omnipulse™ ddc magnetek training. omnipulse™ ddc training the objective of this training is to...

OmniPulse™ DDC

Magnetek Training

OmniPulse™ DDC Training

• The objective of this training is to familiarize service and maintenance personnel with– The many resources available to assist in

• Start up• Maintenance • Troubleshooting

– The training course is designed to provide knowledge on:

• The basics of DC motors and DCCP control• The User Manual layout and information

OmniPulse™ DDC Training

• The basic operating theory of the technology

• Hardware layout, circuit board layout, and circuit board jumper and switch settings

• Navigating the display and software menus

• Understanding each parameter function and how they interrelate and effect drive performance

• Trouble analysis using drive fault messages and trouble flow charts

• Loading control and display software

OmniPulse™ DDC Session One

Basic DC Background

Quadrants of Operation

Quadrants of Operation

In this quadrant the motor must provide the braking Torque to slow the Hoist or plugging in travel motion. The energy is a result from the rotating inertia reflected at the motor shaft.

In this quadrant the motor must provide the physical torque to raise the load or move the Trolley or Bridge.

In this quadrant the motor must provide the physical torque to overcome frictional forces, such as lowering in open hook.

In this quadrant the motor must provide the braking torque to counter act gravity effect when lowering a load at a controlled speed.

Performance CurvesDC Motors

Hoist Control DCCP Panel

Armature

Series Field

Commutator

Brush Rigging -even number of brushes in pairs (Pos and Neg)

DC Motor Construction

DC Motor Connections

Basic Performance Curves

Typical DCCP Hoisting Performance Curves

Series Resistor Hoist

• Hoist connection• High speeds light loads• High torque low speeds• Effect of increasing resistor

– Reduced torque

– Poorer speed regulation

Variable Shunted Armature

• Hoist connection• Good speed regulation @

reduced speeds• Increased current in series

field• Slow down torque available• Decreasing Resistance

– Reduces starting torque

– Improves speed regulation

– Increases slowdown torque

– Increase the current in the series field

Fixed Shunted Armature

• Hoist connection• Increasing resistance

– Decreases starting torque

– Reduces speed regulation

– Decreases slowdown torque

– Decreases current in the series field

Shunted Field Var Res

• Lowering connection

• Increasing series field resistance

– Increases starting torque– Increases dynamic lowering

speed– Reduces speed regulation

Shunted Field Var Arm Res

• Lowering connection

• Increasing resistance– Reduces starting torque– Reduces speed regulation– Increases dynamic lowering

speed

Off Position DB

• Self excited no power required

• No starting torque developed• Increasing resistance

– Increases speed

– Reduces speed regulation

– Reduces deceleration torque

Typical One Line Electrical

DCCP Typical Crane Single Wiring Diagram

DCCP Typical Panel & Resistor

DCCP Hoist Diagram

Hoist Steps

Lowering Steps 1 and 2

Lower Steps 3, 4, and 5

DB Step

End of Session One

Note:

All reference to Figures, Page Numbers and Tables are to be found in the

OmniPulse DDC Technical Manual

OmniPulse™ DDC

Session Two

Changing The RulesOperating Principles Pages12-15

Hoist Power Circuit

DB

L1+

L11

C

M

K PR

R6 R8

F1

RT

Q1P

D1P

CT1

L2ÐLL2

MCB

Q1N

Q2P

D2P

CT2

Q2N

T1

A1 A2

T2 T4 T3

B1 B2

B1S1 B2S2

A2

A1

Q1

Q3P

D3P

CT3Q3N

D3N

LS

Resistor

SeriesField Series

Brake

Q3Q5

Q6

Q4

Q2

Arm

D1N D2N

CollectorRails

MCB

Simplified Motor CircuitSeries Field Hoist Motion

T1, T2, T3 Voltages Referenced to L2(-)

T1 T2 T3

t1 t2 t3 t4

DriveTerminalVoltage

T1

T2

T3

Voltage

Voltage

Motor ArmatureTerminals

T1-T2

Series FieldTerminals

T2-T3

+V0

-V

+V0

-V

+V0

-V

+V0

-V

+V0

-V

Q1P

Q1N

Q3P

Q3N

Q2P

Q2N

0

0Current

Current

PWM Power Hoisting

t1 - t2 Current Path Power Hoisting

t1 t2 t3 t4

Time Period t1 - t2

+V0

-V

+V0

-V

0

0

DB

L1+

L11

C

MCBM

K PR

R6 R8

F1

RT

Q1P

D1P

CT1

L2ÐLL2

MCB

Q1N

Q2P

D2P

CT2

Q2N

T1

A1 A2

T2 T4 T3

B1 B2

B1S1 B2S2

A2

A1

Q1

Q3P

D3P

CT3Q3N

D3N

LS

Resistor

SeriesField Series

Brake

Q3Q5

Q6

Q4

Q2

Arm

D1N D2N

CollectorRails


t1 t2 t3 t4

Time Period t2-t3

+V

0

-V

+V

0

-V

0

0

DB

L1+

L11

C

MCBM

K PR

R6 R8

F1

RT

Q1P

D1P

CT1

L2ÐLL2

MCB

Q1N

Q2P

D2P

CT2

Q2N

T1

A1 A2

T2 T4 T3

B1 B2

B1S1 B2S2

A2

A1

Q1

Q3P

D3P

CT3Q3N

D3N

LS

Resistor

SeriesField Series

Brake

Q3Q5

Q6

Q4

Q2

Arm

D1N D2N

CollectorRails


t1 t2 t3 t4

Time Period t3-t4

+V0

-V

+V0

-V

0

0

DB

L1+

L11

C

MCBM

K PR

R6 R8

F1

RT

Q1P

D1P

CT1

L2ÐLL2

MCB

Q1N

Q2P

D2P

CT2

Q2N

T1

A1 A2

T2 T4 T3

B1 B2

B1S1 B2S2

A2

A1

Q1

Q3P

D3P

CT3Q3N

D3N

LS

Resistor

SeriesField Series

Brake

Q3Q5

Q6

Q4

Q2

Arm

D1N D2N

CollectorRails

t9 t10 t11


T1

T2

T3

Voltage

Voltage


T1-T2


T2-T3

+V

0

-V

+V

0

-V

+V0

-V

+V

0

-V

+V

0

-V

Q1P

Q1N

Q3P

Q3N

Q2P

Q2N

0

0Current

Current

PWM Power Lowering

t10 - t11 Current Path Power Lower

t9 t10 t11

Time Period t10-t11

+V0

-V

+V0

DB

L1+

L11

C

MCBM

K PR

R6 R8

F1

RT

Q1P

D1P

CT1

L2ÐLL2

MCB

Q1N

Q2P

D2P

CT2

Q2N

T1

A1 A2

T2 T4 T3

B1 B2

B1S1 B2S2

A2

A1

Q1

Q3P

D3P

CT3Q3N

D3N

LS

Resistor

SeriesField Series

Brake

Q3Q5

Q6

Q4

Q2

Arm

D1N D2N

CollectorRails

-V

0

0

Power Hoisting

T1 T2 T3

151V 125V

10% RPM

122V

+26V +3V

Deceleration Braking

T1 T2 T3

99V 125V

10% RPM

122V

-26V +3V

Power Lowering

T1 T2 T3

106V 125V

10% RPM

122V

-19V +3V

Dynamic Lowering

T1 T2 T3

144V 125V

10% RPM

122V

+19V +3V

Travel Power Circuit

Simplified Travel Motor Circuit

T1 T2 T3T4

4

T1, T2, T3, T4 Voltages


T1

T2

T3

+V0

-V

+V0

-V

+V0

-V

Q1P

Q1N

Q3P

Q3N

Q2P

Q2N

T4 +V

t1 t2 t3 t4

Voltage

Voltage


T1-T2


T4-T3

+V0

-V

+V0

-V

0

0Current

Current

PWM Travel Motoring

t1 - t2 Current Path Travel Motoring

T1 - T2 =0

T4 - T3 =0

D3P

t2 - t3 Current Path Travel Motoring

T1 - T2 =0T4 - T3 =+V

D3P

t3 – t4 Current Path Tr avel Motoring

T1 - T2 =+VT4 - T3 =0

D3P

Travel Plugging / Braking

T1 - T2 =-VT4 - T3 =+V

D3P

End of Session Two Questions?

OmniPulse™ DDCSession Three

Hardware

Modular Drive Design

NEMA 3Complete

(133A)

NEMA 4Complete

(200A)

Display 144-45063

133A Stack

Driver 144-45058

Control 144-45060

* Interface 144-45062

144-45004

Display 144-45063

200A Stack

Driver144-45059

Control 144-45060


144-45042

*NOTE:Interface Card 144-45062 mounted separately from module enclosure


NEMA 5Complete

(400A)

NEMA 6Complete

(800A)

Display 144-45063

400A Stack

Driver 144-45059

Control 144-45060

144-45005

Display 144-45063

400A Stack

Driver 144-45059

Control 144-45060

400A Follower400A Stack

Driver

144-45059

144-45005

144-45006





NEMA 7Complete

(1200A) Display 144-45063

400A Stack

Driver 144-45059

Control 144-45060

400A Follower

400A Follower



144-45005

400A Stack

Driver 144-45059

144-45006

400A Stack

Driver 144-45059

144-45006


NEMA 8SComplete

(1600A)

400A Follower

400A Follower

Display 144-45-063

400A Stack

Driver 144-45059

Control 144-45060


144-45005

400A Stack

Driver 144-45059

144-45006

400A Stack

Driver 144-45059

144-45006

400A Follower 400A Stack

Driver 144-45059

144-45006



NEMA 8LComplete

(2000A)97-3619-4

400A Follower

400A Follower

400A Follower

400A Follower


Display 144-45-063

400A Stack

Driver 144-45059

Control 144-45060


144-45005

400A Stack

Driver 144-45059

144-45006

400A Stack

Driver 144-45059

144-45006

400A Stack

Driver 144-45059

144-45006

400A Stack

Driver 144-45059

144-45006

Trolley Panel Size 3 133 Amps

Interface Bd

SB Contactor

M Contactor

Hoist Panel Size 5 400 Amps

M ContactorDB Contactor

Interface Bd

Drive

M Contactor

Interface Bd

SB Contactor

MasterFollower

Travel Panel Size 6 800 Amps

SB Contactor

M Contactor

MasterFollower 1Follower 2

Hoist Panel Size 7 1200 Amps

Hoist Panel Size 8S 1600 Amps

Master Drive

Follower 1

M Contactor

DB Contactors

CCB

MCB

Follower 2

Follower 3

Interface Card 144-45007

Interface Card 144-45062

Green LED 230VDC Input Status indicators

Green LED 230VDC Output Status indicators

S1 Reset Switch

Figure 24 User Manual

144-45062

Interface Card 144-45062 Picture

Stop

Enable

Lower

Hoist2nd Speed

3rd Speed

4th Speed

5th Speed

Prog Input

M 230VDC Output

DB 230VDC Output

SB 230VDC Output

L1+

L2-

COM+

230 VDC Conn.

Reset

Output Status Ind.

Input Status Ind.

5 Amp Fuses

144-45062

144-45062 Parameter Reference

133 Amp Drive 144-45004

Control Card 144-45060

Incoming Terminals

Display Assembly 144-45063

Load TerminalsDriver Card 144-45058

Power Supply LED’s

Fuse 144-45065

400 Amp Master Drive 144-45005


Driver Card 144-45059


Discharge Resistor Card

144-45064

Incoming Terminals

Load Terminals

Fuse 144-45066

Master to Follower Conversion



Driver Card 144-45059

Discharge Resistor Card

144-450XX

Incoming Terminals

Load Terminals

Fuse 144-450XX

J 9 connector needs all pins open.

Disconnect these cables from the control board

Follower Driver Board J9 Jumper Positions

Remove Jumper from LK2 and place on pins 11 and 12 of J9

Shift large J9 jumpers to the left keeping top row of pins open

DDC Demo Power Up

Demo power connection will allow you to power the drive up to load a different control program, change parameters, or practice navigation of the menu groups from your shop supply.

144-45060 Control Card Picture Rev 2

Flash

SW2

SW1

LK1

LK2

PWR On

Fault

Driver Card Con

Display Con

Interface Card Con

144-45060 Control Card Rev 3, 4, & 5

Figure 25 User Manual

Driver Card Con

Display Con

Interface Card Con

LK4

Flash boot load link1 -- 2 -- 3

1& 2 Flash boot load2 & 3 Normal

LK31 & 2 RESET input resets CPU2 & 3 RESET input used as logic input

LK3

LK2485 Terminator1&2 120 OHM Connected2&3 120 Ohm not connected

SW2 Analog Input Switch

SW1

Configuration Switch

SC Fault Lockout LED

Power LED

144-45060 Parameter Reference

144-45060 Switch Settings

Table 27 SW2 DIP Switch Settings

SW POS OFF ON

A AN1 -10/+10V

AN1 4/20 mA

B AN1 Diff

AN1 Non Diff

C AN1 X1

AN1 X2

D AN2 -10/+10V

AN2 4/20 mA

Table 28 SW1 DIP Switch Settings

SW1 positions 1 and 2 are used to select the current rating:

Current Class DIP switch setting

NEMA2 67A maximum SW1-1 OFF SW1-2 OFF

NEMA3 133A maximum SW1-1 ON SW1-2 OFF

NEMA4 200A maximum SW1-1 OFF SW1-2 ON

NEMA5 400A maximum SW1-1 ON SW1-2 ON

SW1 position 3 determines hoist or the travel configuration:

Configuration DIP switch setting

HOIST SW1-3 OFF

TRAVEL SW1-3 ON

SW1 position 4 are used to select the voltage rating:

Voltage Class DIP switch setting

200/360V SW1-4 OFF

400/720V SW1-4 ON

1 2 3 4 5 6 7 8

On On Off Off Off Off Off Off

Main Hoist

SW1 Settings

144-45060 Rev 5 Control Board

• New revision 5 control board – Being phased into production July 2006– Can be used with all existing installed drives

• Improves noise immunity of the drive I/O• Component location same as revision 3 and 4 boards

Control Board Software Capability

• Software compatibility– Version 1 control software requires 1.19 Display EPROM in

144-45063 display– Version 2&3 software requires 2.00 Display EPROM in 144-

45063 display

• EPROM Display software version – Determines control software load for 144-45060 control

board– Control software can be loaded into all revisions of control

board 144-45060

Rev 1 & 2 144-45058 Driver Board

+5V

+24V

-15V

+15V

Supply LED

LK1 LK2 Lk3 Link Location

Internal Fan

144-45058 Rev 3 Driver Board

+5V

+24V

-15V

+15V

Supply LED

LinksThermistor

HS Fan

CT1 CT2 CT3

Control Card Conn

Gate Driver

Module

Q1

Q2

Q3

Precharge Charge LED

250 VDC Conn

Driver Card 144-45059 NEMA 4/5

Control Card Conn

-15V +5V +15V +24V

Supply LED

Thermistor

PrechargeQ1

Q2

Q3

CT1 CT2 CT3

Bus Connector Follower Units

Gate Driver

Q2

Gate Driver

Q1

Gate Driver

Q3

HS Fan

250 VDC Conn

LK 2

LK 5

LK 1

Driver Card 144-45059 Test Points

Test Point Description

TP1 DCCT 3 Signal: 4.0 VDC = 600 Amps

TP2 0 Volts Ground (Signal Common)

TP3 DCCT 1 Signal : 4.0 VDC = 600 Amps

TP4 DCCT 2 Signal (Signal Common)

TP5 Volts DC+

TP6 + 24 volt Power Supply

TP7 - 15 volt Power Supply

TP8 CEMF Average volts



TP11 0 Volts Ground (Signal Common)


TP11

TP10

TP9

TP4 TP6

TP1TP2

TP8 TP7

TP3 TP5

Current Feedback - Scaling

Table 29 Gate Drive Board Link Settings

The current feedback scaling is determined by SIP jumpers LK1, LK2 and LK3 or LK5:

Current Class Current Feedback Scaling

NEMA2 67A maximum LK1, LK2, LK3 IN

NEMA3 133A maximum LK1, LK2, LK3 OUT

NEMA4 200A maximum LK1, LK2, LK5 IN

NEMA5 400A maximum LK1, LK2, LK5 OUT

If ground fault detection is enabled, SIP jumper LK10 must be correctly positioned:

Configuration DIP switch setting

HOIST LK10 IN

TRAVEL LK10 OUT

Earlier Printed Circuit Board Revisions

144-45058 rev1 and 2 (used on 200/360V NEMA 2 and NEMA3):

LK10 does not exist. In the TRAVEL or HOIST configuration set Parameter D07 ‘Ground Fault’ to ‘Disabled’

144-45059 Rev 1 and 2 (used on 200/360V NEMA 4 and NEMA5):

LK10 does not exist. In the TRAVEL or HOIST configuration set D07 ‘Ground Fault’ to ‘Disabled’

144-45058 NEMA 2/3 Scaling Links

LK 1LK 2 LK 3

Closed For NEMA 2

Open For NEMA 3

Scaling Link Position

144-45059 Scaling Links NEMA 4/5

LK1 LK2 LK5

Out Out Out

400A Driver Link Position

LK 5

LK 2

LK 1

Bus Connector

Closed For Master Drive

Open For Follower Drive

Buss Link Connector Position

LK1 LK2 LK5

Closed Closed Closed

200A Driver Link Position

400 Amp RPM 144-45061

144-45061 400 Amp RPM Schematic

Stand alone RPM 400 Amp diagram

Common buss RPM 400 Amp diagram

Common buss RPM 800 Amp diagram

144 –45039 144 –45039

RPM and Resistor Required

• For crane mounted DC rectifier or MG set• When Regeneration current exceeds 500 Amps

– Generally simultaneous motions above 150 HP

• Scheme shown requires RPM Unit to be connected behind the M contactor (connected to the DC drive Caps L1+ and L2- drive terminals)

• RPM designed for 20% duty @ 400 Amps

RPM Sizing

• Tabulate all motion FLA – ½ hour FLA for hoist motion– 1 hour FLA for travel motions

• Calculate Regen Current for simultaneous motion operation

• Size RPM as close as possible to calculated value

3.*8.* TRAVELHOISTREGEN FLAFLAI

Line Reactor Required

• For crane mounted DC rectifier or MG set– Provide a line reactor for all motion panels

• For large Bus rectifiers (>500KW)– Generally large DC Bus Rectifiers have a large AC Ripple

content that impact the control performance– Provide a line reactor for all panels

End Session ThreeQuestions?

OmniPulse™ DDC

Session Four

Version 3.10 Software

Main Menu Screen

• Power Up screen• Title Screen: MAGNETEK

OMNIPULSE DDC

Pressing the Down Key

• Title Screen: MAGNETEK

OMNIPULSE DDC

Display Software Version 2.00

Pressing RIGHT MENU Key

• Group A Monitoring• Group B Access• Group C Controller Set Up• Group D Protection• Group E Drive Control Set Up• Group F Speed and Torque Settings• Group G I/O Configuration• Group H Fault History• Main Menu Screen

Hoist motion current loop flowchart

Hoist motion speed loop flowchart

Travel motion current loop flowchart

Travel motion speed loop flowchart

Group A Monitoring (Up Key)

• Tables list are in OmniPulse DDC manual.• Table 13 Motor Current and Voltage

– Armature Current– Field Current– Armature Voltage– DC Bus Voltage

• Table 14 Motor Speed and Torque – Motor CEMF– Flux calculation % of rated value– Motor RPM calculation– Motor Torque calculation % of rated value– Hook Load measurement % of rated value

Group A Monitoring Continued

• Table 15 Power, Energy, and Operation Cycles– Input Power instantaneous power main DC supply– Energy Used: accumulated energy consumption– No of operations or cycles commanded– Elapsed Hours: Accumulated power on time

• Table 16 Analog Input Status– Analog Input 1: % of full scale input 1– Analog Input 2: % of full scale input 2


• Table 17 Current and Speed (Advanced Tools)– Arm Current Ref: calculated Ref % of rated value– Fld Current Ref: calculated Ref % of rated value– Speed Ref: Calculated Ref % of rated value – Upper Control Limit: Fwd current limit applied– Lower Control Limit: Rev current limit applied

• Table 18 Logic I/O Status– Logic Inputs: Eight total binary representation– Logic Outputs: Five total binary representation


• Table 19 Controller Status (Advanced Tool)– Heatsink Temp: Semiconductor Heatsink– Ambient Temp: Temp of electronic control card– Overload Level: Accumulated ovld calculation– T1 Duty Cycle: T1 PWM duty– T2 Duty Cycle: T2 PWM duty– T3 Duty Cycle: T3 PWM duty– Control Status flags: Eight binary representation– Fault Status– Sequence Status

Group B Access

• Table 20 Access– Password: two levels of access for changes

• User • Engineer (2004)

– Access Level: current active level• Monitor• User• Engineer

– Control Firmware– Modbus AN1– Modbus AN2– Tach Coefficient

Monitor transmitted analog reference on communication bus

Group C Control Set Up

• Table 21 Controller Rating Setup– Configuration– Voltage Class– Current Class– Parallel Stacks– Armature Set Up: Internal or External CT– Input Bus Voltage: Sets UV and OV trip points– Field Set Up : Internal or External CT– Default Values: store user settings; restore user settings;

restore factory default settings

Group D Protection

• Table 22 Protection– Motor rated current– Motor rated voltage– Motor rated speed– Motor field current: Motor FLA for series motors– Current limit forward (Hoist)– Current limit reverse (Hoist)– Arm/Field ratio: Defines motor commutation limit– Ground Fault

Armature to Field RatioFIELD WEAKENING ARMATURE FIELD RATIO

0%

50%

100%

150%

200%

250%

300%

0% 10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

% FIELD CURRENT

% A

RM

AT

UR

E C

UR

RE

NT

A/F=1.5

A/F=2

A/F=3

Field Weakening Armature to Filed Ratio

Group D Protection Continued

• Table 22 Protection Continued– OH alarm level: Cuts back current to 150% – OH trip level: HS Temperature trip level– LS detection Sets limit switch mode detection

• Disabled• Hook Sense (Software Detection)• HLS (software detection) no fault registered• LS Relay (Hardware Detection)• ELS (external hardware detection) no fault registered

Group D Protection Continued

• Table 22 Protection Continued– LS lower detection level: 2 to 50% of measured motor volts– LS hoist detection level: 2 to 50% of measured motor volts– LS back out time : timed back out of limit switch– Slack cable: Disabled or enabled – Slack cable torque: Detection level .1 to 25% torque

Group E Drive Setup

• Table 23 Drive Control Setup– Accel Time: set in seconds– Decel Time: set in seconds– Current gain*– Speed P Gain*– Speed I Gain* – IR Comp Gain*

*(It is recommended to use the default values for the parameters highlighted for crane applications)

Group E Drive Setup Continued

• Table 23 Drive Control Setup Continued– Start Delay: time to allow M to close*

*(too low a setting can cause UV faults recommend 300 ms setting)

– Bypass Speed: acceleration time ramp not applied to reach this speed - drive will go to this speed immediately *

*(Normally not used on crane applications)– Stop Speed: speed at which the stop sequence is initiated


• Table 23 Drive Control Setup Continued – DB Delay: time to allow DB to open– DB Time: time for DB braking at end of run request– Lower Minimum Field: sets maximum lowering speed with

empty hook (Hoist Mode Only 200% maximum)– Hoist Minimum Field: sets maximum hoisting speed with

empty hook (Hoist Mode Only 300% maximum)

Stop sequence begins when speed reference equals stop speed value

OmniPulse DDC Version 3.10 Hoist Speed

When speed reference is at or below 15% in the hoist direction the stop sequence is executed immediately without delays.

OmniPulse DDC Version 3.10 Hoist Speed Below 15%

Stop sequence begins when speed reference equals stop speed value

OmniPulse DDC Version 3.10 Travel Motion


• Table 23 Drive Control Setup Continued– Economy Field: starting field current level for empty hook or

free run travel*

*(For economy filed to function properly Minimum field values E15, E16, or E18 must be equal or set at a lower value than E17)

– Minimum Field: sets maximum travel speed (300% maximum)

– Field Rate Change: Limits rate per second change of field current in field weakening operation

Minimum Field Settings

• Acts like an electronic governor limiting the maximum allowable speed of an unloaded DC Series Motors – Upper limit is 300% of rated motor RPM

– Lower limit is 100% of rated motor RPM

– Limit is adjustable within 100 - 300% range

• Modifies the basic DC Series Motor speed / torque curve to a flatter profile

• This ability to change the basic speed / torque characteristic of the DC series motors is an exclusive feature of the OmniPulse DDC technology

Parameter Interaction

• The Minimum Field parameter (E15 and E16 for hoist applications, or E18 for travel applications) acts as the “governor” and limits the top speed of an unloaded motor

• Parameter Group F sets the speeds available for operator commands, however

• Commanded speeds cannot exceed the maximum speed limit set by Parameter Group E

• Speeds above natural motor curve not available

Examples of “Flattened” Curves

0

50

100

150

200

250

300

350

400

450

2 10 20 30 50 100 150

% Torque

% S

peed

Min Field set at 25%




• Table 23 Drive Control Setup Continued– Timer Type defines type of timer function for programmable

outputs• On Delay TC or TO• Off Delay TC or TO

– Timer Time sets the timer length– Micro Speed Factor

• Input function• Reduces programmed or analog speed reference by a

set factor


• Table 23 Drive Control Setup Continued– Shunt Brake Release Point: Mimics series brake release

based on field current– Shunt Brake Release Time:

• Provides additional adjustment to release of shunt brake

• Time begins when SB Rel Pt value is reached – Shunt Brake Time: time for shunt brake to set– Stall Protection Time

• Defines time period to report a fault if armature current is present while CEMF < 25%

• A setting of 0 turns the monitoring function off

Group F Speed & Torque

• Table 24 Speed and Torque Settings.– Reference Source Selection.– Preset Hoist Speeds: Not visible in travel config.– Preset Travel Speeds: Not visible in hoist config.– Preset Travel Torque: Not visible in hoist config.

Group F Speed & Torque Continued

• Table 24 Speed and Torque Settings Continued – Speed Reference source– Torque Reference Source

• Source Selection:– Cntr Switch (Master Switch)– Analog Reference 1– Analog Reference 2– Serial Analog Reference 1– Serial Analog Reference 2


• Table 24 Speed and Torque Settings Continued – Five independent hoist speeds– Five independent lower speeds

• Speeds adjustable from 0 to 300% rated value Hoist and 0 to 200% rated value Lower

• Sub Menu not visible when travel configuration is active• Proprietary constant HP software design maximizes

productivity and safety by controlling the motor speed based on motor loading


• Table 24 Speed and Torque Settings Continued– Five travel speeds

• Speeds same in forward or reverse• Adjustable from 0 to 300% rated value


• Table 24 Speed and Torque Settings Continued– Five Torque (current limit) settings for adjustable torque

when plugging and accelerating from one direction to another

• Adjustable from 0% to 200% rated current• Neutral or OFF Position current setting adjustable from

0% to 200%– 0% setting will stop the drive in coast mode– Settings other than 0% will stop on deceleration ramp or current

limit

• Sub Menu not visible in hoist configuration mode

Group G I/O Configuration

• Table 25 I/O Configuration– Analog IP1 Type: volts or ma– Analog IP1 Gain– Analog IP1 Bias– Tacho FS RPM: Tach Rated RPM at full scale volts– Analog IP2 Type: volts or ma– Analog IP2 Gain– Analog IP2 Bias

Group G I/O Configuration Continued

• Table 25 I/O Configuration– Analog Output Gain– Analog Output Bias– Analog Output Func: Programmable

• Motor speed• Motor torque• Hook Load (Field Current)• Line Voltage


• Table 25 I/O Configuration– Prog IP Func: Programmable input 230 VDC or 24VDC

• Not Used• External limit switch• Travel slowdown• External Fault• Micro Speed


• Table 25 I/O Configuration – Prog OP1 Func: Programmable 230 VDC

(OP1 control of Remote I/O 144-45062 DB terminal is not programmable in Hoist configuration)

– Prog OP2 Func: Programmable 24 VDC (X1-2 terminal 144-45060)

– Prog OP3 Func: Programmable 24 VDC (X1-3 terminal 144-45060)

– Prog OP4 Func: Programmable 24 VDC (X1-4 terminal 144-45060)And 230 VDC (SB terminal on 144-45062)


• Table 25 I/O Configuration– Program Functions

• DB contactor (OP1 Default)• Controller fault: Coil energized when fault occurs (OP2

Default)• Controller ready (OP3 Default)• Shunt brake (OP4 Default)• Timer


• Table 25 I/O Configuration– Serial Baud Rate: 2400 to 19200 baud– RS232/RS485 Select– Serial Format

• 8 bit even or odd parity checking• 1 or 2 stop bits• Modbus RTU 1 enabled

– Modbus address: 1 to 247– Drive Control: Hardware I/O or serial communication

Group H Fault History

• Table 26 Fault History– Record of last 15 faults with elapsed time stamp– Push down stack – Engineer level can reset or clear the fault history

• A value of 1 in H30 clears fault history log– CUV, UV1, and MS faults are not recorded in the fault

history

End of Session FourQuestions?

OmniPulse™ DDCSession Five

Start UP And Trouble Analysis

Service Tools

• Start Up procedures Pages 82-93• Fault code explanation and corrective actions Pages

94-95• Transistor Diode Check Page 95• Trouble charts Pages 96-109• Drive exploded view Pages 117-118• Renewal part component lists Pages 119-124

CUV Fault Control Power Loss

• User Manual Figure 30– 24 V supply has fallen below 19 V– Control input power interrupted for more than 1 second

• Center master switch or controller to neutral (off) position to reset

• Trouble Charts Pages 96 - 97• Active fault not recorded in fault history

UV1 Fault Under Voltage Main Bus

• User Manual Figure 31– Main DC supply voltage below 50% of CO5 Value or below

125 V– M contactor did not close properly

• Center master switch or controller to neutral (off) position to reset

• Trouble Charts Pages 98-99• Active fault not recorded in fault history

OT1 Fault Heat Sink Over Temp

• User Manual Figure 32– Heat sink thermistor has reached parameter D09 trip value

• Heat sink temperature must cool down to below 90°C to reset

• Master switch or controller must be set to neutral (off) position to reset

• Trouble Charts Pages 100 - 101

SC Fault Short IGBT Circuit

• User Manual Figure 33– Internal IGBT power supplies fell below 13 VDC– Disable all IGBT devices

• 10 SC faults in 5 minute window will lock drive from service– Power down of the drive or Reset of the drive required to

clear the lock out


• Trouble Chart Page 102

OV Fault Over Voltage

• User Manual Figure 34– Main DC bus voltage exceeds over voltage trip point set by

parameter C05 (See page 45 for explanation)– Main DC volts exceed 400 V maximum hardware trip



OC Fault Over Current

• User Manual Figure 35– Current loops failed to maintain current inside limits– Disable all IGBT devices



OA Ambient Over Temperature

• User Manual Figure 36– Thermistor hardware trip from the control board 75°C– Finishes current movement before faulting

• Reset cannot occur until thermistor falls below 65°C• Master switch or controller must be set to neutral (off)

position to reset• Trouble Chart Page 105

AOC Armature Open Circuit

• User Manual Figure 37– Motor armature circuit is open– IGBT Q1 or Q2 are not conducting



FL Field Loss

• User Manual Figure 38– Motor field circuit is open– IGBT Q2 or Q3 are not conducting



LS Limit Switch

• User Manual Figure 39– Software detected tripped power limit switch


• Jogging out of Limit switch is required in back out mode


MOL Fault Motor Over Load

• User Manual Figure 40– Current exceeded one minute rating of 150%– Current exceeded 3 second rating of 200%– Integrator increases above 110% current and decrements

below



Motor Stall

• User Manual Table 33 – Armature Current > 0– Armature %CEMF < 25%– For Stall Protection Time Period (E26)

• Drive shuts down and records fault• Master switch or controller must be set to neutral (off)

position to clear fault• A value of 0 turns this function off

MOS

• User Manual Table 33 – MOS Module Out of Service– Error message occurs when one of the follower follower

units loses its power supply

PER

• User Manual table 33– Parameter Exceeds Rating

• Parameter value entered exceeds min max value for the parameter input

EXT

• User Manual Table 33– External limit switch trip detected

• Disables hoist position and enters limit switch back out mode


• Jogging out of Limit switch is required in back out mode

SLC

• User Manual Table 33– Slack Cable– Software detected a slack cable condition– Lowering is disabled until condition clears


MS

• User Manual Table 33– Master Switch

• Software detected the controller inputs are not in the off or neutral position upon start up– Drive disabled until inputs are in neutral position


• Active fault not recorded in fault history

COC

• User Manual Table 33– Change of Configuration

• Error message received when DIP switch settings on the control board are changed when the drive is in a ready state

• Requires power down or Reset of the drive to clear the fault

• Fault is not logged

External Fault

• User Manual Table 33– External fault input activated

• External fault must be removed• Master switch or controller must be set to neutral (off)

position to clear fault

Ground Fault

• Occurs if ground fault is enabled and current CT’s see 50% drive rating current differential

• In Hoist configuration – CT1-CT2 (armature) – CT2-CT3 (Field)

• In Travel configuration CT1-CT2 (armature)


Test Point Description

TP1 DCCT 3 Signal

TP2 0 Volts Ground

TP3 DCCT 1 Signal

TP4 DCCT 2 Signal

TP5 Volts DC+


TP7 - 15 volt Power Supply

TP8 CEMF Average volts



TP11 0 Volts Ground


TP11

TP10

TP9

TP4 TP6

TP1TP2

TP8 TP7

TP3 TP5

Transistor & Diode Check

Transistor & Diode Check

Table 35 User Manual

Diode Check Positive Probe Negative Probe Reading

D1P T1 L1 .312

D2P T2 L1 .312

D3P T3 L1 .312

D1N L2 T1 .312

D2N L2 T2 .312

D3N L2 T3 .312

IGBT Check Positive Probe Negative Probe Reading

Q1P L1 T1 >.6

Q2P L1 T2 >.6

Q3P L1 T3 >.6

Q1N T1 L2 >.6

Q2N T2 L2 >.6

Q3N T3 L2 >.6

L1 is connected to the drive bus through an internal power fuse.

Before taking readings check the power fuse and make sure it is good

RPM Transistor / Diode Check

End of Session Five Questions?

OmniPulse™ DDCSession Six

Loading Software

Software Updates

• The OmniPulse™ DDC has two software programs.

– Display software current version 2.0.0.

• Display software is loaded into a removable EPROM located in the back of the display unit.

• To update display software the EPROM must be changed.

– Control software current version 3.12

• Control software is loaded into a non volatile FLASH memory.

• Updates are loaded through HEX files using a RS232 port, a laptop, and the Flasher Program supplied by Magnetek.

Display EPROM

Removable EPROM Display Software

144-45063 Rev 1 or higher required for Display software 2.00

Control Software Update

• You can make the cable yourself very easily– User manual Figure 23 shows the connections– Requires a D connector, three wires twisted or shielded

cable, and one of the removable terminals from the control board

• There is no part number for the RS485 connector– Hardware is present for RS485 – Software support for RS485 is enabled in version 3 control

software release

Software Update Procedure

• Start Flasher Program– Select Com 1, 57600 Baud Rate, and AMD Flash– Press the Select button and select appropriate DDC HEX file

to load

• On the drive control Card set either LK1 (original board closed) or LK4 on latest board to the boot position (position 1 & 2)

• Reset power to the drive either by the reset button on the interface card or cycle drive power off then on (wait 15 seconds before restart)

DDC Flasher Program

Original 144-45060 Control Board

Flash

SW2

SW1

LK1

LK2

PWR On

Fault

Driver Card Con

Display Con

Interface Card Con

Revised 144-45060 Control Card

SW1

LK4

Driver Card Con

Display Con

Interface Card Con

SW2

Flash boot load link1 -- 2 -- 3

1& 2 Flash boot load2 & 3 Normal

1 & 2 RESET input resets CPU2 & 3 RESET input used as logic input

LK3

LK2

485 Terminator1&2 120 OHM Connected2&3 120 Ohm not connected

Analog Input Switch

Configuration Switch


• Wait for the drive to power back up– In boot mode the drive fan will run constantly– Check for air flow or listen for fan operation

• Click the Update button in the Flasher window– Bar at bottom will begin to increase as the program loads– When loading is complete an upload complete message will

be visible


• Move the LK1 or LK4 links back to original position– LK1 open– LK4 position 2 & 3

• Reset the drive or cycle power to drive• Set parameter (B00) password to 2004• Restore factory defaults via parameter (C07)• Reset the drive or cycle power to drive• Check the Control Software version in the display to

verify the loading process

End of Session Six

Questions?

omnipulse™ ddc magnetek training. omnipulse™ ddc training the objective of this training is to...

Documents

power requiredno

ampshoist panel size

ampstravel panel size

drive fault messages

series fieldslow

circuit board layout

technologyhardware layout

lower steps