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User Guide

Field Controller

Part Number: 0476-0009-03
Issue: 3

FXMP25

Summary of Contents for FXMP25

Page 1: ...www controltechniques com User Guide Field Controller Part Number 0476 0009 03 Issue 3 FXMP25 ...

Page 2: ...ues have the potential to save energy and through increased machine process efficiency reduce raw material consumption and scrap throughout their long working lifetime In typical applications these positive environmental effects far outweigh the negative impacts of product manufacture and end of life disposal Nevertheless when the products eventually reach the end of their useful life they must no...

Page 3: ... Motor 7 1 9 Adjusting parameters 7 1 10 Electrical installation 8 2 Product information 9 2 1 Ratings 9 2 2 Nameplate description 9 2 3 FXMP25 features and options 10 3 Mechanical installation 11 3 1 Fire protection 11 3 2 Electrical terminals 14 3 3 Routine maintenance 14 4 Electrical installation 15 4 1 Electrical connections 16 4 2 Protective ground connections 17 4 3 AC supply requirements 17...

Page 4: ...54 8 6 Temperature and humidity 55 8 7 Storage 55 8 8 Altitude 55 8 9 IP rating 55 8 10 Corrosive gasses 56 8 11 RoHS compliance 56 8 12 Vibration 56 8 13 Acoustic noise 57 8 14 Overall dimensions 57 8 15 Weight 57 8 16 Cable and fuse size ratings 57 8 17 Electromagnetic compatibility EMC 58 9 Diagnostics 60 10 UL listing information 64 10 1 Conditions of acceptability 64 10 2 AC supply specificat...

Page 5: ...egulations depends upon installing and configuring drives correctly including using the specified input filters The drives must be installed only by professional assemblers who are familiar with requirements for safety and 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 User Guide An...

Page 6: ...s guide carefully The electrical inputs of the field controller must not be relied upon to ensure safety of personnel They do not isolate dangerous voltages from the output of the field controller The supply must be disconnected by an approved electrical isolation device before gaining access to the electrical connections The field controller is not intended to be used for safety related functions...

Page 7: ...patibility EMC regulations Particular attention must be given to the cross sectional areas of conductors the selection of fuses and other protection and protective ground connections The FXMP25 User Guide contains instructions for achieving compliance with specific EMC standards Within the European Union all machinery in which this product is used must comply with the following directives 2006 42 ...

Page 8: ...ions Output cables and connections Many internal parts of the field controller Unless otherwise indicated control terminals are single insulated and must not be touched 1 10 2 Stored charge The field controller contains capacitors that remain charged to a potentially lethal voltage after the AC supply has been disconnected If the field controller has been energized the AC supply must be isolated a...

Page 9: ...Output current The continuous output current ratings given on the rating label are for maximum 40 C 104 F and 1000 m altitude Derating is required for higher ambient temperatures 40 C 104 F and higher altitude For derating information refer to Chapter 8 Technical data on page 53 2 2 2 Input current The input current given on the rating label is the typical input current Continuous AC input current...

Page 10: ...rial communications on page 25 for information regarding serial communications FXMP25 M STORED CHARGE 10 min Mode Reset Display Mentor MP serial port connector Armature voltage feedback connections Control terminals Mentor II connector AC supply and field output connections Ground connection Type Cable Name Further Details Serial comms lead CT Comms cable CT EIA RS 232 4500 0087 CT USB 4500 0096 ...

Page 11: ...ntained comply with the requirements of the Health and Safety at Work Act in the United Kingdom or applicable legislation and regulations and codes of practice in the country in which the equipment is used WARNING Competence of the installer The field controller must be installed by professional assemblers who are familiar with the requirements for safety and EMC The assembler is responsible for e...

Page 12: ...ng no openings or by having a baffle construction This means that openings for cables etc must be sealed with materials meeting the 5VB requirement or else have a baffle above See Figure 3 2 for acceptable baffle construction This does not apply for mounting in an enclosed electrical operating area restricted access with concrete floor Figure 3 2 Fire enclosure baffle construction Drive 5 o 5 o N ...

Page 13: ... Parameters Setting up Technical data Diagnostics UL listing information Figure 3 3 Overall dimensions Table 3 1 Back plate information 176mm 6 93in 123 5mm 4 86in 247mm 9 72in 162mm 6 38in 168 5mm 6 63in 192 38 7 57in 90 27 3 55in 123 5mm 4 86in FXMP25 M STORED CHARGE 10 min Mode Reset Recommended screw size Torque range M6 1 5 N m 1 1 Ib ft to 2 5 N m 1 8 Ib ft ...

Page 14: ...5mm Power connections Torque 0 6Nm 0 44 Ib ft 3 5mm Control connections Torque 0 4Nm 0 29 Ib ft 4 5mm Ground connection Torque 0 6Nm 0 44 Ib ft Environment Ambient temperature Ensure the enclosure temperature remains at or below maximum specified Dust Ensure the FXMP25 remains dust free Moisture Ensure the FXMP25 enclosure shows no signs of condensation Enclosure Enclosure door filters Ensure filt...

Page 15: ... voltages from the FXMP25 controller or the driven machine AC supplies to the FXMP25 controller must be disconnected at least 5 minutes before any cover is removed or servicing work is performed WARNING Isolation device The AC supply must be disconnected from the field controller using an approved isolation device before any cover is removed from the field controller or before any servicing work i...

Page 16: ...1 F2 L1 L3 A1 A2 Supply branch fuses Isolator Optional EMC filter Fan supply where applicable Line reactors Armature branch fuses Only required for field weakening applications in stand alone mode To armature controller for field loss detection in stand alone mode If the voltage rating of the field is much lower than the supply voltage it is advisable to use a transformer to reduce the supply volt...

Page 17: ...ctive ground connection to the FXMP25 4 4 Line reactors The FXMP25 in common with all naturally commutated SCR drives causes voltage notches at the input supply terminals To avoid disturbances with other equipment using the same supply the addition of external line inductance is strongly recommended in order to restrict the depth of notches imposed This is generally not necessary where a dedicated...

Page 18: ...bient temperature Control of current below 250 mA thyristor holding currents should be avoided If control at this level is required then line reactors must be installed to reduce the effect of dv dt as thyristors turn off The selection of the correct fuse is essential to ensure the safety of the installation CAUTION WARNING The AC supply inputs in the FXMP25 controller are fitted with auxiliary fu...

Page 19: ...ssman supply branch circuit protection fusing Table 4 6 Siba supply branch circuit protection fusing 4 5 3 Internal semiconductor fuses The internal semiconductor fuses provide protection to the FXMP25 SCR thyristor bridge only The fuses can rupture if there is a fault in the field circuit The user should check the internal semiconductor fuses if the FXMP25 is tripping field loss FdL while enabled...

Page 20: ... Remove mounting screws M6 recommended 2 Apply pressure at the two points shown on the bottom of the FXMP25 to release the terminal cover clips 3 Open the terminal cover in the direction shown 4 Remove the internal semiconductor fuses Isolate the power before removing the internal semiconductor fuses WARNING 1 2 3 4 ...

Page 21: ...tion Additional measures may be required to prevent interference C2 Industrial generic standard EN 61000 6 4 2007 EN 61800 3 2004 first environment restricted distribution The following caution is required by EN 61800 3 2004 Some special measures may be required in certain applications where the control cables are long or pass outside the building See section 4 6 1 Surge immunity of control circui...

Page 22: ...inally grounded points This is a particular risk where the circuits extend outside the protection of a building As a general rule if the circuits are to pass outside the building where the drive is located or if cable runs within a building exceed 30 m some additional precautions are advisable One of the following techniques should be used 1 Galvanic isolation i e do not connect the control 0 V te...

Page 23: ... terminals Signal from plant Signal to drive 0 V 0 V 2 x 15 V zener diode e g 2xBZW50 15 1 Ion Digital input Dual Function Field economy select or enable controller See Pr 81 Type Single ended negative logic 0 V common for normal operation Voltage range 0 V to 24 V Absolute maximum applied voltage range 18 V to 30 V Load 2 4 mA at 0 V sink Input threshold High 11 V Low 9 V Update rate 4 ms 2 0V 0V...

Page 24: ...ture voltage output signal Type Single ended voltage Voltage range 0 to 10 V Maximum output current 5 mA Load resistance 2 kΩ min Protection 5 mA short circuit protection Resolution 10 bits Update period 4 ms 8 Fail relay common 9 Fail relay normally open 10 Fail relay normally closed Function FXMP25 OK indicator See Pr 01 and Pr 27 Type Form C Rating 250 125 Vac category 1 2 5 A nominal resistive...

Page 25: ...e is a RJ45 socket which is isolated from the power stage The communications port applies a 2 unit load to the communications network 4 8 2 Serial communications connections The FXMP25 has a serial communications port serial port as standard supporting two wire EIA RS 485 communications See Table 4 8 for the connection details for the RJ45 connector Figure 4 6 Serial communications port Table 4 8 ...

Page 26: ...ed with the converter 4 8 3 Serial communications set up parameters The following parameters need to be set according to the system requirements This parameter defines the communications protocol used by the 485 comms port on the drive This parameter can be changed via the drive keypad via a Solutions Module or via the comms interface itself If it is changed via the comms interface the response to...

Page 27: ...y flashes the parameter number and the right hand display shows the value of that parameter The left hand display flashing indicates that the up and down keys will select a different parameter to be viewed Holding the up key will cause the parameter number to increment to Pr 99 M STORED CHARGE 10 min Mode Reset FXMP25 Status mode Parameter view mode Parameter edit mode M STORED CHARGE 10 min Mode ...

Page 28: ...omatically 5 2 Resetting the field controller The controller can be reset using the keypad by pressing the mode key for at least two seconds in status or parameter view mode A reset is required in response to the following conditions To reset the controller from a tripped state To implement a change in the value of certain parameters 5 3 Security In the field controller s default state no security...

Page 29: ...s then required to gain access to Pr 00 5 5 Saving parameters Parameters are automatically saved when the MODE key is pressed when going from parameter edit mode to parameter view mode Value Display Function 0 nonE No action 1 Eur Load European defaults 2 USA Load USA defaults If loading default when the drive is active the display will flash FAIL once and then Pr 00 will be change back to nonE NO...

Page 30: ...ain 9 05 Flux reference scaling 9 72 Flux loop I gain 9 06 Armature voltage output scaling 9 73 Rated field voltage 9 07 Field flux output scaling 9 9 9 74 Rated field compensation factor 9 11 Field current feedback scaling 9 75 Field voltage mode select 9 12 Autotune 9 76 AC supply 9 9 25 FXMP25 OK flux level 9 9 77 Enable field control 9 26 FXMP25 OK hysteresis level 9 9 78 Field mode 9 9 9 27 F...

Page 31: ...ad of numbers VM Variable maximum the maximum of this parameter can vary DP Decimal place indicates the number of decimal places used by this parameter ND No default when defaults are loaded except when the drive is manufactured or on EEPROM failure this parameter is not modified US User save saved in drive EEPROM when the user initiates a parameter save RW Read write can be written by the user BU...

Page 32: ...he default for the scaling parameter is 1 so that the demand is 100 for 10 V input The maximum value of Pr 02 is 860 which without any scaling will be converted to 10 V This parameter should be adjusted by the user for other full scale voltages 02 Armature voltage Coding Bit FI Txt VM DP ND US RW BU PS 1 1 1 Range 0 to 860 V Update rate Background write 03 Flux reference Coding Bit FI Txt VM DP ND...

Page 33: ...ff when Pr 81 0 If Pr 81 1 then the controller remains in the enabled condition as controlled by the digital input This parameter sets the level at which field loss is detected and operates the fail relay in Mentor II and standalone mode 100 level 150 flux 10 flux 1 5 6 7 the same level as FXM5 07 Field flux output scaling Coding Bit FI Txt VM DP ND US RW BU PS 3 1 1 1 Range 0 000 to 4 000 Default...

Page 34: ...ip between the field current and the level of flux can be non linear The field controller can include the effects of this non linearity by representing the field current to flux characteristic as a series of three lines as shown in the figure overleaf 26 FXMP25 OK hysteresis level Coding Bit FI Txt VM DP ND US RW BU PS 1 1 1 1 Range 0 0 to 25 0 Default 0 0 Update rate 16 ms 27 Flux threshold level...

Page 35: ...et to their default values of 50 75 100 and 100 respectively Set the speed demand to 1 4 of Base speed and run the machine up to speed and check the speed of the machine using a hand held device If the machine speed is lower than 1 4 of Base speed which is normally the case adjust the Field compensation factor Pr 74 down until the correct machine speed is reached If the machine speed is higher tha...

Page 36: ...ntrol indicates energy absorption to force field down quicker 0 fully phased forward full volts applied to the field 54 Flux feedback Coding Bit FI Txt VM DP ND US RW BU PS 1 1 1 Range 150 0 Update rate Background write 55 Flux voltage demand Coding Bit FI Txt VM DP ND US RW BU PS 1 1 1 Range 120 0 Update rate Mains period 6 ms 56 Field current feedback Coding Bit FI Txt VM DP ND US RW BU PS 1 2 1...

Page 37: ... could cause instability during field weakening When this parameter is set to OFF 0 the field controller operates with the field weakening voltage loop When set to On 1 the flux level is determined by reference on terminal 3 59 Field weakening voltage set point Coding Bit FI Txt VM DP ND US RW BU PS 1 1 1 Range 0 to 750 V Default Eur 400 USA 480 Update rate Background write 60 Field output voltage...

Page 38: ... The minimum value of flux demand to prevent excessive field weakening and hence over speeding Minimum voltage demand when field voltage mode is selected Pr 75 On 1 This parameter will be set to the field current of the motor and will define the 100 point for the field controller 67 Field economy level Coding Bit FI Txt VM DP ND US RW BU PS 1 1 1 1 Range 0 0 to 100 Default 25 0 Update rate Backgro...

Page 39: ...rent is normally quoted for a cold field At this level of current the machine is over fluxed which causes the back EMF of the machine to be higher than expected The parameter can be adjusted by monitoring the armature voltage while running at full speed See Pr 30 on page 30 for further information 71 Flux loop P gain Coding Bit FI Txt VM DP ND US RW BU PS 2 1 1 1 Range 0 to 30 00 Default 3 00 Upda...

Page 40: ...alone half control St H Pr 78 5 Stand alone full control St F A reset is required for the mode change to take effect and the command to be passed through to the power processor A reset can be achieved by holding the mode key for 2 seconds 75 Field voltage mode select Coding Bit FI Txt VM DP ND US RW BU PS 1 1 1 Range OFF 0 to On 1 Default Eur OFF 0 USA On 1 Update rate Background read 76 AC supply...

Page 41: ...than the acceleration required then full field control is required Indicates that field economy level has been selected Select the destination parameter of the digital input terminal 1 If Pr 81 0 Eco the digital input controls parameter Pr 80 This is inverted so Pr 80 is ON by default If Pr 81 1 F Ctl the digital input controls the parameter Pr 77 Reset the drive for the change to take place When ...

Page 42: ...d so this address should not be set in this parameter Used to define the baud rate of the serial interface 90 Trip 0 91 Trip 1 92 Trip 2 93 Trip 3 Coding Bit FI Txt VM DP ND US RW BU PS 1 1 1 1 Range 0 to 255 Update rate Background write 94 Parameter displayed at power up Coding Bit FI Txt VM DP ND US RW BU PS 1 1 1 Range 00 to 98 Default 54 Update rate Background read 95 Serial address Coding Bit...

Page 43: ...fects hardware compatibility yy specifies a change that affects product documentation If any number other than 0 is programmed into this parameter user security is applied so that no parameters can be adjusted When this parameter is displayed and security is locked it appears as zero The power PCB software version consists of two numbers xx yy Where xx specifies a change that affects hardware comp...

Page 44: ...nt in Pr 70 Field rated voltage in Pr 73 From USA defaults Enter Field rated voltage in Pr 73 Select field mode The following modes can be selected for stand alone mode Set Pr 78 Field mode St H 4 for stand alone half control Set Pr 78 Field mode St F 5 for stand alone full control Carry out a reset by pressing the mode button for at least 2 seconds Autotune Autotune for flux loop gains Not requir...

Page 45: ...If field weakening is required From European defaults Set Pr 59 Field weakening voltage set point Set Pr 69 minimum flux voltage limit From USA defaults Set Pr 59 Field weakening voltage set point Set Pr 69 minimum flux voltage limit SetPr70 Fieldratedcurrent Enable the field controller To enable the field controller Set Pr 77 Enable field control On 1 Close field economy jumper Close field econom...

Page 46: ...59 Field weakeneing voltage set point 1 54 Flux feedback Voltage error to error conversion 68 68 69 Minimum flux Maximum flux Compensation factor 62 P gain 63 I gain Field weakening loop 06 Armature voltage Armature voltage output scaling 07 Field flux output scaling Maximum flux Maximum flux Armature voltage output Va Field flux output If Armature voltage feedback Flux input Iref External flux re...

Page 47: ...ing angle _ 71 P gain 72 I gain Flux loop Percentage voltage demand 57 75 Field voltage mode select 55 Flux demand 5 58 60 Field output voltage Rated field voltage Voltage to firing angle conversion 73 Field mode 78 54 Flux feedback 29 Flux calculator Motor saturation breakpoint 1 30 Motor saturation breakpoint 2 70 Rated field current 74 Rated field compensation factor 56 Field current feedback S...

Page 48: ...be V01 05 01 or later Power up the field controller Ensure The field controller displays If the field controller trips see Chapter 9 Diagnostics on page 60 Select Mentor MP mode To select MP mode Set Pr 78 Field mode MP 1 Press the mode button to enter parameter view mode Press and hold the mode button for at least 2 seconds to carry out a reset Setting up the field controller The Mentor MP has ta...

Page 49: ...All parameters except Pr 07 and Pr 78 are set up by the Mentor MP and therefore cannot be adjusted on the FXMP25 field controller 5 73 76 AC supply 5 58 5 58 Field firing angle _ 5 71 P gain 5 72 I gain Flux loop 54 Flux feedback Percentage voltage demand 5 57 5 75 Field voltage mode select 5 55 Flux demand 5 58 5 60 Field output voltage Rated field voltage Voltage to firing angle conversion 5 73 ...

Page 50: ... parameter Pr 11 on FXMP25 to be the same value as Pr 6 11 on Mentor II Select Mentor II mode To select Mentor II mode Set Pr 78 Field mode 2 H 2 for Mentor II mode half control ensure Pr 6 22 on Mentor II is set accordingly Set Pr 78 Field mode 2 F 3 for Mentor II mode full control ensure Pr 6 22 on Mentor II is set accordingly Press the mode button to enter parameter view mode Press and hold the...

Page 51: ...rive healthy OK Thermal overload in Mentor II mode works by forcing current feedback to zero causing the relay to operate When Mentor II is enabled this causes the drive to trip FdL field loss When in the disabled state FdL trip is not active on Mentor II and therefore following loss of feedback Mentor II will advance the firing angle to the end stop which will cause the output of the FXMP to reac...

Page 52: ... to control Pr 6 13 field enable Pr 12 03 604 use programmable threshold to detect when firing angle reaches front end stop Pr 12 04 1000 Pr 9 13 806 Pr 9 15 1201 digital output 1 indicates when firing angle end stop is reached Pr 9 07 806 Pr 9 09 8 11 drive disabled Pr 8 17 1034 force an Et trip if FXMP25 relay opens and firing angle reaches end stop and drive is disabled Connect digital outputs ...

Page 53: ...ired Maximum continuous input current The value of the maximum continuous input current is given to aid the selection of cables and fuses The value is stated for worst case conditions 8 2 FXMP25 derating for extended ambient operation Figure 8 1 FXMP25 derating for extended ambient operation 8 3 Power dissipation Table 8 1 shows the maximum field controller losses assuming 480 V supply on a 300 V ...

Page 54: ...ommendations for added line inductance have been calculated based on the power drive systems standard EN 61800 3 2004 Adjustable speed electrical power drive systems Part 3 EMC requirements and specific test methods Table 8 3 Minimum values of Ladd and inductor current rating for a typical application Specification Product voltage variant Maximum nominal supply 480 V Tolerance 10 Minimum nominal s...

Page 55: ... a storage period of 2 years and are thus the limiting factor Low voltage capacitors cannot be reformed due to their location in the circuit and thus may require replacing if the FXMP25 is stored for a period of 2 years or greater without power being applied It is therefore recommended that the FXMP25 is powered up for a minimum of 1 hour after every 2 years of storage This process allows the FXMP...

Page 56: ...ign bodies φ 50 mm large area contact with the hand 1 Protection against vertically falling drops of water 2 Protection against medium size foreign bodies φ 12 mm finger 2 Protection against spraywater up to 15 from the vertical 3 Protection against small foreign bodies φ 2 5 mm tools wires 3 Protection against spraywater up to 60 from the vertical 4 Protection against granular foreign bodies φ 1 ...

Page 57: ...ually perpendicular axes in turn Referenced standard IEC 60068 2 6 Test Fc Frequency range 5 to 500 Hz Severity 3 5 mm peak displacement from 5 to 9 Hz 10 m s2 peak acceleration from 9 to 200 Hz 15 m s2 peak acceleration from 200 to 500 Hz Sweep rate 1 octave minute Duration 15 minutes in each of 3 mutually perpendicular axes EN 61800 5 1 2007 Section 5 2 6 4 referring to IEC 60068 2 6 Frequency r...

Page 58: ...nt at 5 kHz repetition frequency via coupling clamp Control lines Level 4 industrial harsh 5 50ns 2 kV transient at 5 kHz repetition frequency by direct injection Power lines Level 3 industrial EN 61000 4 5 IEC 61000 4 5 Surges Common mode 4 kV 1 2 50 μs waveshape AC supply lines line to ground Level 4 Differential mode 2 kV AC supply lines line to line Level 3 Common mode 1 kV Control lines1 EN 6...

Page 59: ...first environment is one that includes residential premises It also includes establishments directly connected without intermediate transformers to a low voltage power supply network which supplies buildings used for residential purposes The second environment is one that includes all establishments other than those directly connected to a low voltage power supply network which supplies buildings ...

Page 60: ...25 display Example The FXMP25 display shows an FdL trip on the display as shown in Figure 9 1 below Figure 9 1 Typical example of trip display The above graphic shows the resultant display following an FdL trip This indicates a field loss condition as described in Table 9 1 on page 61 overleaf Users must not attempt to repair a faulty FXMP25 or carry out fault diagnosis other than replace internal...

Page 61: ...cuit cabling Check integrity of motor insulation HF06 Unexpected interrupt Hardware fault return to supplier HF07 Watchdog failure Hardware fault return to supplier HF08 Interrupt clash Hardware fault return to supplier HF11 Access to the EEPROM failed Hardware fault return to supplier HF17 No comms from power processor Hardware fault return to supplier HF19 Flash failure Hardware fault return to ...

Page 62: ...before completion See Pr 12 Autotune Trip Diagnosis Priority Category Trips Comments 1 Hardware faults HF01 to HF11 These indicate fatal problems and cannot be reset The FXMP25 is inactive after one of these trips and the display shows HFxx 2 Self resetting trips UV Under voltage trip cannot be reset by the user but is automatically reset by the FXMP25 when the supply voltage is within specificati...

Page 63: ... cause of the trip Table 9 6 Parameters frozen on trip Analog and digital I O The analog and digital I O on the FXMP25 continue to work correctly if a trip occurs Left hand display Description ih Field controller inhibited The field controller is inhibited because the field controller is disabled Pr 77 OFF 0 tr Field controller has tripped The field controller has tripped The trip code will be dis...

Page 64: ...e of DC drives for field loss detection When other DC drives are used loss of field current or voltage detection shall be provided this detection shall prevent motor over speed upon field loss 6 FS1 and FS2 shall be fuse type FR10GR69V30 by Ferraz Shawmut E76491 rated 30 A 690 Vac 7 Suitable for use on a circuit capable of delivering not more than 100 kA RMS symmetrical Amperes 480 Vac maximum Whe...

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