Home

Digital Acoustics ESBx-110 Specifications

Contents

1. F1 F2 L1 L2 L3 _7 DC CONTACTOR e P d OPTIONAL Ki F8 F9 F10 AN 2 E TR ollel F8 F4 CURRENT TRANSFORMERS CT1 CTS CT4 DC BUS BARS POWER THYRISTORS ONLY CR4 CR5 CR6 _ Z CAUTION CONNECT LEADS AS P SHOWN TO PREVENT E d DAMAGE TO UNIT ud CR7 CR8 AC BUS BARS X1 X2 X3 HEATSINK 7 THERIMISTOR M ATA 11 7 4 EM F6 F7 2 CONTROL POWER TRANSFORMER THYRISTORS Fi FAN CR2 Figure 7 9 Replacing Power Thyristors and Field Thyristor Diode 510 ADC and Below 7 35 Maintenance and Troublesho
2. 4 7 V BRI 4 9 ABSOLUTE Ten diria 4 10 ANALOG INVER Terre 4 11 ANALOG SELECT e e 4 12 ANALOG SWITCH mann arad A n aT 4 13 ASM AUTO SHEET MARKER eerte teretes 4 14 cp RE Ee fs 4 16 BIPCONVERT paese toU EM LI Da En 4 18 ecd conan sa saltu eO NM eS 4 20 BIT SELECT 4 21 BUMPEEBSS SWITCH stretta teli dere eg teens 4 22 CDS COUNTS DURING STOP ccccccccccsssssssecsecsecsecceccessesacsarsecsecsessessecsecasees 4 24 CEAMPING aene 4 26 CONFEOSS odo E ae ai LCD IE 4 28 CONI Dare eth he cite ee e nee eRe 4 29 COMPARATOR 4 30 du scu tut as tA 4 31 CURRENT M 4 32 TD SDAIN Dsante 4 36 DEMU X eA ossa CST Ae A ENO 4 37 Mts 4 38 DERIVATIVE GAIN demde ated 4 40 DEP DRIDS es setate amieta meae ti rtis fel ao Haee staat ERR 4 41 IN aren ote atest cn ba A 4 43 TIGA SOR sue nodos
3. ices Saar E 4 45 DIU IDE nessun deuten tat Stet 4 46 4 46 fedt ber mte 4 48 53 58 GO 4 50 sunto 4 51 A ay pth Made 4 52 Control Block Description Table of Contents Cont 4 37 HVLOW COMPARATOR t anas ep 4 38 sot MA uberi 4 39 p 4 40 EEADIA G oet he ut Peste eite mede bomi 4 41 LEAST WEN ae devote Un dee ci RC 4 42 LOW PASS 4 43 MOST WIN eoa eee tee ee tesa eed 4 44 MOV EN 4 45 ete Tad 4 46 NOTCH FILTER cenena aea 4 47 OFF TIMER D 4 48 ON TIMER 5 Dried UN CEDAR EAT ITI RE 4 49 ONE SHO T dataset ise irt isch Ie 4 50 PEAK DETEGT ene ndi AREE 4 51 PERCENT DIBEBRENGPD ettet eo retorno 4 52 PERCENT MULTIPLY Per Mult eee 4 53 PROPORTIONAL AND INTEGRAL CONTROL PI 4 54 PROPORTIONAL AND INTEGRAL CONTROL WITH CASCADED HOLD BITS PI2 eerte retento 4 55 QUAD LTCH Nt 4 56 ude aA 4 57 RATE CHANGE certe tope RES Ee 4 58 RATIO
4. INPD INPE 5 AND ADDvantage 32 PLUS This block implements a 5 input digital AND gate Inputs INPA INPB INPC INPD INPE Outputs OUT Bit Bit Bit Bit Bit Bit Implementation OUT E 5 INPUT LOGICAL AND FIGURE 4 4 5 AND BLOCK OUT 1 if INPA INPB INPC INPD and INPE are equal to one OUT 0 if any input is equal to zero Control Block Description 4 5 INPA INPB INPC INPD INPE 5 SUMMER ADDvantage 32 PLUS The 5 Summer block selectively sums up to five analog input signals The selection of which inputs are to be summed is set using a series of digital bits 5SUMMER Inputs INPA INPB INPC INPD INPE BIT2 BIT3 BIT4 BITS Output OUT BIT1 BIT2 BIT3 BIT4 BITS A B C D E OUT FIGURE 4 5 FIVE SUMMER BLOCK Analog Analog Analog Analog Analog Bit Bit Bit Bit Bit Analog Control Block Description ADDvantage 32 PLUS 3 Implementation OUT INPA x INPB x BIT2 INPC x BIT3 INPD INPE x BITS If all 5 bits are low then OUT 0 Control Block Description ADDvantage 32 PLUS 46 8 BIT INVERT The 8 BIT INVERT block takes the INP bit and the next seven and inverts them INP OUT j YEON LA lt INP 1 OUT 1 AC INP 7 OUT 7 LAE A 7 DA 8BITI
5. RUNG 3 Ready for a run jog or thread DOK OUT ESTOP IN Ye MC CLOSE RDY TO RUN f MC CLS Jy N DCAFMR3LAN RUNG 4 This bit picks up the drive motor contactor and enables the run reference to the speed loop RUN INPUT PRET TO RUN RUN ENABLE a M JCAFMRALAN Figure 3 1 ADDvantage 32 PLUS Logic Diagram sheet 2 of 14 3 6 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter RUNG 5 This bit picks up the drive motor contactor and enables the jog reference to the speed loop JOG INPUT D RUN ENABLE D ENABLE D RDY TO D JOG ENABLE Hr HF DCAFMRSLAN RUNG 6 This bit picks up the drive motor contactor and enables the thread reference to the speed loop TARD INPUT D JOG ENABLE D HRD ENABLE D RDY TO RUN DCAFMRBLAN RUNG 7 A run jog or thread commandis requested D RUN ENABLE D RUN REQUEST D JOG ENABLE D THRD ENABLE Figure 3 1 ADDvantage 32 PLUS Logic Diagram sheet 3 of 14 3 7 Core Software Operation RUNG 8 ADDvantage 32 PLUS e AC to DC Power Converter D RUNX picked up on a run jog or thread command is requested It stays in until the D SPD MIN PT goes high or there is a fault or ESTOP If you want the contactor to ope
6. user configurable line 4 Figure 2 10 The first line of the four lines shown in the LCD displays shows the parameter group the configuration parameter number and the configuration parameter label 4 Choice Parameter Number Represents data type and number of the configuration choice 2 Configuration Choice Label Each configuration parameter has a unique 11 character label 2 15 ADDvantage 32 PLUS e AC to DC Power Converter CONFIGURATION CHOICE PARAMETER CONFIGURATION NUMBER CHOICE LABEL POO0 JOG REF CO06 JOG SPEED user configurable line 3 Underline user configurable line 4 present when in edit mode Figure 2 11 The second line of the four line LCD display shows the configuration choice parameter group and number and the parameter label for that choice 2 7 EDITING A CONFIGURATION PARAMETER After having used the menus and submenus to arrive at a configuration parameter to be edited pressing the RIGHT key will enter the edit mode for the parameter as shown in Figure 2 11 NOTE If access to the parameter is locked out the message ACCESS DENIED will be displayed To allow entry to the edit mode the proper parameter must be enabled in the ACCESS CODES menu Once the cursor is visible indicating edit mode pressing the UP or DOWN key will cycle through the various choices that can be chosen for the configuration parameter Pressing the ENTER key will save t
7. 4 59 RECIPE 5 TUN 4 60 RESOLVER ao teens nte 4 61 1 4 4 62 a istos Erie base e ees s 4 63 SDS SHEETS DURING 4 64 SETPOINT crusta anre dtr edere eee en ree suas 4 65 SNAPA VG dee a prse hn aue 4 66 SPACER oTt 4 67 SUMMING JUNCTION SELECTABLE 3 INPUT 4 68 TAB EB M N 4 69 TACH SELECT AND TACH 4 70 TIMER qe 4 71 EX PES DE ptt e ie et Un 4 72 eto ad GR e anser 4 73 UNITY SCALE 4 74 UV PROTEC 4 75 WINDER eue 4 76 WINDOW COMPARE ii ADDvantage 32 PLUS Control Block Description ADDvantage 32 PLUS SECTION IV CONTROL BLOCK DESCRIPTION The ADDvantage 32 PLUS application software control scheme is based on control blocks A control block is a software procedure which takes the inputs to the block performs its function and outputs the results The following control blocks are not used in all software applications They are a combination of all available control blocks Refer to Appendix A for software specific control block interconnections 41 2AND This block implements a 2 input digital AND gate INPA OUT
8. CONTIN PI CTL MAX ARM ALP Y TARM FFWD MIN ARM ALP Y a RATE SEL ARM RESIST Z C PGAIN IGAIN IARM D BAND CORRECT R LIM A Parameters A VARM CMD A ARM ALPHA A PCNT DISCON CMD TARM SETPT TARM ERROR TARM INTEG POS I LIMIT NEGILIMIT 300 IIT Curve 10 Second trip at 300 current 60 Second trip at 150 current Parameters MAX A ALPHA MIN A ALPHA TARM MIN PT ARM I HOLD TARM I RES MAX IARM MIN IARM The current loop is the most fundamental control loop in the ADDvantage 32 PLUS It provides digital control for the SCR circuitry Figure 3 3 is a block diagram of the current loop 3 31 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter Using the Self Tune function automatically tunes the current loop for the connected motor The five parameters tuned are as follows X ARM CONTIN This parameter represents the percent motor current at which continuous conduction of the current occurs X 7 C CORRECT To fire the SCR s properly the point at which the line voltage crosses zero must be determined Due to delays in the sensing circuitry an offset number must be entered X 7 C CORRECT is the value used to offset this delay X ARM PGAIN These are the proportional and integral gain co
9. 1 Inputs NUMBER SHTS Analog MARK STPT Analog MARK HOLD Analog MARK RESET Bit 4 14 Control Block Description ADDvantage 32 PLUS 2 Outputs AUTO MARK Bit 3 Implementation If NUMBER SHTS MARK STPT then AUTO MARK goes high If NUMBER SHTS MARK STPT MARK HOLD then AUTO MARK goes low n 1 If MARK RESET bit is high then n 1 4 15 Control Block Description ADDvantage 32 PLUS 4 12 BALANCE The Balance block switches from one control scheme to another without changing the current operating reference a 2 9 gt FDBK OUTPUT REF TIME BAL FIGURE 4 12 BALANCE BLOCK 1 Inputs REF Analog FDBK Analog BAL Bit RET Bit 2 Outputs OUT Analog DIF Analog 3 Implementation On a falling edge of the BAL input DIF will be sampled as REF FDBK DIF will not change until the next falling edge of the BAL input When the BAL input is low OUT REF DIF 4 16 Control Block Description ADDvantage 32 PLUS When the BAL input is high OUT REF Non retentive Block On powerup of the ADDvantage 32 PLUS err 0 Retentive Block On powerup of the ADDvantage 32 PLUS DIF will be initialized under the following conditions If RET 0 DIF 0 If RET 1 DIF is set to its last value DIF must also be configured to a retentive point Y RET SETPT to be updated automatically on powerup 4 17 Control Block Description ADDvantage
10. The first event if enabled by P BYPASS I2R ZERO BIT DEFAULT prevents the drive from faulting on a MOTOR II T fault The current limit block accomplishes this by lowering the current limit when A IIR INTEGR is gt to 25 counts The MOTOR II T fault indicates a motor thermal overload condition where the motor armature current was above 100 for more than the time specified by X Thermal TC The motor will be allowed to operate at 150 armature current for 60 seconds if the Thermal TC is set to 60 0 DEFAULT The motor could operate up to 200 armature current but the MOTOR II T fault would occur much sooner than 60 seconds The user can increase the Thermal TC value up to a maximum of 3 000 seconds The drive will fault on a BRDGE II T fault when drive armature current is 150 of the drive D C MAX CONT nameplate current for 60 seconds This is an Underwriters Laboratories UL mandated fault where the magnitude and time cannot be altered by users When actual motor armature current rises above 11096 motor nameplate IIR INTEGR will count up from zero when current is rising and count down when current falls below 110 The IIR INTEGR is used to calculate motor temperature The rate at which IIR INTEGR counts is determined by the magnitude of armature current above 100 and the thermal TC value The current limit taper feature can be disabled by setting P BYPASS DR ONE BIT In this nontaper mode IIR INTEGR will c
11. 2 Outputs OUT Analog 3 Implementation RATE is scaled in units second If INP is changing less than RATE OUT is equal to INP If INP is changing faster than RATE OUT changes at the RATE value 4 84 Control Block Description ADDvantage 32 PLUS 4 58 RATIO The Ratio Block calculates the diameter of a center driven winder It can be used for a winder or an unwinder The initial diameter is a preset input value to obtain the correct diameter starting speed TACH1 TACH2 GAIN UN OUT BI OUT IDIAM FIGURE 4 58 RATIO BLOCK 1 Inputs IDIAM Analog TACHI Analog 2 Analog GAIN Analog MAX Analog MIN Analog RT Analog HLD Bit 4 85 Control Block Description ADDvantage 32 PLUS Inputs Cont UP Bit RES Bit RET Bit 2 Outputs BIOUT Analog UNOUT Analog 3 Implementation 2 x GAIN BIOUT if it is within MIN and MAX else BIOUT will equal the limit value BIOUT is rate limited by the RT value RT is entered in units second and should be set at maximum rate of change at core at max speed If the HOLD bit goes high then BIOUT and UNOUT will be held at their current values Releasing this bit lets the block resume calculations If UP bit is high then UNOUT equals the highest BIOUT since the last reset If the UP bit is low then the UNOUT equals the lowest BIOUT since the last reset
12. 5 8 Hex Head Socket 3 8 Drive DC054X DC085X Armature Bridge Assembly Hex Head Socket with 2 Phillips screwdriver insert Field Supply Subassembly bit 1 4 drive D21591 and D22716 Thermally Conductive Compound Field Supply Subassembly Avtron P N 950010 D21591 and D22716 2 Phillips screwdriver All assemblies 3 4 Open End Hex Head Wrench DC155X DC300X Armature Bridge Assembly 3 A Hex Head Socket DC155X DC300X 3 8 Drive Armature Bridge Assembly 7 41 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter 7 10 1 REPLACING THE POWER THYRISTOR MODULE ASSEMBLY A101 106 7 10 1 1 Disassembly DANGER HEATSINKS MAY BE ENERGIZED Hazardous voltage will cause severe injury and death Turn off lock all sources of power before proceeding 4 55 1 Remove power from the drive 2 Remove the ground lead s located in the lower left corner or left center of the back of the drive front panel 3 Loosen the front panel screws Using the slotted openings lift the panel up and off 4 Unplug cable connector P1 and move the cable away from the module NOTE All copper to copper bus work connections are assembled with a thin film of anti oxidant joint compound Avtron P N 905122 between mating surfaces We recommend using this during reassembly to prevent corrosion at all conductive junctions DC0540 DC085X Only Items 5 through 7 below 5 Remove the lower bolt
13. APPLICATION DOES MATCH FIRMWARE ID UP key to continue CAL CONFIG DATA is incompatible with drive application CAL CONFIG DATA is corrupt CAL CONFIG Checksum error detected ERROR CODE XX values is bad values Retentive checksum zeroing out PROBLEM unable to be programmed Indication message result of a load of the default application Incompatibility detected between drive hardware and drive firmware Incompatibility detected between drive firmware and drive calibration data Invalid calibration and configuration data detecting Drive detected a checksum error in one or more sections of the drive calibration and configuration data SOLUTION Application memory a Replace microprocessor board Reload drive firmware and calibration data Replace microprocessor board Insure that correct firmware has been loaded into drive This warning will occur for example if six pulse firmware is loaded into a 12 pulse drive Replace microprocessor board When prompted to default the cal config data press UP key to allow defaulting Then reload calibration data Insure calibration data is correct data for this drive Replace microprocessor board When prompted to default the cal config data press UP key to allow defaulting Then reload calibration data Replace microprocessor board When prompted to correct the checksums press the UP key to allow checksums to be
14. CASE FIGURE 7 1 Figure 7 1 Replacing Microprocessor Board in Case NOTE Replacement of the microprocessor board is the same for all ADDvantage 32 PLUS units regardless of size 7 20 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter 7 3 2 REPLACING BRIDGE INTERFACE BOARD AND SNUBBER BOARD A4 510 ADC and Below Refer to Figures 7 2 and 7 5 1 Remove power from the unit 2 Open base assembly door Remove cables on bridge interface board 4 Loosen the two captive screws that secure the bridge interface assembly to the chassis Swing the assembly out on its hinges 5 Remove ground wire 6 Remove J1 from snubber board A4 7 Slide bridge interface assembly off the hinges by lifting upward 8 Place new assembly on hinges 9 Replace ground wire 10 Reconnect cable to snubber board 11 Tighten two captive screws to hold bridge interface assembly in place 12 Replace seven cables on bridge interface board and shut the base assembly door 13 Reapply power to the unit 7 3 3 REPLACING BRIDGE INTERFACE BOARD AND SNUBBER BOARD A4 550 ADC Refer to Figure 7 3 1 Remove power from the unit 2 Open the main drive door 3 Remove cables on bridge interface board 4 Remove ground wire by pulling off the push on terminal located near J3 5 Loosen the two captive screws that secure the bridge interface assembly to the chassis Carefully raise the assembly up a
15. FLD CURRNT Z NP6 DIG D REV BR LED 7 Z INP7 A D Q ANALOG Z NP7 ANALG A FLD CURRNT Z NP7 DIG D REV BR LED 8 Z NP8 A D Q ANALOG Z NP8 ANALG Z NP8 DIG A FLD CURRNT D REV BR LED 5 2 Signal Analyzer TRIGGER Set for a rising edge or falling edge trigger the recorder can be triggered from any analog or digital bit information located in the data tables The recorder must be disabled to ADDvantage 32 PLUS e AC to DC Power Converter change these parameters Default for all eight recorders RECORDER CONFIGURATION DEFAULT CHANNEL PARAMETER VALUE 1 Z TRIGI A D Q ANALOG Z TRIGI ANALOG A ACT SPEED Z TRIGI DIG D FAULT Z TRIG R F 1 Q RISING Z TRIG LEVELI 0 5 2 Z TRIG2 A D Q ANALOG Z TRIG2 ANALOG A ACT SPEED Z TRIG2 DIG D FAULT Z TRIG R F 2 Q RISING Z TRIG LEVEL2 0 5 3 Z TRIG3 A D Q ANALOG Z TRIG3 ANALOG A ACT SPEED Z TRIG3 DIG D FAULT Z TRIG R F 3 Q RISING Z TRIG LEVEL3 0 5 4 Z TRIG4 A D Q ANALOG Z TRIG4 ANALOG A ACT SPEED Z TRIG4 DIG D FAULT Z TRIG R F 4 Q RISING Z TRIG LEVELA 0 5 5 Z TRIG5 A D Q ANALOG Z TRIGS5 ANALOG A ACT SPEED Z TRIGS DIG D FAULT Z TRIG RF 5 Q RISING Z TRIG LEVELS 0 5 6 Z TRIG6 A D Q ANALOG Z TRIG6 ANALOG Z TRIG6 DIG Z TRIG R F 6 Z TRIG LEVEL6 5 3 A ACT SPEED D
16. For example First element VOLTS Next element DRIVE FILE 32 DRIVE CAL HI LIMS This file contains all of the predefined high limit values for each drive calibration value Each element contains one high limit value FILE 33 DRIVE CAL LO LIMS This file contains all of the predefined low limit values for each drive calibration value Each element contains one low limit value FILE 34 DRIVE CAL DEFAULTS This file contains all of the predefined default values for drive calibration Each element contains one default drive calibration value For example First element 7 00 Next element 10 0 9 10 System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter 9 3 27 9 3 28 9 3 29 FILE 35 DRIVE CONFIG LABEL This file contains the drive configuration labels displayed during drive configuration Each element contains one label For example First element DRIVE_PN Next element BRIDGE_SELFTEST FILE 36 DRIVE CONFIG LEGALS This file contains the drive configuration legal options The two bytes per element are grouped as shown bit 15141312 11 10 09 08 07 06 05 04 03 02 01 00 Type Index Value The upper four bits define the type assigned while the lower 12 bits define the index into the file elements defined by the type For example if the type bits were 03 then the index value would be the offset into the drive calibration table Examples of type bits are as follows TYPE File 0 S
17. TLIM HI INP yx ILIM LO INP Figure 3 1 ADDvantage 32 PLUS Logic Diagram sheet 11 of 14 3 15 Core Software Operation ADDvantage 32 PLUS AC to DC Power Converter RUNG 31 The fault FIFO can be cleared from the keyboard or from a digital bit configured to Y F FIFO CLR KEYBOARD CLEAR FIFO CLEAR FAULT FIFO DCAFMR31LAN ee CUR RUNG 32 drive fault can be cleared by the keyboard digital bit configured to Y CLR FLT INP or on the next run jog or thread command if Y F CLR ON M is enabled Faults will also be cleared on a repower of the drive KEYBOARD CLEAR FAULTS CLEAR FAULTS RUN INPUT F CLR ON M DCAFMR32LAN JOG INPUT THRD INPUT CERA EET INP Figure 3 1 ADDvantage 32 PLUS Logic Diagram sheet 12 of 14 3 16 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter RUNG 33 D NOT USER 1 is the inverse of the digital input D USER 1 D USER 1 D NOT USER 1 K a DCAFMR33LAN RUNG 34 D NOT USER 2 is the inverse of the digital input D USER 2 D NOT USER 2 DCAFMR34LAN RUNG 35 D NOT USER 3 is the inverse of the digital input D USER 3 USER 5 NOT USER 5 RUNG 36 D NOT USER 4 is the inverse of the digital input D USER 4 D USER 4 USER 4
18. The RES bit is used to reset both BIOUT and UNOUT to the IDIAM value It stays at this value as long as the RES bit is high The RES bit has a higher priority than the HOLD bit Non retentive Block On powerup of the ADDvantage 32 PLUS UNOUT IDIAM BIOUT Retentive Block On powerup of the ADDvantage 32 PLUS BIOUT and UNOUT will be initialized under the following conditions If RET 0 then UNOUT IDIAM and BIOUT If RET 1 UNOUT and BIOUT set to their last value UNOUT and BIOUT must also be configured to retentive points to be updated automatically on powerup 4 86 Control Block Description ADDvantage 32 PLUS 4 59 RECIPE 1 Inputs RECA Analog RECB Analog RECC Analog ENA Bit ENB Bit ENC Bit EN Bit 2 Outputs OUT Analog FLT Bit 3 Implementation RECA RECB RECC points to the first address of 10 consecutive calibration locations OUT points to the first address of 10 consecutive analog locations On powerup the OUT locations 10 values are set to the RECA values When the EN bit is high the block will select which block of 10 values to output based on the ENA ENB and ENC bits ENA transfers RECA data ENB transfers RECB data ENC transfers RECC data When EN is low no transitions occur ENA has the highest priority and is also used when no enable is present ENB is the second highest priority On powerup FLT output bit is low Whenever EN i
19. 1 33 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter TABLE 1 1 ADDvantage 32 PLUS SPECIFICATIONS Cont DESCRIPTION Chassis Ambient Temperature Enclosed See outline drawing for minimum enclosure size Open Chassis SPECIFICATION 0 to 40 C 32 to 104 F 0 to 50 C 32 to 122 F 50 C maximum surrounding air temperature rating Storage Temperature 20 to 55 C 4 to 131 F Relative Humidity 95 non condensing Operational Altitude 0 to 3 300 feet above sea level no derating required Above 3 300 feet derated linearly by 1 per 300 ft Worst Case Power Loss Drive P N Watts approximate DC0010 150 DC0030 200 DC0056 260 DCO0110 500 DC0180 725 DC0280 1000 DC0360 1150 DC0510 1400 DC054X 1500 DC055X 2050 DCO085X 2300 DC155X 4 3900 DC155X B 4500 DC250X 6100 DC300X A 7900 DC300X B 8300 Power loss follows the approximate curve shown in Figure 1 17 Worst case power loss total is at 100 speed 100 load At other speeds and loads the percent loss is greater but the total loss is less 100 100 LOAD 25 LOAD c N EFFECIENCY o 95 Figure 1 17 Efficiency vs Speed 25 50 75 100 SPEED Additional Specifications are located in the supplemental drawing package A space heater may be necessary if condensation or excessive moisture is expected 1 34 Introductio
20. 7202 7206 7302 7306 50 ANALYZER CONFIG LEGALS I RO N A 51 ANALYZER CONFIG I R W 7007 70 7107 71 7207 72 7307 73 52 DIAGNOSTIC STATUS CHAN 1 2 I RO N A 53 DIAGNOSTIC STATUS CHAN 2 2 I RO N A 54 DIAGNOSTIC STATUS CHAN 3 2 I RO N A 55 DIAGNOSTIC STATUS CHAN 4 2 I RO N A 56 DIAG TRACE DATA CHAN 1 4 FP RO N A 57 DIAG TRACE DATA CHAN 2 4 FP RO N A 58 DIAG TRACE DATA CHAN 3 4 FP RO N A 59 DIAG TRACE DATA CHAN 4 4 FP RO N A 60 RETURN FAULTS 2 I RO N A 61 FACTORY USE do not access 2 I R W N A 62 1 A R W N A 63 FACTORY USE do not access 2 I R W N A 64 2 I R W N A 65 DOWNLOADING 2 I R W N A 66 RETURN FAULTS 2 I RO N A 67 ARM TRACE 2 I RO N A 68 TRACE 2 I R W N A 69 FTRACE o N A 70 LINK CONTROL BITS 2 I RO N A 71 FACTORY USE do not access 2 I RO N A 72 DIAGNOSTIC STATUS CHAN 5 2 I RO N A 73 DIAGNOSTIC STATUS CHAN 6 4 I RO N A 74 DIAGNOSTIC STATUS CHAN 7 4 FP RO N A 75 DIAGNOSTIC STATUS CHAN 8 4 FP RO N A 76 DIAG TRACE DATA CHAN 5 4 FP RO N A TI DIAG TRACE DATA CHAN 6 4 FP RO N A 78 DIAG TRACE DATA CHAN 7 4 FP RO N A 79 DIAG TRACE DATA CHAN 8 4 FP RO N A 9 3 FILE NUMBER DESCRIPTION The files listed in Table 9 1 are described as follows 9 3 1 FILE 9 ANALOG I O This file defines the analog data table where computed analog data values are stored in 9 4 System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter 9 3 2 9 3 4 9 3 5 floating point format
21. A Up Down Y From the SELF TUNE pressing the left key will E006 SELF TUNE gt initiate the drive self tune procedure EFT Tuning will begin upon application of the RUN A Up Down Y input E005 DEFAULT MEM Up Down Y Use Up Down to enter edit an access code to E004 Access Code t 3 allow access to this submenu value of zero V 1 00000 Left Right Enter disables the protection i ENTRY RANGE 0 9999 Up Down y Use Up D t ll th h the selecti Up Down to scroll through the selections E008 cw Jes Left Right Enter p gt on PERMISSION to edit change table data CHOICES NO YES YES NONVOLATILE A Up Down y Use Up D t ll th h the selecti Up Down to scroll through the selections E002 A UNIS Left Right Enter JA on PERMISSION to edit change units data CHOICES NO YES YES NONVOLATILE OWN Figure 2 14 This ADD 32 PLUS keypad syntax shows the ACCESS CODE submenu 2 21 ADDvantage 32 PLUS e AC to DC Power Converter 2 8 2 DIAGNOSTICS SUBMENU The DIAGNOSTICS submenu is shown in Figure 2 15 The figure shows a subsection of the TOP LEVEL menu on the left side and access into the DIAGNOSTICS submenu by pressing the RIGHT key The DIAGNOSTICS submenu provides the user with information related to all the firmware installed on the drive part numbers and versions of all components diagnostic information related to the Ethernet LAN and di
22. ADDvantage 32 PLUS e AC to DC Power Converter TABLE 1 1 ADDvantage 32 PLUS SPECIFICATIONS Cont DESCRIPTION Diagnostics SPECIFICATION 40 fault messages w corrective action 11 front panel LED annunciators 16 event fault memory Signal Analyzer Sampling Rate 360 Samples Second Max 27 8 Seconds Sample Min Recording Duration 61 7 hours Max 22 22 seconds Min RS485 Serial Link Optically isolated Self powered 120V common mode noise rejection Pulse Generator Inputs 2 Phase 3 30V peak to peak 540 ohm impedance Optically isolated 120V common mode rejection 0 20 200 Hz frequency range 50 20 duty cycle Buffered Pulse Generator Outputs 2 Phase 5V 50mA 0 25 KHz frequency range Auxiliary Power Supplies Digital I O Supply Voltage Output 2 24 VDC Nom 26 VDC Max Current Output 80 mADC Max Auxiliary AC Supply Voltage Output 2 115 VAC Nom Power Output 50 VA Max units 56A and under 100 VA Max units 110A and above Safety Interlock Supply Voltage Output 24 VDC Nom 26 VDC Max Current Output 50 mADC Max Pulse Generator Supply Voltage Output 12 VDC Nom 13 2 VDC Max Current Output 300 mA Max Short circuit proof Pot Supplies Voltage Output 10 VDC Max Current Output 5 mA Max Additional Specifications are located in the supplemental drawing package Consult Avtron regarding UNIPULSER information for additional duty cycle applications
23. FAULT Q RISING 0 5 5 3 Signal Analyzer ADDvantage 32 PLUS e AC to DC Power Converter RECORDER CONFIGURATION DEFAULT CHANNEL PARAMETER VALUE 7 Z TRIG7 A D Q ANALOG Z TRIG7 ANALOG A ACT SPEED Z TRIG7 DIG D FAULT Z TRIG R F 7 Q RISING Z TRIG LEVEL7 0 5 8 Z TRIG8 A D Q ANALOG Z TRIG8 ANALOG A ACT SPEED Z TRIG8 DIG D FAULT Z TRIG R F 8 Q RISING Z TRIG LEVEL8 0 5 SAMPLE RATE The sample rate determines the time span between the recording of each data point The rate is determined by specifying the number of 2 777 msec for 60 Hz systems time increments required between samples times are Sample Time Z RATE X 2 777 msec Range of Z RATE X 1 to 99 999 For example the shortest and longest sample Shortest Sample Time 1 2 777 msec 2 777 msec Longest Sample Time 99 999 2 777msec 277 7 sec RECORDER CONFIGURATION DEFAULT RANGE CHANNEL PARAMETER VALUE 1 Z RATE 1 18 50 00 ms 1 99 999 2 2 2 18 1 99 999 3 Z RATE 3 18 1 99 999 4 Z RATE 4 18 1 99 999 5 Z 5 18 1 99 999 6 Z RATE 6 18 1 99 999 7 Z RATE 7 18 1 99 999 8 Z RATES 18 1 99 999 5 4 8 5 Signal Analyzer ADDvantage 32 PLUS e AC to DC Power Converter PREVIEW Information recorded by the signal analyzer channels is broken into 8 000 individual points When a particular channel is triggered a preview can be set to
24. FIGURE 4 9 ANALOG SELECT BLOCK 1 Inputs INPA Analog INPB Analog SELA Bit 2 Outputs OUT Analog 3 Implementation If SEL A bit is high set at 1 the OUTPUT is equal to INPA If SEL A bit is low set at 0 the OUTPUT is equal to INPB 4 12 Control Block Description ADDvantage 32 PLUS 410 ANALOG SWITCH This block is used to switch in references to control the passage of an analog value or signal between control blocks EN INP OUT ANALOG SWITCH ANLOGSWLAN FIGURE 4 10 ANALOG SWITCH BLOCK 1 Inputs INP Analog EN Bit 2 Outputs OUT Analog 3 Implementation If the EN bit is high then OUT is equal to INP If the EN bit is low OUT is equal to zero 4 13 Control Block Description ADDvantage 32 PLUS 4 11 ASM AUTO SHEET MARKER This block sets an output bit high when the number of sheets cut equals an operator entered setpoint MARK STPT The output bit also goes high when the number of sheets cut equals integer multiples of the setpoint Therefore every nth sheet sets the output bit high The output bit remains high for the number of sheets entered in calibration as MARK HOLD then the bit goes low The internal counter resets when the MARK RESET bit is high MARK n 3 MARK STPT n n 2 MARK STPT n n 1 NUMBER OF SHEETS CUT I r gt 2 HIGH AUTO MARK BIT FIGURE 4 11 ASM AUTO SHEET MARKER BLOCK
25. MESSAGE PROBLEM C open SCR fault message SCR CR3 or fuse F10 for 510 amp and below SCR A103 or fuse F3 for 540 amp and above bridges A open SCR fault message SCR CR4 or fuse F8 for 510 amp and below SCR A104 or fuse F4 for 540 amp and above bridges B open SCR fault message SCR 5 or fuse F9 for 510 amp and below SCR A105 or fuse F5 for 540 amp and above bridges C open SCR fault message SCR CR6 or fuse F10 for 510 amp and below SCR A106 or fuse F6 for 540 amp and above bridges Open SCR fault message SCR CRI or fuse F8 for 510 amp and below SCR A101 or fuse F1 for 540 amp and above bridges Open SCR fault message SCR CR2 or fuse F9 for 510 amp and below SCR A102 or fuse F2 for 540 amp and above bridges 7 16 ADDvantage 32 PLUS e AC to DC Power Converter en en en SOLUTION Check fuse Check cable assembly connected to J2 of microprocessor board and its associated connectors Replace SCR or drive base assembly Replace bridge interface board Replace microprocessor board Check fuse Check cable assembly connected to J2 of microprocessor board and its associated connectors Replace SCR or drive base assembly Replace bridge interface board Replace microprocessor board Check fuse Check cable assembly connected to J2 of microprocessor board and its associated connectors Replace SCR or drive base assembly Repl
26. 12 Amps DC0540 150 300 540 Amps DC 440 Amps AC 12 Amps DC DC0541 150 300 540 Amps DC 440 Amps AC 24 Amps DC DC0542 150 300 540 Amps DC 440 Amps AC 48 Amps DC DC0550 150 300 400 550 Amps DC 459 Amps AC 12 Amps DC DC0551 150 300 400 550 Amps DC 470 Amps AC 24 Amps DC DC0552 150 300 400 550 Amps DC 488 Amps AC 48 Amps DC DC0850 250 500 850 Amps DC 700 Amps AC 12 Amps DC DC0851 250 500 850 Amps DC 700 Amps AC 24 Amps DC DC0852 250 500 850 Amps DC 700 Amps AC 48 Amps DC DC1550 500 1000 1250 1550 Amps DC 1265 Amps AC 12 Amps DC DC1551 500 1000 1250 1550 Amps DC 1265 Amps AC 24 Amps DC DC1552 500 1000 1250 1550 Amps DC 1265 Amps AC 48 Amps DC DC3000 900 1800 2500 3000 Amps DC 2460 Amps AC 12 Amps DC DC3001 900 1800 2500 3000 Amps DC 2470 Amps AC 24 Amps DC DC3002 900 1800 2500 3000 Amps DC 2490 Amps AC 48 Amps DC X Additional Specifications are located in the supplemental drawing package Anisolation transformer or line reactor is required when applying each ADD 32 PLUS drive to a power distribution system A total impedance from the power distribution source to the drive input in the range of 3 to 6 is required Total KVA rating of transformer should not exceed 3 times the drive rating If a drive isolation transformer is supplying power to multiple drives then each drive must have a line reactor If a combination of isolation transformer and line reactor is used the reactor should contribute the majority of the line impedance bett
27. 206 IP ADDR LO 256 This would result in an actual drive IP ADDRESS 10 1 206 12 ADDvantage 32 PLUS DRIVE ETHERNET CONFIGURATION The ADDvantage 32 PLUS Application software P N 696xxx support Ethernet A valid IP Address Subnet Mask MSK and Gateway GWY Address must be entered for their respective X parameters in the Drive Calibrate menu These numbers will be the same for all drives in a system except for the last octet LO address of the IP Address if the 256 DRIVE ID address method is used they can all match It will be necessary to manually set the IP Address Subnet Mask Default Gateway and Machine NO parameters of a spare drive or Microprocessor board that is installed to replace a failed drive Until these parameters are correctly set for the replacement drive the drive will not communicate correctly over 8 7 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS ETHERNET You will not be able to download Calibration and Configuration data to the drive via ADDAPT 2000 over ETHERNET until these parameters are correctly set Obtain unused IP addresses from your MIS or IT department when setting up drives on a network so the ID jumper may be set accordingly or set ADDR LO to the available last octet If you are unsure if an IP Address is already used use the PING command at a DOS prompt on a PC connected on the network The PING command can be used to test the communication between the PC and anothe
28. 540POWERLAN Figure 6 4 Block Diagram Armature Bridge Assembly Power Connections 540 850 1550 3000 ADC NOTE Non regenerative bridge assemblies will only have one SCR at 1 A6 locations DC155X A amp B and DC300X units have parallel fuse assemblies in the F1 through F6 positions 6 15 Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter SEE NOTE 1 FROM AC FROM AC FIELD SUPPLY ASSEMBLY CABLE ASSY P N B21317 1 FROM ARMATURE BRIDGE ASSY CABLE ASSY MOTOR FIELD ESTOPIN FB Poms TO ARMATURE BRIDGE mcontactoR ae ASSY BLOWER POWER MAUX G DOK OUT AUXILIARY 115 VAC Hk ok s L CONTROL POWER 115 VAC RDY COIL AUX AUX NOTES K Hy 1 CONNECT H2 TO H3 FOR 480 VAC PRIMARY DC CONTACTOR 2 CUSTOMER SUPPLIED OR PART OF AUXILIARY HARDWARE FLDPOWERLAN Figure 6 5 Block Diagram Field Supply Assembly Power Connections 540 850 1550 3000 ADC 6 16 Preparation for Use por past pen sue S e 0 WO COMMONS TOGETHER FICURE 6 6 ADDvantage 32 PLUS e AC to DC Power Converter ABDI PLUS Ha MICROPROCESSOR BOARD 22 L 2 SCHEMATIC D43963 t AL URE EX 39 7 18 LH USE X HASIER RS 2 G cr mb aC USE S st USE TO t V TO t V TO 78 v 16
29. BARON EINMIT Value Units H HIGH LIMIT 029 SPEED 1750 0 user configurable line 3 user configurable line 4 Underline present when in edit mode Figure 2 7 The second line of the four lines shown in the LCD display shows the data type parameter value and parameter units 2 5 EDITING A NUMERIC PARAMETER After having used the menus and submenus to arrive at a parameter to be edited pressing the RIGHT key will enter the edit mode for the parameter as shown in Figure 2 8 NOTE If access to the parameter is locked out the message ACCESS DENIED will be displayed To allow entry to the edit mode the proper parameter must be enabled in the ACCESS CODES menu 2 12 ADDvantage 32 PLUS e AC to DC Power Converter C025 MAX SPEED V 1750 0 FPM user configurable line 3 Underline user configurable line 4 present when in edit mode Figure 2 8 The LCD display at the start of the edit mode The display has the underline visible on the second line immediately under the V The V indicates that the actual value of C025 MAX SPEED is currently being displayed The user may press the UP or DOWN keys to scroll through three other attributes of the parameter one of which is the MAXIMUM VALUE that the parameter may have as indicated by the V being replaced by See Figure 2 9 C025 MAX SPEED H 9999 9 FPM user configura
30. Calculation for 5 where 5 RND in units sec to obtain desired output which is described below RATE Value of UP 40 FPM sec 10 FPM sec T Chosen as 4 sec 4 sec Re With a process that ramps up at a 40 FPM sec rate entering a SLCK SCURVE RND rounding rate of 10 FPM sec will result in a starting and ending curve that takes 4 seconds to complete FIGURE 4 61E 4 99 Control Block Description 4 62 ADDvantage 32 PLUS RRAMP3 The RRAMP3 block provides a variable rate linear ramp with user programmable smoothing The purpose of this block is to provide a smooth reference from changing setpoint values The difference between the RRAMP3 block and RMP2 is the additional RAMP inputs The RRAMP3 block has four ramp rates instead of two See below ES OEN REF OUT HLD RES ZERI RMP 4 100 Control Block Description ADDvantage 32 PLUS FIGURE 4 62 RRAMP3 BLOCK The RRAMP3 block can be divided internally into three components to aid in the understanding of its operation These components are a Ramp Change Block a Rate of Change Limit Block and Additional Control I O as can be seen in Figure 4 62A ADDITIONAL CONTROL 1 0 RAMP CHANGE CONTROL BLOCK INTBLKS FIGURE 4 62A INTERNAL CONTROL BLOCKS RAMP CHANGE BLOCK 1 Inputs REF Analog AF Analog DF Analog AR Analog DR A
31. DRIVE LAN ID AS SET BY JUMPERS ON TERMINAL J8 Three digits in the range 000 254 Figure 11 4 This illustrates the USB signal analyzer file naming convention When a USB store of the signal analyzer data is requested and if the signal analyzer directory does not exist or contains no files with the appropriate naming conventions the drive will write the analyzer data to a file or files with the storage sequence number of zero 00 If the directory already includes signal analyzer data files with the appropriate naming conventions the drive automatically uses a number sequence that is one greater than the highest storage sequence number listed in the directory The drive will indicate an ANALYZR STORE error if the largest sequence number is 99 EXAMPLE A drive has a drive ID of 22 on which 4 prior stores of analyzer data have been performed Channels 1 2 and 5 of the signal analyzer have completed storage of data This will result in the following files being created DRIVE022 04 CHI ALZ DRIVE022 04 CH2 ALZ DRIVE022 04 CH5 ALZ NOTES The time stamp of the files will always be 1 1 2001 12 00 PM The maximum number of files that are allowed in the SIGNAL subdirectory is 100 files The operation will fail with an analyzer store error if a signal analyzer store operation would result in more than 100 files in the directory The results of the storage operation that attempts to store in excess of 100 files in the directory are unpredictabl
32. Files 14 and 17 9 5 System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter 9 3 6 9 3 7 9 3 8 9 3 9 FILE 14 CAL TABLE DEFAULTS This file contains all of the predefined default values for calibration The organization of this file differs in that the complete table is broken up into four sub files Each sub file is organized as one floating point value grouped in sub files of 32 elements each For example Sub File 0 Value element 0 FP 1 FP element 31 FP Sub File 1 Value element 32 FP element 63 FP FILE 15 CAL TABLE LOLIM This file contains the one predefined low limit value for all calibration entries The element contains the value of 9999 0 as the low limit value Any calibration entry must be greater than this value FILE 16 CAL TABLE HILIM This file contains the one predefined high limit value for all calibration entries The element contains the value of 9999 0 as the high limit value Any calibration entry cannot exceed this maximum value FILE 17 CAL TABLE This file contains all of the calibration values for each entry in the calibration file Before writing any value to this file check the value against the low and high limit values to insure that it is within limits The write procedures in the receiving station do not check to see if a value is within limits The organization of this file also differs in that the complete file is broken up into four sub files Each sub file is o
33. INPB 2 INPUT LOGICAL AND FIGURE 4 1 2 AND BLOCK Control Block Description ADDvantage 32 PLUS 1 Inputs INPA Bit INPB Bit 2 Outputs OUT Bit 3 Implementation OUT is set to one if both INPA and INPB are equal to one OUT is set to a zero bit if either INPA or INPB is equal to zero 4 2 Control Block Description ADDvantage 32 PLUS 42 20R This block implements a 2 input digital OR gate INPA OUT INPB 2 INPUT LOGICAL OR FIGURE 4 2 2 OR BLOCK 1 Inputs INPA Bit INPB Bit 2 Outputs OUT Bit 3 Implementation OUT is set to one if either INPA or INPB is equal to one else OUT 0 Control Block Description 43 4ANALOG SELECT ADDvantage 32 PLUS This block is used to select one of four possible analog signal paths It can be used to control the application of multiple reference signals to a single input point INPA INPB INPC INPD 1 Inputs INPA INPB INPC INPD CNTLI CNTL2 2 Output OUT CNTL1 CNTL2 4 ANALOG SELECT FIGURE 4 3 4 ANALOG SELECT BLOCK Analog Analog Analog Analog Bit Bit Analog OUT 4ANLGSELLAN Control Block Description ADDvantage 32 PLUS 3 Implementation One of the input signals will be directed to the block output by the following combinations of control bits CNTLI CNTL2 OUT 0 0 INPA 1 0 INPC 0 1 INPB 1 1 INPD Control Block Description 4 4 INPA INPB
34. K K K K K KK KKK THYRISTOR MODULE AND FUSE REPLACEMENT 550 ADC E K E K KE K KE E K K K K K K K KK KKK WARNING HAZARDOUS VOLTAGES WHICH CAN CAUSE SEVERE INJURY OR DEATH ARE PRESENT DURING THE OPERATION OF THIS EQUIPMENT TURN OFF AND LOCK OUT ALL SOURCES OF POWER BEFORE MAKING ANY REPAIRS K K K K KK KKK ADDvantage 32 PLUS e AC to DC Power Converter 1 Remove all sources of power from the unit 2 Open the main drive door 3 Refer to Figures 7 3 and 7 6 Remove the bus bar support brace which is just above the bridge interface assembly by removing the two quarter turn fasteners The three AC fuses 8 10 the motor armature fuse F11 and the AC field fuses F1 and F2 lie behind this brace 4 Remove the bridge interface assembly as instructed in section 7 3 4 5 To replace F8 9 10 or 11 fuses perform the following steps in order a Remove the appropriate vertical bus bar b Remove the desired fuse with its adjacent bus bars one at each end as an assembly Do this by removing the two 5 16 18 hex head screws that hold the inner adjacent bus bar in place Use a 1 2 hex head socket wrench Remove the 1 2 13 hex head screws to release the fuse 7 37 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter d Connect the new fuse to the adjacent bus bars using the 1 2 13 screw and 1 2 Belleville springs Tighten to 335 365 i
35. OUT Control Block Description 4 25 DEMUX 1 Inputs BITI Bit BIT2 Bit INP 2 Outputs OUTO OUTI OUT2 OUT3 Bit 3 Implementation The output bits are set as follows If BIT1 0 and BIT2 0 and INP 1 then OUTO 1 Bit Bit Bit Bit else OUTO 0 If BITI 1 and BIT2 0 and INP 1 then OUTI 1 else OUT1 0 If BIT1 0 and BIT2 1 and INP 1 then OUT2 1 else OUT2 0 If BITI 1 and BIT2 1 and INP 1 then OUT3 1 else OUT3 0 BITI 0 0 1 0 BIT2 DEMUX 0 1 1 1 EN INP FIGURE 4 25 DEMUX BLOCK 4 37 OUT 0 OUT 1 OUT 2 OUT 3 DEMUX ADDvantage 32 PLUS Control Block Description 4 26 DENSITY ADDvantage 32 PLUS This block is used to calculate the approximate density of a winding or unwinding reel of product It calculates the density of a roll over specific diameter ranges The range needs to be large enough to make the calculation accurately taking into account error in the diameter measurements COUNT RES PPR DIA WRAPS WEIGHT 1 Inputs CNT PPR DIA WRAPS WGHT RES 2 Outputs DENSITY AVG DIA Analog Analog Analog Analog Analog Bit Analog Analog WEIGHT DENSITY pia DIA X WRAPS DEN DIA DIA AVG DIA DIA DENSITY FIGURE 4 26 DENSITY BLOCK 4 38 Control Block Description ADDvantage 32 PLUS
36. On a low to high transition of the RES bit OUT resets to the REF value DIF is equal to the change of the setpoint If ABS 1 then DIF OUT REF within the limits OUT If ABS 0 then DIF ppp within the limits RETENTIVE BLOCK On powerup of the drive OUT will be initialized under the following conditions If RET 0 and ABS 0 then DIF 1 within limits If RET 0 and ABS 1 then DIF 0 within limits If RET 1 then DIF is not initialized If ABS 0 then OUT INP x DIF If ABS 1 then OUT INP DIF If a retentive setpoint is desired configure a retentive point Y RET SETPT to DIF so it updates automatically upon powerup Configure the RES input to a zero bit to prevent resetting the output to the REF value instead of the retentive value 4 107 Control Block Description ADDvantage 32 PLUS 4 65 SNAPAVG Inputs INP Analog TICS Analog RES Bit HLD Bit RET Bit Outputs OUT Analog TTL Analog CNT Analog Implementation The SNAPAVG block is used to get an average of a value with a specific time frame The block has two internal count values to enable the block to function on short windows or longer windows TICS is internally limited to positive whole numbers On power up if RET is High then the internal Count2 and Sum2 is set equal to Outputs CNT and TTL Otherwise they are set equal to zero Also internal Count and Suml is set to zero on powerup All three outputs
37. PLC Operator Displays Performance View or any other device that may be connected on the network If you are unsure if an IP Address is used use the PING command at a DOS command prompt on a network PC To set your ADDAPT computer IP settings using a Win 2000 operating system go to Start Settings Control Panel Network and Dial up Connections Right click the Local Area Connection for the network board being used and select Properties Highlight the Internet Protocol TCP IP and click on Properties Check circle for Use the following IP address Enter the desired IP Address Subnet Mask and Default Gateway Click and Yes to reboot if prompted Note that Windows 2000 does require rebooting the computer when changing IP settings These IP setting instructions will be different if using a WIN 98 WIN NT or WIN XP operating system Refer to your computer Windows documentation if required To see your computer s own IP Address or MAC Address type IPCONFIG ALL from a DOS command prompt To set up ADDAPT 2000 software for Ethernet communication click on Tools Options Inside the Ethernet tab are selections for Channels 201 208 The last digit of Channel number corresponds to the drives X102 MACHINE NO setting Set the ADDAPT Channel equal to the drive s Machine NO 200 All drives in a system for a specific machine should be given the same MACHINE NO and Channel ADDAPT 2000 looks
38. REF Analog ENABLE Bit Outputs OUT Analog Implementation If ENABLE bit low OUT REF If ENABLE bit high If STPT lt CUR lt STPT then OUT REF If STPT lt CUR then OUT STPT CUR x GAIN REF If STPT lt CUR then OUT STPT CUR x GAIN REF 4 47 Control Block Description ADDvantage 32 PLUS 4 3 EIP TOUT 50 OK Daz ele GENL TU i FIGURE 4 33 EIP TOUT BLOCK 1 Inputs NONE 2 Outputs EIP GENL TO Bit EIP IMPL TO Bit 3 Implementation The EIP TOUT block resides in the ESBX module firmware versions 682767v16 and later The outputs of this block are written from the ESBX module directly to the drive application software digital parameters D321 EIP GENL TO and D322 EIP IMPL TO The functionality of the block outputs is as follows D321 EIP GENL TO This bit will remain low Zero Bit while there is at least one CSP message transfer occurring to the ESBX board within 5 seconds This bit will transition from low to high 5 seconds following the point where all CIP message transfers are terminated The bit will reset to a logic level low when CIP message transfers resume Refer to Appendix I for detailed information regarding the ESBX module interface to Allen Bradley CSP communication protocol D322 EIP IMPL This bit will remain at a logic low while the Ethernet IP Implicit message connection to the ESBX board is active and messaging is taking place at a perio
39. See Appendix of Serial Link Specification ER 14363 001 Table 50 for valid values and note that some are unused Channel 1 choice 0 choice 8 Element 0 SELECT TYPE RISING EOLST Element 1 Element 18 SELECT TYPE FALLING EOLST FILE 51 ANALYZER CONFIG This file contains analyzer configuration data Writing to this table changes the configuration of the channel being monitored and the control variables for each of the four channels The valid control configuration data is contained in File 50 This file is organized as 19 unsigned short integer values for each of the four channels for a total of 76 elements Channel 1 VARIABLE First element ENABLE Next element INP1 A D Last element Channels 2 through 4 are identical in form 9 15 System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter 9 3 44 FILES 52 THROUGH 55 DIAGNOSTIC STATUS TABLES The diagnostic status tables allow recovery of the status of each of the four diagnostic channels Files 56 through File 59 Refer to section 8 19 of ER 14363 001 The complete status data must be recovered to determine the status and state of the diagnostic data table before reading any data table The data from the data tables may not be read until the status indicates that the data sampling and storage is complete and ready for recovery The file number assignments are as follows File
40. This table contains application specific data where size and definition are functions of the software part number and the drive application FILE 10 ADT LABELS Contains all of the predefined label definitions for each analog input listed in File 9 Typical values could be First element FIL SPEED _ spaces are shown as Next element FIL ARM CUR Reading the first element of File 10 would return the following data em 46H 49H 4CH 20H 53H 50H 45H 45H 44H 20H 20H po C L S P EED FILE 11 ADT UNITS Contains the units associated with each of the labels defined in File 10 Typical values could be First element _ FPM__ Reading this element would return the following data Vedi 20H 20H 46H 50H 4DH 20H M This file may be written to and used to modify the units display Sending a write message for this table and the first element of vetns 20H 20H 59H 50H 4DH 20H Y P M would modify the display units to be YPM instead of FPM FILE 12 DEFAULT ADT UNITS This file contains the default units for the corresponding analog input elements FILE 13 CAL TABLE UNITS This file contains all of the calibration unit definitions for the corresponding calibration element of the X Y taper tables This table organization differs from the normal organization The corresponding calibration tables File 14 and File 17 contain 128 elements total but they are organized as four sub tables of 32 elements each Refer to
41. View and Edit the Calibration and Configuration data for channel 4 of the signal analyzer Z300 to Z313 Refer to Chapter 5 for complete documentation of all the signal analyzer calibration and configuration parameters Figure 2 16 This ADD 32 PLUS keypad syntax shows the ANALYZER submenu that is associated with the eight channel signal analyzer 2 25 Up Down Analyzer 1 Data gt lt Left Right 5 A Up Down ADDvantage 32 PLUS e AC to DC Power Converter Analyzer 1 Data U 0 0 Analyzer data display U indicates the analyzer channel is unarmed disabled Analyzer 1 Data A 0 0 Analyzer data display A indicates the analyzer channel is armed enabled Analyzer data display Analyzer 1 Data 0 indicates the analyzer channel has seen a trigger event and is currently collecting data 4 Analyzer 1 Data Analyzer data display D indicates q Left Right p the analyzer channel has completed collecting data and data may be viewed by pressing RIGHT arrow When viewing the data the display will be as follows with being the value of the data sample and ppppp being the sample number Analyzer 1 Data D Figure 2 17 This ADD 32 PLUS keypad syntax shows the ANALYZER submenu that presents status data displays It provides information associated with the eight
42. a dialog box will be displayed to indicate that the conversion is successful Figure 12 19 shows the dialog box 12 23 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter ConvertToAdd32Plus Utility Lx Successfully converted C Addapt Configuration 69401216 add to C Addapt Configuration 69601216 add Figure 12 19 A screen snapshot shows a successful conversion of the ADDvantage 32 calibration and configuration file to ADDvantage 32 PLUS drive If the conversion fails for any reason a dialog box will be displayed to indicate the conversion failed and provide an error message with information about the cause of the failed conversion Table 12 2 provides the complete list of error messages TABLE 12 2 ERROR MESSAGES SEEN IN THE CONVERTTOADD32PLUS SOFTWARE UTITLITY PROGRAM ERROR MESSAGE DESCRIPTION Cannot verify location of ADD32 The corresponding template file for the selected template file lt ADD32 template configuration file could not be found The filename gt for ADD32 configuration template file is based upon the configuration s lt ADD32 configuration part and version filename gt Cannot verify location of The corresponding template file for the ADD ADD32Plus template file 32 PLUS configuration file could not be found lt ADD32Plus template filename The template file is based upon the for ADD32Plus configuration file configuration s part and version lt ADD32Plus confi
43. corresponding FAX 32 J2 terminal is switched to 24 VDC The digital input for USER 7 through USER 14 will equal ZERO OFF when the input s corresponding FAX 32 J2 terminal is switched to 0 VDC 4 44 Control Block Description ADDvantage 32 PLUS 4 30 DIGITAL OR This block implements a 4 input digital OR INPA INPB OUT p INPD DIGITOR 4 INPUT LOGICAL OR FIGURE 4 30 DIGITAL OR BLOCK 1 Inputs INPA Bit INPB Bit INPC Bit INPD Bit 2 Outputs OUT Bit 3 Implementation OUT is set to one if either INPA INPB INPC or INPD is equal to one otherwise OUT equals zero 4 45 Control Block Description ADDvantage 32 PLUS 4 34 DIVIDE The Divide block is used to divide two numbers The block checks for divide by zero to avoid a fault INPA OUT INPB DIVIDE FIGURE 4 31 DIVIDE BLOCK 1 Inputs INPA Analog INPB Analog 2 Output OUT Analog 3 Implementation If INPB 0 then OUT 0 Else OUT INEA INPB 4 46 Control Block Description ADDvantage 32 PLUS 4 32 DROOP The Droop block modifies the speed reference to keep the drive armature current within a particular range This is useful for controlling a nipped roll where it is in contact with another speed controlled section or anywhere a SOFT speed regulator is required Z REF CUR FIGURE 4 32 DROOP BLOCK Inputs CUR Analog STPT Analog GAIN Analog
44. 200 20 200 Hz This frequency output can be used to cascade references FAX32BD NEW 8 DIGITAL INPUTS AND FREQUENCY OUTPUT CABLE Figure 1 5 FAX 32 Module 1 8 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter 1 2 4 BRIDGE INTERFACE BOARD The BRIDGE INTERFACE BOARD Figure 1 6 is an interface between the microprocessor board and the high power thyristor circuits The main functional circuits on this board are as follows Current Feedback Scaling and Isolation SCR thyristor Firing Circuitry and Isolation Power Supplies for all the Drive Boards ESTOP and Drive OK Relays SCR Heat Sink Temperature Feedback Circuitry Gate Power Relay Voltage Feedback Scaling and Isolation 1 9 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter 10 THROUGH 510 AND 550 ADC CONVERTERS POWER SUPPLIES TRANSFORMERS ARMATURE GATE 4 J5 F POWER SUPPLY DOK CONNECTIONS ESTOP RESET DOK RELAYS 7 SINGLE PHASE J6 FIELD FIRING CONNECTIONS gt gt FIELD GATE Bl we aa ARMATURE GATE TRANSFORMERS FIGURE 1 84 GATE POWER RELAY AFMs 540 850 1550 AND 3000 ADC CONVERTERS 1 POWER SUPPLY DOK CONNECTIO
45. 32 PLUS 4 13 BIT CONVERT The Bit Convert block converts 4 input bits into decimal numbers The output changes only when the ENABLE bit is high This block can also be used as the X_IN value of a Table block enabling 16 separate setpoints ENABLE INPA INPB BINARY QUT DECIMAL INPC INPD BITCONVLAN FIGURE 4 13 BIT CONVERT BLOCK Inputs INPA Bit INPB Bit INPC Bit INPD Bit ENABLE Bit Outputs OUT Analog Implementation OUT latches only when the ENABLE input is low OUT defaults to 0 on powerup When the ENABLE bit is high refer to the following table to determine the value of OUT 4 18 Control Block Description ADDvantage 32 PLUS TABLE 4 13 Bit Convert Block OUT Values INPB INPC INPD OUT 0 0 0 0 0 0 0 1 1 0 0 2 1 0 0 3 0 1 0 4 0 1 0 5 1 1 0 6 1 1 0 7 0 0 1 8 0 0 1 9 1 0 1 10 1 0 1 11 0 1 1 12 0 1 1 13 1 1 1 14 1 1 1 15 4 19 Control Block Description ADDvantage 32 PLUS 414 BIT INVERT A Bit Invert block is used to provide an output bit which is always the opposite state of the blocks input bit INP OUT BITINVRT BIT INVERT FIGURE 4 14 BIT INVERT BLOCK 1 Inputs INP Bit 2 Outputs OUT Bit 3 Implementation If INP bit is high OUT bit is set low If INP bit is low OUT bit is set high 4 20 Control Block Description ADDvantage 32 PLUS 4 15 BIT SELECT This block is used to select one of two diff
46. 6 digital inputs 4 digital outputs 2 two phase tach inputs 1 buffered tach output 1 RS485 Serial Link or Additional Specifications are located in the supplemental drawing package 1 31 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter TABLE 1 1 ADDvantage 32 PLUS SPECIFICATIONS Cont DESCRIPTION SPECIFICATION FAX 32 Board 8 digital inputs 2 identical frequency outputs 200 20 200 Hz frequency range Duty cycle of 50 1 50 mA Imax Vout of 5V differential 017 commanded accuracy 017 commanded resolution Digital Input Ratings Input Voltage DC Common Mode Logic High Logic Low Common Mode Rejection Input Impedance Operating Current Required Digital Output Ratings Output Voltage 240 VAC Max Output Current 2 5 Amps Max Form C relay contacts Analog Input Ratings Differential Input Voltage 10 VDC Max Common Mode Input Voltage 200 VDC Max Common Mode Noise Rejection 60 VDC Max Accuracy 0 25 F S Max Drift 0 12 5 Analog Output Ratings Output Voltage 10 VDC Max Output Current 10 mADC Nom 40 mADC Common Mode Noise Rejection 2 VDC Max Drift 1 2 F S Max Resolution 0 025 F S Max Accuracy 1 8 F S Max Additional Specifications are located in the supplemental drawing package 1 32 Introduction and General Information
47. 8 32 11 095 13 87 16 667 Time ms DCAFMC6LAN Figure 3 6 Micro Board Iarm TP Discontinuous Current 3 41 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter 15 16 17 If no current is indicated on the microprocessor board then check to insure that the PHASE A CT is connected to the PHASE A input on the FIRING MODULE PHASE B CT is connected to the PHASE B input and PHASE C CT is connected to the PHASE C input Also check that the cables between the SCR Firing Adapter and the Field Supply Assembly are in place and secured by tightening screws on cable ends If the voltage observed on the scope is negative instead of the positive pulses shown in Figure 3 6 reverse all CT polarities If the CT leads are difficult to reach switch the wires for all CTs at J1 of the SCR Firing Adapter If the voltage waveform observed on the scope has some positive segments and some negative segments as shown in Figure 3 7 then follow either the 3 CT or the 2 CT feedback phasing method using the type your application has been configured with Voltage incorrectly Phased 11 095 16 667 13 87 Time ms DCAFMC7LAN Figure 3 7 Micro Board Iarm TP One CT Incorrectly Phased 3 CT Feedback Phasing Method 18 The 3 CT feedback configuration wiring diagram and jumper settings for the A20651 SCR Firing Adapter are shown in F
48. A20748 3 8 2x 300 MCM i 1 0 AWG 12 AWG T Wire termination is made to lug attached to the drive contactor K1 Indicates two wires of the same size in parallel doe No lugs are required for these connections Strip insulation 0 31 from end of wire Make connections to TB1 on top of the drive 6 5 Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter TABLE 6 2A WIRE TERMINATION KIT GUIDE FOR PART NUMBERS WITH N IN THE NINTH POSITION Example DC0056 4DN2 C MOTOR ARMATURE WIRE AC INPUT L1 L2 L3 OUTPUT CHASSIS GROUND MOTOR DRIVE TERMINA A1 A2 DB FIELD PART NO TION KIT Stud Recommended Bolt Recommended Recommended Recommended PART NO Size Wire Size Size Wire Size Wire Size Wire Size 10 AWG dd 10 AWG 12 AWG 8 AWG d 6 AWG 12 AWG 4 AWG 2 AWG 12 AWG 1 0 AWG 1 4 2 0 AWG 12 AWG STUD 4 0 AWG 3 8 2x 1 0 AWG 12 AWG STUD Ju 2 x 2 0 ANG 3 e 2 x 3 0 AWG 12 AWG STUD ii 2 x 3 0 AWG 3 8 DC0010 A21560 1 4 DC0030 A21561 1 4 DC0056 A21562 1 4 DC0110 A21563 1 4 DC0180 A21564 3 8 DC0280 A21565 3 8 DC0360 A21566 3 8 2 x 250 MCM 12 AWG STUD 77 DC0510 A21567 3 8 2 x 300 MCM 1 2 2 x 400 MCM 1 0 AWG 12 AWG i STUD du Wire termination is made to lug attached to the drive contactor K1 oe Indicates two wires of the same size in parallel Bon No lugs are required for these connections Strip insulation 0 31 from end of wire Make connect
49. ACCU EM MINL Nee ERR lt 0 MIN id IER i Tg PREL PRE FIGURE 4 53 PI BLOCK 1 Inputs Data Type Description ERR Analog Input Signal P Analog Proportional Gain Value I Analog Integral Gain Value MAXL Analog Output High Limit Value MINL Analog Output Low Limit Value PREL Analog Integrator Preload Value HOLD Bit Integrator Hold Enable PRE Bit Integrator Preload Enable 4 75 Control Block Description ADDvantage 32 PLUS 2 Outputs Data Type Description OUT Analog Output Signal TERR Analog Integral Error Value MAX Bit Indication Output is Clamped at High Value MIN Bit Indication Output is Clamped at Low Value 3 Implementation If HOLD LOW and PRE LOW then OUT Proportional Integral error values of block where Proportional ERROR PERR ERR x P Integral Error IERR Old Integral Error Value ma NM I Sample Time 1 Second Iis entered in seconds If I is entered at less than 0 001 seconds then I is set to zero The sample time is used to convert to the block execution rate where typically Armature Current Loop 2 77 msec Speed Loop 8 msec Tension Loop 16 msec If OUT gt MAXL The following sequence of events will occur The MAX bit 1 HIGH The Proportional Error is set so OUT will not exceed MAXL If the Proportional Error 0 the Integral Error will start to increase to keep OUT below the MAXL limit If OUT MINL The following sequence of events will occur The
50. ADDvantage 32 PLUS The USB functionality includes the ability to load and save all calibration and configuration data to a USB memory stick update drive firmware from files contained on the USB memory stick save signal analyzer data to the USB memory stick and save drive diagnostic information to the USB memory stick Refer to Section 11 for a full description of the USB functions implemented on the drive 2 33 ADDvantage 32 PLUS e AC to DC Power Converter E Operate USB CAL STORE USB CAL STORE RM gt MES c LefURIght B cie CAL SAVE 01 Up Down USB ANLYZR STORE USB ANLYZR STORE EAE gt Left Right ELE DRIVE000_02 Up Down Up Down y Edit Units USB FLASH LOAD USB FLASH LOAD USB FLASH LOAD gt mis C ieft Right Be EILE 69600210 DL ENTERS Up Key to Up Down USB FLASH LOAD USB FLASH LOAD U8 re STORE Right ENTER ENTER CODE 0000 ENTER UP Key to Confrm UP X Up Down Pressing ENTER key from USB FLASH LOAD will take the upper path if the flashkey txt file does not exist and will take the lower path if the file does exist USB Right gt lt Up Down y USB CAL LOAD USB CAL LOAD USB CAL LOAD ae gt Left Right PF cic SAVE O1 ENTER Up Key to Confrm NOTE flash load will only occu
51. ADDvantage 32 PLUS e AC to DC Power Converter 27 28 The CT and burden resistor series circuit must produce 2V output given the current calculated in step 26 Calculate and document the resistance value that will produce 2V given the current of step 26 For the example above _2 0 Volts 3 81 Ohms 0 525 Amps Actual Burden Resistor value Ohms Perform a calculation for the power dissipation rating of the burden resistor T I R Use the current and resistance values calculated in steps 26 and 27 For the example calculation 0 525 Amps 0 525 Amps 3 81 Ohms 1 05 Watts AS a precautionary measure use a burden resistor with a power dissipation rating of at least twice the power dissipation rating calculated in step 28 3 45 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter AFM CT Ratio Burden Resistor using Aviron stock CT s and standard burden values Goal is to scale burden for 0 667 V FLA or 2 0V at 300 FLA IOC trip 600 1 CT p n 18751 Enter Pick amp CT Actual Calc Drive CT Enter Scale IOC o 300 FLA Actual Burden Burden FLA DC Ratio Burden A Volt 2 VDC IOC IOC wo wo X061 XXXX 1 Ohms X062 ADC ADC 96 100 96 300 96 100 600 4 150 300 300 30096 150 600 2 5 240 480 450 32096 200 600 2 300 600 600 300 250 600 2 300 600 750 240 300 600 1 600 1200 900 400 2500 1 CT p n A18750 Enter Pick amp CT Actual Calc Drive CT Enter Sc
52. ADDvantage 32 PLUS e AC to DC Power Converter The ADDvantage 32 PLUS performs read to read information previously stored on the USB memory stick and performs write operations to store information to a USB memory All information on the USB memory stick may also be accessed with any personal computer that has a USB port The USB memory stick will appear as a file directory structure when installed and viewed on a personal computer All read to and write from operations performed with the USB memory stick are executed from or to specific directories on the memory stick Figure 11 2 shows the directory structure the user can expect to see As shown there must be an ADD 32 PLUS subdirectory located at the root level of the USB memory stick Under the ADD 32 PLUS subdirectory there will be one or more additional subdirectories Those subdirectories will have a name of DRIVE where the represents the LAN ID of the drive as set by jumpers on connector J8 of the drive refer to Figure 11 3 A memory stick will have only one ADD 32 PLUS subdirectory but that subdirectory may contain more than one DRIVE subdirectory The DRIVE subdirectory will contain additional files and subdirectories that contain information that is specific to the drive that has a LAN ID of For example a directory of DRIVEOOI will contain files and subdirectories for the drive with a LAN ID of 001 The DRIVE may contain three additional subdirectories One of
53. Always review local building and electrical codes before making electrical connections to this device Refer to the appropriate outline drawing and rating nameplate for power requirements fault current interrupt rating control power output rating and field output and armature output ratings Wire units using copper wire with a minimum of 75 C insulation 510 ADC AND BELOW Wire termination kits which provide necessary wire termination lugs for connection of units rated at 510 ADC and below in accordance with the National Electrical Code and Underwriters Laboratory are available See Tables 6 2 and 6 2a to identify the part number of the appropriate kit The instructions included with these kits detail the correct wire gauge used at each connection point and proper torque requirements Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter TABLE 6 2 WIRE TERMINATION KIT GUIDE FOR PART NUMBERS WITHOUT N IN THE NINTH POSITION Example DC0056 4D02 C MOTOR ARMATURE WIRE AC INPUT L1 L2 L3 OUTPUT CHASSIS GROUND MOTOR DRIVE TERMINA A1 A2 DB FIELD PART NO TION KIT Stud Recommended Bolt Recommended Recommended Recommended PART NO Size Wire Size Size Wire Size Wire Size Wire Size A20741 1 4 10 AWG 12 AWG A20742 1 4 10 AWG 12 AWG 20743 1 4 6 AWG 12 AWG A20744 1 4 1 0 AWG 12 AWG A20745 3 8 3 0 AWG 1 4 20 12 AWG A20746 3 8 2x 1 0 AWG 3 8 16 12 AWG A20747 3 8 2x 3 0 AWG 3 8 16 12 AWG
54. Analo Use Up Down to scroll through and view the M 8 lt j Left Right gt CONTROL BLOCK analog operating data RANGE A042 through AHHH Up Down Up Down Y Use Up Down to scroll through and view the OPERATE Left Right pios H Left Right 5 DRIVE analog operating data RANGE A000 through A041 Up Down Up Down Y ES Use Up Down to scroll through and view the Nod Blocks Digital lt q eft Right CONTROL BLOCK digital operating data RANGE 0096 through D Up Down Y Drive Digital Use Up Down to scroll through and view lt j Left Right 5 the DRIVE digital operating data RANGE 0000 through 0095 Figure 2 13 This ADD 32 PLUS keypad syntax shows the OPERATE submenu 2 19 ADDvantage 32 PLUS e AC to DC Power Converter 2 8 2 ACCESS CODE SUBMENU The ACCESS CODE submenu is shown in Figure 2 14 The figure shows a subsection of the TOP LEVEL menu on the left side By pressing the RIGHT key the user enters the ACCESS CODE submenu The ACCESS CODE submenu provides access to various special functions and features of the drive including security tuning and drive reset functions Entry into the ACCESS CODE submenu may be protected with an optional access code If the access code feature is enabled then a user must enter the correct access number before being allowed into the submenu 2 20 Diagnostics gt Up Down Up Down OPERATE gt LEFT Enter CODE
55. Analyzer ADDvantage 32 PLUS AC to DC Power Converter STORED DATA SPEED FDBK 1 SAMPLE 2 777 msec PREVIEW 4000 EVENTS TOTAL 8000 EVENTS TRIGGER 22 222 Seconds SPEED FDBK l 1100 1000 TRIGGER Figure 5 1 An analyzer operation during the capture of an overspeed event Summary The trigger activated when ABS ACT SPD exceeded 1 050 FPM The first 4 000 samples of data collected represent the 11 111 seconds of ABS ACT SPD before ABS ACT SPD exceeded 1 050 The remaining 4000 samples collected represent the 11 111 seconds of ABS ACT SPD after ABS ACT SPD crossed through the trigger level of 1050 FPM signal analyzer data may be viewed using the keypad display or uploaded to ADDAPT for viewing Note that in the above example if the trigger event occurred within the first 11 111 seconds after the signal analyzer channel was enabled the preview time would be reduced to the actual amount of time that had elapsed between the enable of the signal analyzer channel and occurrence of the trigger The signal analyzer would still collect the full 11 111 seconds of data that occurred after the trigger event 5 8 Signal Analyzer ADDvantage 32 PLUS e AC to DC Power Converter 5 0 Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter SECTION VI PREPARATION FOR USE Preparation for use of the ADDvantage 32 PLUS AC to DC Power Converter System includes unpackin
56. Down Tables Calibration 1 gt gt Up Down Up Down Spare Bit Cfg Drive Configure gt gt Up Down Up Down Up Down Bit Config Drive Calibrate gt gt Up Down Up Down Spare Analog Cfg Up Down EGD Config 2 18 Analyzer Menu Up Down Diagnostics Up Down Access Code Figure 2 12 This ADD 32 PLUS keypad syntax shows the TOP LEVEL menu 2 8 2 ADDvantage 32 PLUS e AC to DC Power Converter OPERATE SUBMENU The OPERATE submenu is shown in Figure 2 13 The figure shows a subsection of the TOP LEVEL menu on the left side By pressing the RIGHT key the OPERATE submenu is accessed This submenu provides access to all the real time operating data of the drive specifically all the A and D parameters The submenu subdivides the A into two groups The first group is the A parameters associated with the CORE software refer to Figure 2 5 showing the parameter layout which has a submenu title of DRIVE ANALOG The second A parameter group is the BLOCKS ANALOG which is associated with the BLOCK software in Figure 2 5 Similarly the DRIVE DIGITAL and BLOCKS DIGITAL provide access to the CORE and BLOCK software shown in Figure 2 5 respectively NOTE All the parameters accessed via the OPERATE submenu are read only E Blocks
57. EXPANSION BOARD REFERENCE FREQUENCY OUTPUT GENERATOR IF gt 200 FREQ OUT IF 200 FIGURE 4 35 FREQUENCY OUT BLOCK Inputs INP Analog SPAN Analog OFF Analog Outputs Not Applicable Implementation The output frequency will be Frequency INP x SPAN OFF Frequency is clamped so as not to go below 200 Hz 4 51 Control Block Description ADDvantage 32 PLUS 4 36 GAIN The Gain block is used to scale and offset an analog signal INP GAIN OUT OFF FIGURE 4 36 GAIN BLOCK 1 Inputs INP Analog GAIN Analog OFF Analog 2 Outputs OUT Analog 3 Implementation OUT INP x GAIN OFF 4 52 Control Block Description 4 37 HI LOW COMPARATOR ADDvantage 32 PLUS This block sets the appropriate output bits when the input goes out of limits Corrective action can be taken at this point Overspeed and AT ZERO SPEED detection are implemented using a HILOW Comparator The user can enable overspeed protection by configuring Y USR FAULT 2 OVER SPEED STPT X LOW DCXXXD1SCAN Inputs HI LOW INP HYS STPT Outputs HI LOW FIGURE 4 37 HI LO COMPARATOR BLOCK Analog Analog Analog Analog Analog Bit Bit 4 53 Control Block Description ADDvantage 32 PLUS 3 Implementation If INP increases so INP STPT x HYS 100 gt STPT x HI 100 HI bit goes high If INP decreases so INP S
58. Has the drive s calibration and configuration data been defaulted by mistake Verify all Ethernet Calibration and Configuration parameters defined in Section 8 3 2 7 Has the Ethernet communication problem occurred following replacement of the microprocessor board If it has go in to the DIAGNOSTICS menu on the drive LCD display Verify the ESBX PN VER numbers If the part number appears to be invalid then replace the ESBX board 8 Observe and document the LED s located on the drive s ESBX board at the time of failure STATUS CR2 STATUS RCV LED TX LED IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS 9 10 11 12 LINK ACTIVE LED If ESBX board LINK ACTIVE LED is and Switch port LED is off a Cycle power to ADD 32 PLUS drive and wait for the 45 second boot up to complete Did the LINK ACTIVE LED and Switch port LED turn If so replace the ESBX Board If ESBX LINK ACTIVE LED is on but communication problems still exist a Can ADDAPT 2000 and or Performance View communicate to the drive s b Has another device come online in the network with a duplicate IP Address Isolate the drive network from any other company networks c Go to a DOS command prompt and attempt to PING the drive s Use ADDAPT or PLC computer that is connected on the network Can you ping the drive TYPE ping ip address EXAMPLE ping 10 1 206 6 d Start Internet Explorer from Wi
59. INPB Analog TICS Analog LMT Analog 2 Outputs OUT Analog TRP Bit 3 Implementation OUT is equal to INPA INPB If the absolute value of OUT is greater than LMT then the internal timer will start to count up each time the block is executed 4 4 Control Block Description ADDvantage 32 PLUS When it counts up to the TICS input amount the TRP output will go high It will stay high as long as the absolute value of OUT is greater than LMT As soon as the limit condition goes false the timer is reset to zero and the TRP output goes low NOTE The amount of time associated with a block execution can vary depending on the application Look up the TICS input label in Appendix C of the manual for the timing 4 42 Control Block Description ADDvantage 32 PLUS 4 29 DIGITAL IN The Digital Input block enables the eight digital inputs USER 7 through USER 14 from the optional FAX 32 board to be mapped to eight consecutive digital data table board addresses FAX 32 EXPANSION DIGITAL DATA TABLE BOARD DIGITAL INPUTS ADDRESS D 24VDC N D USER 10 D USER 11 D USER 12 D USER 13 D USER 14 DIGITINSCAN FIGURE 4 29 DIGITAL IN BLOCK 4 43 Control Block Description ADDvantage 32 PLUS 1 Inputs Reference FAX 32 digital inputs on J2 of board 2 Outputs START BIT 3 Implementation The digital input for USER 7 through USER 14 will equal ONE ON when the input s
60. J R VU DCAFMR36LAN Figure 3 1 ADDvantage 32 PLUS Logic Diagram sheet 13 of 14 3 17 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter RUNG 37 D NOT USER 5 is the inverse of the digital input D USER 5 D USER 5 D NOT USER 5 MU i es RUNG 38 D NOT USER 6 is the inverse of the digital input D USER 6 USER 6 NOT USER 6 a EE DCAFMR38LAN RUNG 39 D ONE BIT is always high Applications blocks can use this to always enable a function D ONE BIT 2 RUNG 40 D ZERO BIT is always low Application blocks can use this to always disable a function eer ZERO D ZERO BIT DCAFMRAOLAN Figure 3 1 ADDvantage 32 PLUS Logic Diagram sheet 14 of 14 3 18 3 7 3 8 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter RUN THREAD AND JOG INPUTS Y Parameters Y RUN INPUT Y JOG INPUT Y THRD INPUT These three parameters enable the control loops of the ADDvantage 32 PLUS Each parameter can be configured to a value in the digital data table which enables its particular function These three parameters are interlocked Therefore only one can be enabled at a time Consult the Logic Sequence description provided in this section for specific interlock information Example Assume the following inputs are being u
61. MAXL If the Proportional Error 0 the Integral Error will start to increase to keep OUT below the MAXL limit If OUT lt MINL The following sequence of events will occur The MIN bit 1 HIGH The Proportional error component is set so OUT will not exceed MINL If the Proportional Error 0 the Integral Error component 4 79 Control Block Description ADDvantage 32 PLUS will start to increase to keep OUT above the MINL limit If OUT gt MAXL or H UP 1 The CMX bit 1 HIGH If OUT lt MINL or H DN 1 The CMN bit 1 HIGH If H UP HIGH and PRE LOW then The Integral Error component cannot increase in the positive direction until the H UP input goes low Positive ERR values are ignored by the integral error component The integrator hold up input is used to keep the integrator from increasing in the positive direction during major process disturbances Note that the Proportional Error is not affected by the H UP input If H DN HIGH and PRE LOW then The Integral Error component cannot increase in the negative direction until the H DN input goes low Negative ERR values are ignored by the integral error component The integrator hold down input is used to keep the integrator from increasing in the negative direction during major process disturbances Note that the Proportional Error is not affected by the H DN input If PRE HIGH then The Integral Error component is set to the PREL value and the Proporti
62. MAY STILL BE LIVE ALTHOUGH THE MAIN AC FEED IS OPENED ONLY QUALIFIED PERSONNEL SHOULD PERFORM THE FOLLOWING PROCEDURES ON THIS EQUIPMENT DUE TO THE COMPLEXITY OF THE ADD 32 PLUS POWER CONVERTER PERSONNEL SHOULD BE FAMILIAR WITH ALL SAFETY NOTICES INSTALLATION OPERATION AND MAINTENANCE PROCEDURES IN THE MANUAL PRIOR TO WORKING ON THE ADD 32 PLUS KE E K E K E K KE K K K K K K K K KKK 7 1 7 1 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter MAINTENANCE REQUIREMENTS Proper maintenance of the ADDvantage 32 PLUS and its associated motor and process equipment is required Refer to the instructions supplied with the motor and associated process equipment for proper maintenance procedures PERIODIC MAINTENANCE Under normal operating conditions the ADDvantage 32 PLUS requires minimal periodic maintenance The unit should be checked periodically for dirt accumulation within the enclosure Regularly clean or replace filters on low pressure clean air source ventilation openings Wire terminations on the power converter should be checked periodically for tightness To minimize downtime in the event of a component failure spare parts should be stocked at the installation site Refer to the spare parts list in the supplemental drawing package for recommendations on stocking of spare parts Use the following checklist for periodic maintenance 1 Keep unit free from dirt Vacuum or us
63. MC CLOSE The output is held in until armature current reaches near zero or after a half second after commanded open This is to prevent inverting faults RUNX D SCR ENABLE MC CLS ENA D ESTOP IN D DOK 007 Y MC CLOSE D M CONTACTOR Deer M CONTACTOR D TA SEAL DCAFMR12LAN Figure 3 1 ADDvantage 32 PLUS Logic Diagram sheet 5 of 14 3 9 Core Software Operation D CONTACTOR ADDvantage 32 PLUS e AC to DC Power Converter id TIME _ FRAME X MC DLY ADJT RUNG 13 This delays D ARM ENABLE until the motor contactor has a chance to pick up The delay is based on drive size from 150 ms on a 10 amp drive to 500 ms on a 510 and 550 amp drive and 750 ms on AFM s The parameter X MC DLY can adjust the delay more or less by entering a positive or negative number respectively X can be entered in ticks based on line frequency 2 777 ms on 60 Hz Software will not allow delays less than 27 ms WARNING Incorrect setting of the parameter can result in bridge self test failures or IOC s on application of runs to the drive Also the value SHOULD NOT be changed if there is any intention of applying the ADD 32 PLUS to an already spinning motor TIMER PT SIZE 6 X LINE FREQUENCY TIME DELAY DCAFMR13LAN RUNG 14 _ This delay is to sense if there is actual CEMF on the motor when the conta
64. Replace bridge interface board Replace power module FLD CTL LOS Field cannot reach setpoint Check for proper MOTOR IFLD value Check for low line voltage causing field firing into MIN ALPHA LIMIT c Check for proper FLD MAX LMT value d Replace bridge interface board e Replace microprocessor board FLT CLEARED Faults have been manually N A cleared GATE POWER No gate power available or a Replace bridge interface board gate power present when it b Replace microprocessor board should be inhibited 09 0 FIELD LOSS Eus c 2 7 13 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter FAULT MESSAGE PROBLEM SOLUTION IARM VOFFST The drive firmware has a Replace microprocessor board detected that the zero offset of the armature current feedback exceeded allowable limits INST OVR CU Instantaneous Overcurrent Armature Current above 300 Retune unstable current loop Check for shorted motor armature Check for stable line voltage Replace bridge interface board Replace microprocessor board Replace base L FREQ HIGH Line frequency above 65 Hz Check plant power frequency b Replace power supply board c Replace microprocessor board L FREQ LOW Line frequency below 43 Hz a Check plant power frequency b Replace bridge interface board c Replace microprocessor board LINE VOLTAG Low line voltage Measure incoming volta
65. Rev D and higher ESBX Physical Ethernet interface 100 MHz Fiber full duplex MTRJ connector 10 100 Meg Copper UTP half full duplex RJ 45 connector Each ESBX board has been assigned a unique MAC Address The MAC Address is printed on a label located on the component side of the ESBX board The MAC Address has also been programmed into ESBX firmware by Avtron IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS 01 i RI W02 N02111913N MM Figure 8 1 Avtron ESBX Module The ESBX boards are sensitive to Electro Static Discharge ESD These boards must be properly handled using an Anti Static Wrist Wrap connected to a good ground The ESBX boards must be carried and or shipped in approved Anti Static bags One ESBX Ethernet board is required for each ADDvantage 32 PLUS Drive The ESBX board plugs into SBX connector J4 on the microprocessor board for ADDvantage 32 PLUS DC Drives Install the ESBX board by inserting the board connector into the SBX connector Make sure that both the top and bottom of the ESBX board are fully inserted Screw down the ESBX board using nylon screw The ESBX board has five LED s in the upper left corner for visual indication of board operation The LED s are defined as CRI LED Normally flashing amber about once per second This LED indicates communication between the drive and the ESBX board CR2 LED Normally off This LED is controlled by the processor and is for Avtron debug use onl
66. Right B View and Edit TABLE 2 Calibration data T064 to T095 DOWN Figure 2 19 This ADD 32 PLUS keypad syntax shows the EDIT UNITS submenu The TABLES submenu provides access to nine 9 general purpose tables that may be used for various purposes by the drive software 2 28 2 8 6 ADDvantage 32 PLUS e AC to DC Power Converter Each of the tables consists of sixteen 16 data points and each of the sixteen 16 data points consist of an X data point and a Y data point Figure 2 20 shows a graphical representation of the sixteen data points in a table with the X data point representing the x axis value and the Y data points representing the y axis value X6 Y6 X15 Y15 X axis X10 Y10 X2 Y2 X13 Y13 X12 312 XD Y axis Figure 2 20 Example of a TABLE showing the sixteen 16 data points See section 4 68 TABLE in this manual for the description of the TABLE CONTROL BLOCK for further information on the tables FAULT FIFO SUBMENU The FAULT FIFO submenu is shown in Figure 2 21 The figure shows a subsection of the TOP LEVEL menu on the left side and by pressing the RIGHT key the FAULT FIFO submenu is reached The FAULT FIFO submenu provides the ability to clear the drive fault status and take the drive from a faulted to an unfaulted state Note that if the underlying cause of the drive being in a faulted state has not been resolved the drive will clear and then i
67. Sec 20 FPM SEC 5 Sec 20 FPM SEC Notice that since the input to the filter is 20 0 FPM SEC the rate from 4 to 5 Sec of the output does not increase past 20 FPM SEC At 5 seconds the Rate Change block reaches its final value 100 FPM and the rate of change becomes zero The filter will now cause the output rate to decrease by 5 FPM SEC from its maximum value of 20FPM S while the input rate is zero thus Exact Time Maximum rate of change Slope 1 Sec 5 FPM SEC 2 10 3 15 FPM SEC 4 Sec 20 FPM SEC 5 Sec 20 FPM SEC 6 Sec 15 FPM SEC 7 Sec 10 FPM SEC 8 Sec 5 FPM SEC 9 Sec 0 FPM SEC 10 Sec 0 FPM SEC To accurately select an appropriate value for the RND input apply Equation 4 61 1 in the form S Rate T Where S Value of Analog input RND Rate Value of UP or DWN T Desired time length for ROC to provide rounding Equation 4 61 2 4 96 Control Block Description ADDvantage 32 PLUS ADDITIONAL CONTROL I O 1 Inputs ZERO Bit HLD Bit 2 Outputs RES Bit If ZERO bit is low OUT 0 When ZERO bit goes high OUT ramps to REF by the UP or DWN ramp rates in addition to the RND input If the RES bit is high OUT REF Second in priority If the HLD bit is low OUT is held at its present value The rounding continues to prevent a step response When HLD goes high OUT ramps to REF by the appropriate rate The following figures 4 61C 4 61D and 4 61E graphically represent vari
68. TACH SELECT W block compares the unscaled inputs to MXSPD in determining tach failures 1 tach fail is sensed if CEMF gt 0 2 x MXSPD and TACH lt 0 05 x MXSPD All other block operation and logic are identical 4 118 Control Block Description ADDvantage 32 PLUS 4 70 TIMER The Timer block is used to delay setting a bit until an appropriate count has occurred It can be used to buffer faults for FIFO logging or to shut the drive down if in maximum tension for a period of time CNT INT REF mM RES TM HLD ZERO SET FIGURE 4 70 TIMER BLOCK 1 Inputs HLD Bit RES Bit REF Bit RET Bit CNT Analog 1 1 000 000 25 Outputs SET Bit ZERO Bit VAL Analog 4 119 Control Block Description ADDvantage 32 PLUS 3 Implementation When the RES bit equals zero VAL is set to 0 When VAL 0 then ZERO bit 1 If VAL 0 then ZERO bit 0 When the HLD bit is high VAL is frozen The RES bit has higher priority than the HLD bit If RES 1 and HLD 0 then the following occurs If REF 1 and VAL lt CNT then VAL VAL 1 If REF 0 and VAL gt 0 then VAL VAL 1 If VAL CNT then SET 1 else SET 0 When SET 1 it latches until a reset occurs Non retentive Block On powerup of the ADDvantage 32 PLUS VAL 0 Retentive Block On powerup of the ADDvantage 32 PLUS VAL will be initialized under t
69. TQ 418 V 16 TO 416 V 16 TO 418 Y 48 SERIAL IN IE 2 5 SERIAL TDIDIDIDIDIBIDIDIDID COM 2 4 B 763754178006 B 05 Figure 6 6 Block Diagram Microprocessor Board 6 17 Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter USER SUPPLIED POWER SOURCE SEPARATE FROM POWER SOURCE P N 364909 FAXS2 VO EXPANSION MODULE 3 SCHEMATIC D22136 24VDC _ COMMON i 1 J2 P2 4 a USERIN7 1 14 i 1 2 1 24K 1 Ws USER IN 8 E 1 15 1 1 CABLE i P N B21317 1 C i 2 4K vt USER IN 9 H E i 16 i H i 4 4 2 i 2 4K vx USER IN 10 TYPICAL USER INPUTS 12 1 10 SOURCE CURRENT REQUIRED i T PER INPUT 5 5 VA j 2 4K USER IN 11 18 18 A 6 F ANN 24K USER IN 12 19 19 7 7 W 2 4K USER IN 13 20 20 8 4 WV 24K i USER IN 14 i 21 21 TY A 12 12 TO SLAVE REFERENCE SECTIONTACH2 FREQUENCY OUTPUT PHASE A INPUT 200HZ TO 20 200HZ Ui bz 25 25 13 18 NOTE IT CHASSIS CABLE B21317 1 PROVIDES A POIN
70. The MACHINE NO parameter is used for customer installations that have multiple ADDvantage 32 PLUS based machines process control systems connected to and accessible to the same ETHERNET NETWORK The MACHINE NO parameter is only relevant to ADDAPT 2000 ADDvantage 32 PLUS Application Programming Tools where a Channel from 201 to 208 must be entered in the ADDAPT configuration ADDAPT cfg for each drive section The MACHINE NO is also used in the setup of ADDAPT Real Time Screens The ADDAPT Channel is equal to the X MACHINE NO 200 Typically all ADDvantage 32 PLUS drives on a specific machine drive system would be set to the same Machine Number ADDAPT 2000 uses both the drive s Machine Number and DRIVE ID for identifying and establishing Ethernet communication to drives for each machine drive system within your facility WEB PASSWORD 8 4 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS X WEB passWrd FUTURE USE TO ENABLE ACCESS TO DRIVE S WEB PAGE gt gt gt gt gt gt Drive Configure Menu Parameters Y ETHRNET COM DISABLE ENABLE AUTO ENABLE default AUTO ENABLE This parameter determines if the drive will communicate via ETHERNET If this parameter is set to DISABLE or AUTO ENABLE then an ESBX Ethernet board is not required on the drive for correct operation If the parameter is set to ENABLE then an ESBX Ethernet board must be installed for the drive to operate If there is no ESB
71. These parameters consist of both calibration and configuration parameters which perform the following functions 1 Data Collection 2 Channel Triggering 3 Sample Rate 4 Preview 5 Channel Enable 6 Channel Reset The signal analyzer has eight channels Each channel has a maximum of 8 000 data point of storage If power is lost all information captured by the analyzer is lost Specific parameter numbers have been omitted and replaced with asterisks due to differing parameter numbers between software Consult Appendices A D for exact parameter numbers and descriptions 5 1 5 1 Signal Analyzer DATA COLLECTION ADDvantage 32 PLUS e AC to DC Power Converter The data stored in the recorder channels can be any analog information or digital bit information located in the data tables parameter Defaults The recorder must be disabled to change the RECORDER CONFIGURATION DEFAULT CHANNEL PARAMETER VALUE 1 Z NP A D Q ANALOG Z NP ANALG A TARM CMD Z NP DIG D LIM LED 2 Z NP2 A D Q ANALOG Z NP2 ANALG A FLD CURRENT Z NP2 DIG D RUNX 3 Z NP3 A D Q ANALOG Z NP3 ANALG A MOTOR Z NP3 DIG D FWD BR LED 4 Z NP4 A D Q ANALOG 2 4 ANALG A FLD CURRNT Z NP4 DIG D REV BR LED 5 2 5 A D Q ANALOG Z INPS ANALG A FLD CURRNT Z NP5 DIG D REV BR LED 6 Z NP6 A D Q ANALOG Z INP6 ANALG A
72. Valid code code required V 0 0 entered LEFT no code required ADDvantage 32 PLUS e AC to DC Power Converter E012 C cfgl CKSUM HHHHHHHH A Up Down E011 D cfg CKSUM THEE A Up Down E010 C cal CKSUM HHHHHHHE A Up Down E009 D cal CKSUM HAAR Use Up Down to scroll through the selections E001 Access CFG on PERMISSION to edit change configuration NO r ap Left Right Enter B data i CHOICES NO YES YES NONVOLATILE Up Down Use Up Down to scroll through the selections E009 jc CAL rit Left Right Enter B PERMISSION to edit change calibration data i CHOICES NO YES YES NONVOLATILE Up Down Pressing the UP will initiate a software reset of EE 2 the drive any other key will abort the reset NOTE drive run must be off to allow reset A Up Down Checksum value for all of the drive TABLE data A Up Down Checksum value for all of the drive CONTROL BLOCK configuration data Checksum value for all of the drive configuration data Checksum value for all of the drive CONTROL BLOCK calibration data Checksum value for all of the drive calibration data A Up Down E008 SWR CKSUM HHHHHHHE Checksum value for the drive firmware A Up Down Y E007 SWR VERSION 696pppvv Part number and version of the drive firmware opp is lower 3 digits of part number wv is a 2 digit version number
73. WARNING If SPDVOL high and no redundancy is selected both RED and V RED low then if a tach failure is detected in the primary tach the TL bit will turn on and the output will not switch from the failed tach Similarly if RED high but V RED low and if both tachs fail the TL bit will turn on and the output will not switch but will remain dependent on the failed tach In such a situation a tach failure could cause equipment to run away and damage machinery or injure personnel For this reason any time V RED low and SPDVOL high Avtron HIGHLY RECOMMENDS configuring one of the USR FAULTS described in Section III to the TL output of the TACH SELECT block SE SK sk se sk se sk se st oe t oe t oe ke oe ke che Any time a tach failure is detected the TACH SELECT block will set appropriate output bits and switch speed feedback as the logic requires The outputs will remain in their states until the RES turns on If the RES input is maintained in the high state the TACH SELECT block will not switch to any redundant modes and tach failures will not be detected SPECIAL NOTE The TACH SELECT block differs from the TACH SELECT W block in how the GAIN input is used to scale input feedback The TACH SELECT block scales all inputs TACHI TACH2 and CEMF and compares the scaled inputs to the MXSPD input to determine tach failures i e tach fail is sensed if CEMF x GAIN 0 2 x MXSPD and TACH x GAIN 0 05 x MXSPD The
74. When the Maximum Rate of Change equals the rate of the input the ROC stops limiting the output 4 94 Control Block Description ADDvantage 32 PLUS REF Units 120 4 RMP 2 Block Simulation Ramp Change OUT ss ROC Filter OUT 100 80 Corners Created by Ramp Change Block 60 4 Rounding Created by 40 4 Rate of Change Block 20 qom ugue PPPTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 TIME secs RAMP3MAC FIGURE 4 61B The maximum rate of change allowed by the RMP2 ROC filter block depends upon time This time is measured from the beginning of a ramp input to the present time instant The maximum rate of change of the output of this filter is time dependent of the form Rate S xT Equation 4 61 1 where S is the analog value RND units Sec and T Sec is the point in time since the start of the ramp input The maximum rate of change of the filter output will not exceed that of the input over a long enough time interval As an example note on Figure 4 61B that the plot starts at time t 2 0 Sec The rate of change at the input of the filter block is a constant 20 FPM S The filter limits the rate of change block to 5FPM Sec thus 4 95 Control Block Description ADDvantage 32 PLUS Exact Time ROC Filter Slope at OUT 1 Sec 5 FPM SEC 2 Sec 10 FPM SEC 3 Sec 15 FPM SEC 4
75. Y Y Y Y Y Y 7 11 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter TABLE 7 3 HARDCODED FAULTS AND WARNINGS Cont FAULT F OR MOTOR CONTACTOR FAULT MESSAGE WARNING W MUST BE PICKED UP SCR OPN C R F SCR SHRT A F N SCR SHRT B F N SCR SHRT C F N SCR SHRT A F N SCR SHRT B F N SCR SHRT C F N SINK TEMP F N TUNE FAULT F Y TUNE PASS F Y USER 1 8 FLT F SWR WTCHDOG F N 7 12 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter TABLE 7 4 FAULT DESCRIPTIONS FAULT MESSAGE PROBLEM SOLUTION MESSAGE PROBLEM SOLUTION BRIDGE II T Heatsink overtemperature a Undersized motor b Parameter X001 MOTOR IARM scaled wrong c Parameter X002 MOTOR IFLD scaled wrong Check bearings Check gearbox oil Replace bridge interface board Replace micro board CNTL POWER Loss of power to the unit If only fault check plant power Check other faults NOTE CNTL POWER will appear in FIFO if power is cycled EEPRM WRITE Noncritical fault Check Replace microprocessor board calibration parameters for bad data Field current feedback low a Check parameter X MOTOR I FLD missing for proper motor drive ratio b Check field wiring c Check for field jumpers at TB1 3 5 and 4 6 d Check fuses F1 and F2 e Check FLD I ECON percentage 5096 recommended Check field ohms 100 300 ohms
76. about the Internet originally the ARPANET beginning in 1969 Memos in the RFC series discuss many aspects of computer networking including protocols procedures programs and concepts User Datagram Protocol UDP UDP is a standard protocol described by RFC 768 User Datagram Protocol UDP is an application interface to IP It adds no reliability flow control or error recovery to IP It simply serves as a multiplexer demultiplexer for sending and receiving datagrams using ports to direct the datagrams as shown in the following diagram process 1 process 2 process n UDP Port De Multiplexing Figure 8 9 1 UDP Demultiplexing based on ports UDP provides a mechanism for one application to send a datagram to another The UDP layer can be regarded as being extremely thin and consequently has low overheads but it requires the application to take responsibility for error recovery and so on This format is used by the GE Fanuc Ethernet Global Data EGD and Allen Bradley Implicit Messaging 8 27 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS 8 9 2 Transmission Control Protocol TCP TCP is a standard protocol described by RFC 793 Transmission Control Protocol TCP provides considerably more facilities for applications than UDP notably error recovery flow control and reliability TCP is a connection oriented protocol unlike UDP which is connectionless Most of the user application protocols such as Telnet
77. and Edit a subset of Drive Application Configuration parameters Pnnn through Pmmm These Application Configuration parameters are associated with the analog input selections to the SPARE BLOCKS contained in the application Refer to Appendix C for a listing of all Drive Application Configuration parameters View and Edit a subset of Drive Application Configuration parameters Pnnn through Pmmm These Application Configuration parameters are associated with the analog input selections to the control blocks contained in the application Refer to Appendix C for a listing of all Drive Application Configuration parameters View and Edit a subset of Drive Application Configuration parameters Pnnn through Pmmm These Application Configuration parameters define the drive ANALOG data that is made available for the ETHERNET EGD protocol Refer to Appendix C for a listing of all Drive Application Configuration parameters View and Edit a subset of Drive Application Calibration parameters Cnnn through Cmmm These Application Calibration parameters are associated with the SPARE BLOCKS contained in the application Refer to Appendix C for a listing of all Drive Application Calibration parameters View and Edit a subset of Drive Application Calibration parameters Cyyy through Czzz Refer to Appendix C for a listing of all Drive Application Calibration parameters View Edit a subset of Drive Application Calibration parameters 000 through Cxxx Refer t
78. and or the removable terminal blocks J7 J8 and J9 on the system board Note that all wiring that is removed will directly connect to the ADDvantage 32 PLUS without any change or modification 12 5 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter ETHERNET m CONNECTIONS FIELD WIRING ON CONNECTOR J7 va FIELD WIRING ON CONNECTOR J8 SYSTEM BOARD REV HARURU l fi 11 SUT FIELD WIRING ON CONNECTOR J9 1 2 32 Figure 12 2 ADDvantage 32 electronics enclosure shows the field wiring to be disconnected 12 6 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter 4 Remove the two ribbon cables that provide connections between the electronics enclosure and the bridge interface board The two cables have the part numbers B20726 1 and B20727 The cables that are shown in Figure 12 3 below are plugged into connectors on the printed circuit boards within the ADDvantage 32 electronics enclosure The B20726 1 cable will be reused with the ADDvantage 32 PLUS and should be retained The B20727 cable will not be reused REMOVE CABLES FROM DRIVE Figurel2 3 The ADDvantage 32 electronics enclosure shows the two cables to be removed 12 7 ADDvantage 32 PLUS e AC to DC Power Converter Upgrade to New Control Board Close and latch the ADDvantage 32 electronics enclosure door Open the drive 2 cover Remov
79. and the DC contactor is open If the voltage is above 10 or 20 volts an SCR may be leaking If an SCR is shorted significantly the drive diagnostics should fault out on power up The FAULT FIFO should indicate which SCR is bad The diagnostics may indicate a shorted SCR at drive power up that may actually be the leaking SCR it may be identified as follows SCR SHRT A CRI SCR SHRT A CR4 SCR SHRT B CR2 SCR SHRT B CR5 SCR SHRT C CR3 SCR SHRT C CR6 On the other hand the fault diagnostics may not be able to reliably determine exactly which SCR is leaking For a leaking SCR the fault diagnostics are clearable and the drive will run without blowing the 3 phase line fuses A shorted SCR will cause one or two 3 phase line fuses to blow The following test should be done to make sure FAULT FIFO has correctly identified the shorted SCR or to identify a leaky SCR 1 Power off the drive Open the drive to access the Bridge Interface board 3 Disconnect all the removable connectors on the board and swing open the panel to expose the snubber board 4 Disconnect the snubber board by removing the connector on the snubber board However for large drives this may not be possible Therefore skip this step for drives 540 amperes and above Clip a lead from a DVM to SCR bus A1 BA1 located on main base assembly Reconnect all cables on bridge interface board 7 Power up drive run off Measure and record AC volts between 1 and Phase
80. below apply to DC0003 only Auxiliary input is provided to accept 100mV input signal which is filtered 2 poles at 3 4mS and amplified to 5 0 VDC full scale and placed at an auxiliary output on J11 1 37 ADDvantage 32 PLUS AC to DC Power Converter ADDvantage 32 PLUS e AC to DC Power Converter SECTION II KEYBOARD AND PARAMETER FUNCTIONS WARNING DO NOT OPERATE RADIO TRANSMITTERS or CELL PHONES IN THE VICINITY OF THE ADD 32 PLUS The ADD 32 PLUS is an electronic device Although it is designed to operate reliably in typical industrial environments the ADD 32 PLUS can be affected by radio and or cell phone transmitters It is possible to cause drive faults inappropriate unintended drive I O activity and unpredictable operation that could result in damage to the ADD 32 PLUS damage to other equipment or serious injury to personnel Radio transmitter interference is a site specific phenomenon Generally electrical wires connected to terminals on the ADD 32 PLUS are the conduits for radio interference Interference can be minimized by good wiring design and installation practice It is recommended that signs be posted in and around the drive system warning of the possibility of interference if the drive is in operation DO NOT USE radio transmitters or cell phones in the area Absence of a radio interference problem is no guarantee that a problem will never occur as conditio
81. computer s registry A software error was encountered while comparing the template files This exception is displayed as part of the error message A software error was encountered while accessing the local computer s registry This exception is displayed as part of the error message 12 26
82. configuration parameter is 002 4Q OPERATE that allows the user to select either ENABLE or DISABLE as the option to apply concerning four quadrant operation of the drive The configuration data is stored in non volatile memory to ensure the configuration parameters are not lost when the drive loses power The configuration parameters may be edited by the user via the keypad and LCD display Analog Data is real time numeric information contained in the ADDvantage 32 PLUS analog data table This data represents the actual numeric operating data of the drive analog inputs internal analog control signals and also the values of analog drive outputs The data is stored and presented in engineering units This data is updated by the core software application blocks over the serial link LAN or the hardwired I O analog data with the exception of eight analog data points configured to be non volatile is lost on power loss to the drive Digital Data is real time digital bit information contained in the ADDvantage 32 PLUS digital data table This data represents the actual binary digital operating data of the drive and has a value of ONE TRUE or ZERO FALSE This data is updated by the core software application blocks over the serial link LAN or the hardwired I O All digital data is lost on power loss to the drive PARAMETER GROUPS The ADDvantage 32 PLUS drive parameters are further broken down into logical groups as an aid in identify
83. drive firmware In this case the drive firmware will be updated with the contents of the file 69400110 DLD The DLD extension on the file indicates that it is an ADDvantage 32 PLUS download file The drive will look for the firmware download file in the ADD 32 PLUS DRIVE FIRMWARE directory Note that represents the drive ID as set by jumpers on connector J8 The drive will indicate an error if 1 the firmware directory is not found 2 the firmware directory does not contain a firmware download file with the DLD extension or 3 the firmware directory contains more than one firmware download file Before the drive can successfully update firmware from the USB memory stick the user must create the ADD 32 PLUS DRIVE FIRMWARE directory structure on the memory stick and place the appropriate firmware download file into the firmware directory After confirming that the file displayed is the one to use for the firmware update the user presses the ENTER key Once ENTER is pressed the drive will then show one of two messages on the LCD display The first message is displayed when no authorization code is required This message instructs the user to press the UP key to confirm the firmware update operation de nex AE OUERT E If an authorization code is required before the firmware update operation be initiated a different message is displayed Then the following is seen on the LCD di
84. go to zero on powerup also When the RES bit is high then both counters and sums are set equal to zero When the hold bit is high both counters and sums are held at their current value If both RES and HLD are low then Every time the block is executed INP is added to the internal Suml Also the internal value Count1 is incremented When Countl is greater than TICS then Sum2 Sum Count Count2 is incremented Sum1 and Count is reset to zero OUT Sum2 Count2 TTL Sum2 CNT Count2 4 108 Control Block Description ADDvantage 32 PLUS HLD RES E TIL 1 Y HLD RES K1 HLD RES INP ACCUMULATOR 1 ACCUMULATOR OUT 11 4 COUNTER a gt 1 1 COUNTER CNT TICS SNAPAVGLAN FIGURE 4 65 SNAPAVG BLOCK 4 109 Control Block Description 4 66 PRT TAIL GR LGTH ON DIA GLA SPDR SPLICER ADDvantage 32 PLUS The Splicer block calculates two analog pulse count values one for the pressure roll and one for the knife Each value equals the amount of pulses to be received from the oncoming roll pulse generator before enabling the pressure roll and knife firing outputs SPLICER m PRF Inputs PR T Analog KN T Analog TAIL Analog GR Analog PPR Analog LGTH Analog ON DIA Analog GL A Analog CL A Analog SPD
85. high to low the OUT goes low no matter what the state of the latch bits If either latch LTCH1 or LTCH2 transitions from low to high at the same time as either hold HLD1 or HLD2 transitions from a high to low the hold will have priority over the latch and the OUT goes low High to low transitions of either latch LTCH1 or LTCH2 and low to high transitions of either hold HLD1 or HLD2 will not change the state of the OUT 4 58 Control Block Description ADDvantage 32 PLUS 4 40 LEAD LAG LEAD COMPENSATION is added to a control loop to improve rise time and the damping The disadvantage of LEAD COMPENSATION is that it adds instability to the system by increasing high frequency closed loop gain LAG LEAD is added to a control loop to improve overshoot and relative stability The disadvantage of LAG COMPENSATION is that it results in a lower rise time a E 2 LEAD i 1 FREQ LEAD LAG a E 5 1 LAG FREQ LAG LEAD BODE PLOTS FIGURE 4 40 LEAD LAG BLOCK 1 Inputs INP Analog LEAD Analog LAG Analog 2 Outputs OUT Analog 4 59 Control Block Description ADDvantage 32 PLUS 3 Implementation The LEAD LAG block is implemented to simulate the following equation H s LAG LEAD x s LEAD s LAG Setting the LEAD value equal to LAG gives the block a unity gain 4 60 Control Block Description ADDvantage 32 PLUS 4 41 LEAST WIN The block is used to select the low
86. holding fuse F1 6 associated with the module to be replaced to the bus bar This is located on the left side of modules A101 thru A103 or on the right side of modules A104 thru A106 Remove the bolt attaching the thyristor module assembly to the side bus bar This is found on the upper right side of modules A101 A103 and on the upper left side of modules A104 A106 7 42 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter Using the fuse F1 6 as a handle slowly slide the assembly forward and lift out as a single unit K K K K K K KK KK WARNING THYRISTOR MODULES WEIGH APPROXIMATELY 25 60 LBS AND COULD CAUSE PERSONAL INJURY IF DROPPED EKE EK E E E E E E E E E E E E K E K E E KE E K K K K K K K KK KKK DC155X 2 and DC155X 4 Only Items 8a and 9a below 8a 9a DC Modules A101 A106 Remove the bolt that holds the top of the fuse to the vertical bus link Remove the bolt that holds the module to the side bus bar Using the fuse as a handle slide the assembly forward and lift out as a single unit Modules A107 A112 Remove the bolts that attach the module to the bus bars on both the left and right side Loosen the bolt holding the vertical bus link to the module directly below and rotate the bus link out of the way Slide the module forward and lift out 155X A and B Versions and DC300X Items 8b and 9b below 8b 9b Modules
87. of the RUN input A subsequent failure of a SCR to gate for any reason cannot be detected until the next time the RUN is applied 7 3 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter The ADDvantage 32 PLUS uses built in diagnostics which constantly monitor for faults which may occur in the controller motor or other external inputs The diagnostic levels used to assist in troubleshooting are as follows 1 INITIAL POWERUP CHECK Upon powerup of the drive the diagnostic test checks all boards cables and incoming power While the ADD 32 PLUS software initializes and performs the powerup diagnostics the lower 10 LED s on the Human Interface Module HIM will flash NOTE Faults must be corrected to continue operation of the ADDvantage 32 PLUS There is a slight delay in operation while the powerup check is performed Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter TABLE 7 1 LED DEFINITIONS TITLE COLOR DEFINITION 5 V POWER ON Green Lights when power is present to keypad RUNNING Green Lights when a command is given to close the motor contactor Commands are RUN JOG or THREAD EMERG STOP OK Green Lights when emergency stop input is high and emergency stop reset has been pressed DRIVE READY Green Lights when all internal faults have been cleared and fault reset has been pressed Drive ready and emergency stop inputs must be on to run the unit USER LED Amb
88. on Modbus TCP IP is provided in Appendix G 8 9 5 3 Allen Bradley s Client Server Protocol AB CSP Allen Bradley CSP Ethernet communications encapsulates the PCCC message structure DF 1 style into a packet and delivers this packet to the PLC or ADD 32 PLUS The CSP protocol is used predominately to talk to ADD 32 PLUS drives from PLCS SLC500 PLCs programming typically done in RsLogix5 or RSLogix500 It may also be used from a ControlLogix PLC using RSLogix5000 but this is not recommended the use of EtherNet IP is suggested For the PLC 5 PCCC protocol supports PLC 5 Typed Writes PLC 5 Typed Reads and PLC 2 Unprotected Writes 8 33 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS For the SLC the PCCC protocol supports SLC Protected Typed Logical Writes with three address fields available in the read and receive functions For the ControlLogix the PCCC protocol supports PLC 5 Typed Writes and PLC 5 Typed Reads NOTE Additional information on using AB CSP protocol is provided in Appendix H 8 9 5 4 Ethernet Communications Using Allen Bradley Ethernet IP Control Internet Protocol AB CIP Ethernet Industrial Protocol Ethernet IP is an open industrial networking standard that supports implicit messaging real time I O messaging and explicit messaging message exchange Ethernet IP is a further development of Allen Bradley s Common Industrial Protocol CIP The EtherNet IP protocol is used
89. on it the first signal analyzer USB store operation will created the directories and subdirectories USB Usage ADDvantage 32 PLUS e AC to DC Power Converter The final subdirectory that may exist in the DRIVE directory is the FIRMWARE subdirectory This subdirectory if it exists holds the files necessary for firmware downloads to the drive The firmware file must have a dld extension and only ONE such file may exist in the subdirectory When a USB firmware upgrade is commanded from the keypad the drive will read the dld file ONLY from this directory In addition to the dld file the directory may contain an optional file named FLASHKEY This file provides the ability to specify that a four digit access code is required before a firmware upgrade is allowed ROOT ADD32plus DRIVEOOO0 Drive info txt Diagnostic dat 694912V10 CAL SAVE 01 ADD CAL SAVE 02 ADD HHHHHHHHHHH ADD Signal DRIVEOOO 00 CH1 ALZ DRIVEOOO 00 CH2 ALZ DRIVEOOO 99 CH1 ALZ DRIVEOOO 99 CH2 ALZ DRIVEOOO 99 CH3 ALZ DRIVEOOO 99 CH4 ALZ DRIVEOOO 99 CHS ALZ Firmware 69491210 dld FLASHKEY txt DRIVEOO1 Figure 11 2 The ADDvantage 32 PLUS USB directory and file structure USB Usage ADDvantage 32 PLUS e AC to DC Power Converter Li x rt J8 Connector Figure 11 3 The ADDvantage 32 PLUS electronics enclosure shows connector J8 11 4 11 1 USB Usage ADDvantage 32 PLUS e A
90. overflow of the QUERY command queue Increments of this counter indicate that excessive volumes of QUERY frames are being received by the ESBX module This indicates an application problem QRY Send Fail counter containing the number of failures returned by the QUERY response socket send operation Increments of this counter indicate a probable network configuration problem most likely related to the drive IP address subnet mask or gateway address QRY Fail counter containing the number of QUERY RESPONSE frame transmit failures Increments of this counter could indicate a possible network configuration problem possibly related to the drive IP address subnet mask or gateway address or a software related problem EXCHG Frames number of EXCHANGE FRAMES received by the drive EXCHG Busy counter containing the number of EXCHANGE commands that were aborted due to the buffer between the ESBX and the drive being busy This counter incrementing indicates a communication error between the ESBX module and the drive and should be reported to Engineering ASCAN Frames number of EXCHANGE FRAMES received by the drive ASCAN Overrun counter containing the number of ASCAN or EXCHANGE frames that were discarded due to an overflow of the ASCAN EXCHANGE command queue Increments of this counter indicate that excessive volumes of ASCAN and or EXCHANGE frames are being received by the ESBX module This indicates an application problem ASCAN
91. parameter Parameter Units C025 MAX SPEED H 9999 9 FPM user configurable line 3 user configurable line 4 2 31 ADDvantage 32 PLUS e AC to DC Power Converter Figure 2 23 The LCD display shows the units field in a calibration parameter 2 32 2 8 8 ADDvantage 32 PLUS e AC to DC Power Converter When viewing a parameter from the EDIT UNITS submenu the user can press the RIGHT key to initiate the editing of the units field The cursor will appear under the leftmost character of the units field Note that the character could be a blank space Figure 2 24 shows the LCD display after the RIGHT key has been pressed to begin an edit C025 MAX SPEED H 9999 9 FPM user configurable lin user configurable line 4 EDIT CURSOR Figure 2 24 The LCD display of a calibration parameter shows the units field in edit mode The UP and DOWN keys will scroll through the full set of numbers and letters The RIGHT key will move the cursor to the next units field character to the right The LEFT key will abort the edit and the ENTER key will accept the change made to the units field and save the field in non volatile memory USB SUBMENU The USB submenu is shown in Figure 2 25 The figure shows a subsection of the TOP LEVEL menu on the left side and by pressing the RIGHT key the user enters the USB submenu The USB submenu provides access to the USB functionality implemented on the
92. pins 1 2 Baud rates are incompatible Change LINK BAUD in drive and reset If that does not solve the problem when entering ADDapt type ADDAPT bxxxx where xxxx is either 4800 or 9600 This will override the default computer baud rate If that does not solve the problem change default baud rate in CONFIG SYS by adding BAUD xxxx and reboot Serial link addresses are incompatible Change in CONFIG if that does not solve the problem change jumpers on system board Software part no and version no of flash prom do not match CONFIG If the above is OK and the receive LED on 485 card flashes replace the 485 card or replace the Microprocessor board If all configuration is good then either EMI noise or hardware is the problem Check for loose wiring or change out the microprocessor board 485 card or CPU Cable should be two twisted shielded pairs Shields should be grounded at transmit end only Do not run wiring in high voltage raceway or parallel to any high voltage or AC wiring 10 7 USB Usage ADDvantage 32 PLUS e AC to DC Power Converter SECTION XI USB USAGE The ADDvantage 32 PLUS AC to DC Power Converter System includes a USB interface to allow easy upgrade and programming of the system The USB interface allows operators to save restore calibration data store signal analyzer upgrade firmware and more Figure 11 1 shows the USB keypad syntax and how to navigate around to perform USB ope
93. reset LOAD FAILURE BRG I F FPGA PROGRAM Cycle power to reset B B Com Timeout HWR VALID WAIT FAIL Cycle power to reset INVALID APPLICATION perform DEFAULT UP YES DOWN NO Microprocessor board detected invalid or corrupt drive software Microprocessor unable to load programming into a field programmable gate array Microprocessor board detected invalid or corrupt drive software Microprocessor board detected invalid or corrupt drive software Microprocessor unable to load programming into a field programmable gate array Microprocessor unable to load programming into a field programmable gate array Communication failure between microprocessors Microprocessor board detected invalid or corrupt drive software Replace microprocessor board Cycle power to drive Replace microprocessor board Replace microprocessor board Replace microprocessor board Cycle power to drive Replace microprocessor board Cycle power to drive Replace microprocessor board Cycle power to drive Replace microprocessor board Cycle power to drive Press UP key then reload drive firmware and calibration data Replace microprocessor board Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter TABLE 7 2 POWERUP MESSAGES cont FAULT MESSAGE INVALID APPLICATION DEFAULT FAILED Cycle power to reset NULL APPLICATION has been loaded rload valid firmware
94. show a number of samples before the trigger occurred This allows information leading up to the trigger point to be evaluated For example if the preview is set at 500 then 500 samples will be recorded before the trigger point and 7 500 after Note that the preview specifies the MAXIMUM number of samples that may be collected prior to the trigger event In the event that a trigger event is detected before the number of samples specified by the preview have been collected the preview will be less than what has been specified by the preview calibration factor For example if the preview calibration factor is specified as 4 000 samples but the trigger occurs after only 100 samples have been collected the number of data samples recorded before the trigger will be the 100 samples The number of data samples recorded after the trigger will be the 8 000 maximum less the preview calibration factor or 4 000 samples for this case The total number of data points collected by the analyzer in this case will be 4 100 100 before the trigger event and 4 000 after RECORDER CONFIGURATION DEFAULT RANGE CHANNEL PARAMETER VALUE 1 Z PREVIEW 1 500 1 7999 2 Z PREVIEW 2 500 1 7999 3 Z PREVIEW 3 500 1 7999 4 Z PREVIEW 4 500 1 7999 5 Z PREVIEW 5 500 1 7999 6 Z PREVIEW 6 500 1 7999 7 Z PREVIEW 7 500 1 7999 8 Z PREVIEW 8 500 1 7999 ENABLE This bit enables or disables the recorder The operator must disable the recorder for
95. that the connector on one end of the B33178 cable is keyed and cannot be plugged into the J2 connector on the bridge interface board Figure 12 6 The B33178 ribbon cable plugs into connector J2 on the bridge interface board and routes across the drive cover 12 10 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter 6 The B20726 1 ribbon cable removed in step 4 will be reinstalled One side of the cable plugs into connector J4 on the bridge interface board and routes across the back of the drive cover and through the slot into the electronics enclosure The position and routing of the B20726 1 cable is shown in Figure 12 7 Figure 12 7 The B20726 1 ribbon cable is installed in connector J4 of the bridge interface board and is routed across the drive cover 12 11 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter 7 Close the drive cover and open the electronics enclosure door Install the connectors on the other ends of cables B33178 and B20726 1 as follows e Cable B33178 plugs into connector J1 on the ADDvantage 32 PLUS microprocessor board e Cable B20726 1 fits into connector J2 on the ADDvantage 32 PLUS microprocessor board Figure 12 8 shows both connectors J1 and J2 as well as the installed cables B33178 Cable Installed in J1 B20726 1 Cable Installed in J2 Figure 12 8 The ADDvantage 32 PLUS electronics enclosure shows where and how the ribbon cables B33178 and
96. the REF summing block parameter P141 SPD LP EN to D087 ZERO BIT 3 39 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter Document All Changes Made Completing Step 2 8 PARAMETER NEW VALUE ORIGINAL VALUE Set the following parameters PARAMETER NEW VALUE ORIGINAL VALUE Y FIELD CNTL DISABLED Y BRG SLFTST DISABLED Y 40 OPERATE DISABLED X ARM Resist 0 00 X Jarm Contin 100 X 7 C CORRECT 800 X ARM PGAIN 0 10 X TARM IGAIN 0 00 9 RESET DRIVE 10 11 12 Connect a scope to measure the voltage across one of the CT burden resistors Remember to use an isolation plug on scopes with ground prong on power cord If the burden resistors are located in an inaccessible area the scope may be connected to the SCR Firing Adapter point to which the burden resistor CT wiring terminates See AFM s electrical drawing set for correct interconnections Set the time sweep to 115 per division set the voltage scale to 0 5 volts per division and set the scope sync to the line Observe the armature firing angle A016 ARM ALPHA under OPERATE DRIVE ANALOG and insure that it is approximately 120 degrees If the firing angle is significantly smaller check that all analog values throughout the ARMATURE CURRENT LOOP are all zero Place a clamp on ammeter on one of the armature leads This meter will be used to
97. the armature circuit The resistors bleed off SCR leakage so that false tach loss trips do not occur on the application of a run KIT P N INSTRUCTIONS FOR USE ON A22481 22428 280 360 and 510 Amp DC Drives A22374 A22375 Most others Check with factory INDIVIDUAL SCR MODULE TEST An SCR module can be tested individually when removed from the drive It is recommended that the SCR module be cold for this test and should not have been in operation for a considerable time preceding the test Follow the steps below for each SCR on the module USING AN ANALOG OHMMETER SET TO MEGOHM SCALE 1 Measure the resistance between the Cathode and Anode It should be IMQ or greater 2 Reverse ohmmeter leads It should again read IMQ or greater 3 Connect positive lead of the ohmmeter to anode and negative lead to cathode Jumper anode to gate The resistance should now read less than 1KQ 4 Removing the jumper should indicate a reading of IMQ or greater on the ohmmeter Any variation of readings on the ohmmeter indicates a leaky shorted or open SCR 7 31 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter NOTE IN CASE OF A HOT SCR THE READINGS MAY BE SIGNIFICANTLY LOWER IN STEPS 1 2 AND 4 K1 G1 K2 G2 SCRTEST2LAN Figure 7 8 SCR Module Diagram 7 32 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter 7 8 THYRISTOR DIODE REPLACEMENT 510 ADC and
98. the drive A label is also included which must be affixed to the drive See paragraph 6 6 4 for reconnection instructions 9 The AC field fuses F1 and F2 are located to the right of the motor armature fuse F11 discussed in step 3 After replacement F1 hardware should be tightened to 120 140 in Ib The hardware on F2 should be hand tightened only 10 Reinstall the bridge interface from step 4 see paragraph 7 3 4 11 Attach the bus bar support brace removed in step 3 two quarter turn fasteners 12 Close the main drive door 7 40 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter 7 10 THYRISTOR DIODE FUSE REPLACEMENT 540 850 1550 3000 ADC Refer to Figures 7 11 7 12 and 7 13 K K K K K K K KK KK WARNING HAZARDOUS VOLTAGES WHICH CAN CAUSE SEVERE INJURY OR DEATH ARE PRESENT DURING THE OPERATION OF THIS EQUIPMENT TURN OFF AND LOCK OUT ALL SOURCES OF POWER BEFORE MAKING ANY REPAIRS EE EK EK EE EE E K E K KE K K E K K K K K K K KKK KK TABLE 7 7 TOOLS REQUIRED DESCRIPTION USED ON ASSEMBLIES 1 4 Drive Torque Wrench 0 75 in lb Field Supply Subassembly D21591 and D22716 5 32 Hex Head Socket with Allen wrench insert bit Field Supply Subassembly 1 4 drive D21591 and D22716 3 8 Drive Torque Wrench 0 500 in lb DC054X DC300X Armature Bridge Assembly 9 16 Open End Hex Head Wrench DC054X DC085X Armature Bridge Assembly
99. the green running LED D RUNX D RUN LED DCAFMR23LAN RUNG 24 Lights the amber user defined LED yer USR LED PT D USER LED JCAFMR24LAN Figure 3 1 ADDvantage 32 PLUS Logic Diagram sheet 9 of 14 3 13 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter RUNG 25 Lights the red field loss LED and seals it in until the faults are cleared D EED LOSS PI D FAULT 055 220 DCAFMR25LAN RUNG 26 Lights the red instantaneous overcurrent LED and seals it in until the faults are cleared D PT FAULT D TOC LED FOR A D TOC LED EN FMR26L RUNG 27 Lights the red drive fault LED De FAULT D DFAULT LED l DCAFMR27LAN Figure 3 1 ADDvantage 32 PLUS Logic Diagram sheet 10 of 14 3 14 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter RUNG 28 Lights the green Drive OK LED D DOK DRIVE OK LED DCAFMR28LAN RUNG 29 Lights the green ESTOP OK LED JE ESTOP IN ESTOP LED DCAFMR29LAN RUNG 30 Lights the amber current limit LED To properly light the LED the Y parameters must be set to the in limit conditions of the speed loop PI regulator D MAX TARM D REV LOCKOUT D LIM LED Dee TARM DCAFMR3 LAN Y
100. the subdirectories will contain drive calibration and configuration files that may be read to and or written from the memory stick The name of the subdirectory will be the part number and version number of the software contained on the drive and will be in the form of 696xxxVyy where 696xxx is the software part number and yy is the version number of the software The drive will only read calibration and configuration files from the directory that matches the software part number and version For example the drive with a LAN ID of 001 and a software part number of 696002 version 11 will only read and write calibration and configuration files from the directory ADD 32 PLUS DRIVE001 696002V11 All the calibration and configuration files must have the file extension of add Note that if this directory does not exist on the USB memory stick i e the memory stick is new and has no ADD 32 PLUS files or directories on it the first calibration and configuration USB store operation will create the directories and subdirectories The DRIVE may also contain a SIGNAL subdirectory The drive will use this directory to store signal analyzer data files in response to a keyboard command prompting storage of the files to the USB memory stick Only the signal analyzer files for DRIVE will be stored to this directory Note that if this directory does not exist on the USB memory stick i e the memory stick is new and has no ADD 32 PLUS files or directories
101. this submenu also offers the ability to view the status of each channel When the data collection is completed for a channel this submenu allows the data collected to be viewed Figure 2 17 shows the status data display 2 24 Drive Calibrate 4 Analyzer 3 Setup gt Up Down Y Analyzer2 Setup 1 1 Up Down Analyzer 1 Setup ai Left Right a 1 1 Analyzer 7 Data Up Down y gt l Left Right Analyzer 6 Data Left Right Up Down Analyzer 5 Data i Left Right Left Right Analyzer 3 Data gt Left Right Up Down Y Analyzer 2 Data gt Up Down Analyzer 1 Data gt ma Left Right Up Down Y Analyzer 8 Setup gt Left Right A Up Down Analyzer 7 Setup gt Left Right Up Down y Analyzer 6 Setup gt Left Right A Up Down Analyzer 5 Setup gt Left Right Up Down y Analyzer 4 Setup gt Left Right DOWN ADDvantage 32 PLUS e AC to DC Power Converter View and Edit the Calibration and Configuration data for channel 3 of the signal Left Right analyzer Z200 to Z213 Refer to Chapter 5 for complete docume
102. to Figure 7 9 and Table 7 5 Determine hardware size used to mount bus bar assembly to the thyristors diode Using the torque wrench and the appropriate socket remove the hardware as shown in Figure 7 9 6 Remove bus bars from the thyristor 7 Using the 5 32 Allen wrench socket remove the mounting screws on each end of the thyristor or diode 8 Remove the damaged thyristor or diode 7 8 1 2 Replacement and Reassembly 1 Apply a layer of thermally conductive compound to bottom of new thyristor or diode and reinstall in base assembly 2 Mount new thyristor or diode to heatsink using mounting screws located on each end Torque tighten the mounting screws to 38 50 in lb Recheck torque after a minimum of 3 hours 3 Replace the bus bars on the thyristor 4 Replace the hardware mounting the bus bars to thyristor Torque tighten the screws per the following table TABLE 7 6 TORQUE SPECIFICATION TORQUE DRIVE SIZE SPECIFICATION HARDWARE FIELD THYRISTOR AND DIODE 22 30 in lb 2 Phillips screw DC0010 DC0030 DC0056 22 30 in lb 2 Phillips screw DC0110 DC0180 38 50 in lb 3 Phillips screw DC0280 DC0360 DC0510 68 75 in lb 1 2 hex head bolt 7 34 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter
103. to a value between user selectable high MAXL and low MINL limits MAXL INP MINL OUT MAX MIN FIGURE 4 18 CLAMPING BLOCK 1 Inputs INP Analog MAXL Analog MINL Analog 2 Outputs OUT Analog MAX Bit MIN Bit 3 Implementation 4 26 Control Block Description If INP gt MAXL then OUT MAXL MAX high MIN low If INP lt MINL then OUT MINL MIN high MAX low If MINL lt INP lt MAXL then OUT INP MAX low MIN low 4 27 ADDvantage 32 PLUS Control Block Description 4 19 COM LOSS ADDvantage 32 PLUS The Com Loss block is used as a communication watchdog TIM INT WDIN EN WDOUT 5 1 Inputs TIM EN WDIN 2 Outputs WDOUT TRIP Bit Bit Bit Bit Bit COM LOSSLAN FIGURE 4 19 COM LOSS 4 28 Control Block Description ADDvantage 32 PLUS 420 COM WD 179 40 TIM EN D086 ONE BIT EN COM LOSS COM WD WDOUT D176 WD OUT P180 WD INP D111 LOC BIT 16 WDIN C161 WD TIMOUT 0 25 FIGURE 4 20 COM WD BLOCK 1 Inputs EN Bit WD IP Bit TOUT Analog 2 Outputs WDOUT Bit TRIP Bit 3 Implementation When the EN input of the WD COM block is a logic level high One Bit the block monitors the WDIN input and will set the TRIP output if the input fails to toggle t
104. to talk to ADD 32 PLUS drives from ControlNet or DeviceNet based PLCs programming done with RSLogix5000 Ethernet IP consists of IEEE 802 3 Physical and Data Link standard e Ethernet TCP IP protocol suite Transmission Control Protocol Internet Protocol the Ethernet industry standard CIP the protocol that provides real time I O messaging and information peer to peer messaging ControlNet and DeviceNet networks also use CIP TCP IP is the transport and network layer protocol used by Explicit Messaging The UDP IP User Datagram Protocol is used by Implicit Messaging NOTE Additional information on using AB CIP protocol is provided in Appendix I 8 34 9 1 9 2 System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter SECTION IX SYSTEM DATA STRUCTURES This section details the data structures of all necessary tables and data inputs used to set up and define operation of an ADDvantage 32 PLUS Some parameters are write protected meaning the information is read only and cannot be written to If a write is attempted on a protected area an error message appears All parameters regardless of write protect status can be read over the serial link or Ethernet For additional information on communicating to an ADDvantage 32 PLUS refer to Avtron Engineering Report 14363 001 for the RS 485 serial link or the Avtron ADDvantage 32 PLUS LAN Specification These reports can be obtained upon reques
105. upgrade firmware Single PC board controller design Terminal block compatible with prior generation Add 32 drive HARDWARE AND EQUIPMENT FEATURES Figures 1 1 1 2 and 1 3 illustrate the three typical hardware configurations of the ADDvantage 32 PLUS Power Converters Each hardware configuration contains a microprocessor board bridge interface board and a power base Hardware configuration varies with the output rating of the ADDvantage 32 PLUS being used Figure 1 4 shows a typical Advanced Firing Module The AFM hardware generally includes the same items listed above except for the power base 1 2 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter 10 through 510 Figure 1 1 and 550 ADC Figure 1 2 Power Converters ADDvantage 32 PLUS s rated for 10 through 510 and 550 ADC are packaged as a single unit Brick style or rectangular SCR s are mounted in the power base and allow for convenient packaging 1 1 Figure 1 1 ADDvantage 32 PLUS AC to DC Power Converter 510 ADC and Below 1 3 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter Figure 1 2 ADDvantage 32 PLUS AC to DC Power Converter 550 ADC Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter 540 850 1550 and 3000 ADC Power Converters Units rated at 540 850 1550 and 3000 ADC consist of two modules The micropr
106. 0 ADC and above units Shorted SCR CR2 or snubber on 510 ADC and below units Or Shorted SCR A102 on 540 ADC and above units Shorted SCR CR3 or snubber on 510 ADC and below units Or Shorted SCR A103 on 540 ADC and above units 7 17 ADDvantage 32 PLUS e AC to DC Power Converter en e SOLUTION Check fuse Check cable assembly connected to J2 of microprocessor board and its associated connectors Replace SCR or drive base assembly Replace bridge interface board Replace microprocessor board Check fuse Check cable assembly connected to J2 of microprocessor board and its associated connectors Replace SCR or drive base assembly d Replace bridge interface board en Replace microprocessor board Check fuse Check cable assembly connected to J2 of microprocessor board and its associated connectors Replace SCR or drive base assembly Replace bridge interface board Replace microprocessor board Check fuse Check cable assembly connected to J2 of microprocessor board and its associated connectors Replace SCR or drive base assembly Replace bridge interface board Replace microprocessor board Replace bridge interface board and snubber board if applicable b Replace SCR module Replace microprocessor board Replace bridge interface board and snubber board if applicable b Replace SCR module Replace microprocessor board Replace bridge interface
107. 0003 DC0004 and DC0005 AFMs Outputs up to 24 SCR firing signals 12 forward 12 reverse Firing signal control is configurable through application specific software Consult Avtron Industrial Automation Inc for information Requires external pulse shaping circuitry for SCR firing available from Avtron or others Pulse shaping circuitry can be provided by an Avtron Gate Pulse Amplifier unit P N C23047 Consult Avtron Industrial Automation Inc for application specific information For DC0003 and DC0004 only SCR gate power should be supplied externally J9 and J10 For DC0003 only See paragraph 1 2 7 Also contains connection J6 to support optional firing of an external single phase field bridge Selectable DC0003 and DC0005 0 666V 100 or 5 00V 100 DC0004 0 666V 100 or 3 33V 100 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter TABLE 1 1 ADDvantage 32 PLUS SPECIFICATIONS Cont Bridge Interface Board Cont DRIVE PART NUMBER DC0010 05 10 DC0540 DC0001 and DC0003 DC0004 and and 0550 L 0850 3000 L DC0002 AFMs DC0005 AFMs ARMATURE 0 to 670 VAC 10 VDC 10 VDC DC0003 and DC0005 VOLTAGE Scaled by Avtron Requires customer 10 VDC FEEDBACK supplied Voltage supplied external DC0004 38 3 VDC Isolation Board provided scaling circuit Requires customer on armature bridge supplied external assembly scaling circuit The features
108. 01 2001 at 12 00 00 e AREA 2 source name will be USB_DRV with the three digit drive ID as set by jumpers on connector J8 AREA 3 The comment section will always be Analyzer file stored to USB 11 2 USB Usage ADDvantage 32 PLUS e AC to DC Power Converter Channel Properties 3 11 ue Date Acquired 1 01 01 Signal Name JANALOGINT TimeAcquired 2 000 Signal Units pors 0 001 TITE ra Source Node Number Trigger Name ANALOGINT Number Of Samples Trigger Units Sample Period 0277 Trigger Edge RISING 0 Preview 8 Trigger Level Enable Saurce ENABLED Arm Name Arm Type sammen Arm Level fT Write Analyzer File Figure 11 5 PROPERTY view of an analyzer file that has been saved to the USB memory stick by an ADDvantage 32 PLUS drive USB FLASH LOAD The ADDvantage 32 PLUS drive allows the user to update ADD 32 PLUS firmware from files contained on the USB memory stick To perform a USB flash load of drive firmware from the USB memory stick navigate the USB submenu until reaching the USB FLASH LOAD option as shown below Osis OAR USB Usage ADDvantage 32 PLUS e AC to DC Power Converter Pressing the right arrow will show DME The second line of the LCD display will show the first 11 characters of the file that will be used to update the
109. 1 INPB x BIT2 INPC x BIT3 If all 3 bits are low then OUT 0 4 112 Control Block Description ADDvantage 32 PLUS 4 68 TABLE The Table block is used to modify an analog variable INP by a factor which is proportional to a second analog variable X_IN An example of such an application would be to taper a tension setpoint based on roll diameter f X_IN Y15 ge m Ts P Y6 Y5 gt i Y0 Y1 Y2 amp av X X2 X5 X6 X15 FIGURE 4 68 TABLE BLOCK 1 Inputs INP Analog X_IN Analog GAIN Analog TABLE 0 3 2 Outputs OUT Analog 4 113 Control Block Description ADDvantage 32 PLUS 3 Implementation The Table block is used to perform a non linear look up operation y f X_IN and output a value using the following formula OUT f X_IN x GAIN x INP Where Y is calculated as a function of X_IN by using the selected TABLE values A TABLE is defined as an array 2 x 16 in size of x y points where x values are entered in ascending order Refer to section 6 3 4 Tables Menu for additional explanation If X_IN is less than the first X value in the TABLE then f X_IN the first yo value If X IN is greater than the last X value in the TABLE then f X_IN the yis point If X IN equals an X value in the TABLE then f X IN the y value associated with that X point If X IN falls between two X values in the TABLE t
110. 11 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter RUNG 19 The motor field can be enabled disabled or switched on or off by a digital bit If the field is commanded then it stays picked up until D ARM ENABLE drops out Field loss is enabled whenever D FLD ENABLE is high or if Y FIELD CNTL is set to digital bit pee pLL BOOK PT D FLD ENABLE pore ARM ENABLE FLD ENABLE hu Na y x FIELD CNTL Q ENABLED DCAFMRISLAN FIELD CN TL Doer 39 k RUNG 20 Field loss protection is enabled in the following two sequences If Y FIELD CNTL is set to Q ENABLED and the field voltage reference Y FLD V_CMD is configured to the output of the field current loop A VFLD CMD If Y FIELD CNTL is set to a digital bit then field loss is enabled at any time the armature SCR s are enabled Y FIELD CNTL Q ENABLED Y FLD V CMD A VFLD CMD FIELD LOSS ENABLE Y FIELD D SCR ENABLE DCAFMR2 LAN Figure 3 1 ADDvantage 32 PLUS Logic Diagram sheet 8 of 14 3 12 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter RUNG 21 Lights the amber forward bridge LED D ARM ENABLE D FWD BR ACT D FWD BR LED DCAFMR2ILAN RUNG 22 Lights the amber reverse bridge LED D ARM ENABLE D REV BR ACT REV BR LED JCAFMR22LAN RUNG 23 Lights
111. 12 13 14 15 16 17 18 19 20 21 22 Remove power from the unit Open front cover Remove system interconnections J7 J8 J9 from the microprocessor board shown in Figure 7 1 Close cover and open base assembly door Remove all cables from bridge interface board Remove ground wire from door Remove door with microprocessor board from the base assembly Release two captive screws holding bridge interface assembly to the chassis Swing assembly out on its hinges Remove ground wire from bridge interface assembly Remove snubber cable connector J1 located on back of bridge interface assembly Slide bridge interface assembly up and off of hinges Remove high voltage wiring at L1 L2 L3 Al A2 and Remove wiring from TB1 and GND Detach unit from panel Mount spare base assembly to panel using existing hardware Reattach wiring to and GND Reapply high voltage wiring Slide bridge interface assembly onto its hinges Replace ground wire on bridge interface assembly Attach snubber cable at J1 on back of bridge interface assembly Tighten two captive screws holding bridge interface assembly to base Slide door on the base assembly 7 25 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter 23 Replace ground wire on door 24 Attach all seven bridge interface cables and shut door 25 Open cover and attach J7 J8 J9 to microprocessor board 26 Verify all connecti
112. 14 will result in the file being saved in the ADD 32 PLUS DRIVE022 696002 V 14 directory NOTES A calibration file that has been saved using the USB CAL STORE mode may only be loaded by the drive via the USB memory stick The calibration file will not be able to be read by the ADDAPT 2000 program The drive will not overwrite an existing file A unique file name must be selected each time a USB CAL STORE operation is initiated 11 20 USB Usage ADDvantage 32 PLUS e AC to DC Power Converter The maximum number of files that may exist in a subdirectory is 100 files Any attempt to store a calibration configuration file to a directory that contains 100 files or more will result in an error and the file will not be saved 11 6 1 CAL STORE COMPLETION MESSAGES After the user has initiated the operation to save calibration and configuration data to the USB memory stick one of the following messages will be displayed Message Meaning CAL STORED The operation is completed successfully CAL STORE ERROR An internal software error is detected during a CAL STORE operation If the file exists on the USB memory stick it should be considered invalid CAL STORE CANCEL The CAL STORE operation is aborted by the user and no file is written NO USB DEV PRSNT No USB memory stick is detected in the drive FILE EXISTS The specified cal file already exists and no file is written 11 21 Upgrade to New Control Board ADDv
113. 3 Implementation When RES is high or on power up the outputs 0 When not RES the following occurs The outputs do not change until the number of winder revolutions equals WRAPS 1 winder revolution PPR amount of change in the CNT value When this occurs the following calculations are done DIA DIA at start of wraps count thick DIA DIA 2 x WRAPS DEN WGHTYthick ADIA DIA DIA 2 The outputs do not change until the next time the number of winder evolutions equals WRAPS or a RES occurs 4 39 Control Block Description ADDvantage 32 PLUS 4 27 DERIVATIVE GAIN D DT The D DT block performs a derivative gain function It can be used for inertia compensation GAIN OUT FIGURE 4 27 DERIVATIVE GAIN BLOCK 1 Inputs INP Analog GAIN Analog LP Analog 2 Outputs OUT Analog 3 Implementation INP goes through a third order low pass filter with time constant LP in seconds This filters amplification of high frequency bounce OUT Rate of change of filtered INP x GAIN 4 40 Control Block Description 4 28 DIFF TRIP ADDvantage 32 PLUS This block is a combination differential comparator and timer It is used to detect alarm or fault conditions INPA OUT COUNTER AB T gt LMT NTUP INPB S OUT COUNTU ON TRP ABS OUT sLMT RESET i LIMIT LMT TICS DIFFTRIPLAN FIGURE 4 28 DIFF TRIP BLOCK 1 Inputs INPA Analog
114. 324455 300A 500V 324456 400A 500V 324457 500A 500V 324458 600A 500V 324492 WARNING REPLACE FUSES WITH FUSE OF SAME TYPE AND RATING IMPROPER FUSE REPLACEMENT MAY RESULT IN DAMAGE TO THE ADDvantage 32 PLUS A FIRE HAZARD AND SEVERE INJURY OR DEATH TO PERSONNEL 7 52 F11 RATING P N 50A 700V 324441 50A 700V 324441 80A 700V 324443 200A 700V 324459 300A 700V 324447 400A 700V 324460 500A 700V 324461 700A 700V 324704 Maintenance and Troubleshooting DRIVE RATING 550 ADC Armature 12 ADC Field 550 ADC Armature 24 ADC Field 550 ADC Armature 48 ADC Field F1 F2 RATING P N 60A 700V 324730 60A 700V 324730 60A 700V 324730 ADDvantage 32 PLUS e AC to DC Power Converter TABLE 7 8b FUSE REPLACEMENT GUIDE 550 ADC F3 F4 RATING P N F5 RATING P N 8A 250 VAC 324199 8A 250 VAC 324199 8A 250 VAC 324199 F6 RATING P N 1A 250 VAC 324195 1A 250 VAC 324195 1A 250 VAC 324195 F7 F8 F9 F10 RATING RATING P N P N 1 25A 250 VAC 324397 1 25A 630A 250 VAC 700V 324397 324808 1 25A 630A 250 VAC 700V 324397 324808 F11 RATING P N 700A 1200V 324807 700A 1200V 324807 F12 F13 RATING RATING P N P N 3A 250V 324451 3A 3A 250V 250V 324451 324451 3A 3A 250V 250V 324451 324451 If un
115. 4 105 Control Block Description ADDvantage 32 PLUS 2 Outputs OUT Analog DIF Analog MAX Bit MIN Bit 3 Implementation When the INC bit is high the OUT value starts to ramp up at INCR rate INCR is a rate entered in process units per second The ramp continues until the INCR bit goes low or the OUT value reaches a limit Upon reaching the limit the MAX bit goes high and stays high until the OUT value goes below the limit The limit is defined as follows If the ABS bit is low the OUT value clamps at MAXL x REF If the ABS bit is high the OUT value clamps at MAXL REF The DEC DECR and MIN operate in the same manner as the INC functions If the UP input is high and REF changes OUT will reset to equal REF and the INC DEC changes will be negated If the UP input is low and REF changes OUT changes depending on the ABS input If the ABS bit is low the OUT value changes by the REF value multiplied by the ratio of the INC DEC change Example ABS BIT LOW REF equals 100 and the INC bit is set high until OUT is increased to 150 Then if REF is changed to 200 OUT will equal 300 150 100 x 200 300 If the ABS bit is high the OUT value changes by the REF plus the INC DEC change Example ABS BIT HIGH REF equals 100 and the INC bit is set high until OUT is increased to 150 Then if REF is changed to 200 OUT will equal 250 150 100 200 250 4 106 Control Block Description ADDvantage 32 PLUS
116. 5 0 0 0 These addresses use 7 bits for the lt network gt and 24 bits for the lt host gt portion of the IP address This allows for 27 2 126 networks each with 224 2 16777214 hosts a total of over 2 billion addresses e Loopback The class A network 127 0 0 0 is defined as the loopback network Addresses from that network are assigned to interfaces that process data within the local system These loopback interfaces do not access a physical network 8 29 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS Class addresses 128 x x x to 191 x x x subnet mask 255 255 0 0 These addresses use 14 bits for the lt network gt and 16 bits for the lt host gt portion of the IP address This allows for 214 2 16382 networks each with 216 2 65534 hosts a total of over 1 billion addresses Class C addresses 192 x x x to 223 x x x subnet mask 255 255 255 0 These addresses use 21 bits for the lt network gt and 8 bits for the lt host gt portion of the IP address That allows for 221 2 2097150 networks each with 28 2 254 hosts a total of over half a billion addresses e Class D addresses 224 x x x to 239 These addresses are reserved for multicasting a type of broadcasting but in a limited area and only to hosts using the same class D address Class E addresses 240 x x x to 245 x x x These addresses are reserved for future use 8 9 3 2 Broadcast Addressing An address with all bits one is int
117. 52 Thestatus of channel 1 Data file 56 File53 The status of channel 2 Data file 57 54 The status of channel 3 Data file 58 File55 The status of channel 4 Data file 59 Each of the four status files are organized as a collection of integers and floating point data elements 52 DIAGNOSTIC 2 I RO STATUS CHAN 1 53 DIAGNOSTIC 2 I RO STATUS CHAN 2 54 DIAGNOSTIC 2 I RO STATUS CHAN 3 35 DIAGNOSTIC 2 I RO STATUS CHAN 4 9 3 45 FILES 56 THROUGH 59 DIAGNOSTIC TRACE DATA TABLES 56 DIAGNOSTIC 4 FP RO TRACE DATA CHAN 1 57 DIAGNOSTIC 4 FP RO TRACE DATA CHAN 2 58 DIAGNOSTIC 4 FP RO TRACE DATA CHAN 3 39 DIAGNOSTIC 4 FP RO TRACE DATA CHAN 4 9 3 46 FILE 60 FAULT TABLE This file contains the drive fault FIFO and is organized as 16 short integer elements Each element may contain one fault value detected by the drive 60 RETURN FAULTS 2 I RO 9 16 System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter Each table element is defined as follows bit 15141312 11 10 09 08 07 06 05 04 03 02 01 00 Type Index Value The upper four bits define the type assigned while the lower 12 bits define the index into the table defined by the type For example if the type bits were 00 then the index value would be the offset into the Select List table The defined types and tables are as follows TYPE TABLE Select List Analog Data Table Digital Data Table Drive Calibration Control Cali
118. 575 VAC 3 PHASE possesses Eee MOTOR ARMATURE CR4 CRI F INTERNAL s LINE MOTOR FIELD 115 VAC dp DOK ul 1 NEUT a AC CONTACTOR COIL 1 x LINE me ESIP L ny i Pd ur E STOP IN E S10 M CONTACTOR O mux CATE C46 DOK OUT Roy 24 V OUT L_ 4 DOK Figure 6 2B Block Diagram Power Connections 110 ADC Used Only on DC0110 4 LO C External DC Contactor 6 13 Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter AC LINE 230 460 575 VAC 3 5 m Af MOTOR ARMATURE L7 n 13 eget FIELD F5 X F12 H cor Hi F6 F13 INTERNAL 5 Le 1 7 7 115 VAC a NEUTRAL TB1 T a DOK SEEK M DOK NEUT con CRO n LINE 52 mE 15 CONTACTOR MAUX cat 21 E ESTP tt m a tr ey m O E STOP IN F M CONTACTOR MAUX GATE Otc DOK OUT O 24 V DOK OUT UL OH DOK lt 550POWERSCAN Figure 6 3 Block Diagram Power Connections 550 ADC 6 14 Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter AC LINE 240 480 VAC 3 PHASE etl ui PRETENDEN TO FIELD BRIDGE coon cosh ot data thas eau am AT E 9 MOTOR ARMATURE CABLE ASSY P N B21317 1 TO FIELD SUPPLY ASSY CABLE ASSY P N B21317 1
119. 9pppp Vnn directory use UP and DOWN keys to scroll through the files Again note that only the first 11 characters of the file are shown in the display If two or more files exist in the directory that share the same 11 characters in the first part of their file names the user will be unable to distinguish one from the other when viewing the file names on the display Once the desired calibration configuration file has been located and is displayed the user then presses the ENTER key The display then shows USB CAL LOAD e ITE Pressing the UP key will confirm that the selected calibration configuration data load should be performed NOTES The drive will not allow a USB CAL LOAD when the run is active After performing the USB CAL LOAD a drive reset is required to ensure the drive is using the updated calibration and configuration data The first 11 characters of the calibration file name should be unique to ensure that the files can be distinguished from each other on the drive display 11 18 USB Usage ADDvantage 32 PLUS e AC to DC Power Converter A calibration file that has been saved using the ADDAPT program can be loaded by the drive via the USB memory stick Any calibration file that has been saved in the ADDAPT program will be loaded into the drive in its entirety The drive ignores the MARKED UNMARKED attribute of individual drive calibration and configuration parameters that ADDAPT include
120. A Phase B Phase C 8 Turn power off to drive Move clip lead from bus bar A1 to bus bar 2 BA2 by first removing all the cables on the bridge interface board 9 Reconnect cables on the Bridge interface board 10 Power up drive with run off Measure and record the AC volts between bus bar A2 and Phase A Phase B Phase C AP 7 29 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter PHASE A PHASE B PHASE C BAI SCRTEST1LAN Figure 7 7 SCR Module Layout The measured voltage that is significantly lower than all the others measured indicates a bad SCR and can be determined with the following table 2 Phase CR4 Phase B CR2 5 Phase CR3 CR6 Example Measured AC voltages snubber disconnected BAI BA2 Phase A 285 230 Phase B 150 250 Phase C 327 243 The above table indicates CR2 is leaky NOTE 7 30 7 7 Maintenance Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter IF THE SNUBBER IS NOT DISCONNECTED THE VOLTAGE DIFFERENCE MAY BE VERY SMALL Leaky SCRs on older style drives may require burden resistors There are RESISTOR MODIFICATION KITS which are used as a burden on systems that have leaky SCRs The resistors are standard now on newer drives but on older drives may need to be added There are two different kits the only differences being in the lugs provided The resistors are 25K ohms 50W and are connected across
121. A RO CO000 C 19 CONTROL CAL HIGH LIMITS 4 FP RO CO000 C 20 CONTROL CAL LOW LIMITS 4 FP RO C000 C 21 CONTROL CAL DEFAULTS 4 FP RO CO000 C 22 CONTROL CONFIG LEGALS 2 I RO PO00 P 23 CONTROL CONFIG LABELS 11 A RO PO00 P 24 CONTROL CAL UNITS 6 A R W CO000 C 25 CONTROL CONFIG 2 I R W N A 26 DEFAULT CONTROL CAL UNIT 6 A RO CO000 C 27 CONTROL CAL 4 FP R W CO000 C 28 DIGITAL I O 2 I R W D000 D 29 DDT LABELS 11 A RO D000 D 30 DRIVE CAL LABELS 11 A RO X000 X 31 DRIVE CAL UNITS 6 A RO X000 X 32 DRIVE CAL HIGH LIMITS 4 FP RO X000 X 33 DRIVE CAL LOW LIMITS 4 FP RO X000 X 34 DRIVE CAL DEFAULTS 4 FP RO X000 X 35 DRIVE CONFIG LABEL 11 A RO Y000 Y 36 DRIVE CONFIG LEGALS 2 I RO Y000 Y 37 DRIVE CONFIG 2 I RO Y000 Y 38 DRIVE CAL 4 FP R W X000 X 39 SELECT LIST 11 A RO N A 40 CHECK SUM 4 LI RO N A 41 CAL VERSION 2 42 DRIVE SOFTWARE AND VERSION 2 I RO N A NUMBER 43 TIME ARRAY LI R W N A 44 ANALYZER CAL LABELS A RO Z002 Z006 Z102 Z106 7202 7206 7302 7306 45 ANALYZER CAL HIGH LIM FP RO N A 46 ANALYZER CAL LOW LIMITS FP RO N A 47 ANALYZER CAL DEFAULTS FP RO N A 48 ANALYZER CAL FP R W N A 9 3 System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter TABLE 9 1 DATA FILES Cont Structure File Table Bytes Data Data Number Name Element Type Mode 49 ANALYZER CONFIG PROMPT A RO Z002 Z006 7102 7106
122. A101 A106 If the fuse assemblies are equipped with indicator switches disconnect the wiring from these first Remove the bolts that attach both the top and bottom of the fuse assembly bus links to the AC bus bars and thyristor modules NOTE Remove the fuses as an assembly complete with their attached bus work and indicator switches if so equipped Slide the module forward and lift out Modules A107 A112 Remove the bolts that attach the thyristor module to the bus work on the left and right sides Slide the module forward and lift out 7 43 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter 7 10 1 2 Reassembly NOTE Conical washers are included in the mounting hardware for thyristor and fuse replacement Washers must be installed correctly for proper holding pressure See Figure 7 10 K K K K K K KKK K CAUTION IMPROPER MOUNTING OF CONICAL WASHERS COULD RESULT IN DRIVE FAILURE EE E K E E E E E E SS 2 N N N N N of X Li Pd bs N N Em N S 7 CONICAL CONICAL CONICAL CONICAL WASHER WASHER WASHER WASHER CORRECT INCORRECT Figure 7 10 Conical Washer Installation 1 Slide new thyristor module into drive 2 Reverse the disassembly procedure Use the following table to determine ti
123. ADDvantage 32 PLUS AC TO DC POWER CONVERTER For Use With Software Part Number 696xxx 2011 Avtron Industrial Automation Inc October 1 2011 Cleveland Ohio PROPRIETARY NOTE This document contains information PROPRIETARY to Avtron Industrial Automation Inc It is furnished solely to provide information sufficient for instruction operation maintenance evaluation and testing of the equipment herein disclosed is not to be used for manufacturing or procurement and is not to be disclosed to anyone other than persons in the Division or the Company or the Government as the case may be responsible for action relating to this document without the express written permission of Avtron Industrial Automation Inc WARRANTY The last page of this document contains an express limited warranty The provisions of this watranty cover any and all rights extended to holders of Avtron Industrial Automation Inc equipment Created October 2011 ADDvantage 32 PLUS AC TO DC POWER CONVERTER TABLE OF CONTENTS Section Page SAFETY SUMMARY ii I INTRODUCTION AND GENERAL INFORMATION 1 1 II KEYBOARD AND PARAMETER FUNCTIONS 2 1 III CORE SOFTWARE OPERATION 3 1 IV CONTROL BLOCK DESCRIPTION 4 1 V SIGNAL ANALYZER 5 1 VI PREPARATION FOR USE 6 1 VII MAINTENANCE AND TROUBLESHOOTING 7 1 VIII IEEE 802 3 ETHERNET COMMUNICATION 8 1 Ix SYSTEM DATA STRUCTURES 9 1 X SERIAL LINK INSTALLATION AND TROUBLESHOOTING 10 1 XI USB USAGE 11 1 XII UPGRADE TO NEW CONT
124. Available on 540 850 1550 and 3000 ADC Advanced Firing Modules AFM SELECTION 0 1 ON tA IHR OPTION 1 DESCRIPTION 12 Amp Field 24 Amp Field 48 Amp Field 6 Amp Field 12 Amp Field 4 SCR 24 Amp Field 4 SCR 48 Amp Field 4 SCR On AFM systems this block identifies a customer specific application SELECTION 0 L N DESCRIPTION Non listed UL Listed Modular design used in conjunction with Options 0 2 and 3 of Option 2 When specifying this feature Option 2 must also be specified It can only be specified on units rated 10 through 510 and 550 ADC 4 SCR Field Supply Available on 540 850 1550 and 3000 ADC power converters 1 28 1 4 2 Introduction and General Information OPTION 2 ADDvantage 32 PLUS e AC to DC Power Converter On AFM systems this block identifies a customer specific application SELECTION 0 1 DESCRIPTION Right side AC input 540 850 1550 and 3000 ADC Left side AC input 540 850 1550 and 3000 ADC Specified with Option N of Option with no contactor provided Specified with Option N of Option for a contactor without DB pole Specified with Option N of Option 1 for a contactor with DB pole Only available on units rated 10 through 510 ADC and 550 ADC SOFTWARE PART NUMBER BREAKDOWN The software part number is a six digit number which represents the application software installed in the ADDvantage 32 PLUS Sever
125. B TYPE Y FLD V CMD X MAX FLD ALP X MIN FLD ALP X FLD TX RAT X FLD LOSS X FLD PHASE X FLD PGAIN X FLD IGAIN Select to the hardware supplied either two or four SCR field bridge Standard is two SCR bridge Defaulted to be the output of the field current loop If field voltage control is desired reconfigure this to a field voltage reference Note field loss protection is disabled as soon as this is changed from default Set to the maximum allowable angle at which the field SCR s can fire This parameter should never be changed without first consulting the factory Set to the minimum allowable angle at which the field SCR s can fire This parameter should never be changed without first consulting the factory Set to the ratio of the field supply input voltage vs the armature supply input voltage Used if a step down transformer is needed to feed the field supply Set to the percentage of full field current used to trip the drive out on field loss fault Defaulted to 25 of full rating Degree out of phase the field voltage is from the armature Consult Avtron Industrial Automation Inc if the field is supplied from a separate source Proportional gain constant for the field current loop Default is adequate for most motors Integral gain constant for the field current loop Default is adequate for most motors Gain is entered in seconds per repeat 3 35 Cor
126. B20726 1 are installed into connectors on the printed circuit board 12 12 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter 8 Reinstall all field wiring connectors that were removed in step 3 as shown below in Figure 12 9 ETHERNET CONNECTIONS cS CONNECTOR J7 FIELD WIRIN 3 Bea c lo X ON 1 CONNECTOR i EP 5 7 ane J8 1111 FIELD WIRING ON CONNECTOR PN T unus AO Ae 11 1141 11 FAX 32 CONNECTOR Figure 12 9 The field wiring to be reconnected are shown in this ADDvantage 32 PLUS electronics enclosure image 12 13 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter 10 11 12 13 14 Upgrade the ADDvantage 32 drive calibration and configuration file that was saved in step 1 to begin using ADD 32 PLUS files Refer to the section on software conversion below for instructions on the upgrade procedure Turn on power to the ADDvantage32 PLUS drive After the drive has completed initialization download the drive calibration and configuration file that was upgraded in step 9 The ADDAPT maintenance tool may be used to download the file via Ethernet or the calibration file may be placed on a USB memory stick and downloaded For instructions using the USB memory stick see chapter 11 Reset the drive by cycling power after the calibration and configuration data has been loaded into the drive The drive is now re
127. BLOCK NEG input high by configuring P BLOCK NEG B ONE BIT The NEG LIM output will equal zero when BLOCK NEG is set high If BLOCK NEG is set low zero bit NEG LIM output will equal the negative of the smallest value between NEG I input the output of the I2R Trip table or the SFDBK table 4 34 ADDvantage 32 PLUS Control Block Description WIT SAN Ag O3N 30018 vas v 138 1H3ANI NIM 1no 100 jogas SdNI ino 1 V3l yani 100 199135 ANI SOIWNY SdNI 0 L 095 GdS v3ug8 wn 5 GdSW adsa X ee S S H3d LYVLS 104136 al 10313S NIM SOTWNY 1no no VdNI 1no d 1Sv31 NIT I 50 138 vis VdN SOd 2018 NVILIAFTHOO GNA Yad 1915 A8 FIGURE 4 23 CURRENT LIMIT BLOCK DIAGRAM 4 35 Control Block Description 4 24 DEADBAND ADDvantage 32 PLUS A Deadband block is used to reset an analog signal to zero when it is less than a user selected value REF DBAND DBAND DEADBANDLAN FIGURE 4 24 DEADBAND BLOCK 1 Inputs REF Analog DBAND Analog 2 Outputs OUT Analog 3 Implementation If DBAND lt REF lt DBAND then OUT 0 else OUT REF 4 36
128. Below K K K K K K K KKK WARNING HAZARDOUS VOLTAGES WHICH CAN CAUSE SEVERE INJURY OR DEATH ARE PRESENT DURING THE OPERATION OF THIS EQUIPMENT TURN OFF AND LOCK OUT ALL SOURCES OF POWER BEFORE MAKING ANY REPAIRS E E E KE E K E K K K K K K K K K K KKK TABLE 7 5 SPECIAL TOOLS REQUIRED USED ON QTY DESCRIPTION DRIVE SIZES 1 1 4 Drive Torque Wrench 0 75 in Ib ALL 1 5 32 Hex Head Socket with Allen wrench insert bit 1 4 drive ALL 1 Hex Head Socket with 2 Phillips screwdriver insert bit DC0010 DC0030 1 4 drive DC0056 DC0110 1 Hex Head Socket with 3 Phillips screwdriver insert bit DC0180 0 0280 1 4 drive DC0360 DC0510 1 1 2 Hex Head Socket 1 4 drive DC0280 DC0360 DC0510 1 Thermally Conductive Compound Avtron P N 950010 ALL 1 2 Phillips screwdriver ALL 7 8 1 REPLACING THE POWER THYRISTOR CR1 6 FIELD THYRISTOR CR7 AND FIELD DIODE 8 7 8 1 1 Disassembly 1 Remove all sources of power from the unit 2 Remove microprocessor board per section 7 4 steps through 7 3 Remove bridge interface board per section 7 4 steps 8 through 11 4 Remove the twisted pairs of wires from gate leads of thyristor to be replaced 7 33 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter NOTE Each pair of wires is labeled with a single letter corresponding to a letter silkscreened on the base 5 Refer
129. C to DC Power Converter USB SIGNAL ANALYZER STORE The ADDvantage 32 PLUS drive allows the user to save drive SIGNAL ANALYZER data to an installed USB memory stick To perform a store of signal analyzer data to the USB memory stick navigate the USB submenu until reaching the ANALYZR STORE option as shown below Ue wl Ales Desa Pressing the right arrow will show USB ANALYZR STORE FILE DRIVE NN The second line of the LCD display indicates a file name to which the signal analyzer information will be stored The drive automatically generates the file name and there is no provision to allow the user to edit the file name Pressing ENTER will initiate the storing of any signal analyzer channels that have completed data collection When files are stored on the USB memory stick they will be placed in the ADD 32 PLUS DRIVE SIGNAL directory Note that represents the drive ID as set by jumpers on connector J8 The drive will automatically create the directory structure on the first analyzer store operation if the directory does not already exist The drive creates the name of the file or files to which the signal analyzer data is stored The file naming convention is shown in the following figure USB Usage ADDvantage 32 PLUS e AC to DC Power Converter DRIVE001 01 CHL ALZ SIGNAL ANALYZER CHANNEL NUMBER A single digit in the range of 1 8 SIGNAL ANALYZER STORAGE SEQUENCE NUMBER Two digits in the range of 00 99
130. CD from DCE to DTE Control Secondary CTS from DCE to DTE Control Secondary transmit data from DTE to DCE Timing Transmit on signal element timing from DCE to DTE Control Secondary receive data from DCE to DTE Timing Received signal element timing from DCE to DTE Not assigned NA Control Secondary RTS from DTE to DCE Control Data terminal ready DTR from DTE to DCE Control Signal quality detector from DCE to DTE Control Ring indicator RI modem from DCE to DTE Timing Data signal rate selector either Timing Transmission signal element timing from DTE to DCE Not assigned NA 10 6 Serial Link Installation and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter TABLE 10 2 PROBLEMS WITH THE SERIAL LINK SYMPTOM PROBLEM SOLUTION Xmit light on 485 card does not blink 6 times while ADDapt attempts to connect Xmit light on 485 card is on all the time Xmit light on 485 card flashes 6 times but does not connect ADDapt will not link reliably and or loses the link spontaneously Computer 485 card configuration is not compatible To fix see 485 card instructions and computer setup instructions The 485 card must have its CTS DISABLED An internal 485 card must have its defined COM port usually a jumper on the card DISABLED in the computer s setup For an external 485 card the computer must have its serial port ENABLED The proper COM port must be defined in CONFIG also Check receive wires to J8
131. D USER 3 D USER 4 D USER 5 D USER 6 D NOT USER 1 D NOT USER 2 D NOT USER 3 D NOT USER 4 D NOT USER 5 3 4 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter D NOT USER 6 Y Parameters D Parameters D TARM MIN PT D A MIN DELY D SCR ENABLE D TA SEAL D REV LOCKOUT D ONE BIT D ZERO BIT 3 6 DRIVE SEQUENCE RUNG DESCRIPTIONS Figure 3 1 on the following 15 pages is a ladder logic diagram of the internal interlocks for the core software These rungs determine when specific features are enabled and disabled D parameters listed are values found in the digital data table See Section II and Appendix C for parameter explanations Figure 3 1 applies only to AC to DC Converter software part number 696xxx RUNG 1 Any fault that shuts down the drive picks up this fault bit The bit seals itself in until CLEAR FAULT goes high There are eight user definable faults available Y USR FAULT 1 through Y USR FAULT 8 CLEAR FAULT Dex yr FAULT R PSE TE ANY DRIVE FAULT OR USER FAULT 21 DCAFMRILAN Figure 3 1 ADDvantage 32 PLUS Logic Diagram sheet 1 of 14 3 5 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter RUNG 2 The drive OK output drops out when the D FAULT bit goes high D FAULT D DOK _OUT J X DCAFMR2LAN
132. DDvantage 32 PLUS e AC to DC Power Converter 7 12 THYRISTOR MODULE COOLING BLOWER REPLACEMENT 550 ADC 1 Remove power from the unit 2 Open main drive door 3 Refer to Figure 7 3 Remove the panel with the circular grill by removing eight Phillips head screws The inlet ring is also attached to this panel 4 With a long nut driver remove the four 10 24 self locking nuts that hold the blower support and blower to the base 5 With the blower partially removed reach under the chassis and disconnect the power cable connector from J100 The blower can now be removed 6 Separate the blower support from the blower by removing four M6x12 screws 7 Reverse the above steps to install the new blower 7 58 8 1 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS SECTION VIII IEEE 802 3 ETHERNET COMMUNICATION OVERVIEW The Avtron ADDvantage 32 PLUS DC supports an 802 3 Ethernet star structured network The ADDvantage 32 PLUS supports both 100 base FX Fiber Optic and 10 100 base UTP Copper Ethernet media The Avtron Ethernet network is implemented using an Avtron ESBX Ethernet board P N A26494 that can provide 100 Mbaud fiber full duplex IEEE 802 3 Ethernet communications One ESBX board is required for each ADDvantage 32 PLUS drive The ESBX board includes firmware to implement Ethernet protocols for GE Modicon and Rockwell PLC interfaces In addition the firmware includes Avtron s proprietary communications protoco
133. Data file 74 File71 The status of channel 2 Data file 75 File72 The status of channel 3 Data file 76 File73 The status of channel 4 Data file 77 Each of the four status files are organized as a collection of integers and floating point data elements 70 DIAGNOSTIC 2 1 RO STATUS CHAN 1 71 DIAGNOSTIC 2 I RO STATUS CHAN 2 72 DIAGNOSTIC 2 I RO STATUS CHAN 3 73 DIAGNOSTIC 2 I RO STATUS CHAN 4 9 18 System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter 9 3 52 FILES 74 THROUGH 77 DIAGNOSTIC TRACE DATA TABLES 74 DIAGNOSTIC 4 FP RO TRACE DATA CHAN 1 75 DIAGNOSTIC 4 FP RO TRACE DATA CHAN 2 76 DIAGNOSTIC 4 FP RO TRACE DATA CHAN 3 77 DIAGNOSTIC 4 FP RO TRACE DATA CHAN 4 9 19 System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter 9 20 Serial Link Installation and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter SECTION X SERIAL LINK INSTALLATION AND TROUBLESHOOTING This section contains drawings and tables useful when installing and troubleshooting a serial link Drawing B35141 sheets 1 2 and 3 show ADD 32 PLUS serial link wiring Table 10 1 provides a list of RS232 pin assignments for connectors DB9 and DB25 Table 10 2 provides a list of potential problems along with possible causes and remedies SERIAL DATA FORMAT 1 One Start Bit logic level low 2 Eight Data Bits least significant bit first Bit 0 3 One Parity Bit ev
134. Dvantage 32 PLUS e AC to DC Power Converter 9 3 21 9 3 22 9 3 23 LEAST SIGNIFICANT BYTE MOST SIGNIFICANT BYTE FIRST ELEMENT 0 0 1 0 1 0 9041 0001 D007 FWD BR ACT 0008 D005 D004 E D003 D002 MAX A ALPHA D001 D000 D015 FLD OK PT D014 D013 D012 D011 SPD MIN PT Roto D009 D008 FILE28LAN The illustrated example for File 28 shows that the Forward Bridge is active and maximum firing angle has been reached Additionally the motor field feedback is within the 10 setpoint and the drive is configured for the contactor to remain sealed upon RUN removal until ZERO SPEED FILE 29 DDT LABELS This file contains all predefined label definitions for the digital data table One element is used to produce one label For example First element MAX A ALPHA spaces are shown as Next element MIN A ALPHA FILE 30 DRIVE CAL LABELS This file contains all predefined label definitions for the drive calibration One element is used to produce one label For example First element V REF Next element MOTOR IARM FILE 31 DRIVE CAL UNITS This file contains the units associated with each of the labels defined in Table 30 for drive 9 0 System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter 9 3 24 9 3 25 9 3 26 calibration One element is used to define the units for the associated label
135. Dvantage 32 PLUS e AC to DC Power Converter ADDvantage 32 PLUS faults out and a message is stored in the FAULT FIFO The ADDvantage 32 PLUS must be reset before operating again For example two of the most common user faults are overspeed and tach loss conditions To set up the ADDvantage 32 PLUS to fault on these two conditions perform the following 1 Find D OVER SPEED and D TACH LOSS the two parameters in the digital data table that represent overspeed and tach loss 2 Configure D OVER SPEED to Y USR FAULT 1 Configure D TACH LOSS to Y USR FAULT 2 When either one of these conditions occurs the ADDvantage 32 PLUS faults out MOTOR PARAMETERS X Parameters Y Parameters A Parameters MOTOR Y FIELD CNTRL A FIL ARM CUR X MOTOR IFLD A ARM CURRNT X MFLD SCALE ARM CURRENT X MFLD ASCALE A FLD CURRENT X FLD RESIST A FLD CURRNT A MOTOR Motor parameters are used to determine the amount of armature and field current being supplied to the motor The ADDvantage 32 PLUS current is scaled to the motor current using the following equations t x MOTOR IARM Rated Motor Armature Curren x 100 Rated ADDvantage32 PLUS Current x MOTOR IFLD Rated Motor Field Current x 100 Rated ADDvantage32 PLUS Current Y FIELD CNTRL Enables the field bridge If an external field supply is used disable this function 3 26 Core Software O
136. E d h m s 0 00 00 00 FAULTSTATUS DRIVE NOT FAULTED FAULT FIFO newest at top FLTCLEARED SWR WICHdog CNTL POWER FLTCLEARED SWR WICHdog FLTCLEARED SWR WICHdog CNTL POWER FLTCLEARED CNTL POWER FLTCLEARED ONE BIT FLTCLEARED PLLLOCK SWR WICHdog ONE BIT DRIVE WATCHDOG TIMERS Interproc COM WD 000 Tach Read WD 000 Enet COM WD 000 Link WD 000 Control WD 000 Backround WD 000 DRIVE STACK SIZES USRSTACK 11353 SVC STACK 10096 ABT STACK 10048 IRQ STACK 10147 UND STACK 10048 FIQSTACK 20032 ETHERNET DIAGNOSTIC STATISTICS AVTRON ADD32plus DRIVE INFORMATION FILE END Figure 11 6 An example of the DRIVE INFORMATION store operation during which the drive saves a snapshot of relevant drive information 11 16 USB Usage ADDvantage 32 PLUS e AC to DC Power Converter 11 4 1 DRIVE INFORMATION STORE COMPLETION MESSAGES After the user has initiated the operation to save the drive information to the USB memory stick one of the following messages will be displayed to indicate the results of the requested operation Message Meaning DRIVE INFO SAVED The drive information successfully saved to the USB memory stick D INFO SAVE ERR An internal software error is detected during the writing of the drive information NO USB DEV PRSNT No USB memory stick is detectable in the drive 11 5 USB CALIBRATION CONFIGURATION LOAD The ADDvantage 32 PLUS drive allows the user to load the drive cal
137. ETAL SHAVINGS DO NOT DROP ONTO THE COMPONENTS AVTRON TAPES LARGE SHEETS OF PLASTIC TO THE PANEL AROUND THE COMPONENTS WHEN METAL SHAVINGS ARE LIKELY TO BE PRODUCED WE RECOMMEND THE SAME TO INSTALLERS OF OUR EQUIPMENT E E E E E E E E E E KE E KE E K E K E K K K K K K K KK KK TABLE 6 1 ADD 32 PLUS MECHANICAL SPECIFICATIONS DRIVE PART NUMBER WEIGHT HEIGHT WIDTH DEPTH DC0010 55 lbs 22 5 12 11 0 DC0030 55 lbs 22 5 12 11 0 DC0056 55 lbs 22 5 12 11 0 DC0110 85 lbs 28 19 11 75 DC0180 130 Ibs 31 16 16 0 DC0280 150 Ibs 34 5 18 17 25 DC0360 150 Ibs 34 5 18 17 25 DC0510 150 Ibs 34 5 18 17 25 DC055X 250 Ibs 43 56 21 12 18 25 DCXXXX FIELD CONTROLLER 35 lbs 17 5 12 9 6 DC054X ARMATURE BRIDGE 250 165 33 3 27 4 17 66 DC085X ARMATURE BRIDGE 250 Ibs 37 8 27 4 17 66 DC155X 2 ARMATURE BRIDGE 400 165 65 4 24 1 18 69 DC155X 4 ARMATURE BRIDGE 600 Ibs 65 4 24 1 18 69 DC155X A ARMATURE BRIDGE 575 165 66 5 26 0 19 50 DC155X B ARMATURE BRIDGE 750 Ibs 66 5 26 0 19 50 DC250X ARMATURE BRIDGE 1 400 165 67 1 38 7 23 00 DC300X A ARMATURE BRIDGE 1 050 165 67 1 38 7 23 00 DC300X B ARMATURE BRIDGE 1 400 165 67 1 38 7 23 00 Not including AC input power bus bars 6 3 6 4 6 5 6 6 Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter STORAGE AND INSTALLATION SPECIFICATIONS If the ADD 32 PLUS is to be stored for an extende
138. Event xx f Fault Event xx Left Right 0 oue gt Left Right gt lt lt event label gt gt i Left Right ddd hh mm ss Up Down Up Down Tables CLEAR Faults LEFT From the CLEAR Faults pressing the left key S gt Se will generate a fault reset to the drive Figure 2 21 This ADD 32 PLUS keypad syntax shows the FAULT FIFO submenu 2 30 ADDvantage 32 PLUS e AC to DC Power Converter 2 8 7 EDIT UNITS SUBMENU The EDIT UNITS submenu is shown in Figure 2 22 The figure shows a subsection of the TOP LEVEL menu on the left side and by pressing the RIGHT key the EDIT UNITS submenu is accessed USB Cntl Cal Units Edit the six character units field of the C gt gt Left Right calibration parameters Up Down Y Analog Units i RM NM Left Right Edit the six character units field of the A real time analog parameters Up Down Y Fault Fifo DOWN Figure 2 22 This ADD 32 PLUS keypad syntax shows the EDIT UNITS submenu The ADDvantage 32 PLUS allows the user to specify the units of measure associated with the real time analog data A and the block calibration data C Both the A and the C are presented in engineering units and both specify the units of measure on the LCD display The user is able to define the units of measure and change the value displayed Figure 2 23 shows the units field for a block calibration
139. F lt gt the polarity of TACH then tach failure will be detected regardless of whether the associated tach input is selected or not Therefore if CEMF feedback is used as the speed feedback TACH LOSS should not be configured to a USR FAULT Any time a tach failure is detected the associated WARN bit will turn on That is if a TACHI failure is detected the IWARN bit turns on if a TACH2 failure is detected the 2WARN bit is turned on If tach feedback is used SPDVOL high and if a tach failure is detected then the TACH SELECT block can be configured to automatically switch to the redundant tach or to control in CEMF The logic is described in Figure 4 68 and as follows If SPDVOL high and RED high then if a tach failure is detected the output will switch from the failed tach to the redundant tach For example if 1 OR 2 high and the TACHI input fails OUT will switch from TACHI x GAIN to TACH2 x GAIN If SPDVOL high and V RED high then if a tach failure is detected the output will switch from the failed tach feedback to CEMF feedback For example if 1 OR 2 high and the TACHI input fails OUT will switch from TACHI x GAIN to CEMF x GAIN If SPDVOL high and both RED and V RED high then if a tach failure occurs the TACH SELECT block will switch first to the redundant tach if the redundant tach fails the output will switch to CEMF feedback 4 117 Control Block Description ADDvantage 32 PLUS
140. Flexible or equivalent When axial endplay exceeds 0 020 use Thomas CCX or equivalent Do not use a helical spring type or rubber element type coupling 6 23 Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter SMARTach Alarm ADD 32 PLUS Drive P7 2 6 12 Vdc 15 Tach 1 12Vde 5 16 Tach 1 Com V OUT v 13 424 Vdc ALM 14 User 1 A AC Y Tach Com User Input v N User SMARTachLAN Figure 6 10 SMARTach Alarm Connections 6 24 Preparation for Use ADDvantage 32 PLUS AC to DC Power Converter 6 25 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter SECTION VII MAINTENANCE AND TROUBLESHOOTING K K K K K K KK KK WARNING THIS EQUIPMENT CONTAINS HAZARDOUS VOLTAGES AVOID LOSS OF LIFE SEVERE PERSONAL INJURY OR PROPERTY DAMAGE BY FOLLOWING THE INSTRUCTIONS CONTAINED IN THIS MANUAL THE CONTROLLER PANEL CONTAINS HAZARDOUS VOLTAGES WHEN THE MAIN DRIVE CONTACTOR IS OPEN THE POWER COMPONENTS BRIDGE INTERFACE SNUBBER FIRING AND VOLTAGE ISOLATION BOARDS HAVE CIRCUITS WHICH CONTAIN HAZARDOUS VOLTAGES TURN OFF AND LOCKOUT ALL POWER SOURCES AT THE FEEDER TO THE POWER CONVERTER BEFORE PERFORMING MAINTENANCE OR REPAIR BEWARE OF FOREIGN EXTERNAL POWER SOURCES WHICH
141. IM commands are being received by the ESBX module This indicates an application problem PPR Send Fail counter containing the number of failures returned by the PEER PRIM socket send operation Increments of this counter indicate a probable network configuration problem most likely related to the drive IP address subnet mask or gateway address PPR Xmit Fail counter containing the number of PEER PRIM RESPONSE frame transmit failures Increments of this counter could indicate a possible network configuration problem possibly related to the drive IP address subnet mask or gateway address or a software related problem 8 24 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS PPR No Reply counter containing the number of times the ADD 32 PLUS did not reply to PEER PRIMITIVE transaction initiated by the ESBX module Increments of this counter indicate that the ADD 32 PLUS may not be responding to the ESBX and may be the result of a hardware problem or a possible software problem Contact Engineering if this counter is incrementing QRY Frames the number of QUERY frames received by the module QRY Responses the number of QUERY RESPONSE frames generated by this drive Note that a response will be generated only if a QUERY frame is received and the DRIVE ID and MACHINE number of the drive fall within the range specified by the QUERY frame QRY Overrun counter containing the number of QUERY frames that were discarded due to an
142. L4 DGTL If line 4 display mode is set to DIGITAL this is the starting bit of 10 bits to display in a 0 1 format If line 4 mode is set to DIGITAL BIT then line 3 will show the label of the digital point and indicate ON or OFF Y065 ADD32 COMPT When set to DISABLE the signal analyzer will be able to collect a maximum of 8000 data points When set to ENABLE the operation of the signal analyzer will be restricted to collect a maximum of only 1000 points of data 12 15 12 2 12 2 1 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter ADDVANTAGE 32 TO ADDVANTAGE 32 PLUS CAL CONFIG UPGRADE In addition to upgrading the hardware of an ADDvantage 32 drive to convert it into an ADDvantage 32 PLUS drive the calibration and configuration files that had been saved also require an upgrade before they can be used in the ADDvantage 32 PLUS A software program Convert T oAdd32PLUS Avtron part number 686149 performs the upgrade processing the ADDvantage 32 calibration and configuration file into the format required for the ADDvantage 32 PLUS The software program ensures that all calibration and configuration data saved in the ADDvantage 32 file is fully compatible with and functions exactly like the ADDvantage 32 PLUS If the program detects an incompatibility then the file upgrade will not be performed and the user will be notified of the compatibility issue NOTE The ConvertToAdd32PLU
143. MIN bit 2 1 HIGH The Proportional error component is set so OUT will not exceed MINL If the Proportional Error 0 the Integral Error component will start to increase to keep OUT above the MINL limit 4 76 Control Block Description ADDvantage 32 PLUS If HOLD HIGH and PRE LOW then The Integral Error component is held at its present value until the HOLD input goes low The integrator hold input is used to hold the output value during major process disturbances If PRE HIGH then The Integral Error component is set to the PREL value and the Proportional Error component is set to zero so that OUT IERR PREL The IERR output is equal to the integrator component and can be used for diagnostic purposes 4 77 Control Block Description ADDvantage 32 PLUS 4 54 PROPORTIONAL AND INTEGRAL CONTROL WITH CASCADED HOLD BITS PD The PI2 block performs a proportional and integral gain function on an error signal It has inputs for maximum and minimum limits which prevent the loop from overcompensating as well as separate bits to hold the integrator in either the positive or negative direction only TS P ssa pP MAXL a N Pd MAX 534 y ee OUT ERR gt 0 MAX bd 1 MIN E RN MINL Ae u J gt a gt EA ERR 0 MIN ERR PREL PIBLOCK 1 Inputs ERR MAXL MI
144. NL PREL H UP H DN PRE PRE FIGURE 4 54 PI2 BLOCK Data Type Description Analog Input Signal Analog Proportional Gain Value Analog Integral Gain Value Analog Output High Limit Value Analog Output Low Limit Value Analog Integrator Preload Value Bit Integrator Positive Hold Enable Bit Integrator Negative Hold Enable Bit Integrator Preload Enable 4 78 Control Block Description ADDvantage 32 PLUS 2 Outputs Data Type Description OUT Analog Output Signal TERR Analog Integral Error Value MAX Bit Indication Output is Clamped at High Value MIN Bit Indication Output is Clamped at Low Value CMX Bit Indication Output is Clamped at High Value or is Being Held in the Positive Direction CMN Bit Indication Output is Clamped at Low Value or is Being Held in the Negative Direction 3 Implementation If H UP LOW H DN LOW and PRE LOW then OUT Proportional Integral error values of block where Proportional ERROR PERR ERR x P Integral Error IERR Old Integral Error Value Sample Time 1 Second Iis entered in seconds If I is entered at less than 0 001 seconds then I is set to zero The sample time is used to convert to the block execution rate where typically Armature Current Loop 2 77 msec Speed Loop 8 msec Tension Loop 16 msec If OUT gt MAXL The following sequence of events will occur The MAX bit 1 HIGH The Proportional Error is set so OUT will not exceed
145. NS E STOP RESET DOK RELAYS POWER SUPPLIES gm POWER SUPPLIES ARE SEPARATE 0 0005 SINGLE PHASE 15 FIELD FIRING GONNECTIONS FIELD GATE B ARMATURE BRIDGE 7 H FIELD SNUBBER CABLE CONNECTORS CAPACITORS NOT ON DC0003 DCD004 OR DCOD05 AFMS POWER RELAY NOT 0 0003 AFMS DC0002 DCOD04 amp a ra DC0005 AFMs ONLY FOURE 14 2 J3 J11 19 J10 SENSEIMEET A ery 2 AL 12 FIRING SIGNAL FIRING SIGNAL Figure 1 6 Bridge Interface Board A3 1 10 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter 1 2 5 SNUBBER PC BOARD 10 through 510 and 550 ADC Power Converters only The SNUBBER BOARD Figure 1 7 contains resistor capacitor circuits for protection of the SCR s They are placed on a board instead of across the SCR s so they are not misapplied when replacing an SCR In units rated 540 850 1550 and 3000 ADC the snubbers are mounted directly to the thyristor module assembly Figure 1 7 Snubber PC Board A4 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter 1 2 6 DRIVE BASE ASSEMBLY POWER CONVERTERS ONLY 10 THROUGH 510 and 550 ADC The DRIVE BASE ASSEMBLY Figure 1 8 on power converters rated 10 through 510 and 550 ADC contains all of the high voltage components Heat g
146. NVD101 FIGURE 4 6 8 BIT INVERT BLOCK 1 Inputs INP Digital 2 Outputs OUT Digital 3 Implementation If INP is high 1 then OUT will be low 0 If INP is low 0 then OUT will be high 1 The same occurs for the next seven input bits They are outputted to the next seven output addresses Control Block Description ADDvantage 32 PLUS 4 7 ABSOLUTE VALUE ABS The Absolute Value block selectively takes the absolute value of an analog variable The state of EN BIT determines if the OUT value equals INP or the absolute value of the INP value EN INP OUT ABSVALUELAN ABSOLUTE VALUE FIGURE 4 7 ABSOLUTE VALUE BLOCK Inputs INP Analog EN Bit Output OUT Analog Implementation If EN is low then OUT INP If EN is high then OUT the absolute value of INP 4 10 Control Block Description ADDvantage 32 PLUS 48 ANALOG INVERT The Invert block is used to invert the value of an analog signal EN INP OUT FIGURE 4 8 ANALOG INVERT BLOCK 1 Inputs INP Analog EN Bit 2 Outputs OUT Analog 3 Implementation If EN is low then OUT INP If EN is high then OUT INP Control Block Description ADDvantage 32 PLUS 49 ANALOG SELECT This block is used to select one of two different analog signal paths for example switching from field current reference to field economy reference SELA INPA OUT INPB ANALOG SELECT
147. No flash update performed gt gt LOAD FAILURE The flash load operation is cancelled if an internal software error is detected USB DIAGNOSTIC STORE The ADDvantage 32 PLUS drive provides the ability to store a file of internal diagnostic information to the USB memory stick The diagnostic information provides a history of key internal drive operating parameters and may be used by the factory to diagnose unusual problems or events To perform a USB flash load of drive firmware from the USB memory stick navigate the USB submenu until reaching the USB DGNOST STORE option as shown below USB DENG SS EE Pressing the RIGHT key at this point causes the drive to save internal operating and historical data to the USB memory stick When the store operation is completed a file named DIAGNOSTIC DAT will have been written to the ADD 32 PLUS DRIVE directory 11 13 USB Usage ADDvantage 32 PLUS e AC to DC Power Converter NOTES Each diagnostic store will overwrite the DIAGNOSTIC DAT data file on the USB memory stick so exercise care to only initiate the diagnostic store at the appropriate time after a drive fault has occurred and as directed by the factory Upon completion of the diagnostic store the drive will resume collecting diagnostic data When a fault is detected by the drive diagnostic data collection will again be suspended If the diagnostic store completes and the drive is faulted at that time the collection of da
148. Password for many Switches is User Name admin Password admin 8 6 8 6 1 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS Be aware that some Switches do not have an administrative account or may use a different User Name and Password than above See your Switch manual for specific technical information If the User Name and Password are changed from their factory default Avtron recommends using User Name avtron Password 64183 Once logged in via the provided serial cable an IP address can be assigned to the Switch such that the Web based configuration can be utilized Many Switch manufacturers allow creation of separate user accounts with different privilege levels In general the default Switch configuration settings are used The admin will usually always get you in After the initial setup of Switch IP Address via the serial cable the Switch can be accessed by typing the IP Address as the URL in Internet Explorer Switch ports labeled with an X are internally crossed over When connecting two devices a straight through cable is used if only one device has an X If both or neither device have an X a Crossover cable is required Your computer network port is not internally crossed over Straight through CATS cables are used to connect your ADDAPT computer X link PLC HMI Operator Displays Performance View etc to a Switch but not to each other Crossover cables are used to connect your computer directly to a PLC Xl
149. R Analog Outputs PR F Analog KN F Analog FIGURE 4 66 SPLICER BLOCK Pressure Roll Reaction Time Sec Knife Reaction Time Sec Tail Length Inches Gear Ratio for Oncoming Roll Tach PPR for Oncoming Roll Static Length Inches Oncoming Roll Diameter Inches Glue Line Angle Degrees Clearance Angle Degrees Speed Reference FPM Pressure Roll Pulse Count Preset Knife Pulse Count Preset 4 110 KNF Control Block Description ADDvantage 32 PLUS 3 Implementation K PPR GR RBS SPD R 5x ON DIA PPS K RPS ANGLE RPS PR T 360 TMP GL A ANGLE If TMP 0 1 TMP TMP 360 Else TMP TMP CL A PR F K Pressure Roll Firing Count TMP TMP TMP PPS PR T TMP TMP K 1 360 TMP TMP PPS KN T TMP K TAIL LGTH T ON DIA TMP TMP TMP2 If TMP lt 0 TMP TMP K PRF PRF K Else KNF TMP Knife Firing Count 4 111 Control Block Description ADDvantage 32 PLUS 4 67 SUMMING JUNCTION SELECTABLE 3 INPUT This block adds input signals such as speed reference and tension trim It selects which inputs to add using the bit select lines BIT1 BIT2 BIT3 INPA INPB OUT SUMMING3 FIGURE 4 67 SUMMING BLOCK 1 Inputs INPA Analog INPB Analog INPC Analog BITI Bit BIT2 Bit BIT3 Bit 2 Outputs OUT Analog 3 Implementation OUT INPA x BIT
150. ROL BOARD 12 1 SUPPLEMENTAL DATA ADDvantage 32 PLUS Appendices A thru D ADDvantage 32 PLUS Appendices F thru I Ethernet Communication Protocol Application Notes ADDvantage 32 PLUS Functional Block Diagram Engineering Notes 26 Analog Tach Information Engineering Note 30 SMARTach Application Examples Installation Instructions Avtron Rotary Pulse Generators Flash Upgrade Utility Operation Instructions Software Part Numbers A20227 1 and A20227 2 Safety Summary ADDvantage 32 PLUS e AC to DC Power Converter SAFETY SUMMARY K K K K K K K KKK WARNING HAZARDOUS VOLTAGES ARE USED IN THE OPERATION OF THIS EQUIPMENT AND MAY CAUSE SEVERE PERSONAL INJURY OR THE LOSS OF LIFE IF PROPER PRECAUTIONS ARE NOT TAKEN THE FOLLOWING PRECAUTIONS SHOULD BE TAKEN TO REDUCE THE RISK OF INJURY OR DEATH K K K K K K KK KK WARNING SEPARATE MOTOR OVERCURRENT OVERLOAD AND OVERHEATING PROTECTION IS REQUIRED TO BE PROVIDED IN ACCORDANCE WITH THE CANADIAN ELECTRICAL CODE PART I E E E KE E K E K KE K K K K K K K KK KK AVERTISSEMENT LE MOTEUR DOIT ETRE MUNI D UNE PROTECTION DISTINCTE CONTRE LES SURINTENSITES LA SURCHARGE ET LA SURCHAUFFE CONFORMEMENT AU CODE CANADIAN DE L ELECTRICITIE PREMIERE PARTIE Hae fae tenete tenete ok ae fe ok ae ae te ae fo ae foe ae te potete potete potete ae ae ak ae EEEE DANGER HAZARDOUS VOLTAGE WILL CAUSE SEVERE INJ
151. ROUND ARMATURE BRIDGE Bolt Size 3 8 16 3 8 16 3 8 16 One ground connection No lugs required 3 8 16 3 8 16 3 8 16 3 8 16 3 8 16 3 8 16 1 2 13 x 1 25 1 2 13 x 1 25 1 2 13 x 1 25 Recommended Wire Size 1 0 AWG 1 0 AWG 1 0 AWG 1 0 AWG 1 0 AWG 1 0 AWG 2 0 AWG 2 0 AWG 2 0 AWG 4 0 AWG 4 0 AWG 4 0 AWG 400 MCM 400 MCM 400 MCM Bolt Size 1 4 20 1 4 20 1 4 20 1 4 20 1 4 20 1 4 20 1 4 20 1 4 20 1 4 20 1 4 20 1 4 20 1 4 20 Multiple conductors run in parallel Lugs are supplied attached to input and output bus bars No lugs are required for these connections Make connections to TB1 on top of the field supply assembly Strip insulation 0 59 from end of wire Ground lugs are provided attached to these bolts on both sides of the chassis See outline drawings for wire size range of these lugs These units are designed for direct bus bar connection However the multiple wire connections indicated may be used 6 9 CHASSIS GROUND FIELD SUPPLY Recommended Wire Size Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter 6 7 3 6 7 4 540 850 1550 and 3000 ADC Use the following information to wire units rated at 540 850 1550 and 3000 ADC in accordance with the National Electrical Code Always review local building and electrical codes before making electrical connection
152. RUCTIONS CONTAINED IN THIS MANUAL AS WELL AS PROPER SAFETY PRACTICES HAZARDOUS VOLTAGES MAY ALSO BE PRESENT ON EXTERNAL SURFACES OF THE CONTROLLER CASE IF NOT PROPERLY GROUNDED AVOID LOSS OF LIFE SEVERE PERSONAL INJURY OR SUBSTANTIAL PROPERTY DAMAGE BY FOLLOWING SAFETY PRACTICES EK EE EK E K K K K K K K K KKK NOTE All conductor sizes referenced in this manual are for copper conductors with a minimum insulation rating of 75 C Before wiring units according to the Interconnection Diagrams review the following notes applying to routing and termination of interconnection cables It is recommended that power cables and signal cables be routed in separate conduit When using cable trays route power lines in different trays and keep parallel power trays at a maximum distance from signal wires to avoid possible cross talk 6 21 Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter All pulse generator cables may be run in common conduit or cable trays because these cables include an electromagnetic shield Use of conduit is generally recommended instead of cable trays because protection against physical or chemical damage is provided and if grounded electromagnetic shielding is provided Use the following guidelines to simplify wiring of the individual cables to respective terminal boards in the drive and to minimize the possibility of electrical noise talk between conduc
153. Remote Keypad Kit B39402 instructions for details on how to remotely mount the keypad 6 7 6 7 1 Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter ELECTRICAL CONNECTIONS WARNING DO NOT OPERATE RADIO TRANSMITTERS or CELL PHONES IN THE VICINITY OF THE ADD 32 PLUS The ADD 32 PLUS is an electronic device Although it is designed to operate reliably in typical industrial environments the ADD 32 PLUS can be affected by radio and or cell phone transmitters It is possible to cause drive faults inappropriate unintended drive I O activity and unpredictable operation that could result in damage to the ADD 32 PLUS damage to other equipment or serious injury to personnel Radio transmitter interference is a site specific phenomena Generally electrical wires connected to terminals on the ADD 32 PLUS are the conduits for radio interference Interference can be minimized by good wiring design and installation practice It is recommended that signs be posted in and around the drive system warning of the possibility of interference if the drive is in operation DO NOT USE radio transmitters or cell phones in the area Absence of a radio interference problem is no guarantee that a problem will never occur as conditions and environments can change The following information is for assistance in wiring ADDvantage 32 PLUS accordance with specifications set forth by the National Electrical Code
154. S software utility program may be used on a computer with the Windows 7 Windows Vista Windows XP or Windows NT operating systems INSTALLATION OF CONVERTTOADD32PLUS SOFTWARE UTILITY PROGRAM The ConvertToADD32Plus utility must first be installed on a computer before it can be used All files necessary for the installation can be found on the software CD provided with the drive in the Convert ToADD32Plus subdirectory listing of the contents of the Convert ToADD32Plus subdirectory is shown in Figure 12 10 win7 1 6 2012 8 50 File folder J winXP 1 6 2012 8 16 AM File folder InstallConvertToAdd32PlusUtility bat 1 9 2012 8 52 AM Windows Batch File 2 KB Figure 12 10 The software CD shows the location of the batch procedure for the ConvertToADD32Plus utility installation To install the Convert ToADD32Plus Utility simply double click on the InstallConvertToADD32PlusUtility bat file located in the ConvertToADD32Plus subdirectory on the software CD The installation software will detect the operating system of the computer and will install the necessary software components required for the operating system detected 12 16 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter Follow all prompts as they appear during the installation process The installation may require a reboot of the computer and the user will be prompted to initiate the reboot if it is required On some computers the installation m
155. Send Fail counter containing the number of failures returned by the ASCAN response socket send operation Increments of this counter indicate a probable network configuration problem most likely related to the drive IP address subnet mask or gateway address 8 25 8 8 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS ETHERNET COMMUNICATIONS PROTOCOLS FOR ADD 32 PLUS Ethernet communications with the ADD 32 PLUS drives are implemented using one of four common protocols or proprietary Avtron Peer Primitives such as Avtron s ADDvantage 32 PLUS Application Programming Tools ADDAPT The supported protocols This Schneider Electric s Modbus TCP IP MB TCP GE Fanuc s Ethernet Global Data GE EGD Allen Bradley s Client Server Protocol AB CSP sometimes referred to as Programmable Controller Communication Commands AB PCCC Allen Bradley s Ethernet IP Control Internet Protocol AB CIP section will describe the common concepts of Ethernet communications network addressing and the supported protocols with the exception of the Avtron Peer Primitives which are reserved for Avtron use such as ADDapt2000 8 26 8 9 8 9 1 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS TRANSMISSION CONCEPTS Most Ethernet communications use either the UDP or TCP formats as follows in 8 9 1 and 8 9 2 The Requests for Comments RFC document series referenced below is a set of technical and organizational notes
156. T TO POINT MAPPING BETWEEN J2 ON FAX 32 BOARD AND TB1 OF D SHELL CONNECTOR FOR EXAMPLE J2 PIN 1 IS CONNECTED TO TB1 POINT 1 10 10 23 23 Figure 6 7 Block Diagram FAX 32 Board 6 18 Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter ML COVER MICROPROCESSOR BOARD DOOR CASE BASE Figure 6 8 ADDvantage 32 PLUS System Interconnections NOTE System interconnections are the same for all ADD 32 PLUS units Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter 29 i i FAX 32 INTERCONNECTIONS FIGURE 5 9 CASE MICROPROCESSOR BOARD BASE DOOR Figure 6 9 FAX 32 Board Interconnections NOTE FAX 32 interconnections are the same for all ADD 32 PLUS units 6 20 Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter 6 8 ELECTRICAL INSTALLATION Interconnection wiring and connection diagrams are provided in the supplemental drawing manual and are identified in that Table of Contents These drawings include part numbers of the major assemblies and corresponding Schematic Interconnection Wiring Diagrams WIRING PRACTICES AND NOTES K K K K K K K KKK WARNING THIS EQUIPMENT CONTAINS HAZARDOUS VOLTAGES THE MAIN DISCONNECT DEVICE MAY NOT REMOVE ALL HAZARDOUS VOLTAGE SOURCES TO AVOID LOSS OF LIFE SEVERE PERSONAL INJURY OR PROPERTY DAMAGE FOLLOW ALL INST
157. T0P400 4 324461 500A 700V FWP 500A L70S 500 70 500 4 324475 5A 600V FNQ R 5 KLDR 5 324492 600A 500V 50 600 4 324776 1400A 700V 170M6767 A070URD33L11400 324783 2000 1000V A100URB2002PFBI 324802 700A 700V A070URD33TTIO700 324803 700A 1300V AI30URD73TTIO700 324806 900A 1300V A130URD73TT10900 324807 700A 1200V D075GRBO700K3BI 324808 630A 700V A070URD33TIIO630 7 54 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter 7 11 FUSE REPLACEMENT 540 850 1550 3000 ADC 7 11 1 FUSE REPLACEMENT FOR ARMATURE BRIDGE ASSEMBLY 7 11 11 Disassembly DANGER HEATSINKS MAY BE ENERGIZED Hazardous voltage will cause severe injury and death Turn off and ilock out all sources of power before proceeding 4a 4b Remove power from the drive Disconnect the ground wire s located on the lower left corner or left center on the back of the front panel Loosen the front panel screws Using the slotted openings lift the panel up and off DC054X DC085X and DC155X 2 and 4 versions only Remove the two bolts holding the fuse to be replaced F1 F6 between the bus bars and thyristor module DC155X A and B DC250X and DC300X Remove the wires from the fuse indicator switch if so equipped Remove the mounting bolts that attach the fuse bus links to the AC bus bars and the thyristor module NOTE The fuses indicator switches and associated bus links should be removed
158. THRU A112 AC INPUT LUGS COVER GROUND WIRE 7 50 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter Figure 7 13 Armature Bridge Assembly 155X A amp B and 300X 7 51 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter TABLE 7 8a FUSE REPLACEMENT GUIDE 10 510 ADC Refer to Figure 7 5 for fuse location F1 F2 RATING F3 F4 RATING P N P N 10 5A 500V 2A 600V 324438 324452 30 5A 500V 2A 600V 324438 324452 56 10A 500V 2A 600V 324439 324452 110 10A 500V 3A 600V 324439 324453 180 20A 500V 4A 600V 324440 324454 280 20A 500V 5A 600V 324440 324475 360 20A 500V 5A 600V 324440 324475 510 20A 500V 5A 600V 324440 324475 F5 RATING P N 3A 250V 324451 3A 250V 324451 3A 250V 324451 5A 250V 324184 5A 250V 324184 6 25A 250V 324154 6 25A 250V 324154 6 25A 250V 324154 F8 F9 F10 RATING F6 RATING P N 1A 250V 1A 250V 1A 250V 1A 250V 1A 250V 1A 250V 1A 250V 1A 250V 324195 324195 324195 324195 324195 324195 324195 324195 F7 RATING P N 0 6A 250V 324008 0 6A 250V 324008 0 6A 250V 324008 1 25A 250V 324019 1 25A 250V 324019 1 25A 250V 324019 1 25A 250V 324019 1 25A 250V 324019 P N 40A 500V 324442 40A 500V 324442 60A 500V 324444 175A 500V
159. TPT x HYS 100 lt STPT x HI 100 HI bit goes low If INP increases so INP STPT x HYS 100 STPT x LOW 100 LOW bit goes low If INP decreases so INP STPT x HYS 100 STPT x LOW 100 LOW bit goes high 4 54 Control Block Description ADDvantage 32 PLUS 4 38 1 IIT Inputs IA Analog STPT Analog IGN Analog FST Analog WST Analog SQU Bit ZER Bit IRES Bit Outputs VAL Analog TRP Bit WRN Bit Implementation The IIT block is used to determine the current overload for a motor It can be used when more than one motor is used with the drive When IRES is high the integrator is reset to zero VAL 0 When IRES is low the integrator starts integrating the error If ZER is low then the internal error signal is equal to absolute value of INP minus the STPT input quantity times 0 1 If ZER is HIGH the error is equal to STPT x 0 1 This error is fed into the integrator if the SQU input bit is low giving an IIT function If the SQU input is high then this error is squared the sign of signal is kept after the squaring before it goes into the integrator The integrator works the same as the PI block with the IGN input as its gain value and VAL as its output FST is the upper limit of the integrator output and 0 is the lower limit When VAL goes above the WST input the WRN output bit will go high When VAL goes above the FST input the TRP output bit will go high 4 55 Control Block Descr
160. TS This file contains the analyzer calibration default values for each of the four channels in File 44 that will be loaded into calibration on initial power up Data values for each channel are identical See Section V FILE 48 ANALYZER CAL This file contains the actual calibration values used for each of the four channels in File 44 to process the collected analyzer data The default values initially used for each channel are identical On default initialization the default values from File 47 are copied into this file The user may modify the values which will then be used at all future power up conditions unless the default initialization is repeated See Section V FILE 49 ANALYZER CONFIG LABEL This file contains the analyzer configuration prompts Refer to File 51 FILE 50 ANALYZER CONFIG LEGALS This file contains analyzer configuration legal data 9 14 System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter 9 3 43 This file contains the legal references that may be used to configure control for each channel This table must be used to generate configuration data changes Any data reference not contained in this table will be invalid and control action will be undefined The table is organized as a two dimension array with eight 8 by nineteen 19 unsigned short integer values for each of the four channels Each of the tables consists of a maximum of eight choices for each of the nineteen variables NOTE
161. URY AND DEATH TURN OFF AND LOCK OUT ALL SOURCES OF POWER BEFORE SERVICING K K K K K K KK KK DANGER PRESENCE DE TENSIONS DANGEREUSES POUVANT ET PERTE DE VIE COUPER L ALIMENTATION AVANT LE DEPANNAGE DE CET EQUIPMENT EKE E E E E KE KE E KE E K KE K KE K K K K K K K KK KK ii Safety Summary ADDvantage 32 PLUS e AC to DC Power Converter WARNING DO NOT OPERATE RADIO TRANSMITTERS or CELL PHONES IN THE VICINITY OF THE ADD 32 PLUS The ADD 32 PLUS is an electronic device Although it is designed to operate reliably in typical industrial environments the ADD 32 PLUS can be affected by radio and or cell phone transmitters It is possible to cause drive faults inappropriate unintended drive I O activity and unpredictable operation that could result in damage to the ADD 32 PLUS damage to other equipment or serious injury to personnel Radio transmitter interference is a site specific phenomena Generally electrical wires connected to terminals on the ADD 32 PLUS are the conduits for radio interference Interference can be minimized by good wiring design and installation practice It is recommended that signs be posted in and around the drive system warning of the possibility of interference if the drive is in operation DO NOT USE radio transmitters or cell phones in the area Absence of a radio interference problem is no guarantee that a problem will never occur as c
162. X Ethernet board installed but the ETHRNET COM parameter is set to ENABLE the drive may operate erratically and or reset unexpectedly If ETHRNET COM is set to AUTO ENABLE then the drive will attempt to determine if the ESBX Ethernet board is installed as part of the power up sequence If the ESBX Ethernet board is detected and correctly initialized its presence will be indicated under the DIAGNOSTICS menu of the drive keyboard display The drive LCD display will show DRIVE COM ID xx ETH where xx Drive ID and ETH indicates presence of ESBX Ethernet board Y083 ETH AUT RST DISABLE ENABLE default DISABLE MUST BE SET TO DISABLE ESBX ZAP DOWNLOADING FIRMWARE TO ESBX ETHERNET BOARDS The ESBX Ethernet board firmware is stored in Flash Memory Although not normally a field requirement this firmware can be Field upgraded via Ethernet using Avtron s ESBX Zap program PN 682937 from the source computer usually the ADDAPT 2000 PC Normal operation of the ESBX Ethernet board will cease upon start of ESBX ZAP which will take up to 3 minutes to complete The ESBX board will provide indication of completion of the ZAP program by an alternating flash of CR2 and CR3 LED s Use caution as a power cycle or drive reset during the ZAP operation or before the ZAP is complete will render the ESBX board inoperable and will require factory reprogramming at Avtron Zapping an ESBX board on a running drive is not totally risk free However there s
163. ace as instructed in paragraph 7 3 4 Set aside for reuse later Remove high voltage wiring at L1 L2 L3 Al and A2 Remove wiring from TB1 and GND The complete sub assembly may now be removed and replaced Use existing hardware Reattach wiring to and GND Reattach high voltage wiring at L1 L2 L3 Al and A2 Reinstall the bridge interface from step 8 see paragraph 7 3 4 Replace the door controller from step 7 Replace ground wire on door Attach all seven bridge interface cables and shut door Open cover and attach system connections to the microprocessor board Verify all connections Close cover and reapply power 7 27 Maintenance and Troubleshooting ADDvantage 32 PLUS AC to DC Power Converter f N Figure 7 6 Replacing Power Components 550 ADC 7 28 Maintenance and Troubleshooting ADDvantage 32 PLUS AC to DC Power Converter 7 6 TEST PROCEDURE FOR LEAKING THYRISTORS SCRs An SCR might be leaky or shorted if a false Tach Loss and or SCR SHRTX fault occurs when the DC contactor closes To determine this perform the following steps 1 From the main keyboard display menu use the up and down arrow keys until OPERATE is displayed 2 Press the right arrow key and DRIVE ANALOG will be displayed 3 Press the right arrow key again and A000 FIL SPEED will be displayed 4 Press the up arrow key until A012 ARM VOLTS is displayed Verify that the section is stopped
164. ace bridge interface board Replace microprocessor board Check fuse Check cable assembly connected to J2 of microprocessor board and its associated connectors Replace SCR or drive base assembly Replace bridge interface board Replace microprocessor board Check fuse Check cable assembly connected to J2 of microprocessor board and its associated connectors Replace SCR or drive base assembly Replace bridge interface board Replace microprocessor board Check fuse Check cable assembly connected to J2 of microprocessor board and its associated connectors Replace SCR or drive base assembly Replace bridge interface board Replace microprocessor board Maintenance and Troubleshooting FAULT MESSAGE PROBLEM SOLUTION MESSAGE PROBLEM SCR OPN C R SCR OPN A R SCR OPN B R SCR OPN C R SCR SHRT A SCR SHRT B SCR SHRT C Open SCR fault message SCR CR3 or fuse F10 for 510 amp and below SCR A103 or fuse F3 for 540 amp and above bridges Open SCR fault message SCR CR4 or fuse F8 for 510 amp and below SCR A104 or fuse F4 for 540 amp and above bridges Open SCR fault message SCR 5 or fuse F9 for 510 amp and below SCR A105 or fuse F5 for 540 amp and above bridges Open SCR fault message SCR CR6 or fuse F10 for 510 amp and below SCR A106 or fuse for 540 amp and above bridges Shorted SCR CR1 or snubber on 510 ADC and below units Or Shorted SCR A101 on 54
165. ad Instructions 1 Record Target ADDvantage 32 PLUS drive information Drive IP and Subnet mask addresses From the drive keypad enter the Drive Calibrate menu and record the following parameters The X parameter numbers shown below are for drive application software P N 694012 V13 Please reference Appendix C of your ADDvantage 32 PLUS Drive manual that shows the parameter listing for your specific application software X090 IP ADDR HI X091 IP ADDR HM X092 IP ADDR LM X093 IP ADDR LO X094 MSK ADDR HI X095 MSK ADDR HM X096 MSK ADDR LM X097 MSK ADDR LO NOTE Do not enter the number 256 for X093 Use the actual DRIVE ID jumper settings on J8 as viewed for DRIVE COM ID in the drive s Diagnostic menu If X093 does not equal 256 then use the number in X093 2 Record the ESBX board MAC Address located on label of U1 of the ESBX board 8 12 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS MAC Address gt 3 2 E 3 Record the Source computer s network settings information Computer s IP and Subnet mask addresses This information can usually be found under the Internet Protocol TCP IP properties found in the Local Area Connection properties of computers Network and Dial Up Connections setup IP Address Subnet Mask NOTE The drive and the computer s network address settings must be such that they are both capable of communicating on the same network and have a physi
166. adjustments such as trigger level or sample rate Defaults are as follows 5 6 Signal Analyzer RECORDER CHANNEL CONFIGURATION PARAMETER ADDvantage 32 PLUS e AC to DC Power Converter DEFAULT VALUE 1 2 3 4 5 6 7 8 RESET Defined as a bit in the digital table which clears the done bit it can be defined to reset on a high or low level The recorder can also be reset by a keyboard bit Default for all eight recorders Z ENABLE RECI Z ENABLE REC2 Z ENABLE REC3 Z ENABLE REC4 Z ENABLE 5 Z ENABLE REC6 Z ENABLE Z ENABLE RECS Q DISABLED Q DISABLED Q DISABLED Q DISABLED Q DISABLED Q DISABLED Q DISABLED Q DISABLED RECORDER CONFIGURATION DEFAULT CHANNEL PARAMETER VALUE 1 Z RESET BIT 1 D ZERO BIT 1 Z RESET R F 1 Q RISING 82 Z RESET BIT 2 D ZERO BIT 2 Z RESET R F 2 Q RISING 3 Z RESET BIT 3 D ZERO BIT 3 Z RESET R F3 Q RISING 4 Z RESET BIT 4 D ZERO BIT 4 Z RESET R F 4 Q RISING 5 Z RESET BIT 5 D ZERO BIT 5 Z RESET R F 5 Q RISING 6 2 RESET BIT 6 D ZERO BIT 6 Z RESET R F 6 Q RISING 7 2 RESET BIT 7 D ZERO BIT 7 Z RESET R F 7 Q RISING 8 Z RESET BIT 8 D ZERO BIT 8 Z RESET R F 8 Q RISING 5 7 Signal Analyzer ADDvantage 32 PLUS e AC to DC Power Converter ANALYZER EXAMPLE CAPTURE OF AN OVERSPEED EVENT The signal analyz
167. ady to run Note that there are several drive configuration parameters that have been added to the ADDvantage 32 PLUS drive These parameters are listed in Table 12 1 After following the upgrade procedure these parameters will be set to their default values The parameters can be edited to suit user preferences for the data displayed on lines 3 and 4 of the LCD display 12 14 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter TABLE 12 1 NEW DRIVE CONFIGURATION PARAMETERS CONFIGURATION FUNCTIONALITY PARAMETERS Y059 DPY L3 MODE Sets the data type to be displayed on line 3 of the LCD display Choices are ANALOG DIGITAL DIGITAL or FAULT If Y059 is set to FAULT then the top entry of the Fault FIFO will be shown on line 3 Y060 DPY L3 ANLG If line 3 display mode is set to ANALOG this is the analog value to display Y061 DPY L3 DGTL If line 3 display mode is set to DIGITAL this is the starting bit of 10 bits to display in a 0 1 format If line 3 mode is set to DIGITAL BIT then line 3 will show the label of the digital point and indicate ON or OFF Y062 DPY L4 MODE Sets the data type to be displayed on line 4 of the LCD display Choices are ANALOG DIGITAL DIGITAL BIT or FAULT If Y062 is set to FAULT then the top entry of the Fault FIFO will be shown on line 4 Y063 DPY L4 ANLG If line 4 display mode is set to ANALOG this is the analog value to display Y064 DPY
168. agnostic information intended for factory use 2 22 ADDvantage 32 PLUS e AC to DC Power Converter Analyzer Menu gt Up Down Diagnostics gt Up Down Y Access Code gt 4 ON TIME d h m s 123 22 38 44 A Up Down y gt Up Down y ESBX PN VER 68 Up Down 9 APPL P N 68xxxxvv Up Down STR912 APPL P N 68xxxxvv Up Down y AT9 FPGA P N 68xxxxvv A Up Down y STR912 FPGA P N 68xxxxvv Up Down AT9 B SWR P N 68xxxxvv Clr ETH Histor y LEFT A Up Down STR912 B SWR P N 68xxxxvv Up Down y WD Statistics OWN From the Clr ETH History pressing the left key will cause all Ethernet statistics to be reset to zero Ethernet Diagnostic information UN See section 8 and Appendices for eaae gt rl Left Right further information A Up Down y DRIVE COM ID Display of the DRIVE COMMUNICATIONS ID as set by inputs on Terminal Block J8 1 ETH ETH will be present on display when the option ETHERNET expansion board is present and operational A Up Down y 1 f d h umulative amount of time in days hours minutes i and seconds that drive has been running note time accuracy is 2 seconds per day Up Down Amount of ti
169. al different types are available including a standard speed regulator with tension P N 696002 and a center driven winder P N 696003 Most applications can be covered by the two application programs described Other application software is available To obtain a list or to discuss custom software applications consult the factory NOTE A two digit version number is also required If a specific version is not referenced the latest version will be supplied 1 29 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter 1 5 SPECIFICATIONS Please note that some of the following specifications are not pertinent to all models TABLE 1 1 ADDvantage 32 PLUS SPECIFICATIONS DESCRIPTION SPECIFICATION Input Voltage to Transformer 3 Phase primary windings to standard voltages Phase rotation insensitive Transformer Output to Drive 3 Phase 230 or 460 VAC nominal except 550 ADC Drive only 230 460 or 575 VAC nominal Maximum Currents Drive HP Armature Input Field P N 240 500 700 VDC Output Current Output DC0010 2 5 10 Amps DC 11 Amps AC 3 Amps DC DC0030 7 5 15 30 Amps DC 28 Amps AC 3 Amps DC DC0056 15 30 56 Amps DC 49 Amps AC 6 Amps DC DC0110 30 60 110 Amps DC 95 Amps AC 6 Amps DC DC0180 50 100 180 Amps DC 155 Amps AC 12 Amps DC DC0280 75 150 280 Amps DC 240 Amps AC 12 Amps DC0360 100 200 360 Amps DC 310 Amps AC 12 Amps DC0510 150 300 510 Amps DC 416 Amps
170. ale IOC o 300 FLA Actual Burden Burden FLA DC Ratio Burden A Volt 2 VDC IOC IOC wo X061 1 X062 ADC ADC 100 300 200 2500 8 312 625 600 312 300 2500 5 500 1000 900 333 400 2500 4 625 1250 1200 312 500 2500 3 833 1667 1500 333 600 2500 2 5 1000 2000 1800 333 700 2500 2 5 1000 2000 2100 286 800 2500 2 1250 2500 2400 312 4000 1 CT p n A19489 Enter Pick amp CT Actual Calc Drive CT Enter Scale IOC o 300 FLA Actual Burden Burden FLA DC Ratio Burden A Volt 2 VDC IOC IOC wo wo X061 1 X062 ADC ADC 100 300 300 4000 9 444 889 900 296 350 4000 8 500 1000 1050 286 400 4000 7 571 1143 1200 286 500 4000 5 800 1600 1500 320 600 4000 4 1000 2000 1800 333 700 4000 4 1000 2000 2100 286 800 4000 3 1333 2667 2400 333 900 4000 3 1333 2667 2700 296 1000 4000 2 5 1600 3200 3000 320 1100 4000 2 5 1600 3200 3300 291 1200 4000 2 2000 4000 3600 333 1300 4000 2 2000 4000 3900 308 1400 4000 2 2000 4000 4200 286 1500 4000 2 2000 4000 4500 267 Notes 1 062 ratio R burden 2 Actual IOC 2 VDC X062 3 standard burdens are 9 8 7 6 5 4 5 4 3 5 3 2 5 2 amp 1 Ohm ref D27498 X Cur Fdbk Mod 3 46 3 20 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter RETENTIVE SETPOINTS Y Parameters Y RET SETPT 1 RET SETPT 2 Y RET SETPT Y RET SETPT 4 Y RET SETPT 5 Y RET SETPT 6 Reten
171. ally or by using a screwdriver Install new fuse and tighten the nuts on the studs if necessary Tighten two captive screws holding bridge interface assembly to the base Plug connectors J5 and J6 onto bridge interface board A3 Plug cables into J2 and J3 Close door of field supply assembly and reapply power Qvo ee UT 7 56 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter TABLE 7 10 FUSE REPLACEMENT GUIDE Applies to Amp Ratings DC054X DC085X DC155X DC300X ASSEMBLY RATING BUSSMANN REF DES AVTRON P N P N Field Supply 1A 250V MDA 1 F5 324195 Field Supply 60A 500V FWH60A F3 F4 324444 Field Supply F1 F2 F6 F7 F8 DC0540 DC085X 600A 500V FWH600A Armature Bridge 324492 F1 6 DC155X 2 and 4 1400A 700V Armature Bridge 324776 F1 F6 DC155X A 700A 700V 324802 DC155X B 700A 1300V 324803 DC300X A 1400A 700V 324267 DC300X B 900A 1300V 324806 50 60 50 600 FERRAZ P N 050 060 050 600 A070URD 33LI1400 LITTELFUSE P N 326 1 L50S 60 L50S 600 Application specific fuses Refer to applicable system drawings for current ratings of application specific fuses F1 and F2 must be 500V Class CC fuses rated at a maximum of 25A F6 must be rated at 5A or less 250V minimum F7 must be rated at 12A or less 120V minimum F8 must be rated at 20A or less 120V minimum 7 57 Maintenance and Troubleshooting A
172. ame Files of type g Configuration Files add v Figure 12 15 All the configuration files that will be converted appear in the Open Configuration File dialog box 12 20 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter 12 2 2 2 12 2 2 3 ADD 32 PART AND VERSION NUMBERS Once a valid ADDvantage 32 calibration and configuration file has been specified the utility displays the software part number and software version number of the drive ADD32 Configuration File C AddaptiConfiguration 69401216 add BROWSE Template File Directory C Addaph Template Browse ADD32Plus Configuration File C AddaphiConfiguration69601216 add BROWSE ADD32Plus Part Number 696012 ADD32 Part Number ADD32Plus Version Number 16 ADD32 Version Number CONVERT Figure 12 16 The Convert ToADD32Plus utility screen shows the location of the ADDvantage 32 calibration and configuration file software part number and software version number THE TEMPLATE FILE DIRECTORY FIELD The second field that must be entered in the Convert ToADD32PLUS utility is the Template File Directory field The user may either type in the directory path where the drive template files are located or use the BROWSE button to specify the template file directory Figure 12 17 shows the dialog box that opens in response to the BROWSE button 12 21 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Powe
173. and FTP use TCP The two processes communicate with each other over a TCP connection InterProcess Communication IPC as shown in Figure 8 9 2 TCP connection unreliable IP datagrams Figure 8 9 2 Connection between processes Processes 1 and 2 communicate over a TCP connection carried by IP datagrams A typical set of transactions is shown in Figure 8 9 3 Sender Receiver Send packet 1 gt Receive packet 1 and reply with an ACK 1 Receive ACK Send packet 2 Figure 8 9 3 TCP Transactions 8 28 8 9 3 8 9 3 1 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS This format is used by Modbus TCP and Allen Bradley s Explicit and PCCC formats Network Addressing Concepts The industry standard IP addressing definitions are as follows Class based IP Addresses The first bits of the IP address specify how the rest of the address should be separated into its network and host part The terms network address and netID are sometimes used instead of network number but the formal term used in RFC 1166 Internet Numbers is network number Similarly the terms host address and hostID are sometimes used instead of host number There are five classes of IP addresses They are shown in Figure 8 9 3 1 1 8 Class A 0 host ID Class D multicast Class E future use Figure 8 9 3 1 Sub Net Classes Where e Class A addresses 1 x x x to 127 x x x subnet mask 25
174. antage 32 PLUS e AC to DC Power Converter SECTION XII UPGRADE TO NEW CONTROL BOARD The ADDvantage 32 can be upgraded to an ADDvantage 32 PLUS by replacing the ADDvantage 32 microprocessor and system boards with an ADDvantage 32 PLUS microprocessor board In addition to replacement of hardware the ADDvantage 32 calibration and configuration data may be upgraded for use on the ADDvantage 32 PLUS Prior to performing the upgrade consult Section 6 for information about safety instructions and preparations for use WARNING THIS EQUIPMENT CONTAINS HAZARDOUS VOLTAGES THE MAIN DISCONNECT DEVICE MAY NOT REMOVE ALL HAZARDOUS VOLTAGE SOURCES TO AVOID LOSS OF LIFE SEVERE PERSONAL INJURY OR PROPERTY DAMAGE FOLLOW ALL INSTRUCTIONS CONTAINED IN THIS MANUAL AS WELL AS PROPER SAFETY PRACTICES HAZARDOUS VOLTAGES MAY ALSO BE PRESENT ON EXTERNAL SURFACES OF THE CONTROLLER CASE IF NOT PROPERLY GROUNDED AVOID LOSS OF LIFE SEVERE PERSONAL INJURY OR SUBSTANTIAL PROPERTY DAMAGE BY FOLLOWING SAFETY PRACTICES K K K K K K K KKK 12 1 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter 12 1 INSTALLATION OF HARDWARE The ADDvantage 32 microprocessor board and system board are contained in an enclosure that is mounted to the front of the drive as shown in Figure 12 1 A The hardware upgrade process involves the replacement of that enclosure with a new one that contain
175. antage32 PLUS menus and submenus the user will ultimately be able to locate a drive parameter of interest CALIBRATION ANALOG TABLE PARAMETERS The LCD display of the parameter will be in one of two formats the format for numeric data such as calibration and real time data or the format for configuration data The format for the numeric data is as follows 1 Parameter Group Represents the type of data to be edited See Table 2 1 2 Parameter Number Each parameter within a data type has unique parameter number See Appendix A 3 Label Each parameter has a unique 11 character label See Appendix B 2 10 ADDvantage 32 PLUS e AC to DC Power Converter Parameter Parameter Parameter Group Number Label C025 MAX SPEED V 1750 0 FPM user configurable line 3 user configurable line 4 Figure 2 6 The first line of the four lines shown in the LCD display shows the parameter group the parameter number and the parameter label 4 Bottom Left Character Determines what type of value is displayed The only value which can be edited is V which represents current value 5 Value Represents the value of a particular parameter to nine significant digits 6 Units Represents the value s units of measure This text can be edited using the EDIT UNITS menu ADDvantage 32 PLUS e AC to DC Power Converter DATATYPE V CURRENT VALUE D DEFAULT VALUE Parameter Parameter
176. are most easily identified here Correct the CT polarities by switching the wire pair for the CT s whose feedback pulses are inverted from those shown in Figure 3 5 Return to step 14 3 43 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter SCR FIRING ADAPTER j P N A20651 J TO SCR BRIDGE DCAFMC9SCAN Figure 3 9 Firing Adapter 2 CT Configuration Diagram 24 Return the parameters changed in steps 7 and 8 back to their original values reset drive and begin normal non AFM drive startup procedure Continue on to step 25 if there is concern of having the incorrect burden resistor values Calculating Burden Resistor Values 25 For both the 2CT and configurations see Figures 1 5 and 1 6 the following procedure applies to calculating burden resistor values The value calculated below corresponds to all three resistors R2 26 Obtain the current rating for the CT This is usually given as a turns ratio This is equivalent to a ratio of input current to output current Inpt Amps Oupt Amps Calculate and record the Output Amps of the CT for an input current equal to 300 full load motor current As an example for a CT with an 800 rating and rated motor armature current of 140A the output of the CT at 30096 motor current would be 1A 800A 140A 300 100 0 525 Amps Out Actual CT output current at 30096 motor current Amps 3 44 Core Software Operation
177. as an assembly Once removed the bus links can be detached from the fuses If replacing a fuse that is equipped with an indicator switch remove the two screws that attach the switch to the fuse 7 55 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter 7 11 1 2 Replacement and Reassembly 1 Refer to Figure 7 9 for proper hardware installation 2 Install the new fuse s and torque tighten the bolts per the following table DC054X DC085X DC155X 2 and 4 DC155X A and B DC300X 165 185 In lb 335 365 In lb Bus Link to Bus Bar 390 420 In lb NOTE The 1 2 bolts that attach the bus links to the fuse ends should be torque tightened to 335 365 In lb 3 Replace the front panel 4 Reconnect the ground wire s to the front cover RA Reapply power 7 11 2 FUSE REPLACEMENT FIELD SUPPLY ASSEMBLY 7 11 2 1 Disassembly Remove power from the field supply assembly Unlatch door of main assembly Latches are located on the right side of unit Open the door Bridge interface board A3 will be exposed Remove cables from connectors J2 and J3 Disconnect cable connectors J5 and J6 on bridge interface board and move cables aside 6 Open bridge interface assembly to expose the fuses er toe 7 11 2 2 Replacement Reassembly 1 Fuses F3 and F4 are removed by removing the nuts from the studs to which the fuses are mounted The remainder of the fuses can be removed manu
178. ase assembly door Remove ground wire Remove cables on bridge interface board Loosen the two captive screws holding the bridge interface assembly to the base Slide bridge interface assembly off the hinges Install new assembly on hinges Reconnect ground wire to the bottom left of the front panel Tighten two captive screws to hold bridge interface assembly in place Replace four cables to bridge interface board and shut the drive door Connect armature bridge cables to J2 and J3 Reapply power to the unit OUND CONNECTION REMOVABLE IE ef HINGES BRIDGE INTERFACE BOARD A3 BASE FIGURE 7 4 Figure 7 4 Replacing Bridge Interface Board 540 850 1550 and 3000 ADC 7 24 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter 7 4 REPLACING DRIVE SUB ASSEMBLY 510 ADC and Below Refer to Figure 7 5 K K K K K K K KKK K WARNING HAZARDOUS VOLTAGES WHICH CAN CAUSE SEVERE INJURY OR DEATH ARE PRESENT DURING THE OPERATION OF THIS EQUIPMENT TURN OFF AND LOCK OUT ALL SOURCES OF POWER BEFORE MAKING ANY REPAIRS EKEK EK EE E E K K K K KKK KK This procedure covers replacement of the entire DC Drive Controller Base Sub Assembly To replace individual power components such as thyristors and fuses see section 7 6 1 2 3 po cic 11
179. at all mounting hardware is secure all pulse generators are properly aligned and all wiring interconnections are in accordance with the diagrams in this manual NOTE Insure that ground cables are properly attached to the drive chassis Refer to the outline drawing in drawing package for location of grounding points Note that the 540 amp and above drives have grounding lugs attached to both the armature bridge chassis and the field supply chassis POWER UP AND START UP Applying power and starting up the ADD 32 PLUS should be done only by trained and qualified personnel Familiarity with the hardware the software and the environment in which the equipment is to be applied is critical to safe and efficient system operation PULSE GENERATOR INSTALLATION Proper mechanical and electrical installation of the digital speed feedback device Pulse Generator is critical for optimum performance and reliability Follow the instructions provided by the Pulse Generator manufacturer and system interconnection diagrams if applicable The Microprocessor Board Block Diagram provided earlier in this section shows pulse generator Tach connection terminals In addition for Avtron SMARTach pulse generators models M285 M485 and M685 the following figure shows how the tach alarm output should be connected to an ADD 32 PLUS drive Particular care should be exercised in selecting the shaft coupling Use a zero backlash Thomas Miniature
180. ation ADDvantage 32 PLUS DIAGNOSTIC VALUE 10 MIN UDP Mpool Empty UDP Mpool Err UDP Good Receive UDP Invalid Type UDP Null UDP Invalid Serv PPR Cmd Buf Busy PPR Buf Rclm PPR Respnse Time PPR Reply PPR Overrun PPR Send Fail PPR Xmit Fail PPR No Reply QRY Frames QRY Responses QRY Overrun QRY Send Fail QRY Xmit Fail EXCHG Frames EXCHG Busy ASCAN Frames ASCAN Overrun ASCAN Send Fail ASCAN Xmit Fail BCAST Frames BCAST Busy BCAST Invalid BCAST Overrun BCAST Send Fail Mb PP good rcv Mb PP bad rcv Mb PP err rcv Mb PP timeout Mb PP good xmit Mb pp bad xmit TIE MBus Connect Er 8 2 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS DIAGNOSTIC VALUE 10 MIN MBus Max Connct MBus R Connt Er MBus Disconncts MBus Invld Hdr MBus Rsp Snd Er MBus Connct I s MBus Connct 2 s MBus Connct 3 s MBus Connct 4 s MBus Connct 5 s MBus Connct 6 s MBus Connct 7 s MBus Connct 8 s EGD SND errors EGD errors EGD CNSM Overrun EGD CFG Con ERR EGD CFG Con Good EGD RCV EGD Consume EGD No Match EXTRA 13 EXTRA 14 EXTRA 15 EXTRA 16 EXTRA 17 EXTRA 18 IP packets IP bad rcv chksm IP too short rcv IP too small rcv IP hdr too short IP hdr bad len IP frag s rev d IP frags dropped IP frags timeout IP pks fwrd d TIEN 8 22 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS DIAGNOSTIC VALUE 10 MIN IP can t forward IP fwd same net IP unknw
181. ation code 3 If the second character in the file is in the range of ASCII 0 9 then multiply authorization code by 10 and add that value to the product If the character is not a valid ASCII number then terminate the algorithm and use the authorization code computed in step 2 above 4 If the third character in the file is in the range of ASCII 0 9 then multiply authorization code by 10 and add that value to the product If the character is not a valid ASCII number then terminate the algorithm and use the authorization code computed in step 3 above 5 If the fourth character in the file is in the range of ASCII 0 9 then multiply authorization code by 10 and add that value to the product If the character is not 11 10 USB Usage ADDvantage 32 PLUS e AC to DC Power Converter a valid ASCII number then terminate the algorithm and use the authorization code computed in step 4 above EXAMPLE Use the five steps above to interpret a FLASHKEY TXT file that has the first four characters 1234 1 The authorization code 0 2 First character is 1 Set the authorization code equal to 1 3 Second character is 2 Multiply the authorization code by 10 and then add 2 The authorization code 10 1 2 or 12 4 Third character is 3 Multiply the authorization code by 10 and then add 3 The authorization code 10 12 3 or 123 5 Fourth character is 4 Multiply the authorization code by 10and then add 4 T
182. ay fail if the user does not having sufficient administrative privileges Figure 12 12 shows the typical message displayed when the installation cannot proceed due to insufficient administrative privileges Enlist your corporate information technology IT department to resolve any installation issues related to insufficient administrative privileges Figure 12 11 shows a screen snapshot of what will be observed initially during the installation process if the install program determines that the Microsoft Framework software must be installed 27 Microsoft Framework 4 Setup Installation Progress 4 Please wait while the NET Framework is being installed NET File security verification All files were verified successfully Installation progress Installing NET Framework 4 Client Profile Figure 12 11 This screen snapshot shows the installation of the Microsoft Framework software which might appear The installation of the Microsoft Framework may not be required on all computers 12 17 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter Microsoft NET Framework 2 0 SP1 Setup discovered the following problem You must have administrative privileges to run Microsoft NET Framework 2 0 SP1 Setup Please contact your system administrator Lax Figure 12 12 This screen snapshot shows the message indicating insufficient administrative privileges During the installation procedure t
183. be accessed by this utility please check that that your account has read access to the selected file 12 25 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter ERROR MESSAGE DESCRIPTION ADD32Plus configuration file lt ADD32Plus filename does not exist or proper privileges are not granted to read the file Exception encountered while checking for existence of ADD32 configuration file lt ADD32 filename exception message Cannot find registry key key and value registry value Using default default value Exception encountered for ADD32 configuration file lt ADD32 configuration file gt while comparing ADD32 template file lt ADD32 part gt lt ADD32 version gt tem and ADD32Plus template file lt ADD32Plus part gt lt ADD32Plus version gt tem lt Exception message gt Cannot access windows registry to retrieve configuration and template file folder locations lt exception message gt The ADD 32 PLUS configuration as entered or selected from the Open File Dialog box does not exist If the file does exist can be seen through the Windows Explorer but cannot be accessed by this utility please check that your account has read access to the selected file A software error was encountered while accessing the ADD 32 configuration file This exception is displayed as part of the error message The registry key and look up value is not found in the local
184. ble line 3 Underline user configurable line 4 present when in edit mode Figure 2 9 The LCD display in edit mode shows the maximum limit of the parameter being edited stands for the high limit 2 13 2 6 ADDvantage 32 PLUS e AC to DC Power Converter Pressing the UP or DOWN keys again will scroll through to the MINIMUM VALUE that the parameter may have as indicated by L for low limit replacing the Continue pressing the UP or DOWN to scroll through to a D which indicates the default value of the parameter The default value is the original value before any edits to the parameter were made In order to perform an edit of the numeric value of the parameter the left most character must be the V When the actual value of the parameter is being displayed the RIGHT key is used to move the cursor to the right of the V and begin the edit of the actual parameter value The blank spaces and digits of the number may be edited When the cursor is at the location that is to be changed pressing the UP or DOWN key will scroll through the following character list BLANK SPACE 0 1 2 3 4 5 6 7 8 9 MINUS DECIMAL POINT Once a particular cursor location has been set to the desired value pressing the RIGHT key again will move the cursor to the next character to the right By repeatedly pressing the RIGHT key the cursor will move from left to right and then loop back to
185. board HARDWARE PROBLEM Open circuit detected in Check interconnect cables to and OPEN ARMATURE armature bridge within armature bridge for loose PR IDSE CAB iB interlock loop connections etc PEE 540 ADC and up only 2 FAULTS AND WARNINGS The faults and warnings alert the user to the condition of the drive and motor Faults are conditions that can damage the motor or drive if the condition continues To protect against damage the drive opens the DOK Drive OK contact which in turn opens the motor contactor All faults are level sensed and must be rectified before FAULT RESET can be pressed Warnings occur when limits in the drive have been reached or when a fault is about to occur allowing the user to correct the condition before a drive fault occurs Fault Queue The fault queue stores the last sixteen faults using a FIFO method of data storage The FIFO faults reside in RAM and if a power loss occurs the faults are saved in EEPROM The FIFO stores all faults and issues a FLT CLEARED message indicating that the operator cleared the fault but not the FIFO memory The drive faults may be cleared in one of four ways 1 The user may clear faults by using the RESET key on the HIM 2 The user may clear faults by using the FAULT CLEAR syntax in the FAULT menu 3 The user may configure the drive to clear faults on the positive transition of a bit in the digital table Y CLR FLT INP 4 The user may configure the drive to c
186. board and snubber board if applicable Replace SCR module Replace microprocessor board Maintenance and Troubleshooting SCR SHRT A SCR SHRT B SCR SHRT C SINK TEMP TUNE FAULT USER 1 8 FLT SWR WTCHDOG FAULT MESSAGE PROBLEM Shorted SCR CR4 or snubber on 510 ADC and below units or Shorted SCR A104 on 540 ADC and above units Shorted SCR CR5 or snubber on 510 ADC and below units or Shorted SCR A105 540 ADC and above units Shorted SCR CR6 or snubber on 510 ADC and below units or Shorted SCR A106 on 540 ADC and above units Heat sink gt 65 C Self tune failed TUNE PASS Self tune routine has passed Digital bit configured to Y XXX parameter USER FLT X has gone high 1 XXXXXXXXXXX DPB Label configured to USER FAULTS 1 8 Problem detected by microprocessor portion of the firmware not executing as expected 7 18 ADDvantage 32 PLUS e AC to DC Power Converter SOLUTION Replace bridge interface board and snubber board if applicable b Replace SCR module Replace microprocessor board Replace bridge interface board and snubber board if applicable b Replace SCR module Replace microprocessor board Replace bridge interface board and snubber board if applicable b Replace SCR module e Boop oP Replace microprocessor board Allow drive to cool Replace thermistor RT1 Replace bridge interface board Replace microproce
187. bout 1 4 and then away from the base so that the two tabs at the top separate from the slots 6 Remove J1 from snubber board A4 7 Reconnect J1 cable to new snubber board 8 Place the new bridge interface assembly in position and insert the two tabs at the top into the slots on the base 9 Tighten two captive screws to hold bridge interface assembly in place 10 Replace ground wire 11 Replace seven cables on bridge interface board and shut the main drive door 12 Reapply power to the unit 7 21 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter BRIDGE ASSEMBLY COVER BRIDGE NTERFACE BOARD 3 CAPTIVE DOOR SCREWS Figure 7 2 Replacing Bridge Interface Board 510 ADC and Below 7 22 Maintenance and Troubleshooting ADDvantage 32 PLUS AC to DC Power Converter eee HE BUS BAR SUPPORT BRACE TAB TAB SNUBBER BOARD A4 GROUND CONNECTION J3 BRIDGE J7 INTERFACE CAPTIVE CAPTIVE SCREW SCREW 2 5 SW N i H SS eee TI Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter 7 3 4 REPLACING BRIDGE INTERFACE BOARD A3 540 850 1550 and 3000 ADC Refer to Figure 7 4 COVER 10 11 12 13 k CASE Remove power from the unit Disconnect armature bridge cables from J2 and J3 Open b
188. bration Drive Configuration Control Configuration Reserved nused nused nused nused nused nused nused nused gt Cee eo Cae NOTE For File 60 the type bits must be set at 00 to view faults Faults only reside in the Select List table 9 3 47 FILE 61 THROUGH 62 RESERVE FOR FACTORY USE Files 61 and 62 are reserved for factory use and should not be accessed 9 17 System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter 9 3 48 9 3 49 9 3 50 9 3 51 FILE 63 THROUGH 64 MISC STATUS FILES 63 DOWNLOADING 2 R W 64 RETURN FAULTS 2 I R W FILE 65 THROUGH 68 DIAGNOSTIC TRACE CONTROL FILES 65 ARM TRACE 2 R W ENABLE 66 TRACE 2 67 2 68 LINK CONTROL 2 I R W FILE 69 RESERVED FOR FACTORY USE File 69 is reserved for factory use and should not be accessed FILES 70 THROUGH 73 DIAGNOSTIC STATUS TABLES USE The diagnostic status tables allow recovery of the status of each of the four diagnostic channels Files 70 through File 73 Refer to section 8 19 of ER 14363 001 The complete status data must be recovered to determine the status and state of the diagnostic data table before reading any data table The data from the data tables may not be read until the status indicates that the data sampling and storage is complete and ready for recovery The file number assignments are as follows File 70 The status of channel 1
189. c digital display of plain English messages and engineering units 11 status LED indicators one user definable Integral 8 Channel high speed memory signal analyzer Fully digital standard control loops which may include armature current regulation field current regulation speed control regulation tension control regulation center driven winder regulation 1 1 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter Tach loss and overspeed protection configurable with automatic switchover to a redundant digital tach or armature voltage feedback e Heat sink overtemperature warning DC motor temperature sensing with overtemperature protection AC line fuses and a DC link fuse on regenerative units DC link fuse is only used on units rated 10 through 510 and 550 ADC Individual semiconductor fuses in each leg of SCR bridge applies to units rated at 850A and above Fully rated DC contactor with optional DB pole available Chassis type construction e Instantaneous Over Current IOC protection e Phase loss Phase sequence protection e Field current loss protection e Field economy e Low AC line voltage and frequency protection 16 event Fault FIFO All drive information accessible by remote operator interface over RS485 multidrop link or Ethernet via optional daughter board e USB interface to allow save restore calibration data store signal analyzer data and
190. cal communication path established Execute the ESBX Zap program PN 682937 from the source computer Fill in the following information Drive IP Address Drive Download Port 16726 MAC Address Click the BROWSE button and select the ESBX firmware file 682767 V12 bin or the latest version IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS Avtron ADD32 ETHERNET Downloader 682937_ 10 E ee fiers o M MO M Mc C 682767 682767 v12 bin 6 Click the Send button A progress bar will indicate progression of file transfer When the transfer is complete the following dialog will appear WARNING DO NOT POWER DOWN THE DRIVE DURING AND AFTER THE DOWNLOAD UNTIL THE GREEN AND AMBER LIGHTS ON THE ESBX BOARD START TO BLINK BACK AND FORTH 8 14 8 5 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS lt lt Avion ADD32 ETHERNET Deli 6829370010700 Local Name Local IP Address EXIT SKOVACIK fi 0 1 205 200 ew Cancel IP Address Py Ro OS AL IN Download COMPLETE DO NOT REMOVE POWER FROM DRIVE until an alternating flash pattern is seen on LED s and CR2 on the ETHERNET MODULE OK DOWNLOAD FILE 6827 7 82767 v12 bin BR WSE DOWNLOADING TO DRIVE ESBX ZAP 7 As indicated once the LED s on ESBX module are alternately flashing indicating the firmware has been successfully transferre
191. channel signal analyzer 2 84 DRIVE AND CONTROL BLOCK PARAMETERS SUBMENUS The ADDvantage 32 PLUS provides access to the calibration and configuration parameters directly from the TOP LEVEL menu as shown in Figure 2 18 Figure 2 18 shows a subsection of the TOP LEVEL menu on the left and a description of the calibration or configuration parameters that may be accessed via the various menu options 2 26 ADDvantage 32 PLUS e AC to DC Power Converter Left Right Up Down Bit Config Left Right Up Down Spare Analog Cfg Left Right Up Down Analog Config Left Right Up Down EGD Config Left Right Up Down Spare Cal Left Right J Up Down Calibration 2 Left Right Up Down Calibration 1 Left Right J Up Down Drive Configure Left Right Up Down View and Edit a subset of Drive Application Configuration parameters Pnnn through Pmmm These Application Configuration parameters are associated with digital input selections to the SPARE BLOCKS contained in the application Refer to Appendix C for a listing of all Drive Application Configuration parameters View and Edit a subset of Drive Application Configuration parameters Pnnn through Pmmm These Application Configuration parameters are associated with digital input selections to the control blocks contained in the application Refer to Appendix C for a listing of all Drive Application Configuration parameters View
192. clude Field Supply AC line F3 F4 Control Power Transformer Primary rejection type Fl F2 Board Power F5 Contactor Coil F6 Cooling Blower F7 and Auxiliary Power F8 Fuses F1 F2 F6 and F7 are sized according to the external equipment that is being utilized with the ADDvantage 32 PLUS i e contactors control transformers relays etc These fuses must be supplied by the user or are provided in the optional auxiliary hardware kit which is available in addition to the standard DC motor drive 1 16 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter FIELG SUPPLY FUSES F3 F4 115 CONTROL TRANSFORMER FUSE r5 PRIMARY FUSI 115 VAC FUSES F amp FG EC di L A CAUTION CONNECT LEADS AS vty TO PREVENT DAMAGE TO UNIT C CURRENT TRANSFORMER CT SHUNT FIELD SUPPLY FIELD SCR CR1 FIELD 4 PLEASE LAN NEW TB2 Figure 1 10 Field Controller Base Assembly AFMs and 540 850 1550 3000 ADC Power Converters 1 17 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter 1 2 8 ARMATURE BRIDGE ASSEMBLY 540 850 1550 and 3000 ADC power converters only The ARMATURE BRIDGE ASSEMBLY contains the high voltage armature control components as shown in Figure 1 11 and Figure 1 12 The chassis supports the thyristor module assemblies bus bars fuses and current transformers Blowers on the top of the un
193. cond processor performs the functions required to convert the three phase AC input voltage into the DC voltages that are supplied to motors Flash memory which stores all the drive firmware The firmware may be upgraded easily over the serial link Ethernet interface using the optional Ethernet daughter board or via the USB interface A USB interface to allow convenient and simple storage of drive calibration data signal analyzer data and drive diagnostic data In addition the USB interface allows for the loading of drive calibration data and updating of the drive flash memory The following user I O 6 Analog Inputs 4 Analog Outputs 6 Digital Inputs 4 Form C Digital Outputs 2 Two Phase Tachometer Inputs 1 Buffered Tachometer Output 1 RS485 Serial Link Provides connections for all the user I O via removable terminal blocks The terminal block spacing and layout are fully compatible with the spacing and layout of the ADD 32 drive A serial interface to a Human Interface Module HIM The HIM is supplied installed on the drive but may be easily moved to a location remote from the drive Two daughter board sites to allow optional modules to be installed on the drive The option modules include an Ethernet communication module and an I O expansion module 1 7 122 1 2 3 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter REMOTABLE KEYPAD The ADD 32 PLUS provides a r
194. corrected Then reload calibration data Replace microprocessor board Drive detected a checksum error on one or more of the retentive values saved upon power loss 7 7 Pressing any key will acknowledge this warning Note that the retentive values will be zeroed so extreme caution must be exercised to insure that the zeroing of the retentive value will not compromise the safety and or operation of the drive application Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter TABLE 7 2 POWERUP MESSAGES cont FAULT MESSAGE PROBLEM SOLUTION CONFIG P N DOES NOT MATCH HARDWARE ID UP key to continue FAILURE TO TRANSFER CAL and CONFIG Cycle power to reset ATTEMPTING TO LOCK THE PLL TO THE AC LINE ATTEMPTING TO BRING UP THE FIELD USB INITIALIZATION FAILED UP key to continue The drive part number a Insure that 000 is correct and in DRIVE CONFIG matches the part number of the Y000 DRIVE PN is drive incorrect for the drive b Replace the microprocessor board hardware Replace the bridge interface board Replace the ribbon cable between the microprocessor board and the bridge interface board Failure to transfer Cycle power to the drive necessary calibration Replace microprocessor board and configuration data between processors Status message If good AC power is applied to the indicating drive has not drive and the status
195. ctor is closed The delay is added to allow an accurate reading of motor in the event of a drive starting into a spinning motor I DELAY 0 1 SEC 3 10 DCAFMR14LAN RUNG 15 D ARM ENABLE allows the SCR s to fire and is used in the application portion of the software to release integrators and ramps Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter Figure 3 1 ADDvantage 32 PLUS Logic Diagram sheet 6 of 14 RUNG 16 Delay to check if the gate power has been removed two seconds after the contactor is commanded open M CONTACTOR GATE CHK TIM N Bis DCAFMRI6LAN RUNG 17 Gate error fault if the state of the sense signal is wrong for ten SCR firings If the contactor is opened for two seconds the gate power should be off If D ARM ENABLE is high the gate power should be present already GATE ARM ENABLE D ESTOP IN POWER SENSED CATE ERROR A DELAY a R M 10 FIRES GATE GATE CHK TIM POWER SENSED DCAFMRI7LAN RUNG 18 D CNTL INHIB is the opposite of D ARM ENABLE It is used in the application software to preset integrators and hold ramps D ARM ENABLE X N CNTL INHIB p DCAFMR18LAN Figure 3 1 ADDvantage 32 PLUS Logic Diagram sheet 7 of 14 3
196. d into non volatile memory perform a cold restart of the drive by removing and then re applying control power to the drive ETHERNET SWITCHES A Switch is a network device that connects two or more separate network segments and allows traffic to be passed between them when necessary A Switch determines if a packet should be blocked or transmitted based on the destination address contained in that packet A Switch is like a hub which is an Ethernet 1 or 100BaseT UTP STP repeater However a Switch does not bombard all of the ports with all data A Switch sends incoming data only to its intended device so as to prevent collisions Avtron provides Ethernet Switches from several different manufacturers Please reference your Switch manual for technical information specific to your Switch model While most Switches do not require an IP Address assignment for operation Avtron recommends that Switches be assigned an IP Address so that Switch diagnostic information can be obtained via Internet Explorer web pages Avtron also normally uses the Switch s IP Address for the ADDvantage 32 PLUS drive s Gateway Address as most users would know this IP Address as being used by the Switch and would be less likely to use the address by mistake for other devices Some Switches are factory set with an administrative account and can be accessed over the serial link using a serial link cable provided with the Switch The default Log In User Name and
197. d less than or equal to the R P I requested packet interval time the implicit 4 48 Control Block Description ADDvantage 32 PLUS message is scheduled to occur This bit will transition from low to high if the implicit communication becomes inactive for a time period greater than the R P I time the implicit message was scheduled to occur The bit will reset to a logic level low when Implicit messaging resumes Refer to Appendix I for detailed information regarding the ESBX module interface to Allen Bradley Ethernet IP communications protocol 4 49 Control Block Description ADDvantage 32 PLUS 4 34 ERROR This block is used to generate an error signal such as speed error or current error INPA OUT INPB ERRORD101 FIGURE 4 34 ERROR BLOCK 1 Inputs INPA Analog INPB Analog 2 Outputs OUT Analog 3 Implementation OUT INPA INPB 4 50 Control Block Description ADDvantage 32 PLUS 4 35 INP SPAN OFF FREQUENCY OUT The Frequency Out block is used to output a value to the frequency output located on the optional FAX 32 board For accuracy of the frequency output the frequency cannot go below 200 Hz The full range of the frequency output is from 200 to 20 200 Hz To use the frequency as bidirectional reference set the offset so 10 100 Hz equals zero then scale frequency from 20 200 to 200 The INP to the frequency block is user configurable by P FREQUENCY FAX 32
198. d period of time prior to its installation the storage temperature should not fall below 20 C and noncondensing humidity should be no more than 95 Installation conditions require an ambient temperature of 0 40 C when enclosed Refer to the outline drawing provided in the drawing package for enclosure size and cooling specifications No derating is needed at altitudes between 0 3 300 feet above sea level MOUNTING SPECIFICATIONS All ADDvantage 32 PLUS models should be mounted vertically against a flat panel to allow necessary cooling LOCATION The equipment should be located where the operating ambient temperature does not exceed 50 C within an enclosure and where excessive shock and vibration are not transmitted to the units The equipment should be isolated from or protected against such adverse environmental conditions as oil or water spray and corrosive or conductive air contaminants Ideally the equipment should be installed in an air conditioned control room Refer to appropriate outline drawing for specific enclosure and ambient temperature restrictions Location of Other Equipment The ADD 32 PLUS Power Converter should be installed with sufficient distance from other equipment so that the door may be opened during installation maintenance and servicing without interfering with other equipment REMOTABLE KEYPAD All ADDvantage 32 PLUS models come with a remotable keypad which is supplied installed on the drive Refer to
199. ding on the ADDvantage 32 PLUS Application software being used and will be noted below as Please reference Appendix C of your ADDvantage 32 PLUS Drive manual that shows the parameter listing for your application software Drive Calibrate Menu X Parameters 8 8 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS DRIVE IP ADDRESS X P ADDR HI Highest octet of the DRIVE IP ADDRESS Range 1 255 default 10 X P ADDR HM High Middle octet of the DRIVE IP ADDRESS Range 1 255 default 1 X P ADDR LM Low Middle octet of the DRIVE IP ADDRESS Range 1 255 default 206 X TP ADDR LO Low octet of the DRIVE IP ADDRESS Range 1 256 default 256 Each ADDvantage 32 PLUS drive on the network must have a unique IP address assigned via X parameters shown above Parameter IP ADDR LO may be set to a special value of 256 that indicates the LOW OCTET of the IP address should be set to the DRIVE ID ADDRESS The ADDvantage 32 PLUS drive IP address may need to be changed from default values to meet your specific company s requirements If not specified by your MIS or IT Department the IP address can be left at the default values Be aware that duplicate IP Addresses on the network will cause communication problems and failures DRIVE SUBNET MASK X MSK ADDR HI Highest octet of the DRIVE SUBNET MASK range 0 255 default 255 xX MSK ADDR HM High Middle octet of DRIVE SUBNET MASK range 0 255 de
200. e AC to DC Power Converter 6 Enter the correct calibration values for the following parameters X MFLD SCALE X BRIDGE SIZE X ARM CT OUT e For AFM applications where the line voltage is above 600V enter the correct scaling factors for the voltage sense circuits X AC VT SCALE X DC VT SCALE T Configure the drive to have a current reference from a calibration parameter and disable the CURRENT LOOP FFWD and SPEED LOOP As an example in the Speed Loop of 692002 V21 software the TRQ REF SUM and D DT SPD FFWD blocks can be configured to accomplish both tasks P142 ALT EN D086 ONB BIT 7 A065 SPD REF P141 SPD LP EN D086 ONE BIT P027 D DT GN INP A077 SPEED FFWD 035 8 FFWD GN 0 2 INPA FFWD A076 SPD PI OUT INPB SUMMING TRQ REF SUM INPC P028 ALT TRQ IN C037 ALT STP DCAFMC4SCAN Figure 3 4 692002 V21 Software Block Excerpt a To configure the drive to have a current reference from a calibration parameter for this example set P 42 ALT EN 086 The desired armature current value can be obtained by entering the value into the calibration parameter 037 STP Document Actual Calibration Parameter Used gt 0 b To disable the CURRENT LOOP FFWD for this example set the D DT SPD FFWD gain to zero C035 SPD FFWD GN 0 To disable the SPEED LOOP for this example set the 2 of
201. e Software Operation ADDvantage 32 PLUS e AC to DC Power Converter 3 18 3 19 3 19 1 MOTOR STALL PROTECTION X Parameters Y Parameters D Parameters X STALL SPEED Y STALL PROT D MOTOR STALL X STALL AMP X STALL TIME Motor stall is used to protect a motor that is frozen or overloaded If left in this condition the motor can be permanently damaged Motor stall will fault out the drive if parameter Y STALL PROT is enabled A stall condition is realized when Actual Armature Current gt X STALL AMP Motor Speed In Process Units lt X STALL SPEED Elapsed Time gt X STALL TIME When a motor stall is determined digital data bit D MOTOR STALL turns on regardless of Y STALL PROT bit status This bit can then be configured to a digital output for run removal AVTRON FIRING MODULE DC0001 XXXX X OPTION General X Parameters X BRIDGE SIZE X ARM CT OUT X AC VT SCALE X DC VT SCALE When using the ADDvantage 32 PLUS DCO0001 XXXX X module several parameters must be set so that the module can control the bridge current properly The existing bridge s rating must be known as well as the turns ratio of the feedback CT s the burden resistor value and voltage feedback scaling Paragraph 3 19 3 AFM CURRENT TRANSFORMER PHASING PROCEDURE has steps to determine or calculate necessary values if unknown These values must be accurate or the bridge will not be c
202. e and if any files are created by the signal analyzer store operation in excess of the 100 the contents of those files are likely to be invalid USB Usage ADDvantage 32 PLUS e AC to DC Power Converter 11 1 1 ANALYZER STORE COMPLETION MESSAGES After the user has initiated the operation to store the signal analyzer information to the USB memory stick one of the following messages will be displayed to indicate the results of the requested operation Message Meaning ALYZR SAVED Operation completed successfully ALZR SAVE ERROR Error resulted during the attempt to save analyzer files ALZR SAVE CANCEL Operator cancelled SAVE by hitting LEFT ARROW key NO USB DEV PRSNT No USB memory stick is detectable in the drive NO ANLR CHN DONE No analyzer data is available to be stored 11 1 2 ADDAPT PROPERTIES VIEW OF USB ANALYZER FILES As noted previously files written to the USB memory stick may be viewed on any personal computer equipped with a USB port Specifically the signal analyzer files may be read by the ADDAPT maintenance tool When viewing the files using ADDAPT Figure 11 5 shows the PROPERTY view of an analyzer file that has been saved to the USB stick Several of the properties of an analyzer file stored by the drive to the USB memory stick are set to specific values e AREA 1 The date and time of an analyzer file stored to the USB stick will always show as 01 01 01 or January
203. e condition is present and the following occurs 4 126 Control Block Description ADDvantage 32 PLUS If CEMF is Positive POSO POSI NEGO 0 1 If CEMF is Negative POSO 0 1 NEGO NEGI In the application execute the block between the current limit setpoints and the current loop limit to protect the drive 4 127 Control Block Description ADDvantage 32 PLUS 4 75 WINDER WK D This block calculates the inertia of a winder unwinder The inertia of the material which is essentially a hollow cylinder is equal to WK2 const x width x dia core dia Therefore total inertia of a roll of material is the result of the previous equation plus the fixed inertia FIX CDIA VAR x WID x VAR DIA CDIA 4 WID A B DIA DIA me VDIA FIGURE 4 75 WINDER WK D BLOCK 1 Inputs VAR Analog WID Analog DIA Analog FIX Analog CDIA Analog VDIA Analog 2 Outputs WK Analog 3 Implementation _ VAR WID DIA CDIA FIX VDIA WK 4 128 Control Block Description ADDvantage 32 PLUS The torque required to accelerate a roll is equal to the WK of the body times the change in RPM Torque WK x eee For a Fixed Diameter ime Torque x CER For a Variable Diameter ime Changein FPM The D DT block is used for Time Therefore the amount of current needed to accelerate a roll should equal the output of the WK D block times the o
204. e low pressure air to keep clean 2 If cabinet is equipped with filters keep them free of dirt 3 Check for correct operation of heat sink fans 4 Check wire terminations for tightness K K K K K K KK KK WARNING THE USE OF UNAUTHORIZED PARTS IN THE REPAIR OF THIS EQUIPMENT OR TAMPERING BY UNQUALIFIED PERSONNEL MAY RESULT DANGEROUS CONSEQUENCES AVOID LOSS OF LIFE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE BY FOLLOWING RECOMMENDED SAFETY AND REPAIR PROCEDURES EK EE EE E K E K E K KE E KE K K K K K K K K KKK 7 2 Maintenance and Troubleshooting ADDvantage 32 PLUS AC to DC Power Converter GENERAL DIAGNOSTIC FEATURES The ADD 32 PLUS has an extensive fault and diagnostic check capability Refer to Table 7 3 for a list of faults and warnings that can be detected The design of the ADD 32 PLUS also includes protective functions to insure that the microprocessors are functioning as intended The first protection is the use of a watchdog reset circuit for each processor The watchdog reset circuit will generate a drive reset if the microprocessor has failed to perform a write operation to the watchdog reset circuit for a period of time A reset of either of the processors will cause the DOK Drive OK contactor to be opened The second protective function involves each of the two microprocessors monitoring basic operation of the other In the event that one of the micropr
205. e of the following messages will be displayed to indicate the results of the requested operation Message Meaning No Directory Found Drive did not find an ADD 32 PLUS DRIVE FIRMWARE directory The user is responsible for creation of the directory and placing the appropriate download file in the directory NO FILE FOUND Drive did not find a DLD file in the ADD 32 PLUS DRIVE FIRMWARE directory The user is responsible for placing the appropriate download file in the directory MULT FILES FOUND More than one DLD file is found in the ADD 32 PLUS DRIVE FIRMW ARE directory The user is responsible for placing ONLY ONE download file in the directory NO USB DEV PRSNT No USB memory stick is detectable in the drive gt gt gt gt LOADING lt lt lt lt Message indicates a flash load is currently in progress DO NOT REMOVE POWER while this message is being displayed 11 12 11 3 USB Usage ADDvantage 32 PLUS e AC to DC Power Converter Message Meaning AT9 PROCESSOR FIRMWARE Message displays upon completion of flash UPDATE SUCESSFUL load CYCLE PWR to RESET INVALID CODE Message indicates an invalid AUTHORIZATION CODE is entered by the user The AUTHORIZATION CODE must match the code contained in the FLASHKEY TXT file gt gt LOAD ABORTED The user is cancelling the flash load operation No flash update is performed ABORTED RUN ON The flash load operation is not allowed when drive is running
206. e the four screws attaching the electronics enclosure to the drive cover This is illustrated in Figure 12 4 ADDvantage 32 Electronics Ene a REMOVE FOUR SCREWS BRIDGE INTERFACE 4 zy J BASE BOARD A3 15 COVER Figure 12 4 The ADDvantage 32 drive cover shows the four screws that hold the electronics enclosure in place 12 8 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter 6 Reuse the four screws removed in step 5 to install the ADDvantage 32 PLUS electronics enclosure as shown in Figure 12 5 Eh F2 F8 F9 F10 ADDvantage 32 PLUS F3 F4 Electronics Enclosure Install four screws SU 0 BRIDGE INTE BOARD A3 BASE Figure 12 5 Install the ADD 32 PLUS electronics enclosure to the drive cover with the four screws 12 9 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter 5 After attaching the new electronics enclosure a ribbon cable supplied as part of the upgrade kit will be installed The cable is part number B33178 which is visible on the ribbon cable One side of the cable plugs into connector J2 on the bridge interface board The cable will then be routed across the back of the drive cover and through the slot into the electronics enclosure The position and routing of the B33178 cable is shown in Figure 12 6 Note
207. ected number of sheets REF REF RAT RAT SDS ADJ ADJ SDS SHEETS md DURING STOP WEBS LNGTH FIGURE 4 63 SDS SHEETS DURING STOP BLOCK Inputs REF Analog RAT Analog ADJ Analog WEBS Analog LNGTH Analog EN Digital This function is not part of the ADDvantage 32 PLUS but is part of relay logic 4 103 Control Block Description ADDvantage 32 PLUS 2 Outputs SDS Analog 3 Implementation If EN is high 2 SDS x WEBS RAT x ADJ x LNGTH Where RAT line speed in units per second p 2 60 LENGTH UNITS LINE SPEED UNITS Else SDS 0 nE 60 60 seconds 1 minute to adjust stopping rate in seconds and line speed in minutes 2 the factor used to obtain the integral number of sheets during the ramped stop 4 104 Control Block Description 4 64 SETPOINT ADDvantage 32 PLUS The Setpoint block enables the use of the INC and DEC inputs to modify a setpoint The rates for the INC DEC are adjustable along with the limits The limits can be defined as min max difference or ratio draw This block is used in the beginning of the speed loop and tension loop MAXL MINL INC DEC RES MAX Inputs REF RES INC DEC INCR DECR MAXL MINL ABS UP RET OUT OUT Analog Bit Bit Bit Analog Analog Analog Analog Bit Bit Bit SETPOINT FIGURE 4 64 SETPOINT BLOCK
208. ectrical control panels and distribution equipment with an accurate Arc Flash Hazard Boundary an Arc Flash Hazard Category and the level of the required Personal Protective Equipment PPE The marking shall be per the requirements of the most current version of NFPA 70 National Electric Code The specific marking requirements can be found in the most current version of NFPA 70 E Standard for Electrical Safety Requirement for the Employee Work Place 1 1 ADDvantage 32 PLUS AC TO DC POWER CONVERTER Includes AFM Advanced Firing Module SECTION I INTRODUCTION AND GENERAL INFORMATION DESCRIPTION The ADDvantage 32 PLUS Digital AC to DC Power Converter ADD 32 PLUS provides variable coordinated control process communication and on line status information It provides digital control to DC motors with armature voltages up to 500 VDC and permanent magnet or shunt wound fields up to 300 VDC This manual includes information about the Avtron Advanced Firing Module AFM which is used in retrofit applications that retain existing SCR power conversion The AFM incorporates all the control and diagnostic functions of the ADDvantage 32 PLUS up to and including pulse transformers to fire the existing SCRs STANDARD FEATURES INCLUDE Advanced dual 32 bit ARM processors Fully digital controlled SCR armature bridge and field power converter Remotable maintenance keypad with a 4 line alphanumeri
209. ed to an ADD 32 PLUS drive is damaged it is easy and inexpensive to replace the patch cable leaving the permanently installed fiber cable undisturbed 8 1 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS Avtron PDC 6 drive control systems using 802 3 Ethernet communications provide a high level of reliability performance and diagnostics Utilization of the 802 3 Ethernet requires ADDvantage 32 PLUS hardware and firmware capable of Ethernet support ESBX Ethernet Board The ESBX Ethernet board P N A26494 Rev D and higher is hardware configurable to use either Fiber Optic or Twisted Pair UTP Copper media This board is shipped from Avtron configured for use with fiber optic media To reconfigure ESBX board for twisted pair copper media move jumpers TP2 and TP3 on board from positions 1 and 2 to positions 2 and 3 The ESBX Ethernet board P N A26494 Rev C and lower is pre assembled to use fiber optic media and cannot be modified to use copper The RJ45 connector exists on this fiber version simply for manufacturing simplicity ESBX Ethernet board P N A26495 is pre assembled to use twisted pair Copper media and cannot be modified to use fiber This copper ESBX board P N A26495 has now been replaced with P N A26494 Rev D and higher P N A26494 Rev D and higher Fiber Optic or Twisted Pair UTP Copper Media P N A26494 Rev C and lower Fiber Optic Media Only P N A26495 Twisted Pair UTP Copper Media Only Superseded by P N A26494
210. eedback The tach inputs can be configured to either analog or digital feedbacks 1 Inputs TACHI Analog 2 Analog CEMF Analog MXSPD Analog GAIN Analog SPDVOL Bit 1 OR 2 Bit V RED Bit RED Bit RES Bit 2 Outputs OUT Analog IWARN Bit 2WARN Bit TL Bit 3 Implementation The speed output of the TACH SELECT block is selected from CEMF TACHI or TACH2 inputs and scaled by the GAIN input In order to work properly TACHI and TACH2 inputs need to be properly scaled into the appropriate units If TACH feedback is scaled in FPM or other process units the motor s CEMF input will need to be scaled into the identical units Note If frequency inputs are used as TACH input Section III gives details on how the scaling parameters need to be set in order to get the proper units The GAIN input can be used to scale all inputs into process units that will match the Speed Reference Typical operation of the TACH SELECT block is described below 4 116 Control Block Description ADDvantage 32 PLUS If SPDVOL low OUT x GAIN If SPDVOL high and 1 OR 2 high and no tach loss is detected OUT TACHI x GAIN If SPDVOL high and 1 OR 2 low and no tach loss is detected OUT TACH2 x GAIN Tach failure conditions are detected by comparing CEMF to TACH inputs as follows If CEMF x GAIN 0 20 x MXSPD and TACH x GAIN 0 05 x MXSPD or If CEMF x GAIN gt 0 20 and the polarity of CEM
211. elect List 1 Analog Data Table 2 Digital Data Table 3 Drive Calibration 4 Control Calibration B Drive Configuration 6 Control Configuration FILE 37 DRIVE CONFIG This file contains the drive configuration settings The file is organized the same as File 36 For example First element DRIVE PN Next element BRIDGE SELFTEST System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter 9 3 30 9 3 31 9 3 32 9 3 33 FILE 38 DRIVE CAL This file contains all of the calibration values for each drive calibration entry At initial power up or a power up with default conditions request the default values in File 34 will be written into this file For example First element AD REF Next element ARM SPAN FILE 39 SELECT LIST LABELS The select list table contains ASCII data that may be read but not written to Each element in this table contains generic alpha labels that may be displayed for a number of different variables Some examples are as follows First element _ DISABLED _ Next element _ ENABLED _ FILE 40 CHECKSUM AREA This file contains the checksum values for each of the six calibration and configuration areas Each element is an unsigned long integer value Refer to section 6 2 of ER 14363 001 for recovery of long integers The checksum and element assignment are as follows CHECKSUM AREA ELEMENT NUMBER Drive Calibration Control Calibration Drive Configuration Control Configuration Cal
212. em occurs Emergency Stop ESTOP When the ESTOP input is removed the main contactor opens immediately and the gate firing is suppressed The green EMERG STOP LED on the front of the ADDvantage 32 PLUS will also go out to indicate loss of the ESTOP 3 1 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter After an ESTOP condition has occurred the ESTOP and ESTOP RESET inputs must be applied to reset the ESTOP circuit The EMERG STOP LED will illuminate when the ESTOP circuit is restored 3 1 2 Emergency Stop Reset ESTOP RESET A normally open pushbutton should be used for the ESTOP RESET If the ESTOP input is present then pressing the pushbutton resets the circuit A reset must also be performed if a drive fault has occurred 3 2 DEDICATED OUTPUTS The following dedicated outputs are Form C contact outputs used for ADDvantage 32 PLUS status indication Each output is hard wired and is not user programmable 3 2 1 Drive This Form C contact output signifies that there no fault conditions in the ADDvantage 32 PLUS If a critical fault occurs this output contact opens and remains open until the fault is cleared 32 2 Motor Auxiliary Contactor This Form C contact output opens if the main contactor is open or closes if the main contactor is closed 3 3 CONFIGURABLE DIGITAL INPUTS D Parameters D USER 1 thru D USER 14 The 24 VDC digital inputs are represented by a value
213. emoteable keypad that has the following 4 line x 20 character backlit LCD display The top two lines of the display are dedicated to messaging related to keypad use and is equivalent to the two line display of the ADD 32 The lower two lines are dedicated to the display of fixed drive operating data Each line is configurable by the user to display analog digital or fault information 6 button keypad Four keys up down left right allow the user to navigate through the various drive menus and to select and edit the drive calibration and configuration data The ENTER key is used to accept changes to the calibration and configuration data or to initiate an operation via the keypad The RESET key allows the user to easily reset any drive faults 11 LEDs used to display drive operating status One LED is dedicated to indicating that power is present to the keypad The remaining 10 LEDs are controlled by the ADD 32 PLUS software and have display functions that provide operating and fault information related to the specific functionality of the software installed on the drive The ADD 32 PLUS provides at least one of the LEDs to be user configurable to any digital point in the drive FAX 32 MODULE The FAX 32 MODULE Figure 1 5 is mounted onto one of the expansion sites of the microprocessor board Eight additional digital inputs are added to the ADD 32 PLUS when the FAX 32 module is used The FAX 32 module also provides a frequency output of
214. en parity 4 Stop Bit logic level high 10 1 ADDvantage 32 PLUS e AC to DC Power Converter WH awas ANT TwTH38 Sd 2 00 Ik thet Vs TvIHJLVHM 40 15IT acre tl o ND a5 Assy bon ious ad STONY ORR Sana uiuo Sd did 19 OMY d zr 7 end zd Hd Iv 20 HOLAT 1 LLY HI 1 TSJA Std EINAT ANTI WHA 901 0 uo IHIdd TAHE dU KOLTAI Ld 10 8 SACHS HOUT E 17877510 NN DBS OL T 512 Shar OL 135 SI JAPHHALNT 1409 HA LiNdA Tz OL 136 SI 5535009 JAWIRCHYH 1804 MOLLVOTHTIR CO g Oz seaun PET Wide BAM Moe HL 031480355 ZEIMH HID v CL bx 32 PLUS Serial Link Wiring Sheet 1 of 3 ADD Figure 10 10 2 Serial Link Installation and Troubleshooting merae JH ADDvantage 32 PLUS e AC to DC Power Converter Serial Link Installation and Troubleshooting NTH ANT sd 22 007 JNISIM ANT 1435 Sid LNIOd OL LNIOd 4 1 Sano ALINM THE ITNA NEHE Wd B 5 9 22 019 mwan a eee mi
215. enance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter 7 Plugin cables at J2 and J3 8 Close the door of the field supply assembly and reapply power LLLLLLDLLLLLLLLLLDLLLLLLLLLDLLLLLLLLLLDLDLDLLLLLLLLLDLLLLILILILLI CAUTION IT IS NECESSARY TO FOLLOW THE TORQUE SPECIFICATIONS TO INSURE PROPER OPERATION AND RELIABILITY OF THE UNIT LLLLLLLLLLLLLLLDLLDLLLLLLLLLDLDLLLLLLLDLLDLLLLLLLLLLILILLILILLI 7 47 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter BLOWERS THIS END VOLTAGE ISOLATION GROUND LUG ASSEMBLY ARMATURE BRIDGE THYRISTOR MODULE FUSES F1 THRU F6 ASSEMBLIES A101 THRU A106 AC INPUT LUGS 5 GROUND WIRE DC OUTPUT LUGS ARMBR2SCAN Figure 7 11 Armature Bridge Assembly 540 and 850 Amp 7 48 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter GROUND LUG VOLTAGE ISOLATION ASSEMBLY zi ARMATURE BRIDGE FUSES F1 F6 THYRISTOR MODULE ASSEMBLIES A101 THRU A112 N Q e UIN AC INPUT LUGS COVER GROUND WIRE DC OUTPUT LUGS ARMBR1SCAN Figure 7 12 Armature Bridge Assembly 155x 2 or 4 Only 7 49 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter NOTE Fuses F1 through F6 are parallel fuse units DC250X units VOLTAGE ISOLATION ASSEMBLY ARMATURE BRIDGE FUSES F1 THRU F6 THYRISTOR MODULE ASSEMBLIES A101
216. enerated by the SCR s is dissipated by the heat sinks included in the base assembly The drive base assembly for 510 ADC and below is shown in Figure 1 8 and for 550 ADC in Figure 1 9 The base assemblies include the following Power Thyristor Bridge The POWER THYRISTOR BRIDGE is a 6 pulse bridge which rectifies the incoming 3 phase voltage to DC It permits the DC output voltage to be controlled thereby controlling the speed of the connected DC motor In the 4 quadrant regenerative drive two 6 pulse bridges are arranged in back to back non circulating current configuration which controls voltage and current for motoring and regenerating in both forward and reverse directions Shunt Field Supply The SHUNT FIELD SUPPLY is a single phase thyristor diode bridge which controls the excitation current to the motor s shunt wound field The AC supply comes from the 3 phase main supply AC line fuses protect the converter against overcurrents caused by shorts Control Power Transformer The control power transformer provides 115 VAC power for operation of the control circuitry and cooling fans The only jumper on the drive is the control transformer configuration Correctly jumper the transformer for 230 or 460 VAC incoming line voltage The 550 amp drive base assembly includes optional configurations for 230 460 or 575 VAC input Refer to paragraph 6 6 4 ADDvantage 32 PLUS e AC to DC Power Converter Introduction and Genera
217. er Can be set by user to illuminate when a digital bit in the data table goes high CURRENT LIMIT Amber Lights during a positive or negative current limit This is not a fault condition therefore when the unit goes out of limit the LED turns off FWD BRIDGE ON Amber Lights when forward bridge is being fired Should light during forward motoring or reverse regeneration REV BRIDGE ON Amber Lights when reverse bridge is being fired Should light during reverse motoring or forward regeneration DRIVE FAULT Red Lights when any fault occurs which shuts down the unit Remains lit until all faults are cleared FIELD LOSS Red Lights during an emergency stop on a field loss fault Stays lit until fault is cleared IOC FAULT Red Lights during an emergency stop on an instantaneous overcurrent fault Stays lit until fault is cleared NOTE If all LEDs are flashing on off this indicates a loss of communication between the drive and keypad 7 5 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter TABLE 7 2 POWERUP MESSAGES FAULT MESSAGE SOLUTION PROBLEM SOFTWARE LOAD FAIL invalid APPL SPACE low level download required HARDWARE LOAD FAIL fail to ld AT9 FPGA reset required I SOFTWARE LOAD FAIL missing AT9 FPGA IMG low level download required SOFTWARE LOAD FAIL missing STR FPGA IMG low level download required LOAD FAILURE STR912 FPGA PROGRAM cycle power to
218. er can trigger on an overspeed event and capture a recording of the speed The following shows an example of how one channel of the signal analyzer may be configured to capture a signal when an unusual or unexpected event occurs In this example the analyzer will capture the speed feedback when the speed exceeds a predetermined speed The signal analyzer channel is configured as follows Input Data ABS ACT SPD Trigger Rising at 1 050 of ABS ACT SPD Sample Rate 1 2 777 msec Total Time 8 000 events x 2 777 ms 22 22 seconds Preview 4 000 events Reset Zero bit Enabled One bit The analyzer will capture the speed feedback signal by recording the ABS ACT SPD value The trigger is also set to monitor the speed feedback signal A trigger event will be detected when the speed feedback signal as reported by the ABS ACT SPD value passes through the value of 1 050 in a rising manner the prior sample of ABS ACT SPD was less than 1 050 and the current sample is greater than 1 050 After the trigger is detected the analyzer will collect an additional 4 000 samples of the ABS ACT SPD signal recording a sample every 0 00277 seconds Figure 5 1 shows the trigger and the actual data stored for an event in which the speed feedback exceeds the 1 050 trigger level Note that for this example the analyzer channel had been enabled long enough prior to the trigger to allow the full 4 000 samples of pre trigger data to have been collected Signal
219. er than 2 1 ratio Provided that each ADD 32 PLUS has the proper source impedance any number of drives or frame sizes can be connected to a common power source Connection of any power converter to a transformer with primary rating of 2300 VAC or more may require additional input line conditioning at the power converter to prevent damage to electrical components Contact Avtron Industrial Automation Inc for assistance when this is required A 24 amp field option is available on drives with 12 amp field Consult factory for overload rating 1 30 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter TABLE 1 1 ADDvantage 32 PLUS SPECIFICATIONS Cont DESCRIPTION SPECIFICATION Line Voltage Variation 10 of nominal Line Frequency Range 43 to 63 Hz Armature Voltage Range Armature Drive P N Current Voltage DC0010 0510 XXXX 10 through 510 ADC 240 500 VDC DC054X XXXX 540 ADC 240 500 VDC DC055X XXXX 550 ADC 240 500 650 VDC DC085X XXXX 850 ADC 240 500 VDC DC155X 2XXX 1550 ADC 240 500 VDC 4XXX DC155X AXXX 1550 ADC 240 500 700 VDC BXXX DC300X XXXX 3000 ADC 240 500 700 VDC Armature Current Range 33 to 100 drive rating Below 50 bridge self test may need to be disabled Armature Overload Capacity 150 for 60 seconds Field Current Regulation Continuous throughout speed range User I O 6 analog inputs 4 analog outputs
220. eration ADDvantage 32 PLUS AC to DC Power Converter A DIF FOOTAGE 1 2 or 4 EDGES PULSE PULSES FREQ IN1 X COUNT 1 CAL 1 2 or 4 EDGES PULSE PULSES FREQ IN2 X COUNT 2 CAL The above equation is modified every one million counts to prevent counter overflows This will cause a small floating point error at this event When Y DIF CTR RST is high the differential footage counter is reset When Y DIF CTR HLD is high the differential footage counter is held HARDWARE CONFIGURATION AND DIAGNOSTIC PARAMETERS X Parameters Y Parameters A Parameters D Parameters Y DRIVE P N A LINE VOLTS D REV LOCKOUT X ANLG FSCALE Y BRG SELFTST A LINE FREQ D LINE IMBAL Y 40 OPERATE D ABC ROTATE Y LINK BAUD D PHA LOSS PT Y ANLG DISPLY D PHB LOSS PT D PHC LOSS PT D LOW FREQ PT D HI FREQ PT D SCR ENABLE Hardware configuration parameters are used to set up fundamental operations of the ADDvantage 32 PLUS Refer to Appendix C for an explanation of these parameter functions USER FAULT INPUTS Y Parameters Y USR FAULT 1 Y USR FAULT 2 Y USR FAULT 3 Y USR FAULT 4 Y USR FAULT 5 Y USR FAULT 6 Y USR FAULT 7 Y USR FAULT 8 User fault inputs allow the user to enable fault conditions beyond those generated internally by the ADDvantage 32 PLUS When the fault condition occurs the 3 25 3 14 Core Software Operation AD
221. erent bit signal paths SEL A INPA OUT INPB ur WERE LES BITSELLAN BIT SELECT FIGURE 4 15 BIT SELECT BLOCK 1 Inputs INPA Bit INPB Bit SEL A Bit 2 Outputs OUT Analog 3 Implementation If SEL A bit is high set at 1 OUT is equal to INPA If SEL A bit is low set at 0 OUT is equal to INPB 4 21 Control Block Description 4 16 BUMPLESS SWITCH ADDvantage 32 PLUS This block is used to provide a smooth BUMPLESS transition when switching control reference or feedback between two analog signals REF2 OUT RAT1 RAT2 REF1 SW HOLD DN1 DN2 FIGURE 4 16 BUMPLESS SWITCH BLOCK l Inputs REFI Analog REF2 Analog RATI Analog RAT2 Analog SW Bit HOLD Bit Control Block Description ADDvantage 32 PLUS 2 Outputs OUT Analog DNI Bit DN2 Bit 3 Implementation The RATI input is the rate in units second that the transfer takes place when switching from REF2 to RAT2 is the rate used when switching from to REF2 If the rate input 0 the transfer is performed without ramping When SW goes high the OUT ramps from REF2 to until OUT equals REFI or when REF2 polarity switches from the starting polarity When this condition occurs the DNI bit goes high and the OUT follows REFI without ramping When SW goes low the OUT ramps from to REF2 in the same manner as previous
222. erpreted as all networks or all hosts For example 128 2 255 255 means all hosts on the class B address network 128 2 This is called a directed broadcast address because it contains both a valid network address and a broadcast host address 8 9 3 3 Multicast Addressing Multicast devices use Class D IP addresses to communicate These addresses are contained in the range encompassing 224 0 0 0 through 239 255 255 255 For each multicast address there exists a set of zero or more hosts that listen for packets transmitted to the address This set of devices is called a host group A host that sends packets to a specific group does not need to be a member of the group The host may not even know the current members in the group There are two types of host groups Permanent Applications that are part of this type of group have an IP address permanently assigned by the IANA Membership in this type of host group is not permanent a host can join or leave the group as required A permanent group continues to exist even if it has no members The list of IP addresses assigned to permanent host groups is included in RFC 1700 These reserved addresses include 224 0 0 0 Reserved base address 224 0 0 1 All systems on this subnet 224 0 0 2 All routers on this subnet 8 30 8 9 4 8 9 5 8 9 5 1 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS Interconnect Issues and Notes 1 devices should be connected via a Switc
223. ers p Configuration P parameters configure the application block software used with the ADDvantage 32 PLUS P parameters allow the option to link specific blocks together or configure a C parameter to the input blocks D 7 Q Analog Data Digital Data Calibration Points Calibration and Configuration Data Value A parameters are real time floating point data They represent all the information in the analog data table D parameters are real time bit data They represent all the values in the digital data table A D parameter has a value of either one or zero A one means the condition is true T parameters calibrate the data for the ADDvantage 32 PLUS function tables The ADDvantage 32 PLUS has four function tables each with 16 data points Z parameters are a mix of configurable and calibratable values used for the four built in signal analyzers See Section V Q values are read only parameters used by the Y and Z parameters They represent selections available for certain parameters Figure 2 5 above illustrates where the various parameter groups are used with the ADDvantage 32 PLUS drive The DATA TABLES contain all the real time analog and digital data portions of the data being written by the drive core software portions written by the drive block software portions being read by the drive core so
224. es on the network are passed as lists known as Exchanges The configuration of how these lists are produced and consumed is discussed in Appendix F The Avtron ADD 32 PLUS drives are configured using Avtron s EGDConfig program Avtron P N 683247 The internal data structure of the drive as data is passed from the drive s data tables is illustrated in Figure 8 9 5 1 NOTE Additional information on using EGD protocol is provided in Appendix F 8 31 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS ADD32 PLUS EGD INTERFACE ADD 32 PLUS EGD ANALOG TABLE DRIVE CORE SWR C 3j gt PRODUCERS DRIVE CONTROL BLKS lt EGD CONSUMERS 24 USER OES CONFIGURABLE p f oed ANALOG gt VALUES 1 j gt EGD PRODUCERS DIGITAL TABLE DRIVE CORE SWR E AND Ee DRIVE CONTROL BLKS gt EGD PRODUCERS DRIVE CONTROL BLKS lt 4 3 EGD CONSUMERS 0256 0287 DRIVE CONTROL BLKS lt 7 0288 0361 O STATUS FAULTS FAULT FIFO DRIVE CORE SWR C gt EGD PRODUCERS 16 Faults First Register is the most recent fault v gt PRODUCERS i DRIVE CORE SWR wN Figure 8 9 5 1 ADD 32 PLUS data transfers via EGD 8 32 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS EGD Exchanges are lists of data Each node each unique IP address has its own list of exchanges that it can prod
225. es that may be selected for that particular element of configuration in File 25 FILE 23 CONTROL CFG LABELS This file contains the drive configuration labels One element is used to produce one label For example First element JOG REF Next element MASTER REF FILE 24 CONTROL CAL UNITS This file contains the units associated with each of the labels defined for the control calibration values One element is used to define one unit FILE 25 CONTROL CONFIG This file contains the control configuration data for the particular drive software version and part number 9 7 System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter 9 3 18 9 5 19 9 3 20 FILE 26 DEFAULT CONTROL CAL UNITS This file contains all of the predefined default units for control calibration One element is used to define one unit definition For example First element UNITS Next element UNITS FILE 27 CONTROL CAL This file contains all of the calibration values for each control calibration entry Each element contains one calibration value in floating point format This file will be loaded with the contents of File 21 at initial power up and if the drive is defaulted FILE 28 DIG IO This file defines the digital data table Each bit in the structure represents real time digital data A bit set equal to one 1 indicates an ON condition while a zero 0 indicates an OFF condition 9 8 System Data Structures AD
226. est value of the inputs for a setpoint reference 1 Inputs INPA Analog INPB Analog INPC Analog 2 Outputs OUT Analog 3 Implementation OUT will equal the lowest input value e g If INPA 40 INPB 20 INPC 30 then OUT 30 4 61 Control Block Description ADDvantage 32 PLUS 4 42 LOWPASS FILTER Use to filter out high frequency noise from analog signals such as tension feedback 6 E 1 FREQ TIME C SECONDS BODE PLOT FIGURE 4 42 LOWPASS FILTER BLOCK 1 Inputs INP Analog Tes Analog 2 Outputs OUT Analog 3 Implementation The lowpass filter takes the INP filters it for high frequency then outputs it to OUT The time constant in seconds for the filter is determined by TC Limits of the time constant are from 0 00277 to 2 5 seconds 4 62 Control Block Description ADDvantage 32 PLUS 4 43 MOST WIN The block is used to select the highest value of the inputs for a setpoint reference 1 Inputs INPA Analog INPB Analog INPC Analog 2 Outputs OUT Analog 3 Implementation OUT will equal the highest input value e g If INPA 40 INPB 20 INPC 30 Then OUT 40 4 63 Control Block Description 4 44 MOVS ADDvantage 32 PLUS This block is used to move eight variables to another location when enabled IN1 IN2 IN3 IN4 INS IN6 IN7 IN8 1 Inputs IN2 IN3 IN4 INS INO IN7 8 EN Analog A
227. eter is used to generate the warning bit D M TEMP WARN When the calculated motor temperature goes above this value D M TEMP WARN turns on This bit could then be configured to a user fault or a digital output to display a warning This temperature is calculated from the change in field resistance The drive IIR is not settable and is set to fault when the drive is R A outputting 150 of the rated bridge for 60 seconds On non UL AFM applications this can be disabled by the factory There are three possible IIT curves to choose from one that trips after 8 seconds of 200 one that trips after 10 seconds of 250 and one that trips after 10 seconds of 300 See Figure 3 2B Use parameter Y CURVE to select the desired curve 3 29 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter 100000 10000 1000 100 Time to Trip seconds 10 Figure 3 2A Motor Temperature Overload Curve 3 30 3 16 Core Software Operation TIME to trip SEC 1000 00 100 00 10 00 1 00 100 250 IIT Curve with 120 sec ADD32 PLUS Curve Fig 3 2A ADDvantage 32 PLUS e AC to DC Power Converter 250 IIT Curve 10 Second trip at 250 current 60 Second trip at 150 current Armature Current 96 Figure 3 2B Selectable IIT Curves CURRENT LOOP PARAMETERS X Parameters X Y Parameters
228. expansion module and limited operating data To perform a USB flash load of drive firmware from the USB memory stick navigate the USB submenu to reach the USB FLASH LOAD option as shown below De Press the RIGHT key to save the drive information to the USB memory stick Upon completion of the store operation a file named DRIVE_INFO TXT will have been written to the ADD 32 PLUS DRIVE directory NOTES Each drive information store operation will overwrite the text file on the USB memory stick so only the results of the most recent drive information store operation will be contained on the USB memory stick The time stamp of the DRIVE_INFO TXT file will always be 1 1 2001 12 00 PM The DRIVE INFO TXT file is an ASCII text data file that may be read with WINDOWS NOTEPAD or a similar program Figure 11 6 shows an example of a DRIVE_INFO TXT file 11 15 ADDvantage 32 PLUS e AC to DC Power Converter SAMPLE DRIVE INFO TXT FILE DRIVE ID 001 SOFTWARE PN s and VERSIONS STR BOOT 68588710 STRAPPL 68589110 STR FPGA 68588912 SAM BOOT 68588810 SAM APPL 68589210 SAM FPGA 68589010 APPLICATION 69491210 CAL CONFIG CHECKSUMS DRIVE CAL 6FAOB907 DRIVE 00052CDF APPL CAL F38D6755 APPL CFG 00322592 TABLES 97000000 BRIDGE INTERFACE BOARD A23547 DRIVE CONFIG 000 DC 055x LINE VOLTAGE 1228 LINE FREQUENCY 60 0 DRIVE POWERED TIME d h m s 0 02 40 27 DRIVE RUNNING TIM
229. fault 255 X MSK ADDR LM Low Middle octet of DRIVE SUBNET MASK range 0 255 default 0 X MSK ADDR LO Lowest octet of the DRIVE SUBNET MASK range 0 255 default 0 The Drive Subnet Mask is defaulted to 255 255 0 0 The values of the Subnet Mask may need altered to match the specifics of your company s network Your MIS Department may specify the IP ADDRESS CLASS and subnet range The Subnet Mask will be 255 255 255 0 or 255 255 0 0 depending on your network topology A class A network would be 255 0 0 0 a class B network would be 255 255 0 0 and a Class C would be 255 255 255 0 Be aware that incorrect or inconsistent subnet mask values will cause communication problems and failures A subnet mask divides a network into sub networks For example we use 255 255 0 0 which is a Class B network 255 0 0 0 would be Class A and 255 255 255 0 is Class C The 255 255 0 0 means that any device on a local network with 10 1 xxx xxx can communicate with any other device on the local network with a similar 10 1 xxx xxx IP address and a similar 255 255 0 0 subnet mask That is over 64 000 devices A Class C subdivides this into 254 different networks containing up to 254 each In any given subnet a person can only talk to 253 other devices Computer 10 1 207 213 cannot see a drive at 10 1 206 1 on the Class C network but could on a Class B This will normally be 255 255 0 0 unless the customer specifies otherwise A subnet could be furt
230. ference coming from the first frequency input instead of a calibration number There are two real time data tables in the ADDvantage 32 PLUS All ongoing information is stored in these tables The values can then be used for various functions or be viewed or recorded The first data table is for bit information such as a drive OK bit The second is for floating point data such as actual motor speed The software is also broken down into two parts The first part is the core software which consists of all low level routines including I O scanning SCR firing Diagnostics Serial link communications LAN communications Keypad protocol Inner armature and field current loops The core has its own calibration and configuration parameters and outputs its data to the real time data tables See Section III for a detailed description of the base software The second part of the software is the application code This portion is programmed into software control blocks The blocks are then connected together to form a personality such as speed tension or center driven winder control The inputs of the blocks can come from the real time data tables calibration parameter or a configuration parameter The outputs of the blocks always go to the real time data tables where they can be viewed or used as inputs to other blocks Chapter IV describes the library of blocks that can be used in a particular application Appendices A through D explain all the in
231. for all drives with the MACHINE NO and DRIVE ID corresponding to the channel s that are enabled IP Address settings do not need entered into ADDAPT 2000 You must also set the Channel for each drive section when setting the ADDAPT configuration file for the first time Reference your ADDAPT 2000 manual on the ADDAPT CD or in the C Program Files Avtron Manufacturing ADDAPT Docs folder for further technical information ETHERNET COMMUNICATION TROUBLESHOOTING In the event that you encounter any Ethernet communication problems it will be necessary to isolate the root cause of the problem Follow the Ethernet Troubleshooting Checklist below in the order presented If the problem still cannot be resolved call Avtron s Industrial Automation Field Service Department at 216 642 1230 for further assistance This checklist is a guide for determining where problems exist Jot down notes for each step and present this information to the Avtron service engineer to help isolate the trouble area 1 In what way did Ethernet board fail Was there total loss of communication or intermittent loss of communication 2 Are there any ADD 32 PLUS drive faults or drive LED abnormalities that may indicate a more serious drive problem Refer to Section VII of the ADD 32 PLUS Drive Manual for LED Power Up and Fault definitions 8 18 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS 3 Has the ADD 32 PLUS ESBX board completed its 45 second boot up c
232. ftware and portions being read by the drive block software 2 9 2 4 2 4 1 ADDvantage 32 PLUS e AC to DC Power Converter The drive core software is responsible for the basic functions of the drive including protective functions control of the SCR firing reading analog and digital inputs generating analog and digital outputs measuring the tach feedback and communications In addition the drive core software controls the signal analyzer and maintains the drive table data Below it can be seen that the X and Y parameters are associated with the core software The X calibration parameters define such things as feedback scaling analog input scaling analog output scaling firing angle limits and tach scaling to name a few The Y configuration parameters define such things as the DRIVE PART NUMBER bridge self test mode 2 4 quadrant bridge operation tach type sources for the analog and digital outputs to name a few All of the T table calibration data and the Z signal analyzer calibration and configuration data is also associated with the core software The block software consists of the all of the control blocks required to implement the control scheme in the drive The C calibration parameters and the P configuration parameters allow the user to customize features and functions of the control blocks to meet the needs of their unique applications LCD DISPLAY PARAMETER FORMAT Through navigation of the ADDv
233. g 7 10 2 2 9 10 11 ADDvantage 32 PLUS e AC to DC Power Converter ee K K K K K K K K K K ACAUTION CONNECT LEADS AS SHOWN TO PREVENT DAMAGE TO UNIT For DC0010 through DC0056 drive sizes all SCR gate and cathode leads must be connected as shown For DC0110 and larger drive sizes only field SCR gate and cathode leads must be connected as shown LELLLLLLLLLLLLLLLLLLLLLLLLLLLELLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLI Remove the three Phillips head screws on and CR2 six total Note connection placement Move the two bus bar links away from the thyristor and diode Remove the screws on each end of the device CR1 or CR2 to be replaced Replacement and Reassembly l 25 dd Apply a thin layer of thermally conductive compound to the bottom of new thyristor or diode and reinsert in the field supply base Mount the new thyristor or diode using the screws located on each end Torque tighten the mounting screws to 38 50 in Ib Recheck torque after a minimum of 3 hours Reinstall the wiring bus bar connections and mounting hardware Torque tighten the screws to 22 30 in Ibs Plug in gate leads on CRI observing correct polarity The yellow leads should face the outboard side of the device the red leads should face the inboard side Tighten the two captive screws holding the bridge interface assembly to the base Plug in connectors J5 and J6 to the bridge interface board A3 7 46 Maint
234. g electrical interconnections wiring instructions and installation UNPACKING Inspect all shipping containers for exterior damage Notify the carrier of any damage detected so that the carrier representative may inspect the equipment and shipping containers When removing equipment from shipping containers check carefully that loose items such as connectors nomenclature plates cables manuals etc are removed before discarding packing materials Internal modules and connectors should be checked for proper seating If the ADD 32 PLUS will not be installed right away refer to Storage and Installation Specifications in Section 6 3 for storage instructions MECHANICAL INSTALLATION AND SPECIFICATIONS Outline dimension drawings for the drive are found in the supplemental drawing manual and provide mounting dimensions for physical installation as well as electrical specifications enclosure size specifications grounding requirements and wiring information Recommendations for pulse generator coupling and timing devices are provided in the Avtron Rotary Pulse Generator Installation Instructions Proper mounting of the pulse generator speed feedback device is critical for achieving optimum performance and reliability Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter E KE E K E K E K K K K K K K K K KK KK WARNING WHEN CUTTING OR DRILLING INTO ANY ENCLOSURE HOUSING ALWAYS MAKE SURE THAT M
235. ge MOTOR II T Motor overtemperature due Undersized motor to armature current above b Parameter X001 MOTOR IARM 110 for too long scaled wrong Parameter X002 MOTOR IFLD scaled wrong Check bearings Check gearbox oil Replace bridge interface board Replace micro board MOTOR STALL Motor failed to move with Check setup of stall parameters armature current Check for mechanical binding Check for correct armature and field current scaling d Check for correct speed feedback e Replace motor MOTOR TEMP Motor Thermal Overload a Enable P BYPASS DR to auto Armature Current above phase back current limits 100 for more than rated b Check for proper field current time c Check for a mechanical problem causing excess currents d Check for proper current limit settings 7 14 Maintenance and Troubleshooting FAULT MESSAGE PROBLEM SOLUTION MESSAGE PROBLEM OPEN ARM PHASE IMBAL PHASE LOSS PLL LOCK SCR OPN A F SCR OPN B F No armature resistance detected or more than four SCR s failed Line voltage unstable varies over 20 Line power missing Cannot lock onto line frequency A open SCR fault message SCR or fuse F8 for 510 amp and below SCR A101 or fuse F1 for 540 amp and above bridges B open SCR fault message SCR CR2 or fuse F9 for 510 amp and below SCR A102 or fuse F2 for 540 amp and above brid
236. ge 32 PLUS ADDITIONAL CONTROL 1 0 RAMP CHANGE CONTROL BLOCK FIGURE 4 61A RAMP CHANGE BLOCK 1 Inputs UP Analog DWN Analog REF Analog 2 Outputs RP OUT Analog RMP Bit 3 Implementation The following holds true while the HLD ZERO bits are set high and the RES bit is low explained in detail in ADDITIONAL CONTROL I O 4 93 Control Block Description ADDvantage 32 PLUS If REF is increasing faster than UP the RMP bit is set high and RP OUT ramps at the UP value time period t to t of Figure 4 61 If REF decreases faster than DWN the RMP bit is set high and RP OUT ramps at the DWN value time period t to t4 of Figure 4 61 If neither of the preceding conditions is true the RMP bit is set low and RP OUT equals REF RATE OF CHANGE LIMIT BLOCK 1 Inputs INP Analog Internally connected to the Ramp Output RND Analog Outputs OUT Analog Implementation The rate of change limit block ROC filter is internal to the RMP2 Control Block The purpose of this stage of the RMP2 block is to round the corners created by the ramp change block Figure 4 61B The ROC filter produces rounding by limiting the ramp rate of the input to the output over time The limiting occurs as a result of a calculated value internal to the RMP2 called the Maximum Rate of Change When the input is greater than the Maximum Rate of Change value the output equals the Maximum Rate of Change value
237. ges 7 15 ADDvantage 32 PLUS e AC to DC Power Converter eos GE d SOLUTION Check armature wiring Check motor for open armature through 360 rotation Check fuse F11 for 4 quad drives Check for motor contactor closing Replace bridge interface board Check incoming line voltage Check line fuses Check for excessive line notching Replace bridge interface board Check fuses F8 F9 and F10 Check incoming line voltage Check for excessive line notching Replace bridge interface board NOTE PHASE LOSS will appear in FIFO if power is cycled O g h Check line frequency Check for notching Check fuse F10 Check cable J3 on bridge interface board Check cable J1 on the snubber board Replace cable between bridge board J4 and micro board J2 Replace bridge board Replace micro board NOTE PLL LOCK will appear in FIFO if power is cycled a b en en Check fuse Check cable assembly connected to J2 of microprocessor board and its associated connectors Replace SCR or drive base assembly Replace bridge interface board Replace microprocessor board Check fuse Check cable assembly connected to J2 of microprocessor board and its associated connectors Replace SCR or drive base assembly Replace bridge interface board Replace microprocessor board Maintenance and Troubleshooting FAULT MESSAGE PROBLEM SOLUTION
238. ghtening torque for the bolts 7 44 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter DC54X DC155X DC155X DC85X 2 4 A B DC300X 165 185 in lb 335 365 in lb 390 420 in lb 3 Attach cable connector 1 on all modules 4 Replace the front panel 5 Reconnect the ground wire s to the front panel 6 Reapply power to the unit Hef 29 a 2 a oe fae fae a a oe ae ae fa ae ae aoe ok CAUTION IT IS NECESSARY TO FOLLOW THE TORQUE SPECIFICATIONS TO INSURE PROPER OPERATION AND RELIABILITY OF THE UNIT 7 10 2 REPLACING THE FIELD THYRISTOR AND DIODE 2 7 10 2 1 Disassembly See won Remove power from field supply assembly Unlatch door of main assembly Latches are located on the right side of unit Open the door The bridge interface board A3 will be exposed Remove the cables from connectors J2 and J3 Disconnect cable connectors J5 and J6 on the bridge interface board and move the cables out of the way Loosen the two captive screws holding the bridge interface assembly to the base assembly Open the bridge interface assembly The field thyristor CR1 and field diode CR2 will be exposed Unplug the gate leads on the bottom of CR1 Note the connection placement Twisted pairs of gate lead wires are labeled with a single letter corresponding to a letter silkscreened on the base 7 45 Maintenance and Troubleshootin
239. guration filename gt File Exception encountered while The conversion process encountered a converting ADD32 configuration file Windows exception This exception is ADD232 configuration filename displayed as part of the error message lt exception message gt 12 24 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter ERROR MESSAGE DESCRIPTION Successfully converted The original configuration file lt filename gt to lt configuration filename gt to lt new the new configuration file lt filename gt is configuration file gt successfully converted Cannot convert ADD32 For the original configuration file to configuration file lt ADD32 successfully convert the configuration data of configuration gt ADD32 the ADDvantage 32 PLUS must exactly match template lt ADD32 part gt lt ADD32 the original ADDvantage 32 configuration data version gt ADD32Plus Template in the template files Otherwise the upgrade is lt ADD32Plus part gt lt ADD32Plus not possible version gt are unequal in CFG section at position lt byte gt Cannot convert ADD32 For the original configuration file to configuration ADD32 successfully convert the calibration data of the configuration filename ADD32 ADDvantage 32 PLUS must exactly match the template lt ADD32 part ADD32 original ADDvantage 32 calibration data in the version gt tem ADD32Plus Template template files Otherwise t
240. h the use of hubs is not recommended For more information on Switches vs hubs refer to RFC 0970 On packet Switches with infinite storage A non managed Switch may be used if cost is the only issue but the management and diagnostic capabilities of a managed Switch make the additional cost a good investment to ensure a dependable network 2 Switch port connected to an ADD 32 PLUS drive should be set to 100mb full duplex for best performance 3 Avtron supported protocols may be used separately or together in one system keeping in mind not to exceed 700 frames per second Note that TCP IP protocols use twice the frames of UDP protocols 4 maximum data refresh rate at the drive is 8 33 mSec In most cases read write repetition rates should be expressed in multiples of 10 mSec ie 10 20 50 etc Avtron Supported Protocols The following is a short overview of each of the implemented protocols A more complete explanation of their use and programming is included in the application notes Ethernet Communications Using EGD Protocol GE Fanuc s Ethernet Global Data GE EGD The Ethernet Global Data EGD protocol is a protocol invented by GE Fanuc It may be used to connect ADD 32 PLUS drives to GE Fanuc PLCs and other EGD compliant hardware This protocol is an unsolicited UDP message format Instead of a Server or Client a node on the network can be a Producer or a Consumer The data passed between nod
241. he authorization code 10 124 4 1234 The user would be required to enter an authorization code of 1234 before a firmware update would be allowed EXAMPLE Another example would be a FLASHKEY TXT file that has the first four characters S4ab 1 The authorization code 0 2 First character is 5 Set the authorization code equal to 5 3 Second character is 4 Multiply the authorization code by 10 and then add 4 The authorization code 10 5 4 or 54 4 Third character is The character is not a valid ASCII number and thus the scan is terminated with an authorization code of 54 as computed in step 3 EXAMPLE A final example would be a FLASHKEY TXT file that has the first four characters 111 1 The authorization code 0 2 First character is The character is not a valid ASCII number and the scan is terminated with an authorization code of 0 11 11 USB Usage ADDvantage 32 PLUS e AC to DC Power Converter 11 2 2 NOTES Drive will cease normal operation upon initiation of the flash load Drive will require that power be cycled upon completion of the flash load Drive will not allow a flash load to occur when the drive is running The operator must take great care to insure that the correct file is being downloaded into the drive FLASH LOAD COMPLETION MESSAGES After the user has initiated the operation to update the drive firmware from the USB memory stick on
242. he edited value of the configuration parameter to non volatile memory 2 16 2 8 2 8 1 ADDvantage 32 PLUS e AC to DC Power Converter K K K K K K KK KK CAUTION ALL PARAMETER AND CERTAIN Y PARAMETER CHANGES WILL NOT BE IMPLEMENTED UNTIL POWER IS CYCLED OR THE DRIVE IS RESET E E E E E E EE EK E KE E KE E K E K K K K K K K K K KK KK Pressing the LEFT key will abort the edit and discard any change made to the configuration parameter KEYPAD SYNTAX The following sections describe the various menus and submenus of the ADDvantage 32 PLUS keypad and LCD display TOP LEVEL MENU The TOP LEVEL menu is the initial menu that is visible when the drive has power applied This menu can be accessed from anywhere in the menu system by pressing the LEFT key up to a maximum of seven times to ultimately reach the TOP LEVEL menu 2 17 Up Down ADDvantage 32 PLUS e AC to DC Power Converter OPERATE t 3 DRIVE OPERATING DATA SUBMENU gt Left Right ALL Axxx parameters ALL Dxxx parameters A Up Down USB t USB FUNCTIONS SUBMENU nanan gt Left Right ALL USB load and store functions A Up Down Edit Units Spare Cal gt eas A Up Down Up Down Fault Fifo Calibration 2 a gt gt Up Down Up
243. he equipment must be performed in accordance with the National Electrical Code and any other state or local codes Proper grounding conductor sizing and short circuit protection must be installed for safe operation 3 During normal operation keep all covers in place and cabinet doors shut iv Safety Summary ADDvantage 32 PLUS e AC to DC Power Converter 4 When performing hands on inspections and maintenance be sure the incoming AC feed is turned off and locked out The ADD 32 PLUS and motor may have hazardous voltages present even if the AC feed is turned off NOTE THE ARMATURE CONTACTOR DOES NOT REMOVE HAZARDOUS VOLTAGES WHEN OPENED 5 When necessary to take measurements with the power turned on do not touch any electrical connection points Remove all jewelry from wrists and fingers Make sure test equipment is in safe operating condition 6 While servicing with the power on stand on approved insulating material and be sure not to be grounded 7 Follow the instructions in this manual carefully and observe all danger notices KK WARNING ACCURACY OF CUSTOMER INSTALLED CALIBRATION AND CONFIGURATION DATA IS IMPERATIVE IN THE OPERATION OF THIS EQUIPMENT INCORRECT DATA MAY CAUSE DAMAGE TO THE ADD 32 PLUS MOTOR AND PROCESS EQUIPMENT K K K K K K K KK KK 8 The National Electric Code requires that the end use customer field mark all el
244. he following conditions If RET 0 then VAL 0 If RET 1 VAL is set to its last value prior to power loss VAL must be configured to a retentive point Y RET SETPT to be updated automatically on powerup 4 120 Control Block Description ADDvantage 32 PLUS 471 TYPE2 DIA This block calculates the roll diameter of a center driven winder or unwinder section by using operator entered material thickness value and counting the number of spindle revolutions This diameter calculation block can be used instead of the RATIO block It is as accurate as the value of THCK that is entered THCK is the average thickness of the material RES UP DWN RES LNTH IDIAM 2 ABC GAIN see do IDIAM 2 ABC IDIAM o6 FIGURE 4 71 TYPE 2 DIA BLOCK l Inputs THCK Analog IDIAM Analog LNTH Analog MAX Analog MIN Analog GAIN Analog UP DWN Bit RES Bit 2 Outputs DIA Analog 4 121 Control Block Description ADDvantage 32 PLUS 3 Implementation If RES is high then the output DIA IDIAM If DIA is calculated to go beyond the MAX diameter or MIN diameter limits then DIA will be clamped at the limit When the RES bit is set low the DIA is calculated by the following If UP DWN is high then DIA LNTH GAIN x 2 x THCK IDIAM If UP DWN is low then DIA IDIAM LNTH GAIN x 2 x THCK Length needs to be configured to t
245. he frequency counter from the winder tach The counter needs to be reset at new roll Length divided by Gain should be equal to roll revolutions for the block to work properly 4 122 Control Block Description ADDvantage 32 PLUS 472 TYPE3DIA This block calculates the roll diameter of a winder by counting the footage of the surface roll section The accuracy of this block is comparable to the value of THICK DIA THICK is the average thickness of the material LENGTH DIA RESET IDIAM FIGURE 4 72 TYPE 3 DIA BLOCK 1 Inputs THICK Analog IDIAM Analog LENGTH Analog MAX DIA Analog MIN DIA Analog UP DWN Bit RESET Bit RET Bit 2 Outputs DIA Analog IN MAX Bit IN MIN Bit 4 123 Control Block Description ADDvantage 32 PLUS 3 Implementation If RESET is set high then DIA IDIAM If DIA is calculated to exceed either the MAX DIA or MIN DIA limits then DIA will be clamped at the limit and its corresponding output bit will go high For a winder system set the UP DWN bit high The DIA increases by 2X THICK each time the following equation is true LENGTH New gt x DIA Length Old For an unwinder system set the UP DWN bit low DIA increases by 2X THICK each time the following equation is true LENGTH New x x DIA Length Old NOTE LENGTH Footage value of material from tach counters THICK Average thickness of material Entered in
246. he upgrade is not lt ADD32Plus part ADD32Plus possible version gt tem are unequal in CAL section at position lt byte gt ADD32 Drive Configuration For the original configuration file to lt ADD32 configuration file gt does successfully convert each drive configuration not exist in the ADD32Plus template from the original configuration file s template file lt ADD32Plus file must exist in the new configuration file s part gt lt ADD32Plus version gt tem template file ADD32 Drive Calibration lt ADD32 For the original configuration file to calibration file gt does not exist in the successfully convert each drive calibration ADD32Plus template file from the original calibration file s template file lt ADD32Plus part gt lt ADD32Plus must exist in the new calibration file s template version gt tem file Template File Error lt Detail Either the ADD 32 or ADD 32 PLUS template message gt file could not be accessed See the message for further details Configuration File Error Detail Either the ADD 32 or ADD 32 PLUS message gt configuration file could not be accessed See the message for further details ADD32 configuration file lt ADD32 The ADD 32 configuration as entered or filename does not exist or proper selected from the Open File Dialog box does privileges are not granted to read the not exist If the file does exist can be seen file through the Windows Explorer but cannot
247. he user will typically receive an installation security warning as shown in Figure 12 13 Ignore the warning and click on the Install button to proceed with the installation Application Install Security Warning Publisher cannot be verified Are you sure you want to install this application Name ConvertToAdd32Plus From Hover over the string below to see the full domain C Documents and SettingsYXPMUserlMy DocumentsYAvtroniDeployYConvertToAdd32PlusVwinxP Publisher Unknown Publisher While applications can be useful they can potentially harm your computer IF you do not trust the source do not install this software More Information Figure 12 13 A screen snapshot of the installation security warning that will usually appear The user should ignore this and click on the Install button When the Convert ToADD32Plus software utility program is successfully installed it can be found and launched in the Start Menu It will appear as follows All Programs Avtron Industrial Automation gt ConvertToADD32Plus Utility 12 18 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter 12 2 2 THE CONVERTTOADD32PLUS SOFTWARE UTILITY PROGRAM Once installed and started the ConvertToADD32PLUS utility will appear as shown in Figure 12 14 ConvertToAdd32Plus Utility 686149 v10 MEM x Select Files ADD32 Configuration File C Addapt Configuration 69401216 add BROWSE Template File Direct
248. hen f X IN is the interpolated between the two associated y values 4 114 Control Block Description ADDvantage 32 PLUS 4 69 TACH SELECT AND TACH SELECT W The blocks TACH SELECT and TACH SELECT W are almost identical and behave as described below The difference between the two blocks is described in the SPECIAL TACH 1 FAIL 1WARN fy e RES 1WARN RED sw2 2 FAIL 2WARN E RES 2WARN RED SW1 m T 1WARN 2WARN RED 1WARN 10R2 RED 2WARN 10R2 RED VRED __ SWC 2 x She 4 pij a 4 k lt lt RES TL K l lies SPDVOL 10R2 sw2 SWC KI 1 PX PX SW1 SPDVOL 10R2 swt SWC TACH 2 1 4 ME OUT SPDVOL CEMF T FIGURE 4 69 SELECT AND TACH SELECT W BLOCK 4 115 Control Block Description ADDvantage 32 PLUS This block selects the type of speed feedback to be used by the speed loop Either CEMF or speed feedback may be employed When tach feedback is selected tach loss detection can be used by configuring Y USR FAULT 1 TACH LOSS This block also has the option of using redundant tach inputs On a tach loss of the primary tach it can be specified to switch to a second tach feedback while still running the drive If the tachs fail CEMF feedback can be selected for the speed f
249. her D ZERO BIT or D ONE BIT which holds the output in a constant state For example if a particular application requires that a contact output be closed when a fault occurs perform the following 1 Locate the value the digital data table which signifies ADDvantage 32 PLUS fault D FAULT 2 Configure Y DIG OUT 1 to D FAULT Any time a fault occurs the first digital NORMALLY OPEN output closes The user LED is similar in that it is configured to a digital data bit When the bit is ONE TRUE the LED will light The user LED is the first yellow LED on the drive 3 3 3 5 Core Software Operation LOGIC SEQUENCE Y Parameters Y RUN INPUT Y JOG INPUT Y THRD INPUT FLT INP Y ILIM HI INP Y TLIM LO INP Y MC CLOSE Y MC CLS ENA Y FLD CNTL Y FLD V CMD Y USR LED PT Y E FIFO CLR Y F CLR ON M ADDvantage 32 PLUS e AC to DC Power Converter D Parameters D OC PT D ESTOP IN D FWD BR ACT D REV BR ACT D FLD LOSS PT D SPD MIN PT D FLD ECON PT D M TIMER PT D PLL LOCK PT D ARM ENABLE D FLD ENABLE D DOK OUT D M CONTACTOR D USER LED D LIM LED D FWD BR LED D REV BR LED D DFAULT LED D F LOSS LED D OC LED D RUN LED D RUN ENABLE D JOG ENABLE D THRD ENABLE D FAULT D RUNX D RUN REQUEST D MAX IARM D MIN IARM D CNTL INHIB D USER 1 D USER 2
250. her divided for example 255 255 255 128 8 9 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS 10 1 206 1 10 1 206 127 would be one subnet and 10 1 206 129 10 1 206 254 another not accessible by the other GATEWAY ADDRESS X GWY ADDR HI Highest octet of the GATEWAY IP ADDRESS range 0 255 default 10 X GWY ADDR HM High Middle octet of GATEWAY IP ADDRESS range 0 255 default 1 X GWY ADDR LM Low Middle octet of GATEWAY IP ADDRESS range 0 255 default 205 X GWY ADDR LO Lowest octet of the GATEWAY IP ADDRESS range 0 255 default 3 The GATEWAY IP ADDRESS is defaulted to a value of 10 1 205 3 The Gateway IP Address must be set to a valid address on your network and MUST be in the same subnet as the ADD 32 PLUS Failure to set the GATEWAY IP ADDRESS that is consistent with the DRIVE IP ADDRESS and DRIVE SUBNET MASK will result in a total loss of communications Also failure to set the GATEWAY IP ADDRESS to a valid address may result in failures in communications to devices not on the drive s Subnet or possibly even a total failure of the ESBX Ethernet board Your MIS Department may want to specify the GATEWAY IP ADDRESS Gateway is a generic term for an internetworking system a system that joins two networks together Gateways can be implemented completely in software completely in hardware or as a combination of the two MACHINE NUMBER X MACHINE NO Range 0 7 default 1
251. hould not be a problem unless the drive is configured to generate a fault on a COM LOSS or you have other ETHERNET devices attempting to communicate to the drive during and after the ZAP If 8 11 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS you are attempting to download to a failed Ethernet board whose failure symptom was a total loss in communication then the procedure below for downloading ESBX software to the board will not work as communication with board is required Avtron s factory can program the ESBX board without communication but it is not available for field use at this time The IP ADDRESS that should be entered into the ESBX ZAP program is the IP ADDRESS that is set in the DRIVE CALIBRATION menu The IP ADDRESS is not programmed into the ESBX board the ESBX board obtains its IP ADDRESS from the ADDvantage 32 PLUS drive on which it is mounted The reason the ESBX ZAP program needs the board s IP ADDRESS is because the programming data is sent to the board via ETHERNET and the IP ADDRESS is the board address MAC or Media Access Control address is a unique value associated with a network adapter MAC addresses are also known as hardware addresses or physical addresses The MAC address remains fixed and follows the network device but the IP address changes as the network device moves from one network to another TCP IP protocol is a higher level and requires the IP address ESBX Ethernet Board Firmware Downlo
252. ibration Analyzer Calibration Analyzer Configuration FILE 41 CAL VERSION This file consists of one integer element containing the version number of the calibration data 9 12 System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter 9 3 34 9 3 35 9 3 36 9 3 37 FILE 42 SOFTWARE PART NUMBER AND VERSION NUMBER This file contains the part number and version number for the particular version installed in the unit The table is organized as two bytes per element with two integer elements They are organized as Part Number Element 0 Version Element 1 Reading this file would return the part number and version number of the installed software FILE 43 TIME ARRAY This file is organized as two long integer values of four bytes each The lower element value is a time reference that may be written with a time reference value by the master station If it is not written to it will default to a value of zero 0 The upper element value will be incremented six times for each line cycle after the time reference is set Each element is an unsigned long integer value Refer to section 6 2 of ER 14363 001 for recovery and writing to elements containing long integers Integer 0 Time reference value Integer 1 Time intervals since last time reference FILE 44 ANALYZER CAL LABELS This file contains the analyzer calibration labels Each of the four groups Channels 1 through 4 is
253. ibration and configuration information from a file located on the USB memory stick To perform a USB flash load of calibration and configuration information from the USB memory stick navigate the USB submenu until reaching the USB CAL LOAD option as shown below deeds Pressing the RIGHT key will then display the following USB CAL LOAD ETLE do 049 440 049 4 The second line of the display will show the first 11 characters of the first calibration and configuration file found on the USB memory stick Files with an extension of add are considered to be ADDvantage 32 PLUS calibration configuration files 11 17 USB Usage ADDvantage 32 PLUS e AC to DC Power Converter The drive will look in a specific directory for the calibration configuration files based on both the drive ID as set by jumpers on connector J8 and the part number and version of the firmware installed on the drive The directory will be ADD 32 PLUS DRIVE 69pppp Vnn The represents the drive ID as set by jumpers on connector J8 The 69pppp Vnn represents the part number and version of the drive firmware For example a drive with the drive ID of 22 firmware part number of 696002 and version of 14 will only look in the ADD 32 PLUS DRIVE022 696002 V 14 directory for calibration configuration files that may be loaded into this drive If more than one calibration configuration file with an extension of add exists in the ADD 32 PLUS DRIVE 6
254. ication Notes for the most recent up to date list of supported Ethernet protocols This information can be obtained on Avtron s web site at http www avtron com ADDAPT 2000 and PLC programming packages can operate simultaneously on the same computer if required It does not require two network cards inside the desktop computer to communicate to two devices unless the two devices exist on two totally isolated networks Note In a Windows 2000 system if you disable multiple network adapter NIC cards then re enable them they are re assigned as ports in the order they are enabled This means you can accidentally swap the NIC s used by ethO amp eth2 ADDAPT 2000 ADDAPT 2000 Programming Tools must be used if communicating to drives over Ethernet ADDAPT 98 and the older ADDAPT DOS software do not support Ethernet communication ADDAPT DOS will not work using serial link or any form of communication when drive has Ethernet Application software Before communicating with ADDvantage 32 PLUS drives over 8 17 8 7 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS Ethernet using the ADDAPT 2000 Programming Tools PC you will need to obtain an available IP address for your ADDAPT computer Depending on who designed the Ethernet network you may need to get this information from the Avtron Project Engineer your plant Project Engineer or your MIS Department If you arbitrarily pick an IP Address make sure that it is not used by the drives
255. ich is the default file name A flashing cursor will appear under of CAL SAVE 01 to indicate that the file name may be edited The UP and DOWN keys may be used to scroll through the choices of characters at the indicated cursor position The RIGHT key may be used to move the cursor to select any of the 11 characters in the file name Note that if the cursor is under the right most character and the RIGHT key is pressed it will wrap around to the left most character Once the user has edited the 11 characters to the desired file name pressing the ENTER key will initiate a save of the drive calibration and configuration data to that file The file name to which the drive calibration and configuration data is saved will consist of the 11 characters shown on the display with a file extension of add appended to the end For example saving to the default file name of CAL SAVE 01 will result in the data being saved as CAL SAVE 01 The drive will save the calibration configuration data to a specific directory based on both the drive ID as set by jumpers on connector J8 and the part number and version of the firmware installed on the drive The directory will be ADD 32 PLUS DRIVE 69pppp Vnn The represents the drive ID as set by jumpers on connector J8 The 69pppp Vnn stands for the part number and version of the drive firmware For example a drive with the drive ID of 22 firmware part number of 696002 and version of
256. igure 3 8 Check the polarity of the feedback pulses across each burden resistor with the polarities indicated for each resistor in Figure 3 8 Example Positive pulses Figure 3 4 should be observed for a burden resistor when the scope probe is connected to the resistor and scope ground to the resistor Confirm these pulses at J1 of the SCR Firing Adapter The burden resistor polarities are most easily identified here 3 42 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter 19 20 If any of the pulses are negative switch the leads on the CT for that phase If the CT leads are difficult to reach switch the wires for this CT at J1 of the SCR Firing Adapter Return to step 14 SCR FIRING ADAPTER P N 20651 RI TO SCR BRIDGE DCAFMC8SCAN Figure 3 8 Firing Adapter 3 CT Configuration Diagram 2 CT Feedback Phasing Method 21 22 23 The 2 CT feedback configuration wiring diagram and jumper settings for the A20651 SCR Firing Adapter are shown in Figure 3 9 Check the polarity of the feedback pulses across each burden resistor with the polarities indicated for each CT with the polarities indicated for each CT in Figure 3 8 Example Positive pulses Figure 3 4 should be observed for a CT when the scope probe is connected to the CT and scope ground to the CT Confirm these pulses at J1 of the SCR Firing Adapter points 13 11 for and J1 13 15 for CT2 The polarities
257. in the digital data table Each input is scanned by the core software to determine if it is in an ON or OFF state Once this state is determined the corresponding D USER X parameter is set in the digital data table This bit can then be used by other areas of the application software to enable specific functions Six digital inputs are located on microprocessor board and are represented by parameters D USER 1 thru D USER 6 Eight more inputs are available by adding the FAX 32 board These inputs are represented by D USER 7 thru D USER 14 in the digital 3 2 3 4 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter data table If the FAX 32 board is not used the values for the additional eight parameters are always indeterminate CONFIGURABLE DIGITAL OUTPUTS Y Parameters Y USER LED PT Y DIG OUT 1 Y DIG OUT 2 Y DIG OUT 3 Y DIG OUT 4 The digital outputs are Form C contact outputs located on the microprocessor board Each output is configurable to a value in the digital data table The state of the NORMALLY OPEN contact of a digital output will always match the state of the bit in the digital table to which it is configured If the bit in the digital table is ONE TRUE then the NORMALLY OPEN contact will be closed Otherwise if the bit in the digital table is ZERO FALSE then the NORMALLY OPEN contact will be open Outputs are always functional and can be disabled by configuring them to eit
258. ing machine data 2 phase 240 PPR pulse generator mounted on the motor shaft 3 0 gear ratio from motor to roll Roll diameter of 24 inches l Select the tach type required by setting Y TACH 1 TYPE Q 2 PHASE S or Q TWO PHASE 2 Set X TACH EPR 960 Pulses per revolution of the pulse generator times four edges per pulse 3 Set X TACH GRat 3 0 per the given machine data 4 Set X TACH RDia 2 which is the diameter of the roll in process units feet 3 11 COUNTERS X Parameters Y Parameters Analog Data Table X COUNT 1 CAL Y CTR 1 RESET A FOOTAGE 1 X COUNT 2 CAL Y CTR 1 HOLD A FOOTAGE 2 Y CTR 2 RESET A DIF FOOTAGE Y CTR 2 HOLD Y DIF CTR RST Y DIF CTR HLD The frequency inputs correspond to an associated counter The counter increases one unit for every pulse edge detected The increment value is determined as follows 1 1 2 or 4 Edges Pulse Pulses X COUNT 1 CAL Where 1 Is used when the frequency input is set up for 1 PHASE 3 23 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter one edge operation 2 Is used when the frequency input is set up for 1 PHASE two edge operation 4 Is used when the frequency input is set up for 2 PHASE two edge operation Each counter can be reset or held by configuring Y CTR 1 RESET and Y CTR 1 HOLD to the appropriate bit in the digital data table For exa
259. ing and locating the various parameters ADDvantage 32 PLUS e AC to DC Power Converter Parameters are defined by a four digit code followed by a name or abbreviated description The letter used as the first digit represents the particular group to which a parameter belongs A typical parameter is shown as follows P000 JOG REF Refer to Appendix C for specific parameter numbers and descriptions Table 2 1 lists the nine parameter groups that are defined for the ADDvantage 32 PLUS drive along with a brief description of the group Parameters are organized as shown in Table 2 1 and Figure 2 5 APPLICATION SOFTWARE DATA BLOCK TABLES SOFTWARE CORE SOFTWARE 2 org We dci ES Um PARAMLAYD105 Figure 2 5 Parameter Layout 2 8 ADDvantage 32 PLUS e AC to DC Power Converter TABLE 2 1 PARAMETER ORGANIZATION PARAMETER GROUP Ye PARAMETER TYPE Calibration Configuration DESCRIPTION X parameters calibrate the core software Core parameters perform tasks specific to the ADDvantage 32 PLUS hardware being used Y parameters configure the core software These parameters set up the functionality of the ADDvantage 32 PLUS hardware Cox Calibration C parameters calibrate the application block software being used These parameters can be permanently fixed to specific blocks or can be configured using P paramet
260. ink or even another computer or to connect two or more Switches together Two Switches should be connected by Fiber Optic cable and simply swap connections at one end This generally requires popping the halves of one end out of a clip swapping and reattaching the clip Ethernet Switches can be provided with a combination of both 100 MHz base Fiber Optic and 10 100 MHz UTP Copper ports with the following specifications 100baseTX CATS cable RJ45 connector RJ21 for mini max length 100m 100baseFX fiber optic 2km full duplex multimode cable 412m half duplex singlemode 10km For Switches that provide diagnostics using a web browser start Internet Explorer from Windows using the ADDAPT or PLC computer on the network Type the Switch s IP Address on the Address Line Enter User Name and Password if required for access to the Switch Diagnostics You may want to create a shortcut on your desktop for faster future access to the Switch s Diagnostics PLC s AND ADDAPT 2000 VIA ETHERNET COMMUNICATION PLC s The Avtron ADDvantage 32 PLUS is a high performance and highly configurable digital drive with resident capability to perform drive control functions locally utilizing a PLC for operator interface process I O and permissive logic The PLC is not burdened with time critical and 8 16 8 6 2 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS complex drive control functions yet retains the ability to communicate to the dri
261. input 1 so that a 10 VDC to 10 VDC signal reads 0 to 2500 FPM in the analog data table perform the following 1 Find A ANALOG IN 1 in the analog data table 2 Use this information in the following equations 0 FPM 10VDC X INP 1 CAL X INPT 1 ZERO 2500 FPM 10VDC X INP 1 CAL X INPT 1 ZERO Solving the above equations yields the following results X NPT 1 CAL 125 FPM VDC X INPT 1 ZERO 1250 FPM NOTE The zero value is limited to 150 times the CAL value Erroneous results will occur if this is exceeded 3 20 3 9 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter ANALOG OUTPUT FUNCTIONS X Parameters X OUTPT 1 CAL X OUTPT 1 ZER X DOUTPT2 CAL X OUTPT 2 ZER Y Parameters Y ANLG OUT 1 Y ANLG OUT 2 Y ANLG OUT 3 Y ANLG OUT 4 X DOUTPT3 CAL X OUTPT 3 ZER X OUTPT 4 CAL X OUTPT 4 ZER Analog outputs read information from the analog data table scale it and produce a 10 VDC to 10 VDC output signal Each analog output is configurable to any data table value The output is then scaled by the following function Output VDC Data Table Value X OUTPUT 1 ZERO X OUTPT 1 CAL For example to generate a 10 VDC to 10 VDC signal from the second analog output of the ADDvantage 32 PLUS microprocessor board which represents actual speed 0 2500 FPM perform the following l Find A ACT SPEED in the analog data
262. insure that excessive current is not applied to the motor while phasing the CT feedback Closely watch the ammeter current while performing the following step The armature current should not rise above 1096 of the motor nameplate armature current 3 40 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter 13 Turn the drive on while observing the scope Apply a run command such that the RUNNING LED is illuminated Slowly increase the current command through the calibration parameter documented in step 7 a while observing the scope Stop increasing the current command when voltage pulses are observed on the scope The observed waveform should resemble that of Figure 3 5 Burden Resistor Waveform Discontinuous Current T 05 S 0 gt 0 277 5 545 8 32 11 09 13 87 16 667 05 4 4 Time ms DCAFMC5LAN Figure 3 5 Burden Resistor Waveform Discontinuous Current 14 With an observable current flow at a burden resistor move the scope probe to measure the test point on the bottom of the microprocessor board TP2 is circuit common If all wiring and CT polarities are correct the waveform should resemble that of Figure 3 6 If you observe this waveform go to step 24 or continue on to step 15 if you do not observe this waveform NOTE THAT THERE IS A 5X GAIN BETWEEN THE CT BURDEN RESISTOR AND THIS POINT Voltage Micro Board larm TP Discontinuous Current 0 2 77 5 545
263. ions such as digital and analog inputs and outputs tach serial link etc are made to the quick connect type terminal blocks on the left side of the drive No lugs are required for these connections Use 22 AWG to 14 AWG wire Strip insulation 0 27 from the end of the wire For control power transformer configuration see paragraph 6 7 4 Preparation for Use DRIVE PART NO DC0540 DC0541 DC0542 DC0550 DC0551 DC0552 DC0850 DC0851 DC0852 DC1550 DC1551 DC1552 DC3000 DC3001 DC3002 AC INPUT L1 L2 L3 Recommended Wire Size 2 x 300 MCM 2 x 300 MCM 2 x 300 MCM 2 x 350 MCM 2 x 350 MCM 2 x 350 MCM 3 x 350 MCM 3 x 350 MCM 3 x 350 MCM 5 x 500 MCM 5 x 500 MCM 5 x 500 MCM 6 x 1250 MCM or 8 x 700 MCM kkk 6 x 1250 MCM or 8 x 700 MCM 6 1250 or 8 x 700 MCM ADDvantage 32 PLUS e AC to DC Power Converter TABLE 6 3 RECOMMENDED WIRE SIZES FIELD SUPPLY L1 L2 Recommended Wire Size 10 AWG 8 AWG 6 AWG N A 10 AWG 8 AWG 6 AWG 10 AWG 8 AWG 6 AWG 10 AWG 8 AWG 6 AWG MOTOR ARMATURE A1 A2 Recommended Wire Size 2 x 500 MCM 2 x 500 MCM 2 x 500 MCM 2 x 500 MCM 2 x 500 MCM 2 x 500 MCM 3 x 500 MCM 3 x 500 MCM 3 x 500 MCM 6 x 500 MCM 6 x 500 MCM 6 x 500 MCM 8 x 1000 MCM RK 8 x 1000 MCM RK 8 x 1000 MCM Recommended Wire Size CHASSIS G
264. ions to TB1 on top of the drive NOTE Refer to rating nameplate for voltage and current ratings Recommended wire sizes are based on NEC TABLES 310 16 and 310 17 for copper wire Conductor sizes are based on 60 C table for currents below 100A and 75 C table for currents above 100A Derating factor of 0 82 for 60 degree wire used in 36 40 degree ambient 0 88 for 75 degree wire used in 36 40 degree ambient See N E C Section 250 95 for grounding conductor sizing Sizes may also be adjusted to meet certain lug compatibility requirements These sizes may differ from the drive internal and panel wires Always consult local building codes to determine the requirements of your application The 3 phase AC input power connections L1 L2 L3 are made to studs on top of the drive base assembly Refer to Table 6 2 or 6 2a These connections require terminal lugs for proper connection Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter 6 7 2 Motor armature 1 2 and dynamic braking DB connections are made to terminals attached to the output contactor at the top of the drive Drive sizes DC0010 DC0030 and DC0056 provide lugs at these points Drive sizes DC0110 DC0180 DC0280 DC0360 and DC0510 provide bolts but require terminal lugs for proper connections Refer to Table 6 2 or appropriate outline drawing to determine correct wire terminations Motor field output connections are made to terminals 1 and 2 of terminal b
265. iption ADDvantage 32 PLUS ZER SQU IRES 0 1 d STPT TT INP X A AN x Fal pa 0 1 IGN WST FIGURE 4 38 IIT BLOCK 4 56 FST VAL WRN TRP Control Block Description ADDvantage 32 PLUS 4 39 LATCH LTCH1 LTCH2 HLD1 HLD2 EDGE OUT LEVEL LTCH1 LTCH2 HLD1 HLD2 EDGE OUT Sa T e 0 p LATCHD101 FIGURE 4 39 LATCH BLOCK EDGE INPUT LOW LATCHD101 FIGURE 4 39 A LATCH BLOCK EDGE INPUT HIGH 4 57 Control Block Description 1 Inputs LTCHI Bit 2 Bit HLDI Bit HLD2 Bit EDGE Bit 2 Outputs OUT Bit 3 Implementation ADDvantage 32 PLUS If EDGE is low then If either latch LTCH1 or LTCH2 is high and both holds HLD1 and HLD2 are high then OUT goes high and stays high even if both latches later go low as long as both holds stay high When either hold HLD1 or HLD2 is low then OUT goes low no matter what the state of the latch bits The hold inputs have a higher priority than the latch bits If the hold bits later go high the condition of OUT will be determined by the condition of the latch bits at that time If EDGE is high then If either latch LTCH1 or LTCH2 transitions from low to high the OUT goes high and stays high even if both latches later go low When either hold HLD1 or HLD2 transitions from a
266. it generate airflow across the heatsinks for heat dissipation The armature bridge assembly contains the thyristor modules firing circuitry current sensing blowers on 540 and 850 amp drives and fusing to protect the thyristors ALTARE M ASSENBLT ERDUHD Li RU THYRISTOR ASSEVBILTES AE THRU A138 of E NAMEFLATES Ha JU UU Ul DLITPLIT LUGS Figure 1 11 Armature Bridge Assembly 540 and 850 Amp Power Converters Only 1 18 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter GROUND LUG VOLTAGE ISOLATION ASSEMBLY ARMATURE BRIDGE ASSEMBLIES Ala THRU A112 AC INPUT LUGS FIGURE 1 12 DC OUTPUT Lucas Figure 1 12 Armature Bridge Assembly 1 19 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter 1550 Amp and 3000 Amp Power Converters Only 1 20 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter 1 2 9 THYRISTOR MODULE ASSEMBLY 540 ADC 850 ADC 1550 ADC and 3000 ADC Power Converters The THYRISTOR MODULE ASSEMBLY contains the SCR s firing snubber board air baffle and bus bars Refer to Fig
267. it is operated at 230 VAC input and F4 are 5A 600V Class CC P N 324475 If unit is operated at 460 575 V AC input and F4 are 600V Class CC P N 324453 See Section 6 6 2 for configuration instructions 7 53 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter TABLE 7 9 VENDOR GUIDE BUSSMANN LITTELFUSE MERSEN FERRAZ AVTRON P N FUSE RATING P N P N USA P N P N 324008 06A 250 V MDL 6 10 324019 1 25A 250V MDL 1 1 4 313 1 1 4 324154 6 25A 250V MDA 6 1 4 326 6 1 4 324184 5A 250V MDA 5 326 5 324195 1A 250V MDA 1 326 1 324199 8A 250V MDA 8 326 8 324267 1400A 700V AO70URD33TTI1400 324397 1 25A 250V MDA 1 1 4 326 1 1 4 324438 5A 500V FWH 5AI4F LS0S 5 324439 10A 500V FWH 10A14F 1 505 10 324440 20A 500V FWH 20A14F L50S 20 ASOP20 1 324441 50A 700V FWP 50B L50S 50 A70P50 4 324442 40A 500V FWH 40B L50S 40 50 40 4 324443 80A 700V FWP 80B L70S 80 70 80 4 324444 60A 500V FWH 60B L50S 60 ASOP60 4 324447 300A 700V FWP 300A L70S 300 70 300 4 324451 3A 250V MDA 3 326 3 324452 2A 600V FNQ R 2 KLDR 2 ATQR2 324453 3A 600V FNQ R 3 KLDR 3 ATQR3 324454 4A 600V FNQ R 4 KLDR 4 ATOR4 324455 175A 500V FWH 175A L50S 175 ASOPI75 4 324456 300A 500 FWH 300A L50S 300 ASOP300 4 324457 400A 500V FWH 400A L50S 400 50 400 4 324458 500A 500V 500 L50S 500 50 500 4 324459 200A 700 FWP 200A L70S 200 AT0P200 4 324460 400A 700V FWP 400A L70S 400 A
268. l Peer Primitive Peer Primitive protocol enables Autoscan Exchange communications among ADD 32 PLUS drives and provides the backbone for high speed communications to Avtron s Performance View Graphic Trending Historical Event Recorder and Avtron s ADDAPT 2000 drive maintenance tool The ESBX board can communicate using up to four different Ethernet protocols simultaneously over the same network cable which provides great flexibility in system design A managed high speed Ethernet Switch is usually provided with Avtron s Ethernet based drive systems The Avtron provided Switch may include multiple 100 Mbaud fiber ports and multiple 10 100 Mbaud copper ports The managed Ethernet Switch is the central node of the network and will guarantee deterministic communication to all nodes by providing one full duplex 802 3 communication port for each device on the network Full duplex operation of a single device per port assures no data collisions can occur Many of the provided Switches have built in Switch diagnostic functions These diagnostics greatly enhance network maintenance capability by providing independent diagnostics for each port which can quickly identify and localize a network problem Patch Wic boxes may have been provided to manage excess fiber cable and provide a means to connect each drive to the multi conductor field installed cable by way of an easily replaceable fiber patch cord cable In the event a fiber patch cable connect
269. l Information CURRENT TRANSFORMERS lt 3 HEAT SINK THERIMISTOR CRE SHUNT FIELD SUPPLY FB F7 POWER THYRISTORS Lo CONTACTOR F3 F4 DC BUS BARS F11 BARS X1 X2 X3 CONTROL POWER TRANSFORMER FAN ER1 CRB F POWER THYRISTOR BRIDGE Figure 1 8 Drive Base Assembly 510 ADC and Below 1 13 Introduction and General Information ADDvanta ge 32 PLUS e AC to DC Power Converter Figure 1 9 Drive Base Assembly 550 ADC 1 14 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter DC Contactor A DC contactor is used to positively remove current from the motor armature A dynamic braking DB pole may be provided as an option on all drives Power converters may be purchased with or without contactors and with or without DB pole The 510 ADC and above units have externally mounted contactors while the 10 360 ADC versions are available with contactors mounted within the drive base assembly Fusing 10 Through 510 and 550 ADC WARNING Replace fuses only with same type and rating Replacement with fuses other than those recommended may result in damage to the ADDvantage 32 PLUS and or connected equipment as well as severe injury or death to personnel Fuses located on the Drive Base Assembly for p
270. l data or fault data Each of the lines is configurable independently Figure 2 4 EMEND D SRM CIOS 8 Figure 2 4 Lines 3 and 4 of the LCD display show drive analog data 2 2 MENUS AND SUBMENUS The ADDvantage 32 PLUS drive allows user access to all drive calibration configuration and operating data via the keypad and LCD display based on a menu submenu syntax structure A menu offers the user a list of options from which to select The LCD display will display one of the options at a time The user may navigate through the list of options by using the UP and DOWN keys The ADDvantage 32 PLUS menus are looping menus and the user may reach any option in the list using the UP or DOWN keys without regard to the current menu option displayed A submenu is a secondary menu accessed from another menu The user may enter a submenu from a menu by pressing the RIGHT key The display will indicate that a menu 29 option will lead to a submenu when the RIGHT key is pressed by displaying gt on 2 4 2 2 1 ADDvantage 32 PLUS e AC to DC Power Converter the second line of the LCD display as shown in Figure 2 2 A submenu may be exited by pressing the LEFT key When the LEFT key is pressed the LCD display will then return to the menu option that was displayed prior to entry into the submenu The ultimate purpose of the ADDvantage 32 PLUS keypad and LCD display is to provide the user with access to the calibrati
271. lear faults on the close of the M 7 9 Maintenance and Troubleshooting ADDvantage 32 PLUS AC to DC Power Converter CONTACTOR Y F CLR ON M In addition to clearing the actual fault the fault queue can also be cleared in one of two ways 1 The user may clear the fault FIFO by using the FAULT FIFO CLEAR syntax in the FAULT menu 2 The user may configure the drive to clear the fault fifo on the positive transition of a bit in the digital table Y F FIFO CLR TYPES OF WARNINGS AND FAULTS A Hardcoded Faults and Warnings Hardcoded faults are not user definable Some hardcoded events are only valid when the motor contactor is picked up See Table 7 3 for a list of faults warnings and motor contactor status See Table 7 4 for fault messages and corrective action B User Defined Faults Warnings There are eight possible user defined fault messages which may be configured to any digital data point The defined faults are Y USR FAULT 1 through Y USR FAULT 8 The label of the digital data point the user fault is configured for is shown in the fault FIFO 7 10 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter TABLE 7 3 HARDCODED FAULTS AND WARNINGS FAULT F OR MOTOR CONTACTOR FAULT MESSAGE WARNING W MUST BE PICKED UP w w w N Y L FREQ HIGH F N L FREQ LOW F N LINE VOLTAG F N Y y Y N y Y Y Y y
272. ll equal the smaller value of either the table output or the POS I and NEG I inputs The table output will equal the START PER C START PER S when IIR INTEGR 25 counts When IIR INTEGR 100 counts the table output will equal END PER C END PER S where the user should enter a value of 10096 or less When IIR INTEGR is between 25 to 100 counts the table output is equal to the interpolation between START PER and END PER The POS LIM and NEG LIM outputs are then checked against another hidden SFDBK table within the block to check the current limits by the SFDBK input A ABS ACT SPD When SFDBK BRK SPD the speed table output will equal START PER S IF SFDBK MAX SPD the speed table output will equal END PER S where the user should enter a value of 100 or less When SFDBK is between BRK SPD and MAX SPD the speed table output will equal the interpolation between START PER S and END PER S The POS LIM and NEG LIM outputs will equal the smaller value of either the table output or the POS I and NEG I inputs Block Positive Bridge The Positive Bridge can be blocked by making the BLOCK POS input high by configuring P BLOCK POS B ONE BIT The POS LIM output will equal zero when BLOCK POS is set high If BLOCK POS is set low zero bit POS LIM output will equal the smallest value between POS I input the output of the DR Trip table or the SFDBK table Block Negative Bridge The Negative Bridge can be blocked by making the
273. lock TB1 located on top of the drive base assembly No terminal lugs are required Use 22 AWG to 8 AWG wire Strip insulation 0 59 from end of wire NOTE Refer to appropriate outline drawing to determine voltage and current ratings Optional auxiliary field excitation transformer connections are made directly to terminals 3 4 5 and 6 Use 22 AWG to 12 AWG wire Strip insulation 0 39 from end of wire Auxiliary control power connections are made directly to terminals 7 and 8 Use 22 AWG to 12 AWG wire Strip insulation 0 47 from end of wire M Contactor auxiliary contact connections are made to TB1 terminals 14 15 16 These are rated to interrupt at a maximum of 5A 300 V Use 22 AWG to 14 AWG wire Strip insulation 0 39 from end of wire Additional control connections such as E STOP E STOP RESET and DOK OUT are made to the quick connect plug connector at TB1 terminals 11 12 13 and 17 18 19 and 20 Use 22 AWG to 14 AWG wire Strip insulation 0 27 from end of wire System interconnections such as digital and analog inputs and outputs tach serial link etc are made to the quick connect terminal blocks on the left side of the drive No lugs are required for these connections Use 22 AWG to 14 AWG wire Strip insulation 0 27 from the end of the wire For control power transformer configuration see paragraph 6 7 4 550 ADC The 3 phase AC input power connections Ll L2 L3 and the mo
274. low OUT 0 When ZERO bit goes high OUT ramps to REF by the UP or DWN ramp rates Highest bit priority If the RES bit is high OUT REF Second in priority If the HLD bit is low OUT is held at its present value The rounding continues to prevent a step response When HLD goes high OUT ramps to REF by the appropriate rate The UP DWN inputs are entered in units second The following holds true while the HLD ZERO bits are set high and the RES bit is low If REF is increasing faster than UP the RMP bit is set high and OUT ramps at the UP value If UP is equal to zero then the OUT ramps with the REF If REF decreases faster than DWN the RAMP bit is set high and OUT ramps at the DWN value If DWN is equal to zero then the OUT ramps with the REF If neither of the preceding conditions are true the RMP bit is set low and OUT equals REF The RND input determines the amount of S ramp to be applied to the OUT This is implemented as a low pass filter to the linear ramp The RND value is entered as a time constant in seconds If RND lt 005 no rounding will take place NOTE On powerup OUT REF 4 83 Control Block Description ADDvantage 32 PLUS 4 5 RATE CHANGE This block is used to restrict the rate of change of an analog signal to a user programmable maximum rate limit INP pe MAGNITUDE INPUT FIGURE 4 57 RATE CHANGE BLOCK 1 Inputs INP Analog RATE Analog
275. lowing the bus bars to be lifted 7 38 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter b Remove the terminal screws that attach the remaining wire leads to the device to be replaced Using 5 32 Allen wrench remove the mounting screws each end of the device and remove the device d Apply a layer of thermally conductive compound to bottom of new device and reinstall Tighten the 10 24 socket head screws to 38 50 in lb Recheck torque after a minimum of 3 hours and apply torque seal Replace the leads and the bus bars using the metric hardware provided with the semiconductor device Tighten the terminal screws to 22 30 in Ib using a 2 Phillips screwdriver NCAUTION CONNECT LEADS AS SHOWN TO PREVENT DAMAGE TO UNIT For 550 ADC models this CAUTION applies to the field SCR CR7 only It is important to keep the yellow wire of each pair on the outboard side of the device and the red wire on the inboard side 8 The control power fuses 7 12 and 13 are readily accessible just to the right of the field SCR and diode 7 39 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter NOTE As the unit is shipped fuses F3 and F4 are 3amp for 460 575 V AC operation To use for 230 VAC input and F4 must be changed to 5 amp see Table 7 8b Fuses to make this change are supplied in a bag attached to
276. ly described When OUT equals REF2 the DN2 bit goes high and the OUT follows REF2 without ramping When the HOLD bit goes high the OUT freezes at the current value When deactivated the OUT ramps using the associated rate value to the input value selected by SW If the appropriate DONE BIT was set it will be cleared at the removal of the hold bit until the ramping is complete 4 23 Control Block Description ADDvantage 32 PLUS 4 17 CDS COUNTS DURING STOP This block calculates the number of pulses that will be counted during a controlled stop It is used in turret applications to determine when the drive run should be removed so that the turret will stop at the appropriate index position CDS REF 2 CDS REF STOP RT STOP RT COUNTS DURING CDS ADJ PAP CDS ADJ GEAR RATIO GR x PPR PPR FIGURE 4 17 CDS COUNTS DURING STOP BLOCK 1 Inputs CDS REF Analog STOP RT Analog CDS ADJ Analog GEAR RATIO Analog PPR Analog 2 Outputs COUNT STOP Analog 4 24 Control Block Description ADDvantage 32 PLUS 3 Implementation CDS 2 STOPPING CDS REF GR PPR CDS ADJ STOPPING RT CDS ADJ GR x PPR Where CDS REF REFERENCE IN RPM STOPPING RT RATE IN RPM SEC CDS ADJ 2 x 60 SEC MIN GEAR RATIO NO UNITS PPR PULSES REV 4 25 Control Block Description ADDvantage 32 PLUS 4 18 CLAMPING A Clamping block is used to restrict an analog signal
277. made up of eight elements For example First element TRIG LEVEL 1 Next element RATE 1 NOTE While scrolling through the ADDvantage 32 PLUS keypad in the ANALYZER SETUP menu parameters Z000 RESET 1 and Z001 OUTPUT 1 appear Z000 Z001 Z100 Z101 Z200 etc are not included elements in this file The RESET and OUTPUT functions are only available when executed on the keypad FILE 45 ANALYZER CAL HI LIMS This file contains the analyzer calibration high limit values This file contains eight floating point values for each of the four channels in File 44 Data limits for each 9 13 System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter 9 3 38 9 3 39 9 3 40 9 3 41 9 3 42 channel are identical Elements 0 4 correspond to 7002 7006 Elements 8 12 correspond to Z102 Z106 etc EXAMPLE ANALYZER CAL HI LIMS FILE 45 Analyzer 1 Analyzer 2 Element Element 0 9999 0 8 9999 0 1 9999 0 9 9999 0 2 2999 0 10 2999 0 3 9999 0 11 9999 0 4 9999 0 12 99990 5 0 0 13 00 6 0 0 14 0 0 7 0 0 15 00 Analyzer 3 Analyzer 4 Element Element 16 9999 0 24 9999 0 17 9999 0 25 99990 18 2999 0 26 2999 0 19 9999 0 27 9999 0 20 9999 0 28 9999 0 21 0 0 29 00 22 00 30 00 23 00 31 0 0 FILE 46 ANALYZER CAL LO LIMS This file contains the analyzer calibration low limit values for each of the four channels in File 44 Data limits for each channel are identical See Section V FILE 47 ANALYZER CAL DEFAUL
278. me in days hours minutes and seconds that drive has had power applied note time accuracy is 2 seconds per day STACK USE LEVELS Left Righ Diagnostic for FACTORY ML Software part number of the firmware contained on the optional ETHERNET expansion module only valid if ESBX MODULE installed Software part number of the AT9 processor main program firmware Software part number of the STR912 processor main program firmware Software part number of the AT9 Field programmable gate array firmware Software part number of the STR912 Field programmable gate array firmware Software part number of the AT9 processor boot firmware Software part number of the STR912 processor boot firmware Diagnostic information for FACTORY lt LEFT RIGHT gt USE J Figure 2 15 This ADD 32 PLUS keypad syntax shows the DIAGNOSTICS submenu 2 23 2 8 3 ADDvantage 32 PLUS e AC to DC Power Converter ANALYZER SUBMENUS The ANALYZER submenus are shown in Figures 2 16 and 2 17 Figure 2 16 shows a subsection of the TOP LEVEL menu on the left side and the first level of the ANALYZER submenu which is accessed by pressing the RIGHT key The ANALYZER submenu accesses all configuration and calibration data associated with the eight channel signal analyzer Refer to Section 5 for more information on the signal analyzer In addition to accessing the configuration and calibration data for each signal analyzer channel
279. message persists been able to synchronize a Replace the microprocessor board to the AC line Replace the bridge interface board Replace the ribbon cable between the bridge interface and microprocessor boards By holding down the UP DOWN LEFT and RIGHT keys at the same time the drive will bypass the PLL LOCK The drive will not gate any SCR s while in the bypass mode Status message Status indication only indicating that the drive is starting the field Drive unable to a Cycle power to drive initialize the USB b Replace microprocessor board subsystem Note that by pressing the UP key the drive will complete initialization No USB functions will be successful if the initialization failed 7 8 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter TABLE 7 2 POWERUP MESSAGES cont FAULT MESSAGE PROBLEM SOLUTION H ARI DWARI E PROBLEM Drive detected a missing a Check cable between the m SING CABLE ribbon cable between microprocessor board and bridge BRG BOARD the microprocessor and board bridge interface board Replace bridge interface board Replace microprocessor board Replace ribbon cable HARDWARE PROBLEM Bad thermistor or Check cables at J8 and J2 of bridge MISSING THERMISTOR missing cable interface board CABLE ON Replace thermistor BRIDGE BOARD Replace microprocessor
280. mmediately reenter the fault state The FAULT FIFO submenu also provides the ability to clear all 16 entries in the FAULT FIFO After the FAULT FIFO is cleared the FAULT FIFO will be empty Additionally the submenu allows the user to view the contents of the FAULT FIFO When the 2 29 ADDvantage 32 PLUS e AC to DC Power Converter RIGHT key is pressed from the VIEW FAULT FIFO option the display will initially show FAULT EVENT 1 The first event is the fault that has most recently occurred The second event FAULT EVENT 2 is the next most recent fault to have occurred Use of the UP and DOWN keys will allow the user to examine all of the events logged in the FAULT FIFO While viewing the fault events pressing the RIGHT key will provide the user with a time stamp of when the fault occurred The time stamp is the amount of time that has elapsed since power was last applied to the drive and is in a days hours minutes seconds format Pressing the UP or DOWN key will allow scrolling through the time stamps for the 16 events in the FAULT FIFO Pressing the LEFT key will return to the display of the actual fault event FY From the CLEAR FIFO pressing the left key Edit Units CLEAR FIFO AE gt will cause all entries the fault fifo to be erased emptying the fault fifo of all past faults Up Down Up Down Y Fault Fifo t View Fault Fifo Fault
281. mple a 2 phase tach is connected to frequency input number 2 and produces 750 pulses for every foot of product A reset button is wired into the first digital input on the microprocessor board The counter is to be held any time the second digital input is on To calibrate and configure the counter to count inches of product perform the following l Locate D USER 1 and D USER 2 the parameters in the digital data table which represent the two digital inputs being used 2 Configure Y CTR 2 RESET to D USER 1 Configure Y CTR 2 HOLD to D USER 2 This will reset the counter when the first digital input turns on and will hold the counter when the second input is on 3 To determine the calibration number for the counter the length per pulse must be found It is given that 750 pulses 1 foot Converting this into inches yields 750 pulses ft 62 5 pulses inch 12 inch ft or 1 pulse 1 62 5 pulses inch 016 inches The increment value for the counter is 016 inches every pulse To determine the calibration parameter set the equation up for one increment value as follows A FOOTAGE 2 016 inches pulse 4 X COUNT 2 CAL PULSE X COUNT 2 CAL 004 This value causes the counter to increment 0 016 inches for every pulse detected at the frequency input The differential footage counter keeps track of the difference between the two frequency inputs 3 24 3 12 3 13 Core Software Op
282. n Ib Be certain to orient the bus bars properly to each other now before attaching to the base e Reattach the fuse to the base using the two 1 2 13 screws and 5 16 Belleville springs Tighten to 120 140 in Ib f Reattach the vertical bus bar removed in step a 6 To replace any of the six SCRs 6 perform the following steps in order a Remove the twisted pairs of wires from the gate leads of the thyristor to be replaced NOTE Each pair of wires is labeled with a single letter corresponding to a letter silkscreened on the base b Remove whatever bus bars are required to gain access to the desired SCR c Using a 5 32 Allen wrench remove the mounting screws on each corner of the thyristor and remove the thyristor d Apply a layer of thermally conductive compound to bottom of new thyristor and reinstall Tighten the 10 24 socket head screws to 38 50 in Ib Recheck torque after a minimum of hours and apply torque seal e Replace the bus bars on the thyristor using the metric hardware provided with the semiconductor module Tighten the terminal screws to 70 90 f Reattach the leads removed in step a being certain to match the letter designations 7 The field thyristor CR7 and field diode CR8 on the same panel as CR1 6 near the bottom They may be replaced by the following steps a Remove the four terminal screws in the thyristor and diode that old the two bus bars in place al
283. n and General Information ADDvantage 32 PLUS e AC to DC Power Converter TABLE 1 1 ADDvantage 32 PLUS SPECIFICATIONS Cont DESCRIPTION Worst Case Power Loss Continued Power factor is highly dependent on operating speed The curve in Figure 1 18 approximates power factor SPECIFICATION g 9 9 o 8 P4 vs i 7 6 O 5 lt fi 3 2 25 50 75 100 8 Figure 1 18 Power Factor vs Speed Additional Specifications are located in the supplemental drawing package 1 35 Introduction and General Information TABLE 1 1 ADDvantage 32 PLUS SPECIFICATIONS Cont Bridge Interface Board OUTPUT TO ARMATURE CIRCUIT FIRING SIGNAL T B S FIELD SUPPLY ARMATURE CURRENT FEEDBACK DC0010 0510 and 0550 Outputs up to 12 SCR firing signals 6 forward and 6 reverse Contains pulse shaping circuitry J3 and J7 See paragraph 1 2 6 0 66V 100 Iarm DRIVE PART NUMBER DC0540 DC0001 and 0850 3000 DC0002 AFMs Outputs up to 12 SCR firing signals 6 forward and 6 reverse Pulse shaping circuitry provided on armature bridge assembly J2 and J3 See paragraph 1 2 7 0 66V 100 Iarm 1 36 Outputs up to 12 SCR firing signals 6 forward and 6 reverse SCR gate power supplied through internal 24 VDC supply J2 and J3 See paragraph 1 2 7 0 66V 100 Iarm ADDvantage 32 PLUS e AC to DC Power Converter DC
284. n immediately after run removal configure D SPD MIN PT to D ONE BIT or else set it equal to D AT ZERO SPD RU N REQUEST TO f XUN D RUNX RUNG 9 DCAFMRBLAN Delay to hold in the motor contactor and SCR enable while armature current magnitude is greater than a small minimum value It allows a delay of up to half a second D MIN JP ARM MIN D RUNX TA MIN DELY TIME E E DELAY io 0 5 SEC JCAFMROLAN RUNG 10 This sets the seal in bit to keep the motor contactor in and the SCR s enabled while the magnitude of armature current is greater than a small minimum value or a half second after the contactor is commanded open D MIN DELY IN v ee D SEAL JCAFMRTOLAN Figure 3 1 ADDvantage 32 PLUS Logic Diagram sheet 4 of 14 3 8 Core Software Operation RUNG 11 ADDvantage 32 PLUS e AC to DC Power Converter This is a time delay of 60 seconds after the motor contactor is commanded open Used for the field economy bit D M CONTACTOR D FLD ECON PT TIVE RUNG 12 DELAY 2 60 SE DCAFMRTILAN Commands the motor contactor to close and enables the gate power to the SCR s This can be done automatically when RUNX is applied or by an external motor contactor close command configured to Y
285. n proto IP sent up stack IP local out IP pks dropped IP reassm OK IP frag d OK IP out frg made IP can t frag IP bad options IP no route IP bad version IP raw ip s TCP Connect Init TCP Connect Esbl TCP Connect Drpd TCP 25 TCP 26 TCP 27 TCP 28 TCP 29 TCP 30 TCP 31 TCP 32 ADDvantage 32 PLUS Drive Ethernet Diagnostics Definitions UDP Mpool Empty software error counter Increments if a UDP frame is received and there is no memory buffer available to hold the frame This is an internal error Contact Engineering if this counter is ever observed to be incrementing UDP Mpool Err software error counter Increments if the operating system returns an error in response to a request for a memory buffer Contact engineering if this counter is ever observed to be incrementing 8 23 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS UDP Good Receive counter containing the number of valid UDP frames that have been received by the drive In order for the UDP frame to be valid it must have a valid footprint UDP Invalid Type counter containing the number of UDP frames that were not valid A frame will be considered invalid if it does not have a valid footprint The probable cause of this type error will be a programming error in the device transmitting the UDP frame UDP Null frame counter containing the number of UDP frames received that had a zero data length The probable cause of this type error will be a p
286. nalog Analog Analog Analog Analog Analog Analog Bit FIGURE 4 44 4 64 MOV8SCAN MOV8 BLOCK OUT1 OUT1 1 OUT1 2 OUT1 3 OUT1 4 OUT1 5 OUT1 6 OUT1 7 Control Block Description 2 Outputs Analog 3 Implementation If EN is low the output does not change When EN is high OUTI Next location Next location Next location Next location Next location Next location Next location IN2 IN3 IN4 IN5 IN6 IN7 INS 4 65 ADDvantage 32 PLUS Control Block Description ADDvantage 32 PLUS 4 45 MULTIPLY This block is used to multiply two analog signals For example draw input x speed reference signal INPA OUT INPB FIGURE 4 45 MULTIPLY BLOCK 1 Inputs INPA Analog INPB Analog 2 Outputs OUT Analog 3 Implementation OUT INPA x INPB 4 66 Control Block Description ADDvantage 32 PLUS 4 46 NOTCH FILTER The Notch Filter block is a band reject filter designed to damp out machine resonance In many cases this resonance is speed independent and occurs at approximately 5 7 Hz DEPTH 1 Inputs INP WD DEPTH FREQ 2 Outputs OUT MAGNITUDE o i OUT WD FREQ fc FREQ BODE PLOT FIGURE 4 46 NOTCH FILTER BLOCK Analog Analog Analog Analog Analog 3 Implementation The DEPTH parameter sets the depth of the notch It can range from 0
287. nalog RND Analog RES Digital HLD Digital ZERO Digital 4 101 Control Block Description ADDvantage 32 PLUS 2 Outputs RP OUT Analog RMP Bit 3 Implementation The following holds true while the HLD ZERO bits are set high and the RES bit is low explained in detail in ADDITIONAL CONTROL I O If REF is increasing positive faster than AF the RMP bit is set high and RP OUT ramps at the AF value time period t to tz of Figure 4 61 If AF is equal to zero then the RP OUT ramps with REF If REF decreases but still positive faster than DF the RMP bit is set high and RP OUT ramps at the DF value time period t to t4 of Figure 4 62 If DF is equal to zero then the RP OUT ramps with REF If neither of the preceding conditions is true the RMP bit is set low and RP OUT equals REF AR and DR work the same as AF and DF but are used when RP OUT becomes negative RATE OF CHANGE LIMIT BLOCK The rest of section 4 62 RRAMP3 is similar to the corresponding part of section 4 61 RMP2 4 102 Control Block Description ADDvantage 32 PLUS 4 63 SDS SHEETS DURING STOP This block calculates the number of sheets to be cut during a controlled stop SDS When using the AUTO STOP option the number of sheets entered by the operator is subtracted from the number of sheets cut during the stop When the selected number of sheets has been cut the line will automatically begin to ramp to a stop The line will stop after cutting the sel
288. ndows using the ADDAPT or PLC computer on the network Attempt to WEB BROWSE the drive by typing the drive s IP Address on the Address Line Did ADD 32 PLUS Web page come up e Replace ESBX board on drive if it was not already replaced in step 9 above f Replace Microprocessor Setup IP Address Subnet Mask and Gateway Address If communication is now working use ADDAPT 2000 to download drive Calibration and Configuration data For Switches that can be accessed using a web browser start Internet Explorer from Windows using the ADDAPT or PLC computer on the network Type the Switch s IP Address on the Address Line Enter User Name and Password if required for access to the Switch Diagnostics Reference your Switch manual to confirm that the ports in question are configured to be enabled active and configured for the proper bandwidth Look for diagnostics that may show port status such as errors for frame packets transmitted received In the ADD 32 PLUS Diagnostic Menu write down all the ETHERNET STATISTICS Wait 5 minutes and log the ones that have changed then wait 5 more minutes and log the ones that have changed again You only need to write the non zero s as blanks will be assumed to be zero Most diagnostics should be zero Note that the Ethernet Statistics are found under DIAGNOSTICS VIEW ETH HISTORY on the drive LCD interface This data may require interpretation and analysis by Avtron engineers 8 20 IEEE 802 3 Ethernet Communic
289. nless a non linear value is required Sets the maximum allowable angle at which the armature SCR s fire This parameter should never be changed without first consulting the factory Sets the minimum allowable angle at which the armature SCR s fire This parameter should never be changed without first consulting the factory Dead band range entered in percent motor current is used in situations where a motor is jittery at zero speed This is the allowable rate at which the current reference changes per sample time 2 77 ms on 60 Hz systems This value is entered in percent motor current and is normally 100 FIELD CURRENT LOOP PARAMETERS X Parameters Y Parameters A Parameters D Parameters X MAX FLD ALP Y FLD B TYPE A FLD CURRENT D FLD LOSS PT X MIN FLD ALP Y FLD V CMD A FLD CURRNT D FLD ECON PT X FLD TX RAT A FLD VOLTS D FLD TIMER X FLD LOSS A VFLD CMD D FLD OK PT X FLD PHASE A FLD ALPHA D FLD ENABLE X FLD PGAIN A TFLD CMD D FLD CTL LOS X FLD IGAIN 3 34 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter The ADDvantage 32 PLUS comes supplied with a single phase motor field supply See drive rating for full rating of the supply The standard hardware configuration is a two SCR two diode bridge An optional four SCR bridge can be supplied The following parameters set up the field current loop control Y ELD
290. ns and environments can change 2 1 ADDvantage 32 PLUS e AC to DC Power Converter KEY FUNCTIONS Information generated by the ADDvantage 32 PLUS can be accessed using the remotable alphanumeric keypad and LCD display located on the front of the chassis Figure 2 1 The LCD display provides four rows of 20 alphanumeric characters Editing of displayed information is accomplished using the six keys located below the LCD display ADD VANTAGE 32 PLUS POWER gt SS RUNNING 4 EMERG STOP 4 4 1 DRIVE READY Kom aste O USER LED 4 m Fol CURRENT LIMIT Lo FWD BRIDGE ON AS REV BRIDGE reset enter DRIVE FAULT O FIELD LOSS Q IOC FAULT NEM mammm INOUSTRIAL AUTOMATION INC Figure 2 1 The keypad with directional arrows reset and enter functions and LCD displays are features of the ADDvantage 32 PLUS 2 1 1 ADDvantage 32 PLUS e AC to DC Power Converter KEYPAD BUTTONS Six keys provide instructions to the ADD 32 PLUS By pressing one of the keys the information is shown in the LCD display Keystroke functions are as follows The down arrow key moves down through the loop of options in the menus submenus and parameters T The up arrow key moves up through the loop of options in the menus submenus and parameters xp The right arrow key moves from menus to submenus t
291. nstants for X ARM IGAIN the current loop They determine how the current loop reacts to disturbances X ARM RESIST This is the value of the armature resistance in ohms 3 32 een O318vN3 1000 1514135 9YE saad SLI0A INIT ADDvantage 32 PLUS e AC to DC Power Converter v Y 7 JANI Q318vN3 44 WHY I wA Q3I8vN3 T 3NO e Q 0 Core Software Operation Figure 3 3 Current Loop Block Diagram 3 33 3 17 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter Several other parameters are provided for current loop operation For most applications these parameters do not change Y ARM PI CTL Y ARM FFWD Y Ta RATE SEL X MAX ARM ALP X MIN ARM ALP X ARM D BAND X ARM R LIM Enables or disables the proportional and integral gain in the current loop Normally enabled Enables or disables the feed forward gain in the current loop Feed forward gain enhances the response of the loop normally enabled and enables the drive to start into a spinning motor Selects the value used for armature current rate of change limit Usually left to X TARM R LIM u
292. ntation of all the signal analyzer calibration and configuration parameters View and Edit the Calibration and Configuration data for channel 2 of the signal analyzer Z100 to Z113 Refer to Chapter 5 for complete documentation of all the signal analyzer calibration and configuration parameters View and Edit the Calibration and Configuration data for channel 1 of the signal analyzer 2000 to 2013 Refer to Chapter 5 for complete documentation of all the signal analyzer calibration and configuration parameters Allow viewing of the Analyzer data for each of the 8 channels View and Edit the Calibration and Configuration data for channel 8 of the signal analyzer Z700 to Z713 Refer to Chapter 5 for complete documentation of all the signal analyzer calibration and configuration parameters View and Edit the Calibration and Configuration data for channel 7 of the signal analyzer Z600 to Z613 Refer to Chapter 5 for complete documentation of all the signal analyzer calibration and configuration parameters View and Edit the Calibration and Configuration data for channel 6 of the signal analyzer 2500 to Z513 Refer to Chapter 5 for complete documentation of all the signal analyzer calibration and configuration parameters View and Edit the Calibration and Configuration data for channel 5 of the signal analyzer Z400 to 2413 Refer to Chapter 5 for complete documentation of all the signal analyzer calibration and configuration parameters
293. o Appendix C for a listing of all Drive Application Calibration parameters View and Edit ALL Drive Core Configuration parameters YOOO through Yxxx Refer to Appendix C for a listing of all Drive Core Configuration parameters Fig ure 2 18 This ADD 32 PLUS keypad syntax shows the DRIVE CONFIGURE and DRIVE CALIBRATE portion of the TOP LEVEL menu 2 27 ADDvantage 32 PLUS e AC to DC Power Converter 2 85 TABLES SUBMENU The TABLES submenu is shown in Figure 2 19 The figure shows a subsection of the TOP LEVEL menu on the left side and by pressing the RIGHT key the TABLES submenu is accessed E Fault Fifo Table 1 Left Right View and Edit TABLE 1 Calibration data T032 to T063 Up Down Up Down Table 0 mal Left Right View and Edit TABLE 0 Calibration data TOOO to T031 Up Down Up Down Spare Bit Cf Table 8 p ma Left Right View and Edit TABLE 8 Calibration data T256 to T287 al Left Right View and Edit TABLE 7 Calibration data T224 to T255 Up Down Table 6 mal Left Right View and Edit TABLE 6 Calibration data T192 to T223 Up Down Table 5 Left Right B View and Edit TABLE 5 Calibration data T160 to T191 al Left Right View and Edit TABLE 4 Calibration data T128 to T159 lt j Left Right B View and Edit TABLE Calibration data T096 to T127 Up Down Table 2 lt i Left
294. o parameters The left arrow key moves from parameters to submenus to menus The enter key accepts a change to a calibration or configuration parameter or initiates an operation The reset key clears any ADD 32 PLUS drive faults LCD DISPLAY The LCD display provides the user with ADD 32 PLUS operating and configuration data The data is provided on the LCD display in response to user input via the keypad The display consists of four rows of 20 alphanumeric characters The line information is as follows Line 1 MENU ITEM NAME when at the menu level When at the menu level the lower line indicates that pressing the RIGHT KEY gt will cause entry into a sub level as shown in Figure 2 2 When editing a calibration or configuration parameter the line shows the parameter group the parameter number and the parameter label Line 2 Submenu indicator when in a menu Figure 2 2 When editing a calibration or configuration parameter the line shows actual information associated with the edit in progress Figure 2 3 2 3 ADDvantage 32 PLUS e AC to DC Power Converter OBERATE Figure 2 2 Lines 1 and 2 showing a MENU LEVEL display IE rSn Wie 300077 Figure 2 3 Lines 1 and 2 of the LCD display showing a drive calibration parameter Lines 3 and 4 The lower two lines of the LCD display are dedicated to the display of drive operating data The operating data can be analog data digita
295. ocessor and bridge interface boards are mounted inside the Controller and Field Supply Assembly to allow for easier installation Hockey Puck style or circular SCR s are mounted to individual heat sinks which are housed in the Armature Bridge Assembly COOLING MOUNTING AREA iCONFIGURATICNS VARY ARMATURE BRIDGE ASSEMBLY CONTROLLER AND FIELD SUPPLY ASSEMBLY Figure 1 3 ADDvantage 32 PLUS AC to DC Power Converter 540 850 1550 and 3000 ADC 1 5 ADDvantage 32 PLUS e AC to DC Power Converter Introduction and General Information Figure 1 4 Advanced Firing Module AFM 1 6 1 2 1 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter The following components are contained in most of the hardware configurations Hardware specific to a type will be indicated in the description For example power converters rated at 10 through 510 ADC and 550 amps have the SCR snubbers located on one board Snubbers on units rated at 540 850 1550 and 3000 ADC are mounted directly on the SCR assembly Advanced Firing Modules do not include snubbers MICROPROCESSOR BOARD The MICROPROCESSOR BOARD Figure 1 5 controls all functions including SCR firing diagnostics communications and control block functions The microprocessor board includes the following Two ARM 9 32 bit processors One processor is dedicated to the application control functions and associated user I O The se
296. ocessors detects a problem with the other processor the processor detecting the problem can fault the drive and force the DOK contactor to open The DOK circuit is designed such that both microprocessors must provide a DOK signal before the DOK contactor will close and either microprocessor removing its DOK signal will open the DOK contactor Although fault and diagnostics checks frequently identify problems and signal the occurrence of such problems by opening the DOK circuit not all conditions will be caught Examples of fault conditions that cannot be detected by the ADD 32 PLUS itself include but are not limited to the following including digital and analog A failure in the hardware associated with the inputs or outputs can occur on a chip level and not be detected Broken or loose interconnection wire There are several connections inside the ADD 32 PLUS including critical feedback signals and or connections to I O external to the ADD 32 PLUS that could fail Memory failure after initial power up check The ADD 32 PLUS checks memory as part of initial power up diagnostics but a subsequent failure may go undetected and result in unpredictable operation The watchdog timer is included to guard against this but cannot be guaranteed to catch all possible memory faults once initial power up checks are completed successfully SCR failure during operation The ADD 32 PLUS can be configured to check proper SCR firing on the application
297. oftware Requirements ADDvantage 32 PLUS Application Software P N 696xxx for DC Drives e ADDAPT 2000 must be used if the ADDvantage 32 PLUS Application Programming Tools are required e Performance View System must be used if Historical trending and logging of I O events is required as the DOS version of Event History Recorder does not support Ethernet ADDvantage 32 PLUS DRIVE ID IP ADDRESS AND CONFIGURATION DRIVE ID IP Address The ADDvantage 32 PLUS Drive ID is set by binary weighted inputs from hard wired jumpers on the Microprocessor Board J8 connector This is the only place you can confirm that the terminal blocks are wired as required to give you the desired Drive ID The Drive s ID applies to the RS 485 Serial Link and the 802 3 Ethernet The ADDvantage 32 PLUS drive also has an Ethernet IP address which is relevant when the drive has an ESBX Ethernet board installed and running application software P N 696xxx The Ethernet IP address contains four numeric fields called Octets that are separated by a decimal point between fields An Octet is a numerical value made up of eight binary places bits Octets can represent decimal numbers from zero 0000 0000 to 255 1111 1111 Each of the four fields can contain a number ranging from 0 to 255 An example IP address is 10 1 206 6 referred to as ten point one point two zero six point six 8 3 2 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS The Ethernet IP addres
298. on configuration and operating data contained within the drive The menu submenu syntax is designed to allow the user to navigate to the desired information The drive calibration configuration and operating data is presented at the final lowest level submenu The user will know that the lowest level submenu has been reached when the second line of the LCD display shows a drive calibration configuration or operating parameter An example of this is shown in Figure 2 3 displaying a drive calibration parameter When the lowest level of submenu displays drive calibration configuration or operating information the UP and DOWN keys will allow the user to navigate through a series of parameters The user after navigating the menus and submenus to a specific drive parameter may then edit the parameter by pressing the RIGHT key If the parameter being displayed on the LCD display is a calibration or configuration parameter and if the drive is configured to allow editing of the parameter pressing the RIGHT key will enter the edit mode EXAMPLE OF MENUS AND SUBMENUS NAVIGATION The following illustrates the navigation of the menus and submenus to display a signal analyzer parameter Starting in the uppermost menu at the OPERATE option the display is OPERARE Pressing the UP key three times will result in the ANALYZER MENU option appearing on the display Analyzer Menu ADDvantage 32 PLUS e AC to DC Power Converter Pressing the RIGHT key
299. onal Error component is set to zero so that OUT IERR PREL The IERR output is equal to the integrator component and can be used for diagnostic purposes 4 80 Control Block Description ADDvantage 32 PLUS 4 55 QUAD 1 Inputs BITI Bit BIT2 Bit BIT3 Bit BIT4 Bit EN Bit 2 Outputs Bit OUT2 Bit OUT3 Bit OUT4 Bit 3 Implementation On a low to high transition of the EN input the following outputs are sampled If BITI 21 then OUTI 1 else OUT1 0 If 2 1 then OUT2 1 else OUT2 0 If BIT321 then OUT3 1 else OUT3 0 If BIT4 1 then OUT4 1 else OUT4 0 If EN is low on powerup then all outputs will equal 0 If EN is high on powerup then sample the bits EN BIT1 OUT 1 BIT2 BIT3 oe ee 0 OUT 3 BIT4 OUT 2 OUT 4 QUADLTCHSCAN FIGURE 4 55 QUAD LTCH BLOCK 4 81 Control Block Description ADDvantage 32 PLUS 4 56 RAMP The Ramp block provides a variable rate linear ramp with user programmable smoothing The purpose of this block is to provide a smooth reference from changing setpoint values MAGNITUDE 2 m REF Our 0 OUT TIME HLD RES ZERO FIGURE 4 56 RAMP BLOCK 1 Inputs REF Analog UP Analog DWN Analog RND Analog RES Bit HLD Bit ZERO Bit 4 82 Control Block Description ADDvantage 32 PLUS 2 Outputs OUT Analog RMP Bit 3 Implementation If ZERO bit is
300. onditions and environments can change ill Safety Summary ADDvantage 32 PLUS e AC to DC Power Converter WARNING System Safety Considerations ADD 32 PLUS DOK Fault Contact The ADD 32 PLUS is a sophisticated microprocessor device incorporating many self diagnostic tests The function of its DOK Drive OK fault contact is to detect a variety of faults in the ADD 32 PLUS but it cannot assure fault free operation BE AWARE THAT NOT ALL ADD 32 PLUS FAULTS CAN BE SELF DIAGNOSED AND OR ALARMED THEREFORE THE ADD 32 PLUS CANNOT BE CONSIDERED TO BE FAIL SAFE NOR CAN ITS DOK CONTACT BE RELIED ON TO RESPOND TO ALL POSSIBLE ADD 32 PLUS FAULT CONDITIONS The DOK contact should be incorporated into system interlock logic chains to ensure safe system response to a drive fault DOK output contact opening It is the responsibility of the system designer to understand the system interlock logic chains and to apply the DOK contact appropriately IN SAFETY SENSITIVE APPLICATIONS IT IS STRONGLY SUGGESTED THAT THE SYSTEM DESIGNER UTILIZE A SEPARATE MONITORING DEVICE TO CHECK THE ADD 32 PLUS INPUTS AND OUTPUTS AND OTHER OPERATING CHARACTERISTICS TO ENHANCE THE SAFETY OF PERSONNEL AND PROPERTY 1 Only qualified personnel familiar with this equipment should be permitted to install operate troubleshoot or repair the apparatus after reading and understanding this manual 2 Installation of t
301. ons 27 Reapply power REMOVABLE Fi 2 HINGES PIQUE f Ps F3 F4 CONTACTOR ARMATURE BRIDGE POWER THRYISTOR CR1 CR6 F6 F7 CONTROL POWER DOOR TRANSFORMER BRIDGE INTERFACE ASSEMBLY Figure 7 5 Replacing Power Components 510 ADC and Below Units 7 26 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter 7 5 REPLACING DRIVE SUB ASSEMBLY 550 ADC K K K K K K K K KKK WARNING HAZARDOUS VOLTAGES WHICH CAN CAUSE SEVERE INJURY OR DEATH ARE PRESENT DURING THE OPERATION OF THIS EQUIPMENT TURN OFF AND LOCK OUT ALL SOURCES OF POWER BEFORE MAKING ANY REPAIRS K K K K K K K KKK This procedure covers replacement of the entire DC Drive Controller Base Sub Assembly To replace individual power components such as thyristors and fuses see Section 7 7 1 2 3 apr dE on s 10 11 12 13 14 15 16 17 18 19 20 Remove power from the unit Open the front controller housing cover Refer to Figures 7 1 7 3 and 7 6 Remove system interconnections from the microprocessor board shown in Figure 7 1 Close cover Open the main drive door Remove all cables from the bridge interface board see Figure 7 3 Remove ground wire from the door Remove the door with microprocessor board board in the controller attached from the base assembly Set aside for reuse later Remove the bridge interf
302. ontinue counting when motor armature current is above 110 until it reaches the maximum count of 100 and faults the drive on a MOTOR II T fault The second event provides automatic taper back of the drive current limit to prevent commutation faults due to overcurrenting the armature above base speed The current limit should be set below 15096 at maximum motor speed to prevent flashovers The user can configure the motor current limits using parameters P MAX I LIMIT and P MIN I LIMIT These parameters are defaulted to C POS CUR LMT 100 and C NEG CUR LMT 100 respectively The user can enter different current limits by entering a new value for the C parameter corresponding to the POS CUR LMT or NEG CUR LMT The value is entered as a percentage of the motor nameplate armature current It is assumed the user has correctly scaled the motor armature current to the drive D C MAX CONT nameplate current by setting X MOTOR IARM 4 32 Control Block Description ADDvantage 32 PLUS Regardless of the POS I LIMIT or NEG I LIMIT values for the motor current limits actual armature current cannot exceed 200 of the drive D C MAX CONT nameplate current 1 Inputs POS I Analog 0 300 NEG I Analog 0 300 START PER Analog 100 200 END PER Analog 0 200 DR TRIP Analog 0 100 BY DR Bit SFDBK Analog START PER S Analog 0 200 END PER 65 Analog 0 200 BRK SPD Analog MAX SPD Analog BLOCK POS Bit BLOCK NEG Bit 2 O
303. ontrolled properly When a standard ADDvantage 32 PLUS is being used DC0010 through DC2500 these parameters should be left at default 3 36 Core Software Operation ADDvantage 32 PLUS AC to DC Power Converter 3 19 2 The SCR Firing Adapter Module provides an interface to the existing power bridge Refer to paragraph 3 19 3 AFM CURRENT TRANSFORMER PHASING PROCEDURE for proper installation and setup After completing the procedure continue with Core Software Operation as you would for a standard ADDvantage 32 PLUS Power Converter WARNING Setting these parameters incorrectly can result in loss of life as well as damage to equipment Only qualified personnel should attempt any changes with these values Example Parameter Settings For example an AFM module is going to be installed with an existing 540 ADC rated bridge The bridge has CT s with one turn on the primary and 4 000 turns on the secondary A burden resistor across CT is rated at 5 OHMS 5 WATTS FOR THESE CONDITIONS the parameters are set as follows BRIDGE RATING X BRIDGE SIZE 540 ADC X ARM CT OUT X ARM CT OUT CT Secondary Turns CT Primary Turns Burden Resistor 4000 Turns Turn 5 Ohms 800 3 37 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter 3 19 3 X AC VT SCALE Ratio between sensed AC voltage and actual AC voltage Leave at default except for high horsep
304. ory C Addapt Template BROWSE ADD32Plus Configuration File C Addapt Configuration 69601216 add BROWSE ADD32Plus Part Number 696012 ADD32 Part Number 694012 ADD32Plus Version Number 16 ADD32 Version Number 16 CONVERT New config file is C Addapt Configuration 69601216 add NEN Figure 12 14 A screen snapshot of the Convert ToADD32Plus utility The user must enter information as detailed in the following sections before the utility can convert an ADDvantage 32 calibration and configuration file into an ADDvantage 32 PLUS calibration and configuration file 122 201 THE ADD 32 CONFIGURATION FILE FIELD The top most entry in the ConvertToADD32Plus utility specifies the existing ADDvantage 32 calibration and configuration file that will be converted for use with the ADDvantage 32 PLUS The user may directly enter the full path and file name or may use the BROWSE button to select a file using the Windows file open dialog box 12 19 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter If the BROWSE button is used a dialog box like the one shown in Figure 12 15 will open and show all the configuration files to be converted Open configuration file My Recent Documents Desktop My Documents My Computer My Network Look in Configuration 69200221 add 69401211 add 9 69401216 08 53 69401217 add 2 69491210 add File n
305. oting ADDvantage 32 PLUS e AC to DC Power Converter 2 Plug in all gate leads Match letter designation of twisted wire pair to corresponding letter silkscreened on the base NOTE On thyristors without polarized connector housings it is important to keep the yellow wire of each pair on outboard side of device and the red wire on the inboard side A CAUTION CONNECT LEADS AS SHOWN TO PREVENT DAMAGE TO UNIT For DC0010 through DC0056 amp sizes all SCR gate and cathode leads are connected as shown For DC0110 through DC0510 sizes only field SCR gate and cathode leads must be connected as shown 9 10 11 12 13 14 Slide the bridge interface assembly back on the hinges Reconnect the J1 cable connection to the snubber assembly and replace the ground wire on the terminal Attach the two captive screws holding the bridge interface assembly to the base Slide door assembly onto the hinges Reconnect the seven cables J1 thru J7 to the bridge interface board Replace the ground terminal lug connection on the back of the drive door Reconnect external microprocessor board connections Verify all connections Reapply power to the unit 7 36 Maintenance and Troubleshooting K K K K K K K KK KK CAUTION IT IS NECESSARY TO FOLLOW THE TORQUE SPECIFICATIONS TO INSURE PROPER OPERATION AND RELIABILITY OF THE UNIT
306. ous RMP2 Control block input results 20 0 5 5 0 Slack UP OUT 100 2 100 MN B 3 39 E J DR OE 50 4 F50 ER j WE 1 E 0 pO ae 4 E E lt F 50 4 E 50 1 00 3 a Tcp izle ed a ea E 1 00 3 0 2 8 8 5 14 2 20 0 TIME secs RMP2 Ramps up and performs rounding to max value then switches to ramp and round negative to follow input UP and DWN RATE 20 FPM sec RND 5 FPM sec FIGURE 4 61C 4 97 Control Block Description 50 15 Slack UP OUT 100 4 100 J t 3 E so REF Eso S o 3 a 4 E N 0 d a m z n tr 3 x 50 4 50 100 45 1 100 4 0 4 5 13 0 21 5 30 0 TIME secs 1 RMP2 tries to turn around to follow the input while continuing to perform rounding 2 Easy transition from a small positive slope to change negative and follow input 3 RMP2 not very responsive to switching rates gt RND UP and DWN RATE 50 FPM sec RND 15 FPM sec FIGURE 4 61D 4 98 ADDvantage 32 PLUS REF FPM Control Block Description ADDvantage 32 PLUS C 40 0 S 100 4 Ramp Rate 40 FPM sec 110 4 1 J 1 55 4 i n E 1 NE a 0343 Q J LI 4 55 3 i J 1 110 1 T T T i T T T T T T T T T T T T T T T 4 0 45 40 13 0 21 5 30 0 4 0 TIME secs
307. owe 10 3 Serial Link Installation and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter Figure 10 1 ADD 32 PLUS Serial Link Wiring Sheet 2 of 3 10 4 Serial Link Installation and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter 0 3 ur 3 SHEET LEE ADD 32 PLUS SERIAL LINK WIRING B otoa RE VISIOMS SEALE 1 T SETUP DRIVE ID JUMPERS JE A3 REQUIRED HY 5 LII THER APRHILIE PEA DH FER EUR FA BE 1 Jg 100 42 PLS PROCESSOR 100 28 PLUS PROCESSOR H EMT wm O MEXT 557 UNLESS UTHETTEIZE SPECIE THE MOS Figure 10 1 ADD 32 PLUS Serial Link Wiring Sheet 3 of 3 10 5 Serial Link Installation and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter TABLE 10 1 RS 232C PIN ASSIGNMENTS The following table is a complete list of RS232 pin assignments for DB25 and DB9 connectors REPRESENTS MOST USED PINS Ground Chassis Ground NA Data Xfer Transmit Data from DTE to DCE Data Xfer Receive Data from DCE to DTE Control Request to send RTS from DTE to DCE Control Clear to send CTS from DCE to DTE Control Data set ready DSR from DCE to DTE Ground Signal ground NA Control Data carrier detect DCD from DCE to DTE Test Data set testing NA Test Data set testing NA Not assigned NA Control Secondary D
308. ower AFM applications When 700 volts sense board P N A22056 is used set to 1 9926 X DC VT SCALE Ratio between sensed DC voltage and actual DC voltage Leave at default except for high horsepower AFM applications When 700 volts sense board P N A22056 is used set to 1 9926 AFM Current Transformer Phasing Procedure A20651 SCR Firing Adapter Module WARNING As an initial operation of any AFM startup it is important to insure that the C T s used to sense armature current are correctly phased 1 Before starting this procedure the AFM wiring should be completely checked drive power up complete and proper drive software loaded 2 Remove AFM power Verify the correct part number and polarity of all current transformer assemblies CT P N Also document the burden resistor values R If there is any question on the correct values for the burden resistors go to the burden resistor calculation procedures starting at step 25 3 Have a millwright lock the motor rotor Uncouple motor only if there are felts or machinery sensitive to backward motion 4 Connect test fixture switchbox to the AFM Terminate E Stop wires marked 19 and 20 to TB1 19 and 20 or in series with other E Stop pushbuttons already wired Connect fixture Reset wires marked 17 and 18 to TB1 17 and 18 5 Apply power to the AFM Test E Stop and E Stop Reset functionality 3 38 Core Software Operation ADDvantage 32 PLUS
309. p If an integrator reaches 100 then the drive will fault and shut down If the current goes below its 110 rating its counter will start to count down until it reaches zero There is a scaling factor for the drives thermal protection on the reverse bridge On AFM applications the reverse bridge may only be used for jog reverse and be sized smaller than the forward bridge Set X RBRDG RATIO to the forward bridge capacity over the reverse bridge capacity The hardware is also protected by a thermocouple that monitors the SCR heat sink temperature If the heat sink gets too hot the ADDvantage 32 PLUS faults out Motor temperature can also be monitored by the ADDvantage 32 PLUS This is done by determining the present motor field resistance and comparing it to the original value An 3 28 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter increase in resistance signifies an increase in motor temperature The ADDvantage 32 PLUS takes the difference between the two values and calculates the temperature A MOTOR TEMP THERMAL TC X M TEMP WARN Used to set up the IIR integrator for the motor A 11R INTEGR it is the amount of time the ADDvantage 32 PLUS can operate at 150 rating before a value of 100 is obtained A value of 60 seconds at 150 will allow the motor 8 seconds at 200 A value of 425 seconds at 150 will allow the motor 60 seconds at 200 See the following chart This param
310. peration ADDvantage 32 PLUS e AC to DC Power Converter WARNING DISABLING THE FIELD CONTROL DISABLES THE ADD 32 PLUS FIELD LOSS PROTECTION THIS MAY CAUSE THE MOTOR TO OVERSPEED WHEN APPLYING THE ADD 32 PLUS ON SEPARATELY EXCITED DC MOTOR EXTERNAL PROTECTION SHOULD BE PROVIDED TO PROTECT AGAINST OVERSPEED AND OR LOSS OF FIELD THE PROTECTION SHOULD CAUSE THE ADD 32 PLUS TO FAULT WHEN ANY SUCH EXTERNAL PROTECTION BECOMES ACTIVE For example an ADDvantage 32 PLUS rated for 56 ADC will be used to operate a motor with a 40 ADC armature and a 2 ADC field Set up the parameters for this motor as follows 1 2 Enable Y FIELD CNTRL Calculate X MOTOR IARM as follows X MOTOR IARM OK 56 ADC x 10096 X MOTOR IARM 71 43 An ADDvantage 32 PLUS rated at 56 ADC can provide a maximum of 6 ADC to a motor field Calculate X MOTOR IFLD as follows 2 ADC X MOTOR IFLD x 10096 6 ADC X MOTOR IFLD 33 33 X MFLD SCALE is a scaling factor for percentage field amps vs feedback CT voltage The UL field supply for the 180 amp drive needs this changed to 1 0416 Chassis P N D22976 included in all new drives For AFM applications the drive expects 2 volts feedback equal to 100 field bridge current Adjust this parameter to correct the percentage e g if 1 volt 100 enter 2 volts 1 volt 2 3 27 3 15 Core Software Operation ADDvantage 32 PLUS e AC to DC Powe
311. process units Non retentive Block On powerup of the ADDvantage 32 PLUS DIA IDIAM Retentive Block On powerup of the ADDvantage 32 PLUS DIA will be initialized under the following conditions If RET 0 then DIA IDIAM If RET 1 DIA is set to its last value prior to power loss DIA must be configured to a retentive point Y RET SETPT to be updated automatically on powerup 4 124 Control Block Description ADDvantage 32 PLUS 473 UNITY SCALE The Unity Scale block rescales the minimum and maximum limits of a given value to 0 1 INP MIN INP MIN OUT MIN MAX MAX FIGURE 4 73 UNITY SCALE BLOCK 1 Inputs INP Analog MIN Analog MAX Analog 2 Outputs OUT Analog 3 Implementation If MIN MAX 0 then OUT MIN INP MIN MAX If MIN MAX 0 then OUT 0 4 125 Control Block Description ADDvantage 32 PLUS 4 74 UV PROTECT The block can be used to try to prevent a shoot through condition on a low AC voltage It does this by disabling the regenerating bridge current limit in a low voltage condition VAC VAC gt LOW H VAC lt CEMF gt 0 CEMF lt 0 LOW CEMF POSO NEGO UVPROTSCAN FIGURE 4 74 UV PROTECT BLOCK 1 Inputs POSI Analog Analog VAC Analog LOW Analog Analog 2 Outputs POSO Analog NEGO Analog 3 Implementation If VAC is greater than the LOW input then POSO POSI and NEGO Otherwise a low lin
312. r Converter Browse For Folder Select the directory you want to use to search for your files Desktop G My Documents cS 3 My Computer a My Network Places g Recycle Bin Figure 12 17 This is the dialog box for the Template Open Directory field The template files contain information on all of the calibration and configuration data for a particular part number and version of drive software Although the template files are typically used by the ADDAPT program the Convert ToADD32Plus utility uses information contained in the template files to evaluate if a particular file conversion may be performed The template files for both the ADDvantage 32 drive and the ADDvantage 32 PLUS must exist in the specified template file directory or the utility will be unable to perform a file conversion If the ADDAPT2000 software has been installed on the computer the template file directory will default to the template subdirectory used by ADDAPT2000 12 2 24 THE ADD 32 PLUS CONFIGURATION FILE FIELD The third field that must be entered specifies the location and name of the file that is created as a result of the conversion As with the other two fields the user may either type in the path and file name or use the BROWSE button to set the file path and name If the user enters the path and name of a file that already exists the program will generate a warning when the conversion is initiated indicating that an existing file will be overwri
313. r Converter X MFLD ASCALE is a scaling factor for full field amps vs feedback CT voltage The UL field supplies for the 56 amp and 180 amp drive needs this changed to 2 and 2 083 respectively Chassis P N D22974 and D22976 included in all new drives For 540 850 and 1350 amp drives a 12 amp field supply is expected For 1550 3000 amp drives a 24 amp field supply is expected If a drive is equipped with a different amp field supply this parameter needs to be adjusted e g if an 850 amp drive is equipped with a 24 amp field supply enter 24 amps 12 amps 2 2 See Section 1 4 Identification of Part Numbers for full field rating For AFM applications the drive expects 2 volts feedback equal to a 12 amp field supply Adjust to correct for proper amperage e g if 2 volts 48 amps enter 48 amps 12 amps 4 If the field current required is greater than the ADDvantage 32 PLUS rating modifications can be made Consult the factory for additional information MOTOR THERMAL SETTINGS X Parameters A Parameters D Parameters X THERMAL TC A MOTOR TEMP D M TEMP WARN X M TEMP WARN A HEATSK TEMP D HS TMP WARN X RBRDF RATIO A IIR INTEGR Thermal capacity of the ADDvantage 32 PLUS and motor is represented by two internal counters called IIR as shown in drive integrators Any time the ADDvantage 32 PLUS drive or the motor is operating over 110 of full load its counter starts to count u
314. r from the unit 3 Open front cover 4 Remove cables connecting the bridge interface board to the microprocessor board by unplugging at J1 and J2 of the microprocessor board 5 Remove all field wiring by unplugging the removable terminal blocks from connectors J7 J8 and J9 on the microprocessor board 6 If there is an Ethernet connection to the option Ethernet expansion module plugged into J4 unplug the connection TI If the ADDvantage 32 PLUS drive is using the remote keypad option unplug the remote keypad cable from the bottom of the case 8 If there is an optional FAX 32 plugged into J5 remove the I O expansion cable from the bottom of the case 9 Remove ground wire 10 Open the drive door to gain access to the four screws holding the case to the drive door 11 Remove the four screws Separate the case from the drive door being careful to feed the cables and ground wire through the slot in the case 12 Carefully feed the cables and ground wire through the slot in the new case containing the replacement microprocessor board 7 19 Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter 13 14 15 16 17 BASE Reattach the case to the drive door using the four screws removed in step 11 Replace ground wire Replace all cables removed in steps 4 5 6 7 and 8 Reapply power and re enter data Reset unit MICROPROCESSOR BOARD DOOR
315. r if drive not running ALSO if there is FLASHKEY file the user will be prompted to enter the 4 digit key code before the flash is allowed Figure 2 25 This ADD 32 PLUS keypad syntax shows the USB submenu 2 34 3 1 3 1 1 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter SECTION III CORE SOFTWARE OPERATION The core software performs the following fundamental functions of the ADDvantage 32 PLUS hardware and software Hardware Setup and Diagnostics Configuration and Calibration Input and Output Scanning Individual Control Block Operation Current Loop Operation Eight Channel Signal Analyzer Operation CIA m Up This section describes the capabilities and functions of the core software and the X Y parameters as well as the corresponding A and D data table parameters The data table parameters are shown for reference purposes only and are not explained in detail unless required See Section V for the signal analyzer explanations NOTE Because parameter numbers vary according to software part number specific parameter numbers are not shown To locate a specific parameter number refer to Appendix D DEDICATED INPUTS Dedicated inputs are inputs located on the bridge interface board which perform a specific task Each dedicated input is hard wired and operates independently of the application software allowing failsafe operation even if a software probl
316. r network device over the network To invoke the PING command go to a DOS prompt and type ping where Xxx XXX XXX is the 1 three octets of the other device s IP address and yyy is the number you picked If you receive Request Timeouts there is nothing currently on the network using that address However if the drives are connected to your company s network and you don t obtain an address from your MIS Department there could be a device that is currently off that could be turned on at a later time resulting in problems The following illustrates a return following a PING command C ping 10 1 207 213 Pinging 10 1 207 213 with 32 bytes of data Reply from 10 1 207 213 bytes 32 time lt 10ms TTL 128 Reply from 10 1 207 213 bytes 32 time lt 10ms TTL 128 Reply from 10 1 207 213 bytes 32 time lt 10ms TTL 128 Reply from 10 1 207 213 bytes 32 time lt 10ms TTL 128 Ping statistics for 10 1 207 213 Packets Sent 4 Received 4 Lost 0 0 loss Approximate round trip times in milliseconds Minimum Oms Maximum Average 0115 Request timed out indicates the device is not present or not communicating Destination host unreachable indicates you are not on the correct network or are not connected There are ESBX Ethernet configuration parameters contained in DRIVE CALIBRATE X and DRIVE CONFIGURE Y menus of the ADDvantage 32 PLUS Drive The parameter numbers will vary depen
317. ransition from low to high or transition from high to low within the time period seconds defined by the TOUT input The WD OUT bit equates to the bit inverted state of the WDIN input The TRIP output will be reset to a logic level low Zero Bit when the EN input is set to a logic level low signal or if the WDIN begins to toggle at a rate greater than the TOUT time period 4 29 Control Block Description ADDvantage 32 PLUS 4 21 COMPARATOR Use this block to set an output bit when the input is greater than a setpoint The HYS input sets up hysteresis to debounce the output bit INP OUT COMPARTRLAN FIGURE 4 21 COMPARATOR BLOCK 1 Inputs INP Analog INP Analog HYS Analog 2 Outputs OUT Bit 3 Implementation If INP increases so INP HYS gt INP then the OUT bit will go high If INP decreases so INP HYS lt INP then the OUT bit will go low 4 30 Control Block Description ADDvantage 32 PLUS 4 22 COPY The Copy block takes the analog value at the input and copies the value to the output COPY BLOCK NP OUT FIGURE 4 22 COPY BLOCK 1 Inputs INP Analog 2 Outputs OUT Analog 3 Implementation OUT INP 4 31 Control Block Description ADDvantage 32 PLUS 4 23 CURRENT LIMIT This block provides the user with a feature for selecting an automatic taper back of the drive current limits by two events or using fixed current limits
318. rations The operator uses the keypad to access USB functionality perform operations and upload and download data Operate gt Up Down Up Down Edit Units gt H1 eft Right USB CAL STORE gt i Left Right Up Down USB ANLYZR STORE gt 4 gt Up Down USB FLASH LOAD gt Left Right Up Down USB DGNOST STORE Up Down USB D INFO STORE gt Up Down USB CAL LOAD USB CAL STORE FILE CAL SAVE 01 USB ANLYZR STORE FILE DRIVEOO0 02 USB FLASH LOAD FILE 69600210 DL Left Right USB CAL LOAD FILE CAL SAVE 01 USB FLASH LOAD UP Key to Confrm enTERpe USB FLASH LOAD ENTER CODE 0000 MENTER UP Key to Confrm Pressing ENTER key from USB FLASH LOAD will take the upper path if the flashkey txt file does not exist and will take the lower path if the file ENTER USB CAL LOAD UP Key to Confrm does exist UP gt NOTE flash load will only occur if drive not running ALSO if there is FLASHKEY file the user will be prompted to enter the 4 digit key code before the flash is allowed Figure 11 1 The overview of the ADDvantage 32 PLUS USB Keypad Syntax 11 1 USB FLASH LOAD USB Usage
319. rganized as one floating point value grouped in 32 elements For the file organization refer to File 14 On default initialization the default values are copied from File 14 into this File The user may modify the values which will then be used at all future power up conditions unless the default power up is repeated System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter 9 3 10 9 3 11 9 3 12 9 3 13 9 3 14 9 3 15 9 3 16 9 3 17 FILE 18 CONTROL CAL LABELS This file contains all predefined label definitions for the control calibration One element is used to produce one label For example First element ZERO ANALOG spaces are shown as __ Next element ONE ANALOG Reading the first element returns the following data 5AH 45H 52H 4FH 20H 41H 4EH 42H 4CH 4FH 47H Z E A L FILE 19 CONTROL CAL HI LIMS This file contains all of the predefined high limit values for each control calibration value FILE 20 CONTROL CAL LO LIMS This file contains all of the predefined low limit values for each control calibration value FILE 21 CONTROL CAL DEFAULTS This file contains all of the predefined default values for control calibration FILE 22 CONTROL CONFIG LEGALS This file contains the drive configuration legal and is organized as a two dimensional array of eight integer values per element with 139 elements maximum Each element of eight values represents the legal choic
320. rogramming error in the device transmitting the UDP frame UDP Invalid Serv counter containing the number of UDP frames received that had a valid footprint but did not indicate a valid service The probable cause of this type error will be a programming error in the device transmitting the UDP frame PPR Buf Busy counter containing the number of PEER PRIMITIVE commands that were aborted due to the buffer between the ESBX and the drive being busy This counter incrementing indicates a communication error between the ESBX module and the drive and should be reported to Engineering PPR Cmd Buf counter containing the number of times that the ESBX had to reclaim the PEER PRIMITIVE buffer from the ADD 32 PLUS If this counter is incrementing it indicates a communication error between the ESBX module and the drive and should be reported to Engineering PPR Respnse Time number of 5 millisecond time ticks that the ESBX module waited for a PEER PRIM response from the ADD 32 PLUS Values of 1 3 are to be expected Values in excess of 10 should be reported to Engineering PPR Reply number of valid PEER PRIM replies received from the ADD 32 PLUS This diagnostic incrementing indicates PEER PRIM communications activity to the ESBX PPR Overrun counter containing the number of PEER PRIM commands that were discarded due to an overflow of the PEER PRIM command queue Increments of this counter indicate that excessive volumes of PEER PR
321. rotection of the components Refer to Section VII Tables 7 8 and 7 9 for additional fuse replacement information 3 AC line fuses F8 F9 F10 DC link fuse on regenerative units F11 2 Control transformer primary fuses F3 F4 2 Field supply AC line fuses F1 F2 3 Control power fuses on 10 through 510 ADC units F5 F6 F7 5 Control power fuses on 550 ADC units F5 F6 F7 12 F13 1 15 1 27 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter FIELD CONTROLLER BASE ASSEMBLY AFMs and 540 850 1550 and 3000 ADC Power Converters The FIELD CONTROLLER BASE ASSEMBLY is used on power converters rated 540 850 1550 and 3000 ADC as well as all AFMs It contains the field supply components and the control electronics that operate the entire motor drive See Figure 1 10 Heat generated by the field SCR s is dissipated by the heat sink contained in the base assembly The base includes the Shunt Field Supply fuses bridge interface board and microprocessor board Shunt Field Supply The SHUNT FIELD SUPPLY is a single phase thyristor diode bridge which controls the excitation current to the motor s shunt wound field The AC supply comes from the 3 phase main supply AC line fuses protect the converter against overcurrents caused by shorts Fusing Refer to Section VII Table 7 10 for fuse replacement information Fuses contained in the field controller base assembly in
322. s before OUT goes high If during the waiting REF goes back low the counter is reset Tes ao OUT L ONTIMSCAN FIGURE 4 48 ON TIMER BLOCK 4 70 Control Block Description ADDvantage 32 PLUS 4 49 ONE SHOT The block is used to initiate an action only once 1 EXECUTION TIME ONESHOTSCAN FIGURE 4 49 ONE SHOT BLOCK 1 Inputs INP Bit 2 Outputs OUT Bit 3 Implementation If INP is low then OUT is low When INP goes high OUT will go high for only one execution time NOTE The amount of time associated with a block execution can vary depending on the application Look up the input or output label in Appendix C of the manual for the timing 4 71 Control Block Description ADDvantage 32 PLUS 4 50 PEAK DETECT Inputs INP Analog HLD Bit RES Bit POS Bit Outputs OUT Analog Implementation As long as the RES and HLD bits are low OUT the greater of Old OUT or INP Greatest wins if POS 1 OUT the least of Old OUT or INP Greatest wins if POS 0 If the HLD bit is high then OUT is held and INP is ignored If RES bit is high OUT 0 RES and HLD are both level triggered bits RES has higher priority than HLD On powerup OUT 0 INP RES HLD POS PEAKDETSCAN FIGURE 4 50 PEAK DETECT BLOCK Control Block Description ADDvantage 32 PLUS 4 51 PERCENT DIFFERENCE The Percent Difference block indicates that
323. s can be assigned to the ADDvantage 32 PLUS drive by either the HARD SET or DRIVE ID BASED method The HARD SET IP address method has all four fields of the IP address set by drive calibration parameters in the DRIVE CALIBRATE menu The four calibration parameters that define the IP Address are IP ADDR HI IP ADDR HM IP ADDR LM and IP ADDR LO Note that IP ADDR LO must not be set to 256 for the HARD SET method Be aware that if the HARD SET IP method is used the DRIVE ID is still required for ADDAPT 2000 operation The DRIVE ID BASED address method is the same as the HARD SET IP with the following exception IP ADDR LO must be set to 256 The drive will then use the DRIVE ID as set by the hard wired jumpers for the number in the lowest octet field of the IP ADDRESS The reason for the DRIVE ID BASED address is to allow the drive to have a default ETHERNET IP address that will allow ETHERNET communications from an initial power up without any edit of drive cal data The default IP ADDRESS for any drive is 10 1 206 LAN ID The ADDvantage 32 PLUS Drive reads the DRIVE ID jumper configuration on power up and displays the DRIVE ID as DRIVE COM ID in the DIAGNOSTICS menu Changes to the DRIVE ID jumpers require a drive reset or power cycle before the new DRIVE ID takes effect An example of a DRIVE ID BASED address DRIVE ID 12 IP ADDR HI 10 IP ADDR HM 1 IP ADDR LM
324. s determined by the above table is then converted to a BCD number and then scaled to the block s output value RES as follows BCD number x SPAN ZERO RES EXAMPLE CNT 1 LOW CNT 2 HIGH INPUT BITS 0100 0101 0000 BCD VALUE 4 5 0 SPAN 2 OFF 100 RES 450 x 2 100 1 000 All 16 input bits are outputted as digital bits in consecutive order starting at D IN location Name the next 16 locations but do not connect them to an output of another block or unpredictable results will occur 4 9 Control Block Description ADDvantage 32 PLUS 4 61 RMP2 The RMP2 block provides a variable rate linear ramp with user programmable smoothing The purpose of this block is to provide a smooth reference from changing setpoint values The difference between the RAMP block and RMP2 is the RND input RAMP uses a low pass filter for rounding causing a J curve The RMP2 implements a rate of change limit on the ramp causing a uniform S curve OUT OUT G 5 bf ts te TIME HLD RES ZERO RMP M FIGURE 4 61 RMP2 BLOCK RAMP 1LAN The RMP2 block can be divided internally into three components to aid in the understanding of its operation These components are a Ramp Change Block a Rate of Change Limit Block and Additional Control I O as can be seen in Figure 4 61A 4 92 Control Block Description ADDvanta
325. s enabled the FLT output is checked FLT will go high if no bits are selected or if more than one is selected 4 87 Control Block Description ADDvantage 32 PLUS FIGURE 4 59 RECIPE BLOCK 4 88 Control Block Description ADDvantage 32 PLUS ENA ENB ENC ERR LL RUP 27 o o 9 RECIPE 4 60 RESOLVER 1 The RESOLVER 1 block is only used in conjunction with the Avtron optional Resolver board The Resolver board mounts on the first SBX site on the Maxi system board It provides 16 digital inputs and two digital outputs This block provides the software interface to the board Control Block Description ADDvantage 32 PLUS DO1 TO DICTAE DO2 DIN 16 BIT INPUTS BITS BGB FROM SBX 1 USED CONV 7 RES FOR BCD Y CNT CNT SPAN ZERO i FIGURE 4 60 RESOLVER 1 BLOCK 1 Inputs SPAN Analog ZERO Analog DO 1 Digital DO 2 Digital CNT 1 Digital CNT 2 Digital 2 Outputs RES Analog D IN Digital 4 90 Control Block Description ADDvantage 32 PLUS 3 Implementation DO 1 and DO 2 bits control the two digital outputs on the resolver board When they are equal to one the corresponding output is high CNT 1 and CNT 2 decide how many of the input bits are used in a BCD conversion for a resolver as follows CNT 1 CNT 2 Number of bits used 0 0 4 bits 1 0 8 bits 0 1 12 bits 1 1 16 bits The number of bit
326. s in the add file 11 5 1 CAL LOAD COMPLETION MESSAGES 11 6 Once the loading of calibration and configuration data from the USB memory stick is initiated one of the following messages will be displayed Message Meaning gt gt LOAD FAILED An internal software error is detected during a cal load operation Drive calibration configuration data is considered invalid LD FAIL An attempt to load drive cal config while the drive is running failed No changes are made to drive cal configuration NO CAL FOUND No file is found in the appropriate USB memory stick directory with the add file extension NO USB DEV PRSNT No USB memory stick is detectable in the drive gt gt LOAD ABORTED The CAL LOAD operation is aborted by the user No changes are made to drive cal configuration gt gt LOAD COMPLETE The operation is successfully completed USB CALIBRATION CONFIGURATION STORE The ADDvantage 32 PLUS drive allows the user to store the drive calibration and configuration information to a file located on the USB memory stick To perform a USB flash store of calibration and configuration information to the USB memory stick navigate the USB submenu to reach the USB CAL STORE option as shown below Uses Sw USB Usage ADDvantage 32 PLUS e AC to DC Power Converter Press the RIGHT key to display the following TORE FILE CAL SAVE 01 The display will show a file name of CAL SAVE 01 wh
327. s the ADDvantage 32 PLUS microprocessor board The new ADD 32 PLUS is shown in Figure 12 1 B a ee 12 2 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter Figure 12 1 A The older ADDvantage 32 shows the electronics enclosure which features a maintenance keypad with a two line alphanumeric digital display and 12 status LED indicators 12 3 Upgrade to New Control Board ADDvantage 32 PLUS AC to DC Power Converter J pe Figure 12 1 ADDvantage 32 PLUS shows the electronics enclosure which includes a remotable maintenance keypad with a four line alphanumeric display and 11 status LED indicators 12 4 Upgrade to New Control Board ADDvantage 32 PLUS AC to DC Power Converter 12 1 1 PROCEDURE TO UPGRADE THE HARDWARE DRIVE The upgrading of a drive from the ADDvantage 32 to the ADDvantage 32 PLUS can be accomplished by performing the following steps 1 Use the ADDAPT maintenance tool to upload and save the existing drive calibration and configuration data 2 Shut off all power to the drive 3 Remove all field wiring and field connectors from the ADDvantage 32 electronics enclosure as shown in Figure 12 2 The field wiring can include the Ethernet cable either fiber optic or copper twisted pair wiring to the Ethernet expansion module the DB25 connector at the bottom of the electronics enclosure providing connections to the FAX32
328. s to this device Refer to Table 6 3 for recommended wire sizes System interconnections such as digital and analog inputs and outputs tach serial link etc are made to the quick connect type terminal blocks on the left side of the drive No lugs are required for these connections These terminals accept 22 to 16 AWG wire Strip insulation 0 27 from the end of the wire Auxiliary field excitation transformer emergency stop E stop reset M contactor coil and aux contacts armature bridge blower and aux control power transformer connections are made to the rail mounted terminal block TB1 on top of the field supply and TB2 on the bottom No lugs are required for these connections These terminals accept 22 to 14 AWG wire Strip insulation 0 39 from the end of the wire CONTROL POWER TRANSFORMER CONFIGURATION 10 510 ADC Drives The control transformer T1 is located near the bottom of the base assembly Refer to Figure 6 1 Set the jumpers on for the correct incoming AC line voltage 230 or 460 VAC 550 ADC Drive The control transformer T1 is located near the right center of the base assembly This model may be configured for 230 460 or 575 VAC input Transformer terminals H2 H3 and H4 are used to set the transformer s input voltage Refer to Figure 6 3 Block Diagram Power Connections 550 ADC or the drive schematic D26053 for configuration connection points If the unit is to be operated at 230 VAC remove the inp
329. s written to parameters such as C it is being written into the FLASH memory which has a limited number of write cycles Although writing to the FLASH can occur thousands of times it is not recommended items listed in Table 9 1 are defined as follows 1 2 File Number Number of the table containing the data Table Name Name of the table containing the data Structure Number of bytes required for one element of data in the table Data Type Data format such as FP Floating Point Numbers Four bytes per data element Integer Two bytes per data element LI Long Integer Four bytes per data element ASCII One byte per data element Data Mode Data in the table is either RO or R W Read Only Write Protected R W z Read or Write No Protection PAR Represents the parameter group covered by the table ADDvantage 32 PLUS e AC to DC Power Converter System Data Structures ADDvantage 32 PLUS e AC to DC Power Converter TABLE 9 1 DATA FILES Structure File Table Bytes Data Data Number Name Element Type Mode 9 ANALOG IO 4 FP R W A000 A 10 ADT LABELS 11 A RO A000 A 11 ADT UNITS 6 A R W A000 A 12 DEFAULT ADT UNITS 6 A RO A000 A 13 CAL TABLE UNITS 6 A RO T000 T 127 14 CAL TABLE DEFAULT 4 FP RO T000 T 127 15 CAL TABLE LOW LIMITS 4 FP RO N A 16 CAL TABLE HIGH LIMITS 4 FP RO N A 17 CAL TABLE 4 FP R W T000 T 127 18 CONTROL CAL LABELS 11
330. sed to run jog or thread the section Digital Input 1 Run Section Digital Input 2 Jog Section Digital Input 3 2 Thread Section l The values for the three digital inputs in the Digital Data Table are D USER 1 for digital input 1 D USER 2 for digital input 2 and D USER 3 for digital input 3 2 Configure the parameters as follows Y RUN INPUT D USER 1 Y JOG INPUT D USER 2 Y THRD INPUT D USER 3 ANALOG INPUTS X Parameters A Parameters X INPT 1 CAL A ANALOG IN 1 X NPT 1 ZERO A ANALOG IN 2 X INPT 1 TC A ANALOG IN 3 X INPT 2 CAL A ANALOG IN 4 X NPT 2 ZERO A ANALOG IN 5 X INPT 2 TC A ANALOG IN 6 X NPT 3 CAL X NPT 3 ZERO X INPUT 3 TC X INPUT 4 CAL X INPUT 4 ZERO 3 19 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter X Parameters A Parameters X INPUT 4 TC X INPUT 5 CAL X INPUT 5 ZERO X INPUT 5 TC X NPT 6 CAL X INPT 6 ZERO X NPT 6 TC There are six 10 to 10 VDC analog inputs located on the ADDvantage 32 PLUS microprocessor board Each input is scanned calibrated and written into the analog data table to be used by the application software every SCR firing The value of the input is determined by the following equation A ANALOG IN Input Volts X INPT 1 CAL X INPT 1 ZERO For example to scale analog
331. splay OSs cue Ese OTE TAL ENTE CODE 000 11 9 11 2 1 USB Usage ADDvantage 32 PLUS e AC to DC Power Converter The 0000 on the second line of the display is the initial value that is shown and must be changed to the appropriate authorization code Use the UP DOWN and RIGHT key to change the numbers in the display Once the correct authorization code is reached pressing ENTER will result in the following display VE TFE TO C CONETRM When the UP key is pressed the firmware is updated If any other key is pressed the update will be cancelled and no change will be made to the firmware AUTHORIZATION CODE TO BEGIN FIRMWARE UPGRADE The user controls whether an authorization code is required before a firmware upgrade occurs If an authorization code is required a specific file must be placed in the ADD 32 PLUS DRIVE FIRMWARE directory and must be named FLASHKEY TXT The authorization code will be read from the FLASHKEY TXT file The ADDvantage 32 PLUS reads the FLASHKEY TXT file and from the characters in the file generates the authorization code using the algorithm as follows 1 Set initial authorization code to a value of 0 2 The drive only recognizes ASCII numbers ranging from 0 to 9 If the first character in the file is in the range of ASCII 0 9 then set the authorization code to that value If the character is not a valid ASCII number then terminate the algorithm and use 0 as the authoriz
332. ssor board Self tune aborted by operator Run removed Motor Drive not compatible must manually tune Iarm cont 8096 Check Iarm feedback wires at bridge board for correct polarity If correct manually tune Remove the run and clear the fault Check configuration for USER FLT X Check function of software block that causes the output bit to go high a Insure valid drive installation including good grounding good signal routing proper cable shield terminations etc Replace microprocessor board Maintenance and Troubleshooting ADDvantage 32 PLUS e AC to DC Power Converter 3 SIGNAL ANALYZER The Signal Analyzer refer to Section V also assists the user in diagnosing failures The analyzer can record eight parameters over a specified time period which is useful in detecting machine or system problems For example speed feedback can be recorded to detect a bad gear tooth or out of balance roll Refer to Section V for setup and operation of the signal analyzer 7 3 BOARD REPLACEMENT K K K K K K K K KKK CAUTION THE ADDvantage 32 PLUS PC BOARDS CONTAIN COMPONENTS WHICH MAY BE DAMAGED BY ELECTROSTATIC DISCHARGE ESD EXERCISE CARE DURING HANDLING REPAIR OF THESE BOARDS K K K K K K K KK KK 7 3 1 REPLACING MICROPROCESSOR BOARD IN ITS CASE Refer to Figure 7 1 1 Record all calibration and configuration data 2 Remove powe
333. t DATA TABLES Information in the ADDvantage 32 PLUS is accessed using tables Files Each table contains a specific group of parameters or information associated with those parameters For example one table contains the numerical data for all the C parameters while a second table contains the units for these parameters DATA TABLE STRUCTURES Data tables for the ADDvantage 32 PLUS start at number 9 Each element referenced in the table can be found by referencing its parameter number in Appendix C CAUTION Data contained in the ADDvantage 32 PLUS data tables depends on the software part number and version being used by the unit Each software part number uses different parameters and numbers To locate a particular parameter within a table find the table number that contains the parameter information required Refer to Appendix C to locate the parameter number and its position in the table 9 1 System Data Structures Table 9 1 contains the data files tables available in the ADDvantage 32 PLUS The eee K K K WARNING Particular locations have been set up for writing information to an ADDvantage 32 PLUS These locations are A LOCATION X for analog values and D LOC BIT X for digital values It is highly recommended that all information written to an ADDvantage 32 PLUS be written to these locations These parameters reside in regular system memory and can be written to often If information i
334. ta will start and then be immediately suspended resulting in no diagnostic data being collected The time stamp of the DIAGNOSTIC DATA will always be 1 1 2001 12 00 PM 11 3 1 USB DIAGNOSTIC STORE COMPLETION MESSAGES After the user has initiated the operation to save the diagnostic data to the USB memory stick one of the following messages will be displayed to indicate the results of the requested operation Message Meaning DIAGNOSTIC SAVED The diagnostic data is successfully saved to the USB memory stick D INFO SAVE ERR An internal software error is detected during a diagnostic store operation NO USB DEV PRSNT No USB memory stick is detectable in the drive NO DATA AVAILABL The diagnostic data collection is still in progress so no data is available to be stored Data collection is initiated upon power up of the drive Data collection is terminated upon drive fault Data collection is restarted upon completion of the diagnostic store operation 11 14 11 4 USB Usage ADDvantage 32 PLUS e AC to DC Power Converter USB DRIVE INFORMATION STORE The ADDvantage 32 PLUS drive allows the user to save a text file to the USB memory stick that documents basic drive information such software part numbers and versions for all firmware installed on the drive the checksums for the various calibration and configuration data current fault information LAN diagnostic information if the drive is equipped with an Ethernet
335. table 2 Configure Y ANLG OUT 2 to A ACT SPEED This will send the output to the second analog output 3 Find the calibration values as follows 10VDC 0 FPM X OUTPUT 1 ZERO X OUTPT 1 CAL 10VDC 2500 FPM X OUTPUT 1 ZERO Y X OUTPT 1 CAL Solving the above equations yields the following X OUTPT 1 CAL 008 VDC FPM X OUTPT 1 ZERO 1250 FPM 3 21 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter 3 10 3 10 1 3 10 2 FREQUENCY INPUTS X Parameters Y Parameters A Parameters X lACH 1 GRat Y TACH 1 TYPE A SPEED IN 1 X TACH 1 RDia Y TACH2 TYPE A SPEED IN 2 X lCACH 1 EPR X TACH 1 ZERO X TACH 2 GRat X TACH 2 RDia X lC ACH 2 EPR X TACH 2 ZERO Frequency inputs convert an incoming pulse train into an analog value by counting the number of pulse edges and calibrating it into a user value Counting the number of edges allows for a more accurate representation of the incoming pulse train The analog value is then stored in the analog data table There are two methods used for counting the pulse train edges the averaging method and the direct count method Configuring Y TACH 1 TYPE or Y TACH 2 determines which method is used Both methods measure one or two phase inputs and one or two pulse edges AVERAGING METHOD TWO PHASE 1 PHASE 2X 1 PHASE 1X When one of these options is selected for the TACH TYPE
336. terconnections between the blocks to form the application for the software part number of this manual Other than the Appendices this manual is the same for all ADDvantage 32 PLUS drives 1 24 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter ANALOG INPUTS ANALOG DATA TABLE ANALOG OUTPUTS APPLICATION SOFTWARE DIGITAL INPUTS DIGITAL DATA TABLE DIGITAL OUTPUTS Figure 1 15 Software Format 1 25 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter 1 4 IDENTIFICATION OF PART NUMBERS The part numbering of the ADDvantage 32 PLUS consists of two separate numbers The hardware part number is located on nameplates found on both the inside and outside of the unit and reflects the hardware configuration of the ADDvantage 32 PLUS The software part number as well as the version number identifies the application software used with the ADDvantage 32 PLUS hardware HARDWARE PART NUMBER EXAMPLE QUAD Expansion MODEL TYPE SYSTEM I D AND RANTS ADD32 PETEN OPTION board code ALWAYS DC AMP RATING NIS a Bree RE EXPANSION A19722 FAX 26494 ETHERNET BOARD CODE MODULE MODULE INSTALLED INSTALLED INSTALLED INSTALLED SOFTWARE PART NUMBER EXAMPLE 6 DIGIT SOFTWARE PART NUMBER VERSION NUMBER Figure 1 16 Part Number Breakdown 1 26 Introduction and General Information ADDvantage 32 PLUS e AC
337. the far left of the editable field on the LCD display After completing the number change pressing the ENTER key will then store the value assuming that the value displayed is a valid number and lies within the MINIMUM MAXIMUM limits of the parameter Assuming the edited parameter is valid the updated value will also be stored into non volatile memory when the edit is completed If the user wishes to discard the edit the value may be disposed of by pressing the LEFT key No change will be made to the parameter in non volatile memory and the unedited value of the parameter will be refreshed on the LCD display CONFIGURATION PARAMETERS By navigating the ADDvantage 32 PLUS menus and submenus the user will ultimately be able to locate a drive parameter of interest The LCD display of the parameter will be in one of two formats the format for numeric data such as calibration and real time data or the format for configuration data 2 14 ADDvantage 32 PLUS e AC to DC Power Converter The format for the configuration data is as follows 1 Parameter Group Represents the type of data to be edited See Table 2 1 2 Configuration Number Each configuration parameter has a unique number See Appendix A 9 Configuration Label Each configuration parameter has a unique label See Appendix B Beremater Configuration Configuration Group Number Label eI EE POO0 JOG REF C006 JOG SPEED user configurable line 3
338. the percent difference between the reference and feedback is greater than the setpoint It can be used to detect a web loss condition on a center driven winder application FDBK DIF REF FDBK REF REF PER zi TRIP PERDIFD101 STPT FIGURE 4 51 PERCENT DIFFERENCE BLOCK 1 Inputs REF Analog FDBK Analog STPT Analog 2 Outputs DIF Analog TRIP Bit 3 Implementation DIF 1 FDBK REF x 100 TRIP 1 when the ABSOLUTE DIF gt STPT else TRIP 0 If REF 0 then DIF 0 4 73 Control Block Description ADDvantage 32 PLUS 4 52 PERCENT MULTIPLY Per Mult The Percent Multiply block converts percentages entered using the keypad into actual values to be used in other blocks For example convert percent current limit into actual current limit INP PER peo PERCENT MULTIPLY FIGURE 4 52 PERCENT MULTIPLY BLOCK 1 Inputs PER Analog INP Analog 2 Outputs OUT Analog 3 Implementation _ PER x INP 100 OUT 4 74 Control Block Description 4 53 PROPORTIONAL AND INTEGRAL CONTROL ADDvantage 32 PLUS The PI block performs a proportional and integral gain function on an error signal It has inputs for maximum and minimum limits which prevent the loop from overcompensating al Ae MAXL X 224 MAX CTS OUT ERR zee LE zin MIN
339. the pulse train edges are counted and averaged over an internal sample period This averaging method allows for smoother control but can lead to inaccuracies if the duty cycle of the pulse is not 50 50 Selection of the 1 PHASE 1X one edge option eliminates these inaccuracies but decreases the resolution This method should be used when the frequency input is used for speed feedback and the frequency being applied is fairly low It should also be used for feedback applications that have significant cyclical resonance on the feedback DIRECT COUNT METHOD TWO PHASE S 1 PHASE 2XS 1 PHASE 1XS If one of these options for TACH TYPE is selected the exact number of edges that occur in the same internal sample period are counted This method leads to a more accurate count of the pulse train input but is not quite as smooth as the above method This method should be used for all applications other than those stated for the averaging method 3 22 Core Software Operation ADDvantage 32 PLUS e AC to DC Power Converter Calibrate the pulse train into a user value by using the following equation A SPEED IN 1 QNPUT FREQ x EDGE PULSE TACH 1 ZERO x 60 x x x TACH 1 RDia TACH 1 EPR x TACH 1 GRat EDGES PULSE 1 is used for one phase one edge applications 2 is used for one phase two edge applications 4 is used for two phase two edge applications For example to calibrate the frequency input into feet per minute from the follow
340. tive setpoints allow the user to store values from the analog patchboard A into memory to protect them against power loss If a value is configured to the retentive parameter it is copied into memory at power loss and then restored when power returns The two footage counter values are also stored A FOOTAGE 1 and A FOOTAGE 2 For example an exterior device is sending a setpoint to the ADDvantage 32 PLUS over the RS485 link or 802 4 LAN to A LOCATION 1 If power is lost to the unit the setpoint must be saved so that the section can operate at the same point it was when the power loss occurred To achieve this the following is required Configure Y RET SETPT 1 A LOCATION 1 If a power loss occurs the value will be stored and placed back into A LOCATION 1 when power is restored 3 47 Control Block Description ADDvantage 32 PLUS 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 4 13 4 14 4 15 4 16 4 17 4 18 4 19 4 20 4 21 4 22 4 23 4 24 4 25 4 26 4 27 4 28 4 29 4 30 4 31 4 32 4 33 4 34 4 35 4 36 SECTION IV CONTROL BLOCK DESCRIPTION Table of Contents Page LS ntc acht s dtp ii as 4 1 EROR ROME 4 3 A ANALOG SELECT enni 4 4 M M Ma 4 6 5 SUMMER
341. to 100 Entering a number less than 2 will yield a notch depth of 0 A depth of 3 will reduce the gain by 1 3 3396 at frequency point The FREQ parameter is used to set the center frequency of the notch The usable range is from 2 to 15 Hz 4 67 Control Block Description ADDvantage 32 PLUS The WD parameter sets the width of the notch and is a unitless quantity ranging from 0 1 to 5 0 where 0 1 is the narrowest and 5 0 is the widest For example WD 2 will reach approximately 90 of the input at 2 Hz from the frequency point 4 68 Control Block Description ADDvantage 32 PLUS 4 47 OFF TIMER The block is used to delay actions after the input bit goes low TICS i our 1 __ FIGURE 4 47 OFF TIMER BLOCK 1 Inputs TICS Analog REF Bit 2 Outputs OUT Bit 3 Implementation If REF is high then OUT is high When REF goes low the block waits for TICS amount of block executions before OUT goes low If during the waiting REF goes back high the counter is reset NOTE The amount of time associated with a block execution can vary depending on the application Look up the TICS input label in Appendix C of the manual for the timing 4 69 Control Block Description ADDvantage 32 PLUS 4 48 ON TIMER 1 Inputs TICS Analog REF Bit Outputs OUT Bit Implementation If REF is low then OUT is low When REF goes high the block waits for TICS amount of block execution
342. to DC Power Converter 1 4 1 HARDWARE PART NUMBER BREAKDOWN MODEL TYPE defines the type of armature voltage to be controlled always DC SYSTEM I D AND AMP RATING 3 ADC Supply Power Convener 30 Armature 3 ADC Field Supply Power Convener 56 ADC Armature 6 ADC Field Supply Power Convener 10 30 56 80 80 60 10 40 41 42 50 51 52 50 51 52 3002 3000 ADC Armature 48 ADC Field Supply Power Converter Power converters rated 540 ADC 850 ADC 1550 ADC and 3000 ADC include a control unit separate from the armature bridge assembly These units contain the motor field bridge and are available in various ratings 1 27 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter QUADRANTS AFM FIELD Power Converters SELECTION 2 4 z 7 gt DESCRIPTION Non Regenerative Armature Bridge 240 or 500 VDC selectable Regenerative Armature Bridge 240 or 500 VDC selectable plus 650 VDC on DC0550 Same as 2 except 700 VDC can also be selected on 1550 and 3000A units Same as 4 except 700 VDC can also be selected on 1550 and 3000A units Non Regenerative Modular Design Armature Bridge Regenerative Modular Design Armature Bridge Non regenerative options are only available on units rated 540 850 1550 and 3000 ADC Software parameters allow reverse bridge operation to be disabled on all units
343. tor armature connections Al A2 are made to terminals on top of the drive base assembly These connections require terminal lugs for proper connection Drive size DC0550 has lugs Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter attached for each of the connection points Refer to Table 6 3 for recommended wire Sizes Motor field output connections are made to terminals and of terminal block TB1 located at the bottom of the drive base assembly No terminal lugs are required Use 12 AWG to 4 AWG wire Strip insulation 0 59 from end of wire NOTE Refer to appropriate outline drawing to determine voltage and current ratings Optional auxiliary field excitation transformer connections are made directly to TB1 terminals 3 4 5 and 6 Use 12 AWG to 4 AWG wire Strip insulation 0 39 from end of wire Auxiliary control power connections are made directly to terminals 7 and 8 Use 22 AWG to 12 AWG wire Strip insulation 0 47 from end of wire M Contactor auxiliary contact connections are made to TB1 terminals 14 15 and 16 These are rated to interrupt at a maximum of 5A 300 V Use 22 AWG to 14 AWG wire Strip insulation 0 39 from end of wire Additional control connections such as E STOP E STOP RESET and DOK OUT are made to the quick connect plug connector at TB1 terminals 11 12 13 and 17 18 19 and 20 Use 22 AWG to 14 AWG wire Strip insulation 0 27 from end of wire System interconnect
344. tors in different cables l 2 Avoid excessive lengths of cable or individual conductors While preparing each cable for connection to the terminal strip cut back and remove the cable covering so that exposed insulated wires extend the length of the terminal strip Locate the terminal connection point for each wire Trim the wire to length allowing just enough slack to avoid the wiring being pulled taut over terminal strips or their wiring after harnessing All terminals should be accessible Strip back the insulator approximately 3 8 on each conductor Printed circuit board mounted terminal blocks have clamping type terminals for interconnection of cables Therefore it is not necessary to tin and add lugs to the wires before connection to the terminal board The stripped wire ends are inserted under a clamping plate and a screw tightens the plate down over the wires securing the connection NOTE Use caution in stripping the insulation from wires and tightening terminals of terminal blocks Incorrect stripping or tightening may result in damage to equipment and or injury to personnel NOTE Do not bundle signal and power cables wires in a common harness Separate power wires from signal wires as much as possible 6 22 6 9 6 10 6 11 Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter INSTALLATION CHECKOUT After all equipment is mounted and wired check over the entire installation to be sure th
345. tten with the new configuration result The user will then be able to accept or cancel the conversion Accepting will cause the file to be overwritten cancelling will abort the conversion and allow the user to enter a different and unique file name 12 22 Upgrade to New Control Board ADDvantage 32 PLUS e AC to DC Power Converter 122 25 ADD 32 PLUS PART AND VERSION NUMBERS The final two entries specify the ADDvantage 32 PLUS drive software part number and software version to which the input configuration file see section 12 2 2 1 will be converted Figure 12 18 shows the locations of the part and version numbers ADD32 Configuration File C AddaptiConfiguration 69401216 add BROWSE Template File Directory C AddaptiTempiate srowse ADD32Plus Configuration File C AddaptiConfiguration 69601216 add ADD32Plus Part Number ADD32 Part Number 694012 ADD32Plus Version Number ADD32 Version Number 16 exit CONVERT Figure 12 18 ConvertToADD32Plus Utility screen shows the location of the ADDvantage 32 PLUS calibration and configuration file software part number and software version number entry fields Once all the required fields have been entered pressing the CONVERT button will initiate the conversion of the ADDvantage 32 calibration and configuration file into a new calibration and configuration file that is compatible with the ADDvantage 32 PLUS drive If the conversion process completes successfully
346. uce up to 32 exchanges of data How these data lists are built and how they are interpreted at the consumer end are discussed in the Application Notes section These Exchanges maybe configured as either Uni Cast Producer to a single Consumer or Multi Cast Producer to a group of Consumers 8 9 5 2 Schneider Electric s Modbus TCP IP MB TCP The Modbus TCP IP protocol was developed by Schneider Electric Modicon as an open standard for industrial ethernet communications It is a Client Server protocol of the Master Slave variety implemented via TCP IP This protocol can be used to connect ADD 32 PLUS drives to Modicon PLCs and other Modbus TCP IP compliant hardware The Avtron implementation of Modbus TCP IP MB TCP supports the following Modbus Function Codes MFC s 1 Command Function Code 03 Read Multiple Registers from ADD 32 PLUS This command is used to read a group of 1 to 63 consecutive registers 16 bit words from a given address 2 Command Function Code 16 Write Multiple Registers to ADD 32 PLUS This command is used to write a group of 1 to 63 consecutive registers 16 bit words to a given address 3 Command Function Code 01 Read Multiple Coils from ADD 32 PLUS This command is used to read a group of consecutive coils bits from a given address 4 Command Function Code 05 Write Coil to ADD 32 PLUS This command is used to write a single coil 1bit to a given address NOTE Additional information
347. ures 1 13 and 1 14 The 540 amp and 850 amp THYRISTOR MODULE ASSEMBLY contains one SCR for non regenerative type bridges or two SCR s for regenerative type bridges he a BB THIS SCR IS PRESENT 2 REGENERATIVE 8r T DRIVES ONLY SCR zi p ss HEAT SIMK hey ET FI ilf N Em dil FIRING SNUBBER CIRCUIT BOARD ARMATURE BRIDGE FUSE Figure 1 13 Thyristor Module Assembly 540 and 850 Amp Regen Power Converters Only 1 21 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter HEAT SINK SCR BUS BAR FIRING SNUBBER BOARD FIGURE 1 14 Figure 1 14 Thyristor Module Assembly 1550 Amp and 3000 Amp Power Converters Only FUSE 1 22 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter 1 23 1 3 Introduction and General Information ADDvantage 32 PLUS e AC to DC Power Converter SOFTWARE FEATURES The setup of an ADDvantage 32 PLUS is done through calibrating and configuring the various parameters No programming is necessary The calibration parameters are constant numbers that the user enters into the drive An example would be the maximum line speed or an analog input scaling factor The configuration parameters direct where an input comes from An example would be the speed re
348. ut wire from terminal H3 and connect it to terminal H2 For 575 VAC remove the input wire from terminal H3 and connect it to terminal H4 See step 7 of paragraph 7 7 for required fuse change information 540 850 1550 and 3000 ADC Drives The control transformer is mounted external to the drive 6 10 Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter FOR 230 VAC INPUT FOR 460 VAC INPUT JUMPCONLAN Figure 6 1 T1 Jumper Configuration 10 510 ADC Drives Preparation for Use ADDvantage 32 PLUS AC to DC Power Converter AC LINE 240 480 VAC MOTOR ARMATURE 3 PHASE i i i DB RESISTOR i i i i ANN a 1 1 1 1 H i i i i i i i i i i i s i Ud DBI TBI MOTOR FIELD CR7 1 1 F6 INTERNAL LINE T TB1 COOLING LINE AN Il ASMA NEUTRAL L8 TB1 L SEE LS MAUX E STOP r e Lo 24V 1 RDY 1 beri PEPPER Q E STOP IN RESET M CONTACTOR 9 4 maux GATE Omk DOK OUT RDY 24 DOK OUT Lj Dok 510POWERLAN Figure 6 2A Block Diagram Power Connections 510 ADC and Below Exception See Figure 6 2B for 110A Drives Model DC0110 4 10 6 12 Preparation for Use ADDvantage 32 PLUS e AC to DC Power Converter AC LINE 230 460
349. utput of the D DT block This should be calculated for a core first DIA CDIA and then a full roll of material CDIA MAXIMUM DIAMETER 4 129 Control Block Description ADDvantage 32 PLUS 4 76 WINDOW COMPARE The Window Compare takes an input and checks to see if it is between a high and low setpoint The block offers options for absolute value of the input and a complementary output bit LOW INP IN OUT WINCOMPD101 FIGURE 4 76 WINDOW COMPARE BLOCK 1 Inputs INP Analog Analog LOW Analog ABS Digital 2 Outputs IN Digital OUT Digital 4 130 Control Block Description ADDvantage 32 PLUS 3 Implementation If ABS is Low 0 then IN 1 if LOW lt INP lt HI Else IN 0 If ABS is High 1 then IN 1 if ILOWI lt lt Else IN 0 IfIN 1 OUT 0 Else 1 0 OUT 1 4 131 Signal Analyzer ADDvantage 32 PLUS e AC to DC Power Converter SECTION V SIGNAL ANALYZER The signal analyzer is an eight channel memory recorder capable of recording both digital and analog information Each channel has separate setup and trigger parameters allowing information in the analog and digital tables to be recorded After the information is captured it can be displayed on the LCD display or uploaded to the human interface module Setup of the signal analyzer is accomplished using the Z parameters
350. utputs POS LIM Analog 0 200 NEG LIM Analog 0 200 3 Implementation The Current Limit block emulates the block diagram in Figure 4 21 The POS I LIMIT and NEG I LIMIT outputs are usually configured to the MAXL and MINL inputs on the speed loop PI Control block Non Tapered Current Limits If non tapered current limits are desired the BY I2R input must be high by configuring P BYPASS DR ONE BIT The current limit block constantly monitors the DDR Trip input A IIR INTEGR to detect when the motor armature current rises above 110 The IIR INTEGR value will count up as long as the current is above 110 Should the armature current fall below 11046 the IIR INTEGR will count down IF the armature current stays above 110 long enough for IIR INTEGR to accumulate 100 counts the drive will fault on a MOTOR II T fault The POS I LIMIT and NEG I LIMIT outputs will equal the POS I and NEG I input values respectively 4 33 Control Block Description ADDvantage 32 PLUS Tapered Current Limits If tapered current limits are desired the BY I2R input must be low by configuring P BYPASS DR ZERO BIT The current limit block constantly monitors the I2R Trip input A IIR INTEGR to detect when the motor armature current rises above 110 A hidden D2R Trip table is created within the current limit block to limit the POS LIM and NEG LIM outputs when the motor armature current rises above 110 The POS LIM and NEG LIM outputs wi
351. ves via a high performance Ethernet network Based on high speed open Ethernet communication protocols you get the most flexibility going into the future Avtron s ESBX Ethernet board supports the following protocols that are compatible with popular Programmable Logic Controllers PLC s Modicon Modbus TCP e General Electric Ethernet Global Data EGD drive to drive communication with or without a PLC Includes GE 90 70 90 30 PLC s e Designed and interfaces with Rockwell Ethernet IP 1 ControlLogix Implicit Messaging Type 3 ControlLogix SLC and PLC 5 except 5 250 Includes Allen Bradley Control Logix PLC 5 and SLC PLC s e Avtron Peer Primitive Autoscan ADDAPT and other Avtron tool interfaces All protocols are included with ADDvantage 32 PLUS software and all are active simultaneously These protocols allow high speed communication from PLC s HMI Operator Displays ADDAPT 2000 Avtron Performance View Process Diagnostic System and other external devices to the ADD 32 PLUS drives as well as drive to drive The benefits are minimized system wiring and enhanced system reliability while retaining maximum flexibility through the life of your drive system All Drive related system I O except E Stop can be communicated over the Ethernet network Detailed descriptions of these protocols can be rather complex and lengthy for this user manual Please reference the Ethernet Engineering Reports and technical Appl
352. will enter the ANALYZER submenu and show this display Analyzer 1 Setup Pressing the RIGHT key again will enter the ANALYZER 1 SETUP submenu and the display will be as follows ZI D Resa 1 Pressing the UP key will move to the ANALYZER 1 TRIGGER LEVEL display as shown V Oe Pressing the RIGHT key at this point will initiate the EDIT mode of ANALYZER 1 TRIGGER LEVEL If the LEFT key is pressed instead of the RIGHT key the display will show the exit of the lowest level submenu as follows Analyzer 1 Setup Pressing the RIGHT key again will return from that submenu to the top level menu as shown Analyzer Menu 2 3 2 3 1 ADDvantage 32 PLUS e AC to DC Power Converter PARAMETER DEFINITION AND GROUPINGS The ADDvantage 32 PLUS drive contains four distinct types of parameters two that define how the drive functions and two that provide user access to all the drive real time operating data The parameters are described as follows l Calibration Parameters are numeric data such as limits setpoints or ramp rates The calibration data is stored in non volatile memory to ensure the calibration parameters are not lost when the drive loses power The calibration parameters may be edited by the user via the keypad and LCD display Configuration Parameters are non numeric data that allow the user to select one option out of a list of possible options for a particular function of the drive An example of a
353. y RCV LED Green flash during receive of incoming frame data TX LED Green flash during transmitting of outgoing frame data Link Active LED Illuminates solid Red after 30 second boot up following drive power cycle or drive reset provided there is a valid cable connection to an Ethernet Switch or device 8 3 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS The following picture shows an overview of a typical Avtron Drive System utilizing Ethernet communications 8 4 ADDvantage 32 PLUS IEEE 802 3 Ethernet Communication ONNO Si m 4231100 ABOLSIH NG 8 3NIHOVN 81001 m Ent aono ae It me 10 dien NOL O3NNOO H3ddO2 AMEN pp NOUO3NNOO H3ddOO NOLLO3NNO2 2180 ANVEN 00 ona wn doy 13NH3HI3 SW31SAS JA80 Cad Ed aay 8 5 IEEE 802 3 Ethernet Communication ADDvantage 32 PLUS 82 ADDvantage 32 PLUS HARDWARE SOFTWARE REQUIREMENTS 8 3 8 3 1 The following represents the hardware and software requirements for Ethernet Support Hardware Requirements ESBX Ethernet Board P N 426494 Rev D and higher Hardware configurable for Fiber Optic or UTP Copper twisted pair media e Compatible Managed Ethernet Switch for network e Fiber Optic Cables and or CAT 5 Cables S
354. ycle following a power cycle 4 Did Ethernet communication fail on one or more than one drive If there is communication loss to multiple drives can the problem be traced to a common Switch blade or a common Multi Fiber Cable For communication loss to either single or multiple drives a Measure and verify that Switch power is applied b 65 the Fiber or CATS Cable plugged in at both the Switch port and at the ESBX board or device end Check connections Switch port LED s turned for the section s with communication problems d Temporarily move Fiber or CATS Cables from suspect ports to good ports For communication loss on multiple drives use a port on a different Switch blade If this restores communication the port may be bad or intermittent Replace Switch blade or Switch e If possible run a temporary Fiber or CAT 5 Cable between drive s in question and the Switch port If this restores communication the cable is bad Replace the Fiber Multi Fiber or CAT 5 Cable f Does cycling power to the Switch restore port communications to the drive s If cycling Switch power restores communication replace Switch blade or Switch 5 Has the DRIVE COM ID connector been removed by mistake for connector J8 on microprocessor board If it has re install connector and Reset drive 6 Has the ADD 32 PLUS drive s IP Address Subnet Mask or Gateway Address been changed by mistake in the DRIVE CALIBRATE menu

Download Pdf Manuals

Related Search

Related Contents

Hitachi CP-X3010EN  MultiMix USB 取扱説明書  Mode d`emploi 260914 7082820 - 01  Icon - VTechWorks  Fujitsu CELSIUS H730  取 扱 説 明 書  Superior W200 User's Manual    User`s Manual - RiceLakeRetail.com  Small Vibrating Equipment  

Copyright © All rights reserved.

• https://telegra.ph/Calculate-Length-from-Voltage-Drop-bf0bb6ba-11-16
• https://telegra.ph/Calculate-Wire-Resistor-from-Voltage-Drop-f80e0ddf-11-16
• https://telegra.ph/Calculat-Wire-Area-From-Voltage-Drop-9769062c-11-16
• https://telegra.ph/Round-Column-Concrete-Volume-Calculator-879e7908-11-16
• https://telegra.ph/Round-Column-Concrete-Volume-Calculator-14fe396e-11-16
• https://telegra.ph/1-1-2-Concrete-Mix-Calculator-e6170d9b-11-16
• https://telegra.ph/1-4-8-Concrete-Mix-Calculator-b3e44bcb-11-16
• https://telegra.ph/1-1-2-Concrete-Mix-Calculator-1a49d946-11-17
• https://telegra.ph/Wall-Concrete-Volume-Calculator-e01f6b48-11-13
• https://telegra.ph/Wire-Size-Calculator-From-Voltage-Drop-a48513c6-11-18