Document Outline

• SAFETY SYMBOL LEGEND
  • BLOCK DIAGRAM LEGEND
• 1 - Safety Precautions - Precautions de securité
• 2 - Description, Component Identification and Specifications
  • 2.1 General
    • Functions and features (Overview)
  • 2.2 Upon Delivery Inspection Procedures
    • Storage, Transport
    • 2.2.1 Device setting
  • 2.3 Drive Keypad Description
    • Keypad
    • LEDs
  • 2.4 Specifications
    • 2.4.1 Standards
    • 2.4.2 AC Input
    • 2.4.3 Output
      • Output current
      • Armature circuit
      • Field circuit
      • Output voltage
      • Armature circuit
      • Field circuit
    • 2.4.4 Control section
    • 2.4.5 Accuracy
  • 2.5 Dimension and weights
  • 2.6 Watt Loss
  • 2.7 Motors, encoder, tachometer
    • 2.7.1 Motors
    • 2.7.2 Encoder / Tachometer
• 3 - Installation Guidelines
  • 3.1 Permissible Ambient Condition
  • 3.2 Disposal of the Device
  • 3.3 Installation, Mounting Clearance
    • Mounting the device
• 4 - Wiring Procedures
  • 4.1 Removing the front cover
    • Terminal Assignments/Cable Sections
  • 4.2 Wiring the Drive
  • 4.3 Power Section
  • 4.4 Regulation Section
    • 4.4.1 R-TPD32-GE Regulation Card
  • 4.5 Serial Interface
    • 4.5.1 Description
    • 4.5.2 RS485 serial interface connector description
  • 4.6 Input/Output expansion card 6KCV300TBO
    • 4.6.1 Assignment of the plug-in terminal strip (terminals 1...15) for Option Card 6KCV300TBO
    • 4.6.2 Fitting the option card
  • 4.7 Digital encoder interface 6KDV300DES
    • 4.7.1 Description
    • 4.7.2 Terminal Assignment
  • 4.8 Standard Connection Diagrams
  • 4.9 Circuit Protection
    • 4.9.1 Fuses
    • 4.9.2 Fuses selection when the Overload function is activated
    • 4.9.3 Internal Fuses
    • 4.9.4 AC input contactors
    • 4.9.5 Control power protection
  • 4.10 Reactors / Filters
    • 4.10.1 AC input choke
    • 4.10.2 Interference suppression filters
  • 4.11 Engineering notes
    • Potentials of the regulator section
      • External devices
      • Connection cables
• 5 - Converter Operation
  • 5.1 Keypad
    • 5.1.1 LEDs
    • 5.1.2 Moving inside a menu
    • 5.1.3 Displaying parameters
    • 5.1.4. Changing / Saving parameters / Password
      • Changing numerical values and text
      • Selection from predefined values
      • Autotuning of Analog input
      • Parameters Saving
      • Entering a password
      • General unlocking of the password
    • 5.1.5 Operating the drive via the Keypad
      • 5.1.5.1 Starting and stopping the drive
      • Enabling the converter
      • Disabling the converter
      • Start / Stop
      • 5.1.5.2 Failure register / Acknowledging alarms
      • Clearing the failure register
      • Acknowledging a failure alarm
      • Acknowledging when several failure alarms occur at the same time
      • 5.1.5.3 Motor potentiometer function
      • Acceleration, Deceleration
      • Changing rotation direction
      • Resetting the speed reference value
      • 5.1.5.4. Jog function
  • 5.2. Menu Structure
  • 5.3 Commissioning
    • 5.3.1 Setting jumpers and switch
    • 5.3.2 Checking the wiring and the auxiliary voltages
    • 5.3.3 Basic settings of the converter
    • 5.3.4 START UP procedures
      • Motor data
      • Limits
      • Speed feedback setting
      • Alarms
      • Overload control
      • Analog inputs 1, 2 and 3
    • 5.3.5 Drive tuning
      • 5.3.5.1 Self tuning of the current regulator
      • 5.3.5.1.1 Checking current regulator performance using parameter Eint
      • 5.3.5.2 Self tuning of the speed regulator
      • 5.3.5.3 Field converter
      • Selection of the functioning system
      • Setting the rated field current
      • Flux current min/max
    • 5.3.6 Manual tuning of the regulators
      • Using the Test generator
      • Manual tuning of speed regulator
      • Manual tuning of field current regulator
      • Voltage regulator in the field converter
    • 5.3.7 Others tuning
      • Flux / if curve tuning (Flux / if curve)
      • Speed-up function
      • Setting of the speed zero logic
      • Adaptive of the speed regulator
• 6 - Function Description
  • Functions and parameters
    • Explanation of parameter tables
  • 6.1 Enables
    • 6.1.1 Enable drive
    • 6.1.2 Start / Stop
    • 6.1.3 Fast stop
    • 6.1.4 Quick Stop
    • 6.1.5 External fault
  • 6.2 BASIC START UP MENUS
    • DRIVE STATUS
      • START UP
      • First basic setting
      • Motor data
      • Limits
      • Speed feedback
      • Alarms
      • Overload control
      • Analog inputs
      • Self tuning of current regulator
      • Self tuning of speed regulator
      • Final operation
      • TUNING
      • Current self tuning
      • Speed self tune
      • Manual tuning of speed regulator, field regulator and voltage regulator
  • 6.3 Monitor
  • 6.4 Input Variables
    • 6.4.1 Ramp ref
    • 6.4.2 Speed ref
    • 6.4.3 Torque current reference (T current ref)
  • 6.5 Limits
    • 6.5.1 Speed Limits
    • 6.5.2. Armature current limits (Current limits)
    • 6.5.3 Flux limits
  • 6.6 Ramp
    • 6.6.1 Acceleration, Deceleration, Quick Stop
    • 6.6.2 Ramp shape and control commands
  • 6.7 Speed Regulation (SPEED REGULAT)
    • 6.7.1 Speed regulator
      • 6.7.1.1 Self tuning of Speed regulator
    • 6.7.2 Spd zero logic
    • 6.7.3 Speed up
    • 6.7.4. Droop function
    • 6.7.5 Inertia/Loss compensation
  • 6.8 Current regulation (Current regulAT)
  • 6.9 Flux REGULATION
  • 6.10 Reg Parameters
  • 6.11 Configuration
    • 6.11.1 Operating mode selection
    • 6.11.2 Speed base value, Full load current
    • 6.11.3 Configuration of the OK relay (Terminals 35,36)
    • 6.11.4. Configuration of the speed feedback circuit
      • Ind store ctrl parameter [92]
      • Index storing parameter [13]
    • 6.11.5 “Standard / American” selection, Software Version
    • 6.11.6. Dimension factor, Face value fator
    • 6.11.7. Programmable alarms
    • 6.11.8 Address for bus operation
    • 6.11.9 Password
  • 6.12 I/O Config
    • 6.12.1 Analog Ouputs
    • 6.12.2 Analog Inputs
    • 6.12.3 Digital Outputs
    • 6.12.4 Digital Inputs
    • 6.12.5 Speed reference from encoder input (Tach follower function)
  • 6.13 Additional speed functions (add Speed Funct)
    • 6.13.1 Auto capture
    • 6.13.2 Adptive spd reg
    • 6.13.3 Speed control
    • 6.13.4 Speed zero
  • 6.14 Functions
    • 6.14.1 Motorpotentiometer
    • 6.14.2 Jog function
    • 6.14.3 Multi speed function
    • 6.14.4 Multi ramp function
    • 6.14.5 Speed Draw function
    • 6.14.6 Overload control
    • 6.14.7 Stop control
    • 6.14.8 Brake control
    • 6.14.9 Current limitation according to the speed (I/n curve)
  • 6.15 SPEC FUNCTIONS
    • 6.15.1 Test generator
    • 6.15.2 Saving parameters, loading default factory settings, life time
    • 6.15.3 Failure Register
    • 6.15.4. Signal adaptation
    • 6.15.5 Pads
  • 6.16 Options
    • 6.16.1 Option 1
    • 6.16.2 Option 2
    • 6.16.3 PID Functon
      • 6.16.3.1 General
      • 6.16.3.2 Inputs / Outputs
      • 6.16.3.3 Feed - Forward
      • 6.16.3.4 PID function
      • 6.16.3.5 Proportional - integral block
      • 6.16.3.6 Proportional - Derivative control block
      • 6.16.3.7 Output reference
      • 6.16.3.8 Function of calculation for Initial diameter
      • 6.16.3.9 Procedure of calculation for initial diameter
      • 6.16.3.10 Examples of application
      • 6.16.3.11 Generic PID
      • 6.16.3.12 Application note
  • 6.17 Torque Winder function
    • 6.17.1 Diameter calculation
    • 6.17.2 Torque calculation
      • 6.17.2.1 Compensations and closing of the tension loop
      • 6.17.2.2 Taper function
    • 6.17.3 Calculation of the speed reference
    • 6.17.4 Typical connection diagrams
    • 6.17.5 Control logic
      • Diameter initialization
      • Initial phase
      • Automatic switching
      • Reel stop
      • Jog function
    • 6.17.6 Application example
      • Provisions
      • 1. Drive used as a winder – winding side = up
      • 2. Drive used as a winder – winding side = down
      • 3. Drive used as an unwinder – unwinding side = up
      • 4. Drive used as an unwinder – unwinding side = down
    • 6.17.7 Block diagram
  • 6.18 Drivecom
    • 6.18.1 Control word, status word, malfunction code
    • 6.18.2 ­Speed
    • 6.18.3 Speed limitation
    • 6.18.4 Acceleration / Deceleration
    • 6.18.5 Factor function
  • 6.19 SERVICE
• 7- Maintenance
  • 7.1 Care
  • 7.2 Service
  • 7.3 Repairs
  • 7.4 Customer Service
• 8 - Troubleshooting
  • Failure alarms in the keypad display
    • Other faults
• 9 - Block Diagram
  • 9.1 Control Block Diagrams
    • DV-300 Converter Overview
      • Digital Inputs /Outputs & Mapping Standard and TBO cards
      • Analog Inputs/Outputs & Mapping
      • Speed Reference Generation
      • Ramp reference Block
      • Speed / Current Regulator Overview
      • Speed Feedback setting
      • Speed regulator
      • Speed regulator PI part
      • Speed adaptive and Speed zero logic
      • Current regulator
      • Field current regulator
      • Motor parameters
      • Start and Stop management
      • Droop compensation
      • Inertia / Loss compensation
      • Speed Threshold / Speed control
      • PID function
      • Functions
      • LINKS Function
      • PAD parameters
      • Taper Current Limits
      • Dimension factor - Face value factor
      • Test Generator
      • JOG function
      • Multispeed
      • Motor potentiometer
      • Alarm mapping
  • 9.2 Power Circuit Block Diagrams
  • 9.3 Regulation Card
• 10 - Parameter Lists
  • 10.1 Complete main menu list
  • 10.2 Numerical List
  • 10.3 Parameters in Alphabetical order
  • 10.4 List of High priority parameters
• 11 - Replacement Parts
  • 11.1 Hardware configuration (cards / dip switches / jumpers)
  • 11.2. R-TPD32-GE REGULATION card
  • 11.3 FIR1-... power/driver cardS
  • 11.4 FIR2-... power/driver card
  • 11.6 PBB power connection card
  • 11.7 PFC1-32 field converter
  • 11.8 PFC2-31 field converter
  • 11.9 SN-FC field snubber
  • 11.10 SN4-31, SN5-31 snubber
  • 11.11 SW1-31 power supply card
  • 11.12 SW2-32 power supply card
  • 11.13 FL-31 filter
  • 11.14 CN3 connection card
  • 11.15 I/O option card 6KCV300TBO
• 1 - Safety Precautions - Precautions de securité
• 2 - Description, Component Identification and Specifications
  • Fig 2.1: Base diagram of a converter
  • Fig. 2.5.1: Drive dimensions for 20 A ... 185 A sizes (form 1)
  • Fig. 2.5.2: Drive dimensions for 280 A ... 650 A sizes (form 2)
  • Fig. 2.5.3: Drive dimensions for 770 A ... 1050 A sizes (form 3)
• 3 - Installation Guidelines
  • Figure 3.3.1: max Angle of Inclination
  • Figure 3.3.2: Mounting Clearance
• 4 - Wiring Procedures
  • Figure 4.1.1: Removing the Front Panel
  • Figure 4.4.1: R-TPD32-GE regulation card
  • Figure 4.4.2: Disposition of terminals from 1 to 42
  • Figure 4.5.1.1: RS485 serial interface
  • Figure 4.6.2.1: Installing the option card
  • Figure 4.7.1.1: 6KDV300DES card
  • Figure 4.8.1:Control sequencing
  • Figure 4.8.2: Example for relay interface
  • Figure 4.8.3: Typical connections
  • Figure 4.8.4: Encoder and Tachometer Connections
  • Figure 4.8.5: Programmable Inputs/outputs (option 6KCV300TBO) with relay and contacts
  • Figure 4.8.6: Programmable Inputs/outputs with PLC
  • Figure 4.8.7: 6KCV300DES connection
  • Figure 4.9.1.1: Position of the super fast fuses
  • Figure 4.11.1: Potentials of the regulator section
• 5 - Converter Operation
  • Figure 5.1.2.1: Moving inside a menu
  • Figure 5.3.6.1: Above: Actual spd; Below: Motor current. Speed P too low.
  • Figure 5.3.6.3: Above: Actual spd; Below: Motor current. Speed I too high.
  • Figure 5.3.6.2: Above: Actual spd; Below: Motor current. Speed P too high.
  • Figure 5.3.6.4: Above: Actual spd; Below: Motor current. Speed P and Speed I set correctly.
  • Figure 5.3.6.5: Above: Flux reference; Below: Flux current. The regulator behavior is not good. Jumps are due to field changing.
  • Figure 5.3.6.7: Above: Flux reference; Below: Flux current. The increment in the field current has no jump. Variation compared to Fig. 4.5.7: Increase of Flux P from 2 to 10%. Flux I = 5%.
  • Figure 5.3.6.6: Above: Flux reference; Below: Flux current. The reduction of the field current depends on the field time constant. The reg has no influence.
  • Figure 5.3.6.8: Above: Flux; Below: Output voltage. After a speed change the field current (Flux) has some jumps. Voltage P = 10%, Voltage I = 80%.
  • Figure 5.3.6.10: Above: Flux; Below: Output voltage. After a short transient, the field current and armature voltage are constant. Voltage P = 40%, Voltage I = 50%.
  • Figure 5.3.6.9: Above: Flux; Below: Output voltage. The gain is too low. The armature voltage increases. Voltage P = 3%, Voltage I = 5%.
  • Figure 5.3.7.1: Curve convertion flux/current
  • Figure 5.3.7.2: Blocks diagrams of field current regulator
  • Figure 5.3.7.3: Above: Actual spd; Below: Motor current jumps with the speed changes due to a high moment of inertia. The function Speed-up is not active.
  • Figure 5.3.7.4: Above: Actual spd; Below: Motor current. The same drive with Speed -up function active.
• 6 - Function Description
  • Figure 6.1.1 Enables via potential free contacts and PLC
  • Figure 6.4.1.1: Ramp references
  • Figure 6.4.2.1: Speed reference
  • Figure 6.4.3.1: Torque current reference
  • Figure 6.6.1 : Ramp circuit
  • Figure 6.6.1.1: Accel, decel and Quick stop
  • Figure 6.6.2.1: Ramp shape
  • Figure 6.6.2.2: Ramp delay
  • Figure 6.6.2.3: Ramp control
  • Figure 6.7.1: Speed regulation
  • Figure 6.7.2.1: Speed zero logic
  • Figure 6.7.4.1: Droop compensation
  • Figure 6.7.4.2: Droop function example
  • Figure 6.7.5.1: Inertia/Loss compensation
  • Figure 6.8.1: Torque current regulaton
  • Figure 6.9.1: Motor control
  • Figure 6.11.4.1: Speed feedback
  • Figure 6.11.4.2: Allowed area for Encoder 2 pulses and Motor max speed
  • Figure 6.11.6.1: Calculation using dimension and face value factors
  • Figure 6.11.7.1: Drive enabling sequence: Main command = Terminals
  • Figure 6.11.7.2 Drive enabling sequence: Main command = Digital
  • Figure 6.12.1: Arrangement of the programmable I/O
  • Figure 6.12.1.1: Option card, analog output blocks
  • Figure 6.12.2.1: Analog input
  • Figure 6.12.2.2: Analog Input 1 window comparator
  • Figure 6.12.3.1: Digital outputs
  • Figure 6.12.4.1: Digital inputs
  • Figure 6.12.5.1: Tach follower
  • Figure 6.12.5.2: Example of application of the encoder reference
  • Figure 6.13.2.1: Adaptive of the speed regulator
  • Figure 6.13.3.1: “Speed threshold” (up) and “Set speed” (down) messages
  • Figure 6.13.4.1: Speed zero
  • Figure 6.14.1.1: Motor potentiometer
  • Figure 6.14.2.1: Example of external activation in Jog mode
  • Figure 6.14.3.1: Selection of different references via terminals
  • Figure 6.14.3.2: Multi speed function
  • Figure 6.14.4.1: Multi ramp selection via terminals
  • Figure 6.14.4.2: Multi ramp selection via signals
  • Figure 6.14.5.1: Speed draw block diagram
  • Figure 6.14.5.2: Rubber calender example
  • Figure 6.14.6.1: Overload control (Overload mode = curr limited)
  • Figure 6.14.6.2: Overload control (Overload mode= curr not limited)
  • Figure 6.14.6.3: Example- Operating point of drive
  • Figure 6.14.7.1: Start and stop management
  • Figure 6.14.8.1: Diagram of control
  • Figure 6.14.8.2: Brake control diagram
  • Figure 6.14.8.1 Current limitation according to the speed
  • Figure 6.15.1.1: Test generator output
  • Figure 6.15.4.1: Structure of the signal adaptation
  • Figure 6.15.5.1: Bus pads
  • Figure 6.16.3.1: Feed-forward block description
  • Figure 6.16.3.2: PID blocks description
  • Figure 6.16.3.3: PI block description
  • Figure 6.16.3.4: PD block description
  • Figure 6.16.3.5: Output reference block description
  • Figure 6.16.3.6: Diameter calculation block description
  • Figure 6.16.3.7: Diameter calculation
  • Figure 6.16.3.8: Nip-roll control with dancer
  • Figure 6.16.3.9: Nip-rolls control with load cell
  • Figure 6.16.3.10: Winder/Unwinder control with dancer
  • Figure 6.16.3.11: Diameter calculation
  • Figure 6.16.3.12: Winder/unwinder control with sensor diameter
  • Figure 6.16.3.13: Relation between transducer signal and coil signal
  • Figure 6.16.3.14: Pressure control for pumps and extruder
  • Figure 6.16.3.15: Example with small and large diameter
  • Figure 6.16.3.16: Relation between PI I gain PID and PI I output PID
  • Figure 6.16.3.17: General description of the PID blocks
  • Figure 6.17.1: Acceleration and deceleration indication
  • Figure 6.17.2: Relation among the Taper function parameters
  • Figure 6.17.3: Operative sequence of the functioning status
  • Figure 6.17.4: Functioning with Jog TW enable
  • Figure 6.17.5: Winder with an automatic switch and a closed loop tension regulation
  • Figure 6.17.6: Winder with an automatic switch and a closed loop tension regulation
  • Figure 6.17.7: Winder with an automatic switch and a closed loop tension regulation
  • Figure 6.17.8: Winder with an automatic switch and a closed loop tension regulation
  • Figure 6.17.9: Initial phase with a stopped line
  • Figure 6.17.10: Automatic switching between two coils during a winding/unwinding period
  • Figure 6.17.11: Coil stop after the automatic switching
  • Figure 6.17.12: Jog function to prepare the machine
  • Figure 6.17.13: Drive used as a winder – winding side = up
  • Figure 6.17.14: Drive used as a winder – winding side = down
  • Figure 6.17.15: Drive used as an unwinder – unwinding side = up
  • Figure 6.17.16: Drive used as an unwinder – unwinding side = down
  • Figure 6.17.4.1: Acceleration and deceleration
• 7- Maintenance
• 8 - Troubleshooting
• 9 - Block Diagram
  • Figure 9.2.1: Circuit block diagram: 6KDV3017Q4F ... to 6KDV3148Q4F - 6KDV3020Q4E ... to 6KDV3185Q4E
  • Figure 9.2.2: Circuit block diagram: 6KDV3224Q4F ... to 6KDV3450Q4F - 6KDV3280Q4E ... to 6KDV3650Q4E
  • Figure 9.2.3: Circuit block diagram: 6KDV3560Q4F ... to 6KDV3850Q4F - 6KDV3770Q4E ... to 6KDV310HQ4E
  • Figure 9.2.4: Circuit block diagram: 6KDV3017Q2B ... to 6KDV3148Q2B - 6KDV3020Q2A ... to 6KDV3185Q2A
  • Figure 9.2.5: Circuit block diagram: 6KDV3224Q2B ... to 6KDV3450Q2B - 6KDV3280Q2A ... to 6KDV3650Q2A
  • Figure 9.2.6: Circuit block diagram: 6KDV3560Q2B ... to 6KDV3850Q2B - 6KDV3770Q2A ... to 6KDV310HQ2A
• 10 - Parameter Lists
• 11 - Replacement Parts
• 1 - Safety Precautions - Precautions de securité
• 2 - Description, Component Identification and Specifications
  • Table 2.1.1: Converter size
  • Table 2.3.1: Keypad LEDs
  • Table 2.4.2.1: AC input votages
  • Table 2.4.2.2: AC input curents
  • Table 2.4.3.1: Output currents
  • Table 2.4.3.2: Field current resistors
  • Table 2.4.3.3: Armature circuit output votages
  • Table 2.4.3.4: Field circuit output votages
  • Table 2.6.1: Power Dissipation
• 3 - Installation Guidelines
• 4 - Wiring Procedures
  • Table 4.3.1: Terminals description
  • Table 4.3.2: Cable size for power terminals U, V, W, C, D, PE
  • Table 4.3.3: Cable section for UL approval
  • Table 4.3.4: Wire adapter Kit and lugs suggested for UL approval
  • Table 4.3.5: Cable size for power field terminals U1, V1, C1, D1
  • Table 4.3.6: Cable size for fans, signals, thermistors and regulation supply
  • Table 4.4.1: LEDs on the R-TPD32-GE card
  • Table 4.4.2: Dip-switch S15 adaptation of the regulation card to the device type
  • Table 4.4.3 : Dip-switch S4 adaptation of the tachometer feedback to the input voltage
  • Table 4.4.4: Jumpers on the R-TPD32-GE card
  • Table 4.4.5: Test points on Regulator card
  • Table 4.4.6 - A: Terminal Assignment (terminals from 1 to 20)
  • Table 4.4.6 - B: Terminal Assignment (terminals from 21 to 42)
  • Table 4.4.7: Cable size for fans, signals, and thermistors
  • Table 4.4.8: Terminal strip for the connection of an analog tachometer
  • Table 4.4.9: Assignment of an XE1 connector for a sinusoidal encoder
  • Table 4.4.10: Assignment of the XE2 connector for a digital encoder
  • Table 4.5.2.1: Description of the XS connector for the RS485 serial interface
  • Table 4.6.1.1: Terminal strip connections
  • Table 4.6.1.2: Cable size for terminals of the option card 6KCV300TBO
  • Table 4.7.2.1: Terminal assignment (Terminals 0Venc and +Venc)
  • Table 4.7.2.2: Permissible cable cross section on the terminals of option card 6KDV300DES
  • Table 4.7.2.3: XS1 9-pole connector
  • Table 4.9.1.1: Recommended fuses (externally mounted)
  • Table 4.9.2.1: Overload fuses
  • Table 4.9.3.1: Internal fuses
  • Table 4.9.5: Control power protection
  • Table 4.10.1.1: AC input choke
• 5 - Converter Operation
  • Table 5.3.5.3.1: Tuning resistances of the field current
• 6 - Function Description
  • Table 6.14.2.1: Multi speed function
  • Table 6.14.4.1: Ramp selection
  • Table 6.14.6.1: I2t derating
• 7- Maintenance
• 8 - Troubleshooting
• 9 - Block Diagram
• 10 - Parameter Lists
• 11 - Replacement Parts