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Microdrive Series Instruction Manual

4201-109 Rev I

Summary of Contents for D3-2.5

Page 1: ...109 Rev I MICRODRIVE SERIES AC MOTOR SPEED CONTROLLER INSTRUCTION MANUAL 4201 109 REV I Leaders in AC Motor Controls Head Office 81 Austin Street P O Box 741 Napier New Zealand Tel 64 6 843 5855 Fax...

Page 2: ...Microdrive Series Instruction Manual 4201 109 Rev I 4201 003 Rev A Page 2 of 12...

Page 3: ...nd environment Our NZS ISO 9001 certification gives you the confidence of our international independently certified Quality Assurance program All staff are actively involved in continuous improvement...

Page 4: ...any of your drive application projects Ourservicestaffareavailableforcommissioning aftersalesservice andrepairs 24hoursaday seven days a week We select capable and highly qualified representatives to...

Page 5: ...81 Austin Street Onekawa P O Box 741 Napier New Zealand Tel 64 6 843 5855 Fax 64 6 843 5185 FAX BACK TO 64 6 843 5185 Completing this section would be appreciated but is optional Name Company Address...

Page 6: ...Microdrive Series Instruction Manual 4201 109 Rev I 4201 003 Rev A Page 6 of 12...

Page 7: ...qualified personnel Always isolate and allow to discharge before servicing Always wear safety glasses if operating with the cover removed Never work on live equipment alone Observe all recommended pr...

Page 8: ...10 92 D Update 10 03 93 E UD3 UDi combined documentation CH93 021 03 06 93 F Update 10 11 93 G Update 20 10 94 H Four new models added UD3 12 UD3 60 UDi 205 and UDi 300 RS232 communications card opti...

Page 9: ...Short Menus 29 1 5 COMMISSIONING THE MICRODRIVE 33 1 6 MAINTENANCE 35 1 7 SERVICE 35 1 7 2 RFI Filtering 35 1 7 3 Screen Fault Messages 36 1 7 4 Use Of The LED Indicators 37 1 7 5 Fuse Failure 38 1 7...

Page 10: ...mmable Configurations 41 Figure 2 2 The Microdrive Control Inputs and Outputs 42 Table 1 1 Display Screen Messages Short Menus 31 Table 2 1 1 Display Screen Messages Full Menus 43 Table 2 1 1 Display...

Page 11: ...e 3 UD3 and the Microdrive i UDi the term Microdrive will be used If a feature is applicable only to the UD3 or the UDi then the appropriate term will be used The first section describes the standard...

Page 12: ...Microdrive Series Instruction Manual 4201 109 Rev I 4201 003 Rev A Page 12 of 12...

Page 13: ...ons CONFIGURABLE 0 10V ANALOGUE OUTPUT Output selection 0 100Hz 0 150 UD3 current 0 200Hz 0 500Vac output voltage 0 10V RS232 RS485 Options 0 150 UD3 torque component of current 0 150 motor power DIGI...

Page 14: ...le Tacho speed regulation 0 01 ENVIRONMENTAL Protection standard Cabinet Dust and water splash protected Pollution degree 3 Baseplate IP00 Pollution degree 2 Operating temperature 0 50 C Storage tempe...

Page 15: ...control systems The following monitoring and control functions are available on each Microdrive 4 20mA input 0 10V input Switch input 0 10V output Relay output Tacho signal Instruction Manual PDL Part...

Page 16: ...n room The cabinet version of the Microdrive i has a clean air enclosure for all the power and control electronics Technically the Microdrive operates on the same principles as earlier AC Motor Speed...

Page 17: ...SPECIFICATION NOMINAL AC VOLTAGE RANGE 4807 019 Rev C MANUFACTURED BY PDL ELECTRONICS LTD PO BOX 741 NAPIER NEW ZEALAND WARNING STORED CHARGE PRESENT SERVICING DISCHARGE BEFORE ALLOW 1 MINUTE TO QUALI...

Page 18: ...TACHO ENCODER INPUTS VOLTAGE I P CURRENT I P CONTROL PROCESSOR DC BUS THERMISTOR DIGITAL FREQUENCY OUTPUT PROGRAMMABLE ANALOGUE OUTPUT 0 10VDC PROGRAMMABLE RELAY OUTPUTS SUPPLY _ 4807 022 Rev E CONVE...

Page 19: ...SOR DC BUS THERMISTOR DIGITAL FREQUENCY OUTPUT PROGRAMMABLE ANALOGUE OUTPUT 0 10VDC PROGRAMMABLE RELAY OUTPUTS 230VAC 30VDC SUPPLY 1A FUSE DC BUS SCR CONTROLLED CHOKE LINE INPUT FUSES DC DC CONVERTER...

Page 20: ...NDATIONS The Microdrive is suitable for controlling the speed of all standard three phase induction motors Choose a Microdrive which is capable of supplying the full load current of the motor s to be...

Page 21: ...ate of the switchboard The UDi feet may be removed when mounting on the wall or through a switchboard gear plate If the UDi feet are removed do not mount the UDi directly on the floor as this will blo...

Page 22: ...80 439 680 330 390 511 643 17 145 17 473 145 26 32 15 0 190 15 0 35 23 mm 6 0 6 0 mm mm mm mm mm mm 207 150 360 150 207 511 145 17 326 473 17 145 B A C E D F mm mm mm kg 26 26 15 0 15 0 8 10 11 G H I...

Page 23: ...5 545 506 506 495 495 337 337 545 506 495 480 337 THROUGH THE WALL MOUNTING THROUGH THE WALL MOUNTING FLOW COOLING AIR COOLING AIR FLOW FLOOR MOUNT BRACKETS WALL MOUNT BRACKETS FLOOR SURFACE WALL MOUN...

Page 24: ...5 FOOT PRINT FOR MTG THROUGH A WALL 76 MIN FLOOR SURFACE FLOOR SURFACE MIN 76 20 CLEARANCE HOLES 98 0 250 0 255 5 505 5 WALL MOUNT BRACKETS FLOOR MOUNT BRACKETS FLOW COOLING AIR COOLING AIR FLOW THROU...

Page 25: ...MOUNTING 44 5 122 5 170A 250A 110A 140A M10 HOLES FOOT PRINT FOR WALL MOUNTING FLOOR SURFACE 20 CLEARANCE THROUGH A WALL FOOT PRINT FOR MTG 44 5 FLOOR SURFACE M8 HOLES HOLES 76 340 355 405 366 506 366...

Page 26: ...Be sure that you are using the correct configuration and circuit before wiring up Good control circuit wiring practice should be observed Control wiring must be screened and run physically separate f...

Page 27: ...o the UDi and motor chassis The output cables should be run separate from the input cables especially if not screened 5 The UDi protects the motor with an electronic overload so an external overload r...

Page 28: ...adjust the value Now use and to adjust the value Release select to enter new value Hints For reasons of security the Microdrive must be in commission mode Screen 98 before some adjustments can be mad...

Page 29: ...too much the motor will draw too much current and may overload the Microdrive and overheat the motor Too little may not allow your motor to start Screen No 15 Acceleration Rate Screen No 16 Decelerati...

Page 30: ...R PTC 0V 11 RELAY 3 OUTPUT 8 7 9 10 13 12 14 15 I O NAME TACHO INPUT 0V 10V POTENTIOMETER FREQUENCY INPUT 0V FREQUENCY INPUT FREQUENCY OUTPUT 0 10V ANALOGUE O P 21 17 18 19 20 22 23 24 6 ALL SWITCH IN...

Page 31: ...NAMEPLATE MOTOR FREQUENCY 10 250 HERTZ 14 14 BOOST 0 0 TORQUE BOOST VOLTAGE AT ZERO SPEED 0 0 15 0 V MOTOR 15 15 ACC1 10 0Hz s ACCELERATION RATE NORMAL 0 02 500 HERTZ SEC 16 16 DEC1 10 0Hz s DECELERA...

Page 32: ...econd line of the display SCREEN DESCRIPTION TRIP POINT NOTES NO FAULTS NO FAULTS PRESENT LVDC SUPPLY LOW FAILURE OF 24V OR 15V SUPPLIES 22V 12V SUPPLY FAULT INPUT PHASE VOLTAGE IMBALANCE 40Vac IN DC...

Page 33: ...t supply phases Check that the Microdrive operates normally and displays the status and control line 0 Familiarise yourself with the keyboard displays If any faults are indicated at any time refer to...

Page 34: ...ECTED WIRING OF SWITCHES IS CORRECT FOR THE SELECTED INPUT SPEED DEMANDS IS NOT OVERRIDING FEEDBACK IF SELECTED TO 24 Max Min F1 F2 FREQUENCY ARE SET CORRECTLY SCREENS 21 IS PRESENT SCREEN 3 V mA SCRE...

Page 35: ...necessary the RFI filter capacitors may be disconnected by shifting the earth link position WARNING BEFORE PROCEEDING ENSURE THE MICRODRIVE IS ISOLATED AND STORED CHARGE IS ALLOWED TO DISSIPATE The e...

Page 36: ...nd motor for wiring or winding faults Check output circuit contactors for correct operation Fault IGBT SLAVE FAULT Detail Automatic protection of the internal power switching semiconductor device has...

Page 37: ...M fitted Sense level Possible cause Action Insert correct EPROM replace control PCB Fault HOST TRIP Detail Host computer generated trip Sense level Possible cause Trip generated by the host computer v...

Page 38: ...UD3 power board Possible reason for failure Overload of 24V supply or low voltage supplies derived from 24V faulty fan faulty control PCB Action Check UD3 for obvious faults to low voltage DC supplie...

Page 39: ...persists request service UDi F5 5A SCR gate supply fuse Fitted on UDi Power PCB Possible reason for failure SCR fault Action Replace with correct fuse check operation If failure persists request serv...

Page 40: ...onnection is common with the control PCB circuit 0V connection The current level may be directly observed on Screen 3 at any time Motor PTC PTC thermistor input for motor overheating protection If PTC...

Page 41: ...Microdrive Series Instruction Manual 4201 109 Rev I 41 Figure 2 1 Block Diagram Microdrive Programmable Configurations...

Page 42: ...HOT RESISTANCE 3kOhm 3mA 4 3 MIN LOW THRESHOLD MAX HIGH THRESHOLD CURRENT MIN HYSTERESIS NOMINAL CONTROL VOLTAGE 11 2V 1 28V 12V 0V ISOLATION VOLTAGE MAXIMUM DC RATING CONTACTS ARE PROTECTED MAXIMUM A...

Page 43: ...1 200 200 HERTZ 24 24 FR F2 60 0Hz REFERENCE FREQUENCY SETPOINT 2 200 200 HERTZ 25 25 MIN FLUX 100 DYNAFLUX MINIMUM FLUX LEVEL 40 100 V MOTOR 26 26 DC LEVEL 0 0 DC 0Hz HOLD BRAKE VOLTAGE AT STOP 0 0...

Page 44: ...cond line of the display SCREEN DESCRIPTION TRIP POINT NOTES NO FAULTS NO FAULTS PRESENT LVDC SUPPLY LOW FAILURE OF 24V OR 15V SUPPLIES 22V 12V SUPPLY FAULT INPUT PHASE VOLTAGE IMBALANCE 40Vac IN DC B...

Page 45: ...0 01 02 77 77 AUTOBOOST Y AUTOMATIC BOOST CONTROL Y ES N O 78 78 MIN FREQ RUN N MINIMUM FREQUENCY RUN MODE Y ES N O 79 79 MFI INVERT N MULTI FUNCTION INPUT INVERSION Y ES N O SCREEN CONTROLS NO SCREEN...

Page 46: ...LD ADJUST SLOW SLOW Table 2 1 2 Display Screen Messages Full Menu Modes OUTPUT RELAY MODES SCREENS 67 68 69 NO NAME OPEN STATE CLOSED STATE NOTES NORMALLY OPEN CONTACT 0 FAILSAFE FAULT FAULT NO FAULT...

Page 47: ...e sequence is forward U V W phase sequence According to IEC34 7 the motor rotates clockwise when viewed from the drive end motor terminals U1 V1 and W1 or U2 V2 and W2 are connected to Microdrive phas...

Page 48: ...TOR PTC Indication 0 LOW 1 HIGH Notes 0 0V 1 12V Code 7 Input T17 Function PULSE TACHO Indication 0 LOW 1 HIGH Notes 0 0V 1 12V Code 8 Input Optional RS232 or RS485 PCB Function RX SERIAL COMMS Indica...

Page 49: ...oint 30 Screen OVERCURRENT TRIP Description EXCESSIVE OUTPUT CURRENT Trip Point 180 OF RATED CURRENT Screen IGBT SLAVE FAULT Description MAIN SEMICONDUCTOR OVERLOAD Trip Point SHORT CIRCUIT OTHER Scre...

Page 50: ...hermal model is reset when power is removed from the Microdrive therefore it is usually preferable to maintain power to the Microdrive at all times and use the control inputs to stop and start the mot...

Page 51: ...ntrolled deceleration can be achieved by setting the stop mode Screen 61 to spin 14 TORQUE BOOST Screen 14 BOOST 0 0 Description TORQUE BOOST VOLTAGE AT ZERO SPEED Min Max 0 0 15 0 Units V MOTOR FUNCT...

Page 52: ...nt adjusts the rate of response to the process SETTING UP Unless S curve acceleration or feedback is being employed leave the time constant set to 0 0 seconds Select the appropriate feedback source us...

Page 53: ...observed inverter current See also Appendix 6 Torque Control Using the Microdrive Current Limit SETTING UP Current limit Where not strictly part of the required set up for the particular application...

Page 54: ...EFERENCE FREQUENCY SETPOINT 1 Min Max 200 200 Units HERTZ Screen 24 FR F2 60 0Hz Description REFERENCE FREQUENCY SETPOINT 2 Min Max 200 200 Units HERTZ FUNCTION Minimum Frequency Sets a minimum freque...

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Page 56: ...ons SETTINGUP If the flux reducing feature is not required leave set at 100 factory set value Dynaflux is best suited for slowly varying loads e g pump and fan This is due to the possibility of motor...

Page 57: ...t stop together with the spin stop mode Screen 61 can be useful in positioning control systems Notes To achieve DC holding while the control frequency is at zero but the Microdrive is not stopped use...

Page 58: ...otor by means of a small DC current When enabled a DC heating current flows in the motor whenever the Microdrive is stopped Any fault causing a trip disables DC heat SETTINGUP If not required leave OF...

Page 59: ...the relay outputs using Screens 67 68 69 EXAMPLE OF OPERATION OF FREQUENCY RELAY TIME OUTPUT RELAY TIME FREQUENCY STATUS RELAY OFF RELAY ON ON OFF RELAY OFF RELAY ON 4807 356 Rev A F F 31 CURRENTSENSE...

Page 60: ...f set up 39 40 41 SECONDACCELERATION ANDDECELERATION Screen 39 ACC2 10 0Hz s Description ALTERNATIVEACCELERATIONRATE Min Max 0 02 500 Units HERTZ SEC Screen 40 DEC2 10 0Hz s Description ALTERNATIVEDEC...

Page 61: ...the emergency stop input is activated Notes Emergency stop is not regarded as a fault trip and is not indicated as a fault nor is it latched SETTINGUP AdjustDEC3tothelevelofdecelerationrequired under...

Page 62: ...rtain the expected encoder frequency kHz at a given speed of the master process Calculate the required tacho gain by dividing the required Microdrive output frequency in Hz by the encoder frequency kH...

Page 63: ...ing to the manufacturers resistor specifications The dynamic brake thermal model can only protect the resistor if it is correctly set never consider using larger than specified figures If a Microdrive...

Page 64: ...IALCOMMUNICATIONSADDRESS Min Max 1 240 Units Screen 51 BAUDRATE OFF Description SERIALCOMMUNICATIONSBAUDRATE Min Max 1200 4800 9600 OFF Units BAUD FUNCTION Sets the serial communications address and b...

Page 65: ...SETTINGUP Do not adjust this value unless light load stability problems exist Increasesettingtoimprovestability Increasing the setting too far may induce instability The setting is nominally equal to...

Page 66: ...ency until the frequency matches the speed of the load Once the frequencies match the current will be reduced and the load will be accelerated normally toward the set point Note When spin starting fro...

Page 67: ...veimmediatelyjumpstozerofrequency when commanded to stop allowing the motor to freewheel spin to stop The use of spin to stop in conjunction with DC Hold Brake Screens 26 27 provides a DC injection br...

Page 68: ...rodrive takes evasive action by reducing the deceleration rate as regeneration occurs This is the normal setting Ifadynamicbrakeisfitted thiswillautomatically absorb the regenerated energy In this cas...

Page 69: ...t select the reference and feedback from the same source Examples of the use of feedback are given in the appendices 63 KEYBOARDCONTROL Screen 63 KEYBD CONT N Description LOCALKEYBOARDCONTROL Options...

Page 70: ...uited to small hoists and long and cross travel Speed and direction control by external signals If stopping within slow or working limits the emergency stop deceleration rate DEC3 Screen 42 will be us...

Page 71: ...top Non active State Closed Function Stops Microdrive Conditions Input Stop Reset Non active State Closed Function Stops Microdrive resets fault Conditions Stopped fault removed Input Start Reset Non...

Page 72: ...ses Microdrive to reverse inverts reference frequency Conditions Input Emergency Stop Non active State Closed Function Decelerates according to emergency deceleration rate DEC3 Screen 42 latching Cond...

Page 73: ...P 22 24 0V CONFIGURATION 2 2 WIRE AND STOP RESET PTC POTENTIOMETER SCREEN ALL CONTROL CIRCUITS TYPICAL CONNECTIONS 0V 4 20mA OR 0 10V WHICHEVER IS GREATEST REFERENCE FREQUENCY IS SELECTED AS 12 EMERGE...

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Page 84: ...ficiently higher speed or the current is reduced sufficiently This is a predictive overload and the relay will pulse to warn of impending trip No 6 Name FREQSENSE Open State BELOW Fr OFF Closed State...

Page 85: ...adjustment is required if the analogue output will not be used this screen may be left in any state Select the desired output function 71 REVERSEDIRECTIONINHIBIT Screen 71 REV INHIBIT N Description RE...

Page 86: ...before the DC bus discharges below the switch mode power supply SMPS operating voltage about 200Vdc in the UD3 350Vdc in the UDi and dependinguponthesettingmodeofthisscreen the Microdrive is able to r...

Page 87: ...CURRENT TQ TORQUE FUNCTION Selects current limit to control on inverter current magnitude or on the torque component of inverter current SETTINGUP The Microdrive can be configured to limit the absolu...

Page 88: ...t zero frequency therefore applications which are required to produce torque at zero frequency e g hoists must have Autoboost set to N O Autoboost automatically varies the boost level according to the...

Page 89: ...HIGH LOGIC i Select multi function input mode Screen 66 to disable inputs 66I PMODE 00COMMISSION ii Shift Link J1 on the control PCB to the 2 position iii Set Screen 79 to Y ES to invert all input log...

Page 90: ...drive to a known and defined state if you have become lost or confused about the settings that are entered SETTINGUP WARNING Initialising the Microdrive RESETS ALL SETTINGS to the default settings Use...

Page 91: ...RECORD3 DATE __ __ __ __ __ __ __ __ __ BY _________ _________ _________ ADJUSTMENTS default 10MTRCUR _________ _________ _________ I Inv 11 MTR VOLT _________ _________ _________ 415V 12 MTR FR _____...

Page 92: ...______ _________ 41 BRK FR 0 0Hz _________ _________ 42 DEC3 10 0Hz s _________ _________ RECORD1 RECORD2 43 T GAIN 20 0 _________ _________ 44DBTIME 10s _________ _________ 45 DB DUTY OFF _________ _...

Page 93: ...PUT 1 SWITCH INPUT 2 SWITCH INPUT 3 SWITCH INPUT 4 SWITCH INPUT 5 MOTOR PTC TACHO SUPPLY TACHO INPUT 10V POTENTIOMETER 11 0 3uF X E J2 0V 3 4 5 6 7 8 10 9 12V 2 0V BIAS POSITION J1 1 15V 15 0V 13 12 1...

Page 94: ...ier 1781 504 3 Fuse link 2A 440V ceramic 2401 004 2 Fuse link 2A glass 20x5 2401 017 2 Flat film cable 175mm 2725 003 1 Fan 24Vdc 38x119 2941 006 3 Notes Duetothehighcostanddifficultyofreplacement of...

Page 95: ...ermstrate rectifier packer 1781 504 1 Input fuse A50P200 4 3302 366 3 DC fuse A1 66C350TS 3302 615 1 Transistor 1MBI200F 120 IGBT 1757 012 2 Thermstrate IGBT 1781 104 2 Internal cooling fan 24Vdc 38x1...

Page 96: ...UDi 250 snubber PCB 0375 611S 1 UDi 170 250 SCR gate PCB sub assembly includes SCR 0371 603S 1 Thermstrate rectifier 1781 103 1 Input fuse A1 66C350TS 3302 615 3 DC fuse A1 66C500TS 3302 616 3 Transi...

Page 97: ...12 Internal cooling fan 24Vdc 38x119 2941 006 2 Heatsink fan 440Vac 170 dia 2941 011 5 UDi 830P Spares Basic Full Part Part No Qty Kit Kit UDi 480 drive select module 0377 610S 1 Parallel drive conve...

Page 98: ...t terminals This is not a strictly necessary step you may still use external switch controls with keyboard control of stop start Screen 64 Title Reference Frequency Setting Keyboard Function Selects S...

Page 99: ...4 20mA transducer the range of control will then be 0 100 psi 4B APPLICATION EXAMPLE TACHOFEEDBACK Tacho feedback is used where precision regulation of speed is required This section shows the config...

Page 100: ...25 F 21 20 O P 22 23 V 0V A SOURCE 0 10V 0 100Hz FUNCTION 24 4 20mA 4C APPLICATIONEXAMPLE CONSTANTPRESSUREPUMPING Constant pressure pumping is a common application of AC Motor Speed Controllers This a...

Page 101: ...MINFLUXissetbelow100 andthereference input equals the feedback input then the motor voltage will be reduced to improve motor efficiency However this can cause surging of the motor voltage if the refer...

Page 102: ...ibited The configuration table not including irrelevant and or settings which have not been altered from factory set values and wiring configurations follow CONSTANT PRESSURE PUMPING EXAMPLE CONFIGURA...

Page 103: ...O P RELAY 2 Default 00 NO FAULT Setting 13FEEDBACKSENSE Notes Sets relay 2 to open when the feedback signal is higher than the reference plus half the hysteresis Mode 71 REV INHIBIT Default N Setting...

Page 104: ...op and start the pump Key points are as follows i A minimum speed is set which guarantees to provide a degree of over pressure under the conditions that the pump is supposed to stop i e under zero flo...

Page 105: ...dc Max DC supply voltage range 450 700 Vdc Continuous DC input current 1 2 x UD3 rated current Maximum DC input current 1 7 x UD3 rated current Recommended DC fuse 700Vdc 2 x UD3 rated current DC shou...

Page 106: ...UDi SINGLE PHASE AC SUPPLY The Microdrive i UDi maybe operated from a single phase two phase supply but the power rating must be reduced to prevent overloading of the rectifier and DC power supply How...

Page 107: ...controller but the speed control will be over ridden when the limiting condition is encountered see fig below The current limit will operate with both braking and motoring torques If the inverter spee...

Page 108: ...OFF Set up 9 0Hz Notes Sense frequency for stall detection Adjustment 64 REF FR SEL Set up KEYBD Notes The frequency setpoint is set by the keyboard and is there to limit the speed if the tension is r...

Page 109: ...generation 68 84 E Earth 26 27 30 40 42 Earth Leakage 35 Emergency Stop 29 61 70 Enclosure 20 F Factory Defaults 91 Fail Safe Fault Relay See Fault Relay Fault Chart 34 Fault Messages 36 49 Fault Rela...

Page 110: ...tion 28 Screen Selection 28 Second Acceleration Deceleration 60 70 83 Secondary Screen 28 Security 28 29 90 Serial Communications Address 64 Analogue Output 85 Baudrate 64 Relay Output 84 Timeout 87 S...

Page 111: ...16 DEC1 10 0Hz s DECELERATION RATE NORMAL 17 17 T CONST 0 00s FEEDBACK S CURVE TIME CONSTANT 18 18 I LIMIT 1 2 I Inv CURRENT LIMIT 19 19 ILT T O NONE CURRENT LIMIT TIME OUT 20 20 ILT SLIP 4 0 CURRENT...

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