EIM Manual: Futronic VIII Installation and Operation Manual | EIM Manuals & Guides

Download

(

)

2003-01-31

(

)

Controlinc Digital Futronic VIII User Manual Model DF320A Version 1.0

2003-01-31

Table of Contents

1. Overview ...........................................................................................................................1

1.1. Introduction.................................................................................................................................................. 1

1.2. Product Description..................................................................................................................................... 1

1.2.1. Mechanical Actuator Assembly with M2CP Electrical Enclosure ...................................................................... 1

1.2.2. Variable Frequency Controller Unit (VFC)......................................................................................................... 2

1.2.3. Modular Construction..........................................................................................................................................2

1.3. Theory of Operation .................................................................................................................................... 3

1.3.1. Programmable Speed and Accel/Decel Rates......................................................................................................3

1.3.2. Brakes.................................................................................................................................................................. 3

1.3.3. Position Control................................................................................................................................................... 3

1.3.4. Speed and Acceleration / Deceleration Control...................................................................................................4

1.3.5. Stall Prevention ................................................................................................................................................... 4

1.3.6. Stall Detection ..................................................................................................................................................... 4

2. Installation ........................................................................................................................ 6

2.1. Conduit Entries............................................................................................................................................ 6

2.2. Wiring ........................................................................................................................................................... 7

2.2.1. Power Wiring ......................................................................................................................................................7

2.2.2. Control Wiring .................................................................................................................................................... 7

3. Setup and Calibration...................................................................................................... 8

3.1. Open and Close Limit Switches.................................................................................................................. 8

3.2. Auxiliary Inputs and Outputs..................................................................................................................... 8

3.3. Torque Switches........................................................................................................................................... 8

3.4. DCM320A Module Setup............................................................................................................................ 9

3.5. VFC Configuration.................................................................................................................................... 11

4. Application Tuning ........................................................................................................12

4.1. Bandwidths................................................................................................................................................. 12

4.2. Decel Rates ................................................................................................................................................. 12

4.3. Speeds.......................................................................................................................................................... 12

5. Storage Instructions....................................................................................................... 13

5.1. Short Term Storage ................................................................................................................................... 13

5.2. Long Term Storage.................................................................................................................................... 13

6. Appendices ...................................................................................................................... 14

6.1. Appendix A … Baldor Series 15J............................................................................................................. 14

6.2. Appendix C Baldor Series 15H ............................................................................................................ 15

6.3. Appendix B … AC Tech Drives (SCF Series) ......................................................................................... 16

(

)

Controlinc Digital Futronic VIII User Manual Model DF320A Version 1.0

2003-01-31

1. Overview

1.1. Introduction

This manual covers basic installation, wiring, configuration, and operation of EIM Digital Futronic VIII precision positioning controller installed in EIM 2000 Series valve actuators. The Futronic VIII controller uses a Variable Frequency Controller (VFC) to control the motor. This manual describes the theory of operation and details the settings required for VFC operation of EIM’s Digital Control Module (DCM) 320A with a VFC motor controller. A separate manual is provided with the VFC drive and DCM 320A. Refer to the VFC manual for setup and programming the VFC drive. Refer to manual E796 for mechanical setup and limit switch adjustments of the Series 2000 valve actuator. The valve actuator is based on EIM's Modular Modular Control Package (M2CP). The VFC drive may be internal to the actuator, close coupled to the actuator or remote mounted. EIM will wire all internal and close coupled systems while others wire remote mounted drives during installation. Appendix A covers wiring and programming requirements specific to each drive series provided with the actuator.

Note: Some functions, features, and options described in this manual may be disabled or may not be present in some project specific systems.

1.2. Product Description

EIM's Digital Futronic VIII system is a precision positioner using standard 3-Phase AC motors with EIM actuators. Futronic VIII is based on EIM's standard 320A digital control module used for many years in EIM’s digital networks and analog control systems. The Digital Futronic VIII package uses a unique terminal board module (TBM320A-VFC) that replaces the connection to a conventional motor starter with a connector used for connecting to the VFC. The VFC replaces the motor reversing contactor and inherently provides all solid state motor control and auto phase correction.

1.2.1. Mechanical Actuator Assembly with M2CP Electrical Enclosure

The main drive unit provides mechanical power to operate the valve, damper, or other positioning device. This assembly contains the motor, gear box, hand wheel, declutch, valve position feedback potentiometer, limit switches, and torque switches. The Modular Modular Control Package (M2CP) is the electronic controls part of this assembly. Refer to manual E796 for instructions on setting limit and torque switches. The M2CP consists of a DCM 320A TBM320A-VFC, Limit Switch Module(LSM), and control voltage transformer. The M2CP accepts a 4-20mA command signal or a digital setpoint and provides digital position feedback via the network or an optional 4-20mA signal. It also provides control signals to the VFC based on the difference between the position command signal (setpoint) and the position feedback signal. Control signals from the M2CP to the VFC include speed, and direction to the VFC.

(

)

Controlinc Digital Futronic VIII User Manual Model DF320A Version 1.0

2003-01-31

1.2.2. Variable Frequency Controller Unit (VFC)

Speed of a 3-phase motor is controlled by frequency of the applied power. Operating at 60 Hz will cause motor to run at normal full speed. Operating at a frequency less than 60 Hz will cause motor to run a percentage of normal full speed. The VFC can control frequency of the power output from 0.1 Hz to 400 Hz in 0.1 Hz increments. Variable Frequency Controller (VFC) receives 50 - 60 Hz, single or 3phase AC electrical power input and supplies power to the motor of the actuator on command from the M2CP containing the DCM320A. The AC input power is converted to DC and stored on a bank of capacitors. The DC power is converted back into 3-phase AC power by switching the transistor outputs at a high frequency, typically 10KHz. Power is switched in an alternating pattern from positive polarity to negative polarity to positive polarity, etc. at the frequency rate programmed by the microprocessor to determine motor speed. Switching polarity is done in a sequence on each of the three phases at a delay time equal to 120 degrees separation between phases based on the frequency. Frequency is normally ramped up at a programmed acceleration rate from one frequency to the next higher frequency. Frequency is also ramped down at a programmed deceleration rate from a higher frequency to the next lower frequency. Programming the VFC is typically via a front panel keyboard/display terminal. Some drives may also support programming via special software on a PC. The VFC may be internal, close coupled or enclosed in a separate enclosure remote to actuator. The VFC must be located within 500 feet of the actuator. Refer to the VFC operations manual supplied with the VFC drive for setup and programming instructions.

1.2.3. Modular Construction

Extensive use of surface mount technology (SMT) has allowed EIM to maintain single board construction of the DCM320A which plugs into the M2CP. The digital control module may be replaced by plugging in a replacement module without disabling local control functions. EIM has maintained mechanical gearing of limit and torque switches which keep in step with movement of the actuator when power is removed without battery back-up. Local control pushbuttons and selector switches are not dependent on the DCM320A. The actuator is able to operate in the manual mode even while the DCM320A is removed.

(

)

Controlinc Digital Futronic VIII User Manual Model DF320A Version 1.0

2003-01-31

1.3. Theory of Operation

1.3.1. Programmable Speed and Accel/Decel Rates

The EIM Futronic VIII system uses only two speeds, normal and slow. The speeds are programmable at the VFC. Normal speed is typically set as the standard full speed of the motor at 50 or 60 Hz but may be set at some other frequency. Selection of the two speeds is dependent on the application requirements. The system has two independently programmable acceleration rates. One is from stop to slow speed and the other is from slow speed to normal speed. The system also has two independently programmable deceleration rates. One is from normal speed to slow speed and the other is from slow speed to a minimum frequency at which time electric motor brake may be applied. (See Figures 1-1 and 1-2)

1.3.2. Brakes

Much of the required braking is applied to the motor by the VFC absorbing regenerated energy from the motor during deceleration. Brakes to stop the motor more quickly or under higher load conditions can be in the form of a DC injection brake or a dynamic brake. The type of braking to use is dependent on the application. Selection of the type of brakes is programmable at the VFC. DC injection brake operates by applying the high frequency signal to the motor in only one polarity. Dynamic brakes operate by dumping excessive regenerated energy from the motor into a resistive load, e.g. a bank of high power rated resistors. If dynamic brakes are required, some VFCs require an external braking unit to be added to the system.

1.3.3. Position Control

Precision position control is provided by the DCM320A. This module has a sensitivity of + Precision of control is adjustable by setting the Position Control bandwidth in the DCM320A. The

DCM320A can provide control precision of ±.25% or better in most applications. When used in

conjunction with the VFC, the system has a repeatability of 0.1% or better in most applications. The DCM320A has an adjustment for modulation delay time. This provides a delay from the last time the valve moved to the next time it is allowed to move, preventing valve plugging. This time is normally set to zero in high-speed modulating applications. The DCM320A also has zero and span calibration adjustments for the 4-20mA feedback signal. DCM320A setup can be done with EIM Controls CCU software, or with DIP switches. For DIP switch configuration refer to the Controlinc Quick Startup Guide.

The DCM320A module provides Open and Close outputs to motor controller VFC to control position of actuator or valve to within the adjusted control bandwidth. This is accomplished by comparing valve position feedback signal with position command (setpoint) signal. If a difference between the two signals is greater than bandwidth setting, an Open or Close digital output is generated. Open or Close direction is determined by the difference between the two signals being either positive or negative. The two digital outputs for Open and Close are fed to the VFC interface circuitry, providing isolation and proper electrical interface to the VFC.

0.1%.

(

)

Controlinc Digital Futronic VIII User Manual Model DF320A Version 1.0

2003-01-31

1.3.4. Speed and Acceleration / Deceleration Control

As stated above, the DCM320A regenerates the Open and Close signals through an isolated interface. These two signals control direction of rotation of the motor by shifting the phases of 3-phase power output of the VFC. Open and Close signals also control the normal (1st) frequency (normal speed), the 1st acceleration rate and 1st deceleration rate as shown in Figures 1-1 and 1-2. The interface circuitry provides a third control signal to the VFC which controls a second programmable frequency (low speed), a 2nd acceleration rate, and a 2nd deceleration rate of the VFC. The DCM320A has an adjustable Speed Bandwidth which is normally set outside the position control bandwidth. When a difference between command signal and position feedback signal is less than the speed control bandwidth, the third (speed control) output is turned on. This causes the motor to ramp to slow speed and remain at that speed until difference between the two signals is within control bandwidth as shown in Figure 1-2. If the difference between the two signals is greater than speed control bandwidth, then the third output is turned off, allowing frequency (speed) to ramp to the normal full speed as shown in Figure 1-1. Speed bandwidth always follows control bandwidth. For this reason, if a large change in position command signal is made, the VFC will ramp from the current speed (normally stopped) to normal speed at the 1st accel ramp time as shown in Figure 1-1. If a small change (less than the difference between the two bandwidths) is made in the position command signal, then motor speed will ramp at the 2nd accel rate to slow speed until difference between the two signals is within control bandwidth as shown in Figure 1-2. If the motor is running at normal speed when the difference between the command and feedback signal is within the speed bandwidth, then speed will decelerate from normal speed to slow speed at the 1st deceleration rate. When difference is less than position control bandwidth, the speed will decelerate from slow speed to stop at the 2nd deceleration rate as shown in Figures 1-1 and 1-2. This means of control slows speed of motor as position of valve approaches setpoint, preventing overshoot. This is the primary reason for the outstanding repeatability of the Futronic VIII system.

1.3.5. Stall Prevention

Voltage applied to the motor by the VFC is reduced as frequency is reduced. Thus, the amount of energy supplied to the motor at slow speed is much less than energy at normal speed. Under high load and low power line conditions, the motor may be subject to stall when operating at slow speed. This could prevent the valve from reaching control setpoint within control bandwidth. The DCM320A prevents this possible stall condition by allowing the slow speed output to stay on for a maximum of five seconds. Each time slow speed control output is generated, a timer is started. If time expires prior to the slow speed, open, or close outputs being turned off, then the slow speed output is forced off. This allows VFC power output frequency and voltage to accelerate to normal speed and voltage, preventing stall condition for more than five seconds. Each time any one of the three control outputs (open, close, or slow speed) is turned off, the stall prevention timer is reset.

1.3.6. Stall Detection

Should the stall prevention measures mentioned above fail to recover a stall condition the DCM320A will stop the output to prevent motor or valve damage. The DCM320A monitors the position feedback for change when the motor is commanded to run. When the motor is turned on the stall timer is started. The default stall time is 10 seconds and can be adjusted Using CCU software. If there is no change

+ 12 hidden pages

EIM Manual: Futronic VIII Installation and Operation Manual | EIM Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual