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1. Alarm Fault Summary 07 12 94 08 48 Event History 07 12 94 08 60 Clear or Acknowledge Time Print Cancel Print No Active Filter Clear Time Acknowledge Time igure 1 2 The Alarm Fault Summary Screen a Real Time and Historical Trending SIGMA Universal Process Monitor Trend Screen Return SIGMA Universal Process Monitor Trend Screen er Interval Alm FIt Snapshot Print Return 26 July 94 13 11 15 Description 26 July 94 Bed Drive Fized Elapsed Hours 12 56 01 Calender Diameter PMI Arm Curr Fdbk unfltrd interval Min Couch Torque Split Setpoint Trigger DisArmed Interval 5 Min Trigger DisArmed Jul 26 Jul 26 Jul 26 Jul 26 2 56 24 Jul 26 Jul 26 13 01 24 13 00 24 12 59 24 12 58 24 12 57 24 4 Figure 1 4 The Historical Trend Screen Figure 1 5 The Real Time Trend Screen UPM software may be used alone or be included as part of UOI software UOI software provides diagnostics and control by providing a Power Module screens that provide a remote view of drive indicator lights alarm fault status and power device integrity SIGMA Universal Oy e 1336 Dreynontic Figure 1 6 The AB 1336 Diagnostics Screen E Line Run Permissives screens that lists all drives auxilliary and other associated equipment required to start the line or process SIGMA Universal Operator Interface Line Run Permissives
2. seeeessessesseessessessrcssensonscssensenssrssressessrssressessesseenesse 5 1 5 1 Alarm Fant ig hk ee re he eer ener ny ene ee Re mere Ane re ty are ener ree 5 1 Die Color D scriptions of EXCEpHONS sisisi osien irsin ei aE Ee EEEE EEE ian 5 3 53 The Alm Fault Summary SeN cesen ii a 5 4 54 TheEvent History a iessriensrian n E R a cc ene 5 6 5 4 1 Filtering Evei onini iea ea EEE EEEE ERRE 5 9 5 4 2 P ningan Event Lol ecesicereiira n ea A EA EEEL 5 13 55 NN E sic ceteae OE A E ee ee 5 15 Chapter 6 Drive Overview Screen and Support Screens sssscscsssiectessscesssanvcnasossvessssactiaevaszies 6 1 6 1 The De Overview RG nsis sdiscteccnns sviccaasaceess eiia aarian Aa iaa e arae Eain 6 2 6 1 1 Viewing Bar Chans sen noria E REE ERTE TE 6 5 6 1 2 Viewing Distributive Power Diagnostic Screens ccecseesseceteceseeeeeeeeseeeneees 6 6 E E a D E E E 6 8 6 1 2 2 The PMI SD3000 Diagnostic EN spec ccsticinssttletstbieesietiaeednessmaeaeel 6 11 6 1 2 3 The PMI SD3000 Regen Diagnostic Screen s sssesssessseserssressesersseesseser 6 12 6 124 The PMI SA3000 Diag ostio Sereen ssscirsiiiiiiisiisic iiidid 6 13 6 1 2 5 The PMI SA3000 Parallel Diagnostic Sere ie isis cccssscisasessdiceasssstatessatnesansss 6 14 6 1 2 6 The PMI SA500 Diagnostic Screen cscccssscsssccscccesssosssnensceisvessscassenssceanansentsys 6 15 6 1 2 7 The PMI SB3000 Parallel Diagnostic Berens iscccsitecessiiceciniieiarcseslnesssindaeaines 6 16 6 1 2 8 The GV300
3. SIGMA Universal Process Monitor Trend Screen Memory Trigger Interval Alm FIt Snapshot Print Return Yati T4 13 00 19 Units T2 12 59 14 Delta T 00 01 04 26 July 94 11 R i 31960 00 Hours 32496 00 436 00 13 11 15 319 60 INCHES 324 96 436 1170 69 1190 33 15 98 Interval 5 Min 4701 ALA 26 Jul 1994 13 01 24 gt gt gt K 42 64 28 75 rigger DisArmed Jul 26 13 01 24 Figure 3 3 The Trend Screen with T1 and T2 slider bars Historical Mode displays the variable plots for a specified date and time Before using Historical Mode verify Live Mode is deselected no X appears in the check box To specify a date and time locate the Date and Time display next to the Live check box in the Trend Screen Click once on the display This activates the Historical Mode and allows a user to adjust the date and time While in Historical Mode the arrow push buttons can be used to adjust the display to the appropriate date and time As the date and time are adjusted the plots on the graph move to form the appropriate display Historical Mode provides another feature Slide bars labeled T1 and T2 appear above the graph as shown in Figure 3 3 These slide bars can be moved by placing the cursor directly on them and dragging the cursor to the desired location By positioning T1 above the graph it is possible to find out the exact values within each plot When T1 is moved from its home position it form
4. seesseeeesereseererreresrereseererereees 1 15 Figure 1 19 Creating SIGMA NE Folders and Icons Message Scteen ecescesssssecsssssseseeeseoeees 1 16 Figure L20 SIGMA NE Setup Complete PopUp oniiiniieciciiisreti aitinn osi anii iieis 1 17 Pipe 1 271 Start anid Stop Custori OCX Server KOMS assoc ccadssnviascostssncssantsasencuscoedsenscanesunvesedss 1 17 Figure 1 22 SIGMA NE 32 Bit Applicators Diet snes snccssancacenienssacasantwasesensenoonenicagesunssecins 1 18 Fipnte 1 23 Pine Cornimaad ssn ica gcassa da irere rirorse si na senanaacqnntarannsedsdnaoneanssaasavenvcvameantess 1 19 Figure 1 24 SIGMA NE UOIUPM Title Seteetic c sisiesssssccctansiscsnsatsicctssoereswnsbsdecsarstesmsisiecaness 1 20 Figure 1 25 Dave Ovreriew Seieren aeiio oeiee E Ei AN EEA Eea ER 1 21 Pice 1 Dira Oren er E era E E 2 2 Fipute 2 2 Alano Fault Summary Boen esiosas esei dieses iai evei causieasvenenasseabusdursassaaaoransvans 2 2 Eicmie 2 3 Cull Sergei siirron inn Aea EEE EEEE sen agen cht OR EEE TEESE Re eTR 2 3 Fip re 2 4 Full Screen with Pop Up Overlay siisii eeoxeonicasv vivcacesoavangesbasaesesnavesasserseageneavxagseon 2 3 Fiom A5 lowr Rabani eccna a a iiaii 2 7 Fipnre 26 Intemal Ta oraciones i ngeneaseader susshecsentannsveassaqenanieatosenstivssvamactsans 2 8 Ficne 2 7 Type UPM Main Menu Bat occo scicnco eiaeiiai nten ia anaiai 2 9 Figure 2 8 Accessing Other Screens From The Alarm Fault Summary Screen Main Menu 2 10 Figure 2 9 Accessing Pop Up Box from Dr
5. 90 14 Return PMI Arm Curr Fdbk unfltrd Interval 5 Min Couch Torque Split Setpoint Trigger DisArmed State Armed DisArmed Trigger Variable CL_DRAW Calender Draw Option Snapshot Time Span Trigger High Value Freeze Enable High Print 20 Seconds High Value New High Value z 100 Seconds Se alas 300 Seconds 5 min 5 e la Snapshot Snapshot Description Trigger fired at 11 00 am Trigger Low Value Enable Low Low Value New Low Value 13 01 24 13 00 24 Figure 3 6 The Trigger Window Choosing the Trigger option from the Trend Screen s Main Menu displays the Trigger window as shown in Figure 3 6 A trigger initiates a reaction when something occurs in the system Triggers fire off a series of commands if the system conditions meet preset requirements This process is the most useful to users who are tracking the occurrence of an event within the system The Trigger window aids in the creation and execution of triggers This makes it possible to monitor whether or not a variable s values are staying within a defined range while viewing other variables of interest The process of arming a trigger on the UPM consists of the following assigning a variable as the trigger defining and enabling the high and low trigger values defining the results of a trigger event arming the trigger The actual trigger process is a simple one A trigger is setup to monitor one var
6. a DmiX z022 PTH Fault tt 5 Fluz current loop integrator time constant is not within Reg 22211222 calibrated limits Rockwell Automation Figure A 4 The A3000 Diagnostic Screen 3 2 1 Fault Boxes The following table lists the SA 3000 fault warning names their suggested variable names register bit positions and under what conditions this bit is set Fault boxes are red and Warning boxes are orange Fault Warning Variable Name Register A Name Register B Bit Position DC Bus Over This can either be a fault or a warning Voltage DRV_FLT 202 1202 0 A fault is set when the DC bus voltage exceeds the rating of the Power Module A warning occurs when the DC bus ltage rises above the configured DRV_WRN 203 1203 0 YOS 8 j overvoltage threshold value The torque is automatically limited to avoid an overvoltage fault DC Bus DRV_WRN 203 1203 1 A warning occurs when the DC bus Undervoltage voltage drops below the configured Warning undervoltage threshold value The torque is automatically limited to avoid a further drop in the DC bus voltage No PMI Comm DRV_FLT 202 1202 15 A fault occurs when the fiber optic communication between the PMI DRV STAT processor and the UDC module is lost m o 200 1200 15 due to two consecutive errors of any type PMI PS Power DRV_FLT 202 1202 12 This fault occurs when the PMI power Supply Fault supply is not working correctly DC Bus Over DRV_FLT
7. A current path to earth ground in excess of 100 Amps for 5 to 10 microseconds has been detected at one or more of the drive output terminals When this condition occurs the drive coasts to a stop regardless of the selected stop type Suggested Action Run the power structure diagnostics e Check the motor and external wiring to the drive output terminals for a grounded condition Megger the motor leads to ground DISCONNECT THE MOTOR LEADS FROM THE DRIVE BEFORE MEGGERING MOTOR n Replace the Gate Driver Board Replace the drive Instantaneo us OverCurren t 12019 Adapter Comm Loss 04024 Master Slav e Drive to Drive Comm Timeout 16022 Absolute Overspeed 03025 UC_FAULT S Hard fault Red LED UC_FAULT S Hard Fault Red LED UC_FAULT S Hard Fault Red LED UC_FAULT S Soft Fault Red LED There was too much current in the system When this condition occurs the drive coasts to a stop regardless of the selected stop type Suggested Action Run the power structure diagnostics Check for shorted motor or motor wiring Replace drive A hardware malfunction was detected on power up or reset A software malfunction has occurred When this condition occurs the drive coasts to a stop regardless of the selected stop type Suggested Action Recycle the power If the fault does not clear replace the main control board If the fault continues repl
8. Export Import Files Current Recipe File Used c sigmavb RcpPaper mdb Figure 7 11 Export Import Files Note Export Import Files is an all or none feature All recipes in the Recipe File will be exported or imported If recipes are imported from disk they will overwrite all of the recipes in the SIGMA To import or export the Recipe File if Click File Push button The Export Import Files pop up window see Figure 7 11 displays the Recipe File s path and name in the Current Recipe File Used field To copy the displayed Recipe File to floppy disk click the Export push button Note that the size of the Recipe File cannot exceed the capacity of the floppy disk e g the file cannot be larger than 1 44Mb when being copied to a 3 5 high density disk To copy the Recipe File from a floppy disk to the displayed Recipe File location click the Import push button To exit the Export Import Files pop up window click the Exit push button Prepares the next recipe to be downloaded from the Recipe Manager Screen similar to the Load Next push button in the Recipe Manager screen Refer to 7 3 1 Load Next E Figure 7 12 Load Next Pop Up Window To prepare the next recipe to be downloaded l Click the Load Next Push button The Load Next pop up window see Figure 7 12 is displayed Click the H Push button When the Recipe menu opens click the recipe to be prepared for downloading from the Recipe Ma
9. The following are the steps taken to adjust the center value of a variable Select the appropriate channel push button from the Variable column of the Trend Screen A Channel window appears Notice there are two Center Value fields The Current Center field displays the current center value for the variable The New Center field is used to adjust the center Click once on the New Center field The New Center field becomes active Change the value by either entering a new value or by using the arrow push buttons located to the right of the field If the value is manually entered press lt Enter gt when the correct value is entered When the value is correct click once on the Set push button This will close the Channel window and redraw the plot for the variable in the Trend Screen Adjusting the Time Interval When looking at a graph it may be helpful to view the plots with another time interval For example if the graph is displaying plots for the information collected every 24 hours the activity between the 24 hour time span is not clear or may not even be detectable To view the activity which occurred between the 24 hour time span a user needs to adjust the time interval This is done with the use of the Interval option appearing on the Trend Screen s Main Menu By selecting the Interval option a list of the valid time intervals displays The valid options are 20 seconds 100 seconds 5 minutes 10 minutes 30 minutes 1 hour 2
10. When the recipe menu opens click the recipe to be copied Click the OK button The recipe is displayed in the Edit Field column Note A recipe may also be copied by double clicking on the recipe name of a visible recipe column see call out B in Figure 7 1 Clears the Edit Field column To clear the Edit Field 1 Click the Clear Push button The current values in the Edit Field are cleared Saves the values in the Edit Field column to the Recipe File using the name specified in the Recipe Name cell To save values in the Edit Field column as an existing recipe name l Click the Save Push button If the name specified in the Recipe Name cell already exists in the Recipe File then the Save Recipe pop up box see Figure 7 7 appears asking whether to overwrite the existing recipe in the Recipe File Overwrite pulp in Recipe File Figure 7 7 Save Recipe Overwrite Box Click OK and the values in the Edit Field are saved as the existing recipe To save values in the Edit Field column as a new recipe name 1 Click the Save Push button Add steelbar to Recipe File Figure 7 8 Save Recipe Add Box If the name specified in the Recipe Name cell does not exists in the Recipe File then the Save Recipe pop up box see Figure 7 8 appears asking whether to add the new recipe to the recipe file Click OK The values in the Edit Field are saved as the new recipe Deletes a stored recipe from the Recipe File To
11. field at the top of the screen The name of the section appears above the value and the units e g FPM appear to the right Repeat steps 1 and 2 to select another section Calculating Draws The following lists the steps for calculating draw values Summary Verify that the A and B factors displayed at the top of the screen are correct If not perform the steps in section 6 3 1 Selecting Sections for Calculation before continuing to the next step Click the desired calculation push button The draw value is calculated and displayed in the draw result field in the middle of the screen If necessary clicking another calculation push button displays the new draw result in the field This chapter highlighted the process of monitoring drives by using the Drive Overview Screen and its support screens Again note that the Drive Overview System is configured on an application specific basis Therefore some features presented in this chapter may not be available on your system If features described in this chapter are desired but not provided on your system discuss adding them with your Rockwell Automation sales engineer 6 1 The Drive Overview Screen vccccccccccccsccccdicecesccccccsecssectecdecscusceeclececeacd cd cceesieccccecedecesssbees 112 6 1 1 Viewme Bar AI ices ni iorn i e E E A A N alae ads 115 6 1 2 Viewing Distributive Power Diagnostic Screens ceceesceeseeeeceseceseeneeeseeeeeees 116 0l MS HelPONto Nana a a a a
12. for information on the using section control boxes The SPAD Speed and Draw Screen SIGMA Universal Operator Interface Check C SIGMA LOGFILES WWOI YAR LOG Overview Section SPAD Trend Alarm Flt Snapshot Entry Speed 0 0 ipm Process Speed 0 00 ppm Delivery Speed 0 0 rom Exit Chain Conveyor B A 100 Coil Prep Shear A M eeu 000 B Top Work Roll Entry Chain Conveyor E Bae eao _8 a _ SSSIEEREN Figure 6 18 The SPAD Speed and Draw Screen i l Clicking the SPAD option from the Main Menu displays the SPAD Speed and Draw Screen as shown in Figure 6 18 The SPAD screen is an optional screen of the Drive Overview system This screen typically is used for a paper machine or a similar process where section draw is an important parameter The Overview Screen Configuration Utility is used to configure this screen and the variable used during draw calculation Refer to Chapter 6 Configuring the Drive Overview Screen and Support Screens in the SIGMA Developers Manual for more information Screen Description The Draw Screen is divided into three parts Header section This top section of the Draw Screen is divided into two rows The first row contains the Rockwell Automation logo and or the name of the applicable machine the company name and the date and time The second row displays a data display bar This bar can be configured to display up to 3 variables which an opera
13. 200 1200 1 e PM FLT Power DRV_FLT 202 1202 1 red when either a DC Module Fault Bus Over Current fault an Instantaneous Over Current fault Local Power Interface fault a Charge Bus Timeout DRV_FLT 202 1202 4 fault or an Over Temp Fault occurs DRV_FLT 202 1202 3 DRV_FLT 202 1202 6 DRV_FLT 202 1202 7 EXT FLT DRV_FLT 202 1202 0 red when there is either External Fault an DC Bus Over Voltage fault a Ground Current fault a Charge Bus Time Out fault an Over Speed fault or a user DRV_FLT 202 1202 6 configured fault DRV_FLT 202 1202 2 DRV_FLT 202 1202 1 0 IO_CNTRL 101 1101 2 RAIL FLT DRV_WRN 203 a 1 red when a rail fault is Rail Comm Fault o Resolver and Drive I O FDBK OK DRV_FLT 202 1202 7 green when the resolver Feedback OK feedback device is OK Loss of this LED usually indicates a broken wire DRV_FLT 202 1202 8 to the feedback device RPI Run IO_STAT 201 1201 0 green when the run Permissive Input permissive input is OK IO_STAT 201 1201 1 amber when the status of ee the M Contactor output bit is high AUX IN1 IO_STAT 201 1201 1 green when the auxiliary Auxiliary input 1 input 1 is present AUX IN2 IO_STAT 201 1201 2 1 green when the auxiliary Auxiliary input 2 input 2 is present AUX IN3 IO_STAT 201 1201 3 1 green when the auxiliary Auxiliary input 3 input 3 is present AUX IN4 IO_STAT 201 1201 4 1 green when the auxiliary Auxiliary input 4 input 4 is present AU
14. 3 2 2 LED Lights The following table lists the LED names their associated suggested variable names register bit positions and logic for the LED to be on LED Name Variable Name_ Register A LED Turns Register B Bit Power Supply PMI Processor OK PMI Proc DRV_STAT 200 1200 15 1 green when the PMI processor is OK COMM OK DRV_FLT 202 1202 15 0 green when the PWR OK DRV_FLT 202 1202 12 green when the PMI power supply is OK PM FLT Power Module Fault and DRV_STAT DRV_FLT DRV_FLT DRV_FLT DRV_FLT DRV_FLT 200 1200 15 202 1202 1 202 1202 3 202 1202 4 202 1202 6 202 1202 7 communications between the UDC and PMI is working OK red when either a DC Bus Overcurrent fault an Instantaneous Overcurrent fault a Local Power Interface fault a Charge Bus Timeout fault or an Over Temp fault occurs EXT FLT External DRV_FLT 202 1202 0 red when there is either Fault an DC Bus Over Voltage fault a Ground Current DRV_FLT 202 1202 2 T n fault a Charge Bus Time Out fault an Over Speed DRV_FLT 202 1202 6 fault or a user configured fault DRV_FLT 202 1202 10 IO_CNTRL 101 1101 2 RAIL FLT Rail DRV_WRN 203 1203 13 red when a rail fault is Comm Fault i o Resolver and Drive I O FDBK OK DRV_FLT 202 1202 7 green when the resolver Feedback Ok feedback device is OK and DRV_FLT 202 1202 8 Fess ohms PD usualy indicates a broken wire to the fee
15. AB1336 drive This diagnostics screen information consists of a diagnostic grid showing the following status of Power Diagnostic Fault Non Configurable Faults and Current Processor CP and Velocity Processor VP Configuration Warnings and Faults Fault Type and Fault Names Description Status Grid Box Color Power Diagnostic Faults consists of problems that No Fault Green could occur with powerup of both Fault Red Absolute Overspeed the current CP and velocity VP processors Non Configurable Cannot disable These faults are No Fault Green D C Bus Overvoltage the result of a condition that Fault Red Transistor Desaturation could damage the drive if Ground Fault allowed to persist Instantaneous Overcurrent Adaptor Comm Loss Master Slave Drive to Drive Comm Timeout Power Up Reset Fault Analog Power Supply Tolerance Autocomm Transistor Diag Failure Inverter Temperature Trip Software Malfunction Current Processor CP Can set up to either trip the drive No Fault Green Configurable or provide only a visual warning Warning Yellow as Bus Ridethausheimedut while the drive continues to Fault Red Bus Precharge Timeout opca Bus Drop 150 Volts Below Nom Bus Under Voltage Bus Ridethrough gt 5 Cycles Bus Ridethrough gt 75 Cycles Velocity Processor VP Can set up to either trip the drive No Fault Green Configurable or provide only a visu
16. Each installation step is provided here along with the information needed to make the procedures run smoothly and correctly Summarized List of the Steps Taken during Client Installation Install appropriate Windows platform Windows 2000 Install SIGMA NE Installation CD Verify SIGMA Client Communication with the SIGMA Server Start a SIGMA Client Application Pats Installing Appropriate Windows Operating System Windows 2000 Install Microsoft Windows 2000 on the primary partition drive according to the appropriate Windows documentation At Setup Options pop up choose Typical When selecting Network Protocols choose TCP IP Protocol The installer then needs to know the I P address and host name of each SIGMA NE client and server Using the SIGMA NE Installation CD The SIGMA NE Installation CD is used along with a SIGMA NE License floppy disk to load SIGMA NE software onto a SIGMA client Available SIGMA Client application types are e SIGMA NE 32 bit UPM Systems e SIGMA NE 32 bit UOI Systems All the license information for the system is read from the floppy The SIGMA NE License file ultimately specifies the components that are to be installed on the system The SIGMA NE License file should NOT be changed in any way Changing the file renders the license unusable For example To install SIGMA NE 32 bit UOI client software 1 Load the SIGMA NE License floppy disk into the floppy drive 2 Load the SIGMA NE Instal
17. O0 Wire Turning First Press Second Press F le Third Press Second Dryer F 2 ik 7 o lt HL i E Figure 2 1 Drives Overview Screen For a UPM the Alarm Fault Screen see Figure 2 2 initially is displayed SIGMA Universal Operator Interface Alarm Fault Summary Trend Almj FIlt Snapshot Quit Alarm Fault Summary Exception Time Message 07 07 95 10 37 Acknowledge Clear or Acknowledge Time Figure 2 2 Alarm Fault Summary Screen Types Of Screens Screens can occupy the entire display or popup and overlay only a portion of the display Figure 2 3 and Figure 2 4 show examples of a full screen and a popup screen SIGMA Universal Operator Interface Overview Screen aad SIGMA Universal Uperalvi Inlerloce Overview Sereen 3 General Trend _Alarm Fit Auxiliary Report Snapshot Quit Overview Section SPAD Broke Trend Alm Fit Mcpart Snapshot Quit 07 07 95 10 39 07 07 95 13 34 Entry Speed 0 FPM Process Speed 0 Fm Delivery Speed 0 FPM Machine Speed 495 80 ym Prue Code 42J Section Status Setpoint Tension Load Section Status FPM PL Ch Gc M PayofReel e reaay MESON B5035 a 51 34 E 5531 Top Conveyor nco Mo SOA rg en N
18. Run IO_STAT 201 1201 0 green when the run Permissive Input permissive input is OK MCR IO_STAT 201 1201 1 amber when the status of M Contactor the M Contactor output bit is high AUX IN2 IO_STAT 201 1201 2 green when the auxiliary Auxiliary input 2 input 2 is present AUX IN3 O_STAT 201 1201 3 green when the auxiliary Auxiliary input 3 input 3 is present AUX IN4 IO_STAT 201 1201 4 1 green when the auxiliary Auxiliary input 4 input 4 is present AUX IN5 IO_STAT 201 1201 5 1 green when the auxiliary Auxiliary input 5 input 5 is present AUX OUT IO_CNTRL 101 1101 4 1 amber when the auxiliary Auxiliary output output is on AC Power Technology AUX IN1 IO_STAT 201 1201 1 1 green when the auxiliary Auxiliary input 1 input 1 is present OK AC Power DRV_FLT 202 1202 11 green when the AC power Technology technology card is working OK 3 4 3 IGBT Schematic The following is the list of variables to show an IGBT Short Fault The standard screen looks at the following bits of the IGBT diagnostic register to determine which IGBT has been affected by the Fault The color on the IGBT schematic changes ONLY when both an IGBT bit has been set and the IGBT Short Fault bit has been set Unit x IGBT Number Phase U Upper Phase V Upper Phase W Upper Phase U Lower Phase V Lower Phase W Lower Where x 1 2 or 3 Variable Name DEV_DIAGx DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 DEV_DIAG1 DEV_DIAG
19. detected Resolver and Drive I O FDBK OK DRV_FLT green when the resolver Feedback OK feedback device is OK Loss of this LED usually indicates a broken wire to the feedback device RPI Run IO_STAT green when the run Permissive Input permissive input is OK IO_STAT amber when the status of eee the M Contactor output bit is high AUX IN1 IO_STAT green when the auxiliary Auxiliary input 1 input 1 is present UX IN2 Auxiliary IO_STAT green when the auxiliary put 2 input 2 is present UX IN3 IO_STAT green when the auxiliary aia input 3 input 3 is present AUX IN4 IO_STAT green when the auxiliary Auxiliary input 4 input 4 is present AUX IN5 IO_STAT 5 1 green when the auxiliary Auxiliary input 5 input 5 is present AUX OUT IO_CNTRL 4 1 amber when the auxiliary Auxiliary output output is on 3 6 Troubleshooting The GV 3000 A C Drive Diagnostic Screens The standard GV 3000 A C Drive see Figure A 8 Diagnostic screen uses the following bit positions in registers 12 and 13 for LED light information needed Note It is the responsibility of the person configuring the AutoMax software to make sure the correct information is configured within these variables SIGMA Universal Operator Interface ITALIMPIANTI G 3000 Diagnostics Help Return No 1 Payoff Reel Network Comm Loss First Fault Overcurrent steady state Second Fault None Self Tune Self tuning
20. 0 00 pp DeliverySpeed 0 0 Payoff Top Work Roll Bottom Work Roll TE oe i run i RUN mE jocrwo Zoo TRAWL mE ocr Eror Teror e Higa l Figure 1 9 The Section Control Screen Recipe Manager screen that lets the operator view modify enter or capture setpoints for the production process SIGMA R Exit Manager Editor Figure 1 10 Recipe Manager Screen Recipe Editor screen that lets the operator create store and modify operating recipes which are used by the Recipe Manager to control the production process SIGMA Recipe System Recipe Editor Exit Manager Editor _Detaut _Copy cleat _Save_ betete Print File _LoadNext Figure 1 11 The Recipe Editor Screen Also the UOI system software may provide application specific screens for displaying a process overview and its various parameters tracking a product s position as it passes through the production line SIGMA Universal Operator Interface Winder Overview SIGMA Universal Operator Interface Weld Tracking Screen Overview Setup Trend Control interlocks Alm FIt Snapshot icin Quit General Gecipe Trend Alarm Fit Auxiliary Report Snapshot icip Quit L PACATE rarere 4A A O EA E E U NST CAN EN IEN RA A E AA VENE E E E A Figure 1 12 Process Overview Figure 1 13 Tracking About SIGMA NE Operator Interface Design WARNING THE OPERATOR INTERFACE MAY BE USED TO PERFORM CRIT
21. 202 1202 1 This fault occurs when the DC bus Current Fault current exceeds 125 of the rated Power Module current Error code 1020 will be displayed in the error log of the UDC task in which the fault occurred Ground Current This can either be a fault or a warning A DRV_FLT 202 1202 2 fault condition occurs when ground current exceeds the rating of the Power Module Error code 1021 will be displayed in the error log of the UDC 203 1203 2 task in which the fault occurred DRV_WRN A warning occurs when the ground current exceeds the configured ground fault current level stored in local tunable GIT_E1 PMI Bus Fault DRV_FLT 202 1202 13 This fault occurs when there is a bus fault in the PMI rack This is indicated when the Resolver amp amp Drive I O module and the AC Power Technology module do not respond to requests from the PMI processor PMI Fan Loss DRV_WRN 203 1203 12 The PMI Fan Loss Warning bit is set Warning when the airflow through the PMI rack is not being sensed IOC Fault DRV_FLT 202 1202 3 This fault occurs when there is an overcurrent in one of the power devices Register 204 1204 bits 0 5 indicates which power device detected the overcurrent Bit 6 of register 204 1204 will also be set if the overcurrent was detected in the Intelligent Power Module Resolver Fault This fault is a combination of Fault Register 202 1202 bits 8 and 9 DRV_FLT 202 1202 8 Bit 8 is set if a sine or cosine si
22. 4 1 for more information on the Event History Filter Setup screen Filtering Events Event History Filter Setup Event Type Filter Time Span Filter x High Fault Day Month Year Begin alno Pauls From 12 Jul 94 08 47 47 g g g gt High Alarm To 12 Jul 94 08 47 47 gt ean Example 25 Oct 93 09 24 34 x High Operator Action f Use Time Span Filter Hours Minutes Seconds x Low Operator Action Sort Order x All Types Ascending Descending Tagnamef s Filter Tagnames Available Selected Tagnames Use Tagnamefs Filter Add All Starting With Clear Selected List Figure 5 3 The Event History Filter Setup Screen Clicking the Setup Filter push button displays the Event History Filter Setup screen as shown in Figure 5 3 This screen allows users to set up the event type time span and or tagname parameters for filtering events Screen Description The Event History Filter Setup Screen is divided into multiple sections Each section is explained in detail below The Event Type Filter section allows users to filter events based on the event type of variables When using the Event Type Filter section the user can indicate that one more than one or all of the event types should be included in the filter To make a selection position the cursor in the check box to the left of the event type and click once An X appears to indicate the event type has been included in the filter The Time
23. 5 in VP Fault Warning Configurable Select parameter 88 to 0 and set bit 5 in VP Warning None Configuration Select Parameter 89 to 0 To disregard the alarm set bit 5 in VP Fault Warning Configurable Select parameter 88 and VP Warning None Configuration Select Parameter 89 to 0 The external fault input from the L Option Board is open Suggested Action Check the external circuit for cause of an open input signal To configure the alarm as a fault set bit 6 in VP Fault Warning Configurable Select parameter 88 to 1 To configure the alarm as a Warning set bit 6 in VP Fault Warning Configurable Select parameter 88 to 0 and set bit 6 in VP Warning None Configuration Select Parameter 89 to 0 To disregard the alarm set bit 6 in VP Fault Warning Configurable Select parameter 88 and VP Warning None Configuration Select Parameter 89 to 0 Dynamic Brake Over Temp 09059 Inverter Overload Pending 02061 UC_VP_FLT or UC_VP_WR N UC_VP_FLT or UC_VP_WR N UC_VP_FLT Soft fault Red LED UC_VP_WR N Warning Yell ow LED To configure the alarm as a fault set bit 7 in VP Fault Warning Configurable Select parameter 88 to 1 To configure the alarm as a Warning set bit 7 in VP Fault Warning Configurable Select parameter 88 to 0 and set bit 7 in VP Warning None Configuration Select Parameter 89 to 0 To disregard the alarm set bit 7 in VP Fault Warning Configurable Select parameter 88 and VP W
24. A 4 Troubleshooting The SB 3000 Parallel A B and C Diagnostic Screens A 28 A 4 1 NA EE e E E A E EE E seas tandesaans A 29 A 4 2 LED Li ee eira e E E E E ra aae E n A 35 A 4 3 E CN E A A E E E A A 37 A 5 Troubleshooting The SA 500 Diagnostic Screen ssesssesssesessseessesrssressessrssresse A 39 A 5 1 Failt BORCA oiie AEE AA ce A 39 Oer e E E E E E E E E A 41 A 6 Troubleshooting The GV 3000 A C Drive Diagnostic Screens esssesseeseeeseesee A 43 A 6 1 Panli BOKEB inerea EE E EAE E EAE EE AR A 43 A 7 Troubleshooting The FP 3000 D C Drive Diagnostic Screens ss ssssssessesessesee A 46 A 7 1 Status Faults and Alarm BOXES isnnrensccnsienniar a ai A 47 A 7 2 First Fault Text Message FRST_FLT cssccssscssscsssasostenessieessersceoasnnssnasnsesiness A 49 A 7 3 Stop Code Messages STP_CAUS Y eecicireiinnsirnriiia iiaii A 49 A 7 4 Recent Alarm RCNT_ALM Messages occ ice ssaasscosccseasass savidesesssacteannsoassnss A 49 A 8 Troubleshooting The SA 3100 Diagnostic Screens scssscssecssstssssecseecssecees A 51 A 8 1 Failt BOKER onon a a eee eR A 52 AR LED Lip occiorient ie aa aa aaae anaa Taasis A 57 A 8 3 1GB Sehen Bee a e E AA EEE RA KT EER A 60 A 9 Troubleshooting The AB1336 Drive Diagnostic Screens sessesessessereessssersessese A 61 A 9 1 Status Fault or Warning DORGS os scisiccsaccasnssscssansceesseasscasscetascsnncssscunen
25. AB1336 Section 6 1 2 11 If no appropriate drive diagnostic screen exists for a drive section then the Alarm Fault Screen is displayed For information on this screen refer to Chapter 5 Alarms and Faults System Distributive Power Diagnostic screens may display an expanded drawing of the PMI rack and its diagnostic LEDs a diagnostic grid showing the states active or inactive of drive faults and alarms a diagnostic schematic showing states short or open for SCR DC or IGBT AC output devices The diagnostic grid shows green if a fault or alarm is inactive yellow if a alarm is active red if a fault is active The diagnostic schematic shows the states of an output device SCR for DC and IGBT for AC The schematic for DC SCRs is green when the device is working red when the failed device has a short yellow when the failed device is open The schematic for AC IGBT is green when the device is working e red when the device causes an overcurrent IOC yellow when there is a phase imbalance available only on AC Parallel In the menu bar of the Distributive Power Diagnostic Screen appears 2 options e Help Clicking this option displays the Help Menu window for the section This window contains a list of all the items for which a help dialog window exists From a help dialog box a user can enter notes about a particular item Refer to Section 6 1 2 1 for more information about the Help optio
26. Bit i LED Turns Variable Positio Name n Power Supply PWR OK DRV_FLT green when the PMI power supply is OK PMI Processor OK PMI Proc DRV_STAT p Sc green when the PMI processor is OK COMM DRV_FLT green when the communications Communications between the UDC and PMI is working OK OK DRV_STAT and PM FLT Power DRV_FLT red when there is either a SCR Module Fault fault or a field loss fault DRV_FLT EXT FLT DRV_FLT red when there is either an AC External Fault synchronization loss fault an of DRV FLT instantaneous overcurrent fault an overspeed fault or a user configured fault DRV_FLT IO_CNTRL RAIL FLT Rail DRV_WRN red when a rail fault is detected Comm Fault Resolver and DriveIO S and Drive IO FDBK Feedback DRV_FLT green when the feedback device OK resolver or pulse tachometer is OK Loss of this LED usually indicates a broken wire to the and PRV FLT feedback device RPI Run IO_STAT green when the run permissive Permissive Input input is OK IO_STAT amber when the status of the ie a M Contactor output bit is high UX IN1 IO_STAT green when the auxiliary input 1 is ie input1 present AUX IN2 IO_STAT green when the auxiliary input 2 is Auxiliary input2 present AUX IN3 IO_STAT 3 1 green when the auxiliary input 3 is Auxiliary input3 present AUX IN4 IO_STAT 4 1 green when the auxiliary input 4 is Auxiliary input4 present AUX IN5 IO_ST
27. C WINNT SYSTEM32 DRIVERS ETC HOSTS or in the DNS database Ping Command Example A 32 bit SIGMA client pings its SIGMA server with name sioserv and IP address 161 153 60 170 Ping Command at DOS prompt C gt ping sigserv Expected Server Reply Pinging sigserv 161 153 60 170 with 32 bytes of data Reply from 161 153 60 170 bytes 32 time 101ms TTL 243 C gt ping sigserv Pinging sigserv 161 153 686 176 with 32 bytes of data Reply from 161 153 686 176 Reply from 161 153 686 176 Reply from 161 153 686 176 Reply from 161 153 686 176 G gt Figure 1 23 Ping Command Example bytes 32 time lt i ms TTL 255 bytes 32 time lt i ms TTL 255 bytes 32 time lt i ms TTL 255 bytes 32 time lt i ms TTL 255 SIGMA Client Quick Start To start the following SIGMA Client Applications SIGMA Client Application Click Icon 32 Bit SIGMA NE UPM Client me Sigma UPM 32 Bit SIGMA NE UOI Client aA Sigma UOI Example To start a 32 bit SIGMA UOI client If you had been running a UOI application previously and had not clicked Stop the Custom OCX Server icon after you had Quit the SIGMA NE UOI application click Stop the Custom OCX Server icon before you click Start the Custom OCX Server icon 1 Click the 32 Bit SIGMA UOI icon A Sigma UQI The main SIGMA NE UOI UPM Title screen is displayed OA Rockwell Aviomation Z SIGMA Universa
28. Close Sustained Speed Sustained Armature Current CML Feedback Scaling Error Low Minimum Speed Retentive Memory Save Error The main FN contactor did not open following a stop If a dynamic braking DB kit is used the DB AUX contact is wired in series with the FN AUX contact The main FN contactor did not close following a run or jog command If a dynamic braking DB kit is used the DB AUX contact is wired in series with the FN AUX contact Motor speed did not fall below the Stop Speed Threshold in the required amount of time during a stop this time is automatically set to two times The Deceleration Time time Armature current was unable to reach discontinuous conduction while stopping the drive Armature current feedback could not be scaled properly based on the values entered for Motor Rated Arm Amps and Maximum Current Verify that these parameter values are correct for your application Verify that CT Turns Ratio has been set to the value shown in the instruction manual based on your drive type The Minimum Speed value is less than 10 of the Maximum Speed value This alarm will not be triggered on power up It only occurs when maximum or minimum speed has changed Verify that these parameter values are correct for your application An attempt to save information parameter values fault log data or the keypad reference value to retentive memory failed The drive may continue to be operated 3 8
29. Operator Interface ITALIMPIANTI G 3000 Diagnostics Help Return No 1 Payoff Reel Network Comm Loss Overcurrent Steady State First Fault Overcurrent steady state Second Fault None Self Tune Self tuning successful GW Seele RELIANCE A C Drive ELECTRICEL Figure 6 12 The GV3000 A C Drive Diagnostics Screen The GV3000 A C Diagnostics screen shown in Figure 6 12 displays diagnostic information for an GV3000 A C drive This diagnostics screen information consists of a diagnostic grid showing the states active or inactive of drive faults and alarms text descriptions of the first and second faults that have occurred e text description of the self tune result only in vector mode Possible self tune result messages are Self tuning successful User initiated a normal stop Emergency stop or fault stop occurred during self tuning Motor or pulse tachometer direction in reverse Pulse tachometer PPR out of range Magnetizing current percent out of range Bus voltage error Current limit exceeded For more information on this diagnostics screen information refer to Section 6 1 2 Viewing Distributed Power Diagnostic Screens The FP 3000 D C Drive Diagnostic Screen SIGMA Universal Operator Interface ITALIMPIANTI FP3000 Diagnostics Help Return No 1 Payoff Reel Sync Loss First Fault Instantaneous Armature Overcurrent Stop cause Stop asserted o
30. The second line contains the variable name Type The Type column contains the event type of the variable This information helps determine the severity of the alarm or fault Clear Time This column contains the time the event cleared If it has not been cleared this column is blank Acknowledge Time This column contains the acknowledgement date and time if the event has been acknowledged The Event History Screen contains three push buttons and a display only field at the top of the screen Print push button When the Print push button is selected the Event History Print Setup window appears This allows users to print the entire Event History list or a section of the list Refer to section 5 4 2 for more information on the Event History Print Setup window Note If a filter is currently active then the printed events are also filtered Cancel Print push button The Cancel Print push button terminates a list that is currently printing There may be a few print jobs queued up or waiting to print but only the job that is currently printing is canceled Filter text This field displays the filter parameters established using the Event History Filter Setup screen If a filter has not been established the text No Active Filter displays Setup Filter push button This push button provides access to the Event History Filter Setup screen This screen is used for entering filter configuration information Refer to section 5
31. This fault occurs when the gate driver Power Module turns off an output power device Fault IGBT to protect it from an overcurrent An IOC fault Bit 3 of register 202 1202 will also be set Charge Bus DRV_FLT 202 1202 6 This fault occurs when any of the Time out Fault following conditions occur e The DC bus is not fully charged within 10 seconds after the bus enable bit is set The drive is on and feedback indicates that the pre charge contactor has opened The DC bus voltage is less than the value stored in the Power Loss Fault Threshold PLT_E0 tunable variable a Tepes DIES 202 1202 7 This can either be a fault or a warning i This fault occurs when fault level thermal switch in the Power Module opens Error code 1016 will be displayed in the error log of the UDC task in 203 1203 7 hee the fault occurred DR RN warning occurs when warning level YERIN thermal switch in the Power Module opens Voltage Ripple DRV_WRN 203 1203 3 The Voltage Ripple Warning bit is set if Warning the ripple on the DC bus exceeds the configured voltage ripple threshold value The following logic table explains the Resulting Faults and LED states If Variable Name And Variable Name Resulting Fault or LED State DRV_STAT DRV_FLT 200 1200 Bit 15 202 1202 Bit 15 S S T a a er Co If there is no communication with the PMI rack the purple cross mark is displayed on the diagnostics screen see Figure A 3
32. UC_CP_FLT Soft fault red UC_CP_WR N Warning Yell ow LED UC_CP_FLT 3 5 Soft fault Red LED UC_CP_WR N Warning Yell ow LED At least 5 ridethrough cycles have occurred within a 20 second period This indicates a converter problem or a problem with the incoming power Suggested Action Monitor the incoming AC line for low voltage or line power interruption Refer to the Understanding Precharge and Ridethrough Faults section in the Troubleshooting chapter of the user Manual for more information To configure the alarm as a fault set bit 4 in CP Fault Warning Configurable Select parameter 86 to 1 To configure the alarm as a Warning set bit 4 in CP Fault Warning Configurable Select parameter 86 to 0 and set bit 4 in CP Warning None Configuration Select Parameter 87 to 0 To disregard the alarm set bit 4 in CP Fault Warning Configurable Select parameter 86 and CP Warning None Configuration Select Parameter 87 to 0 The fast flux up current is less than 50 of commanded Suggested Action Make sure the motor is properly connected Refer to the Understanding Precharge and Ridethrough Faults section in the troubleshooting chapter of the user manual for more information To configure the alarm as a fault set bit 5 in CP Fault Warning Configurable Select parameter 86 to 1 To configure the alarm as a Warning set bit 5 in CP Fault Warning Configurable Select parameter 86 to 0 and set bit 5 in CP Warn
33. a e a r a E a A O a Aas 149 T3 Managmg Recipes E E E T AER 156 7 3 1 Preparing The Next Recipe To Run ss sesessssssessssessesesssessrssressessessressessrssresseese 157 Ye Modifying Next Recipe Values Before Downloading cceeeeseeeteeneeeeeees 157 7 3 3 Downloading Recipesics icw ossek otsatia elvan e eee a a a a Were 158 7 3 4 Modifying Setpoint Values i cc c sar enc ascdanediortes voedane ohcats celeadadtSed sheen teatanaane easee tiene 159 7 3 5 Capturing Setpoint Values As a Recipe ccscccsssscssseserssscessnsssnscssccssacsenscenes 160 Fig t 7 1 Recipe Editor SCrg et siicst 5e6accsiskicansesaountare yrownsusreseunpdaeeandasnvaieg aanounadsawonncadsuanna RT EaR 147 Fiure 7 2 Pop Up Keyboard Maced tte soteds uaa Aah dinate cosa dan a e C ty hase T ial tic ba E 148 Figure 7 3 Pop Up Keypad micri abd arog tense aa i dese E gs dade a ones ia iai Sees 148 Figure 7 4 Pop Up Edit Data Message BOX sseeessesessersrteresrsresreseerisesterrssestesteseerenesteetssesrestese 148 Figure 7 5 Edit Function and Load Next ButtonS esseeseesssesreseerreresresiesteresreseerenrestertesesrestese 149 Figure 7 6 Copy Recipe DO oc tua Fugees acacia seu ini ao a a a a a a 150 Figure 7 7 Save Recipe Ovy fwtite Ox 6 asics cases iieii aii i eiiiai ia 151 Figure 7 8 Save Recipe Add Bok as vatecty stacaes aatatiiavte ter aaees ites i t a a i 151 Figure 7 9 Delete Recipe Os vise trenet ieu ten a E E E EAN E Gave eae 152 Figu
34. delete a stored recipe 1 Click Delete Push button The Delete Recipe box see Figure 7 9 is displayed Delete Recipe Figure 7 9 Delete Recipe Box Click the 4 Push button When the recipe menu opens click the stored recipe to be deleted Click the OK button The specified stored recipe is deleted Prints some or all of the stored recipes Print Recipes Print Recipe Group Ending With GS Print Recipe Count 3 Select All Recipes Figure 7 10 Print Recipes Pop Up Window To print all stored recipes Click the Print Push button The Print Recipes pop up window see Figure 7 10 is displayed To print all stored recipes click the Select All Recipes push button The Print Recipe Count displays the number of recipes to be printed 3 Click the OK button to print all the stored recipes To print one or more recipes 1 Click the Print Push button The Print Recipes pop up window see Figure 7 10 is displayed To print one or more stored recipes click the Starting With J push button When the Starting With recipe menu opens click the first to print Recipes are stored in alphabetical order Click the Ending With 1 push button When the Ending With recipe menu opens click the last recipe to print The Print Recipe Count displays the number of recipes to be printed Click the OK button to print the selected stored recipes Saves or loads the Recipe File to or from a floppy disk
35. format and destination exporting the snapshot can take a long time 10 minutes After the snapshot has been exported the Snapshot Export Utility screen remains active and another snapshot can be exported Return push button Click this push button to exit the Snapshot Export Utility screen and return to the SIGMA screen from which the Snapshot Export Utility was entered Selecting Variables with the Export Utility The following are the steps for exporting snapshot files refer to figure 4 6 1 Enter the Export Utility from the Snapshot pull down menu or the Snapshot File Maintenance Screen 2 Locate the desired snapshot by selecting the appropriate drive and directory in the Available snapshots section of the screen 3 Verify the information displayed in the Snapshot Information group pertains to the snapshot file needed 4 Specify the drive and directory to which the snapshot file should be exported in the Export destination section of the screen 5 Select a file format by using the Export Format radio buttons Then select whether to delete the snapshot after it has been exported or not from the Export Options group Summary Scroll through the list in the Variable not to be exported field Determine which variables should be exported IMPORTANT If groups of variables with similar characteristics need to be exported use the Select options group For each variable found click the item to highlight i
36. from the list In addition the acknowledgement time is added to the right hand column of any exceptions that were previously unacknowledged The Event History Screen SIGMA Universal Operator Interface Overview Section SPAD Trend Alarm Flt Snapshot Event History 07 12 94 08 50 Exception Time Message Clear Time Acknowledge Time Figure 5 2 Event History Screen Clicking the Event History option from Alarm FIlt pull down menu displays the Event History screen as shown in Figure 5 2 The Event History screen displays all last events up to 4000 which have occurred cleared or been acknowledged The display lists the events in the same manner as the Alarm Fault Summary Screen refer to section 5 1 However exceptions which are both cleared and acknowledged remain in the list When the Event Summary Screen has reached the maximum number of events it can display it removes the oldest events as new events are added to the list Screen Description The list of events appearing in the Event History Screen is designed in the same column format as the Alarm Fault Summary Screen However the Event History Screen contains four columns instead of three The following are descriptions of the columns which make up the list Exception Time Message This column contains the date and time the event occurred on the first line and the variable name and message associated with the event on the second line
37. hours 4 hours 12 hours 24 hours and 48 hours When the appropriate time interval is found click on it The graph displaying in the Trend Screen will automatically be redrawn reflecting the new time span Long time displays require the recovery of large amounts of data from the hard disk Disk search and data recovery time in excess of 30 seconds are not unusual Selecting a Time Axis The UPM has access to data for hundreds of variables during a period of up to 48 hours prior to the current time By choosing the appropriate time axis and or time interval between data points operators may tailor the Trend Screen graph to best reveal interesting trends in the data Operators may define the time axis and the time interval independently of one another There are two modes for defining a time axis Live Mode and Historical Mode Live Mode Live Mode displays the data fluctuations for variables while they are actually happening This mode displays a graph that is constantly in motion meaning that the plots on the graph are moving with the changes made by the variables Live Mode presents the most current picture of what is happening within the network To activate Live Mode locate the Live check box in the Trend Screen and click once on it The current date and time will be displayed at the left end of the horizontal axis Depending on the chosen time interval the rest of the axis represents a certain amount of time in the past Historical Mode
38. make sure the correct information is configured within these variables 3 1 1 Fault Boxes The following table lists the SD 3000 fault names their suggested variable names bit positions and under what conditions this bit is set Suggested Bit Bit Set When Variable Name Positio AC Loss Fault DRV_FLT an AC voltage stops for 0 5 seconds there is no communications with the No PMI Comm DRV_FLT PMI tack the cml_run signal is turned off and after 2 seconds the drive is still in continuous conduction n Conduction Fault DRV_FLT Field Loss Fault DRV_FLT 6 if the field feedback current is not related to the commanded firing angle PMI Power Supply DRV_FLT 12 PMI rack power supply voltage levels Fault if lit red are not correct PMI Bus Fault DRV_FLT 13 indicates that the Resolver the Drive I O module and the DC Power Technology module do not respond to requests from the PMI processor IOC Instantaneous DRV_FLT occurs when armature current feedback Over Current Fault is greater than the configured limit UDC Run Fault DRV_FLT the UDC module drops out of run before the current minor regulator is requested to turn off Over Speed Fault DRV_FLT the motor velocity exceeds the over speed trip point set in the configuration PMI Fan Loss Alarm DRV_WRN the airflow through the PMI rack is not being sensed Power Power Tech Fault Fault DRV_FLT 7 AC Power Technology Module fails SCR Open Alarm N
39. manual S 3005 The PMI SD3000 Regen Diagnostic Screen SIGMA Universal Operator Interface PMI SD3000 Regen Diagnostics Help Return Payoff Reel ra O PROCESSOR OK COMM OK P M FLT ExT FLT RAIL FLT mocz mocdsEn gt oA Figure 6 7 The SD3000 Regen Diagnostics Screen The SD3000 Regen Diagnostics screen shown in Figure 6 7 displays the diagnostic information for an SD3000 Regen drive This diagnostic screen information consists of an expanded drawing of PMI DCOR rack and its diagnostic LEDs a diagnostic grid showing the states active or inactive of drive faults and alarms a diagnostic schematic showing states short or open for SCR DC output devices For more information on this diagnostic screen information refer to Section 6 1 2 Viewing Distributive Power Diagnostic Screens For more information on the SD3000 drive refer to the AutoMax Distributive Power System manual S 3005 The PMI SA3000 Diagnostic Screen SIGMA Universal Operator Interface PMI 543000 Diagnostics Help Return SA3000 DC Bus No PMI Over Yolt Comm a Bmax 02s PTH Fault 5 Fluz current loop integrator time constant is n calibrated limits Rockwell Automation Figure 6 8 The SA3000 Diagnostics Screen The SA3000 Diagnostics screen shown in Figure 6 8 displays the diagnostic information for an SA3000 medium power drive This dia
40. nasini ieia asariar 202 A 5 Troubleshooting The SA 500 Diagnostic Screen s ss sssessssesseserssressessresseeseesressee 204 A 5 1 Fault BOXES ements eR eer me eee 204 Pees E D DT SUAS Sar E EA AET Sones ec aensen EAS 206 A 6 Troubleshooting The GV 3000 A C Drive Diagnostic Screens ee ceeeeeeeseeeeetee 208 A 6 1 Fault BOXES nseto artean E e eusecuaeenev EEEE EE EEA EA N 208 A 7 Troubleshooting The FP 3000 D C Drive Diagnostic Screens 0ceeesesseeeteeees 211 A 7 1 Status Faults and Alarm Boxes eactisste iin a fn eee AAS 212 A 7 2 First Fault Text Message FRST_FLT scssvect sseaseachanseectecureqscbinarsosacnSnceesttentans 214 A 7 3 Stop Code Messages STP CA US sccstcessccl anes davsaepiandvarhesassnvedelsaeaesadieeplacdilees 214 A 7 4 Recent Alarm RCNT ALM Messages c ccsccssseeseceteceseceeeeeeeeeenseeeaeees 214 A 8 Troubleshooting The SA 3100 Diagnostic Screens ceececsceeseceteceeeeeeeeeeseeesneeees 216 A 8 1 AU ORGS sciatic ee res baie a Bea a eas ne wien aa 217 A82 LEDLi tS sss s iad esse cus ein eqdn a lead saa dad tes vin ee sak ase E EKE 222 A 8 3 IGBT SM RN CLC 1 aia cre tes cent aliens seat oan dated Mast ai dylan nial a a ass boantstise 225 A 9 Troubleshooting The AB1336 Drive Diagnostic Screens sseseesssseseesesseseesesseeee 226 A 9 1 Status Fault or Warning Boxes se ca aieccoccsec desde bodaecs ausasel cy amatec vs toeseteedaten ace 228 Figure A 1 The SO 3000 idee st
41. of section control boxes Three boxes are visible on the screen at a time Both the Section Screen and a single Section Control window in the Drive Overview Screen refer to section 6 1 are the same for a given section Screen Description The Section Screen is divided into two patts Header Section This section is divided into two rows The first row contains the Rockwell Automation logo and or the name of the applicable machine the company s name and the date and time The second row contains a data display bar This bar can be configured to display up to 3 variables which an operator wants to monitor regularly For example section speeds can be displayed The variables displaying here are the same variables shown in the Drive Overview Screen All of this information is display only Section Control Panel This panel contains all of the sections listed in the Drive Overview Screen which permit access to the Section Control window At the top of the panel is a horizontal scroll bar which is used to scroll through the Section Control Panel To scroll one section panel at a time click the arrow push buttons at either end of the scroll bar To move three sections at a time click once directly on the scroll bar roll between an arrow button and the scroll bar button Each section control box works like a Section Control window from the Drive Overview Screen See Section 6 1 3 Changing the Setpoint Value for a Section
42. plots on it just grid lines on a background The graph s grid is divided into eight intervals on its vertical axis and ten intervals on its horizontal axis Screen Description The Trend Screen is divided into three sections The first section contains the variable information for the plots displaying on the screen The following is a component of this section Variable This column displays the four channel push buttons for variable selection Each push button represents a variable and leads directly to a Channel window for variable and parameter specifications By clicking once on a push button in this column a user can enter the Channel window and select a variable for trending The name of the variable chosen displays on the face of the channel push button Located next to each push button is the color used to display the variable plot on the graph Refer to section 3 2 1 Selecting Variables for Trend Screen for more information on using the Channel window The section next to the Variable column contains information about the variables chosen for each channel This information varies based on what is displaying in the graph below If the graph is being used for simply monitoring variables this section contains the current variable value units and description for each channel established If the graph is being used for finding exact values for areas on a certain plot this section contains the plot values units and differences T
43. process line It controls both negative as well as positive values depending on the slider bar s configured ranges and setpoint data format See Sections 6 3 5 and 6 4 2 in the Developers Manual Clicking the slider bar button and holding down the left mouse button modifies the setpoint value using the slider Move the mouse to slide the button up or down The upward action increases the setpoint value Conversely the downward action decreases the setpoint value Using the up and down arrow push buttons located below the slider bar makes small fine tune changes to a setpoint value Clicking the up arrow push button increases the setpoint value Clicking the down arrow push button decreases the setpoint value A change to the setpoint value using the slide bar requires confirmation The OK push button turns orange when confirmation of a setpoint value is needed To confirm a setpoint value click the orange OK push button Changes made using the up and down arrow buttons however do not require confirmation Increase Decrease push buttons optional feature Note These push buttons are not the same as the up and down arrow push buttons located below the slider bar Clicking an Increase or Decrease push button makes small changes one unit at a time to the setpoint Increase Decrease push buttons are the preferred method to control machine parameters Clicking the Increase push button increases the value Clicking the Decrease push but
44. successful GV0 RELIANCE A C Drive ELECTRICAL Figure A 8 The GV3000 A C Drive Diagnostic Screen 3 6 1 Fault Boxes The following table lists the GV 3000 fault names their suggested variable names bit positions in registers 12 and 13 and under what conditions this bit is set Suggested Register Variable I Bit Name Position High D C Bus DRV_FLT1 12 4 D C bus voltage too high capacitor protection Deceleration time may be too short Low D C Bus DRV_FLT1 12 5 D C bus voltage too low Line dip too long or input rectifier diodes defective Overcurrent Steady DRV_FLT1 12 0 Trips at 137 load based on inverter type State current Check power module rating Overcurrent DRV_FLT1 12 1 Acceleration time is too short Accelerating Overcurrent DRV_FLT1 12 2 Deceleration time is too short ns D C D C Braking Fault Fault DRV_FLT1 12 3 D C voltage is too high Self tuning Failure DRV_FLT1 12 12 Self tuning failure Refer to parameter U 009 for details Overfrequency DRV_FLT1 12 15 Drive has exceeded maximum allowable output frequency Motor Motor Phase Loss _ Loss DRV_FLT1 12 14 Phase lost between drive and motor Serial Port DRV_FLT1 12 11 Spurious interrupt received from the serial Spurious Interrupt port The interrupt received was not receive transmit overrun or any expected interrupt while the serial port was the control source P 000 3 Function Loss DRV_FLT1 12 8 Function loss input on control termin
45. the Current Position option make sure the cursor is located exactly at the desired event in the Event History screen Print push button Clicking this push button initiates the printing command Depending upon the number of events being printed this command may take a while to complete If printing needs to be terminated the Cancel Print push button located in the Event History Screen can be used Cancel push button Clicking this push button closes the Event History Print Setup window and returns the user to the Event History Screen Summary Monitoring and fixing alarms and faults are important parts of insuring that a process runs smoothly and properly The Alarm Fault Screen and the Event History Screen allow a user to monitor them and obtain the necessary information to address them Exceptions should not be taken lightly for they can indicate some deeper problem which may occur later and affect the efficiency of a process or cause injury to coworkers 5 1 Alann Fanl DV Cr vie we senicure eoi en a cuasd a idi e aaia 95 5 2 Color Descriptions of Exceptions ss ssssessssessesessseessesesssressesrtssessesstsseesseeseesresseeseee 96 5 3 The Alarm Fault Summary Screen sseseeeseessesseeseessessresresseesesersstesresressressessessresseese 98 S4 The Event History Screech siejimas ar RTS NEE EAE ANAKE ERES 100 5 4 1 Filtering Vents isis Seceicccvas sciats ai a E E E E E E aA 103 5 4 2 Printing an Event List ssses
46. the currently running recipe BEL BAIE SPEED 3RD Dryer Draw 20 2 Click the OK button on the Size Press Top Draw FPM 72 Download pop up window to Save net en w Pa 4TH Dryer Wet Draw FPM 11 download the Next recipe into the Camre 7 drive system Roe Drum Draw rom 30 Reel Speed FPM 1637 Figure 7 16 Download Pop Up Window The column titled Preset see call out C in Figure 7 13 contains the recipe name and setpoint reference values of the recipe elements which were last downloaded to the drive system Also if the Next column had been modified before downloading a modified is displayed in the Recipe Name box The column titled Setpoint see call out B in Figure 7 13 also contains these setpoint values until they are changed either by the user or by the drive system The Recipe Name box displays unsaved until this recipe is captured Modifying Setpoint Values The user can modify each element value in the Setpoint column during line operation Each value is displayed on a push button To modify an element value 1 Click the value s cell push button in the a Setpoint column The cell is then highlighted a and the pop up keypad see Figure 7 17 is displayed BackSp The keypad allows the user to enter values by either pointing device mouse or trackball or using a hardware keybo
47. warning DRV_FLT 202 1202 7 This fault occurs when fault level thermal switch in the Power Module opens Error code 1016 will be displayed in the error log of the UDC task in which the fault occurred A warning occurs when warning level DRV_WRN 203 1203 7 thermal switch in the Power Module opens Unit 1 Over DEV_DIAG1 204 1204 12 Unit 1 detects an over temperature Temp Fault Unit 2 Over DEV_DIAG2 220 1220 12 Unit 2 detects an over temperature Temp Fault Unit 3 Over DEV_DIAG3 221 1221 12 Unit 3 detects an over temperature Temp Fault The following logic table explains the Resulting Faults and LED states If Variable Name And Variable Name Resulting Fault or LED State DRV_STAT DRV_FLT 200 1200 Bit 15 202 1202 Bit 15 If there is no communication with the PMI rack the purple cross mark is displayed on the diagnostics screen see Figure A 3 3 3 2 LED Lights The following table lists the LED names their associated suggested variable names register bit positions and logic for the LED to be on LED Name Variable Name Register A Logic for LED Turns Register B LED ON Bit PWR OK Power DRV_FLT 202 m 1 green when the PMI Supply OK ol supply is OK PMI Processor OK DRV_STAT 200 1200 1 green when the PMI PMI Processor 5 processor is OK COMM OK DRV_FLT 202 1202 1 green when the Communications 5 communications OK between the UDC and PMI is working OK and DRV_STAT
48. windows bar charts and or diagnostic screens e Section Screen This screen allows users to control drives by modifying their setpoint values or by executing simple commands such as Jog Run and Stop Speed and Draw SPAD Screen This screen allows users to calculate draw values using variable data e PMI Diagnostic Screens These screens display the status of card LED s on the Power Module Interface PMI racks GV3000 and FP3000 drives don t have PMI racks with diagnostic LEDs In addition to an illustration a grid of alarms and faults appears for reference All of the screens in this chapter are configured using the Overview Screen Configuration Utility For more information on this utility refer to Chapter 6 Configuring the Drive Overview Screen and Support Screens in the SIGMA Developers Manual The Drive Overview Screen SIGMA Universal Operator Interface 07 12 94 07 49 Entry Speed 0 0 ea Process Speed 0 00 E Delivery Speed i a Setpoint Section Figure 6 1 The Drive Overview Screen ia Clicking the Overview option from the Main Menu displays the Drive Overview Screen as shown in Figure 6 1 The Drive Overview Screen allows users to monitor the current status of the displayed drives The following documentation covers the features common to the Drive Overview Screen only Screen Description The Drive Overview Screen is divided into five parts Header Se
49. 0 Parallel Diagnostic Screen s sesssesseeseesseesseseesseessesrrssresseser 6 17 6 1 2 9 The FP 3000 D C Drive Diagnostic Soteet seccnossiisiciii iisi 6 19 6 1 2 10 The PMI SAS 100 Diagnostics Screech 6c ss scsasssscessausncssiaisnccansasseceoussaccranss 6 21 6 1 2 11 The AB1336 Drive Diag ostics Sereen iasiss sess sev sssccascencieeowaivaransecsavisvaveets 6 24 6 1 3 Changing the Setpoint Value for a Section ss sessseessesesseesseserssresseserssressesee 6 26 62 The Section oee senec anenee enai en cas bscusatragiveate Enee ETa aR TAE RER TATER A 6 29 63 The SPAD Speed and Draw TOI esa cdcssssacoincznstionecdonyosdeseatensasiucnessbarenedusvnsnadves s 6 31 6 3 1 Selecting Sections Tor Caloulation 55 ods csseccanvnsdocapsiascesensvascnsstaccuanmephesennssdectaeis 6 32 6 3 2 Calculating Draws eeens esa ieie opens eave Tirek ra raoin ERSE PER ENEE Eaa EE Saia EREA 6 33 6 4 SLE T e E E E E N ey E OE EE E EE EEA 6 33 Chapter 7 Using The SIGMA NE Recipe System cccsasesssubinusivsresssesacrnnsenddansesunnsetivetiwsesounses 7 1 Al Chapter OVErVIEW crseiscisresiincisorisesseseat arm ae ee 7 1 La Editing Reini eein a a a aE E ET SE EEEa 7 3 721 Browsing Recipe E00 ieor iiuna eni E R i aE 7 4 122 Browsing Stored RECIPES ars lt aaccaasinctssivns casesicceransnansnscsnaninacenesadacneenedecuserntatansnsveconens 7 4 7 2 3 Editing an Existing Recipe or Entering a New Re
50. 1 Bottom Conveyor a N 495 96 SA 5214 Ready First Pr ss 2 Payoff Reel ccoo Ow O r L mu Ready 2 Top Conveyor a ES 52 92 tarmen a a 2 Bottom Conveyor Ready D 502 40 20 34 51 26 _Ready E neons Ou OAL gy mee 2 Bridle Ready NONE gt SS 49 67 em pa 1 Entry Looper D 500 48 49 99 48 01 Rean Crawl Furnace Entry Dancer Roll 5 Ready PO rem 503 13 EA 48 42 Blais rean Figure 2 3 Full Screen Figure 2 4 Full Screen with Pop Up Overlay Typical screens for the SIGMA NE system are Trending Screen Snapshot Screens Recipe Editor and Management Screens Alarm Fault Summary and History Screens Drive Overview Screen and Support PMI Diagnostics and Section Control Screens Application Specific Screens Process Overview Tracking and Auxiliary Control Each screen is comprised of panels that group information so that the user can find it easier Standard screens include the following components Program Title Bar Pull down Main Menu Rockwell Automation Logo Screen Title Date Time Bar The use of color on screens has been purposely limited so that colors convey the following information red means that a fault has occurred e yellow means that an alarm has occurred green means running Refer to section in the Drive Overview for more information on these states Describing Screen Objects Screen Panels may include the following object
51. 2 DEV_DIAG3 DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 Register A Register B Bit 204 1204 0 220 1220 0 221 1221 0 204 1204 1 220 1220 1 221 1221 1 204 1204 2 220 1220 2 221712212 204 1204 3 220 1220 3 221 1221 3 204 1204 4 220 1220 4 221 1221 4 204 1204 5 220 1220 5 221 1221 5 Fault Red on IGBT Schematic When Phase U upper power device detects an ovet current Phase V upper power device detects an ovet current Phase W upper power device detects an ovet current Phase U lower power device detects an ovet current Phase V lower power device detects an ovet current Phase W lower power device detects an ovet current Unit x IGBT Number Phase U Current Sharing Phase V Current Sharing Phase W Current Sharing Where x 1 2 or 3 Variable Name DEV_DIAGx DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 Register A Register B Bit Position 204 1204 13 220 1220 13 221 1221 13 204 1204 14 220 1220 14 221 1221 14 204 1204 15 220 1220 15 22171221 15 Alarm Yellow on IGBT Schematic When Unit x detects a problem with current sharing on phase U between power modules Unit x is not carrying its share of the phase U current Unit x detects a problem with current sharing on phase V between power modu
52. 4 SA3100 ia etiGsties Screenin a ana a a a e a n 131 Figure 6 15 The B 1556 Diagpostcs Scree ragsptotesassanesseauanduttevened an tatovaussauansansandusasoredlacseates 134 Figure 6 16 A Section Control Window with a Slider Bat i csscchacseoeeadvasvabavedudonlosstocasesssabdincss 136 Figure 6 17 The Section Sere er isi e i a e E aa ae a eaa ENa Ea aA 139 Figure 6 18 The SPAD Speed and Draw Screen sessseesesrseeeresrertsrrsrtsiestsresreseerenresteetssesrestese 141 Chapter 7 Using The SIGMA NE Recipe System Chapter Overview The SIGMA NE Recipe System is designed to ease setup and operation of a process line A recipe is a set of setpoints or references for various production parameters such as line speed section draw section tension section position temperatures etc These values are referred to as Recipe Elements The SIGMA NE Recipe System lets the user prepare and download recipes to the control system and then monitor any change in the setpoint values that might occur These reference setpoints can be changed by the SIGMA NE user the process line operator or by the controller The SIGMA NE Recipe System also lets the user capture changed setpoints as a recipe to be used at a later time The SIGMA NE Recipe System is made up of two main screens the Recipe Editor Screen the Recipe Manager Screen These screen titles and the following column titles and push button captions used in this chapter are developer
53. 5 pf o Pat Comm al If there is no communication with the PMI rack the purple cross mark is displayed on the diagnostics screen see Figure A 3 3 4 2 LED Lights The following table lists the LED names their associated suggested variable names register bit positions and logic for the LED to be on LED Name Variable Register A i LED Turns Name Register B Bit Position Power Supply PWR OK Power DRV_FLT 202 1202 12 green when the PMI power Supply OK is OK PMI Processor DRV_STAT 200 1200 15 green when the PMI ae Processor processor is OK COMM OK DRV_FLT 202 1202 15 green when the Communications communications between OK the UDC and PMI is working OK and DRV_STAT 200 1200 15 PM FLT Power DRV_FLT 202 1202 0 red when either a DC Bus Module Fault Over Voltage Fault a DC Bus Over Current Fault an Instantaneous Over DRV_FLT 202 1202 1 Current Fault Local Power Interface Fault a Charge DRV_FLT 202 1202 3 Bus Timeout Fault or an Over Temp Fault occurs DRV_FLT 202 1202 4 DRV_FLT 202 1202 6 DRV_FLT 202 1202 7 EXT FLT DRV_FLT 202 1202 2 1 red when either Ground External Fault Current Fault a Charge Bus Time out Fault a DRV PET 202 1202 6 i Power Loss Fault or a user configured fault occurs DRV_FLT 202 1202 10 1 IO_CNTRL 101 1101 2 1 RAIL FLT DRV_WRN 203 1203 13 red when a rail fault is Rail Comm Fault detected Resolver and Drive I O Feedback OK RPI
54. 9 Pop Up Keyboard escoissen a 7 16 Figure 7 20 Add Recipe Confirmation Pop Up Beis s cssescssassoesaisacosnevasestsaasssbacnpssnseaneesbansebains 7 17 Figure 7 21 Overwrite Recipe Confirmation Pop Up Boi viseisiscssacisssegccsitasscansavadeisiestuonsenssanaten 7 17 Figure A 1 The SD3000 Diapnostie Sereen cecenii iiis a aa NE A 2 Figure A 2 SD3000 Regen Diapnostie Sereen isiin iian iiai E a A A 2 Figure A 3 Diagnostics Screen When No PMI Communication OCCUFS eseeseeseseseeeereereresrereeree A 4 Figure A 4 The A3000 Diapnostic Sereen sisisi iia ana E E A A 8 Figure A 5 The SA3000 Parallel 3 Diagnostic Seredi oseraies a A 16 Figure A 6 The SB3000 Parallel 3 Diagnostic Serem nininini i a A 28 Pigure A 7 The SA00 Diapnostie SCi eeraa a ia A 39 Figure A 8 The GV3000 A C Drive Diagnostic Sereen ensecuiienoiiiiiia taiii A 43 Figure A 9 The FP3000 D C Drive Diagnostic a sa os casccasnsses aiidis aia A 46 Figyte A 110 SA00 Diapnpste EEN rrii ea EE E a EE E EE A 51 Figure A T ABIS 56 DEGNO UCS SCEN oracin rasani EEE EEEE ANAE E TIRAS A 61 Chapter 1 Introducing the SIGMA NE Universal Operator Interface and the SIGMA NE Universal Process Monitor This chapter introduces SIGMA NE Universal Operator Interface UOT and Universal Process Monitor UPM systems and the hardware required for these products This chapter describes specifically a typical SIGMA NE configuration vatious UPM UOI screens SIGMA NE Operator Interface Warnings and Responsib
55. AT 5 1 green when the auxiliary input 5 is Auxiliary input5 present AUX OUT IO_CNTRL 4 1 amber when the auxiliary output is Auxiliary output on Power Technology OK DRV_FLT 11 green when the DC power DC Power technology is working OK Technology 3 1 3 SCR Schematic The following is the list of variables to show an SCR Alarm or Fault The standard screen looks at the following bit positions of the SCR diagnostic register to determine which SCR has been affected by the Alarm or Fault The color on the SCR schematic changes ONLY when both an SCR bit has been set and either the SCR Alarm bit DDRV_WRN or SCR Fault bit DRV_FLT has been set SCR Number Suggested Variable Name Bit Positio SCR_DIAG SCR_DIAG SCR_DIAG SCR_DIAG SCR_DIAG SCR_DIAG SCR_DIAG SCR_DIAG SCR_DIAG SCR_DIAG n o SCR_DIAGY eo SCR_DIAG SCR numbers 11 16 are available on the SD3000 Regen Diagnostic Screen only 3 2 Troubleshooting The SA 3000 Diagnostic Screen The standard SA 3000 see Figure A 4 Diagnostic screens use the following registers and bit positions for Fault boxes LED lights and the IGBT schematic information needed Note It is the responsibility of the person configuring the AutoMax software to make sure the correct information is configured within these variables SIGMA Universal Operator Interface PMI 543000 Diagnostics Help Return O SA O DC Bus No PMI Over Yolt Comm
56. Bus by writing the value of of power level in parameter 178 Other symptoms that can cause Bus Overvoltage are loose connections to the drive at the motor within the drive or within the power cabling that cause arcing When the voltage spike produced by the arc is greater than the drives overvoltage trip threshold the drive will fault Another possibility is Bus Capacitor failure One or more capacitors have been stressed to the point of dielectric breakdown within itself This can also cause arcing within the capacitor Transistor UC_FAULT 2 1 Desaturatio n 12017 Hard fault Red LED Ground UC_FAULT 2 2 Fault 12018 Hard Fault Red LED This fault will occur when the drive has sensed an excess voltage drop across Collector and Emitter of one of the IGBT transistors after it has been commanded to turn FULL ON The Gate Driver Board sensing citcuits have measured in excess of 8 to 20 VDC across the collector emitter junction which should typically be 1 to 3 volts VDC drop When this condition occurs the drive coasts to a stop regardless of the selected stop type Suggested Action Run the power structure diagnostics Check for a shorted motor or motor wiring If the drive faults again consider changing the Gate Driver Power Supply Board If the Transistor Diagnostics tests do not indication which transistor is causing the problem replace all IGBT transistor modules in the inverter section Replace the drive
57. Center Recommended Spares Because of the importance of the SIGMA Server communication with the ControlNet Network it is recommended that a spare ControlNet interface card optionally a PC Link card for DCSNET be purchased with a SIGMA NE system Local Drive Solution Contact Directory New England Southeast Gulf Coast West Coast Ph 508 357 8431 Ph 770 277 0277 Ph 281 233 0300 Ph 626 969 7647 Fax 508 485 5059 Fax 770 682 6491 Fax 281 233 0101 Fax 626 334 8320 Boston MA Atlanta GA Houston TX Los Angeles CA Eastern Carolinas Midwest St Louis MO Ph 732 225 1360 Ph 704 525 1455 Ph 630 860 1090 Ph 314 770 0168 Fax 732 225 7833 Fax 704 525 9025 Fax 630 787 0309 Fax 314 770 0268 Edison NJ Charlotte NC Chicago IL St Louis MO Ohio Valley Great Lakes North Central Ph 513 943 1145 Ph 440 604 8421 Ph 651 633 8015 Fax 513 943 7438 Fax 440 604 8437 Fax 651 633 7181 Cincinnati OH Cleveland OH Minneapolis MN From a network of Local Drive Solution Centers located throughout the country Rockwell Automation can provide you with an adjustable speed drive custom engineered to meet your specific machine or process requirements Each Regional Center is fully staffed with experienced application and control engineers providing a single source for all your drive and automation needs utilizing the Rockwell Automation family of related products The problem solvers at each Local Drive Solution Centers form a team of highly qualifie
58. DRV_FLT 200 1200 15 PMI PS Power Supply Fault 202 1202 12 This can either be a fault or a warning A fault is set when the DC bus voltage exceeds the rating of the Power Module A warning occurs when the DC bus voltage rises above the configured overvoltage threshold value The torque is automatically limited to avoid an overvoltage fault A warning occurs when the DC bus voltage drops below the configured undervoltage threshold value The torque is automatically limited to avoid a further drop in the DC bus voltage A fault occurs when the fiber optic communication between the PMI processor and the UDC module is lost due to two consecutive errors of any type This fault occurs when the PMI power supply is not working correctly DC Bus Over DRV_FLT 202 1202 1 This fault occurs when the DC bus Current Low current exceeds 125 of the rated Bus Fault Power Module current Error code 1020 will be displayed in the error log of the UDC task in which the fault occurred Ground Current This can either be a fault or a Fault or Warning warning DRV_FLT 202 1202 2 A fault condition occurs when ground current exceeds the rating of the Power Module Error code 1021 will be displayed in the error log of the UDC task in which the fault occurred DRV_WRN 203 1203 2 A warning occurs when the ground current exceeds the configured ground fault current level stored in local tunable GIT_E1 PMI Bus Fault DRV
59. ESE 84 4 6 1 Selecting Variables with the Export Utility 0 0 ccc ceccceceeeeeeneeceeeeeeeeeeeenseees 92 4 7 DUNN ANAT ier seca eee Bence ts as a aa as eg Sea ew nan on aaa ew eee Naess 93 Figure 4 1 The Go Snapshot Configuration Window sc iccilvdeie oes ccataantecehaceventedbe canine etoaerecs 73 Fig te 4 2 The Go Windowsni era A a AA A T a n 75 Figute 4 3 Camu WNdOW nrin siina E eae deve nie care EE EAE E E A EEE 71 Pigure 4 4 The Trigger WindoWrssriesriieni Nei iae a e AE EE aiden 78 Figure 4 5 The Snapshot Pile Maintenance Scicetis ciceccteuist waar Steve reaateesaieipes Abaervte does cs 79 Figure 4 6 The SIGMA Snapshot Export Utility Screen cecsessessscssscsescssecesesssesessssosescasones 84 Chapter 5 Alarms and Faults System This chapter describes the SIGMA NE Alarms Faults System Two screens make up the SIGMA NE Alarms Faults System They are The Alarm Fault Summary Screen This screen displays alarms and faults that have occurred most recently and that have not been acknowledged Users are notified that an exception has taken place when the main menu bar of the SIGMA turns red By accessing this screen a user can locate where the alarm or fault occurred and acknowledge it happened The Event History Screen This screen displays operator actions as well as alarms and faults This screen is used to review the exceptions that have occurred in the past By accessing this screen a user can select filter parameters for recordin
60. Element cell e g Press Draw is highlighted the pop up keypad is displayed for data entry see Figure 7 3 If the data entered through the keypad is invalid then a pop up Edit Data message box see Figure 7 4 displays the valid range for the recipe element being modified Save Recipe As Name Figure 7 2 Pop Up Keyboard PRESS DRAW a s e 2s ol Clear Cancel Ok Figure 7 3 Pop Up Keypad A N 753 is an invalid entry Valid range is 200 to 200 Figure 7 4 Pop Up Edit Data Message Box Editing Recipe Files At the top of the Recipe Editor screen there are seven Edit Function buttons and a Load Next button see Figure 7 5 The following table lists each button its description and procedure Edit Functions Figure 7 5 Edit Function and Load Next Buttons Push button Description Loads default recipe element values defined by the recipe during the design of the SIGMA NE Recipe System into the Edit Field column To load default recipe values 1 Click the Default push button The default recipe values are loaded into the Edit Field column Copies a selected recipe into the Edit Field column for modification or as a Starting point for new recipes To copy a recipe l Click Copy Push button The Copy Recipe box see Figure 7 6 is displayed Copy Recipe j Figure 7 6 Copy Recipe Box Click the L Push button
61. F u I l s creen Variable count Samples per variable Trend Full Screen Go File Maintenance Trend AlmjFit Snapshot Export SIGMA Univ Alarm Fault Summary 07 07 95 10 37 dge Time Export gt Full Screen Full Screen Figure 2 8 Accessing Other Screens From The Alarm Fault Summary Screen Main Menu Additional screens may also be accessed by clicking on buttons For example pressing the First Press Section Drive button from The Drive Overview Screen lets you access the First Press section control popup box SIGMA Untversal Operator Intertace Overview Screen rit Qverview Secilon SHAD Lraket trend miit Hepar gnapchat duit 07 07 95 13 29 Paring speru 502 14 pima Paana ae 423 SIGMA Univerzal Operator Intertare Overview Screen lt Overview Secilon SPAD Lake trend amp mAit Hepar gnapchat Quite 07 12 95 15 04 farine Spent 508 26 im praana raae 423 Figure 2 9 Accessing Pop Up Box from Drives Overview First Press Button For example pressing the First Variable in this case A2 B11 CUR button from the Trending Screen lets the user access that Variable Name and Description popup box f SIGMA Universal Process Monitor Trend Screen Memory Trigger Interval Alm Fit Snapshot Printi Betum N SAT Us Deve Variable Name amp Description ja2 pn curs 0 Dridhe 1 motor current Center Value Current Value Currant Con
62. ICAL FUNCTIONS SUCH AS STOPPING THE CONTROLLED EQUIPMENT THE USER MUST DESIGN THE OPERATOR INTERFACE TO ENSURE THAT THE OPERATOR CAN RECOGNIZE AND ACCESS CRITICAL FUNCTIONS QUICKLY FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY WARNING THE USER MUST PROVIDE AN EXTERNAL HARDWIRED EMERGENCY STOP CIRCUIT THAT WILL DISABLE THE SYSTEM IN CASE OF IMPROPER OPERATION UNCONTROLLED MACHINE OPERATION MAY RESULT IF THIS IS NOT DONE FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY The SIGMA NE Universal Operator Interface UOTI permits an operator to control the operation of a wide variety of driven equipment through a personal computer The personal computer can be located anywhere on ControlNet network The specification location and function of the SIGMA NE Universal Operator Interface emergency disconnects guarding and other operating and safety devices must be determined by the user based on the user s knowledge of the design and operation of the driven equipment The user must also ensure that the specification location and function of these devices conforms to applicable safety codes These items are not determined by and are not the responsibility of Rockwell Automation Software Requirements a SIGMA Server iRMX Runtime License MS DOS version 6 0 or later Don t use double space SIGMA Kernel data acquisition system E SIGMA Client Microsoft Windows 2000 SIGMA Client soft
63. MING AS S caian eeraa E ERR E EE EEEE E ER 3 11 e eA Ue AE A E E E E 3 11 Dili Tistorical Mode neriesi a E AE E RAE EAAS 3 12 3 2 4 Saving Loading and Deleting Variable Data with Memory Option 3 13 3 2 5 OTe a Trend Graph ieies aana ae aun rE ERE ETAREN 3 16 3 3 The Trend Sereen Trigger Feature ac cecs ia seesinsdacencassncesvcudsecntes ssnneasbacducamsncasenstacanannnniees 3 16 3 4 PAE E A EAT E AE EE 3 21 Chapter 4 SITEN ON O01 rA A EAA E eeepc A 4 1 4 1 Snapshot Vere W seein a n i E EEE EE EE RRE E ERER Eei 4 1 I E A E E EE E 4 3 4 2 1 Configuring Go RN assosiere E E a s ii 4 3 4 2 2 Generating Go Snapshots sie sssisscsseriiriiiesisrinsridresisesiasirosisssasendenneta siise ss saisons en 4 5 4 3 Be PU AEN E E Minasscelese 4 7 dA Trigger Variable SAS ennnen innn a aR E i ERa 4 8 4 5 Snapshot File Maintenante occ es acins cen aziaaccseatneuezaansenusenncac onestnacosuaneasumenstuaseerntarcnnmmracanens 4 9 4 5 1 Deleting Local Files with the File Maintenance Screen cccccesceseeeereeeeees 4 13 4 5 2 Deleting Server Files with the File Maintenance Screen ccceeeeeeeeeeereeeeees 4 13 40 Suas hoi Epor U eicces aioin aar N E E E EEEE 4 14 4 6 1 Selecting Variables with the Export Utility s ssesessssessessseseessessresresseeseeseessee 4 22 4 7 SAURIA Li a AEA EES E T E gee a A E E A EA E EE 4 23 Chapter 5 Alarms and Faults System
64. NNAT eS ose A EEE SEE Sos os at Soest as aoa ORT Go ah ashen oe don ee 143 Figure 6 1 The Drive Overview Seree tas iiescaiytiaductisueetaig cantata ctydytoabeciaaae can jouatatinedyaedydeadocly aes 112 Figur 6 2 A Bat Chatt Window csi cscerci te segs Gas caees teases ar a a a e E EE 115 Figure 6 3 The Help Met naniii ate aa E A A N 118 Figure 6 4 TheHelp Pex teres seit tinnen inani ho aa a nada streets a a a 119 Figure 6 5 The Note Wind wWiicsrinnenereg ea aa a i a E a EA REE 120 Figure 6 6 The PMI SD3000 Diagnostics Screen iisic secdaossseeiseusdcoaioas easiest dabsccandeeasdeotseedversaces 121 Figure 6 7 The SD3000 Regen Diagnostics Screen sis c ceps cccessvsactecedenceiessncseccssostesstbesbectevoncdiesstees 122 Figure 6 8 The SA3000 Diagnostics Screen cass 1 csis cocscsavecsces soos deed loaseaea sosecibaas scodtbence laesunedseesiees 123 Figure 6 9 The SA3000 Parallel Diagnostics Scteetiss cysissssitesieess cveadssdesyeccssennase iesseucesonesdosseees 124 Figure 6 10 The SA500 Diagnostics Screen sis jetes tise secdandivens stasdeosebad cosseesedaduandserdennedcossbivcesdaves 125 Figure 6 11 The SB3000 Parallel Diagnostics SCreeri 2 01 s4cctath asaustaaread dada babnyssatauntiantandviteosyeradseares 126 Figure 6 12 The GV 3000 A C Drive Diagnostics Screen yilscltaivihamseteaducunphavediisadsalinememsenlonves 127 Figure 6 13 The FP3000 D C Drive Diagnostics Seren yi actactisdatJusasesenncst sees casas seoundatsoucaoasertconsian 129 Pioure 6 1
65. SIGMA NE Installation CD ccccsssccssscsssecssccesecessscessccssncesscessnsenes 22 1 7 4 Verifying SIGMA Client Communication With SIGMA Servet eeceeeeeeee 31 1 7 5 SIGMA C ene Quick Start arcena ena a ner bee suas a a A n a 32 1 8 Installing SIGMA Server Softwares c cc sc ccicvesceaiesecccsscasveecsde sais desduasetacensudsenastaas tease 34 1 8 1 Starting a SIGMA SEL VEL o nnee a e sven east auacee i it enone 34 1 8 2 Changing the SIGMA Server IP Address cccccccccssseesseeseceseceeeeeescecsaeenseeeenes 34 Figure 1 1 Typical SIGMA NE Configuration 0 0 0 0 ccc eseeccssecesecsseeceeceeeeeeseceaeceeeeaeeeeeseeeeaeenaes 14 Figure 1 2 The Alarm Fault Summary Screen aii 5hoei vases aia seine eaiinanes 15 Fig re 1 3 Eyent History ScreeM erein heini et aei tE ia oh Manes Womens 15 Figure 1 4 The Historical Trend Sere ni j sxcsssceazsasazadccessndedarvanehend dasauaaveasiateatanacdaasertuasdiatvnncabsiens 15 Figure 1 5 The Real Time Trend Screen s c ssseciesssecvagssedecty esas te dantecasavtecntisscsecavutdesstasesdovaacetecs 15 Figure 1 6 The AB 1336 Diagnostics Screen esssssesssssesetsesseseessssersessestestssesestssessesseseesessee 16 Figure 1 7 Line Run Permissives Summary sereen ss sssseseesessesesssssersesstsresesseseesesersesseseesessee 16 Figure 1 8 The Drive Overview Screen i ccccissscccsticscsciassicveciacesssseasscvectacvaccatsonsvistadeessctinavaaedaseeses 17 Figure 1 9 The Section Control Scree
66. ST PROVIDE AN EXTERNAL HARDWIRED EMERGENCY STOP CIRCUIT THAT WILL DISABLE THE SYSTEM IN CASE OF IMPROPER OPERATION UNCONTROLLED MACHINE OPERATION MAY RESULT IF THIS IS NOT DONE FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY ATTENTION THE CONTROLLER OPERATOR INTERFACE MAY BE USED TO PERFORM CRITICAL FUNCTIONS SUCH AS STOPPING THE CONTROLLED EQUIPMENT THE USER MUST DESIGN THE OPERATOR INTERFACE TO ENSURE THAT THE OPERATOR CAN RECOGNIZE AND ACCESS CRITICAL FUNCTIONS QUICKLY FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY Table of Contents For The SIGMA NE UOI UPM Operator s Manual Chapter 1 Introducing the SIGMA NE Universal Operator Interface and the SIGMA NE Universal Process MOmitor ccecccecsseesseceteceeeeeeeeeeeeesaeenseeeees 1 1 11 About SIGMA NE UOVUPM os secccssaniensssicianivipadeiasidiennsiaieiatcadiintinatdananaeeuole 1 2 1 2 About SIGMA NE Operator Interface Desigi ccscsssccsstccssscseccsecesssceeccssscesnces 1 8 1 3 A A E A E 1 9 L4 WM as Reguirememis iaoiaee EE EE RE EEEE RANEE Eii 1 9 1 5 Setting Upa SIGMA Client sca scecicoecnnacnacosvasdacesunseecanenseanoustanscennsedesumenstaaseerntansnsunrscaneis 1 9 l Setting Upa SIGMA SEryet en eee ere ee 1 9 1 7 Installing SIGMA Client SoftwafT iisisiscissiisisciriiiissisiesiereiissirsinsiissais seseris 1 10 1 7 1 Client T stallation Foss scan hess necie
67. SYSTEM AUTOMAX RACK FAULT BR1_FLT_TS BRUSH ROLL 1 STARTER FAULT ADC_OK_TS SYSTEM ANALOG CARD NOT OK BR1_FLT_TS BRUSH ROLL 1 STARTER FAULT Figure 3 4 The Memory Save As PopupWindow To save a trend graph of up to 4 variables in a variable configuration with the Memory option 1 Verify that the variable names for each of the four channels of the trend graph are the desired ones to be saved 2 Select the Memory option from the Trend Screen s Main Menu 3 When the four menu options are displayed select Save As The Save As popup window see figure 3 4 displays e the Save As entry box e the Existing Variable Configurations box the Current Settings Variable Name Description of the variable and Units of the four variables currently displayed on the trend screen e The OK and Cancel buttons 4 Enter a variable configuration name using the internal keyboard in the Save As entry box or click on an already saved variable configuration in the Existing Variable Configuration box 5 Click the OK button to save the variable configuration To exit the Memory Save option without saving the variable configuration click the Cancel button To load an available saved variable configuration to graph on the trend screen 1 Select the Memory option from the Trend Screen s Main Menu 2 When four menu options appear select Load The Load popup window see Figure 3 5 appears and displays e Available Variable Configuratio
68. Span Filter section is designed for specifying a date and time range This section contains the following items Use Time Span Filter check box Selecting this check box enables the date and time filters entered in the Begin From and To fields An X in this check box indicates the option has been enabled Begin From Entering a date and time in this field establishes the beginning date time of the range used for filtering events This field automatically defaults to the current date and time By placing the cursor in the field a date can be typed in DD MMM YY format and the time in HH MM SS format To adjust the date or time in small increments place the cursor in this field and use the Day Month Year Hours Minutes or Seconds arrow buttons To Entering a date and time in this field establishes the ending date time of the range used for filtering events This field automatically defaults to the current date and time By placing the cursor in the field a date can be typed in DD MMM YY format and the time in HH MM SS format To adjust the date or time in small increments place the cursor in this field and use the Day Month Year Hours Minutes or Seconds arrow buttons Day Month Year Hours Minutes Seconds arrow buttons These arrow buttons allow a user to make small adjustments to the date and time displayed in the Begin From and To fields By clicking the up or down arrow for any of the items the information displayed is adju
69. Summary Overview Section SPAD Broke Trend Alm FIt Report Snapshot Quit Line Run Permissives Summary 12 13 95 16 28 Entry Section _ _ _ _ __ _ Permissives Indicator Key _ GMB et selected _ WB not Met Selected HE Met HoT Selected Cleaning Area 7 NOT Met amp HOT Selected Tension Leveller Area l UEA Delivery Section Entry Miscellaneous DUNSA Process Section oy Bridle 4 Area J HEB Trim Inspection Areas __ ME Fomei a ees Quench Roll Area m eneon B OO Fumace2Area MB braz Area IBNL_Detivery Miscellaneous Water Cooling Area ei Process Miscellaneous Figure 1 7 Line Run Permissives Summary screen Drive Overview screens that display each drives load speed and status in either digital or bar chart format 07 12 94 07 49 Detivery Speed 0 0 fom EnuySpeed O 0 poy Procers Speed 0 00 pong Status Setpoint eed rension Load a E a wanina GUO _ Wokken M A I g O congre ueno M S g essun m i E gg os screws rcaov M titer warne 007 fest Teel C myc I 30s Eum Figure 1 8 The Drive Overview Screen Section Control screens that let the operator start stop jog thread and adjust individual drive operating setpoints 07 12 94 07 55 Eney Speed 0 0 pp ProcessSpeed
70. These quantities are modified using the Center Value and Unit Div options on the Channel window Scales and center points can be set at any time since these items are associated with the channel rather than the assigned variable If the range of variable values for a period of time is unknown it may be useful to inspect the graph after assigning the variables only to the channels Viewing the graph at this point helps to acquire a feel for how the plot of each variable might best be positioned and scaled This initial display generally gives hints as to how to use the Center Value and Unit Div options for positioning each of the plots on the graph and creating a useful display The scale most often chosen corresponds with the appropriate engineering units e g volts or feet per minute When the Center Value and Unit Div fields are used to change a channel s center point and vertical scale remember that changing one effects that particular channel only Choosing the most suitable values for these quantities may require some plot maneuvering to put the graph in a form which best displays the data For example when the scale and center are set the plot may be centered on the graph and it does not extend above or below the viewing area Changing either of the values may cause the plot to extend beyond the viewing area Therefore new scale and center values have to be chosen to correctly display the plot correctly again Note that choosing display
71. Troubleshooting The SA 3100 Diagnostic Screens The standard SA 3100 see Figure A 10 Diagnostic screens uses the following registers and bit positions for Fault boxes LED lights and the IGBT schematic information needed Note It is the responsibility of the person configuring the AutoMax software to make sure the correct information is configured within these variables SIGMA Universal Operator Interface PMI 543100 Diagnostics Help Return SA3100 DC Bus No PMI Over Volt Comm PT Fault 5 Fluz current loop integrator time constant is not within Reg 22211222 calibrated limits Rockwell Automation Figure A 10 SA3100 Diagnostic Screen 3 8 1 Fault Boxes The following table lists the SA 3100 fault names their suggested variable names register bit positions and under what conditions this bit is set Variable Register A Name Register B Bit Position DC Bus Over Voltage High Bus DRV_FLT 202 1202 0 No PMI Comm DRV_FLT 202 1202 15 and DRV_STAT 200 1200 15 DC Bus Under DRV_WRN 203 1203 1 Voltage Warning This can either be a fault or a warning A fault is set when the DC bus voltage exceeds the rating of the Power Module Error code 1018 will be displayed in the error log of the UDC task in which the fault occurred A warning occurs when the DC bus voltage rises above the configured overvoltage threshold value The torque is automatically limited to avoid an ove
72. User Manual SIGMA NE SIGMA NE UOI UPM Rockwell Automation Publication Date March 10 2003 This document applies to the SIGMA NE UOI UPM Rockwell Publication number 56AMXN UM001A EN P Revision Date Description V1 001 March 10 2003 Initial version V2 001 March 10 2003 V3 001 March 10 2003 V4 001 March 10 2003 V5 001 March 10 2003 V6 001 March 10 2003 V6 002 March 10 2003 V6 003 March 10 2003 Windows MS DOS Visual Basic Excel Access and FoxPro are trademarks of Microsoft Corporation Ethernet is a trademark of Xerox VAX VAXstation DEC and DECnet are trademarks of Digital Equipment Corporation In Touch by Wonderware is a trademark of Wonderware Software Development Corporation iRMX is a registered trademark of Intel Corporation IBM is a registered trademark of International Business Machine Corporation All rights reserved No part of this manual may be reproduced or copied in any form or by any means without written permission of the publisher The information in this users manual is subject to change without notice 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 IN ITS ENTIRETY BEFORE PROCEEDING FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY ATTENTION THE USER MU
73. V_DIAG3 221 f1221 7 DEV_DIAG1 204 1204 8 DEV_DIAG2 220 1220 8 DEV_DIAG3 221 1221 8 DEV_DIAG1 204 1204 12 DEV_DIAG2 220 1220 12 DEV_DIAG3 221 1221 12 Unit 2 GDI Gate Driver Interface Fault Unit 3 GDI Gate Driver Interface Fault nitl Charge Fault nit2 Charge Fault nit3 Charge Fault nit 1 Over Temp Fault nit 2 Over Temp Fault nit 3 Over Temp Fault This warning occurs when a GDI indicates that unit n detected a problem with current sharing between power modules A GDI indicates that unit x where x A B or C detected a problem with current sharing between power modules Unit 1 Intelligent Power Module fault is detected Unit 2 Intelligent Power Module fault detected Unit 3 Intelligent Power Module fault detected Unit 1 detects a problem with its Gate river Interface power supply Unit 2 detects a problem with its Gate river Interface power supply Unit 3 detects a problem with its Gate river Interface power supply Unit 1 detects a problem with charge time out Unit 2 detects a problem with charge ime out Unit 3 detects a problem with charge time out U nit 1 detects an over temperature U nit 2 detects an over temperature U nit 3 detects an over temperature The following logic table explains the Resulting Faults and LED states If Variable Name And Variable Name Resulting Fault or LED State DRV_STAT DRV_FLT 200 1200 Bit 15 202 1202 Bit 1
74. Warning Configurable Select parameter 88 to 1 To configure the alarm as a Warning set bit 1 in VP Fault Warning Configurable Select parameter 88 to 0 and set bit 1 in VP Warning None Configuration Select Parameter 89 to 0 To disregard the alarm set bit 1 in VP Fault Warning Configurable Select parameter 88 and VP Warning None Configuration Select Parameter 89 to 0 Motor Over Temperature Tripped 01050 UC_VP_FLT 5 2 Soft fault Red LED UC_VP_WR N Warning Yell ow LED Motor Overtemperature tripped This fault will occur when the high temperature switch located in the motor senses a high temperature condition and opens When this condition occurs the drive coasts to a stop regardless of the selected stop type Suggested Actions Check for possible motor overheating Ensure that the switch is actually open and the wiring between the switch and drive is not damaged Review the process to determine if something mechanical is causing an overloaded condition Ensure that the motor s cooling fan is operating correctly Inspect the motor and the power wiring located between the drive and the motor Conduct historical trending of the motor s current feedback to determine if overloaded conditions exist If the motor temperature is excessive reduce the accel decel times parameters 125 126 or reduce the load To configure the alarm as a fault set bit 2 in VP Fault Warning Configurable Select pa
75. X IN5 IO_STAT 201 1201 5 1 green when the auxiliary Auxiliary input 5 input 5 is present AUX OUT IO_CNTRL 101 1101 4 1 amber when the auxiliary Auxiliary output output is on AC Power Technology OK DC Power DRV_FLT 202 1202 1 green when the AC Technology 1 ane technology card is working OK 3 3 3 IGBT Schematic The following is the list of variables to show an IGBT Short Fault The standard screen looks at the following bits of the IGBT diagnostic register to determine which IGBT has been affected by the Fault The color on the IGBT schematic changes ONLY when both an IGBT bit has been set and the IGBT Short Fault bit has been set Unit x IGBT Number Phase U Upper Phase V Upper Phase W Upper Phase U Lower Phase V Lower Phase W Lower Where x 1 2 or 3 Variable Name DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 Register A Register B Bit 204 1204 0 220 1220 0 221 1221 0 204 1204 1 220 1220 1 221 1221 1 204 1204 2 220 1220 2 221 1221 2 204 1204 3 220 1220 3 221 1221 3 204 1204 4 220 1220 4 221 1221 4 204 1204 5 220 1220 4 221 1221 4 Fault Red on IGBT Schematic When Phase U upper power device detects an ovet current Phase V upper power device detects an ovet current Phase W upper power d
76. Y 2002 Delete Server 15_15_22 snp 845786 10 NOY 2002 15_13_10 snp 15_15_41 snp 845786 10 NOY 2002 Refresh Figure 4 5 The Snapshot File Maintenance Screen Clicking File Maintenance from the Snapshot pull down menu displays the Snapshot File Maintenance Screen as shown in Figure 4 5 This screen allows users to view retrieve and delete server snapshot files This screen also allows users to delete or access local snapshot files via the Snapshot Export Utility refer to section 4 6 Screen Description The Current local snapshot files section of the Snapshot File Maintenance Screen displays three fields for the selection of local snapshot files Local Snapshot drive Allows the user to select the disk drive where Snapshot File Maintenance looks for local snapshots When a new drive is selected the directories which are found on that drive appear in the local snapshot directory list see Figure 4 5 To select a drive click the arrow at the right side of the field to display a list box containing all available drives and then click the desired drive Local Snapshot directory Allows the user to select the directory on the selected drive where the Snapshot File Maintenance looks for local snapshots When a new directory is selected the snapshots which are found in that directory appear in the local snapshot file list see Figure 4 5 To select a directory click the desired name If more directory names are found than can fit in t
77. _FLT 202 1202 13 This fault occurs when there is a bus fault in the PMI rack This is indicated when the Resolver amp Drive I O module and the AC Power Technology module do not respond to requests from the PMI processor PMI Fan Loss DRV_WRN 203 1203 12 The PMI Fan Loss Warning bit is Warning set when the airflow through the PMI rack is not being sensed IOC DRV_FLT 202 1202 3 This fault occurs when there is an Instantaneous overcurrent in one of the power Overcurrent devices Fault Registers 204 1204 bits 0 5 indicate which power device detected the overcurrent Bit 6 of register 204 1204 will also be set if the overcurrent was detected in the Intelligent Power Module Resolver Fault UDC Run Fault AC PTM Power Technology Module Fault LPI Local Power Interface Fault CCLK Not Synchronized Warning Over Speed Fault DRV_FLT DRV_FLT DRV_FLT DRV_FLT DRV_FLT DRV_WRN DRV_FLT 202 1202 8 202 1202 9 202 1202 14 202 1202 11 202 1202 4 203 1203 14 202 1202 10 This fault is a combination of Fault Register 202 1202 bits 8 and 9 Bit 8 is set if a sine or cosine signal from the resolver is missing due to a broken wire or the resolver gain tunable RES_GAN has been set too low Bit 9 is set if a blown fuse is detected on the Resolver amp Drive I O board The UDC Run Fault bit is set when the UDC task stops while the minor loop is running in the PMI processor T
78. ables Graph means the collection of plots including the horizontal and vertical scales and labels Thus a graph simultaneously shows the plots for all of the selected variables Screen means the entire CRT display including the graph and menu Trending Overview Trending demonstrates a general direction or movement a prevailing tendency or inclination It shows the movement in a course of time for a statistically detectable change such as a variable value fluctuations The graph produced by the trending process shows the statistical curves reflecting such a change The Trend Screen creates such a graph using four user defined variables This graph is designed with plots of real time data collected over a specified time period A user can create a graph with the plots from a past time period or with the plots that are currently being collected The UPM has access to data for hundreds of variables during a period of up to 48 hours prior to the current time The Trending Menu The Trend Screen does not use the standard UPM menu The following items are available from the Trend Screen s Main Menu Memory This option allows users to store the parameters selected in the Trend Screen Trigger With this option users can create triggers used for monitoring the status of a particular variable Interval This option provides a list of time intervals from which a user can select the interval used to draw the graph Alm Fit A user can en
79. ace the adapter board Cable interlock between the Master and Slave drive was opened The motor speed has exceeded the speed limit plus Absolute Overspd parameter 90 settings When this condition occurs the drive coasts to a stop regardless of the selected stop type Suggested Action If operating in torque mode check if the load is allowing excessive motor speed Check if the setting of Absolute Overspd parameter 90 or the speed limits parameters 127 128 are too low Analog Power Supply Tolerance 03026 Autocomm Transistor Diag Failure 12027 Inverter Temperature Trip 02028 UC_FAULT 2 10 Soft fault Red LED UC_FAULT 2 11 Soft Fault Red LED UC_FAULT 2 12 Hard fault Red LED The analog supply tolerance voltage is outside of the 13V to 18V range When this condition occurs the drive coasts to a stop regardless of the selected stop type Suggested Action Possible overloading of the analog 15V power supply Check whether a ScanPort devices is loading the supply by disconnecting them one at a time Or if a Standard Adapter board is part of the drive temporarily remove the L Option interface board Or Change the adapter board Possible faulty analog 15V power supply The power supply gate driver board or the main control board may require replacement The drive encountered a problem while running the auto tune tests When this condition occurs the drive coasts t
80. al is open Check external interlock between terminals 16 and 20 Parameter Non DRV_FLT1 12 9 Failure on write to non volatile memory Bad Volatile Memory NVRAM Failure DRV_FLT1 12 13 RPM is above 130 maximum speed DRV_FLT1 12 7 Cooling fan failure Electronic Thermal DRV_FLT1 12 6 Power module overloaded Overload Network Comm DRV_FLT2 13 0 Communications with the AutoMax network Loss has been lost Drive Not DRV_FLT2 13 3 Drive parameters have been restored to Identified power up defaults Regulator has not been configured to match Power Module Power Unit DRV_FLT2 13 6 Power Module Overloaded Too high D C Overload Braking Voltage H 007 or Torque Boost Z y CE Missing P U ID DRV_FLT2 13 9 Bad or disconnected cable between Regulator Connector and Power Module Encoder Loss DRV_FLT2 13 12 Drive is not detecting feedback from the pulse tachometer Precharge Relay DRV_FLT2 13 1 Failure High Line Voltage DRV_FLT2 13 4 Input line voltage gt 15 above value of line voltage Earth Current DRV_FLT2 13 7 Unintentional Grounding Failure ground fault Unselected Power DRV_FLT2 13 10 Drive started but identification Unit Result zero Fatal Unexpected DRV_FLT2 13 15 Indicates a fatal fault occurred before power Error was lost Contact Rockwell Automation or observe the drive for subsequent fatal errors before turning off power Fatal fault codes are lost after power loss High Time ID DRV_FLT2 13 2 Identifica
81. al snapshot file displays its snapshot information in the Local snapshot data section of the screen Use this information to locate the local snapshot file to delete 4 Once the file is highlighted click the Delete Local File push button The file is deleted from the hard drive These steps can be repeated as often as needed IMPORTANT If the file selected using the steps above needs to be exported instead of deleted use the Goto Export push button Deleting Server Files with the File Maintenance Screen The following are the steps for deleting server files with the Snapshot File Maintenance Screen 1 Enter the Snapshot File Maintenance Screen 2 Select the appropriate file in the Server snapshot files grid 3 Clicking the snapshot file displays its name in the Delete Server File push button 4 Once the file is selected click the Delete Server File push button The file is deleted from the server These steps can be repeated as often as needed Snapshot Export Utility SIGMA Snapshot Export Utility v2 0 1 Available snapshots snap5 snp snap6 snp la scsi Export destination tive tape drive ld scsi_1 Export format Excel XLS Access MDB Binary SNP Export options X Delete snapshot i File name SNAP1_XLS 0 30 MB Snapshot file name d snap1 snp Variable count 478 Trigger time 8 31 94 10 09 46 AM Snapshot duratio
82. al warning Warning Yellow while the drive continues to Fault Red Feedback Loss Inverter Over Temperature Pending Motor Over Temperature Tripped Motor Overload Pending Motor Overload Tripped Motor Stalled External Fault RMS Fault Dynamic Brake Over Temp Inverter Overload Pending Inverter Overload Tripped operate For more information on this diagnostics screen information refer to section A 9 Troubleshooting With The AB1336 Drive Diagnostic Screen Changing the Setpoint Value for a Section SIGMA Universal Operator Interface 07 12 94 07 54 Delivery Speed 0 0 z7 Entry Speed 0 0 eka Process Speed 0 00 FPM Section Status Figure 6 16 A Section Control Window with a Slider Bar Under Development LEE ia Clicking a push button in the Section column of the Drive Overview screen refer to Section 6 1 displays a Section Control window An example is shown in Figure 6 16 This window allows a user to assign the section a setpoint value and or use a push button to control a drive The push button names and functions are application specific For example a paper line may use the names Run Crawl Jog Fwd Jog Rev and Stop for the functions needed A setpoint value is used to adjust the drive to either a desired speed load tension draw etc This value corresponds to the Setpoint column of the Drive Ov
83. ange interval Click lt lt and the date time range interval shifts the graph ahead one time interval set with the time interval option Click lt 4 and the date time range interval shifts the graph ahead 1 4 of the time interval set with the time interval option Click and the date time range interval shifts the graph behind 1 4 of the time interval set with the time interval option Click gt P and the date time range interval shifts the graph behind one time interval set with the time interval option To enter text click the data entry box twice and the internal keyboard see Figure 2 5 is displayed Enter text using the internal keyboard and then click OK Internal Keypad if enabled To enter values click the data entry box twice and the internal keypad see Figure 2 6 is displayed Enter values using the internal keypad and then click OK ele 10m Figure 2 6 Internal Keyboard Accessing Screens The UOI UPM menu bar at the top of the screen varies with the specific application The function of this menu is to access other screens A UOI menu usually also include UPM elements such as Trending Alarm Fault and Snapshots All UOI UPM screens except the Trending Graph screen display the same menu at the top of the screen The Trends menu elements access popup and full screens that specify parameters necessary for trending If elements of the menu end with an exclam
84. ar List Box with Vertical Scroll Bar Variables not to export Option Radio Buttons State C armed disarmed Check Boxes Export options G Delete snapshot To enter a value click and drag the button up or down the scale to the approximate value you want to enter The set entry box above displays this approximate value To select a variable Click the Up Arrow or Down Arrow V button to scroll up or down the list The middle button tells you where you are on the list Click the element of the list to select it To select an option click the O or the text beside it and when the option is displayed as then that option is selected To select an option click the box O or the text next to it and when the option is displayed as x then that option is selected Inc Dec Buttons to increment or decrement entered values gt le Date Time Range Interval Buttons for trended values 44 4 Jul 10 1995 14 28 39 gt gt gt Jul 10 14 28 38 Jul 10 14 27 38 Jul 10 14 26 38 Jul 10 14 25 38 Jul 10 14 24 38 Jul 10 14 23 38 Internal Keyboard If enabled Save Recipe As Name Tiles s eLelr ele 0 ke fr fsfefel To nye Le shir z klel leihin Figure 2 5 Internal Keyboard To enter change values Click the Up Arrow A button to increase the displayed value Click the Down Arrow V button to decrease the displayed value To change an r
85. ard Clear Cancel Ok Figure 7 17 Pop Up Keypad 2 Modify the setpoint value using this keypad If the Clear push button is clicked all keypad entries are cleared from the display If the Cancel push button on this pop up keypad is clicked no action is taken 3 After modifying the setpoint value click the OK push button If the new value is within limits set by the drive system software then it is downloaded to the drive system When the new value has been accepted by the drive system it is displayed in the Setpoint column If the value is not accepted a pop up box see Figure 7 4 displays the valid range for the recipe element Capturing Setpoint Values As a Recipe The Capture push button see call out G in Figure 7 13 allows the values in the Setpoint column to be stored as a recipe To capture setpoint values Capture Recipe 1 Click the Capture push button Save Recipe As The Capture Recipe pop up window see Figure 7 18 appears allowing the user to enter a new recipe name ot overwrite a currently stored recipe name listed in the pull down list To enter a new recipe name 2a Click anywhere in the Capture Recipe box and the pop up keyboard see Figure 7 19 allows the user to enter the recipe name by either pointing device mouse or trackball or using a hardware keyboard If the Cancel push button is clicked no action is taken If the Clear push Figure 7 19 Pop Up Keyboar
86. arning None Configuration Select Parameter 89 to 0 To configure the alarm as a fault set bit 11 in VP Fault Warning Configurable Select parameter 88 to 1 To configure the alarm as a Warning set bit 11 in VP Fault Warning Configurable Select parameter 88 to 0 and set bit 11 in VP Warning None Configuration Select Parameter 89 to 0 To disregard the alarm set bit 11 in VP Fault Warning Configurable Select parameter 88 and VP Warning None Configuration Select Parameter 89 to 0 An inverter IT overload is pending The inverter current has been in excess of 105 of Inverter Amps parameter 220 too long Continued operation at this load level will cause an overload trip Suggested Action Reduce the load or duty cycle if possible To configure the alarm as a fault set bit 13 in VP Fault Warning Configurable Select parameter 88 to 1 To configure the alarm as a Warning set bit 13 in VP Fault Warning Configurable Select parameter 88 to 0 and set bit 13 in VP Warning None Configuration Select Parameter 89 to 0 To disregard the alarm set bit 13 in VP Fault Warning Configurable Select parameter 88 and VP Warning None Configuration Select Parameter 89 to 0 Inverter Overload Tripped 02063 UC_VP_FLT Soft fault Red LED UC_VP_WR N Warning Yell ow LED Inverter IT overload The inverter current has been in excess of 105 of Inverter Amps parameter 220 too long Suggested Action Reduce the
87. asaacnersvcess A 63 List of Figures For The SIGMA UOI UPM NE Operator s Manual Figure 1 1 Typical SIGMA NE are tea oeiee a ee EEEa aneia EEan a 1 2 Figure 1 2 The Alarni Fault Summary Sieen iiics oin eiir ae aaa aaa ae Eaa Rea E ERREEN 1 3 Figure 1 3 a History Sereen oiiire A reai ei E aa aia aedini iia 1 3 Figure 1 4 The Historical Tread SOCED Fase ics cada ca tdscpccean ano cconsessnsendasacs pacenesusntavesennceiosbenlesuosias 1 3 Figure 1 5 The ked Time Teod SOCEM is iesssssicisismiccemi pace sieo eed cama 1 3 Figute 1 6 The AB 1336 Tears sireci ia a a e e A 1 4 Figure 1 7 Line Run Permissives Summary SOEN ia ci csiassascisssiecostgenscnasanssasedidoaenstdieasseniirationse 1 4 Figarte 1 8 The rive Overview Semeen ienn peirina A a T 1 5 Figure 1 9 The Secuon Control SOrCeN orinn ii a ar EE EE EE RSE 1 5 Fip re 1 10 Recipe Manager Sereen oroin uiaiia das E EE E ET i 1 6 Pipore 11 The Recipe Editor Sato isis casiaspafeinias beau a sdadatsssaieniwadacetaasbeaeeiadoaeaiaseanenieapaiowsiuns 1 6 Fipore 1 12 Process 1 eet oanret nanii a NE N RETEA EEE 1 7 ara FE FA AG E E A A 1 7 Figure 1 14 Rockwell Automation SIGMA NE UOI UPM window with Setup popup box 1 11 BT gate 1 15 Ni a Welcome Popup eei nsee iii E OERE 1 12 Figure 1 16 rt Uscr Popup Soei eei eea EA E AET 1 13 Figare 1 17 Tosiallaton lolotmaton Popup Sieh eirean 1 14 Figure 1 18 SIGMA Server Name and IP Address Popup Screen
88. atch Try a Drive Reset or power down and power up the drive and restart the drive If the fault occurs again consider changing the Main Control Board Make sure to set all dip switches and jumpers when replacing the board If the fault occurs after changing the Main Control Board consider changing the Master Slave Control Board Make sure to set all dip switches and jumpers when replacing the board Remember to clear a fault perform a Drive Reset ot power down and power up the drive D C Bus UC_FAULT 2 0 The DC bus voltage has exceeded the maximum value Over When this condition occurs the drive coasts to a stop Voltage regardless of the selected stop type 12016 Suggested Action The input voltage to the drive could be too high Monitor the AC line for high line voltage or transient conditions If the incoming power line conditions experience transient power interruptions or significant voltage spikes and or Power factor correction capacitors on line it is highly recommended to install isolation type transformers or AC line reactors before the input to the drive Increase the deceleration time or install the dynamic brake option because motor regeneration can also cause bus overvoltages Refer to the user manual for a description of Bus Options parameter 13 for additional information about bus overvoltages Another option is to limit the maximum power level that will be transferred from the motor to the DC
89. ation point then clicking that element lets the user directly access another full screen or popup box Elements without the exclamation point 1 when clicked display a pulldown menu of elements to select from Menu choices appearing in a light gray are not allowed from the current screen Figure 2 7 shows an overview of a typical UPM main menu and figure 2 8 shows the screens full and popup that can be accessed Main Menu SIGMA Universal Operator Interface Alarm Fault Summary vis gt Trend Alm Fit Snapshot Quit Alarm Fault Summary 07 07 95 10 37 Acknowledge Exception Time Message Clear or Acknowledge Time Bar Figure 2 7 Typical UPM Main Menu Bar Trend Alm Fit Smapshot Quit Event History 07 11 95 15 13 tac rier Ce T Clear Time Acknowledge Time 5 Snapshot Configure Time Span 20 Seconds C 100 Seconds 300 Seconds 5 min Confi OME OK Cancel Popup Box z Full Screen Go Event History Popup Box NIA MA mtetinne Weer NIA MA Untermes NIA MA umteimet NIA MA uwteiimet doh 14 1995 Ist gt TD Snapshot File Maintenance Current snapshot files c MS DOS_5 Ben sigmavb bitmaps recipe source Snapshot file name c sigmavb snap1 snp Trigger time September 8 93 13 34 52 File gt Trigger event Title ile Bile Ea Gide title Maintenance Tooge cose reson
90. base spreadsheet or binary file This chapter highlights the Snapshot process and discusses how to configure generate maintain and export snapshot files Snapshot Overview Snapshots are of three types Go Trigger Variable Capture Each type of snapshot differs as to when and how long an interval is generated Type of Snapshot Generated for the time interval specified Go immediately by the currently selected radio button in the Snapshot Configure window Capture at the most recent left most by the trend graph interval time currently on the trend must be 20 sec 100 sec or 5 graph minutes Trigger Variable when the trigger variable by the currently selected radio exceeds its high or low limit button in the snapshot time span portion of the Trigger window Snapshot files can be generated at any time The Snapshot option is located on the Main Menu Since only five snapshot files can be saved on the hard drive a user can delete any of the five snapshots stored that are no longer in use or export snapshots to third party software that you want to use at a later time This chapter discusses Go Snapshots Configuring and generating Go Snapshots Refer to section 4 2 Capture Snapshots Configuring and generating Capture Snapshots Refer to section 4 3 Trigger Variable Snapshots Specifying snapshot as the result of a trigger event Setting the Snapshot Time Span Generating the Snapshot Refer to section 4 4 F
91. ce Screen Delete Local File Click this push button to delete the local snapshot file currently selected in the Current local snapshot files fields Refer to section 4 5 1 Deleting Local Files with the File Maintenance Screen on deleting local files with this push button Goto Export Click this push button to use the SIGMA Snapshot Export Utility Screen to export local snapshots to other file formats Refer to section 4 6 for more information about this utility Return Click this push button to exit the Snapshot File Maintenance Screen and return to the previous screen Retrieve File Click this push button to retrieve the server snapshot file currently selected in the Server snapshot files grid Delete Server File Click this push button to delete the server snapshot file currently selected in the Server snapshot files grid Refer to section 4 5 2 Deleting Server Files with the File Maintenance Screen on deleting server files with this push button Refresh Click this push button to refresh the Server snapshot files grid to reflect the present snapshot files available on the server Deleting Local Files with the File Maintenance Screen The following are the steps for deleting local files with the Snapshot File Maintenance Screen 1 Enter the Snapshot File Maintenance Screen 2 Locate the appropriate file by selecting the drive directory and the file name in the Current local snapshot files section 3 Clicking a loc
92. cipe csccssescssscessereeenees 7 4 7 2 4 Editing Recipe File asa sexsstasscas ee pnie EAE EEEE EA S EE ERRi 7 5 is Mangana REPO eoni oe E a Ea NETA EE AAEN EE REE T 7 12 73 1 Prepanng The Next Recipe To RUNM san siesrisans iinan ie nE ERREA 7 13 73 Modifying Next Recipe Values Before Downloading eeeeeeeeereeeees 7 13 13 3 Downosdiny RECIPES rencas arin EE a EEE i Eiin 7 14 7 3 4 Modifying Setpoint VAER visini ei eee ra a oE AE EEAS 7 15 73 5 Capturing Setpoint Values As a RECIPC csscsssscsssccsenssesssosenssersecescesencens 7 16 Chapter 8 SIGMA NE SUG POLE einen E E R ER AEREE R 8 1 8 1 Recommended Spares sncrcca onasin N ee 8 1 Appendix A Troubleshooting With The Drive Diagnostic Screens ccceeceeseeeseeeteeees A 1 A l Troubleshooting The SD 3000 and SD 3000 Regen Diagnostic Screens A 2 A 1 1 AA E gig EE EEA N AE OEE E E A 2 A 1 2 LED LN egne A EE E EE A 5 A 1 3 L E E A EA I AE A A 7 A 2 Troubleshooting The SA 3000 Diagnostic Sereen ccssscssssinsccesssonsccraseeiassdancdentnente A 8 A 2 1 N EE e EE E E E E E E AT A 9 A22 LEOLE escasexcasrrciacsieacve eE AE EEE ENEE AN OEE EEOSE EE ESE A 13 A 2 3 TE Py NS rooien ER AEE eee A 15 A 3 Troubleshooting The SA 3000 Parallel A B and C Diagnostic Screens A 16 A 3 1 ATILE EE cake E E E E E N E E E T A 17 Boe LED LEMS ae EEEE E E E EEA E A 23 A 3 3 DRE BO MAING secina i onia ea r e aan aae ra ETS Eoia adanada a Diadasina A 26
93. ction This section contains two rows The first row displays a title bar with the Rockwell Automation logo and or the name of the applicable machine the name of the process line and a date and time display The second row contains a data display bar This bar can be configured to display up to three variables which a user wants to monitor regularly For example section speeds can be displayed A user can click the Rockwell Automation logo and view license information All of this information is display only Section column This column contains a scrollable list of drive section names 10 drive sections are displayed at a time The Drive Overview screen displays drive data for each drive section in the other columns of the screen which are described below A section name may appear as a display only inset panel or as a push button Clicking the push button displays the Section Control window for the drive section This window allows the operator to assign a setpoint value and perform various drive control operations e g jog start stop Refer to Section 6 1 3 for more information on section control windows e Status column This column displays the current status of each drive listed in the Section column The status e g Running Ready Faulted appears on a push button Clicking the push button displays the SIGMA drive diagnostic screen appropriate for the drive being monitored Refer to Section 6 1 2 for more information on the
94. ction containing the schema of the motoring current from the power module The three faults and the IGBT output devices within this section can either summarize all units or pertain to a specific unit Up to three units can be selected using these radio buttons To select a unit click the corresponding radio button For more information on this diagnostics screen information refer to Section 6 1 2 Viewing Distributive Power Diagnostic Screens For more information on the SA3000 drive refer to the AutoMax Distributive Power System manual S 3005 The PMI SA500 Diagnostic Screen SIGMA Universal Operator Interface PMI 54500 Diagnostics Help Return ESE DS Screws OK COMM OK P M FLT A ae oe AUX IH4 AUX INS AUX OUT RAIL FLT AutoMax FOBK OK RPI MCR AUX IH1 AUX IH2 Distributed Power System AC Power Module AANE pa Figure 6 10 The SA500 Diagnostics Screen The SA500 Diagnostics screen shown in Figure 6 10 displays diagnostic information for an SA500 drive On the left side of the screen is a pictorial view of the applicable drive faceplate which shows the status of the LED s on the appropriate drive section The lights show the states of the inverter circuitry the feedback device the drive I O and the communication link to the UDC module The right side of the screen displays a diagnostic grid showing status active or inactive of drive faults and alarms For more information on th
95. d button is clicked any text on the screen keyboard display is cleared 3a After the new recipe name has been entered in the text box click the OK push button The Add Recipe Confirmation pop up box see Figure 7 1 Figure 7 20 asks to confirm the selection 4a Click the OK push button to add the new recipe to the file The element values in the Setpoint column are stored as a recipe under the new recipe name To overwrite an existing recipe 2b 3b Click the EA push button to view currently stored recipes and then click the recipe name to be overwritten Click the OK push button and the Overwrite Recipe Confirmation Pop up Box see Figure 7 21 asks to confirm the selection Capture Recipe Add recipe to file Tissue Paper Figure 7 20 Add Recipe Confirmation Pop Up Box Capture Recipe Overwrite recipe in file News Print Figure 7 21 Overwrite Recipe Confirmation Pop Up Box 4b Click OK push button to overwrite the existing recipe in the file 7 1 Chapter OVE Vie We eniri oeann ia a a a a e a a is 145 Dede UVR COIS rines ine cles E a E E A AE 147 7 2 1 Browsing Recipe Elements 5 aaccats scucltesesdeac se Senses ve sdeatsauacates Noe ne esSuuce eta aveeens 148 T22 Browsing Stored Recipes nersini eian aE n EAEE T ATA a ESS 148 T 23 Editing an Existing Recipe or Entering a New Recipe eceeccesceteeeeeereeenees 148 7 2 4 Editing Recipe Files suiga
96. d current UDC Run Fault AC PTM Power Technology Module Fault CCLK Not Synchronized Warning LPI Local Power Interface Fault Power Module Overload Warning Power Loss Fault No PMI Power DRV_FLT DRV_FLT DRV_WRN DRV_FLT DRV_WRN DRV_FLT DRV_WRN 202 1202 14 202 1202 11 203 1203 14 202 1202 4 203 1203 9 202 1202 10 203 1203 10 The UDC Run Fault bit is set when the UDC task stops while the minor loop is running in the PMI processor This bit is set to indicate a problem with the AC Power Technology module the Local Power Interface LP1 module in the Power Module ot the cable connection between them The CCLK Not Synchronized Warning bit is set if CCLK counters in the PMI Regulator and the UDC module are momentarily not synchronized This fault occurs when the power supply on the Local Power Interface module located in the Power Module is not within tolerance This warning is set if the continuous current rating of the Rectifier is exceeded for a period of approximately 5 minutes and does not decrease and maintain the continuous rating for at least 45 minutes This fault occurs when an AC line power is lost for more than ten seconds while in run Reference In Limit DRV_WRN 203 1203 4 This warning bit is set if the VDC Warning reference 102 1102 is less than the minimum or greater than the maximum allowed where Minimum 1 1 1 414 AC line VRMS Max
97. d people knowledgeable in machine control solutions Drawing on more than 90 years of experience in supplying equipment to meet the requirements of your industry your Local Drive Solution Center can provide you with a highly reliable cost effective solution to meet your specific control requirements 8 1 Recommended Spares Appendix A Troubleshooting With The Drive Diagnostic Screens This appendix lists the suggested variable names register bit positions and diagnostic information for fault boxes LED lights and schematics shown in diagnostic screens for the following drives SD3000 and SD3000 Regen drives SA3000 drive SA3000 Parallel A B and C drives SB3000 Parallel A B and C drives SA 500 drive e GV 3000 A C drive e FP 3000 D C drive SA3100 drive e AB1336 drive 3 1 Troubleshooting The SD 3000 and SD 3000 Regen Diagnostic Screens SIGMA Universal Operator Interface PMI SD3000 Diagnostics SIGMA Universal Operator Interface PMI SD3000 Regen Diagnostics Help Return Help Return Top Work Roll Payoff Reel Figure A 2 SD3000 Regen Diagnostic Screen The standard SD3000 see Figure A 1 and SD3000 Regen see Figure A 2 Diagnostic screens use the following registers and bit positions for Fault boxes LED lights and the SCR schematic information needed Note It is the responsibility of the person configuring the AutoMax software to
98. dback device RPI Run IO_STAT 201 1201 0 1 green when the run Permissive Input permissive input is OK MCR M Contactor ILO_STAT 201 1201 1 1 amber when the status of the M Contactor output bit is high AUX IN1 IO_STAT 201 1201 1 1 green when the auxiliary input 1 is present AUX IN2 IO_STAT 201 1201 2 1 green when the auxiliary input 2 is present AUX IN3 IO_STAT 201 1201 3 1 green when the auxiliary input 3 is present AUX IN4 IO_STAT 201 1201 4 1 green when the auxiliary input 4 is present AUX IN5 IO_STAT 201 1201 5 1 green when the auxiliary input 5 is present AUX OUT IO_CNTRL 101 1101 4 1 amber when the auxiliary output is on AC Power Technology OK DRV_FLT 202 1202 11 green when the AC power technology card is working OK 3 2 3 IGBT Schematic The following is the list of variables that indicate an IGBT Short Fault The standard screen looks at the following bit positions in the IGBT diagnostic register to determine which IGBT has been affected by the fault The color on the IGBT schematic changes ONLY when both an IGBT bit has been set and the IGBT Short Fault bit has been set IGBT Number Variable Name Register A Fault Red on IGBT Schematic Register B Bit Phase U Upper DEV_DIAG 204 1204 0 Phase U upper power device detects an overt current Phase V Upper DEV_DIAG 204 1204 1 Phase V upper power device detects an overt current Phase W Upper DEV_DIAG 204 1204 2 Phase W upp
99. drive appear in the Destination directory display directly below this field To select a drive click the arrow at the right side of the field to display a list box containing all available drives and then click the desired drive Destination directory display list box This field located directly below the Destination drive display allows a user to select the directory where the Snapshot Export Utility exports the snapshot To select a directory click the desired name If more directory names are found than can fit in the list box then a scroll bar appears at the right side of the list Export format radio buttons This group of radio buttons allows a user to select the export file format To select a file format click the radio button next to the desired format The following formats are supported Excel XLS Microsoft Excel spreadsheet format Rows in the exported spreadsheet are time stamped snapshot samples columns in the exported spreadsheet are the variables exported from the snapshot Snapshot header information appears in the first several rows of the spreadsheet Access MDB Microsoft Access database format Rows in the exported database table are time stamped snapshot samples columns in the exported database table are the variables exported from the snapshot Snapshot header information appears in a memo field in the first row of the database table Binary SNP SIGMA snapshot binary format Only variables which have b
100. e Se rect suusi aa e a E AR E a E 167 Figure A 2 SD3000 Regen Diagnostic Sereeniyce bes dca saswies capsave d caahinacelssdudehaasczssde wade wundseajesheae tenes 167 Figure A 3 Diagnostics Screen When No PMI Communication Occuts cecee cee ceeeseeeeeeeeeees 169 Figu re A 4 The A3000 Diagnostic Sereen uiaei iiia eiie ieaiaia 173 Figure A 5 The SA3000 Parallel 3 Diagnostic Screen sseesessseeseseeesesrsresresrsresreseeresresteeresesresrsse 181 Figure A 6 The SB3000 Parallel 3 Diagnostic Sete etivcs ics casts ccscseiescovnts topedecidesnwads toavdaleacssneses sede 193 Figure A 7 The SA500 Diagnostic Screen acs sancant eS ciecck sy atestic s ais ane tag Redatt se odneba Se eaidd in auc euntagdeaeeseoeed 204 Figure A 8 The GV 3000 A C Drive Diagnostic Screettais ties oy tatcapliatecasedecasgssieitieadedatedoctonay sess 208 Figure A 9 The FP3000 D C Drive Diagnostic SCteetion sieccsctssccsaaseartarnaag ds sauecestadundssvnentsiases 211 Figure A 10 SA3100 Diagnostic Screen sg vicdsssseiseacdisuticassckass card shenay sith cuts susenanesyasonia bey cages seats akes 216 Figure A 11 AB1336 Diagnosti s Sheet anit scecodtaisce ceases selena ae a toda oa 226 www rockwellautomation com Corporate Headquarters Rockwell Automation 777 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions Ame
101. e SA500 drive refer to the AutoMax Distributive Power System manual S 3005 The PMI SB3000 Parallel Diagnostic Screen SIGMA Universal Operator Interface PMI S563000 Parallel Diagnostics B3000 Par 3 DC Bus No PMI Over Volt Comm Help Return aie Automation Figure 6 11 The SB3000 Parallel Diagnostics Screen The SB3000 Parallel Diagnostics screen shown in Figure 6 11 displays diagnostic information for an SB3000 high power drive This diagnostics screen information consists of an expanded drawing of PMI AC Parallel rack and its diagnostic LEDs a diagnostic grid showing the states active or inactive of drive faults and alarms e a diagnostic schematic showing states short or OK for IGBT AC output devices The SA3000 and SB3000 Parallel Diagnostics screens have radio buttons displayed in the IGBT box These buttons control the outlined portion of the screen and appear next to the section containing the schema of the motoring current from the power module The three faults and the IGBT output devices within this section can either summarize all units or pertain to a specific unit Up to three units can be selected using these radio buttons To select a unit click the corresponding radio button For more information on this diagnostics screen information refer to Section 6 1 2 Viewing Distributed Power Diagnostic Screens The GV3000 Parallel Diagnostic Screen SIGMA Universal
102. e which power device detected the overcurrent Error code 1017 will be displayed in the error log of the UDC task in which the fault occurred This fault is a combination of Fault Register 202 1202 bits 8 and 9 Bit 8 is set if a sine or cosine signal from the resolver is missing due to a broken wire or the resolver gain tunable RES_GAN has been set too low Bit 9 is set if a blown fuse is detected PT Power DRV_FLT 202 1202 11 This fault indicates that an error Technology Fault occurred in the PMI Regulator s AC power technology circuitry Power should be cycled to allow the Regulator to clear itself and reboot If DRV RDY LED remains off after repeated cycling of power check Diagnostic Fault Code register 222 1222 for specific information Refer to Chapter 6 in the SIGMA NE Operators Manual for a list of PT Fault messages Power Supply Fault DRV_FLT 202 1202 4 This fault occurs if the voltage level of the 12V Pulse Tach power supply or the external LEM power supply falls below 8V Error code 1022 will be displayed in the error log of the UDC task in which the fault occurred Over Speed Fault DRY eee 262 1200 10 La pesimo velocity exceeds the value entered as the Overspeed Trip RPM configuration parameter Chasee taut DRY PEI OARA This fault occurs when any of the following conditions occur The DC bus is not fully charged within 10 seconds after the bus enable bit is set The drive is
103. eadTemplate Changed Function Logging Disabled 167 0x9e gt ReadTemplate Changed Function Logging Enabled 167 Ux e gt Write Template Function Logging Disabled x 167 Ox8e gt WriteTemplate Function Logging Enabled 14 08 22 167 Oxde gt Re_sigma dil Compiled Aug 19 1998 14 11 22 14 08 20 043 Ox e gt ReadTemplate Changed Function Logging Disabled 08 20 043 Ox e gt ReadTemplate Changed Function Logging Enabled 4 08 20 043 OxSe gt WriteTemplate Function Logging Disabled te 08 20 043 Ox9e gt WriteTemplate Function L agging Enabled 4 08 20 043 Oxe gt ReadTemplate Function Logging Disabled he 08 20 043 Ox9e gt ReadTemplate Function Logging Enabled pe amaes Ox9e gt WriteTemplate Function Logging Disabled 089 0x9e gt Write Template Function Logging Enabled bps os 10 089 0x3e gt ReadTemplate Function Logging Disabled 3 Re boot the SIGMA Servet 4 Re start the SIGMA Clients Installing SIGMA Server Software SIGMA Server software installation is beyond the scope of the average user and therefore is not covered in this manual If there is a need to install SIGMA Server software contact your local Rockwell Drive Solution Center for assistance Starting a SIGMA Server Rebooting the server starts MSDOS Then the user may specify how the machine starts i e with SIGMA or No SIGMA when booting the machine These menu options will appear Start SIGMA Do not start SIGMA Backup P
104. een selected from the variable selection group see below are exported The snapshot created with this option may be re exported at a later time Export options This group allows the user to select export options To select an export option click the check box next to the desired option An option is selected when an X appears in the check box The following option is supported Delete snapshot When enabled the Snapshot Export Utility deletes the snapshot after it has been exported Before deleting the snapshot the user is explicitly asked if the snapshot should be deleted File name Displays the name and approximate size in Megabytes of the export file to be generated by the Snapshot Export Utility The export file name is made up of the file name of the selected snapshot and the file extension which corresponds with the selected export file format e g XLS for Excel format This field is display only In the middle of the Snapshot Export Utility screen appears the Snapshot Information group Data fields in this group pertain to the selected snapshot and are display only The snapshot information group contains the following Snapshot File Name This field displays the name of the snapshot file selected for deletion A snapshot file is selected for deletion using the fields provided in the Current snapshot files section The file s drive directory and file name are displayed For example d snap1 snp A snapshot file na
105. ellow background Alarm is currently active Yellow text on a Black background Alarm has been cleared no longer active but has not been acknowledged by the operator Black text on a Red background Fault is currently active Red text on a Black background Fault has been cleared no longer active but has not been acknowledged by the operator Light blue Cyan text and Black background Operator action has occurred only appears in the Event History Screen Once an alarm or fault has been cleared and acknowledged it no longer appears on the Alatm Fault Summary Screen The Alarm Fault Summary Screen SIGMA Universal Operator Interface Overview Section SPAD Trend Alarm Flt Snapshot Alarm Fault Summary 07 12 94 08 48 Acknowledge Exception Time Message Type Clear or Acknowledge Time Ez gt Z ve an oO uo ae ia D R 3 faan j SS co WN le 5 z D a WN n l O O 5 Clicking the Fault Summary option from the Alarm Fit pull down menu displays the Alarm Fault Summary Screen as shown in Figure 5 1 When the Alarm Fault Summary Screen appeats a list of exceptions automatically appears This screen may also be accessed from a status push button on the Drive Overview Screen refer to Figure 6 1 if its associated section is non distributed power If the list is longer than one screen a scroll bar appears at the right side of the screen Scroll through a list b
106. ept the number Once a value has been entered the Enable Low check box must be selected The following push buttons are contained in the Trigger window Clear push button Click once on this push button to disarm the Trigger window and clear any modifications Use this option when a trigger was armed but there is no longer a need to monitor the variable defined as the trigger Set push button Click once on this push button to confirm the items established in the window as trigger parameters A trigger can not be armed if this push button is not selected Cancel push button Click once on this push button to cancel the changes made and exit the Trigger window Summary This chapter has explained the trending process and how a user can utilize it when monitoring the status of a system Also this chapter discussed the trigger feature This feature offers multiple options for isolating a particular event and retaining the information for troubleshooting purposes A good option to use with trending and triggers is the Snapshot feature Refer to Chapter 4 for more information about Snapshots 3 1 Trending OVervieW oreinen en e a a a EA ie man AA 49 3 1 1 The Trending Men s iaripisniie eeina a E ted A EA ce 50 327 Phe Trend Screen mineda a a a a a aa bean ea aaa 51 3 2 1 Selecting Variables for the Trend Screethis cssssisscssrsepeasessacupsadcdachsanesiassasdvaaisaerneas 54 3 2 1 1 Defining the Center Value and the Units per Divi
107. er power device detects an overt current Phase U Lower DEV_DIAG 204 1204 3 Phase U lower power device detects an overt current Phase V Lower DEV_DIAG 204 1204 4 Phase V lower power device detects an overt current Phase W Lower DEV_DIAG 204 1204 5 Phase W lower power device detects an overt current 3 3 Troubleshooting The SA 3000 Parallel A B and C Diagnostic Screens The standard SA 3000 Parallel see Figure A 5 Diagnostic screens uses the following registers and bit positions for Fault boxes LED lights and the IGBT schematic information needed Note It is the responsibility of the person configuring the AutoMax software to make sure the correct information is configured within these variables SIGMA Universal Operator Interface PMI 543000 Parallel Diagnostics Help Return A43000 Par 3 DC Bus No PMI Over Volt Comm BMX 202x27 gm L__s oe E __o _ y _ y __ yn __ g che Automation Figure A 5 The SA3000 Parallel 3 Diagnostic Screen 3 3 1 Fault Boxes The following table lists the SA 3000 parallel fault names their suggested variable names register bit positions and under what conditions this bit is set Fault or Warning Name Variable Name Register A Register B Bit DC Bus Over DRV_FLT 202 1202 0 Voltage High Bus Fault DC Bus Undervoltage Warning 203 1203 1 DRV_WRN DRV_FLT No PMI Comm Fault 202 1202 15 DRV_STAT
108. ere is No PMI Comm the purple cross mark is displayed on the diagnostics screen see Figure A SIGMA Universal Operator Interface 1336 Diagnostics Help Return Power Up D C Bus Reset Fault f Over Voltage Bus Ridethrough Timeout Feedback Loss Figure A 11 AB1336 Diagnostics Screen Faults fall into three basic categories Table 2 B This type of Has the following definition To remove this fault you need to fault Hard Trips the drive causing it to stop You Perform a Drive Reset command or cannot regain control until you reset cycle drive power the drive Soft Trips the drive causing it to stop 1 Address the condition that caused the fault 2 Perform a Clear Faults command Warning Indicates an undesirable condition Address the condition that caused the The drive will not stop but the condition may lead to a fault that will stop the drive warning To help troubleshoot your 1336 FORCE drive the drive logs any faults or warnings in either the fault or warning queue The faults and warnings that are contained in the queues are either configurable or non configurable Table 2 C This fault type Refers to faults that you Configurable Can set up to either trip the drive or provide only a visual warning while the drive continues to operate Non configurable the drive if allowed to persist Cannot disable These faults are the re
109. erview screen The setpoint value can be set by any of the following devices e keyboard entry of a setpoint value this is always provided in a Section Control window e slider bar optional feature see Figure 6 16 increase decrease push buttons optional feature see Figure 6 17 Screen Description The following fields and push button are at the top of the Section Control window Actual Displays the current reference value of the setpoint This field is display only Set push button field Clicking this push button activates a field for the keyboard entry of the setpoint value When the field is activated enter a setpoint value and press lt Enter gt When a change is made to the setpoint value the new setpoint value is displayed here The Actual field displays the current reference of the setpoint Located next to the Actual and Set fields are two display only indicators The top indicator displays the status of the section The bottom indicator displays the name of the setpoint e g Load Tension The Section Control window may also display the name of the group the section belongs to directly below the setpoint name The Section Control window may contain one of the following optional features for changing the setpoint value Slider Bar optional feature Using a slider bar makes large changes to a setpoint value The slide bar is typically used only for setting the speed of the lead drive section in a
110. es end with the text entered in the field next to the radio button are moved when the Add or Remove push button is clicked For example if the text in the field is CUR_FDBK_ then only variables ending with CUR_FDBK_ are moved To select this criterion click its radio button Add This push button allows variables which match the criteria specified by these fields to be added to the Variables to be exported list When a variable is added to the Variables to be exported list it is removed from the Variables not to be exported list Click this push button to add the variables Remove This push button allows variables which match the criteria specified by these fields to be removed from the Variables to be exported list When a variable is removed from the Variables to be exported list it is returned to the Variables not to be exported list Click on this push button to remove matching variables At the bottom of the Snapshot Export Utility screen appear the following Export push button Click this push button to initiate the export of the selected snapshot The snapshot is selected from the Available snapshots group The export file is written in the format specified by the Export format radio buttons in the Export destination group The export file is written to the drive and directory specified in the Export destination group The export file contains those variables specified in the Variables to be exported list Depending on the specified
111. eseeesressessrssressessrssressersresressee 5 9 Figure 5 4 The Event History Print Setup Window sssssssesessssessessresressersesresseeseesressreseesees 5 13 Figure G41 The Dire veer Ft oordie ipeni ore Ea ELA E EE EE 6 2 Figore GG Bar Chan te ec ercana renra es r ota N A S E a EA E E EER 6 5 Figure 6 3 The Hdp Mot ercon ei EEEE ETE 6 8 Figure 64 The Hdp Tertio ine e a issn eae a E a E E 6 9 Figure 6 5 The Not Window os cissnsaiccnica ta chsna ndsispaibaaicens dapbachpaatuonde ds Eia E adana IA 6 10 Figure 6 6 The PMI SD3000 Diagnostis Seren orsssnnsinaie iida aiiai 6 11 Figure 6 7 The S3000 Regen Diapnosties Seregi cisnienia a aeaii 6 12 Figure 6 8 The SAS000 Dizonosties Sreet sicriu iai a E a 6 13 Figure 6 9 The SA3000 Parallel Diagnostics Sereen sicco aiii 6 14 Figare 6 10 The SAS Lisi ees Sereen incirin a o aa aE E 6 15 Figure 6 11 The SB3000 Parallel Diagnostics Seregi isnin 6 16 Figure 6 12 The GVO A C D ve Diagnostics Seti erea iae 6 17 Figure 6 13 The FP3000 D C Drive Diapnostics Serec eesriie 6 19 Fiure 0 LI SASO Dignosics Sree oiadi ie e AE AE EAE 6 21 Figure 6 15 The AB I336 Diapnostiecs Setinin eroii raui n e t Eai E 6 24 Figure 6 16 A Section Control Window with a Slider Bar ss siasveiacascvascassenternnesoveavastesncsocensessnuts 6 26 Pigre I7 The ccinn Dacei eere EE aE EE E T EEE EE E E 6 29 Ficute 6 18 The SPAD Spred and Drawy Sreem onnnnciiaiciriretiia tiniis iniiai 6 31 Bet grat 7 1 Recipe Editor Sereen so os cniisssnctsninspase
112. evice detects an ovet current Phase U lower power device detects an ovet current Phase V lower power device detects an ovet current Phase W lower power device detects an ovet current Unit x IGBT Number Phase U Current Sharing Phase V Current Sharing Phase W Current Sharing Where x 1 2 or 3 Variable Name DEV_DIAG x DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 DEV_DIAG1 DEV_DIAG2 DEV_DIAG3 Register A Register B Bit 204 1204 13 220 1220 13 221 1221 13 204 1204 14 220 1220 14 221 1221 14 204 1204 15 220 1220 15 221 1221 15 Alarm Yellow on IGBT Schematic When Unit x detects a problem with current sharing on phase U between power modules Unit x is not carrying its share of the phase U current Unit x detects a problem with current sharing on phase V between power modules Unit x is not carrying its share of the phase V current Unit x detects a problem with current sharing on phase W between power modules Unit x is not carrying its share of the phase W current 3 4 Troubleshooting The SB 3000 Parallel A B and C Diagnostic Screens The standard SB 3000 Parallel see Figure A 5 Figure A 6 Diagnostic screen uses the following registers and bit positions for Fault boxes LED lights and the IGBT schematic information needed Note It is the responsibility of the person configuring the AutoMax software to make sure the correct informatio
113. g alarms and faults A user can also print a list of historical events Alarm Fault Overview The SIGMA NE Alarm Fault system monitors and displays diagnostic information about the running process This diagnostic information is generally referred to as exceptions The following types of exceptions are monitored by the system Alarm a non fatal exception which usually allows the process to continue running For example Oil level low Fault a fatal exception which usually stops part or all of the process For example Oil tank empty Operator action an operator initiated exception which affects part or all of the P P P P process For example Pumps started via benchboard Each exception monitored by the system can be in either one of the following states Active the exception has occurred but not yet cleared Inactive the exception has cleared or not yet occurred Each exception s state is detected by the system using one of the following senses High sense exception becomes active occurs based on the rising edge of its digital signal boolean variable becomes inactive clears based on the falling edge i e 1 active 0 inactive Most exceptions use this sense Low sense exception becomes active occurs based on the falling edge of its digital signal boolean variable becomes inactive clears based on the rising edge i e 0 active 1 inactive In addition to the states described above t
114. ger Feature 2 Make sure the Trigger Variable snapshot is specified as the snapshot Option in the Trigger Window refer to section 3 3 for a description of the Snapshot option 3 Set the Snapshot Time Span clicking either one of the three 20 second 100 second or 5 minute radio button 4 Enter a Snapshot Description maximum of 66 characters for the Trigger Variable snapshot file When the snapshot is generated the description is saved and appears as the Trigger Description in the SIGMA Snapshot Export Utility refer to section 4 6 and Snapshot File Maintenance refer to section 4 5 screens If an entry is not made in this field no description appears in these screens 5 Click the Set push button to confirm parameters set for the Trigger Variable snapshot The Trigger Variable snapshot is not generated until the trigger variable exceeds its specified high or low value Snapshot File Maintenance Snapshot File Maintenance Delete Local Je File 15_14 57 snp aca Goto Export sigma amp snapshot _Betum Local Snapshot data Snapshot file name C sigmaisnapshot 15_14_57 snp Trigger time 11 10 02 02 56 14 PM Snapshot duration 00 00 37 Trigger event Go snapshot Trigger description Triggered on F14H_FLD_IFB_ exceeds 150 Variable count 445 Samples per variable 748 50 ms interval Current Server snapshot files 15_13_10 snp Retrieve Fie Name 15_13_10 snp D 845786 10 NOY 2002 15_14_57 snp 845786 10 NO
115. ght side of the field to display a list box containing all available drives and then click the desired drive Snapshot directory Allows the user to select the directory on the selected drive where the Snapshot Export Utility looks for snapshots When a new directory is selected the snapshots which are found in that directory appear in the snapshot file list see below To select a directory click the desired name If more directory names are found than can fit in the list box then a scroll bar appears at the right side of the list Snapshot file Allows the user to select the snapshot from the selected directory which the Snapshot Export Utility exports when the Export push button is clicked Only files with the SNP file extension i e snapshot are listed When a snapshot is selected its file information appears in the snapshot file group see below In the upper right corner of the Snapshot Export Utility screen appears the Export destination group Data fields in this group pertain to how and where the Snapshot Export Utility exports the selected snapshot The snapshot is selected from the Available snapshots group The Export destination group contains the following Destination drive pull down display This field located directly below the Use tape drive check box allows a user to select the disk drive where the Snapshot Export Utility exports the snapshot When a new drive is selected the directories which are found on that
116. gnal from the resolver is missing due to a broken wire or the resolver gain tunable and RES_GAN has been set too low Bit 9 is set if a blown fuse is detected DRV_FLT 202 1202 9 on the Resolver amp amp Drive I O board UDC Run Fault DRV_FLT 202 1202 14 The UDC Run Fault bit is set when the UDC task stops while the minor loop is running in the PMI processor AC Power DRV_FLT 202 1202 11 This bit is set to indicate a problem with Technology the AC Power Technology module the Module Fault Local Power Interface LP1 module in the Power Module or the cable connection between them LPI Local Power DRV_FLT 202 1202 4 This fault occurs when the power supply Interface Fault on the Local Power Interface module located in the Power Module is not within tolerance CCLK Not DRV_WRN 203 1203 14 The CCLK Not Synchronized Warning Synchronized bit is set if CCLK counters in the PMI Warning Regulator and the UDC module are momentarily not synchronized Over Speed Fault DRV_FLT 202 1202 10 This fault occurs when the motor s velocity exceeds the value entered as the Overspeed Trip RPM configuration parameter Reference in Limit DRV_WRN 203 1203 4 The Reference in Limit Warning bit is Warning set if the reference to the regulator exceeds the maximum value permitted 4095 or is being limited by the system in response to an overvoltage or undervoltage warning IPM Intelligent DEV_DIAG 204 1204 6
117. gnostic screen information consist of an expanded drawing of PMI AC rack and its diagnostic LEDs a diagnostic grid showing the states active or inactive of drive faults and alarms a display of the PTM Fault and message a diagnostic schematic showing states short or open for IGBT AC output devices For more information on this diagnostic screen information refer to Section 6 1 2 Viewing Distributive Power Diagnostic Screens For more information on the SA3000 drive refer to the AutoMax Distributive Power System manual S 3005 The PMI SA3000 Parallel Diagnostic Screen SIGMA Universal Operator Interface PMI 543000 Parallel Diagnostics Help Return A43000 Par 3 DC Bus No PMI Over Volt Comm Dmx 102v a a a a a a a Automation Figure 6 9 The SA3000 Parallel Diagnostics Screen The SA3000 Parallel Diagnostics screen shown in Figure 6 9 displays diagnostic information for an SA3000 high power drive This diagnostics screen information consists of an expanded drawing of PMI AC Parallel rack and its diagnostic LEDs a diagnostic grid showing the states active or inactive of drive faults and alarms a diagnostic schematic showing states short or open for IGBT AC output devices The SA3000 and SB3000 Parallel Diagnostics screen have radio buttons displayed in the IGBT box These buttons control this outlined portion of the screen and appear next to the se
118. he Graph section of the Trend Screen displays the plots for the four channels At the top of this section are the following items Live check box Choosing this check box allows the graph to show the most current information Running in live mode displays the actual variable values as they are fluctuating When used with the Time Interval option the axis at the bottom of the screen will reflect the applicable amount of time as it passes An X in this check box indicates the Trend Screen is running in Live Mode To deselect the Live check box click once on the box marked with an X If this check box is blank the Trend Screen is running is Historical Mode Refer to section 3 2 3 Selecting a Time Axis for information on Live and Historical Mode Date and Time display This display allows a user to look at a graph from the past The display will automatically default to the current date and time If a user wishes to view the variable plots for a particular date and time the arrow buttons on either side of this display only field allow the date and time to be adjusted This can only be done if the Trend Screen is not set to run in live mode refer to section above The single arrow push button shifts the graph displayed 1 4 of the time interval set with the Time Interval option The double arrow push button shifts the graph displayed by one time interval of the interval set with the Time Interval option Refer to section 3 2 2 Adjusting the T
119. he list box then a scroll bar appears at the right side of the list Local Snapshot File Allows the user to select the local snapshot from the selected directory Only files with the SNP file extension 1 e snapshot are listed When a snapshot is selected its file information appears in the snapshot information group see Figure 4 5 The field directly below the section title Current local snapshot files displays the names of the files located on the drive and directory selected To select a file click the file name The Local snapshot data section contains various file information for the selected snapshot All fields in this section are display only Snapshot File Name This field displays the name of the local snapshot file selected A snapshot file is selected using the fields provided in the Current snapshot files section The file s drive directory and file name are displayed For example d 15_13_10 snp A snapshot file name is composed of the hour minute and second separated by underscores that the snapshot was generated and the file extension SNP Trigger time Time when the snapshot was generated A snapshot can be generated in several ways Refer to sections 4 2 4 3 and 4 4 for more information about generating a snapshot Trigger event Type of event manual or automatic used to generate snapshots The Trigger Event for Go or Capture snapshots is Manual The Trigger Event for Trigger Variable snapshots is Auto
120. he pop up ila a E keypad see Figure 7 15 is displayed jefes Ea lse The keypad allows the user to enter values by lal2 s either pointing device mouse or trackball or a a ee using a hardware keyboard Clear Cancel Ok Figure 7 15 Pop Up Keypad 2 Modify the Next value using this keypad If the Clear push button is clicked all keypad entries are cleared from the display If the Cancel push button on this pop up keypad is clicked no action is taken 3 After modifying the Next value click the OK push button If the new value is within limits set by the drive system software it is displayed in the Next column Also the user is notified that the Next Recipe has been changed when modified is displayed under the Recipe s Name in the Next column If the value is not within limits a pop up box see Figure 7 4 displays the valid range for the recipe element 4 Re enter an acceptable value and again click on the OK push button Downloading Recipes The Download push button see call out F in Figure 7 13 downloads the recipe in the Next column to the drive system 1 Click the Download push button Eee Recipe Manager DA The Download pop up window oe rra Next appeats see Figure 7 16 which asks Setpoint Preset Next Controlled Variable News Print whether the recipe displayed in the Next column is to be downloaded and become the Preset recipe Make News Print
121. he system permits the operator to acknowledge exceptions Acknowledgment is an indication that an exception which has occurred has been noted by the operator If an alarm or fault occurs the main menu bar turns red This signal which happens no matter where a user is in SIGMA warns that something has occurred that has caused an alarm or fault to occur When an alarm or fault occurs a user should access the Alarm Fault Summary Screen refer to section 5 1 The Alarm Fault Summary Screen displays a list of exceptions which have taken place Exceptions on the list are in one of three conditions Active not acknowledged Active acknowledged Cleared resolved not acknowledged After viewing the list a user must take some action towards correcting the problems so the alarms or faults can be removed from the list Usually the first step is to acknowledge the exceptions Acknowledgement can be performed before or after the alarm or fault has been cleared Only when an exception has cleared and been acknowledged by the operator is it removed from the Alarm Fault Summary Screen The Event History Screen also records operator actions which do not appear on the Fault Alarm Summary Screen These exceptions may be helpful in determining what caused another exception to happen Color Descriptions of Exceptions To identify exceptions more easily when they are in a list the following colors are used for text and background Black text on a Y
122. he units per division Center Value Current Center This field displays the current center value for the plot representing the activity of the variable on the Trend Screen graph This information is display only Center Value New Center Clicking once on this field allows a user to enter a new center value for the channel The new number can be entered manually or the number displaying can be adjusted to the correct value by using the up and down arrows next to the field Refer to section 3 2 1 1 Defining the Center Value and the Units per Division for more information on adjusting the center value Clear button Clicking once on this button allows a user to clear the channel specifications entered If the user has made adjustments to a previously established channel this push button will return the Channel window to the state it was in before modifications were made Set button Clicking once on this button allows a user to finalize the channel configuration displaying in the Channel window When selected the configuration is recognized by the system and the graph in the Trend Screen is redrawn according to the information from the window Cancel button Clicking once on this button allows a user to exit the Channel window No configuration information will be established by the system Defining the Center Value and the Units per Division It is possible to modify the center point and vertical scale of a display channel
123. hich 203 1203 7 the fault occurred A warning occurs when the internal temperature of the Power Module s heatsink exceeds 90 Deg C CCLK Not DRV_WRN 203 1203 The Reference in Limit Warning bit is Synchronized set if the reference to the regulator Warning exceeds the maximum value permitted 4095 or is being limited by the system in response to an overvoltage or undervoltage warning The following logic table explains the Resulting Faults and LED states If Variable Name And Variable Name Resulting Fault or LED State DRV_STAT DRV_FLT 200 1200 Bit 15 202 1202 Bit 15 No PMI Comm Fault No PMI Comm Fault oo o If there is no communication with the PMI rack the purple cross mark is displayed on the diagnostics screen see Figure A 3 3 8 2 LED Lights The following table lists the LED names their associated suggested variable names bit positions and logic for the LED to be on LED Name Variable Name Register Logic for LED Turns AI Register LED ON B Bit Position PWR OK Power DRV_FLT 202 r 1 green when the PMI Supply OK aaa supply is OK PMI Processor OK DRV_STAT 200 1200 1 green when the PMI PMI Processor 5 processor is OK COMM OK DRV_FLT 202 1202 1 green when the Communications 5 communications OK between the UDC and PMI is working OK and DRV_STAT 200 1200 1 1 5 PM FLT Power DRV_FLT 202 1202 1 1 red when either a DC Module Fault Bus Over Current fault an Instanta
124. his bit is set to indicate a problem with the AC Power Technology module the Local Power Interface LP1 module in the Power Module ot the cable connection between them This fault occurs when the power supply on the Local Power Interface module located in the Power Module is not within tolerance The CCLK Not Synchronized Warning bit is set if CCLK counters in the PMI Regulator and the UDC module are momentarily not synchronized This fault occurs when the motor s velocity exceeds the value entered as the Overspeed Trip RPM configuration parameter Reference in Limit Warning DRV_WRN 203 1203 4 DRV_WRN 203 1203 3 DEV_DIAGn 204 1204 6 Where n Unit DRV_WRN 203 1203 6 Voltage Ripple Warning IPM Intelligent Power Module Fault 1 2 or 3 LS Load Sharing Warning Unitl IPM Intelligent Power Module Fault DEV_DIAG1 204 1204 6 DEV_DIAG2 220 1220 6 DEV_DIAG3 221 1221 6 DRV_FLT 202 1202 5 Unit 1 GDI DEV_DIAG1 204 1204 7 Unit 1 detects a problem with its gate Fault driver interface power supply Unit2 IPM Intelligent Power Module Fault Unit3 IPM Intelligent Power Module Fault GDI Gate Driver Interface Fault The Reference in Limit Warning bit is set if the reference to the regulator exceeds the maximum value permitted 4095 or is being limited by the system in response to an overvoltage or undervoltage warning The Voltage Ripple Warning bit is set if
125. his window SIGMA Universal Operator Interface PHI 5D3000 Regen Diagnostics Help Return Com QUE O LL SectionName Payoff Reel l rA m a r r ar i Figure 6 5 The Note Window 4 When finished with a help dialog box or a Note window click the Return push button to return to the previous window 5 To view an explanation or enter view or print notes pertaining to other items repeat steps 1 through 3 To redisplay the Distributive Power Diagnostic Screen click the Return push button The PMI SD3000 Non Regen Diagnostic Screen SIGMA Universal Operator Interface PMI 5D3000 Diagnostics Help Return TECHNO Pi A R 4 T U R auxi E AUX INZ P2 AUXINS F M A auxins 2 auxins g E AUX OUT fo l To D ARMATURE Figure 6 6 The PMI SD3000 Diagnostics Screen The PMI SD3000 Diagnostics screen shown in Figure 6 6 displays diagnostic information for an SD3000 drive This diagnostic screen information consist of an expanded drawing of PMI DC6 rack and its diagnostic LEDs a diagnostic grid showing the states active or inactive of drive faults and alarms a diagnostic schematic showing states short or open for SCR DC output devices For more information on this diagnostic screen information refer to Section 6 1 2 Viewing Distributive Power Diagnostic Screens For more information on the SD3000 drive refer to the AutoMax Distributive Power System
126. iable at a time An upper and lower limit for the variable s value is established thus creating a range where the value will fall and set off the trigger A trigger cannot be armed without enabling a high or low value Once the value range is established the course of action taken by the trigger must be specified After the action is specified the trigger can be armed When a trigger is armed if the variable condition falls within the value range the trigger will be fired Based on the course of action indicated for the trigger a few events will take place to inform the operator the trigger has fired and to help preserve the actual event itself The following is a list of the different actions available and the events that will occur if chosen Continue When Continue is the action indicated for the trigger to take the following events occur The trend graph continues to scroll as it normally does An alarm is triggered and the title bar on any screen turns red alerting the operator to go to the Alarm Fault Summary refer to Chapter 5 or the Event History refer to Chapter 5 screens Freeze When Freeze is the action indicated for the trigger to take the following events occur An alarm is triggered and the title bar on any screen turns red alerting the operator to go to the Alarm Fault Summary or the Event History screens The graph continues to scroll until 1 4 of the selected Trend Screen interval or five minutes has elapsed wh
127. ichever is less On the Trend Screen the T1 bar marks the trigger point and the graph remains frozen until another operation is made or until data for the time interval displayed on the trend screen is no longer available This is when the elapsed time since the trigger has occurred exceeds the 48 hour historic trend storage time IMPORTANT The Freeze option from the Trigger window is only active while viewing the Trend Screen Moving to another screen will cause the trigger mode to change to continue Print When Print is the action indicated for the trigger to take the following events occur An alarm is triggered and the title bar on any screen turns red alerting the operator to go to the Alarm Fault Summary or Event History screens The graph continues to scroll until 1 4 of the selected Trend Screen interval or five minutes has elapsed whichever is less On the Trend Screen the T1 bar marks the trigger point and the graph remains frozen until the print operation is complete IMPORTANT The Print option from the Trigger window is only active while viewing the Trend Screen Moving to another screen will cause the trigger mode to change to continue Snapshot When Snapshot is the action indicated for the trigger to take the following events occur An alarm is triggered and the title bar on any screen turns red alerting the operator to go to the Alarm Fault Summary or the Event History screens The graph continues to
128. ile Maintenance Selecting snapshot files to delete or to export Refer to section 4 5 Snapshot Export Utility Selecting snapshot files to export as a spreadsheet database ot binary file Selecting variables within the snapshot file to be exported Refer to section 4 6 Go Snapshots Use the Go Snapshot option to generate a snapshot immediately containing 20 seconds 100 seconds or 5 minutes of trend data Before generating a Go snapshot its time span must be configured Configuring Go Snapshots SIGMA Universal Process Monitor Trend Screen Memory Trigger Interval Alm FIt Snapshot Print Return T1 13 00 19 Units Delta T 00 01 04 26 July 94 13 21 18 Interval 5 Min NIA i rigger DisArmed Snapshot Configure Time Span 20 Seconds 100 Seconds 300 Seconds 5 min Jul 26 Jul 26 Jul 13 01 24 13 00 24 12 59 24 Figure 4 1 The Go Snapshot Configuration Window Click Configure from the Snapshot pull down menu displays the Snapshot Configure window as shown in Figure 4 1 This window allows a user to specify the time saved in a Go snapshot Once the time span is set it remains in effect until it is changed again from this window Screen Description Time Span radio buttons Clicking one of these radio buttons configures the time that is saved in a Go Snapshot A time span stays in effect for all Go snapshots until it is reconfigured from this window The available choices for the time span are 20 Sec
129. ilities software requirements hardware requirements SIGMA NE setup SIGMA NE software installation About SIGMA NE UOI UPM The SIGMA NE Universal Operator Interface and Universal Process Monitor Systems are operator interfaces which integrates data acquisition supervisory control and information management into a comprehensive Client Server package SIGMA Server monitors the drive control systems through a ControlNet Interface card using the ControlNet network and distributes the data over an Ethernet network to SIGMA Clients Figure 1 1 shows a typical SIGMA NE UOI UPM configuration Client MMI Client MMI ies eae Trend screen Fault and alarm Fault and alarm Engineered i f Engineered Screens ke F ee Screens Client 1 Client N Line area fiber optic by Oth y ers SIGMA real time data server i VersaView Real time data collection and distribution Trending C Fault alarm management SIGMA NE real time server ControlNet Note Only one ControlNet allowed ControlLogix ControlLogix Figure 1 1 Typical SIGMA NE Configuration Universal Process Monitor software simplifies maintenance and troubleshooting by providing a Historical Recording of Alarms Faults and Operator Actions SIGMA Universal Operator Interface SIGMA Universal Operator Interface Overview Section SPAD Trend Alarm Fit Snapshot Overview Section SPAD Trend Alarm Fit Snapshot
130. ime Interval for more information on the Time Interval option Selecting Variables for the Trend Screen SIGMA Universal Process Monitor Trend Screen Memory Trigger Interval Alm FIt Snapshot Print Return 26 July 94 13 05 55 324 24 INCHES Calender Diameter 1187 69 PMI ArmCurr Fdbk unfitrd Interval 5 Min 90 14 w Couch Torque Split Setpoint fi rigger DisArmed 44 4 26 Jul 1994 13 01 24 gt gt gt FE Channel 1 Variable Name amp Description DF ELAPSED MR ed Drive Fixed Elapsed Yous H s Center Value Units Div Current Value Current Center New Center 2425600 8 os Jul 26 Jul 26 ul 26 Jul 26 Jul 26 Jul 26 13 01 24 13 00 24 E 12 58 24 12 57 24 12 56 24 Figure 3 2 The Channel Window Choosing a push button from the Variable column on the Trend Screen displays a Channel window as shown in Figure 3 2 This window allows user to select a variable for the Trend Screen and configure the vertical axis for a variable s plot Four channels can be chosen and assigned in any order and the same variable can be assigned to one or all of the channels Each Channel window displays the color of the line used in the graph for plotting the variable information The vertical scales and center points for the variables can be selected to accommodate the range of values in the plot and to clean up the appearance of the graph Clean up means to adjust the position of the plots on
131. imum 875 volts IPM Intelligent DRV_FLT 202 1202 3 This fault occurs when the gate Power Module Fault driver turns off an output power device IGBT to protect it from an overcurrent An IOC fault Bit 3 of register 202 1202 will also be set GDI Gate Driver DRV_FLT 202 1202 5 This fault occurs when the power Interface Fault on the GDI is not within tolerance Charge Bus Time out DRV_FLT 202 1202 6 This fault occurs when any of the following conditions occur The DC bus is not fully charged within 10 seconds after the bus enable bit is set The drive is on and feedback indicates that the pre charge contactor has opened The DC bus voltage is less than the value stored in the Power Loss Fault Threshold PLT_E0 tunable variable Over Temp Fault DRV_FLT 202 1202 7 This can either be a fault or a warning This fault occurs when fault level thermal switch in the Power Module opens Error code 1016 will be displayed in the error log of the UDC task in which the fault occurred DRV_WRN 203 1203 7 A warning occurs when warning level thermal switch in the Power Module opens LS Load Sharing Warning DRV_WRN 203 1203 6 Unitl IPM Intelligent DEV_DIAG1 204 1204 6 Power Module Fault Unit2 IPM Intelligent DEV_DIAG2 220 1220 6 Power Module Fault Unit3 IPM Intelligent DEV_DIAG3 221 1221 6 Power Module Fault Unit 1 GDI Gate DEV_DIAG1 204 1204 7 Driver Interface Fault DEV_DIAG2 220 1220 7 DE
132. ing None Configuration Select Parameter 87 to 0 To disregard the alarm set bit 5 in CP Fault Warning Configurable Select parameter 86 and CP Warning None Configuration Select Parameter 87 to 0 Feedback Loss 05048 Inverter Over Temperature Pending 02049 UC_VP_FLT 5 0 Soft fault Red LED UC_VP_WR N Warning Yell ow LED UC_VP_FLT Soft fault Red LED UC_VP_WR N Warning Yell ow LED A loss of feedback occurred Suggested Action Check the encoder wiring Verify that the encoder signals are free of noise To configure the alarm as a fault set bit 0 in VP Fault Warning Configurable Select parameter 88 to 1 To configure the alarm as a Warning set bit 0 in VP Fault Warning Configurable Select parameter 88 to 0 and set bit 0 in VP Warning None Configuration Select Parameter 89 to 0 To disregard the alarm set bit 0 in VP Fault Warning Configurable Select parameter 88 and VP Warning None Configuration Select Parameter 89 to 0 An inverter overtemperature is pending The inverter heatsink temperature has exceeded 80 Degrees Celsius and is approaching the trip level Suggested Action Check the cabinet filters drive fans and heatsinks Check the thermal sensor and sensor witing connector Reduce the load or duty cycle if possible Lower the value of PWM Frequency parameter 222 Check the roof fan rotation H frame only To configure the alarm as a fault set bit 1 in VP Fault
133. is on AC Power Technology DRV RDY DC DRV_FLT 202 1202 1 green when the AC Power Technology 1 power technology card is working OK 3 8 3 IGBT Schematic The following is the list of variables to show an IGBT Short Fault The standard screen looks at the following bits of the IGBT diagnostic register to determine which IGBT has been affected by the Fault The color on the IGBT schematic changes ONLY when both an IGBT bit has been set and the IGBT Short Fault bit has been set IGBT Number Variable Name Register A Fault Red on IGBT Schematic Register B Bit Position Phase U Upper DEV_DIAG 204 1204 0 Phase U upper power device detects an over current Phase V Upper DEV_DIAG 204 1204 1 Phase V upper power device detects an over current Phase W Upper DEV_DIAG 204 1204 2 Phase W upper power device detects an over current Phase U Lower DEV_DIAG 204 1204 3 Phase U lower power device detects an over current Phase V Lower DEV_DIAG 204 1204 4 Phase V lower power device detects an over current Phase W Lower DEV_DIAG 204 1204 5 Phase W lower power device detects an over current 3 9 Troubleshooting The AB1336 Drive Diagnostic Screens The standard AB1336 Drive see Figure A 11 Diagnostic screen uses the following bit positions in registers s 1 through 6 for LED light information needed It is the engineer s responsibility to make sure the correct information is configured within these variables If th
134. ive Alarms Faults Summary list and moved to the Event History list When an active alarm or fault is acknowledged it is date time stamped with the acknowledgement time but not removed from the active Alarms Faults Summary list until it clears With either normal or latched alarm or fault handling all alarms or faults that occur within a sample receive the same date time stamp The order of the alarms or faults within the sample does not indicate the actual order of occurrence Therefore there is no way to determine which alarm or fault occurred first within the sample 2 gt I WV OEVI CW cise isa ci ci bees terres IE EEEE hak AE SE EEA EN DREO EEA ease deere 36 Dee lt WVOVUPM Start Up aa i casei ilove oe tiedsosutn E oui Na A V REA 37 2 3 Pype OF SCRE CUS nzo E A a A N a a 38 24 Describing Sereen ObJeCtS iison rnana ea aa TEA K EE A ATERA 39 2 5 Accessing S rechSia ninr E EI EE R ER A a ack eee 44 2 6 Alarm Fault Handling is caesar etyosesacvosaacacedigs aveies denePadevidebuotesbacastinsettee Seeatadamarvon ccna 47 Figure 2 1 Drives Overview Setecin inani i Gara aw teases Rae ets 37 Figure 2 2 Alarm Fault Summary Screen tq dags encarta dyed cman aaa eed 37 Figute 2 3 Full Sereen a ion aaa AE sor gos es aE st a aad osm AE ane 38 Figure 2 4 Full Screen with Pop Up Overlay seessesesesrssesrssteresresteerssrstestesesresresteernsestestnsesreseeseee 38 Figure 2 5Internal Keyboard osdeniiaiy tives tra a a e ad niga a a aai 42 Figu
135. ives Overview First Press Button ssssessesersreeseeee 2 11 Figure 2 10 Accessing a Pop Up Box from the Trending Screen s 1st Variable Button 2 11 SEP oe oF Aid The cco ee rere ee ere eee 3 3 Bay rate 2 4 The Ciopnel Wind oereide eiieeii Earann i E aae a anarien aneian 3 6 Figure 3 3 The Trend Sereen with Tand T2 slider ttt oss ccsse nia casisn secant cevensoneennaionsonunddeaean 3 12 Figure 3 4 The Memory Sare As Popup Wid iocriisireniisiiseirisusrisi ieai ayineesati di siirenean ieis 3 13 Fiponre 3 5 The Memory Load Wind W enres ieiciiriersas ronisin ee dees 3 15 Figure 326 The Tipse VOdo enea e aa E R EA E E ETETE ENEE EAEE 3 16 Figure 4 1 The Go Snapshot Confiouration Wipdow oi ics ss sivessssccancdeseasees soesusnensdavsnnsiscenstsntedoavens 4 3 Pigore ta Tie Go V Gdo roei eE EEEE EE a EEE E AE a 4 5 Fionied 3 Caprie Ne acetates eee i e a iiaa 4 7 Ficneed 4 The Trigger Windawie eeii ripere r na aaa e eaei daaar 4 8 Pipi 4 5 The Smapshot Pile Maintenance Soret osiin esineisiin aseara 4 9 Pipe 4 6 The SIGMA Snapshot Egport Unility Sereen osc scessinsssntsescesusaseseneusecasieaseavsnsteeunes 4 14 Figure 5 1 The Alarm Fault Summary Sereen sessesessseessesesseesstsrrssressessrssressessresressersresressee 5 4 Fig re 5 2 Event History Serei sanicce iieiea Te e S Era a Eea iN EA 5 6 Figure 5 3 The Event History Filter Setup Screen esesesssesessseess
136. l Universal Operator Process Interface Monitor aan vn 2803 Copyright 1997 Rockwell Automation Figure 1 24 SIGMA NE UOI UPM Title Screen 2 Click the Continue button on the SIGMA NE UOI UPM Title screen The initial screen for example standard Drive Overview screen is displayed 8 10 58 Status Setpoint Current Load Wa 1 Payee Cune B0000 wu p00 ihe trianan ed ooo p00 2 Pape eel Diw ODIO sew zm 000 00 Wa 2 Hatter TOODO ww pom 000 9007 tha 2 Pinch ot uane COO wu Soo 0007 0007 Woe Rll a iene DOI wu Soom 000 500057 tha dle al SOOT eu FOOT 000 000 nane BOUDI wu aE ooo EE i i Figure 1 25 Drive Overview Screen Note This initial screen varies depending on the specific application To Restart 32 Bit SIGMA Clients if The SIGMA Server Shuts Down 1 Click the Stop Custom OCX Server icon on the Windows desktop Stop Custom OCX Server Icon 2 Click the Close Button of the SIGMA TCPIP Server LOG T InitTemplate a F Comm F Tag Funct a prer lnr a F WriteTemplate 14 08 27 654 0x9e gt RE_Comm dil Compiled Aug 18 1998 10 33 57 08 26 493 Oxde gt Re_sigma dil Compiled Aug 19 1998 14 11 22 650 0x9e gt Re_sigma dil Compiled Aug 19 1998 14 11 22 8 OxSe gt Write Template Function Logging Disabled 8 Ox3e gt Write Template Function Logging Enabled 8 Ux3e gt Re_sigma dil Compiled Aug 19 1998 14 11 22 167 Ox9e gt R
137. lation CD into the CD ROM drive 3 At the Run prompt in Windows 2000 type lt drive gt setup ex The screen displays the Rockwell Automation SIGMA NE UOI UPM window with the following Setup popup box My Computer 7E Network Neighborhood b Inbox Internet Explorer ieg Recycle Bin which will guide you through the rest of the setup process Please wait amp 2 cw aie Microsoft SIGMA Setup 100 Outlook Figure 1 14 Rockwell Automation SIGMA NE UOI UPM window with Setup popup box The screen then displays the installation Welcome popup screen A SIGMA UOI UPM Setup Of x SIGMA UOVUPM Welcome Ea Welcome to the SIGMA Setup program Before you proceed with the installation make sure the license disk provided by Rockwell Automation is inserted into the floppy drive It is strongly recommended that you exit all Windows programs before running this Setup program Click Cancel to quit Setup and then close any programs you have running Click Next to continue with the Setup program WARNING This program is protected by copyright law and international treaties Unauthorized reproduction or distribution of this program or any portion of it may result in severe civil and criminal penalties and will be prosecuted to the maximum extent possible under law Cancel Figure 1 15 Installation Welcome Popup Read the installation Welcome popup screen and click the Next button to co
138. ld The Recall List From File screen remains active after deletion To delete the file click this push button Cancel Returns to the Snapshot Export Utility screen without recalling any list of variables To return without recalling click this push button Select options These options allow groups of variables to be moved between the Variables not to be exported and the Variables to be exported lists The groups which are moved are determined by the criteria specified by these fields The following are provided All variables Indicates that all variables in the specified list are moved when the Add or Remove push button is clicked on All variables selected check box When this check box is enabled and when the All variables radio button is selected only those variables in the list which are marked as selected are moved when the Add or Remove push button is clicked To toggle this option click the check box This option is selected when an X appears in the check box Variables in the list are selected by clicking them Starting with Indicates that only variables in the specified list whose names start with the text entered in the field next to the radio button are moved when the Add or Remove push button is clicked For example if the text in the field is A00_ then only variables starting with A00_ are moved To select this criterion click its radio button Ending with Indicates that only variables in the list whose nam
139. les Unit x is not carrying its share of the phase V current Unit x detects a problem with current sharing on phase W between power modules Unit x is not carrying its share of the phase W current 3 5 Troubleshooting The SA 500 Diagnostic Screen The standard SA 500 see Figure A 7 Diagnostic screens use the following registers and bit positions to animate Fault boxes and LED lights Note It is the responsibility of the person configuring the AutoMax software to make sure the correct information is configured within these variables SIGMA Universal Operator Interface PMI SA500 Diagnostics Help Return AutoMax Distributed Power System AC Power Module 4e0 ys Figure A 7 The SA500 Diagnostic Screen 3 5 1 Fault Boxes The following table lists the SA 500 fault names their suggested variable names bit positions and under what conditions this bit is set Variable Name Bit Position DC Bus Over Voltage DRV_FLT the DC bus exceeds the maximum voltage allowed No PMI Comm DRV_FLT EJ there is no communications with PMI rack na Davsrarme 15 _ PMI PS Power DRV_FLT 12 the 5v 15v or 15v power supply Supply Fault fails Power Module PS DRV_FLT 3 Voltage Vcc on the power module is Fault too low Resolver Wire Fault DRV_FLT za a broken resolver wire is detected PMI Bus Fault DRV_FLT the address and data bus fails IOC Instantaneous DRV_FLT 1 there is an over curren
140. load or duty cycle if possible To configure the alarm as a fault set bit 15 in VP Fault Warning Configurable Select parameter 88 to 1 To configure the alarm as a Warning set bit 15 in VP Fault Warning Configurable Select parameter 88 to 0 and set bit 15 in VP Warning None Configuration Select Parameter 89 to 0 To disregard the alarm set bit 15 in VP Fault Warning Configurable Select parameter 88 and VP Warning None Configuration Select Parameter 89 to 0 A l Troubleshooting The SD 3000 and SD 3000 Regen Diagnostic Screens 167 A 1 1 I UE SS cote ht ace E E 167 PMD AED SS ee cctca Nace a a a A means Odes av A tae Basteay a eases a 170 A 1 3 SCR OCC MIAUEG 5s siara baa iag e A aT AE a AE EASA AR Te AKERS A ERES 172 A 2 Troubleshooting The SA 3000 Diagnostic Sereen se sesessssessesessseessessrssseessesressee 173 A 2 1 Failt BOXES e a a e n a a e eai 174 A22 EEDE For n e te re RE EE EET 177 A 2 3 IGBT Schematic ei irnod aneia eA aai A a aies 180 A 3 Troubleshooting The SA 3000 Parallel A B and C Diagnostic Screens 0000 181 A 3 1 Fault 10 of eee anai a a Se a a E e a 182 A32 LED Lichts Sc aed ahs a e E E AA S ashaes 188 A 3 3 IGBT Schematic cesen eean aa a araa aa a 191 A 4 Troubleshooting The SB 3000 Parallel A B and C Diagnostic Screens 0 193 A 4 1 Fault BORES A a a a A E E a a ain tee 194 A42 CED Lighten iinan e N E ia E E E a otc at ot 200 A 4 3 IGBT SCHEMA
141. lt Warning Configurable Select parameter 86 to 1 To configure the alarm as a Warning set bit 0 in CP Fault Warning Configurable Select parameter 86 to 0 and set bit 0 in CP Warning None Configuration Select Parameter 87 to 0 To disregard the alarm set bit 0 in CP Fault Warning Configurable Select parameter 86 and CP Warning None Configuration Select Parameter 87 to 0 The precharge function could not complete within 30 seconds Suggested Action Refer to the Understanding Precharge and Ridethrough Faults section in the troubleshooting chapter of the user manual for more information To configure the alarm as a fault set bit 1 in CP Fault Warning Configurable Select parameter 86 to 1 To configure the alarm as a Warning set bit 1 in CP Fault Warning Configurable Select parameter 86 to 0 and set bit 1 in CP Warning None Configuration Select Parameter 87 to 0 To disregard the alarm set bit 1 in CP Fault Warning Configurable Select parameter 86 and CP Warning None Configuration Select Parameter 87 to 0 Bus Drop 150 Volts Below Nom 12034 Bus Under Voltage 12035 UC_CP_FLT 3 2 Soft fault Red LED or UC_CP_WR N Warning Yellow LED UC_CP_FLT 3 3 Soft fault Red LED UC_CP_WR N Warning Yell ow LED The bus voltage dropped 150V below the bus tracker voltage Suggested Action Monitor the incoming AC line for low voltage or line power interruption Refer to the U
142. m of the Snapshot Export Utility screen appears the Variable Selection group Data fields in this group pertain to which variables the Snapshot Export Utility exports from the selected snapshot file All variables in the snapshot may be exported or only a subset The snapshot is selected from the Available snapshots group The variable selection group contains the following Variables not to be exported List of variables from the snapshot which the Snapshot Export Utility does not export When a snapshot is selected all of its variables appear in this list 1 e no variables are selected for exporting Double clicking a variable in this list removes it from the list and adds it to the Variables to be exported list If more variables are in the snapshot than can fit in the list box then a scroll bar appears at the right side of the list Variables to be exported List of variables from the snapshot which the Snapshot Export Utility does export When a snapshot is selected this list box is empty Variables must be added to this list from the Variables not to be exported list Double clicking a variable in this list removes it from the list and returns it to the Variables not to be exported list If more variables are added to this list than can fit in the list box then a scroll bar appears at the right side of the list Save list Allows the list of variables in the Variables to be exported list to be saved in order to be recalled at a late
143. matic Trigger description The snapshot s description text Snapshot descriptions are entered by the user in several ways Refer to sections 4 3 and 4 4 for more information on entering snapshot descriptions Snapshot duration The length of time in the snapshot in HH MM SS format This is based on the trend sample interval and the number of samples per variable in the snapshot see below Variable count The number of variables in the snapshot Snapshots usually contain all trended variables therefore the count which appears here is usually the number of trended variables However a snapshot that is exported by the Snapshot Export Utility selecting the binary file format option may have only a subset of these variables and therefore the count which appears here may be less than the number of trended variables Samples per variable The number of samples for each variable in the snapshot Also the trend sample interval is displayed here The Current server snapshot files section contains a data grid displaying all server snapshot files that are available for retrieval or deletion Server Snapshot Files Grid The Server snapshot files grid displays the file name file size and file creation date for all of the available snapshots on the server Use the grid to select the desired server snapshot file When a file is selected the file name will appear above the grid The following push buttons are located on the Snapshot File Maintenan
144. me is composed of the word SNAP a sequential number generated by SIGMA NE and the file extension SNP Trigger time Time when the snapshot was generated A snapshot can be generated in several ways Refer to sections 4 2 4 3 and 4 4 for more information about generating a snapshot Trigger event Type of event manual or automatic used to generate snapshots The Trigger Event for Go or Capture snapshots is Manual The Trigger Event for Trigger Variable snapshots is Automatic Trigger description The snapshot s description text Snapshot descriptions are entered by the user in several ways Refer to sections 4 3 and 4 4 for more information on entering snapshot descriptions Variable count The number of variables in the snapshot Snapshots usually contain all trended variables therefore the count which appears here is usually the number of trended variables However a snapshot that is exported by the Snapshot Export Utility selecting the binary file format option may have only a subset of these variables and therefore the count which appears here may be less than the number of trended variables Snapshot duration The length of time in the snapshot in HH MM SS format This is based on the trend sample interval and the number of samples per variable in the snapshot see below Samples per variable The number of samples for each variable in the snapshot Also the trend sample interval is displayed here At the botto
145. mmand Example cps seeps alesis tugadiches coda neva iaustncwieddsiade saad eiegandoncdaladnagerdtieents 31 Figure 1 24 SIGMA NE UOI UPM Title Screen ee eecesecneeeneeeeeeeeceseceeeeseeeseseeeeseeeaeenaeeaee 32 Figure 1 25 Drive Overview Sereen s sssesessessesessssetsessesstseestssetsessestestssestestesetsessestesesseseestt 33 Chapter 2 UOI UPM Operation Overview This chapter describes SIGMA NE Universal Operator Interface UOI and Universal Process Monitor UPM operation This chapter describes e UOI UPM Startup Types of Screens Describing Screen Objects Accessing Screens Exception Handling Since each UOI system which usually includes the standard UPM screens varies with respect to the application it is monitoring and controlling the initial screen and elements of the menu will vary UOI UPM Start Up To start the SIGMA NE UOI or UPM Double click the appropriate SIGMA UOI or UPM Icon The first screen of the system is then displayed For many UOI applications the Drives Overview Screen see Figure 2 1 is initially displayed SIGMA Universal Operator Interface Overview Screen Overview Section SPAD Broke Trend Alm Fit Report Snapshot Quit 07 07 95 13 29 4 o Machine Speed 502 11 ipm Product Code 42J Load AHE Section Status Setpoint Speed FPM Oon Oon MO MOD MON MOM Size Press Top N Size Press Bottom Faulted OM m Third Dryer DO m
146. modifications to the trigger before it is armed New High Value Click once on this field to activate for entering a high value A user can either enter the value directly into this field or use the arrow push buttons located to the right of the field If the value is entered manually a user must press lt Enter gt for the window to accept the number Once a value has been entered the Enable High check box must be selected The Trigger Low Value section of the Trigger window allows users to enable the low value of the trigger value range which indicates when the trigger should be fired The following items are contained in this section Enable Low check box Click once on this check box to assign the low value in the New Low Value field as the lower limit in the trigger value range This check box must be selected in order for the trigger to accept the value An X in this box indicates the item has been selected Low Value This field displays the current low value for the trigger This display only field is helpful when making modifications to the trigger before it is armed New Low Value Click once on this field to activate for entering a low value This value must be less than the value entered in the High Value field A user can either enter the value directly into this field or use the arrow push buttons located to the right of the field If the value is entered manually a user must press lt Enter gt for the window to acc
147. n Return Clicking this option redisplays the Drive Overview screen The Help Option SIGMA Universal Operator Interface PMI 5D3000 Regen Diagnostics Help Return es Soa TY AS F af Figure 6 3 The Help Menu Clicking Help from the menu displays a Help Menu window shown in Figure 6 3 with a list of all drive faults and alarms This window lets the user view an explanation of each drive fault or alarm enter view orf print notes pertaining to each drive fault or alarm SIGMA Universal Operator Interface PMI 5D3000 Regen Diagnostics Help Return AC Loss Fault Amon TY i Figure 6 4 The Help Text The following lists the steps for viewing drive fault and alarm explanations viewing entering or printing notes for a drive fault or alarm item I Click the Help option located in the menu bar to display the Help Menu window This window lists all drive faults and alarms 2 Double click a fault or alarm item to display a Help Dialog box shown in Figure 6 4 containing an explanation of that item IMPORTANT The PMI LED item displays a list of defined diagnostic LEDs Double click a diagnostic LED to display a Help Dialog box shown in Figure 6 4 containing an explanation of that item 3 Click the Note push button to display the Note window Refer to Figure 6 5 Notes pertaining to the drive can be read entered and printed through t
148. n 00 00 31 Trigger event Manual Samples per variable 620 50 ms interval Trigger description Manual sample snapshot Variables not to be exported BDF_ELAPSED_HR Select options All variables selected Starting with Ending with Figure 4 6 The SIGMA Snapshot Export Utility Screen 27 variables to be exported Clicking Export from the Snapshot pull down menu displays the SIGMA Snapshot Export Utility Screen as shown in Figure 4 6 The Snapshot Export Utility allows snapshot files generated by SIGMA NE to be converted to other file formats This allows data in the snapshot to be analyzed with a number of popular Microsoft and third party software packages The Snapshot Export Utility supports the following file formats Microsoft Excel spreadsheet files XLS Microsoft Access database files MDB Binary files SNP Screen Description Data fields in the SIGMA Snapshot Export Utility screen are divided into several groups In the upper left corner of the screen appears the Available snapshots group Data fields in this group allow for the selection of the snapshot to export The group contains the following Snapshot drive Allows the user to select the disk drive where the Snapshot Export Utility looks for snapshots When a new drive is selected the directories which are found on that drive appear in the snapshot directory list see below To select a drive click the arrow at the ri
149. n for an SA3100 medium power drive This diagnostic screen information consist of an expanded drawing of PMI AC rack and its diagnostic LEDs a diagnostic grid showing the states active or inactive of drive faults and alarms a PT Power Technology Fault message box a diagnostic schematic showing states short or open for IGBT AC output devices Possible PT Fault Messages are Message Voltage read from the A to D converter indicates the reference voltage is over 10 out of tolerance 3 3v 2 Voltage read from the A to D converter indicates the reference voltage is over 10 out of tolerance 3 3v Output voltage level went below 2 2v with no status bit detected indicating unity index of modulation Harmonic injection D to A converter has reached its limit prior to unity modulation index For more information on this diagnostic screen information refer to Section 6 1 2 Viewing Distributive Power Diagnostic Screens For more information on the SA3100 drive refer to the Distributive Power System manual SA3100 Drive Configuration and Programming S 3056 The AB1336 Drive Diagnostics Screen SIGMA Universal Operator Interface 1336 Diagnostics Help Return Power Up Reset Fault D C Bus Over Yoltage Bus Ridethrough Timeout Feedback Loss Figure 6 15 The AB1336 Diagnostics Screen The AB1336 Diagnostics screen shown in Figure 6 15 displays diagnostic information for an
150. n is configured within these variables SIGMA Universal Operator Interface PMI 563000 Parallel Diagnostics Help Return B3000 Par 3 DC Bus No PMI Over Volt Comm pmax TBOZKOD FEEEEEEEEEEE ONN _ 5 _ s __ g __ y __ Automation Figure A 6 The SB3000 Parallel 3 Diagnostic Screen 3 4 1 Fault Boxes The following table lists the SB 3000 parallel fault and warning names their suggested variable names register bit positions and under what conditions this bit is set Variable Name Register A Register B Bit Position DC Bus Over Voltage DRV_FLT 202 1202 0 This can either be a fault or a High Bus warning A fault is set when the DC bus voltage exceeds the rating of the Power Module DRV_WRN 203 1203 0 A warning occuts when the DC bus voltage rises above the configured overvoltage threshold value The torque is automatically limited to avoid an overvoltage fault DC Bus Undervoltage DRV_WRN 203 1203 1 A warning occurs when the DC bus Warning voltage drops below the configured undervoltage threshold value The torque is automatically limited to avoid a further drop in the DC bus voltage No PMI Comm DRV_FLT 202 1202 15 A fault occurs when the fiber optic communication between the PMI processor and the UDC module is lost due to two consecutive errors of any type PMI PS Power DRV_FLT 202 1202 12 This fault occurs when the PMI Supply Faul
151. n s 03c2 sscastiassaedaciasaectsesnanjaryasaeuiens bandezaryvand epaebelayvaevacaiieoene 17 Figure 1 10 Recipe Manager Screen s 3 casa atic ieee ee ea aa 18 Figure 1 11 The Recipe Editor Screen sa 3ccisssesgcctisasesneessensctasosccseassittacds cvsecstasuedesagascesseasessncdecanecs 18 Figure I 12 Process O Very ew oiiire imena cdi cone eia beau ned cco aed digo E one Ei 19 Fi re T13 Tr ckin eae ae Oe OES RRS eR AE Re Om Pree ne ey aoe an 19 Figure 1 14 Rockwell Automation SIGMA NE UOI UPM window with Setup popup box 23 Figure 1 15 Installation Welcome Popup cecccecsseesseceseceseeeeseeeacecaecneeneeeeeseecsaeceseeseneenseees 24 Figure 1 16 Registered User Popup Screen casscvsnecssetsceashsviseasaticcvayiecasctisasveneaseatecivebsccstesseys 25 Figure 1 17 Installation Information Popup Screen ss sessseessesesseessessesseessesseesresseesesseesseeseese 26 Figure 1 18 SIGMA Server Name and IP Address Popup Screen cceecccscessseceteeeeeeeeeeeeeees 27 Figure 1 19 Creating SIGMA NE Folders and Icons Message Screen cesesceeseereeseceteenseeaee 28 Figure 1 20 SIGMA NE Setup Complete Popup ccccceccceeseeesseesseceeceeeeeeeeeeseeceaeeneeneeeenaeees 29 Figure 1 21 Start and Stop Custom OCX Server ICOMS essssesseeeeeeeceeceseeneeeseeeeeeeeeaeenaeeaee 29 Figure 1 22 SIGMA NE 32 Bit Applications Directory ccc ceeeseeceeeeceteceseeneeeseeeeeeeeceaeeeeenee 30 Figure 1 23 Ping Co
152. nagert screen Click the OK button The selected recipe is displayed in the Next column of the Recipe Manager screen Managing Recipes SIGMA Recipe System Recipe Manager vjs Exit Manager Editor Recipe Manager s j Setpoint Preset Next News Print n Download F Load Next FE Controlled Variable BEL BAIE SPEED FPM EE E pressoraw mm oo A Size Press Top Draw FPM a 4th Dryer Draw FPM _ 17 4TH Dryer Wet Draw FPM mem Calender DrumDrow rem ON ReetDrum Draw rrm mm Reel Speed FPM 1637 Figure 7 13 Recipe Manager ry The recipe manager screen see Figure 7 13 is the on line component of the SIGMA NE Recipe System From this screen the user can display recipe elements and their units display modify and capture the actual setpoints presently running in the drive system display the recipe as it was sent to the drive system download the next recipe to the drive system e load and review the next recipe to be downloaded to the drive system The Controlled Variable column see call out A in Figure 7 13 is a list of the recipe elements and units for the recipe item in each row Note that controlled variables is an application specific title for the recipe elements Up to ten recipe elements can be viewed at a time Other elements can be viewed by using the scroll bar to mo
153. names column field Tagnames Available This field displays a list of all event tagnames variable names Double click on a desired tagname to move it to the Selected Tagnames field Selected Tagnames This field displays the list of tagnames which should appear in the Event History screen Tagnames are moved to this list from the Tagnames Available field or added with the Add All Starting With field To clear all tagnames from this field click the Clear Selected List push button A tagname can be removed from this list by double clicking on it The following three push buttons appear in the top right of the Event History Filter Setup screen OK push button Clicking this push button exits the Event History Filter Setup screen and re displays the Event History screen with events filtered according to the specified parameters Cancel push button Clicking this push button cancels the actions performed while in this screen and returns the user to the Event History screen Reset push button Clicking this push button resets the Event History Filter Setup screen back to the condition it was in before any changes where made Printing an Event List SIGMA Universal Operator Interface Overview Section SPAD Trend Alarm Fit Snapshot _ Event History 07 21 94 10 00 No Active Filter Setup Filter Exception Time Message Type Clear Time Acknowledge Time Event history print setup Enter the number
154. nderstanding Precharge and Ridethrough Faults section in the Troubleshooting chapter of the user Manual for more information To configure the alarm as a fault set bit 2 in CP Fault Warning Configurable Select parameter 86 to 1 To configure the alarm as a Warning set bit 2 in CP Fault Warning Configurable Select parameter 86 to 0 and set bit 2 in CP Warning None Configuration Select Parameter 87 to 0 To disregard the alarm set bit 2 in CP Fault Warning Configurable Select parameter 86 and CP Warning None Configuration Select Parameter 87 to 0 The bus voltage drops below the level set in Line Undervolts parameter 27 This is the level where the drive would enter ridethrough if it occurs before a 150 volt drop in bus voltage Suggested Action Refer to the Understanding Precharge and Ridethrough Faults section in the troubleshooting chapter of the user manual for more information To configure the alarm as a fault set bit 3 in CP Fault Warning Configurable Select parameter 86 to 1 To configure the alarm as a Warning set bit 3 in CP Fault Warning Configurable Select parameter 86 to 0 and set bit 3 in CP Warning None Configuration Select Parameter 87 to 0 To disregard the alarm set bit 3 in CP Fault Warning Configurable Select parameter 86 and CP Warning None Configuration Select Parameter 87 to 0 Bus Ridethrough gt 5 Cycles 12036 Bus Ridethrough gt 75 Cycles Open Circuit 12037
155. neous Over DRV_FLT 202 1202 4 Power Interface fault a Charge Bus Timeout DRV_FLT 202 1202 6 1 fault or an Over Temp Fault occurs DRV_FLT 202 1202 7 EXT FLT External Fault or or or an DC Bus Over Voltage fault a Ground Current fal a Charge Bus Time fault or a user DRV_FLT 202 1202 1 configured fault 0 IO_CNTRL 101 1101 2 IO FLT Flex I O DRV_FLT 203 1203 1 red when a Flex I O Communication 3 Comm fault is detected Fault Resolver and Drive I O LS FDBK OK Feedback OK and ness AUX IN1 Auxiliary input 1 AUX IN2 Auxiliary input 2 AUX IN3 Auxiliary input 3 DRV_FLT 202 1202 7 green when the resolver feedback device is OK Loss of this LED usually DRV_FLT 202 1202 8 indicates a broken wire to the feedback device RPI Run IO_STAT 201 1201 0 gteen when the run Permissive Input permissive input is OK IO_STAT 201 1201 1 amber when the status of the M Contactor output bit is high IO_STAT 201 1201 1 green when the auxiliary input 1 is present IO_STAT 201 1201 2 1 green when the auxiliary input 2 is present IO_STAT 201 1201 3 1 green when the auxiliary input 3 is present AUX IN4 IO_STAT 201 1201 4 1 green when the auxiliary Auxiliary input 4 input 4 is present AUX IN5 IO_STAT 201 1201 5 1 green when the auxiliary Auxiliary input 5 input 5 is present AUX OUT IO_CNTRL 101 1101 4 1 amber when the auxiliary Auxiliary output output
156. ns display box e Variable Name Filter entry box with ON Off buttons e the Settings For Variable Name Description of the variable and Units of the four variables the selected variable configuration e The OK and Cancel buttons SIGMA Universal Operator Interface Trend Screen Available Variable Configurations Variable Name Filter Current Filter oe Nores Off Settings For D3M_FB Variable Na Description O3M_BUS_VOLTS D3 Main DC bus voltage volts OSM_SPEED_FB D3 Main speed fb 20000cnts 4000fpm DGM_TORGQUE_FB D3 Main torq fh 4095ents TROBAR x Iq D3M_MOT_VOLTS D3 Main motor voltage feedback VRMS Figure 3 5 The Memory Load Window Using The Variable Name Filter If there is a large number of available stored variable configurations use the Variable Name Filter to find a variable s in an available variable configuration in which you want to load To use the Variable Name Filter click the variable name filter On and enter the filter prefix suffix of the variable name that is needed to find the variable configuration that includes the variable name you want to load Click the variable name filter Off and then ON to activate the search for the variable name that matches the specified filter If more than one variable configuration whose variable name s match the filter is found the Load popup window lists these variable configurations in the Available Variable Configurations di
157. ntinue with setup After reading and accepting the license agreement click the Yes button to continue The next screen see Figure 1 16 displays the Registered user popup screen that lists the optional software components development configuration editors SLC Database Editor and data monitoring modules with the amount of disk space that each utility occupies to be installed on a designated development machine Make sure the components that you want to install have a check mark in the box along side of them To find out what each utility does click the component and the Description box will describe that component At the bottom of the Registered user popup the total disk space required for the selected components and the disk space available is displayed SIGMA 32 bit Client Standard UOI Setup Registered user Please select the configuration editors and data monitoring modules that you want to install on this system Components m SLC Database Editor 722K Snapshot Viewer 110K Permissive Configurator 246 K Overview Configurator 312K Recipe Configurator 909K Description This utility is used to create and maintain SLC Chanae Databases consisting of SLC configuration information Space Required 5302 K Space Available 2427440 K lt Back Next gt Cancel Figure 1 16 Registered User Popup Screen 6 When you have selected the components that you want to install click the Next b
158. o a stop regardless of the selected stop type Suggested Action Check Autotune Status parameter 44 Additional information to help Understanding the Auto tuning Procedure In the AB1336 Force Drive User s Manual There is excessive temperature at the heatsink When this condition occurs the drive coasts to a stop regardless of the selected stop type Suggested Action Check the cabinet filters drive fans and heatsinks Check the thermal sensor and sensor wiring connector Reduce the load or duty cycle if possible Lower the value of PWM Frequency parameter 222 Check the roof fan rotation H frame only Software Malfunction 14020 Bus Ridethrough Timeout 12032 Bus Precharge Timeout 12033 UC_FAULT S Hard Fault Red LED UC_CP_FLT Soft Fault Red LED UC_CP_WR N Warning Yell ow LED UC_CP_FLT 3 1 Soft fault Red LED UC_CP_WR N Warning Yell ow LED When this condition occurs the drive coasts to a stop regardless of the selected stop type Suggested Action Recycle the power If the fault does not clear replace the main control board There was a bus voltage drop of 150V and power did not return within 2 seconds Suggested Action Check the incoming power and fuses Refer to the Understanding Precharge and Ridethrough Faults section in the Troubleshooting chapter of the user Manual for more information To configure the alarm as a fault set bit 0 in CP Fau
159. o generate the snapshot immediately Cancel push button Click this push button to cancel the generation of the snapshot IMPORTANT The SIGMA NE snapshot system only allows the storage of five snapshots When attempting to take the sixth snapshot after 5 snapshot files already exist a message window appears on the screen The sixth snapshot is written to a file however the Go window takes you directly to the Snapshot File Maintenance Screen to allow you to delete one of the snapshot files If you return from the Snapshot File Maintenance Screen without deleting one of the snapshot files the current or sixth snapshot is deleted for you Capture Snapshots Use the Capture snapshot to generate a snapshot starting at the most recent time currently displayed on the trend graph The time interval for this snapshot is specified by the trend graph interval The Capture option is only available on the Trend Screen s Main Menu refer to Chapter 3 Trending and only when trend interval is 20 seconds 100 seconds or 5 minutes Unlike the Go snapshots a Capture snapshot file is generated for the time interval currently viewed on the Trend Screen This information can be either current or historical To generate a Capture snapshot 1 Make sure that the trend graph interval in the Trend Screen s Main Menu is 20 seconds 100 seconds or 5 minutes Refer to Section 3 2 2 Adjusting The Time Interval Click Capture from the Snapshot pull down men
160. of events to print 2 Start Position NOTE Beginning of List If a filter is currently active then the printed Current Position events will also be filtered Figure 5 4 The Event History Print Setup Window Clicking the Print push button displays the Event History Print Setup windows shown in Figure 5 4 This window allows users to enter a specific number of events to print and the location within the list from which to start printing Printing a list of events may provide further diagnostic information IMPORTANT If a filter is currently active then the printed events are filtered also Screen Description The following are the parameters contained in the Event History Print Setup window Enter the number of events to print This field is used to specify the number of events to print from the Event History Screen It is used in conjunction with the Start Position radio buttons This field defaults to 12 which is exactly one page of events When a start position is established the user can enter the number of events to print from that point using this field If this field is left blank all of the events contained in the list are printed Start Position radio buttons These radio buttons indicate where to start printing events from There are two choices the Beginning of List and the Current Position Choosing the Beginning of List option prints the event list starting from the first event in the list To use
161. on and feedback indicates that the pre charge contactor has opened The DC bus voltage is less than the value stored in the Power Loss Fault Threshold PLT_E0 tunable variable IPD Inverter Power This fault occurs when the gate driver Device Fault turns off an output power device IGBT to protect it from an overcurrent An IOC fault Bit 3 of register 202 1202 will also be set Open Thermistor DRV_WRN 203 1203 9 A warning occurs if an open circuit is detected in the thermistor circuit UDC Run Fault DRV_FLT 202 1202 14 The UDC Run Fault bit is set if the UDC task stops while the minor loop is running in the PMI Regulator Flex I O Comm DRV_WRN 203 1203 13 A warning occurs if a Flex I O Warning communication problem is detected and logged in UDC tegisters 10 22 or 11 23 a DEVeWAN AION The Voltage Ripple Warning bit is set if the ripple on the DC bus exceeds the configured voltage ripple threshold value Reference in Limit DRV_WRN 203 1203 4 The Reference in Limit Warning bit is Warning set if the reference to the regulator exceeds the maximum value permitted 4095 or is being limited by the system in response to an overvoltage or undervoltage warning Over Temperature Fault DRV_FLT This can either be a fault or a warning PO OE A fault occurs when the internal temperature of the Power Module s heatsink exceeds 100 Deg C Error code 1016 will be displayed in the error log of the UDC task in w
162. onds 100 Seconds and 300 Seconds 5 Minutes A black dot appearing in the radio button indicates the selected time span OK push button Clicking this push button activates the time span for the Go snapshot and then removes the Snapshot Configure window from the screen Cancel push button Clicking this push button exits the Snapshot Configure window and cancels any changes made to the time span Generating Go Snapshots SIGMA Universal Process Monitor Trend Screen Interval Alm FIt Snapshot Print 26 July 94 13 23 46 Trigger DisArmed Please enter Snapshot description Interval at 10milliseconds Jul 26 Jul 26 13 01 24 13 00 24 Figure 4 2 The Go Window Click Go from the Snapshot pull down menu to display the Go window as shown in Figure 4 2 This window allows users to generate a snapshot immediately Before generating a Go snapshot the user can enter a description up to 66 characters for the snapshot which can be referred to later when maintaining or exporting snapshot files Screen Description Snapshot Description optional Enter a description for the Go snapshot being generated When the snapshot is generated the description is saved and appears as the Trigger Description in the Snapshot File Maintenance refer to section 4 5 and SIGMA Snapshot Export Utility refer to section 4 6 screens If an entry is not made in this field no description appears OK push button Click this push button t
163. ons Start the Custom OCX Server and Stop the Custom OCX Server and places them on your Windows desktop Figures 1 21 shows these icons Start the Custom OCX Stop the Custom OCX Server Icon Server Icon 5 top the Custom 0 Start the Custom 0 Figure 1 21 Start and Stop Custom OCX Server Icons Also the system creates icons for each selected SIGMA NE component and places it in the open SIGMA NE Applications directory on the Windows desktop To start a designated SIGMA NE component utility double click its icon FS SIGMA Applications x File Edit View Help Overview Permissive Recipe Configurator Configurator Configurator w 2 A Sigma Sigma UOI Sigma UPM Uninstall a 8 object s 3 60KB V3 Figure 1 22 SIGMA NE 32 Bit Applications Directory Verifying SIGMA Client Communication With SIGMA Server Use the ping command to verify availability of the SIGMA Server on the network The ping utility uses the Internet Control Message Protocol ICMP echo request and echo reply packets to determine whether a particular IP system on a network is functional The ping utility is useful for diagnosing IP network or router failures Use the ping utility to test both the computer name and the IP address of the computer If the IP address is verified but the computer name is not there may be a name resolution problem In this case be sure that the computer name you are querying is in either the local HOSTS file
164. ontaining all the variables available for use appears below the bar Any of the variables including one of those already assigned to a display channel can be designated to serve as the trigger variable A scroll bar is available to review the items in the list with To select a variable position the cursor over the desired variable name and click once This designates the chosen variable as the one monitored against High and Low Values Option radio buttons Select one of these radio buttons to assign a course of action to be taken when the trigger is fired A black dot appears next to the item that has been chosen Snapshot Time Span radio buttons Select one of these radio button to set up the time span the snapshot will be saved to a file These radio buttons can only be used only if the snapshot feature is available The Trigger High Value section of the Trigger window allows users to enable the high value of the trigger value range which indicates when the trigger should be fired The following items are contained in this section Enable High check box Click once on this check box to assign the high value in the New High Value field as the upper limit in the trigger value range This check box must be selected in order for the trigger to accept the value An X in this box indicates the item has been selected High Value This field displays the current high value for the trigger This display only field is helpful when making
165. ot DRV_WRN one of the power module s SCRs is not firing correctly firing correctly The schematic diagram shows exactly which SCR is alarmed SCR Short Fault DRV_FLT one of the power module s SCRs is shorted The schematic diagram shows exactly which SCR is being shorted Resolver Loss Fault DRV_FLT 7 the expected relationship between EMF and motor RPM is not maintained When operating at or below motor base speed RPM should be directly related to EMF Above motor base speed RPM should continue to increase and EMF should stay constant Resolver Wire Fault DRV_FLT a broken wire is detected on the motor resolver This is not used when analog tachometer is selected for speed feedback The following logic table explains the Resulting Faults and LED states for No PMI Comm faults If Variable Name And Variable Name DRV_STAT Bit 15 DRV_FLT Bit 15 State off Xorcom C ES ffi comm oD If there is no communication to the PMI rack the purple cross mark is displayed on the diagnostics screen see Figure A 3 SIGMA Universal Operator Interface Check C SIGMA LOGFILES UOI_VAR LOG Help Return Top Work Roll No PMI Comm l ra ae a TELS E WN Figure A 3 Diagnostics Screen When No PMI Communication Occurs 3 1 2 LED Lights The following table lists the LED names their associated suggested variable names bit positions and logic for the LED to be on LED Name Suggested
166. parameters for one channel is also dependent on the display parameters of the other channels For example constructing a useful graph may require several alternate selections before all the plots appear clearly separated Effective manipulation to appropriately tailor the appearance of the screen is a matter of experience The most convenient way to proceed after assigning variables to channels is to define the unit per division first This helps make it easier to select the appropriate center value with the Center Value fields The following are the steps for adjusting the unit per division value for a channel 1 2 4 Select the appropriate channel push button from the Variable column of the Trend Screen A Channel window appears Click once on the Units Div field A list of valid values appears with a scroll bar for paging through the list Locate the appropriate value and double click on it IMPORTANT If the current scale is too large causing the plot for the variable to appear too small reduce the scale by selecting a smaller value If the current scale is too small and the variable takes up too much of the graph increase the scale by selecting a larger value After locating the appropriate unit per division click once on the Set push button This will close the Channel window and redraw the plot in the Trend Screen IMPORTANT These steps may be performed multiple times before the best plot appears in the graph
167. pped The drive has reached the level of accumulated motor current over time as set by Overload Limit parameter 92 Suggested Action Check for possible motor overheating If the motor temperature is excessive reduce the accel decel times parameters 125 126 or reduce the load If the motor temperature is acceptable increase the value of Overload Lomit parameter 92 To configure the alarm as a fault set bit 4 in VP Fault Warning Configurable Select parameter 88 to 1 To configure the alarm as a Warning set bit 4 in VP Fault Warning Configurable Select parameter 88 to 0 and set bit 4 in VP Warning None Configuration Select Parameter 89 to 0 To disregard the alarm set bit 4 in VP Fault Warning Configurable Select parameter 88 and VP Warning None Configuration Select Parameter 89 to 0 Motor Stalled External Fault UC_VP_FLT Soft fault Red LED UC_VP_WR N Warning Yell ow LED UC_VP_FLT 5 6 Soft fault Red LED UC_VP_WR N Warning Yell ow LED The drive is in a limit condition for a period of time in excess of the value specified in Stall Delay parameter 91 with the motor at zero speed Suggested Action Check Torque Limit Sts parameter 183 to see which limit has occurred Increase the appropriate limit parameter or reduce the load To configure the alarm as a fault set bit 5 in VP Fault Warning Configurable Select parameter 88 to 1 To configure the alarm as a Warning set bit
168. r Charts SIGMA Universal Operator Interface 07 12 94 07 50 Entry Speed 0 0 PM Process Speed 0 00 kz Delivery Speed 0 0 F Section Speed FPM 400 800 1200 Figure 6 2 A Bar Chart Window 1600 2000 Clicking the title push button of any of the three Feedback columns displays the Bar Chart window shown in Figure 6 2 The Bar Chart window displays a bar graph of the feedback value for each drive listed in the Section column To the left of each bar graph the feedback value is displayed numerically This window allows a user to view value information both graphically and numerically If the information for the Feedback column is offset in the Drive Overview screen the bar chart is offset in this screen also The information in this window is display only Clicking once the Return push button redisplays the Drive Overview screen Viewing Distributive Power Diagnostic Screens Clicking a push button in the Status column displays the appropriate Distributive Power Diagnostic Screen for the drive section The following Distributive Power Diagnostic Screens are shown and discussed in the following sections of this manual SD3000 Section 6 1 2 2 SD3000 Regen Section 6 1 2 3 SA3000 Section 6 1 2 4 SA3000 Parallel Section 6 1 2 5 SA500 Servo Section 6 1 2 6 SB3000 Parallel Section 6 1 2 7 GV3000 A C Section 6 1 2 8 FP3000 D C Section 6 1 2 9 SA3100 Section 6 1 2 10
169. r Run negated Recent Alarm Motor Brush Wear Low FRPSo ojo RELIANCE D C Drive ELECTRIC EL Figure 6 13 The FP3000 D C Drive Diagnostics Screen The FP3000 D C Diagnostics screen shown in Figure 6 13 displays diagnostic information for an FP3000 Digital D C drive This diagnostics screen information consists of a diagnostic grid showing the states active or inactive of status indicators drive faults and alarms text description of the first fault occurring after last fault reset text description of the stop cause text description of most recent alarm Stop Cause messages are Stop Asserted or Run negated Coast DB stop e Jog de asserted for gt 1 second Fault stop or self tuning completed e Internal stop request e Customer interlock opened Current limit stop Coast DB interlock opened e Ramp stop Main contact opened For more information on this diagnostics screen information refer to Section 6 1 2 Viewing Distributed Power Diagnostic Screens The PMI SA3100 Diagnostics Screen SIGMA Universal Operator Interface PMI 543100 Diagnostics Help Return SA3100 Dc Bus No PMI Over Volt Comm PT Fault 5 Fluz current loop integrator time constant is not within Reg 22211222 calibrated limits Rockwell Automation Figure 6 14 SA3100 Diagnostics Screen The SA3100 Diagnostics screen shown in Figure 6 14 displays the diagnostic informatio
170. r name and IP address Enter the name and IP address of the SIGMA Server that this particular SIGMA Client is going to be connected to NOTE These settings can be changed later by editing the CAINNT System32 Drivers Etc Hosts file T 2 Figure 1 18 SIGMA Server Name and IP Address Popup Screen 8 After verifying that the correct Server name and IP address are specified click the Next gt button The system starts creating SIGMA NE folders and icons see Figure 1 19 J2 SIGMA UOI UPM Setup SIGMA 32 bit Client Standard UOI Setup Creating the SIGMA folders and icons Figure 1 19 Creating SIGMA NE Folders and Icons Message Screen When the installation of files is complete the SIGMA NE Setup Complete popup is displayed This popup asks if you want to restart the computer now or later Note It is recommended that you restart your computer before attempting to execute the installed programs Figure 1 20 SIGMA NE Setup Complete Popup SIGMA UOI UPM Setup SIGMA 32 bit Client Standard UOI Setup SIGMA Setup Complete Setup has finished installing all the needed components It is recommended that you restart your computer before attempting to execute the installed programs C No will restart my computer later Remove any disks from their drives and then click Finish to complete setup 9 Click the Finish button to complete the setup The SIGMA NE 32 Bit system creates two ic
171. r time using the Recall list push button see below To save the list click this push button to display the Save List To File screen This screen contains the following File name The name of the file in which to save the list of variables The file extension cannot be entered and is defined as EXP To specify the name of the file click this field and then type the name Available files List of variable list files i e those with the EXP file extension which already exist in the path displayed by the Path field see below To select one of the listed files as the file in which to save the list of variables click the desired file its name then appears in the File name field If more files are found in the path than can fit in the list box then a scroll bar appears at the right side of the list Path Path where the Save List To File screen looks for variable list files i e those with the EXP file extension already created This field is display only OK Saves the list of variables in the variable list file specified in the File name field and then returns to the Snapshot Export Utility screen To save the list click this push button Cancel Returns to the Snapshot Export Utility screen without saving the list of variables To return without saving the list click this push button Recall list Allows a list of variables saved using the Save list push button see above to be recalled into the Variables to be expor
172. rameter 88 to 1 To configure the alarm as a Warning set bit 2 in VP Fault Warning Configurable Select parameter 88 to 0 and set bit 2 in VP Warning None Configuration Select Parameter 89 to 0 To disregard the alarm set bit 2 in VP Fault Warning Configurable Select parameter 88 and VP Warning None Configuration Select Parameter 89 to 0 Motor OverLoad Pending 01051 Motor OvetrLoad Tripped 01052 UC_VP_FLT 5 3 Soft fault Red LED UC_VP_WR N Warning Yell ow LED UC_VP_FLT 5 4 Soft faul Red LED UC_VP_WR N Warning Yell ow LED A motor overload is pending The drive has reached 95 of the level required for a motor overload trip see fault 01052 for fault or fault 01084 for warning pugEeelcd Action Check for possible motor overheating If the motor temperature is excessive reduce the accel decel times parameters 125 126 or reduce the load If the motor temperature is acceptable increase the value of Overload Limit parameter 92 To configure the alarm as a fault set bit 3 in VP Fault Warning Configurable Select parameter 88 to 1 To configure the alarm as a Warning set bit 3 in VP Fault Warning Configurable Select parameter 88 to 0 and set bit 3 in VP Warning None Configuration Select Parameter 89 to 0 To disregard the alarm set bit 3 in VP Fault Warning Configurable Select parameter 88 and VP Warning None Configuration Select Parameter 89 to 0 Motor overload tri
173. re 7 10 Print Recipes Pop Up WindoW seeeesesessersreeresreresreseeresestenteststresteseerenestentssesrestese 152 Figure 7 11 Export Import Fies a tyc tecit sta derauttys tava hiu io nia a a aa 154 Figure 7 12 Load Next Pop Up WindoW jcc casataiss ce ialy weds tio stwecaytontecgadanvcanjadedestaandyaenysanteciy seas 155 Figur 7 13 Recipe Mana pet nir Bassas viens as re Ais e r rgahe ea aaieast usp a 156 Figure 7 14 Load Next Pop Up Window wvdiseccasindiceepstece si iisennsadiensaessiagseassentess usveccaveccnaceslees 157 Fig te 7 15 Pop Up Keypads ioie n e a sods dens E ia a ia aeei e eaaa Eana 157 Figure 7 16 Download Pop Up Window isc c csscsscaistenacospstanssesitesnueas evento cdueyceapseqntsstivebecceacbendess bees 158 Pioure 7 17 Pop Up Keypad edciessas sites cas naa odie asses a 159 Figure 7 18 Pop Up Capture Recipe Windows ccissisieceps cccesevasstnnceSeneaisstcseccssestess toesdecdevencticsstesd 160 Fig te 7 19 Pop Up Keyboard irienn i sods densouseaes soso E aaa e eaaa 160 Figure 7 20 Add Recipe Confirmation Pop Up BOX essseesssrssesseseeersrestestestsresreseerenresteetnsesresrsse 161 Figure 7 21 Overwrite Recipe Confirmation Pop Up BOX s s sssesesesesesrsresresrsresresterenrrsteerssesresrese 161 Chapter 8 SIGMA NE Support For SIGMA NE technical assistance see the Local Drive Solution Contact Directory at the end of this chapter for the location and contact numbers of the nearest Rockwell Drive Solution
174. rface module OIM or DCM Coast DB DRV_STAT 0 10 the Coast DB interlock terminal block Interlock user supplied is open This light is green when the Coast DB interlock terminal block is closed Customer DRV_STAT the Customer Interlock terminal block Interlock software based stop button is open This light is green when the Customer Interlock terminal block is closed 3 7 2 First Fault Text Message FRST_FLT This message Any of the faults described in the previous table is the first fault that occurred after the last fault reset 3 7 3 Stop Code Messages STP_CAUS The Stop Code message indicates the reason why the drive stopped Stop Code messages are e Stop Asserted or Run negated e Jog de asserted for gt 1 second e Internal stop request e Current limit stop e Ramp stop e Coast DB stop e Fault stop or self tuning completed e Customer interlock opened e Coast DB interlock opened e Main contact opened 3 7 4 Recent Alarm RCNT_ALM Messages The text message listed on this line describes the most recent alarm Besides the alarms described in table x Motor Brush Wear Low AC Line Low and AC Line High the following alarm text message may also be displayed on the Recent Alarm line Alarm Description O O Network Communication Timeout Network Communications is missing or failed to communicate with master Control Source Select Network Main Contactor Did Not Open Main Contactor Did Not
175. ricas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Rockwell Automation SA NV Vorstlaan Boulevard du Souverain 36 BP 3A B 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas Rockwell Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Rockwell Automation Br hlstra e 22 D 74834 Elztal Dallau Germany Tel 49 6261 9410 Fax 49 6261 1774 Asia Pacific Rockwell Automation 55 Newton Road 11 01 02 Revenue House Singapore 307987 Tel 65 351 6723 Fax 65 355 1733 Publication SIG NE UM001A EN P January 2003 Copyright 2001 Rockwell Automation All rights reserved Printed in USA
176. rior SIGMA and AMXLIX Directories Restore a Prior Backup m WDN Ee If no response within 10 seconds SIGMA automatically starts Changing the SIGMA Server IP Address If the SIGMA Server IP address changes after installation change the current IP address to the new IP address in the file c rmx386 config tcp ini onthe SIGMA Server This is also where IP mask and routing changes can be made On the SIGMA Client the file c winnt system32 drivers etc hosts will need to be edited to reflect the change to the SIGMA Server IP address as well The IP address change will take effect the next time the SIGMA Server is rebooted Wb About SIGMA NE UVOVURM nietin whe etched aaa i eei a 14 1 2 About SIGMA NE Operator Interface Design sssnssesessseeseesesseessessrssressesseesresseeseese 20 1 3 Software Reguirements ni ee yc a A A a A a a a aes S 21 LA Hardware Regue mentS esseistinen areae A RTA AEE A AREE TATEK EA ARES 21 1 5 Setting Up a SIGMA Client i ionan dents A tin E E Ei 21 1 6 Setting Up a SIGMA Serfvef s sessseessessesseessessssresseestesresstessesrrsstessesstssressesstesresseesee 21 1 7 Installing SIGMA Client Software s sesesesseesesseesseeseesrssseessesersseessessesseessessrssresseesees 21 1 7 1 Client Installation Procedure sasccccciscoceoss suas tata denescsdnevvaeds dectice suidaba deaecstvotegthdesece s 22 1 7 2 Installing Appropriate Windows Operating System Windows 2000 0 22 1 7 3 Using the
177. rvoltage fault A fault occurs when the fiber optic communication between the PMI processor and the UDC module is lost due to two consecutive errors of any type A warning occurs when the DC bus voltage drops below the configured undervoltage threshold value The torque is automatically limited to avoid a further drop in the DC bus voltage DC Bus Over Current Low Bus Ground Current PMI Bus Fault IOC Instantaneous Over Current Fault Resolver Fault DRV_FLT 202 1202 1 DRV_FLT 202 1202 2 203 1203 2 DRV_FLT 202 1202 13 DRV_FLT 202 1202 3 DRV_FLT 202 1202 8 DRV_FLT 202 1202 9 This fault occurs when the DC bus current exceeds 125 of the tated Power Module current Error code 1020 will be displayed in the error log of the UDC task in which the fault occurred This can either be a fault or a warning A fault condition occurs when ground current exceeds the rating of the Power Module Error code 1021 will be displayed in the error log of the UDC task in which the fault occurred A warning occurs when the ground current exceeds the configured ground fault current level This fault indicates that the Resolver amp Drive I O board and the AC power technology circuitry do not respond to requests from the PMI processor This indicates a hardware failure in the PMI Regulator Occurs when there is an over current in one of the power devices Register 204 1204 bit 0 5 indicat
178. s using the Recipe Editor screen e Managing Recipes using the Recipe Manager screen Editing Recipes The Recipe Editor screen is used to prepare and modify recipes that can be downloaded to the control system using the Recipe Manager screen This screen lets the user browse a recipe s elements browse stored recipes edit an existing recipe or enter a new recipe copy clear save delete print file import or export and load next recipes in the Edit Field or that have been stored SIGMA Recipe System Recipe Editor Manager Editor Defautt Copy Clear Save betete Print File Load Next Figure 7 1 Recipe Editor Screen Browsing Recipe Elements Up to ten recipe elements and their units see call out A in Figure 7 1 can be displayed at one time Use the vertical scroll bar to browse through the recipes that have more than ten recipe elements Browsing Stored Recipes Up to three stored recipes see call out B in Figure 7 1 can be displayed at one time Use the horizontal scroll bar to browse when there are more than three stored recipes Editing an Existing Recipe or Entering a New Recipe The Edit Field column see call out C in Figure 7 1 is used to edit an existing or enter a new recipe Any cell can be highlighted by selecting it with the mouse and clicking When the Recipe Name cell is highlighted the pop up keyboard is displayed for data entry see Figure 7 2 When a Recipe
179. s a vertical line intersecting the plots on the graph Above the graph the Trend Screen lists the exact values for the four variables where the line intersects the plots When the T2 slide is positioned within the graph the screen lists the exact values for the four channels at the position of the T1 slide the T2 slide and gives their difference The slide bar feature enables users to zoom in on a point of interest along the plots also By positioning the T1 slide on a plot point and adjusting the time interval a more detailed view results while leaving the point of interest at the same place on the graph Refer to section 3 2 2 Adjusting the Time Interval for more information on time intervals Saving Loading and Deleting Variable Data with Memory Option The Memory option on the Trend Screen s Main Menu lets the user save a variable s configuration so that the graphs produced by its variables can be loaded and displayed at a later time without having to re enter the information Each variable configuration set consists of up to four variables that make up a single trend graph Information stored for the set include the following e the variable assigned to each channel e the center values assigned to each channel e the unit div assigned to each channel SIGMA Universal Operator Interface Trend Screen Description DM6_FB Existing Variable Configurations Current Settings Variable Name Description AMX_FLT_TS
180. s that lets the user display text display feedback values numerically or graphically enter text or values select text or values from lists or options access other screens issue commands How To Activate Text Display Only Panel Snapshot file name c sigmayb snap1 snp Trigger time September 8 93 13 34 52 Trigger event Manual Trigger description OverLoad Variable count 284 Samples per variable 400 Raised Beveled Text Labeled Pushbuttons Click the button to issue a command or access for issuing commands or accessing full or a new full or popup screen popup screens Acknowledge or Text Entry Box Click the Box to type the text description and then click the OK button to enter this Please enter Snapshot description description Value Pats Tor Click the value to enter or change the value New High Val arf The background color of the box changes to blue Enter values using the PC keyboard or if enabled the internal keypad that is displayed _ Actual Value and Text Display Only Boxes Feedback Value Box inset panel Machine Speed 501 oA pons Graphics Display Boxes with Axes Labeled for Trended Values Return Units Description 24July 95 TOP VIRE fb dia gr constant 09 08 00 WIRE TURNING fb diatgr constant TOP WIRE speed Interval 5 Min TOP VIRE load Trigger DisArmed Slider Buttons for setpoint input a Vertical or Horizontal Scroll B
181. sasunneasinabaneisoungucnisanadaasasbenespooaemavageidengmenene 7 3 Figure 7 A PopUp Keyboard asrianiasr Rei E T i 7 4 Figure 7 3 Pop Up Keypad ocsienssieorirrin ann aE E EE NNN E 7 4 Figure T 4 Pop Up Edit Data Message BOn eraco ae aae n 7 4 Figure 7 5 Cdi FPunctonand Tosd Neri BUNOS vscsscsinssnnsranscsnusduocidssnescsmemsisarsbonnsaauniaccsauvnns 7 5 Piute oC on Deore DOR eeraa A E AN E 7 6 Figure 7 7 Save Recipe OVNE BOR osasin rat renaren eE KNEES E EEEN AER 7 7 Figure 7 8 Sare Reape Add BORi anea KE EAEEREN AEREE 7 7 Pirmie T 9 Delete i DUR seriinin neir san a a tees Map Aone RE 7 8 Figure 7 10 Print Recipes Pop Up Window sa sicsisacinn scingenenscndsr cascandsentannsvinssaceneetsatesexstigsnsaneaeisens 7 9 Ficme TI Espor Dopor Ples onirele ia ip e N a EEEE EEEE Ti 7 10 Figure 7 12 Load Nert Pop Up Widow oiie titaria ai iea EE eea aiaa E EATERS 7 11 Figure 7 13 Recipe Mordet onnon ite iea anei aaa e E ANE Eaa 7 12 Figure 7 4 Load Near Pop Up Window Sissies cots casgiiantvun dstacisphslemiodessaguayosuonass aee iii 7 13 Figure 2 15 Popp Eoad eono i a ea ea E eiia ai a aean S 7 13 Figure 7 16 Download Pop Up Window css sce doinssiadisa chaps cvotsoucissenopdevaaibguasecboncdincibanteosbentenutns 7 14 Figure 2 7 Pop Up Keypad oerion iiie i EAE EENE EEEE ANERE 7 15 Figute 7 18 Pop Up Capture Recipe Wii Os sssssssecesicnevscssasssendesavisgenssbseecaosustacssbeianan edssaastaabns 7 16 Beige 7 1
182. scroll until 1 4 of the screen or five minutes has elapsed whichever is less The T1 bar marks the trigger point and the graph remains frozen until the snapshot capture is complete IMPORTANT The Snapshot option from the Trigger function is only available while the displayed interval is within the normal Snapshot Capture screen intervals 20 seconds 100 seconds or 5 minutes The trigger event may happen at any time or never Assigning other variables to the display channels does not disable the trigger Moving between the Trend Screen and the other screens does not disable the trigger either When a variable has been chosen and the trigger armed the grey Trigger Disarmed label which appears in the upper right corner of the Trend Screen displays Trigger Armed in blue letters When a configured trigger occurs and the Freeze option from the Trigger window has been selected this label displays Trigger Fired Screen Description The following items are contained in the Trigger window State radio buttons These radio buttons reflect whether or not the trigger is armed Before a trigger is considered ready a user must click once on the Armed radio button This sets up the trigger for execution When a trigger has fired or is not ready the DisArmed radio button is selected A black dot appears in front of the option that has been chosen Trigger Variable Click once on this field to assign a variable to the trigger A list c
183. seessessesseessessssseesseossessrsseossesoessrosessesseessessosseesseosoese 107 5 5 SUMMA a a a a e a ie ite ft a at cod ele A T 109 Figure 5 1 The Alarm Fault Summary Screen ssssssesesesessesessresesestereststeesesteteststseseseerentstseseseeree 98 Figure 5 2 Event History Sereen eonna E a eas ea E A E E E TS 100 Figure 5 3 The Event History Filter Setup Screen sessseseerssiereseeererestrsrssreresreseerrsresrenresesresese 103 Figure 5 4 The Event History Print Setup WindoW esseessersseeseseeesesrsresrsstsresreseerenesteerssenrestese 107 Chapter 6 Drive Overview Screen and Support Screens The Drive Overview Screen and its support screens are components of the SIGMA UOI package These screens allow users to monitor and control the drives for a machine or system This chapter highlights the common features of these screens However when using the Drive Overview Screen or a support screen a user may notice functions and features documented in this chapter which are not part of their system This is because there are many options available with the Drive Overview package which may not be needed or appropriate for a particular application Also the user applications may contain custom application specific screens which are not documented in this manual The following screens are documented in this chapter e Drive Overview Screen This screen allows users to monitor the status of drives Included with this screen are section control
184. sion 00 0 0 ce eeeeeseeereereeeeeees 57 3 2 2 Adjusting the Time Interval sssnseesesseessesessseessessessressessresresseesteseessressessressesse 59 3 2 3 Selecting a Time AXIS uenici e e T OE ere een Tere 59 323k Live Modein yri aruia nan a e a naa r a ea oaas 59 3 23 2 Histoncal Modes Fay cag bch tcaieg aevecios hice vane E AR AE tesa aa band acl ano nage 60 3 2 4 Saving Loading and Deleting Variable Data with Memory Option 4 61 3 2 5 Printing a Trend Graphi Geass tae cove opicuteat peace a a a a a a a ates 64 3 3 The Trend Screen Trigger Peatare ts cinspastiasietacrogied ictanndnsattiad iiinn irti 64 3 4 Summary ihanan e E A EE a A ETE A E A AA EN 69 Figure 3 1 The Trend Screen css snee a a east a a i E RS Sl Pioure 3 2 The Channel Windowsis onnar eta ces sade Reese dete deae irae a ea be desde arte 54 Figure 3 3 The Trend Screen with T1 and T2 slider bats icciscsitescccsssscccssaesseassieuessssbaecscaiaves dessus gers 60 Figure 3 4 The Memory Save As Popup Window 0sscsscedsssseas sessiseasoascessacecasnisntosesd sansderises cavsiietee 61 Figure 3 5 The Memory Load Window ssi ss casevedsskstevestpssseaateedscasdeu shaves udbeasbncute aston ctenaiteessecesWecs 63 Fi re 3 6 The Des eer WAM nissai suas e i a E O EEA E a E 64 Chapter 4 Snapshots The Snapshot feature is the process of generating a file of trended data over a specified interval of time This data file is then available for export as a data
185. specified The functions of these screens columns and push buttons are defined below Screen ColunnnPush butfon Function Recipe Editor Screen see Figure 7 1 Lets the user create modify store delete and print recipes retrieve stored recipes save recipes to disk load recipes from disk Recipe Manager Screen see Figure 7 13 Lets the user to prepare and download recipes to the drive system modify setpoints that are currently running on the drive system capture these changed setpoints as a recipe to be used at a later time Setpoint Column see Figure 7 13 Values in this column are currently being applied by the drive system Preset Column see Figure 7 13 Reference Values that were sent down to the drive system from the SIGMA Recipe Manager If no changes have been made this value will match the setpoint Next Column see Figure 7 13 References Values in this column are in queue to be applied for the next product Note that this column is stored only in the SIGMA and does not affect values in the drive system until a download is initiated Capture Push button see Figure 7 13 Allows the values in the Setpoint column to be stored as a recipe Download Push button see Figure 7 13 Downloads the recipe in the Next column to the drive system Load Next Push buttons see Figure 7 1 Lets the user prepare the next recipe to be and Figure 7 13 run This chapter describes Editing Recipe
186. splay box If only one variable configuration includes variable name s that match the filter then the system displays that configuration on the trend screen 3 Click the variable configuration in the Available Variable Configurations display box to verify the variable names of that variable configuration 4 Click the OK push button to setup the variable configuration in the Trend Screen The graph is redrawn according to the variables included in that variable configuration To exit the Memory Save option without loading the variable configuration click the Cancel button Other Memory menu options on the Trend Screen s Main Menu are e Saving trend screen channels for up to 4 variables as an existing variable configuration Deleting an existing variable configuration Printing a Trend Graph The display on the Trend Screen can be printed by using the Print option from the Trend Screen s Main Menu Simply click once on the Print option and printing will begin CAUTION Selecting the Print option causes the screen to lock up for a short time while the picture is sent to the color printer Printing the screen will take approximately one minute The Trend Screen Trigger Feature SIGMA Universal Process Monitor Trend Screen Memory Trigger Interval Alm FIt Snapshot Print Variable T1 13 01 24 Units Description 26 July 94 1 ay 32424 00 HOURS Bed Drive Fized Elapsed Hours 13 02 48 324 24 INCHES Calender Diameter 1187 69
187. sted accordingly Note that the cursor must initially be placed in either the Begin From or To field before using these arrow buttons This indicates which field is to be adjusted In the middle of the Event History Filter Setup screen is a Sort Order section Ascending or Descending radio buttons Click either radio button to specify how the events should be displayed in the Event History screen Users must specify whether to present the events in Ascending the oldest event first or Descending order the recent event first The Tagname s Filter section allows users to select the specific tagnames variable names which should appear in the Event History screen The following items appear in the Tagname s Filter section Use Tagname s Filter check box Select this check box to enable the tagnames filter according to the tagnames appearing in the Selected Tagnames field An X in this check box indicates that this option has been enabled Add All Starting With This field allows the user to specify a character string each tagname must start with in order to be placed in the Selected Tagnames field To use this field enter a letter or series of letters which represents the first character s of the tagnames desired Press lt Enter gt The tagnames beginning with the letters automatically appear in the Selected Tagnames field Clear Selected List push button Clicking this push button clears the list of tagnames in the Selected Tag
188. sult of a condition that could damage This section discusses the following messages for Status Fault or Warning boxes shown on the AB1336 Drive Diagnostic screen 3 9 1 Status Fault or Warning Boxes The following table lists the AB1336 status fault and warning names their suggested variable names register bit positions and under what conditions this bit is set and what action to take Status Fault Suggeste Register I Warning d Variable Name Name Bit Position Power 1 1 These faults primarily consist of problems that could Up Diagnost through occur upon powering up both the current and velocity ic Fault 1 16 processors This fault will occur if a fault condition has been sensed on the drive s Main Control Board 1 Inspect the bad Main Control Board for damage 2 Ensure that the TE ground has not become corroded Check the resistance between the TE and PE grounds Verify PE and TE bus wiring are not shorted together by lifting the TE connection that is tied to building steel and measuring the TE bus to ground There should be a high resistance gt 1 Mohm Check the connection at both the ground bus and the point that the ground is connected to building steel to ensure that no corrosion is present The fault could also occur if you have changed out a Master Slave Control Board and there is a firmware revision mismatch with the PLC Comm Adapter Board Ensure the firmware revisions m
189. t then click the Add to add it to the Variables to be exported field IMPORTANT If a variable needs to be removed from the list click it and click the Remove push button When all variables for exporting are listed in the Variables to be exported field click the Export push button The snapshot file is exported as specified This chapter has highlighted the snapshot process Snapshots are useful for saving trended data for examination at a later time Refer to Chapter 3 for more information on Trending 4 1 Snapshot OVS LV ICW sisene aai daxth a a Naials aa 71 BD AAO SIMA pS hots io a a e A a E E E E A A a a ai 73 4 2 1 Configuring Go Snapshots ccgctaact cosvesrcaietee tee Sei carvan nasuelandauantunace 73 4 2 2 Generating Go Snapshots 2 Sansecvcvclen e accor cacen ed saueanve Seats quae rte tas eastae Santas a tiares 75 4 3 Capture Snapshots 2 craiesazequxssoscaadsenscestansaasdelacepsssardeaduicesassnaueaussesilrante ues eases 77 4 4 Trigger Variable Siapsnots x lt i igistsaiebsctiahsensbainena eisai ctieas cavidoreavanmnmeataies 78 4 5 Snapshot File Iai nen ances sit ts vaca boeedcdatetees ce ete dedudaSeneds boeueebash ones debueades bu aege dong uiceanels 79 4 5 1 Deleting Local Files with the File Maintenance Screen cccceccceesseeeteeeteeeees 83 4 5 2 Deleting Server Files with the File Maintenance Screen cccecceeseceeteeeteeeees 83 46 Snapshot Export Utility ssa arn a AE a aaa ESK R O E a SARA EEA
190. t condition Overcurrent Fault detected Over Speed Fault DRV_FLT 10 over speed is detected In vector mode this bit is set when slip exceeds 100 Over Temp Fault DRV_FLT the temperature of the heat sink exceeds the maximum rating The following logic table explains the Resulting Faults and LED states If Variable Name And Variable Name Resulting Fault or LED State DRV_STAT Bit 15 DRV_FLT Bit 15 Comm OK LED State Comm Fault No PMI Comm Fault If there is no communication with the PMI rack the purple cross mark is displayed on the diagnostics screen see Figure A 3 3 5 2 LED Lights The following table lists the LED names their associated suggested variable names bit positions and logic for the LED to be on LED Name Variable Name Bit i LED Turns Positio n Power Supply PWR OK Power DRV_FLT 12 green when the PMI Supply OK D supply is OK PMI Processor OK DRV_STAT green when the PMI PMI Processor processor is OK COMM OK DRV_FLT green when the Communications communications between OK the UDC and PMI is working OK and DRV_STAT PM FLT Power DRV_FLT red when there is an Over Module Fault Temp Fault or a power module power supply fault DRV_FLT EXT FLT DRV_FLT red when there is either an External Fault Instantaneous Overcurrent fault an Over Speed fault or a user configured fault DRV_FLT IO_CNTRL RAIL FLT DRV_WRN red when a rail fault is Rail Comm Fault
191. t power supply is not working correctly DC Bus Over Current DRV_FLT 202 1202 1 This fault occurs when the DC bus Low Bus current exceeds 125 of the rated Power Module current Error code 1020 will be displayed in the error log of the UDC task in which the fault occurred Ground Current DRV_FLT 202 1202 2 This can either be a fault or a warning A fault condition occurs when ground current exceeds the rating of the Power Module Error code 1021 will be displayed in the error log of the UDC task in which the fault occurred DRV_WRN 203 1203 2 A warning occurs when the ground current exceeds the configured ground fault current level stored in local tunable GIT_E1 PMI Read Write DRV_FLT 202 1202 13 This fault occurs when the PMI Fault read or write operation fails PMI Fan Loss DRV_WRN 203 1203 12 The PMI Fan Loss Warning bit is set when the airflow through the PMI rack is not being sensed IOC Instantaneous DRV_FLT 202 1202 3 This fault occurs when there is an Over Current Fault overcurrent in one of the power devices Registers 204 1204 bits 0 5 indicate which power device detected the overcurrent Bit 6 of register 204 1204 will also be set if the overcurrent was detected in the Intelligent Power Module Phase Loss Warning DRV_WRN 203 1203 3 This warning bit is set if a phase loss occurs in the AC line Note that the phase loss diagnostic cannot detect a phase loss if there is no loa
192. t text messages Drop Area 1 Register 12 Stop Cause text messages Drop Area 4 Register 22 Recent Alarm text message Drop Area 1 Register 14 3 7 1 Status Faults and Alarm Boxes The following table lists the FP 3000 status fault and alarm names their suggested variable names bit positions in register s 0 10 and 13 and under what conditions this bit is set appears yellow on the diagnostic screen Status Fault Suggested Register Bit Alarm Variable Name Position Name AC Line Sync DRV_FLT1 10 0 there is a three phase A C line Loss synchronization circuit failure Motor Field DRV_FLT1 10 1 The field loss detection circuit does not Loss sense any field current flowing in the motor shunt field Sustained DRV_FLT1 10 2 Inverse time overload circuit trips Overload Motor Brush DRV_ALM 13 0 the motor brushes are worn and require Wear Low replacement If a motor brush wear detector is not used customer terminal block pins CTB 12 and CTB 14 must be jumpered to inhibit this alarm Self Tuning DRV_FLT1 10 3 Self Tuning failure Refer to parameters Failure F00060 through F00067 and parameters F00089 through F00099 in the FP 3000 manual for possible causes Motor DRV_FLT1 10 4 the motor thermostat indicates high Thermostat temperature If a motor thermostat is not used customer terminal board pins 13 and 14 must be jumpered to inhibit this fault Controller DRV_FLT1 10 5 the Controller thermostat indica
193. ta iS 1 10 172 Installing Appropriate Windows Operating System Windows 2000 1 10 1 7 3 Using the SIGMA NE Installation CD seesesssenseesessseesseesrssressessresresseessesressee 1 10 1 7 4 Verifying SIGMA Client Communication With SIGMA Servet c ccee 1 19 1 7 5 SK MA Chom Owik S ei EE EE EEE A A A EAR 1 20 1 8 Installing SIGMA Server Software a ca nsccsssccacsvaccaccssundeniaccovsaeansnnsaeennadencenuntendivendencere 1 22 1 8 1 Starting a SIGMA EO ecran ii a EAE A EE ERRE 1 22 1 8 2 Changing the SIGMA Server IP Address ininiecsirniiiesireisrnsrssrnsssiestnsis 1 22 Chapter 2 UOVUPM Pera Ci siessen aE A 2 1 21 Baa a E E E A EEE E 2 1 22 UOLUPM Siart UP einser iaire Ea ee ee 2 2 2 3 Types OF SCreenS niesisiiicesiiisreiideesniri eei ew cates ee iansnaai sneak eni nace ES Seerat aoii ESE 2 3 24 CCA CR ODJ corectie irena r EE EN EATE EE TEE EAA 2 4 2a FS L A 2 9 26 Alann Fault Handling acca caicee a uncecss nator cernceraase encase ate eae 2 12 Chapter 3 TEANS sopes sire e t EERE noi exes he lates E E E AEE EaR 3 1 Emi Trendinp acca a css cau a EE E ER ee 3 1 aLi The Trending Memi aiseee ionin Pewee ns 3 2 22 Te Ten e ei Sev AE AAE A AA EEE AET AREA 3 3 a2 selecting Variables for the Trend Sereen accsiissscssnsssissesssacsssdsacesiansatassenaasesoineas 3 6 3 2 1 1 Defining the Center Value and the Units per Division cceeeeceesteeeteee 3 9 522 Adjusting the Time Ineryal een ee E eer er 3 11 Re SU
194. te 2 6 Internal Keyboatdann gesn Gengrana inaa a a i a a i 43 Figure 2 7 Typical UPM Main Menu Bar sssessesssessesersesseresrestsresrestertssestestestsresteseretseestestesesreseesee 44 Figure 2 8 Accessing Other Screens From The Alarm Fault Summary Screen Main Menu 45 Figure 2 9 Accessing Pop Up Box from Drives Overview First Press Button s ssssssesesessererseresee 46 Figure 2 10 Accessing a Pop Up Box from the Trending Screen s 1st Variable Button 0 46 Chapter 3 Trending This chapter describes the trending process Trending is the act of following general variable movement during the course of time It shows any tendencies among the variables which may be helpful when troubleshooting Within this chapter the following items are discussed The Trend Screen This screen allows users to create a trend graph using up to four variables With the graph the user can monitor the fluctuations in the variable values isolate a section of the graph for comparison purposes and print variable plots The Trigger Window This window allows users to create a trigger for monitoring a specific variable condition Triggers warn a user when the event has happened and can print out a section of the trend graph produced freeze the Trend Screen at the point the trigger was fired or create a snapshot for informational purposes IMPORTANT As a convention in this document plot means the curve for one of the selected vari
195. ted list A variable is recalled only if a match for it is found in the Variables not to be exported list When a variable is recalled it is removed from the Variables not to be exported list and added to the Variables to be exported list To recall a list click this push button to display the Recall List From File screen This screen contains the following File name The name of the file from which to recall the list of variables The file extension cannot be entered and is defined as EXP To specify the name of the file click on this field and then type the name Available files List of variable list files i e those with the EXP file extension which already exist in the path displayed by the Path field see below To select one of the listed files as the file from which to recall the list of variables click the desired file its name then appears in the File name field If more files are found in the path than can fit in the list box then a scroll bar appears at the right side of the list Path Path where the Recall List From File screen looks for variable list files Le those with the EXP file extension already created This field is display only OK Recalls the list of variables from the variable list file specified in the File name field and then returns to the Snapshot Export Utility screen To recall the list click on this push button Delete Deletes the variable list file specified in the File name fie
196. ter the Alarm Fault Screen with this option Refer to Chapter 5 Snapshot This option provides the snapshot menu used when creating snapshots This option is only available if the Snapshot programs are Refer to Chapter 4 Snapshots for more information Print A user can print a picture of the graph in the Trend Screen with this option Return This option allows users to exit the Trend Screen The Trend Screen SIGMA Universal Process Monitor Trend Screen Memory Trigger Interval Alm FIt Snapshot Print Return ee ye a j i Bed Drive Fized Elapsed Hours 12 56 01 PMI Arm Curr Fdbk unfltrd Interval 5 Min Couch Torque Split Setpoint ffrigger DisArmed Jul 26 12 55 Jul 26 Jul 26 50 12 54 50 12 53 50 Figure 3 1 The Trend Screen Choosing the Trend option from the Main Menu displays the Trend Screen as shown in Figure 3 1 The Trend Screen allows for the display of up to four plots superimposed on one graph Each plot represents the data for a variable over a time span and is displayed with one of four channels The channel s scheme allows operators to differentiate between plots and thereby eases graph interpretation The horizontal axis represents the interval in time for which the data was selected The vertical axis displays the units per division for each plot Note that if variables have not been assigned to channels previously or if channel assignments have been cleared the Trend Screen s graph appears with no
197. tes high Thermostat temperature AC Line Low DRV_ALM 13 1 The A C line voltage falls below 90 of the nominal AC line voltage Blower DRV_FLT1 10 6 The blower motor starter is open If a Motor Starter blower motor starter kit is not installed Open connector P8 must be fitted with the proper substitute connector to inhibit this fault Open DRV_FLT1 10 7 The motor armature circuit is open Armatute Circuit IET DRV_FLT1 10 8 Armature current instantaneously exceeds Overcurrent 180 of maximum current AC Line DRV_ALM 13 2 The A C line voltage rises above 115 of High the nominal AC line voltage Overspeed DRV_FLT1 10 9 Motor speed exceeds the 110 of the top Overvoltage speed or armature voltage exceeds 130 of motor rated armature volts Open SCR DRV_FLT1 10 10 one or more SCRs is not working Parameter DRV_STAT 0 12 parameters are unacceptable to the drive If Process this flag is set to 1 light is lit then one or Error Flag more parameters sent to the drive were rejected If this flag is set to 0 light is not lit then all parameters sent to the drive were accepted The processing error flag is updated approximately every 500 msec In Current DRV_STAT the motor is not operating within current ae Se Tach Loss Loss DRV_FLT1 10 12 the tachometer feedback the tachometer feedback signal missing missing OIM DCM DRV_FLT1 10 13 The regulator board was unable to Comm Loss communicate with the inte
198. the graph so they do not overlap and become indistinguishable When a channel configuration is complete a new graph is drawn in the Trend Screen with the color associated with that channel The name of the variable is printed on the push button to which it is assigned Screen Description The following items are contained in the Channel window Variable Name amp Description Clicking once on this field allows a user to assign a variable to the channel When the field is selected a scrolling list appears for the selection of a variable Scroll bars are available for searching through the list To select a variable locate the appropriate one and double click on it Units Div Clicking once on this field allows a user to assign a units per division value to the channel When chosen a scrolling list appears for the selection of a unit These values will adjust the vertical axis gain for the channel The valid values are 1 3 5 10 25 100 250 500 1000 and 2500 Scroll bars are available for searching through the list To select a value locate the appropriate one and double click on it Refer to section 3 2 1 1 Defining the Center Value and the Units per Division for more information on adjusting the units per division value Current Value This field displays the current value for the variable displaying in the Variable Name amp Description field This value is a helpful reference for the selection of the center value and t
199. the ripple on the DC bus exceeds the configured voltage ripple threshold value This fault occurs when the gate driver turns off an output power device IGBT to protect it from an overcurrent An IOC fault Bit 3 of register 202 1202 will also be set a GDI Gate Driver Interface indicates that unit n detected a problem with current sharing between power modules Unit 1 IPM fault is detected Unit 2 IPM fault is detected Unit 3 IPM fault is detected the power on the Gate Driver Interface is not within tolerance Unit 2 GDI DEV_DIAG2 220 1220 7 Unit 2 detects a problem with its gate Fault driver interface power supply Unit 3 GDI DEV_DIAG3 221 1221 7 Unit 3 detects a problem with its gate Fault driver interface power supply Charge Bus DRV_FLT 202 1202 6 This fault occurs when any of the Time out Fault following conditions occur e The DC bus is not fully charged within 10 seconds after the bus enable bit is set The drive is on and feedback indicates that the pre charge contactor has opened The DC bus voltage is less than the value stored in the Power Loss Fault Threshold PLT_E0 tunable variable Unit1 Charge DEV_DIAG1 204 1204 8 Unit 1 detects a problem with charge Fault ime out Unit2 Charge DEV_DIAG2 220 1220 8 Unit 2 detects a problem with charge Fault time out Unit3 Charge DEV_DIAG3 221 1221 8 Unit 3 detects a problem with charge Fault time out Over Temp Fault This can either be a fault or a
200. tion process for V Hz has been Abort aborted EPROM Write DRV_FLT2 13 5 Failure on write to non volatile memory bad Failure NVRAM Asymmetrical Bus DRV_FLT2 13 8 Bad Power Module Charge Input Phase Loss DRV_FLT2 13 11 Voltage ripple on D C bus due to missing input phase or an imbalance between phases If there is no network communication with the drive the purple cross mark is displayed on the diagnostics screen see Figure A 3 3 7 Troubleshooting The FP 3000 D C Drive Diagnostic Screens The standard FP 3000 D C Drive see Figure A 9 Diagnostic screen uses the following bit positions in registers s 0 10 and 13 for LED light information needed Note It is the responsibility of the person configuring the AutoMax software to make sure the correct information is configured within these variables If there is no network communication with the drive the purple cross mark is displayed on the diagnostics screen see Figure A 3 SIGMA Universal Operator Interface ITALIMPIANTI FP3000 Diagnostics Help Return AC Line Sync Loss No 1 Payoff Reel First Fault Instantaneous Armature Overcurrent Stop cause Stop asserted or Run negated Recent Alarm Motor Brush Wear Low FPSO RELIANCE D C Drive ELECTRICEL Figure A 9 The FP3000 D C Drive Diagnostic Screen This section discusses the following messages shown on the FP 3000 Drive Diagnostic screen Status Fault or Alarm boxes First Faul
201. ton decreases the value When either push button is held down the corresponding control variable ramps until the button is released Changes made with these push buttons do not require confirmation The Section Control window may display up to five action push buttons in the lower right corner of the window These push buttons are used to control the drive section and are application specific They can have names such as Run Jog Stop etc The color of the button changes depending on the status of the drive For example if the user clicks the Run push button it lights up when the drive is actually running In the lower right section of the window the following push button appears Return Clicking this push button to return to the Drive Overview Screen Ensure that any setpoint value changes have been confirmed before returning to the Drive Overview Screen or the changes do not take effect The Section Screen SIGMA Universal Operator Interface 07 12 94 07 55 0 a ejo Figure 6 17 The Section Screen Entry Speed 0 0 ner Process Speed 0 00 fal Delivery Speed 0 0 ane Section Control Panel Payoff Top Work Roll Satel l Roll Load Speed Speed Entry Group soo R ann Increase CRAWL Yy 100 Clicking the Section option from the Main Menu displays the Section Screen An example is shown in Figure 6 17 The Section Screen contains a horizontal scrollable list
202. tor Now Contar Units Div ee 2j 200 60 f ee 1G ul 20 Jul zo Jul 20 Jui 20 Jul 20 Jul 20 13 63 13 33 6213 72 61 13 13 60 13 1314913 13 48 13 Figure 2 10 Accessing a Pop Up Box from the Trending Screen s 1st Variable Button Yul 20 Jul 20 Jul zo Sat 20 Jul 20 Jul 20 33 63 13 33 62 13 72 6113 73 60 13 13 48 13 13 48 13 Alarm Fault Handling An SLC database handles alarms and faults as a subset of the data received from the remote systems The SLC uses this data to update the active alarms and faults list in the real time system The SLC also examines the alarms and faults data in those samples and performs several activities depending on the current and previous state of the data With event and exception handling the following occurs When an alarm or fault becomes active it is date time stamped and inserted at the head of the Alarm Fault Summary list If the alarm or fault is already in the active Alarm Fault Summary list it is removed from its current position and inserted at the head of this list If an active alarm or fault clears before it is acknowledged a clear time is added and color is normal video When an acknowledged active alarm or fault clears it receives a clear time stamp and is removed from the active Alarms Faults Summary list and appears on the Event History list When a cleared alarm or fault is acknowledged it is date time stamped to give the acknowledgement time removed from the act
203. tor wants to monitor regularly All of this information is display only A and B Factors section This section displays the A and B factors and the equation and total for the draw This information is display only Sections from the list below are selected as the A or B factor When selected the section s variable value for the section is displayed in the field The same variable is used for all sections in this screen Drive push button section This section contains a scrollable list of sections from the Drive Overview Screen refer to Figure 6 1 Twenty four 24 sections can be shown on the screen at a time Five push buttons appear along the bottom of the screen and serve as the draw screen action buttons They are Select A Clicking this push button selects the section to be used as the A factor in calculating the draw Select B Clicking this push button selects the section to be used as the B factor in calculating the draw B A B 100 B A 100 and B A Clicking one of these push buttons calculates the draw according to the displayed equation They have no effect if either the A factor or the B factor has not been selected Selecting Sections for Calculation l The following lists the steps for selecting a section as either the A or B factor 2 Click either Select A or Select B 3 Click the desired section The current variable value for the section is displayed in the appropriate A or B
204. types of SIGMA drives diagnostics screens and how to use them Setpoint column This column contains the current drive setpoint value for each drive listed in the Section column The setpoint value is display only It may be modified by the operator only if access to the Section Control window is provided for the drive in the Section column see Figure 6 1 Feedback columns These columns are the three columns which appear in the lower right portion of the Drive Overview screen Any of these columns may be unused A Feedback column displays the value of a drive variable e g drive speed in FPM for each drive section listed in the Section column The title of a Feedback column appears at the top of the column as a push button Clicking this push button displays the Bar Chart window for variables in the column Refer to Section 6 1 1 Viewing Bar Charts for more information Note that values in a Feedback column may be offset to display values which are between two adjacent sections For example refer to the Tension column in Figure 6 1 In this case the tension feedback values are shown offset between the two sections where the tension value is generated If a Drive section does not have a corresponding value in one of the feedback columns then either it has not been configured correctly or no corresponding feedback value exists Refer to the Load column for the last three viewable drive sections in Figure 6 1 Viewing Ba
205. u in the Trend Screen s Main Menu to display the Capture window refer to Figure 4 3 which is similar to the one associated with the Go snapshot Please enter Capture description Figure 4 3 Capture Window Enter a description for the Capture snapshot to be generated When the snapshot is generated the description is saved and appears as the Trigger Description in the Snapshot File Maintenance refer to section 4 5 and SIGMA Snapshot Export Utility refer to section 4 6 screens If an entry is not made in this field no description appears in these screens Click the OK push button to generate the snapshot starting at the most recent time currently displayed on the trend graph Trigger Variable Snapshots Armed Trigger Variable State C niearmed F13H FLD IFB_ FIELD CURRENT FEEDBACK Option Snapshot Time Span Freeze i C Print 20 Seconds High Value New High Value ew E 100 Seconds come in Seconds A min L 150 4 Snapshot Snapshot Description Trigger Low Value Low Value New Low Value o Eo e Figure 4 4 The Trigger Window Use the Trigger Variable snapshot to generate a snapshot when a trigger variable exceeds its specified high or low value This snapshot is set up using the Trigger Window accessed from the Trend Screen Main Menu The Trigger Window is shown in Figure 4 4 To set up a Trigger Variable snapshot the user must 1 Arm a trigger variable as explained in 3 3 entitled Trend Screen Trig
206. uton a a a a as 118 6 1 2 2 The PMI SD3000 Diagnostic Screen ss ss ssesessssessessesseessesseesresseeseessresseseese 121 6 1 2 3 The PMI SD3000 Regen Diagnostic Screen ceeceesceesseeeteceteceeeeeeeeeaees 122 6 1 2 4 The PMI SA3000 Diagnostic Screen c ccc ccccadececscsonssesecesiesctavsnceandadaeerdesneecaas 123 6 1 2 5 The PMI SA3000 Parallel Diagnostic Screen ceeeecceeseeeteceeeeeeeeeneees 124 6 1 2 6 The PMI SA500 Diagnostic Screen oo ceeccessccssecesecsecceescecssecesecceseeeeeeesaees 125 6 1 2 7 The PMI SB3000 Parallel Diagnostic Screen cee ceeceeseeseesteceteeeeeeeeseees 126 6 1 2 8 The GV3000 Parallel Diagnostic Screen 1 4 canasatienauh awtnniaanants 127 6 1 2 9 The FP 3000 D C Drive Diagnostic Screen sssssessesseesseeseesrosseesresresssesese 129 6 1 2 10 The PMI SA3100 Diagnostics Screen ee ecscceseceseceeeceeeecsseceteeeeeeeeaeees 131 6 1 2 11 The AB1336 Drive Diagnostics Screen cecceecceesseceteceeeeeeeeeetseeneenteenees 134 6 1 3 Changing the Setpoint Value for a Section 00 cecceeeeesceeseeceeceteeeeeeeeeeenaeens 136 6 2 The Section SOrCeie vette eit ca Shea earache te ahd oc iar an a a 139 6 3 The SPAD Speed and Draw Screen soc css seegscesecigasdecatedeazetenscdvseeguledacchesieauedaaevenseas 141 6 3 1 Selecting Sections for Calculation 2 5 csieetocctsn adele ne nteavaade cae eacia alae nates 142 6 3 2 Calculating DrAWS mni cea eich a vit nau oa asladeean a E 143 6 4 PO ULITDI
207. utton The Installation Information popup screen describing the current setting for User Information Host System Information and Installation Specifics is displayed Use the Page down button V to review the current settings of your SIGMA Client system If you want to review or change any of the settings click the lt Back button A SIGMA UOI UPM Setup O x SIGMA 32 bit Client Standard UOI Setup Installation Information Setup has enough information to begin the file transfer operation If you want to review or change any of the settings click Back If you are satisfied with the settings click Next to begin copying files Current Settings User Information Name Bill Wigglesworth Company Reliance Electric Diy of Rockwell Automatior Host System Information Operating System Windows NT Version 4 0 Installation Specifics Platform Type 32 bit Application Type Standard UO Client Standard Components Md gt Cancel Figure 1 17 Installation Information Popup Screen If you are satisfied with the settings Click the Next gt button to display the SIGMA Server and IP address popup The screen displays the SIGMA Server name and IP address popup If the SIGMA Server name and or IP address is not correct enter the corect name and or IP address of the SIGMA Server that this particular SIGMA Client is going to be connected to 1 SIGMA UOI UPM Setup SIGMA 32 bit Client Standard UOI Setu SIGMA Serve
208. ve up and down the element list As the scroll bar scrolls the Controlled Variable column all other columns scroll synchronously The Setpoint column see call out B in Figure 7 13 contains the current value of each recipe element If no modifications have been made since the recipe was downloaded to the drive system the Setpoint column is identical to the fourth column labeled Preset see call out C in Figure 7 13 If however any of the references are changed by the user or by the drive system the affected elements in the Setpoint column are highlighted in Cyan light blue Preparing The Next Recipe To Run The Load Next push button see call out E in Figure 7 13 lets the user prepare the next recipe to be run To prepare the next recipe to run l Click the Load Next push button A Load Next Load Next pop up window see Figure 7 14 appears ews Pin Click the J button to view the available stored recipes and then click the recipe to be loaded next Figure 7 14 Load Next Pop Up Window Click the OK button and the selected recipe is displayed in the Next column see call out D in Figure 7 13 Modifying Next Recipe Values Before Downloading The user can modify each element value in the Next column during line operation Each value is displayed in a cell To modify an element value 1 Click the value s cell in the Next column g The value is then highlighted and t
209. ware Hardware Requirements Because of hardware and software restrictions on the SIGMA Client Server and its components the computers must be purchased by Rockwell Automation to insure hardware compatibility and functionality Setting Up a SIGMA Client The SIGMA Clients and SIGMA Server use the TCP IP protocol to send messages to one another via EtherNet The Ethernet cables are either coaxial twisted pair or fiber optic and usually run through a central hub using star topology Connect the SIGMA Client to the EtherNet network using the appropriate connector Note that the EtherNet cabling is the responsibility of the user and should be verified before making the SIGMA NE connections see section 1 7 4 Verifying SIGMA Client Communication with SIGMA Server Setting Up a SIGMA Server As discussed in the previous section the SIGMA Server communicates with SIGMA Clients over Ethernet Connect the SIGMA Server to the Ethernet network The SIGMA Server also communicates directly to ControlNet using the ControlNet interface card or optionally DSCNET using the PC Link card Connect the SIGMA Server to the ControlNet network using the standard ControlNet BNC connectors Installing SIGMA Client Software This chapter describes the installation and start up of SIGMA client software Client Installation Procedure The complete installation process for SIGMA NE is relatively easy provided all of the tools and information needed are available
210. y clicking the up or down arrows or by moving the scroll bar up or down in the scroll field The screen description below explains how the Alarm Fault Summary Screen is designed Using this screen may help determine where the problem is located when it occurred and how severe it is Screen Description When an alarm or fault exists it appears as a two line item in the list The line items are displayed in a three column format The following describes each column Exception Time Message Type This column contains the date and time the exception occurred on the first line and the variable name and message associated with the exception on the second line The first line contains the date and time the event was detected The second line contains the variable name The Type column contains the sense type of the variable affected by the alarm or fault This information also determines the severity of the alarm or fault Clear or Acknowledge Time If the exception has been acknowledged this column contains the acknowledgement date and time If an exception was cleared but not acknowledged this column contains the time the event was cleared To acknowledge the exceptions on Alarm Fault Summary screen the following push button is displayed Acknowledge push button Clicking this push button acknowledges all of the alarms and faults that have not been acknowledged As a result SIGMA updates the list by removing all cleared events

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