GD4000

Alspa GD4000
Technical Manual for products GD4010 to GD42262
CEGELEC INDUSTRIAL CONTROLS Ltd Kidsgrove, Stoke-on-Trent, Staffordshire, ST7 1TW ENGLAND
Telephone: Stoke-on-Trent (01782) 781000 Int (44 17 82) 78 10 00 Fax: Stoke-on-Trent (01782) 781001 Int (44 17 82) 78 10 01
Alspa GD4000
Acknowledgements MODBUS is a registered trade name of Modicon Electronics Limited.
Publication No. T1656 Alcatel Alsthom 1998.
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Alspa GD4000
Issue (12-2-98)
Alspa GD4000
Symbols Used in GD4000 Equipment
PROTECTIVE EARTH TERMINAL. THIS MUST BE CONNECTED TO EARTH (GROUND).
CAUTION, READ INSTRUCTION BOOK.
CAUTION
WARNING, DANGER OF ELECTRIC SHOCK
ATTENTION, OBSERVE PRECAUTIONS FOR HANDLING ELECTOSTATIC DISCHARGE SENSITIVE DEVICES.
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SAFETY INSTRUCTIONS FOR ALSPA VARIABLE SPEED DRIVES (in conformity with the Low Voltage Directive 73/23/EEC)
General Electrical equipment represents a risk to life. Safety instructions are given on the product, and in this manual. Reference must be made to the instructions in this manual for any action taken when transporting, commissioning, operating, maintaining and disposing of the Alspa drive. Dangerous voltages appear on the circuitry. There can be moving parts and hot surfaces. Death, severe physical injury and extensive material damage can result if the instructions given in this manual are not observed. Local safety regulations must be observed during erection, commissioning and maintenance of the Alspa drive. Persons performing this work must be suitably skilled and should have been trained in that work for Alspa drives. Electrostatic sensitive components are used within this product. Static handling precautions in accordance with Protection of Electrostatic Sensitive Devices, Part 1, General Requirements, EN 100015 Pt.1:1992 (CECC 00015:1992) must be observed. All products weighing in excess of 20 kg (44 lbs) should be moved by mechanical handling equipment using the lifting points provided. Radio transmitters (e.g. walkie talkies, mobile telephones) can cause incorrect operation. Transmitters with an output of more than 2 watts must not be used in the vicinity of the Alspa drive. Transmitters with output power of 2 watts or less must not be used less than 2 metres (6 feet) from the Alspa drive. Intended use Alspa drives are components designed for incorporation in installations, apparatus and machines. In the European Union, a machine should not be taken into service until the machine has been proven to conform with the provisions of the Machinery Directive, 89/392/EEC. In the European Union the requirements of the EMC Directive, 89/336/EEC, should be established before any installation, apparatus or machine which incorporates the Alspa drive, is taken into service. The Alspa drive complies with the requirements of the Low Voltage Directive, 73/23/EEC. Page iv Alspa GD4000 Issue (12-2-98)
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The Alspa drive complies with the safety and EMC standards listed in the Specifications section of the manual. The technical data and the information concerning the supply conditions should be taken from the rating plate and this manual and must be strictly observed. Transportation and Storage The instructions for storage and transport specified on the packaging and in this manual must be followed. The environmental conditions should be within the limits specified in this manual. Erection and Commissioning Erection and commissioning of, and cooling medium flow to, the Alspa drive should be in accordance with the specifications given in the manual. Erection and commissioning of the Alspa drive must be carried out in line with any local electrical installation and wiring standards and IEC 364 or (in the United Kingdom) BS 7671. The earth terminal must be connected to earth (safety ground) in accordance with local safety regulations and IEC 364-5-54. The Alspa drives must be protected against excessive mechanical stresses. In particular, no components must be bent or isolation distances altered during the transportation, handling, installation or maintenance of the Alspa drive. The degree of protection provided offered with the various products in the Alspa drive range is detailed in the Specification Section 2.11.13. Compliance with the requirements of EMC laws is the responsibility of the installer or the manufacturer of the machine. Instructions for erection and commissioning the Alspa drive in accordance with the EMC requirements of the European Union are given in the manual and must be complied with. These instructions contain information on screening (shielding), earthing (grounding), wiring and relative positioning of electrical equipment. Shrouds may be modified only as described in the manual. Electrical Connection When working on the Alspa drive, the local health and safety legislation must be observed. Conductors, protective devices etc. should be provided in accordance with the requirements stated in the manual.
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Operation The drive must not be used as a single item safety system. It may be used as a component in a voting safety system. Additional control and protective devices must be provided in accordance with the safety requirements of the installation. Changes by means of the application software are admissible. Rotating motors are a source of energy and can apply high voltages to the circuitry. Capacitors can retain these voltages and must be allowed to discharge. A minimum period of 5 minutes must be observed after the input supply is disconnected and the rotating machinery has stopped before access to live connections is permitted. In this respect warning labels must be observed. When the Alspa drive is configured for auto start, it is possible that the motor may turn without an operator command. Precautions must be taken to prevent injury to personnel. During operation all covers and doors must be closed. If covers are removed and not replaced before power is reapplied there is danger of serious personal injury and damage to property. Maintenance and Service The information given in the documentation for maintaining and servicing the Alspa drive must be followed. Disposal Local regulations must be followed when disposing of the Alspa drive. Any question or doubt should be referred back to CEGELEC Industrial Controls Ltd. Store the safety instructions with the Alspa drive.
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Issue (12-2-98)
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CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH

GENERAL Care has been taken with selection of all components, interconnections, housing and packaging and in the design and manufacture of this equipment to minimize the risk to the health and safety of all personnel who are in contact with this equipment during its life, when the equipment is properly handled and used. Modern high technology materials have been used in the manufacture of the equipment to ensure optimum performance. Some of these materials are toxic under certain conditions. Mechanical or electrical damage is unlikely to give rise to any direct hazard, but toxic vapours may be generated if the materials are heated to destruction and it is important that the recommendations given below are observed. Care should be taken to ensure that all personnel who may handle, use or dispose of this equipment are aware of the necessary precautions. DISPOSAL This equipment or any part of the equipment should be disposed of in accordance with the relevant legislation; in the United Kingdom, disposal should therefore be carried out in accordance with the Deposit of Poisonous Waste Act 1972 and the Control of Pollution Act 1974, or with the latest legislation. FIRE The products when used within the specified limits do not present a fire hazard. Electronic devices within this equipment may contain arsenic, beryllium, lead, mercury, selenium, tellurium or similar hazardous materials or compounds which, if exposed to high temperature may emit toxic or noxious fumes. Most device encapsulation materials are flammable and care should be taken in the disposal of the equipment, and, in the event of a fire, the handling of damaged equipment. Toxic fumes may be emitted if the devices are burned. HANDLING Normal handling of the equipment is safe. However, care must be exercised with those devices incorporating glass or plastic. If these devices are broken or damaged, precautions must be taken against the hazards that may arise. For broken glass or ceramic protective clothing, such as gloves, must be worn. For toxic material or vapour, skin contact and inhalation must be avoided.
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SUBSTANCES Substances that may be included in this equipment are:Arsenic Boric acid Ethylene Glycol Phosphoric acid Phthalic acid Tributylamine Triethylamine Certain substances such as those containing arsenic, indium, lead, lithium, selenium, tantalum, etc may be toxic by ingestion or inhalation. Electrolytic capacitors contain a non carcinogenic electrolyte which has a low acute toxicity which may cause slight irritation to the skin if contact is prolonged. HAZARDOUS COMPONENTS Components that may include hazardous substances are:Batteries Optical Devices Electrolytic capacitors All encapsulated Devices Lithium Arsenic Electrolyte. Plastic (generates an inhalation risk in a fire). PRECAUTIONS Precautions to be followed in the event of damage to the equipment except where special precautions to be followed are listed above, include: After skin contact - wash thoroughly with soap and water. If contact is where the skin
is broken, medical advice should be sought.

After eye contact - wash immediately with copious amounts of water and seek
medical advice.
After inhalation - seek medical advice.
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Issue (12-2-98)
Alspa GD4000
TABLE OF CONTENTS
1. Introduction to GD4000 1.1. General Description . . . . . . . . . . . . . . . . . . 1.1.1 Flux Vector Control . . . . . . . . . . . . . . . . . 1.1.2 Variable Voltage Variable Frequency Control (VVVF) . 1.2. Nomenclature . . . . . . . . . . . . . . . . . . . . . 1.2.1 Software Supplied . . . . . . . . . . . . . . . . . 1.2.2 Alternative Drive Topologies . . . . . . . . . . . . 1.3. Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-2 1-2 1-4 1-4 1-4
2. Specification 2.1. Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.1 Current Ratings (GD41128, GD41508, GD41692 and GD42262) 2.2. Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Supply Frequency . . . . . . . . . . . . . . . . . . . . . . . . 2.2.3 Power Factor of Network Rectifier Bridge . . . . . . . . . . . . . 2.2.4 Cooling System Characteristics (GD4010 to GD4160) . . . . . . . 2.2.5 Motor Selection Criteria . . . . . . . . . . . . . . . . . . . . . 2.3. Drive Internal Supplies . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1 Serial Links and Encoder Supply . . . . . . . . . . . . . . . . . 2.3.2 Internal Supplies Hold Up Time . . . . . . . . . . . . . . . . . . 2.4. Drive Identity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5. Board Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6. I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.1 Dedicated Digital Inputs . . . . . . . . . . . . . . . . . . . . . 2.6.2 Basic Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . 2.6.3 Basic Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . 2.6.4 Basic I/O Extended . . . . . . . . . . . . . . . . . . . . . . . . 2.6.5 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.6 Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . 2.7. Incremental Encoder Line Receiver . . . . . . . . . . . . . . . . . . 2.8. Watchdog Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9. Serial Communications . . . . . . . . . . . . . . . . . . . . . . . 2.9.1 Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10. Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11. Environmental Conditions . . . . . . . . . . . . . . . . . . . . . 2.11.1 Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . 2.11.2 Relative Humididty . . . . . . . . . . . . . . . . . . . . . . . . 2.11.3 Vibration (Operational) . . . . . . . . . . . . . . . . . . . . . . 2.11.4 Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.6 Maximum Heat Dissipation . . . . . . . . . . . . . . . . . . . . 2.11.7 Relative Humidity . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.8 Overvoltage Category . . . . . . . . . . . . . . . . . . . . . . 2.11.9 Pollution Degree . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.10 Acoustic Noise Emissions . . . . . . . . . . . . . . . . . . . . . 2.11.11 Radio Frequency Emissions . . . . . . . . . . . . . . . . . . . . 2.11.12 Susceptibility to Radio Frequency Interference . . . . . . . . . . . 2.11.13 Degree of Protection . . . . . . . . . . . . . . . . . . . . . . . 2.12. Size And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13. Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . .
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2-1 2-5 2-5 2-5 2-6 2-6 2-6 2-7 2-7 2-8 2-8 2-8 2-8 2-8 2-8 2-9 2-9 2-10 2-10 2-10 2-10 2-11 2-11 2-11 2-11 2-11 2-11 2-12 2-12 2-12 2-12 2-13 2-13 2-13 2-13 2-13 2-13 2-14 2-14 2-14 2-14 2-15
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2.14. 2.15. 3. 3.1. 3.2. 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.3. 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7 3.3.8 3.3.9 3.3.10 3.3.11 3.3.12 3.3.13 3.3.14 Calender/Clock Functions . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Enhancement Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Technical Description Introduction . . . . . . . . . . . . . . . . . . . . Principles of Operation . . . . . . . . . . . . . . . Network Bridge Operation . . . . . . . . . . . Vector Control Operation . . . . . . . . . . . . Vector Control Block Diagram . . . . . . . . . . Description of Operation . . . . . . . . . . . . Vector Control Performance . . . . . . . . . . . Hardware Description . . . . . . . . . . . . . . . SIGMA Core Board . . . . . . . . . . . . . . . Calendar clock . . . . . . . . . . . . . . . . . Drive I/D . . . . . . . . . . . . . . . . . . . . Board Identifiers . . . . . . . . . . . . . . . . Power Interface Board . . . . . . . . . . . . . . Customer I/O Board . . . . . . . . . . . . . . Analog Termination Panel . . . . . . . . . . . . Incremental Encoder . . . . . . . . . . . . . . Input and Output Power Bridges . . . . . . . . . Precharge Circuits . . . . . . . . . . . . . . . . Switched Mode Power Supply . . . . . . . . . . Cooling Fans (Standard Cooling System) . . . . . Cooling Fans (High Performance Cooling System) Line Contactors and Line Reactors . . . . . . . .
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. 3-1 . 3-1 . 3-1 . 3-1 . 3-3 . 3-4 . 3-4 . 3-5 . 3-7 . 3-8 . 3-8 . 3-9 . 3-9 . 3-9 3-10 3-11 3-11 3-11 3-12 3-12 3-12 3-12
4. The CEGELEC SIGMA Programmer 4.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 The CEGELEC SIGMA Programmer . . . . . . . . . . . 4.1.2 PC Requirements . . . . . . . . . . . . . . . . . . . . 4.1.3 Structure of a User Program . . . . . . . . . . . . . . . 4.1.4 The Software Database . . . . . . . . . . . . . . . . . 4.1.5 System Software Issue Numbers . . . . . . . . . . . . . 4.1.6 Interaction of the CSP Software Packages . . . . . . . . 4.2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Start CSP . . . . . . . . . . . . . . . . . . . . . . . . 4.2.3 Reference . . . . . . . . . . . . . . . . . . . . . . . . 4.3. Top Level Menu . . . . . . . . . . . . . . . . . . . . . . 4.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . 4.3.2 Password System . . . . . . . . . . . . . . . . . . . . 4.3.3 Error Messages . . . . . . . . . . . . . . . . . . . . . 4.3.4 Warning Messages . . . . . . . . . . . . . . . . . . . 4.4. Ladder Editor F1 . . . . . . . . . . . . . . . . . . . . . . 4.4.1 Description . . . . . . . . . . . . . . . . . . . . . . . 4.4.2 Ladder Programming Methods . . . . . . . . . . . . . 4.4.3 LADDER EDITOR F1:Top Level Menu . . . . . . . . . . . 4.4.4 LADDER EDITOR F1: Subsequent level Menus . . . . . . 4.4.5 Options Available from Menus . . . . . . . . . . . . . 4.5. Links Editor F2 . . . . . . . . . . . . . . . . . . . . . . . 4.5.1 Description . . . . . . . . . . . . . . . . . . . . . . . 4.5.2 Selecting File Name . . . . . . . . . . . . . . . . . . . 4.5.3 Display . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4 Portability . . . . . . . . . . . . . . . . . . . . . . . . 4.5.5 Editing Environment . . . . . . . . . . . . . . . . . . . Page x Alspa GD4000
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. 4-1 . 4-1 . 4-1 . 4-2 . 4-2 . 4-2 . 4-3 . 4-4 . 4-4 . 4-5 . 4-5 . 4-5 . 4-5 . 4-6 . 4-6 . 4-7 . 4-7 . 4-7 . 4-9 4-10 4-12 4-14 4-19 4-19 4-19 4-20 4-21 4-21
Issue (12-2-98)
Alspa GD4000
4.5.6 4.5.7 4.5.8 4.5.9 4.5.10 4.5.11 4.6. 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.6.7 4.7. 4.7.1 4.7.2 4.7.3 4.7.4 4.7.5 4.8. 4.8.1 4.8.2 4.8.3 4.8.4 4.8.5 4.8.6 4.8.7 4.8.8 4.8.9 4.8.10 4.9. 4.9.1 4.9.2 4.10. 4.10.1 4.10.2 4.10.3 4.10.4 4.10.5 4.10.6 4.10.7 4.10.8 4.10.9 4.11. 4.11.1 4.11.2 4.11.3 4.11.4 4.11.5 4.11.6 4.11.7 4.11.8 4.11.9 Editing Keys . . . . . . . . . . . Links Editing . . . . . . . . . . . Print Program . . . . . . . . . . Save Program . . . . . . . . . . Normal/Commissioning Program . Error Messages . . . . . . . . . . Compile Program F3 . . . . . . . . Description . . . . . . . . . . . . Procedure . . . . . . . . . . . . Portability . . . . . . . . . . . . Ladder Instructions . . . . . . . . Compiler Error Messages . . . . . Warning Messages . . . . . . . . Timing . . . . . . . . . . . . . . Download Program F4 . . . . . . . . Description . . . . . . . . . . . . Procedure . . . . . . . . . . . . Portability . . . . . . . . . . . . Downloader Messages . . . . . . Input and Output Files . . . . . . Monitor F5 . . . . . . . . . . . . . Description . . . . . . . . . . . . Display . . . . . . . . . . . . . Monitor/Edit Environment . . . . User Keys . . . . . . . . . . . . Function Key Details . . . . . . . Variable Display . . . . . . . . . Address Entry . . . . . . . . . . Editing Variables . . . . . . . . . SIGMA Attributes used by Monitor Error Messages . . . . . . . . . . List File Viewing Utility F6 . . . . . . Description . . . . . . . . . . . . Display . . . . . . . . . . . . . Programmer Set Up F7 . . . . . . . Introduction . . . . . . . . . . . Drive Filename Selection . . . . . Environment Variables . . . . . . Current Database . . . . . . . . Serial Link . . . . . . . . . . . . Colour Selection Menu . . . . . . Drive Mode Selection . . . . . . . Password Selection . . . . . . . . Programmer Set-up . . . . . . . PC Based Interactive Files . . . . . . Firmware Database (ARC.A) . . . Links Program (.GDM) . . . . . . Commissioning Program (.GDC) . Ladder Program (.GLP) . . . . . . Compiler Output File (.DNL) . . . List File (.LST) . . . . . . . . . . Set Up File (CSP.DAT) . . . . . . Printer (Links) File (.PRN) . . . . . Message Files (.MSG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 4-22 4-23 4-23 4-23 4-24 4-26 4-26 4-27 4-28 4-28 4-28 4-31 4-32 4-32 4-32 4-33 4-33 4-34 4-35 4-35 4-35 4-35 4-36 4-37 4-37 4-38 4-38 4-39 4-40 4-40 4-41 4-41 4-41 4-41 4-41 4-42 4-43 4-43 4-44 4-44 4-44 4-44 4-45 4-45 4-45 4-46 4-46 4-46 4-46 4-46 4-47 4-47 4-47
Issue (12-2-98)
Alspa GD4000
Page xi
Alspa GD4000
5. Serial Communications 5.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 Serial Link 0 . . . . . . . . . . . . . . . . . . . . . 5.1.2 Configuration. . . . . . . . . . . . . . . . . . . . . 5.2. Serial Link 1 . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 Features . . . . . . . . . . . . . . . . . . . . . . . 5.2.2 Interface. . . . . . . . . . . . . . . . . . . . . . . . 5.2.3 Configuration . . . . . . . . . . . . . . . . . . . . . 5.2.4 Fault diagnostics . . . . . . . . . . . . . . . . . . . 5.2.5 Connections . . . . . . . . . . . . . . . . . . . . . 5.3. Serial Link 2 . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Features . . . . . . . . . . . . . . . . . . . . . . . 5.3.2 Interface . . . . . . . . . . . . . . . . . . . . . . . 5.3.3 Configuration . . . . . . . . . . . . . . . . . . . . . 5.3.4 Fault diagnostics . . . . . . . . . . . . . . . . . . . 5.3.5 Connection . . . . . . . . . . . . . . . . . . . . . . 5.4. Serial Link 3 (Keypad connector) . . . . . . . . . . . . . 5.4.1 Configuration . . . . . . . . . . . . . . . . . . . . . 5.4.2 Fault diagnostics . . . . . . . . . . . . . . . . . . . 5.4.3 Connection . . . . . . . . . . . . . . . . . . . . . . 5.5. Using ESP J/K table exchange . . . . . . . . . . . . . . . 5.5.1 Receiving data: . . . . . . . . . . . . . . . . . . . . 5.5.2 Transmitting data: . . . . . . . . . . . . . . . . . . . 5.6. Using MODBUS . . . . . . . . . . . . . . . . . . . . . 5.6.1 MODBUS Functions . . . . . . . . . . . . . . . . . . 5.6.2 MODBUS Addressing . . . . . . . . . . . . . . . . . 5.6.3 Statistics . . . . . . . . . . . . . . . . . . . . . . . 5.6.4 ESP Programming messages . . . . . . . . . . . . . . 5.6.5 Connection Details . . . . . . . . . . . . . . . . . . 5.6.6 Switch Settings . . . . . . . . . . . . . . . . . . . . 5.7. Serial Link Fault Finding . . . . . . . . . . . . . . . . . 6. 6.1. 6.2. 6.2.1 6.2.2 6.2.3 6.3. 6.4. 6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.5. 6.5.1 6.5.2 6.5.3 6.5.4 6.5.5 6.5.6 6.5.7 System Design Initial Calculations . . . . . . . . . . . . . . Power Circuits . . . . . . . . . . . . . . . . AC Feed 1 Motor . . . . . . . . . . . . . DC Feed 2 Motors . . . . . . . . . . . . DC Feed 1 Motor . . . . . . . . . . . . . Input Fuse Selection . . . . . . . . . . . . . Incremental Encoders . . . . . . . . . . . . . Mechanical Alignment . . . . . . . . . . . Encoder Screening . . . . . . . . . . . . Calculating Encoder Accuracy . . . . . . . Encoder Line Count . . . . . . . . . . . . Encoder Power Supplies . . . . . . . . . . Motor Parameter Estimation . . . . . . . . . . Motor Inductance Lm . . . . . . . . . . . Motor Resistance Rm . . . . . . . . . . . Stator Resistance Rs and Rotor Resistance Rr Stator Inductance Ls and Rotor Inductance Lr Current Loop Tuning . . . . . . . . . . . Speed/Torque Loop Tuning . . . . . . . . Total System Inertia Estimation . . . . . . .
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. 5-1 . 5-2 . 5-2 . 5-5 . 5-5 . 5-5 . 5-5 . 5-5 . 5-5 . 5-6 . 5-6 . 5-6 . 5-6 . 5-6 . 5-6 . 5-6 . 5-7 . 5-7 . 5-7 . 5-7 . 5-8 . 5-8 . 5-8 . 5-8 . 5-9 . 5-9 5-10 5-10 5-11 5-11
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. 6-1 . 6-2 . 6-2 . 6-2 . 6-3 . 6-4 . 6-5 . 6-5 . 6-5 . 6-5 . 6-7 . 6-8 . 6-9 . 6-9 . 6-9 . 6-9 6-10 6-10 6-11 6-12
Page xii
Alspa GD4000
Issue (12-2-98)
Alspa GD4000
6.5.8 6.5.9 6.6. 6.7. 6.7.1 6.7.2 6.7.3 6.7.4 6.7.5 6.8. 6.8.1 6.9. Calculating the Load Power Factor . . . . . . . . . . . . . Calculating Sigma () . . . . . . . . . . . . . . . . . . . Switched Mode Power Supply Inrush Currents . . . . . . . . . . Specification and Configuration for Various Network Voltages . Introduction . . . . . . . . . . . . . . . . . . . . . . . . Application Specific Configurations . . . . . . . . . . . . . Calculating Network Bridge Parameterisation . . . . . . . . Calculating Total Network Inductance . . . . . . . . . . . . Effective DC Link Capacitance of Common DC Link Systems . Application Considerations . . . . . . . . . . . . . . . . . . GD4000 Stability . . . . . . . . . . . . . . . . . . . . . . Network Bridge Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 6-13 6-14 6-15 6-15 6-16 6-18 6-19 6-19 6-20 6-20 6-20
7. Programming the GD4000 7.1. Introduction . . . . . . . . . . . . . 7.2. Software Structure . . . . . . . . . . 7.3. I/O Synchronisation . . . . . . . . . 7.3.1 Halt/Run/Single Step . . . . . . . 7.3.2 Test Mode . . . . . . . . . . . . 7.4. Access Levels . . . . . . . . . . . . 7.4.1 Keypad Access Levels . . . . . . . 7.4.2 CSP Monitor Access Level . . . . . 7.4.3 CSP Editors Access Level . . . . . 7.5. Firmware Database (System Software) 7.6. Firmware Databases . . . . . . . . . 7.6.1 00S060-4004 Firmware Database 7.6.2 00S060-4005 Firmware Database 7.7. Link Instructions . . . . . . . . . . . 7.7.1 Links Program Header . . . . . . 7.7.2 Editing a Links Program . . . . . 7.8. DEFine Commands . . . . . . . . . 7.8.1 DEF module . . . . . . . . . . . 7.8.2 DEF Table . . . . . . . . . . . . 7.9. Start-up Sequence . . . . . . . . . . 7.9.1 Execution Cycle . . . . . . . . . 7.9.2 Background Loop . . . . . . . . 7.9.3 End of Execution Cycle . . . . . . 7.9.4 HALT/RUN Status . . . . . . . . 7.9.5 TEST/NORMAL Status . . . . . . 7.9.6 SINGLE SCAN Mode . . . . . . . 7.9.7 Commissioning Mode . . . . . . 7.9.8 Execution Cycle Scan Time . . . . 7.10. Generic PID Module Notes . . . . . 7.10.1 Introduction . . . . . . . . . . . 7.10.2 Proportional Control Action . . . . 7.10.3 Integral Control Action . . . . . . 7.10.4 Derivative Control Action . . . . . 7.10.5 Feedback Scaling . . . . . . . . 7.10.6 Output Limiting . . . . . . . . . 7.10.7 Anti Wind Up Code . . . . . . . 7.10.8 Output Clamp . . . . . . . . . . 7.10.9 Test Input . . . . . . . . . . . . 7.10.10 Feedforward Input . . . . . . . . 7.10.11 Feedback Filter Remainder . . . . 7.10.12 Output Limiting . . . . . . . . . 7.10.13 PID Bypassing . . . . . . . . . . Issue (12-2-98)
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7-1 7-1 7-1 7-2 7-2 7-3 7-3 7-3 7-3 7-3 7-4 7-4 7-6 7-7 7-8 7-9 7-10 7-10 7-10 7-12 7-13 7-15 7-15 7-15 7-16 7-17 7-17 7-17 7-17 7-17 7-18 7-18 7-18 7-18 7-18 7-18 7-19 7-19 7-19 7-19 7-19 7-19 Page xiii
Alspa GD4000
Alspa GD4000
7.10.14 7.10.15 7.10.16 7.11. 7.12. 7.13. 7.14. Alternative Derivative Input . . . Error Value Limiting . . . . . . Integral Calculation Alternatives . Fast Task Schematic Diagrams . . . Fast Task 0 . . . . . . . . . . . . Fast Task 1 . . . . . . . . . . . . Fast Task 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 7-19 7-19 7-20 7-21 7-34 7-46
8. Installation 8.1. Receipt of Equipment . . . . . . . . . . . . . . . . . . . . . . . 8.2. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3. Siting Considerations . . . . . . . . . . . . . . . . . . . . . . . 8.3.1 Dimensions and Fixing Centres . . . . . . . . . . . . . . . . 8.3.2 Airflow Requirements . . . . . . . . . . . . . . . . . . . . . 8.4. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.1 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.2 Line Contactor . . . . . . . . . . . . . . . . . . . . . . . . 8.4.3 Precharge Equipment (GD4080, GD4120 and GD4160 only) . 8.5. Power Connections . . . . . . . . . . . . . . . . . . . . . . . . 8.5.1 Supply Voltage Selection (GD4080, GD4120 and GD4160 only) 8.5.2 Power Terminals . . . . . . . . . . . . . . . . . . . . . . . 8.6. Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7. Control Cabling . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.1 Segregation . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.2 Customer I/O Board . . . . . . . . . . . . . . . . . . . . . 8.7.3 RS485 Serial Links . . . . . . . . . . . . . . . . . . . . . . 8.7.4 RS232 Serial Links . . . . . . . . . . . . . . . . . . . . . . 8.7.5 Encoder Connections . . . . . . . . . . . . . . . . . . . . . 8.8. Analog Termination Panel . . . . . . . . . . . . . . . . . . . . 8.8.1 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.2 Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . 8.8.3 Analog I/O Supplies . . . . . . . . . . . . . . . . . . . . . 8.8.4 External Thermistors . . . . . . . . . . . . . . . . . . . . . . 8.9. Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9.1 Notes on Encoder Earthing . . . . . . . . . . . . . . . . . . 8.9.2 Segregation . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9.3 Encoder Power Supply . . . . . . . . . . . . . . . . . . . . . 8.9.4 Cubicle Cable Earthing Notes . . . . . . . . . . . . . . . . . 8.10. Disposal Considerations . . . . . . . . . . . . . . . . . . . . . 9. 9.1. 9.2. 9.3. 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.3.7 9.3.8 9.3.9 9.3.10 9.3.11 9.3.12 Commissioning Introduction . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . Commissioning Procedures . . . . . . . Mechanical checks . . . . . . . . . Electrical Checks . . . . . . . . . . PC Control/Monitoring . . . . . . . User Program Basic Edits . . . . . . Summary of Basic Edits . . . . . . . Connecting the PC to Drive Serial Link Downloading the User Program . . . Monitoring the Drive . . . . . . . . DC Link Voltage . . . . . . . . . . Current Offset Adjustments . . . . . Thermistor checks . . . . . . . . . . Encoder Checks . . . . . . . . . . .
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. 8-1 . 8-1 . 8-1 . 8-2 . 8-8 . 8-8 . 8-8 . 8-9 . 8-9 . 8-9 . 8-9 8-10 8-10 8-12 8-12 8-12 8-13 8-15 8-15 8-21 8-21 8-22 8-23 8-23 8-24 8-24 8-25 8-25 8-25 8-25
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9-1 9-1 9-2 9-2 9-2 9-2 9-3 9-4 9-5 9-6 9-6 9-7 9-7 9-7 9-8
Page xiv
Alspa GD4000
Issue (12-2-98)
Alspa GD4000
9.3.13 Running the Network Bridge . . . . . 9.3.14 Checking the Network Inductances . . 9.3.15 Adjusting the Mains Angle Filter Offset 9.3.16 Running the Machine Bridge . . . . . 9.3.17 Checking Motor Data . . . . . . . . 9.3.18 Turning the Motor . . . . . . . . . . 9.3.19 Oscilloscope Tests . . . . . . . . . . 9.3.20 Checking the Current Loop Response a 9.3.21 Setting the Motor Magnetization Curve 9.3.22 Setting the Speed Loop PID Values . . 9.4. Fast Oscilloscope Outputs . . . . . . . . 9.4.1 Using the Fast Oscilloscope Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zero Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 9-8 9-9 9-9 9-9 9-9 9-10 9-10 9-11 9-12 9-12 9-13
10. Fault Finding and Maintenance 10.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2. Making Equipment Safe . . . . . . . . . . . . . . . . . . . . . . . 10.3. Voltage Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4. Maintenance (GD4000 BDMs Only) . . . . . . . . . . . . . . . . . 10.4.1 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . 10.4.2 Auxilliary Fuse Replacement . . . . . . . . . . . . . . . . . . . . 10.4.3 Switched Mode Power Supply Fuse Replacement . . . . . . . . . . . 10.5. Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5.1 Messages and Indications . . . . . . . . . . . . . . . . . . . . . 10.5.2 SIGMA Core Board LEDs . . . . . . . . . . . . . . . . . . . . . . 10.5.3 Seven Segment Display Indication . . . . . . . . . . . . . . . . . 10.5.4 Power Supply LEDs . . . . . . . . . . . . . . . . . . . . . . . . . 10.5.5 Customer I/O Board LEDs . . . . . . . . . . . . . . . . . . . . . 10.5.6 Power Interface Board (PIB) LEDs . . . . . . . . . . . . . . . . . . 10.5.7 Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5.8 Watchdog Trip Numbers (F1) . . . . . . . . . . . . . . . . . . . . 10.6. Serial Link Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 10.6.1 Downloading A Program For The First Time . . . . . . . . . . . . . 10.6.2 Code Download Successful or Powering Up a Previously Downloaded System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6.3 Basic I/O Highway Trips . . . . . . . . . . . . . . . . . . . . . . 10.6.4 Common Problems on Serial Links . . . . . . . . . . . . . . . . . 10.6.5 Problems with Multidrop Operation (RS485 only, Serial Links 0 and 1 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. Ordering Codes 11.1. Main Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1.1 Alspa GD4000 Drive Units (incorporating the 20X4494/10B SIGMA Core Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1.2 DC Input AC output - 2 motor configuration . . . . . . . . . . . 11.2. Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . 11.2.1 Alspa GD4000 - Line Output Modules . . . . . . . . . . . . . . 11.2.2 Alspa GD4000 - Configurations of Standard DELTA Based Inverters (AC fed, single motor) . . . . . . . . . . . . . . . . . . . . . . 11.2.3 Alspa GD4000 - Configurations High Voltage (690 V) DELTA Based Inverters (AC fed, single motor) . . . . . . . . . . . . . . . . . . 11.2.4 Alspa GD4000 - Configurations of Standard DELTA Based Inverters (DC fed, single motor) . . . . . . . . . . . . . . . . . . . . . . 11.2.5 Alspa GD4000 - Configurations of High Voltage (690 V) DELTA Based Inverters (DC fed, single motor) . . . . . . . . . . . . . . 11.2.6 Alspa GD4000 - DC Fed Inverters - Double Motor Configurations .
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. 10-1 . 10-1 . 10-1 . 10-2 . 10-2 . 10-2 . 10-3 . 10-3 . 10-3 . 10-4 . 10-4 . 10-6 . 10-6 . 10-6 . 10-8 . 10-9 . 10-15 . 10-15
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11-1 11-1 11-1 11-2 11-2 11-4 11-7
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. . . 11-10 . . . 11-13 . . . 11-16
Issue (12-2-98)
Alspa GD4000
Page xv
Alspa GD4000
11.2.7 11.2.8 11.2.9 Alspa GD4000 - Configurations of High Voltage (690 V) DELTA Based Inverters (DC Fed, Double Motor) . . . . . . . . . . . . . . . . Alspa GD4000 - Configurations of Standard DELTA Based Inverters (DC Feeder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alspa GD4000 - Configurations of High Voltage (690 V) DELTA Based Inverters (DC Feeder) . . . . . . . . . . . . . . . . . . . . . 11-19 11-22 11-25
12. Ladder Program Instructions 12.1. Standard Ladder Elements . . . . . . 12.2. Ladder Program Special Functions . . 12.2.1 S0 DBOUNCE . . . . . . . . . . 12.2.2 S3 HISTATE . . . . . . . . . . . 12.2.3 S4 SWAP . . . . . . . . . . . . . 12.2.4 S5 NEGATE . . . . . . . . . . . . 12.2.5 S6 ABS . . . . . . . . . . . . . . 12.2.6 S7 NONZERO . . . . . . . . . . 12.2.7 S8 OUTPUT . . . . . . . . . . . 12.2.8 S11 LINCON . . . . . . . . . . . 12.2.9 S12 SQRT . . . . . . . . . . . . 12.2.10 S20 LOCATE . . . . . . . . . . 12.2.11 S30 FGEN . . . . . . . . . . . . 12.2.12 S31 DEDBAND . . . . . . . . . 12.2.13 S32 LIMIT . . . . . . . . . . . . 12.2.14 S37 ANALAG . . . . . . . . . . . 12.2.15 S42 SWAPE . . . . . . . . . . . 12.2.16 S70 SIN . . . . . . . . . . . . . 12.2.17 S140 GDMMOD . . . . . . . . 12.2.18 T0 COMPARE . . . . . . . . . . 12.2.19 T1 EQ T2 NE T3 GT T4 LT T5 GE T6 LE . . . . . . . . . . . . . . . . . 12.2.20 T7 MAX T8 MIN . . . . . . . . . . . . . 12.2.21 MULT (T10) . . . . . . . . . . . 12.2.22 DIV (T11) . . . . . . . . . . . . . 12.2.23 T17 FILL . . . . . . . . . . . . . 12.2.24 T20 MOVE . . . . . . . . . . . 12.2.25 T33 CONFIG . . . . . . . . . . 12.3. User-Accessible Data Table Addresses 12.3.1 A/B Tables - Digital and Basic I/O . 12.3.2 C/D Tables - Analog I/O . . . . . 12.3.3 E Table . . . . . . . . . . . . . . 12.3.4 F Table - System Fault Table . . . . 12.3.5 G Tables . . . . . . . . . . . . . 12.3.6 I Table . . . . . . . . . . . . . . 12.3.7 J/K Table - Serial Links . . . . . . 12.3.8 P Table . . . . . . . . . . . . . . 12.3.9 V Table . . . . . . . . . . . . . .
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12-1 12-2 12-2 12-5 12-7 12-8 12-9 12-9 12-10 12-11 12-14 12-16 12-18 12-21 12-24 12-27 12-28 12-29 12-30 12-31
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12-33 12-34 12-35 12-36 12-38 12-39 12-41 12-45 12-45 12-46 12-46 12-47 12-48 12-48 12-48 12-48 12-49
13. Software Functions 13.1. Current Control Bridge B, Module 1 (Version 2) . . . . . . . . . . . . . . 13-1 13.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 13.2. Current Control Bridge B, Module 2 (Version 2) . . . . . . . . . . . . . . 13-4 Page xvi Alspa GD4000 Issue (12-2-98)
Alspa GD4000
13.2.1 13.3. 13.3.1 13.4. 13.4.1 13.4.2 13.4.3 13.5. 13.5.1 13.5.2 13.5.3 13.5.4 13.6. 13.6.1 13.7. 13.7.1 13.8. 13.8.1 13.9. 13.9.1 13.9.2 13.9.3 13.10. 13.10.1 13.11. 13.11.1 13.12. 13.12.1 13.13. 13.13.1 13.13.2 13.13.3 13.14. 13.14.1 13.14.2 13.14.3 13.14.4 13.15. 13.15.1 13.16. 13.16.1 13.17. 13.17.1 13.17.2 13.17.3 13.17.4 13.17.5 13.17.6 13.18. 13.19. 13.19.1 Introduction . . . . . . . . . . . . . . . . . . . . . . Polar Conversion Bridge B, Module 3 (Version 2) . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . PWM Generation Bridge B, Module 4 (Version 2) . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . Voltage Calculation . . . . . . . . . . . . . . . . . . Deadtime Calculation . . . . . . . . . . . . . . . . . Current Conversion Bridge B, Module 5 (Version 2) . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . Phase Loss Detector . . . . . . . . . . . . . . . . . . Earth Leakage Fault . . . . . . . . . . . . . . . . . . Filtered Is . . . . . . . . . . . . . . . . . . . . . . . Mains Synchronisation, Module 6 (Version 2) . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . Fast Oscilloscope Outputs, Module 8 (Version 1) . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . Skew Compensation, Module 9 (Version 1) . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . Miscellaneous Hardware Interfaces, Module 10 (Version 3) Introduction . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . Analogue Feedbacks . . . . . . . . . . . . . . . . . . Current Control Bridge A, Module 11 (Version 2) . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . Current Control Bridge A, Module 12 (Version 2) . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . Polar Conversion Bridge A, Module 13 (Version 2) . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . PWM Generation Bridge A, Module 14 (Version 2) . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . Voltage Calculation . . . . . . . . . . . . . . . . . . Deadtime Calculation . . . . . . . . . . . . . . . . . Current Conversion Bridge A, Module 15 (Version 2) . . . Introduction . . . . . . . . . . . . . . . . . . . . . . Phase Loss Detector . . . . . . . . . . . . . . . . . . Earth Leakage Fault . . . . . . . . . . . . . . . . . . Filtered Is . . . . . . . . . . . . . . . . . . . . . . . Position Feedback Encoder A, Module 16 (Version 2) . . . Introduction . . . . . . . . . . . . . . . . . . . . . . PID Regulator, Module 19 (Version 2) . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . Fast History Record, Module 119(V4) . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . Features . . . . . . . . . . . . . . . . . . . . . . . . Method of Operation . . . . . . . . . . . . . . . . . Advanced Features . . . . . . . . . . . . . . . . . . System Logic . . . . . . . . . . . . . . . . . . . . . Application Notes . . . . . . . . . . . . . . . . . . . Fast History Bridge B, Module 159 (Version 4) . . . . . . Position Feedback (Encoder B), Module 216 . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4 13-7 13-7 13-9 13-9 13-9 13-9 13-11 13-11 13-11 13-11 13-11 13-14 13-14 13-16 13-16 13-17 13-17 13-18 13-18 13-18 13-19 13-24 13-24 13-27 13-27 13-30 13-30 13-32 13-32 13-32 13-32 13-34 13-34 13-34 13-34 13-34 13-37 13-37 13-39 13-39 13-43 13-43 13-43 13-43 13-44 13-46 13-49 13-52 13-52 13-52
14. Software Reference (Slow Task Modules) 14.1. Speed Measurement by Encoder, Module 20(V4) . . . . . . . . . . . . . 14.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1.2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Issue (12-2-98) Alspa GD4000
14-1 14-1 14-1 Page xvii
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14.1.3 14.1.4 14.1.5 14.1.6 14.1.7 14.1.8 14.1.9 14.1.10 14.1.11 14.1.12 14.1.13 14.1.14 14.1.15 14.1.16 14.2. 14.2.1 14.2.2 14.2.3 14.3. 14.3.1 14.3.2 14.3.3 14.3.4 14.4. 14.4.1 14.4.2 14.4.3 14.4.4 14.5. 14.5.1 14.5.2 14.5.3 14.5.4 14.6. 14.6.1 14.6.2 14.6.3 14.7. 14.7.1 14.8. 14.8.1 14.8.2 14.8.3 14.9. 14.9.1 14.9.2 14.10. 14.10.1 14.10.2 14.10.3 14.10.4 14.10.5 14.11. 14.11.1 14.12. 14.12.1 Page xviii Biphase Encoders . . . . . . . . . . Average Speed . . . . . . . . . . . Filtered Speed . . . . . . . . . . . Raw Filtered Speed . . . . . . . . . Datum Positions . . . . . . . . . . . Marker detection for Configs 1 and 3 Marker detection for Config 4 . . . . Single Phase Counter . . . . . . . . Preserved Memory . . . . . . . . . Application Notes . . . . . . . . . Module Entry . . . . . . . . . . . . Module Inputs . . . . . . . . . . . Module Outputs . . . . . . . . . . Encoder Connections . . . . . . . . Speed/Voltage Control, Module 21 . . Description . . . . . . . . . . . . . Features . . . . . . . . . . . . . . Application Notes . . . . . . . . . . Reference Circuits, Module 22 . . . . . Description . . . . . . . . . . . . . Features . . . . . . . . . . . . . . Application Notes . . . . . . . . . . Specialised Variables . . . . . . . . Control Available Logic, Module 26 . . Description . . . . . . . . . . . . . Features . . . . . . . . . . . . . . Application Notes . . . . . . . . . . Specialised Variables . . . . . . . . Control On, Module 27 . . . . . . . . Description . . . . . . . . . . . . . Features . . . . . . . . . . . . . . Application Notes . . . . . . . . . . Specialised Variables . . . . . . . . Run Logic, Module 28 . . . . . . . . . Description . . . . . . . . . . . . . Features . . . . . . . . . . . . . . Specialised Variables . . . . . . . . Reference Logic, Module 30 . . . . . . Description . . . . . . . . . . . . . Test/Local Control, Module 31 . . . . . General . . . . . . . . . . . . . . Features . . . . . . . . . . . . . . Interface With Keypad . . . . . . . . Fault Display, Modules 32, 33 And 34 . Overview . . . . . . . . . . . . . . Application Notes . . . . . . . . . . Slow History Record, Module 35V2 . . Overview . . . . . . . . . . . . . . Description of Operation . . . . . . Standard Links . . . . . . . . . . . Memory Structure . . . . . . . . . . Application notes . . . . . . . . . . Cyclic Test, Module 40 . . . . . . . . Description . . . . . . . . . . . . . Staircase Smoothing, Module 44 . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 14-1 14-2 14-2 14-2 14-2 14-3 14-3 14-3 14-3 14-4 14-4 14-5 14-7 14-13 14-13 14-13 14-15 14-21 14-21 14-21 14-22 14-23 14-26 14-26 14-26 14-27 14-28 14-34 14-34 14-34 14-34 14-35 14-38 14-38 14-38 14-38 14-42 14-42 14-44 14-44 14-44 14-44 14-47 14-47 14-47 14-60 14-60 14-60 14-60 14-61 14-62 14-71 14-71 14-73 14-73
Alspa GD4000
Issue (12-2-98)
Alspa GD4000
14.13. 14.13.1 14.13.2 14.13.3 14.14. 14.14.1 14.14.2 14.14.3 14.15. 14.15.1 14.15.2 14.15.3 14.15.4 14.15.5 14.15.6 14.15.7 14.15.8 14.16. 14.16.1 14.17. 14.17.1 14.18. 14.19. 14.19.1 14.19.2 14.19.3 14.19.4 14.19.5 14.19.6 14.19.7 14.20. 14.20.1 14.21. 14.21.1 14.21.2 14.21.3 14.21.4 14.21.5 14.21.6 14.21.7 14.21.8 14.21.9 14.21.10 14.21.11 14.21.12 14.21.13 14.21.14 14.21.15 14.21.16 14.21.17 14.22. 14.22.1 14.22.2 14.22.3 14.22.4 Position Measurement, Module 47 . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . Features . . . . . . . . . . . . . . . . . . . . . . . . . . . Application Notes . . . . . . . . . . . . . . . . . . . . . . Position Control, Module 48 . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . Features . . . . . . . . . . . . . . . . . . . . . . . . . . . Application Notes . . . . . . . . . . . . . . . . . . . . . . HDLC Driver, Module 53 . . . . . . . . . . . . . . . . . . . Features . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . Application Notes . . . . . . . . . . . . . . . . . . . . . . Configuration . . . . . . . . . . . . . . . . . . . . . . . . Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . Initialization . . . . . . . . . . . . . . . . . . . . . . . . . Self Tests . . . . . . . . . . . . . . . . . . . . . . . . . . Linear Conversion, Module 55 . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . PID Regulator, Module 80 (Version 2) . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . Rotor Time Constant Compensator, Module 81 . . . . . . . . Drive Identification, Module 83 (Version 1) . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . DC Link Voltage . . . . . . . . . . . . . . . . . . . . . . . Delta Version . . . . . . . . . . . . . . . . . . . . . . . . Fast Task Type . . . . . . . . . . . . . . . . . . . . . . . . Power Interface Board . . . . . . . . . . . . . . . . . . . . Variable Voltage, Variable Frequency Control Bridge A, Module 84 (Version 1) . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . Control and Reference Support, Module 85 (V1) . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . Features . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Stop Start Control . . . . . . . . . . . . . . . . . . . Extended Stop Start Functions . . . . . . . . . . . . . . . . Application Notes . . . . . . . . . . . . . . . . . . . . . . Enhanced Stop/Start Control . . . . . . . . . . . . . . . . . Miscellaneous Stop/Start Functions . . . . . . . . . . . . . . Resetting the Drive . . . . . . . . . . . . . . . . . . . . . . Speed and Torque Reference Control . . . . . . . . . . . . . Raise Lower Control (Increment Decrement logic) . . . . . . Analog Inputs (Principle Reference and Trim Reference) . . . Cyclic Test - Quasi-Square Wave Generator . . . . . . . . . Preset References . . . . . . . . . . . . . . . . . . . . . . Jog Control . . . . . . . . . . . . . . . . . . . . . . . . Analog Output Switching . . . . . . . . . . . . . . . . . . Input Switches . . . . . . . . . . . . . . . . . . . . . . . Output Switches . . . . . . . . . . . . . . . . . . . . . . General Purpose Functions, Module 86 . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . Sub-Module Generic Description . . . . . . . . . . . . . . . Setting the Configuration Mode for a Sub-module . . . . . . Declaring Inputs and Outputs Using the DEF TABLE Statement Alspa GD4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-75 . 14-75 . 14-75 . 14-76 . 14-79 . 14-79 . 14-79 . 14-80 . 14-88 . 14-88 . 14-88 . 14-88 . 14-89 . 14-90 . 14-92 . 14-92 . 14-93 14-100 14-100 14-102 14-102 14-104 14-105 14-105 14-105 14-105 14-106 14-106 14-106 14-107 14-109 14-109 14-117 14-117 14-117 14-117 14-118 14-120 14-123 14-125 14-125 14-126 14-127 14-129 14-129 14-130 14-130 14-134 14-134 14-134 14-141 14-141 14-142 14-142 14-143 Page xix
Issue (12-2-98)
Alspa GD4000
14.22.5 Programming Errors . . . . . . . . . . . . . . . . . . . . . . . . 14.22.6 Sub-Module Functions . . . . . . . . . . . . . . . . . . . . . . . 14.22.7 Binary Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22.8 Mode 401, NEGATE_1 . . . . . . . . . . . . . . . . . . . . . . . 14.22.9 Mode 501, MODULUS (Sign Changing) . . . . . . . . . . . . . . . 14.22.10 Mode 601, Positive Threshold Detection . . . . . . . . . . . . . . 14.22.11 Mode 701, Dual Level Threshold Detection . . . . . . . . . . . . 14.22.12 Mode 702, Threshold Detect 2 . . . . . . . . . . . . . . . . . . 14.22.13 Mode 703, Threshold Detect 3 . . . . . . . . . . . . . . . . . . 14.22.14 Mode 801, D-type Latch with Set and Reset . . . . . . . . . . . . 14.22.15 Mode 802, D-type Latch with Set and Reset . . . . . . . . . . . . 14.22.16 Mode 901, Pulse Delays 1 . . . . . . . . . . . . . . . . . . . . . 14.22.17 Mode 902, Pulse Delays 2 . . . . . . . . . . . . . . . . . . . . . 14.22.18 Mode 903, Pulse Delays 3 . . . . . . . . . . . . . . . . . . . . . 14.22.19 Mode 904, Pulse Delays 4 . . . . . . . . . . . . . . . . . . . . . 14.22.20 Mode 1001, Maths 1 - Scaling . . . . . . . . . . . . . . . . . . 14.22.21 Mode 1002, Maths 2 - Scaling . . . . . . . . . . . . . . . . . . 14.22.22 Mode 1015, Maths 15 - Scaling and Offset . . . . . . . . . . . . 14.22.23 Mode 1101, Low Pass Filter and Invertor . . . . . . . . . . . . . . 14.22.24 Mode 1201, XY Shaper . . . . . . . . . . . . . . . . . . . . . . 14.22.25 Setting up the XY Shaper . . . . . . . . . . . . . . . . . . . . . 14.22.26 Error Handling . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22.27 Mode 1301, Summation with upper and lower limits . . . . . . . . 14.22.28 Mode 1401, Bit Manipulation 1 . . . . . . . . . . . . . . . . . . 14.22.29 Mode 1501, Edge Counter . . . . . . . . . . . . . . . . . . . . 14.22.30 Mode 1601, Edge Detection . . . . . . . . . . . . . . . . . . . . 14.22.31 Mode 1701, Redefinable Links . . . . . . . . . . . . . . . . . . 14.22.32 Mode 1801, Configure Serial Link . . . . . . . . . . . . . . . . . 14.22.33 Mode 1901, Compare 1 . . . . . . . . . . . . . . . . . . . . . 14.22.34 Mode 1902, Compare 2 . . . . . . . . . . . . . . . . . . . . . 14.22.35 Mode 1903, Compare 3 . . . . . . . . . . . . . . . . . . . . . 14.22.36 Mode 2001, Analog Switches 1 . . . . . . . . . . . . . . . . . . 14.22.37 Mode 2002, Analog Switch 1 . . . . . . . . . . . . . . . . . . . 14.22.38 Mode 2101, Preset Ramp . . . . . . . . . . . . . . . . . . . . . 14.22.39 Mode 2201, Pass Highest/Lowest Input . . . . . . . . . . . . . . 14.22.40 Mode 2202, Pass Highest/Lowest Input . . . . . . . . . . . . . . 14.22.41 Mode 2301, Sample and Hold . . . . . . . . . . . . . . . . . . 14.22.42 Mode 2401, Serial EEPROM Access . . . . . . . . . . . . . . . . 14.22.43 Mode 10001, Stall Detection . . . . . . . . . . . . . . . . . . . 14.22.44 Mode 10101, I2T Overload Detection . . . . . . . . . . . . . . . 14.22.45 Hardware Interfaces . . . . . . . . . . . . . . . . . . . . . . . . 14.23. Analog Switching, Module 87 (V2) . . . . . . . . . . . . . . . . . . 14.23.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.23.2 Analog Switch Specification . . . . . . . . . . . . . . . . . . . . . 14.23.3 Controlling the Input Switches . . . . . . . . . . . . . . . . . . . . 14.23.4 Controlling the Output Switches . . . . . . . . . . . . . . . . . . . 14.23.5 Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . 14.23.6 Using DEF TABLE to Declare the Analog Switches Inputs and Outputs 14.23.7 Using DEF TABLE to Declare the Analog Switch Control Words . . . . 14.23.8 Setting a Combination of Multi-throw switches . . . . . . . . . . . . 14.24. Serial Link Set up Support, Module 89 (V1) . . . . . . . . . . . . . . 14.24.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.24.2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.24.3 Serial Link Configuration . . . . . . . . . . . . . . . . . . . . . . 14.24.4 Serial Link Time-out . . . . . . . . . . . . . . . . . . . . . . . . 14.24.5 Action on Loss of Serial Link . . . . . . . . . . . . . . . . . . . . Page xx Alspa GD4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-144 14-145 14-145 14-145 14-146 14-146 14-147 14-148 14-149 14-150 14-150 14-151 14-152 14-152 14-152 14-153 14-153 14-154 14-155 14-156 14-156 14-157 14-157 14-158 14-159 14-159 14-160 14-161 14-161 14-162 14-162 14-163 14-163 14-164 14-164 14-165 14-165 14-166 14-167 14-167 14-168 14-175 14-175 14-175 14-175 14-176 14-177 14-177 14-178 14-178 14-184 14-184 14-184 14-184 14-186 14-186
Issue (12-2-98)
Alspa GD4000
14.24.6 14.24.7 14.24.8 14.24.9 14.24.10 14.24.11 14.25. 14.25.1 14.25.2 14.25.3 14.25.4 14.26. 14.26.1 14.26.2 14.27. 14.27.1 14.28. 14.29. 14.29.1 14.29.2 14.29.3 14.29.4 14.29.5 14.29.6 14.29.7 14.29.8 14.29.9 14.29.10 14.29.11 14.29.12 14.29.13 14.30. 14.30.1 14.30.2 14.30.3 14.30.4 14.30.5 14.30.6 14.31. 14.32. 14.32.1 14.32.2 14.32.3 14.32.4 14.32.5 14.32.6 14.32.7 14.32.8 14.32.9 14.33. 14.34. 14.35. 14.36. 14.37. 14.37.1 Control Source Switching . . . . . . . . . . . . . . . . . . . . . Alternative Control Source . . . . . . . . . . . . . . . . . . . . . Selecting the Control Source and Mode . . . . . . . . . . . . . . Reference Source Switching . . . . . . . . . . . . . . . . . . . . Selecting the Reference Source and Mode . . . . . . . . . . . . . Application Notes . . . . . . . . . . . . . . . . . . . . . . . . Temperature Feedback, Module 90 (Version 3) . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Interface Board Compatibility . . . . . . . . . . . . . . . . Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIB Fault Monitor And Reset, Module 91 (Version 4) . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PID Regulator, Module 92 (Version 2) . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Available Bridge A, Module 93 (Version 1) . . . . . . . . . . Flux and Torque IT Tables, Module 94 (Version 2) . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slip Gain Ks . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quadrature Current . . . . . . . . . . . . . . . . . . . . . . . . Auto-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use of Duplicate Module . . . . . . . . . . . . . . . . . . . . . . Deflux Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . Headroom Utilisation Factor L9432 . . . . . . . . . . . . . . . . Rotor Time Constant . . . . . . . . . . . . . . . . . . . . . . . . Encoder Pulses Per Rev . . . . . . . . . . . . . . . . . . . . . . . Encoder Scaling Factor . . . . . . . . . . . . . . . . . . . . . . Encoder Scaling Constant . . . . . . . . . . . . . . . . . . . . Overload Protection . . . . . . . . . . . . . . . . . . . . . . . Torque in Max/Min Limits . . . . . . . . . . . . . . . . . . . . . Slip Frequency Calculation, Module 95 (Version 2) . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . Characteristics of AC Machines . . . . . . . . . . . . . . . . . . Maximum Magnetising Current . . . . . . . . . . . . . . . . . . Setting the Limits . . . . . . . . . . . . . . . . . . . . . . . . . . Calculation of Look Up Tables . . . . . . . . . . . . . . . . . . . Derivation of Parameters . . . . . . . . . . . . . . . . . . . . . . Control Available Bridge B, Module 98 (Version 1) . . . . . . . . . . DC Link Control, Module 99 (Version 1) . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . Module Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . Pre-charge Relay and Line Contactor Control . . . . . . . . . . . . Nominal DC Link Volts Level, Under-volts Level, Over-volts Level and Pre-charge Level. . . . . . . . . . . . . . . . . . . . . . . . . . Input Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . Common DC link schemes . . . . . . . . . . . . . . . . . . . . . Filter Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trip outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameter Auto Calculation . . . . . . . . . . . . . . . . . . . . Fast History Record, Module 119 (Version 4) . . . . . . . . . . . . . Fast History Bridge B, Module 159 (Version 1) . . . . . . . . . . . . Program Blocks, Module 186 . . . . . . . . . . . . . . . . . . . . Changeover Switch, Module 187 . . . . . . . . . . . . . . . . . . DC Link Voltage Control, Module 197 (Version 2) . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alspa GD4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-187 14-187 14-187 14-188 14-188 14-190 14-196 14-196 14-196 14-197 14-198 14-201 14-201 14-201 14-205 14-205 14-207 14-209 14-209 14-209 14-210 14-210 14-210 14-211 14-211 14-211 14-211 14-211 14-211 14-212 14-212 14-215 14-215 14-215 14-216 14-216 14-218 14-218 14-226 14-228 14-228 14-228 14-228 14-228 14-229 14-229 14-229 14-229 14-230 14-238 14-238 14-238 14-238 14-239 14-239 Page xxi
Issue (12-2-98)
Alspa GD4000
14.38. 14.39. 14.40. 14.41. 14.42. 14.43. 14.44. 14.45. 14.46. 14.47. 14.48. 14.49. 14.50. 14.51. 14.52. 14.53. 14.54. 14.55. 14.56. 14.57. 14.58. 14.59. 14.60. 14.61. 14.62. A. A.1. A.2. A.2.1 A.2.2 A.2.3 A.2.4 A.2.5 A.3. A.4. A.5. A.5.1 A.5.2 A.6. A.6.1 A.6.2 A.6.3 A.7. A.8. A.9. A.9.1 A.9.2 A.9.3 A.10. A.11. A.11.1 A.11.2 Position Feedback B, Module 216 . . . . . . . . . . . . . Speed Voltage Control, Module 221 (Version 5) . . . . . . Reference Circuits, Module 222 (Version 3) . . . . . . . . . Control Available Logic, Module 226 (Version 5) . . . . . . Control On Logic, Module 227 (Version 4) . . . . . . . . . Run Logic, Module 228 (Version 1) . . . . . . . . . . . . . Reference Logic, Module 230 (Version 1) . . . . . . . . . . Test Local Control, Module 231 (Version 2) . . . . . . . . . Fault Display, Module 232, 233 and 234 (Version 1) . . . . Cyclic Test, Module 240 (Version 1) . . . . . . . . . . . . Staircase Smoothing, Module 244 (Version 1) . . . . . . . . Position Measurement, Module 247 (Version 1) . . . . . . . Position Control, Module 248 (Version 1) . . . . . . . . . . Linear Conversion, Module 255 (Version 1) . . . . . . . . . Speed Control, Module 280 (Version 2) . . . . . . . . . . Rotor Time Constant Compensation, Module 281 (Version 1) Open Loop B, Module 284 . . . . . . . . . . . . . . . . . Stop/Start Logic, Module 285 . . . . . . . . . . . . . . . Program Blocks, Module 286 . . . . . . . . . . . . . . . Changeover Switch, Module 287 . . . . . . . . . . . . . . Speed Control, Module 292 (Version 2) . . . . . . . . . . Flux and Torque Look-up tables, Module 294 . . . . . . . . Slip Calculation, Module 295 . . . . . . . . . . . . . . . General Purpose Functions, Module 300 (Version 1) . . . . General Purpose Functions, Module 320 (Version 1) . . . . Keypad Introduction . . . . . . . . . . . . . . . . . . Specification . . . . . . . . . . . . . . . . . . Display . . . . . . . . . . . . . . . . . . . Keypad . . . . . . . . . . . . . . . . . . . LED Indicators . . . . . . . . . . . . . . . Power Consumption . . . . . . . . . . . . . Dimensions . . . . . . . . . . . . . . . . . Environmental Conditions . . . . . . . . . . . Extension Cable (option) . . . . . . . . . . . . Monitoring and Editing Drive Parameters . . . . Monitoring Variables . . . . . . . . . . . . Changing Variables . . . . . . . . . . . . . Control Keys . . . . . . . . . . . . . . . . . . Alphanumeric Keys . . . . . . . . . . . . . Digital Inputs/Outputs . . . . . . . . . . . . Digital Outputs (LED Indicators) . . . . . . . Keypad Configuration . . . . . . . . . . . . . Serial Link Failure (or keypad disconnection) . . Display Format . . . . . . . . . . . . . . . . . Editing Mode . . . . . . . . . . . . . . . . Monitoring Mode . . . . . . . . . . . . . . Functions of the Keypad . . . . . . . . . . . Keypad Error Messages . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . Fitting the Enhanced Keypad to the Drive Unit Fitting the Keypad in a Remote Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-242 14-242 14-242 14-242 14-242 14-242 14-242 14-242 14-242 14-242 14-242 14-242 14-242 14-242 14-243 14-243 14-243 14-243 14-243 14-243 14-243 14-243 14-243 14-244 14-247
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. A-1 . A-2 . A-2 . A-2 . A-2 . A-2 . A-2 . A-2 . A-2 . A-3 . A-3 . A-3 . A-3 . A-3 . A-4 . A-5 . A-5 . A-6 . A-6 . A-6 . A-6 . A-6 A-11 A-11 A-11 A-11
Page xxii
Alspa GD4000
Issue (12-2-98)
Alspa GD4000
A.11.3 A.11.4 A.11.5 B. Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12 A-12 A-13
Battery Support Unit (GDS1001-4001) B.1. General . . . . . . . . . B.2. Battery Protection . . . . B.3. Battery Sizing . . . . . . B.4. Installation . . . . . . . B.4.1 Location . . . . . . . B.4.2 Electrical Connections C. C1. C1.1. C1.2. C1.2.1 C2. C2.1. C2.1.1 C2.1.2 C2.1.3 C2.2. C2.2.1 C2.3. C2.4. C3. C3.1. C3.2. C3.2.1 C3.2.2 C3.2.3 C3.2.4 C3.2.5 C3.2.6 C3.2.7 C3.2.8 C3.2.9 C3.3. C3.3.1 C3.3.2 C3.4. C3.4.1 C3.5. C3.5.1 C3.5.2 C3.6. C3.6.1
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B-1 B-1 B-1 B-2 B-2 B-3
ALSPA GD4000 Modular Drives General Information Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . C-5 Technical Description Introduction . . . . . . . . . . . . . . . . . . . . . . SIGMA Control Gate Assembly . . . . . . . . . . . Customer I/O Assembly (GDS1004-4002) . . . . . . SMPS Assembly (GDS1010-4003) . . . . . . . . . . Delta Transistor Modules . . . . . . . . . . . . . . . DELTA modules available . . . . . . . . . . . . . . Line Contactors . . . . . . . . . . . . . . . . . . . . Precharge Control Panel (31V1900/20 to 31V1900/50)
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. . C-7 . C-10 . C-12 . C-13 . C-13 . C-14 . C-14 . C-14
Installation Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . Receipt of Equipment on Site . . . . . . . . . . . . . . . . . Identification of Components . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environment . . . . . . . . . . . . . . . . . . . . . . . . . Heat Loss from Unit . . . . . . . . . . . . . . . . . . . . . . Acoustic Noise at the Motor . . . . . . . . . . . . . . . . . . Radio Frequency Emissions . . . . . . . . . . . . . . . . . . Susceptibility to Radio Frequency Interference . . . . . . . . . Cooling and Ventilation . . . . . . . . . . . . . . . . . . . . GD4000 SIGMA Control Gate Assembly - Mechanical Installation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Procedure . . . . . . . . . . . . . . . . . . . . . Switched Mode Power Supply (SMPS) . . . . . . . . . . . . . . Installation Procedure . . . . . . . . . . . . . . . . . . . . . Customer I/O Assembly . . . . . . . . . . . . . . . . . . . . Location . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting the Customer I/O Assembly on the SMPS Unit . . . . Electrical connections . . . . . . . . . . . . . . . . . . . . . . AC Input Power Cables and Motor Cables . . . . . . . . . . .
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C-15 C-15 C-15 C-15 C-15 C-16 C-16 C-16 C-16 C-16 C-16 C-16 C-17 C-18 C-19 C-20 C-20 C-20 C-21 C-21 C-21
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Alspa GD4000
Page xxiii
Alspa GD4000
C3.6.2 C3.6.3 C3.6.4 C3.6.5 C4. C4.1. C5. C5.1. C5.1.1 C5.1.2 C5.2. C5.2.1 C5.2.2 C5.3. C5.4. DC Link . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Connections . . . . . . . . . . . . . . . . . . . . . Customer I/O Board Wiring . . . . . . . . . . . . . . . . . Connecting Thermistor Feedback(s) from DELTA rectifier units(s) . . . . . . . . . . . . . . . . C-21 C-21 C-22 C-22
Commissioning Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-25 System Design Intoduction . . . . . . . . . . . . . . . . . . . . . . . . System examples . . . . . . . . . . . . . . . . . . . . Configuring the SIGMA firmware . . . . . . . . . . . . . Wiring Arrangements for High Voltage DELTA Configurations AC Fed GD4000 Configurations . . . . . . . . . . . . . DC Fed Configurations . . . . . . . . . . . . . . . . . Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . Mechanical Drawings . . . . . . . . . . . . . . . . . . .
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C-27 C-27 C-27 C-27 C-30 C-34 C-35 C-35
D. Terminating Ribbon Cables D.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.1.1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.1.2 Terminating a Ribbon Cable . . . . . . . . . . . . . . . . . . . . . . . E. E.1. E.2. E.3. F. F.1. F.1.1 F.1.2 F.1.3 F.1.4 F.1.5 F.2. F.2.1 F.2.2 F.2.3 F.2.4 F.3. F.3.1 F.3.2 F.3.3 F.3.4 F.3.5 F.3.6 F.3.7 F.4. F.4.1
D-1 D-1 D-1
Firmware Compatibility Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Enhancements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Faults Cured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Electromagnetic Compatibility Introduction . . . . . . . . . . . . . . . . . . . . . . . . . European EMC Directive . . . . . . . . . . . . . . . . . EMC Standard . . . . . . . . . . . . . . . . . . . . . . Industrial Environment . . . . . . . . . . . . . . . . . . . Public Low Voltage Network . . . . . . . . . . . . . . . . Technical Notes . . . . . . . . . . . . . . . . . . . . . . Compliance with EMC Requirements . . . . . . . . . . . . . Immunity . . . . . . . . . . . . . . . . . . . . . . . . . Radio-Frequency Emissions . . . . . . . . . . . . . . . . Harmonic Emissions . . . . . . . . . . . . . . . . . . . . Sinusoidal Rectifier PWM Disturbances . . . . . . . . . . . Installation Instructions for Compliance with EMC Requirements Additional Safety Requirements for Filters . . . . . . . . . Cubicle Layout . . . . . . . . . . . . . . . . . . . . . . Cabling and Segregation . . . . . . . . . . . . . . . . . Contactor Suppression . . . . . . . . . . . . . . . . . . Motor Cable . . . . . . . . . . . . . . . . . . . . . . . Control Connections . . . . . . . . . . . . . . . . . . . Drive Not in a Fully Enclosed Cubicle . . . . . . . . . . . EMC Filters . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions of Filters . . . . . . . . . . . . . . . . . . .
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. F-1 . F-1 . F-1 . F-1 . F-2 . F-2 . F-2 . F-2 . F-4 . F-6 . F-6 . F-6 . F-7 . F-8 . F-9 F-10 F-10 F-12 F-13 F-13 F-15
G. The Minimum User Program G.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.1.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page xxiv Alspa GD4000
G-1 G-1
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Alspa GD4000
G.2. G.2.1 G.2.2 G.3. G.3.1 G.3.2 G.3.3 H. H.1. H.2. H.3. H.4. I. I.1. I.1.1 I.1.2 I.1.3 I.2. I.2.1 I.2.2 I.2.3 I.2.4 I.2.5 I.2.6 I.3. I.3.1 I.3.2 I.3.3 I.3.4 I.3.5 I.3.6 Configuring the Minimum Program . . . . . Link Changes Required for VVVF Control . Link Changes Required for Vector Control . Example Links Editing Session . . . . . . . . Compiling The New Program . . . . . . . Downloading Modified File . . . . . . . . Control And Referencing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 G-2 G-3 G-4 G-6 G-6 G-7
Recommended Tightening Torques for DELTA Drives Scope . . . . . . . . . . . . . . . . . . . . . . . . . Tightening Torques for Busbar to Busbar Joints . . . . . Tightening Torques for Electrical Connections . . . . . Tightening Torques for Mechanical Connections . . . . GD4000E User Guide Introduction . . . . . . . . . . System Requirements . . . . Installation: . . . . . . . . Starting GD4000E . . . . . The Menu Commands . . . . . The File Menu . . . . . . . The Upload Menu . . . . . The View Menu . . . . . . . The Zoom Menu . . . . . . The Config Menu . . . . . The Window Menu . . . . . Application Notes . . . . . . . Speed Buttons . . . . . . . Displaying Graphs . . . . . Displaying Tables . . . . . Displaying the Message Log Displaying Parameter Edits . History . . . . . . . . . . .
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H-1 H-1 H-1 H-2
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I-1 I-1 I-1 I-1 I-1 I-1 I-2 I-2 I-2 I-2 I-3 I-3 I-3 I-3 I-4 I-4 I-4 I-4
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Page xxvi
Alspa GD4000
Issue (12-2-98)
1. Introduction to GD4000
Introduction to GD4000
1.1 General Description
Alspa GD4000 is a range of 4-quadrant drives, for speed and torque control of standard three phase squirrel cage induction motors using closed loop vector control. GD4000 can also be used as a variable voltage, variable frequency (VVVF) open loop drive. GD4000 drives feature sinusoidal input rectifiers achieving unity power factor and low harmonic control of the input current waveform. Standard drives operate on three phase a.c. supplies of 380 V to 480 V, 50 to 60 Hz. High Voltage DELTA modular drives can operate on three phase a.c. supplies up to 690 V 50 to 60 Hz. Alspa GD4000 achieves a high dynamic control performance of induction motors using the latest vector control techniques. Each drive carries full digital communication, I/O and diagnostic facilities, allowing its integration into the most demanding of systems. The drive is Figure 1-1 GD4010 to GD4060 supplied with user-programmable application software in a modular format,which can be quickly tailored to suit individual applications using a PC compatible suite of programming tools. Application software modules cover such features as speed and position measurement and control, reference ramps, control logic, diagnostic functions and history recording. GD4000 utilises the Alspa SIGMA controller; a standardised control system which is used in a wide range of programmable a.c. and d.c. drives manufactured by CEGELEC. Programming is performed by means of a ladder editor, links editor and compiler running on an IBM compatible PC. Once complete, the compiled program is downloaded to the drive via a serial communications port. A monitor program is provided to allow the drive parameters to be viewed and temporary edits to be made while the drive is running. 1.1.1 Flux Vector Control An electric motor generates it maximum torque when the magnetic field created by the field winding (stator) is perpendicular to the magnetic field due to the armature (rotor). This is true for both AC and DC motors. The DC motor maintains this optimum orientation of the magnetic field throughout the speed by virtue of the commutator, and is therefore capable of delivering optimum torque throughout the speed range. Issue (12-2-98) Alspa GD4000 Page 1-1
The orientation of the stator and armature fields of an AC motor is a function of the motor current, the slip angle (and therefore the rotor speed) and the characteristics of the motor itself. GD4000 vector control uses the feedback from an encoder and a model of the characteristics of the motor to calculate the output waveform which will maintain optimum field orientation under all conditions of speed and load. With vector control the motor can deliver its highest torque throughout the operating range, allowing an AC motor to be used in applications where previously only a DC motor would have been considered. The encoder (not supplied) should be considered an integral part of the vector control drive system. Full information for selecting a suitable encoder unit is given in Section 2.7, and suitable units can be obtained through CEGELEC or an approved agent. 1.1.2 Variable Voltage Variable Frequency Control (VVVF) VVVF control is provided for use in applications where the complexity of closed loop vector control can not be justified while retaining the benefits of unity power factor sinusoidal rectifier of Figure 1-2 GD4080 to GD4160 GD4000 for regeneration back the supply network. The GD4000 VVVF implementation includes such features as, forward and reverse acceleration control, torque limit of both motoring and regeneration, fixed and auto-voltage boost, slip compensation, fan fluxing and synchronous restart.
1.2
Nomenclature
The various models in the range are identified by their continuous current rating which is shown in the model name, e.g. a GD4060 is a 60 amp drive and a GD4282 is a 282 amp drive. This manual describes the following standard Alspa GD4000 drives which fall into three general mechanical arrangements: Small common Basic Drive Module (BDM) frame size: GD4010 GD4020 GD4030 GD4040 GD4060
Large common BDM frame size: GD4080 GD4120 GD4160
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Alspa GD4000
Issue (12-2-98)
Kitted, modular form, for installation into appropriate control cubicles (standard DELTA drives): GD4282 GD41131 GD4377 GD41128 GD4564 GD41508 GD4754 GD41692 GD4846 GD42262
Kitted, modular form, for installation into appropriate control cubicles (High Voltage DELTA drives): GD4300 GD4600 GD4900
The standard and high voltage DELTA drives can also be supplied in ready built form, for details contact CEGELEC Industrial Controls, Packaged drives department.
Figure 1-3 Typical large DELTA drive (GD4846 shown)
Issue (12-2-98)
Alspa GD4000
Page 1-3
1.2.1 Software Supplied GD4000 is supplied with the following software:
CEGELEC SIGMA Programmer (CSP) software. The GD4000 Firmware Database. A basic ladder and links program for GD4000 in a.c. in/a.c. out configuration.
These are provided on IBM PC compatible floppy disks. 1.2.2 Alternative Drive Topologies The input and ouput power bridges of GD4000 are identical in each model, the function of the bridges being determined by the application software and the power and control circuit wiring. This allows GD4000 to be used for a range of alternative applications as follows: DC feeder (a.c in to two bridges). DC fed 1 motor drive (two bridges driving one motor). DC fed 2 motor drive (two motors controlled independently by one drive) Power generation (Variable frequency a.c. in constant frequency a.c. out) Standard software is supplied to support these applications.
1.3
Features
Controlled Sinusoidal Input Rectifier.
Unity power factor, with low harmonics and control of the input current waveform. Bi-directional power flow allowing line regenerative operation for decelerating and
overhauling loads.
Control of d.c. link voltage allowing full motor output for all rated supply input
conditions. Full Microprocessor Control

Comprehensive and flexible set of control functions adaptable to a wide range of
industrial applications.
High performance, low drift, digital control of the entire range of drive functions. Comprehensive commissioning and test facilities. History recording for fault diagnostics and process trending. Performance of squirrel cage motor comparable to a d.c. motor.
High Speed Serial Communications

One RS232C serial port for communication with a PC. Two additional ports configurable to either RS485 or RS232 (fully isolated). One enhanced keypad connection port (RS232C). ESP data table exchange, MODBUS RTU and MODBUS ASCII protocols.
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Alspa GD4000
Issue (12-2-98)
Enhancement Options
Keypad for local control and minor program editing functions and fault diagnosis. HDLC Serial communications port enhancement card. FIP Network Enhancement board.
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Alspa GD4000
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Page 1-6
Alspa GD4000
Issue (12-2-98)
2. Specification
Specification
2.1 Power Ratings
The Alspa GD4000 output ratings for standard drives detailed in Tables 2-1, 2-2, 2-3 and 2-3. The d.c. link is maintained at a constant value to provide sufficient headroom for the vector sum of maximum supply voltage and the voltage drop across the input a.c. line reactors in the overload or maximum current condition. As standard, a 10% supply tolerance is allowed for in the rating calculations. The maximum working d.c. link voltage is limited to 750 V for Basic Drive Modules GD4080 to GD4160, to allow sufficient margin for the dynamics of the d.c. link voltage controller. The maximum input power that can be controlled is limited to the overload rating of the input rectifier transistors. The maximum motor shaft power that can be controlled is limited to the lesser of: a) the maximum input power multiplied by the overall inverter and motor efficiencies, or, b) the maximum output inverter kVA at a given motor power factor. The break point between input rectifier limited power throughput and output inverter limited kVA is determined when: Motor Cos = Network bridge Efficiency x Output Bridge Efficiency x Low Supply Typically, input and output bridge efficiencies are 0.98 and a low supply is 0.9 nominal. The overall drive limit will then be output inverter kVA limited for motor power factor (Cos) 0.864. For small motors, the motor power factor tends to be a low value (0.75 - 0.85), defining the limit therefore on the basis of output inverter kVA. The overall limit is therefore defined by the output inverter kVA. This information is reflected in Table 2-1which give the continuous nominal shaft output power ratings for the Alspa GD4000 range from GD4010 to GD4160. In all cases the maximum continuous shaft output power ratings are limited by the output inverter bridge kVA rating. For operation under conditions other than those assumed in Table 2-1 the following calculation method should be used. The maximum continuous shaft kW that can be delivered to the load is defined by the lesser of the following two equations: Shaft kW = Va.c.in x Low Supply x 3 x Ia.c.in x IB x OB x Motor Shaft kW = Va.c.out x 3 x Ia.c.out x Cos x Motor where: Va.c.in Va.c.out = Nominal Supply Voltage (rms) = Nominal Motor Output Voltage (rms) (normally equal to the nominal supply voltage) Low Supply = 0.9 or less dependent upon prevailing site conditions Ia.c.in = Continuous network bridge current rating (rms) Alspa GD4000 Page 2-1
Issue (12-2-98)
2. Specification
Ia.c.out = Continuous output bridge current rating (rms) IB = Network bridge Efficiency (Typically 0.98) OB = Output Bridge Efficiency (Typically 0.98) Motor = Motor Efficiency (Typically 0.8 - 0.9 dependent upon machine) Cos = Motor Power Factor The motor and cos values in Table 2-1 are given to highlight the assumptions made in calculating an effective shaft power rating.
Table 2-1 Power Ratings GD4010 to GD4160
BDM Motor Continuous 1.5x O/L Frame size Rating at 380/415 V 40o C kW amps GD4010 GD4020 GD4030 GD4040 GD4060 GD4080 GD4120 GD4160 4 7.5 11/15 18.5 22/23 37 55 75/90 10 20 30 40 60 80 120 160
Motor Motor Power Efficiency factor Cos (Assumed) (Assumed) 0.81 0.81 0.81 0.81 0.81 0.82 0.84 0.85 82% 88% 88% 89% 91% 88% 90% 92%
Shaft Power 380 V 50 Hz kW 4.4 9.4 14.1 19 29.1 38 60 82
Shaft Power 415 V 50 Hz kW 4.8 10.2 15.4 20.7 31.8 41 65 90
Shaft Power 460 V 60 Hz kW 5.3 11.4 17 23 35.2 46 72 100
Shaft Power 480 V 60 Hz kW 5.5 11.9 17.8 24 36.8 48 75 104
Notes:
For information on de-rating the drives for use at higher ambient temperatures see section 2.11. * The limits and parameterisation of the network bridge control is given for various nominal supply voltage and frequency conditions in Section 6.9.
Notes:
For information on de-rating the drives for use at higher ambient temperatures see section 2.11. ** For GD4080 drives incorporating input a.c. line reactors 33Z0309/10 the overload current is limited to 80 amps rms (ie no overload). Operation above this current level can lead to tripping of the network bridge transistors on instantaneous over-current. ** For GD4120 drives incorporating input a.c. line reactors 33Z0310/10 the overload current is limited to 120 amps rms (ie no overload). Operation above this current level can lead to tripping of the network bridge transistors on instantaneous over-current. * For GD4160 drives incorporating input a.c. line reactors 33Z0311/10 the overload current is limited to 160 amps rms (ie no overload). Operation above this current level can lead to tripping of the network bridge transistors on instantaneous over-current. * The limits and parameterisation of the network bridge control is given for various nominal supply voltage and frequency conditions in Section 6.9.
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Alspa GD4000
Issue (12-2-98)
2. Specification
For other operating conditions follow the calculation routine detailed in Section 6.7.1.
Table 2-2 Power Ratings GD4282 to GD41131
Drive
Continuous Rating at 40oC (amps)
Drive Rating (kW
IEC Motor Frame Size (kW)
Drive Rating (kW)
Standard Fan 1.5 x Overload Voltage GD4282* GD4377 GD4564 GD4754 GD4846 GD41131 272 302 522 580 782 870 400 157 175 302 336 453 503 132 160 280 315 450 500 Standard Fan 1.1 x O/L Voltage GD4282* GD4377 GD4564 GD4754 GD4846 GD41131 308 328 592 630 888 944 400 178 190 343 364 514 546 160 160 315 355 500 500 293 310 563 595 844 893 480 203 215 391 413 586 620 200 200 355 400 560 560 258 286 496 549 744 824 480 179 199 344 381 517 572 160 160 315 355 500 560
Large Fan 1.5 x Overload Voltage GD4282* GD4377 GD4564 GD4754 GD4846 GD41131 282 353 541 678 812 1016 400 163 204 313 392 470 588 160 200 280 355 450 560 Large Fan 1.1 x O/L Voltage GD4282* GD4377 GD4564 GD4754 GD4846 GD41131 368 411 707 790 1061 1185 400 213 238 409 457 614 685 200 200 400 450 560 630 352 411 676 790 1013 1185 480 244 286 469 548 704 823 200 280 450 500 630 800 282 336 541 645 812 967 480 196 233 376 448 564 671 160 200 355 400 560 630
Note:
* For GD4282 drives incorporating input a.c. line reactors 33Z0313/10 the overload current is limited to 282 amps rms (ie no overload). Operation above this current level can lead to tripping of the network Alspa GD4000 Page 2-3
Issue (12-2-98)
2. Specification
bridge transistors on instantaneous over-current. With 50Z015/01 line reactors, see section 11.2.2, standard overload ratings can be achieved
Table 2-3 Power ratings for high voltage drives
Output Current Ratings for GD4282 to GD41131 DELT A drives
Drive
Drive Rating (kW)
Drive Rating (kW)
Standard Fan 1.5 x Overload Voltage GD4300 GD4600 GD4900 211 404 607 600 183 351 527 160 315 500 Standard Fan 1.1 x O/L Voltage GD4300 GD4600 GD4900 227 435 652 600 197 377 566 160 355 560 204 393 589 690 204 392 588 200 355 560 191 366 549 490 190 366 548 160 355 500
Large Fan 1.5 x Overload Voltage GD4300 GD4600 GD4900 235 451 677 600 204 391 587 200 355 560 214 411 617 490 214 411 616 200 400 560
Large Fan 1.1 x Overload Voltage GD4300 GD4600 GD4900 270 519 778 600 235 450 676 560 450 630 246 472 707 490 245 471 706 200 450 630
Output Current Ratings for GD4282 to GD41131 High Voltage DELTA Drives
Notes:
For alternative ratings or environmental conditions please consult CEGELEC or your local agent. Thermal Current Ratings against IEC Specifications, Switching Frequency = 3 kHz Assumptions for Current Ratings IEC Standard Voltage Ambient : : : IEC 146-1-1 10% From Nominal 40 oC
Power Factor Current Ratings apply for power factor in the range -0.9 to +0.9. Output Voltage Ratings apply for inverter output voltage in the range 0 - 100%
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Alspa GD4000
Issue (12-2-98)
2. Specification
Altitude Frequency Re-rating Factors Frequency : Rating at Alternative Frequency = Rating at 50 Hz x (1+ (0.004 x (Actual Frequency - 50))) Linear Interpolate between 415 V and 480 V ratings given in tables Current Rating at alternative ambient = Current Rating at 40 oC x (1 + (0.016 x (40 oC - Alternative Ambient in Degrees C))) Rating at Alternative Altitude = Rating at 1000 metres x (1+ ((1000 - Alternative Altitude) 0.000073)), 2000 m above sea level. For operation at higher altitudes consult CEGELEC. No allowance has been made for external ductwork pressure drops and associated air flow reductions. : : 1000 metres above sea level. 50 Hz 1%
Voltage Ambient
: :
Altitude
Maximum Altitude Ductwork
: :
Ratings are based on the thermal limits for a given IGBT/Heatsink/Fan Combination without absolute silicon limit being considered. Absolute Silicon Limits define the maximum permissible overload and must always be respected. The limits of d.c. link working voltage given in and Section 6.7.1 must also be respected. For information on de-rating the drive for use at higher ambient temperatures (see section 2.11). 2.1.1 Current Ratings (GD41128, GD41508, GD41692 and GD42262) The power ratings for GD4000 drives with four or six DELTA transistor modules connected in parallel are calculated by multiplying the comparable two or three bridge rating by 1.92. E.g. for a GD42262 with turbo fans (this is effectively 2 x GD41131 bridges operating in parallel under the control of one SIGMA controller) the current rating without overload will be: 1185 x 1.92 = 2275 amps.
2.2
Supply Requirements
Alspa GD4000 requires a 3 phase, 3-wire supply (no neutral connection required). This provides for both the power and internal control circuit requirements. The Alspa GD4000 is not phase sensitive for supply side connections, however the precharge and auxiliary connections must be phase related.
2.2.1
Supply Voltage The rating label on the right-hand side panel of the BDM or inside the front door identifies the operating voltage range each drive has been manufactured for.
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Alspa GD4000
Page 2-5
2. Specification
Supply Voltages Range : 3 phase, 380 V - 480 V (standard drives) 525 V to 690 V (High voltage DELTA derived GD4000 drives). 10% for quoted output rating +15% for 30 cycles to IEC 204
Permissible tolerance Over-voltage transient withstand Notes:
: :
The limits and parameterisation of the network bridge control is given for various nominal supply voltage and frequency conditions in Section 6.9.
For other operating conditions follow the calculation routine detailed in section 6.7.1. 2.2.2 Supply Frequency Overall frequency range Maximum Rate of Change 2.2.3 : : 47 - 63 Hz 3% per second
Power Factor of Network Rectifier Bridge Network Cos = +1.0 to 0.985 (motoring) -1.0 to -0.985 (regenerating) Subject to setting up as described in section 9.
2.2.4 2.2.4.1
Cooling System Characteristics (GD4010 to GD4160) Cooling Fan GD4010 to GD4060 GD4010 to GD4040 have one cooling fan fitted within the Basic Drive Module (BDM). GD4060 has two cooling fans fitted within the BDM. Supply voltage Fan speed Noise level : : : Provided by internal SMPS 2950 rpm GD4010 to GD4040 (single fan) 55 dBA (depending on ducting/enclosure). GD4060 (two fans) 58 dBA GD4010 to GD4040 375 m3/hr (220 cfm) at 1.1 in H2O (275 Pa) GD4060 750 m3/hr (440 cfm) at 1.1 in H2O (275 Pa) Stall protected
Maximum airflow : : Fan motor overtemperature protection 2.2.4.2 :
Cooling Fan GD4080 to GD4160 One cooling fan is fitted within the Basic Drive Module (BDM) Supply voltage : 230 V (single phase) from internal transformer.
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Alspa GD4000
Issue (12-2-98)
2. Specification
Supply frequency Input power Fan speed Noise level : : : : 50/60 Hz 150/210 W 3100 rpm (60 Hz) 75 - 81 dBA (depending on ducting/enclosure) 2 off BDMs +3 dBA 5 off BDMs +7 dBA 6 off BDMs +8dBA 370 cfm (630 m3/hr) at 1.1 in H2O (275 Pa) internally connected thermal cut-outs
Typical airflow Fan motor overtemperature protection
: :
Refer to the GD DELTA Technical Manual (T1641) for information on the characteristics of cooling systems for modular drives. 2.2.5 Motor Selection Criteria Induction machines from many manufacturers are compatible with GD4000. When choosing a suitable machine the following aspects should be considered: (1) Cooling provision against application speed range. (2) Encoder mounting provisions. (3) Characteristics of machine to achieve the required output at maximum application speed. (4) Performance of machine bearings and balance specification, with regard to the application speed range. (5) Mechanical resonance considerations. (6) Rating of machine insulation when inverter driven (consult GDLOM Technical Manual (T1622), included as a supplement to this Technical Manual). Any motor manufacturer offering induction machines suitable for inverter connection should be able to answer the points raised in the above list. Please consult CEGELEC or local agent if any difficulties are encountered in resolving these issues. For motor parameterisation guidance refer to section 6.
2.3
Drive Internal Supplies

Internal supplies for the GD4000 BDMs are produced by an internal switched mode power supply (SMPS). The internal supplies for DELTA GD4000 drives are provided by one or more switched mode power supply assemblies which are supplied as loose equipment for mounting in an enclosure. The power input to the SMPS is derived from phases R and S of the main power input supply via fuses.
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Alspa GD4000
Page 2-7
2. Specification
The SMPS produces five separate supplies: Supply 1 Supply 2 Supply 3 Supply 4 Supply 5 : : : : : 5 V, 12 A (except serial links and encoder supply.) +15 V, 2 A -15 V, 1 A 48 V, 5 A (Pre-charge and SMPS relays). 55 V, 0.5 A unregulated (Battery charger supply).
All five outputs are short-circuit protected. 2.3.1 Serial Links and Encoder Supply Five isolated 5 V supplies drive serial links 0, 1, 2 and the encoder interface circuitry. For applications where the encoder cable imposes a significant volt drop there is the option of a 12 V supply (see section 8.7.5.1). This must then be regulated at the encoder using a remote regulator box. Refer to section 11 for the re-order number for suitable remote regulators. Both the 5 V and 12 V encoder supplies are rated at 500 mA maximum. 2.3.2 Internal Supplies Hold Up Time The drive internal supplies will hold up for a minimum of 20 ms from loss of minimum input supply with outputs fully loaded and the network voltage at its lowest level. At least 20 ms before outputs fall below the minimum tolerance, the SMPS will send the early power fail (EPF) signal to the SIGMA core board to initiate a controlled shutdown procedure. Where a greater hold time is required following supply failure, a battery back-up system must be installed. See Appendix B.
2.4
Drive Identity
No of different drive identities Identity Addresses : : 256 A0.0 to A0.07
Set by an 8-way DIL switch (SW2) on the Customer I/O board. Refer to section 7 for further information.
2.5
Board Identifiers
Each major PCB within the drive is fitted with a 1 kbit serial EEPROM providing board identification to the SIGMA core board, on power up.
2.6
2.6.1
I/O
Dedicated Digital Inputs There are eight digital inputs regularly scanned by the microprocessor (independently of the user program scan time). These are grouped into one group of four inputs (with a common return) and four single inputs (with individual returns). Address allocations : A32.0 to A32.7.
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Alspa GD4000
Issue (12-2-98)
2. Specification
Input voltage range Logic 1 Logic 0 Nominal input current for logic 1 Leakage current for logic 0 Response Time Notes: : : : : : 20 to 70 V d.c. 5 V maximum 9 mA 0.5 mA maximum 1 ms
A32.7 is also connected to the firing circuit field programmable gate array (FPGA) to provide a pulse inhibit function (inhibited when low or open circuit).
2.6.2
Basic Digital Inputs There are eight digital inputs scanned by the Basic I/O. Address allocations Input Voltage Range Logic 1 Logic 0 Nominal input current for logic 1 Leakage current for logic 0 Response Time : : : : : 20 to 70 V d.c. 5 V maximum 9 mA 0.5 mA maximum 1 ms (excluding scan time of user program) : A1.0 to A1.7
2.6.3
Basic Digital Outputs There are eight digital outputs connected to the high side of the plant side power supply. Address allocations Plantside Voltage Range Maximum Voltage Transient Maximum Off State Leakage Voltage Drop For On State Output Current Rating Notes: : : : : : : B1.08 to B1.15 20 to 70 V d.c. (sustained) 150 V d.c. 1 mA 2.5 V (At full output current) 250 mA
These outputs are short-circuit protected.
The output circuits are designed to operate with a RC snubber circuit in parallel with the load relay or lamp. The maximum size of snubber capacitor is 0.47 nF in series with a resistor of minimum value 220
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Alspa GD4000
Page 2-9
2. Specification
2.6.4 Basic I/O Extended There are a further 224 basic I/O points available to the user via ribbon cable connector PL3 from the Customer I/O board. Address allocations : A2.0 to A15.15 B2.0 to B15.5
A variety of GEM80 basic I/O modules may be connected via this facility. Further information on GEM80 I/O modules can be obtained from CEGELEC or local agent. 2.6.5 Analog Inputs In the standard hardware the are 4 analog inputs available for customer use. These are connected via the analog termination panel which is mounted on top of the customer I/O board. Signals Input impedance Address locations Resolution Range : : : : : -10V to +10V 500 k C tables - see 8.8.1for details 11 bits plus sign +32767 = +10V.
There is also the option of connecting a second analog termination panel to the drive unit which will provide two additional analog inputs and two dedicated motor thermistor input channels. This additional analog termination panel can only be used when the drive is fitted with a 20X4486 or 20X4489 power interface board (PIB). The motor thermistor inputs are compatible with any PTC motor thermistor whose nominal resistance at its temperature rating is 1 k. 2.6.6 Analog Outputs Signals Source resistance Address allocations Resolution Range : : : : : 10 V @ 5 mA, short circuit proof 10 D0 to D3 11 bits plus sign (approx. 0.05%) +32767 = +10 V
2.7
Incremental Encoder Line Receiver

No. of Channels Signal Range Max. encoder frequency Maximum differential skew between channels Configuration : : : : : : 500 kHz 50 ns (over time and temperature) Encoder type is configured by setting L2090 in module 20 (see section 14.1.14). 1 = Biphase + marker, 1 single phase 2 = 2 x Bidirectional Encoder (biphase) Alspa GD4000 Issue (12-2-98) 5 (A, B, Z and A, B) 5 V RS422 levels. (Differential line receiver input.)
Page 2-10
2. Specification
Encoder line count Encoder speed : These form part of the position measurement/speed measurement modules.
The encoder chosen must provide an RS422 type differential line drive output. Suitable types are: Heidenhain Hohner ROD426 H Series
Selection will depend also on mechanical compatibility.
2.8
Watchdog Relay
Output Contact rating : : normally-open volt-free contact 250 V a.c. 1 A 100 V d.c. 1 A
2.9
Serial Communications
Number of serial links : Three main links are provided for communication/programming functions, plus one link for drive mounted keypad connection.
2.9.1
Format Link 0 Link 1 Link 2 Link 3 : : : : Isolated RS485/RS232 interface Isolated RS485 interface Isolated RS232C interface RS232C interface (keypad)
2.9.2
Configuration Link 0 Link 1 Link 2 Link 3 : : : : Tributary by default (can be control to one tributary) Control (with up to 4 tributaries) or tributary. Control or Tributary (point to point only). Tributary only (for on-board keypad).
2.10
Keypad
Display Communication protocol and electrical format : : 24 characters wide x 2 lines high LCD display RS232
2.11
Environmental Conditions
To ensure trouble-free operation with minimum maintenance, the installation site should fulfil the following requirements: The atmosphere should be clean and dust free, in particular it must be free from corrosive vapours, water absorbent dusts and conductive dusts.
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Alspa GD4000
Page 2-11
2. Specification
Where necessary, measures should be taken to prevent the ingress of metallic swarf generated by process or maintenance activities. Where there is a risk of falling water, a drip proof canopy should be mounted over the drive, to prevent water from entering the drive. 2.11.1 Ambient Temperature The ambient temperature should be in the range 0 oC to 40 oC, with no rapid changes of temperature. At ambient temperatures above 40 oC the continuous output load current for BDMs GD4010 to GD4160 must be de-rated by 2% per oC up to a maximum of 50 oC. 2.11.2 Relative Humididty The Relative Humidity should be in the range 5% to 95% (non condensing). 2.11.3 Vibration (Operational) IEC721-3-3 Class 3M1" and prEN 50178 Vibration Level" Note: To achieve both standards, the products comply with the more severe requirements from from each standard. This is given in the following composite curve:
Frequency 2 Hz to 9 Hz 9 Hz to 28.13 Hz 28.13 Hz to 57 Hz 57 Hz to 150 Hz 150 Hz to 200 Hz IEC 721-3-3 Class 3M1 0.3 mm amplitude 1 m/s
2
prEN 50178
Composite 0.3 mm amplitude
0.032 mm from 10 Hz 0.032 mm amplitude 5 m/s2
1 m/s2 0.032 mm amplitude 5 m/s2 1 m/s2
1 m/s2 1 m/s2 1 m/s2
2.11.3.1
Vibration (Storage, Transport) When equipment is packed for transport Class 2M1 of IEC 721-3-2 : 2 to 9 Hz
2.11.3.2
Drop (Transport) When equipment is packed for transport Class 2M1 of IEC 721-3-2 : mass < 20 kg 20 kg mass < 100 kg 100 kg mass : : : 0.25 m 0.25 m 0.10 m
2.11.4
Altitude The normal operating altitude for the unit is up to 1000 m (3,300 ft) above sea level. Above this altitude the drive should be de-rated by 7.3% per 1000 m (3,300 ft) up to a maximum of 2000 m (6,600 ft). For operation at higher altitude consult CEGELEC.
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Alspa GD4000
Issue (12-2-98)
2. Specification
2.11.5 Storage If equipment delivered to site is not to be installed immediately:
Re-pack it in its original packing material. If this is not possible it should be enclosed
in polythene sheet to protect it from the ingress of dust.

Store it in a clean dry atmosphere, preferably at room temperature. For the product
the storage temperature limits are -25 oC to +70 oC. For batteries the storage temperature limits are +10 oC to +25 oC at a relative humidity of 65%.
2.11.6
Maximum Heat Dissipation A cubicle or restricted environment, into which a GD4000 is installed, must be capable of dissipating the heat generated by both the drive and any other heat sources within that environment.
2.11.7
Relative Humidity 5% to 95% relative humidity non-condensing. For tropicalisation consult CEGELEC Kidsgrove.
2.11.8
Overvoltage Category The products detailed in this manual comply with the insulation co-ordination requirements of IEC644-1 (1992) and UL840 (1993) on the basis of overvoltage category III. The rated impulse voltage for the power circuits of the products is as defined in the table below:
Nominal AC Voltage Rating 380 to 600 V.a.c. rms 601 to 690 V.a.c. rms Rated Impulse Voltage 6000 V 8000 V
External means must be applied to control the overvoltage within the limits of the rated impulse voltage specified above. This is to be achieved by either the characteristics of the electrical supply system, or by the use of specific overvoltage attenuators to limit prospective transient overvoltages. During normal operation the equipments do not generate switching overvoltages above the rated impulse voltage levels defined above. 2.11.8.1 Implications for Compliance with UL508C Devices or systems used to control overvoltages shall meet the requirements of UL1449 (1996), Standard for Transient Voltage Surge Suppressors. 2.11.9 Pollution Degree The Alspa GD4000 power circuits comply with the creepage and clearance distance requirements appropriate for pollution degree III environment to IEC664A/664A. 2.11.10 Acoustic Noise Emissions Both the drive and motor will emit some degree of acoustic noise as a result of the PWM switching of the drive output. The frequency and volume will depend on the PWM frequency and the construction of the motor.
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Alspa GD4000
Page 2-13
2. Specification
2.11.11 Radio Frequency Emissions Alspa GD4000 is designed for use in an industrial environment. If it is to be used in close proximity to sensitive circuits or domestic premises, additional filtering may be required. For details of suitable filters, refer to Appendix G. 2.11.12 Susceptibility to Radio Frequency Interference All Alspa GD4000 drives are screened from radio interference when the front panels are closed. Care should be taken that no radio frequency transmissions (e.g. from portable telephones) take place in the vicinity of the drive when the covers are open. 2.11.13 Degree of Protection GD4010 to GD4160 : IP20 to IEC529: 1989 and BSEN60529: 1992 - Protected against the ingress of solid foreign objects greater than 12.5 mm diameter but is not protected against the ingress of water with harmful effects. GD4000 DELTA drives : IP00 to IEC529: 1989 and BSEN605529: 1992 Non-protected against the ingress of solid foreign objects and against the ingress of water with harmful effects
2.12
Size And Weight

Table 2-4 Equipment Size and Weight
Weight (kg) Unit Nett 87 72 91 72 91 72 106.5 72 106.5 72 131 Gross (inc. pkg) 102 87 106 87 106 87 121.5 87 121.5 87 150 575 465 W
Dimensions (mm) D H
GD4010G GD4010L GD4020G GD4020L GD4030G GD4030L GD4040G GD4040L GD4060G GD4060L GD4080L GD4120 GD4160 GD4080 Line Reactor (50Z0012) GD4120 Line Reactor (50Z0013) GD4160 Line Reactor (50Z0014) Precharge Box
495
750
385
1100
50 90 160 3.5
305 365 542 160
235 255 285 154
315 385 540 300
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Alspa GD4000
Issue (12-2-98)
2. Specification
2.13
Applicable Standards
GD4000 drives generally comply with appropriate sections of: IEC529 Degrees of Protection of Enclosures. IEC641-1 Creepage clearance IEC721-3-3 Vibration Class 3M1 IEC146-1-1 IEC801 UL508 and UL 508C CAN/CSA Standard CS22.2 No. 14. prEN50178. For full details consult CEGELEC or local agents
2.14
Calender/Clock Functions
Resolution Accuracy Clock Modes Address : : : : 1 Second Better than 1 minute per month AM/PM or 24 Hour Clock E1 to E6 (see section 3.3.2)
2.15
Enhancement Bus
The SIGMA Enhancement bus provides connections for up to four enhancement cards.
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Alspa GD4000
Page 2-15
2. Specification
Page 2-16
Alspa GD4000
Issue (12-2-98)
3. Technical Description
Technical Description
3.1 Introduction
This section describes the principles of operation of vector control and this is followed by a brief description of the drive hardware.
3.2
Principles of Operation
Alspa GD4000, in its standard configuration, is effectively two Voltage Source Inverter (VSI) bridges connected in cascade. The network VSI bridge, connected between the a.c. supply and the d.c. link, provides the controlled rectification function. The machine VSI bridge, provides power control between the d.c. link and the induction machine connected to it. The following sections serve to give an introduction to the basic principles of operation.
3.2.1
Network Bridge Operation A sinusoidal network rectifier, as shown in Figure 3-1, is a fundamental part of GD4000. This provides a four quadrant line regenerative capability. The input rectifier is a VSI connected to the network via a.c. line reactors, L, that operate as energy storage and filter components. The rectifier is controlled in a similar manner to the vector controlled machine bridge, with many of the control techniques being identical. Ancillary components are omitted from the block diagram to simplify the explanation.
Figure 3-1 Sinusoidal rectifier block diagram
With such a network rectifier control system, a sinusoidal, unity power factor input current waveform is maintained in both motoring and regenerative modes. The system also has the feature of maintaining a constant d.c. link voltage for all normal supply variations, therefore retaining output inverter voltage capability even during periods of low supply. 3.2.2 Vector Control Operation The performance and maintenance benefits of ac induction motors are well known making them an ideal choice of prime mover for modern processes. The latest vector control techniques now allow the induction motor to replace d.c. motors in parts of the process where precise control is necessary. Uncoilers, coilers,
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Alspa GD4000 Technical Manual
Page 3-1
tension control applications and machine tools spindle drives can now be implemented, using vector controlled ac drives. The vector control system implemented in GD4000 allows the three phase induction motor to be controlled as if it were a d.c. motor, by resolving the rotor flux into its two orthogonal components: magnetising and torque producing. This allows a similar degree of decoupled control to that normally associated with a shunt wound d.c. machine by the mechanical commutator and separately excited field winding. The direct axis (magnetising) and quadrature axis (torque producing) components of motor current can now be controlled by two separate loops operating with d.c. conditions in the steady state. The resulting direct and quadrature voltage signals can be rotated by suitable angle increments determined from rotor slip and incremental rotor position changes to develop a sinusoidal motor driving waveform. Performance can be maintained throughout the motor operating temperature range by monitoring the variation in rotor resistance and applying suitable compensation to the motor model. It is not mandatory to have a precise motor model to take advantage of vector control, but a full model will give better performance following a transient disturbance. The induction machine equivalent circuit parameters are normally provided by reference to the machine manufacturers. A method of calculating the parameters when precise data is not available is given in section 6.
Page 3-2
Issue (12-2-98)
3.2.3 Vector Control Block Diagram
Figure 3-2 GD4000 Vector control block diagram
The block diagram for the vector controller implemented in GD4000 is shown in Figure 3-2.
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Page 3-3
3.2.4 Description of Operation A conventional speed amplifier compares a speed reference, N*, from the preceding ramp and referencing circuits with the speed feedback signal, N, derived from an incremental encoder attached to the machine. The output of the speed control is a torque demand signal to the subsequent stage. The closing of an external torque control loop from a torque feedback signal is optional. Limits to torque reference being applied to the slip calculator are derived from a look-up table precalculated for specific induction motor equivalent circuit parameters. The slip frequency output from the slip calculator is used to calculate the increment of angle that must be added to, or subtracted from r, to produce a resultant stator angle s, to which stator current conversion and pulse-width modulator (PWM) are referenced. The slip frequency output, s, is also fed to the active current calculator to define a current reference, Iq*, to a fast acting current amplifier. The magnetising current control derives a speed dependent reference, Q*, from a second look-up table. This is then converted to an Id* after compensating for iron saturation effects in the motor. The voltage output from the two current controllers is mixed in the PWM to form a resultant stator voltage reference and angle at which this voltage must be applied relative to the reference angle s. The PWM system is based on an improved voltage vector modulation technique which maximises machine voltage for a given d.c. link level. This provides a good quality sinusoidal output waveform with a maximum rms line to line voltage of Vdc/2. Current feedback information is derived from all three phases of the induction motor via simultaneous sampling A-D convertors, synchronised to the PWM system. This reduces the amount of filtering that is required in the current feedback system and so improves the overall system dynamics. 3.2.5 Vector Control Performance The vector control system can achieve speed holding accuracies of up to 0.0175% of full speed by the use of a suitable incremental encoder. This type of control also allows the ac machine to produce full and controllable torque over the entire speed range by the modelling of the motor within the controller. A torque control bandwidth, in excess of that achieved by a dc motor, is possible with vector control. The provision of an incremental encoder on a vector controlled drive also allows torque control to be rapidly re-established on to a rotating machine following a power loss/trip, quickly bringing the process back to set point. The encoder is not supplied in the GD4000 drive package but should be considered an integral part of the overall drive system. Suitable encoders can be obtained through CEGELEC or approved agents.
Page 3-4
Issue (12-2-98)
3.3
Hardware Description
This section describes the function of the main components of a typical Alspa GD4000 vector control drive, when used as the normal a.c. input, vector control a.c. output motor control. The flexible design of GD4000 also allows the unit to used as a d.c. fed a.c. output drive controlling 1 or 2 motors or as an AC fed DC source, by changing the connections to the drive and running appropriate software control tasks. The main components of an Alspa GD4000 are shown in Figure 3-3.
Figure 3-3 SIGMA Controller Schematic Diagram
A typical GD4000 drive comprises the following main components: SIGMA Core Board Power Interface Board Enhancement Interface Customer I/O Board Analog Termination Panel Switched Mode Power Supply Power Interface Board DC Link Network Bridge Machine Bridge Keypad (optional) Pre-charge Panel Encoder Figures 3-4 and 3-5 show the mechanical configuration of a typical drives.
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Page 3-5
1. 2. 3. 4.
DC/AC Motor Inverter Bridge AC/DC Input Rectifier Bridge Customer I/O assembly Control Terminals
5. 6. 7.
Cable Gland Plate Power Interface Board SIGMA Core Board Enclosure
Figure 3-4 Internal Arrangement GD4010 to GD4060
Page 3-6
Issue (12-2-98)
1.
SIGMA Core Board Enclosure with enhancement cards (plus keypad on front cover) Cooling Fan Transformer Analog I/O Terminals
4.
Control Terminals
2. 3.
5. 6.
Power Terminals Gland Plates
Figure 3-5 Internal arrangement GD4080 to GD4160
3.3.1
SIGMA Core Board The SIGMA Core Board provides all the processing requirements of the drive, including switching signals for the network and machine bridges, serial communications, user interface, vector control calculations and process sequencing and logic. The SIGMA Core Board has two microprocessors; an 80166 which performs all the serial communications tasks and an i960 32 bit processor, which performs all other tasks. A simplified arrangement of the core board is shown in Figure 3-6.
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Page 3-7
3.3.1.1 LED Indicators The SIGMA Core Board has two LED indicators, D15 and D16 (see Figure 3-6)
Figure 3-6 SIGMA Core Board simplified layout
3.3.2
Calendar clock The SIGMA core board is provided with battery supported clock and calender facilities. The clock is not synchronized to the system real time clock. The time data is output to the following E-tables: E1 = seconds E2 = minutes E3 = hour E4 = day E5 = month E6 = year The time can be changed by writing to the appropriate E table.
3.3.3
Drive I/D The drive I/D is used to ensure the drive is loaded with the correct software. A number set on switches SW2/1 to SW2/8 is read by the user program and checked against the number placed in the bottom eight bits of P0. If the drive I/D is incorrect the drive will not run and a warning message is displayed. The drive I/D function is enabled when P8 is set to a non-zero value.
Page 3-8
Issue (12-2-98)
Switch SW2 / 8 SW2 / 7 SW2 / 6 SW2 / 5 SW2 / 4 SW2 / 3 SW2 / 2 SW2 / 1 Table Location A0.0 A0.1 A0.2 A0.3 A0.4 A0.5 A0.6 A0.7 Binary Number 1 2 4 8 16 32 64 128 Drive ID (see 7.9.4) Description
3.3.3.1
Enhancement Board Interface The core board also contains interface circuits for optional enhancement boards, which can be fitted into slots on the side of the drive. Up to four enhancement cards can be fitted, these include FIP network and HDLC cards (see Ordering Codes section 11).
Figure 3-7 Side View of SIGMA Controller
3.3.4
Board Identifiers Each of the printed circuit boards and modules which is built into GD4000 is coded to identify its type and modification state. The identifier is read by the system software on boot-up to ensure the drive hardware configuration is compatible with the system software.
3.3.5
Power Interface Board The Power Interface Board converts firing pulse signals from the SIGMA core board to a form suitable for driving the power bridge IGBTs. Monitoring signals from the PIB are fed to the Analog Termination Panel for output.
3.3.6
Customer I/O Board The Customer I/O Board contains all the customer input and ouput connections for serials links 0, 1 and 2, incremental encoders 1 and 2, dedicated digital inputs, Basic I/O digital inputs, watchdog relay outputs and an extended Basic I/O ribbon cable
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Page 3-9
connector. Provision is made on the circuit board for mounting the Analog Termination Panel and the HDLC Termination Panel although there are no electrical connections between this board and the Customer I/O Board. Note: The HDLC termination panel can only be fitted to the Customer I/O Board when the Customer I/O Board is mounted remotely i.e it cannot be mounted inside a BDM enclosure, since it will foul the door when closed. When the HDLC Termination Panel is used with a BDM it must be mounted outside the BDM and connected with the cable provided.
3.3.7
Analog Termination Panel The Analog Termination Panel contains the connections for the analog inputs (on TB17), analog outputs (on TB18) and +15 V and -15 V regulated supplies for the customer analog inputs on TB19. The Analog Input Board is normally mounted on pillars on the Customer I/O Board, but is electrically connected to the PIB by a ribbon cable.
3.3.7.1
Analog Inputs The analog inputs are provided by two four channel A to D converters. The first three channels of each A to D converter are direct inputs and are known as fast inputs. The fourth channel of each of each A to D converter is fed by a 6 into 1 multiplexer as shown in Figure 3-8 giving a total of 22 slow analog input channels. The values for these analog inputs are written to C-tables C0 to C21 as shown.
Figure 3-8 Analog Inputs
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3.3.8 Incremental Encoder GD4000 vector control requires input from an incremental encoder, to determine the speed, slip angles and rotor position of the motor. The incremental encoder is not supplied as part of the GD4000 drive, but suitable encoders are available from CEGELEC on request. The incremental encoder is connected via the Cusomer I/O Board. 3.3.8.1 Encoder Interface Board (option) An optional Encoder Interface Board is available from CEGELEC, this enables the encoder signals to be passed to another device such as GEM80. If fitted, the encoder interface board must be mounted on the Customer I/O Board. 3.3.9 Input and Output Power Bridges There are two identical voltage source inverter bridges. In standard configuration Bridge B is connected between the a.c. supply (network) and the DC Link and Bridge A is connected between the DC Link and the motor (machine). Alternative DC fed 1 motor and 2 motor configurations are shown in Section 6 The power devices used in both bridges are insulated gate bipolar transistors (IGBTs). In GD4010 to GD4160 these are mounted on a vertical heatsink in the rear of the drive. In GD4282 to to GD42262 the power devices are built into individual bridge modules (DELTA modules) which slot into a rack in the control cubicle. The rated output of the larger DELTA drives is achieved by connecting two or three DELTA modules in parallel to from each bridge. A high voltage 300A transistir bridge is available, this bridge can be used with network supplies of 525 V to 690 V and is used in the GD4300, GD4600 and GD4900 range of high voltage DELTA drives. 3.3.9.1 Network Bridge In standard configration, Bridge B (the network bridge) works as a sinusoidal rectifier, with line regeneration capability. The network bridge is controlled by the SIGMA Controller Fast Task software. Operating as an input rectifier the network bridge maintains unity power factor in both motoring and regenerating modes. 3.3.9.2 Machine Bridge In standard configuration, Bridge A (the machine bridge) converts the DC link supply to a variable frequency, PWM, three-phase output, with regeneration capability. The machine bridge is controlled by the SIGMA Controller Fast Task software, using vector control algorithms. 3.3.10 Precharge Circuits The Pre-charge limits the inrush current to the drive when it is energised, to prevent damage to external circuits. When the drive is energised, initially, the supply current to the network transistor bridge is diverted through current limiting resistors, to precharge the transistor bridge capacitors. When a predetermined voltage is reached, relays operate to switch the input supply to pass directly to the transistor bridge.
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On GD4000 models GD4010 to GD4060 the pre-charge circuits are built into the drive. On models GD4080 to GD4160 the pre-charge circuits are provided on a separate panel which which must be mounted in close proximity to the drive. The pre-charge panels used on GD4080 to GD4160 contain fuses which may occasionally require replacement (see Section ). 3.3.11 Switched Mode Power Supply The Switched Mode Power Supply (SMPS) provides the following supplies for the control electronics: +5 V for the SIGMA Core Board +15 V and -15 V supplies for the SIGMA Core Board +48 V supplies for the Customer I/O Board +70 (nominal) for charging the optional standby battery. The input supply to the SMPS is derived from 2 phases of the input ac supply to the drive. The SMPS incorporates an early power fail (EPF) circuit, which monitors the SMPS internal dc link and sends a signal to the core board at least 20 ms before a power supply shut-down occurs. In some circumstances the inrush current to the SMPS can cause difficulties, further information on this topic is given in Section 6.6. 3.3.12 Cooling Fans (Standard Cooling System) All GD4000 model have fan assisted cooling . The number of cooling fans varies according to the drive model. The cooling fans are located at the top of the drive. They draw cooling air through the vents on the bottom of drive and exhaust through a vent at the top. On GD4000 models GD4010 to GD4060 the power supply fo the cooling fans is provided by the internal SMPS. On drive models GD4080 to GD4160 the power supply is derived from an internal fan supply transformer, which is fed from two phases of the a.c. input supply. When installing the drive the fan transformer supply voltage must be selected correctly by the user (see Section 8.5.1). 3.3.13 Cooling Fans (High Performance Cooling System) A high performance cooling system is offered with for some drive models. The power for these fans is derived from a transformer which provides three-phase 400 V a.c. from the three-phase input supply. The correct output voltage for the fans is selected by connecting to the appropriate voltage tap on the transformer output. 3.3.14 Line Contactors and Line Reactors Line contacotrs and line reactors are not included with the drive but can be supplied by CEGELEC. Ideally they should be fitted in a control enclosure with the drive.
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4. The CEGELEC SIGMA Programmer
The CEGELEC SIGMA Programmer

4.1
4.1.1
Introduction
The CEGELEC SIGMA Programmer The CEGELEC SIGMA Programmer is used to develop, compile and download application programmes for the SIGMA Controller. CSP runs on an IBM or IBM compatible PC, which needs to be connected to the SIGMA Controller by a serial link to download the program and monitor the drive. Program development can be carried out on the PC, independently from the drive. The CEGELEC SIGMA Programmer consists of five independent programs:
Links Editor Ladder Editor Compiler DownLoader Drive Monitor
These are accessed from the CSP Program Manager menu. In addition to this standard software, a history viewing program, known as OVERDRIVE is available as an option. This introduces its own high level menu structure, and allows the CSP to be invoked from the OVERDRIVE menus. Please consult CEGELEC for further details. 4.1.2 PC Requirements The minimum PC requirements to run the programming package are: Notes: IBM PC AT compatible, DOS based computer, 640 kB RAM, EGA Graphics capability, One serial communication port, 3.5" 1.44 Mb floppy disk drive Hard disk drive with a minimum 20 Mb free space. Microsoft Windows, Windows 95 or OS/2 (see note) While CSP is a DOS based program and normally runs from DOS, additional memory may be required to compile larger ladder programs and this can most conveniently be provided by running the software under a Windows, Windows 95 or OS/2 environment. If the CSP program is run under Windows 95 and Novell 4.0 it may run very slowly if certain applications (including Microsoft Office applications) have previously been launched and then shutdown during the same session. To prevent this happening it is reccomended that Windows 95 is closed and re-started before launching CSP.
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4.1.3 Structure of a User Program SIGMA user programs are built up from standard software modules which are held in the SIGMA controller firmware database. The user program is written in the GEM 80 ladder programming language, using the Ladder Editor. The standard software modules are declared in the ladder program. Each standard software module used in the application program needs to have a number parameters set to customise the module for the particular application. These parameters are set using the Links Editor. Used with the links program, the ladder program is used to:
Configure serial links, Declare software modules, Performing any special logic requirements.
When the ladder program is complete it is saved by the ladder editor with a .GLP file extension. Similarly the Links editor outputs a file with a .GDM file extension. The .GLP and .GDM files must then be compiled to an object file. The compiler combines information from the .GLP, .GDM and the software database to produce an object file with the extension .DNL. which can then be downloaded to the drive, via the serial link 0 using the DownLoader program. The ladder and links program must therefore have the same filename before the file extension. 4.1.4 The Software Database The software database is a library of software modules, which is loaded on the hard disk of the PC. These software modules are tested and proven subroutines which implement all the basic features of the drive (and many more complex ones). These are linked together using the links editor to produce the user application program. The ladder functions are then included to produce a complete application program. The software modules can be divided into two basic groups: The Fast Task (see section 13.1.1) - these modules control the current regulation and produce the bridge firing patterns. They can only be accessed in the user program for monitoring purposes or to provide input references/parameters to control task modules and can be scaled during commissioning. Control (Slow) Task - these modules are used in the user application program to control the drive and to customise it to the particular application. When the user program is compiled the compiler incorporates all the Fast Task and only those Slow Task modules declared by the ladder program into the object code (the .DNL file) which is to be downloaded to the drive. After downloading to the drive this program is held in battery backed RAM in the controller, and remains resident until either it is replaced by a subsequent user program, or until the RAM backup battery is exhausted and power is removed form the controller. 4.1.5 System Software Issue Numbers The software database for a particular controller depends upon the re-order version of the SIGMA Core Board. This re-order number determines which software modules are available.
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4.1.6 4.1.6.1 Interaction of the CSP Software Packages General CSP provides an integrated editing, compiling and monitoring package for the 32 bit, 80960 microprocessor based SIGMA controller. Programs are written using the CSP Links and Ladder editors. From these two programs, and the Firmware Database, the Compiler produces an error free down-loadable file. The DownLoader checks the compatibility of the program with the hardware and sends the program to the controller. A 32 bit Drive Monitor (part of CSP) is provided. Each of the software packages (except the ladder editor and OVERDRIVE) are designed to have a common user interface with self explanatory prompts and error messages. These are located in .MSG files which may be edited or translated into a differrent language by the customer, using a proprietary text editor, see section 4.11.9 When running from the CSP top level utility, a set-up utility is provided which sets up all parameters needed to run each package. 4.1.6.2 Sequence of Operation The individual parts of the software package are described in detail in section 4.3.1. The normal sequence of operation to edit, save, compile, and download as follows, refer also to the block diagram Figure 4-1. (a) .Edit/write ladder program (off-line) - .GLP file (b) .Edit/write links program (off-line) - .GDM file (c) Compile above plus firmware database (off-line) - .DNL file (d) Download .DNL file to SIGMA controller (e) A .LST file is automatically produced for error messages, status information listing (see section 4.9.1) (f) A .SYM file containing program symbols is created automatically. (g) A .BAK (back-up) links file is also created.
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Figure 4-1 Interaction of Software Packages
4.2
4.2.1
Installation
Procedure Refer also to section 4.1.2 for the PC hardware and software requirements. Note: a working copy of the supplied disk should be first made before the program is used.
The Cegelec SIGMA Programmer must be installed on the hard drive of the PC as follows: a) b) c) Start up the PC and then insert the working copy of the supplied disk. Type A:\INSTALL Enter to run the install program. The install program will run and the user is prompted to specify the directories to be used for the program and other files. To accept the default information [shown in square brackets] press Enter at each prompt. If a different directory or drive is required type in the required path at the prompt and press Enter. If the default information is accepted the display will appear as follows:
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Enter drive letter of Target Drive [C:] > Enter directory for SIGMA Programmer Files [C:\SIGMA] > Creating directory Enter directory for Program Files [C:\SIGMA\PROGS] > Creating directory Enter directory for Firmware Database [C:\SIGMA\DATABASE] > Creating directory Copying CSP.EXE
When this is completed, copy the standard ladder, links (the .GLP and .GDM files) to the C:\SIGMA\PROGS directory and the database file (ARC.A) to the C:\SIGMA\DATABASE directory. 4.2.2 Start CSP To start the CEGELEC SIGMA Programmer will depend upon which directory names were chosen in the set up above. Using the default settings, to start CSP: From the DOS prompt type: CD SIGMA Then type: CSP Alternatively include the path to the SIGMA directory in the PATH statement in the the Autoexec.bat file. And type CSP from the DOS prompt. 4.2.3 Reference CSP is assumed to exist in a sub-directory of the root directory called SIGMA, e.g. C:\SIGMA. The various parts (or tools) of the SIGMA Programmer are then assumed to be in the following directories: Tool CSP Program Manager Links Editor Ladder Editor Compiler DownLoader Monitor Executable File CSP.EXE ED.EXE SIGMAGPP.EXE COMPILER.EXE DOWNLOAD.EXE MONITOR.EXE Directory C:\SIGMA C:\SIGMA C:\SIGMA C:\SIGMA C:\SIGMA C:\SIGMA
4.3
4.3.1
Top Level Menu

Introduction To launch the CSP Program Manager type CSP from the DOS prompt The CSP top level menu is displayed as shown in Figure 4-2. See section 4.2.2. A set-up utility is provided (F7) to configure all the programming options. This and the six main options are then invoked by a single function key press.
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4.3.1.1 Display
Figure 4-2 Top Level Menu
4.3.2
Password System Passwords are required before the link program may be edited using either the Links Editor (see section 4.5.7(7.8.2) or the optional keypad. Passwords are set using the Programmer Set Up option F7, see section 4.10.1.
4.3.3
Error Messages
Error 0 Message Overdrive Dongle not present Command line too large Modeflag argument invalid Path or file not found Not executable file Not enough memory to load program Unknown error spawning program Failed to open CSP.DAT Path not found Invalid COM port Invalid baud rate Invalid tributary address Invalid backslash Cannot find OVERDRIVE on the C: drive Explanation Attempt to run OVERDRIVE but it could not find the dongle. } Spawning errors } Spawn could not find the requested program. Program found is corrupt. Program out of memory. Unknown! Could not save set-ups to disk. No such directory path exists COM port should be between 1 and 4. Baud rate should be between 1 and 38400. Tributary address should be between 0 and 14. full stop or colon in filename OVERDRIVE not installed Type the correct file name. Install OVERDRIVE Check file is in correct directory. re-install the program. Upgrade the PC memory. Report to CEGELEC None. Data not saved. Enter a valid directory. Re-configure serial links (using F7 set-up) it. Action Insert dongle (software key).
1 2 3 4 5 6 7 8 9 10 11 12 13
report to CEGELEC.
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Error 14 15 Message Editor could not find ED.MSG file Out of memory Explanation The Links Editor cannot find a valid .MSG file. Program has run out of memory The .LST file does not exist Action See Editor spec. 4.5.1. Upgrade PC memory see section 4.1.2 for PC requirements. Compile the ladder program to create a new .LST file.
16 17 18
.LST file not found Cannot create %s environment variable Internal Error Occurred
Report to CEGELEC.
4.3.4
Warning Messages
Num 0 1 2 3 Message CSP.DAT file not found, defaults will be set. Feature not yet implemented Invalid CSP.DAT file, defaults will be set. Invalid CSP Environment Variable, default CSP.DAT used. Explanation Set-up data file not found. Attempted feature not implemented. Set-up data file not found. Action None. None. None.
4.4
Ladder Editor F1
The ladder editor is used to create or modify an existing ladder program. Information on Ladder programming can be found in section 12 of this publication and in the GEM80 Programming Manual.
4.4.1
Description a) Starting Editing
All ladder editing is carried out off-line in the PC. A full screen Ladder Editor is provided. This is selected by pressing F1 from the CSP Program manager. The editor allows the adding, changing and deletion of ladder rungs. On line syntax and address checking is provided. The filename to be edited/saved is passed to the Editor by the CSP Program Manager and the directory for the file can be specified by the Location of program Files environment variable, see section 4.10.9. The file name may be changed when exiting the program. (All ladder programs have an implied .GLP extension. b) Language Support
Rung format: GEM80 Standard; A maximum of ten series elements with one output element, and up to five parallel branches.
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Instruction set (GEM80 Standard): SPEC JOIN ADD XOR BLOCK -]/[SUB INV AND -] [COUNT JUMP/LABEL VALUE -( )DELAY -(S)SEQR OR -(Rs)OUT LINK
Special functions, as defined in the SIGMA Controller Technical Manual, are also supported. In addition, the special function S140 is used to declare a control task software module. Mnemonics: 7-character upper case symbolic names can be allocated to any data table bit or word address. Mnemonics can be listed in address or alphabetic order, with a cross reference to the instruction number where they are used. Rung Comments: Text comments, up to six lines of 50 characters, can be allocated to ladder program rungs. Rung comments shown alongside rung when displayed or printed. Data Comments: Text comments, up to two lines of 50 characters, can be allocated to any mnemonic. A list of data comments in address order, with mnemonics, is an option for program printout. Company Heading: Two lines of 50 characters, adjustable by the user using the Programmer Setup option. The System Text is typically the same for a group of programs, and is included in program printouts. Contract Text: Two lines of 63 characters, individually created for each program, and included in program printouts. Issue information: Date and issue letter, may be updated whenever a program is saved. An asterisk is applied if the current issue is amended. The date and issue letter are included on program printouts. Search: Search facilities by instruction number, rung output instruction by type (coil, out, seqr, block, set/reset coil, JUMP), data table bit or word address, or mnemonic. Printing: Comprehensive paginated printing facilities, adjustable for 80/132 column width, line terminator <CR, <LF>, <CRLF>, or <CR><NULL><LF>), and character set (ASCII or Extended IBM). Offline Program Development in Computer RAM: Preparation and printing of ladder rungs. Ladder printouts include a cross reference list with each rung, which shows where that output value is reused.
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4.4.2 Ladder Programming Methods a) Function Key Usage for Ladder Editor
The Ladder Programmer uses 10 function keys, with and without <SHIFT>. The allocation of the function keys is shown below. It is recommended that the user should keep a function key template, based on the table below, adjacent to the keyboard. The size and shape of the required template depends on the computer hardware selected by the user.
Key F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Shift F1 Shift F2 Shift F3 Shift F4 Shift F5 Shift F6 Shift F7 Shift F8 Shift F9 Shift F10
Label SPEC. BLOCK AND VALUE OUT LINK JOIN -] [-]/[-( )ADD SUB COUNT DELAY SEQR. OR XOR INV JUMP -(S)-(R)-
Usage Special function. End of block if first element in rung Bitwise AND. Value constant or address for counter Word output. Draw horizontal line to link instructions. Join branches. N/O contact. N/C contact. Coil (bit output). Addition. Subtraction. Counter. Delay (timer). Press S for Sequencer instruction or E for sequence element. Bitwise logic OR Bitwise logic exclusive OR. Bitwise logic invert. LABEL if first element in rung Press S to set retentive coil Press R to reset coil
b)
Using Mnemonics
It is recommended that mnemonics should be used as simple symbolic names for all variables (data table addresses) in the ladder program. This is an aid to understanding which gives long term benefits in program maintenance. Mnemonics can be allocated both to individual bits and to words. Care is needed if the same location uses both bits and words.
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The ladder editor allows programs to be entered using only mnemonics as the identifiers for all variables. This allows program development to proceed before the final allocation of I/O and working data table values. However, it is necessary to allocate addresses to all mnemonics before the program can be compiled. Sometimes the need arises to change a particular data table address in a program. It can be time consuming searching for, and changing, all references in the program to that address manually. If a mnemonic is allocated to the address, then it is a simple matter to change the address to which that mnemonic refers, and all references in the program are automatically changed. c) Using Data and Rung Comments
It is recommended that comments should be included to explain the function of all rungs and the meaning of all data table addresses. This is an aid to understanding which gives long term benefits in program maintenance. Rung comments should describe the function of the rung, rather than describe the way the rung or group of rungs works, which should be obvious from the ladder rung itself. Rung comments are displayed on the programmer screen at the same time as the rung, but data comments are visible on the screen only if the comment list is selected. It is recommended that data comments should be printed out as a list for reference purposes. 4.4.3 LADDER EDITOR F1:Top Level Menu
+ | SIGMA LADDER EDITOR | | Sigma Ladder Editor - Version 1.00 | | | 1 EDIT PROGRAM IN STORE | | 4 PRINTING | 5 PROGRAMMER SETUP | 6 EXIT | | PLEASE PRESS REQUIRED OPTION [ ] | | | PROGRAMMER STORE : INSTRUCTIONS 490 4 % | PRESET DATA 0 0 % | RUNG COMMENTS 49 9 % | MNEMONICS 284 10 % | DATA COMMENTS 18 1 % + -+ | | | -| | | | | | | | | | | FULL | FULL | FULL | FULL | FULL | -+
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+ -+ | | | Sigma Ladder Editor VERSION xxxx | | | | 1 EDIT PROGRAM IN STORE | | | | 4 PRINTING | | 5 PROGRAMMER SETUP | | 6 EXIT | | | | PLEASE PRESS REQUIRED OPTION [_] | | | | PROGRAMMER STORE : INSTRUCTIONS 0 0 % FULL | | PRESET DATA 0 0 % FULL | | RUNG COMMENTS 0 0 % FULL | | MNEMONICS 160 5 % FULL | | DATA COMMENTS 0 0 % FULL | | | | ISSUE / / NO CONTRACT TEXT ENTERED | + -+
Details of the program that is in the Programmer store are given in the lower half of the screen. The top half of the screen shows the Ladder Editor Top Level Menu and these choices lead into the main sections of the editor. These sections are described briefly below and in greater depth under separate headings. Selecting 1 - Edit Program In Store This causes a second level menu to be displayed, which provides for the editing of a ladder diagram and associated preset data, mnemonics and data comments. Selecting 4 Printing This causes a second level menu to be displayed, which provides for the printing of ladder programs and selected data tables. Selecting 5 Programmer Setup This causes a second level menu to be displayed, which is used for the display screen and printer setup. Selecting 6 EXIT If the ladder program has not been altered, the top level menu is displayed. If the ladder program has been changed then the message
Would you like to save the changes? press Y for yes, N for no.
is displayed: If Yes and the ladder program has been altered, then the contract details are displayed followed by:
Do you wish to edit?
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Type Y to edit or N to return to the menu. If YES, the contract text is edited. If NO then the user is given the option to save the file to a disk drive and workspace (directory). These can be changed if the file needs to be copied for some reason; however the file name and directory are normally kept the same. The links and ladder program need to have the same file and pathname for them to be compiled into a downloadable file (.DNL). Pressing Enter will then save the program, then return the user to the CSP top level menu. 4.4.4 LADDER EDITOR F1: Subsequent level Menus a) 2nd Level Menu - 1 Edit Program in Store
+ | + COMMENTS | | | | | +
+ | EDIT PROGRAM IN STORE + | 1 LADDER DIAGRAM AND RUNG | 3 MNEMONICS | 4 DATA COMMENTS | | R TO RETURN TO PREVIOUS MENU +
This menu leads to a set of facilities which are intended for altering the ladder program. Selecting 1 Ladder Diagram and Rung Comments This allows the user to enter or edit ladder diagram rungs and their associated rung comments. A list of commands is displayed showing the functions that are available to edit ladder diagrams. For further details, see section 4.4.5(a). Selecting 3 Mnemonics Displays a simple third level menu (Menu 1.3) as shown below:
+ + | MNEMONICS | + + | 1 Address Order | | 2 Mnemonics Order | + +
This allows the order of the mnemonics list to specified on entry into the Mnemonics Editor. Address order lists a set of data table addresses in alphabetical and numerical order, showing the associated mnemonic alongside. Example: G1 G2 H1 H2 STOPPB STARTPB ALARM2 ALARM1
Mnemonics order lists the mnemonics in alphabetical order, with the associated data table address alongside.
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Example: ALARM1 H2 ALARM2 H1 STARTPB G2 STOPPB G1 Selecting 1 or 2 determines the initial order of the mnemonics list, and leads into the display and editing of data table addresses and the mnemonic that can be associated with these. For further details, see section 4.4.5(b). Selecting 4 Data Comments This displays a simple third level menu (Menu 1.4) as shown below:
+ + | DATA COMMENTS | + + | 1 Address Order | | 2 Mnemonics Order | + +
After selecting 1 or 2 to determine the initial order of the data comment list, this leads into the display of address/mnemonic pairs and their associated data comments. These data comments can then be edited. For further details see section 4.4.5(c). b) 2nd Level Menu 4 Printing
+ | + | | | | | | | | | | | +
+ | SIGMA LADDER EDITOR + | PRINTING | | 1 LADDER DIAGRAM WITH COMMENTS | 3 MNEMONICS AND DATA COMMENTS IN ADDRESS ORDER | 4 ALPHABETICAL LIST OF MNEMONICS | | FOR A BATCH OF PRINTS ENTER B THEN A SEQUENCE OF THE | NUMBERS 1" 3" or 4" TERMINATED SPACE" | | | R TO RETURN TO PREVIOUS MENU +
All the print facilities provided under this menu apply to programs treated as ladder diagrams with and mnemonics, comments, etc. All the printing operations selectable from this menu are given a header, which includes the Company Title (described in section 4.4.5(i), Issue information and page numbering. Selecting 1 Ladder Diagram With Comments This provides a print of the complete ladder diagram with rung comments and output crossreferences. For further details, see section 4.4.5(d).
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Selecting 3 Mnemonics and Data Comments in Address Order This prints the complete mnemonics list with the associated data comments. For further details, see section 4.4.5(e) Selecting 4 Alphabetical List of Mnemonics This prints the complete mnemonics list with the associated addresses. For further details, see section 4.4.5 (f). Selecting B Batch Print This requests a batch of prints. For further details, see section 4.4.5(g). c) 2nd Level Menu 5 Programmer Setup
+ + | PROGRAMMER SETUP | + + | 1 SCREEN TYPE | | 3 PRINTER PARAMETERS | | | | R TO RETURN TO PREVIOUS MENU | + +
Selecting 1 Screen Type Sets the screen display type. See section 4.4.5(h). Selecting 2 Printer Parameters Sets the printer up for printing the ladder program. See section 4.4.5(i). 4.4.5 Options Available from Menus a) Option 1.1 Ladder Diagram with Rung Comments
This option allows the entry and editing of ladder diagram rungs. Notes: Selecting ? Displays the Help Menu. Selecting C Clear the store to start a new program. Delete all the ladder rungs, the preset data values, the comments and the mnemonics from the Projects Programmer store. Options marked with a * only become available when displaying rungs
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Selecting B Enter a new rung on the display. Sets up a blank rung after the currently displayed rung in the program, displays the blank rung and allows the user to edit it. After completing the edit, the rung can be inserted or discarded by pressing <ESC> for command level. *Selecting I Insert the displayed rung into the store. *Selecting D Delete the displayed rung from the store. A prompt is displayed to confirm this selection. *Selecting R Replace, in store, an old rung with its newly edited form. *Selecting A The Add Rung Comments function sets up an area of six lines of 50 characters, in which text can be typed to help identify the purpose of the rung. It can consist of any characters and is subsequently displayed with its associated rung. *Selecting E This invokes editing on the currently displayed rung. A rung is edited on a display which shows 10 cells horizontally by five cells vertically. The editor is intelligent and only displays the functions which are allowed at any given time, at the bottom of the screen. The cursor keys are used to move from one cell to another. The DELETE key is used to delete the function or its parameter from a given cell. All of the functions can be entered N/O, N/C contacts, BLOCK, etc. These are entered by means of the function keys on the PC keyboard. Note: Pressing [F9] changes N/O to N/C, [F8] changes N/C to N/O.
The parameters needed for some functions can be entered as, a signed decimal or hexadecimal number, a data table (bit or whole word) address or a mnemonic. The ? key causes a help screen for the editor to be displayed. The ESC key is used to exit the editor. After exiting the editor, the rung can be inserted as a new rung, or it can replace the unedited form of the current rung, or it can be discarded.
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Selecting S Search through the stored rungs for (i) (ii) (iii) (iv) An instruction number, A rung output instruction, COIL, OUT, SEQR, BLOCK, SET/RESET coil or JUMP, An address, A mnemonic.
Selection (ii) is made by typing the appropriate function key. Selections (i), (iii) and (iv) are made by typing the text of the address or mnemonic instruction. When a matching item is found, the rung containing the search string is displayed on the screen. The user is presented with the option of stopping at this rung or advancing to the next occurrence of the search string. Selecting F Displays the First rung of the ladder program. Selecting L Displays the Last rung of the ladder program. Selecting P Displays the Previous rung in the ladder program. Selecting N Displays the Next rung in the ladder program. Selecting T This Terminates Option 1.1 and returns to the previous menu. *Selecting K Invokes the marK/Copy/Delete function. Selecting ? Shows a help screen consisting of all the allowed commands for Options 1.1 and 2.1. b) Options 1.3.1 and 1.3.2 Data List in Address or Mnemonic Order
The third level menu for mnemonics allows the user to start with the displayed list in the desired order. The addresses are in one column with their associated mnemonics opposite. The functions which can be used in the mnemonics editing are shown below. Selecting . This changes the listing from alphabetical mnemonic to address order and vice versa. Page 4-16 Alspa GD4000 Issue (12-2-98)

Selecting A to Z The result of this function depends on the current order of the mnemonics list. ADDRESS ORDER Enter or change either mnemonic. A mnemonic is a 7-letter text identifier. This mnemonic can be given to a whole word address or to a single bit address. They can also be used to name nonstandard special functions. Although upper and lower case letters can be typed on the keyboard, all storage, display and printing of mnemonics is in upper case only. The first two characters must be letters, then the next five can either letters or numbers. MNEMONIC ORDER Enter or change address. Mnemonics are used to identify each variable (bit or word) in a ladder program. This function allows a given variable to be placed at a different data table addresses (ie all occurences of that mnemonic can be given a new address). Selecting @ This searches for an entered address or mnemonic and moves the editing cursor to the line holding it, if it can be found. Selecting Delete This removes the current mnemonic or address from the list. Selecting Moves to the first page of the list. Selecting / Moves to the last page of the list. Selecting cursor left Moves to the previous page in the list. Selecting cursor right Moves to the next page in the list. Selecting cursor up Moves the editing cursor to the line above. Selecting cursor down Moves the editing cursor to the line below. Selecting ESC Leaves the mnemonics editing and returns to Menu 2.
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c) Options 1.4.1 & 1.4.2 Data Comments
Data comments are two lines of 50 characters, which are used to provide a means of identifying the use of a particular mnemonic/address. They can be displayed in either address or mnemonic order. The screen shows a list of the mnemonics with their data comments opposite. The functions that can be used are shown below. Selecting . This changes the listing from alphabetical mnemonic to address order and vice versa. Selecting A This allows the editing of the data comment corresponding to the mnemonic/address on the current line. Selecting , /, and cursor keys These move to the first, last, previous and next line or page of the list. (as in Options 1.3.1 and 1.3.2) Selecting @ Searches for address or mnemonic and, if found, moves cursor to the appropriate line. Selecting T Terminates the Data Coments editor and returns to Menu 1. d) Option 4.1 Print Ladder Program with Comments
This option prints all the ladder rungs with mnemonics and rung comments. A list of cross references is provided with each rung, which gives a list of other instructions which use the same data table address as the OUT, COIL, SEQR of the rung above. This helps locate exactly where a particular output value is used within the program. Corresponding block begins and ends are identified with the same block numbers. e) Option 4.3 Print Mnemonics & Data comments in Address Order
This option prints a list of the mnemonics and their associated data comments in address order. It also gives a cross reference list below each address to show the instruction numbers which use the address. f) Option 4.4 Print Alphabetical List of Mnemonics
This prints only the mnemonics and their associated addresses, but with the mnemonics arranged in alphabetical order. g) Option 4.B Batch Print
Pressing B allows the user to request a batch of prints from the above options 4.1, 4.3, 4.4, by entering a sequence of the numbers 1 3 4 terminated by a SPACE. Page 4-18 Alspa GD4000 Issue (12-2-98)

h) Option 5.1 Screen Type
A selection of screen colours are provided, to provide attractive readable displays on screens of various different types, and to allow for user preference. The options are:
1 2 Yellow text on a blue background Blue text on a white background LCD display MONO display Recommended as the first choice for colour displays. Intended for colour displays where users prefer dark writing on a light background corresponding to conventional ink on paper. Intended for use with lap top portable computers. Intended for use with monochrome VDU displays.
3 4
i)
Option 5.3 Printer Parameters
There are the following six parameters which the printer uses. (i) (ii) (iii) (iv) (v) (vi) Local or Networked Printer port (LPT1 or LPT2) Width of paper (80 or 132 characters). Line terminator (CR, LF, CR-LF or CR-NULL-LF). Character set (ASCII or Extended IBM). Company Title (2 lines of 50 characters used in the header for each sheet of paper).
4.5
4.5.1
Links Editor F2
Description All links editing is carried out off-line in the PC. A full screen Links Editor is provided. This is selected by pressing F2 from the top level. The editor allows the adding, changing and deletion of links. On line syntax and address checking is provided. Comments can be added to the file. An existing file or a new file may be edited. The filename to be edited/saved is passed to the Editor by the top level program and the directory for the file can be specified by the Location of Program Files environment variable (see sections 4.4a) and 4.2.1). The file name may be changed when exiting the program if the program has been altered. (All links programs have an implied .GDM extension). After editing, the file is compiled and then downloaded to the SIGMA Controller.
4.5.2
Selecting File Name a) Edit Existing File
To edit an existing Links program file, it must be first selected using the option F7 Programmer Set Up, see section 4.10.1. Then go back to the top level and select F2 Links Editor. The first page of the Links program will then be displayed. b) New File
When CSP is first installed, entering the Links Editor without first using the Programmer Set Up, will automatically produce the option to initiate a new file.
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Once a file has been entered, when exiting CSP, this file will be logged and will be the next default. Then to initiate a new file, first use the F7 option - Programmer Set Up, and the enter a new file name as described in section 4.10.2. When initiating a new file, the following details will be asked, the line numbers in the table below, refer to the example display shown in Figure 4-3. NEW FILE - QUESTION Enter Drive Reference: Enter Issue Record: Enter Fast Task Number: Enter Languages (eg UK, FR etc): Symbol Table Required? Y/N: User download Required? Y/N: 4.5.3 Display The example program below is the first part of a links program for a drive system. The full program would be five to eight pages long. The first eleven lines are called the header, which forms an introduction to the links program which then follows. The header may have up to 17 lines depending upon the hardware fitted. Refer to section 3.3.1 the for full details of the header. The rest of the program is the links program which is described in Chapter 7. 7 8 DETAILS 16 Alpha-numeric characters, user defined. e.g. Rev1 16 Alpha-numeric characters, user defined. e.g. 01-12/3/93 Enter required number 2 4 See section 7.7.1
Figure 4-3 Editor Screen
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4.5.4 Portability A message file ED.MSG is provided which contains all screen messages, including errors and warnings, which may be used by the CSP Links Editor. This is a simple ASCII text file which may be edited to translate all messages into other languages. See section 4.11.9. 4.5.5 Editing Environment The main editing page is 24 lines x 80 columns. A cursor is moved around the screen using the cursor control keys (see section 4.5.6), and any alphanumeric keys pressed are inserted at the cursor. The cursor may not be moved past column 40 when editing the actual links as this area is reserved for link text obtained from the Firmware Database. The single status line (at the bottom of the page) displays any editing error messages else a default line showing the filename, Insert/Overtype status and the function keys allowed. An edited link is validated when the user attempts to move the cursor from the edited line. If the link contains errors, the cursor may not be moved from the line until all errors are corrected or the line is deleted. Link validation also includes fetching of scaling, units and text descriptions of any L tables, plus maximum and minimum bounding. 4.5.6 Editing Keys In addition to the standard alphanumeric and punctuation keys the following keys are used when editing (the Help page repeats some of this information): Function keys F1, F2, F3 F7 and F10: <F1> <F2> <F3> <F7> <F10> <Ctrl><F10> Help pages. Displays all commissioning edits in COMM mode (see section 4.10.7). Search for a link. Prints program to LPT1, LPT2, LPT3 or File - prompted Prompts to save program and exits Editor. Abort Links Editor without saving program.
All cursor movement keys are used to determine editing position on the screen: <Cursor Up> <Cursor Down> <Cursor Right> <Cursor Left> <Ctrl><Right> <Ctrl><Left> <Page Up> <Page Down> <Home> <End> Issue (12-2-98) Move up one line. Move down one line. Move right one character. Move left one character. Move right 5 characters. Move left 5 characters. Move up 24 lines. Move down 24 lines. Move to start of line. Move to end of line or last column allowed. Alspa GD4000 Page 4-21

<Delete> <BKSPC> <Ctrl><Home> <Ctrl><End> <Ctrl><BKSPC> <Insert> 4.5.7 Links Editing a) General Delete character under cursor or current blank line. Delete character to left of cursor. Move to start of file. Move to end of file. Delete current line Toggles between insert and overtype mode.
A list of the links entered for a particular drive is presented on the screen. This list can be paged up and down. The list is sorted according to the left hand side address (i.e. L2101 = L3921 comes before L3922 = L2102). The information is presented in the following format: L2106 = L2219 L Speed ref = Total speed Ref __ table description see section 4.5.7(a).
The addresses are entered by the user. If an address is incorrect (i.e. it does not exist or the user is trying to write to an output) then an error is indicated when the user attempts to move the cursor from the current line (see section 4.5.11 for error messages). The line may be deleted using <CTRL><BKSPC> to remove an error. b) Text Entry
For all tables (most commonly P and W tables), up to 16 characters of text may be input as follows (for example for the editing of text to keypad messages): P150 = RMS OVERLOAD Note: L
This instruction will fill 4, 32 bit, data locations. The next location allowed would be P154.
A table can be set to a single ASCII character value by putting the required character in single quotes: P154 = A This will set P154 to 65. c) d) F1 Help F2 Display Commissioning Edits
Pressing F2 when in the commissioning mode will display all the links with a commissioning edit( see section 4.5.10). e) F3 Search for a link
Pressing F3 invites the user to enter a table location which will be then searched for.
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f) F6 Update
Pressing F6 sorts the links and checks connections. 4.5.8 Print Program When in the links editor, the F7=Print option may be used, which produces an ASCII code suitable for a dot matrix printer. Pressing F7 gives the following options: Print to file [0] LPT1 [1] LPT2 [2] LPT3 [3] (ESC to Cancel)
Printing to file, produces a file with the same file name as the program file and with a .PRN extension. This file can then be used in for example a word processor. 4.5.9 Save Program If the links have been changed, pressing F10 will prompt the user to save the program. 4.5.10 Normal/Commissioning Program The SIGMA Controller can run in two modes of operation, the Normal mode and the Commissioning mode, these are selected from F7 Programmer Set Up. The Normal program is that program which normally runs in the SIGMA Controller, i.e. the normal user program. The Commissioning program is a method by which an experienced engineer can run a program with edits made that would not be allowed in the normal program, for example open loop tests, injection of signals etc. The status of the user program (whether Normal or Commissioning), is passed to the Editor and displayed on screen. When in Commissioning Mode, all links with the C attribute can be edited at password level 1 or above (password level 2 when in Normal Mode) and links with attribute * now become available for editing. Any links with the C attribute are stored to a .GDC file, instead of the .GDM file which will still contain the Normal Program. This allows easy switching between normal and commissioning programs. The file name stays the same. To run the commissioning program in the SIGMA CONTROLLER, compile and then download in commissioning mode. To revert to Normal program, compile then down load in Normal mode. To convert commissioning edits to normal edits, they must be re-entered while in Normal mode. see also section 4.10.7.
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4.5.11 Error Messages The following error messages may be produced by the Editor: 4.5.11.1 General Errors
Error 1 2 3 Message Illegal Filename Failed to open file Bad or Missing Database. Program can not continue. Any key to exit. Explanation may be zero length or contain invalid characters Either the disk is write protected or is full. Fatal Error. Could not find Firmware Database ARC.A in directory specified by the DBASE environment variable. Action Use legal filename. Remove write protect or create suficient space. The Firmware Database must be placed in the specified directory.
4 5 6 7 10 15
DBASE environment variable not set Invalid directory set by DBASE CSPROGS environment variable not set. Invalid directory set by CSPROGS Program out of memory. Press any key to exit Printer output error The program is to large for the the PC memory. Cannot access printer port.
Configure the editor using F7 set-up option
Upgrade PC memory. Check printer is connected and on line.
4.5.11.2
Editing Errors
Error 20 21 22 Message Invalid DEF type STARTHEADER may not be edited Invalid Fast Task The fast task specified is either not numeric or does not exist in the Firmware Database. The first part of this line may not be edited. At least one language must be specified. A valid language must be specified Only 15 languages may be specified. The first part of this line may not be edited. Symbol download option should be YES or NO. The first part of this line may not be edited. User program download option should be YES or NO. The first part of this line may not be edited. Edit a correct fast task number for given Firmware Database. Re-edit first part of line back to original text. Specify a language. Specify a correct language. Remove some of the languages. Default is 2. Re-edit first part of line. Edit first character after : to be Y or N. Re-edit first part of line. Edit first character after : to by Y or N. Re-edit first part of the line. Explanation A DEF type other than Table Action MODULE or HIST has been entered.
23 24 25 26 27 28 29 30 31
FAST TASK : may not be edited No Language Specified Bad Language : Too many languages LANGUAGES : may not be edited Invalid Symbol Option SYMBOLS : may not be edited Invalid Userprog Option USERPROG : may not be edited
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Error 33 34 Message Invalid start of link LHS L table write protected Explanation A link must start with an alphabetic character. The specified L table is an output and cannot be written to. Specified L table not found in the Firmware Database. LHS table is logic but the RHS L table is numeric. LHS table is numeric but the RHS L table is logic. Specified L table not found in the Firmware Database. A valid attribute was not found on the line. A link must have an equals sign between input and output. Link must start with an alphabetic character followed by numbers. Link must start with an alphabetic character followed by numbers. Too many commas or fields in DEF EXPANSION statement. Occurs if a link left hand has just been entered but already exists. It is not permitted to set bits of an L table (whether logic or numeric). New module in a DEF MODULE statement cannot overwrite existing module. Bad source module in DEF MODULE statement. Comma missing in a DEF statement. Bad or non-existent link. Minimum value in a DEF TABLE statement must be less than the maximum. Not allowed to use bits of an L table on the RHS of link. Cannot do this definition yet. Must have one! Action Put a correct character at start of link. Remove this link.
35 36 37 38 39 40
LHS is invalid L table RHS L table is not LOGIC RHS L table is not NUMERIC RHS is invalid L table Invalid Attribute Missing equals sign
Re-edit the LHS to be a correct table. Change either LHS or RHS to be consistent. Change either LHS or RHS to be consistent. Re-edit the RHS to be a correct table. Insert a correct attribute. Insert an equals sign.
41
LHS table invalid
Re-edit the LHS to be a correct table. Re-edit the RHS to be a correct table. Enter statement correctly.
42
RHS table invalid
43
Too many commas/fields
44
Duplicate links
User prompted to delete one link. Remove or edit the link.
45
Cannot set bits of L table
46
New module must be >70
Use a different module number. Correct source module number. Enter statement correctly. Re-edit to be a correct table. Make the minimum less than the maximum. Remove or edit the link.
47 48 49 50
Invalid source module Missing comma Invalid Link in DEF TABLE Minimum is greater than maximum Cannot use L table bits Invalid character being set DEF HIST not yet allowed No full stop in OIS definition
51 52 53 54
Remove this line. Put one in.
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Error 55 56 57 58 59 60 Message %s may not be edited Non numeric character in OIS definition Invalid .GDM file Corruption in .GDM file Unable to rename file Password level not sufficient to edit this line Invalid .GDC file LHS may not be edited in commissioning mode. Previous line restored Can only delete Commissioning edits Program limited to %d lines Maximum %d replacement Commissioning edits allowed No firmware reference in database Firmware reference incompatible (%s) File %s already exists [R]eplace [E]dit [C]ancel Cannot create a NEW programme in Commissioning mode DEF MODULE not yet allowed Two consecutive lines of comments not allowed Cannot have a comment before a links statement Too many lines in file Cannot delete old line deleting new one Explanation The specified part of the line should not be edited. Only numbers are allowed. The header was not found in the .GDM file. The actual and reported length of the files disagree. Cannot create .BAK file. Attribute of link does not allow editing at this password level. File with commissioning edits is invalid. Cannot change normal link LHSs in commissioning mode Only commissioning edits may be removed in commissioning mode. Too many program lines. Too many commissioning edits Action Put it back how it was. Put in numbers. Create a new .GDM file. Create a new .GDM file. Check disk access rights. Change the password level.
61 62
Delete the .GDC file. No action. The previous line is restored. No action. The previous line is restored. Remove some links. Remove some commissioning edits.
63
64 65 66 67 68 69
70 71 72 73 74
4.6
4.6.1
Compile Program F3
Description The Compiler is provided to combine the user programs (the .GLP ladder program the .GDM links program and the .GDC (commissioning edits file when in commissioning mode) with the Firmware Database, and convert them into a .DNL file which may be downloaded to the controller, see Figure 4-1. The compiler is selected by pressing F3 from the CSP Program Manager. The compiler performs the following steps to produce the output file:
Checks that the firmware reference in the .GDM file and the firmware reference in
the Firmware Database are the same.

A preset data table is produced to initialise data variables. This is determined with
the following precedence: Page 4-26 Alspa GD4000 Issue (12-2-98)

Links to constants (Links written to a user specified constant value), L table defaults
(default values) and zero values

Inserts the base system (fast task). Ladder program determines the main loop order. Links program variables are
brought into the user program as follows:

Any L table module link to link statement performed before its control module is
executed (as defined by special function call S140).

All remaining link to link statements (e.g. to fast task or non L table variables) are
performed in alphanumeric order at the end of the ladder scan.

A symbol table is produced during compilation containing limits, comments, write
protection, etc, for all tables used. Any table written to in the user program will be limited according to this symbol table. The code produced is written to an output file (.DNL), which may then be sent to the drive by the SIGMA Downloader, see section 4.7.1). A listing file (.LST) is also created containing all messages, warnings and errors produced during compilation. 4.6.2 Procedure Pressing F3 will initiate the compiling of the user program, producing the display below.
Figure 4-4 Compiler Screen
The Compiler display is a pop-up window which displays messages, errors, warnings, etc as the program is being compiled. The previous screen data is restored on exit.
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The following data is displayed on each line of the display: Line No. 2 3 The filename being read or written. A general message line displaying the current status of the Compiler. The latest warning and error message is also written here as well as in the List file, see section 4.9.1. A count of the number of warnings that have occurred. Each warning message is written to the list file, see section 4.9.1 A count of the number of errors that have occurred. Each error message is written to the list file, see section 4.9.1 A continuous indication of remaining PC memory which may indicate whether the user programs are becoming too large for the PC memory configuration, i.e. the memory available will eventually decrease to zero as the program size increases. This can be overcome by increasing PC memory or decreasing user program size or electing not to down load symbols (* see below). Displays the Ctrl-Break to quit message. On completion states whether there were errors, warning or a successful compilation and prompts the user to press F10 to exit. If symbols are not downloaded, the comments are not displayed when monitoring.
5 6 8
*Note:
At any stage during compilation, the user may abort the program by pressing <CTRL><BREAK>. The output file will be deleted and a message will be inserted in the list file. 4.6.3 Portability A message file COMPILER.MSG is provided which contains all screen messages, including errors and warning, which may be produced by the Compiler. This is a simple ASCII text file which may be edited to translate all messages into other languages, see section a)b). A count of the number of warnings that have occurred. Each warning message is written to the list file, see section 4.11.9. 4.6.4 Ladder Instructions The ladder program instructions that are compatible with the compiler, are listed in section 12.1. A count of the number of warnings that have occurred. Each warning message is written to the list file, see section 4.9.1. 4.6.5 Compiler Error Messages The %s symbol is used in the messages below to indicate text strings that will be inserted by the Compiler.
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4.6.5.1 Internal Errors Any occurrences of internal errors should be reported to the design authority quoting the firmware reference and the version of CEGELEC SIGMA Programmer being used.
Error 5 14 24 Message Invalid opcode %s in ladder No template for function ox%x System Error:%s Explanation A ladder instruction has an undefined opcode. Template for opcode is not in the template file. Internal system error. } } See Above } Action
4.6.5.2
General Errors
Error 3 Message Out of memory Explanation Run out of system memory*. The .GDM file is missing. Action A larger memory PC or smaller user program is needed. Ensure the input files exist in the directories specified by the configuration menu (F7 from the CSP Program Manager). None. Either disk is full or write protected. Get a valid .GDM file. Get a valid .GDC file
18
Links file required
19 20 33 34 35
User break in compilation Unable to create output file Links File Invalid Commissioning edits file invalid Disk full or write protected
The user has pressed Ctrl-Break. Could not open the .DNL file. .GDM file header not found. .GDC file header not found
*Notes:
Long programs may need additional memory to complete the compilation. In this case it will be advantageous to compile the program under the Windows 3.x, Windows 95 or OS/2 environment, to make full use of extended memory in the PC.
4.6.5.3
Firmware Database Errors

Error 1 4 Message Invalid archive file Database not found Explanation Firmware Database file is incorrect format. Failed to open Firmware Database. Action As error 15 below. Ensure Firmware Database is in directory specified by DBASE environment variable.
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Error 15 16 21 23 26 32 37 39 Message File is NOT a COFF file. Base system NOT found in database File not found within database Module header section missing No data area start for module %u %s section not found in database Database V table incompatible with compiler No Firmware Reference in database Database invalid Update Explanation The firmware database is not compatible with the current version of the compiler. Action Install the correct Firmware database.
4.6.5.4
Ladder and Links Program Errors

Error 6 7 Message Incomplete ladder rung found Mismatch in no. of block start/ends Instruction missing VALUE Explanation Incomplete ladder rung. Not enough end of blocks in ladder program. A VALUE statement is required by a ladder instruction. A VALUE statement referencing a table is required. A Control module call (S140) was made to a non L table. Given table reference invalid. An end of block was found before a start of block. Block level is greater than maximum allowed. The slow module requested does not exist. A ladder instruction requires an immediate value Bits of L tables may not be set. Attempt to write to a write protected table. The label referenced by a jump statement was not found in ladder. Action Complete specified ladder rung. Correct the block level structure in the ladder program. Insert a VALUE statement where specified. Insert a table in the VALUE statement. Correct or delete the S140 call. Correct or delete the table reference. Correct the block level structure in the ladder program. Remove some levels of blocking. Correct or delete the slow module call. not a table.
Invalid reference in VALUE statement Control Task call NOT an L table Table reference %s invalid End of Block before Start of Block Block nesting level too deep Control Task %u not found Instruction needs immediate VALUE Unable to set bit in reference %s Table %s is write protected Jump statement missing label %u
10
11 13
17 22 27
28 29 30
Correct or delete specified table ref. Correct or delete output to this table. Either insert label or remove jump statement.
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Error 31 Message Unknown Special Function Explanation No code for given special function was found in database. References were found to basic inputs and basic outputs in the same byte (e.g. A1.1 and B1.4) Cross checks database with compiler Action Cannot use this special function. Remove one of these references.
36
Basic I/O clash in %s byte of A%d/B%d
38
Firmware Ref incompatible with links file.
Ensure latest program software loaded
4.6.5.5
Initialisation Errors Initialisation errors occur before the message file has been read in and hence are not numbered and cannot be translated into other languages.
Message Invalid number of parameters Invalid prefix Unable to open message file Explanation Only the filename prefix should be passed. Prefix should not contain a DOS wild-card or a . . Could not find message file Ensure .MSG file is in the same directory as SIGMAGPP.EXE. Syntax Error Syntax error within message file. Check syntax of .MSG file or reinstall it. Action Pass one argument only. Pass argument correctly.
4.6.6
Warning Messages
Error 1 Message Preset data in ladder file ignored Control Task call corrected Explanation Preset data found in .GLP file but will not be used. An S140 call was not to a modulo 100. It was assumed to be. Failed to open the .GLP file. Action Remove all writing to P tables in the .GLP preset data table. Make the call modulo 100 (ie L2100 not L2133). Ensure .GLP file is in the directory pointed to by the CSPROGS environment variable. Ensure .GDM file is in the directory pointed to by the CSPROGS environment variable. Drive is full or write protected. Define a fast task number in the .GDM file if required. Install the correct firmware database. No languages were defined so no comments will be copied. Delete it for clarity.
Ladder file not found
Links file not found
Failed to open the .GDM file.
6 7 8 9
Unable to create .LST file Fast task is un-defined No symbols found in COFF file No languages defined
Error in opening the .LST file. No fast task was defined. Incompatible firmaware database. defaults used
11
Superfluous VALUE statement No commissioning edits file
Value statement found where not needed in a rung. In commissioning mode but no COMM edits.
12
Normal links program will be used.
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Error 13 14 15 Message CSP.DAT file not found. Default passwords set Test version. Only partial symbol table. The %s environment variable points to an invalid drive Explanation Data file not found. Report to CEGELEC Action
4.6.7
Timing The compilation time depends more upon the number of symbols stored than the number of instructions in the user program. Typical times on a 16Mhz 386 PC are as follows (comparing number of instructions and number of symbols): Instructions 5 5 3100 3100 Symbols 1430 250 1430 250 Approx compilation time 8 seconds 2 seconds 15 seconds 9 seconds
4.7
4.7.1
Download Program F4
Description The function of the DownLoader is to pass the output of the compiler to the SIGMA Controller as quickly and efficiently as possible. It is selected from the top level by pressing F4. The DownLoader communicates with the controller via a serial link using the ESP protocol. Before the downloader can be used the serial link must be configured configured (ie press [F7] and set the baud rate and tributary address to match the drive). When the DownLoader sends a message to the controller, the resident message handler returns the relevant reply. A number of checks are performed by interrogating the controller for information. If there are problems during the download, the user is given warning or error messages. The following checks are made:
Before communication with the controller begins, check that compilation has
occurred since last links/ladder editing, using the creation date of the files.
Check that the controller responds and a download is possible, although the
DownLoader may be passed a baud rate, if it cannot connect at that speed it tries other speeds.
Get the status of the drive. If it is not halted, halt if user wishes and hardware
permissives (A32.7) is low else abort the download.

Ensure the system has enough memory for file to be downloaded. Check for a valid base system. If base system valid, download only those parts of the system that have changed. If base system not valid, download whole system. During the download return messages from the SIGMA Controller indicating its
status (e.g. Halted, Watchdog Tripped, etc).
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4.7.2 Procedure Press F4 to download the user program.
Figure 4-5 Downloader Screen
The DownLoader display is a pop-up window which displays warnings and messages while the download is in progress. The previous screen data is restored on exit. The following data is displayed on each line of the display: Line No. 2 3 The name of the file that is being downloaded. The percentage of the whole download file that has been transferred. If only a partial download was necessary then this can be done very quickly. Messages from the SIGMA indicating status. The latest warning message. A count of the number of warnings that have occurred. Each warning message is written to the list file. Any premature termination messages. Prompt messages for user input.
4 5 6 8 9 4.7.3
Portability A message file DOWNLOAD.MSG is provided which contains all screen messages, including errors, warning and information messages, which may be produced by the DownLoader. This is a simple ASCII text file which may be edited to translate all messages into other languages. Refer to section 4.11.9.
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4.7.4 4.7.4.1 Downloader Messages Downloader Error Messages Error messages will result in the termination of download and the SIGMA system will not be valid.
Error 1 Message Download terminated due to transmission error Explanation Could not connect to SIGMA controller. Action Check serial link connected and configured correctly and that the SIGMA Controller is energised.
ESP message not understood (other source has control) Download terminated by user %s does not exist User has pressed Ctrl-Break. Could not find the .DNL file. None. Check CSPROGS environment variable is correct or compilation was successful. Check Compiler and DownLoader are compatible.
3 4
Unidentified COFF file
Error in .DNL file.
Out of memory,Not enough memory in the PC.
Upgrade the PC memory
4.7.4.2
Warning Messages A warning message does not terminate download and downloading will continue.
Error 1 2 3 5 Message Unable to create text output file Program running, it must be halted Section name not recognised Unable to access %s Downloader can not find ladder or links files on the disk. The .gdm or .glp file have been edited but the system has not been compiled. f %s=Links or Ladder, only a warning. If %s = anything else Download attempted while drive running. Explanation Action Check disk write enable. User prompted to halt drive or abort. Report to CEGELEC No user action
%s.DNL is out of date with %s file No %s section in file
Compile the program.
Check compiler and downloader are compatible.
8 9
Program wouldnt halt Cant download new Base System
Note:
%s will be replaced with text, e.g. a filename.
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4.7.5 Input and Output Files The following files are read by the DownLoader: DOWNLOAD.MSG contains all messages for DownLoader, USERPROG.GDM links program, USERPROG.GLP ladder program, USERPROG.DNL download file. USERPROG.GDC commissioning link program. The creation date of the links (.GDM), the commissioning (.GDC) and the ladder (.GLP) files are read and compared to the creation date of the compiled (.DNL) file to make sure that an edit has not been performed without a re-compile. The DownLoader adds to the list file (.LST) (see section 4.9.1) created by the compiler or if it does not exist it creates its own. All messages produced during download are written to this file.
4.8
4.8.1
Monitor F5
Description The Drives Monitor is used to monitor and edit the drives data tables. Up to 40 variables can be displayed in two columns. The variables text description is also displayed if available. Where applicable, the value is displayed with the appropriate scaling. The drive can also be halted, single cycled and the inputs switched between test and normal mode.
4.8.2
Display Pressing F5 will produce the display shown below. Initially the Parameter settings (Baud rate: Port: Trib no.) will be displayed across the screen, but pressing any key will remove this information.
Figure 4-6 Monitor Screen
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F2 toggles the menu bar:
<F1> HELP <F2> EDIT <F3> HALT <F4> <F5> TEST <F10> EXIT
Control Mode
Screen n/s
<F1> HELP <F2> CTRL <F3> <F4> <F5> BASE NEW SCR <F10> EXIT
Control Mode
Note:
<F3><F4> and <F5> are status dependent when in Control Mode
In the above example, the top line is the status line which displays the information (alternatives given in the line below):
Firmware Reference Run Halt Normal Inputs Test inputs Trip Report -
4.8.3
Monitor/Edit Environment The users screen is split into three areas,(See diagram of screen in section Figure 4-6 Monitor Screen). a) Top Line, Controller Status
This displays:
The firmware reference of the drive being monitored. This description is generated
by the controller.
Running or Halted status (this refers to the scanning of the program, not the actual
drive).
Test/Normal inputs (this refers to I/O scanning). Normal/Commissioning Program. Fault Display, if there is a base system fault or the fault display module (Module 32)
is called. This information is requested from the controller, and is updated every 5 seconds. If the programmer to controller link fails, the message link failure is displayed on the top line. b) The main display screen
See also section 4.8.7 and 4.8.8 for details on entering addresses and changing data. Addresses and data are entered when the system is in edit mode (selected by function key F2). The area where information is entered is highlighted. This highlighted area can be moved around the screen using the cursor control keys. The highlighted area sits over the addresses area if a line is blank. The value area is selected if a variable is already displayed. Variables are written to by typing in the new value when the value field is highlighted.
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Data entry can be aborted by pressing <ESC>, or accepted by pressing one of the arrow keys, <RETURN> or <SPACE>. Lines can be deleted by pressing the <DEL> key, or inserted by pressing the <INSERT> key. New lines can be entered anywhere on the 5 screens. c) The Function key line - Bottom Line
The mode of operation (either edit or control) is shown in the bottom left hand corner. The action of each function key is also shown. The operation of the function keys depends on the current operation. The F2 key toggles between two functions as shown in the display in section 4.8.2 and described in section 4.8.4 and 4.8.5. Where the action required can have serious consequences (e.g. Halting controller, clearing screen) a confirm box is shown which requires the user to either confirm or cancel the action. A file named [filename].MON (where [filename] is the name of the user page), stored in the same directory as the .GDM and .GLP files, contains information about the screen variables selected during the last monitor/edit session. These variables are displayed when the link to the controller is established. 4.8.4 User Keys Cursor Control: Arrow Keys:Move cursor around display screen in edit mode. <HOME> Move cursor to top LH entry in display. Data Entry: <RETURN> Accept entry <SPACE> <ESC> Abort entry <Cursor keys> Accept entry 4.8.5 Function Key Details
<F1> HELP Pressing this key displays help information on the current mode where available <F2> CTRL/EDIT This toggles the display between the edit mode and the CONTROL mode. The default (start up) mode is the CONTROL mode. <F3> HALT/BASE In the CONTROL mode: If the drive is running, HALT the controller (prompts the Confirm box). In the EDIT mode:
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CHANGE the number base. Variables can be displayed in DECIMAL, HEX or BINARY or ASCII character set (see section 4.8.6). <F4> RUN/CLEAR SCREEN In the CONTROL mode: If the controller running : No action. If controller halted : RUN controller. In the EDIT mode :CLEAR the screen <F5> TEST/NORMAL (see section 7.9.5) In CONTROL mode: Toggles the controller between the TEST and the NORMAL INPUTS. If the controller is running: The user is prompted to confirm that the controller can be halted to change mode. If the user accepts, the controller is halted and the mode is changed. If controller halted: The mode is changed.
<F10> EXIT Exit from the monitoring package. The variables displayed on the screen are saved to disk. 4.8.6 Variable Display Numbers are displayed in the following formats. Pressing F3 (BASE) will toggle the available formats. DECIMAL: HEX: BINARY: ASCII: Lxxxx Lxxxx Lxxxx Lxxxx text description=+xxxxx.xx units text description=@xxxxxxxx units .....111....111....1111....111.1 text description= E
The initial number base is determined from the variable attribute information obtained from the controller. If no attribute information is available, the number base defaults to decimal. ASCII letters only use the first eight bits of data. Logic variables are displayed as a 1 or a 0. The variable attribute contains a field defining whether the variable is logic or non logic. Bit addresses are displayed as logics. 4.8.7 Address Entry See section 4.8.8 for information on editing defaults. TO ENTER A NEW ADDRESS
Enter EDIT mode <F2> Place the cursor on a blank line <cursor keys> Enter a data table address.
Data tables addresses up to 99999 can be entered. This allows SIGMA modules up to 999 to be used. Note that if compatibility with previous GEMDRIVE-MICRO 1 (GDM) and GEM80 products is to be maintained, the address should be in the range 0 to 65535.
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Bit addressing can be given (e.g. G1.1 selects bit 1 of address 1). The field-width of the variable is determined by a fieldwidth attribute. GDM1 and GEM80 data tables default to 16 bits wide. SIGMA data tables default to 32 bits wide. If the bit number is greater than the permitted bit width then the bit number is limited to the maximum bit width available. The display formatting allows for 32 bit BINARY values to be displayed.
If the table exists, the data for that table is displayed. The format may be changed
by pressing F3 as indicated in section 4.8.6. TO ENTER THE NEXT ADDRESS IN A SEQUENCE

Place the cursor on the blank line after the required address Press the / key to enter the next address,(single entry).
or Press the @ to select up to the next 8 entries. The number of sequential entries that will be selected depends on the number of blank lines available and the number of tables remaining in the software module/user program. TO DELETE AN ADDRESS
Position the cursor over the data table and press <DELETE>. Note that any
subsequent data tables are NOT shuffled up to fill the gap. TO DELETE A BLANK LINE
Place the cursor over a blank line and press <DELETE>. All variables below are
shuffled up. TO INSERT A LINE

Place the cursor over the line that is going to be after the newly inserted line. Press <INSERT>
4.8.8
Editing Variables The editing functions are as follows: To Change A Variable

Place the cursor over the value to be edited. Enter the new value. The old value is displayed in place of the text description
e.g. Line before editing: L2102 Test Input = +0.01 % Line while entering value: L2102 was +0.01 is = % The new value can be entered in Hexadecimal (prefixed with an @) or decimal. Decimal numbers can be entered either in normal format (1000.00) or in exponent format (1E3). Numbers are entered in real units (i.e. the decimal point can be used). ASCII letters can be entered by preceding the letter with an apostrophe (e.g. L). Issue (12-2-98) Alspa GD4000 Page 4-39

Press <RETURN> or a cursor control key or [SPACE] when complete or <ESC> to
abort. If the number has been entered incorrectly the old number is re-displayed. If the number is outside the limits for the relevant data table, the number is limited. If the table is read only, the old number is displayed. Note: All data values displayed are updated after a new value has been entered. This may affect keystroke response depending on the number of variables displayed.
To Change the Number Base The value displayed can be shown in either DECIMAL, HEXADECIMAL or BINARY or ASCII letter format. Use the F3 function key in monitor mode to select the required format. (See section 4.8.6). To Change a Text Entry Text entry is peformed in the Links Editor only (see section 4.5.7 b). 4.8.9 SIGMA Attributes used by Monitor The following SIGMA atribtes are used by the monitor prgram: Comment Field (16 chars) units field (5 chars) or units index Write permissive scaling logic field access permissive level; 4.8.9.1 Controller Dependant Actions Information is obtained from the controller as to its type. Aspects of the Monitor that are affected are:
Controller GEM80 SIGMA Field Width 16 bits attribute Data Attributes None. Defaults to read/write Comments, units, scaling, write protection, display as (DEC, HEX, TEXT), field width.
4.8.10
Error Messages Error messages come from two sources:

From the controller / serial link - displayed on the top line of the screen. From the monitor program - displayed at the bottom of the screen, as shown the
table below:
Message Illegal Table Table read only Meaning Address specified not present in the controller. Cannot change table Program action Line is blanked. Old value restored
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4.9
4.9.1
List File Viewing Utility F6

Description This List File Viewing utility allows viewing of the .LST file produced by the Compiler and DownLoader. This is accessible from the top level menu.
4.9.2
Display 24 lines of the list file will be displayed at a time, plus a status/instruction line. Any blank lines will be ignored. An example is shown below.
A message will be displayed if the specified list file does not exist. The following keys are allowed: Use the UP and DOWN cursor keys to scrol through the list. Press <F10> to exit the List File Viewer and return to the CSP Program Manager.
4.10
4.10.1
Programmer Set Up F7
Introduction The Programmer Set Up option, F7, serves two functions: (i) sets up the CSP program, passwords, serial link connections etc. (ii) selects the required links program file (.GDM) and the ladder program file (.GLP) by selecting the drive filename. The screen displayed when <F7> is selected from the top menu is shown below. Note: The particular directories will change from application to application.
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4.10.2 Drive Filename Selection This option allows the selection of the required program. Once selected, the program may be edited in the links and ladder editors.
Figure 4-7 Programmer Setup
To select a file:
Highlight the Drive Filename Selection, using the cursor keys. Press <RETURN> The file selection screen (Figure 4-8) is displayed.
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Figure 4-8 File Selection
Use the cursor keys to select the required file name, then press <RETURN>. The files displayed will be the ones in the directory selected for Location of Program Files as described below. To create a new Links file:
Press <F9> (New File). Type the new file name.
When the links editor is selected <F2> from the top level menu the new header data is requested -see section 7.7.1.1. 4.10.3 4.10.3.1 Environment Variables Location of Program Files: This is the directory for the Links and Ladder program files. The default is C:\SIGMA\PROGS\ 4.10.3.2 Location of Database: This is the directory for the Database. It is recommended that this should be C:\SIGMA\GDSXXXX\YYYY\ , where GDSXXXX\YYYY is the complete reference of the firmware, e.g. GDS1019-4001C. The default directory is DATABASE. Highlight the required entry using the cursor keys and edit as required. 4.10.4 Current Database This line automatically displays the current database.
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4.10.5 Serial Link This option allows the selection of: COM Port (the PCs communication port to the drive). Baud Rate Tributary Address Where the baud rate and tributary address must match the customer I/O pcb settings see section 5.1 4.10.6 Colour Selection Menu This option allows the selection of: Colour Screen, Yellow on Blue. Monochrome Screen. 4.10.7 Drive Mode Selection This allows the cursor key selection of: Normal Mode Commissioning Mode 4.10.8 Password Selection The pop-up window below allows for the selection of the required access level.
Figure 4-9 Password Selection

?
Use the cursor keys to select the required access level, type in the four digit password number and if correct the required level of access will be granted. A Password must be a four character string of numeric characters. When CSP is started the lowest password level is assumed. To upgrade to a new level, the appropriate password must be entered. To change a password, the old password must be entered followed by the new password entered twice. Page 4-44 Alspa GD4000 Issue (12-2-98)

The default passwords are : level 0 = 0000 level 1 = 1111 level 2 = 2222 level 3 = 3333 The four levels of password are encrypted and stored in the set-up file. These can also be extracted by the compiler and passed to the SIGMA controller. The level of password is passed to the Links Editor and the Monitor. The SIGMA controller always assumes the lowest password level after a download of code. The relationship between the password and the editing of links is shown in section 4.3.2 4.10.9 Programmer Set-up The Programmer Set-Up option is used to set the PC dependant parameters and user options:
Global filename for the ladder (.GLP), links (.GDM) and output (.DNL) files. Directories where these files are located. The following environment variables are set
to tell the Editor, Compiler and DownLoader the location of the files: CSPROGS The directory where the user program (both links and ladder), Compiler output file and the list file are found. e.g. SET CSPROGS=c:\SIGMA\PROGS . This is used by the Editors, Compiler and downloader. DBASE The directory where the Firmware Database is located, e.g. SET DBASE=c:\SIGMA\DATABASE1A. This is used by the Editor and Compiler.
Password level for editing (see section 4.5.7c and 4.10.8), Normal or Commissioning mode (section 4.10.7), Screen colour configuration (section 4.10.6), The PC Serial link configuration (4.10.5).
The set-up information is saved to the hard drive, to file CSP.DAT on exit. This file is re-loaded on start up. IF CSP.DAT is not found on start-up the configuration data is returned to the default settings.
4.11
4.11.1
PC Based Interactive Files

Firmware Database (ARC.A) The Firmware Database is a common archive file that is produced by the system generation. It contains: the base system, all fast tasks, all control modules, L table, etc, units and scaling information, all special functions, a firmware reference number.
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This is accessed by the Ladder Editor and Compiler. These need the following information: Ladder Editor Header information to check validity of data tables, to check limits and add scaling, units and text comments and to check the validity of the firmware reference. obtains fast task and modules specified by user programs. uses header data for all modules used to compile link descriptors,
Compiler
4.11.2
Links Program (.GDM) The text based output of the Links Editor which contains header information, DEFine statements plus links, attributes and text comments.
4.11.3
Commissioning Program (.GDC) As .GDM above, but contains only edits made while in commissioning mode (* attribute).
4.11.4
Ladder Program (.GLP) The output of the ladder editor, for use by Compiler.
4.11.5
Compiler Output File (.DNL) File output by Compiler containing the compiled base system, fast task and user programme.
4.11.6
List File (.LST) The list file written to by both the Compiler and DownLoader: See example below.
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Figure 4-10 List File Example
4.11.7
Set Up File (CSP.DAT) The set-up file is an encrypted file containing each item of set up data including password levels.
4.11.8
Printer (Links) File (.PRN) A .PRN file is produced by the print to file option as described in section 4.5.8.
4.11.9
Message Files (.MSG) A message file exists, specifically written for each part of CSP. These are read in on program start up and used to display all messages in whatever language they are written. The files have a standard file format: AB0000: This is a message AB0001: and so is this In this line the following letters have significance: 1st Character C D E G L M Message for 2nd Character Compiler E DownLoader W Editor G CSP List File Viewer Monitor Type of message Error Warning General
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e.g. CE006: Incomplete ladder rung found G007: SIGMA Links Editor v
The messages may contain %s, %d, %u, statements which will be filled in by the Compiler. These should NOT be edited or removed. Comments are written in this file by starting a line with a *. All other lines are ignored.
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5. Serial Communications
Serial Communications
5.1 Introduction
Three main serial links (links 0, 1 and 2) are provided via the communications processor on the SIGMA Core Board. A further serial link (link 3) is provided to the optional Enhanced Keypad. Link 0 is used for programming and monitoring, and is usually configured as a Tributary using SW1 on the Customer I/O board to define its trib address and baud rate. However link 0 can be configured as a general purpose communications port or as a MASTER to one tributary using the CONFIG special function if SWl/l is ON. Link 1 can be used as a general purpose communication port, providing ESP table exchange, programming and printer facilities. Typically, Link 1 is configured as a slave (tributary) with a host PLC acting as master. Link 1 can also act as an ESP master (control) to up to 4 tributaries, with baud rates up to 76.8k. Link 2 can be used as a general communication port (point to point only), providing ESP table exchange, programming, and printer facilities. Typically link 2 is configured as a slave for monitoring purposes, or as a slave (tributary) with a host PLC acting as master. Link 2 can also act as an ESP master (control) to one tributary with baud rates upto 19,200. Link 3 can be used in slave mode only, and is used for communication with the enhanced keypad. However, it can be used to download the user program on power-up at a baud rate of 38,400. Note: The configuration of the serial links depends on whether a firmware database is stored or not. The following definitions will be used in the following sections:
No system loaded. - There is no system loaded if the SIGMA has been powered up
for the first time, or if the SIGMA has been powered up after the batteries have been removed to clear out the contents of battery maintained RAM.
System loaded. - There is a system loaded into battery maintained RAM following a
program download. The SIGMA needs a system loaded in order to operate as a drive. If a system is loaded, then serial links 1, 2, and 3 (and link 0 if SW1/1 is ON) are configured using the CONFIG (T33) special function (see also section 12.2.25). If no system is loaded, or if no CONFIG special functions are invoked, then the serial links take the default settings outlined in the following sections. Further links may be provided using the HDLC and/or FIP enhancement cards. These links are documented separately. Figure 5-1 shows a typical arrangement using the serial links.
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Page 5-1
Figure 5-1 GD4000 serial links
5.1.1 5.1.1.1
Serial Link 0 Features Point to point or multidrop link providing:

Fully Isolated RS485 or RS232 interface ESP protocol or MODBUS for communications and programming Baud rates are set by coding switches on Customer I/O board or by using the
CONFIG special function (see later). The following baud rates can be usd: 1200, 2400, 4800, 9600, 19200, 38400, 57200, 76800
Defaults to tributary with baud rate and tributary address as defined by the coding
switches on the Customer I/O Board. 5.1.1.2 Interface

ESP table exchange - J/K tables. Max of 100 (J0-J99;K0-K99) See section 5.5 for
details on the operation of an ESP link.

MODBUS RTU or MODBUS ASCII (slave mode only), see section 5.6, for further
details. 5.1.2 Configuration. No System loaded Configuration as defined on coding switches SW1 on the customer I/O board (see section 8.7.3.3).as given in the following tables.
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5.1.2.1 Baud rate Set by Digital inputs A0.12-A0.14 (DIL switches SW1 positions 2, 3, 4 on Customer I/O Board see section 8, Figure 8-9) as shown in the table below: SW1/2 off off off off on on on on *Note: 5.1.2.2 SW1/3 off off on on off off on on SW1/4 off on off on off on off on Baud rate default to fastest download 57200 2400* 4800* 9600 19200 38400 76800
The baud rate 38400 defaults to 38400 is no system is loaded.
Tributary address Set by Digital inputs A0.8 - A0.11 (DIL switch SW2, positions 5, 6, 7, 8 on the Customer I/O board see section 8, Figure 8-9) as shown in the table below: Address Reserved Do not use 1 2 3 4 5 6 7 8 9 10 11 12 13 14 0 System loaded. Link 0 on the Customer I/O board can be used in two ways when using firmware databases 00S060-4003A (GD4000) or 00S069-4001 (MICRO 3). i) The configuration determined by defaults and switch setting SW1/1 = 0. Link 0 defaults to an ESP tributary, with the baud rate as given in the table, and the tributary number determined in the same way as for a new firmware database. Alspa GD4000 Technical Manual Page 5-3 SW1/5 off off off off off off off off on on on on on on on on SW1/6 off off off off on on on on off off off off on on on on SW1/7 off off on on off off on on off off on on off off on on SW1/8 off on off on off on off on off on off on off on off on
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ii) Configuration via CONFIG special function Set SW1/1 = 1 The configuration of the link defaults to an ESP tributary, with baud rate as given in the table below, and tributary determined in the same way as for a new system. However, the link can be reconfigured using the CONFIG special function. Configuration of Link 0 using the CONFIG special function is as follows: (a) link address: 0 = control 1 to 14 = tributary. 1 to 255 for MODBUS (b) Number of tributaries on link: control or tributary: 0 = point to point link (ie no tri-state control) control multi-drop 1. slave multi-drop 1 (c) Port type (baud rate 1 to 7) (d) parity and data bits: 1 = 8 bits no parity 2 = 8 bits EVEN parity 3 = 8 bits ODD parity 4 = 7 bits EVEN parity 5 = 7 bits ODD parity 6 = 7 bits parity SET 7 = 7 bits parity RESET (e) If printer port number of characters/second (100 to 1000, default 100) (f) port type: 0 = not in use -1 = ESP -2 = Printer port -3 = MODBUS ASCII -4 = MODBUS RTU -5 = link echo-back test (future) See information on CONFIG special function T33 to determine where these values are placed in the CONFIG parameter list (see section 12.2.25). Note: Link 0 can only be a Master to a single tributary.
If SW1/2 to /4 are changed subsequent to SW1/1=1, the configuration will revert to the switch settings, i.e. the last setting takes precedence Note: It is possible to lock out the user by (for example) configuring link 0 as an ESP master. This would mean it could no longer be used for programming. For this reason care must be taken to ensure that at least one of the serial links 0-3 is available for programming.
Fault diagnostics Serial link statistics recorded in table F50-F59. See section 5.6.3 for details
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Connections Serial Link 0 port can be connected either:
as an RS232 port for direct connection to a PC via SK4 (9-way D-type connector) on
the Customer I/O Board. or

as an RS485 port through TB7B on the Customer I/O board. See Section 8 Figure
8-10 for details. Termination resistors are selected with SW3 DIL switch on the Customer I/O Board. The RS485 input for Link 0 is selected by fitting a link between TB7B/1 and TB7B/2. If the link between TB7B/1 and TB7B/2 is not fitted then the RS232 link through SK4 is selected.
5.2
5.2.1
Serial Link 1
Features Point to point or multidrop link providing: - fully isolated RS485 interface - ESP protocol and MODBUS RTU or MODBUS ASCII for communications. - Baud rates: 1200, 2400, 4800, 9600, 19.2k, 38.4k, 57.2k and 76.8k. - Can be configured as communications port (table exchange or programming) - Control port (Master) with up to 4 tributaries (Slave) or tributary port - When configured as a programming tributary, port can have addresses 0-15 15 is a special case for tributary 0).
5.2.2
Interface. a) ESP Table exchange - J/K tables. Max of 100. See section 5.5 for further details on the operation of an ESP port b) MODBUS RTU or ASCII. See section 5.6 for details.
5.2.3
Configuration No System Loaded defaults to ESP tributary, address 1, Baud rate 38,400. System Loaded Configured via the CONFIG Special Function T33 (see section 12.2.25).) and following the information provided for Link 0 configuration in section 5.1.2.2, or defaults to Not In Use if CONFIG Special Function is not invoked.
5.2.4
Fault diagnostics Serial link statistics are recorded in table F60 to F99. See section 5.6.3 for details.
5.2.5
Connections Serial link 1 (RS485) is connected via TB7A on Customer I/O Board. Termination resistors are selected using SW3 the on the Customer I/O Board (see Section 8 Figure 8-10).
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Page 5-5
5.3
5.3.1
Serial Link 2
Features Single point to point link providing:
Full RS232C interface (isolated). 1200, 2400, 9600 and 19200 baud max. ESP. baudrate and protocol configurable (see below). Can be configured as a communications port (table exchange or programming). Control port (Master) to one tributary (slave). When configured as a programming tributary, port can have addresses 1-15
(15 being a special case for tributary 0). 5.3.2 Interface

ESP table exchange - J/K tables. Max of 100. See section 5.5 for further details on
operation of an ESP port.

MODBUS RTU or ASCII. See section 5.6 for details.
5.3.3
Configuration No System Loaded Defaults to ESP Tributary, address 1, Baud rate 19200. System Loaded Configured via the CONFIG Special Function T33 (see section 12.2.25).) and following the information provided for Link 0 configuration in section 5.1.2.2, or defaults to ESP Tributary address 15, baud rate 9,600 if the CONFIG Special Function is not invoked.
5.3.4
Fault diagnostics Serial link statistics recorded in data tables F100 to F109: See section 5.6.3
5.3.5
Connection Serial link 2 (RS232) is connected via a 9 way D-type socket (SK5) situated on the Customer I/O board.
5.4
Serial Link 3 (Keypad connector)

Serial link 3 is used to connect the keypad and display unit and is situated on the front panel of the SIGMA Controller (beneath the keypad blanking panel). Serial Link 3 is a single point to point link providing: - Full RS232C interface non isolated. - 9600 baud for communcation with the keypad or 38400 for program download when no system is loaded.
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Note: The keypad and display unit must not be connected through a cable to link 3 input. Furthermore, it is not intended to use this link for connection to a PC as the noise immunity of the non-isolated RS232 input cannot be guaranteed.
5.4.1
Configuration No system loaded Defaults to ESP tributary, address 1, Baudrate 38400 for program download. System loaded Defaults to ESP tributary, address 15, baud rate 9600 for communication with the enhanced keypad. The CONFIG Special Function can be used to change Link 3 configuration, but only programming operation is possible and for the reasons given above link 3 should only be used for communication with the enhanced keypad
5.4.2
Fault diagnostics Serial link statistics recorded in data tables F110 to F119: See section 5.6.3
5.4.3
Connection 9 way header plug on front panel (beneath blanking panel) provides non-isolated RS232 signal.
5.5
Using ESP J/K table exchange

A block of 100 J/K data tables are allocated when the link is a tributary, or 100 J/K tables per tributary when the link acts as a master talking to up to 4 tributaries (link 1 only). The control of the link is via I tables, and statistics are stored in F tables. The tables are allocated as follows:
Link no 0 1 1 2 3 4 2 3 Trib J and K tables J/K0-J/K99 J/K100-J/K199 J/K200-J/K299 J/K300-J/K399 J/K400-J/K499 J/K500-J/K599 I tables rx = I0 tx = I1 rx = I2 tx = I3 rx = I4 tx = I5 rx = I6 tx = I7 rx = I8 tx = I9 rx = I10 tx = I11 F tables F50-F59 F60-F69 F70-F79 F80-F89 F90-F99 F100-F109 F110-F119 F43-F45 F46-F48 Note 2 Link Activity Table F37-F39 F40-F42 Note 1 Note 1 Note 1 Notes
Notes:
1. Link 1, tributaries 2-4 tables only used if link 1 is configured as a master talking to up to 4 tributaries. Tributary address to be configured as tributary 15, 1, 2, 3 (15 being a special case for Tributary 0). 2. Link 3 does not implement table exchange
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5.5.1 Receiving data: When an ESP table exchange message is received the J tables are updated before the start of the next user scan. Any data in the J table is overwritten by the new data. The receive I table is set to the length of the received data. SIGMA data tables locations are 32 bits in size. Information in an ESP table exchange message is 16 bits in size. The incoming data is sign extended to fit into a 32 bit integer word. 5.5.2 Transmitting data: Data is transferred from the K tables into the transmit buffer at the end of a scan. The amount of data to transfer is defined by the transmit length I table. Any data already in the transmit buffer is overwritten, although data table integrity is maintained (it is not possible to have a partly updated table). If the data to transmit is greater than 16 bits then it will be truncated. The number range that can be transmitted is therefore 32767. If a full 32 bit number needs transmitting then the S42 (SWAPE) special function should be used to transpose the upper and lower 16 bits and the high order 16 bits transmitted in the next data table.
5.6
Using MODBUS
The MODBUS protocol is designed for a PLC (Programmable Logic Controller) where there are separately defined data areas for: Digital inputs Digital outputs Input variables Output variables
This is different to SIGMA, which mixes digital and analogue variables in the same area. In addition, the MODBUS spec was written for PLCs which were not designed for analogue control. The naming of the data areas in such a PLC reflects this. These names are: Logic coils Input status bits Holding register Input register : : : : These are used to control discrete outputs from the controller Discrete inputs to the controller Store numerical values of timers & counters Referencing variables. The MODBUS spec says that these cannot be altered
Functions are provided for reading all of these, and for forcing coils and presetting holding registers. 5.6.1 MODBUS Functions The modbus module provides the necessary functions to service any MODBUS serial link messages received by SIGMA from a MODBUS master. The MODBUS messages implemented are: 01 02 Read coil status Read input status Obtain current status of a number of J table bits Obtain current status of a group of K table bits Issue (12-2-98)
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03 04 05 06 08 Read holding registers Read input registers Force single coil Preset single register Loopback diagnostic test Set number of bits in J table Set number of words in J table Obtain value held in a number of J table words Obtain value held in a number of K table words Set J table bit ON or OFF Set J table word
015 Force multiple coils 016 Force multiple registers
5.6.2
MODBUS Addressing The MODBUS protocol has been developed for machines with a different addressing method to SIGMA. The address mapping is as follows: Words Bits : : Mapped to offset 0 - 83 Mapped to 84.00 to 99.15
The normal link address mapping applies, as follows: Link 0 1 2 5.6.3 Statistics The meaning of the statistics are as follows:
F-Table 0 1 2 3 4 5 6 Statistic Attempts - Number of messages received (included those with errors). Master is requests + errors. Slave is received (with or without error) Requests* - Number of messages replied to CRC - Number of corruptions of the data Hardware errors - fault flagged by the serial link hardware (overrun data error - message too long or incorrect data stuffing timeout* - No reply from tributary Terminator error* - Received message has an incorrect terminator
J/K table 0-99 100-199 500-599
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7 NAK - Other end has not recieved or understood the message (ESP master or tributary). MODBUS: Increments on parity error. Link lost Master: Flag set if the tributary has not responded or there is a hardware failure. Trib: Flag set if there is a hardware failure Not used
Notes:
Not updated if the link is configured as an ESP tributary. NAK = Negative AcKnowledgement.
5.6.4
ESP Programming messages Any of the 4 links can receive programming messages. These messages provide the following functions:
Read and write data tables.
ESP messages are provided to read and write the SIGMA 32 bit tables.
Control the controller:
The controller user program can be HALTED, RUN and SINGLE STEPped. TEST and NORMAL mode can be selected. The CLEAR STORE command completely clears the system, including the firmware, and is only used by the programming tools when a new system is to be downloaded.
Get information
The controller can be interrogated for information about its identity, the facilities it provides, its status and the size of its memory
Read and write SIGMA addresses
Memory reads and writes can be performed on the SIGMA RAM areas. This is used for downloading code and data.
Get history information
A locking mechanism is provided to prevent more than one programming source updating the controller at any one time. Once a programming source has control, it prevents the other sources from making changes until either: a) b) c) The programming source has not made a change for more than 1 minute The programming source is removed. The user program is HALTED and then RUN.
When a programming source sets the lock on a message is displayed Link n programming. This is set on until the lock is released. If two programming sources are connected and one tries to update the controller when it is locked out, then a message is displayed Link n cannot make changes. The message is cleared after 5 seconds. 5.6.5 Connection Details Serial link 0 and 1 connections are via the Customer I/O Board as follows: Serial Link 0 = TB7B Serial Link 1 = TB7A SW3, is a four way switch to select the termination resistors for the RS485 serial links 0 and 1, when in the on position. Page 5-10 Alspa GD4000 Technical Manual Issue (12-2-98)
SW3 / 1 = link SW3 / 2 = link SW3 / 3 = link SW3 / 4 = link 0 0 1 1 Tx Rx Tx Rx
A simplified layout diagram of the Customer I/O Board may be found in section 8.7.5.4. Refer to section 9 and section 8.7.2 Pinouts for SK4 and SK5 Function Rx+ Tx+ 0V Supply 5.6.6 Switch Settings
Switch SW1 / 8 SW1 / 7 SW1 / 6 SW1 / 5 SW1 / 4 SW1 / 3 SW1 / 2 SW1 / 1 Table Location A0.8 A0.9 A0.10 A0.11 A0.12 A0.13 A0.14 Binary Number 1 2 4 8 1 2 4 0 = Configuation by switches 1 = Configuration by CONFIG Special Function T33 See section 12.2.25 Terminating Resistors for serial link 0 Tx (see 8.7.2) Terminating Resistors for serial link 0 Rx Terminating Resistors for serial link 1 Tx Terminating Resistors for serial link 1 Rx Baud Rate (see section 5.1.2.1) Description Trib. Address (see section 5.1.2.2).
Pin 3 2 5 6
SW3 / 1 SW3 / 2 SW3 / 3 SW3 / 4
5.7
Serial Link Fault Finding

See Section 10.6.
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6. System Design
System Design
6.1 Initial Calculations
The basic philosophy of the system design guide is that most of the drive parameterisation can be carried out by calculation, with the live commissioning only proving that the assumptions used in the calculations are correct. Basic application and hardware information is required to configure a standard ladder and links program to suit a particular duty. Most of this data is entered into the links program to configure the user program for the application. Information that will be required before commissioning can commence includes: For Any Type of Machine Bridge:
Motor equivalent circuit parameters, pole number, base speed, voltage at base
speed, Maximum or top speed. Maximum motor current Continuous motor current - for time delayed over-current protection Motor inertia Load inertia reflected to motor Encoder line count Target current loop bandwidth (e.g. 200 radians/second) Target speed loop bandwidth (e.g. 20 radians/second) Special application requirements - acceleration rates, stopping duty, impact response, etc. For AC Fed Systems
Minimum, nominal and maximum supply voltage Maximum supply frequency
Maximum (overload) power throughput requirement For DC Fed Systems

Nominal controlled DC Link Level
Maximum DC Link Level Level for Tripping on DC Link Under-voltage Level for allowing current controllers to be enabled
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6. System Design
6.2
6.2.1
Basic Power Circuit - AC Feed 1 Motor
Power Circuits
AC Feed 1 Motor
Figure 6-1 Basic Power circuit - AC feed 1 Motor
6.2.2
DC Feed 2 Motors
Figure 6-2 Basic Power Circuit - DC Feed 2 Motors

Basic Power Circuit - DC Feed 2 Motors
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6. System Design
6.2.3 DC Feed 1 Motor
Figure 6-3 Basic Power Circuit - DC Feed 1 Motor

Basic Power Circuit - DC Feed 1 Motor
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6. System Design
6.3
Input Fuse Selection

To protect the supply and give the network bridge semi-conductors the best protection during a d.c. link short circuit, each phase of the input supply must be fitted with a fuse of the correct rating. Table 6-1 gives details of suitable fuses.
Table 6-1 Fuse ratings
Drive Type
I cont. Amps 10.00 20.00 30.00 40.00 60.00 80.00 120.00 160.00 282.00 377.00 564.00 754.00 846.00
I rms Including o/l 10.61 21.21 31.82 42.43 63.64 84.85 127.28 169.71 299.11 399.87 598.21 799.74 897.32
Nearest GSGB 16.00 25.00 35.00 45.00 75.00 110.00 150.00 190.00 350.00 500.00 2x 350 2x 500 3x 350 3x 500
Code Ref.
GD4010 GD4020 GD4030 GD4040 GD4060 GD4080 GD4120 GD4160 GD4282* GD4377* GD4564* GD4754* GD4846* GD41131*
82520/151 82520/152 82520/154 82520/156 82520/201 82520/203 82520/204 82520/250 82520/256 82520/259 2 x 82520/256 2 x 82520/259 3 x 82520/256 3 x 82520/259
1131.00 1199.61
DC Feeder GD41128 GD41508 GD41692 GD42262 1128 1508 1692 2262 1196 1599 1795 2399 4 x 350 4 x 500 6 x 350 6 x 500 4 x 82520/256 4 x 82520/259 6 x 82520/256 6 x 82502/259
AC in AC out using GDD300-4601 GD4300 GD4600 GD4900 300 600 900 318 636 955 350 2 x 350 3 x 350 4 x 82520/256 4 x82520/256 4 x 82520/256
DC Feeder using GDD300-4601 GD41200 GD41800 1200 1800 1273 1909 4 x 350 6 x 350 4 x 82520/256 6 x 82520/256
Fuses are per line
Note:
This selection does not include any comparison of surge ratings for fuse and power semiconductors and consequently does not guarantee protection of these devices. It will however offer as much protection as possible by the use of fast fuses. The fuses selected are a.c. line fuses in the input supply to the equipment. * For larger drives the continuous current and rms current can vary depending on the actual operating conditions. In such cases individual calculations may be performed taking the following into account:
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1) 2) 3) The full load continuous ac rated current for the equipment. The overload requirements to calculate a total RMS current. Apply an additional allowance for the type of fuse to be used. For GSGB (GEC ALSTHOM) types, based on experience, this is 95% of the nameplate rating. For other fuse manufacturers this must be assessed from their catalogue, and may involve de-rating depending on the dissipation properties of the fuse connections. Choose a fuse size to cover the above conditions. Check that the fuse does not de-rate to an unacceptable level with operating temperature. If it does, the next larger size of fuse should be selected or air cooling may be considered
4) 5)
6.4
6.4.1
Incremental Encoders
Mechanical Alignment It is essential for the long term integrity of the encoder bearings and coupling that the motor and encoder shaft alignment is to the manufacturers specifications.
6.4.2
Encoder Screening The manufacturers guidelines provided with the encoder should be followed if these are available, alternatively the following screen and electrical connections should be made:
The body of the encoder should be bonded to the motor casing. The screen of the encoder cable should be connected to the case of the encoder
termination box.
The case of the encoder termination box should be connected to the motor frame. The screen of the encoder plant cable back to the inverter cubicle should be
connected to earth at the encoder termination box. The plant side power supply for the encoder electronics does not need to be ground referenced. The encoder shaft should be electrically isolated from the motor shaft to prevent an antenna effect radiating noise directly into the encoder electronics. 6.4.3 Calculating Encoder Accuracy The error in speed feedback signal derived from an incremental encoder is a function of the following factors: Scribing Error Clock Accuracy Clock Resolution Differential Skew in Feedback Electronics
The total error is calculated as the sum of these factors as follows:
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6. System Design
6.4.3.1 Scribing Error The scribing error of an encoder is a measure of the error in pulse position from the ideal. Incremental encoder pulses are typically described as 1 pulse equating to 360 electrical degrees. In each 360 degrees, four states, each of 90 electrical degrees, are present. Worst case pulse-pulse and edge-edge scribing errors of 50 electrical degrees are quoted by some manufacturers. To calculate the speed error the precise characteristics of the specific encoder must be studied. The speed error as a percentage of top speed resulting from scribing error can be calculated from the equation: Speed Error = Where: SE ST ELC EV Nmax 100 x SE x 60 ST x ELC x EV x Nmax x 90
= Scribing Error in electrical degrees = Scan Time of user program = Encoder Line Count = Evaluation multiplier (4 for standard GD4000) = Maximum speed
Some manufacturers quote edge separation instead of scribing error. Scribing error can be calculated as follows: Scribing Error = 90 - (360 x SF x ES) Where: SF = Maximum Scanning Frequency - quoted by encoder manufacturer ES = Edge Separation quoted as a time 6.4.3.2 Clock Accuracy The clock accuracy of the SIGMA core board also effects the speed feedback accuracy as the SIGMA core board clock is used to scan and measure the encoder pulses. The speed feedback error as a percentage of top speed can be calculated from the following equation: Speed Error = PPM 10,000 Where: PPM = accuracy of crystal (in Parts Per Million) for SIGMA Core Board = 100 PPM)
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6.4.3.3 Clock Resolution As the encoder counter can only resolve to the time base determined by the encoder clock, this sets the minimum time that can be resolved. The standard scanning frequency of the SIGMA Core Board encoder program is 4.125 MHz. The speed error as a percentage of top speed resulting from this can be calculated from the following equation: Speed Error = 100 x 8 33 x 106 x ST
Where: ST = Scan Time 6.4.3.4 Differential Skew in Feedback Electronics The encoder feedback circuits include various circuit elements that independently affect the two feedback signals from the incremental encoder. For example, opto-couplers isolating the encoder from the SIGMA Core Board may have different propagation delays. The error due to the differential skew can be calculated from the following equation: Speed Error = 100 x DS ST Where: DS = Differential Skew in ns ST = Scan Time. The worst case differential skew in feedback electronics for the SIGMA core board is 250 ns. 6.4.4 Encoder Line Count The encoder line count (Pulses Per Revolution) is calculated as follows: Encoder Line Count = MEF x 60 Nlim where: Nlim = Maximum Motor Speed, including any allowance for overspeed. MEF = Max Encoder Frequency The Maximum Encoder Frequency (MEF) is determined by the lower value of either:
the maximum pulse frequency into the incremental encoder circuits on the SIGMA
(1)
core board i.e clock limited. or

maximum frequency that can be transmitted across the cabling between encoder
and SIGMA core board i.e. cable limited. Calculate the Encoder line count for both clock limited and cable limited cases and use the lower value of the two.
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6.4.4.1 MEF Clock Limited Calculate the Encoder line count for the clock limited case using MEF value calculated as follows: MEF = Max Encoder Frequency = 33 x (90 - SE) x (106 - PPM) 8 x 360 where:
SE = Scribing error in electrical degrees PPM = Parts Per Million of SIGMA core board clock (see Section 6.4.3.2).
6.4.4.2
MEF Cable Limited A typical relationship between encoder frequency and cable distance is shown in the following graph taken from a typical encoder technical data sheet:
Figure 6-4 Cable length v Encoder output frequency
Read the cable limited MEF value from the graph and use this value to calculate the Encoder Line Count for the cable limited case. A typical encoder cable should be at least to ALPHA 5474 or BELDEN 9504 standard or equivalent. 6.4.5 Encoder Power Supplies If the cabling distance between the motor and drive is greater than 15 metres, it may be necessary to use a remote power supply for the encoder. This should be mounted close to the encoder. Alternatively a remote power supply unit (31V 4400) takes 12 V from the 20X4495 customer termination panel and produces a locally regulated 5 V supply.
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6. System Design
6.5
Motor Parameter Estimation
Figure 6-5 Motor equivalent circuit
If the motor manufacturers data is not available, it is possible to make a reasonable estimate of the parameters required by module 94. However, these estimates are not intended to replace the motor manufacturers data. The calculations for the motor model estimate assume the following data is available: 1) 2) 3) 4) 5) * Note: Motor volts VL-N at base speed. Supply frequency f magnetising current Imag (if this is not known see note * below) Stator current Is Rotor speed Nrotor at rated kW If Imag is not known it can be estimated by running the motor off load and measuring the phase current. Imag is approximately equal to the off-load phase current.
6.5.1
Motor Inductance Lm This assumes that the voltage across the stator impedance will be small compared to that of Lm so that the voltage across Lm is equal to the terminal voltage. Lm = VL-N/2fImag
6.5.2
Motor Resistance Rm For motors < 100 kW Rm = XLM x 15 For motors > 100 kW Rm = XLM x 30
6.5.3
Stator Resistance Rs and Rotor Resistance Rr From the equivalent circuit Rr = (VL-N/Irotor) x S
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6. System Design
Nsync = f x 2 x 60/p assume: Rs = Rr where p = No. of poles S = (Nsync - Nrotor)/Nsync Irotor (Is2 - Imag2) 6.5.4 Stator Inductance Ls and Rotor Inductance Lr Assume: start up current = 6 x FLC Ls+ Lr = VL-N/(2f x 6 x FLC) and Ls = Lr 6.5.5 Current Loop Tuning
6.5.5.1
Proportional gain Factor Kp L1111 = L1211 = Kp = 1024 x 3 x L9410 x (L9402 + L9404) x CLBW L9409 x 106 where: CLBW = Current loop bandwidth i.e. the frequency in radians/sec at which the open (current) loop gain is unity.
6.5.5.2
Integral Gain Factor Ki L1112 = L1212 = Ki = L1111 x CLBW 4096
6.5.5.3
Derivation of PI Gain Factors Kp and Ki K(s) = Kp + Ki/S at the bandwidth point the open loop gain will be unity K(s) x Vpk/Ipk x (1 / RL) = 1 (1 + S x LL/RL) Alspa GD4000 Technical Manual Issue (12-2-98)
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6. System Design
Assuming S ( LL ) >> 1 RL Kp + Ki/S = IpkSLL/Vpk Assuming Ki << Kp Kp = IpkLLS/Vpk where S = 500 rads-1 L L = Ls + Lr As a rule of thumb, to give reasonable gain and phase margins Ki = Kp(CLBW)/4 Note: Kp should be multiplied by 1024 before entering the value into the appropriate L**11.
Ki has no scaling and is entered directly. 6.5.6 Speed/Torque Loop Tuning
6.5.6.1
Proportional gain Factor Kp L9211 = Kp = 1024 x 2 x L2004 x J x SLBW L9425 x 60 where: SLBW = Speed loop bandwidth i.e. the frequency in radians/sec at which the open (speed) loop gain is unity.
6.5.6.2
Integral Gain Factor Ki L9212 = L9211 x SLBW 4096
6.5.6.3
Derivation of PI Gain Factors Kp and Ki K(s) = Kp + Ki/S At the bandwidth of the open loop gain will be unity
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6. System Design
K(s) x (Tpk/Js) x 60/2Nmax = 1 Assuming Kp >> Ki/S Kp = 2NmaxJs / (Tpk x 60) where: SLBW = Speed loop bandwidth i.e. the frequency in radians/sec at which the open (speed) loop gain is unity. S = 125 rads-1 J = Total system inertia (see section 6.5.7) Tpk = Peak torque available from drive Nmax = Max. speed in rpm To give reasonable gain and phase margins Ki = Kp(SLBW)/4 Note: Kp should be multiplied by 1024 before entering the value into the appropriate L**11.
Ki has no scaling and is entered directly. 6.5.7 Total System Inertia Estimation To obtain an estimate of the system inertia, perform the following tests:Measure the input power of the drive, under steady state conditions at various speeds. PD = PL + Jd/dt Where: PD is the drive power PL is the load power J is the Total System Inertia
As the speed is constant for this test the derivative term is zero and therefore PL = PD The corrected load power PL is obtained by subtracting the machine stator loss component. PL = PD - 3IS2RS PD is measured by using VSIScos From the corrected steady state load PD calculate the effective load torque using: ML = PD/ speed (in radians per second) Where ML = Load torque. Note: the load power factor (coscan be calculated as shown by section 6.5.8
Tabulate the calculated values as shown below and from this table plot a graph of speed (y axis) versus ML (x axis).
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Vd L1205 Vq L1105 Vs=(Vd2+Vq2) L1401 Id L1203 Iq L1103 Is= (Id2+Iq2) 3VSIS cos 3ISRS L1501 PD ML
For the second test, sometimes called a run down test the motor is run at a certain speed and the power to it is switched off and the loss of speed recorded with time. This can be done using the oscilloscope outputs monitoring L9204. This result should be plotted on the same graph as the previous results as shown in the figure 6- 0. From the equation: MD = ML + Jd/dt During the run down test MD = 0 (no power connected). Therefore: J = ML()/d/dt() From the 2 curves the system inertia can be approximated. However, it is advisable to obtain an average of several readings for the rate of change of speed from the graph.
6.5.8
Calculating the Load Power Factor For a given load the power factor can be calculated using the following method. The calculation will be valid for a constant load. For a given constant load note the following parameters, L1105, L1205, L1103 and L1203 which are Vq, Vd, Iq and Id respectively. From these recorded parameters the angle between Vs and Is can be calculated using the formula = arctan(Vd/Vq) + arctan(Id/Iq) cos = power factor
6.5.9
Calculating Sigma () Sigma () is calculated as follows: = where: Lm = Magnetizing inductance Ls = Stator inductance Lr = Sotor inductnace 1 - Lm2 (Ls + Lm) (Lr +Lm)
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6. System Design
As this value is subtracted from unity is expressed as a percentage in L9520.
6.6
Switched Mode Power Supply Inrush Currents

When the supply to the drive is switched on, there is a current inrush to the Switched Mode Power Supply (SMPS). The magnitude of this inrush current is depends upon the time which has elapsed since the drive was de-energised and is greater if this elapsed time is short. While the SMPS will withstand the inrush current, regardless of the elapsed off time, without damage to internal components. The cables and other components supplying the SMPS must be rated to withstand the full inrush current. Figure 6-6 shows the relationship between the inrush current to the SMPS and the elapsed OFF time.
Figure 6-6 Delay to ON time after switch-off
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6. System Design
6.7
6.7.1
Specification and Configuration for Various Network Voltages

Introduction The rating at maximum supply voltages is limited by the combination of the following factors: Supply Voltage Upper Tolerance Supply Frequency Upper Tolerance Overload Requirement Value of input a.c. line reactor Maximum working d.c. link voltage Thermal rating of power circuits - for the purpose of this section, the thermal rating will be ignored.
The ongoing descriptions detail the rating of the GD4000 network bridge when network voltage, frequency and current/power levels are considered. For the GD4000 products listed in this technical manual the maximum d.c. link voltage is limited to 750 V. This leaves sufficient margin for the dynamic operation of the d.c. link voltage control without the hardware over-voltage detectors being triggered. The vector sum of the network voltage and the voltage across the ac input line reactor must be less than the maximum rms network voltage. This results in a relationship between supply voltage, overload current and d.c. link voltage of: VDC/2 = (V_AC_MAX2 + (3 x 2 x F_MAX x L x I_OL)2) Where: VDC = V_AC_MAX = F_MAX L I_OL = = = Voltage on DC Link (750 V) Maximum rms line to line voltage at the network side of the input a.c. line reactor Maximum network frequency in hertz Inductance in henries of input a.c. line reactors (per phase) Overload current requirement in amps rms. ...(1)
This equation can be solved for two conditions: 6.7.1.1 Overload Current Limited This is considered as case 1 in the tabulations in section 6.9. The maximum permissible network voltage is calculated such that when running at the overload current level the vector sum of inductor voltage and maximum network voltage is equal to the maximum d.c. link voltage divided by 2. So: V_AC_MAX = ((VDC/2)2 - (3 x 2 x x F_MAX x L x I_OL)2) ...(2)
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6.7.1.2 Network Voltage Limited This is considered as case 2 in the tabulations in Section 6.9. The overload current capability is calculated such that the vector sum of maximum network voltage and maximum permissible inductor voltage is equal to the d.c. link voltage divided by 2. So: (3 x 2 x x F_MAX x L x I_OL) = ((VDC/2)2 - V_AC_MAX2) So the maximum permissible inductor current is: I_OL = ((VDC/2)2 - V_AC_MAX2)/(3 x 2 x x F_MAX L) ...(4) ...(3)
These equations have been used to calculate the configuration data and rating limits given in Section 6.9. The effect is shown diagrammatically in Figure 6-7 for the specific case of a GD41131.
Figure 6-7 Relationship between network voltage and maximum current for GD41131(ignoring thermal effects)
Relationship between network voltage and maximum current for GD41131(ignoring thermal effects)
6.7.2
Application Specific Configurations In many circumstances, and particularly for installations where a dedicated 10, 11 or 33 kV network transformer is to be specified, the voltage to which the GD4000 network bridge is connected can be selected at the application engineering stage by the correct specification of the network transformer secondary voltage.
6.7.2.1
Choice of Transformer Secondary Voltage A double wound transformer must be specified to match the effective a.c. rms voltage capability of the network bridge (determined by the working d.c. link voltage) to the vector sum of input a.c. line reactor voltage drop and maximum transformer secondary voltage for a given overload power throughput requirement. The relationship between
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the various terms is detailed below: VT VL F F_MAX L VB P VDC = = = = = = = = Maximum Transformer secondary voltage (rms) Voltage drop across input line reactors (expressed as an equivalent line to line value) Nominal network frequency in hertz Maximum network frequency in hertz Input line inductance in henries Effective rms network bridge voltage at working d.c. link voltage Net Overload Power to or from network Voltage on DC Link (750 volts for the products covered in this technical manual ...(5) ...(6) ...(7)
VB = VDC/2 VT2 + VL2 = VB2 VT x VL x 3/(2 x x F_MAX x L x 3) = P So: VT = P x 2 x x F_MAX x L/VL Substituting into equation (6): ((P x 2 x x F_MAX x L)2/VL2) + VL2 = VB2 Results in a quadratic in terms of VL2: (P x 2 x x F_MAX x L)2 + VL4 - (VL2 x VB2) = 0
...(8)
...(9)
...(10)
Solving the quadratic in equation (10) for VL2 for the specific conditions detailed above and then substituting the result back into equation (6) gives a value for the maximum line to line network or network transformer secondary voltage that can be utilised. VL = {-[(-(VB2) + [VB4 - 4(P x 2 x F_MAX x L)2])/2]} From this maximum network or transformer secondary voltage a nominal and minimum transformer voltage can be calculated: Nominal Network or transformer secondary voltage of: VAC_NOM = 100 x VT/(100 + POS_TOL%) Where: VAC_NOM = Nominal network or transformer secondary voltage POS_TOL% = Positive supply tolerance expressed in percentage (normally +10%) And minimum network or transformer secondary voltage of: VAC_MIN = VAC_NOM x (100 - NEG_TOL%)/100 Where: VAC_MIN = Minimum network or transformer secondary voltage NEG_TOL% = Negative supply tolerance expressed in percentage (normally -10%) Issue (12-2-98) Alspa GD4000 Technical Manual Page 6-17 ...(13) ...(12) ...(11)
6. System Design
6.7.2.2 Current Ratings of Network Bridge Components The maximum network current and hence the thermal and overload current rating of the network bridge should then be calculated for this minimum supply condition. The thermal rating is determined by the combination of the maximum continuous current condition and the overload current and overload duration. The maximum continuous current is calculated as follows: MAX_CONT_I = CONT_POWER/(3 x VAC_MIN x NET_COS) Where: MAX_CONT_I CONT_POWER NET_COS = Maximum continuous current (rms) in the network bridge = Continuous or rated power in the network bridge = Required network power factor (Unity in most applications) ...(14)
The size of the network bridge power switching components (silicon limited) is determined by the maximum current for the minimum network or transformer secondary voltage: I_OL = OL_POWER/(3 x VAC_MIN x NET_COS) Where: OL_POWER = Overload power throughput requirement. Note: In calculating the overload power throughput requirement the nominal transfer efficiencies of the network and machine bridges of 98% respectively should be used together with due allowance for machine efficiency and cable power losses. For example, for power flow from network to machine (motoring power) the nominal continuous network power, CONT_POWER, is calculated as: ...(15)
CONT_POWER = ((MOTOR_SHAFT_POWER/MOTOR) + CABLE_LOSS)/(0.98 x 0.98) ...(16) Where: MOTOR_SHAFT_POWER = CABLE_LOSS MOTOR 6.7.3 = = Motor Shaft Power in watts (at base speed or the maximum power condition) Watts loss in cables between inverter and motor Per unit efficiency (<1)
Calculating Network Bridge Parameterisation Having calculated the maximum, nominal and minimum transformer voltages for a given DC Link condition, it is now possible to calculate the parameterisation values for the network bridge control.
6.7.3.1
Current Limit Value The setting for the DC Link Controller Limits (Module 97) are determined as follows: L9714 = (I_OL x 100%) / (1.5 x nominal rating) Where I_OL is the required overload.
Page 6-18
Issue (12-2-98)
6. System Design
Note: L9714 has a maximum value of 100% L9715 = -L9714 6.7.3.2 Va Feed Forward Gain Va feed forward gain (L1016) should be set as if the GD4000 is to run at its nominal overload level (even though, from considerations in 6.7.3.1 above, it may not be required). This is done to maintain the overall loop gain of the DC Link voltage controller at its design value. L1016 = (10.24 x 2 x I_OL x 2Fmax x L x 3)/Vdc The limit setting on the Ia and Ib controllers in modules 1 and 2 are calculated as: L214 = Vsupply max x 2 x 100% Vdc L215 = - L214 L114 = ISUPPLY_OL_MIN V x 2fmaxL x 3 x 2 Vdc L115 = - L114 L1016 = IDRIVE_OL x 2FL Vdc Note: 6.7.4 This method has been used in calculating the parameters listed in Section 6.9.
Calculating Total Network Inductance The total network inductance seen be the GD4000 network bridge is the sum of the supply leakage inductance Lnetwork and the input reactor inductances. Lnetwork = Where: X% = Quoted % reactance for transformer. F = Nominal supply frequency VA = Nominal transformer rating. Input reactor inductances can be found by reference to the tables in section 6.9. X% x VnomLL2 100 x VA x 2F
6.7.5
Effective DC Link Capacitance of Common DC Link Systems The gains of the DC link voltage controller (module 197: L19711 & L19712) are automatically calculated based on the drive rating and the sum of the known internal DC link capacitance and the user entered external effective DC link capacitance, L9987. Hence for any common DC link scheme the user is required to enter the total effective DC link capacitance of all the additional equipment connected to the DC link. The effective DC link capacitance of GD4000 equipment is as follow: GD4010 / GD4020 : 1650 F
Issue (12-2-98)
Page 6-19
6. System Design
GD4030 / GD4040 GD4060 GD4080 GD4120 GD4160 282A delta module 377A delta module 300A delta module : : : : : : : : 3300 F 4700 F 6600 F 9900 F 14100 F 13200 F 18800 F 7833 F
6.8
6.8.1
Application Considerations
GD4000 Stability In stabilising a GD4000 drive the following criteria should be considered: Current Loop small signal bandwidth Current Large Signal response e.g. 200 - 250 radians/s e.g. 20 PU/s, (i.e full load torque in 50 ms).
By setting the current loop bandwidth to this level there will not be a requirement for a larger forcing voltage. Speed Loop Bandwidth Speed Feedback Filter e.g. 20 radians/s e.g. 80 radians/s
Drive mechanical resonances and backlash may require a reduction in these targets.
6.9
Network Bridge Parameters
Page 6-20
Issue (12-2-98)
Table of Network Bridge ratings and commissioning parameters for GD4000 drives GD4010 to GD41131.
Supply Voltage Overload Supply Frequency 50 Upper Frequency Tolerance Upper Voltage Tolerance Working DC Link Voltage Case 1 (see Secton 6.7):
Drive Size 4010 4010 4020 4030 4040 4060 4080 4080 4080 4120 4120 4120 4160 4160 4160 4282 4282 4377 4564 4754 4846 41131 Inductor Type 33Z0307/10 50Z0008/01 33Z0308/10 33Z0371/10 33Z0306/10 33Z0306/10 33Z0309/10 33Z0310/10 50Z0012/01 33Z0310/10 33Z0311/10 50Z0013/01 33Z0311/10 33Z0313/10 50Z0014/01 33Z0313/10 50Z0015/01 33Z0314/10 33Z0315/10 33Z0316/10 33Z0317/10 33Z0361/10 Inductor Value (Henries) 8.32E-03 8.32E-03 4.16E-03 2.77E-03 2.17E-03 2.17E-03 1.63E-03 1.16E-03 1.16E-03 1.16E-03 1.38E-03 1.16E-03 1.38E-03 9.00E-04 1.38E-03 9.00E-04 9.00E-04 6.75E-04 4.50E-04 3.40E-04 3.00E-04 2.25E-04
480 1.5 1.01 1.1 750 Reduce Maximum Network Voltage to maintain overload current capability
Issue (12-2-98) Alspa GD4000 Technical Manual Page 6-21

Drive Size 4010 4010 4020 4030 4040 4060 4080 4080 4080 4120 4120 4120 4160 4160 4160 4282 4282 4377 4564 4754 4846 41131
Inductor Limit (Max RMS I) 1.0 1.5 1.5 1.5 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.5 1.5 1.5 1.5
Max AC Supply (1.1 x Nominal) 528 526 526 526 525 519 525 525 525 525 513 518 516 517 498 512 487 487 487 487 487 487
Nominal AC Supply 480 478 478 478 478 472 478 477 477 477 466 471 469 470 453 465 443 443 443 442 443 443
Minimum AC Supply (0.9 * Nominal) 432 430 430 430 430 425 430 429 429 429 419 424 422 423 408 419 399 399 399 398 399 399
Overload Power Throughput (At minimum a.c. supply) 7474 11166 22331 33497 44629 66164 59503 89139 89139 89139 130576 131925 116927 175598 169241 204251 291837 389959 583673 778845 875510 1169878
L9703 139.47% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56%
L9714 66.67% 100.00% 100.00% 100.00% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 100.00% 100.00% 100.00% 100.00%
L9715 -66.67% -100.00% -100.00% -100.00% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -100.00% -100.00% -100.00% -100.00%
L1016 1.32 1.32 1.32 1.32 1.38 2.07 2.07 1.48 1.48 2.21 2.63 2.21 3.51 2.29 3.51 4.04 4.04 4.05 4.04 4.08 4.04 4.05
L114 8.62% 12.92% 12.92% 12.90% 13.48% 20.21% 13.50% 14.41% 14.41% 14.41% 25.71% 21.61% 22.85% 22.36% 34.28% 26.27% 39.41% 39.51% 39.41% 39.80% 39.41% 39.51%
L115 -8.62% -12.92% -12.92% -12.90% -13.48% -20.21% -13.50% -14.41% -14.41% -14.41% -25.71% -21.61% -22.85% -22.36% -34.28% -26.27% -39.41% -39.51% -39.41% -39.80% -39.41% -39.51%
L214 99.63% 99.16% 99.16% 99.16% 99.09% 97.94% 99.08% 98.96% 98.96% 98.96% 96.64% 97.64% 97.35% 97.47% 93.94% 96.49% 91.91% 91.86% 91.91% 91.74% 91.91% 91.86%
L215 -99.63% -99.16% -99.16% -99.16% -99.09% -97.94% -99.08% -98.96% -98.96% -98.96% -96.64% -97.64% -97.35% -97.47% -93.94% -96.49% -91.91% -91.86% -91.91% -91.74% -91.91% -91.86%
Overload Irms 10.0 15.0 30.0 45.0 60.0 90.0 80.0 120.0 120.0 120.0 180.0 180.0 160.0 240.0 240.0 282.0 423.0 565.5 846.0 1131.0 1269.0 1696.5
DC Link 749.5 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0
Case 2 (See Section 6.7):

Inductor Type 33Z0307/10 50Z0008/01 33Z0308/10 33Z0371/10 33Z0306/10 33Z0306/10 33Z0309/10 33Z0310/10 50Z0012/01 33Z0310/10 33Z0311/10 50Z0013/01 33Z0311/10 33Z0313/10 50Z0014/01 33Z0313/10 50Z0015/01 33Z0314/10 33Z0315/10 33Z0316/10 33Z0317/10 33Z0361/10 Inductor Value (Henries) 8.32E-03 8.32E-03 4.16E-03 2.77E-03 2.17E-03 2.17E-03 1.63E-03 1.16E-03 1.16E-03 1.16E-03 1.38E-03 1.16E-03 1.38E-03 9.00E-04 1.38E-03 9.00E-04 9.00E-04 6.75E-04 4.50E-04 3.40E-04 3.00E-04 2.25E-04
Reduce overload current to maintain maximum network voltage capability

Inductor Limit (Max RMS I) 1.0 1.5 1.5 1.5 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.5 1.5 1.5 1.5 Max AC Supply (1.1 * Nominal) 528 528 528 528 528 528 528 528 528 528 528 528 528 528 528 528 528 528 528 528 528 528 Nominal AC Supply 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 Minimum AC Supply (0.9 * Nominal) 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 Overload Power Throughput (At minimum a.c. supply) 7474 11210 22421 33631 44842 31157 59789 58284 58284 58284 48993 58284 48993 75122 48993 75122 75122 100163 150244 198852 225366 300488 L9703 139.47% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% L9714 66.67% 72.49% 72.49% 72.58% 69.48% 46.32% 46.25% 64.99% 64.99% 43.33% 36.42% 43.33% 27.31% 41.88% 27.31% 23.76% 23.76% 23.70% 23.76% 23.53% 23.76% 23.70% L9715 -66.67% -72.49% -72.49% -72.58% -69.48% -46.32% -46.25% -64.99% -64.99% -43.33% -36.42% -43.33% -27.31% -41.88% 27.31% -23.76% -23.76% -23.70% -23.76% -23.53% -23.76% -23.70% L1016 1.32 1.32 1.32 1.32 1.38 2.07 2.07 1.48 1.48 2.21 2.63 2.21 3.51 2.29 3.51 4.04 4.04 4.05 4.04 4.08 4.04 4.05 L114 8.62% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% L115 -8.62% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% L214 99.63% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% L215 -99.63% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% Overload Irms 10.0 15.0 30.0 45.0 60.0 41.7 80.0 78.0 78.0 78.0 65.6 78.0 65.6 100.5 65.6 100.5 100.5 134.0 201.0 266.1 301.5 402.1 DC Link 749.5 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0
6. System Design
Page 6-22
Nominal AC Supply L9703 127.93% 128.64% 128.64% 128.64% 128.75% 130.46% 128.75% 128.95% 128.95% 128.95% 132.33% 130.89% 131.30% 131.13% 136.06% 132.54% 138.73% 138.79% 138.73% 138.95% 138.73% 138.79% 66.67% 100.00% 100.00% 100.00% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 100.00% 100.00% 100.00% 100.00% -66.67% -100.00 -100.00 -100.00 -100.00 -100.00 -66.67% -100.00 -100.00 -66.67% -100.00 -100.00 -66.67% -100.00 -100.00 -66.67% -100.00 -100.00 -100.00 -100.00 -100.0% -100.00 1.44 1.44 1.44 1.43 1.50 2.21 2.25 1.60 1.60 2.40 2.78 2.36 3.73 2.44 3.60 4.25 4.06 4.07 4.06 4.09 4.06 4.07 9.39% 14.01% 14.01% 14.00% 14.61% 21.63% 14.63% 15.59% 15.59% 15.59% 27.12% 23.04% 24.29% 23.79% 35.16% 27.66% 39.64% 39.73% 39.64% 39.98% 39.64% 39.73% -9.39% -14.01% -14.01% -14.00% -14.61% -21.63% -14.63% -15.59% -15.59% -15.59% -27.12% -23.04% -24.29% -23.79% -35.16% -27.66% -39.64% -39.73% -39.64% -39.98% -39.64% -39.73% 99.56% 99.01% 99.01% 99.02% 98.93% 97.63% 98.92% 98.78% 98.78% 98.78% 96.25% 97.31% 97.00% 97.13% 93.61% 96.10% 91.81% 91.77% 91.81% 91.66% 91.81% 91.77% -99.56% -99.01% -99.01% -99.02% -98.93% -97.63% -98.92% -98.78% -98.78% -98.78% -96.25% -97.31% -97.00% -97.13% -93.61% -96.10% -91.81% -91.77% -91.81% -91.66% -91.81% -91.77% L9714 L9715 L1016 L114 L115 L214 L215 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 Minimum AC Supply (0.9 * Nominal) 10.0 15.0 30.0 45.0 60.0 90.0 80.0 120.0 120.0 120.0 180.0 180.0 160.0 240.0 240.0 282.0 423.0 565.5 846.0 1131.0 1269.0 1696.5 Overload Irms DC Link 687.5 691.3 691.3 691.3 691.9 701.1 691.9 693.0 693.0 693.0 711.1 703.4 705.6 704.7 731.2 712.3 745.6 745.9 745.6 746.7 745.6 745.9 Overload Power Throughput (At minimum a.c. supply) 6851 10276 20552 30829 41105 61657 54806 82210 82210 82210 123314 123314 109613 164419 164419 193193 289789 387413 579578 774825 869367 1162238 Nominal AC Supply L9703 Minimum AC Supply (0.9 * Nominal) L9714 L9715 L1016 L114 L115 L214 L215 Overload Irms DC Link 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 Overload Power Throughput (At minimum a.c. supply) 6462 9692 19385 29077 38769 58154 51692 77539 77539 77539 116308 116308 103385 155077 155077 182216 273324 365401 546647 730801 819971 1096202 120.73% 121.48% 121.48% 121.47% 121.60% 123.40% 121.60% 121.80% 121.80% 121.80% 125.38% 123.86% 124.29% 124.12% 129.31% 125.60% 132.12% 132.18% 132.12% 132.35% 132.12% 132.18% 66.67% 100.00% 100.00% 100.00% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 100.00% 100.00% 100.00% 100.00% -66.67% -100.00 -100.00 -100.00 -100.00 -100.00 -66.67% -100.00 -100.00 -66.67% -100.00 -100.00 -66.67% -100.00 -100.00 -66.67% -100.00 -100.00 -100.00 -100.00 -100.00 -100.00 1.53 1.52 1.52 1.52 1.58 2.34 2.38 1.69 1.69 2.54 2.93 2.49 3.94 2.57 3.79 4.48 4.26 4.27 4.26 4.30 4.26 4.27 9.95% 14.84% 14.84% 14.82% 15.47% 22.86% 15.49% 16.51% 16.51% 16.51% 28.62% 24.35% 25.66% 25.14% 37.00% 29.19% 41.62% 41.72% 41.62% 41.97% 41.62% 41.72% -9.95% -14.84% -14.84% -14.82% -15.47% -22.86% -15.49% -16.51% -16.51% -16.51% -28.62% -24.35% -25.66% -25.14% -37.00% -29.19% -41.62% -41.72% -41.62% -41.97% -41.62% -41.72% 99.50% 98.89% 98.89% 98.90% 98.80% 97.35% 98.79% 98.63% 98.63% 98.63% 95.82% 96.99% 96.65% 96.79% 92.90% 95.64% 90.93% 90.88% 90.93% 90.77% 90.93% 90.88% -99.50% -98.89% -98.89% -98.90% -98.80% -97.35% -98.79% -98.63% -98.63% -98.63% -95.82% -96.99% -96.65% -96.79% -92.90% -95.64% -90.93% -90.88% -90.93% -90.77% -90.93% -90.88% 10.0 15.0 30.0 45.0 60.0 90.0 80.0 120.0 120.0 120.0 180.0 180.0 160.0 240.0 240.0 282.0 423.0 565.5 846.0 1131.0 1269.0 1696.5 648.8 652.8 652.8 652.8 653.5 663.2 653.5 654.6 654.6 654.6 673.8 665.6 668.0 667.0 694.9 675.0 710.0 710.3 710.0 711.3 710.0 710.3
Supply Voltage Overload Supply Frequency 50 Upper Frequency Tolerance Upper Voltage Tolerance Working DC Link Voltage
440 1.5
1.01 1.1 750
6. System Design
Drive Size
Inductor Type
Inductor Value (Henries)
Inductor Limit (Max RMS I)
Max AC Supply (1.1 * Nominal)
4010 4010 4020 4030 4040 4060 4080 4080 4080 4120 4120 4120 4160 4160 4160 4282 4282 4377 4564 4754 4846 41131
33Z0307/10 50Z0008/01 33Z0308/10 33Z0371/10 33Z0306/10 33Z0306/10 33Z0309/10 33Z0310/10 50Z0012/01 33Z0310/10 33Z0311/10 50Z0013/01 33Z0311/10 33Z0313/10 50Z0014/01 33Z0313/10 50Z0015/01 33Z0314/10 33Z0315/10 33Z0316/10 33Z0317/10 33Z0361/10
8.32E-03 8.32E-03 4.16E-03 2.77E-03 2.17E-03 2.17E-03 1.63E-03 1.16E-03 1.16E-03 1.16E-03 1.38E-03 1.16E-03 1.38E-03 9.00E-04 1.38E-03 9.00E-04 9.00E-04 6.75E-04 4.50E-04 3.40E-04 3.00E-04 2.25E-04
1.0 1.5 1.5 1.5 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.5 1.5 1.5 1.5
484 484 484 484 484 484 484 484 484 484 484 484 484 484 484 484 484 484 484 484 484 484
415 1.5
1.01 1.1 750
Drive Size
Inductor Type
Issue (12-2-98)
4010 4010 4020 4030 4040 4060 4080 4080 4080 4120 4120 4120 4160 4160 4160 4282 4282 4377 4564 4754 4846 41131
1.0 1.5 1.5 1.5 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.5 1.5 1.5 1.5
457 457 457 457 457 457 457 457 457 457 457 457 457 457 457 457 457 457 457 457 457 457
Issue (12-2-98)
Nominal AC Supply L9703 110.65% 111.47% 111.47% 111.46% 111.60% 113.56% 111.60% 111.82% 111.82% 111.82% 115.70% 114.06% 114.53% 114.34% 119.95% 115.95% 122.98% 123.05% 122.98% 123.23% 122.98% 123.05% 66.67% 100.00% 100.00% 100.00% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 100.00% 100.00% 100.00% 100.00% -66.67% -100.00% -100.00% -100.00% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -100.00% -100.00% -100.00% -100.00% 1.67 1.66 1.66 1.65 1.73 2.54 2.59 1.84 1.84 2.76 3.18 2.71 4.28 2.79 4.08 4.86 4.58 4.59 4.58 4.62 4.58 4.59 10.86% 16.17% 16.17% 16.15% 16.85% 24.84% 16.88% 17.98% 17.98% 17.98% 31.01% 26.44% 27.85% 27.29% 39.88% 31.62% 44.72% 44.81% 44.72% 45.08% 44.72% 44.81% -10.86% -16.17% -16.17% -16.15% -16.85% -24.84% -16.88% -17.98% -17.98% -17.98% -31.01% -26.44% -27.85% -27.29% -39.88% -31.62% -44.72% -44.81% -44.72% -45.08% -44.72% -44.81% 99.41% 98.68% 98.68% 98.69% 98.57% 96.86% 98.57% 98.37% 98.37% 98.37% 95.07% 96.44% 96.04% 96.20% 91.70% 94.87% 89.44% 89.40% 89.44% 89.26% 89.44% 89.40% L9714 L9715 L1016 L114 L115 L214 L215 -99.41% -98.68% -98.68% -98.69% -98.57% -96.86% -98.57% -98.37% -98.37% -98.37% -95.07% -96.44% -96.04% -96.20% -91.70% -94.87% -89.44% -89.40% -89.44% -89.26% -89.44% -89.40% 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 342 342 342 342 342 342 342 342 342 342 342 342 342 342 342 342 342 342 342 342 342 342 Minimum AC Supply (0.9 * Nominal) Overload Irms 10.0 15.0 30.0 45.0 60.0 90.0 80.0 120.0 120.0 120.0 180.0 180.0 160.0 240.0 240.0 282.0 423.0 565.5 846.0 1131.0 1269.0 1696.5 Overload Power Throughput (At minimum a.c. supply) 5917 8875 17750 26625 35500 53249 47333 70999 70999 70999 106499 106499 94666 141998 141998 166848 250272 334584 500544 669167 750817 1003751 594.7 599.0 599.0 599.0 599.7 610.3 599.7 600.9 600.9 600.9 621.8 613.0 615.5 614.5 644.6 623.1 660.9 661.3 660.9 662.2 660.9 661.3
380 1.5
1.01 1.1 750

DC Link
Drive Size
Inductor Type
4010 4010 4020 4030 4040 4060 4080 4080 4080 4120 4120 4120 4160 4160 4160 4282 4282 4377 4564 4754 4846 41131
1.0 1.5 1.5 1.5 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.5 1.5 1.5 1.5
418 418 418 418 418 418 418 418 418 418 418 418 418 418 418 418 418 418 418 418 418 418
6. System Design
Page 6-23
Page 6-24
Nominal AC Supply L9703 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 66.67% 100.00% 100.00% 100.00% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 100.00% 100.00% 100.00% 100.00% -66.67% -100.00% -100.00% -100.00% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -100.00% -100.00% -100.00% -100.00% 1.59 1.59 1.59 1.59 1.66 2.48 2.49 1.77 1.77 2.66 3.16 2.66 4.21 2.75 4.21 4.84 4.84 4.85 4.84 4.89 4.84 4.85 10.33% 15.50% 15.50% 15.48% 16.17% 24.26% 16.20% 17.29% 17.29% 17.29% 30.85% 25.93% 27.43% 26.83% 41.14% 31.52% 47.29% 47.41% 47.29% 47.76% 47.29% 47.41% -10.33% -15.50% -15.50% -15.48% -16.17% -24.26% -16.20% -17.29% -17.29% -17.29% -30.85% -25.93% -27.43% -26.83% -41.14% -31.52% -47.29% -47.41% -47.29% -47.76% -47.29% -47.41% 99.46% 98.79% 98.79% 98.79% 98.68% 97.01% 98.68% 98.49% 98.49% 98.49% 95.12% 96.58% 96.17% 96.33% 91.15% 94.90% 88.11% 88.05% 88.11% 87.86% 88.11% 88.05% -99.46% -98.79% -98.79% -98.79% -98.68% -97.01% -98.68% -98.49% -98.49% -98.49% -95.12% -96.58% -96.17% -96.33% -91.15% -94.90% -88.11% -88.05% -88.11% -87.86% -88.11% -88.05% L9714 L9715 L1016 L114 L115 L214 L215 480 476 476 476 476 468 476 475 475 475 459 466 464 464 439 458 425 424 425 424 425 424 432 429 429 429 428 421 428 427 427 427 413 419 417 418 395 412 382 382 382 381 382 382 Minimum AC Supply (0.9 * Nominal) Overload Irms 10.0 15.0 30.0 45.0 60.0 90.0 80.0 120.0 120.0 120.0 180.0 180.0 160.0 240.0 240.0 282.0 423.0 565.5 846.0 1131.0 1269.0 1696.5 DC Link 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 Overload Power Throughput (At minimum a.c. supply) 7466 11124 22248 33372 44447 65541 59260 88722 88722 88722 128526 130495 115500 173553 164208 200892 279786 373753 559572 745892 839357 1121259 Nominal AC Supply L9703 L9714 Minimum AC Supply (0.9 * Nominal) L9715 L1016 L114 L115 L214 L215 Overload Irms DC Link 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 432 Overload Power Throughput (At minimum a.c. supply) 7474 6772 13544 20340 25964 25964 34565 48570 48570 48570 40827 48570 40827 62602 40827 62602 62602 83469 125203 165710 187805 250407 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 60.41% 60.41% 60.41% 60.48% 57.90% 38.60% 38.54% 54.16% 54.16% 36.11% 30.35% 36.11% 22.76% 34.90% 22.76% 19.80% 19.80% 19.75% 19.80% 19.60% 19.80% 19.75% -60.41% -60.41% -60.41% -60.48% -57.90% -38.60% -38.54% -54.16% -54.16% -36.11% -30.35% -36.11% -22.76% -34.90% -22.76% -19.80% -19.80% -19.75% -19.80% -19.60% -19.80% -19.75% 1.59 1.59 1.59 1.59 1.66 2.48 2.49 1.77 1.77 2.66 3.16 2.66 4.21 2.75 4.21 4.84 4.84 4.85 4.84 4.89 4.84 4.85 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% 9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% -9.36% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% 99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% -99.56% 10.0 9.1 18.1 27.2 34.7 34.7 46.2 65.0 65.0 65.0 54.6 65.0 54.6 83.8 54.6 83.8 83.8 111.7 167.5 221.7 251.3 335.1 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0
480 1.5
1.01 1.1 750
Case 1(See Section 6.7):
Reduce Maximum Network Voltage to maintain overload current capability
6. System Design
Drive Size
Inductor Type
4010 4010 4020 4030 4040 4060 4080 4080 4080 4120 4120 4120 4160 4160 4160 4282 4282 4377 4564 4754 4846 41131
1.0 1.5 1.5 1.5 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.5 1.5 1.5 1.5
527 524 524 524 523 514 523 522 522 522 504 512 510 511 483 503 467 467 467 466 467 467
Case 2 (See Section 6.7)
Reduce Overload Current to maintain overload current capability
Drive Size
Inductor Type
Issue (12-2-98)
4010 4010 4020 4030 4040 4060 4080 4080 4080 4120 4120 4120 4160 4160 4160 4282 4282 4377 4564 4754 4846 41131
1.0 1.5 1.5 1.5 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.5 1.5 1.5 1.5
528 528 528 528 528 528 528 528 528 528 528 528 528 528 528 528 528 528 528 528 528 528
440 1.5
1.01 1.1 750
Issue (12-2-98)
Nominal AC Supply L9703 128.18% 129.19% 129.19% 129.19% 129.35% 131.79% 129.36% 129.63% 129.63% 129.63% 134.45% 132.41% 133.00% 132.76% 139.56% 134.75% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 66.67% 100.00% 100.00% 100.00% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 100.00% 100.00% 100.00% 100.00% -66.67% -100.00% -100.00% -100.00% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -100.00% -100.00% -100.00% -100.00% 1.73 1.71 1.71 1.71 1.79 2.63 2.68 1.91 1.91 2.86 3.28 2.80 4.42 2.89 4.21 5.01 4.84 4.85 4.84 4.89 4.84 4.85 11.25% 16.75% 16.75% 16.73% 17.45% 25.69% 17.47% 18.61% 18.61% 18.61% 32.03% 27.34% 28.78% 28.20% 41.14% 32.65% 47.29% 47.41% 47.29% 47.76% 47.29% 47.41% -11.25% -16.75% -16.75% -16.73% -17.45% -25.69% -17.47% -18.61% -18.61% -18.61% -32.03% -27.34% -28.78% -28.20% -41.14% -32.65% -47.29% -47.41% -47.29% -47.76% -47.29% -47.41% 99.37% 98.59% 98.59% 98.59% 98.47% 96.64% 98.46% 98.25% 98.25% 98.25% 94.73% 96.19% 95.77% 95.94% 91.15% 94.52% 88.11% 88.05% 88.11% 87.86% 88.11% 88.05% L9714 L9715 L1016 L114 L115 L214 L215 -99.37% -98.59% -98.59% -98.59% -98.47% -96.64% -98.46% -98.25% -98.25% -98.25% -94.73% -96.19% -95.77% -95.94% -91.15% -94.52% -88.11% -88.05% -88.11% -87.86% -88.11% -88.05% 440 440 440 440 440 440 440 440 440 440 440 440 440 440 439 440 425 424 425 424 425 424 396 396 396 396 396 396 396 396 396 396 396 396 396 396 395 396 382 382 382 381 382 382 Minimum AC Supply (0.9 * Nominal) Overload Irms 10.0 15.0 30.0 45.0 60.0 90.0 80.0 120.0 120.0 120.0 180.0 180.0 160.0 240.0 240.0 282.0 423.0 565.5 846.0 1131.0 1269.0 1696.5 DC Link 688.9 694.3 694.3 694.3 695.1 708.2 695.2 696.7 696.7 696.7 722.5 711.6 714.7 713.4 750.0 724.2 750.0 750.0 750.0 750.0 750.0 750.0 Overload Power Throughput (At minimum a.c. supply) 6851 10276 20552 30829 41105 61657 54806 82210 82210 82210 123314 123314 109613 164419 164208 193193 279786 373753 559572 745892 839357 1121259 Nominal AC Supply L9703 Minimum AC Supply (0.9 * Nominal) L9714 L9715 L1016 L114 L115 L214 L215 Overload Irms DC Link 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 440 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 396 Overload Power Throughput (At minimum a.c. supply) 6851 10276 20552 30829 41105 61657 54806 82210 82210 82210 123314 123314 109613 164419 164419 193193 289789 387413 579578 774825 869367 1002032 128.18% 129.19% 129.19% 129.19% 129.35% 131.79% 131.80% 129.63% 129.63% 132.41% 134.45% 132.41% 139.56% 132.76% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 139.56% 66.67% 100.00% 100.00% 100.09% 100.00% 100.00% 66.67% 100.09% 100.09% 66.67% 100.00% 100.00% 66.67% 100.00% 99.36% 66.67% 86.45% 86.22% 86.45% 85.58% 86.45% 86.22% -66.67% -100.00% -100.00% -100.09% -100.00% -100.00% -66.67% -100.09% -100.09% -66.67% -100.00% -100.00% -66.67% -100.00% -99.36% -66.67% -86.45% -86.22% -86.45% -85.58% -86.45% -86.22% 1.73 1.71 1.71 1.71 1.79 2.63 2.63 1.91 1.91 2.80 3.28 2.80 4.21 2.89 4.21 4.84 4.84 4.85 4.84 4.89 4.84 4.85 11.25% 16.75% 16.75% 16.73% 17.45% 25.69% 17.15% 18.61% 18.61% 18.22% 32.03% 27.34% 27.43% 28.20% 40.88% 31.52% 40.88% 40.88% 40.88% 40.88% 40.88% 40.88% -11.25% -16.75% -16.75% -16.73% -17.45% -25.69% -17.15% -18.61% -18.61% -18.22% -32.03% -27.34% -27.43% -28.20% -40.88% -31.52% -40.88% -40.88% -40.88% -40.88% -40.88% -40.88% 99.37% 98.59% 98.59% 98.59% 98.47% 96.64% 98.52% 98.25% 98.25% 98.33% 94.73% 96.19% 96.17% 95.94% 91.26% 94.90% 91.26% 91.26% 91.26% 91.26% 91.26% 91.26% -99.37% -98.59% -98.59% -98.59% -98.47% -96.64% -98.52% -98.25% -98.25% -98.33% -94.73% -96.19% -96.17% -95.94% -91.26% -94.90% -91.26% -91.26% -91.26% -91.26% -91.26% -91.26% 10.0 15.0 30.0 45.0 60.0 90.0 80.0 120.0 120.0 120.0 180.0 180.0 160.0 240.0 240.0 282.0 423.0 565.5 846.0 1131.0 1269.0 1462.7 688.9 694.3 694.3 694.3 695.1 708.2 708.3 696.7 696.7 711.6 722.5 711.6 750.0 713.4 750.0 750.0 750.0 750.0 750.0 750.0 750.0 750.0
Reduce Maximum Network Voltage to maintain overload current capability
Drive Size
Inductor Type
4010 4010 4020 4030 4040 4060 4080 4080 4080 4120 4120 4120 4160 4160 4160 4282 4282 4377 4564 4754 4846 41131
1.0 1.5 1.5 1.5 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.5 1.5 1.5 1.5
484 484 484 484 484 484 484 484 484 484 484 484 484 484 483 484 467 467 467 466 467 467
Reduce Overload Current to maintain overload current capability
Drive Size
Inductor Type
6. System Design
Page 6-25
4010 4010 4020 4030 4040 4060 4080 4080 4080 4120 4120 4120 4160 4160 4160 4282 4282 4377 4564 4754 4846 41131
1.0 1.5 1.5 1.5 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.5 1.5 1.5 1.5
484 484 484 484 484 484 484 484 484 484 484 484 484 484 484 484 484 484 484 484 484 484
Page 6-26
Nominal AC Supply L9703 120.99% 122.06% 122.06% 122.06% 122.23% 124.81% 122.24% 122.53% 122.53% 122.53% 127.62% 125.47% 126.08% 125.83% 133.15% 127.93% 137.06% 137.15% 137.06% 137.39% 137.06% 137.15% 66.67% 100.00% 100.00% 100.00% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 100.00% 100.00% 100.00% 100.00% -66.67% -100.00% -100.00% -100.00% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -100.00% -100.00% -100.00% -100.00% 1.83 1.81 1.81 1.81 1.89 2.78 2.84 2.02 2.02 3.02 3.46 2.95 4.66 3.05 4.42 5.28 4.93 4.94 4.93 4.97 4.93 4.94 11.92% 17.72% 17.72% 17.70% 18.46% 27.12% 18.49% 19.69% 19.69% 19.69% 33.74% 28.85% 30.36% 29.76% 43.12% 34.39% 48.15% 48.25% 48.15% 48.52% 48.15% 48.25% -11.92% -17.72% -17.72% -17.70% -18.46% -27.12% -18.49% -19.69% -19.69% -19.69% -33.74% -28.85% -30.36% -29.76% -43.12% -34.39% -48.15% -48.25% -48.15% -48.52% -48.15% -48.25% 99.29% 98.42% 98.42% 98.42% 98.28% 96.25% 98.28% 98.04% 98.04% 98.04% 94.14% 95.75% 95.28% 95.47% 90.23% 93.90% 87.65% 87.59% 87.65% 87.44% 87.65% 87.59% -99.29% -98.42% -98.42% -98.42% -98.28% -96.25% -98.28% -98.04% -98.04% -98.04% -94.14% -95.75% -95.28% -95.47% -90.23% -93.90% -87.65% -87.59% -87.65% -87.44% -87.65% -87.59% 10.0 15.0 30.0 45.0 60.0 90.0 80.0 120.0 120.0 120.0 180.0 180.0 160.0 240.0 240.0 282.0 423.0 565.5 846.0 1131.0 1269.0 1696.5 L9714 L9715 L1016 L114 L115 L214 L215 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 374 Minimum AC Supply (0.9 * Nominal) Overload Irms DC Link 650.2 656.0 656.0 655.9 656.9 670.7 656.9 658.5 658.5 658.5 685.8 674.3 677.6 676.2 715.5 687.5 736.6 737.0 736.6 738.3 736.6 737.0 Overload Power Throughput (At minimum a.c. supply) 6462 9692 19385 29077 38769 58154 51692 77539 77539 77539 116308 116308 103385 155077 155077 182216 273324 365401 546647 730801 819971 1096202 Nominal AC Supply L9703 Minimum AC Supply (0.9 * Nominal) L9714 L9715 L1016 L114 L115 L214 L215 Overload Irms DC Link 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 342 342 342 342 342 342 342 342 342 342 342 342 342 342 342 342 342 342 342 342 Overload Power Throughput (At minimum a.c. supply) 5917 8875 17750 26625 35500 53249 47333 70999 70999 70999 106499 106499 94666 141998 141998 166848 250272 334584 500544 669167 110.94% 112.11% 112.11% 112.10% 112.29% 115.09% 112.30% 112.62% 112.62% 112.62% 118.13% 115.80% 116.47% 116.20% 124.08% 118.47% 128.28% 128.37% 128.28% 128.62% 66.67% 100.00% 100.00% 100.00% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 66.67% 100.00% 100.00% 100.00% 100.00% -66.67% -100.00% -100.00% -100.00% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -66.67% -100.00% -100.00% -100.00% -100.00% 2.00 1.98 1.98 1.97 2.06 3.01 3.09 2.19 2.19 3.29 3.73 3.20 5.05 3.30 4.74 5.70 5.27 5.28 5.27 5.31 13.00% 19.30% 19.30% 19.27% 20.10% 29.42% 20.13% 21.43% 21.43% 21.43% 36.45% 31.26% 32.86% 32.22% 46.27% 37.14% 51.45% 51.55% 51.45% 51.83% -13.00% -19.30% -19.30% -19.27% -20.10% -29.42% -20.13% - 21.43% -21.43% -21.43% -36.45% -31.26% -32.86% -32.22% -46.27% -37.14% -51.45% -51.55% -51.45% -51.83% 99.15% 98.12% 98.12% 98.12% 97.96% 95.58% 97.95% 97.68% 97.68% 97.68% 93.12% 94.99% 94.45% 94.67% 88.65% 92.85% 85.75% 85.69% 85.75% 85.52% -99.15% -98.12% -98.12% -98.12% -97.96% -95.58% -97.95% -97.68% -97.68% -97.68% -93.12% -94.99% -94.45% -94.67% -88.65% -92.85% -85.75% -85.69% -85.75% -85.52% 10.0 15.0 30.0 45.0 60.0 90.0 80.0 120.0 120.0 120.0 180.0 180.0 160.0 240.0 240.0 282.0 423.0 565.5 846.0 1131.0 596.2 602.5 602.5 602.4 603.5 618.5 603.5 605.2 605.2 605.2 634.8 622.3 625.9 624.4 666.8 636.7 689.4 689.8 689.4 691.2
415 1.5
1.01 1.1 750
6. System Design
Drive Size
Inductor Type
4010 4010 4020 4030 4040 4060 4080 4080 4080 4120 4120 4120 4160 4160 4160 4282 4282 4377 4564 4754 4846 41131
1.0 1.5 1.5 1.5 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.5 1.5 1.5 1.5
457 457 457 457 457 457 457 457 457 457 457 457 457 457 457 457 457 457 457 457 457 457
380 1.5
1.01 1.1 750
Drive Size
Inductor Type
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4010 4010 4020 4030 4040 4060 4080 4080 4080 4120 4120 4120 4160 4160 4160 4282 4282 4377 4564 4754
33Z0307/10 50Z0008/01 33Z0308/10 33Z0371/10 33Z0306/10 33Z0306/10 33Z0309/10 33Z0310/10 50Z0012/01 33Z0310/10 33Z0311/10 50Z0013/01 33Z0311/10 33Z0313/10 50Z0014/01 33Z0313/10 50Z0015/01 33Z0314/10 33Z0315/10 33Z0316/10
8.32E-03 8.32E-03 4.16E-03 2.77E-03 2.17E-03 2.17E-03 1.63E-03 1.16E-03 1.16E-03 1.16E-03 1.38E-03 1.16E-03 1.38E-03 9.00E-04 1.38E-03 9.00E-04 9.00E-04 6.75E-04 4.50E-04 3.40E-04
1.0 1.5 1.5 1.5 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.0 1.5 1.5 1.5 1.5
418 418 418 418 418 418 418 418 418 418 418 418 418 418 418 418 418 418 418 418
7. Programming the GD4000
Programming the GD4000

7.1 Introduction
The drive user program is composed of a sequence of ladder and link statements which:
Declare software modules and link the inputs and outputs of these modules together. Link data tables to variables i.e software modules outputs. Set data tables to specific values to configure the drive and serial links.
The combination of ladder and links allows the use of tested and proven standard blocks of software (modules) while retaining the ability to customise the drive to the individual application requirements. The CSP ladder programmer allows the use of logic and data manipulation using mathematical functions, logic functions, and a range of other special functions. An interrupt driven fast task is used to produce the firing patterns. The modules making up this function cannot be relinked, although certain parameters can be modified.
7.2
Software Structure
The drive software provides the background resources to the programmer to enable the I/O to be serviced, the integrity of the microprocessor system to be checked and the application program to be executed. Most of the software is held in battery supported RAM. Only the boot-up code being held in EEPROM. This enables enhancements and corrections to be made to the system without having to change the drive EEPROMs. The software held in RAM is downloaded from a PC via a serial link.
7.3
I/O Synchronisation
The user program accesses the I/O via various data tables such as: A/B tables (Digital I/O including BASIC I/O) C/D tables (Analog I/O) J/K tables (Serial links) These tables are updated by the hardware concerned at the beginning and end of the user-program scan. The fast task is NOT regarded as part of the user program. The I/O hardware itself, however, is not read or written to synchronously with the user program scan time but is processed as follows: BASIC I/O This is processed by the serial communications processor. The scanning of the complete BASIC I/O could take longer than the user program scan time. The A/B tables are only updated when the entire BASIC I/O has been scanned (e.g. BASIC I/O
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takes 3 ms to scan, user program takes 1 ms, so user program A/B tables only updated every 3ms). ANALOG INPUTS Analog inputs are read by the fast task, typically scanning faster than the user program which is driven by the slow task. (e.g. 0.341 s for fast task compared with 1 to 5 ms for slow task). In general therefore, the C tables are updated every slow task scan. The analog inputs are scanned asynchronously to the user program. A full set of analog inputs is therefore scanned over a series of eight fast tasks. Critical analog inputs associated with current feedback signals are scanned every fast task. ANALOG OUTPUTS Analog outputs are updated from the D tables at the beginning of every user program scan. SERIAL LINKS The update rate of the serial links depends upon the baud rate selected. The J tables are updated at the beginning of a scan if a full message has been received. The K tables are copied to the transmission buffer at the beginning of a scan, but any data already in the process of being transmitted is not overwritten. Further guidance on configuring serial links can be found in the GEM80 Serial Communications Manual (T457). Note: 7.3.1 It is the responsibility of the user to ensure that a message is received correctly before transmitting further information.
Halt/Run/Single Step The user program can be halted or single-stepped for fault finding purposes. This does not affect the watchdog. In each of these cases, the user program is not executed, although the base level continues to monitor the I/O and self-test functions.
7.3.2
Test Mode If test mode is selected the inputs are not transferred to the input data tables, and the outputs are set to 0. This affects all A/B tables, all C/D tables, and any I/O tables set by enhancement boards.
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7.4
7.4.1
Access Levels
Keypad Access Levels The following access levels are applied to each variable
Access Level 0 1 2 3 4 5 6 Description Change permissive Password Link Statement Attribute U S P Q L, C1 E, C2 N
Unlocked Safe Password Password Safe Locked Engineer No change
No permissives required Change when E0.15=0 No permissives required Change when E0.15=0 Change when A32.7=0 Change when A32.7=0 Change when A32.7=0
No password No password Password 0 Password 0 Password 1 Password 2 Password 3
Notes:
i) That the attribute C has a different access level, depending on the drive status. C1 is the access level when in commissioning mode, and C2 is the equivalent when NOT in commissioning mode. Also, access level 6 (No change) literally means that the value can only be changed by an engineer with knowledge of the highest password level. This will normally be reserved for development engineers. ii) Access Level takes into account both the password level, and the drive status (for example A32.7). iii) If no keys are pressed for a timeout period of five minutes, the lowest level of password is assumed.
7.4.2
CSP Monitor Access Level Note: When using the CSP Monitor function, the access levels listed for the keypad do not necessarily apply, although some values may be altered whilst the drive is running.
7.4.3
CSP Editors Access Level When using the CSP links editor, the editing is carried out off line, therefore the access levels do not apply, but the password levels do.
7.5
Firmware Database (System Software)

The firmware database (sometimes referred to as the system software) provides the background resources to the application programmer to enable the I/O to be serviced, the integrity of the microprocessor system to be checked and executes the application program. Refer to Section 7.6 for details of the firmware database versions associated with different hardware configurations. As much of the firmware as possible is held in RAM. Only a small portion (the BOOT code) is held in EEPROM. This enables enhancements and bug corrections to be made to the system without having to change EEPROMS. The firmware held in RAM is downloaded via the I/O Processor and the serial links. There are two types of module, referred to as Fast and Slow (which refers to the task priority). Slow modules generally form part of the users application program and deal
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with such things as speed demand, plant interlocks and dc link control. These functions require less frequent attention than do the fast task modules and are allocated less processor time. They are usually updated after several milliseconds. The fast task functions deal with the higher speed requirements e.g. the vector control related functions. To be effective these parameters must be updated in times in the order of microseconds. Modules are referred to by a reference number, e.g. Module 27, Control On. The individual linkable inputs and outputs from the modules are referred to by a number prefixed by a letter L. The first two figures (or three for module references greater than 99) is the number of the module they belong to and the last two figures are the input/output identity.
7.6
Firmware Databases
The firmware modules for GD4000 are provided in the form of a firmware database. The SIGMA firmware database exists in several issues and variants providing different levels of functionality and, in some situations, differing hardware compatibility. It is important that the firmware database in use is compatible with the hardware. For a new drive this will always be so, but problems can arise when using an old database with new hardware or vice-versa. Two databases are supplied with GD4000 drives 00S060-4004 and 00S060-4005. Database 00S060-4004 is the earlier version and is provided in its original form to retain backward compatibility with existing drives. This version of the database includes some modules which are not relevant to the GD4000 A.C drives. As a result it uses most of the available memory of the SIGMA controller, leaving only a small amount of memory for the application program and fast history records. Database 00S060-4005 contains only the modules required to run a GD4000. Several new software modules are incorporated in this database, which combines functions from several modules in the 00S060-4004 database and allows the drive to be configured for basic operations using the links editor only i.e. no additional ladder programming is required. Database 00S060-4005 uses significantly less memory than the 00S060-4004, allowing larger user programs without any reduction in the size of the fast history records. It is recommended that all new applications use database 00S060-4005.
7.6.1
00S060-4004 Firmware Database Below is a list of modules and version numbers of the 00S060-4004 database. In addition to those listed below, the 00S060-4004 database supplied contains the following modules: 37, 45, 56, 57, 237 and 245 These relate to d.c. drives and should be ignored, as they are not relevant to GD4000 applications. No documentation is provided for these modules.
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Module Number 1V2 2V2 3V2 4V2 5V2 6V1 8V1 9V1 10V2 11V2 12V2 13V2 14V2 15V2 16V1 19V2 20V1 21V1 22V1 26V1 27V1 28V1 30V1 31V1 32V1 (33, 34) 35V2 (36, 37) 40V1 44V1 47V1 48V1 53V1 55V1 80V2 81 90V1 91V2 92V2 93V1 94V2 95V2 98V1 99V2 119V4 159V4 197(V1) Bridge B Current Control Bridge B Current Control Bridge B Polar Conversion Bridge B PWM Generation Bridge B Current Conversion Mains Synchronisation Fast Scope Outputs Software Skew Compensation Miscellaneous Hardware Interfaces Bridge A Current Control Bridge A Current Control Bridge A Polar Conversion Bridge A PWM Generation Bridge A Current Conversion Position Feedback Speed Control for Magnetising Curve Characterisation Speed Measurement by Encoder Speed/Voltage Control Reference Circuits Control Available Logic Control On Logic Run Logic Reference Logic Test/Local Control Fault Display Slow History Record Cyclic Test Staircase Smoothing Position Measurement Position Control HDLC Driver Linear Conversion PID Controller (Clone of Module 92) Rotor Time Constant Compensator Temperature Feedback Fast Fault Speed Control Bridge A Control Available Flux and Torque Look-Up Tables Slip Calculation Bridge B Control Available DC Link Control Fast History Bridge A Fast History Bridge B DC Link Voltage Control Description
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Module Number 221V1 222V1 226V1 227V1 228V1 230V1 231V2 232V1 (233, 234) 240V1 244V1 247V1 248V1 255V1 280V2 294V2 295V2 300V1 Speed/Voltage Control Reference Circuits Control Available Logic Control On Logic Run Logic Reference Logic Test/Local Control Fault Display Cyclic Test Staircase Smoothing Position Measurement Position Control Linear Conversion PID Controller (Clone of Module 92) Flux and Torque Look-Up Tables Slip Calculation General Purpose Functions Description
If the module version number is omitted from any part of the documentation then assume V1. Note: 7.6.2 The version number is an important part of the module number. For example module 10V2 is significantly different to 10V1.
00S060-4005 Firmware Database Below is a list of modules and version numbers of the 00S060-4005 database.
Module Number 1V2 2V2 3V2 4V2 5V2 6V1 7V1 8V1 9V1 10V2 11V2 12V2 13V2 14V2 15V2 16V1 19V2 20V1 21V1 Bridge B Current Control Bridge B Current Control Bridge B Polar Conversion Bridge B PWM Generation Bridge B Current Conversion Mains Synchronisation VVVF B Fast Scope Outputs Software Skew Compensation Miscellaneous Hardware Interfaces Bridge A Current Control Bridge A Current Control Bridge A Polar Conversion Bridge A PWM Generation Bridge A Current Conversion Position Feedback Speed Control for Magnetising Curve Characterisation Speed Measurement by Encoder Speed/Voltage Control Description
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Module Number 22V1 32V1/33/ 34 35V2/36V2 47V1 48V1 53V1 70V1 71V1 80V2 81 82 83 84 85 86 87 89 90V1 91V2 92V2 94V2 95V2 97V1 99V2 119V4/120 159V4/160 186V1 187V1 197(V1) 216V1 281 284 285 286 287 294V2 295V2 Reference Circuits Fault Display Slow History Record Position Measurement Position Control HDLC Driver HDLC Driver HDLC Driver PID Controller (Clone of Module 92) Rotor Time Constant Compensator Parameter Edit Drive ID Open Loop A Start/Stop Logic Program Blocks Changeover Switch Serial Comms Support Temperature Feedback Fast Fault Speed Control Flux and Torque Look-Up Tables Slip Calculation DC Link Control/Slow PID DC Link Control Fast History Bridge A Fast History Bridge B Program Blocks Changeover Switch DC Link Voltage Control Position Feedback RTC Tracker Open Loop B Start/Stop Logic Program Blocks Changeover Switch Flux and Torque Look-Up Tables Slip Calculation Description
7.7
Link Instructions
Link instructions are used to link modules and edit parameters in the control task and edit parameters in the fast task. They can also incorporate ladder programs, monitor
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values and preset data tables to configure the drive. The links instructions are stored in the .GDM file which forms part of the user program. 7.7.1 Links Program Header The links program is in two parts, the header and the links program. 7.7.1.1 Header An example of a header might be: Line No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Note: Program STAND F1 MASTER AA1.0002 1105-6004 01-05/05/91 FAST TASK :4 LANGUAGES : UK, FR SYMBOLS : YES USERPROG : NO CORE OIS : 4451.2001 CUST OIS : 1234.5678 FIR0 OIS : 0000.0000 FIR1 OIS : 0000.0000 FIR2 OIS : 0000.0000 ENH0 OIS : 0000.0000 ENH1 OIS : 0000.0000 ENH2 OIS : 0000.0000 ENH3 OIS : 0000.0000 Description <- Drive title <- Drive reference <- Firmware reference <- Issue number & Date <- Fast task type <- See Below <- Allow full symbol table download to drive <- Keep user program backup in drive <- Core board OIS version <- Customer I/O Board OIS version <- Power Interface Board 0 OIS version <- Power Interface Board 1 OIS version <- Power Interface Board 2 OIS version <- Enhancement Board 0 OIS version <- Enhancement Board 1 OIS version <- Enhancement Board 2 OIS version <- Enhancement Board 3 OIS version
the line number is a documentation guide only.
Lines 1,2,4 The Drive Title, Drive Reference and the Issue Number & Date are ASCII text lines of 16 characters. Line 3 The firmware reference (maximum 16 characters) is checked against that specified in the Firmware Database when it is edited and each time the Editor is invoked. If the firmware reference is edited, the Editor checks the existence of each link with the Firmware Database. If any invalid links are now found, the user will be prompted to delete or edit the offending link. Line 5 The Fast Task number must be set to a valid number for the specified firmware reference. This checking function is not yet implemented. Line 6 The LANGUAGE statement above specifies the language of the data table comments to be downloaded to the drive. IBM PC standard abbreviations for languages are used. The SIGMA Controller can hold comments in two languages. At present only the English (UK) language is available. Line 7 If the SYMBOLS option is set to YES, all the links table descriptions (see section 12.3) are downloaded to the SIGMA Controller. If NO is set, only symbol data for the keypad editable parameters is down-loaded, to reduce download time.
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Line 8 If USERPROG option is set to YES then a backup, un-compiled version of both the .GLP (ladder) and .GDM (links) files will be stored in the in the SIGMA Controller. The UPLOAD facility is not yet implemented. If NO is set, the down load time is reduced. Lines 9 onward. Current and future firmware databases The number of lines depends upon the hardware fitted. The OIS definitions consist of a four digit OIS number and a four digit Product Reference. They are passed to the drive to check that the correct hardware is attached. If the OIS version number is entered as 0000.0000 the OIS number is not checked. 7.7.2 Editing a Links Program The links program defines the connections to the software modules. It has three functions:
Linking the data in one location to another
e.g. L10107=L2115 (equivalent to a wire link)

Setting the value of a location
e.g. L2124=95.00 (equivalent to a potentiometer)

A switch or logic value e.g. L2110=0 (equivalent to a switch)
Only four simple rules apply: a) Input on the left hand side Only one input to a location, any number of outputs A link statement takes precedence over a ladder rung A link to a constant can be overwritten by a ladder rung Example
The following example illustrates the principles from a small section of the program. The speed reference is obtained from a serial link, table location N4, and is connected to the input of the speed control module L21 at location L2106. The output of the speed control is connected as the current reference to the current control module L101. The current limit is set at 95% and voltage feedback is not selected. The equivalent links program being: Table descriptions, (from firmware) L10107 = L2106 = L2110 = L2124 = L2115 N4 0 95.00 N CURRENT REF = CONTROL OUTPUT N SPEED REF = L SEL. VOLT FEEDBK =0 C MAX. OUTPUT LIM = 95.00% These letters being the link attribute which are associated with the password level, see section 7.7.2.1. if a value is being linked to a location, this value may be expressed in decimal or hex.
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c) Comments Comments can be added in the middle of the links program as an aid to user program documentation. Comments are preceded by a semicolon (;). 7.7.2.1 Attributes Each variable and each link statement, can have a number attributes as follows: Type Read only Scaling Max, Min logic or integer. It is write enabled if it is an input to a module. Determines the position of the decimal point. Limits of variable. The value of the variable is limited to these settings by: Code generated by the drive compiler on each link defined in the LINKS EDITOR. Any ESP command to read or write the data table. The variable is either set to 0 or a default value at power up or HALT-RUN A value 0-6 defining the access level (See section 7.4.1) Up to 15 characters for a comment Selected from the predefined list, see section 7.8.
Default Access Comments Units
Only inputs may appear on the LHS of a link. The attributes for L tables are found with the diagrams which describe the functions of the modules. These are give in the Control Module Data Sheets in sections 13 and 14. The attributes can also be defined by the DEF TABLE statement in the Links Editor.
7.8
DEFine Commands
A number of definition commands are available in the Editor, these may be inserted between the header and the links program proper.
7.8.1
DEF module not yet implemented
7.8.2
DEF Table The DEF Table statement redefines the six attributes of any data table in the links program, i.e. maximum and minimum limits, scaling, default, units and text comments. All six attributes must be set, or a default value will be applied. e.g. DEF TABLE L7006=10000,-10000,2,0,1,SLAVE SPEED REF
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In the above example we are defining the location L7006 to be: +10000 -10000 2 0 1 SLAVE SPEED REF *Note: = = = = = = Maximum limit * Minimum limit * Scaling, i.e. divide value by 102 Default value Units of displayed value (see table 3.1 below) Text string (max 16 characters) in links listing
limits cannot be written higher than the limits that exist within the module.
If it is only required to change the comment (text string), the user can type, for example: DEF TABLE L2106 =,,,,,NEW TEXT DEF TABLE is normally used at the beginning of the production of a links program, then each time the table is used the required text will be displayed. However if the DEF TABLE is used after the link is made, the required definition will not be applied until F6 is pressed. DEF TABLE Units 0 1 2 3 4 5 6 7 8 9 = = = = = = = = = = blank % PU ms s %/s Pk/s PULSE DEG Hz 10 11 12 13 14 15 16 17 18 = = = = = = = = = /s RPM V A Kw Nm mm ins mils
Password Protection Attributes Each link statement has an attribute which is associated with the password protection level assigned to each link. The following links attributes are allowed:
Letter U P S Q L C E N Name Unlocked Password Safe Password Safe Locked Commissioning Engineer No Change Drive Status Any time Any time Drive stopped Drive stopped Hardware permissives low Password Level None Password 0 None Password 0 Password 1 Password 2* Password 2 Password 3
U P S Q
Edit Edit Edit Edit
on on on on
drive keypad at any time, no password. drive keypad at any time, password 0. drive keypad when drive stopped (i.e. E0.15=0), no password. drive keypad when drive stopped, password 0.
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L Edit on drive keypad when hardware permissive healthy (i.e. A32.7=0), password level 1. C Edit on drive keypad when hardware permissive healthy (i.e. A32.7=0), password level 2. *Note: This changes to password level 1 if SIGMA Controller is running the commissioning program (see section 4.5.10). This attribute is applied to a normal link to allow a lower password level requirement for editing when in commissioning mode.
E Edit on drive keypad when hardware permissive healthy (i.e. A32.7=0), password level 2. N Edit on drive keypad when programming permissive healthy (i.e. A32.7=0), password level 3. Links may not be edited unless the password level passed from CSP is equal to or greater than the password level allowed for the existing link attribute. In addition, if no attribute is specified when inserting or editing a link, the L attribute is added by the Editor provided the editing password level allows, otherwise the highest attribute allowed will be entered. If the user wishes to change this, he can use the Editor to select another attribute. All links edited in commissioning mode are given the commissioning attribute * . On returning to the normal program, the normal attributes are reapplied. Note: a) All keypad edits are temporary only. To make edits permanent use CSP. Table descriptions
The link text descriptions are added by the Editor, derived from the module definition files available in the Firmware Database. These may be over-ridden by a DEF TABLE command. See section 7.8 b) Comments
Comments can be added in the links program as an aid to user program documentation. These are added by preceding the comment with a semicolon (;).
7.9
Start-up Sequence
The following actions are performed on power up: BOOT UP The BOOT EEPROM checks whether a system (firmware database) is loaded. If there is no system loaded, then the BOOT EEPROM waits for a system to be loaded via serial link 0. If a system is present, then execution is passed from the EEPROM to the system in RAM, and execution continues as described below. The error messages that may be generated, are listed in section 12.3.9.
Note: -
MEMORY CHECKS The various memory components are checked. If there is a failure, execution will continue but the watchdog does not pick up and a fault message is displayed. I/O PROCESSOR The I/O processor is started. This enables information to be passed out over the serial link, and information to be obtained about the update status of the boards connected to the system. The I/O Processor performs the following checks
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Dual port RAM check EEPROM CRC RAM Checks Supply checks Basic I/O highway checks Set up serial link systems Set up & read serial EEPROM data Set up software key (20X4494/10B only)
INITIALISE DATA TABLES The data tables are cleared and initialised (see table in section 12.3). FAST TASK The fast task, which drives the power convertor, is started. DIGITAL INPUTS The Digital inputs are read and drive ID information stored. STATUS INITIALISATION The status flags are set. If the drive was running when it was last powered off, a request to run is set, otherwise it is held halted.
The system is now ready to perform its first execution cycle. 7.9.1 Execution Cycle The execution cycle for GD4000 is shown in Figure 7-1
Figure 7-1 Execution cycle flowchart
An execution cycle is the basic program loop performed continually by the SIGMA controller while the drive is powered up. The user program is called within this loop but is only executed if the controller status is running. An execution cycle always occurs, whatever the status of the controller.
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The following actions are performed for each execution cycle STATUS The controller status is determined. Making a transition from halted to running (of the user program) depends on the following: The hardware permissive (A32.7) being LOW Drive ID correct (if P8.0 = 1) Watchdog running.
The controller status is tripped immediately a watchdog trip occurs. If the user program is running, it can only be halted by the user if the hardware permissive is LOW (A32.7 off). A transition from HALT to RUN clears the data tables (as defined in the table in section 12.3). For more details on HALT-RUN and RUN-HALT transitions, see section 7.9.4. OUTPUTS The outputs are written as long as the controller is in the RUN, NORMAL status, otherwise all outputs are set to 0. a) b) The B table values are passed to the I/O processor for writing to the appropriate Basic I/O. The D tables are written to the 4 analog outputs.
INPUTS The inputs are read; The fast digital inputs are debounced by 1 scan of the fast task and transferred to A32 and A33. The Basic I/O inputs are read from the I/O processor and transferred to the A tables. The analog input values read by the fast task are transferred to the C tables. The supply values read by the I/O processor are transferred to the C tables.
SUPPLY CHECKS The supply checks are performed. If there is a supply fault for more than 100 ms then the watchdog is tripped and a fault message is displayed. The supply ranges are given in section 2 HOUSEKEEPING Various housekeeping functions are performed (such as maintaining the 0.1ms and 1 second flags (E0.0 and E0.1)). USER PROGRAM If the controller status is RUNNING then the user program is called. FIRMWARE DIAGNOSTICS Execute the firmware diagnostic module.
The controller now performs a background loop Page 7-14 Alspa GD4000 Technical Manual Issue (12-2-98)

7.9.2 Background Loop The background loop is serviced at least once every execution cycle. The background loop is serviced until the total execution time from the start of the execution cycle to the present time exceeds the time set in P1. The following functions are performed by the background task. SERVICE SERIAL LINKS The I/O processor is responsible for the handling of the communications protocol on links 0-3. The control processor is responsible for transferring the data to and from J and K tables, or responding to control or edit messages. TIMING FUNCTIONS The clock, calendar and timeout functions are updated at this point SELF TESTS The self tests are performed at this point. In order to minimise the effect of self tests on the execution cycle only a section of the memory tests are performed each scan. The total memory is checked within 10 seconds.
7.9.3
End of Execution Cycle At the end of the execution cycle the scan time in E7 is updated. The watchdog is reset if it has not yet be initialised and there are no watchdog faults. At the end of a scan, calculates: User Scan Time (P1 value) - Current Time. If there is time left to do a background loop again, it will. (i.e. Current time - Time now *) If no time is left, it goes back to start of Execution Cycle. If Execution Time is greater than P1, it will compensate for this on the next scan in order to make the average Execution Scan Time = P1
7.9.4
HALT/RUN Status The user program only performs a HALT to RUN transition if the following is true: a) The HARDWARE PERMISSIVE (Digital input A32.7) is LOW. If A32.7 is high and there is a request to run then a warning message is issued. The fault can only be cleared and the controller run by setting the A32.7 low. To allow the user to run the user program on power-up either: i) or: ii) Set P9.0 to 1 (to enable RUN on power up) wire A32.7 via the watchdog relay to allow the user program to enter the RUN state on power up.
Typically the A32.7 input is connected to the convertor supply on logic, and ensures that changes cannot be made unless the supplies are off. The program can only be halted with A32.7 high if the watchdog is tripped.
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b) The Drive ID is correct The Drive ID facility is designed to ensure that the correct user program is loaded into the correct drive. It cross checks a value in the user program with a value read from the hardware in the cubicle. The Drive ID is only checked when P8 is non-zero. The Drive ID is read from SW2 on the Customer I/O Board during power up (digital input A0.0 - A0.7). The setting of the Drive ID switches are explained in section 5.6.6. If P8 is set non-zero then the Drive Identity switch settings are checked against the bottom 8 bits of P0. If there is a discrepancy then the drive will not run, and a warning message is displayed. Note: This fault can only be cleared by either: i) Switching off the drive and changing SW2 to match P0 ii) Changing the value of P0 in the user program, recompiling and reloading the user program iii) Setting P8 to zero in the user program, recompiling and downloading
A copy of the drive ID read from SW2 is held in E21 c) The watchdog is healthy. The controller can only run if the watchdog is healthy. Note: The watchdog is held in an initialising state for the first scan of the execution cycle. This ensures that all the self checks are performed before the watchdog is set running. The consequence of this is that the controller is always in a halted state for the first scan of the execution cycle.
The status of the drive is remembered through power off. ie: If the program is running when the power is removed then the system will come up in the running state, provided that the checks given above are correct. The flag E0.6 is applied for one scan following a halt-run transition. E11.0 is set ON for the program running, set OFF for halted 7.9.5 TEST/NORMAL Status When TEST mode is selected the output values in the data tables can be changed without affecting the plant. In this mode all outputs are written to zero and are not affected by the values in the output data tables. Inputs affected are: All A tables Outputs affected are: All B tables D tables
Flag E11.1 is set ON in test mode. The controller must be halted in order to switch between modes.
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7.9.6 SINGLE SCAN Mode The user program can be run for a single cycle in order to test the operation of the user program logic. The flag E11.3 is set ON for one scan. If the data tables have not been initialised, then the first single scan performs this initialisation. The scan time is forced to the setting of P1 if non zero, or 2 ms if P1 is zero. 7.9.7 Commissioning Mode Commissioning edits can be made using the links editor. These program changes are only applicable when commissioning mode is selected. They are removed when normal mode is selected. The method of making commissioning mode changes is detailed in section 4.5.10. The user program needs recompiling and downloading whenever the mode is changed. A flag E11.2 is set when the program is in commissioning mode. 7.9.8 Execution Cycle Scan Time The scan time of the Slow Task, can be set by the user through P1 in data tables. This has a resolution of 1sec. A maximum scan time of 65 ms can be set. The system clock is used to time out the scan time. If the scan time exceeds P1 then the system will free run (i.e. the background loop only has enough time to execute once in a user scan). Due to other activities of the processor (such as the fast task and serial link information handler) the scan time of the control task varies about the set value. The average scan will be maintained at the level set by P1, provided that the system is not free running. The scan time of the fast task is not user programmable. The scan time for the previous scan is recorded in E7. E10 is incremented for each scan where the user program free runs.
Generic PID Module Notes
7.10
7.10.1
Generic PID Module Notes

Introduction The 3 term controller implemented in the standard modules has the form output = Kperror + Kp(INT[ error dt + Kd de/dt]) As the PID controller is digitised the proportional constant is scaled by 1024 to obtain a reasonable number range. The integral and derivative constants Ki and Kd are NOT scaled. The object of modules 1, 2, 11, 12, 80, 92, 97 and 280 is to enhance the dynamic performance of the controlled variable. A variable is controlled by having a set point or reference, L**03 and the response produced by the system, as a result of the output L**05, fed back at L**04. Some portion of the difference between the desired and the actual value of the controlled variable is output at L**05.
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The dynamic response of the controller can be altered by careful selection of the Kp, Ki and Kd terms, L**11,12 and 13 respectively. As can be seen from the module diagrams other functions have been added around the controller to allow it to: 1) 2) 3) 4) 5) 6) 7.10.2 perform output limiting (independently set min/max values) output the in min/max limit condition clamp the output to 0 on demand sum a test input in with the reference signal freeze the external and internal integral and derivative terms to prevent wind up supply a feed forward term to give instantaneous response of the output
Proportional Control Action For a controller with Proportional control action, the output of the controller is directly proportional to its input, the input being the error signal which is a function of time. So the output from the controller depends only on the size of the error at the instant of time concerned Oo(t) = Kp e(t) Where Kp is termed the proportional gain term.
7.10.3
Integral Control Action With Integral control only, the output of the controller is changed at a rate proportional to the error signal dOo(t) = Kie(t) dt
7.10.4
Derivative Control Action With derivative control only, the output of the controller is proportional to the rate of change of error with time.
7.10.5
Feedback Scaling All PID modules used by the standard ladder and links program have their feedbacks correctly scaled for the references.
7.10.6
Output Limiting The output L**05 of the PID function can be limited by the use of variables L**14 and L**15. The limits will vary depending on the use within the GD4000 e.g. modules 11 and 12 have dynamic limiting operating within the code. When the output is in limit variables L**8 and L**9 indicate this condition.
7.10.7
Anti Wind Up Code If the output of the controller reaches some limit and the feedback does not change to bring about a return to normal control action, then the integral and derivative parts of the error signal would carry on incrementing. If this was allowed to go unchecked then the output would remain in limit for a time after the error reaches zero. To preent this occurring on a limit condition existing within the controller the integral and derivative parts of the error are frozen until such time as the output comes out of limit. The regulator can be frozen from an external source using L**25.
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7.10.8 Output Clamp The output can be clamped to zero at any time by use of the variable L**01 release regulator. 7.10.9 Test Input The regulator has a test input. This allows additional signals to be summed prior to the PID function. This input is useful for tuning operations. 7.10.10 Feedforward Input The feedforward input is summed with the output of the PID regulator prior to being magnitude limited. Modules 1, 2, 11 ,12 and 197 as well as exhibiting all the features of the other modules have additional features indicated here. 7.10.11 Feedback Filter Remainder L**53 selects whether a remainder should be kept when calculating the filtered feedback value. When set to a 1 the remainder is calculated and used. 7.10.12 Output Limiting It is possible to cross-link the output limits from one PID module to another. This allows, for example when two PIDs are controlling orthogonal variables, for one PID to produce an output to its maximum limit and for the limit on the other PID to use the remainder. The limit from the other PID is linked to L**36 and the choice between normal limits and the new dynamic limit is done via L**35, with a 1 selecting the dynamic limit option. 7.10.13 PID Bypassing The user can inject a value that is passed directly to the output of the module, bypassing the usual PID control and output limiting. This is achieved by placing the reference value on L**39 and selecting this reference by setting L**38 to a 1. 7.10.14 Alternative Derivative Input The user may link the input to the derivative term of the PID controller from a signal other than the normal error signal. This additional input should be linked to L**33. For the alternative calculation L**127 needs to be set to a 1. The output of the alternative derivative calculation is then limited to the value given by L**31. In order to then select the alternative derivative calculation output L**30 must also be set to a 1. 7.10.15 Error Value Limiting When the error value is calculated from : error = reference + test input - feedback this error value is limited to a maximum value of 2500. 7.10.16 Integral Calculation Alternatives There are three type of integral calculation that can be performed upon the module error signal. If L**34 is set to a 0 then normal 10 bit calculations are used. If L**34 is set a 1, more accurate 16 bit calculations are performed, and if L**34 is set to a 2 the integral calculation output is set to 0.
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7.11
Fast Task Schematic Diagrams

The fast task diagrams relate to firmware issue 00S060-4002 revision B. There are three basic configurations of GD4000, each requiring a different fast task variant. These are as follows: Fast task 0 Fast task 1 Fast task 2 AC input AC single motor vector control output. DC input two motor vector control output. DC input single motor (2 bridges connected in parallel), vector control output.
The fast task variant required is selected using software module 10 (L1007). The fast task schematic diagrams are nested into a number of levels, each level showing more detail than the previous one. All signals from hardware are shown as dotted lines, double arrowheads show continuous quantities, and single arrow heads showing discontinuous (sampled) values). These diagrams are implementational models for the software and are not meant to be read as circuit diagrams. The firmware database disk contains versions of ladder and links code specific to each application type defined above as follows: 4002B-C0.GDM and 4002B-C0.GLP relate to ac input, single motor vector controlled output (fast task 0). 4002B-C1.GDM and 4002B.C1.GLP relate to dc fed twin motor vector controlled output (fast task 1). 4002B-C2.GDM and 4002B-C2.GLP relate to dc fed single motor vector controlled output, with two output bridges operated in parallel (fast task 2). Note: Although included in the distribution disks, do not invoke the ladder and links programs 4002B-C3.GDM/GLP or 4002B-C4.GDM/GLP.
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7.12
Fast Task 0
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7.13
Fast Task 1
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7.14
Fast Task 2
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8. Installation
Installation
WARNING THIS EQUIPMENT WEIGHS MORE THAN 20 kg. IT SHOULD BE MOVED WITH LIFTING APPARATUS.
8.1
Receipt of Equipment
When the equipment arrives on site, it should be carefully unpacked and inspected. The complete consignment should be checked against the delivery note for any loss in transit. If damage has occurred, or parts are missing, CEGELEC Industrial Controls Limited, Kidsgrove Works, or local agents, should be informed immediately and the following details quoted:
List of damaged or missing items. Description of damage. Delivery/advice note numbers and dates, and any other reference numbers such as
order and item numbers. Note: Failure to inform CEGELEC Industrial Controls Ltd, Kidsgrove Works, or local agents, of shortages or damage to goods within three days from receipt will be held to free CEGELEC Industrial Controls Limited or local agents from liability.
8.2
Storage
GD4000 must always be stored in a clean, dry, dust-free environment. If it is not to be used immediately the drive should be replaced in its original packing after inspection. If the original packing is not available, wrap the drive in a polythene sheet or similar for protection. Refer to Section 2.11.5 for long term storage, temperature and humidity requirements.
8.3
Siting Considerations
Before installing the drive refer to Sections 2.11.6 and 8.3.2 for guidance on cooling requirements (particularly if fitting the drive within a cubicle) and other general environmental considerations. The drive must always be firmly mounted upright to a flat vertical surface. On the GD4080, GD4120 and GD4160 the line reactors, precharge box and the line contactor are not built into the drive. These are supplied as loose items which must be mounted within a suitable control enclosure following the instructions provided in this section.
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8.3.1 Dimensions and Fixing Centres
Figure 8-1 GD4010 to GD4060 dimensions
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Figure 8-2 GD4080 to GD4160 dimensions
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Figure 8-3 Precharge box dimensions (GD4080 to GD4160)
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Figure 8-4 Input line reactor dimensions (GD4080)
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8.3.2 Airflow Requirements When the drive is to be installed into an enclosure or cubicle it is important to ensure adequate airflow for cooling. The cooling arrangement must cope with the maximum heat dissipation of all components operating within that compartment (contactors, relays, resistors, cubicle lighting etc.). The air temperature within any enclosure must remain within the operating limits of the Alspa GD4000 as detailed in Section 2.11 at all times. Where cubicles/enclosures are constructed with extractor fans and filtered inlets the pressure drop across the filters must be kept to a minimum. Always make allowance for the additional pressure drop resulting from the accumulation of dust between filter servicing periods. A minimum clearance of 100 mm should be allowed above and below the drive to ensure adequate airflow. It is the responsibility of the installer to ensure GD4000 is installed and operated within its environmental limits as specified in Section 2.11 of this manual.
8.4
Mounting
8.4.1
Drives The drive should be mounted to a vertical surface by bolting through the keyhole slots in the rear flanges. Use M6 hexagon head bolts minimum grade 8.8 with plain and spring washers, or, if fixing to masonry, use M6 hexagon head expanding masonry bolts minimum grade 8.8. See Section 8.3.1 and figures 8-1 and 8-2 for the drive fixing centres and dimensions. The protective tray and hood are for wall mounted installations only. Ensure all six fixings are secure before removing the lifting gear.
8.4.1.1
Line Reactors
WARNING EXPOSED HIGH VOLTAGES ALL EXPOSED HIGH VOLTAGES MUST BE ENCLOSED BEFORE THE EQUIPMENT IS ENERGISED. Line reactors are supplied as loose equipment and must be mounted close to the drive to keep cable runs short in order to reduce the effects of radiated noise. Figures 8-4 to 8-6 show the fixing centres and dimensions for the input line reactors. These will require shrouding for the terminals and should be mounted within a suitable enclosure. The frame of the line reactors must be connected to Earth (Ground).
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8.4.2 Line Contactor A line contactor contactor should be mounted close to the drive in accordance wtih the manufacturers instructions. Suitable line contactors are available from CEGELEC. 8.4.3 Precharge Equipment (GD4080, GD4120 and GD4160 only) For the GD4080, GD4120 and GD4160 the precharge box is supplied as a loose item and must be mounted close to the drive in an enclosure Figure 8-3 shows the fixing centres for the precharge box. This should be mounted upright to a flat vertical surface by four M5 hexagon head bolts, minmum grade 8.8, through the holes in the rear panel. 8.4.3.1 Precharge Electrical Connections The wiring connections for the precharge unit are shown in Section C5.3 drawing number KC3/10E5402.
8.5
Power Connections
WARNING HIGH VOLTAGES ALL DOORS MUST BE CLOSED AND ALL SHROUDS REPLACED BEFORE THE EQUIPMENT IS ENERGISED. HIGH LEAKAGE CURRENT EARTH (GROUND) CONNECTIONS TO THIS EQUIPMENT AND THE MOTOR(S) DRIVEN BY THE EQUIPMENT MUST BE CONNECTED AT ALL TIMES. Caution All conductors connected to this product must be restrained. In common with all inverters of this type the PWM generates a high leakage current (partially due to the capacitance in the motor). This equipment is designed for fixed installation. It is essential that both the drive and the motor are earthed before the supply is connected.
8.5.1
Supply Voltage Selection (GD4080, GD4120 and GD4160 only) On the GD4080, GD4120 and GD4160 the fan supply transformer should be set to match the supply voltage. Voltage selection is performed by connecting the floating wire (marked 25) on the transformer terminal block, to the appropriate terminal. Terminals are clearly marked with the supply voltage options as shown in Figure 8-7.
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Figure 8-7 Supply voltage selection (GD080 to GD4160)
8.5.2
Power Terminals The power terminals for the GD4010 to GD4060 are located inside the front door of the drive at the bottom right hand side. They are suitable for the direct termination of flexible cables. The power terminals for the GD4080, GD4120 and GD4160 are located inside the front door along the bottom of the drive. Cables should be terminated with M8 ring crimps. Note: The shrouds covering the high voltage terminals must be replaced after installation.
8.6
Earthing
WARNING ALL EQUIPMENT PROVIDED MUST BE CONNECTED TO EARTH (GROUND) FROM THE EARTH TERMINAL PROVIDED. THE MINIMUM SIZE OF THE PROTECTIVE CONDUCTOR MUST BE IN ACCORDANCE WITH LOCAL SAFETY REGULATIONS. The GD4000 must always be earthed via the main earth terminal with a suitably rated cable. The motor connected to the drive must also be earthed.
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8.6.0.1 Torque Settings and Conductor Sizes
Table 8-1 Torque Settings and Conductor Size
Drive Unit GD4010 GD4020 GD4030 GD4040 GD4060
Power Connections
Torque
Terminal Material
Conductor Size
M4 Screw
1.2 Nm (11 lb ins)
Pin crimp CU
2.5 mm2
AC GD4080 GD4120 GD4160 M8 bolt 10 Nm (90 lb ins) Ring crimp CU or Copper clad aluminium 35 mm
2
DC 25 mm2
50 mm2 50 mm2 50 mm2 50 mm2
All power terminals must be connected as described in the relevant installation procedures and tightened to the correct torque loading shown in Table 8-1.
Key: 1 2 3 4 5
DC Link Terminals (M8 bolts) Drive output terminals marked U, V and W (M8 bolts) Drive main earth stud (M8 bolt) Drive input terminals marked R,S and T (M8 bolts) Cable gland plate fitted with blank grommets
Figure 8-8 Power terminals (GD4080 to GD4160)
For conductor sizes for GD4000 DELTA configurations refer to cable manufacturers data.
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8. Installation
8.7
Control Cabling
Caution All conductors connected to this product must be restrained. All control terminations are located on the Customer I/O Board and the optional Analog Termination Panel.
8.7.1
Segregation The control connections are, in general, low voltage and low current signals. This makes them inherently susceptible to interference from electromagnetic noise generated by power cabling. Therefore, in all applications, the control wiring should not be run directly alongside power wiring. Ideally separate trunking should be used to run control wires, if this not possible, a separation of at least 300 mm (12") should be maintained between the control wires and any power cables. General segregation rules are included in the typical schematic 10E5402 in Appendix C section C5.3. To minimise radio frequency emissions and interference, input supply cables should be routed separately from the output cabling to the motor.
8.7.2
Customer I/O Board
Figure 8-9 Layout of 20X4495 Customer I/O Board
Terminals for connection of outgoing and incoming control wiring are found along the lower edge of the Customer I/O Board. These terminals are designed to accept up to 2.5 mm2 cables.
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Note: The HDLC Terminal panel shown Figure 8- 9 cannot be mounted on the Customer I/O Board inside a BDM since it will prevent the door from closing. It can only be mounted as shown on a remote mounted Customer I/O Board. If the HDLC Card is used with a BDM it must be mounted outside the BDM and connected with the cable provided.
8.7.3
RS485 Serial Links
Figure 8-10 TB7A and 7B, Serial Links 1 and 2
8.7.3.1
Serial Link 0 (via TB7B) Terminal TB7B/1 TB7B/2 TB7B/3 TB7B/4 TB7B/5 TB7B/6 TB7B/7 TB7B/8 Note: Board Legend Function 485 485 TX+ TXRX+ RXSCN SCN Select RS485 Select RS485 Transmit + Transmit Receive + Receive Screen 0 V Screen 0 V
To activate the RS485 serial link 0 on TB7B a link must be fitted between TB7B/1 and TB7B/2 (RS485 select) this will cause D65 to be lit. If this link is omitted, serial link 0 will be available as an RS232 link on SK4 and led D94 will be lit. The screen terminals are connected internally via PL15.
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8.7.3.2 Serial Link 1 (via TB7A) Terminal TB7A/1 TB7A/2 TB7A/3 TB7A/4 TB7A/5 TB7A/6 TB7A/7 TB7A/8 *Note: 8.7.3.3 Board Legend Function n/c n/c Transmit + Transmit Receive + Receive Screen 0 V * Screen 0 V *
TX+ TXRX+ RXSCN SCN
These screen terminals are connected to earth internally via PL15.
Serial Link 0 (via SK4)
Figure 8-11 Serial link Connectors SK4 and SK5
Connector type: 9-way D-type socket Pin SK4/1 SK4/2 SK4/3 SK4/4 SK4/5 SK4/6 SK4/7 SK4/8 SK4/9 Note: Function n/c Transmit Receive n/c 0V +8 V n/c +8 V n/c
The metal shell of SK4 is connected to earth internally via PL15.
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8.7.4 RS232 Serial Links See Figure 8-11 8.7.4.1 Serial Link 2 (via SK5) Connector type: 9-way D-type socket Pin SK5/1 SK5/2 SK5/3 SK5/4 SK5/5 SK5/6 SK5/7 SK5/8 SK5/9 Note: 8.7.5 Function n/c Transmit Receive n/c 0V +8 V n/c +8 V n/c
The metal shell of SK5 is connected to earth internally via PL15.
Encoder Connections
Figure 8-12 Encoder Connections TB8A and TB8B
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8. Installation
8.7.5.1 Incremental Encoder 1 (via TB8B) Pin TB8B/1 TB8B/2 TB8B/3 TB8B/4 TB8B/5 TB8B/6 TB8B/7 TB8B/8 TB8B/9 TB8B/10 *Note: Board Legend Function A A B B C C 12 V 5V 0V SCN Encoder A Encoder A* Encoder B Encoder B* Encoder C Encoder C* Isolated 12 V for remote encoder Isolated 5 V for local encoder Isolated 0 V* Screen 0 V
The isolated supply for encoder 1 is not the same supply as the isolated supply for encoder 2. The screen 0V is connected to earth internally via PL15.
PL260, PL261 and PL262 allow the user to select whether or not to include the 220 and 1 nF network on each encoder channel input. It is recommended that under normal circumstances, the jumper link provided is fitted across pins 1 and 2 of each of these. However if the user requires a single encoder to be connected to multiple Customer I/O Boards, the jumper links should be fitted in the R position on the last Customer I/O Board, and position R on all other Customer I/O Boards (pins 2 and 3 connected). See Figure 8-12.
Figure 8-13 Encoder Channel Schematic Diagram
8.7.5.2
Incremental Encoder 2 (via TB8A) Terminal TB8A/1 TB8A/2 TB8A/3 TB8A/4 TB8A/5 TB8A/6 TB8A/7 TB8A/8 TB8A/9 TB8A/10 *Note: D D E E Board Legend Function Encoder D Encoder D Encoder E Encoder E n/c n/c Isolated 12 V for remote encoder Isolated 5 V for local encoder Isolated 0 V* Screen 0 V
12V 5V 0V SCN
The isolated supply for encoder 1 is not the same supply as the isolated supply for encoder 2. Alspa GD4000 Technical Manual Issue (12-2-98)
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8. Installation
The screen 0V is connected to earth internally via PL15. PL263, and PL264 allow the user to select whether or not to include the 220 and 1 nF network on each encoder channel input. It is recommended that under normal circumstances, the jumper link provided is fitted across pins 1 and 2 of each of these plugs in the position marked R in the circuit shown in Figure 8-12. However if the user requires a single encoder to be connected to multiple Customer I/O Boards, the jumper links should be fitted between pins 1 and 2 on the last Customer I/O Board and between pins 2 and 3 on all other boards. Note: PL263 pin 1 and PL264 pin 1 are nearest TB8. To utilise two encoders with firmware database OOS060-4003A/B1/B2: connect encoder 2 channel A and A to TB8B/5 and TB8B/6 respectively. Connect encoder 2 channel B and B to TB8A/1 and TB8A/2 respectively. Link TB8B/9 to TB8A/9. To invoke the second encoder set L2090 = 2 and L2050 = 1 in the links program. 8.7.5.3 Dedicated Digital Input Connections
Note:
The digital I/O can be powered from an external supply if required.
Figure 8-14 Dedicated Digital Inputs TB9A and TB9B
Terminal TB9B/1 TB9B/2 TB9B/3 TB9B/4 TB9B/5 TB9B/6 TB9B/7 TB9B/8 TB9B/9 TB9B/10 TB9A/1 TB9A/2 Issue (12-2-98)
Board Legend Function 0 1 0V V1+ V1+ V1+ V1+ 0V 6 7 0 1 A32.00 Input low A32.01 Input low for 48 V supply Plant supply for digital inputs Plant supply for digital inputs Plant supply for digital inputs Plant supply for digital inputs for 48 V supply A32.06 Input low A32.07 Input low A32.00 Input high A32.01 Input high Page 8-17
8. Installation
TB9A/3 TB9A/4 TB9A/5 TB9A/6 TB9A/7 TB9A/8 TB9A/9 TB9A/10 Note: V1+ 2 3 4 5 V1+ 6 7 Plant supply for digital inputs A32.02 Input high A32.03 Input high A32.04 Input high A32.05 Input high Plant supply for digital inputs A32.06 Input high A32.07 Input high
0, 1, 6, and 7 are the individually isolated reference voltages for digital inputs A32.00, A32.01, A32.06 and A32.07 respectively. The legend shows suggested external links between 0, 1, 6, and 7 and 0V(48V). The reference voltage for digital inputs A32.02, A32.03, A32.04 and A32.05 is V1- (pin 9 on TB10B).
8.7.5.4
Basic I/O Scanned Digital Inputs
Figure 8-15 Basic I/O Scanned Digital Inputs TB10A and TB10B
Basic I/O Scanned DigitalI nputs TB10A and TB10B
Terminal TB10B/1 TB10B/2 TB10B/3 TB10B/4 TB10B/5 TB10B/6 TB10B/7 TB10B/8 TB10B/9 TB10B/10 TB10/A1 TB10/A2 TB10/A3 TB10/A4 TB10/A5 TB10/A6 48V V1+ V1+ V1+ V1+ V1+ V1+ V1+ V10V 48V 0 1 2 3 4
Board Legend Function 48 V supply Plant supply for digital inputs Plant supply for digital inputs Plant supply for digital inputs Plant supply for digital inputs Plant supply for digital inputs Plant supply for digital inputs Plant supply for digital inputs Input low for A32.02 - A32.05 and A1.00 - A1.07 0 V for 48 V supply 48 V supply A1.00 Input A1.01 Input A1.02 Input A1.03 Input A1.04 Input
high high high high high
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TB10/A7 TB10/A8 TB10/A9 TB10/A10 Note: 5 6 7 V1+ A1.05 Input high A1.06 Input high A1.07 Input high Plant supply for digital inputs
V1+ is a node which has no direct connection to the internal circuits on the board. It is there to provide a plant supply reference point from which the user may connect digital inputs. The PCB legend shows a suggested external link between V1+ and 48V. V1- is the common reference voltage for A32.02 to A32.05 and A1.00 to A1.07. The pcb legend shows a suggested external link between V1- and 0V(48V).
8.7.5.5
Basic I/O Scanned Digital Outputs
Figure 8-16 Basic I/O Scanned Digital Inputs TB11A, TB11B, TB12A and TB12B
Basic I/O Scanned DigitalI nputs TB11A, TB11B, TB12A and TB12B
Terminal TB11B/1 TB11B/2 TB11B/3 TB11B/4 TB11B/5 TB11B/6 TB11A/1 TB11A/2 TB11A/3 TB11A/4 TB11A/5 TB11A/6 TB12B/1 TB12B/2 TB12B/3 TB12B/4 TB12B/5 TB12B/6 TB12A/1 TB12A/2 TB12A/3
Board Legend Function 0V V2V2V2V2V248V V2+ 8 9 10 11 0V V3V3V3V3V348V V3+ 12 0 V for 48 V supply B1.08 to B1.11 output low
48 V supply Plant supply for outputs B1.08 to B1.11 B1.08 Output high B1.09 Output high B1.10 Output high B1.11 Output high 0 V for 48 V supply B1.12 to B1.15 output low
48 V supply Plant supply for outputs B1.12 to B1.15 B1.12 Output high Page 8-19
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TB12A/3 TB12A/5 TB12A/6 Note: 13 14 15 B1.13 Output high B1.14 Output high B1.15 Output high
Each of the digital outputs B1.08 - B1.11 will have a voltage level V2+ with respect to V2- when enabled. The pcb legend shows a suggested link between 0V (48V) and V2- and also between 48V and V2+. Similarly each of the outputs B1.12 - B1.15 will have a voltage level of V3+ with respect to V3- when enabled. The pcb legend shows suggested links connected between 48 V and V3+ and between 0V(48V) and V3-.
8.7.5.6
Basic I/O Feedback Configuration Link On the 20X4495 Cusomer I/O board there is a link LK1, physically located beneath the 20X4454 analog termination panel, which configures the way in which the SIGMA checks that basic I/O is operating correctly. This link has two positions as shown in Figure 8-17.
Figure 8-17 Customer I/O Board Showing Link LK1
The GD4000 can operate correctly with this link in either position, but the position of this link must be matched with the value of the P-table P9.02. The value of P9.02 should be: P9.02 = 0 for LK1 in position 1 (pins 1-2 connected) P9.02 = 1 for LK1 in position 2 (pins 2-3 connected) The default setting for LK1 is position 1.
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8.7.5.7 Watchdog Output
WARNING HIGH VOLTAGES AND HIGH STORED ENERGY LEVELS THE INPUT SUPPLY MUST BE ISOLATED AND ALL MOTORS CONNECTED TO THE EQUIPMENT MUST BE AT A STANDSTILL FOR A PERIOD OF 5 MINUTES BEFORE ACCESS TO THE EQUIPMENT IS ALLOWED. HIGH VOLTAGES MAY BE PRESENT ON THESE TERMINALS FROM EXTERNAL WIRING. ALWAYS REPLACE THE SHROUD TO TB13 .
Figure 8-19 Watchdog Terminals TB13
Terminal TB13/1 TB13/2 Note:
Board Legend WD WD
Function Watchdog Relay Output Watchdog Relay Output
The shroud covering the Watchdog terminals must be replaced after installation.
8.8
Analog Termination Panel

Screw-type terminals are provided for the analog inputs and outputs on the analog termination panel (option). Provision is made for mounting the Analog Termination Panel on the right hand side of the Customer I/O Board. See Figure 8-9.
8.8.1
Analog Inputs
Figure 8-18 Analog Input (TB17)
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8. Installation
The Analog Termination Panel provides 4 analog input channels. These inputs are allocated to the following C tables. Terminal TB17/1 TB17/2 TB17/3 TB17/4 TB17/5 TB17/6 TB17/7 TB17/8 TB17/9 Board Legend Function 0+ 01+ 12+ 23+ 3SCN Signal - analog input 0 Common - analog input Signal - analog input 1 Common - analog input Signal - analog input 2 Common - analog input Signal - analog input 3 Common - analog input Customer screen 0V C tables C5 0 C6 1 C7 2 C8 3
Additionally, 20X4486 and 20X4489 PIBs are fitted with a 25 way D-type connector, labelled SK256, to which the user can connect a second analog termination panel which can be mounted externally to the drive. This second analog termination panel provides 2 additional analog inputs plus two dedicated motor thermistor channels. The function of these inputs are as follows: Terminal TB17/1 TB17/2 TB17/3 TB17/4 TB17/5 TB17/6 TB17/7 TB17/8 TB17/9 8.8.2 Analog Outputs Board Legend Function 0+ 01+ 12+ 23+ 3SCN C tables
Signal - analog input 4 C17 Common - analog input 4 Signal - analog input 5 C18 Common - analog input 5 Motor thermistor 1 Motor thermistor 1 Motor thermistor 2 Motor thermistor 2 Customer screen 0V
Figure 8-20 Analog Outputs (TB18)
Terminal TB18/1 TB18/2 TB18/3 TB18/4 TB18/5 Page 8-22
Board Legend Function 0 1 2 3 COM Output 0 Signal D0 Output 1 Signal D1 Output 2 Signal D2 Output 3 Signal D3 Outputs 0 - 3 (Common) Issue (12-2-98)
8. Installation
Note: No additional analog outputs are made available when a second Analog Termination Panel is fitted.
8.8.3
Analog I/O Supplies
Figure 8-21 Analog I/O Supplies
Terminal TB19/1 TB19/2 TB19/3 TB19/6 8.8.4 External Thermistors
Board Legend Function +15V AOV -15V SCN +15 V supply Analog 0 V -15 V supply Customer Screen 0 V
The type 2 PIBs, ie 20X4486 and 20X4489, also support the use of external thermistors and thermostats which can be fed into the drive and treated as part of the drives own protection strategy. The thermistor and thermostat connections available are as follows: 20X4489 A single external temperature feedback is available via a thermistor and thermostat / shorting link and is provided by: PL250 Thermistor connection - suitable for a thermistor of type Microtherm TC25P5KAT(600) as is fitted to DELTA rectifier heatsinks and GD4000 transistor bridge heatsinks PL248 Thermostat or shorting link This temperature feedback will appear as temperature feedback 5 in software, see Module 90 in Section 14.22.1. 20X4486 The 20X4486 PIB is fitted with two 20X4487 daughter boards and each of these daughter boards is fitted with a pair of connectors to connect to an external thermistor and thermostat / shorting link. These connectors are labelled as PL248 and PL250 and provide an identical function to PL248 and PL250 on the 20X4489 board. The two temperature feedbacks generated from the bridge A 20X4487 and the bridge B 20X4487 will appear as temperature feedbacks 9 and 10 respectively. See Module 90 in Section 14.22.1
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8. Installation
8.9
Earthing
WARNING ALL EQUIPMENT PROVIDED MUST BE CONNECTED TO EARTH (GROUND) FROM THE EARTH TERMINAL PROVIDED. THE MINIMUM SIZE OF THE PROTECTIVE CONDUCTOR MUST BE IN ACCORDANCE WITH LOCAL SAFETY REGULATIONS. The GD4000 must always be earthed via the main earth terminal with a suitably rated cable. The motor connected to the drive must also be earthed. Internally, all customer 0 V and screen terminals are routed to earth via the I/O board. It is, however, possible to disconnect the internal earth connections to these terminals, individually or as a complete group, and re-route them to another point. To separate customer 0 V connections from the common drive earth, disconnect the 0 V by removing zero ohm links serial link 0 serial link 1 serial link D type (links 1 & 2) serial link 2 D type via zero ohm link (I/O board) via zero ohm link (I/O board) via zero ohm link (I/O board) via zero ohm link (I/O board)
8.9.1
Notes on Encoder Earthing In order to minimise the electrical noise in the encoder wiring, the following practices should be observed: 1) The motor should be earthed locally, in addition to any safety earth or motor cable or screen earth connections at the drive. 2) Cut back the encoder cable screen the minimum amount required to make the connection and connect the encoder cable screen to TB8A/10 or TB8B/10 on the customer termination panel. The screen connection should be kept as short as possible. The screen should if possible be continuous from the encoder to the termination panel. If it is necessary to break the screen to pass through a termination rail or junction box, the following practices should be observed: i) Cables must be well segregated from other cables.
ii) The screen should continue through the termination rail and should surround the terminations (forming a Faraday cage) with the cage earth connected to the main cubicle earth. iii) The cable pairs for each encoder signal group A, B, etc. should be twisted together as they leave the screened cable and remain tightly twisted up to the termination rail. 3) Connect the transducer end of the cable screen to an earth close to the encoder (i.e. not more than 1 metre from the encoder). Notes: a) Transducers with plug and socket cable connections are preferred to the flying lead type, since it removes the need for a further termination chamber close to the motor, thus reducing cabling errors, connection loss and screening problems; the screen can then be continuous from drive to transducer. An earth wire will need to be Alspa GD4000 Technical Manual Issue (12-2-98)
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8. Installation
connected to the encoder screen inside the plug to connect to the local earth. b) If a flying lead type encoder is used, the flying lead should be kept as short as possible, so that it is earthed close to the encoder, a termination chamber should be used if necessary and the instructions in paragraph 2) should be observed.
4) The screen of the transducer cable should be connected to the case/body of the transducer. Check for continuity between the encoder body and the cable screen. 8.9.2 Segregation The encoder cable must NOT be run from the drive to the motor alongside the motor power cables or any other power cables. 8.9.3 Encoder Power Supply If the cabling length between the motor and drive is greater than 15 metres, it may be necessary to use a remote power supply for the encoder. This should be mounted close to the encoder. Alternatively a remote power supply board (20X4474 contain in 31V4400/10) which takes 12 V from the 20X4495 customer termination panel and produces a locally regulated 5 V supply may be used. 8.9.4 Cubicle Cable Earthing Notes 1) All cubicles should be connected together with an earthing busbar which is rated for the fault current required by the system and earthed at a single point, preferably at the power distribution sub-station. 2) The main drive power earth should be connected to the cubicle busbar earth, as should the cubicle and motor cable armoured/fourth core. 3) All the drives in a system should have their own system 0 V earth connections, with the 0 V earthing conductor for each drive being taken back individually to the main earthing point. 4) Power cabling and signal cabling (including screens) should be segregated from each other; preferably by using one side of the cubicle for power cables and the other side for signal/screen cables.
8.10
Disposal Considerations
The GD4000 contains no components or chemicals which should be considered as harmful. If batteries have been employed in auxiliary supply support these will probably need special disposal considerations. Refer to the battery manufacturers (or suppliers) documentation for guidance. Before dismantling an installation ensure that:
the power supply has been fully disconnected there are no live control inputs to the drive (independently supplied) battery back-up supplies (where fitted) are disconnected.
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8. Installation
After the main supply has been disconnected wait at least 5 minutes to allow the d.c. link capacitors to discharge before starting work. Double-check all terminals with a voltmeter before starting work. Normal handling precautions should be observed; the weight of the GD4000 is listed in Section 2.12.
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Commissioning
WARNING: HIGH VOLTAGES AND HIGH STORED ENERGY LEVELS ALL ELECTRIC SUPPLIES MUST BE ISOLATED AND ALL MOTORS CONNECTED TO THE EQUIPMENT MUST BE AT A STANDSTILL FOR A PERIOD OF 5 MINUTES BEFORE ACCESS TO THE EQUIPMENT IS ALLOWED. CAUTION High voltage insulation tests can damage this equipment. Cables/external components to be insulation tested must be disconnected from this equipment.
9.1
Introduction
This chapter describes the basic commissioning procedures which are required to set an AC input single motor drive to work. These procedures should be carried out in the sequence given in this section. During commissioning the drive will be controlled using a PC connected to the drive via a serial link. The PC must have CSP installed (see Section 4.2.1) together with the correct user program and database. The User Program used to control the drive may be either the standard user program supplied with the drive or an application specific program, which has been developed off-line. Appendix G (Vol 2 Section 2) details the Standard Ladder and Links files supplied with this manual. Subsequent instructions will assume that these files are used.
9.2
Special Tools
The following equipment is required for commissioning GD4000: Digital storage oscilloscope. Digital Multi-Meter. PC with CSP installed and serial link cable. Clip -on current monitor e.g. Heme.
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9. Commissioning
9.3
9.3.1
Commissioning Procedures
Mechanical checks
Ensure that the drive unit has been installed in accordance with the instructions given
in Section 8.
Ensure that there is adequate clearance around the drive for ventilation and that
ventilation openings are not blocked.

Ensure the motor is installed correctly and uncoupled from the load. Ensure the encoder is installed correctly and that encoder shaft alignment is to the
manufacturers specifications. 9.3.2 Electrical Checks

Ensure the voltage of the 3-phase supply is within the range specified in section
2.2.1.
Ensure the correct fuses are fitted (see section 6.3). Complete any insulation tests, ensuring that the cables being tested are NOT
connected to the drive.

Ensure the motor is properly grounded. Ensure the U, V and W motor cables are connected to the U, V and W terminals of
the drive.
Ensure the encoder is connected correctly and that the encoder screening is to the
manufacturers guidelines. If the manufacturers guidelines are not available, guidance on encoder screening is given in section 8.9.1.
Ensure the drive is properly grounded. Connect the 3-phase input supply cables to the R, S and T connections on the drive. Ensure the Aux. Input connections and pre-charge panel input are connected in
accordance with section 8.4.3.1.

Drives with a separate pre-charge panel (GD4080 and above) must be checked for
correct phase rotation (see 9.3.18).

Carry out continuity checks as required.
9.3.3
PC Control/Monitoring
Ensure the PC to used for commissioning the drive has CSP program installed (see
Section 4).
Ensure the correct firmware database is resident on the PC. Ensure the correct User Program is resident on the PC. It is recommended that a
copy of the User Program is made for commissioning, so that the default settings can be restored in the event of any problems occurring.
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9.3.4 User Program Basic Edits Before downloading the User Program to the drive, it must be edited to configure the drive to the supply and motor. The User Program basic edits are split into three categories as follows: 9.3.4.1 Drive Data L1002 = select auto-set-up B - causes the drive to auto-configure the input bridge from the module 99 parameters entered below. L1005 = Drive type e.g. enter 4060 for a GD4060. L9949 = Power throughput - enter the continuous power rating of the motor in kW (from the nameplate). L9950 = Max supply frequency - enter the maximum expected supply frequency. L9951 = Nominal Supply volts - enter the nominal supply voltage of the 3-phase input supply L9952 = +ve volts tolerance - enter the +ve tolerance of the supply voltage (%). L9953 = -ve volts tolerance - enter the -ve tolerance of the supply voltage (%). L9954 = input inductance - enter the input supply inductance (mH) see section 6.7.4. L9963 = Select auto-tune - causes the drive to tune the input bridge filter offset automatically. L9536 = Auto-set sigma. L9522 = Back e.m.f. scaler. - enter after first download see 9.3.9.2 P9.2 = 20X4495 Customer I/O Board fitted. (Set to 0 if 20X4453 is fitted). 9.3.4.2 Basic Output Bridge Parameters Motor Model
Figure 9-1 Motor Equivalent Circuit
The motor model data must be entered in STAR equivalent form i.e. divide DELTA equivalent impedances by 3 and divide DELTA equivalent voltages by 3. L9401 = L9402 = L9403 = L9404 = L9405 = L9406 = L9407 = L9408 = L9409 = L9413 = Issue (12-2-98) Stator resistance in (Rs) m Stator Inductance (Ls) in H Rotor Resistance (Rr) in m Rotor Inductance (Lr) in H Magnetising resistance (Rm) in m Magnetising Inductance (Lm) in H Base frequency in Hz Motor volts at base frequency (Vs) Drive Vmax - entered later see section .9.3.9.1 Motor poles - from motor nameplate. Alspa GD4000 Technical Manual Page 9-3
9. Commissioning
L9434 = Peak motor current - determined from application requirements usually 1.5 x continuous motor current (in amps). L9436 = Continuous motor current - from motor nameplate (in amps). 9.3.4.3 Miscellaneous parameters L1013 = PID set-up read, causes drive to calculate the motor current loop PID settings L1015 = Current loop bandwidth - required bandwidth for motor current loops L2104 = Encoder line count (from encoder label). L2728 = Continuous current level, sets the current level at which I2T overload begins (OOS060-4004 only). L8656 (mode 10101) = Network bridge, continuous current level, sets the current level at which I2T overload begins (OOS060-4005 only). L8666 (mode 10101) = Machine bridge, continuous current level, sets the current level at which I2T overload begins (OOS060-4005 only). Note: This value is calculated as follows: L2728 = Continuous motor current x 101 peak drive current where: Continuous motor current = value placed in L9436 Peak drive current = drive rated current x 1.5 Note: L2728 is linked L9437 in the standard User Program for safety reasons. Replace this link with the calculated value. (%)
L9507 = 1 select RTC comp, the drive compensates automatically for rotor resistance variations with temperature. L8101 = 1 select tracker, the drive tracks changes in rotor resistance with temperature. Note: L8101 and L9507 should be set to 0 for light loads and high transient applications.
When all the basic parameters have been set, save and compile the User Program. 9.3.5 Summary of Basic Edits Drive Data Parameter L1002 L1005 L9949 L9950 L9951 L9952 L9953 Value 1 Description Select auto-set-up B. Drive type. Power throughput (kW). Max supply frequency of the 3-phase input supply. Nominal Supply volts. +ve volts tolerance (%). -ve volts tolerance (%).
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L9954 L9963 L9536 L9522 P9.2 1 1 1 input inductance (mH). Select auto-tune Auto-set sigma Back e.m.f. scaler. - enter after first download. 20X4495 Customer I/O Board fitted
Motor Model Parameter L9401 L9402 L9403 L9404 L9405 L9406 L9407 L9408 L9409 L9413 L9434 L9436 Value (Star Eqiv.) Description Stator resistance in (Rs) m Stator Inductance (Ls) in H Rotor Resistance (Rr) in m Rotor Inductance (Lr) in H Magnetising resistance (Rm) in m Magnetising Inductance (Lm) in H Base frequency in Hz Motor volts at base frequency (Vs) Drive Vmax (enter after first download). Motor poles Peak motor current Continuous motor current
Miscellaneous Parameters Parameter L1013 L1015 L2014 L2728 L86?6 Mode 10101 L9507 L8101 9.3.6 1 1 Value 1 500 Description PID set-up read Current loop bandwidth (rads) Encoder line count Continuous current (OOS060-4004 only) level (%) Continuous current (OOS060-4005 only) level (%) Select RTC comp Select tracker
Connecting the PC to Drive Serial Link

Connect the PC to the drive using an RS232 serial link cable from the COM1 or
COM2 port on the PC to SK4 on the Customer I/O board.

Ensure that SK4 is configured as an RS232 port (ensure the link between terminals
TB7/1 and TB7/2 on the Customer I/O board is removed).

Check that the Link 0 baud rate is set to 38400 baud (see section 5.1.2.1). Ensure SW1/1 is set to off (default configuration see section 5.1.2.1).
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9. Commissioning
Ensure the link 0 tributary number is set to 1 (see section 5.1.2). Switch on the PC and re-start CSP. Select [F7] Set the password Configure the PC serial port as follows:
Set the baud rate to 38400. Set the tributary number to 1.

Return to the CSP top level menu.
Check the drive memory status as follows:

Select [F5] Monitor
Note:
If memory is clear the message at the top of the screen will say SIGMA Boot ### :Waiting for download. If this message is not displayed, clear the memory by removing the batteries for 15 seconds while the auxiliary power is off. When the drive is switched back on, the screen will display SIGMA Boot ### : Waiting for download. On CSP versions GDS1101-4001D and later there is a clear SIGMA store option alleviating the need to remove the batteries.
press [F10] to leave the monitor.
9.3.7
Downloading the User Program Note: If the SIGMA store has been cleared from the CSP tools menu, then the auxiliary power to the drive should be turned off then back on to remove the watchdog failure (follow the instructions on the screen).
9.3.8
Monitoring the Drive

Press [F5] to enter the monitor screen then press <space bar>. Ensure the Hardware permissive A32.7 is low. Run the SIGMA slow task program by pressing [F4].
The top of the screen will display: |Firmware issue|: Run, Normal: ### INPUTS HEALTHY The SIGMA slow task program will be running.
Press [F2] then [F4] to clear the screen, if required.
If the drive does not report INPUTS HEALTHY then:

Reset the control available blocks if required, write L8518 to 1 then back to 0.
The status bar at the top of the screen should say, ### INPUTS HEALTHY
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9.3.9 DC Link Voltage
Check the value of L9915 and record the value. Use this recorded value to calculate:
L9409 Drive Vmax L9522 Back emf scaler Note: L9409 and L9522 are calculated automatically when using OOS060-4005, the method of calculating the L9409 and L9522 are included for information only.
9.3.9.1
L9409 Calculation The value in L9915 is expressed as a percentage. This must be converted to a voltage for entry into L9409. Vdc = L9915 x 537 100 L9409 = Vdc 2
9.3.9.2
L9522 Calculation Calculate the Back EMF as follows: L9522 = L9406 x L9410 x 6 Vdc x 10000
Exit the monitor and edit the values in L9409 and L9522 in the User Program. Save, re-compile and download the user program.
9.3.10
Current Offset Adjustments

Set the fast oscilloscope outputs to read L1019, L1020 and L1021. See section 9.4
for information on using fast oscilloscope outputs.

Adjust L1041, L1042 and L1043 respectively to trim out any offsets found. Read the following output bridge feedbacks, L1030, L1031 and L1032. Adjust L1052, L1053 and L1054 respectively until the offsets are trimmed out. The dc link offset L1044 can be trimmed in a similar manner. Record the offset values from L1041, L1042, L1043, L1052, L1053 and L1054.
Note: 9.3.11
The current offset adjusments are performed automatically if L1086 = 1.
Thermistor checks
Monitor the cell temperatures in module 90. The number of cells will depend on the
drive configuration. The value should read ambient temperature (in oC) if the drive has not yet been running
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9. Commissioning
9.3.12 Encoder Checks
Select Monitor from the CSP program manager:
Monitor L1602, L1603, L1604 and L2002, To do this:

Select EDIT mode Move the highlighted area on the screen to a relevant place then type:
L1602 <ENTER> L1603 <ENTER> L1604 <ENTER> L2002<ENTER> With ONLY Aux supplies on, rotate the motor shaft, by hand, in a forward direction (see definition section) through one complete revolution:
Check that the angular position L1602 increases through 360 degrees and returns
to the same value.

Rotate the motor shaft, by hand, in a forward direction and check that L2002 is +ve,
then rotate the motor shaft in the reverse direction and check that L2002 is -ve. While doing this check that L1604 is set as follows: L1604 = 4 when stationary = 2 when rotating forward = 1 when rotating in reverse.
Rotate the motor shaft by hand and check that L1603 = L1602 x no. of pole pairs
If it is impracticable to rotate the motor or remove the encoder see section 9.3.19 for running checks. 9.3.13 Running the Network Bridge
Ensure A32.7 is high. Ensure the 3-phase supply is ON Set L8503, L8504, L8505, L8506, L8507 and L8508 to 1. The network bridge should start to precharge. Monitor the DC link voltage at L9967 and the input supply frequency (L9966). Set L8505 =0 to disable the network bridge.
9.3.14
Checking the Network Inductances

Set L203 to 0 and record the values of L401 and L501. Set L203 to -66(%) and record the values of L401 and L501
Note:
The value in L401 should fall as the reactive current (L203) becomes more negative.
Total network inductance can then be calculated by: L9954 = VDC x (L4010% - L401-66%) 1.5 x NOMINAL_DRIVE_RATING x (L501-66% - L5010%) x 6 x 2 x x F
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The value obtained for L9954 can be checked by setting L203 to other values between 0 and -66%, recording the values in L401 and L501 and repeating the above calculation. Note: This is the sum of supply, transformer and drive input inductance.
This new value for L9954 will alter the required values for L9409 and L9522. Repeat the procedure in section 9.3.9 to establish the new values for L9409 and L9522. 9.3.15 Adjusting the Mains Angle Filter Offset If L9963 is set to 0, adjust the mains angle filter offset as follows:
With the network bridge running, see section 9.3.13. Adjust L610 until L9705 is zero. At this point it should be possible to hear the
network bridge entering a discontinuous current mode.

Record the value of L610.
9.3.16
Running the Machine Bridge

With the network bridge running (see section 9.3.13) Ensure the speed ref. is set to 0 i.e. set:
L2208 = 0 L9203 = 0 L9207 = 0

Reduce the drive current limits, set:
L9214 = 10 (%) L9215 = -10 (%)

Set L28503, L28504, L28505, L28506, L28507 and L28508 to 1 to enable the
machine bridge. 9.3.17 Checking Motor Data

With the machine bridge running, check the value of L1203 (Mag current).
L1203 is expressed as a percentage of the drive peak current (1.5 x drive rated current). E.g. for a GD4060 (60 amp) drive, if the value in L1203 is 20 (%) then the mag current will be: 20 x (1.5 x 60) = 18 A rms 100 This is the current which should be flowing in an unloaded motor. Check that the value obtained is approximately one third of the motor full load current. 9.3.18 Turning the Motor During the following checks, monitor the phase currents.
Enter a 5% speed reference (L9207 = 5) Check that the motor shaft is rotating in a forward direction.
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9. Commissioning
Check that the value in L2002 is the same polarity as L9207.
Note:
If the motor phase connections are incorrect the drive output will be at slip limit and peak current.
If the motor rotation is correct enter other speed references (+10%, +20%,-20% etc) and check that the correct response is obtained. Note: Do not rotate the motor at high speeds at this stage as the control loops have not yet been tuned.
On completion, switch off the machine bridge (Set L28505 = 0). Switch off the network bridge (set L8505 = 0).
9.3.19
Oscilloscope Tests See Section 9.4 for information on using the Fast Oscilloscope outputs. With the motor rotating:
Connect a two channel oscilloscope to TB8 pin 1 wrt safety earth and TB8 pin 2 wrt
safety earth. Invert channel 2, ADD Channel 1 to Channel 2.

Repeat for the encoder channels B, C and D by moving along TB8 in groups of two
terminals.
The ADD waveform should be equal amplitude + and - about zero, with an
amplitude of approximately 3.4 volts. 9.3.20 Checking the Current Loop Response a Zero Speed This procedure checks the PID values calculated by the drive from data entered earlier (L1013 = 1, L1015 = 500).
Monitor L1111, L1112, L1211 and L1212 Set the fast oscilloscope outputs to monitor L1204 and L1207 (See section 9.4 ). Set the oscilloscope scalers to:
L801 = 500 L805 = 500

Enable the machine bridge (see Section 9.3.13). Set the speed reference to 20% (L9207 = 20). At the oscilloscope, trigger the waveform of L1207. Set a 10% step in L1207 (L1207 = 10). Check the wave form obtained is similar to Figure 9-2. Check that the current loop rise time (on L1501) is approximately 2 ms.
Note:
The values of P and I can be altered manually to give the required response, if required (L1111, L1112, L1211 and L1212 should be altered together). When the required response is obtained, record the values in L1111, L1112, L1211 and L1212. It will be necessary to edit the user program with the values obtained and set L1013 = 1 (disable auto-calculations) to implement the changes.
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Change the oscilloscope outputs to monitor L1030, L1031 and L1032. Monitor the phase current in L1030, L1031 and L1032 to the +10% torque
reference condition. A near pure low frequency sine wave should be present. Check all 6 transistors are operating by monitoring the balance of + and - half cycles for each phase in turn.
On completion set L28505 = 0 then L8505 = 0 to switch off the network and output
bridges.
Figure 9-2 Current Loop Response with Kp and Ki Tuned
9.3.21
Setting the Motor Magnetization Curve To improve the performance of the speed loop and to allow the drive to operate above base speed, the motor magnetization curve needs to be entered. If the motor shaft is uncoupled from the load, the drive can derive the motor magnetization curve by self-test as follows:
Ensure the motor is uncoupled from the load. Enable the network bridge, then the machine bridge. Set L9481 = 0 Set L9479 = 1 (start auto-test).
The drive will measure the magnetization current at 50%, 60%, 70% 80%, 90% and 100% of base volts (star value) and store the values. The drive will return the motor to user control on completion (the drive sets L9480 = 1 and L9478 = 1 to indicate this).
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9. Commissioning
9.3.22 Setting the Speed Loop PID Values The PID values can be calculated if the inertia of the system is known (see section 6.5.7). If the inertia of the system is not known, the speed loop can be tuned manually as follows:
Ensure the motor is coupled to the load Set up the oscilloscope to monitor L9204 and L9207 using fast scope outputs (see
section 9.4).
Set the speed amp outputs L9214 = 100% and L9215 = -100%. Set the speed loop response to be at least 4 times slower than the current loop
response.
Set L2229 = 10000 (= 100%). Set L2209 = 10% (= 1000) Set the integral gain (L9212 = 0). Set the speed ramp test input (L9207 = 10%) and monitor the feed back in L9204. Increase the proportional gain (L9211) until the required rise time is obtained. The increase the integral (L9212) gain to achieve the required critical damped
response.
Record the values in L9211 and L9212.
On completion:
Set the speed reference to 0 and disable the machine bridge then the network bridge. Edit the user program to make all the recorded values permanent, then save,
compile and download the user program. This completes the basic commissioning procedures.
9.4
Fast Oscilloscope Outputs

The fast oscilloscope outputs are described in the manual in Section 13.7.1. The oscilloscope outputs write to analog outputs D0 and D1 respectively, thus ensure they are not being used by the ladder during commissioning. The oscilloscope outputs give an output according to the following equation: Oscilloscope output = (<Table value> + offset) x 10,000 Scaler The oscilloscope output will be a number which is converted into a voltage via a digital to analog converter, scaled such that: 32767 10 V The oscilloscope outputs will saturate if the value exceeds 32767.
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9. Commissioning
9.4.1 Using the Fast Oscilloscope Outputs The offsets and scalers for the outputs are defaulted assuming the table to be monitored has a value 10,000. It is essential that while tuning the drive amplifiers that the scalers for the oscilloscope outputs are the same, to allow comparisons of the results obtained. The oscilloscope outputs should be set as follows: L801 = 3052 L802 = 0 L803 = 76 Oscilloscope 0 scaler Oscilloscope 0 offset Oscilloscope 0 letter *
* This is the letter of the table to be monitored represented as its ASCII value, to obtain the ASCII value for any required letter, type the letter PRECEDED by an apostrophe: e.g. L <ENTER> giving 76. L804 = 1019 L805 = 3052 L806 = 0 L807 = 76 L808 = 1207 Oscilloscope 0 address (channel 0 is now monitoring L1019) Oscilloscope 1 scaler Oscilloscope 1 offset Oscilloscope 1 letter Oscilloscope 1 address
These variables can all be set up on the monitor screen and edited to suit. To change which point of the servo appears on the oscilloscope, simply change the oscilloscope address.
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9. Commissioning
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10. Fault Finding and Maintenance
Fault Finding and Maintenance

10.1 General
Considerable care has been taken in the design, manufacture and selection of components for the Alspa GD4000 range of drives to ensure the highest degree of reliability. Conservative rating of the components should ensure trouble free operation over long periods. If problems do arise however, the fault finding procedures outlined below are intended to aid location of both equipment faults and common application errors. CEGELEC recommends that customers do not attempt repairs to the GD4000. Faulty or damaged units should be returned to the Kidsgrove factory for repair or replacement. If problems cannot be satisfactorily resolved contact CEGELECs Kidsgrove factory where engineers are available to help. It will be helpful to quote the drives model number, serial number, and order number (printed on the rating label). Our address and telephone numbers are printed on the inside front cover of this publication.
10.2
Making Equipment Safe

WARNING: HIGH VOLTAGES AND HIGH STORED ENERGY LEVELS ALL ELECTRIC SUPPLIES MUST BE ISOLATED AND ALL MOTORS CONNECTED TO THE EQUIPMENT MUST BE AT A STANDSTILL FOR A PERIOD OF 5 MINUTES BEFORE ACCESS TO THE EQUIPMENT IS ALLOWED. If a battery-backed-up supply system is installed ensure the batteries are isolated or disconnected from the drive. The equipment should be isolated from the main supply by turning off (and if possible padlocking) the main isolator in the supply line. If there is a separate auxiliary supply to the drive then this must also be turned off and locked/isolated. Wait at least 5 minutes before opening the equipment covers. Check the d.c. link voltage is near zero by measuring with a voltmeter at the d.c. link main terminals (see section 8.5 for terminal details). Check also the supply terminals and output terminals with a suitable voltmeter.
10.3
Voltage Levels
These are the maximum steady state voltages which may be expected on the various circuits within the drive with the power connected. Do not assume the inputs on the I/O board will be off when the main supply to the drive has been isolated. AC motor output Gate drives DC link Core board SMPS Up to 800 Vdc Up to 48 Vdc (SELV) Up to 800 V dc Up to 500 Vac (rms)
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Page 10-1

I/O and I/O board Battery back-up supply Up to 24 Vac (rms), 240 Vac Watchdog contact Up to 400 Vdc
10.4
Maintenance (GD4000 BDMs Only)

CAUTION This equipment should be periodically inspected and tested and a report on its condition obtained, as prescribed in the Requirements for Electrical Installations BS 7671 or local safety regulations. When cleaning the product, never blow; always use suction to avoid damage. The GD4000 should be cleaned every six months or more often if operating in a dusty atmosphere. Before opening the covers make the equipment safe following the instructions in section 10.2 and allow the d.c. link to discharge. Always check the d.c. link voltage is below 50 V with a suitable voltmeter at the main DC+ and DC- terminals before starting work. Open the front cover and use a suction type cleaner with a non-conductive nozzle to remove accumulated dust from within the drive. Check that the incoming and outgoing terminals (power and control) are secure and that the cables are not damaged. Check the cooling airways are clear at the top and bottom of the drive. When supplies are turned back on check the fans are rotating.
10.4.1
Battery Replacement The batteries should be replaced at every 12 months or when indicated by the battery supply monitor (see Section 10.5.5). To replace the memory support batteries: Remove remove the two screws holding the keypad or blank keypad to the drive facia to expose the memory back-up batteries. Replace the existing batteries with three new Duracel MN1400, Procell MN1400 or equivalent. Replace the keypad or blank keypad and secure with the two retaining screws.
10.4.2
Auxilliary Fuse Replacement Fuse reference FS6 on Drawing Number 10E5016 (see section C5.3) protects the 110 Volt output of the auxiliary supply transformer within the GD4000 basic drive module. In the event of failure, check: The wiring between GD4000 BDM and pre-charge control unit 31V1900/10. The state of the coil within the pre-charge control unit. Replace fuse with the correct type - 2A Violet Type 693 DEF63A Size 0 Belling Lee, Cegelec part reference 82030/107.
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10.4.3 Switched Mode Power Supply Fuse Replacement It is essential that the correct type and rating of fuses be fitted in the supply to the switched mode power supply. For GD4000 Basic Drive Modules ratings GD4010 to GD4060, these are fitted within the drive as circuit references FS1 and FS2 on drawing reference 10E5015 (see section C5.3). For larger BDM ratings and GD4000 configurations using DELTA modules, these are fitted within the pre-charge control unit or cubicle. In all cases the fuse is GEC Installation Equipment Limited, Fusegear Division type NIT-6 (6 A, 550 V a.c. rated) also available as Cegelec part number 82120/203.
10.5
10.5.1
Fault Finding
Messages and Indications
10.5.1.1 Warning Messages The system passes information to the user by displaying messages on either the programming message line or on the keypad/display unit The message on the programmer status line is as follows: GDS<reorder no 1><reorder no 2><ver no.>: run_status, test_status;message Where: Run_status = Halt or Run Test_status = Test or Normal message (optional) is as given below Messages can be one of 4 priorities. If a message of a higher priority than the one presently being displayed occurs, then the higher priority message is displayed. The priorities are as follows: 0 1 2 3 4 Urgent Watchdog Warning Application Information There is a fault that requires urgent action by the user. This priority is typically used for initialisating messages Watchdog trip message Informs the user that some action that he has taken is incorrect Messages from application modules such as the fault display module General messages to be displayed
Some of the messages are displayed permanently. Others are displayed for a given time and then cleared. a) Urgent e.g. Software key (dongle) not present (Not applicable to standard GD4000 products using Firmware Database 00S060-4003A) b) Watchdog see Watchdog Trips section 10.5.8.
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c) Warning The following messages and the time they are displayed for are used. Incorrect dongle fitted Drive ID incorrect Hardware Permissive incorrect Controller must be halted d) Information Output Dn in use Link n cannot make changes Link n programming 10.5.2 SIGMA Core Board LEDs Two LEDs are provided on the rear of the SIGMA Core Board: D12 D13 10.5.3 Microprocessor internal checks OK ON = Healthy 5 V supply to microprocessor healthy ON = Healthy 5s 5s Until released 5s 5s 5s 5s
Seven Segment Display Indication Fault indication via the monitor and keypad is only available once the serial links are started, which occurs right at the end of the power up and first execution scan (see section 7.9). There can be occasions when a fault occurs during power up that prevents further execution. The seven segment display is used to provide some indication of such a fault. The LED indication is such that only a limited number of codes can be displayed - less than the possible reasons for failure. The number displayed therefore depends on the type of power up:
10.5.3.1 Fault Detected by Boot Up EEPROM. This normally occurs when a system is switched on without any firmware in it. If the batteries have been removed to clear the contents of the battery maintained RAM, or power has been applied to the board for the first time, then the number sequence will be generated by the boot up EPROM, as follows. These numbers have the following meaning: 9 8 7 6 5 4 3 2 1 0 Note: Failure of EEPROM CRC Failure of Dual port RAM Failure of 960 fast RAM Failure of 960 slow RAM Failure in initialisation of IO processor Fault in downloaded firmware Waiting for system to be downloaded (but see note) Fault in downloaded firmware Under normal conditions the 7-segment LED display will show 2 (waiting for a system to be downloaded). However, the top and top right bars of this display are used under this condition to indicate serial link activity. The top bar flashes every 256 bytes received on link 0; the top right bar flashes for every 256 bytes transmitted on the link.
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10.5.3.2 Fault detected by downloaded firmware If the system is switched on with the firmware already installed then the EEPROM fault detection sequence occurs too quickly to observe. The installed firmware detects any faults present and displays the fault number on the 7-segment LED. The firmware generated fault codes have the following meanings: 2 4 System has been downloaded but the downloaded code is corrupted. I/O Processor performing a RAM test. It can take up to 3 seconds to perform this test. 1 I/O processor performing a CRC test of the run time code. It can take up to 1 second to perform this test. A severe fault has occurred during I/O Processor initialisation, such that the I/O Processor cannot be started. Further execution is useless since no serial link communication is possible to allow further diagnostics
I/O Processor initialised
B (or 8) Fault in setting up the fast task or initiating the enhancement boards. Note that the system pauses at this point for up to 10 seconds when setting up the enhancement boards. C The watchdog cannot be started because there is a fault present. It is likely that the serial links will be operating, and further data can be obtained by looking at the watchdog fault message and at the contents of fault tables F1 to F5. FAIL 0 Sequential message indicating a fault in either the SIGMA core board or in the enhancement boards. Remove the enhancement boards to see if this clears the fault. The board should be powered off, all boards removed and then powered back on. FAIL 1 Sequential message indicating that there has been a failure in the SIGMA fixed data area. The SIGMA processor is halted, since it is not safe to continue execution. Decimal point The decimal point of the seven segment display flashes once per 256 scans of the user program. It flashes whether the user program is Halted or Running. If it is not flashing then it is likely that the fast task which provides the power interface driver is not running. Further details may be available in the watchdog trip message and fault tables F1 to F5 (provided that the serial links are running). If there is doubt as to which mode the fault occurs at, proceed as follows: Cleared the system by removing the batteries and powering off. Wait 5 seconds and then turn power back on. If the display does not show a 2 (the top bar will be flashing) then the fault has been detected by the boot-up EEPROM. Check the fault code against the list of EEPROM generated fault codes. If a 2 is displayed, download the firmware. When the downloader has reported that a successful download has occurred, check any fault codes displayed against the list of firmware generated fault codes.
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Page 10-5

10.5.4 Power Supply LEDs Two indication LEDs are provided: 5 V Healthy ON to indicate healthy supply. DC Link 50 V Present ON to indicate healthy voltage of the SMPS internal reservoir capacitor. 10.5.5 Customer I/O Board LEDs Five indication LEDs are provided on the Customer I/O Board as follows: 48 V Healthy ON to indicate healthy supply. 5 V Healthy ON to indicate healthy supply. Watchdog Healthy ON to indicate the SIGMA watchdog is healthy. Battery Monitor (A35.0) The battery supply is also checked by a battery supply monitor, which sets A35.0 = 0 for battery low. The monitor is checked at power up and subsequently every 5 minutes. (The battery check applies a load to the battery circuit, and therefore is used sparingly to avoid significantly affecting battery life). Early Power Fail (A35.2) The SIGMA power supply provides an early power fail warning. Given that the power supply hold up time is a minimum of 20 ms, the signal will occur 20 ms before the loss of supplies. See also section 12.3.1. The early power fail warning writes 0 to A35.2 to indicate power fail and 1 to indicate healthy. 10.5.6 Power Interface Board (PIB) LEDs
10.5.6.1 20X4486/20X4487 Power Interface Board (The 204486/20X4487 power interface board is fitted to 31V7100 hinged gate assemblies used on DELTA systems) There are 12 LEDs fitted to the 20X4486 power interface board, and one LED fitted to each 20X4487 DDR board fitted on top of the power interface board. The green LED fitted to each 20X4487 differential driver / receiver (DDR) board indicates that the SMPS on that board is running and should be lit whenever the 48V supply to the board is present. The 12 LEDs on the 20X4486 power interface board can be catagorised into four groups:
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10.5.6.1.1 Bridge A LEDs:
Below the bridge A DDR there is a group of 5 LEDs; three green, one yellow and one red. These LEDs indicate bridge A1 configured, bridge A2 configured, bridge A3 configured, bridge A brickwalling and bridge A tripped respectively. For each of the bridge configured LEDs which are lit there should be a delta module connected to the appropriate group of ribbon headers on the DDR. 10.5.6.1.2 Bridge B LEDs: Similarly, below the bridge B DDR there is a group of 5 LEDs; three green, one yellow and one red. These LEDs mean bridge B1 configured, bridge B2 configured, bridge B3 configured, bridge B brickwalling and bridge B tripped respectively. Likewise, for each of the bridge configured LEDs which are lit there should be a DELTA module connected to the appropriate group of ribbon headers on the DDR. 10.5.6.1.3 PIB Watchdog LED: To the bottom left of the bridge B DDR there is a single green LED. This indicates that the PIB watchdog relay is closed. 10.5.6.1.4 Spare Temperature Feedbacks LED: To the bottom left of the bridge A DDR there is a single green LED. This indicates that PIB has been configured to use the external temperature feedback connectors (PL248 and PL250) on both DDRs. 10.5.6.2 20X4489 Power Interface Board (The 20X4489 power interface board is fitted to GD4010 to GD4160 and 31V5300 hinged gate assemblies used on DELTA systems). 10.5.6.2.1 Bridge A LEDs: Above the ribbon headers that feed bridge A there is a group of 3 LEDs; one green, one yellow and one red. These LEDs mean bridge A configured, bridge A in brickwall limit and bridge A tripped respectively. On combination 10 boards (fitted to GD4010 - 4060), the green LED is not fitted because bridge A is always used. 10.5.6.2.1.1 Bridge B LEDs:
Similarly, below the ribbon headers that feed bridge B there is a group of 3 LEDs; one green, one yellow and one red. These LEDs mean bridge B configured, bridge B in brickwall limit and bridge B tripped respectively. On combination 10 boards (fitted to GD4010 - 4060), the green LED is not fitted because bridge B is always used.
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10.5.6.2.2 PIB Watchdog LED: To the left of the bridge B ribbon headers there is a single green LED. This indicates that the PIB watchdog relay is closed. 10.5.6.2.2.1 Miscellaneous Configuration LEDs:
Towards the top left hand side of the board there is a row of 4 green LEDs. On drive units in the range GD4010 - 4060 none of these LEDs are fitted. These LEDs indicate the configuration of the board and have the following meanings (left to right): D1 D2 D3 D9 10.5.7 Watchdog A Watchdog circuit is provided to protect against a fault in the microcontroller going undetected. This is because the normal means of detection and information is performed by the controller itself. If the microprocessor goes faulty, then it could either fail to detect the fault or be unable to inform the user that a fault has occurred. The watchdog is not intended as the prime means of personnel protection or as prime protection against plant damage. The reason for this is that a fault in the code (e.g code corruption) may not be detected for up to 10 seconds after the fault has occurred. 10.5.7.1 Watchdog OK LED A Watchdog OK LED is provided on the Customer I/O Board. See the diagram in section 8.7.2. This LED is ON for the healthy state. 10.5.7.2 Watchdog Circuit The watchdog circuit requires a pulse from the control microprocessor every 5 to 10 ms. Failure to do so within the specified window results in the output of the circuit tripping the watchdog relay on the customer I/O board. A hardware latch prevents the watchdog being picked up again without the board being powered off and on. Tripping the watchdog relay also applies a hard wired pulse inhibit to the pulses. The integrity of the watchdog circuit is also checked by tripping it every 10 seconds, checking that the relay volts start to fall, then resetting it before the contact can drop out. A check is made for a stuck contact at power up by monitoring one of the watchdog relay contacts. Input A35.1 monitors the state of the watchdog contact on the SIGMA core board. A35.1 = 1: A35.1 = 0: Watchdog healthy Watchdog tripped : : : : Temperature feedback from bridge A is expected. This will be lit on GD4080 - 4160 and all delta systems which use bridge A. Temperature feedback from bridge B is expected. This will only be lit on delta applications where bridge B is used. Temperature feedback from PL248 / PL250 expected. This will only be lit when the spare temperature feedback has been selected. PIB has been configured to be compatible with delta bridges.
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10.5.7.3 Watchdog Start Up Checks On start up the following items are checked and the watchdog held tripped if a fault detected: a) b) c) d) e) Microprocessor memory (both control and serial comms). Power supplies (+/-15 V and 5 V) Voltage references (used in A/D, D/A conversion) Presence of main boards (Customer I/O, Power Interface Board, - current and future firmware databases) Basic I/O driver
All items can be masked out by setting the appropriate bit in P3. If possible a message is displayed giving the nature of the fault. See section 10.5.8 for details of the watchdog trip fault codes. 10.5.7.4 Checks When Running If the drive is running and a Watchdog trip occurs, the following items are checked: a) b) c) e) Microprocessor memory Power supplies Voltage references I/O processor checks Serial link subsystem Serial EEPROM system I/OP memory Basic I/O
10.5.8
Watchdog Trip Numbers (F1) The watchdog trip data is defined by the following data tables: F1: F2 to F5: F6: F7: Main watchdog trip number Further information on the trip. Note that in some cases the information is more meaningful if viewed in Hex. Bit set for trips 0-31. e.g bit 1 set for F1=1; Bit 15 set for F1=15. Bit set for trips 32-63.
Trips 1 to 31 can be masked by setting the appropriate bit =1 in P3 The meaning of the code in F1 is as follows: F1= 1 Code area corruption A section of code has been corrupted. The controller execution could become unpredictable.
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Further information is held in F2, as follows F2= 1 2 3 4 5 6 7 Base System code Fast Task code V table data User Program Corruption Preset Table corruption L table descriptor corruption Fixed data area
Further Details The areas given above are CRCed, and the value held in memory. The CRC is calculated for each block at two points in the program a) b) On a Halt/Run transition.(which also occurs at power up) All areas are checked at this point As part of the background self checks. 10 bytes of the block are calculated at a time. When a whole block has been CRCed the value calculated is checked against the value held in memory. If the values do not match, then the watchdog is tripped. Because each block is checked in turn, and only 10 bytes are calculated at a time, a corruption of memory will not be calculated immediately. For example: Total size of all areas = 100 kbytes Scan time = 2 ms Worst case time for detection = 20 s Possible causes Error in firmware has changed a code area. Excessive noise has corrupted memory on core board. Fault occurs when contactors switched or other noisy action occurring Fault in battery backup has not retained code properly. Fault occurs when switching system on. Note: Since the boot code held in EEPROM checks the validity of the base system code and V table, an error in either of these will result in the system starting up as if it is a clean system.
F1= 2 Symbol table corruption A fault has been detected in the table that holds the comments, scaling and access levels. Further information is held in F2, as follows: F2= 1 2 Symbol table corruption Attribute table corruption
Further Details The areas given above are CRCed, and the value held in memory. The CRC is calculated for each block at two points in the program a) b) Page 10-10 On a Halt - Run.(which also occurs at power up) All areas are checked at this point As part of the background self checks. Alspa GD4000 Technical Manual Issue (12-2-98)

10 bytes of the block are calculated at a time. When a whole block has been CRCed the value calculated is checked against the value held in memory. If the values do not match, then the watchdog is tripped. Because each block is checked in turn, and only 10 bytes are calculated at a time, a corruption of memory will not be calculated immediately. For example: Total size of all areas = 100 kbytes Scan time = 2 ms Worst case time for detection = 20 s Possible causes F1= 3 Stack Overflow Fault summary There has been an internal error that has resulted in the end of the stack being written to. Further details are held in F2 as follows F2= 1 2 Base system stack Interrupt stack Error in firmware has changed a code area. Excessive noise has corrupted memory on core board. Fault occurs when contactors switched or other noisy action occurring Fault in battery backup has not retained code properly. Fault occurs when switching system on.
F3 contains the stack index that has been corrupted. F1= 4 5 6 7 Not used Not used Not used Fast task failure An error has been detected when the fast task has been initialised. The fast task will not be executed. F2 = 1: Initialising error. F3 = error code. F2 = any other value: Error in fast task whilst running. Further details The fast task returns a non zero value after initialisation, normally the error code in F2 is set to 1 under these circumstances, with F3 holding the returned error code If the fast task trips the Watchdog while running, record the watchdog trip error codes in F2 to F5 and report the fault to CEGELEC. Possible causes A fault with F2=1 is generally due to a fault in the programming of the XILINX. The value in F3 will help the fast task designer to diagnose this problem.
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8 RAM failure Two types of RAM are fitted to the SIGMA board - FAST & SLOW RAM. Both types of RAM are checked by writing a pattern to them and then reading that pattern (the contents of the RAM address are first saved.) F2 indicates the RAM that has failed as follows: F2= 1 Fast RAM failure 2 Slow RAM failure F3 = Failure address Record in Hex. Further details The RAM checks are performed as part of the background self checks. A small chunk (10 bytes) of fast and slow RAM are checked each time. If the pattern written is not the same as the pattern read then the watchdog is tripped. Possible reasons This points to a genuine problem with the hardware. The address at which the failure occurred should be included when the board is sent back for repair (record F2 & F3 in Hex). 9 Not used 10 Not used 11 Not used 12 XILINX Dual port RAM failure F2= failure address, Record in Hex. Further details The Firing pulses are generated by a XILINX LCA device. Data is transferred to this device via Dual Port RAM. This RAM is checked as part of the initialisation sequence, by writing a pattern to it and then checking that the pattern read back is the same. If there is a discrepancy, then the watchdog is tripped. Possible reasons a) b) There is a genuine fault with the hardware. The fault will always occur under all circumstances. There is a fault in the firmware. The fault does not occur when a new system is downloaded to a clean board (batteries have been removed and the board powered off).
13
Watchdog Confidence check fail. F2= 1 Failure on initialisation F3 gives further details: F3= 1 2 3 4 Coil is on when it should be off Contact is closed when it should be open Watchdog coil not energised when requested Watchdog fails to trip if triggered too soon Issue (12-2-98)
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5 6 7 F2= 2 Watchdog fails to trip if never triggered Watchdog coil has failed to energise Watchdog contact has failed to energise Self Test failure The watchdog circuits are tested periodically to ensure that they have not failed. F3 gives further details of the fault, as follows: Testing watchdog when it is already tripped Watchdog failed to trip when triggered too soon Watchdog fails to pick up after above test Watchdog has tripped too soon on no trigger test Watchdog fails to trip if never triggered Watchdog fails to pick up after above test
F3= 1 2 3 4 5 6 14 Basic I/O failure
F2= 4 Basic I/O highway failure F3 gives further details The Basic IO driver in the I/O processor checks the data integrity on the Basic I/O highway by reading back data it has just written. (For example, when outputting the Basic I/O address, the value written is then read back) F3 contains data on the Basic I/O highway access the fault occurred on: 1 = address lines 2 = Strobe lines 3 = data lines Further data is given in F4 (pattern written) and F5 (pattern read) F3 = 4 Overcurrent failure The Basic I/O circuits measure the current in the Basic I/O 0V supply line. If this current exceeds the rating of the Basic I/O line driver then the Basic I/O overcurrent trips. F3 = 5 Test byte F3 = 6 Overcurrent Reset failure If the overcurrent cannot be reset then this fault is flagged. F2= 5 Basic I/O scan F2= 6 Basic I/O Cross Check failure Customer I/O inputs A32.1, 3, 5, 7 (the fast digital inputs) are also read in via an invisible byte of the BASIC I/O Address 1. Outputs B1.8, 10, 12, 14 are read back in the same invisible byte. If there is a discrepancy between the read back values and the actual values for more than 100 ms, then the watchdog is tripped. Note: that removing the Basic I/O ribbon for A32 bits non zero or B1 bits non zero will cause a trip, since the default state of Basic I/O bits read in is 0.
Further details are held in F3 (A32 bits), F4 (Read back value) and F5 (B1 table bits) 15 Not used Issue (12-2-98) Alspa GD4000 Technical Manual Page 10-13

16 Power Supply failure F2= Channel Number. or -1 = I/OP failure to read values F3= Value. (Not relevant if F2 = -1) Details of supply ranges are given in section 2.2.1. 17 General fault handler This trip is generated if a call to the control processors fault handling procedure is made. This procedure deals with such faults as illegal processor level code and addressing faults. The fault indicates a serious failure in the control processor. The following F tables should be noted (hex values): F2 = Fault type F3 = Fault sub type F4 = Address of fault (view in hex) Fault types & Sub types F2 2=Operation F3 1 = Invalid Opcode 3 = Unaligned fault 4 = Invalid Operand 1 = Constraint range 2 = Privileged 1 = Length 4 = SRAM Protection 1 = Type
5 = Constraint 7 = Protection 10 = Type 18 Not used
19 Hardware trip Most watchdog trips are due to faults detected by the firmware, which then trips the watchdog relay via a watchdog trip code. If the watchdog relay has tripped without a fault code being present, this fault code is generated. The fault indicates that the watchdog circuit has been triggered outside its trigger window of 40 ms to 60 ms, or has not been triggered at all. This is normally due to a failure of the fast task, indicated by the decimal point on the 7 segment display fitted to the core board not flashing. 20 I/O processor failure F2 gives further details F2= 0 Control processor to I/O processor handshake failure 1 Fatal I/O processor fault 2 Internal error 8 Code failure 9 Internal RAM failure 10 Dual port RAM failure 11 Local RAM failure 14 I/O processor watchdog failure 15 Background test failure 21 to 31 Not used
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Trips 32 onwards cannot be masked out and will always trip the watchdog. 32 Not used 33 Slow task scanning failure A handshake is performed between the fast task (which runs at an interrupt level) and the base level. If the base level does not respond within 10 seconds then the watchdog is tripped 34 Board Incorrect A check is made that the firmware is running on the correct core board and that the OIS numbers defined in the links program and the OIS numbers held in the serial EEPROMS fitted to the core board and its attached peripherals is correct (provided that the links program OIS numbers are non zero) If there is a discrepancy then the watchdog is tripped. F2 - F5 give further details: F2 = F3 = F4 = Core board number Core board number required by firmware OIS valid bits
If the OIS check between the values defined by the links editor and the values read from the serial EEPROMs at power up are different then the associated bit in the OIS_CHECK variable (V231) is set off. This variable is copied to F4. The bits are as follows: Bit 0 = Core board Bit 1 = Customer I/O board Bits 2 - 4 = Power interface boards Bits 5 - 8 = Enhancement boards 10.5.8.1 Catastrophic Watchdog failures There are occasions when the system fails in such a way that the serial links no longer operate. Under these circumstances it is impossible to determine the cause of failure, since no watchdog fault codes are available. Because the F tables are cleared on power up a watchdog trip puts a copy into the read only V tables. the offset of these tables are defined by F0: e.g if F0 = 250 F1 copy in 250 F2 copy in 252
etc
In this way the cause of a watchdog trip can be determined even after the controller has been powered off and back on.
10.6
Serial Link Diagnostics

This section gives a guide for diagnosing problems on the serial links and Basic IO highway with the 20X4494-20X4495 combination. The section is not intended to be a definitive fault-finding procedure, but should isolate the bulk of common faults. The information given in this procedure should be correct for 00S060-4002B firmware.
10.6.1
Downloading A Program For The First Time For program download onto a system that has no run-program stored, only serial link 0 on the SIGMA can be used. Connect the SIGMA to the P.C. by a RS232 serial link lead from Serial link 0 (the nearest 9-way D-type to the corner of the 20X4494
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customer IO board) to the COM port on the P.C. Start CSP which will display a menu something like: CEGELEC SIGMA Programmer [F1] Ladder Editor [F2] Links Editor [F3] Compile Program [F4] Download Program [F5] Drive Monitor [F6] View List File [F7] Programmer Setup [F10] Exit Select Required Option [ ] Throughout this document, the selections from the menu will be referred to by their option number (ie option 6 refers to View List File). Select option 7, and set the baudrate to 38400, the trib address to 1, and ensure that DIP switch 1 (see section 10.6.1.6 for diagram of Customer IO board and section 10.6.1.6.3.1 for description of switch settings) is set for 38400 baud trib address 1. 10.6.1.1 Power up the Drive. The Hexled on the control PCB should display a 2 which indicates that the Drive has passed its boot tests and is awaiting a code download. If this is the case, goto 10.6.1.3. 10.6.1.2 Hexled does not Display 2. Look at Hexled on control P.C.B.:
| | | | | | | |
Hexled
0 0 | | D15 D16
Green LEDs
D15 ON = 960 processor internal selfchecks OK D16 ON = 5 V O.K.
Page 10-16
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10.6.1.2.1 LEDs D15 and D16 are not lit. Then there is no 5 V supply. Check cabling and ensure that supplies are connected and switched on. 10.6.1.2.2 LED D16 is ON and D15 is OFF 5 V is O.K., but 960 Processor has failed its internal checks. Replace 960 core-board. 10.6.1.2.3 Hexled displays a number other than 2. Any number on the Hexled (other than 2) will indicate a bootup test failure (see section 10.5.3.1 for further information). 10.6.1.3 Hexled displays a 2. The Drive is ready to be download a program. Note: The LEDs on the 20X4495 customer IO board (see diagram in section 10.6.1.6 should be in the following states:
D1 = ON D22 = ON D94 = ON. If they are not, then refer to sections 10.6.1.6.2.1 to 10.6.1.6.2.3. Download the Drive Program via menu option 4. If Download is successful, go to 10.6.2. 10.6.1.4 Will not attempt to Download If flashing message Establishing Link is displayed, then go to 10.6.1.6. If message is xxxxx.dnl does not exist or similar, choose menu option 6 to view the list file. This will give further information (at the bottom of the file). It may be that the location directories in menu option 7 Programmer Setup are incorrect. If changes are required here, choose Menu Option 7: Location of Program Files Directory Path.... Location of Database Directory Path.... 10.6.1.4.1 Check data base location The database is the arc.a file. This must be located in the directory indicated in the Location of database directory path. If not, change the directory path to indicate where the arc.a file is stored. Go to 10.6.1.4.2 10.6.1.4.2 Check location of program files The program files are the filename.glp, filename.gdm, and filename.dnl files. If all these exist in the directory indicated by the location of program files directory path, then go to 10.6.1.4.3. If not, then change the Path to indicate where these files are.
Issue (12-2-98)
Page 10-17

10.6.1.4.3 Check that filename.dnl exists. If the filename.gdm and filename.glp files are present, and filename.dnl is absent, then the program needs to be compiled: Go to 10.6.1.5. If the gdm, glp, and dnl files exist, then go to 10.6.1.3. 10.6.1.5 Program needs compilation. This is performed via menu option 3. Any errors in compilation are reported in the list file, which can be viewed via menu option 6. If the program will not compile, and the problem can not be found, contact customer support. Note: Old versions of CSP ran under DOS, and could only compile relatively small user programs. Newer versions of CSP run under Windows, and allow compilation of much larger user programs. If the compilation yields the message Out of Memory, ensure that you are running CSP under Windows.
If compilation is successful, go to 10.6.1.3. 10.6.1.6 Downloading gives the flashing message Establishing Link. This means that the P.C. cannot establish communication with the SIGMA. Look at the 20X4495 Customer I/O board:
0 48V | D1 D12 0 0 D13 LK1 | D15 0 0 D16 ... | D21 0 0 D23 123 SW2 | D22 0 | SW1 | | | 0 RS485 SW3 20X4495 CUSTOMER IO BOARD WD | D65 OK | SK5 0 | RS232 0 D94 D64 | SK4 | TB7 TB8 Ded. Dig I/P BasicIO IP BasicIO OP| D1 = 48V_OK D65= RS485 selected on link 0 D94= RS232 selected on link 0 D12 D15 D21 D22 = = = = LK0_TX LK1_TX LK2_TX 5 V OK D13 = LK0_RX D16 = LK0_RX D23 = LK2_RX D64 = WDOG_OK
| | | | | | | | | | | | | |
SK4 = 9-way D-type Socket for Serial link 0 (RS232) SK5 = 9-way D-type Socket for Serial Link 2 (RS232) TB7 = RS485 Connections for Serial links 0 and 1, and wire-link for selection of RS232 or RS485 on serial link 0. SW1 = 8-bit DIP Switch that selects serial link 0 baudrate and trib. address SW2 = 8-bit DIP switch that selects Drive I.D. SW3 = Double-pole DIP switch for Termination resistors (see 10.6.1.6.3. Page 10-18 Alspa GD4000 Technical Manual Issue (12-2-98)

10.6.1.6.1 8.6.1.6.1 Check that Link 0 RX LED D13 flashes during download. The PC will attempt to transmit to the SIGMA for a few seconds, and then stop transmitting and display the message Retry Connection Y/N?. To force the P.C. to try again, press Y. Do this and observe the link 0 RX LED D13.. If this flashes for a brief period, then the P.C. is transmitting to SIGMA. Go to 10.6.1.6.3. 10.6.1.6.2 Link 0 RX LED D13 does not flash during download. Check that Customer I/O board, connections, and selections as follows: 10.6.1.6.2.1 5 V LED D22 is not lit.
Ensure that the 50-way ribbon connection from the Core Board to the Customer I/O board is connected properly. If this LED will not light, try replacing the Ribbon. 10.6.1.6.2.2 48V LED D1 is not lit.
If it is not, check the connecting lead from the main SMPS to the Customer I/O board. 10.6.1.6.2.3 RS232 LED D94 is not lit.
If it is not, ensure that the RS485 selection link in TB7 is NOT connected. 10.6.1.6.2.4 Check connection between P.C. and Customer IO board
Check that the RS232 lead from the P.C. is connected to SK4 (the 9-way D-type nearest the corner of the PCB) and NOT to SK5. Also check that the lead is not loose or badly connected. The connections for this lead are given in section 5.6.5. 10.6.1.6.2.5 Check P.C. Com port selection and operation
Check that the setup in menu option 7 specifies the correct COM port for the P.C. Check the lead that connects the PC to the SIGMA. Check the operation of the PC com port by connecting the PC to another Drive. 10.6.1.6.2.6 Customer IO board, connections, and selections apparently OK.
If ALL the above conditions are O.K., then attempting to download should give a brief flash on the serial link 0 RX LED D13 indicating a transmission of data from the P.C. If it does, go to 10.6.1.6.3. If it does not, then the Customer I/O board may be faulty. Try swapping it, and possibly try another COM port on the P.C. (remembering to change the COM port selection in menu option 7) 10.6.1.6.3 On download, serial link 0 RX LED D13 is flashing, but will not download. P.C. Is transmitting to the SIGMA. The SIGMA does not understand the message, the message is not addressed to it, the message is not getting to the coreboard, or messages transmitted from the SIGMA in reply are corrupted or wrong.
Issue (12-2-98)
Page 10-19

10.6.1.6.3.1 Check Trib Address on the DIP switch SW1:
A0.15.........A0.8 ON | | | | | | | | OFF 1 2 3 4 5 6 7 8 least significant bit DIP Switch SW1
Baudrate = switches 2,3,4 ie 2=ON, 3=ON, 4=OFF = 38400 baud Tributary Address = 5,6,7,8.ie 5=OFF, 6=OFF, 7=OFF, 8=ON =Trib 1 Observe Menu Option 7 Programmer Setup.
IF Tributary Address in Setup = 1 Then 5=6=7=OFF, 8=ON. (Recommended setting) IF Tributary Address in Setup = 2 Then 5=6=8=OFF, 7=ON. etc IF Tributary Address in Setup = 0, this is a special case and the DIP switch setting must be 5=6=7=8=ON. This is NOT a recommended setting for program download because undetected message corruptions may occur during download. Tributary address 0 is acceptable for table-exchange. 10.6.1.6.3.2 Check Basic IO Ribbon.
Check that the Basic IO ribbon is connected from the Core Board to the Customer IO board. Possibly try replacing it if necessary. 10.6.1.6.3.3 Disconnect external Basic IO Modules
Ensure that there are no BASIC I/O Modules connected to the Basic I/O highway on with the Basic I/O extender ribbon to be sure that a) they are not configured for the addresses A0, B0, A1, or B1 hence causing conflict with Basic IO addresses on the Customer IO board. b) they are not dragging down the 15 volt supply on the Customer IO board. Note that external Basic IO modules should have separate supplies. 10.6.1.6.3.4 Check 15 V rail.
For the reasons given in 10.6.1.6.3.3b) Check for short circuits on 15 V rail by disconnecting any PCBs (excluding the Customer IO board and the Core board). The 15 V supply can be checked with a DVM connected from TP5 on the Customer IO board to any of pins 1 to 8 of DIP switch 1 or pins 1 to 8 of DIP switch 2. Check for encoder 5 V and 12 V short circuits by disconnecting the encoder (these should not affect the serial links or the Basic IO highway). 10.6.1.6.3.5 Check Siemens SAB80C166 processor
Check that the Siemens SAB80C166 processor is plugged in correctly.
Page 10-20
Issue (12-2-98)

10.6.1.6.4 If none of the above measures seem to work Try reducing the baud rate on DIP switch 1, and start again. Check P.C. (see section 10.6.1.6.2.5. If this fails, try replacing the Core Board and/or the Customer IO board and start again. 10.6.2 Code Download Successful or Powering Up a Previously Downloaded System. After download or power up onto a previously downloaded system, the Hexled on the Coreboard will display a sequence of changing numbers and should stabilise on a flashing dot (the dot will flash every few scans of the slow task). If this is the case, download or powerup successful go to 10.6.2.2. 10.6.2.1 Hexled does not display flashing dot. Look at Hexled on control P.C.B.:
| | | | | | | | 0 0 | | D15 D16
Hexled
Green LEDs
D15 ON = 960 processor internal selfchecks OK D16 ON = 5 V O.K.
10.6.2.1.1
LEDs D15 and D16 are not lit If LEDs D15 and D16 are not lit, then there is no 5 V supply. Check cabling and ensure that supplies are connected and switched on.
10.6.2.1.2
LED D16 is ON and D15 is OFF 5 V is O.K., but 960 Processor has failed its internal checks. Replace 960 core board.
10.6.2.1.3
Hexled displays a C This may be caused by a permanent fault on the Basic IO highway. Go to 10.6.3.3 to get information on highway faults.
10.6.2.1.4
Hexled displays something other than a flashing Dot. Boot-up test failure (see section 10.5.3.1 for further information).
10.6.2.2 Hexled displays a flashing dot. Download or powerup successful (so far).
Issue (12-2-98)
Page 10-21

Try to monitor the Drive using menu option 5. This will come up HALT, NORMAL if all is OK. If this is so, go to 10.6.2.5. 10.6.2.2.1 Error Message Basic IO Failure If there is an error message Basic IO Failure go to 10.6.3.3 to get information on Basic IO Highway failures. 10.6.2.2.2 10.6.2.2.2.1 Error Message Link Failure Error Message Link Failure just after a download.
If a program has just been downloaded, and the message is link failure, go to 10.6.2.4. 10.6.2.2.2.2 Error Message Link Failure on powerup
If the message is Link Failure, and the Drive is powering up with a program already stored, go to 10.6.2.3. 10.6.2.2.3 Error Message other than Link Failure or Basic IO Highway Failure If there is an error message other than Link Failure or Basic IO Fail then note the watchdog trip number and refer to section 10.5.8. 10.6.2.3 Link failure message displayed on powerup (when monitoring Drive) Look at the 20X4495 Customer IO board
0 48V D1 D12 D15 D21 D22 0 0 D13 0 0 D16 0 0 D23 0 LK1 ... 123
| | | | | | | | | | | | | |
| | | SW2 | | SW1 | | | 0 RS485 SW3 20X4495 CUSTOMER IO BOARD WD | D65 OK | SK5 0 | RS232 0 D94 D64 | SK4 | TB7 TB8 Ded. Dig I/P BasicIO IP BasicIO OP| D1 = 48V_OK D65= RS485 selected on link 0 D94= RS232 selected on link 0 D12 D15 D21 D22 = = = = LK0_TX LK1_TX LK2_TX 5 V OK D13 = LK0_RX D16 = LK0_RX D23 = LK2_RX D64 = WDOG_OK
Page 10-22
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SK4 = 9-way D-type Socket for Serial link 0 (RS232) SK5 = 9-way D-type Socket for Serial Link 2 (RS232) TB7 = RS485 Connections for Serial links 0 and 1, and wire-link for selection of RS232 or RS485 on serial link 0. SW1 = 8-bit DIP Switch that selects serial link 0 baudrate and trib. address SW2 = 8-bit DIP switch that selects Drive I.D. SW3 = Double-pole DIP switch for Termination resistors (see 10.6.1.6.3) 10.6.2.3.1 Link 0 RX LED D13 flashes whilst monitoring Drive. The PC will continuously transmit to the SIGMA. Observe the link 0 RX LED D13. If this flashes, then the P.C. is transmitting to SIGMA. Go to 10.6.2.4. 10.6.2.3.2 Link 0 RX LED D13 does not flash whilst monitoring Drive. Check that Customer I/O board, connections, and selections as follows: 10.6.2.3.2.1 5 V LED D22 is not lit.
Ensure that the 50-way ribbon connection from the Core Board to the Customer I/O board is connected properly. If this LED will not light, try replacing the Ribbon. 10.6.2.3.2.2 48V LED D1 is not lit.
If it is not, check the connecting lead from the main SMPS to the Customer I/O board. 10.6.2.3.2.3 RS232 LED D94 is not lit.
If it is not, ensure that the RS485 selection link in TB7 is NOT connected. 10.6.2.3.3 Check connection between P.C. and Customer IO board Check that the 232 lead from the P.C. is connected to SK4 (the 9-way D-type nearest the corner of the PCB) and NOT to SK5. Also check that the lead is not loose or badly connected. The connections for this lead are given in the manual in section 5.6.5. 10.6.2.3.4 Check P.C. Com port selection Check that the setup in menu option 7 specifies the correct COM port for the P.C. Check the operation of the PC Com port by connecting it to another Drive. 10.6.2.3.5 Customer IO Board, connections, and selections apparently correct. IF ALL the above conditions are O.K., then monitoring the Drive SHOULD cause serial link 0 RX LED D13 to flash indicating a transmission of data from the P.C. If it does, go to 10.6.2.4. If it does not, then the Customer I/O board may be faulty. Try swapping it, and possibly try another COM port on the P.C. (remembering to change the COM port selection in menu option 7).
Issue (12-2-98)
Page 10-23

10.6.2.4 Serial link 0 RX LED D13 is flashing, but Monitor gives Link Failure. P.C. Is transmitting to the SIGMA. The SIGMA does not understand the message, the message is not addressed to it, the message is not getting to the coreboard, or messages transmitted from the SIGMA in reply are corrupted or wrong. 10.6.2.4.1 Check Trib Address on the DIP switch SW1:
A0.15.........A0.8 ON | | | | | | | | OFF 1 2 3 4 5 6 7 8 least significant bit DIP Switch SW1
Baudrate = switches 2,3,4 ie 2=ON, 3=ON, 4=OFF = 38400 baud Tributary Address = 5, 6, 7, 8.ie 5=OFF, 6=OFF, 7=OFF 8=ON =Trib 1 Observe Menu Option 7 Programmer Setup.
IF Tributary Address in Setup = 1 Then 5=6=7=OFF, 8=ON. (Recommended setting) IF Tributary Address in Setup = 2 Then 5=6=8=OFF, 7=ON. etc IF Tributary Address in Setup = 0, this is a special case and the DIP switch setting must be 5=6=7=8=ON. This is NOT a recommended setting for program download because undetected message corruptions may occur during download. Tributary address 0 is acceptable for table exchange. 10.6.2.4.2 Note: Check Serial Link 0 Ladder Configuration If switch 1 of DIP switch 1 is ON, and the Drive is configured to come up in a RUN state, or a HALT to RUN has just been executed, then serial link 0 will take its configuration from a special function in Ladder. See 10.6.2.5.1.1for further information. Check Basic IO Ribbon. Check that the Basic IO ribbon is connected from the Core Board to the Customer IO board. Possibly try replacing it if necessary. 10.6.2.4.4 Disconnect external Basic IO Modules Ensure that there are no BASIC I/O Modules connected to the Basic I/O highway on with the Basic I/O extender ribbon to be sure that a) they are not configured for the addresses A0, B0, A1, or B1 hence causing conflict with Basic IO addresses on the Customer IO board. b) they are not dragging down the 15 volt supply on the Customer IO board. Note that external Basic IO modules should have separate supplies.
10.6.2.4.3
Page 10-24
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10.6.2.4.5 Check 15 V rail. For the reasons given in 10.6.2.4.4b) Check for short circuits on 15 V rail by disconnecting any PCBs (excluding the Customer IO board and the Core board). The 15 V supply can be checked with a DVM connected from TP5 on the Customer IO board to any of pins 1 to 8 of DIP switch 1 or pins 1 to 8 of DIP switch 2. Check for encoder 5 V and 12 V short circuits by disconnecting the encoder (these should not affect the serial links or the Basic IO highway). 10.6.2.4.6 Check Siemens SAB80C166 processor Check that the Siemens SAB80C166 processor is plugged in correctly. 10.6.2.4.7 10.6.2.4.7.1 If none of the above measures seem to work Try Serial link 2
Set up the P.C. for 9600 baud, Trib 0, and connect it to Serial link 2 (SK5 on Customer IO board). If this works, check monitor screen for error messages which might explain the failure of serial link 0. A common possible cause for link 0 failure is a Basic IO Highway trip (see 10.6.3.3). If link 2 will not work, it may be that the Drive is Running and that Link 2 is configured in Ladder to some other baudrate or trib address. Link 2 default configuration of 9600 baud, Trib 0 can be forced by causing a watchdog trip (by removing and replacing link 1 on the customer IO board) which will halt the Drive, and then powercycling it. Doing this may enable link 2 to be used as described above. 10.6.2.4.7.2 Try Serial link 3
Set up the P.C. for 9600 baud, Trib 0, and connect it to Serial link 3. If this works, check monitor screen for error messages which might explain the failure of serial link 0. A common possible cause for link 0 failure is a Basic IO Highway trip (see 10.6.3.3). If serial link 3 works, and serial links 0 and 2 do not, and there is no useful error message, then the problem may be the Customer IO board; try replacing it. If link 3 will not work, it may be that the Drive is Running and that Link 3 is configured in Ladder to some other baudrate or trib address. Link 3 default configuration of 9600 baud, Trib 0 can be forced by causing a watchdog trip (by removing and replacing link 1 on the Customer IO board) which will halt the Drive, and then powercycling it. Doing this may enable link 3 to be used as described above. 10.6.2.4.7.3 None of the Serial Links communicate to the P.C.
The problem may be the P.C. (this could be proved by trying an Enhanced Keypad in links 2 or 3). The P.C. may be configured for the wrong COM port, or the lead to the P.C. may be faulty, or the P.C. COM port may be faulty (try connecting the PC to another Drive and see if it works). If no fault can be found with the P.C., try replacing the Core board and possibly the Customer IO board.
Issue (12-2-98)
Page 10-25

10.6.2.5 Monitoring via menu option 5, message is HALTED. NORMAL. 10.6.2.5.1 Going from Halt to Run Causes Link Failure or Powering Up in a Run State Causes Link Failure Check for Changes in Link Configuration
10.6.2.5.1.1
Going from HALT to RUN may cause link failure on serial link 0 (or on other serial links) for reasons of changed configuration. Note that when the Drive powers up in its HALTED state, the serial link settings used are the DEFAULT settings which are as follows: Serial Link 0: Baud Rate/Trib Address as defined on DIP switch1 (see 10.6.2.4.1) Serial Link 1: Not in use. Serial Link 2: Baudrate 9600, ESP SLAVE, Trib Address 0. Serial Link 3: Baudrate 9600, ESP SLAVE, Trib Address 0. These settings allow a GD4000 Enhanced Keypad to work directly in serial links 2 or 3. If there are no CONFIG special functions (T33) in the Ladder, then on going from HALT to RUN, all the Serial Links will retain their default configurations. However, if there are CONFIG special functions in the Ladder that define new configurations for the links, then these new configurations will take precedence over the default configurations. Note that the configurations of serial links 1,2, and 3 can be set simply by adding appropriate CONFIG special function information. Serial link 0 will generally get its configuration information from DIP switch 1, BUT, it switch 1 of DIP switch 1 is ON, then Serial link 0 will take its configuration from a CONFIG special function in the Ladder (if one exists for serial link 0). Serial link 0 can be forced to take its configuration from DIP switch 1 by setting switch 1 of DIP switch 1 to OFF (this takes immediate effect). On going from HALT to RUN, serial links 1, 2, and 3 (and serial link 0 if switch 1 if DIP Switch 1 is ON) will reconfigure themselves to any mode, baud rate, trib address as defined in the CONFIG special functions for the links. 10.6.2.5.1.2 Check additional Basic IO configuration
Going from HALT to RUN may also cause link failure because the Basic IO Highway configuration will be modified to allow access of any Basic IO tables defined in Ladder. The access to these new tables may cause conflict: See 10.6.3.3 for further information. 10.6.3 Basic I/O Highway Trips Note: In most cases, serial link 0 will take its configuration information (ie its baudrate and Trib address) from DIP switch 1 on the Customer I/O board. This DIP switch occupies address A0 on the Basic I/O highway, so any faults on the Basic I/O highway that affect the reading of A0 will generally mean that the configuration information for Serial Link 0 will be mis-read and apparent failure of serial link 0 will result.
10.6.3.1 Hexled displays C After code download or power-up This can be caused by there being constant failures detected on the Basic IO highway during bootup. See list of common Basic I/O Faults in 10.6.3.3.
Page 10-26
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10.6.3.2 Message Basic IO Failure is displayed on Monitor screen This is caused by a detected fault on the Basic IO Highway. See list of common faults in 10.6.3.3. 10.6.3.3 Common Basic I/O faults. 10.6.3.3.1 Basic I/O Ribbon The Basic IO Ribbon from Core Board to Customer IO Board is loose, damaged, or disconnected. 10.6.3.3.2 External Basic IO Modules connected without an external supply The Customer IO Board is not designed to Drive external Basic IO Modules. If external Basic IO Modules are connected then they must have their own supply. If they do not have a separate supply, then they drag down the 15 V supply on the Customer I/O board causing Basic I/O failures. 10.6.3.3.3 External Basic IO Modules fitted and incorrectly configured External Basic I/O modules are fitted and have their own external supply, BUT they are set up for addresses A0, B0, A1, or B1. Note that these addresses are RESERVED for DIP switches 1 and 2 and Basic IO Digital I/O on the Customer IO Board. If these addresses are also used for external Basic I/O Modules, then a highway conflict will occur giving Basic I/O Highway Trips. 10.6.3.3.4 15 V Supply shorted or disconnected. Anything which can affect the 15 V supply can cause apparent Basic IO Failures. If the reason for the failure cannot be detected by trying the suggestions in section 10.6.3.3, then try disconnecting all boards connected to the SIGMA (excluding the Customer IO board and core-board) to ensure that none of them are having an effect on the 15 V supply. The 15 V supply can be checked with a DVM connected from TP5 on the Customer IO board to any of pins 1 to 8 of DIP switch 1 or pins 1 to 8 of DIP switch 2. 10.6.3.3.5 Hardware/Software configuration for 20X4495 Customer I/O board incorrect The 20X4495 Customer I/O Board is fitted with a link which allows the Basic I/O checking to be configured in two different ways. The drive will function correctly with this link in either position but the position of the link must be correctly matched with the value of P9.2. The allowed configurations are: P9.2 = 0, LK1 connects pins 1 and 2. P9.2 = 1, LK1 connects pins 2 and 3. If the 20X4495 board is being used as a retro-fit item on an older firmware database which does not support P9.2 and has previously been fitted with a 20X4453 Customer I/O Board, then LK1 must be fitted across pins 1 and 2. Refer to section 8.7.5.6 for a details of link LK1.
Issue (12-2-98)
Page 10-27

10.6.4 Common Problems on Serial Links
10.6.4.1 ESP Slave Trib 0 Addressing
Note:
A Slave Trib Address of 0 is a special case for ESP.
To configure Link 0 for ESP Slave Trib address 0 on DIP switch 1, the DIP switch settings are DIP switch 1 switches 5, 6 and 7, and 8 all ON. To use a Config special function to configure a link as an ESP Slave, Trib 0, the address of the Trib must be entered as 15 decimal (0FH), NOT 0. 10.6.4.2 Enhanced Keypad will not work. The Enhanced Keypad is the MASTER, and assumes it is talking to a link that is configured as: ESP Slave with Trib Address 0 @9600 baud. This is the Default Configuration for Serial links 2 and 3. 10.6.4.2.1 Keypad does not work in link 0 Try Keypad in link 2 or 3. If keypad does not work in links 2 or 3 go to 10.6.4.2.2. If keypad works in links 2 or 3, then it should work in link 0. Check the Trib address of link 0: Ensure that DIP switch 1 is set for Trib address 0 (see section 10.6.4.1 for Trib 0 addressing). IF DIP switch 1, switch 1 is ON, check link 0 configuration in ladder/links (see section 10.6.4.1 for information on trib 0 addressing) Check that RS232 LED D94 is ON (see 10.6.2.3.2.3) Check Keypad Lead is OK Check Customer IO board, connections, and selections (see 10.6.2.3). 10.6.4.2.2 Keypad does not work in links 2 or 3 If the Keypad does not work in links 2 or 3, then check the link configurations in the Ladder and links (remember special addressing for Trib 0: see section 10.6.4.1). 10.6.4.2.3 Keypad will not work in links 0, 2, or 3 Check the Keypad lead. Also try another keypad, or try a PC in these links (at baudrate 9600, trib address 0 for links 2 or 3) to ensure that these links are functional. 10.6.5 Problems with Multidrop Operation (RS485 only, Serial Links 0 and 1 only) Multidrop operation is achieved by connecting a MASTER link to many SLAVE links. If multi-drop operation is poor or non-existent: Page 10-28 Alspa GD4000 Technical Manual Issue (12-2-98)

10.6.5.1 Check Fault Messages Check any fault messages on the PC to ensure that there has not been a serious watchdog trip that may explain the link failure (ie IO processor fault). 10.6.5.2 Check connections
Note:
There is a conflict of convention when connecting SIGMA to GEM80, GD2000, GD3000, or Alspa Micro 2 as shown below:
SIGMA RXRX+ TXTX+
CONNECTING TO GEM80 GEM80 TXA TXB RXA RXB -
CONNECTING TO GD2000, GD3000, and ALSPA MICRO2 GD2000, GD3000 ALSPA MICRO2 TX+ TXRX+ RX -
SIGMA RXRX+ TXTX+
CONNECTING SIGMA to SIGMA No conflict of convention.

SIGMA TX+ TXRX+ RX SIGMA RX+ RXTX+ TX-
Issue (12-2-98)
Page 10-29

10.6.5.3 Check if Serial Link 0 is used in the Multidrop Links If serial link 0 is used in the Multidrop links, then check 10.6.5.3.1 and 10.6.2.5 10.6.5.3.1 Check that RS485 LED D65 is lit. If serial link 0 is used as one of the links (MASTER or SLAVE), then check the RS485 LED D65 is LIT (see diagram in section 10.6.2.3). If it is not, connect the RS485 link on TB7. 10.6.5.3.2 Check that Serial Link 0 Configuration is correct. Serial link 0 can be configured using DIP switch 1 on the Customer IO board, or using a CONFIG special function in ladder IF switch 1 of DIP switch 1 is ON (see 10.6.2.5.1.1 for further information). 10.6.5.4 Check Termination resistors Although the system should operate satisfactorily on short multidrop links (< 1 Km) without termination resistors fitted (switches SW3 all set to OFF), it is recommended that they should be fitted by attaching termination resistors to the remote ends of the multidrop link by setting the appropriate switches in SW3 ON (in the direction of the arrows). Note: DP1 = RX Link 0 DP2 = TX Link 0 DP3 = RX Link 1 DP4 = TX Link 1 10.6.5.5 Check that link is not set to point to point There is an allowable link configuration for a point to point link. In the parameter for number of tributaries, if the entry is 0 (it would usually be 1 for a SLAVE on a multidrop link, and the number of Tribs for a MASTER on a multidrop link) then the Tri-states are set to allow permanent connection of the link (ie multidrop will not work). Ensure that for multidrop links, the number of tribs is set appropriately. 10.6.5.6 Check that Slave on Trib address zero exists
Note:
The first SLAVE on a multidrop link MUST be Trib address 0. This is a special case for ESP (see 10.6.4.1).
10.6.5.7 Check for conflicts in link configuration One or more slaves have the same trib address, or the MASTER is not set up to talk to enough slaves. 10.6.5.8 Check all links. If none of the suggestions mentioned above get the multidrop links working, then there may be something wrong with the Customer IO board, connections, or selections. Try the PC in links 0 and 2 (remember to set the PC to the appropriate baudrate/Trib address). If links 0 and 2 will not communicate, Plug a PC into link 0 and go to 10.6.2.2. Page 10-30 Alspa GD4000 Technical Manual Issue (12-2-98)
11. Ordering Codes
Ordering Codes
11.1
11.1.1
Main Equipment
Alspa GD4000 Drive Units (incorporating the 20X4494/10B SIGMA Core Board) Alspa GD4000 Alspa GD4000 Drive Units (incorporating the 20X4451/10B SIGMA Core Board). GD4010G421 GD4020G421 GD4030G421 GD4040G421 GD4060G421 Alspa GD4000 Inverter rated at 10 Amps Alspa GD4000 Inverter rated at 20 Amps Alspa GD4000 Inverter rated at 30 Amps Alspa GD4000 Inverter rated at 40 Amps Alspa GD4000 Inverter rated at 60 Amps
Alspa GD4080 Inverter rated at 80 Amps GD4080L421 50Z0012/10 31V1900/10 84041/312 Alspa GD4000 rated at 2 x 80 amps Input line reactor Precharge unit Line contactor
Alspa GD4120 Inverter rated at 120 Amps GD4120L421 50Z0013/10 31V1900/10 84041/312 Alspa GD4000 rated at 2 x 120 amps Input Line Reactor Precharge unit Line contactor
Alspa GD4160 Inverter rated at 160 Amps GD4160L421 50Z0014/10 31V1900/10 84041/312 11.1.2 Alspa GD4000 rated at 2 x 160 amps Input Line Reactor Precharge unit Line contactor
DC Input AC output - 2 motor configuration GD4010L421 GD4020L421 GD4030L421 GD4040L421 Alspa GD4000 rated at 2 x 10 amps DC fed Alspa GD4000 rated at 2 x 20 amps DC fed Alspa GD4000 rated at 2 x 30 amps DC fed Alspa GD4000 rated at 2 x 40 amps DC fed
Issue (12-2-98)
Page 11-1
11. Ordering Codes

GD4060L421 GD4080L421 GD4120L421 GD4160L421 Alspa GD4000 rated at 2 x 60 amps DC fed Alspa GD4000 rated at 2 x 80 amps DC fed Alspa GD4000 rated at 2 x 120 amps DC fed Alspa GD4000 rated at 2 x 160 amps DC fed
11.2
11.2.1
Optional Equipment
Alspa GD4000 - Line Output Modules GDLOM016-4001 GDLOM032-4001 GDLOM032-4001 GDLOM052-4001 GDLOM080-4001 GDLOM080-4001 GDLOM145-4001 GDLOM207-4001 GDLOM282-4001 GDLOM377-4001 GDLOM754-4001 GDLOM754-4001 GDLOM1131-4001 GDLOM1131-4001 Line Output Module for GD4010 Line Output Module for GD4020 Line Output Module for GD4030 Line Output Module for GD4040 Line Output Module for GD4060 Line Output Module for GD4080 Line Output Module for GD4120 Line Output Module for GD4160 Line Output Module for GD4282 Line Output Module for GD4377 Line Output Module for GD4564 Line Output Module for GD4754 Line Output Module for GD4846 Line Output Module for GD41131
Alspa GD4000 - Programming Tools T1656 GDS1015-4002 Alspa GD4000 Technical Manual + Firmware and Programming tools. RS232 to RS485 Converter with 3m lead Overdrive Alspa GD4000 - Enhanced Keypad GDS1003-4001 GDS1009-4001 Keypad - Mounts on the front of the drive unit. Remote Keypad Cable (3 metres). The cable is fitted with 9-way D-type connectors and connects to the RS232 port on the front panel of the Alspa GD4000.
SIGMA Enhancement Boards GDS1005-4001 GDS1006-4001 GDS1007-4001 31V4200/10 GDS1016-4001 SIGMA Backplane for up to 4 Enhancement Cards SIGMA HDLC Enhancement Card SIGMA HDLC Termination Panel SIGMA HDLC Ribbon Cable FIP Enhancement Card
Page 11-2
Issue (12-2-98)
11. Ordering Codes

T1632 8892-4300 GD4000 Documentation T1656 GD4000 Technical Manual Alspa GD4000 FIP Interface Technical Manual FIP Link AC Earth Connection Assembly (2 required)
Summary of SIGMA Components associated with GD4000 GDS1000-4001 GDS1001-4001 GDS1002-4005 GDS1003-4001 GDS1004-4002 GDS1005-4001 GDS1006-4001 GDS1007-4001 GDS1009-4001 SIGMA Switched Mode Power Supply SIGMA Battery Support Unit SIGMA Core assembly KEYPAD - Mounts on the front of the drive unit. Customer I/O Assembly SIGMA Backplane for up to 4 Enhancement Cards SIGMA HDLC Enhancement Card SIGMA HDLC Termination Panel Remote Keypad Cable (3 metres). The cable is fitted with 9-way D-type connectors and connects to the RS232 port on the Customer I/O Board of Alspa GD4000. SMPS + Mounting Plate RS232 to RS485 Converter with 3m lead Remote Encoder Regulator Unit
GDS1010-4003 GDS1015-4002 31V4400/10 Protective Hoods and Trays For GD4010 to GD4060 50Y8662/01 50Y8662/02 For GD4080 to GD4160 50Y8661/01 50Y8661/02 Thermistor Cables 41Y7408/10 41Y7410/10 41Y7410/20
Protective Hood Protective Tray Protective Hood Protective Tray Thermistor Cable Assembly for 31V5300/80/90/110 Thermistor Cable Assembly for 31V7100/50/60/70 Thermistor Cable Assembly for 31V5300/20/30/40
Issue (12-2-98)
Page 11-3
11. Ordering Codes

11.2.2 Alspa GD4000 - Configurations of Standard DELTA Based Inverters (AC fed, single motor)
GD41131 GD4282 GD4377 GD4564 GD4754 GD4846
Ordercode
DELTA Components - Standard Inverters
No. of motors SIGMA Gate + 1 PIB SIGMA Gate + 3 PIBs
31V5300/90 31V7100/30
1 1 1 1 1
31V1900/20 31V1900/30 31V1900/40 GDS1010-4003 GDS1004-4002
Alspa GD4000 Precharge Unit 282/377 Alspa GD4000 Precharge Unit 564/754 Alspa GD4000 Precharge Unit 846/1131 SMPS + Mounting Plate Customer I/O Assembly
1 1 1 1 1 2 1
1 1
1 1
2 1
2 1
2 1
GDD282-4501 GDD377-4501
GDD282 DELTA Transistor Module 282 Amps GDD377 DELTA Transistor Module 377 Amps
2 2
4 4
6 6
50Z0015/01 33Z0314/10 33Z0315/10 33Z0316/10 33Z0317/10 33Z0361/10 31V5400/10 31V5500/10
Iron Cored Input Reactor for GD4282 Iron Cored Input Reactor for GD4377 Iron Cored Input Reactor for GD4564 Iron Cored Input Reactor for GD4754 Iron Cored Input Reactor for GD4846 Iron Cored Input Reactor for GD41131 Sharing Reactor for GDD282 Sharing Reactor for GDD377
1 1 1 1 1 1 4 4 6 6
31V5200/10 84041/512 84041/712 41Y5829/10 41Y7411/10 41Y7412/10 41Y7413/10
DELTA Fan Unit -Standard Line Contactor for GDD282 Line Contactor for GDD377 Line Contactor Suppression GD4282/4377 Cable Assembly Kit GD4564/4754 Cable Assembly Kit GD4846/41131 Cable Assembly Kit
2 1
4 2
6 3
1 1 1 1 1 1 2
2 2 3
3 3
1 1 1
50Y7527/01 50Y7527/02 50Y7527/03 50Y7527/04
SIGMA/OMEGA Gate Stop Bracket 600 SIGMA/OMEGA Gate Stop Bracket 800 SIGMA/OMEGA Gate Stop Bracket 1000 SIGMA/OMEGA Gate Stop Bracket 1200
2 2 2
31V5800/10 GDD000-4005 GDD000-4006 GDD000-4007
Lower Guide plate Sub-Assembly DELTA Mountings: 600mm 2 modules DELTA Mountings: 800mm 2 modules DELTA Mountings: 1000mm 3 modules
2 1
2 1
Page 11-4
Issue (12-2-98)
11. Ordering Codes

Ordercode DELTA Components - Standard Inverters
GD41131 GD4282 GD4377 GD4564 GD4754 GD4846
GDD000-4008
DELTA Mountings: 1200mm 4 modules
T1656 T1641 T1647
Technical Manual GD4000 + Firmware/Prog Tools Technical Manual DELTA 2 Alspa GD4000 Application Guide
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
DELTA Mountings: 600mm 2 modules 800 deep DELTA Mountings: 800mm 2 modules 800 deep DELTA Mountings: 1000mm 3 modules 800 deep DELTA Mountings: 1200mm 4 modules 800 deep Dirty Air Intake Duct
2 1 1
20T1671/01
31V5300/90 31V7100/30
SIGMA Gate + 1 PIB SIGMA Gate + 3 PIBs
1 1 1 1 1
31V1900/20 31V1900/30 31V1900/40 GDS1010-4003 GDS1004-4002
1 1 1 1 1 2 1
1 1
1 1
2 1
2 1
2 1
GDD282-4501 GDD377-4501
2 2
4 4
6 6
50Z0015/01 33Z0314/10 33Z0315/10 33Z0316/10 33Z0317/10 33Z0361/10 31V5400/10 31V5500/10
1 1 1 1 1 1 4 4 6 6
31V6900/10 84041/512 84041/712 41Y5829/10
DELTA Fan Unit - Large Line Contactor for GDD282 Line Contactor for GDD377 Line Contactor Suppression
2 1
4 2
6 3
1 1 1 2
2 2 3
3 3
Issue (12-2-98)
Page 11-5
11. Ordering Codes

Ordercode DELTA Components - Standard Inverters
GD41131 GD4282 GD4377 GD4564 GD4754 GD4846
, 41Y7411/10 41Y7412/10 41Y7413/10 GD4282/4377 Cable Assembly Kit GD4564/4754 Cable Assembly Kit GD4846/41131 Cable Assembly Kit 1 1 1 1 1 1
50Y7527/01 50Y7527/02 50Y7527/03 50Y7527/04
2 2 2
31V5800/10 GDD000-4005 GDD000-4006 GDD000-4007 GDD000-4008
Lower Guide plate Sub-Assembly DELTA Mountings: 600mm 2 modules DELTA Mountings: 800mm 2 modules DELTA Mountings: 1000mm 3 modules DELTA Mountings: 1200mm 4 modules
2 1
2 1
2 1 1
50Z0018/01 50Z0018/02 50Z0018/03
Transformer Fan/Contactor 2 Fans Transformer Fan/Contactor 4 Fans Transformer Fan/Contactor 6 Fans
T1656 T1641 T1647
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
2 1 1
20T1671/01
Page 11-6
Issue (12-2-98)
11. Ordering Codes

11.2.3 Alspa GD4000 - Configurations High Voltage (690 V) DELTA Based Inverters (AC fed, single motor)
GD4300 GD4600 GD4900
Ordercode
DELTA Components - High Voltage Inverters
31V5300/110 31V7100/40
1 1 1
84041/612 41Y5829/10 62767/843 79320/103 86407/994 71545/450
Precharge Contactor Precharge Contactor Suppression Precharge Resistor Precharge Resistor Mounting Bracket Precharge Relay Precharge Relay Suppressor
1 1 6 12 1 1
2 2 6 12 1 1
3 3 9 18 1 1
GDS1010-4003 50Z0042/01 GDS1004-4002
SMPS + Mounting Plate SMPS Supply Transformer Customer I/O Assembly
1 1 1
2 2 1
2 2 1
GDD300-4601
GDD300 DELTA Transistor Module 300 Amps Iron Cored Input Reactor 335 Amps Iron Cored Input Reactor 670 Amps Iron Cored Input Reactor 1005 Amps Sharing Reactor for GDD282 Sharing Reactor for GDD377
50Z0031/01 50Z0032/01 50Z0033/01 31V5400/10 31V5500/10
1 1 1 4 6
31V5200/10
DELTA Fan Unit -Standard
41Y7411/10 41Y7412/10 41Y7413/10
GD4282/4377 Cable Assembly Kit GD4564/4754 Cable Assembly Kit GD4846/41131 Cable Assembly Kit
1 1 1
50Y7527/01 50Y7527/02 50Y7527/03 50Y7527/04
2 2
31V5800/10 GDD000-4005 GDD000-4006 GDD000-4007
2 1
Issue (12-2-98)
Page 11-7
11. Ordering Codes

GD4300 GD4600
Ordercode
GDD000-4008
50Z0036/01 50Z0036/02 50Z0036/03
DELTA Fan Supply Transformer 2 Modules DELTA Fan Supply Transformer 4 Modules DELTA Fan Supply Transformer 6 Modules
1 1 1
T1656 T1641 T1647
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
20T1671/01
31V5300/110 31V7100/40
1 1 1
84041/612 41Y5829/10 62767/843 79320/103 86407/994 71545/450
1 1 6 12 1 1
2 2 6 12 1 1
GDS1010-4003 50Z0042/01 GDS1004-4002
1 1 1
2 2 1
GDD300-4601
50Z0031/01 50Z0032/01 50Z0033/01 31V5400/10 31V5500/10
1 1 1 4 6
Page 11-8
Issue (12-2-98)
GD4900
1 1 1
3 3 9 18 1 1
2 2 1
11. Ordering Codes

GD4300 GD4600
Ordercode
31V6900/10
DELTA Fan Unit - Large
41Y7411/10 41Y7412/10 41Y7413/10
1 1 1
50Y7527/01 50Y7527/02 50Y7527/03 50Y7527/04
31V5800/10 GDD000-4005 GDD000-4006 GDD000-4007 GDD000-4008
2 1
50Z0037/01 50Z0037/02 50Z0037/03
1 1 1
T1656 T1641 T1647
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
20T1671/01
Issue (12-2-98)
GD4900
1 1 1
Page 11-9
11. Ordering Codes

11.2.4 Alspa GD4000 - Configurations of Standard DELTA Based Inverters (DC fed, single motor)
GD41131 GD4282 GD4377 GD4564 GD4754 GD4846
Ordercode
DELTA Components - DC Fed Single Motor
31V5300/90 31V7100/60
1 1 1
31V1900/20 31V1900/30 31V1900/40 GDS1010-4003 GDS1004-4002
Alspa GD4000 Precharge Unit 282/377 Alspa GD4000 Precharge Unit 564/754 Alspa GD4000 Precharge Unit 846/1131 SMPS + Mounting Plate Customer I/O Assembly 1 1 1 1 1 1 1 1 2 1 2 1
GDD282-4501 GDD377-4501
1 1
2 2
3 3
50Z0015/01 33Z0314/10 33Z0315/10 33Z0316/10 33Z0317/10 33Z0361/10 31V5400/10 31V5500/10
Iron Cored Input Reactor for GD4282 Iron Cored Input Reactor for GD4377 Iron Cored Input Reactor for GD4564 Iron Cored Input Reactor for GD4754 Iron Cored Input Reactor for GD4846 Iron Cored Input Reactor for GD41131 Sharing Reactor for GDD282 Sharing Reactor for GDD377 2 2 3 3
31V5200/10 84041/512 84041/712 41Y5829/10
DELTA Fan Unit - Standard Line Contactor for GDD282 Line Contactor for GDD377 Line Contactor Suppression
41Y7411/10 41Y7412/10 41Y7413/10
1 1 1 1 1
50Y7527/01 50Y7527/02 50Y7527/03 50Y7527/04
31V5800/10 GDD000-4005 GDD000-4006
Lower Guide plate Sub-Assembly DELTA Mountings: 600mm 2 modules DELTA Mountings: 800mm 2 modules
1 1
1 1 1 1
Page 11-10
Issue (12-2-98)
11. Ordering Codes

Ordercode DELTA Components - DC Fed Single Motor
GD41131 GD4282 GD4377 GD4564 GD4754 GD4846
GDD000-4007 GDD000-4008
DELTA Mountings: 1000mm 3 modules DELTA Mountings: 1200mm 4 modules
30Z4592/10 30Z4583/10 30Z4584/10
1 1 1
T1656 T1641 T1647
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
20T1671/01
31V5300/90 31V7100/60
1 1 1
31V1900/20 31V1900/30 31V1900/40 GDS1010-4003 GDS1004-4002
GDD282-4501 GDD377-4501
1 1
2 2
3 3
50Z0015/01 33Z0314/10 33Z0315/10 33Z0316/10 33Z0317/10 33Z0361/10 31V5400/10 31V5500/10
Issue (12-2-98)
Page 11-11
11. Ordering Codes

Ordercode DELTA Components - DC Fed Single Motor
GD41131 GD4282 GD4377 GD4564 GD4754 GD4846
31V6900/10 84041/512 84041/712 41Y5829/10
41Y7411/10 41Y7412/10 41Y7413/10
1 1 1 1 1
50Y7527/01 50Y7527/02 50Y7527/03 50Y7527/04
31V5800/10 GDD000-4005 GDD000-4006 GDD000-4007 GDD000-4008
1 1
1 1 1 1
50Z0018/01 50Z0018/02 50Z0018/03
1 1 1
T1656 T1641 T1647
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
20T1671/01
Page 11-12
Issue (12-2-98)
11. Ordering Codes

11.2.5 Alspa GD4000 - Configurations of High Voltage (690 V) DELTA Based Inverters (DC fed, single motor)
GD4300 GD4600 GD4900
Ordercode
31V5300/110 31V7100/70
1 1
GDS1010-4003 50Z0042/01 GDS1004-4002
1 1 1
1 1 1
2 2 1
GDD300-4601
50Z0031/01 50Z0032/01 50Z0033/01 31V5400/10 31V5500/10
1 1 1 2 3
31V5200/10 84041/512 84041/712 41Y5829/10
41Y7411/10 41Y7412/10 41Y7413/10
1 1 1
50Y7527/01 50Y7527/02 50Y7527/03 50Y7527/04
31V5800/10 GDD000-4005 GDD000-4006 GDD000-4007 GDD000-4008
1 1 1
50Z0036/01 50Z0036/02
DELTA Fan Supply Transformer 2 Modules DELTA Fan Supply Transformer 4 Modules
1 1
Issue (12-2-98)
Page 11-13
11. Ordering Codes

GD4300 GD4600
Ordercode
50Z0036/03
DELTA Fan Supply Transformer 6 Modules
T1656 T1641 T1647
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
20T1671/01
31V5300/110 31V7100/70
1 1
GDS1010-4003 50Z0042/01 GDS1004-4002
1 1 1
1 1 1
GDD300-4601
50Z0031/01 50Z0032/01 50Z0033/01 31V5400/10 31V5500/10
1 1 1 2 3
31V6900/10 84041/512 84041/712 41Y5829/10
41Y7411/10 41Y7412/10 41Y7413/10
1 1 1
Page 11-14
Issue (12-2-98)
GD4900
1 1 1
2 2 1
11. Ordering Codes

GD4300 GD4600
Ordercode
50Y7527/01 50Y7527/02 50Y7527/03 50Y7527/04
31V5800/10 GDD000-4005 GDD000-4006 GDD000-4007 GDD000-4008
1 1 1
50Z0037/01 50Z0037/02 50Z0037/03
1 1
T1656 T1641 T1647
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
20T1671/01
Issue (12-2-98)
Page 11-15
GD4900
1 1 1
11. Ordering Codes

11.2.6 Alspa GD4000 - DC Fed Inverters - Double Motor Configurations
GD41131 GD4282 GD4377 GD4564 GD4754 GD4846
Order Code
DELTA Components - DC Fed Double Motor
31V5300/90 31V7100/30
1 1 1 1 1
31V1900/20 31V1900/30 31V1900/40 GDS1010-4003 GDS1004-4002
GDD282-4501 GDD377-4501
2 2
4 4
6 6
50Z0015/01 33Z0314/10 33Z0315/10 33Z0316/10 33Z0317/10 33Z0361/10 31V5400/10 31V5500/10
31V5200/10 84041/512 84041/712 41Y5829/10
41Y7411/10 41Y7412/10 41Y7413/10
1 1 1 1 1
50Y7527/01 50Y7527/02 50Y7527/03 50Y7527/04
2 2 2
31V5800/10 GDD000-4005 GDD000-4006 GDD000-4007
2 1
2 1
Page 11-16
Issue (12-2-98)
11. Ordering Codes

Order Code DELTA Components - DC Fed Double Motor
GD41131 GD4282 GD4377 GD4564 GD4754 GD4846
GDD000-4008
30Z4592/10 30Z4583/10 30Z4584/10
1 1 1 1 1
T1656 T1641 T1647
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
2 1 1
20T1671/01
31V5300/90 31V7100/30
1 1 1 1 1
31V1900/20 31V1900/30 31V1900/40 GDS1010-4003 GDS1004-4002
GDD282-4501 GDD377-4501
2 2
4 4
6 6
50Z0015/01 33Z0314/10 33Z0315/10 33Z0316/10 33Z0317/10 33Z0361/10 31V5400/10 31V5500/10
Issue (12-2-98)
Page 11-17
11. Ordering Codes

Order Code DELTA Components - DC Fed Double Motor
GD41131 GD4282 GD4377 GD4564 GD4754 GD4846
31V6900/10 84041/512 84041/712 41Y5829/10
41Y7411/10 41Y7412/10 41Y7413/10
1 1 1 1 1
50Y7527/01 50Y7527/02 50Y7527/03 50Y7527/04
2 2 2
31V5800/10 GDD000-4005 GDD000-4006 GDD000-4007 GDD000-4008
2 1
2 1
2 1 1
50Z0018/01 50Z0018/02 50Z0018/03
1 1 1 1 1
T1656 T1641 T1647
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
2 1 1
20T1671/01
Page 11-18
Issue (12-2-98)
11. Ordering Codes

11.2.7 Alspa GD4000 - Configurations of High Voltage (690 V) DELTA Based Inverters (DC Fed, Double Motor)
GD4300 GD4600 GD4900
Ordercode
31V5300/110 31V7100/40
1 1 1
GDS1010-4003 50Z0042/01 GDS1004-4002
1 1 1
2 2 1
2 2 1
GDD300-4601
50Z0031/01 50Z0032/01 50Z0033/01 31V5400/10 31V5500/10
31V5200/10 84041/512 84041/712 41Y5829/10
41Y7411/10 41Y7412/10 41Y7413/10
1 1 1
50Y7527/01 50Y7527/02 50Y7527/03 50Y7527/04
2 2
31V5800/10 GDD000-4005 GDD000-4006 GDD000-4007 GDD000-4008
2 1
2 1
50Z0036/01 50Z0036/02
DELTA Fan Supply Transformer 2 Modules DELTA Fan Supply Transformer 4 Modules
1 1
Issue (12-2-98)
Page 11-19
11. Ordering Codes

GD4300 GD4600
Ordercode
50Z0036/03
DELTA Fan Supply Transformer 6 Modules
T1656 T1641 T1647
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
20T1671/01
31V5300/110 31V7100/40
1 1 1
GDS1010-4003 50Z0042/01 GDS1004-4002
1 1 1
2 2 1
GDD300-4601
50Z0031/01 50Z0032/01 50Z0033/01 31V5400/10 31V5500/10
1 1 1 4 6
31V6900/10 84041/512 84041/712 41Y5829/10
41Y7411/10 41Y7412/10 41Y7413/10
1 1 1
50Y7527/01
SIGMA/OMEGA Gate Stop Bracket 600
Page 11-20
Issue (12-2-98)
GD4900
1 1 1
2 2 1
11. Ordering Codes

GD4300 GD4600
Ordercode
50Y7527/02 50Y7527/03 50Y7527/04
SIGMA/OMEGA Gate Stop Bracket 800 SIGMA/OMEGA Gate Stop Bracket 1000 SIGMA/OMEGA Gate Stop Bracket 1200 2 2
31V5800/10 GDD000-4005 GDD000-4006 GDD000-4007 GDD000-4008
2 1
50Z0037/01 50Z0037/02 50Z0037/03
1 1 1
T1656 T1641 T1647
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
20T1671/01
Issue (12-2-98)
Page 11-21
GD4900
1 1 1
11. Ordering Codes

11.2.8 Alspa GD4000 - Configurations of Standard DELTA Based Inverters (DC Feeder)
GD41131 GD4282 GD4377 GD4564 GD4754 GD4846
Ordercode
DELTA Components - DC Feeders
31V5300/90 31V7100/60
1 1 1
31V1900/20 31V1900/30 31V1900/40 GDS1010-4003 GDS1004-4002
1 1 1 1 1 2 1
1 1
1 1
1 1
1 1
2 1
GDD282-4501 GDD377-4501
1 1
2 2
3 3
50Z0015/01 33Z0314/10 33Z0315/10 33Z0316/10 33Z0317/10 33Z0361/10 31V5400/10 31V5500/10
1 1 1 1 1 1 2 2 3 3
31V5200/10 84041/512 84041/712 41Y5829/10
1 1
2 2
3 3
1 1 1 2
2 2 3
3 3
41Y7411/10 41Y7412/10 41Y7413/10
1 1 1 1 1
50Y7527/01 50Y7527/02 50Y7527/03 50Y7527/04
31V5800/10 GDD000-4005 GDD000-4006 GDD000-4007 GDD000-4008
1 1
1 1 1 1
Page 11-22
Issue (12-2-98)
11. Ordering Codes

Ordercode DELTA Components - DC Feeders
GD41131 GD4282 GD4377 GD4564 GD4754 GD4846
T1656 T1641 T1647
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
20T1671/01
31V5300/90 31V7100/60
1 1 1
31V1900/20 31V1900/30 31V1900/40 GDS1010-4003 GDS1004-4002
1 1 1 1 1 2 1
1 1
1 1
1 1
1 1
2 1
GDD282-4501 GDD377-4501
1 1
2 2
3 3
50Z0015/01 33Z0314/10 33Z0315/10 33Z0316/10 33Z0317/10 33Z0361/10 31V5400/10 31V5500/10
1 1 1 1 1 1 2 2 3 3
31V6900/10 84041/512 84041/712 41Y5829/10
1 1
2 2
3 3
1 1 1 2
2 2 3
3 3
41Y7411/10
GD4282/4377 Cable Assembly Kit
Issue (12-2-98)
Page 11-23
11. Ordering Codes

Ordercode DELTA Components - DC Feeders
GD41131 GD4282 GD4377 GD4564 GD4754 GD4846
41Y7412/10 41Y7413/10
GD4564/4754 Cable Assembly Kit GD4846/41131 Cable Assembly Kit
1 1 1
50Y7527/01 50Y7527/02 50Y7527/03 50Y7527/04
31V5800/10 GDD000-4005 GDD000-4006 GDD000-4007 GDD000-4008
1 1
1 1 1 1
50Z0018/01 50Z0018/02 50Z0018/03
T1656 T1641 T1647
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
20T1671/01
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Issue (12-2-98)
11. Ordering Codes

11.2.9 Alspa GD4000 - Configurations of High Voltage (690 V) DELTA Based Inverters (DC Feeder)
GD4300 GD4600 GD4900
Ordercode
31V5300/110 31V7100/70
1 1
84041/612 41Y5829/10 62767/843 79320/103 86407/994 71545/450
1 1 6 12 1 1
2 2 6 12 1 1
3 3 9 18 1 1
GDS1010-4003 50Z0042/01 GDS1004-4002
1 1 1
1 1 1
2 2 1
GDD300-4601
50Z0031/01 50Z0032/01 50Z0033/01 31V5400/10 31V5500/10
1 1 1 2 3
31V5200/10
DELTA Fan Unit - Standard
41Y7411/10 41Y7412/10 41Y7413/10
1 1 1
50Y7527/01 50Y7527/02 50Y7527/03 50Y7527/04
31V5800/10 GDD000-4005 GDD000-4006 GDD000-4007 GDD000-4008
1 1 1
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Page 11-25
11. Ordering Codes

GD4300 GD4600
Ordercode
50Z0036/01 50Z0036/02 50Z0036/03
1 1
T1656 T1641 T1647
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
20T1671/01
31V5300/110 31V7100/70
1 1
84041/612 41Y5829/10 62767/843 79320/103 86407/994 71545/450
1 1 6 12 1 1
2 2 6 12 1 1
GDS1010-4003 50Z0042/01 GDS1004-4002
1 1 1
1 1 1
GDD300-4601
50Z0031/01 50Z0032/01 50Z0033/01 31V5400/10 31V5500/10
1 1 1 2 3
31V6900/10
DELTA Fan Unit - Large
Page 11-26
Issue (12-2-98)
GD4900
1 1 1
3 3 9 18 1 1
2 2 1
11. Ordering Codes

GD4300 GD4600
Ordercode
41Y7411/10 41Y7412/10 41Y7413/10
1 1 1
50Y7527/01 50Y7527/02 50Y7527/03 50Y7527/04
31V5800/10 GDD000-4005 GDD000-4006 GDD000-4007 GDD000-4008
1 1 1
50Z0037/01 50Z0037/02 50Z0037/03
1 1
T1656 T1641 T1647
1 1 1
1 1 1
Optional Extras
GDD000-4001 GDD000-4002 GDD000-4003 GDD000-4004
20T1671/01
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Page 11-27
GD4900
1 1 1
11. Ordering Codes
Page 11-28
Issue (12-2-98)
12. Ladder Program Instructions
Ladder Program Instructions

12.1 Standard Ladder Elements
This is a quick-reference guide to the elements available on the SIGMA Controller from which the control ladder may be constructed. The elements used are identical in operation to the corresponding standard GEM80 elements (used with the CEGELEC range of GEM80 programmable controllers). For a more detailed explanation of each element with application notes refer to publication T391, GEM80 LADDER DIAGRAM LANGUAGE Programming Manual. -] [- Normally Open Contact Used to transmit a number along a rung when a particular bit is set ON in data tables; when the bit is set to OFF, a zero output is given. -]/[- Normally Closed Contact Used to transmit a number along a rung when a particular bit is set OFF in data tables; when the bit is set to ON, a zero output is given. -( )- Coil (single bit output) Used to set a single bit in a data table to 1 if the rung input is ON; otherwise, if the rung input is off, the bit will be set to 0. <AND> Logic AND Function Used to provide an output whose 16 bits are the result of logically ANDing the 16 rung input bits individually with the 16 bits of a numeric constant or table value. The two most common uses of AND are: a) to insert a number or a value from a table into the start of a rung. b) for masking, i.e. only allowing certain specified bits to pass along a rung. <OR> Logic OR Used to provide an output whose 16 bits are the result of performing an Inclusive OR operation between each bit of the rung input and each bit of a numeric constant, table value, or second branch input. <XOR> Logic EXclusive OR Used to provide an output whose 16 bits are the result of performing an exclusive OR operation between each bit of the rung input and each bit of a numeric constant, table value, or second branch input. <INV> Logic INVersion Used to provide an output whose 16 bits are the inverse of those in the input, i.e. all 0s in the input produce 1s in the output and all 1s in the input produce 0s in the output. Issue (12-2-98) Alspa GD4000 Technical Manual Page 12-1

<OUT> Word OUTput Used to set a word of 16 bits in a data table location to the number or bit pattern present on the rung input. <DELAY> Time DELAY Inserts a time delay into a rung. The units are defined by the user in data table P5 as a multiple of 0.1ms. <COUNT> COUNTer Used to provide an output after the input has changed from OFF to ON a specified number of times. <SEQR> SEQuenceR Used to step through a sequence of up to 16 steps. Provides the software equivalent of a stepping relay or uniselector. <ADD> Logic ADD Used to add two numbers together, each number being a signed integer in the range -232 to + 23 1 (-214783648 to +214783647). <SUB> Logic SUBtract Used to subtract one number from another, each number being a signed integer in the range -232 to +231 (-214783648 to +2147836471). <BLOCK> Start/End of Conditional BLOCK Used to define the start and end of rungs in a program that are to be obeyed only if a given condition is met. If the condition is not met, then the set of rungs will be skipped and program execution will continue at the next rung after the blocked set of rungs. If a block is exited, then bits set within the block are not cleared, allowing the block to be used for one-shot configurations. <SPEC> SPECial Function Used to invoke any of the special functions available in the instruction set of the SIGMA Controller. For a list of the special functions available refer to section 12.2.
12.2
Ladder Program Special Functions

This is a quick-reference guide to the special function elements available on the SIGMA Controller which may be used to complement the standard functions when building ladder programs.
12.2.1
S0 DBOUNCE The DBOUNCE function may be used to condition a logic input signal which is prone to transient or spurious operation. It provides a means of ignoring transient changes of signal state until the signal has remained static for a chosen number of scans of the user program.
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Features
Symmetrical switch ON and switch OFF action Provision for initialisation
Specification Control language:DBOUNCE X -SPEC -VALUE -Q S0 Zm
Table 1
Sym X Q Zm
Program rung data

Location Rung Input Rung Output Value location Use Bouncy input signal Smoothed version of input signal Start of parameter list (5 locations) Range OFF (zero) or ON (non zero) OFF (zero) or ON (-1) Any write enabled table usable by special functions
Table 2
Sym F N*
Value data
Location Zm Zm + 1 Use Fault code and flags User chosen number of scans for which input must be steady. Current count of consecutive scans with input state different from output state. Previous output state Mode control input Range See Table 3. 0 to +32767 Typically 40 to 500 0 to N
Zm + 2
Q M*
Zm + 3 Zm + 4
OFF (zero) or ON (-1) OFF (zero) to hold output to OFF ON (non-zero typically -1) to enable
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* data set up by user Table 3 Fault conditions
Conditions Programming error. Invalid VALUE location: a) Number instead of address b) Zm in write protected memory c) Zm in table not usable by special functions d) Zm + 4 beyond end of data tables memory area. Invalid number of scans: N<0 Mode control input OFF: M = 0 Result Code in Zm Numeric Value Q = 0( OFF) States ON -
Q = Q = 0 C=0 Q = Q = 0 C=0
5 9
0&2 0&3
Application Notes Initialisation For most applications the mode control facility is not required and the mode control input can be preset ON (typically M = -1) so that DBOUNCE operates continuously. Typical applications of the mode control input are: a) To hold the scan count to zero (C = 0) until some initial conditions defined by the user are satisfied. b) To force the output to OFF, avoiding the delay due to DBOUNCE action. Very Bouncy Signals The DBOUNCE function is intended to obtain a single transition for an input which tends to chatter as it reaches the changeover point. It is not suitable for a signal which chatters continuously, because the criterion of N consecutive scans in the same state will be satisfied only if the signal eventually settles firmly in one state or the other. Example a) Requirements A switch (input A1.4) detects the presence of material on a conveyor. The granular nature of the material leads to multiple transitions of the switch at the ends of a batch of material. A signal (output B0.10) is required to give a definite material present/absent indication.
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b) Program rung
| FGEN | + -<AND> SPEC <OUT> -+ | 20 S30 G61 | | | | | + <OUT> -+ | G64 | | | | DBOUNCE | + -] [ -SPEC VALUE ( ) -+ A1.4 S0 G60 B0.10
c) Value data G60 G61 G62 G63 G64 Fault code and flags No. of scans (set to 20 by user) Current scan count Previous output Mode control (set to -1 by user)
d) Remarks This example illustrates the use of program rungs to set up value data. For controllers using functions LOCATE (S20) and MOVE (T20), the same effect may be obtained by entering the data in the preset table and copying to a working value table on start up. The MOVE function data sheet shows a typical program using the P and W tables for this purpose. If the controller has a write enabled preset table, then the preset table itself can be used for the value location. For a typical program repetition interval of 2 ms, the counting of 50 scans would introduce an effective delay of 0.1 seconds. 12.2.2 S3 HISTATE
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Page 12-5

Description The HISTATE function generates a numeric value from a pattern of 32 ON/OFF states. It finds the highest numbered state which is ON and outputs the number of that state. Features
Finds highest priority signal out of a group presented in priority order Can be used to obtain a number representing the current step in a sequence Detects when all states are OFF
Specification Control language:HISTATE X -SPEC Q S3
Table 1
Sym X Q
Program rung data

Location Rung Input Rung Output Use 32 ON/OFF states Number of highest ON state Range Any combination 0 to 31 or -1 if none ON
Application Notes Priority Example The user connects 32 alarms to inputs A1.0 (lowest priority) to A1.31 (highest priority). This rung finds the highest priority of any alarms present e.g. for an operator numeric display, or to choose a message for printout.
| HISTATE | + -<AND> SPEC <OUT> -+ | A1 S3 G70 |
Sequence Example This rung stores the step number of sequencer G14 in location G71 e.g. for operator display.
| + | | | + | | + | | -SEQ -+ G14 | +-RESET | | | -+ | | | -<OUT> -+ G71 |
-] [ E0.1
-] [ A1.31 HISTATE -<AND> SPEC G14 S3
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12.2.3 S4 SWAP
Description The SWAP function interchanges the two bytes of the lower word and the two bytes of the upper word of the 32 bit data location. It provides a simple means of manipulating data when a single data table location is used to store four independent numbers. Features
Simple, easy to use Fast execution No possibility of fault conditions
Specification Control language:SWAP X -SPEC Q S4
Table 1
Program rung data

Sym X Q Location Rung Input Rung Output Range @0000 to @FFFFFFFF. Swaps Bits 0-7 with Bits 8-15 Bits 16-23 with Bits 24-31
Note:
Since the whole location represents four independent numbers, it is best presented in hexadecimal code (prefix @). The first 4 digits represent the upper word, the last 4 digits represent the lower word.
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Page 12-7

Application Notes Extraction of 4 Numbers Example: The program rungs below extract the four count values by using AND instructions to mask one half, and SWAP to move the upper half. The SWAPE special function (S42) is usd to extract the upper word count values (see section 12.2.15).
| + | | | + | | | + | | | + | COUNTS COUNT1 | Extract -<AND> -<AND> <OUT> -+ 1st H3 @00FF G1 | count | COUNTS SWAP COUNT2 | Extract -<AND> -<AND> SPEC <OUT> -+ 2nd H3 @FF00 S4 G2 | count | COUNTS SWAPE COUNT3 | Extract -<AND> -SPEC <AND> <OUT> -+ 3rd H3 S42 @00FF G3 | count | COUNTS SWAPE SWAP COUNT4 | Extract -<AND> -SPEC <AND> -SPEC -<OUT> -+ 4th H3 S42 @FF00 S4 G4 | count
12.2.4
S5 NEGATE Description The NEGATE Special Function changes the sign of a numeric value. The NEGATE function is provided to simplify user programming and to improve execution time. It is entered as a Special Function, but does not involve the same overhead. Execution time is similar to that of a simpler instruction, e.g. coil, contact, AND. Features
Considerable improvement in execution time and complexity over other techniques
that achieve the same result

More readable than other techniques Simple to use No possibility of fault conditions
Specification Control language:NEGATE X -SPEC Q S5
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Equation: Q = -X with one exception that, in integer operation, if X = -2147483648 (or @8000 0000), then Q = 2147483647 (not 2147483648 which falls outside the number range that can be represented by a 32 bit integer) 12.2.5 S6 ABS Description The ABS Special Function converts a number to its absolute value, i.e it provides an output that is always positive. The ABS function is provided to simplify user programming and to improve execution time. It is entered as a Special Function, but does not involve the same overhead. Execution time is similar to that of a simple instruction, e.g. coil, contact, AND. Features

Specification Control language:ABS X -SPEC Q S6
Equation: Q = X if X is positive Q = -X if X is negative with one exception that, in integer operation, if X = -2147483648 (or @80000000), then Q = 214748367 (not 2147483648 which falls outside the number range that can be represented by a 32 bit integer) 12.2.6 S7 NONZERO Description The NONZERO Special Function converts a non-zero input into integer -1. That is, it provides an output word that consists either 32 0s or 32 1s depending on whether the input is zero or non-zero respectively.
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The NONZERO function is provided to simplify user programming and to improve execution time. It is entered as a Special Function, but does not involve the same overhead. Execution time is similar to that of a simpler instruction, e.g. coil, contact, AND. Features

Specification Control language:NONZERO X -SPEC Q S7
Equation: Q = 0 if X = 0 Q = -1 if X 0 12.2.7 S8 OUTPUT Description The OUTPUT Special Function provides an intermediate rung output in the middle of a rung, placing this output in a data table location specified with the following VALUE instruction. The OUTPUT function is provided to simplify user programming and to improve execution time. It is entered as a Special Function but does not involve the same overhead. Execution time is similar to that of a simpler instruction, e.g. coil, contact, AND. Features
Allows monitoring of intermediate rung values without dividing one rung into two
separate rungs
Aids debugging of user program Simple to use No possibility of run-time fault conditions
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Specification Control language:OUTPUT X -SPEC -VALUE -Q S8 Zm
Table 1
Sym X Zm Q
Program rung data

Location Rung Input Value location Rung Output Use Result from previous element in rung Data table location where X is to be stored Input to subsequent computation Any value Any write-enabled table usable by Special Functions Same value as X Range
Q and X always have the same value and are also of the same type. Application Notes Monitoring Intermediate Values By including OUTPUTs you can monitor intermediate values in a rung that would not otherwise be accessible. For instance, when you use ADDs and SUBs in a calculation, the result of either of these operations can not be monitored unless the result is output directly and the rung is terminated. Use as a Commissioning Aid While commissioning your plant, you can edit in OUTPUT Special Functions to examine the intermediate state of a rung. Once the plant has been commissioned, you can then delete the OUTPUT and VALUE from the program. 12.2.8 S11 LINCON
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Page 12-11

Description The LINCON (linear conversion) function may be used for signal scaling or for performing calculations. It provides a combination of multiplication, division and addition for up to four variables. The output is truncated to an integer value in the range 2147483697. Features
Four quadrant operation. User-programmable slope and offset. Automatic limiting at full scale output.
Specification Control language:LINCON X -SPEC -VALUE -Q S11 Zm
Equation: Q = M.X + C D Accuracy:Exact if D is a factor of M.X; otherwise the result is truncated to an integer. Table 1
Sym X Zm Q
Program rung data

Location Rung Input Value location Rung output Use Input variable Start of parameter list (4 locations) Result of calculation Range 2147483647 Any write-enabled table usable by Special Functions Limited at 2147483647
Table 2
Sym F M* D* C*
Value data
Location Zm Zm + 1 Zm + 2 Zm + 3 Use Fault code and flags Multiplier Divisor Offset Range See tables 3,4 (zero = no fault) 2147483647 2147483647 2147483647
Data set up by user.
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Table 3 Fault conditions
Conditions Programming error. Invalid VALUE location: (a) Number instead of address. (b) Zm in write protected memory. (c) Zm in table not usable by special functions. (d) Zm + 3 beyond end of data tables memory areas. Divide by zero (D=0) Calculated result <=-2147483647 Calculated result >= 2147483647 Result Q Code in Zm Numeric Value 0 States ON -
0 -2147483647 2147483647
5 65 129
0&2 0&6 0&7
Table 4
0 2 6 7
Meaning of individual Zm flags

Condition Indicated Any condition leading to wrong answer Divide by zero Negative limit operative Positive limit operative
State ON in Zm
Application Notes Accuracy limitations LINCON provides accurate calculation for reasonably large numeric values. Truncation can lead to a large percentage error in small numeric output. (A) Example of signal scaling Required characteristic Input (location G10): 0 to 90 representing required angle in degrees. Output (location D32): 6400 to 32000 representing 4 to 20 mA corresponding to 0o to 90o. (b) Calculation of scaling factors Output range = M = 32000 - 6400 = 25600 Input range = D = 90 - 0 = 90
Offset = C = output for zero input = 6400 (c) Program rung

| LINCON | + <AND> -SPEC -VALUE -<OUT> -+ | G10 S11 W100 D32 |
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(d) Value data W100 W101 W102 W103 flags 25600 90 6400 (output by LINCON function) (multiplier M) (divisor D) (offset C)
Preset value data It is usual for some of the value data to be calculated during the design stage of the particular application. Such data would be incorporated in the preset data table so that it can be stored. With a write protected P table it is necessary for the user to arrange copying of the preset data into a working value data. The data sheet for MOVE function T20 shows a typical program employing LOCATE and MOVE functions for this purpose. Alternatively the data can be preset in links. 12.2.9 S12 SQRT Description
The SQRT function calculates the square root of a numeric value and scales the result by a user defined gain factor. It provides a simple means for linearizing variables with square law characteristics e.g. flow measurements. Features
High Accuracy Automatic limiting at full scale output.
Specification Control language:(a) Fixed gain factor N

SQRT X -SPEC -VALUE -Q S12 N
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(b) Variable gain factor (location Zm contains gain factor N).
SQRT X -SPEC -VALUE -Q S12 Zm
Equation: Q = N * |X| (sign of Q same as N*X) Accuracy: Calculation better than 1 in 1000. Result rounded to form integer. Table 1
Sym X Q Zm N
Program rung & value data

Location Rung Input Rung Output Value location Value of Zm Result Location for gain factor Gain Factor Use Input variable 2
31
Range -1 Limited at 231-1 Any table usable by special functions 231-1
Fault conditions There are no fault conditions, Application Notes Accuracy Limitations SQRT produces a high accuracy result, provided:(a) Result is a reasonably large numeric value. (b) Result does not exceed 231-1 limits. A gain factor between 50 and 180 (typically 100) satisfies both these criteria, and is suitable for most applications. PROGRAM EXAMPLE Calculate Q = 100 * X, where G10 contains X and Q is to be stored in G11.
| SQRT | |-<AND> SPEC VALUE <OUT>-| | G10 S12 100 G11 |
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Typical Results
Input (X) 10000 3600 64 -3600 +3600 -3600 Gain (N) 100 100 100 100 -100 -100 Output (Q) 10000 6000 800 -6000 -6000 +6000
The following examples show the worst case effect of accuracy and rounding.
49 49 49 49 1 10 100 1000 7 70 699 6999
12.2.10
S20 LOCATE Description
The special functions LOCATE finds the internal memory address of any specified table location. Your program needs to know internal memory addresses when it uses some other types of special function such as MOVE (T20). The software data for any special function explains whether it makes use of internal addresses and whether you need to use LOCATE in conjunction with it. The reason for needing to use LOCATE is that in a SIGMA Controller, the internal address of any given table location is not fixed. It varies depending on what other table locations are used in your program.
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Features
Detects a pseudo address of defined table location. Adds variable offset.
Specification Control language:LOCATE X -SPEC -VALUE -Q S20 Zm
Table 1
Sym X Zm Q
Program rung data

Location Rung Input Value location Rung output Offset Table location to be found SIGMA address Use 9999 Any table usable by special functions Upper 8 bits = ASCII code for letter. Lower 24 bits = offset. Range
Table 2
Fault Conditions
Condition Numeric Value Rung Output States ON All
STATUS Offset X <-9999 or >9999
-1
Notes:
Where special functions make use of internal addresses (provided by LOCATE) as input, they first check that these addresses fall inside the tables area of memory. When LOCATE gives an output of -1 under the fault condition listed in Table 2, then, since -1 is not a address, the particular special function will treat this as a fault condition and produce its own fault code. Refer to the software data for individual special functions for details of their fault codes.
Application Notes Use with MOVE (T20) with a Fixed Offset When you use the MOVE special function T20 in your program, you should take particular care. If wrongly programmed, MOVE can transfer data to the wrong place, and overwrite good data. Use a fixed offset (zero) whenever practical. This reduces the chances of a bug elsewhere in your program causing MOVE to transfer data to the wrong place.
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| + -<AND> | 0 | | | + -<AND> | 0 LOCATE MOVE | -SPEC -VALUE SPEC VALUE <OUT> -+ S20 G20 T20 20 F100 | +-< > | LOCATE | -SPEC -VALUE + S20 G100
This rung copies the data from G20 to G39 into G100 to G119 respectively. Use with MOVE (T20) with a Variable Offset If you substitute the following program for the upper branch in the previous example, it makes the data to be copied dependent on which state in G0 is ON. i.e. G20 to G39 if G0.0 is ON G40 to G59 if G0.1 is ON etc.
| LOCATE + -<AND> ] [ -+ SPEC VALUE | 0 G0.0 | S20 G20 | | | | + -<AND> ] [ -+ | 20 G0.1 | | | | | + -<AND> ] [ -+ | 40 G0.2
The rung assumes only one bit in G0 is ON at any one time, e.g. G0 is a sequencer function. 12.2.11 S30 FGEN Description
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The FGEN function may be used to generate an approximate representation for any continuous function of the form: Q = f(X) It provides linear interpolation between points tabulated by the user. Features
Full four quadrant operation. User chosen quantity of tabulated points. User chosen interval between points.
Specification Control language:

FGEN X -SPEC -VALUE -Q S30 Zm
Function: Linear interpolation between N tabulated points (X1 to Xn at equal intervals delta-X) Q = Q1 for X X1 Q = Qn for X Xn Accuracy: Calculation in 32-bit integer arithmetic produces small errors. Result truncated to nearest integer. Table 1
Sym X Q Zm
Program rung data

Location Rung Input Rung Output Value location Use Input variable Calculated result Start of data list tabulating function (N+4 locations) 2 -1 231-1 Any table usable by special functions
31
Range
Table 2
Sym F X1 * Delta-X * N* Q1 * Qn *
Value data
Location Zm Zm + 1 Zm + 2 Zm + 3 Zm + 4 Zm + 3 + N Use Fault code. Suppressed if Zm in write protected table. Lowest value of X for which Q is tabulated. Interval between points. Number of tabulated points. Tabulated value for X1 Tabulated value for Xn Range See table 3. (Zero for no fault). 231-1 1 to 231-1 1 to 231-1 231-1 231-1
* Data set up by user. Issue (12-2-98) Alspa GD4000 Technical Manual Page 12-19

Restrictions:(a) (X - X1) 231-1 i.e. positive range of X must be limited if X1 (b) (Xn - X1) 231-1 i.e. tabulated function cannot exceed 0.5 x total range of X. Table 2 Fault conditions
Condition Programming error or number (N) of tabulated points too large. Zm+3+N beyond end of data tables area. Number of tabulated points (Delta-X) < 1 [X1 + (N-1)*Delta-X] > 232-1. Detected only when X between X x (N-1) and X x N. This condition means that tabulated function exceeds 0.5 x total range of X. Result Q=0 3 Data in Zm Numeric Value States ON 0&1
Q=0 Q=0
5 9
0&2 0&3
Notes:
If Zm is in write protected memory, then fault code is suppressed, but FGEN operates normally in other respects.
Application Notes Write Protected Value Location For many special functions it is usual to enter preset value data in the write protected P tables and arrange copying on startup into a working value W table used for the special function value location. Whilst this arrangement is perfectly suitable for FGEN it is extravagant in the use of data table space, because the fault code is the only variable data. The user can save data table space by placing Zm in a write protected P table, in which case the fault code output is automatically suppressed. Fault diagnosis becomes slightly more difficult, but the condition Q = 0 can be used to detect a fault condition provided the user can distinguish from normal output Q = 0. Alternatively the data can be preset in links. E.g. Wx = 1, where Wx = Zm + 1
Choice of Delta-x and N The accuracy with which FGEN approximates to a required continuous condition depends on the quantity and spacing of tabulated points. Each FGEN function consists of equal width segments. For the most critical applications it may be appropriate to divide a curve into sections so that some parts can be represented by closely spaced segments without having to tabulate enormous numbers of points on nearly linear parts. The complication of having several FGEN functions would have to be balanced against the saving in data table space.
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PROGRAM EXAMPLE (a) Required characteristic
(b) Program rung.

| FGEN | |-<AND> SPEC VALUE <OUT>-| | G10 S30 P100 G11 |
(c) Value data. P100 P101 P102 P103 P104 P105 P106 P107 12.2.12 0 30 20 4 20 30 50 60 Fault code suppressed if P table write protected. Lowest tabulated input (X1) Interval between points (Delta-X) No. of tabulated points (N) 1st tabulated point (Q1) 2nd tabulated point (Q2) 3rd tabulated point (Q3) 4th tabulated point (Q4)
S31 DEDBAND Description The DEDBAND function provides a unity gain characteristic between input and output, with dead band and offset. Features
User programmable dead band and offset values. Automatic limiting at full scale output. Set of flags detecting in-limit or within dead band.

DEDBAND X -SPEC -VALUE -Q S31 Zm
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Equation: For X < D, For X Q=0
D Q = X+S if X > 0 Q = X-S if X < 0 Q limited at 2147483647 Program rung data

Location Rung Input Value location Rung output Use Input variable Start of parameter list (3 locations) Output variable Range 2147483647 Any table usable by special functions Limited at 2147483647
Table 1
Sym X Zm Q
Table 2
Sym F X1* X*
Value data
Location Zm Zm + 1 Zm + 2 Use Fault code end flags Dead band value Offset value Range See table 3,4 and 5 0 to 2147483647 2147483647
* Data set up by user Restrictions:(a) X-X1 2147483647 i.e. positive range of X must be limited if X1 (b) XN-X1 2147483647 i.e. tabulated function cannot exceed 0.5 x total range of X. Table 3 Fault conditions
Code in Zm Condition Programming error Invalid value location: (a) Number instead of address. (b) Zm in write protected memory. (c) Zm in table not usable by special functions (d) Zm + 2 beyond end of data tables memory area. Invalid dead band value D<0. Result (Q) Numeric Value States ON -
0&2
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Table 4 Conditions indicated by Zm flags
Condition Negative limit operative (X-S)>-2147483647 Positive limit operative (X+S)>+2147483647 Input within dead band -D<X<+D Code in Zm Numeric Value 64 128 8192 States ON 6 7 13
Table 5
Meaning of individual Zm flags

State ON in Zm 0 2 6 7 13 Fault Negative dead band D<0 Negative limit operative (X-S) < -2147483647 Positive limit operative (X+S)>+2147483647 Input within dead band -D<X<+D Condition indicated
Application Notes Example without offset (a) Required characteristic
(b) Program rung

| DEDBAND | + -<AND> SPEC -VALUE -<OUT> -+ | G10 S31 W100 G11 |
(c) Value data W100 flags W101 10 W102 0 Issue (12-2-98) (output by DEDBAND function) (Dead band value) (Offset value) Alspa GD4000 Technical Manual Page 12-23

(d) Typical use of flags
| | + -] [ -( ) -+ | W100.13 B0.0 |
This rung switches on output B0.0 when input is within deadband i.e. -10<G10<+10. Example with offset (same rung as 1(b)) Characteristic Value W100 W101 W102 Preset value data It is usual for some of the value data to be calculated during the design stage of the particular application. Such data would be incorporated in the preset data table so that it can be stored. With a write protected P table it is necessary for the user to arrange copying of the preset data into a working value table. The data sheet for MOVE function T20 shows a typical program employing LOCATE and MOVE functions for this purpose. Alternaltively the data can be preset in links. 12.2.13 S32 LIMIT Introduction The LIMIT function provides a unity gain characteristic between input and output, but with the output restricted to a user defined range. Flags are provided to indicate the relationship of the input variable to the high and low limit points. Features User programmable low and high limit points Comprehensive set of flags detecting above equal or below limits Specification Control language:LIMIT X SPEC VALUE Q S32 Zm
Data Flags +100 -100
Equation: For X L (low limit) X H (high limit) L X H Q=L Q=H Q=X
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Table 1 Program Rung Data
Sym X Zm Q Location Rung input Value location Rung output Use Input variable Start of parameter list (3 locations) Limited version of input variable Range 2147483647 Any write enabled table usable by special functions LQH
Table 2 Value Data

Sym F L* H* Zm Zm + 1 Zm + 2 Location Low limit High limit Use Fault code and flags Range See tables 3, 4 and 5 Each 2147483647 with L<H
* Data set up by user Table 3 Fault Conditions

Code in Zm Condition Programming Error VALUE location invalid:a) Number instead of address b) Zm in write protected memory c) Zm in table not usable by special functions d) Zm+2 beyond end of data tables memory area Invalid limit values L > H Result (Q) Numeric Value States ON -
-12283
0, 2, 12, 14, 15
Table 4 Conditions Indicated by Zm flags

Code in Zm Condition Input above high limit X>H Input equal to high limit X = H Input between limits L<X<H Input equal to low limit X=L Input below low limit X<L Numeric Values -26112 -28672 0 20480 22016 States ON 9, 11, 12, 15 12, 15 None 12, 14 9, 10, 12, 14
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Table 5 Meaning of Individual Zm flags,
State ON in Zm 0 2 9 10 11 12 14 15 Fault condition Low limit not below high limit L H Input outside range between limits X<L or X>H Input below low limit X<L Input above high limit X>H Input equal or outside range between limits X L or Z H Input equal or below low limit X L Input equal or above high limit X H Condition indicated
Application Notes Example Required characteristic
Program rung:
| LIMIT | + -<AND> -SPEC VALUE <OUT> + | G10 S32 W100 G11 |
Value data W100 flags (output by LIMIT function) W101 5 (low limit) W102 15 (high limit) Typical use of flags
| | + ][ () + | W100.9 B0.0 |
This rung switches on output B0.0 when limits are operative, ie. G10<5 or G10>15 and G10 G11.
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Preset Value Data It is usual for some of the value data to be calculated during the design stage of the particular application. Such data would be incorporated in the preset data table so that it can be stored . With a write protected P table it is necessary for the user to arrange copying of the reset data into a working value table. The data sheet for MOVE function T20 shows a typical program employing LOCATE and MOVE functions for this purpose. Alternatively the data can be preset in links 12.2.14 S37 ANALAG Description The ANALAG function provides a digital filter for smoothing fluctuating numeric values. It provides 1st order smoothing of input changes. The mnemonic ANALAG stands for ANAlogue LAG. Features
Equivalent to a single time constant filter User programmable time constant Provision for switching the filtering action into or out of the system and for initialising
the output
AC couple option Execution time of 15 s
Specification
ANALAG X SPEC VALUE Q S37 Zm
Number of value locations: 8 (Zm to Zm+7) Equation when filter switched out (Zm+4 = 0): Q = X Equation when switched in (Zm+4 = 1): Q = X / (1 + sT), where T is the time constant Equation when AC coupled: Q = X - X / (1 + sT)
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Table 1
Sym X Q Zm Zm + 1* Zm + 2 Zm + 3 Zm + 4* Zm + 5* Zm + 6 Zm + 7 Location Rung input Rung output Fault code Time constant Previous output Previous remainder Filter enable AC couple enable Scan time Last time Internal Internal Enable filter Enable AC couple Internal Internal 1 = enable 1 = enable Use Result from previous element in rung Input to subsequent computation Not used Range: 0.000-2000.000 secs 1 = 1 ms Range -2.146E9 to 2.147E9 -2.147E9 to 2.147E9
* = set by user 12.2.15 S42 SWAPE Introduction The SWAPE special function allows the upper and lower 16 bits of a 32 bit SIGMA word to be swapped.
Features
Simple, easy to use Fast Execution No possibility of fault conditions
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Specification Ladder Format
| SWAPE | +-<AND> -SPEC <OUT> + | Input S42 output | | |
RUNG Specification Symbol input Note: Q Location Rung input Range @00000000 to @FFFFFFFF.
The ladder editor will only enter immediate values up to @FFFF. Rung Output As above
Bits 0-15 of input in bits 16-31 of output. Bits 16-31 of input in bits 0-15 of input. Application Notes Example
| SWAPE | +-<AND> -SPEC <OUT> + | G0 S42 G1 | | |
If 12.2.16
G0 = @12345678 G1 = @56781234
S70 SIN
12.2.16.1 Description The SIN function operates with angles in degrees only. 12.2.16.2 Features
Input in the range -2.147E9 to 2.147E9 where 100 = 1 degree Output in the range (-1 * multiplier) to (1 * multiplier) Execution time of 7 s
12.2.16.3 Specification Control language:SIN X SPEC VALUE Q S70 Zm
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Table 1 - Program rung data
Sym X Q Zm Location Rung Input Rung Output Value location Angle in Q = SIN(X+(Zm+1)) x (Zm+2) Start of parameter list (3 locations) Any write enabled table usable by special functions Use Range -2.147E9 to 2.147E9 Scaling: 100 = 1 degree
Table 2 - Value data

Location Zm Zm + 1 * Zm + 2 * Use Fault code and flags Input angle offset Output multiplier Range See Table 3. -2.147E9 to 2.147E9 Scaling: 100 = 1 degree -131000 to 131000
* data set up by user Table 3 - Fault conditions

Code in Zm Condition Programming error. Invalid VALUE location: a) Number instead of address b) Zm in write protected memory c) Zm in table not usable by special functions d) Zm + 4 beyond end of data tables memory area. Zm + 2 < -131000 Zm + 2 > 131000 Result Q=0 (OFF) Numeric Value States ON -
33 65
0&5 0&6
Application Notes
| | | SIN | |+ <AND> SPEC <VALUE> <OUT> + | G10 S70 G11 G14 |
G10 G11 G12 G13 G14 12.2.17
Input in degrees (100=1 degree) Fault code and flags Offset angle Output multiplier Output
S140 GDMMOD Introduction The GDMMOD special function is used to call SIGMA Application modules (modules 20s onwards). It is different from all other GEM80 special functions because it causes the compiler to search the LINKS section in the SIGMA user program and execute all links to the module before executing the module itself.
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GDMMOD X SPEC -VALUE - Q S140 Zm
Table 1 - Program Rung Data

Sym Z Zm value Location rung input not used determines module Use any value 1st location of any SIGMA module data table See Note undefined Range
rung output
not used
Note:
The value must be the first location of the data table of the module to be executed. eg. if we require module 22, REFERENCE CIRCUITS, Zm = L2200.
Any error is reported at compile time and prevents the program currently executing from being changed. 12.2.18 T0 COMPARE
Description The Compare function may be used to perform a numerical comparison between two variables. It provides a set of flags so that the user can make a subsequent program operation depend on the result of the comparison. Features
Takes account of magnitude and sign. Individual flag for each combination of > = <
Specification Control Language:

COMPARE X SPEC VALUE -Q TO Zm + < > | Y +
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Table 1
Sym X,Y Zm Q
Program rung data

Location Rung inputs Value location Rung output Use Numeric values to be compared Location for flags Logic ON for input to subsequent user program 32767 Any write enabled table usable by special functions Normally ON (-1) OFF(zero) under fault conditions (see Table 4) Range
Table 2 - Numeric Values in Zm

Condition X>Y X=Y X<Y Number in Zm 25600 -27648 22528 Remarks These numbers are the values which will be displayed when monitoring a program rung. See Table 3 for flags to include in user program
Table 3 Meaning of Individual Flags

State ON in Zm 10 11 12 13 14 15 Condition Indicated X< |Y(X Y) X >Y X> | Y(X Y) X >Y XY X=Y Remarks For any typical values of X and Y a combination of flags will be ON.
Table 4 Fault Conditions

Condition Programming error. No VALUE after SPEC. Programming error. Invalid VALUE location a) Number instead of address b) Zm in write protected memory c) Zm in table not usable by special functions Result Q=0 (OFF) Q=0 (OFF)
Application Notes Example Logic A lamp connected to output B0.8 is to be switched on when the contents of location G10 are greater (more positive) than the contents of G11.
| COMPARE | +<AND> SPEC VALUE ] [ ( ) + | G10 T0 G59 G59.13 B0.8 | | +< > | | | | + <AND>+ | | G11 |
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Example - Numeric Manipulations To the find greater (more positive) of two numeric values G10 and G11 and store the result in G23.
| COMPARE | +<AND> SPEC VALUE + ] [<AND>+<OUT> + | G10 T0 G60 | G60.13 G10 | G23 | | +< > | | | | | | | | + <AND>+ + ] [<AND>+ | | G11 G60.12 G11 |
12.2.19
T1 T2 T3 T4 T5 T6
EQ NE GT LT GE LE
Description The special functions T1-T6 compare two input values and give a logic output dependent on whether a required condition is met. That is, they each provide a 32-bit word output that consists of: 32 0s if the condition is NOT met, or 32 1s if the condition IS met.
Features


mm X SPEC Q Tn +-< > | Y +
where: mm n = the mnemonic of the function; for example GT = the number of the function, e.g. 3.
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Page 12-33

T1 EQ Equation: Q = -1if X = Y Q = 0 if X Y T2 NE Equation: Q = -1if X Y Q = 0 if X = Y T3 GT Equation: Q = -1if X > Y Q = 0 if X Y T4 LT Equation: Q = -1if X < Y Q = 0 if X Y T5 GE Equation: Q = -1if X Y Q = 0 if X < Y T6 LE Equation: Q = -1if X Y Q = 0 if X > Y 12.2.20 T7 MAX T8 MIN Description The MAX/MIN special functions determine the larger or smaller of two integer values or alternatively find the largest or smallest entry in an array. Page 12-34 Alspa GD4000 Technical Manual Issue (12-2-98) (less than or equals) (greater than or equals) (less than) (greater than) (not equals) (equals)

Specification Control language:MAX/MIN X -SPEC -Q T7/T8 +- < > | Y +
The determination of largest or smallest is on the basis of most positive or most negative respectively. Table 1
Sym X Y Q
Program rung data

Location Upper Rung Input Lower Rung Input Rung Output Maximum or Minimum value Use Range 2147483647 2147483647 2147483647
12.2.21
MULT (T10) The MULT special function multplies two variables. The output is correctly signed giving four-quadrant operation. Control language:MULT X -SPEC -Q T10 +-< > | Y +
Equation: Q=XxY where: X = rung input, upper branch. Y = rung input, lower branch. Q = rung output. Note: Unlike some other special functions, MULT requires no VALUE after it.
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Application Notes Multiplication by a constant
| +-<AND> | G10 | | +-<AND> | 8 MULT | -SPEC <OUT>-+ T10 G22 | +- < > | | | + | |
The above rung makes the contents of G22 equal to 8 times the contents of G10 (subject to the result being within range, otherwise it will be limited to 2147483647) Multiplication by a variable
| +-<AND> | G10 | | +-<AND> | G11 MULT | -SPEC <OUT>-+ T10 G22 | +- < > | | | + | |
The above rung makes the contents of G22 equal to G11 times the contents of G10 (subject to the result being within range, otherwise it will be limited to 2147483647). 12.2.22 DIV (T11) The DIV special function performs an arithmetic division operation on two variables. The output is correctly signed giving four-quadrant operation. Control Language
DIV X -SPEC -VALUE -Q T11 Zm +- < > | Y +
Equation: Q = (X x R) Y Where: X Y Q R = = = = rung input, upper branch. rung input, lower branch. rung output. The remainder of the calculation X/Y. The sign of the R is the same same as the sign of the X input. is the same as the sign of the X input. data table addres where R is to be stored. Alspa GD4000 Technical Manual Issue (12-2-98)
Zm Page 12-36

Notes: 1. Q is limited to the range 2147483647, and R is limited to the range 2147483646. The number below the VALUE, shown above as Zm, must be the address of a table location, e.g. W100. If you key in a number instead of an address, or the address of a table location in write-protected memory, or a table not usable by Special Functions, then you will get a compiler error and the download file will be deleted. If Y is zero, both the rung output Q and the remainder R will be set to zero.
2.
3.
Examples of the Results of Division:

Dividend X 17 17 17 -17 -17 Divisor Y 3 18 -3 3 -3 Quotient Q 5 0 -5 -5 5 Remainder R 2 17 2 -2 -2
Application Notes Division by a constant

| +-<AND> | G20 | | +-<AND> | 16 DIV | SPEC -VALUE -<OUT>-+ T11 W120 G30 | +-< > | | | + | |
In this rung, the contents of G20 are divided by 16, the result placed in G30, and the remainder placed in W120.
| DIV | +-<AND> -ADD SPEC VALUE <OUT>-+ | G20 W120 T11 W120 G30 | | +-< > | | | | +-<AND> -+ | | 16 |
The above rung is a modification of the previous one, where the remainder in W120 calculated on the previous execution of the program is added to the input G20 prior to the division. The DIV function will then recalculate the remainder and place its new value in W120. This method of adding back the remainder avoids cumulative errors with the integer arithmetic in any applications that involve totalisation.
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Division by a variable
| +-<AND> | G20 | | +-<AND> | G22 DIV | -SPEC VALUE -<OUT>-+ T11 W120 G30 | +- < > | | | + | |
In this rung, the contents of G20 are divided by the contents of G22, the result placed in G30, and the remainder placed in W120. 12.2.23 T17 FILL Description The FILL special function sets each element of the input array to the value supplied by the user. The FILL function treats a block of adjacent data table locations as a one dimensional array of numerical values. The elements within an array are referenced by an index commencing at word 0. Features
Input array location and length definable by user User specified initialization value
Specification Control language:FILL X -SPEC -VALUE -Q T17 Zm +- < > | Y +
Table 1
Sym X
Program rung data

Location Upper Rung Input Use Internal SIGMA address of array to be initialised Initialisation value Length of array. May be specified either as a number or as a table location in which the number is located. Error code Range Address of write enabled data table location obtainable by LOCATE Any 32 bit pattern 1 to 4096
Y Zm or N
Lower Rung Input Value
Rung Output
0 for no error. See Table 2
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Table 2 Fault codes
Conditions Programming error. Array length invalid Programming error. Invalid array address: input array a) Not in write enabled table usable by specials; or b) extends beyond end of data table area Rung Output Numeric Value Q=3 Q=5 States ON 0, 1 0, 2
| LOCATE +-<AND> SPEC -VALUE | 0 S20 P100 | | +-<AND> | 32
FILL | -SPEC VALUE -<OUT> -+ T17 8 100 | +-< > | | | + | |
The above rung places the value 32 in 8 P-tables (P100 to P107). The rung output is a fault code (see table 2) placed in data table F100. 12.2.24 T20 MOVE Description MOVE is used to copy the data from one block of data table locations into a different block of locations. The MOVE function transfers a defined number of data items from the source table to the destination table. The source and destination locations are specified using the LOCATE function (S20) Features
User programmable data block size Copies data between different data tables, or can be used to shift data within the
same table. Specification Control language:
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a) Fixed block size (N locations)
MOVE X -SPEC -VALUE -Q T20 N +-< > | Y -+
b) Variable block size (location Zm contains block size N)

MOVE X -SPEC -VALUE -Q T20 Zm +-< > | Y -+
Table 1
Sym X
Program rung & value data

Location Rung Input (upper branch) Use Internal SIGMA address of first source location Internal SIGMA address of first destination location Block size Block size N Fault code (5 locations) Range Addresses of data table locations as obtained by LOCATE function. The destination must not be write protected. 0 to 9999 Any table usable by special functions See table 2 (Zero = no fault)
Y N Zm Q
Rung Input (lower branch) Value integer Value location Rung output
Table 2
Fault codes and flags

Conditions Rung output Numeric Value States ON 0&1
Programming error or block size N too large. Invalid location in source block: X + N beyond end of data table Programming error or block size N too large.Invalid location in destination block: Y + N beyond end of data table Source location not a valid address. Destination location not a valid address or read only Block size N<0 or >9999
0&2
9 17 33
0&3 0&4 0&5
No data transfer occurs if any of above conditions occurs.
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Application Notes Example of Copying Between Tables Typical application of LOCATE and MOVE for special function value data. Preset value data. Preset values in P table (P100 to P199) are to be copied to working W table (W100 to W199) on start up. G0.0 is set OFF automatically on start up, so this is used as condition for executing MOVE rung.
| + | | | | | + | | | | + | | + | | | | | OBEY -+ BLOCK | | * * | | | VALUE <OUT>-+ 100 F100 | | | | | | | ( )-+ G0.0 | | * * | |
-]/[ G0.0 * * START OF BLOCK
LOCATE MOVE <AND> SPEC VALUE SPEC 0 S20 P100 T20 +< > | LOCATE | <AND> SPEC VALUE+ 0 S20 W100
END OF BLOCK
EXAMPLE OF SHIFTING DATA IN SAME TABLE The MOVE function includes checks to ensure satisfactory execution if the source and destination blocks overlap, i.e. MOVE may be used to shift a block of data up or down a table. A typical application is in history recording, and the example below shows a rung for storing ten previous values of variable G20 in locations G21 to G31.
| LOCATE MOVE | + <AND> SPEC VALUE SPEC VALUE <OUT>-+ | 0 S20 G20 T20 10 F101 | | +< > | | | | | LOCATE | | + <AND> SPEC VALUE+ | | 0 S20 G21 |
12.2.25
T33 CONFIG Introduction The CONFIG special function on SIGMA is used to configure the 4 serial links.
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Specification Ladder Representation
| | + <AND> | N | | + <AND> | 0 | CONFIG | SPEC VALUE <OUT> + T33 Zm Q | +< > | | | + | |
Program Rung Data

Symbol N <AND> Zm Location Upper rung input lower rung input value Use Link number set to zero (not used) Address of start of configuration data block (6 words required). Any table useable by the special function Fault if non zero; See Error Codes below. 0 Range 0-3 (see note below)
Rung output
Configuration Data The configuration data is defined by the data table defined by CONFIG. 6 words are required. Note: The configuration is always applicable to links 1-3; link 0 is configured by a switch SW1 on the Customer I/O board, but can be configured using the CONFIG special function if SW1.1 is ON. Link address (See note 1) 0 = ESP Control 1-14 = ESP Tributary address 1-14 15 = ESP tributary address 0 1 to 255 = MODBUS tributary address Number of partners (See note 1) Control or tributaries: 0 = Point to point link (i.e. no tristate control). Control multidrop: 1 to 4 Slave multidrop: 1 Port Type Parity (MODBUS only) 1 = 8 bits no parity 2 = 8 bits even parity 3 = 8 bits odd parity 4 = 7 bits even parity 5 = 7 bits odd parity 6 = 7 bits parity set 7 = 7 bits parity reset.
Zm + 0
Zm + 1
Zm + 2 Zm + 3
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Zm + 4 If printer port, characters/sec (100 to 1000, default 100) data type -1 for -2 for -3 for -4 for -5 for (See note 2) table exchange printer MODBUS ASCII MODBUS RTU Loopback mode.
Zm + 5
Notes:
The following limitations are applied to the configuration: 1) Link 0 defaults to a tributary but can be a master to one tributary. Link 1 can be a tributary or a Master to up to four tributaries. Link 2 can be a tributary (point to point operation only) or a Master to one tributary. Link 3 is a programming port for communication with the enhanced keypad. Link 3 cannot be used for ESP table exchange. Zm + 5 has no meaning for link 3.
2) Port Type
The port type sets up the port baud rate. Link 2 is limited to 19200. Link 3 defaults to 38400 for downloading a program after power-up, but should not be used at baud rates above 19200 after a program is loaded. Port Permitted
No. 0 1 2 3 4 5 6 7 8 Baud Not used 1200 2400 4800 9600 19.2k 38.4k 76.8k 57.2k y y y y y y y y y y y y y y y y y y y y y y y y y y Link 0 Link 1 Link 2 Link 3
Error Codes The following bits are set as error codes:

Bit 0: Bit 1: Bit 2: Bit 3: Bit 4: Bit 5: link not configured or fault Invalid link number (out of range) Invalid tributary (out of range) Invalid no. of partners (out of range or invalid for trib) Invalid port type (out of range for port selected) Invalid mode (out of range or invalid for port selected)
Application Notes (1) Links 1-3 default to ESP table exchange, 9600 baud, trib 0. If a change is required, the CONFIG special function needs to be called with the required configuration. Issue (12-2-98) Alspa GD4000 Technical Manual Page 12-43

(2) The links will only work when the CONFIG special function has finished executing. It is recommended that the function is called on a HALT-RUN (E0.6 high) (3) Any of the Links can be used to either monitor or download a program, irrespective of the configuration. Notes: the SW1 set-up for baud rate and tributaries is always valid for use, except when SW1/1 is ON, when the CONFIG special function is used to configure Link 0.
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12.3
User-Accessible Data Table Addresses

A proportion of the GD4000 memory is arranged as tables. These are simple data storage areas. Each table area is defined by a letter e.g. A-table, C-table, etc. Within any of these tables data is stored as 32-bit words. Each word is held in a table location. To refer to any particular table location its address must be quoted. The address consists of the table letter followed by a number e.g. A15, E0, etc. It is often necessary to refer to an individual bit within a table location. This is done by simply adding a point and the bit number to the address e.g. A15.6, A15.12, B12.0. These addresses are referred to as bit addresses. Notes: In common with most computer based equipment, address numbers start from zero. This applies to both the lowest bit of a word, and to the lowest word in a table.
The following lists give a summary of the data tables accessible to the user program. 12.3.1 A/B Tables - Digital and Basic I/O (See Section 8.7.5.3 to 8.7.5.4 for details of the 20X4495 Customer I/O Board) These are BASIC I/O tables in the range A or B 0 to 15. A prefixes being input references and B being output references. The function of each address is determined by reference in the user program. The same address cannot be an input and an output. An error is flagged if this occurs. Some of the Basic I/O is already predefined by the Customer I/O board, as follows: A0 bits 0-7 bits 8-11 bits 12-14 bit 15 A1 bits 0-7 B1 bits 8-15 A32 bits 0-7 bits 8-15 A33 bits 0-15 A34 A34.0 A34.1 A34.2 A34.3 A34.4 A34.5 A34.6 A35 A35.0 A35.1 A35.2 B32 B32.9 B32.10 B32.11 Issue (12-2-98) Drive identity Link 0 tributary number Link 0 baud rate Link 0 type (INTEL monitor or ESP) Basic I/O scanned inputs via customer I/O board (TB10) Basic I/O outputs via customer I/O board (TB11 & TB12) )Fast digital inputs ) Firing circuit interface board status feedbacks. Keypad local control RUN STOP LOWER RAISE UP KEY DOWN KEY Keypad Present System status bits Battery warning (1 = battery OK) Watchdog closed Early power fail warning: occurs 20ms before power fail. (1=fail). Digital outputs Keypad/display user lamp 1 - healthy Keypad/display user lamp 2 - running Keypad Control Alspa GD4000 Technical Manual Page 12-45

B32.12 B32.13 12.3.2 Warning Tripped
C/D Tables - Analog I/O C0 C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 C33 C35 C36 D0 D1 D2 D3 Power stack analog input 0) Power stack analog input 1) Fast inputs Power stack analog input 2) Power stack analog input 3 Power stack analog input 4 Power stack analog input 5 ) Power stack analog input 6 ) user inputs 0 - 3 Power stack analog input 7 ) Power stack analog input 8 ) 0V reference 10V reference Power stack analog input 9 ) Power stack analog input 10 ) Fast inputs Power stack analog input 11 ) Power stack analog input 12 Power stack analog input 13 Power stack analog input 14 Power stack analog input 15 ) User inputs 4 - 5 Power stack analog input 16 ) Power stack analog input 17 Power stack analog input 18 Power stack analog input 19 3V ref (400 = nominal) 10V ref (610 = nominal) ) ) Not connected ) -15V ref (580 = nominal) +15V ref (580 = nominal) -5V ref (190 = nominal) +5V ref (500 = nominal) 0V ref (0 = nominal) Pulse encoder 0 Pulse encoder 1 Pulse time period encoder 0 Pulse time period encoder 1 Analog Analog Analog Analog output 0 output 1 output 2 output 3
12.3.3
E Table E0 E0.0 E0.1 E0.7 E0.6 E0.8 E1 E2 E3 System flags 0.1 sec timing marker set on for one scan every 100 ms 1 sec timing marker - set on for one scan every second Limit flag set on after any ADD or SUB instruction that results in the output being limited. re-compile flag. Basic I/O Inputs updated Seconds ) Minutes ) Hours ) Real-Time Clock Alspa GD4000 Technical Manual Issue (12-2-98)
Page 12-46

E4 E5 E6 E7 E8 E9 E10 E11 E11.0 E11.1 E11.2 E11.3 E12 E13 E14 E15 E16 E17 E18 E19 E20 E21 E22 E23 E24 E25 12.3.4 Days ) Months) Years ) Last scan flag: Last scan time in 1 ms units Calender adjustment Keypad status see section A6.2). Over-run count. Incremented each time scan time exceeds time set in P1. System flags Run flag Test flag Commissioning Flag Single scan flag Divide by zero flag: Set each time there is a divide by zero interrupt. Oscilloscope output 0 scaler Oscilloscope output 0 offset Oscilloscope output 1 scaler Oscilloscope output 1 offset Oscilloscope output 2 scaler Oscilloscope output 2 offset Oscilloscope output 3 scaler Oscilloscope output 3 offset Drive ID Output 0 address (Null = Not used) ) Oscilloscope output configuration Output 1 address ) (fast/slow task monitor, Output 2 address ) address) Output 3 address )
F Table - System Fault Table F0 Not used F1 Watchdog trip reason F2 - F5 Watchdog trip; additional information F6 Watchdog Mask F7 Extra fault flags F8 (to follow) F9 - F12 960 RAM failure addres F13 - F16 166 RAM failure address F17 - F25 Supply Data F26 - F27 Basic I/O failure F28 - F35 Enhancement card data failures F28/F29 Enhancement card 1 fail data F30/F31 Enhancement card 2 fail data F32/F33 Enhancement card 3 fail data F34/F35 Enhancement card 4 fail data F36 (To follow) F37-F48 Serial link counters F37 Link 0 receive counter F38 Link 0 transmit counter F39 Link 0 error code F40 Link 1 receive counter F41 Link 1 transmit counter F42 Link 1 error code F43 Link 2 receive counter F44 Link 2 transmit counter F45 Link 2 error code F46 Link 3 receive counter F47 Link 3 transmit counter F48 Link 3 error code
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F50 - F129Serial link statistics F150- F199 Available to user 12.3.5 G Tables These tables are available for use as general workspace by the user program. G-tables are allocated dynamically when the user program is compiled. The number of tables allocated is determined by the highest G-table number referred to in the user program. 12.3.6 I Table These tables are used for control of the serial links when in table exchange mode. I0 - I1 I2 - I9 I10 - I11 12.3.7 Serial link 0 transmit and receive lengths to up to 1 secondary. Serial link 1 transmit and receive lengths to up to 4 secondaries. Serial link 2 transmit and receive lengths for 1 secondary.
J/K Table - Serial Links J0 - J99 J100-J499 J500-J599 K0 - K99 K100-K499 K500-K599 Serial link inputs via serial link 0 Serial link inputs via serial link 1 (100 tables per tributary) Serial link inputs via serial link 2 (100 tables per tributary) Serial link outputs via serial link 0 Serial link outputs via serial link 1 (100 tables per tributary) Serial link outputs via serial link 2 (100 tables per tributary)
12.3.8
P Table P0 Unit Identification number: Lower 12 bits cross-checked with drive ID check on start up if P8 is non zero. Scan time in 1 ms units Length of P table message area. (Not writable by user) Fault flags mask Extra fault mask Units of delay function (ms); Minimum of 1 msec (1000) Fast task type required Non zero to enable drive identity check. Enable RUN on power-up. Disable RAM tests. 20X4495 Customer I/O Board fitted. RUN and program. Enable flash memory Monitor letter Monitor offset (see section A7). Keypad Configuration Mask (see section A7). Enhancement Enhancement Enhancement Enhancement card slot 1, 16 bit card card slot 2, 16 bit card card slot 3, 16 bit card card slot 4, 16 bit card fitted. fitted fitted fitted
P1 P2 P3 P4 P5 P6 P8 P9.0 P9.1 P9.2 P9.4 P9.5 P10 P11 P12 P15.0 P15.4 P15.8 P15.12
P16-99 Reserved P100 onwards - available to user
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12.3.9 V Table This table contains a copy of the system table. The table cannot be written to. Data included in this table is: - Boot Up EEPROM CRC - Base level CRC - Fast task CRC - User program/P table CRC. V26 - V57 V89 V121 V153 V185 V217 V249 Core Board Customer I/O Board Firing Circuit I/F Board Enhancement Board 1 Enhancement Board 2 Enhancement Board 3 Enhancement Board 4
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13. Software Modules
Module 1 (V2)
Software Functions
Module 1 (V2)
13.1
13.1.1
Current Control Bridge B, Module 1 (Version 2)

Introduction Module 1, controls the active current Ia for Bridge B. The typical connections already made to Module 1 by the software are listed in the table below.
Parameter L103 L105 L108 L111 L114 L115 L119 L136 L155 L156
Ia ref B Va ref B Va B feed fward Ia B prop gain Va ref max lim Va ref min lim total unlim Other axis OP Freeze Ia B id Freeze Ia B id
Description
Comes From Module(s) 197
Goes To Module(s) 5, 99 2, 3, 5
10 10 3, 99 3, 99 3 2 83 5
For details of the PID function contained in the module see section 7.10.1.
Table 13-1 Current Control Bridge B, Module 1 (V2)
Variable L100 L101 L102 L103 L104 L105 L106 L107 L108 L109 L110 L111 L112 L113 L114 L115
Description
scan time rel Ia B reg freeze Ia B id Ia ref B Ia B Va ref B filtered Ia Ia B test i/p Va B feed fward Va ref B at max Va ref B at min Ia B prop gain Ia B intgl gain Ia B deriv gain Va ref max lim Va ref min lim
Type Minimum Maximum ON IL OL IN ON ON ON IN IN OL OL IN IN IN IN IN 0 0 0 -10000 -231 -231 -231 -10000 -10000 0 0 0 0 -10000 0 -10000 2
32
Default 682 0 0 0 0 0 0 0 0 0 0 0 0 0 3900 -3900

104 = 100% 104 = 100% 10 = 1 ms 1 = release 1 = frozen 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 1 = in limit 1 = in limit
3
Scaling
1 1 10000 231 231 231 10000 10000 1 1 2 2

32 32
10000 10000 0
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Module 1 (V2)
Variable L116 L117 L118 L119 L120 L121 L122 L123 L124 L125 L126 L127 L128 L130 L131 L132 L133 L134 L135 L136 L138 L139 L153 L154 L155 L156 L157 L158 L159 L160 L161 L162 Description
time constant unltd o/p filter enable total unlim user freeze ID Sel user freeze user ref Sel user ref feed forward 2 freeze Va in limit Do alt deriv Alt deriv output Sel alt deriv IP Alt deriv limit Old alt deriv IP Alt deriv IP Integral mode Sel cross lim Other axis OP Sel user output User output ref Sel new filter Filter rem Freeze Ia B id Freeze Ia B id feed forward 3 PID error lim Output lim 1 Output lim 2 Output rel 1 Output rel 2

Type Minimum Maximum IN ON IL ON IL IL IN IL IN IL OL IL ON IL IN ON IN IN IL ON IL IN IL ON OL OL IN IN IL IL IL IL 0 -2
31
Default 250 0 1 0 0 0 0 0 0 0 0 0 0 0 1000 0 0 2 0 0 0 0 0 0 0 0 0 2500 0 0 1 1

1= limit op 1 = limit op 1 = freeze 1 = freeze 104 = 100% 1 = select 104 = 100% 1 = select 104 = 100% 1 = select 104 = 100% 104 = 100% 1 = select 104 = 100% 1 = freeze 1 = select 104 = 100% 1 = select 104 = 100% 1 = freeze 1 = in limit
Scaling
1000 2
31
0 -2
31
1 2
31
0 0 -10000 0 -10000 0 0 0 -2
31
1 1 10000 1 10000 1 1 1 2
31
1 = do calculation 104 = 100% 1 = select 104 = 100%
0 0 -231 -10000 0 0 -2
31
1 10000 231 10000 2 1 2

31
0 -10000 0 -2
31
1 10000 1 2
31
0 0 -10000 0 0 0 0 0
1 1 10000 300000 1 1 1 1
1 = release op 1 = release op
All other tables are write protected internal variables.
* Refer to Sections 6.7.1 and 6.9 for parameterisation information.
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Module 1 (V2)
Figure 13-1 Current Control Bridge B, Module 1 (V2)
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Page 13-3
Module 2 (V2)
13.2
Module 2 (V2)
Current Control Bridge B, Module 2 (Version 2)

Introduction Module 2 controls the active current Ib for Bridge B. The typical connections already made to Module 2 by the software are listed in the table below.
Parameter L201 L203 L204 L205 L214 L215 L219 L233 L236 L255 L256 Description
rel Ib B reg Ib ref B Ib B Vb ref B Vb ref B max lim Vb ref B min lim total unlim Alt deriv IP Other axis OP freeze Ib B id freeze Ib B id
13.2.1
Comes From Module(s)
Goes To Module(s) 5 5
5 1, 3, 4, 5 3, 99 3, 99 3 197 1 83 5
For details of the PID function contained in the module see section 7.10.1.
Table 13-2 Current Control Bridge B, Module 2 (V2)
Variable L200 L201 L202 L203 L204 L205 L206 L207 L208 L209 L210 L211 L212 L213 L214 L215 L216 L217
Description
scan time rel Ib B reg freeze Ib B id Ib ref B Ib B Vb ref B filtered Ib Ib B test i/p Vb B feed fward Vb ref B at max Vb ref B at min Ib B prop gain Ib B intgl gain Ib B deriv gain Vb ref max lim Vb ref min lim time constant unltd o/p
Type Minimum Maximum ON IL OL IN ON ON ON IN IN OL OL IN IN IN IN IN IN ON 0 0 0 -10000 -231 -231 -231 -10000 -10000 0 0 0 0 -10000 0 -10000 0 -2
31
Default 682 0 0 0 0 0 0 0 9000 0 0 100 10 0 9200 -9200 250 0

104 = 100% 104 = 100% 104 = 100% 103 = 1 ms 1 = release 1 = frozen 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 1 = in limit 1 = in limit
Scaling
232 1 1 10000 231 231 231 10000 10000 1 1 2 2

32 32
10000 10000 0 1000 2

31
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Variable L218 L219 L220 L221 L222 L223 L224 L225 L226 L227 L228 L230 L231 L232 L233 L234 L235 L236 L238 L239 L253 L254 L255 L256 L257 L258 L259 L260 L261 L262 Description
filter enable total unlim user freeze ID Sel user freeze user ref Sel user ref feed forward 2 freeze Vb in limit Do alt deriv Alt deriv output Sel alt deriv IP Alt deriv limit Old alt deriv IP Alt deriv IP Integral mode Sel cross lim Other axis OP Sel user output User output ref Sel new filter Filter rem freeze Ib B id freeze Ib B id feed forward 3 PID error lim Output lim 1 Output lim 2 Output rel 1 Output rel 2
Module 2 (V2)
Type Minimum Maximum IL ON IL IL IN IL IN IL OL IL ON IL IN ON IN IN IL ON IL IN IL ON OL OL IN IN IL IL IL IL 0 -2
31
Default 1 0 0 0 0 0 0 0 0 0 0 1 1000 0 0 1 0 0 0 0 0 0 0 0 0 2500 0 0 1 1

1 = limit op 1 = limit op 1 = freeze 1 = freeze 104 = 100% 1 = select 104 = 100% 1 = select 104 = 100% 104 = 100% 1 = select 104 = 100% 1 = freeze 1 = select 104 = 100% 1 = select 104 = 100% 1 = freeze 1 = in limit
Scaling
1 2
31
0 0 -10000 0 -10000 0 0 0 -2
31
1 1 10000 1 10000 1 1 1 2
31
0 0 -231 -10000 0 0 -2
31
1 10000 231 10000 2 1 2

31
0 -10000 0 -2
31
1 10000 1 2
31
0 0 -10000 0 0 0 0 0
1 1 10000 300000 1 1 1 1
* Refer to Sections 6.7.1 and 6.9 for parameterisation information.
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Module 2 (V2)
Figure 13-2 Current Control Bridge B, Module 2 (V2)
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Module 3 (V2)
13.3
Module 3 (V2)
Polar Conversion Bridge B, Module 3 (Version 2)

Introduction Module 3 converts the direct and quadrature voltage demands for bridge B from rectangular to polar coordinates for use by the PWM generator, Module 4. The test inject variables Va and Vb are only used when configured as an output bridge. The outputs from the module are angle B and Vs B. These are used by the PWM generator, module 4. Vs B is equivalent to the PWM modulation depth and angle B is the total angle required. The angle is the sum of theta B, L306, which is the rotating reference frame and beta B which is the angle that Vs makes with the reference frame. L303 automatically compensates for a reversed phase rotation on the supply terminals, which is detected by Module 6. Dynamic limits, L304, are user selectable and change the output limits of the Module 1 and Module 2, the Va and Vb PID modules. See Module 13 for more details. DC link compensation, L313, which compensates the output for variations in the DC link voltage is set globally from L1097.
Table 13-3 Polar Conversion Bridge B, Module 3 (V2)
13.3.1
Variable L301 L302 L303 L304 L306 L307 L308 L309 L310 L311 L313 L314 L315 L316 L317
Vb Va
Description
Type Minimum Maximum ON ON OL IL ON ON ON ON ON ON OL ON ON OL ON -2

31
Default 0 0 0 0 0 0 0 0 3900 9200 0 0 0 0 0

10 = 100% 104 = 100% 1 = selected 1 = selected 10 = 1o 104 = 100% 10 = 1o 10 = 1o 104 = 100% 104 = 100%
4
Scaling
31
-231 0 0 -3600 0 -1800 0 0 0 0 0 0 0 -10000
231 1 1 3600 10000 1800 3600 10000 10000 1 20000 20000 1 10000
rev rot selectd dyn lim selectd theta B Vs B beta B angle B Vb dynamic lim Va dynamic lim dc_link_comp dc link fb dc link ref test inject Vb test inject
1 = compensate 104 = 100% 104 = 100% 1 = inject 104 = 100%
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Page 13-7
Module 3 (V2)
Variable L318 L321 L322 L323 L324 Description
Va test inject Sel inject Vb Vb user inject Sel inject Va Va user inject

Type Minimum Maximum ON IL IN IL IN -10000 0 -10000 0 -10000 10000 1 10000 1 10000 Default 0 0 0 0 0
10 = 100% 1 = select 104 = 100% 1 = select 104 = 100%
4
Scaling
Figure 13-3 Polar Conversion Bridge B, Module 3 (V2)
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Module 4 (V2)
13.4
Module 4 (V2)
PWM Generation Bridge B, Module 4 (Version 2)

Introduction Module 4 provides switching and timing data for bridge B. To process the information the module requires two main inputs. They are L401 and L402; the modulus and angle of the vector required. There are several switchable flags within the module to cater for different modes of operation. L414 operates the skew compensator. When both bridges on a drive are connected to the same load it is necessary to insure the bridges share current equally. For more information see module 9. Once the bridge switching patterns and timings have been calculated they are then passed to the devices connected to the bridges themselves. A flag is set, L424 to indicate when the module has reached its modulation limit.
13.4.1
13.4.2
Voltage Calculation The module calculates the RMS PWM volts present at the terminals of the drive, L429. For an input bridge this calculation is based upon the PID output of Module 2 and the DC Link feedback voltage from Module 197. A second, filtered output, L430, is created by filtering this value with L431 as the filter time constant.
13.4.3
Deadtime Calculation The deadtime calculation is only required when driving a motor, not a network supply. Refer to Module 14 for more details on this calculation.
Table 13-4 PWM Generation Bridge B, Module 4 (V2)
mod B
Description
Type Minimum Maximum ON ON ON IL IL OL OL OL IN IN IN OL OL ON ON IN 0 0 1 0 0 0 0 0 -20000 0 0 0 0 -2 -2

31 31
Default 0 0 1 0 0 0 0 0 0 0 0 0 1 0 0 250
1 = in limit 1 = enable 1 = enable 10 = 100% 10 = 1o
4
Scaling
11547 3600 6 1 1 1 1 1 20000 20000 20000 1 1 231 231 1023
angle B current state B enable bridge B skew comp B skew red B skew yellow B skew blue B speed ref speed thresh speed range in mod limit user enable pwm voltage real pwm volts filter tc
1 = comp. on
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Module 4 (V2)
Figure 13-4 PWM Generation Bridge B, Module 4 (V2)
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Module 5 (V2)
13.5
Module 5 (V2)
Current Conversion Bridge B, Module 5 (Version 2)

Introduction Module 5 performs a 3 phase to 2-phase transformation on the bridge B phase currents L512, L513 and L514. They are transformed to an a/b stationary reference frame by using the theta B variable. This variable is calculated by module 6 and is the mains angle referenced to R-N volts. Theta B=0 corresponds to peak volts. The Ia and Ib values are converted to a magnitude value Is B and the angle that it makes with the reference axis is calculated (Alpha B). As the reference frame is a voltage, the angle is the power factor. The current vector Is B is checked against L505, the over current level is also detected when greater than 100%. The current vector Is B ref and alpha B ref are calculated as above from the demand values of Ia and Ib (L510 and L511). Both are output. The value alpha B ref is used to sum with L516 to calculate a value for the current state L515, which is used by the PWM generator, module 4.
13.5.1
13.5.2
Phase Loss Detector A phase loss detection algorithm is constantly run on the bridge currents. A test is made to see if the reference value of Is is greater than a threshold set on L537. If this threshold is exceeded it then compares the value of the instantaneous current with threshold set by L536. If the current drops below this value then a counter is incremented. If the counter value equals or exceeds the value set on L538 then a phase loss is declared. For this test to work correctly the drive needs to be under load. As these tests are run all the time, it is up to the user to ensure that any logic using the test results ignores the tests until the required load conditions are met.
13.5.3
Earth Leakage Fault An earth leakage fault is also performed upon the bridge currents. This sums the input currents, which should result in a value of 0. If this sum is greater than the threshold set in L540 (earth threshold) then a counter is incremented. If this counter exceeds the limit set in L541 (earth err lim) then a earth leakage fault is signalled. If the sum is ever less than the set threshold, then the counter is reset to zero.
13.5.4
Filtered Is A filtered version of Is is available. The filter time constant is entered into L543, and the filtered version of Is appears of L544.
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Module 5 (V2)
Table 13-5 Current Conversion Bridge B, Module 5 (V2)
Variable L501 L502 L503 L504 L505 L506 L507 L508 L509 L510 L511 L512 L513 L514 L515 L516 L517 L518 L519 L520 L530 L531 L532 L533 L534 L535 L536 L537 L538 L539 L540 L541 L543 L544 L545 L546 L547 L548 L549 L550
Is B
Description
Type Minimum Maximum ON ON ON OL IN OL OL ON ON ON ON ON ON ON ON ON ON ON OL IN IN IN ON ON ON OL IN IN IN OL IN IN IN ON OL IL OL IL IN IN -20000 -3600 -3600 0 0 0 0 -20000 -20000 -20000 -20000 -20000 -20000 -20000 -231 -2
31
Default 0 0 0 1 13000 1 0 0 0 0 0 0 0 0 0 0 0 0 0 50 0 0 0 0 0 0 100 1000 1

1 = healthy 1 = healthy 104 = 100% 104 = 100% 10 = 1o 104 = 100% 10 = 1o 10 = 100% 10 = 1o 10 = 1o 1 = healthy 104 = 100% 1 = invert 1 = select 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100%
4
Scaling
20000 3600 3600 1 20000 1 1 20000 20000 20000 20000 20000 20000 20000 231 2
31
theta B phi B curr lim B OK Is B trip level Sel inv I Sel rev rot Ia B Ib B Ia ref B Ib ref B ph1 curr B ph2 curr B ph3 curr B CS B Theta for cs Is B ref theta B ref Is B peak detect Is ref FTC Theta OS Theta for cs OS Last Vd Last Vq Peak power phase healthy phase threshold Is ref thrshold Phase flt count earth healthy earth threshold earth err lim Time constant Filtered Is User peak detct Sel user peak User curr hlthy Sel user curr Is pk thresh Power time cnst
0 -3600 0 0 -1799 -1799 -2 -2 -2

31 31 31
20000 3600 1 1023 1800 1800 2 2 2

31 31 31
1 = detected
0 0 0 1 0 100 1 0 -2
31
1 10000 10000 232 1 10000 10000 1023 2

31
1000 5 500 0 0 0 1 0 10000 0

104 = 100%
0 0 0 0 0 0
1 1 1 1 2
31
1023
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Variable L552 L553 L554 Description
PTest En I/P1 PTest En I/P2 PTest En I/P3
Module 5 (V2)
Type Minimum Maximum IL IL IL 0 0 0 1 1 1 Default 0 0 0 Scaling
Figure 13-5 Current Conversion Bridge B, Module 5 (V2)
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Module 6 (V2)
13.6
Module 6 (V2)
Mains Synchronisation, Module 6 (Version 2)

Introduction Module 6 provides information about the frequency and angle of the mains supply, this information is used to correctly syncronise the input bridge control to the supply. The rate of change of network frequency warning and trip functions are automatically defeated during DC link precharge. Mains crossing errors are optionally defeated during precharge if L612, mask on, is set to a 1. The frequency warning level is fixed at 2% and the trip level at 3% of the network frequency, The warning and healthy outputs are enabled by the use of L624, select rate. Filter offset is an input that compensates for hardware offsets on the circuits that provide the mains synchronising signals. This value can either be entered by the user or if module 99 autosetup has been enabled, then the value will be automatically calculated and L610 becomes a read only value. A filtered frequency output is also provided for use in module 10, to compenstate for supply frequency variations in the calculation of Vab feedforward gain. The output value is filtered then passed to an output limiter. This limits the output to the entered tolerance (L628) above or below the entered nominal frequency (L627). There are absolute limits on this output of 45Hz and 65Hz.
Table 13-6 Mains Synchronisation, Module 6 (V2)
13.6.1
Variable L601 L609 L610 L612 L620 L621 L622 L623 L624 L625 L626 L627 L628
Description
mains angle mains X valid Filter offset mask on Rate warning Rate OK Network freq Rate of change Select Rate Filtered Freq Freq time const Nominal freq Freq tolerance
Type Minimum Maximum ON OL IN IL OL OL ON ON IL ON IN IN IN 0 0 0 0 0 0 0 0 0 0 0 4500 0 3600 1 1000 1 1 1 2 2

32 32
Default 0 1 680 1 0 1 0 0 1 0 250 5000 100

10 = 1
o
Scaling
1 = valid 10 = 1o 1 = on 1 = warning 1 = healthy 100 = 1 Hz 10 = 1% per sec. 1 = select 100 = 1Hz 1023 = 100% 100 = 1Hz 10 = 1%
1 2
31
1023 6500 100
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Module 6 (V2)
Figure 13-6 Mains Synchronisation, Module 6 (V2)
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Module 8 (V1)
13.7
Module 8 (V1)
Fast Oscilloscope Outputs, Module 8 (Version 1)

Introduction Module 8 provides 2 oscilloscope outputs that are updated at the fast task scan rate. The output of the analog to digital convertor varies in the range +10 V to -10 V. The digital number required to give full output from the convertor is +32767 and -32768 respectively. The outputs are limited to this full scale. As most variables in the fast task vary in the range 10000 to -10000 the value that must be entered into the scaler to achieve +10 V or -10 V needs to be 3052. Should the slow task i.e. ladder or links program be using either analog output D0 or D1 then the slow task configuration takes precedence over the fast task configuration. Once the oscilloscope outputs are configured to be updated from the fast task then the appropriate D table (D0 or D1) will not be updated for monitoring purposes.
Table 13-7 Fast Oscillosope Outputs, Module 8 (V1)
13.7.1
Variable L801 L802 L803 L804 L805 L806 L807 L808
Description
Oscilloscope 0 scaler Oscilloscope 0 offset Oscilloscope 0 letter Oscilloscope 0 address Oscilloscope 1 scaler Oscilloscope 1 offset Oscilloscope 1 letter Oscilloscope 1 address
Type Minimum Maximum IN IN IN IN IN IN IN IN 1 -2

31
Default 3052 0 76 0 3052 0 76 0

in ASCII in ASCII
Scaling
31 31
65 -2
31
90 2 2
31 31 31
module number + variable
1 -2
31
65 -2
31
90 2
31
module number + variable
Note:
ASCII characters are entered by preceding the character with an apostrophe (e.g F).
Figure 13-7 Fast Oscilloscope Outputs, Module 8 (V1)
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Module 9 (V1)
13.8
Module 9 (V1)
Skew Compensation, Module 9 (Version 1)

Introduction Module 9 provides skew compensation when the drive is configured to have two bridges driving the same load. This module must not be enabled unless this situation is satisfied. By coupling two bridges to the same load it is possible for there to be an imbalance in a phase current to the load due to propagation delays of the switching signals. This module monitors the current feedbacks and modifies the PWM patterns to force equal sharing for both bridges. The module is enabled by setting the skew compensation switch high in modules 4 and 14. L904 is the skew threshold value. This threshold value indicates the amount of imbalance between the two phase currents before the software tries to compensate for it.
Table 13-8 Skew Compensation, Module 9 (V1)
13.8.1
Variable L904
Description
Skew threshold
Type Minimum Maximum IN 0 2

31
Default 500
100 = 1%
Scaling
Figure 13-8 Skew Compensation, Module 9 (V1)
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Module 10 (V3)
13.9
Module 10 (V3)
Miscellaneous Hardware Interfaces, Module 10 (Version 3)

Introduction Module 10 is a collection of miscellaneous hardware interfaces. It is mainly concerned with the analog inputs to the SIGMA core board.
13.9.1
13.9.2
Operation L1002 allows certain automatically calculated variables to be used instead of user entered parameters, as in the case of Vab ffwd gain, L1016. L1003 shows the fast task scan time in half micro seconds. L1004 shows the number of fast tasks since the drive was switched on and is just an incrementing number rolling over at 232 L1005 A value corresponding to the drive type should be set here. Allowable drive types are : 4010, 4020, 4030, 4040, 4060, 4080, 4120, 4160, 4282, 4300, 4377, 4564, 4600, 4754, 4846, 4900 and 41131. This value is passed to Module 83 which determines if the drive configuration is permitable. For more information see Module 83. This value also automatically sets up the current feedback gains for both bridges, the drive peak current and the default Vab ffwd gain via look up tables. L1006 This sets the delta power module type. Valid types are 1 and 2. This value is passed to Module 83 which determines if the drive configuration is permitable. For more information see Module 83. L1007 Fast task type wanted is used to select one of a number of drive configurations, permitted values are 0 to 9. This value is passed to Module 83 which determines if the drive configuration is permitable. For more information see Module 83. Once the configuration has been correctly initialised, L1008 will return the same value as in L1007. Should an error occur then L1008 will report a -1. Note: Drive configuration is done only once as the drive powers up. Hence L1005, L1006 and L1007 must be configured in the links file, and any changes will have no effect once the drive has powered up.
L1010 sets whether encoder feedback A or B is read when running one motor, and is echoed to encoder B used, L1011. For more information see module 16. L1013 if set automatically calculates the PID values for all the motor bridges. L1017 allows the user to enter a Vab ffwd gain, which will overwrite the default value as long as sel user gain, L1018, is set correctly. L1018 also allows automatic calculation of Vab ffwd gain from Module 99, or setting of Module 1proportional gain if this is an input bridge. L1086 automaticaaly trims the current A/D offsets. L1097 sets if DC link compensation is required in Modules 3 and 13. If required, then L1098 should be linked to the DC link reference in Module 197. Page 13-18 Alspa GD4000 Issue (12-2-98)

13.9.3 Analogue Feedbacks The table below indicates the analogue feedbacks availible.
L Table Used L1022 L1023 L1024 L1025 L1026 L1027 L1028 L1033 L1034 L1035 L1038 Gain L1066 L1067 L1068 L1069 L1070 L1071 L1072 L1077 L1078 L1079 L1083 L1096 L1087 L1088 L1089 L1090 L1091 Divider Offset L1044 L1045 L1046 L1047 L1048 L1049 L1050 L1055 L1056 L1057 L1060 Function
Module 10 (V3)
DC link feedback Vry voltage feedback Customer input 0 Customer input 1 Customer input 2 Customer input 3 Customer input 4 48V feedback Vby voltage feedback Temperature feedback 1 Customer input 5
Note that Customer inputs 4 and 5 are only availble when using 20X4486 or 20X4489 power interface boards with two analogue termination panels fitted.
Table 13-9 Misc. Hardware Interfaces, Module 10 (V3) Variable L1002 L1003 L1004 L1005 L1006 L1007 L1008 L1010 L1011 L1013 L1014 L1015 L1016 L1017 L1018 L1019 L1020 L1021 L1022 L1023 L1024 L1025 L1026 L1027 Description
auto setup B real time fti count drive type Delta version FT type wanted FT type active Req encoder B Encoder B used pid setup reqd pk drive current Bandwidth va B ffwd gain user gain Sel user gain R curr brdge B Y curr brdge B B curr brdge B DC link volts RY volts brdge B customer i/p 0 customer i/p 1 customer i/p 2 customer i/p 3
Type Minimum Maximum IN ON ON IN IN IN ON IL OL IL IN IN IN IN IL ON ON ON ON ON ON ON ON ON 0 0 0 -2

31
Default 0 0 0
1 = setup 107 = 5s
Scaling
fast task counts
41131 2 9 2
31
0 1 0 0 0 0 0 0 500 0 0 0 0 0 0 0 0 0 0 0 0
1 = required 1 = 1A 1 = 1 rad/s %* 1 = required
1 0 -2
31
0 0 0 0 100 0 0 0 -2 -2 -2 -2 -2
31 31 31 31 31
1 1 1 5000 1000 10000 10000 1 2 2 2 2 2

31 31 31 31 31
-231 -2 -2 -2
31 31 31
231 2 2 2
31 31 31
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Module 10 (V3)
Variable L1028 L1029 L1030 L1031 L1032 L1033 L1034 L1035 L1036 L1037 L1038 L1040 L1041 L1042 L1043 L1044 L1045 L1046 L1047 L1048 L1049 L1050 L1051 L1052 L1053 L1054 L1055 L1056 L1057 L1058 L1059 L1060 L1062 L1063 L1064 L1065 L1066 Description
customer i/p 4 supply 0V A U curr brdge A V curr brdge A W curr brdge A mon 48v BY volts brdge B temp. fb 1 temp. fb 2 temp. fb 3 customer i/p 5 supply 5V R curr B os Y curr B os B curr B os DC link volts os RY volts B os Cust i/p 0 os Cust i/p 1 os Cust i/p 2 os Cust i/p 3 os Cust i/p 4 os 0V A os U curr A os V curr A os W curr A os mon 48v os BY volts B os hsink temp os0 hsink temp os1 hsink temp os2 Cust i/p 5 os supp 5V os R curr B gain Y curr B gain B curr B gain Dc link v gain

Type Minimum Maximum ON ON ON ON ON ON ON ON ON ON ON ON IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN -2
31
Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 9
Scaling
2 2
31 32
0 -231 -2 -2 -2 -2 -2 -2 -2 -2
31 31 31 31 31 31 31 31
231 2 2 2 2 2 2 2 2 2
31 31 31 31 31 31 31 31 32
0 -1000 -1000 -1000 -1000 -1000 -100000 -100000 -100000 -100000 -100000 -1000 -1000 -1000 -1000 -1000 -1000 -1000 -1000 -1000 -100000 -1000 0 0 0 1
1000 1000 1000 1000 1000 100000 100000 100000 100000 100000 1000 1000 1000 1000 1000 1000 1000 1000 1000 100000 1000 10000 10000 10000 10000
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Variable L1067 L1068 L1069 L1070 L1071 L1072 L1073 L1074 L1075 L1076 L1077 L1078 L1079 L1080 L1081 L1082 L1084 L1085 L1086 L1087 L1088 L1089 L1090 L1091 L1096 L1097
L1098
Module 10 (V3)
Type Minimum Maximum IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IL IL IN IN IN IN IN IN IL IN 1 -50000 -50000 -50000 -50000 -50000 1 0 0 0 1 1 1 1 1 -50000 1 0 0 1 1 1 1 1 1 0 -20000 10000 50000 50000 50000 50000 50000 10000 10000 10000 10000 10000 10000 10000 10000 10000 50000 10000 1 1 100000 100000 100000 100000 100000 100000 1 20000 Default 1 10000 10000 10000 10000 10000 1 0 0 0 1 1 1 1 1 10000 1 0 1 10000 10000 10000 10000 10000 10000 0 0 Scaling
Description
RY volts B gain Cust ip 0 gain Cust ip 1 gain Cust ip 2 gain Cust ip 3 gain Cust ip 4 gain supp 0V A gain U curr A gain V curr A gain W curr A gain mon 48v gain BY volts B gain hsink temp gn0 hsink temp gn1 hsink temp gn2 Cust ip 5 gain supp 10V gain Sel FT V reg auto trim o/s Cust ip 0 div Cust ip 1 div Cust ip 2 div Cust ip 3 div Cust ip 4 div Cust ip 5 div dc link comp dc link ref
* Refer to Section 6.5 and for parameterisation information.
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Module 10 (V3)
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Module 10 (V3)
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Module 11 (V2)
13.10
Module 11 (V2)
Current Control Bridge A, Module 11 (Version 2)

Introduction Module 11 controls the quadrature axis current Iq for Bridge A. The typical connections already made to Module 11 by the software are listed in the table below. For details of the PID function contained within this module refer to section 7.10.1. For details on how to configure the Kp and Ki values for stable operation see section 6.5.6.1.
Parameter L1101 L1102 L1103 L1104 L1105 L1108 L1111 L1112 L1113 L1114 L1115 L1119 L1136 L1155 L1156 Description
rel Iq A reg freeze Iq A id Iq ref A Iq A Vq ref A Vq A feed fward Iq A prop gain Iq A intgl gain Iq A deriv gain Vq ref max lim Vq ref min lim total unlim Other axis OP Freeze Iq A id Freeze Iq A id
13.10.1
Goes To Module(s) 15, 81, 95
94 95 15, 94 94 95 10 10 10 13 13 13 12 83 15 15 95 12, 13, 15
Table 13-10 Current Control Bridge A, Module 11 (V2)
Description
scan time rel Iq A reg freeze Iq A id Iq ref A Iq A Vq ref A filtered Iq Iq A test input Vq A feed fward Vq ref A at max Vq ref A at min Iq A prop gain Iq A intgl gain
Type Minimum Maximum ON IL OL IN ON ON ON IN IN OL OL IN IN 0 0 0 -10000 -2 -2

31 31
Default 682 0 0 0 0 0 0 0 0 0 0 200 10

10 = 1 ms 1 = release 1 = frozen 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 1 = in limit 1 = in limit
3
Scaling
32
1 1 10000 2 2
31 31
-231 -10000 -10000 0 0 0 0
231 10000 10000 1 1 2 2

32 32
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Variable L1113 L1114 L1115 L1116 L1117 L1118 L1119 L1120 L1121 L1122 L1123 L1124 L1125 L1126 L1127 L1128 L1130 L1131 L1132 L1133 L1134 L1135 L1136 L1138 L1139 L1153 L1154 L1155 L1156 L1157 L1158 L1159 L1160 L1161 L1162 Description
Iq A deriv gain Vq ref max lim Vq ref min lim time constant unltd o/p filter enable total unlim user freeze ID Sel user freeze user ref Sel user ref feed forward 2 freeze Vq in limit Do alt deriv Alt deriv output Sel alt deriv IP Alt deriv limit Old alt deriv IP Alt deriv IP Integral mode Sel cross lim Other axis OP Sel user output User output ref Sel new filter Filter rem Freeze Iq A id Freeze Iq A id feed forward 3 PID error lim Output lim 1 Output lim 2 Output rel 1 Output rel 2
Module 11 (V2)
Type Minimum Maximum IN IN IN IN ON IL ON IL IL IN IL IN IL OL IL ON IL IN ON IN IN IL ON IL IN IL ON OL OL IN IN IL IL IL IL -10000 0 -10000 0 -2
31
Default 0 8500 -8500 250 0 1 0 0 0 0 0 0 0 0 0 0 0 1000 0 0 1 0 0 0 0 0 0 0 0 0 2500 0 0 1 1

1 = limit op 1 = limit op 1 = freeze 1 = freeze 104 = 100% 1 = select 104 = 100% 1 = select 104 = 100% 104 = 100% 104 = 100% 1 = select 104 = 100% 1 = freeze 1 = select 104 = 100% 1 = select 104 = 100% 1 = freeze 1 = in limit 104 = 100% 104 = 100%
Scaling
10000 10000 0 1000 2

31
0 -2
31
1 2
31
0 0 -10000 0 -10000 0 0 0 -2
31
1 1 10000 1 10000 1 1 1 2
31
0 0 -231 -10000 0 0 -231 0 -10000 0 -2

31
1 10000 231 10000 2 1 231 1 10000 1 2

31
0 0 -10000 0 0 0 0 0
1 1 1000 300000 1 1 1 1
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Module 11 (V2)
Figure 13-10 Current Control Bridge A, Module 11 (V2)
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Alspa GD4000
Issue (12-2-98)
Module 12 (V2)
13.11
Module 12 (V2)
Current Control Bridge A, Module 12 (Version 2)

Introduction Module 12 controls the direct axis current Id for Bridge A. The typical connections already made to Module 12 by the software are listed in the table below.
13.11.1
Parameter L1201 L1202 L1203 L1204 L1205 L1208 L1211 L1212 L1213 L1214 L1215 L1219 L1236 L1255 L1256
Description
rel Id A reg freeze Id A id Id A ref Id A Vd ref A Vd A feed fward Id A prop gain Id A intgl gain Id A deriv gain Vd ref max lim Vd ref min lim total unlim Other axis OP freeze Id A id freeze Id A id
Goes To Module(s) 81,94, 95
94 94 15, 94 94 95 10 10 10 13 13 13 11 83 15 15 94 11, 13, 15,
For details of the PID function contained within this module refer to section 7.10.1. For details on how to configure the Kp and Ki values for stable operation see section 6.5.6.1.
Table 13-11 Current Control Bridge A, Module 12 (V2)
Description
scan time rel Id A reg freeze Id A id Id ref A Id A Vd ref A filtered Id Id A test input Vd A feed fward Vd ref A at max Vd ref A at min Id A prop gain Id A intgl gain
Type Minimum Maximum ON IL OL IN ON ON ON IN IN OL OL IN IN 0 0 0 -10000 -231 -231 -231 -10000 -10000 0 0 0 0 2

32
Default 682 0 0 0 0 0 0 0 0 0 0 200 10

3
Scaling
1 1 10000 231 231 231 10000 10000 1 1 2 2

32 32
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Module 12 (V2)
Variable L1213 L1214 L1215 L1216 L1217 L1218 L1219 L1220 L1221 L1222 L1223 L1224 L1225 L1226 L1227 L1228 L1230 L1231 L1232 L1233 L1234 L1235 L1236 L1238 L1239 L1253 L1254 L1255 L1256 L1257 L1258 L1259 L1260 L1261 L1262 Description
Id A deriv gain Vd ref max lim Vd ref min lim time constant unltd o/p filter enable total unlim user freeze ID Sel user freeze user ref Sel user ref feed forward 2 freeze Vd in limit Do alt deriv Alt deriv output Sel alt deriv IP Alt deriv limit Old alt deriv IP Alt deriv IP Integral mode Sel cross lim Other axis OP Sel user output User output ref Sel new filter Filter rem freeze Id A id freeze Id A id feed forward 3 PID error lim Output lim 1 Output lim 2 Output rel 1 Output rel 2

Type Minimum Maximum IN IN IN IN ON IL ON IL IL IN IL IN IL OL IL ON IL IN ON IN IN IL ON IL IN IL ON OL OL IN IN IL IL IL IL -10000 0 -10000 0 -2
31
Default 0 2000 -2000 250 0 1 0 0 0 0 0 0 0 0 0 0 0 1000 0 0 0 0 0 0 0 0 0 0 0 0 2500 0 0 1 1

Scaling
10000 10000 0 1000 2

31
0 -2
31
1 2
31
0 0 -10000 0 -10000 0 0 0 -2
31
1 1 10000 1 10000 1 1 1 2
31
0 0 -231 -10000 0 0 -231 0 -10000 0 -2

31
1 10000 231 10000 2 1 231 1 10000 1 2

31
0 0 -10000 0 0 0 0 0
1 10000 300000 1 1 1 1 1
* Fast Task module 13 writes to parameters L1214 and L1215 dynamically. These parameters cannot be written to by the user.
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Issue (12-2-98)
Module 12 (V2)
Figure 13-11 Current Control Bridge A, Module 12 (V2)
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Page 13-29
Module 13 (V2)
13.12
Module 13 (V2)
Polar Conversion Bridge A, Module 13 (Version 2)

Introduction Module 13 converts the direct and quadrature voltage demands for bridge A from rectangular to polar coordinates for use by the PWM generator, Module 14. The test inject inputs on Vd and Vq are used by module 94 during an auto-test compilation of a flux table and are selected automatically during the test. The outputs from the module are angle A and Vs A. These are used by the PWM generator, module 14. Vs A is equivalent to the PWM modulation depth and angle A is the total angle required. The angle is the sum of theta A, L1306, which is the rotating reference frame and beta A which is the angle that Vs makes with the reference frame. The reverse rotation flag, L1303, is set to 0 for this module as its function does not apply. (see module 13.3.1 for an explanation). If dynamic limits, L1304, are selected, then modules 11 and 12 have their limits altered by the values in L1310 and L1311. The limits are based on the angle Beta A. The upper limit is set at 67o giving: Vd limit = 39% Vq limit = 92% The lower limit is set at 45o: giving limits of : Vd limit = 70.7% Vq limit = 70.7% In between this limits of beta the Vd/Vq limits vary as: 10000 cos() = Vd limit 10000 sin() = Vq limit DC link compensation, L313, which compensates the output for variations in the DC link voltage is set globally from L1097.
13.12.1
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Table 13-12 Polar Conversion Bridge A, Module 13 (V2)
Module 13 (V2)
Variable L1301 L1302 L1303 L1304 L1306 L1307 L1308 L1309 L1310 L1311 L1313 L1314 L1315 L1316 L1317 L1318 L1321 L1322 L1323 L1324
Vd Vq
Description
Type Minimum Maximum ON ON OL IL ON ON ON ON ON ON OL ON ON OL ON ON IL IN IL IN -2

31
Default 0 0 0 1 0 0 0 0 3900 9200 0 0 0 0 0 0 0 0 0 0

10 = 100% 104 = 100% 1 = selected 1 = selected 10 = 1o 104 = 100% 10 = 1o 10 = 1o 104 = 100% 104 = 100%
4
Scaling
31
-231 0 0 -3600 0 -1800 0 0 0 0 0 0 0 -10000 -10000 0 -10000 0 -10000
231 1 1 3600 10000 1800 3600 10000 10000 1 20000 20000 1 10000 10000 1 10000 1 10000
rev rot selectd dyn lim selectd theta A Vs A beta A angle A Vd dynamic lim Vq dynamic lim dc_link_comp dc link fb dc link ref test inject Vd test inject Vq test inject Sel inject Vd Vd user inject Sel inject Vq Vq user inject
1 = compensate 104 = 100% 104 = 100% 1 = inject 104 = 100% 104 = 100% 1 = select 104 = 100% 1 = select 104 = 100%
Figure 13-12 Polar Conversion Bridge A, Module 13 (V2)
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Page 13-31
Module 14 (V2)
13.13
Module 14 (V2)
PWM Generation Bridge A, Module 14 (Version 2)

Introduction Module 14 provides switching and timing data for bridge A. To process the information the module requires two main inputs. They are L1401 and L1402; the modulus and angle of the vector required. There are several switchable flags within the module to cater for different modes of operation. L1414 operates the skew compensator. When both bridges on a drive are connected to the same load it is necessary to insure the bridges share current equally. For more information see module 9. Once the bridge switching patterns and timings have been calculated they are then passed to the devices connected to the bridges themselves. A flag is set, L1424 to indicate when the module has reached its modulation limit.
13.13.1
13.13.2
Voltage Calculation The module calculates the RMS PWM volts present at the terminals of the drive, L1429. For an input bridge this calculation is based upon the Modulation depth and the DC Link feedback voltage from Module 197. A second, filtered output, L1430, is created by filtering this value with L1431 as the filter time constant.
13.13.3
Deadtime Calculation Deadtime compensation is a method by which the dead time required between turning an upper transistor of a phase off, and the lower on, is optimised. It is possible for the user to choose this operation by manipulating tables L1421 speed ref, L1422 speed threshold and L1423 speed range. If (speed ref) is greater (speed threshold + speed range) then deadtime compensation is turned on. If (speed ref) is less than (speed threshold) then deadtime compensation is turned off. If (speed ref) is between the above conditions then deadtime compensation is increased as the speed ref increases.
Table 13-13 PWM Generation Bridge A, Module 14 (V2)
Description
mod A angle A current state A enable bridge A skew comp A skew red A skew yellow A skew blue A
Type Minimum Maximum ON ON ON IL IL OL OL OL 0 0 1 0 0 0 0 0 11547 3600 6 1 1 1 1 1
Default 0 0 1 0 0 0 0 0
1 = enable 10 = 100% 10 = 1o
4
Scaling
1 = comp. on
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Module 14 (V2)
Description
speed ref speed thresh speed range in mod limit user enable pwm voltage real pwm volts filter tc
Type Minimum Maximum IN IN IN OL OL ON ON IN -20000 0 0 0 0 -2 -2

31 31
Default 0 0 0 0 1 0 0 250
1 = in limit 1 = enable
Scaling
20000 20000 20000 1 1 231 231 1023
Figure 13-13 PWM Generation Bridge A, Module 14 (V2)
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Page 13-33
Module 15 (V2)
13.14
Module 15 (V2)
Current Conversion Bridge A, Module 15 (Version 2)

Introduction Module 15 performs a 3 phase to 2-phase transformation on the bridge A phase currents L1512, L1513 and L1514. They are transformed to a stationary reference frame by using the theta A variable. This is the angle from the shaft encoder and as such is arbitrary, ie not referenced to anything. The resulting Id and Iq values are used by the current regulators modules 11 and 12. The Id and Iq values are converted to a magnitude value Is A and the angle that it makes with the reference axis is calculated (L1513 Alpha A). To find the power factor, module 13 outputs beta A which is the angle that Vs the voltage vector makes with the reference axis. Therefore the power factor can be found by subtracting Alpha A from Beta A (-) then the power factor is cos-1(-). The current vector Is A and Alpha A ref are calculated as above from the demand values Is and Iq (L1510 and L1511). Both are output. The value Alpha A ref is used to sum with L1516 to calculate a value for the current state L1515 which is used by the PWM generator module 14.
13.14.1
13.14.2
Phase Loss Detector A phase loss detection algorithm is constantly run on the bridge currents. A test is made to see if the reference value of Is is greater than a threshold set on L1537. If this threshold is exceeded it then compares the value of the instantaneous current with threshold set by L1536. If the current drops below this value then a counter is incremented. If the counter value equals or exceeds the value set on L1538 then a phase loss is declared. For this test to work correctly the drive needs to be under load. As these tests are run all the time, it is up to the user to ensure that any logic using the test results ignores the tests until the required load conditions are met.
13.14.3
Earth Leakage Fault An earth leakage fault is also performed upon the bridge currents. This sums the input currents, which should result in a value of 0. If this sum is greater than the threshold set in L1540 (earth threshold) then a counter is incremented. If this counter exceeds the limit set in L1541 (earth err lim) then a earth leakage fault is signalled. If the sum is ever less than the set threshold, then the counter is reset to zero.
13.14.4
Filtered Is A filtered version of Is is available. The filter time constant is entered into L1543, and the filtered version of Is appears of L1544.
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Table 13-14 Current Conversion Bridge A, Module 15 (V2)
Module 15 (V2)
Is A
Description
Type Minimum Maximum ON ON ON OL IN OL OL ON ON ON ON ON ON ON ON ON ON ON OL IN IN IN ON ON ON OL IN IN IN OL IN IN IN ON OL IL OL IL IN IN 0 0 0 0 0 0 0 -20000 -20000 -20000 -20000 -20000 -20000 -20000 0 0 0 0 0 0 -1799 -1799 -2 -2 -2
31 31 31
Default 0 0 0 1 13000 0 0 0 0 0 0 0 0 0 0 0 0 0 0 50 0 0 0 0 0 0 100 1000 1

1 = healthy 1 = healthy 104 = 100% 104 = 100% 10 = 1o 104 = 100% 10 = 1o 10 = 100% 10 = 1o 10 = 1o 1 = healthy 104 = 100% 1 = invert 1 = select 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100%
4
Scaling
20000 3600 3600 1 20000 1 1 20000 20000 20000 20000 20000 20000 20000 6 3600 20000 3600 1 1023 1800 1800 2 2 2
31 31 31
theta A alpha A curr lim A OK Is A trip level Sel inv I Sel rev rot Id A Iq A Id ref A Iq ref A ph1 curr A ph2 curr A ph3 curr A CS A Theta for cs Is A ref theta A ref Is A peak detect Is ref FTC Theta OS Theta for cs OS Last Vd Last Vq Peak power phase healthy phase threshold Is ref thrshold Phase flt count earth healthy earth threshold earth err lim Time constant Filtered Is User peak detct Sel user peak User curr hlthy Sel user curr Is pk thresh Power time cnst
1 = detected
0 0 0 1 0 100 1 0 -2
31
1 10000 10000 232 1 10000 10000 1023 2

31
1000 5 500 0 0 0 0 0 10000 0

104 = 100%
0 0 0 0 0 0
1 1 1 1 2
31
1023
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Module 15 (V2)
Variable L1552 L1553 L1554 Description
PTest En I/P1 PTest En I/P2 PTest En I/P3

Type Minimum Maximum IL IL IL 0 0 0 1 1 1 Default 0 0 0 Scaling
Figure 13-14 Current Conversion Bridge A, Module 15 (V2)
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Module 16 (V2)
13.15
Module 16 (V2)
Position Feedback Encoder A, Module 16 (Version 2)

Introduction Module 16 is used to calculate shaft position information produced by an incremental encoder. Hardware within the GD4000 takes raw encoder pulses and converts them into a totalising count and time stamp information. It is this data that the module uses to perform the calculations. In order to calculate shaft position certain system and encoder parameters need to be considered. These are lumped into a single constant called the encoder scaling factor. The encoder scaling factor is calculated by module 94 and output in L9443. The constant is calculated using the equation: (1/10ths degree in 1 rev x 216) / pulses per rev from encoder where: pulses per rev is encoder line count * count multipler This gives a scaled ouput of 1/10ths degree per revolution L1604 Shaft direction is a bit field and is encoded in the following manner bit 0 reverse bit 1 forward 2 stopped The output angle L1614 is outputed as the sum of slip angle and rotor electrical angle.
Table 13-15 Position Feedback Encoder A, Module 16 (V2)
13.15.1
Variable L1602 L1603 L1604 L1605 L1608 L1609 L1610 L1611 L1614 L1615 L1616 L1617 L1618 L1619 L1620 L1621 L1622
Description
rotor pos A rot elec pos A shaft dir A motor poles A encoder ppr A scaling fctr A slip freq A scld slip ang A output angle A zero count det A encoder pos A detector level A zero cnt perm A datum set A user scaling A user poles A user scaling A
Type Minimum Maximum ON ON ON IN IN IN IN ON ON OL ON IN IL IL IL IN IN 0 0 1 2 1 1 -400000 -2

31
Default 150 0 4 4 10000 23592 0 0 0 0 0 100 0 0 0 4 23592

1 = 1mHz mHz x 210 10 = 1o 1= detected 10 = 1
o
Scaling
10 = 1o Bit field
3599 3599 4 36 1000000 1000000 400000 2

31
0 0 -2
31
3599 1 2
31
1 = 1 encoder pulse zero count window width 0 = permit 1 = set 1 = select
0 0 0 0 2 1
10000 1 1 1 36 1000000
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Module 16 (V2)
Variable L1623 L1624 L1625 L1626 L1627 L1628 L1629 Description
user ppr A Sel user slip A user slip freq Sel user epos A user elec pos A Sel user preset user preset

Type Minimum Maximum IN IL IN IL IN IL IN 1 0 -400000 0 0 0 0 1000000 1 400000 1 3599 1 3599 Default 10000 0 0 0 0 0 0
1 = select 1 = 1mHz 1 = select 10 = 1o 1 = select 10 = 1o
Scaling
Figure 13-15 Position Feedback Encoder A, Module 16 (V2)
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Module 19 (V2)
13.16
Module 19 (V2)
PID Regulator, Module 19 (Version 2)

Introduction Module 19 is a clone of Module 1. Its function is dedicated to the torque demand function when using the auto-test facility of module 94 and 294. Module 19 takes over the torque demand from the users signal and drives the machine to its base speed. On completion of the test the machine is returned to its former speed value. Note: The proportional and integral gains should be set low in comparison with values in module 92.
13.16.1
When using this function ia fast task type type 1 environment (AC out AC out) module 19 will either control machine A or B during an auto-test by selection of: for auto-test L9479 =of 1 machine A and: L9479 = 00 L29479 = L29479 = 1 for auto-test of machine B. The typical connections already made to Module 19 by the software are listed in the table below. For a description of the PID function see Section 7.10.1.
Parameter L1901 L1903 L1904 L1905

rel reg ref
Description
Comes From Module(s) 94 94 95
Goes To Module(s)
feedback output
94
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Module 19 (V2)
Table 13-16 PID Regulator, Module 19 (V2)
Variable L1900 L1901 L1902 L1903 L1904 L1905 L1906 L1907 L1908 L1909 L1910 L1911
Description
scan time rel reg freeze id ref feedback output filtered torque test input fdforward in max in min prop gain
Type Minimum Maximum ON IL OL IN ON ON ON IN IN OL OL IN 0 0 0 -50000 -231 -231 -231 -10000 -10000 0 0 0 2

32
Default 0 0 0 0 0 0 0 0 0 0 0 200
3
Scaling
1 1 50000 231 231 231 10000 10000 1 1 2

32
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Variable L1912 L1913 L1914 L1915 L1916 L1917 L1918 L1919 L1920 L1921 L1922 L1923 L1924 L1925 L1926 L1927 L1928 L1930 L1931 L1932 L1933 L1934 L1935 L1936 L1938 L1939 L1953 L1954 L1955 L1956 L1957 L1958 L1959 L1960 L1961 L1962 Description
intgl gain deriv gain ref max lim ref min lim time constant unltd o/p filter enable total unlim user freeze ID Sel user freeze user ref Sel user ref feed forward 2 freeze in limit Do alt deriv Alt deriv output Sel alt deriv IP Alt deriv limit Old alt deriv IP Alt deriv IP Integral mode Sel cross lim Not used Sel user output User output ref Sel new filter Filter rem freeze id freeeze id feed forward 3 PID error lim Output lim 1 Output lim 2 Output rel 1 Output rel 2
Module 19 (V2)
Type Minimum Maximum IN IN IN IN IN ON IL ON IL IL IN IL IN IL OL IL ON IL IN ON IN IN IL ON IL IN IL ON OL OL IN IN IL IL IL IL 0 -10000 0 -10000 0 -2
31
Default 10 0 2000 -2000 250 0 1 0 0 0 0 0 0 0 0 0 0 0 1000 0 0 0 0 0 0 0 0 0 0 0 0 2500 0 0 1 1

Scaling
32
10000 10000 0 1000 2

31
0 -2
31
1 2
31
0 0 -50000 0 -10000 0 0 0 -2
31
1 1 50000 1 10000 1 1 1 2
31
0 0 -231 -10000 0 0 -2
31
1 10000 231 10000 2 1 2

31
0 -10000 0 -2
31
1 10000 1 2
31
0 0 -10000 0 0 0 0 0
1 1 10000 300000 1 1 1 1
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Module 19 (V2)
Figure 13-16 PID Regulator, Module 19 (V2)
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Module 119
13.17
Module 119
Fast History Record, Module 119(V4)

Introduction
This document defines the Fast History Version 4. Unless otherwise stated, references to module 119 also apply to module 159
13.17.1
througout this document.

Module 119 is backwards compatible with version 1, but allows for more fast
channels (up to 6) and more sundry channels (up to 16). The data width is also extended to 32 bits.
The fast history can be accessed using Overdrive, but there will be loss of data due
to the limitations of this product (one fast channel and 10 sundry channels truncated to 16 bits). For internal CEGELEC Projects use only, the history can also be accessed via the CSP history uploader and the Analyse display package. Note: for the purposes of this document both Overdrive and the CSP uploader are referred to as the history uploader.The functional operation of this module is as shown in section .13.17.5.10
13.17.2
Features
*Multiple Trip history buffers (two only with Overdrive) Up to sixteen 32 bit sundry channels. Up to six 32 bit fast channels. Up to sixteen logic channels. Variable number of samples, dependent on the number of buffers, the number of
channels, and the update rate of the fast channels. Note: Overdrive can only cope with a limited number of samples, see apropriate drive type application notes for details.
Overdrive compatible (although only 10 sundry channels and 1 fast channel will be
read, and data truncated to 16 bits).

Two independent histories in module 119 and 159 (if enabled by fast task).
13.17.3
Method of Operation The user interface to the fast history module is as defined by the diagram L119V4. The operation of the history is as follows:
The user sets the addresses to record. This is done by entering the data table letter
in one location and the offset in the next (i.e To monitor L1201 via sundry channel 0). L11904 = L L11905 = 1201
The history is enabled by setting L11901 on. The following items are set up:
a) The internal addresses are calculated. b) The Number of samples, depending on the number of channels, is set up.
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Module 119
c) The number of samples after the trip is calculated
The history recording starts. Data is stored in a circular buffer, with a separate store
for the sample pointers.

If a trip occurs, either via the History enable input L11901, then the buffer staus
changes to tripping.
The history continues sampling until the number of samples after the trip (L11960) is
reached. The history buffer status then changes to tripped. The next buffer is set ready for recording.
If the history is reset (L11956) then the buffer is viewable, and can be accessed by
Overdrive or the uploader.

Once the history is reset it can be used for recording again. The uploader will have interrogated the drive to find out what facilities are available.
The drive indicates that it accepts GDM1 style history messages. The drive also indicates that enhanced histories are available.
The uploader monitors the status of the history. The status can either be Recording,
tripped or halted. If the history has been reset then the buffer is also viewable, otherwise it is empty
If the history is tripped then it can be uploaded. The history uploader issues a view
message, which sets the viewing flag on. The history buffer cannot be used for recording until this flag is set off.
The history uploader then uploads the history record. If the uploading is done via
overdrive, then there is a sequence of getting the header information and then getting each history sample. If the CSP Uploader is being used, then the history is uploaded as a sequence of block transfers - the first block or blocks containing the header information, with the remainder being the contents of the history buffer.
Uploading is complete either when the history uploader issues a leave view
message and all the data has been sent, or there has been no access by the uploader for 5 seconds.
In order to prevent the same history being uploaded for dual histories a flag L11999
is provided. If set to 1 then the history is set to Empty once the Leave History command is sent from the uploader. Note: The upload logic in OVERDRIVE will only upload a history from a SIGMA if the time tag is different to the last history uploaded. In order to allow histories from 119 & 159 to be uploaded, the time tag on 159 is incremented by one second if the tags are the same.
13.17.4
Advanced Features The data tables default to Overdrive compatibility, and the history is set up assuming that one fast set of samples are recorded for each sundry sample. However, certain parameters can be changed
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13.17.4.1 % Samples After Trip
Module 119
The percentage of samples after a trip is defined by L11960, and defaults to 20%. This number can be varied between 1 and 100% 13.17.4.2 Number Of Channels No. fast channels - L11993 This can be set to any number between 1 and 6; default is 1 This number affects buffers size and processor loading. No. of sundry channels - L11959 This can be set to any number between 1 and 16; default is 1. This number affects buffer size and processor loading No. of logic channels - L11965 This can be set to any number between 1 and 16. This number affects processor loading only. 13.17.4.3 Maximum Number of Samples The sample limit L11997 is normally set to between 100 and 300 for Overdrive compatability. However, it can be set to any number between 100 and 10000. The number of samples that can be fitted into the recording buffer is calculated when the history recoring is enabled for a particular buffer. If it exceeds the given limit then the limit is applied; if it is less than the limit then the number of samples recorded is set to theat calculated. The result is placed in L11967. 13.17.4.4 Set Up of Sampling The fast task designer will define the amount of sampling required. There are four parameters of interest: Execution Count - L11968 A setting of n means that sundry channels are recorded every n calls. Note that this cannot be changed by the user Av. and max. fast samples - L11995 and L11996 These figures are used to make the most efficient use of the recording buffer. The av value is the average number of fast samples there will be per sundry sample. The max value is used to allow some leeway to accomodate situations such as phase back on DC drives. Note that this cannot be changed by the user. Size of memory required - L11978 This determines the amount of memory available to the module for recording data. It is set in terms of kbytes. The default is 100 kbyte (giving a default buffer size of 50 kbytes). The amount actually allocated depends on the amount of slow memory available.
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Module 119
13.17.5 System Logic
13.17.5.1 Sequence
Figure 13-17 Buffer memory within SIGMA
The figure shows the states that the history recording can be in. The numbers after each state are the bits that are set in the buffer status for that state. Note: The states are exclusive. It is not possible to have more than one state active for a given buffer at any one time.
The initial state on power up is Halted 13.17.5.2 Recording On entry, the following is set up: No. of samples calculation Internal addresses of data tables linked to history Buffer initialised for recording
When running: - The sundry channel recording procedure and the fast channel recording procedure put data into the data buffer. The sundry channel recording procedure also updates the sundry sample pointer Tripping The data is recorded above until the sample count exceeds the defined number of samples after the trip The time of trip and the pointer to the last sample is then recorded. The trip buffer and view buffer numbers are incremented.
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Tripping complete
Module 119
No action taken. The buffer is waiting for the next buffer to be available (not being viewed). Buffer ready, history tripped Trip buffer incremented, view buffer becomes old trip buffer. Buffer waiting for a reset. Buffer reset No action taken. If the buffer is the view buffer then it is waiting for an enter view history message from the serial link. If the buffer is the recording buffer then the buffer is waiting for a history enable signal (L11901). Being viewed The view buffer is locked and prevents further access from other sources. Information on the trip can be uploaded to a PC. If no access is made within 5 seconds then the buffer is either returned to a RESET state or an EMPTY state (depending on the setting of L11999). Halted No action. If the buffer is the recording buffer then it is waiting for an enable signal. 13.17.5.3 Buffer Status Bits Recording History History Tripping History tripped Tripping complete Halted Buffer ready History fault Buffer reset Sample buffer full Data buffer full Serial link access Enable off Reset on 0x01 0x02 0x04 0x08 0x10 0x20 0x40 0x80 0x100 0x200 0x400 0x800 0x2000 Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Bit 8 Bit 9 Bit 10 Bit 11 Bit 13
13.17.5.4 Buffer Status Reporting The status of the recording buffer and the viewing buffer is reported to the PC as follows: Recording buffer status RECORDING TRIPPING TRIPPED RESET BEING VIEWED HALTED Reported Status R R T T H
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Module 119
Viewing Buffer status RECORDING TRIPPING TRIPPED RESET BEING VIEWED HALTED 13.17.5.5 Access to Variables Reported status E V V E
The address of the variables to record is indicated by using a data table letter/offset location. If the address is invalid then a warning bit is set. The calculation of address is performed each time a history buffer is reset and recording starts 13.17.5.6 Changing the Number of Channels The number of channels can be changed at any time, but do not come into effect until a history buffer is reset. 13.17.5.7 Memory Allocation The amount of buffer memory is allocated according to the following rules: a) The values in L11978 & L15978 determine the total memory required (provided the appropriate module 119 and/or 159 has been defined b) If the memory required memory available, the memory required by easch fast task is reduced in proportion. c) If the memory allocated to a fast history module task is 1000 kbytes, then the module is disabled. Note: Memory is allocated at halt-run time from the free slow memory.
13.17.5.8 Serial Link Access Access to the data is via two means: a) Overdrive. This uses various ESP messages to get individual samples. b) CSP UPLOADER 13.17.5.9 Overdrive This uses ESP commands to get the status, get the header information and then get each sample. The number of channels uploaded is fixed at 1 fast channel and 10 sundry channels. The data is transferred as 16 bit variables. The fast history version 4 provides the history in the required format, as follows:
data is truncated (NOT limited) from 32 bits to 16 bits. This is the same as version
1, which truncated the 32 bit data table values before storing them.
Only Fast channel 0 is sent
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Module 119
Only 10 sundry channels 0-9 are sent. If the module has less channels configured,
the remaining channels contain null data. If more channels are configured, only the first 10 are sent. 13.17.5.10 CSP Uploader The CSP uploader accesses the data via a block transfer command. The data transferred by this block is a header, followed by the data. 13.17.5.11 Backwards Compatibility The Fast History Version 4 is user code compatible with previous versions. The fast history defaults to an OVERDRIVE compatible version. 13.17.5.12 Upload Errors Bits in L11980 are used to indicate errors during upload, as follows: Bit 0 Bit 1 Bit 2 13.17.6 Second half of OVERDRIVE message too big Number of samples 64k; usually indicates a corruption of the fast history work area First sample not found; the algorithm to find the first sample has failed (if bit 1 = 0; Will also be set on if bit 1 = 1)
Application Notes
13.17.6.1 Standard Links It is recommended that the following link statements should be added to the Links program: L11963 Fault Message Ptr = L3275 Fault Mess Ptr L11964 Fault Number = L3274 Fault Mess No. If no further links are made then the system defaults are in force - 1 fast channel, 10 sundry channels and 16 logic channels. The enable signal should be connected to the item tripping the history. Note that the response to a trip will be the user program scan time (indicated by data table E7). If two histories are used (119 and 159) then the empty buffer after upload flag (L11999, L11959) must be set, otherwise OVERDRIVE will continuously pload histories from 119 & 159. The fast history only operates when the user program is running.
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Module 119
Table 13-17 Module 119(V4), Fast History Record
Variable
Description
Type Minimum Maximum ON IL ON ON IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999 90 0 1
Default
Scaling
1mS = 1000
L11900 Repetition Period L11901 History Enable L11902 View Buffer Number L11903 Trip Buffer Number L11904 Analog Channel 0 Letter L11905 Analog Channel 0 Number L11906 Analog Channel 1 Letter L11907 Analog Channel 1 Number L11908 Analog Channel 2 Letter L11909 Analog Channel 2 Number L11910 Analog Channel 3 Letter L11911 Analog Channel 3 Number L11912 Analog Channel 4 Letter L11913 Analog Channel 4 Number L11914 Analog Channel 5 Letter L11915 Analog Channel 5 Number L11916 Analog Channel 6 Letter L11917 Analog Channel 6 Number L11918 Analog Channel 7 Letter L11919 Analog Channel 7 Number L11920 Analog Channel 8 Letter L11921 Analog Channel 8 Number L11922 Analog Channel 9 Letter L11923 Analog Channel 9 Number L11924 Logic Channel 0 Letter L11925 Logic Channel 0 Number L11926 Logic Channel 1 Letter L11927 Logic Channel 1 Number L11928 Logic Channel 2 Letter L11929 Logic Channel 2 Number L11930 Logic Channel 3 Letter L11931 Logic Channel 3 Number L11932 Logic Channel 4 Letter L11933 Logic Channel 4 Number L11934 Logic Channel 5 Letter L11935 Logic Channel 5 Number L11936 Logic Channel 6 Letter L11937 Logic Channel 6 Number L11938 Logic Channel 7 Letter L11939 Logic Channel 7 Number
76 11901 76 11901 76 11901 76 11901 76 11901 76 11901 76 11901 76 11901 76 11901 76 11901 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
99999.99 1190199 90 76
L = 76
99999.99 1190199 90 76
L = 76
99999.99 1190199 90 76
L = 76
99999.99 1190199 90 76
L = 76
99999.99 1190199 90 76
L = 76
99999.99 1190199 90 76
L = 76
99999.99 1190199 90 76
L = 76
99999.99 1190199
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Module 119
Figure 13-18 Module 119(V4), Fast History Record
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Module 159
13.18
Module 159
Fast History Bridge B, Module 159 (Version 4)

Module 159 is a clone, i.e. it is identical to Module 119 except the module variables are accessed using the prefix L159xx instead of L119xx.
13.19
Module 216
Position Feedback (Encoder B), Module 216

Introduction Module 216 is used to calculate shaft position information produced by an incremental encoder. Hardware within the GD4000 takes raw encoder pulses and converts them into a totalising count and time stamp information. It is this data that the module uses to perform the calculations. In order to calculate shaft position certain system and encoder parameters need to be considered. These are lumped into a single constant called the encoder scaling factor. The encoder scaling factor is calculated by module 94 and output in L9443. The constant is calculated using the equation: (1/10ths degree in 1 rev x 216) / pulses per rev from encoder where: pulses per rev is encoder line count * count multipler This gives a scaled ouput of 1/10ths degree per revolution L21604 Shaft direction is a bit field and is encoded in the following manner bit 0 reverse bit 1 forward bit 2 stopped The output angle L21614 is outputed as the sum of slip angle and rotor electrical angle.
Table 13-18 Module 216 (V2), Position Feedback B
13.19.1
Variable
Description
Type Minimum Maximum ON ON ON IN IN IN IN ON ON OL ON IN IL IL 0 0 1 2 1 1 -400000 -2

31
Default 150 0 4 4 10000 23592 0 0 0 0 0 100 0 0

1 = 1 mHz mHz x 210 10 = 1o 1= detected 10 = 1
o
Scaling
10 = 1o Bit field
L21602 rotor pos B L21603 rot elec pos B L21604 shaft dir B L21605 motor poles B L21608 encoder ppr B L21609 scaling fctr B L21610 slip freq B L21611 scld slip ang B L21614 output angle B L21615 zero count det B L21616 encoder pos B L21617 detector level B L21618 zero cnt perm B L21619 datum set B
3599 3599 4 36 1000000 1000000 400000 2

31
0 0 -2
31
3599 1 2
31
1 = 1 encoder pulse zero count window width 0 = permit 1 = set
0 0 0
10000 1 1
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Variable Description Type Minimum Maximum IL IN IN IN IL IN IL IN IL IN 0 2 1 1 0 -400000 0 0 0 0 1 36 1000000 1000000 1 400000 1 3599 1 3599 Default 0 4 23592 10000 0 0 0 0 0 0
1 = select 1 = 1 mHz 1 = select 10 = 1o 1 = select 10 = 1o 1 = select
Module 216
Scaling
L21620 user scaling B L21621 user poles B L21622 user scaling B L21623 user ppr B L21624 Sel user slip B L21625 user slip freq L21626 Sel user epos B L21627 user elec pos B L21628 Sel user preset L21629 user preset
Figure 13-19 Module 216 (V2), Position Feedback B
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Module 216
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Module 20(V4)
Software Reference (Slow Task Modules)

Module 20(V4)
14.1
14.1.1
Speed Measurement by Encoder, Module 20(V4)

Overview The SIGMA Slow Module 20 Version 4 - the Encoder Feedback module is only available on the 20X4494 SIGMA core board. This module has four configurations determined by L2090: L2090 = 1 L2090 = 2 L2090 = 3 L2090 = 4 Biphase encoder A plus marker associated with it, using the 20X4453 Customer I/O board Two biphase encoders using the 20X4453 Customer IO board Two biphase encoders plus marker associated with encoder A, using the 20X4495 Customer IO board Biphase encoder A plus marker and a single phase counter using the 20X4495 Customer IO board or the 20X4453 Customer IO board
14.1.2
Features
Angles calculated from Datum Positions and Marker Pulses. Revolution Counts, angles and position maintained through halt to run or power
down.
Sampling and filtering of speed feedback available. Backwards compatible with L20V2 - it will perform all the functions available in
L20V2 with some additional features. 14.1.3 Biphase Encoders This module provides bi-directional speed and position feedback from biphase encoders which generate two pulse trains (phase A and phase B) in quadrature. All four edges of an electrical cycle are counted therefore the position count changes by 4 * line count for every revolution of the encoder. A positive speed and position change is generated when phase A leads phase B. A negative speed is generated when B leads A. Different encoder manufacturers have different standards for the phase relationship of the pulse trains for positive direction, therefore tables are provided, L2018 and L2068, Encoder Reverse Direction, which when HIGH gives positive speed when B phase leads A phase. Encoder A is always enabled, Encoder B is only available for configurations (L2090=) 2 and 3, but the calculations are only enabled when L2050, Enable Encoder B, is HIGH. 14.1.4 Average Speed The speed can be calculated either by comparing the movement since the last scan of the user program, or the average movement over the last L2006/L2056 scans. This gives a running average value L2002/L2052.
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Module 20(V4)
14.1.5 Filtered Speed
Filtered speed is as the average speed, but through a single order filter with a variable time constant. The time constant can range from 0.0000 ms to 0.5000 ms. The output (L2011/L2061) is calculated from the following equation: Speedfilter = 1 1 + S Where: = L2010 or L2060 = Time Constant
14.1.6
Raw Filtered Speed The speed feedback tables L2015/L2065 are the instantaneous speed i.e no averaging over a number of samples, but again through a single order filter.
14.1.7
Datum Positions The marker is available in configurations (L2090=) 1, 3 and 4. Marker calculations are enabled when L2030 is HIGH. When a marker is detected, the 15 bit position feedback of encoder A is latched (L2039), marker position and angle are relative to this latched position, and based on the change in position of encoder A. After a position change of 4 * line count the angular position will wrap round and the revolution count will be updated. If the position changes from 359.99o to 0.00o the revolution count increments, if it goes from 0.00o to 359.99o the revolution count will be decremented. The marker simply resets the datum position from which the angular position is calculated. Position and revolution count will update based on the line count without receiving a marker. The marker found flag, L2038, indicates that the first valid marker has been detected since a power off and on, or a change in configuration of the module. The Marker healthy flag is set and the revolution count is reset when L2031 is HIGH.
14.1.8
Marker detection for Configs 1 and 3 The marker pulse is assumed to be synchronous with phases A and B i.e generated from the same encoder, and a marker is detected when the marker input, phase A and phase B are all high. This method is compatible with 90o, 180o and 360o markers. This method of detection guarantees the change in pulse count for one revolution is always 4 * line count, if it is not the Marker healthy flag is cleared. If the marker is not synchronous, i.e. generated from a different encoder to the one producing phases A and B, the marker pulse must be wide enough to occur at the same time as A and B phases being high. A flag, L2035, toggles when the latched position count, L2039, has changed. i.e. if the encoder is dithering backwards and forwards through the same marker the flag will not toggle. A toggle of this flag can be used to reset the revolution count if enabled, by L2037.
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14.1.9 Marker detection for Config 4
Module 20(V4)
When using this configuration the marker detection is edge triggered. This means there are no problems with asynchronous markers but the position change for one revolution cannot be guaranteed to be 4 * line count, because this is dependent on the marker pulse width. This means that going through the same marker from different directions generates a different marker position. The flag L2035, will toggle when going backwards and forwards through the same marker, whereas for configurations 1 and 3 with a synchronous marker the flag would not toggle. 14.1.10 Single Phase Counter When L2090=4 the configuration is one biphase counter plus marker and a single phase counter. The single phase counter gives a always increasing count of events on the input. L2044 is the position feedback, this value increments twice for each pulse seen i.e. it increments on the rising edge and falling edge of each pulse. This table is a 32 bit value and will keep incrementing until wrapping round at (232 - 1). L2046 is the datum set for the single phase position. When this table is HIGH the position feedback is zeroed. 14.1.11 Preserved Memory A number of variables are maintained through a halt to run or power down. This is to avoid having to datum set every time the Sigma is halted. The halt or power down must be done when the encoder is stationary and then the encoder must not be moved until the Sigma is running. The variables preserved are: L2021 L2071 L2019 L2069 Biphase encoder A position wrt datum Biphase encoder B position wrt datum Biphase encoder A angle wrt datum Biphase encoder B angle wrt datum
L2020 Biphase encoder A revolution count L2070 Biphase encoder B revolution count L2032 Marker angular position L2033 Marker revolution count L2044 Single phase encoder position wrt datum 14.1.12 Application Notes
14.1.12.1 Restrictions The Sigma hardware is limited to a maximum pulse rate of 500 kHz, not accounting for any scribing error, although encoders themselves are typically rated for 150 kHz. For correct operation of the module the following must apply: Peak speed rpm (L2004) * Line count (L2014) < 30,000,000 pulses per minute (eg 500 kHz) The maximum scan time that can be used with this module is 31.775 ms.
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Module 20(V4)
14.1.13 Module Entry
The execution of the module is performed using the special function GDMMOD S140 in a ladder program. 14.1.14 Module Inputs L2003 Reset A L2031 Reset marker L2053 Reset B The reset for encoders A and B, if set HIGH, will set the appropriate healthy flag, and reset the status word bit. The maximum speed change exceeded trip level counter is also set to zero. For the Marker Pulse, the revolution count is set to zero and the marker healthy flag is set. It is recommended that the following reset links be set up as follows: L2003 Reset A L2031 Reset Marker L2052 Reset B = = = L2621 Reset L2621 Reset L2621 Reset
L2005 Max speed change/scan A L2055 Max speed change/scan B L2007 Speed A exceeded maximum change trip level L2057 Speed B exceeded maximum change trip level The max speed change/scan tables set the level of speed change in one scan which is considered to be an error condition. The trip level tables then set the number of consecutive scans of exceeding the maximum change, to cause the healthy flag to go unhealthy. The module still functions when unhealthy. L2030 Enable marker L2050 Enable encoder B Calculations are only performed for when these flags are set HIGH. L2004 Peak speed A L2054 Peak speed B This sets up the speed of the motor in revolutions per minute, that the module will use to give a speed feedback of 100%. L2014 Encoder A lines count L2064 Encoder B lines count The number of pulses per revolution of the encoder. The module actually counts 4 times this value for one revolution of the encoder. L2010 Filter A time constant L2016 Raw filter A time constant L2060 Filter B time constant L2066 Raw filter B time constant These set up the time constant values used in the single order filter equation. See section 14.1.5 for details. L2017 Datum set A L2067 Datum set B When set HIGH, the Revolution Count with respect to the datum position is zeroed, and the position of the motor is stored. From this position, an angle of the current position is produced (0 to 360 degrees), and the revolution count incremented or decremented as applicable.
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Module 20(V4)
L2018 Encoder A reverse direction L2068 Encoder B reverse direction If set, a positive speed and position change is calculated for phase B of the encoder feedback leading phase A. L2023 Encoder A zero counter permissive L2073 Encoder B zero counter permissive When LOW these tables allow the Encoder position to be datum set. L2024 Encoder A zero count detector level L2074 Encoder B zero count detector level These tables set the range of position count for which L2025, zero count detected, is HIGH. L2046 Single phase encoder datum set This table resets the position count. L2090 Encoder Configuration 1 One biphase encoder plus marker 2 Two biphase encoders 3 Two biphase encoders plus marker 4 One biphase encoder plus marker and one single phase encoder 14.1.15 Module Outputs L2000 Repetition period
This gives the time in milli-seconds since the last call of the module. L2001 Encoder A feedback healthy L2051 Encoder B feedback healthy Healthy if the Xilinx is programmed correctly and the speed change per scan has not been exceeded. L2002 Encoder A speed feedback (10000=peak speed) L2022 Encoder A speed feedback (10000=peak speed) L2052 Encoder B speed feedback (10000=peak speed) L2072 Encoder B speed feedback (10000=peak speed) Average speed feedback, averaged over the last L2006/L2056 samples. L2008 Number of scans speed A exceeded L2058 Number of scans speed B exceeded The Number of scans speed A exceeded tables indicate the current number of consecutive scans that speed change has exceeded its limit, this table is reset on a valid change in speed. L2009 L2059 Previous scan Encoder A speed. Previous scan Encoder B speed
Average speed feedback as calculated on the previous scan. L2011 Filtered A speed feedback L2061 Filtered B speed feedback Filtered version of the average speed feedback (10000=peak speed). L2012 L2062 Issue (12-2-98) Encoder A position Encoder B position Alspa GD4000 Page 14-5
Module 20(V4)
L2013 Encoder A time L2063 Encoder B time The current pulse count and time at which the pulse count last changed. L2015 Raw filtered speed A L2065 Raw filtered speed B Filtered version of the instantaneous speed (10000=peak speed). L2019 Angular position A (with respect to datum) L2069 Angular position B (with respect to datum) Angular position is zeroed when the datum set table is HIGH. L2020 Revolution count A (with respect to datum) L2070 Revolution count B (with respect to datum) The revolution count is incremented when the angular position changes from 359.99o to 0.00o and decremented in the other direction. L2021 Encoder position A (with respect to datum) L2071 Encoder position B (with respect to datum) These values are bidirectional position counts that limit at (231 - 1), they do not wrap round. L2025 Encoder A zero count detected L2075 Encoder B zero count detected When the position count is within the range set by L2024, Encoder zero count detector level, these tables are HIGH. L2026 Raw Xilinx position A feedback (15 bits) L2076 Raw Xilinx position B feedback (15 bits) These tables should not be used in a user program. L2027 Raw Xilinx time A feedback (17 bits) L2077 Raw Xilinx time B feedback (17 bits) These tables should not be used in a user program. L2032 Angular position wrt the marker pulse L2033 Revolution count wrt the marker pulse These are similar to the datum outputs, except that they are relative to the marker. L2034 Marker healthy This table goes LOW when the change in position between markers is not 4 * line count. L2035 Marker detected Toggles on change in marker position (L2039). L2036 Marker position This is a position count relative to the position at the time of the marker. i.e it is datum set on a marker, then counts pulses from encoder A. L2037 Enable marker revolution count resetting on a marker L2038 Marker found Indicates the first valid marker has been detected since power on. L2039 Marker Xilinx feedback This is the position of encoder A latched at the time of the marker. L2044 Single phase encoder position wrt datum This table increases until reaching (232 - 1), then wraps round to 0. Page 14-6 Alspa GD4000 Issue (12-2-98)

L2045 Single phase encoder raw Xilinx position feedback This table should not be used in a user program. L2091 Bit 0 8 16 17 18 31 Status word
Module 20(V4)
Meaning Encoder A unhealthy when set - speed change per scan exceeded or Xilinx error. Encoder B unhealthy when set - speed change per scan exceeded or Xilinx error. Scan time exceeded 31.775 ms when set, invalidating the speed calculations. Xilinx error when set - an error occurred programming the Xilinx Chip. Marker error when set - a change in marker position has not been 4 * line count. Xilinx not reprogrammed when set - if Xilinx is already programmed on a halt to run.
L2092 Initialise Flag This flag is cleared on the first call of the module. L2093 Xilinx Error Value 0 1-5 >5
Meaning Healthy Programming error Verification error
An error implies a hardware fault. Retry by powering the Sigma off then on. 14.1.16 Encoder Connections
14.1.16.1 Customer IO board 20X4453 L2090=3 is not available when using the 20X4453 Customer I/O board.
Encoder connection A /A B /B C /C D /D Not used Encoder type L2090=1 Encoder 1 A phase Encoder 1 B phase Marker L2090=2 Encoder 1 A phase Encoder 1 B phase Encoder 2 A phase Encoder 2 B phase L2090=4 Encoder 1 A phase Encoder 1 B phase Marker
Encoder 2 single phase input
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Page 14-7
Module 20(V4)
Customer IO board 20X4495
Encoder connection A /A B /B C /C D /D E /E Encoder 2 A phase Encoder 2 B phase L2090=3 Encoder 1 A phase Encoder 1 B phase Marker L2090=4 Encoder 1 A phase Encoder 1 B phase Marker
Encoder 2 single phase input Nothing must be connected
Table 14-1 Speed Measurement by Encoder
Description
Repetition Period Encoder A Feedback Healthy Encoder A Speed Feedback Reset A Peak Speed A Max Speed Change/Scan A Number of Samples Per Calculation A Speed A Exceeded Scans Trip Level Number of Scans Speed A Exceeded Previous Scan Encoder A Speed Filter A Time Constant Filtered A Speed Feedback Encoder A Position Encoder A Time Encoder A Lines Count Raw Filtered Speed A Raw Filter A Time Constant Datum Set A Encoder A Reverse Direction Angular Position A (wrt Datum) Revolution Count A (wrt Datum) Encoder Position A (wrt Datum) Encoder A Speed Feedback Encoder A Zero Counter Permissive Encoder A Zero Count Detector Level Encoder A Zero Count Detected
Type Minimum Maximum ON OL ON IL IN IN IN IN ON ON IN ON ON ON IN ON IN IL IL ON ON ON ON IL IN OL 0 0 1 10000 -231 - 1 231 - 1 0.0000 0 0 0.5000 1 1 50 25000 0.0000 0.5000 0 1.0 0.00 1 1 1 25000.0 50.00 63 100
Default
secs
Scaling
healthy = 1 100% = 10000
0 1500.0 5.00 10 50
1 rpm = 10 100% = 10000
100% = 10000
0.0200
1ms = 10000 100% = 10000
3600
100% = 10000
0.0200 0 0
1ms = 10000
100 o = 10000
100% = 10000
0 0
1 = zero
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Issue (12-2-98)

Variable L2026 L2027 L2028 L2029 L2030 L2031 L2032 L2033 L2034 L2035 Description
Raw Xilinx Position A Raw Xilinx Time A not used not used Enable Marker Reset Marker Angular Position A (wrt Marker) Revolution Count A (wrt Marker) Marker Healthy Marker Detected Toggle
Module 20(V4)
Type Minimum Maximum ON ON Default Scaling
IL IL ON ON OL OL
0 0
1 1
0 0
100 o = 10000
Toggles on change in marker Xilinx feedback
L2036 L2037 L2038 L2039 L2040 L2041 L2042 L2043 L2044 L2045 L2046 L2047 L2048 L2049 L2050 L2051 L2052 L2053 L2054 L2055 L2056 L2057 L2058 L2059 L2060 L2061 L2062 L2063 L2064
Marker Position Enable Reset Of Revolution Count On A Marker Toggle Marker Found Marker Xilinx Feedback not used not used not used not used Single Phase Counter Position Single Phase Raw Xilinx Position Single Phase Counter Datum Set not used not used not used Enable Encoder B Encoder B Feedback Healthy Encoder B Speed Feedback Reset B Peak Speed B Max Speed Change/Scan B Number Of Samples Per Calculation B Speed B Exceeded Scans Trip Level Number Of Scans B Exceeded Trip Previous Scan Encoder B Speed Filter B Time Constant Filtered B Speed Feedback Encoder B Position Encoder B Time Encoder B Lines Count
ON IL OL ON 0 1 0
ON ON IL
232 - 1
IL OL ON IL IN IN IN IN ON ON IN ON ON ON IN
0
healthy = 1 100% = 10000
0 1.0 0.00 1 1
1 25000.0 50.00 63 100
0 1500.0 5.00 10 50
1 rpm = 10 100% = 10000
100% = 10000
0.0000
0.5000
0.0200
1ms = 10000 100% = 10000
50
25000
3600
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Page 14-9
Module 20(V4)
Variable L2065 L2066 L2067 L2068 L2069 L2070 L2071 L2072 L2073 L2074 L2075 L2076 L2077 L2078 L2079 L2080 L2081 L2082 L2083 L2084 L2085 L2086 L2087 L2088 L2089 L2090 L2091 L2092 L2093 Description
Raw Filtered Speed B Raw Filter B Time Constant Datum Set B Encoder B Reverse Direction Angular Position B (wrt Datum) Revolution Count B (wrt Datum) Encoder B Position (wrt Datum) Encoder B Speed Feedback Encoder B Zero Counter Permissive Encoder B Zero Count Detector Level Encoder B Zero Count Detected Raw Xilinx Position B Raw Xilinx Time B not used not used not used not used not used not used not used not used not used not used not used not used Encoder Type Status Word Initialise Flag Xilinx Program Error

Type Minimum Maximum ON IN IL IL ON ON ON ON IL IN OL ON ON 0 0 1 10000 0 0
1 = zero
Default
Scaling
100% = 10000
0.0000 0 0
0.5000 1 1
0.0200 0 0
1ms = 10000
100 degs = 10000
-231 - 1
231 - 1
100% = 10000
IN ON OL ON
1
see section 14.1.15 see section 14.1.15 see section 14.1.15
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Alspa GD4000
Issue (12-2-98)
Module 20(V4)
Figure 14-1 Module 20(V1), Speed Measurement by Encoder
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Page 14-11
Module 20(V4)
Figure 14-2 Module 20V1, Speed measurement by encoder
Page 14-12
Alspa GD4000
Issue (12-2-98)
Module 21
14.2
Module 21
Speed/Voltage Control, Module 21

Description The module calculates the error between a reference input and a speed or voltage feedback. Forward and feedback path transfer function compensation terms stabilize closed loop motor speed or voltage control. Constraints on the module output enable control of peak motor current and rate of rise of current. Scaling factors normalize the speed and voltage feedback for use by the module and other modules in the system.
14.2.1
14.2.2
Features Reference The reference L2106 normally comes from the speed ramp (module 22) outputs. L2102 is the test input which is normally only used in commissioning mode. Output Limits True output limits are provided, i.e. L2124, max output limit, and L2125, min output limit, each having a range of 120%. L2103 is the variable limit input which varies both limits. L2126, in max limit and L2128 , in min. limit provide signals for the ramp hold code in module 22. Rate Limit L2119, output rate limit, limits the rate of change of speed/voltage control output. Suicide Setting L2101, release regulator, HIGH releases the action of the forward path transfer functions. Setting L2101 LOW resets the speed/voltage control output to zero; the rate limit does not apply. Feedback Scaling Scaling factors L2132, speed feedback scale, and L2133, voltage feedback scale, enable L2117 speed feedback and L2118 voltage feedback to be normalized to 100% (10000) = top speed and 100% (10000) = full voltage respectively. L2169 the feedback offset trim, allows the feedback to be offset, not normally used. L2140, L2141, L2145 allow the feedback to be monitored as shown in the diagram. Filtered Feedbacks Filtered feedbacks are provided, for sequencing purposes. L2151 is the L2152 is the L2154 is the L2155 is the Deadband If L2108, select deadband, is HIGH, forward path transfer function is not executed and output remains at zero until the error between reference and feedback at L2123 (error speed feedback filter time constant. filtered speed. voltage feedback filter time constant. filtered voltage.
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Page 14-13
Module 21
monitor) exceeds setting at L2120, deadband. This feature is useful in providing speed limit control on tension controlled drives. The deadband can be set asymmetrically about zero speed error. Setting L2157, asymmetric deadband, HIGH, switches the deadband level with negative speed error from L2120 to L2158 (negative deadband value). IZ Compensation L2130 sets the gain, L2131 sets the time constant of the IZ compensation. L2136 is the current input to the IZ calculation. Setting L2107 (select IZ comp) HIGH enables a motor current input to compensate for resistance and inductive voltage drop on a voltage controlled drive. Preset Output On setting L2143, select preset output, HIGH L2115, speed/voltage control output, is preset to the value at L2142, preset output. The output is still subject to suicide control and to maximum and minimum output limits, but not to the rate limit. Resetting L2143 LOW allows the forward path transfer function to be executed normally but starting with the value at L2142 as an initial condition. When drive load changes can be predicted, the preset output can be used to set output to support the new load condition and minimise the impact drop in speed on load change. Ramp Hold When the output at L2115 (speed/voltage control output) is 5% (500) less than Max limit L2125 or 5% (500) greater than Min limit L2114, ramp hold output, starts to be updated. Ramp hold output L2114 increases linearly as the maximum or minimum limit is reached, with an output of +100% (10000) at maximum limit and an output of -100% (10000) at minimum limit. Ramp hold signal L2114 can be used, where the drive is part of a multi-drive system, to restrict the common reference ramp rate to assist in retaining synchronism between the drives. Input L2167, ramp hold bias, is used to set the bias in the range 0 to 25%. Speed Limit In speed limit (L2116) is used, if required, to hold the master ramp controlling a group of drives, when the drive torque reaches a specified value. The limit value is set by L2129. It should be set lower than the local ramp hold L2114. Reduced Bandwidth Operation The main use of this is in flux weakening schemes. A facility exists for reducing the speed control bandwidth. L2160, degain factor, modifies time constants T1 and T2 such that the drive has: new bandwidth = old bandwidth degain factor Page 14-14 Alspa GD4000 Issue (12-2-98)
Module 21
L2159, degain speed control, is set high to select degain speed control. If additional interlocks are needed then L2164 will initiate degain, and L2159 is linked via other interlocks in ladder code to L2165. L2161, degain error, is set HIGH if the degain factor takes T1 and T2 out of range. L2162 is the calculated value of Lead which is used in L2121. L2163 is the calculated value of integrator time constant which is used in L2122 14.2.3 Application Notes Speed Control Compensation The forward path transfer function = 1 [1 + ST1] d 1 + S(T1 + T2/d) and where T1 = L2121 T2 = L2122
d = L2127 if L2109 is HIGH, 100 else d=0 When L2109 is low ie when d = 0 the forward path reduces to: [1 + ST1] ST2 Example: Suppose a forward path transfer function of: 200 [1 + 0.5S] is required 1 + 3S d= 1 = 0.005 200
L2127 = 0.5% L2121 = 0.5 s T1 + T2/d = 3 T2 = 2.5/200 = 0.0125
L2122 = 0.0125 s L2166, variable gain input 2, modifies the forward path transfer function to: 1[+ST1] d[1+S(T1+T2/Gd)] where G = L2166 100
If L2166 = 100% [10000] the transfer function reverts to that previously described. The feedback path transfer function = 1[1 + SKT4] (1 + ST4)(1+ST5) where T4 = L2135 T5 = L2144 K = L2134
T5 provides filtering of feedback noise/ripple. L2104 the variable gain input is not normally used. It is convenient for applications such as dual mode stabilizing. Issue (12-2-98) Alspa GD4000 Page 14-15
Module 21
Overshoot Control
With K (L2134) set to 1, the feedback transfer function is a simple lag (T5), irrespective of the value of T4. If the response of the speed loop to a step input exhibits x% overshoot returning to the desired speed with a dominant time constant T, set L2134 = 1 + x 100 and L2135 = Ts
Voltage Control If L2110, select voltage feedback, is HIGH the forward path transfer function. =1 1 [1 + ST1] d 1 + S(T1 + T2/d)(1 + ST3) where T3 = L2149 T1, T2 and d are as defined previously. Ramp Hold
The gain of the output of L2114, ramp hold, is 20 irrespective of the maximum or minimum limit settings. The function of this signal will vary greatly with the application. It should only be used by experts, as care must be exercised in the use of this signal. The resulting bandwidth of any control loop must be checked for compatibility with SIGMA Controller scan times. Specialised Variables There are a number of variables which are for expert use only, these are: L2137, L2138, L2139, L2146, L2148, L2150, L2153, L2156, L2168.
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Issue (12-2-98)

Table 14-2 Module 21(V5), Speed/Voltage Control
Module 21
Variable L2100 L2101 L2102 L2103 L2104 L2105 L2106 L2107 L2108 L2109 L2110 L2111 L2112 L2113 L2114 L2115 L2116 L2117 L2118 L2119 L2120 L2121 L2122 L2123 L2124 L2125 L2126 L2127 L2128 L2129 L2130 L2131
Description
Repetition Period Release Regulator Test Input Variable Limit Input Variable Gain Input Not Used Speed Reference Select IZ Compensation Select Deadband Apply Droop Select Voltage Feedback Feedback Gain Trim Speed Feedback Voltage Feedback Ramp Hold Speed/Voltage Control Output In Speed Limit Scaled Speed Feedback Scaled Voltage Feedback Output Rate Limit Deadband Lead Time Constant Integrator Time Constant Error Monitor Max Output Limit Min Output Limit In Max Limit Droop Regulation (D) In Min Limit Speed Limit Detect IZ Compensation Gain IZ Compensation Time Constant
Type Minimum Maximum ON IL IN IN IN 0 -30% 0 0 1 +30% 100% 100%
Default
Scaling
1mS = 1000
0 0% 100% 100%
100%[104]= Top Speed 100%[104]= Full Limit 100%[104]= Max Gain
IN IL IL IL IL IN IN IN ON ON OL ON ON IN IN IN IN ON IN IN OL IN OL IN IN IN
-120% 0 0 0 0 -10% -32767 -32768
+120% 1 1 1 1 +10% +32767 +32767
0% 0 0 0 0 0% 0 0
100%[104]= Top Speed
100%[104]= Top Speed Set By L2132 Set By L2133 100% = 5% Current Limit 100%[104]= Current Limit 1 = Reference Detected 100%[104]=Top Speed 100%[104]=Full Volts
2 0% 0 0.001 sec
100 25% 6.5 sec 4.5 sec
10 0% 0.5 sec 0.05 sec
1 = Current Limit/sec 100%[104]= Top Speed Error 1[103]= 1 sec 1[103]= 1 sec 100%[104]= Top Speed Error
-120% -120%
+120% +120%
100% -100%
100%[104]= Current Limit 100%[104]= Current Limit
0%
25%
100%[104]= Top Speed Reg For Current Limit
0% 0% 0.01 sec
25% 50% 0.1 sec
0 0 0.01 sec
100%[104]= Current Limit 100% = Unity Gain 1[104]= 1 sec
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Page 14-17
Module 21
Variable L2132 L2133 L2134 L2135 L2136 L2137 L2138 L2139 L2140 L2141 L2142 L2143 L2144 L2145 L2146 L2147 L2148 L2149 L2150 L2151 L2152 L2153 L2154 L2155 L2156 L2157 L2158 L2159 L2160 L2161 L2162 L2163 L2164 L2165 L2166 L2167 L2168 L2169 Description
Speed Feedback Scale Voltage Feedback Scale Lead Factor Lag Time Constant Current Limited Error Control Output Remainder Previous Current Compensated Feedback Feedback Preset Output Select Preset Output Feedback Filter Filtered Feedback Feedback Filter Remainder Feedback Compensation Remainder Feedback Control Output Voltage Control Filter Voltage Control Filter Remainder Speed Feedback Filter Filtered Speed Feedback Filtered Speed Remainder Volt Feedback Filter Filter Volt Feedback Filter Volt Remainder Asymmetric Deadband Negative Deadband Value Degain Speed Control Degain Factor Degain Error Used Lead Time Constant Used Integrator Time Constant Initiate Degain Degain Permissive Variable Gain Input 2 (G) Ramp Hold Bias Variable Gain Remainder Feedback Offset Trim

Type Minimum Maximum IN IN IN IN IN ON ON ON ON ON IN IL IN ON ON ON ON IN ON IN ON ON IN ON ON IL IN IL IN OL ON ON IL OL IN IN ON IN -10% +10% 0%
100%[104]= Full Volts 100%[104]= Top Speed or Full Volts 100%[104]= Top Speed or Full Volts
Default 1024 1024 1 0.5 sec 0
Scaling
Integer Value of L2112 for Top Speed Integer Value of L2113 for Full Voltage 1 = [102] 1[104]= 1 sec 100%[104]= Current Limit 100%[104]= Top Speed Error
100 100 1
32767 32767 2
0.05 sec 3.2 SECS -100% +100%
-120% 0 0 sec
+120% 1 0.5 sec
0% 0 0.01 sec
100%[104]= Current Limit
1[104] = 1 sec 100%[104]= Top Speed
0 sec
3.0 sec
0.1 sec
1[104]= 1 sec
0 sec
0.5 sec
0.1 sec
1[104]= 1 sec 100%[104]= Top Speed
0 sec
0.5 sec
0.1 sec
1[104]= 1 sec 100%[104]= Full Speed
0 -25% 0 1
1 0% 1 5
0 0% 0 1
1 = Error 1[103] = 1 sec 1[103 = 1 sec 100[104]= Top Speed Error
0
100%[104]= Full Limit 100%[104]
0% 0%
100% 25%
100% 5%
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Alspa GD4000
Issue (12-2-98)
Module 21
Figure 14-3 Module 21(V1), Speed/Voltage Control sht 1
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Alspa GD4000
Page 14-19
Module 21
Figure 14-4 Speed/Voltage Control sht 2
Page 14-20
Alspa GD4000
Issue (12-2-98)
Module 22
14.3
Module 22
Reference Circuits, Module 22

Description The module produces an amplitude limited combined reference from a number of jog, trim and run reference inputs. The run and jog references can be conditioned by a ramp function to control acceleration rate.
14.3.1
14.3.2
Features Dual Ramp rate The drive acceleration and deceleration rates are independently controlled. L2222 sets acceleration rate; L2223 sets deceleration rate. Setting L2215, select rate 2 (A), or L2216, select rate 2 (B), HIGH transfers the rate control to two other inputs: L2233 sets acceleration rate; L2234 sets deceleration rate. Large Ramp Rate Range Ramp rates are adjustable from 1%/s to 1000%/s. S-Shaping of Ramp L2221, S-shaping, controls rate of change of acceleration at the start of the ramp, enabling the initial jerk on the drive to be controlled. Rate of change of acceleration at the end of the ramp is inherent in the ramp design and takes place when the error between the ramp output and input is within 5% of top speed. Input Scaling Scaling factors L2229, L2230, L2251 and L2252 enable external reference data to be normalized to 100% (10000) = top speed or voltage reference. Jog Circuits L2226, preset jog ref, and L2227, jog slow ref, provide preset fast/slow jog references respectively. The jog reference can be applied directly or via the ramp to the speed or voltage control. Preset ramp Output On setting input L2236, initiate preset ramp, HIGH the ramp output immediately jumps to the value set in L2235, preset ramp output. On L2236 reverting to a LOW the output ramps towards the input obeying the ramp rate constraints. Ramp Hold In conjunction with the speed/voltage control module (L21) ramp rate can be modified to a value consistent with the speed control being just in current limit.
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Page 14-21
Module 22
14.3.3 Application Notes Ramp Function Figure 14- 5 shows the ramp function in more detail.
Figure 14-5 Ramp Block Diagram
Ramp Preset Output Feature A common use is in presetting the ramp output to zero. This is achieved by setting L2236, initiate preset ramp, HIGH, with L2235, preset ramp output, set at zero. By linking L2235 to the drive speed feedback and pulsing L2236 the ramp output can be synchronised to drive speed. Ramp Hold Where the speed reference to the speed control module (L21) is supplied from the ramp, the ramp hold feature can be used to modify the ramp output so that it does not get out of step with actual drive speed. This would occur if the ramp rate and/or drive load condition forces the speed control into current limit. The ramp hold feature readjusts the ramp output such that the speed control is just maintained in current limit. For example if the drive stalls the speed reference is reduced towards zero, if the stall condition is removed the drive accelerates to try to achieve the target speed, the S-shaping providing a smooth increase in acceleration. The following link statements are required to introduce the ramp hold feature; L2212 L2213 L2238 L2239 L2241 = L2126 = L2128 = L2137 = L2117 = 0 to 0.5 s. In max. limit In min. limit Limited error Scaled speed feedback Speed filter
An input of actual speed (input L2239, speed,) is required from which drive acceleration is calculated, This speed input is filtered so that amplification of noise in the acceleration calculation can be controlled. The value for L2241, feedback filter, Page 14-22 Alspa GD4000 Issue (12-2-98)
Module 22
should be adjusted during site trials such that; with the drive forced to accelerate in current limit, the signal at L2240, limited rate, is relatively smooth. 14.3.4 Specialised Variables There are a number of variables which are for expert use only, these are; L2232, L2243, L2244, L2245, L2250
Table 14-3 Module 22(V3), Reference Circuits
Variable L2200 L2201 L2202 L2203 L2204 L2205 L2206 L2207 L2208 L2209 L2210 L2211 L2212 L2213 L2214 L2215 L2216 L2217 L2218 L2219 L2220 L2221 L2222 L2223 L2224 L2225 L2226 L2227 L2228 L2229 L2230
Description
Repetition Period Apply Jog Ref. Reverse Jog Slow Jog Direct Jog Input Trim Ref. 1 Select Ramp Output Start Ramp Ramp Input Test Input Ramped Jog Input Non Ramp Input In Max. Limit In Min. Limit Lift Ref. Clamp Select Rate 2 (A) Select Rate 2 (B) Jog Ref. Speed Ref. Total Speed Ref. Ramped Output S-Shaping Rate 1 (Accel) Rate 1 (Decel) +ve Top Speed Limit -ve Top Speed Limit Preset Jog Ref. Jog Slow Ref. Reference Direction Ramp Input Scaling Non-Ramp Input Scaling
Type Minimum Maximum ON IL IL IL IN IN IL IL IN IN IN IN IL IL IL IL IL ON ON ON ON IN IN IN IN IN IN IN OL IN IN 100 100 32767 32767 -270% 0.05s 1%/s 1%/s 0 -120% 0 0 +270% 2s 1000%/s 1000%/s 120% 0 30% 30% 0 0 0 -100% -32767 0 0 -32767 -120% -30% -3267 0 0 0 0 0 1 1 1 +100% +32767 1 1 +32767 +120% +30% +32767 1 1 1 1 1
Default
Scaling
1 ms = 1000
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
100%[104] = Top Speed 100%[104] = Top Speed 100%[104] = Top Speed 100%[104] = Top Speed Set By L2229 100%[104] = Top Speed 100%[104] = Top Speed Set By L2230 100%[104] = Top Speed 100%[104] = Top Speed
0.5s 100%/s 100%/s 100% -100% 0 0
1[104] = 1s 1%/s[10] = Top Speed in 100s 1%/s[10] = Top Speed in 100s 100%[104] = Top Speed 100%[104] = Top Speed 100%[104] = Top Speed 100%[104] = Top Speed 1 = Positive Output
1024 1024
Integer Value Of L2208 For Top Speed Integer Value Of L2211 For Top Speed
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Page 14-23
Module 22
Variable L2231 L2232 L2233 L2234 L2235 L2236 L2237 L2238 L2239 L2240 L2241 L2242 L2243 L2244 L2245 L2246 L2247 L2248 L2249 L2250 L2251 L2252 L2253 L2254 L2255 L2256 L2257 L2258 L2259 L2260 L2261 L2262 Description
Current Rate Ramped O/P Remainder Rate 2 (Accel) Rate 2 (Decel) Preset Ramp Output Initiate Preset Ramp Ramp Target Limited Speed Error Speed Limited Rate Feedback Filter Filtered Speed Old Filtered Speed Remainder 2 Rate Remainder Select Trim Ref. 2 Trim Ref. 2 Select Trim Ref. 1 Direction Compliment Old Limited Speed Error Trim 2 Scaler Trim 1 Scaler Scaled Trim Ref. 2 Scaled Trim Ref. 1 Filter 1 Input Filter 1 Filter 1 Output Filter 2 Input Filter 2 Filter 2 Output Filter 1 Remainder. Filter 2 Remainder.

Type Minimum Maximum ON ON IN IN IN IL ON IN IN ON IN ON ON ON ON IL IN IL OL ON IN IN ON ON IN IN ON IN IN ON ON ON -150% 0 +150% 5s 0 0
1[103] = 1s
Default
1%/s[10]
Scaling
ON ON 1%/s 1%/s -150% 0
ON ON 1000%/s 1000%/s 150% 1 100%/s 100%/s 0 0
1%/s[10] = Top Speed in 100s 1%/s[10] = Top Speed in 100s 100%[104] 1 = Preset Ramp Output = L2235 100%[104] = Top Speed
-50% -120%
50% 120%
0 0
100%[104] = Top Speed 100%[104] = Top Speed 1%/s[10]
0.5s
1[104] = 1s 100%[104] = Top Speed 100%[104] = Top Speed
0 -32767 0
1 +32767 1
0 0 0
1 = Negative Output 100%[104] = Top Speed 100%[104] = Top Speed
100 100
32767 32767
1024 1024
-150% 0
+150% 5s
0 0
1[103] = 1s
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Alspa GD4000
Issue (12-2-98)
Module 22
Figure 14-6 Module 22(V3), Reference Circuits
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Alspa GD4000
Page 14-25
Module 26
14.4
Module 26
Control Available Logic, Module 26

Description This module marshals drive trip interlocks, both internal and external to the SIGMA controller, to produce a protection healthy signal. A control available signal is generated provided permissive and trip interlocks are healthy. Field contactor closing logic is also incorporated in the module.
14.4.1
14.4.2
Features Trip Memories Trip memories enable fleeting trip inputs to be captured aiding fault diagnosis. Permissive Interlocks These interlocks are masked out whilst the drive is running. They enable the drive to have lockout or start-up interlocking features. Loss of Speed Feedback Protection The module allows drive speed and voltage feedback signals to be compared. Allowance is made for field weakening operation controlled by voltage spillover control. A comprehensive check on the integrity of both voltage and speed feedbacks is obtained. Overspeed Trip If the speed input, checked by the loss of speed protection, exceeds L2656, overspeed setting, for a time greater than L2669, overspeed trip delay, a trip is generated. Field Contactor Closing Circuit Closing signals for both generator and motor field contactors are produced. In the motor field case, a field mask signal is produced which inhibits the field loss protection for a time defined by L2644, field loss mask time. The delay should be sufficient to establish field current above field loss level. Enhanced Voltage and Speed Monitoring Feedback The accuracy of speed feedback loss protection is improved by the addition of IZ compensation. This enables motor speed to be compared with motor e.m.f. derived from L2614, motor voltage feedback. The protection is further improved by the addition of L2691, converter voltage feedback. Discrimination between speed, motor voltage and converter voltage feedback failure is obtained. If a speed feedback failure is detected for a time greater than L2670, feedback loss trip delay, L2638 tacho loss healthy, is set LOW and control available is tripped. Similarly L2688, motor voltage feedback healthy, and L2690, converter voltage feedback healthy, are set LOW on fault detection. Setting L2698, inhibit motor voltage feedback trip, HIGH prevents loss of motor voltage feedback tripping control available. Loss of converter voltage feedback does not automatically trip control available. The appropriate shutdown action must be set by the user program.
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14.4.3 Application Notes Trip Inputs
Module 26
Trip interlocks 110 and 14-17 are all associated with memories and should be used for inputs external to the SIGMA Controller. Other interlock inputs without memories are generally intended for internally generated trip signals. For these, memories associated with trip signal generation usually exist in the module. Note: The logic convention throughout the SIGMA Controller protection circuits is HIGH = HEALTHY, with occasional exceptions (eg L2089 Low = Healthy)..
Module 32, fault diagnostics, is closely associated with the control available module. Whilst interlocks programmed to module 26, control available logic, are required to trip the drive, they can be programmed to the fault diagnostic module to provide indication as text messages on the keypad and display of unhealthy trip inputs. Loss of Speed Feedback Protection The following notes apply specifically to the use of Module 26 in DC drive applications and may not apply to AC drives. Setting up and adjustment of this protection is minimal. Provided the standard SIGMA scaling is used [100% (10000) = Top speed and 100% (10000) = FULL VOLTS] and L2642 = Top speed base speed speed and voltage shadow each other within tolerances defined by the IZ drop and response of the voltage spillover control for field weakening schemes. The setting of L2641, trip level, should be sufficient to mask out the IZ drop in the armature. The setting is not critical. To check the correct setting for the protection run the drive with L2661, inhibit loss of speed feedback, set HIGH, and monitor error signal at L2658, speed feedback protection error, during drive operation. L2641, tacho loss trip level, should be set greater than maximum error recorded. Start up with either speed or voltage feedback missing produces a trip out immediately the drive speed exceeds L2641 setting. Start up with incorrect connection of speed transducer producing positive feedback is also detected. Instantaneous loss of feedback with drive running above speed equivalent to L2641 setting produces an immediate trip on all drives. Changes in feedback, transducer gain or scaling are detected on fixed field drives, but may go undetected on drives operating in the field weakening region. As far as possible motor voltage should be used to shadow speed. If converter voltage is used and the drive is tripped, a spurious feedback loss trip can occur because converter voltage is no longer equivalent to drive speed. Voltage and Speed Feedback Monitoring The following notes apply specifically to the use of Module 26 in DC drive applications and may not apply to AC drives.
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Page 14-27
Module 26
On drives with only one voltage feedback, usually fixed field drives, the voltage comparison requires inhibiting by setting L2696 HIGH. Discrimination between speed feedback failure and the single voltage feedback cannot be obtained and any failure trips control available. On drives with two voltage feedbacks, usually field weakening drives, discrimination between feedbacks can be obtained. Loss of speed feedback trips control available. Action on loss of voltage feedback must be programmed by the user. The recommended action is: Fault Motor voltage failure L2688 LOW Converter Voltage failure L2690 LOW With the standard SIGMA scaling of: 100% (10000) = top speed, 100% (10000) = full volts and 100% (10000) = peak armature current: set L2642 = Top speed [1-X] Base speed L2686 = X [Peak current] Full load current L2687 = Motor time constant where X = Full load IR drop Full voltage Action Trip control available Trip field contactor Start up lockout or alarm
The setting of L2683 is dependent on the type of field control. For fixed field drives set L2683 = 120% (max), since a limit is not required. For spillover field weakening schemes which regulate constant e.m.f., L2683 = 100% [1-X]. For spillover field weakening schemes which regulate constant terminal volts set L2683 = 100% [strictly for ultimate accuracy L2683 should be a variable (spillover bias -motor IR drop). This could be arranged by setting L2683 = (L3807 or L4507) - L2694]. 14.4.4 Specialised Variables There are a number of variables which are for expert use only, these are: L2640, L2646, L2647.
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Table 14-4 Module 26(V5), Control Available
Module 26
Variable L2600 L2601 L2602 L2603 L2604 L2605 L2606 L2607 L2608 L2609 L2610 L2611 L2612 L2613 L2614 L2615 L2616 L2617 L2618 L2619 L2620 L2621 L2622 L2623 L2624 L2625 L2626 L2627 L2628 L2629 L2630 L2631 L2632 L2633 L2634 L2635 L2636 L2637
Description
Repetition Period Reset A Trip Interlock 1 Healthy Trip Interlock 2 Healthy Trip Interlock 3 Healthy Trip Interlock 4 Healthy Trip Interlock 5 Healthy Trip Interlock 6 Healthy Trip Interlock 7 Healthy Trip Interlock 8 Healthy Trip Interlock 9 Healthy Trip Interlock 10 Healthy Initial Reset Count Speed Feedback Voltage Feedback Current Control Protection Healthy Field Control Protection Healthy Field Protection Permissive Permissive Interlocks Permissive Interlocks DC Loop Closed Reset Protection Healthy Control Available Close Field Contactor Field Loss Mask Dc Loop Closed Trip Interlock 1 Memory Trip Interlock 2 Memory Trip Interlock 3 Memory Trip Interlock 4 Memory Trip Interlock 5 Memory Trip Interlock 6 Memory Trip Interlock 7 Memory Trip Interlock 8 Memory Trip Interlock 9 Memory Trip Interlock 10 Memory AC ON Memory
Type ON IL IL IL IL IL IL IL IL IL IL IL ON IN IN IL IL IL IL IL IL OL OL OL OL OL OL OL OL OL OL OL OL OL OL OL OL OL
Minimum
Maximum
Default
Scaling
1 ms = 1000
0 0 0 0 0 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1
0 1 1 1 1 1 1 1 1 1 1
1 = Healthy 1 = Healthy 1 = Healthy 1 = Healthy 1 = Healthy 1 = Healthy 1 = Healthy 1 = Healthy 1 = Healthy 1 = Healthy 1 = Healthy 5 = Scan 5 And Later Scans
-327.68% -327.68% 0 0 0 0 0 0
+327.67% +327.67% 1 1 1 1 1 1
0 0 0 0 0 0 0 0
100%[104] = Top Speed 100%[104] = Full Volts 1 = Healthy 1 = Healthy 1 = Healthy 1 = Healthy 1 = Healthy
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Module 26
Variable L2638 L2639 L2640 L2641 L2642 L2643 L2644 L2645 L2646 L2647 L2648 L2649 L2650 L2651 L2652 L2653 L2654 L2655 L2656 L2657 L2658 L2659 L2660 L2661 L2662 L2663 L2664 L2665 L2666 L2667 L2668 L2669 L2670 L2671 L2672 L2673 L2674 L2675 L2676 Description
Tacho Loss Healthy OVERSPEED TRIP Healthy Old Reset Tacho Loss Trip Level Field Weakening Range Reset Pulse Time Field Loss Mask Time Field Mask Elapsed Time Scan Remainder Scan Time Ten Reset B Test Flag Main AC ON Trip Interlock 11 Healthy Trip Interlock 12 Healthy Trip Interlock 13 Healthy Reset Elapsed Time Control Available Remote Indication Overspeed Setting Intermediate Logic Speed Fb Protection Error Overspeed Elapsed Time Tach Loss Elapsed Time Inhibit Loss Of Speed FB Mask Trip Interlock 10A Permissive Interlock 3 Permissive Interlock 4 Gen Field Protection Permissive Close Gen Field Contactor Permit Generator Field Gen Field Control Protection Healthy Overspeed Trip Delay Feedback Loss Trip Delay Not Reset Mask Interlock 10B Permissive Interlock Permissive Interlock Trip Interlock 14 Healthy Trip Interlock 15 Healthy

Type OL OL OL IN IN IN IN ON ON ON IL IL IL IL IL IL ON OL IN OL ON ON ON IL IL IL IL IL OL OL IL IN IN OL IL IL IL IL IL 0 0 0 0 0 1 1 1 1 1 0 0 0 1 1
1 = Healthy 1 = Healthy 1 = Healthy 1 = Healthy 100%[104] = Top Speed 100%[104] = Top Speed 1 = 1 msec 1 = Healthy
Minimum
Maximum
Default
Scaling
5% 0.8 0 0
50% 5.0 10 sec 10 sec
25% 1.0 0 5 sec
100%[104] = Top Speed 1 _ 100?? 1[103] = 1 sec 1[103] = 1 sec 1[103] = 1 sec
0 0 0 0 0 0
1 1 1 1 1 1
0 0 0 0 0 0
1 _ TEST?? 1 _ OFF?? 1 = Healthy 1 = Healthy 1 = Healthy 1[103] = 1 sec
100%
125%
100%
100%[104] = Top Speed
0 0 0 0 0
1 1 1 1 1
0 0 0 0 0
0 0 0
1 0.2 sec 0.2 sec
0 0.1 sec 0.1 sec

1[104] = 1 sec 1[104] = 1 sec
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Variable L2677 L2678 L2679 L2680 L2681 L2682 L2683 L2684 L2685 L2686 L2687 L2688 L2689 L2690 L2691 L2692 L2693 L2694 L2695 L2696 L2697 L2698 L2699 Description
Trip Interlock 16 Healthy Trip Interlock 17 Healthy Trip Interlock 14 Memory Trip Interlock 15 Memory Trip Interlock 16 Memory Trip Interlock 17 Memory Base Speed Limit EMF Current Feedback Motor Resistance Motor Time Constance Motor Voltage FB Healthy Not Motor Volt FB Healthy Convertor Volt FB Healthy Convertor Voltage FB Voltage Comparison Error Voltage Comparison Trip Level IZ Compensation Filter TC Inhibit Volts Comp (A) Inhibit Volts Comp (B) Inhibit Motor Volt Feedback Trip Old Current Feedback
Module 26
Type IL IL OL OL OL OL IN ON IN IN IN OL OL OL IN ON IN ON IN IL IL IL ON 0 0 0 0 0.2 sec 1 1 1 0 0 0 0
100%[104] = Top Speed 100%[104] = Full Volts 100%[104] = Full Volts
Minimum 0 0
Maximum 1 1
Default 1 1
Scaling
1 = Healthy 1 = Healthy
80%
100%
100%
-100% 0 0.01 sec
+100% 50% 0.2 sec
0 0 0.01 sec
100%[104] = Current Limit 100%[104] = Full Volts for Current Limit 1[104] = 1 sec 1 = Healthy 1 = Unhealthy 1 = Healthy
-327.68%
+327.67%
100%[104] = Full Volts 100%[104] = Full Volts
20%
10%
100%[104] = Full Volts 100%[104] = Full Volts 1[104] = 1 sec
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Module 26
Figure 14-7 Module 26(V5), Control Available (sht 1)
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Module 26
Figure 14-8 Module 26(V5), Control Available (sht. 2)
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Module 27
14.5
Module 27
Control On, Module 27

Description The primary function of the module is to provide logic sequencing for closing/tripping the d.c. loop contactor. Interlocks ensure safe conditions for closing the d.c. loop contacts. A Control On signal is generated when d.c. breaker closure is confirmed. True RMS overcurrent and stall protection are also featured and it is these features which are used by GD4000.
14.5.1
14.5.2
Features Control ON Logic Speed and voltage feedback detectors can be used to ensure the drive is at rest and loop voltage is zero, before closing the d.c. loop. If required, speed and current reference detectors can ensure closing of d.c. loop with zero reference. L2742, d.c. loop closed timer, can delay confirmation of loop closure and is useful where auxiliary contacts close in advance of the main loop contactor poles. I2T Protection True RMS protection is provided. Two parameters L2728, set continuous current level and L2729, averaging time constant, enable adjustment of the protection. An alarm output gives prior warning of an impending trip. Stall Protection If the absolute current is greater than L2733, current det, is detected and absolute speed is greater than L2734, speed det, a trip is generated after L2720, time at stall, is exceeded.
14.5.3
Application Notes Setting up I2T Protection The protection I2t characteristic can be obtained from: Trip time t= T x loge I2 -Ii2 I2 - Ic2 where: T = L2729 (secs) Ic = L2728 continuous current setting. t = tripping time for an increase in current from initial current Ii to I. I = current at L2702. Ii = Initial current When the overload characteristic is defined for operation from cold condition. Trip time t = T x loge I2 I - Ic 2
2
Usually L2728, set continuous current level, is set to a maximum of 5% above required continuous current setting and reduced to zero for machines without thermal protection Page 14-34 Alspa GD4000 Issue (12-2-98)
Module 27
(ie Ic= Ii = Motor full load current from the nameplate). L2729, averaging time constant, is calculated to provide the required time to trip for peak current. The alarm I2t characteristic can be obtained from: Alarm time t =T x loge I2 - Ii2 I2 - 0.9Ic2 Note: Neither I2T protection nor stall protection inherently trip control available or the DCCB. The action on a trip condition is dependent upon user program operating on the two outputs L2727, I2T protection healthy, and L2714, stall protection healthy.
Example: Suppose it is required to trip after 15 s at current limit operating from the full load condition, current limit being 2 x FLC. Current limit Set L2728 = 100% [10000] at L2702 = 1.1 x FLC
= 1.1 x 10000 = 5500 2 15 = T x loge 22 - 1 22 - 1.22 so L2729 = 207 s 14.5.4 Specialised Variables There are a number of variables which are for expert use only, these are: L2738, L2739, L2740, L2743, L2747.
Table 14-5 Module 27(V4), Control On
Variable L2700 L2701 L2702 L2703 L2704 L2705 L2706 L2707 L2708 L2709 L2710
Description
Repetition Period Select Stall Detection Current Feedback Speed Feedback Reset Controlled Stop Trip Voltage Feedback I2T Remainder DC Loop Closed Control Available Request Close DC Loop
Type Minimum Maximum ON IL IN IN IL IL IN ON IL IL IL 0 0 0 1 1 1 0 1
Default
Scaling
1 ms = 1000
0 0 0 0 0 0
100%[104] = Full Volts 100%[104] = Current Limit 100%[104] = Top Speed
327.68% 327.67% -327.68% 327.67% 0 0 1 1
-327.68% 327.67%
0 0 0
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Module 27
Variable L2711 L2712 L2713 L2714 L2715 L2716 L2717 L2718 L2719 L2720 L2721 L2722 L2723 L2724 L2725 L2726 L2727 L2728 L2729 L2730 L2731 L2732 L2733 L2734 L2735 L2736 L2737 L2738 L2739 L2740 L2741 L2742 L2743 L2744 L2745 L2746 L2747 Description
Maintain Close DC Loop Speed Reference Current Reference Stall Protection Healthy Low Speed Low Voltage Command To Close DC Loop Control ON Stall Detected Time At Stall Loop Trip Delay Stall Elapsed Time Trip Delay Elapsed Time Zero Speed Reference Zero Current Reference I T Alarm I2T Protection Healthy Set Continuous Current Level Averaging Time Constant I T Output Permit Closure Of Loop Close Dc Loop Current Det Speed Det Voltage Det Speed Ref Det Current Ref Det Initial Reset Count Ten Scan Time Scan Count Drive Running DC Loop Closed Timer DC Loop Delay Elapsed Time DC Loop Closed Old Request Close DC Loop Control On Complement Stall Time Remainder
2 2

Type Minimum Maximum IL IN IN OL OL OL OL OL OL IN IN ON ON OL OL OL OL IN IN ON OL OL IN IN IN IN IN ON ON ON IL IN ON OL OL OL ON 0 0 1 0.5 sec 0 0.25 sec
1[104] = 1 msec 1[104] = 1 sec 100%[104] = Current Limit 100%[104] = Top Speed 100%[104] = Full Volts 100%[104] 100%[104] 1 = Alarm 1 = Healthy 1[103] = 1 sec 1[104] = 1 sec 1[103] = 1 sec 1[104] = 1 sec
Default 0 0 0
Scaling
100%[104] = Top Speed 100%[104] = Current Limit
327.68% 327.67% -327.68% 327.67%
0.5 sec 0
10 sec 0.5 sec
0.5 sec 0
15% 20 sec
100% 1000 sec
35% 20 sec
100%[104] = Current Limit 1[10] = 1 sec 100%[104] = (Current Limit)
0 0 0 0 0
40% 5% 10% 5% 5%
0 0 0 0 0
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Module 27
Figure 14-9 Module 27(V4), Control On
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Module 28
14.6
Module 28
Run Logic, Module 28

Description The module generates a request current control on signal as a function of Run or Jog request signals. Controlled stop logic is incorporated in the module. Drive stopped detection logic is used to sequence the removal of current control on.
14.6.1
14.6.2
Features Jog and Run Memories L2812, run, is HIGH provided L2804, request run, and L2831, controlled stop healthy, are HIGH and L2835, jog memory, is LOW. L2812, run, is used by other modules to apply run references to the drive. L2812, run, also sets L2834, run memory, HIGH. Run memory can only be reset when the drive is stopped as indicated by L2813, drive running, LOW, or L2839, drive stopped, HIGH. The Run and Jog memories maintain request current control on until the drive stops. On changing from request run to request jog, or vice versa, whilst the drive is running, the memories ensure that changeover only occurs with the drive stopped. Drive and Stopped Detection L2805, low speed, or L2807, low volts, input is used to indicate a drive stopped condition. On position controlled drives L2809, zero position error, can also be included as a condition for drive stopped. L2816, standstill apply suicide delay, allows a delay to be programmed before L2813 is set LOW and L2839 set HIGH; this allows the drive to come completely to rest before suicides are applied. Controlled Stop Logic Inputs at L2823, L2824, L2825 initiate a drive controlled stop. L2831, controlled stop healthy, initiates a stop on being set LOW. Run or Jog signals are removed and the drive regenerates to a stop. Controlled stop memory outputs L2827, L2828, L2829 can be programmed to adjust the drive ramp (module 22) and set the controlled stop deceleration rate. L2841, controlled stop breaker trip, can be used to trip the dc breaker, the output is set LOW when the controlled stop has brought the drive to rest. L2826, delayed shutdown healthy, produces a controlled stop when setting of L2832, delayed shutdown time, is exceeded.
14.6.3
Specialised Variables There are a number of variables which are for expert use only, these are: L2836, L2737, L2738.
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Table 14-6 Module 28(V1), Run Logic
Module 28
Description
Repetition Period Control ON Request Jog Fwd Request Jog Rev Request RUN Low Speed Select Voltage Control Low Volts Select Position Control Zero Position Error Request Current Control ON Jog Run Drive Running Drive Request Suicide Delay Elapsed Time Standstill Apply Suicide Delay Current Control Off Delay Elapsed Time Reference Applied Reset Reset Interlock Test Run Controlled Stop 1 Healthy Controlled Stop 2 Healthy Controlled Stop 3 Healthy Delayed Shutdhown Healthy Controlled Stop 1 Memory Controlled Stop 2 Memory Controlled Stop 3 Memory Delayed Shutdown Memory Controlled Stop Healthy Delayed Shutdown Time Delayed Shutdown Elapsed Time Run Memory Jog Memory Initial Reset Count Scan Count Ten Scan Time Drive Stopped
Type Minimum Maximum ON IL IL IL IL IL IL IL IL IL OL OL OL OL OL ON IN IN ON OL IL IL IL IL IL IL IL OL OL OL OL OL IN ON OL OL ON ON ON OL 0 320 sec 0 0 0 0 0 0 0 1 1 1 1 1 1 1 0 0 10 sec 0.2 sec 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1
Default
Scaling
1 ms = 1000
0 0 0 0 0 0 0 0
1[103] = 1 sec
0 0
1[103] = 1 sec 1[104] = 1 sec 1[104] = 1 sec
0 0 0 0 0 0 0
1 = Healthy
1[102] = 1 sec 1[102] = 1 sec
5 = Scan 5 And Later Scans
1[104] = 1 sec
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Module 28
Variable L2840 L2841 L2842 L2843 L2844 L2845 L2846 L2847 L2848 L2849 Description
Interlocked Reset Controlled Stop Breaker Trip Reset Flag Permit Voltage Control Release Current Control Field Control On Mask/Test Mask/Test Permit Control ON Permit Current Control ON

Type Minimum Maximum OL OL OL OL OL IL IL IL IL IL 0 0 0 0 0 1 1 1 1 1 0 0 0 0 0 Default Scaling
Figure 14-10 Module 28(V1), Run Logic (sht 1)
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Module 28
Figure 14-11 Module 28(V1), Run Logic (sht 2)
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Module 30
14.7
Module 30
Reference Logic, Module 30

Description This module is used for the enabling of regulators and the applying of references. The module provides link outputs which can enable the speed/voltage regulator and lift the reference circuit module clamp. The module also provides outputs for the applying of the current reference, ramp reference, jog reference and external current reference.
Table 14-7 Module 30(V1), Reference Logic
14.7.1
Description
Repetition Period Current Control ON Master Select Tension Control Lift Reference Clamp Stall Protection Healthy Jog Run Apply External Current Reference Release Speed / Voltage Regulator Lift Reference Clamp Apply Jog Reference Apply Reference To Ramp Apply Current Reference Current Reference Applied Speed/Voltage Reference Applied
Type Minimum Maximum ON IL IL IL IL IL IL IL OL OL OL OL OL OL IL IL 0 0 1 1 0 0 0 0 0 0 0 1 1 1 1 1 1 1
Default
Scaling
1 ms = 1000
0 0 0 0 0 0 0
0 0
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Module 30
Figure 14-12 Module 30(V1), Reference Logic
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Module 31
14.8
Module 31
Test/Local Control, Module 31

General This module is normally used in conjunction with the keypad to provide local control or a test injection facility.
14.8.1
14.8.2
Features Module 31 carries the following features: Reference Map On L3112 (raise input) being set high, the ramp output at L3104 (local reference) moves towards L3110 (maximum reference) at a rate set by L3111 (ramp rate). Similarly, selecting L3113 (lower input) moves the output towards L3109 (minimum reference). Ramp output is held at the value existing at the instant raise or lower input is set low. On Version 2 (V2) onwards, setting L3122 (reset ramp) high, or L3123 (reset ramp - low) low, resets the ramp output to zero. Toggle This feature can be used to generate a square waveform reference as a drive test input.
14.8.3
Interface With Keypad Keypad local control keys, RUN , STOP , , and to control the test module. The following edits are required: L3112 = A34.3L Raise input = L3113 = A34.2L Lower input = L3114 = A34.0L Run input = L3115 = A34.1L Stop input = Note: L is the link attribute locked. are normally used
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Table 14-8 Module 31(V2), Test/Local Control
Module 31
Variable L3100 L3101 L3102 L3103 L3104 L3105 L3106 L3107 L3108 L3109 L3110 L3111 L3112 L3113 L3114 L3115 L3116 L3117 L3118 L3119 L3120 L3121 L3122 L3123
Description
Repetition Period Test Flag Reset Test Reference Local Reference Raise Lower Test Run Local Run Minimum Reference Maximum Reference Ramp Rate Raise Input Lower Input Run Input Stop Input Target Reference Toggle Period Toggle Ref 1 Toggle Ref 2 Toggle Out Enable Toggle Reset Ramp Reset Ramp (Low)
Type ON IL IL ON ON OL OL OL OL IN IN IN IL IL IL IL ON IN IN IN ON IL IL IL
Minimum
Maximum
Default
Scaling
1 ms = 1000
0 0
1 1
0 0
1 = Test
100% = [104] 100% = [104]
-327.67% -327.67% 0%
+327.67% +327.67% +327.67%
0% 0% 0%
100% = [104] 100% = [104] 100% = [104]
5 -15000 -15000
2000 +15000 +15000
5 0 0
Multiples Of Scan Time
100% = [104]
0 0 0
1 1 1
0 0 0
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Module 31
Figure 14-13 Module 31(V2), Test/Local Control
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Module 32, 33 and 34
14.9
Fault Display, Modules 32, 33 And 34

Overview The SIGMA Software Module 32 - Fault Display is a slow task module. It scans a number of logical inputs and depending on configuration reports their state. The logical inputs are typically linked to status flags from other modules. Each input can be configured to be high or low healthy and trip or alarm only. Associated with each input is a 16 character fault message. The message of the first trip detected is made available for other modules to use. Fault messages can be viewed with either the SIGMA monitor, or the SIGMA keypad. Alarm messages can also be displayed when no trips are present and reset and start-up logic is also provided.
14.9.1
14.9.2
Application Notes As well as using tables in the L3200 to L3299 range the module will also use L3300 to L3399 and L3400 to L3499. As per the standard requirement for a slow task module at each execution the module calculates the time since the last execution and places this time in L3200. L3300 and L3400 are declared as outputs. As part of the start up routine they are zeroed and there after left alone. Module Inputs The fault display module has the following inputs: Fault message pointers L3201 L3202 Table letter and number containing the first characters of the fault messages for fault channels 0 through 7. 32 consecutive tables are required to hold the eight messages. The defaults are: L3201 = P and L3202 = 100. Table letter and number containing the first characters of the fault messages for fault channels 8 through 15. The defaults are L3203 = Pand L3204 = 100 Table letter and number containing the first characters of the fault messages for fault channels 184 through 191. Trip or alarm only selection for fault channels 0 through 31. An appropriate bit set causes alarm only. A bit cleared to 0 (the default) enables the trip. Trip or alarm only selection for fault channels 32 through 63.
L3203 L3204 to L3247 L3248
L3249
L3250 to
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L3254

Trip or alarm only selection for fault channels 160 through 191. Healthy low / high selection for fault channels 0 through 31. An appropriate bit set causes low to be considered healthy and high to indicate a trip. A bit clear (the default) causes high to be healthy and low to indicate a trip. Healthy low / high selection for fault channels 160 through 191. This input high holds the module in reset. The following actions are taken: 1) 2) There is no checking of the fault channel inputs. All status outputs are zeroed, indicating healthy.
Fault channel healthy low / high selection
L3255
to
L3260
Reset
L3265
3 ) The equivalent of setting L3266, clear 1st up fault is done. 4) 5) 6) L3270, fault present is cleared. L3274, fault message number is set to -1 L3275, the fault message pointer is set to say INPUTS HEALTHY L3279, time to 1st fault is unfrozen by the low to high transition of L3265. When L3265 is high L3279 counts. L3267, delay count is left alone
7)
8)
Clear 1st fault
L3266
This input set high does the following: 1) 2) 3) L3269, ready for 1st fault is set high L3271, first fault present is set low L3272, first fault number is set to -1
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Start up delay L3267

When L3267 is found to be non-zero variables will be initialised. L3267 initialisation will be done once, on a halt to run transition. The module will be held in a reset state while L3267 is none zero. On subsequent executions L3267 should be decremented down to zero after which the module will execute normally. When its value is one, the fault channel inputs should be written to the healthy state. This means that there is no need to write links to put unused ones so. The default for L3267 should be 50 giving about 100 ms of settling time for the trip inputs.
Inputs scanned
L3268
This table controls the number of input channels scanned. It is only checked at start up. Its default value will be 1. L3268 0 1 2 3 4 5 6 Channels scanned None 0 to 31 0 to 64 0 to 95 0 to 127 0 to 159 0 to 191
L3276
A low to high transition of this table, will instruct the module to send the next fault message to the monitor, and keypad. If there are no faults, no message is sent. A low to high transition of this table, will instruct the module to send the previous fault message to the monitor, and keypad. If there are no faults found, no message is sent. A low to high transition on this logic input causes L3279 Fault channel inputs 0 to 95
L3277
L3280 L3301 to L3396 L3401 to L3496
Fault channel inputs 96 to 191
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Module Outputs The fault display module has the following outputs. Ready for first fault L3269
This logical table is high when the module is ready to detect a first fault. That is, after reset (L3265) or clear first fault (L3266) have been operated. If there are trips present when L3265 or L3266 are operated then when they go low again the trips will be instantly detected. This logical output is set high when a trip is detected, alarms have no effect on it. It is reset by L3265. This logical table is set high when a first trip is detected, alarms have no effect on it. It is reset by L3265 or L3266. This table contains the channel number of the first trip detected, alarms are not reported. It is reset to -1 by L3265 or L3266. This table contains the channel number of the first trip detected. It is reset to -1 by L3265. This table contains a pointer to the message for the first fault detected. It is reset by L3265 to point to a string saying: INPUTS HEALTHY
Fault present
L3270
First fault present L3271
First fault number L3272
Fault message number Fault message
L3274
L3275
Current Fault
L3278
Fault number of the current fault message, arrived at by the use of L3276 and L3277. When no trips are present this table indicates the number of milliseconds from the last low to high transition of L3280, the re-sync signal. When a trip occurs the table value is frozen. It will restart counting from where it is on a low to high transition of L3265. An invalid time is given by a time of -1 (appropriate for 16-bit and 32-bit operations). The time is invalid prior to the first re-sync signal and if the time between re-sync signals is greater than 2147.483 seconds. (=231-1/1000)
Time since first fault
L3279
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Fault channel status outputs L3397 L3398 L3399 L3497 L3498 L3499

These six tables contain the status of the input channels, one bit for each channel. If a channel is in its unhealthy state, alarm or trip, the appropriate bit in the status words is set. L3397.0 to L3397.31 indicate channels 0 to 31 respectively. Similarly: L3398 indicates channels 32 to 63 L3399 indicates channels 64 to 95 L3497 indicates channels 96 to 127 L3498 indicates channels 128 to 159 L3499 indicates channels 160 to 191
Table 14-9 Modules 32, 33 and 34 Fault Tables
Variable L3200 L3201 L3202 L3203 L3204 L3205 L3206 L3207 L3208 L3209 L3210 L3211 L3212 L3213 L3214 L3215 L3216 L3217 L3218 L3219 L3220 L3221 L3222 L3223 L3224 L3225 L3226 L3227 L3228 L3229
Description
Repetition Period Message Table Letter 0 to 7 Message Table Number 0 to 7 Message Table Letter 8 to 15 Message Table Number 8 to 15 Message Table Letter 16 to 23 Message Table Number 16 to 23 Message Table Letter 24 to 31 Message Table Number 24 to 31 Message Table Letter 32 to 39 Message Table Number 32 to 39 Message Table Letter 40 to 47 Message Table Number 40 to 47 Message Table Letter 48 to 55 Message Table Number 48 to 55 Message Table Letter 56 to 63 Message Table Number 56 to 63 Message Table Letter 64 to 71 Message Table Number 64 to 71 Message Table Letter 72 to 79 Message Table Number 72 to 79 Message Table Letter 80 to 87 Message Table Number 80 to 87 Message Table Letter 88 to 95 Message Table Number 88 to 95 Message Table Letter 96 to 103 Message Table Number 96 to 103 Message Table Letter 104 to 111 Message Table Number 104 to 111 Message Table Letter 112 to 119
Type Minimum Maximum ON IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN A 0 A 0 A 0 A 0 A 0 A 0 A 0 A 0 A 0 A 0 A 0 A 0 A 0 A 0 A W 99999 W 99999 W 99999 W 99999 W 99999 W 99999 W 99999 W 99999 W 99999 W 99999 W 99999 W 99999 W 99999 W 99999 W
Default
Scaling
1 ms = 1000
P 100 P 100 P 100 P 100 P 100 P 100 P 100 P 100 P 100 P 100 P 100 P 100 P 100 P 100 P
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Variable L3230 L3231 L3232 L3233 L3234 L3235 L3236 L3237 L3238 L3239 L3240 L3241 L3242 L3243 L3244 L3245 L3246 L3247 L3248 L3249 L3250 L3251 L3252 L3253 L3254 L3255 L3256 L3257 L3258 L3259 L3260 L3261 L3262 L3263 L3264 L3265 L3266 L3267 L3268 L3269 L3270 L3271 L3272 L3273 Description
Message Table Number 112 to 119 Message Table Letter 120 to 127 Message Table Number 120 to 127 Message Table Letter 128 to 135 Message Table Number 128 to 135 Message Table Letter 136 to 143 Message Table Number 136 to 143 Message Table Letter 144 to 151 Message Table Number 144 to 151 Message Table Letter 152 to 159 Message Table Number 152 to 159 Message Table Letter 160 to 167 Message Table Number 160 to 167 Message Table Letter 168 to 175 Message Table Number 168 to 175 Message Table Letter 176 to 183 Message Table Number 176 to 183 Message Table Letter 184 to 191 Message Table Number 184 to 191 Alarm / Trip 0 to 31 Alarm / Trip 32 to 63 Alarm / Trip 64 to 95 Alarm / Trip 96 to 127 Alarm / Trip 128 to 159 Alarm / Trip 160 to 191 Healthy High / Low 0 to 31 Healthy High / Low 32 to 63 Healthy High / Low 64 to 95 Healthy High / Low 96 to 127 Healthy High / Low 128 to 159 Healthy High / Low 160 to 191 Not Used Not Used Not Used Not Used Reset Clear First Up Fault Startup Delay Inputs Scanned Ready For First Fault Fault Present First Fault Present First Fault Number Not Used

Type Minimum Maximum IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN 0 A 0 A 0 A 0 A 0 A 0 A 0 A 0 A 0 A 0 0 0 0 0 0 0 0 0 0 0 0 0 99999 W 99999 W 99999 W 99999 W 99999 W 99999 W 99999 W 99999 W 99999 W 99999 Default 100 P 100 P 100 P 100 P 100 P 100 P 100 P 100 P 100 P 100 0 0 0 0 0 0 0 0 0 0 0 0
Refer 14.9.2 Refer 14.9.2 Refer 14.9.2 Refer 14.9.2 Refer 14.9.2 Refer 14.9.2 Refer 14.9.2 Refer 14.9.2 Refer 14.9.2 Refer 14.9.2 Refer 14.9.2 Refer 14.9.2
Scaling
IL IL IN IN OL OL OL ON
0 0 0 0
1 1 200 6
0 0 50 1
1 SCAN = 1 Refer 14.9.2
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Variable L3274 L3275 L3276 L3277 L3278 L3279 L3280 L3281 L3282 L3283 L3284 L3285 L3286 L3287 L3288 L3289 L3290 L3291 L3292 L3293 L3294 L3295 L3296 L3297 L3298 L3299 L3300 L3301 L3302 L3303 L3304 L3305 L3306 L3307 L3308 L3309 L3310 L3311 L3312 L3313 L3314 L3315 L3316 Description
Fault Message Number Fault Message Pointer Next Fault Message Previous Fault Message Current Fault Message Number Elapsed Time Re-Sync Signal Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Fault Channel 0 Fault Channel 1 Fault Channel 2 Fault Channel 3 Fault Channel 4 Fault Channel 5 Fault Channel 6 Fault Channel 7 Fault Channel 8 Fault Channel 9 Fault Channel 10 Fault Channel 11 Fault Channel 12 Fault Channel 13 Fault Channel 14 Fault Channel 15

Type Minimum Maximum ON ON IL IL ON ON IL 0 1 0 0 0 1 1 0 0 Default Scaling
IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
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Fault Channel 16 Fault Channel 17 Fault Channel 18 Fault Channel 19 Fault Channel 20 Fault Channel 21 Fault Channel 22 Fault Channel 23 Fault Channel 24 Fault Channel 25 Fault Channel 26 Fault Channel 27 Fault Channel 28 Fault Channel 29 Fault Channel 30 Fault Channel 31 Fault Channel 32 Fault Channel 33 Fault Channel 34 Fault Channel 35 Fault Channel 36 Fault Channel 37 Fault Channel 38 Fault Channel 39 Fault Channel 40 Fault Channel 41 Fault Channel 42 Fault Channel 43 Fault Channel 44 Fault Channel 45 Fault Channel 46 Fault Channel 47 Fault Channel 48 Fault Channel 49 Fault Channel 50 Fault Channel 51 Fault Channel 52 Fault Channel 53 Fault Channel 54 Fault Channel 55 Fault Channel 56 Fault Channel 57 Fault Channel 58

Type Minimum Maximum IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Scaling
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Fault Channel 59 Fault Channel 60 Fault Channel 61 Fault Channel 62 Fault Channel 63 Fault Channel 64 Fault Channel 65 Fault Channel 66 Fault Channel 67 Fault Channel 68 Fault Channel 69 Fault Channel 70 Fault Channel 71 Fault Channel 72 Fault Channel 73 Fault Channel 74 Fault Channel 75 Fault Channel 76 Fault Channel 77 Fault Channel 78 Fault Channel 79 Fault Channel 80 Fault Channel 81 Fault Channel 82 Fault Channel 83 Fault Channel 84 Fault Channel 85 Fault Channel 86 Fault Channel 87 Fault Channel 88 Fault Channel 89 Fault Channel 90 Fault Channel 91 Fault Channel 92 Fault Channel 93 Fault Channel 94 Fault Channel 95 Fault Status Word 0 Fault Status Word 1 Fault Status Word 2 Not Used Fault Channel 96 Fault Channel 97

Type Minimum Maximum IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL ON ON ON 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Refer 14.9.2 Refer 14.9.2 Refer 14.9.2
Scaling
IL IL
0 0
1 1
0 0
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Variable L3489 L3490 L3491 L3492 L3493 L3494 L3495 L3496 L3497 L3498 L3499 Description
Fault Channel 184 Fault Channel 185 Fault Channel 186 Fault Channel 187 Fault Channel 188 Fault Channel 189 Fault Channel 190 Fault Channel 191 Fault Status Word 3 Fault Status Word 4 Fault Status Word 5

Type Minimum Maximum IL IL IL IL IL IL IL IL ON ON ON 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 Default 0 0 0 0 0 0 0 0
Refer 14.9.2 Refer 14.9.2 Refer 14.9.2
Scaling
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Figure 14-14 Module 32, Fault Diagnostics
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Module 35V2
14.10
Module 35V2
Slow History Record, Module 35V2

Overview The Control History Module L35V2 records a variable number of logic and analog data tables which can be viewed at a later time for fault investigation. The Control History Record module has improved memory usage and is able to hold multiple trip histories. It is able to record up to 4070 individual samples of the total analog channels. The module has provision for the sampling a maximum of 10 x 16 bit analog channels and 16 logic channels. The control history module produces trip histories which are accessed through OVERDRIVE. The control history also has facilities for recording of the stimulation data in conjunction with module 49. The control history record module L35V2 can operate with the auxiliary control history module L235V1. Both modules operation is identical and for L table numbers replace L35 with L235. When running the control history record both modules (L35V2 and L235V1) must be executed to ensure that the memory is initialised correctly. Failure to do initialise both modules may cause problems when connected to OVERDRIVE. If OVERDRIVE is to be used then BOTH modules must have been initialised.
14.10.1
14.10.2
Description of Operation The Control History module stores history records when requested by the user program. Recording is enabled via the history enable input (L3501). The history records are stored in history buffers and are examined via the OVERDRIVE diagnostic software utility. The history buffer can have a variety of states. These states are shown below: The record buffer has the following states: R - recording T - tripped H - halted The view buffer has the following states: E - empty V - viewable B - being viewed The two tables L03501 (History enable) and L03556 (Reset history) are responsible for the history buffers moving between these states according to the following rules: IF H & L3501 THEN R IF R & NOT L3501 THEN T IF T & NOT B & L3556 THEN H The V goes to B when OVERDRIVE requests the history. OVERDRIVE causes the switch back from B to V at the end of the history transfer. Further there is a 5 second no access time out which would cause the return to the V state.
14.10.3
Standard Links The software module requires some standard links to operate correctly within the SIGMA system. Listed below are some recommended standard inter-module links that should be used.
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L3501 History Enable L3559 Samples after Trip L3556 Reset History L3558 Number Ana Chs L3563 Fault Pointer L3564 Fault Number 14.10.4 Memory Structure = L2623 = 25 = L2621 = 10 = L3275 = L3274
Module 35V2
The control history module utilizes memory in two main areas. Firstly there is the general data tables used for operation of the module. The second type of memory is used for the storage of history records. This memory is to be located in the slow memory. It contains not only the history record samples but also the information required for retrieving the data. History Buffers The control history records the data into a memory buffer which can be viewed to interrogate the history record. The control history buffers are stored in the slow memory and the number of buffers that can be used is calculated from the size of the available slow memory to the module. The calculation of the total number of buffers is performed during the initialisation of the module. The way the buffers are laid out in the slow memory is shown in Figure 14-15.
Figure 14-15
Figure 14-16
Figure 14-17
The recording of samples into the memory buffer is shown in the Figure 14-16. The buffer is laid out in a column array where at each sample the data is stored. After the sample has been stored, the buffer pointer is incremented so it is ready for the next sample. If the entire buffer is full a flag will be set and the module will start recording over the oldest samples. This can be seen in the Figure 14-16. The way the channels are recorded within each sample is shown in Figure 14-17. The first word used will Issue (12-2-98) Alspa GD4000 Page 14-61
Module 35V2
contain all the sample information ie. time, sample number etc. The second word contains the logic channels. The next group of words are the analog channels. This can be a variable number from 2 to 10 channels. The software will record into only one buffer at one time and once the history is tripped it will finish recording into that buffer and then increment the buffer number to the next available buffer. This will continue until all the buffers are filled, then no more history records can be recorded until the buffers are reset. The interrogation of the history records is performed by the Overdrive diagnostic software utility. 14.10.5 Application notes Module Entry The execution of the module is performed using the special function GDMMOD S140 from the ladder user program. The operation of this special function is explained in detail in its corresponding software data specification. Module Inputs The control history record module has the following inputs. L3501 History enable (Logic Input) Logic table for starting and stopping recording. L3504 Analog channel 0 letter (Numeric Input) L3505 Analog channel 0 number (Numeric Input) The module will record any data table. To set up channel 0 the ASCII code or the letter eg. L for the table is put into L3504 and the table number is put into L3505. Similarly channels 1 to 9 are set up by setting the next 9 pairs of tables. L3524 Logic channel 0 letter (Numeric Input) L3525 Logic channel 0 number (Numeric Input) Again the module will record any data table or indeed any bit from any data table. To set up channel 0 the ASCII code or the letter eg. L for the table is put into L3504 and the table number and bit position are put into L3505. L3505 is a number of the form tttttbb where ttttt is the table number and bb is the bit position. If bb is between 0 and 31 that bit position is logged but if bb is greater than 31 then the zero/none-zero state of the whole table is logged Similarly channels 1 to 9 are set up by setting the next 9 pairs of tables. L3556 Reset history (Logic Input) Logic table for initiating transfer of tripped history from the record buffer to the view buffer. L3558 Number of Analog Channels This can be a value between 1 and 10 inclusive. It should be setup in the links program, as a link to a constant, as the value is only used on the first scan of the user program. Note: The more channels recorded, the less samples per channel will be allocated.
L3559 Samples after trip (Numeric Input) This is the number of samples that will be recorded after a trip of the record buffer is initiated that is after L3501 goes low. It is a percentage of the number of samples per buffer (L3567). The value is used during the set-up in the first scan of the user program, and requires a Halt to Run to change it.
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Module 35V2
L3562 Clear History This table can be used to re initialise the history record module. It will clear all previous histories and setup the various analog and logic channel pointers. L3563 Fault message pointer (Numeric Input) L3564 Fault number (Numeric Input) These tables are intended to provide an interface to a fault display module. The tables can be driven from ladder. Simply after recording the samples after trip, if L3564 is greater than -1, the table contents are taken as a pointer to a fault message and the fault number. L3565 Re Enable Upload This table clears the bit 4 , history retrieved signal in the buffer status words. It will then enable OVERDRIVE to upload the history again. (Overdrive will not re upload the same history record if that was the latest record on the history list). L3568 Scans per Sample (Numeric Input) This table indicates how many user program scans will be performed between each recording of the sundry channels. This value can be changed at any time and will immediately affect the recording channel and all subsequent recordings. L3569 Number of Buffers (Numeric Input) This input will allow the user to control the number of buffers that can be recorded into. For this version the number of buffers is limited to 2 due to restriction with the OVERDRIVE diagnostic utility. L3579 Startup Flag (Logic Input) It is used to indicate the first scan, and such initiate the set-up logic. The variable is only initialised on the power up of a new system. L3601 Number of Analog Stimulation Channels (Numeric Input) This value sets up the number of analog stimulation channels to be recorded. If this value is greater than the number set L3558, then this value will be used. This is because there is only enough memory available for this many channels. L3602 Number of Logic Stimulation Channels (Numeric Input) This sets up the number of logic inputs to record during the stimulation test. The value can range between 1 and 16 inclusive. L3604 Analog Stimulation Channel 0 Letter (Numeric Input) L3605 Analog Stimulation Channel 0 Number (Numeric Input) These tables, and the following ones are similar to tables L3504 to L3523. They set up the analog channels to be recorded during the stimulation test. They can be any valid GEM table. L3624 Logic Stimulation Channel 0 Letter (Numeric Input) L3625 Logic Stimulation Channel 0 Number (Numeric Input) These tables and the following ones, are similar to tables L3524 to L3555. They set up the logic inputs to record, during the stimulation tests. L3656 Select Stimulation Inputs (Logic Input) If one buffer is recording, and this table is taken high, the stimulation channels are recorded into the next buffer, until the buffer is full (ie L3567 samples recorded). This buffer is made immediately viewable, and can be uploaded into Overdrive without having to press reset. The original buffer then starts recording once more. Note: that the stimulation test will overwrite any data in the buffer that it is allocated. Also, the recording buffer re-starts with an empty buffer. Alspa GD4000 Page 14-63
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Module 35V2
Module Outputs The control history record module has the following outputs.
L3500 Scan time Indicated the scan time taken between the execution of the consecutive scans of the history record module. L3570 Buffer status 0 to L3577 Buffer status 7 (Numeric Output) The control history modules has a number history record buffers. The number of buffers available to the user is determined by the total amount of memory available. There is a maximum of 8 buffers that can be available. Each of these buffers has its own status word and within each word it has certain bits used to indicate the current status.
Bit 0 1 2 4 5 6 Meaning Recording history - The record buffer is in the R state. Trip history - The samples after trip are being recorded. History tripped - The samples after trip have been recorded so the record buffer is now in the T state. History Retrieved - Indicates the record has been successfully retrieved by Overdrive. Sundry channels recorded. History set up fault - One or more of the tables specified for recording does not exist, the ones that can be recorded will be recorded. Details of which channels are set up incorrectly are contained in L35xx. View buffer ready - The view buffer is not empty, it contains a valid history. Sundry channel buffer full - The record buffer has wrapped round, there are the total number of samples in the recording history. Serial view history - OVERDRIVE is accessing the history. Ladder trip history - Set when L3501 is low, cleared when it is high. Ladder reset history - This reflects the status of L3556.
7 9 10 11 13
L3560 Logic word (Numeric Output) This is a copy of the status of the logic channels last recorded. Bits 0 to 15 correspond to logic channels 0 to 15. L3561 Channel programming fault (Numeric Output) Bits set in this word indicate that tables set up for recording do not exist. Bits 0 to 15 correspond to faults in logic channels 0 to 15 and bits 16 to 25 correspond to faults in analog channels 0 to 9. L3567 Number of Samples (Numeric Output) This tells the user exactly how many samples there are per buffer. The product of this number, the scan time and the value of L3568 (scans per sample), gives a rough indication of the store time length. L3580 Slow Real Time (Numeric Output) This output is used for keeping a copy of the last slow real time. L3581 History Pointer (Logic Output) This table is used by Overdrive to indicate that either all the history records for the module have been uploaded or there are none available for viewing. The pointer is incremented to enable the other history module (if used) , to communicate with Overdrive so that its history records can then be uploaded.
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L3603 Stimulation Logic Channel (Numeric Output) This is a copy of the logic inputs, read during the current scan.
Module 35V2
L3657 Old Select Stimulation Inputs (Logic Output) This table is used by the code to check for a LOW to HIGH transition of the Select Stimulation Inputs table, L3656. L3658 Recording Stimulation (logic Output) This table, when HIGH, informs the user that the history currently being recorded are the stimulation channels.
Table 14-10 Modules 35 and 36, Control Micro History
Description
Repetition Period History Enable View Buffer Number Trip Buffer Number Analog Channel 0 Letter Analog Channel 0 Number Analog Channel 1 Letter Analog Channel 1 Number Analog Channel 2 Letter Analog Channel 2 Number Analog Channel 3 Letter Analog Channel 3 Number Analog Channel 4 Letter Analog Channel 4 Number Analog Channel 5 Letter Analog Channel 5 Number Analog Channel 6 Letter Analog Channel 6 Number Analog Channel 7 Letter Analog Channel 7 Number Analog Channel 8 Letter Analog Channel 8 Number Analog Channel 9 Letter Analog Channel 9 Number Logic Channel 0 Letter Logic Channel 0 Number
Type Minimum Maximum ON IL ON ON IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999.99 0 1
Default
Scaling
1 ms = 1000
76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
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Module 35V2
Logic Channel 1 Letter Logic Channel 1 Number Logic Channel 2 Letter Logic Channel 2 Number Logic Channel 3 Letter Logic Channel 3 Number Logic Channel 4 Letter Logic Channel 4 Number Logic Channel 5 Letter Logic Channel 5 Number Logic Channel 6 Letter Logic Channel 6 Number Logic Channel 7 Letter Logic Channel 7 Number Logic Channel 8 Letter Logic Channel 8 Number Logic Channel 9 Letter Logic Channel 9 Number Logic Channel 10 Letter Logic Channel 10 Number Logic Channel 11 Letter Logic Channel 11 Number Logic Channel 12 Letter Logic Channel 12 Number Logic Channel 13 Letter Logic Channel 13 Number Logic Channel 14 Letter Logic Channel 14 Number Logic Channel 15 Letter Logic Channel 15 Number Reset History View History Number of Analog Channels Samples After Trip Logic Word Channel Programming Fault Clear History Fault Message Pointer Fault Number

Type Minimum Maximum IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IL IL IN IN ON ON IL IN IN 0 0 -1 1 0
Refer 2.3
Default 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 0 0 10 20
Scaling
L = 76
64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 0 0 1 0
90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 1 1 10 100
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
L = 76
1% = 1
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Variable L3565 L3566 L3567 L3568 L3569 L3570 L3571 L3572 L3573 L3574 L3575 L3576 L3577 L3578 L3579 L3580 L3581 L3582 L3583 L3584 L3585 L3586 L3587 L3588 L3589 L3590 L3591 L3592 L3593 L3594 L3595 L3596 L3597 L3598 L3599 L3600 L3601 L3602 L3603 L3604 Description
Re Enable Upload Not Used Number of Samples Scans per Sample Max Number of Buffers Buffer Status 0 Buffer Status 1 Buffer Status 2 Buffer Status 3 Buffer Status 4 Buffer Status 5 Buffer Status 6 Buffer Status 7 Not Used History Startup Slow Real Time History Pointer Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Number of Analog Stimulation Channels Number of Logic Stimulation Channels Stimulation Logic Channel Analog Stimulation Channel 0 Letter
Module 35V2
Type Minimum Maximum IL 0 1 Default 0 Scaling
ON IN IN ON ON ON ON ON ON ON ON 1 2 100 2 1 2
IL ON ON
0
1 ms = 1000
IN IN ON IN
1 1
10 16
10 16
64
90
76
L = 76
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Module 35V2
Variable L3605 L3606 L3607 L3608 L3609 L3610 L3611 L3612 L3613 L3614 L3615 L3616 L3617 L3618 L3619 L3620 L3621 L3622 L3623 L3624 L3625 L3626 L3627 L3628 L3629 L3630 L3631 L3632 L3633 L3634 L3635 L3636 L3637 L3638 L3639 L3640 L3641 L3642 L3643 L3644 L3645 Description
Analog Stimulation Channel 0 Number Analog Stimulation Channel 1 Letter Analog Stimulation Channel 1 Number Analog Stimulation Channel 2 Letter Analog Stimulation Channel 2 Number Analog Stimulation Channel 3 Letter Analog Stimulation Channel 3 Number Analog Stimulation Channel 4 Letter Analog Stimulation Channel 4 Number Analog Stimulation Channel 5 Letter Analog Stimulation Channel 5 Number Analog Stimulation Channel 6 Letter Analog Stimulation Channel 6 Number Analog Stimulation Channel 7 Letter Analog Stimulation Channel 7 Number Analog Stimulation Channel 8 Letter Analog Stimulation Channel 8 Number Analog Stimulation Channel 9 Letter Analog Stimulation Channel 9 Number Logic Stimulation Channel 0 Letter Logic Stimulation Channel 0 Number Logic Stimulation Channel 1 Letter Logic Stimulation Channel 1 Number Logic Stimulation Channel 2 Letter Logic Stimulation Channel 2 Number Logic Stimulation Channel 3 Letter Logic Stimulation Channel 3 Number Logic Stimulation Channel 4 Letter Logic Stimulation Channel 4 Number Logic Stimulation Channel 5 Letter Logic Stimulation Channel 5 Number Logic Stimulation Channel 6 Letter Logic Stimulation Channel 6 Number Logic Stimulation Channel 7 Letter Logic Stimulation Channel 7 Number Logic Stimulation Channel 8 Letter Logic Stimulation Channel 8 Number Logic Stimulation Channel 9 Letter Logic Stimulation Channel 9 Number Logic Stimulation Channel 10 Letter Logic Stimulation Channel 10 Number

Type Minimum Maximum IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 99999 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 Default 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501 76 3501
L = 76 L = 76 L = 76 L = 76 L = 76 L = 76 L = 76 L = 76 L = 76 L = 76 L = 76 L = 76 L = 76 L = 76 L = 76 L = 76 L = 76 L = 76 L = 76 L = 76
Scaling
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Variable L3646 L3647 L3648 L3649 L3650 L3651 L3652 L3653 L3654 L3655 L3656 L3657 L3658 L3659 Description
Logic Stimulation Channel 11 Letter Logic Stimulation Channel 11 Number Logic Stimulation Channel 12 Letter Logic Stimulation Channel 12 Number Logic Stimulation Channel 13 Letter Logic Stimulation Channel 13 Number Logic Stimulation Channel 14 Letter Logic Stimulation Channel 14 Number Logic Stimulation Channel 15 Letter Logic Stimulation Channel 15 Number Select Stimulation Inputs Old Select Stimulation Inputs Recording Stimulation Test Stimulation Test Passed
Module 35V2
Type Minimum Maximum IN IN IN IN IN IN IN IN IN IN IL OL OL IL 0 1 0 64 0 64 0 64 0 64 0 64 0 0 90 99999.99 90 99999.99 90 99999.99 90 99999.99 90 99999.99 1 Default 76 3501 76 3501 76 3501 76 3501 76 3501 0
L = 76 L = 76 L = 76 L = 76
Scaling
L = 76
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Module 35V2
Figure 14-18 Module 35, Slow History Record
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Module 40
14.11
Module 40
Cyclic Test, Module 40

Description The cyclic test module is used to generate a speed reference which is varied and at different ramp rates. The reference is increased over a specified time period then brought back to a base level. Once the reference has reached its maximum level it is then taken to zero and the cycle is repeated. Table 4.32: Module 40 (Ref L40V1) Cyclic Test Module
Table 14-11 Module 40(V1), Cyclic Test
14.11.1
Variable L4000 L4001 L4002 L4003 L4004 L4005 L4006 L4007 L4008 L4009 L4010 L4011 L4012 L4013 L4014 L4015 L4016
Description
Time Period Test Enable Rate Increment Reference Increment Ramp Rate Max Rate Min Rate Speed Reference Max Reference Min Reference Present Speed Reference Stage Time Count Seconds Counter Stage First Time Deselect Negative Cycle
Type Minimum ON IL IN IN ON IN IN ON IN IN ON IN ON ON ON OL IL 0 0% 0% 0% 0 sec 0 %/S 0 %/S 0 0 %/s 0%
Maximum
Default
secs
Scaling
1 +3276.7 %/s +327.67%
0 0 %/s 0%
100 %/s = [103] 100% = [104] 100 %/s = [103]
+3276.7 %/S +3276.7 %/S
0 %/s 0 %/s
100 %/s = [103] 100 %/s = [103] 100% = [104]
+327.67% +327.67% +327.67% 32767 sec
0% 0% 0% 0 sec
100% = [104] 100% = [104] 100% = [104] 1 = 1 sec 1[103] = 1 msec 1 = 1 sec
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Module 40
Figure 14-19 Module 40(V1), Cyclic Test
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Module 44
14.12
Module 44
Staircase Smoothing, Module 44

Description The staircase smoother modules contains three general purpose smoothers that can be used to average out an input over a number of scan time steps. The operation of the smoother is described by the smoothing algorithm shown on the module specification diagram.
Table 14-12 Module 44, Staircase Smoothing
14.12.1
Description
Repetition Period Input 1 Output 1 Old Input 1 Total Steps 1 Present Step 1 Input 2 Output 2 Old Input 2 Total Steps 2 Present Step 2 Input 3 Output 3 Old Input 3 Total Steps 3 Present Step 3
Type Minimum Maximum ON IN ON ON IN ON IN ON ON IN ON IN ON ON IN ON 0 500 -32760 +32760 0 500 -32760 +32760 0 500 -32760 +32760
Default
Scaling
1 ms = 1000
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Module 44
Figure 14-20 Module 44, Staircase Smoothing
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Module 47
14.13
Module 47
Position Measurement, Module 47

Description The Position Measurement module generates a scaled position output as a function of a position transducer feedback. A datum set feature allows the re-initialisation of the position output. Use of preserved RAM for datum memory allows position output recovery after a power off/on situation. Protection features detect :
On power-up, the Valid Position Measurement flag (L4709) is cleared to zero. This
14.13.1
can be set again without the need for a new Datum Set by setting the Revalidate Position Measurement flag (L4703) high.
An abnormal change in position output from one scan to the next.
14.13.2
Features Datum Setting Datum Set Memory (L4720) is set HIGH on a LOW to HIGH transition of Datum Set (L4702) or Revalidate Position Memory (L4703); and is reset LOW via Reset 1 (L4704) or Reset 2 (L4705). A LOW to HIGH transition of Datum Set (L4702) updates Datum Memory (L4719) and clears Position Feedback in preserved memory (L4707). Power Off Operation Provided the position transducer is at rest when the controller is powered off and the transducer is not moved then Position feedback is recovered on power on. Position Feedback IN Use (L4719) is updated from preserved RAM. Excess Position Change Detection If the change in position feedback is greater than the Maximum Position Change Per Scan (L4716) then the new position is rejected and Excessive Position Change Per Scan (L4718) is set. If the number of consecutive measurements rejected exceeds the trip setting Number of Scans L4718 High (L4717) then Position Feedback Healthy (L4708) is set LOW. A LOW to HIGH transition of Datum Set (L4702) or Revalidate Position Measurement (L4703) will mask the excess position change check, and reset the Position Feedback Healthy to HIGH. Position Feedback for Display Position Feedback to Display (L4726) enables the position feedback to be scaled down. Feedback at L4726 is scaled according to the Divisor for the Secondary Scale (L4711) if the absolute value of Position Feedback (L4706) is greater than Scale Change level (L4713). Secondary Scale Selected (L4712) indicates whether the secondary display scaling is being used.
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Module 47
14.13.3 Application Notes Position feedback Scaling The Position Feedback is defined to be : L4701 x L4710 + Datum Memory L4714 x L4727 Where :
L4701 is the Transducer Feedback. (2 x 109) L4710 is the Normal Scaled Value for 1 revolution. (0-104) L4714 is the Transducer Value for 1 revolution. (103-106) L4727 is the Divisor (1-1000) Datum Memory is a record of Position Feedback Datum. (L4715) when the value of Datum Set (L4702) last went from low to high. (1 x 108) Figures in brackets give the range of the variables. The scaling divisor allows the feedback to be scaled with a much higher resolution than that required for control and prevents errors accumulating over many turns of the feedback transducer. Example Suppose a screw-down with total travel 2 m is required to be controlled to an accuracy of 1 m. A pulse encoder is used as the feedback transducer. Let 1 revolution of the feedback transducer = 1255.5 m. The bi-phase pulse-train encoder has 2500 lines (nb. 4 edges are read for each line giving 10000 for each revolution). The accuracy in one revolution is therefore at least 0.125 m. Let Normal Scaled Value for 1 revolution (L4710) = 1255.5 so that each revolution is measured accurately. Transducer Value for 1 revolution (L4714) = 10000 Divisor (L4727) = 1 gives a feedback resolution of 1 bit = 1 m for control. The Position Feedback Datum (L4715) can be set in the range 1 x 108m.
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Table 14-13 Module 47(V1), Position Measurement
Module 47
Description
Repetition Period Transducer Feedback Datum Set Revalidate Position Measurement Reset 1 Reset 2 Position Feedback Scaled Position Feedback Position Feedback Healthy Valid Position Measurement Normal Scaled Value For 1 Rev Divisor For Secondary Scale Secondary Scale Selected Scale Change Level Transducer Value For 1 Rev Position Feedback Datum Max Position Change Per Scan No. Of Program Scans L4718 High Excessive Position Change Per Scan Position Feedback Datum In Use Datum Set Memory Position Feedback Primary Scaler Freeze Position Feedback System Powered Up Not Used Not Used Position Feedback To Display Divisor Not Used Not Used Not Used
Type Minimum Maximum ON IN IL IL IL IL ON ON OL OL IN IN OL IN IN IN IN IN OL ON OL IN OL OL 1 1000 0 1000 -1 x 10 0 0

8
Default
Scaling
1 ms = 1000
-2.1 x 109 2.1 x 104 0 0 0 0 1 1 1 1
0 0 0 0 0
0 1
10000 1000
0 10
1 = 105
1000000 1000000 1 x 10
8
0 1000 0 0 0
1000000 1000
10
ON IN 1 1000 1
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Module 47
Figure 14-21 Module 47(V1), Position Measurement
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Module 48
14.14
Module 48
Position Control, Module 48

Description The Position Control module calculates the difference between a reference input and a position feedback. Forward path compensation terms enable control of static and dynamic position controls. ie. position control maintained at zero or non-zero speed. A combined position reference is generated from various reference inputs and is updated via a position reference memory. A unidirectional approach feature allows the final position to be approached from one direction only, reducing any errors due to backlash. The module can also be used for Mean and Differential Position Control if two position measurement systems are being used.
14.14.1
14.14.2
Features Position Reference Gain The Total Position reference (L4814) is the sum of coarse and normal references ({if they are selected by L4816 being set HIGH, or L4805 being set LOW respectively). The normal reference is the sum of Position Ref Input 2 (L4808) and Position Ref Input 3 (L4810) (if they are not deselected by L4807 or L4809 respectively being set HIGH) minus Position Ref Input 1 (L4806). The normal reference is subject to scaling by Normal Reference Scaling (L4811). The coarse reference is the sum of Coarse Position Ref Input 2 (L4819) and Coarse Position Ref Input 3 (L4821) {if they are not deselected by L4818 or L4820 respectively being set HIGH} minus Coarse Position Ref Input 1 (L4817). The coarse reference is subject to scaling by Coarse Reference Multiplier (L4822). Position Reference Memory (L4815) is updated to be the Total Position Reference when Position Update (L4824) is HIGH. Static Position Control Provided Datum Set (L4801) and Select Position Control (L4802) are both set HIGH then the Actual Position Error (L4853) is multiplied by Position Control Gain (L4835) and output as Speed Reference (L4830). Speed Reference is taken via a shaper to produce the Shaped Speed Reference (L4831). The shaper can be used to provide a top speed limit and maintain maximum deceleration rate, consistent with power available, as the drive moves into position. Dynamic Position Control Provided Datum Set (L4801) and Select Position Control (L4802) are both set HIGH then the Actual Position Error (L4853) is modified by the dynamic position control transfer function and output as Speed Trim (L4832).
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Module 48
Unidirectional Approach
If Select Unidirectional Approach (L4827) is HIGH then the position is forced to overshoot by Overshoot Bias (L4839). Zero Position Error is only set HIGH when the drive is positioned within Zero Position Error Detection (L4840) bits of the reference. 14.14.3 Application Notes Scaling Shaped Speed Reference (L4831) is scaled 10000 [100%] = top drive speed (1pu). Scaling of the position feedback is dependent upon the accuracy and range required on a particular application. Per unit feedback is defined as the distance traveled in 1 second at top drive speed. For the example given in the Product Specification Application Notes for module 47, if top drive speed is 1 m/min, 1 pu feedback = 16666. Assuming unity gain on the shaper, the bandwidth of the position control is the result of : L4835 = 16666 r/s 10000 so a link statement L4835 = 3 produces a position control bandwidth of 5 r/s. No account so far has been taken of drive power limits. Assuming constant retarding torque, a maximum deceleration rate must not be exceeded. Since: dN = dN . dp dt dp dt where: N = speed and p = position. Shaper gain (dN/dp) must be programmed to be less than or equal to: maximum deceleration rate speed This defines the shaper characteristic as a square root function. The following shaper parameters construct a typical normalized square root function. X1 (L4841) = 2 X2 (L4843) = 6.5 X3 (L4845) = 20 X4 (L4847) = 60 X5 (L4849) = 100 Y1 Y2 Y3 Y4 Y5 (L4842) = 10 (L4844) = 23 (L4846) = 44 (L4848) = 80 (L4850) = 100
Equivalent negative values are required to set up L4854 to L4863. If the maximum deceleration of the drive in our example is defined as top speed to rest in 3s, then position error at start of deceleration = 16666 x 3 = 25000 2
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Note:
Module 48
It is important that this figure is less than 108 since the position control only operates on the limited position error (L4853).
The Position Control Gain (L4835) can now be used to adjust the actual position error to the normalized square root function. ie. L4835 = 10000 = 0.4 25000 Since the maximum gain of the normalized square root function is 5, the small signal bandwidth of the position control is now 3.3 r/s.
Table 14-14 Module 48(V1), Position Control
Description
Repetition Period Datum Set Select Position Control 1 Apply Position Ref Test Input Deselect Normal Ref Position Ref Input 1 Deselect Position Ref Input 2 Position Ref Input 2 Deselect Position Ref Input 3 Position Ref Input 3 Normal Reference Scaling Maximum Limit Minimum Limit Total Position Ref Position Ref Memory Select Coarse Ref Coarse Pos Ref Input 1 Deselect Coarse Pos Ref Input 2 Coarse Pos Ref Input 2 Deselect Coarse Pos Ref Input 3 Coarse Pos Ref Input 3 Coarse Ref Multiplier Not Used Position Update Not Used Not Used Select Unidirectional Approach Maximum Speed Limit Minimum Speed Limit Speed Reference
Type Minimum Maximum ON IL IL IL IN IL IN IL IN IL IN IN IN IN ON ON IL IN IL IN IL IN IN 0 0 0 -1 x 10 0 -1 x 10 0 -1 x 108 0 -1 x 10 1024 0 -1 x 10 -1 x 10 -1 x 10 0 -32767 0 -32767 0 -32767 1

8 8 8 8 8 8
Default
Scaling
1 ms = 1000
1 1 1 1 x 10 1 1 x 10 1 1 x 108 1 1 x 10
8 8 8
0 0 0 0 0 0 0 0 0 0 4096 0 0
8 8
4096 1 x 10 0 1 x 10 1 x 10 1 32767 1 32767 1 32767 100

8
0 0 0 0 0 0 0 100 1
IL
IL IN IN ON
0 0 -100%
1 100% 0
1 100% -100%
100% = 10000 100% = 10000 100% = 10000
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Module 48
Shaped Speed Reference Speed Trim Position Overshoot On Zero Position Error Position Control Gain Integrator Constant Lead Time Constant Trim Speed Limit Overshoot Bias Zero Position Error Detection Shaper Co-Ordinate X1 Shaper Co-Ordinate Y1 Shaper Co-Ordinate X2 Shaper Co-ordinate Y2 Shaper Co-ordinate X3 Shaper Co-ordinate Y3 Shaper Co-ordinate X4 Shaper Co-ordinate Y4 Shaper Co-ordinate X5 Shaper Co-ordinate Y5 Apply Position Ref Memory Not Used Actual Position Error Shaper Co-ordinate -X1 Shaper Co-ordinate -Y1 Shaper Co-ordinate -X2 Shaper Co-ordinate -Y2 Shaper Co-ordinate -X3 Shaper Co-ordinate -Y3 Shaper Co-ordinate -X4 Shaper Co-ordinate -Y4 Shaper Co-ordinate -X5 Shaper Co-ordinate -Y5 Unidirection Minimum Level Not Used Not Used Unidirection Homed Bias Within Unidirection Homed Bias Position Feedback Input 1 Deselect Position Feedback Input 2 Position Feedback Input 2 Deselect Position Feedback Input 3 Position Feedback Input 3

Type Minimum Maximum ON ON OL OL IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN OL -1 x 108 -100% -100% -100% -100% -100% -100% -100% -100% -100% -100% 0 1 x 108 0 0 0 0 0 0 0 0 0 0 32767 0 0 0 0 0 0 0 0 -100% -100% 0
100% = 10000 100% = 10000 100% = 10000 100% = 10000 100% = 10000 100% = 10000 100% = 10000 100% = 10000 100% = 10000 100% = 10000 On For Zero Error
Default
Scaling
100% = 10000 100% = 10000
0 0.1 sec 1 sec 0 -32767 0 0 0 0 0 0 0 0 0 0 0
100.000 1 sec 10 sec 100% 32767 10000 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
5.000 0.1 sec 1 sec 10% 0 0 0 0 0 0 0 0 0 0 100% 100%
1 = 1000 1 sec = 1000 1 sec = 1000 100% = 10000
100% = 10000 100% = 10000 100% = 10000 100% = 10000 100% = 10000 100% = 10000 100% = 10000 100% = 10000 100% = 10000 100% = 10000
ON IN IN IN IN IN IN IN IN IN IN IN
IN OL IN IL IN IL IN
0 -1 x 108 0 -1 x 10 0 -1 x 10
8 8
32767 1 x 108 1 1 x 10 1 1 x 10
8 8
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Variable L4874 L4875 L4876 L4877 L4878 L4879 L4880 L4881 L4882 L4883 L4884 L4885 L4886 L4887 L4888 L4889 L4890 L4891 L4892 L4893 L4894 Description
Position Feedback Scaling Scaled Position Feedback First Deselect Shaped Speed Ref 2 Second Deselect Shaped Speed Ref 2 Shaped Speed Ref 2 Negated Shaped Speed Ref 2 Deselect Shaped Speed Ref 1 Shaped Speed Ref 1 Position Control Request 2 Request Run Ultimate Limit Switch 1 Operated Ultimate Limit Switch 2 Operated Permit Backout Backout PB Operated Select Position Control request Ultimate Limits Healthy Request Run Request Jog Forward Request Jog Reverse Position Feedback Error Detection Position Feedback Error
Module 48
Type Minimum Maximum IN ON IL IL ON ON IL ON IL IL IL IL IL IL OL OL OL OL OL IN OL 0 10000 0
On For Error Detected
Default 4096
Scaling
1024 -1 x 10 0 0
8
4096 1 x 10 1 1
8
0 0
100% = 10000 100% = 10000
0
100% = 10000
0 0 0 0 0 0
1 1 1 1 1 1
0 0 0 0 0 0
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Module 48
Figure 14-22 Module 48(V1), Position Control (sht. 1)
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Module 48
Figure 14-23 Module 48(V1), Position Control (sht 2)
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Module 48
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Module 48
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Module 53
14.15
Module 53
HDLC Driver, Module 53

Features
2 links per card HDLC (up to 180k) Up to 3 secondaries per link Table exchange Broadcast with response Broadcast without response
14.15.1
14.15.2
Overview The HDLC Enhancement Card is a serial communications card which is used for communicating with other drives, and any GEM80 with a Starnet card. The basic mode of communication uses HDLC (Normal Response Mode subset). The HDLC card provides 2 links at up to 180k baud rate, with up to 3 secondaries per link. The HDLC enhancement card is designed to fit in with the SIGMA philosophy. It uses EEPROM to hold enhancement card configuration data, and downloads the majority of its code from the SIGMA core board. A total of 4 HDLC Enhancement Cards may be used in any 1 system (i.e. if all available slots for enhancement cards are used for HDLC communications). If more than one card is required then the HDLC driver module (module 53) must be duplicated using the DEF MODULE statement.
14.15.3
Protocols Synchronous Operation Frequency of Operation Encoding Methods : HDLC protocol : 180 kbaud 48 kbaud : NRZI FM0 FM1 : Broadcast [up to 100 data tables] Data Table Exchange [up to 100 data tables per secondary] Broadcast with response The HDLC card cannot be used as a master in broadcast modes, i.e. it can only receive broadcasts.
Port Type
Note:
Can multi-drop to up to 3 secondaries when configured as a primary. Note that in this configuration the other port cannot be used, since the card will only support connections to three other ports. Page 14-88 Alspa GD4000 Issue (12-2-98)
Module 53
Can be one of up to 31 secondaries connected on the serial link (depending on the capability of the master). Table exchange the master polls each of the secondaries in turn, transferring data tables to the secondary and receiving data tables back. the master (e.g Starnet) sends the same block of tables to all slaves by setting the broadcast bit in the message, and receives a block of tables from one slave at a time. The address in the broadcast message defines which slave is to respond. the master (Starnet) sends the same block of tables to all slaves. No response is given from the slaves.
Broadcast with response
Broadcast without response 14.15.4 Application Notes Module Entry
The HDLC driver is called by one of two methods, depending on the issue of firmware. The SIGMA Firmware issued before the 1st quarter 94 did not make use of the DEF ENHANCEMENT and DEF MODULE statements. See the appropriate section for the necessary implementation. No DEF ENHANCEMENT Only a single HDLC card can be used, and can be placed in any enhancement slot. The module is called by used of the GDMMOD special function in ladder. DEF ENHANCEMENT available The position of the card in the SIGMA enhancement slots is defined by the DEF ENHANCEMENT statement, as follows: DEF EXPANSION Description, Application module number, Position number Where: Description is a description of the card Application module number is 53. If more than one card is to be used then the DEF MODULE statement must be used to define the duplicate module number, and this number must be referenced in the DEF EXPANSION statement Position is the card position as defined in the SIGMA Product Data section on enhancement cards The DEF ENHANCEMENT statement must follow the DEF MODULE statement The Ladder program does not need to call the module with the GDMMOD special function.
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Module 53
14.15.5 Configuration For each link, configure: a) b) c) d) e) Link address (0 - 4) Number of partners Port type. Interface mode Table addresses
(details differ slightly according to type of port, see table)

Module Input L5302,9 HDLC Link address (0 for primary) (1..31 for secondary) Number of partners on the link 1..4 for primary 1 for secondary Port Type 0 - Port Not in Use 1 - 48 kbps NRZI 2 - 48 kbps FM0 3 - 48 kbps FM1 4 - 180 kbps NRZI 5 - 180 kbps FM0 6 - 180 kbps FM1 L5305,12 L5306,13 L5307,14 Not used Not used Interface mode -1 = table exchange +1= broadcast, no response +2 = broadcast with response
L5303,10
L5304,11
The addresses for the source of outgoing data and destination of incoming data are set for the start and end of the appropriate table.
Link 0 as Master Input Table addresses Table L5316 L5317 L5320 L5321 L5324 L5325 L5328 L5329 Desc. Start End Start End Start End Not Allowed Output Table addresses Table L5318 L5319 L5322 L5323 L5326 L5327 L5330 L5331 Desc. Start End Start End Start End Sec. 1 Sec 2 Sec. 3 Sec Link 1 as Master Input Table addresses Table L5332 L5333 L5336 L5337 L5340 L5341 L5344 L5345 Desc. Start End Start End Start End Not Allowed Output Table addresses Table L5334 L5335 L5338 L5339 L5342 L5343 L5346 L5347 Desc. Start End Start End Start End Not Allowed
Not Allowed Sec
Link 0 as Secondary Input Table addresses Table L5316 L5317 Desc. Start End Output Table addresses Table L5318 L5319 Desc. Start End
Link 1 as Secondary Input Table addresses Table L5332 L5333 Desc. Start End Output Table addresses Table L5334 L5335 Desc. Start End
To configure the port, the tables given above are set up, and then the configure flag (L5301) is set high. The low to high transition of this line implements the configuration. Page 14-90 Alspa GD4000 Issue (12-2-98)

If no data is set up then the default values are used. If the port type = 0 then the configuration data is ignored. If there is a fault in the configuration, then the following bits are set in the configuration fault word (L5352)
Bit 0 1 2 3 4 5 6 7 Description Configuration error Link 0 invalid config. data Link 1 invalid config. data Link 0 invalid table address Link 1 invalid table address Link 0 invalid data table length Link 1 invalid data table length Not configured Hex Value @1 @2 @4 @8 @10 @20 @40 @80
Module 53
The fault word is cleared when there is a valid reconfiguration 14.15.5.1 Data Table Exchange Outgoing data Outgoing data is sent by setting the transmit length for the appropriate secondary to a non zero number. Data is transferred from the data tables specified by table address in the configuration tables across to the HDLC card transmit buffers. If the transmit length is zero then no data is transmitted. If the transmit length exceeds the relevant data table length then the actual data table length is used. No error is generated. Incoming Data Incoming data is transferred from the HDLC receive buffer into the appropriate incoming data table. The receive length is set for the appropriate link/secondary. If the number of data variables received exceeds the data table length, then only the defined number of tables are transferred. If the number of tables received is less than the data table length, then the remaining data in the table is left unchanged. The receive length can be set to zero by the user as an indication to the user program that the latest data has been processed. The receive length is set to zero if the appropriate secondary is not used.
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Module 53
Link 0 as Master Transmit length L5353 L5354 L5355 L5356 Receive Length L5361 L5362 L5363 L5364 Sec 1 Sec. 2 Sec. 3 Not Allowed Link 1 as Master Transmit Length L5357 L5358 L5359 L5360
Receive Length L5365 L5366 L5367 L5368
Link 0 as Secondary Transmit length L5353 Receive Length L5361
Link 1 as Secondary Transmit Length L5357 Receive Length L5365
14.15.6
Statistics The following statistics are maintained for each secondary:

Module Input L5382 L5383 L5384 L5385 L5387 L5388 L5389 L5390 L5391 HDLC Number of frames acknowledged Number of messages Number of CRC failures Number of length errors L5386 Number of timeouts Number of times Buffer exhausted Number of data re-transmitted Number of times link reconnected
The statistics for a required link/ secondary are selected by defining the link required (0 or 1) and the secondary required (0 to 3) Link required Secondary Required Statistics valid : : : L537 L5380 L5381
The data for the appropriate link is transferred from the HDLC cards statistics table into the given data tables. An output table indicates when the data is valid (1 = valid, 0 = not valid). If the selected link/secondary is not configured then the tables will not be updated and the valid flag will remain at 0. 14.15.7 Initialization The initialization process transfers the operating code from the main RAM on the control side over to the HDLC cards RAM. Certain checks are also made on the memory of the card. Various self tests are performed at initialisation to determine the integrity of the card and the interface between the HDLC card and the main control board. Failure of the self tests sets the hardware fault flag, L5350
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14.15.8 Self Tests Tests On Initialization The following tests are performed on initialisation:
Module 53
- Card is present - Dual port RAM healthy - Card is healthy. This is a result of self tests performed by the card itself. These include: - Dual port RAM healthy - Internal RAM healthy - Internal ROM healthy - Serial Comms controller hardware healthy - Card is correct type (HDLC) Tests Whilst Running The following checks are performed as part of a background check -Handshake check
checks that the HDLC card and the main controller are still talking to one another. If
a failure occurs, serial link activity is suspended.

-Dual port RAM check. Checks that the interface between the main control board
and the HDLC card is correct. Serial link activity is suspended if there is a failure. Fault codes If hardware faults are detected during initialisation or whilst doing the background self checks then an appropriate bit is set in the hardware fault word, L5350. If a hardware fault is detected then further operation of the card is suspended. The fault can only be cleared by powering the board off and back on.
Bit set 0 1 2 3 4 5 6 7 8 9 10 11 12 13 Meaning HDLC Card fault (any of subsequent bits on) Core board Dual port RAM failure HDLC Dual port RAM failure HDLC ROM failure HDLC Static RAM failure, HDLC Serial Comms. chip failure HDLC Code CRC failure Handshake failure Card not present HDLC card hung up during initialisation tests HDLC card hung up during code download Background dual port RAM test failed Initialization in progress Enhancement card not HDLC Extra fault data
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Module 53
Application Code
The following notes are to aid in the application of the HDLC driver. Note: The terminology used for defining secondaries is: If the port is configured as a secondary, then the applicable data tables and statistics are referenced as secondary 0 If the port is defined as a primary port, then it talks to secondaries with addresses 1-4. Data tables referenced as secondary 0 contain the data for the first secondary, secondary 1 for the second, etc. Configuration Use ladder to configure the link on a recompile
+-|E0.6|(L5301)-+
The ladder should also be used to allocate the start and end addresses of the link I/O tables by means of the LOCATE special function e.g Link 0 configured as tributary. Input data table N0-N15; output table O0-030
+-<AND><SPEC>-<VALUE>(OUT)+ 0 LOCATE N0 +-<AND><SPEC>-<VALUE>(OUT)+ 0 LOCATE N15 +-<AND><SPEC>-<VALUE>(OUT)+ 0 LOCATE O0 +-<AND><SPEC>-<VALUE>(OUT)+ 0 LOCATE O30
L5316
L5317
L5318
L5319
The action of defining the data table in the user program also gets the compiler to allocate memory for the I/O tables. Sending data The transmit length word (L5353-L5360) defines the amount of data to send. The length of data sent can be less than the size of the output table. Note that the transmit length for a master must be set non zero to initiate communication. If the length is subsequently set to zero, no data is sent although HDLC communication will be maintained by the enhancement card. Note: SIGMA data tables are 32 bits.
When a data table is transferred it is truncated to 16 bits. If the upper word is required, then special function T42 (SWAPE) can be used to transpose the upper and lower 16 bits of a 32 bit SIGMA data table. When data is received the 16 bit word is sign extended and stored in the 32 bit SIGMA data table.
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Using the statistics
Module 53
The statistics can be referenced by defining the port number and the secondary number. If the port is configured as a secondary, then the statistics number is 0. If the port is configured as a primary, then statistics no. 0 gives the statistics for communication with the first tributary, 1 gives statistics for the second tributary etc. Connections The HDLC Enhancement card is fitted into the SIGMA moulding. The HDLC Interface card is mounted either on the Customer I/O board or elsewhere is the cubicle. The card requires a 25 way ribbon connection to the enhancement card, together with a 50 V connection, which can be either to the pick off point on the Customer I/O board or from the Power Supply (See Figure 14-26) Plant connections are as shown in the Figure. The last card in a chain needs to have the termination resistors fitted, as shown on Port 0 in the diagram.
Figure 14-26 HDLC Plant Connections
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Page 14-95
Module 53
Table 14-15 Module 53(V1), HDLC Driver
Variable L5300 L5301 L5302 L5303 L5304 L5305 L5306 L5307 L5308 L5309 L5310 L5311 L5312 L5313 L5314 L5315 L5316 L5317 L5318 L5319 L5320 L5321 L5322 L5323 L5324 L5325 L5326 L5327 L5328 L5329 L5330 L5331 L5332
Description
Healthy Configure Link Address 0 No Partners 0 Port Type 0 Reserved Reserved Interface Mode 0 Char (MODBUS) 0 Link Address 0 No Partners 0 Port Type 0 Reserved Reserved Interface Mode 0 Char (MODBUS) 0 Link 0/0 In Start Link 0/0 In End Link 0/0 Out Start Link 0/0 Out End Link 0/1 In Start Link 0/1 In End Link 0/1 Out Start Link 0/1 Out End Link 0/2 In Start Link 0/2 In End Link 0/2 Out Start Link 0/2 Out End Link 0/3 In Start Link 0/3 In End Link 0/3 Out Start Link 0/3 Out End Link 1/0 In Start
Type Minimum Maximum OL IL IN IN IN ON ON IN IN IN IN IN ON ON IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN -1 2 0 1 0 31 4 27 -1 2 0 0 1 0 1 31 4 27
Default
Scaling
0 1 1
-1
1 1
-1
N0 N99 O0 O99 N0 N99 O0 O99 N0 N99 O0 O99 N0 N99 O0 O99
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Variable L5333 L5334 L5335 L5336 L5337 L5338 L5339 L5340 L5341 L5342 L5343 L5344 L5345 L5346 L5347 L5348 L5349 L5350 L5351 L5352 L5353 L5354 L5355 L5356 L5357 L5358 L5359 L5360 L5361 L5362 L5363 L5364 L5365 Description
Link 1/0 In End Link 1/0 In Start Link 1/0 In End Link 1/1 In Start Link 1/1 In End Link 1/1 In Start Link 1/1 In End Link 1/2 In Start Link 1/2 In End Link 1/2 In Start Link 1/2 In End Link 1/3 In Start Link 1/3 In End Link 1/3 In Start Link 1/3 In End Char (MODBUS) Char (MODBUS) Hardware Fault Fault Info Config. Fault Link 0/0 TX Len Link 0/1 TX Len Link 0/2 TX Len Link 0/3 TX Len Link 1/0 TX Len Link 1/1 TX Len Link 1/2 TX Len Link 1/3 TX Len Link 0/0 RX Len Link 0/1 RX Len Link 0/2 RX Len Link 0/3 RX Len Link 1/0 RX Len
Module 53
Type Minimum Maximum IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN ON ON ON IN IN IN IN IN IN IN IN ON ON ON ON ON 0 0 0 0 0 0 0 0 100 100 100 100 100 100 100 100 Default Scaling
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Module 53
Variable L5366 L5367 L5368 L5369 L5370 L5371 L5372 L5373 L5374 L5375 L5376 L5377 L5378 L5379 L5380 L5381 L5382 L5383 L5384 L5385 L5386 L5387 L5388 L5389 L5390 L5391 L5392 L5393 L5394 L5395 L5396 Description
Link 1/1 RX Len Link 1/2 RX Len Link 1/3 RX Len Timeout Val L0 Timeout Val L1 Link 0/0 Timeout Link 0/1 Timeout Link 0/2 Timeout Link 0/3 Timeout Link 1/0 Timeout Link 1/1 Timeout Link 1/2 Timeout Link 1/3 Timeout Link Stats Select Sec Stats Select Stats Valid Statistics - Frames Ack Statistics - Messages Statistics - Crc Failures Statistics - Length Errors Statistics - Sequence Fail Statistics - Timeouts Statistics - Buffer Exh. Statistics - Retransmissions Statistics - Reconnections Statistics Resevered Reserved Reserved CRC Data 186

Type Minimum Maximum ON ON ON IN IN IN IN IN IN IN IN IN IN IN IN ON ON ON ON ON ON ON ON ON ON ON IN IN IN IN IN 0 0 1 3 Default Scaling
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Alspa GD4000
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Module 53
Figure 14-27 Module 53(V1), HDLC Driver
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Alspa GD4000
Page 14-99
Module 55
14.16
Module 55
Linear Conversion, Module 55

Description The linear conversion module contains three general purpose linear conversion functions and two general purpose filters. These can be used to scale and filter a variety of signals according to the required application.
Table 14-16 Module 55(V1), Linear Conversion
14.16.1
Variable L5500 L5501 L5502 L5503 L5504 L5505 L5506 L5507 L5508 L5509 L5510 L5511 L5512 L5513 L5514 L5515 L5516 L5517 L5518 L5519 L5520 L5521
Description
Repetition Period Input 1 Input 2 Input 3 Output 1 Output 2 Output 3 Offset 1 Offset 2 Offset 3 Multiplier 1 Multiplier 2 Multiplier 3 Divisor 1 Divisor 2 Divisor 3 Filter 1 Input Filter 2 T.C. Filter 1 Output Filter 2 Input Filter 2 T.C. Filter 2 Output
Type Minimum Maximum ON IN IN IN ON ON ON IN IN IN IN IN IN IN IN IN IN IN ON IN IN ON -150% 0 +150% 0.5 sec. -32767 -32767 -32767 -32767 -32767 -32767 1 1 1 -150% 0 +32767 +32767 +32767 +32767 +32767 +32767 +32767 +32767 +32767 +150% 0.5 sec. -32767 -32767 -32767 +32767 +32767 +32767
Default
Scaling
0 0 0
0 0 0 0 0 0 1 1 1 0 0
104 = 100% 104 = 1 sec.
0 0
104 = 100% 104 = 1 sec.
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Alspa GD4000
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Module 55
Figure 14-28 Module 55(V1), Linear Conversion
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Alspa GD4000
Page 14-101
Module 80 (V2)
14.17
Module 80 (V2)

Introduction Module 80 is a clone of module of module 92 and is not required by the standard user program. For details of the PID function refer to Section 7.10.1. For details of speed/torque loop tuning (configuring Ki and Kp) refer to section 6.5.6.1.
14.17.1
Description
Scan time release reg freeze id reference feedback output filtered speed test input o/p fforward in max limit in min limit prop gain intgl gain deriv gain max o/p limit min o/p limit time constant unltd o/p enable filter total unlim user freeze ID Sel user freeze user ref Sel user ref feed forward 2 freeze in limit output lim 1 output lim 2 output ref 1 output ref 2 o/p rate limit
Type Minimum Maximum ON IL IL IN IN ON ON IN IN OL OL IN IN IN IN IN IN ON IL ON IL IL IN IL IN IL OL IL IL IL IL IN -2

31
Default 0 0 0 0 0 0 0 0 0 0 0 2000 10 0 10000 -10000 500 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1000

104 = 100% 1 = select 104 = 100% 1 = freeze 1 = select 104 = 100% 1 = select 104 = 100% 1 = freeze 1 = in limit 1 = limit 1 = limit 0 = limit 0 = limit 104 = 100% 104 = 100% 10 = 1 ms 1 = release 1 = frozen 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 1 = in limit 1 = in limit
3
Scaling
31
0 0 -40000 -40000 -40000 -231 -10000 -40000 0 0 0 0 0 0 -10000 0 -2

31
1 1 40000 40000 40000 231 10000 40000 1 1 232 232 2

32
10000 0 1000 2
31
0 -2
31
1 2
31
0 0 -40000 0 -40000 0 0 0 0 0 0 0
1 1 40000 1 40000 1 1 1 1 1 1 20000
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Module 80 (V2)
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Page 14-103
Module 81
14.18
Module 81
Rotor Time Constant Compensator, Module 81

The power developed by an induction motor is a function of the voltage developed across the rotor resistance. However, resistance is a quantity that will vary with temperature. As a result one can say that for a fixed voltage across the rotor resistance the power developed will vary with temperature changes. The aim of module 81 and module 281, when drive configured as fast task type 1, is to estimate the rotor resistance. The estimation process utilises 2 methods, the VA and VArs methods. The speed of the motor influences the choice of method employed. Below 50% base speed the VArs method is used and the VA method for speeds above this. To stop dither at the 50% base speed point the module the hysteresis threshold can be set in L8103. Both methods employ input averaging and can be controlled by L8108. As the rotor resistance will vary relatively slowly compared to scan times a computation rate variable is also available to the user. To stop the tracker value (L8102) wandering, both torque and frequency thresholds are selectable, below which the rotor resistance is frozen. L8106 is also available to the user allowing some control over the error value being summed with the current value of rotor resistance. The module can be disabled by setting L8101 = 0. Variable L9507 needs to be cleared also. Once this has been done the user can vary the rotor time constant by use of L9516 (rotor time constant offset)
Table 14-18 Module 81, Rotor Time Constant Compensation
Description
Scan time Sel tracker tracker hysteresis tracker used tracker in limit tracker gain Comp rate Samples/calc PHI gap sigmaLs torque cutoff freq cutoff
Type Minimum Maximum ON IL ON IN OL OL IN IN IN ON ON IN IN 0 1
Default
Scaling
1 L9403 50 0 0 1000 100 50 1 1 1000 0
1 = Select 1 = 1 m 1= 1/10 Hz 1 = VArs 1 = limit 100 = 1 pu 1 = 1 ms 1 = 1xL8100 100% = 10000 1 = 1 H 100% = 10000 100 = 1 Hz
L9403/8 2xL9403 10 0 0 00 0 10 0 0 0 0 100 1 1 5000 200 200 2 2

32 32
10000 1000
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Alspa GD4000
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Module 83 (V1)
Figure 14-30 Module 81, Rotor Time Constant Compensation
14.19
Module 83 (V1)
Drive Identification, Module 83 (Version 1)

Introduction Module 83 runs as the drive powers up, and checks various drive parameters against the hardware configuration present. If a mismatch occurs the module flags a warning and prevents the drive from running. To cure this problem the drive parameters in the links program must be changed and re-downloaded.
14.19.1
14.19.2
Operation This module takes inputs from Module 10 and produces only seven outputs, four of which are fault flags. The rest of the function of module 83 is hidden from the user and is concerned with configuring other modules. This information can not be altered other than by configuring the drive differently.
14.19.3
Drive Type The first parameter is Drive Type which comes from L1005. This parameter indicates the current rating of bridge B, and in the case of small drives should be written on the drive label. Valid drive types are given in the list below 4010, 4020, 4030, 4040, 4060, 4080, 4120, 4160, 4282, 4300, 4377, 4564, 4600, 4754, 4846, 4900, 41131.
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Page 14-105
Module 83 (V1)
Module 83 outputs a 1on L8305 if an incorrect drive type has been entered, and the drive type used is echoed to L8301. 14.19.4 DC Link Voltage DC link voltage, L8303, specifies the intended DC link maximum operating voltage. For drives sized 4160 and below this value is always assumed to be 800 volts. For the remaining drive sizes the table below indicates valid options
Drive Type 4282 4300 4377 4564 4600 4754 4846 4900 41131 Valid Link Ratings 800, 900 1200 800, 900 800, 900 1200 800, 900 800, 900 1200 800, 900
14.19.5
Delta Version Delta Version is copied from L1006, and refers to the version of Delta module fitted to large drives. For drives sized 4160 and below this value is ignored. There are 2 delta versions, version 1 and version 2. The table below indicates the valid delta type values for the various DC link voltage ratings.
DC Link Voltage 800 900 1200 Valid Delta Version 1 2 2
If there is an erroneous mix of drive type, DC link voltage and Delta version then wrong stack type (L8308) will be set to the value 1. 14.19.6 Fast Task Type Fast task type is a direct copy of L1007, fast task type wanted. Valid fast task types and their meanings are listed in the table below.
Fast Task Type 0 1 2 3 4 5 6 7 8 9 Bridge A Function Vector Machine bridge Vector Machine bridge Bridge B Function Vector Input Bridge Vector Machine bridge
Paralleled Vector Machine bridge Scalar Machine bridge Scalar Machine bridge Scalar Machine bridge Vector Input Bridge
Paralleled Vector Input Bridge Paralleled Scalar Machine bridge Vector Input Bridge Vector Machine bridge Scalar Machine bridge
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Issue (12-2-98)
Module 83 (V1)
Note that fast task types 7, 8 and 9 do not use bridge A at all, and are only available on 20X4486 and 20X4489 power interface boards. If the fast task type has been entered incorrectly into L1007, or is unsupported by the mix of drive type and DC link voltage, then wrong fast task (L8307) will be set to the value 1. The fast task type used is echoed to L8302. 14.19.7 Power Interface Board From the information available to it the drive is able to determine what power interface board (PIB) should be fitted. By interrogating the hardware it is able to detect what PIB is fitted. If the PIB type fitted does not correspond to type of PIB expected for the inputted mix of drive type, fast task type and DC link voltage, then wrong PIB found (L8306) will be set to a 1. Assumed PIB type (L8304) echos the PIB type detected by the drive.
Table 14-19 Drive Identification, Module 83 (V1)
Description
drive type used fast task used DC link rating assumed pib type wrong drive type wrong pib found wrong fast task wrong stack type
Type Minimum Maximum ON ON IN ON OL OL OL OL 4010 0 800 4460 0 0 0 0 41131 9 1200 4489 1 1 1 1
Default 4080 0 800 4486 0 0 0 0
Scaling
copied from L1005 copied from L1007 1=1V board 20X number 1 = fault 1 = fault 1 = fault 1 = fault
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Alspa GD4000
Page 14-107
Module 83 (V1)
Figure 14-31 Drive Identification, Module 83 (V1)
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Alspa GD4000
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Module 84 (V1)
14.20
Module 84 (V1)
Variable Voltage, Variable Frequency Control Bridge A, Module 84 (Version 1)

Operation L8401, L8402. Ramp up, ramp down rates. These parameters indicate the prevailing rates set by the ramp rate calculator block. These rates can be manually overridden by use of L8465. The maxima that can be attained by these variables are set using L8421 and L8424 inclusive. L8403 Ramp enabled. Indicates that the ramp block is enabled. L8404 , L8405 Frequency reference, frequency demand. This provides one of the 2 inputs for speed/frequency for the ramp generator. The output of which is frequency demand. The alternative input is L8434. L8406, L8407 Motoring and regeneration torque limit user defined per unit limits for maximum torque produced. L8408, L8409 Icos Motoring and regen current Icos is the system name for that part of the load current in phase with the stator voltage. In other words its the load current multiplied by the power factor. The parameters are displayed (in Amps) for reference calculated from L8406 and L8409. L8409 Base speed volts Specifies the voltage applied to the motor when it is running at base frequency. The value is usually given on the motor name plate. L8411, L8412 Icos and Irms feedback. Reference values calculated from the 3 phase current measurement system (module 15). Note that these are raw unfiltered values. Irms being the load current and Icos being the component in phase with the stator voltage. L8414 Base frequency specifies the frequency at which full volts (base volts) are applied to the motor. The value is usually given on the motor name plate. L8415 Power factor defines the level of in phase current at full load torque. The value is usually given on the motor name plate. L8416 Motor full load current. The value of load current at which maximum torque is achieved. The value is checked against drive type and the value limited if set too high. The value is usually given on the motor name plate. L8418 Motor full load speed defines the speed at which the motor turns when producing full load torque. The value is usually given on the motor name plate. L8419 Current limit. Defines the current level at which the software limits. The value is checked against drive type and the value limited if set too high. If set to -1 the value defaults to motor FLC (L8416). The operating limit is the smaller of drive rating, L8416 and L8419. L8420 Reverse Signal indicating when the motor is rotating in the reverse direction. At present the signal is taken from L8404 changing sign. L8421 - L8424 Rate limits. Defines the absolute maximum ramp rates applied to the ramp generator. Rates can be set individually in both forward and reverse directions when accelerating or decelerating.
14.20.1
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Page 14-109
Module 84 (V1)
L8425 Regen power limit. Defines the per unit value for the power when regenerating. L8426 Stop. Disables pulses to the motor at any stage of the starting/stopping sequences. L8427, L8428 Ramp up, down freeze indicate when the ramp generator is frozen due to limits imposed. L8429, L8430, L8431, L8463 Previous, next, current and pwm angle indicate the angle being applied to the pwm generator. The user need only confine himself to using L8463. L8435, L8437, L8466 Slip compensation, f comp, slip comp TC. Slip compensation system parameters. L8435 is a user input defining the slip frequency at full load. L8437 indicates the frequency added to L8405 as a compensation term. L8466 defines the time constant for the compensating system. L8436, L8438, L8464 Stability compensation, f stab, stability TC. Stability compensation parameters. L8436 is a user input defining a stability gain term. L8438 indicates the frequency added to L8405 as a stability term. The stabilizing frequency should be subtracted from the demand value. The diagram does not show this as it is inverted in the code. L8440 Current filter TC defines the time constant for the current filters used by the limit calculator. L8441 Select fan fluxing selects a square law fluxing curve for the motor. L8442 Total volts. This indicates the total voltage applied to the motor. The total can comprise 3 parts. The fix and auto boost terms plus the term derived solely from the frequency demand. L8443 Total frequency. This indicates the total frequency applied to the motor. The total can comprise 3 parts. The demand value, the slip compensation term and the stability term. L8444 , L8446 Fixed boost, calculated voltage. User input defining the level of fixed boost required to overcome the stator resistance at full load current. L8446 indicates the level of boost applied. The boost is tapered to 0 at 75% base frequency. L8445 Auto boost User input defining the level of boost applied proportional to the load. L8447 Calculated voltage due to frequency component indicates the level of voltage due to the frequency component only. L8448, L8496 Modulation depth, scaled volts. This is the per unit value of the total voltage, L8442, based on prevailing DC link values and is the parameter passed to the pwm generator after integration of L8496, scaled volts. L8452 - L8454, Integrator variables. Defines variables for the integration of L8496. L8450, L8400 Time period, scan time. Indicate timings associated with various blocks of software.
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Module 84 (V1)
L8455, L8456 , L8477 Power, filtered power and PU peak power indicates the per unit power and filtered power produced by the motor. The filter time constant is L8440. L8477 is a signed version of L8456. L8458, L8459 Max fwd and rev frequency. User defined inputs limiting the max frequency in the forward and reverse directions. L8460, L8476, L8490, L8488, L8491 Flycatch rate, flycatch current, flycatch power, flycatch, search pattern. User defined parameter setting the scan rate at which the synchro starting software reduces the applied frequency. L8476 sets the level of injected current during the synchronizing phase. L8490 the flycatch power is the threshold at which the drive detects a catch and is indicated by L8488. L8491 selects the search pattern adopted by the drive. See table below for detail. L8462 Start. Setting this variable enables pulses to the motor bridge. L8468, L8469 Start, Stop modes Selectable modes in which the drive will operate on starting or stopping, see table below for detail. L8470 - L8473 , L8483 Inject freq, current, time , delay, low frequency inject. Parameters required for stop mode 3. L8470 defines the frequency at which injection current is applied when braking. The motor will ramp to this frequency if above it. To stop the motor a DC signal should be applied. However this will concentrate all the bridge losses in a pair of transistors. By setting L8483 parameter to a very low frequency then the losses are spread around the devices. L8471 defines the current level for braking , limiting to a maximum of drive limit. If defaulted to -1 then it is set to motor FLC (L8416). L8472 defines the time for which the current will be applied. L8473 defines the delay time before which the current will be applied. This is to allow the motor flux to decay. L8474 start up frequency when in start mode 1 this frequency is applied as a step change to L8405 frequency demand. L8475 Voltage control indicates that the motor bridge is being run under voltage control. During synchro starting and DC injection braking the bridge will be run under current control. L8478, L8479 Started, stopped indicate selected phases of L8482 status word L8481 Deadband time constant. L8482 Status. Indicates the start, stop status of the motor bridge software, see table below for detail. L8484 Synchro start status. Indicates the status of the drive during synchro starting. L8485, L8486 Select S shaping, S shaping TC. Selects S shaping and time constant on the ramp rates applied to the ramp generator. L8492, L8493, L8494, L8489, L8487 Filtered Irms, Icos, Vrms, heavy filtered Icos, Heavy TC indicate the filtered values for the associated variables. L8495 S shaping time. Displays the time that the S shaping has been running. Issue (12-2-98) Alspa GD4000 Page 14-111
Module 84 (V1)
L8413 Kr defines a gain term dictating how fast that ramp rates change when not in limit. L8433 Kf defines a gain term dictating how fast the frequency demand is reduced if the ramp is frozen
Table 14-20 VVVF Control Bridge A, Module 84 (V1)
Variable L8400 L8401 L8402 L8403 L8404 L8405 L8406 L8407 L8408 L8409 L8410 L8411 L8412 L8413 L8414 L8415 L8416 L8418 L8419 L8420 L8421 L8422 L8423 L8424 L8425
Description
scan time ramp up rate ramp down rate ramp enable Frequency ref Frequency demd Torq lim motor Torq lim regen Icos FL motor Icos FL regen Base speed volts Icos feedback Irms feedback Kr Base frequency Power factor Motor FLC Full load speed Current limit reverse Fwd accel rate Fwd decel rate Rev accel rate Rev decel rate Regen power lim
Type Minimum Maximum ON ON ON OL IN ON IN IN ON ON IN ON ON IN IN IN IN IN IN OL IN IN IN IN IN 0 0 0 0 -2000 -2000 0 0 0 0 0 -2

31 31 31
Default 0
10 = 1 ms 1 = 0.1Hz/s
3
Scaling
2 2
0 0 0 0 0 10000 10000 0 0 0 0 0 10 500 84 0 1500 -1 0 10000 10000 10000 10000 10000
1 = 0.1 Hz/s 1= enable 1 = 0.1 Hz 1 = 0.1 Hz 104 = 100.00% 104 = 100.00% 1 = 1 amp 1 = 1 amp 1 = 1 volt 104 = 100.00% 104 = 100.00%
1 2000 2000 10000 10000 231 2

31
1000 2
31
-231 0 0 0 0 100 -1 0 1 1 1 1 0
231 231 4000 100 2000 4000 10000 1 20000 20000 20000 20000 10000
1 = 0.1 Hz 1= 0.1 1 = 1 amp 1=1 rpm 1 = 1 amp 1= reverse 1 = 0.01 Hz/s 1 = 0.01 Hz/s 1 = 0.01 Hz/s 1 = 0.01 Hz/s 104 = 100.00%
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Stop Ramp up freeze Ramp down freeze Min fwd freq Min rev freq Kf PU freq ref slip comp stability comp f comp f stab Peak Frequency I filter TC Sel fan fluxing total Volts total frequency fixed boost auto boost calcd V boost calcd V freq mod depth In time period Integral gain reference feedback power filt power Max fwd freq Max rev freq Flycatch rate Total freq ref Start pwm_angle stability TC Sel demd rates Slip comp TC I error regen
Module 84 (V1)
Type Minimum Maximum IN OL OL IN IN IN IN IN IN ON ON IN IN IL ON ON IN IN ON ON ON ON ON IN ON ON ON ON IN IN IN ON IL ON IN IN IN ON 0 0 0 0 0 0 -10000 -200 0 -2 -2
31 31
Description
Default 0 0 0 0 0 2 0 10 40 0 0 500 10 0 0 0 200 100 0 0 0 0 341

1= 1 sec 1 = 0.1 Hz 1 = 0.1 Hz 1 = 0.1Hz 1 = 1 ms 1 = select 1 = 0.1 volt 1 = 0.1 Hz 1 = 0.1 volt 1 = 0.1 volt 1 = 0.1 volt 1 = 0.1 volt 104 = 100% 1 = 0.1 Hz 0 = stop 1 = freeze 1 = freeze 1= 0.1Hz 1= 0.1Hz
Scaling
1 1 1 2000 2000 2000 10000 200 10000 2 2

31 31
0 10 0 0 -2
31
2000 10000 1 2 2
31 31
0 0 -2 -2
31 31
500 200 2 2
31 31
0 -2
31
10000 2
31
104 = 100.00%
0 1 10000 -2
31
100 10000 2
31
2 10000 0 0 0 500 500 200 0 0 0 200 0 500 0

fixed at 104 = 100% Irms 104 = 100% (mod depth * Icos )104 = 100% filtered L8455 104 = 100% 1 = 0.01 Hz 1 = 0.01 Hz 1 = 0.01 Hz/s 1 = 0.1 Hz 1 = start 1 = 0.1o 1 = 1 ms 1 = select 1 = 1 ms
-231 -231 0 0 10 -2
31
231 231 2000 2000 5000 2

31
0 0 100 0 100 -2
31
1 3600 1000 1 1000 2

31
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Page 14-113
Module 84 (V1)
Variable L8468 L8469 Description
Start mode Stop mode

Type Minimum Maximum IN IN 1 1 2 3 Default 1 1 Scaling
1 = low freq start 2 = syncro start 1= disable and coast 2 = ramp to stop 3= DC inject brake 1 = 0.1 Hz 1 = 1 amp 1 = 1 sec 1 = 0.1 sec 1 = 0.01 Hz 1 = voltage control 104 = 100.00% ((L8494* L8492) / 104) 1= started 1= stopped
L8470 L8471 L8472 L8473 L8474 L8475 L8476 L8477 L8478 L8479 L8480 L8481 L8482
DC inject freq DC inject curr DC inject time DC inject delay Start up freq Voltage control Fly catch I PU pk power started stopped I error motor Deadband TC Status
IN IN IN IN IN OL IN ON OL OL ON IN ON
0 -1 0 0 -500 0 1000 0 0 0 -2
31
4000 10000 60 100 500 1 10000 231 1 1 2

31
100 -1 5 20 0 1 1000 0 0 1 0 100 32
0 0
1000
1 = 1ms 1 = start 2= starting 4 = started 8 = stop 16 = stopping 32 = stopped 1 = 0.1 Hz 0 = syncro setup 1 = catch current 2 = freq scanning fwd 3 = freq scanning rev 4 = volts scanning 1 = select 1 = 0.1 ms 1= 1 ms 1 = caught 104 = 100.00% 104 = 100.00% 0 = fwd 1 = fwd then rev 2 = rev 3 = rev then fwd 104 = 100.00% 104 = 100.00% 104 = 100.00% 1 = 1 ms 104 = 100.00%
L8483 L8484
Low freq inject sync start stat
IN ON
0 0
2000 128
1 0
L8485 L8486 L8487 L8488 L8489 L8490 L8491
Sel S shaping S shaping TC Hvy flt Icos TC flycatch h filt Icos flycatch power search pattern
IL IN IN OL ON IN IN
0 0 200 0 0 -10000 0
1 10000 1000 1 2
31
1 200 200 0 0 0 0
10000 3
L8492 L8493 L8494 L8495 L8496
filt Icos filt Irms filt Vrms s shaping time scaled volts
ON ON ON ON ON
-231 -231 -231 0 0
231 231 231 231 10000
0 0 0 0 0
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Module 84 (V1)
Figure 14-32 VVVF Control Bridge A, Module 84 (V1) Sht 1
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Alspa GD4000
Page 14-115
Module 84 (V1)
Figure 14-33 VVVF Control Bridge A, Module 84 (V1) Sht 2
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Module 85 (V1)
14.21
Module 85 (V1)
Control and Reference Support, Module 85 (V1)

Introduction Module 85 provides the facilities required to configure stop and start sources, speed/torque reference sources and jog controls. This module also determines the action taken on loss of control or reference sources and provides two system reset inputs which can be configured to give either manual or auto-resetting of trip.
14.21.1
14.21.2
Features
Start, Stop Control from multiple sources. Keypad connection/disconnection logic. Reset timing for power up and trip reset. Jog Control Support Motor brake control logic and timer Timer for motor fluxing prior to running. Raise/Lower pushbutton reference control, with reset to zero. Two analog reference inputs, with summing amplifier for reference trimming. Preset reference inputs automatically selected on Jog request. Output limits Quasi-square wave generator Programmable reference selection switch. General Purpose analog data switches
14.21.3
Basic Stop Start Control The basic stop start configuration is suitable for simple drive applications such as pumps and fans, where there is no brake fitted and where there is no requirement for interlocking stop modes. The method of configuring the drive for basic stop/start operation i.e. stop and start pushbuttons with no keypad fitted is as follows: Set the following parameters to the values shown: Keypad Inhibit L8501 Remote Request L8520 Control passed L8521 Start Pulse L8522 Present Flag L8523 =1 =1 =0 =0 =0
With L8520 set to 1, start control is derived from the Start 1 and Start 2 inputs only, any keypad inputs are ignored and the following outputs are set: In Local L8538 is set to 0 No Keypad L8539 is set to 1 Illegal Keypad L8540 is set to 0 (indicating unhealthy) Issue (12-2-98) Alspa GD4000 Page 14-117
Module 85 (V1)
14.21.3.1 Start Control
Two Start inputs, L8503 and L8504 are provided. These two inputs are ORed together so that a logic 1 on either input will generate a run request. To implement a panel mounted start button control:
Connect a normally open pushbutton to digital input A32.00 on the Customer I/O
board and link this to the Start 1 input (L8503) (i.e. L8503 = A32.00). Start 2 (L8504) must be set to zero. If an automatic Run request on power up is required:
Set L8503 or L8504 to 1 in the links editor. In this configuration the drive will
automatically generate a Run request after INITialization following a power cycle or after a reset, provided the Stop inputs are healthy. 14.21.3.2 Stop Control Four stop inputs are provided (L8505 to L8508 inclusive). These four together with the keypad Stop (L8509), the INIT and the Illegal keypad removal signals are ANDed together so that a logic 0 on any of the inputs will generate a stop request. To implement a panel mounted STOP button:
Connect a normally closed pushbutton to digital input A32.01 on the Customer I/O
panel and link this to L8505 (i.e. L8505 = A32.01). The other three Stop inputs (L8506 to L8508) are intended for use as internal interlocks and should be linked as follows: L8506 = A32.07 (Pulse Inhibit) L8507 = L3269 (Drive Healthy) L8508 = L9969 (DC Link Allowed). 14.21.3.3 Keypad Stop Start Control To configure the drive for keypad stop/start operation, ensure the keypad is fitted and use the links editor to set the following links: Keypad Inhibit (L8501) Keypad Run (L8502) Keypad Stop (L8509) Remote Request =1 = A34.00 = A34.01 =0
In this configuration the following three outputs will be set: In LOCAL (L8538) is set to 1 (indicating the drive is in local control) No Keypad (L8539) is set to 1 (i.e. the keypad is not yet recognized) Illegal Keypad (L8540) is set to 0 (i.e keypad unhealthy). To activate the keypad, the drive must be reset see Section14.21.8.1. 14.21.4 Extended Stop Start Functions In addition to the basic stop/start functions a number of additional functions are provided to allow:
The system to be controlled from either a Remote source or a Local source.
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Module 85 (V1)
The system to revert to Remote control if a keypad is not present when the drive
powers up. Irrespective of the state of the Remote/Local source input switch.
The system to revert to Local control if a keypad is connected after the system was
initially powered up with no keypad present.

To provide an indication, if the keypad is removed without first being given
permission by the system. To achieve this functionality the following links need to be made. L8570 to L8571 to L8572 to L8573 to a digital input i.e. A01.07 the Control Passed flag for the keypad serial link i.e. E9.07 a signal which is set high once on power up i.e.E0.06 the system keypad present flag i.e. A34.06
With these links set, the module outputs will depend on the keypad status on power up and keypad removal logic configuration as follows: Drive is powered up with a keypad present If the drive is powered up with a keypad present and Remote Request is set to a 0 then START control will be transferred to the keypad i.e. Local Control and the output flags will be set as follows: The IN LOCAL (L8538) output is set to a 1 indicating the drive is in Local Control. The NO KEYPAD (L8539) output to a 0 to indicate that there is a keypad fitted. The ILLEGAL KEYPAD (L8540) removal trip output is set to 1 indicating healthy. The Remote Request input, if set to 1, forces the logic to always take the START control signal from the remote sources i.e. the signals linked to inputs Start 1 and/or Start 2. If this input is left at 0 then START control will always revert to the keypad if the keypad is present. If this input is set to a 1 then the LOCAL output will go to 0 to indicate that the drive is in Remote control. Drive is powered up with no keypad present The action taken by the drive on power up when the keypad is not connected and with Remote Request set at logic 0 is as follows: LOCAL output is to 0 (indicating the drive is in remote control) NO KEYPAD output is set to 1. ILLEGAL KEYPAD removal trip output is set to 1 indicating healthy. 14.21.4.1 Connecting the Keypad After Power Up If the keypad is connected after power up, the action taken by the drive when the keypad is detected depends on the state of the Remote Request input: With Remote Request set to 0 the action taken is as follows: LOCAL output is to 1 (indicating the drive in LOCAL (keypad) control) NO KEYPAD output is set to 0 (keypad fitted). ILLEGAL KEYPAD removal trip output is set to 1 indicating healthy.
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Module 85 (V1)
With Remote Request set to 1 the action taken is as follows:
LOCAL output is set to 0 (the drive remains in Remote control). NO KEYPAD output is set to 0 (keypad fitted). ILLEGAL KEYPAD removal trip output is set to 1 indicating healthy. 14.21.4.2 Enabling/Disabling Illegal Keypad Removal Logic Data table A34.06 is normally linked to input L8523 (Keypad present) so that L8540 (Illegal Keypad removal) is reset to 0 if the keypad is removed when the drive is operating. This signal is normally used to trip the drive when the keypad is removed illegally. If the Illegal keypad removal trip is not required it can be disabled using the Control Passed Input (L8521). Four data tables E9.04 to E9.07 (Control Passed for serial links 0 to 3 respectively) are provided in system software for this purpose and each of these data tables has a preset bit (P12.04 to P12.07 respectively). To allow the keypad to be removed while the drive is running without causing a trip:
Link the Control passed E-table for the keypad serial link to L8521.
In this state the keypad can be removed from a drive as follows:

Press the ESC key twice.
The keypad will display:

1. keypad Disconnection 2. Return to Main Menu Select option 1.
This action sets the corresponding preset bit and displays the message:
* * DISCONNECT KEYPAD * (control passed) *
Disconnect the keypad
The will set the following outputs:The LOCAL output is set to a 0 indicating the drive is in Remote Control. The NO KEYPAD output to a 1 to indicate that there is no keypad fitted. The ILLEGAL KEYPAD removal trip output is set to 1 indicating healthy. Disconnection Prohibited If L8521 is not linked to Control Passed and the keypad is removed a stop is generated and the illegal Keypad output L8540 is set to 0. 14.21.5 Application Notes To sample the Keypad present flag on a Halt/RUN transition, connect the Start Pulse input (L8522) to E0.06.
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Module 85 (V1)
If no keypad is to be used or the keypad present logic is to be disabled to prevent a stop input, set the Control Passed (L8521) input to 1. Failure to configure this keypad logic correctly or disable it, will prevent the main start/stop logic from working correctly. If Modules 85 and its clone Module 285 are used simultaneously, care must be taken when setting up the Illegal Keypad Removal logic within each module to prevent unwanted effects. The Keypad Present flag (A34.06) is set when the keypad is recognized by the system and is cleared when the keypad has been removed for more than 10 seconds. When the drive is connected to a PC using CSP, some PC keystrokes can be misinterpreted by the drive software as keypad messages. If this happens A34.06 will be set for 10s inadvertently and, if the keypad is not connected, a spurious stop request is generated, which sets the Illegal Keypad Removal output. To prevent this, the Keypad Present flag is only passed to the keypad removal logic if the Keypad Present input lasts more than 20 seconds. Figure - shows the timing of these signals.
1=keypad in A34.6 delayed A34.6
10s
11s
9s
20s
10s
keypad not recognised
total time >20s keypad recognised and will trip if removed
Figure 14-34 Keypad Present Timing
14.21.5.1 Summary of Basic Stop Start Controls

Module No. L8501 L8502 I = Input O = Output I I CSP Mnemonic Functional Description
Keypad Run Inhbt If left at a 0 it will prevent a keypad run. Set to a 1 for basic start/stop Keypad Run If RUN control from a keypad is required then link this to A34.00. Otherwise leave unlinked (defaults to 0, 1 required for run) Start 1 Start 2 are OR together so that a 1 on either input will generate a run request. These inputs should be linked to normally open pushbuttons via the digital inputs. Four stop inputs are provided for to allow multiple stop buttons to be implemented and for internal interlocking. All the stop inputs are ANDed together so any input going to a 0 will generate a stop request. Note that Stop requests always override Start requests. One or more of these inputs should be linked to normally open pushbuttons via the digital inputs. This stop input is inverted to allow direct connection to the keypad stop output. If a keypad is to be fitted to the drive then this input must be linked to the keypad stop output i.e. L8509=A34.01. Otherwise leave unlinked (defaults to 0, 1 required for stop). Please note that due to the importance of stop inputs, this input, when linked, is always active. This unlatched interlock input is ANDed with the Run Requested output to produce the Run Req I/lock output. Its purpose is to give an interlock/acknowledgment into the Run Requested output.
L8503 L8504 L8505 L8506 L8507 L8508
Start 1 Start 2 Stop 1 Stop 2 Stop 3 Stop 4
L8509
Keypad Stop
L8517
Running I/lock
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Module No. L8518 L8519 L8520 I = Input O = Output I CSP Mnemonic Reset 1 Reset 2 Remote Request

Functional Description Reset 1 and Reset 2 are reset request inputs. They are Ored together so that an input on either will generate a reset. This input is used to switch start control only between local (digital inputs) and remote control (keypad) control. All stops connected to the system are always active. This input was designed to be connected to a switch which would be mounted on the cubicle door or on a control desk. A 1 on this input forces start control to be derived from the digital inputs. If keypad control is not required then link this input to 1. If remote control is not required then link this input to 0. The default for this input is 0 i.e. keypad control. Used by keypad disconnection function. Set this to a 1 to disable illegal keypad disconnection. Used in conjunction with L8530 In basic Start Stop operation the Run Requested and Run Request Mem outputs mimic each other. Therefore any reference to timing within this section relating to Run Requested applies equally to Run Request Mem and vice versa. If all stop inputs are healthy when any or all start inputs are set to 1 then this output goes to a 1 and remains at a 1 even when the start input is removed. In this mode this output only returns to a 0 if any one or more than one of the stop inputs becomes unhealthy i.e. 0 for Stops 1-4 or 1 for keypad stop. This is basically a delayed Run Request Mem output. In certain applications of this module it is useful to have both a Run Request Mem output and a delayed version of the Run Request Mem output. This feature has been implemented in this module using this Delayed Run output, and the Run Delay 1 input described earlier. When Run Request Mem goes low then Delayed Run goes low immediately. An application where this may be used is when this module is used to Start and Stop a machine bridge. In this application a delay is required between the enabling the current loops and the enabling of the speed/torque loops. This is so that the motor has time to magnetize (Flux) before it is allowed to produce any torque. The required delay can be found within the module controlling the motor model (Module 94) and the delay is given on output L9495. This can therefore be linked into the delay time i.e. L8524=L9495. This output is an ANDed output of both Run Request Mem AND Running I/lock. An example of where this may be used is in the startup sequencing of a DC link. A start button may be provided to request a DC link, if the stop circuit is healthy then the Run Request Mem output will go high, initiating the DC charging cycle. However you will not want to be able to run the machine bridge until the DC link charging circuit has returned its finished charging signal. The finished charging signal could then be linked into the Running I/lock input described earlier and this output linked into the stop circuit of the machine bridge. This output Run Req I/lock would then only go high when a DC link had been requested AND it had successfully finished charging the link, thus preventing the machine bridge from running until this condition was true. There are three reset outputs but this is the primary output. This output only goes to a 1 if Run Request Mem is 0 AND whilst either or both of the Reset inputs are high. It will remain at a 1 for 3 seconds after the reset inputs have returned to a 0. For a complete description of the reset logic see section Section 14.21.8.1
L8521 L8524 L8527 & L8528
I I O O
Control Passed Run Delay 1 Run Requested & Run Request Mem
L8530
Delayed Run 1
L8534
Run Req I/lock
L8537
Reset
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14.21.6 Enhanced Stop/Start Control
Module 85 (V1)
Enhanced mode provides additional features to allow more complex Stop/Start Controls to be implemented, such as:
Disabling the machine bridge only when specified conditions are met i.e. zero speed
or zero torque, at a pre-defined speed threshold or a pre-defined torque threshold.

Stopping the motor at a pre-defined position on a stop request. Applying the brake at zero speed only. Releasing the brake when torque is applied Move to jog reference when jog is requested while motor is moving Move to jog reference when jog is requested only after the motor has come to rest.
In order to implement these requirements the enhanced mode provides inputs for feedback signals such as: zero speed, brake applied limit switch, mode inputs and mode override inputs 14.21.6.1 Summary of Enhanced Mode Functions
Module No. I = Input O = Output CSP Mnemonic Functional Description
The following five inputs only have an effect if the module is in the waiting to stop mode. This mode exists when a stop is requested whilst this module is in the running mode AND L8510=1 AND L8511=0 AND ((L8512=1 OR L8513=1) AND L8514=1). In this state the Run Requested and Run Request Mem outputs are not the same. Run Requested. output L8527 will be 0 but Run Request Mem, output L8528 will still be at 1. If a stop is not requested then these inputs are ignored. L8510 L8511 L8512 I I I Not OR I/P OR I/P A 0 on this input will clear the running memory latch if a stop has previously been requested. A 1 on this input will clear the running memory latch if a stop has previously been requested.
OR AND OR I/P1 If L8514 = 1 and this input becomes a 1 then the running memory latch will be cleared if a stop has previously been requested. OR AND OR I/P2 If L8514 (see following description) = 1 and this input becomes a 1 then the running memory latch will be cleared if a stop has previously been requested. AND OR I/P Run Delay 2 Run Request Mem A 1 on this input allows either L8512 or L8513 to clear the running memory latch if either goes to a 1 and See L8532 Dly Lat for information relating to this input. When used in the enhanced mode this output becomes a latched version of L8527. It provides a facility to decelerate the motor to a preset speed (usually zero speed) before the machine bridge is disabled
L8513
L8514 L8525 L8528
I I O
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Module No. L8532 I = Input O = Output O CSP Mnemonic Dly Lat

Functional Description This output provides a motor brake release output. This output goes high to release the brake L8525 ms after the Run Request Mem output has gone high. Typically the delay set by L8525 will be equal to L8524 or greater. If this module is used to control an machine bridge the sequence of events is:Start Button pressed L8528 goes high to enable the current loops and the PWM generation etc. to flux the motor. After Run Delay 1 given by L8524 L8530 goes high to enable the torque control loops and provide torque ready for when the brake is released. After Run Delay 2 given by L8525 L8532 goes high to release the brake. On disabling the machine bridge the timer resets immediately but the latch remains set until L8514 (see previous description) becomes a 1. To ensure that the brake is not applied until the motor is at zero speed or a low speed. Connect a zero speed detector output into L8514
14.21.6.2 Application Notes In Enhanced mode the user program must clear the Run Request Mem latch when the drive trips. Failure to implement this may result in the current/torque or PWM modules not being disabled on a trip. If the DlyLat (L8532) output is used to operate a brake then do not reset its latch on a trip unless the brake mechanics have been designed to stop the motor and load from maximum speed. The following drawing shows a typical example of how this module can used in the enhanced Start Stop configuration to control the enabling and disabling of a GD4000 machine bridge.
Figure 14-35 Extended Stop/Start Configuration
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14.21.7 Miscellaneous Stop/Start Functions
Module No. L8526 I = Input O = Output O CSP Mnemonic Start Req Denied
Module 85 (V1)
Functional Description Outputs a 1 whenever any start input is requested and the stop circuit is unhealthy. This output has been provided to simplify the method of generating useful fault or warning messages when a stop circuit is preventing a Run Request. By ANDing this signal with the inverse of each stop source it is possible to then generate warning messages to indicate which stop circuit is responsible. XORs Run Request Mem and Delayed Run 1 i.e. Run Request 0 0 1 1 Mem 0 0 1 1 0 1 1 0 Delayed Run 1 XOR 1 Timing prevents this state
L8529
XOR 1
Outputs a 1 to indicate that Run Request Mem was high but the delayed version of Run Request Mem, Delayed Run 1 was still low i.e. waiting for time-out. On a machine bridge controller it can be used to indicate that the motor is still fluxing. L8531 O XOR 2 XORs Delayed Run 1 and Dly Lat i.e. Delayed Run 1 0 0 1 1 L8538 O In Local Dly Lat 0 0 1 1 0 1 1 0 XOR 2
This output has been provided to indicate the mode of start control. If this output is a 1 then control is in local (keypad) otherwise it is in remote (digital inputs). It is intended for use when the recognition/disable illegal keypad disconnection software is enabled (see section 14.21.4.2
14.21.8
Resetting the Drive
14.21.8.1 Reset on Power Up On power up the INIT signal generates a reset request and Stop request to reset the drive on power up. The stop request sets RUN REQUEST MEM to 0 to ensure that the drive is always reset on power up regardless of the state of the other Stop/Start inputs. 14.21.8.2 Remote Reset Two inputs Reset 1 and Reset 2 (L8518/L8519) are provided to allow a remote reset facility to be implemented. These inputs, which are both active high, and the INIT signal generated on power up are ORed together to produce a single reset signal. If a value of 1 is entered on either or both inputs a system Reset Request is issued. This reset request is ANDed with the RUN REQUEST MEM output from the start/stop logic to generate a system reset. The purpose of the RUN REQUEST MEM signal is to ensure that a system reset cannot be generated while the drive is running. 14.21.8.3 Reset Timing The reset timing block issues three active high output signals RES P1 (L8535), RES P2 (L8536) and RESET (L8537) and is enabled on a 1-0 transition of the reset REQUEST signal i.e. when Reset 1 and Reset 2 and INIT have become 0. The RESET output signal Issue (12-2-98) Alspa GD4000 Page 14-125
Module 85 (V1)
becomes a 1 as soon as a valid reset REQUEST signal is seen and remains in the 1 state for a further 3 seconds after the reset REQUEST signal has been removed. This means that the shortest recognizable reset input request will always generate a system reset signal of sufficient length to fully reset any system. RES P1 produces a 100 ms high pulse only on the 1-0 transition of the reset REQUEST signal, indicating a release from reset and a start of reset timing. RES P2 produces a 100 ms high pulse only on the 1-0 transition of the output RESET signal, indicating that the system has been reset and an end of reset timing. During a power cycle some systems require a reset period guaranteed to be longer than 10 seconds. This requirement has been catered for via the internal system INIT signal which is generated on power cycles and on a Halt to Run transition. When INIT is generated it is guaranteed to last for 12 seconds which therefore generates a system reset period on power cycles of 12s + 3s =15s.
INIT 1=Module 85 running Reset Input Reset Output Res P1 Res P2 100mS Pulses
12s INITialising Power Cycle Or Halt to Run
3s Either Reset Button Pressed
3s
Figure 14-36 Reset Timing
14.21.9
Speed and Torque Reference Control Module 85 provides the means of controlling analog output L8571 and its inverse output L8572 for use as a reference for speed or torque control. The output of L8571/8572 is controlled by an 8-input switch,, which is used to select the signal source from one of the following: Preset 0 Increment decrement function (raise lower control) Analog Inputs (Trim reference control) Summation Amplifier Offset Preset inputs 1 to 4 Quasi square wave generator The output from the 8-way switch has maximum and minimum limits and deadband controls applied before output to L8571/L8572.
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14.21.9.1 Output Switch Control
Module 85 (V1)
The output L8571/L8572 can be switched between 9 different sources by writing a value in the range 0 to 8 to L8555 as follows:
Switch setting 0 1 2 3 4 5 6 7 8 0 Output derived from increment / decrement output L8570 Output derived from the summation amplifier output L8571 Output derived from the summation amplifier offset L8550 Output derived from preset 1 L8551 Output derived from preset 2 L8552 Output derived from preset 3 L8553 Output derived from preset 4 L8554 Output derived from the quasi square wave generator Switch output
In addition to the above L8555 has a number of extended settings (values 10 to 32) which are used for Jog Control. These are described in Section 14.21.14. 14.21.9.2 Output Limits and Deadband The maximum and minimum positive values which can pass to the output L8571 are set in parameters L8557 and L8558 respectively and the maximum and minimum negative values which can pass to the output L8571 are set in parameters L8559 and L8569 respectively. the difference between the values in L8558 and L8559 gives a deadband either side zero. The output reference is not allowed to take any value between the minimum positive and minimum negative limits but jumps instantaneously to the limit closest to the reference demand. The purpose of this is to prevent the motor oscillating when the reference demand is close to zero. 14.21.9.3 Summary of Reference Output Limits
Limit Mnemonic Max Limit 1 Par Number L8557 Description If this set to be more negative than Min Limit 1 the module will overwrite this input to be equal to Min Limit 1. The output is never allowed to more positive than this value. The output is never allowed to be between the values Min Limit 1 and Min Limit 2. If this set to be more positive than Min Limit 1 the module will overwrite this input to be equal to Min Limit 1. The output is never allowed to be between the values Min Limit 1 and Min Limit 2. If this set to be more positive than Min Limit 2 the module will over write this input to be equal to Min Limit 2. The output is never allowed to more negative than this value.
Min Limit 1 Min Limit 2
L8558 L8559
Max Limit 2
L8560
14.21.10 Raise Lower Control (Increment Decrement logic) The Increment/Decrement logic is used to implement a pushbutton operated Raise/Lower analog reference control. There are seven active high digital inputs to this function; three increment inputs (L8541 to L8543), three decrement inputs (L8545 to L8547) and zero output (L8544)
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Module 85 (V1)
To implement a simple Raise/Lower reference control, connect two normally open pushbuttons to digital inputs on the Customer I/O board and link these digital inputs to L8541 and L8545 to provide increment and decrement reference controls. A third pushbutton may be connected to the Customer I/O board and linked to L8544 to provide a zero reference pushbutton. To activate the Raise/Lower pushbuttons, set the output switch L8555 to 1. The response of the increment and decrement inputs is as follows: When a pushbutton is depressed for less than 1 second, the output changes only once. When a pushbutton is depressed for more than 1 second the pushbuttons will auto-repeat at a rate which depend on the length of time the pushbutton is depressed and the setting of L8599.28 to L8599.31. The effect of parameters L8599.28 to L8599.31 is as follows: With L8599.28 set to 1, when a pushbutton is pressed between 1 and 4 seconds, the output changes once every half of a second. With L8599.29 set to 1, when a pushbutton is pressed between 4 and 7 seconds the output changes by 10 every second. With L8599.30 set to 1, when a pushbutton is pressed between 7 and 10 seconds the output changes by 100 every second. With L8599.31 set to 1, when a pushbutton is pressed for longer than 10 seconds the output changes by 1000 every second. Setting any of the bits L8599.29 to L8599.31 to 0 will disable the corresponding auto-repeat function. Because it is possible to press any combination of the increment/decrement/output to zero buttons simultaneously, the effect on the output reference is specified as follows:
Zero Output 1 0 0 0 0 Increment X 0 1 0 1 Decrement X 0 0 1 1 Result Output set to zero No change Output increments Output decrements No change
Note:
X indicates dont care.
To allow this logic to be used independently the Increment/Decrement block has its own output and a switch to isolate its output from the summation amplifier. In this mode the Increment/Decrement output is limited to 100,000. To add the Increment/Decrement output to the analog inputs set L8599.24 to 1. The Increment/Decrement output will remain limited to 100,000 and not to the Output Limits defined in L8557 to L8560. To prevent the Increment/Decrement output from exceeding the output limits, set L8599.26 to 1. This will disable the Increment input if the main O/P goes into positive limit and disable the Decrement input if the O/P goes into negative limit.
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Because the logic disables the Increment/Decrement inputs, the Increment/Decrement output will not always equal the main O/P (L8571) for the following reasons:If the output is 1 below the Max Output 1 limit on one scan and Increment/Decrement output is changing by 1000 each scan then on the following scan the Increment/Decrement output will be 999 greater than the limit before the increment input has been disabled. Before the main output will start to decrement, 999 must be decremented from the Increment/decrement output. If one of the analog inputs is non-zero then the Increment/Decrement output must compensate for this input. i.e. if one of the analog inputs has -1000 on its input then the Increment/Decrement output will have to be 11000 to make the main O/P 10000. The Allow Auto Limit input (L8599.27) can be used to prevent the Increment/Decrement output overshooting the output limits when the changing by 1000s. This facility, if enabled, automatically reduces the Increment/Decrement rate as the main O/P gets closer to the limits. This facility also disables the auto increment rate of 1 every 0.5 seconds and as such there may be occasions where the Increment/Decrement inputs have to be pressed several times to move from the limit condition. 14.21.11 Analog Inputs (Principle Reference and Trim Reference) Their are two analog inputs L8548 and L8549 for use as principal and trim reference sources . The two inputs are identical and are summed to provide an offset to the principal source to align it with the required operating range. The summed inputs are then filtered using the formula below: New Output = present output + (present output - present input) L8556 L8556 is the Filter Value. If this value is set to 1, the filter is effectively turned off. The higher the filter value the longer the output takes to reach the input value. Note: If the filter value is set 0, this value is overwritten by 1 to avoid a divide by zero error.
14.21.12 Cyclic Test - Quasi-Square Wave Generator The quasi-square generator allows a sequence of four reference values and the time at each reference value to be defined, for use as a simple motor test cycle. The test cycle is defined in parameters L8561 to L8568 as follows:
L8561 1st reference value L8563 2nd reference value L8565 3rd reference value L8567 4th reference value L8562 time at 1st reference in ms L8564 time at 2nd reference in ms L8566 time at 3rd reference in ms L8568 time at 4th reference in ms
The minimum time at any reference value and the resolution is 1 slow scan period. The maximum time which can be entered is 9999999000 ms which is more than 115 days. To start the cyclic test set L8555 to 8. The test cycle will repeat until L8555 is set to a different value. Note: The output is initialized when L8555 is set to 8. The output reference will therefore always start at the value set in L8561 regardless of the state when last de-selected. Alspa GD4000 Page 14-129
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Module 85 (V1)
The quasi-square wave generator can be monitored by reading L8573. This parameter combines both current reference value and time left in one output word, which is interpreted as follows:
Character 8 used for Current state Character 7 used for Character 6 used for Character 5 used for Character 4 used for Character 3 used for Character 2 used for tens of seconds Character 1 used for seconds
thousands hundreds tens of thousands hundreds of of thousands of seconds of seconds thousands thousands of seconds of seconds of seconds 0-9 0-9 0-9 0-9 0-9
0-3
0-9
0-9
Note:
The time is displayed as seconds remaining, with a resolution of 1 second. As leading zeroes are omitted, the current state of 0 has to be inferred. For example in state 1 the output might be 10000123, indicating state 1 with 123 seconds remaining. In state 3 the output might be 30099999, indicating state 3 with 99999 seconds remaining. However in state 0 the output would be 52, leading zeroes have been omitted and therefore state 0 should be inferred with 52 seconds remaining.
14.21.13 Preset References There are four preset references defined in parameters L8551 to L8554 for use in jog control or other applications where predetermined references are required. The preset references 1 to 4 are selected by setting the output switch (L8555) to values 4 to 7 respectively. 14.21.14 Jog Control Module 85 provides extensive Jog control support, which makes use of the extended reference switching modes available via parameter L8555. To implement a Jog Control:
Connect two normally open pushbutton switches to digital inputs on the Customer
I/O Board and link these digital inputs to L8515 (Jog 1 input) and L8516 (Jog 2 input). The digital inputs and outputs associated with the jog function are summarized below:
Module No. L8515 I = Input O = Output I CSP Mnemonic Jog 1 Functional Description This is the first of two jog request inputs. Designed to be linked to a normally open pushbutton via the digital inputs i.e. L8515=A32.03 This is the second of two jog request inputs. Designed to be linked to a normally open pushbutton via the digital inputs i.e. L8516=A32.04 This output goes to 1 if a jog pushbutton is pressed when the stop circuit is unhealthy. This output has been provided to simplify the method of generating useful fault or warning messages.
L8516
Jog 2
L8533
Jog Req Denied
14.21.14.1 Reference Selection and Mode the action taken when a jog pushbutton is pressed is determined by the Extended Switch Setting and the mode Selection defined by the setting of L8555. The extended switch settings and their effects are shown below:
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Switch Settings (L8555) 10 11 12 Effect of the Jog buttons
Module 85 (V1)
Output derived from increment / decrement output. Changes to preset 1 if jog 1 OR jog 2 pressed Output derived from increment / decrement output. Changes to preset 1 if jog 1 AND jog 2 pressed Output derived from increment / decrement output. Changes to:preset 1 if jog 1 is pressed, preset 2 if jog 2 is pressed, preset 3 if jog 1 AND jog 2 are pressed. Output derived from summation amplifier output. Changes to preset 1 if jog 1 OR jog 2 pressed Output derived from summation amplifier output. Changes to preset 1 if jog 1 AND jog 2 pressed Output derived from summation amplifier output. Changes to:preset 1 if jog 1 is pressed, preset 2 if jog 2 is pressed, preset 3 if jog 1 AND jog 2 are pressed. Output derived from preset 4 output. Changes to preset 1 if jog 1 OR jog 2 pressed Output derived from preset 4 output. Changes to preset 1 if jog 1 AND jog 2 pressed Output derived from preset 4 decrement output. Changes to:preset 1 if jog 1 is pressed, preset 2 if jog 2 is pressed, preset 3 if jog 1 AND jog 2 are pressed.
20 21 22
30 31 32
14.21.14.2 Jog Mode Settings The mode settings are used to:
Automatically change the switch setting and therefore the output reference when stop
is selected.
To enable or disable the jog buttons under various operating conditions.
The running, stopping, stopped and jog conditions that apply for the given modes are shown in the following table.
Mode Value 0 i ii iii Effect The jog buttons are disabled if disable jogs is set to a 1. Run requested (L8527) has no effect. DLYLAT (L8532) has no effect.
Notes: Only allows the user to Jog when not running. The output switch state and therefore the output reference does not change when in the stopping or stopped state. 1000 i ii iii The jog buttons are disabled if disable jogs is set to a 1. Output is clamped at 0 if Run requested (L8527) is set to a 0. DLYLAT (L8532) has no effect
Notes: Only allows the user to Jog when not running. The output switch state goes to 0 and therefore the output reference is clamped to 0 when a stop is requested. Included to allow the user to drive to a zero reference before the drive is disabled. In this mode the reference will be re-applied as soon as the Run Request signal goes to 1. If a brake is being driven from the DLYLAT signal then this may mean that a reference is applied during the brake release time out period. See modes 6000 onwards if this causes a problem.
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Module 85 (V1)
Mode Value 2000 i ii iii Effect The jog buttons are permanently enabled. Run requested (L8527) has no effect. DLYLAT (L8532) has no effect
Notes: Allows the user to Jog at any time. The output switch state and therefore the output reference does not change when in the stopping or stopped state. 3000 i ii iii The jog buttons are permanently enabled. Output is clamped at 0 if Run requested (L8527) is set to a 0. DLYLAT (L8532) has no effect
Notes: Allows the user to Jog at any time. The output switch state goes to 0 and therefore the output reference is clamped to 0 when a stop is requested. Included to allow the user to drive to a zero reference before the drive is disabled. In this mode the reference will be re-applied as soon as the Run Request signal goes to 1. If a brake is being driven from the DLYLAT signal then this may mean that a reference is applied during the brake release time out period. See modes 6000 onwards if this causes a problem. 4000 i ii iii The jog buttons are disabled if disable jogs is set to a 1. Output is clamped to preset 4 if Run requested (L8527) is set to a 0. DLYLAT (L8532) has no effect
Notes: Only allows the user to Jog when not running. The output switch state goes to 7 and therefore the output reference is clamped to preset reference 4 when a stop is requested. Included to allow the user to drive to a user defined reference before the drive is disabled. In this mode the reference will be re-applied as soon as the Run Request signal goes to 1. If a brake is being driven from the DLYLAT signal then this may mean that a reference is applied during the brake release time out period. See modes 6000 onwards if this causes a problem. 5000 i ii iii The jog buttons are permanently enabled. Output is clamped to preset 4 if Run requested (L8527) is set to a 0. DLYLAT (L8532) has no effect
Notes: Allows the user to Jog at any time. The output switch state goes to 7 and therefore the output reference is clamped to preset reference 4 when a stop is requested. Included to allow the user to drive to a user defined reference before the drive is disabled. In this mode the reference will be re-applied as soon as the Run Request signal goes to 1. If a brake is being driven from the DLYLAT signal then this may mean that a reference is applied during the brake release time out period. See modes 6000 onwards if this causes a problem. 6000 i ii iii The jog buttons are disabled if disable jogs is set to a 1. Output is clamped at 0 if Run requested (L8527) is set to a 0. Output is clamped at 0 if DLYLAT (L8532) is set to a 0
Notes: Only allows the user to Jog when not running. The output switch state goes to 0 and therefore the output reference is clamped to 0 when a stop is requested. Included to allow the user to drive to a zero reference before the drive is disabled. In this mode the reference will only be re-applied when the Run Request signal goes to 1 and the DLYLAT signal becomes 1. This means that if a brake is being driven from the DLYLAT signal then the reference is only applied after the brake release time out period. 7000 i ii iii The jog buttons are permanently enabled. Output is clamped at 0 if Run requested (L8527) is set to a 0. Output is clamped at 0 if DLYLAT (L8532) is set to a 0
Notes: Allows the user to Jog at any time. The output switch state goes to 0 and therefore the output reference is clamped to 0 when a stop is requested. Included to allow the user to drive to a zero reference before the drive is disabled. In this mode the reference will only be re-applied when the Run Request signal goes to 1 and the DLYLAT signal becomes 1. This means that if a brake is being driven from the DLYLAT signal then the reference is only applied after the brake release time out period.
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Mode Value 8000 i ii iii Effect
Module 85 (V1)
The jog buttons are disabled if disable jogs is set to a 1. Output is clamped at preset 4 if Run requested (L8527) is set to a 0. Output is clamped at preset 4 if DLYLAT (L8532) is set to a 0
Notes: Only allows the user to Jog when not running. The output switch state goes to 7 and therefore the output reference is clamped to preset reference 4 when a stop is requested. Included to allow the user to drive to a user defined reference before the drive is disabled. In this mode the reference will only be re-applied when the Run Request signal goes to 1 and the DLYLAT signal becomes 1. This means that if a brake is being driven from the DLYLAT signal then the reference is only applied after the brake release time out period. 9000 i ii iii The jog buttons are permanently enabled. Output is clamped at preset 4 if Run requested (L8527) is set to a 0. Output is clamped at preset 4 if DLYLAT (L8532) is set to a 0
Notes: Allows the user to Jog at any time. The output switch state goes to 7 and therefore the output reference is clamped to preset reference 4 when a stop is requested. Included to allow the user to drive to a user defined reference before the drive is disabled. In this mode the reference will only be re-applied when the Run Request signal goes to 1 and the DLYLAT signal becomes 1. This means that if a brake is being driven from the DLYLAT signal then the reference is only applied after the brake release time out period.
To define the mode and the extended switch settings in L8555 the switch setting value is added to the mode value. Example 1 To set up a jog mode to fulfill the following requirements: To derive the reference source from the summation amplifier output. Allow the drive to go to the jog reference set on preset reference 1 if Jog 1 and Jog 2 inputs are on. To allow the drive to go to the jog reference only if the drive is in the stopped state. To preset the reference output to zero and decelerate to this zero reference before stopping. For this example the most suitable mode is 6000 with extended switch setting of 21. The value to write to L8555 is 6000+21 = 6021. Example 2 To set up a jog mode to fulfill the following requirements: To derive their reference source from the increment/decrement output. To allow the drive to go to the jog reference set on preset reference 1 if Jog 1 input is on. To allow the drive to go to the jog reference set on preset reference 2 if Jog 2 input is on. To allow the drive to go to the jog reference set on preset reference 3 if Jog 1 AND Jog 2 inputs are on.
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Module 85 (V1)
To allow the drive to go to the jog reference at any time.
To preset the reference output to the reference set on preset reference 4 and to accelerate/decelerate to this reference before stopping. For this example the most suitable mode is 9000 with extended switch setting 12. The value to write to L8555 is 9000+12 = 9012. 14.21.15 Analog Output Switching Module 85 contains six analog switches, three 3-input to 1 output and three 1 input to 3-outputs. The arrangement and the input and output parameters for these switches is shown in Figure 14
Each of the six switches is controlled by two bits of parameter L8598 as shown:
L8598 bits Switch 0 A 1 2 B 3 4 C 5 6 D 7 8 E 9 10 F 11
14.21.16 Input Switches The two bits controlling each input switch operate as shown:
Bit setting 1st bit 0 0 1 1 Bit setting 2nd bit 0 1 0 1 Output is connected to Fixed to zero Input 1 Input 2 Input 3
14.21.17 Output Switches The two bits controlling each output switch operate as shown:
Bit setting 1st bit 0 0 1 1 Bit setting 2nd bit 0 1 0 1 Output 1 is connected to Fixed to zero Input Fixed to zero Fixed to zero Output 2 is connected to Fixed to zero Fixed to zero Input Fixed to zero Output 3 is connected to Fixed to zero Fixed to zero Fixed to zero Input
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Table 14-21 Module 85, Control and Referencing
Module 85 (V1)
Variable L8500 L8501 L8502 L8503 L8504 L8505 L8506 L8507 L8508 L8509 L8510 L8511 L8512 L8513 L8514 L8515 L8516 L8517 L8518 L8519 L8520 L8521 L8522 L8523 L8524 L8525 L8526 L8527 L8528 L8529 L8530 L8531 L8532 L8533 L8534 L8535 L8536 L8537 L8538
Description
Scan Time Keypad Run Inhbt Keypad Run Start 1 Start 2 Stop 1 Stop 2 Stop 3 Stop 4 Keypad Stop Not OR I/P OR I/P OR AND OR I/P1 OR AND OR I/P2 AND OR I/P Jog 1 Jog 2 Running I/lock Reset 1 Reset 2 Remote Request Control Passed Startup Pulse Present Flag Run Delay 1 Run Delay 2 Start Req Denied Run Requested Run Request Mem XOR 1 Delayed Run 1 XOR 2 Dly Lat Jog Req Denied Run Req I/lock Res P1 Res P2 Reset In Local
Type Minimum Maximum ON IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IN IN OL OL OL OL OL OL OL OL OL OL OL OL OL 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2

32
Default 0 0 0 0 0 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1000 2000 0 0 0 0 0 0 0 0 0 0 0 0 0

1 = 1 ms 1 = 1 ms 1 = Jog 1 = Jog 1 = Start 1 = Start 1 = Stop 1 = Stop 1 = Stop 1 = Stop 0 = Stop
Scaling
1000 = 1 ms
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2
32 32
1 1 1 1 1 1 1 1 1 1 1 1 1
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Module 85 (V1)
Variable L8539 L8540 L8541 L8542 L8543 L8544 L8545 L8546 L8547 L8548 L8549 L8550 L8551 L8552 L8553 L8554 L8555 L8556 L8557 L8558 L8559 L8560 L8561 L8562 L8563 L8564 L8565 L8566 L8567 L8568 L8569 L8570 L8571 L8572 L8573 L8574 L8575 L8576 L8577 L8578 Description
No Keypad Illegal Keypad Inc 1 Inc 2 Inc 3 Zero Output Dec 1 Dec 2 Dec 3 Sum 1 Sum 2 Sum Offset Preset 1 Preset 2 Preset 3 Preset 4 Switch Setting Filter Value Max Limit 1 Min Limit 1 Min Limit 2 Max Limit 2 Ref [0] Time [0] Ref [1] Time [1] Ref [2] Time [2] Ref [3] Time [3] Inc/Dec Output Summation O/P Switched Output Inverse Output State/Time Left A In 1 A In 2 A In 3 A Out B In 1

Type Minimum Maximum OL OL IL IL IL IL IL IL IL IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN ON ON ON ON ON IN IN IN ON IN 0 0 0 0 0 0 0 0 0 -2 -2 -2 -2 -2 -2 -2
31 31 31 31 31 31 31
Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 10000 0 0 -10000 0 1000 0 1000 0 1000 0 1000 0 0 0 0 0 0 0 0 0 0

1 =1 ms 1 =1 ms 1 =1 ms 1 =1 ms
Scaling
1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2
31 31 31 31 31 31 31 32 32
0 1 -99997 -99998 -99999 -100000 -100000 0 -100000 0 -100000 0 -100000 0 -10000 -10000 -10000 -10000 0 -2 -2 -2 -2
31 31 31 31
100000 99999 99998 99997 100000 99999990 00 100000 99999990 00 100000 99999990 00 100000 99999990 00 10000 10000 10000 10000 2 2 2 2 2
32 31 31 31 31
-231
231
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Module 85 (V1)
Variable L8579 L8580 L8581 L8582 L8583 L8584 L8585 L8586 L8587 L8588 L8589 L8590 L8591 L8592 L8593 L8594 L8595 L8596 L8597 L8598 L8599
B In 2 B In 3 B Out C In 1 C In 2 C In 3 C Out D In
Description
Type Minimum Maximum IN IN ON IN IN IN ON IN ON ON ON IN ON ON ON IN ON ON ON IN IN IL IL IL IL IL IL IL -2 -2

31 31 31 31 31 31 31 31 31 31 31
Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Scaling
2 2 2 2 2 2 2 2 2 2 2
31 31 31 31 31 31 31 31 31 31 31
-2 -2 -2 -2
-2 -2
D Out 1 D Out 2 D Out 3 E In E Out 1 E Out 2 E Out 3 F In F Out 1 F Out 2 F Out 3 Switch Select Mode Set Bits
-2 -2 -2
-231 -2 -2 -2 -2
31 31 31 31 31 31 31
231 2 2 2 2 2 2 2
31 31 31 31 31 31 31
-2 -2 -2
0 0 0 0 0 0 0 0 0
4095 2
32
L8599.24 Add Inc/DecToSum L8599.26 Limited Inc/Dec L8599.27 Allow Auto Rate L8599.28 Allow 1Inc/Dec L8599.29 Allow 10Inc/Dec L8599.30 Allow 100Inc/Dec L8599.31 Allow1000Inc/Dec
1 1 1 1 1 1 1
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Module 85 (V1)
Figure 14-37 Control and Referencing, Module 85 part 1
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Module 85 (V1)
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Module 85 (V1)
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Module 86 (V1)
14.23
Module 86 (V1)
General Purpose Functions, Module 86

Introduction Module 86 contains 10 independent sub-modules each of which can be configured to perform any of the different functions summarized in the table below.
Mode Number 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 18 19 20 21 50 101 102 103 104 105 106 107 108 110 111 112 113 114 115 116 5 input AND TWO_AND_THREE_AND TWO_OR_FOUR_AND TWO_NOR_FOUR_AND FIVE_AND_B2 TWO_AND_B1_THREE_AND TWO_OR_B1_FOUR_AND TWO_NOR_B1_FOUR_AND TWO_OR_THREE_AND_IND TWO_OR_B1_THREE_AND_IND TWO_OR_B2_THREE_AND_IND TWO_OR_THREE_AND_B1_IND TWO_OR_THREE_AND_B2_IND TWO_OR_THREE_AND_B3_IND TWO_OR_B1_THREE_AND_B1_IND TWO_OR_B2_THREE_AND_B1_IND TWO_OR_B1_THREE_AND_B2_IND TWO_OR_B2_THREE_AND_B2_IND TWO_OR_B1_THREE_AND_B3_IND TWO_OR_B2_THREE_AND_B3_IND AND_SWITCHED_TWO_AND FIVE_OR TWO_OR_THREE_OR TWO_AND_FOUR_OR TWO_NAND_FOUR_OR FIVE_OR_B2 TWO_OR_B1_THREE_OR TWO_AND_B1_FOUR_OR TWO_NAND_B1_FOUR_OR TWO_AND_THREE_OR_IND TWO_AND_B1_THREE_OR_IND TWO_AND_B2_THREE_OR_IND TWO_AND_THREE_OR_B1_IND TWO_AND_THREE_OR_B2_IND TWO_AND_THREE_OR_B3_IND TWO_AND_B1_THREE_OR_B1_IND Function Mode Number 117 118 119 120 121 150 201 202 203 204 205 206 207 208 301 401 501 601 701 702 703 801 802 901 902 903 904 1001 1002 1015 1101 1201 1301 1401 1501 1601 Function TWO_AND_B2_THREE_OR_B1_IND TWO_AND_B1_THREE_OR_B2_IND TWO_AND_B2_THREE_OR_B2_IND TWO_AND_B1_THREE_OR_B3_IND TWO_AND_B2_THREE_OR_B3_IND OR_SWITCHED_TWO_OR FIVE_XOR TWO_XOR_THREE_XOR TWO_XOR_FOUR_OR TWO_XOR_FOUR_AND FIVE_XOR_B2 TWO_XOR_B1_THREE_XOR TWO_XOR_B1_FOUR_OR TWO_XOR_B1_FOUR_AND NOT Negate Sign Change (posifiers/negifiers) Positive threshold detect Dual threshold detect 1 Dual threshold detect 2 Dual threshold detect 3 D-type latch 1 D-type latch 2 Delay pulse 1 Delay pulse 2 Delay pulse 3 Delay pulse 4 Maths 1 Maths 2 Maths 3 Analog data Negater/Filter XY Shaper Analog Summation Bit manipulation Counter Bit logic edge detect
14.23.1
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Mode Number 1701 1801 1901 1902 1903 2001 2002 Function Redefinable link Serial link configuration Variable magnitude compare 1 Variable magnitude compare 2 Variable magnitude compare 3 Analog switch 1 Analog switch 2 Mode Number 2101 2201 2202 2301 2401 10001 10101

Function preset ramp High/Low input pass 1 High/Low input pass 2 Sample/hold calculate Access SEEPROM Stall detect I2T protection
14.23.2
Sub-Module Generic Description Each of the sub-modules has five inputs and three outputs and is of the general form shown in Figure 14-40.
Figure 14-40 General Purpose Sub-modules, Module 86
The sub-modules are numbered 0 to 9 and the individual sub-module to be accessed in ladder or links files is determined by the second digit from the right of the parameter number (e.g. L8621 is the mode input parameter for sub-module 2). 14.23.3 Setting the Configuration Mode for a Sub-module The function of a sub-module is determined by the mode number written to the mode input parameter (L86x1) for each module. A complete list of sub-module mode numbers and functions is given in table on page14 -141. When a valid mode number is entered the module configures itself and starts running. During configuration, the module clears any internal variables and sets the outputs to zero. It does not clear any Page 14-142 Alspa GD4000 Issue (12-2-98)
Module 86 (V1)
input values. The outputs are then rewritten depending upon the inputs and configuration mode. It is possible, and valid, to change the mode of operation of a sub-module while the drive is running. 14.23.3.1 Input and Output Variable The data types for the inputs and outputs of a sub-module depend on the, user defined, configuration mode, which may require single bit I/O, multiple bit I/O or 32-bit word I/O. To accommodate this requirement the input and outputs of each of the sub-modules are standardized as follows:
All the inputs and outputs are 32 bit integers (long int) which means that they can
only accommodate values between -2,147,483,648 and 2,147,483,647.

There are no minimum, maximum or default values defined for the input or outputs. Descriptive labels (mnemonics) for inputs and outputs have not been assigned since
their function is unknown prior to user configuration. Because of this standardization, the inputs and outputs of a sub-module are not pre-defined and must be declared using the CSP DEF TABLE statement before they can be linked to the source and destination variables in a user program. 14.23.4 Declaring Inputs and Outputs Using the DEF TABLE Statement When using Module 86 it is necessary to declare the sub-module inputs and outputs and assign mnemonics using the CSP DEF TABLE statement before they can be linked to the source and destination variables in the user program. The DEF TABLE statement in the CSP Links editor is used to define the maximum and minimum values, scaling, default value, units and mnemonic for variable. A full description of the DEF TABLE statement and its uses is given in Section 7.8. 14.23.4.1 Using DEF TABLE to Declare Sub-module I/O Variables Typical DEF TABLE statements to declare sub-module input and output variables are as follows: Logic (bit) variable DEF TABLE L8632.0=1,0,0,1,0,LOGIC BIT 1 The above statement defines input 1 of sub-module 3 as single bit variable, with a default value of 1 and assigns the mnemonic LOGIC BIT 1. Numeric (32 bit word) Variable DEF TABLE L8624.0=2147483647,-2147483648,0,0,0,INT WORD 1 The above statement defines input 3 of sub-module 4 as a signed 32 bit integer and assigns the mnemonic INT WORD 1. An alternative way of doing this would be to enter: DEF TABLE L8624.0=,,,,,,
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In this case the CSP links editor will set any undefined parameters in the statement to default values and produce the statement: Note: There is no default mnemonic.
DEF TABLE L8624.0=2147483647,-2147483648,0,0,0, Note: Only the input and output variables require DEF TABLE statements, L8600 (Scan rate), L8610 (configuration error word), L8601, L8611, L8621, L8631, L8641, L8651, L8661, L8671, L8681 and L8691 (configuration modes for each sub-module) are pre-defined.
14.23.5
Programming Errors Due to the flexibility of these modules it is possible to cause nonsensical output through incorrect or unwise usage. It is the responsibility of the user to ensure correct operation of the module under these circumstances. Three common causes of errors are: 1) Divide by zero errors. It is not possible to divide a number by zero and obtain a meaningful result. Because of this, the modes where division is required usually rewrite any divisor of 0 to a 1. 2) Calculation rollovers. By using very large numbers in some calculations it is possible that the 32 bit arithmetic will rollover. Generally, catches have not been put into the module to indicate/solve this problem, and if they have the mode description will indicate the fact. It is the responsibility of the user to be aware of this problem when considering the maximum possible input values. 3) Signed/unsigned conversion. Because of the flexibility of the module, the inputs are always declared as being signed integer values. The sign bit is bit 32, the most significant bit. If an unsigned 32 bit integer is passed to an input expecting a signed input it will treat it as a signed value. Thus if the unsigned bit has the most significant bit set the module will consider this to be a negative value.
14.23.5.1 Invalid Mode Errors If an invalid mode is chosen then a bit is set in the bit fault field (L8610), and the mode value is ignored. The bit fault field flag indicates the state of each of the modules 10 sub-modules, using one bit for each sub-module. A 1 in a bit indicates a sub-module configuration error, see the table below. In addition to the individual error flags a global error flag is set to 0 upon a sub-module configuration error. This global configuration error bit can be linked into the fault trip logic used by the user to prevent the system from running if any of the modules are incorrectly setup. A configuration error can be removed by reconfiguring the sub-module correctly.
Bit fault field bit 8610 Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Meaning Sub-module 1 configuration error Sub-module 2 configuration error Sub-module 3 configuration error Sub-module 4 configuration error Sub-module 5 configuration error Sub-module 6 configuration error Sub-module 7 configuration error
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Bit fault field bit 8610 Bit 7 Bit 8 Bit 9 Bit 31 Meaning
Module 86 (V1)
Sub-module 8 configuration error Sub-module 9 configuration error Sub-module 10 configuration error Global configuration error
14.23.6
Sub-Module Functions Functional diagrams, to accompany these descriptions of the Module 86 modes can be found in Figures 14-41 to 14-45.
14.23.7
Binary Logic The binary logic functions (modes 1 to 301 inclusive) is self evident from the diagrams which can be found in Figures 14-41 to 14-43.
14.23.8
Mode 401, NEGATE_1 Mode 401 provides two switched analog invertor functions and one unswitched analog invertor. When selected the output is the 2s complement of the input. Note: The sign bit is the most significant bit of the 32 bit word passed to this module.
Input Decimal 0 45 2147483647 -2147483648 -2147483647 -3 -1 Hexadecimal 0x00000000 0x0000002D 0x7FFFFFFF 0x80000000 0x80000001 0xFFFFFFFD 0xFFFFFFFF Decimal 0 -45 -2147483647 -2147483648 2147483647 3 1 Output Hexadecimal 0x00000000 0xFFFFFFD3 0x80000001 0x80000000 0x7FFFFFFF 0x00000003 0x00000001
Table Address L86?2
I/O Type Input 1
Suggested Mnemonic Invertor1 Input
Functional Description The value passed into this input will be passed to Invertor1 Output; inverted or Not inverted depending upon the state of L86?3. If this input is non-zero the switch will pass the value on Invert1 Input to Invertor1 Output unchanged. However if the value on this input equals zero then the value on Invertor1 Output will be inverse of the value entered on Invertor1 Input. The value passed into this input will be passed to Invertor2 Output; inverted or Not inverted depending upon the state of L86?5.
L86?3
Input 2
Invertor1 Switch
L86?4
Input 3
Invertor2 Input
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Table Address L86?5 I/O Type Input 4 Suggested Mnemonic Invertor2 Switch

Functional Description If this input is non-zero the switch will pass the value on Invert2 Input to Invertor2 Output unchanged. However if the value on this input equals zero then the value on Invertor2 Output will be inverse of the value entered on Invertor2 Input. The value on this input will always be inverted before being passed to its corresponding output. Output of switch which will contain the inverted or Not inverted value of Invertor1 Input depending upon the state of L86?3. Output of switch2 which will contain the inverted or Not inverted value of Invertor2 Input depending upon the state of L86?5. Invertor3 Output which will always contain the inverse of Invertor3 Input.
L86?6
Input 5
Invertor3 Input
L86?7
Output 1
Invertor1 Output
L86?8
Output 2
Invertor2 Output
L86?9
Output 3
Invertor3 Output
14.23.9
Mode 501, MODULUS (Sign Changing) Mode 501 provides three identical operators, which give outputs which are the modulus of the inputs (i.e. if the input is positive, the output is identical to the input, but if the input is negative the the output is positive with the same amplitude. The functional description for this sub-module inputs and outputs are as follows:Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Posifier1 Input Unused Posifier2 Input Unused Posifier3 Input Posifier1 Output Posifier2 Output Posifier3 Output Input is ignored Input is ignored Functional Description
14.23.10 Mode 601, Positive Threshold Detection Mode 601 provides two independent threshold detectors. When an input exceeds the value set as the threshold the output delay timer starts to count down. If an input exceeds the threshold level for a time greater than the value set in the delay timer, the first two bits of the corresponding output are changed (see table below for details). If the input returns to a level below the threshold before the delay count down is completed, then the output remains unchanged and the delay timer is reset.
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Table Address L86?2 L86?3 L86?4 L86?5 L86?6 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Suggested Mnemonic Input 1 Threshold 1 Input 2 Threshold 2 Common Delay
Module 86 (V1)
Functional Description This input will be compared against Threshold 1. The output delay timer will start to time out if Input 1 exceeds this value. This input will be compared against Threshold 2. The output delay timer will start to time out if Input 2 exceeds this value. This input defines the delay time in milliseconds, from the input exceeding the threshold to the output state changing. Bit00=1 Bit01=0 if Input 1 is less than or equal to Threshold 1. Bit00=0 Bit01=1 if Input 1 is greater than Threshold 1 for longer than time defined by Input 4. Bit00=1 Bit01=0 if Input 2 is less than or equal to Threshold 2. Bit00=0 Bit01=1 if Input 2 is greater than Threshold 2 for longer than time defined by Input 4. preset to 0
L86?7
Output 1
Output 1
L86?8
Output 2
Output 2
L86?9
Output 3
Unused
Note:
The delay time can only be a positive value, if a negative value is entered it will be re-written to 0. The maximum time obtainable is 2147483647mS (0x7FFFFFFF) or 24.85 days.
14.23.11 Mode 701, Dual Level Threshold Detection Mode 701 provides two threshold detection levels for one data input. Each threshold level has an associated time delay. If the input exceeds a threshold level for more than the associated time delay T1, then the appropriate threshold status output is changed to indicate this as shown in the table below. If the input returns to a level below the threshold before the delay time T2 is completed, then the output remains unchanged and the delay timer is reset.
Table Address L86?2 L86?3 L86?4 I/O Type Input 1 Input 2 Input 3 Suggested Mnemonic Enter threshold window timer Exit threshold window timer Input Functional Description This input defines the threshold 1 time delay in milliseconds. This input defines the threshold 2 time delay in milliseconds. This is the data input which will be compared with Threshold 1 and Threshold 2. The output delay timer will start to count down if Input 3 exceeds this value. The output delay timer will start to count down if this value exceeds Input 3.
L86?5
Input 4
Threshold 1
L86?6
Input 5
Threshold 2
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Table Address L86?7 I/O Type Output 1 Suggested Mnemonic Threshold 1 Status O/P

Functional Description Bit00=1 Bit01=0 if Input 3 is less than or equal to Threshold 1. Bit00=0 Bit01=1 if Input 1 is greater than Threshold 1 for longer than time defined by Input 1. If Output 1 or output 3= 1 then Bit 00 = 1 and Bit01 = 0 else Bit 00 = 0 and Bit 01 = 1. Bit00=1 Bit01=0 if Input 3 is less than or equal to Threshold 2. Bit00=0 Bit01=1 if Input 3 is greater than Threshold 2 for longer than time defined by Input 2.
L86?8
Output 2
Global Status O/P
L86?9
Output 3
Threshold 2 Status O/P
14.23.11.1 Operation If input If input If input If input Notes 3 > input 4, output 1 goes high after a time of input 2 3 <= input 4, output 1 goes low after a time of input 1 3 < input 5, output 3 goes high after a time of input 2 3 >= input 5, output 3 goes high after a time of input 1 High - Bit 0 = 1, Bit 1 = 0 Low - Bit 0 = 0, Bit 1 = 1 The negative threshold value has an internal -1 multiplier. This means that putting a positive value on input 5 will produce a negative threshold value. This mode also has two optional delay values. Input 1 specifies the output delay when going from a low to a high, and input 2 specifies the output delay when going from a high to a low. Both times are entered in ms. Note: The delay time can only be a positive value, if a negative value is entered it will be re-written to 0. The maximum time obtainable is 2147483647mS (0x7FFFFFFF) or 24.85 days.
14.23.12 Mode 702, Threshold Detect 2

Table Address L86?2 L86?3 L86?4 I/O Type Input 1 Input 2 Input 3 Suggested Mnemonic Threshold Timer T1 Threshold Timer T2 Input Functional Description This input defines the threshold 1 time delay in milliseconds. This input defines the threshold 2 time delay in milliseconds. This is the data input which will be compared with Threshold 1 and Threshold 2. The output delay timer will start to count down if Input 3 exceeds this value. The output delay timer will start to count down if this value exceeds Input 3 (-ve value taken). Bit00=1 Bit01=0 if Input 3 is less than or equal to Threshold 1. Bit00=0 Bit01=1 if Input 1 is greater than Threshold 1 for longer than time defined by Input 1.
L86?5
Input 4
Threshold 1
L86?6
Input 5
Threshold 2
L86?7
Output 1
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Table Address L86?8 I/O Type Output 2 Suggested Mnemonic Global Status O/P
Module 86 (V1)
Functional Description If Output 1 or output 3= 1 then Bit 00 = 1 and Bit01 = 0 else Bit 00 = 0 and Bit 01 = 1. Bit00=1 Bit01=0 if Input 3 is less than or equal to Threshold 2. Bit00=0 Bit01=1 if Input 3 is greater than Threshold 2 for longer than time defined by Input 2.
L86?9
Output 3
14.23.12.1 Operation If input If input If input If input Notes: 3 > input 4, output 1 goes high after a time of input 2 3 <= input 4, output 1 goes low after a time of input 1 3 < input 5, output 3 goes high after a time of input 2 3 >= input 5, output 3 goes high after a time of input 1 High - Bit 0 = 1, Bit 1 = 0 Low - Bit 0 = 0, Bit 1 = 1 Negative threshold value has an internal -1 multiplier. This means that putting a positive value on input 5 will produce a negative threshold value. This mode also has two optional delay values. Input 1 specifies the output delay when going from a low to a high, and input 2 specifies the output delay when going from a high to a low. Both times are entered in ms. Note: The delay time can only be a positive value, if a negative value is entered it will be re-written to 0. The maximum time obtainable is 2147483647mS (0x7FFFFFFF) or 24.85 days.
14.23.13 Mode 703, Threshold Detect 3

Table Address L86?2 L86?3 L86?4 I/O Type Input 1 Input 2 Input 3 Suggested Mnemonic Threshold Timer T1 Threshold Timer T2 Input Functional Description This input defines the threshold 1 time delay in milliseconds. This input defines the threshold 2 time delay in milliseconds. This is the data input which will be compared with Threshold 1 and Threshold 2. The output delay timer will start to count down if Input 3 exceeds this value. The output delay timer will start to count down if this value exceeds Input 3 (-ve value taken). Bit00=1 Bit01=0 if Input 3 is less than or equal to Threshold 1. Bit00=0 Bit01=1 if Input 1 is greater than Threshold 1 for longer than time defined by Input 1. If Output 1 or output 3= 1 then Bit 00 = 1 and Bit01 = 0 else Bit 00 = 0 and Bit 01 = 1. Bit00=1 Bit01=0 if Input 3 is less than or equal to Threshold 2. Bit00=0 Bit01=1 if Input 3 is greater than Threshold 2 for longer than time defined by Input 2.
L86?5
Input 4
Threshold 1
L86?6
Input 5
Threshold 2
L86?7
Output 1
L86?8
Output 2
Global Status O/P
L86?9
Output 3
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14.23.13.1 Operation If input If input If input If input Note:
3 > input 4, output 1 goes high after a time of input 2 3 <= input 4, output 1 goes low after a time of input 1 3 < input 5, output 3 goes high after a time of input 2 3 >= input 5, output 3 goes high after a time of input 1 High - Bit 0 = 1, Bit 1 = 0 Low - Bit 0 = 0, Bit 1 = 1
14.23.14 Mode 801, D-type Latch with Set and Reset Mode 801 provides a D-type SR latch and a separate negate function. The latch is a full 32 bits wide, and can be used as either a single 32-bit latch or 32 single bit latches. the latch works in accordance with the following truth table:
Set X high low Reset high low low Data X X D Clock X X Q Output 0 1 D
When used as a 32-bit latch the data input is 32bits wide and the set, rest and clock signal are all set to 0 for a low and 0xFFFFFFFF (hex) for a high. When used as 32 single bit latches, each bit of the latch can be set, reset and clocked individually. To set, reset or clock any particular bit it is only necessary to set the relevant bit in the set, reset and clock words. Thus to reset bit 3 output, bit 3 of the reset word is set to a 1. If the other bits are all set to zero, the reset of the output bits will remain unaffected. Note: In this mode, the reset value is read last and will override any previously set bits.
I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Set Input Data Input PosClock Input Reset Input Not Input Latch O/P Inv Latch O/P Not Output Functional Description User Input User Input User Input Resets Outputs User Input User Output User Output User Output
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9
14.23.15 Mode 802, D-type Latch with Set and Reset Mode 802 provides a D-type SR latch and a separate negate function. The latch is a full 32 bits wide, and can be used as either a single 32-bit latch or 32 single bit latches. The operation of this mode differs from mode 801 in that set input overrides the reset input. The latch works in accordance with the following truth table:
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Set high low low Reset low high low Data X X D Clock X X Q Output 1 0 D
Module 86 (V1)
When used as a 32-bit latch the data input is 32bits wide and the set, rest and clock signal are all set to 0 for a low and 0xFFFFFFFF (hex) for a high. When used as 32 single bit latches, each bit of the latch can be set, reset and clocked individually. To set, reset or clock any particular bit it is only necessary to set the relevant bit in the set, reset and clock words. Thus to reset bit 3 output, bit 3 of the reset word is set to a 1. If the other bits are all set to zero, the reset of the output bits will remain unaffected. Note: In this mode, the set value is read last and will override any reset bits.
I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Set Input Data Input PosClock Input Reset Input Not Input Latch O/P Inv Latch O/P Not Output Functional Description User Input User Input User Input Resets Outputs User Input User Output User Output User Output
14.23.16 Mode 901, Pulse Delays 1 Mode 901 provides two independent pulse delays, which operate as follows: 14.23.16.1 Pulse Delay 1 The output delay timer is triggered on the leading edge of the input pulse. After the user specified delay the output goes high. The output returns to low immediately on the trailing edge of the input pulse. If the input is high for less than the user delay time, no output high is generated. 14.23.16.2 Pulse Delay 2 Output delay timer 2 is triggered on the leading edge of the input pulse. After the first user specified delay (Dly2) the output goes high. Output delay timer 3 is triggered on the trailing edge of the input pulse and the output returns to low at the end of the second user specified delay (Dly3). If the input returns to low before delay 2 is complete, the output remains low. If the input returns to high before delay 2 is complete, the output will remain low for until delay 2 is completed and then go high.
Table Address L86?2 L86?3 L86?4 I/O Type Input 1 Input 2 Input 3 Suggested Mnemonic Dly On Input On Delay Dly1 Dly On/Off Input input On delay value in ms. input Functional Description
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Table Address L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic On Delay Dly2 Off Delay Dly3 Dly On O/P Dly On/Off O/P Unused

Functional Description On delay value in ms Off delay value in ms Output Output preset to 0
14.23.17 Mode 902, Pulse Delays 2 Mode 902 provides two independent pulse delays with a set width. 14.23.17.1 Pulse Delay 1 The output is triggered on a zero to non-zero transition of the input pulse and immediately goes high for the period specified in Delay 1. If the input makes another zero to non-zero transition during the time the output is high, the output is re-triggered, and will remain high for the period specified in delay 1 after the latest zero to non-zero transition. 14.23.17.2 Pulse Delay 2 Output delay timer 2 is triggered on a zero to non-zero transition of the input pulse. On completion of the delay period the output goes high for the period specified in delay 3. If a second zero to non-zero transition occurs during the output high period the output is re-triggered and remains high for the period specified in delay 3 starting from the last zero to non-zero transition. Similarly, if a zero to non-zero transition occurs during the first delay period (delay 2) the timer is re-triggered and restarts its count down so that the output remains low for the delay period specified in delay 2 starting at the last zero to non-zero transition. The output will then go high as for a normal sequence. The functional descriptions for the inputs and outputs are as follows:Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Dly On Input On Delay Dly1 Dly On/Off Input On Delay Dly2 Off Delay Dly3 Dly On O/P Dly On/Off O/P Unused Functional Description Pulse Input On delay value Pulse Input On delay value Off delay value Output Output preset to 0
14.23.18 Mode 903, Pulse Delays 3 the operation of Mode 903 is identical to Mode 901. 14.23.19 Mode 904, Pulse Delays 4 the operation of Mode 904 is identical to Mode 902
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14.23.20 Mode 1001, Maths 1 - Scaling
Module 86 (V1)
Mode 1001 provides two scaled and offset outputs calculated as follows: Output 1 L86?7 = (L86?2 x L86?3) + L86?6 L86?5 Output 2 Output 2 is preset to 0. Output 3 L86?9 = (L86?2 x L86?4) + L86?6 L86?5 Note: If a 0 is entered as a divisor it is rewritten to 1 internally to prevent a divide by zero error.
I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Input Top Multiplier Bottom Multiplier Common Divisor Common Addition Top Maths O/P Unused Bottom Maths O/P Functional Description This is the first variable in the equation. User Input User Input User Input User Input Output preset to 0 Output
14.23.21 Mode 1002, Maths 2 - Scaling Mode 1002 provides one scaled output calculated as follows: Output 1 Output 1 (L86?7) is preset to 0 Output 2 L86?8 = (L86?4 + L86?5 - L86?3) x L86?2 L86?6 Note: If L86?6 is written set to 0, it will be reset to 1 to avoid the divide by zero error.
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Module 86 (V1)
Output 3 Output 3 L86?9 is preset to 0
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Multiplier Subtractor Input 1 Input 2 Divisor Unused Output Unused
Functional Description User Input User Input User Input User Input User Input not used - preset to 0 Output not used - preset to 0
14.23.22 Mode 1015, Maths 15 - Scaling and Offset Mode 1015 provides one scaling and offset mathematical function, calculated as follows: Output 1 L86?7 = (L86?2 x L86?3) + L86?5 L86?4 Outputs 2 and 3 If L86?7 is greater than L86?6 then L86?8 = L86?6 L86?9 = B4 hex If L86?7 is less than -L86?6 then L86?8 = -L86?6 L86?9 = E1 hex Else L86?8 = L86?7 L86?9 = D2 hex
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Suggested Mnemonic Input 1 Input 2 Input 3 Input 4 Threshold Output Input Input Input Input level for output reaction function of inputs 1, 2, 3 and 4 Functional Description
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Table Address L86?8 L86?9 I/O Type Output 2 Output 3 Suggested Mnemonic Limited output bit flags
Module 86 (V1)
Functional Description limited to threshold level if Output 1 > Input 4 bit field
Note:
Input L86?4; the divisor can not be 0 if 0 is entered it is overwritten with 1. Inputs L86?2 and L86?6 cannot be negative. If a negative number is enter the sign will be removed but the value will remain the same. i.e. The modulus of the value will be used.
14.23.23 Mode 1101, Low Pass Filter and Invertor Mode 1101 provides an analog RC filter and an analog invertor. Analog Invertor The value to be inverted is written to L86?2 and the inverted value is output on L86?7. Low Pass Filter The analog signal is written to input 3 (L86?4) and the RC time constant to input 5 (L86?6), the filtered value is calculated as follows: New Output = (Present Input - Present Output) x Scan Time Time Constant x 1000 The scan time is the slow task scan time in milliseconds and is calculated by the module. The result of this calculation is presented as a dividend (L86?8) and a remainder (L86?9). There are limitations placed on the user inputs to avoid internal errors: i) The entered time constant must be greater than 1 otherwise it is rewritten to a one.
ii) The time constant must be greater than the scan time. If it is less than the scan time, it is rewritten to be the same as the scan time. iii) The input value to be filtered is limited to (100,000 to avoid overflow. iv) The maximum time constant value is 1,000,000 ms. The output should reach 63% of the input value after 1 time constant and should reach the input value after 5 time constants.
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Input 1 not used Filter I/P not used Time constant Inverted O/P Filter output Remainder Functional Description input to be inverted Not connected in this configuration Signal that requires low pass filtering Not connected in this configuration Time constant value Inverse of Input 1 Output from the filter integer maths result in rounding errors so remainders are included in the calculation
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14.23.24 Mode 1201, XY Shaper
Mode 1201 provides a user entered conversion function. The conversion function is defined by series of XY points entered in data tables. When an X value is placed in the input 1 (L86?2), the module uses linear interpolation to calculate the corresponding Y value which is placed in output 1 (L86?7). The location of the first XY data table is specified in inputs 3 (L86?4) and 4 (L86?5) and the number of XY points in input 5 (L86?6). 14.23.25 Setting up the XY Shaper To configure the drive to use the XY shaper feature:
Write the XY data to data tables, the table below shows 6 data points written to data
tables starting at G100.

G100 G101 G102 G103 G104 G105 X1 Y1 X2 Y2 X3 Y3 G106 G107 G108 G109 G110 G111 X4 Y4 X5 Y5 X6 Y6
Define location of the first data table in inputs 3 and 4 and the number of XY points
in input 5 as follows: Input 3 (L86?4) = 71 (the ASCII code for an uppercase G.) Input 4 (L86?5) = 100 (the data starts at G100) Input 5 L86?6) = 6 (number of XY data points) Configuration is now complete. If a valid X coordinate is now written to input 1 (L86?2), the corresponding Y coordinate will be written to output 1 (L86?7)
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 O/P Output Input out of range of data in table Shaper error code Suggested Mnemonic Input not used Data Table address - see text Functional Description User Input
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14.23.26 Error Handling
Module 86 (V1)
Output 2 is set to a one when the entered X co-ordinate input is beyond the range of the entered graph data. Output 3 contains the shaper error code. The meanings of these error codes is shown in the table below.
Shaper Error 1 2 4 8 16 32 Output 3 Incorrect number of XY data points, must be between 2 and 20. Two points have the same X co-ordinate. This would cause a divide by zero error when computing the gradient of the graph. Unable to read entered points, an illegal table may have been entered. Entered X point is before the plotted X beginning Unable to read initial entered point, an illegal table may have been entered. Entered X point is after the plotted X end.
14.23.27 Mode 1301, Summation with upper and lower limits Mode 1301 calculates an output from three input values and applies upper and lower limits to the calculated value. An unlimited output and output limit status are also generated. The output value is calculated as follows: Unlimited output (L86?9) = input 3 + input 4 - input 2 the value written to the limited output L86?8 is calculated in the same way as L86?8 but has the positive and negative limits specified in inputs L86?2 and L86?6 applied. Output L86?7 is the limit status word, which has both active high and active low bits to indicate that the output has gone into limit as follows: Bits 0-2 inclusive are active high indicators, bit3 is always a 0. Bits 4-6 inclusive are active low indicators, bit7 is always a 1. Bits 8-31 are always 0. Bit0 high/Bit4 low indicates that the output is in negative limit. Bit1 high/Bit5 low indicates that the output is not in limit. Bit2 high/Bit6 low indicates that the output is in positive limit. If the output is not in limit the limit status word is:0000 0000 0000 0000 0000 0000 1101 0010 0 0 0 0 0 0 d 2 If the output is in positive limit the limit status word becomes:0000 0000 0000 0000 0000 0000 1011 0100 0 0 0 0 0 0 b 4 If the output is in negative limit the limit status word becomes:0000 0000 0000 0000 0000 0000 1110 0001 0 0 0 0 0 0 e 1
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Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Suggested Mnemonic Positive Limit Variable 1 Variable 2 Variable 3 negative limit Limit Status Word

Functional Description This defines the max positive value the limited output can achieve. This is the first variable in the equation. This variable gets added to the first variable. This variable gets subtracted from the sum of the first two variables. This defines the min negative value the limited output can achieve. Bits in this word are set or reset dependent on whether the output is in limit or not. The output of the equation but limited by the values placed on the limit inputs. The output of the equation which does not get limited.
L86?8 L86?9
Output 2 Output 3
Limited Output Unlimited Output
14.23.28 Mode 1401, Bit Manipulation 1 Mode 1401 provides two basic bit manipulation functions; rotate left and shift left. They operate on a 32 bit word as follows: 14.23.28.1 Rotate Left Function The rotate left function moves the individual bits of the 32-bit input a specified number of places to the left. At each execution the most significant bit becomes the least significant bit. The example below shows the result of two rotate left executions: input rotate left rotate left 110010100000000000000000000000000 100101000000000000000000000000001 001010000000000000000000000000010
Input 1 is the 32-bit word to be operated upon. Input 2 defines the number of rotate left operations to be executed. The result is written to output 1. 14.23.28.2 Shift Left The shift left function moves the individual bits of the 32-bit input a specified number of places to the left. At each execution the original most significant bit is lost and a the new least significant bit becomes a 0. The example below shows the result of two shift left executions: input shift left shift left 110010100000000000000000000000000 100101000000000000000000000000000 001010000000000000000000000000000
Input 1 is the 32-bit word to be operated upon. Input 2 defines the number of shift left operations to be executed. The result is written to output 1. The value written to input 2 must be in the range 0 to 32 since any greater number will result in all 32 bits being written to 0.
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Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Input Rotate by not used Input Rotate by Rotated O/P L rotated O/P R rotated O/P Input
Module 86 (V1)
Functional Description
Rotate input1 by this amount
left rotated input 1 by input 2 left rotated input 4 by input 5 right rotated input 4 by input 5
14.23.29 Mode 1501, Edge Counter Mode 1501 provides a 32-bit counter which increments or decrements whenever an input signal edge is received. The input signal is received via input 3 and inputs 1 and 2 determine whether the count output is decremented or incremented. The pre-load facility allows a count output to be started from a predetermined value and comprises the pre-load enable (input 4) and the pre-load value (input 5). The edge counter obeys the following truth table:
Up x 0 High High Down x High 0 High Clock x Pre-load High 0 0 0 Pre-load Value P x x x New Output P Previous Output - 1 Previous Output + 1 Previous Output
Where: high is defined as being any non zero value. is defined as any zero to non-zero transition. x is a dont care state. Output 2 goes high when the current count is zero. Output 3 goes high when the current count is equal to, or greater than, half the pre-load value. When the counter reaches its maximum or minimum value it will simply roll over if the count continues.
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Decrement Increment Trigger Preload Value Count Zero reached 1 => 1/2 input 5 Functional Description 1 = decrement count 1 = Increment count Trigger edge input 1 = preload preload count value current count value
14.23.30 Mode 1601, Edge Detection Mode 1601 is used to detect a change of state of the signal on Input 2. Input 1 specifies the period of the module clock in ms. Input 3 controls how the input transition is signaled at the outputs.
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Module 86 (V1)
The Input 1 is checked every clock period. If the state of input 1 has changed since the last clock period, then Outputs 1 to 3 are set according to the configuration of input 3. If Input 3 is set to 0 the outputs 1 to 3 change from 0 to 1 for an input transition, if input 3 is set to 1 the outputs 1 to 3 change from 1 to 0 to indicate an input transition. Outputs 1 to 3 indicate the following: Output 1- Indicates a rising edge on Input 2. If the state of input 2 has changed from low to high, Output 1 changes state for 1 clock period and then returns to the original state. Output 2 - Indicates both the rising and the falling edge of a transition on input 2. Output 3 - Indicates a falling edge on Input 2. If the state of input 2 has changed from high to low, Output 3 changes state for 1 clock period and then returns to the original state.
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Period Monitor Value Active On state Functional Description Monitor time Value input Sets Active On state for o/ps 1 = Active low Not used Not used See description See description See description
14.23.31 Mode 1701, Redefinable Links Mode 1701 allows the user to specify two links that can later be changed by editing parameters from the keypad. A table number and module offset are placed on two inputs. The module then puts the value stored at this location on to an output. The contents of the data table defined by inputs 1 and 2 are written to output 1 and the contents of the data table defined by Inputs 3 and 4 are written to Output 2. As it is possible to change the module inputs whilst the drive is running, it is effectively possible to alter a link after compilation. Errors are reported on output 3. The most significant bit is the global healthy signal, this goes low if an invalid table has been used. The two least significant bits are used to indicate that the two outputs are healthy. Bit 0 is the healthy signal for output 1, and Bit 1 is the healthy signal for output 2. L86?6 determines the Output Mode as follows: 0 = contents of data table 1 = bitwise negation of contents data table 2 = Arithmetic invert of contents data table
Table Address L86?2 L86?3 I/O Type Input 1 Input 2 Suggested Mnemonic Data table letter 1 Data table address 1 Functional Description e.g. ASCII L = 76 e.g. 1401
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Table Address L86?4 L86?5 L86?6 I/O Type Input 3 Input 4 Input 5 Suggested Mnemonic Data table letter 2 Data table address 2 O/P Mode
Module 86 (V1)
0 = contents of data table 1 = bitwise negate of contents of data table 1 = Invert of contents of data table Contents of data table address 1 Contents of data table address 2 Error code
L86?7 L86?8 L86?9
Output 1 Output 2 Output 3
14.23.32 Mode 1801, Configure Serial Link Mode 1801 allows the user to configure the serial links. This mode is an additional interface to Special Function T33 CONFIG. A full description of Special Function T33 and the valid input values is given in Section 5.1.
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Link No. Tributary Baud rate code Parity Port type Set up error preset to 0 preset to 0 Functional Description
14.23.33 Mode 1901, Compare 1 Mode 1901 compares the input on L86?6 to four threshold values set in inputs 1 to 4 and sets the output depending on the result. The threshold values set in inputs 1 to 4 must be in ascending order for the module to work; i.e Input 4 must be greater than Input 3 which must be greater than input 2, and input 2 must be greater than input 1. If the threshold vlaues are not entered in the correct order, then output 3 is cleared and the module does not function. The output is set as follows: If input 5 is less than threshold 1 then bit 0 is set If input 5 is equal to threshold 1 then bit 1 is set If input 5 is greater than threshold 1 then bit 2 is set If input 5 is greater than threshold 1 but less than threshold 2 then bit 3 is set If input 5 is less than threshold 2 then bit 4 is set If input 5 is equal to threshold 2 then bit 5 is set If input 5 is greater than threshold 2 then bit 6 is set If input 5 is greater than threshold 2 but less than threshold 3 then bit 7 is set If input 5 is less than threshold 3 then bit 8 is set If input 5 is equal to threshold 3 then bit 9 is set If input 5 is greater than threshold 3 then bit 10 is set If input 5 is greater than threshold 3 but less than threshold 4 then bit 11 is set If input 5 is less than threshold 4 then bit 12 is set If input 5 is equal to threshold 4 then bit 13 is set If input 5 is greater than threshold 4 then bit 14 is set
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Module 86 (V1)
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Threshold 1 Threshold 2 Threshold 3 Threshold 4 Input Output Inverted O/P Setup error

Inverted Output error flags
14.23.34 Mode 1902, Compare 2 Mode 1902 operates in the same way as Mode 1901 except that the input is posified and the threshold can only be positive.
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Threshold 1 Threshold 2 Threshold 3 Threshold 4 Input Output Inverted O/P Setup error Inverted Output error flags Functional Description
14.23.35 Mode 1903, Compare 3 Mode 1903 compares the values in the 5 inputs and sets the three outputs according to the results as follows: If Input 1 < input 2, output 1 = E1 hex. If input 1= input 2, output 1 = D2 hex. If input 1> input 2, output 1 = B4 hex. If Input 3 < input 4, output 2 = E1 hex. If input 3= input 4, output 2 = D2 hex. If input 3> input 4, output 2 = B4 hex. If Input 5 < 0, output 3 = E1 hex. If input 5= 0, output 3 = D2 hex. If input 5> 0, output 3 = B4 hex.
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Threshold 1 Threshold 2 Threshold 3 Threshold 4 Input Output Inverted O/P Setup error Inverted Output error flags Functional Description
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14.23.36 Mode 2001, Analog Switches 1
Module 86 (V1)
Mode 2001 provides two 2-pole analog switches, A and B. The output from each of these switches is selected from two inputs sources and is controlled by input 5 as follows: Analog Switch A If bit 0 is set in input 5 then Output 1 = Input 2 If bit 0 is cleared in input 5 then Output 1 = Input 1 Analog Switch B If bit 1 is set in input 5 then Output 2 = Input 4 If bit 1 is cleared in input 5 then Output 1 = Input 3
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Functional Description Switch A Input 1 Switch A input 2 Switch B input 1 Switch B input 2 Switch settings Switch A output Switch B output Preset to 0
14.23.37 Mode 2002, Analog Switch 1 Mode 2002 provides one 4-pole analog switch. The output of this switch is selected from the four inputs sources and is controlled by input 5 as follows:
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Functional Description Switch input 1 Switch input 2 Switch input 3 Switch input 4 Switch setting Switch output Preset to 0 Preset to 0
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14.23.38 Mode 2101, Preset Ramp
Mode 2101 Provides a pre-programmed acceleration/deceleration output for use as a reference signal. 14.23.38.1 Inputs The target reference is written to input 1 and the initial value of the ramp signal is written to input 5. The acceleration and deceleration rates are written to inputs 2 and 3 respectively. The output can be reset to 0 by writing a non-zero value to input 4. 14.23.38.2 Outputs The reference signal is output on output 1and output 2 goes high when the ramp is working and low when the ramp is idle. Output 3 is not used.
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Target Accel. Rate Decel Rate Reset Initial Value Reference Ramp Working NOt used Non-zero value to reset Functional Description
14.23.39 Mode 2201, Pass Highest/Lowest Input Mode 2201 compares the values on the inputs and, depending on the pass mode (input 5) passes either the greatest or the least values to the outputs. There are three outputs: Output 1 contains the result of the comparison of inputs 1 and 2 and output 3 contains the result of the comparison of inputs 3 and 4. Output 2 contains the result of a comparison of outputs 1 and 3 14.23.39.1 Pass Mode The comparison or pass mode determines whether the greater or lesser value is passed to the output. The three outputs are controlled individually by setting individual bits of input 5 (L86?6) as follows: L86?6.00 = 1 selects output 1 as greater of inputs 1 and 2. L86?6.00 = 0 selects output 1 as lesser of inputs 1 and 2. L86?6.04 = 1 selects output 3 as greater of inputs 3 and 4. L86?6.04 = 0 selects output 3 as lesser of inputs 3 and 4 L86?6.08 = 1 selects output 2 as greater of outputs 1 and 3. L86?6.08 = 0 selects output 2 as lesser of outputs 1 and 3.
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Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Target Accel rate Decel rate Reset ramp Preset Ramp Ramping
Module 86 (V1)
Functional Description This is the target for the ramping output Rate at which the ramp increments Rate at which the ramp decrements Any non-zero value will cause the ramp to reset Value at which the ramp starts from Ramping output Indicates that the ramping is working Not used
14.23.40 Mode 2202, Pass Highest/Lowest Input Mode 2202 is identical in operation to Mode 2201 except that the modulus (i.e. any negative values are converted to positive) of the inputs is used for evaluation.
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Input 1 Input 2 Input 3 Input 4 Pass mode Output 1 Output 2 Output 3 1 selects greater than Greater or smaller of Input 1 and Input 2 depending on pass mode Greater or smaller of Output 1 and Output 3 depending on pass mode Greater or smaller of Input 3 and Input 4 depending on pass mode Functional Description
14.23.41 Mode 2301, Sample and Hold Mode 2301 provides a scaled or scaled and offset output derived from three inputs; input 1 sampled value and inputs 2 and 3 which contain user entered preset values. The form the calculation takes is determined by the output mode entered in input 5 and the result is written to Output 1 and to the outputs 2 and 3 switch. Output 2 can be switched between the value on Output 1 and Input 2, while Output 3 is the Output 2 signal inverted. The calculation mode, the output switch configuration and the sample enable are all controlled by the mode switch (Input 5). 14.23.41.1 Mode Switch The modes are as follows Mode 0 This mode provides a (a*b)/c function. The sampled value is Input 1 = a . b = Input 2 and c = Input 3 Mode 1 This mode provides a (a*b)/c function. The sampled value is Input 1 = c . b = Input 2 and a = Input 3 Issue (12-2-98) Alspa GD4000 Page 14-165
Module 86 (V1)
Mode 2
This mode provides a (a/b) + c function. The sampled value is Input 1 = a . b = Input 2 and c = Input 3 Mode 3 This mode provides a (a/b) + c function. The sampled value is Input 1 = b . a = Input 2 and c = Input 3 Mode 4 This mode provides a (a/b) + c function. The sampled value is Input 1 = c . a = Input 2 and b = Input 3
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Input 1 Input 2 Input 3 Input 4 Mode switch Output 1 Output 2 Output 3 Functional Description Sampled input
14.23.42 Mode 2401, Serial EEPROM Access Mode 2401 provides a means of writing data to the Serial EEPROM (SEEPROM) To enter ASCII characters enter them in reverse order. To enter a four character name or your initials into the modified by fields within the SEEPROM. This data is stored in offset locations 6&7 within the serial proms. To enable you to read the name or initials the right way round when the information is read back into the E tables it must be stored in the following order:ASCII Name to be written away corresponds to the following ASCII codes converted to hex because its easier to understand M 77 4D I 73 49 K 67 43 E 75 4B
Location 9
Location 8
Location 7
Location 6
Location 5
Location 4
HByte LByte HByte LByte HByte LByte HByte LByte HByte LByte HByte LByte How it is stored in SEEPROM ASCII Name as it is stored in SEEPROM 4B E 43 K 49 I 4D M
Therefore, to write MIKE, convert the characters to HEX and then:

Set location to 6 and enter @494D (EK) for the data to be written Set the action to 2 to force the write to occur. Output 1 should return a @FF to indicate completion. Set location to 7 and enter @4B43 (IM) for the data to be written
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Set the action to 2 to force the write to occur. Output 1 should return a @FF to indicate completion.
Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Output 1 Suggested Mnemonic
Module 86 (V1)
14.23.43 Mode 10001, Stall Detection

Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Speed Threshold Time Speed Threshold detected Stall detected Set when Input 3 is below the Speed Threshold Set when input 3 is below Speed Threshold and input 1 is above Current Threshold Set to 0 when Output 2 has been set for the Time specified Current Threshold Speed input Suggested Mnemonic Functional Description Current input
L86?9
Output 3
14.23.44 Mode 10101, I2T Overload Detection

Table Address L86?2 L86?3 L86?4 L86?5 L86?6 L86?7 L86?8 L86?9 I/O Type Input 1 Input 2 Input 3 Input 4 Input 5 Output 1 Output 2 Output 3 Suggested Mnemonic Not used Current Time constant Warning level Contin current level I2T Warning level reached Trip Level which the current must exceed to start to time out square of the current x time Set to 1 when warning level reached Set to 0 when tripped Input for the current feedback Functional Description
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Module 86 (V1)
14.23.45 Hardware Interfaces
Table 14-22 General Purpose Sub-Modules, Module 86
Variable L8600 L8601 L8602 L8603 L8604 L8605 L8606 L8607 L8608 L8609 L8610
Description
Scan time A Mode A Input 1 A Input 2 A Input 3 A Output 1 A Output 2 A Output 3 A Output 4 A Output 5 Bit Fault Field
Type Minimum Maximum ON IN IN IN IN ON ON ON ON ON ON 0 0 -2 -2 -2

31 31 31 31 31 31 31 31
Default 0 0 0 0 0 0 0 0 0 0 0
Scaling
1000 = 1 ms
0 232 2 2 2 2 2 2 2 2 2
32 32 32 32 32 32 32 32 32
-2 -2 -2 -2 -2
L8611 - A Repeat Of L8601 To L8609 For Sub-module B L8619 L8621 - A Repeat Of L8601 To L8609 For Sub-module C L8629 L8631 - A Repeat Of L8601 To L8609 For Sub-module D L8639 L8641 - A Repeat Of L8601 To L8609 For Sub-module E L8649 L8651 - A Repeat Of L8601 To L8609 For Sub-module F L8659 L8661 - A Repeat Of L8601 To L8609 For Sub-module G L8669 L8671 - A Repeat Of L8601 To L8609 For Sub-module H L8679 L8681 - A Repeat Of L8601 To L8609 For Sub-module I L8689 L8691 - A Repeat Of L8601 To L8609 For Sub-module J L8699
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Module 86 (V1)
Figure 14-41 Module 86, General Purpose Modes 1 to 16
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Module 86 (V1)
Figure 14-42 Module 86, General Purpose modes 17 to 111
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Module 86 (V1)
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Module 86 (V1)
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Module 86 (V1)
Figure 14-45 Module 86, Modes 904 to 1903
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Module 86 (V1)
Figure 14-46 Module 86, Modes 2001 to 10101
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Module 87 (V1)
14.24
Module 87 (V1)
Analog Switching, Module 87 (V2)

Introduction Module 87 contains twenty 4-pole analog switches which can be used to re-direct analog data to any required destination under program control. This module can be used to select data and reference sources and to re-direct analog data output. There are sixteen 4 pole switches whose output can be selected from up to three analog sources or set to 0 (these will be referred to as input switches), and four 4-pole switches whose single input can be directed to up to one of three different destinations or set to not connected (referred to as output switches). The input sources and output destinations are determined by linking the module input and output parameters using the CSP Links Editor or by the ladder program. The four output switches can be configured in the user program to act as: 1 four throw 4-pole switch 2 two throw 4-pole switches 4 single throw 4-pole switches The switch configuration is controlled by parameters L8776 to L8778. The sixteen input switches can be configured in the user program to act as: 1 16 throw 4-pole switch 2 8 throw 4-pole switches 4 four throw 4-pole switches 8 two throw 4-pole switches 16 single throw 4-pole switches. The switch configuration is controlled by parameters L8768 to L8771.
14.24.1
14.24.2
Analog Switch Specification The inputs and outputs to the analog switches are signed integers and must be in the range -231 to +231 (-2,147,483,648 to +2,147,483,647). Note: If an unsigned variable is linked to an analog switch the variable will pass through the switch unchanged but will be displayed at the switch output as a signed variable.
14.24.3
Controlling the Input Switches The sixteen input switches are identified by the letters A to P and are controlled by the input switch state monitor word. The input switch state monitor word (L8767) is a 32 bit unsigned integer which cannot be written to directly by the user but can be read. Each switch is controlled by two bits of L8767, which are decoded as follows: 0 0 output set to 0 0 1 output = input 1 1 0 output = input 2 1 1 output = input 3 The 16 input switches are allocated to the L8767 control word as shown below:
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Module 87 (V1)
Input Switch Control Word L8767 switch switch switch switch switch switch switch switch switch switch switch switch switch switch switch switch P O N M L K J I H G F E D C B A
control control control control control control control control control control control control control control control control bits bits bits bits bits bits bits bits bits bits bits bits bits bits bits bits 30&31 28&29 26&27 24&25 22&23 20&21 18&19 16&17 14&15 12&13 10&11 08&09 06&07 04&05 02&03 00&01
The value in the input state monitor word (L8767), and hence the configuration of the input switches, is determined by the input switch control parameters L8768 to L8771. Each parameter is used to control one of the four switch modes as follows: L8768 - 16 Single throw switches L8769 - 8 two throw switches L8770 - 4 four throw switches L8771 - 2 eight throw switches L8772 - 1 sixteen-throw switch To derive the input state monitor word a sequence of logical OR operations is performed on parameters L8769 to L8772 as shown below and the result is written to L8767.
00 00 00 00 00 16 Input Switches Paralleled Control Word L-8772 00 00 00 00 00 00 00 00 00 00 00&01 ABCD EFGH IJKL MNOP
00
00
00
00
00
8 Input Switches Paralleled Control Word L-8771 00 00 16&17 00 00 00 IJKL MNOP
00
00
00
00
00&01 ABCD EFGH
00
00
00
24&25 MNOP
00
4 Input Switches Paralleled Control Word L-8770 00 00 16&17 00 00 00 08&09 IJKL EFGH
00
00
00
00&01 ABCD
00
28&29 OP
00
24&25 MN
00
2 Input Switches Paralleled Control Word L-8769 20&21 00 16&17 00 12&13 00 08&09 KL IJ GH EF
00
04&05 CD
00
00&01 AB
Individual Input Switch Control Word L-8768 K J I H G F
Not Used and masked to 0
14.24.4
Controlling the Output Switches The four output switches are identified by the letters W to Z and are controlled by bits 0 to 7 of the output switch state monitor word. The output switch state monitor word (L8775) is a 32 bit unsigned integer which cannot be written to directly by the user but can be read. Bits 8 to 31 of the output state monitor word are unused and are masked internally. Each switch is controlled by two bits of L8775, which are decoded as follows: 0 0 output set to 0 0 1 output1 = input
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1 0 output 2 = input 1 1 output 3 = input
Module 87 (V1)
The 4 output switches are allocated to the L8775 control word as shown below:
Output Switch Control Word L8775 switch switch switch switch Z Y X W
control control control control bits bits bits bits 06&07 04&05 02&03 00&01
Not Used and masked off internally
The value in the input state monitor word (L8775), and hence the configuration of the input switches, is determined by the output switch control parameters L8776 to L8778. Each parameter is used to control one of the four switch modes as follows: L8776 - 4 single throw switches L8771 - 2 two throw switches L8772 - 1 four-throw switch To derive the input state monitor word a sequence of logical OR operations is performed on parameters L8776 to L8778 as shown below and the result is written to L8775.
4 Output Switches Paralleled Control Word L-8778
00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00&01
WXYZ
2 Output Switches Paralleled Control Word L-8777

00 00 00 00 00 00 00 00 00 00 00 00 00 04&05 00 00&01
YZ
WX
Individual Output Switch Control Word L-8776

00 00 00 00 00 00 00 00 00 00 00 00 06&07 04&05 02&03 00&01
Not Used and masked off internally
14.24.5
Application Notes When using module 87 it is necessary to declare all variables using the CSP DEF TABLE statement before they can be linked to the source and destination variables in the user program A full description of the DEF TABLE statement and its uses is given in Section 7.8.
14.24.6
Using DEF TABLE to Declare the Analog Switches Inputs and Outputs Typical DEF TABLE statements to declare the analog input and output variables are as follows: DEF TABLE L8701=10000,-10000,0,2,1,SW A IP 1 DEF TABLE L8702=10000,-10000,0,2,1,BACKUP SPD REF DEF TABLE L8704=10000,-10000,0,2,1,SPEED REF
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Module 87 (V1)
14.24.7
Using DEF TABLE to Declare the Analog Switch Control Words The input and output switch control variables (in L8769 to L8772 and L8776 to L8778 respectively) Typical DEF TABLE statements to declare two bits of a switch control word as binary data to control a single switch and assign a mnemonic are as follows: DEF TABLE L8768.00=0,1,0,0,0,IP SW A BIT 0 DEF TABLE L8768.01=0,1,0,0,0,IP SW A BIT 1 Note: When configuring input or output switch control words it is essential that all the unused bits in all the controlling L Tables (i.e. L8768 to L8771 for input switches and L8776 to L8778 for output switches) are set to zero. If this is not done, a setting in one L-Table may be overwritten by a spurious setting in another.
14.24.8
Setting a Combination of Multi-throw switches The following example shows the DEF TABLE STATEMENTS which are requires to declare the individual bits of the input switch control words achieve a combination of: 1 off 1 off 1 off 2 off 8-throw switch 4-throw switch 2-throw switch and single throw switches BIT 0 BIT 1 BIT 16 BIT 17 BIT 24 BIT 25 BIT 28 BIT 29 BIT 30 BIT 31
DEF TABLE 8771.00=0,1,0,0,0,8_THROW DEF TABLE 8771.01=0,1,0,0,0,8_THROW DEF TABLE 8770.16=0,1,0,0,0,4_THROW DEF TABLE 8770.17=0,1,0,0,0,4_THROW DEF TABLE 8769.24=0,1,0,0,0,2_THROW DEF TABLE 8769.25=0,1,0,0,0,2_THROW DEF TABLE 8768.28=0,1,0,0,0,1_THROW DEF TABLE 8768.29=0,1,0,0,0,1_THROW DEF TABLE 8768.30=0,1,0,0,0,1_THROW DEF TABLE 8768.31=0,1,0,0,0,1_THROW
The state of the switches cn now be controlled by the user program link statements or ladder program. The effect of the above DEF TABLE statements is as shown:
Control Word L-8771 (Bits 00 and 01) -1-off 8-pole input switch ABCD EFGH
Control Word L-8770 (Bits 16 and 17) 1-off 4-pole input switches IJKL
Control Word L-8769 (Bits 24 and 25) 1 off 2-pole input switches MN
Control Word L-8768 (Bits 28,29,30 and 31) 2 off 1-pole switches P O These bits must be set to 0 for correct operation
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Table 14-23 Module 87, Analog Switches
Module 87 (V1)
CSP mnemonic
Scan Time A in 1 A in 2 A in 3 A out B in 1 B in 2 B in 3 B out C in 1 C in 2 C in 3 C out D in 1 D in 2 D in 3 D out E in 1 E in 2 E in 3 E out F in 1 F in 2 F in 3 F out G in 1 G in 2 G in 3 G out H in 1 H in 2 H in 3 H out I in 1 I in 2 I in 3 I out J in 1
Type Minimum Maximum ON IN IN IN ON IN IN IN ON IN IN IN ON IN IN IN ON IN IN IN ON IN IN IN ON IN IN IN ON IN IN IN ON IN IN IN ON IN 0 -2

31 31
Default 0
Scaling
1000 = 1 ms
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
-231 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2
31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31
231 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31
-231 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2
31 31 31 31 31 31 31 31 31 31 31 31 31 31 31
231 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
31 31 31 31 31 31 31 31 31 31 31 31 31 31 31
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Module 87 (V1)
Variable L8738 L8739 L8740 L8741 L8742 L8743 L8744 L8745 L8746 L8747 L8748 L8749 L8750 L8751 L8752 L8753 L8754 L8755 L8756 L8757 L8758 L8759 L8760 L8761 L8762 L8763 L8764 L8765 L8766 L8767 L8768 L8769 L8770 L8771 L8772 L8773 L8774 L8775 L8776 CSP mnemonic
J in 2 J in 3 J out K in 1 K in 2 K in 3 K out L in 1 L in 2 L in 3 L out M in 1 M in 2 M in 3 M out N in 1 N in 2 N in 3 N out O in 1 O in 2 O in 3 O out P in 1 P in 2 P in 3 P out Not used Not used ActualIP SwCntrl 1 IP SwtchCntrl 2 IP SwtchCntrl 4 IP SwtchCntrl 8 IP SwtchCntrl 16 IP SwtchCntrl Not used Not used ActualOP SwCntrl 1 OP SwtchCntrl

Type Minimum Maximum IN IN ON IN IN IN ON IN IN IN ON IN IN IN ON IN IN IN ON IN IN IN ON IN IN IN ON ON ON ON IN IN IN IN IN ON ON ON IN -2 -2
31 31
Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Scaling
2 2
31 31
-231 -2 -2 -2
31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31
231 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31
-2 -2 -2 -2
-2 -2 -2 -2
-2 -2 -2 -2
-2 -2 -2 -2
-231 -2 -2 -2
31 31 31 31 31 31
231 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
31 31 31 31 31 31 32 32 32 32 32 32 31 31 32 32
-2 -2 -2
0 0 0 0 0 0 -2 -2
31 31
0 0
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Variable L8777 L8778 L8779 L8780 L8781 L8782 L8783 L8784 L8785 L8786 L8787 L8788 L8789 L8790 L8791 L8792 L8793 L8794 L8795 L8796 L8797 L8798 L8799 CSP mnemonic
2 OP SwtchCntrl 4 OP SwtchCntrl Not used Not used Not used Not used W in W out 1 W out 2 W out 3 X in X out 1 X out 2 X out 3 Y in Y out 1 Y out 2 Y out 3 Z in Z out 1 Z out 2 Z out 3 Not used
Module 87 (V1)
Type Minimum Maximum IN IN ON ON ON ON IN ON ON ON IN ON ON ON IN ON ON ON IN ON ON ON ON 0 0 -231 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2
31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31
Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Scaling
2 2
32 32
231 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31
-231
231
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Module 87 (V1)
Figure 14-47 Analog Switching part 1 Input switches
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Module 87 (V1)
Figure 14-48 Analog Switching part 2 Output Switches
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Module 89 (V1)
14.25
Module 89 (V1)
Serial Link Set up Support, Module 89 (V1)

Introduction This module provides additional facilities to simplify the serial link configuration, and control and reference source configuration and to allow dynamic switching between different control and reference sources in the event of a control or reference source failure and automatic reconnection when the primary control or reference is restored. The control and reference source functions are independent of each other to give greater programming flexibility. This module also incorporates a number of features to improve the operation of the serial links including detection of ESP or MODBUS message protocols with automatic re-mapping of J/K tables to speed serial link data transmissions.
14.25.1
14.25.2
Features
Two Serial link setup function calls (based on T33) with auto configuration change
recognition. Serial links will automatically reconfigure if any serial link parameter changes.
Two Serial link time out functions with enable/disable facility. JK table to Modbus mapping support to allow minimum table transfer using JK
tables but still allow Modbus coil transfers.

Control and Reference source loss detection.
Supports automatic backup Control and Reference source switching logic with auto reconnect if primary source returns. Up to 3 levels deep.
Provides 4 internal Control source selector switches with 2 sets of Alternative source
inputs (controlled by Modbus active).

Provides 4 internal Reference source selector switches Provides Control Source and Reference source outputs in word and bit formats to
simplify the addition of further paralleled switches. 14.25.3 Serial Link Configuration Module 89 provides facilities for configuring two separate serial links, selected from the four hardware serial links provided by GD4000. These configuration blocks are referred to as Serial Link A and Serial Link B, to avoid confusion with the hardware serial links 0 to 4. The use of this function obviates the need to configure the two serial links by setting P-tables and using the CONFIG (T33) Special function in a one shot block in the ladder program. All the parameters which would normally be entered in P-tables and via the T33 Special Function are include as inputs to this module. Configuration errors, MODBUS/ESP used signals and serial link time-outs are outputs from this module. To configure the serial links the following parameters must be set:
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CSP Mnemonic Link Number Serial Setup A L8901 Serial Setup B L8921 Valid data entries on inputs and data output information 0=Link 0* 1=Link 1 2=Link 2 3=Link 3 0=ESP Control 1-14=ESP Trib 15=ESP Trib 0 1-255 for Modbus ID 0=point to point no tristate 1 Slave Multidrop 1-4 Control Multidrop 1=1200 2=2400 3=4800 4=9600 5=19200 6=38400 7=76800 (not links 2 & 3) 8=57600 (not links 2 & 3) 1=8 bits No Parity 2=8 bits Even Parity 3=8 bits Odd Parity 4=7 bits Even Parity 5=7 bits Odd Parity 6=7 bits Parity Set 7=7 bits Parity Reset 100 to 1000 defaults to 100 -1 = JK Table Ex -2 = Printer -3 = MODBUS ASCII -4 = MODBUS RTU -5=Loop back test
Module 89 (V1)
Link Address
L8902
L8922
No of Partners Baud Rate
L8903
L8923
L8904
L8924
Parity Modbus Only
L8905
L8925
Chars Per Sec Port Type
L8906 L8907
L8926 L8927
The following L Tables give serial link status information.

CSP Mnemonic Config Error Serial Setup A L8908 Serial Setup B L8928 Valid data entries on inputs and data output information bit 0=1fault or not configured bit 1=1invalid link no bit 2=1invalid tributary bit 3=1invalid no of partners bit 4=1invalid port type bit 5=1invalid mode 1 = MODBUS Used 0 = MODBUS not used
MODBUS Used
L8909
L8929
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Module 89 (V1)
14.25.4 Serial Link Time-out
Each of the serial link configuration blocks has a time-out detection function.
CSP Mnemonic Rx Count Mon Time-out Time time-out time-out B A
L8910
Functionality Description This Input is monitored by the time-out detection logic. Whenever the value linked to this input changes the time-out detection logic resets an internal timer to 0. The value entered on this input determines the time out period of the time-out detection logic. This input is scaled in milliseconds. i.e. 100 entered results in a 100 mS time-out time. This is an output that indicates the time elapsed since the Rx Count Mon input changed. This output is scaled in microseconds but displays its output in milliseconds If the time elapsed output becomes greater than the value entered on the Time-out Time input this output becomes a 1 otherwise it is 0. This output is not latched This is an invert of the Timed Out signal. i.e. Active low rather than active high. A 1 on this input enables the time-out fault to be passed to this modules output pins. This input can be used to mask off serial link time-outs.
L8930
L8911
L8931
Time Elapsed L8912
L8932
Timed Out
L8913
L8933
Inv Timed Out Enable Time-out
L8914 L8915
L8934 L8935
The RX Count Monitor input must be linked to the link receive counter F-table for the selected serial link. These are as follows: F37 F40 F43 F46 Note: Link 0 Receive Counter Link 1 Receive Counter Link 2 Receive Counter Link 3 Receive Counter
The I table Rx counters and the F table serial link statistics tables should NOT be used to detect a serial link time-out as they also increment for invalid messages. A disconnected serial link in an electrically noisy environment can also increment the value in these table addresses. The F table serial link statistics tables also provide a Link link number LOST flag. This flag is set for the following conditions, but takes longer to set because it retries the link a preset number of times before setting the flag. This delay may be too long in many applications where the data being transmitted or received by the serial link is critical.
14.25.5
Action on Loss of Serial Link It is the users responsibility to define the action taken by the drive on loss of a serial link, in the user program. Typical options are: 1) Link the Inv Time Out L8814/L8834) output to the fault logic (Module 32/33/34) to trip the drive on link loss. 2) Enable the serial link backup options (see section 14.25.7) and issue a warning message on link loss.
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14.25.6 Control Source Switching
Module 89 (V1)
Control source switching facilities have been included in this module to allow alternative control sources to be selected as a backup on loss of the primary control source. The control source switching function is comprised of four 4-pole switches numbered 0 to 3. The active control source is selected from the inputs to these switches by the control source logic and is determined by the setting of parameter L8940 and the Serial link time-outs. There are alternative inputs to poles 01 and 03 of each of the 4-pole switches enabling them to support dynamic switching of ESP and MODBUS protocol serial links. 14.25.7 Alternative Control Source In order to implement auto-switching between ESP and MODBUS protocol serial links the presence of a serial link using the MODBUS protocol must be indicated by the setting in the Port Type L8907/L8927 to either option -3 (MODBUS ASCII) or -4 (MODBUS RTU). These settings cause MODBUS USED to be set to logic 1 and this is used in conjunction with the Alt Ctrl Source Used parameter (L8943/L8944) to select the active control source. 14.25.8 Selecting the Control Source and Mode The active source is determined by the Control Source switching logic. The inputs to this function are L8940 and the serial link time-outs, this allows the user to implement a primary and backup control facility. The control source logic provides four possible switching states as follows:
State L8941 0 1 2 3 L8941 bit 1
0 0 1 1
L8941 bit 0 0 1 0 1
Control Source
Description The control mode block input states are selecting the data provided by see below Reserved the serial link setup by Serial Link Setup block B to be the source of control. the serial link setup by Serial Link Setup block A to be the source of control. This is the default state the switch returns to if both serial link time-outs are active. i.e. they have timed out Time Out A & Time Out B=1. The switch can also forced into this state. This state should be used to pass hardware inputs i.e. pots on analog inputs
Reserved Serial B active Serial A active Default
There are two outputs from the Control mode switching logic, these are: L8942 - this parameter indicates the status of the control source - 0 = Control Lost 1 = Control available. The circumstances under which the output is set depend on the mode setting in L8940. L8941 - the first two bits of this parameter indicate the control source switch position output as a binary number. They can be used as a monitoring facility and as an input to Module 87 Analog Data Switching, for use in more complex analog switching. To select the reference source and mode, set a value in the range 0 and 6 in L8940. The value placed in L8940 determines the primary and backup control sources and the error output placed in L8941 and L8942 as follows:
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Module 89 (V1)
Control Timed Mode Out A (L8940) 0 1
0 1

Timed Out B Switch State 3 2 2 0 1
0 1
Control Lost 1 1 0 1 0 1 1
Description
Switch is forced into the default state. Hardware inputs would control system if linked. Use data provided by the serial link configured using serial link setup block A. If the serial link is lost; the control lost output is set i.e.0 = fault Use data provided by the serial link configured using serial link setup block B. If the serial link is lost; the control lost output is set i.e.0=fault Use data provided by the serial link configured using serial link setup block A. If the serial link is lost; the switch reverts to the default state. Hardware inputs would control system if linked. Use data provided by the serial link configured using serial link setup block B. If the serial link is lost; the switch reverts to the default state. Hardware inputs would control system if linked. Use data provided by the serial link configured using serial link setup block A. If the serial link is lost; the source is automatically switched to the data provided by the serial link configured using serial link setup block B. If this second serial link is lost; the control lost output is set i.e.0 = fault Use data provided by the serial link configured using serial link setup block A. If the serial link is lost; the source is automatically switched to the data provided by the serial link configured using serial link setup block B. If this second serial link is lost; the switch reverts to the default state. Hardware inputs would control system if linked.
1 1 2 3
0 1
1 3
1 1
1 1 0 0 1 1 0 0
1 0 1 0 1 0 1 0
2 2 1 1 2 2 1 3
1 1 1 0 1 1 1 1
14.25.9
Reference Source Switching Reference source switching facilities have been included in this module to allow alternative reference sources to be selected as a backup on loss of the primary reference source. The reference source switching function is comprised of four 4-pole switches numbered 0 to 3. The active reference source is selected from the inputs to these switches by the reference source logic and is determined by the setting of parameter L8946 and the Serial link time-outs.
14.25.10 Selecting the Reference Source and Mode The active source is determined by the Reference Source switching logic. The inputs to this function are L8946 and the serial link time-outs, this allows the user to implement a primary and backup reference facility. The reference source logic provides four possible switching states as follows:
State L8946 0 1 2 L8946 bit 1
0 0 1
L8946 bit 0 0 1 0
Control Source
Description The control mode block input states are selecting the data provided by see below Reserved the serial link setup by Serial Link Setup block B to be the source of reference. the serial link setup by Serial Link Setup block A to be the source of reference.
Reserved Serial B active Serial A active
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State L8946 3 L8946 bit 1
1
Module 89 (V1)
L8946 bit 0 1 Control Source Description The control mode block input states are selecting the data provided by see below This is the default state the switch returns to if both serial link time-outs are active. i.e. they have timed out Time Out A & Time Out B=1. The switch can also forced into this state. This state should be used to pass hardware inputs i.e. pots on analog inputs. In this way if the serial links fail the hardware inputs can be used as a final backup condition.
Default
There are two outputs from the Reference mode switching logic, these are: L8947 - this parameter indicates the status of the reference source: 0 = Reference Lost 1 = Reference available. The circumstances under which the output is set depend on the mode setting in L8945. L8946 - the first two bits of this parameter indicate the control source switch position output as a binary number. To select the reference source and mode, set a value in the range 0 and 6 in L8945. The value placed in L8945 determines the primary and backup control sources. The switch setting is placed in L8941 and L8942 as follows:
Control Timed Mode Out A (L8945) 0 1 0 1 0 1 0 1 Timed Out B Switch Reference State Lost 3 2 2 1 1 2 3 1 1 0 1 0 1 1 Description
Switch is forced into the default state. Hardware inputs would control system if linked. Use data provided by the serial link configured using serial link setup block A. If the serial link is lost; the control lost output is set i.e.0 = fault Use data provided by the serial link configured using serial link setup block B. If the serial link is lost; the control lost output is set i.e.0=fault Use data provided by the serial link configured using serial link setup block A. If the serial link is lost; the switch reverts to the default state. Hardware inputs would control system if linked. Use data provided by the serial link configured using serial link setup block B. If the serial link is lost; the switch reverts to the default state. Hardware inputs would control system if linked. Use data provided by the serial link configured using serial link setup block A. If the serial link is lost; the source is automatically switched to the data provided by the serial link configured using serial link setup block B. If this second serial link is lost; the control lost output is set i.e.0 = fault Use data provided by the serial link configured using serial link setup block A. If the serial link is lost; the source is automatically switched to the data provided by the serial link configured using serial link setup block B. If this second serial link is lost; the switch reverts to the default state. Hardware inputs would control system if linked.
0 1
1 3
1 1
1 1 0 0 1 1 0 0
1 0 1 0 1 0 1 0
2 2 1 1 2 2 1 3
1 1 1 0 1 1 1 1
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Module 89 (V1)
14.25.11 Application Notes
L8907 and L8927 set to illegal state to ensure module is set up before use.
Table 14-24 Module 89, serial Link Support
Variable L8901 L8902 L8903 L8904 L8905 L8906 L8907 L8908 L8909 L8910 L8911 L8912 L8913 L8914 L8915 L8916 L8917 L8918 L8919 L8920 L8921 L8922 L8923 L8924 L8925 L8926 L8927 L8928 L8929 L8930 L8931 L8932 L8933 L8934 L8935 L8936
CSP mnemonic
Link Number A Link Address A No Of Partners A Baud Rate A Parity A Chars Per Sec A Port Type A Config Error A Modbus Used A Rx Count Mon A Time-out Time A Time Elapsed A Timed Out A Inv Timed Out A Enable Time-out A Spare 3 A Spare 2 A Spare 1 A Spare 0 A Misc Spare 0 Link Number B Link Address B No Of Partners B Baud Rate B Parity B Chars Per Sec B Port Type B Config Error B Modbus Used B Rx count Mon B Time-out Time B Time Elapsed B Timed Out B Inv Timed Out B Enable Time-out B Spare 3 B
Type Minimum Maximum IN IN IN IN IN IN IN OL OL IN IN ON OL OL IL IN IN IN IN IN IN IN IN IN IN IN IN OL OL IN IN ON OL OL IL IN 0 0 0 0 0 0 -2

31
Default 2 14 1 1 0 2 -1 0 0 0 1000 0 0 1 1 0 0 0 0 0 2 14 1 1 0 2 -1 0 0 0 1000 0 0 1 1 0

1 = 1 ms 1 = 1 ms
Scaling
1000 = 1 ms
3 15 4 7 7 1000 2
31
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -2
31
1 1 2
32
60000 2
32
1000 = 1 ms
1 1 1 2 2 2 2 2
32 32 32 32 32
3 15 4 7 7 1000 2
31
0 0 0 0 0 0 0 0 0
1 1 2
32
60000 2
32
1000 = 1 ms
1 1 1 2
32
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Variable L8937 L8938 L8939 L8940 L8941 CSP mnemonic
Spare 2 B Spare 1 B Spare 0 B Control Mode Control Source
Module 89 (V1)
Type Minimum Maximum IN IN IN IN ON OL OL OL IL IL IN ON OL OL OL IN IN IN IN IN IN ON IN IN IN IN ON IN IN IN IN ON IN IN IN IN ON 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -2 -2
31 31
Default 0 0 0 0 3 1 1 1 0 0 0 3 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Scaling
2 2
32 32
232 7 3 1 1 1 1 1 7 3 1 1 1 2 2 2 2
32 32 31 31
L8941.00 Ctrl Src Bit 00 L8941.01 Ctrl Src Bit 01 L8942 L8943 L8944 L8945 L8946
0=Control Lost Use AltCtrlSrc 2 Use AltCtrlSrc 1 Refer Mode Refer Source
L8946.00 Refer Src Bit 00 L8946.01 Refer Src Bit 01 L8947 L8948 L8949 L8950 L8951 L8952 L8953 L8954 L8955 L8956 L8957 L8958 L8959 L8960 L8961 L8962 L8963 L8964 L8965 L8966 L8967 L8968 L8969
0=Refer Lost Refer Spare 1 Refer Spare 0 Cntrl Src IP0 0 Cntrl Src IP0 1 Cntrl Src IP0 2 Cntrl Src IP0 3 Cntrl Src OP0 Cntrl Src IP1 0 Cntrl Src IP1 1 Cntrl Src IP1 2 Cntrl Src IP1 3 Cntrl Src OP1 Cntrl Src IP2 0 Cntrl Src IP2 1 Cntrl Src IP2 2 Cntrl Src IP2 3 Cntrl Src OP2 Cntrl Src IP3 0 Cntrl Src IP3 1 Cntrl Src IP3 2 Cntrl Src IP3 3 Cntrl Src OP3
-231 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2
31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31
231 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31
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Module 89 (V1)
Variable L8970 L8971 L8972 L8973 L8974 L8975 L8976 L8977 L8978 L8979 L8980 L8981 L8982 L8983 L8984 L8985 L8986 L8987 L8988 L8989 L8990 L8991 L8992 L8993 L8994 L8995 L8996 L8997 CSP mnemonic
Refer Src IP0 0 Refer Src IP0 1 Refer Src IP0 2 Refer Src IP0 3 Refer Src OP0 Refer Src IP1 0 Refer Src IP1 1 Refer Src IP1 2 Refer Src IP1 3 Refer Src OP1 Refer Src IP2 0 Refer Src IP2 1 Refer Src IP2 2 Refer Src IP2 3 Refer Src OP2 Refer Src IP3 0 Refer Src IP3 1 Refer Src IP3 2 Refer Src IP3 3 Refer Src OP3 AltCntrlSrcIP0 1 AltCntrlSrcIP0 2 AltCntrlSrcIP1 1 AltCntrlSrcIP1 2 AltCntrlSrcIP2 1 AltCntrlSrcIP2 2 AltCntrlSrcIP3 1 AltCntrlSrcIP3 2

Type Minimum Maximum IN IN IN IN ON IN IN IN IN ON IN IN IN IN ON IN IN IN IN ON IN IN IN IN IN IN IN IN -2 -2
31 31
Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Scaling
2 2
31 31
-231 -2
31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31
231 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31
-2 -2 -2 -2 -2
-2 -2 -2 -2 -2
-2 -2 -2 -2 -2
-2 -2 -2
-231 -2 -2 -2 -2 -2
31 31 31 31 31
231 2 2 2 2 2
31 31 31 31 31
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Module 89 (V1)
Figure 14-49 Module 89, Serial Link Support part 1
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Module 89 (V1)
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Module 89 (V1)
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Module 90 (V3)
14.26
Module 90 (V3)
Temperature Feedback, Module 90 (Version 3)

Introduction Module 90 provides the user with temperature warning and temperature trip signals. These signals are generated from the analog temperature feedback signals. The warning/trip signals are in addition to the thermostat trip signal which is available through the general PIB fault handling module, module 91. Module 90 automatically handles differences in systems, that is it automatically accommodates different numbers of temperature feedbacks depending on the type of drive, or the type of power interface board (PIB) fitted.
14.26.1
14.26.2
Operation Temperature scaling: 1 = 1 oC Temperature trip: The over-temperature trip value of the drive is under user control, but the maximum and default values are set up within the system. Over-temperature trips are latched. No hysteresis is provided on this signal. Over Temperature warning: The temperature warning is under user control but the maximum and default values are set-up within the system. Over temperature warnings are not latched. Under temperature warning: Fixed at 0oC. Under temperature warnings are not latched. Hardware Faults: Occur due to faults in the thermistor, for example the thermistor not connected. Hardware faults are latched. In this case the temperature feedback circuit displays the last legitimate value before the hardware fault. Individual feedback temperature data: For each temperature analog feedback fed into the module, the following output data is provided: temperature over temperature warning over temperature trip under temperature warning hardware fault
The same temperature warning and trip levels are used throughout the system. The temperature feedback signal will remain valid even though an over-temperature trip may have occurred. If a hardware fault occurs then the last valid temperature value is displayed.
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Global temperature data: The following global data will be provided :-
Module 90 (V3)
global temperature (corresponds to the maximum of the individual temperature
feedbacks)
global temperature warning global over temperature trip global under temperature trip global hardware fault
All global warnings/trips are set if any individual warnings/trips are active. In addition, a global temperature healthy signal, L9005 is provided. This is generated from all the individual trip signals. Note: The global healthy signal will function (1 = healthy) if any cell generates a trip.
14.26.2.1 External Thermistor If a 20X4486 or 20X4489 power interface board has been fitted then the user has the choice of generating temperature feedbacks from external thermistors. The type of thermistor and an explanation of the hardware connections required are specified by the hardware section of this manual. The 20X4489 PIB supports one external thermistor and the 20X4486 PIB supports two external thermistors. In order to configure the drive to produce the software feedbacks and hardware trips from the external devices, L9001 should be set to 1 in the links file. For 20X4489 this will allow a single external thermistor to be fed back as temperature 5, and for 20X4486 this will allow two external thermistors to be fed back as temperature 9 and temperature 10. 14.26.2.2 Motor Thermistors If a 20X4486 or 20X4489 power interface board has been fitted then the user has the choice of fitting motor thermistors. The type of thermistor and an explanation of the hardware connections required are specified by the hardware section of this manual. If fitted, the temperatures of these devices are displayed on L9015 (temperature 1) and L9020 (temperature 2). As a default, these inputs do not cause the drive to trip but produce an unlatched warning flag on L9066 which is set to a 1 for either of the motor thermistor trips. There is also an optional feature of producing a full hardware trip on these two feedbacks. This can be configured by setting L9067 to a 1 (enables the trip from motor thermistor 1) and/or setting L9068 to a 1 (enables the trip from motor thermistor 2). Also note that due to the characteristics of the thermistor, temperatures below 60 oC are not resolvable accurately, so temperatures below this value should produce the value 1 in the temperature feedback reading to indicate a healthy temperature. 14.26.3 Power Interface Board Compatibility To cater for all types of power interface board, the L tables for this module correspond to different physical temperatures. The type of power interface board fitted is automatically detected. The functional description for each PIB type is listed below.
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Module 90 (V3)
PIB Type 20X4468/20X4460 Temperature Feedback Temperature 1 Temperature 2 Temperature 3 20X4486 Temperature 1 Temperature 2 Temperature 3 Temperature 4 Temperature 5 Temperature 6 Temperature 7 Temperature 8 Temperature 9 Temperature 10 20X4489 Temperature 1 Temperature 2 Temperature 3 Temperature 4 Temperature 5

Functional Description Bridge 1 temperature feedback. Bridge 2 temperature feedback. Bridge 3 temperature feedback. Motor thermistor 1 Motor thermistor 2 Bridge A1 temperature feedback. Bridge A2 temperature feedback. Bridge A3 temperature feedback. Bridge B1 temperature feedback. Bridge B2 temperature feedback. Bridge B3 temperature feedback. Spare/Rectifier 1 temperature feedback. Spare/Rectifier 2 temperature feedback. Motor thermistor 1. Motor thermistor 2. Bridge A temperature feedback. Bridge B temperature feedback. Spare/Rectifier temperature feedback.
14.26.4
Reset A reset will clear all latched trip signals if the individual fault has been cleared.
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Table 14-25 Temperature Feedback, Module 90 (V3)
Module 90 (V3)
Variable L9000 L9001 L9002 L9003 L9005 L9006 L9007 L9008 L9009 L9010 L9011 L9012 L9013 L9014 L9015
Description
Repetition Period External Temp fb Global trip level Global warning level Global healthy signal Global Over-temp warning Global Over-temp trip Global Under-temp warning Global Hardware fault Global temperature Over-temp warning 1 Over-temperature trip 1 Under-temp warning 1 Hardware fault 1 Temperature 1
Type Minimum Maximum ON IL IN IN OL OL OL OL OL ON OL OL OL OL ON 0 85 0 0 0 0 0 0 0 0 0 0 0 0 1 112 95 1 1 1 1 1 200 1 1 1 1 200
Default
3
Scaling
10 = 1 ms
0 85 75 1 0 0 0 0 0 0 0 0 0 0
1 = Enable feedback 1 = 1 oC 1 = 1 oC 1 = healthy 1 = warning 1 = trip 1 = warning 1 = fault 1 = 1 oC 1 = warning 1 = trip 1 = warning 1 = Fault 1 = 1 oC
L9016- Group 2 L9020 L9021 Group 3 -L9025 L9026- Group 4 L9030 L9031 Group 5 -L9035 L9036- Group 6 L9040 L9041 Group 7 -L9045 L9046- Group 8 L9050 L9051 Group 9 -L9055 L9056- Group 10 L9060 L9062 L9066 L9067 L9068
Reset trip Motor temperature warning Enable Motor Trip 1 Enable Motor Trip 2
As L9011to L9015 As L9011 to L9015 As L9011 to L9015 As L9011 to L9015 As L9011 to L9015 As L9011 to L9015 As L9011 to L9015 As L9011 to L9015 As L9011 to L9015 IL OL IL IL 0 0 0 0 1 1 1 1 0 0 0 0
1 = reset 1 = warning 1 = Enable Trip 1 = Enable Trip
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Module 90 (V3)
Figure 14-52 Temperature Feedback, Module 90 (V3)
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Module 91(V4)
14.27
Module 91(V4)
PIB Fault Monitor And Reset, Module 91 (Version 4)

Introduction Module 91 is used to monitor and reset faults that occur on the power interface board (PIB). Should a bridge fault occur, bridge A healthy, L9110 and bridge B healthy, L9111 will change to 0 indicating a PIB fault has been detected. In order to clear the fault it is only necessary to toggle the module reset signal, L9108, on and then off again. This will then start a reset sequence that will reset all the possible faults. Once a trip has occurred the module stores all the various data from the PIB such as the state of the transistor feedbacks and the global temperature fault latch. All this data is reset if L9108 is toggled. The module will automatically register all the fault feedback information from all the PlBs fitted.
14.27.1
14.27.2
Operation Power Interface Board Compatibility The faults displayed depend upon the type of PIB fitted to the system. The faults available are highlighted in the following table. Those marked * are only available on 20X4486 and 20X4489 and those marked ** are only available on 20X4486. Fault Description Some of the faults require explanation. Pulse enable feedback - this is the state of A32.7, the hardware permissive, and should be high for enabling PWM pulses to the drive. PIB DDR trip - the 20X4486 is fitted with 2 differential driver/receivers (DDRs), each fitted with an SMPS. If the SMPS should fail this signal will go high. Brickwalling - the 20X4486 and 20X4489 are fitted with a brickwalling feature to limit the maximum current the bridge can source. These unlatched flags go high to signal that this feature is operating. SMPS trip - each phase has a separate SMPS. If a SMPS should fail this signal will go high. Read Next fault - a feature available on 20X4486 and 20X4489 PIBs. The internal hardware on the PIB latches and feeds back the first fault to occur only. By toggling read next fault the PIB is forced to feedback all current faults. PIB temperature trip - on the 20X4489 PIB this is a 3 bit bitfield where a 1 (bit 0) indicates a trip on bridge A, a 2 (bit 1) indicates a trip on bridge B and a 4 (bit 2) indicates a trip on the selected external thermistor. On all other PIBs the flag is simply set to a 1 if any of the bridges report an over-temperature. The bridge which created the fault can be determined by looking at the individual temperature feedback values. Shoot-through detected - on the 20X4486 PIB this is set to a 1 if the upper and lower of any phase have been sent a transistor turn on signal simultaneously. On the 20X4489 PIB this is a 2 bit bitfield where a 1 (bit 0) indicates that the shoot-through was detected on bridge A and a 2 (bit 1) indicates that the shoot-through was detected on bridge B.
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Module 91(V4)
Phase trips On MkII delta systems the transistor fault feedbacks are not arranged as upper transistor trip and lower transistor trip as they are on MkI deltas and BDM drives. For MkII deltas there is a single phase fault which indicates that there has been a transistor trip on either the upper or the lower of that phase, but does not discriminate between the two. The phase trip signal is a 2 bit bitfield where a 1 (bit 0) indicates that the transistors own overcurrent mechanism has tripped and a 2 (bit 1) indicates that the overcurrent detector external to the transistor has tripped.
Table 14-26 PIB Fault Monitor and Reset, Module 91(V4)
Variable L9100 L9101* L9108 L9110 L9111 L9112 L9113 L9114* L9115* L9116* L9117 L9118 L9119** L9120** L9121* L9122* L9123# L9124 L9125 L9126 L9127 L9128 L9129 L9130 L9131 L9132 L9133 L9134
# # # # # # # # # # #
Description
Refresh Rate Read Next Fault Reset Trip Bridge A OK Bridge B OK PIB Temperature Trip Pulse Enable Feedback Under volts Warning Over volts Trip Shoot Through Detected Bridge A Trip Bridge B Trip PIB DDR A Trip PIB DDR B Trip Bridge A Brickwalling Bridge B Brickwalling Bridge A1 Red Upper Trip Bridge A1 Red Lower Trip Bridge A1 Yellow Upper Trip Bridge A1 Yellow Lower Trip Bridge A1 Blue Upper Trip Bridge A1 Blue Lower Trip Bridge B1 Red Upper Trip Bridge B1 Red Lower Trip Bridge B1 Yellow Upper Trip Bridge B1 Yellow Lower Trip Bridge B1 Blue Upper Trip Bridge B1 Blue Lower Trip
Type Minimum Maximum ON IL IL OL OL ON OL OL OL ON OL OL OL OL OL OL OL OL OL OL OL OL OL OL OL OL OL OL OL OL 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 7 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Default
3
Scaling
10 = 1 ms
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1 = Read 1 = Reset 1 = Healthy 1 = Healthy 0 = Healthy 1 = Trip 1 = Trip 1 = Trip 0 = Healthy 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip
L9135 Bridge A2 Trips -L9140# L9141 Bridge B2 Trips -L9146#
PIB Fault Monitor and Reset, Module 91(V4)
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Issue (12-2-98)

Variable Description Type Minimum Maximum OL OL OL OL OL OL OL OL OL OL ON ON ON ON ON ON ON ON 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 3 3 3 3 3 3 3 3 Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Module 91(V4)
Scaling
1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 1 = Trip 0 = Healthy 0 = Healthy 0 = Healthy 0 = Healthy 0 = Healthy 0 = Healthy 0 = Healthy 0 = Healthy
L9147 Bridge A3 Trips -L9152# L9153 Bridge B3 Trips -L9158# L9159 L9160 L9161 L9162 -L9164 L9165 -L9167 L9168 -L9170 L9171 -L9173 L9174 -L9176
## ##
Bridge A1 Red SMPS Trip Bridge A1 Yellow SMPS Trip Bridge A1 Blue SMPS Trip Bridge B1 SMPS Trips Bridge A2 SMPS Trips Bridge B2 SMPS Trips Bridge A3 SMPS Trips Bridge B3 SMPS Trips
L9177## Bridge 1 A red phase trip L9178 L9179

Bridge 1 A yellow phase trip Bridge 1 A blue phase trip
L9180 Bridge 1 B phase trips -L9182## L9183 Bridge 2 A phase trips -L9185## L9186 Bridge 2 B phase trips -L9188## L9189 Bridge 3 A phase trips -L9191## L9192 Bridge 3 B phase trips -L9194##
* Indicates a fault is only available on the 20X4486 PIB and 20X4489 PIBs. ** Indicates a fault is only available on the 20X4486 PIB.
#
Variables applicable to DELTA I only. Variables applicable to DELTA II only.
##
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Alspa GD4000
Page 14-203
Module 91(V4)
Figure 14-53 Module 91 (V3), Fast Task Fault Monitor
Page 14-204
Alspa GD4000
Issue (12-2-98)
Module 92 (V2)
14.28
Module 92 (V2)

Introduction Module 92 is a PID regulator that may be used to control speed demand. For details of the PID function refer to Section 7.10.1. For details of speed/torque loop tuning (configuring Ki and Kp) refer to section 6.5.6.1.
14.28.1
Description
Scan time release reg freeze id reference feedback output filtered speed test input o/p fforward in max limit in min limit prop gain intgl gain deriv gain max o/p limit min o/p limit time constant unltd o/p enable filter total unlim user freeze ID Sel user freeze user ref Sel user ref feed forward 2 freeze in limit output lim 1 output lim 2 output rel 1 output rel 2 o/p rate limit
Type Minimum Maximum ON IL IL IN IN ON ON IN IN OL OL IN IN IN IN IN IN ON IL ON IL IL IN IL IN IL OL IL IL IL IL IN -2

31
Default 0 0 0 0 0 0 0 0 0 0 0 2000 10 0 10000 -10000 500 0 0 0 0 0 0 0 0 0 0 0 0 1 1 10000

104 = 100% 1 = select 104 = 100% 1 = freeze 1 = select 104 = 100% 1 = select 104 = 100% 1 = freeze 1 = in limit 1 = limit 1 = limit 0 = limit 0 = limit 104 = 100% 104 = 100% 10 = 1ms 1 = release 1 = frozen 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 1 = in limit 1 = in limit
3
Scaling
31
0 0 -40000 -40000 -40000 -231 -10000 -40000 0 0 0 0 0 0 -10000 0 -2

31
1 1 40000 40000 40000 231 10000 40000 1 1 2 2 2

32 32 32
10000 0 1000 2
31
0 -2
31
1 2
31
0 0 -40000 0 -40000 0 0 0 0 0 0 0
1 1 40000 1 40000 1 1 1 1 1 1 20000
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Alspa GD4000
Page 14-205
Module 92 (V2)
Page 14-206
Alspa GD4000
Issue (12-2-98)
Module 93 (V1)
14.29
Module 93 (V1)
Control Available Bridge A, Module 93 (Version 1)

Module 93 Control Available monitors 11 trips, each with a mask, and produces a latched version of the trip signal for fault indication proposes. The latched trip conditions of the 11 channels are then ANDed together with a control permitted signal (L9331) to produce a control available signal (L9334). All trip conditions are active low. The control available signal, once low, can be reset by setting L9332 to 1. Two alternative outputs are provided. One, L9337, active on assertion of L9336 & L9334, and the other, L9338, is a delayed version of L9337.
Table 14-28 Module 93(V1), Bridge A Control Available
Description
repetition period trip 1 trip 1 mask latched trip 1 trip 2 trip 2 mask latched trip 2 trip 3 trip 3 mask latched trip 3 trip 4 trip 4 mask latched trip 4 trip 5 trip 5 mask latched trip 5 trip 6 trip 6 mask latched trip 6 trip 7 trip 7 mask latched trip 7 trip 8 trip 8 mask latched trip 8 trip 9 trip 9 mask latched trip 9 trip 10 trip 10 mask latched trip 10
Type Minimum Maximum OL IL IL OL IL IL OL IL IL OL IL IL OL IL IL OL IL IL OL IL IL OL IL IL OL IL IL OL IL IL OL 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Default
10 = 1ms
3
Scaling
1 0 0 1 0 0 1 0 0 1 0 0 1 0 0 1 0 0 1 0 0 1 0 0 1 0 0 1 0 0
1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY
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Alspa GD4000
Page 14-207
Module 93 (V1)
control perm rst ltchd trips protection OK cntl available req m/c control rel I loops rel Trq.ref field_delay trip 11 trip 11 mask latched trip 11

Type Minimum Maximum IL IL OL OL IL OL OL IN IL IL OL 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 5 x 10 1 1 1
6
Default 0 1 0 0 0 0 0 106 1 0 0
103 = 1ms
Scaling
1 = CONTROL PERMITTED 1 = RESET LATCH 1 = HEALTHY 1 = CONTROL AV.
1 = HEALTHY 1 = MASK 1 = HEALTHY
Figure 14-55 Module 93(V1), Control Available
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Alspa GD4000
Issue (12-2-98)
Module 94 (V2)
14.30
Module 94 (V2)
Flux and Torque IT Tables, Module 94 (Version 2)

Introduction On running the user program module 94 initially calculates both the flux and torque look up tables from the motor and drive parameters entered by the user. Then the tables not valid flag (L9412) is cleared. The module then starts to output maximum flux and torque limit value (L9418) for the frequency set at L9415. The limited torque demand (L9429) is outputted after comparing torque demand (L9428) with the look up table of maximum torque for the set frequency (L9415). L9401 to L9406 are the equivalent STAR motor parameters. If DELTA parameters are available, divided impedances by 3 and voltage by 3 to obtain the equivalent STAR parameters. L9407 Base frequency is the motor name plate rating. L9408 Supply volts at base speed is the RMS phase to neutral voltage for the motor. L9409 Max drive output voltage is the Vdc/2 (Vdc = DC link voltage) to give the maximum line to line voltage applied to the motor e.g at a dc link voltage of 710 V L9409 should be 502 V. L9410 and L9434 are the peak RMS drive and motor currents respectively. These are usually set to 1.5 times the drive continuous rated current. e.g. for a GD4060, L9410 will be set at 90 A rms by the system software (see module 10 L1005). L9410 is set automatically from the selection of L1005. L9436 allows the continuous motor current to be set. Both look up tables can be seen after calculation using the tables viewer provided by L9438, L9439 and L9440. The look up tables are stored in 0.5 Hz increments up to 400 Hz i.e. 800 steps (0 to 799). By setting a value in L9438 the flux and torque values can be viewed in L9439 and L9440 respectively. This process could be automated by writing a suitable ladder and links program to increment L9438 and output L9439 and L9440 to the oscilloscope outputs. The motor base speed and number of motor poles are set in L9414 and L9413 respectively. Various other system variables are calculated in this module for use by other modules as follows.
14.30.1
14.30.2
Slip Gain Ks This is a constant used by module 95 in the calculation of slip frequency. Ks = Tpk . Rr 3 . P . 2.Ipk2Lm2
Where: Tpk is peak torque in Nm (L9425) Rr is Rotor resistance in ohms (L9403) P is motor pole pairs (L9413/2) Ipk is the drive peak current (L9410) Lm is the magnetising inductance in henries (L9406)
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Alspa GD4000
Page 14-209
Module 94 (V2)
14.30.3 Quadrature Current
This is the constant used by module 95 in the calculation of Iq* Ki = Tpk . (1 +Lr/Lm) 3 . Ipk2 Lm P Where: Tpk is peak torque in Nm (L9425) Rr is Rotor resistance in ohms (L9404) P is motor pole pairs (L9413/2) Ipk is the drive peak current (L9410) Lm is the magnetising inductance in henries (L9406) The module performs a secondary function of producing a flux to Id* conversion. This done using a look up table. The look-up table can be filled in either manually or automatically by running an off-load test on the motor. The table comprises five points set at 100, 90, 80, 70, 60 and 50% of base speed volts. To enter values manually L9479, start auto-test has to be set to 0. L9484, manual has to be set to 1. A voltage can now be entered into L9484 as a line to neutral voltage . The software will return a value to the nearest decile in the range. L9408 to L9408/2. The current for that voltage can be entered into L9482. L9483 the flux value in Wb is for information only. Once the user has entered the data (which can be entered in any order) L9481 should be returned to 0. The software will then check and validate the entered table. If validated , L9478 will be set to zero. 14.30.4 Auto-Test To run the auto-test L9481 must be set to 0 and L9479 set to 1. On this action the software will, in conjunction with module 19 (PID) ramp the motor to the base speed to perform the test. The voltage applied to the motor is reduced from Vnb to vnb/2. At 100, 90, 80, 70, 60 and 50% the stator current is measured. For a no-load condition it is assumed that the magnetizing current equals the stator current. Note: If a significant torque is detected the test will be aborted and the fault flag L9489 set to 1. Once the test has been completed L9480 is set to 1 and the tables are validated as for the manual test.
If for any reason the motor cannot be allowed to reverse, then L9490 should be set. Should table valid flag (L9478) not be set the software will assume a default value for the magnetizing current (not allowing for any iron saturation effects). For the above three cases the software linearly interpolate between points. From 50% to 0% it is assumed to be linear. Note: 14.30.5 the mag tables are retained during power down (assuming batteries are used to support memory).
Use of Duplicate Module When using L294 the variable L29499 should be set to 1. This is to allow the software to select the correct tables. L9499 should be set to 0. For auto mag test L19 is used for L94 to L294. The switching of L19 is automatic. This obviously precludes the auto-testing of both motors simultaneously.
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Alspa GD4000
Issue (12-2-98)

14.30.6 Deflux Factor
Module 94 (V2)
L9430 This is a value by which both torque and flux are limited. The factor is ramped on release of current regulators at a rate of 5 time rotor constant. 14.30.7 Headroom Utilisation Factor L9432 This used by the tables calculator to decide on how much of the dc link voltage above Vnbase2.3 that can be used.
For a constant flux (constant V/F), the voltage applied to the motor can be greater than Vnbase (as per the rating plate), up to a maximum of Vdclink/2 which will correspond to a speed of Ni. The user can select how much of region 1 volts (see figure 14-0) (Vdclink/2) - Vnbase is used by entering a percentage into L9432. 100% would mean that all the dc link volts are used. In this case the voltage or modulation depth (L1401) would carry on increasing past the ((L9408/L9409) x 10000) reaching 10000 at a speed of Ni. 14.30.8 Rotor Time Constant This is calculated based on the motor parameters entered (Lm + Lr)/Rr and is available on L9416. (L9406) Lm = Mag inductance (L9404) Lr = Rotor inductance (L9403) Rr = rotor resistance 14.30.9 Encoder Pulses Per Rev This is calculated from the encoder line count and the count multiplier, L9426 and L9427 respectively. The resultant encoder pulses per rev (L9442) is the product of the 2 variables. 14.30.10 Encoder Scaling Factor This is a constant, based on system and encoder parameters, that is required by various other modules in the system namely L9617 and L1609 for the calculation of position and speed. 14.30.11 Encoder Scaling Constant The encoder scaling constant (L9443) is passed by the links program to module 16.
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Alspa GD4000
Page 14-211
Module 94 (V2)
14.30.12 Overload Protection
Scaled outputs are provided (L9435 and L9437) for use with module 27 to provide thermal overload protection for the motor bridge. Inputs L9434 and L9436 are required to be set in order to set the scaled outputs. 14.30.13 Torque in Max/Min Limits L9444 and L9445 are fed back through the standard ladder program to the freeze integral inputs of module 92. This is to prevent integral wind-up in the PI speed regulator.
Table 14-29 Module 94(V2), Flux and Torque IT Tables
Description
repetition period stator resistance stator inductance rotor resistance rotor inductance magnetising resistance magnetising inductance base frequency motor volts at base speed max drive output volts peak drive current Iq gain Ki tables not valid number of motor poles base speed output frequency rotor time constant Id demand torque limit Last scans Id Slip gain (Ks) Peak Torque encoder line count count multiplier torque demand limited torque_demand
Type Minimum Maximum ON IN IN IN IN IN IN IN IN IN ON ON OL IN ON IN ON ON ON ON ON ON IN IN IN IN 1 1 1 1 1 1 1 1 1 1 0 0 2 0 -400000 1 -10000 0 0 0 0 256 1 -10000 -10000 100000 30000 100000 100000 10000000 1000000 400 400 848 3398 2
31
Default
3
Scaling
10 = 1ms 10 = 1m 1 = 1H 10 = 1m 1 = 1H 1 = 1m 1 = 1H 1 = 1 Hz 1 = 1 volt rms 1 = 1 volt 1 = 1 amp
1940 1240 2410 833 222000 46600 50 190 1 90 0 1 4 1500 0 200 0 0 0 0 0 1024 4 0 0
1 36 10000 400000 100000 10000 10000 10000 231 2

31 31
1 = not valid 1=1 1 = rpm 1 = 1 mHz 1 = 1 ms 104 = 100% of Ipk drive 104 = 100% 104 = 100% of Ipk drive
1000 = 1 Nm
100 10000 10000
104 = 100% 104 = 100%
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Alspa GD4000
Issue (12-2-98)

deflux factor Calc error Headroom utilisation Ramp time pk motor current scaled pk motor current cont motor current scaled cont motor current view array flux array torque array rpm constant encoder pulses per rev encoder scaling constant Torque in max. limit Torque in min. limit Torque in limit Select Phase Advance At deflux Value Phi D stator Phi D rotor Phi remainder Rotor TC Leakage TC Phi shaped RTC lead offset Id Ref at 50% Id Ref at 60% Id Ref at 70% Id Ref at 80% Id Ref at 90% Id Ref at 100% mag tab valid Start auto-test Test completed Manual entry Imag value Flux Vmotor L-N
Module 94 (V2)
Type Minimum Maximum IN ON IN IN IN ON IN ON IN ON ON ON ON OL OL OL OL IL OL ON ON ON ON ON ON IN IN IN IN IN IN IN OL OL OL OL IN ON IN 0 0 0 1 0 0 0 0 0 0 0 0 1 -2
31
Default 10000 0 1000 100 80 10000 0 10000 0 0 0 24750 10000 1 0 0 0 1 0 0 0 0 100 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 240
1 = 1 ms 1 = 1 ms
4
Scaling
10 = 100% bit field 104 = 100% 100 = 1 ms 1 = 1 Amp 104 x L9434/L9410 1 = 1 Amp 104 x L9436/L9410 1 = 1 Hz 1000 = 1 Wb 1000 = 1 Nm clkppmin/encppr
10000 2
31
10000 2000 4000 10000 10000 10000 400 2 2

31 31
1000000 1000000 2
31
deg/encppr x 216 1 = in limit 1 = in limit 1 = in limit 1 = select
0 0 0 0 0 -2
31
1 1 1 1 1 2
31
104= 100% 104 = 100%
-231 -2
31
231 2
31
0 0 -2
31
231 2 2
31 31
104 = 100% 1 = 1ms 100 = 1 amp 100 = 1 amp 100 = 1 amp 100 = 1 amp 100 = 1 amp 100 = 1 amp 1 = table valid 1 = start test 1 = test completed 1 = manual entry 100 = 1 A 1000 = 1 mWb 1 = 1 volt
-104 0 0 0 0 0 0 0 0 0 0 0 0 0
104 50000 50000 50000 50000 50000 50000 1 1 1 1 2

32
10000 1000
Issue (12-2-98)
Alspa GD4000
Page 14-213
Module 94 (V2)
Test status Base speed timer Start volts Test modulation Fault flag No reverse End of ramp Flux Ramp Time Power Throughput Back EMF Scaler Duplicate module number

Type Minimum Maximum ON ON ON ON ON IL OL IN ON ON IL 0 0 0 0 0 0 0 0 0 -4000 0 2
31 31
Default 0 0 0 0 0 0 0 0 0 0 0
bit field
Scaling
106 = 1 sec 1000 = 2 DC link Voltage 1000 = 2 DC link Voltage 1 = fault 1 = No reverse 1 = End of ramp 1 = 1 ms 10 = 1 kW
2 2
31 32
1 1 1 2000 20000000 4000 1
1 = 294 0 = 94
Figure 14-56 Module 94(V2), Flux and Torque IT Tables
Page 14-214
Alspa GD4000
Issue (12-2-98)
Module 95 (V2)
14.31
Module 95 (V2)
Slip Frequency Calculation, Module 95 (Version 2)

Introduction The generation of magnetising current and maximum torque look-up tables is explained in the following notes.
14.31.1
14.31.2
Characteristics of AC Machines The torque/slip characteristic of a standard squirrel cage induction motor is shown in Figure 14-57.
Figure 14-57 Induction Motor Torque/Slip characteristics
For variable speed operation from an inverter the induction motor must always be operated in the region between positive and negative break out torque conditions. By varying the operating frequency on the motor, as required by the process to achieve the necessary speed control, a family of torque/slip characteristics can be developed. By plotting the locus of positive and negative break out torque conditions for each operating frequency the resulting torque versus speed characteristic of a given motor can be produced. This is shown in Figure 14-58.
Figure 14-58 Motor Torque/Speed Characteristics
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Alspa GD4000
Page 14-215
Module 95 (V2)
Constant Rotor Flux Linkages
The vector controller in GD4000 operates by maintaining constant rotor flux linkages in the induction motor for a given frequency. This is explained by reference to the single phase equivalent circuit for the motor shown in figure 14-59.
Figure 14-59 Motor Single Phase Equivalent Circuit
For a particular operating frequency the voltage across the rotor resistance is held constant as the torque in the motor is varied by controlling slip. As torque increases, the voltage drop across the rotor increases, stator leakage inductances increase, and stator resistance increases, to cause an increase in motor terminal voltage. As terminal voltage on the motor is derived from an inverter with a finite limit on output voltage, equal to Vdclink/2 for sinusoidal excitation, then maximum torque becomes inverter output voltage limited. As torque increases by controlling slip, the output current from the inverter must increase to meet the power requirements of the load. The maximum slip must be limited to ensure that the inverter does not operate beyond its overload current rating. By maintaining constant rotor flux linkages the torque/slip characteristic of an induction motor controlled by a GD4000 is linearised. 14.31.3 Maximum Magnetising Current As induction motors are generally designed for constant frequency operation, they must have sufficient iron to support the flux resulting from excitation at full nameplate voltage on no load. Excluding a small allowance for stator voltage drops, this operating condition would result in the full terminal voltage being applied to the rotor circuit. This condition is used to define the maximum magnetising current for any load or speed. By limiting the maximum magnetising current, low voltage motors can be connected to the output of an inverter with a higher output voltage without the risk of over fluxing the motor. By using this feature, the frequency for changing from constant (maximum) rotor flux to a constant voltage condition rises. 14.31.4 Setting the Limits The factors of: Break out torque Inverter Voltage Limit Inverter Current Limit Maximum Magnetising Current
must all be respected if stable variable speed operation is to be achieved.
Page 14-216
Alspa GD4000
Issue (12-2-98)
Module 95 (V2)
This can be seen by reference to the torque versus speed characteristic of the resulting drive shown in Figure 14-60.
Figure 14-60 Overall Drive Torque/Speed Characteristic
Region 1 Maximum magnetising current and drive current limit define operation in this region. In calculating look up tables the lesser of inverter current limit or motor overload current is taken in defining overall drive current limit. At low speed the power lost in the iron loss resistance, Rm, is low, therefore more current can flow in the rotor circuit and hence more torque be produced by the induction motor. The terminal voltage will always be less than Vdclink/2 for all load and speed conditions in this region. Region 2 As the speed rises, the induction motor terminal voltage during overload reaches the inverter output voltage limit. The magnetising current will reduce and the torque available from the motor for a given drive current limit will reduce. Region 3 Continued increase in speed, further reduces magnetising current and hence torque for a given drive current limit. Operation in regions 2 and 3 are effectively inverter load impedance (Z) limited. The maximum torque being determined by the inverter voltage and drive current limits. The motor impedance, Z, must not fall below: Zmin = Inverter Maximum Output Voltage Drive Current Limit Region 4 In region 4 there is no benefit in increasing slip beyond the break out torque condition as this will only lead to increasing motor current for a reducing torque output, which would result in unstable operation. In this region the maximum inverter output voltage and induction motor equivalent circuit parameters determine the maximum torque. The inverter output current will always be less than the limit set for the lesser of L9410 or L9434. Issue (12-2-98) Alspa GD4000 Page 14-217
Module 95 (V2)
14.31.5 Calculation of Look Up Tables
The magnetising current and maximum torque possible for any operating speed of GD4000 is defined by look up tables calculated for a given induction motor and inverter combination. The calculation requires knowledge of the equivalent circuit parameters for the particular induction motor and inverter rating. Parameters must be entered into the appropriate L table location of module 94 when the drive is commissioned. These parameters can be modified and the look up tables recalculated provided that the drive is disabled. To force a recalculation of the tables used by module 94, the motor/drive parameters may be written to by R tables (battery retentive) after suitable links are made. The slow task is halted after the R tables have been modified and then run. The parameters are usually specified by the motor manufacturer on the basis of per phase equivalent circuit values. As induction motors can be wound for star or delta connection this can easily lead to confusion. The parameters for GD4000 must be entered on the basis of a star connection. Delta equivalent circuit parameters can be converted to star equivalents by dividing the delta values by 3. The phase voltage then becomes: VLine-Line 3 The following data should be requested from the motor manufacturer: Stator Resistance Stator Leakage Inductance Magnetising Inductance Iron Loss Resistance * Rotor Leakage Inductance Rotor Resistance (at maximum rotor temperature) Phase Voltage for basis of parameters (Vline-line for a star connected motor) Base Frequency - Fb Connection - Star or Delta (for basis of parameters) Magnetising Current Motor full load current Motor overload current for specific overload torque requirement * Iron loss resistance is not always specified in such cases set the iron loss resistance to the maximum value given in Table 14-0 or refer to the motor parameter estimation section. The units for entering this data into Module 94 should be derived from that particular module (see scalings in Table 14-0). Where reactance is supplied by the motor manufacturer instead of inductance, convert by dividing reactances by 2Fb. where Fb = Base frequency 14.31.6 Derivation of Parameters In situations where manufacturers data is not available the parameters can be derived by a series of tests on the induction motor. Refer to section 6.5 Page 14-218 Alspa GD4000 Issue (12-2-98)
Module 95 (V2)
Module 95 is used to calculate motor slip frequency and quadrature current demand from Module 95s torque demand signal. Module 95 can either accept rotor time constant information from module 81 and module 94 or run in a stand alone mode using the nominal value plus an offset. L9507 is used to select between the two. When using information from modules 81 and 94 Ks is no longer a constant and varies proportionally with rotor resistance. Slip frequency is calculated using the equation: Fs = T* . Ks *r2 where: Fs is slip frequency in mHz T* is torque demand in pu (100% = L9425) Ks is a constant (depending on L9507) *r is rotor flux demand in pu (100%= L9425) The above equation is derived from the following torque equation: T* = 3P . Id2 . Ws . Lm2 2 Rr where: T* is torque in Nm P is number of motor poles Rr is motor rotor resistance in ohms s is slip frequency in radians/sec Lm is motor magnetising inductance in Henries Id is magnetising component of the stator current in amps Rearranging this equation gives: s = As IdLm is the rotor flux r s = 3T*Rr 3pr2 (4) 2T*Rr 3P Id2 Lm2 (3) (2) (1)
Converting this equation for use in the GD4000 per unit system gives rise to the following steps: The units for eqn. 4 are:Ws[rad/s] = 2T*[Nm] . Rr[] 3P . r[Wb]2 (5) (6)
Fs[Hz] = T*[Pu] . 2PkT[Nm] .10000 . Rr[] r[PU]2 2 3P Lm[H]2 PKC[A]2 Fs[Hz] = T*[PU] . Ks r[PU]2 (7)
Issue (12-2-98)
Alspa GD4000
Page 14-219
Module 95 (V2)
As Ks is constant for the preset conditions set by the user in module 94, then the calculation is performed once only and passed to the module from Module 94. Note: The GD4000 calculated peak torque and fs in mNm and mHz respectively . The peak current PKC is the drive peak current used by module 94 (L9410).
Due to the heating of the rotor circuit during operation the rotor resistance will vary; so, the value of ks is further modified by :
r +ros
where:
r = rotor time constant ros = rotor time constant offset

Quadrature current demand is calculated from:Iq = T* . Ki + 2FoLm r* Rm where: The second term is due to iron losses and can be selected (L9534) Iq is the torque producing component of the stator current T* is torque demand in pu (100% = L9425) Q* is rotor flux demand in pu (100% = Idmax lim) Fo is output frequency. The total current Iq is the sum of IRr and Img where the q axis is in phase with the voltage across Rr. IRr = Vlrs Rr Img = VLr XLm and VLr = IRr. XLr so Img = s . Lr . VRr RrLm Iq* = VRrs + sLrVRr Rr sRrLm now Id = VRr Lm (14) (12) (13) (11) (s = slip in pu) (9) (10) (8)
Page 14-220
Alspa GD4000
Issue (12-2-98)

Eqn 13 becomes Iq* = Ids (Lm +Lr) Rr Substituting eqn 3 for s gives Iq* = 2T* . Lm + Lr 3P IdLm2 As IdLm is the rotor flux the equation becomes Iq* = 2T* . Lm + Lr 3P r* Lm Converting the equation for use in the GD4000 per unit system gives Iq*[PU] = 2T*[Nm] . (Lm[H] + Lr[H]) 3P r*[Wb] . Lm[H] (16) (15)
Module 95 (V2)
(17)
(18)
Iq*[PU] = 10000 . 2 . T*[PU] . PKT[Nm] . (Lm[H] + Lr[H] (19) PKC[A] 3P PKC[A] r*[PU] Lm[H] Iq*[PU] = T*[PU] . Ki r*[PU] Note: The peak torque is in Nm (L9425). (20)
Output power is calculated using the following equation Po = Id x Iq x frotor Id at standstill where: Frotor is rotor electrical frequency Po is the per unit power output K is a constant (changes dependant on polarity of regen flag) Iq is the quadrature (torque producing) component of stator current feedback Id is the magnetising component of the stator current feedback. Note: The calculation for Po does not represent the absolute power output in kW.
Cross Coupling Terms The equations for Vd and Vq do not solely rely on the respective Id or Iq term but have a component derived from the corresponding Iq and Id terms:Vd is a function of Id and Iq Vq is a function of Iq and Id An expression for the derivative of the stator current is: Now for the steady state conditions Id = 0 and Iq = 0 Rearranging (21) and (22) in terms of Vd and Vq gives: Vd = RsId - LseIq - Lm(rd -rrq) (24) Lr Tr
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Alspa GD4000
Page 14-221
Module 95 (V2)
Vq = RsIq + LseId -Lm(rrd - rq) (25) Lr Tr
As the flux on the quadrature axis is 0 eqns 24 and 25 become Vd = RsId -LseIq -Lmrd LrTr Vq = RsIq -LseId -Lmrd Lr The drive uses the constant flux mode, therefore -Lmrd is constant LrTr and Lmrrd is the back emf term Lr where: Rs is the stator resistance Ls is the stator inductance + magnetising inductance. e is the stator frequency r is the rotor frequency Lr is the rotor inductance + magnetising inductance Lm the magnetising inductance rd is the rotor flux = Note: 1 - Lm2 (Ls + Lr)(Lr + Lm) (26) (27)
In the equation implementation both and the back emf terms have a scaling term associated with them in order to vary their effect.
Id and Iq have scaling terms associated with them. The cross coupled terms are calculated by module 95 and are linked to the appropriate Vq and Vd demands (modules 11 and 12) via the feed forward inputs L1108 and L1208. The cross coupled terms are a function of speed and therefore become increasingly important as rotor speed rises. Guidance on the set-up for the cross-coupling terms is given in the commissioning notes, see Section 12.3.3.
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Issue (12-2-98)

repetition period torque demand direct current Id quadrature current Iq rotor TC slip frequency direct current at standstill Select RTC Comp o/p frequency power rotor electrical frequency regen flag output power motoring scale factor regen scale factor Iq feedback rotor TC offset Iq scaler Id scaler Ls dash sigma Release outputs Back emf scaler Id feed forward Iq feed forward Sigma Ls Ws Scaled back emf Normalised shaft speed Peak speed A Motor poles Ki Ks Flux demand Select Iron loss comp. Iq (Rm) Select sigma Ls Sigma Ls select lim Iq working Iq lim
Module 95 (V2)
Type Minimum Maximum ON IN IN ON IN ON ON IN ON ON ON OL ON IN IN IN IN IN IN ON IN ON IN ON ON ON ON IN IN IN IN IN IN IN ON IN ON IL ON -10000 -10000 -10000 0 -400000 -10000 0 -400000 -2
31
Default 0
10 = 1 ms
3
Scaling
100% = 104 = Peak torque 100% = 104 = Peak current 100% = 104 = Peak current ms 1000 = 1 Hz 100% = 104 = peak current 1 = select 1000 = 1 Hz 100 = 1kW 1000 = 1Hz 1 = regen 100% = 104 = Peak power
10000 10000 10000 10000 400000 10000 1 400000 2

31
0 2500 0 400 0 1 1 0 0 0 0 0 12 12 0 0 0 0 300 0 0 0 0 0 0 0 0 15000 4 1 1 1 1 0 1 0 1 0
-400000 0 -10000 -10000 -10000 -10000 0 -4000 -4000 0 -1000 0 -4000 -10000 -10000 -2
31
400000 1 10000 10000 10000 10000 500 +4000 +4000 10

6
100% = 104 = Peak current ms 10 = 1% 10 = 1% Ls + Lm H 10 = 1% 1 = released 103= 1% 104 = 100% * 104 = 100% ** 104 = 100%
+1000 1 +4000 +10000 +10000 2

31
-2 31 -20000 10 2 0 0 1 0 -10000 0 1 0 2
31
231 20000 200000 36 2 2

32 32
104 = 100% 10 = 1 rpm
10000 1 10000 1 2
32
100% = 104 = peak flux 1 = select 104 = 100% 1 = select 1 = 1 H 1 = selected 104 = 100%
1 2
31
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Page 14-223
Module 95 (V2)
Variable L9547 L9548 L9549 L9550 L9552 L9553 L9555 L9556 L9557 L9558 L9559 L9560 L9561 L9562 L9563 L9564 L9565 L9566
Is lim Iq at pos lim Iq at neg lim fast_output power fast Iq fb sel Iq fb sel alt power ff alt power alt power scaling factor alt power multiplier unselect deflux back emf deflux back emf deflux back emf time sigma conductance actual torque actual rpm scaled rpm actual rads

Description Type Minimum Maximum IN ON ON ON IN ON IN ON IN IN IL ON IN ON ON ON ON ON 0 0 0 -2
31
Default 10000 0 0 0 0 0 1 0 0 1024 0 0 0 0 0 0 0 0

1 = 1 Nm 1 = 1 rpm 1 =1ms 1 = selected 10 = 100% 1 = at limit 1 = at limit 104 = 100% 104 = 100% 1 = select 1 = select 10 = 1% 104 = 1pu
4
Scaling
10000 1 1 2
31
-10000 0 0 -2
31
10000 1 1 2
31
-20000 0 0 0 0 0 0 -2
31
20000 231 1 2 2 2 2 2 2 2
31 31 31 31 31 31 31
0 -2
31
L9523 is connected to L1208 in the standard links program.
** L9524 is connected to L1108 in the standard links program. L9506 is a snapshot of L9502 when L9510 = 0
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Alspa GD4000
Issue (12-2-98)
Module 95 (V2)
Figure 14-61 Module 95(V2) Slip Frequency Calculation
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Page 14-225
Module 98 (V1)
14.32
Module 98 (V1)
Control Available Bridge B, Module 98 (Version 1)

Module 98 Control Available monitors 11 trips, each with a mask, and produces a latched version of the trip signal for fault indication proposes. The latched trip conditions of the 11 channels are then ANDed together with a control permitted signal (L9831) to produce a control available signal (L9834). All trip conditions are active low. The control available signal, once low, can be reset by setting L9832 to 1. Two alternative outputs are provided. One, L9837, active on assertion of L9836 & L9834, and the other, L9838, is a delayed version of L9837.
Table 14-30 Module 98(V1), Bridge B Control Available Variable L9800 L9801 L9802 L9803 L9804 L9805 L9806 L9807 L9808 L9809 L9810 L9811 L9812 L9813 L9814 L9815 L9816 L9817 L9818 L9819 L9820 L9821 L9822 L9823 L9824 L9825 L9826 L9827 L9828 L9829 L9830 Description
repetition period trip 1 trip 1 mask latched trip 1 trip 2 trip 2 mask latched trip 2 trip 3 trip 3 mask latched trip 3 trip 4 trip 4 mask latched trip 4 trip 5 trip 5 mask latched trip 5 trip 6 trip 6 mask latched trip 6 trip 7 trip 7 mask latched trip 7 trip 8 trip 8 mask latched trip 8 trip 9 trip 9 mask latched trip 9 trip 10 trip 10 mask latched trip 10
Type Minimum Maximum ON IL IL OL IL IL OL IL IL OL IL IL OL IL IL OL IL IL OL IL IL OL IL IL OL IL IL OL IL IL OL 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Default
10 = 1 ms
3
Scaling
1 0 0 1 0 0 1 0 0 1 0 0 1 0 0 1 0 0 1 0 0 1 0 0 1 0 0 1 0 0
1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY 1 = HEALTHY 1 = MASK 1 = HEALTHY
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Issue (12-2-98)

control perm rst ltchd trips protection OK cntrl available req m/c control rel I loops rel Trq.ref field_delay trip 11 trip 11 mask latched trip 11
Module 98 (V1)
Type Minimum Maximum IL IL OL OL IL OL OL IN IL IL OL 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 5 x 10 1 1 1
6
Default 0 1 0 0 0 0 0 106 1 0 0
103 = 1ms
Scaling
1 = control permitted 1 = reset latch 1 = HEALTHY 1 = CONTROL AV.
1 = HEALTHY 1 = MASK 1 = HEALTHY
Figure 14-62 Module 98(V1), Bridge B Control Available
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Page 14-227
Module 99 (V2)
14.33
14.33.1
Module 99 (V2)
DC Link Control, Module 99 (Version 1)

Introduction This module controls the charging of the DC link. Once established, the DC link voltage is controlled to a reference level by module 97. The module controls the charging of the DC link by the use of 2 relays: line contactor charge relay As the DC link comprises a bank of discrete capacitors and snubber components for 6 transistors it is impossible to apply full mains rectified volts instantaneously to them without damage to the circuitry and fuses. To circumvent this problem a charge relay is used to connect the network phase voltages to the drive via a resistive network. Thus the charging current is reduced. Once a software determined DC link voltage level is attained the line contactor is energised.
14.33.2
Module Diagrams Because of the complexity of this module the module diagram has had to be split into seperate parts. Part 1 illustrates the basic inputs and outputs of the module during normal running. Part 2 is a diagram that shows the sequence performed when trying to close either the line contactor or the precharge relay. Each stage of this sequence corresponds to a sub module marked A to G. The final sub module H shows the actions performed when auto setup of parameters is requested, L1002.
14.33.3
Pre-charge Relay and Line Contactor Control When the charge relay is requested (L9931 is set) the DC link feedback is fed into a rate of rise detector whose gain is set by L9968. Should the DC link feedback fail to rise within the time period set by L9976 (charge relay close time) then L9978 (pre-charge fault) will flag a fault and the drive will trip. L9977 indicates whether the charge relay has closed and L9975 is a switch which allows this feedback to create the pre-charge fault. Similarly, when the line contactor is requested (L9930 is set) the DC link feedback is fed into a rate of rise detector whose gain is set by L9968. Should the DC link feedback fail to rise within the time period set by L9911 (contactor changeover delay) then L9981 (line contactor fault) will flag a fault and the drive will trip. L9979 indicates whether the line contactor has closed and L9980 is a switch which allows this feedback to create a line contactor fault. However, by setting L9980 to a 1, the line contactor fault will instead be driven by A32.6, a dedicated digital input available on the customer I/O board. A trip will occur if A32.6 fails to go high within the contactor changeover delay. If a 31V7100 hinged gate assembly is being used, the line contactor feedback is via a dedicated input on the PIB regardless of the state of L9980. DC link requests are masked by L9969 dependent upon the level of the DC link feedback. By masking the DC link request when the DC link voltage is close to but less than the pre-charge level, or close to the nominal voltage level, then a greater rate of change of DC link feedback can be generated and a successful relay / contactor closure can be determined. The mask is also applied to prevent multiple charge relay closures within a predetermined time, L9971.
14.33.4
Nominal DC Link Volts Level, Under-volts Level, Over-volts Level and Pre-charge Level. These are all user inputs and are scaled as 100% (10000) = (2 x 380V. The nominal volts level (L9915) is the DC link voltage that the volts controller is aiming for, the
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Issue (12-2-98)
Module 99 (V2)
under-voltage level (L9914) and over-voltage level (L9916) are software trip levels. The pre-charge level (L9909) is the level at which the line contactor closes whilst the DC link is pre-charging. The defaults are 130%, 80%, 150% and 80% respectively but can be automatically calculated by setting L1001 auto setup B in module 10 to a 1 in the links file. Under-voltage trips are masked during the pre-charge sequence for a predetermined time set by L9917. The auto calculated value of L9915, nominal volts level, is calculated based the minimum level required to satisfy the DC link loading requirements plus L9992, the DC link headroom voltage (which can be entered into the links file). The loading requirements are calculated from the power throughput, L9949, the maximum supply frequency, L9950, the nominal supply voltage, L9951, the supply tolerances, L9952 and L9953, the input inductance, L9954, and for AC in AC out systems, the required motor voltage. L9949 - L9954 are to be entered in the links file but for fast task type 0 the power throughput, L9949, will automatically be passed a value from module 94 if no value is entered into the links file. The input inductance, L9954, can also be automatically calculated (see later). The calculated values of under-volts and over-volts level are 0.75 and 1.25 times the nominal voltage level and the pre-charge level will be set to the lesser of 0.75 times nominal DC link volts level and 0.9 times the peak of the nominal supply voltage. Drive V max, L9984, is calculated to be nominal volts level / (2 and is an outputted to module 94. 14.33.5 Input Inductance The drive default inductance is displayed in L9985, based on the nominal choke inductance for the drive type chosen. L9986 allows the network supply inductance to be inputted and this value will be added to the default inductance and passed to L9954 (the total input inductance) during a halt to run if auto setup B has been selected in module 10. However, if the total input inductance is already known, it can be linked directly into L9954 and will override the L9985 + L9986 summation. 14.33.6 Common DC link schemes For common DC link schemes, the effective DC link capacitance of all additional equipment connected to the GD4000 should be entered into L9987 in the links file. This will allow the auto-calculation of the PI gains of module 197 to be correctly determined. 14.33.7 Filter Offset In order to tune out the offset given by the mains synchronisation hardware filtering, select auto-tune, L9963 can be set to a 1 in the links file. This will allow the drive to measure the filter offset and pass it to module 6 automatically. 14.33.8 Trip outputs Module 99 trip, L9982, is a global fault output comprising the individual trip outputs; pre-charge fault (L9978), contactor fault (L9981), under-volts (L9925), over-volts (L9928) and auto-setup error (L9962). The following signals are provide as outputs for monitoring use L9927 Pre charge level reached L9930 Line contactor
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Page 14-229
Module 99 (V2)
L9931 Charge relay L9932 DC link charged The following signals are provided as trip signals L9925 DC link under volts L9926 DC link charging fault L9928 DC link over-volts Note:
This module has certain variables declared for use with ride through operation when the mains supply fails. The L tables concerned with ride through operation are L9901 to L9906 inclusive. The ride through request signal is currently disabled (L9913). Other associated signals that will be of limited use until the feature is introduced are L9919, L9920, L9921, L9922 and L9923.
14.33.9
Parameter Auto Calculation If L1002, autosetup B, is enabled, then the drive automatically calculates several parameters on power up. The equations for these parameters are quite complex, and so are given here rather than drawn on the module diagrams
14.33.9.1 DC Link Voltage Calculations V1 = (Vnom * 10000) + (Vnom * tol) / 10000) Where Vnom = Nominal supply volts, L9951 tol = Positive supply tolerance, L9952 Is = Pth * 100 * OLF 3 * 10 * V1 Where Pth = Power throughput, L9949 OLF = Over load factor, L9960 If Is is greater than the peak drive current, then it is limited to the peak drive current. Inductor volts = 0.2 * Pi * 3 * Fmax * L * Is 10000000 Where Fmax = Maximum supply frequency, L9950 L = Supply inductance, L9954 DC Link Volts = 2 * ( Inductor volts2 + V12) If this value is less than the volts required by the motor, it is made to equal the volts required by the motor, passed from module 94, and any headroom volts are added, L9992. If this final value is greater than the permitted hardware limit then error flag is set, L9962. If this voltage is less than the rectified input voltage, then the error flag is also set. A range of values are then calculated Page 14-230 Alspa GD4000 Issue (12-2-98)

L9984 = DC Link Volts / 2 L9915 = (DC Link Volts * 10000) / 380 * 2 L9914 = (DC Link Volts * 7500) / 380 * 2 L9916 = (DC Link Volts * 11500) / 380 * 2 L9909 = (DC Link Volts * 7500) / 380 * 2 14.33.9.2 Voltage Limits V2 = (Vnom * 10000) + (Vnom * tol) / 10000) Is = Pth * 100 * OLF 3 * 10 * V2 Positive Volts Limit, L9956 = Is * 10000 / Ipk Where Ipk = Peak drive current from Module 10 Negative Volts Limit, L9957 = - Positive Volts Limit 14.33.9.3 Vab feedforward gain Vab = Ipk * 15.39 * Fnom * 1024 * L DC Link Volts * 100000000 Where Fnom = Nominal supply frequency from module 6 14.33.9.4 Active And Reactive Limits Reactive Limit, L9958 = V1 * 2 * 10000 DC Link Volts V3 = Vnom * 10000 + (Vnom * neg tol) / 10000
Module 99 (V2)
Is = Pth * 100 * OLF 3 * 10 * V3 Inductor Volts = 0.2 * Pi * 3 * Fmax * L * Is / 10000000 Active Limit, L9959 = Inductor Volts * 2 * 10000 / DC Link Volts 14.33.9.5 Under Volts And Contactor Change Over Delay The contactor change over delay, L9911, is either set to 400ms or 700ms depending on the drive size. Similarily, the under volts mask time, L9917, is either set to 4 or 10 seconds depending on the drive size. 14.33.9.6 Alternative Power Scaling Factor Scaling Factor, L9993 = 380 * Nominal Volts Level / Vnom Guidance for the parameterization of Module 99 is provided in section 6.5. Issue (12-2-98) Alspa GD4000 Page 14-231
Module 99 (V2)
Table 14-31 Module 99(V2), LINKON
Variable L9900 L9901 L9902 L9903 L9904 L9905 L9906 L9907 L9908 L9909 L9911 L9912 L9913 L9914 L9915 L9916 L9917 L9918 L9919 L9920 L9921 L9922 L9923 L9924 L9925 L9926 L9927 L9928 L9929 L9930 L9931 L9932 L9934
Description
Repetition Period RY Peak Volts RY Scaling Factor BY Peak Volts BY Scaling Factor Supply Loss Level Mains Sync Loss DC Link Volts DC Link Volts Scaling Factor Pre Charge Level Contactor Change Over Delay DC Link Request Ride Through Request DC Link Under Volts Level DC Link Nominal Volts Level DC Link Over Volts Level DC Link Under Volts Mask Time DC Link Reference Scaled RY Peak Volts Scaled BY Peak Volts RY Lost BY Lost Peak Volts Void Scaled DC Link Volts DC Link Under Volts DC Link Charging Fault DC Link Pre Charge Level Reached DC Link Over Volts Ride Through Relay ON Line Contactor ON Charge Relay ON DC Link Charged Ramp Rate
Type Minimum Maximum ON IN IN IN IN IN IL IN IN IN IN IL OL IN IN IN IN ON ON ON OL OL OL ON OL OL OL OL OL OL OL OL IN 0 1 0 1 5000 0 0 1 3000 10000 0 0 3000 5000 5000 10000 10 10000 10 100000 1 20000 10 16500 1000000 1 1 16500 22000 23000
Default
3
Scaling
10 = 1 ms 104 = 3802 V
0 1 0 1 5000 0 0 1 8000 35000 0 0 8000 10000 15000
104 = 3802 V
Volts x Scaling Factor 1 = Loss 104= 380 V
100 = 1% 103 = 1 ms 1 = Request 1 = Request 100 = 1% 100 = 1% 100 = 1%
1000000 20000000 3000000 103 = 1 ms 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1000 22000 100000 100000 1 1 1 22000 1 1 1 1 1 1 1 1 20000 0 0 0 0 0 0 0 1 1 0 1 0 0 0 0 5000
100 = 1% L9901 x Scaling Factor L9903 x Scaling Factor 1 = Lost 1 = Lost 1 = Void L9907 x Scaling Factor 0 = Under Volts 0 = Charging Fault 1 = Pre Charge Level Reached 0 = Overvolts 1 = On 1 = On 1 = On 1 = Charged 1000 = 1%/sec
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Variable L9935 L9936 L9937 L9949 L9950 L9951 L9952 L9953 L9954 L9955 L9956 L9957 L9958 L9959 L9960 L9961 L9962 L9963 L9964 L9966 L9967 L9968 L9969 L9971 L9975 L9976 L9977 L9978 L9979 L9980 L9981 L9982 L9983 L9984 L9985 L9986 L9987 L9992 L9993 L9994 L9995 L9996 Description
Limit Time Limit Timer Output DC Link At Nominal Power Throughput Max. Supply F Nominal Supply Volts Positive Supply Tol. Negative Supply Tol. Input Inductance Va Feed Forward Positive Volts Limit Negative Volts Limit Reactive Limit Active Limit Overload Factor Error Code Auto Calc Error Select Auto-tune Tuned Network Freqency DC Link Volts slope gain permit contactor control precharge repeat time permit precharge fault charge relay close time charge relay closed OK precharge fault line contactor closed OK A32.6 wanted line contactor fault module 99 trip OK to boost drive V max default input inductance network inductance external DC link cap Volts headroom Alt Scaling Factor Filtered Vb Filter TC 1 Filter TC 2
Module 99 (V2)
Type Minimum Maximum IN OL OL IN ON IN IN IN IN ON ON ON ON ON IN ON OL IL OL ON ON IN OL IN IL IN OL OL OL IL OL OL OL ON ON IN IN IN IN ON IN IN 0 0 0 0 -2
31
Default 500000 0 0 0 0 380 1000 -1000 0 0 10000 -10000 0 0 15 0, 0 0 0 0 0 20 0 30 x10 1 200000 0 0 0 0 0 1 0 0 1000 0 0 0 0 0 250 250
6
Scaling
1 = 1 s
5000000 1 1 20000000 2
31
1 = at nominal 10 = 1 kW 1 = 0.01 Hz 1=1V 100 = 1% 100 = 1% 1000 = 1 mH
380 0 -2000 0 -2
31
750 2000 0 10000 2

31
0 -10000 -2 -2
31 31
10000 0 2 2
31 31
104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100%
1 -231 0 0 0 0 0 1 0 1000 0 1000 0 0 0 0 0 0 0 0 10 0 0 0 -2

31 31
25 231 1 1 1 2 2
31 31
1 = select 1 = select 1 = tuned 1 = 0.01 Hz 1 = 1 volt 10 = gain of 1 1 = permit 106 = 1 second 1 = permit fault 1000 = 1 ms 1 = closed 1 = fault 1 = closed 1 = read A32.6 1 = fault 0 = trip 1 = OK to boost 1=1V 1000 = 1 mH 1000 = 1 mH 1 = 1 F 1=1V
100 1 100000 1 1000000 1 1 1 1 1 1 1 850 100000 100000 200000 100 2 2

31 31
-2
1=1V
0 0
1023 1023
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Alspa GD4000
Page 14-233
Module 99 (V2)
Figure 14-63 DC Link Control, Module 99 (V2)
Page 14-234
Alspa GD4000
Issue (12-2-98)
Module 99 (V2)
Figure 14-64 DC Link Control, Module 99(V2)
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Alspa GD4000
Page 14-235
Module 99 (V2)
Page 14-236
Alspa GD4000
Issue (12-2-98)
Module 99 (V2)
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Alspa GD4000
Page 14-237
Module 119 (V4)
14.34
Module 119 (V4)
Fast History Record, Module 119 (Version 4)

Module 119 is a Fast Task module, see Section 13.17.1.
14.35
Fast History Bridge B, Module 159 (Version 1)

Clone of Module 119, see Section 13.18
14.36
Program Blocks, Module 186

Module 186 is a Clone of Module 86.
14.37
Changeover Switch, Module 187

Module 187 is a Clone of Module 87.
Page 14-238
Alspa GD4000
Issue (12-2-98)
Module 197 (V2)
14.38
Module 197 (V2)
DC Link Voltage Control, Module 197 (Version 2)

Introduction
Parameter L19704 L19705 L19708
ref output fd forward
14.38.1
Description
Comes From Module(s) 10
Goes To Module(s) 4, 14 1, 2
95
Module 197 controls the voltage of the DC link. The typical connections already made to Module 197 by the software are listed in the table below. For a description of the PID function refer to Section 7.10.1.
Table 14-32 module 119 (V4) Fast History Record
Variable
Description
Type Minimum Maximum ON IL OL IN IN ON ON IN IN OL OL IN IN IN IN IN IN ON IL ON IL IL IN IL IN -2

31
Default 682 0 0 0 0 0 0 0 0 0 0 0 0 0 10000 -10000 250 0 1 0 0 0 0 0 0

3
Scaling
10 = 1 ms 1 = release 1 = frozen 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 104 = 100% 1 = in limit 1 = in limit 0 = auto calculate 0 = auto calculate
L19700 Scan time L19701 rel reg L19702 freeze id L19703 ref L19704 feedback L19705 output L19706 filtered output L19707 test input L19708 fd forward L19709 in max L19710 in min L19711 prop gain L19712 intgl gain L19713 deriv gain L19714 ref max lim L19715 ref min lim L19716 time constant L19717 unltd o/p L19718 filter enable L19719 total unlim L19720 user freeze ID L19721 Sel user freeze L19722 user ref L19723 Sel user ref L19724 feed forward 2
31
0 0 -40000 -231 -231 -231 -10000 -40000 0 0 0 0 -10000 0 -10000 0 -2

31
1 1 40000 231 231 231 10000 40000 1 1 2 2

32 32
10000 10000 0 1000 2

31
104 = 100% 104 = 100%
104 = 100% 1 = select 104 = 100% 1 = freeze 1 = select 104 = 100% 1 = select 104 = 100%
0 -2
31
1 2
31
0 0 -40000 0 -40000
1 1 40000 1 40000
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Alspa GD4000
Page 14-239
Module 197 (V2)

Variable L19725 freeze L19726 in limit L19727 Do alt deriv L19728 Alt deriv output L19730 Sel alt deriv IP L19731 Alt deriv limit L19732 Old lt deriv IP L19733 Alt deriv IP L19734 Integral mode L19735 Sel cross lim L19736 Other axis OP L19738 Sel user output L19739 User output ref L19753 Sel new filter L19754 Filter rem L19755 freeze id L19756 freeze id L19757 feed forward 3 L19758 PID error lim L19759 Output lim 1 L19760 Output lim 2 L19761 Output rel 1 L19762 Output rel 2 Description Type Minimum Maximum IL OL IL ON IL IN ON IN IN IL ON IL IN IL ON OL OL IN IN IL IL IL IL 0 0 0 -2
31

Default 0 0 0 0 0 1000 0 0 1 0 0 0 0 0
0
Scaling
1 = freeze 1 = in limit 1 = do calculation 104 = 100% 1 = select 104 = 100%
1 1 1 2
31
0 0 -231 -10000 0 0 -2
31
1 10000 231 10000 2 1 2

31
104 = 100%
1 = select 104 = 100% 1 = select
0 10000 0 -2
31
1 10000 1 2
31
0 0 -40000 0 0 0 0 0
1 1 40000 300000 1 1 1 1
0 0 0 2500 0 0 1 1
1 = freeze 1 = freeze 104 = 100%
1 = limit op 1 = limit op 1 = release op 1 = release op
Note:
100% DC link = 380 x 2 = 537 Vdc
Page 14-240
Alspa GD4000
Issue (12-2-98)
Module 197 (V2)
Figure 14-67 Module 197, PID Regulator
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Page 14-241
Module 197 (V2)
14.39
Position Feedback B, Module 216

Clone of Module 16.
14.40
Speed Voltage Control, Module 221 (Version 5)

Clone of Module 21
14.41
Reference Circuits, Module 222 (Version 3)

Clone of Module 22
14.42
Control Available Logic, Module 226 (Version 5)

Clone of Module 26
14.43
Control On Logic, Module 227 (Version 4)

Clone of Module 27
14.44
Run Logic, Module 228 (Version 1)

Clone of Module 28
14.45
Reference Logic, Module 230 (Version 1)

Clone of Module 30
14.46
Test Local Control, Module 231 (Version 2)

Clone of Module 31
14.47
Fault Display, Module 232, 233 and 234 (Version 1)

Clone of Modules 32, 33 and 34.
14.48
Cyclic Test, Module 240 (Version 1)

Clone of Module 40
14.49
Staircase Smoothing, Module 244 (Version 1)

Clone of Module 44
14.50
Position Measurement, Module 247 (Version 1)

Clone of Module 47
14.51
Position Control, Module 248 (Version 1)

Clone of Module 48
14.52
Linear Conversion, Module 255 (Version 1)

Clone of Module 55
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Alspa GD4000
Issue (12-2-98)
Module 292 (V2)
14.53
Speed Control, Module 280 (Version 2)

Clone of Module 80
14.54
Rotor Time Constant Compensation, Module 281 (Version 1)

Clone of Module 81
14.55
Open Loop B, Module 284

Clone of Module 84
14.56
Stop/Start Logic, Module 285

Clone of Module 85
14.57
Program Blocks, Module 286

Clone of Module 86
14.58
Changeover Switch, Module 287

Clone of Module 87
14.59
Module 292 (V2)
Clone of Module 92
Speed Control, Module 292 (Version 2) Flux and Torque Look-up tables, Module 294
14.60
Clone of Module 94
14.61
Slip Calculation, Module 295

Clone of Module 95
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Alspa GD4000
Page 14-243
Module 300 (V1)
14.62
Module 300 (V1)
General Purpose Functions, Module 300 (Version 1)

Module 300 provides 10 linear conversion functions and 2 ramp functions.
Table 14-33 General Purpose Functions, Module 300 (V1)
Variable
Description
Type Minimum Maximum ON IN IN IN IN ON IN IN IN IN ON IN IN IN IN ON IN IN IN IN ON IN IN IN IN ON IN IN IN IN ON IN IN IN -65536 -10000 1 -10000 -2

31
Default
103 = 1 ms
Scaling
L30000 Repetition period L30001 input 1 L30002 mult1 L30003 div1 L30004 offset1 L30005 output1 L30006 input2 L30007 mult2 L30008 div2 L30009 offset2 L30010 output2 L30011 input3 L30012 mult3 L30013 div3 L30014 offset3 L30015 output3 L30016 input4 L30017 mult4 L30018 div4 L30019 offset4 L30020 output4 L30021 input5 L30022 mult5 L30023 div5 L30024 offset5 L30025 output5 L30026 input6 L30027 mult6 L30028 div6 L30029 offset6 L30030 output6 L30031 input7 L30032 mult7 L30033 div7
65536 10000 10000 10000 2

31
0 10000 10000 0 0 0 10000 10000 0 0 0 10000 10000 0 0 0 10000 10000 0 0 0 10000 10000 0 0 0 10000 10000 0 0 0 10000 10000
-65536 -10000 1 -10000 -2

31
65536 10000 10000 10000 2

31
-65536 -10000 1 -10000 -2

31
65536 10000 10000 10000 2

31
-65536 -10000 1 -10000 -231 -65536 -10000 1 -10000 -2

31
65536 10000 10000 10000 231 65536 10000 10000 10000 2

31
-65536 -10000 1 -10000 -2

31
65536 10000 10000 10000 2

31
-65536 -10000 1
65536 10000 10000
Page 14-244
Alspa GD4000
Issue (12-2-98)

Variable Description Type Minimum Maximum IN ON IN IN IN IN ON IN IN IN IN ON IN IN IN IN ON IN ON IN IN IN IN IN OL OL IL IL IL IL IN ON ON IN IN IN IN OL OL IL IL IL IL -10000 -2
31
Module 300 (V1)

Default 0 0 0 10000 10000 0 0 0 10000 10000 0 0 0 10000 10000 0 0 0 0 0 0 0 15000 -15000 0 0 0 0 0 0 0 0 0 0 0 15000 -15000 0 0 0 0 0 0
100 = 1%/s 100 = 1%/s 100 = 1% 100 = 1% 1 = in limit 1 = in limit 1 = enable 1= suicide 1 = hold 1 = init preset 100 = 1%/s 100 = 1%/s 100 = 1% 100 = 1% 1 = in limit 1 = in limit 1 = enable 1 = suicide 1 = hold 1 = init preset
Scaling
L30034 offset7 L30035 outptut7 L30036 input8 L30037 mult8 L30038 div8 L30039 offset8 L30040 output8 L30041 input9 L30042 mult9 L30043 div9 L30044 offset9 L30045 output9 L30046 input10 L30047 mult10 L30048 div10 L30049 offset10 L30050 output10 L30051 ramp1 input L30052 ramp1 output L30053 preset output1 L30054 accel rate1 L30055 decel rate1 L30056 pos. limit1 L30057 neg. limit1 L30058 in pos. lmt1 L30059 in neg. lmt1 L30060 ramp1 enable L30061 suicide1 L30062 hold1 L30063 init preset1 L30071 ramp2 input L30072 ramp2 output L30073 preset output2 L30074 accel rate2 L30075 decel rate2 L30076 pos. limit2 L30077 neg. limit2 L30078 in pos. lmt2 L30079 in neg. lmt2 L30080 ramp2 enable L30081 suicide2 L30082 hold2 L30083 init preset2
10000 2
31
-65536 -10000 1 -10000 -2

31
65536 10000 10000 10000 2

31
-65536 -10000 1 -10000 -2

31
65536 10000 10000 10000 2

31
-65536 -10000 1 -10000 -2 -2 -2

31 31 31
65536 10000 10000 10000 2 2 2

31 31 31
-15000 0 0 0 -15000 0 0 0 0 0 0 -2 -2
31 31
15000 100000 100000 15000 0 1 1 1 1 1 1 2 2

31 31
-15000 0 0 0 -15000 0 0 0 0 0 0
15000 100000 100000 15000 0 1 1 1 1 1 1
Issue (12-2-98)
Alspa GD4000
Page 14-245
Module 300 (V1)
Figure 14-68 Module 300(V1), General Purpose Functions
Page 14-246
Alspa GD4000
Issue (12-2-98)
Module 320 (V1)
14.63
Module 320 (V1)
General Purpose Functions, Module 320 (Version 1)

Clone of Module 300
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Alspa GD4000
Page 14-247
Appendix A. Keypad
Keypad
A1
Introduction
Figure A-1 Keypad
The optional keypad provides control and programming facilities for the SIGMA series of drive controllers. It can either be mounted directly on the front of the drive unit, or it can be mounted remotely giving more convenient access to the SIGMA control and monitoring functions. The keypad is a small moulded unit with a super-twist liquid crystal display and a membrane keypad containing nineteen programming keys, four drive control keys and 5 LED indicators. A 9-way D-type connector at the rear of the keypad connects directly to the RS232 port or connector on the front panel of a SIGMA unit (link 3), or an extension cable can be used to mount the keypad in a remote location, up to 15 m away, on link 2. The general appearance of the unit is shown above. Power for the keypad is derived from the 9-way D-type connector. The keypad is powered up when it is connected to the drive unit. The unit can be connected via the local keypad link (link 3) on the front of the SIGMA Controller, or remotely via the Customer I/O Board (link 2). It is possible to connect more than one keypad to the drive but only one keypad can change variables at any one time. The keypad can also be connected to links 0 and 1, but special RS485 to RS232 adaptors must be used. The keypad handler itself is part of the base system, and is called as part of the message handler loop. To allow user configuration, certain P-tables have been reserved for keypad use (refer to section A7).
Issue (12-2-98)
Page A-1
Appendix A. Keypad
A2 A2.1
Specification
Display The 2-line by 24 column super-twist l.c.d. is, capable of displaying a full alphanumeric character set.
A2.2
Keypad This is a sealed membrane type keypad with 23 keys with four drive control keys and 19 Programming Keys
A2.3
LED Indicators Five l.e.d. indicators provide status information as follows: HEALTHY RUNNING KEYPAD CONTROL WARNING TRIPPED : : : : : green green green yellow red
A2.4
Power Consumption Power Consumption (from the drive SMPS) : negligible.
A2.5
Dimensions Width Height Depth : : : 180 mm (7.1"). 124 mm (4.9"). 15 mm (0.6").
A3
Environmental Conditions
Storage temperature Operating temperature Note: : : -25 oC to +70 oC 0 oC to 50 oC (external case temperature)
The l.c.d. may blacken at temperatures above 50 oC. : : : : : Negligible. 5% to 95% non-condensing IP65 (NEMA 4) when sealed on facia. 2000 metres Screened against RFI.
Heat Output Relative Humidity IP rating Maximum Operating Altitude RFI susceptibility A4
Extension Cable (option)

Length : 3 m (9-10").
Page A-2
Issue (12-2-98)
Appendix A. Keypad
A5
Monitoring and Editing Drive Parameters

The keypad is used to:
Monitor the status of the drive (including fault data). Monitor the drive variables. Edit drive parameters.
A5.1
Monitoring Variables Variables can be displayed on the keypad unit together with a text description (up to 16 characters), units and decimal point scaling. The text description is predefined for certain variables (e.g L tables and certain E tables) and can be defined in the links program for other variables.
A5.2
Changing Variables The keypad can be used to change certain parameter variables. These are variables that have been set to a fixed constant as opposed to being linked to another variable. The parameter can have one of a number of different attributes (or editor equivalents) and this also governs the access level. These attributes and access levels are all described in section 7.4.1.
A6
Control Keys
There are four control keys RUN , STOP , RAISE and LOWER . These are used to stop and start the drive and control the drive frequency from the keypad. These keys act directly on the A table digital inputs table (refer to section A6.2). The appropriate bit is set high, when the key is pressed, and remains high until the key is released. To activate the Control keys the the keypad digital inputs must be linked to Module 31 (see Section 14.8.1. Two other keys, which are keypad mode dependent, also affect the A table. These are the and keys. If in fault display mode (refer to section A9.3.1), then the status of these keys are reflected in the A table.
A6.1
Alphanumeric Keys The alphanumeric keypad contains 19 keys as shown below: The alphanumeric keys 1A, 2B, 3C, 4D, 5E, 6F, 7H, 8L, 9P, 0S and .. These keys are used to input a table reference, and alter its value, if applicable. (Refer to section A9.3.4) - Switches to the previous display level. - Moves up the parameter list or increments values. - Moves down the parameter list or decrements values. - Displays further information. - Changes sign of a numerical value
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Page A-3
Appendix A. Keypad
- When entering data, Terminates entry of required data, and enables modification of value of the variable being monitored. When monitoring, allows the currently displayed variable to be edited. - Performs a backspace when in editing mode. - Switches between monitoring and data entry (or editing) modes; the displayed variable is retained. A6.2 Digital Inputs/Outputs The following table shows how keypad inputs affect A-table bits. Note: The A34.0 to A34.6 are set as the logical OR of the status of all keypads connected to the SIGMA. Bits A34.8 to A34.29 show the status of keypads on each individual serial link. Cause RUN pressed STOP pressed LOWER pressed RAISE pressed pressed and in fault display mode pressed and in fault display mode Keypad connection healthy (refer to section A8) Link 0 - RUN, STOP, LOWER, RAISE Link 1 - RUN, STOP, LOWER, RAISE Link 2 - RUN, STOP, LOWER, RAISE Link 3 - RUN, STOP, LOWER, RAISE
Table Reference A34.0 A34.1 A34.2 A34.3 A34.4 A34.5 A34.6 A34.8 - A34.11 A34.14 - A34.17 A34.20 - A34.23 A34.26 - A34.29
Also E-tables E9.0 to E9.7 are used to record the status of the serial links as follows: E9.0 - E9.3 E9.4 - E9.7 Link healthy for Link 0, 1, 2 and 3 Control Passed for Link 0, 1, 2 and 3
Page A-4
Issue (12-2-98)
Appendix A. Keypad
A6.3 Digital Outputs (LED Indicators) There are 5 l.e.ds located on the left-hand side of the keypad. These will be under application program control, except in the instance of a watchdog trip, when all LEDs will be turned off. The following table shows the digital outputs (B-table bits) to which each LED is connected. Setting the bit to a HIGH value, will turn the LED on. LED indicator Healthy Running Keypad Control Colour Green Green Green B table ref B32.9 B32.10 B32.11 Example Use Control Available (L2623) Control On (L2718) Set when Application Program is using Control Keys (L3101) Battery Warning Light (inverse of A35.0) Drive Tripped *
Warning Tripped Notes:
Yellow Red
B32.12 B32.13
The Tripped l.e.d: 1) Will flash when the application program is not running. 2) Will light if the keypad serial link fails and the Tripped is off. 3) Will be off if the user program is running. 4) May be configured in the user program to indicate a required condition.
A7
Keypad Configuration
Data tables P10 to P14 control the configuration of the keypad as follows: Table P10 P11 P12 P12.0 P12.4 P12.5 P12.6 P12.7 P13 P14 Format Default table letter (e.g. L) Table Offset (e.g. 2002) Keypad Configuration Mask Enable Drive Trip Menu Enable Link 0 disconnection Enable Link 1 disconnection Enable Link 2 disconnection Enable Link 3 disconnection Unused Unused
Tables P10 and P11 set up the default table to be monitored, every time the monitor/edit option is accessed from the main menu. If the table letter is set to a @ (the default), then no table is assumed, and the monitor/edit option will require a table to be entered on entry into the option. Table P12.0 is used to enable the user to select whether permission is required to remove the keypad. If set, then the Keypad Removal menu option becomes available.
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Page A-5
Appendix A. Keypad
A8
Serial Link Failure (or keypad disconnection)

When the keypad s connected to the SIGMA controller, on any serial link, A34.6 is set HIGH (refer to section A6.2). If the keypad is physically removed from the SIGMA, a timeout period of 10 seconds is initiated, at the end of which, the keypad is assumed to be removed permanently. This means that on re-connection, the user is returned to the main menu. If P12.0 is set (Enable Drive Trip), and the user has not been given permission to remove the keypad, then (for the appropriate link) the healthy bit will go LOW, and the control passed bit will stay LOW, indicating to the application program, that it should trip the drive. If the keypad is connected to the SIGMA, and the serial link fails, then the Tripped LED will light and an appropriate message will be displayed on the LCD screen.
A9 A9.1
Display Format
Editing Mode Only two options from a given list can be displayed at any one time. The following shows a typical example:-
A character in the top right-hand corner, indicates that there are options above the one displayed on the top line. Pressing the key will then move the menu window up to the next option. Similarly, a character in the bottom right-hand corner, indicates more menu options below the ones displayed, and pressing the key will move the window down one option. Pressing the given number, selects the listed facility, regardless of whether the option is visible or not. A9.2 Monitoring Mode The figure below is a typical view of the LCD display, when monitoring a parameter:
The first line contains the table letter and number (including a specific bit position, if required), followed by the value and its associated units. The letter in the top right-hand corner indicates the attribute of the link. The second line displays the comment attached to the table, either from the database, or a DEF TABLE statement within the links program. A ? at the right-hand side, indicates that further information exists about the monitored table (refer to section A9.3.4). A9.3 Functions of the Keypad On power up, or when the key pad is connected to an already powered up drive, the keypad will display the first two lines of its main menu of facilities as follows: 1. 2. 3. Fault Display Password Facilities Monitor/Edit Parameters
Page A-6
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Appendix A. Keypad
4. 5. Pressing A9.3.1 or SIGMA Language Selection Display Issue Information
scrolls up and down the menu as required.
Fault Display On order to display fault messages Module 32 (Fault Display) must be configured and included in the user program, see section 14.9.1. When Fault Display is selected, the keypad will interrogate the drive, and first check to see if there are any system messages. It will display these messages only. If a system message is present, then the application program will not run and no fault messages will be displayed. If no system messages are present, and the user program is running, then the fault display module is interrogated (if part of the application program), and any trip messages are displayed, along with a trip number. The message 1st FAULT is used to denote the first fault message. This assumes that there will only ever be one master fault display module called as part of the application program. If no trip messages are found, or the fault display module is not called as part of the user program, then other application modules messages can be displayed. Any application module can potentially send a message to the keypad/monitor. These will also include any alarm messages from the fault display module. If no messages of any form are found by the keypad, then a message NO MESSAGES AVAILABLE is displayed. Pressing <ESC> returns control to the main facilities menu.
A9.3.2
Fault Message Scrolling The and keys can be used to scroll through the messages. To activate this facility link digital inputs A34.4 and A34.5 to L3276 and L3277 respectively in the fault Display module.
A9.3.3
Password Facilities This section presents the user with the following two choices: 1. 2. Set Password Level Remove Password
On entry into option 1, the user is asked for the password level, for the password which is to be entered. Only the numbers 0 to 3, and <ENTER> are valid. If <ENTER> is pressed, the password level is set to 0 or 1, depending on the value of E0.15 (refer to section 7.4.1). Entering a valid password level, displays the message ENTER PASSWORD. The user must then type in a password which has been previously set using CSP or OVERVIEW. The keypad handler will then decide which access level (refer to section 7.4.1) to grant to the user. If an un-recognised password is entered, a message INCORRECT PASSWORD is displayed, and the user is prompted to try again. A password is always made up of 4 digits, terminated by <ENTER>. The digits are not printed to the display, but a * will appear after each keystroke. Pressing <ESC> will return control to the main menu. Issue (12-2-98) Alspa GD4000 Technical Manual Page A-7
Appendix A. Keypad
e.g.
On choosing option 2, the password level is removed, and the access level is set to either 0 or 1, depending on the state of E0.15 (see section 7.4.1). This effectively removes all access rights, except to the safest of links. A password timeout facility is incorporated, see section 7.4.1. A9.3.4 Monitor/Edit Parameter On entry into this option, one of two things will occur. If the default monitor variable tables have been set up correctly (see section A7), then the display will monitor this value immediately. Otherwise, the keypad displays the message ENTER VARIABLE. It then waits for a table address to be entered. i.e.
The first key stroke of the alphanumeric keys (1A, 2B, 3C, 4D, 5E, 6F, 7H, 8L, 9P and 0S) is interpreted as a letter and subsequent ones as numbers. After the first key press, the ENTER VARIABLE message is removed, and the keystrokes are copied directly to the first line of the display. The address entry is terminated by <ENTER>. After the first keystroke, the key will scroll the letter backwards through the alphabet, towards A, and the will scroll the entered letter forwards, towards Z. In this way all the tables may be accessed. When the address entry is complete, the reference is validated. If the entered address is that of a valid table location, the contents of that address are displayed as a decimal number with units and data comments. Otherwise, the message NO SUCH TABLE is displayed, before re-prompting the user for a new table.
Whilst monitoring the data table the following key presses will have the given effects: Pressing (Previous) or (Next) will scroll the display backwards and forwards through the data table. Pressing <ESC> whilst monitoring returns control to the main facilities menu. A ? symbol in the bottom right corner of the display indicates that further information is available about the currently monitored variable. Pressing ?, will bring up the information. The table comment is over-written with each new piece information. The ? symbol remains displayed whilst there is further information to display. Only the maximum and minimum values of the table (if defined as non-default values) are displayed. Pressing <ESC>, re-displays the parameter comment. Pressing <ENTER> or <MODE> allows the value of the variable being monitored to be modified. This function is only available when monitoring a variable in decimal format. If the link is not to a constant, the message LINK NOT TO CONSTANT is displayed on the second line. The symbol comments are re-displayed after the error message is removed. Note: This does not work if the user is in the display information mode (i.e. after pressing ?) the user must first <ESC> out of that mode. Alspa GD4000 Technical Manual Issue (12-2-98)
Page A-8
Appendix A. Keypad
If the access level is insufficient to edit the variable, the message INSUFFICIENT ACCESS LEVEL is displayed. Otherwise, this function causes the data comments field on the second line, to be replaced by the message NEW = so that new data may be entered. Pressing <ENTER> updates the value of the link, and waits for a new value to be entered. Pressing <ESC> or <Mode> during entry of the new value leaves the original data unchanged, and returns control to the monitoring of the variable. Pressing the decimal point key <.> on the keypad gives access to the keypad function keys. A symbol (made up of an F and an n) will appear in the bottom right corner of the display, to show that the next key will be interpreted as a function key. If an invalid key is pressed, the symbol will disappear. The valid keys are as follows: Key D H B S Function Monitor in Decimal (includes scaling and units) Monitor in Hexadecimal (begins with a @ and includes units) Monitor in Binary (displayed as a series of .s and ]s) Scope Output (GD4000 only).
The B, H and D keys alter the base of the displayed data. For non-decimal displays the decimal point is ignored and the data displayed as if it were an integer. With a data table location displayed, entering another data table location will display the new data table location (do not press <ESC> first). A9.3.5 SIGMA Language Selection A SIGMA database can store comments in fifteen different languages. However, only the English language is available at this time. Comments in up to two of these languages may be downloaded to the drive. The available languages are set up within the application program. To alternate between the two languages, this menu presents the user with those languages available, and an arrow pointing to the current selection:-
Pressing the appropriate number selects the associated language. A9.3.6 Display Issue Information This option will present a sub-menu, giving the user the ability to view the current firmware database reference, and the information about each attached board. This data is stored in the serial EEPROM, located on each board. (Not yet implemented). The options are as follows: 1. 2. 3. 4. 5. Firmware Ref. Core Board Customer I/O Board Enhancement Cards Power Interface Board
The firmware reference gives an indication of the software running within the drive controller. An example of a firmware reference display would be:
Issue (12-2-98)
Page A-9
Appendix A. Keypad
On choosing the Enhancement or Power Interface Board, the user is asked which card number is to be examined. There are four enhancement cards and three Power Interface Boards available. If the chosen card is not present, a message CARD NOT PRESENT is displayed. The issue information displayed takes the following form: [OIS No & Product Ref] [Board Ref]/[Comb No] [EEPROM Issue] [ENU Status] [Author] [Modification Date] An example of a board/card information display would be:
A9.3.7
Disconnecting the Keypad The keypad may be disconnected while the drive is running if the relevant bit of P12 is set (refer to section A7). To disconnect the keypad while the drive is running press <ESC> twice to display the Keypad disconnection menu. This menu presents the user with the following two choices: 1. 2. Keypad Disconnection Return To Main Menu
Choosing option 1, will request keypad removal. If the relevant P12 bit is set (refer to section A7),enabling disconnection, then the keypad will display an appropriate message, and set the appropriate bit of E9 (refer to section A6.2). Pressing <ESC> will return the user back to the main menu, if removal is not required. If removal is prohibited, then an error message will be displayed, and control will pass back to the main menu. Choosing option 2, returns the user to the main menu. A9.3.8 Oscilloscope Outputs (GD4000 only) Pressing the <.> then <S> keys whilst monitoring a variable, connects that variable to a scope output. The user is asked to type in the number of the output (0-3) on the Analog Termination Unit, given that the outputs are available for scope monitoring. Pressing <ENTER> accepts the choice, <ESC> aborts the operation. If the output is already in use as an application output, an error is indicated by displaying the message Scope Not Available.
Page A-10
Issue (12-2-98)
Appendix A. Keypad
On choosing a valid scope output, the user will be requested to enter the offset and scaling values. By pressing <ENTER>, without entering any other digits, the current value will be used. Refer also to section 9.4 and 12.3.3 of the GD4000 Technical Manual for further details of the scope outputs and their configuration. A10
Keypad Error Messages

The following error messages may be displayed on the keypad. They will remain on the display either for 5 seconds or until <ESC> is pressed.
Displayed Error Message No Messages Available Incorrect Password Out Of Range Reason / Comment There are no system, trip or alarm messages present. An un-recognised password was entered. The newly entered value is outside the range set by the maximum and minimum attributes for the given table. The monitored link is not set to a constant value in the links program, and therefore cannot be modified. The drive permissives are incorrect, and therefore the value cannot be modified. Another serial link has locked out the keypad, and modification is temporarily disabled. The user has tried to modify the value of a parameter of which he doesnt have the authority to do. The chosen interface card is not installed within the SIGMA controller. The data table number is not within the size of the data table. The chosen scope output is in use (refer section A9.3.8).
Link Not To Constant Write Access Denied Unable To Modify Table Insufficient Access Level Card Not Present No Such Table Scope Not Available
A11
Installation
The keypad may either be fitted directly to the front of the drive unit, or mounted remotely using an extension cable (see ordering codes).
A11.1
Fitting the Enhanced Keypad to the Drive Unit

Energise the drive. Remove the yellow blanking plug covering the 9-way D-type socket on the front
panel of the drive unit.

Position the keypad in the rectangular recess on the front panel of the drive unit
taking care to align the 9-way D-type connector and push the keypad home.
Secure the keypad using the two retaining screws.
A11.2
Fitting the Keypad in a Remote Location The enhanced keypad may be fitted to a remote position e.g. in a cubicle door if required. The keypad must be sited on a flat panel, and requires a cut-out to the dimensions shown in Figure A-2. Rear access is required for cable entry.
Issue (12-2-98)
Page A-11
Appendix A. Keypad
A11.3 Mounting Requirements
Figure A-3 Keypad Dimensions
The dimensions of the unit are shown in Figure A-3. A clearance of approximately 50 mm (2") is required at the rear of the unit for the cable and connector. The site chosen should conform to the environmental conditions detailed in the specification section. If the unit is to mounted on the outside of an IP65 (NEMA 4) enclosure, a neoprene seal (see Ordering Codes) must be fitted between the unit and the enclosure. To effect a proper seal the seating area around the cut-out must be within 0.25 mm (0.010 inch) of a flat plane. A11.4 Installation Procedure
Figure A-2 Cut-out Dimensions
Page A-12
Issue (12-2-98)
Appendix A. Keypad
Refer to Figure A-2 and proceed as follows:
Mark and cut out the aperture as shown. Drill two holes suitable for 4 mm fixing screws as shown. Fit the neoprene seal to the groove at the rear of the keypad. Position the keypad over the aperture and secure with 2 off 4 mm fixing screws, nuts
and washers.
Connect the plug end of the extension cable to the 9-way D-type socket on the front
panel of the drive unit. Route the cable carefully with regard to the segregation requirements. Connect the socket to the connector at the rear of the keypad. A11.5 Maintenance There are no user maintainable components within the enhanced keypad. The unit may be cleaned periodically using soap solution and a damp cloth.
Issue (12-2-98)
Page A-13
Appendix A. Keypad
Page A-14
Issue (12-2-98)
Appendix B Battery Support Unit
Battery Support Unit (GDS1001-4001)

WARNING BATTERIES ARE SOURCES OF HIGH CURRENT. ENSURE ADEQUATE PROTECTION (FUSES or CIRCUIT BREAKER). DISCONNECT DURING MAINTENANCE. B1
General
This equipment consists of an optional, externally mounted, battery back-up unit which can be connected to the SMPS. Battery back-up allows the SMPS to temporarily give its full rated output to support the drives internal control circuits, serial links, and I/O. The standard SMPS unit provides the supply (about 65 Vd.c.) for the charger/discharger which controls the rate at which the batteries are charged. CAUTION: Battery support unit may be damaged if the battery voltage exceeds 70 V. When there is a supply failure the battery back-up unit acts as a d.c. to d.c. convertor in producing a 400 V output which is connected to the d.c. link of the SMPS.
B2
Battery Protection
To prevent fire it essential that the fuses shown in Figure B-3 are fitted as close to the battery as possible to provide short circuit protection for the battery cabling.
B3
Battery Sizing
The battery pack should be sized according to:
the anticipated duration of support required (typically in the range 1 to 30 minutes), the anticipated duration between supply interruptions (to allow for recharge), the power required (maximum 583 W)
The anticipated support time required and duration between supply interruptions must be assessed by the user before calculating battery sizes. The selected battery pack must be capable of sustaining the following output for the required support duration: Power output Nominal voltage Minimum end voltage Maximum current : : : : 583 W 48 V 40 V 14.5 A
The minimum end voltage is the minimum voltage at which the SMPS will continue to draw from the battery supply (further discharge being considered harmful to the Issue (12-2-98) Alspa GD4000 Page B-1

batteries) and at this voltage an under-voltage cut-out in the SMPS inhibits the discharger at 40 V to prevent deep discharge of the batteries. A range of suitable batteries are manufactured by Sonnenschein, and can be obtained from: F.W.O. Bauch Ltd, 14, Gunnels Wood Industrial Estate, Gunnels Wood Road, Stevenage, Hertfordshire. SG1 2BH Tel: 01438 359090 Fax: 01483 727684 The ideal nominal float charge level at 20oC is 55.2 V 1.3%. A potentiometer is provided on the SMPS to allow adjustment of the float charge level over the range 52.8 V to 58.8 V for applications in a reasonably constant ambient temperature. To allow for applications where a wide ambient range is expected, a temperature compensation circuit is available which uses an external thermistor, mounted adjacent to the batteries. The operating potentiometer in this arrangement allows the charger unit to be set up to provide the correct float charging conditions for the prevailing ambient temperature condition. Under all specified ambient temperature conditions the charger will maintain float charging levels to within 0.72 V of the curve specified in Figure B-1 when the thermistor is connected. Thermistor connection details are shown in Figure B-3.
Figure B-1 Battery Float Charge/Temperature Graph
B4 B4.1
Installation
Location The Battery Support Unit must be installed inside the drive enclosure. The dimensions and fixing details of the battery support unit are shown in Figure B-2. The battery pack should preferably be located in the base of the drive enclosure. If this is not possible the battery pack should be situated as close to the drive enclosure as possible.
Page B-2
Alspa GD4000
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Figure B-2 Battery support unit dimensions
B4.2
Electrical Connections Figure B-3 shows the electrical connections for the Battery Support Unit.
Figure B-3 Battery support unit electrical connections
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Page B-4
Alspa GD4000
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Appendix C GD4000 Modular Drives
ALSPA GD4000 Modular Drives
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GD4000 Technical Manual
Page C-1
Page C-2
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General Information
Introduction
This appendix gives details of the SIGMA control equipment and shows how this equipment is used with the GD DELTA power equipment to build the following modular GD4000 systems:
AC input drives in the range GD4282 to GD41131. DC Fed 2 Motor drives in the range GD4282 to GD41131. DC Fed 1 Motor drives in the range GD4564 to GD42262.
Suitable software to operate the drives in each of these configurations is supplied with the SIGMA Controller, see GD4000 Technical Manual section 7.11. This appendix should be read in conjunction with the GD DELTA Technical Manual T1641 which gives details of the power equipment and this Manual which contains programming and other information. A typical GD4000 modular drive is shown in Figure C-1. The GD4000 range of modular drives can be supplied either packaged complete by CEGELEC, or as a number of modules to be assembled into a customers own designed enclosure.
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Page C-3
Figure C-1 Typical arrangement of a modular drive (GD4754 shown)

Typical arrangementof a modular drive (GD4754 shown)
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Power Topologies Supported By selecting the value of the firmware database parameter fast task type wanted (L1007) the SIGMA Control Gate Assembly can be configured to support one of a number of different power topologies:
Table C-1 Fast tasks for different power topologies
Bridge A Fast Task Type 0 Fast Task Type 1 Fast Task Type 2 Fast Task Type 3 Fast Task Type 4 Fast Task Type 5 Fast Task Type 6 Fast Task Type 7 Fast Task Type 8 Vector control - single motor Vector control - motor 1 Vector control - single motor Scalar control - motor 1 Scalar control - single motor AC in Scalar control - single motor -
Bridge B AC in Vector control - motor 2 Vector control - single motor Scalar control - motor 2 AC in AC in Scalar control - single motor AC in Vector control - single motor
Specification
The technical specifcations for the SIGMA Controller, SMPS and the Customer I/O Assembly are given in Section 2 of this manual. The technical specification for the Pre-charge panels is given in publication the Alspa GD DELTA Technical Manual (T1641). Environmental Protection The SIGMA Controller, SMPS and Customer I/O Assembly must be installed in a suitable enclosure. The environmental protection standard of the drive depends upon the design of enclosure or panel into which the equipment is installed. It is the responsibility of the user or system integrator to ensure that the equipment is adequately protected.
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Page C-5
Page C-6
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Technical Description
Introduction
This chapter gives a brief description of the function of the control component parts which are used to build a GD4000 modular drive, these are:
The SIGMA Controller assembly. The SMPS Assembly The Customer I/O Assembly
Note:
These modules must always by installed in an appropriate enclosure with restricted access.
Figures C-2, C-3 and C-4 show simplified schematic diagrams for AC fed 1 motor, DC fed 2 motor and DC fed 1 motor configurations respectively and show how these units are utilised. Fully detailed schematic diagrams for each configuration of drive are given in Section C5.1.
Figure C-2 Simplified diagram AC input AC output drive configuration.

Simplified diagram AC inputA C output drive configuration.
Notes: * In some configurations, the sharing reactor function is merged with the input line reactor. # In some configurations, the output sharing reactors are eliminated by the use of multi-core cabling/motor phase.
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Page C-7
Figure C-3 Simplified diagram DC input 1 motor output drive configuration.
Simplified diagram DC input1 motor output drive configuration.
# In some configurations, the output sharing reactors are eliminated by the use of multi-core cabling/motor phase.
Page C-8
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Figure C-4 Simplified diagram DC input 2 motor output drive configuration
Simplified diagram DC input2 motor output drive configuration
# In some configurations, the output sharing reactors are eliminated by the use of multi-core cabling/motor phase.
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Page C-9

SIGMA Control Gate Assembly The SIGMA Control Gate Assembly provides all the control and I/O functions for the drive. The Control Gate Assembly provides independent control for up to two DELTA bridges. A drive can therefore be configured to act as either one input and one output bridge, two independent d.c. fed output bridges or two d.c. fed parallel output bridges by running the appropriate software. See Table C-1 on page C-5. The SIGMA Control Gate Assembly comprises a SIGMA Controller (20X4494 Core Board) together with a Power Interface Board, mounted on a hinged Gate assembly. SIGMA Control Gate Assembly Variants There are two basic variants of SIGMA Control Gate Assembly available to support the various bridge topologies and DELTA module voltage grades. These are: 31V5300 31V7100 A typical arrangement of the 31V5300 Control Gate is shown in Figure C-5.
Figure C-5 GD4000 SIGMA Control Assembly (rear view)
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Figure C-6 Rear view of 31V7100 control gate
The 31V5300 assemblies use a power interface board which can can support either one or two DELTAs, and the 31V7100 based assemblies use a different power interface board which can support up to six DELTAs. The power interface board can be configured to support the required number of DELTA modules by changing the SIGMA firmware parameters. Table C-2 shows the SIGMA gate variants used for 900 V systems. Voltage grade: 900 V:
Table C-2 SIGMA Control Gate and Drive Configurations
Control Assembly 31V5300/90 31V5300/90 31V7100/60 31V7100/30 31V7100/30
Bridge A single DELTA bridge two parallel DELTA bridges three parallel DELTA bridges
Bridge B single DELTA bridge single DELTA bridge three parallel DELTA bridges two parallel DELTA bridges three parallel DELTA bridges
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Page C-11

Table C-3 shows the SIGMA gate variants used for 1200 V systems. Voltage grade: 1200 V:
Table C-3 SIGMA Control Gate and Drive Configurations
Control Assembly 31V5300/110 31V5300/110 31V7100/70 31V7100/40
Bridge A single DELTA bridge two parallel DELTA bridges
Bridge B single DELTA bridge single DELTA bridge three parallel DELTA bridges two parallel DELTA bridges
Customer I/O Assembly (GDS1004-4002)
Figure C-7 Customer I/O Assembly
The Customer I/O Assembly comprises a Customer I/O Board and Analog Termination Panel fitted to a mounting plate. The Customer I/O Board is a printed circuit board, which carries all the user control terminations (see Section 8). The Analog Termination Panel is mounted on the Customer I/O Board on pillars. Provision is also made for mounting the optional HDLC Board on the Customer I/O Board alongside the Analog Termination Panel. There are no electrical connections between the Customer I/O board and either the Analog Termination Panel. The 48 V d.c. supply to the HDLC board is derived from PL61 on the Customer I/O Board. Figure C-7 shows the general arrangement of the Customer I/O Assembly.
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SMPS Assembly (GDS1010-4003)
Figure C-8 General Arrangement of SMPS Assembly
GD4000 variants incorporating the 31V5300 Control Gate Assembly use a single Switched Mode Power Supply (SMPS) which powers the SIGMA Control Module and the DELTA Transistor Module gate drive circuits on the Power Interface Board. GD4000 variants using the 31V7100 Control Gate Assembly use two SMPSs. SMPS1 powers the 20X4494 Core Board and SMPS2 powers the gate drive circuits on the Power Interface Board. The input supply to the SMPS(s) is taken from two phases of the 3-phase AC supply and must configured by the user to suit the supply voltage. The input supply to the SMPS must be fused (see Section 10.4.2). Note: If the SMPS is installed in a system with a floating input supply, then earth fault detection equipment must be fitted exernal to the GD4000 product to give warning of any earth fault..
The SMPS is fan cooled. Further details of the SMPS are included in the Section 2.3. The multi-core cable connecting the SMPS to the SIGMA Control Gate Assembly, provided as part of the standard kits, must not be extended. Note: For 690 V applications, a step down transformer is required to drive the GDS1010-4003 SMPS. Refer to the GD DELTA Technical Manual (T1641) for details.
Delta Transistor Modules

The DELTA Transistor Module can be used to convert either AC input to DC output or DC input to AC output. Up to three modules can be connected in parallel to form a single input bridge or output bridge. The function of each bridge is determined by the software control task. See Table C-1 on page C-5. Up to two bridge groups can be connected in parallel allowing DELTA configurations up to six in parallel to be created.
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Page C-13

DELTA modules available Three types of DELTA module are available: 282A nominal, 900V dc withstand, order code: GDD282 - 4501 377A nominal, 900V dc withstand, order code: GDD377 - 4501 300A nominal, 1200V dc withstand, order code: GDD300 - 4601 Note: DELTA types cannot be mixed within a unit.
Full technical details and installation instructions for the GD DELTA power equipment are given in the GD DELTA Technical Manual (T1641). Schemes using DELTAs in GD4000 configurations are shown in Section C5.1.
Line Contactors
Line contactors are supplied for AC fed GD4000 drives. Two ratings are available, the type supplied depends on the drive size, and installation instructions are provided with the contactors. Note: Line suppression units must be fitted in parallel with the coils of each contactor.
Precharge Control Panel (31V1900/20 to 31V1900/50)

The Precharge Control Panel is used on AC fed systems only. It limits the inrush current to the drive when it is energised, to prevent damage to external circuits. Details of the Precharge Control Panel are given in the GD DELTA Technical Manual (T1641) Appendix B.
Page C-14
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Installation
Introduction
This chapter describes the method of installing the GD SIGMA Control Assembly, SMPS and Customer I/O Board for a GD4000 modular drive, and includes general cabling instructions. Full wiring schematic diagrams for each drive model are included in Section C5.3. (1) General Information which is common to all drives or equipment. (2) Installation details for the Control Unit. (3) Installation details for the SMPS. (4) Installation details for the Customer I/O Board. The method of installing the DELTA transistor modules and the Pre-charge panel, including connection to input power supplies and motor is described in the GD DELTA Technical Manual (T1641).
General Information
Receipt of Equipment on Site When the equipment arrives on site, unpack it carefully and inspect it for any sign of damage. Check the complete consignment against the packing slip for any loss in transit. If any damage or loss has occurred, contact CEGELEC immediately giving the following details:
A list of damaged or missing items. A description of damage. The order number or packing slip details.
Identification of Components Details of the type of drive unit, serial number, modification status and basic electrical information are given on the identification label fixed to the the units. Storage If equipment delivered to site is not to be installed immediately:
Re-pack it in its original packing material. If this is not possible it should be enclosed
in polythene sheet to protect it from the ingress of dust.

Store it in a clean dry atmosphere, preferably at room temperature (The storage
temperature limits are -25o C to +70o C).
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Page C-15

Environment To ensure trouble-free operation with minimum maintenance, the installation site should fulfil the following requirements:
The atmosphere should be clean and dust free, in particular it must be free from
corrosive vapours and conductive dusts.

The ambient temperature should be in the range 0 C to 40 C, with no rapid
o o
changes of temperature.
The Relative Humidity should be in the range 5% to 95% (non condensing).
Where necessary measures should be taken to prevent the ingress of metallic swarf generated by process or maintenance activities. Altitude. The normal operating altitude for the unit is up to 1000 m (3,300 ft) above sea level. Above this, the drive should be derated by 7.3% per 1000 m (3,300 ft) up to a maximum of 2000 m (6,600 ft). Heat Loss from Unit The maximum heat loss of the units are as follows: GD4000 Control Module & ) DELTA control electronics - 350 W max. ) depending on the configuration. SMPS (per unit) - 150 W max. )
Acoustic Noise at the Motor Acoustic noise is generated at the motor as a consequence of the PWM switching of the output power. The noise output and frequency depend on the PWM switching frequency and the construction of the motor. Radio Frequency Emissions If it is necessary to use shielded cables to satisfy RF emission requirements then output filters must be connected into the output cables. See GDLOM Technical Manual T1622 included with this manual. Susceptibility to Radio Frequency Interference All GD4000 modules are designed for operation within a cubicle, which will shield the modules from radio frequency interference. Care should be taken that no radio frequency transmissions (e.g. from portable telephones) take place in the vicinity of the unit, when panel doors are open and the drive is energised. Cooling and Ventilation The GD4000 units are air cooled. It is essential that adequate clearance to allow a free flow of cooling air through external panel airways is maintained at all times.
GD4000 SIGMA Control Gate Assembly - Mechanical Installation

The method installing two variants of the SIGMA Control Gate Assembly is identical though the fixing and overall dimensions differ. The dimensions for the 31V5300 SIGMA Control Gate Assembly are shown in Figure C-9 and the dimensions of the 31V7100 SIGMA Control Gate Assembly are given in Section C5.1 Drawing Number KC1/41Y7129GA. Page C-16 GD4000 Technical Manual Issue (12-2-98)
Figure C-9 31V5300 SIGMA Control Gate Fixing Dimensions

31V5300 SIGMA Control Gate Fixing Dimensions
Location The rail asembly of the SIGMA Control Gate is intended to be fixed behind the front flanges of a CEGELEC Q80 cubicle and can be supplied in four sizes to suit differing cubicle widths, see Figure C-9 and Drawing No. KC1/41Y7129GA or KC1/41Y7263 in Section C5.3. The rail assembly fixing points are fitted with M5 captive nuts. Clearances The location chosen should provide adequate clearance for cabling to the rear of the Control Gate Assembly, and clearance for fan and cooling vents at the top and on on both sides of the control module.
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Page C-17

Installation Procedure
Figure C-10 Mounting the SIGMA Control Gate Assembly
The SIGMA Control Gate Assembly is supplied with the Control Gate Assembly detached from the rail assembly to facilitate installation. Refer to Figure C-9 and C-10. and proceed as follows:
Mark out and drill four 5.5 mm holes in the flanges of the cubicle (these holes are
already drilled in the CEGELEC Q80 cubicle).

Position the rail assembly behind the front flanges of the cubicle, align the fixing
holes and secure it with M5 fixings inserted from the front. To ensure earth continuity between the rail assembly and the cubicle Taptite fixings or external tooth washers should be used to break through the paint surface.
Lift the control module into position and carefully the locate the hinge pins into the
lower hinge fittings on the rail assembly.

Secure the Control Gate Assembly with the two screw fasteners. To ensure earth
continuity between the SIGMA Gate assembly and the rail assembly, Taptite fixings or external tooth washers should be used to break through the paint surface.
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Switched Mode Power Supply (SMPS)
Figure C-11 SMPS Fixing Dimensions
The SMPS unit is supplied fitted to a mounting plate which has four keyhole slots, suitable for either vertical or horizontal mounting (with the fan at the bottom). The fixing dimensions for the SMPS unit are shown in Figure C-11. Cooling and Ventilation The SMPS unit is forced air cooled. It is essential to provide adequate clearance to allow a free flow of cooling air through the louvres and at the fan outlet. Clearance for Cabling Ensure that adequate clearance for cabling to front of the SMPS unit is provided (see Figure C-8). Note: The multi-core cable connecting the SMPS to the SIGMA Control Gate Assembly provided as part of the standard kits, must not be extended.
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Page C-19

Installation Procedure Refer to Figure C-11 and proceed as follows:
Mark out and drill four holes for 4 off M6 anchor nuts to the dimensions shown and
fit 4 off anchor nuts.

Assemble four M6 retaining bolts hexagon head (min. grade 8.8), into the retaining
holes and leave 6 mm protruding.

Position the SMPS over the four bolts and tighten them evenly.
Customer I/O Assembly

Location The Customer I/O Board is supplied fitted to a mounting plate (see Figure C-12) which has four keyhole slots suitable for use with M5 fixings. The Customer I/O Board may be mounted vertically on a suitable flat surface in a free location or it may be mounted on the front face of the SMPS. Clearance space is required around and to the front of the Customer I/O Board for the user control cabling.
Figure C-12 Customer I/O Board Fixing Dimensions
Mounting the Customer I/O Board in a Free Location

Mark out and drill 4 holes suitable for M5 anchor nuts and fit 4 off anchor nuts. Fit the four fixing bolts, leaving approximately 6 mm protruding. Position the Customer I/O Board assembly on the fixing bolts and tighten them
evenly.
Page C-20
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Mounting the Customer I/O Assembly on the SMPS Unit Provision has been made for mounting the Customer I/O Assembly on the front face of the SMPS as follows:
Remove the Customer I/O Board 20X4495 from the mounting plate by slackening
the two fixing screws and sliding the board towards the top of the plate.
Refit the board, aligning on the fixing tabs and re-tighten the two fixing screws. Align the six fixing holes in the backplate with the screw inserts in the front face of
the SMPS and secure with six M4 screws. Caution The screws must not penetrate the SMPS cover more than 6 mm or damage to SMPS will occur.
Electrical connections
WARNING HIGH VOLTAGES MAY BE PRESENT ON THESE TERMINALS FROM EXTERNAL WIRING. ALWAYS REPLACE ALL SHROUDS. The electrical connections are divided into three separate categories: AC Input Power Cables and Motor Cables Connect the motor and, on AC powered drives, the AC input using suitably rated cables and in accordance with relevant national standards in the country of use. Refer to the appropriate circuit diagrams in Section C5.1 for details of the power connections required for standard drive configurations. DC Link The DC link and DC connections between modules are not provided in the standard kit. The requirements for DC link and inter connection busbars are detailed in the GD DELTA Technical Manual (T1641). For DC Fed drives The DC input should be connected in accordance with relevant national standards in the country of use. It is recommended that the d.c. supply is fed through suitably rated semi-conductor grade fuses. Refer to the appropriate circuit diagrams in Section C5.1 for details of the DC power connections required on standard drive configurations. Control Connections These are low voltage connections between the Control Module, and the transistor and rectifier bridges and the Control Module and SMPS. The control connections for each configuration of drive are shown in Section C5.1. Segregation The control connections are, in general, low voltage and low current signals. This makes them inherently susceptible to interference from electromagnetic noise Issue (12-2-98) GD4000 Technical Manual Page C-21

generated by power cabling. Therefore, in all applications, the control wiring should not be run directly alongside power wiring. Ideally separate trunking should be used to run control wires, if this not possible, a separation of at least 300 mm (12") should be maintained between the control wires and any power cables. To minimise radio frequency emissions and interference, input supply cables should be routed separately from the output cabling to the motor. General segregation rules are included in drawing reference 10E5402 and 10E5403. Customer I/O Board Wiring WARNING HIGH VOLTAGES MAY BE PRESENT ON THESE TERMINALS FROM EXTERNAL WIRING. ALWAYS REPLACE ALL SHROUDS. The Customer I/O Board wiring will depend on the individual application. Full details of the I/O connections are given in the Section 8.7.2 of this manual. Connecting Thermistor Feedback(s) from DELTA rectifier units(s) It is possible to connect the thermistor(s) of a DELTA rectifier unit(s) to the SIGMA hinged gate assembly in order to produce an additional temperature feedback(s). This is achieved by fitting an external thermistor / thermostat cable assembly to the hinged gate assembly and connecting the DELTA thermistor to this cable assembly. 31V5300 hinged gate assemblies (fitted with 20X4489 PIB). For systems which use a 31V5300 hinged gate assembly, the external thermistor / thermostat cable assembly to be fitted is 41Y7408/10. This provides connections for a single thermistor and a single N/C thermostat (or shorting link) and will produce an additional analogue temperature feedback (temperature 5) and hardware overtemperature trip. For a description of how to configure the 20X4489 power interface board to use this additional feedback and where to monitor the analog feedback produced, see the software modules section 14.22.1, module 90. 31V7100 hinged gate assemblies (fitted with 20X4486 PIB). For systems which use a 31V7100/50, 31V7100/60 or 31V7100/70 hinged gate assembly, the external thermistor / thermostat cable assembly to be fitted is 41Y7410/10. This provides connections for a single thermistor and a single N/C thermostat (or shorting link) and will produce an additional analogue temperature feedback (temperature 10) and a hardware overtemperature trip. For systems which use a 31V7100/20, 31V7100/30 or 31V7100/40 hinged gate assembly, the external thermistor / thermostat cable assembly to be fitted is 41Y7410/20. This provides connections for two thermistors and two N/C thermostats (or shorting links) and will produce two additional analogue temperature feedbacks (temperatures 9 and 10) and hardware overtemperature trips. For a description of how to configure the 20X4486 power interface board to use the additional feedback(s) and where to monitor the analogue feedback(s) produced, see the software modules section 14.22.1, module 90. Attaching the 41Y7408/10 Cable Assembly to the 31V5300 Hinged Gate Assembly. For 31V5300 hinged gate assemblies using the 41Y7408/10 cable assembly, mount the 10 way plug and socket on the upper flange of the hinged gate metalwork using the drillings and screws provided. Connect the two-way plugs into PL248 and PL250 which are located on the outer edge of the 20X4489 PIB. Wires 2481 and 2482 should connect into PL248 and wires 2501 and 2502 should connect into PL250. Page C-22 GD4000 Technical Manual Issue (12-2-98)

Attaching the 41Y7410/10 Cable Assembly to the 31V7100 Hinged Gate Assembly. For 31V7100/50, /60 or /70 hinged gate assemblies using the 41Y7410/10 cable assembly, mount the 10 way plug and socket on the lower flange of the hinged gate metalwork (alongside TB1) using the drillings and screws provided. Connect the two-way plugs into PL248 and PL250 which are located on the 20X4487 DDR board. Wires 2481B and 2482B should connect into PL248 and wires 2501B and 2502B should connect into PL250. Plug the loose 96 way connector into SK251 on the 20X4486 PIB. Attaching the 41Y7410/20 Cable Assembly to the 31V7100 Hinged Gate Assembly. For 31V7100/20, /30 or /40 hinged gate assemblies using the 41Y7410/20 cable assembly, mount the 10 way plug and socket on the lower flange of the hinged gate metalwork (alongside TB1) using the drillings and screws provided. Connect the two-way plugs into PL248 and PL250 which are located on each 20X4487 DDR board. Wires 2481A and 2482A should connect into PL248 and wires 2501A and 2502A should connect into PL250 on the 20X4487 DDR board located in the bridge A position (the upper position). Wires 2481B and 2482B should connect into PL248 and wires 2501B and 2502B should connect into PL250 on the 20X4487 DDR board located in the bridge B position (the lower position). Connecting the thermistor(s) and thermostat(s) to the 10 way terminal block. For the 41Y7408/10 and 41Y7410/10 cable assemblies, connect the thermistor to screw terminals 1 and 2 and the N/C thermostat (or shorting link) to screw terminals 3 and 4 on the 10 way terminal block. For the 41Y7410/20 cable assembly, connect the first thermistor to screw terminals 1 and 2 and the first N/C thermostat (or shorting link) to screw terminals 3 and 4 on the 10 way terminal block, and connect the second thermistor to screw terminals 7 and 8 and the second N/C thermostat (or shorting link) to screw terminals 9 and 10 on the 10 way terminal block.
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Commissioning
Introduction
Because of the nature of the GD4000 modular drives it is not possible to give detailed commissioning instructions for modular drives in this manual. It is the responsibility of the drive builder to provide full pre-commissioning checks for GD4000 modular drives, to a point at which it is safe to connect the drive to the supply and motor. To ensure safety of personnel and equipment, these commissioning instructions must include the following:
Warnings and Cautions as necessary. Mechanical checks Electrical checks
On completion of the drive builders pre-commissioning checks, the commissioning instructions in Chapter 9 of this manual must be followed.
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Page C-25
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System Design
Intoduction
This section details the electrical interconnections which need to be made to complete each DELTA based drive in the range GD4564 to GD42262 and high voltage GD4300 to GD41800. The power cabling of the DELTA units and the control connections are detailed separately for each size of drive. For details of connections to the Customer I/O Board see Section 8. System examples Example 1: If the system is a 480 V vector controlled DC fed single motor 1508 A (4x 377 A) unit, the drive type will be 4754, the fast task type will be 2 and the DC link rating will be 900. This system will use a 31V7100/30 hinged gate assembly and the firmware will configure the power interface board to use two DELTAs on bridge A and two DELTAs on bridge B. Example 2: If the system is a 480 V vector controlled DC fed single motor 1131 A (3x 377 A) unit, the drive type will be 41131, the fast task type will be 8 and the DC link rating will be 900. This system will use a 31V7100/60 hinged gate assembly and the firmware will configure the power interface board to use no DELTAs from bridge A and three DELTAs on bridge B. Example 3: If the system is a 690 V scalar controlled 300 A AC-in AC-out unit, the drive type will be 4300, the fast task type will be 4 and the DC link rating will be 1200. This system will use a 31V5300/110 hinged gate assembly and the firmware will configure the power interface board to use one DELTA on bridge A and one DELTA on bridge B. Configuring the SIGMA firmware There are three main SIGMA firmware parameters which are used to configure the SIGMA hinged gate controller to suit the required power topology. These are drive type (L1005), fast task type (L1006), and DC link rating (L8303). The drive type to be entered should be 4 followed by the current rating of bridge B only. Valid drive types for DELTA systems are: 4282, 4300, 4377, 5464, 4600, 4754, 4846, 4900 and 41131. The DC link rating is the nominal maximum DC link withstand voltage of the DELTA modules. Valid DC link ratings for DELTA systems are 800, 900 and 1200. This is to be set to 900 for GDDxxx-4501 type DELTA modules and 1200 for GDDxxx-4601 type DELTA modules. The fast task type should be chosen from Table C-1 on page C-5.
Wiring Arrangements for High Voltage DELTA Configurations

The wiring arrangements for the high voltage DELTA based drives differ from the wiring arrangements for standard DELTA drives in three areas as follows: Issue (12-2-98) GD4000 Technical Manual Page C-27

Mains supply and synchronisation. Auxiliary supplies Fan supplies. The wiring scheme for a high voltage DELTA based GD4000 drives can be derived from the wiring scheme shown in the KC3/10E series of schematic diagrams, in section C5.3, for the equivalent standard drive by incorporating the changes described in the notes that follow. A list of the schematic diagrams for each drive type is given in Table C-4.
Table C-4 Drawing reference for high voltage DELTA configurations
Configuration/Type
Guide Schematic AC in/AC Out
Supplementary Notes
GD4282 GD4300 GD4377 GD4564 GD4600 GD4754 GD4846 GD4900 GD41131
10E5064 10E5064 10E5064 10E5065 10E5065 10E5065 10E5066 10E5066 10E5066 DC Fed Single Motor
Refer to Appendix C Refer to Appendix C and Section C5.2 Refer to Appendix C Refer to Appendix C Refer to Appendix C and Section C5.2 Refer to Appendix C Refer to Appendix C Refer to Appendix C and Section C5.2 Refer to Appendix C
GD4282 GD4300 GD4377 GD4564 GD4600 GD4754 GD4846 GD4900 GD41128 GD41131 GD41200 GD41508 GD41692 GD41800 GD42262
10E5043 10E5043 10E5043 10E5045 10E5045 10E5045 10E5075 10E5075 10E5076 10E5075 10E5076 10E5076 10E5077 10E5077 10E5077
Refer to Appendix C Refer to Appendix C and Section C5.2 Refer to Appendix C Refer to Appendix C Refer to Appendix C and Section C5.2 Refer to Appendix C Refer to Appendix C Refer to Appendix C and Section C5.2 Refer to Appendix C Refer to Appendix C Refer to Appendix C and Section C5.2 Refer to Appendix C Refer to Appendix C Refer to Appendix C and Section C5.2 Refer to Appendix C
Drawing reference for high voltage DEL TA configurations
Page C-28
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DC Fed Twin Motor GD4282 GD4300 GD4377 GD4564 GD4600 GD4754 GD4846 GD4900 GD41131 10E5044 10E5044 10E5044 10E5078 10E5078 10E5078 10E5079 10E5079 10E5079 DC Feeder GD4282 GD4300 GD4377 GD4564 GD4600 GD4754 GD4846 GD4900 GD41128 GD41131 GD41200 10E5404 10E5404 10E5404 10E5405 10E5405 10E5405 10E5072 10E5072 10E5073 10E5072 10E5073 Refer to Appendix C Refer to Appendix C and Section C5.2 Refer to Appendix C Refer to Appendix C Refer to Appendix C and Section C5.2 Refer to Appendix C Refer to Appendix C Refer to Appendix C and Section C5.2 Refer to Appendix C Refer to Appendix C Refer to Appendix C and Section C5.2 Refer to Appendix C Refer to Appendix C and Section C5.2 Refer to Appendix C Refer to Appendix C Refer to Appendix C and Section C5.2 Refer to Appendix C Refer to Appendix C Refer to Appendix C and Section C5.2 Refer to Appendix C
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Page C-29

AC Fed GD4000 Configurations Mains Supply and Synchronisation Circuits For GD4600 and GD4900 configurations, special a.c. input reactors have been designed with multi-filar windings per phase that eliminate the need for input sharing reactors under each DELTA module. This offers the benefit of reduced losses, lower cost and less cubicle volume needed to house the power electronics. Figure C-13 details the arrangement for a GD4900, for the GD4600 delete all circuitry associated with Bridge B3, and reconnect the pre-charge wiring from R3, R6 and R9 to Bridge B2 A, B and C respectively via fuses as shown. For the GD4300 delete all circuitry associated with Bridges B2 and B3 and reconnect the pre-charge wiring from R3, R6 and R9 to Bridge B1, A, B and C respectively via fuses as shown.
Page C-30
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Figure C-13 Supply and synchronising circuits
The synchronising supply must be derived from the mains side of the a.c. input reactor. Fuses between the line contactor(s), LCN1 etc. as appropriate, and the DELTA bridges must be sized by reference to Section 6.3.
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Page C-31

For 4 and 6 paralleled DELTA based a.c. feeders, i.e. GD41200 and GD41800 please consult CEGELEC or the local agent. Auxiliary Supplies The standard arrangement for GD4300 to GD4900 drive configurations assumes a 690 V a.c. supply for both main and auxiliary power. A step down transformer is necessary to reduce the mains voltage to be within the range of the standard GD4000 switched mode power supply modules. See Figure C-14 for details.
Figure C-14 Auxiliary supplies
Page C-32
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For installations with separate main (690 V) and auxiliary (380 to 480 V) supplies, connect the SMPS units via appropriate fuses and supply isolators to the auxiliary supply. Fan Supplies Supplies for DELTA cooling fans are derived through 380 to 480 V or 690 V transformers as necessary for the application. The 690 V transformer range provides a double wound configuration in the step down transformer to avoid excessive line to earth voltages being applied to the fans. Fan Configurations The high voltage GD4000 schemes can be arranged with Standard, Turbo or Bi-Flow fan arrangements depending on the rating requirements and environmental conditions. Refer to section 4.7.2 of T1641 for details of typical Turbo fan connection diagrams. Figure C-15 shows a typical configuration for a GD4900 Bi-Flow fan system fed from a three phase star connected auto-transformer. For GD4000 ratings with Bi-Flow cooling please consult CEGELEC or the local agent
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Page C-33
Figure C-15 Fan supplies
DC Fed Configurations Consult CEGELEC or the local agent.
Page C-34
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Wiring Diagrams
The following wiring diagrams are included in this manual. 10E5015 GD4010 - GD4060 AC Fed 10E5016 GD4080 - GD4160 DC Fed (also applies to a.c. fed) 10E5038 GD4010 - GD4060 DC Fed
10E5021 31V1900/10 Precharge Unit 10E5032 31V1900/20 - 50 Precharge Unit
10E5043 DC Fed Single Motor GD4282/4300/4377 (31V5300) 10E5044 DC Fed Dual Motor GD4282/4300/4377 (31V5300) 10E5045 DC Fed Single Motor GD4564/4600/4754 (31V5300)
10E5402 Typical circuit GD4080 to GD4160 10E5403 Typical circuit GD4900
10E5064 AC Fed GD4282/4300/4377 (31V5300) 10E5065 AC Fed GD4564/4600/4754 (31V7100) 10E5066 AC Fed GD4846/4900/41131 (31V7100) 10E5404 10E5405 10E5072 10E5073 10E5074 DC DC DC DC DC Feeder Feeder Feeder Feeder Feeder GD4282/4300 (31V5300) GD4564/4600 (31V5300) GD4846/4900/41131 (31V7100) GD41128/41200/41508 (31V7100) GD41692/41800/42262 (31V7100)
10E5075 DC Fed Single Motor GD4846/4900/41131 (31V7100) 10E5076 DC Fed Single Motor GD41128/41200/41508 (31V7100) 10E5077 DC Fed Single Motor GD41692/41800/42262 (31V7100)
10E5078 DC Fed Dual Motor GD4564/4600/4754 (31V7100) 10E5079 DC Fed Dual Motor GD4846/4900/41131 (31V7100) 10E5085 10E5086 10E5087 10E5088 Switched Mode Power Supply Sub-Assembly - without relay Customer I/O Assembly Hinged Gate 31V5300 Hinged Gate 31V7100
Mechanical Drawings
41Y7129 Sheet 2Mounting Details Hinged SIGMA Gate - 31V7100. 41Y7263 GA Hinged SIGMA Gate, single PIB, flash memory
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Page C-36
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Appendix D
Terminating Ribbon Cables

D1
Introduction
Some Alspa drives are supplied with un-terminated ribbon cables, to give the customer maximum flexibility when designing the installation. This Appendix gives details of the method of terminating ribbon cables, with insulation displacement connectors, provided with the kit. The instructions apply to all ribbon cables supplied.
D1.1
Special Tools The following tools are required to assemble connectors on to ribbon cables.
T & B Ansley 779-2100 Tool frame T & B Ansley 779-2150 Die for use with Tool frame T & B Ansley 779-5030 Tool frame Cable Cutter
These tools are available from: Thomas and Betts Limited Sedgewick Road Luton LU4 9DT Bedfordshire Telephone 0582 597271 D1.2 Terminating a Ribbon Cable
Cut the ribbon cable to length, using the cutting tool. To ensure the cut is
perpendicular to the run of the cable, the cable should be flush with the alignment guide on the cutting tool as shown in Figure D-1.
Figure D-1 Cutting ribbon cable
Figure D-2 Fitting connector and cover
Fit the cover loosely over the main body of the connector. Insert the cable between the cover and the connector body, with the coloured edge
of the cable aligned with Pin 1 of the connector (indicated by a triangle symbol on the connector) and the end of the cable flush with the face side of the connector body.
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Page D-1
Appendix D
Note: Ensure the connector is facing the correct direction compared to the connector at the other end of the cable, since the cable will be doubled back over the connector when the strain relief is fitted. See Figure D-5.
Figure D-3 Using hand tool
Figure D-4 Cover fitted
Using T & B Ansley hand tool fitted with the die, press the cover down until the side
tangs click home. During this operation the contacts on the connector body penetrate the cable insulation to make the connection with the cable cores.
Figure D-5 Fitting strain relief
Figure D-6 Completed connector
Fold the cable back over the connector body and fit the strain relief. Press the strain
relief on to the body of the connector until it clicks home. The cable termination is now complete.
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Appendix E Firmware Compatibility
Firmware Compatibility
E1
Introduction
Software release 00S060 4003A1 is for the 20X4494 SIGMA board only. The arc.a database is a self extracting archive called arc.exe. Executing this file will produce the arc.a database file. Multiple ladder and links files are provided to use with each of the fast task configurations. They are designated 4003_C0.* to 4003_C5.*, where the C0 to C5 signifies the bridge type configuration. See module 10 and selection of variable L1007, fast task type wanted, in Section 13 of this manual.
E2
Enhancements
1. Frequency rate trip. If the network frequency changes at a rate of 2.0 Hz then a warning flag, L620 is set and a trip flag, L621 set if a rate of 3.0 Hz is reached. The feature is de-selectable using L624, and the actual rate can be monitored using L623. 2. DELTA 2 compatible. Selectable using L1006 = 2. 3. L9002 global trip level max value raised to 112o C. 4. Auto trim for current offsets added. 5. L9408 base speed volts max increased to 400 V and L9409 drive Vmax max increased to 848 V. 6. Resolution of L9401 and L9403 increased to 1/10ths of m..
E3
Faults Cured
1. Smaller drives can display a fault message on first running the slow task. Modifications to the reset circuit have been made as follows. In the links program: add link L2620 = L2621 add DEF TABLE L2620 to redefine L table symbol from DC Loop closed to MASK MESG MOD Remove link L2618 = L9110 Remove link L2619 = L9111 2. Drive type 4040 omitted. 3. Thermostat trip cured. 4. Ghost trip fault cured. 5. Re-allocation of analog inputs to correct C table addresses.
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Page E-1
Appendix E Firmware Compatibility
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Appendix F. Electromagnetic Compatibility

Issue 21/2/97
Electromagnetic Compatibility
F1
F1.1
Introduction
European EMC Directive The purpose of the European Unions EMC (Electromagnetic Compatibility) Directive, 89/336/EEC, is to prevent maloperation of equipment due to electromagnetic disturbances. The maloperation may be due to excessive emissions or inadequate immunity of equipment. The essential protection requirements in Article 4 of the Directive state that apparatus shall be so constructed that: (a) the electromagnetic disturbance it generates does not exceed a level allowing radio and telecommunications equipment and other apparatus to operate as intended; (b) the apparatus has an adequate level of intrinsic immunity of electromagnetic disturbance to enable it to operate as intended." EMC legislation also exists in other parts of the world, but the details may vary. The essential protection requirements must always be observed but, particularly for emissions, the measures required will vary according to the environment of the installation.
F1.2
EMC Standard The appropriate EMC standard for drives is IEC 1800-3: Adjustable speed electrical power drive systems - Part 3: EMC product standard including specific test methods. It is expected that this will be harmonized and published by CENELEC as EN 61800-3. According to the classification of IEC 1800-3, the Alspa GD4000 range of products have been designed and specified as components for restricted distribution i.e. for use by professional installers. Consequently, customers and users, separately or jointly, need to have technical competence in the EMC requirements of the application of drives.
F1.3
Industrial Environment Due to the design of the GD4000, providing that it is installed in accordance with Section 8 of this manual, it is unlikely that it will suffer or cause any maloperation relating to EMC in an industrial installation - Second Environment as specified in IEC 1800-3. However, to further reduce the risk of maloperation and hence maximize the operational integrity of an installed GD4000 with respect to EMC, it is strongly recommended that the installation guidelines in this Appendix are followed as closely as possible.
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Page F-1

Unless otherwise specified in this manual (e.g. where sensitive equipment is on the same supply - see section F2.2.3), no EMC filters are necessary when using GD4000 in the Second Environment. F1.4 Public Low Voltage Network When using a GD4000 in the First Environment category of IEC 1800-3 (public power distribution network i.e. no transformer between the users installation and domestic premises), optional EMC filters are available to suppress conducted radio-frequency interference. For compliance with the limits for the first environment, both the GD4000 and the filter must be installed as specified in this Appendix. F1.5 Technical Notes In this Appendix, some text which does not contain instructions but may aid understanding is identified as technical notes.
F2
F2.1
Compliance with EMC Requirements

Immunity If installed in accordance with the instructions in this manual, Alspa GD4000 will comply with the immunity requirements of IEC 1800-3. In particular, this includes: Electrostatic discharge Electromagnetic field Electrical fast transients/burst Surge IEC 1000-4-2 IEC 1000-4-3 IEC 1000-4-4 IEC 1000-4-5 6 kV contact discharge 8 kV air discharge 20 MHz - 1 GHz, 10 V/m 2 kV 1 kV line-line 2 kV line-ground.
All GD4000 units are shielded from radio interference when the front panels and (in the case of modular drives) the cubicle doors are closed. Care should be taken that no radio frequency transmissions (e.g. from portable telephones) take place in the vicinity of the unit, when the front door is open and the drive powered up. F2.1.1 Supply Voltage Distortion GD4000 drives are immune to harmonics according to class 2 of IEC 1000-2-4 (total voltage harmonic distortion = 8%). GD4000 drives are immune to commutation notches according to immunity class B of IEC 146-1-1 (notch depth = 40%). GD4000 drives are immune to 2% voltage unbalance (IEC 1000-2-4 class 2). The supply frequency range over which the drive can operate is listed in section 2.
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F2.1.2 Voltage Changes, Dips and Interruptions The voltage range over which the drive may operate is detailed in section 2.2.1. The behaviour of the drive when a supply loss occurrs is determined by the combination of the standard firmware modules and the user program. Without a user program the drive will not run. The drive is protected from supply loss, supply dips or frequency variations which exceed user programmable tolerances. If the supply is lost for less than one user program slow scan period (typically 10 ms) then the drive will continue to operate normally. Certain supply loss conditions, such as a short circuit of the supply can generate excessive currents in the input bridge in which case the drive will trip with the following fault message:
Instantaneous Over Current on the input bridge.
If the supply is lost temporarily1 the drive will trip on one or more of the following trips: Input Phase Loss Trip Mains Frequency Outside Limits Trip Mains Frequency Rate of Change Trip
Temporarily is defined as a minimum of one user program scan period or a maximum time which depends on several factors including:
The severity of the loss. Whether there is a single phase loss or multiple phase loss. Whether the drive is motoring or regenerating.
If for any reason (e.g. the trips have been masked out by the user) the previously stated trips do not occur, then, after a time dependent on the auxiliary loading of the main switched mode power supply (SMPS) unit, the SMPS will itself issue an Early Power Fail (EPF) signal to the drive controller. The drive controller will then disable the drive output pulses and the motor will coast. If the supply returns before the main SMPS supply has completely collapsed, the following will occur:
If the drive has tripped on one of the faults indicated previously, then it will, via
the default user program, remain in a tripped state. Optionally, the user can program the drive to reset its own faults, in which case it will return to the ready to run state, awaiting new commands from the user. Further to this, the user can also program the drive to automatically resume running when the ready to run state is established. Due attention must be given to user safety if this automatic restart mode is configured - see warning below.
If for any reason a supply loss is not detected and the drive does not trip, then it
will always restart in the running state and the drive will return to its normal operating condition.
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Page F-3

If the supply does not return before the main SMPS supply has collapsed then the whole system will shut down. On restoring power to the drive the following will occur:
If the drive control program is backed up, i.e. either in static memory supported
with healthy batteries or in flash memory, then the drive will normally start up in the ready to run state. Optionally, the user can program the drive to automatically resume running when the ready to run state is established. Due attention must be given to user safety if this automatic restart mode is configured - see warning below.
If the drive control program has not been backed up, then the drive will start up
in the waiting to download state. The user will then have to connect a PC to the drive and download the required program before the drive can be run. WARNING WHEN THE DRIVE IS CONFIGURED TO AUTO-RESTART, IT IS POSSIBLE FOR THE MOTOR TO START ROTATING WITH NO OPERATOR COMMAND. IF THE DRIVE IS CONFIGURED TO AUTO-RESTART, IT MUST BE ENSURED THAT ALL NECESSARY PRECAUTIONS TO PREVENT INJURY TO PERSONNEL ARE TAKEN. F2.1.3 Power Frequency Magnetic Fields GD4000 drives are immune to field strengths of 30 A/m (38 T, 0.38 Gauss) continuously and 300 A/m (380 T, 3.8 Gauss) short term, according to IEC 1000-4-8. F2.2 F2.2.1 Radio-Frequency Emissions Nature of Radio-Frequency Emissions from Drives The principal source of radio-frequency emissions from a GD4000 is conducted emissions due to the fast switching edges of the pulse width modulation (PWM) voltage which is applied to the motor. TECHNICAL NOTE Due to the inductance of the motor windings, a PWM waveform of a few kHz will produce a nearly sinusoidal current waveform in the motor. However, the motor windings contain stray capacitance to the motor frame. Therefore, the fast voltage edges of the PWM waveform cause some high-frequency current to flow from the drive into the motor frame. If this high-frequency current does not have a clearly defined return path, it can return by unexpected routes, possibly causing disturbances to other equipment. If an EMC filter is fitted and the other instructions in this appendix are followed, the high-frequency current will return to the drive via the filter rather than via the mains supply. If no EMC filter is fitted, the emissions (measured using a quasi-peak detector) are typically 115 dBV at 150 kHz, dropping to about 60 dBV at 30 MHz. The correct installation of a filter will reduce the emissions by up to 50 dB, the greatest reduction occurring near 150 kHz.
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F2.2.2 First Environment IEC 1800-3 defines the First Environment as the environment in which equipment is directly connected to a public low voltage supply which also supplies domestic premises. Therefore, there will be no galvanic isolation between the 3-phase input terminals of the drive and the mains supply sockets in the neighbouring domestic premises, i.e. the drive and the domestic premises are fed from the same supply transformer. This type of supply is frequently used to supply small commercial and light industrial premises. If drives are installed in this environment, the filters described in this appendix must be used. It is assumed that the supply network is a TN or TT system according to the definitions in IEC 364 i.e. the neutral of the supply is grounded somewhere in the supply network. F2.2.3 Second Environment IEC 1800-3 defines the Second Environment as the environment in which there is one or more supply transformers isolating the drive from domestic premises. IEC 1800-3 does not require the use of filters in this environment. TECHNICAL NOTE Isolating transformers provide significant attenuation of conducted radio-frequency interference. Therefore, emissions from drives installed in this environment are very unlikely to disturb equipment in domestic premises. Other equipment installed in an industrial environment which has the correct immunity for this environment will not be disturbed by emissions from drives. Occasionally, very sensitive equipment (e.g. thermocouples, pH meters etc with long unscreened leads, radio-controlled equipment) may be in use in the same environment as the drive. If it is not practical to improve the immunity of such equipment, it may be necessary to filter the emissions from all power electronic equipment, including drives. Alternatively the drives and the sensitive equipment may be fed from separate transformers. F2.2.4 Supply Networks in which the Neutral is Not Grounded WARNING IF THE NEUTRAL OF THE SUPPLY SYSTEM IS NOT CONNECTED TO GROUND SOMEWHERE IN THE SUPPLY SYSTEM, THE FILTERS DESCRIBED IN THIS APPENDIX MUST NOT BE USED. THE USE OF THESE FILTERS IN SUCH A SYSTEM WOULD CAUSE DANGER. In the following supply systems, the neutral of the supply is not grounded and the filters described in this appendix must not be used: (1) Ungrounded Network - the neutral is either isolated from ground or connected to ground through a high impedance (this is known as an IT network according to the definitions in IEC 364); (2) Line Grounded or Corner Grounded network - one of the three phases is grounded and the other two phases are at the line-line voltage with respect to ground (used in some countries particularly the USA).
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Page F-5

TECHNICAL NOTE EMC filters contain capacitors to ground. If an EMC filter is connected in either of these two networks, the voltage rating of these capacitors may be exceeded. Ungrounded networks are used in certain industries to permit continued operation (with alarm) in the presence of a single ground fault. In some countries, safety regulations prohibit the use of high leakage current equipment, such as these filters, in ungrounded networks. If drives are used in such a network, all other equipment connected to this network must have sufficient immunity for use in this environment. F2.2.5 Other Emission Standards The following standards contain the same emission limits as the First Environment emission limits of IEC 1800-3: EN 50081-2 EN 55011 / CISPR 11 class A group 1 EN 55022 / CISPR 22 class A * Note: Generic emission standard for the industrial environment.* Industrial, scientific and medical (ISM) radio-frequency apparatus. Information technology equipment (ITE).
This standard does not contain conducted radio-frequency emission limits for equipment rated greater than 1000 V. Therefore, if a drive (or group of drives) has a dedicated isolating transformer with a primary voltage greater than 1000 V, this transformer may be regarded as part of the drive and EMC filters are not then required.
Certain aspects of EN 55014 / CISPR 14 (household and similar) are inappropriate for drives such as GD4000. F2.3 Harmonic Emissions The harmonic emissions produced by GD4000 drives are significantly lower than the emissions from many drives of this type by virtue of the sinusoidal network rectifier. Refer to Chapter 2 of CEGELEC publication T1647 GD4000 In Its Environment for details of harmonic emissions. F2.4 Sinusoidal Rectifier PWM Disturbances Refer to Chapter 2 of CEGELEC publication T1647 GD4000 In Its Environment for full details.
F3
Installation Instructions for Compliance with EMC Requirements

These instructions are supplementary to the installation instructions in section 8 of this manual. The instructions in section 8 must always be followed.
Page F-6
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F3.1 Additional Safety Requirements for Filters WARNING THE EQUIPMENT SUPPLIED EXPOSES HIGH VOLTAGES. THE EQUIPMENT MUST BE ENCLOSED WHEN THE EQUIPMENT IS INSTALLED AND BEFORE THE EQUIPMENT IS ENERGISED. WARNING HIGH LEAKAGE CURRENT FLOWS TO GROUND WHEN THIS EQUIPMENT IS ENERGISED. GROUND CONNECTIONS TO THE EMC FILTERS, THIS EQUIPMENT AND TO THE MOTOR(S) POWERED BY THE EQUIPMENT MUST BE CONNECTED AT ALL TIMES. WARNING HIGH VOLTAGES AND HIGH ENERGY LEVELS EXIST WITHIN THE EMC FILTER AND THIS EQUIPMENT AND MAY BE PRESENT FOR 5 MINUTES AFTER THE EQUIPMENT IS ISOLATED FROM ALL ENERGY SOURCES. THE INPUT SUPPLY MUST BE ISOLATED AND ALL MOTORS CONNECTED TO THE EQUIPMENT MUST BE AT A STANDSTILL FOR A PERIOD OF 5 MINUTES BEFORE ACCESS TO THE EMC FILTERS OR THE EQUIPMENT IS ALLOWED. Local safety regulations and, in particular, the safety regulations for equipment with high leakage current, must be observed. If there is a conflict between safety rules and the installation instructions below, the safety rules must be observed. Neither the filter nor the drive may be subjected to high voltage insulation tests. RCDs/Ground Fault Protection Drives and their EMC filters (where fitted) produce high leakage currents (> 3.5 mA). Therefore an RCD (earth leakage circuit breaker/ground fault detection) may produce nuisance trips if connected to the a.c. line (mains) input. If ground fault protection is required, then a core-balanced current transformer and a ground fault relay may be used. The relay should have adjustable sensitivity. If the relay is only required to protect against ground faults in the motor, the current transformer could be placed on the cable to the motor. If the relay is required to protect against ground faults in the drive and motor, the current transformer could be placed between the filter and the drive.
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Page F-7

F3.2 Cubicle Layout
Figure F-1 Power Circuit
The power circuit of a drive system is shown in Figure G-1. In a particular system, certain components may be omitted. All equipment in the cubicle must be mounted directly on the same metal back sheet as the drive. If this is not possible, then the extra equipment must be mounted on a metal sheet which has a continuous metal-metal contact to this back sheet. Connecting metal sheets to each other by wire or braid is not adequate. To ensure a good metal-to-metal contact, the drive and filter must be mounted on the metal back sheet. The metal sheet should preferably be plated but unpainted. If the metal sheet has been painted, the paint must be removed from around and under all the screws, to allow metal-to-metal contact. All cables in the cubicle should be mounted as close as possible to the metal back sheet, preferably within 50 mm (2"). Cables between items on different metal sheets bonded to each other should be routed close to the metal back sheets and not through mid-air.
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F3.3 F3.3.1 Cabling and Segregation Cabling and Segregation Within Cubicle
Figure F-2 Segregation Rules in cubicle
Figure F-2 illustrates the segregation rules within the cubicle, but does not indicate a preference for any particular layout. The numbers in the Figure are explained as follows: (1) The cables and components between the a.c. line input and the input of the EMC filter must be kept at least 300 mm (12") away from cables and components on the drive side of the filter. (2) Cables and components on the a.c. line input to the EMC filter must be kept at least 300 mm (12") away from the cables and components which are connected to the d.c. link or between the drive and the motor. The areas near these two types of cable are shown with different types of shading in Figure G-2. (3) An output line reactor (if fitted) must be kept at least 300 mm (12") away from the input line reactor and from the EMC filter. Additionally, reactors must be mounted such that their axes are mutually perpendicular or separated by a minimum 300 mm (12"). Control and signal cables, including serial communications cables, must be kept at least 300 mm (12") away from any power cables and components.
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Page F-9

If the above segregation distances between cables and components cannot be achieved, metal barriers should be placed between the groups of cables and components. The metal barriers should be connected to the cubicle back sheet. However, this technique cannot be used to reduce the distances between reactors. Where cables of different types must cross each other, they should cross at right angles. Subject to the above segregation rules, cables should be kept as short as possible. Similar segregation rules apply for other equipment which may be mounted in the cubicle. The installation instructions for that equipment should be consulted. F3.3.2 Conductor Sizes The cables to the filter must be the same size as the power connections to the drive see section 8.5.2 of this manual. The ground conductors should be the same size as the other power conductors unless local safety regulations, in particular the regulations for equipment with high leakage current, dictate a larger size. F3.3.3 Cabling and Segregation External to Cubicle In the wiring external to the cubicle, three types of cable can be identified: (1) mains supply cable; (2) motor cable; (3) control and signal cables including serial communications cables. These groups of wiring must be kept at least 300 mm (12") away from each other. If they are in metal conduits or trunking, then each group must be in a separate conduit or trunking. F3.4 Contactor Suppression Contactor coil suppression is strongly recommended, even if the contactor is outside the drive cubicle. If the contactor is inside the drive cubicle, its coil must be suppressed. Suppression components should be sized to match the rating of the contactor. Suitable components can be supplied by CEGELEC on request. F3.5 Motor Cable The motor cable must be shielded and the shield bonded solidly to both the drive cubicle and the motor. If this is not done properly, an EMC filter on the drive input will not be fully effective. The motor cable must be either: (1) steel wire armoured, or (2) enclosed in a conduit or metallic trunking which contains no other cables.
Page F-10
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All three phases must be enclosed by the same armour or conduit. If the current rating of a high-power motor is beyond the capabilities of a single armoured 3-core cable, several 3-core armoured cables should be connected in parallel, with each cable carrying all three phases. The armouring or conduit must be continuous throughout its length. The armour or conduit must be connected to the motor by a 360o metal cable gland. A pig-tail (short piece of wire linking the shield to the motor or cubicle) is not an acceptable alternative to a 360o gland. The armour or conduit must be connected to the cubicle back sheet by the use of a 360o metal cable gland in a glanding plate or by a metal saddle-clip. The gland plate or saddle-clip must be bolted directly to the back sheet and not spaced off by pillars or brackets. Again, the use of a pig-tail is not permitted. If local safety regulations do not accept the grounding of the motor via the cable armour or shield alone, an armoured or shielded four-core cable should be used. The fourth core must then be connected both to the drive cubicle and the motor frame. The armour or shield must still be connected at both ends as described above. While the motor already has a connection to ground via the drive and the motor cable, the motor frame and the ground connection of the driven plant should be electrically connected to each other. TECHNICAL NOTE This equipotential bonding conductor between the motor and the driven equipment: (1) prevents voltages hazardous to personnel being developed between the motor and the driven equipment and (2) prevents current flowing through the shaft bearings and causing their premature failure. Minimizing the length of the motor cable will generally reduce the radio-frequency emissions. F3.5.1 Circulating Currents In some installations, equipment of much higher power rating than the drive may cause large potential differences between the ground at the drive cubicle and the ground at the motor. Grounding of both ends of the motor cable would then result in large currents flowing in the armour or conduit. If this problem is likely to occur then precautions such as the following must be taken. (1) Connect a potential compensation cable in parallel with the motor cable. This cable is of much larger cross-sectional area than the motor cable, so the induced current flows through this rather than through the shield of the motor cable.
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Page F-11

(2) As an alternative, ground the armour/conduit and any fourth core at one end only. The armour/conduit and fourth core should be indirectly grounded at the other end via a 1 F capacitor. The capacitor must be of at least X2-class safety rating, for example Rifa PHE 820EF7100M. This option should be used if safety rules prevent the grounding of both ends of the motor cable. TECHNICAL NOTE The connection of a capacitor in series with the cable shield will introduce a pig-tail connection. This will give some degradation of the shielding performance of the shield. However, it may be the best that can be achieved in the circumstances. F3.6 Control Connections With the exception of relay outputs, all control connections on the GD4000 are referenced to protective ground within the drive and are not isolated. All cable shields must be connected to the appropriate Shield/Screen terminals on the Customer I/O Board. The Shield/Screen terminals are connected to protective ground within the drive. The 0 V wires inside the various cables must be connected to the appropriate 0 V terminals on the drive. The various 0 V connections (A0V, B0V) should not be confused with each other or with the shield connections. F3.6.1 Shielding of Cables The following cables must be shielded: (1) (2) (3) (4) analog inputs and outputs; RS485 serial link; RS232 serial link; Incremental encoder(s).
The shield of the RS232 serial link cable must be connected to the metal backshell of the D-type connector and not to the connector pins. The shields of the other shielded control cables must be connected to the appropriate Shield terminals on the GD4000 Customer I/O Board. Connecting the shield to a ground/earth bar in the cubicle is not an acceptable alternative. The shields of shielded cables must be continuous throughout their length. If the shielded cable is contained within an overall armoured cable or conduit, the armour or conduit should be connected to the cubicle back sheet in the same manner as the motor cable. While the shield of a shielded cable must be connected to the Shield terminal on the drive, the correct connection for the shield at the other end of the cable will depend on the nature of the equipment connected there. The user instructions for the associated equipment should be consulted. In the absence of such information, the following guidelines may be used: (1) If the input or output of the associated equipment is isolated from ground and has very low capacitance to ground; the shield should generally be grounded at the GD4000 end only.
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Issue (12-2-98)

(2) If the input or output of the associated equipment is not isolated; the cable shield must be grounded at both ends. If it is necessary to disconnect one end of the cable shield to prevent disturbance current from other equipment flowing through the shield, then galvanic isolation must also be provided for all of the wires inside the cable. Proprietary analog or digital galvanic isolation units should be used for this purpose. The break in the shield must be at the same point as the galvanic isolation. (3) Some equipment contains inputs and outputs which are galvanically isolated but in which there is some stray capacitance to ground. In this case, the associated equipment may provide a shield connection in which the shield is capacitively connected to ground. F3.7 Drive Not in a Fully Enclosed Cubicle If a drive is not installed in a fully enclosed cubicle, it is the responsibility of the installer to take any additional safety precautions which may be necessary. In particular, the EMC filters are not suitable for mounting outside a cubicle, so the installer will have to provide an additional enclosure for the filter. The filter and drive must still be mounted on the same metal sheet and the motor cable armour/conduit must be directly bonded to this metal sheet. The cable between the EMC filter and the drive must be shielded or armoured, with the shield or armour bonded to both the drive and the filter enclosure. At the drive end of the motor cable, the shield or armour must be directly bonded to the drive and not just to the metal sheet which supports the drive.
F4
EMC Filters
If EMC filters are required, the filters below should be used. They are suitable for use on supplies up to 480 V nominal in which the neutral is grounded (i.e. TN or TT system according to IEC 364). For correct performance, they must be installed in accordance with the instructions in this manual and the motor cable should be less than 100 m (328 ft) in length. Filters for GD4000 drives are listed in Table F-1. Select the the filter on the basis of the required continuous drive power for the minmum supply voltage condition. As an example, a GD4377 rated for 200 kW on a 400 V 10% supply will have filter current ratings of : 200 x 103 = 320 amps. (3 x 360) Therefore use 350 A filter order number 78899/679. Consult CEGELEC for details of EMC filters for 690 V supply operation.
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Table F-1 Filters for GD4010 to GD4160 drives
Filter CEGELEC Order code 78899/670 78899/671 78899/672 78899/673 78899/674 78899/675 78899/676 78899/677 78899/678 78899/679 78899/680 78899/681 78899/682 78899/683 78899/684 78899/685 78899/686 78899/687 78899/688
Current Rating 8A 16 A 25 A 36 A 50 A 80 A 110 A 180 A 280 A 350 A 400 A 450 A 500 A 550 A 600 A 700 A 800 A 900 A 1000 A
New Part Number P2E/008/3/H1/P2E/016/3/H1/P2E/025/3/H1/P2E/036/3/H1/P2E/050/3/H1/P2E/080/3/H1/P2E/110/3/H1/P2E/180/3/H1/ P2E/280/3/H1/ P2E/350/3/H1/ P2E/400/3/H1/P2E/450/3/H1/P2E/500/3/H1/P2E/550/3/H1/P2E/600/3/H1/P2E/700/3/H1/P2E/800/3/H1/P2E/900/3/H1/P2E/1000/3/H1/-
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F4.1 Dimensions of Filters
Amp
78899/670 78899/671 78899/672 78899/673 78899/674 8 16 25 35 50
A
225 (8.9")
B
200 (13.8")
C
6.5 (0.33")
D
85 (3.3")
E
100 (3.9")
F
115 (4.5")
G
60 (3.4")
H
115 (4.5")
245 (9.6")
200 (7.9")
6.5 (0.33")
120 (4.7")
135 (5.3")
150 (5.9")
65 (2.6")
115 (4.5")
Figure F-3 Filter Dimensions
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Amp
78899/675 78899/676 80 110
A
420 (16.5")
B
350 (13.8")
C
15 (0.6")
D
190 (7.5")
E
6.5 (0.26")
F
400 (15.7")
G
100 (3.9")
H
130 (5.1")
I
375 (14.8")
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Amp
78899/677 78899/678 78899/679 78899/680 78899/681 78899/682 78899/683 78899/684 78899/685 78899/686 78899/687 78899/688 180 280 350 400 450 500 550 600 700 800 900 1000
A
460 (18.1") 740 (29.1")
B
340 (13.4") 540 (21.3")
C
15 (0.6") 20 (0.8")
D
200 (7.9") 270 (10.6")
E
6.5 (0.26") 10.5 (0.4")
F
490 (19.3") 740 (29.1")
G
145 (5.7") 200 (7.9")
H
170 (6.7") 210 (8.3")
I
400 (15.7") 640 (25.2")
824 (32.4")
640 (25.2")
20 (0.8")
400 (15.7")
10 (0.4")
840 (33.1")
200 (7.9")
320 (12.6")
740 (29.1")
884 (34.8")
700 (27.6")
20 (0.8")
450 (17.7")
12 (0.5")
900 (35.4")
250 (9.8")
350 (13.8")
800 (31.5")
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Appendix G The Minimum User Program
The Minimum User Program

G1
Introduction
The basic user program supplied with the standard software 00S060-4005 is called MINIMUM and comprises the following files: MINIMUM.GLP (Ladder program) MINIMUM.GDM (Links program) The Minimum program, when configured, provides basic control of a GD4000 in either VVVF or Vector control modes. The purpose of the Minimum program is to provide a means of running the drive with a minimum of user programming, to allow commissioning of the basic drive. For simple applications, such as fan installation, the minimum program may require only minor modifications to meet the application requirements. It can also form the basis of a complex application. To configure the drive to suit the application a number of link changes must be made using the CSP programming tools.
G1.1
Preparation To configure the Minimum program the CSP programming tools must be loaded on to a PC as described in Section 4. It is recommended that a copy of the Minimum program is made so that you can revert to the original should any difficulties arise. Links editing and program compiling can be carried out on a PC without connection to the drive. To download the program a serial link connection from the PC to the drive is required. Before the drive can run the Hardware Interlock, digital input A32.07, must be set up as described in Section G1.1.2. Note: Before operating the drive the mechanical checks described in Section 9.3.1 and the electrical checks described in Section 9.3.2 must be carried out.
G1.1.1
Serial Link Connection For serial communications between the host PC and the drive, connect a serial link cable between RS232 serial port and the host PC and the Serial Link 0 connector (SK4 on the Customer I/O Board). Connections for a suitable cable are shown in Figure G-1.
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Page G-1
Figure G-1 Wiring schematic for RS232 cable
G1.1.2
Hardware Interlock Digital input A32.07 is used as a hardware interlock to ensure the output bridge is only energising in response to a deliberate command. It is also used to disable the output and to allow Halt/Run and Run/Halt transitions during commisioning. A32.07 must be in the Off (0) state when the drive is powered up, if it is On (1) then the drive will be halted. The minimum program requires A32.07 to Off when the drive is powered up and then set to On after power up. To achieve this, connect A32.07 (TB9A/10 on the Customer I/O Board) to digital Output B1.08 (TB11A/3) on the Customer I/O Board with a wire link. A switch can be connected into the wire link so that A32.07 can also be disabled manually. To run the drive with the Minimum Program; add the statement B1.8 = 1 to the Minimum program Links file using the CSP links editor. The Minimum Program does not use or define any other Inputs or Outputs.
G2
Configuring the Minimum Program

Before the Minimum Program can be used the Links File must be edited to configure the drive to operate in the chosen mode (either VVVF or Vector control) and with the selected motor. It is recommended that the values to be written to the drive parameters are established prior to the CSP Links editing session and written into the Users Value column in the appropriate link changes table.
G2.1
Link Changes Required for VVVF Control The changes which must be made to the minimum program to operate in VVVF mode are shown below. An example links editing session is described in Section 4.5.7.
G2.1.1
Link Changes For VVVF Mode

Parameter L1005 CSP Mnemonic drivetype Default 4030 Users Values Description Enter the relevant numeric code from the product description field. Valid values are:4010 4020 4030 4060 4120 4160 4282 4300 4377 4564 4600 4754 4846 4900 41131 4 selects VVVF mode Nominal network (mains) supply voltage in volts.
L1007 L9951
FTtypewanted Nomsupplyvolts
4 415V
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Parameter L9952 CSP Mnemonic +veVstol Default 10.00% Users Values Description Supply positive tolerance as a percentage of the nominal supply voltage. Typical values are less than 10%. Supply negative tolerance as a percentage of the Nominal Supply voltage. Typical values are less than 15%. Motor volts when running at nominal operating frequency (base frequency). Typical values are 415 V. Can be found on motor nameplate The base frequency is the nominal operating frequency of the motor found on the motor Name Plate. The motor power factor obtained from the motor name plate. Typical values vary between 0.89 and 0.98. Motor full load current. This can be obtained from the Motor Nameplate The speed of the motor in rpm when operating at full load current and motor base frequency. This value can be found on the motor nameplate
L9953
-veVstol
-10.00%
L8410
Basespeedvolts
330 V
L8414
Base frequency
50.0 Hz
L8415
Powerfactor
0.90
L8416 L8418
MotorFLC Fullloadspeed
30 A 1470 rpm
When the links have been edited, the program can be compiled and downloaded to the drive (see sections G3.1 and 4.7.1. G2.2 Link Changes Required for Vector Control The changes which must be made to the minimum program to operate in Vector Control mode are shown below. An example links editing session is described in Section 4.5.7. G2.2.1 Link Changes For Vector Mode
Parameter L1005 CSP Mnemonic drivetype Default 4030 Users Values Description Enter the relevant numeric code from the product description field. Valid values are:4010 4020 4030 4060 4120 4160 4282 4300 4377 4564 4600 4754 4846 4900 41131 Selects Vector mode Nominal network (mains) supply voltage in volts. Supply positve tolerance as a percentage of the nominal supply voltage. Typical values are less than 10%. Supply negative tolerance as a percentage of the Nominal Supply voltage. Typical values are less than 15%. These parameters are sometimes given on the motor product data sheet. The motor manufacture may need to be contacted to acquire this data.
L1007 L9951 L9952
FTtypewanted Nomsupplyvolts +veVstol
0 415V 10.00%
L9953
-veVstol
-10.00%
L9401 L9402 L9403 L9404 L9405 L9406 L9407
statorresist statorinduct rotorresist rotorinduct magresist maginduct basefrequency
194.0 1240 241.0 833 222000 46600 50Hz
The base frequency is the nominal operating frequency of the motor. This can be found on the motor Name Plate.
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Parameter L9408 CSP Mnemonic motorVatNb Default 190V Users Values Description This is the phase to neutral voltage that the motor has been designed to operate at when running at its designed base frequency. The motor phase to phase voltage for base frequency operation is given on the motor nameplate. The phase to neutral voltage is given by: Phase to phase volts/1.732 The number of motor poles can be determined as follows: motorpoles=(basefrequencyx120)/Name Plate stated RPM at basefrequency Encoder Line count can be found on the encoder Name Plate Peak motor Current in amps. This is a user application dependent variable. Motor break out torque and motor thermal considerations need to be taken into account but typical values are:- 1.1 x L9434 1.5 x L9434 2.0 x L9434 Motors full load current in amps. This is obtained from the motor Nameplate Peak speed (rpm). This is the maximum speed at which the motor is required to run in the application.
L9413
motorpoles
L9426 L9434
enclinecount pkmotorI
2500 45A
L9436 L9528
contmotorI PeakSpeed
30A 1500.0RPM
When the links have been edited, the program can be compiled and downloaded to the drive (see sections G3.1 and 4.7.1. G3
Example Links Editing Session

This section describes the procedure for editing, compiling and downloading the Minimum Program to a drive. It should be read in conjunction with either Section G2.1.1 if the drive is to operate in VVVF mode or Section G2.2.1 if the drive is to operate in Vector Control Mode. Guidance on using the CSP program suite can be found in section 4.
Ascertain the values for each of the parameters listed in the links to be changed
table and write these values in the relevant boxes in the column headed Users Values. The description column in the table explains where to find the required variable data. This data will be used to customise the links file using the CSP editor.
Copy the Minimum program files to a directory on the PC. Start CSP and press F7 to display the Programmer Setup Menu. The following screen
will be displayed. Write down the name of the directory where the program files are located (in the example screen shown, this is U:\PROGRAMS\LL_FILES\MINIMUM\.
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PROGRAMMER SET-UP Drive Filename Selection ENVIRONMENT VARIABLES Location of Program Files Location of Database MINIMUM U:\PROGRAMS\LL_FILES\MINIMUM\ U:\PROGRAMS\DATABASE\
SERIAL LINK COM port BAUD rate Tributary Address
1 38400 1 COLOUR SELECTION MENU DRIVE MODE SELECTION PASSWORD LEVEL SELECTION
[ENTER] to Select
[F9] View database,
[F10] Exit
[CTRL][F10] Abort
Figure G-2 CSP Programmer setup screen
Open the Windows File Manager and copy the MINIMUM.GDM, MINIMUM.GLP
and MINIMUM.MON files from the floppy disk supplied into the programs directory. Note: It is recommended that a second copy of the standard program files (.GLP and .GDM) is made with a new name and that these files are used to operate the drive. This will allow the original program configuration to be recovered should difficulties arise. The procedure below shows the original filename being used.
Retain the floppy disk for use as Master Template files. Switch back (Alt -Tab) to the CSP set-up window and position the highlight box over
the filename next to the Drive Filename Selection menu. If this is the first time CSP has run the filename will be DEFAULT. Press the <Enter> key. A CHANGE CURRENT FILE list box appears.
If there is more than one file listed; use the cursor keys to select the MINIMUM file
and press <Enter> MINIMUM will appear against the Drive Filename Selection field.
Press F10 to exit the set-up screen. Press F2 to start the Links Editor.
The Links Editor screen will be displayed with the MINIMUM program.
Use the cursor keys to find the relevant parameter (the parameters are ordered
alphanumerically) and enter the values listed in the Link changes table. Each parameter edit is terminated by pressing the <Return> key.
When all parameters have been entered. Press the F10 key to exit the Links Editor.
The following message will be displayed: > Save File MINIMUM ? { [Y]es, [N]o, [C]hange filename, [A]mend issue }
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Page G-5

Press [Y] to save the file. The Links Editor will save the file, close and return to the
main menu screen. G3.1 Compiling The New Program To Compile the new User program:
Press the F3 key. The program will be compiled and the result of the compilation will
be displayed in a dialogue box. Check to see if there are any Errors or Warnings, and then press F10 to exit back to the main menu screen.
If there were NO Errors or Warnings then the program is ready to be downloaded. If
there are any Errors or Warnings, press F6 to review them in more detail and modify the links file accordingly and then re-compile. G3.2 Downloading Modified File To download the file, a serial link between the host PC and the drive must be established. The drive has been set up by default to communicate via serial link 0 at 38400 using tributary 1. Connect a serial link lead, connected as shown Section G1.1.1, between COM1 of the host PC and the RS232 link 0 connector on the Customer Termination Panel of the drive. Enter the CSP set-up screen and ensure that its serial link settings are as follows: SERIAL LINK COM port Baud Rate Tributary Address 1 38400 1
With drive powered up and in Halted state.

Press the F4 key to down load the program. On completion of the download, press
F10 to return to the main menu. The program is stored in RAM at this point and must be transferred to Flash memory. To complete the download operation:
Press F5 in the main menu to display the Monitor Menu. Press F2 to put the Monitor in Control Mode. Press F4 to Run the drive.
The message WRITING TO FLASH will be displayed. When the program transfer to Flash memory is complete the message RUNNING is displayed.
Remove power from the drive for 5 seconds and then restore the power supply. This
action is required for two reasons: to ensure that the program which has been downloaded will be restored in later power cycles. to initialize the drive with the new parameter settings. When initialization is complete the drive is ready to Run.
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G3.3 Control And Referencing Parameters The following parameters will be required to control the drive/motor from the CSP monitor screen.
Parameter L1008 L8505 CSP Mnemonic FT type active Stop 1 Default 4 0 Description Operating mode confirmation parameter. Read Only Set to a 1 to start the input bridge. Set to a 0 to stop the input bridge. Only works if there are no faults in the system and A32.07=1. Set to a 1 to start the output bridge. Set to a 0 to stop the output bridge. Only works if input bridge is running and the DC Link is established i.e. L9937=1 Only required for Vector mode. This input controls the torque limits i.e. L9214 and L9215. Only required for Vector mode. This input controls the speed reference of the drive. Only required for Vector mode. This program does not define which inputs control the ramp rates. Module 22 defaults to using these values. Only required for Vector mode. Only required to stabilise the motor. Only required for VVVF mode. VVVF does not use module 22 to control its ramp rates. In VVVF mode the ramp rates are controlled by these parameters.
L28505
Stop 1
L8548 L28548 L2222 L2223 L9211 L9212 L8421 L8422 L8423 L8424
Sum 1 Sum 1 Rate 1 acc Rate 1 dec prop gain intgl gain Fwd accel rate Fwd decel rate Rev accel rate Rev decel rate
5000 0 100%
2000 5 5 Hz/s
G3.3.1
Example Monitor Screen

096-4005 ax6: Run, Normal:### INPUTS HEALTHY L1008 FT type active= +4 L8421 L8422 L8423 L8424 Fwd Fwd Rev Rev accel decel accel decel rate= rate= rate= rate= 5.00 5.00 5.00 5.00 Hz/s Hz/s Hz/s Hz/s
L8505 L28505 L8548 L28548 L2222 L2223 L9211 L9212
Stop 1= Stop 1= Sum 1= Sum 1= Rate 1 acc= Rate 1 dec= prop gain= intgl gain=
1 1 +5000 0 +100.0 %/s +100.0 %/s 2000 5
Screen 1/5 Edit Mode
<F1> HELP
<F2> CTRL
<F3> BASE
<F4> NEW SCR
<F5>
<F10> EXIT
Figure G-3 CSP Monitoring screen
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Thsi page has been left blank for pagination purposes.
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Appendix H Recommended Tightening Torques for DELTA Drives
Recommended Tightening Torques for DELTA Drives

H1
Scope
This document details the recommended tightening torques for the connections used on the DELTA based modules. The recommended torque settings are applicable to high-tensile steel fasteners, 8.8 Grade, fitted with a single coil spring washer under the nut, and with the threads being zinc plated, chromate passivated and unlubricated over the normal operating temperature of these components . Specifically excluded are: i) ii) iii) Fasteners with any other material (e.g. brass) Fasteners with any other finish (e.g raw steel, cadmium plated, lubrication of any sort). Slotted holes in either steel or copper.
H2
Tightening Torques for Busbar to Busbar Joints

Fastener Size Steel (8.8) M8 M10 M12 Torque Setting Nm 20 40 64 lbs ft 15 30 48
H3
Tightening Torques for Electrical Connections

These figures do not include busbar joints.
Fastener Size Steel (8.8) M5 M6 M8 M10 M12 M16 Torque Setting Nm 3.5 TO 5.5 7 TO 10 10.5 to 16 27 to 40 40 to 60 90 to 135 lbs ft 2.5 to 4 5 to 7.5 8 to 12 20 to 30 30 to 48 65 to 100
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Page H-1
Appendix H Recommended Tightening Torques for DELTA Drives

H4
Tightening Torques for Mechanical Connections

These figures are for the assembly and mounting of steel parts, where specific electrical connection, other than continuity, is not involved.
Fastener Size Steel (8.8) M5 M6 M8 M10 M12 M16 Torque Setting Nm 4 to 6 7 to 10 16 to 25 34 to 47 54 to 82 135 to 200 lbs ft 2.5 to 4 5 to 7.5 8 to 12 20 to 30 30 to 48 65 to 100
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Appendix I GD4000E User Guide
GD4000E User Guide

I1
Introduction
GD4000E is a Microsoft Windows based utility for Viewing and uploading trip history, parameter value and message log information. GD4000E Can be used with GD4000 firmware database 00S029-4001 Revision A and all later versions.
I1.1
System Requirements GD4000E requires a PC with: a minimum of 4MB of RAM a hard disk with 450 KB of free storage space a 3.5" floppy disk drive a VGA Monitor Microsoft Windows 3.1 or later. A serial link cable to connect the PC to the GD4000 drive
I1.2
Installation: To install GD4000E: With the PC running in the Windows environment

Insert the installation disk into drive 3.5 inch floppy drive (assumed to be drive A: for
these instructions).
From the Program Manager select Run from the File Menu. Type a:setup and press Enter.
After a short time you will be prompted for the directory into which the package should be installed. The default is C:\GD4000E. This can be changed if desired. The set-up program will generate a Program Group called GD4000E and place the icon for GD4000E in this group. I1.3 Starting GD4000E To launch the GD4000E application, ensure the PC is connected to the drive via a serial cable:
Double click on the GD4000E icon.
This will display the GD4000E main menu. I2 I2.1
The Menu Commands

The File Menu Open-This is used to open a fast or control history file previously saved to disk. Save- This is used to save to disk a history with a predefined name. If the file does not have a predefined name then the user is prompted with the Save As dialogue box.
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Page I-1

Save As- This is used to save a history without a predefined name. This would be a history which has just been uploaded from a drive. The user is prompted with the Save As dialogue box. Print Graph- This is used to print a history graph to a local or networked printer. This is only enabled when a graph is currently being displayed. Printer Setup- This is used to configure the software for a particular printer. I2.2 The Upload Menu Fast History- This is used to upload a fast history from a drive, the baud rate, serial port and tributary address being configured in Serial Port under the Config Menu. Control History- This is used to upload a control history from a drive. Message Log/Parameters- This used to upload the Message Log and Parameter Edits stored in the drive. I2.3 The View Menu Graph- If this option is selected, the currently loaded history will be displayed in graphical format. The user is presented with a dialogue box containing two list boxes with analog and logical signal names and tables. The user selects which signals will be plotted. A maximum of 15 analog and 15 logical signals can be selected. When the user selects the OK button, the graph is displayed. Table- If this option is selected, the currently loaded history will be displayed in tabular format. The user is presented with a dialogue box containing two list boxes with analog and logical signal names and tables. The user selects these to determine which signals will be displayed. A maximum of 15 analog and 15 logical signals can be selected. If the user selects the OK button, the table content is displayed. Message Log- When the user selects this option, a table of messages and their times and dates is displayed. Parameter Edits- When the user selects this option, a list of changed parameters and their current values is displayed. I2.4 The Zoom Menu Zoom Out- This is used to replot a graph, once it has been zoomed into. The graph is displayed in its original size and format. This option is only enabled after zooming in. I2.5 The Config Menu Serial Port- The port number, Baudrate and Tributary address can be configured using this option. Graph Plotting- The maximum and minimum of the range for the plotting of graphs can be configured using this option. The zoom mode can also be configured. If X Axis zoom mode is selected then when a zoom is carried out only the X axis is changed, whereas with X and Y axis both axes are changed. Offsets- When plotting signals on a graph it may be difficult to view all the signals as they cover the same plot area. A signed offset can be added to each analog signal to aid visibility. The value to be added is typed in. The value can be switched in or out by
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Issue (12-2-98)

selecting the check box associated with each signal. The value will only affect the graph if the OK button is pressed. Stats- This dialogue box displays the serial link statistics. The values can be reset using the Clear button. I2.6 The Window Menu Cascade- Selecting this option causes the graph, table , message log and parameter edit windows to be cascaded (if open) i.e. stacked on top of each other. Tile- Selecting this option causes the graph, table, message log and parameter edit windows to be tiled. Below these two options is a list of the currently open windows. The window that currently has focus has a tick by it. Focus can be changed by selecting the appropriate window name from this menu. About This displays the issue of the software. I3 I3.1
Application Notes
Speed Buttons Many of the functions on the menu are duplicated as speed buttons giving faster access to the following functions: Open a file Save a file Print a graph Display a graph Display a table Zoom out of a graph and the about box.
I3.2
Displaying Graphs When a graph is displayed, various parameters can be changed. To change the position of the blue cursor bar on the graph, click on the left mouse button The blue cursor bar moves on both the logical graph and the analog graph. The current time position of the bar is displayed in the bottom right hand corner of the graph. The value of each signal at that time is displayed to the right hand side of each graph legend. Initially the blue cursor bar is at the trip position (the red bar). To zoom in to a part of a graph, select the area to be viewed as follows:
Move the cursor to the first corner of the area to be viewed. Click on the right mouse
button and, holding the button down, drag the second corner of the zoom box to enclose the required viewing area. Release the right hand button of the mouse. The zoom is reflected in both the logical and analog graphs. To zoom out to the original position, zoom out can be selected from the menu or by selecting the zoom out speed button. To change the appearance of a graph, fonts, line thickness and colour can be changed. To change an the item: Position the cursor over the required part of the graph and press the shift key and the left mouse button simultaneously. Select the required line thickness font or colour by holding down SHIFT and double clicking the left mouse button. Issue (12-2-98) GD4000 Technical Manual Page I-3

I3.3 Displaying Tables When a history is displayed in tabular form, the values of each signal are tabulated against the time relative to the trip point (trip point equals time 0). By selecting the Copy to Clipboard button it is possible to copy the contents of the table to the clipboard so that the information can be imported into a spreadsheet or word processor. I3.4 Displaying the Message Log When the message log is displayed, a list of messages and the time and date that these occurred is displayed. Current Position gives an indication of the latest message. This would be of use in a situation where the buffer has wrapped around to the start and messages are being overwritten. The buffer can store up to 100 messages before wrapping round. I3.5 Displaying Parameter Edits Parameter edits are displayed as a list of data-tables and their current values. The value can be displayed in decimal or hexadecimal. Up to 256 parameter edits can be stored and displayed. After this number has been stored, no more edits will be permitted and the changes will be lost. I3.6 History There are two types of history information which can be uploaded into GD4000E. These are Fast Histories produced by software modules 119 and 159 and Control Histories which are produced by software modules 35 and 235. Details of modules 119 and 35 can be found in Sections 13 and 14 respectively. GD4000E uploads the values of the configured signals along with the signal comments and table values. Up to sixteen 32 bit sundry channels, up to six 32 bit fast channels and up to 16 logical channels in a Fast History can be uploaded. In a Control History, up to ten 16 bit analog channels and up to 16 logical channels can be uploaded When a Fast History is saved, by default the file is given a .fht extension. Control histories are saved with a .cht extension. The file extensions other than the defaults can be specified by the user and the software will automatically detect the type of history file. If an incompatible file is detected the message This file is not a control or fast history file is displayed.
Page I-4
Issue (12-2-98)
Index
INDEX
!
Clock /Calender , 2-15 HDLC Termination Panel, 3-10 .DAT, 4-47 .DNL, 4-46 .GDC, 4-46 .GDM, 4-46 .GLP, 4-46 .LST, 4-46 .MSG, 4-47 .PRN, 4-23, 4-47
C
Cabling segregation, 8-25 checks when running, 10-9 Clock calender clock, 3-8 Clock Calender, 2-15 Colour Selection, 4-44 COMM attribute, 7-12 comments , 7-12 commisioning basic edits, 9-3 commissioning current loop response, 9-10 electrical checks, 9-2 encoder checks, 9-8 mechanical checks, 9-2 monitoring, 9-6 motor data checking, 9-9 motor model, 9-3 oscilloscope tests, 9-10 speed loop values, 9-12 thermistor checks, 9-7 commissioning mode, 7-17 Commissioning Program, 4-46 Compilation time, 4-32 Compiler, 4-26 compiler messages, 4-28 Compiler Output File (.DNL), 4-46 Control available module 93, 14-207 module 98, 14-226 Control available logic module 26, 14-26 Control connections cabling, 8-12 terminal location, 8-12 Control On module 27, 14-34 controlled rectifier, 1-4 Controller Status, 4-36 Cooling, C-16 Cooling airflow, 8-8 CRC, 10-10 CSP Uploader, 13-49 CSP.DAT, 4-47 CSPROGS, 4-45 Current control, 13-24, 13-27 Bridge B, 13-4, 13-7 Current conversion, 13-34 current loop tuning, 6-10 current ratings, 6-18 Customer I/O Assembly, C-12 Customer I/O Board, C-12 LEDs, 10-6 SW2, 3-9 SW3, 5-10 - 5-11
A
access level, 7-3 access levels CSP editor, 7-3 CSP monitor, 7-3 acoustic noise emissions, 2-13 Address Drive Identity, 2-8 Address Entry, 4-38 Airflow cooling, 8-8 Altitude, 2-12 derating with, C-16 operating, C-16 re-rating factor, 2-5 Ambient temperature, C-16 Analog Inputs, 3-10 Addresses, 2-10 analog outputs, 2-10 Analog termination panel, C-12 application software, 7-3 ARC.A, 4-45 Atmosphere, C-16 attributes, 7-3, 7-11 Auto test, 13-39
B
background loop, 7-15 Base (number), 4-37 Basic I/O, 7-14 extended, 2-10 integrity checks, 10-13 Batteries disposal, 8-25 Battery replacement, 10-2 Battery supply monitor, 10-6 board identifiers, 3-9 BOOT EEPROM, 7-12 Boot-up faults, 10-4
Issue (12-2-98)
Index Page 1
Index
Switch Setting, 5-11 Cyclic test module 40, 14-71
E
Early Power Fail Warning, 10-6 Earthing, 8-10, 8-24 cubicle, 8-25 incremental encoder, 8-24 Electrical connections power, 8-9 power terminals, 8-10 encoder, 3-11, 9-2 accuracy calculation, 6-5 alignment, 6-5 biphase, 14-1 clock accuracy, 6-6 clock resolution, 6-7 differential skew, 6-7 enable, 14-4 Interface Board, 3-11 line count, 6-7 power supply, 6-8 screening, 6-5 scribing error, 6-6 supply, 2-8 enhancement bus, 2-15 enhancement card HDLC, 3-9 issue information, A-10 environment, 2-11, C-16 altitude, 2-12 relative humidity, 2-12 equipment dimensions, 2-14 Equivalent circuit, 3-2 error messages keypad, A-11 ESP programming messages, 5-10 receiving data, 5-8 transmitting data, 5-8 ESP J/K Table Allocation, 5-7 ESP J/K table exchange, 5-7 ESP protocol, 5-2 execution cycle, 7-13 end of, 7-15 execution cycle scan time, 7-17
D
d.c. link, 2-1 Data Comments, 4-13 Datum position, 14-2 DBOUNCE, 12-2 DC fed drives, 1-4 DC feeder, 1-4 DC link capacitance, 6-19 DC link control module 99, 14-228 dc link current limit, 6-18 DC link voltage control module 197, 14-239 de-rating temperature, 2-2, 2-5 Dead time compensation, 13-9, 13-32 deadband, 14-127 DEF module, 7-10 DEF table, 7-10 limits, 7-11 scaling, 7-11 text string, 7-11 DEFine commands, 7-10 degree of protection, 2-14 DELTA drives, 2-7 DELTA modules, C-14 Delta power modules, C-13 Derating altitude, C-16 Derivative control, 7-18 differential skew, 6-7 digital inputs Basic I/O, 2-9 dedicated, 2-8 Voltage, 2-9 digital outputs Basic I/O, 2-9 Current Rating, 2-9 Dimensions fixing centres, 8-2 GD4010 to GD4060, 8-2 GD4080 to GD4160, 8-3 line reactor, 8-5, 8-7 Precharge box, 8-4 Disposal dismantling for, 8-25 Disposal instructions, 8-25 Downloader, 4-32 Drive ID, 3-8, 7-16 drive identity, 2-8 Drive Mode Selection, 4-44 drive status, 7-16 Dynamic limits, 13-7 dynamic response, 7-18
F
Fast history, 13-43 fast oscilloscope outputs, 9-12 Fast Task, 7-1, 7-17 fast task schematic diagrams, 7-20 fault codes firmware generated, 10-5 Fault display, A-7 module 32, 14-47 using the keypad, A-7 Fault finding, 10-1 feedback filter, 7-19 FIP network card, 1-5 firmware, 7-3
Index Page 2
Issue (12-2-98)
Index
Firmware database, 4-3, 7-4, 9-2 Firmware database (ARC.A), 4-45 Firmware:Reference, A-9 firmware:system software, 7-3 Flux and torque IT tables module 94, 14-209 flux vector control, 1-1 Fuses selection, 6-4 drives, 8-8 precharge box, 8-9 Integral control, 7-18 integral gain, 6-10 issue information using keypad, A-9
J
Jog circuits, 14-21 jog control, 14-130
G
GD DELTA, C-14 General purpose functions module 300, 14-244
K
Keypad, A-1 - A-14 password level, A-7 access levels, 7-3 configuration, A-5 control keys, A-3 digital I/O, A-4 disconnecting, A-10 edit parameter, A-8 editing, A-3 error messages, A-11 fault display, A-7 functions of, A-6 issue information, A-9 language selection, A-9 LED indicators, A-5 menu options, A-6 monitor parameter, A-8 monitoring, A-3 monitoring a parameter, A-6 password, A-7 RS232 port, A-1 serial link failure, A-6 Specification, 2-11 Keypad Edit, A-8 Keypad LEDs, A-5 Keypad Messages, A-7 Keypad Mode, A-8 Keypad Monitor, A-8
H
HALT/RUN status, 7-15 HALT/RUN transition, 7-14 HDLC enhancement card, 1-5, 3-9 HDLC driver module 48, 14-88 header drive reference, 7-8 drive title, 7-8 fast task, 7-8 firmware reference, 7-8 issue number, 7-8 heat dissipation, 2-13 Heat loss, C-16 high performance cooling system, 3-12 high voltage drives, 1-1, 1-3 History record, 13-43 hold-up time internal supplies, 2-8
I
I/O Processor, 7-12 Identification of components, C-15 incremental encoder, 3-4, 3-11 earthing, 8-24 line count, 6-7 line receiv, 2-10 power supply, 8-25 Inductance total network, 6-19 Inertia total system, 6-12 inrush current SMPS, 6-14 installation category, 2-13 Installing
L
ladder tables, 12-48 A tables, 12-45 ABS, 12-9 ANALAG, 12-27 B tables, 12-45 blocks, 12-2 C tables, 12-46 COMPARE, 12-31 CONFIG, 12-41 D tables, 12-46
Issue (12-2-98)
Index Page 3
Index
data tables, 12-45 DEDBAND, 12-21 E tables, 12-46 F tables, 12-47 FGEN, 12-19 FILL, 12-38 GDMMOD, 12-30 HISTATE, 12-6 I tables, 12-48 K tables, 12-48 LIMIT, 12-24 LINCON, 12-12 LOCATE, 12-16 MAX, 12-34 MIN, 12-34 MOVE, 12-39 NEGATE, 12-8 NONZERO, 12-9 OUTPUT, 12-10 P tables, 12-48 SIN, 12-29 special functions, 12-2 SQRT, 12-14 SWAPE, 12-28 V tables, 12-49 Ladder Diagram Rung Comments, 4-12 ladder editor subsequent level menus, 4-12 top level menu, 4-10 LADDER EDITOR F1, 4-7 Contract Text, 4-8 Data Comments, 4-8 Instruction set, 4-8 Issue information, 4-8 Mnemonics, 4-8 Printing, 4-8 Rung Comments, 4-8 Search, 4-8 System Text, 4-8 ladder instructions, 12-1 Ladder Program (.GLP), 4-46 language, 7-8 LEDs Customer I/O board, 10-6 Power Supply, 10-6 SIGMA core board, 10-4 LEDs:Keypad, A-5 limits, 7-10 line reactor, 2-2 Linear conversion module 55, 14-100 Link attribute, 7-9 Links Editing, 4-22 links editor attributes, 7-11 comments, 7-12 Commissioning Edits, 4-22 DEFine commands, 7-10 Edit Existing File, 4-19 Error Messages, 4-24 Links Editing, 4-22 New File, 4-19 password protection, 7-11 Portability, 4-21 Print, 4-23 Search, 4-22 Selecting File Name, 4-19 table descriptions , 7-12 Text Entry, 4-22 links editor:Description, 4-19 links editor:Display, 4-20 links program, 7-8 editing, 7-9 function, 7-9 Header, 7-8 rules, 7-9 Links Program (.GDM), 4-46 List File (.LST), 4-46 LIST FILE VIEWING UTILITY F6, 4-41 load power factor, 6-13 location of files database, 4-43 program, 4-43
M
Mains synchronisation, 13-14 Maintenance, 10-1 memory Checks, 7-12 Message File (.MSG), 4-47 messages system, A-7 trip, A-7 Mnemonics, 4-12 MODBUS, 5-2 addressing, 5-9 Functions, 5-8 statistics, 5-9 using, 5-8 MONITOR F5 Address, 4-38 Display, 4-35 Error Messages, 4-40 Function Key Details, 4-37 SIGMA Attributes, 4-40 User Keys, 4-37 Variable Display, 4-38 monitoring, 9-2 monitoring parameters using the keypad, A-6 motor magnetization curve, 9-11 motor data checking, 9-9 motor model, 3-2, 9-3 Motor parameters estimation, 6-9 motor selection, 2-7
Index Page 4
Issue (12-2-98)
Index
network bridge, 3-1 network bridge parameters, 6-18, 6-20 network inductance calculation, 6-19 network voltage configuration, 6-15 Normal Inputs, 4-38 Normal/Commissioning Program, 4-23 Power topologies, C-5 power topology fast task type], C-5 Power Up, 7-12 Print Links Program, 4-23 Printing Ladder, 4-13 Product reference, 7-9 Programmer Set Up F7, 4-41 Colour Selection, 4-44 Current Data, 4-43 Drive Filename Selection, 4-42 Drive Mode Selection, 4-44 proportional control, 7-18 proportional gain, 6-10 protection degree of, 2-14 Pulse width modulation, 3-4, C-16 PWM, 3-4, 13-7, 13-9, 13-17, 13-30, 13-32
O
OIS, 7-9 oscilloscope outputs, 9-12, 13-16, A-9 using the keypad, A-10 output bridge parameters, 9-3 output clamp, 7-19 output limits, 14-127 Overdrive, 13-48 overload current limited, 6-15 network voltage limited, 6-16 overload current, 2-2
R P
password, 7-3, 7-11, A-7 keypad, A-7 password level keypad, A-7 password levels, 7-12 PC Requirements, 4-1 PID alternative derivative input, 7-19 anti wind up, 7-18 bypassing, 7-19 checking speed loop values, 9-12 error value limiting, 7-19 feed forward input, 7-19 feedback scaling, 7-18 integral calculation, 7-19 output limiting, 7-19 test input, 7-19 PID regulator module 80, 14-102 PID, notes on, 7-17 PL4 Pin Out, 5-11 PL5 Pin Out, 5-11 polution degree, 2-13 Position control module 48, 14-79 Position feedback encoder A, 13-37 Position feedback.Encoder B, 13-52 Position measurement module 47, 14-75 Power factor network rectifier bridge, 2-6 power ratings, 2-1 Power supply LEDs, 10-6 requirements, 2-5 radio frequency emissions, 2-14 Radio frequency emissions, C-16 radio frequency interference, C-16 susceptibility to, 2-14 ratings thermal current, 2-4 re-rating factors, 2-5 altitude, 2-5 ambient temperature, 2-5 frequency, 2-5 voltage, 2-5 Receipt of equipment, C-15 Reciept of equipment, 8-1 Reference circuits module 22, 14-21 Reference logic module 30, 14-42 relative humidity, 2-12, C-16 rotor inductance, 6-10 Rotor Time Constant compensator module 81, 14-104 Run logic module 28, 14-38
S
scaling, 7-10 scan time, 7-17 Scope Outputs, A-9 - A-10 Scribing errors, 6-6 Segregation, 8-12, C-21 cabling, 8-25 serial communications, 1-4, 2-11 Serial link connections, 5-5 fault diagnostics, 5-4
Issue (12-2-98)
Index Page 5
Index
RS485, 8-13 Serial link 1, 5-5 Serial Link 2, 5-6 Serial Link 3, 5-6 tributary address, 5-3 Serial link 1 fault diagnostics, 5-5 Serial link 2 connections, 5-6 fault diagnostics, 5-6 Serial link 3 configuration, 5-7 connections, 5-7 fault diagnostics, 5-7 serial links, 5-1, 7-15 connection details, 5-10 ESP Programming messages, 5-10 supply, 2-8 Serial Links:Statistics, 5-9 Set Up File (CSP.DAT), 4-47 seven segment display, 10-4 SIGMA control module, C-10 core board identification, 2-8 sigma calculation, 6-13 SIGMA core board, 2-8 LEDs, 10-4 Single Cycle, 4-37, 7-17 single scan mode, 7-17 sinusoidal rectifier, 3-1 Siting considerations, 8-1 Skew compensation, 13-17 Slow history module 35, 14-60 slow task, 7-17 SMPS, C-13 Early power fail indication, 3-12 Outputs, 2-7 SMPS inrush current, 6-14 Software Modules 00S060-4004 database, 7-4 00S060-4005 database, 7-6 Speed control module 92, 14-205 Speed feebback, 3-4 speed loop tuning, 6-11 Speed measurement module 20, 14-1 Speed/torque loop tuning, 6-11 Speed/voltage control module 21, 14-13 module 22, 14-242 stability, 6-20 Staircase smoothing module 44, 14-73 standards, 2-15 star equivalent, 9-3 start-up sequence, 7-12 stator inductance, 6-10 storage, 2-13, 8-1, C-15 Supplies Internal, 2-7 Supply frequency, 2-6 supply voltage, 2-5 selection, 8-9 symbols, 7-8 system firmware power up, 7-12 self tests, 7-15 supply checks, 7-14 system inertia calculation, 6-12 system messages, A-7
T
table descriptions , 7-12 Test Inputs, 4-38 Test/local control module 31, 14-44 TEST/NORMAL status, 7-16 text comments, 7-10 Text Entry, 4-22 Thermal current ratings, 2-4 thermistor checks, 9-7 Top level menu, 4-5 torque loop tuning, 6-11 transformer secondary voltage selection, 6-16 trip instantaneous overcurrent, 2-2 messages, A-7 Trip History, 13-43
U
Uploader, 13-49 user program, 9-2 USERPROG, 7-9
V
vector control, 1-1, 3-1 Ventilation, C-16 Voltage levels, 10-1 VVVF, 3-4 VVVF control, 1-2
W
Warning messages, 10-3 watchdog, 7-16 catastrophic failure, 10-15 connections, 8-21 relay, 2-11 trip, 10-14 Trip Numbers, 10-9 Watchdog Circuit, 10-8
Index Page 6
Issue (12-2-98)
Index
XILINX, 10-11
Issue (12-2-98)
Index Page 7
Alspa GD4000
Glossary
Glossary
ADC (Analog-to-Digital convertor) A device which converts an analog input signal into a digital output signal. Alphanumeric Containing both letters and numbers Analog Continuously variable, as distinct from variable in discrete steps. ASCII Short for American Standard Code for Information Interchange. This is a 7-bit code basically consisting of 32 control codes and 96 character codes. It is widely used for data transmission, especially in the data messages sent to printers and VDUs. Asynchronous Motor Another name for an induction motor. Base Drive and Gate Drive Printed circuit assembly containing circuits for: Baud The unit for the measurement of the rate at which data is transmitted during data communications. 1 Baud = 1 bit of information/second. As virtually all communications uses just two signal levels (one for 0 and one for 1), Baud can normally be taken as synonymous with bits/second. Binary Numerical representations using 1s and 0s or ON and OFF states only. The digits in a pure binary number have weightings in ascending powers of 2, i.e. 20, 21, 22, 23, 24 etc. Thus, decimal 79 = binary 1001111 (64+8+4+2+1) Broadcast Serial link transmission by a control port of a common message to all tributary ports on a network, rather than sending separate messages one at a time to each secondary port. Broadcast messages therefore get the information to the secondaries quicker, but the secondaries cannot then immediately acknowledge the message. Closed Loop Control A control system in which a measurement is continually made of the quantity being controlled, and compared against a reference value. Corrective action is then taken as necessary to reduce the difference between the reference signal and the measurement signal. Commissioning The process of setting a newly installed equipment or system to work, and checking that it performs to the design specifications after installation. Control Port A serial port that acts as the master port on a serial link. It exercises control over the message traffic on a serial link network (ie a control port can initiate a message transaction). See also Tributary port.. Convertor Power electronics circuit that changes one or more of the properties of the power supply, e.g. frequency, magnitude, or a.c.-to-d.c.
signal isolation between control and power stages; the generation of appropriate voltage or current driving
pulses for the base of bipolar power transistors, or the gates of IGBTs, or GTO thyristors. The printed circuit may also contain circuits for monitoring the performance of the driven device, e.g. for overcurrent protection. Base Frequency On an a.c. drive, the frequency of the power output from the drive determines the speed of the motor. So as to keep the flux constant, the voltage is made proportional to the frequency (see: V/F Ratio). However, at a certain frequency, the maximum voltage of which the drive is capable is reached. This is called the base frequency of the drive. Base Speed Base speed is the speed at which a motor runs when supplied at full rated voltage from the drive output, with full field strength and with the motor providing full load torque.
Issue (12-2-98)
Alspa GD4000
Glossary Page 1
Glossary
CRC (Cyclic Redundancy Check) A method of checking the integrity of data. CRC checks are often used to check data transmitted over communications links or to check data being read from magnetic or other media. Current Fed Start The drive operates as a constant current source during start up. The constant current is maintained at the current limit by varying the voltage applied to the motor. DAC (Digital-to-analog convertor) Electronics device that converts a digital input signal into an analog output signal. D.C. Link In the GD 2000 the power circuit, the alternating supply voltage is rectified to a direct voltage. Filtering and energy storage components form the d.c. link to the inverter bridge. The two main components are the d.c. link choke and the d.c. link capacitor bank. DC Injection Braking DC current is injected into the motor for a short period of time to establish a magnetic flux in the stator. This gives increased the braking torque and a zero speed braking torque. Digital A digital circuit is one that responds only to discrete input voltage levels, and whose output consists only of discrete voltage levels. Usually, only two voltage levels are recognized. Disturbance Any undesired change of variable affecting the operation of the plant. The main purpose of closed loop control systems is to hold the output variable at the correct value despite disturbances. Not all disturbances are rapid. Some are (e.g. change of load torque applied to a drive, changes on power input voltages), but others are slow (e.g. changes in ambient temperature). Dynamic Braking A method of braking which is depends on the motor to generate a braking effect. This is achieved by using the motor and inverter to convert the kinetic energy of the load back in to electrical energy, which is then dissipated in a resistor, under the control of a Dynamic Braking Unit. Earth (Ground) 1. Safety Earth
Alspa GD4000
Earth connection used for safety purposes in case of electrical insulation breakdown. Safety earth connections must be permanently and directly connected to earth without fuses or links; they must use cable of a heavy enough gauge to conduct any fault currents without the equipment voltage rising to levels unsafe for personnel. 2. Signal Ground Noise-free earth connection used for the 0V of the control electronics. Encoder Device coupled to the motor shaft that provides feedback information about the position/speed of the motor armature or rotor. Encoders are of two types: 1. Incremental See: Pulse Generator. 2. Absolute Provides a number representing position. The speed of the encoder can be deduced by subtracting one position number from another position number measured a given time apart. An absolute encoder does not lose its datum on power outage, and therefore requires no zeroing procedure. Error Signal The difference between the reference (setpoint) signal and the feedback (measured value) signal on a closed loop control. Under steady state conditions, error signals tend to zero on controls that include integral action. ESP (Extended Simple Protocol) Standard protocol for serial link communications by CEGELEC Industrial Control products. ESP gives a very high confidence that data transmission errors are detected at the receiving end of the link and that detected errors are corrected by automatic retransmission.
Glossary Page 2
Alspa GD4000
Issue (12-2-98)
Alspa GD4000
Fan Fluxing The torque characteristics of an ac motor connected to a variable frequency ac drive are determined by the relationship between voltage and output frequency. Some motor loads such as pumps and fans have a torque characteristic which is proportional to the square of the motor speed. Fan fluxing provides a square law output voltage/frequency relationship to match torque of the motor to a fan or pump type load. Fast Fluxing Start DC current is injected into the motor to establish the magnetic flux before rotation begins. This gives high starting torque with fast acceleration, but causes a short delay before the motor begins to rotate. Feedback Signal In a closed loop control system, a signal taken from the output being controlled, normally isolated from it and scaled to electronics levels (e.g. +10V full scale). The closed loop control compares this signal against the reference signal so as to determine what action to take if it is not of the correct value. Forced Ventilation (F.V.) Ventilation where cooling is effected by a ventilation fan. History Record A diagnostic aid and a feature of the GD 2000 series of drive units, whereby specified drive data is recorded, while the drive is operating and can be replayed later. IGBT (Insulated Gate Bipolar Transistor) A power semiconductor device, used to switch the three phase power output of the GD 2000 series of drives. Induction motor A form of motor having a 3-phase stator winding and a passive cage rotor. As the rotor has no commutator, slip rings or brushgear, an induction motor is rugged and relatively maintenance free. Formerly, induction motors were always connected to the a.c. supply and therefore ran at a nominally constant speed. When connected to a variable frequency drive unit such as GD2000 an induction motor can be used for variable speed and torque applications which previously would have required a dc motor. Inertia A measure of the tendency of a mechanical body to resist any change to its present state of motion.
Glossary
For an object that rotates such as a motor, its inertia defines how much torque it requires to make it accelerate at a certain rate. For a drive system, the total inertia will consist of the moment of inertia of the motor and the rotational or linear inertia of the equipment being driven. Inertia Compensation Additional current reference, often provided on tension control systems as an open loop correction, that calls for the portion of motor current required to accelerate the drive. The signal is required where no tension feedback from a tension transducer is available, or where the response of this feedback cannot be made fast enough. Input Term applied to all signals coming from the plant and/or the operator into a functional device or item of equipment. Integral Control Closed loop control in which the control amplifier (if analog) or control algorithm (if digital) includes an integral term. The output from an integral term tends to ramp up or down as long as there is any input signal, and only stops moving when its input is zero. If the input signal is, in fact, the error between the reference and feedback for a particular quantity, then integral control will tend to make the feedback signal exactly equal to the reference, in the steady state. Interlock Any hardwired circuit or software algorithm ensuring that operations are carried out in the correct sequence. This is particularly important on the start up and shutdown of a drive. On many types of drive and industrial plant, operations carried out in an incorrect sequence can result in equipment damage or personnel hazard. Inverter Equipment which converts a d.c. input into an a.c. output. Inverting Bridge An electrical circuit which converts a dc input to an ac ouput. IR Comp See: Voltage Control with IR Comp.
Issue (12-2-98)
Alspa GD4000
Glossary Page 3
Glossary
I2T A quantity proportional to the total heat produced by a given current I. The power dissipated in resistance R equals I2R. For a fixed value of resistance, the energy dissipated in a given time t is therefore proportional to I2T. This quantity is often referred to in the context of devices, circuits and algorithms, that provide protection of motors and power semiconductor devices. Leg Memory That part of a bridge circuit that has one a.c. line connection and one d.c. output connection. Limits In a control system, circuits (analog) or algorithms (digital) that prevent variables exceeding safe values, despite what is done to the reference by an operator, programmable controller or computer, or to the load. Line (a.c.) Monitoring The incoming a.c. supply wires or busbars. Measured Value
Alspa GD4000
Synonym for feedback signal, used more widely in process control than motor control. In a closed loop control system, it is the signal taken from the output being controlled, normally isolated from it and scaled to electronics levels (e.g. +10V full scale). The closed loop control compares this signal against the setpoint signal so as to determine what action to take if it is not of the correct value.
The storage space on a microprocessor-based drive that a user can store data or instructions in. It also includes internal work space used by the processor but not visible to the user. Module An assembly designed to be easily removable for maintenance or replacement.
The observation of the working of a system or equipment. Link Multidrop Serial Link 2. Link for a.c. drives: See DC Link. 3. Link for serial I/O: See Serial Link. Load 1. Convertors The circuit connected to the convertor output terminals. Normally consists of a motor armature, or a motor or generator field, or, on an a.c. drive, an inverter. 2. Inverters The 3-phase circuit connected to the inverter output terminals. Normally consists of an a.c. induction motor. 3. Motors The torque applied mechanically to the motor by the process being driven. The purpose of a drive system is to control the motor torque so as to balance the applied load. Serial link using the same wires to connect a controller to two or more tributary devices e.g. drives or programmable controllers. Natural Ventilation (N.V.) Ventilation where all the cooling is by natural convection. Non-inverting Bridge A bridge that is NOT capable of returning energy from the load to the a.c. supply. Open Loop Control A control system that has no feedback from any measurement transducer. Optical Isolation Means of achieving a high degree of electrical isolation between conductors in different parts of a system. Uses a light source in one circuit to activate a light sensitive device in a second electrically separate circuit. Besides preventing the imposition of high voltages on sensitive electronic equipment, it also prevents the passage of high frequency electrical interference. Parameter A value placed in a specific location in memory which is used to control the operation of GD2000 and to provide information about the operation of the drive.
Glossary Page 4
Alspa GD4000
Issue (12-2-98)
Alspa GD4000
Point-to-Point Serial Link A serial communications link connecting a controller to a single tributary. Position Control Closed loop control in which the position of some output shaft or device must follow a position reference. Accurate position controls are always digital to avoid drift. They usually incorporate speed inner loops with speed limits to prevent excessive speed being called for on large position movements. Program Set of logical instructions that determines the behaviour of a microprocessor-based drive. Normally, the term is used to refer just to the instructions provided by the user as the user program. In addition, the microprocessor obeys program instructions provided as firmware permanently built into a drive during manufacture. Pulse Generator A speed transducer producing pulses at a rate proportional to speed. Before it can be used, the pulse train has to be converted into an analog signal or a digital number (e.g. by counting pulses over a defined time interval). PWM - Pulse Width Modulation. 2. Motor A method of controlling power output of a drive, by switching the output, which has a fixed voltage, on and off. The total period of the on off cycle is fixed at a constant value and power is varied by altering the mark space ratio ie the time switched off compared to the time switched off within the fixed period. Rated Speed For an induction motor, the shaft speed of the motor when operating at rated voltage and supply frequency with rated torque applied. The rated speed will be less than the corresponding synchronous speed by a fraction of synchronous speed called the rated slip. Rectifier A circuit that converts a.c. to d.c. Reference A signal (analog or digital) representing the required value of the quantity being controlled. Synonym for setpoint, the term more commonly used in process control, whereas reference is more commonly used in motor control. Regeneration The returning of power from a motor back into the supply or into a resistor.
Glossary
With a d.c. motor, regeneration can occur if the motor is fed via a full controlled convertor of a type capable of inversion, and if the control system is suitably designed. With an a.c. motor, regeneration occurs when power flows from the motor back through the inverter to the d.c. link. So as not to cause the d.c. link voltage to rise and the drive to trip as a result of Overvoltage, this regenerated energy can be accommodated in one of two ways:
the regenerated energy can be dissipated in a resistor

connected across the d.c. link (resistive regeneration) under the control of a dynamic braking unit.
if the drive is equipped with a convertor capable of

inversion, the regenerated energy can be returned to the supply as for the d.c. drive case. Regulation 1. Supply The regulation of the supply from a source of power is the fractional drop in volts that occurs when the current drawn is increased from zero to the rated (full load) current. Thus, a transformer will be said to have a 7% regulation if its output voltage falls from 100% (when open circuit) to 93% (when in a circuit drawing full load current).
The regulation of a motor (on its own, not controlled by a drive) is the fractional drop in speed that occurs when the torque on its shaft is increased from zero to the rated (full load) torque. Thus, a motor is said to have a 5% regulation if its speed falls from 1500 rev/min to 1425 rev/min when full load torque is applied to its shaft. The regulation of a motor is normally quoted in terms of base speed. See also Slip. 3. Drive The regulation of a drive is measured in the same way as for a motor. However, where the drive incorporates a closed loop speed control, for instance, regulation depends on the characteristics of the drive, not on those of the motor. The regulation of a drive is normally quoted in terms of base speed of the motor. Resolution The smallest change of reference or setpoint to which the control must respond. In digital systems, the resolution cannot be better than 1 bit, but may be worse depending on the system. In an analog system, the resolution may be defined as the smallest change in voltage, current, speed, etc., that the system will respond to.
Issue (12-2-98)
Alspa GD4000
Glossary Page 5
Glossary
Resolver Position transducer that resolves an angular position into sine and cosine components. It is in effect a transformer where the coupling between windings varies with angle. Resolvers normally operate at frequencies of 400 Hz and above. May also be used as a speed transducer on systems that can detect the change in position over a defined time interval. Ribbon Cable Flat cable of multiple conductors with insulation joined edge-to-edge in the form of a ribbon. You can make connections between plugs or sockets and ribbon cable in a single, simple operation that bares and connects all the wires at once. Scaling The multiplication of any signal or parameter value by a factor. Serial Link Snubber Circuit Data communication path that carries signals one after another (serially) along a pair of wires, rather than simultaneously along several wires in parallel. Serial Link Protocol
Alspa GD4000
Single Ended Non-inverting (SENI) Convertor A single bridge giving only one polarity of output and incapable of transferring energy back into the supply. Slip When load torque is applied to the shaft of an induction motor, the shaft speed drops. If this speed drop is expressed as a fraction of the synchronous speed of the motor, then this quantity is called the slip. Thus, if a motor is operating at a synchronous speed of 1200 rev/min and, because of load torque, is running at 1080 rev/min, then it is said to be running with a slip of 0.1 (or 10%). See also: Rated speed; synchronous speed. Slip Compensation An adjustable control on GD2000 series drives. It attempts to compensate for changes in motor speed (or slip) caused by changes in load torque. The drive output frequency is increased in response to an increase in motor current.
A circuit fitted to protect power semiconductor devices against voltage or current surges. Snubber circuits are used:
in convertors, across thyristors or diodes to limit the

Definition of the way in which data to be communicated is packaged for transmission serially along a link. The protocol allows the data to be routed to the correct destination, and allows for error detection and correction. The Alspa GD series of drives generally drives support three protocols, GEM80 ESP which is also used by GEM80 programmable controllers, MODBUS ASCII and MODBUS RTU which are used by GEM80-16 controllers. Serial Port A serial link interface of a drive unit or controller i.e the output connector and the associated internal circuitry and logic. Setpoint A signal (analog or digital) representing the required value of the quantity being controlled. Synonym for reference, the term more commonly used in motor control, whereas setpoint is more commonly used in process control. Signal Ground See Induction Motor. See: Earth voltage stress on them due to stored charge recovery effects;
in inverter circuits, to limit the rate of rise of voltage

across a device that has been commutated off;
in some inverters, to limit the rate of rise of current in a

device that has been commutated on. Software Any program in a microprocessor-based system (drive or programmable controller). Usually taken to mean a user program, as the built-in executive software programmed into the system when manufactured is normally referred to as firmware. Speed Control Closed loop control of motor speed using a speed feedback signal. In most cases, this signal comes from a tachogenerator, but on digital systems may on occasion be taken from a pulse generator or resolver. Squirrel Cage Motor
Glossary Page 6
Alspa GD4000
Issue (12-2-98)
Alspa GD4000
Stall The condition of a motor when stationary but producing a torque. Status Operational condition of a GD2000 or GEM80 programmable controller e.g. Stopped, Running, Healthy, Tripped. Steady State Regulation The steady state regulation of a drive is the drop in motor speed, expressed as a fraction of base speed, that occurs after full load torque has been applied to the motor output shaft, measured after sufficient time has elapsed for any transient effects to have died away. Speed controlled drives incorporating speed feedback and integral action in the controller have zero steady state regulation. Striker Pin Fuse (S.P.F.) Sometimes referred to as a Trip Indicator Fuse. It indicates when a main fuse has ruptured. The striker pin consists of a spring-loaded plunger with the spring held under compression by a high resistance fuse wire. Rupture of the fuse wire releases the plunger which, normally, operates the microswitch. Suicide Variable The killing off of any residual voltage from a generator, convertor or inverter before any contactor or circuit breaker completing the motor armature or stator circuit is closed. Synchronous Speed The theoretical operating speed of an induction motor on no-load (with no torque applied to the motor shaft) at a particular supply frequency. This is given by the formula: Synchronous speed = (Supply frequency x 120)/No. of poles For instance, the synchronous speed of a 4-pole induction motor on a 50 Hz supply is 1500 rev/min. See also: Slip. Tension Control A control system trying to maintain tension, usually in strip material. Often associated with unwinding and rewinding the strip, a process rather like that on a tape recorder. 1. Physical Quantity Toggle
Glossary
Any action that has two stable states. Often used for the action of any key on a keypad where successive presses of the key cause alternating results. eg the mode key toogles between Parameter value and Parameter number each time it is pressed. Torque Control A control system setting the torque provided by a motor. It is usually difficult to directly measure torque, and therefore a torque control will generally set the torque indirectly. Tributary Port A serial communications port which can only respond to messages addressed to it by the control port on the link. A tributary port cannot initiate a message transaction. Uncontrolled Convertor Otherwise called an uncontrolled rectifier. Consists of a bridge in which all the legs contain diodes. Has the ability to rectify only, with no ability to control the output voltage. Unit A self-contained piece of equipment or assembly.
Any quantity, whether controlled or not, that changes during system operation and affects the system. Typical variables on a motor control system are convertor output voltage, armature loop current, field current, ambient temperature etc. 2. Program variable Any data value in a program that changes during system operation. Some program variables will correspond to physical quantities (i.e. to external variables) whereas other data values will be used just for internal calculation purposes (internal variables). Vector Control A technique used to maintain optimum spatial orientation between the effective flux and the rotor current in a.c. machines to give d.c. motor equivalent performance. See: Field Orientation control; Voltage Vector.
Issue (12-2-98)
Alspa GD4000
Glossary Page 7
Glossary
V/F Ratio To maintain a constant flux within the motor, the applied voltage is made proportional to the output frequency. This avoids magnetic saturation at low frequency and maintains torque at high frequency. See also Base frequency. Voltage Boost The output voltage of the drive is the increased at low output frequencies to compensate for the voltage drop in the stator of the induction motor. Voltage Boost is needed to maintain torque at low speeds. Voltage Source A voltage source inverter has a voltage-stiff d.c. link by virtue of the use of a large value of d.c. link capacitance connected across the power input to the inverter bridge. This is in contrast with a current source inverter, which has a current-stiff d.c. link by virtue of a large value of d.c. link inductance connected to the inverter bridge. All Alspa GD-AC equipments manufactured at Kidsgrove are of the voltage source type. Some of those manufactured at Rugby are of the current source type. Voltage Vector
Alspa GD4000
A method of calculating PWM patterns that differs from the sinusoidal method. It determines the spatial position of the voltage vector. Watchdog Circuit devoted to checking the health of a controller, used both in microprocessor-based drives and programmable controllers. To achieve a high confidence of fail-safe operation, the final device in a watchdog is a relay that is de-energized under fault conditions. A volt-free contact of the relay is provided for you to include in the power supply switching and distribution circuits to achieve a safe shutdown appropriate to the application. Self test procedures and duplication of the watchdog hardware guard against failure of a watchdog circuit. Watchdog circuits usually depend on hardware timer circuits that must be reset within a given time window by the microprocessor. If the microprocessor fails to do this, then the controller will shut down.
Glossary Page 8
Alspa GD4000
Issue (12-2-98)

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Alspa GD4000

Technical Manual for products GD4010 to GD42262

Publication No. T1656 Alcatel Alsthom 1998.

Symbols Used in GD4000 Equipment

PROTECTIVE EARTH TERMINAL. THIS MUST BE CONNECTED TO EARTH (GROUND).

CAUTION, READ INSTRUCTION BOOK.

WARNING, DANGER OF ELECTRIC SHOCK

ATTENTION, OBSERVE PRECAUTIONS FOR HANDLING ELECTOSTATIC DISCHARGE SENSITIVE DEVICES.

CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH

is broken, medical advice should be sought.

. . 10-21 . . 10-26 . . 10-28 . . 10-28

11-1 11-1 11-1 11-2 11-2 11-4 11-7

. . . 11-10 . . . 11-13 . . . 11-16

14-1 14-1 14-1 Page xvii

B-1 B-1 B-1 B-2 B-2 B-3

. . C-7 . C-10 . C-12 . C-13 . C-13 . C-14 . C-14 . C-14

C-27 C-27 C-27 C-27 C-30 C-34 C-35 C-35

D-1 D-1 D-1

H-1 H-1 H-1 H-2

This page has been left blank for pagination purposes.

Large common BDM frame size: GD4080 GD4120 GD4160

Figure 1-3 Typical large DELTA drive (GD4846 shown)

conditions. Full Microprocessor Control

High Speed Serial Communications

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Shaft Power 380 V 50 Hz kW 4.4 9.4 14.1 19 29.1 38 60 82

Shaft Power 415 V 50 Hz kW 4.8 10.2 15.4 20.7 31.8 41 65 90

Shaft Power 460 V 60 Hz kW 5.3 11.4 17 23 35.2 46 72 100

Shaft Power 480 V 60 Hz kW 5.5 11.9 17.8 24 36.8 48 75 104

Continuous Rating at 40oC (amps)

Drive Rating (kW

IEC Motor Frame Size (kW)

Continuous Rating at 40oC (amps)

Drive Rating (kW)

IEC Motor Frame Size (kW)

Output Current Ratings for GD4282 to GD41131 DELT A drives

Continuous Rating at 40oC (amps)

Drive Rating (kW)

IEC Motor Frame Size (kW)

Continuous Rating at 40oC (amps)

Drive Rating (kW)

IEC Motor Frame Size (kW)

Maximum Altitude Ductwork

Permissible tolerance Over-voltage transient withstand Notes:

Maximum airflow : : Fan motor overtemperature protection 2.2.4.2 :

Typical airflow Fan motor overtemperature protection

Drive Internal Supplies

These outputs are short-circuit protected.

Incremental Encoder Line Receiver

Selection will depend also on mechanical compatibility.

Composite 0.3 mm amplitude

0.032 mm from 10 Hz 0.032 mm amplitude 5 m/s2

1 m/s2 0.032 mm amplitude 5 m/s2 1 m/s2

1 m/s2 1 m/s2 1 m/s2

in polythene sheet to protect it from the ingress of dust.

Size And Weight

305 365 542 160

235 255 285 154

315 385 540 300

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Figure 3-1 Sinusoidal rectifier block diagram

Alspa GD4000 Technical Manual

Alspa GD4000 Technical Manual