GE Industrial Solutions DV-300 DC Drive Users Manual User Manual

GE Industrial Solutions Equipment

Table of contents

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
- 2.5 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
- 4.10 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
- 5.2. Menu Structure
- 5.3 Commissioning
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
- 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
- 6.17 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
  - 6.17.6 Application example
  - 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
- 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