlock bit will also be set when turning on the drive if the bus enable bit (register 100/1100, bit 4) has not been set. Refer to the SA3100 Power Modules instruction manual (S-3058) for more information about internal DC bus control.

MCR Did Not Close Bit 7

The MCR Did Not Close bit is set if the optional output contactor did not close when commanded to do so.

Hex Value: 0080HSug. Var. Name: IC_MCR@Access: Read onlyUDC Error Code: N/ALED: N/A

C-2 Diagnositics, Troubleshooting, and Start-Up Guidelines

Incompatible Resolver Bit 10

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.

Hex Value: 0400HSug. Var. Name: IC_IRES@Access: Read onlyUDC Error Code: N/ALED: N/A

Interlock Register C-3

C-4 Diagnositics, Troubleshooting, and Start-Up Guidelines

APPENDIX DDiagnostic Fault Code

Register

Diagnostic Fault Code Register 222/1222

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.

Sug. Var. Name: DIAG_FLT%Units: N/ARange: N/AAccess: Read only

Diagnostic Fault Code Register D-1

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 Fault Action

1 D/A high voltage error (+3.3V 10% out of tolerance)

Replace PMI Regulator Motherboard

2 D/A low voltage error (-3.3V 10% out of tolerance)

3 Torque current loop proportional gain not within calibration limits (14<g<30)

4 Flux current loop proportional gain not within calibration limits (14<g<30)

5 Flux current loop integrator time constant not within calibrated limits

6 Torque current loop integrator time constant not within calibrated limits

7 Modulation index error

8 Harmonic DAC limit error

9 Modulation range error

10 Harmonic DAC range error

11 Programmable current limit or the ground fault limit fault

12 Voltage feedback integrator error

13 A/D converter interrupt error

14 Pulse Width Modulator frequency error

15 DC bus current not zero at power-up.

16 Phase U current not zero at power-up.

17 Phase W current not zero at power-up.

D-2 Diagnositics, Troubleshooting, and Start-Up Guidelines

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.

22 A/D interrupt overrun An interrupt from the power technology circuit was detected before the previous interrupt was processed. Replace the PMI Regulator motherboard.

23 Gate power test 1 fault Gate power is on when the MCR is off and Gate Enable is on. Replace the PMI Regulator motherboard.

24 Not used.

25 Gate power test 3 fault Gate power is on when the MCR is off and Gate Enable is on. Replace the PMI Regulator motherboard.

26 Gate power loss Loss of gate power feedback while in run. Replace the PMI Regulator motherboard.

DC Bus Pre-charge Faults

Code Fault Description/Action

100 Pre-charge closed Pre-charge is requested to close when pre-charge is already closed.

101 Pre-charge did not close The pre-charge did not close within 2 seconds.

102 Pre-charge open Pre-charge is closed but AC power technology status indicates it is open.

103 Pre-charge did not open Pre-charge is commanded to open but does not do so after one second.

104 Pre-charge opened The AC power technology circuit detected that the pre-charge opened while in run.

105 No used

106 Charge time-out Minimum bus voltage is not detected within 10 seconds after bus enable.

107 AC line fault AC line status from Power Module not detected.

108 Charge ripple fault DC ripple voltage above tolerance.

Diagnostic Fault Code Register D-3

D-4 Diagnostics, Troubleshooting, and Start-Up Guidelines

APPENDIX ESummary 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. On subsequent power-ups, the LED will turn on to indicate that the OS is still resident in the module. Note that this LED is also used to indicate any failure that may occur during the power-up diagnostics. If the UDC module fails any of its power-up diagnostics, the module must be replaced.

COMM A OK and COMM B OK (green) - The Communication Status LEDs will turn on after the UDC module has established communication with the PMI rack(s) over the fiber-optic link(s). COMM A indicates the status of communication link A. COMM B indicates the status of communication link B. When an LED is lit, it indicates that messages are being received over that channel. Each channel operates independently of the other. If a channel is not being used, its LED will remain off. If communication errors are detected in two consecutive messages, the COMM OK LED will turn off and the DRV FLT LED will turn on. If the next message received by the UDC module is correct, the COMM OK LED will turn back on. The Communication Fault bit (register 202/1202, bit 15, FLT_COM@ ) will remain latched.

DRV FLT A and DRV FLT B (red) - The Drive Fault LEDs are normally off. If a Drive Fault LED is lit, it indicates the a Drive Shutdown fault has been detected for the indicated drive. When a drive fault is detected, a bit is set in register 202 for drive A or register 1202 for drive B in the UDC module’s dual port memory. Bit 8 of the Drive Status register (200/1200) is also set.

Summary of UDC Module Drive Fault Indicators E-1

Drive Fault Error Codes

Drive faults are reported in the error log for the task in which the error occurred. The drive fault error codes are defined below:

Error Codes

The UDC module can generate three error codes which will be displayed on the leftmost AutoMax Processor:

Error 38 indicates that the UDC module has generated a Stop All. If this error occurs, refer to the UDC task error log for additional information regarding the error.

Error 39 indicates a UDC module interrupt allocation has failed. In this case, try to cycle power to the rack and reload the rack configuration and application tasks.

Error 3A indicates the UDC module’s operating system and the AutoMax operating system are not compatible. If this error occurs, reload the most current operating systems.

1008 Broken wire in resolver

1009 Resolver board fault

1010 Overspeed fault

1011 Power technology fault

1012 not used

1013 PMI bus fault

1014 UDC run fault

1015 Fiber-optic link communication fault

1016 Over temperature fault

1017 Instantaneous overcurrent fault

1018 DC bus overvoltage fault

1019 not used

1020 DC bus overcurrent fault

1021 Ground current fault

1022 not used

1023 not used

1024 Charge bus time-out fault

E-2 Diagnositics, Troubleshooting, and Start-Up Guidelines

APPENDIX FPMI 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.

LED COMM OK When lit, indicates messages are being received correctly by the PMI Regulator over the fiber-optic link.

LED DRV RDY When lit, indicates that the AC power technology hardware is functioning properly.

Related Reg/Bit 202/1202 bit 11FLT_PTM@

Power Technology Fault

LED P.M. FLT When lit, indicates one of the following fault conditions has been detected by the PMI Regulator:

Related Reg/Bit 202/1202 bit 1FLT_DCI@

DC Bus Overcurrent Fault

Related Reg/Bit 202/1202 bit 3FLT_IOC@

Instantaneous Overcurrent Fault

Related Reg/Bit 202/1202 bit 6FLT_CHG@

Charge Bus Time-out Fault

Related Reg/Bit 202/1202 bit 7FLT_OT@

Over Temperature Fault

LED EXT FLT When lit, indicates one of the following fault conditions has been detected by the PMI Regulator:

Related Reg/Bit 202/1202 bit 0FLT_OV@

DC Bus Overvoltage Fault

Related Reg/Bit 202/1202 bit 2FLT_GND@

Ground Current Fault

Related Reg/Bit 202/1202 bit 6FLT_CHG@

Charge Bus Time-out Fault

Related Reg/Bit 202/1202 bit 10FLT_OSP@

Over Speed Fault

Related Reg/Bit 101/1101 bit 2EXT_LED@

Application Program Control

PMI Regulator LED Summary F-1

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 13WRN_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.

Related Reg/Bit 202/1202 bit 8FLT_TBW@

Resolver Feedback Broken Wire

LED RPI When lit, indicates the run permissive input signal has been detected.

Related Reg/Bit 201/1201 bit 0RPI@

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.

Related Reg/Bit 201/1201 bit 1M_FDBK@

Aux Input 1/MFDBK Status


Related Reg/Bit 201/1201 bit 2AUX_IN2@

Aux Input 2 Status



Aux Input 3 Status



Aux Input 4 Status



Aux Input 5 Status

LED AUX OUT When lit, indicates the output signal has been turned on.

Related Reg/Bit 101/1101 bit 4AUX_OUT@

Aux Output Status

Name Description

F-2 Diagnositics, Troubleshooting, and Start-Up Guidelines

APPENDIX GStatus of Data in the AutoMax

Rack After a STOP_ALLCommand or STOP_ALL Fault

AutoMaxProcessor UDC Module

PMIProcessor

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

inputs retained and updated;outputs are reset to 0

all I/O is reset to 0

Input values, including:Feedback registersUDC/PMI communication status registersUDC Error Log info

retained retained N/A

Output values, including:Command registersApplication registersISCR registersScan-per-interrupt registerScans-per-interrupt counter

reset to 0 reset to 0 N/A

Parameter configuration variables N/A retained N/A

UDC test switch information N/A retained N/A

D/A setup configuration N/A retained N/A

Operating system retained retained retained

Status of Data in the AutoMax Rack After a STOP_ALL Command or STOP_ALL Fault G-1

G-2 Diagnositics, Troubleshooting, and Start-Up Guidelines

APPENDIX HAutoMax Programming

Executive Access Levels

Rack Power Supply Keyswitch Position

AnyPosition PROTECT SETUP PROGRAM

User’s Access Level

Action NoneAny

Level Data Task Rack Data Task Rack

Force Common 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 No No Yes Yes No Yes Yes

Load Normal Config No No No No No No No Yes

Load Debug Config No No No No No No No Yes

Load Single POB File No No No No No No Yes1

1. Must have Task access to both tasks in the UDC

Yes

Load Single Task No No No No No No2

2. A single task may be loaded with only Data access if the task does not already exist on the AutoMax Processor or UDC module.

Yes Yes

Delete Task No No No No No No Yes Yes

Start Task No No No No No No Yes Yes

Stop Non-Critical Task No No No No No No Yes Yes

Save Task from Rack No Yes3

3. Requires Task or Rack access.

No Yes Yes No Yes Yes

Load All POB Files No No No No No Yes Yes Yes

Load All No No No No No No No Yes

Delete All Tasks No No No No No No Yes4

4. Must have Task access to all tasks.

Yes

Start All Tasks No No No No No No Yes4 Yes

Stop All Tasks No No No No No No Yes4 Yes

Load AutoMax OS No No No No No No No Yes

Load Single UDC OS No No No No No No Yes1 Yes

Load All UDC OS No No No No No No Yes1 Yes

Modify PC Task No No No No No No Yes Yes

Auto Run No No No No No Yes Yes Yes

Monitor Yes Yes Yes Yes Yes Yes Yes Yes

Note that a user with privileged (Data, Task, or Rack) access may relinquish this privilege by timing out after two minutes off-line, or by selecting to relinquish access on-line. Functions not listed in the table do not require privileged access.

AutoMax Programming Executive Access Levels H-1

H-2 Diagnositics, Troubleshooting, and Start-Up Guidelines

APPENDIX ITerminal Block Locations

and Test Points

Figure I.1 – Terminal Block Locations

Frames B, C Frame D

Frame F

TB4

TB1

TB1

TB4

TE

TB1Location

TB1

TB4

TB1Location

Frame E

TB1

TB4

TE

TB1

Location

BrakeTerminals

TE

Frame G

TB4

TB1Location

TE

PEGround

TB1

R,S,T

Frame H

TB4

TB1Location

TE

PEGround

TB1

+,–

TB1 Power Terminal BlockTB4 24V DC Auxiliary InputTE Shield Terminals

1

1. Terminal block TB4 is an auxiliary 24V DC input that can be used to operate the PMI Regulator when incoming AC or DC power is removed.

TE

Terminal Block Locations and Test Points I-1

Figure I.2 – Terminal Block TB1 (B Frame Drives)

PE PE R(L1)

S(L2)

T(L3)

U(T1)

V(T2)

W(T3)

DC+

DC-

RequiredInput Fusing

AC Input Line

To Motor

200-240V, 7.5-11 kW (10-15 HP) Terminal Designations380-480V, 15-22 kW (20-30 HP) Terminal Designations

500-600V, 15 kW (20 HP) Terminal Designations

Dynamic Brake

To Motor1

1Required BranchCircuit Disconnect

PE PE R(L1)

S(L2)

T(L3)

U(T1)

V(T2)

W(T3)

DC+

DC-

AC Input Line

To MotorTo Motor

200-240V, 5.5 kW (7.5 HP) Terminal Designations380-480/500-600V, 11 kW (15 HP) Terminal Designations

Dynamic Brake



Common BusConnection

B1Frame

B2Frame

Common BusConnection 1 User supplied.

I-2 Diagnositics, Troubleshooting, and Start-Up Guidelines

Figure I.3 – Terminal Block TB1 (C and D Frame Drives)

1 User supplied.

PEGRD

PEGRD

DC+

Dynamic Brake


1

DC-

R(L1)

S(L2)

T(L3)

W(T3)

U(T1)

V(T2)

To Motor

AC Input Line

200-240V, 15-22 kW (20-30 HP) Terminal Designations380-480V, 30-45 kW (40-60 HP) Terminal Designations

500-600V, 18.5-45 kW (25-60 HP) Terminal Designations

1Required BranchCircuit DisconnectTo Motor

CFrame

PE PE TEDC +Brake


1

DC -Brake

R(L1)

S(L2)

T(L3)

W(T3)

U(T1)

V(T2)

To Motor

AC Input Line

200-240V, 30-45 kW (40-60 HP) Terminal Designations380-480V, 45-112 kW (60-150 HP) Terminal Designations500-600V, 56-112 kW (75-150 HP) Terminal Designations


To Motor

D Frame


Figure I.4 – Terminal Block TB1 (E, F, and G Frame Drives)

380-480V, 187-336 kW (250-450 HP) Terminal Designations

To Motor

T-L3R-L1 S-L2 W-M3U-M1PE V-M2

Input Fusing(Supplied)

AC Input Line


DC -Brake

DC +Brake

FFrame

200-240V, 56-75 kW (75-100 HP) Terminal Designations380-480V, 112-187 kW (150-250 HP) Terminal Designations500-600V, 112-224 kW (150-300 HP) Terminal Designations

TEBUS INPUT OUTPUT

-DC+DC PE PE R-L1 S-L2 T-L3 U-M1 V-M2 W-M3


1To Motor

AC Input Line


To Motor

EFrame

typical terminal

R(L1)

S(L2)

T(L3)


To Motor


1

AC Input Line

W(M3)

U(M1)

V(M2)1Required Branch

Circuit Disconnect

1 User supplied.

DC+Brake

DC-Brake

RS

T typical terminal layout(located at top of drive)

GFrame

(located at bottom of drive) W

UV


Figure I.5 – Terminal Block TB1 (H Frame Drives)

R(L1)

S(L2)

T(L3)


To Motor


1

AC Input Line

W(M3)

U(M1)

V(M2)1Required Branch

Circuit Disconnect

1 User supplied.

DC+Brake

DC-Brake

RS

T typical terminal layout(located at top of drive)

HFrame

(located at bottom of drive) W

UV



APPENDIX JPMI 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.

CON7 = V-U Volts

CON8 = V-V Volts

CON9 = V-W Volts

CON10 = U Current

CON11 = V Current

CON12 = W Current

CON13 = DC Bus Current

CON14 = DC Bus Voltage

CON15 = ID

CON16 = IQ

CON17, 18, 19 = Analog Ground

CON20, 21, 22 = Digital Ground

U CURR V CURR W CURR

SA3100 Power Module

PMI Regulator Test Points J-1

Figure J.1 shows the test point arrangement on the PMI regulator mother board.

Figure J.1 – PMI Regulator Mother Board - Test Points

CON21

DGND

CON11

Iv FBK

CON20

DGND

CON17

AGND

P8

PE

P7

PE

P6

PE

CON13

BUS CUR

CON14

BUS VOLT

CON10

Iu FBK

CON19

AGND

CON12

Iw FB

CON15

Id

CON16

Iq

CON18

AGND

CON7

V-UVOLT

CON8

V-VVOLT

CON9

V-WVOLT

CON22

AGND

J-2 Diagnositics, Troubleshooting, and Start-Up Guidelines

INDEX

A

Accessing the AutoMax rack, 4-1 to 4-2AutoMax programming executive

access levels, H-1AutoMax rack

status of data, G-1

B

Basic drive interconnections, 4-3 to 4-4Bridge test mode, 3-4 to 3-7

bridge test connections, 3-5power device test locations, 3-6

C

Checking installation with power off, 4-6

D

DC bus monitoringduring bridge test mode, 2-7during torque minor loop mode, 2-7

DC bus supply, 4-9Definition of terms, 2-1Diagnostic fault code register, D-1 to D-3Diagnostics and troubleshooting, 2-1 to 2-7Drive fault, 2-4 to 2-6

clearing, 2-6how the system reacts, 2-4 to 2-5

Drive fault register, A-1 to A-4Drive inspection and start-up guidelines, 4-4 to 4-18

checking installation with power off, 4-6 to 4-7checking the DC bus supply, 4-9dynamic motor tests, 4-17feedback registers and bits, 4-14 to 4-15Flex I/O registers, 4-11 to 4-12

I/O verification, 4-10 to 4-16physically inspecting the drive, 4-6physically inspecting the motor, 4-6PMI regulator meter ports, 4-16recommended start-up sequence, 4-4testing AC Power Modules with power on, 4-8testing DC Power Modules with power on, 4-9UDC module meter ports, 4-15UDC module test switch register, 4-15UDC/PMI communication status, 4-10uncoupled motor tests, 4-16 to 4-17updating drawings and software listings, 4-18

Drive warning, 2-6clearing, 2-6

Drive warning register, B-1 to B-4Dynamic motor tests, 4-17

E

Environmental requirements, 4-2

F

Feedback registers and bits, 4-14 to 4-15Flex I/O, 4-11 to 4-12

analog data formats, 4-13digital data formats, 4-12register formats, 4-11

I

I/O verification, 4-10Idle mode, 3-4Installation and start-up guidelines, 4-1 to 4-18Installing the drive, 4-3

enclosed drives, 4-3open chassis drives, 4-3

Index Index-1

Installing the motor, 4-3Interlock register, C-1 to C-3Interlock tests, 2-3Internal DC bus diagnostics, 2-7Introduction, 1-1 to 1-5

L

LED summary (PMI regulator), F-1 to F-2

M

MCR output control, 2-5 to 2-6Meter ports

PMI regulator, 4-16UDC module, 4-15

Minor loop run mode, 3-8

O

Operating modes and diagnostics, 3-2

P

PMI regulator operating modes, 2-2, 3-1 to 3-9overview, 2-2

PMI tuning mode (automatic gain calculation), 3-8Power-up diagnostics, 2-3

R

Recommended test equipment, 4-5Regulator test points, J-1Related Publications, 1-1Run-time diagnostics, 2-4 to 2-6

S

Service manual cross reference, 1-2 to 1-4

T

Terminal block locations, I-1Terminal block TB1, I-1

B frame drives, I-2Test points

PMI Regulator, J-1Power Module, I-1 to I-5

Typographical conventions, 1-5

U

UDC module drive fault indicators, E-1 to E-2UDC module meterports, 4-15UDC/PMI communication status register, 4-10Unexpected test results, 4-4Updating drawings and software listings, 4-18

V

Volts per Hertz regulatortuning, 3-8

W

Wiring the drive, 4-3

Index-2 Diagnostics, Troubleshooting, and Start-Up Guidelines

Rockwell Automation / 24703 Euclid Avenue / Cleveland, Ohio 44117 / (216) 266-7000

Printed in U.S.A. S-3059-1 July 1999

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