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DCV 700 DC Drives Software Description ABB Industry

1. TREF_TORQMAX TORQ REF A a PORT a c20 Go701 _ 4 FILTER MUL V Scale 4000 Tn motor 2000 TORQUE REFERENCE Fe i TORQ_REF1 SELECTOR LOAD_SHARE TORQ REF A FTC 103 02 Scale 4000 100 LL 0 TORQUE_REF B oko TORQ_REF3 OO 02 gt _ 112 04 3 emm 103 04 MN 45 Gre TREF_TORQMIN an MX SPEED STEP TORQ REF B SLOPE Guo Y Scale 4000 Tn motor LG SPEED_REF4 103 72 9 wm mmm HIR FT i oD TORQSEL SPEED_ACT ae FRS WOW 404 05 CROPRNE 10101 10 scale 10 1 MAIN_CONTROL WORD Gam DROOPNG SPEED_ERROR_ALT a X Goa Figure 15 Torque reference selector 44 3AFE61101446 Software Description The operation mode of the torque control is selected by the torque reference selector The selection mode is set by means of parameter TORQSEL 11 01 5 no torque or speed control The output of the speed controller is selected to the torque reference TORQ_REF2 103 03 The external torque reference is selected to the torque reference TORQ_REF1 103 02 selects minimum value on the basis of the speed difference A negative speed difference SPEED_REF4 lt SPEED ACT causes a change over to speed control A change over from speed control to ext torque ref takes place when the torque reference is smaller than the speed controller output TORQ_REF1 lt TORQ_REF2 and SPE
2. MASTER_FOLLOWER_MODE 20 01 1 Drive is selected to slave FOLLOWER_SIGNAL 20 03 destination of reference value FOLLOWER_TIMEOUT 20 04 time elapsed from the last received value 120 3AFE61101446 Software Description In case of time out the slave updates AUX_STATUS_WORD 101 05 7 The drive does not react to the time out the supervision must be done in the APC application program SELECTION OF VOLTAGE SUPPLY FOR Figure 41 Strap settings of voltage source 29 11 Field excitation communication Between control board and field exciters SDCS FEX 1 DCF503 4 are RS 485 serial communication link with speed of 62 5 kbits The update interval of the field current reference is 10 ms To the link it is possible to connect up to two field exciters so that the second unit is always DCF503 4 Address coding for the link is made by means hardware jumper in the second unit The unit reads the address only when power are connected The parameters of field exciters are downloaded every time when power are connected to the converter or during normal operation every time when some parameter changes are done 121 3AFE61101446 SDCS First field exciter AC INPUT CON 1 x14 9DCS DC OUTPUT FEX 2 Armature controller DT BE ans Total D LE 2 X16 length g EE GE d Le Power supply SDCS AC INPUT AC INPUT CON 1 D
3. Figure 9 Speed error filter and the window control 5 1 Speed error filter The SPEED_REF4 103 12 is used as the speed reference and the SPEED_ACT 104 05 is actual speed from the speed measurement The error value can be filtered by the low pass filter The time constant is given by the parameter FRS 4 06 Scaling is 1 1 ms 37 Software Description 3AFE61 101446 5 2 PID controller For tuning of the PID four parameters are needed KPS 4 01 TIS 4 02 TD 4 02 TF 4 02 The proportional gain of the speed controller Scaling 100 1 The integrator time constant Scaling ms 1000 1s Time Derivation The time constant for derivation Scaling ms 1000 1s Time Filter The filter time constant for derivation Scaling ms 1000 1s TD KPS TIS BEE S nN TFK Figure 10 The step response of the PID controller 5 3 Adaptive P gain The P gain of the controller can be reduced automatically when the load is small This is sometimes necessary when the mechanic part has a slack somewhere The proportional gain when the controller output is zero is defined by the parameter KPSMIN 4 03 Scaling 100 1 38 3AFE61101446 Software Description The amount of the load where P gain is the same as KPS is set by the parameter KPSWEAKPOINT Scaling speed unit 20000 max speed 4 04 Wh
4. Figure 22 Principle of the digital outputs 68 3AFE61101446 Software Description 11 3 Analogue inputs EARTH FAULT SDCS 10B 3 ATAC VALUE SCALE X81 ANE GER AITAC_HIGH_VALUE16 01 H X3 2 Lamm Haam AITAC_LOW_VALUE 16 02 4096 LL 10V ANALE SCALE AIMEAS CEW Al_HIGH_VALUE 1603 m X3 3 4095 __ HL 10v Al1_LOW_VALUE 1604 X3 4 4098 LL 10V SCALE USE OF ANALOG INPUTS AIMEAS 11603 e A x85 Te Hes Al2_HIGH_VALUE 1605 A EE Al2_LOW_VALUE 1606 SPEED MEASUREMENT ANALE SPEED_MEAS_MODE 18 04 AIMEAS Cm SCALE ACK EXT FIELD EXCITER X37 5647 estoy AI3_HIGH_VALUE 1609 FECX SEL 11 10 X3 8 2048 Ll 10V AI3_LOW_VALUE 1610 MOT 1 TEMP MEASUREMENT MOT _TEMP_AI_SEL 15 09 X3 9 AMERS PAVALUE MOT 2 TEMP MEASUREMENT a some E GER SCALE MOTi_TEMP_AI_SEL 15 12 2048 J LL 10V Al4_HIGH_VALUE 1607 EARTH FAULT MONITORING Raat il Al4_LOW_VALUE 1608 EARTH_CUR_SEL 15 19 X3 11 J X3 12 mA N SE Current source for PT100 6mA and PTC 1 5mA elements Figure 23 Basics of DCH 700 s analogue inputs Analogue inputs consist of five 5 channels All connections are on the SDCS IOB 3 board All channels are programmable and can be scaled when needed for the
5. 3AFE61101446 It is possible to force drive to use a defined field direction This gives the possibility to user to allow the direction change only when it is needed Using the force command makes the drive less sensitive to the torque reference Two signals are defined for forcing the field direction FORCE_FIELD1_FWD 0 no force 108 04 lt gt 0 force FWD field FORCE_FIELD1_REV 0 no force 108 05 lt gt 0 force REV field 9 12 3 Field monitoring when changing direction Normally field current is compared to minimum level and if current falls below the minimum limit all control functions are blocked and the drive goes to the state RDYRUN 0 and RDYREF 0 During the field change the situation differs It is allowed to be under the minimum field level certain time because the field current must pass over the zero current In the process of field changing the current controller is blocked speed controller l part is frozen and speed ramp output is updated by the measured speed value The field current must change the direction in a period of 2 sec otherwise signal ACK_FEXC1_ON goes to 0 This causes the situation RDYRUN 0 and RDYREF 0 In order to supervise the function next parameters are needed FIELD1_CUR_GT_MIN_L the minimum level for the 8 17 the field current Scale 4095 nominal FIELD1_REV_HYST The sign of the field current 8 18 defines used direction To avoid signal noise problems a small hystere
6. The purpose of the window control is to keep the speed of the slave section inside defined speed window When window control is activated the speed controller is forced to zero as long as the speed deviation remains within defined limits In window control mode the speed controller output and the external torque reference are added together The adding is done when the parameter TORQ_SEL 11 01 5 The window size is determined by the parameter WINDOW_WIDTH Scaling speed unit 4 08 20000 nominal speed 40 3AFE61101446 Software Description The program calculates values for the MinWindow and MaxWindow as follows MaxWindow WINDOW_WIDTH 2 MinWindow MaxWindow TORQ REF L 2 D SPC OUTPUT SPEED_ACT SPC OUTPUT a ee m TIME gt SPEED ERROR gt WINDOW WIDTH 1 gt SPEED ERROR lt WINDOW WIDTH gt gt SPEED ERROR 0 l l l l S Figure 13 Effect of load change on a torque controlled drive in window control The window control mode is selected by setting the bit WINDOW_CONTROL in the signal MAIN_ CONTROL_WORD 101 01 10 10101 10 1 the window control is enabled The program sets automatically the integral time constant TIS to zero In the window control mode the speed controller works only as a P control 10101 10 0 the window control is disabled APC can supervise how well the drive stays inside given window by reading the bit OUT_OF_WINDO
7. 1 ROM memory test error E 2 RAM memory test error E 3 No TC link board E 4 Bad TC link board E 5 No control program in memory E 6 Incompatible hardware A XX Alarm code F XX Fault code Table 37 Status codes of the drive shown on the seven segment display of the SDCS CON 1 28 2 Supply voltage monitoring The control board monitors the following voltage levels Supply voltage Under voltage limit 5 V 4 55 V 15V 12 4 V 15 V 12 0 V 24 V 19 V 48 V1 38 V If 5 V drops under the tripping limit it causes a master reset by hardware causing a power fail message to be displayed and the firing pulses are suppressed 28 3 Watchdog function The control board contains an internal watchdog The watchdog supervises program running on the control board If watchdog trips the HW takes care of the next functions FPROM programming voltage is forced low Thyristor firing control is reset and disabled Digital outputs are forced low Programmable analogue outputs are reset to zero OV 102 3AFE61101446 l Software Description 28 4 Jumpers on the SCDS CON 1 board By means of jumpers S2 and S3 user can by pass the backup flash reading at a power up state and disable totally writing to the backup flash Jumpers must not be removed or connected when power is on Jumpers have four pins and the pins are marked on the circuit board beside each jumper The following table shows factory settings o
8. depending on the settings of the terminal board SDCS IOB 2 18 5 Position counter diagram DI7 SYNC_RDY GE Caor 04 8 DCV_FAULT FORWARD A7 amp BACKWARD AB ZERO_CH_SYNC l D APC_SYNC_CMND 101 01 5 A10 SEL SYNC_INPUT iz 501 SYNC_DISABLE 101 01 6 RESET_SYNC_RDY 101 01 7 POS_COUNT_SYNC_LOW gd POS_COUNT_SYNC_HIGH l POS_COUNT_LOW wem D i Cios D POS_COUNT_HIGH PULSES FROM INCREMENTAL PULSE ENCODER Figure 31 Position counter logic 80 3AFE61101446 Software Description 19 MONITORING FUNCTIONS 19 1 Speed measurement supervision The supervision of the speed measurement is based on the relation between the measured speed and measured calculated EMF SPEED_ACT 104 05 FIELD1_REV_ACK 108 14 EMF_V 118 07 SPEED_MON_MEAS_LEV P15 23 SPEED_MON_EMF_V P15 24 AND2 SPEED_MEAS_FAULT 122 07 B5 SW C1 ACT w O a K Da ol D RESET AND2 MUL xX Figure 32 The speed measurement supervision Above certain EMF voltage the measured speed must also be above zero and the sign of the speed measurement must be correct Otherwise the SPEED_MEAS_ FAULT 14 will be g
9. reference chain and speed controller 11 EMF controller 92 3AFE61101446 l Software Description 23 1 Square Wave generator The output of the square wave generator is adjusted by using 3 parameters POT1 23 03 Higher value of the generator POT2 23 04 Lower value of the generator PERIOD 23 05 Time between values Scale 1 10 ms The output of the square wave generator can be monitored from the signal SQRW 123 02 23 2 Test reference selection The test reference can be selected by the signal TEST_REF_SEL 123 17 0 0 1 POT1 23 03 2 POT2 23 04 3 SQWAVE 123 02 4 TEST REF 123 03 Finally start the drive or only close main contactor in a case of field exciters Measurements are recommended to do with DDCTool 23 3 Manual tuning of the speed loop The test reference replaces LOCAL_SPEED_REF that normally comes from the DDCTool When using the square wave function the drive can be set to accelerate and decelerate continuously without giving the new reference from the DDCTool Used when acceleration compensation is tuned 23 4 Manual tuning of field exciters The test reference replaces normal field exciter references coming from the controlling software When using the square wave function the field reference can be stepped Actual values FIELD1 2 CUR_ACT 118 10 12 can be monitored by the DDCTool and with help of reference and actual value monitoring the gain values can easily be adjuste
10. A D conversion The default value is 10 This means that the free wheeling starts if AC input voltage measurement increases more than 7 6V ms 9 10 Filter for actual field current The field exciter unit has a filter for smoothing the actual field current measurement transferred to the drive software The filter is meant for smoothen actual current measurement value for displays The filter time constant should not be increased too much because the same signal is also used for supervising overcurrent of the field overcurrent FEXC1_CUR_TC 8 01 Scaling 1 0 01 sec FEXC2_CUR_TC 8 07 9 11 Current controller The current controller of the field excitation unit is located inside the field excitation unit Some parameters are accessible via serial communication link if the current controller needs manual tuning The current controller is normal Pl control that has one parameter for P gain and second parameter for I time constant P gain parameters FEXC1_KP 8 02 Scale 1 100 FEXC2_KP 8 07 3AFE61101446 Software Description Pl controllers input value quality is current and output value quality is voltage Lime constant parameters FEXC1_KI 8 03 Scale 1 10 ms FEXC2_KI 8 09 The maximum output voltage of the Pl controller can be limited by means of 2 parameters When the bridge is full open the output voltage is 0 9 VAC This equals the limit value 4095 The limitation is linear so 2048 0 5 0 9 VA
11. D SH d J W Te e Yad 7 SC z434 OHOL 4H il Ges OGNIM HO daads t4347033dS Wooltz ops YHATIOULNOO Teor mmm HU COT lt 4 ken Se SUE 9434 OHOL p S434 0801 D dals aaads 39Vd wer XVWOYOL OdS SO CO mm eat COL E 0 JOYULNOOS 033dS aD t439 OHOL 439 OYOL XWWOHOL 2901 0 i SG Ef SZ SS SI K as G ae Gr ae Be SEN G aay H aay YOLOI1SS bday OYOL 39JN343434 SNOYOL LO 01 gt AE SOV 00D NOLLVSNadWOD OO i 020D dals 3NOYOL NIVHO 39N3493434 JNOHYOL Figure2 Speed measurement speed controller and torque reference chain 16 Software Description 3AFE61101446 LL So YNIA CLOW Te CEL LOL f YSLIOX4a Mdl GNOOAS f SEKISaaREIE C Ok el el DUR RE LCLOeMOCLOCOL SS LS clSNOo LOL D i FL Sl SNOSITI 1Ov da3dS f HOMLNOS vr Leo el NOTA L LOW t4 YOOL 4M3 Lal ESAN aay E wiowuna zatals inawaynsvan GE Cat NGMMAD CSI AU OD La dae anol EH CHD steisst en NOLLVIMWANIT EE CERT eae OD E ER ee A CLRID MINES are OD Lo
12. Dee wee ea Aiea a E tes See 91 23 MANUAL TUNING eege See Eege See 92 23 1 Square Wave generator EE 93 23 2 Test reference E 93 23 3 Manual tuning of the speed loop 93 23 4 Manual tuning of field exciters ANNE EEN EEN 93 23 5 Manual tuning of Armature Current CGontroller 94 23 5 1 Find continuous discontinuous Current mt 94 23 5 2 Tuning of the armature Current Controller eseeeeseeeeeeseeeeeees 94 23 6 Manual tuning of the EMF controller ccccccceceeeeeeeeneeeeeeeeeeeeaeeeeeeeeeeeneeeees 94 2A ETA RE TIONS EE 95 24 1 Torque and armature Current Wmtaton 95 24 2 Gear backlash compensation cccccceeceeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeaeeeeeeeeeeeeaaees 96 24 3 Speed reference Tu Ce EE 97 24 4 Zero speed Ke EE 97 ZO CONVERTER SETTINGS e e eae ee aeaa aA a Bad ag aN ae 99 25 1 Converter rating plate data eee cece EEN 99 25 2 Nominal network voltage EE 99 ZO MOTOR SE DT Hl e 100 27 PARAMETER BACKUP rantre Ee Ee i ate 100 26 4DIAGNOS KE 101 28 1 Control board self diagnostic et geegent geegent e 101 28 2 Supply e Ee enen e ln EE 102 28 3 Watchdog TUNGOR EE 102 28 4 Jumpers on the SCDS CON 1 board ANNE 103 26 Sokat ogg EE 103 28 6 Redl TMG ClO ke a a A ala a ela 103 20 Data He Le EE 104 28 8 Monitoring of the APC application Signals 0 ceccceeeeeeeeeeeeeeeeeeteeeeeeeeeeteee 105 28 9 Fault and alarm texts and codes isis sclissietecssiedinntewensss snes Eege eege
13. EMF greater than 15 55 Inductance cannot be determined Fuse blown thyristor not firing or no motor load 56 Limit for continous current flow cannot be determined 57 The field removal takes longer time than 10 s 58 Blocking or stop signal appears during autotuning 91 3AFE61101446 23 MANUAL TUNING In order to facilitate the tuning of the drive DCV700 has several manual tuning functions With help of the manual tuning next functions can be tuned Armature current controller Field exciters EMF controller Speed loop When manual tuning is activated normal reference is switched off from the function and replaced by test reference The test reference can be either Square wave generator or adjustable test reference Manual tuning can be activated only in LOCAL mode LOCAL ME RES DRIVEMODE P11 04 mas HMC Mon tun m ntrol a i ee hep DRIVEMODE4 DS 2 1 lt 2 JL o ch DRIVEMODE7 H a ep mm Mn tun second field exc er a DRIVEMODES UE MES went ste PONE ia ak Ze L Manet Se ORIVEMODES 1 lt 12 COMP Mon tun of EMF controller eene o Ui EE lt 2 REF2 Figure 34 Object and test reference selections in the manual tuning The activation of the manual tuning parameter DRIVEMODE 11 04 4 armature current controller 7 first field exciter 8 second field exciter 9 speed loop
14. If acknowledges are not received after 6 seconds of ON command the corresponding fault is generated These are NO_EXT_FAN_ACK 40 NO_MAIN_CONT_ACK 41 NO_FIELD_ACK 39 NO C FAN ACK 50 Two acknowledges can alternatively generate alarms These are CONV FAN ACK ALARM 126 EXT FAN ACK ALARM 127 19 4 1 External FAN acknowledge The function of the program can be selected in case where acknowledge information of the external fan s is not available EXT_FAN_ACK_MODE 11 12 0 drive is tripped and NO_EXT_FAN_ACK fault will be given 1 only EXT_FAN_ACK alarm will be given 2 acknowledge not used 19 4 2 Converter FAN acknowledge Constructions C1 C2 and C3 generates alarm when the acknowledge signal is missing The construction C4 generates fault 82 3AFE61101446 l Software Description 20 CONVERTER PROTECTION 20 1 Armature overcurrent Used overcurrent limit can be checked from the signal TRIP_A 113 02 scale 1 1A The limit can be reduced by the parameter ARM_OVCUR_LEV 18 05 scale 100 nominal current of converter L CONV_A 113 01 20 2 Over temperature The maximum temperature of the bridge can be checked from the signal MAX_BRIDGE_TEMP 113 04 scale 1 1C Exceeding this limit will cause the CONVERTER_OVERTEMP 04 fault The alarm limit is 10C under the tripping limit The measured temperature can be monitored from the signal BRIDGE_TEMP 118 14 scale 1 1C 20 3 Network over voltag
15. SEL SPEEDMIN SEL SPEED_SOFT_ TI 203 MAIN_STATUS_WORD 401 04 LOCAL MODE MAIN CONTROL WORD SELECTOR Se 10101 IENLOCALSEL 11 15 ae Won LOCAL MODE 11101 101 03 Figure 7 The speed reference chain 4 1 Speed ramp The speed reference value SPEED_REF2 103 10 is passed through the speed ramp function The ramp function is selected when the bit MAIN_CONTROL_WORD 10 101 ramp is set to 1 When using the DDCTool the ramp function is always used 34 3AFE61101446 Software Description Acceleration and deceleration times can be set by parameters ACCEL_TIME The time in which the drive will accelerate 2 01 from zero speed to maximum speed Scaling 1 0 1 sec DECEL_TIME The time in which the drive will decelerate 2 02 from maximum speed to zero Scaling 1 0 1 sec In case of the emergency stop a different ramp down time can be chosen by the parameter EMESTOP_TIME The time in which the drive will decelerate 2 04 from maximum speed to zero Scaling 1 0 1 sec If 0 1 sec resolution for the ramp is too inaccurate you can select a more accurate base scale for the ramp times by the parameter RAMPTIMESCALE The time scale for the ramp 2 05 100 time resolution is 100 ms 10 time resolution is 10 ms 4 2 Variable slope The APC can control the slope of the DCV700 ramp if the more complicated ramp function is needed The base idea is that APC has the system main ramp When APC calculates the ne
16. SPEED_ACT_FILT 40Q5 10V arD LOWMALUE ER ACT A AITAC HIGH VALUE 16 OI SDCS IOB3 AITAC_LOW_VALUE 16 02 EMF_V GD TET CALCULATION Se SPEED_ACTFILT_FTR ENF gt SPEED Gu 0 ZZ SPEED_ACT_RPM CE Figure 6 The actual speed measurement 3 1 1 Scaling of the speed measurement The base scaling for the speed as units is 20000 The maximum speed of the drive is set by the parameter SPEED_SCALING 13 18 with the resolution of 0 1 rom 3 1 2 Pulse encoder The incremental encoder can be used as one or two channel encoder The range of tacho pulses per revolution is 125 6000 Selection of the speed measurement mode depends on the type of the pulse encoder 27 3AFE61 101446 SPEED MEAS MODE 18 04 0 ch A positive edges for speed ch B direction 1 ch A positive and negative edges for speed ch B not used 2 ch A positive and negative edges for speed ch B direction 3 ch A ch B all edges are used Modes 0 1 2 are not recommended Number of pulses per revolution for the used pulse encoder is set by the parameter TACHOPULS_NR 18 02 2048 def Number of pulses received from pulse encoder can be monitored by the signal TACHO_PULSES 123 04 Analog tachometer The signal of the analogue tachometer is recommended to scale so that the input value of the AIlTAC channel at the maximum speed of the motor is below 8 V This provides safety marginal for possible instantaneous overspeed because the co
17. The field exciter called first field exciter can be controlled normally Another field exciter for the motor 2 is controlled only by using constant field current reference This function is used e g in the crane application where one motor is used for lift the load with adjustable field and the other motor is used e g moving the whole crane Only one motor is driven simultaneously DCV 700 Converter CONTROL BOARD SCDS CON 1 FIRST FIELD EXCITER i SECOND FIELD_EXCITER DCF503 504 DCF503 504 RS 485 FIRST FIELD EXCITER 7 yay Address of RS485 X2 SES for second unit Control Control Control SDCS FEX 2 Figure 29 Principle of the shared motion The type of the first field exciter can be either SDCS FEX 2 or DCF503 504 The second unit must be DCF503 504 For second unit the address of the RS485 serial link is set by the hardware jumper in the DCF503 504 terminal blocks The control program of the converter includes parameters and signals for both field exciters If tyoe of the motors or settings of controllers for motors are different the changes of these parameters must be handled by means of APC application program 74 3AFE61101446 l Software Description 16 POWER LOSS MONITORING AND AUTO RECLOSING The Auto Reclosing function allows to continue drive operation immediately after a sh
18. can also be controlled into desired level 61 3AFE61101446 9 15 Field reduction when stand still The motor field can be reduced at a stand still situation in order to avoid overheating when motor is not running The function can be activated by means of two parameters FIELD1_RED_ SEL 11 18 Selection for first motor FIELD2_RED_SEL 11 19 Selection for second motor in case of shared motion The used current reference can be selected by means of two parameters FIELD1_REF_RED 8 13 Reference for first motor FIELD2_REF_RED 8 21 Reference for second motor in case of shared motion The function is activated when ON command is 1 so the main contactor is closed the drive is in RDYREF state 10 second is elapsed 9 16 Field heating when OFF state The motor field can have a small value in order to avoid condensation when motor is in OFF state The function can be activated by means of parameter FIELD HEAT SEL 11 17 The used current reference are the same as with the field reduction function FIELD1_REF_RED 8 13 reference for first motor FIELD2_REF_RED 8 21 reference for second motor in case of shared motion The function is activated when command ON is 0 so the main contactor is open The function closes the field contactor 3AFE61101446 Software Description 10 EMF CONTROLLER The EMF controller has two main control functions When running the motor above base sp
19. capacitor that supplies power to the memory circuits during supply voltage shut down in order to keep data in the fault logger and the data logger 28 1 Control board self diagnostic The control board has one 7 segment display in order to facilitate trouble shooting in various situations After switching on the supply voltages for the control board the program starts to test HW During initialization RAM and ROM flash memories memories are tested If ROM or RAM tests fail the communication will not start and an error message will appear on the control board 7 segment display E 1 or E 2 The diagnostic tests also that the communication board SDCS COM 1 exist The board is compulsory because that is the only way to control the drive Such faults that would prevent to start running the program totally is shown by the 7 segment display always with the letter E and code During normal running fault codes and alarm codes shown by the 7 segment If message error code has more than one number or letter to display the code is displayed so that every number and letter are alternating with each others in the period of 0 7 seconds This sequence is repeated indefinitely 101 3AFE61101446 The seven segment display is located on the control board Codes are Code Description 0 7s 0 7s i Normal situation no fault no alarm During downloading PC gt drive sequence Program is not runnin m 8 E
20. exciters can be checked from the signals FEXC1_SW_VERSION 123 10 Software Description 3AFE61 101446 FEXC2_SW_VERSION 123 11 10 3AFE61101446 Software Description 1 1 3 DRIVE ID The parameter DRIVE ID 23 01 is freely definable by the user in order to mark the section number of the machine The drive software does not use that parameter at all 1 2 Handling of parameters and signals 1 2 1 Parameters are values that define the operation of the DCV700 Parameters can be modified by the APC application program or with a PC based commisioning and maintenance tool the DDCTool The DCV700 has 23 parameter groups which are numbered from 1 to 23 Parameters of a certain group belong to the same functional part of the program Signals are reference values or commands from the APC or DDCTool results from measurements or calculations done by the DCV 700 control program The drive tool can access the signals in the same way as parameters The DCV700 has 23 signal groups which are numbered from 101 to 123 Signals of a certain group belong to the same functional part of the program as the parameters In this manual all references to the parameters and the signals are done by using brackets 12 34 equals the group 12 signal 34 Detailed description of parameter and signal names as well as scaling factors are presented in document DCV700 Control program Parameter and Signal Description Sca
21. is always sent without the Basic Message With the Broadcast Message it is possible to carry out the Master Slave communication The master DCV sends e g TORQ_REF6 103 07 to the APC which sends it further to the slave DCV s The minimum theoretical transmission interval is 8 ms In practice the interval is longer than this because other messages are transmitted on the link and number of the DCV 700s can be more than two 29 2 4 Fault upload message APC sends a Fault Message request to the DCV if the DRFLT block is activated to upload fault information The DCV responds with Fault Message response which contains a fault code and the time and date when the fault occurred 3AFE61101446 l Software Description 29 2 5 Parameter download message APC sends a parameter download request message which contains indexes and values for max five parameters When background communication task in the DCV has processed the message it gives a response message to the TC link driver The parameter downloaded response message is returned when the next poll arrives and there are no other higher priority messages waiting for transmission 29 2 6 Parameter upload message APC sends a parameter upload request which contains indexes for max five parameters When the background communication task in the DCV has processed the message it gives a response message The parameter upload response is returned when the next poll arrives and there are
22. le e EE 50 8 7 Additional commutation reserve DAN 51 8 8 Bridge selection ue lee EE 51 9 FIELD EXCITATION E 52 9 1 Field exciter type selection EE 52 9 2 Internal diode field exciter SDCS FEX 1 sssssensseesssseeenrresserrenrrnnerrrnernnneesne 53 9 3 Internal field exciter GDCG FEN 53 9 4 External field exciter DCEBOA een 53 9 5 External field exciter DE RS 08 iaco coc dearest ie actan nest weseeb acd vne de aededdas we hedierdts 53 9 6 Al DI based field exciters bk 54 9 6 1 Use of Dl channel snieni ege EE 54 9 6 2 Dl channel selection ig eg egstggeteeeeieggie eg eta rete pg eege eegg 54 9 6 3 Use of Al channel ek 54 9 6 4 Al channel eelechon ek 55 9 7 Two field exciters at a same time EEN 55 DO NN Sia sda aca ck E cae ee at le ter pee rege een ote oe tage hae E eae 55 9 9 Free wheeling DEE ee Ee E Eege 56 9 10 Filler for actual field Curent cctetecavetaslacnsnaeniet nanmetaelaontneaelendiad 56 GK ee 56 9 12 Changing of field direction EE 57 9 12 1 Field direction change bwvsteress 57 9 12 2 Force field CIPO CH OMe et Nee NEEN NEE NEE dun 58 9 12 3 Field monitoring when Changing direction cceeeeeeeeeeeeeeeeeeees 58 E e an E ele EE 59 9 13 1 Selection Of OP TtOrqQue ebeegeeggeedeg Ascvcetcaiee decedent ZeEegegg Ze gg 59 9 13 2 Field current reduction proportionally to torque rel 59 9 13 3 Field monitoring when OPTI torque changes field direction 60 9 14 Field curr
23. the U SUPPLY 18 03 default value 0 To avoid shooting trough of the converter the adjusted values of alpha should only be changed after consultation with ABB 8 8 Bridge selection monitoring The bridge used during running can be monitored by the signal ARM_DIR 118 09 0 no bridge 1 motor bridge 1 generator bridge 51 3AFE61101446 9 FIELD EXCITATION DCV700 has a possibility to use several kind of field exciters or combination of them depending on application This chapter explains the basic differences of various field exciters Functions which are using field exciters are also explained in this chapter EXTERNAL FIELD EXCITER Acknowledge IER DCV 700 Converter ae 1 0 i 8 cards CONTROL CARD A D DCF503 504 SDCS FEX 1 Figure 19 Basic parts of the field excitation 9 1 Field exciter type selection The used type of the field exciter is selected by parameter FEXC_SEL 11 10 No field exciter selected Internal diode field exciter SDCS FEX 1 Internal SDCS FEX 2 or ext DCF503 504 external DCF503 504 as a second field exciter internal SDCS FEX 2 or ext DCF503 504 as a first field exciter and external DCF503 504 as a second field exciter 5 8 other field exciter acknowledge through DIx 9 13 other field exciter acknowledge through Alx POUONO 52 3AFE61101446 l Software Description T
24. voltage is detected When connecting some DO channel to follow this signal in that special case the DO channel is updated as fast as possible immediately after detecting the tripping situation 72 3AFE61101446 l Software Description 14 DYNAMIC BRAKING In cases of emergency stop or a communication break of the TC link the drive can be stopped by using the function dynamic braking in order to transfer the power of the machine inertia into the braking resistor The function opens the main contactor but keeps the field ON After the acknowledge signal of the main contactor is OFF the function produces the signal which can be used to connect breaking resistors in parallel to the armature circuit MAIN CONTACTOR Dynamic braking indication BRAKE CONTACTOR J Figure 28 The application example of the dynamic breaking BRAKING RESISTORS One channel of DOs is connected to the signal DYN_BRAKE_ON 110 08 APC must keep the ON command active during breaking Otherwise the field contactor will open The function is activated by the parameters APC_COM_BREAKRESP 19 02 4 use dynamic braking in case of APC time out EMESTOPMODE 11 05 3 use dynamic braking in case of emergency stop 73 3AFE61101446 15 SHARED MOTION When the same converter controls two motors the connections for motors are made with external contactors Both motors have still their own field exciters
25. 0 the current reference is nominal of the motor The scale of the current reference 4095 given data of motor MOTN_A 8 2 Reference slope The rise time of the current reference can be adjusted That can be used if fast rise time causes problems to the motor commutator The rise time is defined by the parameter 47 Software Description l 3AFE61101446 ARM_CUR_REF_SLOPE Scale current units 3 3 ms 50 Hz 13 10 Default 1366 33 3 3 ms 50 Hz scan time 2 77 ms 60 Hz 8 3 Reference limitation The current reference is limited by the parameters ARM_CUR_LIM_P Positive motor bridge current limit 12 05 Scale 4095 motor nominal current ARM_CUR_LIM_N Negative motor bridge current limit 12 06 Scale 4095 motor nominal current Additionally the current reference can also be limited proportionally to the motor speed 8 4 Armature current deviation alarm If the current controller cannot yield to the given reference the alarm signal is created Normally the reason is too small AC voltage compared to the motor EMF If the difference between the ARM_CUR_REF 103 13 and the ARM_CUR_ACT 118 07 is bigger than 20 of nominal longer than 5 seconds the alarm ARM_CUR_DEV_ALARM 120 will be generated The drive is not tripped for this reason 8 5 Armature current controller The armature current regulator has two controlling methods These are PI controller and IP controller The IP con
26. 08 ALARM_WORD1 combined alarm word 1 Scaling see below Read only Type BOOLEAN Bit APC alarm status text Signal code alarm status code o Start inhibition 101 1 Emergency stop 102 2 Motor 1 temp alarm 103 3 Motor 1 overl alarm 104 4 Conv overtemp alarm 105 l E TC address alarm 106 6 7 Ram backup failed 108 8 Motor 2 temp alarm 123 9 Motor 2 overload alarm 124 10 Mains underv alarm 118 11 Mas foll index alarm 112 l 12 Conv FAN ack alarm 126 13 Arm cur dev alarm 120 l 14 Mas Foll tout alarm 125 l 15 Ext FAN ack alarm 127 l _Index 12209 ALARM WORD2 combined alarm word 2 Scaling see below Type BOOLEAN Bit APC alarm status text Signal code alarm status code 0 APC link closed 128 1 Type code changed 129 2 Aux underv alarm 132 3 4 5 6 7 8 9 10 11 3AFE61101446 Software Description 28 12 Static fault and alarm words All faults and alarms are copied to the static fault and alarm words These words hold their information although the alarm disappears or the reset command is issued from APC or DDCTool Static fault and alarm words can be reset by using bit 2 STATIC_RESET in AUX_CONTROL_WORD 101 02 If any of the static fault bits is set this is informed by AUX_STATUS_WORD 101 02 bit 13 STATIC_FAULT If any of the static alarm bits is set this is informed by AUX_STATUS WOR
27. 104 09 Used for speed control Can be filtered by setting time constant to the parameter SPEED ACT FTR 4 09 scale 1 1ms Used for displays like DDCTool Can be filtered by means of the parameter SPEED_ACT_FILT_FTR 4 10 scale 1 1ms Used for DDCTool displays 29 3AFE61101446 3 2 Armature current measurement DC armature current is measured on the AC side using the current transformer The measured AC current is rectified and scaled to the DC voltage signal so that 1 5V in SCDS CON 1 board equals always the nominal current of the converter The measured current is scaled in two ways The overcurrent protection needs the current measurement which is scaled so that the converter nominal current equals 4095 The control of the motor is scaled so that 4095 equals the nominal current of the motor 3 2 1 Converter current Converter current is relative to the nominal current of the converter The converter current is used for overcurrent protection CONV_CUR_ACT Converter armature current 118 05 4095 equals to nominal converter current CONV_CUR_ACT_A Converter current as amps 118 06 1 1A 3 2 2 Armature current Armature current is relative to the nominal current of motor The measurement is divided into two signals where the sign of the signals is handled differently in order to facilitate diagnosing ARM_CUR_ACT Measurement for the current controller 107 08 4095 MOTN_A 13 02 The sign
28. 2 06 95 3AFE61101446 24 2 Gear backlash compensation The gear backlash compensation function can be used for backlash affected drives When the torque reference passes through zero at first only small torque limits are used After the GEAR_TORQ_TIME 12 14 has elapsed the torque limits are stepped to the defined level TORQ_MAX2 TORQ_REF6 GEAR_START_ TORQUE TORQ_MIN2 GEAR_TORQ_ GEAR_TORQ_ TIME RAMP Figure 35 Torque limitation during gear backlash The gear backlash function is adjusted by setting next parameters GEAR_START_TORGQ 12 13 When the torque is changing the direction torque limits are reduced for a while GEAR_START_TORQ is the torque limit right after the direction changes Scale 4000 motor nominal torque GEAR_TORQ_TIME 12 14 The time after the direction change when GEAR_START_TORQ Q is used Scale ms GEAR_TORQ_RAMP 12 15 When the torque is changing the direction torque limits are reduced for a while GEAR_TORQ_RAMP defines the slope to the normal torque limit after GEAR_TORQ_TIME is elapsed maximum change of limit 3 3 ms 2 7 ms 60 Hz 3AFE61101446 l Software Description 24 3 Speed reference limitation The speed reference is limited by parameters SPEED_MAX 12 03 scale speed units SPEED_MIN 12 04 scale speed units Speed reference 20000 equals to the speed which is set into the parameter SPEED_SCALING 13 18 0 1 rpm 24 4 Zero speed l
29. 3 84 3AFE61101446 Software Description the SDCS IOB 3 board has one selectable current generator for the PT100 5 mA or PTC 1 5 mA elements Unit of the measurement depends on the selected measurement mode For PT100 the unit is Celsius For PTC the unit is 21 3 1 Measurement selection Max 3 PT100 elements can be connected in serial In case of only one PT100 element the Al channel measurement range must be jumpered to use the voltage range 0 1V The selection for the measurements are done by the parameters MOT TEMP_AI SEL 15 09 For analogue input 2 MOT2_TEMP_AIL SEL 15 12 For analogue input 3 O not used default value 1x PT100 C 5 mA current generator voltage range 0 1 V 2 2xPT100 C 5 mA current generator voltage range 0 10 V 3 3xPT100 C 5 mA current generator voltage range 0 10 V 4 PTC Q 1 5 mA current generator voltage range 0 10 V 5 current or voltage measurement ranges 1 V 1 V 10 V 10 V 0 4 20 mA When voltage or current measurement are selected 5 the scaling are made with the parameters Al2_HIGH_VALUE 16 05 Al2_LOW_VALUE 16 06 analogue input 2 Al2_HIGH_VALUE 16 07 Al2_LOW_VALUE 16 08 analogue input 3 Note These scaling are not used with measurements which are based on the PT100 and the PTC elements 85 3AFE61101446 Measured values can be monitored from signals MOT1_MEAS_TEMP 115 03 analogue input 2 MOT2_ME
30. 4 closed 5 mA 11 4 Analogue outputs PTC PT100 The analogue outputs consist of three 3 channels All connections are in the SDCS IOB 3 board First two outputs are programmable The range of outputs is 10V 10V and the resolution are 11 bits sign The third output is fixed and used for indication of armature actual current directly from HW measurement The basic scale of the output 3V equal to converter nominal current The gain can be adjusted by means of potentiometer R110 in the SDCS IOB 3 board 70 3AFE61101446 Software Description A01_IND COD SCALE ADD2 HL SIDD AQ1_NOMINAL_V X1 16 17 AO1_NOMINAL_VAL Sr tiny X14817 DIV AO1_OFFSET_V X119 20 SDCS OB 3 AQ2_IND Sen Cir jin SCALE 5 ADD2 HL AQ2_NOMINAL_V x434 C7 MUL LL AQ2_NOMINAL_VAL 10000 HL 10V ties e tegt 5 AO2_OFFSET_V ARM_CUR_ACT_FILT AL LL 4095 J HL 10V o LLeov Figure 25 Basics of the analogue outputs The signal selections for analogue outputs are made by the parameters 0 APC commands the channel 0 signal number AO1_IND 17 01 AO2_IND 17 04 lt gt The output is scaled by the parameters AO1_NOMINAL_V 17 02 Output V in mV when measured signal equal to the value given by parameter 17 17 AO1_NOMINAL_
31. AS _TEMP 115 04 analogue input 3 The unit for the measurement PT100 Celsius PTC ohms Other Scaled value 21 3 2 Alarm and tripping limits The over temperature fault belongs to tripping level 2 In case of over temperature the main and the field contactors will be opened but fans are kept run until temperature falls under the alarm limit In the PT100 measurement alarm and tripping limits are set directly as Celsius degrees In the case of thermistor measurement PTC limits are set as resistance values 0 4000 ohms Alarm levels can be set by the parameters MOT1_TEMP_ALARM_L 15 10 analogue input 2 MOT2_TEMP_ALARM_L 15 13 analogue input 3 Tripping limits can be set by the parameters MOT1_TEMP_FAULT_L 15 11 analogue input 2 MOT2_TEMP_FAULT_L 15 14 analogue input 3 When some limit is set to zero then the appropriate function is by passed 21 4 Motor thermal model 21 4 1 General In DCV700 there are two thermal models that can be used at a same time Two models are sometimes needed when one converter is switched between two motors e g shared motion drive sections By means of one signal the measured armature current is directed to wanted model In normal case only one thermal model is needed 3AFE61101446 l Software Description The thermal model of the motor is recommended to use when a direct temperature measurement from the motor is not available and the current limits of the drive are set h
32. C FESCH U LIM_N 8 05 negative limit FEXC2_U_LIM_P 8 06 positive limit FESCH U LIM_N 8 11 negative limit FEXC2_U_LIM_P 8 12 positive limit 9 12 Changing of field direction Changing of field direction is needed when the drive has only one armature bridge 1 quadrant This gives the possibility to change a speed direction and also regenerating energy back to network when decelerating a speed down with a heavy inertia The sign of the Torque reference defines the wanted direction of the field 4 Quadrant equipped drive does not have the field direction changing facilities The field direction change can be activated by means of parameter FIELD1_MODE 11 11 no EMF control 4 quadrant EMF control Field reversal 1 quadrant Field rev EMF control Ste Field rev OPTITORQUE ame Field rev OPTITORQUE EMF control DN OO E ob A OH When using 4 quadrant type drive the field reference value is always positive 100 unit value 4095 If EMF controller is activated then field current is controlled but still it can never be bigger than 100 9 12 1 Field direction change hysteresis To avoid too sensitive function when the torque reference value is small one parameter is needed to form hysteresis around zero torque reference The hysteresis is symmetrical against zero The hysteresis value is set by the parameter FIELD1_REF_HYST Scale Field current unit 8 19 4095 nominal 9 12 2 Force field direction 57
33. C OUTPUT DC OUTPUT Armature controller e D Total A 3 m Total D SS ERT EA ch E Second WS KR field dap exciter ime r Power supply Power supply Figure 42 Serial communication cable connection and address setting In the program the selection between field exciters is made by means of the parameter FEXC_SEL 11 10 0 1 2 3 4 No field exciter Internal diode field exciter SDCS FEX 1 Internal SDCS FEX 2 or external DCF503 504 as a first field exciter ext DCF503 504 as a second field exciter Int SDCS FEX 2 or ext DCF503 504 as a first field exciter and ext DCF503 504 as a second field exciter 5 13External field exciters Both field exciters have own individual status signals for the communication FEXC1_COM_STATUS 123 12 first field exciter FEXC2_COM_STATUS 123 13 second field exciter 0 BO B1 B2 B3 OK time out when write parameter no echo for address time out when write parameter no values received time out when read parameters no echo for address time out when read parameters no values received 122 3AFE61101446 l Software Description B4 time out when read actual values no values received Communication errors can be read out from the signals FEXC1_COM_ERRORS 123 14 first field exciter FEXC2_COM_ERRORS 123 15 second field exciter 123 3AFE61101446 30 REVISION HISTORY A brief description of the differences in program versions and the versions of t
34. CE_SP_CNTR Speed controller l part is forced Speed controller part is released 13 DIG_OUT4 set DO4 ON Leet DO4 OFF l 14 DIG_OUT5 Leet DOS ON Leet DO5 OFF l 15 DIG_OUT6 set_DO6 ON set DO6 OFF Note i edge sensitive signal AUX CONTROL WORD the auxiliary control word of DCV700 index 10102 Bit Name Value 1 Value 0 0 RESTART DOG i restart collecting of data 1 APC_ WATCH DOG toggle bit 1 toggle bit 0 N STATIC_RESET APC_EMESTOP APCDISLOCAL DIG_OUT7 DIG_OUT8 Note i edge sensitive signal reset bits in static fault alarm words activate emergency stop sea disable local mode set DO7 ON set DO8 ON enable local mode set DO7 OFF set DO8 OFF 19 Software Description l 3AFE61101446 2 3 DDCTool command words LOCAL_CONTROL_WORD the local control word of DCV700 lindex 10103 Bit Name Value 1 Value 0 0 1 E i Start fans field and close the Open contactor stop field and main contactor fans 2 Ka i run the drive with selected stop the drive according to reference STOP_MODE parameter 3 RESET i acknowledge a fault indic l 4 COAST coast stop l 5 6 7 8 9 TRIGG LOG i external trigger for loggers l 10 11 12 13 14 ER Note edge sensitive signal 20 3AFE61101446
35. D 101 02 bit 14 STATIC_ALARM STATIC_FAULT_WORD1 122 10 STATIC_FAULT_WORD2 122 11 STATIC_ALARM_WORD1 122 12 STATIC_ALARM WORD2 122 13 111 3AFE61101446 29 COMMUNICATION DCV 700 has three optical fibre communication channels in the SDCS COM 1 board Two of these channels run at 1 5 Mbits s using the HDLC protocol They are used for APC and DDCTool communication The third channel is asynchronous protocol with a speed of 25 kbits s That channel is used for master follower communication TC link ea z Other drives 1 3 DISTRIBUTOR YPC 111A DCV 700 V3 MA Master Follower link SDCS COM 1 Other drives 1 vi v2 S m z Other drives 1 3 Ht Z itis possible to connected up to 1 249 DISTRIBUTOR drives with the distributors YPC 111 A DDCTool program Figure 38 Basics of the DCV 700 s communication 29 1 TC link protocol TC link protocol is used in communication between APC and DCV 700 The TC link protocol supports two types of services cyclic messages and service messages Cyclic messages are not acknowledged and the previous value is used until a new one is received correctly The cyclic communication operates cyclically with short update intervals and the update time is equidistant Cyclic communication messages are Basic message Cycli
36. DCV 700 DC Drives Software Description Code Revision Language 3AFE61101446 B EN SPEED_ STEP SPC_TORQMAX 11201 10402 SPEED_ REF4 from speed measurement panes SPEED_ ACT SPEED ACT FILTER SPEED_ACT_FTR Scale 1 1 ms PISPEED CONTROLLER Scale 4000 Tn motor TORQ_REF2 401 SPEED ERROR FILTER WINDOW TF Window_width MAIN_CONTROL_WORD SPEED_ACT_FILT SPEED_ACT T FILTER for display SPEED ERROR DROOP DATE 4 02 4 03 4 04 411 4 12 112 02 SPS_TORQMIN SPEED_ACT_FILT_FTR xX an ABB Industry Software Description 3AFE61101446 Issued by FIDRI ETE Date 22 5 1995 File SFTWMAN DOG Created with Designer 3 1 Printed with Postcript printer Table of revisions Date Code 1994 05 26 3AFE61101446 1995 05 22 3AFE61101446 Table of references For information on See Commissioning Hardware Installation Service Word for Windows 2 0 Rev Remark A First issue B Second issue DCV 700 Commissioning Manual DCV 700 Hardware Description DCV 700 Installation Manual DCV 700 Service Manual The technical data and specifications are valid at the time of printing We reserve the right to subsequent alterations 3AFE61101446 l Software Description Contents Page 1 AE NEAL iere eege 9 1 1 Identification of
37. DING_FAULT 17 PAR_BACKUP_FAULT 18 APC_LINK_COMM_ERROR 20 FIELD EX 1 NOT OK 42 FIELD_EX_2 NOT_OK 43 25 Software Description l 3AFE61101446 2 5 7 Fault resetting The drive is reset by the RESET bit in MAIN CONTROL WORD The drive notices the rising edge of the signal To be able to restart the drive after tripping a rising edge must be formed to the ON and RUN signals The technique prevents the RESET signal to command contactors ON by itself STATUS FOR THE APC COMMANDS The point where the main contactor and Lie exciter are tripped TRIP2 P The point where fans are switched off Motor temperature tripping limit Motor temperature alarm limit e lt 7 gt TEMPERATURE TEMPERAT W mT V Ser me LI 7 RDYON ALARM ALARM FAULT FAULT ON ON RUN RUN RESET RESET This RESET command has not effect because ALARM is still active Figure 5 Example of the behaviour of the program in a case of over temperature fault 26 3AFE61101446 l Software Description 2 6 Emergency stop Emergency stop can be activated by the digital input DI5 AUX_CONTROL_WORD 101 02 bit 12 from APC The function of the DCV700 when emergency stop is activated can be defined by the parameter EMESTOPMODE 11 05 Default mode is stop with ramp EMESTOPMODE 11 05 stop with ramp defau
38. ED_REF4 gt SPEED_ACT selects maximum value on the basis of the speed difference A positive speed difference SPEED_REF4 gt SPEED ACT causes a change over to speed control A change over from speed control to ext torque ref takes place when the torque reference is greater than the speed controller output TORQ_REF1 gt TORQREF2 and SPEED_REF4 lt SPEED ACT Window control external torque reference and speed controller output are added together APC can read the status of the torque selector by reading the bit TORQUE _CONTR in the MAIN_STATUS_WORD 101 04 torque control is active 0 speed control is active 45 Software Description l 3AFE61101446 LOAD_COMPENSATION 7 2 Torque reference chain After the selection of the torque reference source the program can add certain signals to the reference These signals are e Torque Step e Load Compensation e Acceleration compensation After adding the reference is limited The bit TREF_IN_LIMIT 5 in the AUX_STATUS_WORD 101 05 informs when TORQ_REF5 103 06 is in the limit TORQUE_STEP Qoz 03 6 107 05 ADD ACC_COMP ADD 2 Ga s TORQ_REF3 TORQ REF4 TORQ MAX2 CD Di et 03 05 S yong Me 4000 Tn motor TORQ_REF5 HE TORQ_REF6 103 06 J m 0307 To the armature current control Scale 4000 Tn motor TORQ_MIN2 Figure 16 Torque reference chain 46 3AFE61101446 l Software Desc
39. ENERAL The documentation of the DCV700 is divided into separate manuals in order to provide quick access to the required information This manual Software Description describes in detail the DCV 700 software and the utilization of field exciter units SDCS FEX 1 SDCS FEX 2 and DCF503 504 Commissioning Manual covers instructions for commissioning from the incomer section to the drive section and Hardware Description introduces and describes all the external connections and settings of the DCV700 circuit boards All these manuals of the DCV700 complements each other Installation Manual is for installing Service Manual is for fault tracing and maintanance 1 1 Identification of the software revision 1 1 1 1 1 2 Identification of the converter software program revision The converter program is stored in two FLASH memory circuits D33 D34 on the control board SCDS CON 1 The labels of the memories identifies the revision of the software FLASH Software revision D33 DC11 106 D34 DC11 106 The number 11 is an identification number reserved for DCV700 The 106 is a running number which will be increased always when the new program revision is released The program revision number can also be checked from The signal CNT_SW_VERSION 123 01 Parameters are stored in one FLASH memory circuit D35 on the control board SCDS CON 1 Identification of the field exciter program revision The software revisions of the field
40. ENee 106 28 10 Combined fault Words sco ecole ad ce etaulete ned iaeeli cee aelede cand ues wevesuiots Ganled 109 28 11 Combined alarm WOrdS eteusegerge Neie EN NEE ee EN 110 28 12 Static fault and alarm ele EE 111 29 COMMUNICATION ss ccorscctacesesteaustscngackvenaeuaansc ee raaa RE a Eechen 112 PAo AOA PROLOG E 112 29 2 Message TE 113 29 2 1 ee 113 29 2 2 Cycle MESSAGE EE 114 29 2 3 Broadcast message ose pete ender ees Blade ae 114 3AFE61101446 Software Description 29 2 4 Fault upload message eee cece eeeeeteeeeeeeeeeeeeeeeeeeeeeeaaeeeeeeeeeeneeeeeeeeeee 114 29 2 5 Parameter download message 115 29 2 6 Parameter upload message EE 115 29 3 TC address selection BEE 115 29 4 DCV700 does not aANSWEF EE 116 29 5 DCV700 does not receive ANY message EEN 116 29 6 APC watch dog function 5 2 ccteiseseecedceaetvease belees ees AEEAE NEE 116 29 6 1 Principle of the watch dog EE 116 29 7 Special cases in APC DCV700 Communication 117 29 8 APC function blocks for communicatton 117 29 9 DDG ROG ll 119 29 10 Master Follower Jmk nnna 119 29 11 Field excitation Communication 121 BOO REVISION HISTORY EE 124 30 1 VersionmiDGi E LEE 124 30 2 MEIER ee gaer 124 APPENDIX A DCV 700 Control program APPENDIX B Parameter and signal list DCV 700 PROGRAM DIAGRAM code 37021717 Software Description l 3AFE61101446 This paper intentionally left blank 3AFE61101446 Software Description 1 G
41. I torque The OPTI TORQUE can be selected by parameter FIELD1_ MODE 11 11 no EMF control 4 quadrant EMF control n Field reversal 1 quadrant Field rev EMF control si Field rev OPTITORQUE ae Field rev OPTITORQUE EMF control DN akRWNM OCH 9 13 2 Field current reduction proportionally to torque ref The relationship between torque reference and field current is defined by parameter FIELD1_REF_GAIN 8 20 Scaling is per cent The value 100 means that field current is directly proportional to torque reference When it is wanted that 10 torque reference can produce full field current then the gain value is set to 1000 59 3AFE61101446 9 13 3 Field monitoring when OPTI torque changes field direction Field monitoring differs from normal field changes that during field reversal other controllers are not blocked The signal TCFIELDCHANGE 110 06 is clamped to zero Minimum field signal is normally delayed by 2 seconds and this time is fixed Because the time how long the field current stays under the minimum level is also a function of torque reference and torque reference depends on process and speed controllers gain values this 2 second can be too short time for some application For this reason the minimum field monitoring is by passed if field current reference goes under certain level Two parameters are needed for declaring the threshold to the reference when minimum level is by passed FIELD1
42. I7 enables local 5 DI8 enables local With default settings DDCTool can command the drive to local at any time The status of the Local mode can be checked from next signals LOCAL_MODE 111 01 the Local command request from the DDCTool 0 remote is requested 1 local is requested LOCAL 111 02 the actual state of the drive 0 APC commands the drive 1 DDCTool commands the drive The APC application program can also see the state from the bit BO on the signal AUX_STATUS_WORD 101 05 BO 0 APC commands the drive BO 1 DDCTool commands the drive 18 3AFE61101446 Software Description 2 2 APC command words MAIN_CONTROL_WORD the main control word of DCV 700 index 101 01 Bit Name Value 1 Value 0 o 1 ON i Start fans feld and close the Open contactor stop field and main contactor fans 2 RUN run the drive with selected stop the drive according to reference STOP_MODE parameter RESET i acknowledge a fault indic COAST coast stop i synchronising command SYNC_DISABLE synchronising is disabled RESET_SYNC_RDY reset synchronised ready 3 4 5 SYNC_CMND 6 7 8 9 TRIGG_LOG i external trigger for loggers Seene is enabled WINDOW_CONTROL Window function enabled Window function disabled 11 RAMP Ramp function is used Variable slope is used 12 FOR
43. MF_ACT 108 06 where 3786 1 35 U_SUPPLY 18 06 The signal EMF_V 118 07 gives EMF in volts 31 3AFE61101446 Normally the Auto tuning facilities calculate the resistance and inductance values of the motor The values can also be defined manually using next formulas The relative resistance of armature circuit ARM_R 13 12 I_CONV_A 11301 U_SUPPLY 1806 OE 22444 RA Q where RA armature resistance The relative inductance of armature circuit ARM_L 13 11 LA mH T_ CONV_A 11301 245 ARM_L U_SUPPLY 1806 scantime where LA mH armature inductance in mH sample time 3 33 ms 50 Hz network or 2 77 ms 60 Hz 3 7 Field current 3 7 1 3 7 2 Two field exciters are possible to connect to one converter unit 2 DCF503 504 or 1 SDCS FEX 2 plus 1 DCF503 504 From both field exciters there are two measurements available relative and absolute current values Motor 1 field current FIELD1_CUR_ACT Motor 1 actual relative field current 118 10 4095 MOT1_FIELDN_A 13 03 FIELD1_ CUR_ACT A Motor 1 actual absolute field current in amps 118 11 1 0 01A Motor 2 field current FIELD2_CUR_ACT Motor 2 actual relative field current 118 12 4095 _MOT2_FIELDN_A 13 17 FIELD2_CUR_ACT A Motor 2 actual absolute field current in amps 118 13 1 0 01A 32 3AFE61101446 l Software Description 3 7 3 Customer supplied field exciter When a customer supplied field exciter i
44. OND 033d DOS 9 434 OHOL D 4 9 aa8 ano0 NINOHOL 01 GD Goow u L 000p oe Cp Va OHOL FL IHAIA V E0 ZLE XVWOHOL PL J m Oh H Golow UL 0006 afeg 5 mmm KA geg ALE SOND ANOYOL Y LOL oiv mu byo HS Oo HL 10 201 VI OHOL 3AFE61101446 15 The speed and the torque references Bold lines show the main line from given references to the firing unit Figure 1 3AFE61101446 Software Description aaads lt 3wa DEET DE j NOLLWINOWO A AWS 2091 INWA MOT VLIV 1091 INWA HOW VIY go1 so9as amva MO1 f AOL 9607 DE l E INWA HOH EWEG l4 LOW 033dS A C SE gt 0 8L IAOW SvAW 033dS A l PENNE 208 YN SINdOHOWL NEE rs DEE dads SOPOT A LIN Gages KE nmr an I nr YH YOLOATSS IQON SvaW 0334S Ce a330S SEI OHOVL LNA SYNSVAW G3adS e ED X I 408449 033dS ONIdOCHO i Cor LYH dOOud sud E SE 5 SZ 5 z z GE SC SC SE SC Pia INOHOL Ods Tom INIOd HLAIM MOQNIM COP CZE MME SS HOLL THSOHOL Et NINSJJ ZNINOHOL 4201 7 Zor SIL 90 Ztt soj0w u 000r aire
45. RAM memory Alarm Alarm indi Self reset RAM backup failed cator after first run 110 System cold start Status Self reset after System restart indicator init 112 Master Follower index is incorrect Alarm Alarm indi Self reset Mas Foll index alarm cator 114 APC communication started Alarm Alarm indi Self reset APC connection OK cator 118 Main supply under voltage Alarm Alarm indi Self reset Mains underv alarm cator 120 Armature current deviation Alarm Alarm indi Self reset Arm curr dev alarm cator 123 Motor2 temperature measurement Alarm Alarm indi Self reset Motor 2 temp alarm cator 124 Motor2 thermal model alarm Alarm Alarm indi Self reset Motor 2 overl alarm cator 125 Master Follower time out Alarm Alarm indi Self reset Mas Foll tout alarm cator 126 Missing acknowledge of conv FAN Alarm Alarm indi Self reset Conv FAN ack alarm cator 127 Missing acknowledge of ext FAN Alarm Alarm indi Self reset Ext FAN ack alarm cator 128 APC link close command received Alarm Alarm indi Self reset APC link closed cator 129 Type code changed during power down Alarm Alarm indi Self reset Type code changed cator 130 Gap in AC voltage noticed Alarm Alarm indi Self reset Auto reclosing cator 132 Aux voltage switched off OFF state Alarm Alarm indi Self reset Aux underv alarm cator 108 3AFE61101446 Softwa
46. RD 101 02 faster than the time defined by parameter WATCH DOG TIME OUT 19 03 DCV700 reads the bit and writes the value in to AUX_STATUS_WORD 101 05 bit 10 If the APC application program checks this bit it can also supervise the drive control in DCV700 If DCV700 does not detect a changing polarity during the defined time out time the drive will be stopped using a method defined by WATCH DOG BREAK_ ACK 19 04 and to the fault logger is written the text APC watch dog error 21 The state of the Watch dog function can be seen from the signal APC_WDOG_STATE 119 03 This signal is 1 after watch dog has tripped the drive and stays 1 as long as the fault is reset This signal can be connected to some free DO channel for external indication 29 7 Special cases in APC DCV700 communication When DCV700 is in LOCAL mode the APC time out supervision does not trip the drive In LOCAL mode the time out is 10 sec This is for the reason that Windows based DDCTool is able to write collected data to the disk During the disk writing Windows does not run the communication link In LOCAL mode the Watch dog function is disabled When the APC communication is started the state of the toggle bit received from the APC is immediately written to the AUX_STATUS_WORD 101 05 but the watch dog time out function is not activated until 1 sec has elapsed The link close command is handled as a normal time out situation The APC se
47. Using steps gain values of Pl controllers are tuned 94 3AFE61101446 l Software Description 24 LIMITATIONS 24 1 Torque and armature current limitation Torque and current limits can be selected independently If selected armature current limits are smaller than selected torque limits the program automatically limits used torque limits so that the output of the speed controller cannot be bigger than the torque the current controller can produce Armature current can also be limited proportionally to the actual speed Limits for the armature current are set by parameters ARM_CUR_LIM_ P 12 05 scale 4095 MOTN_A 13 02 ARM_CUR_LIM_P 12 06 scale 4095 MOTN_A 13 02 Speed dependent limits for the armature current are set by parameters MAX_CUR_LIM_SPEED 13 04 The speed level for armature current limit reduction 20000 max speed ARM_CUR_LIM_N1 13 05 Armature current limit at speed 13 14 ARM_CUR_LIM_N2 13 06 Armature current limit at speed 13 04 20000 13 04 4 ARM_CUR_LIM_N3 13 07 Armature current limit at speed 13 04 2 20000 13 04 4 ARM_CUR_LIM_N4 13 08 Armature current limit at speed 13 04 3 20000 13 04 4 ARM_CUR_LIM_N5 13 09 Armature current limit at speed 20000 Torque limits are set by the parameters TORQMIN 12 02 scale 4000 Tn motor TORQMAX 12 01 scale 4000 Tn motor Used torque limit can be monitored from signals TORQ_MIN2 112 05 TORQ_MAX2 11
48. VAL 17 17 The nominal value of the measured signal AQ2_NOMINAL_V 17 05 AO2_NOMINAL_VAL 17 18 Certain offset voltage can be given by the parameters AO1_OFFSET_V 17 03 Scale mV AOQ2_OFFSET_V 17 06 71 3AFE61 101446 12 ELECTRICAL DISCONNECTION The start sequence can be prevented by digital inputs This is normally used during maintenance of the motor The function of the current controller is also prevented APC can monitor the status of the electrical disconnection by reading bit INH OF F START 15 from the MAIN_STATUS_WORD 101 04 DI4 is selected to control the OFF1 as a default MUX I5 OR2 BLOCK A1 o gt I D7 Wi Generates tripping of contactors A4 and blocks the current controller Figure 26 The selections of the electrical disconnection The selections of the OFF commands are made by the parameters OFF1_SEL 14 02 1 Dl4 disable the ON command default value OFF2_SEL 14 03 0 not used default value 13 DC BREAKER The DC breaker is used to protect the motor from overcurrent or if in case of mains under voltage the generator bridge is shooting through OVERCURREN 122 06 81 ORD MONOT RIP_DC_BREAKER O 110 07 122 06 B11 Figure 27 The control of a DC breaker The program produces the signal TRIP_DC_BREAKER 117 07 immediately after overcurrent or mains under
49. W in the AUX_STATUS WORD 101 05 2 10105 2 1 The speed is out of the given window 10105 2 0 The speed is inside the given window 41 Software Description l 3AFE61101446 6 TORQUE REFERENCE DCV700 has two inputs for the external torque reference The handling features of the external torque references are Torque scaling load sharing reference filtering ramp for the torque reference torque reference limitation TORQ PEF A PEN 10701 7 BES PLR ML Scale 4000 Tr motr Se HL 4000 TORQ REF ONE TORQ REF A FIC 10704 Scale 4000 100 L TOQUE RF B 10702 m C208 RAP TREF TCROMN TORQ REF B SLOPE Figure 14 Torque reference modification External torque reference A The channel A can be filtered and scaled The reference is written to the signal TORQ_REF_A Scale 4000 nominal torque of the motor 107 02 The time constant for the filter is set by parameter TORQ_REF_A_ FTC Scale ms 7 07 1000 1s The scaling of the torque reference is done by signal LOAD_SHARE Scale torque unit 107 04 4000 100 42 3AFE61101446 l Software Description 6 2 External torque reference B The channel B has a ramp function The reference is written to the signal TORQ_REF_B Scale 4000 nominal torque of the motor 107 02 The time for the ramp is set by parameter TORQ_REF_B_SLOPE Scale ms 7 08 1000 1 sec 0 ramp is by p
50. _REF_MIN_L 8 14 614 15 of nominal When field reference falls below this limit the minimum field monitoring is by passed FIELD1_REF_MIN_TD 8 15 Extra delay to keep by passing activated after the field current is again aroused above reference level 9 14 Field current motor FLUX linearization When it is needed to control accurate torque e g winders uncoilers the field current must be linearised The reason is that torque motor armature current multiplied by motor FLUX but motor FLUX is not directly proportional to field current Motor flux Id Figure 20 Flux of DC motor in function of the field current The magnetisation of the motor starts to saturate after certain field current and thus the motor flux does not increase linearly For this reason the field current cannot be directly used to define FLUX inside the motor On the other hand the motor armature voltage without load EMF is directly proportional to the motor flux and motor speed below field weakening area E g if motor nominal 3AFE61101446 Software Description DC voltage is 440V and the motor is run using half speed and full FLUX then the DC voltage is about 220V Then if the flux is reduced by 50 and while keeping the same speed the DC voltage is about 110V Only an example Because the motor EMF voltage is directly proportional to motor FLUX it is possible to define relationship between field current and motor FLUX by means of measu
51. ackup mode of the FPROM is selected by means parameter BACKUP_STORE__MODE 11 07 0 no backup 1 backup to FLASH memory After writing the mode is changed to 0 2 reserved 3 default values are restored to the RAM After reading values the mode is automatically changed to 0 During backup function operation an internal counter counts down from 255 to 0 The value of the counter can be monitored from the BACKUP_STORE_MODE 11 07 When the value of the counter has reached 0 the backup is done If different value than zero appears during backup means this some kind of fault Possible reasons are listed below 5 unknown missing FPROM 7 erasing failed 9 programming failed 100 3AFE61101446 l Software Description 28 DIAGNOSTIC DCV700 has versatile diagnostic functions in order to monitor HW functions and to facilitate trouble shooting Function are Control board self diagnosing Supply voltage monitoring Watchdog Fault logger Data logger Diagnostic information are divided into 2 main classes These are ALARM An announcement that some limit is reached Alarm does not prevent the drive to run FAULT The drive is always tripped Faults and alarms have a numerical code and 20 character long text for fault logger Codes that are numbered between 0 and 99 are reserved for faults Code numbers bigger than 100 are reserved for alarms The text language is English The control board SDCS CON 1 has the giant
52. al torque reference needed during acceleration deceleration using a function called Acceleration Compensation The speed of the motor is controlled by the PID control The controller is designed so that it can easily be adjusted to the different environment in order to facilitate the commissioning work 13 Software Description 3AFE61101446 Torque reference Current controller Field excitation EMF controller Limitations Diagnostic Communication The APC can command the DCV700 also by using torque reference In case of Master Follower connection the master drive can transfer its torque reference to the slave The current of the motor is controlled by the Pl type controller The controller can be tuned using an Auto Tuning facilities There are several different ways to control motor field depending on the application like uncontrolled diode field exciter SDCS FEX 1 1Q current controlled field exciter SDCS FEX 2 and DCF503 enabling field weakening area 2Q current controlled field exciter DCF503 enabling field weakening area and field reversal Additionally it is also possible to use non ABB field exciters In that case acknowledge signals are read using DCV700 Al or DI channels When an accurate torque control is needed or the field weakening function is used the EMF control adjusts the field so that the armature voltage stays at a desired level The user can select current limits for the arm
53. applications Resolution of channels 1 2 is 12 bits sign and channels 3 5 11 bits sign SDCS IOB 3 e input range 10 V 10 V 0 4 mA 20 mA 1 V 1 V ch 3 and ch 4 e The input range is selected by jumpers of the board see figure below e all analogue inputs are galvanically isolated e current generator for PT100 5 mA and PTC 1 5 mA elements e Earth fault monitor input Analogue inputs can be used for following internal applications e acknowledge external field exciter FECX_SEL 11 10 9 13 speed measurement SPEED MEAS _MODE 18 06 e temperature measurement s of the motor s e Earth fault monitoring 69 3AFE61101446 o SDCS IOB 3 Switch Input area 0 4 20 mA Gain 1 Input area 10V 410V Gain 10 Input area 1V 1V Earth fault measuring selected Tu S1 1 2 Kee X3 Cl o S1 3 4 Kee 1 5 6 2 1 2 2 3 4 2 5 6 2 7 8 Ee ao NEA o of N St EE No ao E GE ee ESCH 1 7 8 3 1 2 3 3 4 3 5 6 3 7 8 Z x ZATZ N EREA No ao C S1 9 10 S1 11 12 81 13 14 o o S1 9 10 S1 11 12 S1 13 14 Figure 24 The jumpers coding of the analogue inputs Current generator settings for the PT100 and PTC elements are following S5 1 2 closed 5 3 4 open 1 5 mA S5 1 2 open S5 3
54. assed 6 3 External torque reference limitation Both above mentioned references are added together and then limited The sum of the references can be measured from the signal TORQ_REF1 103 02 The torque references are limited by the signals TREF_TORQMAX Scale 4000 nominal torque of the motor 112 03 Factory set value 16000 TREF_TORQMIN Scale 4000 nominal torque of the motor 112 04 Factory set value 16000 APC can check the status of the limitation by reading the bit 4 TREF_IN_LIMIT in the AUX_STATUS_WORD 101 05 4 10105 4 1 The torque reference is in the limit 10105 4 0 The torque reference is between the limits 43 Software Description 3AFE61101446 7 TORQUE REFERENCE CHAIN AND SELECTOR DCH 200 offers versatile possibilities for selecting the torque reference between speed controller output and an externally given torque references These are Speed controlled External torque reference controlled Minimum selector either speed control or external torque reference Maximum selector either speed control or external torque reference Window controlled When the drive is controlled by the external torque reference the output of the speed controller is updated by the used torque reference value This allows a bumbles transfer from the torque controlled mode to the speed controlled mode 7 1 Torque reference selector
55. ature controller There is also a possibility to reduce the armature current limit proportionally to the speed APC can independently limit also the speed controller output and the external torque reference if the application demands that The DCV700 check the condition of the SCDS CON 1 board every time when an auxiliary power is switched on The board has also the Watch Dog function that supervises the condition during running For the user there are Fault logger that stores 100 latest fault and alarm events the time for each events a short text explanation and the numeric code Data logger that has 6 channels each 1000 samples long and the shortest sampling interval is 1 ms The DCV700 has 4 communication links TC link for the APC DDCTool link for PC tool Master Follower link between drives FEX link for SDCS FEX 2 DCF503 504 units 14 Software Description NK INIL dw soz TIVSINWILAWYVH GG L 10S Opel HOLOFIAS zoe SWE 1050 3GOW WO LOZ INLO HOS dads NN d Ciel as e GD dvd OD POTE 434 Oe MO COL en cn vull EU UL Ju WOOT Bee gee z439 CERS WH bet DC E 2 CED 43403398 wdi Co L EHONNYOS 0IIdS 000 02 ee xwwagads z tL IHA O aay widit Ox BL PUNK Ode 02 98 IER Cen NOLLOSHHOS 033 DON AN ON rauen Ce oer C d D0 NOLLVSNadWOd SIVY AdO1S HVA NOLLWHSTSIO0 BED iL S
56. be read from the signal DLOG_STATUS 121 07 0 logger is empty 1 logger is collecting data 2 a trigger has occurred logger has stopped after the trigger 4 logger has stopped after the stop command 5 logger has stopped after the trigger and the stop command 28 8 Monitoring of the APC application signals DCV700 has 8 free signals which are not used by the DCV700 software These can be used for measuring APC signals by the DDCTool DLOG_APC1 DLOG_APC1 DLOG_APC1 DLOG_APC1 DLOG_APC1 DLOG_APC1 DLOG_APC1 DLOG_APC1 121 08 121 09 121 10 121 11 121 12 121 13 121 14 121 15 105 3AFE61101446 28 9 Fault and alarm texts and codes Definition Type of Mode of Reset Fault text Signal Action Method No faults or alarms Resets all resettable faults Reset Reset d d 1 Auxiliary voltage fault Fault Trips To be reset Auxil undervoltage 2 Armature overcurrent Fault Trips To be reset Overcurrent 4 Measured over temperature of converter Fault Trips To be reset Converter overtemp 5 Earth fault Fault Trips Tobereset 6 Measured over temperature of motor 1 Fault Trips To be reset Motor 1 overtemp 7 Calculated over temperature of motor 1 Fault Trips To be reset Motor 1 overload 14 Speed measurement fault Trips To be reset Speed meas fault 17 Type code of the converter not found Trips Can t be reset Type coding fau
57. c message Broadcast message 112 3AFE61101446 Software Description In service communication every message must be transferred from the sender to the receiver If there is an error in transmission the message is repeated Service communication messages are Fault Upload Message Parameter Download Message Parameter Upload Message Communication Management Message Service Tool Message In Cyclic Communication both APC and DCV are initiators of communication while in Message based communication the APC is the initiator in all messages 29 2 Message types A DATA field of a TC link frame can contain one or two messages In case of two messages the first is always the Basic Message Structure of the DATA field A frame with Basic Message only BASIC MESSAGE time interval 2 8 ms 1 4 drive s are connected to the APC A frame with Basic Message and the second message BASIC MESSAGE MESSAGE 2 time interval 2 8 ms depends on application program of the APC message 2 could be a cyclic message or a service communication message A frame with a second message only MESSAGE 2 29 2 1 Basic message When the drive is controlled through a communication link there are some basic requirements for the communication protocol First the communication has to operate cyclically with short update intervals and secondly the update must be equidistant In the TC link protocol this is achieved wit
58. ced to zero 21 4 3 Alarm and tripping limits Alarm and tripping limit calculations use as a base current lref a value given by parameters TEMP_MODEL1_CUR 15 02 TEMP_MODEL2_CUR 15 06 The normal value is 4096 motor rated current This value should not normally be changed If for some reason it is not possible to run the motor continuously with rated current e g poor cooling environment then the value can be decreased E g the wanted continuous load is 85 of the used motor rated current The value for parameters are then 0 85 4096 3481 Alarm and tripping limits can be selected by means of four parameters TEMP_MODEL1_ALARM_L 15 03 TEMP_MODEL1_TRIP_L 15 04 TEMP_MODEL2 ALARM_L_ 15 07 TEMP_MODEL2 TRIP_L 15 08 Default values are selected so that the overload ability is quite high E g the current must continuously be V120 100 109 5 before alarm is given and for trippings the current must be V130 100 114 Recommended values for alarms is 102 and for trippings 106 Value for recommended alarm 104 100 1 022 Value for recommended trip 112 100 1 062 21 4 4 Thermal time constant The time constant for both thermal models are given by two parameters TEMP_MODEL1_TC 15 01 TEMP_MODEL2_TC 15 05 One has to bear in mind that the thermal time constant cannot be used directly when calculating the tripping time Many cases the motor manufacturer presents a curve that defines how long t
59. d 93 3AFE61101446 23 5 Manual tuning of Armature Current Controller During the test the field contactor is automatically opened to prevent the motor running Test reference replaces the ARM_CUR_REF current limits is not by passed 23 5 1 Find continuous discontinuous current limit The continuous current limit can be found by slowly increasing the current reference and at a same time by monitoring with the DDCTool the bit CONTINOUS CURR 9 in AUX_STATUS_WORD 101 05 The limit is reached when the bit signal oscillated in the DDCTool screen After the limit is reached the actual current is read and the value is set to the limit parameter CONV_CUR_ACT 118 05 ARM _CONT_CUR_LIM 7 06 23 5 2 Tuning of the armature current controller After discontinuous current limit is defined the Pl controller can be tuned normally either using square wave function or step buttons of the DDCTool 23 6 Manual tuning of the EMF controller Before tuning of the EMF controller the field controller must first be tuned The tuning principle The motor is started to run about half speed of the used field weakening area The signal EMF_ACT 108 06 is read and the value is used for defining used steps The higher value of the step can be the value that are read The lower value of the step can be 15 less The autotuning function is activated Steps can be given either using square wave generator or step buttons of the DDCTool
60. e The over voltage limit is fixed 130 1 3 U_SUPPLY 18 06 If the limit is exceeded longer than 10 seconds then the MAINS OVERVOLTAGE 30 fault will be generated 83 3AFE61101446 21 MOTOR PROTECTION 21 1 Stall protection The stall protection trips the converter when the motor is in apparent danger of overheating The rotor is either mechanically stalled or the load is otherwise continuously too high The selection of the stall protection is made by the parameter STALL_PROT_SEL 11 14 O Not used 1 stall protection selected The stall protection trips the drive when Actual speed is below the given limit Actual torque exceeds the given limit The condition last longer than given time Next parameters define limits for the stall protection STALL_SPEED 15 16 Scale speed unit 200 1 STALL_TORQUE 15 17 Scale torque unit 4000 motor nominal STALL_TIME 15 15 Scale ms 21 2 Overspeed protection The drive is protected against overspeed e g in a case where drive section is controlled by the torque reference and the load falls down unexpectedly The limit of the overspeed is set into the parameter OVSPEED LIMIT 12 10 scale speed units 0 30 000 21 3 Measured motor temperature Two motor temperatures can be measured at a same time Both measurements have one alarm limit and one tripping limit The limits are programmable The temperature measurements use Al channels Al2 and AI
61. e rapidly or APC command ON off ON 00 gt The main field and fan contactors are opened o lt RDYRUN 0 24 3AFE61101446 Software Description 2 5 3 Drive is tripping If the drive trips the fan the field and the main contactor are opened in defined order that depends on the type of the fault For example if the drive trips to over temperature of the converter the main contactor and the field contactor are opened but the fan contactor is kept on until the temperature of the bridge falls below the over temperature level of the bridge Finally all contactors are opened After this sequence the drive accept the reset command 2 5 4 Faults that trip first the main contactor OVERCURRENT 2 MAINS UNDERVOLTAGE 29 NOT IN SYNCHRONISM 31 ARM_CURRENT_RIPPLE 34 PHASE SEQUENCE FAULT 38 SPEED_MEAS FAULT 14 NO_MAIN_CONT_ACK 41 MOTOR_STALLED 23 MOTOR_OVERSPEED 37 2 5 5 Faults that trip first the main contactor and the field contactor MOTOR_1_OVERTEMP 6 MOTOR_1_ OVERLOAD 7 MOTOR_2_OVERTEMP 48 MOTOR_2 OVERLOAD 27 CONVERTER_OVERTEMP 4 APC WATCH DOG ERROR 21 NO C FAN ACK 50 2 5 6 Faults that trip the main the field and the fan contactors AUXIL UNDERVOLTAGE 1 ARMATURE OVERVOLTAGE 28 EARTH_FAULT 5 UO BOARD NOT FOUND 44 MAINS OVERVOLTAGE 30 FIELD EX 1 OVERCURR 32 FIELD EX 1 COMERROR 33 FIELD EX 2 OVERCURR 35 FIELD_EX_2 COMERROR 36 NO_FIELD_ACK 39 NO_EXT_FAN_ACK 40 TYPE_CO
62. edure sesciede cw actie uta esrtadhsoadde de lesciedch eoemesuted neaeeedaseeeesnetantads 78 18 2 Synchronisation ia a EEEEEER ANERE ee ae ee 78 18 3 Selection of synchronisation input kee 79 18 4 E tee ENEE 80 18 5 Position counter diagram veiccocs edecadecshoneiteevanyds cauentaecaniendecteaeekeeeehacttaeneeeeae ee 80 19 MONITORING FUNCTIONS EE 81 19 1 Speed measurement supervision ENEE 81 19 2 Network phase seguencge REENEN 81 19 3 Firing Re E neng e TE 82 19 4 Fan field and main contactor acknowledge ssssssessesssenrrsseeertrrnsrrrnerrrerrnne 82 19 4 1 External FAN acknowledge AAA 82 19 4 2 Converter FAN acknowledge AAA 82 20 CONVERTER PROUT EC TION E 83 20 1 Armature OVEFCUITONE eegene Eege Sege ieak ada dames ade 83 20 2 OVE EIERE gege eege 83 20 3 Network over voltage Au 83 21 MOTOR RA KEE 84 EE protectio Manian e E a aE E ETE aE TEE 84 21 2 Overspesd ege EE 84 21 3 Measured motor temperature ke 84 Software Description l 3AFE61101446 21 3 1 Measurement selection ENEE 85 21 3 2 Alarm and tripping limits s ee ege otacasieeeeds dateenewsedriskeweetes 86 21 4 Motor Thermal MOG Sl ees eeh eeh eet gege 86 Bal AS OIG el ES E E nthe eds Sa A cece es eet se Alita Ace chads 86 21 4 2 Thermal model selection tc ese tries cee resiue eege eege A 87 21 4 3 Alarm and tripping al 88 21 4 4 Thermal time constant NENNEN 88 21 5 KEXON EE 90 21 6 Armature over voltage ENEE 90 22 AU TOTOUNING ace ota
63. eed the EMF controller reduces motor field on purpose of maintains the EMF voltage constant at a maximum level This must be done to avoid armature over voltage and on the other hand maximum EMF is needed to hold FLUX as high as possible When an accurate torque controller loop is needed the EMF controller can be used to form wanted FLUX The APC application program can calculate what the value of the motor EMF ought to be with used speed and used FLUX reference The EMF controller adjust then field current so that the measured EMF correspond with a wanted EMF reference 10 1 Selection of EMF controller The EMF control function can be activated by means of parameter FIELD1_MODE 11 11 akRWNM OoO No EMF control constant field without field reversal EMF control without field reversal No EMF control constant field with field reversal EMF control with field reversal OPTITORQUE without EMF control OPTITORQUE with EMF control Field reversal is normally meant for 1 quadrant drive type The type of the field exciter must also be such that field current can be controlled like SDCS FEX 2 DCF503 504 10 2 Field weakening area Above certain speed the motor FLUX must be reduced in order to avoid armature over voltage This area is called field weakening area and the speed point where the field reduction starts is called field weakening point Above field weakening point the motor FLUX is reduced by ratio 1 n Two parameter
64. eeded In this case APC has such a program that EMF reference follows the speed actual of the drive The level for EMF reference is given by signal 3786 x EMF ref voltage EMF_REF 108 03 1 35 U_SUPPLY 10 5 FLUX EMF reference selectors There are two ways to select between internal and external FLUX and EMF reference Either selecting them separately by means of parameters or together by means of one signal 3AFE61101446 Software Description When selecting FLUX and or EMF reference separately only EMERGENCY STOP can by pass the selection so that always max possible FLUX is used The selection can be done by the parameters EXT_FLUX_REF_SEL 10 07 EXT_EMF_REF_SEL 10 08 APC can command both references ON OFF by means of signal EXT_EMF_FLUX_SEL 108 02 This is useful e g when web break occurs By selecting OFF the EMF controller starts immediately use max possible FLUX so the function is similar than the EMERGENCY STOP function 10 6 PI controller Pl controller corrects inaccuracies caused by process e g network AC voltage variations l part of the controller is reset below certain EMF level because the rotor resistance value IR would otherwise cause an erroneous result The limit when I part is released can be defined by parameter EMF_REL_REF 10 05 default value is 50 100 50 3786 1 3 10 6 1 Scaling of PI P gain of the controller is reduced above field weakening point by the facto
65. elected with a call parameter C1 The number of transmitted data is determined with a call parameter C2 The block transmits integer values Call parameters Se e o l Parameter Significance Permissible values l C1 Selection of transmission mode 0 basic message 1 cyclic message 2 broadcasting message C2 Number of transmitted data 3 ifC1 0 1 8 ifC1 1 1 5 ifC1 2 The DRUPL C1 DRive parameter UPLoad block is used to upload parameters from the DCV 700 An address determines from which drive the message is received The number of received parameters are determined with a call parameter C1 All received values are integers Callparameters f Parameter Significance Permissible values l C1 Number of received parameters TaD The DRPAR C1 DRive PARameter download block is used to download parameters to the DCV 700 A drive number determines to which drive the parameters are sent The number of transmitted parameters is determined with a call parameter C1 The block transmits integer values of parameters 118 3AFE61101446 Software Description Call parameters Son n Parameter _Significance Permissible values C1 Number of transmitted parame 1 5 ters The DRFLT DRive FauLT element is used to read fault information number and time from the DVC 700 and write the appropriate Drive Fault Event to the selected Event Logger buffer 29 9 DDCTool link 29 10 The DDCTool link r
66. en load is between zero and KPSWEAKPOINT the used P gain is interpolated The P gain cannot be changed too fast For this reason there is a filter between calculated P gain and used P gain The time constant for this filter can be set by parameter KPSWEAKFILT Scaling ms 4 05 GAIN KPS KPSMIN T SPC OUTPUT TORQ_REF2 0 KPS 4000 WEAK POINT Figure 11 P gain reduction as a function of torque reference 5 4 Force speed controller output APC can set the speed controller output if needed The set value is given by the signal SPEED C FORCE VAL Scale 4000 motor nominal torque 103 08 The force command is given by setting or resetting the bit FORCE_SP_CNTR in the signal MAIN_CONTROL_WORD 101 01 12 10101 12 1 The output of the speed controller is forced 10101 12 0 The speed controller is released 39 Software Description l 3AFE61101446 5 5 Drooping The drooping function is used when there is a need to adapt the speed proportionally to the load The amount of speed decrease caused by the load is determined by parameter DROOPING Scaling 10 1 4 07 the nominal torque reference will decrease the speed by 1 SPEED ACT 20000 19000 __ 18800 4 DROOPING SPC OUTPUT TORQ_REF2 0 4000 Figure 12 Drooping as a function of torque reference 5 6 Window control The window control is used when master follower connections are needed
67. enerated The level of EMF voltage when the supervision is activated is set by parameter SPEED_MON_EMF_V 15 24 default 50V How much the speed must at least be is set by the parameter SPEED_MON_MEAS LEV 15 23 default 200 1 19 2 Network phase sequence The direction of network phases is checked when the main contactor is closed The measured direction must correspond to the value given by parameter PHASE SEO CW 18 01 1 R T S 2 R S T default set If the measurement mismatch the PHASE SEQUENCE FAULT 38 is generated 81 3AFE61101446 The firing unit can run with both network direction The parameter facilitates to remember that when using a counter clockwise direction also other equipment like fans inside the cubicle must be taken into consideration 19 3 Firing unit synchronisation After closing of the main contactor and when the firing unit is once synchronised the program starts to supervise the synchronisation If the synchronisation fails the faut NOT IN SYNCHRONISM 31 will be generated The synchronisation of the firing unit takes typically aprx 300 ms before the current controller is ready 19 4 Fan field and main contactor acknowledge When the drive is started the program closes the FAN contactor and waits for acknowledge After ack is received the field contactor is closed and the program waits that the field ack is received Finally the main contactor is closed and ack is waited
68. ent motor FLUX linearization Ne 60 9 14 1 An example of the linearisation procedure sseseeeeeesserrereesserrr ne 61 9 15 Field reduction when stand ent ENEE 62 3AFE61101446 l Software Description 9 16 Field heating when OFF state ANEN EEN 62 10 EMF CONTROLLER EE a i EE ee eee Gas 63 10 1 Selection of EMF ut UE 63 10 2 Field weakening Area EE 63 10 3 FLUX reference ege gek deeg a E E a danse lend een einen 64 TOA EMP Ent 64 10 5 FLUX EMF reference selechors ANNE 64 10 6 Pl COntrOller ege e ee te a E ea eA a eebe See Ee eege 65 10 6 Scaling ot EE 65 10 6 2 Pl controller output limitation ss nnseeeesseennnrnneesseernnrrnnersserrnerrnneesne 66 10 7 Force to max possible field NEE 66 11 A NALOG AND DIGITAL I O znan sine EE EE EE 67 Uh Ka lp e E LEE 67 11 1 1 Fixed digital TEE 67 RESCH Re WER ut E 68 11 3 Analogue iNputs EE 69 WA ne Eet e 70 12 ELECTRICAL DISCONNEG TION EE 72 KS DO BREAKER E 72 14 e delt Te E 73 15 SRIARED MO TION EE 74 16 POWER LOSS MONITORING AND AUTO RECLOSING cc ccccceeeeeteeeeteeeeeeeeeeteee 75 16 1 Function during a short network failure ccccccceeeeeeeeeeeeeeeeeeeeeeeteeseeaeeeeeeees 75 16 2 MAIN_STATUS WORD during net failure ccc c ccc cceeeeeeeeeeeeeeeeeeeeeeeees 76 16 3 When aux supply voltage fails ENNEN 76 17 EARTH FAULT MONITORING pareen a ieveah a peed ee he ened eee 77 18 POSION era RT hn EE 78 18 1 Counting proc
69. ent isccisecieszeckacadeat etevanieh ETC ENER EEN SEENEN 32 3 7 2 ee Ru EE EE 32 3 7 3 Customer supplied field evciter 33 3 8 Cooling unit TEMPS EE 33 4 SPEED REFERENGEGHAIN DEE 34 E ER nl WEE 34 4 2 Variable Slope dinn scent ethene teenie ened Weaken deena edad 35 4 3 Ramp output smooth function eege Sege deeg ege degen ggf 36 4 4 Acceleration COMPENSATION ceettee eee eeeeeneee sete eee eteneeeeeeeeeetteeenaeeeeeennee 36 5 SPEED CONTRO copia a ences Aisa cue aces eho Gee ha es neared aaa Meee eee 37 H Speed erfor Hiter da eege deeg 37 Software Description l 3AFE61101446 EE e Ee ee 38 5 3 Adaptive P ga EE 38 5 4 Force speed controller ir TEE 39 B23 HDPOOPING 4 cate tea he eee te ttc tite e e 40 5 6 Window COMME EE 40 6 TORQUE REFERENCE ee EE EE 42 6 1 External torque reference Ah 42 6 2 External torque reierenceb AAA 43 6 3 External torque reference mation EEN 43 7 TORQUE REFERENCE CHAIN AND GELECTOR 44 7 1 Torque reference selector sncsciccspieccudiceds ehbecedsdeeiaged das heletdeneardoceene EE 44 7 2 Torque reference EE 46 8 ARMATURE CURRENT CGONTROLULER 47 8 1 Reference E 47 8 2 Reference Slope EE 47 8 3