OmniPulse™ DDC Magnetek Training. OmniPulse™ DDC Training The objective of this training is to...
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Transcript of OmniPulse™ DDC Magnetek Training. OmniPulse™ DDC Training The objective of this training is to...
OmniPulse™ DDC
Magnetek Training
OmniPulse™ DDC Training
• The objective of this training is to familiarize service and maintenance personnel with– The many resources available to assist in
• Start up• Maintenance • Troubleshooting
– The training course is designed to provide knowledge on:
• The basics of DC motors and DCCP control• The User Manual layout and information
OmniPulse™ DDC Training
• The basic operating theory of the technology
• Hardware layout, circuit board layout, and circuit board jumper and switch settings
• Navigating the display and software menus
• Understanding each parameter function and how they interrelate and effect drive performance
• Trouble analysis using drive fault messages and trouble flow charts
• Loading control and display software
OmniPulse™ DDC Session One
Basic DC Background
Quadrants of Operation
Quadrants of Operation
In this quadrant the motor must provide the braking Torque to slow the Hoist or plugging in travel motion. The energy is a result from the rotating inertia reflected at the motor shaft.
In this quadrant the motor must provide the physical torque to raise the load or move the Trolley or Bridge.
In this quadrant the motor must provide the physical torque to overcome frictional forces, such as lowering in open hook.
In this quadrant the motor must provide the braking torque to counter act gravity effect when lowering a load at a controlled speed.
Performance CurvesDC Motors
Hoist Control DCCP Panel
Armature
Series Field
Commutator
Brush Rigging -even number of brushes in pairs (Pos and Neg)
DC Motor Construction
DC Motor Connections
Basic Performance Curves
Typical DCCP Hoisting Performance Curves
Series Resistor Hoist
• Hoist connection• High speeds light loads• High torque low speeds• Effect of increasing resistor
– Reduced torque
– Poorer speed regulation
Variable Shunted Armature
• Hoist connection• Good speed regulation @
reduced speeds• Increased current in series
field• Slow down torque available• Decreasing Resistance
– Reduces starting torque
– Improves speed regulation
– Increases slowdown torque
– Increase the current in the series field
Fixed Shunted Armature
• Hoist connection• Increasing resistance
– Decreases starting torque
– Reduces speed regulation
– Decreases slowdown torque
– Decreases current in the series field
Shunted Field Var Res
• Lowering connection
• Increasing series field resistance
– Increases starting torque– Increases dynamic lowering
speed– Reduces speed regulation
Shunted Field Var Arm Res
• Lowering connection
• Increasing resistance– Reduces starting torque– Reduces speed regulation– Increases dynamic lowering
speed
Off Position DB
• Self excited no power required
• No starting torque developed• Increasing resistance
– Increases speed
– Reduces speed regulation
– Reduces deceleration torque
Typical One Line Electrical
DCCP Typical Crane Single Wiring Diagram
DCCP Typical Panel & Resistor
DCCP Hoist Diagram
Hoist Steps
Lowering Steps 1 and 2
Lower Steps 3, 4, and 5
DB Step
End of Session One
Note:
All reference to Figures, Page Numbers and Tables are to be found in the
OmniPulse DDC Technical Manual
OmniPulse™ DDC
Session Two
Changing The RulesOperating Principles Pages12-15
Hoist Power Circuit
DB
L1+
L11
C
M
K PR
R6 R8
F1
RT
Q1P
D1P
CT1
L2ÐLL2
MCB
Q1N
Q2P
D2P
CT2
Q2N
T1
A1 A2
T2 T4 T3
B1 B2
B1S1 B2S2
A2
A1
Q1
Q3P
D3P
CT3Q3N
D3N
LS
Resistor
SeriesField Series
Brake
Q3Q5
Q6
Q4
Q2
Arm
D1N D2N
CollectorRails
MCB
Simplified Motor CircuitSeries Field Hoist Motion
T1, T2, T3 Voltages Referenced to L2(-)
T1 T2 T3
t1 t2 t3 t4
DriveTerminalVoltage
T1
T2
T3
Voltage
Voltage
Motor ArmatureTerminals
T1-T2
Series FieldTerminals
T2-T3
+V0
-V
+V0
-V
+V0
-V
+V0
-V
+V0
-V
Q1P
Q1N
Q3P
Q3N
Q2P
Q2N
0
0Current
Current
PWM Power Hoisting
t1 - t2 Current Path Power Hoisting
t1 t2 t3 t4
Time Period t1 - t2
+V0
-V
+V0
-V
0
0
DB
L1+
L11
C
MCBM
K PR
R6 R8
F1
RT
Q1P
D1P
CT1
L2ÐLL2
MCB
Q1N
Q2P
D2P
CT2
Q2N
T1
A1 A2
T2 T4 T3
B1 B2
B1S1 B2S2
A2
A1
Q1
Q3P
D3P
CT3Q3N
D3N
LS
Resistor
SeriesField Series
Brake
Q3Q5
Q6
Q4
Q2
Arm
D1N D2N
CollectorRails
t2 - t3 Current Path Power Hoisting
t1 t2 t3 t4
Time Period t2-t3
+V
0
-V
+V
0
-V
0
0
DB
L1+
L11
C
MCBM
K PR
R6 R8
F1
RT
Q1P
D1P
CT1
L2ÐLL2
MCB
Q1N
Q2P
D2P
CT2
Q2N
T1
A1 A2
T2 T4 T3
B1 B2
B1S1 B2S2
A2
A1
Q1
Q3P
D3P
CT3Q3N
D3N
LS
Resistor
SeriesField Series
Brake
Q3Q5
Q6
Q4
Q2
Arm
D1N D2N
CollectorRails
t3 - t4 Current Path Power Hoisting
t1 t2 t3 t4
Time Period t3-t4
+V0
-V
+V0
-V
0
0
DB
L1+
L11
C
MCBM
K PR
R6 R8
F1
RT
Q1P
D1P
CT1
L2ÐLL2
MCB
Q1N
Q2P
D2P
CT2
Q2N
T1
A1 A2
T2 T4 T3
B1 B2
B1S1 B2S2
A2
A1
Q1
Q3P
D3P
CT3Q3N
D3N
LS
Resistor
SeriesField Series
Brake
Q3Q5
Q6
Q4
Q2
Arm
D1N D2N
CollectorRails
t9 t10 t11
DriveTerminalVoltage
T1
T2
T3
Voltage
Voltage
Motor ArmatureTerminals
T1-T2
Series FieldTerminals
T2-T3
+V
0
-V
+V
0
-V
+V0
-V
+V
0
-V
+V
0
-V
Q1P
Q1N
Q3P
Q3N
Q2P
Q2N
0
0Current
Current
PWM Power Lowering
t10 - t11 Current Path Power Lower
t9 t10 t11
Time Period t10-t11
+V0
-V
+V0
DB
L1+
L11
C
MCBM
K PR
R6 R8
F1
RT
Q1P
D1P
CT1
L2ÐLL2
MCB
Q1N
Q2P
D2P
CT2
Q2N
T1
A1 A2
T2 T4 T3
B1 B2
B1S1 B2S2
A2
A1
Q1
Q3P
D3P
CT3Q3N
D3N
LS
Resistor
SeriesField Series
Brake
Q3Q5
Q6
Q4
Q2
Arm
D1N D2N
CollectorRails
-V
0
0
Power Hoisting
T1 T2 T3
151V 125V
10% RPM
122V
+26V +3V
Deceleration Braking
T1 T2 T3
99V 125V
10% RPM
122V
-26V +3V
Power Lowering
T1 T2 T3
106V 125V
10% RPM
122V
-19V +3V
Dynamic Lowering
T1 T2 T3
144V 125V
10% RPM
122V
+19V +3V
Travel Power Circuit
Simplified Travel Motor Circuit
T1 T2 T3T4
4
T1, T2, T3, T4 Voltages
DriveTerminalVoltage
T1
T2
T3
+V0
-V
+V0
-V
+V0
-V
Q1P
Q1N
Q3P
Q3N
Q2P
Q2N
T4 +V
t1 t2 t3 t4
Voltage
Voltage
Motor ArmatureTerminals
T1-T2
Series FieldTerminals
T4-T3
+V0
-V
+V0
-V
0
0Current
Current
PWM Travel Motoring
t1 - t2 Current Path Travel Motoring
T1 - T2 =0
T4 - T3 =0
D3P
t2 - t3 Current Path Travel Motoring
T1 - T2 =0T4 - T3 =+V
D3P
t3 – t4 Current Path Tr avel Motoring
T1 - T2 =+VT4 - T3 =0
D3P
Travel Plugging / Braking
T1 - T2 =-VT4 - T3 =+V
D3P
End of Session Two Questions?
OmniPulse™ DDCSession Three
Hardware
Modular Drive Design
NEMA 3Complete
(133A)
NEMA 4Complete
(200A)
Display 144-45063
133A Stack
Driver 144-45058
Control 144-45060
* Interface 144-45062
144-45004
Display 144-45063
200A Stack
Driver144-45059
Control 144-45060
* Interface 144-45062
144-45042
*NOTE:Interface Card 144-45062 mounted separately from module enclosure
Modular Drive Design
NEMA 5Complete
(400A)
NEMA 6Complete
(800A)
Display 144-45063
400A Stack
Driver 144-45059
Control 144-45060
144-45005
Display 144-45063
400A Stack
Driver 144-45059
Control 144-45060
400A Follower400A Stack
Driver
144-45059
144-45005
144-45006
* Interface 144-45062
* Interface 144-45062
*NOTE:Interface Card 144-45062 mounted separately from module enclosure
Modular Drive Design
NEMA 7Complete
(1200A) Display 144-45063
400A Stack
Driver 144-45059
Control 144-45060
400A Follower
400A Follower
* Interface 144-45062
*NOTE:Interface Card 144-45062 mounted separately from module enclosure
144-45005
400A Stack
Driver 144-45059
144-45006
400A Stack
Driver 144-45059
144-45006
Modular Drive Design
NEMA 8SComplete
(1600A)
400A Follower
400A Follower
Display 144-45-063
400A Stack
Driver 144-45059
Control 144-45060
* Interface 144-45062
144-45005
400A Stack
Driver 144-45059
144-45006
400A Stack
Driver 144-45059
144-45006
400A Follower 400A Stack
Driver 144-45059
144-45006
*NOTE:Interface Card 144-45062 mounted separately from module enclosure
Modular Drive Design
NEMA 8LComplete
(2000A)97-3619-4
400A Follower
400A Follower
400A Follower
400A Follower
*NOTE:Interface Card 144-45062 mounted separately from module enclosure
Display 144-45-063
400A Stack
Driver 144-45059
Control 144-45060
* Interface 144-45062
144-45005
400A Stack
Driver 144-45059
144-45006
400A Stack
Driver 144-45059
144-45006
400A Stack
Driver 144-45059
144-45006
400A Stack
Driver 144-45059
144-45006
Trolley Panel Size 3 133 Amps
Interface Bd
SB Contactor
M Contactor
Hoist Panel Size 5 400 Amps
M ContactorDB Contactor
Interface Bd
Drive
M Contactor
Interface Bd
SB Contactor
MasterFollower
Travel Panel Size 6 800 Amps
SB Contactor
M Contactor
MasterFollower 1Follower 2
Hoist Panel Size 7 1200 Amps
Hoist Panel Size 8S 1600 Amps
Master Drive
Follower 1
M Contactor
DB Contactors
CCB
MCB
Follower 2
Follower 3
Interface Card 144-45007
Interface Card 144-45062
Green LED 230VDC Input Status indicators
Green LED 230VDC Output Status indicators
S1 Reset Switch
Figure 24 User Manual
144-45062
Interface Card 144-45062 Picture
Stop
Enable
Lower
Hoist2nd Speed
3rd Speed
4th Speed
5th Speed
Prog Input
M 230VDC Output
DB 230VDC Output
SB 230VDC Output
L1+
L2-
COM+
230 VDC Conn.
Reset
Output Status Ind.
Input Status Ind.
5 Amp Fuses
144-45062
144-45062 Parameter Reference
133 Amp Drive 144-45004
Control Card 144-45060
Incoming Terminals
Display Assembly 144-45063
Load TerminalsDriver Card 144-45058
Power Supply LED’s
Fuse 144-45065
400 Amp Master Drive 144-45005
Control Card 144-45060
Driver Card 144-45059
Display Assembly 144-45063
Discharge Resistor Card
144-45064
Incoming Terminals
Load Terminals
Fuse 144-45066
Master to Follower Conversion
Display Assembly 144-45063
Control Card 144-45060
Driver Card 144-45059
Discharge Resistor Card
144-450XX
Incoming Terminals
Load Terminals
Fuse 144-450XX
J 9 connector needs all pins open.
Disconnect these cables from the control board
Follower Driver Board J9 Jumper Positions
Remove Jumper from LK2 and place on pins 11 and 12 of J9
Shift large J9 jumpers to the left keeping top row of pins open
DDC Demo Power Up
Demo power connection will allow you to power the drive up to load a different control program, change parameters, or practice navigation of the menu groups from your shop supply.
144-45060 Control Card Picture Rev 2
Flash
SW2
SW1
LK1
LK2
PWR On
Fault
Driver Card Con
Display Con
Interface Card Con
144-45060 Control Card Rev 3, 4, & 5
Figure 25 User Manual
Driver Card Con
Display Con
Interface Card Con
LK4
Flash boot load link1 -- 2 -- 3
1& 2 Flash boot load2 & 3 Normal
LK31 & 2 RESET input resets CPU2 & 3 RESET input used as logic input
LK3
LK2485 Terminator1&2 120 OHM Connected2&3 120 Ohm not connected
SW2 Analog Input Switch
SW1
Configuration Switch
SC Fault Lockout LED
Power LED
144-45060 Parameter Reference
144-45060 Switch Settings
Table 27 SW2 DIP Switch Settings
SW POS OFF ON
A AN1 -10/+10V
AN1 4/20 mA
B AN1 Diff
AN1 Non Diff
C AN1 X1
AN1 X2
D AN2 -10/+10V
AN2 4/20 mA
Table 28 SW1 DIP Switch Settings
SW1 positions 1 and 2 are used to select the current rating:
Current Class DIP switch setting
NEMA2 67A maximum SW1-1 OFF SW1-2 OFF
NEMA3 133A maximum SW1-1 ON SW1-2 OFF
NEMA4 200A maximum SW1-1 OFF SW1-2 ON
NEMA5 400A maximum SW1-1 ON SW1-2 ON
SW1 position 3 determines hoist or the travel configuration:
Configuration DIP switch setting
HOIST SW1-3 OFF
TRAVEL SW1-3 ON
SW1 position 4 are used to select the voltage rating:
Voltage Class DIP switch setting
200/360V SW1-4 OFF
400/720V SW1-4 ON
1 2 3 4 5 6 7 8
On On Off Off Off Off Off Off
Main Hoist
SW1 Settings
144-45060 Rev 5 Control Board
• New revision 5 control board – Being phased into production July 2006– Can be used with all existing installed drives
• Improves noise immunity of the drive I/O• Component location same as revision 3 and 4 boards
Control Board Software Capability
• Software compatibility– Version 1 control software requires 1.19 Display EPROM in
144-45063 display– Version 2&3 software requires 2.00 Display EPROM in 144-
45063 display
• EPROM Display software version – Determines control software load for 144-45060 control
board– Control software can be loaded into all revisions of control
board 144-45060
Rev 1 & 2 144-45058 Driver Board
+5V
+24V
-15V
+15V
Supply LED
LK1 LK2 Lk3 Link Location
Internal Fan
144-45058 Rev 3 Driver Board
+5V
+24V
-15V
+15V
Supply LED
LinksThermistor
HS Fan
CT1 CT2 CT3
Control Card Conn
Gate Driver
Module
Q1
Q2
Q3
Precharge Charge LED
250 VDC Conn
Driver Card 144-45059 NEMA 4/5
Control Card Conn
-15V +5V +15V +24V
Supply LED
Thermistor
PrechargeQ1
Q2
Q3
CT1 CT2 CT3
Bus Connector Follower Units
Gate Driver
Q2
Gate Driver
Q1
Gate Driver
Q3
HS Fan
250 VDC Conn
LK 2
LK 5
LK 1
Driver Card 144-45059 Test Points
Test Point Description
TP1 DCCT 3 Signal: 4.0 VDC = 600 Amps
TP2 0 Volts Ground (Signal Common)
TP3 DCCT 1 Signal : 4.0 VDC = 600 Amps
TP4 DCCT 2 Signal (Signal Common)
TP5 Volts DC+
TP6 + 24 volt Power Supply
TP7 - 15 volt Power Supply
TP8 CEMF Average volts
TP9 + 5 volt Power Supply
TP10 + 15 volt Power Supply
TP11 0 Volts Ground (Signal Common)
Driver Card 144-45059 Test Points
TP11
TP10
TP9
TP4 TP6
TP1TP2
TP8 TP7
TP3 TP5
Current Feedback - Scaling
Table 29 Gate Drive Board Link Settings
The current feedback scaling is determined by SIP jumpers LK1, LK2 and LK3 or LK5:
Current Class Current Feedback Scaling
NEMA2 67A maximum LK1, LK2, LK3 IN
NEMA3 133A maximum LK1, LK2, LK3 OUT
NEMA4 200A maximum LK1, LK2, LK5 IN
NEMA5 400A maximum LK1, LK2, LK5 OUT
If ground fault detection is enabled, SIP jumper LK10 must be correctly positioned:
Configuration DIP switch setting
HOIST LK10 IN
TRAVEL LK10 OUT
Earlier Printed Circuit Board Revisions
144-45058 rev1 and 2 (used on 200/360V NEMA 2 and NEMA3):
LK10 does not exist. In the TRAVEL or HOIST configuration set Parameter D07 ‘Ground Fault’ to ‘Disabled’
144-45059 Rev 1 and 2 (used on 200/360V NEMA 4 and NEMA5):
LK10 does not exist. In the TRAVEL or HOIST configuration set D07 ‘Ground Fault’ to ‘Disabled’
144-45058 NEMA 2/3 Scaling Links
LK 1LK 2 LK 3
Closed For NEMA 2
Open For NEMA 3
Scaling Link Position
144-45059 Scaling Links NEMA 4/5
LK1 LK2 LK5
Out Out Out
400A Driver Link Position
LK 5
LK 2
LK 1
Bus Connector
Closed For Master Drive
Open For Follower Drive
Buss Link Connector Position
LK1 LK2 LK5
Closed Closed Closed
200A Driver Link Position
400 Amp RPM 144-45061
144-45061 400 Amp RPM Schematic
Stand alone RPM 400 Amp diagram
Common buss RPM 400 Amp diagram
Common buss RPM 800 Amp diagram
144 –45039 144 –45039
RPM and Resistor Required
• For crane mounted DC rectifier or MG set• When Regeneration current exceeds 500 Amps
– Generally simultaneous motions above 150 HP
• Scheme shown requires RPM Unit to be connected behind the M contactor (connected to the DC drive Caps L1+ and L2- drive terminals)
• RPM designed for 20% duty @ 400 Amps
RPM Sizing
• Tabulate all motion FLA – ½ hour FLA for hoist motion– 1 hour FLA for travel motions
• Calculate Regen Current for simultaneous motion operation
• Size RPM as close as possible to calculated value
3.*8.* TRAVELHOISTREGEN FLAFLAI
Line Reactor Required
• For crane mounted DC rectifier or MG set– Provide a line reactor for all motion panels
• For large Bus rectifiers (>500KW)– Generally large DC Bus Rectifiers have a large AC Ripple
content that impact the control performance– Provide a line reactor for all panels
End Session ThreeQuestions?
OmniPulse™ DDC
Session Four
Version 3.10 Software
Main Menu Screen
• Power Up screen• Title Screen: MAGNETEK
OMNIPULSE DDC
Pressing the Down Key
• Title Screen: MAGNETEK
OMNIPULSE DDC
Display Software Version 2.00
Pressing RIGHT MENU Key
• Group A Monitoring• Group B Access• Group C Controller Set Up• Group D Protection• Group E Drive Control Set Up• Group F Speed and Torque Settings• Group G I/O Configuration• Group H Fault History• Main Menu Screen
Hoist motion current loop flowchart
Hoist motion speed loop flowchart
Travel motion current loop flowchart
Travel motion speed loop flowchart
Group A Monitoring (Up Key)
• Tables list are in OmniPulse DDC manual.• Table 13 Motor Current and Voltage
– Armature Current– Field Current– Armature Voltage– DC Bus Voltage
• Table 14 Motor Speed and Torque – Motor CEMF– Flux calculation % of rated value– Motor RPM calculation– Motor Torque calculation % of rated value– Hook Load measurement % of rated value
Group A Monitoring Continued
• Table 15 Power, Energy, and Operation Cycles– Input Power instantaneous power main DC supply– Energy Used: accumulated energy consumption– No of operations or cycles commanded– Elapsed Hours: Accumulated power on time
• Table 16 Analog Input Status– Analog Input 1: % of full scale input 1– Analog Input 2: % of full scale input 2
Group A Monitoring Continued
• Table 17 Current and Speed (Advanced Tools)– Arm Current Ref: calculated Ref % of rated value– Fld Current Ref: calculated Ref % of rated value– Speed Ref: Calculated Ref % of rated value – Upper Control Limit: Fwd current limit applied– Lower Control Limit: Rev current limit applied
• Table 18 Logic I/O Status– Logic Inputs: Eight total binary representation– Logic Outputs: Five total binary representation
Group A Monitoring Continued
• Table 19 Controller Status (Advanced Tool)– Heatsink Temp: Semiconductor Heatsink– Ambient Temp: Temp of electronic control card– Overload Level: Accumulated ovld calculation– T1 Duty Cycle: T1 PWM duty– T2 Duty Cycle: T2 PWM duty– T3 Duty Cycle: T3 PWM duty– Control Status flags: Eight binary representation– Fault Status– Sequence Status
Group B Access
• Table 20 Access– Password: two levels of access for changes
• User • Engineer (2004)
– Access Level: current active level• Monitor• User• Engineer
– Control Firmware– Modbus AN1– Modbus AN2– Tach Coefficient
Monitor transmitted analog reference on communication bus
Group C Control Set Up
• Table 21 Controller Rating Setup– Configuration– Voltage Class– Current Class– Parallel Stacks– Armature Set Up: Internal or External CT– Input Bus Voltage: Sets UV and OV trip points– Field Set Up : Internal or External CT– Default Values: store user settings; restore user settings;
restore factory default settings
Group D Protection
• Table 22 Protection– Motor rated current– Motor rated voltage– Motor rated speed– Motor field current: Motor FLA for series motors– Current limit forward (Hoist)– Current limit reverse (Hoist)– Arm/Field ratio: Defines motor commutation limit– Ground Fault
Armature to Field RatioFIELD WEAKENING ARMATURE FIELD RATIO
0%
50%
100%
150%
200%
250%
300%
0% 10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
% FIELD CURRENT
% A
RM
AT
UR
E C
UR
RE
NT
A/F=1.5
A/F=2
A/F=3
Field Weakening Armature to Filed Ratio
Group D Protection Continued
• Table 22 Protection Continued– OH alarm level: Cuts back current to 150% – OH trip level: HS Temperature trip level– LS detection Sets limit switch mode detection
• Disabled• Hook Sense (Software Detection)• HLS (software detection) no fault registered• LS Relay (Hardware Detection)• ELS (external hardware detection) no fault registered
Group D Protection Continued
• Table 22 Protection Continued– LS lower detection level: 2 to 50% of measured motor volts– LS hoist detection level: 2 to 50% of measured motor volts– LS back out time : timed back out of limit switch– Slack cable: Disabled or enabled – Slack cable torque: Detection level .1 to 25% torque
Group E Drive Setup
• Table 23 Drive Control Setup– Accel Time: set in seconds– Decel Time: set in seconds– Current gain*– Speed P Gain*– Speed I Gain* – IR Comp Gain*
*(It is recommended to use the default values for the parameters highlighted for crane applications)
Group E Drive Setup Continued
• Table 23 Drive Control Setup Continued– Start Delay: time to allow M to close*
*(too low a setting can cause UV faults recommend 300 ms setting)
– Bypass Speed: acceleration time ramp not applied to reach this speed - drive will go to this speed immediately *
*(Normally not used on crane applications)– Stop Speed: speed at which the stop sequence is initiated
Group E Drive Setup Continued
• Table 23 Drive Control Setup Continued – DB Delay: time to allow DB to open– DB Time: time for DB braking at end of run request– Lower Minimum Field: sets maximum lowering speed with
empty hook (Hoist Mode Only 200% maximum)– Hoist Minimum Field: sets maximum hoisting speed with
empty hook (Hoist Mode Only 300% maximum)
Stop sequence begins when speed reference equals stop speed value
OmniPulse DDC Version 3.10 Hoist Speed
When speed reference is at or below 15% in the hoist direction the stop sequence is executed immediately without delays.
OmniPulse DDC Version 3.10 Hoist Speed Below 15%
Stop sequence begins when speed reference equals stop speed value
OmniPulse DDC Version 3.10 Travel Motion
Group E Drive Setup Continued
• Table 23 Drive Control Setup Continued– Economy Field: starting field current level for empty hook or
free run travel*
*(For economy filed to function properly Minimum field values E15, E16, or E18 must be equal or set at a lower value than E17)
– Minimum Field: sets maximum travel speed (300% maximum)
– Field Rate Change: Limits rate per second change of field current in field weakening operation
Minimum Field Settings
• Acts like an electronic governor limiting the maximum allowable speed of an unloaded DC Series Motors – Upper limit is 300% of rated motor RPM
– Lower limit is 100% of rated motor RPM
– Limit is adjustable within 100 - 300% range
• Modifies the basic DC Series Motor speed / torque curve to a flatter profile
• This ability to change the basic speed / torque characteristic of the DC series motors is an exclusive feature of the OmniPulse DDC technology
Parameter Interaction
• The Minimum Field parameter (E15 and E16 for hoist applications, or E18 for travel applications) acts as the “governor” and limits the top speed of an unloaded motor
• Parameter Group F sets the speeds available for operator commands, however
• Commanded speeds cannot exceed the maximum speed limit set by Parameter Group E
• Speeds above natural motor curve not available
Examples of “Flattened” Curves
0
50
100
150
200
250
300
350
400
450
2 10 20 30 50 100 150
% Torque
% S
peed
Min Field set at 25%
Min Field set at 90%
Min Field set at 100%
Group E Drive Setup Continued
• Table 23 Drive Control Setup Continued– Timer Type defines type of timer function for programmable
outputs• On Delay TC or TO• Off Delay TC or TO
– Timer Time sets the timer length– Micro Speed Factor
• Input function• Reduces programmed or analog speed reference by a
set factor
Group E Drive Setup Continued
• Table 23 Drive Control Setup Continued– Shunt Brake Release Point: Mimics series brake release
based on field current– Shunt Brake Release Time:
• Provides additional adjustment to release of shunt brake
• Time begins when SB Rel Pt value is reached – Shunt Brake Time: time for shunt brake to set– Stall Protection Time
• Defines time period to report a fault if armature current is present while CEMF < 25%
• A setting of 0 turns the monitoring function off
Group F Speed & Torque
• Table 24 Speed and Torque Settings.– Reference Source Selection.– Preset Hoist Speeds: Not visible in travel config.– Preset Travel Speeds: Not visible in hoist config.– Preset Travel Torque: Not visible in hoist config.
Group F Speed & Torque Continued
• Table 24 Speed and Torque Settings Continued – Speed Reference source– Torque Reference Source
• Source Selection:– Cntr Switch (Master Switch)– Analog Reference 1– Analog Reference 2– Serial Analog Reference 1– Serial Analog Reference 2
Group F Speed & Torque Continued
• Table 24 Speed and Torque Settings Continued – Five independent hoist speeds– Five independent lower speeds
• Speeds adjustable from 0 to 300% rated value Hoist and 0 to 200% rated value Lower
• Sub Menu not visible when travel configuration is active• Proprietary constant HP software design maximizes
productivity and safety by controlling the motor speed based on motor loading
Group F Speed & Torque Continued
• Table 24 Speed and Torque Settings Continued– Five travel speeds
• Speeds same in forward or reverse• Adjustable from 0 to 300% rated value
Group F Speed & Torque Continued
• Table 24 Speed and Torque Settings Continued– Five Torque (current limit) settings for adjustable torque
when plugging and accelerating from one direction to another
• Adjustable from 0% to 200% rated current• Neutral or OFF Position current setting adjustable from
0% to 200%– 0% setting will stop the drive in coast mode– Settings other than 0% will stop on deceleration ramp or current
limit
• Sub Menu not visible in hoist configuration mode
Group G I/O Configuration
• Table 25 I/O Configuration– Analog IP1 Type: volts or ma– Analog IP1 Gain– Analog IP1 Bias– Tacho FS RPM: Tach Rated RPM at full scale volts– Analog IP2 Type: volts or ma– Analog IP2 Gain– Analog IP2 Bias
Group G I/O Configuration Continued
• Table 25 I/O Configuration– Analog Output Gain– Analog Output Bias– Analog Output Func: Programmable
• Motor speed• Motor torque• Hook Load (Field Current)• Line Voltage
Group G I/O Configuration Continued
• Table 25 I/O Configuration– Prog IP Func: Programmable input 230 VDC or 24VDC
• Not Used• External limit switch• Travel slowdown• External Fault• Micro Speed
Group G I/O Configuration Continued
• Table 25 I/O Configuration – Prog OP1 Func: Programmable 230 VDC
(OP1 control of Remote I/O 144-45062 DB terminal is not programmable in Hoist configuration)
– Prog OP2 Func: Programmable 24 VDC (X1-2 terminal 144-45060)
– Prog OP3 Func: Programmable 24 VDC (X1-3 terminal 144-45060)
– Prog OP4 Func: Programmable 24 VDC (X1-4 terminal 144-45060)And 230 VDC (SB terminal on 144-45062)
Group G I/O Configuration Continued
• Table 25 I/O Configuration– Program Functions
• DB contactor (OP1 Default)• Controller fault: Coil energized when fault occurs (OP2
Default)• Controller ready (OP3 Default)• Shunt brake (OP4 Default)• Timer
Group G I/O Configuration Continued
• Table 25 I/O Configuration– Serial Baud Rate: 2400 to 19200 baud– RS232/RS485 Select– Serial Format
• 8 bit even or odd parity checking• 1 or 2 stop bits• Modbus RTU 1 enabled
– Modbus address: 1 to 247– Drive Control: Hardware I/O or serial communication
Group H Fault History
• Table 26 Fault History– Record of last 15 faults with elapsed time stamp– Push down stack – Engineer level can reset or clear the fault history
• A value of 1 in H30 clears fault history log– CUV, UV1, and MS faults are not recorded in the fault
history
End of Session FourQuestions?
OmniPulse™ DDCSession Five
Start UP And Trouble Analysis
Service Tools
• Start Up procedures Pages 82-93• Fault code explanation and corrective actions Pages
94-95• Transistor Diode Check Page 95• Trouble charts Pages 96-109• Drive exploded view Pages 117-118• Renewal part component lists Pages 119-124
CUV Fault Control Power Loss
• User Manual Figure 30– 24 V supply has fallen below 19 V– Control input power interrupted for more than 1 second
• Center master switch or controller to neutral (off) position to reset
• Trouble Charts Pages 96 - 97• Active fault not recorded in fault history
UV1 Fault Under Voltage Main Bus
• User Manual Figure 31– Main DC supply voltage below 50% of CO5 Value or below
125 V– M contactor did not close properly
• Center master switch or controller to neutral (off) position to reset
• Trouble Charts Pages 98-99• Active fault not recorded in fault history
OT1 Fault Heat Sink Over Temp
• User Manual Figure 32– Heat sink thermistor has reached parameter D09 trip value
• Heat sink temperature must cool down to below 90°C to reset
• Master switch or controller must be set to neutral (off) position to reset
• Trouble Charts Pages 100 - 101
SC Fault Short IGBT Circuit
• User Manual Figure 33– Internal IGBT power supplies fell below 13 VDC– Disable all IGBT devices
• 10 SC faults in 5 minute window will lock drive from service– Power down of the drive or Reset of the drive required to
clear the lock out
• Master switch or controller must be set to neutral (off) position to reset
• Trouble Chart Page 102
OV Fault Over Voltage
• User Manual Figure 34– Main DC bus voltage exceeds over voltage trip point set by
parameter C05 (See page 45 for explanation)– Main DC volts exceed 400 V maximum hardware trip
• Master switch or controller must be set to neutral (off) position to reset
• Trouble Chart Page 103
OC Fault Over Current
• User Manual Figure 35– Current loops failed to maintain current inside limits– Disable all IGBT devices
• Master switch or controller must be set to neutral (off) position to reset
• Trouble Chart Page 104
OA Ambient Over Temperature
• User Manual Figure 36– Thermistor hardware trip from the control board 75°C– Finishes current movement before faulting
• Reset cannot occur until thermistor falls below 65°C• Master switch or controller must be set to neutral (off)
position to reset• Trouble Chart Page 105
AOC Armature Open Circuit
• User Manual Figure 37– Motor armature circuit is open– IGBT Q1 or Q2 are not conducting
• Master switch or controller must be set to neutral (off) position to reset
• Trouble Chart Page 106
FL Field Loss
• User Manual Figure 38– Motor field circuit is open– IGBT Q2 or Q3 are not conducting
• Master switch or controller must be set to neutral (off) position to reset
• Trouble Chart Page 107
LS Limit Switch
• User Manual Figure 39– Software detected tripped power limit switch
• Master switch or controller must be set to neutral (off) position to reset
• Jogging out of Limit switch is required in back out mode
• Trouble Chart Page 108
MOL Fault Motor Over Load
• User Manual Figure 40– Current exceeded one minute rating of 150%– Current exceeded 3 second rating of 200%– Integrator increases above 110% current and decrements
below
• Master switch or controller must be set to neutral (off) position to reset
• Trouble Chart Page 109
Motor Stall
• User Manual Table 33 – Armature Current > 0– Armature %CEMF < 25%– For Stall Protection Time Period (E26)
• Drive shuts down and records fault• Master switch or controller must be set to neutral (off)
position to clear fault• A value of 0 turns this function off
MOS
• User Manual Table 33 – MOS Module Out of Service– Error message occurs when one of the follower follower
units loses its power supply
PER
• User Manual table 33– Parameter Exceeds Rating
• Parameter value entered exceeds min max value for the parameter input
EXT
• User Manual Table 33– External limit switch trip detected
• Disables hoist position and enters limit switch back out mode
• Master switch or controller must be set to neutral (off) position to reset
• Jogging out of Limit switch is required in back out mode
SLC
• User Manual Table 33– Slack Cable– Software detected a slack cable condition– Lowering is disabled until condition clears
• Master switch or controller must be set to neutral (off) position to reset
MS
• User Manual Table 33– Master Switch
• Software detected the controller inputs are not in the off or neutral position upon start up– Drive disabled until inputs are in neutral position
• Master switch or controller must be set to neutral (off) position to reset
• Active fault not recorded in fault history
COC
• User Manual Table 33– Change of Configuration
• Error message received when DIP switch settings on the control board are changed when the drive is in a ready state
• Requires power down or Reset of the drive to clear the fault
• Fault is not logged
External Fault
• User Manual Table 33– External fault input activated
• External fault must be removed• Master switch or controller must be set to neutral (off)
position to clear fault
Ground Fault
• Occurs if ground fault is enabled and current CT’s see 50% drive rating current differential
• In Hoist configuration – CT1-CT2 (armature) – CT2-CT3 (Field)
• In Travel configuration CT1-CT2 (armature)
Driver Card 144-45059 Test Points
Test Point Description
TP1 DCCT 3 Signal
TP2 0 Volts Ground
TP3 DCCT 1 Signal
TP4 DCCT 2 Signal
TP5 Volts DC+
TP6 + 24 volt Power Supply
TP7 - 15 volt Power Supply
TP8 CEMF Average volts
TP9 + 5 volt Power Supply
TP10 + 15 volt Power Supply
TP11 0 Volts Ground
Driver Card 144-45059 Test Points
TP11
TP10
TP9
TP4 TP6
TP1TP2
TP8 TP7
TP3 TP5
Transistor & Diode Check
Transistor & Diode Check
Table 35 User Manual
Diode Check Positive Probe Negative Probe Reading
D1P T1 L1 .312
D2P T2 L1 .312
D3P T3 L1 .312
D1N L2 T1 .312
D2N L2 T2 .312
D3N L2 T3 .312
IGBT Check Positive Probe Negative Probe Reading
Q1P L1 T1 >.6
Q2P L1 T2 >.6
Q3P L1 T3 >.6
Q1N T1 L2 >.6
Q2N T2 L2 >.6
Q3N T3 L2 >.6
L1 is connected to the drive bus through an internal power fuse.
Before taking readings check the power fuse and make sure it is good
RPM Transistor / Diode Check
End of Session Five Questions?
OmniPulse™ DDCSession Six
Loading Software
Software Updates
• The OmniPulse™ DDC has two software programs.
– Display software current version 2.0.0.
• Display software is loaded into a removable EPROM located in the back of the display unit.
• To update display software the EPROM must be changed.
– Control software current version 3.12
• Control software is loaded into a non volatile FLASH memory.
• Updates are loaded through HEX files using a RS232 port, a laptop, and the Flasher Program supplied by Magnetek.
Display EPROM
Removable EPROM Display Software
144-45063 Rev 1 or higher required for Display software 2.00
Control Software Update
• You can make the cable yourself very easily– User manual Figure 23 shows the connections– Requires a D connector, three wires twisted or shielded
cable, and one of the removable terminals from the control board
• There is no part number for the RS485 connector– Hardware is present for RS485 – Software support for RS485 is enabled in version 3 control
software release
Software Update Procedure
• Start Flasher Program– Select Com 1, 57600 Baud Rate, and AMD Flash– Press the Select button and select appropriate DDC HEX file
to load
• On the drive control Card set either LK1 (original board closed) or LK4 on latest board to the boot position (position 1 & 2)
• Reset power to the drive either by the reset button on the interface card or cycle drive power off then on (wait 15 seconds before restart)
DDC Flasher Program
Original 144-45060 Control Board
Flash
SW2
SW1
LK1
LK2
PWR On
Fault
Driver Card Con
Display Con
Interface Card Con
Revised 144-45060 Control Card
SW1
LK4
Driver Card Con
Display Con
Interface Card Con
SW2
Flash boot load link1 -- 2 -- 3
1& 2 Flash boot load2 & 3 Normal
1 & 2 RESET input resets CPU2 & 3 RESET input used as logic input
LK3
LK2
485 Terminator1&2 120 OHM Connected2&3 120 Ohm not connected
Analog Input Switch
Configuration Switch
Software Update Procedure
• Wait for the drive to power back up– In boot mode the drive fan will run constantly– Check for air flow or listen for fan operation
• Click the Update button in the Flasher window– Bar at bottom will begin to increase as the program loads– When loading is complete an upload complete message will
be visible
Software Update Procedure
• Move the LK1 or LK4 links back to original position– LK1 open– LK4 position 2 & 3
• Reset the drive or cycle power to drive• Set parameter (B00) password to 2004• Restore factory defaults via parameter (C07)• Reset the drive or cycle power to drive• Check the Control Software version in the display to
verify the loading process
End of Session Six
Questions?