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Troubleshooting guide

26.04.2005

the root cause of a warning is removed, the AC SuperDrive automatically removes any reduced
capacity restriction related to the warning condition.

When a warning is detected:

•

The warning bit in the Status Word is set.

•

The appropriate warning bit in the Extended Error register is set.

•

The LED indicator starts to flash slowly (1Hz).

7.5 S

TATUS INDICATOR

The LED status indicator, shown in

provides a visual identification of the AC

SuperDrives operating status.

S

TATUS

D

ESCRIPTION

Steady green light.

The controller is ok.

Fast flashing light. (10Hz)

An error is reported to the controller.
When an error occurs, the AC SuperDrive immediately stops
motion then shuts down the drive’s power output to the motor.

Slow flashing light. (1Hz)

A warning is active.

Figure 36. The LED status indicator placement.

7.6 U

SING THE TROUBLESHOOTING GUIDE

CAUTION

♦

Do not manually operate main contactor or override system
control of main contactor without first isolating AC
SuperDrive B+ (or +) terminal from main contactor output.

This troubleshooting guide is organized by visual symptoms and error/warning codes produced
by the AC SuperDrive. Error/warning codes are usually displayed or available on an operator
display under supervision of the truck controller. For each visual symptom and error/warning
code there is a troubleshooting chart that lists possible causes and corrective actions.

Each troubleshooting chart presents:

•

possible causes and relevant conditions (in oval blocks)

•

with connections to corrective actions (in rectangular blocks). Supplemental comments and

explanations are enclosed in oval shaped blocks constructed with dashed lines.

Item No. 89Y05120A

User's Guide 1.0

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Содержание SuperDrive ACS24 Series

Страница 1: ...AC SuperDrive The AC motor controller Generation 5 User s Guide 1 0 Item No 89Y05120A 26 04 2005 Solution by...

Страница 2: ...o ensure accuracy and ratability of the specification in this publication Specifications are subject to change without notice Danaher motion provides this information AS IS and declines all warranties...

Страница 3: ...terface 14 2 1 3 Speed control 14 2 1 4 Flux control 15 2 1 5 Slip and stator frequency estimation 15 2 1 6 Current control and SPWM sym 15 2 1 7 Power conversion section 15 2 1 8 Speed sensor interfa...

Страница 4: ...9 3 13 4 ACS ID1 and ID2 inputs 30 3 13 5 Temperature sensor 31 3 14 Can bus communications 32 4 Start up commissioning 35 4 1 General 35 4 2 Checks prior to initial power up 35 4 3 Verifying AC Super...

Страница 5: ...65 6 14 How the AC SuperDrive handles parameters 66 6 14 1 General 66 6 14 2 Parameter verification at startup 66 6 14 3 Saving parameters 67 6 14 4 Duplicating a configuration 67 6 14 5 Reverting to...

Страница 6: ...93 8 2 Current and power output ratings 93 8 3 DC supply voltage requirement 94 8 4 Isolation 94 8 5 CAN communications interface 94 8 6 Safety system 94 8 7 Operating environment 94 8 8 EMC 95 8 9 S...

Страница 7: ...ly powered vehicle utilizing the CAN Bus and CANopen protocol for communications and control 1 1 4 WARNING CAUTION AND INFORMATION NOTICES Special attention must be paid to the information presented i...

Страница 8: ...nstallation that the AC SuperDrive model is correct for the vehicle s battery supply voltage The DC Supply nominal voltage is stated on a label on the cover of each AC SuperDrive 1 2 2 OEM S RESPONSIB...

Страница 9: ...CONFIGURATIONS The AC SuperDrive is manufactured in the following two configurations Convection cooled models see Figure 1 employing a heat sink with cooling fins that transfer heat to the surrounding...

Страница 10: ...umber within a production lot Manufacture date Year month and day of manufacture Table 1 AC SuperDrive Product expressions 1 4 STANDARD FEATURES AND CAPABILITIES The AC SuperDrive incorporates a numbe...

Страница 11: ...software configurability eliminates all operator adjustments and assures absolutely reproducible performance of identically configured AC SuperDrives All heat generating components mounted on a massi...

Страница 12: ......

Страница 13: ...ersion section A PTC Positive Temperature Coefficient resistance limits inrush current to a bank of filter capacitors when power is first turned on via the disconnect switch The key start contactor co...

Страница 14: ...ls on each functional block Figure 4 AC SuperDrive Block Diagram 2 1 2 CAN INTERFACE The CAN Interface manages communications between the AC SuperDrive and the CAN Bus The CAN controller provides the...

Страница 15: ...ture and frequency related changes in motor winding impedance as well as variations in the DC supply voltage thereby providing precise control of motor flux and torque over a wide range of operating c...

Страница 16: ...as a generator supplying power to the battery The change from motor to generator is smooth and instant when rotor speed exceeds synchronous speed The AC SuperDrive supplies a magnetizing current at th...

Страница 17: ...t continued operation of the AC SuperDrive Less serious problems that permit continued AC SuperDrive operation often at reduced capacity produce warnings For some items monitored the AC SuperDrive pro...

Страница 18: ...oadcast periodically by the master to all slaves to synchronize network devices and processes with the master NETWORK MANAGEMENT NMT Transmitted by the master to control network boot up initialization...

Страница 19: ...tion from liquids and particles dripping splashing or spraying onto the unit however the AC SuperDrive is not environmentally sealed It should not be located in a place where it is subjected to liquid...

Страница 20: ...94 3 3 CLEARANCES FOR ACCESS AND AIR CIRCULATION For all AC SuperDrive models 50 mm clearances in front of and behind the AC SuperDrive are required for airflow 50 mm clearance above the AC SuperDrive...

Страница 21: ...EQUIPMENT REQUIRED The following tools and hardware are recommended for mounting an AC SuperDrive Four 4 bolt M6S M6 x yy 8 8 fzb yy mm see Figure 8 internal hex head bolts pos 1 Four 4 washer BRB 6...

Страница 22: ...8 8 fzb mm bolts or equivalent 5 16 UNC bolts pos 1 Four 4 washer BRB 8 8 HB 200 fzb 16 x 8 4 x 1 5 Pos 2 13 mm Box wrench Thermal grease type of grease is typically Electrolube HTC or Dow Corning 34...

Страница 23: ...motor This configuration utilizes an on board fuse and main contactor under direct control of the truck controller Table 2 provides a description of the six terminal post connections on the AC SuperDr...

Страница 24: ...or and battery currents otherwise overheating will occur Crimp ring lugs onto the motor wires then secure the lugs to terminal posts using bolts M8 x 25 pos no 1 and pos 7 in Figure 14 and lock washer...

Страница 25: ...G AND SELECTION i An on board fuse is not supplied with the AC SuperDrive This component must be ordered separately An on board fuse installed between the B and terminals on each AC SuperDrive protect...

Страница 26: ...1 KEY START FUSE F2 Fuse F2 should be sized according to the number of AC SuperDrives in the circuit Refer to Table 3 the current consumption of the KEY START input Refer to Figure 11 for A CAN based...

Страница 27: ...th the PTC resistance prevents the energy stored in the SuperDrive s internal capacitors from powering the truck controller when the start key is switched off See Figure 11 The configuration shown in...

Страница 28: ...AL Connector K1 Plug AMPseal 23P 770680 1 Contact 770854 1 provides the electrical interface for all control and I O connections to an AC SuperDrive Figure 16 illustrates wiring of the mating interfac...

Страница 29: ...Output CAN_H One for IN and one for OUT to the next device 7 8 Output CAN GND One for IN and one for OUT to the next drive From November 2004 9 Output CAN 120R CAN 120 ohm termination resistor To use...

Страница 30: ...ity of electrical noise coupling into encoder lines avoid routing encoder cables next to conductors carrying high currents or high current pulses Noise immunity may also be improved by using twisted c...

Страница 31: ...manufacturer provides a means for the AC SuperDrive to monitor motor temperature The connector on the AC SuperDrive side is an AMP Superseal 282080 1 Table 6 lists the color coding and signal names f...

Страница 32: ...in a Daisy chain arrangement as shown in Figure 18 Twisted pair wiring is required for the CAN_H and CAN_L signals Both physical ends of the CAN Bus must be terminated with 120 ohm resistances A servi...

Страница 33: ...d these should all be grouped together at one end on the CAN bus and the GND connection to these units should be taken from one common point star connection if possible see Figure 19 Under no circumst...

Страница 34: ......

Страница 35: ...ge to equipment prior to applying power for the first time Make sure that the motor and battery cables are connected correctly Incorrect motor or battery connections may destroy the AC SuperDrive 4 2...

Страница 36: ...the AC SuperDrive at page 41 The general procedure for obtaining the correct configuration in the final product requires normally that the established parameter values are used as default values in th...

Страница 37: ...pump Make sure that the motor and battery cables are connected correctly Incorrect motor or battery connections may destroy the AC SuperDrive 1 With the main contactor open not enabled apply battery...

Страница 38: ......

Страница 39: ...e due to voltage transients the AC SuperDrive s internal filter capacitors must be discharged as described in Drive Removal on page 40 Do not short the to B terminal 5 1 PERIODIC PREVENTIVE MAINTENANC...

Страница 40: ...latch on connector housing and remove mating connector from K1 5 Remove on board fuse if applicable for use in replacement drive 6 On units with fins loosen four bolts securing drive to its mounting...

Страница 41: ...tics of the controlled motor and define the operating envelope of the motor drive combination A step in each new design is to establish the parameter values for the motor drive in its application This...

Страница 42: ...egularly to the ACS with a constant frequency the speed of the motor and the status of the ACS can be controlled In its basic configuration the Command Word and the Command Speed is sent to the ACS vi...

Страница 43: ...e CANopen state of the ACS becomes OPERATIONAL via the NMT message Start Remote Node PDO communication must start within one second Once the first PDORx is received subsequent PDORx s must be received...

Страница 44: ...error condition has occurred the NMT message Reset Node has to be sent After that the procedure from point 1 and forward has to be repeated A restart of the ACS can also be done by turning off and the...

Страница 45: ...ilteredValue FilteredValue FilterGain 256 RawValue FilteredValue Filter gain 256 means no filtering 2050h 5 Acceleration Read only variable rpm 20ms Table 8 Speed Measurement Parameters 6 3 1 TUNING O...

Страница 46: ...ommand Speed is the input to the speed controller and the limited Torque Current is the output It is also possible to disable the speed controller and use torque control instead The input then is the...

Страница 47: ...or 5 During constant speed and acceleration 2092h 1 2 Speed PI Controller I gain Medium Set 0 1 Speed Control Mode 1 Not used Speed Control Mode 4 or 5 During rollback 2093h 1 2 Speed PI Controller I...

Страница 48: ...erating in an steep uphill slope Bit 2 Enter Rollback Mode At Zero Speed If set to true the truck stops before it eventaully starts to roll Only used if Rollback Speed is NOT zero 2095h 9 Speed Change...

Страница 49: ...faster than the Internal Speed Reference In order to allow the truck to decelerate faster than the ramp the ramp is adjusted to the actual speed when decelerating in a steep slope as can be seen in F...

Страница 50: ...n uphill slope the truck will reach zero speed and then start rolling backwards down the slope with a speed larger than zero but less than or equal to the Rollback Speed value The bit 9 Rollback disab...

Страница 51: ...ctionality it is also possible to include the parameters 2000h 7 and 2000 8 shown in Table 15 in the PDO The receive PDO then looks as in Table 14 1 2 3 4 5 6 7 8 Command Word Command Speed Accelerati...

Страница 52: ...according to bits 11 12 in the Command Word 1 Parameter Set 0 2 Parameter Set 1 3 Parameter Set 2 Forward Deceleration 2101h and Reverse Deceleration 2103h 4 Parameter Set 3 Used according to bits 11...

Страница 53: ...A Torque Current and a Speed give each point Figure 25 Best Performance CurveOption 6 5 2 SPEED PI CONTROLLER The Speed PI controller is a normal PI controller with two inputs the Internal Speed Refer...

Страница 54: ...2095h 6 Reverse Max Acceleration Torque Current Unit ARMS 2095h 7 Forward Max Brake Torque Current Unit ARMS 2095h 8 Forward Max Brake Torque Current Unit ARMS Table 17 Torque Current Limitation Para...

Страница 55: ...mp modes Table 9 explains during which operation conditions the Small Medium and Large I gain respectively are used The Torque Current Limitation parameters Table 17 also have to be set to appropriate...

Страница 56: ...etization Current i e the rotor flux is kept constant up to the Base Speed Above the Base Speed the Magnetization Current is reduced Since the Slip Gain is reciprocally proportional to the Magnetizati...

Страница 57: ...0 C change in rotor temperature The motor manufacturer or Danaher Motion usually supplies this parameter 2070h 2 Nominal Magnetization Current Nominal magnetization current for the motor connected to...

Страница 58: ...tion Angle is computed as the sum of the Actual Speed electrical and the Slip Speed Figure 27 Slip and Stator Frequency Estimation 6 9 1 PARAMETERS AND VARIABLES The Number of Motor Poles is the only...

Страница 59: ...oid damage of the drive if a too high magnetization current is set via the CANopen object dictionary From the measured current in phase U and V the current in phase W is computed based on that the sum...

Страница 60: ...ices of the variables read only within the Current Control that are accessible via CANopen Index Sub Index Name Description 2070h 1 Iq Measured instantaneous torque current in deciA Iq is sampled ever...

Страница 61: ...r s c 3 256 f 1 4 I 3 U R R f 2 Igain s base dc r s c where fc Current control bandwidth 200 Hz fs Sampling execution frequency of the current control 4000 Hz Ls Lr Stator and rotor leakage inductanc...

Страница 62: ...n gives the switching instants The frequency of the triangular carrier wave determines the PWM switching frequency Nominally the switching frequency is equal to 8 kHz but with the parameter SPWM Switc...

Страница 63: ...er wave during a number of PWM switching periods i e the MOSFETs are mainly switching during the zero crossings of the reference voltages The use of over modulation will increase the harmonic content...

Страница 64: ...pen drain output 1 on and bit 7 Open drain ouput 2 on in the Command Word The Open Drain Outputs are voltage controlled in both modes and the voltage is defined as the voltage between B and Pin 2 in K...

Страница 65: ...l Time During this time in ms the Pull Voltage is generated 2060h 3 Open Drain Output 1 Pull Voltage Initial voltage in centiV between B and output Pin 2 in K1 when output is enabled 2060h 4 Open Drai...

Страница 66: ...copies parameter values from EEPROM memory into a segment of RAM memory reserved for parameters The operating software then performs several checks to verify the validity of the parameter set in RAM...

Страница 67: ...e value 65766173h to CANopen object Store All Parameters 1010h 1 Saving parameters shall be performed with the vehicle at standstill Figure 34 Procedure for saving Parameters to Flash Memory 6 14 4 DU...

Страница 68: ...rs stored in flash memory along with the AC SuperDrive software using a procedure similar to saving parameters i e by writing the value 64616F6Ch to CANopen object Restore All Default Parameters 1011h...

Страница 69: ...r the vehicle We can provide this troubleshooting information on electronic media in various formats for OEMs who wish to import it into their documentation 7 3 ERRORS The AC SuperDrive continuously m...

Страница 70: ...shing light 1Hz A warning is active Figure 36 The LED status indicator placement 7 6 USING THE TROUBLESHOOTING GUIDE CAUTION Do not manually operate main contactor or override system control of main c...

Страница 71: ...chart Symptom code See page Main contactor doesn t close within 10 seconds after switching on key switch 73 Fuse to Power Stage is blown 74 AC SuperDrive Status indicator is blinking or off 75 Motor...

Страница 72: ...emperature sensor 1 not connected short circuit 87 0x0200 Heat sink temperature 2 low 20 C 88 0x0400 Heat sink temperature 2 high 85 C 80 0x0800 Heat sink temperature sensor 2 not connected short circ...

Страница 73: ...26 04 2005 Troubleshooting guide 7 7 1 MAIN CONTACTOR DOESN T CLOSE Symptom User s Guide 1 0 Item No 89Y05120A 73...

Страница 74: ...l operation Replace fuse and restart drive Replace drive start end Increased friction heavier load high speed and rapid start stop all increase average current drawn by the drive Vehicle may have been...

Страница 75: ...26 04 2005 Troubleshooting guide 7 7 3 AC SUPERDRIVE STATUS INDICATOR IS FLASHING OR OFF Symptom User s Guide 1 0 Item No 89Y05120A 75...

Страница 76: ...Troubleshooting guide 26 04 2005 7 7 4 MOTOR RUNS ONLY AT LOW SPEED Symptom Item No 89Y05120A User s Guide 1 0 76...

Страница 77: ...26 04 2005 Troubleshooting guide 7 7 5 SPEED FEEDBACK SENSOR NOT CONNECTED Warning Code 0x4000 User s Guide 1 0 Item No 89Y05120A 77...

Страница 78: ...26 04 2005 7 7 6 MOTOR TEMPERATURE ERROR Error Code 0x4210 POWER LIMITED DUE TO OVER TEMPERATURE Warning Code 0x2000 POWER REDUCTION DUE TO MOTOR OVER TEMPERATURE Warning Code 0x0010 Item No 89Y05120...

Страница 79: ...26 04 2005 Troubleshooting guide User s Guide 1 0 Item No 89Y05120A 79...

Страница 80: ...TSINK OVER TEMPERATURE ERROR Error Code 0x4310 POWER LIMITED DUE TO HEATSINK OVER TEMPERATURE 1 2 85 O C Warning Code 0x0080 1 0x0400 2 POWER REDUCTION DUE TO TEMPERATURE Warning Code 0x2000 See next...

Страница 81: ...26 04 2005 Troubleshooting guide User s Guide 1 0 Item No 89Y05120A 81...

Страница 82: ...Troubleshooting guide 26 04 2005 Item No 89Y05120A User s Guide 1 0 82...

Страница 83: ...26 04 2005 Troubleshooting guide 7 7 8 AC CURRENT OVER CURRENT Error Code 0x2310 AC CURRENT SHORT CIRCUIT Error Code 0x2340 User s Guide 1 0 Item No 89Y05120A 83...

Страница 84: ...Troubleshooting guide 26 04 2005 7 7 9 DC BUS HIGH HARDWARE DETECTED Error Code 0x3212 DC BUS HIGH SOFTWARE DETECTED Error Code 0x3211 Item No 89Y05120A User s Guide 1 0 84...

Страница 85: ...26 04 2005 Troubleshooting guide 7 7 10 DC BUS LOW Error Code 0x3221 NO CHARGING DC BUS Error Code 0x3120 User s Guide 1 0 Item No 89Y05120A 85...

Страница 86: ...Troubleshooting guide 26 04 2005 7 7 11 CAN TIME OUT Error Code 0x8100 Item No 89Y05120A User s Guide 1 0 86...

Страница 87: ...26 04 2005 Troubleshooting guide 7 7 12 HEATSINK TEMPERATURE SENSOR 1 2 OPEN CIRCUIT SHORT CIRCUIT Warning Code 0x0100 1 0x0800 2 User s Guide 1 0 Item No 89Y05120A 87...

Страница 88: ...leshooting guide 26 04 2005 7 7 13 MOTOR TEMP 50 C Warning Code 0x0008 HEATSINK MOTOR TEMP 1 2 20 C Warning Code 0x0040 1 0x0200 2 POWER REDUCTION Warning Code 0x2000 Item No 89Y05120A User s Guide 1...

Страница 89: ...26 04 2005 Troubleshooting guide 7 7 14 MOTOR TEMPERATURE SENSOR OPEN CIRCUIT SHORT CIRCUIT Warning Code 0x0020 User s Guide 1 0 Item No 89Y05120A 89...

Страница 90: ...shooting guide 26 04 2005 7 7 15 15 V SUPPLY LOW VOLTAGE Error Code 0x5111 15 V SUPPLY LOW OR HIGH VOLTAGE Error Code 0x5113 CURRENT CALIBRATION ERROR Error Code 0x5210 Item No 89Y05120A User s Guide...

Страница 91: ...26 04 2005 Troubleshooting guide 7 7 16 REVERTED TO DEFAULT PARAMETERS Warning Code 0x1000 User s Guide 1 0 Item No 89Y05120A 91...

Страница 92: ......

Страница 93: ...24 36 450 200 18 2 8 1 3615 675 xxx 24 36 675 300 27 3 12 1 3620 900 xxx 36 900 400 36 4 16 2 4810 350 xxx 48 350 150 19 3 8 3 4815 525 xxx 48 525 225 28 9 12 4 4820 700 xxx 48 700 300 38 6 16 5 4825...

Страница 94: ...okay LED indicator is steady green When error condition s exist LED is flashing fast 10Hz When warning condition s exist LED is flashing slow 1Hz OVERCURRENT Power Conversion section disabled on over...

Страница 95: ...iated immunity emission ESD ELECTRICAL FAST TRANSIENT BURST EN61000 4 4 level 2 8 9 SAFETY AND TESTING STANDARDS COMPLIANCE SAFETY INDUSTRIAL TRUCKS EN 1175 1 BASIC ENVIRONMENTAL TESTING PROCEDURES IE...

Страница 96: ...ion Y1 Y2 Y3 Y4 ACSxx 10 165 120 9 ACSxx 15 233 6 150 41 8 ACSxx 20 302 2 215 107 5 43 6 ACSxx 25 370 8 250 125 60 4 Finned version Y1 X1 X2 X3 ACSxx 10 165 25 5 114 ACSxx 15 233 6 25 5 182 6 ACSxx 20...

Страница 97: ...26 04 2005 AC SuperDrive specifications Figure 37 Dimensions for AC SuperDrive with finned heatsink mm User s Guide 1 0 Item No 89Y05120A 97...

Страница 98: ...AC SuperDrive specifications 26 04 2005 Figure 38 Dimensions and surface roughness for flat heatsink mm Item No 89Y05120A User s Guide 1 0 98...

Страница 99: ...rompt attention to customers needs Call the nearest office listed for ordering and application information or for the address of the closest authorized distributor SWEDEN Danaher Motion Stockholm AB S...

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