Rockwell Automation PowerFlex series User Manual

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PowerFlex® Digital DC Drive

USER MANUAL

Firmware Version 1.006 - 2.001

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Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at www.rockwellautomation.com/literature) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited.

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Throughout this manual, when necessary we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous

environment, which may lead to personal injury or death, property damage, or economic loss.

Important: Identifies information that is critical for successful application and

understanding of the product.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequences.

Shock Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present.

Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures.

PowerFlex, DriveExplorer, DriveTools SP, DPI, and SCANport are either trademarks or registered trademarks of Rockwell Automation, Inc. Klixon® is a registered trademark of Sensata Technologies, Inc.

PowerFlex Digital DC Drive User Manual

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Summary of Changes

Manual Updates

The information below summarizes the changes to the PowerFlex Digital DC Drive User Manual, publication 20-UM001… since the October 2007 release.

Change Page(s)

Updated the Using Contactors section to include new Contactor Control selections for configuring AC versus DC contactors.

Added the “Cable and Wiring Recommendations” table. 1-14 Updated the “Typical Power Wiring Diagrams” to include terminal and parameter

designations. Added “Sourcing Digital Outputs, 24V DC external supply” diagram to I/O Wiring

examples. Added an illustration and instructions for routing I/O and control wiring. 1-42 Added a graphical indicator for parameters accessible only when parameter 211

[Param Access Lvl] = 1 “Advanced”. Added parameter 1409 [Jog Off Delay], to allow you to specify the minimum delay

between removing the Jog input and commanding the main contactor to open. This delay reduces the wear on the contactor when repeatedly opening and closing the Jog input over a short period of time.

Added parameter 1410 [Jog Ramp Time], to allow you to set the rate of acceleration and deceleration while the Jog function is active.

Changed option 3 "Quick Stop" to "Fast Stop" for parameters 354 [Aux Inp Flt Cfg] and 365 [OverTemp Flt Cfg].

Changed option 35 “Fld Weak En” to “Force MinFld” for parameters 133-144 [Digital Inx Sel].

Added option 64 “Invert Flt” to parameters 133-144 [Digital Inx Sel], to allow a digital input wired to an inverting fault device to issue an “Inverting Fault” (F37).

Updated the options for parameter 1391 [ContactorControl] to accommodate the use of a AC or DC contactor with or without a dynamic brake resistor.

Added the new “Inverting Fault” (F37) fault to indicate that the associated inverting fault device has opened.

Updated the following drive specifications:

• Maximum short circuit rating

• Control speed regulation

• Torque regulation

Updated the fuses identified in the “Drive Power Circuit Protection” tables. A-7 Updated the “Control Power Circuit Protection Fuses” tables and fuse location

illustrations. Added the “Lug Kit Specifications” table. A-21 Added the instructions for operating the PowerFlex DC drive in field weakening

mode and using a DC contactor and/or an inverting fault device in the armature circuit with firmware version 1.006.

Updated the “Fine Tuning the Speed Regulator” procedure. C-29 Updated the terminal numbers indicated in the Digital Inputs/Outputs block

diagram. Updated the Ramp Reference block diagram to include the new parameter 1410

[Jog Ramp Time]. Removed the 20-COMM-L communication adapter from the compatible

Communication Adapter Kits table.

1-9

1-17

1-39

3-1

3-24

3-29

3-53

3-65

3-67

4-5

A-2

A-15

C-5

D-3

D-7

E-1

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

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soc-ii

The information below summarizes the changes to the PowerFlex Digital DC Drive User Manual, publication 20-UM001… since the initial release.

Change Page(s)

Removed erroneous derating information. 1-2 Updated AC Input Voltages tables. 1-15 Updated “AnalogCflct” Alarm description to include parameters 1323-1327 [DPI Px

Select]. Updated Agency Certification Information. A-1 Added notation regarding required installation in a Pollution Degree 2 environment. A-1 Updated the Maximum Short Circuit Ratings data. A-2 Added footnote regarding coil voltage to DC Loop Contactor table information. A-19 Updated block diagrams to correct parameter numbers and names. D-2

, A-1

4-7

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

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Table of Contents

Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Summary of

Manual Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . soc-i

Changes

Preface Overview

Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1

What is in this Manual?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1

Drive Storage Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1

Drive Nameplate Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-2

Drive Frame Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-2

Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-2

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-3

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-3

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-4

Chapter 1 Installation and Wiring

Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Operating Conditions and Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Mounting Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Lifting PowerFlex DC Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Mounting Frame C Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Removing the Drive Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Frame A Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Frame B and C Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Line Reactors / Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Using Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

AC Input Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

DC Output Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Dynamic Brake Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Control Power Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

General Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Safety Ground (PE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Power Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Encoder Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Tachometer Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Power Circuit Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Cable and Wiring Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

AC Input Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

DC Output Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Typical Power Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Armature Converter Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Field Circuit Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Field Current Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Thermistors and Thermal Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Control Circuit Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

Frame C Heatsink Cooling Fans and Armature Fuse Signal Terminals . . . . . . . . . . . 1-31

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

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I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

DIP Switch and Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

I/O Signal and Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35

I/O Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

Digital Encoder Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40

DC Analog Tachometer Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

I/O and Control Wire Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

Chapter 2 Drive Start Up

Drive Start Up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Before Applying Power to the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Applying Power to the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Speed-Up Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Configuring the Speed Zero Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Adaptive Speed Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Chapter 3 Programming and Parameters

About Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

How Parameters are Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

File–Group–Parameter Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Numbered List View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Cross Reference Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Basic Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Advanced Parameter View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Monitor File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Motor Control File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Speed Command File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Dynamic Control File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Applications File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Utility File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Communications File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Input / Output File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

Parameter Cross Reference – by Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

Parameter Cross Reference – by Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77

Chapter 4 Troubleshooting

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

HIM Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Manually Clearing Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Clearing Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Alarm Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Common Drive Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Drive will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Drive starts but motor does not turn and no armature current. . . . . . . . . . . . . . . . . . . 4-12

The motor does not reach commanded speed.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

The motor is turning in the wrong direction.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

The motor reaches maximum speed immediately.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Testpoint Codes and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Page 7

Appendix A Supplemental Drive Information

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

IP20 (NEMA UL/Type Open) Watts Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Typical Programmable Controller Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Logic Command/Status Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Drive Power Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Frame A and B Fuse Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Frame C Fuse Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

Control Power Circuit Protection Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15

AC Input Line Reactors and AC Input Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17

DC Output Contactors and Dynamic Brake Resistor Kits . . . . . . . . . . . . . . . . . . . . . . . A-19

DC Contactor Crimp Lug Kit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21

Appendix B HIM Overview

External and Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

LCD Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

ALT Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Using the S.M.A.R.T. List Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Viewing and Editing Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

LCD HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Removing/Installing the HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Appendix C Application Notes

Analog Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Example 1:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Example 2:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Analog Input Signal Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Current / Speed Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Droop Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Field Weakening Mode Configuration (v1.006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Using a DC Contactor Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

Using a DC Contactor and a Dynamic Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

Using an Inverting Fault Device Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

Using a DC Contactor and an Inverting Fault Device. . . . . . . . . . . . . . . . . . . . . . . . . . C-7

Using a DC Contactor, a Dynamic Brake and an Inverting Fault Device. . . . . . . . . . . C-7

PID Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8

Configure a Line Speed Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9

Configure the Feedback Signal in the Follower Drive(s) . . . . . . . . . . . . . . . . . . . . . . C-10

Configure the Tension Set Point Signal in the Follower Drive(s). . . . . . . . . . . . . . . . C-12

Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13

“Auto” Speed Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13

“Manual” Speed Sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13

Changing Speed Sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13

Torque Reference Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14

Auto/Manual Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14

Speed Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-15

Scale Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16

Linking Parameters Via the Scale Block Parameters . . . . . . . . . . . . . . . . . . . . . . . . . C-17

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 8

Speed Regulation Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-17

Adaptive Speed Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-17

Speed Up Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-20

Speed Threshold Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-20

Speed Zero Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-22

Speed Draw Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-23

Start At Powerup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-24

Fine Tuning the Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-25

Manually Adjusting the Current Regulator Tune Settings. . . . . . . . . . . . . . . . . . . . . . C-26

Fine Tuning the Field Current Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-26

Fine Tuning the Speed Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-29

Fine Tuning the Voltage Regulator in the Field Converter . . . . . . . . . . . . . . . . . . . . . C-31

Tuning the Field Current Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33

Appendix D Control Block Diagrams

Diagram Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Appendix E Installing a Communication Adapter

Communication Adapter Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

What The Communication Adapter Kit Includes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

Tools That You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Installing the Communication Adapter Module in the Drive . . . . . . . . . . . . . . . . . . . . . . E-2

Appendix F Optional Analog and Digital I/O Expansion Circuit Board

What This Option Board Provides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

I/O Expansion Board Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

Appendix G Optional 115V AC to 24V DC I/O Converter Circuit Board

What This Option Board Provides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

I/O Converter Board Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2

Index

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 9

Preface

Overview

The purpose of this manual is to provide you with the basic information needed to install, start-up and troubleshoot the PowerFlex DC drive.

For information on . . . See page . . .

Who Should Use this Manual? What is in this Manual? Preface-1 Drive Storage Conditions Preface-1 Drive Nameplate Data Preface-2 Reference Materials Preface-2 Drive Frame Sizes Preface-2 Manual Conventions Preface-3 General Precautions Preface-3 Catalog Number Explanation Preface-4

Preface-1

Who Should Use this Manual?

What is in this Manual?

Drive Storage Conditions

This manual is intended for qualified personnel. You must be able to program and operate DC drives. In addition, you must have an understanding of the parameter settings and functions detailed in this manual.

The PowerFlex DC User Manual is designed to provide installation, basic start-up information, and drive parameter definitions. For detailed drive information, please refer to “Reference Materials” on page Preface-2 list of additional publications.

If it is necessary to store the drive for any length of time before installation, follow these storage guidelines in order to ensure satisfactory operation at start up and to maintain warranty coverage:

• After receipt and inspection, repack the drive in its original shipping

container and store in a clean, dry place.

• Place where the ambient temperatures do not exceed -25°C (-13°F) or +55°C (131°F)

• Place where the relative air humidity range does not exceed 5% - 95%.

for a

• At an altitude of less than 3,000 meters (10,000 ft.) above sea level.

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 10

p-2 Overview

Drive Nameplate Data

Drive Frame Sizes

The PowerFlex DC drive contains a data nameplate located on the side of each drive that identifies the specific model number design, applicable AC input power and DC output power data. All communication with Rockwell Automation personnel concerning this product should include this information.

Cat No.

20P41AD4P1RA0NNN

UL Type OPEN/IP20

Input: 460VAC 50/60 Hz 3.3A 3 Phase

Output: 500VDC 4.1A REGEN 1.0HP

1 Min Overload Amps

3 Sec Overload Amps

DC Field:

Input: 460VAC 50/60 Hz 10A max. 1 Phase

Output: 360VDC 10A max.

Regulator Power: 115/230VAC 50/60 Hz 1.0/0.5A 1 Phase

MFD. in 2XXX on MMM DD

Made in Italy

6.2

8.2

EXAMPLE ONLY

Series: A

I/O: 24VDC (Standard) Original Firmware V. 1.001

N223

Frame: A

Serial Number: A23E0042

Ind. Cont.

Eq. 31KF

Listed

Note: Certification

Marks Location.

Refer to the data nameplate label on your drive for actual agency certifications.

Similar PowerFlex DC drive sizes are grouped into frame sizes to simplify spare parts ordering, dimensioning, etc. Refer to the Catalog Number

Explanation on page Preface-4 for a list of drive catalog numbers and their

respective frame sizes.

Reference Materials

The following manuals are recommended for general drive information:

Title Publication Available Online at . . .

Preventive Maintenance of Industrial Control and Drive System Equipment

Safety Guidelines for the Application, Installation and Maintenance of Solid State Control

A Global Reference Guide for Reading Schematic Diagrams

Guarding Against Electrostatic Damage 8000-4.5.2

DRIVES-TD001…

SGI-1.1

100-2.10

www.rockwellautomation. com/literature

For Allen-Bradley Drives Technical Support:

Title Online at . . . Allen-Bradley Drives Technical Support www.ab.com/support/abdrives

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 11

Overview p-3

Manual Conventions

General Precautions

• To help differentiate parameter names and LCD display text from other text, the following conventions will be used:

– Parameter Names will appear in [brackets].

For example: [Armature Voltage].

– Display Text will appear in “quotes.” For example: “Enabled.”

• The following words are used throughout the manual to describe an action:

Word Me aning

Can Possible, able to do something Cannot Not possible, not able to do

something May Permitted, allowed Must Unavoidable, you must do this Shall Required and necessary Should Recommended Should Not Not recommended

ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control

precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook.

ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring

or application errors, such as, undersizing the motor, incorrect or inadequate AC supply, or excessive surrounding air temperatures may result in malfunction of the system.

ATTENTION: Only qualified personnel familiar with DC drives and associated machinery should plan or implement the

installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.

ATTENTION: An incorrectly applied or installed bypass system can result in component damage or reduction in product life. The

most common causes are:

• Wiring AC line to drive output or control terminals.

• Improper bypass or output circuits not approved by

Allen-Bradley.

• Output circuits which do not connect directly to the motor. Contact Allen-Bradley for assistance with application or wiring.

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 12

p-4 Overview

Catalog Number Explanation

Position

1-3 4 5 6 7 8-10 11 12 13 14 15 16

20P 4 1 A D 4P1 R N 0 N N N

abcdef gh i jkl

Drive

Code Type

20P PowerFlex DC

Motor Operation

Code Type

2 Two Quadrant Operation

4 Four Quadrant Operation

Input Type

Code Type

1 6 Pulse

2 12 Pulse

Enclosure

Code Enclosure Rating

A IP20, NEMA/UL Type Open

IP43, NEMA/UL Type 1 -

G IP54, NEMA/UL Type 12

IP54, NEMA/UL Type 12 -

N IP00, NEMA/UL Type Open

Filter

Fan/Filter

Input Voltage

Code Voltage

B 230V ac

C 400V ac

D 460V ac

E 600V ac

F 690V ac

Conform.

Coat

230V, 60 Hz Input

Code Hp

7P0 1.5 7 A 10

9P0 2 9 A 10

012 3 12 A 10

020 5 20 A 10

029 7.5 29 A 10

038 10 38 A 10

055 15 55 A 10

073 20 73 A 14

093 25 93 A 14

110 30 110 A 14

146 40 146 B 20

180 50 180 B 20

218 60 218 B 20

265 75 265 B 20

360 100 360 B 20

434 125 434 B 20

521 150 521 C 20

Armature

Amps

Frame

460V, 60 Hz Input

Code Hp

4P1 2 4.1 A 10

6P0 3 6 A 10

010 5 10 A 10

014 7.5 14 A 10

019 10 19 A 10

027 15 27 A 10

035 20 35 A 10

045 25 45 A 10

052 30 52 A 10

073 40 73 A 14

086 50 86 A 14

100 60 100 A 14

129 75 129 A 14

167 100 167 B 20

207 125 207 B 20

250 150 250 B 20

330 200 330 B 20

412 250 412 B 20

495 300 495 C 20

667 400 667 C 20

Armature

Amps

Frame

Field

Amps

Field

Amps

Field Supply

Code Type

A Three-Phase Regulated

F Fixed Field w/Economy

R Single-Phase Regulated

Packaging/Documentation

Code Shipping Carton User Manual

0No No

AYes Yes

NYes No

QNo Yes

HIM

Code Operator Interface

0 Blank Cover

Standard - for additional selections, refer to the PowerFlex Digital DC Drive Technical Data, publication 20P-TD001. . .

I/O Options

Code Control

I/O Expansion Card (4 Additional 24V

dc Digital Inputs & Outputs, 2 Analog

115V ac Conversion Card (8 Digital

I/O Expansion Card + 115V ac

None (8 - 24V dc Digital Inputs & Outputs, 3 Analog Outputs and 2

Outputs)

Inputs & Outputs)

Conversion

Analog Inputs are Standard)

Communication Options

Code Description

Standard - for additional selections, refer to the PowerFlex Digital DC Drive Technical Data, publication 20P-TD001. . .

None

Cabinet Options

Code Type

N None

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 13

Chapter 1

Installation and Wiring

This chapter provides information on mounting and wiring the PowerFlex DC drive.

For information on . . See page For information on. . See page

Mounting Considerations Mounting Dimensions and Weights 1-3 General Grounding Requirements 1-12 Lifting PowerFlex DC Drives 1-5 Power Circuit Protection 1-13 Removing the Drive Covers 1-7 Cable and Wiring Recommendations 1-14 Line Reactors / Filters 1-9 Power Wiring 1-15 Using Contactors 1-9 I/O Wiring 1-32

Most start-up difficulties are the result of incorrect wiring. Every precaution must be taken to assure that the wiring is done as instructed. All items must be read and understood before the actual installation begins.

1-2 Control Power Protection 1-11

Important:The PowerFlex DC drive is not

motor applications.

ATTENTION: The following information is merely a guide for proper installation. Rockwell Automation cannot assume

responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.

designed for use with multiple

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 14

1-2 Installation and Wiring

Mounting Considerations

Operating Conditions and Temperatures

PowerFlex DC drives are designed to operate at 0° to 50° C surrounding air temperature without derating. The drive must be mounted in a clean, dry location. Contaminants such as oils, corrosive vapors and abrasive debris must be kept out of the enclosure. NEMA/UL Type Open, IP20 enclosures are intended for indoor use primarily to provide a degree of protection against contact with enclosed equipment. These enclosures offer no protection against airborne contaminants.

Minimum Mounting Clearances

Minimum clearance requirements (indicated in Figure 1.1) are intended to be from drive to drive. Other objects can occupy this space; however, reduced airflow may cause protection circuits to fault the drive. The drive must be mounted in a vertical orientation as shown below and must not be mounted at an angle greater than 30° from vertical. In addition, inlet air temperature must not exceed the product specification.

Figure 1.1 Drive Enclosure Minimum Mounting Clearances

10 mm (0.4 in.)

150 mm (6.0 in.)

PORT

MOD

NET A

NET B

STS

10 mm (0.4 in.)

150 mm (6.0 in.)

PORT

MOD

NET A

NET B

150 mm (6.0 in.)

STS

10 mm (0.4 in.) (2.0 in.)

50 mm

Airflow through the drive must not be impeded.

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 15

Installation and Wiring 1-3

Mounting Dimensions and Weights

The PowerFlex DC drive is available in a NEMA/UL Type Open, IP20 enclosure. Following all mounting instructions in order to ensure proper operation.

ATTENTION: Remove all loose packing materials, including the container(s) of desiccants (if any), from the drive enclosure

before mounting and energizing the drive.

Figure 1.2 Frame A Approximate Dimensions

ABCA1B1

mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) 267 (10.5) 359 (14.0) 287 (11.3) 250 (9.8) 275 (10.8)

PORT

MOD

NET A

NET B

STS

Table 1.A Frame A Weights

Weight Drive Current Rating Code 230V 460V kg (lbs.) kg (lbs.)

7P0 4P1 8.4 (19.5) 10.5 (23.1) 9P0 6P0 012 010 020 014 – 019 029 027 038 035 8.8 (19.4) 11 (24.3) 055 045 – 052 073 073 10.8 (23.8) 13 (28.7) 093 086 110 100 – 129

Drive Drive & Packaging

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 16

1-4 Installation and Wiring

Figure 1.3 Frame B Approximate Dimensions

A A1A2B B1C

mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) 311 (12.2) 275 (10.8) 16.5 (0.65) 388 (15.3) 375 (14.8) 350 (13.8)

PORT

MOD

NET A

NET B

STS

Table 1.B Frame B Weights

Weight Drive w/ND Rating Code 230V 460V kg (lbs.) kg (lbs.)

146 167 25.5 (56.2) 27.5 (60.6) 180 207 218 – 265 250 29.5 (65.0) 31.5 (69.4) 360 330 32 (70.5) 34 (75) 434 412

Drive Drive & Packaging

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 17

Installation and Wiring 1-5

Figure 1.4 Frame C Approximate Dimensions

A A1 B B1 B2 B3 B4 C

mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) 521 (20.5) 499 (19.7) 511 (20.1) 400 (15.7) 200 (7.9) 55 (2.2) 56 (2.2) 416 (16.4)

A1 C

PORT

MOD

NET A

NET B

STS

Lifting PowerFlex DC Drives

Table 1.C Frame C Weights

Weight - Regenerative Drives Weight - Non-regenerative Drives Drive w/ND Rating Code 230V 460V kg (lbs.) kg (lbs.) kg (lbs.) kg (lbs.)

– 495 61 (134.5) 74 (163.1) 57 (125.7) 70 (154.3) 521 667 65 (143.3) 81 (178.6) 62 (136.7) 75 (165.3)

Drive Drive & Packaging Drive Drive & Packaging

The dimensions and weights specified above must be taken into consideration when mounting the device. Use the proper equipment to safely lift and hold the weight of the drive while mounting.

ATTENTION: To guard against possible personal injury or equipment damage . . .

• Inspect all lifting hardware for proper attachment before lifting

the drive.

• Do Not allow any part of the drive or lifting mechanism to

make contact with electrically charged conductors or components.

• Do Not subject the drive to high rates of acceleration or

deceleration while transporting to the mounting location or when lifting.

• Do Not allow personnel or their limbs directly underneath the

drive when it is being lifted and mounted.

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 18

1-6 Installation and Wiring

Mounting Frame C Drives

All lifting equipment and lifting components (hooks, bolts, lifts, slings, chains, etc.) must have a minimum

Important:Verify that all mounting screws are properly tightened before

and after drive operation.

1. Verify the hole pattern on the panel to which the drive will be mounted.

Refer to Figure 1.4 on page 1-5

2. Insert, but do not tighten, one bolt in one of the top holes in the panel.

The bolt must be fully threaded into the panel before hanging the drive.

3. Insert the properly sized and rated lifting hooks into the holes on the

lifting flanges at the top of the drive. To limit the pull in forces on the drive, the lifting devices connected to the hooks must be long enough to make the angle between the chain or cable and a vertical line extending up from the flange center less than 45 degrees as illustrated below.

Figure 1.5 Lifting Angle

lifting capacity of 453.6 kg (1,000 lb.).

Angle Must Be Less

Than 45 Degrees

Lifting flange

4. Lift the drive into place on to the bolt installed in the panel.

5. Install the remaining five bolts into the panel. Tighten all bolts to a

torque of 22.6 N•m (200 lb•in).

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 19

Installation and Wiring 1-7

Removing the Drive Covers

The lower protective cover must be removed in order to access the drive’s power and I/O terminals. The upper cover only needs to be removed to install an optional communication adapter and service the drive. (Refer to

Installing a Communication Adapter on page E-1

Frame A Drives

You must remove both the lower protective cover and the power terminal cover on frame A drives to access the power terminals.

Remove the Power Terminal Cover

Remove the two screws as shown below and slide the cover down and off the chassis.

Figure 1.6 Frame A Power Terminal Cover Removal

for information.)

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 20

1-8 Installation and Wiring

Remove the Lower Protective Cover

Remove the two screws as shown below and, while gently lifting along the top edge, slide the cover down and off the chassis.

Figure 1.7 Frame A Lower Cover Removal

PORT

MOD

NET A

NET B

STS

Frame B and C Drives

Loosen, but do not remove, the two screws that secure the bottom cover. Then, slide the cover down until the screw heads line up with the key holes and lift the cover off the chassis.

Figure 1.8 Frame B & C Drive Cover Removal

Frame B Shown

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 21

Installation and Wiring 1-9

Line Reactors / Filters

Using Contactors

When connecting the drive directly to the main distribution system an AC line reactor must be used to guard against system disturbance. The type of line reactor used depends upon the following:

• the current absorbed by the AC input

• the AC input voltage

• the relative short circuit voltage

• the AC input frequency

Refer to AC Input Line Reactors and AC Input Contactors on page A-17 a list of recommended AC line reactors.

When using an AC input contactor, the IEC AC1 rating of the contactor must be equal to the rated thermal (RMS) current value at the mains input of the drive.

Drive configurations for AC or DC contactors, with or without a dynamic brake, are as follows (refer to Typical Power Wiring Diagrams on page 1-17 for wiring examples):

• When only an AC contactor is used:

❏ Set parameter 1391

value)

(1)

[ContactorControl] to 1 “AC Cntctr” (default

for

❏ Set one [Relay Out x Sel] parameter and one [Digital Inx Sel]

parameter to “Contactor” (default value for parameters 1392 Out 1 Sel] and 140

• When only a DC contactor is used:

❏ Set parameter 1391

❏ Set one [Relay Out x Sel] parameter and one [Digital Inx Sel] to

“Contactor” (default value for parameters 1392 and 140

• When an AC contactor and dynamic brake contactor are used:

❏ Set parameter 1391

❏ Set one [Relay Out x Sel] parameter (1392 [Relay Out 1 Sel] or 629

[Relay Out 2 Sel]) to “Contactor” and the other relay output to “ContactorDB”

❏ Set one [Digital Inx Sel] parameter to “Contactor” (default value

for parameter 140

[Digital In8 Sel])

[ContactorControl] to 3 “DC Cntctr”

[Relay Out 1 Sel]

[ContactorControl] to “AC Cntctr+DB”

[Digital In8 Sel])

(1)

[Relay

(1)

Par 1391 [ContactorControl] is contained in the “Advanced” parameter configuration group. Refer to How

Parameters are Organized on page 3-3 for more information.

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 22

1-10 Installation and Wiring

• When a DC contactor and dynamic brake contactor are used:

❏ Set parameter 1391

❏ Set one [Relay Out x Sel] parameter (1392 [Relay Out 1 Sel] or 629

[Relay Out 2 Sel]) to “Contactor” and the other relay output to “ContactorDB”

❏ Set one [Digital Inx Sel] parameter to “Contactor” (default value

for parameter 140

• When a contactor is NOT used:

❏ Set parameter 1391

❏ Do NOT set either [Relay Out x Sel] parameter to “Contactor” or

“ContactorDB”

❏ Do NOT set any [Digital Inx Sel] parameter to “Contactor”

When operating a drive with firmware version 1.006 in field weakening mode with a DC contactor and/or inverting fault device installed in the armature circuit, refer to Field Weakening Mode Configuration (v1.006) on

page C-5.

[ContactorControl] to “DC Cntctr+DB”

[Digital In8 Sel])

[ContactorControl] to “None”

(1)

AC Input Contactors

Refer to AC Input Line Reactors and AC Input Contactors on page A-17 for a list of recommended AC input contactors.

DC Output Contactors

A DC output contactor can be used to connect the output of the armature circuit to the DC motor. If a DC output contactor is used, an AC input contactor is not needed.

Refer to DC Output Contactors and Dynamic Brake Resistor Kits on

page A-19 for a list of recommended DC output contactors.

Dynamic Brake Resistors

Refer to DC Output Contactors and Dynamic Brake Resistor Kits on

page A-19 for a list of recommended dynamic brake resistor kits.

(1)

Par 1391 [ContactorControl] is contained in the “Advanced” parameter configuration group. Refer to How

Parameters are Organized on page 3-3 for more information.

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Installation and Wiring 1-11

Control Power Protection

The 115V / 230V AC control circuit power input terminals U2 and V2 are required to be short circuit protected. This protection can be provided by using standard time delay fuses or a circuit breaker.

The time delay fuses or circuit breaker must be selected to survive the short circuit available current of the feeder source for this circuit and the inrush current of the drive’s power supply.

The rating of the fuses or circuit breaker should be sized mainly to protect the wiring from the fuses/circuit breaker connections to terminals U2 and V2, and not nuisance trip or blow from the inrush current.

The table below lists the input current characteristics of the control power.

Table 1.D Control Power Protection

Drive Current Rating Code

Frame

B & C

(1)

230V 460V 115V 230V 115V 230V

7P0 4P1

110 129 146 167

521 667

Refer to Catalog Number Explanation on page Preface-4, positions 8-10 for corresponding drive HP rating, armature amp rating and field amp rating.

(1)

Control Power Supply

Rated input current Inrush input current

Board ID Power

SW1-31 60 W 1 A 0.5 A 20 A 10 Athrough through

SW2-32 110 W 1.2 A 0.7 A 15 A 7.5 Athrough through

Control power input should be supplied by a power source that is stabilized and buffered from the power system transients. The control power of many drives can be fed from a single source, as long as proper distribution protection is provided.

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1-12 Installation and Wiring

General Grounding Requirements

The drive Safety Ground - PE must be connected to system ground. Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked.

For installations within a cabinet, a single safety ground point or ground bus bar connected directly to building steel should be used. All circuits including the AC input ground conductor should be grounded independently and directly to this point/bar.

ATTENTION: In order to comply with the essential requirements of the CE Low Voltage Directive 2006/95/EC,

PowerFlex DC drives may not be powered from a corner-earthed (TN with one phase earthed) supply system. Although PowerFlex DC drives are compliant with the requirements of the CE Low Voltage Directive when powered from an IT or impedance-earthed supply system, power must be removed from the drive as soon as possible after an earth fault is detected in the power system to satisfy CE safety requirements related to the insulation system of the drive.

Figure 1.9 Typical Grounding

AC Mains Supply

Safety Ground

Earth

Transformer

PE1

PORT

MOD

NET A

NET B

STS

AC Line

Reactor

All wires (including motor ground) must be connected inside the motor terminal box.

Safety Ground (PE)

This is the safety ground for the drive that is required by code. This point must be connected to adjacent building steel (girder, joist), a floor ground rod or bus bar (see above). Grounding points must comply with national and local industrial safety regulations and/or electrical codes.

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Installation and Wiring 1-13

Power Feeder

Each power feeder from the substation transformer to the drive must be provided with properly sized ground cables. The conduit or cable armor should be bonded to the substation ground at both ends. Each transformer enclosure and/or frame must be bonded to ground at a minimum of two locations.

Encoder Ground Connections

If used, must be routed in grounded steel conduit. The conduit must be grounded at both ends. The encoder cable shield must be connected to the shield ground on the drive side. Do not connect the encoder cable shield to ground on the motor side.

Tachometer Ground Connections

If used, ground connections must be routed in grounded steel conduit. The conduit must be grounded at both ends. Ground the cable shield at the drive end only using the shield clamps on the grounded metal plate supporting the control board (refer to I/O Terminal Block Locations on page 1-36 shield clamp location).

for

Power Circuit Protection

It is recommended that you install the PowerFlex DC drive with fast acting fuses to protect the armature converter on the AC input and DC output (for four quadrant drives only) sides. Internally mounted fuses for armature converter protection are provided with 230V, 521A and 460V, 495A and 667A frame C PowerFlex DC drives. Refer to Drive Power Circuit

Protection on page A-7 for a list of replacement fuses and general fuse

locations.

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Page 26

1-14 Installation and Wiring

Cable and Wiring Recommendations

Power Wiring

AC Input Voltages

575 volts – proportional to 12 in. (305 mm) per 1000 volts.

PowerFlex DC drives are rated for the following AC input voltages:

Armature Circuit Field Circuit Control Circuit Terminals U, V, W Terminals U1, V1 Terminals U2, V2

230V ±10 %, 3Ph 400V ±10 %, 3Ph 440V ±10 %, 3Ph 460V ±10 %, 3Ph 480V ±10 %, 3Ph @ 50/60 Hz ±5 %

(1)

For frame B and C drives only, a jumper must be placed between terminals SA-SB on the Switching Power Supply circuit board for the control circuits to work with 115V AC input. Refer to Figure 1.26 on page 1-29 terminal block location on frame B drives and Figure 1.27 on page 1-30 drives.

230V ±10 %, 1Ph 400V ±10 %, 1Ph 460V ±10 %, 1Ph @ 50/60 Hz ±5 %

115V ±15 %, 1 Ph or 230V ±15 %, 1Ph @ 50/60 Hz ±5 %

for terminal block location on frame C

(1)

for

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1-16 Installation and Wiring

DC Output Voltages

The output voltages below take into account an AC input undervoltage within the stated tolerance limits and a voltage drop of 4% due to an AC input line reactor. It is the same as the rated armature voltage suggested for the connected motor.

Armature Circuit

AC Input Voltage DC Output Armature Voltage (Terminals C & D) (Terminals U, V, W) Two Quadrant Drive Four Quadrant Drive

230V ±10 %, 3Ph 260V 240V 400V ±10 %, 3Ph 470V 420V 440V ±10 %, 3Ph 530V 460V 460V ±10 %, 3Ph 560V 480V 480V ±10 %, 3Ph 580V 500V

Field Circuit

AC Input Voltage DC Output Field Voltage (Terminals U1 & V1) Fixed Field Adjustable Field

230V ±15 %, 1Ph 200V 200V 400V ±15 %, 1Ph 310V 310V 460V ±10%, 1Ph 360V 360V

(1)

The max field voltage is equal to 0.85 x AC input line voltage

(1)

(Terminals C1 & D1)

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Installation and Wiring 1-17

Typical Power Wiring Diagrams

Figure 1.10 - Figure 1.13 represent recommended power wiring

configurations.

Figure 1.10 Power Wiring with AC Input Contactor

3 Phase AC line

(1)

(on I/O TB4)

(N.O. Relay)

M1 AC C ontactor

Aux

13 14

FU8 FU9

FU3

FU4

FU5

19 (+24V - on I/O TB2)

PowerFlex DC

Drive

Control

Board P/S

Field Power

460V 115V

FU6

FU7

(3)

Control Power / Relay Terminal Block

Terminal Block

(2)

FU1

(2)

FU2

(1)

Par 140 [Digital In8 Sel] set to 31 “Contactor”

(2)

Armature output fuses are required on four quadrant and are recommended on two quadrant Frame A and B drives. Fuses with Trip Indicator Switches are recommended for Inverting Fault protection when the motor will be Field Weakened and run above base speed. Refer to Figure 1.13 on

page 1-19.

(3)

Par 1391 [ContactorControl] = 1 “AC Cntctr” and Par 1392 [Relay Out 1 Sel] = 25 “Contactor”. Important: Terminal 35 and 36 are on the Control Power / Relay Terminal block, NOT the I/O terminal blocks. See Figure 1.20

through Figure 1.22.

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1-18 Installation and Wiring

Figure 1.11 Power Wiring with DC Output Contactor

3 Phase AC l i ne

34 (on I/O TB4)

19 (+24V on I/O TB2)

FU8 FU9

FU3

FU4

FU5

460V 115V

FU6

FU7

PowerFlex DC

Drive

Control Power /

(3)

Relay Terminal

(3)

Block

Field Power

Terminal Block

Control

Board P/S

(1)

(N.O. Relay)

M1 DC Contactor

Aux

13 14

FU1

(2)

FU2

(1)

Par 140 [Digital In8 Sel] set to 31 “Contactor”

(2)

page 1-19.

(3)

Par 1391 [ContactorControl] = 3 “DC Cntctr” and Par 1392 [Relay Out 1 Sel] = 25 “Contactor”. Important: Terminal 35 and 36 are on the Control Power / Relay Terminal block, NOT the I/O terminal blocks. See Figure 1.20

through Figure 1.22.

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Installation and Wiring 1-19

Figure 1.12 Power Wiring with DC Output Contactor and a Dynamic Brake

3 Phase AC l i ne

34 (on I/O TB4)

19 (+24V on I/O TB2)

FU8 FU9

(1)

(2)

Switches are recommended for Inverting Fault protection when the motor will be Field Weakened and run above base speed. Refer to Figure 1.13 on

page 1-19.

(3)

Important: Terminal 35, 36, 75 and 76 are on the Control Power / Relay Terminal block, NOT the I/O terminal blocks. See Figure 1.20

1.22.

FU3

FU4

FU5

460V 115V

FU6

FU7

Par 140 [Digital In8 Sel] set to 31 “Contactor”

Armature output fuses are required on four quadrant and are recommended on two quadrant Frame A and B drives. Fuses with Trip Indicator

Par 1391 [ContactorControl] = 4 “DC Cntctr+DB”, Par 1392 [Relay Out 1 Sel] = 25 “Contactor”, and Par 629 [Relay Out 2 Sel] = 24 “ContactorDB”.

PowerFlex DC

Drive

(3)

Control Power /

(3)

Relay Terminal Block

(3)

Field Power

Terminal Block

Control

Board P/S

(1)

(N.O. Relay)

M1 DC Contactor

Aux

13 14

DB Resistor

(N.C. Relay)

DB Contactor

Aux

14L1T1

through Figure

(2)

FU1

(2)

FU2

Figure 1.13 Power Wiring with Armature Output Fuses and Inverting Fault Status

(1)

FU1

PowerFlex DC

Drive

(2)

(on I/O TB4)

19 (+24V on I/O TB2)

(1)

FU2

(1)

(2)

Par 139 [Digital In7 Sel] set to 64 “Invert Flt”.

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1-20 Installation and Wiring

Armature Converter Connections

Terminals Description

U, V, W Three phase AC input to the armature converter C, D DC output to the motor armature PE Safety ground

Figure 1.14 Frame A Armature Converter Terminal Block Location

Front View

Note: Front view of drive shown with bottom protective and power terminal covers removed. Refer to Removing the Drive Covers on page 1-7

for information on removing the drive covers.

UCV DWPE

ATTENTION: Do not operate the drive with the power terminal cover removed. Operating the drive with the power

terminal cover removed may result in a hazardous condition that could cause personal injury and/or equipment damage.

Figure 1.15 Frame B Armature Converter Terminal Block Location

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

UCVDW

Page 33

Installation and Wiring 1-21

Figure 1.16 Frame C Armature Converter Terminal Block Location

Front View

UCVDW

Bottom View

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1-22 Installation and Wiring

Table 1.E Armature and Safety Ground (PE) Terminal Specifications

Drive Current Rating Code

Frame

A7P0 4P1

9P0 6P0 012 010 020 014 –019 029 027 038 035 055 045 –052 073 073 093 086 110 – –100 –129

B 146 167 U, V, W, C, D 10 50 / 442.5

180 – U, V, W, C, D 10 50 / 442.5

218 207 U, V, W, C, D 10 50 / 442.5

265 250 U, V, W

–330U, V, W

360 412 U, V, W

434 – U, V, W

C 521 495 U, V, W

–667U, V, W

(1)

See to Catalog Number Explanation on page Preface-4, positions 8-10 for corresponding drive HP rating, armature amp rating and field amp rating.

(1)

Terminals Wire Size and Type

U, V, W, C, D, PE

U, V, W, C, D, PE Terminal Block 12 / 106

PE 8 25 / 221

C, D PE 8 25 / 221

See Cable and Wiring

Recommendations on page 1-14

Terminal Bolt

Size (mm)

5 6 / 53

10 50 / 442.5

Tightening Torque

(N•m / lbs•in)230V 460V

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Page 35

Field Circuit Connections

Terminals Description

U1, V1 Single phase AC input to the field circuit C1, D1 DC output to the motor field

Figure 1.17 Frame A Field Circuit Terminal Block Location

Installation and Wiring 1-23

Bottom of Drive

Figure 1.18 Frame B Field Circuit Terminal Block Location

Top of drive

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1-24 Installation and Wiring

Figure 1.19 Frame C Field Circuit Terminal Block Location

Front of drive

V1U1C1D1

Table 1.F Field Circuit Wire Sizes and Terminal Specifications

Drive Current Rating

(1)

Code

Frame

All All All U1, V1, C1, D1

(1)

Refer to Catalog Number Explanation on page Preface-4, positions 8-10 for corresponding drive HP rating, armature amp rating and field amp rating.

(2)

See Cable and Wiring Recommendations on page 1-14 for more information.

Termi nals Wire Size and Type

24-10 AWG/kcmils 0.5 - 0.8 / 4.4 - 7.1

Tightening Torque

(2)

•m / lbs•in)230V 460V

Field Current Resistors

The drive’s control circuit board is factory set to the minimum field current rating based on the drive size. The setting of DIP switch S14 must be changed to be ≥ the rated field current specified on the motor nameplate or possible motor damage may result. In addition, the value selected with switch S14 must be entered in parameter 374 control software when the drive is commissioned (refer to Drive Start Up on

page 2-1.)

[Drv Fld Brdg Cur] in the

ATTENTION: DIP switch S14 must be set to be ≥ the rated field current specified on the motor nameplate or possible motor

damage may result.

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Page 37

Installation and Wiring 1-25

Compare the field current value of the motor to the rated value of the internal field converter of the drive (see Table 1.G

below) and set switch

S14 to the closest value.

Note: The configuration of switch S14 is not required if the motor’s field control is provided via an external source, however, in this case it is recommended that the switch settings be completed as described above.

Table 1.G DIP Switch S14 Field Current Configuration Settings

Switch ohms 148 330 182 36.4 845 1650 Field current

scale S14-1 S14-2 S14-3 S14-4 S14-5 S14-6 S14-7 S14-8

1.0 A OFF OFF OFF OFF OFF ON

2.0 A OFF OFF OFF OFF ON OFF 845 ohm

3.0 A OFF OFF OFF OFF ON ON 558.8 ohm

5.0 A OFF ON OFF OFF OFF OFF 330 ohm

10.0 A ON OFF OFF OFF OFF OFF 168 ohm

12.9 A ON OFF OFF OFF ON ON 129.2 ohm

17.2 A OFF ON ON OFF ON ON 97 ohm

20.0 A ON OFF ON OFF OFF ON 83 ohm

24.1 A ONONONOFFOFFOFF 69 ohm

DIP

Note: Illustration is an example configuration only. DIP switch S14 must be set ≥ the rated field current specified on the motor nameplate or possible motor damage may result.

Equivalent Resistance

1650 ohm

Not used

Relay Outputs

Terminals Description

35, 36 Normally open contact. Configured with parameter 1392 [Relay

Out 1 Sel] - set to 25 “Contactor” by default.

Out 2 Sel] - set to 5 “Ready” by default.

78, 79 Motor thermistor connections (PTC)

Maximum Vol ta ge

250V AC 1A75, 76 Normally open contact. Configured with parameter 629 [Relay

Maximum Current

Terminals 35 and 36 and 75 and 76 are N.O. relay outputs. The relay output between terminals 35 and 36 is configured with parameter 1392

[Relay Out 1 Sel]. The relay output between terminals 75 and 76 is configured with parameter 629

[Relay Out 2 Sel]. See Using Contactors on page 1-9 for

more information.

Thermistors and Thermal Switches

To detect motor overheating and protect the motor from overloading, an external, user-supplied thermistor (PTC) or thermal switch must be connected to terminals 78 and 79. The drive’s response to a motor over temperature fault is configured in parameter 365 temperature sensor is not used, a 1k ohm resistor must be connected

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

[OverTemp Flt Cfg]. If a

Page 38

1-26 Installation and Wiring

between terminals 78 and 79 (installed at the factory). Follow the appropriate instructions below when installing a thermal sensor.

Thermistors (PTC)

PTC thermistors fitted in the motor can be connected directly to the drive via terminals 78 and 79. In this case the 1k ohm resistor is not required between terminals 78 and 79.

Thermal Switches (Klixon

“Klixon” type temperature-dependent contacts can disconnect the drive from the motor via an external control or can be configured as an external fault using a digital input on drive. They can also be connected to terminals 78 and 79 in order to indicate a drive “Motor Over Temp” fault (F16), though this is not recommended due to the noise sensitivity of the current threshold circuitry. If a thermal switch is used a 1k ohm resistor must be placed in series between the switch and one of the terminals.

Table 1.H Relay Outputs and Thermistor/Thermal Switch Wire Sizes and Specifications

Signal Type Terminals

Relay Outputs 35 & 36, 75 & 76 Thermistor and

Thermal Switches

(1)

See Cable and Wiring Recommendations on page 1-14 for more information.

Figure 1.20 Frame A Relay and Thermistor/Thermal Switch Terminal Block Locations

) in the Motor Windings

78 & 79

Wire Size and Type

Flexible (mm2)

0.140 - 1.500 0.140 - 1.500 26-14 0.5 (4.4)

(1)

Multi-core (mm2)AWG

Tightening Tor qu e N•m (lb•in)

Note: Terminals 78 and 79 shown with 1k ohm resistor in place of temperature sensor.

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

78 79 35 36 75 76

Page 39

Installation and Wiring 1-27

Figure 1.21 Frame B Relay and Thermistor/Thermal Switch Terminal Block Locations

78 79 35 36 75 76

Figure 1.22 Frame C Relay and Thermistor/Thermal Switch Terminal Block Locations

35 36 75 76 78 79

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1-28 Installation and Wiring

Control Circuit Input Power

Terminals Description

U2, V2 Single phase AC power for the control circuits

The control circuit must be powered by an external 230V AC or 115V AC single phase power supply. For frame B and C drives only, a jumper is required between terminals SA and SB for 115V AC control input power. For frame B drive SA-SB terminal block location, refer to Figure 1.26 on

page 1-29. For frame C drive SA-SB terminal block location, refer to Figure

1.27 on page 1-30.

Figure 1.23 Frame A Control Circuit Terminal Block Location

U2 V2

Figure 1.24 Frame B Control Circuit Terminal Block Location

U2 V2

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Installation and Wiring 1-29

Figure 1.25 Frame C Control Circuit Terminal Block Location

U2 V2

The SA-SB terminal block is located at the top of the drive.

Table 1.I Control Circuit Wire Sizes and Terminal Specifications

Drive Current Rating

(1)

Code

Frame

All All All U2, V2 0.14 - 1.5 0.14 - 2.5 26 - 14 0.5 / 4.4

(1)

Refer to Catalog Number Explanation on page Preface-4, positions 8-10 for corresponding drive HP rating, armature amp rating and field amp rating.

(2)

See Cable and Wiring Recommendations on page 1-14 for more information.

Figure 1.26 SA-SB Terminal Block Location on Frame B Drives

Termi nals

Wire Size and Type

Flexible (mm2)

(2)

Multi-core (mm2)AWG

Tightening Torque (N

•m / lbs•in)230V 460V

Front of drive

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1-30 Installation and Wiring

Figure 1.27 SA-SB Terminal Block Location on Frame C Drives

The SA-SB terminal block is located on the Switching Power Supply circuit board on the back of the Control EMI Shield.

Switching Power Supply board SA-SB terminals Back of Control EMI shield

To access the SA-SB terminal block:

1. Remove the top protective cover from the drive.

3. Loosen captive screws.

XSW connector

2. Disconnect cables XFCD and XR.

3. Loosen captive screws.

4. Lower EMI shield and disconnect cable XSW from Switching Power Supply board (see above).

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Installation and Wiring 1-31

Frame C Heatsink Cooling Fans and Armature Fuse Signal Terminals

Frame C drives require an external power supply for the heatsink cooling fans and include internal armature circuit protection fuses (drives rated 521A @ 230V AC and 495A and 667A @ 460V AC input only). The terminals for the internal armature circuit protection fuses can be connected to an external device to provide indication that the fuses have opened.

Table 1.J Heatsink Cooling Fans and Fuse Signal Terminal Designations

Terminal Description Maximum Voltage Maximum Current

U3 V3 81 82

Table 1.K Heatsink Cooling Fans and Fuse Signal Wire Sizes and Terminal Specifications

All All All U3, V3,

(1)

(2)

Single-phase AC input power for cooling fans. 230V AC 1A

Internal armature fuse intervention signal. 250V AC 1A

Drive Current Rating

(1)

Code

Frame

Refer to Catalog Number Explanation on page Preface-4, positions 8-10 for corresponding drive HP rating, armature amp rating and field amp rating.

See Cable and Wiring Recommendations on page 1-14 for more information.

Termi nals

81, 82

Wire Size and Type

Flexible (mm2)

0.14 - 1.5 0.14 - 2.5 26 - 16 0.4 / 3.5

(2)

Multi-core (mm2)AWG

Tightening Torque (N

•m / lbs•in)230V 460V

Figure 1.28 Frame C Heatsink Cooling Fan and Internal Fuse Signal Terminal Block Locations

81 82

U3 V3

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1-32 Installation and Wiring

I/O Wiring

Observe the following points when installing I/O wiring:

• Use copper wire only.

• Wire with an insulation rating of 600V or greater is recommended?

Important:I/O terminals labeled “(–)” or “Common” are

not referenced to earth ground and are designed to greatly reduce common mode interference. Grounding these terminals can cause signal noise.

ATTENTION: Configuring an analog input for current operation and driving it from a voltage source could cause component

damage. Verify proper switch configuration prior to applying input signals. Refer to DIP Switch and Jumper Settings on page 1-32.

ATTENTION: Hazard of personal injury or equipment damage exists when using bipolar input sources. Noise and drift in

sensitive input circuits can cause unpredictable changes in motor speed and direction. Use speed command parameters to help reduce input source sensitivity.

DIP Switch and Jumper Settings

DIP switches and jumpers on the Control circuit board are used to configure the drive for flashing firmware to the control board EEPROM, the appropriate speed feedback device settings, analog input signals and minimum field current. Most switches and jumpers are set to the appropriate configuration at the factory.

➋

- A B C +

Figure 1.29 Control Circuit Board DIP Switch and Jumper Locations

Refer to Table 1.L on page 1-33 for descriptions corresponding to the ID numbers shown below.

= ON

1 2 3 4 5 6 7 8

S14

➑

S20

1 2 3 4 5 6 7 8

➒

S21

ENC_5 ENC_12

A+ A- B+ B- Z+ Z- COM +V

➎

➌

S11

S10

21 22 23 24 25 26 27 28 29 30

1 2 3 4 5 6 7 8 9 10

31 32 33 34 35 36 37 38 39 40

11 12 13 14 15 16 17 18 19 20

➏

➊

S15

DEBUG

1 2 3 4 5 6 7 8

RST

ACT RUN

PWR

➐

S18

S12

➍

= OFF

=OFF

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Installation and Wiring 1-33

Table 1.L Control Circuit Board Jumper and DIP Switch Settings

Jumper/

Switch Function

S0 For factory boot flashing only. Leave set to the factory setting. Jumper Off

➊

S1 For factory boot flashing only. Leave set to the factory setting. Jumper Off

S2 Not used. Leave set to the factory setting. Jumper Off S3 For factory boot flashing only. Leave set to the factory setting. Jumper Off

S4 Configures the input voltage of the DC analog tachometer.

➋

S9 Configures the input signal of Analog Input 1 (terminals 1 and 2): On

➌

S10 Configures the input signal of Analog Input 2 (terminal 3 and 4): On

S11 Configures the input signal of Analog Input 3 (terminals 5 and 6): On

S12 Not used. Leave set to the factory setting. Off

➍

S14 Field current resistors setting, see Table 1.G on page 1-25

➎

S15 Configuration of the control circuit board to the appropriate drive size.

➏

S18 Not used. Leave set to the factory setting. Off

➐

S20 Monitoring of the Z channel of the Digital Encoder on connector XE2: On

➑

S21 Encoder power supply voltage and input selection:

➒

Jumper On Firmware boot Jumper Off Normal function

Jumper On Write firmware boot code Jumper Off Boot code on flash is protected

Jumper On Reset Jumper Off Normal function

Refer to Table 1.M on page 1-34

Off Position 0 - 20 mA / 4 - 20 mA On Position 0 - 10V / ±10V Note: The input signal type must also be programmed accordingly

using Par 71 [Anlg In1 Config].

Off Position 0 - 20 mA / 4 - 20 mA On Position 0 - 10V / ±10V Note: The input signal type must also be programmed accordingly

using Par 76 [Anlg In2 Config].

Off Position 0 - 20 mA / 4 - 20 mA On Position 0 - 10V / ±10V Note: The input signal type must also be programmed accordingly

using Par 81 [Anlg In3 Config].

Important: In addition, the value selected with switch S14 must be

entered in Par 374 [Drv Fld Brdg Cur] in the control software when the drive is commissioned.

Leave set to the factory setting, unless the control board has been supplied as a spare part. Refer to Table 1.N on page 1-34

1.O on page 1-35 for switch configuration based on drive current

rating code.

Off Position Z-channel monitored On Position Z-channel not monitored

Note: When control power is supplied to the drive, the appropriate LED lights to indicate the selection of the switch.

ENC_5 +5 V encoder (+2.5 - 5.4V input range) ENC_12 +12-15 V encoder (+5.4V - 15.2V input range)

for configuration.

and Ta bl e

Factory Default

90V

Minimum field current rating based on drive size.

Armature current based on drive size.

12-15 V

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1-34 Installation and Wiring

ATTENTION: The Drive can overspeed if DIP switch S4 is set incorrectly, or the tachometer is wired incorrectly. Failure to

observe this precaution could result in damage to, or destruction of, the equipment.

Figure 1.30 DC Analog Tachometer DIP Switch S4 Example

Note: Illustration for example only.

Table 1.M DC Analog Tachometer DIP Switch S4 Configuration

DIP

Maximum DC Input Voltage

22V ON ON ON ON 45V ON ON ON OFF

90V ON ON OFF OFF 180V ON OFF OFF OFF 300V OFF OFF OFF OFF

Figure 1.31 Drive Size DIP Switch S15 Example

Table 1.N Drives with 230V Input - DIP Switch S15 Configuration

Drive Current

Rating Code S15-1 S15-2 S15-3 S15-4 S15-5 S15-6 S15-7 S15-8

Frame

A 7P0 ON OFF OFF OFF OFF OFF OFF OFF

9P0 OFF ON OFF OFF OFF OFF OFF OFF 012 ON ON OFF OFF OFF OFF OFF OFF 020 OFF OFF ON OFF OFF OFF OFF OFF 029 ON OFF ON OFF OFF OFF OFF OFF 038 OFF ON ON OFF OFF OFF OFF OFF 055 ON ON ON OFF OFF OFF OFF OFF 073 OFF OFF OFF ON OFF OFF OFF OFF 093 ON OFF OFF ON OFF OFF OFF OFF 110 OFF ON OFF ON OFF OFF OFF OFF

146 ON ON OFF ON OFF OFF OFF OFF 180 OFF OFF ON ON OFF OFF OFF OFF 218 ON OFF ON ON OFF OFF OFF OFF 265 OFF ON ON ON OFF OFF OFF OFF 360 ON ON ON ON OFF OFF OFF OFF 434 OFF OFF OFF OFF ON OFF OFF OFF 521 ON OFF OFF OFF ON OFF OFF OFF

S4-1 S4-8

S4-2 S4-7

S4-3 S4-6

Note: Illustration for example only.

DIP

S4-4 S4-5

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Installation and Wiring 1-35

Table 1.O Drives with 460V Input - DIP Switch S15 Configuration

Drive Current

Rating Code S15-1 S15-2 S15-3 S15-4 S15-5 S15-6 S15-7 S15-8

Frame

B 167 ON OFF ON ON OFF OFF ON OFF

4P1 OFF OFF OFF OFF OFF OFF ON OFF 6P0 ON OFF OFF OFF OFF OFF ON OFF 010 OFF ON OFF OFF OFF OFF ON OFF 014 ON ON OFF OFF OFF OFF ON OFF 019 OFF OFF ON OFF OFF OFF ON OFF 027 ON OFF ON OFF OFF OFF ON OFF 035 OFF ON ON OFF OFF OFF ON OFF 045 ON ON ON OFF OFF OFF ON OFF 052 OFF OFF OFF ON OFF OFF ON OFF 073 ON OFF OFF ON OFF OFF ON OFF 086 OFF ON OFF ON OFF OFF ON OFF 100 ON ON OFF ON OFF OFF ON OFF 129 OFF OFF ON ON OFF OFF ON OFF

207 OFF ON ON ON OFF OFF ON OFF 250 ON ON ON ON OFF OFF ON OFF 330 OFF OFF OFF OFF ON OFF ON OFF 412 ON OFF OFF OFF ON OFF ON OFF 495 OFF ON OFF OFF ON OFF ON OFF 667 ON ON OFF OFF ON OFF ON OFF

I/O Signal and Control Wiring

Eight (8) digital inputs, four (4) digital outputs, three (3) analog inputs, and two (2) analog outputs are available on the standard I/O terminal blocks provided with the drive. One digital input (1-8) must be configured for “Enable”. Refer to I/O and Control Wire Routing on page 1-42 O wire routing locations.

Additional digital and analog I/O is available when using the optional I/O Expansion circuit board. Refer to Appendix F

Optional Analog and Digital

I/O Expansion Circuit Board for more information. Also, you can use the

optional 115V AC Converter circuit board to convert 115V AC digital input signals to 24V DC digital inputs signals to interface with the digital inputs on the standard I/O terminal blocks. Refer to Appendix G

AC to 24V DC I/O Converter Circuit Board for more information.

Table 1.P Analog I/O, Digital I/O and DC Analog Tachometer Wire Sizes and Terminal Specifications

Wire Size and Type

Signal Type

Analog and Digital I/O TB1 - 4 (1 - 40) DC Analog Tach M3 (+ and –)

(1)

See Cable and Wiring Recommendations on page 1-14 for more information.

Terminal Block (Terminals)

Flexible (mm2)

0.140 - 1.500 0.140 - 1.500 26-16 0.4 (3.5)

(1)

Multi-core (mm2)AWG

for proper I/

Optional 115V

Tightening Tor qu e

•m (lb•in)

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1-36 Installation and Wiring

Figure 1.32 I/O Terminal Block Locations

Terminal Block 3 Terminal Block 4

Terminal Block 1

Terminal Block 2

Table 1.Q I/O Terminal Block 1 Designations

No. Signal Description Factory Default Config. Parameter

1 Analog Input 1 (+) Isolated

2 Analog Input 1 (–) 3 Analog Input 2 (+) 0 “Off” 75 [Anlg In2 Sel] 4 Analog Input 2 (–) 5 Analog Input 3 (+) 0 “Off” 80 [Anlg In3 Sel] 6 Analog Input 3 (–)

7 +10V Pot Reference 2-5k ohm load. Max ±10V, 10mA. – – 8 –10V Pot Reference 9 Pot Common For (+) and (–) 10V pot references. – – 10 PE ground PE ground to drive chassis. – –

(1)

Differential Isolation - External source must be maintained at less than 160V with respect to PE. Input provides high common mode immunity.

(1)

, bipolar, differential

±10V / 0-20mA or 4-20mA. Important: 0-20mA or 4-20mA operation requires that switch S9, S10, and S11 on the Control board be in the “Off” position. Drive damage may occur if the switch is not in the correct position based on the type of input signal. Refer to Table 1.L on

page 1-33.

Max ±10V, Max 0.25mA.

1 “Speed Ref A” 70 [Anlg In1 Sel]

Table 1.R I/O Terminal Block 2 Designations

No. Signal Description Factory Default Config. Parameter

11 Internal 0V (Gnd) – –

12 Digital Input 1 Max +30V, 15V/3.2mA, 24V/5mA, 13 Digital Input 2 3 “Start” 134 [Digital In2 Sel] 14 Digital Input 3 11 “Jog” 135 [Digital In3 Sel]

and 30V/6.4mA.

15 Digital Input 4 1 “Enable” 16 Digital Input Common

(2)

17 Not Used – – 18 24V Supply Common Common for the internal power supply. – – 19 +24V DC Supply Drive supplied control input power.

Max. +20-30V, 200mA

(3)

20 PE ground PE ground to drive chassis. – –

(1)

A digital input (1-8) must be configured for “Enable”.

(2)

When using the internal +24V DC supply (terminal 19) for digital inputs 1-4, you must connect the digital input common (terminal 16) to the +24V supply common (terminal 18).

(3)

The total current draw is the sum of encoder power, digital outputs and any other loads connected to terminal 19.

2 “Stop/CF” 133 [Digital In1 Sel]

(1)

136 [Digital In4 Sel]

––

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Installation and Wiring 1-37

Table 1.S I/O Terminal Block 3 Designations

Factory

No. Signal Description

Default Config. Parameter

21 Analog Output 1 (+) Max. ±10V, 5 mA. 12 “Motor Speed” 66 [Anlg Out1 Sel]

22 Analog Output 1 (–) 23 Analog Output 2 (+) 13 “Motor Curr” 67 [Anlg Out2 Sel] 24 Analog Output 2 (–) 25 Digital Output Common – – 26 Digital Output 1 Max. +30V, 50mA 5 “Ready” 145 [Digital Out1 Sel] 27 Digital Output 2 9 “Fault” 146 [Digital Out2 Sel] 28 Digital Output 3 2 “Spd Thresh” 147 [Digital Out3 Sel] 29 Digital Output 4 4 “CurrentLimit” 148 [Digital Out4 Sel] 30 External +24V DC Supply Supply voltage for the Digital Outputs.

––

Max. +30V DC, 80mA.

Table 1.T I/O Terminal Block 4 Designations

No. Signal Description Factory Default Config. Parameter

31 Digital Input 5 Max +30V, 15V/3.2mA, 24V/5mA, 32 Digital Input 6 18 “Speed Sel 2” 138 [Digital In6 Sel]

and 30V/6.4mA.

33 Digital Input 7 19 “Speed Sel 3” 139 [Digital In7 Sel] 34 Digital Input 8 31 “Contactor” 140 [Digital In8 Sel]

35 Digital Input Common Important: When using the internal +24V

DC supply (terminal 19) for digital inputs 5-8, you must connect the digital input common (terminal 35) to the +24V supply common (terminal 18).

36-40Not Used – –

17 “Speed Sel 1” 137 [Digital In5 Sel]

––

I/O Wiring Examples

Input/Output Connection Example Potentiometer Unipolar

Speed Reference

10k Ohm Pot. Recommended (2k Ohm Minimum)

Joystick Bipolar Speed Reference

±10V Input

(1)

Required Parameter Changes

• Adjust Scaling:

72 [Anlg In1 Scale] and

73 [Anlg1 Tune Scale]

• View Signal Value:

1404 [Analog In1 Value]

• View Signal Output:

385 [Speed Ref Out]

• Set Direction Mode:

1322 [Direction Mode]

= 1 “Bipolar”

• Adjust Scaling:

72 [Anlg In1 Scale] and

73 [Anlg1 Tune Scale]

• View Signal Value:

1404 [Analog In1 Value]

• View Signal Output:

385 [Speed Ref Out]

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1-38 Installation and Wiring

Input/Output Connection Example Analog Input Bipolar Speed

Reference

±10V Input

Analog Input Unipolar Speed Reference

0 to +10V Input

(1)

Common

or 0 to 20 mA

Analog Output Bipolar Signal

±10V Bipolar (based on the signal of the selected input

+–

(i.e., selection “Analog In 1”) 0-10V/0-20mA Unipolar

(shown)

Enable Input

24V DC internal supply

Required Parameter Changes

22 23

27 28

29 30

12 13

17 18

• Set Direction Mode:

1322 [Direction Mode] = 1 “Bipolar”

• Adjust Scaling:

72 [Anlg In1 Scale] and 73 [Anlg1 Tune Scale]

• View Signal Value:

1404 [Analog In1 Value]

• View Signal Output:

385 [Speed Ref Out]

• Configure for Voltage or

Current: 71 [Anlg In1 Config]

• Adjust Scaling:

72 [Anlg In1 Scale] and 73 [Anlg1 Tune Scale]

• View Signal Value:

1404 [Analog In1 Value]

• View Signal Output:

385 [Speed Ref Out]

• Select Source Value:

66 [Anlg Out1 Sel]

• Adjust Scaling:

62 [Anlg Out1 Scale]

• No Changes Required.

(3)

Note: If the digital input used for “Enable” is changed from the default setting of digital input 4, the wiring must be changed accordingly.

2-Wire Control Non-Reversing

(2)

24V DC internal supply

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Stop-Run

• Disable Digital Input 1:

12 13

17 18

133 [Digital In1 Sel] = 0 “Not Used”

• Set Digital Input 2:

134 [Digital In2 Sel] = 5 “Run”

Page 51

Installation and Wiring 1-39

Input/Output Connection Example 2-Wire Control

Reversing

(2)

Run Fwd.

24V DC external supply

Run Rev.

Neutral/

+24V

Common

3-Wire Control

24V DC internal supply

Stop

Start

3-Wire Control

24V DC external supply

Stop

Requires 3-wire functions only ([Digital In1 Sel]). Using 2-wire selections will cause a type 2 alarm (page page 4-7

+24V

Start

Neutral/

Common

Required Parameter Changes

12 13

17 18

12 13

17 18

• Set Digital Input 1:

133 [Digital In1 Sel] = 6 “Run Forward”

• Set Digital Input 2:

134 [Digital In2 Sel] = 7 “Run Reverse”

• No Changes Required.

• No Changes Required

Sourcing Digital Outputs

24V DC external supply

(1)

Refer to the Attention statement on page 1-32 for important bipolar wiring information.

(2)

Important: Programming inputs for 2 wire control deactivates the HIM Start and Jog buttons.

(3)

0-20mA or 4-20mA operation requires that the switch at S9, S10, or S11 be set to the “ON” position or drive damage may occur. Refer to Table 1.L on page 1-33

External

+24V DC

Ready

Fault

Spd Thresh

External Neutral/

Common

• No Changes Required

22 23

27 28

29 30

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1-40 Installation and Wiring

Digital Encoder Terminal Block

The encoder connection cables should always be connected directly to the terminals on the encoder terminal block. The encoder cable must be made up of twisted pairs with the shield connected to the shield ground on the drive side. Do not connect the shield to ground on the motor side. In some cases (i.e., cable lengths that exceed 100 meters), it may be necessary to ground the shield of each twisted pair on the power supply. Refer to

page A-3

Figure 1.33 Digital Encoder Terminal Block Location

for Digital Encoder specifications.

Shield ground

Digital Encoder

terminal block

Table 1.U Digital Encoder Terminal Designations

No. Description

A+ Encoder A Single channel or quadrature A A- Encoder A (NOT)

A+

A-

B+

B-

Z+

Z-

COM

(1)

Selectable via switch S21 on the Control board. Refer to Table 1.L on page 1-33.

(2)

Selectable via switch S20 on the Control board. Refer to Table 1.L on page 1-33.

B+ Encoder B Dual channel quadrature B input B- Encoder B (NOT) Z+ Encoder Z Pulse, marker or registration Z- Encoder Z (NOT) COM +5/12-15V +V +5/12-15V

(1)

DC Return Internal power common

(1)

DC Power

Control EMI Shield

input

(2)

input

Internal power source 200 mA

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Page 53

Figure 1.34 Sample Encoder Wiring

I/O Connection Example Encoder Power –

Internal Drive Power

Internal (drive) +5/12-15V DC, 200mA

(1)

COM

Z-

Z+

B-

B+

A-

A+

+5/12-15V DC (200 mA)

Common

to Shield

Installation and Wiring 1-41

(1)

Encoder Power –External Power Source

Encoder Signal – Single-Ended, Dual Channel

Encoder Signal –Differential, Dual Channel

COM

Z-

Z+

B-

B+

A-

A+

COM

Z-

Z+

B-

B+

A-

A+

COM

Z-

Z+

B-

B+

A-

A+

Common

External

Powe r Supply

to Power

Supply Common

Z NOT

B NOT

A NOT

Shield

to Shield

Z NOT

B NOT

A NOT

(1)

to Shield

(1)

Shield connection is on drive Control EMI shield. Refer to Figure 1.33 on page 1-40.

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1-42 Installation and Wiring

DC Analog Tachometer Terminal Block

Figure 1.35 Analog Tachometer Terminal Block Location

Analog

Tachometer

terminal block

Refer to page A-3 for DC Analog Tachometer specifications.

ATTENTION: The Drive can overspeed if DIP switch S4 is set incorrectly, or the tachometer is wired incorrectly. Failure to

observe this precaution could result in damage to, or destruction of, the equipment.

Table 1.V DC Analog Tachometer Terminal Designations

No. Signal Description

– Negative input – A (Not Used)

−

(1)

Maximum voltage depends on the configuration of DIP switch S4. Refer to DC Analog Tachometer DIP Switch

S4 Example on page 1-34

B C + Positive input

Clockwise rotation = positive Counterclockwise rotation = negative

22.7 / 45.4 / 90.7 / 181.6 /

(1)

302.9V 8 mA max. current

max voltage

I/O and Control Wire Routing

Route all I/O and control wires from through the bottom of the drive, between the bottom front protective cover and the terminal cover (frame A) or plastic covers (frames B and C).

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Chapter 2

Drive Start Up

This chapter describes how to start up the PowerFlex DC drive. The drive is configured at the factory for speed regulation with encoder feedback and independant motor field current regulation with constant current to control the motor from zero to base speed.

If using the LCD HIM (Human Interface Module) to commission the drive, it is recommended that you read Appendix B procedures.

ATTENTION: Power must be applied to the drive to perform the following start-up procedure. Some of the voltages present are at

incoming line potential. To avoid electric shock hazard or damage to equipment, only qualified service personnel should perform the following procedure. Thoroughly read and understand the procedure before beginning. If an event does not occur while performing this procedure, Do Not Proceed. Remove Power including user supplied control voltages. Correct the malfunction before continuing.

before performing these

Important:It is recommended that you uncouple the motor from all loads

at this time, until otherwise directed.

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2-2 Drive Start Up

Drive Start Up Checklist

This checklist contains the major steps required to complete the drive commissioning procedure.

❏ 1. Verify all Drive Configuration Settings - page 2-2

❏ 2. Verify the Power Wiring - page 2-2

❏ 3. Verify the Control and I/O Wiring - page 2-3

❏ 4. Apply Voltage to the Control Circuits - page 2-4

❏ 5. Verify the Control Voltages - page 2-5

❏ 6. Load the Default Settings - page 2-6

❏ 7. Configure the Most Commonly Used Parameters - page 2-6

❏ 8. Tune the Current Regulator - page 2-10

❏ 9. Verify Motor Rotation and Run Feedback Polarity Checks -

page 2-11

❏ 10. Configure the Speed Feedback Parameters - page 2-14

❏ 11. Tune the Speed Regulator - page 2-15

❏ 12. Verify Speed Reference Settings and Drive Operation - page 2-16

Before Applying Power to the Drive

1. Verify all Drive Configuration Settings:

1. With the bottom cover removed from the drive (refer to Removing

the Drive Covers on page 1-7), verify that DIP switch S14 is set

correctly to be ≥ the rated field current specified on the motor nameplate. Refer to Table 1.G on page 1-25

2. Verify all switch settings (S9, S10, and S11) for the analog inputs.

Refer to Table 1.L on page 1-33

3. Verify all DIP switch and jumper settings for the digital encoder or

analog tachometer feedback device. Refer to Table 1.L on

page 1-33 and Figure 1.30 on page 1-34.

ATTENTION: The Drive can overspeed if DIP switch S4 is set incorrectly, or the tachometer is wired incorrectly. Failure to

observe this precaution could result in damage to, or destruction of, the equipment.

2. Verify the Power Wiring:

Verify that the AC line power at the disconnect device is within the rated value of the drive and that all power wiring is correct. Refer to

Power Wiring on page 1-15

for further information.

ATTENTION: Do not connect any external power to the armature output terminals, personal injury and/or equipment

damage can occur.

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Drive Start Up 2-3

3. Verify the Control and I/O Wiring:

1. Verify that control power and I/O wiring is correct. A digital input

(1-8 only) must be wired and configured as a drive enable. Refer to

Control Circuit Input Power on page 1-28 page 1-32 for further information.

2. If you are using a PTC thermistor or thermal switch to protect the

motor from overloading, remove the 1k ohm resistor between terminals 78 and 79. Refer to Thermistors and Thermal Switches on

page 1-25

and I/O Wiring on

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2-4 Drive Start Up

Applying Power to the Drive

The remainder of the “Drive Start Up” procedure in this manual uses a HIM to configure and autotune the drive. If you prefer, you can use the DriveExplorer™ or DriveTools™ SP software parameters or use the drive “Start Up” wizard available with both software packages.

If an operator interface is not available, remote devices should be used to start up the drive. For information on using the HIM, refer to the HIM

Overview on page B-1.

Important:When power is first applied, the HIM may require

approximately 5 seconds until commands are recognized (including the Stop key).

4. Apply Voltage to the Control Circuits:

1. Apply power to the control circuits (terminals U2 and V2) of the

drive. If any of the digital inputs are configured to “Stop/CF” (CF = Clear Fault), “Enable” or “Aux Fault,” verify that signals are present or reconfigure [Digital Inx Sel]. If a fault code appears, refer to Chapter 4 - Troubleshooting on page 4-1

2. If the STS LED is not flashing green at this point, refer to “Drive

Status Indicators” below.

(1)

to program drive

(1)

You must use DriveExplorer v5.02 or higher or DriveTools SP v4.01 or higher with a PowerFlex DC drive specific software patch. The patch can be downloaded from http://www.ab.com/support/abdrives/webupdate/

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Page 59

Figure 2.1 Drive Status Indicators

PORT

MOD

NET A

NET B

Drive Start Up 2-5

➋

STS

# Name Color State Description

STS

➊

(Status)

PORT Refer to the Communication

➋

MOD Status of communications module (when installed). NET A Status of network (if connected). NET B Status of secondary network (if connected).

Green Flashing Drive ready, but not running and no faults are present.

Steady Drive running, no faults are present.

Yellow Flashing,

Drive Stopped

Flashing, Drive Running

Steady, Drive Running

Red Flashing A fault has occurred. Check [Fault x Code] or view the

Steady A non-resettable, non-configurable fault has occurred.

Adapter User Manual.

A condition exists that is preventing the drive from starting. Check parameters 1403 [Start Inhibits] and/or 1380 [Drive Alarm 1].

An intermittent type 1 alarm condition is occurring. Check parameter 1380 [Drive Alarm 1]. Refer to Fault

Descriptions on page 4-4 and/or Alarm Descriptions on page 4-7.

A continuous type 1 alarm condition exists. Check parameter 1380 [Drive Alarm 1]. Refer to Fault

Descriptions on page 4-4 and/or Alarm Descriptions on page 4-7.

Fault Queue on the HIM. Refer to Fault Descriptions on

page 4-4.

Check [Fault x Code] or view the Fault Queue on the HIM. Refer to Fault Descriptions on page 4-4

Status of DPI port internal communications (if present).

➊

5. Verify the Control Voltages:

❏ Verify that the following voltages are present at I/O terminal block

1 and 2. Refer to I/O Signal and Control Wiring on page 1-35

Terminal Number . . . Voltage to Terminal Number . . .

7 +10V 9 8 -10V 9 19 +24 - 30V 18

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2-6 Drive Start Up

6. Load the Default Settings:

It is recommended that you reset the drive to the default settings. By resetting the drive to the default settings, any previous parameter modifications you have made will be overwritten.

1. On the HIM, from the “Main” menu scroll to the “Memory

Storage” menu and press Enter.

2. Scroll to “Reset To Defaults” and press Enter. A message displays

to verify that you want to reset the drive to the factory settings.

3. Press Enter.

Note: A “Params Defaulted” (F48) entry will be made in the drive’s Fault Queue to indicate the change.

7. Configure the Most Commonly Used Parameters:

If your application only requires basic drive parameter set up, you can use the S.M.A.R.T. list screen available on the HIM to program the drive. Refer to Using the S.M.A.R.T. List Screen on page B-2 information.

Important:In order to access all parameters in this procedure you must

set the Parameter View option to “Advanced”.

for more

1. At the Main menu, scroll to the Parameter option and press the ALT

and then Sel button.

2. Scroll to the Numbered List option and press Enter.

3. Type 211 and press Enter.

4. Press the Sel button.

5. Type 1 and press Enter.

6. Press the Esc button.

7. Press the ALT and then Sel button.

8. Scroll to the File-Group-Par option and press Enter.

9. Scroll to the “Motor Control” file and press Enter.

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Drive Start Up 2-7

10. With the “Motor Data” group selected, press Enter and configure

the following parameters:

❏ 45 [Max Ref Speed] - Enter the motor nameplate base speed. If

the application requires field weakening to operate above base speed, enter the maximum reference speed required.

❏ 162 [Max Feedback Spd] - Enter the motor nameplate base

speed. If the application requires field weakening to operate above base speed, enter the maximum feedback speed that could be encountered.

❏ 175 [Rated Motor Volt] - Enter the rated motor nameplate

armature voltage. This value should be the measured armature voltage when the motor is running at base speed with rated field current. This value should represent 100% of the rated armature voltage when field weakening is not used. If field weakening is used, this value should be set to 90% of the rated armature voltage to prevent a possible overvoltage condition when the drive transitions to the field weakening mode.

❏ 179 [Nom Mtr Arm Amps] - Enter the rated motor nameplate

armature current.

❏ 374 [Drv Fld Brdg Cur] - Enter the rated current of the field

bridge regulator to match the value set using the DIP switch S14. Refer to Field Current Resistors on page 1-24

❏ 280 [Nom Mtr Fld Amps] - Enter the rated motor nameplate

field current.

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2-8 Drive Start Up

11. Access the “Field Config” group and configure the following

parameters:

❏ If the motor field power is supplied by an external source, set

Par 497 [Field Reg Enable] = 0 “Disabled”. Otherwise, verify that this parameter is set to 1 “Enabled” (default).

❏ If you are utilizing field economy when the drive is stopped or

at zero speed, set Par 1407 [Field Econ Delay] to the desired amount of time to elapse after the drive stops or reaches zero speed before field economy becomes active (the value set in Par 468 [Min Fld Curr Pct]). The default value is 300 seconds.

❏ Par 469 [Field Mode Sel] - select the desired field mode

(default = 0 “Base Speed”, constant field current):

❍1 “Field Weaken”, field weakening mode

❍2 “External”, power to the field is supplied externally

❏ If you are utilizing field economy at zero speed, set 468 [Min

Fld Curr Pct] to the desired minimum field current for field economy (default = 30%).

❏ If you are operating the drive in field weakening mode, set Par

456 [Fld Weaken Ratio] = Motor nameplate base speed / Par 45 [Max Ref Speed] x 100.

Important:When operating the drive in field weakening mode, it is

necessary to refer to the CEMF value or to the crossover data. If the maximum field current is not within 10% of the maximum value of the internal field converter, configure the current feedback using DIP switch S14. Refer to Field

Current Resistors on page 1-24.

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Drive Start Up 2-9

12. Access the “Utility” file and press Enter.

13. Access the “Alarms” group and configure the following parameters:

❏ Par 481 [UnderVolt Thresh] - Enter the value at which a drive

under voltage condition will be detected (default = 230V).

❏ Par 584 [OverCurrent Thr] - Enter the value at which a drive

over current condition will be detected (default = 175%). The threshold level should be at least 10% above the selected operating current limit (Par 7 [Current Limit]).

14. Access the “Input & Output” file and press Enter.

15. Access the “Analog Inputs” group and configure the following:

❏ If you have connected a potentiometer to analog input 1 for a

speed reference:

❍Verify that Par 70 [Anlg In1 Sel] is set to 1 “Speed Ref A”

(default).

❍Verify that switch S9 and Par 71 [Anlg In1 Config] are

configured to match (voltage versus a current signal). Refer to DIP Switch and Jumper Settings on page 1-32

❍Set Par 72 [Anlg In1 Scale] and Par 74 [Anlg In1 Offset]

appropriately.

❏ If you are using the HIM on the drive cover (Port 1) for the

speed reference, set Par 70 [Anlg In1 Sel] to 0 “Off”.

16. Access the “Digital Inputs” group and configure the following

parameters:

❏ Par 1391 [ContactorControl] - Select the type of contactor(s)

used with the drive: 1 “Contactor” (default, AC input or DC output contactor), 2 “Contactor+DB” (AC input or DC output contactor and dynamic brake contactor), or 0 “None”.

Note: If you select 0 “None” for Par 1391 [ContactorControl], a “CntactrCflct” alarm will display. The alarm will be resolved and automatically clear when you complete the Digital Output configuration below.

Note: If Par 1391 [ContactorControl] is set to 1 or 2, an Auxiliary Status contactor must be wired to a digital input (default for digital input 8).

❏ Par 140 [Digital In8 Sel] - If a contactor is NOT used, set to

other than 31 “Contactor” (e.g., 0 “Not Used”).

❏ If an auxiliary status contactor is wired to a digital input, set the

appropriate [Digital Inx Sel] parameter to 31 “Contactor”.

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2-10 Drive Start Up

17. Access the “Digital Outputs” group and configure the following

parameters:

❏ If a contactor and a dynamic brake resistor is used:

❍Par 629 [Relay Out 2 Sel] = 24 “ContactorDB”.

❏ If a neither a contactor and a dynamic brake resistor is used:

❍Par 629 [Relay Out 2 Sel] = Set to other than 24

“ContactorDB” or 25 “Contactor” (e.g., 0 “Not Used”).

❍Par 1392 [Relay Out 1 Sel] = Set to other than 24

“ContactorDB” or 25 “Contactor” (e.g., 0 “Not Used”).

18. If you are using the HIM on the drive cover (Port 1) for the speed

reference, access the “DPI Inputs” group and set the appropriate [DPI Px Select] parameter to 1“Speed Ref A”.

8. Tune the Current Regulator:

ATTENTION: Prior to tuning the current regulator, you must provide a hard wired maintained external operator accessible

coast/stop push button to disable the machine in case of improper operation. Uncontrolled machine operation can result if this is not done. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: Prior to tuning the current regulator, uncouple the motor from equipment or processes that may be damaged by

incorrect rotation of the motor or speed references.

Complete this test before running the drive for the first time. Upon completing this tuning procedure, the armature resistance value is stored in Par 453 [Arm Resistance] and the armature inductance value is stored in Par 454 [Arm Inductance]. If needed, these values can be manually adjusted.

1. If an external supply is used to power the motor field, disconnect

the wires from the motor field terminals. If the drive supplies power to the motor field, the internal field circuit will automatically be disabled during this test.

Important:The drive must be under at least a 40% load in order to

properly tune the current regulator. Verify that the motor does not start rotating during the Current Regulator tuning test (due to remnant magnetization, field series, etc.). If necessary, mechanically block the motor shaft so it does not turn.

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Drive Start Up 2-11

2. Access the “Motor Control” file, the “Torq Attributes” group and

set Par 7 [Current Limit] to the appropriate level for your application. This parameter defaults to 150%. The drive’s armature output current will correspond to Par 179 [Nom Mtr Arm Amps] x Par 7 [Current Limit].

Note: Par 8 [Current Lim Pos], the drive current limit for the

positive direction and Par 9 [Current Lim Neg], the drive current limit for the negative direction, are set to 150% by default. If necessary, you can change the value of these parameters to suit your application.

3. Access the “Speed Feedback” group and verify that Par 414 [Fdbk

Device Type] is set to 3 “Armature” (default).

4. Press the Esc key until you return to the “File” menu and access Par

452 [CurrReg Autotune] in the “Autotune” group, in the “Motor Control” file, and select 1 “On” and press Enter.

5. Press the Start button on the HIM. This will start the current

regulator auto tuning test, which could take several minutes.

At the end of the test, the drive will automatically be stopped and Par 452 [CurrReg Autotune] will be set to 0 “Off”.

If the value of Par 587 [I Reg Error] is greater than -/+40, refer to

Manually Adjusting the Current Regulator Tune Settings on page C-26

for more information. If a drive fault occurs during the tuning procedure, refer to Fault

Descriptions on page 4-4 for a list of fault descriptions and actions.

9. Verify Motor Rotation and Run Feedback Polarity Checks:

The jog function (on the HIM or terminal block) will be used to check motor direction and encoder operation. If the STS LED is not flashing green at this point, refer to Figure 2.1 on page 2-5

ATTENTION: Prior to running the motor direction and polarity checks, you must provide a hard wired maintained external

operator accessible coast/stop push button to disable the machine in case of improper operation. Uncontrolled machine operation can result if this is not done. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: Prior to running the motor direction and polarity checks, uncouple the motor from equipment or processes that

may be damaged by incorrect rotation of the motor or speed references.

for more information.

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2-12 Drive Start Up

1. When checking motor polarity, the drive will have power applied

and the motor will rotate. Verify that the motor is uncoupled from the load. If the motor cannot be uncoupled from the load, the following motor checks are recommended:

❏ All electrical connections are tight.

❏ The brushes are properly seated.

❏ The motor shaft is free to rotate.

2. Access the “Motor Control” file, “Speed Feedback” group and

verify that Par 414 [Fdbk Device Type] is set to 3 “Armature” (default).

3. Access the “Speed Command” file, “Discrete Speeds” group and

verify that Par 266 [Jog Speed] is set to the default value (100 RPM) or to an acceptable speed level for this test.

4. If analog input 1 is wired, access the “Analog Inputs” group and

verify that the voltage level is 0V in Par 1404 [Analog In1 Value].

5. While viewing Par 233 [Output Voltage], assert a Jog command

6. If the observed rotation direction is incorrect, remove power from

7. Make certain power is turned off and locked out.

8. Switch the armature leads connected to C (+) and D (-).

Figure 2.2 Motor Connections

C1 (+)

C (+)

D (-)

D1 (-)

PowerFlex DC Motor

F1 (+)

F2 (-)

(2)

(via the HIM keypad or digital input on the I/O terminal block) and observe the motor rotation direction. Verify whether or not Par 233 [Output Voltage] is positive.

the drive and continue with step 6 below, while referring to the motor connection diagrams in Figure 2.2

below. If the observed

rotation direction is correct, continue with step 10 below.

C1 (+)

C (+)

D (-)

D1 (-)

PowerFlex DC Motor

F1 (+)

F2 (-)

(2)

Straight Shunt Machine,

CCW Rotation Facing Commutator End

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Straight Shunt Machine,

CW Rotation Facing Commutator End

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Drive Start Up 2-13

9. Apply power to the drive.

10. Repeat steps 4 and 5 above and verify that the motor rotation is

correct.

11. Complete the appropriate procedure based on the type of feedback

device used for the application:

❏ For Armature Voltage feedback - Continue with Step 10

Configure the Speed Feedback Parameters: on page 2-14

❏ For Analog Tachometer feedback - Assert a Jog command and

verify that the sign and value of Par 1408 [Tachometer Speed] corresponds with the actual direction of the motor. If the sign and value of Par 1408 [Tachometer Speed] and the motor direction do not correspond, remove power from the drive and reverse the tachometer connections at the drive. Continue with Step 10 Configure the Speed Feedback Parameters: on

page 2-14.

❏ For Encoder feedback - Assert a Jog command and verify that

the sign and value of Par 420 [Encoder Speed] correspond with the actual direction of the motor. If the sign and value of [Par 420 [Encoder Speed] and the motor direction do not correspond, remove power from the drive and reverse the encoder connections at the drive. Reverse the polarity of only one channel, e.g., B and B NOT. Refer to Table 1.U on

page 1-40 for digital encoder terminal block designations.

Continue with Step 10 Configure the Speed Feedback

Parameters: on page 2-14.

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2-14 Drive Start Up

10. Configure the Speed Feedback Parameters:

1. Access the “Speed Feedback” group and configure the following

parameters:

❏ Par 414 [Fdbk Device Type] - Select the source for motor

velocity feedback: 1 “Encoder”, 2 “DC Tach” or 3 “Armature” (default). If operating the drive in field weakening mode, Par 414 [Fdbk Device Type] must be set to 1 "Encoder" or 2 "DC Tach ".

❏ Par 457 [Spd Fdbk Control] - If you are using an encoder or

tachometer, set this parameter to 1 “Enabled” to activate speed feedback control.

❏ If the speed feedback source is an analog tachometer, set the

fine scaling value in Par 562 [Anlg Tach Gain]. This value is used to scale the analog tachometer feedback signal after it has been conditioned by the drive hardware.

ATTENTION: The drive can overspeed if DIP switch S4 is set incorrectly, or the tach is wired incorrectly.

Failure to observe this precaution could result in damage to the drive or process equipment. Refer to Figure 1.30 on

page 1-34.

❏ If the speed feedback source is a digital encoder, enter the

pulses per revolution from the encoder nameplate in Par 169 [Encoder PPR].

❏ If the speed feedback source is a digital encoder, set Par 652

[Encoder Err Chk] to 1 “Enabled” to activate monitoring of the digital encoder signals (verifies the presence of the A, B, A-, Bsignals). Par 457 [Spd Fdbk Control] must be set to 1 “Enabled” for encoder monitoring to occur. Switch S20 must be set correctly to prevent Encoder faults. Refer to Table 1.L on

page 1-33.

2. Access the “Speed Command” file and press Enter.

3. With the “Limits” group selected, press Enter and configure the

following parameters:

❏ Par 1 [Minimum Speed] - Enter the minimum speed reference

limit.

❏ Par 2 [Maximum Speed] - Enter the maximum speed required

by the application (this can be above the motor base speed if field weakening is used).

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Drive Start Up 2-15

4. Access the “Dynamic Control” file and press Enter.

5. Access the “Ramp Rates” group and configure the following

parameters:

❏ Par 660 [Accel Time 1] - Set the desired acceleration ramp

time.

❏ Par 662 [Decel Time 1] - Set the desired deceleration ramp

time.

11. Tune the Speed Regulator:

The speed regulator auto tuning test detects the total inertia value of the motor shaft (in Kg-m proportional (P) and integral (I) gains of the speed regulator.

Important:The test is carried out by using the torque limit value set in

Important:In applications where the system total inertia value is very

), the friction value (in N-m) and the calculation of the

ATTENTION: This test requires the free rotation of the motor shaft combined with the load. The auto tuning test of the speed loop cannot be carried out on machines with a limited stroke.

the Par 1048 [Autotune Cur Lim] (recommended value = 20%). The torque reference is applied via a step reference (without a ramp); therefore there must not be any “backlash” in the mechanical transmission and it must be compatible with those operations using the torque limit value set in the Par 1048 [Autotune Cur Lim]. You can modify the torque limit value via this parameter.

high, it is necessary to increase the value of Par 1048 [Autotune Cur Lim] in order to avoid “Time out” errors. The speed regulator auto tuning test of the speed loop is not suitable for drives used in “elevator” and/or lifting system applications.

1. While still in the “Autotune” group, configure the motor shaft

rotation direction via Par 1029 [Speed Tune Dir]; 1 “Forward” = clockwise or 2 “Reverse” = counter-clockwise, with reference to the motor commutator end.

2. Select the Par 1027 [Spd Reg Autotune], enter “1” and press Enter.

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2-16 Drive Start Up

3. Press the Start button on the HIM. This will start the speed regulator

auto tuning test, which could take several minutes. When the test has been completed, the drive will automatically stop.

During the test the following are completed:

❏ An acceleration test, with the torque limit value set in the Par

1048 [Autotune Cur Lim].

❏ A deceleration test, with a lower torque limit value applied,

until zero speed has been reached.

❏ Par 1013 [Torque Const] is calculated and updated based on the

entered motor data.

The test threshold speed is 33% of the lowest value set in the following Pars:

❏ 45 [Max Ref Speed]

❏ 3 [Max Speed Fwd] or 4 [Max Speed Rev] based on the rotation

direction chosen in Par 1029 [Speed Tune Dir]

The drive will determine the speed loop gains (Pars 87 [Spd Reg Kp] and 88 [Spd Reg Ki]) based on the motor and load inertia and friction characteristics.

If any fault occur during the test, refer to Auto Tuning Faults on

page 2-17 for a description and more information.

Note: If any manual adjustments are required (due to vibrations,

etc.), these should be carried out according to the value of the integral gain Par 88 [Spd Reg Ki]. If the speed regulator auto tuning test does not provide satisfactory results, refer to Fine Tuning the Regulators on page C-25

The values determined by the Speed Regulator tuning tests are updated in Pars 87 [Spd Reg Kp], 88 [Spd Reg Ki], 1014 [Inertia] and 1015 [Friction] and displayed in the corresponding Pars 1032 [Speed Tune Kp], 1033 [Speed Tune Ki], 1030 [Spd Tune Inertia] and 1031 [SpdTune Friction], respectively. The values of Pars 1030 - 1033 can be used as a record of the Speed Regulator auto tuning results if the values of Pars 87, 88, 1014 and 1015 are subsequently changed.

12. Verify Speed Reference Settings and Drive Operation:

Verify the following speed and direction (for four quadrant drives) references of the drive under a load.

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

ATTENTION: This test requires the free rotation of the motor shaft combined with the load. All of the steps in the “Drive Start Up” procedure must have been completed before completing this step.

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Drive Start Up 2-17

1. Set the speed reference to “0” (zero) using the assigned source

(HIM or analog potentiometer). Refer to Reference Control on

page C-13 for more information on speed reference sources.

2. View Par 385 [Speed Ref Out] and verify that the value is “0”.

3. Press the Start button on the HIM and slowly increase the speed

reference until full speed is reached (viewed in Par 385 [Speed Ref Out] ).

4. If using a four quadrant (regenerative) drive, press the Direction

button on the HIM and verify that the motor ramps down to “0” speed and then to full speed in the opposite direction.

5. Press the Stop button on the HIM and verify that the drive ramps to

“0” speed and stops.

Auto Tuning Faults

Following is a list of faults that may display during the speed regulator auto tuning test. In some cases, the drive’s control circuits may detect a value(s) that is out of range for the configuration settings during the speed regulator auto tuning test. In these cases, make the suggested adjustments and repeat the test. If the fault occurs again, complete the

Fine Tuning the Regulators

Fault No. Description Action

STune Overspeed

STune Stalled 57 The drive stalled during the

STune LoadHi 58 The loading torque value is too

STune CurLimit 59 The value of Par 1048 [Autotune

STune FrictionLo 60 The friction value attained during

STune Timeout 61 The speed regulator auto tuning

STune Aborted 62 The speed regulator auto tuning

56 The measured motor speed is

too high during the speed regulator auto tuning procedure.

speed regulator auto tuning procedure.

high at zero speed to complete the speed regulator auto tuning procedure.

Cur Lim] for auto tuning the speed regulator is set too high.

the auto tuning procedure is zero or lower than the control precision limit.

procedure did not complete within the available time.

procedure has been stopped by the user.

procedures beginning on page C-25.

Decrease the value of Par 1048 [Autotune Cur Lim] and repeat the auto tune procedure.

Increase the value of Par 1048 [Autotune Cur Lim] and repeat the auto tune procedure.

Decrease the load torque, where applicable, and repeat the auto tune procedure.

Decrease the value of Par 1048 [Autotune Cur Lim] and repeat the auto tune procedure.

Verify the value in Par 1048 [Autotune Cur Lim]. If this value is set to low, the motor will not be able to reach a maximum speed of 33% of the lower of the values in Par 45 [Max Ref Speed] or Par 3 [Max Speed Fwd] or Par 4 [Max Speed Rev] and not be able to complete the test. Set these values appropriately and repeat the auto tuning procedure.

Informational only.

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2-18 Drive Start Up

For additional regulator fine tuning procedures, refer to Fine Tuning the

Regulators on page C-25.

Speed-Up Function

Oscillation may occur during a speed change with loads presenting a high moment of inertia. These oscillations can be reduced by enabling the “Speed Up” function. Refer to Speed Up Function on page C-20 information.

Configuring the Speed Zero Logic

The speed zero logic is factory set to 0 “Disabled”. Refer to Speed Zero

Function on page C-22 for more information.

Adaptive Speed Regulation

for more

The adaptive function of the speed regulator is factory set to 0 “Disabled”. It should only be used when the gain of the speed regulator must go higher than the speed range. For instructions on configuring these parameters refer to Adaptive Speed Regulator on page C-17

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Chapter 3

Programming and Parameters

This chapter provides a complete listing and description of the PowerFlex DC drive parameters. The parameters can be programmed (viewed/edited) using a Human Interface Module (HIM). As an alternative, programming can also be performed using DriveExplorer™ or DriveTools™ SP software description of the LCD HIM. Refer to Appendix D diagrams.

For information on . . . See page . . .

About Parameters How Parameters are Organized 3-3 Monitor File 3-11 Motor Control File 3-14 Speed Command File 3-23 Dynamic Control File 3-29 Applications File 3-34 Utility File 3-46 Communications File 3-58 Input / Output File 3-62 Parameter Cross Reference – by Name 3-72 Parameter Cross Reference – by Number 3-77

(1)

and a personal computer. Refer to Appendix B for a brief

for drive control block

3-1

About Parameters

To configure a drive to operate in a specific way, certain parameters may need to be changed from the default value. Three types of parameters exist:

• ENUM Parameters

ENUM parameters allow a selection from two or more items. The LCD HIM will display a text message for each item.

• Bit Parameters

Bit parameters have individual bits associated with features or conditions. If the bit is “0”, the feature is off or the condition is false. If the bit is “1”, the feature is on or the condition is true.

• Numeric Parameters

These parameters have a single numerical value and unit (i.e. 0.1 Volts).

The example on the following page shows how each parameter type is presented in this manual.

(1)

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3-2 Programming and Parameters

➊➌➋➏➎➍

File

SPEED COMMAND

Group

Speed Regulator

Parameter Name & Description Values

No.

388 [Flying Start En]

Enables/Disables the ability of the drive to connect to a

spinning motor at actual RPM when a start command is issued.

• “Enabled” = When the drive is turned on, the speed of the

motor is measured and the ramp output is set accordingly. The drive then runs at the set reference value.

• “Disabled” = When the drive is turned on, the ramp starts

from zero. Main uses:

•To connect to a motor that is already spinning due to its

load (e.g. in the case of pumps, the flowing medium).

•Re–connection to a spinning motor after a fault or alarm.

Note: If the Flying Start function is disabled, ensure that the motor is not spinning when the drive is turned on, or harsh motor deceleration in current limit may occur.

445 [Spd Up Gain Pct]

The Speed Up function gain as a percentage of Par 446

[Speed Up Base].

591 [Logic Mask]

Determines which ports can control the drive when Par 1377 [Write Mask Act], bit 15 is set to “1.” If the bit for a port is set to “0,” the port will have no control functions except for stop. 0 = Control Masked, 1 = Control Permitted, x = Reserved.

Default:

Options:

Default:

Min/Max: Units:

0 =

“Disabled”

0 =

“Disabled”

1 =

“Enabled”

0.00

0.00 / 100.00 %

1377

Masks & Owners

COMMUNICATIONS

No. Description

➊ ➋ ➌

➍ ➎

➏

File – Lists the major parameter file category.

Group – Lists the parameter group within a file.

No. – Parameter number. = The parameter is only accessible when Par 211 [Param Access Lvl] = 1 “Advanced”.

= The parameter value cannot be changed until the drive is stopped.

Parameter Name & Description – Parameter name as it appears on an LCD HIM, with a brief description of the parameters function.

Value s – Defines the various operating characteristics of the parameter. Three types exist. ENUM Default:

Bit Bit: Lists the bit place holder and definition for each bit. Numeric Default:

Related – Lists parameters (if any) that interact with the selected parameter. The symbol “ ” indicates that additional parameter

information is available in Appendix C - Application Notes on page C-1

Reserved

DPI Port 5

DPI Port 4

DPI Port 3

DPI Port 2

DPI Port 1

Default

Bit

xxxxxxxxxx000011 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Digital In

Lists the value assigned at the factory. “Read Only” = no default.

Options:

Min/Max: Units:

Important: Some parameters will have two unit values:

• E.g.: Analog inputs can be set for current or voltage as with Par 71 [Anlg Inx Config].

Important: When sending values through DPI ports, simply remove the decimal point to arrive at the correct value (i.e. to send “5.00 RPM”, use “500”).

Displays the programming selections available.

Lists the value assigned at the factory. “Read Only” = no default.

The range (lowest and highest setting) possible for the parameter. Unit of measure and resolution as shown on the LCD HIM.

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Programming and Parameters 3-3

How Parameters are Organized

The LCD HIM displays parameters in a File–Group–Parameter or Numbered List view order. To switch display mode, access the Main Menu, press ALT,

then Sel (View) while the cursor is on the Parameter menu selection. In addition, using Par 211 [Param Access Lvl] the most commonly used parameters (Basic Parameter view) or all parameters (Advanced Parameter View).

File–Group–Parameter Order

This simplifies programming by grouping parameters that are used for similar functions. The parameters are organized into files. Each file is divided into groups, and each parameter is an element in a group. By default, the LCD HIM displays parameters by File–Group–Parameter view.

Numbered List View

All parameters are in numerical order.

Cross Reference Tables

Refer to Parameter Cross Reference – by Name on page 3-72 and Parameter

Cross Reference – by Number on page 3-77 for a list of parameters and

page numbers.

, you have the option to display

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3-4 Programming and Parameters

Basic Parameter View

Parameter 211 [Param Access Lvl] set to option 0 “Basic”.

File Group Parameters Monitor Speed Meters

Monitor

Current Meters

Drive Data

Motor Control Motor Data

Motor Control

Field Config

Torq Attributes

Speed Feedback

Autotune

Speed Command Limits

Speed Command

Discrete Speeds

Speed References

Speed Regulator

Dynamic Control Ramp Rates

Dynamic Control

Restart Modes

[Speed Ref A] 44 [Speed Ref A Pct] 47 [Speed Ref B] 48 [Speed Ref B Pct] 49 [Speed Ref Out] 385 [Spd Ref Out Pct] 384 [Ramp In] 110

[Spd Reg Out Pct] 236 [Current Reg In] 41 [Arm Current] 200 [Arm Current Pct] 199

[FaultCode] 57 [AC Line Voltage] 466 [AC Line Freq] 588

[Max Ref Speed] 45 [Max Feedback Spd] 162

[Field Reg Enable] 497 [Field Economy En] 499 [Field Econ Delay] 1407

[Current Limit] 7 [Current Lim Pos] 8 [Current Lim Neg] 9

[Fdbk Device Type] 414 [Anlg Tach Gain] 562

[Autotune Cur Lim] 1048 [CurrReg Autotune] 452 [Arm Resistance] 453 [Arm Inductance] 454

[Minimum Speed] 1 [Min Speed Fwd] 5

[Jog Speed] 266 [Jog Off Delay] 1409 [Preset Speed 1] 154 [Preset Speed 2] 155

[Trim Ramp] 42 [Trim Ramp Pct] 378

[Speed Reg En] 242 [Arm Volt Kp] 493

[Speed Ramp En] 245 [Ramp Type Select] 18 [Accel Time 1] 660 [Decel Time 1] 662

[Start At Powerup] 1344 [Powerup Delay] 1345

[Ramp In Pct] 111 [Ramp Out] 113 [Ramp Out Pct] 114 [Speed Draw Out] 1018 [Spd Draw Out Pct] 1019 [Speed Reg In] 118 [Speed Reg In Pct] 117

[Field Current] 351 [Fld Current Pct] 234 [Cur Lim Pos Out] 10 [Cur Lim Neg Out] 11

[Output Voltage] 233 [Output Power] 1052 [Drive Type] 300

[Rated Motor Volt] 175 [Nom Mtr Arm Amps] 179

[Field Mode Sel] 469 [Max Fld Curr Pct] 467 [Min Fld Curr Pct] 468

[Torque Ref] 39 [Trim Torque] 40 [Torque Reduction] 342

[Anlg Tach Zero] 563 [Spd Fdbk Control] 457

[Spd Reg Autotune] 1027 [Speed Tune Dir] 1029 [Speed Tune Kp] 1032 [Speed Tune Ki] 1033

[Min Speed Rev] 6 [Maximum Speed] 2

[Preset Speed 3] 156 [Preset Speed 4] 157 [Preset Speed 5] 158 [Preset Speed 6] 159

[Trim Speed] 43 [Trim Speed Pct] 379

[Spd Reg Kp] 87 [Arm Volt Ki] 494

[Accel Time 2] 24 [Decel Time 2] 32 [MOP Accel Time] 22 [MOP Decel Time] 30

[Spd Feedback] 122 [Spd Feedback Pct] 121 [Actual Speed] 924 [Encoder Speed] 420 [Tachometer Speed] 1408

[Filt TorqCur Pct] 928 [Field Ref Pct] 500

[Drive Size] 465 [Elapsed Lifetime] 235 [Software Version] 331

[Nom Mtr Fld Amps] 280 [Drv Fld Brdg Cur] 374

[Fld Weaken Ratio] 456

[Zero Torque] 353

[SpdReg FB Bypass] 458

[Spd Tune Inertia] 1030 [SpdTune Friction] 1031

[Max Speed Fwd] 3 [Max Speed Rev] 4

[Preset Speed 7] 160 [TB Manual Ref] 267

[Speed Ratio] 1017

[Spd Reg Ki] 88

[Jog Ramp Time] 1410 [S Curve Time] 19

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File Group Parameters Utility Reference Config

Utility

Drive Memory Diagnostics

Faults

Alarms

Communications Comm Control

Communication

Masks & Owners

Datalinks

Input / Output Analog Inputs

Inputs / Outputs

Analog Outputs

Digital Inputs

Digital Outputs

DPI Inputs

[Direction Mode] 1322 [Save HIM Ref] 209

[Param Access Lvl] 211 [Reset Defaults] 258

[Drive Status 1] 381 [Drive Status 2] 382 [Last Stop Source] 1402

[Clear Fault Que] 263 [Fault Clear] 1347 [Fault Clr Mode] 1348 [Status1 at Fault] 1349

[Drive Alarm 1] 1380

[DPI Baud Rate] 589 [DPI Port Sel] 590

[Logic Mask] 591 [Start Mask] 592 [Jog Mask] 593 [Direction Mask] 594 [Reference Mask] 595 [Accel Mask] 596 [Fault Clr Mask] 597

[Data In A1] 610 [Data In A2] 611 [Data In B1] 612 [Data In B2] 613 [Data In C1] 614 [Data In C2] 615

[Anlg In1 Sel] 70 [Anlg In1 Config] 71 [Anlg In2 Sel] 75 [Anlg In2 Config] 76 [Anlg In3 Sel] 80 [Anlg In3 Config] 81

[Anlg Out1 Sel] 66 [Anlg Out2 Sel] 67 [Anlg Out3 Sel] 68

[Dig In Status] 564 [Digital In1 Sel] 133 [Digital In2 Sel] 134 [Digital In3 Sel] 135 [Digital In4 Sel] 136 [Digital In5 Sel] 137 [Digital In6 Sel] 138 [Digital In7 Sel] 139 [Digital In8 Sel] 140

[Dig Out Status] 581 [Digital Out1 Sel] 145 [Digital Out2 Sel] 146 [Digital Out3 Sel] 147

[DPI P1 Select] 1323 [DPI P2 Select] 1324

Programming and Parameters 3-5

[Man Ref Preload] 210 [Save MOP Ref] 249

[Start Inhibits] 1403 [Drive Logic Rslt] 1328 [At Speed] 394

[Status2 at Fault] 1350 [Fault Arm Amps] 1371 [Fault Speed] 1372 [Fault Field Amps] 1373

[DPI Fdbk Select] 1321 [DPI Port Value] 1343

[MOP Mask] 598 [Local Mask] 599 [Decel Mask] 631 [Stop Owner] 600 [Start Owner] 601 [Jog Owner] 602 [Direction Owner] 603

[Data In D1] 616 [Data In D2] 617 [Data Out A1] 618 [Data Out A2] 619 [Data Out B1] 620 [Data Out B2] 621

[Anlg In1 Target] 295 [Anlg In2 Target] 296 [Anlg In3 Target] 297 [Anlg In1 Cmp] 1042 [Anlg In1 Cmp Err] 1043 [Anlg In1 Cmp Dly] 1044

[Anlg Out4 Sel] 69 [Analog Out1 Scale] 62 [Analog Out2 Scale] 63

[Digital In9 Sel] 141 [Digital In10 Sel] 142 [Digital In11 Sel] 143 [Digital In12 Sel] 144 [Dig In Term 1] 565 [Dig In Term 2] 566 [Dig In Term 3] 567 [Dig In Term 4] 568 [Dig In Term 5] 569

[Digital Out4 Sel] 148 [Digital Out5 Sel] 149 [Digital Out6 Sel] 150 [Digital Out7 Sel] 151

[DPI P3 Select] 1325 [DPI P4 Select] 1326

[MOP Select] 1375

[At Zero Speed] 395 [CurrLimit Active] 349 [Spd Limit Active] 372

[Fault Voltage] 1374 [Fault 1 Code] 1351

[Reference Owner] 604 [Accel Owner] 605 [Fault Clr Owner] 606 [MOP Owner] 607 [Local Owner] 608 [Decel Owner] 609

[Data Out C1] 622 [Data Out C1] 623 [Data Out D1] 624 [Data Out D2] 625 [Data In Val Sel] 1319 [Data In SelData] 1320

[Anlg In1 Cmp Eq] 1045 [Analog In1 Value] 1404 [Analog In2 Value] 1405 [Analog In3 Value] 1406

[Analog Out3 Scale] 64 [Analog Out4 Scale] 65

[Dig In Term 6] 570 [Dig In Term 7] 571 [Dig In Term 8] 572 [Dig In Term 9] 573 [Dig In Term 10] 574 [Dig In Term 11] 575 [Dig In Term 12] 576

[Digital Out8 Sel] 152 [Relay Out 1 Sel] 1392 [Relay Out 2 Sel] 629

[DPI P5 Select] 1327

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

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3-6 Programming and Parameters

Advanced Parameter View

Parameter 211 [Param Access Lvl] set to option 1 “Advanced”.

File Group Parameters Monitor Speed Meters

Monitor

Current Meters

Drive Data

Motor Control Motor Data

Motor Control

Field Config

Torq Attributes

Speed Feedback

Autotune

Test Generator

Speed Command Limits

Speed Command

Discrete Speeds

Speed References

Speed Regulator

[Speed Ref A] 44 [Speed Ref A Pct] 47 [Speed Ref B] 48 [Speed Ref B Pct] 49 [Speed Ref Out] 385 [Spd Ref Out Pct] 384 [Ramp In] 110

[Spd Reg Out Pct] 236 [Current Reg In] 41 [Arm Current] 200 [Arm Current Pct] 199

[FaultCode] 57 [AC Line Voltage] 466 [AC Line Freq] 588

[Max Ref Speed] 45 [Max Feedback Spd] 162 [Rated Motor Volt] 175

[Field Reg Enable] 497 [Field Economy En] 499 [Field Econ Delay] 1407 [Field Mode Sel] 469 [Max Fld Curr Pct] 467 [Min Fld Curr Pct] 468

[Current Limit] 7 [Current Lim Pos] 8 [Current Lim Neg] 9 [Torque Ref] 39 [Trim Torque] 40

[Fdbk Device Type] 414 [Anlg Tach Gain] 562 [Anlg Tach Zero] 563 [Spd Fdbk Control] 457 [SpdReg FB Bypass] 458

[Autotune Cur Lim] 1048 [CurrReg Autotune] 452 [Arm Resistance] 453 [Arm Inductance] 454 [Spd Reg Autotune] 1027

[TstGen Output] 58 [TstGen Frequency] 59

[Minimum Speed] 1 [Min Speed Fwd] 5

[Jog Speed] 266 [Jog Off Delay] 1409 [Preset Speed 1] 154 [Preset Speed 2] 155

[Trim Ramp] 42 [Trim Ramp Pct] 378

[Speed Reg En] 242 [Arm Volt Kp] 493 [Arm Volt Ki] 494 [Spd Reg Kp] 87 [Spd Reg Ki] 88 [Arm Volt Kp Base] 495 [Arm Volt Ki Base] 496 [Spd Reg Kp Base] 93 [Spd Reg Ki Base] 94 [Spd Reg Kp Outpt] 99 [Spd Reg Ki Outpt] 100 [Speed Thresh Pos] 101

[Ramp In Pct] 111 [Ramp Out] 113 [Ramp Out Pct] 114 [Speed Draw Out] 1018 [Spd Draw Out Pct] 1019 [Speed Reg In] 118 [Speed Reg In Pct] 117

[Field Current] 351 [Fld Current Pct] 234 [Cur Lim Pos Out] 10 [Cur Lim Neg Out] 11

[Output Voltage] 233 [Output Power] 1052 [Drive Type] 300

[Nom Mtr Arm Amps] 179 [Nom Mtr Fld Amps] 280 [Drv Fld Brdg Cur] 374

[Fld Weaken Ratio] 456 [Fld Reg Kp] 91 [Fld Reg Ki] 92 [Force Min Field] 498 [Out Volt Level] 921 [Fld Reg Kp Base] 97

[Torque Reduction] 342 [Zero Torque] 353 [TrqTpr_Enable] 750 [TrqTpr_Lim0] 751 [TrqTpr_Lim1] 752

[Spd Fdbk Error] 455 [Act Spd Filter] 923 [Encoder PPR] 169 [Encoder Out Sel] 1021 [Encoder Err Chk] 652

[Speed Tune Dir] 1029 [Speed Tune Kp] 1032 [Speed Tune Ki] 1033 [Spd Tune Inertia] 1030 [SpdTune Friction] 1031

[TstGen Amplitude] 60 [TstGen Offset] 61

[Min Speed Rev] 6 [Maximum Speed] 2

[Preset Speed 3] 156 [Preset Speed 4] 157 [Preset Speed 5] 158 [Preset Speed 6] 159

[Trim Speed] 43 [Trim Speed Pct] 379

[Speed Thresh Neg] 102 [Threshold Delay] 103 [At Speed Error] 104 [At Speed Delay] 105 [Ref Zero Level] 106 [Speed Zero Level] 107 [Speed Zero Delay] 108 [Spd Zero I En] 123 [Spd Ref Zero En] 124 [Spd Zero P En] 125 [Spd Zero P Gain] 126 [Lock Speed Integ] 348

[Spd Feedback] 122 [Spd Feedback Pct] 121 [Actual Speed] 924 [Encoder Speed] 420 [Tachometer Speed] 1408

[Filt TorqCur Pct] 928 [Field Ref Pct] 500

[Drive Size] 465 [Elapsed Lifetime] 235 [Software Version] 331

[Drive Type Sel] 201

[Fld Reg Ki Base] 98 [Set Fld Curve] 919 [Reset Fld Curve] 920 [Fld Const 40 Pct] 916 [Fld Const 70 Pct] 917 [Fld Const 90 Pct] 918

[TrqTpr_Lim2] 753 [TrqTpr_Lim3] 754 [TrqTpr_Lim4] 755 [TrqTpr_Spd] 756 [Filt Torq Cur] 926

[Z Channel Enable] 911 [Z Capture Pos En] 912 [Z Captured Pos] 913

[I Reg Error] 587 [Inertia C Filter] 1012 [Torque Const] 1013 [Inertia] 1014 [Friction] 1015

[Max Speed Fwd] 3 [Max Speed Rev] 4

[Preset Speed 7] 160 [TB Manual Ref] 267

[Speed Ratio] 1017

[Flying Start En] 388 [Spd Fdbk Filter] 444 [Spd Up Gain Pct] 445 [Speed Up Base] 446 [Speed Up Filter] 447 [SpdReg Kp Bypass] 459 [SpdReg Ki Bypass] 460 [SpdFuncSelect] 1016 [InertiaCompAct] 1191 [InertiaCompVar] 1192

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Page 79

File Group Parameters Dynamic Control Ramp Rates

Dynamic Control

Load Limits

Stop Modes

Restart Modes Adaptv Regulator

[Speed Ramp En] 245 [Ramp Type Select] 18 [Accel Time 1] 660 [Decel Time 1] 662 [Accel Time 2] 24 [Decel Time 2] 32 [MOP Accel Time] 22

[Enable Droop 699 [Droop Percent] 696 [Droop Filter] 697

[Fast Stop Time] 38 [Spd 0 Trip Delay] 627

[Start At Powerup] 1344 [Powerup Delay] 1345 [Adaptive Spd En] 181

[Adaptive Reg Typ] 182 [Adaptive Ref] 183 [Adaptive Spd 1] 184 [Adaptive Spd 2] 185

[MOP Decel Time] 30 [Jog Ramp Time] 1410 [S Curve Time] 19 [S Curve Accel 1] 665 [S Curve Decel 1] 666 [S Curve Accel 2] 667 [S Curve Decel 2] 668

[Droop Limit] 700 [Load Comp] 698 [Torq Red CurLim] 13

[Closing Speed] 1262 [Opening Delay] 1263

[Adaptive Joint 1] 186 [Adaptive Joint 2] 187 [Adaptive P Gain1] 188 [Adaptive I Gain1] 189 [Adaptive P Gain2] 190

Programming and Parameters 3-7

[Ramp Delay] 20 [Zero Ramp Output] 344 [Zero Ramp Input] 345 [Freeze Ramp] 373 [Acc Dec Filter] 1212

[Torq Limit Type] 715

[Ramp In Zero En] 1265 [Actuator Delay] 1266

[Adaptive I Gain2] 191 [Adaptive P Gain3] 192 [Adaptive I Gain3] 193

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3-8 Programming and Parameters

File Group Parameters Applications PI Control

Applications

PD Control

PID Control

Scale Blocks

Diameter Calc

Winder Functions

[Enable PI] 769 [PI Steady Thrsh] 695 [PI Integral Gain] 764 [PI Prop Gain PID] 765 [PI Output] 771

[Enable PD] 770 [PD Output PID] 421 [PD Deriv Gain 1] 766

[Enable PID] 1258 [Real FF PID] 418 [PID Steady Delay] 731 [PI Init Intgl Gn] 734 [PID Clamp] 757 [Feed Fwd PID] 758 [PID Error] 759

[Scale1 Input] 484 [Scale1 Output] 485 [Scale1 Mul] 486 [Scale1 Div] 487 [Scale1 In Max] 488 [Scale1 In Min] 489 [Scale1 In Off] 490 [Scale1 Out Off] 491 [Scale1 In Abs] 492 [Scale2 Input] 553 [Scale2 Output] 554 [Scale2 Mul] 555 [Scale2 Div] 556 [Scale2 In Max] 557 [Scale2 In Min] 558 [Scale2 In Off] 559 [Scale2 Out Off] 560 [Scale2 In Abs] 561

[Diameter Calc] 794 [DncrPosSpd] 795 [Max Deviation] 796 [Gear Box Ratio] 797 [Dancer Constant] 798 [Minimum Diameter] 799 [Diameter Calc St] 800 [Max Diameter] 1153 [Roll Diameter] 1154

[Variable J Comp] 1171 [Constant J Comp] 1172 [Materl Width Pct] 1173 [Static Friction] 1174 [Dynamic Friction] 1175 [Taper Enable] 1176 [Initial Diameter] 1177 [Final Diameter] 1178 [Tension Reduct] 1179 [Tension Ref] 1180 [Tension Scale] 1181 [Time AccDec Min] 1182 [Int Acc Calc En] 1183 [Line Accel Pct] 1184 [Line Decel Pct] 1185

[PI Central v1] 776 [PI Central v2] 777 [PI Central v3] 778 [PI Central v sel] 779 [PI Central vs0] 780

[PD Deriv Filter] 767 [PD Prop Gain 1] 768 [PD Prop Gain 2] 788

[PID Setpoint 0] 760 [PID Setpoint 1] 761 [PID Setpoint Sel] 762 [PID Feedback] 763 [PID Output Sign] 772 [PID Output Scale] 773 [PID Output] 774

[Scale3 Input] 1218 [Scale3 Output] 1219 [Scale3 Mul] 1220 [Scale3 Div] 1221 [Scale3 In Max] 1222 [Scale3 In Min] 1223 [Scale3 In Off] 1224 [Scale3 Out Off] 1225 [Scale3 In Abs] 1226 [Scale4 Input] 1227 [Scale4 Output] 1228 [Scale4 Mul] 1229 [Scale4 Div] 1230 [Scale4 In Max] 1231 [Scale4 In Min] 1232 [Scale4 In Off] 1233 [Scale4 Out Off] 1234 [Scale4 In Abs] 1235

[Line Spd Thresh] 1155 [Line Spd Gain] 1156 [Diameter Reset] 1157 [Diam Threshold] 1158 [Diameter Reached] 1159 [Line Speed Pct] 1160 [Diam Calc Dis] 1161 [Diameter Filter] 1162 [Base Omega] 1163

[Line FastStp Pct] 1186 [Winder Type] 1187 [Torq Current Pct] 1193 [Act Ten Ref Pct] 1194 [Speed Match] 1195 [Spd Match Acc] 1196 [Spd Match Dec] 1197 [Offs Accel Time] 1198 [W Offset] 1199 [Spd Match Gain] 1200 [Winder Side] 1201 [W Gain] 1202 [Spd Match Compl] 1203 [Line Spd Source] 1204 [Close Loop Comp] 1208

[PI Central vs1] 781 [PI integr freeze] 783 [PI Upper Limit] 784 [PI Lower Limit] 785 [PI Init Prop Gn] 793

[PD Deriv Gain 2] 789 [PD Prop Gain 3] 790 [PD Deriv Gain 3] 791

[PID Target] 782 [PID Source] 786 [PID Source Gain] 787 [PID Accel Time] 1046 [PID Decel Time] 1047 [PID Error Gain] 1254

[Scale5 Input] 1236 [Scale5 Output] 1237 [Scale5 Mul] 1238 [Scale5 Div] 1239 [Scale5 In Max] 1240 [Scale5 In Min] 1241 [Scale5 In Off] 1242 [Scale5 Out Off] 1243 [Scale5 In Abs] 1244 [Scale6 Input] 1245 [Scale6 Output] 1246 [Scale6 Mul] 1247 [Scale6 Div] 1248 [Scale6 In Max] 1249 [Scale6 In Min] 1250 [Scale6 In Off] 1251 [Scale6 Out Off] 1252 [Scale6 In Abs] 1253

[Diam Preset 0] 1164 [Diam Preset 1] 1165 [Diam Preset 2] 1166 [Diam Preset 3] 1167 [Diam Preset Sel] 1168 [Diam Inc Dec En] 1205 [Diam init filter 1206 [Diam stdy delay] 1207

[Torque Winder En] 1209 [W Target] 1210 [Actual Comp] 1213 [Closed Loop En] 1214 [Speed Demand En] 1215 [Spd match torque] 1216 [W Reference] 1217 [Jog TW Speed] 1255 [Jog TW Enable] 1256 [Ref Spd Source] 1284 [Ref Speed Gain] 1285 [Ref Line Speed] 1286 [Static F Zero] 1287

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

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File Group Parameters Utility Reference Config

Utility

Drive Memory Diagnostics

Faults

Alarms

User Defined

Communications Comm Control

Communication

Masks & Owners

Datalinks

Security

[Direction Mode] 1322 [Save HIM Ref] 209

[Param Access Lvl] 211 [Reset Defaults] 258 [Drive Status 1] 381

[Drive Status 2] 382 [Last Stop Source] 1402 [Start Inhibits] 1403 [Drive Logic Rslt] 1328 [At Speed] 394 [At Zero Speed] 395 [CurrLimit Active] 349 [Spd Limit Active] 372 [Speed Threshold] 393

[Clear Fault Que] 263 [Fault Clear] 1347 [Fault Clr Mode] 1348 [Status1 at Fault] 1349 [Status2 at Fault] 1350 [Fault Arm Amps] 1371 [Fault Speed] 1372 [Fault Field Amps] 1373 [Fault Voltage] 1374 [Fault 1 Code] 1351

[Drive Alarm 1] 1380 [OverVolt Flt Cfg] 203 [Aux Inp Flt Cfg] 354

[UsrDsplyMult0] 50 [UsrDsplyDiv0] 51 [UsrValMult1] 53 [UsrValDiv1] 54 [UserDefined0] 503 [UserDefined1] 504 [UserDefined2] 505 [UserDefined3] 506 [UserDefined4] 507 [UserDefined5] 508 [UserDefined6] 509 [UserDefined7] 510 [UserDefined8] 511 [UserDefined9] 512 [UserDefined10] 513 [UserDefined11] 514 [UserDefined12] 515 [UserDefined13] 516

[DPI Baud Rate] 589 [DPI Port Sel] 590

[Logic Mask] 591 [Start Mask] 592 [Jog Mask] 593 [Direction Mask] 594 [Reference Mask] 595 [Accel Mask] 596 [Fault Clr Mask] 597

[Data In A1] 610 [Data In A2] 611 [Data In B1] 612 [Data In B2] 613 [Data In C1] 614 [Data In C2] 615

[Logic Mask] 591 [Logic Mask Act] 1376

Programming and Parameters 3-9

[Man Ref Preload] 210 [Save MOP Ref] 249

[Torque Positive] 346 [Torque Negative] 347 [MOP Inc Active] 396 [MOP Dec Active] 397 [Spd Select 0] 400 [Spd Select 1] 401 [Spd Select 2] 402 [Ramp Select 0] 403 [Ramp Select 1] 404 [Encoder State] 651

[Fault 2 Code] 1352 [Fault 3 Code] 1353 [Fault 4 Code] 1354 [Fault 5 Code] 1355 [Fault 6 Code] 1356 [Fault 7 Code] 1357 [Fault 8 Code] 1358 [Fault 9 Code] 1359 [Fault 10 Code] 1360 [Fault 1 Time] 1361

[OverTemp Flt Cfg] 365 [FldLoss Flt Cfg] 473 [Spd Loss Flt Cfg] 478

[UserDefined14] 517 [UserDefined15] 518 [UsrDefBitWrdA] 519 [UsrDefBitWrdA0] 520 [UsrDefBitWrdA1] 521 [UsrDefBitWrdA2] 522 [UsrDefBitWrdA3] 523 [UsrDefBitWrdA4] 524 [UsrDefBitWrdA5] 525 [UsrDefBitWrdA6] 526 [UsrDefBitWrdA7] 527 [UsrDefBitWrdA8] 528 [UsrDefBitWrdA9] 529 [UsrDefBitWrdA10] 530 [UsrDefBitWrdA11] 531 [UsrDefBitWrdA12] 532 [UsrDefBitWrdA13] 533 [UsrDefBitWrdA14] 534

[DPI Fdbk Select] 1321 [DPI Port Value] 1343

[MOP Mask] 598 [Local Mask] 599 [Decel Mask] 631 [Stop Owner] 600 [Start Owner] 601 [Jog Owner] 602 [Direction Owner] 603

[Data In D1] 616 [Data In D2] 617 [Data Out A1] 618 [Data Out A2] 619 [Data Out B1] 620 [Data Out B2] 621

[Write Mask Act] 1377 [Write Mask Cfg] 1378

[MOP Select] 1375

[Accel Status] 1188 [Decel Status] 1189 [Fast Stop Status] 1190 [TestPoint Sel] 1381 [TestPoint Data] 1382 [TaskLoad 32 ms] 1383 [TaskLoad 1 ms] 1384 [TaskLoad 2 ms] 1385 [TaskLoad 8 ms] 1386

[Fault 2 Time] 1362 [Fault 3 Time] 1363 [Fault 4 Time] 1364 [Fault 5 Time] 1365 [Fault 6 Time] 1366 [Fault 7 Time] 1367 [Fault 8 Time] 1368 [Fault 9 Time] 1369 [Fault 10 Time] 1370

[UnderVolt Thresh] 481 [OverCurrent Thr] 584

[UsrDefBitWrdA15] 535 [UsrDefBitWrdB] 536 [UsrDefBitWrdB0] 537 [UsrDefBitWrdB1] 538 [UsrDefBitWrdB2] 539 [UsrDefBitWrdB3] 540 [UsrDefBitWrdB4] 541 [UsrDefBitWrdB5] 542 [UsrDefBitWrdB6] 543 [UsrDefBitWrdB7] 544 [UsrDefBitWrdB8] 545 [UsrDefBitWrdB9] 546 [UsrDefBitWrdB10] 547 [UsrDefBitWrdB11] 548 [UsrDefBitWrdB12] 549 [UsrDefBitWrdB13] 550 [UsrDefBitWrdB14] 551 [UsrDefBitWrdB15] 552

[Reference Owner] 604 [Accel Owner] 605 [Fault Clr Owner] 606 [MOP Owner] 607 [Local Owner] 608 [Decel Owner] 609

[Data Out C1] 622 [Data Out C1] 623 [Data Out D1] 624 [Data Out D2] 625 [Data In Val Sel] 1319 [Data In SelData] 1320

[Port Mask Act] 1379

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3-10 Programming and Parameters

File Group Parameters Input / Output Analog Inputs

Inputs / Outputs

Analog Outputs

Digital Inputs

Digital Outputs

DPI Inputs

[Anlg In1 Sel] 70 [Anlg In1 Config] 71 [Anlg In1 Scale] 72 [Anlg1 Tune Scale] 73 [Anlg In1 Offset] 74 [Anlg In1 Tune] 259 [Anlg In1 Filter] 792 [Anlg In2 Sel] 75 [Anlg In2 Config] 76 [Anlg In2 Scale] 77

[Anlg Out1 Sel] 66 [Anlg Out2 Sel] 67 [Anlg Out3 Sel] 68

[ContactorControl] 1391 [Dig In Status] 564 [Digital In1 Sel] 133 [Digital In2 Sel] 134 [Digital In3 Sel] 135 [Digital In4 Sel] 136 [Digital In5 Sel] 137 [Digital In6 Sel] 138 [Digital In7 Sel] 139 [Digital In8 Sel] 140 [Digital In9 Sel] 141 [Digital In10 Sel] 142 [Digital In11 Sel] 143

[Dig Out Status] 581 [Digital Out1 Sel] 145 [Digital Out2 Sel] 146 [Digital Out3 Sel] 147 [Digital Out4 Sel] 148 [Digital Out5 Sel] 149 [Digital Out6 Sel] 150

[DPI P1 Select] 1323 [DPI P2 Select] 1324

[Anlg2 Tune Scale] 78 [Anlg In2 Offset] 79 [Anlg In2 Tune] 260 [Anlg In3 Sel] 80 [Anlg In3 Config] 81 [Anlg In3 Scale] 82 [Anlg3 Tune Scale] 83 [Anlg In3 Offset] 84 [Anlg In3 Tune] 261 [Anlg In1 Target] 295

[Anlg Out4 Sel] 69 [Analog Out1 Scale] 62 [Analog Out2 Scale] 63

[Digital In12 Sel] 144 [Inversion In 1] 1276 [Inversion In 2] 1277 [Inversion In 3] 1278 [Inversion In 4] 1279 [Inversion In 5] 1280 [Inversion In 6] 1281 [Inversion In 7] 1282 [Inversion In 8] 1283 [Inversion In 9] 1387 [Inversion In 10] 1388 [Inversion In 11] 1389 [Inversion In 12] 1390

[Digital Out7 Sel] 151 [Digital Out8 Sel] 152 [Relay Out 1 Sel] 1392 [Relay Out 2 Sel] 629 [Inversion Out 1] 1267 [Inversion Out 2] 1268 [Inversion Out 3] 1269

[DPI P3 Select] 1325 [DPI P4 Select] 1326

[Anlg In2 Target] 296 [Anlg In3 Target] 297 [Anlg In1 Cmp] 1042 [Anlg In1 Cmp Err] 1043 [Anlg In1 Cmp Dly] 1044 [Anlg In1 Cmp Eq] 1045 [Analog In1 Value] 1404 [Analog In2 Value] 1405 [Analog In3 Value] 1406

[Analog Out3 Scale] 64 [Analog Out4 Scale] 65

[Dig In Term 1] 565 [Dig In Term 2] 566 [Dig In Term 3] 567 [Dig In Term 4] 568 [Dig In Term 5] 569 [Dig In Term 6] 570 [Dig In Term 7] 571 [Dig In Term 8] 572 [Dig In Term 9] 573 [Dig In Term 10] 574 [Dig In Term 11] 575 [Dig In Term 12] 576

[Inversion Out 4] 1270 [Inversion Out 5] 1271 [Inversion Out 6] 1272 [Inversion Out 7] 1273 [Inversion Out 8] 1274 [Inversion Relay1] 1393 [Inversion Relay2] 1275

[DPI P5 Select] 1327

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 83

Monitor File

Programming and Parameters 3-11

Parameter Name & Description

File

Group

44 [Speed Ref A]

47 [Speed Ref A Pct]

48 [Speed Ref B]

49 [Speed Ref B Pct]

110 [Ramp In]

111 [Ramp In Pct]

113 [Ramp Out]

114 [Ramp Out Pct]

MONITOR

Speed Meters

117 [Speed Reg In Pct]

118 [Speed Reg In]

121 [Spd Feedback Pct]

122 [Spd Feedback]

384 [Spd Ref Out Pct]

385 [Speed Ref Out]

420 [Encoder Speed]

See page 3-2 for symbol descriptions

No.

First speed reference for the drive. Negative values apply to four quadrant drives only. Note: This parameter is assigned to analog input 1 (terminals 1 & 2, Par 70 [Anlg In1 Sel]) by default, but can be assigned to any analog input.

First speed reference for the drive as a percentage of the value defined in Par 45 [Max Ref Speed].

Second speed reference for the drive. Negative values apply to four quadrant drives only. Note: This parameter can be assigned to an analog input.

The second speed reference for the drive as a percentage of the value defined in Par 45 [Max Ref Speed].

Total reference value input to the ramp in RPM. Note: This parameter can be assigned to an analog output.

Total reference value input to the ramp as a percentage of Par 45 [Max Ref Speed]. Note: This parameter can be assigned to an analog output.

Output of the ramp in RPM. Note: This parameter can be assigned to an analog output.

Output of the ramp as a percentage of Par 45 [Max Ref Speed].

Total reference value input to the Speed Regulator as a percentage of Par 45 [Max Ref Speed].

Total reference value input to the Speed Regulator in RPM. Note: This parameter can be assigned to an analog output.

Actual speed as a percentage of the Par 45 [Max Ref Speed]. Note: This parameter is assigned to analog output 1 (terminals 21 and 22, Par 66 [Anlg Out1 Sel]) by default, but can be assigned to any analog output.

Actual speed in RPM.

Output of the Speed Reference selection as a percentage of Par 45 [Max Ref Speed].

Output of the Speed Reference selection.

Actual speed measured by the digital encoder.

Value s

Default:

Min/Max: Units:

(1)

The value of [Max Ref Speed] cannot exceed 8192 RPM.

Default:

Min/Max: Units:

Default:

Min/Max: Units:

(1)

The value of [Max Ref Speed] cannot exceed 8192 RPM.

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Read Only

–/+ Par 45 [Max Ref Speed] RPM

Read Only

–/+100.00 %

Read Only

–/+ Par 45 [Max Ref Speed] RPM

Read Only

–/+100.00 %

Read Only

–/+32766 RPM

Read Only

–/+100.00 %

Read Only

–/+32766 RPM

Read Only

–/+100.00 %

Read Only

–/+100.00 %

Read Only

–/+32766 RPM

Read Only

–/+100.00 %

Read Only

–/+32766 RPM

Read Only

–/+100.00 %

Read Only

–/+32766 RPM

Read Only

–/+8192 RPM

(1)

45, 923

414

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Page 84

3-12 Programming and Parameters

Parameter Name & Description

File

MONITOR

Group

Speed Meters

Current Meters

See page 3-2 for symbol descriptions

No.

924 [Actual Speed]

Filtered value of Par 122 [Spd Feedback]. Note: This parameter can be assigned to an analog output.

1018 [Speed Draw Out]

Speed draw output value. Note: This parameter can be assigned to an analog output.

1019 [Spd Draw Out Pct]

Speed value as a percentage of Par 45 [Max Ref Speed].

1408 [Tachometer Speed]

Actual speed measured by the DC analog tachometer.

10 [Cur Lim Pos Out]

Displays the value of the current limit for the positive torque direction, expressed as a percentage of the value in Par 179 [Nom Mtr Arm Amps].

11 [Cur Lim Neg Out]

Displays the value of the current limit for the negative torque direction, expressed as a percentage of the value in Par 179 [Nom Mtr Arm Amps].

41 [Current Reg In]

Total current reference value expressed as a percentage of the value in Par 179 [Nom Mtr Arm Amps]. Note: This parameter can be assigned to an analog output.

199 [Arm Current Pct]

Armature current expressed as a percentage of the value in Par 179 [Nom Mtr Arm Amps]. Note: This parameter is assigned to analog output 2 (Terminals 23 and 24, Par 67 [Anlg Out2 Sel]) by default, but can be assigned to any analog output.

200 [Arm Current]

Armature current in Amperes.

234 [Fld Current Pct]

Field current (present value) as a percentage of Par 280 [Nom Mtr Fld Amps]. Note: This parameter can be assigned to an analog output.

236 [Spd Reg Out Pct]

Output value of the speed regulator used as the reference for the current regulator. Note: By default, this parameter is linked to Par 39 [Torque Ref].

351 [Field Current]

Present value of the field current. The value of this parameter equals the value of Par 468 [Min Fld Curr Pct] when Par 499 [Field Economy En] = 1 “Enabled” and Field Economy becomes active.

500 [Field Ref Pct]

Field current (reference) as a percentage of Par 280 [Nom Mtr Fld Amps]. Note: This parameter can be assigned to an analog output.

928 [Filt TorqCur Pct]

Percent filtered value of Par 199 [Arm Current Pct]. Note: This parameter can be assigned to an analog output.

Value s

Default:

Min/Max: Units:

Default:

Min/Max: Units:

(1)

The value of [Max Ref Speed] cannot exceed 8192 RPM.

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Read Only

–/+32766 RPM

Read Only

–/+ Par 45 [Max Ref Speed] RPM

Read Only

–/+100.00 %

Read Only

–/+32770 RPM

Read Only

0 / 200 %

Read Only

0 / 200 %

Read Only

–/+200 %

Read Only

–/+250 %

Read Only

–/+2.5 x [Nom Mtr Arm Amps] A

Read Only

0.00 / 100.00 %

Read Only

–/+200 %

Read Only

0.00 / 99.90 A

Read Only

0.00 / 100.00 %

Read Only

–/+200 %

121

179

280

1193

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Page 85

Programming and Parameters 3-13

Parameter Name & Description

File

Group

57 [FaultCode]

233 [Output Voltage]

235 [Elapsed Lifetime]

300 [Drive Type]

331 [Software Version]

465 [Drive Size]

MONITOR

Drive Data

466 [AC Line Voltage]

588 [AC Line Freq]

1052 [Output Power]

See page 3-2 for symbol descriptions

No.

A code that represents the fault that tripped the drive. Refer to

Fault Descriptions on page 4-4 for a list of fault codes and

descriptions.

Armature Voltage U Note: This parameter can be assigned to an analog output.

Shows the operating time of the drive. This parameter counts the time for which the drive is energized (even if the drive is disabled).

Displays of the drive type. “10” = Non-Regenerative

“11” = Regenerative

Displays the software version number active in the drive.

Armature current rating (as indicated by the configuration of DIP switch S15 on the Control board). Note: S15 is set to the appropriate value at the factory. However, if the Control board was supplied as a replacement part, S15 must be manually set to the appropriate drive size. Refer to DIP

Switch and Jumper Settings on page 1-32.

AC input voltage.

AC input frequency.

Output power. Note: This parameter can be assigned to an analog output.

in VAV.

Value s

Default:

Min/Max:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max:

Default:

Min/Max: Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Read Only

0 / 65535

Read Only

-/+999.00 Vdc

Read Only

0.00 / 65540.00 H.m

Read Only

10 / 11

Read Only

1.00 / 999.00 Read Only

0 / Based on drive current rating A

Read Only

0 / 960 Vac

Read Only

0.00 / 70.00 Hz

Read Only

0.00 / 9999.99 kW

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 86

3-14 Programming and Parameters

Motor Control File

Parameter Name & Description

File

MOTOR CONTROL

Group

Motor Data

Field Config

See page 3-2 for symbol descriptions

No.

45 [Max Ref Speed]

Maximum reference speed as determined by the application. If Field Weakening is not required, this value will be equal to the Motor Nameplate Base Speed (RPM). The value of this parameter is used to scale all of the other speed reference related parameters.

162 [Max Feedback Spd]

Maximum feedback speed as determined by the application. If Field Weakening is not used, the value of this parameter will be equal to the Motor Nameplate base speed. This value must be at least 10% lower than the Motor nameplate maximum safe speed (in order to allow an “Overspeed” fault to occur). The value in this parameter is also used to convert tachometer and armature feedback values to rpm. When armature voltage feedback is used, the value of Par 175 [Rated Motor Volt] is considered equivalent to Par 162 [Max Feedback Spd]. Therefore, this parameter should be set appropriately.

175 [Rated Motor Volt]

Maximum armature voltage of the drive. Typically, this value is set to the Motor Nameplate Armature voltage. When Par 469 [Field Mode Sel] is set to 1 = “Field Weaken”, the value in this parameter equals the voltage that begins the weakening phase of the field. Note: This parameter affects the threshold of an overvoltage condition, as indicated by an “Arm Overvoltage” fault (F5).

179 [Nom Mtr Arm Amps]

Rated motor nameplate armature current. The settings for the current limit and the overload function are based on this current value.

201 [Drive Type Sel]

This parameter is only applicable to non-regenerative (2-quadrant) drives. It allows non-regenerative drives to use an external 4-quadrant controller.

• “On” = Ramp, Speed, Torque current references and Speed

measurement have the same behavior of a four quadrant drive.

280 [Nom Mtr Fld Amps]

Rated motor nameplate field current (I

374 [Drv Fld Brdg Cur]

Drive rated field bridge current (I be set equal to the value chosen with DIP switch S14 on the Control board (refer to Table 1.G on page 1-25 for DIP switch configuration).

91 [Fld Reg Kp]

Proportional gain (K

percentage of Par 97 [Fld Reg Kp Base].

92 [Fld Reg Ki]

Integral gain (K

of Par 98 [Fld Reg Ki Base].

97 [Fld Reg Kp Base]

The proportional gain (K value).

dFN

). The value in this field must

dFN

) of the flux regulator expressed as a

) of the flux regulator expressed as a percentage

) of the field current regulator (base

Value s

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Options:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max:

1750

1 / 16383 RPM

1750.00

1.00 / 6553.00 RPM

500.00

20.00 / 999.00 V

Based on drive current rating

0.10 / Based on drive current rating A

0 =

“Off”

0 =

“Off”

1 =

“On”

Par 374 [Drv Fld Brdg Cur] x 0.33

0.00 / [Drv Fld Brdg Cur] A

1.00

0.50 / 80.00 A

2.00

0.00 / 100.00 %

1.00

0.00 / 100.00 %

3277.00

0.10 / 32770.00

162, 175

469

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 87

Programming and Parameters 3-15

Parameter Name & Description

File

Group

98 [Fld Reg Ki Base]

See page 3-2 for symbol descriptions

No.

Integral gain (K

456 [Fld Weaken Ratio]

The ratio of Motor Nameplate Base Speed to Par 45 [Max Ref Speed] when Par 469 [Field Mode Sel] = 1 "Field Weaken". It is the percentage of maximum application speed when field weakening will begin. This value is "Motor Base Speed" / Par 45 [Max Ref Speed] x 100. If Par 469 [Field Mode Sel] = 0 “Base Speed”, this parameter must be = 100%.

467 [Max Fld Curr Pct]

Maximum allowable field current. The maximum value (100%) corresponds to the value set in Par 280 [Nom Mtr Fld Amps]. The value of this field linearly affects the field current, unless a flux curve is set in Pars 916, 917, and 918 [Fld Const xx Pct]. Note: This parameter can be assigned to an analog input or output.

468 [Min Fld Curr Pct]

Minimum allowable field current. The value set in this parameter also influences the threshold at which the “Fld Current Loss” (F6) fault occurs. The threshold is half of the value of Par 468 [Min Fld Curr Pct]. The value of Par 351 [Field Current] equals the value of this parameter when Par 499 [Field Economy En] = 1 “Enabled” and Field Economy becomes active.

469 [Field Mode Sel]

Operating mode of the field controller.

Field Config

MOTOR CONTROL

497 [Field Reg Enable]

498 [Force Min Field]

• “Base Speed” = The motor field is regulated with constant

• “Field Weaken” = The motor field is regulated with a

• “External” = The motor field power is supplied by an external

Enables/Disables the field regulator.

• “Enabled” = The field regulator is enabled and controlling the

• “Disabled” = The field regulator is disabled. (i.e., The field

Note: This parameter can be assigned to a digital input.

Enables/Disables the minimum field current value.

• “Enabled” = The field current corresponds to the value set via

•

Note: This parameter can be assigned to a digital input (35 “Force MinFld”).

) of the field current regulator in (base value).

current and controls the motor from zero to base speed. If a curve is defined through Pars 916, 917 and 918 [Fld Const xx Pct], this value will change linearly through Par 467 [Max Fld Curr Pct] (which is a percentage of the nominal flux value set in Par 280 [Nom Mtr Fld Amps]).

combination of torque and constant power (armature and field regulation, i.e., field weakening). The maximum armature voltage is configured in Par 175 [Rated Motor Volt].

rectifier/converter (the drive’s field output is disabled).

field output.

current is zero.) In addition, Par 473 [FldLoss Flt Cfg] should be set to 0 “Ignore”.

Par 468 [Min Fld Curr Pct]. “Disabled” = The field current is regulated based on the quadrant mode and situation in which the drive is operating.

Value s

Default:

Min/Max:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Options:

Default:

Options:

Default:

Options:

3277.00

0.10 / 32770.00

100

0 / 100 %

100

Par 468 [Min Fld Curr Pct] / 100 %

0 / Par 467 [Max Fld Curr Pct] %

0 =

“Base Speed”

0 =

“Base Speed”

1 =

“Field Weaken”

2 =

“External”

1 =

“Enabled”

0 =

“Disabled”

1 =

“Enabled”

0 =

“Disabled”

0 =

“Disabled”

1 =

“Enabled”

468

467, 499

916, 917, 918

473

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 88

3-16 Programming and Parameters

Parameter Name & Description

File

Group

See page 3-2 for symbol descriptions

No.

499 [Field Economy En]

When this parameter is set to 1 = “Enabled” and the value in Par 107 [Speed Zero Level] is reached, the minimum field current (set via Par 468 [Min Fld Curr Pct]) is produced (field economy).

• “Disabled” = Disables the field economy function

• “Enabled” = Enables the field economy function

916 [Fld Const 40 Pct]

Current value at 40% of the field current.

917 [Fld Const 70 Pct]

Current value at 70% of the field current.

918 [Fld Const 90 Pct]

Current value at 90% of the field current.

919 [Set Fld Curve]

When set to “0”, this parameter controls the motor field current to field reference curve according to the values specified in the [Fld Const xx Pct] parameters. With this curve is defined, the

Field Config

MOTOR CONTROL

Torq Attributes

result of [Max Fld Curr Pct] / [Field Ref Pct] equals the percentage of field current according to the characteristic of the curve. This field is Write Only. After the value of this field is set to “0”, it will automatically return to “1”.

920 [Reset Fld Curve]

when set to “1”, resets the drive to use a linear field curve. When this parameter is set, Par 280 [Nom Mtr Fld Amps] is linearly changed through [Max Fld Curr Pct] / [Field Ref Pct]. This field is

Write Only. After the value of this field is set to “1”, it will automatically return to “0”.

921 [Out Volt Level]

The percentage of maximum output voltage based on the value

in Par 175 [Rated Motor Volt]. This parameter allows you to change the output voltage at the motor end when the drive is in "Field Weaken" mode. Typically set to the default value when the drive is in Field Weakening mode. Note: This parameter can be assigned to an analog output or analog input.

1407 [Field Econ Delay]

Amount of time to elapse after the drive reaches zero speed (as determined by Par 107 [Speed Zero Level]) before field economy becomes active.

7 [Current Limit]

Symmetrical current limit expressed as a percentage of the value in Par 179 [Nom Mtr Arm Amps]. This value applies to both current directions for four quadrant drives.

• If Par 7 [Current Limit] is changed, Pars 8 [Current Lim Pos]

and 9 [Current Lim Neg] are set to the same value. If subsequently changed, the value of Pars 8 [Current Lim Pos] and/or 9 [Current Lim Neg] override the value of Par 7 [Current Limit].

Value s

Default:

Options:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

1 =

“Enabled”

0 =

“Disabled”

1 =

“Enabled”

40.00

0.00 / 100.00 %

70.00

0.00 / 100.00 %

90.00

0.00 / 100.00 %

0 / 1

100.00

0.00 / 100.00 %

300

0 / 1800 s

150

0 / 200 %

395, 468

469

916, 917, 918

8, 9, 179

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 89

Programming and Parameters 3-17

Parameter Name & Description

File

Group

8 [Current Lim Pos]

9 [Current Lim Neg]

39 [Torque Ref]

40 [Trim Torque]

Torq Attributes

342 [Torque Reduction]

MOTOR CONTROL

353 [Zero Torque]

See page 3-2 for symbol descriptions

No.

The drive current limit for the positive current direction expressed as a percentage of the value in Par 179 [Nom Mtr Arm Amps]. Note: This parameter can be assigned to an analog input.

The drive current limit for the negative current direction expressed as a percentage of the value in Par 179 [Nom Mtr Arm Amps]. This parameter is not active for two quadrant drives. Note: This parameter can be assigned to an analog input.

First current reference value, before any trim signals are incorporated, as a percentage of the value set in Par 179 [Nom Mtr Arm Amps]. This parameter is only used when Par 242 [Speed Reg En] = 0 "Disabled". Note: The current reference value is proportional to the armature current of the motor and determines the torque. The polarity determines the torque direction.

Second current reference value as a percentage of the value set in Par 179 [Nom Mtr Arm Amps]. [Trim Torque] is added to Torque Reference and can be used as a correction value for the torque reference (regardless of the value of Par 242 [Speed Reg En]).

Selection for torque reduction. When the torque reduction function is active (1 “Active”), the current limit changes accordingly by the percentage defined in Par 13 [Torq Red CurLim]. When this parameter is set to 0 “Not Active”, torque reduction is not active. For example:

Note: This parameter can be assigned to a digital input.

Sets the reference value for the armature current (Par 41 [Current Reg In]) to zero so that the drive has no torque.

• “Not Active” = Par 41 [Current Reg In] is not set to zero.

• “Active” = Par 41 [Current Reg In] is set zero. The drive has

Par 7 [Current Limit] (or Pars 8 [Current Lim Pos] and 9 [Current Lim Neg]) = 80 % Par 13 [Torq Red CurLim] = 70% If Par 342 [Torque Reduction] = 0 “Not Active”, the current limit = 80 % If Par 342 [Torque Reduction] = 1 “Active”, the current limit = 70 %

no torque.

Value s

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Options:

Default:

Options:

150

0 / 200 %

150

0 / 200 %

– / +200 %

0 =

0 = 1 =

1 =

0 = 1 =

“Not Active”

“Not Active” “Active”

“Not Active”

“Active” “Not Active”

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 90

3-18 Programming and Parameters

File

Group

No.

750 [TrqTpr_Enable]

751 [TrqTpr_Lim0]

Torq Attributes

MOTOR CONTROL

752 [TrqTpr_Lim1]

753 [TrqTpr_Lim2]

754 [TrqTpr_Lim3]

755 [TrqTpr_Lim4]

756 [TrqTpr_Spd]

Parameter Name & Description

See page 3-2 for symbol descriptions

Enables/Disables the current/speed function. The current/speed function allows you to change the current limits set in Pars 8 [Current Lim Pos] and 9 [Current Lim Neg] by setting up to five setpoints using parameters [TrqTpr_Limx] and a threshold speed in Par 756 [TrqTpr_Spd].

• “Disabled” = The limits current /speed curve is disabled

• “Enabled” = The limits current /speed curve is enabled

Par 10 [Cur Lim Pos Out]

Par 11 [Cur Lim Neg Out]

rqTpr_Lim0]

rqTpr_Lim1]

rqTpr_Lim2]

rqTpr_Lim3] rqTpr_Lim4]

Par 756 [TrqTpr_Spd]

The current limit of the current/speed curve that operates constantly up to the speed set in Par 756 [TrqTpr_Spd]. The value specified in this parameter overrides the values specified in Pars 8 [Current Limit Pos] and 9 [Current Lim Neg].

First reduced current limit of the current/speed curve. The value defined in this parameter must be less than the value in Par 751 [TrqTpr_Lim0] and greater than the values in Pars 753 [TrqTpr_Lim2], 754 [TrqTpr_Lim3] and 755 [TrqTpr_Lim4].

Second reduced current limit of the current/speed curve. The value defined in this parameter must be less than the value in Par 752 [TrqTpr_Lim1] and greater than the values in Pars 754 [TrqTpr_Lim3] and 755 [TrqTpr_Lim4].

Current/Speed

Third reduced current limit of the current/speed curve. The value defined in this parameter must be less than the value in Par 753 [TrqTpr_Lim2] and greater than the value in Par 755 [TrqTpr_Lim4].

Last reduced current limit of the current/speed curve. The value defined in this parameter must be less than the value in Par 754 [TrqTpr_Lim3]. The drive will operate at this current limit up to the value set in parameter 162 [Max Feedback Spd].

Threshold speed at which torque reduction begins, as determined by the current/speed curve.

Value s

Default:

Options:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

0 =

“Disabled”

0 =

“Disabled”

1 =

“Enabled”

Par 162 [Max Feedback Spd]

0 / 200 %

0 / Par 162 RPM

751, 752, 753, 754, 755, 756

750, 756

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 91

Programming and Parameters 3-19

Parameter Name & Description

File

Group

926 [Filt Torq Cur]

Torq Attributes

169 [Encoder PPR]

414 [Fdbk Device Type]

455 [Spd Fdbk Error]

457 [Spd Fdbk Control]

MOTOR CONTROL

See page 3-2 for symbol descriptions

No.

First rate low-pass filter for Par 1193 [Torq Current Pct].

Number of pulses per revolution of the digital encoder. The value of Pars 169 [Encoder PPR] and 162 [Max Feedback Spd] must be set as indicated in Speed Feedback on page C-15

The source of speed feedback.

• 1 “Encoder” = Digital encoder

• 2 “DC Tach” = DC analog tachometer

• 3 “Armature” = Internal measurement of the armature voltage

The maximum allowable speed feedback error expressed as a

percentage of the maximum output voltage set in Par 175 [Rated Motor Volt]. By means of Par 175 [Rated Motor Volt], Par 456 [Fld Weaken Ratio] and the motor nominal speed, a relationship between motor speed and armature voltage is obtained. If the difference is higher than the value set in Par 455 [Spd Fdbk Error], an “Encoder Loss” fault (F91) occurs.

Enables/Disables speed feedback control. This function controls the speed feedback, where a comparison is made between the armature voltage and the speed value read by the encoder or tachometer. When the value set in Par 455 [Spd Fdbk Error] is signaled, the fault message “Encoder Loss” (F91) displays. This function is automatically disabled when the armature feedback has been selected (Par 414 [Fdbk Device Type] = 3 “Armature”).

Value s

Default:

Min/Max: Units:

Default:

Min/Max:

Default:

Options:

Default:

Min/Max: Units:

Default:

Options:

0.100

0.001 / 0.250 s

1024.00

100.00 / 32770.00

3 =

“Armature”

1 =

“Encoder”

2 =

“DC Tach”

3 =

“Armature”

0 / 100 %

1 =

“Enabled”

0 =

“Disabled”

1 =

“Enabled”

1193

162

455

Speed Feedback

458 [SpdReg FB Bypass]

Enables/Disables an automatic switch to armature feedback when the “Encoder Loss” (F91) fault occurs due to an encoder or tachometer feedback loss. When this parameter is set to “Enable”, Par 478 [Spd Loss Flt Cfg] must be set to 1 “Alarm”. After an automatic switch to armature feedback, the speed regulator works with Pars 459 [SpdReg Kp Bypass] and 460 [SpdReg Ki Bypass] and the D derivative part of the speed regulator is automatically excluded. Pars [SpdReg Kp Bypass] and [SpdReg Ki Bypass] must be properly tuned. An automatic switch to armature feedback can only be accomplished when running the motor with constant field current.

562 [Anlg Tach Gain]

Fine scaling of the speed feedback received from the DC analog tachometer (Par 414 [Fdbk Device Type] = 2 “DC Tach”). The voltage feedback value received from the tachometer is multiplied by this value.

563 [Anlg Tach Zero]

Offset scaling of the feedback circuit.

ATTENTION: If speed feedback control is disabled (Par 457 [Spd Fdbk Control] set to 0 “Disabled” and Par 414 [Device Type] is set to 1 “Encoder”, the motor could run at excessive

speed or become damaged, which could result in personal injury or destruction of equipment.

Default:

Options:

Default:

Min/Max:

Default:

Min/Max: Units:

0 =

“Disabled”

0 =

“Disabled”

1 =

“Enabled”

1.00

0.90 / 3.00

0.00

–/+20.00 RPM

478

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 92

3-20 Programming and Parameters

Parameter Name & Description

File

MOTOR CONTROL

Group

Speed Feedback

Autotune

See page 3-2 for symbol descriptions

No.

652 [Encoder Err Chk]

Enables/Disables monitoring of the digital encoder connection

status. When an alarm is detected, the HIM displays the “Encoder Loss” (F91) fault. This parameter can be programmed on a digital output. This function is activated by setting Par 457 [Spd Fdbk Control] = “Enabled”.

911 [Z Channel Enable]

Determines whether the encoder zero pulse (qualification signal

or “zero cam”) will be read by the drive. This parameter is used for systems implementing position control.

• “Enabled” = The encoder zero pulse is read.

• “Disabled” = The encoder zero pulse is not read.

912 [Z Capture Pos En]

Control register of the zero pulse and of the encoder

qualification signal.

913 [Z Captured Pos]

Data and function status register.

923 [Act Spd Filter]

First order low pass filter time constant for Par 121 [Spd

Feedback Pct].

1021 [Encoder Out Sel]

Defines the speed reference to which the encoder signal can be input. This parameter is typically set to 0 "Off" and the encoder is used for speed feedback only. When set to other than 0 "Off",

the choice of the speed reference destination must be made according to the configuration of the speed regulator (for example "Speed Ref A" cannot be used with an active ramp).

452 [CurrReg Autotune]

Setting this parameter to 1 “On” and pressing Enter on the HIM keypad initiates the current regulator auto tuning procedure. When the auto tuning procedure is complete, this parameter automatically resets to 0 “Off”. The resulting armature resistance and inductance values are set in parameters 453 [Arm Resistance] and 454 [Arm Inductance], respectively.

453 [Arm Resistance]

Motor armature resistance. This parameter can be manually changed to a value other than the value obtained when the current regulator auto tuning is completed.

454 [Arm Inductance]

Motor armature inductance. This parameter can be manually changed to a value other than the value obtained when the current regulator auto tuning is completed.

587 [I Reg Error]

The auxiliary signal used to determine whether the current

regulator is correctly tuned. The value should be as near to zero as possible, but values between -/+40 are acceptable.

1012 [Inertia C Filter]

First order low–pass filter used to reduce noise caused by the

speed differentiation process in the Inertia/Loss compensation block.

1013 [Torque Const]

The Motor torque constant used to calculate inertia and friction

compensation. The value in this parameter is automatically adapted in the field weakening mode. This value is determined during speed auto tuning.

Value s

Default:

Options:

Default:

Options:

Default:

Min/Max:

Default:

Min/Max:

Default:

Min/Max: Units:

Default:

Options:

Default:

Options:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

“Disabled”

0 =

“Disabled”

1 =

“Enabled”

0 =

“Disabled”

0 =

“Disabled”

1 =

“Enabled”

0 / 6553

Read Only

0 / 2

–1

0.100

0.001 / 1.000 s

0 =

“Off”

0 =

“Off”

1 =

“Trim Ramp”

2 =

“Trim Speed”

3 =

“Speed Ref A”

4 =

“Speed Ref B”

0 =

“Off”

0 =

“Off”

1 =

“On”

0.50

Based on drive current rating Ohm

4.00

Based on drive current rating mH

Read Only

–/+80 V

0 / 1000 ms

Based on drive current rating

0.01 / 99.99 N–m/A

457

121

452

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 93

Programming and Parameters 3-21

Parameter Name & Description

File

Group

1014 [Inertia]

1015 [Friction]

1027 [Spd Reg Autotune]

1029 [Speed Tune Dir]

Autotune

1030 [Spd Tune Inertia]

MOTOR CONTROL

1031 [SpdTune Friction]

1032 [Speed Tune Kp]

1033 [Speed Tune Ki]

1048 [Autotune Cur Lim]

See page 3-2 for symbol descriptions

No.

Motor inertia value.

1 Kg–m2 = 23.76 lb–ft

Motor friction value.

1 N–m = 0.738 lb–ft

Starts the auto tuning procedure for the speed regulator. Setting this parameter to 1 “On” and pressing Enter on the HIM keypad initiates the speed regulator auto tuning procedure. When the auto tuning procedure is complete, this parameter automatically resets to 0 “Off”.

Choice of the rotation direction of the motor shaft (rotation, as seen from the motor shaft side) for the speed regulator auto tuning procedure.

• “Forward” = Clockwise rotation

• “Reverse” = Counter-clockwise rotation

Motor inertia value identified during the speed regulator auto tuning procedure.

Motor friction value identified during the speed regulator auto tuning procedure.

Proportional gain value of the speed regulator identified during the speed regulator auto tuning procedure.

Integral gain value of the speed regulator identified during the speed regulator auto tuning procedure.

Value of the torque current limit applied during the speed regulator auto tuning procedure.

Value s

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Options:

Default:

Options:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max:

Default:

Min/Max:

Default:

Min/Max: Units:

Based on drive current rating

0.001 / 999.999

Kg–m Based on drive current rating

0.000 / 99.990 N–m

0 =

“Ready”

0 =

“Ready”

1 =

“Start”

1 =

“Forward”

1 =

“Forward”

2 =

“Reverse”

Read Only

0.00 / 1000.00

Kg x m Read Only

0.00 / 99.99 N-m

Read Only

0.00 / 100.00

Read Only

0.00 / 100.00

0 / Based on drive current rating %

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 94

3-22 Programming and Parameters

File

Group

No.

58 [TstGen Output]

Parameter Name & Description

See page 3-2 for symbol descriptions

Allows you to select a simulated parameter as the output for the test generator. The test generator is used to manually tune the regulators. It consists of a square wave generator whose frequency, offset and amplitude can be manipulated.

• “NotConnected” - No internal parameters defined by the

generator.

• “Reserved” - Not used.

• “Torq Cur Ref” - The output of the generator defines the

reference value of the torque current. 100% corresponds to “full load torque current” (FLT).

• “Field Ref” - The output of the generator defines the field

reference value. 100% corresponds to the rated field current based on the motor nameplate data parameters.

• “Ramp Ref” - The output of the generator defines the ramp

reference value. 100% corresponds to the value specified in Par 45 [Max Ref Speed]. This is the value immediately before the Ramp function.

• “Speed Ref” - The output of the generator defines the speed

reference value. This is the value immediately before the Speed Regulator function.

P58 TstGen Output

Generator

Output

Value s

Default:

Options:

0 =

0 = 1 = 2 = 3 = 4 = 5 =

“NotConnected”

“NotConnected” “Reserved” “Torq Cur Ref” “Field Ref” “Ramp Ref” “Speed Ref”

59, 60, 61

Test Generator

MOTOR CONTROL

59 [TstGen Frequency]

Output frequency of the test generator.

60 [TstGen Amplitude]

Amplitude of the delta signal produced by the test generator.

61 [TstGen Offset]

Offset of the test generator.

P59 TstGen Frequency

Time

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

P60 TstGen Amplitude

P61 TstGen Offset

0.10

0.10 / 62.50 Hz

0.00

0.00 / 200.00 %

0.00

–/+200.00 %

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 95

Speed Command File

Programming and Parameters 3-23

Parameter Name & Description

File

Group

Limits

SPEED COMMAND

Discrete Speeds

See page 3-2 for symbol descriptions

No.

1 [Minimum Speed]

Defines the minimum speed of the drive. This value applies to both directions of motor rotation for four quadrant drives. A speed below the value set in [Minimum Speed] is not possible, regardless of the set speed reference value. If the value of [Minimum Speed] is changed, Pars 5 [Min Speed Fwd] and 6 [Min Speed Rev] are set to the same value. If either Par 5 [Min Speed Fwd] or Par 6 [Min Speed Rev] is changed later, the last change is valid.

2 [Maximum Speed]

Defines the maximum speed of the drive. This value applies to both directions of motor rotation for four quadrant drives. The value of this parameter is input to the speed regulator and therefore takes into account the reference value that comes from the ramp as well as the direction of rotation. If the value of [Maximum Speed] is changed, Pars 3 [Max Speed Fwd] and 4 [Max Speed Rev] are set to the same value. If either Par 3 [Max Speed Fwd] or Par 4 [Max Speed Rev] is changed later, the last change is valid.

3 [Max Speed Fwd]

Defines the maximum speed for forward (clockwise) rotation of the motor. The value of [Max Speed Fwd] affects the input of the speed regulator and therefore takes into account both the reference values that come from the ramp as well as the direction of motor rotation.

4 [Max Speed Rev]

Defines the maximum speed for reverse (counterclockwise) rotation of the motor for four quadrant drives only. The value of [Max Speed Rev] affects the input of the speed regulator and therefore takes into account both the reference values that come from the ramp as well as the direction of rotation.

5 [Min Speed Fwd]

Defines the minimum speed for forward (clockwise) rotation of the motor. Speed reference values below the value in this parameter are clamped until the reference exceeds this limit.

6 [Min Speed Rev]

Defines the minimum speed for reverse (counterclockwise) rotation of the motor for four quadrant drives only. Speed reference values below the value in this parameter are clamped until the reference exceeds this limit.

154

[Preset Speed 1]

155

[Preset Speed 2]

156

[Preset Speed 3]

157

[Preset Speed 4]

158

[Preset Speed 5]

159

[Preset Speed 6]

160

[Preset Speed 7]

Provides an internal fixed speed command value. In bipolar mode, direction is commanded by the sign of the reference. Note: [Preset Speed 1] cannot be directly selected by the Speed Sel digital inputs. However, Par 154 [Preset Speed 1] can be directed to Par 42 [Trim Ramp] via the Scale Block parameters.

266 [Jog Speed]

Reference value for jog mode. Note: This parameter can be assigned to an analog input.

Value s

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default: Default: Default: Default: Default: Default: Default:

Min/Max: Units:

Default:

Min/Max: Units:

0 / Par 45 [Max Ref Speed] RPM

1750

0 / Par 45 [Max Ref Speed] RPM

1750

0 / Par 45 [Max Ref Speed] RPM

1750

0 / Par 45 [Max Ref Speed] RPM

150 300 600 900 1200 1500 1750

-32768 / +32767 RPM

100

-/+32767 RPM

5, 6

3, 4

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 96

3-24 Programming and Parameters

Parameter Name & Description

File

SPEED COMMAND

Group

Discrete Speeds

Speed References

See page 3-2 for symbol descriptions

No.

1409 [Jog Off Delay]

Specifies the amount of time that will elapse between removing the Jog input and commanding the main contactor to open. The amount of time specified in [Jog Off Delay] will not begin to elapse until the measured speed feedback is less than or equal to the value of parameter 107 [Speed Zero Level]. This delay reduces the wear on the contactor when repeatedly opening and closing the Jog input over a short period of time. Note: This parameter was added with firmware version 2.001.

267 [TB Manual Ref]

Reference value for the drive when the Terminal Block asserts Manual reference control. Note: This parameter can be assigned to an analog input.

42 [Trim Ramp]

This value is added to the speed reference just before the Speed Ramp function. Note: This parameter can be assigned to an analog input.

43 [Trim Speed]

This value is added to the speed reference just before the speed regulator (and after the Speed Ramp function). Note: This parameter can be assigned to an analog input.

378 [Trim Ramp Pct]

Trim ramp value defined as a percentage of the value defined in Par 45 [Max Ref Speed].

379 [Trim Speed Pct]

Trim speed reference value defined as a percentage of the of the value defined in Par 45 [Max Ref Speed].

1017 [Speed Ratio]

Determines the speed ratio value for the Speed-Draw function. Note: This value can be input to the drive digitally, or via an analog input.

87 [Spd Reg Kp]

Proportional gain of the speed regulator that can be adjusted while the drive is running.

88 [Spd Reg Ki]

Integral gain of the speed regulator that can be adjusted while the drive is running.

93 [Spd Reg Kp Base]

The proportional gain (K

94 [Spd Reg Ki Base]

Speed Regulator

The integral gain (K

99 [Spd Reg Kp Outpt]

Displays the active proportional coefficient of the speed regulator as a

percentage of the value defined in Par 93 [Spd Reg Kp Base].

100 [Spd Reg Ki Outpt]

Displays the active integral coefficient of the speed regulator as a

percentage of the value defined in Par 94 [Spd Reg Ki Base].

) of the speed regulator (base value).

Value s

Default:

Min/Max: Units:

Default:

Min/Max: Units:

(1)

The value of [Max Ref Speed] cannot exceed 8192

RPM.

Default:

Min/Max: Units:

(1)

The value of Par 45 [Max Ref Speed] cannot exceed

8192 RPM.

Default:

Min/Max: Units:

(1)

The value of Par 45 [Max Ref Speed] cannot exceed

8192 RPM.

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

0 - 10 s

–/+ Par 45 [Max Ref Speed] RPM

–/+Par 45 [Max Ref Speed] RPM

–/+ Par 45 [Max Ref Speed] RPM

0.00

–/+100.00 %

0.00

–/+100.00 %

10000

0 / 32767

10.00

0.00 / 100.00 %

1.00

0.00 / 100.00 %

0.30 x Par 93

0.01 / Based on drive current rating A / RPM

0.30 x Par 94

0.01 / Based on drive current rating A/ RPM x ms

Read Only

0.00 / 100.00 %

Read Only

0.00 / 100.00 %

max

(1)

378

(1)

379

(1)

93, 99

94, 100

87, 99

88, 100

87, 93

88, 94

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 97

Programming and Parameters 3-25

Parameter Name & Description

File

SPEED COMMAND

Group

Speed Regulator

See page 3-2 for symbol descriptions

No.

101 [Speed Thresh Pos]

Threshold speed for the drive above or below which the value of Par

393 [Speed Threshold] changes. When the speed of the drive exceeds the value of this parameter, Par 393 [Speed Threshold] displays “Above Thresh” (0). When the speed of the drive is below the value of this parameter, Par 393 [Speed Threshold] displays “Below Thresh” (1).

102 [Speed Thresh Neg]

Threshold speed for the drive above or below which the value of Par

393 [Speed Threshold] changes. When the speed of the drive exceeds the value specified in this parameter, Par 393 [Speed Threshold] displays “Above Thresh” (0). When the speed of the drive is below this threshold, Par 393 [Speed Threshold] displays “Below Thresh” (1).

103 [Threshold Delay]

Amount of time that must elapse before indication that the drive speed

is above the value set in Par 101 [Speed Thresh Pos] or below the value set in Par 102 [Speed Thresh Neg].

104 [At Speed Error]

Defines the speed above and below the speed reference (in Par 118

[Speed Reg In]) at which the value of Par 394 [At Speed] changes. When the difference between the speed reference and the actual speed is greater than the value of this parameter, Par 394 [At Speed] displays “Not Equal” (0). When the difference between the speed reference and the actual speed is less than the value of this parameter, Par 394 [At Speed] displays “Equal” (1).

105 [At Speed Delay]

Amount of time that must elapse before indication that the drive speed

reference is within the range specified in Par 104 [At Speed Error] occurs.

106 [Ref Zero Level]

Speed below which speed references are equal to zero speed. Switch

used in the Speed Zero function.

Value s

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

1000

1 / 32767 RPM

1000

1 / 32767 PRM

100

0 / 65535 ms

100

1 / 32767 RPM

100

0 / 65535 ms

1 / 32767 RPM

393

394

123, 124, 125, 126

107 [Speed Zero Level]

Speed below which the actual speed is considered equal to zero.

When a Stop command is issued and actual speed goes below this value, drive output is disabled. The value applies to both rotation directions for four quadrant drives. Note: Setting the value of this parameter too low could prevent the proper functioning of field economy.

Actual Speed

Actual Speed = 0

Par 395 [At Zero Speed]

Par 108 [Speed Zero Delay]

108 [Speed Zero Delay]

Amount of time that must elapse after the actual speed goes below

the value set in Par 107 [Speed Zero Level] before Par 395 [At Zero Speed] changes state.

Par 107 [Speed Zero Level]

Default:

Min/Max: Units:

Fwd

Rev

Default:

Min/Max: Units:

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

1 / 32767 RPM

100

0 / 65535 ms

395

Page 98

3-26 Programming and Parameters

Parameter Name & Description

File

SPEED COMMAND

Group

Speed Regulator

See page 3-2 for symbol descriptions

No.

123 [Spd Zero I En]

Enables/Disables the output of the integral section of the speed regulator. Used in the Zero Speed function.

• “Enabled” = The output of the integral section of the speed

• “Disabled” = Disables the output of the integral section of the speed

124 [Spd Ref Zero En]

This parameter is only active when Par 125 [Spd Zero P En] = 1 “Enabled”. Used in the Zero Speed function.

• “Enabled” = The proportional gain, equal to Par 126 [Spd Zero P

• “Disabled” = The proportional gain, equal to Par 126 [Spd Zero P

125 [Spd Zero P En]

“Enabled” = When both the speed reference value and the actual speed value = 0, the proportional gain value in Par 126 [Spd Zero P Gain] is active after the delay time defined in Par 108 [Speed Zero

Delay]. Used in the Zero Speed function. “Disabled” = The speed regulator keeps its proportional gain component when the drive is stopped.

126 [Spd Zero P Gain]

The proportional gain of the speed regulator that is only active when

the value of the speed reference and actual speed = 0. This parameter is only active when Par 125 [Spd Zero P En] = 1 “Enabled”. Used in the Zero Speed function.

242 [Speed Reg En]

Enables/Disables the speed regulator output to the torque/current regulator.

• “Enabled” = The speed regulator output is connected to the input of

• “Disabled” = The speed regulator output is not connected to the

348 [Lock Speed Integ]

Enables or disables the integral (I) function of the speed regulator.

• “Not active” = The integral component of the speed regulator is

• “Active” = The integral component of the speed regulator is

regulator is set to zero when the speed reference and the speed feedback are equal to zero. The I component is enabled when a reference value is entered to restart acceleration.

regulator.

Gain] at zero speed, is equal to Par 87 [Spd Reg Kp] when the speed reference is higher than the value defined in Par 106 [Ref Zero Level].

Gain] at zero speed, is equal to the value in Par 87 [Spd Reg Kp] when the speed reference or the actual speed is higher than the value defined in Par 106 [Ref Zero Level].

the torque/current regulator.

input of the torque/current regulator. Par 39 [Torque Ref] is connected to the input of the current regulator.

enabled.

disabled.

Value s

Default:

Options:

Default:

Options:

Default:

Options:

Default:

Min/Max: Units:

Default:

Options:

Default:

Options:

0 =

“Disable”

0 =

“Disable”

1 =

“Enable”

0 =

“Disable”

0 =

“Disable”

1 =

“Enable”

0 =

“Disable”

0 =

“Disable”

1 =

“Enable”

10.00

0.00 / 100.00 %

1 =

“Enabled”

0 =

“Disabled”

1 =

“Enabled”

1 =

“Not active”

0 =

“Active”

1 =

“Not active”

39, 41, 236

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 99

Programming and Parameters 3-27

Parameter Name & Description

File

Group

Speed Regulator

SPEED COMMAND

See page 3-2 for symbol descriptions

No.

388 [Flying Start En]

Enables/Disables the ability of the drive to connect to a spinning

motor at actual RPM when a start command is issued.

• “Enabled” = When the drive is turned on, the speed of the motor is

measured and the ramp output is set accordingly. The drive then runs at the set reference value.

• “Disabled” = When the drive is turned on, the ramp starts from

zero. Main uses:

•To connect to a motor that is already spinning due to its load (e.g.

•Re–connection to a spinning motor after a fault or alarm.

Note: If the Flying Start function is disabled, ensure that the motor is not spinning when the drive is turned on, or harsh motor deceleration in current limit may occur.

444 [Spd Fdbk Filter]

Time constant used by the filter for the Speed Feedback circuit.

Filtering of the high frequency components of the speed feedback signal is useful in the case of elastic coupling between the motor and load (i.e., joints or belts).

445 [Spd Up Gain Pct]

The Speed Up function gain as a percentage of Par 446 [Speed Up

Base].

446 [Speed Up Base]

The Speed Up function maximum gain. This value corresponds to

100% of Par 445 [Spd Up Gain Pct].

447 [Speed Up Filter]

The time constant of the filter for the D (derivative) component of the

Speed Up function.

459 [SpdReg Kp Bypass]

The proportional gain (K

percentage of Par 93 [Spd Reg Kp Base], when an encoder or tachometer feedback signal is changed to armature feedback (Par 458 [SpdReg FB Bypass] = “Enabled”).

460 [SpdReg Ki Bypass]

The integral gain (K

percentage of Par 94 [Spd Reg Ki Base], when an encoder or tachometer feedback signal is changed to armature feedback (Par 458 [SpdReg FB Bypass] = “Enabled”).

493 [Arm Volt Kp]

Proportional gain (K percentage of the value defined in Par 495 [Arm Volt Kp Base].

494 [Arm Volt Ki]

Integral gain (K percentage of the value defined in Par 496 [Arm Volt Ki Base].

495 [Arm Volt Kp Base]

The proportional gain (K

496 [Arm Volt Ki Base]

The integral coefficient (K

in the case of pumps, the flowing medium).

) of the speed regulator, expressed as a

) of the field voltage regulator expressed as a

) of the field voltage regulator (base value).

Value s

Default:

Options:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

0 =

“Disabled”

0 =

“Disabled”

1 =

“Enabled”

0 / 1000 ms

0.00

0.00 / 100.00 %

1000.00

0.00 / 16000.00 ms

0 / 1000 ms

10.00

0.00 / 100.00 %

1.00

0.00 / 100.00 %

30.00

0.00 / 100.00 %

40.00

0.00 / 100.00 %

Based on drive current rating

0.10 / Based on drive current rating A / V

Based on drive current rating

0.01 / Based on drive current rating A / V / ms

121, 122

458

495

496

493

494

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Page 100

3-28 Programming and Parameters

File

Group

No.

1016 [SpdFuncSelect]

1191 [InertiaCompAct]

Speed Regulator

SPEED COMMAND

1192 [InertiaCompVar]

Parameter Name & Description

See page 3-2 for symbol descriptions

Selection of the “Speed Up” or “Inertia/Loss compensation” function. Note that these two functions are mutually exclusive - if one is selected, the other is off.

Displays the active compensation of the fixed section as a percentage of the drive rated current.

Displays the active compensation of the variable section as a percentage of the drive rated current.

Value s

Default:

Options:

Default:

Min/Max: Units:

Default:

Min/Max: Units:

0 =

“Speed Up”

0 =

“Speed Up”

1 =

“Inertia/loss”

Read Only

0.00 / 200.00 %

Read Only

0.00 / 200.00 %

444, 445, 447, 1012, 1013, 1014, 1015

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008