Yaskawa DSD312 DSD412 Drive Manual

MagneTek

DSD 406 / DSD 412

Technical Manual

Revision

History

The following table shows all pages that have been revised since the first issue of this manual.

Revision

Date

4/15/94

3/21/96

Initial

Overall revision

Affected Pages

Related

Documents List

The following publications provide additional information on the DSD 406 / 412 drives. Each is available from MagneTek.

●

PCDU Guide TM 6305

Additional copies of this manual can also be ordered by specifying the

DSD 406 / 412 Product Guide (TM 6107).

© 1996 by

MagneTek, Inc.

New Berlin, Wisconsin

All rights reserved. No part of this publication may be reproduced or used in any form by any means – graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems – without written permission of the publisher.

MicroTrac, DSD, PAC and MagneTek are trademarks of MagneTek, Inc.

3/21/96

a

3/21/96

Warranty

Warranty Standard products manufactured by MagneTek are warranted to be free from defects in workmanship and material for a period of one year from date of shipment and any products which are defective in workmanship or material will be repaired or replaced, at MagneTek's option, at no charge to the Buyer. Final determination as to whether a product is actually defective rests with MagneTek.

The obligation of MagneTek hereunder shall be limited solely to repair or replace, at MagneTek's discretion, products that fall within the foregoing limitations, and shall be conditioned upon receipt by MagneTek of written notice of any alleged defects or deficiency promptly after discovery and within the warranty period, and in the case of components or units purchased by

MagneTek, the obligations of MagneTek shall not exceed the settlement that

MagneTek is able to obtain from the supplier thereof. No products shall be returned to MagneTek without its prior consent. Products which MagneTek consents to have returned shall be shipped prepaid f.o.b. MagneTek's factory.

MagneTek cannot assume responsibility or accept invoices for unauthorized repairs to its components, even though defective. The life of the products of

MagneTek depends, to a large extent, upon the usage thereof, and MAGNETEK

MAKES NO WARRANTY AS TO FITNESS OF ITS PRODUCTS FOR THE

SPECIFIC APPLICATIONS BY THE BUYER NOR AS TO PERIOD OF

SERVICE UNLESS MAGNETEK SPECIFICALLY AGREES OTHERWISE

IN WRITING AFTER THE PROPOSED USAGE HAS BEEN MADE

KNOWN TO IT.

Limitation of Liability

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL

OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, BUT

NOT LIMITED TO, ANY WARRANTY OF MERCHANTABILITY OR OF

FITNESS FOR A PARTICULAR PURPOSE AND BUYER HEREBY

WAIVES ANY AND ALL CLAIMS THEREFORE.

IN NO EVENT SHALL MAGNETEK BE LIABLE FOR LOSS OF PROFIT,

INDIRECT, CONSEQUENTIAL OR INCIDENTAL DAMAGES WHETHER

ARISING OUT OF WARRANTY, BREACH OF CONTRACT OR TORT.

Warranty i

ii

Manual Contents

Table of

Contents

Page

Introduction ........................................................................................................ 1

How To Use This Manual ............................................................................. 1

Controls and Indicators ................................................................................. 1

Safety Statements .......................................................................................... 2

How To Contact MagneTek .......................................................................... 2

DSD Drive Description ................................................................................. 3

System Considerations .................................................................................. 5

Installation and Start-Up .................................................................................. 9

Pre-Installation Considerations ..................................................................... 9

Physical Installation ...................................................................................... 9

Electrical Hook-Up ..................................................................................... 14

Use of An Analog Tachometer ................................................................... 20

Pre-Power Check ......................................................................................... 20

Drive Start-Up ............................................................................................. 21

Operation .......................................................................................................... 23

Controls and Indicators ............................................................................... 23

Start-Up Operation ...................................................................................... 25

General Operation ........................................................................................ 26

Parameter Functions .................................................................................... 28

Monitor Functions ....................................................................................... 30

Upload/Download of Program/Parameters ................................................. 31

Upload/Download Introduction and Definitions......................................... 31

General Upload/Download Procedures ....................................................... 33

Error Handling/Reporting ........................................................................... 45

Non-Volatile “Ram”-Access ....................................................................... 51

Load Defaults Function ............................................................................... 53

Self-Tune (PCU Parameter Measurement) ................................................. 54

Maintenance ..................................................................................................... 57

Preventive Maintenance .............................................................................. 57

Power Conversion Unit Diagnostics............................................................ 58

Troubleshooting Guide................................................................................. 61

Replacing Fuse(s)......................................................................................... 77

Replacing DSD Drive Control PCB ............................................................ 79

Replacing the Fan......................................................................................... 81

Replacing the Power Supply........................................................................ 85

Replacing the DSD Armature Interface PCB.............................................. 87

Spare Parts List ............................................................................................... 89

Glossary ............................................................................................................ 95

Index .............................................................................................................. 104

Table of Contents

3/21/96

Manual Contents

List of

Illustrations

Figure

Number

4

5

6

11

12

13

14

7

8

9

10

1

2

3

3.1

Title Page

Typical MicroTrac DSD System Diagram ..................................... 7

Dimensions and Mounting Holes

DSD 406/412 1-60 Hp Versions..................................................... 10

Dimensions and Mounting Holes

DSD 406/412 75-125 Hp Versions................................................. 11

Dimensions and Mounting Holes

DSD 412 150-200 Hp Versions...................................................... 13

Shield Sheath Termination ............................................................ 16

Basic Connections for DSD Power Cube –

Ratings up to 206 Amps ................................................................. 17

Connections to TB3 and TB1 DSD Power Cube –

Ratings up to 206 Amps ................................................................. 18

Grounding of Multiple Units.......................................................... 19

Operator Controls and Indicators ................................................... 23

DSD 406/412 to IBM PC Compatible Comp. Inter. Diagram ...... 31

DSD Drive Fuse Replacement ....................................................... 76

DSD Drive Control PCB ................................................................ 78

Replacing DSD Fan........................................................................ 66

DSD Power Supply Replacement .................................................. 84

DSD Armature Interface PCB Replacement ................................. 86

List of Tables Table

Number

6

7

4

5

8

1

2

3

Title Page

Drive Ratings and Specifications.................................................... 5

# Function Code Descriptions ........................................................ 27

Troubleshooting Guide .................................................................. 61

Connectors on Drive Control PCB................................................. 79

230 Volt Drives Spare Parts............................................................ 89

460 Volt Drives Spare Parts ........................................................... 91

Burden Resistor .............................................................................. 93

Power Range Resistor..................................................................... 94

3/21/96

List of Illustrations iii

Introduction

How To Use

This Manual

MagneTek has made this product guide an easy to use reference. To help you use this manual, we have provided the following guides:

●

The top of each page has an identification of the section. For example, notice that at the top of this page

Introduction 1 appears. This identifies the page as part of Section 1, Introduction. There are four sections in this manual: Introduction, Installation and Start-Up, Operation and Maintenance.

Controls and

Indicators

Status LEDs

Ready

●

Each section is organized into one or more major subject headings. These are the main topics covered in that section. You will recognize major subject headings by their distinctive appearances. The next line illustrates an example:

This is an example of a major subject heading from Section 3.

Each major subject heading may have one or more minor topics that are covered. The next line illustrates an example:

This is a minor topic covered under “Controls and Indicators.”

Each minor topic may have one or more descriptive headings. These identify items covered within the minor topic. The next line illustrates an example:

This is a descriptive heading covered under “Status LEDs.”

At the bottom of each page is the name of the first major subject heading covered on that page. The page number and revision date are also included.

For example, at the bottom of this page, the information indicates that “How to Use This Manual” is the first major subject heading. The revision date indicates the last date the page was changed in any way.

Using the information on the top of the page to find the section, the bottom of the page to find the major subject heading and the left margin to find the minor topics and descriptive headings, you can easily page through the manual to find the information you need.

A table of contents and index are also included. The Table of Contents can be used to locate sections and major topics. The Index is helpful in locating specific terms or topics. A glossary is provided to define terms which may be unfamiliar.

1

3/21/96

How To Use This Manual 1

1 Introduction

Safety

Statements

In addition to notes, the following types of precautionary statements appear in this manual.

IMPORTANT

A statement of conditions which should be observed during drive setup or operation to ensure dependable service.

CAUTION

A statement of conditions which must be observed to prevent undesired equipment faults or degraded drive system performance.

WARNING

A statement of conditions which MUST BE OBSERVED to prevent personal injury or serious equipment damage.

How To Contact

MagneTek

For additional information, contact any MagneTek Representative, or

Authorized Distributor, or contact the DSD Technical Support Staff at:

MagneTek, Inc.

16555 West Ryerson Road

New Berlin, WI 53151

(800) 541-0939 (414) 782-0200

FAX: (414) 782-1283

2 Safety Statements

3/21/96

Introduction

DSD Drive

Description

Regeneration

Capability

The MicroTrac ® DSD is a complete digital system drive which provides individual drive and system control in one compact package. This manual describes two basic configurations, the DSD 406 (6SCR) Nonregenerative and the DSD 412 (12SCR) Regenerative. All descriptions pertain to both configurations unless specifically noted.

The nature of an electric motor is such that, if more torque is applied to the motor by the load than is applied to the load by the motor, the motor will act as an electrical generator, producing an electrical current. This phenomenon, called regeneration, occurs anytime the speed of the motor is above the reference (or preset) speed, sometimes referred to as an “overhauling load” condition. A regenerative drive, such as the DSD 412, has the capability to feed the electrical power generated by the motor back into the supply mains. Also referred to as four-quadrant operation, it is this capability which requires that the DSD 412 contain a total of 12 SCRs, rather than the six included in the two-quadrant,

Nonregenerative DSD 406.

Flexibility

The drive uses two microprocessors, one for the Power Conversion Unit circuitry, one for the Drive Control Unit circuitry, and is totally software configurable to the application through a high level language. This provides complete flexibility without having to make hardware adjustments. Interface to other equipment is provided with Local Input/Output (I/O) or a high speed Local

Area Network. Use of the MicroTrac Local Area Network (LAN) means that a single coaxial cable eliminates multiple conductor cables and provides high noise immunity.

Control

Extensive diagnostics and setup capability are provided through two

Control/Display Units. The Standard Control/Display Unit (SCDU) is mounted on the Drive Control PCB and consists of a 4-1/2 digit numeric LED display, four push buttons and LEDs. The SCDU can be used for all setup functions and many diagnostics. The Portable Control/Display Unit (PCDU) is an optional hand-held device that can be plugged into any DSD drive and used for all the same functions as the SCDU plus some advanced diagnostics. The PCDU has two lines of sixteen alphanumeric characters and a thirty-key keypad.

Accuracy

The distributed control architecture of the DSD systems means that each drive performs its own regulation calculations synchronized to a common high accuracy crystal master. Thus even minute crystal drift will not affect multiple drive tracking. This allows a DSD system to maintain the drift between sections at 0.00% steady state. The fully digital nature of the regulation means that an individual drive can maintain a 0.00% average difference between set and actual speed from no-load to full-load when using digital tachometer speed feedback.

Digital setup and performance assure exact process line and finished product duplication shift to shift and month to month.

1

3/21/96

DSD Drive Description 3

1 Introduction

Useability

Characteristics

PAC Language

Programming

Speeds, tensions, ratios, draws, limits, ranges, alarms, and other control parameters can be set as percentages or exact numerical values. Parameters are entered and displayed in common understandable units. The drive can be completely setup prior to actual running and changes can be made during operation. Keypad entry of changed parameters, protected memory, and factory default values allow the operator to modify data with minimum risk to the process.

The DSD is available for general use as a complete panel mounted enclosed drive (NEMA 1 or NEMA 12).

Authorized system integrators can also purchase the drive as a power cube. The power cube is designed for mounting in a cabinet; space allowances for air circulation, additional components, outgoing terminals, and wire bends must be provided.

The enclosed drive consists of the DSD power cube mounted on a panel with a skirted NEMA 1 or NEMA 12 enclosure, with added fused control transformer for 115V supply, armature loop contactor, and field wiring terminals. An input circuit breaker with through-the-door operator is available as an option.

The DSD drive is designed to be connected to a three wire ungrounded power system, or a four wire grounded or ungrounded power system.

All DSD drives are programmed using MagneTek's PAC language. The drive programming consists of two portions; the standard control programs shared by all DSD drives and the application specific programming which defines how the drive operates in the particular application. The latter portion of DSD drive programs are developed based on the PAC language, wherein different drive functions are represented by interconnected graphical symbols, called PAC blocks, much like an electronic schematic. This provides the ability to quickly modify programs, along with an assurance of program repeatability and stability.

4 DSD Drive Description

3/21/96

Introduction

System

Considerations

Table 1. Drive Ratings and Specifications

●

●

●

●

●

Ratings

3.3 - 206 Amps

3 Phase, 48-62 Hz

1.0 Service Factor

150% full load current for one minute

200% full load current for 10 seconds

Basic Drive Specifications

●

●

●

●

●

Full-wave six-pulse SCR control

Regulation (of set speed) to

0.00% with digital tachometer speed feedback

Current regulated shunt field

Capable of constant HP operation (requires tachometer)

Self-adapting to incoming line power of 230 or 460 VAC.

Service Conditions

●

●

●

●

●

●

●

Line voltage 230 or 460 Vac, 3 phase, ±10% of nominal setting

115 volt, 1 phase control power from separate source

Frequency 48-62 Hz

Incoming line impedance range

2%-10% of rated

Operating Temperature 0-45° C

(55° C max at DSD chassis)

Altitude to 3300 feet above sea level

Relative Humidity 95%

(noncondensing)

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

Protective Features

Programmed memory protection

Self-protected control power supply

Fast phase-back of current before loop contactor opens

I

Contact interlock for E-Stop

2 t motor overload protection

AC line current limiting fuses

DC bus fuse (DSD 412 only)

Instantaneous over-current protection

Phase loss protection

Input line monitoring

Phase sequence insensitive dv/dt protection (snubbers)

1400 Peak Reverse Voltage thyristors

Field current economizer and loss protection

Tachometer monitoring and loss protection

Heat sink thermostat

Automatic test of power circuit upon power-up

Control power supply loss detection

Isolated I/O and grounded electronics

In order to operate in a system application, the DSD drive may be used with other MagneTek devices with which it will communicate by means of the

MicroTrac Local Area Network (LAN). Refer to Figure 1 for a typical DSD

System.

Each of the following remote devices (board or assembly) is described in detail in a separate User Reference Sheet.

●

Remote Display Controller LAN Node PCB (RDC) – This board provides a means for the DSD system to have system operating parameters displayed

1

3/21/96

System Considerations 5

1 Introduction

6

●

●

●

●

●

●

●

●

● at locations remote from the DSD drive. The RDC communicates with the drive through the LAN. A single RDC can support up to 31 Remote Display

Units (RDUs). By means of a Portable Control/Display Unit (PCDU), the

RDC allows the selected display for each RDU to be changed at anytime.

Remote Display Unit (RDU) – Designed for mounting in a panel cutout, the

RDU provides a two-line LED display (16 character alphanumeric, and 5-1/2 digit numeric). It constitutes a terminal with the information on its display transmitted to it by a Remote Display Controller LAN Node PCB (RDC).

Remote Keyboard Assembly – Designed for mounting on a panel with or near a Remote Display Unit (RDU), the Remote Keyboard allows initiation of RDU display changes without the need for a Portable Control/Display

Unit (PCDU) plugged into the Remote Display Controller LAN Node PCB

(RDC).

Remote I/O [Input/Output] Controller LAN Node PCB (RIO) – This board provides a means for the DSD system to have inputs or outputs at locations remote from the DSD drive. The RIO communicates with the drive through the LAN. A single RIO can support up to 6 Remote I/O boards, using any combination of the following three available types.

Remote Logic I/O PCB (LOGIO) – This board provides isolated and non isolated remote logic signal input/output capability for the DSD system. It is connected to a Remote I/O Controller LAN Node PCB (RIO) for communication with the DSD drive.

Remote Analog I/O PCB (ANIO) – This board provides isolated and non isolated remote analog signal input/output capability for the DSD system. It is connected to a Remote I/O Controller LAN Node PCB (RIO) for communication with the DSD drive.

Remote Thumbwheel Switch I/O PCB (TWIO) – This board provides remote thumbwheel switch input/output capability for the DSD system. It can support up to 9 Thumbwheel Switch Assemblies. This board is connected to a Remote I/O Controller LAN Node PCB (RIO) for communication with the DSD drive.

Remote Programmable Logic Controller (PLC) Interface – Available for

PLCs from many major manufacturers. It allows bi-directional communication via the MicroTrac LAN between DSD drives and the PLC.

Both logic and numeric data can be transferred.

Remote Power Supply – The Remote Power Supply produces control level voltages for use by a Remote LAN Node PCB or a Remote Display Unit.

Remote Serial Communication Controller LAN Node PCB (RSC) – This board provides a means for the DSD system to have input from or output to other equipment that uses RS-232 serial communication. The RSC communicates with the DSD drive through the LAN.

System Considerations

3/21/96

Introduction 1

MicroTrac

Drive

DRIVE

CONTROL

UNIT

93 Ohm

Terminator

MicroTrac

Drive

MicroTrac

Drive

LOCAL

I/O

DRIVE

CONTROL

UNIT

LOCAL

I/O

RG 62/U Coaxial Cable

DRIVE

CONTROL

UNIT

2.5 million bits/second

93 Ohm

Terminator

LOCAL

I/O

3/21/96

REMOTE

INPUT/OUTPUT

CONTROLLER

PCB (RIO)

REMOTE

PLC

INTERFACE

REMOTE

COMMUNICATIONS

CONTROLLER

PCB (RSC)

RS-232

REMOTE

DISPLAY

CONTROLLER

PCB (RDC)

PCDU

PROGRAMMABLE

LOGIC

CONTROLLER (PLC)

REMOTE

LOGIC

INPUT/OUTPUT

PCB

(LOGIO)

REMOTE

ANALOG

INPUT/OUTPUT

PCB

(ANIO)

REMOTE

THUMBWHEEL

INPUT/OUTPUT

PCB

(TWIO)

UP TO 6 REMOTE INPUT/OUTPUT PCBS

8 ISOLATED LOGIC

I/O MODULES

7 NON-ISOLATED

LOGIC OUTPUTS

16 NON-ISOLATED

LOGIC INPUTS

2 NON-ISOLATED

ANALOG OUTPUTS

4 ISOLATED ANALOG

I/O MODULES

4 NON-ISOLATED

ANALOG OUTPUTS

4 NON-ISOLATED

ANALOG INPUTS

PERSONAL

COMPUTER

DISPLAY #1

REMOTE

DISPLAY

UNIT (RDU)

DISPLAY #2

MESSAGE

SELECT

DISPLAY #3

UP TO 9 BANKS OF

6 DIGITS

+1 8 8 8 8 8

DISPLAY #4

8 8 8 8 8 8

KEYBOARD

ENABLE

+1 8 8 8 8 8

THUMB

WHEELS

1 2 3 D C

4 5 6 D N

+

7 8 9

-

0 • N E

KEYBOARD

UP TO 31 REMOTE

DISPLAY UNITS

LA-8

Figure 1.

Typical MicroTrac DSD System Diagram

System Considerations 7

Installation and Start-Up

Pre-Installation

Considerations

Receipt of

Shipment

Storage

Unpacking

The “Installation and Start-Up” section describes and illustrates the following:

●

●

●

●

How to select the site to install your DSD drive.

How to mount your DSD drive.

How to connect your DSD drive to incoming power and the motor .

How to start-up the system after it is installed.

The DSD drive is air cooled. The lowest HP rated units are cooled by convection; all other units are equipped with a fan to ensure adequate air flow.

Select a site for installing the drive which is clean and well ventilated.

Maintenance will be minimized if the drive is located in a clean atmosphere. The standard drive is designed for vertical mounting.

All equipment is fully tested at the factory. Any damage or shortages evident when the equipment is received must be reported immediately to the commercial carrier who transported the equipment. Assistance, if required, is available from your MagneTek representative. Always refer to the order number, equipment description, and serial number when contacting MagneTek.

For long periods of storage, equipment should be covered to prevent corrosion and should be placed in a clean, dry location. If possible, equipment should be stored in its original crating. Periodic inspection should be made to ensure that the equipment is dry and that no condensation has accumulated. The equipment warranty does not cover damage due to improper storage.

Remove the protective shipping material from around the equipment. Remove all packing material. Unbolt the equipment from its crate. Inspect for loose wiring. Make sure that all contact wedges and other shipping devices have been removed.

CAUTION

The DSD Drive Control PCB has electrostatic sensitive components. You must follow Electrostatic Discharge (ESD) procedures to protect the components.

Re-Packing

Physical

Installation

The drive should be bolted in a crate which provides at least 2 inches clearance.

The drive should then be wrapped in polyethylene and covered with wax impregnated double walled # 350 corrugation and crated. Assistance, if required, is available from your MagneTek representative.

Attach the drive to a cabinet panel or other vertical structure using the mounting holes provided at the back of the drive (refer to Figure 2, 3 or 3.1 for dimensions and mounting hole locations). Allow six inches top and bottom and two inches at sides for free air circulation. For either style, hinged door swing-out clearance is the same as the width dimension. Ensure that the unit is level.

2

3/21/96

Pre-Installation Considerations 9

2 Installation and Start-Up

9.75

MIN. DOOR

SWING

CLEARANCE

(APPROX. 6.75"

ABOVE MTG. SURFACE)

2.00

0.50

0.31

ARM.

NEG.

GND.

L1

12.25

11.25

L2

NEG GND L1 L2

L3

L3

ARM.

POS.

POS

A4

TB3

2

1

4

3

6

5

8

7

S3

J3

17.12

19.87

TB3

8

7

6

5

4

3

2

1

A1

J2

TB1 TB1

TB4

TB4

2.44

FAN (WHEN SUPPLIED)

AIR

FLOW

F2(–)

FAN (WHEN SUPPLIED)

MOTOR

FIELD

CONNECTIONS

3" MINIMUM CLEARANCE REQUIRED

11.25

0.31

0.50

LA-4

10 Physical Installation

Figure 2.

Dimensions and Mounting Holes

DSD 406/412

1-60 Hp Versions

4/15/94

Installation and Start-Up 2

3/21/96

GND

MIN. DOOR SWING

WITH MATING DB9

CONNECTOR IN J1

11.00

13.06

F1 F2 F3 F4

0.31

GND

A4

TB3

2

1

4

3

6

5

8

7

2.69

0.38

0.94

ARM (–) L1

12.00

L2

11.25

L3 ARM (+)

GND

S3

J3

18.06

21.06

TB3

8

7

6

5

4

3

2

1

0.44

FAN

AIR FLOW

13.88

MOTOR FIELD

CONNECTIONS

A1

J2

TB1

AC1

TB4 07

A3

0.31

0.38

4.00

FAN

ALLOW APPROX. 4" BELOW FAN FOR SERVICING

OF FAN, AND UNRESTRICTED AIR INTAKE.

0.38

1.25

LA-4A

Figure 3. Dimensions and Mounting Holes

DSD 406/412

75 - 125 Hp Versions

Physical Installation 11

2 Installation and Start-Up

12 Physical Installation

3/21/96

Installation and Start-Up 2

L1 F1 L2 F2 L3 F3

F4

ARM(+)

12.93

ARM (–)

GND

2

1

4

3

6

5

8

7

2.38 MIN.

DOOR SWING

0.58

1.94

A4

TB3

0.438

GND

UNPLUG TB3

FROM HEADER

WHILE

INSTALLING

WIRES.

17.09

10.75

MOTOR

FIELD

CONNECTIONS

12.50 MIN.

WIRE BEND

ALLOWANCE

0.505

0.83

19.50

23.49

3/21/96

J2 TB1

(TERMINAL BLOCK QTY PER DRIVE SPECIFICATION)

A1

FAN

AIR FLOW

4.00 MINIMUM

CLEARANCE

REQUIRED

1.94

2.13

FAN

1.69

3.50

0.50

LA-100

Figure 3.1. Dimensions and Mounting Holes

DSD 412

150-200 Hp Versions

Physical Installation 13

2 Installation and Start-Up

Electrical

Hook-Up

Ensure that wire size and disconnect devices conform to the installation contractor’s drawings and to all applicable codes.

●

Although the three phase input power line is fuse protected internal to the drive, it is recommended to provide branch circuit protection by means of a circuit breaker in accordance with the National Electrical Code, local codes and with a rating of not less than 5,000 rms Symmetrical Amperes and 600

Volts for 2 to 25 Hp rated drives or 10,000 rms Symmetrical Amperes and

600 volts for 30 to 60 Hp rated drives.

●

Electronic overload protection is provided as part of the standard DSD product. It si electronically timed and will shut down the drive along a time/output current curve which provides shutdown at 60 seconds at 150% or 10 seconds at 200% of rated output current. An overload relay may be added external to the drive in accordance with the National Electrical Code and local codes for additional protection.

●

Main Circuit Input/Output Wire Sizing:

L1-3: Using 600V vinyl-sheathed wire per the following table.

25

30

40

50

60

75

100

125

150

200

7

10

15

20

2

3

5

Drive Hp

Recommended Wire Gauge (Copper Only)

Torque

60°C 75°C

(in-lbs)

6

6

8

8

14

14

14

4

4

14

14

14

10

10

8

8

1

1

4

4

1/0

3/0

3/0

250 MCM

600 MCM

600 MCM

35

35

35

40 - 35 *

40 - 35 *

45 - 40 *

45 - 40 *

45

45

150

150

180

250

250

325

375

375

* Torque per wire gauge.

14 Electrical Hook-Up

3/21/96

3/21/96

Installation and Start-Up

ARM (–): Using 600V vinyl-sheathed wire per the following table.

30

40

50

60

75

100

125

150

200

10

15

20

25

5

7

2

3

Drive Hp

Recommended Wire Gauge (Copper Only)

Torque

60°C 75°C 90°C

(in-lbs)

6

4

4

14

14

14

6

4

3

8

4

14

14

14

8

3

1/0

1/0

3/0

250 MCM

250 MCM

350 MCM

500 MCM

750 MCM

50

50

50

50

325

325

325

375

375

35

35

35

45 - 40 *

45 - 40 *

45

45

50

* Torque per wire gauge.

ARM (+): Using 600V vinyl-sheathed wire per the following table.

25

30

40

50

60

75

100

125

150

200

7

10

15

20

2

3

5

Drive Hp

Recommended Wire Gauge (Copper Only)

Torque

60°C 75°C 90°C

(in-lbs)

4

4

6

6

14

14

14

4

4

8

8

14

14

14

3

3

1/0

1/0

3/0

250 MCM

250 MCM

350 MCM

500 MCM

700 MCM

35

35

35

45 - 40 *

45 - 40 *

45

45

50

50

180

180

250

325

325

325

375

375

* Torque per wire gauge.

●

Field Current Wire Sizing: The recommended conductor for field current ratings between 10.0 Ampere and 16.0 Ampere is 12 AWG. The recommended conductor for field current ratings below 10.0 AMpere is 14

AWG. use 600 V vinyl-sheathed 105°C wire or equivalent. The recommended torques on the field lugs for 14-10 AWG is 25 in-lbs.

2

Electrical Hook-Up 15

2 Installation and Start-Up

●

GND: Recommended conductor size, 2 AWG 600 V vinyl-sheathed for

COPPER wire, 1/0 AWG 600 V vinyl-sheathed for ALUMINUM OR

COPPER CLAD ALUMINUM wire. Recommended torque on the GND lug is 50 in-lbs.

●

Control Wire Sizing:

TB1: Recommended conductor size, 22-18 AWG 300 V 105°C vinyl-sheathed wire. Recommended torque is 3.4 in-lbs.

TB3: Recommended conductor size, < 12 AWG 300 V 105°C vinyl-sheathed wire. Recommended torque is 5 in-lbs.

TB1: Recommended conductor size, 14 AWG 300 V 105°C vinyl-sheathed wire. Recommended torque is 3.4 in-lbs.

Observe the following when wiring:

●

Separate the leads used for speed reference, feedback, and other low level signals from those used for the motor armature, field and AC power.

Do not run these two groups in the same conduit or wire trough.

●

Provide shielded and twisted leads as indicated on the Schematic and/or

Interconnection Diagrams. Connect all shields on shielded wire to system common (not ground) on one end only. Twisted shielded pair wire should be used for long runs. (Refer to Figure 4 for proper cable preparation.)

SHIELD SHEATH

OUTER JACKET

TO DSD

406/412

SIGNAL

TERMINALS

TO SHIELD

SHEATH

TERMINAL

CRIMP

CONNECTION

WRAP BOTH ENDS

OF SHEATH WITH

INSULATING TAPE

DO NOT

CONNECT

TO

EXTERNAL

CIRCUIT

LA-9

Figure 4. Shield Sheath Termination

●

If the DSD drive is being used in a system application, use a BNC "T" connector to connect LAN (Local Area Network) coaxial cable to J3 on the

DSD Drive Control PCB.

●

The coaxial cable must ultimately be terminated at both ends by a 93 ohm termination resistor. (MagneTek part number 05P00034-0586)

16 Electrical Hook-Up

3/21/96

3/21/96

Installation and Start-Up

For a NEMA 1 or open panel mounted drive, refer to the equipment

Interconnection Diagram for detailed wiring information.

WARNING

The external COAST STOP circuit shown on the

Schematic Diagram MUST BE WIRED to the drive as a safety consideration in case of microprocessor failure.

If only a power cube was ordered, the following connections need to be made

(refer to Figures 5 and 6 for location of terminating points on drives rated up to

330 Amps):

❏ On units rated at 206A armature current (206A Iarm) or less, connect the three phases of the line from the load side of the isolation transformer or input circuit breaker to fuses F1, F2, and F3 (marked L1, L2, and L3).

(Refer to Figure 5.) Phase rotation is not important.

2

NEG

3 PHASE 230-460 VAC INPUT POWER

FROM CIRCUIT BREAKER OR

ISOLATION TRANSFORMER.

PHASE ROTATION IS NOT IMPORTANT

GND

F1

L1

F2

L2

F3

L3 POS

F4

(DSD

412

ONLY)

K1

DBR

A2

MTR

ARM.

K1

A1

OR

OR

K1

CONNECT TO

ONLY ONE

TERMINAL

PER

APPLICATION

CONNECT HERE

FOR DSD412

ONLY

CONNECT

HERE FOR

DSD406

ONLY

ARMATURE INTERFACE PCB (A2)

(MOUNTED ON SCR BUS BARS)

TB5 (PART OF E5

SCR BUS BAR)

+ 2

– 1

FIELD INTERFACE PCB (A3)

F2(-)

AC

AC

2

TB4

F1

(+)

F2

(–)

MOTOR FIELD

FIELD

CONTROL

MODULE

(LOCATED UNDER

FIELD INTERFACE

PCB

)

FRONT VIEW OF POWER CUBE INTERIOR WITH SWING DOOR OPEN

LA-2

Figure 5. Basic Connections for DSD Power Cube –

Ratings up to 206 Amps

Electrical Hook-Up 17

2 Installation and Start-Up

❏ On units rated 206A Iarm or less, connect the motor armature A1 lead through contactor N.O. contact to fuse F4 (in a DSD 412) or terminal E5 (in a DSD 406). (Refer to Figure 5.)

❏ On units rated at 206A Iarm or less, connect the motor armature A2 lead through armature contactor N.O. contact to terminal ‘NEG’. (Refer to

Figure 5.)

DSD POWER SUPPLY PCB (A4)

115 VAC LO

(NEUTRAL)

MOTOR

THERMOSTAT

MOTOR

LOOP

K1

CONTACTOR

COAST

STOP

TB3

5

4

3

2

1

8

7

6

DSD DRIVE CONTROL PCB (A1)

115 VAC HI

(HOT)

TBI

1

43 48

7 42

84

K1 AUX

FRONT VIEW OF SWING OUT DOOR

LA-1

Figure 6. Connections to TB3 and TB1 DSD Power Cube –

Ratings up to 206 Amps

❏ On units rated at 206A or less, connect the motor field lead F1 (+) to

A3TB4(F1+), and motor field lead F2 (-) to Field Control Module (F2–).

(Refer to Figure 5.)

❏ On units rated at 206A Iarm or less, connect armature voltage sensing lead

(A1) to Armature Interface PCB(A2) TB5-2(+), and connect armature voltage sensing lead (A2) to Armature Interface PCB TB5-1(–).

(Refer to Figure 5.)

18 Electrical Hook-Up

3/21/96

3/21/96

Installation and Start-Up

❏ Connect 115 VAC control power to the DSD Power Supply PCB(A4), TB3-

1 (Hot) and (A4)TB3-7 (Neutral). This source must be rated at 250 VA or greater. (Refer to Figure 6.)

❏ Connect the armature (motor loop) contactor coil to DSD Power Supply

PCB, (A4)TB3-4 and (A4)TB3-5. (Refer to Figure 6.)

❏ An auxiliary 10ma, 24VDC, low power, normally open (N.O.) contact from the armature (motor loop) contactor must be connected to DSD Drive

Control PCB, (A1)TB1-48 and (A1)TB1-7, for the drive to operate.

(Refer to Figure 6.)

❏ The Coast Stop push button (maintained, 10ma, 24VDC, low power), MUST

BE CONNECTED to the DSD Power Supply PCB, (A4)TB3-3 and (A4)

TB3-6. (Refer to Figure 6.)

❏ Connect a grounding wire from the ground pole to the ground terminal provided. The ground terminal is marked GND, and is located near the power input and output terminals.

❏ Where several units are used side by side, all units should be grounded directly to the ground pole. However, it is permissible to connect all the ground terminals in series and ground only one unit to the ground pole (refer to Figure 7). DO NOT FORM A LOOP WITH THE GROUND WIRES.

2

GROUND

POLE

CORRECT

GROUND

POLE

CORRECT

GROUND

POLE

NOT

ACCEPTABLE

LA-10

Figure 7. Grounding of Multiple Units

❏ If dynamic braking resistors (DBR) are to be used, connect across motor armature in series with loop contactor N.C. contact. (See Figure 5.)

Electrical Hook-Up 19

2 Installation and Start-Up

Use of An

Analog

Tachometer

The DSD 406 / 412 has provisions for an analog tachometer input at TB1 terminals 22 and 23. Either a DC or AC tachometer may be used as selected in the PAC program. The hardware circuitry is designed for 75-120 volts DC or

50-85 volts AC of nominal input at rated top speed. For best performance, it is recommended that a 50 volts per 1,000 rpm DC tachometer be used with 1750 or

2300 rpm motors.

CAUTION

The analog tachometer input channel may saturate if input voltages exceed 150 volts DC or 106 volts AC at terminal 23.

This may cause loss of drive control and a drive speed runaway or component damage.

If higher tachometer voltages are required, add an external resistor in series with the tachometer wiring signal at terminal 23. Use 107 Kohms (±1%, 1/2 watt) for each additional 100 volts expected signal. [ For example, add a 107 Kohm, 1%,

1/2 watt resistor in series with the tachometer wire at terminal 23 if a 100 volts per 1,000 rpm DC tach is used with 1750 or 2300 rpm motors. ]

Pre-Power

Check

IMPORTANT

In order to produce output to a motor, the power cube may also need input and output signal connections for Local I/O. See

Schematic and/or Interconnection Diagrams for specific connections.

CAUTION

To prevent damage to the drive, the following checks must be performed before applying the input power.

❏ Inspect all equipment for signs of damage, loose connections, or other related problem areas.

❏ Ensure the three phase line voltage is within +10% of the nominal input voltage range of 230/460 VAC. Also verify that frequency is correct for the drive system. Note that the drive is not sensitive to phase sequence. Input power specifications are contained on the drive nameplate or the drive system Schematic Diagram.

❏ Remove all shipping devices and relay wedges. Manually operate all contactors and relays to ensure that they move freely.

20 Using of An Analog Tachometer

3/21/96

Installation and Start-Up

Drive Start-Up ❏ Ensure that all electrical connections are secure.

❏ Ensure that all transformers are connected for proper voltage according to the drive system Schematic Diagram.

❏ Attach a DVM across the 115 VAC control power, at transformer T1 secondary terminals X1 and X2.

❏ Apply the three phase power and verify that the control power is between

103 VAC and 126 VAC as read on the DVM. Then press the RESET push button on the front of the power cube, and observe the “Drive power-up sequence” as described below.

NOTE: The "Drive Power-Up Sequence" is also described in the Operation section of this manual under “Start-Up Operation”. If using upload/download capabilities, please refer to DSD 406/412 Upload/Download procedure in the

Operation section.

❏ The “Drive Power-Up Sequence” can be observed by monitoring the

Standard Control/Display Unit (SCDU) on the front of the power cube.

❶

First, all of the segments on the digital LED display and all of the LEDs will light for about one second.

❷

Then the LEDs and display extinguish and the drive will perform internal checks.

❸

If the drive passes the self-test, then the READY LED will light and the

SCDU will display 'P-UP' to indicate a proper power-up.

Displays other than those mentioned above may occur. If abnormal display conditions occur, the following actions maybe necessary to correct the situation:

●

If no digits or LEDs ever light up, check for proper voltage between the 115

VAC control power lines, or for blown 115 VAC control power fuses, or for a defective control voltage power supply in the power cube.

●

If horizontal segment(s) of the SCDU display are lit, then one or more phases of the three phase power are missing. Check the three phase power fuses. See Section 3, Start-Up Operation, for more detailed information about this test.

2

3/21/96

Drive Start-Up 21

2 Installation and Start-Up

Parameter

Verification

●

If the FAULT LED lights and a fault code appears on the SCDU, then refer to the Fault/Error Codes List in Section 4, Maintenance, to see what caused the fault and to find the correct solution. A fault code is the letter 'F' followed by a number representing the fault. See Section 3, Operation, for more detailed information about fault reporting and clearing.

●

If the SCDU displays 'Prot', then the initial checks found that the protected non-volatile RAM (NVRAM) has not been initialized. Move the NVRAM

PROTECTION switch to "OFF" in order to allow the CPU to initialize the

NVRAM with preprogrammed default values. Notice that the NVRAM

UNPROTECTED LED is now lit to indicate the NVRAM

PROTECTION switch position. Next, press the RESET push button. The drive will go through its power up sequence again; however, this time it will initialize the protected NVRAM. After the power up sequence has finished, return the NVRAM PROTECTION switch to "ON" in order to assure protection of this memory area. Notice that the NVRAM UNPROTECTED

LED is now turned off.

❏ On drives with fans, verify that the fans are working.

When the READY LED on the SCDU is lit, all the selectable parameter data should be verified for the proper values as follows. See the PCDU Guide for information on verifying and entering parameter values on a PCDU:

❏ VERIFY OR CHANGE EACH PARAMETER VALUE for the particular application and motor involved.

❏ PCU DIAGNOSTICS (function # 998) should now be performed to verify armature and field circuitry.

❏ SELF-TUNE (PCU Parameter Measurement) (function # 997) should be performed before the drive is “RUN”. This gives the drive various motor parameters essential for optimal operation. NVRAM protection must be off to store parameters.

❏ SELF-TUNE SELECT (Function # *) should be turned on for optimal operation. (* Check the PAC diagram for correct function number.)

❏ STORE PARAMETERS, (function # 994) so that power can be removed and reapplied without losing the entered parameters. Remember that NVRAM protection must be OFF to store parameters.

❏ Operate drive, using external control signal inputs shown on the system schematic.

22 Drive Start-Up

3/21/96

Operation

Controls and

Indicators

The “Operation” Section describes and illustrates the following:

●

●

●

●

●

●

●

●

●

Operator’s controls and indicators.

Steps you need to follow to start-up your DSD drive.

Types of parameters that can be entered after start-up.

Types of monitor functions available after start-up.

Upload/Download of Programs or Parameters procedure.

How to access error and fault lists and clear them.

How to access non-volatile “RAM”.

How to reload the default functions.

Self-tuning feature.

The upper right corner of the power cube cover contains the operator controls and indicators of the SCDU. Figure 8 identifies these operator components.

Although accessible with the cover in place, all of these components are part of the DSD Drive Control PCB.

RUN (green)

READY (green)

TORQUE

LIMIT

(yellow)

OVERLOAD

(yellow)

+

RESET

BUTTON

E-STOP

(red)

FAULT (red) DATA

LED

DATA/FCTN

DATA

PENDING

UP

SCDU

MEM

UNPROT

DOWN

ENTER

Figure 8. Operator Controls and Indicators

NV RAM

PROTECTION

LA-3

RESET Button

Pressing the reset button causes the drive to clear faults, or in some cases to reset the drive, depending on the context.

Status LEDs

To the right of the RESET button is a vertical strip of six light emitting diodes

(LEDs):

All status LEDs are under the control of the application specific software.

However, the following descriptions indicate typical uses for the LEDs. The

PAC diagram for this drive must be consulted to determine the actual meaning for each LED.

Ready Indicates that the drive is ready to operate.

Run DC loop contactor is closed and drive is controlling motor speed.

Torque Limit Drive is demanding armature current at or above the preset current limits.

3

3/21/96

Controls and Indicators 23

3 Operation

Overload

E-Stop

Fault

Standard

Control/Display

Unit (SCDU)

Non-Volatile

“RAM” Protection

Current exceeded safe levels for too long and drive was stopped to protect the motor.

Drive contactor safety interlock is detected as open. Drive will not run when this light is on.

Indicates that a declared drive fault exists. The Fault/Error Code List defines what conditions the drive will recognize as faults.

IMPORTANT

Clearing a Fault from the Fault List is NOT THE SAME as resetting the fault. Some faults are transient in nature and require no further action after clearing the fault from the Fault List.

Others require some additional positive action to allow the drive to continue to run. See the Fault/Error Code List for further details.

The major part of the SCDU is a 4-1/2 digit numeric LED display. Each of its four full digits can display the values of 0 to 9 plus limited alphabetic characters.

The so-called half digit can display only the value “1” and a plus or minus sign.

Below the numeric LED, is a single indicator and four push buttons. The four push buttons (DATA/FCTN,

⇑

[UP],

⇓

[DOWN], and ENTER) are used to operate the SCDU.

Next to the numeric displays of the SCDU is a red LED labeled MEM

UNPROT. This LED is lit when the “protected” portion of the non-volatile random access memory (NVRAM) can be written to. Protection of the NVRAM is determined by the switch labeled NVRAM PROTECTION. When this switch is in the "ON" position, the MEM UNPROT LED is off and the protected portion of the NVRAM can not be written to. This prevents setup parameters and other important constants from being accidentally erased or changed. When these parameters need to be changed the switch can be moved to the "OFF" position, removing the write protection and causing the MEM

UNPROT LED to be lit.

CAUTION

The NVRAM PROTECTION switch should be left in the

"ON" position to protect the NVRAM during the critical power-up and power-down periods.

Portable

Control/Display

Unit Connection

The optional Portable Control/Display Unit (PCDU) plugs into a telephone-style jack at the bottom left of the DSD Drive Control PCB (accessible through a cutout at the bottom left of the front cover). If your unit is equipped with this option, refer to the PCDU guide provided with the unit for operating procedures.

24 Controls and Indicators

3/21/96

3/21/96

Operation

Start-Up

Operation

❏ When power is first applied to the drive, all of the segments on the 4-1/2 digit display will turn on briefly in order to show that all are functioning:

..

-

1.8.8.8.8.

❏ After this lamp test is completed, an internal check is made to determine if the NVRAM chips have ever been used before, or if the EPROMs are the same as before power-down. If not, the drive software will attempt to load the defaults into the NVRAM chips. The SCDU displays the word ‘Prot’ if the NVRAM PROTECTION switch is in the “ON” position; this prevents

NVRAM updates:

3 prot

If the display shows ‘Prot’, it is necessary to move the NVRAM

PROTECTION switch to the "OFF" position and press the RESET button in order to load defaults into NVRAM and restart the drive. Then set the

NVRAM PROTECTION switch back to "ON". This message will only happen when the drive is powered up for the very first time or if the software in the drive or the NVRAM chips are changed.

❏ After the LED lamp test has completed, the drive software will now perform a fuse test on each of the three line fuses. If any power conversion fuse is open, the SCDU will indicate this on its display as follows:

DATA

RED

-

Start-Up Operation 25

3 Operation

If two fuses are blown, the SCDU display will be:

- -

DATA

RED

The drive will not operate unless all three line fuses are functional. If the SCDU indicates a bad fuse, power must be removed from the drive, the fuse replaced and power reapplied.

❏ After the drive has performed all three tests (lamp test, “RAM” test, and fuse test), the SCDU displays one of two final messages. If there are any faults present at this time, the SCDU will display a Fault code. The display will be similar to: f 102

DATA

OFF where the leading ‘F’ indicates a fault and the 3 digits following the ‘F’ indicate the fault number. If however, there are no faults present, the SCDU displays the normal power-up message: p-up

DATA

OFF

General

Operation

This ‘P-UP’ display will remain on the SCDU until a key is pressed or a fault occurs.

After the drive has powered up and the SCDU display is showing ‘P-UP’ or a fault number, it can be used to enter new parameters, monitor drive operation, and/or perform certain drive diagnostics. Every operation that the SCDU can perform is called a ‘function’. There may be up to 1000 functions defined.

The function codes between # 000 and # 999 are grouped as follows:

3/21/96

26 General Operation

3/21/96

Operation

Function #

# 000

Table 2. # Function Code Descriptions

Description

Reserved for the Fault Display/Clear Function

# 001 - 299 PAC dependent Parameter Mode (Settable Parameters)

# 600 - 799

# 800 - 899

# 900 - 999

PAC dependent Monitor Mode (View Only Values)

Reserved for Advanced Fault/Error Routines

Reserved for Diagnostic/Test Routines

Function

Levels

All SCDU functions have at least 2 levels and some functions use 3 levels. The data indicator below the lower left corner of the 4-1/2 digit display is used to indicate which level of a particular function the SCDU is currently at. The top level of the SCDU operation is called the "Function" level. The data indicator is off when the SCDU is in the "Function" level. The

⇑ or

⇓ keys are used to select a function number to be accessed while at this level. The

⇑ key increments the function number in the display while the

⇓ key decrements it. The SCDU will ramp the displayed function number when the

⇑ or

⇓ key is pressed and held for

1/2 second or longer.

DATA/FCTN

Key

The DATA/FCTN key is used to toggle between the “Data” level and the

“Function” level. Press the DATA/FCTN key when the desired function number is in the display. At this point, the SCDU leaves the "Function" level and enters the "Data" level. Note that the data indicator is now GREEN. This operation is consistent for every function on the SCDU, although the data actually displayed while the indicator is GREEN is function-number specific.

Examples of every type of SCDU function are given in subsequent sections. All function numbers are the same for both the SCDU and the PCDU (Portable

Control/Display Unit). (See the “PCDU Guide” for steps required for PCDU function entry.) There are some functions, however, that can only be performed with the PCDU. When such a function number is selected on the SCDU and the

DATA/FCTN key is pressed, the SCDU’s display will change to:

3 pcdv

DATA

OFF

General Operation 27

3 Operation

Parameter

Functions

SCDU functions # 001 through # 299 inclusive are used to modify and/or display setup points that the drive needs for operation. Items that would typically fall into this category are functions such as Accel Times, Regulator

Gains, Rated Speed and any other parameter that has been previously programmed in the PAC diagram for the drive. The following steps show how to modify a given parameter via the SCDU display.

❏ Use the ⇑ and

⇓ keys to select the function number (between # 001 and

# 299) to be accessed. The data indicator is turned off during this step.

In the example below, function # 040 is chosen:

40

DATA

OFF

❏ Press the DATA/FCTN key to enter the "Data" level for this function number. The data indicator is GREEN to verify that the number being shown is the current actual value for this parameter. For example, if function

# 040 is currently set for a value of 10.6, it will be displayed as follows:

10.6

DATA

GREEN

❏ Use the ⇑ and

⇓ keys to ramp the number in the SCDU display to the desired value. Note that the data indicator is RED to verify that the value being displayed is NOT the actual value, but rather is in the process of being changed. Each parameter has an upper and lower limit depending on the

PAC diagram. The following display will occur when the lower limit is exceeded:

DATA

-

RED

❶

Similarly, if the upper limit is exceeded, the SCDU displays:

3/21/96 28 Parameter Functions

3/21/96

Operation 3

-

DATA

RED

❷

The SCDU display will increment from ‘10.6’ to ‘11.0’ if the

⇑ key is pressed 4 times:

11.0

DATA

RED

❏ Press the ENTER key to transfer the value in the SCDU display to the actual value used by the drive. Note that the data indicator will change back to

GREEN to indicate that this value is now the actual value for this parameter:

11.0

DATA

GREEN

If the ENTER key is pressed while the display is indicating that the upper or lower limit has been exceeded, the display will change to the appropriate limit value and the LED will change to GREEN.

The DATA/FCTN key can be pressed any time before the ENTER key is pressed, to cancel the changes and return to the initial value.

❏ Press the DATA/FCTN key to put the SCDU back into the "Function" level.

As with the example above, the SCDU display will be:

40

DATA

OFF

All changes made become active values upon pressing the ENTER key.

They remain active until the next reset, or until the drive is powered down.

Parameter Functions 29

3 Operation

When the drive is reset or powered up the value reverts to the value stored in

NVRAM. If changes are to be permanent, use function # 994 (described later) to save the changed value in NVRAM.

Due to PAC programming considerations it may be possible to access a value which cannot be changed. In this case the CDU function will proceed as described until the ENTER key is pressed to change the value. In this case the value will simply ignore any requested changes and remain the same.

Monitor

Functions

SCDU functions # 600 through # 799 inclusive are used to monitor those values that cannot be directly changed by the operator. Items that would typically fall into this category are Speed Feedback, Armature Current and Armature Voltage.

To view one of these values, it must have been previously programmed in the

PAC Diagram for the drive. The following steps show how to display a given value on the SCDU display.

❏ Use the ⇑ and

⇓ keys to select the function number (between # 600 and

# 799) to be accessed. The data indicator is turned off during this step. For example, if function # 604 is selected, the SCDU display will be:

604

DATA

OFF

❏ Press the DATA/FCTN key to enter the "Data" level for this function number. The data indicator is GREEN to indicate that actual data is currently being viewed. If the data for function # 604 is currently at 20.94

for example, the SCDU display will change to:

20.94

DATA

GREEN

The SCDU’s display is updated immediately if the value for the selected function changes.

NOTE : Values displayed with these function numbers cannot be modified.

3/21/96 30 Monitor Functions

Operation

Upload/

Download of

Programs or

Parameters

(T992)

The “Upload/Download of Programs or Parameters” Section describes and illustrates the following:

●

●

●

●

●

●

●

What is upload/download.

General upload/download procedures.

How to upload program into a new Flash ROM chip.

How to upload a program.

How to download a program.

How to upload parameters.

How to download parameters.

Upload/

Download

Introduction and Definitions

The DSD 406/412 have the ability to pass program and parameter information between the drive’s memory and a computer with a serial port. The direction of data flow is defined as Upload (from the computer to the drive) or Download (from the drive to the computer).

Figure 9 shows the electrical connections required to connect the serial port of the DSD 406/412 to the serial port (COM1 or COM2) of an IBM

PC compatible computer. The PC utilized must have a serial port and disk drive.

3

9 TO 25 PIN

CONVERTER

(P/N 50210702)

RJ12 CABLE

(P/N 05P00211-004)

COM 1

DB25 TO RJ12

CONVERTER

(P/N 46S03027-0010)

ISOLATED

RS232 PORT

IBM PC

COMPATIBLE

Figure 9: DSD 406/412 to IBM PC Compatible

Computer Interconnect Diagram

In addition to the electrical connections, a serial communications program must be used by the computer to access data through the serial port. The serial port communications program must support Y

Modem Batch file transfer protocol (i.e. Qmodem).

3/21/96

Upload/Download of Program/Parameters 31

3 Operation

32

The default data bit, stop bit and parity values of the drive are “8”, “1” and “NO”, respectively. These settings can not be changed. The Y

Modem Batch file transfer is the only protocol available for communicating with the DSD 406/412.

CAUTION

The communications software must be set up to match the baud rate of the drive.

In uploading and downloading files, the drive behaves like a bulletin board service to the PC.

A file upload means that a file is sent from the PC to the drive.

A file download means that a file is sent from the drive to the

PC.

Communications Program Set-up protocol: Y Modem Batch parity: data: stop: speed:

NO

8

1

9600 or 19200

There are two file types associated with upload and download. The

PAC program file (i.e. the .PRG file) contains the executable instructions that determine the application characteristics of the drive.

The parameter file is the file of all the parameter settings of a drive at the time the .PAR file was captured.

●

●

●

Program upload is the process of a computer sending a new

PAC program (i.e. the .PRG file) to a DSD 406/412 through the drive’s serial port. This process may be required when, upon application of power, the drive finds the PAC program loaded into memory is invalid. This process may also be used when it is desired to change the PAC program from what was previously loaded. Some of the steps shown below are skipped when the

PAC program in memory is found to be invalid.

Program download is the process of the DSD 406/412 drive sending the PAC program (i.e. the .PRG file) through the drive’s serial port to a computer. This process can be used for memory backup.

Parameter upload is the process of a computer sending all settable parameters (i.e. the .PAR file) to a DSD 406/412 drive.

This process can be used to set up the drive with a set of tuned constants.

Upload/Download of Program/Parameters

3/21/96

3/21/96

●

Operation

Parameter download is the process of the DSD 406/412 drive sending all of its settable parameter values (i.e. the .PAR file) to a computer. This process can be used for memory backup. A parameter download is the only data transfer process that can occur while the drive is running a motor.

NOTE

The DSD 406 / 412 can not be running a motor while uploading parameters or a program. It cannot also be running a motor if a program download is occurring. The PAC program stops execution during this time.

3

CAUTION

The NVRAM PROTECTION switch needs to be in the

“OFF” position to perform an upload.

The MEM UNPROT light will also need to be lit.

General

Upload/

Download

Procedures

To perform an upload or download use function # 992. This will allow you to upload or download PAC programs and parameters. The following steps explaining how to perform these operations from the

Command/Display Unit, SCDU, resident on the drive:

❏

❏

Check to verify the DATA PENDING light is “OFF”. If not, press the DATA/FCTN key.

Use the

⇑ and

⇓ keys to select function # 992. The display will show the function number.

992

DATA

OFF

❏ Press the DATA/FCTN key. At this point the DATA/FCTN key, the

⇑ key and the

⇓ key may be pressed.

●

Press the DATA/FCTN key to return to the function entry mode without performing any data transfers.

General Upload/Download Procedures 33

3 Operation

❏

❏

●

●

●

●

●

Press the ⇑ key to select an upload operation.

recv

DATA

GREEN

Press the

⇓ key to select a download operation.

send

DATA

GREEN

Press the ENTER key to accept the Upload or Download selection. At this point the DATA/FCTN key, the

⇑ key, and the

⇓ key may be pressed.

Press the DATA/FCTN key to return to the function entry mode without performing any data transfers.

Press the

⇑ key to select transfer of the program.

pa(

DATA

GREEN

Press the

⇓ key to select transfer of the parameters.

data

DATA

GREEN

Press ENTER to accept the given action.

3/21/96 34 General Upload/Download Procedures

Operation

Upload

Procedure for a

New Flash ROM

Chip

The DSD 406/412 will automatically go into the upload/download function # 992, on power up of a drive without DCU software or replacement of a Flash ROM chip. The default baud rate of 19,200 will be displayed.

WARNING

After putting in a new Flash ROM chip and

19,200 baud is not displayed on the SCDU, contact MagneTek for assistance.

3

19200

❏ Use the

⇓ key to select the another baud rate if your terminal does not support 19,200 baud. This will decrease the baud rate.

The

⇑ key is not applicable here since 19,200 is the maximum baud rate.

CAUTION

The communications software must be set up to match the baud rate of the drive.

❏ Press the ENTER key to accept the displayed baud rate. The

DSD 406/412 will begin to initiate transfer sequence.

CAUTION

When the program transfer begins it must be completed.

A message will appear explaining that permanent storage memory is being erased.

eras

3/21/96

General Upload/Download Procedures 35

3 Operation

A message will appear explaining that the DSD 406/412 is attempting to start the program transfer.

l0ad

At this time, the DSD 406/412 is waiting to communicate with the PC.

You will see the LED’s on drive scroll upward to indicate it is ready to upload. Y Modem protocol will be sent to the serial port in the form of a ‘C’ character indicating that the transfer can start.

Initiate a Y Modem Batch file transfer from the PC (i.e. for Q modem users, press the PgUp key for an upload and select the Y Modem batch mode).

When transfer begins, a message will appear showing how much of the transfer has already taken place. For a baud rate of 19,200, the transfer will take approximately five minutes. The completion percentage number counts as more data is transferred.

78

DATA

GREEN

The LED’s will continue to scroll upward until the upload is complete.

When the upload finishes, the drive resets itself, runs an internal check, and then executes the PAC program.

3/21/96 36 General Upload/Download Procedures

Program Upload

❏

❏

❏

❏

Operation

Check to verify that the DATA PENDING light is “OFF”. If not, press the DATA/FCTN key.

Use the

⇑ and

⇓ keys to select function # 992. The display will show the function number.

3

992

DATA

OFF

Press the DATA/FCTN key.

Press the

⇑ key to select an upload operation.

❏

❏

❏ re(v

DATA

GREEN

Press the ENTER key to accept the Upload selection.

Press the

⇑ key to select transfer of the program.

pa(

DATA

GREEN

CAUTION

When the program transfer begins, it must be completed because the existing program is erased.

Use the DATA/FCTN key to exit out of the program upload without performing any data transfers.

3/21/96

General Upload/Download Procedures 37

3 Operation

❏ Press the ENTER key to accept the transfer of the program.

The current baud rate will be displayed.

19200

❏ Use the

⇓ key to select the another baud rate.

❏ Press the ENTER key to accept the displayed baud rate. The

DSD 406/412 will begin to initiate transfer sequence.

A message will appear explaining that permanent storage memory is being erased.

eras

A message will appear explaining that the DSD 406/412 is attempting to start the program transfer.

l0ad

At this time, the DSD 406/412 is waiting to communicate with the PC.

You will see the LED’s on drive scroll upward to indicate it is ready to upload. Y Modem protocol will be sent to the serial port in the form of a ‘C’ character indicating that the transfer can start.

CAUTION

The communications software must be set up to match the baud rate of the drive.

Initiate a Y Modem Batch file transfer from the PC (i.e. for Qmodem users, press the PgUp key for an upload and select the Y Modem batch mode).

3/21/96 38 General Upload/Download Procedures

3/21/96

Operation

When transfer begins, a message will appear showing how much of the transfer has already taken place. For a baud rate of 19,200, the transfer will take approximately five minutes. The completion percentage number counts as more data is transferred.

78

DATA

GREEN

3

The LEDs will continue to scroll upward until the transfer is complete.

Program

Download

When the upload finishes, the drive resets itself, runs an internal check, and then executes the PAC program.

❏

❏

Check to verify that the DATA PENDING light is “OFF”. Press the DATA/FCTN key.

Use the

⇑ and

⇓ keys to select function # 992. The display will show the function number.

992

DATA

OFF

❏ Press the DATA/FCTN key.

send

DATA

GREEN

Press the ENTER key to accept the Download selection.

❏

General Upload/Download Procedures 39

3 Operation

❏

❏ Press the ⇑ key to select transfer of the program.

pa(

DATA

GREEN

❏

❏

Use the DATA/FCTN key to exit out of the program download without performing any data transfers.

Press the ENTER key to accept the transfer of the program.

The current baud rate will be displayed.

9600

Use the

⇓ key to select the another baud rate if your terminal does not support 9,600 baud. The maximum baud rate for a download is 9,600.

❏

CAUTION

The maximum baud rate is different from a program download.

Press the ENTER key to accept the displayed baud rate. The

DSD 406/412 will begin to initiate transfer sequence.

CAUTION

File can not already exist in directory you are trying to download to.

Initiate a Y Modem Batch file transfer from the PC (i.e. for Qmodem users, press the PgDn key for a download and select the Y Modem batch mode).

3/21/96 40 General Upload/Download Procedures

3/21/96

Operation

Parameter

Upload

❏

❏

NOTE

The downloaded program is already named in the PAC program.

At this time, the DSD 406/412 is waiting to communicate with the PC.

When the transfer begins, a message will appear showing how much of the transfer has taken place. The completion percentage number counts as more data is transferred. This transfer should take ten minutes at 9,600 baud.

78

DATA

GREEN

Check to verify the DATA PENDING light is “OFF”. If not, press the DATA/FCTN key.

Use the

⇑ and

⇓ keys to select function # 992. The display will show the function number.

❏

❏

992

DATA

OFF

Press the DATA/FCTN key.

Press the

⇑ key to select an upload operation.

re(v

DATA

GREEN

3

General Upload/Download Procedures 41

3 Operation

❏

❏

❏ Press the ENTER key to accept the Upload selection.

❏

❏ data

DATA

GREEN

Use the DATA/FCTN key to exit out of the parameter upload without performing any data transfers.

Press ENTER to accept the transfer of the parameters.

The current baud rate will be displayed.

9600

Use the

⇓ key to select the another baud rate if your terminal does not support 9,600 baud. The maximum baud rate for a download is 9,600.

CAUTION

The maximum baud rate is different from a program download.

Press the ENTER key to accept the displayed baud rate. The

DSD 406/412 will begin to initiate transfer sequence.

42

CAUTION

The communications software must be set up to match the baud rate of the drive.

Initiate a Y Modem Batch file transfer from the PC (i.e. for Qmodem users, press the PgUp key for an upload and select the Y Modem batch mode).

At this time, the DSD 406/412 is waiting to communicate with the PC.

When the transfer begins, a message will appear showing how much of

General Upload/Download Procedures

3/21/96

3/21/96

Operation

Parameter

Download

❏

❏ the transfer has already taken place. For a baud rate of 9,600, the transfer will take approximately thirty seconds. The completion percentage number counts as more data is transferred.

78

DATA

GREEN

Check to verify the DATA PENDING light is “OFF”. If not, press the DATA/FCTN key

Use the

⇑ and

⇓ keys to select function # 992. The display will show the function number.

992

DATA

OFF

Press the DATA/FCTN key. ❏

❏ send

DATA

GREEN

Press the ENTER key to accept the Download selection.

data

DATA

GREEN

3

General Upload/Download Procedures 43

3 Operation

❏

❏

❏

Use the DATA/FCTN key to exit out of the parameter download without performing any data transfers.

Press ENTER to accept the transfer of the parameters.

The current baud rate will be displayed.

9600

Use the

⇓ key to select the another baud rate if your terminal does not support 9,600 baud. The maximum baud rate for a download is 9,600.

❏

CAUTION

The maximum baud rate is different from a program download.

Press the ENTER key to accept the displayed baud rate. The

DSD 406/412 will begin to initiate transfer sequence.

CAUTION

The communications software must be set up to match the baud rate of the drive.

Initiate a Y Modem Batch file transfer from the PC (i.e. for Qmodem users, press the PgDn key for a download and select the Y Modem batch mode). The PAC program will assign a name to the downloaded file.

At this time, the DSD 406/412 is waiting to communicate with the PC.

When the transfer begins, a message will appear showing how much of the transfer has already taken place. The completion percentage number counts as more data is transferred. This transfer should take approximately thirty seconds at 9,600 baud.

78

DATA

GREEN

3/21/96 44 General Upload/Download Procedures

Operation

Error Handling/

Reporting

The drive has two methods available to report errors. Each error condition may utilize ONE OR BOTH OR NEITHER of the reporting methods.

The most conventional method is called ‘fault recording’. If this method is enabled for a particular error, the red FAULT LED and a unique fault code number will appear on the SCDU at the moment the error occurs. Each occurrence of a fault is recorded in an area in “RAM” called the Fault List. The

Fault List stores the first 16 faults to occur after the drive is powered up, meaning it will contain the 16 “oldest” faults. Recording of faults stops as soon as the 16th fault occurs. This list is erased when the drive is powered down or reset. Whether the drive stops or continues to run is dependent on the way the particular fault is implemented within the PAC diagram. Most standard faults are set up so that the drive will stop if a fault occurs.

The second method for error handling is called ‘error recording’. Error recording differs from fault recording in three respects:

❶

The error condition will not be shown on the SCDU or the red FAULT LED.

❷

The error list stores the last errors to occur, meaning it will contain the 16 most recent errors. Each new error over-writes the oldest error in the list.

❸

This list is maintained in battery-backed-up “RAM” and is retained when the drive is powered down or reset.

Again, the action taken by the drive when an error occurs depends on how the particular error is implemented within the PAC Diagram.

Function # 801 is used to display or alter the Error Disposition List. This list can be consulted at any time to determine whether a particular condition should be reported as an error, a fault, or both. The process for changing the entry in the disposition list for a particular condition using the SCDU is as follows:

❏ Use the ⇑ and

⇓ keys to select function # 801 from the function level. The data indicator is off during this step.

3

801

DATA

OFF

3/21/96

Error Handling/Reporting 45

3 Operation

❏ Press the DATA/FCTN key to enter the "Data" level for function # 801.

The data indicator is GREEN and the error code last modified with function

# 801 will be in the SCDU display. The SCDU displays error code # 13

(illegal instruction) initially after power up:

13

DATA

GREEN

❏ Use the ⇑ and

⇓ keys to select the error code entry in the Disposition List that is about to changed/viewed. For example, if the disposition for error code # 102 (Numeric Underflow) is to be modified, press the

⇑ key until the

SCDU display changes to:

102

DATA

GREEN

❏ Press the ENTER key when the desired error code is displayed on the

SCDU. The data indicator changes from GREEN to RED, and the SCDU display changes as well to a format of ‘E.xF.y’. The ‘E’ and ‘F’ are abbreviations for Error and Fault respectively. The ‘x’ and ‘y’ will be either

‘1’ or ‘0’ to indicate which list will record the error. For example, if the display is ‘E.1F.1’, the error is recorded in both lists. If the display is

‘E.0F.1’, the error is recorded in the fault list, but not in the error list. If the display is ‘E.0F.0’, neither list records the error. In the example above, the factory set default disposition for a Numeric Underflow (code # 102) is to record the error in the Error List, but not in the Fault List. In this case, the

SCDU display is:

DATA

RED e.if.0

3/21/96 46 Error Handling/Reporting

3/21/96

Operation

❏ Press either the ⇑ or

⇓ keys repeatedly to change the numbers after the ‘E’ and ‘F’ from ‘1’ to ‘0’ and vice-versa. Starting from no declarations, the displays are: ‘E.0F.0’, ‘E.0F.1’, ‘E.1F.0’, and ‘E.1F.1’. For example, if the disposition for this error should be changed so that it is NOT recorded in either the Fault or Error list.

❶

Press the

⇓ key once so the display changes to:

3 e.0f.1

DATA

RED

This display indicates that the Numeric Underflow error will now be recorded in the Fault List, but not in the Error List.

❷

Pressing the

⇓ key once more will change the display to: e.0f.0

DATA

RED

This is the desired status for the new disposition of the Numeric Underflow error, which is to not report it to either the Fault or Error List.

❏ Press the ENTER key when the new disposition code is in the display. At this point, the data indicator changes from RED to GREEN, and the SCDU displays the error code again:

102

DATA

GREEN

Error Handling/Reporting 47

3 Operation

❏ The ⇑ and

⇓ keys will now be used to select which error code is being modified.

When all changes in the Error Disposition List are finished, the

DATA/FCTN key will exit back to the function level:

801

DATA

OFF

Fault

Display/Clear

The drive stores the first 16 faults that have been reported to the Fault List.

Once the Fault List is filled with 16 faults, it will not accept any more entries.

The data in this buffer is not retained when the power is lost. Each time a fault condition occurs, and its entry in the Disposition List is set to allow recording in the Fault List, that new fault is placed on the list.

Function # 000 is reserved for viewing the Fault List. Each fault in the Fault List can be shown on the SCDU display and optionally cleared. The steps to view the

Fault List are as follows:

❏ Use the ⇑ and

⇓ keys to select function # 000. The data indicator is off during this step. Note that this function can be accessed simply by pressing the

⇑ key once if the SCDU display is ‘P-UP’.

0

DATA

OFF

❏ Press the DATA/FCTN key to enter the "Data" level for this function. The data indicator is GREEN to indicate that the fault codes currently in the Fault

List are being displayed. The very first display at this point is the word

'TOP': t0p

DATA

GREEN

3/21/96 48 Error Handling/Reporting

3/21/96

Operation

❏ To view the first fault on the list, press the ⇓ key. If there is a Numeric

Underflow fault on the Fault List, for example, the SCDU display will change to:

102

DATA

GREEN

❏ The contents of the Fault List may be examined by using the ⇑ and

⇓ keys.

The first fault in the list is the first fault actually declared. When the first fault in the list is displayed, pressing the

⇓ key will cause the next fault to be displayed. Repeatedly pressing this key will move toward the end of the list.

The SCDU displays the word 'End' after the last fault has been displayed:

3 end

DATA

GREEN

Error Display

❏ When any fault other than the first fault is displayed, pressing the ⇓ key will cause the previous fault to be displayed.

For example, if the 10th fault in the list was displayed, the end of the list

(“End”) could be reached by repeatedly pressing the

⇓ key, and the beginning of the list (“top”) could be reached by repeatedly pressing the

⇑ key.

The drive is able to store the most recent 16 errors that have been reported to the

Error List. This list is constantly updated, with the newest error overwriting the oldest in the list. This list is held in battery-backed-up “RAM” (NVRAM), so it is retained when power is lost. Each time an error condition occurs, and if its entry in the Disposition List is set to allow recording in the Error List, that new error is placed in the list. In addition to the error code, the Error List holds number of the PAC block that declared the error, and a time-stamp to indicate how much time has elapsed since the error occurred. This timer is only updated while power is applied to the drive. The time-stamp can only be viewed by the

PCDU (see the PCDU Guide), but the PAC block number can be read by the

SCDU.

Error Handling/Reporting 49

3 Operation

Function # 800 is reserved for viewing the Error List in NVRAM. The steps to view the Error List are as follows:

❏ Use the ⇑ and

⇓ keys to select function # 800. The data indicator is off during this step.

❏ Press the DATA/FCTN key to enter the "Data" level for the view error function.

800

DATA

OFF

❶

The data indicator is GREEN to indicate that an error code is currently being viewed. If the error in this slot is a Numeric Underflow for example, the SCDU will display:

102

DATA

GREEN

❷

The number of the PAC block that declared this error can be viewed by pressing the ENTER key. If block 485 had declared the Numeric

Underflow error, for example, the SCDU would change to:

485

DATA

RED

If the number displayed during this step is 0, the error was not declared by a

PAC block, but rather by the Kernel of the DCU.

Other errors currently in the Error List can be viewed by pressing the ENTER key to display the Error Code again, then either the

⇑ or

⇓ key to move to the next or previous slot in the list. The procedure outlined above should be repeated as necessary to view the Error Code and PAC block number for other errors in the Error List.

3/21/96 50 Error Handling/Reporting

Operation

Non-Volatile

“RAM”-Access

Every parameter that the drive uses has three separate areas in memory associated with it. There is a factory-set default value for each parameter which is stored in the read only EPROM chips. There is an area in the active “RAM” which the drive uses while it is running. There is also an area in NVRAM reserved for each parameter. The values in the NVRAM area are copied to the active “RAM” every time the drive is powered up . This split level approach makes it possible to return to the last set of ‘stable’ parameters in NVRAM if some errors are made during fine-tuning of the active drive parameters.

Function # 994 is used to perform the transfer of data between the NVRAM and active parameter lists. The process for copying data to or from the NVRAM parameter list is as follows:

❏ Use the ⇑ and

⇓ keys to select function # 994 from the function level. The dual-colored LED is off during this step.

994

DATA

OFF

❏ Press the DATA/FCTN key to enter the "Data" level for function # 994.

The data indicator is GREEN to indicate that this function is currently being accessed. It is possible to SAVE the current active parameters in “RAM” to the NVRAM parameter list, or to RESTORE the current parameters from the NVRAM parameter list to the active “RAM”. Note that a RESTORE is the same operation that occurs inherently every time the drive is powered up. Upon entering the data level for this function, the SCDU displays: rest

DATA

GREEN

❏ The ⇑ and

⇓ keys can be used to toggle between the above display, which indicates a pending RESTORE operation, and the following display, which indicates a pending SAVE: saue

DATA

RED

3

3/21/96

Non-Volatile “RAM”-Access 51

3 Operation

Note that as soon as either the

⇑ or

⇓ key is pressed, the data indicator will change to RED.

❏ Press the ENTER key to actually perform the transfer of data. If ENTER is pressed while 'SAVE' is displayed, the SCDU display may change to: prot

This display means that the NVRAM PROTECTION switch is in the “ON” position preventing writes to the NVRAM. Move the switch to the "OFF" position, press the DATA/FCTN key, and start over from step #2. (See

Figure 3 in Section 3, Controls and Indicators for the location of the

NVRAM PROTECTION switch.)

During SAVE or RESTORE operation, the DATA/FCTN,

⇑ and

⇓,

ENTER keys will not function. Functionality will resume when operation is complete.

saue

DATA

RED

IMPORTANT

During normal operation, and during drive power-up or -down, the NVRAM PROTECTION switch should ALWAYS be in the

“OFF” position which prevents writes to the NVRAM.

3/21/96 52 Non-Volatile “RAM”-Access

3/21/96

Operation

Load Defaults

Function

Every parameter in the drive has a factory-set default value that is loaded when the drive is powered up for the very first time. These default parameters may not be optimal values for the drive when actually running, but they will generally allow the drive to function. It is possible to reload these default parameters with function # 995 of the SCDU. A re-load of the defaults would generally be done when the drive is operating erratically and it is suspected that one or more parameters were improperly set and saved.

CAUTION

Use of the LOAD DEFAULTS function will overwrite EVERY parameter currently being used by the drive with the factory-set default for each parameter. There is no way to restore parameters to their previous value once this function is used.

3

CAUTION

The NVRAM protection switch must be off and the drive must be in the stop condition.

Function # 995 is used to perform the transfer of data from the default parameter list to the ACTIVE “RAM” parameter list. The process for accessing the Load

Defaults Function is as follows:

❏ Use the ⇑ and

⇓ keys to select function # 995 from the function level. The data indicator is off during this step.

995

DATA

OFF

❏ Press the DATA/FCTN key to enter the "Data" level for function # 995. The data indicator is GREEN to indicate that this function is currently being accessed. The SCDU display may change to: l0ad

DATA

GREEN

❏ Press the ENTER key to actually perform the Load Defaults transfer.

Load Defaults Function 53

3 Operation

The drive will then do a complete reset and the program defaults are now loaded.

If the SCDU display does not change to LOAd, the following may display.

St0p

If the drive is still in a run condition: To correct, put the drive in a stop condition and press the DATA/FCTN key to continue with loading defaults.

Prot

Self-Tune (PCU

Parameter

Measurement)

If the NVRAM protection switch is “ON”: To correct, turn off the NVRAM protection switch and press the DATA/FCTN key to continue with loading defaults.

The DSD drive has a built-in current regulator SELF TUNING feature. When activated, this feature measures total motor armature circuit resistance, inductance including wiring, and the field L/R time constant. The drive then uses the measured value in conjunction with the parameter entered for

“crossover frequency” to calculate integral and proportional gains for the current regulator and to set the field regulator gains properly. After running the PCU

Parameter Measurement function, the values for armature resistance and armature inductance are stored in NVRAM. Note that the NVRAM protection must be turned “OFF” so that the results can be stored. It is possible to override the values dynamically calculated for armature resistance and inductance values by disabling the “USE SELF-TUNE” item in the parameter menu.

The dynamically calculated values are used if “USE SELF-TUNE” is set to

“ON” while the manually entered values are used if this item is set to “OFF”.

WARNING

Armature current is circulated through the armature circuit during parts of the PCU Parameter Measurement function. The PCU will reduce the field current to zero on motors with a shunt field in order to minimize motor rotation. However, a PERMANENT MAGNET motor must have its shaft locked mechanically prior to running the PCU Parameter Measurement routine. If the PCU detects significant motor voltage during the test, the PCU parameter measurement function will abort.

54 Self-Tune (PCU Parameter Measurement)

3/21/96

3/21/96

Operation

The process for accessing the PCU PARAMETER MEASUREMENT function is as follows:

❏ Use the ⇑ and

⇓ keys to select function # 997 from the function level. The data indicator is turned off during this step.

997

DATA

OFF

❏ Press the DATA/FCTN key to enter the "Data" level for function # 997. The data indicator will be GREEN to indicate that this function is currently being accessed. The SCDU displays the word 'Prot' if the NVRAM

PROTECTION switch is in the position that will not allow any updates to the NVRAM:

3 prot

If the ‘Prot’ message appears, press the DATA/FCTN key to return to the

"Function" level, move the NVRAM PROTECTION switch to the "OFF" position, and press the DATA/FCTN key again. The SCDU will jump to the

‘Entr’ message (below) if the NVRAM PROTECTION switch is in the correct position upon entering this function.

The SCDU displays the word ‘Entr’ to prompt the user to press the ENTER key as further confirmation that the PCU parameter measurement function is about to be performed: entr

DATA

GREEN

❏ Press the ENTER key to actually start the PCU Parameter Measurement function. The PCU will not begin the measurement routine if a SEVERE

PCU FAULT exists. The PCU will declare a SEVERE FAULT under several conditions including an IST fault, power supply failure, loss of line synchronization, low line, or DCU failure. If a SEVERE FAULT exists when the PCU starts the parameter measurements, the SCDU displays:

Self-Tune (PCU Parameter Measurement) 55

3 Operation sflt

DATA

GREEN

❏ Severe faults can only be cleared by cycling power to the drive and replacing the bad component if applicable. The SCDU displays the word ‘tESt’ while it is performing the parameter measurements if there were no SEVERE

FAULTS when the ENTER key was pressed: test

DATA

GREEN

❏ Upon completion of the measurement, the SCDU will indicate the status of the test. If an error occurred, the SCDU will display an appropriate fault number. If all tests were completed properly, the SCDU displays ‘PASS’: pass

DATA

GREEN

❏ When testing is complete, press the DATA/FCTN key to exit the PCU parameter measurement routine and return to the "Function" level. The

SCDU displays:

997

DATA

GREEN

3/21/96 56 Self-Tune (PCU Parameter Measurement)

Maintenance

The “Maintenance” Section describes and illustrates the following procedures:

●

●

●

●

Preventive Maintenance

PCU Diagnostics

Troubleshooting Guide

Replacement Procedures for fuses, DSD Drive Control PCB, Armature

Interface PCB, fan, and power supply.

4

Preventive

Maintenance

WARNING

Hazardous voltages may exist in the drive circuits even with drive circuit breaker in off position. Never attempt preventive maintenance unless incoming three-phase and control power is disconnected and locked out.

Preventive maintenance is primarily a matter of routine inspection and cleaning.

The most important factors are that there is sufficient air flow to cool the drive and that vibration has not loosened any connections.

The DSD drive is designed to have sufficient air flow for long, reliable operation. Accumulated dust or dirt can reduce this air flow. Check and clean all fans, filters (if any), and the air flow across the heat sinks for dust or dirt at least once every three months. It may be necessary to do this more often if conditions are harsh dirty filters should be replaced.

If the drive is subjected to vibration, all mounting and electrical connections should be checked at three month intervals. Any loose hardware should be tightened.

3/21/96

Preventive Maintenance 57

4 Maintenance

Power

Conversion

Unit

Diagnostics

The drive has built-in diagnostic routines that can be performed via the SCDU.

The PCU diagnostic routines are able to test for four failure modes. The first test checks the integrity of the three line fuses. Assuming the three line fuses are all

OK, the PCU then performs a test for shorted SCRs/doubler packs. If this test indicates no shorted SCRs/doublers, the PCU then verifies that less than 5% of the value entered for “Rated Field Current” is attainable. The PCU then tests for open SCRs by passing current through the forward bridge followed by the reverse bridge, and finally checks polarity of voltage feedback. The result of the test is displayed on the SCDU after the test completes. The SCDU will light certain unique LED patterns on its display corresponding with the failure (see displays in the procedure that follows). The Fault Codes F910, F911, F912, and

F917 will not appear on the SCDU if the Error Disposition List is programmed so that they are not reported to the Fault List (see “Error Handling/Reporting” in the Operation Section).

WARNING

Armature current is circulated through the armature circuit during parts of the PCU diagnostics function. The

PCU will reduce the field current to zero on motors with a shunt field in order to minimize motor rotation. However, a permanent magnet motor must have its shaft locked mechanically prior to running the PCU diagnostics routine.

If the PCU detects significant motor voltage during the test, the PCU diagnostics function will abort.

The process for accessing the PCU diagnostics function is as follows:

❏ Use the ⇑ and

⇓ keys to select function # 998 from the function level. The

DATA Indicator is off during this step.

998

DATA

OFF

❏ Press the DATA/FCTN key to enter the "Data" level for function # 998. The

DATA Indicator is GREEN to indicate that this function is currently being accessed. The SCDU prompts the user to press the ENTER key by displaying: entr

DATA

GREEN

3/21/96 58 Power Conversion Unit Diagnostics

3/21/96

Maintenance

❏ Press the ENTER key to actually start the PCU diagnostics. While the PCU is performing the diagnostics test, the SCDU displays:

4 test

DATA

GREEN

The PCU will not begin the diagnostic routines if a SEVERE PCU FAULT exists. The PCU will declare a SEVERE FAULT under several conditions including an IST fault, power supply failure, line sync loss, low line, or DCU failure. If a SEVERE FAULT exists when the PCU starts the diagnostic tests, the SCDU displays: sflt

DATA

GREEN

➊

Severe faults can only be cleared by pressing the RESET button on the Main CPU Control PCB or by cycling power to the drive.

❷

If the display stays on 'tESt' and the contactor doesn't pick up, there is a fault in the motor field connections.

❸

There are 4 different kinds of displays possible on the SCDU after the

PCU diagnostic routines complete. If all tests indicate that there are no failed power components (SCRs and fuses), the SCDU displays: pass

DATA

GREEN

Power Conversion Unit Diagnostics 59

4 Maintenance

❏ Press the DATA/FCTN key to exit the PCU diagnostic routine and return to the "Function" level. The SCDU displays:

998

DATA

OFF

➊

If the PCU detects one or more open AC fuses, it displays the fault code for a blown fuse ( F910 ): f910

DATA

OFF

❷

If the PCU detects one or more shorted SCR/doubler packs, the SCDU displays the fault code for a shorted doubler ( F911 ): f911

DATA

OFF

❏ Remove power from the drive, consult the Maintenance Guide, or call

MagneTek for assistance, to replace the SCR(s) that are shorted, and perform this test again.

If the PCU detected one or more open SCR/doubler packs, the SCDU displays the fault code for an open SCR/doubler pack ( F912 ): f912

DATA

OFF

❏ Remove power from the drive, consult the Maintenance Guide, or call

MagneTek for assistance, to replace the SCR(s) that are open, and repeat this test until the SCDU displays the 'PASS' massage.

3/21/96 60 Power Conversion Unit Diagnostics

– – –

– –

–

Fault/Error Name

Control Power Loss

●

Line Fuse(s) Open

Maintenance

Troubleshooting

Guide

This section lists the fault and error codes along with their possible causes and corrective actions. The possible cause(s) are listed in order of most likely to least likely. The corrective actions are listed in order of simplest to most difficult to perform.

Use the procedures listed in Section 3, Operation, to display and clear the faults and errors listed in Table 3.

NOTES

●

............... Bulleted Faults/Errors require a microprocessor reboot. Press the RESET button located on the main PCB or remove and reapply 120VAC control power.

DCU ........

(Drive Control Unit) This is the microprocessor that primarily executes the PAC code. This code is customized to user applications.

PCU ........

(Power Conversion Unit) This is the microprocessor that primarily executes the standard code and controls the firing of the SCRs.

EPROM ... Type of memory chip, “Erasable Programmable Read Only

Memory”.

PAC ........

DSD custom software, “Programmable Application Control” language.

Table 3. Troubleshooting Guide

Fault/Error

Code

P.L.

Possible Causes &

Corrective Actions

120 VAC control power is not present.

➊

Check any circuit breakers or fuses in this circuit. See “Replacing Fuse(s)”/

Maintenance Section.

❷

Check connection at J11. See

“Connectors on Drive Control PCB”/

Maintenance Section.

Each line indicates a blown fuse.

➊

Check for blown fuses. See “Replacing

Fuse(s)”/Maintenance Section.

❷

Check cable connection at J14. See

“Connectors on Drive Control PCB”/

Maintenance Section.

❸

Check for proper 3 phase voltage applied.

4

3/21/96

Troubleshooting Guide 61

4 Maintenance

62

Fault/Error

Code

– – –

13

14

15

16

17

21

Table 3. Troubleshooting Guide – Continued

Fault/Error Name

●

Line Fuses Open

● Bad Instruction

● Exception Vector 10

● Exception Vector 11

● Privilege Violation

DCU Divide By Zero

● Watchdog Trip

Possible Causes &

Corrective Actions

Application of 120 VAC control power with 3 phase power off.

➊

Remove 120 VAC control power and reapply after 3 phase power is present.

❷

New PCU EPROMs that allow control power to be applied without 3 phase present is available. Contact MagneTek.

Main PCB Hardware.

Invalid DCU Instruction.

➊

Unplug and reseat all cables and socketed devices.

❷

Replace main drive PCB. See “Replacing

Drive Control PCB”/Maintenance Section.

❸

Electromagnetic noise near the drive’s main PCB may be the cause. Record the situations during which this fault occurred. Eliminate noise.

Divide By Zero

➊

If this fault occurs a few times on powerup, then it can be ignored if the drive is operating properly. The purpose of this fault is to assist in checking new code.

Disable this unnecessary fault by using

Function 801/See “Error Handling &

Reporting”/Operation Section. Remove this fault from both the fault list and the error list.

❷

If this error occurs at times other than at power-up, or if the drive is not operating properly, then the drive’s PAC code should be reviewed. The fault producing

Block can be identified by accessing the

Error or Fault List.

Main PCB Hardware

➊

Unplug and reseat all cables and socketed devices.

❷

Replace main drive PCB. See “Replacing

Drive Control PCB”/Maintenance Section.

❸

Electromagnetic noise near the drive’s main PCB may be the cause. Record the situations during which this fault occurred. Eliminate noise.

Troubleshooting Guide

3/21/96

3/21/96

Fault/Error

Code

22

23

24

25

26

96

97

Maintenance

Table 3. Troubleshooting Guide – Continued

Fault/Error Name

DCU Reserved Interrupt

DCU Uninitialized Interrupt

DCU Trace Exception

DCU User Exception

DCU Spurious Exception

Web Break

Overspeed Trip

Possible Causes &

Corrective Actions

Main PCB Hardware

➊

Unplug and reseat all cables and socketed devices.

❷

Replace main drive PCB. See “Replacing

Drive Control PCB”/Maintenance Section.

❸

Electromagnetic noise near the drive’s main PCB may be the cause. Record the situations during which this fault occurred. Eliminate noise.

This fault is declared by the WEBB_0 PAC block. This is a backup level web break detection fault and is not capable of detecting all valid web breaks.

➊

If an actual web break has not occurred, then the parameter for this fault may have to be adjusted. Functions 150, 151, and

152 are usually used to setup this fault.

This fault is declared by the TMON_0 PAC block.

➊

Function 41, “Overspeed Trip”, should normally be set to 110%. If this DC drive is used above base speed, then this overspeed trip point should be increased to allow for higher speeds.

❷

A tach loss could also cause this fault.

Check that the tach signal is reaching the drive, that tach wiring is correct, and that the tach is not damaged, loose, or cracked.

❸

Noise on the tach wires or airborne noise near the Main PCB can cause this fault.

Check that tach wiring does not run parallel to power wiring. Tach wires should be run with signal level wires only.

❹

A speed command that exceeds the tach overspeed setting can cause this fault.

Reduce speed reference or increase overspeed setpoint. A trim to the speed reference could cause an overspeed.

Check that speed trims are limited properly.

➎

An improperly tuned speed regulator can cause an overspeed. Check tuning.

4

Troubleshooting Guide 63

4 Maintenance

Fault/Error

Code

97

(continued)

98

99

100

101

102

103

Table 3. Troubleshooting Guide – Continued

Fault/Error Name

Tach Loss Trip

Reverse Tachometer Connection

Not a Number

Math Overflow

Math Underflow

Floating Point Divide By Zero

Possible Causes &

Corrective Actions

➏

This fault could be caused by this motor being pulled along by the load.

➐

Try running this DC drive in voltage feedback to see if this fault still occurs.

This fault is declared by the TMON_0 PAC block.

➊

This fault may be set too sensitive. On a

DC drive increase the setting of Function

42, “Volt Sense Level”, to 20 and increase the setting of Function 43, “Tach

Sense Level”, to 15.

❷

Check tach wiring for loose or improper connections both at tach and at drive.

❸

Check for a loose, damaged, or slipping tach coupling.

❹

Try running this DC drive in voltage feedback to see if this fault still occurs.

This fault is declared by the TMON_0 PAC block.

➊

Correct tach wiring at drive or at tach.

❷

Try running this DC drive in voltage feedback to see if this fault still occurs.

PAC Block Math Error

➊

If any of these faults occurs a few times on powerup, then it can be ignored if the drive is operating properly. The purpose of these faults is to assist in checking new code. Disable the unnecessary fault by using Function 801/See “Error Handling

& Reporting”/Operation Section. Remove this fault from both the fault list and the error list.

❷

If any of these errors occur at times other than powerup, or if the drive is not operating properly, then the drive’s PAC code should be reviewed. The fault producing Block can be identified by accessing the Error or Fault Lists.

64 Troubleshooting Guide

3/21/96

3/21/96

224

232

240

241

220

221

222

223

242

243

244

252

Fault/Error

Code

104

110

111

113

Maintenance 4

Table 3. Troubleshooting Guide – Continued

Fault/Error Name

Sign Error in Speed Regulator

Bad Thumbwheel Digit

Missing Thumbwheel Switch

● Missing PCU

●

68K ROM Bus Error

●

68K RAM Bus Error

●

68K NVRAM Bus Error

●

68K DPRAM Bus Error

●

LAN Bus Error

●

Unknown Bus Error

●

68K ROM Address Error

●

68K RAM Address Error

●

68K NVRAM Address Error

●

68K DPRAM Address Error

●

LAN Address Error

●

Unknown Address Error

Possible Causes &

Corrective Actions

Often caused by slipping nip or improper data entry to the drive.

➊

Regulator settings need adjusting.

❷

Check all parameters and inputs against application limits.

1. Thumbwheel switch connected directly to drive contains an invalid digit

2. Selected bank of Thumbwheel switches is not present.

➊

Check cables and connections.

❷

Check Bank Select jumper positions on the Thumbwheel Selector Switch

Assemblies.

Hardware Failure in the Power Conversion

Unit

➊

Replace main drive PCB board. See

“Replacing Drive Control PCB”/

Maintenance Section.

Hardware or Software Failure/Improper

Addressing Attempted

➊

Unplug and reseat all cables and socketed devices.

❷

Replace drive main PCB board. See

“Replacing Drive Control PCB”/

Maintenance Section.

Troubleshooting Guide 65

4 Maintenance

Fault/Error

Code

260

261

262

263

264

265

Table 3. Troubleshooting Guide – Continued

Fault/Error Name

Iteration Time-Out

Out of Sequence

Byte Time Out

Wrong File Type

Null Block Expected

User Canceled

Possible Causes &

Corrective Actions

YMODEM transfer is stopped. The drive has tried to send or receive a character and failed to do so within a specific timeout period.

➊

Verify that the serial cables are attached properly between the source PC and the drive.

❷

Verify that the PC has the correct serial communications settings for communications with a drive.

YMODEM transfer is stopped. YMODEM protocol has been violated by an out of sequence block.

➊

Cancel and try to start over again.

YMODEM transfer is stopped.

Same corrective actions as 260.

YMODEM transfer is stopped. The drive was sent a file whose file extension was not recognized. The drive will accept either a

.PRG file or a .PAR file.

➊

Cancel and try again with a valid file name.

YMODEM transfer is stopped. The

YMODEM protocol has been violated. A null block was expected but never received.

➊

Re-initialize up load procedures on the

YMODEM software and the drive and try again.

YMODEM transfer is stopped. A user has aborted the file transfer from the PC.

➊

Start again if desired.

66 Troubleshooting Guide

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3/21/96

Fault/Error

Code

266

267

268

269

270

271

272

273

274

Maintenance

Table 3. Troubleshooting Guide – Continued

Fault/Error Name

Unexpected Null Block

Wrong S-Record Type

Bad S-Record Check

Bad S-Record End Record

File Too Large

Wrong File Name

No Memory Here

NVRAM Protected

Motor Running

Possible Causes &

Corrective Actions

YMODEM transfer is stopped. The

YMODEM protocol has been violated. A null block was received but not expected.

➊

Re-initialize up load procedures on the

YMODEM software and the drive and try to start again.

YMODEM transfer is stopped. The program information data is corrupted.

➊

Try again from backup file.

❷

Recompile PAC program.

YMODEM transfer is stopped. The file to be transmitted is too large to fit in drive’s memory.

➊

PAC program is too large. Redo, recompile and try again.

YMODEM transfer is stopped. The parameter file sent does not belong to the drive.

➊

Verify the file belongs to the drive and try again.

YMODEM transfer is stopped. The file attempted to write to non-existent memory.

➊

Verify drive type in PAC file is correct.

❷

Replace drive PCB or flash ROM chips.

See “Replacing Drive Control PCB”/

Maintenance Section.

YMODEM transfer is stopped. The

NVRAM switch is set to write protect the

NVRAMs.

➊

Put the NVRAM Protection switch to the

“off” position and retry transfer.

YMODEM transfer is stopped. The motor was running during an operation that required the motor to be stopped.

➊

Verify that the motor is not being pulled by its load.

❷

Stop motor and retry the transfer.

4

Troubleshooting Guide 67

4 Maintenance

Fault/Error

Code

274

(continued)

275

301

302

303

304

295

296

298

300

305

306

307

308

291

292

293

294

276

277

278

290

68

Table 3. Troubleshooting Guide – Continued

Fault/Error Name

Not a Parameter File

Flash RAM Program 00 Error

Flash RAM Program FF Error

Flash RAM Verify Error

Board Status Bus Error

Board Control Bus Error

D/A 1 Bus Error

D/A 2 Bus Error

A/D Bus Error

Clock Bus Error

Tachometer Bus Error

Expansion 2 Bus Error

Board Status Address Error

Board Control Address Error

D/A 1 Address Error

D/A 2 Address Error

A/D Address Error

Clock Address Error

Tachometer Address Error

Expansion 1 Address Error

Expansion 2 Address Error

Possible Causes &

Corrective Actions

❸

If drive has failed to stop motor, replace main drive PCB board. See “Replacing

Drive Control PCB”/Maintenance Section.

YMODEM transfer is stopped. The .PAR

file is corrupt or not in the correct format to be a .PAR file.

➊

Re-down load with backup .PAR file.

YMODEM transfer is stopped. The .PRG

file does not agree with the PROMs installed in the drive.

➊

Replace Main drive PCB or flash ROM chips. See “Replacing Drive Control

PCB”/Maintenance Section.

CPU halted.

Communications Failure.

➊

Call MagneTek for field service assistance.

Troubleshooting Guide

3/21/96

3/21/96

Fault/Error

Code

800

801

802

803

804

805

806

900

901

902

Maintenance

Table 3. Troubleshooting Guide – Continued

Fault/Error Name

●

LAN Hardware Error

Maximum LAN Retries Exceeded Error

Illegal LAN Message Type Error

LAN Broadcast Message Missed Error

LAN Directed Message Missed Error

LAN-No Transmit Room

LAN-No Receive Room

PCU Loop Fault

Possible Causes &

Corrective Actions

Local Area Network (LAN) Error

➊

Check T connectors.

❷

Verify 93 ohm value for terminating resistors.

❸

Verify that cable lengths do not exceed recommended values.

❹

Verify that drive is properly grounded.

Instantaneous Overcurrent Trip (IST)

●

Power Supply Fault

1. a. Coast Stop Circuit was opened.

b. Contactor Failure (coil or interlock contact).

2. Contact pilot relay failure.

➊

Check coast stop circuit and repair.

Check contactor and repair.

❷

Replace Power Supply. See “Replacing the Power Supply”/Maintenance Section.

1. Short circuit in motor armature wiring.

2. Poor current regulator tuning.

➊

Check motor armature and repair as necessary.

❷

Check current regulator settings.

1. Short circuit in remote power wiring: a. +5V to tachometer b. +24V to 24VDC logic c. +/–15V to Aux circuits

2. Shorts on internal boards.

3. Loss of 115 VAC power

4. Failed power supply

(See Corrective Actions on next page)

4

Troubleshooting Guide 69

4 Maintenance

Fault/Error

Code

902

(continued)

903

904

905

Table 3. Troubleshooting Guide – Continued

Fault/Error Name

●

Line Sync Loss Fault

Low Line Fault

Field Loss Fault

Possible Causes &

Corrective Actions

➊

Check wiring and repair as necessary.

❷

Check boards for shorts and replace as necessary.

❸ a. Check output of 1PT b. Check and replace fuses as necessary.

See “Replacing Fuse(s)”/Maintenance

Section.

c. Check wiring and repair as necessary.

d. Check transformer and replace as necessary

❹

Replace DSD Power Supply. See

“Replacing the Power Supply”/

Maintenance Section.

1. Excessively noisy or intermittent power connections.

2. Faulty voltage dividers on Armature

Interface PCB.

3. Loss of 3 phase or 1 phase power.

➊

Check power input for problems.

❷

Replace Armature Interface PCB. See

“Replacing Armature Interface

PCB”/Maintenance Section.

1. Power line dips.

a. 1 cycle below 50%.

b. 2 cycles below 70%.

c. 3 cycles below 80%.

2. Loss of power fuse.

➊

Check input power for problems.

❷

Check for blown fuses. See “Replacing

Fuse(s)”/Maintenance Section.

1. Motor field or wiring open.

2. a. Wrong trip level set.

b. Field Economy set too low.

➊

Check motor and wiring.

❷ a. Check trip level setting.

b. Change economy setting as required.

70 Troubleshooting Guide

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3/21/96

Fault/Error

Code

906

907

908

909

Maintenance

Table 3. Troubleshooting Guide – Continued

Fault/Error Name

DCU Loss Fault

Thermistor Fault

Over Temperature Fault

Excessive Current Ripple Fault

Possible Causes &

Corrective Actions

1.

Too much code in the faster scans and/or excessive DSD LAN traffic caused the PCU to run out of scan time.

2.

DCU microprocessor failure.

➊

Reduce the number of LAN broadcasts or reduce the number of directed messages to this drive.

❷

PAC code might need to be revised in order to optimize the

PAC execution time (contact Magnetek)

❸

Replace main PCB. See “Replacing

Drive Control PCB”/Maintenance

Section.

Thermistor on heat sink open or shorted.

➊

Check connections.

❷

Check Thermistor with ohmmeter.

❸

Replace Thermistor.

1.

Too high ambient temperature.

2.

Clogged air filter in cabinet.

3.

Clogged heat sinks.

4.

Cooling fan failure.

➊

Check for cause of increased ambient temperature.

❷

Clean heat sink fins. See

“Preventive Maintenance”.

❸

Check Cooling Fan. See “Replacing the Fan”/Maintenance Section.

1.

a. Loose connections in power circuit. b. Loose connections in gate leads or from DSD Drive Control PCB to

Armature Interface PCB.

2.

a. Faulty Armature Interface PCB.

b. Faulty DSD Control PCB.

3.

Poor current or speed regulator tuning.

➊

Check all connections inside the power cube.

❷

Run self-diagnostics to check for bad

SCRs.

4

Troubleshooting Guide 71

4 Maintenance

72

Fault/Error

Code

909

(continued)

910

911

912

915

Table 3. Troubleshooting Guide – Continued

Fault/Error Name

●

Blown Fuse Fault

●

Shorted or leaky SCR

●

Open SCR Fault

●

Bad Set-Up Parameter Fault

Possible Causes &

Corrective Actions

❸ a. Replace Armature Interface PCB.

See “Replacing Armature Interface

PCB”/Maintenance Section.

b. Replace main PCB. See “Replacing

Drive Control PCB”/Maintenance

Section.

Main Fuses blown:

1.

Power Circuit problem; shorts or loose connections.

2.

Faulty SCR.

3.

Poor regulator tuning.

➊

Check power circuit for shorts or loose connections and repair.

❷

Test for defective SCR(s) and replace as necessary.

❸

See “Replacing Fuse(s)”/Maintenance

Section. PERFORM THIS STEP

LAST.

1. Loose gate lead connector.

3.

Faulty Armature PCB.

➊

Replace faulty SCR.

❷

Replace Armature Interface PCB.

See “Replacing Armature Interface

PCB”/Maintenance Section.

One or more of the drive’s set-up parameters is not in the range of the HP selected:

●

●

●

●

●

●

Rated AC line volts setting is out of range.

Rated Motor Armature Volts setting is out of range.

Rated Load Current Setting is out of range.

Rated Source Frequency Setting is out of range.

Rated Field Current setting is out of range.

IST setting is too high.

➊

Access the Fault or Error List to determine the faulty parameter(s), and the corresponding fault(s)/error(s).

Troubleshooting Guide

3/21/96

3/21/96

Fault/Error

Code

916

917

918

919

Maintenance 4

Table 3. Troubleshooting Guide – Continued

Fault/Error Name

Forcing Fault

●

Reverse Armature Voltage Connection Fault The polarity of the armature voltage feedback is reversed or missing.

➊

Check polarity of wiring.

❷

Replace Armature Interface PCB.

See “Replacing Armature Interface PCB”/

Maintenance Section.

IST Setting Error

Possible Causes &

Corrective Actions

No rotation was selected while the loop contactor was energized.

➊

Stop drive and re-enter Forcing mode.

Setting for IST is above hardware limitations of approximately 325% of rated drive armature current.

➊

Check setting and adjust as required.

Line Voltage Setting Error Setting for Rated Line Voltage is not within the acceptable range of 160-525 VAC or zero (which will allow the drive to decide if the input voltage is either 230 or 460 VAC).

➊

Check setting and adjust as required.

Troubleshooting Guide 73

4 Maintenance

Fault/Error

Code

920

921

922

923

Table 3. Troubleshooting Guide – Continued

Fault/Error Name

Load Voltage Setting Error

Bridge Fault

Frequency Setting Error

Load Current Setting Error

Possible Causes &

Corrective Actions

Setting for Rated Armature Voltage is not within the acceptable range of 150-700 Vdc.

If a setting of zero is selected, the drive will sense the line voltage and output a corresponding Armature Voltage.

➊

Check setting and adjust as required.

1.

Connector J14 is out of place.

2.

Faulty Armature Interface PCB.

3.

Faulty DSD Drive Control PCB.

➊

Verify J14 is in proper location.

❷

Replace Armature Interface PCB. See

“Replacing the Armature Interface PCB”/

Maintenance Section.

❸

Replace Drive main PCB.

See “Replacing DSD Drive Control

PCB”/Maintenance Section.

Setting for Source Frequency is not within the acceptable range of 48 to 62 Hz or zero

(the drive will default to 60 Hz if zero is entered).

➊

Check setting and adjust as required.

Setting for Rated Armature Current is not within a range of 1/8 to 2 times the nominal bridge current rating. Also see the possible causes for F921.

➊

Check setting and adjust as required.

74 Troubleshooting Guide

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3/21/96

Fault/Error

Code

924

925

926

Maintenance 4

Table 3. Troubleshooting Guide – Continued

Fault/Error Name

Field Current Setting Error

Field Sense Resistor Fault

PCU Watchdog Timeout Fault

Possible Causes &

Corrective Actions

Setting for Rated Field Current is not within a range based on the version of Field

Interface PCB present in the power cube.

See “Field Interface PCB Ratings”/

Maintenance Parts List. Also see the possible causes for F925.

➊

Check setting and adjust as required.

1.

Connector J13 is out of place.

2.

Faulty Field Interface PCB.

3.

Faulty DSD Drive Control PCB.

➊

Verify J13 is in proper location.

❷

Replace Field Interface PCB.

❸

Replace Drive main PCB.

See “Replacing DSD Drive Control

PCB”/Maintenance Section.

1.

Problem with either hardware or software on the DSD Drive Control

PCB.

2.

Ambient noise near the drive's main

PCB.

➊

Electromagnetic noise near the drive's main PCB may be the cause. Record the situations during which this fault occurred. Eliminate noise.

❷

Contact MagneTek for assistance.

Troubleshooting Guide 75

4 Maintenance

SEE DETAIL

GND

F1 F2 F3 F4

DETAIL OF FUSE

INSTALLATION (F1-F4)

APPLY

PENETROX

LOCKWASHER

1/4-20 NUT

TORQUE TO

70 IN LBS

BUS BAR

FLAT

WASHER

APPLY PENETROX

LOCKWASHER

LA-7

76 Replacing Fuses

Figure 10. DSD Drive Fuse Replacement

3/21/96

3/21/96

Maintenance

If you suspect that one of the fuses, the DSD Drive Control PCB, the fan, or the power supply needs to be replaced, follow the procedures in this section.

4

WARNING

Before performing any maintenance, disconnect all input and output power from the DSD drive.

Replacing

Fuse(s)

To replace one or more fuses, follow this procedure:

❏ Disconnect all input and output power to the DSD drive.

❏ Pull the handle on the right side of the DSD Drive Control PCB (see Figure

11) towards you and swing the top chassis clear of the lower chassis.

❏ Remove both 1/4-20 hex nuts from the suspected fuse(s) (see Figure 10).

❏ Remove the lockwashers and flat washers (see Figure 10).

❏ Apply Penetrox or equivalent Copolymer oil (PN# 05G10017-001) to the surfaces between the fuses and the bus bar to ensure a good electrical connection.

❏ Replace flat washers, lockwashers, and hand tighten 1/4-20 nuts (see

Figure 10.)

❏ Torque 1/4-20 nuts to 70 inch pounds.

❏ Close top chassis.

❏ Reconnect input and output power.

❏ See Section 3, Operation, for start-up procedure.

Replacing Fuses 77

4 Maintenance

+

U39

U48

U40

U49

HANDLE

PCB

MOUNTING

SCREWS

Figure 11. DSD Drive Control PCB

78 Replacing DSD Drive Control PCB

PCB

MOUNTING

SCREWS

LA-5

3/21/96

Maintenance 4

Replacing DSD

Drive Control

PCB

CAUTION

The DSD Drive Control PCB has electrostatic sensitive components. You must follow Electrostatic Discharge (ESD) procedures to protect the components.

To replace the DSD Drive Control PCB, follow this procedure:

NOTE: You may need a helper to hold the PCB during replacement.

WARNING

Before performing any maintenance, disconnect all input and output power from the DSD drive.

❏ Remove all input and output power to the DSD drive.

❏ Note where all cables/wires are connected, especially those connected to

TB1 (see Figure 11). Label any cables/wires, as necessary, to insure proper reinstallation.

Table 4. Connectors on Drive Control PCB

Connector Type Function

J1

J2

J3

J11

J12

J13

J14

TB1

DB-9

RJ12 Connector

BNC Connector

20 Pin Header

40 Pin Header

10 Pin Header

40 Pin Header

Screw Terminals

(12 Gauge Wire)

Bare Screw Terminal

* RS422 Communications Port.

* RS 232 Port for Portable Control/

Display Unit (PCDU).

Optional LAN Connection.

Power Supply, E-Stop, Motor Thermal

Guard, Loop Contactor Control.

Connector for auxiliary Interface

Card (optional).

Field Control.

Armature Firing Control.

Analog and Digital Local I/O.

TB11 Earth Ground

* Either connector J1 or J2 will be present on the board.

3/21/96

Replacing DSD Drive Control PCB 79

4 Maintenance

❏ Remove cables/wires connected to J1, J2, J3, J11, J13, J14, TB1 and TB11

(see Figure 11).

❏ Remove flash RAM U39, U40, U48, and U49 to reinstall on new Board (see figure 11)

❏ Remove the nine mounting screws (see Figure 11).

❏ Remove the DSD Drive Controller PCB.

❏ Position the replacement DSD Drive Control PCB over the mounting holes.

❏ Fasten the nine PCB mounting screws.

❏ Replace cables/wires previously connected to J1, J2, J3, J11, J13, J14, TB1 and TB11.

❏ Reconnect input and output power.

❏ See Section 3, Operation, for start-up procedure.

80 Replacing DSD Drive Control PCB

3/21/96

Maintenance

Replacing the Fan

To replace the DSD Drive Fan, follow the procedure given for the HP of your

DSD drive:

DSD 406 or 412:

15-30 HP, 230V,

30-60 HP, 460V

NOTE : Observe where all cables/wires are connected, to insure proper reinstallation.

❏ Disconnect all input and output power to the DSD drive.

❏ Remove four, #8-32 fan bracket mounting, screws from the DSD chassis as illustrated in Figure 12. Loosen, do not remove, two #8-32 positioning screws from top of fan mounting bracket as illustrated in Figure 12. Fan bracket can be removed from DSD chassis.

❏ Unplug cord assembly from connector on fan.

❏ Fan can be removed from bracket by unscrewing four #6-32 screws and locknuts. The #6-32 screws and locknuts mount both the fan and the fan guard to the fan bracket.

❏ Position new fan over the mounting holes on the inside of the fan bracket.

Note air flow arrow. Position fan guard over mounting holes on the outside of the fan bracket and fasten with #6-32 screws and locknuts.

❏ Position fan bracket in a manner that the cord assembly can be plugged into the fan.

❏ Position fan bracket with the two position screws so the four, #8-32 fan bracket mounting, screws can be fastened. Refer to Figure 12.

❏ Reconnect input and output power.

❏ See Section 3, Operation, for start-up procedure.

4

3/21/96

Replacing the Fan 81

4 Maintenance

TB 42

CORD

ASSEMBLY

FAN BRACKET

MOUNTING

SCREWS

FRONT VIEW

POSITIONING

SCREWS

BOTTOM VIEW

20-60 HP UNITS

#8 - 32

SCREWS

FAN BRACKET

MOUNTING

SCREWS

FRONT VIEW

BOTTOM VIEW

150-200 HP UNITS

CORD

ASSEMBLY

#8 - 32

SCREW

(2 PL)

BOTTOM VIEW

75-125 HP UNITS

Figure 12. Replacing DSD Fan

82 Replacing the Fan

GRILL

PARTIAL

RIGHT

SIDE VIEW

LA-82

3/21/96

Maintenance

DSD 406 or 412:

40-60 HP, 230V,

75-125 HP, 460V

❏ Disconnect all input and output power to DSD drive.

❏ Remove grill and fan by unscrewing two #8-32 screws as illustrated in

Figure 12. Be careful when removing fan as cord assembly will be plugged into fan.

❏ Unplug cord assembly from fan.

❏ Plug cord assembly into new fan.

❏ Fit two #8-32 screws, with star washers and split washers, through grill and new fan, as illustrated in Figure 12. Note air flow arrow. Position fan over mounting holes and tighten the screws.

❏ Reconnect input and output power.

❏ See Section 3, Operation, for start-up procedure.

4

DSD 412 only:

75-100 HP, 230V,

150-200 HP, 460V

❏ Disconnect all input and output power to DSD drive.

❏ Remove grill by unscrewing four #8-32 screws and locknuts.

❏ Remove fan by unscrewing five #8-32 screws and locknuts.

❏ Unplug cord assembly from fan.

❏ Plug cord assembly into new fan.

❏ Position new fan over mounting holes and reinstall the five #8-32 screws and locknuts. Note the air flow arrow.

❏ Position fan grill over new fan and reinstall the four #8-32 screws and locknuts.

❏ Reconnect input and output power.

❏ See Section 3, Operation, for start-up procedure.

3/21/96

Replacing the Fan 83

4 Maintenance

TB3

TB42 POWER SUPPLY

POWER SUPPLY

MOUNTING SCREWS

TB41

DSD DRIVE CONTROL

PCB STANDOFFS

LATCH

LA-6

84 Replacing the Power Supply

Figure 13. DSD Power Supply Replacement

3/21/96

Maintenance

Replacing the

Power Supply

To replace the DSD power supply, follow this procedure.

CAUTION

The DSD Drive Control PCB has electrostatic sensitive components. You must follow Electrostatic Discharge (ESD) procedures to protect the components.

4

WARNING

Before performing any maintenance, disconnect all input and output power from the DSD drive.

❏ Disconnect all input and output power from the DSD drive.

❏ Remove the DSD Drive Control PCB (see previous procedure).

❏ Note which cables/wires are connected to TB3, TB41, and TB42 on the

DSD Power Supply (see Figure 13). Label any cables/wires, as necessary, to insure proper reinstallation.

❏ Remove cables/wires from TB3, TB41, and TB42.

❏ Remove six mounting screws (see Figure 13).

❏ Place new power supply on mounting holes.

❏ Fasten the six power supply mounting screws.

❏ Connect cables/wires to TB3, TB41, and TB42.

❏ Replace DSD Drive Control PCB.

❏ Reconnect input and output power.

❏ See Section 3, Operation, for start-up procedure.

3/21/96

Replacing the Power Supply 85

4 Maintenance

NEG GND L1 L2 L3 POS

CURRENT

SENSOR

ARMATURE INTERFACE PCB

RED

WHT

BLK

TB6

G2

Q1

G1 G2

Q3

G1 G2

Q5

G1

E2

E4

E6 E8 E10 E12

THERMISTOR

WIRES

TB5

(+)

(–)

(N)

6 5 4 3 2 1

TB6

ALIGNING

PEG

MOUNTING SCREW

(9 TOTAL)

J24

E13 E15 E17 E19 E21 E23

G1

Q4

G2 G1

Q6

G2 G1

Q2

G2

A3

TB4

CONNECTORS FOR

MOTOR ARMATURE

SENSOR FEEDBACK

LA-101

Figure 14. DSD Armature Interface PCB Replacement

86 Replacing the DSD Armature Interface PCB

3/21/96

Maintenance

Replacing the

DSD Armature

Interface PCB

CAUTION

The DSD Armature Control PCB contains electrostatic sensitive components. You must follow Electrostatic Discharge

(ESD) procedures to protect the components.

To replace the DSD Drive Armature Interface PCB, follow this procedure:

WARNING

Before performing any maintenance, disconnect all input and output power from the DSD drive.

❏ Remove all input and output power to the DSD drive.

❏ Locate the Armature Interface PCB. This board is located behind the door assembly.

❏ Allow the DSD drive to sit for a few seconds to allow the SCRs to discharge.

❏ Remove the J24 connector (see Figure 14).

❏ Remove (unscrew) the wire connectors to the motor armature sensor feedback wires at TB5 (see Figure 14).

❏ Disconnect the SCRs (Q1 through Q6) gate leads (12 leads) using a needle nose pliers. Six leads are located on the top and six on the bottom section of the armature PCB.

❏ Disconnect (unscrew) the thermistor wires at terminals 4 and 5 at TB6 (see

Figure 14).

❏ Disconnect the current sensor (see Figure 14).

❏ Remove the mounting screws (9 screws).

❏ Hold board from top left corner and center bottom and pull out.

❏ Install new board. Line up new board with peg (see Figure 14), and push new board in making sure not to pinch any wires under the board.

❏ Install the mounting screws (Torque specification of 5-1/2 inch-pounds).

❏ Reconnect the current sensor.

❏ Reconnect the thermistor wires at terminals 4 and 5 at TB6.

4

3/21/96 Replacing the DSD Armature Interface PCB 87

4 Maintenance

❏ Reconnect the SCR gate leads making sure they are not crossed, and are pushed all the way in (gate leads will first “click” and can then be pushed in for an additional 1/8” to 1/64”).

❏ Reconnect the Armature sensor feedback wires making sure to observe the polarity. If these leads are connected in reverse, a Fault 917 (Reverse

Armature Voltage Connection Fault) will occur.

❏ Reconnect the J24 connector.

❏ Apply power to the drive.

88 Replacing the DSD Armature Interface PCB

3/21/96

Maintenance

DSD 406 and 412

Spare Parts List

The parts in Table 5 are replacements for DSD 406 / 412 230 Volt drives.

The parts in Table 6 are replacements for DSD 406 / 412 460 Volt drives.

4

Description

Drive Control PCBA

Armature Interface PCBA

DSD 406: 1 - 15 HP

20 - 30 HP

40 - 60 HP

DSD 412: 1 - 15 HP

20 - 30 HP

40 - 60 HP

75 - 100 HP

Field Interface PCBA

0.2 - 1.9 A

0.8 - 4.0 A

1.4 - 6.9 A

2.0 - 9.6 A

2.0 - 16 A

5.0 - 24 A

Power Supply PCBA

Snubber PCBA

1 - 7.5 HP

10 - 15 HP

20 - 30 HP

40 - 60 HP

75 - 100 HP (DSD 412 only)

SCR

1 - 15 HP

20 - 30 HP

40 - 60 HP (DSD 412 only)

SCR

40 - 60 HP (DSD 406 only)

Table 5. 230 Volt Drives Spare Parts

Ref. Design.

A1

A2

Qty/Drive

1

1

A3

A4

A5

DSD 406: Q1-3

DSD 412: Q1-6

1

1

1

DSD 406: 3

DSD 412: 6

SCR

75 - 100 HP (DSD 412 only)

Q1, 3, 5

Q2, 4, 6

Q1-12

3

3

12

Part Number

46S02975-0202

46S03049-0010

-0020

46S02976-0040

46S02976-0010

-0020

-0030

46S03088-0010

46S03046-0010

-0020

-0030

-0040

-0050

-0060

05P00090-0293

46S03020-0010

-0020

-0030

46S03017-0010

46S03089-0010

05P00050-0409

-0410

-0412

05P00050-0446

-0447

46S03214-0010

3/21/96

Spare Parts List 89

4 Maintenance

Table 5. 230 Volt Drives Spare Parts - Continued

Description

Fan / Guard

1 - 10 HP

15 - 30 HP

40 - 60 HP

75-100 HP (DSD 412 only)

Current Transducer

1 - 7.5 HP

10 - 15 HP

20 - 30 HP

40 - 60 HP

75 - 100 HP (DSD 412 only)

Field Power Module

AC Line Fuse

1 HP (10 A)

1.5 - 2 HP (12 A)

3 - 5 HP (35 A)

7.5 - 10 HP (50 A)

15 HP (70 A)

20 - 25 HP (125 A)

30 HP (150 A)

40 - 50 HP (200 A)

60 HP (200 A)

75 - 100 HP (400 A) (DSD 412 only)

DC Bus Fuse (DSD 412 Only)

1 HP (10 A)

1.5 HP (12 A)

2 HP (15 A)

3 - 5 HP (50 A)

7.5 - 10 HP (70 A)

15 HP (100 A)

20 - 25 HP (150 A)

30 HP (200 A)

40 - 50 HP (250 A)

60 HP (300 A)

75 HP (400 A)

100 HP (500 A)

Burden Resistor

Power Range Resistor

Ref. Design.

B1

U1

Q7

F1-3

F4

R4

R5

Qty/Drive

1

1

1

1

1

3

1

Part Number

None

05P00016-0048

-0012

-0008

05P00217-0015

-0014

-0013

-0012

-0020

05P00050-0442

05P00017-0387

-0349

-0226

-0227

-0155

-0228

-0166

-0179

-0220

-0234

05P00017-0387

-0349

-0243

-0227

-0155

-0178

-0166

-0179

-0220

-0366

-0234

-0235

See Table 7

See Table 8

90 Spare Parts List

3/21/96

Maintenance 4

Description

Drive Control PCBA

Armature Interface PCBA

DSD 406: 2 - 30 HP

40 - 60 HP

DSD 412:

75 - 125 HP

2 - 30 HP

40 - 60 HP

75 - 125 HP

150 - 200 HP

Field Interface PCBA

0.2 - 1.9 A

0.8 - 4.0 A

1.4 - 6.9 A

2.0 - 9.6 A

2.0 - 16 A

5.0 - 24 A

Power Supply PCBA

Snubber PCBA

2 - 15 HP

20 - 30 HP

40 - 60 HP

75 - 125 HP

150 - 200 HP (DSD 412 only)

SCR

2 - 30 HP

40 - 60 HP

75 - 125 HP (DSD 412 only)

SCR

75 - 125 HP (DSD 406 only)

Table 6. 460 Volt Drives Spare Parts

Ref. Design.

A1

A2

Qty/Drive

1

1

A3

A4

A5

DSD 406: Q1-3

DSD 412: Q1-6

1

1

1

DSD 406: 3

DSD 412: 6

Q1, 3, 5

Q2, 4, 6

Q1-12

3

3

12 SCR

150 - 200 (DSD 412 only)

Fan

2 - 25 HP

30 - 60 HP

75 - 125 HP

150 - 200 HP (DSD 412 only)

B1 1

Part Number

46S02975-0202

46S03049-0010

-0020

46S02976-0040

46S02976-0010

-0020

-0030

46S03088-0010

46S03046-0010

-0020

-0030

-0040

-0050

-0060

05P00090-0293

46S03020-0010

-0020

-0030

46S03017-0010

46S03089-0010

05P00050-0409

-0410

-0412

05P00050-0446

-0447

46S03214-0010

None

05P00016-0048

-0012

-0008

3/21/96

Spare Parts List 91

4 Maintenance

Table 6. 460 Volt Drives Spare Parts - Continued

Description

Current Transducer

2 - 15 HP

20 - 30 HP

40 - 60 HP

75 - 125 HP

150 - 200 HP (DSD 412 only)

Field Power Module

AC Line Fuse

2 HP (10 A)

3 - 5 HP (12 A)

7.5 - 10 HP (35 A)

15 - 20 HP (50 A)

25 - 30 HP (70 A)

40 - 50 HP (125 A)

60 HP (150 A)

75 - 100 HP (200 A)

125 HP (200 A)

150 - 200 HP (400 A) (DSD 412 only)

DC Bus Fuse (DSD 412 Only)

2 HP (10 A)

3 HP (12 A)

5 HP (15 A)

7.5 - 10 HP (50 A)

15 - 20 HP (70 A)

25 - 30 HP (100 A)

40 - 50 HP (150 A)

60 HP (200 A)

75 - 100 HP (250 A)

125 HP (300 A)

150 HP (400 A)

200 HP (500 A)

Burden Resistor

Power Range Resistor

Ref. Design.

U1

Q7

F1-3

F4

R4

R5

Qty/Drive

1

1

1

1

3

1

Part Number

05P00217-0015

-0014

-0013

-0012

-0020

05P00050-0442

05P00017-0387

-0349

-0226

-0227

-0155

-0228

-0166

-0179

-0220

-0234

05P00017-0387

-0349

-0243

-0227

-0155

-0178

-0166

-0179

-0220

-0366

-0234

-0235

See Table7

See Table 8

92 Spare Parts List

3/21/96

Maintenance 4

230V

HP Rating

460V

40

50

60

75

100

15

20

25

30

5

7.5

10

—

2

3

1

1.5

75

100

125

150

200

30

40

50

60

10

15

20

25

5

7.5

2

3

Table 7. Burden Resistor

Part No.

Description

05P00225-2250 64.9 ohms, 1% metal film, 1/4 Watt.

05P00225-2250

05P00225-2260 76.8 ohms, 1% metal film, 1/4 Watt.

05P00225-2260

05P00225-2260

05P00225-2260

05P00225-1610 38.3 ohms, 1% metal film, 1/4 Watt.

05P00225-1610

05P00225-1610

05P00225-3600 9.53 ohms, 1% metal film, 1/4 Watt.

05P00225-3600

05P00225-3600

05P00041-0703 4.32 ohms, 1% metal film, 3 Watt.

05P00041-0703

05P00041-0703

05P00225-1992 20.0 ohms, 1% metal film, 1 Watt.

05P00225-0022 15 ohms, 1% metal film, 1 Watt.

1

1

1

1

1

Qty.

1

Ref. Design.

R4

1 R4

R4

R4

R4

R4

R4

3/21/96

Burden Resistor List 93

4 Maintenance

230V

HP Rating

460V

40

50

60

75

100

15

20

25

30

5

7.5

10

—

2

3

1

1.5

75

100

125

150

200

30

40

50

60

10

15

20

25

5

7.5

2

3

Table 8. Power Range Resistor

Part No.

Description

05P00225-2060 26.7 ohms, 1% metal film, 1/4 Watt.

05P00225-2060

05P00225-2300 86.6 ohms, 1% metal film, 1/4 Watt.

05P00225-2300

05P00225-2770 196 ohms, 1% metal film, 1/4 Watt.

05P00225-2770

05P00225-0200 332 ohms, 1% metal film, 1/4 Watt.

05P00225-0200

05P00225-0200

05P00225-0230 499 ohms, 1% metal film, 1/4 Watt.

05P00225-0230

05P00225-0230

05P00225-3590 715 ohms, 1% metal film, 1/4 Watt.

05P00225-3590

05P00225-3590

05P00225-3780 953 ohms, 1% metal film, 1/4 Watt.

05P00225-3790 1.27 K ohms, 1% metal film, 1/4 Watt.

Qty.

1

Ref. Design.

R5

1 R5

1

1

1

1

1

R5

R5

R5

R5

R5

94 Power Range Resistor List

3/21/96

3/21/96

Glossary

Glossary

A/D – Analog to Digital converter.

Active Hub – A central component in LAN star networks that ensures data integrity over distances of up to 2000 feet by regenerating the network signal.

Active menu item – The menu item for an RDU that will be used to get the source of the information to be displayed. When a menu item number is selected, the Control/Display Unit (CDU) menu item data will be used; if there is no data in the CDU menu item for the selected menu item number, then the default menu item data is used.

Active Link – A device that interconnects two LAN bus networks.

ANIO – Remote Analog I/O [Input/Output] PCB.

Broadcast message – A type of LAN message which is capable of being received by all nodes on the LAN. The message contains the source of the message, but the destination is all nodes that have been enabled to receive broadcast messages.

CDU – Control/Display Unit. There are two CDUs supported for the MicroTrac

DSD drive: the Standard CDU (see SCDU definition) and the Portable CDU (see

PCDU definition).

CDU menu item – A menu item of an RDU that was built by using the PCDU.

Channel – The second level address used to further define the location of information external to the the PAC environment (the first level of addressing being the Node number - see NODE definition). To access information external to the PAC environment requires reference to that information by an address which includes all levels of addressing defined for that particular information.

That is, to use a Channel number also requires the associated Node number such as Node 50, Channel 21. The system will support a maximum of 256 (0 through

255) Channel numbers.

Complex PAC task – Any of the more complicated PAC functions (as opposed to the simpler elemental functions), which consists of two (or more) interrelated

PAC tasks. These interrelated tasks are referred to as segments. Each segment is a self-contained module which executes sequentially, although each segment executes separately. The interrelated segments exchange information between each other which has predefined significance. The various segments need not be programmed in a common scan (see SCAN definition).

An example of a complex task would be SPDR, the speed regulator task, which consists of two related segments. One segment executes in the fast scan, and consists of the actual function of regulating the speed by comparing the speed

Glossary 95

Glossary

96 Glossary reference to the feedback and generating a torque command based on the difference and the required gains of the regulator. The other segment consists of the code used to calculate the gains required for the speed regulation function in the format required by that segment. In other words, it translates from the engineering terms used to describe regulator performance (such as load inertia and desired crossover frequency) to the integral and proportional gains required by the regulator segment. Since these defining parameters are rarely changed, this segment needs to execute only rarely, thus saving processor time for other functions which do require frequent execution.

Conditional scan – Conditional scan tasks define sub-programs (i.e. subprograms consisting of unique interconnections of PAC tasks) which execute only when certain logic conditions related to the conditional scan task are satisfied. When the conditional scan executes, the program defined for the conditional scan executes at the scan level at which the conditional scan task is programmed (see SCAN definition). The use of conditional scans allows greater utilization of the limited processor time.

Custom fault – A fault (or error) defined via the PAC task “FLTD”. These faults have significance only to a particular PAC design. (See Fault or Error definition).

D/A – Digital to Analog converter.

DCU – Drive Control Unit. The drive control unit refers to the hardware and software used to control the drive as opposed to the hardware and software used to control the power conversion process. Specifically, it refers to the hardware and software associated with the DCU microprocessor. The DCU software includes the variable software generated as a result of the PAC program and the fixed software (see Kernel definition) used to control execution of the PAC program.

Default menu – A menu for an RDU that contains the default menu items as received through the LAN from the drives. Each drive connected to the LAN can have default menu items that are to be displayed on specific RDUs. The default menu items and the order of the menu items are determined by the PAC programmer.

Directed message – A type of LAN message which can be received only by one

LAN Node. This type of message contains both the source and destination Node numbers.

Elemental PAC task – The simpler PAC language functions where everything associated with that function is contained in one sequentially executed module.

3/21/96

3/21/96

Glossary

EPROM – Erasable Programmable Read Only Memory. An integrated circuit that is usually used to hold the instructions for a microprocessor’s program.

Error – An abnormal condition considered less serious than a fault (see FAULT definition). The difference between the two is that an error is recorded in the

NVRAM, but not announced on the CDUs. The declaration of a fault will cause immediate display of the fault code number on the SCDU and the lighting of the

FAULT LED. Any abnormal condition, standard or custom (also see

STANDARD FAULT and CUSTOM FAULT definitions) may be declared as an error, a fault or both. Each abnormal condition is given an initial default classification as either an error, a fault, or both an error AND a fault. A special

CDU function is provided to override that initial default classification.

The declaration of an error places the error number assigned to that error at the end of the Last Error List. This error list is of fixed length (16) and allows display via the CDU of the latest errors (note this differs from the First Fault

List, which displays the oldest faults). In addition to the display of the error code number, this error list also allows the display of the task number of the PAC task generating the error (if the error was not generated by a PAC task, then task number zero [0] is displayed) and a time stamp of when the error occurred.

Fault – An abnormal condition generally requiring corrective action. A fault is considered to be a condition more serious than an error (see ERROR definition).

The difference between the two is that an error is recorded in the NVRAM, but not announced on the CDUs. The declaration of a fault will cause immediate display of the fault code number on the SCDU and the lighting of the Fault LED.

If multiple faults occur, the last declared fault is the fault displayed on the CDU.

A fixed number of faults (16) are recorded in order of declaration. This Fault

List may be reviewed by order of fault declaration via a special CDU function.

Once the Fault List is full, declaration of additional faults will not appear on the

Fault List until space on the list is made available. The same CDU function used to display the Fault List may be used to clear from the list either all the faults or individual faults. The FAULT LED will remain lit until all the faults have been cleared from the Fault List.

Faults can be classified into two categories: “Standard” (see STANDARD FAULT definition) and “Custom” (see CUSTOM FAULT definition).

In most cases, no action is taken when a fault is declared. In these cases, the corrective action is the responsibility of the PAC program. In some cases, however, the abnormal condition is so severe that corrective action must be taken without regard to the PAC program (see SEVERE FAULT definition).

All defined abnormal conditions may be categorized as a fault or not a fault via a special CDU function. Each of these conditions is given an initial default (i.e. it

Glossary 97

Glossary

98 Glossary is either categorized as a fault or not). The special CDU function allows overriding of that initial definition.

Fixed point number – A number system used internally in the computer which is encoded in a specific manner. Fixed point numbers have a limited range of values which they can represent. In the case of the fixed point numbering system used for the PAC language, the maximum value which can be represented is +/- 32,767.99998 and the smallest non-zero value is +/- 0.000015.

The advantage of fixed point numbers is that some of the arithmetic operations such as addition, subtraction, and comparison execute much faster than a value represented in floating point.

Floating point number – A number system used internally in the computer which is encoded in a specific manner. In this case the encoding method (i.e.

format) is a widely used format developed by the IEEE organization. The encoding scheme is similar to scientific notation of numbers which make use of number field and exponent. For example, 1.2 x E-2 is a scientific notation of the number 0.012 (1.2 times ten to the minus 2 power). The advantage of floating point numbers is that they can represent a very large range of values from the very small to the very large.

HIT – High Impedance Transceiver. A type of transceiver circuitry on a LAN

Node that electrically connects to the coaxial cable. HIT Nodes may be interconnected in star or bus networks. MicroTrac DSD uses this type of transceiver.

Kernel – This is the fixed (i.e. non-changeable) code for the DCU microprocessor which forms the operating system of the microprocessor. As such, it controls the generation of the various scans, the order of execution of the

PAC tasks, the information passed to and from the PAC tasks and the execution of other standard code not directly associated with the PAC tasks such as the control of the CDU or LAN handler.

LAN – Local Area Network. A high speed serial communication network which allows two-way communications between multiple devices (referred to as

Nodes) all connected to the same communications cable. The specific LAN used is “ARCNET”.

LAND – LAN Driver transceiver. A type of transceiver circuitry on a LAN

Node that electrically connects to the coaxial cable. LAND Nodes may be interconnected in a star network only.

LAN Node – A point in a network where service is provided, service is used, or communications channels are interconnected.

3/21/96

3/21/96

Glossary

LCD – Liquid crystal display.

LED – Light emitting diode.

Local I/O – The class of Input and Output hardware located on the MicroTrac

DSD chassis. All connections between the Main CPU Control PCB and these

I/O boards are made via ribbon cables. All connections between the actual I/O devices (i.e. push buttons, thumbwheel switches, lights etc.) are made with individual wires between the I/O device and the drive.

Local RDU – When referring to a keyboard, the local RDU is the RDU that the keyboard is connected to.

Locked RDU – An RDU whose display may not be modified by a keyboard or push button connected to another RDU.

LOGIO – Remote Logic I/O [Input/Output] PCB.

Menu – A list of items for an RDU, any one of which may be selected to be displayed on that RDU.

Menu item – A source definition of where the information to be displayed on an

RDU, when selected, is to come from. The source definition includes the Drive

Node number, the Channel number, and the Subchannel number. The decimal point location is also defined.

Node – Originally a term used to identify the base address of devices connected to the LAN. For MicroTrac DSD this term has been expanded to refer to the base address of anything outside the PAC program environment. Thus, the PCU and Local I/O PCBs are each assigned a Node number, even though the DCU does not communicate with those devices over the LAN. The system will support Node numbers 1 thru 258.

Node numbers assigned to devices on the LAN are unique, and refer to only one device on the LAN. Node numbers other than those on the LAN are predefined and not changeable. (Also see LAN Node definition.)

NVRAM – Non-Volatile Random Access Memory. Memory that can be written to as well as read from. In addition, this memory is protected from losing data when the power is lost. Usually this is accomplished with a battery that is good for at least 10 years.

PAC – Programmable Application Control. The graphically oriented task-based language used to customize the DCU (i.e. customize the drive for a specific application).

Glossary 99

Glossary

100 Glossary

PAC Diagram – A drawing, resembling a schematic diagram, which shows the various PAC tasks and the unique interconnection of those PAC tasks.

PAC task – The smallest unit which can be programmed in the PAC language.

Numerous types of PAC tasks are provided, each performing a specific, well defined function. Each type of PAC task may be used numerous times in a PAC design. Each PAC task is represented by a block on the PAC Diagram.

PAC task number – A unique number assigned by the PAC programmer to each PAC task on the PAC Diagram. These numbers may be assigned in any order and serve only as a means of identifying unique sources of information in the PAC program. The system will support up to 32,767 PAC tasks with the allowable task numbers being 1 to 32767.

Parameter upload – The process of a computer sending all settable parameters (i.e. the .PAR file) to a DSD 406/412 drive. This process can be used to set up the drive with a set of tuned constants.

Parameter download – The process of the DSD 406/412 drive sending all of its settable parameter values (i.e. the .PAR file) to a computer. This process can be used for memory backup. A parameter download is the only data transfer process that can occur while the drive is running a motor.

Passive Hub – A central component in LAN star networks that splits the network signal. Data integrity is ensured over a distance of 100 feet for a 4-port

Passive Hub.

PCB – Printed Circuit Board.

PCDU – Portable Control/Display Unit. A device which can plug into a drive or an RDC, via a cable with a modular connector (similar to a telephone cord), that has two lines of 16 character alphanumeric display and a 30 key keyboard. It allows the viewing and setting of variables.

PCU – Power Conversion Unit. The power conversion unit refers to the hardware and software associated with the power conversion from the AC lines to the motor. Specifically, it refers to the hardware and software associated with the PCU microprocessor as well as the power related components. The PCU is responsible only for the power conversion process, not determination of how much power should be converted (which is a function of the DCU).

Per-unit value – A per-unit value is a method of representing a quantity where the value 1.0 represents the “Rated” value for that quantity. Whereas the

“Rated” value is generally a dimensioned value, the Per-Unit value is a dimensionless quantity.

3/21/96

3/21/96

Glossary

Power cube – The MicroTrac DSD chassis and all components mounted on or inside it. A power cube alone cannot operate a motor; auxiliary items such as isolation transformer, input circuit breaker, control power transformer and motor loop contactor are needed to make up a complete MicroTrac DSD drive.

Program upload – The process of a computer sending a new PAC program

(i.e. the .PRG file) To a DSD 406/412 through the drive’s serial port. This process may be required when, upon application of power, the drive finds the

PAC program loaded into memory is invalid. This process may also be used when it is desired to change the PAC program from what was previously loaded. Some of the steps shown below are skipped when the PAC program in memory is found to be invalid.

Program download – The process of the DSD 406/412 drive sending the PAC program (i.e. the .PRG file) through the drive’s serial port to a computer. This process can be used for memory backup.

Queue – A list consisting of values where each new value is entered at the end of the list and values read from the list are taken from the beginning of the list.

In other words, a first-in first-out [FIFO] buffer.

“RAM” – Random Access Memory. Memory that can be written to as well as read from. The data in this memory is lost when the power is lost.

RDC – Remote Display Controller LAN Node PCB. A board that includes the

LAN Node circuitry and the software to control what is displayed on each of up to 31 RDUs. This device also communicates with the drives over the LAN.

RDU – Remote Display Unit. A device that has a 16 character alphanumeric display and a 5-1/2 digit plus sign numeric display. This device is controlled by an RDC.

RDU message – The data that is displayed on both displays of the RDU. The source of the message is defined in the RDC by a Menu Item number, Drive number, Channel number, Subchannel number, decimal position, a flag stating what type of message it is (whether the message is modifiable or not), and - if it is modifiable - the minimum and maximum allowable limits of an entered value.

RIO – Remote I/O [Input/Output] Controller LAN Node PCB. A board that includes the LAN Node circuitry and the software to control outputs to and monitor inputs from Remote (Logic or Analog) I/O boards. This device also communicates with the drives over the LAN.

Scan – This term refers to the frequency at which a particular PAC task will execute. All PAC tasks programmed in a particular scan will execute in the

Glossary 101

Glossary

102 Glossary same time frame. MicroTrac DSD is provided with four timed scans and one background scan. Each PAC task programmed in a timed scan will execute once in that time frame. The background scan executes each PAC task once in whatever time is left over from the timed scans and then starts over executing each task again.

SCDU – Standard Control/Display Unit. The 4-1/2 digit numeric display, 4 push buttons (keypad) and multi-color LED on the drive. It allows viewing and setting of variables.

Selected menu item – The menu item number in the RDU’s menu that is being displayed.

Severe fault – An abnormal condition whose severity requires immediate action by the microprocessor sensing the error. An example of a severe error is an IST condition sensed by the PCU. In this case, the PCU disconnects the load; it does not wait for the PAC program to command load disconnect. (Also see FAULT definition.)

Speed Command – The desired speed setpoint prior to local PAC task modification such as linear accel/decel control, draw modification, trim modification, etc. (Also see SPEED REFERENCE definition.)

Speed Reference – The speed reference signal after all PAC task modification such as linear accel/decel control, draw modification, trim modification, etc.

That is, the instantaneous value of the reference which is applied to the speed regulator. (Also see SPEED COMMAND definition.)

Standard fault – A fault (or error) which is independent of a particular PAC design. These conditions are associated with the operation of the DCU microprocessor or the PCU or the LAN handler. (See FAULT or ERROR definition.)

Subchannel – The PAC language defines a particular input or output by use of a

Node, a Channel, and a Subchannel. The Subchannel refers to a specific input or output of a given Node and Channel.

The third level of addressing which further defines the location of information external to the PAC program environment; the first level is the Node number

(see NODE definition) and the second level is the Channel number (see

CHANNEL definition). To access information requires specifying all levels of addressing defined for that piece of information. For example, Node 251,

Channel 4, Subchannel 0 refers to the Local Digital I/O PCB connected to connector J1 (assigned Node 251), Thumbwheel switch inputs (assigned as

3/21/96

Glossary

Channel 4 of the Digital I/O PCB), and specifically the set of thumbwheel switches designated as Bank 0 (i.e. Subchannel 0).

Token – A term used with the LAN to describe a special LAN message. This message is passed from one LAN Node to another. When a LAN Node receives this message (i.e. the token), it is allowed to transmit a message it has generated while waiting to receive permission to transmit. Once it has completed its transmission, it must pass the token to the next node (in numerical sequence).

Nodes which do not have the token may receive messages but may not transmit a message until the token is received. If the node receiving the token does not have any messages to transmit, it simply passes the token to the next node.

TWIO – Remote Thumbwheel I/O [Input/Output] PCB.

Unlocked RDU – An RDU whose display may be modified by a keyboard or push button connected to another RDU. This is the default RDU lock state.

3/21/96

Glossary 103

Index

Index

A

Accuracy ................................................................. 3

B - C

Control .................................................................. 3

Controls and Indicators .................................. 1, 19

Reset Button ..................................................... 23

Fig. 8 Operator Controls and

Indicators ................................................. 23

Status LEDs .................................................. 1, 23

Standard Control/Display Unit

(SCDU) ..................................................... 24

Non-Volatile “RAM” Protection ................... 24

Portable Control/Display Unit

Connection .............................................. 24

Characteristics......................................................... 4

D

DATA/FCTN Key ............................................... 27

Drive Start-Up ...................................................... 21

Parameter Verification .................................... 22

DSD Drive Description ......................................... 3

Regeneration Capability .................................. 3

Flexibility ............................................................ 3

Control ................................................................ 3

Accuracy ............................................................. 3

Useability ........................................................... 4

Characteristics ................................................... 4

PAC Language Programming ......................... 4

DSD 406 and 412 Spare Parts List ..................... 89

E

Electrical Hook-Up .............................................. 14

Fig. 4 Shield Sheath Termination ................. 16

Fig. 5 Basic Connections for DSD Power

Cube – Ratings up to 206 Amps ........... 17

Fig. 6 Connections to TB3 and TB1

DSD Power Cube – Ratings up to

206 Amps ................................................. 18

Fig. 7 Grounding of Multiple Units ............. 19

Error Display ........................................................ 49

Error Handling/Reporting ................................ 45

Fault Display/Clear ........................................ 48

Error Display ................................................... 48

F

Fault Display/Clear ............................................ 48

Function Levels .................................................... 27

Flexibility ................................................................ 3

G

General Operation ............................................... 26

Table 2 # Function Code Descriptions ........ 27

Function Levels ............................................... 27

DATA/FCTN Key ........................................... 27

General Upload/Download Procedures .......... 33

Upload Procedure for a New

Flash ROM Chip ..................................... 35

Program Upload .............................................. 37

Program Download ........................................ 39

Parameter Upload ........................................... 41

Parameter Download ..................................... 43

Glossary ................................................................ 95

H

How To Contact MagneTek ................................. 2

How To Use This Manual ..................................... 1

I

Index .................................................................... 104

Installation and Start-Up ...................................... 9

Introduction ........................................................... 1

J - K - L

Load Defaults Function ...................................... 53

M

Maintenance ......................................................... 57

Monitor Functions ............................................... 30

N

Non-Volatile “RAM”

Access ............................................................... 51

Protection ......................................................... 24

104 Index

3/21/96

O

Operation .............................................................. 23

Controls and Indicators .................................. 23

P

PAC Language Programming .............................. 4

Parameter Download .......................................... 43

Parameter Functions ........................................... 28

Parameter Upload ............................................... 41

Parameter Verification ........................................ 22

Physical Installation .............................................. 9

Fig. 2 Dimensions and Mounting Holes

DSD 406/412 1-60 Hp Versions ............ 10

Fig. 3 Dimensions and Mounting Holes

DSD 406/412 75-125 Hp Versions ........ 11

Fig. 3.1 Dimensions and Mounting Holes

DSD 412 150-200 Hp Versions .............. 13

P ortable Control/Display Unit Connection .... 24

Power Conversion Unit Diagnostics .................58

Pre-Installation Considerations ........................... 9

Receipt of Shipment .......................................... 9

Storage ................................................................ 9

Unpacking .......................................................... 9

Re-packing ......................................................... 9

Pre-Power Check ................................................. 20

Preventive Maintenance ..................................... 57

Program Upload .................................................. 37

Program Download ............................................. 39

Q - R

Receipt of Shipment .............................................. 9

Regeneration Capability ....................................... 3

Re-packing .............................................................. 9

Replacing DSD Drive Control PCB ................... 79

Fig. 11 DSD Drive Control PCB ................... 78

Table 4 Connectors on Drive

Control PCB ............................................ 79

Replacing Fuse(s) ................................................ 77

Fig. 10 DSD Drive Fuse Replacement ......... 76

Replacing the DSD Armature Interface PCB ... 87

Fig. 14 DSD Armature Interface PCB .......... 86

Replacing the Fan ................................................ 81

Fig. 12 Replacing DSD Fan ........................... 82

2-60 HP Units ................................................... 81

75-125 HP Units ............................................... 83

Index

Replacing the Power Supply ............................. 85

Fig. 13 DSD Power Supply Replacement ... 84

Reset Button ......................................................... 23

S

Safety Statements .................................................. 2

Self-Tune (PCU Parameter Measurement) ....... 54

Spare Parts List .................................................... 89

Table 5 230 Volt Drives Spare Parts ............. 89

Table 6 460 Volt Drives Spare Parts ............. 91

Table 7 Burden Resistor ................................. 93

Table 8 Power Range Resistor ...................... 94

Standard Control/Display Unit ........................ 24

Start-Up Operation .............................................. 25

Status LEDs ............................................................ 1

Storage .. .................................................................. 9

System Considerations ......................................... 5

Table 1 Drive Ratings and Specifications ...... 5

Fig. 1 Typical MicroTrac DSD

System Diagram ....................................... 7

T

Troubleshooting Guide ....................................... 61

Table 3 Troubleshooting Guide .................... 61

U

Unpacking .............................................................. 9

Upload Procedure for a New Flash

ROM Chip ..................................................... 35

Upload/Download Introduction and

Definitions ..................................................... 31

Fig. 9 DSD 406/412 to IBM PC

Compatible Computer

Interconnection Diagram ...................... 31

Upload/Download of Programs or

Parameters (T992) ........................................ 31

Useability ................................................................ 4

Use of An Analog Tachometer .......................... 20

3/21/96

Index 105

Effective 02/06/95

MICROTRAC

DIGITAL

SYSTEM

DRIVES

Electrical Hook-up Addendum

The following additional information must be followed when performing Electrical Hook-Up of a

DSD 406 or DSD 412 drive, according to the procedures listed on pages 12-15 of technical manual

TM 6107, dated 4/15/94.

– Although the three phase input power line is fuse protected internal to the drive, it is recommended to provide branch circuit protection by means of a circuit breaker in accordance with the National Electrical Code, local codes and with a rating of not less than 5,000 rms Symmetrical Amperes and 600 Volts for 2 to 25 Hp rated drives or 10,000 rms Symmetrical Amperes and 600 Volts for 30 to 60 Hp rated drives.

– Electronic overload protection is provided as part of the standard DSD product. It is electronically timed and will shut down the drive along a time/output current curve which provides shutdown at 60 seconds at 150% or 10 seconds at 200% of rated output current. An overload relay may be added external to the drive in accordance with the National Electrical Code and local codes for additional protection.

– Main Circuit Input/Output Wire Sizing:

L1-3: Using 600V vinyl-sheathed wire per the following table.

30

40

50

60

75

100

125

150

200

10

15

20

25

5

7

2

3

Drive Hp

Recommended Wire Gauge (Copper Only)

Torque

60°C 75°C

(in-lbs)

6

4

8

6

4

14

14

14

8

10

8

8

4

14

14

14

10

4

1

1

1/0

3/0

3/0

250 MCM

600 MCM

600 MCM

45

150

150

180

250

250

325

375

375

35

35

35

40 - 35 *

40 - 35 *

45 - 40 *

45 - 40 *

45

* Torque per wire gauge.

© Copyright 1995 MagneTek, Inc.

TM 6107 Addendum 1

PAGE 1

MICROTRAC

DIGITAL

SYSTEM

DRIVES

Electrical Hook-up Addendum

ARM(–): Using 600V vinyl-sheathed wire per the following table.

30

40

50

60

75

100

125

150

200

10

15

20

25

5

7

2

3

Drive Hp

Recommended Wire Gauge (Copper Only)

Torque

60°C 75°C 90°C

(in-lbs)

6

4

4

14

14

14

6

4

3

8

4

14

14

14

8

3

1/0

1/0

3/0

250 MCM

250 MCM

350 MCM

500 MCM

700 MCM

50

50

50

50

325

325

325

375

375

35

35

35

45 - 40 *

45 - 40 *

45

45

50

* Torque per wire gauge.

ARM(+): Using 600V vinyl-sheathed wire per the following table.

30

40

50

60

75

100

125

150

200

10

15

20

25

5

7

2

3

Drive Hp

Recommended Wire Gauge (Copper Only)

Torque

60°C 75°C 90°C

(in-lbs)

6

4

4

14

14

14

6

4

3

8

4

14

14

14

8

3

1/0

1/0

3/0

250 MCM

250 MCM

350 MCM

500 MCM

700 MCM

50

180

180

250

325

325

325

375

375

35

35

35

45 - 40 *

45 - 40 *

45

45

50

* Torque per wire gauge.

© Copyright 1995 MagneTek, Inc.

TM 6107 Addendum 1

PAGE 2

MICROTRAC

DIGITAL

SYSTEM

DRIVES

Electrical Hook-up Addendum

– Field Current Wire Sizing: The recommended conductor for field current ratings between 10.0 Ampere and 16.0

Ampere is 12 AWG. The recommended conductor for field current ratings below 10.0 Ampere is 14 AWG. Use 600

V vinyl-sheathed 105°C wire or equivalent. The recommended torques on the field lugs for 14-10 AWG is 25 in-lbs.

– GND: Recommended conductor size, 2 AWG 600 V vinyl-sheathed for COPPER wire, 1/0 AWG 600 V vinylsheathed for ALUMINUM OR COPPER CLAD ALUMINUM wire. Recommended torque on the GND lug is 50 in-lbs.

– Control Circuit Wire Sizing:

TB1: Recommended conductor size, 22-18 AWG 300 V 105°C vinyl-sheathed wire. Recommended torque is 3.4 in-lbs.

TB3: Recommended conductor size, < 12 AWG 300 V 105°C vinyl-sheathed wire. Recommended torque is 5 in-lbs.

TB5: Recommended conductor size, 14 AWG 600 V 105°C vinyl-sheathed wire. Recommended torque is 3.4 in-lbs.

© Copyright 1995 MagneTek, Inc.

TM 6107 Addendum 1

PAGE 3

Please send information concerning scheduled dates of Training

Seminar(s) for the DSD 406 / 412

Send information to: MagneTek

Attn: Training Department

16555 West Ryerson Road

New Berlin, WI 53151

(800) 541-0939, Ext 449

(414) 782-0200 Ext. 449

Applicant Name

Position/Title

Company

Address

Telephone ( )

Number of Attendees

Fax (414) 782-3418

DSD 406 / DSD 412

Data subject to change without notice. DSD, MicroTrac, PAC, and Century are trademarks of MagneTek, Inc.

MagneTek

Drives & Systems

16555 West Ryerson Road

New Berlin, WI 53151

(800) 541-0939, (414) 782-0200, FAX (414) 782-3418

MagneTek

TM 6107 © 1997 Magne Tek, Inc. 1/97