GEH-6385 g GE Industrial Systems ACMVAC2-G Innovation Series ™ Medium Voltage – GP Type G Drives Reference and Troubleshooting 2300 V Drives
g GE Industrial Systems Publication: Issued: GEH-6385 2000-06-29 ACMVAC2-G Innovation Series ™ Medium Voltage – GP Type G Drives Reference and Troubleshooting 2300 V Drives
© 2000 General Electric Company, USA. All rights reserved. Printed in the United States of America. These instructions do not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met during installation, operation, and maintenance. If further information is desired or if particular problems arise that are not covered sufficiently for the purchaser’s purpose, the matter should be referred to GE Industrial Systems, Salem, Virginia, USA.
Safety Symbol Legend Indicates a procedure, condition, or statement that, if not strictly observed, could result in personal injury or death. Indicates a procedure, condition, or statement that, if not strictly observed, could result in damage to or destruction of equipment. Note Indicates an essential or important procedure, condition, or statement.
This equipment contains a potential hazard of electric shock or burn. Only personnel who are adequately trained and thoroughly familiar with the equipment and the instructions should install, operate, or maintain this equipment. Isolation of test equipment from the equipment under test presents potential electrical hazards. If the test equipment cannot be grounded to the equipment under test, the test equipment’s case must be shielded to prevent contact by personnel.
Contents Chapter 1 Overview 1-1 Introduction ...................................................................................................................... 1-1 Using Toolbox Help for Reference and Troubleshooting ................................................... 1-2 Related Documents........................................................................................................... 1-3 How to Get Help.........................................................................................
LAN Signal Map.......................................................................................................3-38 Motor Control Functions..................................................................................................3-44 Motor Control Overview ...........................................................................................3-44 Flux Curve................................................................................................................
Chapter 4 Wizards 4-1 Introduction ...................................................................................................................... 4-1 Cell Test Wizard............................................................................................................... 4-4 Cell Test Options ....................................................................................................... 4-4 Running the Fiber-Optic Test .................................................................
Drive Commissioning: Current Limits.......................................................................4-27 Drive Commissioning: Power Dip Ride-Through.......................................................4-27 Drive Commissioning: Parameter Calculation............................................................4-27 Drive Commissioning: Simulator Mode.....................................................................4-27 Drive Commissioning: Hardware Fault Strings in Simulator Mode ....................
Chapter 5 Signal Mapping 5-1 Introduction ...................................................................................................................... 5-1 LAN Interfaces ................................................................................................................. 5-2 Parameter Configuration for Signal Mapping .................................................................... 5-3 Variable Mapping ...............................................................................
Chapter 1 Overview Introduction This document provides reference and troubleshooting information for the 2300 V model of the Innovation Series™ Medium Voltage – GP Type G drives. The purpose of the document is to assist installation and maintenance technicians in understanding the drive’s diagnostic and configuration software, as well as using fault codes to troubleshoot drive problems. Chapter 1 defines the document contents.
Using Toolbox Help for Reference and Troubleshooting GE document GEH-6401 describes toolbox features and use. The GE Control System Toolbox is an optionally purchased drive configuration program used to tune and commission the drive as needed for each application. The toolbox provides Microsoft® Windows®-based menus, block diagrams, dialog boxes, and wizards on a PC-based drive interface. When you choose Help on the toolbox main menu bar, a drop-down menu provides several options for finding information.
Related Documents If needed for supplementary information, refer to the following documents for the Innovation Series Medium Voltage – GP Type G drives, as applicable: GEH-6381, Installation and Startup GEH-6382, User’s Guide GEH-6401, Control System Toolbox How to Get Help If help is needed beyond the instructions provided in the documentation, contact GE as follows: “+” indicates the international access code required when calling from outside of the USA.
Notes 1-4 • Chapter 1 Overview Innovation Series Medium Voltage GP Type - G Drives GEH-6385
Chapter 2 Faults and Troubleshooting Introduction For information on using the keypad refer to the drive User's Guide, GEH-6382. GEH-6401 describes the toolbox. The drive software includes selftest diagnostics to aid in troubleshooting. When these tests detect an unfavorable condition, they output fault indications to the drive’s operator interfaces: the door-mounted Drive Diagnostic Interface (DDI, referred to as the keypad) or a connected PC running the GE Control System Toolbox (the toolbox).
Types of Faults There are currently two types of fault conditions: • Alarm faults indicate conditions that you should note, but that are not serious enough to automatically shut down or trip the drive. If the condition goes away, some alarm faults clear themselves and the display then identifies the alarm as brief. Otherwise, you must stop the drive to clear this type of fault. • Trip faults indicate a more serious condition that needs to be corrected. Therefore, it trips the drive.
Fault Descriptions Note When troubleshooting leads to a hardware inspection or component replacement, be sure to follow the procedures described in the drive User’s Guide, GEH-6382. This will help ensure that the equipment operates correctly. When troubleshooting leads to a hardware inspection or component replacement, be sure to follow the procedures described in the drive User’s Guide, GEH-6382.
No. 3 Name Type Description Cont failed to close Trip The Cont failed to close trip fault occurs when contactor A is commanded to open or close and fails to do so within the allowed time (defined by parameter MA pickup time). Primary causes: The contactor A feedback is missing or bad. Possible configuration faults: The allowed time for contactor A to open and close is too short. The allowed time is represented by parameter MA pickup time.
No. Name Type Description 10 Run cmd w high flux Alarm The Run cmd w high flux alarm occurs when a Run request, Jog request, Full flux request, or diagnostic test (cell test, pulse test, autotune) request is issued and the variable Flux reference is greater than 2 percent rated flux (100% Flux). Primary causes: An attempt is made to restart the drive quickly. Normally four rotor time constants are required to allow the flux to decay after the drive stops running.
No. Name Type Description 16 Illegal req for xfer Alarm The Illegal req for xfer alarm occurs when a motor transfer command is issued and a trip fault is present in the drive. The alarm may also occur when a motor transfer command is issued at the same time a diagnostic test (cell test, pulse test, autotune) is active. Primary causes: The external application layer issues an inappropriate motor transfer request.
No. Name Type Description 24 Power dip Trip The Power dip trip fault occurs when the DC link voltage feedback (variable DC bus voltage) falls below the power dip level and remains below the power dip level longer than the power dip time. The power dip time is configurable through parameter Power dip control. If the DC link voltage feedback is at some moments below the power dip level and at some moments above the power dip level, the trip fault can occur.
No. Name Type Description 31 Tach loss alarm Alarm The Tach loss alarm occurs when the difference between the tachometer feedback (variable Motor speed) and the estimated speed (variable Calculated speed) is too large. When the alarm occurs, the drive dynamically switches to tachless control mode. The drive continues tachless operation until the fault is cleared by an operator. Tach loss fault mode can be used to change the fault behavior to trip if required.
No. Name Type Description 36 BICM card clock fail Trip The BICM card clock fail trip fault occurs when FPGA logic on the BICM cannot detect the presence of either one of its clock signals. One of the clocks it is looking for is generated by a crystal on the BICM itself and the other is transmitted via the rack backplane from DSPX. Primary causes: Card or connector failure.
No. Name Type Description 42 DC bus under voltage Trip The DC bus under voltage trip fault occurs when the DC link voltage feedback (variable DC bus voltage) is too low. The trip fault only occurs when the drive is running. Possible board failures: FOSA DSPX 43 Ground flt alm, LP Alarm The Ground flt alm, LP alarm occurs when a large ground current is detected by the BICM Motor Ground Protection.
No. Name Type Description 46 X stop Trip The X stop trip fault occurs when the X stop circuit is open and when X stop is configured as a trip fault. X stop is configured as a trip fault when parameter X stop mode is set equal to Trip flt stop. Any other setting for parameter X stop mode disables the X stop trip fault. The state of the X stop circuit is determined by the value of the variable to which parameter X stop request sel points.
No. Name Type Description 50 HtSink DS temp low Trip The HtSink DS temp low trip fault occurs when the diode source heatsink temperature (variable DS heat sink temp) is too low. The main purpose of the fault is to detect the absence of the thermal sensor input from the heatsink. Primary causes: The DS heatsink thermal sensor input is not present. No power to TFBA card or TFBA card failure.
No. Name Type Description 57 DB resistor hot Alarm The DB resistor hot alarm occurs when the dynamic braking resistor thermal model indicates that the dynamic braking package is approaching its rating. Primary causes: Incorrect configuration of DB thermal model. DB resistor package is marginal for application. 58 Motor reac parms bad Trip The Motor reac parms bad trip fault occurs when the primary motor reactance parameters have values that are not appropriate relative to one another.
No. Name Type Description 68 HtSink C over temp Trip The HtSink C over temp trip fault occurs when heatsink C temperature (variable Heat sink C temp) is too high. Related functions: Heatsink Thermal Protection 69 BICM card hot Alarm The BICM card hot alarm occurs when the sensor on BICM measures a temperature that is hot. The sensed temperature is above 55C and the control electronics are operating outside of their design parameters.
No. Name Type Description 77 HtSink DS rise high Alarm The HtSink DS rise high alarm occurs when the diode source heatsink temperature (variable DS heat sink temp) is too far above the ambient temperature (variable Bridge ambient temp). Related functions: Heatsink Thermal Protection 78 HtSink A rise high Alarm The HtSink A rise high alarm occurs when heatsink A temperature (variable Heat sink A temp) is too far above the ambient temperature (variable Bridge ambient temp).
No. Name Type Description 85 Flux req while flt Alarm The Flux req while flt alarm occurs when a flux command is issued and a trip fault is present in the drive. The alarm may also occur when a flux command is issued at the same time a diagnostic test (cell test, pulse test, autotune) is active. Primary causes: The external application layer issues an inappropriate flux enable request.
No. Name Type Description 88 AC line under volt Trip The AC line under volt trip fault occurs when the control firmware detects that the magnitude of the ac line is below the value of Line UV fault level, which has a suggested value of 50% of the nominal ac line input. The voltage magnitude used for this comparison is a low-pass filtered version of the signal. The filter is set to 1.2 rad/sec as a default, so transient voltages below the alarm turn-on value can occur without causing this trip fault.
No. Name Type Description 91 AC line freq high Alarm The AC line freq high alarm occurs when the control firmware detects that the frequency of the AC line is above the value of Over freq alm level, which has a suggested value of nominal frequency plus 17.3 rad/sec. The frequency value used for this comparison is a low-pass filtered version of the fastest version. The filter is set to .
No. Name Type Description 93 AC line freq low Alarm The AC line freq low alarm occurs when the control firmware detects that the frequency of the AC line is below the value of Under freq alm level, which has a suggested value of nominal minus 17.3rad/sec. The frequency value used for this comparison is a low-pass filtered version of the fastest version. The filter is set to .2 rad/sec as a default, so transient under-frequency values are allowed below the threshold value without causing this alarm.
No. Name Type Description 98 Ambient over temp Trip The Ambient over temp trip fault occurs when the ambient temperature (variable Bridge ambient temp) is too high. The main purpose of the trip fault is to use the ambient temperature measurement to detect a condition which could endanger the power bridge. Primary causes: The bridge environment and running conditions cause the ambient temperature to rise above a safe operating level.
No. Name Type Description 103 A-B voltage offset Trip The A-B voltage offset trip fault occurs when the A-B line-line voltage offset (variable A-B, Voltage offset) is too large. A-B, Voltage offset is the output of an automatic voltage offset calculation. The trip fault only occurs when the offset calculation is not active. A-B voltage offset evaluates A-B voltage feedback information collected while the power bridge is turned off, when voltage feedbacks should be zero.
No. Name Type Description 109 Task 1 exec overrun Alarm The Task 1 exec overrun alarm occurs when Task 1 exceeds its allotted CPU execution time. This alarm may occur during system development but should not occur in the field. Primary causes: Task 1 contains too much functionality to complete in the specified execution time. Possible board failures: DSPX 110 Task 2 exec overrun Alarm The Task 2 exec overrun alarm occurs when Task 2 exceeds its allotted CPU execution time.
No. Name Type Description 114 Ain 1 signal alarm Alarm The Ain 1 signal alarm occurs when the level of analog input number 1 (variable Analog input 1) is too low. The alarm level is specified by parameter Analog in 1 flt lev. The alarm can occur only when parameter Analog in 1 flt mode is set equal to Low level alarm. The alarm is disabled for any other setting for parameter Analog in 1 flt mode. The main purpose of Ain 1 signal alarm is to detect a low 4-20 mA signal.
No. Name Type Description 116 Ain 2 signal alarm Alarm The Ain 2 signal alarm occurs when the level of analog input number 2 (variable Analog input 2) is too low. The alarm level is specified by parameter Analog in 2 flt lev. The alarm can occur only when parameter Analog in 2 flt mode is set equal to Low level alarm. The fault is disabled for any other setting for parameter Analog in 2 flt mode. The main purpose of Ain 2 signal alarm is to detect a low 4-20 mA signal.
No. Name Type Description 119 Start permissive bad Alarm The Start permissive bad alarm occurs when the start permissive circuit is open and the drive is stopped. The state of the start permissive circuit is determined by the value of the variable which parameter Start permissive sel selects. The alarm can be disabled by setting parameter Start permissive sel equal to Unused.
No. Name Type Description 123 AS1 IGDM card flt Trip The AS1 IGDM card flt trip fault is hardware generated. The trip fault occurs when the bridge control has lost communication with the indicated IGDM module. This communication occurs via fiber optic cable between the FOSA and the IGDM. During normal operation the IGDM transmits continuous light back to FOSA. Any loss of this signal triggers this trip fault. Several unrelated situations can cause the light to stop transmitting.
No. Name Type Description 125 AS3 IGDM card flt Trip The AS3 IGDM card flt trip fault is hardware generated. The trip fault occurs when the bridge control has lost communication with the indicated IGDM module. This communication occurs via fiber optic cable between the FOSA and the IGDM. During normal operation the IGDM transmits continuous light back to FOSA. Any loss of this signal triggers this trip fault. Several unrelated situations can cause the light to stop transmitting.
No. Name Type Description 127 BS1 IGDM card flt Trip The BS1 IGDM card flt trip fault is hardware generated. The trip fault occurs when the bridge control has lost communication with the indicated IGDM module. This communication occurs via fiber optic cable between the FOSA and the IGDM. During normal operation the IGDM transmits continuous light back to FOSA. Any loss of this signal triggers this trip fault. Several unrelated situations can cause the light to stop transmitting.
No. Name Type Description 129 BS3 IGDM card flt Trip The BS3 IGDM card flt trip fault is hardware generated. The trip fault occurs when the bridge control has lost communication with the indicated IGDM module. This communication occurs via fiber optic cable between the FOSA and the IGDM. During normal operation the IGDM transmits continuous light back to FOSA. Any loss of this signal triggers this trip fault. Several unrelated situations can cause the light to stop transmitting.
No. Name Type Description 131 CS1 IGDM card flt Trip The CS1 IGDM card flt trip fault is hardware generated. The trip fault occurs when the bridge control has lost communication with the indicated IGDM module. This communication occurs via fiber optic cable between the FOSA and the IGDM. During normal operation the IGDM transmits continuous light back to FOSA. Any loss of this signal triggers this trip fault. Several unrelated situations can cause the light to stop transmitting.
No. Name Type Description 133 CS3 IGDM card flt Trip The CS3 IGDM card flt trip fault is hardware generated. The trip fault occurs when the bridge control has lost communication with the indicated IGDM module. This communication occurs via fiber optic cable between the FOSA and the IGDM. During normal operation the IGDM transmits continuous light back to FOSA. Any loss of this signal triggers this trip fault. Several unrelated situations can cause the light to stop transmitting.
No. Name Type Description 135 AC line transient Alarm The AC line transient alarm occurs as a result of significant phase lock loop error or significant phase imbalance. A phase imbalance signal is calculated by subtracting a control calculated threshold from a filtered signal which is formed by filtering the sum of two signals. One of these signals is the phase lock loop error and the other is the error between the demodulated real component of line voltage and the measured magnitude of the line.
No. Name Type Description 136 AC line watchdog Trip The AC line watchdog trip fault will occur when the AC line transient alarm persists for about one second. Both the trip fault and the alarm are a result of significant phase lock loop error or significant phase imbalance. A phase imbalance signal is calculated by subtracting a control calculated threshold from a filtered signal which is formed by filtering the sum of two signals.
No. Name Type Description 138 AC line vfb offset Trip The AC line vfb offset trip fault occurs when the voltage feedback offset being calculated for line voltage feedbacks is above the allowable threshold. The system integrates the voltages seen on the AC input terminals. The results of this integration should be near zero since the input waveform is a sine wave. If the input line-line voltages integrate to a non-zero value above a predefined threshold this trip fault is generated.
No. Name Type Description 145 Customer use NC flt Trip The Customer use NC flt trip fault occurs when the customer normally closed circuit is open. The state of the normally closed circuit is selected by parameter User NC fault sel. 146 Customer use NC alm Alarm The Customer use NC alm alarm occurs when the customer normally closed circuit is open. The state of the normally closed circuit is selected by parameter User NC fault sel.
No. Name Type Description 153 DSPx Watchdog Trip Locke d The DSPx Watchdog trip fault occurs when the DSPX EPLD stops seeing a watchdog toggle bit from the processor. A hard reset occurs and the fault is declared at initialization. DSPx Watchdog requires a hard reset to clear. Possible board failures: DSPX 154 Reverse rotation Trip The Reverse rotation trip fault occurs when the motor shaft is rotating opposite to the requested direction.
No. Name Type Description 162 LAN watchdog alarm Alarm The LAN watchdog alarm occurs when the connection between DSPX and the Application/LAN interface becomes invalid. This includes one of the following conditions, depending upon the selection of Network interface: The Application/LAN interface Dual-Port RAM watchdog stops. The ISBus frames stop. The alarm is declared after the condition persists for several hundred microseconds.
No. Name Type Description 169 Frame PLL not OK Alarm The Frame PLL not OK alarm occurs when phase-lock between the DSPX control and the System ISBus or (local ACL) is not assured. Detection of the fault is enabled when the parameter Network interface is configured to select an interface for which synchronized operation is supported. The presence of this alarm indicates that data coherency is compromised. Verify the integrity of IsBus connections and configurations.
Chapter 3 Paramters/Functions Introduction Chapter 4 describes wizards. Application firmware consists of coordinated blocks of code called functions. Each function performs a specific task in controlling the drive. Parameters are adjustable values within a function that allow you to configure and adjust the drive behavior. Parameters can be set and modified using wizards within the keypad and the optional toolbox.
LAN Overview............................................................................................3-34 Frame Phaselock Loop ................................................................................3-34 LAN Configuration and Health....................................................................3-35 LAN Signal Map.........................................................................................3-38 Motor Control Functions ................................................................
Motor winding cfg.....................................................................................3-114 Preflux Forcing .........................................................................................
Diagnostic and Utility Functions Diagnostic and Utility Overview The Innovation Series products contain a number of diagnostic functions. More information is available for the following topics. • Capture Buffer • General Purpose Constants • General Purpose Filters • Oscillator • Position Feedback • Predefined Constants • Signal Level Detector (SLD) • Simulator Capture Buffer The Innovation Series capture buffer is used to collect coherent data at a specified rate in the drive.
The following variable is also an input to the Capture Buffer function. Variable Description Capture buffer ready Enables or disables the capture buffer data collection. Function Outputs The following table specifies the status variables of the Capture Buffer function. Variable Description Capture buffer stat Indicates the status of the capture buffer. Possible values are: Complete - Capture buffer has completed its collection of data and is disabled.
Function Configuration The following table specifies the parameters that configure the size and execution rate of the capture buffer. Parameter Description Capture buff config Specifies the number of channels to collect. The depth of the capture buffer is inversely proportional to the number of channels collected.
The following table specifies the parameters that configure the capture buffer trigger control. The capture buffer will also automatically trigger on the rising edge of Trip fault active. Parameter Description Capture pre trigger Specifies the portion of the capture buffer that will be collected before the trigger occurs. Percent. Capture trig select Selects capture buffer trigger variable. The capture buffer will also automatically trigger on the rising edge of Trip fault active.
Function description The capture buffer can be accessed from the Trend Recorder in the Control System Toolbox. To enable the Trend Recorder: • From the View menu, select Trend Recorder OR select the Trend Recorder button on the toolbar: . To enable the Innovation Series capture buffer from the Trend Recorder: 1. From the Edit menu, select Configure OR select the Configure button from the Trend Recorder toolbar: 2.
Capture Buffer Compatible Behavior To view more than 4 channels or more than 512 samples, the Capture Buffer function should be used with a GE Control System Toolbox with a release of at least V6.1. Toolbox version prior to the V6.1 release can handle a maximum capture buffer size of 4 channels x 512 samples.
General Purpose Constants Each Innovation Series product provides three general purpose constants. The general purpose constants allow users to place constant values in device variables. The general purpose constants are particularly useful in configuring diagnostic functions. Function inputs The following table specifies the input parameters of the General Purpose Constants function.
General Purpose Filters Each Innovation Series product contains four general purpose filters. The general purpose filters allow users to filter signals with a specified bandwidth. Function inputs The following table specifies the input parameters of the General Purpose Filters function.
The general purpose filters run at the fastest execution rate available in the product. This is the same rate at which bridge feedbacks are collected, the fastest regulators are operated, and hardware commands are issued. The filter execution rate is generally faster than the 1-millisecond rate at which the application functions and the LAN communications occur. Related diagrams • Diagnostic & Utility Functions (Diag_Util) Oscillator Each Innovation Series product contains a diagnostic oscillator.
Position Feedback The Position Feedback function provides a set of position feedback signals in 22-bit floating point format. Function inputs The following tachometer signals are inputs to the Position Feedback function. • Tachometer position: This signal is a 16-bit integer with units of A-quad-B counts. • Marker count: This signal is a 16-bit integer that increments every time a marker pulse is detected. • Marked tachometer position: This signal is a 16-bit integer with units of A-quadB counts.
Predefined Constants Each Innovation Series product contains a number of predefined constants. These constants are available for use in a variety of functions. They are generally found on the selection lists for parameters that select control signals. Floating point constants The following floating point constants are available. • Constant float 0.0 • Constant float -1.0 • Constant float 1.0 Integer constants The following integer constants are available.
Signal Level Detector (SLD) Each Innovation Series product supplies three SLD channels. Each SLD does a level comparison on two inputs. The Boolean output of the SLD represents the status of the comparison. The nature of the comparison is configurable. Function inputs The following table specifies the input parameters of the Signal Level Detector (SLD) function.
Function description The following description explains the operation of SLD1. It also applies to SLD2 and SLD3. Parameters SLD1 input 1 select and SLD1 input 2 select select device variables. They define the inputs for SLD1. The following table specifies how the inputs are formed based on the value of parameter SLD1 input 1 abs val.
SLD1 compare mode = In1=In2 Turn on condition Absolute value of (Input 1 - Input 2) <= SLD1 sensitivity Turn on delay time Turn on condition must remain valid for SLD1 pick up delay. After the delay SLD1 status = True. Turn off condition Absolute value of (Input 1 - Input 2) > (SLD1 sensitivity + SLD1 hysteresis) Turn off delay time Turn off condition must remain valid for SLD1 drop out delay. After the delay SLD1 status = False.
Simulator The Simulator function allows the user to simulate the operation of the drive and motor without applying power to the motor, power bridge, and other equipment. Function inputs The following table specifies the input parameters of the Simulator function. Parameter Description Ext sim spd enb sel Selects the signal that disables the calculated model speed and allows the speed to be specified by another source.
Control Diagnostic Variables The Control Diagnostic Variables function outputs filtered diagnostic variables that are available to the user. Function outputs The following table specifies the output variables of the Control Diagnostic Variables function. Variable Description AC line voltage mag Filtered ac line magnitude. A true magnitude calculation of Vab and Vbc which is then filtered. AC line frequency Filtered ac line frequency produced by the phase lock loop.
Function outputs The following table specifies the output variables of the Line Simulator function.
Pattern field The pattern field is designated by the character G. The character has the following meaning: G General industrial application firmware pattern Frame size field The frame size field is designated by the characters FRAM. The designation has the following meaning: FRAM Bridge frame size The following medium voltage drive frame sizes are supported: 0700 (Eupec IGBTs) 0701 (Powerex IGBTs) System voltage field The system voltage field is designated by the characters VOLT.
The following table lists the user-entered parameters that specify the primary motor and application data: Parameter Description Motor rated current Motor nameplate current. Amps Motor rated voltage Motor nameplate voltage. Volts Crossover Voltage Voltage at which field weakening begins. RMS volts Motor rated power Motor nameplate power. Kilowatts or Horsepower Motor rated freq Motor nameplate frequency. Hertz Motor rated rpm Motor nameplate speed. RPM The number of magnetic poles in the motor.
Calculated control variables The Innovation Series drive contains a set of variables that are calculated from the primary motor parameters but are not exact reflections of the primary parameters. These calculated variables are used in motor control and protective functions. The values of the variables are calculated at drive initialization after power up or a hard reset.
General Setup Functions Keypad Overview The Drive Diagnostic Interface (DDI; also known as the keypad) is mounted on the door of an Innovation Series drive. The DDI provides a simple, easily accessible means for a user to set, monitor, and maintain the drive locally. The DDI provides both analog and digital representations of drive functions and values. Its keypad is logically organized into two functional groups: navigation keys and drive control keys.
Keypad Contrast Adjustment Normally the LCD contrast of the Drive Diagnostic Interface (DDI) should be adjusted at the DDI or keypad. The user can modify the Keypad contrast adj parameter under the General Setup -> Keypad -> Keypad Functions menu. A special keypad key sequence is also available to make this adjustment and is especially useful when the contrast is too light or too dark to navigate the menus.
The variables displayed by the meters and the meter ranges can be modified by configuring the following parameters: Function configuration Parameter Description Keypad meter 1 sel Selects a floating-point variable that is displayed in Meter #1 on the DDI Status screen. Keypad meter 2 sel Selects a floating-point variable that is displayed in Meter #2 on the DDI Status screen. Keypad meter 3 sel Selects a floating-point variable that is displayed in Meter #3 on the DDI Status screen.
Keypad Security Configuration The DDI contains security controls to keep unauthorized personnel from operating or reconfiguring the drive. These security controls can be modified from the toolbox or from the DDI. The controls are password protected in the DDI. Function configuration Parameter Description Keypad privilege Selects the privilege level in the DDI. Possible levels are: Read only - Disables both drive controls and configuration functions. Allows user to view but not edit parameters.
Function description The following table displays a list of all DDI functions. Available functions for each privilege level are marked with a check mark (ü).
Three different unit systems are available: • Imperial (English) • Metric (SI) • Native (Platform) If Display units is set to Native (Platform), then values are displayed in the same units that the internal control uses. The following table specifies some of the unit system differences.
The toolbox will then build the DDI Menu file and can be downloaded to the DDI. Once the download is completed, the user can then modify the Language parameter to the desired value. The DDI will display its text in the selected language the next time its screen is updated I/O Functions Analog and Digital I/O Testing The Analog and Digital I/O Testing function is intended for factory use only.
Digital inputs The following table specifies the signals available for testing the digital inputs. Variable Description Digital input 1 test Unfiltered value of digital input 1. Digital input 2 test Unfiltered value of digital input 2. Digital input 3 test Unfiltered value of digital input 3. Digital input 4 test Unfiltered value of digital input 4. Digital input 5 test Unfiltered value of digital input 5. Digital input 6 test Unfiltered value of digital input 6.
Relay outputs The following table specifies the parameters that configure the relay output test. Parameter Description Relay 1 test Relay 1 output. Relay 2 test Relay 2 output. Relay 3 test Relay 3 output. SS relay driver test Relay 4 output. Related diagrams • Analog and Digital I/O Testing (HWIO_Tst) Analog Inputs/Outputs and Mapping Analog Inputs Two bipolar (±10 volts) analog inputs are available at the terminal board (ATB).
Digital Inputs/Outputs and Mapping Digital inputs and outputs provide an interface between the outside world and the control. The ATB (terminal board) provides six general purpose digital inputs. Three dry contact relays and one solid state relay driver are provided as outputs. System and Local fault strings provide start and trip interlocks to the control. Isolated digital inputs are listed with their associated terminal board points. A filter debounces a noisy input signal.
LAN Functions LAN Overview Information is available for the following LAN topics: • Frame Phaselock Loop • LAN Configuration and Health • LAN Signal Map Frame Phaselock Loop The Frame Phaselock Loop function can synchronize the execution of the Innovation Series drive control firmware with the communication frame of the product application interface. This feature is available only for those interface which support synchronous communications, such as ISBus.
Function description The product completely handles configuration of the Frame Phaselock Loop function. Appropriate user selections of Network interface activate the function, and user specification of LAN frame time sets the nominal period. The Boolean variable Frame PLL OK status indicates the status of the Frame Phaselock Loop. The asserted state indicates that the function has been activated and that lock status has been validated.
Configuration parameters The following table specifies the configuration parameters of the LAN Configuration and Health function. Parameter Description Network interface Network interface type. Specifies one of the following interface types: No interface ACL dual port memory ISBus DRIVENET - Other optional LAN modules such as Genius and Profibus LAN frame time Expected communication frame period. Allowed frame periods are 1, 2, 4, and 8 milliseconds.
Diagnostic variables The following table specifies variables that indicate the LAN health and status for the LAN Configuration and Health function. Variable Description LAN connection ok Indicates that the health of the LAN connection is good, such that the LAN watchdog function is satisfied. LAN commands OK Indicates that the health of the LAN references is good, based upon detection of two successive LAN connection ok indications.
The LAN watchdog function describes the set of mechanisms the drive uses to determine the status of the connection between DSPX and the module immediately “above” the drive in the LAN hierarchy. For Dual-Port RAM interfaces, such as that used for an embedded ACLA controller and for a direct LAN interface, the watchdog takes the form of a handshake protocol. In this handshake protocol, the drive determines the presence of a minimum level of intelligence on the host on the LAN side of the shared memory.
Each 32-bit element in the LAN Signal Map is assigned a data type. The following data types are used. • Single precision floating point, IEEE 754 format (23-bit mantissa, 8-bit exponent, 1-bit sign). • Two’s complement integer. • Individual 1-bit Boolean signals. LAN References The following table specifies the LAN Signal Map reference signals. Page & Element Signal Data Type Description Boolea n bits Boolean requests. See table below for definition of request bits.
The following table specifies the LAN Signal Map request bits that appear in Page 1, Element 1 of the reference signal map. Bit Signal Description 0 Heartbeat ref, lan Heartbeat signal to validate LAN health. 1 Fault reset req, lan Request to reset drive faults. Functionality is always enabled. 2 Trip request, lan Request to trip the drive. Functionality is always enabled. 3 Alarm request, lan Request to declare an alarm in the drive. Functionality is always enabled.
LAN Feedbacks Several LAN feedback signals are averaged versions of internal drive signals. The signals that fall in this category appear in dedicated floating point feedback channels. The averaging is sequential (not rolling), and the averaging time is specified by parameter LAN fbk avg time. The following table specifies the LAN Signal Map feedback signals. Page & Element 1 1 1 2 1 Signal Data Type Description Boolean bits Boolean feedbacks. See table below for definition of feedback bits.
The following table specifies the LAN Signal Map feedback bits that appear in Page 1, Element 1 of the feedback signal map. Bit Signal Description 0 1 2 3 4 Heartbeat fbk, lan No faults active Trip fault active Local fault string System fault string Ready to run Bridge is on Running Heartbeat signal to validate LAN health. No trip faults or alarms are active in the drive. Trip fault is active in the drive. Local hardware permissive fault is active in the drive.
The following parameters are used to select the general purpose feedback bits.
Motor Control Functions Motor Control Overview The Innovation Induction motor control algorithm utilizes a Flux-Vector control strategy.
Flux Curve The Flux Curve describes the relationship between the induction motor voltage and current. Specifically, each point of the curve specifies the voltage that is measured at the motor terminals for a particular excitation current, under no load conditions at the nameplate frequency. Function configuration The Flux Curve consists of five voltage and current points. Two parameters are associated with each point. The following table lists the parameters that configure the Flux Curve.
Leakage Inductance Curve The Leakage Inductance Curve describes the relationship between motor leakage flux and torque current. The motor data sheet does not provide Leakage Inductance Curve information. The characteristics of the curve can be obtained experimentally or by running the Motor Control Tuneup. Line Transfer The Line Transfer function transfers a motor from the drive to the utility line and captures a motor from the utility line to return control to the drive.
Motor transfer functionality The following table specifies parameters relating to the motor transfer function. Parameter Description Transfer mtr req sel Selects the source of motor transfer requests. The following table specifies variables relating to the motor transfer function. Variable Description Transfer motor req Indicates that the user has requested a motor transfer.
External line reference functionality The use of an ELR is recommended when the phase angle and magnitude of the utility feed the drive is expected to transfer the motor to cannot be accurately predicted from the phase angle and magnitude of the ILR. Such situations can arise when transferring the motor to a generator, to a utility feed separate from the one supplying the drive or in certain plants where multiple transformers with varying loads are involved.
Motor Temperature Estimation The Motor Temperature Estimation function estimates the rotor and stator temperatures. Function inputs The Motor Temperature Estimation uses the following information to calculate the rotor and stator temperatures: • Estimated rotor and stator resistances • Thermal properties of the stator and rotor winding materials • Motor ambient temperature The estimated rotor and stator temperatures are calculated using online parameter estimation.
Faults and alarms The following table specifies the faults and alarms that the Power Dip Protection function declares. Fault Description Power dip Trip fault that occurs when the DC link voltage remains below the power dip activation level for a specified period of time. Causes drive to stop running. Function description The Power Dip Protection function is activated when the drive determines that the DC link voltage is low. The power dip voltage level is defined as 80% x 1.357 x IPN volt rating.
Function inputs The following table specifies the input variables of the Tach Loss Detection function. Variable Description Output freq, unfil Motor electrical frequency. Hertz Tach speed, instr. Tachometer speed feedback. Radians/second Function configuration The following table specifies the configuration parameters for the Tach Loss Detection function.
Protective Functions Custom User Faults Each Innovation Series product provides the capability to configure two fault circuits. The trip faults Customer use NC flt and Customer use NO flt trigger on input signals that are the states of the fault circuits. Customer use NC flt occurs when the normally closed circuit is open. Customer use NO flt occurs when the normally open circuit is closed. Function inputs The following table specifies the input parameters of the Custom User Faults function.
Function configuration The following table specifies the DC Link Protection configuration parameters. Parameter Description DC bus region max High boundary of user specified DC link voltage region. DC volts DC bus region min Low boundary of user specified DC link voltage region. DC volts Faults and alarms The following table specifies the faults and alarms associated with the DC Link Protection. Fault/Alarm Description DC bus over voltage Trip fault that occurs when the DC link voltage is too high.
Ground Fault Protection (Fast) The Ground Fault Protection (Fast) tests the phase currents to verify that there is no ground current in the system. Function inputs The following table specifies the input parameters of the Ground Fault Protection (Fast) function. Parameter Description Phase A current Phase A current feedback. Amps Phase B current Phase B current feedback. Amps Phase C current Phase C current feedback.
Hardware Fault Strings Each Innovation Series product provides a hardwired, fail-safe circuit to turn off bridge power and to shut down its control. The circuit consists of two independent isolated inputs designated the local and system fault strings. The loss of either input results in the shutdown of the power bridge and control. Diagnostic variables The following table specifies the Hardware Fault Strings diagnostic variables.
Heatsink Thermal Protection The Heatsink Thermal Protection function measures the power bridge heatsink and ambient temperatures and verifies that they are at a safe operating level. Function inputs The inputs to the Heatsink Thermal Protection function are hardware thermal sensor connections. The bridge ambient temperature thermal sensor connects to backplane connector J4. The control rack ambient temperature thermal sensor is located on BICM. The heatsink thermal sensors connect to FOSA.
Related faults and alarms The following faults and alarms are declared by the Heatsink Thermal Protection function. Temperatures are described as "high" and "low", relative to non-adjustable setpoints in the control. Fault/Alarm Description Ambient temp hot Ambient temperature (variable Bridge ambient temp) is high. Ambient over temp Ambient temperature (variable Bridge ambient temp) is too high. Ambient temp low Ambient temperature (variable Bridge ambient temp) is too low.
Fault/Alarm Description HtSink DS temp hot Diode source heatsink temperature (variable DS heat sink temp) is high. HtSink DS over temp Diode source heatsink temperature (variable DS heat sink temp) is too high. HtSink DS rise high Diode source heatsink temperature (variable DS heat sink temp) is too far above ambient temperature (variable Bridge ambient temp). HtSink DS temp low Diode source heatsink temperature (variable DS heat sink temp) is too low.
Function description The variables Output volts, A-B and Output volts, B-C are filtered versions of the measured line-line voltage feedbacks. The default filter frequency is 1000 rad/sec. When the drive is stopped, it performs an automatic voltage offset calculation. If the drive does not have a contactor, the offset calculation happens continuously. If a contactor is present, the calculation occurs when the contactor closes immediately before the drive begins running.
Faults and alarms The following table specifies the faults and alarms that the Motor Overtemperature Detection function declares.
Function description The variables Phase A current, Phase B current, and Phase C current are filtered versions of the measured phase current feedbacks. The default filter frequency is 1000 rad/sec. When the drive is stopped, it performs an automatic current offset calculation. During the calculation the power bridge is turned off, and the phase currents should be zero. Any appreciable phase current that is detected during the calculation indicates a potential power bridge or feedback circuitry problem.
Faults and alarms The following table specifies the faults and alarms associated with the Timed Overcurrent Detection function. Fault/Alarm Description Timed over current Trip fault that occurs when one or more of the squared phase currents is too high for an extended period of time. TOC pending Alarm that occurs when one or more of the squared phase currents is too high for an extended period of time.
The following graphs show the time a motor of each of the protection classes can operate before reaching trip conditions. The time is a function of the load applied to the motor. The first graph assumes the motor was not running before the overload condition was applied. The second graph assumes the motor was running continuously at rated current.
The capability of the drive to produce the overload current depends on the capacity of its power circuit. Especially at higher overload levels, the drive may not be able to sustain the motor's overload current as defined by Motor protect class. The motor heating model has the capability of implementing a speed dependent motor cooling characteristic. The user defined cooling characteristic is activated when Disable TOC profile is False.
Transformer Overtemperature Detection Those Innovation Series products that are part of a system containing a transformer provide the capability to detect transformer overtemperature condition. The Xfrmr over temp trip fault and the Xfrmr temp hot alarm trigger on a signal that is a digital input from the transformer overtemperature fault circuit. Either the fault or alarm occurs when the transformer overtemperature circuit is open.
Motor Ground Protection The Motor Ground Protection function detects a ground fault condition in the motor phases. The function is automatically configured by the control; no user configuration is necessary. Function inputs The following table specifies the input variables of the Motor Ground Protection function. Variable Description DC neut volt mag Absolute value of the DC bus neutral voltage Function outputs The following table specifies the output variables of the Motor Ground Protection function.
Diagnostic variables The following table specifies the diagnostic variables of the Motor Ground Protection function. Variable Description Gnd flt warning This variable is for external use to indicate that the alarm, Ground flt alm, LP is present. Gnd flt trip This variable is for external use to indicate that the fault, Gnd flt trip is present. Faults and alarms The following table specifies the faults and alarms of the Motor Ground Protection function.
Phase Imbalance Monitor The Phase Imbalance Monitor function monitors the condition of the phase imbalance on the ac line as well as the status of the phase lock loop. Function inputs The following table specifies the input parameters of the Phase Imbalance Monitor function. Variable Description PLL error This is the error signal of the phase lock loop. X axis line voltage The demodulated, x-component of the ac line voltage. This variable is also used in the Phase Lock Loop function.
Faults and alarms The following table specifies the faults and alarms of the Phase Imbalance Monitor function. Fault/Alarm Description AC line transient This alarm occurs as a result of significant phase lock loop error or significant phase imbalance. AC line watchdog This trip fault will occur when the AC line transient alarm persists for about one second. Both the trip fault and the alarm are a result of significant phase lock loop error or significant phase imbalance.
Line Monitor The Line Monitor function monitors the AC line voltage and frequency and compares them to acceptable limits. Several faults may result. The Drive Commissioning wizard automatically configures this function. Run the Line Protection Setup wizard to reconfigure this function. Function inputs The following table specifies the input parameters of the Line Monitor function.
Parameter Description Utility feed Determines the bandwidth of the Phase Lock Loop function. If set to True, the bandwidth is set to obtain an amount of “sluggishness” appropriate for a utility feed. The pll will be more robust and less sensitive to unreal disturbances. It should be set to True only if the line is a diesel-generator or other spongy line source. The bandwidth ratio of True versus True is 4:1. The default setting is True to assume a utility feed.
Phase Lock Loop The Phase Lock Loop function outputs magnitude, frequency, and phase information to the rest of the control, including the Line Monitor. A few configuration parameters are critical. See the parameters in the function configuration section. Function inputs The following table specifies the input variables of the Phase Lock Loop function. Variable Description Y axis line voltage The feedback for the phase lock loop regulator.
Variable Description PLL proven This boolean indicates whether the pll is locked. It is used throughout the control as a permissive to run or check various protections. Line monitor volt The filtered AC line voltage magnitude which is used by the Line Monitor function to protect the drive from overvoltage and undervoltage conditions. It is calculated as the square root of the sum of the squares of variables Y axis line voltage and X axis line voltage.
Sequencer Functions Sequencer Overview Sequencing is a key function of the Innovation Series drive. The sequencer oversees the starting and stopping of the drive. It keeps the drive from mis-operating during fault or diagnostic conditions. The sequencer also provides drive status information that can be used by various drive and application functions.
Function outputs Variable Description Trip fault active Indicates when a Trip fault is present. Trip fault active is True when a Trip fault exists. It is a NC contact in the Ready to run permissive string. Refer to Sequencer Permissives. No trip fault Indicates when a Trip fault is NOT present. Is True when there is no Trip fault. (Alarm may exist). No faults active Indicates when no Trip faults or Alarms are present. Is True when no faults or alarms exist in the drive.
Sequencer Permissives Sequencer permissives are used to prevent or allow the drive to run if the permissive condition exists in the drive. Two types of permissives exist: internal permissives and application permissives. Internal permissives are internal drive conditions that must be satisfied before the drive will run (for example, DC bus charged must be True before the drive can run.
Internal Permissive Inputs Variable Description Local fault string Local hardware permissive. When Local fault string is True, it will prevent the drive from starting or running. If a run is requested while Local fault string is True, a Trip fault, Local flt, will be generated. System fault string System hardware permissive. When System fault string is True, it will prevent the drive from starting or running.
Related faults and alarms The following faults and alarms may be generated when the Ready to run permissive is not satisfied. • Run permissive lost • Start permissive bad • Run cmd w high flux • Local flt • System flt • Run before MA closed • Flying restrt disabl • Run req & xstop open Related diagrams • General Sequencing #2 (GenSeq_2) Stopping Commands and Modes The sequencer provides two mechanisms for issuing a controlled stop of the drive: a Normal stop and an X-stop.
Normal Stop The Normal stop is the typical way to stop the drive in a controlled manner. A Normal stop can be configured as Ramp stop, Coast stop, or Quick stop. Function inputs The following parameters drive the function input variables: Parameter Description Run request select See Sequencer Commands for a description of this parameter. Jog request select See Sequencer Commands for a description of this parameter.
Function configuration Parameter Description Normal stop mode Selects the behavior of a normal stop. Possible choices are: Ramp stop Quick stop Coast stop (See below.) Flux off delay time Sets a time delay for which the drive remains fluxed after it has stopped. Allows the drive to be quickly restarted after it has stopped, without the delay of prefluxing the drive.
Function inputs Parameter Description X stop request sel Selects the variable that is inverted and then used to drive X stop active. The variable selected by X stop request sel must be False to initiate an X-stop. Variable Description X stop request, lan Is used to drive X stop active from the LAN when LAN commands OK is True. X stop request, lan must be True to initiate an X-stop. Please note that this is OPPOSITE the behavior of X stop request sel. (See also LAN Signal Map.
Sequencer Commands A sequencer request is generated from various user inputs to direct the sequencer to run or flux the drive. A sequencer command is the internal “go ahead” to sequencer once the permissive logic has been satisfied (see Sequencer Permissives). The variables Run request and Jog request are associated with Run Commands. They direct the sequencer to run the drive using the appropriate speed reference.
Function outputs Variable Description Run request The request to run the drive. The details of the logic which forms this signal is shown in the sequencer diagrams. Jog request The request to run the drive at the appropriate jog reference (see Local Speed Reference or Remote Speed Reference for details on speed reference). The details of the logic which forms this signal is shown in the sequencer diagrams.
Function outputs Variable Description Full flux request A request to enable the bridge and pre-flux the drive. This signal is the output of Full flux req sel and Full flux req, lan. Full flux command Internal sequencer command to enable the bridge and preflux the drive. This output requires that the Ready to run permissive string be satisfied. The details of the logic which forms this signal is shown in the sequencer diagrams.
Sequencer Status The sequencer provides drive status information that can be used by various application functions and is also used for internal sequencing functions. The status information is divided into 2 types: • Drive status variables • Sequencer status variables Drive status variables Drive status variables provide general information about the status of the drive (for example, whether it is running, stopped, and so forth).
Sequencer status variables Sequencer status variables are used to request and report status of internal regulator sequencing. These variables normally come in pairs of a Request and a Status. The Request is a command to either enable or disable the appropriate function. The Status is a feedback that indicates the command has been successfully executed (that is, enabled or disabled) and the sequencer can proceed to its next state.
Main Contactor Configuration The sequencer normally controls the operation of the main (MA) contactor. The contactor is picked up when the drive is powered up and only drops out when a Trip fault exists in the drive. The contactor may also be independently controlled from an external input. Function input Parameter Description MA close req sel Selects the Boolean variable that drives MA cont enable req to independently control the contactor.
Function description The main (MA) contactor can be either be automatically controlled by the sequencer, or independently controlled by using the parameter, MA close req sel. When controlled by the sequencer, the contactor is picked up when the drive is powered up and dropped out only on trip faults. When independently controlled, the contactor must be picked up before a run is requested. The contactor will also drop out on a trip fault regardless of the command.
Speed Reference Functions Critical Speed Avoidance The Critical Speed Avoidance function prevents the speed reference from entering speed avoidance zones. The user can specify three positive and three negative speed avoidance zones. The Critical Speed Avoidance function operates on the pre-ramp speed reference. Function inputs The following table specifies the input variables of the Critical Speed Avoidance function.
The table below lists how the parameters define the center speeds of each of the speed avoidance zones. Speed Avoidance Zone Center Speed Positive zone 1 Critical speed 1 Positive zone 2 Critical speed 2 Positive zone 3 Critical speed 3 Negative zone 1 -1 x Critical speed 1 Negative zone 2 -1 x Critical speed 2 Negative zone 3 -1 x Critical speed 3 The hysteresis is the same for all of the speed avoidance zones.
Function description The Local Speed Reference function is part of the Speed Reference Generation function. It forms a speed reference signal from the local source (the DDI). The Local Speed Reference function produces a local speed reference. This becomes the speed reference used by the Speed Reference Generation function if the drive is in local mode (when Local mode active is True). Local mode is enabled using the DDI Remote/Local button.
Function description The Minimum Speed Limit function is part of the Speed Reference Generation function. It operates on the speed reference after the Speed Reference Reverse and before the Critical Speed Avoidance function. The Minimum Speed Limit function prevents the speed reference from falling below a specified magnitude. The minimum speed magnitude is defined by parameter Minimum speed.
Function description The Remote Speed Reference function is part of the Speed Reference Generation function. It forms a speed reference signal from the remote source (typically a system level controller or an adjustable analog input). The Remote Speed Reference function produces a local speed reference that becomes the speed reference used by the Speed Reference Generation function if the drive is in remote mode (when Local mode active is False). Remote mode is enabled using the DDI Remote/Local button.
After the speed reference has been selected from the local or remote source, the Speed Reference Generation function allows several subordinate functions to operate on the speed reference. The Speed Reference Reverse function reverses the speed reference if the user has requested that action. The Minimum Speed Limit function makes sure the speed reference magnitude is above a specified level. The Critical Speed Avoidance function prohibits the speed reference from entering specified ranges.
The following table specifies the configuration parameters for the speed independent ramp rate mode, which is active when Ramp rate mode is set to Indep accel/decel. Parameter Description Acceleration rate 1 Ramp rate that is effective when the magnitude of Speed ref, pre ramp is increasing and ramp rate set 1 is active. RPM/second Acceleration rate 2 Ramp rate that is effective when the magnitude of Speed ref, pre ramp is increasing and ramp rate set 2 is active.
Function description The Speed Reference Ramp function is part of the Speed Reference Generation function. It operates on the speed reference after the Critical Speed Avoidance function and before its use in the Speed/Torque Overview function. The Speed Reference Ramp function limits the rate of change of the speed reference. Its input (Speed ref, pre ramp) may experience a step change of large magnitude. Its output (Speed ref, ramped) has the rate limit imposed on it.
The rate of change of the speed reference is limited to the acceleration rate when the magnitude of the speed reference is increasing. The rate of change of the speed reference is limited to the deceleration rate when the magnitude of the speed reference is decreasing. When an emergency stop is commanded, the Speed Reference Ramp decelerates the speed reference to zero at a rate defined by Emerg ramp rate. Emergency stop act indicates that an emergency stop has been commanded.
Function description The Speed Reference Reverse function is part of the Speed Reference Generation function. It reverses the speed reference in response to a user request. The speed reference input to the Speed Reference Reverse originates in the Local Speed Reference if Local mode active is True, or in the Remote Speed Reference if Local mode active is False. The value of Local mode active is selected with the DDI Remote/Local button.
Speed/Torque Control Functions Droop The Droop function adjusts the speed reference to compensate for the difference between the desired and actual load torque. Function inputs The following table specifies the input parameters of the Droop function. Parameter Description Droop comp ref sel Selects the load torque compensation. Per unit torque The following table specifies the input variables of the Droop function.
Motor Control Interface The Motor Control Interface function describes the main signals with which the application layer of drive functionality controls the inner motor control algorithm. The primary interface is represented by Torque ref pre limit, which is constrained by limits and transformed into a torque-producing current command Torque current ref.
Function outputs The following table specifies the output variables of the Motor Control Interface function. Variable Description Torque ref post lim Torque reference after application of positive & negatvie torque limits. Newton-meters or Pound-feet Trq cur ref pre lim Torque-producing current reference, transformed from Torque ref post lim by torque compensations, and enabled by Torque enable req.
Function configuration The following table specifies the configuration parameters of the Motor Control Interface function. Parameter Description Motoring torque lim1 Defines the motoring torque limit (or maximum value of the variable limit specified by Adj mtr trq lim sel) when the value of the Boolean signal selected by Torque lim 2 sel is False.
The active generating torque limit is subject to further limiting by the DC Bus Regeneration Control. The Regeneration Control can be configured to limit regenerative capability in response to DC Bus Voltage exceeding programmed limits. Both motoring & generating torque limits are dynamically applied as positive & negative torque limits according to the detected quadrant of operation.
Failure to rotate configuration and operation The following parameters configure the Failure to rotate fault. Parameter Description Rotate fail flt lvl The level which the speed regulator error must exceed for the fault condition to exist. RPM Rotate fail spd lim The level which the speed regulator feedback must remain below for the fault condition to exist. RPM Rotate fail delay The time for which the fault condition must persist before the fault is declared.
Speed Feedback Calculation The Speed Feedback Calculation function provides a set of speed feedback signals for control and display purposes. Function inputs There are three main sources of speed feedback information: tachometer feedback, estimated speed, and simulated speed. The following table specifies the input variables of the Speed Feedback Calculation function. Variable Description Tach speed, instr. Measured tachometer speed.
Function configuration The following table specifies the configuration parameters of the Speed Feedback Calculation function. Parameter Description Motor tach PPR Tachometer pulses per revolution. Quantize Sim Spd Enables tachometer quantization in the simulated speed feedback. Speed feedback fil Control filter frequency for Speed reg fbk. Radians/second Tach speed filter Display filter frequency for Motor speed. Radians/second Spd fbk display fil Display filter frequency for Speed feedback.
Related functions The speed and torque control functions included in the Speed/Torque Overview function are listed below. • Speed Feedback Calculation • Droop • Speed/Torque Regulator • Motor Control Interface Related diagrams • Speed / Torque Overview (Ovr_SpTq) Speed/Torque Regulator The Speed/Torque Regulator function.
Function outputs The following table specifies the continuous signal variables of the Speed/Torque Regulator function. Variable Description Speed reg output Core regulator output of the Speed/Torque Regulator function, the scaled and gated sum of proportional (variable Speed reg prop term) and integral (variable Speed reg int term) regulator components.
Function configuration The following table specifies parameters that select input variables of the Speed/Torque Regulator function. Parameter Description Torque mode sel Selects the Boolean variable used to enable Torque ref input in Speed and Torque modes, and to control entry & exit of Ovrd/Spd forced mode within Torque, spd override modes. Torque ref select Selects the signal used as the Torque ref input signal.
Function description The Speed/Torque Regulator function is an important focal point for both Speed and Torque regulation systems within the drive. The parameter Regulator type configures the basic regulation mode of the drive, and the variable Speed reg mode reflects the active regulation state of the drive. Speed reference and feedback signals converge at the Speed Regulator along with Torque reference and feedforward signals.
Ovrd/Spd forced Forced Torque, spd override mode: Speed regulation mode dynamically forced because either the value of the signal specified by Torque mode sel is False, or the Torque reg stop mode is commanded by the sequencer. Ovrd/Spd Low Active Torque, spd override mode: Speed regulation mode dynamically overrides torque mode due to Speed reg error having exceeded limit specified by Spd reg pos err lim.
System Data Parameters Exec time/Chop freq The parameter Exec time/Chop freq defines the Task 1 execution period and the chopping frequency for the Innovation Series drive product. Task 1 is the fastest scheduled software process executed within the control. Primary bridge interface and high-bandwidth aspects of the motor control algorithm operate in Task 1. Slower tasks execute at integer multiples of the Task 1 interval.
Flux decay waiting: When a V/Hz or Torque regulated Tachless drive is stopped and the motor is de-energized there is a requirement to wait for the motor flux to decay before restarting (1 to 20 seconds, depending on motor rotor circuit time constant). If a restart is attempted before the flux decays to a low enough level (2% of rated), the drive will be blocked from a restart and a Run cmd w high flux alarm will occur.
Motor service factor Parameter Motor service factor specifies the ratio of the actual maximum power of the motor to its nameplate rated power. Units Motor service factor is a unitless number. Motor winding cfg Parameter Motor winding cfg specifies the winding configuration of the motor. The following values are available for Motor winding cfg: • Wye E-LN=Sqrt3*E-PH: Wye configuration. • Delta E-LN = E-PH: Delta configuration.
Chapter 4 Wizards Introduction The drive’s operator interface software includes wizards, which are automated Windows-based “forms” for drive configuration and tuneup. The wizards lead the user through critical setup parameters and calculate internal settings. The drive Commissioning wizard must be run on every new configuration. After the initial configuration, use of the drive Commissioning wizard is optional, but still recommended.
Drive Commissioning: Starting and Stopping the Drive................................4-19 Drive Commissioning: Manual Reference....................................................4-19 Drive Commissioning: Maximum Speed References ....................................4-20 Drive Commissioning: Jog Speed Setpoints .................................................4-20 Drive Commissioning: Reference Ramp Bypass...........................................4-20 Drive Commissioning: Reference Ramp Mode.................
Pulse Test ..........................................................................................................4-34 Pulse Test: Introduction...............................................................................4-34 Pulse Test: Analog Output Configuration.....................................................4-35 Pulse Test: Bridge State Configuration ........................................................4-35 Pulse Test: Timer Configuration .....................................................
Cell Test Wizard Cell Test Options The Cell Test wizard executes either the Fiber-Optic Test or the Bridge Cell Test depending on the value of the Type of Cell Test parameter. Selecting one of the Cell Tests and proceeding to the next Wizard page sets the Type of Cell Test parameter to the appropriate value. Fiber-Optic Test The Fiber-Optic Test verifies that the gate drive fiber-optics between the fiber-optic interface board (IS200FOSA) and the IGBT gate driver boards (IS200IGDM) are properly connected.
Running the Fiber-Optic Test Running the Test Read all of the Fiber-Optic Test instructions in this section before running the test. The user must be familiar with the correct LED lighting sequence in order to determine if the fiber-optics are connected properly. Once you are familiar with the test instructions, run the test as follows. 1. De-energize the drive following the procedures outlined in the installation and startup manual GEH-6381.
Following is the correct LED lighting sequence for a drive with the dynamic brake option. 1. DBS1 8. BS3 2. DBS2 9. BS2 3. AS4 10. BS1 4. AS3 11. CS4 5. AS2 12. CS3 6. AS1 13. CS2 7. BS4 14. CS1 If the drive you are testing does not have the dynamic brake option, then the LED sequence will begin with device AS4 instead of DBS2. The sequence from AS4 to CS1 will remain the same.
The following are descriptions of error messages. Error Message Description/Procedure Cell Test invoked in simulator mode. The simulator mode variable Simulate mode act is TRUE. The Fiber-Optic Test cannot be run in simulator mode. Change the simulator mode by setting request parameter Simulate mode to FALSE and run the FiberOptic Test again. Cell Test did not run to completion. Cell Test request was removed. The Cell Test command was removed during Cell Test. The user may have aborted the test.
Running the Bridge Cell Test Running the Test Run the test as follows: 1. Confirm that the drive switchgear is open and the drive is ready to be charged. To prepare the drive for charging, follow the re-energizing procedures outlined in the installation and startup manual GEH-6381. (Safety grounds removed, converter doors closed, locks and tags cleared, charger switch LSW1 and control breaker CB1 closed and control cabinet door closed). 2.
The following are descriptions of bridge test failure messages. Error Message Description/Procedure Short circuit detection test failed. Check for one or more of the following. An undesirable conductive path was detected in the drive. This message will be followed by messages describing the nature of the test failure. POSSIBLE SHORTED DEVICES: All IGBTs and diodes that may be shorted will be listed.
Dynamic brake open circuit detection test did not run. The dynamic brake open circuit detection test is not performed if the short circuit detection test fails. Dynamic brake voltage feedback evaluation was not performed. The dynamic brake voltage feedback evaluation is not performed if the short circuit detection test or the open circuit detection test fails. The following are descriptions of error messages: Error Message Description/Procedure Cell Test invoked in simulator mode.
Drive Commissioning Drive Commissioning: Overview The Drive Commissioning wizard guides the user through the process of configuring the drive for a particular application. It asks a series of questions that allow the user to specify important control parameters. It also directs the drive to perform calculations that determine the values of other parameters. At the conclusion of the wizard, the drive has most of the information that it needs to run successfully.
Drive Commissioning: AC Source Selection The frequency selection is used to calibrate the input line monitor. Use the frequency of the AC line input to this Innovation Series Drive. The choices are usually either 50 or 60 Hertz. Dynamic braking (DB) is an option in some drives. If your drive has been provided with this equipment configure it for operation. DB absorbs energy from the load in applications where fast deceleration is required.
Drive Commissioning: Motor Crossover Voltage Crossover Voltage specifies the voltage above which field weakening occurs. Field weakening allows the drive to achieve greater motor speeds without increasing voltage by decreasing the volts per hertz ratio. Set Crossover Voltage to the appropriate voltage level. If Crossover Voltage is set to , the drive begins field weakening at the voltage specified by Motor rated voltage, which was defined previously.
Motor Nameplate and Equivalent Circuit Data Flux Curve Data Drive Commissioning: Motor Data Sheet Equivalent Circuit Data The motor data sheet is available from the motor supplier. It is a useful source of motor operating parameters that may not be listed on the motor nameplate. The motor data sheet is also a good way to verify motor nameplate data. The Motor Data Sheet should contain hot resistance values for Stator(R1), Rotor (R2), and the 'Hot' temperature at which they were measured.
Motor winding resistances: Stator hot res R1and Rotor hot res R2 values are listed above as R1 and R2. The “hot” temperature is listed here as RQWDG, is in units of degrees Celsius. It is the temperature at which the hot resistances were calculated. It should be entered in Rated rotor temp. Stator cold res R1 and Rotor cold res R2 are not listed in the sample motor data sheet. As such, their entries should be left blank.
Drive Commissioning: Tachometer Support The Innovation Series drive can operate with or without a tachometer. Three different tachometer modes are available in the drive: • Tachless control: The tachless motor control algorithm provides motor speed and torque control without tachometer feedback. • Tach control and sfb: The tachometer-based motor control algorithm uses tachometer feedback to provide motor speed and torque control.
Drive Commissioning: Stopping Configuration When the drive is running normally and the run request becomes false, the drive will be brought to a stop. A normal stop can be generated from one of several different inputs, but has 1 of 3 stopping behaviors as configured by the parameter Normal stop mode. Value of Normal stop mode Behavior Ramp stop The drive follows a linear speed deceleration ramp down to zero speed as configured by the Speed Reference Ramp function.
Drive Commissioning: X-Stop Configuration The Run req & xstop open trip fault occurs when the X stop circuit is open, the drive is stopped, and one of the following requests is issued: Run request, Jog request, or Full flux request. The state of the X stop circuit is determined by the value of the variable to which parameter X stop request sel points. The trip fault can be disabled, along with all other X stop behavior, by setting parameter X stop request sel equal to Unused.
Drive Commissioning: Run Ready Permissive String Bypass Q/C stop This parameter removes Coast stop active and Quick stop active from the Ready to run permissive, when they are normally included. Bypass Q/C stop should be set to Yes if Normal stop mode is set to Quick stop or Coast stop. (Also see Stopping Commands and Modes.
Drive Commissioning: Maximum Speed References Parameter Description Max forward speed Maximum forward reference to the speed regulator. This maximum is enforced immediately prior to the speed regulator and after all other speed offsets have been summed into the reference path. Max reverse speed Maximum reverse reference to the speed regulator. This minimum is enforced immediately prior to the speed regulator and after all other speed offsets have been summed into the reference path.
When the programmed ramp rate mode is active, the acceleration and deceleration rates depend on the magnitude of the speed reference. Three separate acceleration rates and three separate deceleration rates may be defined for the ramp. The rate of change of the speed reference is limited to the active acceleration rate when the magnitude of the speed reference is increasing.
Drive Commissioning: Reference Ramp Programmed Acceleration Rates The programmed ramp rate implements a speed dependent ramp rate profile. The acceleration rate depends on the magnitude of the speed reference. The rate of change of the speed reference is limited to the acceleration rate when the magnitude of the speed reference is increasing. Each of the three acceleration ramp rates is active in a particular speed region.
Drive Commissioning: Reference Ramp Programmed Deceleration Speeds The programmed ramp rate implements a speed dependent ramp rate profile. The deceleration rate depends on the magnitude of the speed reference. The rate of change of the speed reference is limited to the deceleration rate when the magnitude of the speed reference is decreasing. There are three speed regions which are characterized by unique acceleration ramp rates. Region 1 is defined for speed magnitudes less than Accel break point 1.
Related functions • Speed/Torque Regulator Drive Commissioning: Torque Regulator Reference and Output When the torque regulator mode is selected, the drive sets the output of the regulator to a selected torque reference signal. The torque reference signal is selected by Torque ref select. Torque ref select may specify normal signal sources acquired at the application loop rate or one analog high bandwidth signal source acquired at the motor control loop rate.
Spd reg pos err lim specifies the allowable difference between the speed command and the speed feedback when the motor is running too slow. If the feedback is less than the command and the difference between the two is greater than Spd reg pos err lim, then the drive switches from torque regulation to speed regulation. Spd reg neg err lim specifies the allowable difference between the speed command and the speed feedback when the motor is running too slow.
Drive Commissioning: Failed Calculation The calculation FAILED because of improperly entered motor data. Check: • Motor nameplate data • Motor data sheet data • Flux curve points are monotonic Check the FAULTS that were generated to help determine the source of this error. Drive Commissioning: Torque and Current Limit Selection Normal and alternate torque and current limits are available. They can be dynamically selected by the state of the boolean variable at Torque lim 2 sel.
Drive Commissioning: Current Limits Enter the normal (1) and alternate (2) per-unit current limits: Current limit 1 will be used when Torque lim 2 sel is false. Current limit 2 will be used when Torque lim 2 sel is true. Drive Commissioning: Power Dip Ride-Through Power dip ride-through can allow the drive to recover from a momentary loss of line. The Power Dip Protection attempts to sustain DC link voltage for a selectable time interval when a low voltage condition is detected.
Drive Commissioning: Exit Reminder After the Drive Commissioning wizard completes, the drive should have a hard reset performed. This should clear any faults that have occurred because of intermediate parameter values during the setup process. The following wizards should be run to complete the start-up process: • Cell Test • Motor Control Tuneup • Speed Regulator Tuneup Drive Commissioning: Conclusion The Drive Commissioning Wizard has concluded.
Line reference specifies the source of the utility line reference. Set to Internal to use the internally generated line reference signal. If required by your application an external line reference may be needed in which case set Line reference to match the type of external line reference signal you have. Utility swgr close specifies the I/O point that drives the utility switchgear close command during the motor transfer sequence. Set Utility swgr close to the desired I/O point.
Drive response window for internal line reference Display Description Phase angle no load The phase angle difference measured between the drive source voltage and the utility voltage. The utility voltage was measured at the drive output. A positive phase angle indicates the utility lags the drive source. For a negative phase angle, the utility leads the drive source. Utility phase offset Offsets consisting of the phase angle no load plus phase compensation due to transformer loading.
Motor Control Tuneup Motor Control Tuneup: Equivalent Circuit The equivalent circuit for the induction motor used in the motor control tune-up is: Lsigma Bridge Flux R1 Lsigma outer I V R2 inner R2 outer Flux Saturation Curve The motor elementals and flux saturation curve will be measured for the phase combinations of AB and BC. After both sets of measurements are completed the balance of each phase pair will be compared for each motor elemental and saturation curve data point.
Motor Control Tuneup: Measurements When selecting all the measurements the VCO’s will be calibrated and for both phase combinations, AB and BC, the measurements of Tau, R1, R2 inner, R2 outer, Lsigma starting, Lsigma outer, Lsigma curve, Bridge flux and the Flux saturation curve will be performed. These measurements will be checked for balance between phase combinations and monotonically increasing curves.
Line Protection Setup Line Protection: Introduction The Line Protection Setup wizard sets parameters which affect line protection functions concerning overfrequency, underfrequency, overvoltage, and undervoltage. If the Drive Commissioning wizard has been performed, these parameters were setup automatically. Perform the Line Protection Setup wizard only if you need to restore these parameters to their original settings or if you need to override the default parameter settings.
Line Protection: Overfrequency These parameters set the level of protection of the ac line overfrequency protection. It is highly recommended to use the control default values as calculated in the previous steps (you can go backward). • Over freq flt level is the ac line frequency above which the AC line over freq trip fault occurs. • Over freq alm level is the ac line frequency above which the AC line freq high alarm occurs.
Pulse Test: Analog Output Configuration The Pulse Test user may configure two analog output channels from within the Pulse Test Wizard. During the course of the Pulse Test it is often useful to observe certain drive variables, such as phase currents (variables Phase A current, Phase B current, and Phase C current) and line-line voltages (variables Output volts, A-B and Output volts, B-C).
Detailed descriptions of the Park and Pulse states are as follows: Bridge State Description Off state All the power devices in the bridge are turned off. Due to the nature of the power devices and the topology of the power circuit any currents which exist in off phases are quickly driven to zero. Phases not included in the pulse or park state remain in the off state. Park state The devices in the bridge are turned on in such a way as to impress no voltage between the selected drive terminals.
Pulse Test: Timer Configuration The Pulse Test allows up to two voltage pulses to be commanded and produced by the power bridge. The duration of the voltage pulses, and the duration of the current decay time between the pulses and after the pulses, is specified by the pulse test timer parameters Pulse 1 on time, Pulse 2 on time, Mid pulse off time, and Post pulse off time. The diagram below shows a Pulse Test profile and indicates how the timer parameters are defined.
Simulator Setup Simulator Setup: Introduction The Simulator Setup configures the drive to run in simulator mode. Simulator Setup: Simulator Mode If you would like to run the drive in simulator mode, select Yes. If you do not want to run the drive in simulator mode, select No. Related functions • Simulator Simulator Setup: Hardware Fault String Override If you would like to disable the Local flt and System flt trip faults in simulator mode, select Yes.
Speed Regulator Tuneup Speed Regulator Tuneup: Model The simplified model of the speed regulator is: proportional command gain proportional feedback gain proportional filter + Σ - Filter net gain integral gain Speed Command Speed Feedback 2π π 60 Integrator + system inertia Σ + - Torque Command + Σ The system inertia can be either measured or entered and the gains can be entered separately or calculated from bandwidth, damping and stiffness for a 1st and 2nd order closed loop response.
Speed Regulator Tuneup: Speed Regulator Mode • Manually tune-up individual gains • 1st order closed loop response • 2nd order closed loop response • 2nd order closed loop response with stiffness filter for load disturbances Speed Regulator Tuneup: Manual Regulator Tuneup Enter the requested gains based on the diagram below: proportional command gain proportional feedback gain proportional filter + Σ - Filter net gain integral gain Speed Command 2π π 60 Integrator + Speed Feedback Σ + +
Speed Regulator Tuneup: 2nd Order Response with Stiffness Filter Calculate speed regulator gains based on 2nd order closed loop response and set the speed feedback filter to 10 times the bandwidth.
Notes 4-42 • Chapter 4 Wizards Innovation Series Medium Voltage GP Type - G Drives GEH-6385
Chapter 5 Signal Mapping Introduction The IS200DSPX Digital Signal Processor board (DSPX) contains and implements the drive’s control software. The DSPX is located in the drive’s control rack. The drive software’s Motor Control Layer (MCL) performs motor control functions, such as current regulation. MCL interfacing is through a signal map. An operator can configure the signal map using either the Drive Diagnostic Interface (keypad) or the GE Control System Toolbox (see Figure 5-1).
LAN Interfaces The LAN interfacing for the MCL requires the addition of a communications module to the control rack, as follows (refer to Figure 5-2): Interface Profibus™-DP Slave Module IS215PBIA Communications Supported Freeze and synchronous mode 9.
Parameter Configuration for Signal Mapping Parameters are used in the drive for configuration of functions. For example, six parameters are used to configure the ramp rate function generator in the general industries pattern. The 64-byte, bi-directional signal map is configured with either the keypad or the toolbox. Refer to the data sheets associated with these interface modules for a detailed description of the configuration.
Variable Mapping Also refer to “Variable Maps” in this chapter. The drive software uses variables either of two ways: As dynamic references for controlling the drive • To contain feedback on the drive status For example, the variables Speed Feedback and Speed Reference are associated with the speed regulator function.
Applying the LAN Heartbeat Echo Feature When controlling a drive over a LAN, both the controller and the drive need to monitor and react to changes in the status of LAN health. The heartbeat echo feature in the drive provides a mechanism for this function. The following illustrations indicate how the drive and controller obtain status on the LAN integrity and possible configuration options.
Application of Feedback Signals In most control systems the LAN (Genius, Profibus-DP, and such) operates asynchronous with the execution of control logic. Two situations can occur: • Under Sampling - If the control logic sweep rate is slower than the LAN sweep rate, certain samples of feedback signals from the drive are not seen by the control logic.
Real Variable Map Reference Byte 1-4 5-8 9-12 13-16 17-20 Variable Feedback Functionality Variable Functionality Request bits 1, lan multiple bits, Feedback bits 1, lan multiple bits, (Lan_Req1_Wrd) see table below (Lan_Fbk1_Wrd) see table below Auto speed ref, lan Auto analog ref sel Fault number number of the active fault with (Lan_Spd_Ref) (Auto_Ref_Adr) (Lan_Flt_Code) SpeedRpm_Scl Behavior 2 (1) highest severity (trip/alarm) (2) earliest time-stamp Spd ref offset, l
Boolean Variable Map Reference Byte 1 2 Variable Feedback Functionality Variable Functionality Heartbeat ref, lan Heartbeat function: Heartbeat fbk, lan Heartbeat function: (Lan_Htbt_Ref) transitions expected (Lan_Htbt_Fbk) loopback Heartbeat ref, lan Fault reset req, lan Fault reset select No faults or alarms no active (uncleared) faults, (Lan_Flt_Rst) (Flt_Rst_Adr) (No_Flt) "not (trip OR alarm)" Behavior 1, edge 3 Trip request, lan Fault.
Reference Byte 15 Variable Feedback Functionality Variable Droop disab req, lan Droop disable select Speed mode active (Lan_Drp_Inh) (Drp_Inh_Adr) (Spd_Mode_Act) Functionality speed regulator function is regulating speed Behavior 2 16 Trq lim 2 req, lan Torque lim 2 sel In cur or trq lim (Lan_Tlim_Sel) (Tlim_Sel_Adr) (Trq_Lim_Act) Inner torque regulator in limit=(Sreg_Frz_Pos||_Neg) Behavior 2 17 Ramp rate 2 req, lan Ramp rate 2 select (Lan_Rmp_Sel) Not Used (Rmp_Sel_Adr) Behavior 2
Notes 5-10 • Chapter 5 Signal Mapping Innovation Series Medium Voltage GP Type - G Drives GEH-6385
Appendix A Function Block Diagrams Introduction Application firmware consists of coordinated blocks of code called functions (refer to Chapter 3). The drawings in this section are function block diagrams for the Innovation Series Medium Voltage – GP Type G drive. To prevent personal injury or equipment damage caused by equipment malfunction, only adequately trained personnel should modify any programmable machine.
Diagram Title Page Name Motor Control Interface..................................................................................... Core Motor Control ......................................................................................... Ovr_MCtrl Diagnostic & Utility Functions .................................................................. Diag_Util Signal Level Detection ...................................................................................... SLD Capture Buffer Configuration .........
L M I J 16 K L PRODUCT: Innovation Control Ovr_MCtrl Motor Control Ovr_Lin_Mon AC Line Monitor R S Page name: T U 09 08 07 06 05 04 03 02 01 saved date: January 14, 2000 ISD1 Device name: Jun 06, 2000 Date: Overview.vsd 15 GE Motors and Industrial Systems Salem, Va.
C D Contents E F G Analog Inputs/Outputs & Mapping (HWIO) 16 15 14 B C D F G H I J K L O P Speed Reference Ramp Critical Speed Avoidance Droop Speed Regulator Speed Feedback Motor Control Q R Factory Test Only Position Feedback Instrument Capture Buffer Configuration Signal Level Detection 27) AC Line Monitor 26) 25) 24) 23) Diagnostic & Utility Functions 22) 21) Motor Control Interface 20) 19) 18) 17) Speed / Torque Overview 16) 15) 14) Speed Reference Generat
16 15 14 13 12 11 10 09 08 53 51 9 6- 6+ 5- 5+ 4- 4+ 3- 3+ 2- 2+ 1- B /MKR MKR MA- MA+ ATBA 7 36 34 32 30 28 26 24 07 20 18 16 1+ C * * * * * * * E 0 0 0 0 0 0 Digital input 6 Digital input 5 Digital input 4 Digital input 3 Digital input 2 D - 2-5ms HW Filtering E VCO 3 unfiltered Tachometer Marker MA contactor closed MA Feedback Dedicated Digital Inputs Digital in 6 filter Digital in 5 filter Digital in 4 filter Digital in 3 filter Dig
16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 A A 46 44 ATBA 40 38 ATBA B Ai2+ V C O Ai2- Ai1+ V C O Ai1- Overview C HWIO_Dig - + Σ - + Σ D Analog in 2 flt lev 0 Volts Analog input 2 volts 1 /Volt E Thrsh <= In Out F G 1 /Volt Low level trip Low level alarm Unused G Low level trip Low level alarm I Analog input 1 H I Ain 2 signal trip Ain 2 signal alarm No Faulting Analog input 2 unfil Analog in 2 filter 100 Rads/s Analog input 2 Ain 1 signal t
D F 16 G H I J No 8 7 6 5 4 3 2 1 K Variable No L GP lan ref 4 GP lan ref 3 Signal P saved date: PRODUCT: GP lan fbk reg 4 GP lan fbk reg 3 Motor voltage, lan Motor power, lan Page 2 O GE Motors and Industrial Systems Salem, Va. USA general purpose real var general purpose real var Droop comp ref sel Constant float 0.0 Flux ref ratio sel Unused float Torque feed fwd sel Constant float 0.
E 16 F H result of Xstop requests X stop active X stop request sel Unused boolean X stop request, lan active trip fault, "trip" G K L M I J flux model indicates that net commanded flux is established Flux enable status Full flux req sel Unused boolean Full flux req, lan 11 local hardware permissive: bridge inhibited Local fault string Fault.
J K L M N 16 C D E F G H I J K L saved date: PRODUCT: June 10, 1999 Innovation Control Page name: 11 10 09 08 07 06 05 04 03 02 01 ISD1 Device name: Jun 06, 2000 Date: SigMap_Bit2.vsd 15 U 15 GE Motors and Industrial Systems Salem, Va.
16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 A A NAVIGATION C abs Σ Σ G G J K L Flt. AC line freq high Frequency Monitor Flt. AC line over voltage Line monitor volt Voltage Magnitude Monitor M Line UV fault level V rms Line Monitor Overview I Flt.
D E - + Σ F + PLL error F Σ G G PLL integral gain H I J K L M I J K PLL min frequency PLL max frequency L + + Σ Phase Lock Loop Regulator PLL prop gain H O GE Motors and Industrial Systems Salem, Va.
G H J H I GenSeq_2 Stop Commands (Hardware, Push Button, LAN) G GenSeq_2 Ready to Run Permissive 16 J K L saved date: March 10, 1998 ISD1 Device name: Jun 06, 2000 Date: Ovr_Seq.vsd 15 08 07 06 05 04 03 02 01 15 U 14 Page name: T 14 S 13 Innovation Control R 13 Q 12 PRODUCT: P 12 E O GE Motors and Industrial Systems Salem, Va.
C E F G Stopped G H H J K L M X stop active I No faults active (Clear_Flt) Clear Faults Request J K X stop active Coast stop active X stop active Running Standby command Coast stop X stop mode Coast stop Normal stop mode Coast Stop Command Standby command Quick stop X stop mode Quick stop Normal stop mode Quick Stop Command O P Emergency Stop Command N Running Full flux command Run command Running Full flux command Run command Running Q S Emergency stop act C
16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 A A Run permissive sel B Lan Stop One-shot Hardware Stop One-shot Local mode active Stop PB select, lan Unused boolean False Stop PB select Unused boolean False D E Stop One-Shot LAN commands OK Lan Stop One-Shot LAN commands OK Not Used Run request, lan C Flux Ready Stop PB select, lan Stop PB select Not Used Coast stop active F G Unused boolean Stop PB select, lan T Bypass Q/C stop Quick stop active G Ready to
C 16 D E F G H Locked shaft restart Disable fly restart Enable fly restart Flying restart Jog active Run active Running J K L M I J K L Standby command Full flux command - Running Status - Run/Jog Active Status - Regulator Commands General Sequencing #3 I O GE Motors and Industrial Systems Salem, Va.
M 16 J K L Page name: U 07 06 05 04 03 02 01 saved date: March 10, 1998 ISD1 Device name: Jun 06, 2000 Date: GenSeq_4.vsd 15 Innovation Control T 15 S 14 PRODUCT: R 14 Q 13 GE Motors and Industrial Systems Salem, Va.
16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 A A B Ref enable request Run command Run command Sreg enable request Run command Run command Torque enable req Running Run command Flux enable request Full flux command Standby command Running Run command C F Torque reg enabled Zero speed active Sreg enable status E Quick stop active F Speed Reference Enable Speed ref enabled D Torque Enable Flux Enable E Speed Regulator Enable Flux enable status MA cont enable
1 0 RPM F G Drive Diagnostic Reference E I J K L M Local mode active Forward/Reverse Speed reference N Min Speed Limit Speed Reference Generation H O Critical Speed Avoidance P Q Crit speed avoidance R T T Speed ref, pre ramp S U 01 Auto Reference E Jog request F 16 H I Local mode active Local rev request G Local mode active Local mode active Reverse select Unused boolean Remote jog speed 60 RPM Auto mode select Force False Auto mode select Force False Jog request
C E Speed avd func input D F F G G H H J K L M Critical speed 3 0 RPM Speed In Critical Speed Avoidance I O Crit speed avoidance N PRODUCT: P Speed ref, pre ramp Q R S Page name: T U 01 E I J Innovation Control L February 23, 1998 ISD1 Device name: Jun 06, 2000 Date: CrSpdAvd.vsd 15 15 K 14 14 saved date: 13 13 16 12 12 D GE Motors and Industrial Systems Salem, Va.
D D J K L E F G Acceleration rate 3 500 RPM/s Acceleration Rate 1 Acceleration Rate 2 16 H Deceleration Rate 2 Deceleration Rate 1 Deceleration rate 3 500 RPM/s I J K Emergency stop act L Decel break point 1 2000 RPM t Emerg ramp rate 1000 RPM/s Programmed Ramp Rate Function Generator F Ramp rate mode Ramp accel rate Abs M N Ramp bypass F O GE Motors and Industrial Systems Salem, Va.
Overview Back to Overview NAVIGATION B F G Speed reg fbk Enable fly restart Flying restart I Speed feedback fil 60 rad/s H L J K Droop output L Torque ref select Constant float 0.0 Torque feed fwd sel Constant float 0.0 SReg - + + Speed Regulator + + O 16 GE Motors and Industrial Systems Salem, Va. USA Droop 0 pu - + Torque ref pre limit N Droop Droop gain + M Q PRODUCT: Droop feedback Droop comp ref sel Constant float 0.
C D H K L I J K L Speed feedback fil 60 rad/s N Speed reg fbk O GE Motors and Industrial Systems Salem, Va. USA Motor speed Selected Speed Feedback Tach speed filter 90 rad/s Speed feedback selection based on Tach presence and algorithm choice.
16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 A A B Torque feed fwd sel Constant float 0.0 Torque ref select Constant float 0.
Torque ref post lim Ovr_SpTq Back NAVIGATION B 16 J K L 06 05 saved date: March 17, 1998 ISD1 Device name: Jun 06, 2000 Date: Droop.vsd 15 Page name: Ovr_SpTq 04 03 02 01 15 Innovation Control U To Speed Regulator Reference Droop output T 14 S 14 PRODUCT: Droop disable sel Force False R 13 Q 13 GE Motors and Industrial Systems Salem, Va.
16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 A A C From Speed Regulator E F B Flux ref ratio sel Unused float Flux ref ratio setpt Adj cur lim ref sel Unused float Current limit 2 Current limit 1 Adj gen trq lim sel Unused float Torque lim 2 sel Force False C 1 D Flux Adjust Select 1 pu 1 pu Torque lim 2 sel Force False Current Limit Select Regen torque lim 2 1 pu Regen torque lim 1 1 pu Adj mtr trq lim sel Unused float Motoring torque lim2 1 pu Motoring torque l
16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 Overview A B + + Crossover Voltage V rms Flux ref ratio Core C C Σ D D Spd_Fbk To Speed Feedback E F Estimated R1 &R2 Motor flux Torque fbk, calced Calculated speed Modulation Index Limit Field-Weakening Control Voltage Limit F Flux reference Slewed trq cur ref E Command Flux Ramping Slew Rate Limit Field weak ctl out 100% Flux Torque current ref Back to Overview NAVIGATION B From Motor Control Int
G D E G PosFbk I J K L M H I J K GP Constant 3 GP Constant 2 GP Constant 1 0 0 0 L General Purpose Constants N Oscillator 1/2 cycle 7 sec Diagnostic & Utility Functions H -1 Oscillator pos mag 0.0 Oscillator enable Q R T Page name: Sqr wave osc output S U 05 04 03 02 01 Innovation Control 13 12 11 10 16 saved date: November 20, 1998 ISD1 Device name: Jun 06, 2000 Date: Diag_Util.
16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 A A C 0 0 0 0 B C SLD3 hysteresis SLD3 sensitivity 0 0 SLD3 input 2 select Constant float 0.0 SLD3 input 1 select Constant float 0.0 SLD2 hysteresis SLD2 sensitivity SLD2 input 2 select Constant float 0.0 SLD2 input 1 select Constant float 0.0 SLD1 hysteresis SLD1 sensitivity SLD1 input 2 select Constant float 0.0 SLD1 input 1 select Constant float 0.
16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 A A B C Back C NAVIGATION Diag_Util B D D E E G 1 0 J I J Channel #8 Signal Capture ch8 select Reg_Mode Channel #6 Signal Capture ch6 select Speed reg reference Channel #7 Signal Channel #5 Signal Capture ch5 select Torque ref pre limit Capture ch7 select DC bus voltage Channel #4 Signal Capture ch4 select Motor voltage Channel #3 Signal Capture ch3 select Motor current Level or Edge Trigger Trigger comparison va
16 I Task Interval Strobe J Pos sample cmd sel Unused boolean K 22-bits 22-bits Edge Detect L SPFP SPFP O Pos up edge sample Pos down edge smp P PRODUCT: Pos cntr mark Position counter GE Motors and Industrial Systems Salem, Va. USA SPFP SPFP N Q Innovation Control R S Page name: T U 09 08 07 06 05 04 03 02 01 saved date: June 1, 1998 ISD1 Device name: Jun 06, 2000 Date: PosFbk.
E Index 1 115VAC, 3-55 2 24 VDC, 3-33 B bar graph, 3-26 baud rate, 3-36 C CB1, 4-5, 4-8 Control Cards IS200ACL_ Application Control, 3-34, 3-35, 3-36, 338, 5-2, 5-3 IS200ATBA Application I/O TB, 3-55 IS200BAIA Basic I/O, 3-32 IS200BICM Bridge Interface, 3-56, 3-58, 3-66 IS200CTBC Drive I/O TB, 3-33 IS200DSPX Motor Control, 3-38, 5-1 IS200FOSA Fiber Optic Hub, 3-56, 4-6 IS200IGDM Gate Driver, 4-4, 4-5, 4-6, 4-9 Control System Toolbox, 1-1, 1-2, 1-3, 2-1, 2-22, 3-8, 3-9, 3-25, 3-28, 5-1 D DC Bus Chargin
Ground flt, LP, 2-10 HtSink A over temp, 2-13, 3-57 HtSink A rise high, 2-15, 3-57 HtSink A temp hot, 2-14, 3-57 HtSink A temp low, 2-12, 3-57 HtSink B over temp, 2-13, 3-57 HtSink B rise high, 2-15, 3-57 HtSink B temp hot, 2-14, 3-57 HtSink B temp low, 2-12, 3-57 HtSink blower failed, 3-58 HtSink C over temp, 2-14, 3-57 HtSink C rise high, 2-15, 3-57 HtSink C temp hot, 2-14, 3-57 HtSink C temp low, 2-12, 3-57 HtSink DB over temp, 3-57 HtSink DB rise high, 3-57 HtSink DB temp hot, 3-57 HtSink DB temp low, 3
Motor Temperature Estimation, 3-49 Oscillator, 3-4, 3-12 Phase Current Protection, 3-60 Phase Imbalance Monitor, 3-68, 3-69, 3-71, 3-73 Phase Lock Loop, 3-68, 3-69, 3-71, 3-72, 3-73 Position Feedback, 3-4, 3-13 Power Dip Protection, 3-44, 3-49, 3-50, 4-27 Predefined Constants, 3-4, 3-14 Primary Motor & Application Data, 3-21, 4-12, 4-13, 4-15 Remote Speed Reference, 3-83, 3-92, 3-93, 3-98 Sequencer Commands, 3-74, 3-77, 3-79, 3-82, 3-86, 3-91, 3-93, 3-113 Sequencer Overview, 3-74 Sequencer Permissives, 2-5,
Analog out 1 select, 3-32 Analog out 1 test, 3-31 Anticipated torque, 3-47, 4-29 Applied top RPM, 3-22, 3-91, 4-15 Auto analog ref sel, 3-92, 3-93, 5-7 Auto mode select, 3-92, 3-93, 5-9 Bypass Q/C stop, 3-77, 3-80, 4-17, 4-19 Calculated spd fil, 3-106 Calibrate VCO offset, 4-32 Cap re-enable delay, 3-6 Capture buff config, 3-4, 3-5, 3-6 Capture ch1 select, 3-4 Capture ch2 select, 3-4 Capture ch3 select, 3-4 Capture ch4 select, 3-4 Capture ch5 select, 3-4 Capture ch6 select, 3-4 Capture ch7 select, 3-4 Captu
Jog request select, 3-79, 3-82, 4-19, 5-8 Keypad contrast adj, 3-25 Keypad meter 1 range, 3-26 Keypad meter 1 ref, 3-26 Keypad meter 1 sel, 3-26 Keypad meter 2 range, 3-26 Keypad meter 2 sel, 3-26 Keypad meter 3 range, 3-26 Keypad meter 3 sel, 3-26 Keypad meter 4 range, 3-26 Keypad meter 4 sel, 3-26 Keypad password, 3-27 Keypad privilege, 3-27 LAN cmds inhibit, 3-36 LAN fbk avg time, 3-36, 3-41, 5-6 LAN frame time, 2-38, 3-34, 3-35, 3-36, 5-6 LAN heartbeat time, 2-37, 3-36 LAN parameter 1, 3-36 LAN paramete
Run permissive sel, 3-76, 4-19 Run request select, 3-79, 3-82, 4-19, 5-8 Sim A-N volt scale, 3-19 Sim B-N volt scale, 3-19 Sim C-N volt scale, 3-19 Sim const friction, 3-18, 4-27, 4-38 Sim freq slew rate, 3-19 Sim line frequency, 3-19 Sim visc friction, 3-18 Simulate mode, 2-36, 3-18, 3-20, 3-30, 4-7, 4-10 Simulated inertia, 3-18, 4-27, 4-38 Simulated load, 3-18, 4-27 Simulated stiction, 3-18 SLD1 compare mode, 3-15, 3-16, 3-17 SLD1 drop out delay, 3-15, 3-16, 3-17 SLD1 hysteresis, 3-15, 3-16, 3-17 SLD1 inp
T tachometer, 3-13, 3-44, 3-50, 3-51, 3-105, 3-106, 3107, 3-112, 4-16 Timed overcurent, 3-62, 3-64 Toolbox, Control System, 1-1, 1-2, 2-1, 3-9, 3-25 V Variable Mapping, 5-4 Application of Feedback Signals, 3-13, 5-6 Applying the LAN Heartbeat Echo Feature, 2-37, 5-2, 5-4, 5-5 Variable Maps, 1-1, 1-2, 2-4, 2-5, 2-6, 2-7, 2-8, 2-9, 210, 2-19, 2-20, 2-21, 2-34, 2-36, 3-4, 3-12, 3-13, 3-26, 5-1, 5-4, 5-6, 5-7, 5-8, 5-9 Real Variable Map, 5-7, 5-8 Variables 100% Applied RPM, 3-22 100% Flux, 3-23, 3-77 100% Flux
Gnd current, coarse, 3-54 Gnd flt trip, 3-66, 3-67 Gnd flt warning, 3-66, 3-67 GP Constant 1, 3-10 GP Constant 2, 3-10 GP Constant 3, 3-10 GP filter 1 output, 3-11 GP filter 2 output, 3-11 GP filter 3 output, 3-11 GP filter 4 output, 3-11 GP lan fbk bit 1, 3-42, 3-43 GP lan fbk bit 2, 3-42, 3-43 GP lan fbk bit 3, 3-42, 3-43 GP lan fbk bit 4, 3-42, 3-43 GP lan fbk bit 5, 3-42, 3-43 GP lan fbk bit 6, 3-42, 3-43 GP lan fbk bit 7, 3-42, 3-43 GP lan fbk bit 8, 3-42, 3-43 GP lan fbk reg 1, 3-41, 5-7 GP lan fbk re
Pos down edge smp, 3-13 Pos up edge sample, 3-13 Position counter, 3-13 Quick stop active, 3-77, 3-85, 4-19 Ramp rate 2 sel, lan, 3-40 Ramp ref enabled, 3-85, 3-94, 3-96 Ready to run, 3-42, 3-75, 3-76, 3-77, 3-78, 3-81, 3-83, 3-84, 3-85, 4-19 Ref enable request, 3-86 Regen torque limit, 3-101 Relay 1 state, 3-33 Relay 2 state, 3-33 Relay 3 state, 3-33 Rev mode req, lan, 3-40, 5-8 Reverse mode active, 3-42, 3-97, 3-98, 5-8 Rotor temp, 3-49 Run active, 3-42, 3-83, 5-8 Run command, 3-83 Run permissive, 3-76, 3
X axis line voltage, 3-68, 3-69, 3-72, 3-73 X stop active, 3-42, 3-76, 3-81, 4-18, 5-8 X stop request, lan, 3-40, 3-81, 5-8 Y axis line voltage, 3-68, 3-72, 3-73 Zero speed active, 3-42, 3-85, 5-9 VCO, 3-31, 4-32 W Wizards Cell Test, 2-5, 2-25, 2-26, 2-27, 2-28, 2-29, 2-30, 231 Cell Test Options, 4-4 Cell Test Wizard, 4-4, 4-5 DAC Setup, 4-10 Drive Commissioning, 3-21, 3-23, 3-70, 3-71, 3-73, 4-11, 4-12, 4-13, 4-14, 4-15, 4-16, 4-17, 4-18, 419, 4-20, 4-21, 4-22, 4-23, 4-24, 4-25, 4-26, 4-27, 4-28, 4-33 AC
Running the Fiber-Optic Test, 4-5 Simulator Setup, 4-38 Conclusion, 4-38 Hardware Fault String Override, 4-38 Introduction, 4-38 Simulator Mechanical Configuration, 4-38 Simulator Mode, 4-38 Speed Regulator Tuneup, 4-23, 4-28, 4-39, 4-40, 4-41 1st Order Response, 4-40 2nd Order Response, 4-40, 4-41 2nd Order Response with Stiffness Filter, 4-41 Calculate Speed Regulator Gains Command, 4-41 Inertia Measurement Command, 4-39 Manual Regulator Tuneup, 4-40 Model, 4-39 Speed Regulator Mode, 4-40 System Inertia,
Notes 12 • Index Innovation Series Meduim Voltage GP – Type G Drives GEH-6385
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