Brief Commissioning Instruction

Transcription

1 Brief Commissioning Instruction 5th Generation of Inverters COMMISSIONING BASICS REPLACEMENT SERVICE V /2007 GB MI BCI AM Fieldbus Applications POSI Switch

2 Brief Commissioning Instructions 5th Generation of Inverters Table of Contents TABLE OF CONTENTS 1. Notes on Safety Hardware Software 3 2. Description 4 3. Device Device states Standard state machine State machine acc. to DSP Parameters 9 4. User Interfaces POSITool Operator panel LED Display General Event indications Event list Commissioning an Inverter Service Replacing inverters Change an application by exchanging the Paramodule 27

3 5th Generation of Inverters 1. Notes on Safety 1 NOTES ON SAFETY This manual contains information which must be adhered to in order to prevent personal injury and property damage. This information is graduated by degree of damage as shown below. ATTENTION Means that an undesired result or undesired state may occur if this note is not heeded. CAUTION Without warning triangle: Means that property damage may occur if appropriate precautions are not taken. CAUTION With warning triangle: Means that minor personal injury and property damage may occur if appropriate precautions are not taken. WARNING Means that major danger of death and substantial property damage may occur if appropriate precautions are not taken. DANGER Means that great danger to life and substantial property damage will occur if appropriate precautions are not taken. NOTE Indicates an important piece of information on the product or the drawing of attention to a part of the documentation requiring special attention. ACTION Means the description of an action which is particularly important for handling the product. 1

4 5th Generation of Inverters 1. Notes on Safety 1.1 Hardware WARNING To ensure that avoidable problems do not occur during commissioning and/or operation, be sure to read these installation and commissioning instructions before installation and commissioning. In the sense of DIN EN (formerly VDE 0160), the FDS and MDS model series of POSIDRIVE are electrical components of power electronics for the regulation of energy flow in high-voltage systems. They are exclusively designed to power servo (MDS) and asynchronous (FDS, MDS) machines. Utilization, installation, operation and maintenance are only permitted under observation and adherence to valid regulations and/or legal requirements, applicable standards and this technical documentation. This is a product of the restricted sales class in accordance with IEC In a residential zone, this product may cause high-frequency interference in which case the user may be requested to take suitable measures. Strict adherence to all rules and regulations must be ensured by the user. The safety notes contained in further sections (items) and specifications must be adhered to by the user. WARNING Caution! High touch voltage! Danger of shock! Danger to life! When network voltage is applied, never under any circumstances open the housing or disconnect the connections. When installing or removing option boards, you may only open the inverter in the dead state (all power plugs disconnected) and only after a waiting period of at least 5 minutes after the network voltage is switched off. Prerequisite for the correct functioning of the inverter is the correct configuration and installation of the inverter drive. Transport, installation, commissioning and handling of the device may only be performed by qualified personnel who have been especially trained for these tasks. Pay particular attention to the following: Permissible protection class: Protective ground. Operation is only permitted when the protective conductor is connected in accordance with regulations. Direct operation of the devices on IT networks is not possible. Installation work may only be performed in the dead state. For work on the drive, lock enable and disconnect the complete drive from the power. (Observe the 5 safety rules.) Leave the plug for the DC link coupling connected even when the DC link coupling is not being used (BG0-BG2: X22)! Discharge time of the DC link capacitors > 5 minutes. Do not penetrate the device's interior with any kind of object. During installation or any other work in the switching cabinet, protect the device against falling parts (pieces of wire, stranded wire, pieces of metal, and so on). Parts with conductive properties may cause a short circuit within the inverter or device failure. Before commissioning, remove extra coverings so that the device cannot overheat. The inverter must be installed in a switching cabinet in which the maximum ambient temperature (see technical data) is not exceeded. Only copper lines may be used. The line cross sections to be used are contained in table of the NEC standard at 60 o C or 75 o C. The company GmbH + Co. KG accepts no liability for damages resulting from non-adherence to the instructions or the particular regulations. 2

5 5th Generation of Inverters 1. Notes on Safety The motor must have an integral temperature monitor with basis insulation as per EN or external motor overload protection must be used. Only suitable for use on supply current networks which cannot deliver more than a maximum symmetric, nominal, short-circuit current of 5000 A at 480 Volt. Subject to technical changes without prior notification which changes serve to improve the devices. This documentation is purely a product description. It does not represent promised properties in the sense of warranty law. 1.2 Software Use of the POSITool software The POSITool software package can be used to select an application, adjust parameters and signal monitoring of the 5th generation of inverters. The functionality is specified by the selection of an application and the transmission of these data to an inverter. The program is the property of GmbH + Co. KG and is protected by copyright. The program is licensed for the user. The software is provided exclusively in machine-readable format. The customer receives from GmbH + Co. KG a nonexclusive right to use the program (license) if the program was obtained legally. The customer has the right to utilize the program for the above stated activities and functions and to make and install copies of the program, including one backup copy, for support of said utilization. The conditions of this license apply to all copies. The customer is obligated to place the copyright note and all other ownership notes on every copy of the program. The customer is not authorized to use, copy, change or pass on/transmit the program for reasons other than those covered by these conditions; the customer is also not authorized to convert the program (reverse assembly, reverse compilation) or compile the program in any other manner, or to sublicense, rent or lease the program. Product maintenance The obligation to perform maintenance applies to the two last current program versions prepared and released for use by GmbH + Co. KG. GmbH + Co. KG can either correct program errors or provide a new program version. The choice is up to GmbH + Co. KG. If, in individual cases, the error cannot be corrected immediately, GmbH + Co. KG will provide an intermediate solution which, if necessary, requires adherence by the user to special operating regulations. The claim to error correction only exists when reported errors are reproducible or can be recorded by machine-made outputs. Errors must be reported in reconstructable form giving useful information for error correction. The obligation to correct errors is invalidated for such programs which the customer changes or manipulates unless the customer can prove when reporting the error that the manipulation is not the cause of the error. GmbH + Co. KG is obligated to keep the currently valid program versions in a specially protected place (fire-resistant data safe, safety deposit box at a bank). 3

6 Brief Commissioning Instructions 5th Generation of Inverters 2. Description 2 DESCRIPTION Introduction Up to four axes can be configured for a 5th generation inverter. An axis can be used as parameter record. This allows a motor to be operated with various applications. Up to four motors can be connected and operated on devices of the MDS 5000 series with the POSISwitch AX 5000 option. This option requires the following system structure. The system of the 5th generation of inverters is divided into two areas - the global area and the axis area. The global area contains the programming and parameterization related to the inverter. This includes device control, the setting of I/O components such as brake resistors and so on. In addition, it is responsible for managing the axis area. The axis area is divided into up to four axes. Each axis contains the programming and parameterization for one motor and is addressed by the global area. The axis area contains the motor setting and the application of the motor. The uses are defined by in so-called applications or, optionally, can be programmed as desired by the user. Global area Axis areas ESC # Axis 1 X3 I/O Axis 2 Axis 3 Axis 4 Purpose of the manual Circle of readers Other manuals Other support Figure 2-1 Setup of global and axis area This manual gives you information on commissioning the 5th generation of inverters. The principal procedures are explained. The purpose of the manual is: To familiarize you with the basic knowledge about the inverter system To enable you to commission a drive system quickly To permit you to replace an inverter quickly Users who are familiar with controlling and commissioning drive systems are the target group of this manual. For further information, see the following manuals. Mounting instructions for mounting of the FDS 5000 (publ. no ) respectively for mounting of the MDS 5000 (publ. no ). Application manual (publ. no ) for a description of the applications which makes available to you Programming manual (publ. no ) for a detailed description of the system and its free programming If you have questions about the use of devices of the 5th generation of inverters which are not answered by these manuals, we will be glad to advise you under the telephone number To simplify getting started with the use of our software, we also offer courses. Contact our training center at the following address. GmbH + Co. KG Training Center Kieselbronner Strasse Pforzheim 4

7 Brief Commissioning Instructions 5th Generation of Inverters 3. Device 3 DEVICE General The 5th generation of inverters is primarily a freely programmable system. Two ways of programming are available to the user. Applications defined by which can be selected via an assistant in the POSITool software. Parameterization is performed to adapt the application to its task. The application is then transferred to the inverter. On delivery, the application fast reference value is stored. The option free, graphic programming with the aid of the POSITool software This chapter describes the general reactions of the MDS 5000 in interplay with the applications defined by. NOTE Please note the peculiarities of commissioning an inverter with the safety function "safe torque off." For details see the Mounting Instructions for the MDS 5000, publ. no , chap for the FDS 5000 publ. no , chap Device States Indroduction For the solution of a technical drive task, the programming of the inverter system must conform to the sequence of certain device states. They define the state of the power portion and implement functions such as the control of the end stage, restart of the drive and fault handling. This is the only way to ensure safe operation and the defined state of the devices. The device state can be changed with control commands and internal events. The 5th generation of inverters offers you a choice between a standard state machine and a state machine as per DSP 402. You can select the state machines in the Configuration Assistant of the POSITool software (see chap. 5 of the application manual, publ. no ) Standard state machine Description Display Designation Behavior The following eight states exist in the standard state machine in accordance with the DRIVECOM profile for drive technology. MDS 5000** V5.X Or ±0Rpm 0.0A 0: Self test Not ready to switch on - The electronics are powered. - Self-test is running. - Initialization is running. - Drive function* is disabled. - Ready-for-operation relay is open. ±0Rpm 0.0A 1: ONdisable Switchon disable - Software/hardware initialization is finished. - The application was reparameterized. - The drive function* is disabled. - The ready-for operation relay is closed. - The option ASP 5001 (starting lockout) is active. ±0Rpm 0.0A 2: ReadyforON Ready to switch on - The application can be reparameterized. - The drive function* is disabled. - The ready-for-operation relay is closed. ±0Rpm 0.0A 3: Switched on Switched on - The application can be reparameterized. - The drive function* is disabled. - The ready-for-operation relay is closed. ±0Rpm 0.0A 4: Enabled Operation enabled - The application can be partially reparameterized. - The drive function* is enabled. - The ready-for-operation relay is closed. 5

8 Brief Commissioning Instructions 5th Generation of Inverters 3. Device Display Designation Behavior No.X: type of fault (2nd line flashing) ±0Rpm 0.0A 7: Quick stop reaction active Quick stop active - The application can be partially reparameterized. - The drive function* is disabled. - The ready-for-operation relay is open. - The application can be reparameterized. - An error-dependent action is being executed (disable drive function or quick stop). - The drive function* can be enabled. - The ready-for-operation relay is open. - The application can be reparameterized. - The quick stop function is being executed. - The drive function* is enabled. - The ready-for-operation relay is closed. * The drive function includes everything from the power portion of the inverter and the application. A disabled drive function means the same as a power part which is switched off and a reset application (e.g., reset ramp generator). This means that the drive is not following the reference value. ** Depends on the device family being used Changes in state The following figure 3-1 shows which state changes are possible in the inverter system. The table below shows which conditions apply. 14 Störungsreaktion reaction active aktiv 0 15 Not Nicht ready Einschaltbereit for switchon Störung Switchon Einschaltsperre disable Ready Einschaltbereit for switchon Eingeschaltet Switched on 4 Operation Betrieb freigegeben enabled 7 8 Quick Schnellhalt stop active aktiv Change in State Figure 3-1 Standard state machine Conditions 0 Input, state machine Not ready for switchon - Control power portion switched on 1 Not ready for switchon Switchon disable - Self-test without errors and initialization concluded 2 Switchon disable Ready for switchon 3 Ready for switchon Switched on - Enable on low level or autostart active during first startup - DC link charged - option ASP 5001 deactivated - Axis activated - Enable on high level - Option ASP 5001 inactive 4 Switched on Operation enabled - Enable on high level 5 Switched on Ready for switchon - Enable on low level 6

9 Brief Commissioning Instructions 5th Generation of Inverters 3. Device Change in State 6 Ready for switchon Switchon disable 7 Operation enabled Quick stop active 8 Quick stop active Operation enabled 9 Quick stop active Ready for switchon Conditions - DC link not charged or option ASP 5001 active or axis deactivated - "Quick stop" signal on high level or enable on low level and "quick stop with enable off" signal active - Enable for high level and "quick stop" signal on low level and quick stop end reached in accordance with parameterization - Enable for low level and quick stop end reached in accordance with parameterization 10 Quick stop active Switchon disable - Option ASP 5001 active 11 Operation enabled Ready for switchon - Enable for low level and "quick stop with enable off" inactive 12 Operation enabled Switchon disable - Option ASP 5001 active 13 Switched on Switchon disable - DC link not charged or option ASP 5001 active 14 All states reaction active - detected 15 reaction active - reaction concluded 16 Switchon disable - No fault is queued and rising edge of the "acknowledgment" signal 7

10 Brief Commissioning Instructions 5th Generation of Inverters 3. Device State machine acc. to DSP 402 Description The state machine as per DSP 402 has the same states as the standard state machine. The following table shows the designation of the states as per DSP 402. Display* Designation acc. to DSP 402 Or MDS 5000** V5.X ±0Rpm 0.0A 0: Self test ±0Rpm 0.0A 1: ONdisable ±0Rpm 0.0A 2: ReadyforON ±0Rpm 0.0A 3: Switched on ±0Rpm 0.0A 4: Enabled Störung Nr.X: type of fault (2nd line flashing) ±0Rpm 0.0A 7: Quick stop Not Ready to Switch On Switch On Disabled Ready to Switch On Switched On Operation Enable Reaction Active Quick Stop Active Table 3-1 Designation of the device states as per DSP 402 * Depending on the applications, indication of the device states may differ from what is shown. ** Depends on the device family being used Commands of the state machine Some changes in state require that the state machine detect certain commands. The commands are bit combinations in the DSP 402 control word (parameter A576 Controlword). Table 3-2 shows the states of the bits in parameter A576 and their combination for the commands. Command Bit of the control word (A576 Controlword) Bit 7 Bit 3 Bit 2 Bit 1 Bit 0 Reset Enable Operation Quick Stop Enable Voltage Switch On Shutdown 0 X Switch On Disable Voltage 0 X X 0 X QuickStop 0 X 0 1 X Disable Operation Enable Operation Reset Pos. edge X X X X Table 3-2 Definition of the commands for the state machine as per DSP 402 (the bits marked with X are irrelevant). 8

11 Brief Commissioning Instructions 5th Generation of Inverters 3. Device State machine The difference between the state machines is the possible state changes and the conditions for the changes. Figure 3-2 shows the possible changes in state. 13 Störungsreaktion reaction active aktiv 0 14 Not Nicht ready Einschaltbereit for switchon Störung Switchon Einschaltsperre disable Ready Einschaltbereit for switchon 3 6 Switched Eingeschaltet on 4 5 Operation Betrieb freigegeben enabled 11 Quick Schnellhalt stop active aktiv Figure 3-2 State machine as per DSP 402 The following table lists the conditions for changes in the state machine. Change in State Conditions 0 Input, state machine Not ready for switchon - Control power portion switched on 1 Not ready for switchon Switchon disable - Self-test without errors and initialization concluded 2 Switchon disable Ready for switchon 3 Ready for switchon Switched on 4 Switched on Operation enabled 5 Operation enabled Switched on 6 Switched on Ready for switchon 7 Ready for switchon Switchon disable - Enable on high level and command Shutdown and option ASP 5001 deactivated - Enable on high level and command Switch On u and option ASP 5001 deactivated - Enable on high level and command Enable Operation and option ASP 5001 deactivated - Enable on high level and command Disable Operation and option ASP 5001 deactivated - Enable on high level and command Shutdown and option ASP 5001 deactivated - Enable on low level or - Command Quickstop or - Command Disable Voltage or - Option ASP 5001 activated 8 Operation enabled Ready for switchon - Command Shutdown 9 Operation enabled Switchon disable - Enable on low level or - Command Disable Voltage or - Option ASP 5001 activated - Enable on low level or 10 Switched on Switchon disable - Command Quickstop or - Command Disable Voltage or - Option ASP 5001 activated 11 Operation enabled Quick stop - Command Quickstop 12 Quick stop Switchon disable - Quick stop finished 13 All states reaction active - detected 14 reaction active - reaction concluded 15 Switchon disable - Command Reset (positive edge) Table 3-3 Conditions of the change in state for the state machine as per DSP 402 9

12 Brief Commissioning Instructions 5th Generation of Inverters 3. Device 3.2 Parameters Introduction Structure Parameters perform various tasks in the inverter system. Adjust the application to exterior conditions such as motor type Indicate values such as the current speed or the torque Trigger actions such as store the values or the phase test Parameters are assigned to the global or the axis area. The parameter structure is set up as shown in the adjacent example. The axis code identifies an axis parameter when it is shown mixed with global parameters. The group divides the parameters into functional characteristics. The line distinguishes the individual parameters in a group. The element subdivides a parameter into subfunctions. Axis (only for axis parameters) Group Figure 3-3 Parameter structure 1.E250.2 Line Element The individual subject areas of the parameter groups are listed in the table below. Parameter Group A.. Inverter B.. Motor C.. Machine D.. Reference Value E.. Display Value F.. Control Interface G.. Technology H.. Encoder I.. Positioning J.. Process Blocks L.. PLCopen Reference Values N.. Posi.Switches P.. Customer-specific parameters Q.. Customer-specific parameters, dependent on instance R.. Production data T.. Scope Subject Area/Dependency Inverter, bus, cycle time Motor Speed, torque Speed ref. values, reference value generator Indication for device and application Analog inputs / outputs, binary inputs / outputs, brake Depends on the application (e.g., synchronous running) Encoder Only with positioning applications Only with positioning application motion block positioning Only with positioning application PLCopen Only with positioning applications Only with free, graphic programming option Only with free, graphic programming option Production data of inverter, only visible during online operation Scope parameters U.. Protection functions Parameterizing the results, see chap. 4 Z.. counter counter of events; In POSITool only visible during online operation. 10

13 Brief Commissioning Instructions 5th Generation of Inverters 3. Device Data types Name Abbrev. Name Description Value Range Boolean B 1 Bit (internal: LSB in 1 Byte) Unsigned 8 U8 1 byte, without sign Integer 8 I8 1 byte, with sign Unsigned 16 U16 2 bytes 1 word, without sign Integer 16 I16 2 bytes 1 word, with sign Unsigned 32 U32 4 bytes 1 double word, without sign Integer 32 I32 4 bytes 1 double word, with sign Float R32 Floating decimal, simple accuracy Double R64 Floating decimal, double accuracy In acc. w. ANSI / IEEE 754 String 8 STR8 Text, 8 characters String 16 STR16 Text, 16 characters Posi 64 P64 32 bits, increments bits, remainder Parameter list structure The following information is important when parameters are to be addressed via fieldbus. Value range Scaling via fieldbus if this differs from the scaling via POSITool. Rounding error via fieldbus if present Data type They are specified in the parameter table of the application description. Fieldbus addresses are specified in hexadecimal format. For CANopen, index and subindex can be used as is. For PROFIBUS DP-V1, index = PNU and subindex = index. For more details, see documentations of the fieldbus interface (CANopen, publ. no ; PROFIBUS DP, publ. no ). 11

14 Brief Commissioning Instructions 5th Generation of Inverters 4. User Interfaces 4 USER INTERFACES Description The user interfaces of the 5th generation of inverters consist of several elements with different functionalities (see figure 4-1 user interfaces). To program a device of the 5th generation of inverters, the user needs the POSITool software. With the POSITool software, either an application defined by or a freely programmed application can be used as an option. POSITool provides a parameter list with which the application can be adjusted. The software also has comprehensive diagnostic functions. Parameters can also be changed via the operator panel on the front of the inverter. It consists of a keyboard for calling the menu functions and the display for indication. When appropriately programmed, the keyboard can be used to implement functions such as manual operation or tipping. Response messages on the device status are shown by the LEDs on the front. The display provides detailed information. P T S o Program Parameterize Diagnose X3 Display Oper. panel LED Oper. indication Device states Events Parameterize Device states Figure 4-1 User interfaces 4.1 POSITool POSITool Programming Parameterization Interface The POSITool software represents the many-sided interface between user and inverter. If offers a wide variety of ways to configure an inverter. POSITool offers a user interface for the representation of the programming. In the option "free, graphic programming," blocks are linked here to implement a control sequence. In addition to this provides defined applications for programming. This includes applications such as fast reference value and command positioning which can be selected via an assistant. For parameterization, POSITool offers the user parameters lists. The lists are used to adjust the control sequence to external conditions such as motor type, shaft encoder or bus systems. In addition, limit values such as maximum speed are specified or indicator values such as the current speed are presented. Using a serial interface (RS 232), program and parameters are transferred to the inverter. The inverter then begins with processing. The user can monitor the parameters via the serial connection. A scope function is available for expanded diagnostics to record the time progression of various values. For more details on the use of POSITool, see the applicable chapter of the application manual or programming manual (publ. no and publ ). 12

15 Brief Commissioning Instructions 5th Generation of Inverters 4. User Interfaces 4.2 Operator Panel Description The operator panel of the 5th generation of inverters is used for monitoring and for changing parameter values. The operator panel consists of a two-line display with 16 characters each and a keyboard. The keyboard has six keys for menu functions and two keys for local operation. ESC Jump back to operator level Reset parameter value # Enter key: Open the menu level, menu groups and the parameters. Accept a changed parameter value. Selects a parameter in the menu group. During entry, increments/decrements the parameter value (positive/negative). Selects the menu group. During entry, changes the decade (ones, tens, hundreds, and so on). Activate/deactivate local mode (if programmed). In local mode deactivation also deletes the enable. I/O Enable for local mode I/O (if programmed) LED status indicator Figure 4-2 Operator panel Paramodule Menu prompting The parameter menu of the inverter is divided into menu groups. The menu groups are arranged in alphabetical order, beginning with the group A.. Inverter, B.. Motor, C.. Machine, and so on. Each menu group contains a list of parameters which are identified by the letter of the group and a consecutive number such as A00, A01, A02, etc. A.. Inverter Parameter groups Oper. indicator 3000 Rpm 1.3 A 4: Enabled B.. Motor C.. Machine To change a parameter, proceed as shown below. Use the Enter key # to go from the operation indicators to the menu level. The menu groups are selected with the arrow keys and activated with #. Use the keys to select the desired parameter within the menu group. You can switch back and forth between the elements in an array parameter with the keys. A parameter is then activated with #. The value flashes to indicate that it can be changed with. The keys can be used to select which decade (ones, tens, hundreds, and so on) is to be adjusted. The value is then accepted with the # key or reset with the ESC key. Use the ESC key to access a higher menu level. B20 Ctrltype 0: U/f control Parameter entry Value flashing To save safe from power failure, all changes must be stored with the A00 save parameter = 1: active! Parameter selection B26 Crtltype 3: X140 B26 Ctrltype 3: X140 Accept change Reject change Figure 4-3 Menu structure 13

16 Brief Commissioning Instructions 5th Generation of Inverters 4. User Interfaces 4.3 LEDs Description The LEDs on the front of the inverter give you a quick overview of the state of the inverter. A green and a red LED which light up in different combinations and frequencies provide information on the device's status based on the following table. LEDs State of the inverter ERROR Red RUN Green OFF OFF No power ERROR (red) RUN (green) Figure 4-4 LED ERROR Red RUN Green ERROR Red RUN Green OFF/ON Flashing at 8 Hz OFF Flashing at 1 Hz Device initialization (startup phase) or data action (A00 is active). Paramodule is not installed correctly. Ready for operation (not enabled) ERROR Red RUN Green OFF ON Operation (enabled) ERROR Red RUN Green Flashing at 1 Hz ON or flashing Warning (see chap ) ERROR Red RUN Green ON OFF (see chap ) ERROR Red RUN Green Flashing at 8 Hz OFF No configuration active 14

17 Brief Commissioning Instructions 5th Generation of Inverters 4. User Interfaces 4.4 Display Description General Description The display gives the user a detailed response message on the state of the inverter. In addition to the indication of the parameters and events, the device states are shown. The display permits an initial diagnosis without additional aids. After the self-test of the inverter, the operation indication appears on the display. Depending on the configuration and the current device state, the first and second line of the display may differ from what is shown in the example. In the figure, the configuration fast reference value is shown in the device state "enabled" (for device states, see chap. 3). If no axis is active, this is indicated with an asterisk (*). The active axis is then shown when it differs from axis no. 1. Only for active brake chopper or active local mode does the appropriate symbol appear on the display. Speed Current 3000 Rpm 1.3A 4: Enabled Device state (see chap. 3) Axis no. 2 active Figure 4-5 Display indication Brake chopper active Event Indications Events Event level Event indications on the display give the user information on the status of the device. A list of event indications is contained in the following table. Other displays than shown in the table are also possible. For more information, see the application and system manuals (publ. no and ). Various levels exist for events: messages, warnings and faults. Message: A message does not affect the operation of the drive. It is indicated on the display. Warning: A warning is shown on the display. If the cause of the event is queued during a parameterizable period of time, a fault is generated. During this period of time, the warning does not affect operation. : When an event occurs with the level "fault," the inverter changes to the device states "fault reaction" and "fault." The event appears on the display Event list No: Name 31:Short/ground. 32:Short/gr.int. 33:Overcurrent Description The hardware overcurrent switchoff is active. The motor requires too much current from the inverter (interwinding fault, overload) Acknowledgment: Turn device off/on or programmed acknowledgment Other: The motor always coasts down. counter: Z31 An internal check is performed when the inverter is enabled. An existing short circuit will cause a fault. An internal device error exists. Acknowledgment: Turn device off/on or programmed acknowledgment Other: The motor always coasts down. counter: Z32 The total motor current exceeds the permissible maximum. Acceleration times too short Wrong torque limitations in parameters C03 and C05 Acknowledgment: Turn device off/on or programmed acknowledgment. Other: The motor always coasts down. counter: Z33 15

18 Brief Commissioning Instructions 5th Generation of Inverters 4. User Interfaces No: Name 34:Hardw.fault 35:Watchdog 36:High voltage 37:n-feedback Description A hardware error occurred. 1: FPGA; error while loading the FPGA. 2: NOV-ST; Control unit memory defective (FERAM). 3: NOV-LT; Power unit memory defective (EEPROM). 10: ST <-> LT; Power unit serial number does not match requirement in control unit. 11: currentmeas; current offset measurement when device starts up - deviation too great Acknowledgment: Cannot be acknowledged Other: The inverter must be sent in for repairs. counter: Z34 The watchdog of the microprocessor has triggered. The microprocessor is busy or it is faulty. Acknowledgment: Turn device off/on or programmed acknowledgment. Other: The motor always coasts down. counter: Z35 The voltage in the DC link exceeds permissible maximum (indication DC link voltage in E03). Network voltage too high Feedback of drive in braking mode (no brake resistor connected brake chopper deactivated with A20=inactive or defective). Brake resistor too low (overcurrent protection) Ramp too steep Acknowledgment: Turn device off/on or programmed acknowledgment. Other: The motor always coasts down. counter: Z36 Error by encoder. 1: Para <-> encoder; parameterization does not match onnected encoder. 2: ParaChgOffOn; Parameterchange; encoder parameterization cannot be changed during operation. Save and then turn device off and on so that the change takes effect. 4: Chan.A/Clk; wire break, track A / clock 5: Chan.B/Dat; wire break, track B / data 6: Chan.0; wire break, track 0 7: EnDatAlarm; alarm bit of EnDat encoder is queued. 8: EnDatCRC; too many errors during redundancy check (EnDat ), e.g., wire break, error in cable shield) 9: Comm. offset; commutating offset is not correct. 10: Resol.carrier; resolver is not or wrong connected, wirebreak is possible 11: Resol.undervolt.; wrong transmission factor 12: Resol.overvolt.; wrong transmission factor 13: Resol.parameter; 14: Resol.failure; wirebreak 15: X120-double tr.; Different values were determined during the double transmission to X : X120-Busy; encoder gave no response for too long; For SSI slave: No telegram for the last 5 ms and drive is enabled. 17: X120-wirebreak; 18: X120-Timeout; 19: X4-double tr.; Different values were determined during the double transmission to X4. 20: X4-Busy; encoder gave no response for too long 21: X4-wirebreak; 22: AX5000; Acknowledgment of the axis switch is not effected. 23: Ax5000required; comparison of E57 and E70. 24: X120-speed; B297, G297 or I297 exceeded. 25: X4-speed; B297, G297 or I297 exceeded. 26: No Enc. found; either no encoder was found on X4 or the EnDat /SSI encoder has a wire break. 27: AX5000 found; a functional AX 5000 option board was found on X4 although incremental encoder or EnDat encoder was parameterized, or no EnDat encoder is connected to the AX 5000 option board. 16

19 Brief Commissioning Instructions 5th Generation of Inverters 4. User Interfaces No: Name 38:TempDev.sens Par. U02 39:TempDev.i2t 40:Invalid data 41:Temp.MotorTMP Description 28: EnDat found.; an EnDat encoder was found on X4 although another encoder was parameterized. 29: AX5000/IncEnc; either X4 has a faulty AX 5000 option board or the A-track of an incremental encoder has a wire break. 30: Opt2 incomp.; Version of option 2 is not current. Acknowledgment: Turn the device off/on for causes 7, 10, 11, 12, 13 and 14. Programmed acknowledgment for other causes. Other: The motor always coasts down. Caution: With positioning applications, the reference is deleted by the event "37:n-feedback." After acknowledgment, referencing must be performed again. counter: Z37 The temperature measured by the device sensor exceeds the permissible maximum value or is below the permissible minimum value. Ambient/switching cabinet temperatures too high or to low. Acknowledgment: Turn device off/on or programmed acknowledgment. Other: The permissible temperatures are stored on the power section of the inverter. counter: Z38 The i 2 t model for the inverter exceeds 100% of the thermal load. Inverter overloaded (e.g., because motor blocked). Too high clock pulse frequency. Inactive, message, warning or fault, can be parameterized in U02 (Default: fault). Other: When the event is triggered, a current limitation occurs initially for control types servo and vector control. At the same time, a quick stop is triggered as a fault when parameterized in U02. Reduction of the current may mean that the quick stop is no longer executed correctly! counter: Z39 A data error was detected when the non-volatile memory was initialized. 1 to 7: Control unit memory 1: ; low-level read/write error or timeout. 2: BlockMiss; unknown data block. 3: DatSecur; block has no data security. 4: Checksum; block has checksum error. 5: R/o; block is r/o. 6: ReadErr; startup phase: block read error. 7: BlockMiss; block not found. 17 to 23: power unit memory 17: ; low-level read/write error or timeout. 18: BlockMiss; unknown data block. 19: DatSecur; block has no data security. 20: Checksum; block has checksum error. 21: R/o; block is r/o. 22: ReadErr; startup phase: block read error. 23: BlockMiss; block not found. 32 and 33: encoder memory. 32: el. mot-type; no nameplate data present. 33: el.typelim; elecronic motor-type limit; nameplate parameters cannot be entered. 48: Optionmodule2; error in memory of option 2 with REA 5000 and XEA 5000 respectively XEA Acknowledgment: The event cannot be acknowledged for cause 1 to 23 and 48. The inverter must be sent in for repairs. The event can be acknowledged for causes 32 and 33. counter: Z40 Motor temperature sensor reports excess temperature. (Connection terminals X2.3, X2.4). The motor is overloaded. The temperature sensor is not connected. Acknowledgment: Turn device off/on or programmed acknowledgment. counter: Z41 17

20 Brief Commissioning Instructions 5th Generation of Inverters 4. User Interfaces No: Name 42:TempBrakeRes External fault: 44:Text from U180 Par U10 45:oTempMot.i2t Par. U00 46:Low voltage Par. U20 47:TorqueLimit 52:Communication Description The i 2 t model for the brake resistor exceeds 100% of the load. The brake resistor may not be adequate for the application. Acknowledgment: Programmed acknowledgment. Acknowledgment by turning the device off/on is not recommended since the i 2 t model would be reset to 80% in this case and there is a danger of the deceleration resistor being damaged. counter: Z42 Application specific or by free programming option. Acknowledgment: Turn device off/on or programmed acknowledgment. Other: Should only be used for application events which may not be set lower than the "fault" level. counter: Z44 The i 2 t model for the motor has reached 100% of load. The motor is overloaded. Can be parameterized as inactive, message or warning in U10 and U11. Acknowledgment: Turn device off/on or programmed acknowledgment. counter: Z45 The DC link voltage is lower than the limit value set in A35. 1: Low Voltage; the value in E03 DC-link-voltage has dropped below the value parameterized in A35 low voltage limit. 2: Network phase; phase monitoring has found that a switched-on power unit is missing a phase. 3: Drop in network; when phase monitoring finds that the network voltage is missing, the charging relay is immediately switched off. Normal operation is maintained. If the power unit is still switched on after network voltage returns, a fault is triggered after 0.5 s. Can be parameterized for cause 1 in U00 and U01. Warning with 10-second warning time for cause 2, fault for cause 3. Acknowledgment: Can be acknowledged for "fault" level by turning device off/on or programmed acknowledgment. Other: The motor always coasts down for cause 3. counter: Z46 The maximum torque permitted for static operation is exceeded for the control types servo control, vector control or senorless vector control (E62:act.pos.M-max, E66:act.neg.M-max). Limitation by parameters C03 and C05. Can be parameterized in U20 and U21. counter: Z47 Communication fault 1: CAN LifeGuard; recognized the "life-guarding-event" (master no longer sends RTR). 2: CAN Sync Error; the sync message was not received within the time set in parameter A201 Cycle Period Timeout. 3: CAN Bus Off; went off when bus went off. The driver started it again. 4: PZD-Timeout; failure of the cyclic data connection (PROFIBUS). 5: USS; (under preparation) failure of the cyclic data connection (USS). 6: Systembus; (under preparation) Acknowledgment: Turn device off/on or programmed acknowledgment. counter: Z52 18

21 Brief Commissioning Instructions 5th Generation of Inverters 4. User Interfaces No: Name 55:OptionBoard 56:Overspeed 57:Runtime usage 58:Grounded 59:TempDev.i2t : Applikationsevents :Text from U181 #External fault Description Error during operation with option board. 1: CAN 5000 failure; CAN 5000 was recognized, installed and failed. 2: DP 5000 failure; DP 5000 was recognized, installed and failed. 3: REA 5000 failure; REA 5000 was recognized, installed and failed. 4: SEA 5000 failure; SEA 5000 was recognized, installed and failed. 5: XEA 5000 failure; XEA 5000 or XEA 5001 was recognized, installed and failed. 6: EncSim-init; could not be initialized on XEA. The motor may have turned during initialization. 7: WrongOption; wrong or nonexisting option board (compar. E54/E58 with E68/E69) 8: LEA 5000 failure; LEA 5000 was recognized, installed and failed. 9: ECS 5000 failure; ECS 5000 was recognized, installed and failed. 10: 24V failure; Failure of the 24 V supply for XEA 5001 or LEA :SEA 5001 failure; SEA 5001 was recognized, installed and failed. Acknowledgment: Turn device off/on for all causes or programmed acknowledgment of causes 1 to 6 and 8 to 10. counter: Z55 The measured speed is greater than C01*1, rpm. Encoder defective Acknowledgment: Turn device off/on or programmed acknowledgment. Other: The motor always coasts down (from V5.0D on). counter: Z56 The cycle time of a real-time task was exceeded. 2: RT2; cycle time of real-time task 2 exceeded (1 msec) 3: RT3; cycle time of real-time task 3 exceeded (technology task) 4: RT4; cycle time of real-time task 4 exceeded (32 msec) 5: RT5; cycle time of real-time task 5 exceeded (256 msec) Acknowledgment: Turn device off/on or programmed acknowledgment. counter: Z57 Hardware signal from power section with MDS 5000 BG3. Asymmetrical motor currents. Acknowledgment: Turn device off/on or programmed acknowledgment. Other: The motor always coasts down. counter: Z58 The i 2 t model calculated for the inverter exceeds 105% of the thermal load. Inverter overloaded (e.g., because motor is blocked). Clock pulse frequency too high. Acknowledgment: Turn device off/on or programmed acknowledgment. counter: Z59 Application specific or by free programming option. Can be programmed as desired for each axis separately. Can be parameterized in system parameters U100, U110, U120, etc. to U170. Acknowledgment: Turn device off/on or programmed acknowledgment. Other: - Message/warning: Evaluation in 256-msec cycle. - : Evaluation in parameterizable cycle time (A150). Texts, times and level can be set in parameter group U.. starting with U100. counter: Z60 to Z67 Application specific or by free programming option. Acknowledgment: Turn device off/on or programmed acknowledgment. Other: Should be used for application events which can only be parameterized at the "fault" level. counter: Z68 19

22 Brief Commissioning Instructions 5th Generation of Inverters 4. User Interfaces No: Name Par. U12 69:Motor connect. 70:Param.consitency Description Connection error of the motor. 1: MotorNotDiscon; the contactor did not open when the axis changed. This cause can only be determined when at least two phase contacts are stuck and the DC link is charged (see E03). No magnetization could be established with asynchronous motors. 2: No motor; possibly no motor connected or line to motor interrupted. Can be parameterized as inactive or warning in U12. Acknowledgment: Turn device off/on or programmed acknowledgment. counter: Z69 The parameterization is contradictory. 1: no servoencoder; control mode B20 is set to "servo" but no appropriate encoder is selected (B26, H.. parameter). 2: X120 direction; X120 is used as source in one parameter but is parameterized in H120 as drain (or vice versa). 3: B12<->B20; Control mode B20 is not set to servo but the nominal motor current (B12) exceeds the 4-kHz nominal current (R24) of the device by more than 1.5 times. 4: B10<->H31; Resolver/motorpoleno.; the set motor pole number (B10) and the resolver pole number (H31) do not match. 5: neg.slip; with the control modes V/f, SLVC or VC (B20). The values for motor nominal speed (B13), motor nominal frequency (B15) and motor pole number (B10) indicate a negative slip. 7: B26:SSI-Slave; SSI slave may not be used as motor encoder (synchronization problems). 8: C01>B83; C01 may not be greater than B83. Acknowledgment: Turn device off/on or programmed acknowledgment. Other: With an incorrect parameterization, a fault is not triggered until enabling takes place. counter: Z70 20

23 Brief Commissioning Instructions 5th Generation of Inverters 5. Commissioning an Inverter 5 COMMISSIONING AN INVERTER Introduction This chapter discusses the commissioning of a motor on a MDS The commissioning procedure described here assumes that you begin with an inverter in the state it was in on delivery. The "fast reference value" application stored by may not be changed with POSITool. Only one motor may be connected to the inverter. The motor must be a servo motor of the type ED or EK with EnDat encoder. The procedure described requires no knowledge of the POSITool software. WARNING The drive is to be commissioned with the described procedures. Commissioning is used exclusively to test the drive. For this reason, do not run the motor without a load. Make sure that commissioning cannot cause damage! Before regular operation with the "fast reference value" application, you must read the application manual (publ. no )! Connection Connection motor and inverter as described below. MDS 5000 Bottom of device X2 X22 X302 X300 X301 X4 X20 X21 Encoder connection Power connection Brake module for 24 V brake BRM V Servo motor MDS 5000 Top of device X11 X10 Power connection 24 V - power (only with device model MDS 5xxx/L) Figure 5-1 Diagram of the connections 1. Connect the power cable between motor and terminal X If the motor is equipped with a brake, connect this to the inverter (X2) or to the brake module (X301) (brake line is integrated in power cable). If you use the brake module, the module must be connected with the inverter to terminals X2 and X302. See also chap. 4 of the mounting instructions (publ. no ). 3. Connect the motor temperature sensor to terminal X2 or, if a brake module is used, to X301 (temperature sensor is integrated in the power cable). 4. If you use a device with 24 V auxiliary voltage (model key MDS 5xxx/L), connect the 24 V power supply for the control electronics (X11). 5. Connect the voltage supply to terminal X10 of the inverter. 21

24 Brief Commissioning Instructions 5th Generation of Inverters 5. Commissioning an Inverter Settings During commissioning, a servo motor of the type ED or EK with EnDat encoder must be used.. servo motor with EnDat encoder When a servo motor with EnDat encoder is used, proceed as shown below. 1. On the operator panel of the inverter select the parameter B06 motor-data. Set the parameter to 0:el. motor-type (default value). 2. On the operator panel of the inverter, set the parameter B04 el. motor-type. Select the setting 1:all data (default value). 3. When a brake is installed on the motor, set the parameter F100 to 1:high. 4. Save your entries with A00 save values: 1:active. 5. Turn off the power supply and wait until the display disappears. Turn the power back on again to accept the data of the electronic nameplate. The inverter has accepted the data of the electronic nameplate. Operation ESC I/O # After you have made the settings, you can commission the drive in local mode. 1. Use the key on the operator panel to change to local mode. 2. Use the I/O key to enable operation. 3. The arrow keys can be used to change the speed to a maximum of ±300 Rpm. The keys provide the immediate jump to ±300 Rpm. The keys can be used to increase the speed in increments up to the maximum speed. Pressing the ESC key causes a stop. 4. The I/O key cancels the drive enable. 22

25 Brief Commissioning Instructions 5th Generation of Inverters 5. Commissioning an Inverter Parameter table Par. Description Fieldbus Address A00.0 Save values & start: When this parameter is activated, the inverter saves the current 2000h configuration and the parameter values in the Paramodule. After power-off, the inverter starts with Global the saved configuration. If the configuration data on the inverter and Paramodul are identical, only r=0, w=0 the parameters are saved (speeds up the procedure). 0: fehlerfrei; 10: Schreibfehler; 11: ungültige Daten; 12: Schreibfehler; 14: Warnung; Fieldbus: 1LSB=1; Type: U8; USS-Adr: hex 0h B04 Axis, OFF r=1, w=1 El. motor-type: motors of the ED/EK series are available with electronic single and multi-turn encoders. These encoders offer a special parameter memory. In all standard models places all motor data in this memory including any existing halting brake ("electronic nameplate"). B04 is only used when B06=0 is set. With B04=0, only the commutation offset is read. The other motor data can be entered as desired. When B04=1 is set, the following parameters are read from the nameplate. B00, B02, B05, B10, B11, B12, B13, B15, B16, B17, B51, B52, B53, B62, B64, B65, B66, B67, B68, B70, B71, B72, B73, B74, B82, B83, F06, F07 With B04=1, the motor data are read from the encoder after each power-on. Any manual changes to motor data are only effective until the next power-off and power-on even when the changes are stored non-volatilely in Paramodule. For permanent changes to the motor data, set B04=0. Then store the changes with A00=1. Electronic nameplates of other motor manufacturers cannot be evaluated with the MDS Note: Correct evaluation of the electronic nameplate after a change in parameter B04 is not ensured until after a device new start. 2204h 0h 0: Commutation; 1: All data; Fieldbus: 1LSB=1; Type: U8; USS-Adr: hex B06 Axis, OFF r=1, w=1 Motor-data: motors of the ED/EK series are available with electronic single and multiturn encoders. These encoders offer a special parameter memory. In all standard models places the entire motor data in this memory including any existing halting brake ("electronic nameplate"). 2206h 0h With B06=0, the data set in B04 are read from the encoder after each power-on. Any manual changes in motor data only remain effective until the next power-off and power-on even when the changes are stored in Paramodule non-volatilely. Set B06=1 for motors without electronic nameplates. The default values of the motor data entered in the parameter list must then be checked and adjusted. The commutation offset can be autotuned with the action B40. The changes must then be stored with A00=1. Electronic nameplates of other motor manufacturers cannot be evaluated with the MDS NOTE Up to and including firmware status V 5.2, correct evaluation of the nameplate after a change in parameter B06 does not occur until a device new start. Starting with firmware status V 5.3, the nameplate is evaluated immediately. The parameter G06 only appears for inverters of the MDS 5000 series. 0: El. motor-type; 1: User defined; Fieldbus: 1LSB=1; Type: U8; USS-Adr: hex 23

26 Brief Commissioning Instructions 5th Generation of Inverters 5. Commissioning an Inverter Par. Description Fieldbus Address F100 Brake release source: Selection of the source for the "release brake" signal. The signal can be 2A64h 0h permanently pre-specified as supplied by the binary inputs or the fieldbus. With F100=2:Parameter, Global, OFF A180, bit 6 (global parameter) is used as the signal source. This is the setting for fieldbus r=1, w=1 operation. CAUTION The "release brake" signal releases the brake regardless of the device state - this may cause accidental movements. 0: Low; 1: High; 2: Parameter; 3: BE1; 4: BE1-invers; 5: BE2; 6: BE2-invers; 7: BE3; 8: BE3-invers; 9: BE4; 10: BE4-invers; 11: BE5; 12: BE5-invers; 13: BE6; 14: BE6-invers; 15: BE7; 16: BE7-invers; 17: BE8; 18: BE8-invers; 19: BE9; 20: BE9-invers; 21: BE10; 22: BE10-invers; 23: BE11; 24: BE11-invers; 25: BE12; 26: BE12-invers; 27: BE13; 28: BE13-invers; Fieldbus: 1LSB=1; Type: U8; USS-Adr: hex 24

27 Brief Commissioning Instructions 5th Generation of Inverters 6. Service 6 SERVICE Introduction 6.1 Replacing Inverters Introduction This chapter lists various service jobs and explains their performance. This chapter provides you with an introduction to the simple replacement of two inverters without additional aids. Only the Paramodule from the replaced inverter must be used on the new inverter. In the Paramodule, the action A00: save values stores the programming and the parameterization of the inverter safe from a power failure. The following conditions apply to the replacement. 1. The new inverter takes over the job of the replaced inverter. There are no changes in the drive task. 2. Inverters of the same device type are exchanged. 3. None of the devices or components (motor, shaft encoder, option board, and so on) to be configured on the inverter change. Paramodule What to do A00: Save values Proceed as shown below. 1. Start the action "A00: save values." Wait until the action has been concluded with the result "0:error free." OFF 2. Turn the power supply of the inverter off. Wait until the indication on the display disappears. Old MDS Remove the Paramodule from the old inverter to be replaced. New MDS Install the Paramodule on the new inverter! 5. Remove the inverter to be replaced and install the new inverter. Adhere to the mounting instructions (publ.- no )! ON 6. Connect the power supply. Figure 6-1 Exchanging an inverter Result During startup, the inverter loads the configuration from the Paramodule and accepts the application of the previously installed inverter. 25