Bardac PL, PLX Quick Start Guide

20)MOTOR 1,2 SELECT
MOTOR 1

19)EL1/2/3 RATED AC

460.0 VOLTS

18)RATED ARM VOLTS

500.0 VOLTS

6)DESIRED MAX RPM
1750 RPM

5)BASE RATED RPM
1750 RPM

2)RATED ARM AMPS

35.0 AMPS

4)RATED FIELD AMPS

1.35 AMPS

SPD% Iarm Ifld RJSC
0 0 0 0000

Sref Ilim –Ilim mode
0 150 -150 STOP

Bardac

drives

basic

PL/X Quick Start

This Quick Start is a supplement to
the standard product manuals
intended for use as a guide to get

your PL/X Drive up and running as
a basic speed controller in a safe and efficient manner. For
all other applications, refer to the PL/X Product and
Applications Manuals.

Only qualified personnel who thoroughly
understand the operation of the machine
on which the PL/X is installed and who
are familiar with electrical wiring and
safety standards should attempt to
commission this equipment.

With ALL Power OFF

A. Connect up the drive
Hook your drive up according to the following diagrams.
Ensure power and control wiring are routed in separate
conduit/cable trays and wiring meets applicable national
and local electrical codes.

Power Wiring Diagram

PL/X POWER WIRING

51

EARTH

53

CNTRL

L

52

CNTRL

N

L1

MAIN

POWER

L2

MAIN

POWER

L3

MAIN

POWER

EL1

AUX

SPPLY

EL2

AUX

SPPLY

EL3

AUX

SPPLY

FIELD

(+)

F+

FIELD

(-)

F-

ARM

(+)

A+

EARTH

GND

G

ARM

(-)

A-

THERM

IP

30

0V

COM

36

CON145CON2

46

LR

FIELD

300V+1.3/0.8 A

M

500V

20 HP

+

1750RPM

36A THERM

CON

F4 F5 F6

F1 F2 F3

CONCON

CON

CRA1A2

F8

See Product Manual for fuse specifications.

Power Terminals

Control Wiring Diagram

PL/X CONTROL WIRING

SIG

COM

1

RAMP

IP

4

START

33

JOG

32

MAIN

I CLAMP

6

+10VDC

REF

27

CONTROL

COM

13

RUN

SCR ENA

31

CSTOP34+24VDC

35

POT

1K THRU 10K

SPEED

ENA JOG

CSO

STRT

Control Terminals

Contact Descriptions (All are maintained-type)

CSO (Coast Stop Override): Must be closed prior to all

other control signals for proper sequencing. When opened,
the drive immediately stops generating armature current
and the contactor drops out. Motor coasts to stop.

ENA (Enable): Electronic inhibit for all modes of operation.
When closed, the drive may generate current. If open, no
armature current will generated. May be jumpered to
Terminal 35 in most applications.

JOG: When closed, the drive’s contactor comes in and the
motor will run at the Jog Speed 1 setting (Default 5%
speed). When opened, the drive ramps to zero and
contactor opens after a delay (Default = 2 secs).

STRT (Start): When closed, the drive’s contactor comes in
and the motor will run at potentiometer speed setting.
When opened, the drive ramps to zero and contactor
opens after a delay (Default = 2 secs).

As programmed from the factory, after removal of the
control input, the motor field current will be present until
the field quench delay is completed (Default = 10 secs).

Optional Feedback Devices

DC Tachometer Encoder

TACHOMETER

50V/1000RPM

+

DC

EARTH

GND

G

TACH

IP

26

TACH

COM

25

TACH FEEDBACK

EARTH

GND

G

ENCODER FEEDBACK

+24 VDC35COM

25

ENC

Z

15

ENC

B

16

ENC

A

17

21 3 4

SUPPLY

COM

(-)

CHNL

A

OUT

CHNL

B

OUT

SUPPLY

24 VDC

(+)

MRKR

Z

OUT

ENCODER 1024 PPR

5

TWISTED SHIELDED PAIRS

54321

MARKER Z OPTIONAL (WIRE NO. 5)

A. Get the supply and motor nameplate data

Description

Typical

Actual

Units

Supply Voltage (VL)

480

VAC

Armature Volts (VA)

500

VDC

Armature Current (IA)

35

ADC

Base Speed (BS)

1750

RPM

Maximum Speed (MS)

2300

RPM

Field Volts (VF)

300

VDC

Field Current @ BS (IFb)

1.35

ADC

Field Current @ MS (IFm)

0.8

ADC

Feedback Device

DC Tachometer (TV)

50

V/1000

Encoder (PPR)

1024

PPR

Supply Volts (EV)

5 - 24

VDC

Navigating through the menus

The green keys are used to
setup the drive. In this Quick
Start, the required key
sequences are displayed to
the left of each parameter to
be modified. When executed
correctly, the display on the
drive should match the one
shown.

Legend of abbreviations used for keystrokes:

L,R,U,D = Press the specified button EXACTLY once.
8xU = Press the Up button 8 times.
U/D = Use the Up button to increase the value, use

the Down button to decrease the value.

Final Power OFF Checks

Recheck all your wiring, especially the drive’s chassis
ground. Also, use your multimeter to check the L1, L2, L3,
F+, F-, A+, and A- Terminals for short circuits to ground.
All readings should be greater than 1 MΩ. Correct any low
resistances prior to applying power.

It is essential to perform all of the following
steps in their entirety and in the proper
sequence! If in doubt, call 1-888-667-7333
(International 410-604-3400).

Power ON Checks

1. Apply Control Power and Calibrate

Apply 100-240 VAC control power to T53 (Line) and T52
(Neutral).

2. Calibrate the Drive to the Motor

At power up, the Diagnostic Summary Screens are
displayed. By pressing the Left key at least 5 times, you
will return you to these screens from any menu level.

5xL

When at the top level, the display toggles between the
Diagnostic Summaries about every 5 seconds.

Press the keys in the sequence below to set the rated
armature current from the nameplate data you recorded.

R,R,U,R,R – U/D

Use the up and down keys to change the values.

Now, to move to the rated field current:

L,D,D,R – U/D

Repeat these steps for the following:

L,D,R - U/D

L,D,R - U/D

L,9xD,R - U/D

L,D,R - U/D

Also check the following to ensure they have not been
modified from the factory default settings:

L,D,R - U/D

L,8xU,R - U/D Then 4xL

Although the drive regulates field current by default, set the
field voltage clamp as a percentage of AC supply volts.

FV % = (FV ÷ VL) x 100

R,R,7xD,R,D,R – U/D Then 4xL

Feedback calibration

If you do not have a DC tachometer or encoder, skip this
section and go to Step 3.

DC Tachometer Calibration

For a tachometer, initially calibrate the drive for the
expected DC voltage at base speed.

TVb = (BS ÷ 1000) x TV

100)FIELD VOLTS OP %

65.00 %

IA

IFb

BSBSVAVLFV%

T 1-12

T 13-24

T 25-36

T 41-48

T 51-53

A+

A-

L2

L1

L3

EL1,2,3

F-,+

Ground Lug

9)SPEED FBK TYPE
ARMATURE VOLTS

U

DRL

Note: Jumper T6 to T27



Caution:

TVb must not exceed 200 VDC.

R,R,U,R,6xD,R – U/D Then 4xL

Encoder Calibration

Ensure quadrature is enabled and enter the PPR.

R,R,U,R,8xD,R,R – U/D

L,D,R – U/D Then 4xL

3. Save Parameters

To save your work thus far, from the Diagnostic Screens:

R,U,R

U

When done Then 2xL

4. Check Control Terminals

The next few checks are to ensure the drive contactor is
sequenced properly prior to applying three phase power.
The value under the letters TRJSC in the display indicate
the actual Control Input (CIP) terminal status.

Letter

Terminal

Contact

Thermistor

30

THERM

Run31ENA
Jog32JOG
Start33STRT
Coast Stop

34

CSO

From the Diagnostic Screens, go to the CIP Diagnostic.

R,D,R,4xD,R,D,D,R

Leaving the CSO contact of your control wiring open (a 0
under the C), close the other control contacts. Check to
see if the digit under the appropriate letter changes as you
cycle of the contact. Generally, 1 = ON while 0 = OFF (for
the thermistor T, 0 = OK while 1 = Motor Overtemp).

Once satisfied with the operation of the T,R,J, and S
control inputs, leave R,J, and S OFF and check the C
control input for proper operation.

5. Apply Main Three Phase Power

6. Autotune the PL/X

Prior to running the motor, the current loop of the drive
must be tuned to the motor and cabling (PIN’s 93,94,& 95).

a) Ensure the drive is in a normal stop condition. The
CIP’s should match TRJSC below:

Still from Step 4 Then 4xL

b) Enable the autotune mode.

R,R,6xD,R,7xD,R – U Then 4xL

c) Start the drive by energizing the Start Input (T33).

R,D,R,4xD,R,D,D,R Then 4xL

The contactor will close and an autotune will be performed
(takes 10 - 60 seconds). When complete, the drive’s
contactor will open. Turn off the Start Input (T33).

Now, SAVE PARAMETERS as described in Step 3.

7. Motor Rotational Checks

Ideally, you would like to perform these running checks
with the motor disconnected from the gear box and the
machine.

As an additional precaution, restrict the available current to
the drive by reducing the Current Limit to just enough
current to turn the motor (usually 5 to 10%).

R,R,U,R,D,R - D

Check operation of the speed potentiometer by monitoring
the Ramp Input. Leave the reference at zero after checking
for proper operation.

L,L,D,R,5xD,R Then 4xL

Start the drive by energizing the Start Input (T33). Check
the field voltage at the F+ and F-. When the motor is cold,
you will measure somewhat less than the rated field
voltage (approximately 240 VDC for a 300 VDC rated
field).

Confirm the field current matches the IFb nameplate data.

R,D,R,D,D,R,D,D,R Then 4xL

Increase the potentiometer setting until the motor is turning
slowly. Check motor rotation. If backwards, stop, turn off
ALL power to the drive, and swap the field leads (F+, F-).
Recheck after changes.

Now, slowly bring the motor up to full speed while checking
the voltage on the A+ and A- terminals.

R,D,R,R,3xD,R

If you have neither a tachometer nor encoder, skip to Step

9. If using a tachometer or encoder, check to ensure the
speed reference is positive (+).

3xU

Then, check the sign of the feedback, as follows:

Tachometer Feedback

6xD Then 4xL

If positive (+), skip to Step 8. If negative (-), stop, power off
the drive, then swap the tachometer leads on T25 and T26
and recheck.

Encoder Feedback

2xU Then 4xL

If positive (+), skip to Step 8. If negative (-), stop the drive
and invert the encoder sign and recheck.

R,R,U,R,8xD,R,3xD,R - D 5xL

8. Switching Feedback Type

Now, stop the drive and select the appropriate feedback.

Tachometer Feedback

R,R,U,R,7xD,R - U Then 4xL

Encoder Feedback

R,R,U,R,7xD,R – 2xU Then 4xL

Again, start the drive and ensure maximum speed can be
obtained and the armature voltage does not exceed the
nameplate VA.

9. Increase the Current Limit to Rated Value

At this point, the Current Limit may be returned to 150%.

R,R,U,R,D,R - U Then 4xL

Now, SAVE PARAMETERS as described in Step 3.

10. Adjusting the Speed Calibration at Base Speed

Gradually, increase your potentiometer to the maximum
position and then adjust the final speed of the motor.

Depending on the final feedback type, different parameters
(PIN’s 16, 17,& 6) are used for speed calibration.

Do NOT exceed the base speed (BS) value while adjusting
these parameters. These calibration parameters may be
adjusted while the drive is running.

Armature Voltage

R,R,U,R,5xU,R – U Then 4xL

Increase this value to reduce the armature voltage. If this
parameter does not provide enough adjustment , stop and
readjust PIN 18 - Rated Arm Volts from Step 2.

Tachometer Feedback

R,R,U,R,4xU,R – U Then 4xL

Increase this value to reduce the motor speed. If this
parameter does not provide enough adjustment, stop and
readjust PIN 8 - Analog Tacho Volts from Step 2.

Encoder Feedback

R,R,U,R,4xD,R – U/D Then 4xL

Change this value to achieve the desired motor speed.

Again, SAVE PARAMETERS.

11. Setting Up Field Weakening

When using either tachometer or encoder feedback, field
weakening may be enabled for a motor which supports an
extended speed range.

a) First, stop the drive and enable the field weakening
mode.

R,R,7xD,R,4xD,R,R - U

b) Next, set the minimum field expected (with a 10%
safety margin).

Min Field % = (Ifm ÷ Ifb) x 90

L,7xD,R – U/D Then 4xL

Finally, adjust the maximum speed as described in Step

10. Again, do NOT exceed the maximum speed (MS)

value noted on the motor nameplate.

Again, SAVE PARAMETERS as described in Step 3.

Congratulations, you have successfully commissioned
your Bardac PL/X Digital DC Drive.

If you have any questions or do not understand a portion of
this Quick Start Manual, please contact us:

Bardac Corporation

40 Log Canoe Circle

Stevensville MD 21666 USA

Phone: 888-ON-SPEED (888-667-7333)

International: 410-604-3400

FAX: [phone]

Website: www.bardac.com

Email: [e-mail]

HG501504; Issue 3

8)ANALOG TACHO VOLTS

87.50 VOLTS

10)QUADRATURE ENABLE
ENABLED

11)ENCODER LINES
1024

164)DOP 123TRJSC CIP
10100000

164)DOP 123TRJSC CIP
10101001

164)DOP 123TRJSC CIP
10101011

92)AUTOTUNE ENABLE
ENABLED

3)CURRENT LIMIT(%)

5.00 %

26)RAMP INPUT

75.14 %

145)FLD CUR AMPS MON

1.35 AMPS

126)ARM VOLTS MON

500.0 VOLTS

129)TACHO VOLTS MON

-23.19 VOLTS

13)ENCODER SIGN
INVERT

9)SPEED FBK TYPE
ANALOG TACHO

9)SPEED FBK TYPE
ENCODER

16)ARM VOLTS TRIM

1.0000

17)ANALOG TACHO TRIM

1.0000

6)DESIRED MAX RPM
1750 RPM

3)CURRENT LIMIT(%)

150.00 %

103)FLD WEAK ENABLE
ENABLED

110)MIN FLD CURRENT

53.33 %

TVb

PPR

PARAMETER SAVE 2
UP KEY TO CONTINUE

PARAMETER SAVE 2
SAVING

PARAMETER SAVE 2
FINISHED

123)TOTAL SPD REF MN

26.50 %

132)ENCODER RPM MON

-464 RPM