Distributed Power System SA500 'ULYH &RQILJXUDWLRQ DQG 3URJUDPPLQJ Version 2.
Throughout this manual, the following notes are used to alert you to safety considerations: ! ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Important: Identifies information that is critical for successful application and understanding of the product.
CONTENTS Chapter 1 Introduction Chapter 2 Configuring the UDC Module, Regulator Type, and Parameters 2.1 Adding a UDC Module ..................................................................................... 2-1 2.2 Entering the Drive Parameters ........................................................................ 2-2 2.3 Using the Brushless Parameter Entry Screens ............................................... 2-5 2.3.1 Power Module Data Screen (Brushless) ........................................
Chapter 5 On-Line Operation 5.1 Loading the UDC Module’s Operating System ................................................5-1 5.2 Loading the Drive Parameters and UDC Tasks ...............................................5-1 5.3 Running, Stopping, and Deleting UDC Application Tasks ...............................5-2 5.4 UDC Information Log and Error Log ................................................................5-3 Appendix A SA500 Drive Register Reference .............................................
List of Figures Figure 2.1 – SA500 Drive Parameter Entry Screen (Vector) .................................... 2-4 Figure 2.2 – Power Module Data Parameter Entry Screen (Brushless) ................... 2-5 Figure 2.3 – Motor Data Parameter Entry Screen (Brushless) ................................. 2-6 Figure 2.4 – Motor Data Parameter Entry Screen (Brushless - Speed Loop Enhanced) ................................................... 2-7 Figure 2.5 – Feedback Data Parameter Entry Screen (Brushless) ............
IV SA500 Drive Configuration and Programming
List of Tables Table 1.1 – SA500 Documentation........................................................................... 1-2 Table 2.1 – Restricted Drive Type Combinations ..................................................... 2-2 Table 2.2 – Resolvers for Brushless Regulators .................................................... 2-10 Table 2.3 – Resolvers for Brushless - Speed Loop Enhanced Regulators............. 2-11 Table 2.4 – Resolvers for Vector Regulators..............................................
VI SA500 Drive Configuration and Programming
CHAPTER 1 Introduction Rockwell Automation SA500 drives operate under the control of the AutoMax™ Distributed Power System (DPS). DPS drives are controlled through coordination among: • Tasks written by the programmer for the AutoMax Processor. • Tasks written by the programmer for the Universal Drive Controller (UDC) module. • The control algorithm and a number of software routines executed by the Power Module Interface (PMI) regulator.
Related Publications The user must become familiar with the other instruction manuals that describe the SA500 drive system. The documentation that describes the SA500 drive is listed in table 1.1. Table 1.1 – SA500 Documentation Document Document Part Number AutoMax Programming Executive Version 3.
CHAPTER 2 Configuring the UDC Module, Regulator Type, and Parameters ! ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
Step 4. Select a product type and a regulator (control) type for both drive A and drive B. See the following section for regulator restriction rules. The remainder of this chapter assumes that you have selected an SA500 product type and have chosen one of the following regulator selections: Vector, Brushless, Vector - Speed Loop Enhanced, or Brushless - Speed Loop Enhanced.
Use the following procedure to enter the drive parameters. Note that if you enter drive parameter data that is unexpected or out of range, a “warning” or “error” message will appear on the screen. A warning message indicates that the data you have just entered will be accepted by the Programming Executive, and you will be able to generate drive parameter files. However, you may experience degradation of drive performance.
Note that you cannot attach a Local I/O Head to the PMI’s rail ports. You can, however, mix input and output modules in a Digital I/O Rail. You can also mix rail types, i.e., add both a Digital I/O Rail and an Analog Rail (rail mode only) to a PMI. Select the Configure Variables option from the Configure menu in order to configure the variables for the attached rails. Zoom out to return to the PMI screen. Step 3. Use the Configure Parameters option to access the Parameter Entry screens.
2.3 Using the Brushless Parameter Entry Screens The following sections describe the parameter entry screens for the SA500 Brushless and Brushless - Speed Loop Enhanced regulators. These screens are accessed by selecting SA500 as the product type and Brushless or Brushless - Speed Loop Enhanced as the regulator type when configuring the UDC module. 2.3.
2.3.2 Motor Data Screen (Brushless) The Motor Data parameter screen allows you to select the motor you are using. You must select your motor from the list displayed. See figure 2.3. Figure 2.3 – Motor Data Parameter Entry Screen (Brushless) • Motor List You can select a part number from a list of supported motors to have the specified default Motor Data values entered automatically. These values should not be changed or degraded regulator performance may result.
• Motor Overload Ratio (%) (Range: 100 to 400) The motor overload ratio is used in calculating the torque limit. Enter the value in percent. A warning will be generated if the value entered is not within the limits of the following equation: Rated Motor Amps ∗ Motor Overload ÷ 100 ≤ Power Module Amps • Stator Inductance (mH) (Range: 0.01 to 50.0) The stator inductance is used to calculate the amplitude of the triangle wave that produces the PWM output to the motor.
• Motor List You can select a part number from a list of supported motors to have the specified default Motor Data values entered automatically. These values should not be changed or degraded regulator performance may result. The list box will show only the part number, the horsepower, and the RPM for each motor. When a motor is selected, the Rated Speed and other motor data parameters will be filled in automatically.
2.3.4 Feedback Data Screen (Brushless) The Feedback Data parameter screen allows you to enter specific information about the resolver used with the motor, the motor overspeed limit, and the direction of motor rotation. See figure 2.5. Figure 2.5 – Feedback Data Parameter Entry Screen (Brushless) • Over Speed Limit (RPM) (Range: 10 to 10000) The over speed limit is used to select the speed at which the over speed fault should be generated by the PMI. Enter the value in RPM.
Table 2.2 – Resolvers for Brushless Regulators Resolver Base Part No. x1 x2 613469 -1R -1S 613469 -2R -2S 800123 -R -S 800123 -1R -1S 800123 -2R -2S Suffix For the most accurate velocity control, always select the resolver (x1 or x2) whose maximum speed is closest to, and greater than, the maximum speed for your application. Refer to the SA500 Power Modules instruction manual (S-3018) for more information regarding the PMI’s resolver-to-digital converter and the supported resolvers.
• Over Speed Limit (RPM) (Range: 10 to 10000) The over speed limit is used to select the speed at which the over speed fault should be generated by the PMI. Enter the value in RPM. A typical value is 110% of gear-in speed. Resolver Data • Resolver Type (x1 or x2) Select x1 (default) or x2. • Resolution (12-bit or 14-bit) This value is used to configure the PMI’s resolver-to-digital converter for either 12-bit or 14-bit conversion of the resolver data.
2.4 Using the Vector Parameter Entry Screens The following sections describe the parameter entry screens for the SA500 Vector and Vector - Speed Loop Enhanced regulators. These screens are accessed by selecting SA500 as the product type and Vector or Vector - Speed Loop Enhanced as the regulator type when configuring the UDC module. 2.4.
2.4.2 Motor Data Screen (Vector) The Motor Data parameter screen allows you to select the motor you are using. You must select your motor from the list displayed. See figure 2.8. Figure 2.8 – Motor Data Parameter Entry Screen (Vector) • Motor List You can select a part number from a list of supported motors to have the specified default Motor Data values entered automatically. These values should not be changed or degraded regulator performance may result.
• Motor Overload Ratio (%) (Range: 100 to 400) The motor overload ratio is used in calculating the torque limit. Enter the value in percent. A warning will be generated if the value entered is not within the limits of the following equation: Rated Motor Amps ∗ Motor Overload ÷ 100 ≤ Power Module Amps • No Load Stator Current (Amps RMS) (Range: 0.25 to 25.00) The no load stator current is used to select the level of magnetizing current. Enter the value in amps. The resolution is 0.01 amps.
2.4.3 Motor Data Screen (Vector - Speed Loop Enhanced) The Motor Data parameter screen allows you to select the motor you are using. You must select your motor from the list displayed. See figure 2.9. Figure 2.9 – Motor Data Parameter Entry Screen (Vector - Speed Loop Enhanced) • Motor List You can select a part number from a list of supported motors to have the specified default Motor Data values entered automatically. These values should not be changed or degraded regulator performance may result.
• Motor Overload Ratio (%) (Range: 100 to 400) The motor overload ratio is used in calculating the torque limit. Enter the value in percent. A warning will be generated if the value entered is not within the limits of the following equation: Rated Motor Amps ∗ Motor Overload ÷ 100 ≤ Power Module Amps • No Load Stator Current (Amps RMS) (Range: 0.25 to 25.00) The no load stator current is used to select the level of magnetizing current. Enter the value in amps. The resolution is 0.01 amps.
• External Speed for Constant Power This option allows you to supply an external speed reference (RPM) to the drive. The drive uses this speed feedback reference from the UDC in place of the PMI speed feedback signal to reduce the magnetizing current when motor is operating in the constant power region. 2.4.
Table 2.4 – Resolvers for Vector Regulators Resolver Base Part No. x1 x2 613469 -1R -1S 613469 -2R -2S 800123 -R -S 800123 -1R -1S 800123 -2R -2S Suffix For the most accurate velocity control, always select the resolver (x1 or x2) whose maximum speed is closest to, and greater than, the maximum speed for your application. Refer to the SA500 Power Modules instruction manual (S-3018) for more information regarding the PMI’s resolver-to-digital converter and the supported resolvers.
2.4.5 Feedback Data Screen (Vector - Speed Loop Enhanced) The Feedback Data parameter screen allows you to enter specific information about the resolver used with the motor, the motor overspeed limit, and the direction of motor rotation. See figure 2.11. Figure 2.11 – Feedback Data Parameter Entry Screen (Vector - Speed Loop Enhanced) • Over Speed Limit (RPM) (Range: 10 to 10000) The over speed limit is used to select the speed at which the over speed fault should be generated by the PMI.
Table 2.5 – Resolvers for Vector - Speed Loop Enhanced Regulators Resolver Base Part No. x1 x2 613469 -1R -1S 613469 -2R -2S 800123 -R -S 800123 -1R -1S 800123 -2R -2S Suffix For the most accurate velocity control, always select the resolver (x1 or x2) whose maximum speed is closest to, and greater than, the maximum speed for your application.
2.5 Generating the Drive Parameter Files and Printing Drive Parameters When you have completed all of the drive parameter screens, you can select “Close” to leave the Parameter Entry Screens and return to the master rack diagram with the UDC module selected. Zoom out or select the Exit command from the Configure menu to return to the System Configurator. You can generate the drive parameter files by using the steps that follow. Step 1.
2-22 SA500 Drive Configuration and Programming
CHAPTER 3 Configuring the UDC Module’s Registers ! ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
• The Feedback Registers view is used to configure the feedback registers that display the current status of the drive. These registers are written to by the PMI. • The Application Registers Updated Every Scan view is used to configure the application registers that are used for the passing of application-specific control and status data between an AutoMax Processor and the UDC module on every scan. This register range is shared by drive A and drive B.
• Register Name: Functional name of the register (e.g., Torque Reference Register). • Register A/B Numbers: Memory addresses of registers A and B. • Sug. Var. Name: Suggested variable name for the register (e.g., TRQ_REF%). • Units: Scaling unit applied to the value stored in the register (e.g., counts, amps *10, etc.). • Range: The upper and lower limits of the value, where applicable (e.g. -4095 to +4095). • Access: The level of access by the application task (Read, Write, or Read/Write).
Table 3.1 – UDC Module Configuration Views and Registers View Register Range Described in Section: Port 0 Drive A: 0- 5 Drive B: 12-17 3.2 Port 1 Drive A: 6-11 Drive B: 18-23 3.2 UDC/PMI Communication Status Registers Drive A: 80-89 Drive B: 1080-1089 3.3 Command Registers Drive A: 100-149 Drive B: 1100-1149 3.3 Volatile Gain Registers Drive A: 150-199 Drive B: 1150-1199 3.4 Feedback Registers Drive A: 200-221 Drive B: 1200-1221 3.5 Application Registers Updated Every Scan 300-599 3.
Table 3.2 – UDC Module Dual Port Memory Register Organization.
3.2 Rail I/O Port Registers (Registers 0-23) The Rail I/O Port 0 and Port 1 views are used to assign variable names to the rail ports on the PMI. If you have no hardware attached to these ports, do not configure these registers. All of the Rail data for PMI A and PMI B is combined into one section of the dual port memory. Refer to table 3.3. Note that the usage of each register is a function of the type of Rail that is configured.
Table 3.3 – Rail I/O Port Registers Rail Type and Signal 2 Input3 2 Output Digital I/O4 Input 0 Output 0 Digital Output 1 Input 1 Output 1 N/A Port 0 - Channel 2 Output 2 Input 2 Input 2 N/A 15 Port 0 - Channel 3 Output 3 Input 3 Input 3 N/A 4 16 Port 0 - Fault Register (Tables 3.4 - 3.6) 5 17 Port 0 - Check Bit Fault Count Register (Tables 3.4 - 3.
Table 3.
3.3 UDC/PMI Communication Status Registers (Registers 80-89/1080-1089) The UDC/PMI Communication Status Registers display the status of the fiber-optic communications between the UDC module and the PMI. Two consecutive errors will be indicated by a communication fault, and the drive will stop. Refer to register 202/1202, bit 15, for more information. Note that the communication status registers are for system use only and can only be monitored.
UDC Module Ports A/B Communication Status Register (Continued) 80/1080 DMA Format Error The DMA Format Error bit is set if the length of the received message does not match the length encoded in the message itself. Bit 4 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0010H N/A Read only N/A N/A Transmitter Underrun The Transmitter Underrun bit is set if the USC reports a transmit first-in, first-out underrun. Bit 5 Hex Value: Sug. Var.
UDC Module Ports A/B Communication Status Register (Continued) 80/1080 Multiplexed Data Verification Failure The Multiplexed Data Verification Failure bit is set if data which is multiplexed into command/feedback messages does not verify correctly. Bit 9 Hex Value: Sug. Var.
UDC Module Ports A/B CRC Error Count Register This register contains the number of messages with CRC errors received by the UDC module on port A and port B. 82/1082 Sug. Var. Name: Units: Range: Access: UDC Module Ports A/B Format Error Count Register This register contains the number of messages with format errors received by the UDC module on port A and port B. N/A Counts N/A Read only 83/1083 Sug. Var.
PMI A/B Communication Status Register (Continued) 84/1084 Overrun Error The Overrun Error bit is set if the USC reports a receive first-in, first-out overrun. Bit 3 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0008H N/A Read only N/A N/A DMA Format Error The DMA Format Error bit is set if the length of the received message does not match the length encoded in the message itself. Bit 4 Hex Value: Sug. Var.
PMI A/B Communication Status Register (Continued) 84/1084 Multiplexed Data Verification Error The Multiplexed Data Verification Error bit is set if data multiplexed into command/feedback messages does not verify. Bit 9 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0200H N/A Read only N/A N/A Invalid PMI Start Operating System Address The Invalid PMI Start Operating System Address bit is set by the PMI if the operating system is not within the allocated operating system address area.
PMI A/B Communication Status Register (Continued) 84/1084 PMI Operating System Overflow into Stack Memory The PMI Operating System Overflow into Stack Memory bit is set by the PMI if the loading of the PMI operating system will overrun the PMI stack memory area. Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: Bit 15 8000H N/A Read only N/A N/A This condition will cause the loading of the PMI operating system to fail.
UDC Module Ports A/B Fiber-Optic Link Communication Status Register This register shows the current operating state of fiber-optic links A and B. The lower byte (bits 0-7) shows the actual link status while the upper byte (bits 8-15) shows whether the communication taking place is synchronized or not. Sug. Var. Name: Units: Range: Access: 88/1088 N/A N/A N/A Read only If the lower byte is equal to: xx01H: the UDC module is waiting for a request from the PMI for an operating system.
3.3 Command Registers (Registers 100-149/1100-1149) The Command Registers view is used to configure command registers. These registers are used for command data sent to the PMI by the UDC module at the end of every scan of the UDC Processor. Note that the bits in these registers (except bit 15 in register 100/1100) are used to command action only and do not indicate the status of the action commanded. The feedback registers (registers 200/1200 to 299/1299) are provided for this purpose.
Drive Control Register (Continued) 100/1100 Speed Loop On Bit 3 The Speed Loop On bit is set to enable the PMI speed loop. This bit must be set for the position loop (see bit 4) to run. All speed loop variables are reset when this bit is turned off. Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0008H SPD_ON@ Read/Write N/A N/A Position Loop On Bit 4 The Position Loop On bit is set to enable to PMI position loop. The Speed Loop Enable bit (see bit 3) must also be set.
Drive Control Register (Continued) 100/1100 Enable Notch Filter The Enable Notch Filter bit is set to attenuate an undesired frequency in the speed feedback signal using the speed loop’s notch filter. Bit 10 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: UDC Program In Run The UDC Program In Run bit is a status bit that indicates that the UDC task is running. This bit is used by the PMI Regulator to prevent the minor loop from running if the UDC task is not running.
I/O Control Register (Continued) 101/1101 Auxiliary Output The Auxiliary Output bit is set to turn on the auxiliary output on the PMI. If a communication fault occurs, the auxiliary output will be turned off. Bit 4 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: Enable Resolver Calibration The Enable Resolver Calibration bit is set to begin the test that determines the resolver’s balance value. This value will be stored in the pre-defined local tunable RES_BAL%.
I/O Control Register (Continued) 101/1101 Calculate Iz Value The Calculate Iz Value bit is set to start the procedure to tune the value of STATOR_IZ_E2%. Appendix E describes how to perform this procedure. Bit 10 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0400H TUNE_IZ@ Read/Write N/A N/A Note that bit 0 of register 101/1101 must be in a reset condition to perform this procedure.
Position Reference Register The value in the Position Reference register is the PMI setpoint in reference to position feedback. This value must not change by more than 32767 counts per PMI scan, where 4095 equals one mechanical revolution of the resolver. 106/1106 Sug. Var. Name: Units: Range: Access: POS_STPT% Counts +32767 to -32768 Read/Write Note that +32767 to -32768 is a single count change.
3.4 Volatile Gain Registers (Registers 150-199/1150-1199) The Command Register view is used to configure the volatile gain registers. These registers are used for volatile gain data sent to the PMI by the UDC module. This data is sent to the PMI asynchronously and is only transmitted when a gain value is changed. The values in these registers, including changes made on-line, will be lost when power is removed. At power-up, register default values will be active.
Notch Filter Center Frequency Register The value in this register specifies the center frequency which is to be rejected by the speed loop’s notch filter. The value (in rad/sec) is scaled times 10 so that a value of 10 rad/sec is entered as 100. 154/1154 Sug. Var. Name: Sug. Def. Value: Low Limit: High Limit: Step: Notch Filter Q Factor Register The value in this register is divided into the notch filter center frequency (NTCH_W%) to specify the bandwidth of the speed loop’s notch filter.
Position Loop Damping Factor Register The value in this register is the damping factor which provides independent control of the position loop’s integral gain. Refer to appendix C for more information. This value is scaled times 10 so that a value of 0.7 is entered as 70. 161/1161 Sug. Var. Name: Sug. Def. Value: Low Limit: High Limit: Step: Position Loop Rate Limit Register The PMI position loop uses the value in this register to limit the position reference value's rate of change.
3.5 Feedback Registers (Registers 200-299/1200-1299) The Feedback Registers view is used to configure the feedback registers that display the current status of the drive. These registers are updated by the PMI and sent to the UDC module over the fiber-optic link before every scan of the UDC task. The status of these registers is retained after a Stop All. Drive Status Register 200/1200 The bits in the Drive Status register indicate the current state of the drive.
Drive Status Register (Continued) 200/1200 Positive Position Limit The PMI sets the Positive Position Limit bit to indicate that the motor has reached its positive position limit. When the motor moves away from the positive position limit, this bit will be turned off. Bit 4 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0010H POS_SP@ Read only N/A N/A Negative Position Limit The PMI sets the Negative Position Limit bit to indicate that the motor has reached its negative position limit.
Drive Status Register (Continued) 200/1200 Torque Loop Reference in Positive Saturation The PMI sets this bit if it detects that the torque loop reference signal is in positive saturation. Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: Bit 11 4000H TRF_SP@ Read only N/A N/A Torque Loop Reference in Negative Saturation The PMI sets this bit if it detects that the torque loop reference signal is in negative (minus) saturation. Hex Value: Sug. Var.
I/O Status Register 201/1201 The bits in the I/O Status register indicate the current state of the inputs on the PMI. Run Permissive Input The Run Permissive Input bit displays the status of the input signal connected to pin A on the DRIVE I/O connector. When the signal is present, this bit is set. Bit 0 Hex Value: Sug. Var.
I/O Status Register (Continued) 201/1201 Auxiliary Input 5 The Auxiliary Input 5 bit reflects the status of the 115 VAC auxiliary input 5. When the input signal is present, this bit is set. Bit 5 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0020H AUX_IN5@ Read only N/A AUX IN5 Resolver Gain Calibration OK The Resolver Gain Calibration OK bit is set when the resolver gain calibration procedure is complete.
I/O Status Register (Continued) 201/1201 Tuned Iz Done The Tuned Iz Done bit is set to indicate that the system has successfully tuned the value in STATOR_IZ_E2%. Bit 10 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0400H TUNED_IZ@ Read only N/A N/A Note that this bit is used in Constant Power applications only. Refer to Appendix E for more information on this procedure. Drive Fault Register 202/1202 The bits in the Drive Fault register indicate the cause of a drive shutdown.
Drive Fault Register (Continued) 202/1202 DC Bus Overvoltage The DC Bus Overvoltage bit is set if the DC bus voltage exceeds 400 VDC. Bit 2 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0004H FLT_OV@ Read only 1018 P.M. FLT Vcc Power Supply Undervoltage The Vcc Power Supply Undervoltage bit is set if the input to the +5V supply for the PMI drops below the necessary voltage to maintain regulation. Bit 3 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0008H FLT_VCC@ Read only 1019 P.
Drive Fault Register (Continued) 202/1202 Overspeed / Slip > 100% The Overspeed / Slip > 100% bit is set if the motor’s velocity exceeds the value entered as the Overspeed Trip (RPM) configuration parameter. Bit 10 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0400H FLT_OSP@ Read only 1010 EXT FLT PMI Power Supply Fault The PMI Power Supply Fault bit is set if the PMI power supply is not providing the required output. Bit 12 Hex Value: Sug. Var.
Drive Warning Register 203/1203 The warnings indicated by the Drive Warning register cause no action by themselves. Any resulting action is determined by the application task. The user must ensure that the AutoMax application task monitors register 203/1203 and takes appropriate action if any of these conditions occurs. If a warning condition is detected, the corresponding bit is latched until the Warning Reset bit (bit 9) of the Drive Control register (register 100/1100) is set.
Drive Warning Register (Continued) 203/1203 CCLK Not Synchronized in PMI The CCLK Not Synchronized in PMI bit is set if the CCLK counters in the PMI and UDC modules are momentarily unsynchronized. Bit 14 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 4000H WRN_CLK@ Read only N/A N/A PMI Communication Warning The PMI Communication Warning bit is set if a fiber-optic communication error is detected between the PMI and the UDC module. Bit 15 Hex Value: Sug. Var.
Interlock Register 205/1205 Interlock tests are executed whenever bit 0 or 1 of register 100/1100 is set. The first problem detected will be indicated by the identifying bit in the Interlock register. Note that these bits will prevent the vector or brushless minor loop from running. Refer to the SA500 Diagnostics, Troubleshooting, and Start-Up Guidelines instruction manual (S-3022) for more information about interlock tests.
Interlock Register (Continued) 205/1205 Rising Edge Required The Rising Edge Required bit is set if a rising edge is required on any command bit in register 100/1100. Bit 4 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0010H IC_RISE@ Read only N/A N/A This bit will be set if the application task has set the Fault Reset bit (register 100/1100, bit 8) but has not cleared and then re-set any command bits.
Position Loop Register 209/1209 The Position Loop register contains the velocity output value from the Sug. Var. Name: PMI position loop. This value can be used to indicate that the position loop is active. Units: Range: Access: Current Feedback (Normalized) Register The Current Feedback (Normalized) register contains the measured RMS motor current. The data is normalized so that 4095 counts is equal to the current limit. POS_REG_OUT % Counts +/-4095 Read only 211/1211 Sug. Var.
Motor Speed in RPM Register The Motor Speed in RPM register contains the speed of the motor in revolutions per minute. A positive number in this register indicates a forward direction; a negative number indicates a reverse direction. 217/1217 Sug. Var. Name: Units: Range: Access: RPM% RPM N/A Read only Note that this register is not intended for closed loop control. Position Error Register The Position Error register contains the error output value of the position loop.
3.6 Application Registers (Registers 300-599, Every Scan) (Registers 1300-1599, Every Nth Scan) The application registers are used to pass application-specific data between the AutoMax Processor and the UDC module. Memory is allocated for a maximum of 600 application registers. There are 300 registers that can be used every scan (registers 300-599) and 300 registers that can be used every Nth scan (registers 1300-1599). “N” is defined in register 2001.
to respond to an interrupt from the UDC module. Registers within this range that are written to by an AutoMax task are read by the UDC operating system from dual port memory and copied into the UDC local memory at the beginning of the Nth scan. See figure 3.2. The following data types can be defined in the application register area: boolean (bit), integer (16 bits), double integer (32 bits), and real (32 bits).
Figure 3.2 – Nth Scan Interrupts 3-42 SA500 Drive Configuration and Programming Scan 2 Scan 3 Scan 4 Input A Write “every scan" registers that are outputs from task A Latch “every scan" registers that are inputs to task B Write “Nth scan" registers that are outputs from both tasks A and B Write “every scan” registers that are outputs from task B. Run B Output B Write “every scan” registers that are outputs from task A UDC operating system generates interrupt to AutoMax Processor.
3.7 UDC Module Test I/O Registers (Registers 1000-1017) This view is used to configure the UDC module’s Test Switch Inputs Register and the Meter Port Setup Registers. 3.7.1 UDC Module Test Switch Inputs Register (Register 1000) This view is used to configure the register that displays the status of the test switches and LED indicators on the UDC module. Writing to this register will not change the state of the LEDs. The status of this register is retained during a Stop All.
UDC Test Switch Inputs Register (Continued) 1000 COMM A OK LED The COMM A OK LED bit shows the status of the COMM A OK LED on the UDC module (0 = OFF; 1 = ON). Bit 9 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: Drive A Fault LED The Drive A Fault LED bit shows the status of the Drive A Fault LED on the UDC module (0 = OFF; 1 = ON). Bit 10 Hex Value: Sug. Var.
3.7.2 UDC Module Meter Port Setup Registers (Registers 1000-1017) Registers 1001-1017 are used to configure the UDC module’s meter ports. This configuration determines what variables from the UDC module’s dual port memory are to be displayed on the meter ports at the end of the UDC scan. At system power-up, the output values of the ports are reset to zero. To map a UDC variable to a specific meter port at power-up, refer to table 3.7 and use the following procedure.
3.7.2.1 Resolution of Meter Port Data For meter ports, the output values will be clamped at the outside (+/-10V) limits. Note that if you select to display a data range that is narrower than the actual range of the data, your output values will not change until the value returns to within the range you selected to display. In other words, data is being updated at the rate described above, but the actual output voltage may not change.
Meter Port 1 Port 1 UDC Register Number Enter the UDC register number (0 - 2044) to be mapped to meter port 1. 1002 Sug. Var. Name: Units: Range: Access: N/A N/A N/A Read/Write Port 1 Bit Number Register Bit number of the UDC register specified in register 1002 that is to be mapped to port 1. Enter a value of 100 (bit 00) to 115 (bit 15) as required. Enter a value of zero if all of the register’s bits are to be displayed. 1003 Sug. Var.
Meter Port 2 Port 2 UDC Register Number Enter the UDC register number (0 - 2044) to be mapped to meter port 2. 1006 Sug. Var. Name: Units: Range: Access: N/A N/A N/A Read/Write Port 2 Bit Number Register Bit number of the UDC register specified in register 1002 that is to be mapped to port 2. Enter a value of 100 (bit 00) to 115 (bit 15) as required. Enter a value of zero if all of the register’s bits are to be displayed. 1007 Sug. Var.
Meter Port 3 Port 3 UDC Register Number Enter the UDC register number (0 - 2044) to be mapped to meter port 3. 1010 Sug. Var. Name: Units: Range: Access: N/A N/A N/A Read/Write Port 3 Bit Number Register Bit number of the UDC register specified in register 1002 that is to be mapped to port 3. Enter a value of 100 (bit 00) to 115 (bit 15) as required. Enter a value of zero if all of the register’s bits are to be displayed. 1011 Sug. Var.
Meter Port 4 Port 4 UDC Register Number Enter the UDC register number (0 - 2044) to be mapped to meter port 4. 1014 Sug. Var. Name: Units: Range: Access: N/A N/A N/A Read/Write Port 4 Bit Number Register Bit number of the UDC register specified in register 1002 that is to be mapped to port 4. Enter a value of 100 (bit 00) to 115 (bit 15) as required. Enter a value of zero if all of the register’s bits are to be displayed. 1015 Sug. Var.
3.8 Interrupt Status and Control Registers (Registers 2000-2047) This view is used to configure registers that control the operation of interrupts to a task on an AutoMax Processor in the rack and to enable CCLK in the rack. These registers are used for Drive A and B. Only one UDC task should write to these registers. Note that the status of these registers is not retained after a Stop All. Interrupt Status Control Register The Interrupt Status Control register contains the following information.
Interrupt Status Control Registers (Continued) 2000 CCLK Counting Bit 5 Hex Value: Sug. Var. Name: Access: UDC Error Code: LED: 0010H N/A Read only N/A N/A Enable CCLK CCLK must be enabled for the UDC module to execute its task(s) and communicate synchronously with the PMI. Bit 6 Hex Value: 0001H Sug. Var. Name: UDC_CCLK_ENA@ Access: Read/Write UDC Error Code: N/A LED: N/A Only one module per rack should enable CCLK.
Scans Per Interrupt Register (Nth scan) The Scans Per Interrupt register contains the number of times a UDC task is to be scanned between updates of the Nth scan application registers. 2001 Sug. Var. Name: Units: Range: Access: UDC_SPI% N/A See below. Read/Write Note that you must write the desired value to this register before you turn on CCLK. The default value is zero (i.e., not applicable because an interrupt is not being used but is updated each scan). One is a permissible value.
3-54 SA500 Drive Configuration and Programming
CHAPTER 4 Application Programming for DPS Drive Control ! ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
Executive software. Like Control Block tasks on AutoMax Processors, UDC tasks can include a number of BASIC language statements and functions; however, those that allow task suspension or delay are not supported. UDC tasks are created, compiled, loaded, and monitored in the same way as Control Block tasks for AutoMax Processors. UDC task variables can be monitored, set, tuned, and forced like AutoMax task variables.
All common input values for the UDC task are first read from the dual port memory and then stored in a local buffer in order to have a consistent context for evaluation. The task is then executed. After the task has been executed, the common output values from the UDC task are written from the local memory buffer to dual port memory. The only exception to this pattern are the common variables in the “Nth” scan application register area.
Step 4. SCAN_LOOP block/Enabling CCLK This control block tells the UDC operating system how often to execute the task based on the constant clock (CCLK) signal on the rack backplane. Note that the CCLK signal must be enabled by a task in the rack before any UDC tasks in the rack can b scanned beyond their SCAN_LOOP blocks. Note that CCLK must be enabled again after a STOP ALL in the rack.
Step 6. Motor thermal overload protection Electronic thermal overload protection for SA500 drives is normally provided by the THERMAL OVERLOAD block. The following briefly describes how the THERMAL OVERLOAD block works, how to program the block, and what adjustments are possible. Each UDC task must contain a THERMAL OVERLOAD block, unless motor thermal overload protection is provided by a hardware device. See J-3676, the Control Block Language instruction manual, for the structure of the block.
Consider an example in which LIM_BAR is defined to be 150% of full load current, THRESHOLD is 114%, and TRIP_TIME is 60 seconds. When I_FDBK is at 100%, CALC_RISE will reach a steady state value of 1000 (1002 / 10). With THRESHOLD at 114%, the trip point for CALC_RISE will be 1300 (1142 / 10). If I_FDBK is at steady state (100%) and then is stepped to 150%, CALC_RISE will integrate up to 1300 in 60 seconds and OVERLOAD will turn on. The OVERLOAD output will stay on until the rise decays to less than 1000.
Like all tunable values in the AutoMax environment, the values of these UDC task tunables are retained through a power loss. Note that the programmer can also define other local tunable variables for application-specific purposes, but the number of local tunables in each UDC cannot exceed 127. 4.2.2.1 Calculating Local Tunable Values Depending upon the type of local tunable variable, the “CURRENT” value, i.e.
same time base for task execution. Note that all UDC modules in a rack are not required to have the same value in the TICKS parameter of the SCAN_LOOP block in both their tasks. In other words, if the UDC module in slot 6 has TICKS = 10 in its tasks, and the UDC module in slot 7 has TICKS = 20 in its tasks, the tasks on the UDC module in slot 6 will execute twice as often as the tasks on the UDC module in slot 7, but they will execute on the same time basis, i.e.
CCLK_OK@ COM_FLT@ RUN_PERM@ Start Permissive Logic RUN_PERM@ Figure 4.2 – Recommended Run Permissive Logic Refer to the individual bit descriptions in this manual for more information. 4.3 AutoMax Processor Task and UDC Task Coordination Recall that all tasks running on AutoMax Processors have access to the UDC dual port registers, but that UDC tasks can only access those common variables that represent registers in their own dual port memory.
Figure 4.3 – Data/Time Flow for UDC Module and PMI 4-10 SA500 Drive Configuration and Programming Vector * Diagnostics, Communication, Management, etc. 10 msec. (20 ticks) dual port memory application registers in UDC values to control command and AutoMax task writes new *Communication of command and feedback registers between the UDC and PMI synchronized UDC tasks and PMI control algorithms are not synchronized. The vector control algorithm runs, on the average, every 1 msec. 1.
CHAPTER 5 On-Line Operation ! ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
The option “A” for ALL will automatically load the rack (i.e., AutoMax Processor configuration, the drive parameters for all the UDC modules in the rack, and all tasks for the rack, including all UDC tasks). The drive parameters may be loaded to the UDC module in a specified slot or to all UDC modules in the rack. When the drive parameters are loaded, the AutoMax Programming Executive will determine if the drive parameters are compatible with the existing rack configuration.
• the PMI Regulator’s operating system has been loaded from the UDC module to the PMI Regulator (which happens automatically when the PMI Regulator is connected to the UDC module). Stopping UDC Tasks UDC application tasks (both tasks A and B together) must run at least every 10 milliseconds. Once the SCAN_LOOP statement is executed, the UDC module will cause a Stop All in the rack if the task does not complete its scan within 10 milliseconds.
5-4 SA500 Drive Configuration and Programming
APPENDIX A SA500 Drive Register Reference Registers 0-23 24-79 80-89 90-99 100-108 109-149 150-199 200-221 222-299 300-599 600-999 1000 1001-1017 1018-1079 1080-1089 1090-1099 1100-1108 1109-1149 1150-1199 1200-1221 1222-1299 1300-1599 1600-1999 2000-2010 2011-2047 REGISTER MAP Function Rail I/O port registers System Use Only UDC/PMI comm.
FEEDBACK REGISTERS (Continued) 201/1201 I/O status Bit 0 Run permissive input 1 M-contactor feedback or auxillary input 1 2 Auxiliary input 2 3 Auxiliary input 3 4 Auxiliary input 4 5 Auxiliary input 5 6 Resolver gain calib OK 7 Resolver balance calib OK 8 External strobe detected 9 External strobe level 10 Tuned Iz done 202/1202 Drive Fault Bit 0 PM overtemperature 1 Instantaneous overcurrent 2 DC bus overvoltage 3 Vcc pwr supply undervoltage 4 Position following error 5 Velocity error exceeded 8 Motor spd
APPENDIX B SA500 Local Tunable Variables Resolver Balance and Gain Variables The resolver gain and balance variable values are used to compensate for varying lengths of resolver wiring. The balance value can be generated automatically by commanding the resolver calibration test in register 101/1101. The gain value will be generated automatically when the RES_GAN% variable is equal to zero, i.e., on power-up.
RES_GAN% When RES_GAN% is equal to zero, the gain tuning procedure is performed automatically by the operating system. Zero is the default value. The value can range from 0 to 255 counts, with 1 count representing 0.15 volts of gain. Resolver Gain 8QLWV &RXQWV 'HIDXOW 9DOXH /RZ /LPLW +LJK /LPLW 6WHS This value should be generated using the auto-tuning procedure because the PMI Processor can take into account the entire resolver circuit when setting the proper gain value.
Constant Power Calibration Variables When configuring the SA500, whether Brushless, Brushless - Speed Loop Enhanced, Vector, or Vector - Speed Loop Enhanced, the block task must contain the following local tunables or an error will occur when you try to download the tasks.
B-4 SA500 Drive Configuration and Programming
APPENDIX C SA500 Control Algorithms Depending upon the type of AC motor being controlled, one of four control algorithms can be configured for each SA500 drive: • Vector (torque loop) • Vector (torque loop with speed and position loops and constant power capability) • Brushless DC (torque loop) • Brushless DC (torque loop with speed and position loops) Drives controlling induction motors require a vector algorithm. Drives controlling brushless DC motors require a brushless DC algorithm.
algorithm, this is determined from Iq and the rotor position feedback signal. The torque algorithms produce three current reference output signals, one for each phase of the motor. The current reference signals are compared with the current feedback signals, producing error signals which feed proportional + integral function blocks. The output of these blocks is a voltage reference. The voltage reference is then compared against a triangle wave.
Input position reference values are received from UDC tasks. These position reference values are then converted into position data which is scaled and compared with position feedback values to calculate the amount of position error (POS_ERR%, register 218/1218). The source of position feedback is selectable: resolver, analog, or register.
OUTER CONTROL LOOP(S) UDC MODULE PMI_REF% +4095 -4095 C C C SCALING TORQUE GAIN SLIP GAIN SCALING C = DERIVED FROM CONFIGURATION PARAMETER Id Iq INT SCALING C DIFF SCALE RPM% Iw Iu SUM – Iv C Θ (ANGLE OF VECTOR) SUM VECTOR ROTATOR & CONVERSION TO 3-PHASE + C – C-4 + Figure C.
SA500 Control Algorithms OUTER CONTROL LOOP(S) UDC MODULE PMI_REF% +4095 -4095 TORQUE GAIN C SCALING C C = DERIVED FROM CONFIGURATION PARAMETER Id (= 0) Iq SCALING C DIFF SCALE RPM% SUM + Iw Iu Iv C Θ (ANGLE OF VECTOR) SUM VECTOR ROTATOR & CONVERSION TO 3-PHASE + RES_ALN% C + + Figure C.
Figure C.3 – Position and Speed Loops C-6 SA500 Drive Configuration and Programming 38/6( 38/6( 08/7 *7 &203$5( (4 /7 326B)'%. 6&$/,1* /,0,7 83 287 )2//2:,1* 3523 ,17 '2:1 (5525 /,0,7 326B)) &2817(5 326,7,21 /223 08/7 (;7B9$5B)'%.B(1 (;7B9$5B)'%. $1$/2*B)'%.B(1 $1$/2*B)'%. 5(6B)'%.
APPENDIX D Status of Data in the AutoMax Rack After a STOP_ALL Command or STOP_ALL Fault AutoMax Processor UDC Module PMI Processor LOCAL tunable variables retained retained retained LOCAL variables retained reset to 0 N/A COMMON memory variables non-volatile are retained; others are reset to 0 N/A N/A inputs retained and updated; outputs are reset to 0 see below all I/O is reset to 0 Input values, including: Feedback registers UDC/PMI communication status registers UDC Error Log info ret
D-2 SA500 Drive Configuration and Programming
APPENDIX E Constant Power Calibration Typically, an induction motor operating at or less than its rated speed will be capable of generating its rated torque output. When a motor is operating at more than its rated speed, its ability to generate torque decreases as the speed increases. To compensate for this reduction of torque-producing capability, the magnetizing current can be reduced as a function of motor speed or an external RPM signal.
If application performance in the constant power region is at expected levels, you do not need to perform the following calibration procedure. If application performance in the constant power region is not at expected levels, you may be able to improve it by changing the Iz current values stored in the STATOR_IZ tunables. See table E.1. The default current values were chosen to work with a wide variety of motors.
Step 13. Determine the number of reference points to be used from the STATOR_IZ reference table by looking up the number of speed reference counts (from step 11) in table E.1. Find the reference point corresponding to the next highest speed reference value. This is the number of Iz current reference points that will have to be calibrated and stored in the STATOR_IZ tunables. Step 14. Set the application’s Speed Reference equal to 1023 (reference point 2, STATOR_IZ1E2%).
E-4 SA500 Drive Configuration and Programming
APPENDIX F Calculating Slip Gain, Torque Gain, and Stator Inductance For motors not in the pulldown menu, calculate the slip gain, torque gain, and stator inductance for the motor using the following formulas. FOR THE INFORMATION NEEDED, USE THE DATA FROM THE MOTOR DATA SHEETS. Most errors occur in the calculation of the slip gain parameter. F.
F.2 Torque Gain 60∗P_Base K_torq = (W_base∗2∗π) ∗ 2∗ ( Ifl 2 – Im 2 ) Where P_base = Rated Motor Power (W) (1HP = 746W) W_base = Rated Full Load Speed (rpm) Ifl = Rated Motor Current (rms) Im = NL Stator Current (rms) Nm = ft-lbs. ∗ 1.35582 K_torq = (Nm/Amp) The torque producing component of the full load current, Iq, in the above equation is: Iq = F.
INDEX A Access level, 3-3 Application programming, 4-1 to 4-10 AutoMax and UDC task coordination, 4-9 AutoMax tasks, 4-1 local tunable variables, 4-6 to 4-7 Rail I/O port registers, 3-6 to 3-8 recommended run permissive logic, 4-9 typical structure of a UDC task, 4-3 to 4-6 UDC task scan, 4-2 UDC tasks, 4-1 to 4-9 UDC/PMI task communication, 4-7 to 4-9 Application registers, 3-40 to 3-42 AutoMax rack status of data after STOP_ALL, D-1 B Bit Name, 3-3 Bit Number, 3-3 Brushless configurations.
resolver scan position, 3-38 resolver strobe position, 3-38 slip rpm, 3-39 speed error, 3-38 speed feedback, 3-37 speed loop feedforward output, 3-39 speed loop P+I output, 3-39 torque feedback, 3-37 user analog input, 3-38 G Generating drive parameter files, 2-21 H O On-line operation, 5-1 to 5-3 deleting UDC tasks, 5-3 loading drive parameters, 5-1 to 5-2 loading the UDC operating system, 5-1 loading UDC tasks, 5-1 to 5-2 running UDC tasks, 5-2 stopping UDC tasks, 5-3 UDC information and error logs, 5-
T Torque gain calculation, F-1 U UDC Error Code, 3-3 UDC module adding a UDC module, 2-1 to 2-2 initiate change in setup register, 3-46 meter port setup registers, 3-45 to 3-50 task scan, 3-40 test I/O registers, 3-43 to 3-50 test switch inputs register, 3-43 to 3-44 UDC/PMI communication status registers, 3-9 to 3-16 PMI communication status, 3-12 to 3-15 PMI CRC error count, 3-15 PMI format error count, 3-15 PMI receive count, 3-15 UDC communication status, 3-9 to 3-11 UDC CRC error count, 3-12 UDC fiber
Index-4 SA500 Drive Configuration and Programming
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