Calibration and Re-programming Requirements for MM4

Calibration and Re-programming Requirements for MM4................................1

General notes: .................................................................................................1
MM420: frame Sizes A, B, C............................................................................1
MM440 Frame Sizes A, B, C. ..........................................................................2
MM440 Frame Sizes D, E................................................................................2
MM440 Frame Size F ......................................................................................2
MM440 Frame Size Fx, Gx. .............................................................................3
Control Board setting up. .................................................................................3
Calibration information. ....................................................................................3
Current and Voltage calibration. ......................................................................4
Power Stack EEPROM Programming..............................................................6
Programme installation ....................................................................................6
Programming the EEPROM.............................................................................6

General notes:

1. Calibration, firmware and Power Stack Data are stored in different ways on
MM4, therefore when boards are exchanged and repaired different
calibration procedures are required. This document describes the different
programming or calibration requirements for each type of MM4, and then
describes how to carry them out.
2. Power stack Data. The power stack data (power rating, currents, some
calibration information) is stored on an EEPROM in the power part of the
inverter. This location varies with different frame sizes. If this part is
replaced, then the EEPROM must be loaded with the correct Power stack
data for that inverter. See Power Stack EEPROM Programming. This
information needs to be copied to the control board, either when a control
board is replaced, or when a power part with a new EEPROM is replaced.
See Control Board setting up.
3. Calibration settings. Many calibration settings are stored in hidden
parameters. These need to be adjusted when certain boards are
exchanged. See Current and Voltage Calibration
4. Firmware. Upgrading the firmware is not usually carried out other than in
central repair workshops.

MM420: frame Sizes A, B, C.

These units are manufactured as complete power assemblies with control
board fitted at final test. Therefore these are the only exchangeable parts.
That is, in the case of power board damage all three PCB parts of the power
assembly must be replaced.

When a control board is replaced, or a new power assembly installed, the

Control Board Setting Up must be carried out. This uploads the EEPROM
(Powerstack) data to the control board, and sets certain parameters.

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MM440 Frame Sizes A, B, C.
These units are manufactured as complete power assemblies with the i/o
board and control board fitted at final test. Therefore these are the only
exchangeable parts. That is, in the case of power board damage all three
PCB parts of the power assembly must be replaced.

When a control board is replaced, or a new power assembly installed, the

Control Board Setting Up must be carried out. This uploads the EEPROM
(Powerstack) data to the control board, and sets certain parameters.

The customer removable i/o board may be exchanged without recalibration.

MM440 Frame Sizes D, E.

These MM440 units contain several boards which may be individually

exchanged, requiring different calibration procedures.

1. When a control board is replaced, or a new power assembly installed, the

Control Board Setting Up must be carried out. This uploads the EEPROM
(Powerstack) data to the control board, and sets certain parameters.

2. The EEPROM containing the power stack data is mounted on the Gate
Driver (GAP) board. If the GAP board is replaced the EEPROM must be
programmed with the correct settings as described in EEPROM
Programming. Read out the calibration information from the GAP Board
before it is replaced if possible, otherwise carry out Current and Voltage
Calibration.

3. If a power board alone is replaced, then it is only necessary to carry out

Current and Voltage Calibration. The correct Power board variant must be
used, otherwise EEPROM data will not match.

MM440 Frame Size F

These MM440 units contain several boards which may be individually

exchanged, requiring different calibration procedures.

1. When a control board is replaced, or a new power assembly installed, the

Control Board Setting Up must be carried out. This uploads the EEPROM
(Powerstack) data to the control board, and sets certain parameters.

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2. The EEPROM containing the power stack data is mounted on the
Combined power and driver board (GPC). If this board is replaced, the
EEPROM must be programmed with the correct settings as described in
EEPROM Programming. It is also necessary to carry out Current and
Voltage Calibration.

3. The Current shunt is mounted on the heatsink. This unit is pre-calibrated,

so current calibration is not necessary if it is changed.

MM440 Frame Size Fx, Gx.

These units are supplied with pre-calibrated control assemblies and power
stacks which are fully interchangeable without re-calibration. The EEPROM
containing the power stack information is on the ABO board, part of the
control assembly.

Therefore calibration is only required when a control board is replaced.. In

this case, the Control Board Setting Up must be carried out. This uploads the
EEPROM (Powerstack) data to the control board, and sets certain
parameters.

Control Board setting up.

The control board must be loaded with the EEPROM Power stack data, and
test status values reloaded.

Calibration information.

Enter Service mode: P0003=4, P3950=71(password – keep confidential)

From the existing control board, read and note:

P3901 5V calibration setting*

If possible, also record the following – this information is used if the drive is
returned for repair to the factory
P3918 Test Status
P3919 Test Status
P3920 Test Status

Remove existing control board, install new board

Enter Service mode as above

Read parameter r0200 (Power stack type) and write this value to P0201. This
programmes the control board with the power stack type.

Factory reset P0010=30, P0970=1

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Power cycle

Enter Service mode again

Reload values P3901, (3918, 3919, 3920).

Power cycle.

*If the control board information cannot be read, measure the 10V output on
the i/o board (terminals 1 and 2) and adjust 3901 in service mode to give
exactly 10V. Don’t worry about P3918 etc.

Analog Output Calibration.

If necessary, the Analog output may be calibrated as follows:

Enter Service mode

R0774 displays the value of the analogue output in mA. A reading of 20mA
between terminals 12 and 13 should be displayed on a multimeter when 50Hz
is reached. Using the following formula correct any discrepancy. ( (I
measured - 20) x 100) +Val P3906 = new value of P3906. Enter new value
in P3906. Verify result by checking multimeter reading = 20mA at 50Hz.

Current and Voltage calibration.

Current and voltage calibration is required when power measuring

components are replaced, such as the current shunts, voltage dividers etc on
the power board.

Voltage Calibration.
Enter Service mode (P0003 = 4, P3950 = 71)

Parameter P3902 is used to adjust the voltage calibration.

Measure the DC Voltage (DC +, DC -) and adjust the value of P3902 so that
the displayed value matches the measured value. The setting should be +/-
6V maximum error.

EEPROM contents are automatically updated.

Power cycle to leave service mode.

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Current Calibration.
It is necessary to make as accurate a measurement as possible to set the
current calibration. The current measuring device should have an accuracy of
at least 1% to ensure correct calibration.

Either (1) run the motor to measure the current and make adjustments, or (2)
make the measurements in each phase using DC as detailed below.

1. Running the motor.

Run the motor on load to draw about 75% of full load current, ideally at about
45Hz. Measure the current in U phase and adjust P3907 index 0 so that the
value in r0069 index 0 is equal to the measured value. Repeat with phases V
and W using P3907 indexes 1 and 2 respectively (referring to r0069 index
1and 2 respectively).

On MM440 frame sizes A to C W phase adjustment is not necessary.

2. Using DC.

A more accurate, steady current can be generated by injecting DC into the

motor as follows;

P1910 = 20 to set voltage control

P1931 = 1,2, or 3 for phase U, V, or W
P1930 = Voltage output.

Using P1930, adjust the voltage to generate approximately 50 to 75%

current.
Note! Prolonged operation may overheat the motor.

To adjust U Phase:
Make P3907.0 = 1000
P1931 = 1
Adjust P1930 to give about 75% full load current.
Measure U phase current.
Read r0069.0
Make P3907= 1000 x ( measured current/ r0069.0)

Repeat for V and W phases using P1931=2 and 3, and P3907.1,2 and
r0069.1,2.
On MM440 frame sizes A to C, W phase adjustment is not necessary.

EEPROM contents are automatically updated.

Power cycle to leave service mode.

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Power Stack EEPROM Programming

EEPROM Programming requires a programme to load the EEPROM Data,

(which is contained in an Excel csv file) and an PC to Drive interface lead.

Programme installation
Follow the instructions in the readme file supplied under the software and
support directory.

Programming the EEPROM

To programme the Power Stack, connect the PC interface to the drive, double
click on the icon (Vector for MM440, Basic for MM420) and follow the
instructions, making sure the correct power stack ID is selected.

The power stack id can be read from r0200, or from the Excel csv table
included in the folder, or from the manual listed in r0200.

When the programming is finished, check that P0201 = to the value of r0200
to set the correct power stack for the control board, then cycle the power.

It is very important that the correct power stack ID is loaded into the drive,
otherwise damage may result.
It is not possible to reprogramme MM420 or MM410s with this software.

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