Tuning DC Drives Training Material: G. Franklin Stephenson Abb LTD Bangalore

G.
Franklin Stephenson Tuning

ABB Ltd DC Drives
Insert image
Bangalore
here
Training Material
© ABB Limited / Page 1
10/07/21
Training Contents.
 Introduction
 Basics Motor/Drives
 Applications
 Drive Tuning
 Field Tuning
 Armature Tuning
 Flux Linearization
 EMF Tuning
 Ramp Test
 Speed Controller Tuning
 Torque Step
 Noload Loss Measurement
 Inertia of System Calculation

Introduction
 Why Tuning/Parameterization is Required ?
 For good System response.

 Improve the performance of drive.
 To meet the requirement of Demanding Application.
 Wrong parameter settings - Fusing of DC-drives
 Wrong tuning of regulators -Fusing of DC-drives
DC-motor basics – DC-motor
Main parts:
 Stator
 Rotor with commutator
DC-motor basics – Separate excited DC-motor
Characteristics:
 Both armature and excitation are
supplied by a separate power source
Equivalent circuit diagram:

T = Torque
IA RA LA
T  k  IA 
k=
k U i constant
IF n  = Flux
U1
Ui 
UF dI A
U i  U 1  RA  I A  LA 
dt
Armature Excitation
DC-motor basics – Characteristics of sep.ex.
DC-motor UN
Armature Voltage UA
IAN
Armature Current IA
IN
Excitation Current If
TN
Torque T
PN
Power P
n
nb Field nmax
Basic Speed
Weakening
Speed
C1
DC-Drive
C2
A5
A6
A7
DC-drive basics – General layout
MV line
MV/LV transformer
Field transformer
AC-breaker
Semiconductor fuses
Field fuse
Line reactors
Field contactor
PLC
Field converter
~ ~ Armature converter
MMI /
Panel
DC fuses
Speed
feedback
DC motor
Field Winding
Load
DC-drive basics – Armature converter
AC line current DC current
DC voltage
Line reactors Id
1 3 5
3 AC network Principle circuit diagram:
Xk iL Id
~ ik

= Ud  cos  M
~ Ud  E
Usupply uL
~ Converter Motor
Voltage source characteristic:
4 6 2 Ud
Ud  cos 
6-pulse thyristor bridge (line commutated) 

 = 90°
 controlled voltage source (firing angle )
 output voltage can be positive or negative
DC-drive basics – Single bridge (2-Q)
Speed (voltage)
ID
II I
Braking Driving M
Torque
UD
(current)
III IV
Driving Braking Typical applications:
 Extruder
 Mixer
Negative current is not possible  Rod and bar mills
DC-drive basics – Double bridge (4-Q)
Speed (voltage) ID
II I
Braking Driving M
Torque
UD
(current)
III IV Typical applications:
Driving Braking  Ski lifts
 Coiler,Mill
 For smooth and
Negative current is possible
fast torque reversal

DC-drive basics – Example double bridge (4-Q)
 Motor accelerating from zero
speed to maximum speed 6
1 2 34 5 7
and then reversing to
maximum negative speed
Speed
Speed (voltage)
(EMF) t
4 3
5 2
1
Torque
(current) Torque
6 (current) t
7
Application – FAN
Application - Pump
Application – Paper Machine
Application - Winders
Application – Roller tables
Application - Conveyors
Mill
20Hi mill
Field Auto Tuning
 Open the drive window & select the drive in local mode
 select Field Current ref (par 3.17)and

Field Current act (par 3.19),put it for monitoring
Close main contactor (No Start-command)
 Select para 15.02 and put it in online monitoring.
 Set value 5 to para 15.02 DRIVE_MODE
 Monitor Para 15.02
If the value change to 0 after One or Two minute Auto Tuning done.
If the value changes to -1 then there is fault.

Check the error code of the fault in para 6.02 COMMIS_STATUS
If the tuning fails,look for Para 44.17 Field_1_MIN_TRIP and set to 30%
Also look for Para 20.16 FIELD_CURRENT_LIMT and set to 120%
Open main contactor

Field Auto Tuning

Field Auto Tuning – 3ph Field
Field Manual Tuning
Open main contactor
Set following values

Para 17.01 POT1 = 3686 (90% of nominal field current,
Para 41.03 Nominal Scaling value = 4095 = 100%)
Para 17.02 POT2 = 3276 (80% of nominal field current)
Para 17.03 SQR_WAVE_PERIOD = 3000msec
Para 15.02 DRIVE_MODE = 7 (Manual tuning of 1st field exciter)
Select Field Current ref (par 3.17)and

Field Current act (par 3.19),put it for monitoring
Give ON command and start the monitor tool.

Observe the waveform of para 3.19 REL_FIELD_CUR_M1.
Field Manual Tuning

Field Manual Tuning
Change the parameters
44.02 (P-GAIN_FEX_1) and
44.03 (INTEG_TIME FEX_1)
To get good response (e.g 80 to 100msec)
Drive window Settings (e.g.): Sampling interval 10ms

Axis length 5s
Signal 3.17 70%-100%
Signal 3.19 70% - 100%
After tuning Give OFF command
Set Para 15.02 DRIVE_MODE = 0
Set Para 17.04 TEST_REF_SELECT = 0

Armature Auto tuning
Open the main contactor
Set following parameters
50.03 SPEED_FB_SEL = 5
(Speed actual measured on EMF, recommended if the motor has no
mechanical load )
15.02 DRIVEMODE = 3
Within 20 seconds close the main contactor and start the converter
Tuning is completed, when Par.15.02 changes back to zero.
Switch off the drive.
If Para 1502 is set to -1 an error has occured. The cause of the error can be
seen from signal Signal 602 COMMISS_STAT.
15.02 DRIVEMODE = 0
After autotuning new values of armature current controller can be seen
43.02 ARM_CUR_PI_P-GAIN
43.03 ARM_CUR_PI_I-GAIN
43.06 DISCONT_CUR_LIMIT
41.11 ARM_L
41.12 ARM_R
Armature Auto tuning

Armature Manual Tuning
Open main condactor
Set following parameters
15.02 = 4 (Manual tuning of the armature current controller)
At first you have to find the current limit where the armature current changes
from continuous to discontinuous current.
There are two ways to get this value:

 By measuring with a scope the voltage between the terminals X4:5 and X4:6
of the IOB-3 board, where you have a direct access to the armature current
(represented as 3V-signal)
 By using the Drives Window Tool and watching bit 12 (continuous current
flow) of signal 6.05 CON2_BITS. Bit 12 oszillates, when you reach the limit
of continuous armature current.
17.04 TEST_REF_SEL = 1 (POT1)

Armature current reference is set during the test by POT1.
Close main contactor, give ON-command

Give start command.
17.01 POT1 increase value( armature current ref) slowly till bit 12 of
signal 6.05 CON2_BITS oszillates (e.g. at a value of POT1 of 3000)
Settings: 6.05, Bit 12 -1 - +1
Then read signal 1.15 RL_CONV_CUR_ACT and
Set the same value to the Para 43.06 DISCONT_CUR_LIMIT
Give Stop Drive
Give OFF Command

Set following parameter
1701 = 2000
1702 = 3000
1703 = 3000ms
1704 = 3 (SQUARE_WAVE)
Monitor following parameter
3.3 Square Wave
1.15 REL_CONV_CUR_ACT
Give ON command
Give Start command
Change the following parameter to get good response of 5 to 10msec
43.01
43.02(40.04)
43.03(43.05)
Tuning is over give STOP command
Give OFF command.
Change following parameter
1704 TEST_REV_SEL reset to 0

1502 DRIVE_MODE reset to 0
Flux Linearization
 Set following parameter
15.06 FIELD_CONTROL_MODE = 1 (EMF_CON)
46.01 POS_LIM_EMF_CON = 0 (pos. limit of EMF-controller output)
46.02 NEG_LIM_EMF_CON = 0 (neg. limit of EMF-controller output)
45.02 FLUX/EMF_REF_SEL = 1 (EXT_REF)
45.01 FLUX_REF = 100%
Give ON command
Give START Command
Set the motor speed to about half of nominal speed.
Read signal 1.18 EMF_VOLT_ACT, corresponds to a field current of 100%
(signal 3.19 REL_FIELD_CUR_M1)
Calculate the EMF-values (1.18) for 90%, 70% and 40% of flux
Adjust flux-values by using signal 45.01 FLUX_REF to get 90% of Emf Voltage
but don‘t change the speed.
Hint: If it is not possible to adjust the value of 40% because the
converter trips, at first arise the tripping level of the field current,
parameter 44.17 FIELD_1_MIN_TRIP
(default value = 50%)

Flux Linearization
Read the corresponding values of the field current from signal 3.19 and
Note it down it has to be entered Later in Para 41.14.
Adjust flux-values 45.01 FLUX_REF to get 70% of Emf Voltage.

Adjust flux-values 45.01 FLUX_REF to get 40% of Emf Voltage.

Give STOP Command

Give OFF comand.
Flux Linearization
Set the field current value to following parameters which has been noted .
Para 41.14 FLD_CUR_@40% FLUX

Revert back following values to
Para 45.01 FLUX_REF = 100%

Para 45.02 FLUX/EMF_REF_SEL = LOCAL REF
Para 46.01 POS_LIM_EMF_CON = 10%
Para 46.02 NEG_LIM_EMF_CON = -99%
Flux Linearization
Emf Tuning
Start the drive
Increase the local speed reference up to 50% of the nominal speed.
Read the value of signal 1.17 RL_EMF_VOLT_ACT
(Remember the scaling factor of EMF, 3786 == 135%)
Stop the drive.
Set the following parameters:
17.01 POT1_VALUE = 95% of read EMK value

17.02 POT2_VALUE = 100% of read EMK value
17.03 PERIOD = 3000 (3s)
17.04 TEST_REV_SEL = 3 (SQRW)
15.02 DRIVE_MODE = 11 (manual tuning of EMF-controller)
15.06 FIELD1_MODE = 1 (EMF-control without field reversal)
50.03 SPEED_FB_SEL = Con-Encoder
Emf Tuning
Start the drive.

Increase the local speed reference up to 50% of the nominal speed.
Observe the actual value of EMF, signal 1.17
To get good response(e.g 100 to 150msec)

Change the Para 46.03 EMF_CON_KP
Change the para 46.04 EMF_CON_KI
Stop the drive and open the main contactor.
1704 TEST_REV_SEL set back to 0.
1502 DRIVE_MODE set back to 0.
Emf Tuning
Ramp up
Once all tuning is through.
Run the drive to it max speed with short Acc of 10/20sec.
Also Run in reverse directions to full speed.
While Acc armature voltage should not over shoot and
It should be steady above base speed.
Stop the drive and now motor is ready for coupled trials.
Ramp up
Speed Controller Manual Tuning
Start drive at 200rpm.
Select following parameter for monitoring in 10ms
1.04 Speed act
23.10 Speed step
2.09 Torque ref 2
1.16 Convertor current
Set value 10rpm to 23.10 speed step
(Don’t give more than 15rpm which may create mechanical
damage )
Observe the response
Again set 23.10 speed step to 0rpm
Observe the response.
To get better response

 change the para 24.03 Kps and
 change the para 24.09 Tis
Give speed step and see the response
Repeat the speed step procedure until getting good response of
100 to 200ms
And also check for various speed range.
Coiler
Coiler consist of:

 Motor with gearbox Wind up direction
and mandrel
(some applications are
gearless) Unwind direction
 Coil with strip

 Coil wind up or unwind
from the mandrel
Recoiler
 Wind up process from
top definition (tension reel)
 dv/dt Ref. and acceleration
torque
+ Plant & + Drive Speed Ref.
(Acc. Tq) is positive
+ Tension
 Positive Mill / Plant speed
reference
+ Diameter
 Diameter increase
 Tension is positive
 Loss torque is positive + Loss Torque
+ rpm speed
 Drive and rpm speed + dv/dt Ref.
reference is positive + Acc. Tq
Uncoiler
 Unwind process from top
definition (pay off reel)
 Positive Mill / Plant speed
reference
+ Plant & - Drive Speed Ref.
 Diameter decrease
+ Tension
 Tension is positive
 Loss torque is negative - Diameter
 Drive and rpm speed
reference is negative
- Loss Torque
 dv/dt Ref. and acceleration - rpm speed
torque - dv/dt Ref.
(Acc. Tq) is negative - Acc. Tq
Recoiler
 Wind up process from
bottom definition (tension
reel)
 Positive Mill / Plant speed + Plant & + Drive Speed Ref.
reference
 Diameter increase
 Tension is positive + Diameter
 Loss torque is negative
- Loss Torque
 Drive speed reference is - rpm speed
positive; + dv/dt
- Acc. Tq
rpm reference is negative
+ Tension
 dv/dt Ref. is positive and
acceleration torque
(Acc. Tq) is negative
Uncoiler
 Unwind process from
bottom definition (pay off
reel)
 Positive Mill / Plant speed + Plant & - Drive Speed Ref.
reference
 Diameter decrease
 Tension is positive + Diameter
 Loss torque is positive
+ Loss Torque
 Drive speed reference is + rpm speed
negative; - dv/dt
+ Acc. Tq
rpm reference is positive
+ Tension
 dv/dt Ref. is negative and
acceleration torque
(Acc. Tq) is positive
Loss torque compensation
 What is no load Loss?

 No load Loss is nothing but minimum torque required to run the
motor at a particular constant speed.
 No load Losses = Motor Loss + Gear Box Loss+ Bearing losses
 Why it is so important ?
 To get a accurate tension torque.
 Making speed controller more dynamic and faster.
 Normally size of the losses are in the range of 3% of

nominal torque.
Loss torque compensation
Measurement procedure: Characteristic:
 Average loss value over the [Nm]

Loss torque compensation = f (n)
measured time related to the

speed reference M (L)
 Maximum loss value over the

speed reference
 Minimum loss value over the
speed reference
 Average percent loss value n [rpm]
over the measured time
related to the speed reference

Inertia compensation
Why inertia is to be known ?

Acc Torque is depend on inertia of system.
Tacc = J*d/dt
So if inertia is known, the torque correction can be
given to drive before speed controller getting activated.
With this compensation drive response is very fast.
Report
Protection philosophy
 Size of the system (cost of investment)

 Application (2-Q, 4-Q, mainly regenerative)
 Acceptable downtime, availability of system
 Risk the customer wants to take
 Supply voltage conditions (stable networks)
Protection settings
 Armature/ Convertor over current

 Armature over Voltage
 Field overcurrent
 Field under current
 Mains Undervoltage
Notes
3BYN20080000103 Rev -
ABB Limited
Plot 5 & 6, 2nd Phase,
Peenya Industrial Area,

Peenya,
Bangalore – 560058
India

Tuning DC Drives Training Material: G. Franklin Stephenson Abb LTD Bangalore

Uploaded by

Copyright:

Available Formats

You might also like

Tuning DC Drives Training Material: G. Franklin Stephenson Abb LTD Bangalore

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Tuning DC Drives Training Material: G. Franklin Stephenson Abb LTD Bangalore

Uploaded by

Copyright:

Available Formats

G.

Franklin Stephenson Tuning

 Inertia of System Calculation

 For good System response.

Equivalent circuit diagram:

6-pulse thyristor bridge (line commutated) 

fast torque reversal

 select Field Current ref (par 3.17)and

 Select para 15.02 and put it in online monitoring.

 Set value 5 to para 15.02 DRIVE_MODE

 Monitor Para 15.02

If the value changes to -1 then there is fault.

Also look for Para 20.16 FIELD_CURRENT_LIMT and set to 120%

Open main contactor

Field Auto Tuning

Set following values

Select Field Current ref (par 3.17)and

Give ON command and start the monitor tool.

Field Manual Tuning

Drive window Settings (e.g.): Sampling interval 10ms

After tuning Give OFF command

Set Para 15.02 DRIVE_MODE = 0

Set Para 17.04 TEST_REF_SELECT = 0

After autotuning new values of armature current controller can be seen

Armature Auto tuning

There are two ways to get this value:

17.04 TEST_REF_SEL = 1 (POT1)

Close main contactor, give ON-command

Then read signal 1.15 RL_CONV_CUR_ACT and

Set the same value to the Para 43.06 DISCONT_CUR_LIMIT

Give Stop Drive

Give OFF Command

1704 TEST_REV_SEL reset to 0

(default value = 50%)

Adjust flux-values 45.01 FLUX_REF to get 70% of Emf Voltage.

Adjust flux-values 45.01 FLUX_REF to get 40% of Emf Voltage.

Give STOP Command

Para 41.14 FLD_CUR_@40% FLUX

Revert back following values to

Para 45.01 FLUX_REF = 100%

Set the following parameters:

17.01 POT1_VALUE = 95% of read EMK value

Start the drive.

Observe the actual value of EMF, signal 1.17

To get good response(e.g 100 to 150msec)

Run the drive to it max speed with short Acc of 10/20sec.

Also Run in reverse directions to full speed.

While Acc armature voltage should not over shoot and

It should be steady above base speed.

To get better response

Coiler consist of:

 Coil with strip

 What is no load Loss?

 Normally size of the losses are in the range of 3% of

Measurement procedure: Characteristic:

 Average loss value over the [Nm]

measured time related to the

 Maximum loss value over the