4201-003 Rev C Page 1 of 8 ELITE SERIES TECHNICAL MANUAL PART NO. 4201-180 REV J Head Office: 81 Austin Street P.O. Box 741 Napier New Zealand Tel.: +64-6-843-5855 Fax.: +64-6-843-5185 Elite Series Technical Manual PDL Part No.
4201-003 Rev C Page 2 of 8 Elite Series Technical Manual PDL Part No.
IMPORTANT NOTES SAFETY WARNINGS: – It is the installer’s responsibility to ensure the configuration and installation of the Elite Series meets the requirements of any site specific, local and national electrical regulations. – The Elite Series operates from HIGH VOLTAGE, HIGH ENERGY ELECTRICAL SUPPLIES. Stored charge is present after switch off.
DEDICATION TO QUALITY AC Motor Control Products can dramatically improve your process control, productivity and energy efficiency, but only if they are working correctly. Which is why we at PDL Electronics go to great lengths in our design and manufacturing, to ensure that our products operate correctly first time, every time.
4201-003 Rev C Page 5 of 8 CONTENTS 1 INTRODUCTION TO THE ELITE SERIES AC MOTOR CONTROLLER 9 1.1 THE CONCEPT 9 1.2 THE ELITE SERIES RANGE 9 1.3 THE BASIC PRINCIPLE OF FLUX VECTOR CONTROL 9 1.4 CONFIGURATION OF CONTROLLER TYPE 9 1.5 CONTROL CONFIGURATION OPTIONS 9 2 ELITE SERIES SPECIFICATIONS 10 2.1 ELITE SERIES SPECIFICATIONS 10 3 DESCRIPTIONS 13 3.1 DESCRIPTION OF THE ELITE SERIES HARDWARE 3.1.1 Overview 3.1.2 Power Conversion 3.1.3 Control Board 3.1.
5.9 ANCILLARY EQUIPMENT 29 5.10 COMMISSIONING DETAILS 29 6 SERVICE AND MAINTENANCE 33 6.1 FAULT FINDING 6.1.1 Electrical Failure 6.1.2 Protective Fault Operation 6.1.3 Encoder Failure 6.1.4 Incorrect Set-up or Adjustment 6.1.5 Poor Vector Control Tuning 6.1.6 Failure of External Control Device 6.1.7 Failure of the Display Unit 33 33 33 33 33 33 33 33 6.2 THE FAULT SCREEN 6.2.1 Control of the Fault Screen 6.2.2 Fault Messages 34 34 34 6.3 USE OF LED INDICATORS 37 6.4 FUSE FAILURE 38 7.
4201-003 Rev C Page 7 of 8 FIGURES Figure 2.1: Figure 2.2: Figure 3.1: Figure 3.2: Figure 3.3: Figure 3.4: Figure 3.5a: Figure 3.5b: Figure 3.5c: Figure 3.5d: Figure 3.6: Figure 3.7a: Figure 3.7b: Figure 3.8: Figure 3.9: Figure 3.10: Figure 4.1: Figure 4.2: Figure 4.3: Figure 5.1: Figure 5.2: Figure 5.3: Figure 5.4: Figure 5.5: Figure 5.6: Figure 5.7: Figure 5.8: Figure 7.1: Figure 7.2: Figure 7.3: Figure 7.4: Figure 7.5: Figure 7.6: Figure 9.1a: Figure 9.1b: Figure 9.1c: Figure 9.1d: Figure 9.2: Figure 9.
SYMBOLS USED Caution, risk of electric shock ISO 3864, No. B.3.6 Caution (refer to accompanying documents) 3 Three-phase alternating current ISO 3864, No. B.3.1 IEC 617-2, No. 02-02-06 ________ __ __ __ Direct Current IEC 417, No. 5031 Protective Earth (PE) Terminal IEC 417 No. 5019 Earth (ground) Terminal IEC 417 No. 5017 M Induction motor, three phase, squirrel cage IEC 617-2, No. 06-08-01 4201-003 Rev C Page 8 of 8 3 Elite Series Technical Manual PDL Part No.
1 1.1 INTRODUCTION TO THE ELITE SERIES AC MOTOR CONTROLLER THE CONCEPT The AC induction motor is the preferred choice of motive power for many industrial applications. With the development of electronic variable voltage variable frequency (VVVF) controllers, it became possible to control the speed of the induction motor. PDL Electronics has been at the forefront of development of VVVF controllers for the past 25 years.
2 2.1 ELITE SERIES SPECIFICATIONS ELITE SERIES SPECIFICATIONS INPUT Input frequency range Input current Input displacement factor Input current THD Power loss ride through Input voltage 48 to 62Hz < output current > 0.99 < 40% > 2 seconds at nominal voltage (model dependant) refer Figures 2.1 and 2.2 for details.
Elite Series 400V Ratings Rated Voltage (VIN) Supply type 380Vac to 440Vac (-10% to +10%) 3 phase earthed neutral RECOMMENDED CABLE SIZING PER PHASE 380V-440V (Note 1) ENCLOSURE RATING FRAME 1 Nema 12 & Nema 1 models available IEC IP54 & IP20 models available 2 3 Nema 12 IEC IP54 Electronics Enclosure Nema 1 IEC IP20 Termination 6 7 Parallel Drives Note Note Note Note Note 1: 2: 3: 4: 5: I[A] @ 50°C (Note 2) MOTOR kW @ 400V 50°C (Note 3) ME-2.5 2.5 0.75 3.1 14 to 12 2.5 to 4 6 ME-6.
I[A] (Note 2) 1 2 3 PDL Part No.
3 3.1 DESCRIPTIONS DESCRIPTION OF THE ELITE SERIES HARDWARE 3.1.1 Overview The Elite Series range is a family of advanced AC induction motor controllers, presented in seven frame styles. All models are available with IP54 ingress protection rating, suitable for installation in an environment where dust and splashing water may be present. Alternatively, IP20 rated models are also available for the Microdrive Elite Series. Ensure the correct model was specified for the intended environment.
28 (1.1) 14 Lifting Lugs All dimensions in millimetres and (inches) 136 (5.4) 675 (26.6) 970 (38.2) AC MOTOR CONTROLLER 168.5 (6.6) 116 (4.6) 313 (12.3) 347 (13.7) 4808-090 REV F Net Weight kg (lbs) Packaged Weight kg (lbs) UE-60, UE-75 73.5 (162.04) 90 (198.42) UE-90 77.5 (170.86) 94 (207.24) UE-115, UE-140 80.5 (177.47) 97 (213.85) MODELS Figure 3.2: Elite Series Technical Manual Ultradrive Elite Frame 4 Dimensions PDL Part No.
DIMENSIONS W 500V 400V MODELS MODELS mm (inches) WALL MOUNT BRACKETS THROUGH THE WALL MOUNTING UE-170D UE-170 545 (21.5) 160 (353) UE-205D UE-210 545 (21.5) 160 (353) UE-250D UE-250 545 (21.5) 175 (386) UE-305D UE-305 965 (38) 320 (668) UE-370D UE-340 965 (38) 320 (668) UE-440D UE-420 965 (38) 350 (734) UE-540D UE-480 965 (38) 350 (734) UE-620D UE-575 1385 (54.6) 525 (1005) UE-700D UE-660 1385 (54.
+HVDC U V W L1 L2 L3 POWER ELECTRONICS ENCODER MOTOR PE -HVDC PE DISPLAY ON RUN +24V OK PTC/TRIP INPUT DATA START 0V STOP RESET SHAFT ENCODER INPUT FOR DIFFERENTIAL OR SINGLE-ENDED ENCODERS +5V / +24V USER +24V I/O 500mA SUPPLY 0V PROGRAMMABLE ANALOGUE INPUTS POT.
B DYNAMIC BRAKE RESISTOR (OPTIONAL) L3 RFI FILTER L1 L2 RFI FILTER +HVDC U V W PE PE -HVDC RECTIFIER INVERTER 4808-093 Rev C Figure 3.5a: Power Electronics - Microdrive Elite Frames 1 & 2 L2 L3 RFI FILTER L1 RFI FILTER +HVDC U V W PE PE -HVDC RECTIFIER INVERTER 4808-094 Rev C Figure 3.5b: Power Electronics - Microdrive Elite Frame 3 L3 RFI FILTER L1 L2 RFI FILTER +HVDC U V W PE PE -HVDC RECTIFIER INVERTER 4808-095 Rev B Figure 3.
Power On No Fault (Flashing=Fault) Drive Running Alternatively, the START push-button can be configured to be in parallel with an external START switch, and the STOPRESET push-button in series with an external STOP-RESET switch. Backlit LCD Display Details on configuring these push-buttons are given in Section 9 of this manual. Status Line Control Line SCREEN ORGANISATION Screens can be arranged in folded format.
For further connection information to these terminals, refer to Elite Series Getting Started Manual, Part No. 4201-179. Terminals T1 to T7 - Configurable Relay Outputs These are low power relay contacts offering operation at signal or 250Vac levels (referenced to the protective earth PE). Selection of their function is made through Screen Group O. Avoid settings which cause the relays to switch excessively as this will reduce their life expectancy.
Terminals T31 to T34 - Incremental Quadrature Encoder Inputs Screen all control cables The Elite Series is designed to accept input from a standard quadrature encoder designed to operate from +5Vdc to 24Vdc and having single ended open collector outputs, push-pull open collector outputs, or differential logic driver outputs. This encoder is only required if operating in Closed Loop Vector control mode. The encoder type and pulses per revolution may be configured from Screen Group N.
display unit. Each analogue output can have its format configured, with a choice of 0 to 10Vdc (unipolar), –10 to +10Vdc (bipolar), 0 to 20mA or 4 to 20mA using Screens O1a to O1h. COMPARATOR Comparator -Two software comparators allow relay outputs to respond to analogue levels. The comparators may be individually selected to any analogue output source. Individual ON and OFF levels may be set. A window function may also be selected. Configuration is by Screens C1 to C6.
Elite Series Technical Manual SWITCH INPUTS OUTPUT TERMINALS I7c MFI1 SEL I7d MFI1 SEL I7e MFI2 SEL I7f MFI3 SEL I7g MFI4 SEL I7h MFI5 SEL I7b POLARITY RLY3 O2e RLY3 SEL I7a I/P MODE O2c RLY2 SEL INTERNAL CONTROL SIGNAL OUTPUTS STOPR O2a RLY1 SEL RELAY SOURCES 22 / ALTERN ACCEL Figure 3.8: MFI1 MFI2 MFI3 MFI4 MFI5 MFI6 INVERT ALL INPUTS 6 / 5 / MULTI-FUNCTION INPUTS PDL Part No.
Elite Series Technical Manual Figure 3.9: PROCESS CONTROL A2 LOCAL TQ NULL = 0 FIBRE MOTOR POT MULTI REF. AIN1+2 SCALED AIN2 SCALED AIN1 SCALED TORQUE REFERENCE PROCESSING PROCESS CONTROL A3 LOCAL SP NULL = 0 FIBRE MOTOR POT MULTI REF.
FEEDBACK SELECTION P2 FB SRC AIN1 SCALED P3 Kc AIN2 SCALED P5 Td P4 Ti P7 INVERT AIN1+2 SCALED FIBRE SETPOINT SELECTION P1 PR SRC PID PROCESS CONTROL AIN1 SCALED AIN2 SCALED AIN1+2 SCALED 4808-070 Rev F FIBRE LCD Line 2 P6 Error= A3 LOCAL SP MULTI REF. MOTOR POT Figure 3.10: Elite Series Technical Manual Process Control PDL Part No.
4 APPLICATION RECOMMENDATIONS 4.1 THE MOTOR 2.1, if the Elite Series is to be operated in an environment of an ambient temperature not exceeding 40°C. 4.1.1 Sizing the Motor and Elite Series The Elite Series is suitable for controlling all standard three phase induction motors. In sizing the Elite Series, the torque requirements of the load must first be assessed. Under flux vector control conventional induction motors are able to provide at least 200% of rated torque (often 250%).
be effective if the Elite Series is running more than one motor. will also accept input pulses from an encoder operating off a supply up to 24Vdc. 4.1.5 Large Frame-size Motor Considerations 4.2.2 Connection of the Encoder Large frame-size motors (typically greater than 315 frame) have additional installation requirements when used with AC motor controllers. These motors may exhibit rotor voltage build-up due to parasitic capacitance.
To run in torque control mode, it is necessary to employ Closed Loop Vector control mode and use a shaft encoder on the motor. DB RESISTOR POWER RATING (MIN-kW) ELITE SERIES DB RESISTOR MINIMUM (Ohms) ME-2.5 500 1.1 ME-2D 500 1.4 ME-6.5 180 3 ME-6D 180 3.8 ME-10.5 130 4 ME-9D 130 5.3 ME-12 100 5.3 ME-11D 100 6.7 ME-18 50 10.6 ME-16D 50 13.5 ME-22.5 50 10.6 ME-21D 50 13.5 4.4.
5 UNPACKING, INSTALLATION AND CONNECTION 5.1 5.3 UNPACKING Full details on the unpacking procedure are given in the Elite Series Getting Started Manual (Part No. 4201-179). Ensure that all of the listed items are supplied, and that there is no visible damage. The packaging material must be disposed of thoughtfully.
generated by it will not ignite or damage its surroundings. 5.5 8 The location and order of the power terminals varies from model to model. Refer to the terminals labels before connection. Figure 5.1 provides recommended tightening torques for the power terminals. Control wiring should be done using screened cable. The screen is earthed at one end only (at the Elite Series end). For safety reasons, the Elite Series control 0V should be linked to earth at some point.
_ _ SWAP A ,A TO REVERSE PULSE DIRECTION +5V +5V T30 A T31 _ A T32 A _ A B T33 _ B T34 B _ B T35 0V 0V DIFFERENTIAL OUTPUT ENCODER 4808-042 Rev.D GROUND SCREEN AT DRIVE END ONLY (a) DIFFERENTIAL ENCODER +VE CONNECTION TO SUIT ENCODER RATING +24V +5V T36 SWAP A ,B TO REVERSE PULSE DIRECTION T30 +VE A T31 _ A T32 NC A B T33 _ B T34 NC B T35 0V 0V SINGLE ENDED OUTPUT ENCODER 4808-042 Rev. D GROUND SCREEN AT DRIVE END ONLY (b) SINGLE-ENDED ENCODER Figure 5.
PROTECTIVE EARTH SHIELD CLAMP SCREENED MOTOR CABLE SUPPLY CABLE 4808-110 Rev A Figure 5.5: U OUTPUT Ultradrive Elite Frame 4 Cable Configuration V HVDC INPUT L1 L2 L3 MOTOR CABLE SUPPLY CABLE PROTECTIVE EARTH 4808-128 Rev A Figure 5.6: Elite Series Technical Manual Ultradrive Elite Frame 5 Cable Configuration PDL Part No.
OUTPUT HVDC U W V +HVDC INPUT L3 L2 MOTOR CABLE PE PE PROTECTIVE EARTH SUPPLY CABLE 4808-129 Rev A Figure 5.7: OUTPUT U Ultradrive Elite Frame 6 Cable Configuration HVDC W V + HVDC INPUT L1 L2 L3 MOTOR CABLE PE PE PROTECTIVE EARTH SUPPLY CABLE 4808-130 Rev A Figure 5.8: Elite Series Technical Manual Ultradrive Elite Frame 7 Cable Configuration PDL Part No.
6 SERVICE AND MAINTENANCE WARNING: 6.1 Observe the safety precautions detailed at the beginning of this manual. FAULT FINDING Faults in the Elite Series will fall into one of five major categories: • • • • • Failure of an external control device, e.g., switch or analogue input device. Protective fault operation with resulting display message. Incorrect settings, set up or adjustment resulting in unsatisfactory performance. Encoder failure. Electrical failure within the drive. 6.1.
6.2 THE FAULT SCREEN (See also Status Messages, Screen AA) 6.2.1 Control of the Fault Screen Fault messages are automatically displayed on the Fault Screen (Screen F). There is a fault log folded as subscreens of the fault screen. This fault log records the previous five faults, with the first screen being the most recent fault. This fault log may be inspected at any time.
Fault Detail 17 BRAKE O/L The temperature calculated by the thermal model of the dynamic brake resistor has reached a dangerous level. Sense level Set by dynamic brake thermal model in Screens D1 and D2. Possible cause Excessive regeneration for the resistor specified in Screens D1 and D2. Incorrect values entered. Action Check values (refer detailed descriptions of Screens D1 and D2). Reduce regeneration via Screen L8. Select a bigger braking resistor. Reduce deceleration rate (Screen R2).
Possible cause Load condition or inappropriate setting of Screen L6. Action Check load condition or alter Screen L6. Fault Detail 31 CAL FLT Internal reference voltage levels are incorrect. Possible cause Elite Series fault. Seek service. Fault 32 S/W T/O Detail Internal timing requirements exceeded. Possible cause PDL Vysta® for Windows configuration too complex. Action Simplify configuration. Fault 33 LVDC FLT Detail Failure of the low voltage dc power supplies.
Action Check entire output circuit including IGBTs output bus work, DC bus fuses and input rectifier. Fault Detail 59 SLV HS FLT The SLAVE Drive has detected either MASTER or SLAVE drive heatsink is TOO HOT. Sense Level 80°C. Possible CausePoor ventilation; obstructed ventilation path, Elite Series cooling fan failure; local ambient temperature exceeds 50°C. Action Check fan is operating; check ventilation and thermal conditions. Improve cooling. Clean fins with compressed air. Seek service.
Implication 6.4 A fault (Screen F) has tripped the Elite Series. FUSE FAILURE The Elite Series incorporates electronic protection. The few fuses included are for SAFETY back up. Supply fuses Fitted by customer at point of supply Possible reason for failure Wrong fuses; Supply surge; Age or cyclic stress failure; Fault in supply cable to Elite Series; Elite Series failure. Action Check supply cable; check Elite Series unit . Isolate Elite Series and replace fuses.
7 7.1 THE ELITE SERIES DISPLAY UNIT DISPLAY UNIT CONTROLLABILITY The Display Unit, as described in Section 3.1.4, is shown in Figure 7.1. The degree of control and monitoring available from this display will be as set up at the time of commissioning. subscreen. Only subscreens that do not have attributes set to “hidden” will be visible. Scroll down the subscreens by using “+” key. Scroll up using “–” key.
7.2.5 Off to Modify Z COMMISSION = N For maximum flexibility, most screens can be adjusted while the Elite Series is running. For reasons of safety, however, certain settings may not be adjusted while running. Attempts to do so will cause the display of the message OFF TO MODIFY. To cancel setting Press " " and "+" or " " password, press * "+" or " " Z1 PASSWRD = ZZZZZ Press and hold " ", * adjust using "+ " or " " Z1 PASSWRD = XXXXX 7.
7.3.3 MENU SET-UP Mode Entering MENU SET-UP mode The drive must be stopped before entering MENU SET-UP Mode. While in COMMISSIONING mode and displaying the commissioning screen (Screen Z), press “∗” for five seconds. The status (top) line of the display will be replaced with the message: MENU SET-UP MODE Figure 7.5 illustrates the procedure for entering to and exiting MENU SET-UP mode.
8 8.1 CUSTOMISATION OF CONTROL PDL VYSTA® FOR WINDOWS CONFIGURATION SOFTWARE assigned when configuring processing blocks, or system names. Customisation of Control 8.3 PDL DRIVELINK FOR WINDOWS SOFTWARE PACKAGE The Elite Series Control Board processor has a number of logic and processing blocks integrated into the firmware. These can be configured to enhance one of the existing default configuration, or for configuring a completely new control system.
9 THE DEFAULT SCREEN LIST The Elite Series provides as a default a very flexible set of formats and functions for control inputs and outputs. The Elite Series can be operated in Open Loop mode as a speed controller, or in Closed Loop mode as a torque or speed controller. The Screen List available in the default configuration is shown in Figure 9.1. READ-WRITE RUN t+100% S +100% A1 LOCAL MODE=SP READ ONLY HIDDEN A2 LOCAL TQ= +0.0% A3 LOCAL SP=+100.0% A4 TQ=+100%SP=+100% A5 +7.
NONE RESET ONLY STOP-RESET START/STOP-RST NULL AIN1 AIN2 AIN1+2 FIBRE LOCAL MREF MTRPOT PROCESS I INPUTS I1 LOCAL S/STP=3 I2 REF S=LOCAL I3 REF T=NULL I4 AREF S=AIN1 I5 AREF T=NULL I6 ANALOGUE I/P I6b AI1 LO=+0% 0-10V +/-10V 4-20mA 0-20mA I6c AL1 HI=+100% -400% to 400% I6d AI2=0-10V DISABLED 3 WIRE ALL PROG MULTIREF 2 WRE MULTIREF 3 WRE MOTOR POT I6a AI1=0-10V I6e AI2 LO=+0% I6f AI2 HI=+100% I6g ZERO BAND=N/Y HI/LO I7 DIGITAL I/P I8c FIBREMODE=0 UNUSED START STOP ASTOP - RESET STOP-RESET ST
0-10V +/-10V 4-20mA 0-20mA O OUTPUTS O2d RELAY2 INV=N/Y ALWAYS OFF ALWAYS ON NO FAULTS DRIVE FAULT SUPPLY FAULT O/L FAULT O/L WARNING START RUN ZERO SPEED AT SET SPEED TORQUE SIGN SPEED SIGN TQ REF SIGN SP REF SIGN SPEED LIMIT TORQUE LIMIT VOLTAGE LIMIT CURRENT LIMIT COMPARATOR 1 COMPARATOR 2 WINDOW COMP BRK RELEASE VISTA CONTROL O2e RELAY3=08 -250% to+250% O2f RELAY3 INV=N/Y NULL FULL SCALE OUTPUT CURR OUTPUT VOLTS BUS VOLTAGE MOTOR POWER MOTOR SPEED MOTOR TORQUE REF SPEED REF TORQUE MOTOR TEMP I
R RATES R1 ACC= 10.0%/s R2 DEC= 10.0%/s R3 AACC= 10.0%/s 0.02 to 1300%/s R4 ADEC= 10.0%/s OFF/0.1 to 250% R5 BRK S= OFF 0.02 to 1300%/s R6 STOPR= 1300%/s 0 to 60sec R7 SP FILT= 0.000s 0 to 10sec R8 TQ FILT= 0.00s NORMAL SPIN S START/STOP S4 ASTOP= NORMAL NORMAL RAMP SPIN STOP R OFF DC BRK S5 STR DLY= 0.00s 0.00 to 5.00s S6 OFF DLY T= 1.0s 0 to 3600sec S1 START=NORMAL S2 STOP= NORMAL S7 LOW V TRIP= N /Y S8 BRAKE I= 0% 0 to150% S9 HOLD V= 0.
Status Messages STATUS LINE Indication STP STOPPED Motor stopped. AA STATUS LINE Message Notes Screen AA OFF 0.0% 0.0% STP t+000% S+000% Indication SPG Description STATUS, OVERLOAD, TORQUE/ CURRENT, SPEED, INDICATION % OF RATED MOTOR TORQUE/AMPS, % OF RATED MOTOR SPEED ALWAYS DISPLAYED Message Notes STOPPING Motor is stopping. Indication RDY Message Notes READY Elite Series is ready to run.
SCREEN GROUP A: STATUS DISPLAYS A1 READ-WRITE RUN t+100% S +100% READ ONLY HIDDEN A2 LOCAL TQ= +0.0% A2 A3 LOCAL SP=+100.0% A4 TQ=+100%SP=+100% A5 +7.5kW +1480RPM 4808-072 Rev C A1 LOCAL MODE=SP A6 +16A +50.0Hz A6a O/P CURRENTS A7 Tm=100% Ti=100% A3 A7a TH= Ti= A8 565Vdc 400Vac A4 A5 A3 LOCAL SPEED REFERENCE Screen LOCAL SP=+100.
A6 MOTOR CURRENT, STATOR FREQUENCY Screen +16A Description Units Attribute MOTOR CURRENT, FREQUENCY OF AC APPLIED TO STATOR Amps; HERTZ Read Only +50.0Hz A6a PHASE OUTPUT CURRENTS Screen 1.2A 1.2A 1.2A Description Range Units Attribute PHASE OUTPUT CURRENTS 0 to 1999A Amps Read Only FUNCTION This screen displays the individual phase currents of the Elite Series.
C1 SCREEN GROUP C: LEVEL COMPARATOR Group Attribute Hidden SCREEN GROUP D: DYNAMIC BRAKE CONTROLS C3 1 OFF= + 90% C3 to +250% C4 COMP2 SEL= 02 -250% to C2 C5 2 ON= +100% C6 to +250% C6 2 OFF= + 90% -250% to C5 C3 C COMPARATOR C1 COMP1 SEL= 02 C4 C5 C6 D1 D2 Screen C1 COMP1 SEL =02 C4 COMP2 SEL =02 Description Range Default Value OFF to Modify COMPARATOR SOURCE SELECTION 00-18, REFER FIGURE 9.
SCREEN GROUP F: FAULT HISTORY SCREENS Group Attribute Read-Write SCREEN GROUP H: SERIAL COMMUNICATION CONTROLS F Group Attribute Hidden F2 NO FAULTS F3 NO FAULTS F4 NO FAULTS F5 NO FAULTS H SERIAL COMMS 4808-075 Rev B F1 NO FAULTS H1 PROTOCOL = M MODBUS DEVICENET H2 COMM T/O= OFF 1s/5s/25s/OFF H3 MODBUS 1 to 240 H3a COMMS ADR= 10 F6 CLEAR HIST = N/Y H3b BAUDRATE= 9600 OFF /1200/2400/ 4800/9600 H3c PARITY= EVEN EVEN/ODD/NONE 125/250/500kbps H4b Baud= 125kbps F NO FAULTS H4c Ass In=
H3a H3b H3c SUBGROUP H3: MODBUS COMMUNICATION PARAMETERS Screen MODBUS SERIAL COMMUNICATIONS ADDRESS Range 1–240 Units Default Value 10 OFF to Modify NO Screen H4a H4b H4d H4e H4f H3b BAUD=9600 Description MODBUS SERIAL COMMUNICATIONS BAUDRATE Range 1200/2400/4800/9600/OFF Units Default Value 9600 OFF to Modify NO FUNCTION H4c H3a COMM ADR=10 Description Sets the Modbus serial communication Baudrate.
H4g Description Range DeviceNet Interface Status Off Line Interface board not responding or network not powered up. No Net Power 24Volts missing on DeviceNet network Self-Testing Powering up. Standby Network power OK but no communications established. Operational Network is OK and communication is established. R Fault Recoverable network fault has occurred. NR Fault Non-recoverable network fault has occurred.
I2 I3 I4 I5 I2, I4 SPEED REFERENCE SOURCES Screen I2 REF S=LOCAL NULL NO SOURCE SELECTED Description Range Default Value OFF to Modify SPEED REFERENCE SOURCE REFER FIGURE 9.4 LOCAL YES AIN1 ANALOGUE INPUT 1 Screen I4 AREF S=AIN1 Description ALTERNATIVE SPEED REFERENCE SOURCE Range REFER FIGURE 9.
SUBGROUP I6: ANALOG INPUTS I6a - I6f ANALOGUE INPUT FORMATTING AND SCALING CONTROLS Screen I6a AI1=0-10V Description Range Default Value OFF to Modify ANALOGUE INPUT 1 FORMAT REFER FIGURE 9.
forms part of a feedback loop, set the zero band to NO. I7a Note: Zero band is provided since the digital tacho feedback employed in the Elite Series in Closed Loop Mode control mode is absolute i.e., it cannot lose counts. Therefore any error in zero speed reference setting, however small, will be integrated over time causing the shaft to rotate. The zero band function does not apply to the digital speed references (e.g.
MFI 4 selects which reference is to be adjusted (Speed = Open & Torque = Closed). MULTI-FUNCTION SETTING UP WARNING Altering the multi-function input mode of the Elite Series completely reconfigures the logic of operation of the input control terminals. Be very sure that you understand the operating mode that you require, and that any inputs already connected will not cause the unit to automatically start once your mode is selected.
I7b I7b MULTI-FUNCTION INPUT INVERSION Screen I7b POLARITY=HI Description I7c I7d MULTI-FUNCTION INPUT LOGICAL INVERSION Range HI (active high) or LO (active low) Default Value HI (active high) OFF to Modify YES FUNCTION The Elite Series has the ability to have its input circuits operated in two modes: ACTIVE HIGH (I7b POLARITY= HI) Pull input high to activate I7e ACTIVE LOW (I7b POLARITY= LO) Pull input low to activate This screen changes the biasing of the digital input circuits, to bias low
No. Input Inactive State 00 Unused N/A 01 Start Open SUBGROUP I8: FIBRE OPTIC INPUT Action Function/Notes I8a - I8d FIBRE OPTIC INPUT SCALING CONTROLS Commands start, latching Screen I8a F LO=–100.
L2 SCREEN GROUP L: LIMITS connected is able to supply the current necessary to supply the torque required. Do not select minimum or maximum torque which will require the Elite Series to produce more than 150% of its rated output current. Group Attribute READ L LIMITS L2 MIN S= -110% -250% to L3 * L3 MAX S=+110% L2 to +250% L4 MIN T=-150% -250% to L5 L5 MAX T=+150% L4 to +250% L6 SP T/O= INF 0 to 25s,INF L7 TQ T/O= INF L4 L8 REGEN= 150% L9 I LIMIT=3.
SETTING UP (whether relying on natural losses or using a dynamic brake). L10, L11, L12 In utilising this function the optimum braking performances can be achieved without danger of loss of control due to regeneration beyond the system’s ability to dispose of it. Screen L10 SKIP 1 =+0.0% Description Range Default OFF to Modify SKIP SPEED 1 -250% to +250% 0% No If the application does not involve regeneration, this screen need not be adjusted.
L14 L13 Screen L13 GND ILT=12A Description Range Units Default FUNCTION GROUND CURRENT LIMIT OFF/0.1 to 9999A Amps/Phase 30% of Inverter rated current per phase To set the limit of ground current that is acceptable. M1 M3 SCREEN GROUP M:MULTI-REFERENCE SETPOINTS Group Attribute HIDDEN M MULTIREFS M1 MREF1=+0.00% M2 MREF2=+0.00% M3 MREF3=+0.00% -250% to+250% M4 MREF4=+0.00% M5 MREF5=+0.
SC R EEN TITLE MFI4 (T16) X MFI5 (T17) Y MFI6 (T18) Z ZERO O O O MREF1 O O X SCREEN GROUP N: MOTOR NAMEPLATE DATA Attribute N1 MTR CUR= 14.6A * M2 MREF2 O X MREF3 O X X M4 MREF4 X O O M5 MREF5 X O X M6 MREF6 X X O M7 MREF7 X X X O= Open X = Closed Figure 9.16: N4 MTR P=7.5kW O M3 Function of Multi - Reference 3 Wire Note: Figure 9.16 shows special functions assigned to multi-reference setpoints M1-M7 when using Input Mode O4 (MRef 3W).
N8 kw = hpx746 1000 The thermal model includes correction for the reduced efficiency of standard motor cooling at reduced speed by interpolating between the zero speed cooling term (Screen N6) and rated cooling at rated speed (refer Figure 4.2). The thermal model is reset when power is removed from the Elite Series. N9 SETTING UP These parameters must be set before operating the Elite Series. Invalid combinations of values will be detected as “Parameter Fault” error, tripping the Elite Series.
SCREEN GROUP O: OUTPUTS Group Attribute HIDDEN O OUTPUTS O2d RELAY2 INV=N/Y ALWAYS OFF ALWAYS ON NO FAULTS DRIVE FAULT SUPPLY FAULT O/L FAULT O/L WARNING START RUN ZERO SPEED AT SET SPEED TORQUE SIGN SPEED SIGN TQ REF SIGN SP REF SIGN SPEED LIMIT TORQUE LIMIT VOLTAGE LIMIT CURRENT LIMIT COMPARATOR 1 COMPARATOR 2 WINDOW COMP BRK RELEASE VISTA CONTROL O2e RELAY3=08 -250% to+250% O2f RELAY3 INV=N/Y NULL FULL SCALE OUTPUT CURR OUTPUT VOLTS BUS VOLTAGE MOTOR POWER MOTOR SPEED MOTOR TORQUE REF SPEED REF
thus providing inverse control (i.e., increasing the analogue output source level decreases the analogue output signal level). O1b O1b-O1d, O1f-O1h ANALOGUE OUTPUT FORMATTING AND SCALING CONTROLS O1c Screen O1b AO1=+/-10V No action is required if no devices are connected to these terminals. Description Range Default Value OFF to Modify ANALOGUE OUTPUT 1 FORMAT REFER FIGURE 9.
Set the scaling via Screens O1g and O1h to: O1g AO2 LO=0.0% O1h AO2 HI=+250% With this setup, Analogue Output 2 (AO2) would source 10.4mA when the motor was drawing 20A. SUBGROUP O2: DIGITAL O/P RELAYS O2a,O2c,O2e Screens RELAY SELECTIONS O2a O2c O2e RELAY1=02 RELAY2=05 RELAY3=08 Description Range Default Value RELAY CONTROL SOURCE SELECTION 00 TO 23, REFER FIGURE 9.
O3a SCREEN GROUP P: PROCESS CONTROL SUBGROUP O3: FIBRE OUTPUT FIBRE OUTPUT SOURCE SELECT Screen FIBRE O/P=06 Description FIBRE OUTPUT SOURCE SELECTION NULL AIN1 AIN2 AIN1+2 FIBRE LOCAL MREF MTRPOT P PROCESS P1 PR SRC=NULL P2 FB SRC=NULL P3 Kc=0.1 P1 FUNCTION Provides the ability to select the driving source for Fibre Optic output. SETTING UP Select the desired Fibre signal source. NULL AIN1 AIN2 AIN1+2 FIBRE P4 Ti=INF Range 00 TO 19 - REFER TO FIGURE 9.17.
P2 PROCESS CONTROL FEEDBACK SOURCE Screen P2 FB SRC=NULL Description PROCESS CONTROL FEEDBACK SOURCE Range REFER FIGURE 9.22 Default Value NULL OFF to Modify YES FUNCTION SETTING UP Select the desired differentiation time to suit your requirements. Typically left at the default value of 0.0s for pump and HEVAC applications. Screen P6 ERROR=+0.0% Description Default Value PROCESS ERROR 0.
R1 SCREEN GROUP R: ACCEL/DECEL RATES R3, R4, R5 ALTERNATIVE ACCELERATION RATES Screen R3 AACC=10%/s Group Attribute HIDDEN R RATES R2 R1 ACC= 10.0%/s R3 R4 R5 R3 AACC= 10.0%/s 0.02 to 1300%/s R4 ADEC= 10.0%/s OFF/0.1 to 250% R5 BRK S= OFF 0.02 to 1300%/s R6 STOPR=1300%/s 0 to 60sec R7 SP FILT= 0.000s 0 to 10sec 4808-083 Rev C R2 DEC= 10.0%/s R8 TQ FILT= 0.00s R1, R2 ACCELERATION AND DECELERATION RATES Screen R1 ACC=10.0%/s Description ACCELERATION RATE Screen R2 DEC=10.
Note: Remember when using extended (long) deceleration rates, adjust the Stop Timeout (Screen S11) appropriately. R6 STOP DECELERATION RATE Screen R6 STOPR=1300%/s Description DECELERATION (STOPPING) RATE USED WHEN STOPPING Range 0.02 to 1300%/SEC Units % OF RATED MOTOR SYCNCHRONOUS SPEED PER SECOND Default Value 1300 OFF to Modify NO Attribute HIDDEN FUNCTION R8 TORQUE FILTER TIME CONSTANT Screen R8 TQ FLT=0.
SCREEN GROUP S: START AND STOP MODES S1 Group Attribute HIDDEN S2 S5 STR DLY= 0.00s 0.00 to 5.00s S6 OFF DLY T= 1.0s 0 to 3600s S2 STOP= NORMAL S3 4808-084 Rev F S4 ASTOP= NORMAL NORMAL RAMP SPIN STOP R OFF DC BRK S1 START=NORMAL STOP MODE Screen S2 STOP=NORMAL Description Range NORMAL SPIN S START/STOP S2 USUAL STOPPING MODE NORMAL/RAMP/SPIN/STOP-RATE/OFF/DCBRAKE Default Value NORMAL OFF to Modify NO FUNCTION Select the stopping mode to use (see figure 9.24).
reason for this is that when starting from the “OFF” state, flux must first be built up before attempting to accelerate the motor or provide torque. This may take several hundred milliseconds, and such a delay may be undesirable in some situations). The delay may also be used in applications to maintain control of the motor at zero speed, until the brake is applied, before turning the motor off.
automatically. S8 If the high voltage (mains supply) power loss function is set to trip (Y), the Elite Series will trip and register a mains low fault after a two second power loss and require resetting. If the mains returns to normal within two seconds, the Elite Series will restart automatically.
SCREEN GROUP X: TUNING select Closed Loop Vector Mode, Open Loop Mode or V/Hz as required. Group Attribute HIDDEN X TUNING X1 CTRL TYPE = V/Hz X2 AUTOTUNE = N X3 MOTOR TUNE X3a Lm = 190% V/Hz mode must also be employed when multiple motors are connected to the Elite Series output. O/L VECTOR C/L VECTOR V/Hz Y/N 40 to 800% X3b Rs = 3.0% X3d SIGMA = 6.
X3a X3b X3c X3d X3e SUBGROUP X3: MOTOR TUNING X3a-X3d MOTOR IMPEDANCES Note: Only applies to Elite Series operated in open loop or closed loop vector mode. Screen X3a Lm=190% Description Range Units Default Value OFF to Modify MAIN INDUCTANCE 40 to 800% PERCENTAGE OF RATED IMPEDANCE 190% (Dependant on Elite Series model) NO FUNCTION The main inductance of the motor defines the magnetising current. This is a key parameter directly affecting motor fluxing.
SUBGROUP X4: LOAD TUNING Screen X4a MIN. FLX=100% Description Range Default DYNAFLUX MINIMUM FLUX LEVEL 40% to 100% 100% Note Dynaflux only operates in V/Hz control mode. FUNCTION Sets the minimum flux level that the motor will be operated at under reduced load conditions. The Elite incorporates the Dynaflux (dynamic flux) automatic motor flux optimising system.
X4d FUNCTION For Open Loop, this parameter determines the transition from Open Loop start mode to Open Loop normal mode. When stopping, the drive will re-enter the Open Loop start mode from Open Loop normal mode. This will occur when the speed drops to 4.5% below the STR BAND value. In Open loop mode this cannot be increase above 50% as the overspeed band can be reduced to 50% speed.
X4k INERTIA COMPENSATION Screen X5c DAMPING=2.0% Screen X4k INERTIA k=1 Description Range NO LOAD DAMPING 0% TO 20% Description Range Units Default FUNCTION INERTIA COMPENSATION 1 to 10 none 1 The compensation factor for inertia is required for large inertia loads if slip compensation or open loop mode is used. Used for enhancing stability and not for tuning of the speed controller. Default Value 2.
X5h Y2 Group Attribute HIDDEN SPANISH ENGLISH DEUTSCH Y MENU OPTIONS SETTING UP X5i Y1 SCREEN GROUP Y: MENU OPTIONS X5g, X5h To allow for direct comparison of the motor acoustic noise level, this mode may be switched while the Elite Series is running. Choose the option that you find most suitable. Screen Whisper Wave or Narrow Band should be selected to minimise the audible noise.
Screen Y3 PROG 1 of 1 Description Default OFF to Modify Attribute SELECTS PROGRAM TO USE 1 YES READ ONLY FUNCTION Determines the Control program that is running. See Section 8. SCREEN GROUP Z: COMMISSIONING SCREENS Y3 Group Attribute READ ONLY Z COMMISSION= NO Z1 PASSWRD=OFF OFF/1 to 65535 Z2 S/W1.1 H/W1.1 Z4 Al2=99=+20mA Z5 AO1=99=+9.9V Z6 AO2=99=+20mA Z7 MFI:XOOXOX X Z8 FI:X SERIAL:O 4808-087 Rev C Z3 Al1=99=+9.9V Z9 ENCODER= 0000 Z9a TACHO= 0.0% Z10 RLY:OXX DB:X Z11 F I/P=+0.
The display’s control (bottom) line will now read: Z COMMISSION=Y Z1 All screens will now be visible, and all parameters adjustable. Z2 Selecting OPERATION Mode: To change from COMMISSIONING Mode to OPERATION Mode, scroll to Screen Group Z. Z3 The display’s control line will read: Z COMMISSION=Y Use “∗” and “+” or “–” to toggle to : Z COMMISSION=N Z4 Z5 Z1 Commissioning Mode Password Screen Z1 PASSWORD=OFF Z3 ANALOGUE INPUT 1 STATUS Screen Z3 AI1=99=+9.
Reference 2: Status of Analogue Output 1 (Terminal T23) For For For For ±10V output, -10V to 0-10V output, 0V to 4-20mA output, 4mA to 0-20mA output, 0mA to +10V +10V 20mA 20mA Z8 FIBRE OPTIC INPUT STATUS; SERIAL INPUT STATUS Screen Z8 FI:O SERIAL:O Description Z6 ANALOGUE OUTPUT 2 STATUS Range Screen Z6 AO2=99=+9.
Z10 Z11 Z10 Screen Z10 RLY:XX X DB:X Description Attribute STATUS OF OUTPUT RELAYS; STATUS OF DYNAMIC BRAKE OUTPUT O (OPEN) or X (CLOSED); O (OPEN) or X (CLOSED); Read Only Screen Z10 RLY:XX X DB:X Reference Reference 0: Reference 1: 0 123 4 Screen number Z10 Status of Output Relay 1 (Terminals T1/T2) O (Open) X (Closed) Status of Output Relay 2 (Terminals T4/T5) O (Open) X (Closed) Status of Output Relay 3 (Terminals T6/T7) O (Open) X (Closed) Status of Dynamic Brake (DB) Output O (Open) X (C
10 APPLICATION EXAMPLE - SIMPLE FAN SPEED CONTROL A typical application example is for simple fan speed control using a potentiometer to set 0-10V speed reference, and pushbuttons for start and remote stop-reset control. External speed monitoring is achieved using a simple 0-10V meter representing 0-100% speed. This section shows the configuration, wiring and adjustment of a typical example.
COMMISSIONING CONFIGURATION RECORD — SCREENS DRIVE NO: _____________ MODEL: _______________ LOCATION: _____________________________________ MOTOR kW: _________ A: ___________ POLES: _______________ V: _______ RPM: ________________ I4 AREF S=AIN1 _______ ______ I5 AREF T=NULL _______ ______ SCREEN UNIT I6a AI1=0-10V _______ ______ I6b AI1 LO=0% % _______ ______ % _______ ______ I6c AI1 HI=+100% RECORD 1 RECORD 2 I6d AI2=0-10V DATE: __/__/__ __/__/__ I6e AI2 LO= 0% % BY
M7 MREF7=+0.00% % _______ ______ START/STOP MODES MOTOR NAMEPLATE PARAMETERS S1 START=NORMAL _______ ______ N1 MTR CUR* AMP _______ ______ S2 STOP=NORMAL _______ ______ N2 MTR VOLT=400V VOLT _______ ______ S4 ASTOP=NORMAL STR DLY=0.
COMMISSIONING CONFIGURATION CONTROL — TERMINALS Wire Designation N.O. T1 T2 Relay 1 O2a T1 O2b Relay Selection = Wire Colour T2 Inverted=Y/N N.C. T3 T3 T4 O2c T4 O2d N.O. Relay 2 T5 T6 Relay 3 Relay Selection = T5 Inverted=Y/N O2e T6 O2f N.O. T7 Relay Selection = Inverted=Y/N T7 External T8 D1 D2 T8 D.B. Switch T9 D.B. Time = D.B.
ELITE SERIES SPARES LIST COMMON SPARES Description Elite Control Board Control board fuse link set 1A Ceramic, 20x5mm Control Wiring plug set PDL Part No. E000-610S 2401-037 Quantity 1 1 10 1 MICRODRIVE ELITE SPARES (FRAME SIZE 1) Common to 400Vac and 500Vac models: Heatsink cooling fan Terminal Shield Elite Display 3m cable Microdrive Elite Series display unit ME2.5A to 12A: ME-2.5 Gate drive PCB ME-2.5 Terminal PCB ME-2.5/6.5 Power Board ME-6.5 Gate Drive Board ME-6.5 Terminal Board ME-10.
MICRODRIVE ELITE SPARES (FRAMES SIZE 3) Common to 400Vac and 500Vac models: Microdrive Elite Series display unit Heatsink cooling fans ME-31A to 46A: ME-31 Power Board ME-31 Gatedrive Board ME-31 Capacitor Board ME-38/46 Power Board ME-38 Gatedrive Board ME-38 Capacitor Board ME-38/46 Power Board ME-46 Gatedrive Board ME-31/46 Rectifier Board ME-46 Capacitor Board ME-31/46 DCCT Interface Board ME-30D to 41D: ME-30A 500V Power Board ME-30A 500V Capacitor Board ME-35A 500V Capacitor Board ME-35/46A 500V Po
ULTRADRIVE ELITE SPARES 400VAC (FRAMES 5-7) Description Elite control PCB Elite Series display unit - 1.2m cable Elite Series display unit - 1.7m cable Elite Series display unit - 850mm cable Fuse link, UE DC fuse board, 2A ceramic 32x6.3mm Fuse link, UE SCR board, 10A ceramic 32x6.3mm Fuse: A1-66C350TS Fuse: A1-66C500TS (E210, E190, E250, E420, E480) Heatsink cooling fan , Dia.
ULTRADRIVE ELITE SPARES 500V (FRAMES 5-7) Description PDL Part No. SCR Rectifier: PD160F-160 1421-040 Transistor: SKM 300 GA 123 D, IGBT (E170, E305, E370) 1757-136 Transistor: SKM 400 GA 124 D, IGBT (All other models) 1757-135 Thermstrate, rectifier 1781-103 Thermstrate, IGBT 1781-104 Fuse link, UE DC fuse board, 6.3A ceramic 32x6.3mm 2404-063 Fuse link, UE SCR board, 10A ceramic 32x6.
Multi-function Input Inversion Multi-function Input Modes Multi-reference INDEX N A Acceleration Rate Alternative Acceleration Rate Alternative Deceleration Rate Alternative References Alternative Stopping Mode Analogue Input Scaling Anti-condensation Heater 70 70 70, 72 52, 54 72 54 74 73 C Commissioning Comparators Contactor Cooling Coupling Current Control Current Limit 57 21, 49, 50 26 34, 35, 49 80 61, 76 50 D DC Brake DC Heating DC Holding Deceleration Rate DeviceNet Digital Inputs Digital
Manufactured by: HEAD OFFICE: 81 Austin Street, Napier, New Zealand s Phone: +64 6 843 5855 s Fax: +64 6 843 5185 Internet: www.pdl.co.nz s Email: electronics@pdl.co.nz Germany: Nuremberg s Phone: +49 9128 91990 s Fax: +49 9128 9199 80 Distributors in most countries worldwide. Specifications are subject to change without notice. Distributed by: Elite Series Technical Manual 4880-012 Rev I PDL Part No.
