Carotron EP2020-000 User manual

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
V3

2
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 ............................................................................................................................. 9
4.3 Signal Connections .......................................................................................................................... 11
5. Human Machine Interface (HMI)..................................................................................................................... 14
5.1 Description of Interface .................................................................................................................... 14
5.2 Menu Structure................................................................................................................................. 15
6. Start Up Procedure ......................................................................................................................................... 17
6.1 Pretest.............................................................................................................................................. 17
6.2 Adjustment Procedure: Velocity (Speed) Regulator.........................................................................17
6.3 Adjustment Procedure: Constant Horsepower.................................................................................19
6.4 Adjustment Procedure: Torque (Current) Regulator........................................................................19
6.5 Calibration & Fine Tuning.................................................................................................................19
6.4 Password Protection ........................................................................................................................ 21
7. Programming & Adjustments .......................................................................................................................... 22
7.1 A: Options ........................................................................................................................................ 22
7.2 B: Digital Inputs ................................................................................................................................ 23
7.3 C: Analog Inputs............................................................................................................................... 29
7.4 D: Digital Outputs ............................................................................................................................. 34
7.5 E: Analog Outputs ............................................................................................................................ 38
7.6 F: Motor Data ................................................................................................................................... 40
7.7 G: Control Loops .............................................................................................................................. 44
7.8 H: Start/Stop Logic ........................................................................................................................... 52
7.9 I: Setpoints ....................................................................................................................................... 56
7.10 J: Ramps........................................................................................................................................ 58
7.11 K: Fault Logic ................................................................................................................................. 62
7.12 L: Applications................................................................................................................................ 68
7.13 M: Thresholds ................................................................................................................................ 78
7.14 N: Timers ....................................................................................................................................... 81
7.15 O: Logic Gates ............................................................................................................................... 83
7.16 P: Switches .................................................................................................................................... 86
7.17 Q: Internal Links ............................................................................................................................. 87
7.18 R: Communications........................................................................................................................ 88
7.19 S: Zero Speed ................................................................................................................................ 91
7.20 T: System ....................................................................................................................................... 92
7.21 U: Auxiliary ..................................................................................................................................... 94
7.22 Parameter Table ............................................................................................................................ 95
8. Troubleshooting ............................................................................................................................................ 109
9. Serial Network Communications................................................................................................................... 113
9.1 Physical.......................................................................................................................................... 113
9.2 Modbus® Protocol.......................................................................................................................... 113
10. Spare Parts ................................................................................................................................................. 115
10.1 Printed Circuit Assemblies ........................................................................................................... 115
10.2 Fuses ........................................................................................................................................... 115
10.3 Power Components...................................................................................................................... 117
11. Prints ........................................................................................................................................................... 118
D14171 Control Board Assembly......................................................................................................... 118
D14163 Trigger Board Assembly......................................................................................................... 119
D14177 Regulator Board Assembly..................................................................................................... 120
C14188 Snubber Board Assembly....................................................................................................... 121
C14166 CT ID Board Assembly........................................................................................................... 122
C14045 Processor Board Assembly .................................................................................................... 123

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
DXXXXX Assembly, Heatsink Chassis, 200-300HP Regen Models....................................................134
DXXXXX Assembly, Heatsink Chassis, 400HP Regen Model.............................................................135
D14350 Assembly, Heatsink Chassis, 500-700HP Non-Regen Models ..............................................136
D14351 Assembly, Heatsink Chassis, 500-700HP Regen Models......................................................137
D14248 Wiring Diagram, 20-60HP Non-Regen Models ......................................................................138
D14249 Wiring Diagram, 20-60HP Regen Models ..............................................................................139
D14322 Wiring Diagram, 75-150HP Non-Regen Models ....................................................................140
D14314 Wiring Diagram, 75-150HP Regen Models ............................................................................141
DXXXXX Wiring Diagram, 200-400HP Non-Regen Models ................................................................142
DXXXXX Wiring Diagram, 200-400HP Regen Models ........................................................................143
D14353 Wiring Diagram, 500-700HP Non-Regen Models ..................................................................144
D14354 Wiring Diagram, 500-700HP Regen Models ..........................................................................145
D14308 General Connections ..............................................................................................................146
D14306 RS422/485 Network Connections ..........................................................................................147
C14307 Sonic Transducer Option Connections...................................................................................148
D14309 Software Block Diagram .........................................................................................................150
12. Standard Terms & Conditions of Sale.........................................................................................................155
List of Tables
Table 1: Model Rating Data...................................................................................................................................9
Table 2: HMI Description.....................................................................................................................................14
Table 3: Drive Monitor Descriptions ....................................................................................................................16
Table 4: Common Digital Input Functions ...........................................................................................................23
Table 5: Common Analog & Freq Input Functions ..............................................................................................29
Table 6: Analog Input Status Readings...............................................................................................................30
Table 7: Common Relay & Digital Output Functions...........................................................................................34
Table 8: Common Analog & Freq Output Functions ...........................................................................................38
Table 9: Analog Output Status ............................................................................................................................39
Table 10: Drive Modes ........................................................................................................................................54
Table 11: Reference Select.................................................................................................................................56
Table 12: Faults 1................................................................................................................................................64
Table 13: Faults 2................................................................................................................................................64
Table 14: Alarms 1 ..............................................................................................................................................65
Table 15: Inertia Sensitivity .................................................................................................................................75
Table 16: Logic Gates Truth Table......................................................................................................................85
Table 17: Parameters..........................................................................................................................................95
Table 18: Faults.................................................................................................................................................109
Table 19: Supported Modbus® Functions.........................................................................................................114
Table 20: Field Fuses........................................................................................................................................115
Table 21: Recommended Line Fuses ...............................................................................................................116
Table 22: Armature Bridge Modules .................................................................................................................117
Table 23: Field Supply Modules ........................................................................................................................117

4
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.
Specifications
2.1 Electrical
A.C. Input Voltage Range
• 3 phase, 230-460 VAC ± 10%, 50/60 Hz ± 2 Hz
• 1 phase, 115 VAC ± 10%, 50/60 Hz ± 2 Hz, 5A
A.C. Line Field Supply - 1 Phase (Optional)
• 230-460 VAC ± 10%, 50/60 Hz ± 2 Hz
Armature Output
• 0-240VDC @ 230 VAC input
• 0-415VDC @ 380 VAC input
• 0-500VDC @ 460 VAC input
Field Output
• Voltage
0-200VDC @ 230 VAC input
0-330VDC @ 380 VAC input
0-400VDC @ 460 VAC input
• Current
EPx020-000 thru EPx060-000: 8A max
EPx075-000 thru EPx150-000: 10A max
EPx200-000 thru EPx700-000: 12A max
Power Supplies
• +24V (TB1-1): 50mA
• +12V (TB1-17): 100mA
• +10V (TB1-16): 50mA
• -10V (TB1-46): 50mA
Digital Inputs (Qty: 7)
• Sink Mode
V
ih
=20.0 VDC max
V
il
=0.0 VDC min to 17.0 VDC max
• Source Mode
V
ih
=8.0 VDC min to 30.0 VDC max
V
il
=5.0 VDC max
Analog Inputs (Qty: 5)
• Voltage Mode
Max Input:±10 VDC
Input Impedance: 1MΩ
• Current Mode
Max Input: ±20 mADC
Input Impedance: 250Ω
• Resolution: 12 bit
Tachometer Feedback Input
• Max Input: ±200 V (AC or DC)
Encoder Feedback Input
• Frequency: 200kHz max
• Uni-directional (single channel) or Quadrature
• Single ended or differential
• Voltage: 12 VDC max
Frequency Input
• Frequency: 40kHz max, square wave
• Voltage: 12 VDC max
V
il
=0.0 VDC to 1.5 VDC max
V
ih
=2.5 VDC min to 12.0 VDC max
Relay Outputs (Qty: 3)
Form-C contact:
• 2 A @ 115 VAC (resistive)
• 2 A @ 60 VDC (resistive)
Armature Pilot Relay Output
• 30 A @ 120 VAC (resistive)
• 30 A @ 28 VDC (resistive)
Analog Outputs (Qty: 2)
• ±10 VDC max, 20mADC max
• Resolution: 12 bit + sign
Frequency/Digital Output
• Frequency: 10kHz max, square wave
• Sink current: 100mA max
• Voltage: 30VDC max
Speed Regulation
• Armature Feedback: ±1%
• Tachometer Feedback: ±0.01%
• Encoder Feedback: ±0.01% (with 1024 min ppr)
Torque Regulation
• ±1% of Range Selected
Speed Range
• 100:1 typical when using tachometer or encoder
feedback. May be less depending upon motor
characteristics
Temperature Range
• Chassis: 0-55C
• Enclosed: 0-40C
1
11
1
2
22
2

5
EPx075-000 thru EPx150-000
EPx020-000 thru EPx060-000
PRO
2.2 Physical
PRO

6
EPx500
-
000 thru EPx600
-
000
PRO
EPx200
-
000 thru EPx400
-
000
PRO

7
Installation
3.1 Control Installation
Elite Pro motor controls require mounting in an upright position in an area that will permit adequate
airflow for cooling and ready access for making connections and for servicing. Because cooler air is
drawn in from the bottom and exhausted from the top, these areas should be kept clear for about a
six inch distance. Stacking of controls with one mounted above the other should be minimized so that
the upper control is not ventilated with hot exhaust air from the lower control.
Enclosures should be sized to provide adequate surface area for dissipating heat or provided with
forced ventilation with outside air from a duct system or enclosure fan. They should be mounted to a
cool surface not exposed to heat generated by nearby equipment.
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.
Make no connections to ground other than the designated terminal strip location.
Use fully insulated and shielded cable for all signal wiring. The shield should be connected at one
end only to circuit common. The other end of the shield should be clipped and insulated to prevent
the possibility of accidental grounding.
Signal level wiring such as listed above should be routed separately from high level wiring such as
armature, field, and relay control wiring. When these two types of wire must cross, they should cross
at right angles to each other.
Any relays, contactors, starters, solenoids or electro-mechanical devices located in close proximity to
or on the same line supply as the motor control should have a transient suppression device such as
an MOV or R-C snubber connected in parallel with its coil (for AC coils). Diode suppression should
be used for DC coils. The suppressor should have short leads and should be connected as close to
the coil as possible.
Terminal Connections & Functions
4.1 AC Power Connections & Fusing
Terminals L1, L2, and L3 are the AC line inputs for the armature power bridge. High speed
semiconductor fuses must be provided externally. Refer to Figure 1 and Figure 2 on the next page
and Table 21 in the Spare Parts Section on page 116 for common manufacturers and part numbers.
In most cases, the drive will use the internal field supply wiring scheme (Figure 1). The field bridge
is powered from the auxiliary L1 and L2 output terminals via factory installed jumpers. However, in
some cases, the field voltage required by a motor exceeds the maximum obtainable field voltage that
can be produced using the required AC line voltage for the motor armature. In these cases, an
external single phase AC supply for the field bridge must be used. The factory supplied terminal
jumpers should be removed and the external supply connects to FL1 and FL2 (Figure 2). Note the
external supply must be in phase with the L1 and L2 armature supply terminals.
3
33
3
4
44
4

8
For example, consider the motor that has a rated armature voltage of 240VDC and a rated field of
240VDC. The rated armature voltage requires that an input supply of 230VAC be connected to L1,
L2, and L3. However, the maximum field voltage attainable from the field bridge using the internal
supply would be 200VDC. In order to obtain the required 240VDC field, an external single phase
460VAC supply (obtained via a transformer) can be connected to FL1 and FL2.
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. Refer to Table 1 as a
general guide in sizing line supply transformers and wiring.
Figure 2: External Field Supply Wiring
Figure 1: Internal Field Supply Wiring

9
Drive
Model
Arm
Volts
Motor
HP
Approx. Full Load
Line Amps
3 Phase DIT
KVA Rating
Arm
Amps
Contactor
Rating
D.B. Resistor
Rating
5 18 7.5 18 10Ω, 300W
7.5 26 11 28.1 5Ω, 600W
240
10 34 14 36
40 Amps
4.4Ω, 750W
5 9 7.5 8.5 40Ω, 375W
7.5 14 11 13.2 20Ω, 750W
10 18 14 17.2 20Ω, 750W
15 25 20 25.2 14Ω, 1000W
EPx020-000
500
20 34 27 36
40 Amps
10Ω, 1500W
15 50 20 55 3Ω, 1000W
240 20 65 27 71 75 Amps 2.2Ω, 1500W
25 40 34 43 7Ω, 2000W
30 47 40 51 6Ω, 2000W
EPx040-000
500
40 63 51 71
75 Amps
5Ω, 3000W
25 84 34 91.1
240 30 98 40 107 110 Amps 1.7Ω, 2000W
50 78 63 83.7
EPx060-000
500 60 93 75 107 110 Amps 3.4Ω, 4000W
240 40 118 51 180 Amps 1.3Ω, 2080W
EPx075-000 500 75 106 93 140 180 Amps 2.6Ω, 4160W
240 50 148 63 180 Amps 0.62Ω, 2232W
EPx100-000 500 100 141 118 174 180 Amps 1.24Ω, 4464W
240 60 174 75 260 Amps 0.62Ω, 2232W
EPx125-000 500 125 177 145 206 260 Amps 1.24Ω, 4464W
240 75 93 260 Amps 0.62Ω, 2232W
EPx150-000 500 150 213 175 256 260 Amps 1.24Ω, 4464W
240 100 118 360 Amps 0.47Ω, 4700W
EPx200-000 500 200 283 220 340 360 Amps 1.02Ω, 6500W
240 125 145 535 Amps 0.37Ω, 5300W
EPx250-000 500 250 354 275 425 535 Amps 0.82Ω, 11000W
240 150 175 535 Amps 0.31Ω, 7000W
EPx300-000 500 300 426 330 510 535 Amps 0.65Ω, 14600W
240 200 220
EPx400-000 500 400 555 440 688 Consult
Factory
Consult
Factory
240 250 275
EPx500-000 500 500 694 550 850 Consult
Factory
Consult
Factory
240 300 330
EPx600-000 500 600 832 660 1020 Consult
Factory
Consult
Factory
240 350 385
EPx700-000 500 700 950 770 1165 Consult
Factory
Consult
Factory
Table 1: Model Rating Data
x=2 for non-regenerative models
x=4 for regenerative models
4.2 Motor Connections
Field
Most motor fields consist of two windings that are connected in parallel for low voltage operation and
in series for high voltage operation. Refer to Figure 3. The winding leads are individually marked
and have a polarity that must be observed for proper and safe operation. Since direction of rotation is
controlled by field polarity as well as armature polarity, it is sometimes more convenient to swap the
smaller field leads when making corrections to the direction of rotation during initial installation. An
energized field should never be switched by relay, contactor, switch or any other manual or electro-
mechanical device.
In most cases, when the Elite Pro is supplied with 230VAC, the field should be wired for low voltage
operation. When supplied with 460VAC, the motor field is typically wired for high voltage operation.
The F1 and F3 leads should always have the same polarity regardless of the mode used.

10
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. Figure 4 shows a typical armature wiring scheme
using a contactor. An optional dynamic breaking resistor is also shown.
Series Field
When present, the S1 and S2 for the SERIES field winding is placed in series with the armature
leads on non-regenerative models only! They should NOT be used with the EP4 Series
regenerative models. On regenerative models, the leads should not be connected and should be
individually insulated. On non-regenerative models the series field winding polarity must be kept at
the same polarity as the shunt field winding, i.e. F1 and S1 the same, F2 (or F4) and S2 the same. If
during startup the field windings are reversed to change direction of the motor, the series windings
should also be reversed to maintain the proper polarity. Figure 5 shows a typical wiring scheme
using the series field with a non-regenerative drive. Note the polarity of the shunt field and series
field windings (S1 is positive with respect to S2, F1 is positive with respect to F2).
Figure 4
Figure 3

11
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 & 39.
4.3 Signal Connections
Figure 6 shows the typical signal connections to an Elite Pro drive. When operated, the Emergency
Stop contacts at terminals 6 and 7 will immediately clamp all control signals. The armature contactor
will also de-energize to disconnect the armature from the bridge output. Motor stopping time is
determined by inertia and friction characteristics of the load and can be decreased by use of a brake
resistor. Refer to Table 1 for recommended resistor values. If a maintained Emergency Stop push-
button is used, the E-Stop Reset contacts at TB1-8 & 9 can be jumpered. Otherwise, a momentary
push-button can be used to reset the E-Stop condition.
Figure 5

12
Figure 6: Signal Connections

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). In the Run/Direction
scheme, a single contact starts and stops the drive. Another contact selects direction. In the final
scheme, each contact starts the drive and selects the direction. Parameter H1.01 needs to be set
appropriately.
Figure 7
The drive also has the capability to interface with either sinking or sourcing logic controls. Sourcing
(PNP) logic is selected by jumpering TB1 terminals 2 & 3. This places an internal pull down resistor
on each input. The external switch or sensor must then drive the input high to activate the input.
Sinking (NPN) logic is selected by jumpering TB1 terminals 1 & 2. This places an internal pull up
resistor on each input. The external switch or sensor must then sink (pull down) the input to common
to activate the input.
Figure 8

14
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.
Figure 9
Index Item Description
1 F1-F3
Softkeys. The functionality of each of these keys varies depending
upon the displayed menu. When utilized, text above the key
displays its function.
2 Run Key Places the drive in run mode when in local mode
3 Stop Key Stops the drive in all modes
4 Esc Key •Returns to the previous menu
•Moves cursor one place to the left
5 Reset/Right Key •Clears drive fault (on a DM screen)
•Moves cursor one place to the right
6 Local/Remote Key Switches the drive between local and remote control
7 Enter Key •Used to accept/enter parameter values
•Moves cursor one place to the right
8 Up/Down Keys •Scrolls to the next menu display
•Increments/decrements cursor value
9 Run LED
On: Drive is in run mode and has reference
Flashing: Drive is in run mode with no reference
Off: Drive is not in run mode
10 Local LED On: Drive is in Local mode
Off: Drive is in Remote mode
11 Alarm LED On: An alarm is present
Off: No alarms present
12 Fault LED
On: A fault is present. Fault is not active and can be reset.
Flashing: Fault present and currently active. Cannot be reset.
Off: No faults present
Table 2: HMI Description
5
55
5
DM01: ELITE PRO V3
REFERENCE: 12.34%
SPEED: 0.00%
STATUS: STOP

15
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

16
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 Loop Outputs
DM10 Feedback Status
DM11 Drive Model/Firmware
Table 3: Drive Monitor Descriptions
Programming
The drive parameters are located under the Programming section. Each drive parameter has a
unique identifier tag that consists of an alpha group code, and numeric block code, and a two digit
numeric index. For example, parameter C2.04 is in Group C, Block 2, and Index 4. When the
programming section is first displayed, the first parameter (A1.01) is displayed with the Group Code
flashing (i.e. the 'A'). The Up/Down keys are then used to change the Group Code to the desired
value. Pressing the Reset/Right key will move the cursor to the right and cause the Block Code to
begin flashing. The Up/Down keys are then used to change the Block Code. Pressing the
Reset/Right key will move the cursor to the right and cause the Index Code to begin flashing. Again,
the Up/Down keys are used to change the Index to display the desired parameter. Pressing Escape
will move the cursor left.
In order to simplify the menu, some parameters are hidden when they are not applicable. However,
in some cases it may be desired to view these hidden parameters. There are two ways to view these
hidden parameters. The first method is to change parameter A1.01 from STANDARD to
ADVANCED. This makes all parameters visible. The second method is to use a certain keystroke
while scrolling through the parameters. Pressing the F2 key before pressing the Up or Down keys
will force the display to show the next/previous parameter (whether it is hidden or not).
Once a parameter is displayed, pressing the Enter key will allow its value to be modified. The current
value of the parameter (or a digit in its value) will begin flashing. The Up/Down keys are used to
adjust the value. If the parameter is a numeric value, the Reset/Right key can be used to shift the
cursor to the right to allow other digits to be adjusted. Pressing the Reset/Right key when the cursor
is on the last digit will cause the cursor to be placed on the first digit. Once the desired value is
displayed, the value can be entered by pressing the Enter key. The Escape key will exit the
parameter adjustment screen without changing the parameter value.
Note: When parameters are altered via the keypad, the changes are saved automatically.
Modified Parameters
This section contains a list of parameters that have been modified from the default factory preset
value. The Up/Down keys are used to scroll through the list.
Wizards
This section contains various drive related wizards that aid in drive setup.

17
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. Ground faults in un-isolated circuits of the armature
and field can cause fuse blowing and damage to the motor and control. To check for
grounds with an ohmmeter, select a high resistance scale such as R x 100K ohms or
greater. Test from each connection terminal (including shields) to chassis ground and be
suspicious of any resistance reading less than 500K ohms. NOTE: An exception to this
test would be made where the drive's 3 phase input is connected to a grounded "Y" type
transformer secondary.
3. Adjust external reference (Analog Input 1) at terminal 10 to 0 volts.
4. Apply single phase control power and three phase bridge power. On initial power up, the
drive should display an Invalid Motor Data fault. Press CLOSE to exit. When asked to
run the Basic Setup Wizard, select YES. If the wizard was cancelled, it can be re-started
from the Wizards section in the menu.
6.2 Adjustment Procedure: Velocity (Speed) Regulator
1. Presets
Use the Basic Setup Wizard to set the required parameters. The wizard will step you
through various drive parameters. When a parameter is displayed, press the ENT key
to edit its value. There are a number of required parameters. The wizard will not
allow you to proceed until a valid value has been entered. It is recommended that the
drive initially be setup using armature feedback even if a tachometer or encoder will
be used. This allows the proper feedback signal to be verified before using it for
control. After the motor data is entered in the wizard, the drive should begin
producing field output. Depending upon the wizard data entered, you may have the
option to operate the field in either open or closed loop mode. After the field mode is
selected, the wizard will display a field status screen showing the field voltage and
field current. Verify the displayed values correspond to the motor nameplate. In many
cases, when a motor is cold and the nameplate field voltage is applied, the field
current will be much higher than its rated nameplate value. As the motor warms up,
the field winding resistance should increase, which will cause the field current to
decrease. If open loop was selected and the field output requires additional
adjustment, press the ENT key while the status screen is displayed. This allows
adjustment of Open Loop Reference (G3.03). Regardless of the mode, please
ensure the field levels are correct before proceeding.
2. Clear any Faults
When the wizard is completed, the drive will try to clear any faults that are present. If
a fault is still present (i.e. the Fault LED is on or flashing), navigate to the DM04
screen to display the current fault. Once the fault condition is removed, the fault can
be cleared by pressing the RESET key while on any DM screen.
3. Validate E-STOP
When an E-STOP is activated, the status display on the DM01 screen should display
E-STOP. When the E-STOP is cleared, the status should display STOP or FAULT. If
E-STOP is always displayed, not all interlocks have been made. Please refer to the
wiring diagram in Figure 6 on page 12. The 24V from terminal 38 should flow through
all the interlocks to terminal 9. Do not proceed until the E-STOP functions properly.
4. Safety Check
During the following steps the motor will be rotated. If excessive speed or wrong
direction of rotation could damage the load, it may be wise to de-couple the load until
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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. Release F1 to stop the drive. If the motor rotation is
reversed, remove all power and reverse the motor armature or field wires. If used,
observe proper polarization of the series field winding per the instructions in Section
4.2. After re-applying power, repeat this step to verify motor direction.
6. Validate External Start/Stop
Press the LOCAL/REMOTE key to return the drive to Remote mode. The Local mode
LED should be off. Adjust the external reference signal connected to terminal 10 to its
minimum. Typically, the reference value on DM01 should be approximately zero.
Place the drive in Run mode via the external contacts. Slowly increase the external
reference until the motor is rotating. Issue a stop command using the external
contacts and verify the motor stops and the contactor de-energizes.
7. Validate Reverse Direction (optional, EP4 regenerative unit required)
With reference at minimum, run the drive in the reverse direction. Slowly increase the
reference and verify motor runs in reverse direction. Stop drive.
8. Validate Tachometer Feedback (required only if a motor mounted tachometer is used)
Proper tachometer operation should be checked while the drive is running in Armature
Feedback. Place the drive in run mode and run at a low speed (approximately 20%).
On the display, navigate to DM10. Compare Armature feedback to Tachometer
feedback. The values should be approximately equal (within 5%). If the values have
approximately the same value but the wrong polarity, press the Stop button and invert
the tachometer feedback by setting parameter F2.02 to On. Place the drive back in
the run mode and re-check. If the values are not equal, verify the tachometer data is
entered properly in section F2 (or the wizard) and jumpers J1-J3 are set properly.
Once corrected and the values are equal at low speeds, increase speed and check at
higher speeds. If the values are approximately equal throughout the speed range, the
drive can be placed in the tachometer feedback. With the drive in the stop mode, set
parameter G2.15 to Tachometer. Run drive and verify proper operation.
9. Validate Encoder Feedback (required only if a motor mounted encoder is used)
Proper encoder operation should be checked while the drive is running in Armature
Feedback. Place the drive in run mode and run at a low speed (approximately 20%).
On the display, navigate to DM10. Compare Armature feedback to Encoder feedback.
The values should be approximately equal (within 5%). If the values have
approximately the same value but the wrong polarity, press the Stop button and invert
the encoder feedback by setting parameter F3.03 to On. Place the drive back in the
run mode and re-check. If the values are not equal, verify the encoder data is entered
properly in section F2 (or the wizard). Once corrected and the values are equal at low
speeds, increase speed and check at higher speeds. If the values are approximately
equal throughout the speed range, the drive can be placed in the encoder feedback.
With the drive in the stop mode, set parameter G2.15 to Encoder. Run drive and verify
proper operation.

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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.
2. Parameters
Re-run the Basic Setup Wizard and set the Operating Mode to CONST HP
(CROSSOVER). Continue through the wizard and enter additional motor data
(specifically the extended speed field amps, and extended speed value). If
tachometer is used, re-scale Jumpers J1-J3 as instructed by the wizard.
3. Test
With reference at minimum, place drive in run mode. Navigate to DM03 and verify the
motor field current is at the base speed level. Navigate to DM02 to display the
armature voltage. Slowly increase reference until armature voltage is approximately
85% of the nameplate value (204V for 240V armatures, or 425V for 500V armatures).
Return to DM03 and monitor the motor field current, while increasing the speed
reference. The field current should begin decreasing as the speed reference is
increased. When the maximum reference is applied, the field current should be
approximately at the extended speed field current level. Return to DM02 and verify
armature voltage is at the motor's rated armature voltage level.
6.4 Adjustment Procedure: Torque (Current) Regulator
1. Presets
Set up the Elite Pro V3 drive as a normal velocity regulator to run at the motor's base
speed using armature feedback. Refer to Section 6.2. Once correct operation in this
mode has been achieved, proceed with the following steps.
2. Parameters
Re-run the Basic Setup Wizard and set the Operating Mode to TORQUE. Continue
through the wizard and enter any required data.
3. Test
With reference at minimum, place drive in run mode. Navigate to DM02 to display the
armature current. Slowly increase reference and verify control of armature current.
6.5 Calibration & Fine Tuning
1. If the drive is using armature feedback (i.e. G2.15 is set to ARMATURE), then IR
Compensation (G2.09) can be adjusted to improve the speed regulation with load
changes. Adjustment is best done when the motor or machine can be loaded normally. If
the motor is normally operated at a particular speed, adjust IR Compensation (G2.09)
while running at that speed. If the motor operates under load over a wide speed range,
pick a speed near mid-range to make the adjustment. Adjust as follows:
Operate the unloaded motor at the normal or mid-range speed and note the exact
speed using a hand tachometer or other speed measuring device. While still
monitoring speed, apply normal load. The reduction in speed of a fully loaded motor
will usually fall between 2 and 13% of rated or "base" speed. Slowly increase IR
Compensation (G2.09) until the loaded speed equals the unloaded speed measured
in the previous step. Making this adjustment may now cause the unloaded speed to
be slightly higher. Repeat this procedure until there is no difference between loaded
and unloaded speed levels. Use care not to set the adjustment too high or speed
increase with load and instability may result. NOTE: For this adjustment, do not use
armature voltage feedback (AFB) to measure speed. Armature voltage is not an exact
indication of loaded motor speed!

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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. The adjustments are complex
though and can adversely affect operation if not properly set. In general, the settings that
give the most stable operation do not always give the fastest response.
Current Loop
The current loop can be manually tuned by directly applying a stepped reference and
monitoring the current feedback. In order to adjust properly, connect an oscilloscope
between common and the A.IFB testpoint on the control board. The rotor shaft must not
rotate during this procedure. Therefore, set Field Enable (G3.01) to DISABLE to remove
voltage from the shunt field. Set Reference Select (G1.01) to STEP. Set the Step
Reference (G1.22) initially to a low value (around 20%). Set the Step Duration (G1.23) to
500ms. Place the drive in the run mode. Set Step Enable (G1.24) to ENABLE to apply a
step change to the PI loop. The current feedback signal should respond quickly with
minimum overshoot. Adjust the Current Proportional Gain (G1.16) and Current Integral
Time (G1.17) parameters and re-apply the Step Enable until a critically damped waveform
as seen in Figure 11. Increasing the proportional gain improves the response but
increases the overshoot. Reducing the integral time improves the response but can cause
instability if set too low. Once a critically damped waveform is obtained, increase the Step
Reference to 40% and repeat above. Continue until a Step Reference of 100% is
achieved. Return Field Enable (G3.01) to ENABLE and Reference Select (G1.01) to
NORMAL when complete.
Figure 11
Velocity Loop
In order to adjust properly, connect an oscilloscope to Analog Output 1 Terminal 21
(Velocity Feedback). Using the HMI, temporarily set the Reference Select (G2.29) to
STEP. Set Step Reference (G2.30) to 20% and Step Duration (G2.31) initially to 2
seconds. Place the drive in the run mode and apply a step change by setting Step Enable
(G2.32) to ENABLE. Observe the response of the drive on the oscilloscope. The motor
speed should respond quickly with minimum overshoot. Adjust the Velocity Proportional
Gain (201) and Velocity Integral Time (202) parameters to obtain a critically damped
waveform as seen in Figure 12. Increasing the proportional gain improves the response
but increases the overshoot. Reducing the integral time improves the response but can
cause instability if set too low. Repeat above in steps gradually increasing the Step
Reference to 100% (or the max required speed is obtained). Once complete, return
Reference Select (G2.29) to NORMAL.