PowerTec Digimax Installation And Operation Instruction Manual

Repair Center for Powertec Drives and Motors
460 Milford Parkway
Milford, OH . 45150
www.motorsystems.com
513-576-1725

ADVANCED

MICROPROCESSOR CONTROLLED

DIGITAL SPEED / RATIO CONTROLLER

INSTALLATION AND OPERATION

MADE IN USA

This manual is fully implemented with software version (SFWVER)
93271 and later. See page 10 to find the software version of your
unit

INSTRUCTION MANUAL

Revision 2A

October 6, 1993

POWERTEC Publication # DGMAX4IM

Page ii © copyright 1992-1996 by Powertec Industrial Motors

DIGIMAX® Manual

Table of Contents

INTRODUCTION ....................................................................................................... 1

1.0 INSTALLATION ......................................................................................................... 3

1.1 CUSTOMER CONNECTIONS................................................................................... 3

2.0 ORIENTATION .......................................................................................................... 9

3.0 SET UP PARAMETERS .......................................................................................... 13

#1 Maximum Motor Speed............................................................................................ 15

#2 Maximum Display Value .......................................................................................... 15

#3 Decimal Places ........................................................................................................ 16

#4 Slave Ratio Setting .................................................................................................. 16

#5 Feedback PPR......................................................................................................... 16

#6 Acceleration Time.................................................................................................... 16

#7 Deceleration Time ................................................................................................... 17

#8 Master/Slave............................................................................................................ 17

#9 Preset Speed ........................................................................................................... 17

#10 Jump UP Change .................................................................................................... 17

#11 Jump Down Change ................................................................................................ 18

#12 Up-to-Speed Tolerance ........................................................................................... 18

#13 M.O.P./Jump ............................................................................................................ 18

#14 Freeze/Float ............................................................................................................ 18

#15 Display Sample Rate ............................................................................................... 18

#16 Setup During Run .................................................................................................... 18

#17 Unit I.D.....................................................................................................................19

#18 Baud Rate................................................................................................................ 1 9

#19 Local/Remote/Keylock............................................................................................. 1 9

#20 Speed/Ratio SETPOINT........................................................................................ 1 9

#21 Operator Security Code........................................................................................... 19

#22 A to D Low Engineering Units ................................................................................. 19

#23 A to D High Engineering Units ................................................................................ 2 0

#24 A to D Display Mode................................................................................................ 2 0

#25 A to D Sample Rate ................................................................................................. 20

#26 A to D Trim Enable .................................................................................................. 20

#27 Communications Protocol........................................................................................ 21

#28 D to A Source .......................................................................................................... 21

#29 D to A Low Engineering Units ................................................................................. 21

#30 D to A High Engineering Units ................................................................................ 2 1

#31 Maximum Ratio ........................................................................................................ 21

#32 PRESET Input Mode ............................................................................................... 21

#33 REVERSE Input mode............................................................................................. 22

#34 UP Input Mode......................................................................................................... 22

#35 DN Input Mode......................................................................................................... 22

#36 Installed Option Enable ........................................................................................... 22

#37 Command Ratio Setpoint......................................................................................... 22

#38 Maximum Command Ratio....................................................................................... 22

#39 Debounce Value ...................................................................................................... 22

#40 AT SPEED Source................................................................................................... 22

#41 Communications Turn Around Time........................................................................ 22

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Manual

Revised 10/06/93

Page iiiDIGIMAX

TABLE OF CONTENTS (continued)

4.0 SETUP AND OPERATION ...................................................................................... 23

LOCAL OR REMOTE .............................................................................................. 23

COMMAND OR ACTUAL ........................................................................................ 25

SETUP OR NORMAL .............................................................................................. 25

ERROR CODES ...................................................................................................... 27

JUMP OR MOP........................................................................................................ 30

FREEZE OR FLOAT................................................................................................ 3 1

MASTER OR SLAVE ............................................................................................... 31

Basic Master Mode setup ................................................................................... 31

Basic Slave Mode setup..................................................................................... 32

ADVANCED FUNCTIONS ....................................................................................... 33

List of Illustrations

1. Physical Dimensions ................................................................................................. 2

2. Rear Terminal Strip connections ............................................................................... 5

3. Connections to the

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......................................................................................................................

4. Front panel Display. .................................................................................................. 9

5. Typical connections to Model 500........................................................................... 24

6. Typical connections to Non-regenerative control .................................................... 26

7. Standard connections to Regenerative control ....................................................... 28

8. Standard Connections to the MILLENNIUM® drive ................................................. 30

8

List of TABLES

1 Basic Parameters Table (1 to 21)............................................................................ 1 4

1A Extended Parameters Table (22 to 36) ................................................................... 2 0

2 Error Codes ............................................................................................................ 27

Page iv © copyright 1992-1996 by Powertec Industrial Motors

WARNING!

THE DIGIMAX®AS SHIPPED FROM THE FACTORY OPERATES ON
115VAC POWER INPUT ONLY AT TB1 TERMINALS 1 AND 3.

230 VAC UNITS MAY BE OBTAINED BY SPECIAL ORDER, IN WHICH
CASE IT WILL HAVE A 230VAC NAMEPLATE AND STICKER.

DO NOT APPLY 230 VAC TO THE DIGIMAX® UNLESS YOU HAVE

CHECKED FOR THE PROPER CONNECTIONS.

NOTICE!

If you are replacing a DIGIMAX III with a

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DIGIMAX®, check TB2

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terminals 1,2, and 3 to be sure that there are no connections to these
terminals! These terminals weren't used on the DIGIMAX III, but they
are used internally on the
TIONS on TB2 terminals 1,2, and 3 when the

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DIGIMAX®. There should be NO CONNEC-

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DIGIMAX® is used.

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Page vDIGIMAX

SUMMARY OF WARRANTY AND DISCLAIMER

POWERTEC Industrial Motors, warrants the

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DIGIMAX® to be free from defects in materials and

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workmanship for a period of one year from the date of shipment from the factory, or, if purchased from an
authorized 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 of the

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DIGIMAX® on other equipment or effects on the

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caused by other equipment; attempted use outside of specified ranges; or any other situation which is deemed
to be outside of the control of POWERTEC.

The user is responsible for the application of the product and/or the programming thereof.
Programs which attempt to use the communications capability of the

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DIGIMAX® are the responsibility

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of the user.

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

consequential damages.

This instruction 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.

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Page vi © copyright 1992-1996 by Powertec Industrial Motors

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Manual

Page viiDIGIMAX

INTRODUCTIONINTRODUCTION

INTRODUCTION

INTRODUCTIONINTRODUCTION

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The

DIGIMAX® is an advanced, micro-processor based, digital speed reference

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designed for use with POWERTEC Brushless motors and controls. It is a reliable and
repeatable pulse train source with features designed for the needs of computer controlled
process lines. It may be used for master speed setting or as an extremely accurate ratio
setting device.

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The

DIGIMAX® is an "open loop" type of control, i.e., speed feedback information

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to this speed setting device is not necessary to maintain the speed regulation of the
system. The nature of the permanent magnet based Brushless motor and control system
is that it will maintain zero percent speed regulation from no load to full load over its entire
speed range. Closing the speed loop for speed regulation is unnecessary. Speeds
generated by the
operating conditions. The Brushless motor will run at exactly the speed at which it is told
to run, and the next time that same speed is commanded, it will be repeated exactly.

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The

DIGIMAX® is as much at home in the ratio mode as it is in the speed mode,

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and it can switch between the two on the fly. This consistent speed control is invaluable
in setting up processes which vary from day to day, but must be duplicated from order
to order.

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The

DIGIMAX® is also easy to apply and use. It can be installed in locations where

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it is easily accessible to operators, which may be remote from the location of the motor
control. Control inputs and outputs are isolated, for flexibility and immunity to interactions
between units.

Speed or ratio setpoints and operating parameters are entered via a 16-key keypad
on the face of the
entered by remote connection to an industry standard RS-422 or RS-485 communica­tions link with a variety of protocols.

The five place digital readout may be set for motor RPM, process speed, or other
useful engineering units, from the motor or from another source besides the motor being
controlled. Indicators show when the speed is attained and whether the unit's control is
local or remote.

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The

DIGIMAX® has six programmable output switches (open collector transistors),

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offering the possibility of operation completely through the communications link.

There is a position registration function (temporary increase or decrease in speed)
which may be alternatively programmed as a motor operated potentiometer. There are
UP and DOWN controls are on the front panel, and there are remote inputs for these
functions as well. The MOP function may be programmed to stay at its former speed after
a stop, or to return to zero speed when stopped.

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DIGIMAX® represents a high level of sophistication for users of POWERTEC

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Brushless motors and controls. It is very effective in operator controlled or computer
controlled systems when precision, repeatability, flexibility, and ease of interface to the
host unit are required.

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DIGIMAX® are accurate within 50 parts per million under all specified

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DIGIMAX®. Speed or ratio setpoints and parameters may also be

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DIGIMAX® is a registered trademark of POWERTEC Industrial Corporation

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Manual

Page 1DIGIMAX

Figure 1: Physical dimensions of the DIGIMAX®.

Page 2 © copyright 1992-1996 by Powertec Industrial Motors

1.0 INST1.0 INST

1.0 INST

1.0 INST1.0 INST

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The

DIGIMAX® may be installed in any orientation in a clean, dry location. Care should

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be exercised in making the cutout in the mounting panel, since the pinch bars must be placed
firmly against the mounting panel just outside of the cutout section to hold the unit in place.

The front panel has sealed membrane switches, but the front panel should be protected

against moisture falling directly onto it and seeping into the box around the faceplate.

The front panel should be protected against physical damage, but accidental casual

contact with the front panel is not likely to cause a problem.

The customer connection terminals at the rear of the box require at least 2" (50mm) of
free space behind the box for installation, removal and wiring. It is advisable to not install
high energy switches or electro-magnetic devices next to the
to run wires carrying high energy in the same groupings as the wires to and from it.

1.1 CUSTOMER CONNECTIONS1.1 CUSTOMER CONNECTIONS

1.1 CUSTOMER CONNECTIONS

1.1 CUSTOMER CONNECTIONS1.1 CUSTOMER CONNECTIONS

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The

DIGIMAX® has two terminal strips on the back of the unit for customer connections

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(see figure 2 on page 5). These terminal strips are removable for ease of wiring and to
facilitate the replacement of the unit, should that become necessary for any reason. The
terminal strips are keyed differently to prevent mix-ups.

All connections except the AC input power are low voltage, low current, DC circuits
which may be susceptible to system electrical noise interference. Directions for wiring and
shielding must be followed exactly for best results (see figure 3 on page 8).

Wires to and from the

All relays used in conjunction with, or in the vicinity of, the DIGIMAX® must have arc
suppressors (if they have AC coils) or free wheeling diodes (if they are DC). Keep high power
switching relays and contactors away from the
interference from arcing and magnetic field fluxes.

ALLAALLA

ALLA

ALLAALLA

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TIONTION

TION

TIONTION

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DIGIMAX®, nor is it advisable

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must be kept away from power wiring.

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DIGIMAX® and its wiring to prevent

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BOTTOM TERMINAL STRIP TB1BOTTOM TERMINAL STRIP TB1

BOTTOM TERMINAL STRIP TB1

BOTTOM TERMINAL STRIP TB1BOTTOM TERMINAL STRIP TB1

1 115 VAC HOT line

2 unconnected pin

3 115 VAC NEUTRAL

4 CASE GROUND

5 EARTH GROUND

The DIGIMAX® must be operated on 115VAC, single phase. Tolerance is +/- 10%.
Frequency range is 48 to 62 hertz. If one side of the supply is grounded, the hot side of the
supply should be connected to terminal 1. The other wire is connected to terminal 3.

230VAC
of 230VAC power is discouraged due to the noisy nature of this type of power.

Terminal 2 is not connected to anything. It is used for voltage separation on the
terminals. Do not make connections of low-voltage, noise sensitive signals on terminal 2.

Terminal 4 is used for grounding the metal case of the
mounting screws, and terminal 5 should be solidly grounded to an earth ground. The earth
ground must be tied to a system ground which is tied into the system power ground at a
central location. Where long and (electrically) noisy runs are involved, an earth ground rod
in the vicinity of the drive cabinet is recommended.

The AC supply should not have excessive line noise. The input power to the unit is
filtered, but excessive line gaps or spikes could cause erratic power supplies.

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Manual

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DIGIMAX® units may be obtained on special order from the factory. The use

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DIGIMAX® with one of the case

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Page 3DIGIMAX

6 10 -> 12 VDC output, unregulated, 100 mA
7 24 VDC output, unregulated, 100 mA
8 NO CONNECTION
9 NO CONNECTION

If you have an application where you wish to use DC power to power a

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DIGIMAX®,

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you must either use a UPS or contact POWERTEC for a special unit.

Terminal 6 may be used for small 12VDC loads up to 100 mA.

Terminal 7 can supply up to 50 mA at 20 to 24 VDC, unregulated. Terminal 7 is most
often used to turn on the DIGITAL mode in the Model 1000 series and larger drives (using
the 141-108 series Current Controller board), and this is, in fact, recommended.

The output level of these two terminals is dependent on the AC supply voltage.Other
loads on the unit and the load on each of these terminals will also affect the voltage level.
If either of these terminals are overloaded, the accuracy of the

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DIGIMAX® will be degraded.

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Terminal 4 or 5 may be used as a common for these terminals.

Voltage levels on terminals 6 and 7 ARE NOT GUARANTEED. These outputs are
for convenience only for small loads associated with the

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DIGIMAX®. If stable and/or

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regulated voltages are needed for external relays and devices used for system purposes,
the user should incorporate in the system a separate power supply for them.

10 - FREQUENCY OUTPUT

11 + FREQUENCY OUTPUT

This is the output frequency to the controlled drive or drives. It is capable of driving up
to ten inputs of motor controls or ten other

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DIGIMAX® inputs or a combination of the two

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adding up to ten inputs. Output from these terminals is a square wave from a "totem-pole"
driver with a +24 VDC peak and an off value less than 0.5 VDC. The duty cycle may vary.

12 - ANALOG OUTPUT

13 + ANALOG OUTPUT

The analog output at TB1 terminals 12 and 13 may be used to read a voltage signal
proportional to one of the

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DIGIMAX® speed sources, or from the RS-422 link, or from the

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keypad. This output ranges from 0 to +10 VDC. The source and level of this output is set by
parameters #28 (source of the output signal), #29 (the lowest value for the output), and #30
(the highest value for the output). See page 21.

14 EMITTERS OF AUXILIARY OUTPUTS

15 "AT SPEED" OUTPUT (open collector)

16 AUXILIARY OUTPUT #1 (open collector)

17 AUXILIARY OUTPUT #2 (open collector)

18 AUXILIARY OUTPUT #3 (open collector)

19 AUXILIARY OUTPUT #4 (open collector)

20 AUXILIARY OUTPUT #5 (open collector)

21 AUXILIARY OUTPUT #6 (open colllector)

22 OUTPUTS SUPPLY CONNECTION

An external power supply MUST be used to power any devices connected to
these outputs. These outputs are "open collector" outputs with all of the emitters brought

together at TB1 terminal 14 (see figure 2). The positive side of the supply has to be connected
to TB1 terminal 22 (this supplies the drivers on the board), and the negative side of the supply
must be connected to TB1 terminal 14. All of these outputs are isolated from the DIGIMAX

Page 4 © copyright 1992-1996 by Powertec Industrial Motors

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Figure 2: Rear terminal strip connections of the

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common, but their emitters are all common to each other. The maximum allowable voltage
between TB1 terminals 22 (+) and 14 (-) is 30VDC. The maximum allowable current on each
of the TB1 terminals 15 thru 21 is 100 mA. Snubber diodes are built into the outputs. If the
wiring to the external relays is run more than a few feet, additional snubber diodes should
be used at the external relay coils.

Do not run any large solenoid valves or large contactors directly from these outputs.

Use interface relays connected to these outputs to run this other equipment.

The AT SPEED output operates with the AT SPEED indicator on the front panel. The
adjustment of the AT SPEED tolerance is controlled by parameter #12. The AT SPEED
output and the AT SPEED front panel LED work only in the MASTER mode. In SLAVE mode,
the AT SPEED LED and the AT SPEED output are on all of the time, except when changing
to a newly entered ratio..

The other six outputs are controllable by protocol commands through the RS-422 link.
They can also be operated from the keypad on the front (see page 11). These outputs may
be used for run, stop, man/auto, fwd/rev, or for peripheral device control.

By connecting relays to these outputs and using the relays to control the drive, it is
possible to run the

TOP TERMINAL STRIP TB2TOP TERMINAL STRIP TB2

TOP TERMINAL STRIP TB2

TOP TERMINAL STRIP TB2TOP TERMINAL STRIP TB2

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DIGIMAX® and motor control entirely through the communications link.

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1 HARDWARE RESET

2 DO NOT USE!

3 DO NOT USE!

Terminal 1 on TB2 is used for a hardware reset. When terminal 1 is connected to a
ground (such as TB1 terminal 5), the DIGIMAX® resets just as if the power to the unit were
turned off and the power was then turned back on again. The parameters are NOT cleared
by this operation.

It is NOT recommended that wires be permanently attached to these terminals
because there is a possibility that a noise pulse or accidental activation of the switch may
cause an unintentional reset, interrupting normal operation. Such noise may come from
nearby power components or a difference in potential between the case or terminals of the

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DIGIMAX® and ground.

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DO NOT MAKE ANY CONNECTIONS TO TB2 TERMINALS 2 and 3! These terminals
are used for programming functions. Connecting anything to these inputs will result in
damage to the unit.

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Page 5DIGIMAX

4 CATHODES OF CONTROL INPUTS (ground or common)
5 RUN INPUT (+24 VDC)
6 PRESET INPUT (+24 VDC)
7 EMERGENCY STOP INPUT (+24 VDC)
8 REVERSE INPUT (+24 VDC)
9 JUMP/MOP UP INPUT (+24 VDC)

10 JUMP/MOP DOWN INPUT (+24 VDC)

Power for the control inputs must be supplied from a separate source. Usually this
power comes from the Brushless drive being controlled. Nominal supply voltage is 24 VDC,
which need not be regulated, but must be filtered. The tolerance is +/- 25%.

The control inputs do not control any functions on the controlled drive. Commands
given to the

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DIGIMAX® must also be given to the drive at the same time.

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The EMERGENCY STOP input must be activate before the unit will respond to any
external input or keyboard commands. This input normally parallels the E.STOP of the drive.

Activating the RUN input starts the DIGIMAX®, and will it run until the RUN input is
removed. Usually, the run relay contact on the speed board of the drive is used for this. A
SETPOINT value should be entered prior to the first time a RUN command is entered after
power is applied; otherwise the unit will start at zero speed (or ratio) and wait for a SETPOINT
to be entered by the operator. If parameter #14 is set to 1 (see page 18), on all subsequent
RUN commands, the DIGIMAX® will start at the last speed or ratio entered.

The PRESET command changes the speed output to go to the value in parameter #9.

The REVERSE input causes the frequency output to decelerate, at the rate set into
parameter #7, to zero speed, and then to accelerate back to the setpoint at the rate set into
parameter #6. Giving a reverse command to the

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DIGIMAX® does NOT cause the drive to

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reverse. A separate, simultaneous command must be given to the drive. If the drive is given
a reverse command, it will not reverse until the

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DIGIMAX® is given a reverse command,

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because the drive input frequency must be at zero before the drive will reverse direction.

The JUMP/MOP UP and JUMP/MOP DOWN inputs duplicate the functions of the UP
and DN inputs on the front panel.

11 - TACHOMETER INPUT

12 + TACHOMETER INPUT

13 - FOLLOWER INPUT

14 + FOLLOWER INPUT

These two inputs are isolated from the

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DIGIMAX® electronics and from each other.

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Both inputs require a +24VDC nominal peak input and a low of less than 1VDC. Both inputs
will accept signals up to 50 kilohertz. Minimum pulse width for both inputs is 10 microsec­onds. Wider pulse widths are desireable. Rise times are not critical, but they should be less
than 5% of the duty cycle.

The tachometer input is for the

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DIGIMAX® display and it also supplies a zero speed

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signal. It normally comes from the motor control, but it may come from any frequency
reflecting the driven process. With a 1750 RPM small frame motor, a standard POWERTEC
Brushless motor control supplies a 3500 Hertz pulsed waveform to this input, but larger
motors' controls supply a 7000 hertz signal to the tachometer input and servo rated controls
may supply frequencies of up to 50 kilohertz.

The follower input is the frequency which the

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DIGIMAX® follows in SLAVE mode. A

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standard 1750 RPM low horsepower Brushless motor control operates at 3500 Hertz input
frequency. This is the ideal input frequency for the follower input if the follower motor is 1750
RPM. The

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DIGIMAX® can multiply by a factor of up to eight, but performance and resolution

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at high multiples may be degraded.

Page 6 © copyright 1992-1996 by Powertec Industrial Motors