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Carotron EP2020-000 Instruction Manual

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Instruction Manual
Models
EP2020-000
EP2040-000
EP2060-000
EP2075-000
EP2100-000
EP2125-000
EP2150-000
EP2200-000
EP2250-000
EP2300-000
EP2400-000
EP2500-000
EP2600-000
EP2700-000
EP4020-000
EP4040-000
EP4060-000
EP4075-000
EP4100-000
EP4125-000
EP4150-000
EP4200-000
EP4250-000
EP4300-000
EP4400-000
EP4500-000
EP4600-000
EP4700-000
V3

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  • Page 1 Instruction Manual Models EP2020-000 EP4020-000 EP2040-000 EP4040-000 EP2060-000 EP4060-000 EP2075-000 EP4075-000 EP2100-000 EP4100-000 EP2125-000 EP4125-000 EP2150-000 EP4150-000 EP2200-000 EP4200-000 EP2250-000 EP4250-000 EP2300-000 EP4300-000 EP2400-000 EP4400-000 EP2500-000 EP4500-000 EP2600-000 EP4600-000 EP2700-000 EP4700-000...

  • Page 2: Table Of Contents

    Table of Contents 1. General Description ............................4 2. Specifications ..............................4 2.1 Electrical............................. 4 2.2 Physical .............................. 5 3. Installation ................................. 7 3.1 Control Installation ..........................7 3.2 Wiring Guidelines..........................7 4. Terminal Connections & Functions ........................7 4.1 AC Power Connections & Fusing....................... 7 4.2 Motor Connections ..........................
  • Page 3 D14270 Assembly Drawing, 20-60HP Models ..................124 D14316 Assembly Drawing, 75-150HP Models ...................125 DXXXXX Assembly Drawing, 200-400HP Models ................126 D14356 Assembly Drawing, 500-700HP Models .................127 D14263 Assembly, Heatsink Chassis, 20-60HP Non-Regen Models ..........128 D14264 Assembly, Heatsink Chassis, 20-60HP Regen Models............129 D14347 Assembly, Heatsink Chassis, 75-150HP Non-Regen Models ..........130 D14318 Assembly, Heatsink Chassis, 75-150HP Regen Models............131 DXXXXX Assembly, Heatsink Chassis, 200-300HP Non-Regen Models..........132 DXXXXX Assembly, Heatsink Chassis, 400HP Non-Regen Model.............133...

  • Page 4: General Description

    1 1 1 1 General Description The Elite® Pro V3 Series is Carotron's 3rd generation of microprocessor based D.C. motor controls. The series provides control of speed and torque control of 5-700HP D.C. motors rated for NEMA type "C" power supplies. The EP2 (non-regenerative) series and the EP4 (regenerative) series are offered in compact panel mounted assemblies.

  • Page 5: Physical

    2.2 Physical EPx020-000 thru EPx060-000 EPx075-000 thru EPx150-000...
  • Page 6 EPx200-000 thru EPx400-000 EPx500-000 thru EPx600-000...

  • Page 7: Installation

    Excess ambient temperatures within enclosures can reduce the life expectancy of electronic components and can cause a heatsink over temperature fault on the Elite Pro control. Contact Carotron for assistance in sizing enclosures for particular horsepower ratings. 3.2 Wiring Guidelines To prevent electrical interference and to minimize start-up problems, adhere to the following guidelines.
  • Page 8 The drive also requires a fused single phase 115VAC control power on terminals L and N. Carotron recommends the use of three phase DIT, drive isolation type transformers. While Elite Pro controls do not require these transformers for proper operation, they can be helpful in reducing the effects of line transients on this control and generated by this control on other products and can provide fault current limiting in the event of severe motor or control failure.

  • Page 9: Motor Connections

    Drive Motor Approx. Full Load 3 Phase DIT Contactor D.B. Resistor Model Volts Line Amps KVA Rating Amps Rating Rating 10 , 300W 40 Amps 28.1 5 , 600W 4.4 , 750W EPx020-000 40 , 375W 13.2 20 , 750W 17.2 40 Amps 20 , 750W...
  • Page 10 Figure 3 Armature The armature leads are usually the highest current wires associated with the drive and warrant special attention to sizing based on current rating as well as length of run. Extra care should be used where terminations and splices are made. Refer to Table 1 for typical armature voltage, current, contactor and dynamic braking resistor ratings.

  • Page 11: Signal Connections

    Figure 5 Motor Thermostat Most motors include "J" or "P" leads that connect to an internal normally closed thermostat. Connecting the thermostat to TB1-38 & 39 as shown in Figure 6 will allow a motor over-temperature condition to shut down the control as in an Emergency Stop condition. If the motor does not provide a thermostat or the thermostat wiring is not used, a jumper must be placed across terminals 38 &...
  • Page 12 Figure 6: Signal Connections...
  • Page 13 The Elite Pro V3 supports three different start/stop logic schemes (four including the local mode). Refer to Figure 7 below. The momentary scheme (often called 3 wire) uses momentary pushbuttons to control the starting and stopping of the drive. A selector switch or a contact controls the direction. The other two schemes use maintained contacts (often called 2 wire mode).

  • Page 14: Human Machine Interface (Hmi)

    5 5 5 5 Human Machine Interface (HMI) 5.1 Description of Interface The Human Machine Interface (HMI) is the primary method for accessing the drive's parameters. It allows for custom user configuration, monitoring, and troubleshooting. As seen in Figure 9, the HMI consists of a 4 line by 20 characters display, 11 button keypad, and 4 LEDs.

  • Page 15: Menu Structure

    5.2 Menu Structure When power is applied to the drive, the HMI displays the drive's firmware version. After a short timeout, the Drive Monitor 1 (DM1) screen is displayed. Navigation through the menu is achieved by using the Up, Down, Escape, and Enter keys. Figure 10...

  • Page 16: Table 3: Drive Monitor Descriptions

    Monitors The Monitors section contain the Drive Monitor screens. Each of theses screens displays various drive status information. Monitor Description DM01 Reference/Speed DM02 Armature Status DM03 Field Status DM04 Fault Status DM05 Alarm Status DM06 Velocity Loop Status DM07 Current Loop Status DM08 Field Loop Status DM09...

  • Page 17: Start Up Procedure

    6 6 6 6 Start Up Procedure 6.1 Pretest 1. Verify each phase of the 3 phase power supply. Input voltage should be checked ahead of the supplying circuit breaker, disconnect switch, etc. before it is switched on. 2. Connections should be visually inspected and checked for tightness. An ohmmeter can be used to check for ground faults.
  • Page 18 proper control is verified. 5. Check Motor Rotation While displaying the DM01 screen, place the drive in local mode by pressing the LOCAL/REMOTE key. The Local LED should be on. Press and hold the F1 key to jog the drive. The armature contactor should close and the motor should rotate slowly. Observe the direction of rotation.

  • Page 19: Adjustment Procedure: Constant Horsepower

    6.3 Adjustment Procedure: Constant Horsepower 1. Presets Set up the Elite Pro V3 drive as a normal velocity regulator to run at the motor's base speed using tachometer or encoder feedback with closed loop field control. Refer to Section 6.2 above. Once correct operation in this mode has been achieved, proceed with the following steps.
  • Page 20 2. The Current Proportional Gain (G1.16), Current Integral Time (G1.17), Velocity Proportional Gain (G2.21), and Velocity Integral Time (G2.22) parameters are preset by Carotron to provide stable and responsive performance under most load conditions. When required, the drive performance can be optimized for a particular application or to correct undesirable operation by use of these adjustments.

  • Page 21: Password Protection

    Figure 12 6.4 Password Protection If password protection is required, set the appropriate password under A1.04. Please note that this is a special hidden parameter. You must first display A1.03. Then press F2 key and then the Up key to display A1.04. Once A1.04 has a value other than zero, parameters can be viewed but cannot be changed.

  • Page 22: Programming & Adjustments

    7 7 7 7 Programming & Adjustments Programming and adjustment of the Elite Pro is accomplished by changing parameter settings. Each parameter has a Tag identifier and a descriptive name. Parameters are separated into groups and blocks according to their function. The following sections contain each software block diagram and descriptions of each parameter function.

  • Page 23: B: Digital Inputs

    7.2 B: Digital Inputs These parameters configure the drive's physical digital inputs (digital & frequency). B1: Digital Input 1 Figure 15 B1.01 Digital Input 1 Destination (ICR, Preset: H1.02 [Run]) Determines the function of the digital input. Each digital input can control (or write to) any R/W parameter in the drive.
  • Page 24 B1.04 Digital Input 1 On Value (RW) This is the value written to the target parameter when the digital input's status is ON. The limits and units of these parameters will change to match the limits and units of the target parameter. B2: Digital Input 2 Figure 16 B2.01 Digital Input 2 Destination (ICR, Preset: H1.03 [/Stop])
  • Page 25 B4: Digital Input 4 Figure 18 B4.01 Digital Input 4 Destination (ICR, Preset: H1.05 [Reverse]) B4.02 Digital Input 4 Status [Terminal 34] (RO) B4.03 Digital Input 4 Off Value (RW) B4.04 Digital Input 4 On Value (RW) Digital Input 4 is functionally equivalent to Digital Input 1. Refer to B1.XX B5: Digital Input 5 Figure 19 B5.01 Digital Input 5 Destination (ICR, Preset:...
  • Page 26 B6: Digital Input 6 Figure 20 B6.01 Digital Input 6 Destination (ICR, Preset: 1.03 [RefSelLsb]) B6.02 Digital Input 6 Status [Terminal 36] (RO) B6.03 Digital Input 6 Off Value (RW) B6.04 Digital Input 6 On Value (RW) Digital Input 6 is functionally equivalent to Digital Input 1. Refer to B1.XX B7: Digital Input 7 Figure 21 B7.01 Digital Input 7 Destination (ICR, Preset: K1.15 [ExtFaultReset])
  • Page 27 The frequency input can operate in either the FREQ INPUT or SONIC INPUT modes. In the frequency input mode, the input level is determined by the input frequency. The sonic mode is used in conjunction with Carotron's sonic transducer (P/N: C10757-000 or C11307-000) to measure distance.
  • Page 28 B8.09 Freq Input 100% Calibration (R/W, Preset: 420.00") Defines the maximum input distance in inches. An input value above this level will be ignored. This parameter is only used when in the SONIC INPUT mode. Range: 0..420" B8.10 Freq Input Bias (R/W, Preset: 0.00) Defines the value of the target parameter when the input signal is less than or equal to the 0% Calibration.

  • Page 29: C: Analog Inputs

    7.3 C: Analog Inputs These parameters configure the drive's physical analog inputs. C1: Analog Input 1 Figure 23 C1.01 Analog Input 1 Destination (ICR, Preset: 1.04 [Reference A]) Each of the analog inputs can control (or write to) any R/W parameter in the drive. The destination parameter contains the tag of the parameter the input will control (i.e.

  • Page 30: Table 6: Analog Input Status Readings

    C1.02 Analog Input 1 Status (RO) Displays the raw analog to digital conversion value. Table 6 below lists the typical status values for common input levels. Signal Input Status Voltage Current Unipolar Bipolar +10V 4095 2047 +7.5V 3070 1535 20mA 2047 1023 +2.5V...
  • Page 31 Figure 24 C2: Analog Input 2 Figure 25 C2.01 Analog Input 2 Destination (ICR, Preset: 00.00 [Not Set]) C2.02 Analog Input 2 Status (RO) C2.03 Analog Input 2 Polarity (ICR, Preset: Unipolar) C2.04 Analog Input 2 Filtering (R/W, Preset: 0) C2.05 Analog Input 2 Type (ICR, Preset: Voltage) C2.06 Analog Input 2 0% Calibration (R/W, Preset: 0) C2.07 Analog Input 2 100% Calibration (R/W, Preset: 4095)
  • Page 32 C3: Analog Input 3 Figure 26 C3.01 Analog Input 3 Destination (ICR, Preset: 00.00 [Not Set]) C3.02 Analog Input 3 Status (RO) C3.03 Analog Input 3 Polarity (ICR, Preset: Unipolar) C3.04 Analog Input 3 Filtering (R/W, Preset: 0) C3.05 Analog Input 3 Type (ICR, Preset: Voltage) C3.06 Analog Input 3 0% Calibration (R/W, Preset: 0) C3.07 Analog Input 3 100% Calibration (R/W, Preset: 4095) C3.08 Analog Input 3 0% Calibration (R/W, Preset: 0)
  • Page 33 C5: Analog Input 5 Figure 28 C5.01 Analog Input 5 Destination (ICR, Preset: 00.00 [Not Set]) C5.02 Analog Input 5 Status (RO) C5.03 Analog Input 5 Polarity (ICR, Preset: Unipolar) C5.04 Analog Input 5 Filtering (R/W, Preset: 0) C5.05 Analog Input 5 Type (ICR, Preset: Voltage) C5.06 Analog Input 5 0% Calibration (R/W, Preset: 0) C5.07 Analog Input 5 100% Calibration (R/W, Preset: 4095) C5.08 Analog Input 5 0% Calibration (R/W, Preset: 0)

  • Page 34: D: Digital Outputs

    7.4 D: Digital Outputs These parameters configure the drive's physical digital outputs (relay & frequency/digital). D1: Relay Output 1 Figure 29 D1.01 Relay Output 1 Source (ICR, Preset: S1.06 [Zero Speed]) The function of the relay output is configured by this parameter. Each output can be controlled by any parameter in the drive.
  • Page 35 D2: Relay Output 2 Figure 30 D2.01 Relay Output 2 Source (ICR, Preset: H1.16 [Drive Running]) D2.02 Relay Output 2 Absolute Value (R/W, Preset: Off) D2.03 Relay Output 2 On Value (R/W, Preset: On) D2.04 Relay Output 2 Off Value (R/W, Preset: Off) D2.05 Relay Output 2 Status (RO) Relay Output 2 is functionally equivalent to Relay Output 1.
  • Page 36 D4: Frequency/Digital Output Figure 32 D4.01 Freq/Digital Output Source (ICR, Preset: 00.00 [Not Set]) The function of this output is configured by this parameter. The output can be controlled by any parameter in the drive. The source parameter contains the tag of the parameter that will control the relay output.
  • Page 37 D5: Aux LED Output Figure 33 D5.01 Aux LED Source (ICR, Preset: H1.16 [Arm Pilot Status]) The function of this output is configured by this parameter. The output can be controlled by any parameter in the drive. The source parameter contains the tag of the parameter that will control the relay output.

  • Page 38: E: Analog Outputs

    7.5 E: Analog Outputs These parameters configure the drive's physical analog outputs. E1: Analog Output 1 Figure 34 E1.01 Analog Output 1 Source (ICR, Preset: G2.18 [Filtered Velocity Feedback]) The function of this output is configured by this parameter. The output can be controlled by any parameter in the drive.

  • Page 39: Table 9: Analog Output Status

    E1.05 Analog Output 1 Status (RO) Displays the raw digital to analog output level. Refer to Table 9 for typical values. Status Voltage +10V 4095 2047 -2047 -10V -4095 Table 9: Analog Output Status E2: Analog Output 2 Figure 35 E2.01 Analog Output 2 Source (ICR, Preset: G1.13 [Filtered Current Feedback]) E2.02 Analog Output 2 Gain (R/W, Preset: 100.00%) E2.03 Analog Output 2 Bias (R/W, Preset: 0.00%)

  • Page 40: F: Motor Data

    7.6 F: Motor Data F1: Motor Data Figure 36 F1.01 AC Line Voltage (ICR, Preset: 0V) Enter the approximate input voltage level of the incoming three phase. This value is used to pre- calculate the Field Open Loop Reference (G3.03). F1.02 Armature Current (ICR, Preset: 0A) Enter the motor nameplate armature current rating.
  • Page 41 F2: Tachometer Data This section is utilized only if a motor mounted tachometer is used for speed feedback. Figure 37 F2.01 Tachometer Type (ICR, Preset: 0 RPM) Select the type of tachometer used: AC or DC. F2.02 Invert Tachometer (ICR, Preset: Off) The tachometer feedback signal is polarity sensitive.
  • Page 42 F3: Encoder Data This section is utilized only if a motor mounted encoder is used for speed feedback. Figure 38 F3.01 Encoder Type (ICR, Preset: Quadrature) Select the type of encoder used. A QUADRATURE encoder has two channels (typically labeled A and B) that conveys speed and direction information.
  • Page 43 F3.09 Reset Value Lo (R/W, Preset: 0) F3.10 Reset Value Hi (R/W, Preset: 0) The 32 bit counter will be preset to the value in these two registers when F3.08 is ON. F3.11 Counter Value Lo (RO) F3.12 Counter Value Hi (RO) The 32 bit counter is split into two 16 bit sections (F3.11:F3.12).

  • Page 44: G: Control Loops

    7.7 G: Control Loops G1: Current Loop Figure 39 G1.01 Reference Select (ICR, Preset: Normal) Selects the reference source for the loop. This parameter should always be set to NORMAL except when performing a step response loop tuning sequence. G1.02 Torque Reference (R/W, Preset: 0.00%) This is the current loop's reference when A1.02 is set to TORQUE mode.
  • Page 45 This is a calibration adjustment that is set at the factory. Customer adjustment is typically not required. Range: 90..110% G1.12 Current Feedback (RO) This status parameter indicates the level of armature current flowing in the motor. The reading is a percentage of F1.02. G1.13 Filtered Current Feedback (RO) A filtered version of G1.12.
  • Page 46 G2: Velocity Loop Figure 40 G2.01 Velocity Demand (RO) This value is the summation of the setpoints in the Setpoint Sum ( 2) block. It serves as the initial reference for the velocity (or speed) loop. G2.02 Forward Max Speed Scale (R/W, Preset: 100.00%) This parameter allows scaling of the Velocity Demand (G2.01).
  • Page 47 G2.12 Tachometer Feedback Filtered (RO) Filtered version of G2.11. G2.13 Encoder Feedback (RO) This status parameter indicates the level of encoder feedback. The reading is a percentage of the maximum encoder frequency calculated from F1.07 (Base Speed) or F1.08 (Extended Speed) and F3.02 (Encoder PPR).
  • Page 48 the displayed Motor RPM (G2.28) may not be correct due to motor inconsistencies. When set to ON, a Custom Scale (G2.29) can be used so that the correct motor RPM is displayed. G2.29 Custom Scale (R/W, Preset: 0 RPM) When G2.28 is set to ON, the filtered velocity feedback is multiplied by this parameter to produce the Motor RPM (G2.30).
  • Page 49 G3: Field Loop Figure 41 G3.01 Field Enable (R/W, Preset: On) This setting must be ON in order for the drive to produce field output. If using a permanent magnet motor or a non-motor application, this setting should be set to OFF. G3.02 Loop Mode (R/W, Preset: Open Loop) Sets the operating mode of the field loop.
  • Page 50 This is the raw analog to digital conversion value of the field voltage feedback signal. G3.12 Field VFB (RO) This status parameter indicates the level of field voltage on in the motor. The reading is a percentage of the drive's rated maximum field voltage of 400V. G3.13 Field VFB Fil (RO) Filtered version of G3.12.
  • Page 51 G3.29 Field Cond Angle Raw (RO) The raw conduction value. G3.30 Field Sync Phase (RO) Displays the input phase synchronizing circuit that the drive is using. G3.31 Over Voltage Alarm (RO) Displays the status of the field over voltage alarm. ON indicates the alarm is active. Refer to K1.05 - K1.07 for alarm details.

  • Page 52: H: Start/Stop Logic

    7.8 H: Start/Stop Logic H1: Start/Stop Logic Figure 42 H1.01 Logic Select (ICR, Preset: Maintained Run/Dir) Determines how the drive is started and stopped. There are four parameters that control the drive's mode and direction: H1.02-H1.05. Each of these parameters will have a different function depending upon the selection of H1.01.
  • Page 53 H1.07 Safe Start Mode (ICR, Preset: Enabled) The drive incorporates a safety feature that prevents the drive running if a run command is present during power up. While NOT recommended by Carotron, this feature can be disabled if other external safety logic is used.

  • Page 54: Table 10: Drive Modes

    H1.13 Run Status (RO) Status of drive. ON indicates the drive is in the run mode. Note that this does not include the jog mode. H1.14 Jog Status (RO) Status of drive. ON indicates the drive is in the jog mode. H1.15 Direction Status (RO) Indicates the commanded direction of the drive: FWD or REV.
  • Page 55 H2:Local/Remote Logic H2.01 In Local Mode (ICR, Preset: No) Determines if the drive is in the Local mode of operation. The LOCAL/REMOTE key toggles this value. H2.02 Local Options (ICR, Preset: LOCAL SS/LOCAL REF) The drive can operate in one of three local modes. LOCAL SS / LOCAL REF Starting, stopping, &...

  • Page 56: I: Setpoints

    : Setpoints 1: Setpoints Figure 43 1.01 Aux Reference Enable (R/W, Preset: Enabled) Both H1.17 and this parameter must be ENABLED in order for the selected reference to be passed to the Ramp 1 block (J1). When used, this parameter is often linked from a digital input to confirm the armature contactor has closed.
  • Page 57 1.09 Local Reference (R/W, Preset: 0.00%) This value serves as the speed reference when the drive is in the local mode. See H2.02 for exceptions. Typically, this parameter value is edited by pressing the ENTER key when the DM01 screen is displayed and the drive is in LOCAL mode. Range: -300..300% 1.10 Reference (RO) This parameter indicates the value of the selected reference.

  • Page 58: J: Ramps

    7.10 J: Ramps J1: Ramp 1 The Ramp 1 block takes the reference output from the Setpoints block and applies a ramp rate to the signal. The ramped reference is an input to the Setpoint Sum block. Parameters J1.01-J1.04 set the linear acceleration and deceleration times.
  • Page 59 J1.05 S Accel Begin Time A (R/W, Preset: 0.0 Secs) Defines the S Curve characteristic at the beginning of the acceleration ramp. Range: 0..10 Secs J1.06 S Accel End Time A (R/W, Preset: 0.0 Secs) Defines the S Curve characteristic at the ending the acceleration ramp. Range: 0..10 Secs J1.07 S Decel Begin Time A (R/W, Preset: 0.0 Secs) Defines the S Curve characteristic at the beginning of the deceleration ramp.
  • Page 60 J1.22 Ramping Status (RO) Indicates whether the Ramp Output (J1.21) is increasing or decreasing to the value of the Ramp Input (J1.20). J2: Ramp 2 The Ramp 2 block is very similar to the Ramp 1 block. It can be used for custom applications. Figure 48 J2.01 Fwd Accel Time A (R/W, Preset: 5.0 Secs) Defines the time that it takes for the ramp output to increase from 0.00% to +100.00%.
  • Page 61 J2.09 Fwd Accel Time B (R/W, Preset: 1.0 Secs) J2.10 Fwd Decel Time B (R/W, Preset: 1.0 Secs) J2.11 Rev Accel Time B (R/W, Preset: 1.0 Secs) J2.12 Rev Decel Time B (R/W, Preset: 1.0 Secs) J2.13 S Accel Begin Time B (R/W, Preset: 0.0 Secs) J2.14 S Accel End Time B (R/W, Preset: 0.0 Secs) J2.15 S Decel Begin Time B (R/W, Preset: 0.0 Secs) J2.16 S Decel End Time B (R/W, Preset: 0.0 Secs)

  • Page 62: K: Fault Logic

    7.11 K: Fault Logic K1: Fault Options Figure 49 K1.01 Feedback Loss Enable (R/W, Preset: Enabled) Only used if G2.15 is set to TACHOMETER or ENCODER. In order to prevent excessive speed in a run away condition, the drive has the capability to detect the loss of a speed feedback signal. When detected, the drive will generate a Feedback Loss fault.
  • Page 63 K1.08 Field OC Enable (R/W, Preset: Enabled) When ENABLED, the drive will generate a field over current fault if excessive field current is detected. The over current level is set by K1.09. The amount of time the over current condition must be present before the fault is generated is set by K1.10.

  • Page 64: Table 12: Faults 1

    K2: Fault Status K2.01 Power On Reset (RO) The drive generates an internal reset by setting this parameter to ON after power is applied. After the reset expires, the value returns to OFF. K2.02 Internal Fault Reset (RO) This parameter is set to ON when the RESET button on the keypad is used to clear a fault.

  • Page 65: Table 14: Alarms 1

    cleared. A '1' indicates the fault occurred and is latched. A fault reset will clear the '1' back to a '0' (assuming the fault is no longer active). Refer to Table 12. K2.06 Latched Faults 2 (RO) Refer to K2.05. Refer to Table 13. K2.07 Fault Description (RO) Indicates the current fault.
  • Page 66 K3: Fault Log K3.01 Most Recent Fault (RO) K3.02 2nd Most Recent Fault (RO) K3.03 3rd Most Recent Fault (RO) K3.04 4th Most Recent Fault (RO) K3.05 5th Most Recent Fault (RO) K3.06 6th Most Recent Fault (RO) K3.07 7th Most Recent Fault (RO) K3.08 8th Most Recent Fault (RO) K3.09 9th Most Recent Fault (RO) K3.10 10th Most Recent Fault (RO)
  • Page 67 K4: Fault Capture The fault capture block captures the values of certain operating parameters when a fault occurs. The captured values can be used as a troubleshooting/diagnostic aid in determining the cause of the fault. K4.01 Fault (RO) A description of the fault. K4.02 Armature Volts (RO) The armature voltage level (G2.08) when the fault occurred.

  • Page 68: L: Applications

    7.12 L: Applications L1: Aux PID Loop Figure 53 L1.01 PID Enable (R/W, Preset: Disabled) Enables/disables the PID loop. The output (L1.25) is held at zero when DISABLED. L1.02 PID Reset (R/W, Preset: Off) Resets the PID loop. The output (L1.25) is held at zero when ON. L1.03 Prop Gain (R/W, Preset: 5.00) Sets the loop response.
  • Page 69 L1.12 Controller Action (R/W, Preset: ERR=SP-FB) Determines how the error is calculated. The error is the difference between the Setpoint and Feedback parameters. This effectively determines the direction of correction that the PID loop provides. Available options are ERR=SP-FB or ERR=FB-SP. L1.13 Setpoint (R/W, Preset: 0.00%) The desired position on dancer systems or the desired tension on loadcell systems.
  • Page 70 L2: Diameter Calculator Figure 54 L2.01 Diameter Select (R/W, Preset: None) Selects the method of diameter calculation. NONE The diameter calculator is disabled. EXTERNAL An external device measures the diameter (such as a sonic or a laser). The external device is connected to an analog or freq input.
  • Page 71 L2.04 Thickness (R/W, Preset: 0.0001") Used only when L2.01 is set to ROLL REVOLUTIONS or LINE REVOLUTIONS. The actual thickness of the material being used should be entered here. If a range of material thicknesses are used, an average of the thickness should be used. Alternatively, an external controller (such as an HMI) could be used to change this value for different products.
  • Page 72 L3: Roll Speed Calculator A problem encountered in center driven takeup and letoff applications is the nonlinear relationship between the diameter of a roll and the motor speed required to maintain constant surface speed of the roll during diameter increase or decrease. A plot of this relationship shows a hyperbolic curve. Refer to Figure 57.
  • Page 73 L4: Taper Tension Calculator When center winding material, in some cases decreasing tension (taper tension) is desirable to prevent telescoping and/or wrinkling of inner layers of material. The taper tension calculator can be configured to provide tapering tension starting at any point in the roll diameter. Tension Demand (L4.04) will decrease by a percentage of the Tension Setpoint (L4.01) from the Taper Diameter (L4.02) setting to the Max Diameter (L2.03).
  • Page 74 L5: CTCW Calculator The CTCW (Constant Tension Center Wind) block allows the drive to provide constant or taper tension control without external tension sensors. The CTCW block provides a torque reference output that is composed of diameter torque, inertia torque, friction torque, static friction torque, and pulse torque.

  • Page 75: Table 15: Inertia Sensitivity

    would need to be increased. Refer to the following table for recommended initial values depending upon the line accel/decel rates. Note that these values may need to be adjusted to obtain steady levels of Inertia Torque depending upon the amount of electrical noise present on the signal.
  • Page 76 L5.15 Torque Sum (R/W, Preset: 0.00%) This parameter provides an auxiliary summing point before the Total Torque is calculated. A typical use would be to sum in a correction signal from the output of a PID block when loadcells are used with the CTCW Calculator. Range: 0..100% L5.16 Total Torque (RO) The sum of the L5.02, L5.07, L5.09, L5.10, L5.14 &...
  • Page 77 L6: MOP (Motor Operated Potentiometer) In many industrial applications, a potentiometer is used to provide a reference signal (typically speed) to a machine. Often, it would be advantageous to allow the machine operator to adjust this potentiometer from multiple locations (especially on large machines). However, this is not possible with a standard analog potentiometer.

  • Page 78: M: Thresholds

    7.13 M: Thresholds The threshold blocks compare an input value to two threshold levels. When the input value equals or exceeds the On Level, an internal switch is turned on. When the input equals or falls below the Off Level, the switch turns off. Two threshold levels are provided so that a hysteresis may be created if desired.
  • Page 79 Figure 63 M7.01 Enable (R/W, Preset: Disabled) Enables/disables the latch. When disabled, all three of the Limit Exceeded outputs are OFF. M7.02 Input (R/W, Preset: 0.00%) The input to the latch. This value is compared to the Upper Limit and Lower Limit values. When the input exceeds the Upper Limit for a defined time period, the Upper Limit Exceeded output becomes ON.
  • Page 80 M8: Threshold 8 (Latch) M8.01 Enable (R/W, Preset: Disabled) M8.02 Input (R/W, Preset: 0.00%) M8.03 Upper Limit (R/W, Preset: 90.00%) M8.04 Lower Limit (R/W, Preset: 10.00%) M8.05 Delay Time (R/W, Preset: 0.0Secs) M8.06 Reset Mode (R/W, Preset: Manual) M8.07 Manual Reset (R/W, Preset: Off) M8.08 Upper Limit Exceeded (R/O) M8.09 Lower Limit Exceeded (R/O) M8.10 Limit Exceeded (R/O)

  • Page 81: N: Timers

    7.14 N: Timers The drive provided six timer blocks. Each of the timers can operate in one of six modes. N1: Timer 1 Figure 64 N1.01 Timer 1 Mode (R/W, Preset: On Delay) Selects the operating mode of the timer. Refer to Figure 65. ON DELAY When N1.02 changes to ON, the internal switch turns on after a delay set by N1.03.
  • Page 82 N1.03 Timer 1 Delay Time 1 (R/W, Preset: 5.0 Secs) Second delay time. Used only when N1.01 is set to SINGLE CYCLE or REPEAT CYCLE. Range: 0.1..600 Secs N1.05 Timer 1 On Value (R/W, Preset: 100.00%) The ON input to the switch. The value is selected when the switch is on. Range: -300..300% N1.06 Timer 1 Off Value (R/W, Preset: 0.00%) The OFF input to the switch.

  • Page 83: O: Logic Gates

    7.15 O: Logic Gates The Logic Gate blocks provide basic boolean logic and comparison functions. O1: Logic Gate 1 Figure 66 O1.01 Logic Gate 1 Mode (R/W, Preset: A And B) Selects the function of the logic gate. A AND B Performs a logical AND between Inputs A (O1.02) and Input B (O1.03).
  • Page 84 The output (O1.04) will be ON when Input A (O1.02) is less than Input B (O1.03). A <= B? The output (O1.04) will be ON when Input A (O1.02) is less than or equal to Input B (O1.03). A EQUALS B? The output (O1.04) will be ON when Input A (O1.02) is equal to Input B (O1.03).

  • Page 85: Table 16: Logic Gates Truth Table

    Output (O1.04) Input A Input B (O1.02) (O1.03) NAND XNOR SR FF No Change Table 16: Logic Gates Truth Table O2: Logic Gate 2 O3: Logic Gate 3 O4: Logic Gate 4 O5: Logic Gate 5 O6: Logic Gate 6 Logic Gates 2-6 are functionally identical to Logic Gate 1.

  • Page 86: P: Switches

    7.16 P: Switches The drive provides 6 internal single pole double throw switches. P1: Switch 1 Figure 67 P1.01 Switch 1 Coil (R/W, Preset: Off) Defines the status of the switch: ON or OFF. P1.02 Switch 1 On Value (R/W, Preset: 0.00%) The ON input to the switch.

  • Page 87: Q: Internal Links

    7.17 Q: Internal Links The internal links can be used to connect or link parameters together. The source parameter selects the parameter from which data will be retrieved. The destination parameter selects the parameter to which the data will be written. In other words, the value of the parameter identified by Source will be written to the parameter identified by Destination.

  • Page 88: R: Communications

    7.18 R: Communications R1: Com Port A (CN12: USB) R1.01 PortA Clear Counters (R/W, Preset: Off) Resets R1.02-R1.10 to zero when set to ON. Value automatically returns to OFF. R1.02 PortA Bus Messages (RO) The total number of bus messages. R1.03 PortA Bus Com Errors (RO) The total number of bus messages that have errors.
  • Page 89 R2: Com Port B (CN9: Keypad) R2.01 PortB Clear Counters (R/W, Preset: Off) Resets R2.02-R2.10 to zero when set to ON. Value automatically returns to OFF. R2.02 PortB Bus Messages (RO) The total number of bus messages detected. R2.03 PortB Bus Com Errors (RO) The total number of bus messages that have errors.
  • Page 90 R3: Com Port C (TB2: RS422/485) R3.01 PortC Modbus Address (R/W, Preset: 1) Sets the Modbus® network address of the drive. Range: 1..247 R3.02 PortC Baud Rate (R/W, Preset: 38400) Sets the communication speed. Available rates are 2400, 4800, 9600, 19200, 38400, 57600, 76800, & 115200. R3.03 PortC Parity (R/W, Preset: None) Sets the parity.

  • Page 91: S: Zero Speed

    7.19 S: Zero Speed S1: Zero Speed Figure 72 S1.01 Zero Speed Setpoint (R/W, Preset: 2.00%) Sets the speed level that the drive considers to be stopped. When ramping to stop, the drive drops out the armature contactor when this level is reached. Range: 0.5..25% S1.02 Standstill Enable (R/W, Preset: Enabled) In applications where the drive is in the Run mode with zero velocity reference, motor creepage may be apparent under some load conditions.

  • Page 92: T: System

    7.20 T: System T1: System Status T1.01 Drive Model (RO) Displays the drive's model number. T1.02 Rated Armature Curr (RO) Displays the drive's rated armature current. T1.03 Rated Field Current (RO) Displays the drive's rated field current. T1.04 Firmware Version (RO) Displays the drive's firmware version.
  • Page 93 T2: System Options T2.01 Parameter Save (R/W, Preset: Off) When parameter changes are made via the keypad, the changes are automatically saved. Parameters changes made over one of the communication ports are not saved. Setting this parameter to ON will save all of the current drive parameters.

  • Page 94: U: Auxiliary

    7.21 U: Auxiliary The drive provides 20 auxiliary parameters for general purpose use. Many times they are used when it is desired to link an input to an output. Since this cannot be done directly, an auxiliary parameter can be used as a tie point. Also, the drive's inputs and outputs can be used as remote I/O via the communications ports.

  • Page 95: Parameter Table

    7.22 Parameter Table The following table lists all the Elite Pro V3 parameters and their properties. ICR=Inhibit Change while Running R/W=Read/Write RO=Read Only Table 17: Parameters Modbus Parameter Name Access Range Preset Note Address A1.01 2177 Parameter Visibility Standard..Advanced Standard A1.02 2178 Operating Mode...
  • Page 96 Modbus Parameter Name Access Range Preset Note Address B8.26 5146 Reset Value High 0..65535 B8.27 5147 Count Low 0..65535 B8.28 5148 Count High 0..65535 B8.29 5149 Divisor 1..65535 C1.01 6273 Analog Input 1 Destination A1.01..U1.20 1.04 C1.02 6274 Analog Input 1 Status -2048..4095 C1.03 6275...
  • Page 97 Modbus Parameter Name Access Range Preset Note Address D2.04 8452 Relay Output 2 Off Value -300.00..300.00% 0.00% D2.05 8453 Relay Output 2 Status Off..On D3.01 8577 Relay Output 3 Source A1.01..U1.20 K2.08 D3.02 8578 Relay Output 3 Absolute Value Off..On D3.03 8579 Relay Output 3 On Value...
  • Page 98 Modbus Parameter Name Access Range Preset Note Address G1.05 14469 Positive Current Limit 0..150.00% 150.00% G1.06 14470 Negative Current Limit 0..150.00% 150.00% G1.07 14471 Slew Rate 0..100.00% 0.00% G1.08 14472 Final Current Demand -150.00..150.00% 0.00% G1.09 14473 Final Current Demand Filtered -150.00..150.00% 0.00% G1.10...
  • Page 99 Modbus Parameter Name Access Range Preset Note Address G3.04 14724 Field Economy Enable Disabled..Enabled Enabled G3.05 14725 In Field Economy No..Yes G3.06 14726 Field Economy Ratio 0.00%..100.00% 60.00% G3.07 14727 Field IFB Raw 0..4095 G3.08 14728 Field IFB 0.00..100.00% 0.00% G3.09 14729 Filtered Field IFB...
  • Page 100 Modbus Parameter Name Access Range Preset Note Address I1.04 18564 Reference A -300.00%..300.00% 0.00% I1.05 18565 Reference B -300.00%..300.00% 10.00% I1.06 18566 Reference C -300.00%..300.00% 15.00% I1.07 18567 Reference D -300.00%..300.00% 20.00% I1.08 18568 Jog Reference -300.00%..300.00% 5.00% I1.09 18569 Local Reference -300.00%..300.00% 0.00%...
  • Page 101 Modbus Parameter Name Access Range Preset Note Address K1.03 22659 Field Loss Enable Disabled..Enabled Enabled K1.04 22660 Field Loss Level 0.00..100.00% 2.00% K1.05 22661 Field Over Voltage Enable Disabled..Enabled Enabled K1.06 22662 Field Over Voltage Level 100.00..150.00% 110.00% K1.07 22663 Field Over Voltage Time 1..60Mins 10Mins...
  • Page 102 Modbus Parameter Name Access Range Preset Note Address L1.07 24711 Integral Clamp Off..On L1.08 24712 Integral Hold Off..On L1.09 24713 Integral Mode Classical..Linear Linear L1.10 24714 Max Output 0.00..100.00% 100.00% L1.11 24715 Min Output -100.00..0.00% -100.00% L1.12 24716 Controller Action Err=Sp-Fb..Err=Fb-Sp Err=Sp-Fb L1.13...
  • Page 103 Modbus Parameter Name Access Range Preset Note Address L6.06 25350 MOP Min Value -300.00..300.00% 0.00% L6.07 25351 MOP Reset Off..On L6.08 25352 MOP Reset Value -300.00..300.00% 0.00% L6.09 25353 MOP Output -300.00..300.00% 0.00% M1.01 26753 Threshold 1 Input -300.00..300.00% 0.00% M1.02 26754 Threshold 1 Absolute Value...
  • Page 104 Modbus Parameter Name Access Range Preset Note Address M8.01 27649 Threshold 8 Enable Disabled..Enabled Disabled M8.02 27650 Threshold 8 Input -300.00..300.00% 0.00% M8.03 27651 Threshold 8 Upper Limit -300.00..300.00% 90.00% M8.04 27652 Threshold 8 Lower Limit -300.00..300.00% 10.00% M8.05 27653 Threshold 8 Delay Time 0.0..60.0Secs 0.0Secs...
  • Page 105 Modbus Parameter Name Access Range Preset Note Address N6.03 29443 Timer 6 Delay Time 1 0.1..600.0Secs 5.0Secs N6.04 29444 Timer 6 Delay Time 2 0.1..600.0Secs 5.0Secs N6.05 29445 Timer 6 On Value -300.00..300.00% 100.00% N6.06 29446 Timer 6 Off Value -300.00..300.00% 0.00% N6.07...
  • Page 106 Modbus Parameter Name Access Range Preset Note Address Q1.07 34951 Internal Link 4 Source A1.01..U1.20 00.00 Q1.08 34952 Internal Link 4 Destination A1.01..U1.20 00.00 Q1.09 34953 Internal Link 5 Source A1.01..U1.20 00.00 Q1.10 34954 Internal Link 5 Destination A1.01..U1.20 00.00 Q1.11 34955 Internal Link 6 Source...
  • Page 107 Modbus Parameter Name Access Range Preset Note Address R1.09 37001 Overrun Error Count 0..65535 R1.10 37002 Parity Error Count 0..65535 R2.01 37121 Clear Counters Off..On R2.02 37122 Bus Message Count 0..65535 R2.03 37123 Bus Com Error Count 0..65535 R2.04 37124 Bus Exception Error Count 0..65535 R2.05...
  • Page 108 Modbus Parameter Name Access Range Preset Note Address T2.05 41221 Fan(s) Mode Auto..On Auto T2.06 41222 Fan(s) Status Off..On U1.01 43137 Aux 1 -327.68..327.67% 0.00% U1.02 43138 Aux 2 -327.68..327.67% 0.00% U1.03 43139 Aux 3 -327.68..327.67% 0.00% U1.04 43140 Aux 4 -327.68..327.67% 0.00% U1.05...

  • Page 109: Troubleshooting

    8 8 8 8 Troubleshooting Table 18: Faults Fault Description Suggested Action HARDWARE FAULT A0 Internal hardware error Contact Carotron HARDWARE FAULT A1 Internal hardware error Contact Carotron Ensure the CN6 (control board to trigger board) ribbon cable is connected HARDWARE FAULT B0 Internal hardware error properly.
  • Page 110 Fault Description Suggested Action Disable this fault (See K1.17). Please note that disabling this fault only applies when the drive is in The CN9 cable from the Control board to KEYPAD DISCONNECT remote operation. Even the keypad was disconnected. when disabled, this fault will still occur if the keypad is disconnected and the drive is running in local mode.
  • Page 111 Fault Description Suggested Action G2.15=Tachometer Verify tachometer rating and F2.01 and F2.03 are set properly. Also ensure jumpers J1-J3 are set properly (see F2.04-F2.06). Ensure proper polarity of The motor speed exceeded the level set by tachometer signal (F2.02). MOTOR OVERSPEED K1.13.
  • Page 112 Fault Description Suggested Action When the drive is in the constant horsepower mode of operation, either tachometer or encoder feedback is required. Install FB CONFIG FAULT A1.02=Const HP and G2.15=Armature a motor mounted tachometer or encoder and set G2.15 appropriately. Don't operate the drive in the constant horsepower mode.

  • Page 113: Serial Network Communications

    9 9 9 9 Serial Network Communications 9.1 Physical The serial interface is a standard feature on all Elite Pro V3 drives. The interface enables other equipment such as a computer, programmable logic controller (PLC), or Human Machine Interface (HMI) to monitor, modify, and/or log data. The network is physically implemented on an RS-422/485 D14306 medium (2 or 4 wire selectable) using the Modbus®...

  • Page 114: Table 19: Supported Modbus® Functions

    frame varies depending upon which function code is used. Each frame is started by the slave address and ends with a CRC-16 error checking code. If the slave addresses do not match or the CRC-16 code is invalid, the slave ignores the message and no response is returned.

  • Page 115: Spare Parts

    Control Board All models......................D14171-000 Regulator Board All models......................D14177-000 Snubber Board All models......................C14188-000 10.2 Fuses Terminal Block Field Fuses: Fast Acting, 600VAC Model Amps Carotron P/N Manufacturer P/N EPx020-000 Bussmann KTK-10 thru FUS1004-04 Littelfuse KLK-10 EPx060-000 EPx075-000 Bussmann KTK-15...

  • Page 116: Table 21: Recommended Line Fuses

    Recommended Line Fuses: Semiconductor , 500VAC (Very Fast Acting) (Not included with basic drive package) Model Amps Carotron P/N Manufacturer P/N Bussmann FWH50 EPx020-000 FUS1009-00 Littelfuse L50S50 Bussmann FWH100 EPx040-000 FUS1009-01 Littelfuse L50S100 Bussmann FWH150 EPx060-000 FUS1009-02 Littelfuse L50S150 Bussmann FWH175...

  • Page 117: Power Components

    Semikron modules. The gate and cathode signal leads on IR modules are reversed on the second SCR device. Consult factory for assistance when replacing a Eupec or Semikron module with an IR module or vice-versa. Model Amps Carotron P/N Manufacturer P/N Eupec TT31N14KOF EPx020-000 PMD1025-00...

  • Page 118: Prints

    Prints CN9A CN1A CN6A CN3A CN10 CN4A CN12 J3 ONES J2 TENS HUNDREDS D14171 CONTROL BOARD ASSEMBLY...

  • Page 119: D14163 Trigger Board Assembly

    CN8B CN26 CN6B CN25B CN29B CN23 CN24 D14163 TRIGGER BOARD ASSEMBLY...

  • Page 120: D14177 Regulator Board Assembly

    CN1B CN50 CN8A D14177 REGULATOR BOARD ASSEMBLY...

  • Page 121: C14188 Snubber Board Assembly

    C14188 SNUBBER BOARD ASSEMBLY...

  • Page 122: C14166 Ct Id Board Assembly

    CN25A C14166 CT ID BOARD ASSEMBLY...

  • Page 123: C14045 Processor Board Assembly

    C14145 PROCESSOR BOARD ASSEMBLY...

  • Page 126: D14270 Assembly Drawing, 20-60Hp Models

    Assembly Drawing, 200-400HP Models...
  • Page 130 CN40...
  • Page 131 C N 40...
  • Page 132 Assembly, Heatsink Chassis, 200-300HP Non-Regen Models...
  • Page 133 Assembly, Heatsink Chassis, 400HP Non-Regen Model...
  • Page 134 Assembly, Heatsink Chassis, 200-300HP Non-Regen Models...
  • Page 135 Assembly, Heatsink Chassis, 400HP Regen Model...
  • Page 142 Wiring Diagram, 200-400HP Non-Regen Models...

  • Page 143: D14249 Wiring Diagram, 20-60Hp Regen Models

    Wiring Diagram, 200-400HP Regen Models...
  • Page 150 PRO V3 FIRMWARE...
  • Page 151 BLOCK DIAGRAM...
  • Page 154 Notes...

  • Page 155: Standard Terms & Conditions Of Sale

    Company's satisfaction to have failed to so perform, or The Standard Terms and Conditions of Sale of Carotron, Inc. (here- refund to the Purchaser the purchase price paid by the Purchaser to inafter called “Company”) are set forth as follows in order to give the...
  • Page 156 3204 Rocky River Road Heath Springs, SC 29058 Phone: 803.286.8614 Fax: 803.286.6063 Email: saleserv@carotron.com Web: www.carotron.com MAN1063-00 Rev. B Issued 02-01-2017...

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