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Control Techniques 1850A

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*CSA C22.2 0.4-M1982 Bonding & Grounding of Electrical Equipment (Protective Grounding)
* Applies to Mentor II current range 900A - 1850A only These products comply with the Low Voltage Directive 73/23/EEC and the CE Marking Directive 93/68/EEC.
W. Drury Executive VP Technology Newtown Date: 30 April 1998. This electronic drive product is intended to be used with an appropriate motor, controller, electrical protection components and other equipment to form a complete end product or system. It must only be installed by a professional assembler who is familiar with requirements for safety and electromagnetic compatibility ("EMC"). The assembler is responsible for ensuring that the end product or system complies with all the relevant laws in the country where it is to be used. Refer to the product manual or EMC data sheet for further information on EMC standards complied with by the product, and guidelines for installation.

Features of Mentor II

Mentor II parameters

Control

Mentor II is equipped with a range of parameters designed to give the utmost flexibility of application to industrial requirements. The parameters are arranged in menus, as being the most convenient way of making access easy and quick for the user. Within each menu, those parameters which are needed only for customization of the drive for the more complex applications have been made invisible - that is, they are normally inaccessible except through high level security access. With low level security access, invisible parameters do not appear in the digital display. This arrangement has the effect of reducing the apparent size of the menus for greater convenience in normal use, and ensuring the maximum protection for the parameters which are specially set up for a particular application or process.
All analog and most digital inputs configurable by the user for specific applications. PID speed loop algorithm. Provision for encoder inputs for position control. On-board provision for tachogenerator (tachometer) calibration. Programmable control of field-weakening. Phase sequence and phase-loss detection. Software includes current loop self-tuning algorithm. Menu-driven parameter structure. Drive returns to last parameter adjusted in each menu. User-defined menu for quick access to most-used parameters.

Speed resolution

Reference Feedback Armature volts Tachogenerator (tachometer) Tachogenerator (tachometer) Encoder Encoder Encoder 0.83V 0.1% 0.1% 0.01% 0.01% Combined resolution 0.83V 0.125% 0.2% 0.035% 0.11% Absolute

Analog

0.025% 0.025% 0.1% 0.025% 0.1%

Supply phase-sequence

Analog Digital Analog

Effective heat-conducting area

Cooling

There are certain variations across the Mentor II range of drives, in respect of mounting and cooling arrangements. With most models there is the option of surface or through-panel mounting. The higher-rated drives require forced ventilation and can optionally be supplied complete with ducted cooling fans. Alternatively, the installer may arrange to use separately-provided ducted cooling air. Air flow requirements are shown in the table in section 4.2.3 Ventilation and weight on page 11. The variants are summarized in the following table. Mounting Drive model M25 to M75 M25R to M75R M105 and M105R M155 and M155R M210 and M210R M350 to M550 M350R to M550R M700 and M825 M700R and M825R M900 to M1850 M900R to M1850R Surface Yes Yes Yes Yes Yes Yes (1) Yes (1) Yes (1) Yes (1) Only Only Throughpanel Yes Yes Yes Yes Yes Yes (2) Yes (2) Yes (2) Yes (2) Ventilation Heat Sink Natural Natural Natural Forced (fan built in) Forced (fan built in) Forced Forced Forced Forced Forced (3) Forced (3) Isolated* Isolated* Isolated* Isolated* Isolated* LIVE LIVE LIVE LIVE LIVE (4) LIVE (4)
The required surface area Ae for an enclosure containing equipment which generates heat is calculated from the following equation: P A e = -------------------------------k ( T i T amb ) where Ae Effective heat-conducting area, in m2, equal to the sum of the areas of the surfaces which are not in contact with any other surface. Power loss of all heat-producing equipment in Watts. Max. permissible operating temperature of the drive in oC. Maximum external ambient temperature in oC. Heat transmission coefficient of the material from which the enclosure is made in W/m2/ oC. Example: Calculation of the size of an IP54 (NEMA 12) enclosure for a drive size M210 The worst case is taken as the basis of the example, for which the following conditions are assumed: The installation is to conform to IP54 (NEMA 12), which means that the drive and its heatsink are to be mounted wholly within the enclosure, and that the enclosure is virtually sealed and without any ventilation of the air inside. Heat can escape only by conduction through the skin of the enclosure, which is cooled by conduction, convection and radiation to the external air. The enclosure is to stand on the floor and against a wall, so that its base and back surfaces cannot be considered to play any part in the cooling process.The effective heat-conducting area Ae is provided by the top, front, and two sides only, Figure 5-2. The enclosure is to be made of 2mm (0.1in) sheet steel, painted. The maximum ambient temperature is 25 oC.

P Ti Tamb k

* Isolated heat sinks must be earthed (grounded) for safety. A terminal is provided. 1. Surface-mounting requires the optional fan ducting, with integral fans, mounting flanges and earthing (grounding) stud. 2. Adequate forced ventilation must be provided. 3. A suitable fan can be supplied as an optional extra. 4. Enclosed.

+10V (5mA) -10V (5mA) Reference GP1 GP2 GP3 GP4 Thermo Tacho 0V 9 10
T _ 0 to + 10V _ 0 to + 10V _ 0 to + 10V _ 0 to + 10V
F1 Run F2 Inch Rev. F3 Inch Fwd. F4 Run Rev. F5 Run Fwd. F6 F7 F8 F9 F30

Programmable outputs

Terminal block TB2 Terminals 12 to 14 inclusive Analog Terminals 15 to 19 inclusive Open collector (digital) Terminal block TB4 Terminals 34 to 36 inclusive Relay
Current DAC1 DAC2 DAC3 ST1 ST2 ST3 ST4 ST5 0V 19 20
Enable Reset +24V (200mA) 35

Programmable inputs

Terminal block TB1 Terminals 3 to 7 inclusive
Terminal block TB3 Terminals 22 to 30 inclusive Digital

Drive Healthy (Normal)

GP 100k in DAC 5mA max ST 100mA max
Programmable Pull-up resistor
F 10k input impedance Relays 240V AC 2.2A

Operating procedures

Keypad and displays

Keypad

Figure 7-1 Keypad
The keypad serves two purposes: 1. It allows the operator to configure the drive to match particular applications and to change its behavior in a variety of ways, for example by altering the times of acceleration and deceleration, presetting levels of protection, and so on. Subject to safety considerations, adjustments may be made with the drive running or stopped. If running, the drive will respond immediately to the new setting. 2. It provides full information about the settings and the operational status of the drive, and extensive diagnostic information if the drive trips. For parameter adjustment, the keypad has five keys, Figure 8-1. Use the LEFT or RIGHT keys to select a Menu (functional group of parameters). The menu number appears to the left of the decimal point in the Index window. Use the UP or DOWN keys to select a Parameter from the chosen menu. The parameter number appears to the right of the decimal point in the Index window, and the value of the chosen parameter appears in the Data window. Press the MODE key once to access the displayed parameter value for adjustment. The value flashes if access is permitted. Use the UP or DOWN keys to adjust the value. To adjust rapidly, press and hold a key. Press the MODE key again to exit from the adjustment mode. Store (make permanently effective) parameter values after changes, otherwise the new values will be lost when the drive is powered-off. To store, set Parameter 00 = 1 and press RESET.

Displays

1. Index The lower four-digit display indicates menu number to the left of the (permanent) decimal point, and parameter number to the right. 2. Data The upper four-digit display indicates the value of a selected parameter. The present value of each parameter in turn appears in the data display as parameter numbers are changed. Numerical parameters have values in ranges of 000 to 255, 000 to +1999, or 000 to 1000. Refer to Chapter 6 for parameter unit values, e.g. volts, rpm, etc. Bit parameter values are displayed as 0 or 1, preceded by a b. The first digit for integer parameters (0 to 255) is a. 3. Status Indicators Nine LEDs to the right of the parameter data and index panels present information, continuously updated, about the running condition of the drive and enable basic information to be seen at a glance. LED Illuminated Drive ready Information The drive is switched on and is not tripped The drive is in an overload trip condition or is integrating in the I x t region Motor speed < zero speed threshold (programmable) Motor running forward Motor running in reverse Output bridge 1 is enabled Output bridge 2 is enabled (Inactive in 1-quad drives) Motor running at the speed demanded by the speed reference Drive running and delivering maximum permitted current

Link LK1 (jumper) and switches
The link LK1 (jumper) and switch block are located on PCB MDA2B (Figure 6-5), accessible when the lower, snap-on front cover is removed (Figure 6-1). Control Purpose Logic input polarity. MDA2B is marked POS. POWER-OFF BEFORE and NEG. to indicate the CHANGING positions of SW1A. Pos. = 24V Neg. = 0V. 60V to 300V 50V to 200V 10V to 50V Tachogenerator (tachometer) potentiometer calibration adjustable link (jumper) +15V +12V +5V Encoder supply voltage selector* Encoder supply voltage selector* Encoder supply voltage selector* Tachogenerator (tachometer) feedback range* Tachogenerator (tachometer) feedback range* Tachogenerator (tachometer) feedback range*

SW1H SW1G SW1F

SW1D SW1C SW1B

set 04.06 = 890 also.

* ONE ONLY to be selected

Pot. RV1

Potentiometer RV1
Purpose Tachogenerator (tachometer) feedback adjustment
Current resolution The rating of the selected drive is typically higher than the rating of the motor, but it should not be very much higher. It would not be prudent to select a drive-to-motor ratio less than 2/3 (current limit parameter setting 600).Current feedback resolution at any lower ratio would be unable to give good current loop control. Although full scale resolution can be achieved by changing the burden resistors of the drive current transformer, this would create a non-standard drive that is not a stock item. The risk is that the drive might be replaced by a standard drive of the same nominal rating; the motor could be permanently damaged. Special modifications of this nature should always be supported by thorough documentation, and the non-standard drive should itself be indelibly tagged in some way.

Refer to Figure 6-5.

Procedure for Adjustment 1. Select the appropriate tachogenerator range using SW1. 2. Set LK1 in the ADJUST position. 3. Adjust RV1 until the value of parameter 03.02 (Speed Feedback) is: 10, 000 03.02 = -----------------V max where Vmax = Tach. voltage at full speed. 4. Set LK1 in the FEEDBACK position and fine tune RV1 with the motor running at between half to three-quarter speed.
Current overload I x t The threshold at which I x t integration begins in parameter 05.06 is typically 105%. The parameter full-scale value is 1000, corresponding to 150%, so that : 05.06 threshold = ---------------------------- = This value, as with the Current Limit, must be adjusted to take account of the actual motor full load amps by applying the factor already calculated for Current Limit, namely, 0.89. The actual value required for this motor and drive combination is therefore : 700 x 0.89 =623 Set 05.06 = 623 Access to these parameters To gain access to these parameters and set the values select parameter 00 and enter 200. This permits access to all required parameters.

NOTE 6 6

240PPR 1750rpm 1710rpm
Motor reduced field current 0.5 ----------------------------------------------------------------------------- = ---------- 1000 = 270 Motor max field current 1.85
Set 06.09 = 270 Test the effect by temporarily setting the Field Economy Time-out, 06.12, to 2 seconds (06.12 = 2).Disable the drive and monitor the current value at parameter 06.03. Two seconds after the drive is disabled, 06.03 will be seen to reduce to the selected value of 06.09.
When this type of feedback is applied there are several additional factors to consider. The instrument should be a dual-channel quadrature type with line driver outputs (using RS485 line drivers).The Mentor II onboard power supply for the encoder (pulse tachometer) is selectable to 5V, 12V or 15V by means of the red DIP switch on PCB MDA2B. (Refer to Figure 6-5) This supply can deliver 300mA. It is not isolated from the drive. Transmission line terminating resistors should be installed on the mounting pillars (stand-offs) provided at the lower left-hand corner of the PCB, Figure 6-5. These resistors help to prevent line reflections and to reduce noise pick-up into the differential receiver on the drive. When an encoder (pulse tachometer) is employed, the P and I gains should be adjusted to the following suggested values as a starting point 03.09 = 15 03.10 = 5
Internal field regulator If Mentor II is supplied with the Internal Field Regulator, field economy is under automatic control of the software and an external field ON-OFF control switch (Figure 6-2 and Figure 6-3) is not required. Link out (jumper across) terminals L11 and L12 with wire which is capable of carrying the field current.

Field weakening

User-defined parameters
In the example, the maximum armature voltage is 500V DC. If field weakening is required, a typical practical setting for the back-emf crossover point 06.07 would be 15 to 20 volts below the maximum armature voltage. For example,set 06.07 = 480. At the reduced voltage, the field would begin to weaken progressively down to the value set by parameter 06.10. Since the field current feedback setting 06.11 in this example is 204 - 2A range - the minimum is a selected percentage of it. Suppose 90% is selected. Then: Selected value 0.9 ------------------------------------------------ = ------- = 0.45 Feedback setting 2.0 The setting for minimum field current is : 06.10 = 0.45 x 1000= 450 For correct operation, field weakening requires speed feedback. (Armature voltage feedback would not be adequate to ensure control.) Therefore, 03.13 would be set to 0 for AC or DC tach. feedback, and speed scaling 03.16 would be set to 250, corresponding to 2500rpm maximum permissible motor speed. Parameter 03.03 will then correctly read out the actual motor rpm. If an encoder (pulse tach.) were to be employed, parameter 03.12 would be set to 1 and the encoder scaling 03.14 would need to be set accordingly. The value of 03.14 is dependent on : The maximum motor speed required, and The number of encoder (pulse tach.) pulses per revolution.

Although the following parameter settings are optional it is desirable to set them because doing so allows the user to view various critical drive values without having to run through several menu sets to find them. All are collected together in Menu 00 Parameter 11.01 11.02 11.03 11.04 11.05 Drive quantity Armature voltage Armature current Motor rpm Speed reference AC line voltage Setting 03.04 05.02* 03.03 01.02 07.06 Accessed at 00.01 00.02 00.03 00.04 00.05
* A direct armature current reading can be read on parameter 05.02 if 05.05 is set with the appropriate scale factor. Using the same figures as before, for an M75 drive, in this instance the setting would be 150% of 75A, 05.05 = 113. As for the motor and drive configuration parameters, perform a Save parameter values procedure before disconnecting the drive; refer to section To Save the value(s) written on page 30.

Current loop self-tuning

The following procedure is optional, and for most general applications is not required. However, if optimum dynamic response is desirable, the current loop, which is the innermost control loop, must be set up to enable the outer control loop (such as the speed loop) to function correctly. The dynamics of the current loop are principally a function of the electrical characteristics of any particular motor. The Mentor II has a built-in self-tuning procedure. First, the motor rotor must be locked or the field disconnected to allow the drive to inject armature current and determine the electrical characteristics of the armature. The rotor must not be allowed to rotate during the self-tuning procedure. (Normally, if the field is disconnected, the rotor of a shunt wound motor will not move.) Mentor II units from M25 through to M210 contain an internal field regulator and do not require the field to be disconnected. Self-tuning procedure 1. Power-up the drive. 2. Set parameter 00 = 200 to satisfy security. 3. Set 05.09 = 1 4. Enable the drive connect terminal TB4-31 to 0V 5. Perform a Save parameter values procedure before disconnecting the drive. The parameters affected by the self-tuning procedure are 05.12 to 05.15.(For the save procedure, refer to section To Save the value(s) written on page 30. 6. The drive also has the facility to carry out a continuous autotune by setting parameter 05.27 which will adjust the current loop gains to keep the current loop performance optimised in the case of varying load conditions.

Number 06.01 06.02 06.03 06.04 06.05 06.06 06.07 06.08 06.09 06.10 06.11 06.12 06.13 06.14 06.15 06.16 06.17 06.18 06.19 06.20 06.21 06.22 06.23 06.24 * **
Menu 07: Analog inputs and outputs
Description General purpose input 1 General purpose input 2 General purpose input 3 General purpose input 4 Speed reference input RMS input voltage Heatsink temperature DAC 1 source DAC 2 source DAC 3 source GP1 destination GP2 destination GP3 destination GP4 destination Speed reference destination GP1 scaling GP2 scaling GP3 scaling GP4 scaling Speed reference scaling DAC1 scaling DAC2 scaling DAC3 scaling Reference encoder scaling Encoder reference selector Current input selector Current input mode selector Current input mode selector Invert GP3 and GP4 analog inputs Range to to to to to to to to to to to to to to to to to to to or or or or or 1 Type RO RO RO RO RO RO RO RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW + 201 + 302 + 304 + 318 + 408 + 119 + 120 + 117 +1000 +1000 +1000 +1000 +1000 +1000 +1000 +1000 +Default
Number 07.01 07.02 07.03 07.04 07.05 07.06 07.07 07.08 07.09 07.10 07.11 07.12 07.13 07.14 07.15 07.16 07.17 07.18 07.19 07.20 07.21 07.22 07.23 07.24 07.25 07.26 07.27 07.28 07.29

Menu 08: Logic inputs

Description F1 input run permit F2 input inch reverse F3 input inch forward F4 input run reverse F5 input run forward F6 input F7 input F8 input F9 input F10 input Enable input F2 destination F3 destination F4 destination F5 destination F6 destination F7 destination F8 destination F9 destination F10 destination Disable normal logic functions Invert F2 input Invert F3 input Invert F4 input Invert F5 input Invert F6 input Invert F7 input Invert F8 input Invert F9 input Invert F10 input Enable Inch Reverse Enable Inch Forward Enable Run Reverse Enable Run Forward Range 0 or or or or or or or or or or or to to to to to to to to to or or or or or or or or or or or or or or 1 Type RO RO RO RO RO RO RO RO RO RO RO RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW + 000 + 000 + 000 + 000 + 000 + 000 + 000 + 000 + 0 Default
Number 08.01 08.02 08.03 08.04 08.05 08.06 08.07 08.08 08.09 08.10 08.11 08.12 08.13 08.14 08.15 08.16 08.17 08.18 08.19 08.20 08.21 08.22 08.23 08.24 08.25 08.26 08.27 08.28 08.29 08.30 08.31 08.32 08.33 08.34

8.5.10

Number 09.01 09.02 09.03 09.04 09.05 09.06 09.07 09.08 09.09 09.10 09.11 09.12 09.13 09.14 09.15 09.16 09.17 09.18 09.19 09.20 09.21 09.22 09.23 09.24 09.25 09.26

Menu 09: Status outputs

Parameters 11.07 through to 11.10 have functions associated with the MD29 PCB. Refer to the MD29 Users Guide. Number 11.01 11.02 11.03 11.04 11.05 11.06 11.07 11.08 11.09 11.10 11.11 11.12 11.13 11.14 11.15 11.16 11.17 11.18 11.19 11.20 11.21 11.22 11.23 11.24

8.5.13

Number 12.01 12.02 12.03 12.04 12.05 12.06 12.07 12.08 12.09 12.10 12.11 12.12
Menu 12: Programmable thresholds
Description Threshold 1 exceeded Threshold 2 exceeded Threshold 1 source Threshold 1 level Threshold 1 hysteresis Invert threshold 1 output Threshold 1 destination Threshold 2 source Threshold 2 level Threshold 2 hysteresis Invert threshold 2 output Threshold 2 destination Range 0 or or to to to or to to to to or to 1999 Type RO RO RW RW RW RW RW RW RW RW RW RW + 302 + 0 + 000 + 501 + 0 + 000 Default

8.5.14

Number 13.01 13.02 13.03 13.04 13.05 13.06 13.07 13.08 13.09 13.10 13.11 13.12 13.13 13.14

Menu 13: Digital lock

Description Master encoder counter Slave encoder counter Master counter increment Slave counter increment Position error Precision reference (lsb) Precision reference (msb) Position loop gain Position loop correction limit Enable digital lock Rigid lock selector Precision reference selector Precision reference latch Precision speed reference (16-bit) Range 0 to to 0 to to to to or or or or to 65535 Type RO RO RO RO RO RW RW RW RW RW RW RW RW RW 025 + Default

8.5.15

Number 14.01 14.02 14.03 14.04 14.05 14.06 14.07 14.08 14.09 14.10 14.11 14.12 14.13 14.14 14.15 14.16 14.17 11.09 11.10 11.10 16.62 16.63
Menu 14 plus MD29 system set-up
Description ANSI serial address RS485 mode RS485 baud rate CLOCK task time-base (ms) CTNet Node Address (MD29AN only) Autorun enable Global run-time trip enable I/O link trip enable Enable watchdog (WDOG) Trip if a parameter write over-ranges Disable monitor port protocol Position controller enable I/O link synchronisation source Encoder time-base select Reserved Flash store request RS232 drive-drive comms enable RS485 parameter pointer RS485 parameter pointer #2 (mode 4) RS485 mode 3 scaling CT Net messages per second Line number of error Range 0 to to to to to or or or or or or or or or or or or to to to to to 1999 Type RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RW RO RO Default 0 0
For further information on Menu 14 parameters, please refer to the MD29 User Guide.

8.5.16

Number 15.01 15.02 15.03 15.04 15.05 15.06 15.07 15.08 15.09 15.10 15.11 15.12 15.13 15.14 15.15 15.16 15.17 15.18 15.19 15.20 15.21 15.22 15.23 15.24 15.25 15.26 15.27 15.28 15.29 15.30 15.31 15.32 15.33 15.34 15.35 15.36 15.37 to 15.59 15.60 15.61 15.62 15.63

03.05 IR Compensation output
RO 1000 The result of selected value of IR compensation 03.17 acting on the speed loop integral output. Bi
The principal inputs are the post-ramp reference 02.01 and the hard speed reference 03.18. The post-ramp reference can be summed with or replaced by the hard speed reference. The speed reference can, alternatively, be the hard speed reference alone. The selected input can be modified by the addition of an offset. The result of this summation is the final speed demand (03.01) which is added algebraically to the speed feedback to become the speed error (03.06). The speed error is finally processed by the PID function to become the speed loop output. Speed feedback is derived from one of three possible sources, encoder (pulse tach.), tachogenerator (tachometer) or armature voltage. Whichever source is selected becomes the speed feedback (03.02). If the armature voltage is selected it is first summed with the IR compensation (03.05), which is derived from the integral function of the speed error and the IR compensation factor is then either added to or subtracted from the scaled armature voltage feedback according to whether IR compensation or IR droop is selected. The armature voltage feedback is passed to a comparator to provide a voltage clamp, used internally to prevent armature overvoltage. Parameter 03.15 becomes the clamp level. The speed feedback value is used for two further purposes to supply a speed indication in rpm, and to indicate zero speed.

Speed error

The result of the summation of the final speed demand and the speed feedback, after filtering.

Speed loop output

Final speed demand
Output of the PID speed loop which becomes current demand (menu 04).

Speed error integral

Monitors the value of the speed reference after it has bypassed or been modified by the ramps and/or by the hard speed reference (03.18) and speed offset fine (03.22). It is the speed reference which is presented to the speed control loop of the drive via the speed summation point.
The integrated value of the speed error 03.06, used as input to the IR compensation calculation when using armature voltage feedback (AVF).
Speed loop proportional gain

RW 0 to 255 Uni 080

Monitors the value of the speed feedback, derived from one of the following three sources encoder (pulse tach.), tachogenerator (tachometer), or armature voltage. The selection is controlled by 03.12 and 03.13. The value is used for the closed-loop speed control of the motor. Scaling of the encoder (pulse tach.) signal is set by 03.14, and of the armature voltage feedback is controlled by the setting of maximum armature voltage 03.15. A potentiometer is provided for scaling the tachogenerator (tachometer) feedback signal. The speed feedback 03.02 is summed with the final speed demand 03.01 at the speed loop summation point.

Speed loop gains / 8

The threshold may be adjusted to any value up to 25.5% of maximum speed. Refer also to 10.09.
When set the speed loop gains are reduced by a factor of 8 so that: 03.09 PGAIN = -------------64 03.f IGAIN = -------------------------------2048
Menu 04: Current selection and limits
04.06 Current limit bridge 2

RW 0 to 1000 Uni +1000

The principal input is the speed loop output 03.07 in combination, for torque- or current-control modes, with the torque reference 04.08. These inputs become the current demand to which an offset or trim option may be applied. The result is then subject to an over-riding limitation derived from several sources including the speed feedback. Six bit-parameters determine the mode of control speed control, current control, number of quadrants, etc. A feature in this menu is the facility to apply a second current limit (04.07) automatically refer to 04.10, 04.18 and 04.19 which allow current limit 2 to be applied after a chosen time delay. This is appropriate to applications where the initial load torque on start-up is high, but after some period becomes less, as with some mechanical mixing processes, for example.
Determines the maximum limit of current demand when bridge 2, the negative bridge, is conducting. It causes any demand for current in excess of the limit set point to be ignored.

Current limit 2

Current demand
Available as an additional current limit. Applies to both bridges. The drive can be programmed, if desired, to select 04.07 automatically at a programmed time interval after a RUN signal. Refer to 04.10, 04.18 and 04.19.
The current demand signal is the controlling input to the current loop when the drive is being operated in speed-control mode. The signal is subject to limitation by 04.04, 04.05 and 04.06 before being passed to the current loop.

Torque reference

Final current demand
This value is an input to the current loop and can be selected for use in applications requiring direct control of current (motor torque).
Current demand final output, to the current loop (Menu 05) after limits have been applied.

Current offset

Over-riding current limit
Current offset is used to apply a trim to the current demand 04.01.

Current limit 2 selector

This is the limiting value of current demand and is the result of the speed-dependent current taper calculation or I-limit 2 (if selected), whichever is the lower.
Current limit (taper start point)

RW 0 to 1000 Uni

Set 04.10 = 1 to select current limit 2. Can be caused to change automatically refer to 04.18 and 04.19.
+1000 This parameter provides symmetrical current-limitation for bridges 1 and 2 and is the datum level from which the current taper functions operate refer to 04.20 and 04.21. I-limit 1 can be used in application where the motor kW rating is somewhat less than that of the drive, as an alternative to changing the fixed current-burden resistors.

IN channel 2 mapping

RW 101 to 1941 Int 302
This parameter specifies the source parameter for IN cyclic channel 2.

IN channel 3 mapping

RW 101 to 1941 Int 501
This parameter specifies the source parameter for IN cyclic channel 3.

OUT channel 1 mapping

RW 101to 1940 Int 1940
This parameter specifies the destiantion parameter for the OUT cyclic channel 1. A mapping value of 1940 selects the MD24-PROFIBUS-DP control word as the destination parameter.

OUT channel 2 mapping

RW 101 or 1941 Bit 118
This parameter specifies the destination parameter for OUT cyclic channel 2.

OUT channel 3 mapping

This parameter specifies the destination parameter for OUT cyclic channel 3.

8.6.17

MD25-DeviceNet set-up

RW 101to 1940 Int 501

The set-up parameters take effect only after the MD25-DeviceNet or drive has been reset.

DeviceNet node address

RW 0 to 63 Int 63
This parameter specifies the source parameter for IN polled channel 2.

RW 101 or 1941 Bit 1940

This parameter defines the node address to be used by the MD25DeviceNet.

DeviceNet data rate

RW 0 to 2 Int 0
This parameter specifies the destination parameter for OUT polled channel 1. A mapping value of 1940 selects the MD25-DeviceNet control word as the destination parameter.
This parameter specifes the data rate of the DeviceNet network.

Node status

RO 1 to 10 Int N/A

RW Bit 408

Indicates the current operating status of the MD25-DeviceNet.

Network status

RW 1 to 10 Int N/A

101 or 1941

Indicates the current operating status of the DeviceNet network.

Network loss trip enable

Set to 1 to enable the DeviceNet network loss trip.
This parameter specifies the source parameter for IN polled channel 1. A mapping value of 1941 selects the MD25-DeviceNet status word as the destination parameter.

8.6.18

MD-IBS (INTERBUS) set-up
the destination parameter.
The set-up parameters take effect only after the MD-IBS or drive has been reset.
Parameter map source data

RW 0 or 1 Int 1

Specifies which data mapping information to use. 0 = EEPROM mode. 1 = manual parameter mapping mode
INTERBUS network loss trip

RW 0 to 100 Int 1

Specifies the network loss trip tmie-delay in intervals of 20ms. A value of 5 gives a trip time of 100ms.

OUT process data disable

RW 0 to 48 Int 48
Enables and disables data transfer from the INTERBUS master controller to the MD-IBS. 0 - enabled >= 1 - disabled.

KEY R/W logic R/O logic Internal logic Summation Overload 05.11 Alarm Invisible parameters are in italics, eg 05.10 10.13
Scaling 05.06 05.07 05.08

CURRENT FEEDBACK

Overload threshold Overload time - heating Overload time - cooling
R/W logic Summation Max. field 2 select 06.14 Internal logic Invisible parameters are in italics, eg 06.Enable speed loop gain adjustment 06.18 R/O logic P +I P + I loop

Figure 8-15

DRIVE ENABLE 06.12 06.15 Division

Field economy

Economy timeout Enable economy timeout

Limitation

Menu 06 Field control
Max. field current 2 06.09

Max. field current 1

speed loop gain adjustment Current loop Integral gain 06.16 06.23 03.09 03.10
Field feedback scaling I - Gain 06.17 06.11
Field current feedback 06.03 06.24
Firing angle front endstop 06.21

1 06.04

ARMATURE VOLTAGE Back emf 06.01

Back - emf set point

Field current demand P +I 06.02

Absolute value

Scaling X1 03.02 x 06.07
0 P +I 06.19 FIRING ANGLE

06.10 Min. field current

06.22 Full control
IR Comp. 2 source selector IR Comp. 2 06.05 output

SPEED ERROR INTEGRAL

06.13 Speed feedback Back - emf set point 03.02 06.07

IR Comp. 2

3300 1800

Figure 8-16

Current loop select Speed ref. destination 10.Disable o/temp. trip 07.10.21 Motor temp. Thermistor (Thermal switch) Input
Current Loop / Encoder (Pulse Tach.) Inputs Encoder CURRENT LOOP ref. select INPUT SELECTION 07.28 07.27 Input 07.26 Current loop 0-20mA 07.25 20-0mA mode select 4-20mA Voltage07.27 20-4mA to-frequ. 07.28 convertor 1 Speed ref. TB1 - 03 Speed ref. Input V scaling 07.05 07.20 Encoder scaling 1 PL4 07.24 1H 9 10
Menu 07 Analog inputs and outputs
Hard speed ref. Default 03.18 Scaling 07.16 07.01

60 to 300V 1G 50 to 200V

NOTE GP2 becomes dedicated as Mains Healthy (AC Power Normal) input when parameter 11.24 = 1
Tachogenerator (Tachometer) Input
Input impedance 100k 07.12 Scaling 07.17 07.08 Analogue Outputs
10 to 50V Final speed demand Default 02.01 Scaling 07.21 Imotor Switches SW1F, G, H, refer to Fig 14 RV1
Speed ref. 3 Default 04.08 07.02
07.13 Scaling 07.18 07.09 07.03 Scaling 07.22 07.14 Scaling 07.19 07.10 07.04 Scaling 07.23

ST1 = I lim AND Z speed = Stall
37 Default 38 Drive ready 39 Contact loading 5A, 240V AC
Invisible parameters are in italics, eg 09.07

Figure 8-19

Threshold destination 12.07 12.12 12.xx Hysteresis 12.05 12.10 12.xx 12.xx Output invert 12.06 12.11
Threshold source 12.03 12.08
Menu 12 Programmable thresholds
Threshold level 12.04 12.09

12.xx 12.xx

Examples of the use of Programmable Thresholds: 1
Threshold exceeded 12.01 12.1
to change ramp rates at a certain speed. 2 Torque-proving (hoists and strip handling).
KEY R/W logic Internal logic Inversion
To control parameter 02.18, the Common Ramp Selector,

Hysteresis loop

Reference encoder selector Reference source Speed ref. input 13.07.0 13.10 Position software enable 07.25 1

Figure 8-20

Master Encoder (Reference)
Reference ON 01.11 INCH selector 01.13

Speed feed fwd. 01.18 1

Menu 13 Digital lock
Precision reference latch 13.13 Hard speed ref. Selector 03.19 Ramp output ref. Selector 03.21 Position software enable 13.10 x (-1) At speed 10.07 Rigid lock enable 13.11 Disable normal logic functions 08.1 Reverse selector 0 01.12 F2 input inch rev. 08.02 1

(13.07x 256) + 13.06

Precision references

F3 input inch fwd.

Correction limit

Inch reference

1 EPOS bit

Position gain

Speed correction
13.1 Digital feedback selector 03.12

x (-1)

Slave Encoder (Feedback) Encoder scaling 03.14
Speed feedback 1 R/W logic R/O logic Internal logic Limitation KEY Summation 1 03.02
Invisible parameters are in italics, eg 08.21

Diagnostic procedures

Trip codes
An instantaneous protection trip has been activated due to excess current in the armature circuit Drive has detected that the firing angle has advanced but no current feedback has been detected Indicates that an error has been detected in the parameter set read from the EEprom at power-up Overcurrent trip at the 24V supply output terminal (TB4-33) has operated, indicating an overload in the external circuit connected to this supply. Maximum current available is 200mA Parameter 10.34 = 1. The external trip set up by the user has operated No signal from tachogenerator (tachometer) or encoder (pulse tachometer) The polarity of the feedback tacho or encoder polarity is incorrect. This trip does not operate on 1Q drives No current in field supply circuit The user has initiated self-tuning (05.09) and field current has been detected Excess current detected in field current feedback. If current feedback is present and firing angle is phased back, then trip A hardware fault has been detected during the self-diagnosis routine performed after power-up. Users are recommended to consult the supplier of the drive The integrating overload protection has reached trip level Thyristor (SCR) heatsink overtemperature. Only on drives equipped with heatsink thermistors (thermal switches) Indicates a fault in the MDA1 hardware has been detected by malfunctioning of Processor 1 software Indicates a Processor 2 malfunction, or a software bug (MD29 option) Connections to E1 and E3 are not the same phases as are connected to L1 and L3. Investigate and correct One or more of the internal power supplies is out of tolerance (Only in serial comms mode 3) No input data detected One or more of the power (input) supply phases is open-circuit Motor protection thermistor (thermal switch) has initiated a trip indicating windings overheating. Trip threshold 3k5%. Reset 1.8k Refer to the MD29 Users Guide Trip codes in numerical order A29 hF PhS Et EPS cL ScL FOC Oh FdO Fbr FdL FbL SL AOC It th Pc1 PS AOP Pc2 EEF 40 - MD29 fault Hardware fault Phase sequence External trip External power supply Current (control) loop open circuit Serial communications link (interface) loss Field overcurrent Overheat Field on Feedback reversal Field loss Feedback loss Supply loss Armature overcurrent I x t trip Thermistor (thermal switch) Processor 1 watchdog Power supply Armature open circuit Processor 2 watchdog EEprom failure.

doc1

Mentor II
Digital DC Drive 25 A-1850 A
CTi Automation - Phone: 800.894.0412 - Fax: 208.368.0415 - Web: www.ctiautomation.net - Email: info@ctiautomation.net
Mentor II: the most versatile DC systems drive in the world
The Mentor ll provides a wide power range of fully programmable DC drives with a unified control interface. Simple stand-alone applications are quickly configured with a minimum of parameters. Add the application module (MD29) to implement high performance drive systems with local intelligence. This intelligence can then be utilised to eliminate the master PLC by constructing a distributed control system, using the CTNet fieldbus with the System Programming Tool (SYPT). When integration with a master PLC system is required, a range of fieldbus adapters is available. Wide range of network communication options Integrated communication to PLC and host computer User configurable analogue and digital drive inputs Reduced commissioning time with simplified drive set-up Elongation or shrinkage control through position synchronisation Constant web tension by continuous torque adjustment Easy to use PC configuration Software: Mentorsoft. Better Control A comprehensive self-tuning algorithm gives improved current loop performance for a more uniform response at all speeds. Drive performance is also enhanced with full PID digital speed control. More Functions The main circuit board has been developed to incorporate many additional features as standard not as costly options. These include serial communications and a field-weakening controller for constant power applications (M25 - M210 R). Massive Systems Potential All analogue inputs and most of the digital control inputs are userconfigurable, making Mentor II a true systems drive having more versatility and flexibility than ever before. Wide Ranging, More Flexible Communications A standard RS485 port enables Mentor II to communicate directly with PLCs and host computers. Optical Isolation means that a number of drives can be multidropped onto a standard RS485 interface for networking with other control devices. A port is also provided to accept interface cards for CT Net, Profibus-DP Interbus S and DeviceNet. , Mentorsoft WINDOWS Based commissioning tool
Simple Operation Easy set up of the drive can be done using the main control panel or via a standard communications interface from a host computer. All operating parameters are organised into logically structured function menus. Fast configuration of standard applications can be achieved using 10 parameters or less. Faster Drive Set-Up Programming the Mentor II has never been easier. Designed to save commissioning time the drive has comprehensive data displays, easily assimilated function menus and a five-key control panel.
. A flexible digital DC drive for.
multiple plant applications
CT Net Interface (MD29AN) High speed network protocol De-centralised peer-to-peer networking requiring no master PLC controller Programmed using SYPT Profibus-DP Interface (MD24) High speed network protocol Works on a centralised network system Generic configuration file available for Siemens S5 PLC DeviceNet Interface (MD25) High speed network protocol using the CAN hardware layer Works on a centralised network system EDS files available Interbus-S Interface (MDIBS) Easyfit interface card for Interbus-S network communications Works as a centralised master controller 500 kbit/sec fixed data rate Network loss detection Expansion I/O Module (I/O box) Connects to the MD29 using RS485 comms and provides remote I/O capability 5 analog inputs 3 analog outputs 8 digital inputs 8 digital outputs Digital I/O expandable to 32 inputs and 32 outputs Up to 15 I/O Boxes can be controlled on one serial communications link 100 metres (330 feet) maximum serial - communications cable length Field Controller For DC Motors (FXM5) Armature voltage feedback 220 V to 600 V DC Field current to 20 A 1phase input Half or fully controlled thyristor output
Standard Features Microprocessor based control circuits Logical push-button programming Advanced auto-diagnostics Software expandable Regeneration up to 1.15 x VRMS Serial interface - RS232/485 Non-volatile memory for parameter storage Single and four quadrant models Armature voltage, tacho or encoder feedback Phase sequence tolerant 0.025% resolution for analogue speed demand 0.1% speed holding for 100% load change with tacho feedback Field loss protection Electronic motor-overload protection Feedback loss protection Phase loss protection 150% overload capacity for 30 seconds Taper current limit Armature current slew rate limiting

Easy Expansion

Application Module (MD29) Easy plug in second processor Cost saving facility to write application specific programs without the need to use a PLC or stand alone controller Programmed using DPL or SYPT an IEC 1131 compliant programming tool incorporating ladder and function block programming. Embedded single axis position controller
Multiple application solutions
Digital Speed And Position Loop This allows several drives to be run in speed or position synchronisation. Shaft positions can be offset or an adjustable speed ratio introduced to control elongation or shrinkage in applications such as plastics extrusion, wire drawing and textile manufacture. Centrewinder Designed for maintaining a constant web tension in coiling and uncoiling applications mainly in the paper, wire, plastics and metals industries. The drive torque is continuously adjusted to compensate for changing coil diameter, machine losses and coil inertia. Shaft Orientation This allows the user to specify the final position of the motor shaft relative to an electronic feedback datum, for example a marker pulse from an encoder. The position is adjusted by simply changing the value of the appropriate parameter. An output signal is provided on completion of orientation. This
function is widely used for CNC machine toolchanging and other automated applications. Field Controller On drives from M25 M210/R the MDA3 controller is fitted as standard. The field controller provides total control over the motor field current such that a constant kW characteristic can be obtained. This facility is particularly useful for constant power applications such as machine tools, mixers, coilers and winders. An integral field failure detector ensures full protection, and full digital control assists commissioning and operation. A fixed field supply is provided on units in the range M350 M1850. For applications requiring a field controller of up to 20 A the FXM5 is available. S Ramp This facility provides a curved function at each end of a user defined acceleration/ deceleration ramp. The S ramp in each quadrant is determined by parameters which control the linear part and the curved part of the S respectively.

S-RAMP acceleration/time

S-RAMP velocity/time
Due to the greater smoothness and progressive speed transitions, typical applications are lifts, hoists, cranes and conveyors.

Technical data

DRIVE RATINGS Drive type & Model Four Single Quadrant Quadrant
M25 M45 M75 M105 M155 M210 M350 M420 M550 M700 M825 M900 M1200 M1850 M25R M45R M75R M105R M155R M210R M350R M420R M550R M700R M825R M900R M1200R M1850R
Typical (1) Motor Rating @ 400 DC

KW 7.30 37.750

Maximum Continuous Current Rating (Amps)

AC Input 1000 1540

DC Output

603 1105

1200 1850
(1) This rating may be increased at higher armature voltage. (2) DC fuses must be fast semiconductor type, with a rated voltage of 500V DC for 400V supply and 700V DC for 480V supply. (3) The cable sizes are for 3-core (3-wire) and 4-core (4-wire) pvcinsulated armoured (conduited) cable with copper conductors, and laid in accordance with defined conditions. (4) Typical wire gauge sizes based on 300C (860F) ambient, 1.25 x rated current, 750C (1670F) copper wire with no more than 3 conductors in a conduit or raceway. Branch circuit protection must be provided by the user. All wiring must conform to NEC Art. 310 and applicable electrical codes. (5) Not required for Single Quadrant. May not be required in applications where load inertia is low and regeneration infrequent. (6) Refer to NEC Table 310-16 for wire sizes. (7) M25 - M210 fitted with MDA3 field controller as standard. (8) Fixed voltage. Optional field controller FXM5 available.

INSTALLATION DATA

Drive Type & Model Single Quadrant M25 M45 M75 M105 M155 M210 M350 M420 M550 M700 M825 M900 M1200 M1850 Four Quadrant M25R M45R M75R M105R M155R M210R M350R M420R M550R M700R M825R M900R M1200R M1850R Recommended Fuse Ratings Semiconductor (2) HRC AC In (A) AC In (A) DC Out (A) 2x700 2x(5) 70 (5) 125 (5) 175 (5) 250 (5) 300 (5) 550 (5) 700 (5) 900 (5) 1000 (5) 1200 (5) 2x700 (5) 2x900 (5) 2x1000 (5) Typical Cable Size AC Input & DC Output mm2(3) 4mm2 6mm2 25mm2 35mm2 50mm2 95mmmm2 185mm2 300mm2 2x185mm2 2x240mm 2x240mm2 3x400mm2 3x400mm2 AWG (4) 2 1/0 3/0 300MCM (6) (6) (6) (6) (6) (6) (6) (6) Convection Convection Convection Fan Cooled Fan Cooled Fan Cooled Fan Cooled Fan Cooled Fan Cooled Fan Cooled Fan Cooled Fan Cooled Fan Cooled Fan Cooled Max Field Current Rating (A) 8 (7) 8 (7) 8 (7) 8 (7) 8 (7) 8 (7) 10 (8) 10 (8) 10 (8) 10 (8) 10 (8) 20 (8) 20 (8) 20 (8)

Cooling Method

 

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