Rockwell Automation SA500 User Manual

Distributed Power System SA500 Drive
Diagnostics, Troubleshooting,
and Start-Up Guide lines

Instruction Manual

S-3022-1

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

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

!

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

signify new or revised text or figures.

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

!

Read and understand this manual and other applicable manuals in their entirety before
proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:DC bus capacitors retain hazardous voltages after input power has been
disconnected. After disconnecting input power from the DC bus supply, wait five (5) minutes and
then measure the voltage at the POS and NEG terminals of the DC bus supply and each Power
Module to ensure the DC bus capacitors are discharged before touching any internal components.
Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:For brushless motor applications, changing any resolver wiring, breaking the
resolver coupling, replacing the resolver, or replacing the motor and resolver for any reason
requires that the shaft alignment test be performed again. Resolver wiring changes always affect
shaft alignment. A resolver change and/or a new motor/resolver combination will affect the shaft
alignment. Improper shaft alignment can cause motor overspeed when the motor is started. Failure
to observe this precaution could result in bodily injury.

ATTENTION:The user must provide an external, hardwired emergency stop circuit outside of the
drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled
machine operation may result if this procedure is not followed. Failure to observe this precaution
could result in bodily injury.

ATTENTION:Inserting or removing a module or its connecting cables may result in unexpected
machine motion. Turn off power to the rack before removing a module or its connecting cables.
Failure to observe these precautions could result in bodily injury.

ATTENTION:Only qualified Rockwell personnel or other trained personnel who understand the
potential hazards involved may make modifications to the rack configuration, variable
configuration, and application tasks. Any modifications may result in uncontrolled machine
operation. Failure to observe these precautions could result in damage to equipment and bodily
injury.

ATTENTION:Registers and bits in the UDC module that are described as “read only” or for “system
use only” must not be written to by the user. Writing to these registers and bits may result in
improper system operation. Failure to observe this precaution could result in bodily injury.

ATTENTION:The user is responsible for conforming with all applicable local, national, and
international codes. Failure to observe this precaution could result in damage to, or destruction
of, the equipment.

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

AutoMax™ is a trademark of Rockwell Automation.
©1998 Rockwell International Corporation

Chapter 1 Introduction

1.1 Related Publications........................................................................................1-1

1.2 Typographical Conventions .............................................................................1-2

Chapter 2 Diagnostics and Troubleshooting

2.1 Definition of Terms Used in Diagnostics and Troubleshooting........................2-1

2.2 Power-up Diagnostics in the UDC Module and PMI........................................2-3

2.3 Interlock Tests ................................................................................................. 2-3

2.4 Run-time Diagnostics ......................................................................................2-3

2.4.1 Drive Faults...........................................................................................2-4

2.4.1.1 How the System Reacts to Drive Faults .................................2-4

2.4.1.2 MCR Output Control ......... ...... ....... ....................................... .. 2-5

2.4.2 Drive Warnings...................................................................................... 2-5

2.4.3 How to Clear the Drive Fault and Drive Warning Registers .................. 2-6

Chapter 3 PMI Operating Modes

3.1 Idle Mode......................................................................................................... 3-1

3.2 PMI Run Mode................................................................................................. 3-1

3.3 Alignment Test Mode....................................................................................... 3-4

C

ONTENTS

Chapter 4 Installation and Start-Up Guidelines

4.1 Using the AutoMax Programming Executive to Access the Rack ...................4-1

4.2 Installation Requirements................................................................................4-2

4.3 Installing the Motor ............................. ....... ...... ....... ...... ....... ............................ 4-3

4.4 Installing the Drive........................ ...... ....................................... ....... ...... ....... .. 4-3

4.4.1 Cabinet-Enclosed Wall-Mounted Drives................................................ 4-3

4.4.2 Floor-Mounted Drives...................... ...... ....... ...... ....... ...... ...................... 4-3

4.4.3 Panel-Mounted Drives........................................................................... 4-3

4.5 Wiring the Power Module ................................................................................4-3

4.6 Basic Drive Interconnections........ ...... ....... ...... ....................................... ....... .. 4-4

4.7 Drive Inspection and Start-up Guidelines........................................................4-4

4.7.1 What To Do After Unexpected Test Results ......................................... 4-5

4.7.2 Recommended Test Equipment............................................................ 4-7

4.7.3 Physically Inspecting the Equipment..................................................... 4-7

4.7.4 Physically Inspecting the Motor............................................................. 4-8

4.7.5 Checking the Installation with Power Off............................................... 4-8

4.7.6 Testing Power Modules with Power On ................................................ 4-9

4.7.7 I/O Verification..................................................................................... 4-10

4.7.7.1 Testing UDC/PMI Communication Status............................. 4-10

4.7.7.2 Testing Rail I/O Registers .....................................................4-11

4.7.7.3 Testing Feedback Registers and Bits ................................... 4-12

4.7.7.4 Testing the UDC Module Test Switch Register.....................4-13

4.7.7.5 Testing UDC Module Meter Ports.........................................4-14

4.7.8 Performing Uncoupled Motor Tests. ....................................... ...... ....... 4-14

4.7.9 Running Dynamic Motor Tests............................................................ 4-15

4.7.10Updated Drawings and Software Listings ...........................................4-16

Table of Contents

I

Appendix A Drive Fault Register ................................................................................................. A-1

Appendix B Drive Warning Register............................................................................................ B-1

Appendix C Interlock Register ..................................................................................................... C-1

Appendix D Summary of UDC Module Drive Fault Indicators .....................................................D-1

Appendix E Power Module LED Summary.................................................................................. E-1

Appendix F Status of Data in the AutoMax Rack After

a STOP_ALL Command or STOP_ALL Fault.......................................................... F-1

Appendix G AutoMax Prog rammi ng Ex ecuti ve Acces s Levels........................ ....... ...... ....... ...... ..G-1

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

II

SA500 Diagnostics, Troubleshooting, and Start-Up Guidelines

List of Figures

Figure 2.1 – PMI Operating Modes Overview........... ....... ...... ....... ...... ....... ...... .........2-2

Figure 3.1 – PMI Operating Modes and Diagnostics................................................3-3

Figure 4.1 – POS and NEG Terminals on the DC Bus Supply................................. 4-6

Table of Contents

III

IV

SA500 Diagnostics, Troubleshooting, and Start-Up Guidelines

List of Tables

Table 1.1 – SA500 Documentation (Binder S-3002) ................................................1-1

Table 3.1 – PMI Operating Modes............................................................................3-1

Table 4.1 – UDC/PMI Communication Status Register Formats............................ 4-10

Table 4.2 – Rail I/O Register Formats....................................................................4-11

Table 4.3 – Feedback Registers and Bits...............................................................4-12

Table of Contents

V

VI

SA500 Diagnostics, Troubleshooting, and Start-Up Guidelines

C

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1

Introduction

This instruction manual is divided into two sections: 1) a description of SA500 drive
diagnostics and troubleshooting, 2) start-up guidelines. This manual is intended for
users of SA500 drives who have training and experience in AC drive control and who
are familiar with all other SA500 drive documentation.

The diagnostics and troubleshooting chapters (chapters 2-3) describe the error
checking built into the PMI Regulator operating system and how to use warning and
fault registers, LEDs, and the error log to diagnose drive problems.

Chapter 4 provides guidelines on starting up Distributed Power SA500 AC drives.
Although initial start-up services are usually provided by Rockwell personnel, it is
recommended that the user become familiar with the general guidelines in this chapter
in order to be better prepared to work with the Rockwell service engineer.

This manual does not describe specific applications of the standard SA500 hardware
and software. Always refer to the wiring diagrams supplied with your system for
information specific to your installation.

1.1 Related Publications

You user must become familiar with the other instruction manuals that describe the
SA500 drive system. The documentation that describes the SA500 drive is listed in
table 1.1.

Table 1.1 – SA500 Documentation (Binder S-3002)

Document Document Part Number

DPS Overview S-3005
Universal Drive Controller Module S-3007
Fiber Optic Cabling S-3009
SA500 DC Bus Supply S-3017
SA500 AC Power Modules S-3018
SA500 Diagnostics, Troubleshooting, & Start-Up

Guidelines
SA500 Information Guide S-3024
SA500 Drive Configuration & Programming S-3044

Additional information about using the SA500 drive is found in the prints and other
documentation shipped with each drive system. Always consult the prints and other
documents shipped with your drive system for specific information about installing,
operating, and maintaining your drive.

S-3022

Introduction

1-1

1.2 Typographical Conventions

The following typographical conventions are used in this manual:

•

Variable names
Variables names are shown in all capital letters followed by the appropriate

terminating character. The variable names shown in this manual are suggested
names only and may vary from the names used in your application.

Example: MCR@

•

Register names
Register names are shown with the initial letters capitalized followed by the

corresponding register number for both drive A and drive B. The drive A register
number is shown first followed by the drive B register number (A/B).

Example: Drive Fault register (202/1202)

•

Bit names
Individual bit names are shown with the initial letters capitalized. Also shown, in

parentheses, is the bit’s register number, bit number, and suggested variable name.
Example: Fault Reset bit (register 100/1100, bit 8, FLT_RST@)

•

Parameter entry screen titles
Parameter entry screen titles and the parameters themselves are shown with the

initial letters capitalized.
Example: Feedback Data parameter entry screen

1-2

SA500 Diagnostics, Troubleshooting, and Start-Up Guidelines

C

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Diagnostics and Troubleshooting

The Distributed Power System contains built-in comprehensive diagnostics. In order
to diagnose and correct problems quickly, it is important to understand the types of
diagnostics that are performed, when they are performed, and how the results are
reported. This chapter describes the different types of diagnostics performed by the
system’s modules and how the results of these diagnostics are reported. This chapter
also describes how the system reacts if an error is detected.

An overview of these modes is shown in figure 2.1. The Distributed Power System
provides diagnostics at each level of operation as shown in figure 3.1.

Use these figures as a reference to quickly identify the system's requirements for
entering and operating in each mode. These figures also refer to specific sections in
the manual that provide additional information.

2.1 Defini tion of Terms Used in Diagnostics and
Troubleshooting

For the purpose of describing diagnostics and troubleshooting, this instruction manual
will use specific terms to refer to the types of errors that can be detected by the PMI
and the response of the PMI and UDC module to those errors.

diagnostic

A
There are three types of diagnostics in SA3100 drives: power-up diagnostics, interlock
diagnostics, and run-time diagnostics.

drive fault

A
shut the drive down. Faults are reported in the Drive Fault register (202/1202) of the
UDC module and in the error log for the UDC task in which the fault occurred.

drive shut-down

A
occurs.

drive warning

A
indicates the drive is not operating in an optimum manner. Drive warnings will not
shut the drive down.

error

An

Interlock diagnostics

in response to a drive control request from the programmer, e.g., PMI_RUN@, in
register 100/1100 of the UDC module dual port memory.

Power-up diagnostics

all printed circuit board modules.

Run-time diagnostics

background task after it has received its operating system from the UDC module.

is a software routine specifically designed to check for error conditions.

is an error specifically checked for by the PMI operating system that will

occurs when any fault reported in the Drive register (202/1202)

is an error specifically checked for by the PMI operating system that

is any condition other than the desired condition.

are those diagnostics performed by the PMI operating system

consist of the initial tests for basic functionality performed by

are those diagnostics performed continuously by the PMI as a

2

Diagnostics and Troubleshooting

2-1

POWER-UP

DIAGNOSTICS

IDLE

SELECT PMI_RUN@

OR ALN_TST@

CLOSE MCR

2-2

PMI RUN

ALIGN RESOLVER

OPEN MCR

Figure 2.1 – PMI Operating Modes Overview

SA500 Diagnostics, Troubleshooting, and Start-Up Guidelines

2.2 Power-up Diagnostics in the UDC Module and PMI

Power-up diagnostics execute in the UDC module in the AutoMax™ rack and in the
PMI in the Power Module. When power is applied to the AutoMax rack, the UDC
module performs a series of self-tests. When all of the tests are successfully
completed, the CARD OK LED on the UDC module's faceplate will turn on. If a failure
occurs, the OS OK LED will flash rapidly.

When power is applied to the Power Module, the PMI performs a series of self-tests.
When all of the tests are successfully completed, the OK LED on the Power Module’s
faceplate will turn on. If a failure occurs, the P.M. FLT LED on the Power Module will
flash rapidly.

If a UDC module or a Power Module does not pass its power-up tests, it must be
replaced. After all of the power-up tests are passed, the system continues its
power-up routine. The PMI requests the appropriate operating system from the UDC
module. The UDC module downloads the operating system and the parameter
configuration data, if available, to the PMI. The PMI then runs under the control of its
operating system and begins performing the run-time diagnostics. Run-time
diagnostics are descr ib ed in sec ti on 2.4.

2.3 Interlock Tests

Interlock tests are performed by the PMI whenever one of the PMI's operating modes
is selected by the programmer through the Drive Control register (100/1100). These
diagnostics verify that all conditions required for the operating mode selected are
satisfied. If the interlock tests are completed successfully, then the operating mode
requested by the programmer can be entered. If any of the interlock diagnostics fails,
the PMI will latch a bit in the Interlock register (205/1205) corresponding to the first
diagnostic test that failed, and the requested operating mode will not be entered (i.e.,
the PMI will remain in the idle mode).

If an interlock test failure occurs, follow the procedure below:
Step 1. Reset the command bit that is currently set in the Drive Control register

Step 2. Correct the condition that caused the test failure.
Step 3. Set the desired command bit in the Drive Control register (100/1100).

The PMI will perform the interlock tests each time a rising edge is detected on the
command bits. The results of subsequent interlock tests will overwrite the previous
test’s results.

2.4 Run-time Diagnostics

Run-time diagnostics are performed continuously by the PMI after its operating
system has been downloaded by the UDC module. These diagnostics test the status
of the PMI and the connected hardware and also check the integrity of the
communication link between the UDC module and the PMI.

Diagnostics and Troubleshooting

(100/1100).

2-3

The results of the diagnostics are stored in either the Drive Warning register
(203/1203) or the Drive Fault register (202/1202) in the UDC module's dual port
memory. How drive faults and drive warnings are indicated and how they affect the
operation of the drive is described in the following sections.

2.4.1 Drive Faults

When the PMI detects any of the conditions identified in the Drive Fault register, it will
shut down the drive as described below. To determine the cause of a drive shutdown,
the following indicators are provided:

•

Drive Fault register (202/1202)

The PMI will set a bit in the Drive Fault register to indicate the condition that caused
the shutdown. The interlock tests check this register for fault conditions that have
occurred. Refer to Appendix A for a complete description of the Drive Fault Register.

•

Drive Status Register (200/1200)

The PMI will set the Fault Detected bit (bit 8, FLT@) of the Drive Status register when
a drive fault has been detected.

•

LEDs on the UDC module

If either LED (DRV FLT A or DRV FLT B) is on, a drive fault has been detected for the
drive using that communication channel.

•

LEDs on the Power M odu le

The Power Module’s faceplate contains 15 status/fault LED board. Refer to Appendix
E for LED definitions.

•

Error log for the UDC task

The error log for the task in which the fault occurred is accessed through the ON LINE
menu of the AutoMax Programming Executive. A list of the drive fault error codes can
be found in Appendix D. Refer to appropriate AutoMax Programming Executive
instruction manual for more information regarding the Programming Executive and the
ON LINE menu.

2.4.1.1 How the System Reacts to Drive Faults

As described in section 2.4.1, if the PMI detects any of the conditions identified by the
Drive Fault register, it will shut down the drive. This means that the PMI responds by
immediately disabling the gates of the power devices, causing the motor to begin a
coast-to-rest stop. The PMI will wait 100 msec after the fault before turning off the
MCR output.

Note that the UDC task is not stopped automatically is a drive fault causes a
shut-down of the drive. The user must ensure that the application task(s) test the
Drive Fault register (202/1202) and takes any appropriate action if a fault is detected.

2-4

SA500 Diagnostics, Troubleshooting, and Start-Up Guidelines

2.4.1.2 MCR Output Control

The MCR output on the Power Module is used to control an output contactor. This
output contactor, sometimes referred to as an M-contactor, disconnects power from
the motor. This option is selected during UDC module parameter configuration. If the
programmer selects to connect the MCR output to an output contactor, auxiliary
contacts from this device must be wired to the AUX IN1/MFDBK input as feedback.
The PMI operating system will wait for AUX IN1/MFDBK to turn on before executing
any operating mode.

The Run Permissive input (RPI) on the Power Module and the MCR output are
interlocked in hardware. The MCR output can be turned on only when the RPI is
asserted. The MCR output itself is under the control of the PMI. Application tasks
have no direct control of the MCR output. RPI is controlled by the user. When RPI is
off, MCR cannot be activated.

The following conditions will cause the MCR output to turn off:

•

Absence of the RPI signal

•

Occurrence of a drive fault

•

Control algorithm is turned off (PMI_RUN@ = 0)

When any of the above conditions occurs, the PMI will disable the power device gates
and the motor will begin a coast-to-rest stop. The PMI will wait 100 msec and then turn
off the MCR output.

In addition, if the RPI signal is removed, the MCR output and gate power will be
removed under hardware control within approximately 0.5 seconds of the removal of
the RPI signal to provide an additional interlock. This is done regardless of the actions
taken by the PMI.

2.4.2 Drive Warnings

The PMI will check for conditions that are not serious enough to shut down the drive,
but may affect its performance. If the PMI detects any of the conditions described in
the Drive Warning register, it will set the appropriate bit but will NOT shut down the
drive. The user must ensure that the application task tests the Drive Warning register
(203/1203) and takes any appropriate action if a warning condition is detected.

The PMI will also set the Warning Detected bit (register 200/1200, bit 9, WRN@) if a
drive warning has been detected.

Appendix B provides a complete description of the Drive Warning register.
rail faults, drive warnings are not indicated by LEDs (a rail fault will turn on the RAIL
FLT LED on the Power Module).
error log.

Except for

Drive warnings are not displayed in the UDC task's

Diagnostics and Troubleshooting

2-5

2.4.3 How to Clear the Drive Fault and Drive Warning Registers

After a drive fault has been detected, the programmer must do the following before the
drive can be restarted:

Step 1. Reset the command bit that is currently set in the Drive Control register

(100/1100).
Step 2. Correct the fault.
Step 3. Set and reset the Fault Reset bit (register 100/1100, bit 8, FLT_RST@) to

clear the Drive Fault register (200/1200). (Note that the Fault Reset bit is

edge sensitive.)
Step 4. Set the desired command bit in the Drive Control register (100/1100).

After a drive warning has been detected, the programmer can clear the entire Drive
Warning register by setting and resetting the Warning Reset bit (register 100/1100,
bit 9, WRN_RST@). (Note that the Warning Reset bit is edge sensitive.)

2-6

SA500 Diagnostics, Troubleshooting, and Start-Up Guidelines

C

HAPTER

3

PMI Operating Modes

The PMI's default operating mode is idle. All other operating modes are selected by
the programmer in the Drive Control register (100/1100). T ab le 3.1 shows the available
operating modes. Note that the operating modes are mutually exclusive, i.e., only one
mode may be enabled at a time (this is checked by the interlock tests).

The PMI's operating modes are shown in figure 3.1 and are described in the following
sections.

Table 3.1 – PMI Operating Modes

Operating

Mode

Idle N/A The PMI’s default operating mode during which no algorithms are

PMI Run 0 Executes the torque, speed, or position control algorithm.

Alignment Test 1 Enables the resolver alignment procedure for brushless drives.

Drive Control

Register Bit Mode Description

running.

3.1 Idle Mode

The PMI's default operating mode after passing the power-up diagnostics is idle.
When in idle mode, the PMI is waiting for a command from the Drive Control register
(100/1100) to change operating modes.

In order for the PMI to enter the requested operating mode, the Interlock tests must be
passed. If any of the Interlock tests fails, or if any fault is latched in the Drive Fault
register (202/1202), the PMI will remain in the idle mode.

The PMI will return to the idle mode when it exits any of the other operating modes.

3.2 PMI Run Mode

To execute the control algorithm(s), the programmer sets:

PMI Operating Modes

•

the PMI Run Enable bit (register 100/1100, bit 0, PMI_RUN@) for the torque minor
loop

and, if required,

•

the Speed Loop Enable bit (register 100/1100, bit 3, SPD_ON@) for the speed
minor loop

•

the Position Loop Enable bit (register 100/1100, bit 4, POS_ON@) for the position
minor loop.

3-1

Before the control algorithm(s) can be executed, all of the following conditions must be
met:

•

The interlock tests, register 205/1205, must be passed successfully. See
section 2.3.

•

The M-contactor must be closed, if configured. See section 2.4.1.2.

•

The UDC task in the AutoMax rack must be running. The status of the UDC task is
indicated by the UDC Task Running bit (register 100/1100, bit 15, UDC_RUN@).

If any of these requirements are not met or if a fault is latched in the Drive Fault
register (202/1202), the PMI will remain in the idle mode.

If these requirements are met, the PMI will execute the torque minor loop, and if
selected, the speed and position minor loops. At this time, the PMI will set the PMI On
bit (200/1200, bit 0, PMI_ON@) to indicate that the torque minor loop is executing.

Important: Note that if a brushless motor is being used, the resolver and rotor shafts

must be aligned before the torque minor loop is executed or the motor
may not run properly. This is not tested by the Interlock tests as a
requirement to enter the PMI run mode. See section 3.3 for description of
this procedure.

The torque minor loop executes until one of the following occurs:

•

The PMI Run Enable bit (register 100/1100, bit 0, PMI_RUN@) is reset by the
application task.

•

A drive fault is detected. Refer to Appendix A for a description of the Drive Fault
register.

•

The RPI signal (register 201/1201, bit 0) is removed.

The speed minor loop executes until one of the following occurs:

•

The Speed Loop Enable bit (register 100/1100, bit 3, SPD_ON@) is reset by the
application task.

•

The PMI Run Enable bit (register 100/1100, bit 0, PMI_RUN@) is reset by the
application task.

•

A drive fault is detected. Refer to Appendix A for a description of the Drive Fault
register.

•

The RPI signal (register 201/1201, bit 0) is removed.

The position minor loop executes until one of the following occurs:

•

The Position Loop Enable bit (register 100/1100, bit 4, POS_ON@) is reset by the
application task.

•

The Speed Loop Enable bit (register 100/1100, bit 3, SPD_ON@) is reset by the
application task.

•

The PMI Run Enable bit (register 100/1100, bit 0, PMI_RUN@) is reset by the
application task.

3-2

SA500 Diagnostics, Troubleshooting, and Start-Up Guidelines