Technical Program Description ST-790 L

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Technical Program Description


ST-790 L

Standard Version


Modification list

Project : ST 790-L Standard Version. Date : 07.07.2005
Author : Bradu

Version Date Name Chapter Remark / Index


































MODIFICATION LIST 2
1. GENERAL 4
2. ERROR CODES 5
2.1. OVERVIEW 5
2.2. ERROR CODES EXPLANATION 6
Error -1-: Sequence stopp switch 6
Error -21: Phase fault inverter 6
Error-3-: Positioning error 6
Error-32 / -33 / -34: Non equivalence Ex Or 7
Error -41: Overtemperature Motor 7
Error -51: Overcurrent Motor 7
Error-52: Overload Inverter 7
Error -53: Overcurrent inverter 8
Error -6-: Servo trip 8
Error-71: Final stage error 8
Error -72: Overtemperature inverter 8
Error -9-: Parameter error 9
Error -PAr 9
Error -C01/-C05: Error Hardware Configuration X3-X7 9
Fehler -C06 /-C15: Error Software Configuration 9
Error -C16: Positoning 9
Error -C17: Control rail 10
3. CONFIGURATION 11
4. PARAMETER: 12
4.1. OVERVIEW PARAMETER 12
4.2. PARAMETER DESCRIPTION 13
5. DISPLAY 19
5.1 DISPLAY MODE 19
5.2. OTHER DISPLAYS 20
6. REMOTE CONTROL FB-606 21
7. PCM COMMANDS 21
8. TECHNICAL APPENDIX 22
8.1. THE HANDHELD PROGRAMMING DEVICE MU 505 22
8.2. DISPLAY OF INPUT SIGNALS OR CONTROL FLAGS 23

1. General


Date of creation: 24.01.2005
Programmer: Bradu

Parameter set: ST-790L Ver. 1.0

Boot loader: BV 94045_00

Master computer: BV 94050_02 WNR 181180 (IR download)

Initiator board: WNR 181190

Inverter: WNR 181197

Display: 4-digit


Error message: with negative half wave on signal rail M (passive)

Presence: with positive half wave on signal rail M (permanent)























2. Error codes
2.1. Overview

Display Meaning
-1- Sequence Stop activated
-21 24V Supply error
-3- Positioning error
-31 Proximity switch activated
-32 Non-equivalence X4
-33 Non-equivalence X5
-34 Non-equivalence X6
-41 Overtemperature Motor
-51 Overcurrent Motor
-52 Overload Inverter
-53 Overcurrent Inverter
-6- Servo trip
-71 Final stage error
-72 Overtemperature Inverter
-9- Parameter error
PAr Control not parametrized
C01 Configuration error X3
C02 Configuration error X4
C03 Configuration error X5
C04 Configuration error X6
C05 Configuration error X7
C06 Configuration error Magnetic switch 1 (MRS1)
C07 Configuration error Magnetic switch 2 (MRS2)
C08 Configuration error Magnetic switch 3 (MRS3)
C09 Configuration error Proximity switch 1 (INI-1)
C10 Configuration error Proximity switch 2 (INI-2)
C11 Configuration error Photoelectric switch 1 (LT-1)
C12 Configuration error Photoelectric switch 2 (LT-2)
C13 Configuration error Positioning Initiator -1
C14 Configuration error Positioning Initiator -2
C15 Configuration error Stopp Button (STT)
C16 Configuration error POS Positioning
C17 Configuration error Control rail (S1)


2.2. Error codes explanation

Negative blinking figures are error messages only !

Error -1-: Sequence stopp switch

Cause: - The push button will be activated
- No connection between push button and control

Solution: - Unlock push button, the trolley starts after parametrized time again
- Check the connection between push button and control

Error -21: Phase fault inverter

Cause: - 24V Voltage to low

Lösung: - Measure voltage of phases
- Check installation for short
- Check fuses

Error-3-: Positioning error

Positioning is not possible or lost of actual position

Cause: - The trolley will be pushed from the position
- Positioning Initiator defective

Solution: - Check positioning initiators


Error -31: Proximity switch activated

This error will be generated only by a correspondent configuration of proximity switch (see parameter).

Cause: - Proximity switch activated
- Proximity switch defective

Solution: - Proximity switch and cable is to check


Error-32 / -33 / -34: Non equivalence Ex Or

Cause: - The initiator is not Ex Or but configurated as an Ex Or
- A configured initiator no exists or the cable connection is not fixed.
- Both contacts of an initiator are open or both are closed
(Initiator defective)

Solution: - Check parameter settings of initiator ( see parameter MU )
- Mounting initiator , check plug that it is correct fixed
- Change the initiator

Error -41: Overtemperature Motor

Cause: - Motor has no temperature sensor (PTC)
- Motor parameter are wrong
- Cable break
- Mechanically stissness
- Motor defective

Solution: - Check type plate of motor
- Check parameter (see parameter MU)
- Check motor cable (Cable for PTC must be shielded)
- Check motor und mechanics

Error -51: Overcurrent Motor

Cause: - Motor parameter are wrong
- Mechanically stissness
- Motor defective

Solution: - Check parameter (see parameter MU)
- Check motor und mechanics

Error-52: Overload Inverter

The maximum power rate of inverter is overstepped.

Cause: - Inverter power rate for this application to small.
- Mechanically stissness

Solution: - Check load of trolley
- Check mechanics
- Put in inverter with higher power rate


Error -53: Overcurrent inverter

In normal operation the current output is higher than nominal current of inverter.
With selected automatically IxR compensation the error will be generated if current
is 200% higher than nominal current of motor.

Cause: - Motor defective (Interturn short-circuit)
- Parameter adjustment wrong

Lösung: - Check the motor
- Check parameter for nominal current / adjust value from type plate

Error -6-: Servo trip

The in parameter ABS given value is overstepped.

Cause: - The parameters of trolley are wrong
- The drivemotor is disconnected
- The brake do not open

Lösung: - Check parameter for synchronous drive
- Check mechanics
- Check brake

Error-71: Final stage error
To high starting current of inverter.

Cause: - Mechanically stissness
- Missing phase at drive motor
- Brake not opened

Solution: - Check mechanics
- Check cable to motor terminal
- Check brake
Error -72: Overtemperature inverter
In the semiconductor combination (Skiip) of power circuit are temperature sensors integrated for monitoring of chip temperatur.
Especially by driving synchronous via long distances the Skiip will be heating.

Cause: - Inverter power rate for this application to small
- Parameter of inverter wrong

Solution: - Put in inverter with higher power rate
- Check the load of trolley
- Check parameter (see parameter MU)

Error -9-: Parameter error

Cause: - The control is new and without parameter

Solution: - Write parameter into the control by MU

Error -PAr

Cause: - Wrong code for release of control

Solution: - Write in the correct code (see parameter MU)

Error -C01/-C05: Error Hardware Configuration X3-X7

Cause: - Hardware configuration wrong

Solution: - Check parameter (see parameter MU)

Fehler -C06 /-C15: Error Software Configuration

Cause: - Software configuration wrong
- Software is configurated, but hardware not allocated.
- Hardware is configurated, but software not allocated.
- Double software definition for the same hardware

Solution: - Check parameter (see parameter MU).

Error -C16: Positoning

Cause: - Positioning command is given and minimum one positioning initiator is not defined

Solution: - Check parameter (siehe parameter MU).
- Configurate both of positioning initiators.


Error -C17: Control rail

Cause: - Definition Magnetic switch wrong for configuration 9.

Solution: - Check parameter (see parameter MU).
- MRS1 & MRS2 or MRS2 & MRS3 wiil be used for speed odds (Configuration S1 == 9).


In case a control must be changed, please send this control with an precise error description. This description will be helpful to reduce the time of repair.
Then we are able to send back the control earlier.












3. Configuration
Name Function
Motortemperature Motortemperature monitoring
SW15 IR-Hand operation gives error message
SW14 Automatically IxR adjustment
SW13 No error display
SW12 Handoperation without conditions
SW11 Position monitoring
SW10 Changing positive / negative half wave for half wave control
SW9
SW8
SW7
SW6
SW5
SW4
SW3
SW2
SW1

I0 Test (SW14)
Preconditions:
- The corresponding parameter (In) for the motor's current limit must be set to the motor's rated current (read from the motor's type plate).
- The corresponding parameter (IxR) for the motor's IxR compensation must be set to a value that approximately matches the necessary IxR compensation.

Method of operation:
Before motion begins, the inverter generates a voltage corresponding to 2/3 of the set IxR compensation at a frequency of 0 Hz. This voltage value is then increased (by increasing the set IxR compensation internally) until the motor current has reached the parameter set for rated motor current. Using the IxR-compensation reached at that moment, the motor begins travel in accordance with the given drive command.

If the voltage is increased so much that it reaches 200 % of the specified IxR compensation, and the motor current has not attained the rated motor current, then the inverter send the error message "Inverter Overcurrent".

As long as the corresponding software switch remains selected, this measurement is repeated for each new drive command before motion begins.

Follow-up action:

Once IxR compensation has been set automatically, the IxR compensation then reached must be set as the new M1 parameter using the MU.
4. Parameter:
4.1. Overview Parameter
Name Unit Range Meaning
T0 ms 200 – 20000 Start delay time
T1 ms 0 – 60000 Waiting time after proximity switch free
T2 ms 0 – 60000 Waiting time after Z-Stopp free
T3 ms 0 – 60000 Slow drive after proximity switch free
T4 ms 0 – 60000 Follow up time vacuum cleaner/ pretravel time start message
T5 ms 0 – 60000 Waiting time after sequence stopp free
Ac1 ms/Hz 5 – 200 Acceleration ramp at even level (PCM 2-10)
Dc1 ms/Hz 5 – 200 Deceleration ramp at even level (PCM 2-10)
DcA ms/Hz 5 – 200 Deceleration ramp with activated proximity switch
DcZ ms/Hz 5 – 200 Deceleration ramp with Z-block
V0 xm/min 1 – 32700 Speed PCM 2/3, IR slow
V1 xm/min 1 – 32700 Speed PCM 4/5, IR fast
V2 xm/min 1 – 32700 Speed PCM 6/7
V3 xm/min 1 – 32700 Speed PCM 8
V4 xm/min 1 – 32700 Basic speed synchronous drive (PCM 20)
V5 xm/min 1 – 32700 Cumulative speed synchronous drive (from PCM 21)
V6 xm/min 1 – 32700 Maximum speed magnetic switch 1
V7 xm/min 1 – 32700 Maximum speed magnetic switch 2
V8 xm/min 1 – 32700 Maximum speed magnetic switch 3
V9 xm/min 1 – 32700 Maximum speed Photoelectric switch/ proximity switch
V10 xm/min 1 – 32700 Speed selfpositioning
V11 xm/min 1 – 32700 Speed PCM 10
V12 xm/min 1 – 32700 Speed Reserve
AB1 xm 1 – 32700 Drive distance (pulled with proximity switch)
AB2 xm 1 – 32700 Maximum servo trip
G %/Incr 1 – 255 Gain servo
Gmn % 1 – 100 Minimum gain servo
In 100mA 1 – 200 Nominal current
M1 % 0 – 25 IxR Compensation
M21 Hz 40 – 130 Corner frequency
GET xm/min 100 – 32700 Speed at 50Hz
Geb xm/kIncr 5 – 32000 Scaling DLS 2
BO1 1/10 Hz 1– 100 Frequency open brake in even level (PCM 2-10)
BC1 1/10 Hz 1– 100 Frequency close brake in even level (PCM 2-10)
Rs1 0 – 65535 Reserve
Fz 4 – 16 Interfrequency
X3 0 – 255 Configuration X3
X4 0 – 255 Configuration X4
X5 0 – 255 Configuration X5
X6 0 – 255 Configuration X6
X7 0 – 255 Configuration X7
CMR1 0 – 255 Configuration magnetic switch 1
CMR2 0 – 255 Configuration magnetic switch 2
CMR3 0 – 255 Configuration magnetic switch 3
CA1 0 – 255 Configuration Proximity switch 1
CA2 0 – 255 Configuration Proximity switch 2
CLT1 0 - 255 Configuration Photoelectric switch 1
CLT2 0 - 255 Configuration Photoelectric switch 2
CST 0 – 255 Configuration Stopp button
X7_5 0 – 255 Configuration Output
S1 0 – 255 Configuration Control rail S1
S2 0 – 255 Configuration Z-Block S2
Res 0 – 65535 Configuration Reserve
Key 0 – 65535 Parameter release

Legend
xm: Units of measurement, e.g. mm, cm, dm, inches, ... . All parameters must be input using the same units of measurement. Select the unit in accordance with installation requirements, but using the smallest unit possible.

4.2. Parameter description

T0 Start delay time

After switching on the controller, the controller remains inactive for the amount of time set in this parameter. ‘LJU’ appears on the display.


T1 Waiting time after proximity switch free

After proximity switch has been released, the controller remains inactive for the amount of time set in this parameter. After this time period has elapsed, the vehicle begins to move again.


T2 Waiting time after Z-Stop free

After Z stop release, the controller remains inactive for the time specified by this parameter. After this time period has elapsed, the vehicle begins to move again.


T3 Slow drive after proximity switch free

After after proximity switch free, the controller travels for the time specified by this parameter with speed V7. After this time period has elapsed, the vehicle travels at the speed corresponding to the drive command.


T5 Waiting time after sequence stop free

After the sequence stop switch has been free, the controller remains inactive for the amount of time set in this parameter. After this time period has elapsed, the vehicle begins to move again.


Acx Acceleration ramp

The diagram below shows an example graph of frequency against time, with a set acceleration ramp of 10 ms/Hz.











Dcx Deceleration ramp

Deceleration ramp analogous to acceleration


V4 Basic speed for servo drive and
V5 Cumulative servo drive speed

The synchronous speed to be driven at is calculated from drive command 20:



In Nominal current motor

The nominal current of motor must be read from the motor’s type plate and then entered as a parameter here.



M1 I*R Compensation
M2 Corner frequency

These influence the level-control characteristics dependent on frequency.
General explanation of the IxR compensation using an example IxR compensation set at 0 % and 10 %:















GET Gear factor

Synchronous speed at 50 Hz. This parameter is used to calculate the driving frequency. This value must always correspond to the speed for 50 Hz, even with 60 Hz line frequency.


Geb Position encoder scale

Specifies the length unit for 1000 increments of the position encoder.


Key Parameter key

The parameter key is ´2064´.



Fz Setting the inverter intermediate frequency

Value Intermediate circuit frequency
4 4kHz
5 5kHz
6 6kHz
7 7kHz
8 8kHz
9 9kHz
10 10kHz
11 11kHz
12 12kHz
13 13kHz
14 14kHz
15 15kHz
16 16kHz


X3-X7 Hardware configuration

Configuration 0 1 2 3 4 5 +128
Outlet
X3 No exists. MRS-1 Pos-1
X4 No exists. DLS MRS-2 A-INI-2 LT-2 Pos-2 Ex Or
X5 No exists. A-INI-1 LT-2 Ex Or
X6 No exists. LT-1 A-INI-2 MRS-3 Pos-1 Ex Or
X7 No exists. Stop MRS-3 Pos-2

Remark: - Synchronous drive is activated if DLS is configurated.
- Selfpositioning is activated if Pos-1 and Pos-2 are configurated.

MRSx Configuration of Magnetic switch

Value Function
0 No exists
1 open -> Speed limitation on (V6 – MRS1 / V7 – MRS2 / V8 – MRS3)
2 open -> Bisection of speed
3 closed-> Speed limitation on (V6 – MRS1 / V7 – MRS2 / V8 – MRS3)
4 closed-> Bisection of speed
5 Closed and no drive command -> open brake
6 Closed and motor is stopped -> open brake
7 Speed monitoring with 2 MRS
+64 In synchronous mode faded (Bit 6 setted)


INIx Configuration of Proximity switch

Value Function
0 No exists
1 Stop of trolley, restart after T1, limitation of speed on V9 for T3.
2 Stop of trolley, restart after T1
3 Stop of trolley by driving onward, restart after T1, limitation of speed on V9 for T3.
4 Stop of trolley by driving onward, restart after T1
5 Stop of trolley by driving backwards, restart after T1, limitation of speed on V9 for T3
6 Stop of trolley by driving backwards, restart after T1
7 Error message with activation
+32 (Bit 5 setted)
With PCM 9: - by activation of proximity switch -> Error message on M1
+64 (Bit 6 setted)
With PCM 10: - by activation of proximity switch -> Error message on M1

Remark: DcA – Deceleration ramp proximity switch


CLTx Configuration of Photoelectric switch

Value Function
0 No exists
1 E_4 open -> Limitation of speed on V9
2 E_4 open -> Bisection of speed
3 E_2 open -> Limitation of speed on V9
4 E_2 open -> Bisection of speed
+16 E_2 open -> Stop
+32 E_4 open -> Stop
+64 in synchronous mode faded (Bit 6 setted)


CST Configuration of Sequence stop (Sequence stop resets all errors)

Value Function
0 No exists
1 Stop without error message on M
2 Stop with error message on M
3 Stop keying without error message on M
4 Stop keying with error message on M

Remark: T5 – Start delay time after sequence stop free.

A7_5 Configuration Output

Value Function
Signal lamp
0 Normally off, blinking with error, on with activated sequence stop
1 Normally on, blinking with error, slow blinking with activated sequence stop
Vacuum cleaner/ Start warning
2 Activation with running motor and follow up time T4
3 Start delay of control for T4, Activation before start and with running motor
4 Start delay of control for T4, Activation for this time only

Output: 24V / max. 100mA.

S1 Configuration of Control rail S1

Value Function
0 No control rail
1 PCM 50Hz
2 PCM 60Hz
3 Full wave V0, pos. Half wave V1, neg. Half wave V2
4 Full wave V0, pos. Half wave V1, neg. Half wave open brake
5 Full wave V2, pos. Half wave V1, neg. Half wave V0
6 Full wave V1, pos. Half wave V0, neg. Half wave open brake
7 Full wave V1, pos. Half wave V0 onward, neg. Half wave V0 backwards
8 PCM10 old 50Hz
9 Full wave activation
Speed via MRS1 and MRS2 or MRS2 and MRS3:
0 0 - V0
0 1 - V1
1 0 - V2
1 1 - V3
The functions 3 up to 8 are described for SW10 = ´+´ . With SW10 = ´-´ the Half waves will be changed + / -
.
S2 Configuration Z-Block Control rail 2

Value Function
0 No exists
1 Z-Block stopps without conditions
2 Z-Block stopps onward only

Remark: DcZ – Deceleration ramp Z-Block.



5. Display
5.1 Display mode
0: Frequency in Hz with preceding sign
3: Motor current in 100 mA unit U
4: Chiptemperatur [°C]
5: 24V Versorgung in Volt.
6: Motortemperatur unskaliert
7: Umrichterleistung
8: Anzeige Steuerbefehl Umrichter
Display Meaning
0001 Parameter set selection
0002 Parameter set selection
0004 Parameter set selection
0008 Monitor I²t
0010 Monitor overcurrent
0020 Zwischenkreisspannung überwachen
0040 Zwischenkreisspannung kompensieren
0080
0100
0200
0400 Release brake
0800 Servo travel
1000 Manual mode (restricted error evaluation)
2000 Initialize servo trip
4000 Activation command
8000 Release inverter

9: Inverter speed setting
10: Display IxR compensation [1/10 %]
11: Display inverter status
Display Meaning
01 in Position
02 Drive release inverter
04 Hardware locker released
08
10 Inverter runs
20
40
80 Inverter error pending

16: Servo level control (amplitude) %
17: Servo trip
20: PCM commands S1
21: PCM commands S2

40: Display inputs
Display Plug
0001 X3/4
0002 X5/2
0004 X5/4
0008 X7/4
0010 X6/2
0020 X6/4
0040 X4/2
0080 X4/4

41: Display outputs
Display Plug
01 X7/5

42: Hardware Configuration
Display Meaning
0001 Magnetic switch 1
0002 Magnetic switch 2
0004 Magnetic switch 3
0008 DLS-2
0010 Proximity switch 1
0020 Proximity switch 2
0040 Photoelectric switch 1
0080 Photoelectric switch 2
0100 Positioning initiator 1
0200 Positioning initiator 2
0400 Stop button

43: Display Periphery inputs on E4 (see 42)
44: Display Periphery inputs on E2 (see 42)

49: Display IR-Drive command

Explanation of tables see point 8.2. !


5.2. Other displays

Point on 2. digit: IR-Communication
Left digit of display blinks: H ( Hand operation)




6. Remote control FB-606

Button Function
 Hand operation
# Normal operation
 Onward driving with V0
 Onward driving with V1
 Backwards driving with V0
 Backwards driving with V1
 Open brake
 Without function
 Without function
 Without function


7. PCM Commands

Command Speed Remark
0 Stopp
1 Stopp
2 V0 onward
3 V0 backwards
4 V1 onward (Positioning)
5 V1 backwards (Positioning)
6 V2 onward
7 V2 backwards
8 V3 onward
9 Stop Open brake
10 V12 onward Proximity switch–> signal on signal rail
11..19 Stopp
20 V4 Basic speed synchronous drive
21 V4+V5 Synchronous drive
22 V4+(2*V5) Synchronous drive

191 V4+(171*V5) Synchronous drive





8. Technical Appendix
8.1. The Handheld Programming Device MU 505

- The software in the MU 505 is organized into menus.
- A menu item is selected by pressing the corresponding number.
- You change to the next highest menu with the ‘*’ key.
- In the upper menus the MU 505 can be switched off with the ‘0’ key.

The most important menu points and paths are as follows:

- Main menu
- Parameters
- Write data: Transmit the set parameters and versions to the controller
- Read data:
- Change data:
- Data: Parameters can be input here.
- Version:
- Test
- Remote control: The MU must be pointed towards the controller for all described operations. (The range is very limited.)
- Selecting this menu command sets the controller to manual operation.
- The arrow keys correspond to those on the remote control.
- The key combinations with ‘*’ are not functional.
- When leaving this menu item by pressing ‘*’, normal mode is switched on.
- Target/number: is not used
- Configuration:
- Switch-off time: Unit switches off automatically to save batteries
- Language: Switch between the stored languages

Minor variations in detail according to specific projects!



8.2. Display of Input Signals or Control Flags

An input or flag can have one of two states: ‘0’ or ‘1’. This corresponds to one digit in the binary number system.
Computer technology works with bits and bytes. One bit corresponds to one binary digit. Eight bits are combined to one byte. Therefore, one byte corresponds to an eight digit binary number: e.g. 10010111b.
Conversion to a decimal number is carried out bit-by-bit using the formula: D = B x 2¬n. ‘n’ indicates the position in the binary number. The 0 (zero) position is on the right, then we count up moving to the left. The sum of all values equals the decimal number.

1 0 0 1 0 1 1 1
| | | | | | | 20- 1 x 1
| | | | | | 21- ----- 1 x 2
| | | | | 22- ----- ----- 1 x 4
| | | | 23- ----- ----- ----- 0 x 8
| | | 24- ----- ----- ----- ----- 1 x 16
| | 25- ----- ----- ----- ----- ----- 0 x 32
| 26- ----- ----- ----- ----- ----- ----- 0 x 64
27- ----- ----- ----- ----- ----- ----- ----- 1 x 128
= 151d

In the hexadecimal numbering system, a digit can have 16 values (0..9 + A..F). These represent all possible combinations of four bits. A byte can therefore be represented by two hexadecimal digits. The valency of the bits is as follows:

Bit 0: 01 Bit 4: 10
Bit 1: 02 Bit 5: 20
Bit 2: 04 Bit 6: 40
Bit 3: 08 Bit 7: 80

As long as only one of these bits is active, the number indicated can be allocated directly to the input / flag belonging to it.
If more than one bit is active, their values are added together. For the sake of simplicity, only the lower four bits / the right hexadecimal digits are considered in the following examples.

Display: 9 = 1 + 8 => bit 0 and bit 3 are active
Display: 7 = 1 + 2 + 4 => bit 0, bit 1 and bit 2 are active

The letters A..F stand for the numbers 10..15:
Display: A (10) = 2 + 8
Display: d (13) = 1 + 4 + 8
Display: F (15) = 1 + 2 + 4 + 8

The advantage of this logic is that it is closely related to how the processor works. In this way, a substantial amount of information can be represented with very little effort.
 
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