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Diagnostics and Troubleshooting

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1. 2 6 PMI Operating Modes 34 Jddle Mode uiieuisepo Rheni etai deed 3 1 3 2 PM Run Modes nerdene uten 3 1 3 3 Alignment Test Mode mnnnnnnnvonnnnnnnnvnnnnnnnnvnnnennnvnnnnnnnnnennennnnnennsennnnneneennnnnnnsen 3 4 Installation and Start Up Guidelines 4 1 Using the AutoMax Programming Executive to Access the Rack 4 1 4 2 Installation Requirements ssseeeennneeenn eene 4 2 4 3 Installing the Motor i eret ec eger rere ctp tes 4 3 4 4 Installing the Drive 3 tri Eti e ettet a een ta 4 3 4 4 1 Cabinet Enclosed Wall Mounted Drives ssssseee 4 3 4 4 2 Floor Mounted Drives esseeeenm nennen 4 3 4 4 3 Panel Mounted Drives rrmmnvvrnrrnnvvvvnrnnnnnnvnnnnnannnvnnnnannvnnennnnnnnnnnsannnnnen 4 3 4 5 Wiring the Power Module ssseeeeeene enne 4 3 4 6 Basic Drive Interconnections sessee enne eene 4 4 4 7 Drive Inspection and Start up Guidelines ssssssesss 4 4 4 7 1 What To Do After Unexpected Test Results sssess 4 5 4 7 2 Recommended Test Equipment ssseen 4 7 4 7 3 Physically Inspecting the Equipment eee 4 7 4 7 4 Physically Inspecting the Motor seeee 4 8 4 7 5 Checking the Installation with Power Off ssssssssessss 4 8 4 7 6 Testing Power Modules with Power On ssee 4
2. 16 variables per rack can be forced Appendix G describes the type of access required by the user in order to carry out common Programming Executive operations Refer to the AutoMax Programming Executive instruction manual for more specific information Installation Requirements The installation must meet the following requirements Ambient Temperature Power Modules 0 to 60 C 32 to 140 F Cooling Air for cooling must be of sufficient quality and flow to avoid recycling the heated exhaust air back into the drive air inlets Relative humidity 5 9596 non condensing Altitude Maximum 1000 meters 3300 feet above sea level Refer to instruction manual S 3018 for derating information when operating above 1000 meters Air Quality Clean No flammable vapors chemical fumes or oil vapor Clearances Must allow access to the equipment within the cabinet for inspection maintenance and replacement Must provide non restricted air flow to and from the intake and exhaust openings See the following instruction manuals for more detailed information about installation requirements S 3018 SA500 Power Modules e 5 3017 SA500 DC Bus Supplies 4 2 SA500 Diagnostics Troubleshooting and Start Up Guidelines 4 3 Installing the Motor The motor should be installed in accordance with its own installation instructions Refer to the instruction manual that was provided for the motor in the Instruction
3. 9 ATT VO NVelflcatioris ice potet peti ee eter eate 4 10 4 7 7 1 Testing UDC PMI Communication Status 4 10 4 7 7 2 Testing Rail I O Registers ssssseee 4 11 4 7 7 3 Testing Feedback Registers and Bits 4 12 4 7 7 4 Testing the UDC Module Test Switch Register 4 13 4 7 7 5 Testing UDC Module Meter Ports ssesesssss 4 14 4 7 8 Performing Uncoupled Motor Tests sseeeenee 4 14 4 7 9 Running Dynamic Motor Tests ssseeeen 4 15 4 7 10 Updated Drawings and Software Listings sssssssss 4 16 Table of Contents Drive Fault Register cec tenete m ee eec tte iue tte bnc te cedere A 1 Drive Warning Registe oiire aara eani a E A NEEE a REEE B 1 Interlock Ftegister ainera ie R E A ette C 1 Summary of UDC Module Drive Fault Indicators sse D 1 Power Module LED Summary rrnannvnnnannvnnnnvrnnnnnvnnnnrrennnnvnnnnnrennnnrnnannnennnrrnnennnnenennne E 1 Status of Data in the AutoMax Rack After a STOP ALL Command or STOP ALL Fault F 1 AutoMax Programming Executive Access Levels sseeeeee G 1 TAE E E Index 1 SA500 Diagnostics Troubleshooting and Start Up Guidelines Figure 2 1 PMI Operating Modes Overview ssseeeee Figure 3 1 PMI Operating Modes and Diagnostics Figure 4 1 POS a
4. Book for specific instructions 4 4 Installing the Drive The drive is most often supplied in its own NEMA 1 enclosure It is also available in NEMA 4 and NEMA 12 cabinets in free standing floor mounted cabinets in an open panel configuration for mounting in the customer s enclosure or in a custom built control room 4 4 4 Cabinet Enclosed Wall Mounted Drives The drive in a wall mounted NEMA 1 enclosure is force ventilated by means of its own internal cooling fan s and additional cabinet fans Air is drawn into the enclosure through slots in the cabinet bottom and in the lower portion of the cabinet sides Air is forced out through internally shielded slots near the top of the cabinet sides Air intake and exhaust openings are unfiltered NEMA 4 and NEMA 12 cabinet enclosures are unventilated Although an internal circulating fan is employed to move air around within the confines of the cabinet to better utilize the cabinet skin for heat dissipation and reduce internal hot spots there is no air exchange with the atmosphere outside of the enclosure 4 4 2 Floor Mounted Drives NEMA 1 free standing floor mounted cabinets draw cooling air from slots in the lower portion of the cabinet door and force air through slots near the door s top if a cabinet fan is supplied NEMA 4 and NEMA 12 floor mounted cabinet enclosures are unventilated 4 4 3 Panel Mounted Drives The drive is available as a panel mounted assembly where mounting of the
5. Example MCR Register names Register names are shown with the initial letters capitalized followed by the corresponding register number for both drive A and drive B The drive A register number is shown first followed by the drive B register number A B Example Drive Fault register 202 1202 Bit names Individual bit names are shown with the initial letters capitalized Also shown in parentheses is the bit s register number bit number and suggested variable name Example Fault Reset bit register 100 1100 bit 8 FLT_RST Parameter entry screen titles Parameter entry screen titles and the parameters themselves are shown with the initial letters capitalized Example Feedback Data parameter entry screen SA500 Diagnostics Troubleshooting and Start Up Guidelines Diagnostics and Troubleshooting The Distributed Power System contains built in comprehensive diagnostics In order to diagnose and correct problems quickly it is important to understand the types of diagnostics that are performed when they are performed and how the results are reported This chapter describes the different types of diagnostics performed by the system s modules and how the results of these diagnostics are reported This chapter also describes how the system reacts if an error is detected An overview of these modes is shown in figure 2 1 The Distributed Power System provides diagnostics at each level of operation as shown in figure 3 1 Use
6. Hex Value Sug Var Name Access UDC Error Code LED Bit 13 2000H WRN_RAL Read only N A I O FLT Bit 14 4000H WRN_CLK Read only N A N A Bit 15 8000H WRN_COM Read only N A N A Communication errors in two consecutive messages will result in a drive fault B 2 SA500 Diagnostics Troubleshooting and Start Up Guidelines Interlock Register Interlock Register 205 1205 Interlock tests are executed whenever bit 0 or 1 of register 100 1100 is set The first problem detected will be indicated by the identifying bit in this register Note that these bits will prevent the vector or brushless minor loop from running Configuration Parameters Not Loaded The Configuration Parameters Not Loaded bit is set if Hex Value Sug Var Name Access UDC Error Code LED Bit 0 0001H IC CNFQ Read only N A N A the configuration parameters have not been downloaded into the UDC module from the Programming Executive or the alignment test has been enabled register 100 1100 bit 1 when an induction motor has been configured Gains Not Loaded The Gains Not Loaded bit is set if the required pre defined local tunables are zero or if a UDC task containing these tunables has not been loaded to the PMI RPI Missing The RPI Missing bit is set if the Run Permissive input on the Power Module is not on Faults Need Reset The Faults Need Reset bit is set if previous
7. The Reference in Limit Warning bit is set if Hex Value 0010H the PMI torque reference value register Sug Var Name WRN_RIL 102 1102 exceeds the maximum value Access Read only permitted 4095 and is being limited by UDC Error Code N A the system LED N A Tuning Aborted Warning Bit 5 The Tuning Aborted Warning bit is set if any Hex Value 0020H of the automatic tuning procedures e g Sug Var Name WRN_TUN resolver balance and gain calibration is not Access Read only LED N A Volatile Gain Limit Warning Bit 10 The Volatile Gain Limit bit is set if a speed or Hex Value 0400H position loop volatile gain value is out of Sug Var Name WRN_VGN limit This bit will only be set if the position Access Read only or speed loops are enabled UDC Error Code N A LED N A Drive Warning Register B 1 Rail Communication Warning The Rail Communication Warning bit is set if a rail communication problem is detected and logged in registers 4 10 16 or 22 CCLK Not Synchronized Warning The CCLK Not Synchronized Warning bit is set if the CCLK counters in the PMI Regulator and the UDC module are momentarily not synchronized PMI Communication Warning The PMI Communication Warning bit is set if a fiber optic communication error is detected between the PMI Processor module and the UDC module Hex Value Sug Var Name Access UDC Error Code LED Hex Value Sug Var Name Access UDC Error Code LED
8. cause damage to the drive ATTENTION If a megohmmeter is used disconnect all leads between the rotating equipment and the drive cabinet This will prevent damage to electronic circuitry Power Modules and their associated circuits etc due to the high voltage generated by the megger Failure to observe this precaution could result in damage to or destruction of the equipment 4 7 3 Physically Inspecting the Equipment Before operating the equipment DISCONNECT AND LOCK OUT ALL INCOMING LINE POWER AND CONTROL POWER TO THE DRIVE and perform the following steps Step 1 Carefully inspect the Power Module and other drive components for physical damage Verify free operation of all switch relays auxiliary contacts and contactors Step 2 Visually inspect internal wiring for loose or broken connections or damaged wires Step 3 Visually check for damaged components Step 4 Check fuses Step 5 Verify that all shutdown interlocks around the machine are operational Installation and Start Up Guidelines 4 7 4 7 4 Physically Inspecting the Motor 4 7 5 Carefully read and understand the instruction manual that describes your motor Then make the following motor inspection Refer to section 4 7 1 What to Do After Unexpected Test Results for more information Step 1 Disconnect and lockout all incoming line power and control power to the drive Step 2 Check that the motor is installed according to the motor s instruction
9. in 0 5 second Hardware detects that the temperature of the Power Module s heatsink exceeds the configured maximum rating Instantaneous Overcurrent Fault Bit 1 The Instantaneous Overcurrent Fault bit is Hex Value 0002H set if any of the three motor feedback Sug Var Name FLT_lIOC currents lu lv lw exceeds 133 of Access Read only maximum RMS current UDC Error Code 1017 LED EXT FLT DC Bus Overvoltage Fault Bit 2 The DC Bus Overvoltage Fault bit is set if Hex Value 0004H the DC bus voltage exceeds 400 VDC Sug Var Name FLT OV Q Access Read only UDC Error Code 1018 LED P M FLT Drive Fault Register A 1 Vcc Power Supply Undervoltage Fault The Vcc Power Supply Undervoltage Fault bit is set if the input to the 5V supply on the PMI drops below the necessary voltage to maintain regulation Position Error Fault The Position Error Fault bit is set if the position error exceeds the value set in the PMI Tach Loss Maximum Position Error register register 166 1166 Speed Error The Speed Error Fault bit is set if the maximum velocity error exceeds the value set in the PMI Tach Loss Maximum Velocity Error register register 156 1156 Resolver Broken Wire Fault The Resolver Broken Wire Fault bit is set if a sine or cosine signal from the resolver is missing due to a broken wire or if the resolver gain tunable RES GAN has been set too low Overspeed Fault The Overspeed Fault bit is set if
10. operating System are not compatible If this error occurs reload the most current operating systems D 2 SA500 Diagnostics Troubleshooting and Start Up Guidelines LED Related Reg Bit Power Module LED Summary The following table summarizes the LEDs on the SA500 Power Module Refer to the SA500 Power Modules instruction manual S 3018 for more information regarding the Power Module Refer to the SA500 Drive Configuration and Programming instruction manual S 3044 for more information regarding the UDC module s dual port registers Name Description PWR OK 202 1202 bit 12 FLT PS When lit all power supply voltages for the PMI are at acceptable operating levels PMI Power Supply Fault LED OK When lit indicates the PMI has passed its internal power up diagnostics and the on board watchdog timer is being updated LED COMM OK When lit indicates messages are being received correctly from the UDC module over the fiber optic link LED Related Reg Bit Related Reg Bit Related Reg Bit LED Related Reg Bit Related Reg Bit Related Reg Bit P M FLT 202 1202 bit 2 FLT OVE 202 1202 bit 3 FLT_VCC 202 1202 bit 0 FLT_OT EXT FLT 202 1202 bit 1 FLT_lIOC 202 1202 bit 10 FLT_OSP 101 1101 bit 2 EXT_LED When lit indicates one of the following fault conditions has been detected by the PMI DC Bus Overvoltage Vcc Power Supply Undervoltage Power Module Overtemperatur
11. passed the system continues its power up routine The PMI requests the appropriate operating system from the UDC module The UDC module downloads the operating system and the parameter configuration data if available to the PMI The PMI then runs under the control of its operating system and begins performing the run time diagnostics Run time diagnostics are described in section 2 4 2 3 Interlock Tests Interlock tests are performed by the PMI whenever one of the PMI s operating modes is selected by the programmer through the Drive Control register 100 1100 These diagnostics verify that all conditions required for the operating mode selected are satisfied If the interlock tests are completed successfully then the operating mode requested by the programmer can be entered If any of the interlock diagnostics fails the PMI will latch a bit in the Interlock register 205 1205 corresponding to the first diagnostic test that failed and the requested operating mode will not be entered i e the PMI will remain in the idle mode If an interlock test failure occurs follow the procedure below Step 1 Reset the command bit that is currently set in the Drive Control register 100 1100 Step 2 Correct the condition that caused the test failure Step 3 Set the desired command bit in the Drive Control register 100 1100 The PMI will perform the interlock tests each time a rising edge is detected on the command bits The results of subse
12. pulled out of the motor remove AC input power from the blower motor and interchange any two AC line power wires feeding the blower motor Note that the blower motor must be wired to a fixed AC power source and not to the Power Module Installation and Start Up Guidelines 4 9 4 7 7 4 7 7 1 I O Verification I O verification consists of ensuring that all physical I O is properly connected and functional and that all critical registers and bits can be accessed in the UDC dual port memory Before verifying the I O ensure that the following have been loaded to the AutoMax rack Note that the application tasks should not be put into run before you have verified all I O AutoMax Processor and UDC operating systems Rack configuration Drive parameters All application tasks The procedures described in the following sections are performed using the Monitor I O function in the AutoMax Programming Executive software Testing UDC PMI Communication Status This section describes how to test the UDC PMI communication status registers Use the AutoMax Programming Executive software I O Monitor function to display the UDC PMI Communication Status registers in the format listed in table 4 1 Table 4 1 UDC PMI Communication Status Register Formats Register Name format 80 1080 UDC Module Ports A B Status binary 81 1081 UDC Module Ports A B Receive Count decimal 82 1082 UDC Module Ports A B CRC Error Count deci
13. these figures as a reference to quickly identify the system s requirements for entering and operating in each mode These figures also refer to specific sections in the manual that provide additional information 2 1 Definition of Terms Used in Diagnostics and Troubleshooting For the purpose of describing diagnostics and troubleshooting this instruction manual will use specific terms to refer to the types of errors that can be detected by the PMI and the response of the PMI and UDC module to those errors A diagnostic is a software routine specifically designed to check for error conditions There are three types of diagnostics in SA3100 drives power up diagnostics interlock diagnostics and run time diagnostics A drive fault is an error specifically checked for by the PMI operating system that will shut the drive down Faults are reported in the Drive Fault register 202 1202 of the UDC module and in the error log for the UDC task in which the fault occurred A drive shut down occurs when any fault reported in the Drive register 202 1202 occurs A drive warning is an error specifically checked for by the PMI operating system that indicates the drive is not operating in an optimum manner Drive warnings will not shut the drive down An error is any condition other than the desired condition Interlock diagnostics are those diagnostics performed by the PMI operating system in response to a drive control request from the programmer
14. 02 and verify that the motor is turning d If the motor shaft is turning in a counter clockwise direction and the application requires that a clockwise shaft rotation be identified as forward i e the value in register 215 1215 is increasing perform the following Turn the drive off and switch the resolver s cosine wires Change the Output Rotation parameter Regenerate the parameter object file and reload it to the rack ATTENTION For brushless motor applications changing any resolver wiring breaking the resolver coupling replacing the resolver or replacing the motor and resolver for any reason requires that the shaft alignment test be performed again Resolver wiring changes always affect shaft alignment A resolver change and or a new motor resolver combination will affect the shaft alignment Improper shaft alignment can cause motor overspeed when the motor is started Failure to observe this precaution could result in bodily injury e If a brushless motor is used and the resolver has been removed replaced or had its cosine wires changed the resolver alignment test must be performed as described in section 3 3 f Verify the motor shaft rotation is in the desired direction by repeating steps a and b Step 5 Verify that the motor speed can be regulated The method used to verify speed regulation will depend upon your application Step 6 Perform the resolver balance calibration procedure This procedure is also de
15. C OS Load All UDC OS Modify PC Task Auto Run Monitor Note that a user with privileged Data Task or Rack access may relinquish this privilege by timing out after two minutes off line or by selecting to relinquish access on line Functions not listed in the table do not require privileged access 1 Must have Task access to both tasks in the UDC 2 A single task may be loaded with only Data access if the task does not already exist on the AutoMax Processor or UDC module 3 Requires Task or Rack access 4 Must have Task access to all tasks AutoMax Programming Executive Access Levels G 1 G 2 SA500 Diagnostics Troubleshooting and Start Up Guidelines A Accessing the AutoMax rack 4 1 to 4 2 Alignment test mode 3 4 AutoMax programming executive access levels G 1 AutoMax rack status of data F 1 D DC bus supply POS and NEG terminals 4 6 Definition of terms 2 1 Diagnostics and troubleshooting 2 1 to 2 6 Documentation 1 1 Drive fault register A 1 to A 3 Drive inspection and start up guidelines 4 4 to 4 16 checking installation with power off 4 8 to 4 9 dynamic motor tests 4 15 I O verification 4 10 physically inspecting the drive 4 7 physically inspecting the motor 4 8 recommended start up sequence 4 5 testing feedback registers and bits 4 12 to 4 13 testing power modules with power on 4 9 testing rail I O registers 4 11 testi
16. Distributed Power System SA500 Drive Diagnostics Troubleshooting and Start Up Guidelines Instruction Manual S 3022 1 62 Rockwell Automation Throughout this manual the following notes are used to alert you to safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Important Identifies information that is critical for successful application and understanding of the product The thick black bar shown on the outside margin of this page will be used throughout this instruction manual to signify new or revised text or figures ATTENTION Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install adjust operate or service this equipment Read and understand this manual and other applicable manuals in their entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power from the DC bus supply wait five 5 minutes and then measure the voltage at the POS and NEG terminals of the DC bus supply and each Power Module to ensure the DC bus capacitors are discharged before touching any internal components Failure to observe this precaution could result in severe bodily injury or loss of li
17. Drive Warning Register Rail I O Communication Error 206 1206 SPD_FB Speed Feedback 4095 to 4095 207 1207 TRQ_FB Torque Feedback 4095 to 4095 208 1208 POS_FB Position Feedback 32768 to 32767 209 1209 POS REG OUT Position Loop Output 4095 to 4095 211 1211 FBN Current Feedback normalized 4095 to 4095 213 1213 SPD_ERR Speed Error 4095 to 4095 214 1214 Analog Input 2048 10 V to 2047 10V 215 1215 RES SCN POS Resolver Scan Position 32768 to 32767 216 1216 RES STR POS Resolver Strobe Position 32768 to 32767 217 1217 RPM Revolutions Per Minute 218 1218 POS ERR Position Error 4095 to 4095 219 1219 SPI OUT Speed Loop P l Output 4095 to 4095 220 1220 WR2_COMP Speed Loop Feedforward Output 4095 to 4095 221 1221 Step 2 USER_AIN SLP_RPM RPM Slip Step 1 Verify that register 200 1200 bit 15 is on This bit is on when PMI operating system has been successfully downloaded from the UDC module to the PMI Check each of the inputs identified by bits 1 through 5 of register 201 1201 by applying 115V to the appropriate pins on the Drive I O connector on the Resolver and Drive I O module and verifying that the appropriate bit is on Refer to the SA500 Power Modules i
18. SA500 drive requires interconnecting wiring per applicable codes between the drive and the following motor e operators control station if used resolver UDC module earth ground Refer to the Elementary Diagram W E and the Interconnection Diagram W l if provided supplied with your drive for these interconnections Be sure that the W E number corresponds to that on the drive s cabinet or Power Module nameplate All interconnecting wiring must be sized and installed in conformance with the National Electrical Code and applicable local or other codes Unless a standard pre built fiber optic cable was included with your system the fiber optic cabling that links the UDC module s in the AutoMax rack with the Power Module s containing the PMI s must be installed by someone experienced in installing fiber optic cables Unless you have in house expertise in installing fiber optic cable it is recommended that you contact an experienced contractor to perform the installation Information regarding the selection and installation of fiber optic cabling is contained in the Distributed Power System Fiber Optic Cabling instruction manual S 3009 4 7 Drive Inspection and Start up Guidelines ATTENTION Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install adjust operate or service this equipment Read and understand this manual and other applicable manuals in
19. Setup UDC PMI screen Check each UDC Meter Port being used as follows Step 1 Step 2 Step 3 Step 4 Map registers that you want to display to UDC meter ports 1 2 3 and 4 Set the desired maximum and minimum values Using the Monitor I O screen force a value within the range configured to each UDC register being output on the meters Use a voltmeter to verify that the signal on the terminal points 10V to 10V of each meter port is proportional to the value in the corresponding register Unforce the registers being output on the meter ports to zero Performing Uncoupled Motor Tests The following tests are performed with the motor uncoupled from the load Ensure that the limit values entered through the parameter entry screens are correct Step 1 Step 2 Step 3 Step 4 Verify that the parameter screen information Power Module data motor data speed feedback data and meter port setup is correct Perform the resolver gain calibration procedure This procedure is described in the SA500 Power Modules instruction manual S 3018 The Resolver Gain Calibration Completed bit register 201 1201 bit 6 RES GANOQ will be set to indicate the procedure is complete Check the value in the local tunable RES GAN Large gain values close to 255 may indicate a problem with the resolver wiring or connections Refer to the SA500 Drive Configuration and Programming instruction manual S 3044 for a list of the resolver
20. T A and DRV FLT B red The Drive Fault LEDs are normally off If a Drive Fault LED is lit it indicates the a Drive Shutdown fault has been detected for the indicated drive When a drive fault is detected a bit is set in register 202 for drive A or register 1202 for drive B in the UDC module s dual port memory Bit 8 of the Drive Status register 200 1200 is also set Summary of UDC Module Drive Fault Indicators D 1 Drive Fault Error Codes Drive faults are reported in the error log for the task in which the error occurred The drive fault error codes are defined below 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 Broken wire in resolver Not used Overspeed fault Not used PMI power supply fault PMI bus fault UDC run fault Fiber optic link communication fault Power Module overtemperature fault Instantaneous overcurrent fault DC bus overvoltage fault Vcc power supply undervoltage Error Codes The UDC module can generate three error codes which will be displayed on the leftmost AutoMax Processor Error 38 indicates that the UDC module has generated a Stop All If this error occurs refer to the UDC task error log for additional information regarding the error Error 39 indicates a UDC module interrupt allocation has failed In this case try to cycle power to the rack and reload the rack configuration and application tasks Error 3A indicates the UDC module s operating system and the AutoMax
21. Troubleshooting and Start Up Guidelines Drive Fault Register 202 1202 The bits in the Drive Fault register indicate the cause of a drive shutdown The bits in this register are latched until they are reset by setting the Fault Reset bit bit 8 of the Drive Control register 100 1100 bit 8 After turning the Fault Reset bit on the drive may be re started after turning the desired command bit in register 100 1100 off and then back on again If the fault condition still exists the identifying bit in this register will immediately be set again Drive Fault Register The fault conditions reported in this register result in turning off the drive The UDC task is not stopped automatically if a drive fault occurs unless it is specifically instructed to do so in the application task The user must ensure that the AutoMax application task tests register 202 1202 and takes appropriate action if a fault occurs Note that the status of this register is also reported in the error log for the task in which the error occurred Power Module Overtemperature Fault Bit 0 The Power Module Overtemperature Fault Hex Value 0001H bit is set if either of the following conditions Sug Var Name FLT OTQ occurs Access Read only UDC Error Code 1016 LED P M FLT The PMI detects that motor current exceeds 100 of the Power Module s continuous capacity at maximum current for a pre determined amount of time At maximum rated current this trip will occur
22. als of the DC bus supply and each Power Module to ensure the DC bus capacitors are discharged before touching any internal components Failure to observe this precaution could result in severe bodily injury or loss of life Step 2 Visually check that the AC supply to the DC bus supply is of the correct voltage and frequency and that the plant supply branch from which the drive is to be operated is of sufficient ampacity to supply drive input current requirements 4 8 SA500 Diagnostics Troubleshooting and Start Up Guidelines Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Verify that all drive components have been properly installed and interwired per the instructions provided in the wiring diagrams W Ds W Es W Ls W Os and W ls Rotate the 1 4 turn cover fasteners securing the Power Module cover Remove the cover Inspect the Power Module for cables that may have come loose during shipping Replace and re secure the Power Module cover Check for grounds in the magnetic control circuits Always use an ohmmeter to check for grounds in resolver circuits Check rotating equipment for grounds Check for tight connections on all wiring Check circuit breaker trip settings Verify that all safety devices are in place Check fuses 4 7 6 Testing Power Modules with Power On ATTENTION Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved s
23. are reset to 0 N A N A I O variables including UDC dual port memory inputs retained and updated outputs are reset to 0 see below all I O is reset to 0 Input values including Feedback registers UDC PMI communication status registers UDC Error Log info retained retained Output values including Command registers Application registers ISCR registers Scan per interrupt register Scans per interrupt counter reset to 0 reset to 0 Parameter configuration variables N A retained N A UDC test switch information N A retained N A D A setup configuration N A retained N A Operating system retained retained retained Status of Data in the AutoMax Rack After a STOP ALL Command or STOP ALL Fault F 1 F 2 SA500 Diagnostics Troubleshooting and Start Up Guidelines AutoMax Programming Executive Access Levels Rack Power Supply Keyswitch Position Any Position PROTECT SETUP PROGRAM User s Access Level Any Action Level Task Rack Force Common Force Local Force I O Set Common Set Local Set I O Set Tune Tunable Load Normal Config Load Debug Config Load Single POB File Load Single Task Delete Task Start Task Stop Non Critical Task Save Task from Rack Load All POB Files Load All Delete All Tasks Start All Tasks Stop All Tasks Load AutoMax OS Load Single UD
24. ating drawings and software listings 4 16 Index 2 SA500 Diagnostics Troubleshooting and Startup Guidelines Documentation Improvement Form Use this form to give us your comments concerning this publication or to report an error that you have found For convenience you may attach copies of the pages with your comments After you have completed this form please return it to Rockwell Automation RGA Technical Publications 25001 Tungsten Road Cleveland Ohio 44117 Fax 216 266 7120 Publication Name Publication Number Publication Date Comments Your Name Date Company Name Phone Address Thank you for your comments Technical Writing Internal Use Date DIF Number Follow Up Action RN Rockwell Automation Rockwell Automation 24703 Euclid Avenue Cleveland Ohio 44117 216 266 7000 OA Rockwell Automation Printed in U S A S 3022 1 August 1998
25. d to verify the status of drive I O and to make drive adjustments Section 4 1 describes some of the restrictions imposed by the AutoMax Programming Executive software 4 1 Using the AutoMax Programming Executive to Access the Rack The AutoMax Programming Executive enables four users to access and work in the same rack simultaneously However certain restrictions exist when more than one user is working in a rack The maximum number of users is four 4 per rack one user connected directly to the rack and three users connected via the DCS AutoMax Network or four users connected via the DCS AutoMax Network Data access is required for the user to Set Force COMMON variables All users must assure that variable values are not written over by other users working in the rack Task access is required for the user to load a single task and to Set Tune Force LOCAL variables in a task Only one user will be granted Task access for each task in the rack Rack access is required to load the rack configuration and to load all application tasks AutoMax tasks and UDC tasks If a user has Rack access no other user can make changes in that rack All other users will be limited to monitoring tasks and variables Installation and Start Up Guidelines 4 1 4 2 Each user can monitor up to 16 COMMON and or LOCAL variables A maximum of 32 LOCAL variables per UDC module can be monitored regardless of the number of users A maximum of
26. drive within a customer supplied enclosure is desired In these instances the user is responsible for ensuring that the maximum temperature within this enclosure remains at or below the rated ambient temperature under worst case operating conditions Note that the same fan cooling as described in the previous two sections will be provided for the Power Module 4 5 Wiring the Power Module Verify that the input power to the DC bus supply is of the correct voltage and sufficient ampacity to support the Power Module s input current requirements Note that the maximum available current from the DC bus supply must be less than the Power Module s short circuit current rating RMS Refer to the drive cabinet and motor nameplates for correct current ratings and input power information Installation and Start Up Guidelines 4 3 4 6 Basic Drive Interconnections ATTENTION If your drive cabinet is mounted in such a way that the cabinet itself is not grounded a ground wire must be connected to the drive cabinetto provide safety for personnel Also the motor frame should be grounded by solidly connecting a ground wire to a screw in the conduit box Failure to observe these precautions could result in severe bodily injury or loss of life ATTENTION The user is responsible for conforming with all applicable local national and international codes Failure to observe this precautions could result in damage to or destruction of the equipment The
27. e When lit indicates one of the following external fault conditions has been detected by the PMI Instantaneous Overcurrent Overspeed User programmed LED Related Reg Bit RAIL FLT 203 1208 bit 13 WRN_RAL When lit indicates communication between a rail and the PMI has been disrupted or that a rail is configured but is not plugged in Rail Communication Warning LED Related Reg Bit FDBK OK 202 1202 bit 8 FLT_TBW When lit indicates that the PMI is receiving feedback from the resolver and no resolver feedback faults have been detected Resolver Feedback Broken Wire Power Module LED Summary E 1 Name Description LED Related Reg Bit RPI 201 1201 bit 0 RPIO When lit indicates the run permissive input signal has been detected RPI Input Status LED MCR When lit indicates that the MCR output signal is being driven on LED Related Reg Bit AUX IN1 201 1201 bit 1 M FDBKO When lit indicates the presence of a 115V signal on this input Aux Input 1 MFDBK Status E 2 SA500 Diagnostics Troubleshooting and Start Up Guidelines Status of Data in the AutoMax Rack After a STOP ALL Command or STOP ALL Fault LOCAL tunable variables AutoMax Processor retained UDC Module retained PMI Processor retained LOCAL variables retained reset to 0 N A COMMON memory variables non volatile are retained others
28. e g PMI_RUN in register 100 1100 of the UDC module dual port memory Power up diagnostics consist of the initial tests for basic functionality performed by all printed circuit board modules Run time diagnostics are those diagnostics performed continuously by the PMI as a background task after it has received its operating system from the UDC module Diagnostics and Troubleshooting 2 1 POWER UP DIAGNOSTICS SELECT PMI RUNG OR ALN_TST PE Sent Dres CLOSE MCR ALIGN RESOLVER OPEN MCR Li tt er dL Figure 2 1 PMI Operating Modes Overview 2 2 SA500 Diagnostics Troubleshooting and Start Up Guidelines 2 2 Power up Diagnostics in the UDC Module and PMI Power up diagnostics execute in the UDC module in the AutoMax rack and in the PMI in the Power Module When power is applied to the AutoMax rack the UDC module performs a series of self tests When all of the tests are successfully completed the CARD OK LED on the UDC module s faceplate will turn on If a failure occurs the OS OK LED will flash rapidly When power is applied to the Power Module the PMI performs a series of self tests When all of the tests are successfully completed the OK LED on the Power Module s faceplate will turn on If a failure occurs the P M FLT LED on the Power Module will flash rapidly If a UDC module or a Power Module does not pass its power up tests it must be replaced After all of the power up tests are
29. ed to work with the Rockwell service engineer This manual does not describe specific applications of the standard SA500 hardware and software Always refer to the wiring diagrams supplied with your system for information specific to your installation Related Publications You user must become familiar with the other instruction manuals that describe the SA500 drive system The documentation that describes the SA500 drive is listed in table 1 1 Table 1 1 SA500 Documentation Binder S 3002 Document Document Part Number DPS Overview Universal Drive Controller Module Fiber Optic Cabling SA500 DC Bus Supply SA500 AC Power Modules SA500 Diagnostics Troubleshooting amp Start Up Guidelines SA500 Information Guide SA500 Drive Configuration amp Programming Additional information about using the SA500 drive is found in the prints and other documentation shipped with each drive system Always consult the prints and other documents shipped with your drive system for specific information about installing operating and maintaining your drive Introduction 1 2 Typographical Conventions The following typographical conventions are used in this manual Variable names Variables names are shown in all capital letters followed by the appropriate terminating character The variable names shown in this manual are suggested names only and may vary from the names used in your application
30. er by setting and resetting the Warning Reset bit register 100 1100 bit 9 WRN_RST Note that the Warning Reset bit is edge sensitive 2 6 SA500 Diagnostics Troubleshooting and Start Up Guidelines Operating Mode Idle PMI Operating Modes The PMI s default operating mode is idle All other operating modes are selected by the programmer in the Drive Control register 100 1100 Table 3 1 shows the available operating modes Note that the operating modes are mutually exclusive i e only one mode may be enabled at a time this is checked by the interlock tests The PMI s operating modes are shown in figure 3 1 and are described in the following sections Table 3 1 PMI Operating Modes Drive Control Register Bit Mode Description The PMI s default operating mode during which no algorithms are running PMI Run Executes the torque speed or position control algorithm Alignment Test 3 1 3 2 Enables the resolver alignment procedure for brushless drives Idle Mode The PMI s default operating mode after passing the power up diagnostics is idle When in idle mode the PMI is waiting for a command from the Drive Control register 100 1100 to change operating modes In order for the PMI to enter the requested operating mode the Interlock tests must be passed If any of the Interlock tests fails or if any fault is latched in the Drive Fault register 202 1202 the PMI will remain in the
31. faults register 202 1202 have not been cleared Hex Value Sug Var Name Access UDC Error Code LED Hex Value Sug Var Name Access UDC Error Code LED Hex Value Sug Var Name Access UDC Error Code LED Bit 1 0002H IC GAINQ Read only N A N A Bit 2 0004H IC RPIQ Read only N A N A Bit 3 0008H IC FLTQ Read only N A N A Interlock Register C 1 Rising Edge Required The Rising Edge Required bit is set if a rising edge is required on any command bit in register 100 1100 Hex Value Sug Var Name Access UDC Error Code LED Bit4 0010H IC RISEQ Read only N A N A This bit will be set if the application task has set the Fault Reset bit register 100 1100 bit 8 but has not cleared and then re set any command bits More Than One Request The More Than One Request bit is set if more than one operating mode is requested at a time in register 100 1100 bits 0 and 1 MCR Did Not Close The MCR Did Not Close bit is set if the optional output contactor did not close when commanded to do so Hex Value Sug Var Name Access UDC Error Code LED Hex Value Sug Var Name Access UDC Error Code LED Bit 5 0020H IC MOREQ Read only N A N A Bit 7 0080H IC MCRQ Read only N A N A C 2 SA500 Diagnostics Troubleshooting and Start Up Guidelines Summary of UDC Module Drive Fault Indicators Stat
32. fe ATTENTION For brushless motor applications changing any resolver wiring breaking the resolver coupling replacing the resolver or replacing the motor and resolver for any reason requires that the shaft alignment test be performed again Resolver wiring changes always affect shaft alignment A resolver change and or a new motor resolver combination will affect the shaft alignment Improper shaft alignment can cause motor overspeed when the motor is started Failure to observe this precaution could result in bodily injury ATTENTION The user must provide an external hardwired emergency stop circuit outside of the drive circuitry This circuit must disable the system in case of improper operation Uncontrolled machine operation may result if this procedure is not followed Failure to observe this precaution could result in bodily injury ATTENTION Inserting or removing a module or its connecting cables may result in unexpected machine motion Turn off power to the rack before removing a module or its connecting cables Failure to observe these precautions could result in bodily injury ATTENTION Only qualified Rockwell personnel or other trained personnel who understand the potential hazards involved may make modifications to the rack configuration variable configuration and application tasks Any modifications may result in uncontrolled machine operation Failure to observe these precautions could result in damage to equipment and bodily
33. hould install adjust operate or service this equipment Read and understand this manual and other applicable manuals in their entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION This procedure is performed with power on Exercise extreme caution as hazardous voltage exists Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION Before proceeding make sure that you can quickly stop the drive if necessary If the input power disconnect and or stop push button are out of yourreach have an associate stationed to operate them in the event of drive malfunction during these initial power checks and drive adjustment Failure to observe this precaution could result in damage to equipment and bodily injury The following steps are required to test SA500 Power Modules before they can be put into service Perform the following steps before attempting to start the drive Step 1 Step 2 Check the DC bus supply s DC power levels a Verify that DC input power to the Power Module is off b Connect a DC voltmeter to the POS and NEG terminals on the Power Module c Apply power to the drive and verify that the DC voltage level is correct If the motor uses 3 phase AC to power its blower motor verify proper blower motor rotation Check to see that air is being forced into the motor If air flow is reversed air is being
34. idle mode The PMI will return to the idle mode when it exits any of the other operating modes PMI Run Mode To execute the control algorithm s the programmer sets the PMI Run Enable bit register 100 1100 bit 0 PMI RUNQ2 for the torque minor loop and if required the Speed Loop Enable bit register 100 1100 bit 3 SPD ONQ2 for the speed minor loop the Position Loop Enable bit register 100 1100 bit 4 POS ONQ for the position minor loop PMI Operating Modes 3 1 Before the control algorithm s can be executed all of the following conditions must be met The interlock tests register 205 1205 must be passed successfully See section 2 3 The M contactor must be closed if configured See section 2 4 1 2 The UDC task in the AutoMax rack must be running The status of the UDC task is indicated by the UDC Task Running bit register 100 1100 bit 15 UDC RUNQ If any of these requirements are not met or if a fault is latched in the Drive Fault register 202 1202 the PMI will remain in the idle mode If these requirements are met the PMI will execute the torque minor loop and if selected the speed and position minor loops At this time the PMI will set the PMI On bit 200 1200 bit 0 PMI ONO to indicate that the torque minor loop is executing Important Note that if a brushless motor is being used the resolver and rotor shafts must be aligned before the torque minor loop is executed or the m
35. injury ATTENTION Registers and bits inthe UDC module that are described as read only or for system use only must not be written to by the user Writing to these registers and bits may result in improper system operation Failure to observe this precaution could result in bodily injury ATTENTION The user is responsible for conforming with all applicable local national and international codes Failure to observe this precaution could result in damage to or destruction of the equipment The information in this user s manual is subject to change without notice AutoMax is a trademark of Rockwell Automation 91998 Rockwell International Corporation Introduction 1 Related Publications c tede m de bees 1 1 1 2 Typographical Conventions sssssssssseseeee eere 1 2 Diagnostics and Troubleshooting 2 1 Definition of Terms Used in Diagnostics and Troubleshooting 2 1 2 2 Power up Diagnostics in the UDC Module and PMI eese 2 3 2 3 InterlOCK TGSltS zt rre tI En do MR Averter 2 3 2 4 Run time Diagnostics sepiii ae ni E E nennen nennen AAN nnne nnns 2 3 24 1 Drive Faults n tel teat id 2 4 2 4 1 1 How the System Reacts to Drive Faults 2 4 2 4 1 2 MCR Output Control istoire aeanoea aieas anani 2 5 2 4 2 Drive Warnings nde eet ec he e Ene perte A 2 5 2 4 8 How to Clear the Drive Fault and Drive Warning Registers
36. input channel being used by measuring with an ammeter or voltmeter to verify the signal on the terminal points 4 20mA or 0 10V is proportional to the value displayed in appropriate register Step 3 Test each digital input by initiating the input and verifying that the appropriate bit displayed on the screen turns on Step 4 Test each digital output by forcing the bit on and verifying that the signal is present on the terminal points Installation and Start Up Guidelines 4 11 4 7 7 3 Testing Feedback Registers and Bits This section describes how to test the feedback registers and bits Feedback information provided by the fault warning and interlock registers is described in Appendices A B and C Use the AutoMax Programming Executive software I O Monitor function to display the registers and bits in the format listed in table 4 3 Table 4 3 Feedback Registers and Bits Drive A B 200 1200 Bit 15 Variable Name PMI OKQ Description Drive Status Register PMI Operating System Loaded 201 1201 Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 8 RPI M_FDBK AUX_IN1 AUX_IN2 AUX_IN3 AUX_IN4 AUX_IN5 STR_DET I O Status Register Run Permissive Input M Contactor Feedback Input or 115VAC Auxiliary Input 1 115VAC Auxiliary Input 2 115VAC Auxiliary Input 3 115VAC Auxiliary Input 4 115VAC Auxiliary Input 5 External Strobe Detected 203 1203 Bit 13 WRN_RAL
37. lt of this test is written to the tunable variable RES ALN by the PMI If a problem is detected during the alignment procedure e g the incorrect number of motor poles or resolver type was entered during configuration the Tuning Aborted Warning bit register 203 1203 bit 5 WRN TUNQ is set When the alignment procedure is turned off the PMI returns to the idle state SA500 Diagnostics Troubleshooting and Start Up Guidelines Installation and Start Up Guidelines ATTENTION Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install adjust operate or service this equipment Read and understand this manual and other applicable manuals in their entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION The user is responsible for conforming with all applicable local national and international codes Failure to observe this precaution could result in damage to or destruction of the equipment This section describes general guidelines that should be followed when verifying the correct installation of the drive hardware and in performing the drive start up For more information regarding installation guidelines refer to instruction manual D2 3115 Installing Operating and Maintaining Engineered Drive Systems As part of the start up procedure the AutoMax Programming Executive software is use
38. mal 83 1083 UDC Module Ports A B Format Error Count decimal 84 1084 PMI A B Status binary 85 1085 PMI A B Receive Count decimal 86 1086 PMI A B CRC Error Count decimal 87 1087 PMI A B Format Error Count decimal 88 1088 UDC Module Ports A B Fiber Optic Link Status hexadecimal 89 1089 UDC Module Ports A B Transmitted Message Count decimal Step 1 Examine registers 80 1080 and 84 1084 for any errors reported to the UDC module and PMI related to UDC PMI communication If any bits in these registers are on try to determine what caused the error Step 2 Examine registers 81 1081 and 85 1085 for the number of messages received by the UDC module and PMI Over time this 16 bit value should increase to its maximum value 32767 and then roll over Step 3 Examine registers 82 1082 and 83 1083 and 86 1086 and 87 1087 for the number of CRC and format errors received on the UDC module and PMI If either of these values is incrementing it indicates a problem 4 10 SA500 Diagnostics Troubleshooting and Start Up Guidelines Step 4 Examine register 88 1088 for the status of the fiber optic ports on the UDC module If the operating systems are loaded and no tasks are running the lower byte should be equal to xx03H UDC module and PMI are exchanging data The upper byte should be equal to 02xxH communication between the UDC module and PMI is unsynchronized Note that xx in the b
39. manual Step 3 If possible uncouple the motor from the driven machinery Step 4 Rotate the motor shaft by hand to check that the motor is free from any binding or mechanical load problem Step 5 Check that no loose items such as shaft keys couplings etc are present Step 6 Check all connections for tightness and proper insulation Step 7 Check that the interior of the motor is clean and dry ATTENTION Before starting the motor remove all unused shaft keys and loose rotating parts to prevent them from flying off Replace all covers and protective devices Failure to observe these precautions could result in damage to equipment and bodily injury Checking the Installation with Power Off Perform the following tests to verify that Correct power is being supplied to the drive Wiring has been done properly There are no grounds in the magnetic control circuits or rotating equipment All safety devices are in place and functional Step 1 If the drive is powered up disconnect and lock out all incoming line power and control power to the drive Refer to section 4 7 1 for additional information on measuring and discharging DC bus voltage If the drive is not under power proceed to step 2 ATTENTION DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power from the DC bus supply wait five 5 minutes and then measure the voltage at the POS and NEG termin
40. nd NEG Terminals on the DC Bus Supply Table of Contents SA500 Diagnostics Troubleshooting and Start Up Guidelines Table 1 1 SA500 Documentation Binder S 3002 sssssssss 1 1 Table 3 1 PMI Operating Modes sse nnne 3 1 Table 4 1 UDC PMI Communication Status Register Formats Table 4 2 Rail l O Register Formats rernrrnnnnnvnnnonrnnnnnrnnnrnvnnnnnrnnnnnrenrnrrrernnnnernnn 4 11 Table 4 3 Feedback Registers and Bits Table of Contents VI SA500 Diagnostics Troubleshooting and Start Up Guidelines 1 1 Introduction This instruction manual is divided into two sections 1 a description of SA500 drive diagnostics and troubleshooting 2 start up guidelines This manual is intended for users of SA500 drives who have training and experience in AC drive control and who are familiar with all other SA500 drive documentation The diagnostics and troubleshooting chapters chapters 2 3 describe the error checking built into the PMI Regulator operating system and how to use warning and fault registers LEDs and the error log to diagnose drive problems Chapter 4 provides guidelines on starting up Distributed Power SA500 AC drives Although initial start up services are usually provided by Rockwell personnel it is recommended that the user become familiar with the general guidelines in this chapter in order to be better prepar
41. ng UDC module meter ports 4 14 UDC module test switch register 4 13 UDC PMI communication status 4 10 to 4 11 uncoupled motor tests 4 14 to 4 15 unexpected test results 4 5 to 4 7 updating drawings and software listings 4 16 Drive warning register B 1 to B 2 Dynamic motor tests 4 15 F Faults 2 4 to 2 5 A 1 to A 3 how the system reacts to drive faults 2 4 Feedback registers and bits 4 12 to 4 13 I O verification 4 10 Idle mode 3 1 Installation and start up guidelines 4 1 to 4 16 basic drive interconnections 4 4 cabinet enclosed wall mounted drives 4 3 floor mounted drives 4 3 installation requirements 4 2 installing the drive 4 3 installing the motor 4 3 panel mounted drives 4 3 wiring the power module 4 3 Interlock register C 1 to C 2 Interlock tests 2 3 Introduction 1 1 to 1 2 L LED summary E 1 to E 2 MCR output control 2 5 Meter ports UDC module 4 14 P PMI operating modes 3 1 to 3 4 overview 2 2 PMI operating modes and diagnostics 3 3 PMI run mode 3 1 to 3 3 Power up diagnostics 2 3 R Rail I O registers 4 11 Related Publications 1 1 Run time diagnostics 2 3 to 2 6 T Test equipment recommended 4 7 Typographical conventions 1 2 Index Index 1 U W UDC module Warnings 2 5 to 2 6 B 1 to B 2 drive fault indicators D 1 to D 2 clearing drive warnings 2 6 meterports 4 14 Wiring the Power Module 4 3 UDC PMI communication status register 4 10 Upd
42. nstruction manual S 3018 for the pinout description SA500 Diagnostics Troubleshooting and Start Up Guidelines Step 3 You may want to create a separate monitor screen for registers 206 1206 through 221 1221 and save it This will allow you to recall the screen later without having to enter the entire list each time you need to monitor feedback registers Note that registers 210 1210 and 212 1212 are not used Step 4 Check the User Analog Input register 214 1214 by applying an input signal to the appropriate pins on the Resolver Feedback connector on the Resolver and Drive I O module and verifying that register 214 1214 displays an appropriate value Refer to instruction manual S 3018 for additional information Step 5 Test the resolver Be sure the resolver s sine cosine wires are connected per the W E diagrams Monitor the value displayed in the Resolver Scan Position register 215 1215 The value in this register can range from 32768 to 32767 Rotate the resolver by hand by turning the motor shaft if the resolver is mounted coupled first in one direction then in the other direction The value in the register should steadily increase in one direction and steadily decrease in the other direction If the value in the register does not change at all or if the value does not increase decrease smoothly a problem may exist with the resolver and or its wiring Step 6 Test the external strobe if used as follows Note that
43. ntactor sometimes referred to as an M contactor disconnects power from the motor This option is selected during UDC module parameter configuration If the programmer selects to connect the MCR output to an output contactor auxiliary contacts from this device must be wired to the AUX IN1 MFDBK input as feedback The PMI operating system will wait for AUX IN1 MFDBK to turn on before executing any operating mode The Run Permissive input RPI on the Power Module and the MCR output are interlocked in hardware The MCR output can be turned on only when the RPI is asserted The MCR output itself is under the control of the PMI Application tasks have no direct control of the MCR output RPI is controlled by the user When RPI is off MCR cannot be activated The following conditions will cause the MCR output to turn off Absence of the RPI signal Occurrence of a drive fault e Control algorithm is turned off PMI_RUN 0 When any of the above conditions occurs the PMI will disable the power device gates and the motor will begin a coast to rest stop The PMI will wait 100 msec and then turn off the MCR output In addition if the RPI signal is removed the MCR output and gate power will be removed under hardware control within approximately 0 5 seconds of the removal of the RPI signal to provide an additional interlock This is done regardless of the actions taken by the PMI 2 4 2 Drive Warnings The PMI will check for conditions tha
44. oA indu ov esnJ e 9 youms Bunoeuuoosiq esnJ SAN SOd e npojy JEMOd OV OOSVS DAN SOd e npojN JEMOd OV OOGVS SAN SOd LI 9JoH LA sng OG ojnseew A ddns sng OG 00SvS e npojy JEMOd SAN SOd OV OOSVS o 9 SAN SOd anpop Jeog OV OOGVS Figure 4 1 POS and NEG Terminals on the DC Bus Supply SA500 Diagnostics Troubleshooting and Start Up Guidelines 4 6 Step 5 Verify the following a All connections are in strict conformance to the wiring diagrams b There are no loose or broken connections c There are no damaged components Step 6 Repeat the original test that failed 4 7 2 Recommended Test Equipment Rockwell recommends the following test equipment Isolated oscilloscope with a current probe and x100 probe for DC bus measurements An isolation transformer is needed to isolate the oscilloscope and any other equipment AC and DC clamp on ammeters Isolated multimeter having a sensitivity of 20KO volt Chart recorder Isolated voltmeter 50 ohm 50W resistor for discharging bus capacitors Appropriate safety equipment e g safety glasses and safety gloves A megohmmeter megger may be used to reliably verify the absence of inadvertent grounding of the motor Failure to follow proper procedure when using a megger may
45. otor may not run properly This is not tested by the Interlock tests as a requirement to enter the PMI run mode See section 3 3 for description of this procedure The torque minor loop executes until one of the following occurs e The PMI Run Enable bit register 100 1100 bit 0 PMI_RUN is reset by the application task A drive fault is detected Refer to Appendix A for a description of the Drive Fault register The RPI signal register 201 1201 bit 0 is removed The speed minor loop executes until one of the following occurs The Speed Loop Enable bit register 100 1100 bit 3 SPD_ON is reset by the application task e The PMI Run Enable bit register 100 1100 bit 0 PMI_RUN is reset by the application task A drive fault is detected Refer to Appendix A for a description of the Drive Fault register The RPI signal register 201 1201 bit 0 is removed The position minor loop executes until one of the following occurs The Position Loop Enable bit register 100 1100 bit 4 POS_ON is reset by the application task The Speed Loop Enable bit register 100 1100 bit 3 SPD ONO is reset by the application task The PMI Run Enable bit register 100 1100 bit 0 PMI_RUN is reset by the application task 3 2 SA500 Diagnostics Troubleshooting and Start Up Guidelines A drive fault is detected Refer to Appendix A for a description of the Drive Fault register The RPI signal regi
46. quent interlock tests will overwrite the previous test s results 2 4 Run time Diagnostics Run time diagnostics are performed continuously by the PMI after its operating system has been downloaded by the UDC module These diagnostics test the status of the PMI and the connected hardware and also check the integrity of the communication link between the UDC module and the PMI Diagnostics and Troubleshooting 2 3 2 4 1 2 4 1 1 The results of the diagnostics are stored in either the Drive Warning register 203 1203 or the Drive Fault register 202 1202 in the UDC module s dual port memory How drive faults and drive warnings are indicated and how they affect the operation of the drive is described in the following sections Drive Faults When the PMI detects any of the conditions identified in the Drive Fault register it will shut down the drive as described below To determine the cause of a drive shutdown the following indicators are provided Drive Fault register 202 1202 The PMI will set a bit in the Drive Fault register to indicate the condition that caused the shutdown The interlock tests check this register for fault conditions that have occurred Refer to Appendix A for a complete description of the Drive Fault Register Drive Status Register 200 1200 The PMI will set the Fault Detected bit bit 8 FLT of the Drive Status register when a drive fault has been detected LEDs on the UDC module If eithe
47. quires that the shaft alignment test be performed again Resolver wiring changes always affect shaft alignment A resolver change and or a new motor resolver combination will affect the shaft alignment Improper shaft alignment can cause motor overspeed when the motor is started Failure to observe this precaution could result in bodily injury Important This procedure will cause the motor to move less than one revolution in both forward and reverse direction for under three minutes Uncouple the motor from the load to run this test if this motion would be harmful to your machine The programmer sets the Enable Resolver Alignment Test bit register 100 1100 bit 1 ALN_TST to request the PMI to execute the alignment procedure Before the alignment test can be executed all of the following conditions are required The interlock tests described in section 2 3 must be passed successfully The M contactor if configured must be closed described in section 2 4 1 2 If any of the requirements are not met of if a fault is latched in the Drive Fault register 202 1202 the PMI will remain in the idle mode If these requirements are met the PMI will execute the alignment procedure When the alignment procedure is successfully completed the PMI will set the Alignment OK bit register 200 1200 bit 1 ALN_OK The programmer can then turn off the Enable Resolver Alignment Test bit This will also turn off the Alignment OK bit The resu
48. r LED DRV FLT A or DRV FLT B is on a drive fault has been detected for the drive using that communication channel LEDs on the Power Module The Power Module s faceplate contains 15 status fault LED board Refer to Appendix E for LED definitions Error log for the UDC task The error log for the task in which the fault occurred is accessed through the ON LINE menu of the AutoMax Programming Executive A list of the drive fault error codes can be found in Appendix D Refer to appropriate AutoMax Programming Executive instruction manual for more information regarding the Programming Executive and the ON LINE menu How the System Reacts to Drive Faults As described in section 2 4 1 if the PMI detects any of the conditions identified by the Drive Fault register it will shut down the drive This means that the PMI responds by immediately disabling the gates of the power devices causing the motor to begin a coast to rest stop The PMI will wait 100 msec after the fault before turning off the MCR output Note that the UDC task is not stopped automatically is a drive fault causes a shut down of the drive The user must ensure that the application task s test the Drive Fault register 202 1202 and takes any appropriate action if a fault is detected 2 4 SA500 Diagnostics Troubleshooting and Start Up Guidelines 2 4 1 2 MCR Output Control The MCR output on the Power Module is used to control an output contactor This output co
49. r Unexpected Test Results If itis not possible to obtain the correct meter reading or proper operation during any of the tests or adjustment procedures described in the following sections perform the following steps Step 1 Stop the drive Step 2 Turn off and lock out all incoming power ATTENTION DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power from the DC bus supply wait five b minutes and then measure the voltage at the POS and NEG terminals of the DC bus supply and each Power Module to ensure the DC bus capacitors are discharged before touching any internal components Failure to observe this precaution could result in severe bodily injury or loss of life Step 3 Wait five minutes to allow the DC bus voltage to dissipate Step 4 Measure the voltage at the POS and NEG terminals on the DC bus supply and each Power Module before working on any unit Refer to figure 4 1 When the DC bus potential is down to less than 5 volts touch a 50 ohm 50 W or larger resistor to each unit s POS and NEG terminals for 20 seconds to allow any remaining voltage to dissipate Remove the resistor and re measure the DC bus potential to ensure the DC bus capacitors are completely discharged Installation and Start Up Guidelines 4 5 dd L AS Bulpjing 10 1 pos GuipunojB 0 esnj e e esnJj e p eseud eBey
50. s that may be used with SA500 drives Perform the resolver alignment procedure if you are using a brushless motor Refer to section 3 3 note that this procedure can be performed with the motor coupled to the load However it will cause the motor to move less than one revolution in both the forward and reverse directions If this motion would be harmful to your machine uncouple the motor from the load before performing this procedure The Power Module s AC output phase rotation must match the resolver s orientation Output phase rotation UVW or UWV is determined by setting the Output Rotation parameter assuming the motor leads are correctly connected Resolver orientation is determined by the cosine lead connections a Place a value of zero in the External Torque Reference register register 102 1102 TRQ REF Turn on the drive b Slowly increase the value in register 102 1102 c If the motor begins turning verify that the motor shaft is turning in a clockwise direction Examine the contents of the Resolver Scan Position register register 215 1215 RES SCN POS The value in the register should be increasing SA500 Diagnostics Troubleshooting and Start Up Guidelines If the motor does not turn place a value of zero in register 102 1102 and turn off the drive Change the Output Rotation parameter Regenerate the parameter object file and reload it to the rack Restart the drive Slowly increase the value in register 102 11
51. scribed in the SA500 Power Modules instruction manual S 3018 The Resolver Balance Calibration Completed bit register 201 1201 bit 7 RES BALG will be on when the procedure is complete The result of this procedure is stored in local tunable RES BAL If the Tuning Aborted Warning bit register 203 1203 bit 5 WRN_TUN is also on it indicates that the procedure was unsuccessful caused by leaving the resolver uncoupled during the procedure or using longer than recommended cable runs or yielded unusual results sine cosine magnitudes are not within 5 of each other 4 7 9 Running Dynamic Motor Tests The dynamic motor tests complete the drive start up The drive is tuned by running the single drive section under test in order to adjust motor tracking maximum speeds vernier adjustments and machine section speed adjustments The driven machine is then run under actual operating conditions with a load in order to adjust gain values feedback devices limit switches etc as required to obtain the specified performance Installation and Start Up Guidelines 4 15 4 7 10 Updated Drawings and Software Listings When start up is performed by Rockwell personnel the W E W M W P drawings and all software listings are updated after start up and are re issued as revised pages of the Instruction Book Refer to Installing Operating and Maintaining Engineered Drive Systems D2 3115 for more information 4 16 SA500 Diagnostics
52. ster 201 1201 bit 0 is removed POWER UP DIAGNOSTICS SECTION 2 2 IDLE SECTION 3 1 SELECT PMI RUNG or ALN_TST INTERLOCK TESTS OK INTERLOCK TESTS FAILED and PMI RUNQ OR ALN_TST r a Ta CLOSE MCR SECTION 2 4 1 2 MCR DID NOT CLOSE MCR CLOSED or NOT USED MCR CLOSED or NOT USED and and PMI_RUN REG 100 BIT 0 ALN TST Q REG 100 BIT 2 and CONFIGURED FOR BRUSHLESS DC PMI RUNG OFF REG 100 BIT 0 ALN_TST OFF REG 100 BIT 1 or or FAULT PRESENT REG 202 FAULT PRESENT REG 202 or or RPI MISSING REG 201 BIT 0 RPI MISSING REG 201 BIT 0 OPEN MCR SECTION 2 4 1 2 Lo eg L Xu Figure 3 1 PMI Operating Modes and Diagnostics PMI Operating Modes 3 3 Alignment Test Mode For SA500 drives controlling brushless DC motors the resolver shaft and the rotor shaft must be aligned in order to ensure that maximum torque is generated Therefore an alignment procedure must be performed before the torque speed and position minor loops are executed The alignment procedure automatically determines the offset required to bring the rotor and the stator fields 90 apart This procedure must be performed whenever the resolver has been disconnected from the motor for any reason including reversing cosine leads to the resolver ATTENTION For brushless motor applications changing any resolver wiring breaking the resolver coupling replacing the resolver or replacing the motor and resolver for any reason re
53. t are not serious enough to shut down the drive but may affect its performance If the PMI detects any of the conditions described in the Drive Warning register it will set the appropriate bit but will NOT shut down the drive The user must ensure that the application task tests the Drive Warning register 203 1203 and takes any appropriate action if a warning condition is detected The PMI will also set the Warning Detected bit register 200 1200 bit 9 WRN if a drive warning has been detected Appendix B provides a complete description of the Drive Warning register Except for rail faults drive warnings are not indicated by LEDs a rail fault will turn on the RAIL FLT LED on the Power Module Drive warnings are not displayed in the UDC task s error log Diagnostics and Troubleshooting 2 5 2 4 8 How to Clear the Drive Fault and Drive Warning Registers After a drive fault has been detected the programmer must do the following before the drive can be restarted Step 1 Reset the command bit that is currently set in the Drive Control register 100 1100 Step 2 Correct the fault Step 3 Set and reset the Fault Reset bit register 100 1100 bit 8 FLT_RST to clear the Drive Fault register 200 1200 Note that the Fault Reset bit is edge sensitive Step 4 Set the desired command bit in the Drive Control register 100 1100 After a drive warning has been detected the programmer can clear the entire Drive Warning regist
54. the motor s velocity exceeds the value entered as the Overspeed Trip RPM configuration parameter PMI Power Supply Fault The PMI Power Supply Fault bit is set if the PMI power supply is not working correctly Hex Value Sug Var Name Access UDC Error Code LED Hex Value Sug Var Name Access UDC Error Code LED Hex Value Sug Var Name Access UDC Error Code LED Hex Value Sug Var Name Access UDC Error Code LED Hex Value Sug Var Name Access UDC Error Code LED Hex Value Sug Var Name Access UDC Error Code LED Bit 3 0008H FLT VCCQ Read only 1019 P M FLT Bit 4 0010H FLT SPDQ Read only N A N A Bit 5 0020H FLT SPDQ Read only N A N A Bit 8 0100H FLT_TBW Read only 1008 FDBK OK Bit 10 0400H FLT_OSP Read only 1010 EXT FLT Bit 12 1000H FLT_PS Read only 1012 PWR OK SA500 Diagnostics Troubleshooting and Start Up Guidelines PMI Bus Fault The PMI Bus Fault bit is set if a problem is detected with the address and data bus on the PMI regulator board in the Power Module UDC Run Fault The UDC Run Fault bit is set if the UDC task stops while the minor loop is running in the PMI Communication Lost Fault The Communication Lost Fault bit is set if the fiber optic communication between the PMI Processor and the UDC module is lost due to two consecutive errors of any type Hex Val
55. the resolver and external strobe must be connected Force register 101 bit 8 STR ENAQ Enable External Strobe on Verify that register 201 1201 bit 8 STR DET External Strobe Detected is on Check the values displayed for registers 215 1215 RES SCN POS and 216 1216 RES STR POS The values displayed for these two registers should be very close if not identical if the resolver has not turned After you have finished unforce register 101 bit 8 4 7 7 4 Testing the UDC Module Test Switch Register This section describes how to test the UDC module test switch register Use the AutoMax Programming Executive software I O Monitor function to display register 1000 in binary format Register 1000 reflects the status of the test switches and LED indicators on the UDC module Step 1 Verify the function of the UDC push button When the push button is pressed register 1000 bit 0 should be on When the push button is released this bit should be off Step 2 Verify the function of the UDC Test Switch When the switch is in the up position register 1000 bit 1 should be on When the switch is in the down position register 1000 bit 2 should be on When the switch is in the center position both of these bits should be off Installation and Start Up Guidelines 4 13 4 7 7 5 Testing UDC Module Meter Ports 4 7 8 This section describes how to test the UDC module meter ports Use the AutoMax Programming Executive software Monitor
56. their entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power from the DC bus supply wait five 5 minutes and then measure the voltage at the POS and NEG terminals of the DC bus supply and each Power Module to ensure the DC bus capacitors are discharged before touching any internal components Failure to observe this precaution could result in severe bodily injury or loss of life SA500 Diagnostics Troubleshooting and Start Up Guidelines Use the procedures that follow to locate any shipping damage to the drive to verify proper installation and field wiring and to start the drive Recommended Start Up Sequence 1 Physical inspection of equipment Motor checks 2 3 Preliminary inspection with power off 4 Inspection with power on 5 I O verification Before attempting to perform this start up procedure you should be familiar with the general arrangement and function of the drive equipment and should verify that it has been installed and wired as described in the following documents which are included in the Instruction Book provided with your drive system Wiring Diagrams W Ds Elementary Diagrams W Es Panel Layout Diagrams W Ls Operator s Station Diagrams W Os and Interconnection Diagrams W Is if supplied 4 7 1 What To Do Afte
57. ue Sug Var Name Access UDC Error Code LED Hex Value Sug Var Name Access UDC Error Code LED Hex Value Sug Var Name Access UDC Error Code LED Bit 13 2000H FLT_BUS Read only 1013 N A Bit 14 4000H FLT_RUN Read only 1014 N A Bit 15 8000H FLT_COM Read only 1015 COMM OK This bit is set only after communication between the PMI Regulator and UDC module has been established This bit should be used in the run permissive logic for the drive Also refer to the CCLK Synchronized bit register 200 1200 bit 14 Drive Fault Register A 3 A 4 SA500 Diagnostics Troubleshooting and Start Up Guidelines Drive Warning Register Drive Warning Register 203 1203 The warnings indicated by the Drive Warning register cause no action by themselves Any resulting action is determined by the application task The user must ensure that the AutoMax application task monitors register 203 1203 and takes appropriate action if any of these conditions occurs If a warning condition is detected the corresponding bit is latched until the Warning Reset bit bit 9 of the Drive Control register register 100 1100 is set Ground Current Warning Bit 0 The Ground Current Warning bit is set if Hex Value 0001H ground current exceeds the value stored in Sug Var Name WRN GNDQ local tunable GIT E196 Access Read only UDC Error Code N A LED N A Reference In Limit Warning Bit 4
58. us Fault LEDs CARD OK green The CARD OK LED will turn on after the UDC module s power up self tests have been successfully completed The LED will remain on unless there is a watchdog time out or until power is cycled OS OK green The OS operating system OK LED will turn on after the UDC operating system is loaded into the module It will remain on until power is cycled On subsequent power ups the LED will turn on to indicate that the OS is still resident in the module Note that this LED is also used to indicate any failure that may occur during the power up diagnostics If the UDC module fails any of its power up diagnostics the module must be replaced COMM A OK and COMM B OK green The Communication Status LEDs will turn on after the UDC module has established communication with the PMI rack s over the fiber optic link s COMM A indicates the status of communication link A COMM B indicates the status of communication link B When an LED is lit it indicates that messages are being received over that channel Each channel operates independently of the other If a channel is not being used its LED will remain off If communication errors are detected in two consecutive messages the COMM OK LED will turn off and the DRV FLT LED will turn on If the next message received by the UDC module is correct the COMM OK LED will turn back on The Communication Fault bit register 202 1202 bit 15 FLT COMQ will remain latched DRV FL
59. yte descriptions indicates not used Step 5 Examine register 89 1089 for the number of messages transmitted by the UDC module Over time this 16 bit value should increase to its maximum value 32767 and then roll over 4 7 7 2 Testing Rail I O Registers This section describes how to test the rail I O registers if used in your system configuration Use the AutoMax Programming Executive software I O Monitor function to display the Rail I O registers in the format listed in table 4 2 Display these registers in decimal format if they are used for analog I O Display them in binary format if they are used for digital I O Table 4 2 Rail I O Register Formats Register Name PMI Port 0 Channel 0 PMI Port 0 Channel 1 PMI Port 0 Channel 2 PMI Port 0 Channel 3 PMI Port 0 Faults display in binary format PMI Port 0 Check Bit Fault Counter display in decimal format PMI Port 1 Channel 0 PMI Port 1 Channel 1 PMI Port 1 Channel 2 PMI Port 1 Channel 3 PMI Port 1 Faults display in binary format PMI Port 1 Check Bit Fault Counter display in decimal format Step 1 Test each analog current or voltage output channel being used by writing a value between 0 and 4095 to the appropriate register and measuring with an ammeter or voltmeter to verify the signal on the terminal points 4 20mA or 0 10V is proportional to the register value Step 2 Test each analog current or voltage

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