PowerTec DFS-1 User Manual

POWERTEC

Industrial Motors

DFS-1

SOFTWARE RELEASE 1.0

MICROPROCESSOR B ASED

BRUSHLESS D.C.

MOTOR CONTROLLER

INSTALLATION AND

OPERATION

INSTRUCTION MANUAL

PRODUCTION RELEASE

AUGUST, 1994

A subsidiary of

POWERTEC Industrial Corporation

Mailing Address: P.O.Box 2650 • Rock Hill, South Carolina USA 29732 • PHONE: 803-328-1888

Shipping Addre

ss: 2606 Eden Terrace • Rock Hill, South Carolina USA 29730 • FAX: 803-328-1870

PM080994

Corrections to page 44 of the manual, Attachment A: Detailed Commands Read Speed/Status (81)

Changes shown in gray

[ST2] - 7 6 5 4 3 2 1 0

Local/Remote (0,1) Master/slave (0,1) At Speed (1) Fwd. Dir. Set Fault Detected (1) Drive Enabled (1) Microprocessor Fault Zero Speed

ERRA T A

[ST1] - 7 6 5 4 3 2 1 0

Bus not charged (1) IOC (1) Stall Inverse Time OL (1) Heatsink Thermal OT Commutation Fault Overvolt Undervolt

DFS-01IM PM94290

Additional Info

DFS Software Modification For

Dynamic Braking or Output Contactor

Operation

25 October, 1994

Functional Description

A new function for Contactor Aux has been added to the digital input choices. When configured as described in the example, 24VDC must be present at this input for the drive to run. Parameter #62, Contactor Delay, is a number of 25ms intervals that will occur between the DFS controller acceptance of a run command and the firing of the transistors. If the Contactor Aux input signal is low, the DFS starts the timer and closes the Contactor Output. If the Contactor Aux input does not switch high before the timer runs out, the drive will return to the stop condition. If the Contactor Aux input does switch high, the drive will start running when the timer runs out.

Example Setup for Dynamic Braking

1 Set Digital Input #7 mode to Contactor Aux, polarity to Active Low . 2 Set Digital Output #4 mode to Contactor, polarity to Normally Closed. 3 Set Contactor Delay to 20 (20 x 25ms = 500ms = 1/2 second).

Run command causes the Contactor Output to close, the Contactor Relay opens, the feedback contacts close and the drive starts to run.

Example Setup for Output Contactor

1 Set Digital Input #7 mode to Contactor Aux, polarity to Active Low . 2 Set Digital Output #4 mode to Contactor, polarity to Normally Closed. 3 Set Contactor Delay to 10 (10 x 25ms = 250ms = 1/4 second).

Run command causes the Contactor Output to close, the Contactor Relay closes, the feedback contacts close and the drive starts to run.

The difference in the operation of the two types of contactors is that the Dynamic Braking Contactor is normally closed whereas the Output Contactor is normally open. In both contactors, the auxilliary contacts are normally open.

Terms Used

1 Contactor Aux - The digital input on the DFS board which is connected to the feedback contacts on the

contactor relay.

2 Contactor Output - The digital output on the DFS board which activates the solenoid on the contactor

relay. 3 Signal low - 0VDC 4 Signal high - 24VDC

1.0 INSTALLATION

The DFS-1 printed circuit board mounts on any POWERTEC Brushless DC motor control except the Model 500. The Model 1000 is used here for illustration purposes only.

1.1 MOUNTING -- READ THIS ENTIRE

SECTION BEFORE STARTING!

The DFS-1 printed circuit board mounts on the Model 1000 or Model 1000AR motor control in place of both the Current Controller board (part #141-108) and the Speed Controller board (part #141-107 on the non-regenerative model 1000, part # 147-101 on the regenerative model 1000AR). These boards are mounted side by side on all standard motor controls. TB1 is located on the Current Controller (left hand board) and TB2 is on the Speed Controller (right hand board). The first eight connections which normally come into TB1 (the motor cable leads) will connect to the same places on the DFS-1. The connections going into TB2 (mainly operators and speed pot) on the standard motor control will go to different connections on the DFS-1.

There are two flat ribbon cables which must be connected from the DFS-1 to the other parts of the motor control: one goes to the Base Driver Board (part #141-105), and the other cable goes to the Capacitor Board (part #141-106). See figure 2 for the physical layout of the control and the location of these boards. If the DFS-1 board is being installed in the field, the cables should come with the new board, since the connectors on the DFS-1 end are different from the connectors on the Speed and Current controller ends of the previous cables. Make sure that you have these new cables before proceeding to install the board. If you do not have them, call POWERTEC's service department before proceeding.

The DFS-1 board may be used as either a nonregenerative control or as a regenerative control. This selection is made by one of its parameter settings. The DFS-1 may be installed on a Model 1000 non-regenerative brushless DC control, but if the unit is to be used for a regenerative application, a bus loader of the appropriate voltage and resistors of sufficient wattage must be added before the drive may be used regeneratively. If a bus loader is not installed before regenerative operation occurs, it is likely that the control will trip out repeatedly. A Model 1000AR will already have a bus loader and resistors attached.

Figure 1: The DFS-1 replaces two boards.

If the board is being installed to replace the boards on a standard control, unplug the strips on TB1 and TB2, but do not disconnect any wires from them yet. Unplug the 14-pin connector on P2 (at the Base Driver Board) and the 10-pin connector on P3 (at the Capacitor Board). Remove these cables and the Speed and Current controller boards from the chassis and set them aside. Remove the studs at the top right of where the Current Controller board was, and at the top left of where the Speed Controller was located ( the center studs - see figure 1).

Figure 2: The Model 1000 chassis

Page 1

CONTENTS

Introduction ...............................................................................................................................1

Summary of Warranty and Disclaimer ......................................................................................2

WARNING!...............................................................................................................................2

1.0 Connections ........................................................................................................................3

POWER CONNECTIONS: ............................................................................................................. ............... 3

MOTOR ENCODER CABLE: ....................................................................................................................... 4

ANALOG INPUTS:........................................................................................................................................ 4

ANALOG OUTPUTS:................................................................................................................................... 5

FREQUENCY INPUT:................................................................................................................................... 5

FREQUENCY OUTPUT:............................................................................................................................... 6

DIGITAL INPUTS:......................................................................................................................................... 6

DIGITAL OUTPUTS:..................................................................................................................................... 7

COMMUNICATIONS:................................................................................................................................... 7

DEFAULT SETUP.......................................................................................................................................... 9

2.0 Specifications ................................................................................................................... 11

POWER SUPPLIES...................................................................................................................................... 11

ANALOG INPUTS....................................................................................................................................... 11

ANALOG OUTPUTS................................................................................................................................... 11

FREQUENCY INPUTS AND OUTPUTS...................................................................................................12

DIGITAL INPUTS........................................................................................................................................ 12

DIGITAL OUTPUTS.................................................................................................................................... 12

COMMUNICATIONS.................................................................................................................................. 13

3.0 DFS-1 Parameters.............................................................................................................15

1. UNIT ID ................................................................................................................................................ 15

2. BAUD RATE......................................................................................................................................... 15

3. LOCAL / REMOTE CONTROL ........................................................................................................... 15

4. COMMUNICATIONS PROTOCOL ..................................................................................................... 16

5. MODES OF OPERATION..................................................................................................................... 16

6. MAXIMUM MOTOR SPEED...............................................................................................................17

7. ENCODER PULSES PER REVOLUTION .......................................................................................... 17

8. MASTER RAMP UP TIME .................................................................................................................. 18

9. MASTER RAMP DOWN TIME ........................................................................................................... 18

10. SLAVE RAMP UP TIME ...................................................................................................................... 1 8

11. SLAVE RAMP DOWN TIME............................................................................................................... 18

12. MASTER PRESET SPEED ................................................................................................................... 19

13. SLAVE RATIO PRESET ....................................................................................................................... 1 9

14. ENGINEERING UNITS ........................................................................................................................ 19

15. BASE RATIO......................................................................................................................................... 19

16. MAXIMUM RATIO ..............................................................................................................................20

17. ANALOG INPUT #1 MODE SELECT................................................................................................. 20

18. ANALOG INPUT #1 SIGNAL CONDITIONING............................................................................... 21

19. ANALOG INPUT #1 LOW ENGINEERING UNITS (EGU).............................................................. 21

20. ANALOG INPUT #1 HIGH ENGINEERING UNITS (EGU) ............................................................. 22

21. ANALOG INPUT #2 MODE SELECT................................................................................................. 22

22. ANALOG INPUT #2 SIGNAL CONDITIONING............................................................................... 22

23. ANALOG INPUT #2 LOW ENGINEERING UNITS (EGU).............................................................. 22

24. ANALOG INPUT #2 HIGH ENGINEERING UNITS (EGU) ............................................................. 22

25. ANALOG OUTPUT #1 MODE SELECT............................................................................................. 23

26. ANALOG OUTPUT #1 LOW ENGINEERING UNITS (EGU).......................................................... 23

27. ANALOG OUTPUT #1 HIGH ENGINEERING UNITS (EGU) ......................................................... 23

28. ANALOG OUTPUT #2 MODE SELECT............................................................................................. 23

29. ANALOG OUTPUT #2 LOW ENGINEERING UNITS (EGU).......................................................... 24

30. ANALOG OUTPUT #2 HIGH ENGINEERING UNITS (EGU) ......................................................... 24

31. DIGITAL INPUT #1 FUNCTION......................................................................................................... 25

32. DIGITAL INPUT #2 FUNCTION......................................................................................................... 25

33. DIGITAL INPUT #3 FUNCTION......................................................................................................... 25

34. DIGITAL INPUT #4 FUNCTION......................................................................................................... 25

35. DIGITAL INPUT #5 FUNCTION......................................................................................................... 26

36. DIGITAL INPUT #6 FUNCTION......................................................................................................... 26

37. DIGITAL INPUT #7 FUNCTION......................................................................................................... 26

38. DIGITAL OUTPUT #1 FUNCTION..................................................................................................... 26

39. DIGITAL OUTPUT #2 FUNCTION..................................................................................................... 27

40. DIGITAL OUTPUT #3 FUNCTION..................................................................................................... 27

41. DIGITAL OUTPUT #4 FUNCTION..................................................................................................... 27

42. DRIVE GAIN SETTING ....................................................................................................................... 27

43. DRIVE STABILITY SETTING............................................................................................................. 27

44. DRIVE MOTORING CURRENT LIMIT ............................................................................................. 27

45. DRIVE REGENERATIVE CURRENT LIMIT..................................................................................... 28

46. PULSE MULTIPLIER ........................................................................................................................... 28

47. MODULATION AND OPERATION MODES..................................................................................... 28

48. JUMP OR MOP OPERATION .............................................................................................................. 28

49. MASTER JUMP UP AMOUNT............................................................................................................ 29

50. MASTER JUMP DOWN AMOUNT .................................................................................................... 29

51. SLAVE JUMP UP AMOUNT................................................................................................................ 29

52. SLAVE JUMP DOWN AMOUNT ........................................................................................................ 29

53. INPUT DEBOUNCE VALUE ............................................................................................................... 30

54. FLOAT OR FREEZE ............................................................................................................................. 30

55. MINIMUM RATIO................................................................................................................................30

56. COMMUNICATIONS TURNAROUND DELAY................................................................................ 30

57. MASTER JOG SPEED .......................................................................................................................... 31

58. SLAVE JOG RATIO .............................................................................................................................. 31

59. EGU TAG SELECT ............................................................................................................................... 31

60. MASTER PRESET #2 ........................................................................................................................... 31

61. SLAVE PRESET #2...............................................................................................................................31

4.0 DFS - 1 Setup ..................................................................................................................33

4.1 BASIC SETUP OF THE DFS-1 CONTROLLER................................................................................. 34

4.2 MASTER MODE SETUP..................................................................................................................... 35

4.3 SLAVE MODE SETUP......................................................................................................................... 36

4.4 INPUTS AND OUTPUTS SETUP....................................................................................................... 37

4.5 COMMUNICATIONS SETUP.............................................................................................................38

5.0 DFS-1 ERROR CODES ..................................................................................................39

6.0 COMMUNICATION PROTOCOL..................................................................................41

COMMAND LIST........................................................................................................................................ 42

PARAMETER LIST ..................................................................................................................................... 43

ATTACHMENT A: DETAILED COMMANDS......................................................................................... 44

ATTACHMENT B: PARAMETER DESCRIPTION.................................................................................. 50

Additional Info ................................................................................................................ ........51

Typical Output Contactor Connections ........................................................................................................ 52

Typical Dynamic Braking Connections........................................................................................................ 53

Appendix A .............................................................................................................................55

RETROFITTING THE MODEL 1000,1000A, OR 1000AR

Appendix B..............................................................................................................................57

MENU AND KEYPAD HIERARCHY

THIS PAGE WAS INTENTIONALLY LEFT BLANK.

Page 4

DFS-1 Manual Revised 7/95

POWERTEC Ind. Corp.©

INTRODUCTION

s the computer revolution takes greater control of industrial processes, there is

the process parameters. It is becoming ever more necessary to control the important characteristics of motors directly from computers and microprocessorbased controllers. Such control cannot wait for operator intervention when changes occur in milliseconds and tolerances are measured in thousandths.

are controllable by manipulating its speed, torque, and power. POWERTEC digitally implemented, speed, torque, and power control - the DFS-1.

digitally based, and are a natural choice for a computer controlled environment. Now computers and PLC's talk to the drive itself when the field- installable DFS-1 control board replaces the Speed and Current boards on the standard POWERTEC Brushless DC drive.

DFS-1 is that there are no adjustment potentiometers and no setup switches. All characteristics of the drive

are controlled by software parameters which may be entered by the optional KDU-1 keypad or host computer. The KDU-1 keypad can be mounted on the DFS-1 board, in a remote location (usually the enclosure door), or in a handheld unit. A default set of parameters which represent the most common operating conditions will facilitate immediate operation and testing after installation.

networks, the DFS-1 is programmable by an optional keypad with its two line, 16-character display. A single computer port may be used to monitor and control up to 32 units in an RS-485 communications link.

a growing need for more intimate control of

All of the operational characteristics of a motor

The Brushless DC motor and its control are

One of the first things you will notice about the

Capable of operating on a single drive or in

Programmable analog inputs and analog outputs allow many possibilities for control through external voltages, currents, and frequencies. They may also be used to monitor drive operation. Digital inputs and outputs (also programmable) give control and monitoring flexibility as well as coordination functions.

Provision is made for plug-in options which add input and output options and accomplish special functions. Optional software packages may be ordered for specific application needs.

Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.©

Page 5

SUMMARY OF WARRANTY AND DISCLAIMER

POWERTEC Industrial Corporation warrants the DFS-1 to be free from defects in materials and work- manship for a period of one year from the date of shipment from the factory, or if purchased from an authorized POWERTEC distributor or Original Equipment Manufacturer, not more than 18 months from the date of shipment from the factory. Upon written notification to the factory of a possible defect in materials or workmanship, POWERTEC will, at its sole option, repair or replace, at the factory, such defective parts as it deems necessary to restore the unit to its original specifications.

There is no other warranty, express or implied, including fitness of purpose for the application intended. This warranty does not cover accidental or intentional damage; physical or electrical misuse or abuse; defective or incorrect installation; effects on other equipment or caused by other equipment; attempted use outside of specified ranges; or any other situation outside of the control of POWERTEC Industrial Corporation.

The user is responsible for the application of the DFS-1 product and the programming thereof.

This warranty does not encompass any other claims, including, but not limited to, special, incidental, or consequential damages.

This manual has been assembled as a guide to the use of a POWERTEC product. It represents the best efforts to compile and present the information herein. Such errors as may appear in no way affect the above stated warranty. If mistakes of fact are found or suspected in this manual, please notify the factory or your distributor at once.

WARNING!

The DFS-1 contains static sensitive parts which may be damaged by careless handling of the printed circuit board. You can avoid this type of damage by always touching the frame of the drive before you touch the printed circuit board or any of its connections.

The DFS-1 is supplied for field installation in a protective bag. Bring the bag into contact with the

motor controller frame before removing the board from the bag.

Page 6

DFS-1 Manual Revised 7/95

POWERTEC Ind. Corp.©

1.0 CONNECTIONS

POWER CONNECTIONS:

POWERTEC Brushless DC motor controllers are supplied with nominal input voltages of 230, 380, and 460VAC. Three phase input power is required. The input is not phase sensitive. Connect the appropriate power supply to the input fuses at L1, L2, and L3 (check nameplate for proper input voltage and capacity).

Connect the output terminals T1, T2, and T3 to the respective terminals on the Brushless DC motor. It is very important that the T1 terminal on the motor connects to T1 on the drive, T2 of the motor connects to T2 of the drive, and T3 of the motor connects to T3 of the drive. An earth ground wire of the same gauge as the motor power leads or one gauge smaller (no smaller than #14 AWG) must be run from a bolt

Orange

Motor

T1 T2 T3

Brown

Red

Blue

Yellow

Black

Green

Purple

White

Shield

in the motor junction box to the ground terminal on the drive. A wire must then be run from the ground terminal on the drive (next to the motor terminals) to an earth ground at or near the power source. The Model 1000 drive does not have the common circuitry connected to earth ground (chassis). In most cases this works best, but in some cases it does not. POWERTEC recommends connecting a short jumper wire from the drive common at any one of the several places available on the terminal strips to a nearby point on the drive chassis or backpanel that will establish this ground. This is more important in applications where multiple drives are connected together or serial communications from a host are used. All other POWERTEC drives have the common grounded by mounting screws on the regulator boards.

Run

Stop

Fwd Rev

E-Stop

RS-485 Communications

POWERTEC

Brushless DC Drive

COMMUNICATIONS+

COMMUNICATIONS-

COMMUNICATIONS SHIELD

24V COMMON

Digital Input COMMON Cathodes

E-STOP

Digital In 1

Digital In 2

Digital In 3

Digital In 4

Digital In 5

Digital In 6

Digital In 7

FREQ REF IN+

FREQ IN-

FREQ REF SHIELD

Digital Out 4A

Digital Out 4B

FREQ REF OUT-

FREQ REF OUT+

+24V

Spacer

TB3

Spacer

SPEED OUT

Speed Out COMMON

FREQ REF COMMON

HALL SHIELD

HS1

HS3

HS2

HS4

HS5

HALL COMMON

HALL POWER

THERMAL

THERMAL POWER

-10VREF

Analog In 2-

Analog Out 1+

Spacer

1 2 3 4 5 6 7 8 9 10 11 12 13 14

TB2

1 2 3 4 5 6 7 8 9 10 11 12 13 14

+24V

Spacer

Analog Out 2+

Digital Out 1A

Analog Out COMMON

Digital Out 1B

Digital Out 2A

Digital Out 2B

Digital Out 3A

Digital Out 3B

T3 T2 T1

L3 L2 L1

Analog Speed Pot

1 2 3 4 5 6 7 8 9 10

TB1

1 2 3 4 5 6 7 8 9 10

+10VDC

Analog In 1+

Analog In COMMON

Analog In 1-

Analog In 2+

1 2 3 4

DISPLAY POWER

1 2 3 4

Keypad Display Unit

COMMUNICATIONS COMMON

DISPLAY-

DISPLAY +

Display COMMON

DFS-1 Board

KDU Cable is Belden # 9463 “Blue Hose” or equivalent

Figure 3: Basic connections to the DFS-1 controlled POWERTEC Brushless DC motor control, using the factory default settings for some of the inputs and outputs. Note that the speed pot input is the default, and that using the 4-20mA input will require a change in the DFS-1 setup.

Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.©

Page 7

MOTOR ENCODER CABLE:

The motor encoder cable is connected to plug-in

terminal strip TB1:A on the DFS-1 PC board. A shielded cable must be used for the motor encoder cable. The recommended cable is a 9-conductor shielded cable (Belden Cable part # 9539 or equivalent). The shield should be connected at the drive end to the shield terminal (TB1:A1) and to terminal 10 (if there is one) at the motor terminal strip and if not (as on motors built prior to April 1992), the shield should be cut off at the motor end and taped up.

The DFS-1 PC Board contains all of the func-

tions necessary to operate the Brushless DC motor control according to the inputs connected to its terminals and the programmed information in memory. The DFS-1 board takes care of all speed, torque, and control functions. It takes speed information from the encoder, environmental information and current (load) information from the power output circuits of the drive, and compares all that information to the input conditions and programmed parameters. It processes this information and turns the power transistors on and off according to the needs of the system.

The DFS-1 is delivered with an installed set of

default parameters which will allow it to operate with a standard set of connections (as illustrated in Figure

3) of the types used with standard motor controls.

However, these standard connections will not be in the same physical positions as they are in the standard control, and the default setting will not take care of any optional modes of operation.

There are three plug-in terminal strips on the bottom of the DFS-1 PC board labelled in sections from left to right: TB1, TB2, and TB3. Though the three sections look like two rows of strips, there is a small separator between each of the sections. Each of the sections has an upper row (A) and a lower row (B). The B row is closest to the PC board. The terminals are numbered consecutively from left to right on each level.

ANALOG INPUTS:

There are two analog input ports to the DFS-1 on TB1:B. When used as a voltage input, both of the analog inputs are a differential type of input with a minimum input impedance of 200 Kohms. When using one of the analog inputs for a voltage input, the input common at terminal 1 on TB1:B should be used for shields.

When using an analog input as a milliamp input, the (-) side of the input (terminal 4 for Analog Input #1 or terminal 6 for Analog Input #2) should be connected to the common of the milliamp current source. The milliamp source should be connected to the (+) input (terminal 3 for Analog Input #1 or terminal 5 for Analog Input #2).

COMMUNICATIONS+

COMMUNICATIONS-

COMMUNICATIONS SHIELD

1 2 3 4

DISPLAY-

DISPLAY +

DISPLAY POWER

COMMUNICATIONS COMMON

Display COMMON

HALL SHIELD

HS1

HS3

HS2

1 2 3 4 5 6 7 8 9 10

TB1

1 2 3 4 5 6 7 8 9 10

+10VDC

Analog In 1+

Analog In COMMON

HS4

HS5

HALL COMMON

-10VREF

Analog In 1-

Analog In 2-

Analog In 2+

HALL POWER

THERMAL

THERMAL POWER

Spacer

TB2

Spacer

Analog Out 1+

Analog Out 2+

Analog Out COMMON

COMMON

Digital Input COMMON Cathodes

E-STOP

Digital In 1

Digital In 2

Digital In 3

Digital In 4

Digital In 5

Digital In 6

Digital In 7

1 2 3 4 5 6 7 8 9 10 11 12 13 14

+24V

Digital Out 1A

Digital Out 1B

Digital Out 2A

Digital Out 2B

Digital Out 3A

Digital Out 3B

Digital Out 4A

Digital Out 4B

FREQ REF OUT+

FREQ REF IN+

FREQ IN-

FREQ REF SHIELD

+24V

Spacer

TB3

Spacer

SPEED OUT

FREQ REF OUT-

Digital out COMMON

Speed Out COMMON

A B

Figure 4: Assignments of the DFS-1 terminals. There are default assignments, but any of the analog and digital inputs and outputs (except the motor connections, power supplies, commons, emergency stop input, and frequency input) may be changed by setup.

Page 8

DFS-1 Manual Revised 7/95

POWERTEC Ind. Corp.©

The default speed reference input is Analog Input #1, located on TB1:B. The default input is for a 0 to +10VDC for zero to full speed of the motor. Terminal 3 is the positive side of the input and terminal 4 is the negative side. If the speed signal being used is externally supplied, the differential input will have a noise cancelling effect. Terminal 1 on TB1:B is a common for shields.

Reference sources of +10VDC and -10VDC are supplied on the terminal strips at TB2:B2 and TB2:B7, respectively. The default speed pot connections should be made as illustrated in figure 3. Notice that the (-) side of the differential input (terminal 4) is connected by a jumper to common (terminal 1), because the DFS-1 reference source is being used. If an external reference source is to be used, no jumper is necessary.

IN THE DEFAULT SETUP, ONLY ANALOG INPUT #1 IS ACTIVE. WHILE THE OTHER ANALOG INPUT HAS A DEFAULT SETUP, IT IS NOT ACTIVE UNTIL THE USER CHANGES THE SETUP TO MAKE IT ACTIVE.

The microprocessor will look ONLY to Analog Input #1 for speed information until it is told to do otherwise in the setup program.

The other analog input to the DFS-1 is at TB1:B (lower level) terminals 5 (+) and 6 (-). Both of the inputs may be programmed for one of six inputs as shown in the table below.

4. Comm set (value is set via Communications)

5. Commanded speed

Analog Output #1 default is a -10 to +10VDC signal representing motor speed. The outputs are on TB1:B terminals 8 (+) and 10 (-). The opposite polarity is available by a parameter change. See the description for parameters #26 and #27.

The default for Analog Output #2, terminals 9 (+) and 10 (-), is -10 to +10VDC representing motor load, 0% to 150% load. The opposite polarity is available by changing a parameter.

The maximum output current for the analog outputs is 20 milliamps.

FREQUENCY INPUT:

There is only one frequency input on the DFS-1. This input is used by the drive as the reference to follow when the drive is in the SLAVE Mode of operation. This input cannot be reassigned.

If the DFS-1 is in the MASTER mode, it will ignore the frequency input.

The Frequency input is located at TB2:A terminals 11(+) and 12 (-). This input is a differential line receiver type intended to interface directly with another DFS-1, a BCDMAX or CRM-1. There may be multiple slaves connected to a single Master by

Input Signal Level (+) input term (-) input term jumper terms input impedance

-10 to +10 VDC 3 or 5 4 or 6 none ** 200 Kohms 0 to +10 VDC 3 or 5 4 or 6 none ** 200 Kohms 0 to +5 VDC 3 or 5 4 or 6 none ** 200 Kohms 1 to +5 VDC 3 or 5 4 or 6 none ** 200 Kohms 0 to 20 mADC 3 or 5 1 4 or 6 to 1 250 ohms 4 to 20 mADC 3 or 5 1 4 or 6 to 1 250 ohms

TB1:B TB1:B

** if the DFS-1 supplies are used, jumper 4 or 6 to 1 to establish the reference common.

ANALOG OUTPUTS:

daisy-chaining the frequency reference line. The last slave on the line should have the jumper at JP1 on the

There are two analog outputs on TB1:B. Each of

the outputs may be programmed in several ways:

1. Disabled

2. Actual speed (value is proportional to motor speed)

3. Load output (value is proportional to motor load)

Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.©

two rightmost pins. This inserts a terminating resistor at the end of the line to help eliminate electrical noise from the system. All others should be on the two leftmost pins.

Contact POWERTEC’ s Application Engineering Department before trying to use another type of frequency on this input.

Page 9

FREQUENCY OUTPUT:

DIGITAL INPUTS:

There are two outputs available to supply a

frequency for external use.

The first is located at TB2:B terminal 10 (+) and 11 (-). This is an output which is intended to provide a reference frequency input for another DFS-1,

BCDMAX or CRM-1. This output is not compatible with the DIGIMAX. It will provide a signal of +/-

1.5V minimum when connected to another DFS-1's reference frequency input. This output on a unit configured as a master, operates at 16 times the frequency of the motor speed output reference. There is a 120 ohm termination resistor built into the output for transmission line termination.

When operating the DFS as a slave, the output frequency is internally divided by 16 in addition to being multiplied by the set ratio from the slave. As a consequence, the frequency output from a DFS slave cannot be used as the reference to another DFS slave without some way of first multiplying this frequency by 16. POWERTEC’s Cascade Ratio Multiplier option board (4001-153430-XXX) can be used for this purpose. Contact the factory for any frequency following application which requires a reference source other than a master DFS.

The other frequency output is at TB2:B13. This is a 24VDC peak square wave referenced to the DFS- 1 common (TB2:B14). This signal is at the motor speed output reference frequency and may be used to interface with a DIGIMAX or a BLDC motor control. This output sources a maximum of 10mA and can sink 30mA.

There are eight digital control inputs on TB2:A as well as a +24VDC supply (TB2-A14) and common (TB2-A1). The eight inputs are optical isolator input diodes with a common cathode connection at TB2-A2. When the +24VDC, DFS-1 supply is used to power the inputs, TB2:A2 must be jumpered to the 24VDC common terminal on TB2:A1.

The functions of all inputs are programmable except Emergency Stop (TB2-A3). All digital inputs are electrically isolated from the DFS-1 power supplies and common when an external power supply is used to power the digital inputs (such as from a PLC).

The default parameter setup is for a set of standard motor controller input connections on TB2:A terminal strip (see figure 3 on page 3).

Five of the inputs are set up for standard pushbutton operation of the DFS-1. They are:

Run 4 (+)

Preset 5 (+)

UP (increase) 6 (+)

DOWN (decrease) 7 (+)

Reverse 8 (+)

All of these inputs are referred to TB2-A2. Note that TB2-A2 (the common cathode connection) must be jumpered to common (TB2:A1) in the basic connections.

Each of these inputs will take a +24VDC input (no more than 30VDC, not less than 18VDC). If an external source of +24VDC is used, TB2-A2 on the upper level must be connected to the negative side of the external source.

Mode of Operation: differential Number of receivers: 32 maximum Maximum Cable Length: 4000 feet Maximum Frequency: 10 Megahertz Common Mode Voltage: +12V, -7V maximum Driver Output: +/-1.5V minimum Driver Load: 60 ohm minimum Driver Short Circuit: 1 50 mA to ground Driver Output Resistance: 120 ohms (ON) Receiver Input Resistance: 12 Kohms Receiver Sensitivity: +/-200 mA

Figure 5: Slaving DFS-1 units with the Reference Frequency Output.

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The programmable inputs (TB2-A4 through TB2-A10) may be programmed for jog, thread, or other preset speeds. The inputs may also be used to change torque levels, trim values, or ramp rates. Any value which can be affected by a parameter can be changed by a digital input.

DIGITAL OUTPUTS:

Digital outputs are located on TB2:B. The four outputs are normally open relay contacts. The contacts are rated at 120VAC at 1 amp, resistive.

The default setup assigns the outputs as follows:

Digital Out #1 Run

Digital Out #2 No Fault

Digital Out #3 At Speed

Digital Out #4 Reverse These assignments may be changed by parameters.

All of the digital outputs are programmable and may be configured as Normally Open or Normally Closed. If more than one contact is required for a certain function, an external relay may be used, or more than one output may be programmed for the same function.

COMMUNICA TIONS:

The standard communications for the DFS-1 is the EIA standard RS-485 communications format over a single twisted pair cable into TB3:A terminals 1 and 2. Terminal 3 is for the shield. DO NOT CONNECT TERMINAL 3 TO GROUND! Maximum allowable distance for twisted pair operation is 4000 meters (about 12,000 feet). Maximum nodes without repeaters is 32. Maximum communications rate is 38.4 kilobaud. The last unit on the comm line should have a jumper at JP2 on the rightmost 2 pins. All other units should have the jumper on the leftmost two pins.

There is an RS-485 local programming input at TB3:B for an optional keypad display unit.

RS485 Communications Connections:

Most host or converter devices (including the RS232/485 converter made by POWERTEC) include

1.2 Kohm pull up resistors which insure rx-tx- is pulled down to ground and rx/tx+ is pulled up to +5V when the line is inactive (tristated). This ensures the high impedance (floating) line does not change state due to noise when the line is not being driven. No matter how many units are connected in the network, only one such set of pull ups should be installed.

NOTE: The Allen Bradley RS485 connections on their coprocessor module for the Series 5 PLCs do not provide these pull ups and must be installed or noise will prevent proper communications.

1.2K ohm

tx/rx+

tx/rx-

1.2K ohm

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TB1A-8

TB3A-1

TB3A-2

TB3A-4

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The concept behind the DFS-1 calls for fully programmable inputs and outputs. The ability to change analog and digital inputs and outputs at will lends a whole new meaning to the word "flexibility".

POWERTEC has established a set of "default" parameters which will leave the setup of the DFS-1 in a way that will operate a motor in the basic configuration (see figure 3 on page 3 and figure 4 on page 4). There are two good reasons for doing this:

1. This default setup allows the user to connect and operate a motor using common, everyday connections without having to program the DFS-1 prior to its initial use.

2. The default setup provides a baseline to which the user can return if it appears that something is wrong with either the user's setup or the motor control. There is a command which allows the "reset" of the setup to the default configuration.

DEFAULT SETUP

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2.0 SPECIFICATIONS

POWER SUPPLIES

+24VDC • Available at TB2:A14, and TB2:B1.

• The combination is fused at 250 milliamps

(mA). The fuse is self-healing.

• The opening of the fuse alerts the microprocessor.

• These supplies should only be used for push-buttons, relays, PLC outputs, etc. which interface directly with the DFS-1. They should not be used as general purpose supplies.

+10VDC • Reference supply available at TB1:B2.

This output is rated at 100mA. This output is current limited and thermally protected.

-10VDC • Reference supply available at TB1:B7. This output is rated at 100mA, current limited and thermally protected.

+5VDC • Supply for motor encoder available at

TB1:A9. This supply is fused at 100mA with a self-healing fuse. When the fuse opens, it alerts the microprocessor.

5.0 Each of the two inputs may be set up one of six ways:

1. -10 to +10 VDC

2. 0 to +10 VDC

3. 0 to 5 VDC

4. 1 to 5 VDC

5. 0 to 20 mADC

6. 4 to 20 mADC

6.0 Setup is by parameter selection (#18 for Analog Input #1 and parameter #22 for Analog Input #2).

7.0 Voltage inputs are a differential input connection.

8.0 Input impedance of each input in voltage input mode is 200 Kilohms minimum.

9.0 Input impedance in milliamp input mode is 250 ohms.

Factory default setups are included so that the DFS-1 does not have to be programmed prior to its initial use. Factory defaults are only one of the many ways the DFS-1 can be set up.

Default setups are as follows:

INPUT SETUP FUNCTION

1. 0 to +10VDC Speed Reference Input

2. -10 to +10VDC General Purpose Input

THIS SUPPLY IS FOR THE MOTOR ENCODER ONLY!

ANALOG INPUTS

1.0 There are two analog inputs on TB1:B. (see section 1.2, page 4)

2.0 Each input may be set up in one of several modes.

3.0 Pre-programmed modes are:

3.1 General purpose Input

3.2 Speed Reference Input

3.3 Trim (dancer or load cell) Input

3.4 External Motoring Torque Limit

3.5 External Regenerative Torque Limit

3.6 Horsepower Mode

4.0 The mode of the input is set by parameter (#17 for Analog Input #1 and parameter #21 for Analog Input #2).

ANALOG OUTPUTS

1.0 There are two analog outputs on TB1:B.

2.0 The analog outputs may be programmed for

3.0 Output impedance is less than 100 ohms.

4.0 Maximum output voltage is +/- 10VDC.

5.0 Maximum current is 25mADC.

one of five modes:

2.1 Disabled

2.2 Motor Speed Output -10 to +10VDC = 0 to 100% (Actual Motor Speed) Default - Analog Output #1

2.3 Motor Load Output -10 to +10VDC = 0 to 150% Default - Analog Output #2

2.4 Set by Communications Link

2.5 Commanded Motor Speed

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FREQUENCY INPUTS AND OUTPUTS

There is one frequency input and there are two

frequency outputs available.

INPUT

#1 REFERENCE FREQUENCY INPUT

TB2:A Terminals 11 (+) and 12 (-).

• This is a line receiver type input which must be driven by a differential line driver output.

• This frequency input requires a frequency 16 times the feedback from the motor.

• The feedback from the motor is normally 120 PPR for 4 pole motors and 240 PPR for 8 pole motors.

• Normal input is 56 Kilohertz for 0 to full speed for a 1750 RPM motor with a 120ppr encoder.

• Terminal 13 is for the shield. Do not ground terminal 13 directly. It is internally terminated.

OUTPUTS

#1 REFERENCE FREQUENCY OUTPUT

TB2:B Terminals 10 (+) and 11 (-),

• This is a differential line driver output which must be used with a differential line driver input.

• This frequency output is 16 times the reference frequency to the motor.

• This output may drive up to 32 receivers.

• Connect the shield to terminal 12. This will ground the shield internally.

#2 MOTOR SPEED FREQUENCY OUTPUT

TB2:B Terminals 13 (+) and 14 (common),

• This output is a +24VDC peak square wave at the motor feedback pulse rate, which is 2 times RPM for 4 pole motors and 4 times RPM for 8 pole motors.

The reference frequency input and output are

capable of receiving and sending at up to 1 Megahertz.

Motor Speed output emits frequencies up to 100

Kilohertz.

DIGITAL INPUTS

The eight digital inputs of the DFS-1 are optically coupled requiring +24VDC (+/-6VDC) at about 5mA each. These inputs are isolated from the common of the board.

All inputs are programmable as to function, EXCEPT the EMERGENCY STOP input. Inputs #1 through #7 may be assigned as general purpose inputs.

The defaults are as follows:

TB2:A terminal 3(+) Emergency Stop

(Cannot be reassigned) DI 1. TB2:A4(+) Run DI 2. TB2:A5(+) Preset Speed DI 3. TB2:A6(+) Up (Increase) DI 4. TB2:A7(+) Down (Decrease) DI 5. TB2:A8(+) Reverse DI 6. TB2:A9(+) Frequency Mode DI 7. TB2:A10(+) Local/Remote

Inputs #1 through #7 may also be programmed

for inverted input, i.e., active when input is low.

DIGITAL OUTPUTS

There are four dry contact outputs from the DFS-1. All of these outputs are on TB2:B. All outputs are programmable as to function, and all outputs may be set up as either normally open or normally closed.

Each relay output has a single, isolated, contact output which may be programmed as normally open or normally closed, with the contact rated at 1 Amp, 125VAC resistive.

The default assignments are as follows: DO 1. TB2:B terminals 2 and 3 Run relay contact

Closed while running

DO 2. TB2:B terminals 4 and 5 No fault relay

Closed while no faults

DO 3. TB2:B terminals 6 and 7 At Speed relay

Closed when at speed

DO 4. TB2:B terminals 8 and 9 Remote Mode

Closed when in Remote

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COMMUNICA TIONS

Standard: RS-485 Data Rates: 300, 600, 1200, 2400, 4800, 9600,

19.2K, and 38.4K baud Addresses: 1 to 255 Protocols: POWERTEC Binary protocol Distance: 4000 meters (about 12,000 feet)

maximum with twisted pair shielded cable

Nodes: 32 maximum

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3.0 DFS-1 PARAMETERS

DFS-1 parameters are stored as DOUBLE WORD values (32 bits), regardless of the actual size of the data. This method is used to simplify the entire system at a cost of a little extra data storage.

A double word consists of four BYTES (8 bits). Each byte is a hexadecimal (base 16) value which ranges from 00h (0 decimal) to FFh (255 decimal). The largest number used in the DFS-1 parameters is 99,999 decimal, which, in hexadecimal notation is 0001 869Fh.

In many cases, information other than numbers is passed and stored in the parameters. The left byte is the most significant and the last byte is the least significant. The arrangement of the bytes for this purpose is: VL4 VL3 VL2 VL1 where VL4 is the Most Significant Bit (MSB) and VL1 is the Least Significant Bit (LSB). Each parameter breaks down the bytes accordingly.

All four bytes are required in communications. A number which must be either 0 or 1 must be passed as either 0000 0000h or 0000 0001h.

1. UNIT ID

USE PARAMETER #1 TO IDENTIFY THE ADDRESS OF THE UNIT ON A NETWORK. RANGE OF VALUES: 0000 0001h to 0000 00FFh

1 to 255 (decimal)

Default Value: 0000 0001h 1 (decimal)

The Unit ID number is installed in parameter #1. This serves as an address on the external communications link. Two DFS-1 units cannot have the same address while installed on the same communications link.

There are 254 possible addresses if the default value of 1 is not used as an address. Since the default value is 1, there could be a problem if a new unit is installed without changing the #1 parameter.

2 . BAUD RA TE

USE PARAMETER #2 TO SET THE COMMUNICATIONS SPEED OF THE NETWORK. RANGE OF VALUES: 0000 0000h to 0000 0007h

0 to 7 (decimal)

Default Value: 0000 0002h 2 (decimal)

This establishes the rate at which data is exchanged in the communications link. Every DFS-1 in the communications link must have the same baud

rate set up in parameter #2. The parameter selects from among eight industry standard baud rates:

NUMBER BAUD RATE 0000 0000h 38.4 Kilobaud (38,400 baud)

. . . . 01 19.2 Kilobaud (19,200 baud)

. . . . 02 9,600 baud

. . . . 03 4,800 baud

. . . . 04 2,400 baud

. . . . 05 1,200 baud

. . . . 06 600 baud

. . . . 07 300 baud

3 . LOCAL / REMOTE CONTROL

USE PARAMETER #3 TO SET UP WHICH FUNCTIONS ARE CONTROLLED REMOTELY. RANGE OF VALUES: 0000 0000h to 0000 007Fh

0 to 127 (decimal)

Default Value: 0000 0000h 0 (decimal)

Parameter #3 is first broken down into bytes, and

then VL1 is further broken down into bits.

When broken down into bits, 00h = 0000 0000b,

and 7Fh = 0111 1111b.

VL4 is always 00h. VL3 is always 00h. VL2 is always 00h. VL1 is broken down into eight bits, which are

numbered from right to left: 7654 3210h.

Functions are assigned as follows:

Bit Position Function 7 NOT USED 6 Master/Slave (not presently functional) 5 Frequency Mode 4 Reverse 3 Down 2Up 1 Preset 0 Run

A zero in a bit position means that function may be controlled from an input terminal assigned to it. A one in a bit position means that the function may only be controlled via a communications link, such as the operator’s station connection or the external RS485 communications link.

For instance, if VL1 is given a value of 01 (0000

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0001b) , the Run FUNCTION cannot be controlled from the terminal strip, but can only be controlled through the external communications link or the local comm link (keypad display unit).

If VL1 has a value of 73 (0111 0011b), all functions except UP and DOWN are controlled remotely.

NOTE: Parameter #3 ONLY determines whether a FUNCTION is controlled locally or remotely. This parameter has nothing to do with the assignment of functions to terminals.

Any input function can be assigned to any input terminal with the exception of the Emergency Stop

input. The Emergency stop function is hard-wired on the DFS-1 board and cannot be changed by either programming or parameters.

If the RUN function is assigned to an input terminal, and this parameter is set to remote the RUN function control, the terminal will be IGNORED.

4. COMMUNICATIONS

PROTOCOL

5 . MODES OF OPERA TION

USE PARAMETER #5 TO SET UP MASTER/ SLAVE AND TORQUE LIMITING MODES. RANGE OF VALUES: 0000 0000h to 0003 0002h

no decimal significance

Default Value: 0000 0000h no decimal

significance

This parameter is a dual purpose command used

to set operational modes of the DFS-1:

VL2 VL1 sets the basic operation of the board. There are three modes of basic operation used to determine where the speed and/or torque commands originate:

0000h MASTER mode (the board generates its

own speed/torque based on its parameters)

0001h SLAVE mode (the board follows an

external signal in direct proportion)

0002h INVERSE Slave mode (board follows

an external signal in inverse proportion)

USE PARAMETER #4 TO IDENTIFY THE NETWORK COMMUNICATIONS LANGUAGE. RANGE OF VALUES: 0000 0000h to 0000 0001h

0 to 1 (decimal)

Default Value: 0000 0000h 0 (decimal)

At the present time, the only communications protocol available is Powertec’ s Binary protocol. This parameter has been included with the intent of providing alternative protocols at some time in the future.

The DFS-1 board in MASTER mode generates

its own speed and torque commands.

In SLAVE mode the board follows a reference frequency at TB2:A terminals 11(+) and 12(-), which should be nominally 16 times the desired speed of the motor. This signal is available from another DFS-1 board or from a BCDMAX board. It may also come from another source which has a compatible line driver output. (See the description for frequency input elsewhere in this manual).

In INVERSE slave mode, the board follows the external frequency in a proportion of 1/RATIO. Instead of setting a direct ratio of 0.5000, a ratio of

2.0000 may be entered for half speed. This is useful in cases requiring draw settings where the slave is physically located before the master, which is set for line speed.

VL4 VL3 contains information on modified operational modes in which the torque in the motor is limited below the current limit level (current limits are always set by parameters 44 and 45). These optional modes are defined as follows:

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DFS-1 Manual Revised 7/95

0000h Normal current limits (motor current

not limited at a lower level)

0001h Motoring torque setpoint (motoring

current to be limited at a lower level)

0002h Regenerative torque setpoint (regenera-

tive current to be limited at a lower level)

0003h Horsepower setpoint (the product of

motor current and motor speed is limited)

0004h through 000Fh available for future use When in the normal mode, the current in the

motor is not controlled below current limit.

If one of the modified operational modes is chosen, the torque/horsepower setpoint is selectable in one of three places:

1. Analog Input #1 (must be set up in parameter #17)

2. Analog Input #2 (must be set up in parameter #21)

3. The Set Application Mode (8F) Command via communications

If one of these three setpoints is not present, the setpoint defaults to the appropriate current limit level.

6. MAXIMUM MOTOR SPEED

USE PARAMETER #6 TO SET THE ABSOLUTE MAXIMUM MOTOR SPEED. RANGE OF VALUES: 0000 0001h to 0000 2710h

1 TO 10,000 (decimal)

Default Value: 0000 06D6h 1750 (decimal)

The maximum motor speed parameter is set directly in Revolutions Per Minute (RPM) once the Encoder Pulses Per Revolution (PPR) is set in parameter # 7. If the incorrect PPR is set in parameter #7, the maximum motor speed will not be correct and the motor may overspeed or not be able to go fast enough.

The maximum motor speed is normally the number given on the nameplate of the motor. This number may be set higher than the motor nameplate in some situations because the Brushless DC motor is capable of some overspeed with light loads.

This parameter may be set to a value which is lower than the motor’s base speed in cases where it is not desired to use the full speed of the motor.

7 . ENCODER PULSES PER

REVOLUTION

USE PARAMETER #7 TO ESTABLISH THE PULSE FEEDBACK RATE FROM THE MOTOR. RANGE OF VALUES: 0000 0001h to 0000 4E20h

1 TO 20,000 (decimal)

Default Value: 0000 0078h 120 (decimal)

This parameter tells the DFS-1 the resolution of the encoder in Pulses Per Revolution (PPR). This is normally four times (4X) the rate of one channel of the motor’s encoder.

Motors from the 42 frame through the 259T frame have a 30 PPR, two channel, quadrature internal encoder. For these motors using the internal encoders the parameter should be set to 120 PPR.

Motors from 287TZ through 5010ATZ have an internal 60 PPR, two channel, quadrature encoder. The parameter for these motors using the internal encoders should be set to 240 PPR.

External encoders may have almost any PPR rate, and they must have two channels in quadrature (the channels have the same pulse rate, but they are 90° out of phase with each other). The pulse rate will be on the ENCODER nameplate.

Encoders with higher pulse rates are normally used to obtain lower speeds and/or finer resolution of motor shaft position. The most common external encoder on POWERTEC motors is a 600 PPR, two channel, quadrature optical encoder. For this encoder the PPR in this parameter will be 2400.

For other encoders, multiply the pulse rate for one channel (the usual number given on the nameplate) by four and enter that number in this parameter.

This parameter may not be changed while running. Attempting to change this parameter while running will result in the effect being delayed until the next time a setpoint command is given or until the control is stopped. Changing this number will drastically affect the calibration of the system.

(Also see Parameter 46)

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