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MP25A4
Emerson MP25A4 User Manual
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User Guide
Mentor MP
High performance DC drive
25A to 7400A, 480V to 690V
T
wo or four quadrant operation
Part Number: 0476-0000-03
Issue: 3
www.controltechniques.com
2
Table of Contents
Table of Contents
3
1 Safety Information
5
Warnings, Cautions and Notes
5
Electrical Safety - General Warning
5
System Design and Safety of Personnel
5
Environmental Limits
5
Access
5
Fire Protection
5
Compliance with Regulations
5
Adjusting Parameters
5
2 Product Information
6
Ratings
6
Table 2-1 Model to Frame Size Cross Reference
6
Table 2-4 690V Current Ratings
6
Table 2-2 480V Current Ratings
6
Table 2-3 575V Current Ratings
6
Model Number
7
Figure 2-1 Maximum Overload Duration Available
7
Figure 2-2 Model Number
7
Compatible Encoders
8
Nameplate Description
8
Figure 2-3 Typical Drive Rating Label
8
Table 2-5 Encoders Compatible with Mentor MP
8
Drive Features and Options
9
Figure 2-4 Drive Features and Options on Size 1
9
Figure 2-5 Drive Features and Options for Size 2
9
Table 2-6 Solutions Module Identification
10
Table 2-7 Keypad Identification
11
Table 2-8 Serial Comms Lead
11
Table 2-9 External Field Control
11
Items Supplied with the Drive
12
Table 2-10 Parts Supplied with the Drive
12
3 Mechanical Installation
13
Planning the Installation
13
Terminal Cover Removal
14
Figure 3-1 Removing the Control Terminal Cover (Size 1 Shown)
14
Figure 3-2 Removing the Finger-Guard Break-Outs
14
Figure 3-3 Installation and Removal of the Solutions Module
15
Figure 3-4 Removal and Installation of a Keypad
16
Mounting Method
17
Figure 3-5 Overall Size 1A Dimensions
17
Figure 3-6 Overall Size 1B Dimensions
18
Figure 3-7 Installing the Mounting Feet Bracket on Size 1 Drives
19
Figure 3-8 Overall Size 2A / 2B Dimensions
19
Figure 3-9 Size 2C Front View and Mounting Dimensions
20
Figure 3-10 Size 2C Back-Plate and Mounting Detail
21
Figure 3-11 Size 2D Front View and Mounting Dimensions
22
Figure 3-12 Size 2D Back-Plate and Mounting Detail
23
Installing and Removing the Terminal Shrouds
24
Figure 3-13 Mounting Methods of Size 2C / 2D Air Duct
24
Figure 3-14 Installing the Terminal Shrouds on Size 1 Drives
24
Figure 3-15 Removing the Terminal Shrouds on Size 1 Drives
25
Figure 3-16 Installing the Terminal Shrouds on Size 2 Drives
25
Enclosure
26
Figure 3-17 Enclosure Layout
26
Heatsink Fan Operation
27
IP Rating (Ingress Protection)
27
Figure 3-18 Enclosure Having Front, Sides and Top Panels Free to Dissipate Heat
27
Electrical Terminals
28
Figure 3-19 Location of the Power and Ground Terminals on Size 1 Drives
28
Figure 3-20 Location of the Power and Ground Terminals on Size 2A and 2B Drives
29
Figure 3-21 Location of the Power and Ground Terminals on Size 2C and 2D Drives
30
Table 3-1 Drive Control, Status Relay and Encoder Terminal Data
30
Table 3-3 Drive Power Stage Terminals on Size 1 Drives
30
Table 3-4 Drive Power Stage Terminals on Size 2 Drives
30
Routine Maintenance
31
4 Electrical Installation
32
Electrical Connections
33
Figure 4-1 Power Connections for 480V Drive
33
Figure 4-2 Power Connections for 575V / 600V / 690V Drives
34
Ground Connections
35
Figure 4-3 Location of Ground Connection on Size 1 Drives
35
Figure 4-4 Location of Ground Connections on Size 2A / 2B Drives
35
Figure 4-5 Location of Ground Connections on Size 2C / 2D Drives
35
AC Supply Requirements
36
Figure 4-6 Removing the MOV Ground Connection on Size 1 Drives
36
Figure 4-7 Removing the MOV Ground Connection on Size 2A / 2B Drives
36
Figure 4-8 Removing the MOV Ground Connection on Size 2C / 2D Drives
36
Line Reactors
37
Control 24Vdc Supply
37
Table 4-1 Three Phase AC Supply
37
Table 4-2 Minimum Required Line Inductance for a Typical Table 12-6 Application (50% Ripple Content)
37
Table 4-3 Terminal Functions
37
Table 4-4 Line to Line Supply
37
Table 4-5 Current Ratings
37
Cable and Fuse Size Ratings
38
Table 4-6 Typical Cable Sizes for Size 1 Drives
38
Table
39
Table 4-7 Auxiliary Wiring for Size 1 Drives
39
Table 4-8 Typical Cable Sizes for Size 2 Drives
39
Table 4-9 Auxiliary Wiring for Size 2 Drives
39
Table 4-10 Ferraz Shawmut Semiconductor Fusing for Size 1 Drives
40
Table 4-11 Ferraz Shawmut Branch Circuit Protection Fusing for Size 1 Drives
40
Table 4-12 Ferraz Shawmut DC Protection Fusing for Size 1 Drives
41
Table 4-13 Ferraz Shawmut Semiconductor Fusing for Size 2 Drives
42
Table 4-14 Ferraz Shawmut Branch Circuit Protection Fusing for Size 2 Drives
43
Table 4-15 Ferraz Shawmut DC Protection Fusing for Size 2 Drives
43
External Suppressor Resistor
44
Figure 4-9 Removing the Internal Field Fuses
44
Table 4-16 Mentor MP Size 1 Drive Thyristor I
44
Table 4-17 Mentor MP Size 2 Drive Thyristor I
44
Table 4-18 Recommended External Suppressor Resistors
44
Figure 4-10 Location of External Suppressor Resistor Terminals on Size 1 Drives
45
Figure 4-11 Location of External Suppressor Resistor Terminals on Size 2 Drives
45
Figure 4-12 Removal of Bucket Suppressor Terminals Cover on Size 2C and 2D
45
Ground Leakage
46
EMC (Electromagnetic Compatibility)
46
Figure 4-13 Protection Circuit for an External Suppression
46
Table 4-19 Minimum Allowable External Suppression Resistance
46
Table 4-20 Mentor MP and EMC Filter Cross References
47
Table 4-21 Emission Compliance
47
Serial Communications Connections
48
Figure 4-14 Surge Suppression for Digital and Unipolar Inputs and Outputs
48
Figure 4-15 Surge Suppression for Analog and Bipolar Inputs and Outputs
48
Figure 4-16 Serial Communications Port
48
Table 4-22 RJ45 Connections
48
Table 4-23 Isolated Serial Comms Lead Details
48
Shield Connections
49
Connecting the Fan on Size 2C and 2D Drives
49
Figure 4-17 Fitting of Grounding Bracket
49
Figure 4-18 Grounding of Signal Cable Shields Using the Grounding Bracket
49
Figure 4-19 Fan Connection
49
Control Connections
50
Table 4-24 Fan Supply Specification
50
Table 4-25 the Control Connections Consist of
50
Table 4-26 Control Connection Recommended Cable Sizes
50
General
51
Figure 4-20 Default Terminal Functions
51
Connecting an Encoder
54
Figure 4-21 Feedback Cable, Twisted Pair
54
Figure 4-22 Feedback Cable Connections
55
Table 4-27 Encoder Types
55
5 Getting Started
56
Understanding the Display
56
Keypad Operation
56
Figure 5-1 SM-Keypad
56
Figure 5-2 MP-Keypad
56
Figure 5-3 Display Modes
57
Figure 5-4 Mode Examples
57
Menu 0 (Sub Block)
58
Figure 5-5 Sub Block Navigation
58
Table 5-1 Keypad Navigation
58
Pre-Defined Sub Blocks
59
Menu 0 (Linear)
60
Menu Structure
60
Figure 5-6 Menu 0 Copying
60
Figure 5-7 Menu Structure
60
Advanced Menus
61
Saving Parameters
61
Restoring Parameter Defaults
61
Table 5-2 Advanced Menu Descriptions
61
Table 5-3 Menu 40 Parameter Descriptions
61
Table 5-4 Menu 41 Parameter Descriptions
61
Differences between European and USA Defaults
62
Displaying Parameters with Non-Default Values Only
62
Displaying Destination Parameters Only
62
Parameter Access Level and Security
62
Figure 5-8 User Security Open
62
Table 5-5 User Security and Parameter Access Levels
62
Serial Communications
63
6 Basic Parameters
64
Table 6-1 Pre-Defined Sub Block Parameters
64
Full Descriptions
65
Figure 6-1 Speed Feedback Filter Arrangement
68
7 Running the Motor
72
Table 7-1 Minimum Control Connection Requirements for each Control Mode
72
Quick Start Commissioning / Start-Up (from European Defaults)
73
Quick Start Commissioning / Start-Up (from USA Defaults)
75
Ctsoft Software Commissioning / Start-Up Tool
76
Setting up a Feedback Device
77
Armature Current
78
Speed Feedback
78
Field Current
78
Current Loop Gains Self-Tuning
78
Speed Loop Gains Tuning
79
Figure 8-1 Responses
79
Current Limit Tapers
80
9 SMARTCARD Operation
81
Introduction
81
Easy Saving and Reading
81
Transferring Data
81
Figure 9-1 Installation of the SMARTCARD
81
Table 9-1 SMARTCARD Data Blocks
81
Data Block Header Information
83
SMARTCARD Parameters
83
SMARTCARD Trips
84
10 Onboard PLC
86
Onboard PLC and SYPT Lite
86
Benefits
86
Limitations
86
Figure 10-1 Mentor MP Onboard PLC Program Scheduling
86
Getting Started
87
Onboard PLC Parameters
87
Figure 10-2 Programming Options for Mentor MP
87
Onboard PLC Trips
88
Onboard PLC and the SMARTCARD
88
11 Advanced Parameters
89
Table
90
Table
92
Menu 1: Speed Reference
94
Figure 11-1 Menu 1 Logic Diagram
94
Menu 2: Ramps
98
Figure 11-2 Menu 2 Logic Diagram
98
Menu 3: Speed Feedback and Speed Control
101
Figure 11-3 Menu 3 Logic Diagram
102
Menu 4: Torque and Current Control
104
Figure 11-4 Menu 4 Logic Diagram
104
Menu 5: Motor and Field Control
108
Figure 11-5 Menu 5 Field Control Logic Diagram
108
Figure 11-6 Menu 5 Armature Control Logic Diagram
110
Menu 6: Sequencer and Clock
112
Figure 11-7 Menu 6 Logic Diagram
112
Menu 7: Analog I/O
114
Figure 11-8 Menu 7 Logic Diagram
114
Menu 8: Digital I/O
116
Figure 11-9 Menu 8 Logic Diagram
116
Figure 11-10 Menu 8 Logic Diagram (Cont)
117
Figure 11-11 Menu 8 Logic Diagram (Cont)
118
Menu 9: Programmable Logic, Motorized Pot and Binary Sum
120
Figure 11-12 Menu 9 Logic Diagram: Programmable Logic
120
Figure 11-13 Menu 9 Logic Diagram: Motorized Potentiometer and Binary Sum
121
Menu 10: Status and Trips
123
Menu 11: General Drive Set-Up
124
Menu 12: Threshold Detectors, Variable Selectors and Brake Control Function
125
Figure 11-14 Menu 12 Logic Diagram
125
Figure 11-15 Menu 12 Logic Diagram (Continued)
126
Figure 11-16 Menu 12 Brake Control Function
127
Figure 11-17 Brake Sequence
127
Menu 13: Position Control
130
Figure 11-18 Menu 13 Logic Diagram
130
Menu 14: User PID Controller
134
Figure 11-19 Menu 14 Logic Diagram
134
Menus 15, 16 and 17: Solutions Module Slots
137
Menu 18: Application Menu 1
138
Menu 19: Application Menu 2
138
Menu 20: Application Menu 3
138
Menu 21: Second Motor Parameters
139
Menu 22: Additional Menu 0 Set-Up
139
Menu 23: Header Selections
139
Advanced Features
140
Table
140
Figure 11-20 Current Limit Versus Speed
143
Figure 11-21 Digital Input Connections When Pr 6.04 Is
143
12 Technical Data
145
Drive Technical Data
145
Figure 12-1 Maximum Overload Duration Available
145
Figure 12-2 Mentor MP Size 1A Derating for Extended Ambient Operation
146
Figure 12-3 Mentor MP Size 1B Derating for Extended Ambient Operation
146
Figure 12-4 Mentor MP Size 2A Derating for Extended Ambient Operation
147
Figure 12-5 Mentor MP Size 2B Derating for Extended Ambient Operation
147
Figure 12-6 Mentor MP Size 2C and 2D Derating for Extended Ambient Operation
148
Cable and Fuse Size Ratings
151
Table 12-10 Overall Drive Weights
151
Table 12-11 Typical Cable Sizes for Size 1 Drives
151
Table 12-12 Auxiliary Wiring for Size 1 Drives
152
Table 12-13 Typical Cable Sizes for Size 2 Drives
152
Table 12-14 Auxilliary Wiring for Size 2 Drives
152
Table 12-15 Ferraz Shawmut Semiconductor Fusing for Size 1 Drives
153
Table 12-16 Ferraz Shawmut Branch Circuit Protection Fusing for Size 1 Drives
153
Table 12-17 Ferraz Shawmut DC Protection Fusing for Size 1 Drives
154
Table 12-18 Ferraz Shawmut Semiconductor Fusing Alternatives for Size 1 Drives
154
Table 12-19 Ferraz Shawmut Semiconductor Fusing for Size 2 Drives
155
Table 12-20 Ferraz Shawmut Branch Circuit Protection Fusing for Size 2 Drives
156
Table 12-21 Ferraz Shawmut DC Protection Fusing for Size 2 Drives
156
Table 12-22 Cooper Bussmann Semiconductor Fusing for Size 1 Two Quadrant Drives
157
Table 12-23 Cooper Bussmann North American Alternative Semiconductor Fusing for Size 1 Two Quadrant 480V Drives Only
157
Table 12-24 Cooper Bussmann North American Alternative Semiconductor Fusing for Size 1 Two Quadrant 480V and 575V Drives
157
Table 12-25 Cooper Bussmann North American Alternative Semiconductor Fusing for Size 1 Two and Four Quadrant Drives
157
Table 12-26 Cooper Bussmann Branch Circuit Protection Fusing for 480V and 575V Size 1 Drives
157
Table 12-27 Cooper Bussmann DC Protection Fusing for 480V and 575V Size 1 Drives
158
Table 12-28 Cooper Bussman Semiconductor Fusing for Size 2 Drives
159
Table 12-29 Cooper Bussman Branch Circuit Protection Fusing for Size 2 Drives
160
Table 12-30 Cooper Bussmann DC Protection Fusing for Size 2 Drives
160
Table 12-31 Siba Semiconductor Fusing for 480V and 575V Size 1 Drives
161
Table 12-32 Siba Branch Circuit Protection Fusing for 480V and 575V Size 1 Drives
161
Table 12-33 Siba DC Protection Fusing for 480V and 575V Size 1 Drives
161
Table 12-34 Siba Semiconductor Fusing for Size 2 Drives
162
Table 12-35 Siba Branch Circuit Fusing for Size 2 Drives
163
Table 12-36 Siba DC Protection Fusing for Size 2 Drives
163
Table 12-37 Mentor MP Size 1 Drive Thyristor I 2 T Ratings for Semiconductor Fusing
164
Table 12-38 Mentor MP Size 2 Drive Thyristor I 2 T Ratings for Semiconductor Fusing
164
Table 12-39 Drive Control, Status Relay and Encoder Terminal Data
164
Table 12-40 Drive Auxiliary and Machine Armature Terminal Data
164
Table 12-41 Drive Power Stage Terminals
164
Table 12-42 Drive Power Stage Terminals on Size 2 Drives
164
Table 12-43 Immunity Compliance
164
Table 12-44 Emission Compliance
165
Optional External EMC Filters
166
Table 12-45 Mentor MP and EMC Filter Cross Reference
166
Trip Indications
167
Figure 13-1 Keypad Status Modes
167
Figure 13-2 Location of the Status LED
167
Table 13-1 Trip Indications
167
Trip Categories
174
Table 13-2 Serial Communications Look-Up Table
174
Table 13-3 Trip Categories
174
Alarm Indications
175
Status Indications
175
Displaying the Trip History
175
Behaviour of the Drive When Tripped
175
Trip Masking
175
Table 13-4 Alarm Indications
175
Table 13-5 Status Indications
175
Table 13-6 Trips
175
Table 13-7 Parameters Frozen on Trip
175
14 UL Information
176
Common UL Information
176
AC Supply Specification
176
Maximum Continuous Output Current
176
Safety Label
176
UL Listed Accessories
176
List of Figures
177
4
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Emerson MP25A4 Specifications
General
Model
MP25A4
Category
DC Drives
Amperage
25A
Input Voltage
115/230 VAC
Protection Features
Overload, Overvoltage
Voltage
115/230V AC
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