Rockwell Automation FlexPak 3000 Digital DC Drive User Manual

FlexPak 3000 Digital DC Drive Software Reference Manual Version 4.3

Instruction Manual

D2-3405-2

The information in this manual is subject to change without notice.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Throughout this manual, the following notes are used to alert you to safety considerations:

ATTENTION:Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.

Important: Identifies information that is critical for successful application and understanding of the product. The thick black bar shown on the outside margin of this page will be used throughout this instruction manual to

signify new or revised text or figures.

ATTENTION:Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, operate, or service this equipment. Read

and understand this manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

Reliance, FlexPak, AutoMax, and E.S.P. are trademarks of Rockwell Automation. DeviceNet is a trademark of the Open DeviceNet Vendor Association.

Chapter 1 ‘ Introduction

1.1 Before You Start..............................................................................................1-1

1.2 Where to Find Information...............................................................................1-1

1.3 Conventions.....................................................................................................1-1

1.4 Getting Assistance from Reliance Electric.......................................................1-2

1.5 Drive Description ............................................................................................. 1-2

Chapter 2 Drive Sequencing

2.1 Run and Jog Sequencing ................................................................................ 2-2

2.2 Stop Sequencing ............................................................................................. 2-2

Chapter 3 Initial Configuration

3.1 Selecting a Control Source........... ...... ....... ...... ....... ...... ....... ...... ......................3-1

3.2 Configuring the AC Line Parameters............................................................... 3-2

3.3 Self-Tuning Parameters...................................................................................3-3

Chapter 4 Configuring the Speed Reference

4.1 Configuring the Speed Reference Source Block.............................................4-2

4.1.1 Configuring the Keypad (OIM) Speed Reference..................................4-4

4.1.2 Configuring the Analog Auto Reference................................................4-4

4.1.3 Configuring the Analog Manual Reference ........................................... 4-6

4.1.4 Configuring the Serial Speed Reference...............................................4-8

4.1.5 Configuring the Network Speed Reference...........................................4-8

4.1.6 Configuring the Motor-Operated Potentiometer (MOP) Reference.......4-8

4.1.7 Configuring the Preset Speed References..........................................4-11

4.2 Configuring Trim............................................................................................4-13

4.3 Speed Reference Ramp................................................................................4-16

4.3.1 Configuring the Speed Reference Ramp ............................................ 4-18

4.4 Final Speed Reference Logic ........................................................................ 4-23

4.4.1 Configuring Jog ...................................................................................4-25

4.4.2 Configuring Current Compounding......................................................4-28

ONTENTS

Contents

Chapter 5 Configuring the Speed/Voltage Loop

5.1 Configuring the Speed Loop Scan Time..........................................................5-2

5.2 Configuring the Speed Loop Feedback...........................................................5-3

5.2.1 Configuring Armature Voltage Feedback..............................................5-3

5.2.2 Configuring AC or DC Analog Tachometer Feedback .......................... 5-6

5.2.3 Configuring the Pulse Encoder Feedback.............................................5-9

5.2.4 Configuring Speed Loop Feedback Lead/Lag Block...........................5-11

5.3 Reading the Speed Loop Error Signal........................................................... 5-12

5.4 Configuring the Speed Loop Forward Path Lag Block ..................................5-13

5.5 Configuring the Speed Loop Current Limits ..................................................5-14

5.6 Configuring the Speed Loop PI Block............................................................5-17

5.7 Configuring Parameters for Winding Applications ......................................... 5-20

Chapter 6 Configuring the Current Minor Loop

6.1 Configuring Inertia Compensation....................................................................6-2

6.2 Selecting and Conditioning CML Reference Selection ....................................6-3

6.3 Configuring the Armature Current Feedback...................................................6-6

6.4 Configuring the CML Forward Path..................................................................6-9

Chapter 7 Configuring the Metering Outputs

Chapter 8 Configuring the Field Supply

8.1 Configuring Field Economy..............................................................................8-2

8.2 Configuring the Enhanced Field Supply...........................................................8-4

8.3 Configuring the Field Current Regulated Supply..............................................8-5

8.3.1 Configuring Automatic Field Weakening................................................8-8

Chapter 9 Configuring the Outer Control Loop

9.1 Enabling the Outer Control Loop......................................................................9-2

9.2 Outer Control Loop Signal Processing.............................................................9-4

9.2.1 Configuring the OCL Reference Path....................................................9-4

9.2.2 Configuring the Outer Control Loop Forward Path ................................9-6

9.3 Configuring the Outer Control Loop Feedback Path........................................9-9

Chapter 10 Configuring a Network

10.1 Configuration for All Networks........................................................................10-2

10.2 Configuring Parameters for DeviceNet ..........................................................10-7

10.3 Configuring Parameters for the AutoMax Network.........................................10-8

10.4 Configuring Parameters for the ControlNet Network......................................10-9

Chapter 11 Configuring Parameters for the I/O Expansion Kit

11.1 Configuring the Digital Outputs......................................................................11-2

11.2 Configuring the Analog Inputs........................................................................11-5

11.3 Configuring the Analog Outputs.....................................................................11-8

11.4 Configuring the Frequency Input..................................................................11-10

11.5 Configuring the Frequency Output...............................................................11-11

Chapter 12 Configuring the Drive to Use Level Detectors

Chapter 13 Troubleshooting the FlexPak 3000 Drive

13.1 Fault and Alarm Messages, Descriptions, and Code Numbers .....................13-1

13.2 Adjusting the Tachometer or Encoder Loss Sensitivity................................13-12

13.3 Phase Locked Loop (PLL) Maximum Error..................................................13-13

13.4 SCR Diagnostics and Adjusting Open SCR Sensitivity................................13-14

13.5 Armature Phase Fire Test............................................................................13-16

13.6 Setting Reversed Tachometer or Reversed Encoder Lead Detection .........13-19

13.7 Setting Up Inverting Fault Avoidance...........................................................13-20

13.8 Checking the AC Line Period and Voltage...................................................13-22

13.9 Checking Drive Information..........................................................................13-23

Appendix A Block Diagrams............................................ ...... ....... ...... ......................................... A-1

Appendix B New Features in Version 4.3.................................................................................... B-1

Appendix C Parameter Settings Record......................................................................................C-1

FlexPak 3000 DC Drive Software Reference

Appendix D Numeric Parameter List............................................................................................D-1

Glossary ......................................................................................................................Glossary-1

Index ........................................................................................................................... Index-1

Contents

III

FlexPak 3000 DC Drive Software Reference

List of Figures

Figure 1.1 – Block Diagram of the FlexPak 3000 Drive............................................ 1-2

Figure 2.1 – Drive Sequencing Overview................................................................. 2-1

Figure 4.1 – Speed Reference Overview.................................................................. 4-1

Figure 4.2 – Speed Reference Source Select Block Diagram.................................. 4-3

Figure 4.3 – MOP Block Diagram.............................................................................4-9

Figure 4.4 – Preset Speed Block Diagram .............................................................4-11

Figure 4.5 – Speed Reference Ramp Block Diagram............................................. 4-17

Figure 4.6 – S-Curve Rounding..............................................................................4-21

Figure 4.7 – Speed Reference Mode Select Block Diagram..................................4-23

Figure 5.1 – Speed Loop Block Diagram.................................................................. 5-1

Figure 5.2 – Armature Voltage Block Diagram.........................................................5-3

Figure 5.3 – AC or DC Analog Tachometer Feedback Block Diagram..................... 5-6

Figure 5.4 – Pulse Encoder Feedback Block Diagram.............................................5-9

Figure 6.1 – Current Minor Loop Reference Path Block Diagram ............................ 6-1

Figure 6.2 – Current Minor Loop Block Diagram...................................................... 6-6

Figure 7.1 – Metering Outputs Block Diagram.........................................................7-1

Figure 8.1 – Field Block DIagram if Field Current Regulator Kit is Installed.............8-5

Figure 9.1 – Outer Control Loop Block Diagram.......................................................9-1

Figure 9.2 – Outer Control Loop Enable Logic......................................................... 9-2

Figure 9.3 – OCL Reference Signal Rounding......................................................... 9-6

Figure 11.1 – Digital Outputs Block Diagram.......................................................... 11-2

Figure 11.2 – Analog Inputs Block Diagram........................................................... 11-5

Figure 11.3 – Analog and Frequency Outputs Block Diagram ...............................11-8

Figure 11.4 – Frequency Input Block Diagram..................................................... 11-10

Figure 12.1 – Level Detectors Block Diagram ........................................................ 12-1

Figure 13.1 – SCR Armature Current During Normal Operation ..........................13-14

Figure 13.2 – Load SCRs Fail to Turn On............................................................13-15

Figure 13.3 – Thyristors Fail to Conduct............................................................... 13-17

Contents

FlexPak 3000 DC Drive Software Reference

List of Tables

Table 4.1 – Effect of Control Source and Reference Settings..................................4-2

Table 4.2 – Preset Speed Reference Selections.................................................... 4-11

Table 4.3 – Conditions Indicated by

Table 7.1 – Options for Metering Parameters .......................................................... 7-4

Table 9.1 – OCL Enable Signal Source.................................................................... 9-2

Table 9.2 – Conditions Indicated by

Table 11.1 – Options for Metering Parameters .................................................... 11-12

Table 13.1 – Fault Codes ...................................................................................... 13-1

Table 13.2 – Alarm Codes ................................. ...... ....... ...... ....... ...... ....................13-9

Table 13.3 – Inverting Fault Avoidance Settings .................................................13-21

0 (P.490)..............................................4-25

DIG IN

0 (P.490)................................................ 9-3

DIG IN

Contents

VII

VIII

FlexPak 3000 DC Drive Software Reference

1.1 Before You Start

This manual assumes that the hardware has already been installed. See the FlexPak 3000 drive hardware manual, D2-3404, for detail.

HAPTER

Introduction

Important:

See the

Before operating the drive, you must perform Quick Start and the self-tuning procedure, described in the configure the most commonly used parameters through one menu and includes self-tuning. This helps you set up the drive as quickly as possible.

manual for information on configuring parameters and using Quick Start.

OIM

1.2 Where to Find In formation

This manual describes the software of the FlexPak 3000 drive DC drive. It does not describe hardware or the operator interface. To find information on:

• Hardware, including installation and wiring information: See D2-3404, FlexPak 3000 DC Drive Hardware Reference.

• The Operator Interface Module ( parameters, and using Quick Start: See D2-3344, FlexPak 3000 Drive Operator Interface Module (

• Kits: See the instruction manual supplied with the kit.

This manual groups parameters by function. To find a specific parameter, see the index or Appendix D, Numeric Parameter List, for a list of parameters with their page numbers.

) User Guide.

OIM

), including setting parameters, saving

OIM

manual. Quick Start lets you

OIM

Introduction

As you change parameter values, you can record them using the table in Appendix C, Parameter Settings Record.

1.3 Conventions

Parameter names: In most instances, parameter names are shown as the parameter name followed by the parameter number. For example:

For text parameter options, the options are shown in all caps. For example:

ACCELERATION TIME

(P.001).

TERMBLK

1-1

1.4 Getting Assistance from Reliance Electric

If you have any questions or problems with the products described in this instruction manual, contact your local Reliance Electric sales office. For technical assistance, call 1-800-726-8112.

1.5 Drive Description

The FlexPak 3000 drive drive is a full-wave power converter without back rectifier, complete with a digital current minor loop and a digital major loop for armature voltage or speed regulation by tachometer or encoder feedback. Figure 1.1 shows the block diagram of the drive.

The drive employs a wireless construction and uses a keypad (

) for drive setup,

OIM

including parameter adjustments and measurement unit selection, monitoring, and diagnostics. Multiple language capability in English, French, German, Spanish, and Italian is built-in. Reference, feedback, and metering signals can be interfaced to the drive.

The drive can be controlled:

• Locally by the Operator Interface Module (

OIM

• Remotely by using the terminals at the Regulator board terminal strip.

• Remotely by the CS3000 software or a an optional network kit (AutoMax, ControlN et, or others).

The reference source ( through the

OIM

KEYPAD, TERMBLK, NETWORK

, or

) can be selected

SERIAL

1-2

Figure 1.1 – Block Diagram of the FlexPak 3000 Drive

FlexPak 3000 DC Drive Software Reference

HAPTER

Drive Sequencing

This chapter describes run, jog, and stop sequencing of the FlexPak 3000 drive. Figure 2.1 shows an overview of the sequencing of the drive.

To Figure 4.5,

Reference Ramp Block Diagram Speed Reference Mode Select Block Diagram

To Figure 4.7,

Reference Mode Sele ct Bloc k Diagram

To Figure 6.1,

Loop Reference Path Block Diagram

To Figure 4.7,

Reference Mode Sele ct Bloc k Diagram

To Figure 4.7,

Reference Mode Sele ct Bloc k Diagram

To Figure 4.5,

Ramp Block Diagram

Figure 4.7,

Mode Select Block Diagram

To fault processing

To Figure 4.2,

Reference Source Select Bloc k Diagram Speed Reference Mode Select Block Diagram

Speed

, and Figure 4.7,

Speed

Current Minor

Speed

Speed Reference

, and

Speed Reference

Speed

, and Figure 4.7,

Drive Sequencing

Figure 2.1 – Drive Sequencing Overview

2-1

2.1 Run and Jog Sequencing

When powered, the drive is in one of three operating states:

•

armature not active (main contactor open)

•

run mode

•

jog mode

The drive is in run mode if it was started by the the completion of a stop sequence.

Important:

If you switch from jog mode to run mode, the drive accelerates or decelerates to the selected run reference as configured by

(P.002).

TIME

The drive is in jog mode if it was started by the mode until the completion of a stop sequence or until the asserted. If the run mode. You cannot switch from run mode to jog mode by asserting the

input. You must stop the drive before switching to jog mode.

JOG

2.2 Stop Sequencing

ATTENTION:

stop circuit outside of the drive circuitry. This circuit must disable the

The FlexPak 3000 drive can be stopped by:

system in case of improper operation. Uncontrolled machine operation can result if this procedure is not followed. Failure to observe this precaution could result in bodi ly inj ury.

The user must provide an external, hardwired emergency

input. It remains in run mode until

RUN

input. It remains in jog

JOG

input is

RUN

input is asserted, the drive switches from jog mode to

RUN

ACCELERATION TIME

(P.001) or

DECELERATION

2-2

•

Asserting an active stop input

•

Opening a permissive input (coast/DB interlock or customer interlock)

•

Deasserting the jog input if the drive is in jog mode. Deasserting the jog input will not initiate the stop sequence until the speed feedback is less than or equal to

SPEED THRESHOLD

whichever occur s last.

•

Detecting a fault condition

There are three types of stop sequences: Coast/DB, ramp, and current limit. The type of stop sequence used depends on the source of the stop and your parameter configuration, as described below.

If a run or jog command is received while the drive is in a ramp or current limit stop sequence, the stop sequence will be aborted and the drive will continue running or jogging. Coast/DB stop sequences cannot be aborted.

(P.113) or until the

JOG OFF DELAY TIME

FlexPak 3000 DC Drive Software Reference

(P.121) is exceeded,

STOP

Coast/DB Stop Sequencing

Coast/DB stop sequencing is used when one of these conditions occurs:

•

an active stop input is asserted and

•

a permissive input is opened

•

a fault condition is detected

STOP MODE SELECT

(P.114) is set to

COAST/DB

In a coast/DB stop sequence:

1. Armature firing angle is forced to a small non-zero value.

2. The drive waits until armature current reaches discontinuous conduction.

3. The main contactor is opened and the DB contactor is closed.

Ramp Stop Sequencing (Run Mode)

Run mode ramp stop sequencing is used when all of these conditions exist:

•

an active stop input is asserted

•

STOP MODE SELECT

•

the drive is in run mode

(P.114) is set to

RAMP STOP

In a ramp stop sequence from run mode:

1. A zero reference is input to the S-curve block.

2. The speed reference ramps toward zero at the rate set by

(P.002) or

DECEL SELECT

RAMP STOP DECEL TIME

(P.122)).

3. The drive waits until speed feedback falls below

(P.018) (as determined by the setting of

STOP SPEED THRESHOLD

DECELERATION TIME

4. A zero reference is input to the current minor loop reference path.

5. The drive waits until armature current reaches discontinuous conduction.

6. The main contactor is opened and the DB contactor is closed.

Ramp Stop Sequencing (Jog Mode)

In jog mode, ramp stop sequencing is used when all of these conditions exist

•

STOP MODE SELECT

•

the drive is in jog mode

•

the jog input is deasserted

(P.114) is set to

RAMP STOP

STOP

(P.113).

Drive Sequencing

•

Speed feedback is less than or equal to

DELAY TIME

(P.121) is exceeded, whichever occurs last

STOP SPEED THRESHOLD

In a ramp stop sequence from jog mode:

1. A zero reference is input to the jog reference ramp block.

2. The jog reference ramps toward zero at the rate set by

(P.013).

3. The drive waits until speed feedback falls below

STOP SPEED THRESHOLD

(P.113) or

JOG ACCEL/DECEL TIME

JOG OFF

(P.113).

2-3

4. A zero reference is input to the current minor loop reference path.

5. The drive waits until armature current reaches discontinuous conduction.

6. The main contactor is opened and the DB contactor is closed.

Current Limit Stop Sequencing

Current limit stop sequencing is used when one of these conditions occurs:

•

an active stop input is asserted,

STOP MODE SELECT

(P.114) is set to

CURRENT LIMIT

and the drive is in run mode

•

the jog input is deasserted when the drive is in jog mode and (P.114) is set to

CURRENT LIMIT

sequence until the speed feedback is less than or equal to (P.113) or until the

JOG OFF DELAY TIME

. Deasserting the jog input will not initiate the stop

STOP SPEED THRESHOLD

(P.121) is exceeded, whichever occurs last.

STOP MODE SELECT

In a current limit stop sequence:

1. From run mode: A zero reference is input to the speed loop reference path at the speed loop summing junction.

From jog mode: A zero reference is input to the jog reference ramp block.

2. Jog mode only: The jog reference ramps toward zero at the rate set by

ACCEL/DECEL TIME

3. The drive waits until speed feedback falls below

(P.013).

STOP SPEED THRESHOLD

JOG

If the drive is regenerative (S6R), this phase of the current limit stop sequence takes little time. If the drive is non-regenerative (S6), the motor coasts during this phase of the current limit stop sequence.

4. A zero reference is input to the current minor loop reference path.

5. The drive waits until armature current reaches discontinuous conduction.

6. The main contactor is opened and the DB contactor is closed.

(P.113).

2-4

FlexPak 3000 DC Drive Software Reference

This chapter describes settings you might need to make when initially starting your drive, including selecting a control source and changing the settings of the AC line parameters. Before using the parameters in this chapter, perform Quick Start (see the

manual for detail).

OIM

3.1 Selecting a Control Sou rce

The control source determines the source of drive control signals. Control signals include drive operating signals, such as run and jog, and the drive reference.

HAPTER

Initial Configuration

CONTROL SOURCE

Selects the source of the drive control signals.

You can select the control source on the your

OIM

manual.

using the front panel key ( ). See

OIM

(P.000)

Parameter Range:

Default Setting: Parameter Type: OIM Menu Path(s):

If the drive is configured as a current (torque) regulator (jumper J15 is set to

CURRENT

The possible control sources are:

•

), the control source can only be set to

KEYPAD

TERMBLK

hardware manual for terminal descriptions and wiring instructions.

: Control is through the keypad.

: Control is through Regulator board terminals 16 through 20. See the

KEYPAD SERIAL TERMBLK NETWORK

KEYPAD

Configurable

OIM

keypad:

TERMBLK

NETWORK

Initial Configuration

•

NETWORK

Communication kit, DeviceNet Interface kit, or ControlNet Network Communicaiton kit.

•

SERIAL

: Control is through a network such as the AutoMax Network

: Control is through a personal computer running the CS3000 software.

3-1

3.2 Configuring the AC Line Parameters

In addition to performing Quick Start, you might need to configure the AC line parameters for your application. Generally, you only need to configure these parameters if the default values for these parameters are incorrect for your application. These parameters should be configured before completing Quick Start. See the manual for information on Quick Start.

OIM

NOMINAL AC LINE FREQ

The nominal AC line frequency (typically 50 or 60 Hz).

Parameter Range: Default Setting: Parameter Type: OIM Menu Path(s):

NOMINAL AC LINE VOLTS

The nominal AC line

voltage.

RMS

Parameter Range: Default Setting: Parameter Type: OIM Menu Path(s):

(P.306)

(P.307)

48 to 62 Hz 60 Hz Configurable Current Minor Loop (

AC Line

200 to 575 VAC 230 VAC Configurable Current Minor Loop (

AC Line

) - Three Phase

CML

) - Three Phase

CML

3-2

FlexPak 3000 DC Drive Software Reference

3.3 Self-Tuning Parameters

See the

SELF TUNE BRIDGE

Determines the

(P.220)

Parameter Range:

direction the motor shaft will rotate during the speed loop self-tune process b y selecting the

SCR

bridge. If the reverse bridge will be

Default Setting: Parameter Type: OIM Menu Path(s):

predominant in the application, select

REVERSE

For non-regenerative (S6) drives, this is fixed to Must be set before starting speed loop self-tuning.

SELF TUNE FIELD RANGE

Ratio of motor top speed to base speed. Typical value is 1.00, where

TOP SPEED

(P.011) is equal to base speed. Applies to speed loop tuning only.

Parameter Range: Default Setting: Parameter Type: OIM Menu Path(s):

manual for detail on using self-tuning and the self-tuning parameters.

OIM

FORWARD REVERSE

FORWARD

Tunable Current Minor Loop (

) - Tuning - Self Tuning

CML

Setup

Speed/Voltage Loop (

) - Tuning - Self Tuning

SPD

Setup

FORWARD

(P.218)

0.90 to 5.00

1.00 Tunable Current Minor Loop (

Setup

Speed/Voltage Loop (

Setup

) - Tuning - Self Tuning

CML

) - Tuning - Self Tuning

SPD

Initial Configuration

Must be set before starting speed loop self-tuning.

3-3

SELF TUNE STABILITY

(P.219)

Determines the self-tune stability, which configures the performance of the speed loop.

Parameter Range: Default Setting: Parameter Type: OIM Menu Path(s):

10 to 100 25 Tunable Current Minor Loop (

) - Tuning - Self Tuning

CML

Setup

Speed/Voltage Loop (

) - Tuning - Self Tuning

SPD

Setup

Low values increase the speed loop response. High values decrease the speed response, but result in more stability. The typical value is 25. This parameter applies to speed loop tuning only.

Must be set before starting speed loop self-tuning.

3-4

FlexPak 3000 DC Drive Software Reference

HAPTER

Configuring the Speed Reference

The FlexPak 3000 drive can be configured as a speed regulator or as an armature voltage regulator, depending on the value of the phrase “speed loop” refers to either configuration unless otherwise noted.

The drive can also be configured as either a speed/voltage or current regulator. If the drive is to be configured as a current regulator, skip this chapter and see Chapter 6.

The speed reference is the speed the speed loop tries to maintain. The drive processes and scales the speed reference input for use by the speed loop.

The speed loop uses the selected reference value and attempts to keep the speed feedback from the motor equal to the reference value. If the feedback is less than the reference, the speed loop increases the motor speed by commanding more current to the motor. If the reference is less than the feedback, the speed loop decreases the motor speed by commanding less current to the motor. The speed loop tries to minimize the amount of error between the speed reference and the speed feedback. The speed and accuracy with which the speed loop responds to reference or motor load changes is determined by the speed loop parameters.

Processing the speed reference consists of three major blocks, shown in figure 4.1.

FEEDBACK SELECT

(P.200). In this chapter,

T o Figure6.2,

Current Minor Loop Block Diagram

(Figure 9.1)

To Figure 5.1,

(Figure 4.2)

Figure 4.1 – Speed Reference Overview

In the speed reference source select block, the selected reference is scaled and the amplitude is limited. See section 4.1.

In the speed reference ramp block, the reference value from the speed reference source select block is modified based on your parameter settings. For example, trim and rate limiting are applied. See section 4.3.

(Figure 4.5)

(Figure 4.7)

Speed Loop Block Diagram

In the speed reference mode select block, the ramped speed reference signal is summed with current compounding and outer control loop outputs. See section 4.3.

Configuring the Speed Reference

4-1

4.1 Configuring the Speed Reference Source Block

The speed reference can be either automatic or manual. An automatic (auto) reference usually comes from a device such as a reference typically comes from a speed potentiometer or the manual for information on auto and manual references.

or a network master. A manual

PLC

keypad. See the

OIM

ATTENTION:

auto, the drive will ramp to the reference lev el provided by the new source

at the rate specified by (P.002). Be aware that an abrupt speed change might occur, depending on the new reference and the rate specified in these parameters. Failure to observe this precaution could result in bodily injury.

If an I/O Expansion kit is installed, the selected speed reference can be overridden by a preset speed reference if selected (terminals 59 and 60). See section 4.1.7.

Table 4.1 shows the possible control source and reference source settings. It also shows the display for the key indicator under .

Most systems will use one primary reference source. For example, you might use a network for your reference most of the time, but have the terminal strip reference available for occasions when the network is not running or for troubleshooting.

The block diagram for the speed reference source is shown in figure 4.2.

Table 4.1 – Effect of Control Source and Reference Settings

Control Source Reference Set Through:

KEYPAD

TERMBLK

(Regulator type is speed/voltage)

Automatic reference from the terminal strip as set by

REFERENCE SELECT OIM MANUAL KEYPAD REF

AUTO

(P.103)

Automatic reference from the terminal strip as set by

REFERENCE SELECT

AUTO

(P.103)

Manual reference from the terminal strip as set by

(P.106)

AUTO

(P.103)

SERIAL

MANUAL REF SELECT

Automatic reference from the terminal strip as set by

REFERENCE SELECT

Serial device (PC)

NETWORK

TERMBLK

(Regulator type is current/torque)

Network

Automatic reference from the terminal strip as set by

REFERENCE SELECT

AUTO

(P.103)

When switching from auto to manual or from manual to

ACCELERATION TIME

OIM

Key Indicator

AUTO TERMBLK REF RPM

(P .001) or

DECELERATION TIME

OIM Reference Display

(Monitor Mode) Units

percentage, or user-defined units

AUTO TERMBLK REF

MANUAL

AUTO

MANUAL SERIAL REF

AUTO

not available)

AUTO

not available)

(Manual

NETWORK REF

TORQUE REF MOTOR LOAD

From network

units

4-2

FlexPak 3000 DC Drive Software Reference

Current

To Figure 6.1,

To Figure 4.5, Speed

Reference Ramp Block

Path Block D iagram

Minor Loop Reference

Diagram

T o Figur e4.5, Speed

Reference Ramp Block

Diagram

Configuring the Speed Reference

Block Diagram

Frequency Input

From Figure11.4,

Figure 4.2 – Speed Reference Source Select Block Diagram

Analog

Inputs Block Diagram

From Figure11.2,

4-3

4.1.1 Configuring the Keypad (OIM) Speed Reference

CONTROL SOURCE SELECT

must be set to

KEYPAD

to use the keypad reference. When manual mode is selected, you enter the speed reference manually through the See the

manual for information on setting the speed reference through the

OIM

The keypad reference cannot be configured to less than greater than

MINIMUM SPEED

MAXIMUM SPEED

ATTENTION:

(P.003).

(P.004). The default value of the keypad reference is

When switching from auto to manual or from manual to

auto, the drive will ramp to the reference lev el provided by the new source

at the rate specified by (P.002). Be aware that an abrupt speed change might occur, depending

ACCELERATION TIME

on the new reference and the rate specified in these parameters. Failure to observe this precaution could result in bodily injury.

4.1.2 Configuring the Analog Auto Reference

CONTROL SOURCE SELECT

auto input as a speed reference. When you use this speed reference, the signal is the analog auto reference from terminals 19(+) and 20(–) of the Regulator board. Note that this input can also be used as a current reference to the current mi nor loop.

You must specify the type of signal that is at terminals 19 and 20 by setting

SIGNAL TYPE ANLG AUTO SIGNAL TYPE

(P.100) and jumpers J10 and J12 on the Regulator board. The settings of

manual for information on setting the jumpers.

must be set to

TERMBLK, SERIAL

(P.100) and the jumpers must be the same. See the hardware

MINIMUM SPEED

(P .001) or

, or

KEYPAD

OIM OIM

(P.003) or

DECELERATION TIME

to use the a nal og

ANLG AUTO

. .

The drive used the

ANLG AUTO ZERO ADJ

and 20 of the Regulator board to produce the

ANALOG AUTO REFERENCE

The analog reference value in auto mode. This is the value output by the drive after all hardware and software scaling.

Parameter Range: Default Setting: Parameter Type: OIM Menu Path(s):

ANLG AUTO GAIN ADJ

(P.102) to scale the analog auto reference signal from terminal 19

(P.188)

(P.101),

ANALOG AUTO REFERENCE

ANLG AUTO SIGNAL TYPE

(P.100), and

(P.188) signal.

n/a n/a Output Drive Reference - Drive Reference Scaling

Drive Reference - Test Points

4-4

FlexPak 3000 DC Drive Software Reference

ANLG AUTO GAIN ADJ

(P.101)

Scales the analog

Parameter Range:

auto reference signal after it is conditioned by the drive hardware.

Default Setting: Parameter Type: OIM Menu Path(s):

Typically, this parameter is set to 1.000.

Example

ANLG AUTO SIGNAL TYPE

only 82% of the drive’s full scale value. To produce the drive’s full scale value, change

Important:

ANLG AUTO SIGNAL TYPE

Selects the type of signal applied to the drive analog auto reference input. This is the signal at terminals 19 and 20 on the Regulator board.

Parameter Range:

Default Setting: Parameter Type:

(P.100) is set to 0-10V, a 0 to 8.2VDC signal produces

ANLG AUTO GAIN ADJ

Adjust the zero point ( gain adjust.

(P.100)

0.750 to 1.250

1.000 Tunable Drive Reference - Drive Reference Scaling



------- -

to properly scale the signal to 1.22 .

ANLG AUTO ZERO ADJ

(P.102)) before setting the

1.22



8.2

0–10V +/–10V 4-20mA 10-50mA

0–10V Configurable

ANLG AUTO ZERO ADJ

Removes any offset from the analog auto reference signal.

Configuring the Speed Reference

OIM Menu Path(s):

Important:

Jumpers J10 and J12 must be set for the type of analog auto reference

Drive Reference - Drive Reference Configure

selected. See the hardware manual for instruct ion.

(P.102)

Parameter Range: Default Setting: Parameter Type: OIM Menu Path(s):

ANALOG AUTO REFERENCE

reference signal is set to its minimum value (for example, 0 volts or 4mA), adjust

ANLG AUTO ZERO ADJ

up or down until

–200 to 200 0 Tunable Drive Reference - Drive Reference Scaling

(P.188) is not equal to zero when the analog auto

ANALOG AUTO REFERENCE

(P.188) equals zero.

4-5

AUTO REFERENCE SELECT

(P.103)

AUTO REFERENCE SELECT

determines if the drive uses a frequency or analog input reference source when the drive is in and

CONTROL SOURCE SELECT KEYPAD, TERMBLK SERIAL

is set to

AUTO

mode

, or

4.1.3 Configuring the Analog Manual Reference

Parameter Range:

Default Setting: Parameter Type: OIM Menu Path(s):

When

AUTO REFERENCE SELECT

ANALOG FREQUENCY

ANALOG

Configurable Drive Reference - Drive Reference Configure

is set to

FREQUENCY IN

, the reference is from the

frequency input (terminals 39, 40, and 41 on the I/O Expansion kit). When

AUTO REFERENCE SELECT

is set to

ANALOG

, the reference is from the analog

auto input (terminals 19 and 20 on the Regulator board). If the I/O Expansion kit is not installed, this parameter is automatically configured to

ANALOG

CONTROL SOURCE SELECT

and cannot be changed.

must be set to

TERMBLK

to use the analog manual reference input as a speed reference. This reference can only be used when the drive is configured as a speed regulator and

MANUAL REF SELECT

(P.106) is set to

ANALOG

When you use this speed reference, the drive uses the analog manual reference from terminals 16(+10V), 17(+), and 18(–) of the Regulator board.

The software uses the parameters described in this section to scale the analog manual reference signal at terminal 16, 17, and 18 to produce the

REFERENCE

The analog manual reference input can also be used for the trim reference. Make sure they are not being used for both functions at the same time.

ANALOG MAN REFERENCE

The analog reference value in manual mode. This is the value output by the drive after all hardware and software scaling.

Parameter Range: Default Setting: Parameter Type: OIM Menu Path(s):

This parameter is only used when the drive is configured as a speed/voltage regulator.

(P.192) signal.

(P.192)

ANALOG MAN

n/a n/a Output Drive Reference - Drive Reference Scaling

Drive Reference - Drive Reference Test Points

4-6

FlexPak 3000 DC Drive Software Reference

ANLG MAN REF GAIN ADJ

(P.104)

Scales the analog

Parameter Range:

manual speed reference signal after it is conditioned by the drive hardware.

Default Setting: Parameter Type: OIM Menu Path(s):

Typically, this parameter is set to 1.000.

Important:

ANLG MAN REF ZERO ADJ

Removes any offset from the analog manual reference signal.

Parameter Range: Default Setting: Parameter Type: OIM Menu Path(s):

ANALOG MAN REFERENCE

terminal 17 on the Regulator board, adjust the analog auto reference signal is set to its minimum value (for example, 0 volts or 4mA), adjust down until

Adjust the zero point ( the gain adjust.

(P.105)

(P.192) is not equal to zero when 0 volts is applied to

ANALOG MAN REFERENCE

0.750 to 1.250

1.000 Tunable Drive Reference - Drive Reference Scaling

ANLG MAN REF ZERO ADJ

(P.105)) before setting

–200 to 200 0 Tunable Drive Reference - Drive Reference Scaling

ANLG MAN ZERO ADJ

(P.192) equals zero.

up or

MANUAL REF SELECT

Sets the source of the reference for the speed loop when the drive is in manual mode and

SOURCE SELECT

TERMBLK

Configuring the Speed Reference

CONTROL

is set

(P.106)

Parameter Range:

Default Setting: Parameter Type: OIM Menu Path(s):

When set to

ANALOG

, the analog

on the Regulator board) is the speed reference. When set to

MOP, MOP OUTPUT

be adjusted through terminals 62 and 63 on the I/O Expansion kit. See the I/O Expansion kit manual for more information.

If the I/O Expansion kit is not installed, the parameter value is fixed to

ANALOG MOP

ANALOG

Configurable Drive Reference - Drive Reference Configure

MANUAL

reference input (terminals 16, 17 and 18

(P.191) is the speed reference. This reference can

ANALOG

4-7

4.1.4 Configuring the Serial Speed Reference

CONTROL SOURCE SELECT

must be set to

the CS3000 software) and

AUTO/MANUAL

(in the FlexPak 3000 drive or through

SERIAL

must be set to

MANUAL

to use the serial

speed reference. If you are using the serial reference from a source such as the CS3000 software, the

reference is input directly from the serial source to the speed reference ramp. The only parameter related to the serial speed reference is

SPD SOURCE SELECT OUT

(P.193).

You can use this parameter to check the reference value.

4.1.5 Configuring the Network Speed Reference

CONTROL SOURCE SELECT

When the control source is

must be set to

NETWORK

, the drive is forced into automatic mode.

NETWORK

The only parameter related to the network speed reference is (P.193). You can use this parameter to check the reference value.

to use the network speed reference.

SPD SOURCE SELECT OUT

4.1.6 Configuring the Motor-Operated Potentiometer (MOP) Reference

The

MOP

•

function can be used as a manual reference for the speed loop. To use the

MOP

function:

The I/O Expansion kit must be installed.

CONTROL SOURCE SELECT

must be set to

TERMBLK

•

MANUAL REF SELECT

•

Switches must be attached to digital inputs 3 and 4 (terminals 63 and 64) of the I/O Expansion kit. These inputs decrement and increment, respectively, the

(P.106) must be set to

MOP

MOP OUTPUT

(P.191) value.

•

The

The decremented when digital input 3 (terminal 62) is

MAXIMUM SPEED

same time, the

MOP ACCEL TIME OUTPUT

block from limiting the rate of change from the limit equal to

DECELERATION TIME

To obtain a negative

When when the drive is stopped following a run or jog. If it is its present level when the drive is stopped.

block is shown in figure 4.3.

MOP

output is incremented when digital input 4 (terminal 63) is ON and

MOP

ON. MOP OUTPUT

(P.004) and

output remains at its present value.

MOP

(P.115) and

can change from zero to

ACCELERATION TIME. MOP DECEL TIME

MINIMUM SPEED

MOP DECEL TIME

TOP SPEED

(P.003). If both digital inputs are ON at the

(P.120) set the time in which the

and vice versa. To prevent the S-curve

MOP OUTPUT, MOP ACCEL TIME

has a low limit equal to

reference, the reverse direction must be selected.

MOP

MOP RESET ENABLE

is ON, the

output goe s t o

MOP

MOP RESET ENABLE

MINIMUM SPEED

, the

OFF

MOP OUTPUT

also affects the

is limited between

MOP

has a low

at the moment

remains at

operation of the keypad reference, even if the I/O Expansion kit is not installed.

4-8

FlexPak 3000 DC Drive Software Reference

To Figure 4.2, Speed Reference Source Select B lock Diagram

Figure 4.3 – MOP Block Diagram

* Default Selection

To Figure 4.2, Speed Reference Source Select Block Diagram

DIG IN

3 (P.497)

The state of digital input 3 (terminal 62 on the I/O Expansion kit), which is the

MOP

decrement input.

DIG IN

4 (P.498)

The state of digital input 4 (terminal 63 on the I/O Expansion kit), which is the

MOP

increment input.

Parameter Range:

Default Setting: Parameter Type: OIM Menu Path(s):

The input is 0VDC is applied.

Parameter Range:

Default Setting: Parameter Type: OIM Menu Path(s):

ON OFF

n/a Output Input/Output - Digital I/O

when +24VDC is applied for more than 10msec. It is

ON OFF

n/a Output Input/Output - Digital I/O

OFF

when

Configuring the Speed Reference

The input is

when +24VDC is applied for more than 10msec. It is

0VDC is applied.

OFF

when

4-9

MOP ACCEL TIME

(P.115)

Minimum time in which

MOP OUTPUT

can change from zero to

TOP SPEED

MOP DECEL TIME

Minimum time in which

MOP OUTPUT

can change from

to zero.

SPEED

MOP OUTPUT

The output of the motor-operated potentiometer (

TOP

(P.191)

MOP

Parameter Range: Default Setting: Parameter Type: OIM Menu Path(s):

(P.120)

Parameter Range: Default Setting: Parameter Type: OIM Menu Path(s):

Parameter Range: Default Setting:

ACCELERATION TIME

to 300.0 seconds

5.0 seconds Tunable Drive Reference - Drive Reference Ramp

DECELERATION TIME

to 300.0 seconds

5.0 seconds Tunable Drive Reference - Drive Reference Ramp

MINIMUM SPEED

MAXIMUM SPEED

n/a

Parameter Type: OIM Menu Path(s):

To get a negative If the I/O Expansion kit is not installed,

MOP RESET ENABLE

Determines if

OUTPUT

MOP

(P.191) and the keypad reference values reset or stay at the present level when the drive stops.

Parameter Range:

Default Setting: Parameter Type: OIM Menu Path(s):

When reference are reset to I/O Expansion kit is not installed. If it is set to keypad reference remain at their present levels when the drive is stopped.

(P.116)

MOP RESET ENABLE

Output Drive Reference - Drive Reference Test Points

reference, the reverse direction must be selected.

MOP

MOP OUTPUT

OFF ON

OFF

is meaningless.

Configurable Drive Reference - Drive Reference Configure

is set to ON (enabled),

MINIMUM SPEED

(P.003) when the drive is stopped, even if the

MOP OUTPUT

(disabled),

OFF

and the keypad

MOP OUTPUT

and the

4-10

FlexPak 3000 DC Drive Software Reference

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Rockwell Automation FlexPak 3000 Digital DC Drive User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual