Rockwell Automation FlexPak 3000 OIM User manual

Instruction Manual
FlexPak®3000 Drive Operator Interface
Module (OIM) User’s Guide
D2-3344

©1997 Rockwell International Corporation
The information in this manual is subject to change without notice.
Throughout this manual, the following notes are used to alert you to safety considerations:
Important: Identifies information that is critical for successful application and understanding of the product.
!ATTENTION:Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss.
Reliance, FlexPak, and AutoMax are trademarks of Rockwell International or its subsidiaries.
!ATTENTION:Only qualified electrical personnel familiar with the construction and operation of
this equipmentandthehazards involvedshould install,adjust,operate,orservicethisequipment.
Read and understand this section in its entirety before proceeding. Failure to observe this
precaution could result in severe bodily injury or loss of life.
ATTENTION:Pressing or on the OIM immediately starts the motor if the control
source is set to KEYPAD. Make sure the motor and driven machinery are safe to start before
pressingeitherof thesekeys.Failuretoobservethisprecautioncould result inseverebodily injury
or loss of life.

Contents
I
CONTENTS
Chapter 1 Introduction to the FlexPak OIM
1.1 Related Publications........................................................................................1-1
1.2 Getting Assistance from Reliance Electric.......................................................1-1
Chapter 2 Description of the OIM Keypad, Display, and Indicators
2.1 Keypad ............................................................................................................2-1
2.2 The Display......................................................................................................2-5
2.2.1 Drive Status Indicators..........................................................................2-6
2.2.2 Key Indicators .......................................................................................2-6
2.2.3 Special Display Characters...................................................................2-8
Chapter 3 Powering Up and Adjusting the OIM
3.1 Powering Up the OIM ......................................................................................3-1
3.2 Adjusting the Screen Contrast.........................................................................3-2
3.3 Changing the Language Displayed on the OIM...............................................3-3
3.4 Scaling Values Displayed on the OIM .............................................................3-4
3.4.1 Changing the Scaling of Speed, Load, and Outer Control Loop Units..3-5
3.4.2 Scaling Speed or Outer Control Loop Units to Custom Settings...........3-6
Chapter 4 Basics of Configuring the Drive Using the OIM
4.1 Types of Parameters .......................................................................................4-1
4.2 Accessing OIM Menus and Parameters..........................................................4-2
4.2.1 Accessing the Menus............................................................................4-2
4.2.2 Using Help in Program Mode................................................................4-3
4.2.3 Accessing the Parameters ....................................................................4-4
4.2.4 Viewing Parameter Values....................................................................4-5
4.2.5 Changing Parameter Values.................................................................4-5
4.2.6 Parameter Values That Cannot Be Changed........................................4-7
4.3 Using a Password to Protect Configuration.....................................................4-7
4.4 Saving and Restoring Parameter Values ........................................................4-9
4.4.1 Using Memory Operations to Save and Restore Parameter Values.....4-9
4.4.2 Saving Parameter Values When Exiting Program Mode.....................4-10
Chapter 5 Using Quick Start
5.1 Preparing for Quick Start.................................................................................5-1
5.2 Using the Quick Start Exit Menu......................................................................5-1
5.3 Configuring the Drive Using Quick Start..........................................................5-2
5.4 Self-Tuning the Current Minor and Speed Loops............................................5-4
5.4.1 Setting Up the OIM for Self-Tuning.......................................................5-4
5.4.2 Performing the Self-Tuning Procedure..................................................5-5
5.4.3 Exiting Before Self-Tuning is Complete.................................................5-7
5.4.4 What To Do if a Fault Occurs During Self-Tuning.................................5-7
5.4.5 Self-Tune Parameter Descriptions........................................................5-7
5.5 Quick Start Parameter Descriptions ................................................................5-8

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FlexPak 3000 DC Drive OIM User’s Guide
Chapter 6 Using the OIM to Monitor and Control the Drive
6.1 Using the OIM to Monitor Drive Outputs..........................................................6-1
6.1.1 Description of the Monitor Mode Outputs ..............................................6-1
6.1.2 Selecting the Outputs to Monitor ...........................................................6-2
6.1.3 Using Help in Monitor Mode ..................................................................6-2
6.2 Control Source.................................................................................................6-2
6.2.1 About the Control Source ......................................................................6-3
6.2.2 Setting the Control Source.....................................................................6-4
6.3 Changing the Manual Reference Using the OIM .............................................6-4
6.4 Using the OIM to Control the Drive..................................................................6-5
6.4.1 Starting the Drive...................................................................................6-5
6.4.2 Stopping the Drive.................................................................................6-5
6.4.3 Changing Drive Direction.......................................................................6-6
Chapter 7 Troubleshooting the Drive Using the OIM
7.1 Identifying Problems Indicated by Faults or Alarms.........................................7-1
7.2 Reviewing and Resetting Faults and Alarms ...................................................7-2
7.2.1 Reviewing the Fault and Alarm Logs.....................................................7-3
7.2.2 Resetting Faults and Alarms and Clearing the Logs .............................7-4
7.3 Using Diagnostics to Solve Drive Problems.....................................................7-5
7.4 Clearing a Programming Error Message..........................................................7-6
7.5 Determining Why the OIM is Not Communicating with the Drive.....................7-6
7.6 Replacing the OIM ...........................................................................................7-7
7.6.1 Preparing to Replace the OIM...............................................................7-7
7.6.2 Accessing the OIM and Disconnecting It from the Regulator Board......7-7
7.6.3 Replacing the OIM Circuit Board Only...................................................7-8
7.6.4 Replacing the Entire OIM Assembly......................................................7-8
7.7 Resetting the Clock..........................................................................................7-9
Appendix A OIM Menu Structure
A.1 FlexPak 3000 Main Menu ...............................................................................A-1
A.2 Complete OIM Menu Structure .......................................................................A-1

List of Figures
III
List of Figures
Figure 2.1 – OIM Keypad, Display, and Indicators...................................................2-1
Figure 2.2 – OIM Display in Program Mode .............................................................2-5
Figure 3.1 – OIM Power-Up Sequence.....................................................................3-1
Figure 3.2 – Contrast Adjustment Screen.................................................................3-2
Figure 3.3 – Language Selection Screen .................................................................3-3
Figure 3.4 – Define User Units Menu .......................................................................3-5
Figure 3.5 – Define Speed Units Screen..................................................................3-5
Figure 3.6 – Define Custom Speed Units — Tag Screen.........................................3-6
Figure 3.7 – Define Speed Units — Full Scale Value Screen...................................3-6
Figure 3.8 – Define Speed Units — Decimal Place Screen......................................3-7
Figure 4.1 – Main Menu Screen ...............................................................................4-2
Figure 4.2 – Main Menu Help Screen.......................................................................4-3
Figure 4.3 – Example of the Drive Reference Menu Help Screen............................4-3
Figure 4.4 – Example of a Parameter Help Screen..................................................4-3
Figure 4.5 – Selecting the Input/Output Menu..........................................................4-4
Figure 4.6 – Input/Output Menu................................................................................4-4
Figure 4.7 – Meter Outputs Menu.............................................................................4-5
Figure 4.8 – Example of a Parameter Entry Screen.................................................4-5
Figure 4.9 – Parameter Entry Screen with a List of Options.....................................4-6
Figure 4.10 – PASSWORD Parameter Entry Screen...............................................4-8
Figure 4.11 – Memory Operations Screen................................................................4-9
Figure 4.12 – Memory Save Screen.......................................................................4-10
Figure 4.13 – Parameters Have Been Modified Screen.........................................4-10
Figure 4.14 – Save Current Parameter Values Screen..........................................4-10
Figure 5.1 – Quick Start Exit Menu...........................................................................5-1
Figure 5.2 – First Quick Start Parameter Entry Screen............................................5-3
Figure 5.3 – Quick Start Complete Screen...............................................................5-3
Figure 5.4 – Self-Tuning Screen...............................................................................5-6
Figure 5.5 – Self-Tuning Complete Screen ..............................................................5-6
Figure 6.1 – First Monitor Mode Screen...................................................................6-1
Figure 6.2 – Second Monitor Mode Screen..............................................................6-2
Figure 6.3 – CONTROL SOURCE SELECT Screen ................................................6-4
Figure 7.1 – Example of a Fault Screen...................................................................7-1
Figure 7.2 – Example of an Alarm Screen................................................................7-2
Figure 7.3 – Fault Menu............................................................................................7-2
Figure 7.4 – Alarm Menu..........................................................................................7-2
Figure 7.5 – Example of a Fault Log Screen............................................................7-3
Figure 7.6 – Example of a Fault Detail Screen.........................................................7-3
Figure 7.7 – Example of an Alarm Detail Screen......................................................7-3
Figure 7.8 – Diagnostics Menu.................................................................................7-5
Figure 7.9 – Reset Clock Message Screen..............................................................7-9

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FlexPak 3000 DC Drive OIM User’s Guide

List of Tables
V
List of Tables
Table 2.1 – Programming Key Descriptions.............................................................2-2
Table 2.2 – Control Key Descriptions.......................................................................2-4
Table 2.3 – Drive Status Indicators...........................................................................2-6
Table 2.4 – Key Indicators........................................................................................2-7
Table 2.5 – Special Display Characters....................................................................2-8
Table 3.1 – Parameter Displays That are Affected by Scaled Units.........................3-4
Table 5.1 – Parameters Configured by CML and Speed Loop Self-Tuning .............5-4
Table 6.1 – Effect of Control Source and Reference Settings on the AUTO/MANUAL
Indicator and OIM Displays...................................................................6-3
Table 7.1 – OIM Failure Causes and Solutions........................................................7-6

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FlexPak 3000 DC Drive OIM User’s Guide

Introduction to the FlexPak OIM
1-1
CHAPTER 1
Introduction to the FlexPak OIM
The FlexPakOperator Interface Module (OIM) is a keypad and display that connects
to FlexPak 3000 DC drives. It communicates serially to the drive Regulator board and
allows you to change drive parameters, operate the drive, and monitor drive operation.
Changing Drive Parameters
Drive parameters set critical information about the drive, such as the motor rated
amps and top speed. You can also use parameters to fine-tune the drive for your
application, scale inputs and outputs, view the values of output signals, and configure
remote interfaces. For detail on accessing parameters, see chapter 4.
To view and set the most critical parameters quickly, you can use the OIM’s Quick Start
option, described in chapter 5.
Operating the Drive
After the parameters are configured, you can operate the drive through the OIM.
Operation includes setting the source for control (such as the terminal strip, serial
port, or OIM) and starting and stopping the drive. For detail on these functions, see
chapter 6.
Monitoring Drive Operation
During normal drive operation, the OIM displays the values of two or four drive outputs,
such as motor speed and motor load. For information on determining which outputs
are displayed, see chapter 6.
If a fault or alarm occurs, the output display is replaced by an alarm or fault message.
For information on resolving, clearing, and resetting fault and alarm messages, see
chapter 7.
1.1 Related Publications
This manual describes how to use the OIM with the FlexPak 3000 drive. For
information on drive installation and drive startup, see the hardware manual shipped
with your drive. For parameter descriptions and troubleshooting procedures, see the
software manual shipped with your drive.
1.2 Getting Assistance from Reliance Electric
If you have any questions or problems with the products described in this instruction
manual, contact your local Reliance Electric sales office. For technical assistance, call
1-800-726-8112.

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FlexPak 3000 DC Drive OIM User’s Guide

Description of the OIM Keypad, Display, and Indicators
2-1
CHAPTER 2
Description of the OIM Keypad, Display,
and Indicators
This chapter describes how to use the keypad, display, and indicators on the OIM to
configure, monitor, and control the drive.
Figure 2.1 shows the OIM in program mode with keys, indicators, and screen
information identified.
2.1 Keypad
The OIM keys are grouped by programming and control functions, as shown in
figure 2.1. Programming keys are described in table 2.1. Control keys are described in
table 2.2.
Important: is always active when the OIM is communicating with the drive.
Figure 2.1 – OIM Keypad, Display, and Indicators
+
-

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FlexPak 3000 DC Drive OIM User’s Guide
Table 2.1 – Programming Key Descriptions
Key Mode Function
Program or
Monitor Switches between program mode and the two monitor mode screens.
In fault, alarm, or diagnostics menus, returns you to the
program or monitor screen you were in previously. See chapter 7
for information.
Program or
Monitor Cycles through the Fault, Alarm, and Diagnostics menus. Use these
menus to review, reset, and clear faults and alarms. You can also
display diagnostic information for troubleshooting the drive. See
chapter 7 for information.
Program Provides help for menus or parameters.
In the Main Menu, provides information about using the menus. In
other menus, gives a brief overview of the menu options.
In a parameter entry screen, displays the parameter name,
number, type (input or output, retentive or non-retentive), and units of
measure.
To exit a help screen and return to program mode, press .
Monitor Displays the status indicators in the selected language.
Press to return to the monitor mode display.
Program or
Monitor If a fault, alarm, or programming error message is displayed, clears
the message and goes to the previous screen.
In a fault, alarm, or diagnostics menu, goes to previous screen.
In a help screen, exits help and goes to the previous screen.
Program In menus, goes to the previous menu until it reaches the Main Menu.
At the Main Menu, it has no effect.
In parameter entry screens:
•If you have started making a change to a value, restores the
original value.
•If you have not made any changes or pressed to accept the
change, returns you to the menu.
Monitor Goes to program mode from either of the monitor mode screens.

Description of the OIM Keypad, Display, and Indicators
2-3
Program In a menu, selects the option at the cursor.
In a parameter entry screen, allows you to change input
parameter values. If a list is available for the parameter,
selects the value at the cursor. When the parameter value has been
changed, saves the new value.
Monitor Saves the keypad reference. See section 6.3 for information on the
reference.
Program These keys move the cursor between menu items or between the
parameters and options in the menus.
After you select a parameter to change, these keys increase or
decrease the digit at the cursor, or move between items in a list. See
chapter 4 for information on changing values.
In help screens and fault messages, these keys display more text if it
is available.
Monitor These keys increase or decrease the keypad reference. See
section 6.3 for information on changing the reference.
Program or
Monitor In menus and the monitor mode screen, accesses the Language
Selection screen. See section 3.3.
In menus and the monitor mode screen, displays the Contrast
Adjustment screen. See section 3.2.
In parameter entry screens, and move the cursor left
and right.
Table 2.1 – Programming Key Descriptions
Key Mode Function

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FlexPak 3000 DC Drive OIM User’s Guide
Table 2.2 – Control Key Descriptions
Key Mode Function
Program or
Monitor Allows you to select from a list of possible sources for drive control
signals. is not active when the drive is running or jogging, and
during Quick Start and self-tuning. See section 6.2 for information on
selecting a control source.
Program or
Monitor Determines which reference the drive uses. See section 6.3 for
information on selecting the reference.
This key is only active when is set to KEYPAD.
!ATTENTION: When switching from auto to manual or from manual
to auto,the drive ramps to the reference from the new source at the
rate specified by ACCELERATION TIME (P.001) or DECELERATION TIME
(P.002). An abrupt speed change might occur, depending on the
new reference and the rate specified in these parameters. Make
surepersonnelareclearofthedriveandmotorwhenswitchingfrom
AUTO to MANUAL or from MANUAL to AUTO. Failure to observe this
precaution can result in bodily injury and damage to the equipment.
Program or
Monitor Toggles direction of motor rotation when is set to KEYPAD.
The direction is fixed to FORWARD:
•for non-regenerative drives
•if REVERSE DISABLE (P.015) is set ON
•when an AC tachometer is used
•when a pulse encoder with quadrature disabled is used
Program or
Monitor When is set to KEYPAD and the drive is ready, holding
down jogs the motor. The motor stops when is released.
When jogging, the motor ramps up to JOG SPEED (P.012) or JOG
SPEED 2 (P.017) at the speed set by JOG ACCEL/DECEL TIME (P.013).
When is released, the drive reference ramps down to zero at
the same rate.
JOG SPEED 2 (P.017) is only available if DIG IN 0 SELECT (P.428) is set
to JOG SPEED SELECT and digital input 0 (terminal 12 on the Regulator
board) is on. See your software manual for information.
Program or
Monitor When is set to KEYPAD and the drive is ready, applies
power to the motor and allows it to accelerate to the reference.

Description of the OIM Keypad, Display, and Indicators
2-5
2.2 The Display
The OIM screens help you configure and monitor the drive. Figure 2.2 shows the OIM
screen at the Main Menu in program mode.
The display contains three main areas:
•The drive status indicator area.
•The display area, where the program or monitor mode information is displayed. See
chapter 4 for information on program mode. See chapter 6 for information on
monitor mode.
•The key indicator area.
Program or
Monitor If the drive is running, stops the drive as selected by STOP
MODE SELECT (P.114). When the OIM is connected and
communicating with the drive, is always active, regardless of
the setting of .
If the drive is not running and is set to KEYPAD, resets
any active faults and alarms. It does not clear the fault and alarm
logs. See chapter 7 for information on resetting faults and alarms.
!ATTENTION:The user must provide an external,
operator-accessible coast/stop pushbutton at terminals 7 and 8 on
the Regulator board to disable the machine in case of improper
operation. Uncontrolled machine operation can result if this
procedure is not followed. Failure to observe this precaution could
result in severe bodily injury or loss of life.
Table 2.2 – Control Key Descriptions
Key Mode Function
Figure 2.2 – OIM Display in Program Mode

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FlexPak 3000 DC Drive OIM User’s Guide
2.2.1 Drive Status Indicators
The indicators on the right of the display allow you to check the status of the drive. In
figure 2.2, the Interlock OK and Drive Ready indicators are shown on. The indicators
are described in table 2.3.
2.2.2 Key Indicators
There are five indicators at the bottom of the screen above the keys. When is
set to KEYPAD, these indicators tell you which setting is selected by the key. If one of
the other control sources is selected, these indicators tell you the setting selected by
that control source.
Table 2.3 – Drive Status Indicators
Indicator State Description
Fault On At least one fault has occurred. See chapter 7 for fault information.
Off There are no faults.
Alarm On At least one alarm has occurred. See chapter 7 for alarm information.
Off There are no alarms.
Interlock OK On The coast/DB contact and all customer interlocks (Regulator board terminal 9) are
closed. See the hardware manual for more information.
Off One or more customer interlocks or the coast/DB contact is open.
Drive Ready On Drive is ready to run or jog. All customer interlocks are closed, the coast/DB
contact is closed, and there are no faults.
Off Drive is not ready. See chapter 7 for diagnostics information.
Running On The contactor is closed and the motor armature is energized in either run or jog
mode. The drive is running.
Off The contactor is open and the drive is not running.
Current Limit
Torque Limit On Drive is operating at the maximum allowable current or torque.
Off Drive is not at the maximum allowable current or torque.

Description of the OIM Keypad, Display, and Indicators
2-7
In figure 2.2, the keys are set to PROGRAM, KEYPAD, MANUAL, and FORWARD. Indicators
are described in table 2.4.
Table 2.4 – Key Indicators
Key Indicator Above Possible Indications Description
PROGRAM OIM is in program mode.
MONITOR OIM is in monitor mode.
(blank) OIM is in a fault, alarm, or diagnostic menu.
FAULT Fault Menu is displayed.
ALARM Alarm Menu is displayed.
DIAGS Diagnostics Menu is displayed.
TERMBLK Signals at the Regulator board terminal strip control the drive.
NETWORK A network is controlling drive operation. Blinks when network
communication is not active.
SERIAL Drive is controlled through its serial port, typically by the
CS3000 software.
KEYPAD OIM keys control drive operation.
AUTO or
MANUAL Depends on the setting of . See section 6.2.
FORWARD The drive is configured to run the motor in the forward
direction.
REVERSE The drive is configured to run the motor in the reverse
direction.

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FlexPak 3000 DC Drive OIM User’s Guide
2.2.3 Special Display Characters
There are several special characters you might see on the display. They are described
in table 2.5.
Table 2.5 – Special Display Characters
or ]The cursor. Indicates the currently selected options. Use
and to move the cursor. Use and to
move the ]cursor.
▲Displayed if more text or options are available above the
top selection. Press to view the information.
▼Displayed if more text or options are available below the top
selection. Press to view the information.
Locked cursor. Displayed instead of if a menu or
parameter option is not available.

Powering Up and Adjusting the OIM
3-1
CHAPTER 3
Powering Up and Adjusting the OIM
This chapter tells you what to expect on power-up and power-down and how to make
adjustments for your application.
3.1 Powering Up the OIM
The OIM is powered when the drive is powered. During power up, the OIM establishes
communication with the drive and reads drive information from the Regulator board.
The OIM indicators are off and the display goes through the power-up sequence shown
in figure 3.1.
Important: See the hardware manual for instructions on powering up the drive.
When the power-up sequence is complete, the OIM enters program or monitor mode,
depending on the mode when it was powered down. Any faults or alarms detected
during power-up are displayed before you see the normal displays. See chapter 7 for
information on alarms and faults.
Important: The OIM is powered down with the drive. Make sure changes are saved
before powering down the drive. If parameter changes are not saved, they
will be lost. See section 4.4, “Saving and Restoring Parameter Values”.
Figure 3.1 – OIM Power-Up Sequence
First Screen on Power-Up
Second Screen on Power-Up

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FlexPak 3000 DC Drive OIM User’s Guide
3.2 Adjusting the Screen Contrast
If the display is difficult to read, you can adjust the contrast. You can do this at any time
except when you are in a parameter value entry screen or during self-tuning. You
might need to change the display contrast periodically because of ambient
temperature changes.
To adjust the screen contrast:
Step 1. Press . The contrast adjustment screen is displayed, as shown in
figure 3.2.
Step 2. Use to increase the contrast (make the screen darker) or to decrease
the contrast (make the screen lighter).
Step 3. Press to accept the new contrast. The previous screen is displayed.
To save the new configuration through a power cycle, you must use Memory Save.
See section 4.4, “Saving and Restoring Parameter Values”.
Figure 3.2 – Contrast Adjustment Screen