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PowerFlex Digital DC Drive User Manual

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1. Refer to Table 1 M on page 1 33 B Fo for descriptions corresponding kK m O D the ID numbers shown below HOME o O 00 d z D co o U O lg o O Es Ung m 6 O Om 15 FOOD B O m JE l deb hob O O Q oe ZE m SE SIS ho D a a ew Q o p ig d li L ON Q SEEE
2. UO Connection Example Encoder Power 7 Internal Drive Power v Gi m Internal drive 5 12 15V I l DC 200 mA COM Common A z z B to Shield B A A II Encoder Power External Q Power Source Ho AS e com IP zlodi i Y 2 to e 1 91 Shield B External B Supply A A Encoder Signal to Power Single Ended Dual Channel ev Supply Common ZNOT t z EH 74 B O B A Encoder Signal Differential Dual Channel IO COM z Zz B B A IG to Shield UT Shield connection is on drive Control EMI shield Refer to Figure 1 36 on page 1 48 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 50 Installation and Wiring DC Analog Tachometer Terminal Block Figure 1 38 Analog Tachometer Terminal Block Location Ka in ys cae coke 343 Chey CEUX 77 si 1 d A A B B Z Z COM Tachometer ER terminal block aes t l q q ay Le es Refer to page A 4 for DC Analog Tachometer specif
3. Name No Group Page Name No Group Page PID Source 786 PID Control 3 42 Scale3 Input 1218 Scale Blocks 3 43 PID Source Gain 787 PID Control 3 42 Scale3 Mul 1220 Scale Blocks 3 43 PID Steady Delay 731 PID Control 3 40 Scale3 Out Off 1225 Scale Blocks 3 44 PID Target 782 PID Control 3 42 Scale3 Output 1219 Scale Blocks 3 43 Port Mask Act 1379 Security 3 66 Scale4 Div 1230 Scale Blocks 3 43 Powerup Delay 1345 1 Restart Modes ER Scale4 In Abs 1235 Scale Blocks 3 44 Preset Speed 1 154 Discrete Speeds 3 26 Scale4 In Max 1231 Scale Blocks 3 43 Preset Speed 2 155 Discrete Speeds 3 26 Scale4 In Min 1232 Scale Blocks 3 43 Preset Speed 3 156 1 Discrete Speeds 21 Scale4 In Off 1233 Scale Blocks 3 44 Preset Speed 4 157 1 Discrete Speeds 3 26 Scale4 Input 1227 Scale Blocks 3 43 Preset Speed 5 158 Discrete Speeds 3 26 Scale4 Mul 1229 Scale Blocks 3 43 Preset Speed 6 159 Discrete Speeds 3 26 Scale4 Out Off 1234 Scale Blocks 3 44 Preset Speed 7 160 Discrete Speeds 3 26 Scale4 Output 1228 Scale Blocks 3 43 Ramp Delay 20 Ramp Rates 3 33 Scale5 Div 1239 Scale Blocks 3 43 Ramp In 110 1 Speed Meters 11 Scale5 n Abs 1244 Scale Blocks 3 44 Ramp In Pct 111 Speed Meters 3 11 Scaled In Max 1240 Scale Blocks 3 43 Ramp In Zero En 1265 Stop Modes 3 36 Scaled In Min 1241 Scale B
4. No Parameter Name Group Page No Parameter Name Group Page 928 Filt TorqCur Pet Current Meters 3 13 1195 Speed Match VVinder Functions 3 48 1012 Inertia C Filter Autotune 3 23 1196 Spd Match Acc Winder Functions 3 48 1013 1 Torque Const Autotune 2 1197 1 Spd Match Dec VVinder Functions 3 48 1014 Inertia Autotune 3 23 1198 Offs Accel Time Winder Functions 3 48 1015 Friction Autotune 3 23 1199 W Offse Winder Functions 3 48 1016 1 SpdFuncSelect Speed Regulator 31 1200 Spd Match Gain Winder Functions 3 48 1017 Speed Ratio Speed References 3 27 1201 Winder Side Winder Functions 3 48 1018 Speed Draw Out Speed Meters 3 12 1202 W Gain Winder Functions 3 48 1019 Spd Draw Out Pct Speed Meters 12 1203 Spd Match Compl VVinder Functions 48 1021 Encoder Out Sel Speed Feedback 3 22 1204 Line Spd Source Winder Functions 3 48 1022 Encoder Counts Speed Feedback 3 22 1205 Diam Inc Dec En Diameter Calc 3 46 1027 Spd Reg Autotune Autotune 3 2 1206 1 Diam init filter Diameter Calc 3 46 1029 Speed Tune Dir Autotune 3 23 1207 Diam stdy delay Diameter Calc 3 46 1030 1 Spd Tune Inertia Autotune 3 23 1208 Close Loop Comp Winder Functions 3 48 1031 SpdTune Friction Autotune 2 1209 1 Torque Winder En Winder Functions 48 1032 Speed Tune Kp Autotune 3 23 1210 W Target Winder Functions 3 48 1033 Speed Tune Ki Aut
5. Position 1 3 4 5 6 7 8 10 11 12 13 14 15 16 a b c d e f g h i j k fl g Drive 230V 60 Hz Input Field Supply Code Type Code Hp 577 Frame re Code Type 20P PowerFlex DC mps mps R Single Phase Regulated 7P0 1 5 7 A 10 9P0 2 9 A 10 b 012 3 12 A 10 h Motor Operation 020 5 20 A 10 Packaging Documentation Code Type 029 75 29 A 10 Code Shipping Carton User Manual p Two Quadrant Operation 038 10 38 10 Yes Yes 4 Four Quadrant Operation 055 B A 10 Not available for 230V AC input drives y 20 LE 093 25 93 14 i 110 30 110 A 14 HIM 146 40 146 20 Operator Interface Input Type 180 50 180 B 20 0 Blank Cover Code Type 218 60 218 B 20 Standard for additional selections refer to the 1 6 Pulse 265 75 265 B 20 PowerFlex Digital DC Drive Technical Data 360 100 360 B 20 publication 20P TD001 434 125 434 B 20 d 521 150 521 C 20 Enclosure EO NN 1 0 Options Conform Code Enclosure Rating Coat f2 Code Control A IP20 NEMA UL Type Open No 460V 60 Hz Input I O Expansion Card 4 Additional 24V C A dc Digital Inputs amp Outputs 2 Analog Armature Field Code Hp A Frame Outputs mps Amps e 281 2 21 A 10 B 115V ac Conversion Card 8 Digital Inputs amp Outputs Mutola 0 3 S A 10 c 1 0 Expansion Card 115V ac Code Voltage
6. Programming and Parameters 3 83 No Parameter Name Group Page No Parameter Name Group Page 84 Anlg In3 Offset Analog Inputs 3 68 175 1 Rated Motor Volt Motor Data 3 15 87 Spd Reg Kp Speed Regulator 3 27 179 Nom Mtr Arm Amps Motor Data 3 15 88 Spd Reg Ki Speed Regulator 27 181 Adaptive Spd En Adaptv Regulator 3 3 91 Fid Reg Kp Field Config 3 16 182 1 Adaptive Reg Typ Adaptv Regulator 3 36 92 Fld Reg Ki Field Config 3 16 183 1 Adaptive Ref Adaptv Regulator 3 36 93 Spd Reg Kp Base Speed Regulator 3 27 184 1 Adaptive Spd 1 Adaptv Regulator 3 36 94 Spd Reg Ki Base Speed Regulator 3 27 185 Adaptive Spd 2 Adaptv Regulator 3 36 95 Spd Reg Pos Lim Speed Regulator 3 27 186 1 Adaptive Joint 1 Adaptv Regulator 3 36 96 Spd Reg Neg Lim Speed Regulator 28 187 Adaptive Joint 2 Adaptv Regulator 3 37 97 Fid Reg Kp Base Field Config 3 16 188 Adaptive P 1 Adaptv Regulator 3 37 98 Fid Reg Ki Base Field Config 3 16 189 Adaptive Gain1 Adaptv Regulator 3 37 99 Spd Reg Kp Outpt Speed Regulator 3 2 190 1 Adaptive P Gain2 Adaptv Regulator 37 100 Spd Reg Ki Outpt Speed Regulator 3 28 191 Adaptive Gain2 Adaptv Regulator 3 37 101 Speed Thresh Pos Speed Regulator 3 28 192 1 Adaptive P Gain3 Adaptv Regulator 3 37 102 Speed Thresh Neg Speed Regulator 3 28 193 1 Adaptive Gain3 Adaptv Regulator 3 37 103 Threshold Delay Speed Regulator 3 28 199 Arm Current Pct Cu
7. 2 34 on I O TB4 Fs26 N O Relay C M1 AC Contactor Aux m 19 24V on I O TB2 13 14 Fst 1A1 A L1 5 Li Ti U N EST Armature Volt At L2 T2 Fdbk Term L2 e e V 1A2 M is Ta P 3 Phase AC line L3 W A2 A A2 A2 PovverFlex DC Fs29 Drive Control f U2 Board P S 460V 115V V2 35 D Control Power Relay 36 Terminal Block Field Power Terminal Block U1 C1 F1 FU1 FV1 V1 D1 F2 1 AC input fuses for the armature converter are customer supplied for frame A and B drives and are internally mounted on frame C drives See Drive Power Circuit Protection on page A 8 for fuse recommendations 2 Par 140 Digital In8 Sel set to 31 Contactor 8 Customer supplied armature output fuses are required on four quadrant and are recommended on two quadrant Frame A and B drives See Drive Power Circuit Protection on page A 8 for fuse recommendations 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 23 4 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 23 through Figure 1 25 5 Optional armature voltage feedback sensing not needed wi
8. When metal pin fits in keyhole lift cover off drive chassis PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installing a Communication Adapter E 5 b On frame B and C drives loosen but do not remove the screws that secure the top cover to the drive then slide the cover up and off the drive chassis Important The HIM assembly is connected via a cable to the Control board and therefore will not pull free from the drive until disconnected See page E 6 for instructions Frames B amp C Frame B shown L Alen Bradiey PowerFlex L 1 9 2 72 Oe PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 E 6 Installing a Communication Adapter 5 Disconnect the HIM Communication cable from the connector on the upper right corner of the Control board and set the cover aside All Frames Frame A shown OG Pull tabs out to disconnect cable 6 Secure and ground the Communication Adapter to the EMI Shield on the drive using the four captive screws Important All screws must be tightened because the adapter is grounde
9. 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 and C Drives Frame B Shown nal 8 8 C l td 0220 N PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Line Reactors Using Contactors Installation and Wiring 1 9 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 18 for a list of recommended AC line reactors When using an AC input contactor the TEC ACT 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 20 for wiring examples e When only an AC contactor is used S
10. 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 Nem 200 Ibein PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Removing the Drive Covers Installation and Wiring 1 7 The lower protective cover must be removed in order to access the drive s power and VO 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 for information Frame Drives You must remove both the lower protective cover and the power terminal cover on frame 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 H c v D w v Yu ex oves H W R urines WE PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 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 ua TTTTTTTTUUT
11. C 11 Using an Inverting Fault Device Only C 11 Using a DC Contactor and an Inverting Fault Device C 11 Using a DC Contactor a Dynamic Brake and an Inverting Fault Device C 12 PID PUNCHOMN D e ee o on Use D Sese MO d oe er C 13 Configure a Line Speed Signal C 14 Configure the Feedback Signal in the Follower Drive s C 15 Configure the Tension Set Point Signal in the Follower Drive s C 17 Reference Control ces esa cewek cea ea E E a ee e b C 18 Auto Speed Ee 2eme bake abonner Re RU gp ea om RADI rg C 18 Manual Speed Sources C 18 Changing Speed Sources C 18 Torqu Reference adu e ada pie oda aa a Aba CL CR sd o C 18 Auto Manual Examples C 19 Speed Feedback oc sia 088 den pause Frane edom ARENS d A C 20 scale Blocks se tex unis qoe IP m ad pa an b nn dal al ee AEN C 21 Linking Parameters Via the Scale Block Parameters C 22 Speed Regulation Functions C 22 Adaptive Speed Regulator dee cee eae qae E WEE C 22 Speed Up bunctnon 0 0 cece C 25 Speed Threshold Indic
12. B 1 LCD Display Blements oret ere ee per ete Genie E Rt d B 1 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Appendix C ALT PunctiOnS 1 raro Ru ence epu 7 Tap RUE ep tw Ede eee B 2 Using the S M A R T List Screen B 2 Men Stricture cites ea ur aod Lie eR eb e RATER RC a e PaL Ow ae B 3 Viewing and Editing Parameters B 5 ECD HIM eese 7 B 5 Removing Installing the HIM B 6 Application Notes Alpha Test Mode cete Rer e pr Ee eR PEN AH ee ie C 1 Alpha Test Setup and Operation C 2 Analog Input Configuration C 4 Example 17 5 s cesse stad me bre OT th Eae Ea ied nies C 4 Example 22 e bee da ar du hes cea d deb edet isin C 4 Analog Input Signal Comparison C 5 Current Speed Curve s ka ha hehe C 6 Drive Reference and Feedback Scaling C 7 Droop Compensation C 9 Field Weakening Mode Configuration v1 006 C 10 Using a DC Contactor Only 2 C 10 Using a DC Contactor and a Dynamic Brake
13. PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 4 16 Troubleshooting Notes PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Specifications Appendix A Supplemental Drive Information For information on See page Specifications A 1 IP20 NEMA UL Type Open Watts Loss A 5 Communication Configurations A 6 Drive Power Circuit Protection A 8 Control Power Circuit Protection Fuses A 16 AC Input Line Reactors and AC Input Contactors A 18 DC Output Contactors and Dynamic Brake Resistor Kits A 20 DC Contactor Crimp Lug Kit Specifications A 22 Category Agency Certification Category Drive Type Specification According to file E59272 for the series of the approved devices C In conformity with the following European Directives EMC Directive 2004 108 EC Low Voltage Directive 2006 95 EC Standards applied EN 50178 1997 EN 61800 3 2004 In conformity with the following Australian Communications and Media Authority Radio communications Act 1992 Radio communications Standard 2008 Radio communications Labelling Notice 2008 Standards applied EN 61800 3 2004 The drive is also designed to meet the following specifications NFPA 70 US National Electrical Code Specification Full Wave Regen 6 Pulse Regulated Field Supply Protection Heat S
14. 2 g o S g Parameter Name amp Description s ip Z See page 3 2 for symbol descriptions Values ka 239 SpdOut FiltBW Default 0 238 First order lead lag filter bandwidth on the speed regulator output Min Max 0 2000 signal Units ms Note This parameter was added with firmware version 3 001 242 Speed Reg En Default 1 Enabled 39 2 Enables Disables the speed regulator output to the torque current Options 0 Disabled H regulator 1 Enabled 236 e Enabled The speed regulator output is connected to the input of the torque current regulator e Disabled The speed regulator output is not connected to the input of the torque current regulator Par 39 Torque Ref is connected to the input of the current regulator Note This parameter is only available for use with firmware version 2 005 and lower ATTENTION Failure to correctly set speed and voltage parameters or provide overspeed protection when operating as a torque current regulator could result in high motor speeds equipment damage and or personal injury 348 Lock Speed Integ Default 1 Not active Enables or disables the integral I function of the speed regulator Options 0 Active e Not active The integral component of the speed regulator is 1 Not active enabled a e Active The integral component of the speed regulator is E 5 disabled 1388 Flying Start En Default 0
15. o Parameter Name amp Description s See page 3 2 for symbol descriptions Values Data In 11 Link Word 1 Default 0 0 Disabled Data In A2 Link A Word 2 Min Max 0 1408 Parameter number whose value will be written from a communications device data table The value will not be updated until the drive is stopped Refer to your communications option manual for datalink information Data In B1 Link B Word 1 See Data In A1 Link A Word 1 Data In B2 Link B Word 2 Data In C1 Link C Word 1 See Data In A1 Link A Word 1 Data In C2 Link C Word 2 Data In D1 Link D Word 1 See Data In A1 Link A Word 1 Data In D2 Link D Word 2 Data Out A1 Link A Word 1 Default 0 0 Disabled Data Out A2 Link A Word 2 Min Max 011408 Parameter number whose value will be written to a communications device data table Data Out B1 Link B Word 1 See Data Out A1 Link A Word 1 Data Out B2 Link B Word 2 Data Out C1 Link C Word 1 See Data Out A1 Link A Word 1 Data Out C2 Link C Word 2 Data Out D1 Link D Word 1 See Data Out A1 Link A Word 1 Data Out D2 Link D Word 2 Data In Val Sel Default 610 1320 Selects the Datalink parameter register to display in Par 1320 Min Max 610 617 Data In Sel Data Data In SelData Default Read Only 1319 Displays the value selected in Par 1319 Data In Val Sel Min Max 423 Logic Mask Determin
16. PXXX Parameter Number ParName z Parameter Name PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Control Block Diagrams D 2 112 DI AO red HE Sduly D AN WON gi wa u Big g w43 ul Big y Wiel ul Big 0822 9 Sd 2154 8994 LE ue ui big 1 ue l big Wiel u Big GS LS 199 a HN I 01 uuo uj biq 9 ue l Big z wa uy Big 1041009 Dia Hd 0 Sd 9934 yuaung d km m m 1 6 ue u Big c ue l big ue uj biq Sd 6954 8954 ul Bay Juang 22 l uoisuedxz v yoolg jeuruuo L z 19019 Ieuuuel Y snes s ndui jeu6ig yoeqp i pds 011002 1010 J a 7 ES H d 140 99U919 9H ul Beg peeds 110 dwey ul dureg CL uj Bopeuy s da ED JoyejnBay 1ueun 2 p ds 8113 eiig 0114 ll Ka 199188 RNT Joye nBay p ds wey 6614 b 0000000000000 O Gu O Sou LES peedg 1v ejelg jepoou3 enneBen enbio L env Wun VUE red 1994 Led bred 1 jenb3 ON 1 plouseuu 1 mojeg L L L0LL00000LLL0000 enba O 0 e oqv O 0 O 0 O smejs peedg 0187 1v piouseiu peedg eniisog nbiop Jur pds 1964 9664 8664 9764 lled 18M
17. PI Central vs1 The output selector of the initial PI block With the value of Par 780 PI Central vs0 determined through binary selection what between the four possible settings of the integral initial level correspondent to initial diameter can be used See Par 780 PI Central vsO for binary selections PI integr freeze Locks the selections made for the integral component of the PID regulator PI Upper Limit Defines the upper limit of the adapting block for correction of the PI block PI Lower Limit Defines the lower limit of the adapting block for correction of the PI block PI Init Prop Gn The initial value of the proportional gain This parameter is active when its value has exceeded the value of Par 695 PI Steady Thrsh e the amount of time defined in Par 731 PID Steady Delay has elapsed and feed forward is less than the value defined in Par 695 PI Steady Thrsh or e Par 769 Enable PI transitions from 0 low to 1 high and the amount of time defined in Par 731 PID Steady Delay has elapsed Values Default Min Max Default Min Max Default Min Max Default Options Default Min Max Default Min Max Default Min Max Programming and Parameters 0 3 0 1 0 1 Off Off 0 0 1 On 10 00 Par 785 PI Lower Limit 10 00 0 00 10 00 Par 784 PI Upper Limit 10 00 0 00 100 00
18. 3 50 Programming and Parameters Utility File a S g Parameter Name 8 Description it Z See page 3 2 for symbol descriptions Values 209 Save HIM Ref Enables a feature to save the present reference value issued by the HIM to drive memory when a power loss occurs The value is restored to the HIM at power up Bit 0 At Pwr Down 0 Do not save 1 Save at power down g7 gZ ggg ggg g ggg glg gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt 29 2 els else mmm md o o o o o o o o o o o o o o o P m m m x E aq mz E E e E O E a Defaut x X X Xx X X X X X X x x x x x 1 Bit 15 14 13 12 11 109 8 7 6 5 4 3 2 1 10 210 Man Ref Preload Default Enabled Enables disables a feature to automatically load the present Auto Options Disabled reference value into the HIM when Manual is selected Allows Enabled smooth speed transition from Auto to Manual 249 Save MOP Ref Enables Disables the feature that saves the present MOP reference at power down or at stop o Note This parameter can be assigned to a digital input 8 e Bit 0 At Pwr Down When set to 0 Do not save 1 Save o e Bit 1 At Stop When set to 0 Do not save 1 Save M c TD L L Q Q Q V L Q L Q 2 9 9 9 0 o io o o olo lo io olo Jo lo 2 Z 8 8 8 8 8 618 8 618 8 818 8 m x x
19. o 1 a 2 A m 2 0 LC z Ss EE DO rge o Dele LR gu zuo o o LI 9 8e eo v 4 NO m and Q Gg c ER a e ERE 8 eo NO r SC a o ag S st Ss TO oo oo v D on NO oo o tr ae 8 x Gc e oo A o 2 o gt o ES E o E er o O 6 o Qs ca c Es o 2 LL o mm i NO SE 88 E 22 c o o o N 82 Ge o QA E o o o o o o o o o o o o o o o D To pds yoeqpee XEN 291 12d PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 21 Scale Blocks The Scale Blocks function allows you to link or rescale dissimilar parameter types for example integer vs real though multiply divide maximum and minimum limits input and output offsets and absolute value functions There are six individually configurable Scale Blocks A representative block diagram is shown below Important The Scale Blocks functions are executed sequentially in the background which can cause a delay in processing data between the input and output values The amount of delay is dependant on the application The following rules apply to Scale Blocks Scale Block 1 All input Scalex Input and output Scalex Output values are specified as a parameter
20. vK 115V AC to 24V DC I O Board To Digital Inputs Terminals 12 15 31 34 on Control Board To Drive To Digital Input Common Supplied Terminal 16 or 35 24V DC and 24V Supply Common Terminal 19 Terminal 18 on Control Board on Control Board Internal Wiring I 1 1 I 1 1 I 1 External 115V AC 1 1 1 I Customer Wiring Figure G 3 1 0 Converter Board with External Supply Wiring Diagram ek Main Control Board 115V AC to 24V DC I O Board AC INPUT 2 3 4 5 6 7 80 1 To Drive Digital Inputs Terminals 12 15 31 34 1 1 1 1 1 l i 1 1 d d eu 1 l 1 B i 1 To Digita 1 1 From InputCommon To External External 115V AC External Terminal 16 or 35 24VDC 24VDC Supply Supply Internal Wiring Common 1 Customer Wi
21. 6914 2 p ds LOIS x pul Z lt 3 S a S Jepoou3 m o o L g FE 8 ed 89110 Xqp4 2 Vzilid 49 qid MANO qa Ltd Le peedg jepoou3 SJES 1epoou3 V 9 rd 1992 Le y s 19d peqp z pds Lg X JOSHO xoeqpee S 214 Vie 8954 1013 03 peeds 2 10A 100W Da ypeqp i pds soyd 9214 0214 SS SS x ms ue peedg jejeuioupe g Y g0rld 4 abe y l Od E e o o uoe 2 ed q yap ured upe Buy 2 2 lid 2924 E HOA JOJO Pavey 9 14 16 une 5507 xoeqpee enjeu y H Q o o obeon enjeuuv V ed 80118 XAPA CES 8 7194 ssed g g4 Deupde 8974 ssed g xoeqpee einjeuuy YoBqp 4 peeds Control Block Diagrams D 12 guey Ian 6614 LUE ex depy 1614 Ure eandepy 6814 1O ni Bey pds 0197 0014 uq pas 1814 19d l Bay peeds 9 601 0187 p ds 2114 ndino xoeqpee Jj pue UreJDeiq yoolg endepy p ds Jeu enidepy JoyeinBay peedg uio14 8814 Dou p ds 4907 ged indino Id ureJ amp eiq yoolg JoyeinBey p ds oL dnpuim nuy Cured 2614 cured 49 0 0614 EURO d enidepy mo dy Bay pds 66d syw Wan enbioL dnpuiM nuv ug pds 1814 ley yap pds ssedfg ty Baypds eseg iy Day pas Teen eq o yoeqp i 0974 2 eBeyoa enjeuuy Busnes s0 s euis 10 eu pue 1 ssedAg g4 D
22. nput Current 4 5 mA 6 8 10 9 mA each channel Quadrature 90 27 25 C Duty cycle 50 10 Source Sink capable Pulses Per Revolution 600 to 9999 Maximum Frequency 150 kHz Maximum Cable Length Shielded 150m 0 75 mm 125m 0 5 mm 55m 0 22 mm DC Analog Tachometer Input Voltage 22 7 45 4 90 7 181 6 amp 302 9V max nput Current 8 mA full scale Maximum Cable Length Shielded depends on the installation typical 150m Inputs Analog Inputs Three configurable isolated differential HOV 0 10V 0 20mA or 4 20mA Resolution 11 Bit sign Digital Inputs Eight standard configurable four additional configurable with the 1 0 Expansion circuit board Max Voltage 30V DC input 200mA total current draw is the sum of encoder power digital outputs and any other loads connected to terminal 19 Outputs Analog Outputs Two standard configurable two additional configurable with the 1 0 Expansion circuit board Sampling rate 2 ms x 10V 5mA bipolar current is not bipolar Resolution 11 Bit sign Digital Outputs Four standard configurable four additional configurable with the 1 0 Expansion circuit board 30V 50mA Relay Outputs PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Two configurable N O contacts Max 250V AC 1A AC1 Supplemental Drive I
23. 10 24VDC Drive supplied power for Digital Outputs Max volt 30V max cur 80mA Table F C 1 0 Expansion Board Terminal Block 2 Designations No Signal Description Factory Default Config Parameter 11 Digital Input 9 Max volt 30V max cur 15V 3 2mA 24V 5mA 12 Digital Input 10 and 30V 6 4mA 13 Digital Input 11 14 Digital Input 12 15 Digital Input Common Figure F 2 1 0 Expansion Board Wiring Diagram Control Board g Analog Outputs Digital Outputs Digital Inputs o Ei 5 vie e S x 5 6 T 5 9 10 11 12 di E Q E o 9 o o o 24V 0v PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 What This Option Board Provides Appendix G Optional 115V AC to 24V DC I O Converter Circuit Board The 115V AC to 24V DC I O Converter circuit board allows you to convert 115V AC digital input signals to 24V DC digital input signals in order to interface with the standard digital I O terminal blocks on the PowerFlex DC drive Control board The card consists of e Eight 8 opto isolated 115V AC digital inputs Eight 8 interface outputs for the digital inputs on Control board of the drive e Two 2 input terminals for the 24V DC power supply voltage Figure G 1 115V AC to 24V DC I O Conve
24. o 1 354 365 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 36 Programming and Parameters 2 g 8 g Parameter Name amp Description iz Z See page 3 2 for symbol descriptions Values m 1265 Ramp In Zero En Default 0 Disabled 3 Enables Disables the setting of the ramp input to zero Used with Options 0 Disabled E External Brake Control Enabled 2 1266 Actuator Delay Default 0 o Amount of time before the actuator releases the load Used with Min Max 0 30000 External Brake Control Units ms 1344 Start At Powerup Default Disabled 1345 Enables Disables the ability to issue a Run command and Options 0 Disabled e automatically resume running at commanded speed after drive input 1 Enabled power is restored and the time in Par 1345 Powerup Delay has elapsed Requires a digital input configured for Run and a valid start condition o 8 2 Y ATTENTION Equipment damage and or personal injury may result if this parameter is used in S an inappropriate application Do not use this function without considering applicable local 8 national and international codes standards regulations or industry guidelines 1345 Powerup Delay Default 1 1344 Defines the programmed delay time in seconds before a start Min Max 17 10800
25. Key Press GP to move between menu items Press e to select a menu item Press to move 1 level back in the menu structure Press Ep 62 to select how to view parameters PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 B 4 HIM Overview Diagnostics Menu VVhen a fault trips the drive use this menu to access detailed data about the drive Option Description Faults View fault queue or fault information clear faults or reset drive Status Info View parameters that display status information about the drive Device Items View statistics associated with DPI Communications Device Version 1 View the firmware version and hardware series of components Parameter Menu Use this menu to view and edit parameters for the drive When you enter the the Parameter menu by default the File Group Parameter view is displayed To access other views for the Parameter menu with Parameter highlighted in the Main menu press Alt then Sel View select the desired view in the list and press Enter The following selections are available Option Description Param Access Lvl Displays parameter 211 Param Access Level The PowerFlex DC drive is initially set to the Basic Parameter view To view all parameters set parameter 211 Param Access Lvl to option 1 Advanced File Group Par FGP Displays all parameters in a File Group Parameter structure This simplifies programm
26. the last value of the integral component calculated corresponding to roll diameter is stored in Par 771 PI Output This value is used by the PID regulator when the PI block is enabled again and the drive is restarted This function is useful when for any reason the drive must be turned off or if incoming power is removed from the drive 1 2 or 3 When the PI block is disabled Par 769 Enable PI Disabled the value of PI Output will be set to the value of the selected parameter 1 776 PI Central v1 2 777 PI Central v2 or 3 778 PI Central v3 x1000 This value is only used by the PID regulator when the drive is powered up and Par 769 Enable PI is already enabled Note Par 779 PI Central v sel can be set directly from the HIM or through two digital inputs set respectively as PI central vs0 and PI central vs1 Refer to Pars 780 PI Central vs0 and 781 PI Central vs1 for more information on this configuration PI Central vs0 When assigned to a digital input and used in combination with Par 781 PI Central vs1 through binary selection determines which of the four possible output values is used as the initial level of the integral component corresponding to the initial diameter of the PI block Par 780 Par 781 0 0 Selects the value in Par 771 PI Output 0 1 Par 776 PI Central v1 1 0 Par 777 PI Central v2 1 1 Par 778 PI Central v3
27. 100195 dOW 9614 ang z p d s lq 9614 les gul DU 084 195 eui ouv 9 4 les Lui bu 04d 104 g jeu peeds d 8 Jeu poods 874 V Jeu poods LOL 001 110 Jeu pds G8Ed LLO 10d INO jeu 005 ged 1 renuen 010 100 Z va p sd ui Y 9a geck A mox 1 210 L SNIS SAUA 186 Jed 924nos jenuel yo S pma pasds uy Vl un 204 USH 91507 SAUA 8ZEL 1ed 342 Bor peeds uinum oL Id qur peeds uinum gi 001 9011 920v dON 0 any 224 73914 7399Y GLq 1 smeis OALA Lge Jed 90 enuen ony Mu peeds mum 100 Id p ds wnwixey 000 zd TT indui pg KKK D dO do dOlN 93a o q dON o o E ONI ndu jey 61p T mes oul dON peuyep ou ji A sinduj 2610 indui epp yoolg jeuruue L jeseu d l U ll l S2U919J04 p ds ttd Pd v jeu peeds Led 8S MO J6poou3 1201 4 199195 Sd Idd 12614 199195 yd Idd 92614 Top Ed Idd 92614 19919S cd Idd 72614 199195 bd Idd 82614 les 641 Djuv 08d 195 cui ouv 5 4 les Lu bjuv 04d PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 Control Block Diagrams D 6 0000 oleu p ds 110 mesq p ds 81014 19d 1no weg pds 61014 oneu pads HIR meid p ds uz dwey p ds
28. B ME EZ 35 36 75 76 78 79 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 29 on page 1 35 For frame C drive SA SB terminal block location refer to Figure 1 30 on page 1 36 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 34 Installation and Wiring Figure 1 26 Frame A Control Circuit Terminal Block Location U2 VZ Figure 1 27 Frame B Control Circuit Terminal Block Location JUN Zr sL iS Di DESS DRETT xy Hr Vr a d PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring 1 35 Figure 1 28 Frame C Control Circuit Terminal Block Location DANGER RISK OF ELECTRIC SHOCK DISCONNECT INPUT POWER BEFORE SERVICING EQUIPMENT a DO e aiaia oaa 35 36 75 76 7 H U2 V2 PE Table 1 J Control Circuit Wire Sizes and Terminal Specifications Drive Current Rating o Code Wire Size and Type E Multi core Tightening Torque re Terminals mm mm AWG Nem Ibein 0 5 44 Refer to Standard Drive Catalog Number Explana
29. June 2009 Control Block Diagrams D 8 eseg dn p ds 1911 dN p ds 104 ute 00 pds gird Lrtd gird dn p ds o o yoajagounspds 91014 dn p ds yoeqp i pds x Zld etd Daach 19d yoeqpae pds 214 8S ING Jepoou3 peedg Em m smo 12013 7464 11 83 pds 9164 8e1peo1 TUIS DY 6264 um s Pass Sd Idd ured 11 g4 005 LeEld l6d 109199 bd Idd 9214 l 1098 d Ida AU d p ds ur 92614 uiri Be sod Bay pds E Y ed J Poles Zd Idd Ulu Joq6169 u DCH 1 veeld 5 LLq Dap Ld 140 ulrisodf upds 014 60614 c SNJEIS eAug 2964 9160 dnpum nue le eui s pnioul 10jejnai yd 08d Ben Set pd 1111 les zu u TE opis ur Deu Se 1dino ni Bey pds Id es z l du 0014 pmd peeds UN dino dy Beg pd es Lu Du Uri MOPS rr sog Bay ps PRO 5 AEN BS S6d 1 7 QE Deppen yur weiBeiq yoolg m Yd 1no Bay pds 110 mesq peeds Dog poyy nbiol oL RISCH 9624 81014 Jod INQ asiq pds 1 d Bou peeds 61014 ul Bay p ds paeds VE weeg uonejeuac 804 Yd eouejejag p ds wol4 Pd ul peeds pm peeds xeyy 114 d p
30. Min Max Default Min Max Default Min Max Units Default Min Max Default Options Default Min Max Default Min Max Default Min Max Default Min Max Default Min Max Default Min Max Units Default Min Max Read Only 10000 1 00 0 00 100 00 0 1 1000 ms 10 00 0 00 100 00 Disabled Disabled 1 Enabled 10 0 0 0 100 0 0 0 10 0 0 0 100 0 10 0 0 0 100 0 1 00 0 00 100 00 Read Only 10000 0 0 60000 ms 10 00 0 00 100 00 Related 181 181 181 181 181 181 758 771 695 734 793 695 731 769 File APPLICATIONS Group PID Control No 757 758 759 760 761 762 763 772 773 774 Parameter Name amp Description See page 3 2 for symbol descriptions PID Clamp The PID clamp allows a smooth tension setting of a controlled system winder unwinder when the calculation of the initial diameter function cannot be used e When enabling the drive the dancer is at the lowest point of its full scale In this case with Par 759 PID Error at its maximum value the motor could accelerate too fast to properly configure the dancer for its central operating position By setting the value of Par 757 PID Clamp sufficiently low e g 1000 when the drive starts and Par 770 Enable PD 1 Enable the value of Par 759 PID Error
31. Reserved 20 UsrDefined1 Par 504 36 Out Volt Lvi Par 921 bz IrgRedCurLim Par 13 121 UsrDefined2 Par 505 37 z Reserved 6 Torque Ref Par 39 22 UsrDefined3 Par 506 38 Speed Ratio Par 1017 7 Trim Torque Par 40 23 UsrDefined4 Par 507 39 Reserved 8 Reserved 24 UsrDefined5 Par 508 40 Reserved 9 Trim Ramp Par 42 25 UsrDefined6 Par 509 41 Tension Red Par 1179 10 Speed Par 43 26 UsrDefined7 Par 510 42 Reserved 11 Reserved 27 UsrDefined8 Par 511 43 Reserved 12 Reserved 28 UsrDefined9 Par 512 44 CloseLp Comp Par 1208 13 Reserved 29 UsrDefined10 Par 513 145 Reserved 14 Adaptive Ref Par 183 30 UsrDefined11 Par 514 146 Reserved 15 Reserved 31 UsrDefined12 Par 515 Default 0 Not Used 787 PID Source Gain 1046 PID Accel Time 1047 PID Decel Time Gain of the input value to Par 786 PID Source Ramp acceleration time after the block PID offset Ramp deceleration time after the block PID offset PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Options 0 Not Used 16 SpdRegOutPct Par 236 32 UsrDef
32. by Number 3 82 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 e ENUM Parameters ENUM parameters allow a selection from two or more items The LCD HIM will display a text message for each item e 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 for example 0 1 Volts The example on the following page shows how each parameter type is presented in this manual II 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 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 2 Programming and Parameters 0 860 o 2 2 2 2 o ET L z Parameter Name amp Description Values m 388 Flying Start En Default 0 Disabled Enables Disables the ability of the drive to connect to a Options 0 9y Disabled spinning motor at actual rpm when a start command
33. 10V 200 of Par 179 Nom Mtr Speed Arm Amps x Par 175 Rated Motor Volt 13 Motor Curr Par 199 10V 200 of Par 179 Nom Mtr 131 Roll Diam Par 1154 0 10V 0 100 of Par 1153 Max Arm Amps Diameter 14 Motor Volts Par 233 10V 100 of Par 175 Rated Motor 32 Tension Ref Par 1180 0 10 0 100 of Par 1153 Max Volt Diameter 15 Analog In 1 Par 70 10V 10V on Analog Input 1 33 Torque Curr Par 1193 10V 200 of Par 179 Nom Mtr Arm Amps 16 Analog In 2 Par 75 10V 10V on Analog Input 2 34 Winder Ref Par 1217 x10V 100 of Par 45 Max Ref Speed 17 Analog In 3 Par 80 10V 10V on Analog Input 3 35 Active Comp Par 1213 10V 200 of Par 179 Nom Mtr Arm Amps PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 70 z 133 134 135 136 137 138 139 140 141 142 143 144 INPUT OUTPUT Programming and Parameters Parameter Name amp Description See page 3 2 for symbol descriptions Values Digital In1 Sel Default 2 Stop CF Digital In2 Sel Default 3 Start Digital In3 Sel Default 11 Jog Digital In4 Sel Default 1 Enable Digital In5 Sel Default 17 Speed Sel 1 Digital In6 Sel Default 18 Speed Sel 2 Digital In7 Sel Default 19
34. Deceleration Rate 1 command Bit 11 Decel 2 Deceleration Rate 2 command Bit 12 14 Spd Ref ID 0 2 Speed reference source Bit 15 MOP Dec MOP Decrement command Related File No o N e m o A JQ 815 lz Ble sie 2 23 SESE SEESESES EES Default 0 0 0 0 0 0 0 00 00 0 1 Bit 15 14 113 1211109 8 7 6 5 4 B 2 1 0 Bits 14 13 112 Description 0 0 0 No Command Manual Mode 0 0 1 Spd Ref A Auto 0 1 0 Spd Ref B Auto 0 1 1 Preset Spd 3 Auto 1 0 0 Preset Spd 4 Auto 1 0 1 Preset Spd 5 Auto 1 1 0 Preset Spd 6 Auto 1 1 1 Preset Spd 7 Auto PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 56 Programming and Parameters g Parameter Name amp Description See page 3 2 for symbol descriptions 1381 TestPoint Sel 2 information TestPoint Data TaskLoad 32 ms TaskLoad 1 ms TaskLoad 2 ms TaskLoad 8 ms Last Stop Source Start Inhibits The load percentage of the 32 ms task in the firmware The load percentage of the 1 ms task in the firmware The load percentage of the 2 ms task in the firmware The load percentage of the 8 ms task in the firmware Selects the function whose value is displayed in TestPoint Vall These are internal values that are
35. Field Weakening Mode Important This configuration applies only to firmware version 1 006 For Configuration v1 006 instructions on configuring a drive with firmware version 2 001 for use with an AC or DC contactor with or without a dynamic brake refer to Using Contactors on page 1 0 The following configuration is required when operating the drive in field weakening mode with a DC contactor and or inverting fault device installed in the armature circuit proper installation Rockwell Automation Inc 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 hazard of personal injury and or equipment damage exists if codes are ignored during installation ATTENTION The following information is merely a guide for When operating the PowerFlex DC drive in field weakening mode parameter 469 Field Mode Sel set to 1 Field VVeaken and using a DC contactor and or an inverting fault device in the armature circuit you must complete the appropriate installation and programming requirements detailed below Using a DC Contactor Only 16 Set parameter 1391 ContactorControl to Contactor default value 17 Set one Relay Out x Sel parameter and one Digital Inx Sel parameter to Contactor default value for parameters 1392 Relay Out 1 Sel and 140 Digital In8 Sel 18 Connect the DC contactor au
36. Line speed Diam Calc Dis Enables Disables the diameter calculation see also Par 1155 Line Spd Thresh The last calculated diameter value is saved if this parameter is changed to 0 Off while the diameter is being calculated Diameter Filter Diameter calculation filter Base Omega Winder speed at the maximum line speed and minimum diameter of the winder unwinder motor shaft side Diam Preset 0 First preset starting diameter The value of this parameter must be set between the value of Pars 799 Minimum Diameter and 1153 Max Diameter Values Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Default Min Max Default Min Max Units Default Min Max Default Min Max Units Default Options Default Min Max Units Default Min Max Units Default Min Max Units Programming and Parameters 1 00 0 00 32 00 m Read Only 0 00 32 00 m 5 00 0 00 150 00 0 0 32767 0 071 10 00 0 00 150 00 Read Only 071 Read Only 0 00 150 00 1 On 0 Off 1 On 100 0 5000 ms 1500 078191 rpm 1 00 0 00 32 00 m 3 45 Related 1162 1206 1207 1286 1160 1284 1168 1153 1159 1158 1155 799 1153 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 46 Programming and
37. Par 504 10V 2047 in Par 504 Speed UserDefined1 3 Ramp In Par 110 10V 100 of Par 45 Max Ref 21 UserDefined4 Par 507 10V 2047 in Par 507 Speed UserDefined4 4 Ramp Out Par 113 10V 100 of Par 45 Max Ref 22 UserDefined5 Par 508 10V 2047 in Par 508 Speed UserDefined5 5 Spd Draw Out Par 1018 10V 100 of Par 45 Max Ref 23 UserDefined6 Par 509 10V 2047 in Par 509 Speed UserDefined6 6 Trim Speed Par 43 10V 10096 of Par 45 Max Ref 24 Field Ref Par 500 0 10V 0 100 of Par 280 Nom Mtr Speed Fld Amps 7 Spd Reg ln Par 118 10V 100 of Par 45 Max Ref 25 PID Output Par 774 10V 10000 in Par 774 PID Output Speed 8 Spd Reg Out Par 236 10V 100 of Par 179 Nom Mtr 126 Out Volt Lvl Par 921 10V 100 Par 175 Rated Motor Arm Amps Volt 9 Torque Ref Par 39 10V 100 of Par 179 Nom Mtr 27 Fld Cur Max Par 467 1 0 10V 0 100 of Par 280 Nom Mtr Arm Amps Fld Amps 10 Trim Torque Par 40 10V 100 of Par 179 Nom Mtr 28 Filtered Spd Par 924 1 10V 100 of Par 45 Max Ref Arm Amps Speed 11 Torq Reg In Par 41 10V 100 of Par 179 Nom Mtr 129 Filtered Cur Par 928 10V 200 of Par 179 Nom Mtr Arm Amps Arm Amps 12 Motor Speed Par 121 1 x10V 100 of Par 45 Max Ref 30 Output Power Par 1052
38. PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 Chapter 2 Chapter 3 Power WIPE ice epe 7 dod eps 1 19 AC Input Voltages 4 44 444 seie he e Rr p asa b 1 19 DC Output Voltages nero hee o ee E baci e oet eee ea mea de 1 19 Typical Power Wiring Diagrams 1 20 Armature Converter Connections 1 23 Armature Voltage Feedback Connections 1 26 Field Circuit Connections 1 28 Field Current Configuration 1 30 Relay Outputs pa ee ha wa E RUE si 1 31 Thermistors and Thermal Switches 1 31 Control Circuit Input Power 1 33 Frame C Heatsink Cooling Fans and Armature Fuse Signal Terminals 1 37 dup 1 38 DIP Switch and Jumper Settings 1 38 VO Signal and Control Wiring 1 42 VO Wiring Examples A e es dg Re eer wpa eae aw aed NEE ER A 1 45 Digital Encoder Terminal Block 1 48 DC Analog Tachometer Terminal Block 1 50 VO and Control Wire Routing 1 50 Drive Start Up Drive Start Up Ch
39. Programming and Parameters 3 3 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 you have the option to display 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 77 and Parameter Cross Reference by Number on page 3 82 for a list of parameters and page numbers PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 4 Programming and Parameters Basic Parameter View Parameter 211 Param Access Lvl set to option 0 Basic File Group Parameters Monitor Speed Meters Speed Ref A 44 Ramp In Pct 111 Spd Feedback 122 Speed Ref A Pol 47 Ramp Out 113 Spd Feedback Pct 121 Speed Ref B 48 Ramp Out Pet 114 Actual Speed 924 Spee
40. Reserved Digital In11 Default x Reserved So 9 Digital In10 9 Digital Ing O Digital In8 9 9 Digital In7 Ov 9 Digital In6 gt Digital In5 Digital In4 T Digital In3 Digital n Digital In1 co o e Bit Dig In Term 1 Dig In Term 2 Dig In Term 3 Dig In Term 4 Dig In Term 5 Dig In Term 6 Dig In Term 7 Dig In Term 8 Dig In Term 9 Dig In Term 10 Dig In Term 11 Dig In Term 12 Status of the digital inputs 0 Low 1 High Inversion In 1 Inversion In 2 Inversion In 3 Inversion In 4 Inversion In 5 Inversion In 6 Inversion In 7 Inversion In 8 Inversion In 9 Inversion In 10 Inversion In 11 Inversion In 12 inverts the digital input signal ContactorControl Selects the type of contactor to be controlled by the drive Either style of contactor AC or DC can be used with or without dynamic braking DB contactor AC Cntctr indicates an AC contactor is used AC Ontctr DB indicates that an AC contactor and dynamic brake resistor is used DC Cntctr indicates a DC contactor is used DC Cntctr DB indicates that a DC contactor and dynamic brake resistor is used The type of control selected determines how many I O points will be required for contactor control and status AC Cnic
41. ds wnwxew ed 5507 4 spur peedg joajagounspds 91014 duo 55071 210 doolq ejqeu3 6694 1g INO Bay pds 9620 dwog peo1 869d Jeu ssed Mo 1ojejnbog p ds uonesu dulo2 doolq PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 D 9 Control Block Diagrams Uo em XNA 6974 Jeubio payajas tld Jet enbio 01165 51 BUSES D Pd epa xni 2974 ueuw am Aq ip seu jeg bil 1010N Abd Spa xn 4 etd Tm duo 0 l anbio wuy Otd amoy B Y ANNOY JON m W1DIQ yoolg Jeu bil 100 JoyeinBay juaun oL FE 4 o o X nb 0 0197 6964 les gu Du 08d les cui Du 9 4 leg pul Du enbio 6q Old apow paads gq aoe 0000 pdg reno q pu c SNAS enug 2864 eui ng 1v 1S 1 914 xt y ve IR I 1065 3 LYTS wu Sid uWl1vis Wu z Bay anbuot 1 wesbeig yoolg 0 Bay peeds JoyeinBay peedg wol4 0 arbnt 0197 0 195 epo bil pds ed L I pds peo104 q Z SENS ag Z8Ed uonoe es poyi enbJo PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 Control Block
42. eve Ad be mad erred LR Uy doe s z 1 9 Using Contactots socrum er ve e eg eR DR x re am eer does 1 9 AC Input Contactors 1 10 DC Output Contactors 1 388 daga xc E pe RUR OR T su Dan deu 1 10 Dynamic Brake Resistors 1 10 General Grounding Requirements 1 11 Safety Ground PE 2 1 12 Power Beedet ve deeg iene ia bunches ebore epo ode ha E ee 1 12 Encoder Ground Connections 1 12 Tachometer Ground Connections 1 12 CE Conformity 1 cer 7 1 13 Low Voltage Directive 2006 95 EC 1 13 EMC Directive 2004 108 EC 1 13 General Considerations 1 13 Installation Requirements Related to the Low Voltage Directive 1 14 Installation Requirements Related to EN 61800 3 and the EMC Directive 1 14 Pollution Degree Ratings According to EN 61800 5 1 1 15 Power Circuit Protection sa mae bg tea EUR ed Go ger acd 1 16 Control Power Protection 1 16 Cable and Wiring Recommendations 1 17
43. time Tune the Speed Regulator The speed regulator auto tuning test detects the total inertia value of the motor shaft in Kg m the friction value in N m and the calculation of the proportional P and integral 1 gains of the speed regulator Important This test requires the free rotation of the motor shaft combined vvith the load The auto tuning test of the speed loop cannot be carried out on machines vvith a limited stroke procedure Hazard of personal injury exists due to motor shaft ATTENTION The motor will rotate during this tuning rotation and or machinery motion Important Important The test is carried out by using the torque limit value set in 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 In applications where the system total inertia value is very 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 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June
44. 495 495 14044 3 170M5464 switch 170H0069 6 9 URD 32 TTF 800 switch MS3 V1 5BS 120 671 32 800 switch 2800104 667 667 5449 3 170M5466 switch 170 0069 6 9 URD 32 TTF 1000 switch MS3 V1 5BS 20 671 32 1000 switch 2800104 Figure A 9 Frame C Non Regenerative Drive AC Input Line Fuse Location AC Input fuses and switches are located on the bus bars behind the Control EMI shield which holds the Control board Note Drive shown with front covers removed and Control EMI shield lowered PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 A 16 Supplemental Drive nformation Control Povver Circuit The follovving fuses are used to protect the Svvitching Povver Supply circuit Protection Fuses and the MOVs on the Pulse Transformer circuit board frame B drives only or Transient Noise Filter circuit board frame C drives only Frame Mounted on Designation Fuse A Switching Power Supply circuit board 1F1 1A 250V slow 5x20mm B and C Switching Power Supply circuit board F1 3 15A 250V fast 5x20mm F2 2 5A 250V slow 5x20mm B Pulse Transformer circuit board F1 F2 F3 16A 500V fast 6x32mm C Transient Noise Filter circuit board F11 F21 F31 25A 500V fast 6x32mm Figure A 10 Frame A Switching Power Supply Fuse Location Top View of Drive Switching Power Supply fuse Figure A 11 Frame B Switching Power Supply Fuse Location Top View of Drive F1 3 15A fuse
45. Advanced File Group Parameters Monitor Speed Meters Speed Ref A 44 Ramp In Pct 111 Spd Feedback 122 Speed Ref A Pol 47 Ramp Out 113 Spd Feedback Pct 121 Speed Ref B 48 Ramp Out Pct 114 Actual Speed 924 Speed Ref B Pct 49 Speed Draw Out 1018 Encoder Speed 420 Speed Ref Out 385 Spd Draw Out Pct 1019 Tachometer Speed 1408 Spd Ref Out Pct 384 Speed Reg In 118 Ramp In 110 Speed Reg In Pct 117 Current Meters Spd Reg Out Pct 236 Field Current 351 Filt TorqCur Pct 928 Current Reg In 41 Fld Current Pet 234 Flux Ref Pct 500 Arm Current 200 Cur Lim Pos Out 10 Selected TorqRefl 14 Arm Current Pct 199 Cur Lim Neg Out 11 Motor Trq Ref 17 Drive Data FaultCode 57 Output Voltage 233 Drive Size 465 AC Line Voltage 466 Output Power 1052 Elapsed Lifetime 235 AC Line Freq 588 Drive Type 300 Software Version 331 Motor Control Motor Data Max Ref Speed 45 Nom Mtr Arm Amps 179 MtrOvrld Type 376 Ws Max Feedback Spd 162 Nom Mtr Fld Amps 280 Drive Type Sel 201 Rated Motor Volt 175 Drv Fld Brdg Cur 374 Field Config Field Reg Enable 497 Fld Reg Kp 91 Reset Fld Curve 920 Field Economy En 499 Fld Reg Kil 92 Fld Const 40 Pct 916 Field Econ Delay 1407 Force Min Field 498 Fld Const 70 Pct 917 Field Mode Sel 469 Out Volt Level 921 Fld Const 90 Pct 918 Max Fld Curr Pct 467 Fld Reg Kp Base 97 Flux Divide 462 Min Fld Curr Pct 468 F
46. Base Omega Diameter Calc 3 45 1231 Scale4 In Max Scale Blocks 3 43 1164 Diam Preset 0 Diameter Calc 3 45 1232 Scale4 In Min Scale Blocks 3 43 1165 Diam Preset 1 Diameter Calc 3 46 1233 Scale4 In Off Scale Blocks 3 44 1166 Diam Preset 2 Diameter Calc 3 46 1234 Scale4 Out Off Scale Blocks 3 44 1167 Diam Preset 3 Diameter Calc 3 46 1235 Scale4 In Abs Scale Blocks 3 44 1168 1 Diam Preset Sel Diameter Calc 3 46 1236 Scale5 Output Scale Blocks 3 43 1171 Variable J Comp Winder Functions 3 46 1237 Scale5 Input Scale Blocks 3 43 1172 1 Constant J Comp Winder Functions 3 46 1238 Scale5 Mul Scale Blocks 3 43 1173 Materl Width Pct Winder Functions 3 46 1239 Scale5 Div Scale Blocks 3 43 1174 Static Friction Winder Functions 3 46 1240 Scale5 In Max Scale Blocks 3 43 1175 Dynamic Friction VVinder Functions 3 47 1241 Scale5 In Min Scale Blocks 3 43 1176 aper Enable Winder Functions 3 47 1242 Scaled In Off Scale Blocks 3 44 1177 Initial Diameter Winder Functions 3 47 1243 Scale5 Out Off Scale Blocks 3 44 1178 Final Diameter Winder Functions 3 47 1244 Scale5 In Abs Scale Blocks 3 44 1179 ension Reduct Winder Functions 3 47 1245 Scale6 Output Scale Blocks 3 43 1180 ension Ref Winder Functions 3 47 1246 Scale6 Input Scale Blocks 3 43 1181 ension Scale Winder Functions 3 47 1247 Scale6 Mul Scale Blocks 3 43 1182 ime AccDec Min Winder Functions 3 47 1248 Scale6 Div Scale Blocks 3 43 1183 Int Acc Calc En Winder Functions 3
47. Disabled m Enables Disables the ability of the drive to connect to a spinning Options 0 Disabled ED motor at actual rpm when a start command is issued 1 Enabled Di 2 e Enabled When the drive is turned on the speed of the motor is LE measured and the ramp output is set accordingly The drive then runs at the set reference value e 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 for example in the case of a pump the flowing medium e 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 Default 0 121 Time constant used by the filter for the Speed Feedback circuit Min Max 0 1000 122 Filtering of the high frequency components of the speed feedback Units ms signal is useful in the case of elastic coupling between the motor and load i e joints or belts 445 Spd Up Gain Pct Default 0 00 The Speed Up function gain as a percentage of Par 446 Speed Min Max 0 00 100 00 Base Units 446 Speed Up Base Default 1000 00 e The Speed Up function maximum gain This value corresponds to Min Max 0 00 16000 00 100 of Par 445 Spd Up Gain Pct Units ms 447 Speed Up Filter Default 0 The time
48. Drive Type Displays of the drive type 10 Non Regenerative 11 Regenerative Software Version Displays the Major and Minor Major Minor firmware version numbers active in the drive Drive Size Armature current rating as indicated by the configuration of DIP switch S15 on the Control board This value is used to determine the Drive Overload fault F64 Note S15 is set to the appropriate value at the factory However if the Control board was supplied separate from the drive and installed as a replacement part S15 must be manually set to the appropriate drive size Refer to DIP Switch and Jumper Settings on page 1 38 AC Line Voltage AC input voltage AC Line Freq AC input frequency Output Power Output power Note This parameter can be assigned to an analog output PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Values 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 9
49. Min Max Default Min Max Default Min Max Default Min Max Default Min Max Default Options Default Min Max Default Options Default Min Max Default Min Max Programming and Parameters 10000 0 10000 Read Only 10000 Read Only 10000 0 10000 0 10000 Setpoint 0 Setpoint 0 Setpoint 1 0 0 1 0 10000 Bipolar Positive Bipolar 1 0 1 1 00 100 00 Read Only 10000 3 41 Related 759 763 763 763 763 774 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 42 z 9 o a CS lt Group e E A a Programming and Parameters Parameter Name amp Description See page 3 2 for symbol descriptions No Values 782 PID Target Parameter number to which the PID Output value will be written 0 Not Used Default 786 PID Source Parameter number from which the PID source value will be read Options 0 Not Used 16 Reserved 32 UsrDefined13 Par 516 1 Cur Lim Pos Par 8 17 Max Fld Pct Par 467 33 UsrDefined14 Par 517 2 Cur Lim Neg Par 9 18 Reserved 34 UsrDefined15 Par 518 3 Reserved 19 0 Par 503 35 Load Comp Par 698 4
50. Tightening Torque Nem bein 5 6 53 Terminal Block 12 106 10 50 442 5 8 25 221 10 50 442 5 8 25 221 10 50 442 5 25 221 10 50 442 5 8 25 221 10 50 442 5 8 25 221 10 50 442 5 8 25 221 10 50 442 5 8 25 221 10 50 442 5 8 25 221 10 50 442 5 8 25 221 II See to Standard Drive Catalog Number Explanation on page Preface 4 positions 8 9 and 10 for corresponding drive HP rating armature amp rating and field amp rating PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 26 Installation and Wiring Armature Voltage Feedback Connections When a DC output contactor is used with the drive and a speed feedback device tachometer or encoder is not used the Armature Voltage Feedback terminals can be used to monitor the armature voltage at the motor regardless of the state of the contactor When this terminal block is not connected to the motor armature terminals the terminals must be jumpered as described in the table below and the armature voltage feedback is monitored internally within the drive In this case when a DC contactor is used with the drive a speed feedback device is not used and the contactor opens the drive will no longer receive the armature voltage feedback signal Important By default these terminals are jumpered 1A1 to A1 and 1A2 to A2 If these terminals are not wired
51. e the motor speed e the output signal from the Speed Up function Figure C 3 Speed Up function inactive Figure C 4 Speed up function active Oscillation during a speed change due to a high moment of The same drive with Speed up function active inertia Top Par 122 Spd Feedback Top Par 122 Spd Feedback Bottom Par 199 Arm Current Pct Bottom Par 199 Arm Current Pct Parameters used in the example e Par 445 Speed Up Gain Pct 50 96 e Par 446 Speed Up Base 14 rpm ms e Par 447 Speed Up Filter 20 ms Speed Threshold Indicators There are two speed threshold functions available that can be programmed via a digital output to provide indication of when the drive has exceeded certain set points Par 393 Speed Threshold displays whether the speed of the drive is above or below a set speed for clockwise and counter clockwise rotation Set the threshold speed for clockwise rotation in Par 101 Spd Thresh Pos and set PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 C 26 Application Notes the threshold speed for counter clockwise rotation in Par 102 Speed Thresh Neg You can specify a delay time before indication that the speed has fallen below the threshold values in Par 103 Threshold Delay Par 393 Speed Threshold can be assigned to a di
52. feedback line of the HIM 1 Current 0 Speed Speed feedback units are in rpm e 1 Current Current feedback units are in 1343 DPI Port Value Default Read Only 590 Unscaled value of the DPI reference selected in Par 590 DPI Min Max 32767 Port Sell 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 BIRIBBBEBBEBEEL EES ele le ee le le le le le Le le Le e ES o o lolo A n na n Aa S l g le lo le le lolo o a la la ja wae je mec je jc je er jaja ja aa a Default x X X X X Xx X x x x d 1 14 1 1 Bit 15 14 13 12 11 10 9 8 765 4 B 2 f 0 592 Start Mask See Logic Mask eb Controls which adapters can issue start commands 593 Jog Mask See Logic Mask Controls which adapters can issue jog commands 594 Direction Mask See Logic Mask q b Controls which adapters can issue forward reverse direction commands 595 Reference Mask See Logic Mask Controls which adapters can select a manual reference 596 Accel Mask See Logic Mask 24 d Controls which adapters can select the acceleration ramp 660 rates Pars 660 Accel Time 1 and 24 Accel Time 2 of the drive 597 Fault Clr Mask See Logic Mask O Control
53. tuning An input voltage greater than 1V or an input current greater than 2 mA e Positive polarity The value found is automatically set for the opposite direction for four quadrant drives Note The automatically calculated value can if necessary be modified manually via parameter Ainx Tune Scale When using analog input tuning Pars Analog Inx Scale are normally set to 0 Anlg In1 Target Anlg In2 Target Anlg In3 Target Enables sampling for the analog inputs Anlg In1 Filter Analog input 1 filter Anlg Ini Cmp Defines a reference point for the signal of analog input 1 around which a comparison range can be set via Par 1043 Anlg In1 Cmp Err and monitored Anlg Int Cmp comparison value x 10000 max reference value where the values of comparison and max reference are determined by the min max of the related parameter selected via Par 70 Anlg In1 Sel Anlg In1 Cmp Err Defines a value above and below the value set in parameter 1042 Anlg Int Cmp at which Par 1045 Anlg Int Cmp Eq will transition Anlg Int Cmp Err tolerance value x 10000 max reference value where the values of tolerance and max reference are determined by the min max of the parameter selected via Par 70 Anlg In1 Sel Anlg Ini Cmp Dly Amount of time that must elapse after the value in Par 1043 Anlg In1 Cmp Err has been reached before Par 1045 Anlg In1 Cmp Eq transitions Anl
54. 1 10 A1 1A2 A2 E 1A1 A1 1A2 0 A2 qo O Bottom of Drive Table 1 F Armature Voltage Feedback Circuit Wire Sizes and Terminal Specifications Drive Current Rating Code Tightening Torque Frame 230V Terminals Wire Size and Type Nem Ibein All 1A1 A1 1A2 A2 0 5 0 6 4 4 5 3 Refer to Standard Drive Catalog Number Explanation on page Preface 4 positions 8 9 and 10 for corresponding drive HP rating armature amp rating and field amp rating EI Wire with an insulation rating of 600V or greater is recommended See Cable and Wiring Recommendations on page 1 17 for cable spacing information PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 1 28 Installation and Wiring Field Circuit Connections Terminals Description Ut V1 Single phase AC input to the field circuit C1 D1 DC output to the motor field Figure 1 20 Frame A Field Circuit Terminal Block Location Bottom of Drive Figure 1 21 Frame B Field Circuit Terminal Block Location tAd ind Top of Drive PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring 1 29 Figure 1 22 Frame C Field Circuit Terminal Block Location DANGER RISK OF ELECTRIC SHOCK DISCONNECT INPUT POWER BEFORE SERVICING EQUIPMENT Front of Drive 57 E E ET ET ETAT Di C1
55. 230V AC Input Frame A and B Regenerative Drives Only Fuse Code FS2 7 See Figure A 3 on page A 8 Drive Bussmann Ferraz Shawmut Gould Shawmut Current AC North S Rating Line Ferrule FWP Ferrule North American American Ferrule North American GC Code Amps Amps Type Fuse Block FWP Type Fuse Block A70QS Type A70P A70QS Type A 7P0 7 5 7 FWP 15A14F CH142D FWP 15B A70QS16 14F 70 15 4 9P0 9 74 FWP 20A14F FWP 20B A70QS20 14F 70 20 4 012 12 9 8 FWP 25A14F FWP 25B m A70QS25 14F 1 A70P25 4 020 20 16 FWP 40A14F FWP 40B A70QS40 14F A70QS40 4 029 29 24 FWP 63A22F CH222D FWP 60B A70QS63 22F A70QS60 4 038 38 31 FWP 80A22F FWP 80B A70QS80 22F A70QS80 4 055 55 45 FVVP 125A ST14 7005125 4 073 73 60 FWP 150A A70QS150 4K 093 93 76 FWP 200A A70QS200 4K 110 110 90 E 225 7005250 4 146 146 119 m FVVP 300A 7005300 4 180 180 147 FVVP 350A 7005350 4 218 218 178 m FVVP 450A ST38 72612 A70QS450 4 265 265 217 FWP 600A 7005600 4 360 360 294 FWP 700A 7005700 4 434 434 355 FWP 900A A70P900 4 1 Required on four quadrant drives only highly recommended on two quadrant drives PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 A 10 Supplemental Drive Information Table A D Recommended Arm
56. 75 100 100 D110D11 20P 41AD167 167 136 4 100 1321 3R160 B 56 75 75 100 100 D140D11 20P 41AD207 207 169 1 125 1321 3RB250 B 93 112 125 150 100 D180D11 20P 41AD250 250 204 3 150 1321 3RB250 B 93 112 125 150 100 D210ED11 20P 41AD330 1330 269 6 200 1321 3RB320 B 149 200 100 D300ED11 20P 41AD412 412 336 6 250 1321 3RB400 B 186 4 250 100 D420ED11 20P 41AD495 495 404 4 300 1321 3R500 B 223 7 300 100 D420ED11 20P 41AD667 667 544 9 400 1321 3R600 B 298 3 400 100 D630ED11 Table A P 460V AC Input Non Regenerative Drives AC Line IP00 Open Style Drive Cat No DC Amps Amps HP Line Reactor Cat No Line Reactor KW HP AC Input Contactor Cat No 20P 21AD4P1 41 3 3 2 1321 3R4 A 55 75 100 C12D10 20P 21AD6P0 6 49 3 1321 3R8 A 75 1 100 C12D10 20P 21AD010 10 8 2 5 1321 3R18 B 1 5 7 5 2 10 100 C12D10 20P 21AD014 14 11 4 7 5 1321 3R18 B 1 5 7 5 2 10 100 C12D10 20P 21AD019 19 15 5 10 1321 3R18 B 1 5 7 5 2 10 100 C23D10 20P 21AD027 27 22 1 15 1321 3R55 B 11 22 15 30 100 C23D10 20P 21AD035 135 28 6 20 1321 3R55 B 11 22 15 30 100 C30D10 20P 21AD045 45 36 8 25 1321 3R55 B 11 22 15 30 100 C37D10 20P 21AD052 52 42 5 30 1321 3R55 B 11 22 15 30 100 C43D10 20P 21AD073 173 59 6 40 1321 3R80 B 30 40 100 C60D10 20P 21AD086 186 70 3 50 1321 3R100 B 37 45 50 60 100 C85D10 20P 21AD100 100 81 7 60 1321 3R100 B 37 45 50 60 100 C85D10 20P 21AD129 129 105 4 75 1321 3R160 B 56 75 75 100 100 D110D11 20P 21AD167 167 136 4 100 1321 3R160 B 56
57. Digital In11 Sel 143 1 Digital Inputs 3 70 Fault 4 Time 1364 Faults 3 57 Digital In12 Sel 144 1 Digital Inputs 3 70 Fault 5 Code 1355 Faults 3 57 Digital In2 Sel 134 Digital Inputs 3 70 Fault 5 Time 1365 Faults 3 57 Digital In3 Sel 135 Digital Inputs 3 70 Fault 6 Code 1356 Faults 3 57 Digital In4 Sel 136 Digital Inputs 3 70 Fault 6 Time 1366 Faults 3 57 Digital In5 Sel 137 Digital Inputs 70 Fault 7 Code 1357 Faults 3 57 Digital In6 Sel 138 Digital Inputs 3 70 Fault 7 Time 1367 Faults 3 57 Digital In7 Sel 139 Digital Inputs 3 70 Fault 8 Code 1358 Faults 3 57 Digital In8 Sel 140 Digital Inputs 3 70 Fault 8 Time 1368 Faults 3 57 Digital In9 Sel 141 Digital Inputs 3 70 Fault 9 Code 1359 Faults 3 57 Digital Out Sel 145 1 Digital Outputs 3 73 Fault 9 Time 1369 Faults 3 57 Digital Out2 Sel 146 1 Digital Outputs 3 73 Fault Arm Amps 1371 Faults 3 57 Digital Out3 Sel 147 1 Digital Outputs 3 73 Fault Clear 1347 Faults 3 56 Digital Out4 Sel 148 1 Digital Outputs 3 73 Fault Clr Mask 597 Maske 8 Owners 3 63 Digital Out5 Sel 149 1 Digital Outputs 3 73 Fault Clr Mode 1348 Faults 3 56 Digital Out6 Sel 150 1 Digital Outputs 3 73 Fault Clr Owner 606 Masks 8 Owners 3 64 Digital Out7 Sel 151 Digital Outputs 3 73 Fault Field Amps 1373 Diagnostics 3 57 Digital Out8 Sel 152 1 Digital Outputs 3 73 Fault Speed 1372 Diagnostics 3 57 Direction Mask 594 Masks amp Owners 3 63 Fault Voltage 1374 Diagnostics 3 57 Direction Mode 1322 Reference Config 3 50 F
58. Ki closed loop control is used in order to adjust the torque current value to the real tension on the material measured by the load cell 1182 Time AccDec Min Default 9 00 The amount of time corresponding to the lower acceleration deceler Min Max 0 15 300 ation and fast deceleration time Units S 1183 Int Acc Calc En Default 1 Enabled 1182 g Enables Disables the calculation for coil acceleration Options 0 Disabled 1184 e Enabled This function carries out the calculation of the angular 1 Enabled 1185 acceleration inside the drive In this case it is necessary to set just 1186 the value of Par 1182 Time AccDec Min e Disabled It is necessary to set Pars 1184 Line Accel Pct 1185 Line Decel Pct 1186 Line FastStp Pct and 1182 Time AccDec Min and to supply the corresponding status indication to the digital inputs 1184 Line Accel Pct Default 100 00 1182 Acceleration time as a percentage Par 1182 of Time AccDec Min 1 Min Max 0 00 100 00 Units 1185 Line Decel Pct Default 100 00 1182 Deceleration time as a percentage of Par 1182 Time AccDec Min Min Max 0 00 100 00 Units 1186 Line FastStp Pct Default 100 00 1182 Fast deceleration time as a percentage of Par 1182 Time AccDec HMin Max 0 00 100 00 Min Units 96 1187 Winder Type Default 0 Winder Winder unwinder selection If the selection is carried out via a digital Options 0 Winder in
59. 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 Programming and Parameters Read Only 0 200 D Read Only 0 200 Read Only 4200 Read Only 4200 D Read Only 4200 D Read Only 250 Read Only 2 5 x Nom Mtr Arm Amps A Read Only 0 00 100 00 D Read Only 200 76 Read Only 0 00 99 90 A Read Only 0 00 100 00 0 Read Only 200 2 3 13 amp Related 179 179 241 179 179 179 280 179 280 926 1193 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 3 14 Programming and Parameters 2 T 57 MONITOR o Parameter Name amp Description See page 3 2 for symbol descriptions FaultCode 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 Output Voltage Measured output armature voltage Note This parameter can be assigned to an analog output and is the default selection for Par 69 Anlg Out4 Sel Elapsed Lifetime Shows the operating time of the drive This parameter counts the time for which the drive is energized even if the drive is disabled
60. PID Output Sign 3 41 PID Setpoint 0 3 41 PID Setpoint 1 3 41 PID Setpoint Sel 3 41 PID Source 3 42 PID Source Gain 3 42 PID Steady Delay 3 40 PID Target 3 42 Port Mask Act 3 66 Powerup Delay 3 36 Preset Speed 1 3 26 Preset Speed 2 3 26 Preset Speed 3 3 26 Preset Speed 4 3 26 Preset Speed 5 3 26 Preset Speed 6 3 26 Preset Speed 7 3 26 Ramp Delay 3 33 Ramp In 3 11 Ramp In Pct 3 11 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 Index 16 Ramp In Zero En 3 36 Ramp Out 3 11 Ramp Out Pct 3 11 Ramp Select 0 3 54 Ramp Select 1 3 54 Ramp Type Select 3 32 Rated Motor Volt 3 15 Real FF PID 3 40 Ref Line Spd 3 49 Ref Spd Source 3 49 Ref Speed Gain 3 49 Ref Zero Level 3 28 Reference Mask 3 63 Reference Owner 3 64 Relay Out 1 Sel 3 75 Relay Out 2 Sel 3 75 Reset Defaults 3 50 Reset Fld Curve 3 18 Roll Diameter 3 45 S Curve Accel 1 3 34 S Curve Accel 2 3 34 S Curve Decel 1 3 34 S Curve Decel 2 3 34 S Curve Time 3 33 Save H M Ref 3 50 Save MOP Ref 3 50 Scale1 Div 3 43 Scale1 In Abs 3 44 Scale1 In Max 3 43 Scale1 In Min 3 43 Scale1 In Off 3 44 Scale1 Input 3 43 Scale1 Mul 3 43 Scale1 Out Off 3 44 Scale1 Output 3 43 Scale2 Div 3 43 Scale2 In Abs 3 44 Scale2 In Max 3 43 Scale2 In Min 3 43 Scale2 In Off 3 44 Scale2 Input 3 43 Scale2 Mul 3 43 Scale2 Out Off 3 44 Scale2 Output 3 43 Scale3 Div 3 43 Scale3 In Abs 3 44 Scale3 In Max 3 43 Scale3 In Min 3 43 Scale3 In Off 3 44
61. Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations that can cause an explosion in a hazardous environment which may lead WARNING Identifies information about practices or circumstances 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 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 Shock Hazard labels may be located on or inside the equipment e g PowerFlex DriveExplorer DriveExecutive DPI and SCANport are either trademarks or registered trademarks of Rockwell Automation Inc PowerFlex Digital DC Drive User Manual Summary of Changes Manual Updates The information below summarizes the changes to the PowerFlex Digital DC D
62. Speed Sel 3 Digital In8 Sel Default 31 Contactor Digital In9 Sel Default 0 Not Used Digital In10 Sel Default 0 Not Used Digital In11 Sel Default 0 Not Used Digital In12 Sel Default 0 Not Used Selects the function driven by the digital input Refer to Option Definitions for Digital Inx Sel on page 3 71 These parameters are used to configure the digital inputs on the I O Expansion circuit board Notes Option 35 was changed from Fld Weaken En to Force MinFld and option 64 Invert Fit was added with firmware version 2 001 Option 34 Field Reg En was changed to Reserved with firmware revision 3 001 Options 0 Not Used 17 Speed Sel 1 34 Reserved 51 Diam Reset 1 2 18 Speed Sel 2 35 Force MinFld 6 52 DiamCalc Dis 2 Stop CF 2 19 Speed Sel 3 36 Freeze Ramp 53 Torq Wind En 3 Start 20 PI Enable 37 UsrDefinedAO 54 Speed Match 4 Fwd Reverse 21 PI Hold 38 UsrDefinedA1 55 Diam I D En 5 1 Run 9 22 PI Reset 39 UsrDefinedA2 56 Wind Unwind 6 Run Forward 23 Pl Invert 40 UsrDefinedA9 57 Diam Preseft0 7 Run Reverse 24 Local 41 UsrDefinedA4 58 Diam Preset1 8 Run Level 25 Acc2 8 Dec 42 UsrDefined
63. T 3 72 Anlg In Scale and Important Refer to the 73 Anlg Tune Scale Attention statement on 27 View Signal Value page 1 38 for important bipolar 8 1404 Analog Int Value wiring information l View Signal Output 385 Speed Ref Out 191 Note DIP switch S9 should be set to On 0 10V Refer to Table 1 M on page 1 39 Analog Input Bipolar Speed 2 Set Direction Mode Reference _ 1 1322 Direction Mode Common TT L1 1 Bipolar HOV Input 5 213 Adjust Scaling IT 4 72 Anlg Int Scale and Important Refer to the 73 Anlg Tune Scale Attention statement on 2116 View Signal Value page 1 38 for important bipolar ELT 1404 Analog In1 Value wiring information 2018 View Signal Output CO 385 Speed Ref Out L1 10 Note DIP switch S9 should be set to On 0 10V Refer to Table 1 M on page 1 39 Analog Input Unipolar Speed e Configure for Voltage or Reference T yma Current Common EE 2 71 Anlg Int Config 0 10 Input nu e Adjust Scaling or 1114 72 Anlg Int Scale and 1115 73 Anlg1 Tune Scale 2118 View Signal Value Li 1404 Analog Int Value 2118 e View Signal Output r 385 Speed Ref Out mq Note DIP switch S9 should be set to On for 0 10V operation or Off for 0 20 mA or 4 20 mA operation Refer to Table 1 M on page 1 39 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 46
64. U2 V2 is too low due to e The AC input voltage is too low e There are poor cable connections e The fuse s on the Switching Power Supply circuit board have blown Verify AC input power level e Check all connections Check and replace the fuse s if necessary e The line fuses have tripped e The AC input voltage dips or there is a high disturbance in the supply voltage There is an overvoltage on the armature circuit Possible causes include 1 Remove power from the drive 2 Eliminate AC input voltage dips and or disturbances 3 Replace any blown fuses e Par 175 Rated Motor Volt is set too low Set Par 175 Rated Motor Volt correctly e The drive is not configured to use field weakening but the motor can only reach the set speed when the drive is in field weakening mode Check the value of Par 469 Field Mode Sel and set accordingly Note Configure with Par 203 OverVolt Fit Cfg An auxiliary input interlock is open or a voltage 415 30 V or reference signal is missing for the digital input set to 14 Aux Fault Note Configure with Par 354 Aux Inp Fit Cfg The rated drive current Par 465 Drive Size has been exceeded by 150 for 1 minute or 200 for 3 seconds A non resettable software error exists on the Control board There was a problem saving parameter values or there has been a control board change Note When this fault occurs the parameters will be reset to the
65. drives 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 amp D Terminals U V W Two Quadrant Drive Four Quadrant Drive 230V 10 3Ph 260V 240V 400V 10 96 3Ph 470V 420V 440V x10 3Ph 530V 460V 460V 10 3Ph 560V 480V 480V 10 3Ph 580V 500V Field Circuit AC Input Voltage DC Output Field Voltagel Terminals C1 amp D1 Terminals U1 amp V1 Fixed Field Adjustable Field 230V 15 96 1Ph 200V 200V 400V 15 1Ph 310V 310V 460V 10 1Ph 360V 360V UI The max field voltage is equal to 0 85 x AC input line voltage PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 20 Installation and Wiring Typical Power Wiring Diagrams Figure 1 10 Figure 1 13 represent recommended power wiring configurations Figure 1 10 Power Wiring with AC Input Contactor
66. e Not Active The ramp output is enabled and Pars 113 Ramp Out and 114 Ramp Out Pct follow the Ramp Reference block commands 345 Zero Ramp Input Default 1 Not Active 110 Activates or deactivates the ramp input Options 0 Active H Active The ramp input is not active and Pars 110 Ramp In and 1 Not Active 111 Ramp In Pct e Not Active The ramp input is activated and Pars 110 Ramp In and 111 Ramp In Pct correspond to the set reference 373 Freeze Ramp Default 1 Not Active Determines whether the last ramp output reference value is retained Options 0 Active or whether the ramp output reference value is active 1 Not Active e Active The value of the ramp output at the time of activation is retained irrespective of any possible reference value changes at the ramp input 2 e Not Active The ramp output value follows the ramp input value s according to the Ramp Reference Block commands e 660 Accel Time 1 Default 10 2 2 Sets the rate of acceleration for Ramp 1 Min Max 0 65535 Acceleration rate for Ramp 1 Par 2 Maximum Speed Par 660 Units S Accel Time 1 662 Decel Time 1 Default 10 2 Sets the rate of deceleration for Ramp 1 Min Max 0 65535 Deceleration rate for Ramp 1 Par 2 Maximum Speed Par 662 Units S Decel Time 1 665 S Curve Accel 1 Default 1 00 Defines the acceleration curve for S shaped ramp 1 Min Max 0 10 60
67. indicates that the drive is actively accelerating The state of the assigned digital output matches the state of bit 4 Accelerating of Par 381 Drive Status 1 and the state of Par 1188 Accel Status Decelerating When set to 1 the drive is actively decelerating The state of the assigned digital output matches the state of bit 5 Decelerating of Par 381 Drive Status 1 and the state of Par 1189 Decel Status Brake Cmd Energized 1 at run opens the brake after the value in Par 1263 Opening Delay has been exceeded De energized 0 at stop closes the brake after the drive speed goes below the value of Par 1262 Closing Speed ContactorDB 1 issues the close command to the main contactor and dynamic brake contactor Contactor 1 issues the close command to the main contactor Alarm 0 indicates that a drive alarm has occurred Refer to Par 1380 Drive Alarm 1 Running 1 indicates that the drive is active in Run mode The state of the assigned digital output matches the state of bit 2 Running of Par 381 Drive Status 1 Jogging 1 indicates that the drive is active in Jog mode The state of the assigned digital output matches the state of bit 3 Jogging of Par 381 Drive Status 1 Active 1 indicates that the drive is active in Run or Jog mode The state of the assigned digital output matches the state of bit 1 Active of Par 381 Drive Status 1 Publication 20P UM00
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69. page 1 40 ATTENTION The drive can overspeed if DIP switch 3 If the speed feedback source is a digital encoder enter the pulses per revolution from the encoder nameplate in Par 169 Encoder PPR Refer to Speed Feedback on page C 20 for more information on setting the value of this parameter 3 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 B signals 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 M on page 1 39 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Drive Start Up 2 15 2 Access the Speed Command file and press Enter 3 With the Limits group selected press Enter and configure the following parameters 41 Par 1 Minimum Speed Enter the minimum speed reference limit 41 Par 2 Maximum Speed Enter the maximum speed required by the application this can be above the motor base speed if field vveakening is used 4 Access the Dynamic Control file and press Enter 5 Access the Ramp Rates group and configure the following parameters LI Par 660 Accel Time 11 Set the desired acceleration ramp time 1 Par 662 Decel Time 11 Set the desired deceleration ramp
70. to maintain the desired speed This is the default setting Operating as a speed regulator is the most common and simplest mode to set up Examples of speed regulated applications are blowers conveyors feeders pumps saws and tools In a speed regulated application the speed regulator output generates the torque reference Note that under steady state conditions the speed feedback is steady while the torque reference is a constantly adjusting signal This is required to maintain the desired speed In a transient state the torque reference changes dramatically to compensate for a speed change A short duration change in speed is the result of increasing or decreasing the load very rapidly Note Inertia compensation is summed with the output of the speed regulator PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 C 30 Application Notes Torque Regulation Mode Par 241 Spd Trq Mode Sel is set to 2 Torque Reg for torque mode In torque regulation mode the drive controls the desired motor torque The motor speed is the result of torque command and load present at the motor shaft The reference signal is equal to the value of Par 39 Torque Ref A torque regulated application can be described as any process requiring some tension control An example is a winder or unwinder with material being drawn or pulled with a specific tension required Note If the material being wound unwound
71. 0 Fdbk Device Type 41 4 The source of speed feedback Some important Start Up parameters are not included in this screen Refer to Drive Start Up on page 2 1 for detailed instructions PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Menu Structure HIM Overview B 3 Figure B 1 HIM Menu Structure User Display FT Go e e5 See Key below for button descriptions YY Faults gt Fault Info Diagnostics status Into Drive Status 1 View Fault Queue Drive Status 2 Clear Faults Device Items e OH Device Version PowerFlex DC Drive Alarm 1 Clr Fault Queue Product Data Spd Feedback Reset Device Control Board Arm Current Main Control Bd Output Voltage Boot Code Field Current Main Control Bd AC Line Voltage Application Code Output Power amp select via QI G EC via Sani Nul Y Param Access Ly gt Basic 0960 File Group Par FGP File Advanced Numbered List File 1 Name FGP Group Changed Params 2 Name Group 1 Name gt FGP Parameter File3Name Group 2 Name Parameter Name default selection e PowerFlex DC Device Select Connected DPI Devices HIM CopyCat gt Device gt HIM Memory Storage EZ Reset To Defaults Device H M Delete HIM Set Device ldentity e Change Password User Dspy Lines oo Group 3 Name Parameter Name Parameter Name
72. 001 AN 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 Feedback Offset Offset scaling of the feedback circuit The value of this parameter applies regardless of the type of feedback device selected in Par 414 Fdbk Device Type Note The name of this parameter was changed from Anlg Tach Zero to Feedback Offset with firmware version 3 001 destruction of equipment the equipment Values Default Min Max Units Default Options Default Options Default Options Default Min Max Default Min Max Units Programming and Parameters 22 0 100 96 1 Enabled 0 Disabled 1 Enabled 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 or 2 DC Tach the motor could run at excessive speed or become damaged which could result in personal injury or Disabled Disabled Enabled Disabled Disabled Enabled ATTENTION The Drive can overspeed if Par 461 Spd Fdbk Invert is set incorrectly for your application Failure to observe this precaution could result in damage to or destruction of 1 0000 0 9000 3 0000 0 00 20 00 rpm 3 21 Related 457 47
73. 1 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 OCCUIS Ref Zero Level Speed below which speed references are equal to zero speed Switch used in the Speed Zero function PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Values 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 200 00 200 00 gt Read Only 0 00 100 00 Read Only 0 00 100 00 1000 1 32767 rpm 1000 1 32767 rpm 100 0 65535 ms 100 1 32767 rpm 100 0 65535 ms 20 1 32767 rpm Related 87 88 94 393 393 393 394 394 123 124 125 126 File SPEED COMMAND Group Speed Regulator No 107 108 123 124 125 126 238 Parameter Name amp Description See page 3 2 for symbol descriptions 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 par
74. 1 1073741823 units Note This parameter is not used UsrValMult1 Default 1 Numerator in the calculation for scaling the user defined drive speed Min Max 1 32767 display units Note This parameter is not used UsrValDiv1 Default 1 Denominator in the calculation for scaling the user defined drive Min Max 1 32767 speed display units Note This parameter is not used PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 59 R3 Related 1322 3 60 Programming and Parameters Related g Parameter Name amp Description Z See page 3 2 for symbol descriptions Values 503 UserDefined0 Default 0 504 UserDefinedi 505 UserDefined2 Min Max 32768 32767 506 UserDefined3 507 UserDefined4 508 UserDefined5 509 UserDefined6 510 UserDefined7 511 UserDefined8 512 UserDefined9 513 UserDefined10 514 UserDefined11 515 UserDefined12 516 UserDefined13 517 UserDefined14 518 UserDefined15 General use signed 16 bit variables used for data exchange Note Pars 503 506 can be assigned to analog inputs The values of Pars 508 504 and 507 509 can be assigned to an analog output 519 UsrDefBitWrdA Default 0 520 A bitmap of Pars 520 UsrDefBitWrdAO through 535 Min Max 0 65535 935 UsrDefBitWrdA15 With a parameter it is possible to read or write all of the bits inside a word Example UsrDefBitWrdAO UsrDefBitWrd
75. 1 8 must be configured for 19 Speed Sel 3 139 Digital In7 Sel 34 Digital Input 8 Enable 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 Not Used 40 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring 1 45 UO Wiring Examples Required Parameter Input Output Connection Example Changes Potentiometer Unipolar e Adjust Scaling Speed Reference 2 72 Anlg Int Scale and 73 Anlg1 Tune Scale 10kQ Pot Recommended 3 view Signal Value 20 Minimum 4 1404 Analog In1 Value r1 e View Signal Output 385 Speed Ref Out I 7 Note DIP switch S9 should be set 8 On 0 10V Refer to Table 9 1 M on page 1 39 10 Joystick Bipolar Speed 7 Set Direction Mode Reference ac 1322 Direction Mode e 12 1 Bipolar 10V Input BL Adjust Scaling
76. 1 1 0 DPIPort6 Manual 1 1 1 11 Jog Ref PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Read Only Related File No 382 393 394 395 396 Parameter Name amp Description See page 3 2 for symbol descriptions Drive Status 2 Present operating condition of the drive Bit 0 Ready When set 1 the drive is ready Bit 1 Active When set the drive is active Bit 2 Running When set the drive is running Bit 3 Jogging When set the drive is being jogged Bit 4 Stopping When set the drive is stopping Bit 6 Auto Tuning When set the drive is auto tuning Bit 7 Forced Spd When set the drive is in forced speed mode Bit 8 Speed Mode When set the drive is in speed mode Bit 9 Torque Mode When set the drive is in torque mode Values Bit 12 ArmAlphaTest When set the Armature Alpha test is active Bit 13 FldAlphaTest When set the Field Alpha test is active Note Added bits 7 13 with firmware version 3 001 Bit 10 SpdRegPosLim When set the Speed Regulator PI positive limit is active Bit 11 SpdRegNegLim When set the Speed Regulator PI negative limit is active Programming and Parameters Read Only SpdRegNegLim Reserved Reserved ArmAlphaTest SpdRegPosLim Default gt 9 Stopping Jogging 9 Running 9 A
77. 10 8 Le A gt C gt A UT DO DD OR 4 lt M Table 1 A Frame A Weights Weight Drive Current Rating Code Drive Drive amp Packaging 230V 460V kg Ib kg Ib 7P0 4P1 8 4 19 5 110 5 23 1 9P0 6P0 012 010 020 014 019 029 027 038 035 8 8 19 4 111 24 3 055 045 052 073 073 10 8 23 8 13 28 7 093 086 110 100 129 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 4 Installation and Wiring Figure 1 3 Frame B Approximate Dimensions A A1 A2 B B1 C mm in mm in mm in mm in mm in mm in 311 12 2 1275 10 8 16 5 0 65 1388 15 3 1375 14 8 1350 13 8 Table 1 B Frame B Weights Weight Drive w ND Rating Code Drive Drive amp Packaging 230V 460V kg Ib kg Ib 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 5 134 75 434 412 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring 1 5 Figure 1 4 Fram
78. 10 Code 3 57 Fault 10 Time 3 57 Fault 2 Code 3 57 Fault 2 Time 3 57 Fault 3 Code 3 57 Fault 3 Time 3 57 Fault 4 Code 3 57 Fault 4 Time 3 57 Fault 5 Code 3 57 Fault 5 Time 3 57 Fault 6 Code 3 57 Fault 6 Time 3 57 Fault 7 Code 3 57 Fault 7 Time 3 57 Fault 8 Code 3 57 Fault 8 Time 3 57 Fault 9 Code 3 57 Fault 9 Time 3 57 Fault Arm Amps 3 57 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Fault Clear 3 56 Fault Clr Mask 3 63 Fault Clr Mode 3 56 Fault Clr Owner 3 64 Fault Field Amps 3 57 fault queue B 4 Fault Speed 3 57 fault type non configurable 4 1 user configurable 4 1 Fault Voltage 3 57 FaultCode 3 14 faults AC Undervoltage 4 4 Arm Overvoltage 4 4 Auxiliary Input 4 4 clear 4 3 descriptions 4 4 Index 7 field current configuration 1 30 DC output voltage 1 19 input terminals 1 28 output terminals 1 28 terminal block frame A 1 28 Drive Overload 4 4 terminal block frame B 1 28 Dsp Error 4 4 terminal block frame C 1 29 EEPROM Error 4 4 wire size 1 29 Feedback Loss 4 5 Field Config group 3 16 3 17 3 18 Fld Current Loss 4 5 Field Configuration Conflict alarm 4 10 Hardware Fault 4 5 fala converter Heatsink OvrTemp 4 5 Interrupt Error 4 5 Inverting Fault 4 5 tune voltage regulator C 43 Field Current 3 13 Main Contactor 4 5 field current curve C 45 Motor Over Temp 4 6 tune C 45 Motor Overload 4 5 Field Current Loss alarm 4 10 No Fault 4 6 Field Current Loss
79. 100 0 to 200 0 with firmware version 3 001 Speed Ref Oui Output of the Speed Reference selection Notes This parameter can be assigned to an analog output The min and max values of this parameter were changed from 32766 to 8192 with firmware version 3 001 Encoder Speed Actual speed measured by the digital encoder Actual Speed Filtered value of Par 122 Spd Feedback Par 923 Act Spd Filter can be used to provide limited first order low pass filtering of this value Notes This parameter can be assigned to an analog output The min and max values of this parameter were changed from 32766 to 8192 with firmware version 3 001 Speed Draw Out Speed draw output value Note This parameter can be assigned to an analog output Spd Draw Out Pct Speed value as a percentage of Par 45 Max Ref Speed Notes This parameter can be assigned to an analog output The min and max values of this parameter were changed from 100 00 to 100 0 with firmware version 3 001 Tachometer Speed Actual speed measured by the DC analog tachometer Note The min and max values of this parameter were changed from 32770 to 8192 with firmware version 3 001 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Par 45 Max Ref Speed 1 The value of Max Ref Speed cannot exceed 8192 rpm Values Default Read Only Min Max 200 0 Units Default
80. 1094 peugeqiesm 9094 epeugaqiesm 9094 peujaquesri opeugaquesri Y0Sd 6094 peuijeg Jes PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 D 21 Control Block Diagrams peeds xe N 1010 1 syur uan jede no ur in Jo INQ Sog un in our idibiy 5 4 ejqeu3 idibir 0S d PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Control Block Diagrams D 22 lQELEA 011402 HINWEIS Sd vSd 101284 onjeA Jaen olniy idsqisn 094 e qeueA eue 4 sn bulle s hun 402581 ege PUN PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Control Block Diagrams D 23 Test Generator P58 TstGen Output Generator output CE TstGen CE nw Offset P59 TstGen Frequency PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 D 24 Control Block Diagrams Speed Reference Selection P402 P401 P400 Spd Select 2 Spd Select 1 Spd Select 0 Reference P44 Speed Ref A P48 Speed Ref B 1 P155 Preset Speed 2 P156 s f ooa f ao Preset Speed 4 P158 Lu P159 el e P160 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Control Block Diagrams D 25 Fault Alarm
81. 13 Stop Control 21 Accelerating 29 Active 6 Ramp Pos 14 Feld Loss 22 Decelerating 7 Ramp Neg 15 Spd Fbk Loss 123 Brake Cmd 1267 inversion Out 1 Default 0 Disabled 1268 Inversion Out 2 z nM 1269 lnversion Out 3 Options 5 75 1270 Inversion Out 4 7 nage 1271 Inversion Out 5 1272 Inversion Out 6 1273 Inversion Out 7 1274 Inversion Out 8 Reverses the digital output signal 1275 Tinversion Relay2 Default 0 Disabled Inverts the signal for Relay Output 2 Options 0 Disabled 1 Enabled 1392 Relay Out 1 Sel Default 25 Contactor Selects the source of the value that drives the N O relay between the terminals 35 and 36 Refer to Option Definitions on page 3 74 Options 0 Not Used 8 Spd Limited 16 Encoder Err 24 ContactDB 1 Zero Th 9 Fault 17 Diam Calc 25 Contactor 2 Spd Thresh 10 Power Loss 18 nput1 26 Alarm 3 At Speed 11 UserDefinedA 19 Diam Reached 27 Running 4 CurrentLimit 12 UserDefinedB 120 Speed Match 28 Jogging 5 13 Stop Control 21 Accelerating 29 Active 6 Ramp Pos 14 Field Loss 22 Decelerating 72 Ramp Neg 15 Spd Fbk Loss 23 Brake Cmd 3 75
82. 2 Sel on page 3 74 These parameters are used to configure the digital outputs on the I O Expansion circuit board Options 0 Not Used 8 Spd Limited 16 Encoder Err 24 Reserved 1 Zero Th 9 Fault 17 Diam Calc 25 Reserved 2 Spd Thresh 10 Power Loss 18 Input Cmp 26 Alarm 3 At Speed 11 UserDefinedA 19 Diam Reached 127 Running 4 CurrentLimit 12 UserDefinedB 20 Speed Match 28 Jogging 5 Ready 13 Stop Control 121 Accelerating 129 Active 6 Ramp Pos 14 Pied Loss 22 Decelerating Ramp Neg Spd Fbk Loss 123 Brake Cmd 3 73 o Related PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 74 INPUT OUTPUT PowerFlex Digital DC Drive User Manual Digital Outputs Programming and Parameters Parameter Name amp Description See page 3 2 for symbol descriptions Values Option Definitions for Digital Outx Sel Relay Out 1 Sel and Relay Out 2 Sel Option Description Spd Zero Thr O indicates that the drive is operating below the value set in Par 107 Speed Zero Level 1 indicates that the drive is operating above Par 107 Speed Zero Level Spd Thresh 0 indicates that the drive is operating ab
83. 2009 2 16 Drive Start Up 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 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 41 An acceleration test with the torque limit value set in the Par 1048 Autotune Cur Lim 1 A deceleration test with a lower torque limit value applied until zero speed has been reached 4 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 1 45 Max Ref Speed LI 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 o
84. 3 2 3 63 3 64 Motor Data 3 15 3 16 PD Control 3 40 PI Control 3 38 3 39 PID Control 3 40 3 41 3 42 3 43 Ramp Rates 3 32 3 33 3 34 Reference Config 3 50 Restart Modes 3 36 Scale Blocks 3 43 3 44 Security 3 65 3 66 Speed Feedback 3 20 3 21 3 22 Speed Meters 3 11 3 12 Speed References 3 27 Speed Regulator 3 27 3 28 Stop Modes 3 35 3 36 Test Generator 3 24 3 25 Torq Attributes 3 19 3 20 User Defined 3 59 3 60 3 61 3 62 Winder Functions 3 46 3 47 3 48 3 49 parameter views advanced 3 6 basic 3 4 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 parameters AC Line Freq 3 14 AC Line Voltage 3 14 Acc Dec Filter 3 34 Accel Mask 3 63 Accel Owner 3 64 Accel Status 3 55 Accel Time 1 3 34 Accel Time 2 3 33 Act Spd Filter 3 22 Act Ten Ref Pct 3 47 Actual Comp 3 48 Actual Speed 3 12 Actuator Delay 3 36 Adaptive Gain1 3 37 Adaptive Gain2 3 37 Adaptive Gain3 3 37 Adaptive Joint 1 3 36 Adaptive Joint 2 3 37 Adaptive P Gain1 3 37 Adaptive P Gain2 3 37 Adaptive P Gain3 3 37 Adaptive Ref 3 36 Adaptive Reg Typ 3 36 Adaptive Spd 1 3 36 Adaptive Spd 2 3 36 Adaptive Spd En 3 36 Alpha Test 3 25 Analog In1 Value 3 69 Analog In2 Value 3 69 Analog In3 Value 3 69 Anlg In1 Cmp 3 68 Anlg In1 Cmp Dly 3 68 Anlg In1 Cmp Eq 3 68 Anlg In1 Cmp Err 3 68 Anlg In1 Config 3 67 Anlg In1 Filter 3 68 Anlg In1 Offset 3 68 Anlg In1 Scale 3 67 Anlg In
85. 3 62 481 UnderVolt Thresh Alarms 3 58 550 UsrDefBitWrdB13 User Defined 3 62 484 Scale1 Input Scale Blocks 3 43 551 UsrDefBitWrdB14 User Defined 3 62 485 Scalet Output Scale Blocks 3 43 552 UsrDefBitWrdB15 User Defined 3 62 486 Scale1 Mul Scale Blocks 3 43 553 Scale2 Input Scale Blocks 3 43 487 Scale1 Div Scale Blocks 3 43 554 Scale2 Output Scale Blocks 3 43 488 Scale1 In Max Scale Blocks 3 43 555 Scale2 Mul Scale Blocks 3 43 489 Scale1 In Min Scale Blocks 3 43 556 Scale2 Div Scale Blocks 3 43 490 Scale1 In Off Scale Blocks 3 44 557 Scale2 In Max Scale Blocks 3 43 491 Scale1 Out Off Scale Blocks 3 44 558 Scale2 In Min Scale Blocks 3 43 492 Scale In Abs Scale Blocks 3 44 559 Scale2 In Off Scale Blocks 3 44 493 Arm Volt Kp Speed Regulator 3 31 560 Scale2 Out Off Scale Blocks 3 44 494 Arm Volt Ki Speed Regulator 3 91 561 Scale2 In Abs Scale Blocks 3 44 495 Volt Kp Base Speed Regulator 3 31 562 Anlg Tach Gain Speed Feedback 3 21 496 Volt Ki Base Speed Regulator 3 31 563 Feedback Offset Speed Feedback 3 21 497 Field Reg Enable Field Config 3 17 564 Dig In Status Digital Inputs 3 72 498 Force Min Field Field Config 3 17 565 Dig In Term 1 Digital Inputs 3 72 499 Field Economy En Field Config 3 18 566 Dig In Term 2 Digital Inputs 3 72 500 Flux Ref Pct Current Meters 3 13 567 Dig In Term 3 Digital Inputs 3 72 503 UserDefinedO User Defined 3 60 568 Dig In Term 4 Digital Inputs 8 72 504 UserDefined1 User Defined 3 60 569 Dig In Term 5 Dig
86. 6 ABB EHDB520C2P 1L ABB contactor for drives with no dynamic brake ABB EHDB520C 1L ABB contactor for drives with a dynamic brake Must be sourced separately from drive ABB EHDB650C2P 1L ABB contactor for drives with no dynamic brake ABB EHDB650C 1L ABB contactor for drives with a dynamic brake Must be sourced separately from drive 9 ABB EHDB800C2P 1L ABB contactor for drives with no dynamic brake ABB EHDB800C 1L ABB contactor for drives with a dynamic brake Must be sourced separately from drive 8 See DC Contactor Crimp Lug Kit Specifications on page A 22 for more information 10 Wire and Lug size dependant on Cabinet dims and local codes DC Contactor Crimp Lug Kit Use the information provided in the table below to assist you in ordering the Specifications correct Lug kit for your application Rated Motor Armature Conductor DB Condyctor Size Armature Current DC Contactor Rating Size 2 H Armature Conductor DB Conductor Crimp Lug Kit Catalog A DC AWG AWG Crimp Lug Hole Size Lug Hole Size Number 4 1 35 56 8 8 10 10 1370 LG40 45 52 56 6 8 10 10 1370 LG52 55 56 4 8 10 10 1370 LG56 60 86 110 2 6 0 25 in 0 25 in 1370 LG92 100 110 110 1 0 4 0 25 in 0 25 in 1370 LG110 129 180 2 0 2 0 3125 in 0 3125 in 1370 LG140 146 180 3 0 2 0 3125 in 0 3125 in 1370 LG160 147 167 180 4 0 2 0 3125 in 0 3125 in 1370 LG180 207 218 280 300MCM 1 0 0 5 in 0 375 i
87. 60 UsrDefBitWrdA 3 60 UsrDefBitWrdAO 3 61 UsrDefBitWrdA1 3 61 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 Index 24 UsrDefBitWrdA10 3 61 UsrDefBitWrdA11 3 61 UsrDefBitWrdA12 3 61 UsrDefBitWrdA13 3 61 UsrDefBitWrdA14 3 61 UsrDefBitWrdA15 3 61 UsrDefBitWrdA2 3 61 UsrDefBitWrdA3 3 61 UsrDefBitWrdA4 3 61 UsrDefBitWrdA5 3 61 UsrDefBitWrdA6 3 61 UsrDefBitWrdA7 3 61 UsrDefBitWrdA8 3 61 UsrDefBitWrdA9 3 61 UsrDefBitWrdB 3 61 UsrDefBitV rdB0 3 62 UsrDefBitWrdB1 3 62 UsrDefBitWrdB10 3 62 UsrDefBitWrdB11 3 62 UsrDefBitWrdB12 3 62 UsrDefBitWrdB13 3 62 UsrDefBitWrdB14 3 62 UsrDefBitWrdB15 3 62 UsrDefBitWrdB2 3 62 UsrDefBitWrdB3 3 62 UsrDefBitWrdB4 3 62 UsrDefBitWrdB5 3 62 UsrDefBitWrdB6 3 62 UsrDefBitWrdB7 3 62 UsrDefBitWrdB8 3 62 UsrDefBitWrdB9 3 62 UsrDsplyDiv0 3 59 UsrDsplyMultO 3 59 UsrValDiv1 3 59 UsrValMult 3 59 Utility file 3 50 V Variable J Comp 3 46 view changed parameters B 4 parameters B 5 peripheral device parameters B 4 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 voltage regulator tune C 43 W W Offset 3 48 W Reference 3 49 W Target 3 48 warning bipolar inputs 1 38 watts loss data A 5 weights frame A 1 3 frame B 1 4 frame C 1 5 Winder Functions group 3 46 3 47 3 48 3 49 Winder Side 3 48 Winder Type 3 47 wire size armature terminals 1 25 armature voltage feedback 1 27 field 1 29 IO converter circuit b
88. 9 Eg 20 2 Wire Control e Set Digital Input 1 Reversing Run Fwd 1 133 Digital In1 Sel V DC 2 6 Run Forward m external supply 3 e Set Digital Input 2 Run Rev T 14 134 Digital In2 Sel Important Programming inputs for 5 7 Run Reverse 2 wire control deactivates the HIM 6 Start and Jog buttons 7 424V Neutral Common 8 9 20 3 Wire Control 2 Changes Required top T 24V DC internal supply 3 Start 1 DT 15 6 907 8 9 Eq 20 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring 1 47 Required Parameter Input Output Connection Example Changes 3 Wire Control No Changes Required 24V DC external supply Requires 3 wire functions only Digital In1 Sell Using 2 wire ek 3 j j Start 14 selections will cause a type 2 R alarm page page 4 9 m 7 18 424V MNeufral 9 Common 20 Sourcing Digital Outputs ee No Changes Required 21 24V DC external supply sum qM 23 24 25 Ready 26 Fault Spd Thresh IE ZA 27 28 29 30 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 48 Install
89. A Not or B with B Not If using a DC analog tachometer then the tachometer leads must be reversed e The Polarity of the analog speed reference signal is incorrect for the required direction ATTENTION If the motor is turning the wrong direction and the drive is PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Testpoint Codes and Functions Troubleshooting 4 15 The motor reaches maximum speed immediately Drive Symptom The motor accelerates to maximum speed and cannot be controlled Action Check the analog input voltage and speed reference values e Parameters 1404 Analog Int Value 1405 Analog In2 Value 44 Speed Ref A and 48 Speed Ref B e Check the setting of switch S9 and parameter 71 Anlg Int Config 510 and 76 Anlg In2 Config or S11 and 81 Anlg In3 Config The feedback device encoder or DC analog tachometer is not connected incorrectly connected or has failed e Change parameter 414 Fdbk Device Type to 3 Armature to test the encoder or DC analog tachometer feedback Select a testpoint with Par 1381 TestPoint Sel Values can be viewed with Par 1382 TestPoint Data Values No 1 Description Minimum Maximum Default 566 Rx count 567 Tx count 568 BusLoss count 569 Port 1 Timeout 570 Port 2 Timeout 10 65535 0 571 Port 3 Timeout 572 Port 4 Timeout 573 Port 5 Timeout 574 Port 6 Timeout 1 Enter in TestPoint Sel
90. AC to 24V DC I O Converter Circuit Board for more information Table 1 Q Analog I O Digital I O and DC Analog Tachometer Wire Sizes and Terminal Specifications Wire Size and Type Tightening Terminal Block Flexible Multi core Torque Signal Type Terminals mm mm Nem Ibin Analog and Digital O TB1 4 1 40 DC Analog Tach M3 and See Cable and Wiring Recommendations on page 1 17 for more information 0 140 1 500 0 140 1 500 26 16 0 4 3 5 Figure 1 35 1 0 Terminal Block Locations T Bite a A b Pa Fa 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 ig e CRINE ISO O06 6 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 r f Terminal Block 3 Terminal Block 4 Terminal Block 1 Terminal Block 2 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Table 1 R 1 0 Terminal Block 1 Designations Installation and Wiring 1 43 No Signal Description Factory Default Config Parameter 1 Analog Input 1 solated bipolar differential 1 Speed Ref A 70 Anlg In1 Sel 2 Analog Input 1 HOV 0 20 mA or 4 20 mA 3 Analog Input 2 Important 0 20 mA or 4 20 mA 0 Off 75 Anlg In2 Sel 4 Analog Input 2 operation requires that switch S9 S10 and 5 Analog Input 3 11 on the Con
91. Adaptive Gain3 P183 Adaptive Ref PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 23 The adaptive speed regulator is enabled with parameter 181 Adaptive Spd En 1 Enabled Normally the gain depends on the speed of the drive It can however vary according to a variable defined in parameter 183 Adap Ref The type of regulation used is selected in parameter 182 Adaptive Reg Typ 0 Speed or 1 Adaptive Ref Parameters 184 Adaptive Spd 1 and 185 Adaptive Spd 2 are used to define the three ranges that may have different gains A parameter set can be defined for each of these ranges with each set containing an individually definable P and I component i e Pars 188 Adaptive P Gain1 and 189 Adaptive I Gain1 190 Adaptive P Gain2 and 191 Adaptive I Gain2 and 192 Adaptive P Gain3 and 193 Adaptive I Gain3 When the adaptive speed regulator is enabled the first set of parameters is active until the speed specified in Par 184 Adaptive Spd 1 or Par 183 Adap Ref is reached Parameters 186 Adaptive Joint 1 and 187 Adaptive Joint 2 ensure a smooth transition between the different parameter sets The fields must be defined so that Adaptive Joint 1 and Adaptive Joint 2 do not overlap When the adaptive speed regulator is enabled parameters 87 Spd Reg Kp and Spd Reg Ki parameters have no effect on the speed regulator They do
92. Angle 3 25 Arm Volt Ki 3 31 Arm Volt Ki Base 3 31 Arm Volt Kp 3 31 Arm Volt Kp Base 3 31 Armature Overvoltage fault 4 4 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 armature terminals wire size 1 25 Armature Voltage alarm 4 9 armature voltage feedback terminal block frame A 1 26 terminal block frame B 1 27 terminal block frame C 1 27 terminals 1 26 wire size 1 27 At Speed 3 53 At Speed Delay 3 28 At Speed Error 3 28 At Zero Speed 3 53 auto speed sources C 18 Auto Manual examples C 19 Autotune Cur Lim 3 23 Autotune group 3 22 3 23 Aux Inp Fit Cfg 3 58 Auxiliary Input alarm 4 9 Auxiliary Input fault 4 4 Base Omega 3 45 basic parameters 3 4 Bipolar Conflict alarm 4 9 bipolar inputs warning 1 38 bipolar signal analog output 1 46 bipolar speed reference analog input 1 45 block diagrams D 1 brake resistors A 20 C cables recommendations 1 17 spacing 1 17 spacing example 1 17 spacing notes 1 18 can t start drive 4 11 CE Compliance General Considerations 1 13 CE Conformity 1 13 change speed sources C 18 changed parameters view B 4 circuit breaker control circuit 1 16 clear faults 4 3 Clear Fault Que 3 56 Close Loop Comp 3 48 Closed Loop En 3 49 Closing Speed 3 35 Comm Control group 3 63 common mode interference 1 38 communication adapter install E 1 kits E 1 communications logic command word A 6 logic status word A 7 programmable controller A 6 Co
93. Bit 9 Torque Mode 1 0 Zero Trq Ref 0 0 1 1 Speed Reg 0 1 0 2 Torque Reg 0 0 1 3 SLAT Min 1 b7 b8 4 SLAT Max 2 57 b8 5 Sum 0 1 1 b not b7 b8 if b7 1 amp b8 0 then b9 0 1 3 SLAT Min Bit 7 Forced Spd 0 Not in Forced Speed Mode FSM 0 gt 1 Speed error lt 0 i e Feedback gt Reference preload the speed regulator integrator with the value of Par 14 Selected Torque Ref Forced Speed Mode FSM speed error lt 0 Error i e Reference Feedback gt Par 15 SLAT Err Stpt for more than the value of Par 16 SLAT Dwell Time Bit 8 Speed Mode 10 Par 236 Spd Reg Pct Out gt Par 39 Torque Ref 2 4 SLAT Max Bit 7 Forced Spd 0 Par 236 Spd Reg Pct Out lt Par 39 Torque Ref Not in Forced Speed Mode FSM 0 gt 1 Speed error gt 0 i e Feedback lt Reference preload the speed regulator integrator with the value of Par 14 Selected Torque Ref 1 Forced Speed Mode FSM speed error gt 0 1 gt 0 Error i e Reference Feedback lt Par 15 SLAT Err Stpt for more than the value of Par 16 SLAT Dwell Time Bit 8 Speed Mode 10 Par 236 Spd Reg Pct Out lt Par 39 fTorque Ref 1 Par 236 Spd Reg Pct Out gt Par 39 Torque Ref Note When Par 241 Spd Trq Mode Sel is changed to 1 Speed Reg the speed regulator integrator i
94. CurrReg Autotune Autotune 3 22 530 UsrDefBitWrdA10 User Defined 3 61 453 Arm Resistance Autotune 3 22 531 UsrDefBitWrdA11 User Defined 3 61 454 Arm Inductance Autotune 22 532 UsrDefBitWrdA12 User Defined 3 61 455 Spd Fdbk Error Speed Feedback 3 21 533 UsrDefBitWrdA13 User Defined 3 61 456 Fld Weaken Ratio Field Config 3 16 534 UsrDefBitWrdA14 User Defined 3 61 457 SpdFdbk Control Speed Feedback 21 535 UsrDefBitWrdA15 User Defined 3 61 458 SpdReg FB Bypass Speed Feedback 3 21 536 UsrDefBitWrdB User Defined 3 61 459 SpdReg Kp Bypass Speed Regulator 3 31 537 UsrDefBitWrdBO User Defined 3 62 460 SpdReg Ki Bypass Speed Regulator 31 538 UsrDefBitWrdB1 User Defined 62 461 Spd Fdbk Invert Speed Feedback 3 21 539 UsrDefBitWrdB2 User Defined 3 62 462 Flux Divide Field Config 3 16 540 UsrDefBitWrdB3 User Defined 3 62 463 Flux Filter BW Field Config 3 16 541 UsrDefBitWrdB4 User Defined 3 62 465 Drive Size Drive Data 3 14 542 UsrDefBitWrdB5 User Defined 3 62 466 AC Line Voltage Drive Data 3 14 543 UsrDefBitWrdB6 User Defined 3 62 467 Max Fld Curr Pct Field Config 3 17 544 UsrDefBitWrdB7 User Defined 3 62 468 Min Fld Curr Pct Field Config 3 17 545 UsrDefBitWrdB8 User Defined 3 62 469 Field Mode Sel Field Config 3 17 546 UsrDefBitWrdB9 User Defined 3 62 473 FldLoss Fit Cfg Alarms 3 58 547 UsrDefBitWrdB10 User Defined 3 62 478 Spd Loss Fit Cfg Alarms 3 58 548 UsrDefBitWrdB11 User Defined 3 62 479 MirOvrld Fit Cfg Alarms 3 58 549 UsrDefBitWrdB12 User Defined
95. Data Out Ax 3 65 Data Out B1 3 65 Data Out B2 3 65 Data Out C1 3 65 Data Out C2 3 65 Data Out D1 3 65 Data Out D2 3 65 Datalinks group 3 65 DC contactor crimp lugs kits A 22 DC output contactors A 20 configure 1 9 recommended A 20 DC output voltage 1 19 Decel Mask 3 64 Decel Owner 3 64 Decel Status 3 55 Decel Time 1 3 34 Decel Time 2 3 33 defaults reset B 4 definitions digital input option selections 3 71 digital output option selections 3 74 relay output option selections 3 74 diagnostic data viewing B 4 Diagnostics group 3 51 3 52 3 53 3 54 3 55 3 56 diagrams control block D 1 power wiring 1 20 Diam Calc Dis 3 45 Diam Inc Dec En 3 46 Diam init filter 3 46 Diam Preset 0 3 45 Diam Preset 1 3 46 Diam Preset 2 3 46 Diam Preset 3 3 46 Diam Preset Sel 3 46 Diam stdy delay 3 46 Diam Threshold 3 45 Diameter Calc 3 44 Diameter Calc group 3 44 3 45 3 46 Diameter Calc St 3 44 Diameter Filter 3 45 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Diameter Reached 3 45 Diameter Reset 3 45 Dig In Status 3 72 Dig In Term 1 3 72 Dig In Term 10 3 72 Dig In Term 11 3 72 Dig In Term 12 3 72 Dig In Term 2 3 72 Dig In Term 3 3 72 Dig In Term 4 3 72 Dig In Term 5 3 72 Dig In Term 6 3 72 Dig In Term 7 3 72 Dig In Term 8 3 72 Dig In Term 9 3 72 Dig Out Status 3 75 Digital Int Sel 3 70 Digital In10 Sel 3 70 Digital In11 Sel 3 70 Digital In12 Sel 3 70 Dig
96. Default Default Default Min Max Units Default Min Max Units 0 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 0 0 Par 45 Max Ref Speed rpm 0 0 Par 45 Max Ref Speed rpm 150 300 600 900 1200 1500 1750 32768 432767 rpm 100 32767 rpm on ROS Related Group D Discrete Speeds SPEED COMMAND Speed Regulator 1409 267 88 Parameter Name amp Description See page 3 2 for symbol descriptions 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 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 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 Trim Speed This va
97. Diagnostics 3 56 1285 1 Ref Speed Gain Winder Functions 3 49 1403 Start Inhibits Diagnostics 3 56 1286 1 Ref Line Speed VVinder Functions 49 1404 1 Analog Int Value Analog Inputs 3 6 1287 Static F Zero Winder Functions 3 49 1405 1 Analog In2 Value Analog Inputs 3 69 1290 MtrOvrid Status Diagnostics 3 55 1406 Analog In3 Value Analog Inputs 3 69 1319 Data In Val Sel Datalinks 3 65 1407 Field Econ Delay Field Config 18 1320 1 Data In SelData Datalinks 3 65 1408 Tachometer Speed Speed Meters 3 12 1321 DPI Fdbk Select Comm Control 3 63 1409 Jog Off Delay Discrete Speeds 3 27 1322 1 Direction Mode Reference Config 50 1410 Jog Ramp Time Ramp Rates 3 3 1323 DPI P1 Select DPI Inputs 3 76 1324 DPI P2 Select DPI Inputs 3 76 1325 DPI P3 Select DPI Inputs 3 76 1326 1 DPI P4 Select DPI Inputs 3 76 1327 DPI P5 Select DPI Inputs 3 76 1328 Drive Logic Rsit Diagnostics 3 55 1343 DPI Port Value Comm Control 3 63 1344 Start At Powerup Restart Modes 3 36 1345 1 Powerup Delay Restart Modes 3 36 1347 Fault Clear Faulis 3 56 1348 Fault Clr Mode Faults 3 56 1349 Status1 at Fault Faults 3 57 1350 1 Status at Fault Faults 3 57 1351 Fault 1 Code Faulis 3 57 1352 Fault 2 Code Faults 3 57 1353 Fault 3 Code Faults 3 57 1354 Fault 4 Code Faults 3 57 1355 Fault 5 Code Faults 3 57 1356 Fault 6 Code Faults 3 57 1357 Fault 7 Code Faults 3 57 1358 Fault 8 Code Faulis 3 57 1359 Fault 9 Code Faults 3 57 1
98. Fault 4 Code 1354 Fault 4 Time 1364 Status1 at Fault 1349 Fault 5 Code 1355 Fault 5 Time 1365 Status2 at Fault 1350 Fault 6 Code 1356 Fault 6 Time 1366 Fault Arm Amps 1371 Fault 7 Code 1357 Fault 7 Time 1367 Fault Speed 1372 Fault 8 Code 1358 Fault 8 Time 1368 Fault Field Amps 1373 Fault 9 Code 1359 Fault 9 Time 1369 Fault Voltage 1374 Fault 10 Code 1360 Fault 10 Time 1370 Fault 1 Code 1351 Fault 1 Time 1361 Alarms Drive Alarm 1 1380 FldLoss Fit Cfg 473 OverCurrent Thr 584 OverVolt Cfg 203 Spd Loss Fit Cig 478 Overspeed Val 585 Aux Inp Fit Cfg 354 MtrOvrid Fit Cfg 479 OverTemp Fit Cfg 365 UnderVolt Thresh 481 User Defined UsrDsplyMult0 50 UserDefined14 517 UsrDefBitWrdA15 535 UsrDsplyDivO 51 UserDefined15 518 UsrDefBitWrdB 536 UsrValMult1 53 UsrDefBitWrdA 519 UsrDefBitWrdBO 537 UsrValDiv1 54 UsrDefBitWrdAO 520 UsrDefBitWrdB1 538 UserDefinedO 503 UsrDefBitVVrdA11 521 UsrDefBitWrdB2 539 UserDefined1 504 UsrDefBitWrdA2 522 UsrDefBitWrdB3 540 UserDefined2 505 UsrDefBitWrdA3 523 UsrDefBitWrdB4 541 UserDefined3 506 UsrDefBitWrdA4 524 UsrDefBitWrdB5 542 UserDefined4 507 UsrDefBitWrdA5 525 UsrDefBitWrdB6 543 UserDefined5 508 UsrDefBitWrdA6 526 UsrDefBitWrdB7 544 UserDefined6 509 UsrDefBitWrdA7 527 UsrDefBitWrdB8 545 UserDefined7 510 UsrDefBitWrdA8 528 UsrDefBitWrdB9 546 UserDefined8 511 UsrDefBitWrdA9 529 UsrDefBitWrdB10 547 User
99. Hu OFF Note The input signal type must also be programmed accordingly using Par 71 Anlg Int Config 10 Configures the input signal of Analog Input 2 terminal 3 and 4 On Off Position 0 20 mA 4 20 mA On Position 0 10V 10V ae The input signal type must also be programmed accordingly using Par 76 Anlg In2 onfig 11 Configures the input signal of Analog Input 3 terminals 5 and 6 On 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 o S12 Not used Leave set to the factory setting Off S14 Field current resistors setting see Table 1 H on page 1 30 Minimum field e current rating Important The value selected with switch S14 must be entered in Par 374 Drv Fld Brdg based on drive Cur when the drive is commissioned size o S15 Configuration of the control circuit board to the appropriate drive size Leave set to the factory Armature current setting unless the control board has been supplied as a spare part Refer to Table 1 0 on based on drive page 1 40 and Table 1 P on page 1 41 for switch configuration based on drive current rating size code o S18 Not used Leave set to the factory setting Off S20 Monitoring of the Z channel of the Digital Encoder on connector XE2 On ON Off Position Z channel monitored On Position Z channel not monitored ETT OFF Important The S20 setting should match the value
100. In to zero so that the drive has no torque e Not Active Par 41 Current Reg In is not set to zero e Active Par 41 Current Reg In is set zero The drive has no torque Values Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Options Default Options Programming and Parameters 150 0 200 150 0 200 150 0 200 200 0 200 Not Active Not Active Active Not Active Active Not Active Oo a 3 19 Related so go 179 13 41 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 20 Programming and Parameters 2 ir MOTOR CONTROL Speed Feedback 1750 Parameter Name amp Description See page 3 2 for symbol descriptions TrqTpr Enable Enables Disables the current speed curve function Disabled The limits current speed curve is disabled e Enabled The limits current speed curve is enabled TrqTpr Lim0 The current limit of the current speed curve that operates constantly up to the speed set in Par 756 TrqTpr Spd When the current speed curve function is enabled set in Par 750 TrqTpr Enable this parameter will override the current limits set in Pars 10 Cur Lim Pos
101. June 2009 C 46 Application Notes Field Current Curve Tuning Procedure 1 2 Reset the field current curve by setting Par 920 Reset Fld Curve to 1 Configure the following parameters L Enter the percentage 100 of the maximum motor nameplate rated armature voltage in Par 921 Out Volt Level 1 Set Par 469 Field Mode Sel Base Speed 1 Set Par 467 Max Fld Curr Pct 100 Start the drive Increase the motor speed until the value electromotive force displayed in Par 233 Output Voltage corresponds to the value previously set in Par 175 Rated Motor Volt Decrease the value of Par 467 Max Fld Curr Pct until the value displayed in Par 233 Output Voltage is equal to 90 of Par 175 Rated Motor Volt When you have reached this value read the value displayed in Par 234 Fld Current Pct and enter the value into Par 918 Fld Const 90 Pct Decrease the value of Par 467 Max Fld Curr Pct until the value displayed in Par 233 Output Voltage is equal to 70 of Par 175 Rated Motor Volt When you have reached this value read the value displayed in Par 234 Fld Current Pct and enter the value into Par 917 Fld Const 70 Pct Decrease the value of Par 467 Max Fld Curr Pct until the value displayed in Par 233 Output Voltage is equal to 4096 of Par 175 Rated Motor Volt When you have reached this value read the value displayed in Par 234 Fld Current Pct and enter the value into Par 91
102. Min Max 432766 of the last fault Units rpm 1373 Fault Field Amps Default Read Only Captures and displays the field current as a percentage of rated Min Max 0 00 100 00 current at the time of the last fault Units 1374 Fault Voltage Default Read Only Captures and displays the armature voltage at the time of the last 1 Min Max 999 00 fault Units Vde PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 3 58 File UTILITY Group Alarms Programming and Parameters Note Refer to Chapter 4 for a list of fault and alarm descriptions encountered 479 MtrOvrld Fit Cfg F7 Motor Overload This parameter was added with firmware version 3 001 481 UnderVolt Thresh while the drive is running Note Refer to Chapter 4 for a list of fault descriptions 584 TOverCurrent Thr detected Note Refer to Chapter 4 for a list of fault descriptions PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Determines the response of the drive to a motor overload condition Notes Refer to Chapter 4 for a list of fault and alarm descriptions The AC input voltage level below which an undervoltage fault F4 AC Undervoltage will be detected A typical value is 85 of the nominal AC line voltage Par 466 AC Line Voltage This fault can only occur Value at which an overcurrent condition F13 O
103. 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 H DIP Switch 914 Field Current Configuration Settings ON DIP Note Illustration is an example configuration only DIP switch 514 must be set gt the rated field current specified on the motor nameplate or possible motor damage may result Equivalent Switch ohms 168 5 333 3 182 36 4 1845 1668 Resistance Field current scale S14 1 S14 2 S14 3 S14 4 514 5 S14 6 S14 7 S14 8 Ohm 1 0 A OFF OFF OFF OFF OFF JON 1668 2 0A OFF OFF OFF OFF ON OFF 845 3 0 OFF OFF OFF OFF ON ON 560 9 5 0A OFF ON OFF OFF OFF OFF Not used 333 10 0 A ON OFF OFF OFF OFF OFF 168 5 13 0A ON OFF OFF OFF ON ON 129 6 17 0A OFF ON ON OFF ON ON 97 3 20 0 A ON OFF ON OFF OFF ON 83 1 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring 1 31 Relay Outputs Maximum Maximum Terminals Description Voltage Current 35 36 Normally open contact Configured with parameter 1392 Relay Out 1 Sel set to 25 Contactor by default 75 76 Normally open contact Configured with parameter 629 Relay 250V 1A Out 2 Sel set to 5 Ready by d
104. Numbered List Ve sese RM NEE RUE e a BARLAR NN s 3 3 Cross Reference Tables e eU era ER Ret nur A ns al 3 3 Basic Parameter NIE teases Re n OP E ane ed e eu au a oe lcs 3 4 Advanced Parameter View 3 6 Monitor Fil rete I Rok due P ug 3 11 Motor vacet bx Rada a ea ce Pee ac ed d ewe nd 3 15 Speed Command Pile nd cesis rp Red ax re rta pe ee qe 3 26 Dynamic Control File csse y e sue a me o ee vepres 3 32 Applications File nese se eue eR iii RR EORR RU Ee E Een ds 3 38 Utility Pile ol rer ete Rada lp UE oa ede a Ad e tunc eed 3 50 Communications File 3 63 Input Output File eee 3 67 Parameter Cross Reference by Name 3 77 Parameter Cross Reference by Number 3 82 Troubleshooting Faults and Alarms 22a cdam o aa ERR sala a sek Pura en Riya il 4 1 Driv Status accent 7 4 2 HIM Indicators niece ADR exa A pad dae qa dd 4 3 Manually Clearing Faults 2 4 3 Fault Descriptions eoe names acs 4 4 Alarms vine we eat oder ede da pied pee ke ON gc cn 4 9 Alarm Descriptions uses Men ad bi anne bay ee eda at 4 9 Common Drive Symptoms a
105. Out and 11 Cur Lim Neg Out TrqTpr_Lim1 First reduced current limit of the current speed curve The value defined in this parameter must be less than the value in Par 751 TraTpr_LimO and greater than the values in Pars 753 TrqTpr Lim2 754 TrqTpr_Lim3 and 755 TrqTpr_Lim4 TrqTpr_Lim2 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 TrqTpr_Lim3 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 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 TrqTpr_Spd Threshold speed at which torque reduction begins as determined by the current speed curve Torq Cur Filter First rate low pass filter for Par 1193 Torq Current Pct Note The name of this parameter was changed from Filt Torq Cur to Torq Cur Filter with firmware version 3 001 Encoder PPR Number of pulses per revolution of the digital encoder The value of Pars 169 Encoder PPR and 162 Max Feedback Spd must
106. Parameters 2 g 8 x Parameter Name 8 Description m ip 2 See page 3 2 for symbol descriptions Values ka 1165 Diam Preset 1 Default 1 00 799 Second preset starting diameter The value of this parameter must be Min Max 0 00 32 00 1153 set between the value of Pars 799 Minimum Diameter and 1153 Units m Max Diameter 1166 Diam Preset 2 Default 1 00 799 Third preset starting diameter The value of this parameter must be Min Max 0 00 32 00 set between the value of Pars 799 Minimum Diameter and 1153 Units m Max Diameterl 1167 Diam Preset 3 Default 1 00 799 Fourth preset starting diameter The value of this parameter must be Min Max 0 00 32 00 5 set between the value of Pars 799 Minimum Diameter and 1153 Units m Max Diameter This parameter can be assigned to an analog input If an analog input is used 10V corresponds to the value of Max Diameter and the voltage corresponding to the minimum diameter 10 x Minimum Diameter Max Diameter 1168 Diam Preset Sel Default 0 1164 Selects the starting diameter for the Diameter Calculation function Min Max 0 3 1165 0 Par 1164 Diam Preset 0 1166 e 1 Par 1165 Diam Preset 1 1167 2 2 Par 1166 Diam Preset 2 o e 3 Par 1167 Diam Preset 3 s This parameter can also be set via tuvo digital inputs programmed as E 57 Diam Preset0 and 58 Diam Preset1 the selection in this case is carried ou
107. Pct 3 18 Fld Const 70 Pct 3 18 Fld Const 90 Pct 3 18 Fld Current Pct 3 13 Fld Reg Ki 3 16 Fld Reg Ki Base 3 16 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Fld Reg Kp 3 16 Fld Reg Kp Base 3 16 Fld Test Angle 3 25 Fld Weaken Ratio 3 16 FldLoss Fit Cfg 3 58 Flux Current Pct 3 13 Flux Divide 3 16 Flux Filter BW 3 16 Flying Start En 3 30 Force Min Field 3 17 Freeze Ramp 3 34 Friction 3 23 Gear Box Ratio 3 44 Reg Error 3 23 Inertia 3 23 Inertia C Filter 3 23 InertiaCompAct 3 31 InertiaCompVar 3 31 Initial Diameter 3 47 Int Acc Calc En 3 47 Inversion In 1 3 72 Inversion In 10 3 72 Inversion In 11 3 72 Inversion In 12 3 72 Inversion In 2 3 72 Inversion In 3 3 72 Inversion In 4 3 72 Inversion In 5 3 72 Inversion In 6 3 72 Inversion In 7 3 72 Inversion In 8 3 72 Inversion In 9 3 72 Inversion Out 1 3 75 Inversion Out 2 3 75 Inversion Out 3 3 75 Inversion Out 4 3 75 Inversion Out 5 3 75 Inversion Out 6 3 75 Inversion Out 7 3 75 Inversion Out 8 3 75 Inversion Relay1 3 76 Inversion Relay2 3 75 Jog Mask 3 63 Jog Off Delay 3 27 Jog Owner 3 64 Jog Ramp Time 3 33 Jog Speed 3 26 Jog TW Enable 3 49 Jog TW Speed 3 49 Language 3 51 Last Stop Source 3 56 Line Accel Pct 3 47 Line Decel Pct 3 47 Line FastStp Pct 3 47 Line Spd Gain 3 45 Line Spd Source 3 48 Line Spd Thresh 3 45 Line Speed Pct 3 45 Load Comp 3 35 Local Mask 3 64 Local Owner 3 64 Lock Speed Integ 3 30 Logic Ma
108. Read Only Min Max 8192 Units rpm Default Read Only Min Max 200 0 Units Default Read Only Min Max 8192 Units rpm Default Read Only Min Max 200 0 Units Default Read Only Min Max 8192 Units rpm Default Read Only Min Max 8192 Units rpm Default Read Only Min Max 8192 Units rpm Default Read Only Min Max Units rpm Default Read Only Min Max 100 0 Units Default Read Only Min Max 8192 Units rpm Related 66 162 45 121 222 923 45 45 File MONITOR Group Current Meters 199 200 234 236 351 500 928 Parameter Name amp Description See page 3 2 for symbol descriptions Cur Lim Pos Oui Displays the value of the current limit for the positive torque direction as a percentage of the value in Par 179 Nom Mtr Arm Amps Cur Lim Neg Out Displays the value of the current limit for the negative torque direction as a percentage of the value in Par 179 Nom Mtr Arm Amps Selected TorqRef Displays the selected torque reference based on Par 241 Spd Trq Mode Sel value Scaled as a percentage of Par 179 Nom Mtr Arm Amps Note This parameter was added with firmware version 3 001 Motor Trq Ref Displays the total motor torque reference Scaled as a percentage of Par 179 Nom Mtr Arm Amps Note This parameter was added with firmware version 3 001 Current Reg In Total current reference value ex
109. Related PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 76 File INPUT OUTPUT Digital Outputs Group DPI Inputs Programming and Parameters Parameter Name amp Description Selects the destination of the reference value from DPI Port 5 communications adapter when installed PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 o ge Z See page 3 2 for symbol descriptions Values 1393 Inversion Relay1 Default 0 Disabled o Inverts the signal for Relay Output 1 Options 0 Disabled 1 Enabled 1323 DPI P1 Select Default 0 Off 6 Selects the destination of the reference value from DPI Port Options 0 Off HIM on drive cover when installed 1 Speed Ref A 2 Speed Ref B 3 Trim Ramp 4 Speed 5 Torque Ref 6 Torque 7 Pos Cur Lim 8 Neg Cur Lim 1324 DPI P2 Select Refer to Par 1323 DPI P1 Select e Selects the destination of the reference value from DPI Port 2 handheld and remote option when installed 1325 DPI P3 Select Refer to Par 1323 DPI P1 Select O Selects the destination of the reference value from DPI Port 3 handheld and remote option when installed 1326 DPI P4 Select Refer to Par 1323 DPI P1 Select Selects the destination of the reference value from DPI Port 4 1327 DPI P5 Select Refer to P
110. S t q amp ad Q r eoa les zu enbia zi 1 9L o o VAR veld e Z uj UOISISAUT 790 udd 3 Q awl 4 19 o o VR uj uoisJeAU 490 9214 2 9 5100 121010 g Y90018 eurude PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Control Block Diagrams D 4 A WOO 8S INO Jepoou3 12014 1111111 Ty yoolg euiuue 1epoou3 260 T molo 0981 Aa dui kul C 18SJO Cu Djuy Yad 9jeog gui Du PS 2 enjeA cuj ouy 9074 JeDIEL g l bluy E PY 1624 a 9 vals Xi SIN ndu q d MH z seen les g l bluy 9 eos euni 60 aun Buy 8d V9zd IEI IO Wol4 le s g l Duy 114 DUO Eu Duy 18d du nipA z l Dopeuy X je SOA X eun 201 Du ejeos eun 20 0924 8 4 4 bz duo Lu juy 9 014 D 2 le Le C ES x vOV y 69d EE l nooy 2 ole X le C 199 2 OV 894
111. Sel is set to 24 ContactorDB The drive starts from the HIM but will not start from the terminal block PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Check masks for Terminal Block control see parameters 591 Logic Mask and 592 Start Mask Troubleshooting 4 13 Drive starts but motor does not turn and no armature current Drive Symptom The drive starts but there is no armature current and the motor does not respond to a speed signal Action e Verify the wiring to the analog input s selected for speed reference refer to UC Wiring Examples on page 1 45 e Verify the setting s of switch S9 and Par 71 Anlg In1 Config or S10 and Par 76 Anlg In2 Config or 11 and Par 81 Anlg In3 Config refer to DIP Switch and Jumper Settings on page 1 38 e Verify the speed selection digital input s and the respective input terminal voltage s if used e Verify the analog input s voltage s displayed in parameters 1404 Analog In1 Value 1405 Analog In2 Value or 1406 Analog In3 Value The drive starts and armature current is present but the motor does not turn e The Load may be too great for the motor and drive e Remove the load from the motor and test for motor rotation If the motor rotates then verify that the measured armature current using an in line current meter or DC clamp on meter equals the armature current feedback value displayed i
112. Sel is set to TB Man Ref The value of analog input 2 can be viewed in parameter 267 TB Manual Ref To switch between Auto and Manual parameter 136 Digital In4 Sel is set to Auto Manual Acquire Manual Control e Close the digital input With the input closed the speed command comes from the pot Release to Auto Control e Open the digital input With the input open the speed command returns to the PLC Auto Manual Notes 1 Manual control is exclusive If a HIM or Terminal Block takes manual control no other device can take manual control until the controlling device releases control 2 If a HIM has manual control and power is removed from the drive the drive will return to Auto mode when power is reapplied PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 C 20 Application Notes Speed Feedback Regardless of the type of speed feedback device used selected in Par 414 Fdbk Device Type the value of parameters 162 Max Feedback Spd and 169 Encoder PPR must be in the allowed area shown in figures C 2 below based on the value of Par 175 Rated Motor Volt Figure C 2 Par 162 and 169 Settings when Par 175 Rated Motor Volt 700V or Lower
113. Spd Torque Attribute 3 20 589 DPI Baud Rate Comm Control 63 757 PID Clamp PID Control 3 41 590 DPI Port Sel Comm Control 3 63 758 Feed Fwd PID PID Control 3 41 591 Logic Mask Masks amp Owners 3 63 759 PID Error PID Control 3 41 Security 35 760 PID Setpoint 0 PID Control 4 592 Start Mask Masks amp Owners 3 63 761 PID Setpoint 1 PID Control 341 593 Jog Mask Masks amp Owners 13 68 762 P D Setpoint Sel PID Control 341 594 Direction Mask Masks amp Owners 3 63 763 PID Feedback PID Control 341 595 Reference Mask Masks amp Owners 3 63 764 PI Integral Gain PI Control 3 88 596 Accel Mask Masks amp Owners 3 63 765 PI Prop Gain PID PI Control 3 88 597 Fault Clr Mask Masks amp Owners 3 63 766 PD Deriv Gain 1 PD Control 340 598 Mask Masis amp Owners BGs 767 PD Deriv Filter PD Control 3 40 599 Local Mask Masks amp Owners 3 64 768 PD Prop Gain 1 PD Control 3 40 600 Stop Owner Masks amp Owners 3 64 769 Enable PI PI Control 3 38 601 Start Owner Masks 8 Owners 3 64 770 Enable PD PD Control 3 40 602 Jog Owner Masks amp Owners 3 64 711 PI Output PI Control 3 38 603 Direction Owner Masks amp Owners 3 64 772 PID Output Sign PID Control 41 604 Reference Owner Masks amp Owners 3 64 773 PID Output Scale PID Control 341 605 Accel Owner Masks amp Owners 3 64 774 PID Output PID Control 341 606 Fault Clr Owner Masks amp Owners 3 64 776 PI Central vi PI Control 3 38 607 MOP Owner Masks 8 Owners 3 64 777 Pl Central v2 PI Con
114. The value of Par 19 S Curve Time is added to the ramp time of linear ramps regardless of speed changes If the value of S Curve Time is changed Pars 665 and 667 S Curve Accel x and 666 and 668 S Curve Decel x are set to the same value If any of parameters 665 668 are changed later the last change is valid S Curve Time Ramp Delay Defines a ramp delay time when the ramp is active Works with par Digital Outx Sel set to 6 Ramp Pos or 7 Ramp Neg Par 113 Ramp Out Par 346 Torque Positive Par 347 Torque Negative ET Par 20 Ramp Delay T MOP Accel Time The acceleration rate for the MOP reference in response to a digital input The MOP acceleration rate Par 2 Maximum Speed Par 22 MOP Accel Time If 0 is entered in this parameter the ramp output directly follows the reference value Accel Time 2 Sets the rate of acceleration for Ramp 2 Acceleration rate for Ramp 2 Par 2 Maximum Speed Par 24 Accel Time 2 MOP Decel Time The deceleration rate for the MOP reference in response to a digital input The MOP deceleration rate Par 2 Maximum Speed Par 30 MOP Decel Time Jog Ramp Time Sets the rate of acceleration and deceleration while the Jog function is active The Jog rate Par 2 Maximum Speed Par 1410 Jog Ramp Time Note This parameter was added with firmware version 2 001 Decel Time 2 Sets the rate of decelera
115. Typically this value is approximately 85 of the nominal AC line voltage 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 Par 585 OverSpeed Val Enter a value that is 10 above the maximum speed that the motor will achieve Typically 10 above Par 162 Max Feedback Spd 14 Access the Input amp Output file and press Enter 15 Access the Analog Inputs group and configure the following m m If you have connected a potentiometer to analog input 1 for a speed reference O Verify that Par 70 Anlg Inl Sel is set to 1 Speed Ref A default O Verify that switch S9 and Par 71 Anlg Inl Config are configured to match voltage versus a current signal Refer to DIP Switch and Jumper Settings on page 1 38 OSet Par 72 Anlg Inl 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 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Drive Start Up 2 9 16 Access the Digital Inputs group and configure the following parameters 1 Par 1391 ContactorControl Select the type of contactor s used with the drive 1 Contactor default AC input or DC output contact
116. U1 V1 Table 1 G Field Circuit Wire Sizes and Terminal Specifications Drive Current Rating Codel Tightening Torque Frame 230V Terminals Wire Size and Type Nem Ibein AL JAN Ai U4 V4 Ct 01 24 10 AWG Kcmils 0 5 0 8 4 4 7 1 Refer to Standard Drive Catalog Number Explanation on page Preface 4 positions 8 9 and 10 for corresponding drive HP rating armature amp rating and field amp rating 2 See Cable and Wiring Recommendations on page 1 17 for more information PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 30 Installation and Wiring Field Current Configuration 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 2 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 Drv Fld Brdg Cur in the control software when the drive is commissioned refer to Drive Start Up on page 2 1 field current specified on the motor nameplate or possible motor ATTENTION DIP switch S14 must be set to be 2 the rated damage may result Compare the field current value of the motor to the rated value of the internal field converter of the drive see Table 1 H below and set switch 14 to the closest value
117. Updated the Fine Tuning the Speed Regulator procedure C 41 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 soc iv Change Page s Updated the terminal numbers indicated in the Digital Inputs Outputs block D 3 diagram Updated the Ramp Reference block diagram to include the new parameter 1410 D 7 Jog Ramp Time Removed the 20 COMM L communication adapter from the compatible E 1 Communication Adapter Kits table The information below summarizes the changes to the PowerFlex Digital DC Drive User Manual publication 20 UMO01 since the initial release Change Page s Removed erroneous derating information 1 2 A 1 Updated AC Input Voltages tables 1 19 Updated AnalogCfict Alarm description to include parameters 1323 1327 DPI Px 4 9 Select Updated Agency Certification Information A 1 Added notation regarding required installation in a Pollution Degree 2 environment A 2 Updated the Maximum Short Circuit Ratings data A 3 Added footnote regarding coil voltage to DC Loop Contactor table information A 20 Updated block diagrams to correct parameter numbers and names D 2 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Summary of Changes Preface Chapter 1 Table of Contents Important User Information 1 2 Manual Updates inca etal iad g
118. a flux change Tune the regulator so that the armature voltage undergoes very small changes Important Before the optimization of the voltage regulator the speed and field current regulators must have already been tuned Refer to Tune the Current Regulator on page 2 10 and Fine Tuning the Field Current Regulator on page C 38 1 Configure the following Test Generator parameters 41 Set Par 58 TstGen Output 4 Ramp Ref Set Par 59 TstGen Frequency 0 2 Hz d D Set Par 60 TstGen Amplitude 10 m Set Par 61 TstGen Offsetl to the switching point from the armature to the field regulation For example If Par 162 Max Feedback Spd 2000 rpm field vveakening starts at 1500 rpm Therefore set Par 61 TstGen Offset 75 2 Measure the field current and the armature voltage using analog outputs 1 and 2 by setting LI Par 66 Anlg Ou Sel 18 Fld Current LI Par 67 Anlg Out Sel 14 Motor Volts 3 Start the drive 4 Check the armature voltage via analog output 2 After a possible short oscillation the voltage should remain constant Refer to the Field Voltage Regulator examples below You can change the Proportional and Integral gains of the Field Voltage regulator via Pars 493 Arm Volt Kp and 494 Arm Volt Ki 5 Stop the drive 6 Set Par 58 TstGen Output 0 NotConnected PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 44 Applic
119. actual direction of the motor 0 Reverse 1 Forward Bit 4 Accelerating When set the drive is accelerating Bit 5 Decelerating When set the drive is decelerating Bit 6 Alarm When set the drive is in an alarm state Bit 7 Fault VVhen sef the drive is faulted Bit 8 At Speed When set the drive is at the commanded speed Bit 9 11 Local ID 0 2 Bit 12 15 Spd Ref ID 0 3 E ev p D a a Ja Jo m LE 53 55 fe 2 9 alg lo BO s c C C ig a a e 2 5 TELIS 22 2 RSS 212 a3 98 8 818 58g 02 40 02 Oo joa joa jt O et O jt E Defaut 0 0 0 0 0 0 1 0 0 0 0 0 1 1 Bit 15 14 113 12 111 10 9 8 7 6 5b 4 B 2 1 0 OBits Bits 15 14 13 12 Description 11 10 9 Description 0 0 0 0 Spd Ref Auto 0 0 0 Port 0 TB 0 0 0 1 SpdRefB Auto 0 0 1 DPI Port 1 0 0 1 0 Preset Spd 2 Auto 0 1 0 DPI Port 0 0 1 1 Preset Spd 3 Auto 0 1 1 DPI Port 3 0 1 0 0 Preset Spd 4 Auto 1 0 0 DPI Port 4 0 1 0 1 Preset Spd 5 Auto 1 0 1 DPI Port 5 0 1 1 0 Preset Spd 6 Auto 1 1 0 DPI Port 6 O 1 1 11 Preset Spd 7 Auto 1 1 1 No Local Control 1 0 0 10 Manual 1 0 0 11 DPI Port 1 Manual 1 0 1 0 DPI Port 2 Manual 1 0 1 1 DPI Port 3 Manual 1 1 0 0 DPI Port 4 Manual 11 0 11 DPI Port 5 Manual 1
120. and any other loads connected to terminal 19 20 PE ground PE ground to drive chassis PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 44 Installation and Wiring Table 1 T 1 0 Terminal Block 3 Designations Factory No Signal Description Default Config Parameter 21 Analog Output 1 Max HOV 5 mA 12 Motor Speed 66 Anlg Out1 Sel 22 Analog Output 1 23 Analog Output 2 13 Motor Curr 67 Anlg Out Sel 24 Analog Output 2 25 Digital Output Common 26 Digital Output 1 Max 30V 50 mA 5 Ready 145 Digital Out Sel 27 Digital Output 2 9 Fault 146 Digital Out2 Sel 28 Digital Output 3 2 Spd Thresh 1147 Digital Out3 Sel 29 Digital Output 4 4 CurrentLimit 148 Digital Out4 Sel 30 24VDC Supply Supply voltage for the digital outputs Max 30V DC 80 mA Important When using the internal 24V DC supply terminal 19 for digital outputs 1 4 you must connect the digital output common terminal 25 to the 24V supply common terminal 18 Table 1 U 1 0 Terminal Block 4 Designations No Signal Description Factory Default Config Parameter 31 Digital Input 5 Max 30V 15V 3 2 mA 24V 5 mA 17 Speed Sel 1 137 Digital In5 Sel 32 Digital Input 6 and 30V 6 4 mA 18 Speed Sel 2 138 Digital In6 Sel 33 Digital Input 7 A digital input
121. and write all of the bits associated with UsrDefBitWrdA to a digital output UsrDefBitWrdB A bitmap of Pars 537 UsrDefBitWrdBO through 552 UsrDefBitWrdB15 With a parameter it is possible to read or write all of the bits inside a word Example UsrDefBitWrdBO UsrDefBitWrdB1 UsrDefBitWrdB2 UsrDefBitWrdB3 UsrDefBitWrdB4 UsrDefBitWrdB5 UsrDefBitWrdB6 UsrDefBitWrdB7 UsrDefBitWrdB8 UsrDefBitWrdB9 UsrDefBitWrdB10 UsrDefBitWrdB1 1 UsrDefBitWrdB1 2 UsrDefBitWrdB1 3 UsrDefBitWrdB1 4 UsrDefBitWrdB 15 UsrDefBitWrdB 2 32 64 1024 4096 5218 Note This parameter can be assigned to a digital input or output The bit number corresponds to the digital input output number for example digital input 3 uses UsrDefBitWrdA3 Relay Outputs 1 and 2 use bits 14 and 15 respectively 1 y Il D 5 32 po no o o E 20 1024 212 4096 CO CO CD A OO OO OO LN OO OO o Values Default Min Max Default Min Max Programming and Parameters 0 1 0 0 65535 3 61 Related o co 537 552 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 62 Programming and Parameters Parameter Name amp Description See page 3 2 for symbol descriptions Values UsrDefBitWrdBO Default UsrDefBitWrdB1 UsrDefBitWrdB2 Min Max 0 1 UsrDefBitWrdB3 UsrDefBitV rdB41 UsrDefBitWrdB5 UsrDe
122. aq m x E m x Default x X X X X X X X X X x x x 0 Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 10 1322 Direction Mode Default 0 Unipolar Selects the method that will be used for changing direction Options 0 Unipolar e Unipolar Drive Logic determines the direction 1 Bipolar Bipolar The sign of the reference determines the direction 2 Rev Disable e Rev Disable Forward direction only not changeable 1375 MOP Select Default 0 Selects the destination of the MOP signal Options 0 1 Speed Ref A 2 Speed Ref B 3 Trim Speed 4 TBManRef 211 Param Access Lvl Default 0 Basic Selects the parameter display level Options 0 Basic Basic Reduced parameter set 1 Advanced 2 Advanced Full parameter set S 258 Reset Defaults Default 0 Ready 9 ating this parameter to 1 Factory will load the default settings in Options 0 Ready the drive firmware 1 Factory PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Related File Group Drive Memory No 302 346 347 Parameter Name amp Description See page 3 2 for symbol descriptions Language Selects the operating language of the drive Only two languages are available in the drive at any given time English and one of the following Fr
123. aseg d Dou eBeyoA 1ojejnbag 149 112 pi l i PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 Control Block Diagrams D 16 10113 Bay H 1854 110110 quaung wy 6624 0024 104 uung wy yuaung DEU 6614 1564 LY Sduly DU AN WON 0824 eouejonpuy UN SOUEISISOH WY 4 6974 gt 19d am Pld XEN Yd UND PH UIN 195 PON DEL 6974 jueuieDeuejv JoyeinBey Da p ds Joy xe Pas yoeqpes xey Std ogey yc M DU 9574 2914 J8MOg 1481540 D IO 1010 parey S ld enbio aBeyon anbJo 1uejsuo jndino 101011 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 D 17 Control Block Diagrams peeds iv g ld p ds 1v v6Ed O e peeds iy ies xno rysia 10113 peeds 1y Y ld xoeqpee pds 0214 Dousou 6 d O e fejeq piouseiu 6014 4489 pds Z ies xno eysa ul De p ds 814 Ban us lu 1 p ds 2014 ypeqp z pds 2214 Sog Useiu p ds LOld 021402 pae S PJouse1u p ds PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Control
124. breaks the load will decrease dramatically and the motor can potentially go into a runaway condition Speed Limited Adjustable Torque SLAT Min Mode and SLAT Max Mode SLAT Min Mode Par 241 Spd Trq Mode Sel set to 3 and SLAT Max Mode Par 241 Spd Trq Mode Sel set to 4 are for applications that require a smooth transition from a torque mode to a speed mode of operation for example web handling center winders and center unwinds where the drive is normally following a torque reference but a break or slippage could occur Direction of the applied torque and direction of the material movement determine whether SLAT Min or SLAT Max mode should be used SLAT Min Mode In SLAT Min mode you would typically configure a speed reference that forces the speed regulator into saturation the speed reference is slightly above the speed feedback In this case the drive would follow the torque reference until there was a breakage or slippage in the application When the drive is following a torque reference torque mode in SLAT Min mode either one of two conditions will force the drive into following the speed reference speed mode 1 Theoutput of the speed regulator becomes less than the torque reference 2 The speed error becomes negative the speed feedback becomes greater than the speed reference This is forced speed mode Parameter 15 SLAT Err Stpt and parameter 16 SLAT Dwell Time allow you to set some hysteresis for t
125. constant of the filter for the D derivative component of the Min Max 0 1000 Speed Up function Units ms PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Programming and Parameters 3 31 3 E 8 g Parameter Name amp Description s 2 See page 3 2 for symbol descriptions Values 459 SpdReg Kp Bypass Default 10 00 458 The proportional gain Kp of the speed regulator expressed as a Min Max 0 00 100 00 percentage of Par 93 Spd Reg Kp Base when an encoder or Units tachometer feedback signal is changed to armature feedback Par 458 SpdReg FB Bypass Enabled 460 SpdReg Ki Bypass Default 1 00 458 The integral gain Kj of the speed regulator expressed as a Min Max 0 00 100 00 percentage of Par 94 Spd Reg Ki Base when an encoder or Units tachometer feedback signal is changed to armature feedback Par 458 SpdReg FB Bypass Enabled 493 Am Volt Kp Default 30 00 495 Proportional gain Kp of the field voltage regulator expressed asa Min Max 0 00 100 00 percentage of the value defined in Par 495 Arm Volt Kp Base Units 926 494 Volt Ki Default 40 00 496 Integral gain Kj of the field voltage regulator expressed as a Min Max 0 00 100 00 percentage of the value defined in Par 496 Arm Volt Ki Base Units E 495 Volt Kp Base Default Based on drive current rating 493 8 O The proportional gain Kp of the field
126. defined in Par 106 Ref Zero Level 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 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 SpdOut FiltGain First order lead lag filter gain on the speed regulator output signal Note This parameter was added with firmware version 3 001 Values Default Min Max Units Default Min Max Units Default Options Default Options Default Options Default Min Max Units Default Min Max Programming and Parameters 20 1 32767 rpm 100 0 65535 ms Disable 0 0 Disable 1 Enable Disable Disable Enable 0 0 1 Disable Disable 0 0 1 Enable 10 00 0 00 100 00 0 010 0 010 1 000 3 29 amp Related 3 395 239 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 30 Programming and Parameters
127. doud jul ld 6 d did UE9 dard ld S9 d UE inos 14 184d AL 891N0S Aid 98 d 101009 did e ueg ld pM4 pee4 8SLd PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 D 19 Control Block Diagrams leu UMOUS Z pue Log ejeos se MOJ uge OY 9 6 S30010 ALIS lQE EAB eie sxoo q 9 eos xis 0 dN e1oN HO ul cereos 6994 SCH ul Cape 1954 AQ 291895 MN cereos 9954 5964 UIN ul cereos HO MO eene 8699 0964 1100 221225 994 SON ul l leos c6vd AQ LOPI MN Loge 2874 98 d UIN Ul Lore HO MO LIS 6874 1674 NANO Loge ndul zejeog ESSd HO IEIS indu ojeos S8 d XEN l Lejeos 8874 SH90 9 eje s 0 4 op PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 Control Block Diagrams D 20 sip ul ql sri 8154 Yyip ul qi sn 2154 glp uy gl sn cL peugeqiesp Vip ull ql sn 9154 9154 vlSd lp l qi sn 8154 6peujaquesr 2154 gp u ql si 1peujaquesr Va 0194 SJojoUlEJed eJouot C SPAMS 9694 E VPAMilgiequsm 61Sd C 9pougaqiesm Spougaquesm vpaujequesr 6094 8094
128. dynamic brake ABB EHDB520C 1L ABB contactor for drives with a dynamic brake Must be sourced separately from drive ABB EHDB650C2P 1L ABB contactor for drives with no dynamic brake ABB EHDB650C 1L ABB contactor for drives with a dynamic brake Must be sourced separately from drive ABB EHDB800C2P 1L ABB contactor for drives with no dynamic brake ABB EHDB800C 1L ABB contactor for drives with a dynamic brake Must be sourced separately from drive 8 See DC Contactor Crimp Lug Kit Specifications on page A 22 for more information 10 Wire and Lug size dependant on Cabinet dims and local codes PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 A 22 Supplemental Drive nformation Table A T 460V AC Input Non Regenerative Drives DB AC Armature Resistor Brake DC Loop DC Contactor DC Line Dynamic Brake Voltage DB Resistor Size Amps Contactor onmp Lugs Cat Drive Cat No Amps Amps HP Resistor Kit Cat No Volts Size ohms Watts Required Cat No 9 20P 21ADAP1 4 1 13 3 2 11370 DBH63 500 81 255 6 17 1370 DC56 11370 LG40 20P 21AD6P0 6 49 3 11370 DBH64 500 62 245 8 06 1370 DC56 1370 1640 20P 21AD010 10 8 2 5 11370 DBH65 500 45 245 11 11 1370 DC56 1370 1640 20P 21AD014 14 111 4 17 5 11370 DBH66 500 27 350 18 52 1370 DC56 1370 1640 20P 21AD019 119 115 5 110 1370 67 500 20 420 25 00 13
129. fault 4 6 Port 2 Adapter fault 4 6 Port 2 DPI Loss fault 4 6 Port 3 Adapter fault 4 6 Port 3 DPI Loss fault 4 6 Port 4 Adapter fault 4 6 Port 4 DPI Loss fault 4 6 Port 5 Adapter fault 4 6 Port 5 DPI Loss fault 4 6 PORT LED 4 2 Port Mask Act 3 66 potentiometer wiring 1 45 power circuit fuses 1 16 protection 1 16 Power Failure fault 4 7 power feeder ground 1 12 power terminals armature converter 1 23 Index 19 power wiring 1 19 AC input contactor 1 20 armature output terminals 1 23 armature voltage feedback terminals 1 26 contact terminals 1 31 DC output contactor 1 21 diagrams 1 20 dynamic brake 1 22 field input terminals 1 28 field output terminals 1 28 motor thermistor terminals 1 31 normally open contact terminals 1 31 Powerup Delay 3 36 preferences set B 5 Preset Speed 1 3 26 Preset Speed 2 3 26 Preset Speed 3 3 26 Preset Speed 4 3 26 Preset Speed 5 3 26 Preset Speed 6 3 26 Preset Speed 7 3 26 programmable controller communications A 6 configure A 6 PTC configure 1 31 R Ramp Delay 3 33 Ramp In 3 11 Ramp In Pct 3 11 Ramp In Zero En 3 36 Ramp Out 3 11 Ramp Out Pct 3 11 Ramp Rates group 3 32 3 33 3 34 Ramp Select 0 3 54 Ramp Select 1 3 54 Ramp Type Select 3 32 Rated Motor Volt 3 15 Real FF PID 3 40 Ref Line Spd 3 49 Ref Spd Source 3 49 Ref Speed Gain 3 49 Ref Zero Level 3 28 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 Index 20 Referen
130. fault has occurred Check Fault x Code or view the Fault Queue on the HIM Refer to Fault Descriptions on page 4 4 Steady A non resettable non configurable fault has occurred Check Fault x Code or view the Fault Queue on the HIM Refer to Fault Descriptions on page 4 4 PORT Refer to the Communication Status of DPI port internal communications if present MOD Adapter User Manual Status of communications module when installed NETA Status of network if connected NET B Status of secondary network if connected PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Manually Clearing Faults HIM Indicators Troubleshooting 4 3 The LCD HIM also provides visual notification of a fault or alarm condition Condition The drive is indicating a fault The LCD HIM immediately reports the fault condition by displaying the following Faulted appears in the status line e Fault number Fault name e Time that has passed since the fault occurred Press Esc to regain HIM control Display FolFaulted Auto Fault F5 Arm OverVoltage Time Since Fault 0000 23 52 The drive is indicating an alarm The LCD H M immediately reports the alarm condition by displaying the following Alarm name Alarm bell graphic F gt DigIncflctaA jjjauto rpm Main Menu Diagnostics Parameter Device Select Step Ke
131. however retain their value and are active when the adaptive speed regulator is disabled Configuring the Adaptive Speed Regulator Set Par 181 Adaptive Spd En 1 Enabled e Ifthe gain must be changed on the basis of units other than the drive s speed reference set Par 182 Adaptive Reg Typ 1 Adaptive Ref The adaptive reference is provided to the drive as an analog value via an analog input For this reason Par 183 Adaptive Ref must be assigned to an analog input The other possibility is to enter the value of Par 183 Adaptive Ref via the HIM In this case the an analog input is not necessary e Enter the appropriate values in Par 184 Adaptive Spd 1 and Par 185 Adaptive Spd 2 to define the three speed ranges Values are expressed as a percentage of Par 45 Max Ref Speed and the maximum value of Par 183 Adaptive Ref e When Par 182 Adaptive Reg Typ 0 Speed tuning is completed via Fine Tuning the Regulators on page C 36 In this case the following points must be taken into consideration 3 The value entered in Par 61 TstGen Offset must be at the low end of the speed range to be tuned but is also outside the range set in Par Adaptive Joint x PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 C 24 Application Notes 3 Enter the step value in Par 60 TstGen Amplitude so that the speed remains inside the range to be tuned 3 The optimization is carried out
132. is 1 Enabled issued e 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 e Disabled When the drive is turned on the ramp starts s from zero s Main uses gt e 10 connect to a motor that is already spinning due to its load for example in the case of a pump the flowing d E medium E a e 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 Default 0 00 The Speed Up function gain as a percentage of Par 446 Min Max 0 00 100 00 Speed Up Basel Units o 591 Logic Mask 1377 o 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 o set to 07 the port will have no control functions except for stop 0 Control Masked 1 Control Permitted x E 5 Reserved hao io lo 2 IT L AN Irie gt elele x iz x iz x x 12 5 5 5 S 5 Sc o S o o o o o o go c A xs 9 6 8 ls 9 9 ojs 8 la ja a zm jc ie je je E O q qa O a a Default X X X X Xx x XX 000 0 1 1 Bit 15 14 13 12 11 109 8 7 6 54 3 2 1 0 No Description File Lists
133. is disabled residual flux If possible the motor armature shaft should be locked to prevent rotation or decrease the maximum amplitude of current applied per step to minimize armature movement Armature rotation will interfere with getting acceptable tuning values 1 Disable the field regulator by setting Par 497 Field Reg Enable to 0 Disabled 2 Verify that Par 351 Field Current is set to zero 0 3 Disable the speed regulator by setting Par 242 Speed Reg En to 0 Disabled 4 Set verify that Parameters 7 Current Limit 8 Current Lim Pos and 9 Current Lim Neg are at 100 5 Set Par 453 Arm Resistance calculated as Par 175 Rated Motor Volt Par 179 Nom Mtr Arm Amps x 0 04 6 Set Par 454 Arm Inductance to the minimum value 4 mH 7 Set Par 39 Torque Ref to 30 this is a percentage relative to Par 179 Nom Mtr Arm Amps 8 Start the drive and observe the value of Par 587 I Reg Err for a few seconds it should settle to a value Verify that the motor shaft does not rotate a small amount of movement is OK 9 Stop the drive PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 C 38 Application Notes 10 11 12 13 14 15 16 a If Par 587 I Reg Err is positive increase the value of Par 454 Arm Inductance The magnitude of change is determined by the value of parameter 587 Generally make large increases for example double when
134. number not parameter values Both Sink read write and Source read only parameters can be used as input values Scalex Input Only Sink read write parameters can be used as the output value Scalex Output Configuration parameters parameters that can only be changed while the drive is stopped can be used as the output value Scalex Output However any value written to a configuration parameter will not take effect in the drive until it is stopped The output value is truncated to a whole number when different parameter types are used for example a real input value of 54 97 becomes an integer output value of 54 rpm Dividing by zero 0 does not cause an error but will result in an output value of zero 0 Turning off setting 0 the input parameter or changing the output parameter number does not reset or change the original output value i e the output parameter remains at the last value written P488 Scale1 In Max b P484 gt Scale1 Input P492 Scale1 In Abs P490 Scale1 In Off P485 Scale Output P491 Scale1 Out Off P487 Scale1 Div P486 Scale1 Mul P489 Scale1 In Min PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 C 22 Application Notes Linking Parameters Via the Scale Block Parameters Most parameter values are entered directly by the user However certain
135. parameter and parameter set 2 is valid above the value set in this parameter The transition between the values is defined by Par 186 Adaptive Joint 1 185 Adaptive Spd 2 Default 40 69 183 percentage of Par 45 Max Ref Speed or the maximum value of Par Min Max 0 00 200 00 187 183 Adaptive Ref Units Ki Parameter set 2 is valid below the value set in this parameter and parameter set 3 is valid above the value set in this parameter The transition between the values is defined by Par 187 Adaptive Joint 21 186 Adaptive Joint 1 Default 6 11 184 Defines a range above and below the value set in Par 184 Adaptive Min Max 0 00 200 00 o Spd 1 within which there is a linear change in gain from parameter Units set 1 to parameter set 2 in order to prevent jumps in the adaptive speed regulator The value in this parameter is defined as percentage of the value defined Par 45 Max Ref Speed PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Programming and Parameters 3 37 3 E 8 g Parameter Name amp Description s Z See page 3 2 for symbol descriptions Values 187 Adaptive Joint 2 Default 6 11 185 Defines a range above and below the value set in Par 185 Adaptive Min Max 0 00 200 00 Spd 2 with in which there is a linear change in gain from parameter Units 96 set 2 to parameter set 3 in order to prevent jumps in the adaptive speed regul
136. parameters can be linked via the Scale Block parameters so the value of one parameter becomes the value of another For example the value of an analog input 1 parameter 70 Anlg Inl Sel can be linked to parameter 660 Accel Time 1 In order to do so Set parameter 70 Anlg In1 Sel to 12 UserDefined0 e Set parameter 484 Scalel Input to 503 the parameter number of UserDefined0 e Set parameter 485 Scale Output to 660 the parameter number of Accel Time 1 In this way rather than entering an acceleration time directly via HIM the link allows the value to change by varying the analog signal This can provide additional flexibility for certain applications This functionality should be tested for the desired response before applying to an application Speed Regulation Functions The PowerFlex DC Digital drive provides a flexible speed regulator circuit that can be adapted to the requirements of a variety of applications The drive is set to PI regulation by default Adaptive Speed Regulator The adaptive speed regulator function enables different gains of the speed regulator depending on the speed reference or another variable adaptive reference This allows optimum adaptation of the speed regulator to the specific application P187 Adaptive Joint 2 P188 P189 Adaptive P Gaint Adaptive Gain P190 mm Adaptive P Gain2 Adaptive Gain2 re P193 Adaptive P Gain3
137. selected in Par 911 IZ Channel Enable For example If S20 Off then Par 911 1 Enabled 21 Encoder power supply voltage and input selection 12 15 V Note When i appl the drive the appropriate LED lights to indicate the Laj 12 15V selection of the switch O ms ENC 5 ENC_12 5 V encoder 2 5 5 4V input range 12 15 V encoder 5 4V 15 2V input range ENC5 ENC 12 Le T sv E 5 12 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 40 Installation and Wiring incorrectly or the tachometer is wired incorrectly Failure to observe this precaution could result in damage to or destruction of the equipment ATTENTION The drive can overspeed if DIP switch S4 is set Figure 1 33 DC Analog Tachometer DIP Switch S4 Example ON DiP Note The illustration depicts the DIP switch settings for 90V factory default Table 1 N DC Analog Tachometer DIP Switch S4 Configuration Maximum DC S41 S42 S3 S4 Input Voltage S4 8 S4 7 S4 6 S4 5 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 34 Drive Size DIP Switch 15 Example ON DiP Note Illustration for example only Table 1 0 Drives with 230V Input DIP Sw
138. separately for each range and the parameters of the regulator are set for each range with Pars Adaptive P Gainx and Adaptive I Gainx L1 After the optimization of the different phases review the entire speed range By changing the value of Adaptive Joint x it is possible to reduce the instabilities present in the transients during the changes from one range to the other Increasing the values transients are slighter e When Par 182 Adaptive Reg Typ 1 Adaptive Ref tuning is application specific e When the speed zero logic see page C 27 is disabled factory default setting and the drive is disabled the gains of the speed regulator are active These are set via Pars 188 Adaptive P Gain1 and 189 Adaptive I Gain1 When the speed zero logic is enabled the values set when the motor is stopped are valid PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 25 Speed Up Function The Speed up function is used to avoid oscillations in the presence of loads with a high moment of inertia When this function is enabled default value of 0 Speed Up in Par 1016 SpdFuncSelect a D derivative value is added to the speed feedback circuit vvhich allovvs you to increase the integral gain of the speed regulator It is also useful in the case of cyclical non constant loads on the motor for example cams The feedback applied to the speed regulator is made of two components
139. signaled by the thermistor connected to the drive terminals 78 and 79 Bit 9 Aux Input An auxiliary input interlock is open or a voltage 15 30 V or reference signal is missing for the digital input set to 14 Aux Fault Bit 10 Field Loss The field current is too low Bit 11 Feedback Loss The drive is not receiving a speed feedback signal Bit 12 PwrUp Start Indicates that the drive is starting or has automatically resumed running at commanded speed after drive input power is restored Bit 13 Mtr Overload Indicates when the Motor Overload alarm level has been reached Bit 14 FldCfg Cflct Indicates a field configuration conflict Notes Refer to Chapter 4 Troubleshooting on page 4 1 for information Changed bit 11 name from Encoder Loss to Feedback Loss and added bits 13 and 14 with firmware version 3 001 5 8t 8 B S 15 Is 5 lo lm Je o o B15 4 S S IS B FI 15 B S 8 B B l gt els A dz 42 15 13 15 15 5 15 2160 8 B le 51 5 8 8 8 415 15 5 r S 619 2 2 6 615 218 6 Defaut x 0 0 0 00 0 0 0 00 00 0 Bit 15 14 13 12 11 10 9 8 7 6 5 4 B 2 1 10 UsrDsplyMult0 Default 1 Numerator in the calculation for user defined drive speed display Min Max 1 1073741823 units Note This parameter is not used UsrDsplyDiv0 Default 1 Denominator in the calculation for user defined drive speed display Min Max
140. temperature rating as signaled by the thermistor connected to the drive terminals 78 and 79 Possible causes include The motor does not have a thermistor and Refer to Thermistors and Thermal Switches on there is no resistor between terminals 78 and page 1 31 for configuration information 79 on the drive e The cable between the thermistor connection Check and repair any damage to or loss of connection on the motor and terminals 78 and 79 on the of the thermistor cables between the motor and drive drive has been broken e The overheating of the motor may have been caused by one of the following The Load cycle is too extreme The surrounding air temperature at the site Reduce the load of motor is too high e The motor has an external fan and the fan 222 failed Reduce the surrounding air temperature The motor does not have an external fan and the load is too large at low speeds The cooling effect of the internal fan on the motor s shaft is too low for this load cycle 7 the load cycle or fit the motor with an external an Note Configure with Par 365 OverTemp Fit Cfg No Fault 0 There are currently no faults in the drive nformational only Overcurrent 13 o An overcurrent has occurred in the motor circuit Possible causes include There is a short circuit or ground fault at the Verify the armature circuit wiring is correct output of the drive e The current regulator was not properly fin
141. the major parameter file category 2 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 o Parameter Name amp Description Parameter name as it appears on an LCD HIM with a brief description of the parameters function e Values Defines the various operating characteristics of the parameter Three types exist ENUM Default Lists the value assigned at the factory Read Only indicates that the parameter is not configurable Options Displays the programming selections available Bit Bit Lists the bit place holder and definition for each bit Numeric Default Lists the value assigned at the factory Read Only indicates that the parameter is not configurable Min Max The range lowest and highest setting possible for the parameter Units Unit of measure and resolution as shown on the LCD HIM Important Some parameters will have two unit values e For example Analog inputs can be set for current or voltage as with Par 71 Anlg Inx Config Q Related Lists parameters if any that interact with the selected parameter The symbol 69 indicates that additional parameter information is available in Appendix C Application Notes on page C 1 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 How Parameters are Organized
142. voltage regulator base value Min Max 0 10 Based on drive current rating ER Units 5 o m m b 496 Arm Volt Ki Basel Default Based on drive current rating 494 a LE Sen The integral coefficient Kio of the field voltage regulator base value Min Max 0 01 Based on drive current rating Units A V ms 1016 SpdFuncSelect Default 0 Speed Up 444 Selection of the Speed Up or Inertia Loss compensation function Options 0 Speed Up 445 Note that these two functions are mutually exclusive if one is 1 lnertia loss 447 selected the other is off 7 1014 1015 1191 InertiaCompAct Default Read Only Displays the active compensation of the fixed section as a percentage Min Max 0 00 200 00 of the drive rated current Units 1192 InertiaCompVar Default Read Only Displays the active compensation of the variable section as a Min Max 0 00 200 00 percentage of the drive rated current Units PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 32 Program ming and Parameters Dynamic Control File File Group Control Config Ramp Rates No 16 241 18 Parameter Name amp Description See page 3 2 for symbol descriptions SLAT Err Stpt Configures the condition for transfer between Speed and Torque operation during SLAT Min or SLAT Max mode If the Speed Error is grea
143. 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 e Wiring AC line to drive output or control terminals e Improper bypass or output circuits not approved by Allen Bradley e 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 UM001E EN P June 2009 p 4 Overview Standard Drive Catalog Number Explanation
144. with Rockwell Automation personnel concerning this product should include this information f Ca No 20P41AD4P1RAONNN UL Type OPENIIP20 Series A WO 24VDC Standard ET deeg CE O Input 460VAC 50 60 Hz 3 3A 3 Phase Output 500VDC 4 1A REGEN 1 0HP 1 Min Overload Amps 6 2 Listed 3 Sec Overload Amps 8 2 L H Refer to the data DC Field nameplate label Input 460VAC 50 60 Hz 10A max 1 Phase n your drive for Output 360VDC 10A max on your drive fo actual agency Regulator Power 115 230VAC 50 60 Hz 1 0 0 5A 1 Phase certifications MFD in 2XXX on MMM DD Allep Bradlley M Frame Drive frame size Serial Number A23E0042 Drive serial number A Similar PowerFlex DC drive sizes are grouped into frame sizes to simplify spare parts ordering dimensioning etc The drive frame size can be located just above the serial number on the data nameplate label Refer to the Standard Drive Catalog Number Explanation on page Preface 4 for a list of drive catalog numbers and their respective frame sizes The original firmware version of the drive as shipped from the factory appears on the data nameplate label just above the certifications If the firmware version has been upgraded since the drive was shipped you can view the current version on the HIM if installed See Diagnostics Menu on page B 4 for details The following manuals are recommended for gener
145. 0 Default 0 00 Min Max 0 00 900 00 Units S Default 0 00 Min Max 0 00 900 00 Units S Related 786 File APPLICATIONS Group PID Control Scale Blocks Programming and Parameters 3 43 3 g Parameter Name amp Description m Z See page 3 2 for symbol descriptions Values E 1254 PID Error Gain Default 1 005 759 Gain percentage of Par 759 PID Error Min Max 0 000 32 010 Units 1258 Enable PI PD Default Read Only 769 Indicates the combined status of Par 769 Enable PI and 770 Enable Min Max Disabled Enabled 770 PD If both Par 769 and Par 770 are enabled then Par 1258 Enable PI PD displays Enabled If either of Par 769 or Par 770 is disabled Par 1258 Enable PI PD displays Disabled Scale1 Input Default 0 ren input Min Max 0 1408 Scale4 Input o Scale5 Input Scale6 Input Parameter number from which the value is read and used as the input quantity to the Scale block Refer to the Scale Blocks block diagram on page D 19 for more information 485 Scale1 Output Default 0 554 Scale2 Output 1219 Scale3 Output Min Max 071408 1228 Scale4 Output 1237 Scale5 Output 1246 Scale6 Output Parameter number to which the value of the Scale block output is written Refer to the Scale Blocks block diagram on page D 19 for more information 486 Scalei Mul Default 1 00 1220 Min Max 810000 00 1229 Scale4 Mul o 123
146. 0 Ref Spd Source 1284 Tension Scale 1181 Winder Side 1201 Ref Speed Gain 1285 Time AccDec Min 1182 W Gain 1202 Ref Line Speed 1286 Int Acc Calc En 1183 Spd Match Compl 1203 Static F Zero 1287 Line Accel Pct 1184 Line Spd Source 1204 Line Decel Pct 1185 Close Loop Comp 1208 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Programming and Parameters 3 9 File Group Parameters Utility Reference Config Direction Model 1322 Man Ref Preload 210 MOP Select 1375 Save HIM Ref 209 Save MOP Ref 249 Drive Memory Param Access Lvl 211 Reset Defaults 258 Language 302 Diagnostics Drive Status 1 381 Torque Positive 346 Accel Status 1188 Drive Status 2 382 Torque Negative 347 Decel Status 1189 Last Stop Source 1402 MOP Inc Active 396 Fast Stop Status 1190 Start Inhibits 1403 MOP Dec Active 397 MtrOvrld Status 1290 Drive Logic Rslt 1328 Spd Select 0 400 TestPoint Sel 1381 At Speed 394 Spd Select 1 401 TestPoint Data 1382 At Zero Speed 395 Spd Select 2 402 TaskLoad 32 ms 1383 CurrLimit Active 349 Ramp Select 0 403 TaskLoad 1 ms 1384 Spd Limit Active 372 Ramp Select 1 404 TaskLoad 2 ms 1385 Speed Threshold 393 Encoder State 651 TaskLoad 8 ms 1386 Faults Clear Fault Que 263 Fault 2 Code 1352 Fault 2 Time 1362 Fault Clear 1347 Fault 3 Code 1353 Fault 3 Time 1363 Fault Clr Mode 1348
147. 0 DBH68 1500 12 405 41 67 1370 DC56 1370 LG40 20P 41AD035 35 128 6 20 1370 DBH69 1500 5 330 100 00 1370 DC56 1370 LG40 20P 41AD045 45 136 8 125 11370 DBH70 1500 45 330 111 11 1370 DC56 1370 LG52 20P 41AD052 52 1425 130 1370 DBH71 1500 3 5 385 142 86 1370 DC56 1370 LG52 20P 41AD073 73 159 6 40 1370 DBH72 1500 2 6 345 192 31 1370 DC110 1370 LG92 20P 41AD086 86 170 3 50 1370 DBH73 1500 2 345 250 00 1370 DC110 1370 LG92 20P 41AD100 100 81 7 160 1370 DBH74 1500 2 345 250 00 1370 DC110 1370 LG110 20P 41AD129 129 105 4 175 1370 DBH75 1500 1 270 500 00 1370 DC180 1370 LG140 20P 41AD167 167 1136 4 100 1370 DBH76 1500 0 7 280 714 29 1370 DC180 1370 LG180 20P 41AD207 207 169 1 1125 1370 DBH77 1500 0 7 280 714 29 1370 DC280 1370 LG228 20P 41AD250 250 204 3 1150 1370 DBH78 1500 0 5 365 1000 00 11370 DC280 1370 LG268 20P 41AD330 330 269 6 1200 1370 79 1500 0 7 280 714 29 6 0 20P 41AD412 1412 1336 6 1250 17 500 0 808 7292 6 10 20P 41AD495 495 404 4 1300 500 0 595 6069 7 10 20P 41AD667 667 544 9 1400 9 500 0 542 6439 8 10 1 HUBBELL Y95W808GB Must be sourced separately from drive HUBBELL Y101W595GB Must be sourced separately from drive 3 HUBBELL Y109W542GB Must be sourced separately from drive 4 voltage 115V AC 50 60Hz 6 ABB EHDB360C 1L 22 ABB Contactor for drives with a dynamic brake Must be sourcing separately from drive 6 ABB EHDB520C2P 1L ABB contactor for drives with no
148. 00 Units S 666 S Curve Decel 1 Default 1 00 Defines the deceleration curve for S shaped ramp 1 Min Max 0 10 60 00 Units S 667 S Curve Accel 2 Default 1 00 Defines the acceleration curve for S shaped ramp 2 Min Max 0 10 60 00 Units S 668 S Curve Decel 2 Default 1 00 Defines the deceleration curve for S shaped ramp 2 Min Max 0 10 60 00 Units S 1212 Acc Dec Filter Default 30 Internal acceleration deceleration calculation filter for the Torque Min Max 0 5000 Winder line speed reference Units ms 2 13 Torq Red CurLim Default 100 342 5 The armature current limit defined as a percentage of the value Min Max 0 200 IS defined in Par 179 Nom Mtr Arm Amps when Par 342 Torque Units K Reduction is set to 1 Active PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 File Group Load Limits Stop Modes No 696 697 698 699 700 715 38 627 1262 1263 Parameter Name amp Description See page 3 2 for symbol descriptions Droop Percent Droop function gain is a percentage of the ratio between Par 45 Max Ref Speed and the difference of Par 698 Load Comp Par 41 Current Reg In Therefore when the difference between Par 698 Load Comp and Par 41 Current Reg In 100 and Par 696 Droop Percent 100 the speed reference correction signal is equal to Par 45 Max Ref Speed Droop Filter Droop filte
149. 01 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 at which the field weakening phase begins Note This parameter affects the threshold of an overvoltage condition as indicated by an Arm Overvoltage fault F5 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 Drive Type Sel Important This parameter is only applicable to non regenerative 2 quadrant drives Allows non regenerative drives to use an external 4 quadrant controller On Ramp Speed Torque current references and Speed measurement have the same behavior as a four quadrant drive ZN Nom Mtr Fld Amps Rated motor nameplate field current lae Values Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Options Programming and Parameters 1750 1 6000 rpm 1750 00 1 00 6000 rpm 500 00 20 00 999 00 V Based on drive current rating 0 10 Based on drive current rating A Off Off On ATTENTTON Failure to set this parameter to a value appropriate for the intended application could result in equipment damage and or personal inj
150. 010 5 10 A 10 Conversion B 230V AC 014 75 14 A 10 None 8 24V dc Digital Inputs amp D 460V AC 019 10 19 A 10 N Outputs 3 Analog Outputs and 2 E 600V AC 027 15 27 A 10 Analog Inputs are Standard F 690V AC 035 20 35 A 10 All I O Options are purchased separately and are Use this code for 400V AC input applications 045 25 45 A 10 user installed 052 30 52 A 10 073 40 73 A 14 k 086 50 86 A 14 Communication Options 100 60 100 A 14 Code Description 129 75 129 A 14 N None 167 100 167 B 20 Standard for additional selections refer to the 5 207 B 20 PowerFlex Digital DC Drive Technical Data 250 150 250 B 20 publication 20P TD001 330 200 330 B 20 412 250 412 B 20 495 300 495 C 20 667 400 667 20 Cabinet Options Code Type N None PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 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 1 2 CE Conformity 1 13 Mounting Dimensions and Weights 1 3 Power Circuit Protection 1 16 Lifting PowerFlex DC Drives 1 5 Control Power Protection 1 16 Removing the Drive Covers 1 7 Cable and Wiring Recommendations 1 17 Line Reactors 1 9 Power Wiring 1 19 Using Contactors 1 9 V O Wiring 1 38 General Grounding Requirements 1 11 Most start up diffic
151. 1 Ramp In Pct Total reference value input to the ramp as a percentage of Par 45 Max Ref Speed Notes This parameter can be assigned to an analog output The min and max values of this parameter were changed from 100 0 to 200 0 with firmware version 3 001 Ramp Out Output of the ramp in rpm Notes This parameter can be assigned to an analog output The min and max values of this parameter were changed from 32766 to 8192 with firmware version 3 001 Ramp Out Pct Output of the ramp as a percentage of Par 45 Max Ref Speed Note The min and max values of this parameter were changed from 100 0 to 200 0 with firmware version 3 001 1 The value of Max Ref Speed cannot exceed 6000 rpm Default Min Max Units Default Min Max Units Read Only 4130 0 Read Only 1 3 x Par 45 Max Ref Speed rpm The value of Max Ref Speed cannot exceed 6000 rpm Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Read Only 130 0 Read Only 8192 rpm Read Only 200 0 Read Only 8192 rpm Read Only 200 0 3 11 Related 4 45 45 45 45 45 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 12 Programming and Parameters File Group 117 11
152. 1 Sel 3 67 Anlg In1 Target 3 68 Anlg In1 Tune 3 68 Anlg In2 Config 3 67 Anlg In2 Offset 3 68 Anlg In2 Scale 3 67 Anlg In2 Sel 3 67 Anlg In2 Target 3 68 Anlg In2 Tune 3 68 Anlg In3 Config 3 67 Anlg In3 Offset 3 68 Anlg In3 Scale 3 67 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 Anlg In3 Sel 3 67 Anlg In3 Target 3 68 Anlg In3 Tune 3 68 Anlg Out1 Scale 3 69 Anlg Out1 Sel 3 69 Anlg Out2 Scale 3 69 Anlg Out2 Sel 3 69 Anlg Out3 Scale 3 69 Anlg Out3 Sel 3 69 Anlg Out4 Scale 3 69 Anlg Out4 Sel 3 69 Anlg Tach Gain 3 21 Anlg1 Tune Scale 3 67 Anlg2 Tune Scale 3 67 Anlg3 Tune Scale 3 67 Arm Current 3 13 Arm Current Pct 3 13 Arm Inductance 3 22 Arm Resistance 3 22 Arm Test Angle 3 25 Arm Volt Ki 3 31 Arm Volt Ki Base 3 31 Arm Volt Kp 3 31 Arm Volt Kp Base 3 31 At Speed 3 53 At Speed Delay 3 28 At Speed Error 3 28 At Zero Speed 3 53 Autotune Cur Lim 3 23 Aux Inp Fit Cfg 3 58 Base Omega 3 45 Clear Fault Que 3 56 Close Loop Comp 3 48 Closed Loop En 3 49 Closing Speed 3 35 Constant J Comp 3 46 ContactorControl 3 72 Cur Lim Neg Out 3 13 Cur Lim Pos Out 3 13 Current Lim Neg 3 19 Current Lim Pos 3 19 Current Limit 3 19 Current Reg In 3 13 CurrLimit Active 3 51 CurrReg Autotune 3 22 Dancer Constant 3 44 Data In A1 3 65 Data In A2 3 65 Data In Ax 3 65 Data In B1 3 65 Data In B2 3 65 Data In C1 3 65 Data In C2 3 65 Data In D1 3 65 Data In D2 3 65 Data In SelData 3 65 Dat
153. 10 Datalinks 3 65 Anlg Int Cmp Diy 1044 Analog Inputs 3 68 Data In A2 611 Datalinks 3 65 Anlg Int Cmp Eq 1045 Analog Inputs 3 68 Data In B1 612 Datalinks 3 65 Anlg Int Cmp Err 1043 1 Analog Inputs 3 68 Data n B2 613 Datalinks 3 65 Anlg Int Config 71 Analog Inputs 3 67 Data In C1 614 Datalinks 3 65 Int Offse 74 Analog Inputs 3 68 Data In C2 615 Datalinks 3 65 Anlg In1 Scale 72 Analog Inputs 3 67 Data In D1 616 Datalinks 3 65 Anlg In1 Sel 70 Analog Inputs 3 67 Data In D2 617 Datalinks 3 65 Anlg Int Targe 295 Analog Inputs 3 68 Data In SelData 1320 Datalinks 3 65 Anlg Int Tune 259 Analog Inputs 3 68 Data In Val Sel 1319 Datalinks 3 65 Anlg In2 Config 76 Analog Inputs 3 67 Data Out A1 618 Datalinks 3 65 Anlg 112 Offse 79 Analog Inputs 3 68 Data Out A2 619 Datalinks 3 65 Anlg In2 Scale 77 Analog Inputs 3 67 Data Out B1 620 Datalinks 3 65 Anlg In2 Sel 75 Analog Inputs 3 67 Data Out B2 621 Datalinks 3 65 Anlg In2 Targe 296 Analog Inputs 3 68 Data Out C1 622 Datalinks 3 65 Anlg In2 Tune 260 Analog Inputs 3 68 Data Out C2 623 Datalinks 3 65 Anlg In3 Config 81 Analog Inputs 3 67 Data Out D1 624 Datalinks 3 65 113 Offse 84 Analog Inputs 3 68 Data Out D2 625 Datalinks 3 65 Anlg In3 Scale 82 Analog Inputs 3 67 Decel Mask 631 Masks amp Owners 3 64 Anlg In3 Sel 80 Analog Inputs 3 67 Decel Owner 609 Masks amp Owners 3 64 Anlg In3 Targe 297 Analog Inputs 3 68 Decel Status 1189 1 Diagnostics 3 55 Anlg In3 Tune 261 Analog Inputs 3
154. 1E EN P June 2009 Related e a o E Qa Group Digital Outputs Parameter Name amp Description See page 3 2 for symbol descriptions Values No Programming and Parameters 581 Dig Out Status Read Only Status of the standard digital outputs and relay outputs on the drive and on the optional I O Expansion circuit board if present a r g Iz g g J LISE 6 S S 8 S 8 8 9 S 8 je le le 8 ee 129 9 8988 E S S S S S S S 5 5 l s e lo 10 gt gt gt j dc c 6 lo nala Default O x x x x x x 00000 0 0 0 Bit 15 14 13 12 11 10 9 8 7 6 5 4 B 2 1 0 629 Relay Out 2 Sel Default 5 Ready 0 Selects the source of the value that drives the N O relay between the terminals 75 and 76 Refer to Option Definitions on page 3 74 Options 0 Not Used 8 Spd Limited 16 Encoder Err 24 ContactDB 1 Zero Thr 9 Fault 17 Diam Calc 25 Contactor 2 Spd Thresh 10 Power Loss 18 Input 26 Alarm 3 At Speed 11 UserDefinedA 19 Diam Reached 127 Running 4 CurrentLimit 12 UserDefinedB 20 Speed Match 28 Jogging 5 Ready
155. 3 18 in See Note 6 1 2 5 Or Greater Local Codes 76 229 mm 76 229 mm 76 457 mm 2 AC Power Less 460V 3 ph AC Lines 3 9 in 0 3 6 in 3 12in See Note 6 1 2 5 Than 600V 76 229 mm 76 152 mm 76 305 mm 3 DC Power DC Motor Armature 4 DC Power DC Motor Field Control 5 115V AC DC Relay Logic PLC 1 0 3 9 in 3 6 in 0 3 9 in See Note 6 1 2 5 Logic Motor Thermostat 76 229 mm 76 152 mm 76 229 mm 115V AC Power Power Supplies Instruments 6 24V AC DC Logic PLC HO Signal 7 Analog Signals Reference _ ShieldedCable 3 18 in 3 12 in 3 9 in 0 1 8 in 2 3 4 5 Process DC Supplies Feedback Signal 5 Belden 8736 76 457 mm 76 305 mm 76 229 mm 25 76 mm Digital Low TTL Speed 8 Digital High 1 0 Encoder Count Shielded Cable Speed Pulse Tach Belden 9728 Signal 9 Serial RS 232 Shielded Cable See Note 6 1 3 in 0 Comm Communication 20 422 Belden To Terminals RS 232 25 76 mm printers 8735 8737 RS 422 9729 9730 11 Serial PLC Remote I O Twinaxial Communication PLC Data Highway Cable Greater Than Belden 9463 20k Baud A B 1770 CD Example Spacing relationship between 480V AC incoming power leads and 24V DC logic leads 480V AC leads are Class 2 24V DC leads are Class 6 For separate steel conduits the conduits must be 3 inches 76 mm apart e Ina cable tray the two groups of leads are to be 6 inches 152 mm apart Minimum Spacing B
156. 3 23 Torque Reduction 342 1 Torque Attribute 3 19 Spd Up Gain Pct 445 Speed Regulator 30 Torque Ref 39 Torque Attribute 19 Spd Zero En 123 Speed Regulator 3 29 Torque Winder En 1209 Winder Functions 3 48 Spd Zero P En 125 Speed Regulator 3 29 Trim Ramp 42 Speed Reference 3 27 SpdFuncSelect 1016 Speed Regulator 3 31 Trim Ramp Pct 378 Speed Reference 27 SpdOut FiltBW 239 Speed Regulator 3 30 Trim Speed 43 Speed Reference 327 SpdOut FiltGain 238 Speed Regulator 3 29 Trim Speed Pct 379 Speed Reference 3 27 SpdReg FB Bypass 458 Speed Feedback 3 21 Trim Torque 40 orque Attribute 19 SpdReg Ki Bypass 460 Speed Regulator 3 31 TrqTpr Enable 750 orque Attribute 3 20 SpdReg Kp Bypass 459 Speed Regulator 3 31 TrqTpr_LimO 751 orque Attribute 3 20 SpdTune Friction 1031 1 Autotune 3 2 TrqTpr_Lim1 752 orque Attribute 3 20 Speed Demand En 1215 1 Winder Functions 3 49 TrqTpr_Lim2 753 orque Attribute 3 20 Speed Draw Out 1018 Speed Meters 3 12 TrqTpr_Lim3 754 orque Attribute 3 20 Speed Match 1195 1 Winder Functions 48 TrqTpr_Limd 755 orque Attribute 3 20 Speed Ramp En 245 Ramp Rates 3 33 TrqTpr_Spd 756 orque Attribute 3 20 Speed Ratio 1017 Speed References 3 27 TstGen Amplitude 60 est Generator 3 24 Speed Ref A 44 Speed Meters 3 11 TstGen Frequency 59 est Generator 24 Speed Ref A Pct 47 Speed Meters 3 11 TstGen Offset 61 Test Generator 3 24 Speed Ref B 48 Speed Meters 3 11 TstGen Output 58 Test Generator 3 24 Speed Ref B Pct 49 Speed Meters 3 11 U
157. 3 39 Related 780 781 695 731 769 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 40 Programming and Parameters Group File No 421 766 767 768 770 PD Control 788 789 790 APPLICATIONS 791 418 731 PID Control 734 Parameter Name amp Description See page 3 2 for symbol descriptions PD Output PID Proportional Derivative PD block output PD Deriv Gain 1 First derivative gain of the PD block The value specified in this field depends on the enabling and configuration of Par 181 Adaptive Spd En PD Deriv Filter Time constant of the filter from the derivative portion of the PD block PD Prop Gain 1 First proportional gain of the block PD The value specified in this field depends on the enabling and configuration of Par 181 Adaptive Spd En Enable PD Enables disables the PD portion of the PID regulator Note This parameter can be assigned to a digital input PD Prop Gain 2 Second proportional gain of the block PD The value specified in this field depends on the enabling and configuration of Par 181 Adaptive Spd En PD Deriv Gain 2 Second derivative gain of the PD block The value specified in this field depends on the enabling and configuration of Par 181 Adaptive Spd En PD Prop Gain 3 Third proportional gain of the block PD The value specified in this field depends on the enabli
158. 360 Fault 10 Code Faults 3 57 1361 Fault 1 Time Faults 3 57 1362 1 Fault 2 Time Faults 3 57 1363 1 Fault 3 Time Faults 3 57 1364 1 Fault 4 Time Faults 3 57 1365 1 Fault 5 Time Faults 3 57 1366 1 Fault 6 Time Faults 3 57 1367 Fault 7 Time Faults 3 57 1368 1 Fault 8 Time Faults 3 57 1369 1 Fault 9 Time Faults 3 57 1370 Fault 10 Time Faults 3 57 1371 Fault Arm Amps Faults 3 57 1372 Fault Speed Diagnostics 3 57 1373 1 Fault Field Amps Diagnostics 3 57 1374 1 Fault Voltage Diagnostics 3 57 1375 MOP Select Reference Config 3 50 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 3 88 Programming and Parameters Notes PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Faults and Alarms Chapter 4 Troubleshooting This chapter provides information to guide you in troubleshooting the PovverFlex DC drive Included is a listing and description of drive faults with possible solutions when applicable and alarms See For information on page Faults and Alarms 4 1 Drive Status 4 2 Manually Clearing Faults 4 3 Fault Descriptions 4 4 Clearing Alarms 4 9 Alarm Descriptions 4 9 Common Drive Symptoms and Corrective Actions 4 11 Testpoint Codes and Functions 4 15 A fault is a condition that always stops the drive and prevents it from starting until the fault condition is corrected There a
159. 3R100 A 18 5 22 25 30 100 C85D10 20P 41AB110 110 90 30 1321 3R100 A 18 5 22 25 30 100 D110D11 20P 41AB146 146 119 40 1321 3R160 A 30 37 40 50 100 D140D11 20P 41AB180 180 147 50 1321 3R160 A 30 37 40 50 100 D180D11 20P 41AB218 1218 178 60 1321 3RB250 A 45 56 60 75 100 D180D11 20P 41AB265 265 217 75 1321 3RB250 A 45 56 60 75 100 D250ED11 20P 41AB360 360 294 100 1321 3RB320 A 75 100 100 D300ED1 1 20P 41AB434 434 355 125 1321 3RB400 A 93 125 100 D420ED11 20P 41AB521 521 426 150 1321 3R500 A 112 150 100 D630ED11 Table A N 230V AC Input Non Regenerative Drives AC Line IP00 Open Style Drive Cat No DC Amps Amps HP Line Reactor Cat No Line Reactor kW HP AC Input Contactor Cat No 20P 21AB7PO 17 5 7 1 5 1321 3R8 A 75 1 100 C12D10 20 21 9 9 74 2 1321 3R12 A 1 49 2 100 C12D10 20P 21AB012 112 9 8 3 1321 3R18 A 0 75 3 7 1 5 100 C12D10 20P 21AB020 20 16 5 1321 3R18 A 0 75 3 7 1 5 100 C23D10 20P 21AB029 29 24 7 5 1321 3R55 A 5 5 11 7 5 15 100 C30D10 20P 21AB038 138 31 10 1321 3R55 A 5 5 11 7 5 15 100 C37D10 20P 21AB055 55 45 15 1321 3R55 A 5 5 11 7 5 15 100 C60D10 20P 21AB073 173 60 20 1321 3R80 A 15 20 100 C60D10 20P 21AB093 93 76 25 1321 3R100 A 18 5 22 25 30 100 C85D10 20P 21AB110 1110 90 30 1321 3R100 A 18 5 22 25 30 100 D110D11 20P 21AB146 1146 119 40 1321 3R160 A 30 37 40 50 100 D140D11 20P 21AB180 1180 147 50 1321 3R160 A 30 37 40 50 100 D180D11 20P 21AB218 1218 178 60 1321 3RB250 A 45
160. 4 N OH 2 2 D Q Az D A2 DOC Ore DOC O F2 PowerFlex DC Motor PowerFlex DC Motor Straight Shunt Machine Straight Shunt Machine CCW Rotation Facing Commutator End CW Rotation Facing Commutator End 9 Apply power to the drive 10 Repeat steps 4 and 5 above and verify that the motor rotation is correct PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Drive Start Up 2 13 11 Complete the appropriate procedure based on the type of feedback device used for the application m m For Armature Voltage feedback Continue with 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 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
161. 41 Inversion In 10 1388 Dig In Term 11 575 Digital In10 Sel 142 Inversion In 11 1389 Dig In Term 12 576 Digital In11 Sel 143 Inversion In 12 1390 Digital Outputs Dig Out Status 581 Digital Out7 Sel 151 Inversion Out 4 1270 Digital Out1 Sel 145 Digital Out8 Sel 152 Inversion Out 5 1271 Digital Out2 Sel 146 Relay Out 1 Sel 1392 Inversion Out 6 1272 Digital Out3 Sel 147 Relay Out 2 Sel 629 Inversion Out 7 1273 Digital Out4 Sel 148 Inversion Out 1 1267 Inversion Out 8 1274 Digital Out5 Sel 149 Inversion Out 2 1268 Inversion Relay1 1393 Digital Out6 Sel 150 Inversion Out 3 1269 Inversion Relay2 1275 DPI Inputs DPI P1 Select 1323 DPI P3 Select 1325 DPI P5 Select 1327 DPI P2 Select 1324 DPI P4 Select 1326 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Monitor File File MONITOR Group Speed Meters No 44 47 48 49 110 111 113 114 Parameter Name amp Description See page 3 2 for symbol descriptions Speed Ref A Displays the first speed reference of the drive in rpm This parameter can be sourced from many signals and is the factory default selection for Par 70 Anlg In1 Sel See block diagram Speed Reference Selection on page D 5 for possible source signals Note The maximum value of this parameter was changed from Par 45 to 1 3 x Par 45 with firmware version 3 001 Spe
162. 414 Fdbk Device Type Armature Par 469 Field Mode Sel Field Weaken or External and Par 478 Spd Loss Fit Cfg Alarm e Par 469 Field Mode Sel Field Weaken or Base Speed and Par 497 Field Reg En Disabled e Par 469 Field Mode Sel Base Speed and Par 498 Force Min Field Enabled e Par 469 Field Mode Sel Base Speed and Par 133 144 Digital Inx Sel Force Min Fld The field current is too low Refer to the Fld Current Loss fault description on page 4 5 for more information The selected motor overload current level has been exceeded Refer to the Motor Overload fault description on page 4 5 for more information The motor has exceeded its temperature rating as signaled by the thermistor connected to the drive terminals 78 and 79 Refer to the Motor Over Temp fault description on page 4 6 for more information Par 1344 Start At Powerup is enabled The drive may start at any time after drive power up and the time specified in Par 1345 Powerup Delay has elapsed Common Drive Symptoms and Corrective Actions Drive will not start Drive Symptom An external Start command was issued but the drive does not start Troubleshooting 4 11 Action Verify that no faults or alarms are displayed If a fault or alarm is displayed follow the corrective action provided refer to Fault Descriptions on page 4 4 or
163. 42 wiring examples 1 45 Start At Power Up alarm 4 10 Start At Powerup 3 36 start at powerup configure C 35 Start Inhibits 3 56 Start Mask 3 63 Start Owner 3 64 start up drive 2 1 Static F Zero 3 49 Static Friction 3 46 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 status indicators 4 2 Status1 at Fault 3 57 Status at Fault 3 57 Stop Modes group 3 35 3 36 Stop Owner 3 64 storage drive altitude p 1 humidity p 1 temperature p 1 STS LED green flashing 4 2 green steady 4 2 red flashing 4 2 red steady 4 2 yellow flashing 4 2 yellow steady 4 2 STune Overspeed fault 4 7 STune Stalled fault 4 7 STune Timeout fault 4 7 Sustained Curr fault 4 7 T tachometer DIP switch 1 40 ground 1 12 terminal block 1 50 Taper Enable 3 47 TaskLoad 1 ms 3 56 TaskLoad 2 ms 3 56 TaskLoad 32 ms 3 56 TaskLoad 8 ms 3 56 TB Manual Ref 3 27 temperature drive 1 2 Tension Reduct 3 47 Tension Ref 3 47 Tension Scale 3 47 tension set point signal configure C 17 terminal blocks analog tachometer 1 50 armature converter frame 1 23 armature converter frame B 1 24 armature converter frame C 1 24 armature voltage feedback frame A 1 26 armature voltage feedback frame B 1 27 armature voltage feedback frame C 1 27 control circuit power 1 33 encoder 1 48 field frame A 1 28 field frame B 1 28 field frame C 1 29 I O converter circuit board G 2 I O expansion circuit board F 2 motor thermi
164. 47 1249 Scale6 In Max Scale Blocks 3 43 1184 Line Accel Pct Winder Functions 3 47 1250 Scale6 In Min Scale Blocks 3 43 1185 Line Decel Pct Winder Functions 3 47 1251 Scale6 In Off Scale Blocks 3 44 1186 Line FastStp Pct Winder Functions 3 47 1252 Scale6 Out Off Scale Blocks 3 44 1187 Winder Type Winder Functions 3 47 1253 Scale6 In Abs Scale Blocks 3 44 1188 Accel Status Diagnostics 3 55 1254 1 PID Error Gain PID Control 3 43 1189 Decel Status Diagnostics 3 55 1255 Jog TW Speed Winder Functions 3 49 1190 Fast Stop Status Diagnostics 3 55 1256 Jog TW Enable Winder Functions 3 49 1191 1 nertiaCompAct Speed Regulator 3 31 1258 1 Enable PID PID Control 3 43 1192 1 InertiaCompVar Speed Regulator 3 31 1262 1 Closing Speed Stop Modes 3 35 1193 1 Torq Current Pet VVinder Functions 3 47 1263 1 Opening Delay Stop Modes 3 35 1194 Act Ten Ref Pct Winder Functions 3 47 1265 Ramp n Zero En Stop Modes 3 36 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Programming and Parameters 3 87 No Parameter Name Group Page No Parameter Name Group Page 1266 1 Actuator Delay Stop Modes 3 36 1376 Logic Mask Ac
165. 56 60 75 100 D180D11 20P 21AB265 1265 217 75 1321 3RB250 A 45 56 60 75 100 D250ED11 20P 21AB360 1360 294 100 1321 3RB320 A 75 100 100 D300ED11 20P 21AB434 1434 355 125 1321 3RB400 A 93 125 100 D420ED11 20P 21AB521 521 426 150 1321 3R500 A 112 150 100 D630ED11 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Supplemental Drive Information Table A O 460V AC Input Regenerative Drives A 19 AC Line IP00 Open Style Drive Cat No DC Amps 5 HP Line Reactor Cat No Line Reactor kW HP AC Input Contactor Cat No 20P 41AD4P1 4 1 3 3 2 1321 3R4 A 55 75 100 C12D10 20P MAD6PO 6 49 3 1321 3R8 A 75 1 100 C12D10 20P 41AD010 10 8 2 5 1321 3R18 B 1 5 7 5 2 10 100 C12D10 20P 41AD014 14 11 4 7 5 1321 3R18 B 1 5 7 5 2 10 100 C12D10 20P 41AD019 19 15 5 10 1321 3R18 B 1 5 7 5 2 10 100 C23D10 20P 41AD027 27 22 1 15 1321 3R55 B 11 22 15 30 100 C23D10 20P 41AD035 135 28 6 20 1321 3R55 B 11 22 15 30 100 C30D10 20P 41AD045 45 36 8 25 1321 3R55 B 11 22 15 30 100 C37D10 20P 41AD052 52 42 5 30 1321 3R55 B 11 22 15 30 100 C43D10 20P 41AD073 173 59 6 40 1321 3R80 B 30 40 100 C60D10 20P 41AD086 186 70 3 50 1321 3R100 B 37 45 50 60 100 C85D10 20P 41AD100 1100 81 7 60 1321 3R100 B 37 45 50 60 100 C85D10 20P 41AD129 129 105 4 75 1321 3R160 B 56 75
166. 6 Fld Const 40 Pct Stop the drive Set the desired method of field control in Par 469 Field Mode Sel 0 Base Speed or 1 Field Weaken 10 Reset the value of 467 Max Fld Curr Pct to 10096 If you change the value of Par 175 Rated Motor Volt or par 280 Nom Mtr Fld Amps the field current curve will need to be re tuned PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Appendix D Control Block Diagrams For information on See page PowerFlex DC Drive Overview D 2 Digital Inputs Outputs amp Mapping Standard and I O Expansion Card D 3 Analog Inputs Outputs and Mapping D 4 Speed Reference Selection D 5 Speed Reference Generation D 6 Ramp Reference Block D 7 Speed Regulator D 8 Torque Mode Selection D 9 Droop Compensation Inertia Loss Compensation D 10 Speed Feedback D 11 Speed Regulator PI Block D 12 Speed Adaptive and Speed Zero Logic D 13 Current Regulator D 14 Field Current Regulator D 15 Motor Parameters D 16 Speed Threshold Speed Control D 17 PID Control D 18 Scale Blocks D 19 User Defined Variables D 20 Taper Current Limits D 21 Unit Scaling D 22 Test Generator D 23 Speed Reference Selection D 23 Fault Alarm Mapping D 25 Diagram Conventions Examples PXXX ParName PXXX ParName 0 Read Write Parameter Read Only Parameter
167. 60 20 1370 DBL69 1240 2 6 385 92 31 1370 DC110 1370 LG92 20P 41AB093 93 76 25 1370 DBL70 1240 2 330 120 00 1370 DC110 1370 LG92 20P 41AB110 1110 190 30 11370 DBL71 240 2 330 120 00 1370 DC110 1370 LG110 20P 41AB146 146 119 40 1370 DBL72 1240 0 7 280 342 86 1370 DC180 1370 LG160 20P 41AB180 180 1147 50 11370 DBL73 1240 0 5 365 480 00 1370 DC180 1370 LG180 20P 41AB218 1218 1178 60 11370 DBL74 1240 0 5 365 480 00 1370 DC280 1370 LG228 20P 41AB265 265 1217 75 1370 DBL75 1240 2 330 120 00 1370 DC280 1370 LG268 20P 41AB360 360 1294 100 1370 DBL76 1240 1 4 290 17143 7 20P 41AB434 434 1355 1125 240 0 5 1458 651 6 17 20P 41AB521 1521 1426 150 27 240 0 322 6221 781 Si 17 1 Qty 4 CUTLER HAMMER G3AP50 Two in series two in parallel Must be sourced separately from drive 2 HUBBELL_Y139W322GB Must be sourced separately from drive 3 Coil voltage 115V AC 50 60Hz 5 ABB EHDB520C2P 1L ABB Contactor for drives with no Dynamic Brake ABB EHDB520C 1L ABB Contactor for drives with Dynamic Brake Must be sourced separately from drive 9 See DC Contactor Crimp Lug Kit Specifications on page A 22 for more information 7 Wire and Lug size dependant on Cabinet dims and local codes d ABB EHDB360C 1L 22 ABB Contactor for drives with a dynamic brake Must be sourcing separately from drive Table A R 230V AC Input Non Regenerative Drives Dynamic
168. 68 Decel Time 1 662 Ramp Rates 3 34 Anlg Out Scale 62 Analog Outputs 3 69 Decel Time 2 32 Ramp Rates 3 33 Anlg Out Sel 66 Analog Outputs 3 69 Diam Calc Dis 1161 Diameter Calc 3 45 Anlg Out2 Scale 63 Analog Outputs 3 69 Diam Inc Dec En 1205 Diameter Calc 3 46 Anlg Out2 Sel 67 Analog Outputs 3 69 Diam init filter 1206 Diameter Calc 3 46 Anlg Out3 Scale 64 Analog Outputs 3 69 Diam Preset 0 1164 Diameter Calc 3 45 Anlg Out3 Sel 68 Analog Outputs 3 69 Diam Preset 1 1165 Diameter Calc 3 46 Anlg Out4 Scale 65 Analog Outputs 3 69 Diam Preset 2 1166 Diameter Calc 3 46 Anlg Out4 Sel 69 Analog Outputs 3 69 Diam Preset 3 1167 Diameter Calc 3 46 Anlg Tach Gain 562 Speed Feedback 3 21 Diam Preset Sel 1168 Diameter Calc 3 46 Anlg1 Tune Scale 73 Analog Inputs 3 67 Diam stdy delay 1207 Diameter Calc 3 46 Anlg2 Tune Scale 78 Analog Inputs 3 67 Diam Threshold 1158 Diameter Calc 3 45 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 78 Programming and Parameters Name No Group Page Name No Group Page Diameter Calc 794 Diameter Calc 3 44 Enable Droop 699 Load Limits 3 35 Diameter Cal
169. 70 DC56 1370 1640 20P 21AD027 27 1221 115 11370 DBH68 500 12 405 41 67 1370 DC56 11370 LG40 20P 21AD035 35 128 6 120 11370 DBH69 500 5 330 100 00 1370 DC56 1370 1640 20P 21AD045 45 136 8 125 11370 DBH70 500 45 330 111 11 1370 DC56 11370 LG52 20P 21AD052 52 142 5 130 1370 DBH71 500 8 5 385 142 86 1370 DC56 11370 LG52 20P 21AD073 73 159 6 140 1370 DBH72 500 2 5 345 192 31 1370 DC110 11370 LG92 20P 21AD086 86 170 3 150 11370 DBH73 500 2 345 250 00 1370 DC110 11370 LG92 20P 21AD100 100 81 7 160 11370 DBH74 500 2 345 250 00 1370 110 11370 LG110 20P 21AD129 1129 1105 4 75 11370 DBH75 500 1 270 500 00 1370 DC180 1370 LG140 20P 21AD167 1167 1136 4 1100 1370 76 500 0 7 280 714 29 1370 DC180 1370 LG180 20P 21AD207 1207 1169 1 1125 1370 77 500 07 280 714 29 1370 DC280 1370 16228 20P 21AD250 1250 1204 3 150 1370 78 500 05 365 1000 00 1370 0 280 1370 LG268 20P 21AD330 1330 1269 6 200 1370 DBH79 500 0 7 280 714 29 6 10 20P 21AD412 412 1336 6 1250 500 0 808 7292 6 10 20P 21AD495 1495 1404 4 300 500 0 595 6069 7 10 20P 21AD667 667 1544 9 1400 500 0 542 6439 8 10 1 HUBBELL Y95W808GB Must be sourced separately from drive HUBBELL Y101W595GB Must be sourced separately from drive 6 HUBBELL Y109W542GB Must be sourced separately from drive 4 Coil voltage 115V AC 50 60Hz 6 ABB EHDB360C 1L 22 ABB Contactor for drives with a dynamic brake Must be sourcing separately from drive
170. 75 75 100 100 D140D11 20P 21AD207 207 169 1 125 1321 3RB250 B 93 112 125 150 100 D180D11 20P 21AD250 250 204 3 150 1321 3RB250 B 93 112 125 150 100 D210ED11 20P 21AD330 1330 269 6 200 1321 3RB320 B 149 200 100 D300ED11 20P 21AD412 412 336 6 250 1321 3RB400 B 186 4 250 100 D420ED11 20P 21AD495 495 404 4 300 1321 3R500 B 223 7 300 100 D420ED11 20P 21AD667 667 544 9 400 1321 3R600 B 298 3 400 100 D630ED11 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 A 20 Supplemental Drive nformation DC Output Contactors and Table A Q 230V AC Input Regenerative Drives Kits Dynamic DB Brake Armature DB Resistor Brake DC Loop DC Contactor DC ACLine Resistor Kit Voltage Resistor Size Amps Contactor Cat ore Lugs Cat Drive Cat No Amps Amps HP Cat No Volts Size ohms Watts Required Nol No 20P 41AB7P0 7 5 7 1 5 11370 08162 240 20 420 12 00 1370 DC56 1370 LG40 20P 41AB9P0 9 74 2 1370 DBL63 1240 20 420 12 00 1370 DC56 1370 LG40 20P 41AB012 12 9 8 3 1370 DBL64 1240 15 420 16 00 1370 DC56 1370 LG40 20P 41AB020 20 16 5 1370 DBL65 1240 8 6 420 27 91 1370 DC56 1370 LG40 20P 41AB029 29 24 7 5 1370 DBL66 1240 6 345 40 00 1370 DC56 1370 LG40 20P 41AB038 38 31 10 1370 167 1240 5 330 48 00 1370 56 1370 LG40 20P 41AB055 55 45 15 1370 168 1240 3 5 385 68 57 1370 DC56 1370 LG56 20P 41AB073 73
171. 8 121 122 384 385 MONITOR Speed Meters 420 924 1018 1019 1408 Parameter Name amp Description See page 3 2 for symbol descriptions Speed Reg In Petl Total reference value input to the Speed Regulator as a percentage of Par 45 Max Ref Speed Notes This parameter can be assigned to an analog output The min and max values of this parameter were changed from 100 0 to 200 0 with firmware version 3 001 Speed Reg In Total reference value input to the Speed Regulator in rpm Notes This parameter can be assigned to an analog output The min and max values of this parameter were changed from 32766 to 8192 with firmware version 3 001 Spd Feedback Pct Actual speed as a percentage of the Par 162 Max Feedback Spd Notes This parameter can be assigned to an analog output and is the factory default selection for Par 66 Anlg Out1 Sel The min and max values of this parameter were changed from 100 0 to 200 0 with firmware version 3 001 Spd Feedback Actual speed in rpm Notes This parameter can be assigned to an analog output The min and max values of this parameter were changed from 32766 to 8192 with firmware version 3 001 Spd Ref Out Pct Output of the Speed Reference selection as a percentage of Par 45 Max Ref Speed Notes This parameter can be assigned to an analog output The min and max values of this parameter were changed from
172. 8 414 455 478 459 460 469 478 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 22 Programming and Parameters a 3 2 9 D 652 911 912 913 x 914 5 z 915 o 8 o d 923 m ke z 8 1021 zl eo 1022 452 453 Autotune 454 Parameter Name amp Description See page 3 2 for symbol descriptions Encoder Err Chk Enables Disables monitoring of the digital encoder connection status When an alarm is detected the HIM displays the Feedback Loss F91 fault This parameter can be programmed on a digital output This function is activated by setting Par 457 Spd Fdbk Control Enabled 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 e Disabled The encoder zero pulse is not read Z Capture Pos En Control register of the zero pulse and of the encoder qualification signal Z Captured Pos Data and function status register Spd FB Filt Gain First order lead lag filter gain on the speed feedback signal Note This parameter was added with firmware version 3 001 Spd FB Filt BW First order lead lag filter bandwidth on the speed feedback signal Note This parameter was added with firmware version 3 001 Act Spd
173. 8 Scale5 Mul 1247 Scale6 Mul Multiplier of the input quantity after a possible limitation Resolution 5 digits Refer to the Scale Blocks block diagram on page D 19 for more information 487 Scalei Div Default 1 00 1221 cales DI Min Max 810000 00 1230 Scale4 Div 1239 Scale5 Div 1248 Scale6 Div Divisor through which it is possible to divide the input quantity already multiplied and limited Resolution 5 digits Refer to the Scale Blocks block diagram on page D 19 for more information 488 Scalei In Max Default 0 00 557 Scale2 In Max 1222 Scale3 In Max Min Max 297427 1 1231 Scale4 In Max 1240 Scale5 In Max 1249 Scale6 In Max Maximum limit of the input quantity Resolution 5 digits Refer to the Scale Blocks block diagram on page D 19 for more information 489 Scale1 In Min Default 0 00 558 Scale2 In Min 1223 Scale3 In Min Min Max 297427 1 1232 Scale4 In Min 1241 Scale5 In Min 1250 Scale6 In Min Minimum limit of the input quantity Resolution 5 digits Refer to the Scale Blocks block diagram on page D 19 for more information PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 3 44 Programming and Parameters 2 g g Parameter Name 8 Description m ip Z See page 3 2 for symbol descriptions Values 490 Scalei In Off Default 0 00 559 Scale2 In Off 1224 Scale3 In Off Min Max 2 g
174. 8 potentiometer 1 45 voltage 1 19 Input Output file 3 67 input current control circuit 1 16 input power circuit protection A 8 fuses A 12 input voltage AC 1 19 install communication adapter E 1 HIM B 6 I O converter circuit board G 1 I O expansion circuit board F 1 Int Acc Calc En 3 47 interference common mode 1 38 Interrupt Error fault 4 5 Inversion In 1 3 72 Inversion In 10 3 72 Inversion In 11 3 72 Inversion In 12 3 72 Inversion In 2 3 72 Inversion In 3 3 72 Inversion In 4 3 72 Inversion In 5 3 72 Inversion In 6 3 72 Inversion In 7 3 72 Inversion In 8 3 72 Inversion In 9 3 72 Inversion Out 1 3 75 Inversion Out 2 3 75 Inversion Out 3 3 75 Inversion Out 4 3 75 Inversion Out 5 3 75 Inversion Out 6 3 75 Inversion Out 7 3 75 Inversion Out 8 3 75 Inversion Relay1 3 76 Inversion Relay2 3 75 Inverting Fault 4 5 Index 9 J Jog Mask 3 63 Jog Off Delay 3 27 Jog Owner 3 64 Jog Ramp Time 3 33 Jog Speed 3 26 Jog TW Enable 3 49 Jog TW Speed 3 49 joystick wiring 1 45 K kits communication adapter E 1 Klixon configure 1 31 L Language 3 51 Last Stop Source 3 56 LED status green flashing 4 2 green steady 4 2 red flashing 4 2 red steady 4 2 yellow flashing 4 2 yellow steady 4 2 LEDs 4 2 MOD 4 2 NET A 4 2 NET B 4 2 PORT 4 2 STS 4 2 lifting drives 1 5 Limits group 3 26 Line Accel Pct 3 47 Line Decel Pct 3 47 Line FastStp Pct 3 47 line reactor A 18 configuration 1 9 using 1 9 Line Spd G
175. 8 Application Notes Speed Draw Function The Speed Draw function can be used to apply a configurable speed ratio set in Par 1017 Speed Ratio to the main speed reference of the drive This function is useful in a multi drive system where a proportional speed increase between the motors is required The range of parameter 1017 Speed Ratio can be set between 0 and 32767 if written in digital form or can be set from to 20000 to 10V if assigned via an analog input The resulting speed value can be viewed in Par 1018 Speed Draw Out via an analog output Figure C 5 Speed Draw Example Master 1000 RPM 1050 RPM 1100 RPM Drive A Drive B Drive C Anlg Input Anlg Input Anlg Input 1 1 2 1 2 Line Speed ratio 1 5 T Speed Ratio 5 25V 10500 count Line Speed ratio 2 10 1 Speed Ratio 5 5V 11000 count Line Speed Speed Draw Example Configuration Drive A e Set parameter 70 Anlg Inl Sel to 4 Trim Speed Drive B e Set parameter 70 Anlg Inl Sel to 4 Trim Speed e Set parameter 75 Anlg In2 Sel to 22 Speed Ratio e Set parameter 1017 Speed Ratio to 10500 Drive C e Set parameter 70 Anlg Inl Sel to 4 Trim Speed e Set parameter 75 Anlg In2 Sel to 22 Speed Ratio e Set parameter 1017 Speed Ratio to 11000 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Speed Torque Mode Selection Application Notes C 29 Paramet
176. 87 Winder Functions 3 49 UsrDefBitWrdA10 530 User Defined 3 61 Static Friction 1174 Winder Functions 3 46 UsrDefBitWrdA11 531 User Defined 3 61 Status1 at Fault 1349 1 Faults 3 57 UsrDefBitWrdA12 532 User Defined 3 61 Status at Fault 1350 1 Faults 3 57 UsrDefBitWrdA13 533 User Defined 3 61 Stop Owner 600 Masks amp Owners 3 64 UsrDefBitWrdA14 534 User Defined 3 61 achometer Speed 1408 Speed Meters 3 12 UsrDefBitWrdA15 535 User Defined 3 61 aper Enable 1176 Winder Functions 3 47 UsrDefBitWrdA2 522 User Defined 3 61 askLoad 1 ms 1384 Diagnostics 3 56 UsrDefBitWrdA3 523 User Defined 3 61 askLoad 2 ms 1385 1 Diagnostics 3 56 UsrDefBitWrdA4 524 User Defined 3 61 askLoad 32 ms 1383 Diagnostics 3 56 UsrDefBitWrdA5 525 User Defined 3 61 askLoad 8 ms 1386 1 Diagnostics 3 56 UsrDefBitWrdA6 526 User Defined 3 61 B Manual Ref 267 Discrete Speeds 3 27 UsrDefBitWrdA7 527 User Defined 3 61 ension Reduct 1179 Winder Functions 3 47 UsrDefBitWrdA8 528 User Defined 3 61 ension Ref 1180 Winder Functions 3 47 UsrDefBitWrdA9 529 User Defined 3 61 ension Scale 1181 Winder Functions 3 47 UsrDefBitWrdB 536 User Defined 3 61 estPoint Data 1382 Diagnostics 3 56 UsrDefBitWrdBO 537 User Defined 3 62 estPoint Sel 1381 Diagnostics 3 56 UsrDefBitWrdB1 538 User Defined 3 62 hreshold Delay 103 Speed Regulator 3 28 UsrDefBitWrdB10 547 User Defined 3 62 ime AccDec Min 1182 Winder Functions 3 47 UsrDefBitWrdB1 1 548 User Defined 3 62 orq Cur Filter 926 Torque Attrib
177. 999 99 kW Related Motor Control File r File MOTOR CONTROL Group Motor Data 162 175 179 n2 Ol 6 280 Parameter Name amp Description See page 3 2 for symbol descriptions Max Ref Speed Highest speed reference that can be commanded The value of this parameter also scales external speed reference values rpm to internal units counts including analog inputs 10V Par 45 rpm Notes If a speed feedback device is used encoder or tachometer refer to Drive Reference and Feedback Scaling on page C 7 for instructions The maximum value was changed from 16383 to 6000 with firmware version 3 001 Max Feedback Spd Specifies the scaling between internal counts and external speed feedback values Typically this parameter is set to the same value as Parameter 45 Max Ref Speed If an analog DC tachometer is used this parameter s value must be set to be compatible with the S4 switches on the control board see DIP Switch and Jumper Settings on page 1 38 If armature voltage feedback is used this parameter must be set to the motor nameplate base speed Par 585 Overspeed Val should be set 10 higher than the value entered into Par 162 Notes If a speed feedback device is used encoder or tachometer refer to Drive Reference and Feedback Scaling on page C 7 for instructions The maximum value was changed from 16383 to 6000 with firmware version 3 0
178. A digital input Pars 133 144 configured as 64 Invert Fit has been asserted One of the following has occurred e The Main and or Dynamic Brake DB contactor failed to open or close in the proper amount of time A digital input and or relay output 1 is incorrectly wired and or configured e Wiring to a digital input configured for contactor has opened The selected motor overload current level has been exceeded The limits are based on the value of Par 376 MtrOvrld Type 0 StandardDuty is 150 for 60 sec or 200 for 3 sec 1 HeavyDuly is 200 for 1 minute Clean the heatsink Report this error to the manufacturer Check the status of the inverting fault device connected to the digital input e Check all contactor wiring and drive jumpers Repair or replace the contactor s if the problem s persist e Check the digital input and or relay output 1 terminals 35 and 36 wiring and configuration using Pars 1391 ContactorControl 1392 Relay Out 1 Sel and Digital Inx Sel Refer to Using Contactors on page 1 9 for more information Reduce the motor load current limits and or ramp times Note Configurable with Par 479 MtrOvrld Fit Cfg PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 4 6 Troubleshooting Fault No Type Description Possible Cause s Action s Motor Over Temp 16 o The motor has exceeded its
179. A1 UsrDefBitWrdA2 UsrDefBitWrdA3 UsrDefBitWrdA4 UsrDefBitWrdA5 UsrDefBitWrdA6 UsrDefBitWrdA7 UsrDefBitWrdA8 UsrDefBitWrdA9 UsrDefBitWrdA 10 UsrDefBitWrdA1 1 UsrDefBitWrdA12 UsrDefBitWrdA13 UsrDefBitWrdA14 UsrDefBitWrdA15 UsrDefBitWrdA 2 32 64 1024 4096 5218 Note This parameter can be assigned to a digital input or output The bit number corresponds to the digital input output number for example digital input 3 uses UsrDefBitWrdA3 Relay Outputs 1 and 2 use bits 14 and 15 respectively 2 b 1 D 5 32 Po no b o A 20 1024 212 4096 CO OO CD xD OO Dn OO OO OO o PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 File 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 Parameter Name amp Description See page 3 2 for symbol descriptions UsrDefBitWrdA0 UsrDefBitWrdA1 UsrDefBitWrdA2 UsrDefBitWrdA3 UsrDefBitWrdA4 UsrDefBitWrdA5 UsrDefBitWrdA6 UsrDefBitWrdA7 UsrDefBitWrdA8 UsrDefBitWrdA9 UsrDefBitWrdA10 UsrDefBitWrdA11 UsrDefBitWrdA12 UsrDefBitWrdA13 UsrDefBitWrdA14 UsrDefBitWrdA15 Bit variables The individual User Defined bits can be read or written to Itis possible to process a word with Par 519 UsrDefBitWrdA see example Note You can read bits 0 7 of a digital input with Par 519 UsrDefBitWrdA
180. A5 59 Taper Enable 9 RunFud Level 26 Accel 2 43 UsrDefinedA6 60 Spd DemandEn 10 RunRev Level 27 Decel 2 44 UsrDefinedA7 61 Winder Side 112 Jog 28 MOP Inc 45 Droop Enable 62 PI PD Enable 12 Jog Forward 29 MOP Dec 46 PD Enable 63 Jog TW En 13 Jog Reverse 2 130 Fast Stop 47 PID SetptSel 64 Invert Fit 14 Aux Fault 31 Contactor 48 PI Cent vs0 15 Clear Faults 32 MOP Reset 49 PI Cent vs1 16 Auto Manual 33 TorqueReduce 50 Diam Calc 1 A digital input 1 8 only must be configured for Enable 2 For digital inputs 9 12 this option displays as Reserved indicating that it is not available for use do not select Reserved options A PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 ATTENTION Enabling forcing the minimum field current while the drive is running could result in excessive motor speed equipment damage and or bodily injury o Related Programming and Parameters 3 71 Related Parameter Name amp Description D See page 3 2 for symbol descriptions Values Option Definitions for Digital Inx Sel Note When assigning digital inputs to certain options that are associated with parameters those parameter values may be
181. Alarm Descriptions on page 4 9 e The external wiring to the programmed Start terminal block connection is missing Verify that 24V DC is present at terminal block connection e Verify that 24V Supply Common is connected between terminals 18 and 16 e Verify that the configuration for Pars 133 144 Digital Inx Sel matches the switch wiring The drive is not in a Ready state is not Enabled or a Stop is asserted Check the Enable and Stop inputs Verify that the wiring is correct refer to UO Wiring Examples on page 1 45 External AC Input or DC Output contactor if used has not closed If using an AC Input contactor Verify that the drive is Ready then verify that the required coil voltage is present at terminals 35 and 36 Relay Output 1 If the coil voltage is present at terminals 35 or 36 then verify that proper voltage is at the AC Input contactor coil e nspect the contactor for mechanical problems Verify that Par 1391 ContactorControl is set properly e Verify that the contactor and or auxiliary contact is properly wired to a digital input on the drive and that the appropriate digital input selection parameter 133 144 Digital Inx Sel is set to 31 Contactor e Verify that parameter 1392 Relay Out 1 Sel is set to 25 Contactor If using an external DC Output contactor Verify that the drive is Ready then verify that the required coil voltage is present a
182. Autotune Cur Lim 1048 Auto Tune 3 2 Adaptive Gain2 191 Adaptv Regulator 3 37 Aux Inp Fit Cig 354 Alarms 3 58 Adaptive Gain3 193 Adaptv Regulator 3 37 Base Omega 1163 Diameter Calc 3 45 Adaptive Joint 1 186 Adaptv Regulator 3 36 Clear Fault Que 263 Faults 3 56 Adaptive Joint 2 187 1 Adaptv Regulator 3 37 Close Loop Comp 1208 Winder Functions 3 48 Adaptive P Gain1 188 1 Adaptv Regulator 3 37 Closed Loop En 1214 1 Winder Functions 3 49 Adaptive P Gain2 190 1 Adaptv Regulator 3 37 Closing Speed 1262 1 Stop Modes 3 35 Adaptive P Gain3 192 1 Adaptv Regulator 3 37 Constant J Comp 1172 Winder Functions 3 46 Adaptive Ref 183 1 Adaptv Regulator 3 36 ContactorControl 1391 Digital Inputs 3 72 Adaptive Reg Typ 182 1 Adaptv Regulator 3 3 Cur Lim Neg Out 11 Current Meters 3 13 Adaptive Spd 1 184 1 Adaptv Regulator 3 36 Cur Lim Pos Out 10 Current Meters 3 13 Adaptive Spd 2 185 1 Adaptv Regulator 3 36 Current Lim Neg 9 Torque Attribute 3 19 Adaptive Spd En 181 Adaptv Regulator 3 3 Current Lim Pos 8 Torque Attribute 3 19 Alpha Test 166 Test Generator 3 25 Current Limit 7 Torque Attribute 3 19 Analog 111 Value 1404 1 Analog nputs 3 69 Current Reg In 41 Current Meters 3 13 Analog In2 Value 1405 1 Analog nputs 69 CurrLimit Active 349 Diagnostics 1 Analog In3 Value 1406 1 Analog nputs 3 69 CurrReg Autotune 452 1 Autotune 3 22 Anlg In 1 Filter 792 Analog Inputs 3 68 Dancer Constant 798 Diameter Calc 3 44 Anlg Int Cmp 1042 1 Analog nputs 3 68 Data In A1 6
183. Block Diagrams D 18 juejsuo jeoueq Vote xew indino Id 4 Id ogey Xog 1295 2624 Jejeureq num 66 d 9je2 1ejeureig v64d qoyenoreo Jup 18 9189 aowe 0084 MANO Qld tlld 4 uouisog jepoou3 edf eoweq xqp3 tlid EA fENU Q 14 84d NO 1 Qd lqeuq 0 4 les eue Id 6424 Za enug Id 2 214 Saal Bau d 8 d uteg Aueg 04 16 4 c ueg ed Ad 6824 ules Aueq ad 99 d 1013 qid 6344 EURE 0014 Gd 06 d z uteg doid qd dure qid 2924 y eqp zi id 9 d 88 d ure 0014 dd 89 d uBis indino aid eld DEL did 28 4 aeos NANO did 6 4 up esu 1d e xoeqpeeJ did 9 d SUL jeoed Ald Ly0ld Did TA JERUSD Id 2 Die SOEN did INNO Id Lid qur Jovo11d S8 d A m NO UE Ben x Le 6e L 1189 504 a fe URSS id t SE ufig pw peoJ 19 4 69 d ured Ie 1uodjes did 0140095 did indino id C Wel i Ld yaza EN id 44 1884 gird 4 u9
184. Central v sel as the initial output of the PID regulator s integral component corresponding to initial diameter 3 The value entered in this parameter must be less than the value set in Par 784 PI Upper Limit and greater than the value set in Par 785 PI Lower Limit Note This parameter can be assigned to an analog input PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Values Default Min Max Default Min Max Default Min Max Default Options Default Min Max Default Min Max Default Min Max Default Min Max 0 0 10000 10 00 0 00 100 00 10 00 0 00 100 00 Disabled 0 0 Disabled 1 Enabled Read Only 0 10000 0 00 Par 785 PI Lower Limit Par 784 PI Upper Limit 0 00 Par 785 PI Lower Limit Par 784 PI Upper Limit 0 00 Par 785 PI Lower Limit Par 784 PI Upper Limit amp Related 7 784 785 779 784 785 779 784 785 779 784 785 779 File APPLICATIONS Group PI Control No 779 780 781 783 784 785 793 Parameter Name amp Description See page 3 2 for symbol descriptions PI Central v sel Selects one of the four possible initial output values of the PID regulator integral component corresponding to the initial diameter of the PI block e 0 When the PI block is disabled Par 769 Enable PI Disabled
185. Curr Set Par 660 Accel Time 1 0 sec Set Par 662 Decel Time 1 0 sec Set Par 87 Spd Reg Kp 0 00 88 Spd Reg Ki 0 00 Start the drive Increase the value of Par 87 Spd Reg Kp until the overshoot is lower than 4 with the shortest possible acceleration or deceleration time Increase the value of Par 88 Spd Reg Ki until the overshoot is higher than 4 Then decrease the value of this parameter until its value becomes slightly lower than 4 Stop the drive Set Par 58 TstGen Output 0 NotConnected Important When the Bypass function is enabled Par 458 SpdReg FB Bypass 1 Enabled the drive is automatically switched to armature feedback when a Speed fbk loss fault occurs due to an encoder or tachometer feedback loss In this case you must repeat steps 1 9 of the Fine Tuning the Speed Regulator procedure when the fault has been cleared 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 When it is necessary to have different gains for the speed regulator above the speed range you can utilize the adaptive speed regulator For further information about this function refer to the Adaptive Speed Regulator block diagram page C 22 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 C 42 Applicati
186. DB DB AC Brake Armature Resistor Resistor Brake DC Loop DC Contactor Drive Cat DC Line Resistor Kit Voltage Size Size Amps Contactor Cat Crimp Lugs Cat No Amps Amps HP Cat No Volts ohms Watts Required No No 6 20P 21AB7P0 7 5 7 1 5 1370 DBL62 240 20 420 12 00 1370 DC56 1370 LG40 20P 21AB9P0 9 74 2 1370 DBL63 240 20 420 12 00 1370 DC56 1370 LG40 20P 21AB012 12 9 8 3 1370 DBL64 240 15 420 16 00 1370 DC56 1370 LG40 20P 21AB020 20 16 5 1370 DBL65 240 8 6 420 27 91 1370 DC56 1370 LG40 20P 21AB029 29 24 7 5 1370 DBL66 1240 6 345 40 00 1370 DC56 1370 LG40 20P 21AB038 38 31 10 1370 DBL67 240 5 330 48 00 1370 DC56 1370 LG40 20P 21AB055 55 45 15 1370 DBL68 240 3 5 385 68 57 1370 DC56 1370 LG56 20P 21AB073 73 60 20 11370 DBL69 1240 2 6 385 92 31 1370 DC110 1370 LG92 20P 21AB093 93 76 25 11370 DBL70 1240 2 330 120 00 1370 DC110 1370 LG92 20P 21AB110 110 190 30 1370 171 1240 2 330 120 00 1370 110 1370 10110 20 21 146 146 119 40 11370 DBL72 1240 0 7 280 342 86 1370 DC180 1370 LG160 20P 21AB180 180 1147 50 1370 DBL73 240 0 5 365 480 00 1370 DC180 1370 LG180 20P 21AB218 218 178 60 1370 174 1240 0 5 365 480 00 1370 DC280 1370 LG228 20P 21AB265 265 1217 75 1370 DBL75 1240 2 330 120 00 1370 DC280 1370 LG268 20P 21AB360 360 1294 100 1370 DBL76 240 1 4 290 171 43 4 7 20P 21AB434 434 355 125 7 240 0 5 1458 6 17 20P 21AB521 521 426 150 240 0 322 6221 b 17 1 Qty 4 CUTLER HAMMER_G3AP50 Two in series two in pa
187. Defined9 512 UsrDefBitWrdA10 530 UsrDefBitWrdB11 548 UserDefined10 513 UsrDefBitWrdA11 531 UsrDefBitWrdB12 549 UserDefined1 1 514 UsrDefBitWrdA12 532 UsrDefBitWrdB13 550 UserDefined12 515 UsrDefBitWrdA13 533 UsrDefBitWrdB14 551 UserDefined13 516 UsrDefBitWrdA14 534 UsrDefBitWrdB15 552 Communications Comm Control DPI Baud Rate 589 DPI Fdbk Select 1321 DPI Port Value 1343 S DPI Port Sel 590 s Masks amp Owners Logic Mask 591 MOP Mask 598 Reference Owner 604 Start Mask 592 Local Mask 599 Accel Owner 605 Jog Mask 593 Decel Mask 631 Fault Clr Owner 606 Direction Mask 594 Stop Owner 600 MOP Owner 607 Reference Mask 595 Start Owner 601 Local Owner 608 Accel Mask 596 Jog Owner 602 Decel Owner 609 Fault Clr Mask 597 Direction Owner 603 Datalinks Data In A1 610 Data In D1 616 Data Out C1 622 Data In A2 611 Data In D2 617 Data Out C1 623 Data In B1 612 Data Out A1 618 Data Out D1 624 Data In B2 613 Data Out A2 619 Data Out D2 625 Data In C1 614 Data Out B1 620 Data In Val Sel 1319 Data In C2 615 Data Out B2 621 Data In SelData 1320 Security Logic Mask 591 Write Mask Act 1377 Port Mask Act 1379 Logic Mask Act 1376 Write Mask Cfg 1378 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 10 Programming and Parameters File Input Output Group Parameters Analog nputs A
188. Diagrams D 10 Pd Jeu XNA ndno uoyesu dulo2 SS07 EILOU 4 Jojejn amp eu p ds oL l0Id due ejuaul oi 198 5 F auo eueu me pu xni4 2974 ueum xny Aq Ip sey uomesueduio erau Paa xni ESCH A L Jeu enbio Je ssed MO ysuog enbio p l0Id 5 4 yndjno 21014 uohesu dul02 5501 21190 1u99194 4000 9694 vom 0014 uonesueduio 0000 lt lt JoyeinBay peeds o lei ssed Mo 19487 0187 JOY 9014 Yo ino Bay pds Io 0000 2694 uonesu dulo2 4000 9624 dwo9 peo7 8694 jndu 10 Bumeg 1e161q uo Bey peeds 80 4 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 D 11 Control Block Diagrams 011400 xqp4 pds jeuueu 2 2574 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 1464 MES H U WO Yuo 113 49poouq L 2694 pds yoeqp Xew oey uexeeM DEL LI 2 Send Had Jepoou3 5 d Buuois
189. Drive Memory group 3 50 3 51 Drive Overload fault 4 4 drive problems drive starts motor does not turn 4 13 drive will not start 4 11 motor does not reach commanded speed 4 14 motor reaches maximum speed immediately 4 15 motor turning wrong direction 4 14 Drive Size 3 14 drive starts motor does not turn 4 13 Drive Status 1 3 52 Drive Status 2 3 53 Drive Type 3 14 Drive Type Sel 3 15 drive will not start 4 11 DriveExplorer 2 3 3 1 DriveTools SP 2 3 3 1 droop compensation C 9 Droop Filter 3 35 Droop Limit 3 35 Droop Percent 3 35 Drv Fld Brdg Cur 3 16 Dsp Error fault 4 4 dynamic brake resistor configure 1 9 recommended A 20 using 1 10 Dynamic Control file 3 32 Dynamic Friction 3 47 E edit parameters 3 1 B 5 EEPROM Error fault 4 4 Elapsed Lifetime 3 14 electrostatic discharge precaution p 3 EMC Directive Installation Requirements 1 14 EN 61800 3 Installation Requirements 1 14 Enable Droop 3 35 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 Index 6 enable input wiring 1 46 Enable PD 3 40 Enable PI 3 38 Enable PID 3 43 enclosure rating 1 2 encoder ground 1 12 terminal block 1 48 wiring 1 49 Encoder Conflict alarm 4 10 Encoder Counts 3 22 Encoder Err Chk 3 22 Encoder Out Sel 3 22 Encoder PPR 3 20 Encoder Speed 3 12 Encoder State 3 54 F factory defaults reset B 4 Fast Stop Status 3 55 Fast Stop Time 3 35 Fault 1 Code 3 57 Fault 1 Time 3 57 Fault
190. EEEERE gp asan EEEEEEEEEE DE inini n ini al 94 de Als o denb o cse mum x S21 ONE O O LE 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Q DR OOOO0000000 0000000000 A BC ENCS A A B B Z Z COM V 1234567 8 910 Il 1213 14 15 161718 1920 00000 O0000000 OOOOO000000 0000000000 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring Table 1 M Control Circuit Board Jumper and DIP Switch Settings 1 39 Jumper ID Switch Function Factory Default Example 90 For factory boot flashing only Leave set to the factory setting Jumper Off Jumper On Firmware boot VN Jumper Off Normal function ZON S1 For factory boot flashing only Leave set to the factory setting Jumper Off VN Jumper On Write firmware boot code SR Jumper Off Boot code on flash is protected S2 Not used Leave set to the factory setting Jumper Off au S3 For factory boot flashing only Leave set to the factory setting Jumper Off Jumper On Reset Jumper Off Normal function e S4 Configures the input voltage of the DC analog tachometer 90V Refer to Table 1 N on page 1 40 for configuration S9 Configures the input signal of Analog Input 1 terminals 1 and 2 On e Off Position 0 20 mA 4 20 mA ILTT oN On Position 0 10V 10V
191. Err Stpt was added to the Dynamic Control file 3 32 Control Config group Added parameter 16 SLAT Dwell Time was added to the Dynamic Control file 13 32 Control Config group PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 soc ii Change Page s Added parameter 241 Spd Trq Mode Sel was added to the Dynamic Control file 3 32 Control Config group Added parameter 302 Language to the Utility file Drive Memory group 3 51 Added new bits 7 13 to parameter 382 Drive Status 21 3 53 Added parameter 1290 MtrOvrld Status to the Utility file Diagnostics group 3 55 Added parameter 479 MtrOvrld Fit Cfg to the Utility file Alarms group 3 58 Updated the definition for parameter 481 UnderVolt Threshl 3 58 Added parameter 585 Overspeed Vall to the Utility file Alarms group 3 59 Renamed bit 11 and added bits 13 and 14 to parameter 1380 Drive Alarm 11 3 59 Changed option 34 to Reserved for Digital Input parameters 3 70 Renamed Fault 91 Encoder Loss to Feedback Loss 4 5 Added Fault 7 Motor Overload 4 5 Added note that Fault 25 Overspeed is now configurable via Par 585 Overspeed 4 6 Vall Added CE and C Tick certifications to the drive specifications A 1 Added Maximum rate of change of input frequency specifications A 3 Updated the ALT Functions to reflect availabilit
192. F2 2 5A fuse leallllilililliliililir TTA 9 11111 na 4 i ir r n Lan lu PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Supplemental Drive Information A 17 Figure A 12 Frame C Switching Power Supply Fuse Location F1 3 15A fuse F2 2 5A fuse Fuses are located on the Switching Power Supply circuit board SVV 2 on the back of the Control EMI shield which holds the Control board PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 A 18 Supplemental Drive nformation AC In put Line Reactors and If a DC Contactor is used an AC Input contactor is not needed AC Input Contactors Table A M 230V AC Input Regenerative Drives AC Line IP00 Open Style Line Reactor Drive Cat No Amps Amps HP Cat No Line Reactor kW HP AC Input Contactor Cat No 20P 41AB7P0 17 5 7 1 5 1321 3R8 A 45 1 100 C12D10 20P MAB9PO 19 74 2 1321 3R12 A 1 49 2 100 C12D10 20P 41AB012 112 9 8 3 1321 3R18 A 0 75 3 7 1 5 100 C12D10 20P 41AB020 120 16 5 1321 3R18 A 0 75 3 7 1 5 100 C23D10 20P 41AB029 129 24 7 5 1321 3R55 A 5 5 11 7 5 15 100 C30D10 20P 41AB038 38 31 10 1321 3R55 A 5 5 11 7 5 15 100 C37D10 20P 41AB055 55 45 15 1321 3R55 A 5 5 11 7 5 15 100 C60D10 20P 41AB073 173 60 20 1321 3R80 A 15 20 100 C60D10 20P 41AB093 93 76 25 1321
193. Filter First order low pass filter time constant for Par 924 Actual Speed 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 Encoder Counts Displays an accumulated pulse count 32 bit integer from the Encoder Each edge is counted so a 1024 PPR device would produce 4096 counts per revolution Movement in either the forward or reverse direction results in an increase in the counter value Note This parameter was added with firmware version 3 001 CurrReg Autotune Setting this parameter to 1 On and pressing Start 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 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 Arm Inductance Motor armature inductance This parameter can be manually changed to a value other than
194. In x parameters 1276 1283 or 1387 1390 to 1 Enabled Using a DC Contactor and an Inverting Fault Device DC Contactor Configuration 1 2 3 4 5 Set parameter 1391 ContactorControl to Contactor default value Set one Relay Out x Sel parameter and one Digital Inx Sel parameter to Contactor default value for parameters 1392 Relay Out 1 Sel and 140 Digital In8 Sel Connect the DC contactor auxiliary status contact to a digital input Set the corresponding Digital Inx Sel parameter 133 144 to 35 Fld Weak En Set the corresponding Inversion In x parameter 1276 1283 or 1387 1390 to 1 Enabled PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 C 12 Application Notes Inverting Fault Device Configuration 1 2 Connect the inverting fault device contact to a digital input Set the corresponding Digital Inx Sel parameter 133 144 to 14 Aux Fault Set the corresponding Inversion In x parameter 1276 1283 or 1387 1390 to 1 Enabled Using a DC Contactor a Dynamic Brake and an Inverting Fault Device DC Contactor and Dynamic Brake Configuration 1 2 Set parameter 1391 ContactorControl to Contactor DB 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 Con
195. Installation and Wiring Input Output Analog Output Bipolar Signal H0V Bipolar based on the signal of the assigned input source for example Analog nput 1 or 0 10V 0 20 mA Unipolar shown AS 21 22 23 24 25 26 27 28 29 30 Required Parameter Connection Example Changes Select Source Value 66 Anlg Out1 Sel Adjust Scaling 62 Anlg Out Scale Enable Input 24V DC internal supply Changes Required Note If the digital input used for Enable is changed from the default setting of digital input 4 the wiring must be changed accordingly 20 2 Wire Control e Disable Digital Input 1 Non Reversing EL 133 Digital In1 Sel Stop Run 2 0 Not Used 24V DC internal supply m Set Digital Input 2 EG 14 134 Digital In2 Sel Important Programming inputs for ET s 5 Run 2 wire control deactivates the HIM Start and Jog buttons 6 7 7 18
196. Intgl Gn will be brought automatically to the values specified in Pars 765 PI Prop Gain PID and 764 PI Integral Gain respectively PI Integral Gain Integral gain of the PI block PI Prop Gain PID Proportional gain of the PI block Enable PI Enables Disables the PI portion of the PID regulator If assigned to a digital input this parameter must be brought at a high logical level 24V PI Output Output value of the PI block adapted to the value between the values defined in Pars 784 PI Upper Limit and 785 PI Lower Limit When the drive is turned on the value of this parameter is acquired automatically based on the value of Par 779 PI Central v sel x 1000 PI Central v1 The first value that can be selected via Par 779 PI Central v sel as the initial output of the PID regulator s integral component corresponding to initial diameter 1 The value entered in this parameter must be less than the value set in Par 784 PI Upper Limit and greater than the value set in Par 785 PI Lower Limit PI Central v2 The second value that can be selected via Par 779 PI Central v sel as the initial output of the PID regulator s integral component corre sponding to initial diameter 2 The value entered in this parameter must be less than the value set in Par 784 PI Upper Limit and great er than the value set in Par 785 PI Lower Limit PI Central v3 The third value that can be selected via Par 779 PI
197. Kp Basel The proportional gain Kp of the field current regulator base value Fld Reg Ki Base Integral gain Kio of the field current regulator in base value 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 This value is the percentage of the maximum application speed when field weakening will begin Motor Base Speed Par 45 Max Ref Speed x 100 If Par 469 Field Mode Sel 0 Base Speed this parameter must be 100 Flux Divide Selects division by flux for Inertia Compensation or Torque Reference Note Added with firmware version v3 001 Flux Filter BW Adjustable low pass filter on the value of Par 500 Flux Ref Pct The filtered result is used by the Torque Reference divide by flux function Note Added with firmware version v3 001 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Values Default Min Max Units Default Options Default Min Max Units Default Min Max Units Default Min Max Default Min Max Default Min Max Units Default Options Default Min Max Units 1 00 0 50 80 00 A StandardDuty StandardDuty HeavyDuty 0 0 1 2 00 0 00 100 00 0 1 00 0 00 100 00 0 3277 00 0 10 32770 00 3277 00 0 10 32770 00 0 100 X Torque Ref Torque
198. Limit 59 The value of Par 1048 Autotune Decrease the value of Par 1048 Cur Lim for auto tuning the speed regulator is set too high Autotune Cur Lim and repeat the auto tune procedure PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 2 18 Drive Start Up Fault No Description Action STune FrictionLo 60 The friction value attained during Decrease the value of Par 1048 the auto tuning procedure is zero Autotune Cur Lim and repeat the or lower than the control auto tune procedure precision limit STune Timeout 61 The speed regulator auto tuning Verify the value in Par 1048 procedure did not complete Autotune Cur Lim If this value is within the available time set to low the motor will not be able to reach a maximum speed of 3396 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 STune Aborted 62 The speed regulator auto tuning Informational only procedure has been stopped by the user For additional regulator fine tuning procedures refer to Fine Tuning the Regulators on page C 36 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 S
199. M requesting manual control see ALT Functions on page B 2 or the control terminal block analog input or MOP if a digital input is programmed to Auto Manual Changing Speed Sources The selection of the active speed reference can be made through the digital inputs DPI command Jog button or Auto Manual HIM operation Figure C 1 Speed Reference Selection Chart e Digital Inx Sel Auto Reference Options Speed Sel Anig In 1 3 Sel 3 2 1 DPI P 1 5 Select P44 Speed Ref A MOP Select Encoder Out Sel Anlg In 1 3 Sel DPI P 1 5 Select MOP Select Encoder Out Sel P155 Preset Speed 2 P155 Preset Speed 3 P155 Preset Speed 4 P155 Preset Speed 5 P155 Preset Speed 6 gt P155 Preset Speed 7 4 01010 P385 Speed Ref Out P48 Speed Ref B lolo xl ol ol Al Manual Reference Options HIM Requesting Manual Man Ang 1 3 Sel P267 TB Manual Ref DG MOP Select E P266 Jog Speed o 3 3 D 4 a Torque Reference Source The torque reference can only be supplied by an analog input the HIM ora network reference Switching between available sources while the drive is running is not available Digital inputs programmed as Speed Sel 1 2 3 and the HIM A
200. MM Q Remote 1 0 Communication Adapter 20 COMM R RS 485 DF1 Communication Adapter 20 COMM S External Comms Power Supply 20 XCOMMAC PS1 DPI External Communications Kit 20 XCOMMDC BASE External DPI VO Option Board 20 XCOMMIO OPT1 Compact I O to DPI SCANport Module 1769 SM1 Serial Null Modem Adapter 1203 SNM Smart Self povvered Serial Converter RS 232 1203 SSS includes 1203 SFC and 1202 C10 Cables Universal Serial Bus USB Converter 1203 USB includes 2m USB 20 HIM H10 amp 22 HIM H10 Cables 1 For use only with External DPI Communications Kits 20 XCOMM DC BASE What The Communication Communication Adapter module w captive screws Adapter Kit Includes e Internal Interface cable e Communication Adapter User Manual Additional components based on the option selected Tools That You Need e Phillips screwdriver Phillips is a registered trademark of Phillips Screw Company PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 E 2 Installing a Communication Adapter Satety Precautions Installing the Communication Adapter Module in the Drive gt ZN 2 ATTENTION Only qualified personnel familiar with drives power products and associated machinery should plan or implement the installation start up configuration and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION To avoid an electric shock hazard ensure tha
201. Mapping Arm Overvoltage F5 Fld Current Loss F6 P203 P473 OverVolt Fit Cig FldLoss Fit Cfg 0 Ignore 0 Ignore 1 Alarm 1 Alarm 2 Fault Auxiliary Input F2 Feedback Loss F91 Aux Inp ER Cfg Spd Loss Fit Cfg 1 Alarm E 2 Fault T Aarin 3 Fast Stop em Fault 4 Normal Stop 5 CurrLim Stop Motor Over Temp F16 Motor Overload F7 Pags P479 OverTemp Fit Cfg MtrOvrld Fit Cfg 0 Ignore 0 Ignore 1 Alarm 1 Alarm 2 Fault 2 Fault 3 Fast Stop 4 Normal Stop 5 CurrLim Stop PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 D 26 Control Block Diagrams Notes PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Appendix E Installing a Communication Adapter Communication Adapter The following Communication Adapter kits are available for use with the Kits PowerFlex DC drive Comm Option Catalog Number BACnet MS TP RS 485 Communication Adapter 20 COMM B ControlNet Communication Adapter Coax 20 COMM C DeviceNet Communication Adapter 20 COMM D EtherNet IPTM Communication Adapter 20 COMM E HVAC Communication Adapter 20 COMM H Interbus Communication Adapter 20 COMM I PROFIBUS DP Communication Adapter 20 COMM P ControlNet Communication Adapter Fiber 20 CO
202. ON ON OFF OFF OFF ON OFF 052 OFF OFF OFF ON OFF OFF ON OFF 073 ON OFF OFF JON OFF OFF JON OFF 086 OFF ON OFF ON OFF OFF ON OFF 100 ON ON OFF ON OFF OFF ON OFF 129 OFF OFF ON OFF OFF ON OFF B 167 ON OFF ON ON OFF OFF JON OFF 207 OFF ON ON ON OFF OFF ON OFF 250 ON ON ON ON OFF OFF JON OFF 330 OFF OFF OFF OFF ON OFF ON OFF 412 ON OFF OFF OFF ON OFF ON OFF C 495 OFF ON OFF OFF ON OFF ON OFF 667 ON ON OFF OFF ON OFF JON OFF PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 42 Installation and Wiring UO 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 digital input 4 by default Enable Refer to I O and Control Wire Routing on page 1 50 for information on routing I O signal and control wires 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 Optional 115V
203. Od indino quaung wiy yoeqp 4 pds 110 weg p ds 110 Jeu paeds eS0ld 0024 cold 91014 9864 Buiddejy Buiddejy uuely ney do ndul jueun DS eBeyoA ndino ul Bay 1ueun mo dwey g jeu peeds 1964 6624 Wd ELL 8 d eBeyoA eur1 OV bel eur 9Y Bay p ds ul dwey v Jeu p ds 99vd 88Sd 804 0014 ttd snjejs pue u s H eui jeoeq Bim 299d 099d edi 89 18 XAPA peeds uinuixey l d Zd ANd bpig pi uq Sd ly DU AA WON Ed 0824 Sduly wy D WON HOA 1OJON pere 6 14 GLld id Ta MOIA9AQ DQ 4 NOILVYNDIANOD SISVA PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 D 3 Control Block Diagrams lt q B es ano ria s x o Q o99 Lis BMO olstenul EJ l onoo p s ano eba s O zu lt Z4NQ uoisieAu L td 81 1 l RL les gno eia S lt pa 90d V lt 9 NO uoisieAu 0914 L l 2214 l 1 or ef nog lt 4 p les gno ebia om D xil Se O lt G nQ uoisieAu rld 9 4 jeuondo sindino Ef uorsuedx3 o OI SC 4 les vino retifiq 0 lt o d Qm 1 lt y no uoisieAu 8rid 0 214 EE 0
204. Par 587 is large greater than 40 and smaller increases as Par 587 gets closer to zero b If Par 587 I Reg Err is negative decrease the value of Par 454 Arm Inductance Again proportional to the magnitude of Par 587 Repeat step 9 until Par 587 I Reg Err is made as close to zero as possible Values less than 20 are acceptable as close to zero With higher current steps values can be less than 10 or less than 5 Repeat steps 9 and 10 with Par 39 Torque Ref set to 60 and then again at 100 If motor rotation occurs try lowering the current step value The higher the current step the better the tuning results will be If motor rotation still occurs experiment with trying to set the highest current step that doesn t cause rotation but is long enough for Par 587 I Reg Err to reach a stable value typically less than 2 seconds The current loop should be tuned with the final values of Pars 453 Arm Resistance and 454 Arm Inductance and a small value in Par 587 I Reg Err Restore Pars 497 Field Reg Enable 242 Speed Reg En 7 Current Limit 8 Current Lim Pos and 9 Current Lim Neg to their original values Unlock the motor armature if necessary Verify that the motor is attached to any normal application inertia not process material and perform a speed regulator autotune by setting Par 1027 Spd Reg Autotune 1 and pressing the Start button When autotuning completes speed regulator tuning values should b
205. PowerFlex Digital DC Drive Allen Bradley User Manual V1 006 3 001 Rockwell Allen Bradley Rockwell Software Automation 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 http 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
206. Ref 0 0 1 Inertia Comp 50 0 2000 ms Related 179 479 1290 921 469 File MOTOR CONTROL Group Field Config 467 468 469 497 498 Parameter Name amp Description See page 3 2 for symbol descriptions Max Fld Curr Pct Maximum allowable field current The maximum value 10096 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 A Min Fid 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 AN Field Mode Sel Operating mode of the field controller e Base Speed The motor field is regulated with constant 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 e Field Weaken The motor field is regulated with a combina
207. Ref Par 1180 7 Man Ref Par 267 16 Load Comp Par 698 25 Diam Preset3 Par 1167 8 Pos Cur Lim Par 8 17 PID Setpt 0 Par 760 Anlg In1 Config Default 0 4 10V Anlg In2 Config 77 Anlg In3 Config Options 2 5 Selects the signal input voltage or current mode for the analog 2 0 20mA input Configure switches S9 S10 and S11 on the Control 3 410 20mA board according to the input signal used The inputs of the drive are factory set for voltage signals Refer to DIP Switch and Jumper Settings on page 1 38 for information on switch configuration 10V A maximum voltage of 10V is connected to the analog input If the signal is used as a reference value a polarity reversal can be used to reverse the rotation direction of the drive four quadrant only when Par 1322 Direction Model 1 Bipolar Two quadrant drives accept only positive references as the speed reference Negative references are not accepted and the drive will run at zero speed e 0 10V A maximum voltage of 10V is connected to the analog input For reference values only positive references are allowed 0 20mA A maximum current signal of 0 20 mA is connected to the analog input The signal must be positive 4 to 20mA A current signal of 4 20 mA is connected to the analog input The signal must be positive Anlg In1 Scale Default 1 00 Anlg In2 Sca
208. Scale3 Input 3 43 Scale3 Mul 3 43 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Scale3 Out Off 3 44 Scale3 Output 3 43 Scale4 Div 3 43 Scale4 In Abs 3 44 Scale4 In Max 3 43 Scale4 In Min 3 43 Scale4 In Off 3 44 Scale4 Input 3 43 Scale4 Mul 3 43 Scale4 Out Off 3 44 Scale4 Output 3 43 Scale5 Div 3 43 Scale5 In Abs 3 44 Scale5 In Max 3 43 Scale5 In Min 3 43 Scale5 In Off 3 44 Scale5 Input 3 43 Scale5 Mul 3 43 Scale5 Out Off 3 44 Scale5 Output 3 43 Scale6 Div 3 43 Scale6 In Abs 3 44 Scale6 In Max 3 43 Scale6 In Min 3 43 Scale6 In Off 3 44 Scale6 Input 3 43 Scale6 Mul 3 43 Scale6 Out Off 3 44 Scale6 Output 3 43 Selected TorqRef 3 13 Set Fld Curve 3 18 SLAT Dvvell Time 3 32 SLAT Err Stpt 3 32 Software Version 3 14 Spd 0 Trip Delay 3 35 Spd Draw Out Pct 3 12 Spd FB Filt BW 3 22 Spd FB Filt Gain 3 22 Spd Fdbk Control 3 21 Spd Fdbk Error 3 21 Spd Fdbk Filter 3 30 Spd Fdbk Invert 3 21 Spd Limit Active 3 51 Spd Loss Fit Cfg 3 58 Spd Match Acc 3 48 Spd Match Compl 3 48 Spd Match Dec 3 48 Spd Match Gain 3 48 Spd match torque 3 49 Spd Ref Zero En 3 29 Spd Reg Autotune 3 23 Spd Reg Ki 3 27 Spd Reg Ki Base 3 27 Spd Reg Ki Outpt 3 28 Spd Reg Kp 3 27 Spd Reg Kp Base 3 27 Spd Reg Kp Outpt 3 28 Spd Reg Neg Lim 3 28 Spd Reg Out Pct 3 13 Spd Reg Pos Lim 3 27 Spd Select 0 3 54 Spd Select 1 3 54 Spd Select 2 3 54 Spd Trq Mode Sel 3 32 Spd Tune Inertia 3 23 Spd Up Gain Pct 3 30 Spd Ze
209. Setpoint for SLAT Dwell Time FSM State Controller 5 VU l FSM On ili Internal Torque LI Speed Regulator Reference ITR pl Output SRO Speed Error Regulator Min off Select Reference ETR SLAT MAX Mode In SLAT Max mode the user would typically configure a speed reference that forces the speed regulator into saturation the speed reference is slightly below the speed feedback In this case the drive would follow the torque reference until there was a breakage or slippage in the application In SLAT Max mode the drive will switch from torque mode to speed mode when either one of the two following conditions occur 1 Theoutput of the speed regulator becomes more than the torque reference This is speed mode 2 The speed error becomes positive the speed feedback becomes less than the speed reference This is forced speed mode Parameter 15 SLAT Err Stpt and parameter 16 SLAT Dwell Time allow you to set some hysteresis for turning off the forced speed mode They are set to 0 as default so that there is no hysteresis In SLAT Max mode Par 15 SLAT Err Stpt sets how much more the speed feedback should be than the speed reference before turning off the forced speed mode Par 16 SLAT Dwell Time sets how long the speed error must exceed the SLAT error set point before turning off the forced speed mode At the time the d
210. Signal Wire Size Wire Type and Size Tightening Torque Flexible mm multi core mm AWG Nem bein 75 x 2 5 x 0 4 mm 3 0 x 0 1 x 0 02 in flathead screwdriver is recommended for connecting wire to the terminal block inputs Strip the ends of the cables to a length of 6 5 mm 0 26 in Important To improve the noise immunity it is recommended that you connect the common of the outputs terminals 2 4 5 and 15 of the I O Expansion board with the ground terminal 10 or 20 on the standard I O terminal blocks on the Control board If this is not possible these terminals must be grounded by means of a 0 1 uf 250V capacitor II The Analog and Digital UO Expansion circuit board is not factory installed PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 F 2 Optional Analog and Digital I O Expansion Circuit Board Table F B 1 0 Expansion Board Terminal Block 1 Designations No Signal Description Factory Default Config Parameter 1 Analog Output 3 410V 5mA maximum 18 Fld Current 68 Anlg Out3 Sel 2 Analog Output 3 3 Output 4 1 510V 5mA maximum 14 Motor Volts 69 Anlg Out4 Sel 4 Analog Output 4 5 Digital Output Common 6 Digital Output 5 Max volt 30V max cur 50mA 26 Alarm 149 Digital Out5 Sel 7 Digital Output 6 8 Digital Output 7 m 9 Digital Output 8
211. Speed 1 Min Speed Rev 6 Max Speed Fwd 3 Min Speed Fwd 5 Maximum Speed 2 Max Speed Rev 4 Discrete Speeds Jog Speed 266 Preset Speed 3 156 Preset Speed 7 160 Jog Off Delay 1409 Preset Speed 4 157 TB Manual Ref 267 Preset Speed 1 154 Preset Speed 5 158 Preset Speed 2 155 Preset Speed 6 159 Speed Trim Ramp 42 Trim Speed 43 Speed Ratio 1017 References Trim Ramp Pct 378 Trim Speed Pct 379 Speed Regulator Speed Reg En 242 1 SpdOut FiltGain 238 Spd Zero P Gain 126 Arm Volt Kp 493 SpdOut FiltBW 239 Lock Speed Integ 348 Arm Volt Ki 494 Speed Thresh Pos 101 Flying Start En 388 Spd Reg Kp 87 Speed Thresh Neg 102 Spd Fdbk Filter 444 Spd Reg Ki 88 Threshold Delay 103 Spd Up Gain Pct 445 Arm Volt Kp Base 495 At Speed Error 104 Speed Up Base 446 Arm Volt Ki Base 496 At Speed Delay 105 Speed Up Filter 447 Spd Reg Kp Base 93 Ref Zero Level 106 SpdReg Kp Bypass 459 Spd Reg Ki Basel 94 Speed Zero Levell 107 SpdReg Ki Bypass 460 Spd Reg Kp Outpt 99 Speed Zero Delay 108 SpdFuncSelect 1016 Spd Reg Ki Outpt 100 Spd Zero En 123 InertiaCompAct 1191 Spd Reg Pos Lim 95 Spd Ref Zero En 124 InertiaCompVar 1192 Spd Reg Neg Lim 96 Spd Zero P En 125 1 This parameter available for use with firmware version 2 005 and lower only Dynamic Control Control Config Spd Trq Mode Sel 241 SLAT Err Stpt 15 SLAT Dwell Time 16 Ramp Rates Speed Ramp En 245 MOP Decel Time 30 Ram
212. Speed 1 Discrete Speeds 3 26 351 Field Current Current Meters 3 13 155 Preset Speed 2 Discrete Speeds 3 26 353 Zero Torque Torque Attribute 3 19 156 Preset Speed 3 Discrete Speeds 3 26 354 Aux Inp Fit Cfg Alarms 3 58 157 Preset Speed 4 Discrete Speeds 3 26 365 OverTemp Fit Cfg Alarms 3 58 158 Preset Speed 5 Discrete Speeds 3 26 372 Spd Limit Active Diagnostics 8 51 159 Preset Speed 6 Discrete Speeds 3 26 373 Freeze Ramp Ramp Rates 3 34 160 Preset Speed 7 Discrete Speeds 3 26 374 Div Fid Brdg Cur Motor Data 3 16 162 Feedback Spd Motor Data 3 15 376 MtrOvrid Type Motor Data 3 16 166 Alpha Test Test Generator 3 25 378 Trim Ramp Pet Speed Reference 3 27 167 Arm Text Angle Test Generator 3 25 379 Trim Speed Pct Speed Reference 3 27 168 Fld Test Angle Test Generator 3 25 381 Drive Status 1 Diagnostics 3 52 169 Encoder PPR Speed Feedback 3 20 382 Drive Status 2 Diagnostics 3 53 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 84 Programming and Parameters No Parameter Name Group Page No Parameter Name Group Page 384 Spd Ref Out Pct Speed Meters 3 12 509 UserDefined6 User De
213. TB4 N O Relay M1 DC Contactor AUX 19 424V on I O TB2 131 114 rel e Dun JU 517 L2 T2 e V Gem PowerFlex DC L3 473 W Drive A1 A2 M 1A1 FU FU At Control 1A2 j LV Board P S Ue Armature 95 Voltage af Control Power Relay Fdbk 7 Terminal Block PRSE 75 76 Field Power Terminal Block Fi Ut em C1 FV1 vi 01 2 red Fs2 1 AC input fuses for the armature converter are customer supplied for frame A and B drives and are internally mounted on frame C drives See Drive Power Circuit Protection on page A 8 for fuse recommendations 2 Par 140 Digital In8 Sel set to 31 Contactor 3 Customer supplied armature output fuses are required on four quadrant and are recommended on two quadrant Frame A and B drives See Drive Power Circuit Protection on page A 8 for fuse recommendations 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 23 4 Par 1391 ContactorControl 4 DC Cntctr DB Par 1392 Relay Out 1 Sel 24 ContactorDB Important Terminal 35 and 36 are on the Control Power Relay Terminal block NOT the I O terminal blocks See Figure 1 23 through Figure 1 25 5 Optional armature voltage feedback sensing not needed with AC
214. TION Only qualified electrical personnel familiar with ATTENTION This is an open loop test disconnect the motor armature and field leads and replace them with dummy loads Failure to observe this precaution could result in machine damage and or bodily injury ATTENTION Uncontrolled machine operation could result with a motor connected during these tests and may cause personal injury and or equipment damage Verify that the drive is not connected to a motor armature circuit before enabling these test modes gt b Important The Alpha Test requires the use of an isolated oscilloscope that will be attached to the armature or field leads of the drive connections When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by ATTENTION Remove power before making or breaking cable e sending an erroneous signal to your system s field devices causing unintended machine motion e causing an explosion in a hazardous environment Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts may create electrical resistance 1 Remove and lock out all incoming power to the drive PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 10 11 12 13 14 15 Application Notes C 3 Disconnect the motor armature leads and mechanicall
215. a soc i Overview Who Should Use this Manual pl What sum this Manual AEN EE dina gea ge pl Drive Storage Conditions pl Drive Nameplate Dat A deefe caet aan Med A erae ga ee eg d ad d oa p 2 Drive Frame Size sud Rer reps oped dake sen p 2 Drive Firmware Version p 2 Reference Materials p 2 Manual Conventions c l s er ea AORA Ra hae er tata p 3 General Precautions p 3 Standard Drive Catalog Number Explanation p 4 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 aie ere dr RR ed 1 5 Mounting Frame C Drives 1 6 Removing the Drive Covers 1 7 Frame RO PR Re EP Re tad 1 7 Frame B and D ves uses ERE Rp ARES WE e daa 1 8 Line Reactors oi esd det
216. a 1 1233 Scale4 In Off 1242 Scale5 In Off 1251 Scale6 In Off Offset to be added to the input quantity Resolution 5 digits Refer to the Scale Blocks block diagram on page D 19 for more information 491 Scalei Out Off Default 0 00 560 Scale2 Out Off 1225 Scale3 Out Off MaMa 5200006 1234 Scale4 Out Off 1243 Scale5 Out Off 5 1252 Scale6 Out Off m Offset to be added to the output quantity Resolution 5 digits Refer to 5 the Scale Blocks block diagram on page D 19 for more information 492 Scale1 In Abs Default 0 Off 561 Scale2 In Abs SN ang 1226 Scale3 In Abs Options x 1235 Scale4 In Abs 1244 Scale5 In Abs 1253 Scale6 In Abs Controls how the input value is processed Off The input quantity is processed with its sign e On The input quantity is processed with a positive sign absolute value t is possible to have the polarity change with the signs of the ScalexMul or ScalexDiv parameters Refer to the Scale Blocks o block diagram on page D 19 for more information 5 794 Diameter Calc Default 0 Geh Enables Disables the diameter calculation function If this parameter Min Max 0 1 a has been programmed via a digital input it must be brought to a amp logical high level 0 The diameter calculation is disabled 1 The diameter calculation is enabled 795 DncrPosSpd Default 0 Desired motor s
217. a In Val Sel 3 65 Data Out A1 3 65 Data Out A2 3 65 Data Out Ax 3 65 Data Out B1 3 65 Data Out B2 3 65 Data Out C1 3 65 Data Out C2 3 65 Data Out D1 3 65 Data Out D2 3 65 Decel Mask 3 64 Decel Owner 3 64 Decel Status 3 55 Decel Time 1 3 34 Decel Time 2 3 33 Diam Calc Dis 3 45 Diam Inc Dec En 3 46 Diam init filter 3 46 Diam Preset 0 3 45 Diam Preset 1 3 46 Diam Preset 2 3 46 Diam Preset 3 3 46 Diam Preset Sel 3 46 Diam stdy delay 3 46 Diam Threshold 3 45 Diameter Calc 3 44 Diameter Calc St 3 44 Diameter Filter 3 45 Diameter Reached 3 45 Diameter Reset 3 45 Dig In Status 3 72 Dig In Term 1 3 72 Dig In Term 10 3 72 Dig In Term 11 3 72 Dig In Term 12 3 72 Dig In Term 2 3 72 Dig In Term 3 3 72 Dig In Term 4 3 72 Dig In Term 5 3 72 Dig In Term 6 3 72 Dig In Term 7 3 72 Dig In Term 8 3 72 Dig In Term 9 3 72 Dig Out Status 3 75 Digital In1 Sel 3 70 Digital In10 Sel 3 70 Digital In11 Sel 3 70 Digital In12 Sel 3 70 Digital In2 Sel 3 70 Digital In3 Sel 3 70 Digital In4 Sel 3 70 Digital In5 Sel 3 70 Digital In6 Sel 3 70 Digital In7 Sel 3 70 Digital In8 Sel 3 70 Digital In9 Sel 3 70 Digital Out1 Sel 3 73 Digital Out2 Sel 3 73 Digital Out3 Sel 3 73 Digital Out4 Sel 3 73 Digital Out5 Sel 3 73 Digital Out6 Sel 3 73 Digital Out7 Sel 3 73 Digital Out8 Sel 3 73 Direction Mask 3 63 Direction Mode 3 50 Direction Owner 3 64 DncrPosSpd 3 44 DPI Baud Rate 3 63 DPI Fdbk Select 3 63 DPI P1 Select 3 76 DPI P2 Select 3 76 DPI P3 S
218. a percentage of the drive rated Min Max 0 00 199 99 current Units PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 File APPLICATIONS Group Winder Functions not enabled it corresponds to the value displayed in Par 1180 Tension Ref Programming and Parameters 3 47 5 2 g Parameter Name amp Description s Z See page 3 2 for symbol descriptions Values 1175 Friction Default 0 00 Compensation for dynamic friction as a percentage of the drive rated Min Max 0 00 199 99 current Units 926 1176 Taper Enable Default 0 Disabled Enables Disables the Taper function Options 0 Disabled Enabled 1177 Initial Diameter Default 0 10 Diameter that starts the taper tension reduction Min Max 0 00 32 00 Units m 1178 Final Diameter Default 1 00 Diameter that ends the taper tension reduction Min Max 0 00 32 00 Units m 1179 Tension Reduct Default 0 00 1180 Taper tension reduction as a percentage of Par 1180 Tension Ref Min Max 0 00 199 99 Units 1180 Tension Ref Default 0 00 Tension reference Min Max 0 00 199 99 Note This parameter can be assigned to an analog output Units 1181 Tension Scale Default 100 Scale factor of the torque current This parameter is used when the Min Max 0 200 value of the maximum winding torque must be limited or when a Units
219. age C 38 e Field current curve tuning Flux if curve e Voltage regulator in the field converter Refer to Fine Tuning the Voltage Regulator in the Field Converter on page C 43 Figure C 16 Curve Conversion Flux Current Par 234 Fld Current Pct Par 280 Nom Mtr Fld Amps 10096 E d Par 916 Fld Const 90 Pct Curve A 7 R Par 280 Nom Mtr Fld Amps 50 i ar 280 No ps 4 Curve B Par 917 Fld Const 70 Pct Par 918 Fld Const 40 Pct 40 50 70 90 100 Par 500 Field Ref Pct Examples e Curve A If the default settings of the drive are retained the flux current to flux reference will remain linear when the value of Par 500 Flux Ref Pct changes For example o If Par 467 Max Fld Curr Pct Par 500 Flux Ref Pct 100 then Par 234 Fld Current Pct Par 500 Flux Ref Pct Par 280 Nom Mtr Fld Amps o If Par 467 Max Fld Curr Pct Par 500 Flux Ref Pct 50 then Par 234 Fld Current Pct Par 500 Flux Ref Pct 50 of Par 280 Nom Mtr Fld Amps e Curve B If the field current curve fine tuning procedure is completed the flux current to flux reference curve will follow a curve determined by the real flux percentage of Par 500 Flux Ref Pct necessary to determine the circulation of the field current for the connected system Refer to the Current Regulator block diagram on page D 14 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P
220. ain 3 45 Line Spd Source 3 48 Line Spd Thresh 3 45 Line Speed Pct 3 45 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 Index 10 line speed signal PID C 14 linear parameter list 3 3 link parameters C 22 Load Comp 3 35 Load Limits group 3 34 3 35 Local Mask 3 64 Local Owner 3 64 Lock Speed nteg 3 30 logic command word A 6 Logic Mask 3 2 3 63 3 65 Logic Mask Act 3 65 logic status word A 7 Low Voltage Directive Installation Requirements 1 14 Low Voltage Directive and Electromagnetic Compatibility Directive 1 13 M Main Contactor fault 4 5 Man Ref Preload 3 50 manual speed sources C 18 manuals reference p 2 Masks amp Owners group 3 2 3 63 3 64 Materl Width Pct 3 46 Max Deviation 3 44 Max Diameter 3 45 Max Feedback Spd 3 15 Max Fld Curr Pct 3 17 Max Ref Speed 3 15 Max Speed Fwd 3 26 Max Speed Rev 3 26 Maximum Speed 3 26 menu HIM B 3 B 4 Min Fld Curr Pct 3 17 Min Speed Fwd 3 26 Min Speed Rev 3 26 Minimum Diameter 3 44 Minimum Speed 3 26 MOD LED 4 2 Monitor file 3 11 MOP Accel Time 3 33 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 MOP Dec Active 3 54 MOP Decel Time 3 33 MOP Inc Active 3 53 MOP Mask 3 63 MOP Owner 3 64 MOP Select 3 50 Motor Control file 3 15 Motor Data group 3 15 3 16 motor not reaching commanded speed 4 14 motor not turning 4 13 Motor Over Temperature alarm 4 10 Motor Over Temperature f
221. al drive information Title Publication Available Online at Preventive Maintenance of Industrial Control and DRIVES TD001 Drive System Equipment Safety Guidelines for the Application Installation SGI 1 1 and Maintenance of Solid State Conirol A Global Reference Guide for Reading Schematic 100 2 10 Diagrams Guarding Against Electrostatic Damage 8000 4 5 2 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 UM001E EN P June 2009 Manual Conventions General Precautions Overview p 3 e 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 e The following words are used throughout the manual to describe an action Word Meaning 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 ZN Dp ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required
222. al speed equal to the line speed Winder Side Selection of the winding unwinding side e 0 Up 1 Down Note This parameter can be assigned to a digital input W Gain Sets the speed reference gain used to saturate the speed loop This parameter is a percentage of the increasing decreasing value of the angular speed reference Spd Match Compl Indicates a completed launching ramp If this parameter is assigned to a programmed digital output it can be used to indicate that the coil can be changed e 1 Launching ramp completed 0 Launching ramp not completed Line Spd Source Number of the parameter read as the line speed for the winder function Close Loop Comp Active compensation status output of the PID regulator Torque Winder En Enables disables the center winder function W Target Number of the parameter to which the winder speed reference is written Actual Comp Active compensation status sums up the static dynamic and inertial frictions as a percentage of the drive rated current Note This parameter can be assigned to an analog output PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Values 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 Default Min Max U
223. alarm conditions are present 3 The terminal block programmed enable input is closed 4 All Stop inputs are maintained Y Yes Is the terminal block Run No Run Forward or Run Reverse Input Closed Yes Y Powerup Start Powerup Terminated Normal Mode During the time specified in parameter 1345 Powerup Delay the alarm indicator e is displayed on the HIM and bit 12 PwrUp Start of parameter 380 Drive Status 1 is set to 1 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 C 36 Application Notes Fine Tuning the Regulators The PowerFlex DC drive control regulators have predefined values meant to provide consistent drive performance without performing any further configuration with the exception of the armature current regulator which must always be tuned When the armature current regulator has been tuned to meet the requirements of the application the fine tuning procedures for the other regulators are not necessary However the fine tuning procedures can be used to optimize the output and control features of the drive The drive contains the following regulation circuits Armature current regulator The armature current auto tuning procedure is run via Par 452 CurrReg Autotune Refer to Chapter 2 Drive Start Up Tune the Current Regulator on page 2 10 D A manual procedure to adjust the armature inductance when the autotune steps yi
224. alue of Par 1164 Diam Preset 0 1165 Diam Preset 1 Par 1166 Diam Preset 2 or Par 1167 Diam Preset 3 See Par 1168 Diam Preset Sel Taper Enable Enables disables the Taper function Par 1176 Taper Enable Spd DemandEn Enables disables the speed reference calculation winder operation Par 1215 Speed Demand En Winder Side Selection of the winding unwinding side 0 up 1 down PI PD Enable Selection between PI and PD winder operation Par 1201 Winder Side Jog TW En Enables disables the Torque Winder jog function Par 1256 Jog TW Enable Invert Fit Must be used when the digital input is wired to the status of an inverting fault device fuse circuit breaker etc When asserted causes an Inverting Fault F37 Refer to Figure 1 13 on page 1 23 for more information 1 A digital input 1 8 only must be configured for Enable 2 For digital inputs 9 12 this option is not available displays as Reserved PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 72 2 T 2 564 566 567 568 569 570 571 572 573 574 575 576 INPUT OUTPUT Programming and Parameters Parameter Name amp Description See page 3 2 for symbol descriptions Dig In Status Status of the digital inputs Values Read Only Digital In12 Reserved Reserved
225. ameter too low could prevent the proper functioning of field economy Actual Speed Par 107 Speed Zero Level N A qd Actual Speed 0 i um Par 395 At Zero Speed ET o Sat dem Par 108 Speed Zero Delay 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 Spd Zero 1 En Enables Disables the output of the integral section of the speed regulator Used in the Zero Speed function e Enabled The output of the integral section of the speed regulator is set to zero when the speed reference and the speed feedback are equal to zero The component is enabled when a reference value is entered to restart acceleration e Disabled Disables the output of the integral section of the speed regulator Spd Ref Zero En This parameter is only active when Par 125 Spd Zero P En 1 Enabled Used in the Zero Speed function e Enabled The proportional gain equal to Par 126 Spd Zero P 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 Disabled The proportional gain equal to Par 126 Spd Zero P 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
226. ameters B 5 ALT Functions B 2 Removing Installing the HIM B 6 The PowerFlex DC drive provides a number of cable connection points for the HIM Frame A shown Connector Description DPI Port 1 HIM connection when installed in cover DPI Port 2 Cable connection for handheld and remote options DPI Port 3 or 2 Splitter cable connected to DPI Port 2 provides additional port SG l DPI Port 5 Cable connection for communications adapter View with front cover removed Display F gt Pover Loss BlAuto iz Description Direction Drive Status Alarm Auto Man Information rpm Commanded or Output Speed or Current Main Menu Diagnostics Parameter Device Select The top line of the HIM display can be configured with parameter 1321 DPI Fdbk Select Programming Monitoring Troubleshooting PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 To use an ALT function press the ALT key release it then press the programming key associated with the function printed on the HIM above Performs this function B 2 HIM Overview ALT Functions the key Table B A ALT Key Functions Press the ALT Key and then S M A R T Displays the S M A R T list screen See Using the S M A R T List Screen below for more information View Allows the select
227. ance 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 Control Power Supply Rating Code Rated input current Inrush input current Frame 1230 460V Board ID Power 115V 230V 115V 230V 7P0 4P1 A through through SW1 31 60W 1A 0 5A 20A 10A 110 129 146 167 B amp C through through SW2 32 110W 1 2A 0 7 15A 7 5 521 667 II Refer to Standard Drive Catalog Number Explanation on page Preface 4 positions 8 9 and 10 for corresponding drive HP rating armature amp rating and field amp rating 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 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring 1 17 Cable and Wiring Use the following cable and spacing recommendations for all drives sizes Recommendations Minimum Spacing Between Classes Steel Conduit Tray See Spacing Wiring Notes Category Class Signal Definition Signal Example Cable Type 1 2 3 4 5 6 7 8 9 10 11 page 1 18 Power 1 AC Power 600V 12 3kV 3 ph AC Lines Per NEC amp 0 3 9 in 3 9 in
228. and set Par 70 Anlg In1 Sel to 0 Not Used If you are using another source for the speed reference select either the appropriate DPI Px Select parameter to 1 Speed Ref A or the appropriate Anlg Inx Sel parameter to 1 Speed Ref A and set Par 70 Anlg In1 Sel to 0 Not Used if appropriate PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 2 10 Drive Start Up Tune the Current Regulator 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 you must the motor from equipment or processes that may be damaged by ATTENTION Prior to tuning the current regulator uncouple 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 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 Im
229. anual Publication 20P UM001E EN P June 2009 UsrValMult1 3 59 Variable J Comp 3 46 view B 5 W Offset 3 48 W Reference 3 49 W Target 3 48 Winder Side 3 48 Winder Type 3 47 Write Mask Act 3 66 Write Mask Cfg 3 66 Z Capture Pos En 3 22 Z Captured Pos 3 22 Z Channel Enable 3 22 Zero Ramp Input 3 34 Zero Ramp Output 3 34 Zero Torque 3 19 PD Control group 3 40 PD Deriv Filter 3 40 PD Deriv Gain 1 3 40 PD Deriv Gain 2 3 40 PD Deriv Gain 3 3 40 PD Output PID 3 40 PD Prop Gain 1 3 40 PD Prop Gain 2 3 40 PD Prop Gain 3 3 40 PE ground wire size 1 25 peripheral devices view B 4 PI Central v sel 3 39 PI Central v1 3 38 PI Central v2 3 38 PI Central v3 3 38 PI Central vst 3 39 PI Central vs1 3 39 PI Control group 3 38 3 39 PI Init Intgl Gn 3 40 PI Init Prop Gn 3 39 PI integr freeze 3 39 PI Integral Gain 3 38 PI Lower Limit 3 39 PI Output 3 38 PI Prop Gain PID 3 38 PI Steady Thrsh 3 38 PI Upper Limit 3 39 PID feedback signal C 15 function C 14 C 15 C 17 line speed signal C 14 PID Accel Time 3 42 PID Clamp 3 41 PID Control group 3 40 3 41 3 42 3 43 PID Decel Time 3 42 PID Error 3 41 PID Error Gain 3 43 PID Feedback 3 41 PID Output 3 41 PID Output Scale 3 41 PID Output Sign 3 41 PID Setpoint 0 3 41 PID Setpoint 1 3 41 PID Setpoint Sel 3 41 PID Source 3 42 PID Source Gain 3 42 PID Steady Delay 3 40 PID Target 3 42 Pollution Degree Ratings 1 15 Port 1 Adapter fault 4 6 Port 1 DPI Loss
230. ar 1323 DPI P1 Select Related Programming and Parameters 3 77 Parameter Cross Reference Name No Group Page Name No Group Page Anlg3 Tune Scale 83 Analog Inputs 3 67 m by Name AC Line Freq 588 Drive Data 3 14 Arm Current 200 Current Meters 3 13 AC Line Voltage 466 Drive Data 3 14 Arm Current Pet 199 Current Meters 3 1 Acc Dec Filter 1212 Ramp Rates 3 34 Arm Inductance 454 Autotune 3 22 Accel Mask 596 Masks amp Owners 3 63 Arm Resistance 453 Autotune 3 22 Accel Owner 605 Masks amp Owners 64 Arm Test Angle 167 Test Generator 25 Accel Status 1188 Diagnostics 3 55 Arm Volt Ki 494 1 Speed Regulator 3 31 Accel Time 1 660 Ramp Rates 3 94 Arm Volt Ki Base 496 Speed Regulator 31 Accel Time 2 24 Ramp Rates 3 3 Arm Volt Kp 493 1 Speed Regulator 1 Act Spd Filter 923 Speed Feedback 3 22 Arm Volt Kp Base 495 Speed Regulator 3 31 Act Ten Ref Pct 1194 Winder Functions 3 47 At Speed 394 Diagnostics 3 53 Actual Comp 1213 Winder Functions 3 48 At Speed Delay 105 Speed Regulator 3 28 Actual Speed 924 Speed Meters 3 12 At Speed Error 104 Speed Regulator 3 28 Actuator Delay 1266 Stop Modes 3 36 At Zero Speed 395 Diagnostics 3 53 Adaptive Gaint 189 1 Adaptv Regulator 8 37
231. ar 185 Adaptive Spd 2 The value in this parameter 5 Units o defined as percentage of the value defined Par 93 Spd Reg Kp Basel 193 Adaptive Gain3 Default 1 00 94 ntegral gain for the range of values beginning above the value Min Max 0 00 100 00 183 defined in Par 185 Adaptive Spd 2 The value in this parameter is Units o defined as percentage of the value defined Par 94 Spd Reg Ki Basel PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 38 Programming and Parameters Applications File m Group e Z 695 File 764 765 769 771 APPLICATIONS PI Control 776 777 778 Parameter Name amp Description See page 3 2 for symbol descriptions PI Steady Thrsh Feed forward threshold for PI e f the value if Par 758 Feed Fwd PID is less than the value of Par 695 PI Steady Thrsh the integral regulation will be locked and the proportional gain assumes the value set in Par 793 PI Init Prop Gn When the value of Par 758 Feed Fwd PID exceeds the value of Par 695 PI Steady Thrsh the integral regulation with the gain set in Par 734 PI Init Intgl Gn will be enabled e The Proportional Integral PI block will maintain the gain values specified in Pars 793 PI Init Prop Gn and 734 PI Init Intgl Gn for the time specified in Par 731 PID Steady Delay once this time delay has elapsed the values of PI Init Prop Gn and PI Init
232. arameter Drive Running 1380 Drive Alarm 1 Refer to Fault Descriptions on page 4 4 and or Alarm Descriptions on page 4 9 Red Flashing A fault has occurred Check Fault x Code or view the Fault Queue on the HIM Refer to Fault Descriptions on page 4 4 Steady A non resettable non configurable fault has occurred Check Fault x Code or view the Fault Queue on the HIM Refer to Fault Descriptions on page 4 4 PORT Beier to the Status of DPI port internal communications if present MOD Communication Adapter Status of communications module when installed NETA User Manual Status of network if connected NET B Status of secondary network if connected PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Drive Start Up 2 5 Verify the Control Voltages 3 Verify that the following voltages are present at I O terminal block and 2 Refer to I O Signal and Control Wiring on page 1 42 Terminal Number Voltage ro Terminal Number 7 10V 9 8 10V 9 19 24 30V 18 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 t
233. are recommended D All electrical connections are tight D The brushes are properly seated 41 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 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 2 12 Drive Start Up 4 If analog input 1 is wired access the Analog Inputs group and verify that the voltage level is OV in Par 1404 Analog In1 Value 5 While viewing Par 233 Output Voltage assert a Jog command 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 6 Ifthe observed rotation direction is incorrect remove power from 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 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 4 1 9 C1 61 Ot oar C
234. assigned to an analog output or analog input by selecting Out Volt Lvl The maximum value of this parameter was changed from 100 to 110 with firmware version 3 001 1407 Field Econ Delay Default 300 107 Amount of time to elapse once the drive reaches zero speed as Min Max 0 1800 499 determined by Par 107 Speed Zero Level before field Units S economy becomes active PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 File No MOTOR CONTROL 40 342 353 Parameter Name amp Description See page 3 2 for symbol descriptions 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 f Par 7 Current Limit is changed Pars 8 Current Lim Pos and 9 Current Lim Neg are set to the same value If either the value of Pars 8 Current Lim Pos or 9 Current Lim Neg is changed later the last change is valid Current Lim Pos 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 Current Lim Neg 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
235. ation Notes Field Voltage Regulator Tuning Examples Figure C 13 Field voltage oscillation Oscillation after a speed change where Arm Volt Kp 10 and Arm Volt Ki 80 Top Par 234 Fld Current Pct Bottom Par 233 Output Voltage Figure C 14 Too small of a gain The armature voltage increases where Arm Volt Kp 3 and Arm Volt Ki 5 Top Par 234 Fld Current Pct Bottom Par 233 Output Voltage PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Figure C 15 Optimal field regulation After a short transient the field current and armature voltage are constant Arm Volt Kp 40 Arm Volt Ki 596 Top Par 234 Fld Current Pct Bottom Par 233 Output Voltage Application Notes C 45 Tuning the Field Current Curve The function of the field current curve is to control the actual motor flux and subsequently motor torque if the field goes into an overvoltage condition Figure C 15 below illustrates the relationship between flux and flux current when the field current curve is defined versus not defined Important Complete the procedures in the order listed below when tuning the field current curve e Field current regulator Refer to Fine Tuning the Field Current Regulator on p
236. ation 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 for example 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 4 for Digital Encoder specifications Figure 1 36 Digital Encoder Terminal Block Location As A n B 7 7 COM V AN E 33 Shield ground Digital Encoder Control EMI Shield terminal block Table 1 V Digital Encoder Terminal Designations No Description A Encoder A Single channel or quadrature A A A NOT input B Encoder B Dual channel quadrature B input B Encoder B NOT Z Encoder Z Pulse marker or registration Z Z NOT input COM 5 12 15V DC Return Internal power common AN 45 12 15V DC Power Internal power source 200 mA Selectable via switch S21 on the Control board Refer to Table 1 M on page 1 39 Selectable via switch S20 on the Control board Refer to Table 1 M on page 1 39 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring 1 49 Figure 1 37 Sample Encoder Wiring
237. ator The value in this parameter is defined as percentage of the value defined Par 45 Max Ref Speed 188 Adaptive P Gain1 Default 10 00 93 Proportional gain for the range from zero to the value set in Par 184 Min Max 0 00 100 00 184 Adaptive Spd 1 The value in this parameter is defined as Units o percentage of the value defined in Par 93 Spd Reg Kp Basel 189 Adaptive Gain11 Default 1 00 94 Integral gain for the range from zero to Par 184 Adaptive Spd 1 The Min Max 0 00 100 00 ms value in this parameter is defined as percentage of the value defined Units 96 He Par 94 Spd Reg Ki Base 190 Adaptive P Gain2 Default 10 00 93 D Proportional gain for the range of values defined beginning with the 1 Min Max 0 00 100 00 184 value of Par 184 Adaptive Spd 1 to the value defined in Par 185 Units 185 amp Adaptive Spd 2 The value in this parameter is defined as o 9 percentage of the value defined Par 93 Spd Reg Kp Basel 191 Adaptive Gain2 Default 1 00 94 Integral gain for the range of values defined beginning with the value Min Max 0 00 100 00 184 of Par 184 Adaptive Spd 1 to the value defined in Par 185 Adaptive Units 185 Spd 2 The value in this parameter is defined as percentage of the o value defined Par 94 Spd Reg Ki Basel 192 Adaptive P Gain3 Default 10 00 93 Proportional gain for the range of values beginning above the value Min Max 0 00 100 00 5 defined in P
238. ators C 25 Speed Zero Function mh C 27 Speed Draw Function ANE ter ege RE VR RENE EE C 28 Speed Torque Mode Selection C 29 Zero lorque 1066606000 ee C 29 Speed Regulation Mode iss sa sans esa cipia eda sped epe RR E Ra Rara C 29 Torque Regulation Mode C 30 Speed Limited Adjustable Torque SLAT Min Mode and SLAT Max Mode C 30 Sum Mode spa dep bee EE ENEE aidant dud EEN C 33 Start At POWETUD 2 ed sae he 7 ed RR RU E E RR Teo C 35 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Appendix D Appendix E Appendix F Appendix G Index Fine Tuning the Regulators C 36 Manually Adjusting the Current Regulator Tune Settings C 37 Fine Tuning the Field Current Regulator C 38 Fine Tuning the Speed Regulator C 41 Fine Tuning the Voltage Regulator in the Field Converter C 43 Tuning the Field Current Curve C 45 Control Block Diagrams Diagram Conventions a z vu e pe debo ge don aile deed due eed bsc D 1 Installing a Communication Adapter Communication Adapter Kits E 1 W
239. ature DC Output Fuses 460V AC Input Frame A and B Regenerative Drives Only Fuse Code FS2l See Figure on page A 8 Drive Bussmann Ferraz Shawmut Gould Shawmut Current AC North E Rating DC Line Ferrule FWP Ferrule North American American Ferrule North American Code Amps Amps Type Fuse Block FWP Type Fuse Block A70QS Type A70P A70QS Type A 4P1 4 1 3 3 FWP 10A14F CH142D FWP 10B m A70QS10 14F 1 A70P10 4 6P0 6 4 9 FWP 15A14F FWP 15B A70QS16 14F A70P15 4 010 10 8 2 FWP 20A14F FWP 20B m A70QS20 14F 1 A70P20 4 014 14 11 4 FWP 30A14F FWP 30B A70QS32 14F A70P30 4 019 19 15 5 FWP 40A14F FWP 40B A70QS40 14F A70QS40 4 027 37 22 1 FWP 63A22F CH222D FWP 60B A70QS63 22F 7009560 4 035 35 28 6 FWP 80A22F FWP 70B A70QS80 22F A70QS70 4 045 45 36 8 FWP 100A22F FWP 90B 700590 4 052 52 42 5 FWP 100A22F FWP 100B m 7005100 4 073 73 59 6 FWP 150A ST14 7005150 4 086 86 70 3 FWP 175A A70QS175 4K 100 100 817 FWP 200A A70QS200 4K 129 129 1105 4 FWP 250A A70QS250 4 B 167 167 1136 4 m FVVP 350A m 7005350 4 207 207 169 1 FWP 400A 7005400 4 250 250 204 3 FWP 500A ST38 72612 A70QS500 4K 330 330 269 6 FWP 700A 7005700 4 412 412 1336 6 m FVVP 800A 7005800 4 gt Frame Required on four quadrant drives only highly recommended
240. ault 4 6 Motor Overload alarm 4 10 Motor Overload fault 4 5 motor reaches maximum speed immediately 4 15 Motor Trq Ref 3 13 motor turning wrong direction 4 14 mounting dimensions 1 3 drive 1 2 lifting 1 5 weights 1 3 MtrOvrld Fit Cfg 3 58 MtrOvrid Status 3 55 MtrOvrid Type 3 16 N NET A LED 4 2 NET B LED 4 2 Nom Mtr Arm Amps 3 15 Nom Mtr Fld Amps 3 15 numbered parameter list 3 3 B 4 0 Ofis Accel Time 3 48 Opening Delay 3 35 Out Volt Level 3 18 Output Power 3 14 Output Voltage 3 14 Overcurrent fault 4 6 OverCurrent Thr 3 58 Overspeed fault 4 6 Overspeed Val 3 59 OverTemp Fit Cfg 3 58 OverVolt Fit Cfg 3 58 P Param Access Lvl 3 50 parameter access level change B 4 parameter files Applications 3 38 Communications 3 63 Dynamic Control 3 32 Input Output file 3 67 Monitor 3 11 Motor Control 3 15 Speed Command 3 26 Utility 3 50 Index 11 parameter groups Adaptv Regulator 3 36 3 37 Alarms 3 58 3 59 Analog Inputs 3 67 3 68 3 69 Analog Outputs 3 69 Autotune 3 22 3 23 Comm Control 3 63 Control Config 3 32 Current Meters 3 13 Datalinks 3 65 Diagnostics 3 51 3 52 3 53 3 54 3 55 3 56 Diameter Calc 3 44 3 45 3 46 Digital Inputs 3 70 3 71 3 72 Digital Outputs 3 73 3 74 3 75 3 76 Discrete Speeds 3 26 3 27 DPI Inputs 3 76 Drive Data 3 14 Drive Memory 3 50 3 51 Faults 3 56 3 57 Field Config 3 16 3 17 3 18 Limits 3 26 Load Limits 3 34 3 35 Masks amp Owners
241. aultCode 57 Drive Data 3 14 Direction Owner 603 Masks 8 Owners 3 64 Fdbk Device Type 414 1 Speed Feedback 3 20 DncrPosSpd 795 Diameter Calc 3 44 Feed Fwd PID 758 PID Control 3 41 DPI Baud Rate 589 Comm Control 3 63 Feedback Offset 563 Speed Feedback 3 21 DPI Fdbk Select 1321 Comm Control 3 63 Field Current 351 Current Meters 3 13 DPI P1 Select 1323 DPI Inputs 3 76 Field Econ Delay 1407 Field Config 3 18 DPI P2 Select 1324 DPI Inputs 3 76 Field Economy En 499 Field Config 3 18 DPI P3 Select 1325 DPI Inputs 3 76 Field Mode Sel 469 Field Config 3 17 DPI P4 Select 1326 DPI Inputs 3 76 Field Reg Enable 497 Field Config 3 17 DPI P5 Select 1327 DPI Inputs 3 76 Filt TorqCur Pct 928 Current Meters 3 13 DPI Port Sel 590 Comm Control 3 63 Final Diameter 1178 Winder Functions 3 47 DPI Port Value 1343 Comm Control 3 63 Fld Const 40 Pct 916 Field Config 3 18 Drive Alarm 1 1380 1 Alarms 3 59 Fld Const 70 Pct 917 Field Config 3 18 Drive Logic Rsit 1328 Diagnostics 3 55 Fld Const 90 Pct 918 Field Config 3 18 Drive Size 465 Drive Data 3 14 Fld Current Pct 234 orque Attribute 3 13 Drive Status 1 381 Diagnostics 3 52 Fld Reg Ki 92 Field Config 3 16 Drive Status 2 382 Diagnostics 3 53 Fld Reg Ki Base 98 Field Config 3 16 Drive Type 300 Drive Data 3 14 Fld Reg Kp 91 Field Config 3 16 Drive Type Sel 201 Motor Data 3 15 Fld Reg Kp Base 97 Field Config 3 16 Droop Filter 697 Load Limits 3 35 Fid Test Angle 168 est Generator 3 25 Droop Limit 700 Load Li
242. ay produce leakage current in the protective earthing conductor which exceeds 3 5 mA AC and or 10 mA DC The minimum size of the protective earthing grounding conductor used in the application must comply with local safety regulations for high protective earthing conductor current equipment Installation Requirements Related to EN 61800 3 and the EMC Directive The drive must be earthed grounded as described in this User Manual PowerFlex DC drives require the use of an external EMC filter in order to comply with the EMC directive 2004 109 EC and emission limits of EN 61800 3 2004 PowerFlex DC drives have only been tested and verified for compliance to the emission limits of EN 61800 3 2004 using the specific input filters and motor cable lengths listed in the table below Frame Rasmi Filter Max Motor Cable Length EN 61800 3 Emission Limit A RF 3xxx S El series 50m Category C3 B RF 3xxx MHU series 50m Category C2 C 3xxx MHU series 50m Category C3 TT Rasmi filters are manufactured by Rasmi Electronics Ltd Refer to the manufacturer s literature for details xxx designates the filter current rating Important Use of other filters should be verified in the application Output power wiring to the motor must employ cable with a braided shield providing 75 or greater coverage or the cables must be housed in metal conduit or equivalent shielding must be provided Continuous shielding must be provid
243. be set as indicated in Speed Feedback on page C 20 Fdbk Device Type The source of speed feedback e 1 Encoder Digital encoder jumpers S20 S21 e 2 DC Tach DC analog tachometer jumper S4 e 3 Armature Internal measurement of the armature voltage PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Values 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 Default Options Disabled Disabled Enabled 0 200 0 200 0 200 0 200 0 200 0 0 Par 162 rpm 0 100 0 001 0 250 S 1024 00 100 00 32770 00 Armature Encoder DC Tach Armature co no co n 750 756 750 756 750 756 750 756 750 756 750 756 1193 162 File MOTOR CONTROL Group Speed Feedback No 455 457 458 461 562 563 Parameter Name amp Description See page 3 2 for symbol descriptions Spd Fdbk Error 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 sp
244. bol descriptions Minimum Speed Defines the minimum speed of the drive This value applies to both directions of motor rotation for four quadrant drives 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 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 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 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
245. c St 800 Diameter Calc 3 44 Enable PD 770 PD Control 3 40 Diameter Filter 1162 Diameter Calc 3 45 Enable PI 769 PI Control 3 38 Diameter Reached 1159 Diameter Calc 3 45 Enable PID 1258 PID Control 3 43 Diameter Reset 1157 Diameter Calc 3 45 Encoder Counts 1022 Speed Feedback 3 22 Dig In Status 564 Digital Inputs 9 72 Encoder Err Chk 652 Speed Feedback 3 22 Dig In Term 1 565 Digital Inputs 3 72 Encoder Out Sel 1021 Speed Feedback 3 22 Dig In Term 10 574 Digital Inputs 3 72 Encoder PPR 169 Speed Feedback 3 20 Dig In Term 11 575 Digital Inputs 72 Encoder Speed 420 Speed Meters 3 12 Dig In Term 12 576 Digital Inputs 3 72 Encoder State 651 Diagnostics 3 54 Dig In Term 2 566 Digital Inputs 3 72 Fast Stop Status 1190 Diagnostics 3 55 Dig In Term 3 567 Digital Inputs 72 Fast Stop Time 38 Stop Modes 3 3 Dig In Term 4 568 Digital Inputs 3 72 Fault 1 Code 1351 Faults 3 57 Dig In Term 5 569 Digital Inputs 3 72 Fault 1 Time 1361 Faults 3 57 Dig In Term 6 570 Digital Inputs 72 Fault 10 Code 1360 Faults 3 57 Dig In Term 7 571 Digital Inputs 3 72 Fault 10 Time 1370 Faults 3 57 Dig In Term 8 572 Digital Inputs 3 72 Fault 2 Code 1352 Faults 3 57 Dig In Term 9 573 Digital Inputs 3 72 Fault 2 Time 1362 Faults 3 57 Dig Out Status 581 Digital Outputs 3 75 Fault 3 Code 1353 Faults 3 57 Digital In1 Sel 133 Digital Inputs 3 70 Fault 3 Time 1363 Faults 3 57 Digital In10 Sel 142 1 Digital Inputs 70 Fault 4 Code 1354 Faults 3 57
246. ce Config group 3 50 Reference Mask 3 63 reference materials p 2 Reference Owner 3 64 regulators fine tune C 36 Relay Out 1 Sel 3 75 Relay Out 2 Sel 3 75 relay outputs option definitions 3 74 terminals 1 31 remove HIM B 6 Reset Defaults 3 50 Reset Fld Curve 3 18 Reset to Defaults B 4 Restart Modes group 3 36 Roll Diameter 3 45 route control wire 1 50 UO wire 1 50 S S Curve Accel 1 3 34 S Curve Accel 2 3 34 S Curve Decel 1 3 34 S Curve Decel 2 3 34 S Curve Time 3 33 S M A R T list screen access B 2 use B 2 safety ground 1 12 save data B 4 Save HIM Ref 3 50 Save MOP Ref 3 50 scale blocks function C 21 link parameters C 22 Scale Blocks group 3 43 3 44 Scale1 Div 3 43 Scale1 In Abs 3 44 Scale1 In Max 3 43 Scale In Min 3 43 Scale1 In Off 3 44 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Scale1 Input 3 43 Scale1 Mul 3 43 Scale1 Out Off 3 44 Scale1 Output 3 43 Scale2 Div 3 43 Scale2 In Abs 3 44 Scale2 In Max 3 43 Scale2 In Min 3 43 Scale2 In Off 3 44 Scale2 Input 3 43 Scale2 Mul 3 43 Scale2 Out Off 3 44 Scale2 Output 3 43 Scale3 Div 3 43 Scale3 In Abs 3 44 Scale3 In Max 3 43 Scale3 In Min 3 43 Scale3 In Off 3 44 Scale3 Input 3 43 Scale3 Mul 3 43 Scale3 Out Off 3 44 Scale3 Output 3 43 Scale4 Div 3 43 Scale4 In Abs 3 44 Scale4 In Max 3 43 Scale4 In Min 3 43 Scale4 In Off 3 44 Scale4 Input 3 43 Scale4 Mul 3 43 Scale4 Out Off 3 44 Scale4 Outp
247. circuit protection fuses can be connected to an external device to provide indication that the fuses have opened or can be wired to drive digital input terminals and configured for Invert Flt Table 1 K Heatsink Cooling Fans and Fuse Signal Terminal Designations Terminal Description Maximum Voltage Maximum Current aa Single phase AC input power for cooling fans 1230V AC 1A S Internal armature fuse intervention signal 250V AC 1A Table 1 L Heatsink Cooling Fans and Fuse Signal Wire Sizes and Terminal Specifications Drive puren Rating a Code Wire Size and Type E Flexible Multi core Tightening Torque 230V 460V Terminals mm mm AWG Ibein All All All U3 V3 0 14 1 5 0 14 2 5 26 16 0 4 3 5 81 82 Refer to Standard Drive Catalog Number Explanation on page Preface 4 positions 8 9 and 10 for corresponding drive HP rating armature amp rating and field amp rating 2 See Cable and Wiring Recommendations on page 1 17 for more information Figure 1 31 Frame C Heatsink Cooling Fan and Internal Fuse Signal Terminal Block Locations A DANGER RISK OF ELECTRIC SHOCK DISCONNECT INPUT POVVER BEFORE SERVICING EQUIPMENT CI YOOX XY 82 35 36 75 76 7t U2 V2 PE PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 38 Installation and Wiring UO Wiring Observe the following points when installing VO wiring e Use cop
248. ck Loss 4 10 Fld Current Loss 4 10 FldCfg Cflct 4 10 Motor Over Temp 4 10 Motor Overload 4 10 Start At PowerUp 4 10 visual notification 4 3 Alarms group 3 58 3 59 Alpha Test 3 25 ALT key functions B 2 Analog Conflict alarm 4 9 Analog In1 Value 3 69 Analog In2 Value 3 69 Analog In3 Value 3 69 analog inputs configure C 4 signal comparison C 5 wiring 1 45 Analog Inputs group 3 67 3 68 3 69 analog outputs wiring 1 46 Analog Outputs group 3 69 analog tachometer DIP switch 1 40 ground 1 12 terminal block 1 50 Anlg In1 Cmp 3 68 Anlg Int Cmp Diy 3 68 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Index 2 Anlg Int Cmp Eq 3 68 Anlg In1 Cmp Err 3 68 Anlg In1 Config 3 67 Anlg In1 Filter 3 68 Anlg In1 Offset 3 68 Anlg In1 Scale 3 67 Anlg In1 Sel 3 67 Anlg In1 Target 3 68 Anlg In1 Tune 3 68 Anlg In2 Config 3 67 Anlg In2 Offset 3 68 Anlg In2 Scale 3 67 Anlg In2 Sel 3 67 Anlg In2 Target 3 68 Anlg In2 Tune 3 68 Anlg In3 Config 3 67 Anlg In3 Offset 3 68 Anlg In3 Scale 3 67 Anlg In3 Sel 3 67 Anlg In3 Target 3 68 Anlg In3 Tune 3 68 Anlg Out1 Scale 3 69 Anlg Out1 Sel 3 69 Anlg Out2 Scale 3 69 Anlg Out2 Sel 3 69 Anlg Out3 Scale 3 69 Anlg Out3 Sel 3 69 Anlg Out4 Scale 3 69 Anlg Out4 Sel 3 69 Anlg Tach Gain 3 21 Anlg1 Tune Scale 3 67 Anlg2 Tune Scale 3 67 Anlg3 Tune Scale 3 67 Applications file 3 38 Arm Current 3 13 Arm Current Pct 3 13 Arm Inductance 3 22 Arm Resistance 3 22 Arm Test
249. command is accepted after a power up If a Start Run or Stop Units S command is asserted before the time in this parameter expires the Start At Powerup function will be aborted 181 Adaptive Spd En Default 0 Disabled 182 Enables Disables adaptive speed regulation Options 0 Disabled 183 The adaptive speed regulator function enables different gains of the 1 Enabled o speed regulator depending on the speed or another variable Par 183 Adaptive Ref This allows optimum adaptation of the speed regulator to your specific application When adaptive speed regulation is disabled the regulator operates based on the settings in the individual regulation parameters T182 Adaptive Reg Typ Default D Speed 183 9 Selects the type of regulation used Options 0 Speed Speed The regulator parameters follow a speed reference 1 Adaptive Ref e Adaptive Ref The regulator parameters follow the reference produced by Par 183 Adaptive Ref 183 Adaptive Ref Default 1000 182 5 The variable reference that the speed regulator parameter will follow Min Max 32768 32767 o s when Par 182 Adaptive Reg Typ 1 Adaptive Ref Units rpm 8 184 Adaptive Spd 1 Default 20 34 183 Z A percentage of Par 45 Max Ref Speed or the maximum value of Par Min Max 0 00 200 00 186 sS 183 Adaptive Ref Units Ki o lt Parameter set 1 is valid below the value set in this
250. contactor if Fuses with Trip Indicator are used and wired to Inverting Fault input See Figure 1 13 on page 1 23 If regular fuses are used armature voltage TB can be used for overvoltage fault 8 The Enable input must be removed in order to preform a dynamic braking stop PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring 1 23 Figure 1 13 Power Wiring with Armature Output Fuses and Inverting Fault Status rel At A2 PowerFlex DC Drive Feo 337 on I O TB4 1 Customer supplied armature output fuses are required on four quadrant and are recommended on two quadrant Frame A and B drives See Drive Power Circuit Protection on page A 8 for fuse recommendations Fuses with Trip Indicator Switches are recommended for Inverting Fault protection when the motor will be Field Weakened and run above base speed 19 24V on I O TB2 2 par 139 Digital In7 Sel set to 64 Invert FIt Armature Converter Connections Terminals Description U VW Three phase AC input to the armature converter CD 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 o
251. counts for firmware version 2 005 and lower external reference and feedback speed values are scaled to rpm x 4 counts The value of parameter 45 Max Ref Speed rpm will determine the correlation scaling between DPI speed reference counts and rpms as well as the analog input reference values 10V Par 45 rpm All speed reference values are based on the value of Max Ref Speed The value of Max Ref Speed represents the maximum speed the motor can attain also known as Gear in Speed If field weakening is used Max Ref Speed would be set to the field weakened speed Otherwise the motor base speed is typically used The value of parameter 162 Max Feedback Spd rpm will determine the correlation scaling between DPI speed feedback counts and rpms as well as the DC tachometer values All speed feedback values are based on Max Feedback Spd Typically Max Feedback Spd is set to the same value as parameter 45 Max Ref Speed but this is not required because each is separately scaled to 25000 counts When armature voltage feedback is configured either directly Par 414 Fdbk Device Type 3 Armature or indirectly Par 458 SpdReg FB Bypass 1 Enabled Par 162 Max Feedback Spd must be set to the motor base speed rpm value associated with Par 175 Rated Motor Volt Using a DC tachometer requires that Par 162 Max Feedback Spd be set to the rpm value indicated by the maximum tachometer input voltage on t
252. ctive gt Ready FldAlphaTest EE O Torque Mode 9 Speed Mode N 9 Forced Spd gt C Auto Tuning gn 9 Ourr Limit o A D Bit Speed Threshold Default in parameters 101 Speed Thresh Pos clockwise rotation and 102 Speed Thresh Neg counter clockwise rotation 0 Above Thresh The speed has exceeded the set speed threshold e 1 Below Thresh The speed has not exceeded the set speed threshold Note This parameter can be assigned to a digital output At Speed Default to the speed reference specified in Par 118 Speed Reg In before the speed regulator and the ramp reference if enabled are applied The speed above and below the speed reference at which At Speed will indicate 1 Equal is set in Par 104 At Speed Error e 0 Not Equal The drive is not working at the set speed reference e 1 Equal The drive is working at the set speed reference Note This parameter can be assigned to a digital output It also corresponds to the At Speed indication on the Status Line of the HIM zero speed threshold as specified in Par 107 Speed Zero Level e 0 Equal The actual speed is below the value of Par 107 Speed Zero Level and Par 108 Speed Zero Delay has timed out e 1 Not Equal The actual speed is above the value of Par 107 Speed Zero Level Note This parameter can be assigne
253. d Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 20P UMOO 1E EN P June 2009 Supersedes 20P UMO01D EN P November 2008 Copyright 2009 Rockwell Automation Inc All rights reserved Printed in USA
254. d equipment damage and or personal injury Base Speed Base Speed Field Weaken 0 0 1 2 External Enabled Disabled Enabled Disabled Disabled Enabled ATTENTION Enabling forcing the minimum field current while the drive is running could result in excessive motor speed equipment damage and or bodily injury 3 17 Related 4 467 499 456 916 917 918 921 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 18 Programming and Parameters 2 2 olg Parameter Name amp Description s L z See page 3 2 for symbol descriptions Values 499 Field Economy En Default 1 Enabled 395 When this parameter is set to 1 Enabled and the value in Par Options 0 Disabled 468 107 Speed Zero Level is reached after the amount of time 1 Enabled 1407 specified in Par 1407 Field Econ Delay has elapsed the minimum field current set via Par 468 Min Fld Curr Pct is produced e Disabled Disables field economy e Enabled Enables field economy 916 Fld Const 40 Pct Default 40 00 469 O Current value at 40 of the rated field flux Min Max 0 00 100 00 Units 917 Fld Const 70 Pct Default 70 00 469 Current value at 70 of the rated field flux Min Max 0 00 100 00 Units 918 Fld Const 90 Pct Default 90 00 469 Current value at 90 of the rated field flu
255. d 6 111 Ref 7 Preset Spd 7 X MOP 0 Not Decrement Decrement 1 Decrement II Not Stop condition logic 0 must first be present before a 1 Start condition will start the drive The Start command acts as a momentary Start command A 1 will start the drive but returning to 0 will not stop the drive T is Start will not function if a digital input parameters 131 144 is programmed for 2 VVire Control option 5 Run 6 Run Forward or 7 Run Reverse 6 This Reference Select will not function if a digital input parameters 131 144 is programmed for Speed Sel 1 2 or 3 option 17 18 or 19 Note that Reference Selection is Exclusive Ownership see Reference Owner on page 3 64 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Supplemental Drive Information Figure A 2 Logic Status Word Logic Bits 15 14 13 12 11 10 Status Ready x A 7 Description 0 Not Ready 1 Ready x Active 0 Not Active 1 Active Command Direction 0 Reverse 1 Forward X Actual Direction 0 Reverse 1 Forward X Accel 0 Not Accelerating 1 Accelerating X Decel 0 Not Decelerating 1 Decelerating Alarm 0 No Alarm 1 Alarm Fault 0 No Fault 1 Fault At Speed 0 Not At Re
256. d Pct 3 27 Trim Torque 3 19 TrqTpr Enable 3 20 TrqTpr Limo 3 20 TrqTpr Lim 3 20 TrqTpr Lim2 3 20 TrqTpr Lim3 3 20 TrqTpr Lim4 3 20 TraTpr_Spd 3 20 TstGen Amplitude 3 24 TstGen Frequency 3 24 TstGen Offset 3 24 TstGen Output 3 24 UnderVolt Thresh 3 58 UserDefined0 3 60 UserDefined1 3 60 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Index 18 UserDefined10 3 60 UserDefined11 3 60 UserDefined12 3 60 UserDefined13 3 60 UserDefined14 3 60 UserDefined15 3 60 UserDefined2 3 60 UserDefined3 3 60 UserDefined4 3 60 UserDefined5 3 60 UserDefined6 3 60 UserDefined7 3 60 UserDefined8 3 60 UserDefined9 3 60 UsrDefBitWrdA 3 60 UsrDefBitWrdAO 3 61 UsrDefBitWrdA1 3 61 UsrDefBitWrdA10 3 61 UsrDefBitWrdA11 3 61 UsrDefBitWrdA12 3 61 UsrDefBitWrdA13 3 61 UsrDefBitWrdA14 3 61 UsrDefBitWrdA15 3 61 UsrDefBitWrdA2 3 61 UsrDefBitWrdA3 3 61 UsrDefBitWrdA4 3 61 UsrDefBitWrdA5 3 61 UsrDefBitWrdAG 3 61 UsrDefBitWrdA7 3 61 UsrDefBitWrdA8 3 61 UsrDefBitWrdA9 3 61 UsrDefBitWrdB 3 61 UsrDefBitWrdBO 3 62 UsrDefBitWrdB1 3 62 UsrDefBitWrdB10 3 62 UsrDefBitV rdB11 3 62 UsrDefBitWrdB12 3 62 UsrDefBitV rdB13 3 62 UsrDefBitV rdB14 3 62 UsrDefBitWrdB15 3 62 UsrDefBitWrdB2 3 62 UsrDefBitWrdB3 3 62 UsrDefBitWrdB4 3 62 UsrDefBitWrdB5 3 62 UsrDefBitWrdB6 3 62 UsrDefBitWrdB7 3 62 UsrDefBitWrdB8 3 62 UsrDefBitWrdB9 3 62 UsrDsplyDiv0 3 59 UsrDsplyMultO 3 59 UsrValDiv1 3 59 PowerFlex Digital DC Drive User M
257. d Ref B Pct 49 Speed Draw Out 1018 Encoder Speed 420 Speed Ref Out 385 Spd Draw Out Pct 1019 Tachometer Speed 1408 Spd Ref Out Pct 384 Speed Reg In 118 Ramp In 110 Speed Reg In Pct 117 Current Meters Spd Reg Out Pct 236 Field Current 351 Filt TorqCur Pct 928 Current Reg In 41 Fld Current Pet 234 Flux Ref Pct 500 Arm Current 200 Cur Lim Pos Out 10 Selected TorqRefl 14 Arm Current Pct 199 Cur Lim Neg Out 11 Motor Trq Ref 17 Drive Data FaultCode 57 Output Voltage 233 Drive Size 465 AC Line Voltage 466 Output Power 1052 Elapsed Lifetime 235 AC Line Freq 588 Drive Type 300 Software Version 331 Motor Control Motor Data Max Ref Speed 45 Rated Motor Volt 175 Nom Mtr Ed Amps 280 Max Feedback Spd 162 Nom Mir Arm Amps 179 Drv Fld Brdg Cur 374 Cong Field Config Field Reg Enable 497 Field Mode Sel 469 Fld Weaken Ratio 456 Field Economy En 499 Max Fld Curr Pct 467 Flux Filter BW 463 Field Econ Delay 1407 Min Fld Curr Pct 468 Torq Attributes Current Limit 7 Torque Ref 39 Zero Torque 353 Current Lim Pos 8 Trim Torque 40 Current Lim Neg 9 Torque Reduction 342 Speed Feedback Fdbk Device Type 414 Feedback Offset 563 SpdReg FB Bypass 458 Anlg Tach Gain 562 Spd Fdbk Control 457 Autotune Autotune Cur Lim 1048 Spd Reg Autotune 1027 Spd Tune Inertia 1030 CurrReg Autotune 452 Speed Tune Dir 1029 SpdTune Friction 1031 Arm Resistance 453 Speed Tune K
258. d are internally mounted on frame C 3 Customer supplied armature output fuses are required on four quadrant and are recommended on two quadrant Frame A and B drives See Drive Power Circuit Protection on page A 8 for fuse recommendations 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 23 4 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 23 through Figure 1 25 5 Optional armature voltage feedback sensing not needed with AC contactor if Fuses with Trip Indicator are used and wired to Inverting Fault input See Figure 1 13 on page 1 23 If regular fuses are used armature voltage TB can be used for overvoltage fault PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 22 Installation and Wiring ON 3 Phase AC line L3 Figure 1 12 Power Wiring with DC Output Dynamic Braking Contactor and a Dynamic Brake 34 on VO
259. d through a screw to the EMI shield Recommended tightening torque is 0 9 Nem 8 Ibein 7 Connect the Internal Interface cable to the DPI connectors on the Control board and the communication Adapter board UN Secure adapter to EMI Shield with four 4 screws Connect cable to DPI connectors on adapter and control board 8 Referto the Adapter s User Manual for network connection commissioning and configuration information PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installing a Communication Adapter E 7 9 Install the HIM Communication cable in reverse order or removal 10 Install the drive covers in reverse order of removal PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 E 8 Installing a Communication Adapter Notes PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 What This Option Board Provides UO Expansion Board Wiring Appendix F Optional Analog and Digital I O Expansion Circuit Board The optional I O Expansion circuit board is mounted on the Control board of the drive and provides these additional I O signals e Four 4 Digital Inputs e Four 4 Digital Outputs e Two 2 Analog Outputs Figure F 1 1 0 Expansion Board Mounting Location I O Expansion Board I O Expansion Board Control Board Standard Drive I O Terminal Blocks Terminal Blocks aper Table F A Recommended
260. d to a digital output preselected ramp 0 No Accel the drive is not accelerating using a preselected ramp 1 Accel the drive is accelerating using a preselected ramp Indicates if the drive is above or below the threshold speed specified Min Max Indicates whether or not the current speed of the drive corresponds Min Max At Zero Speed Default Indicates whether or not the actual speed of the motor is below the Min Max MOP Inc Active Default Indicates whether or not the drive is accelerating using the Min Max Read Only 0 1 Read Only 0 1 Read Only 0 1 Read Only 0 1 3 53 Related 101 102 103 104 105 107 108 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 54 Programming and Parameters g Parameter Name amp Description Z See page 3 2 for symbol descriptions Values 397 MOP Dec Active Default 2 ramp 0 No Decel The drive is not decelerating using a preselected ramp 1 Decel The drive is decelerating using a preselected ramp Spd Select 01 Default 17 Speed Sel 1 Refer to Option Definitions for Digital Inx Sel on page 3 71 for instructions on how to set digital input speed selects to different speed references 0 Digital input Digital Inx Sel set to 17 Speed Sel 1 not asserted 1 Digital input Digital Inx Sel se
261. d to indicate the state of a digital input Encoder State Default 0 Fault 4 This parameter be assigned to a digital output PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Indicates whether the drive is decelerating using the preselected Min Max Indicates the state of the assigned digital input Digital Inx Sel set to Min Max Indicates the state of the assigned digital input Digital Inx Sel set to Min Max Indicates the state of the assigned digital input Digital Inx Sel set to Min Max Indicates the state of the assigned digital input Digital Inx Sel set to Min Max Indicates the state of the assigned digital input Digital Inx Sel set to Min Max Indicates the connection status of the digital encoder or tachometer Min Max Read Only 0 1 Read Only 0 1 Read Only 0 1 Read Only 0 1 Read Only 0 1 Read Only 0 1 Read Only 0 1 Related 401 402 400 402 400 401 404 403 Programming and Parameters 3 55 Parameter Name amp Description See page 3 2 for symbol descriptions Values 1188 Accel Status Default Read Only ndicates the drive acceleration status Min Max 0 1 0 Off Drive not accelerating e 1 On Drive accelerating Note This parameter can be assigned to a digital output Decel Status Default Read Only ndicates the drive dec
262. default settings PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Check remote wiring Reduce the drive current limits or change the selected motor overload type to 0 StandardDuty Par 376 MtrOvrld Type Cycle power to the drive If the problem persists replace the Control board 1 Reset the fault 2 If this fault occurs again cycle power to the drive 3 If the problem persists replace the Control board Troubleshooting 4 5 Fault No Type Description Possible Cause s Action s Feedback Loss Fld Current Loss Hardware Fault Heatsink OvrTemp Interrupt Error Inverting Fault Main Contactor Motor Overload 91 6 130 8 131 3 10 10 12 7 Possible causes include The drive is not receiving a speed feedback signal due to e The conductors of the feedback signal have been interrupted Current from one or more of the feedback device wires is not reaching the drive Check the feedback device wiring e One or several encoder channels are missing conductor interruption no encoder power supply Check the encoder connections and power supply The measured speed from an encoder or analog tach differs from the calculated speed based on armature voltage by more than the value in Par 455 Spd Fdbk Error due to e The motor voltage is incorrect 1 Verify that Par 175 Rated Motor Volt is set correctly 2 Tun
263. drives Note This parameter can be assigned to an analog input Torque Ref First current reference value before any trim signals are incorporated as a percentage of the value set in Par 179 Nom Mtr Arm Amps For firmware version 2 005 or lower 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 Trim Torque 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 Torque Reduction 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 Par 7 Current Limit or Pars 8 Current Lim Pos and 9 Current Lim Neg 80 Par 13 Torq Red CurLim 70 f Par 342 Torque Reduction 0 Not Active the current limit 80 f Par 342 Torque Reduction 1 Active the current limit 70 96 Note This parameter can be assigned to a digital input Zero Torque Sets the reference value for the armature current Par 41 Current Reg
264. e P61 TstGen Offset TstGen Frequenc TstGen Frequency Default 0 10 Output frequency of the test generator Min Max 0 10 62 50 Units Hz TstGen Amplitude Default 0 00 Amplitude of the delta signal produced by the test generator Min Max 0 00 200 00 Units TstGen Offset Default 0 00 Offset of the test generator Min Max 200 00 Units PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Related 59 60 61 58 58 58 File MOTOR CONTROL Parameter Name amp Description See page 3 2 for symbol descriptions Alpha Test Diagnostic test mode that selects the SCR bridge to activate The SCR firing angles are specified by Pars 167 Arm Test Angle and 168 Fld Test Angle Important Alpha Test is an open loop diagnostic tool that requires a hardware Enable input be wired and functional at the terminal block Reading Alpha Test Mode on page C 1 is required before completing this test 0 Off 1 Armature Forward 2 Armature Reverse 3 Field Forward Note This parameter was added with firmware version 3 001 damage and or bodily injury PPP Arm Test Angle Sets the armature SCR firing angle for the Armature Forward and Armature Reverse tests 180 deg minimum voltage 5 deg maximum voltage Note This parameter was added with firmware version 3 001 Fld Test Angle Sets the field SCR firing angle for t
265. e 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 degrees from vertical In addition inlet air temperature must not exceed the product specification Figure 1 1 Drive Enclosure Minimum Mounting Clearances 500017 j 8 8 E 1 x 150 mm 6 0 in RR n m L 10 mm 10 mm s 10 mm gt 50 mm Airflow through 11 0 4 in 0 4 in 150 mm 6 0 in 0 4 in 2 0 in the drive must i not be impeded PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Mounting Dimensions and Weights Installation and Wiring 1 3 The PowerFlex DC drive is available in a NEMA UL Type Open IP20 enclosure Following all mounting instructions in order to ensure proper operation the container s of desiccants if any from the drive enclosure ATTENTION Remove all loose packing materials including before mounting and energizing the drive Figure 1 2 Frame A Approximate Dimensions A B C A1 B1 mm in mm in mm in mm in mm in 267 10 5 359 14 0 287 11 3 250 9 8 275
266. e automatically updated 3 If the drive is configured as an armature voltage regulator Par 414 Fdbk Device Type 3 Armature the calculated gains Pars 87 Spd Reg Kp and 88 Spd Reg Ki may have to be adjusted because this type of regulator voltage is less responsive than a true speed regulator that uses encoder or tachometer feedback Fine Tuning the Field Current Regulator Important In most cases motors with a direct current and an independent excitation work with a constant field Par 469 Field Mode Sel 0 Base Speed In this case it is not necessary to optimize the field current or armature voltage regulators PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 39 The procedure below is used for drives that use constant torque and power mixed armature and field regulation In these cases it is necessary to configure the field converter according to this method Important Do not issue a Start command to the drive during the field current regulator fine tuning procedure Follow the procedure below to fine tune and optimize the field current regulator Configure the following parameters LI Set Par 467 Max Fld Curr Pct 100 of the field rated current of the connected motor LI Set Par 468 Min Fld Curr Pct D Set Par 91 Fld Reg Kp 0 00 1 Set Par 92 Fld Reg Ki 0 00 Measure the field current using an analog output by set
267. e Blocks 3 44 Spd Reg Autotune 1027 Autotune 3 23 Scale2 Input 553 Scale Blocks 3 43 Spd Reg Ki 88 Speed Regulator 3 27 Scale2 Mul 555 Scale Blocks 3 43 Spd Reg Ki Base 94 Speed Regulator 3 27 Scale2 Out Off 560 Scale Blocks 3 44 Spd Reg Ki Outpt 100 1 Speed Regulator 3 28 Scale2 Output 554 Scale Blocks 3 43 Spd Reg Kp 87 Speed Regulator 3 27 Scale3 Div 1221 Scale Blocks 3 43 Spd Reg Kp Base 93 Speed Regulator 3 27 Scale3 In Abs 1226 Scale Blocks 3 44 Spd Reg Kp Outpt 99 Speed Regulator 3 28 Scale3 In Max 1222 Scale Blocks 3 43 Spd Reg Neg Lim 96 Speed Regulator 3 28 Scale3 In Min 1223 Scale Blocks 3 43 Spd Reg Out Pct 236 Speed Regulator 3 12 Scale3 In Off 1224 Scale Blocks 3 44 Spd Reg Pos Lim 95 Speed Regulator 3 27 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Programming and Parameters 3 81 Name No Group Page Name No Group Page Spd Select 0 400 Diagnostics 3 54 Torq Red CurLim 13 Load Limits 3 34 Spd Select 1 401 Diagnostics 3 54 Torque Const 1013 Autotune 3 23 Spd Select 2 402 Diagnostics 3 54 Torque Negative 347 Diagnostics 3 51 Spd Trq Mode Sel 241 Control Config 3 29 Torque Positive 346 Diagnostics 3 51 Spd Tune Inertia 1030 Autotune
268. e C Approximate Dimensions A AM B B1 B2 B3 B4 C mm in mm nl mm in mm in mm in mm fin mm in mm Un 521 20 5 499 19 7 511 20 1 400 15 7 1200 7 9 55 2 2 56 2 2 1416 16 4 gt RE JC a a m eH Ss m a m gt Ce Ce n H Le Co gt E o o S E gt Table 1 C Frame C Weights Weight Regenerative Drives Weight Non regenerative Drives Drive w ND Rating Code Drive Drive amp Packaging Drive Drive amp Packaging 230V 460V kg Ib kg Ib kg Ib kg Ib m 495 61 134 5 174 163 1 57 125 7 170 154 3 521 667 65 143 3 81 178 6 62 136 7 175 165 3 Lifting PovverFlex DC Drives The dimensions and vveights specified above must be taken into consideration vvhen mounting the device Use the proper equipment to safely lift and hold the vveight of the drive vvhile mounting ATTENTION To guard against possible personal injury or A 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 conductor
269. e Refer to Tune the Current Regulator on page 2 10 tuned The value of Par 584 OverCurrent Thr is too Increase the value of Par 584 OverCurrent Thr low accordingly Overspeed 25 2 Encoder or Tachometer feedback indicated a Remove the excessive load or overhauling conditions speed that is more than the value of Par 585 or increase the value of Par 585 Overspeed Val Overspeed Val Note Configurable with Par 585 Overspeed Val Params Defaulted 48 Q User parameters have been reset to their default Informational only values Port 1 5 Adapter 71 75 2 The communications card has a fault Check the DPI device event queue and corresponding fault information for the device Port 1 5 DPI Loss 81 85 The DPI port stopped communicating 1 Check the HIM connection 2 f adapter was not intentionally disconnected check the wiring to the port Replace the wiring port expander adapters Control Board or complete drive as required 3 If an adapter was intentionally disconnected and the bit for that adapter in Par 591 Logic Mask is set to 1 this fault will occur To disable this fault set the appropriate bit in Logic Mask for the adapter to 0 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Troubleshooting 4 7 Description Possible Cause s There is a fault in the 24V Control board supply the voltage is belovv the permitted value n most case
270. e machine pump and extruder pressure control and extruder temperature control applications Refer to the complete PID Control block diagram on page D 18 Examples are included below for configuring the following applications Speed winder with a load cell and tension control 1 Line speed signal see Configure a Line Speed Signal on page C 14 14 Closed loop dancer load cell feedback see Configure the Feedback Signal in the Follower Drive s on page C 15 3 Tension set point see Configure the Tension Set Point Signal in the Follower Drive s on page C 17 e Torque winder with a load cell and tension control D Line speed signal see Configure a Line Speed Signal on page C 14 11 Closed loop dancer load cell feedback see Configure the Feedback Signal in the Follower Drive s on page C 15 3 Tension set point see Configure the Tension Set Point Signal in the Follower Drive s on page C 17 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 C 14 Application Notes Configure a Line Speed Signal The line speed signal is the main reference for the speed or current regulator in the follower drive s In the Master drive e Configure an analog output for the main speed reference 1 Spd Ref Out In the Follower drive Set Par 80 Anlg In3 Sel to 12 UserDefined0 e Set Par 786 PID Source to 8695 503 8192 503 the parameter n
271. e screws that secure the bottom cover to the drive then slide the cover down and off the drive chassis Frame A ga 14 25 On frame B and drives loosen but do not remove the screws that secure the bottom cover to the drive then slide the cover down and off the drive chassis Frames B amp C Frame B shown T T e QUUUUUUUUUUUUUUUUUUUUUUUUUU Aad 8 8 Disconnect DPI cable _ 8 8 I LT s 0000000208000800000000 n Lo 7 X PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 E 4 Installing a Communication Adapter 4 Remove the top cover from the drive a For frame A drives press in on the sides at the bottom edge of the top cover and at the same time pull the cover toward you to pull it partially off the drive chassis Next at the top of the drive pull the cover forvvard avvay from the drive until the pins fit in the keyhole in the top of the cover then carefully lift the cover off of the drive chassis Important The HIM assembly is connected via a cable to the Control board and therefore will not pull free from the drive until disconnected See page E 6 for instructions Frame A
272. e 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 procedures beginning on page C 36 Fault STune Overspeed No 56 Description The measured motor speed is too high during the speed regulator auto tuning procedure Action Decrease the value of Par 1048 Autotune Cur Lim and repeat the auto tune procedure STune Stalled 57 The drive stalled during the Increase the value of Par 1048 speed regulator auto tuning Autotune Cur Lim and repeat the procedure auto tune procedure STune LoadHi 58 The loading torque value is too Decrease the load torque where high at zero speed to complete applicable and repeat the auto the speed regulator auto tuning tune procedure procedure STune Cur
273. e the motor e The ramp rate is too fast for the connected load 1 Reduce the load 2 Reduce the ramp rate e Field Weakening is set incorrectly Verify the that the value of Par 456 Fld Weaken Ratio is set properly Note Par 455 Spd Fdbk Error can be adjusted if needed to reduce fault occurrences Configure with Par 478 Spd Loss Fit Cfg The field current is too low Possible causes include e The field current regulator is currently not enabled Enable the field current regulator via Par 497 Field Reg Enable e The conductors in the field circuit have been interrupted Check the motor field wiring Measure the resistance of the motor and verify that it matches motor nameplate data e The field fuses are currently open Check the field fuses and replace as necessary Note Configure with Par 473 FldLoss Fit Cfg A non resettable hardware error has occurred The heatsink temperature is too high Possible causes include Cycle power to the drive If the problem persists replace the Control board e The surrounding air temperature is too high Lower the surrounding air temperature e The drive s cooling fans have failed drives gt 110 A Check the fan fuses and fans If the fan fuses have failed replace the fuses The fans have failed replace the fans e The heatsink is dirty A non resettable software error has occurred in the main application
274. e values of the appropriate parameters via the HIM The maximum possible analog value in this case 9 8V would have to be present at the terminal with a positive polarity PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 5 Analog Input Signal Comparison This feature provides an indication via the HIM or a digital output when the signal of analog input 1 has reached a limit above or below a set reference point Anlg Ini Err 0 Anlg In1 0 Anlg Int Cmp Eq Anlg Int Cmp 0 ms Calculations used to determine Pars1042 Anlg In Cmp and 1043 Anlg In Err Anlg Inl Cmp comparison value x 10000 max reference value e Anlg Inl Cmp Err tolerance value x 10000 max reference value Example 1 An application requires an indication via a digital output that the motor speed is within 100 rpms of 700 rpm e Par 45 Max Ref Speed 1500 rpm maximum reference value For Analog Input 1 10V or 20mA sets the maximum value of Par 44 Speed Ref A Par 45 Max Ref Speed Configure the following Set Par 70 Anlg Inl Sel Speed Ref A Set Digital Outx Sel Input1 Par 1045 Anlg Inl Cmp Eq Set Par 1042 Anlg Inl Cmp 4667 700 x 10000 1500 Set Par 1043 Anlg Inl Cmp Err 666 100 x 10000 1500 e Par 1045 Anlg In Cmp Eq 1
275. ecklist sete bet da a ue ee dune 2 1 Before Applying Power to the Drive 2 2 Verify all Drive Configuration Settings 2 2 Verify the Power Wiring llle hh hn 2 2 Verify the Control and VO Wiring 2 2 Applying Power to the Drive 2 3 Apply Voltage to the Control Circuits 2 3 Verify the Control Voltages 2 5 Load the Default Settings 2 5 Configure the Most Commonly Used Parameters 2 5 Tune the Current Regulator 2 10 Verify Motor Rotation and Run Feedback Polarity Checks 2 11 Configure the Speed Feedback Parameters 2 14 Tune the Speed Regulator 2 15 Verify Speed Reference Settings and Drive Operation 2 17 Programming and Parameters About Parametets ea a a 3 1 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Chapter 4 Appendix A Appendix B How Parameters are Organized 3 3 File Group Parameter Order 3 3
276. ed 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 Pet The default value is 300 seconds Par 469 Field Mode Sel select the desired field mode default O Base Speed constant field current O1 Field Weaken field weakening mode O2 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 2 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 1046 of the maximum value of the internal field converter configure the current feedback using DIP switch S14 Refer to Field Current Configuration on page 1 30 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 2 8 Drive Start Up 12 Access the Utility file and press Enter 13 Access the Alarms group and configure the following parameters m Par 481 UnderVolt Thresh Enter the value at which an AC under voltage condition will be detected by the drive default 200V on a 240V AC line and 400V on a 480V AC line
277. ed Ref A Pct Displays the first speed reference of the drive as a percentage of Par 45 Max Ref Speed This parameter can be sourced from Values Default Min Max Units Programming and Parameters Read Only 1 3 x Par 45 Max Ref Speed rpm many signals See block diagram Speed Reference Selection on page D 5 for possible source signals Notes This parameter can be assigned to an analog input The min and max values of this parameter were changed from 100 0 to 130 0 with firmware version 3 001 Speed Ref B Displays the second speed reference of the drive in rpm This parameter can be sourced from many signals See block diagram Speed Reference Selection on page D 5 for possible source signals Note The maximum value of this parameter was changed from Par 45 to 1 3 x Par 45 with firmware version 3 001 Speed Ref B Pct Displays the second speed reference of the drive as a percentage of Par 45 Max Ref Speed This parameter can be sourced from many signals See block diagram Speed Reference Selection on page D 5 for possible source signals Note The min and max values of this parameter were changed from 100 0 to 130 0 with firmware version 3 001 Ramp In Total reference value input to the ramp in rpm Notes This parameter can be assigned to an analog output The min and max values of this parameter were changed from 32766 to 8192 with firmware version 3 00
278. ed from the drive enclosure to the motor enclosure Both ends of the motor cable shield or conduit must terminate with a low impedance connection to earth At the motor end the motor cable shield or conduit must terminate in a shielded connector which must be properly installed in an earthed motor wiring box attached to the motor The motor wiring box cover must be installed and earthed PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring 1 15 All control I O and signal wiring to the drive must use cable with a braided shield providing 7546 or greater coverage or the cables must be housed in metal conduit or equivalent shielding must be provided When shielded cable is used only the drive end of the cable shield should be terminated with a low impedance connection to earth Motor cabling must be separated from control and signal wiring wherever possible Maximum motor cable length must not exceed the maximum length indicated in the table on page 1 14 for compliance with radio frequency emission limits for the specific standard and installation environment Pollution Degree Ratings According to EN 61800 5 1 Pollution Degree Description 1 No pollution or only dry non conductive pollution occurs The pollution has no influence 2 Normally only non conductive pollution occurs Occasionally however a temporary conductivity caused by condensation is to be ex
279. edback loss using parameter 478 Spd Loss Fit Cfg Added an Attention statement to parameter 242 Speed Reg En to warn against 3 30 the dangers of improper setting of speed and voltage parameters or not providing overspeed protection when operating the drive as a torque current regulator Updated the description for parameter 1204 Line Spd Source 3 48 Updated the description for parameter 1210 W Target 48 Added an Attention statement to parameter 478 Spd Loss Fit Cfg warning against 3 58 the improper setting of this parameter if speed regulator feedback switch over is not enabled Par 458 SpdReg FB Bypass Added scaling values for the Anlg Outx Sel parameters Pars 66 69 3 69 Updated the description for the digital input Enable option 71 Updated the description of Fault 64 Drive Overload to reflect a current overload 1 4 4 condition based on the rated motor current PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 soc iii Change Page s Updated the drive s Maximum Short Circuit rating specification A 3 Added the resolution for the Analog Inputs and Analog Outputs A 4 Updated the quantity of fuses identified in the following tables A 10 A 15 Table A E Recommended Field Circuit Fuses 230V AC Input Frame A and B e Table A F Recommended Field Circuit Fuses 460V AC Input Frame A and B e Table A G Recommended Field Circuit Fuse
280. ee J ieuondo sndno Hoyeuy uoisuedxz 1 nooy 4 SS ane a zov i ez i 1 noo v 22 e 214 Var C les 110 7 2 l v v n e OO UI sindino bojeuy 413 dui ut Buy 6 014 JOgejeduioo MOpUL M duo Lu uy 27014 s 1944 Lu Bue 262d SES Lu Buy Zld f s ul Suy Old jeybiq wol4 o Buy 9624 A r x X JesyO Lui Duy vld g rld peu edA du d MH e DYUOD z l DIU 9 d z indul Bopeuy mp ul Bopeuy v0vld Pu SHON Sun LU Bjuy 6924 areo euni d S ndino sindu bojeuy Tu DYUOD EU Duy Md du Bopeuy y90lg euren 5000 boje PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 D 5 Control Block Diagrams weeg uoneiousn peeds oL ps ds for o o ol l v G Jod 140 t uod Idd eouoJojoH uod 140 Z uod 40 eouoj9jaH HOd 140 jeu enuen aL 2924 1 peeds 195914 0914 9 paads 814 6914 eui 9990 dOW 064 185814 8914 p poads 185814 1614 p d s lq 9514
281. eed a relationship between motor speed and armature voltage is obtained If the difference is larger than the value set in Par 455 Spd Fdbk Error a Feedback Loss condition set in Par 478 Spd Loss Fit Cfg will be activated Spd Fdbk Control Enables Disables speed feedback control This function affects the comparison made between the armature voltage and the speed value measured by the encoder or tachometer When the value set in Par 455 Spd Fdbk Error is exceeded a Feedback Loss condition set in Par 478 Spd Loss Fit Cfg will be activated The speed feedback control function is automatically disabled when armature voltage feedback is selected Par 414 Fdbk Device Type 3 Armature AN SpdReg FB Bypass Enables Disables an automatic switch to armature voltage feedback when a Feedback Loss F91 condition occurs due to an encoder or tachometer feedback signal loss When this parameter is set to Enable Par 478 Spd Loss Fit Cfg must be set to 1 Alarm to allow the motor to continue to run with no speed feedback signal 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 Spd Fdbk Invert Enables Disables speed feedback negation Note This parameter was added with firmware version 3
282. eedback Polarity Checks page 2 11 Configure the Speed Feedback Parameters page 2 14 Tune the Speed Regulator page 2 15 Oc D LU LL D CU O Verify Speed Reference Settings and Drive Operation page 2 17 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 2 2 Drive Start Up Before Applying Power to the Drive 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 5 the rated field current specified on the motor nameplate Refer to Table 1 H on page 1 30 Verify all switch settings S9 S10 and S11 for the analog inputs Refer to Table 1 M on page 1 39 Verify all DIP switch and jumper settings for the digital encoder or analog tachometer feedback device Refer to Table 1 M on page 1 39 and Figure 1 33 on page 1 40 incorrectly or the tachometer is wired incorrectly Failure to ATTENTION The Drive can overspeed if DIP switch S4 is set observe this precaution could result in damage to or destruction of the equipment 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 19 for further information armature output terminals personal injury and or equipment ATTENTION Do not connect any ex
283. efault 78 79 Motor thermistor connections PTC 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 OverTemp Fit Cfg If a temperature sensor is not used a 1k ohm resistor must be connected 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 in the Motor Windings 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 rec
284. elded a value outside the recommended setting Refer to Manually Adjusting the Current Regulator Tune Settings on page C 37 e Field current regulator L1 A fine tuning procedure is available below Refer to Fine Tuning the Field Current Regulator on page C 38 e Speed regulator The speed auto tuning procedure is run via Par 1027 Spd Reg Autotune Refer to Chapter 2 Drive Start Up Tune the Speed Regulator on page 2 15 A fine tuning procedure is available below Refer to Fine Tuning the Speed Regulator on page C 41 e Armature voltage regulator A fine tuning procedure is available below Refer to Fine Tuning the Voltage Regulator in the Field Converter on page C 43 The fine tuning procedures are included below In order to obtain a step function the internal Test generator can be used The goal of the fine tuning procedures is to obtain an optimal step response For example it is recommended that you directly measure the step response for the field current regulator The field current can be directed to an analog output on the Terminal Block with a 2ms sampling rate Using the Test Generator The Test Generator function creates signals with a rectangular wave form based on a specific frequency and amplitude The frequency and amplitude can be added to a configurable offset value if needed Par 58 TstGen Output determines which regulator input signal reference is used torque current field ra
285. elect 3 76 DPI P4 Select 3 76 DPI P5 Select 3 76 DPI Port Sel 3 63 DPI Port Value 3 63 Drive Alarm 1 3 59 Drive Logic Rslt 3 55 Drive Size 3 14 Drive Status 1 3 52 Drive Status 2 3 53 Drive Type 3 14 Drive Type Sel 3 15 Droop Filter 3 35 Droop Limit 3 35 Droop Percent 3 35 Drv Fld Brdg Cur 3 16 Dynamic Friction 3 47 edit B 5 Elapsed Lifetime 3 14 Enable Droop 3 35 Enable PD 3 40 Enable PI 3 38 Enable PID 3 43 Encoder Counts 3 22 Encoder Err Chk 3 22 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Index 14 Encoder Out Sel 3 22 Encoder PPR 3 20 Encoder Speed 3 12 Encoder State 3 54 Fast Stop Status 3 55 Fast Stop Time 3 35 Fault 1 Code 3 57 Fault 1 Time 3 57 Fault 10 Code 3 57 Fault 10 Time 3 57 Fault 2 Code 3 57 Fault 2 Time 3 57 Fault 3 Code 3 57 Fault 3 Time 3 57 Fault 4 Code 3 57 Fault 4 Time 3 57 Fault 5 Code 3 57 Fault 5 Time 3 57 Fault 6 Code 3 57 Fault 6 Time 3 57 Fault 7 Code 3 57 Fault 7 Time 3 57 Fault 8 Code 3 57 Fault 8 Time 3 57 Fault 9 Code 3 57 Fault 9 Time 3 57 Fault Arm Amps 3 57 Fault Clear 3 56 Fault Clr Mask 3 63 Fault Clr Mode 3 56 Fault Clr Owner 3 64 Fault Field Amps 3 57 Fault Speed 3 57 Fault Voltage 3 57 FaultCode 3 14 Fdbk Device Type 3 20 Feed Fwd PID 3 41 Feedback Offset 3 21 Field Current 3 13 Field Econ Delay 3 18 Field Economy En 3 18 Field Mode Sel 3 17 Field Reg Enable 3 17 Filt TorqCur Pct 3 13 Final Diameter 3 47 Fld Const 40
286. eleration status Min Max 0 1 e 0 Off Drive not decelerating 1 On Drive decelerating Note This parameter can be assigned to a digital output Fast Stop Status Default Read Only ndicates the drive fast stop status Min Max 0 1 0 Off Drive is not fast stopping e 1 On Drive is fast stopping MtrOvrld Status Default Read Only 376 Current percentage of motor overload 100 motor overload The Min Max 0 100 Vo current percentage displays regardless of the configuration of the Units motor overload condition Par 479 MtrOvrld Fit Cfg Fault Alarm or Ignore Note This parameter was added with firmware version 3 001 Drive Logic Rslt The final logic command resulting from the combination of all DPI and discrete inputs This parameter has the same structure as the product specific logic command received via DPI and is used in peer to peer communications For each bit 1 Condition true and 0 Condition false Bit 0 Stop Stop command Bit 1 Start Start command Bit 2 Jog Jog command Bit 3 Clear Faults Clear faults command Bit 4 Forward Forward direction command Bit 5 Reverse Reverse direction command Bit 6 Local Local control command Bit 7 MOP Inc MOP Increment command Bit 8 Accel 1 Acceleration Rate 1 command Bit 9 Accel 2 Acceleration Rate 2 command Bit 10 Decel 1
287. ence sampling parameter used for inertia compensation and line speed reference Ref Speed Gain Gain value for the line speed reference The value of this parameter depends on the value of Par 1284 Ref Spd Source The value of Ref Speed Gain is used to obtain a line speed reference 100 at its maximum value Ref Line Speed Line speed percentage Static F Zero Enables Disables friction compensation e Enabled The fiction compensation value is added to all speed values e Disabled The static friction compensation value is added to Par 1286 Ref Line Speed 1 596 Values Default Options Default Options Default Min Max Units Default Min Max Units Default Min Max Units Default Options Default Min Max Default Min Max Default Min Max Units Default Options Programming and Parameters Disabled Disabled Enabled Disabled Disabled Enabled Read Only 48192 rpm 0 0 100 0 Disabled Disabled Enabled ojo 65535 0 0 32767 Read Only 0 00 150 00 Disabled Disabled Enabled 3 49 Related 1160 1160 1284 1286 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009
288. ench German ltalian Portuguese or Spanish The drive ships with the default language options of English and Spanish only The additional language files can be downloaded at http www ab com support abdrives webupdate powerflexdc html Note This parameter was added with firmware version 3 001 Torque Positive Indicates whether the drive is operating with a positive torque reference e 1 Active The drive is operating with a positive torque reference The motor is accelerating in the forward direction or decelerating in the negative direction and Par 20 Ramp Delay has timed out 0 Not Active The drive is not operating with a positive torque reference Note This parameter can be assigned to a digital output Torque Negative Indicates whether the drive is operating with a negative torque reference e 1 Active The drive is operating with negative torque reference The motor is accelerating in the reverse direction or decelerating in the forward direction and Par 20 Ramp Delay has timed out 0 Not Active The drive is not operating with negative torque reference Note This parameter can be assigned to a digital output and is used for four quadrant drives only CurrLimit Active Indicates whether or not the drive is working within the set current limits e 1 Active The drive is currently in a current limited state 0 Not Active The drive is not in a current l
289. ent on page 3 70 for this option Freeze Ramp Holds the speed ramp at the present value Par 373 Freeze Ramp UsrDefinedA0 7 Writes the value of the digital input to Pars 520 UsrDefBitWrdAO 527 UsrDefBitWrdA7 Droop Enable Enables disables the Droop function 699 Enable Droop PD Enable Enables disables the PD block of the PID regulator Par 770 Enable PD PI Cent vs0 1 In combination the digital inputs set to PI Central vs0 and PI Central vs1 through binary selection determine which of the four possible output values is used as the initial level of the integral component corresponding to the initial diameter of the PI block Refer to Par 780 PI Central vs01 for binary selection values Diam Calc When asserted initiates the diameter calculation Par 794 Diameter Calc Diam Reset Sets the diameter starting value to the value in Par 1168 Diam Preset Sel DiamCalc Dis Enables disables the diameter calculation Par 1161 Diameter Calc Dis Torq Wind En Enables disables the Center wind function Par 1209 Torque Winder En Speed Match When asserted issues the coil launch phase command for automatic switching Par 1195 Speed Match Diam I D En Enables disables the ability of the diameter calculation to increase for an unwider or decrease for a winder Par 1205 Diam Inc Dec En Wind Unwind Sets the value of Par 1187 Winder Type to 0 Winder or 1 Unwinder Diam Preset0 1 Selects the v
290. entral vs0 780 PI Init Prop Gn 793 PD Control Enable PD 770 PD Deriv Filter 767 PD Deriv Gain 2 789 PD Output PID 421 PD Prop Gain 1 768 PD Prop Gain 3 790 PD Deriv Gain 1 766 PD Prop Gain 2 788 PD Deriv Gain 3 791 PID Control Enable PID 1258 PID Setpoint 0 760 PID Target 782 Real FF PID 418 PID Setpoint 1 761 PID Source 786 PID Steady Delay 731 PID Setpoint Sel 762 PID Source Gain 787 PI Init Intgl Gn 734 PID Feedback 763 PID Accel Time 1046 PID Clamp 757 PID Output Sign 772 PID Decel Time 1047 Feed Fwd PID 758 PID Output Scale 773 PID Error Gain 1254 PID Error 759 PID Output 774 Scale Blocks Scale1 Input 484 Scale3 Input 1218 Scale5 Input 1236 Scale1 Output 485 Scale3 Output 1219 Scale5 Output 1237 Scale1 Mul 486 Scale3 Mul 1220 Scale5 Mul 1238 Scale1 Div 487 Scale3 Div 1221 Scale5 Div 1239 Scale1 In Max 488 Scale3 In Max 1222 Scale5 In Max 1240 Scale In Min 489 Scale3 In Min 1223 Scale5 In Min 1241 Scale1 In Off 490 Scale3 In Off 1224 Scale5 In Off 1242 Scale1 Out Off 491 Scale3 Out Off 1225 Scale5 Out Off 1243 Scale1 In Abs 492 Scale3 In Abs 1226 Scale5 In Abs 1244 Scale2 Input 553 Scale4 Input 1227 Scale6 Input 1245 Scale2 Output 554 Scale4 Output 1228 Scale6 Output 1246 Scale2 Mul 555 Scale4 Mul 1229 Scale6 Mul 1247 Scale2 Div 556 Scale4 Div 1230 Scale6 Div 1248 Scale2 In Max 557 Scale4 In Max 1231 Sca
291. er Note This parameter can be assigned to an analog output as a percentage of Par 1153 Max Diameterl Line Spd Threshl Line speed detecting threshold When the value of Par 1286 Ref Line Speed is lower than the value of Line Spd Threshl the diameter calculation stops and the diameter is kept at a constant value When the value of Ref Line Speed overcomes the threshold the diameter calculation is enabled with an initial filter corresponding to the value in Par 1206 Diam init filter for the time set in Par 1207 Diam stdy delay At the end of this time the filter will be set to the value of Par 1162 Diameter Filter Line Spd Gain Calibration value used to obtain Par 1160 Line Speed Pct 100 at its maximum value The value of this parameter depends on the value of Par 1284 Ref Spd Source Line Spd Gain 32768 x 16384 maximum value of Ref Spd Source x 8 1 Diameter Reset Diameter reset When this parameter is set to 1 the diameter starting value is set to the value in Par 1168 Diam Preset Sel Diam Threshold Diameter threshold as a percentage of Par 1153 Max Diameter Par 1159 Diameter Reached is set to 1 when the value in this parameter is exceeded Diameter Reached Indication that the diameter threshold set in Par 1158 Diam Threshold has been exceeded 0 The diameter threshold has not been exceeded e 1 The diameter threshold has been exceeded Line Speed Pct
292. er 1177 Winder Functions 3 47 MOP Inc Active 396 Diagnostics 3 53 nt Acc Calc En 1183 Winder Functions 3 47 MOP Mask 598 Masks amp Owners 3 63 nversion In 1 1276 1 Digital Inputs 3 72 MOP Owner 607 Masks amp Owners 3 64 nversion In 10 1388 1 Digital Inputs 3 72 MOP Select 1375 1 Reference Config 3 50 nversion n 11 1389 1 Digital Inputs 3 72 Motor Trq Ref 17 Current Meters 3 1 nversion In 12 1390 Digital Inputs 3 72 MtrOvrld Fit Cfg 479 Alarms 3 58 nversion In 2 1277 Digital Inputs 3 72 MtrOvrld Status 1290 Diagnostics 3 55 Inversion In 3 1278 Digital Inputs 72 MtrOvrid Type 376 Motor Data 3 34 nversion In 4 1279 1 Digital Inputs 3 72 Nom Mir Arm Amps 179 Motor Data 3 15 nversion In 5 1280 Digital Inputs 3 72 Nom Mtr Fld Amps 280 Motor Data 3 15 Inversion In 6 1281 Digital Inputs 3 72 Offs Accel Time 1198 Winder Functions 3 48 Inversion In 7 1282 Digital Inputs 3 72 Opening Delay 1263 Stop Modes 3 35 nversion In 8 1283 1 Digital Inputs 3 72 Out Volt Level 921 Field Config 3 18 nversion In 9 1387 Digital Inputs 3 72 Output Power 1052 Drive Data 14 nversion Out 1 1267 1 Digital Outputs 3 75 Output Voltage 233 Drive Data 3 14 nversion Out 2 1268 1 Digital Outputs 3 75 OverCurrent Thr 584 Alarms 3 58 nversion Out 3 1269 1 Digital Outputs 3 7 Overspeed Val 585 Alarms 3 59 nversion Out 4 1270 1 Digital Outputs 3 75 OverTemp Fit Cfg 365 Alarms 3 58 Inversion Out 5 1271 1 Digital Outputs 3 75 OverVolt Fit Cfg 203 Alarms 3 58 Invers
293. er 241 Spd T q Mode Sel is used to choose whether the drive operates as a speed regulator a torque regulator or a combination of the two Each mode is discussed in more detail below Refer to the Torque Mode Selection block diagram on page D 9 for more information Note This function is only available for firmware version 3 001 Zero Torque Mode Zero torque current is allowed when Par 241 Spd T q Mode Sel is set to 0 Zero Trq Ref Operation in zero torque mode allovvs the motor to be fully fluxed and ready to rotate vyhen a speed command or torque command is given This mode can be used for a eyclical application vvhere throughput is a high priority The control logic can select zero torque during the rest portion of a machine cycle instead of stopping the drive When the cycle start occurs instead of issuing a start to the drive a speed regulation mode can be selected The drive vvill then immediately accelerate the motor without the need for flux up time Important Zero Torque may excessively heat the motor if operated in this mode for extended periods of time No load or flux current is still present vvhen the drive is operating in zero torque mode A motor vvith an extended speed range or separate cooling methods blovver may be required Speed Regulation Mode When Par 241 Spd Trq Mode Sel is set to 1 Speed Reg the drive and motor are operated in speed mode The torque command changes as needed
294. er terminals 1 24 dimensions 1 5 PE ground terminal 1 24 weights 1 5 Freeze Ramp 3 34 Friction 3 23 functions adaptive speed regulator C 22 ALT key B 2 current speed curve C 6 droop C 9 PID C 17 scale blocks C 21 speed draw C 28 speed regulation C 22 speed threshold indicators C 25 speed up C 25 speed zero C 27 fuses control power circuit 1 16 A 16 frame A A 8 frame B A 8 frame C A 12 input power circuit 1 16 A 8 G Gear Box Ratio 3 44 ground encoder 1 12 PE 1 12 power feeder 1 12 requirements 1 11 safety 1 12 tachometer 1 12 typical scheme 1 11 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 H Hardware Fault 4 5 Heatsink Over Temperature fault 4 5 HIM ALT key B 2 connection B 1 display B 1 DPI Port 1 B 1 DPI Port 2 B 1 DPI Port 3 B 1 DPI Port 5 B 1 edit parameters B 5 indicators 4 3 install B 6 LEDs 4 2 menu structure B 3 menus B 4 remove B 6 view parameters B 5 HIM menus Device Select B 4 Diagnostics B 4 Memory Storage B 4 Parameter B 4 Preferences B 5 Reg Error 3 23 IO converter circuit board install G 1 terminal block G 2 wire size G 2 wiring diagrams G 3 UO expansion circuit board install F 1 terminal block F 2 wire F 1 wire size F 1 wiring diagram F 2 UO wire routing 1 50 Inertia 3 23 Inertia C Filter 3 23 nertiaCompAct 3 31 InertiaCompVar 3 31 nitial Diameter 3 47 input contactors A 18 line reactor A 1
295. es are labeled FU1 and FV1 on the drive Table A H Recommended Field Circuit Fuses 460V AC Input Frame C Regenerative and Non Regenerative Drives Drive Fuse Code FS3 See Figure A 6 on page A 12 and Current Figure A 7 below for location Rating ul Ferraz Shawmut Code Amps Type Quantity Bussmann Gould Shawmut SIBA 495 20 10x 38mm 2 FWC 25A10F A60Q25 2 60 033 05 25 Il Internal fuses provided with the drive These fuses are labeled FU1 and FV1 on the drive Figure A 7 Frame C Field Circuit Fuse Location Field circuit fuses are located on the Control EMI shield which holds the Control board Note Drive shown with front covers removed PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 A 14 Supplemental Drive nformation Table A I Recommended Leg Fuses 230V AC Input Frame C Regenerative Drives Oniy Drive Fuse Code FS4 See Figure A 6 on page A 12 and Figure A 8 below for location Current AC Bussmann Ferraz Shawmut Gould Shawmut SIBA Rating DC Une Code Amps Amps Quantity Square Body Flush End Contact 521 170M5464 switch 170 0069 6 9 URD 32 TTF 800 switch MS3 V1 5BS 120 671 32 800 switch 2800104 Table AJ Recommended Leg Fuses 460V AC Input Frame C Regenerative Drives Only Drive Fuse Code FS4 See Figure A 6 on page A 12 and Figure A 9 on page A 15 for location Current Buss
296. es 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 o lo io ee fo fo lee 2 F 19 WW ile 2 lf 2 2 22 2 25 ES S o o o lo o o lolo A nm na a Aa g 2 o o lo lg lols lolo lo ja a la ja amp 9 je je E je m je je AO O O O O an Defaut x X X X X Xx X x x x d II Bit 15 14 13 1211109 8 7 6 5 4 B 2 H 40 Logic Mask Act Read Only 591 Indicates the status of the logic mask for the DPI ports When bit 15 is set network security is controlling the logic mask instead of Par 591 Logic Mask 0 Control Masked 1 Control Permitted x Reserved I q o le le le Jo mu LO r Je 85 55 5155151518 5151551512 S A c ja ja ja ja ac ga m ja ja es 8 5 515 3 3 S 515 n au axa s lt lt lt lt lt lt lt A A A A A j Defaut 0 x x x x x x x x x d 1 1 14 14 dH Bit 15 14 13 1211109 8 7 6 5 4 B 2 1 40 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 66 Programming and Parameters 5 a o e g Parameter Name amp Description s e See page 3 2 for symb
297. et parameter 1391 ContactorControl to 1 AC Cntctr default value D LI Set one Relay Out x Sel parameter and one Digital Inx Sel parameter to Contactor default value for parameters 1392 Relay Out 1 Sel and 140 Digital In8 Sel e When only a DC contactor is used C1 Set parameter 1391 ContactorControl to 3 DC Cntetr Li Set one Relay Out x Sel parameter and one Digital Inx Sel to Contactor default value for parameters 1392 Relay Out 1 Sel and 140 Digital In8 Sel When an AC contactor and dynamic brake contactor are used Set parameter 1391 ContactorControl to AC Cntctr DB 3 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 l Set one Digital Inx Sel parameter to Contactor default value for parameter 140 Digital In8 Sell II 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 20 001 June 2009 1 10 Installation and Wiring e When a DC contactor and dynamic brake contactor are used L1 Set parameter 1391 ContactorControl to DC Cntctr DB D 1 Set one Relay Out x Sel parameter 1392 Relay Out 1 Sel or 629 Relay Out 2 Sel to Contactor and the other re
298. eters a d 45 Max Ref Speed Enter the motor nameplate base speed 162 Max Feedback Spd Enter the motor nameplate base speed 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 9096 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 14 Refer to Field Current Configuration on page 1 30 280 Nom Mtr Fld Amps Enter the rated motor nameplate field current PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Drive Start Up 2 7 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 Othervvise 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 desir
299. etween Classes Steel Conduit Tray Wiring Category Class Signal Definition Signal Example 1 2 3 4 5 6 Povver 2 AC Power less 460V 3 Ph AC 3 6 in than 600V Lines 76 152 mm Control 6 24V AC DC PLC 1 0 3 6 in Logic 9 76 152 mm PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 1 18 Installation and Wiring Spacing Notes 1 Both outgoing and return current carrying conductors are to be pulled in same conduit or laid adjacent in tray 2 Cables of the following classes can be grouped together b c d e som Ro Conduit Spacing 115V 1 in 25 mm a Class 1 Equal to or above 601 V Classes 2 3 and 4 may have their respective circuits pulled in the same conduit or layered in the same tray Classes 5 and 6 may have their respective circuits pulled in the same conduit or layered in the same tray Note Bundle may not exceed conditions of NEC 310 Classes 7 and 8 may have their respective circuits pulled in the same conduit or layered in the same tray Note Encoder cables run in a bundle may experience some amount of EMI coupling The circuit application may dictate separate spacing Classes 9 10 and 11 may have their respective circuits pulled in the same conduit or layered in the same tray Communication cables run in a bundle may experience some amount of EMI coupling and corresponding communication faults The applica
300. eupds 86 4 ueuw Deen aie sur ssedig ssed g dy R aseg d p ds yoolg Id Jo1ejnbeg peeds PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 D 13 Control Block Diagrams Jeu enndepy 10d l Det pds uo 6814 2114 eAndepy p ds JL 0187 p ds U3 0187 pds 6214 uz 0197 jou 095 jeu peeds jeu dwey veld 0 Jed 18497 0187 Jed peeds 4907 aw ued d 0187 pds 9214 uJ d 0187 pas Seld z pds 9814 21507 0192 peads gules exidepy DOE dan 6614 2614 2120 ondepy quie d anndepy V ld 0614 jules eandepy Lures q anndepy 6814 8814 Z tor enndepy 1814 uer 9814 21607 0197 poods pue Aldepy poods PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 Control Block Diagrams D 14 uondo x9eqpee4 SJojouleJed J0JO 0 05 F Wr enbior qur enbjoj Durereues x 0011010 1 pds yoeqp i xen Hatz wrung pig aen pads pds yoeqpae xeyy nt wrang pig pmd ung Bpig pmd puewwog uononpeg queuing wiy 0024 Jod jueun UU 6614 abeyo ndino 6624 91601 dnpulyu nuy s pni
301. f this type of alarm is left uncorrected a fault condition may eventually occur 2 T is type of alarm is always enabled and will prevent the drive from starting until the alarm condition is corrected PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 4 2 Troubleshooting Drive Status The condition or state of your drive is constantly monitored Any changes will be indicated through the LEDs and or the HIM if present Figure 4 1 Drive Status Indicators e PORT O MOD O NETAO NETBO Po werFlex Osrs C Allen Bradley Name Color State Description STS Green Flashing Drive ready but not running and no faults are present Status Steady Drive running no faults are present Yellow Flashing A condition exists that is preventing the drive from Drive Stopped starting Check parameters 1403 Start Inhibits and or 1380 Drive Alarm 1 Flashing An intermittent type 1 alarm condition is occurring Drive Running Check parameter 1380 Drive Alarm 1 Refer to Fault Descriptions on page 4 4 and or Alarm Descriptions on page 4 9 Steady A continuous type 1 alarm condition exists Check Drive Running parameter 1380 Drive Alarm 1 Refer to Fault Descriptions on page 4 4 and or Alarm Descriptions on page 4 9 Red Flashing A
302. fBitWrdA digital output 1 uses bit digital output 2 uses bit 1 etc Par 1392 Relay Out 1 Sel uses bit 14 only Par 629 Relay Out 2 Sel uses bit 15 only UserDefinedB Indicates the status of Par 536 UsrDefBitWraB digital output 1 uses bit 0 digital output 2 uses bit 1 etc Par 1392 Relay Out 1 Sel uses bit 14 only Par 629 Relay Out 2 Sel uses bit 15 only Stop Control Energized 1 at run and de energized 0 based on the value of Par 627 Spd 0 Trip Delay Field Loss 0 indicates the loss of the field voltage current while the drive is running Spd Fbk Loss 0 indicates the loss of Speed Feedback Encoder due to an excessive calculated error as determined by the drive firmware Encoder Err 0 indicates a loss of the DC tachometer or encoder Matches the state of Par 651 Encoder State Diam Calc Energized 1 when Par 800 Diameter Calc St 1 and de energized 0 when Diameter Calc St 0 Input Cmp 1 indicates that the value of analog input 1 is inside the comparison window 0 indicates that the value of analog input 1 is outside the comparison window Par 1045 Anlg Int Cmp Eql Diam Reached Energized 1 when the value of Par 1158 Diam Threshold has been exceeded Speed Match Energized 1 when the value of Par 1203 Spd Match Compl 1 launching ramp completed Accelerating 4
303. fBitWrdB6 UsrDefBitWrdB7 UsrDefBitWrdB8 UsrDefBitWrdB9 UsrDefBitWrdB10 UsrDefBitWrdB11 UsrDefBitWrdB12 UsrDefBitWrdB13 UsrDefBitWrdB14 UsrDefBitWrdB15 Bit variables The individual User Defined bits can be read or written to t is possible to process a word with Par 536 UsrDefBitWrdB See the example in Par 536 UsrDefBitWrdB Note You can read bits 0 7 of a digital input with Par 536 UsrDefBitWrdB and write all of the bits associated with UsrDefBitWrdB to a digital output File Related PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Programming and Parameters 3 63 Communications File File Group Comm Control COMMUNICATIONS Masks amp Owners o g Parameter Name 6 Description s Z See page 3 2 for symbol descriptions Values 589 DPI Baud Rate Default Read Only Shows the data transfer rate for attached drive peripherals Min Max 1 1 1 500 kbps 590 DPI Port Sel Default 1 DPI Port 1 1343 Selects which DPI port reference value unscaled will Options 1s DPI Port 1 appear in Par 1343 DPI Port Value 2 DPI Port 2 3 DPI Port 3 4 DPI Port 4 5 DPI Port 5 1321 DPI Fdbk Select Default 0 Speed Selects the feedback variable and DPI units displayed on the Options 0 Speed
304. fault F25 will occur 1 Min Max 0 7800 Notes Typically set at 110 of Par 162 Max Feedback Spd Refer Units rpm to Chapter 4 for a list of fault and alarm descriptions This parameter was added with firmware version 3 001 application Incorrectly setting this parameter may cause a hazard of personal injury and or ATTENTION Verify that you have correctly set this parameter appropriately for your Loi equipment damage Drive Alarm 1 Alarm conditions that currently exist in the drive For each bit 1 Condition true and 0 Condition false Bit 0 DiginCflctA Digital input functions are in conflict Bit 1 DiginCflciB A digital Start input has been configured without a Stop input or other functions are in conflict Bit 2 DiginCflctC More than one physical input has been configured to the same input function Bit 3 BipolarCflct Parameter 1322 Direction Model is set to Bipolar or Reverse Dis and one or more of the following digital input functions is configured Fuvd Reverse Run Forward Run Reverse Jog Forward or Jog Reverse Bit 4 AnalogCfiet Analog input functions are in conflict Bit 5 CntactrCfiet Contactor input functions are in conflict Bit 6 Encoder Cflc Indicates an encoder configuration conflict Bit 7 Overvoltage There is an overvoltage on the armature circuit Bit 8 Over Temp The motor has exceeded its temperature rating as
305. fault 4 5 Overcurrent 4 6 field current regulator Overspeed 4 6 tune C 38 Params Defaulted 4 6 Field Econ Delay 3 18 Port 1 Adapter 4 6 Port 1 DPI Loss 4 6 Field Economy En 3 18 Field Mode Sel 3 17 Port 2 Adapter 4 6 Port 2 DPI Loss 4 6 Field Reg Enable 3 17 Port 3 Adapter 4 6 file group parameter 3 3 Port 3 DPI Loss 4 6 File Group Parameter list B 4 Filt TorqCur Pct 3 13 Ge 7 Final Diameter 3 47 Port 5 DPI Loss 4 6 Power Failure 4 7 fine tune regulators C 36 STune Aborted 4 7 Fld Const 40 Pct 3 18 STune CurLimit 4 7 Fld Const 70 Pct 3 18 STune FrictionLo 4 7 Fld Const 90 Pet 3 18 STune LoadHi 4 7 Fld Current Pct 3 13 STune Overspeed 4 7 Fld Reg Ki 3 16 Shine Timeout 7 Fd Reg Ki Base 3 16 Sustained Curr 4 7 Fld Reg Kp 3 16 visual notification 4 3 Fld Reg Kp Base 3 16 Faults group 3 56 3 57 Fld Test Angle 3 25 Fdbk Device Type 3 20 Fld Weaken Ratio 3 16 Feed Fwd PID 3 41 FldLoss Fit Cfg 3 58 Feedback Loss alarm 4 10 Flux Current Pct 3 13 Feedback Loss fault 4 5 Flux Divide 3 16 Feedback Offset 3 21 Flux Filter BW 3 16 feedback signal Flying Start En 3 30 configure C 15 Force Min Field 3 17 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 Index 8 frame armature converter terminals 1 23 dimensions 1 3 PE ground terminal 1 23 weights 1 3 frame B armature converter terminals 1 24 dimensions 1 4 PE ground terminal 1 24 weights 1 4 frame C armature convert
306. ference 1 At Reference Local Control 1 000 Port 0 TB 001 Port 1 010 Port 2 011 Port 3 100 Port 4 101 Port 5 110 Reserved 111 No Local 0 Reference Source Refer to Masks 8 Owners on page 3 63 for further information 0000 Spd Ref A Auto 0001 Spd Ref B Auto 0010 Preset Spd 2 Auto 0011 Preset Spd 3 Auto 0100 Preset Spd 4 Auto 0101 Preset Spd 5 Auto 0110 Preset Spd 6 Auto 0111 Preset Spd 7 Auto 1000 Term Bik Manual 1001 DPI 1 Manual 1010 DPI 2 Manual 1011 DPI 3 Manual 1100 DPI 4 Manual 1101 DPI 5 Manual 1110 Reserved 1111 Jog Ref PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 A 8 Supplemental Drive nformation Drive Povver Circuit Protection gt Frame The tables on the follovving pages provide drive ratings and the recommended fuses for protecting the armature and field circuits Externally mounted fuses as indicated in Figure A 3 on page A 8 must be sourced separately vvhen installing the drive Internally mounted fuses are provided vvith the drive Frame A and B Fuse nformation Figure A 3 Frame A and B Fuse Table Designations FS1 Externally mounted fuses for the armature converter on the AC input side FS3 Internally mounted fuses for the field circuit on the AC input side FS2 Externally FS2 mounted fuses for the armat
307. fined 3 60 385 Speed Ref Out Speed Meters 3 12 510 UserDefined7 User Defined 3 60 388 Flying Start En Speed Regulator 30 511 UserDefined8 User Defined 3 60 393 Speed Threshold Diagnostics 3 53 512 UserDefined9 User Defined 3 60 394 At Speed Diagnostics 3 53 513 UserDefined10 User Defined 3 60 395 At Zero Speed Diagnostics 5 514 UserDefined11 User Defined 3 60 396 MOP Inc Active Diagnostics 3 53 515 UserDefined12 User Defined 3 60 397 MOP Dec Active Diagnostics 3 54 516 UserDefined13 User Defined 3 60 400 Spd Select Diagnostics 54 517 UserDefinedi4 User Defined 60 401 Spd Select 1 Diagnostics 3 54 518 UserDefined15 User Defined 3 60 402 Spd Select 2 Diagnostics 3 54 519 UsrDefBitWrdA User Defined 3 60 403 Ramp Select 0 Diagnostics 54 520 UsrDefBitWrdAO User Defined 3 61 404 Ramp Select 1 Diagnostics 3 54 521 UsrDefBitWrdA1 User Defined 3 61 414 Fdbk Device Type Speed Feedback 3 20 522 UsrDefBitWrdA2 User Defined 3 61 418 Real FF PID PID Control 40 523 UsrDefBitWrdA3 User Defined 3 61 420 Encoder Speed Speed Meters 3 12 524 UsrDefBitWrdA4 User Defined 3 61 421 PD Output PID PD Control 3 40 525 UsrDefBitWrdA5 User Defined 3 61 444 Spd Fdbk Filter Speed Regulator 3 526 UsrDefBitWrdA6 User Defined 3 61 445 1 Spd Up Gain Pct Speed Regulator 3 30 527 UsrDefBitWrdA7 User Defined 3 61 446 1 Speed Up Base Speed Regulator 3 30 528 UsrDefBitWrdA8 User Defined 3 61 447 Speed Up Filter Speed Regulator 30 529 UsrDefBitWrdA9 User Defined 3 61 452
308. g In Cmp Eq Provides an indication after the amount of time specified in Par 1044 Anlg In1 Cmp DIy has elapsed when the value set in parameter 1043 Anlg In1 Cmp Err has been reached 0 The value of analog input 1 is above or below the value set in Par 1043 Anlg Int Cmp Err 1 The value of analog input 1 is within the range set in Par 1043 Anlg Int Cmp Err Note This parameter can be assigned to a digital output PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Values Default Min Max Default Options Default Options Default Min Max Units Default Min Max Default Min Max Default Min Max Units Default Min Max 0 32768 32767 0 Ready 0 Ready 1 Tune 0 Assigned 0 Assigned 1 Not Assigned 0 0 1000 ms 0 410000 0 0 10000 0 0 65000 ms Read Only 0 1 Related 1043 1044 1045 1042 1044 1045 1042 1043 1045 1042 1043 1044 File INPUT OUTPUT Group Analog Inputs Analog Outputs Programming and Parameters 3 69 Parameter Name amp Description s Z See page 3 2 for symbol descriptions Values c 1404 Analog In1 Value Default Read Only 71 Value of the signal at a
309. g Tach Gain 144 Par 585 Overspeed Val 2750 rpm Par 162 Max Feedback Spd 2500 rpm 54 180 Based on 50V 1000 50V 1 44 2 5 rpm 2500 rpm 1 1 137 5V Encoder with Field Weakening bypass Par 175 Rated Motor Volt 500V 7500 fpm 25000 counts 7500 fpm 25000 counts not allowed Par 45 Max Ref Speed 2500 rpm 0 3 fpm count 0 3 fpm count Par 162 Max Feedback Spd 2500 rpm Par 169 Encoder PPR 240 ppr Par 585 Overspeed Val 2750 rpm Droop Compensation The Droop function is used when the current must be balanced between two drives A typical situation is when two motors are mechanically coupled and must run at the same speed If because of differences in the drive s speed regulators one of the motors runs at a higher speed it will be overloaded and the second motor will function essentially as a brake The Droop function allows you to overcome this difference by adding a load compensation component to the speed reference which is proportional to the actual load differences of the drives For Example Master Drive Slave Drive Anlg 111 Sel Speed Ref A Anlg Ini Sel Speed Ref A Anlg Out Sel Torque Ref Anlg In2 Sel Load Comp Enable Droop Enabled Droop Percent 5 Droop Filter 100 ms Droop Limit 1000 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 C 10 Application Notes
310. gital output digital output so assigned will only change state at the clockwise positive speed threshold P101 Speed Thresh Pos P122 Spd Feedback P102 Speed Thresh Neg P103 Threshold Delay Digital Outx Sel 2 Spd Thresh gt P393 Speed Threshold Par 394 At Speed indicates whether or not the speed of the drive corresponds to the set speed reference specified in Par 118 Speed Reg m before the speed regulator and the ramp reference if enabled are applied The speed above and below the speed reference at which indication will occur is set in Par 104 At Speed Error You can specify a delay time before indication that the speed reference is within the range set in Par 104 At Speed Error will occur using Par 105 At Speed Delay Par 394 At Speed can be assigned to a digital output P118 Speed Reg In P122 Spd Feedback y P104 At Speed Error Digital Outx Sel 3 At Speed O P394 At Speed Lo P105 At Speed Delay PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 27 Speed Zero Function The Speed Zero Logic determines the behavior of the drive when the motor is at zero speed Refer to the Speed Adaptive and Speed Zero Logic block diagram on page D 13 Configuring the Speed Zero Logic It is possib
311. han 1 of Par 162 Max Feedback Spd the active positive and negative torque limits are set by the value defined in Par 8 Current Lim Pos Fast Stop Time The amount of time to decelerate the drive to a complete stop and disable the drive The deceleration rate for Fast stop Maximum Speed Fast Stop Time This feature can be used when Digital Inx Sel is set to 30 Fast Stop or when certain alarms are configured for Fast Stop See Pars 354 Aux Inp Fit Cfg and 365 OverTemp Fit Cfg Spd 0 Trip Delay The amount of time that will elapse after the drive reaches zero speed before it is disabled Closing Speed Motor speed at which the brake is closed Used with External Brake Control Opening Delay Amount of time before the brake will open after the drive has been enabled Used with External Brake Control Programming and Parameters Values Default 0 00 Min Max 0 00 100 00 Units 96 Default 0 Min Max 0 1000 Units ms Default 0 Min Max 200 Units Default 0 Disabled Options 0 Disabled 12 Enabled Default 1750 Min Max 0 Par 45 Max Ref Speed Units rpm Default 0 Torq Lim Pos Options 0 Torq Lim Pos 1 Lim Mtr Default 10 Min Max 0 65535 Units S Default 0 Min Max 0 40000 Units ms Default 30 Min Max 0 200 Units rpm Default 0 Min Max 0 30000 Units ms 3 35 Related percentage of ER
312. hat The Communication Adapter Kit Includes E 1 Tools That You Need ss gia sien e me nk ea ee AUR ENER eke a CR E 1 Safety Nee ioo eet pede 777 E 2 Installing the Communication Adapter Module in the Drive E 2 Optional Analog and Digital I O Expansion Circuit Board What This Option Board Provides F 1 VO Expansion Board Wiring F 1 Optional 115V AC to 24V DC UO Converter Circuit Board What This Option Board Provides G 1 VO Converter Board Wiring G 2 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 vi PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Who Should Use this Manual What is in this Manual Drive Storage Conditions 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 Preface 1 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 Standard Drive Ca
313. he control board S4 switches see DIP Switch and Jumper Settings on PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 C 8 Application Notes page 1 38 To maximize the feedback speed resolution Par 562 Anlg Tach Gain is used to scale the selected S4 switch selection to Par 162 Max Feedback Spd set to motor base speed This setting is required when Par 458 SpdReg FB Bypass 1 Enabled Using an Encoder has the same limitations except that no scaling or switch setting is needed because Par 169 Encoder PPR is used instead If Par 458 Spd Reg FB Bypass 1 Enabled then Par 162 Max Speed Feedback must be set to motor base speed rpm Refer to Speed Feedback on page C 20 for more information on settings parameters 162 Max Speed Feedback and 169 Encoder PPR Note that setting Par 458 SpdReg Bypass 1 Enabled is not permitted when field weakening is enabled These scaling changes required the correction of limit values for read only speed parameters 200 Par 384 Par 111 Par 114 Par 117 Par 121 8192 rpm Par 385 Par 110 Par 113 Par 118 Par 122 Par 924 Par1408 Par 1372 Below are some examples based on the following data e 500V motor with base speed 1750 rpm e Weakened spd 2500 rpm e Weakened ratio 70 e 50V 1000 rpm tachometer e 240 ppr encoder 7500 fpm application Feedback and Configurat
314. he Field Forward test 180 deg minimum voltage 5 deg maximum voltage Note This parameter was added with firmware version 3 001 Values Default Options Default Min Max Units Default Min Max Units Programming and Parameters 0 Off 0 Off 1 Arm Fwd 2 Arm Rev 3 0 Fwd ATTENTION Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should perform this test Failure to observe this precaution could result in equipment damage and or bodily injury ATTENTION This is an open loop test disconnect the motor armature and field leads and replace them with dummy loads Failure to observe this precaution could result in machine ATTENTION Uncontrolled machine operation could result with a motor connected during these tests and may cause personal injury and or equipment damage Verify that the drive is not connected to a motor armature circuit before enabling these test modes 180 0 180 deg 180 0 180 deg 3 25 amp Related 166 166 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 26 Programming and Parameters Speed Command File r Group File No Limits SPEED COMMAND 154 155 156 157 158 159 160 Discrete Speeds 266 Parameter Name amp Description See page 3 2 for sym
315. he field current with oscillation Figure C 8 Increase in the field current without Non optimal response of the regulator oscillation Top Par 500 Flux Ref Pct This graph as compared to the graph in Figure C 5 shows an Bottom Par 234 Fld Current Pct increase in Fld Reg Kp from 2 to 10 with Fld Reg Ki 5 Top Par 500 Flux Ref Pct Bottom Par 234 Fld Current Pct Figure C 7 Too high of a time constant on the field The reduction of the field current depends on the field time constant Therefore the regulator has no influence on the flux current Top Par 500 Flux Ref Pct Bottom Par 234 Fld Current Pct PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 41 Fine Tuning the Speed Regulator Follovv the procedure belovv to fine tune and optimize the speed regulator 1 10 11 Configure the following Test Generator parameters D Set Par 58 TstGen Output 4 Ramp Ref D Set Par 59 TstGen Frequency 0 2 Hz 1 Set Par 60 TstGen Amplitude 10 LI Set Par 61 TstGen Offset 20 Measure the results on analog outputs 1 and 2 by setting D Par 66 Anlg Outl Sel 8 Spd Reg Out LI Par 67 Anlg Out Sel 13 Motor
316. high when the signal on Analog Input 1 is within the range specified in Par 1043 Anlg Inl Cmp Err Par 1045 Anlg m1 Eq low when the signal on Analog Input 1 is outside the range specified in Par 1043 Anlg In Cmp Err PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 C 6 Application Notes Example 2 An application requires an indication via a digital output that the output current is Within 2 of 50 of the maximum current limit e Par 7 Current Limit 100 maximum reference value For Analog Input 1 10V or 20mA sets the maximum value Par 7 Current Limit Configure the following Set Par 70 Anlg Inl Sel Pos Cur Lim Set Digital Outx Sel Input1 Par 1045 Anlg Inl Cmp Eq Set Par 1042 Anlg Inl Cmp 5000 50 x 10000 100 Set Par 1043 Anlg Inl Cmp Err 200 2 x 10000 100 Current Speed Curve The current speed curve function allows you to establish a current limit lower than the standard current limits of the drive specified in parameters 8 Current Lim Pos and 9 Current Lim Neg and reduce the output current torque of the drive through a defined curve of five equally divided set points as the speed increases based on a threshold speed effectively reducing torque Par 10 Cur Lim Pos Out or Current Speed Par 11 Cur Lim Neg Out Par 751 TrqTpr_LimO Par 752 TrqTpr Lim Curre
317. ications incorrectly or the tachometer is vvired incorrectly Failure to observe this precaution could result in damage to or destruction Of the equipment ATTENTION The Drive can overspeed if DIP switch S4 is set Table 1 W DC Analog Tachometer Terminal Designations No Signal Description Negative input m Not Used t OJU gt Positive input 22 7 45 4 1 90 7 181 6 Ve 1 Clockwise rotation positive 302 9V max voltage 8 mA max current Counterclockwise rotation negative Maximum voltage depends on the configuration of DIP switch S4 Refer to DC Analog Tachometer DIP Switch S4 Example on page 1 40 1 0 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 TAF SE a a PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Drive Start Up Checklist Chapter 2 Drive Start Up This chapter describes how to start up the PowerFlex DC drive The drive is co
318. icient of the speed regulator as a percentage of the value defined in Par 94 Spd Reg Ki Base 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 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 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 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
319. imited state Note This parameter is assigned to digital output 4 Par 148 Digital Out4 Sel by default Spd Limit Active Indicates whether the current speed reference value is limited by the defined minimum and maximum limit values e 1 Active The reference value is currently limited since the value entered is out of range of the limit values defined 0 Not Active The reference value is within the defined limit values Note This parameter can be assigned to a digital output Values Default Options Default Min Max Default Min Max Default Min Max Default Min Max Programming and Parameters 0 Not Selected 0 Not Selected 1 English 2 French 3 Spanish 4 ltalian 5 German 6 Reserved 7 Portuguese Read Only 0 1 Read Only 0 1 Read Only 0 1 Read Only 0 1 3 51 Related 20 20 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 52 Programming and Parameters No 381 Parameter Name amp Description See page 3 2 for symbol descriptions Values Drive Status 1 Present operating condition of the drive Bit 0 Ready When set 1 the drive is ready Bit 1 Active When set the drive is active Bit 2 Command Dir The direction of commanded rotation 0 Reverse 1 Forward Bit 3 Actual Dir The
320. in an area where it will not be exposed to a corrosive atmosphere Relative Humidity Operating 5 to 85 non condensing Storage 5 95 non condensing Shock 15G peak for 11ms duration 1 0 ms Vibration 1 PowerFlex DC drives must be installed in a Po PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 0 152 mm 0 006 in displacement 1G peak lution Degree 2 environment Supplemental Drive Information A 3 Category Specification Drive Type Full Wave Regen 6 Pulse Regulated Field Supply Electrical Input Voltages 230 to 480V AC 10 3 Phase Input Frequency 50 60 Hz 5 Max Rate of Change of 2 Hz Sec Input Frequency Armature Output Voltage Two Quadrant Drives Four Quadrant Drives 260V DC 230V AC 240V Q 230V AC 470V DC 400V 420V Q 400V AC 530V DC 440V AC 1460V 440V 560V DC 460V AC 480V DC 460V 580V DC 480V 500V DC 480V Output Horsepower Cont 1 5 to 150 HP 230V AC 2 to 400 HP 460V AC Output Current 4 1 to 667A Overload Capability 100 rated continuous current 150 rated current for one minute then fault 200 rated current for three seconds then fault Field Output Voltage 200V DC 230V AC 310V DC 400V AC 360V DC 460V AC Maximum field output voltage is 0 85 x AC input line voltage Controller Current Overload 150 ra
321. ine Fuses 460V AC Input Frame A and B Regenerative and Non Regenerative Drives Fuse Code FS1 See Figure A 3 on page A 8 Drive Bussmann Ferraz Shawmut Gould Shawmut Current AC North S Rating Line Ferrule FWP Ferrule North American American Ferrule A70QS North American Code Amps Amps Type Fuse Block FWP Type Fuse Block Type A70P A70QS Type A 4P1 4 1 33 FWP 10A14F CH143D FWP 10B A70QS10 14F 1A70P10 4 6P0 6 4 9 FMP 10A14F FWP 10B A70QS10 14F 7 A70P10 4 010 10 82 FWP 20A14F FWP 20B A70QS20 14F A70P25 4 014 14 11 4 FWP 25A14F FWP 25B A70QS25 14F A70P25 4 019 19 15 5 FWP 25A14F FWP 25B A70QS25 14F A70P25 4 027 37 22 1 FWP 40A22F CH223D FWP 40B A70QS40 22F A70QS40 4 035 35 28 6 FWP 63A22F FWP 60B A70QS63 22F 700560 4 045 45 36 8 FWP 80A22F FWP 80B A70QS80 22F 700580 4 052 52 42 5 FWP 80A22F FWP 80B A70QS80 22F 700580 4 073 73 59 6 FWP 100A ST14 A70QS100 4K 086 86 703 FWP 150A 7005150 4 100 100 181 7 FWP 175A 7005175 4 129 129 105 4 FVVP 175A 7005175 4 B 167 167 1364 FWP 300A m A70QS300 4 207 207 169 1 FWP 350A m A70QS350 4 250 250 120433 m FWP 400A ST38 72612 7005400 4 330 330 269 6 FWP 600A A70QS600 4K 412 412 336 6 FVVP 600A 7005600 4 Table Recommended Armature DC Output Fuses
322. ined13 Par 516 1 Lim Pos Par 8 17 Max Fld Pct Par 467 33 UsrDefined14 Par 517 2 Cur Lim Neg Par 9 18 Fld Ref Pct Par 500 34 UsrDefined15 Par 518 3 CurLimPosOut Par 10 119 UsrDefined0 Par 503 35 Load Comp Par 698 4 CurLimNegOut Par 11 720 UsrDefined1 Par 504 36 Out Volt Lvl Par 921 bz TrqRedCurLim Par 13 121 UsrDefined2 Par 505 37 Filt T q Cur Par 928 Torque Ref Par 39 22 UsrDefined3 Par 506 38 Speed Ratio Par 1017 7 Torque Par 40 23 UsrDefined4 Par 507 39 Spd Draw Out Par 1018 TorqueReg In Par 41 24 UsrDefined5 Par 508 40 Roll Diam Par 1154 9 Trim Ramp Par 42 25 UsrDefined6 Par 509 41 Tension Red Par 1179 10 Trim Speed Par 43 26 UsrDefined7 Par 510 42 Torq Cur Pct Par 1193 11 Ramp In Par 110 27 UsrDefined8 Par 511 43 Ten Ref Pct Par 1194 12 Ramp Out Par 113 28 UsrDefined9 Par 512 44 CloseLp Comp Par 1208 13 Speed Reg In Par 118 129 UsrDefined10 Par 513 45 Actual Comp Par 1213 14 Adaptive Ref Par 183 30 UsrDefined11 Par 514 146 W Reference Par 1217 15 Arm Cur Pct Par 199 31 UsrDefined12 Par 515 Default 1 00 Min Max 100 0
323. ing by grouping parameters that are used for similar functions Numbered List Displays all parameters in numerical order Changed Params Displays the most recently changed parameter You can scroll through the list of all changed parameters to the least recently changed The new and default values are listed for each parameter Refer to Viewing and Editing Parameters on page B 5 for more information Device Select Menu Use this menu to access parameters in connected peripheral devices Memory Storage Menu Drive data can be saved to or recalled from HIM sets HIM sets are files stored in permanent nonvolatile HIM memory performing a download to the drive using the HIM CopyCat ATTENTION It is recommended that you stop the drive before function DriveExecutiveTM or DriveExplorerTM Option Description HIM CopyCat Device HIM X Save data to a HIM set Device HIM TLoad data from a HIM set to active drive memory Delete HIM Set Delete a HIM set Reset To Defaults Restore the drive to its factory default settings PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Viewing and Editing Parameters HIM Overview B 5 Preferences Menu The HIM and drive have features that you can customize Option Description Drive Identity Add text to identify the drive User Dspy Lines Select the display parameter scale and text for the User Display The User Display
324. ink Thermistor Monitored by microprocessor overtemp trip Drive Overcurrent Trip Software Overcurrent Trip Hardware Overcurrent Trip 200 of rated current typical 220 300 of rated current dependent on drive rating Line transients Up to 2000 volts peak per IEC 6100 4 5 Control Logic Noise Immunity Showering arc transients up to 1500V peak Power Ride Thru 15 milliseconds at full load Logic Control Ride Thru 0 5 seconds minimum 2 seconds typical Ground Fault Trip Phase to ground on drive output Short Circuit Trip Phase to phase on drive output PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 A 2 Supplemental Drive Information Category Specification Eavrenment Altitude 1000 m 3300 ft max without derating De rate output power by 1 2 for every 100 meters 328ft above 1000 meters 3300ft Maximum Surrounding Air Temperature IP20 NEMA Type Open 0 50 C 32 122 F typical De rate 1 25 for every 1 C over 50 C 122 F to 55 C 131 F Additional cooling is required for temps above 55 C Storage Temp all const 25 to 55 degrees C 13 to 131 degrees F Atmosphere Important Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas vapors or dust If the drive is not going to be installed for a period of time it must be stored
325. ion Out 6 1272 1 Digital Outputs 3 7 Param Access Lvl 211 Drive Memory 3 50 inversion Out 7 1273 Digital Outputs 3 75 PD Deriv Filter 767 PD Control 3 40 inversion Out 8 1274 Digital Outputs 3 75 PD Deriv Gain 1 766 PD Control 3 40 Inversion Relay1 1393 Digital Outputs 3 76 PD Deriv Gain 2 789 PD Control 3 40 inversion Relay2 1275 Digital Outputs 3 75 PD Deriv Gain 3 791 PD Control 3 40 Jog Mask 593 Masks amp Owners 3 63 PD Output PID 421 PD Control 3 40 Jog Owner 602 Masks amp Owners 3 64 PD Prop Gain 1 768 PD Control 3 40 Jog Off Delay 1409 1 Discrete Speeds 3 27 PD Prop Gain 2 788 Control 3 40 Jog Ramp Time 1410 1 Ramp Rates 3 33 PD Prop Gain 3 790 Control 3 40 dog Speed 266 Discrete Speeds 3 26 PI Central v sel 779 PI Control 3 39 Jog TW Enable 1256 Winder Functions 3 49 PI Central v1 776 PI Control 3 38 Jog TW Speed 1255 Winder Functions 3 49 PI Central v2 777 PI Control 3 38 Language 302 Drive Memory 3 51 PI Central v3 778 P Control 3 38 Last Stop Source 1402 Diagnostics 3 56 PI Central vs0 780 PI Control 3 39 Line Accel Pct 1184 Winder Functions 3 47 PI Central vs1 781 PI Control 3 39 Line Decel Pct 1185 Winder Functions 8 47 PI Init Intgl Gn 734 PID Control 3 40 Line FastStp Pct 1186 Winder Functions 3 47 PI Init Prop Gn 793 PI Control 3 39 Line Spd Gain 1156 Diameter Calc 3 45 PI integr freeze 783 PI Control 3 39 Line Spd Source 1204 Winder Functions 3 48 PI Integral Gain 764 PI Control 3 38 Line Spd Thre
326. ion Parameter DIP Switch Setting Reference Resolution Feedback Resolution Armature Voltage overvoltage fixed at Par 175 Rated Motor Volt 500V 5250 fpm 25000 counts 5250 fpm 25000 counts 20 Par 45 Max Ref Speed 1750 rpm 0 21 fpm count 0 21 fpm count Par 162 Max Feedback Spd 1750 rpm DC Tachometer with No Bypass Par 175 Rated Motor Voli 500V 5250 fpm 25000 counts 0 62 fpm count Par 45 Max Ref Speed 1750 rpm 0 21 fpm count Par 562 Anlg Tach Gain 1 0000 Par 585 Overspeed Val 1925 rpm Par 162 Max Feedback Spd 3600 rpm 84 180V Based on 50V 1000 180V 50V 3 6 rpm 1750 rpm 1 1 96 25V DC Tachometer with Bypass no field Par 175 Rated Motor Volt 500V 5250 fpm 25000 counts 5250 fpm 25000 counts weakening Par 45 Max Ref Speed 1750 rpm 0 21 fpm count 0 21 fpm count Par 562 Anlg Tach Gain 2 057 Par 585 Overspeed Val 1925 rpm Par 162 Max Feedback Spd 1750 rpm S4 180V Based on 50V 1000 180V 50V rpm 1750 rpm 1 1 96 25V 2 057 1 750 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 9 Feedback and Configuration Parameter DIP Switch Setting Reference Resolution Feedback Resolution DC Tachometer with Field Weakening Par 175 Rated Motor Volt 500V 7500 fpm 25000 counts 7500 fpm 25000 counts bypass not allowed Par 45 Max Ref Speed 2500 rpm 0 3 fpm count 0 3 fpm count Par 562 Anl
327. ion of how parameters will be viewed or detailed information about a parameter or component Lang Displays the language selection screen Auto Man Switches between Auto and Manual Modes Allows HIM removal without causing a fault if the HIM is not the last controlling device and does not have Manual control of the drive 8 8 2 o Allows value to be entered as an exponent Not available on the PowerFlex DC drive Param Allows entry of a parameter number for viewing editing Using the S M A R T List Screen The LCD HIM provides the SMART list screen which contains some of the most commonly changed parameters including the following Parameter Name Number Max Ref Speed 45 Description The nameplate base motor speed Rated Motor Volt 175 The maximum armature voltage of the drive output Nom Mtr Arm Amps 179 Corresponds to 100 of the current limit Nom Mtr Fld Amps 280 Rated motor nameplate field current Anlg In1 Sel 70 Selects the parameter to which a value will be written from analog input 1 default Speed Ref A Maximum Speed 2 Defines the maximum speed of the drive Current Limit 7 Symmetrical current limit for both current directions for four quadrant drives expressed as a percentage of the value in parameter 179 Nom Mtr Arm Amps Accel Time 1 660 Sets the rate of acceleration for Ramp
328. is algebraically larger in value than the speed regulator s output The drive may automatically enter speed regulation mode based on conditions within the speed regulator and the magnitude of the speed regulator s output relative to the torque reference Sum The drive operates as a speed regulator The reference is derived from the sum of the speed regulator output Par 236 Spd Reg Out Pct and the torque reference Par 39 Torque Ref Notes Refer to Speed Torque Mode Selection on page C 29 in Appendix C for more detailed information This parameter was added and is only available with firmware version 3 001 and higher Ramp Type Select Determines the type of ramp used e 0 Linear Linear ramp 1 S shaped S shaped ramp PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Values Default Min Max Units Default Min Max Units Default Options Default Options 0 000 0 000 350 000 rpm 0 0 5 S 1 Speed Reg 0 Zero Trq Ref 1 Speed Reg 2 Torque Reg 3 SLAT Min 4 2 SLAT Max 5 Sum 0 Linear 0 Linear 1 S shaped Related 16 15 241 39 236 382 File Group Ramp Rates S No 1 20 22 24 30 1410 32 245 Parameter Name amp Description See page 3 2 for symbol descriptions S Curve Time S shaped curve time constant
329. is limited to 1000 until the signal coming from the dancer via Par 763 PID Feedback goes above the value in this field Then the value of PID Clamp is automatically returned to its maximum value of 10000 The PID clamp is kept at 10000 until the drive stops or Par 770 Enable PD 0 Disabled Feed Fwd PID Feedback from the transducer position dancer or tension PID Error Error value input to the PID function output of the PID Clamp block PID Setpoint 0 First offset value added to Par 763 PID Feedback This parameter can be assigned to an analog input for example for the tension setting when a load cell must be used as feedback PID Setpoint 1 Second offset value added to Par 763 PID Feedback PID Setpoint Sel Selects the offset value added to Par 763 PID Feedback This parameter can be assigned to a digital input PID Feedback Analog input feedback value received from the transducer position dancer or tension load cell PID Output Sign Determines whether the output of the PID regulator is bipolar or positive clamp of the negative side PID Output Scale Scale factor for Par 774 PID Output The value of this parameter depends on to which parameter you want to send the PID regulator output PID Output Displays the PID regulator output Note This parameter can be assigned to an analog output in order to provide a cascaded reference in multi drive systems Values Default
330. is two lines of user defined data that appears when the HIM is not being used for programming LCD HIM Step Key s Example Displays 1 In the Main Menu press the Up Arrow or Down Arrow to scroll to Parameter eo or 639 2 Press Enter FGP File appears on the lt m Fi top line and the first three files appear iar File SS or A Speed Command 3 Press the Up Arrow or Down Arrow to scroll through the files HEP Group Motor Data Field Config 4 Press Enter to select a file The groups CENT in the file are displayed under it 2777 5 Repeat steps 3 and 4 to select a group DON Parameter and then a parameter The parameter 22 value screen will appear Field Mode Sel 6 Press Enter to edit the parameter or e FG Par 499 7 Press the Up Arrow or Down Arrow to ce 1 change the value If desired press Sel Enabled to move from digit to digit letter to letter or bit to bit The digit or bit that you can change will be highlighted Uem ar 8 Press Enter to save the value If you 0 want to cancel a change press Esc or A Disabled 9 Press the Up Arrow or Down Arrow to scroll through the parameters in the group or press Esc to return to the group list Numeric Keypad Shortcut If using a HIM with a numeric keypad press the ALT key and the key to access the parameter by typing its number PowerFlex Digital DC Dri
331. ital In2 Sel 3 70 Digital In3 Sel 3 70 Digital In4 Sel 3 70 Digital In5 Sel 3 70 Digital In6 Sel 3 70 Digital In7 Sel 3 70 Digital In8 Sel 3 70 Digital In9 Sel 3 70 Digital Input Conflict A alarm 4 9 Digital Input Conflict B alarm 4 10 Digital Input Conflict C alarm 4 10 Digital nputs group 3 70 3 71 3 72 Digital Out1 Sel 3 73 Digital Out2 Sel 3 73 Digital Out3 Sel 3 73 Digital Out4 Sel 3 73 Digital Out5 Sel 3 73 Digital Out6 Sel 3 73 Digital Out7 Sel 3 73 Digital Out8 Sel 3 73 digital outputs option definitions 3 74 Digital Outputs group 3 73 3 74 3 75 3 76 dimensions frame 1 3 frame B 1 4 frame C 1 5 DIP switch S0 1 38 1 39 S1 1 38 1 39 S10 1 38 1 39 S11 1 38 1 39 S12 1 38 1 39 S14 1 30 1 38 1 39 S15 1 38 1 39 1 40 S18 1 38 1 39 S2 1 38 1 39 S20 1 38 1 39 S21 1 38 1 39 S3 1 38 1 39 S4 1 38 1 39 1 40 S9 1 38 1 39 Direction Mask 3 63 Direction Mode 3 50 Direction Owner 3 64 Discrete Speeds group 3 26 3 27 DncrPosSpd 3 44 DPI Baud Rate 3 63 DPI Fdbk Select 3 63 DPI Inputs group 3 76 DPI P1 Select 3 76 DPI P2 Select 3 76 DPI P3 Select 3 76 DPI P4 Select 3 76 DPI P5 Select 3 76 DPI Port Sel 3 63 DPI Port Value 3 63 drive clearance 1 2 data nameplate p 2 enclosure 1 2 mounting 1 2 1 3 power wiring 1 19 problems 4 11 start up 2 1 status 4 2 storage p 1 temperature 1 2 weights 1 3 Drive Alarm 1 3 59 Drive Data group 3 14 Index 5 Drive Logic Rslt 3 55
332. ital Inputs 3 72 505 UserDefined2 User Defined 3 60 570 Dig In Term 6 Digital Inputs 3 72 506 1 UserDefined3 User Defined 3 60 571 Dig In Term 7 Digital Inputs 3 72 507 UserDefined4 User Defined 3 60 572 Dig In Term 8 Digital nputs 3 72 508 UserDefined5 User Defined 3 60 573 Dig In Term 9 Digital Inputs 3 72 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Programming and Parameters 3 85 No Parameter Name Group Page No Parameter Name Group Page 574 Dig In Term 10 Digital Inputs 3 72 734 PI Init Intg Gn PID Control 3 40 575 Dig In Term 11 Digital Inputs 3 72 750 TrqTpr Enable Torque Attribute 3 20 576 Dig In Term 12 Digital Inputs 3 72 751 TrqTpr Limo Torque Attribute 3 20 581 Dig Out Status Digital Outputs 3 75 752 TrqTpr Lim1 Torque Attribute 3 20 584 OverCurrent Thr Alarms 3 58 753 TrqTpr_Lim2 Torque Attribute 3 20 585 Overspeed Val Alarms 3 59 754 TrqTpr Lima Torque Attribute 3 20 587 I Reg Error Autotune 3 23 755 TrqTpr Lim4 Torque Attribute 3 20 588 AC Line Freq Drive Data 3 14 756 TrqTpr
333. itch S15 Configuration E Drive Current Rating Code S15 1 1S15 2 S15 3 915 4 S15 5 S15 6 S15 7 S15 8 7P0 ON OFF OFF OFF OFF OFF OFF OFF 9P0 OFF 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 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 OFF ON OFF OFF OFF OFF B 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 C 521 ON OFF OFF OFF ON OFF OFF OFF 700 OFF ON OFF OFF ON OFF OFF OFF PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring 1 41 Table 1 P Drives with 460V Input DIP Switch S15 Configuration e 5 Drive Current Rating Code S15 1 515 2 S15 3 S15 4 S15 5 S15 6 515 7 S15 8 A 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 JON 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
334. itten only to RAM and will not be saved by the drive This is the preferred attribute for continuous transfers If attribute 9 is selected each program scan will complete a write to the drives non volatile memory EEprom Since the EEprom has a fixed number of allowed writes continuous block transfers will quickly damage the EEprom Do Not assign attribute 9 to continuous block transfers Refer to the individual communications adapter User Manual for additional details Logic Command Status Words Refer to parameter 1328 Drive Logic Rslt for more information Figure A 1 Logic Command Word Logic Bits 15114 13112 1111019 8 7 6 5 4 312 110 Command Description x Stop 10 Not Stop 1 Stop x Start 10 Not Start 1 Start X Jog 0 Not Jog 1 X Clear 0 Not Clear Faults Faults 1 Clear Faults X x Direction 00 No Command 01 Forward Command 10 Reverse Command 11 Hold Present Direction X Local 0 No Local Control Control 1 Local Control X MOP 0 Not Increment Increment 1 Increment X X Accel Rate 00 No Command 01 Use Accel Time 1 10 Use Accel Time 2 11 Use Present Time x X Decel 00 No Command Rate 01 Use Decel Time 1 10 Use Decel Time 2 11 Use Present Time X X X Reference 000 No Command Select 001 Ref 1 Spd Ref A 010 Ref 2 Spd Ref B 011 Ref 3 Preset Spd 3 100 Ref 4 Preset Spd 4 101 Ref 5 Preset Spd 5 110 Ref 6 Preset Sp
335. ja ja ja ja 23 3 3 15 15 5 515 19 a a a 8 D x Z A a a a Ir Default x x x x x x x x x 1d 1 1 1 1 Bit 15 14 13 12 11 109 8 7 6 5 4 3 2 1 0 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 File INPUT OUTPUT Group Analog Inputs z 70 75 80 71 76 81 72 77 82 73 78 83 Programming and Parameters Input Output File Parameter Name amp Description See page 3 2 for symbol descriptions Values Anlg In1 Sel Default 1 Speed Ref A Anlg In2 Sel Default 0 Anlg In3 Sel Default 0 Off Selecis the parameter to which a value will be written from the analog input Options 0 Off No signal Cur Lim Par 9 18 PI CentralV3 Par 778 1 Speed Ref A Par 44 10 Ref Par 266 19 PID Feedback Par 763 2 Speed Ref B Par 48 11 Adaptive Ref Par 183 120 Fld Cur Max Par 467 3 Ramp Par 42 12 UserDefined0 Par 503 121 OutVoltLevel Par 233 4 Speed Par 43 13 UserDefined1 Par 504 22 Speed Ratio Par 1017 5 Torque Ref Par 39 14 UserDefined2 Par 505 23 Tension Red Par 1179 6 Torque Par 40 15 UserDefined3 Par 506 24 Tension
336. l Publication 20P UM001E EN P June 2009 4 8 Troubleshooting Table 4 B Fault Cross Reference by Number Ne Fault No Fault 2 Auxiliary Input 62 STune Aborted 3 Power Failure 64 Drive Overload 4 AC Undervoltage 70 Sustained Curr 5 Arm Overvoltage 71 Port 1 Adaptor 6 Fld Current Loss 75 Port 2 Adaptor 7 Motor Overload Port 3 Adaptor 8 Heatsink OvrTemp Port 4 Adaptor 10 Main Contactor Port 5 Adaptor 13 Overcurrent 81 Port 1 DPI Loss 16 Motor Over Temp 85 Port 2 DPI Loss 25 Overspeed Port 3 DPI Loss 37 Inverting Fault Port 4 DPI Loss 48 Params Defaulted Port 5 DPI Loss 56 STune Overspeed SA Feedback Loss 57 STune Stalled 100 1EEPROM Error 58 STune LoadHi 130 Hardware Fault 58 STune CurLimit 131 Interrupt Error 60 STune FrictionLo 132 Dep Error 61 STune Timeout Fault numbers not listed are reserved for future use PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Clearing Alarms Alarm Descriptions Troubleshooting 4 9 Alarms are automatically cleared when the condition that caused the alarm is no longer present The status of the alarms can be viewed in 1380 Drive Alarm 1 Table 4 C Alarm Descriptions and Actions Alarm AnalogCflct Type Description More than one of the drive s reference inputs Pars 70 75 and 80 Anlg Inx Sel Pars 1323 1327 DPI Px Select or Par 1021 Encoder Out Sel a
337. lay output to ContactorDB Set one Digital Inx Sel parameter to Contactor default value for parameter 140 Digital In8 Sel e When a contactor is NOT used 1 Set parameter 1391 ContactorControl to None 1 D Do NOT set either Relay Out x Sel parameter to Contactor or ContactorDB LI Do NOT set any Digital Inx Sel parameter to Contactor VVhen operating a drive vvith firmvvare version 1 006 in field vveakening mode vvith a DC contactor and or inverting fault device installed in the armature circuit refer to Field VVeakening Mode Configuration v1 006 on page C 10 AC Input Contactors Refer to AC Input Line Reactors and AC Input Contactors on page A 18 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 20 for a list of recommended DC output contactors Dynamic Brake Resistors Refer to DC Output Contactors and Dynamic Brake Resistor Kits on page A 20 for a list of recommended dynamic brake resistor kits 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 Pub
338. ld Reg Ki Base 98 Flux Filter BW 463 Fld Weaken Ratio 456 Set Fld Curve 919 Torq Attributes Current Limit 7 Torque Reduction 342 TrqTpr Lima 753 Current Lim Pos 8 Zero Torque 353 TrqTpr Lim3 754 Current Lim Neg 9 TrqTpr Enable 750 TrqTpr Lim4 755 Torque Ref 39 TrqTpr Limo 751 TrqTpr Spd 756 Trim Torque 40 TrqTpr_Lim1 752 Torq Cur Filter 926 Speed Feedback Fdbk Device Type 414 Spd Fdbk Error 455 Encoder Err Chk 652 Anlg Tach Gain 562 Spd FB Filt Gain 914 Z Channel Enable 911 Feedback Offset 563 Spd FB Filt BW 915 Z Capture Pos En 912 Spd Fdbk Control 457 Act Spd Filter 923 Z Captured Pos 913 SpdReg FB Bypass 458 Encoder PPR 169 Encoder Counts 1022 Spd Fdbk Invert 461 Encoder Out Sel 1021 Autotune Autotune Cur Lim 1048 Speed Tune Dir 1029 l Reg Error 587 CurrReg Autotune 452 Speed Tune Kp 1032 Inertia C Filter 1012 Arm Resistance 453 Speed Tune Ki 1033 Torque Const 1013 Arm Inductance 454 Spd Tune Inertia 1030 Inertia 1014 Spd Reg Autotune 1027 SpdTune Friction 1031 Friction 1015 Test Generator TstGen Output 58 TstGen Offset 61 Fld Test Angle 168 TstGen Frequency 59 Alpha Test 166 TstGen Amplitude 60 Arm Test Angle 167 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Programming and Parameters 3 7 File Group Parameters Speed Command Limits Minimum
339. le Anlg In3 Scale Min Max 10 00 Scales the value in the corresponding Anlg Inx Sel parameter Anlg1 Tune Scale Default 1 00 Anlg2 Tune Scale Anlg3 Tune Scale Min Max 0 10 10 00 Fine tuning of the analog input when the maximum signal does not correspond exactly to the rated value Scales according to the following equation Anlg Inx Sel Anlg Inx Offset x Anlg Inx Scale x Ainx Tune Scale 3 67 o Related 1322 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 68 Programming and Parameters Group 2 T 74 79 84 259 260 261 295 296 297 792 1042 INPUT OUTPUT Analog Inputs 1043 1044 1045 Parameter Name amp Description See page 3 2 for symbol descriptions Anlg In1 Offset Anlg In2 Offset Anlg In3 Offset Offset value for the analog inputs If the input has an offset or if the variable assigned to the input already has a value although there is no input signal present this can be compensated for via the value in this parameter Anlg In1 Tune Anlg In2 Tune Anlg In3 Tune Automatic fine tuning of the analog inputs If this command is given parameter Ainx Tune Scale is automatically selected so that the input signal present normally full scale corresponds to the maximum variable value such as the value of Par 45 Max Ref Speed Two conditions are necessary for automatic fine
340. le Motor Data group 3 16 Added parameter 462 Flux Divide to the Motor Control file Field Config group 3 16 Added parameter 463 Flux Filter BW to the Motor Control file Field Config group 3 16 Changed the name of parameter 926 from Filt Torq Cur to Torq Cur Filter 3 20 Added parameter 461 Spd Fdbk Invert to the Motor Control file Speed Feedback 3 21 group Changed the name of parameter 563 from Anlg Tach Zero to Feedback Offset 3 21 Added parameter 914 Spd FB Filt Gain to the Motor Control file Speed Feedback 3 22 group Added parameter 915 Spd FB Filt BW to the Motor Control file Speed Feedback 3 22 group Corrected a parameter reference in the definition for parameter 923 Act Spd 3 22 Filter Added parameter 1022 Encoder Counts to the Motor Control file Speed 3 22 Feedback group Added option values Off 0 and On 1 to parameter 1027 Spd Reg Autotune 3 23 Added parameters 166 Alpha Test 167 Arm Test Angle and 168 Fld Test Angle 3 25 to the Motor Control file Test Generator group Added parameter 95 Spd Reg Pos Lim to the Speed Command file Speed 3 27 Regulator group Added parameter 96 Spd Reg Neg Lim to the Speed Comand file Speed 3 28 Regulator group Added parameter 238 SpdOut FiltGain to the Speed Comand file Speed 3 29 Regulator group Added parameter 239 SpdOut FiltBW to the Speed Comand file Speed 3 30 Regulator group Added parameter 15 SLAT
341. le to avoid drive creep when the motor is at zero speed by disabling the Integral section of the Speed regulator By default the output of the Integral portion of the Speed regulator is disabled Par 123 Spd Zero I En 0 Disabled Important If the speed regulator is disabled the motor cannot receive a load when it is stopped Therefore this function is not suitable for all applications Disable the output of the P gain of the Speed regulator by setting Par 126 Spd Zero P Gain to one of the following settings e Ifthe speed reference is above the value set in Par 106 Ref Zero Level Set Par 124 Spd Ref Zero En 1 Enabled e Ifthe speed reference and or the reaction are above the value set in Par 106 Ref Zero Level set Par 124 Spd Ref Zero En 0 Disabled Par 124 Spd Ref Zero En is active only when Par 125 Spd Zero P En 1 Enabled Set the P gain for zero speed e Ifthe P gain corresponds to the value set in Par 126 Spd Zero P Gain then set Par 125 Spd Zero P En 1 Enabled e If the P gain corresponds to the normal P gain then set Par 125 Spd Zero P En 0 Disabled The P gain at zero speed is set via Par 126 Spd Zero P Gain when Par 125 Spd Zero P En 1 Enabled The threshold for the recognition of zero speed is determined by the value in Par 106 Ref Zero Level PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 C 2
342. le6 In Max 1249 Scale2 In Min 558 Scale4 In Min 1232 Scale6 In Min 1250 Scale2 In Off 559 Scale4 In Off 1233 Scale6 In Off 1251 Scale2 Out Off 560 Scale4 Out Off 1234 Scale6 Out Off 1252 Scale2 In Abs 561 Scale4 In Abs 1235 Scale6 In Abs 1253 Diameter Calc Diameter Calc 794 Line Spd Thresh 1155 Diam Preset 0 1164 DncrPosSpd 795 Line Spd Gain 1156 Diam Preset 1 1165 Max Deviation 796 Diameter Reset 1157 Diam Preset 2 1166 Gear Box Ratio 797 Diam Threshold 1158 Diam Preset 3 1167 Dancer Constant 798 Diameter Reached 1159 Diam Preset Sel 1168 Minimum Diameterl 799 Line Speed Pet 1160 Diam Inc Dec En 1205 Diameter Calc St 800 Diam Calc Dis 1161 Diam init filter 1206 Max Diameterl 1153 Diameter Filter 1162 Diam stdy delayl 1207 Roll Diameter 1154 Base Omega 1163 Winder Functions Variable J Comp 1171 Line FastStp Pct 1186 Torque Winder En 1209 Constant J Comp 1172 Winder Type 1187 W Target 1210 Materl Width Pct 1173 Torq Current Pct 1193 Actual Comp 1213 Static Friction 1174 Act Ten Ref Pct 1194 Closed Loop En 1214 Dynamic Friction 1175 Speed Match 1195 Speed Demand En 1215 Taper Enable 1176 Spd Match Acc 1196 Spd match torque 1216 Initial Diameter 1177 Spd Match Dec 1197 W Reference 1217 Final Diameter 1178 Offs Accel Time 1198 Jog TW Speed 1255 Tension Reduct 1179 W Offset 1199 Jog TW Enable 1256 Tension Ref 1180 Spd Match Gain 120
343. lication 20P UM001E EN P June 2009 General Grounding Requirements Installation and Wiring 1 11 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 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 When operating PowerFlex DC drives from an IT or impedance earthed supply system only temporary operation is permitted after an earth fault is detected in the power system ATTENTION In order to comply with the essential Figure 1 9 Typical Grounding 00000000000000000000 1 T PN E All wires including motor L oa H ground must be connected UIR PPP Ol H inside the motor terminal box 24 ED i AC Line Reactor ransformer PowerFlex Digital DC Drive User Manual Publication 20 001 J
344. ll cause an alarm Stop Jog Fwd CF Start Run Run Fwd Run Revl 1 2 JogFwd Jog Rev Rev Start A A A A A Stop CF Run Run Fwd Run Rev dB E3 Jog 1 2 Jog Fwd Jog Rev Fwd Rev m BL More than one physical input has been configured to the same input function Multiple configurations are not allowed for the following input functions Forward Reverse Run Reverse Run Forward Jog Forward Jog Reverse Speed Select 1 Speed Select 2 Speed Select3 2 2 Accel 2 Decel 2 Run One of the following has occurred Par 414 Fdbk Device Type is set to 1 Encoder and Par 1021 Encoder Out Sel is not set to Off If you are using an encoder set Par 1021 Encoder Out Sel to 0 Off e More than one of the following parameters contains the same value Pars 1021 Encoder Out Sel 70 75 and 80 Anlg Inx Sel and or 1323 1327 DPI Px Select The drive is not receiving a speed feedback signal from the encoder Refer to the Feedback Loss fault description on page 4 5 for more information The selected operating mode of the field controller is in conflict with another setting in the drive This alarm displays under the following conditions e Par 469 Field Mode Sel Field Weaken or External and Par 458 SpdReg FB Bypass Enabled e Par 469 Field Mode Sel Field Weaken or External and Par
345. locks 3 43 Ramp Out 113 Speed Meters 3 11 Scaled In Off 1242 Scale Blocks 3 44 Ramp Out Pct 114 1 Speed Meters 3 11 Scaled Input 1237 Scale Blocks 3 43 Ramp Select 0 403 Diagnostics 3 54 Scale5 Mul 1238 Scale Blocks 3 43 Ramp Select 1 404 Diagnostics 3 54 Scale5 Out Off 1243 Scale Blocks 3 44 Ramp Type Select 18 Ramp Rates 3 32 Scale5 Output 1236 Scale Blocks 343 Rated Motor Volt 175 Motor Data 3 15 Scale6 Div 1248 Scale Blocks 3 43 Real FF PID 418 PID Control 3 40 Scale6 In Abs 1253 Scale Blocks 3 44 Ref Line Speed 1286 Winder Functions 3 49 Scale6 In Max 1249 Scale Blocks 3 43 Ref Spd Source 1284 Winder Functions 3 49 Scale6 In Min 1250 Scale Blocks 3 43 Ref Speed Gain 1285 Winder Functions 49 Scale6 In Off 1251 Scale Blocks 3 44 Ref Zero Level 106 Speed Regulator 3 28 Scale6 Input 1246 Scale Blocks 3 43 Reference Mask 595 Masks amp Owners 3 63 Scale6 Mu 1247 Scale Blocks 3 43 Reference Owner 604 Masks amp Owners 3 64 Scale6 Out Off 1252 Scale Blocks 3 44 Relay Out 1 Sel 1392 1 Digital Outputs 3 75 Scale6 Output 1245 Scale Blocks 3 43 Relay Out 2 Sel 629 Digital Outputs 3 75 Selected TorqRef 14 Current Meters 3 34 Reset Defaults 258 Drive Memory 3 50 Set Fld Curve 919 Field Config 3 18 Reset Fld Curve 920 Field Config 3 18 SLAT Dwell Time 16 Control Config 3 32 Roll Diameter 1154 Diameter Calc 3 45 SLAT Err Stpt 15 Control Config 3 32 S Curve Accel 1 665 Ramp Rates 3 34 Software Version 331 Configuration 3 14 S Cu
346. lt a eod 610 uoisieAu 2714 698 d l OG Avc o lt q 3 L ps ano P lt o o Z INO UOISISAU 9714 42 oq A z b Fe pno ebia woe SEI o O lt il Lino uoisieAu Sbld 9c 1924 sindino 2610 yoolg euw les gul ag lt 1 ge o o KA Orid 8 Ul UOISISAU a 890 8214 2 les Zu PO 1 UJ UOISISAU 28214 EENG geld 9 U UOISIAU 990 1821 d I 0 1 2 soa EINEN 196 LV 1614 G Ul UOISIGAU 690 08214 2 Ti v HOOIG IEUILLIEL 2190 2 les 2141 ebia 4 rd 211 Ul UOISIAU 06 1d les Lu eg lt O LE uj uoisjenu 68614 ioa les 01 Ef lt O 01 uj UOISISAU 88614 69a les 641 PO lt O Hid 6 Ul UOISISAU 18614 ieuondo sindu ef uorsuedx3 Woozd o d 911 ongu o o D 2 eje UOISISAU 18S Z MO fel H SL 9 214 6294 1 wn lt o 4 9 1 oun 4 Agjay uoisienu 195 MO feet S 66ld 28214 s nd no uoisuedx3 pue piepuels s nd no s ndui 211010 yoq ri amp les pul Elifiq 3 1 9 O o o A 9614 e Ul UOISISAU 90 amp ad 9 90 les eui Elifiq lt 19 O o o A Seid Ul UOISJOAU
347. lue 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 Trim Ramp Pct Trim ramp value defined as a percentage of the value defined in Par 45 Max Ref Speed Trim Speed Pct Trim speed reference value defined as a percentage of the of the value defined in Par 45 Max Ref Speed 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 Spd Reg Kp Proportional gain of the speed regulator that can be adjusted while the drive is running Spd Reg Ki Integral gain of the speed regulator that can be adjusted while the drive is running Spd Reg Kp Base The proportional gain of the speed regulator base value Spd Reg Ki Base The integral gain Kio of the speed regulator base value Spd Reg Pos Lim Positive Speed Regulator output limit When this limit is active the positive integrator portion of the PI regulator is held to prevent windup Note This parameter was added with firmware version 3 001 Programming and Parameters Values Default 1 Min Max 0 10 Units S Default 0 Min Max Par 45 Max Ref Speed 1 Units rpm The value of Max Ref Speed cannot exceed 8192 rpm Default 0 Min Max Par 45 Max Ref Speed Units rpm The value of Par 45 Ma
348. mann Ferraz Shawmut Gould Shawmut SIBA Rating DC Code Square Body Flush End Contact 495 170M5462 switch 170H0069 16 9 URD 32 TTF 630 switch MS3 V1 5BS 20 671 32 630 switch 2800104 667 170M5464 switch 170H0069 6 9 URD 32 TTF 800 switch MS3 V1 5BS 120 671 32 800 switch 2800104 Figure A 8 Frame C Regenerative Drive Leg Fuse Location Leg fuses and switches are located on the bus bars behind the Control EMI shield which holds the Control board Note Drive shown with front covers removed and Control EMI shield lowered PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Supplemental Drive Information A 15 Table A K Recommended AC Input Line Fuses 230V AC Input Frame C Non Regenerative Drives Only Drive EE Fuse Code FS4 See Figure A 6 on page A 12 and Figure A 8 below for location Current AC Bussmann Ferraz Shawmut Gould Shawmut SIBA Rating Line Code Amps Amps Quantity Square Body Flush End Contact 521 170M5466 switch 170H0069 6 9 URD 32 TTF 1000 switch MS3 V1 5BS 20 671 32 1000 switch 2800104 Table A L Recommended AC Input Line Fuses 460V AC Input Frame C Non Regenerative Drives Only Drive Fuse Code FS4 See Figure A 6 on page A 12 and Figure A 9 on page A 15 for location Current Bussmann Ferraz Shawmut Gould Shawmut SIBA Rating DC Code Amps Amps Quantity Square Body Flush End Contact
349. mits 3 35 Hd Weaken Ratio 456 Field Config 3 16 Droop Percent 696 Load Limits 3 35 FldLoss Flt Cfg 473 Alarms 3 58 Div Fld Brdg Cur 374 1Motor Data 3 16 Flux Divide 462 Field Config 3 16 Dynamic Friction 1175 Winder Functions 3 47 Flux Filter BW 463 Field Config 3 16 Elapsed Lifetime 235 Drive Data 3 14 Flux Ref Pct 500 Current Meters 3 13 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Programming and Parameters 3 79 Name No Group Page Name No Group Page Flying Start En 388 Speed Regulator 3 30 Max Speed Rev 4 Limits 3 26 Force Min Field 498 Field Config 3 17 Maximum Speed 2 Limits 3 26 Freeze Ramp 373 Ramp Rates 3 34 Min Fld Curr Pct 468 Field Config 3 17 Friction 1015 Autotune 3 23 Min Speed Fwd 5 Limits 3 26 Gear Box Ratio 797 Diameter Calc 3 44 Min Speed Rev 6 Limits 3 26 Reg Error 587 Autotune 23 Minimum Diameter 799 Diameter Calc 44 nertia 1014 Autotune 3 23 Minimum Speed 1 Limits 3 26 nertia C Filter 1012 Autotune 3 23 MOP Accel Time 22 Ramp Rates 3 33 nertiaCompAct 1191 Speed Regulator 3 91 MOP Dec Active 397 Diagnostics 54 nertiaCompVar 1192 1 Speed Regulator 3 31 MOP Decel Time 30 Ramp Rates 3 33 nitial Diamet
350. mmunications file 3 63 compare analog input signals C 5 compensation droop C 9 configure AC input contactor 1 9 analog inputs C 4 DC output contactor 1 9 dynamic brake resistor 1 9 feedback signal C 15 Klixon 1 31 line speed signal C 14 programmable controller A 6 PTC 1 31 start at powerup C 35 tension set point signal C 17 thermal switch 1 31 thermistor 1 31 Constant J Comp 3 46 Contactor Conflict alarm 4 9 ContactorControl 3 72 contactors AC input A 18 configure 1 9 DC output A 20 control block diagrams D 1 Control Config group 3 32 Index 3 control power circuit fuses A 16 control wire routing 1 50 Copycat B 4 corrective actions for drive problems 4 11 cross reference parameter name 3 77 parameter number 3 82 Cur Lim Neg Out 3 13 Cur Lim Pos Out 3 13 current configuration field 1 30 Current Lim Neg 3 19 Current Lim Pos 3 19 Current Limit 3 19 Current Meters group 3 13 Current Reg In 3 13 current regulator adjust C 37 tune settings C 37 current speed curve function C 6 CurrLimit Active 3 51 CurrReg Autotune 3 22 D Dancer Constant 3 44 data save B 4 Data In A1 3 65 Data In A2 3 65 Data In Ax 3 65 Data In B1 3 65 Data In B2 3 65 Data In C1 3 65 Data In C2 3 65 Data In D1 3 65 Data In D2 3 65 Data In SelData 3 65 Data In Val Sel 3 65 data nameplate p 2 Data Out A1 3 65 Data Out A2 3 65 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 Index 4
351. mp or speed PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 37 Manually Adjusting the Current Regulator Tune Settings While the drive is operating the value of Par 587 I Reg Error is updated in response to changes in the current output to the motor By manually applying current steps to the motor this parameter can be used as an indication whether the current regulator in the drive is correctly tuned Ideally the value should be as near to zero as possible but values between 40 and 40 are acceptable during normal operation because the drive is responding to changing current demands Manually tuning the Current Regulator will attempt to have Par 587 I Reg Error reach its lowest value in response to applied steps in current to the motor Adjustments to Par 587 I Reg Error are made by changing Par 454 Arm Inductance and stepping the current to the motor Par 587 I Reg Error values are only valid when the drive is operating under at least a 3096 current load The manual tuning procedure will progress through larger current steps up to 100 Par 454 Arm Inductance and Par 453 Arm Resistance are the current regulator tuning parameters and typically will not match motor data sheets values Manual Current Loop Tuning When attempting to manually tune the current loop the current reference will be stepped to values that may cause the motor to rotate even while the field
352. n 1370 LG228 250 265 280 400MCM 2 0 0 5 in 0 375 in 1370 LG268 1 The Rated Motor Armature Current is taken directly from the motor nameplate or motor data The current listed in this column is the maximum current allowed for the Armature Conductor Size column 3 and the DC Contactor Rating column 2 The armature conductors are sized by multiplying the Rated Motor Armature Current by 1 25 as provided for in NEC 420 22 1987 The DC lug ratings are determined from NEC Table 310 16 1987 for copper conductors insulation temperature rated at 75 C 167 F at an ambient temperature of 30 C 86 F If conditions are other than shown in NEC Table 310 16 then refer to application codes 8 The dynamic braking DB conductors are sized as in footnote 2 above but at half ampacity due to the short time duration of current flow in these conductors and has been sized to satisfy NEMA Standard ICS 3 302 62 Dynamic Braking f the load inertia is larger than that of the motor calculations must be made to determine correct conductor sizing and DB resistor wattage per NEMA Standard ICS 3 302 62 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 External and Internal Connections LCD Display Elements HIM Overview Appendix B For information on See page For information on See page External and Internal Connections 1 Menu Structure B 3 LCD Display Elements B 1 Viewing and Editing Par
353. n page 1 7 for information on removing the drive covers 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 ATTENTION Do not operate the drive with the power PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 24 Installation and Wiring Figure 1 15 Frame B Armature Converter Terminal Block Location Figure 1 16 Frame C Armature Converter Terminal Block Location Front View PE D ADANGER bai Bottom View PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Table 1 E Armature and Safety Ground PE Terminal Specifications E Rating Code 230V 460V Terminals Wire Size and Type A 7P0 4P1 9PO 6 012 010 020 014 019 U V W C D PE 029 027 038 035 055 045 052 073 073 093 086 110 U V W C D PE 100 129 B 146 167 U V W C D PE 180 1 U V W C D ee o 218 207 UV WC D See Cable and Wiring Recommendations on PE page 1 17 265 250 U VW C D PE 330 U V W C D PE 360 412 U VW C D PE 434 U VW C D PE C 1521 495 U VW C D PE 667 U VW C D PE Installation and Wiring Terminal Bolt Size mm 1 25
354. n parameters 200 Arm Current and 199 Arm Current Pct Increase the value of parameter 7 Current Limit 8 Current Lim Pos or 9 Current Lim Neg e Verify that the measured motor field current using an in line current meter or DC clamp on meter equals the feedback value displayed in parameter 351 Field Current e Verify that the motor nameplate value equals the value displayed in parameter 280 Nom Mtr Field Amps e Measure the DC voltage supplied to the motor field Verify that the value of parameter 374 Drv Fld Brdg Cur equals the setting of DIP Switch 14 f the motor does not rotate with the load removed check the motor e Verify that parameter 353 Zero Torque is not enabled PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 4 14 Troubleshooting The motor does not reach commanded speed Drive Symptom Action The drive starts and the motor turns but does The load may be too great for the motor and drive reach the commanded speed e Remove the load from the motor and test for the correct commanded speed If the motor reaches the commanded speed then verify that the measured armature current using an in line current meter or DC clamp on meter equals the armature current feedback value displayed in parameters 200 Arm Current and 199 Arm Current Pct Increase the value of parameter 7 Current Limit 8 Current Lim Pos or 9 Current Lim Neg Verify that the meas
355. nalog input 1 Units based on the value Min Max 20 00 set in Par 71 Anlg In1 Config Units VormA 1405 Analog In2 Value Default Read Only 76 Value of the signal at analog input 2 Units based on the value Min Max 20 00 set in Par 76 Anlg In2 Config Units VormA 1406 Analog In3 Value Default Read Only 81 Value of the signal at analog input 3 Units based on the value Min Max 20 00 set in Par 81 Anlg In3 Config Units VormA 62 Anlg Outi Scale Default 1 00 63 Anlg Out2 Scale a 64 Anlg Out3 Scale Min Max 410 00 65 Anlg Out4 Scale Scaling of the analog outputs 66 Anlg Outi Sel Default 12 Motor Speed 67 Anlg Out2 Sel Default 13 Motor Curr 68 Anlg Out3 Sel Default 18 Ed Current 69 Anlg Out4 Sel Default 14 Motor Volts Selects the source of the value that drives the analog output This parameter is used to configure an analog output on the UO Expansion circuit board Refer to Appendix F Optional Analog and Digital I O Expansion Circuit Board Options No Option Par Scaling of Analog Output Value No Option Par Scaling of Analog Output Value 0 Off Not used n a 18 Fld Current Par 234 0 10V 0 100 of Par 280 Nom Mir Fld Amps 1 Spd Ref Out Par 385 10 100 of Par 45 Max Ref 19 UserDefined0 Par 503 10V 2047 in Par 503 Speed UserDefinedO 2 Trim Ramp Par 42 10V 100 of Par 45 Max Ref 20 UserDefined1
356. nd Corrective Actions 4 11 Drive will not Start Dee Hee e FAC Ee CR NR test 4 11 Drive starts but motor does not turn and no armature current 4 13 The motor does not reach commanded speed 4 14 The motor is turning in the wrong direction 4 14 The motor reaches maximum speed immediately 4 15 Testpoint Codes and Functions 4 15 Supplemental Drive Information Specifications m T A 1 IP20 NEMA UL Type Open Watts Loss A 5 Communication Configurations A 6 Typical Programmable Controller Configurations A 6 Logic Command Status Words A 6 Drive Power Circuit Protection llle A 8 Frame A and B Fuse Information A 8 Frame C Fuse Information A 12 Control Power Circuit Protection Fuses A 16 AC Input Line Reactors and AC Input Contactors A 18 DC Output Contactors and Dynamic Brake Resistor Kits A 20 DC Contactor Crimp Lug Kit Specifications A 22 HIM Overview External and Internal Connections
357. nderVolt Thresh 481 Alarms 3 58 Speed Ref Out 385 Speed Meters 3 12 UserDefinedO 503 User Defined 3 60 Speed Reg En 242 Speed Regulator 3 30 UserDefined1 504 User Defined 3 60 Speed Reg In 118 Speed Meters 3 12 UserDefined10 513 User Defined 3 60 Speed Reg In Pet 117 Speed Meters 3 12 UserDefined11 514 User Defined 3 60 Speed Thresh Neg 102 Speed Regulator 3 28 UserDefined12 515 User Defined 3 60 Speed Thresh Pos 101 Speed Regulator 28 UserDefined13 516 User Defined 3 60 Speed Threshold 393 Diagnostics 3 53 UserDefined14 517 User Defined 3 60 Speed Tune Dir 1029 Autotune 3 23 UserDefined15 518 User Defined 3 60 Speed Tune Ki 1033 Autotune 3 23 UserDefined2 505 User Defined 3 60 Speed Tune Kp 1032 1 Autotune 3 23 UserDefined3 506 User Defined 3 60 Speed Up Base 446 Speed Regulator 3 30 UserDefined4 507 User Defined 3 60 Speed Up Filter 447 Speed Regulator 3 30 UserDefined5 508 User Defined 3 60 Speed Zero Delay 108 Speed Regulator 3 29 UserDefined6 509 User Defined 3 60 Speed Zero Level 107 Speed Regulator 3 29 UserDefined7 510 User Defined 3 60 Spd Zero P Gain 126 Speed Regulator 3 29 UserDefined8 511 User Defined 3 60 Start At Powerup 1344 Restart Modes 3 36 UserDefined9 512 User Defined 3 60 Start Inhibits 1403 Diagnostics 3 56 UsrDefBitWrdA 519 User Defined 3 60 Start Mask 592 Masks amp Owners 3 63 UsrDefBitWrdAO 520 User Defined 3 61 Start Owner 601 Masks amp Owners 3 64 UsrDefBitWrdA1 521 User Defined 3 61 Static F Zero 12
358. ne Analog Inputs 3 68 135 Digital In3 Sel Digital Inputs 3 70 261 AnlgIn3 Tune Analog Inputs 3 68 136 Digital In4 Sel Digital Inputs 3 70 263 Clear Fault Que Faults 3 56 137 Digital In5 Ge Digital Inputs 3 70 266 Jog Speed Discrete Speeds 3 26 138 Digital In6 Sel Digital Inputs 3 70 267 TB Manual Ref Discrete Speeds 3 27 139 Digital In7 Sel Digital Inputs 3 70 280 Nom Mtr Ed Amps Motor Data 3 15 140 Digital In8 Sel Digital Inputs 3 70 295 AnlgIn1 Target Analog Inputs 3 68 141 Digital In9 Sel Digital Inputs 3 70 296 10 In2 Target Analog Inputs 3 68 142 Digital In10 Sel Digital Inputs 3 70 297 Anlgin3 Target Analog Inputs 3 68 143 Digital In11 Sel Digital Inputs 3 70 300 Drive Type Drive Data 3 14 144 Digital In12 Sel Digital nputs 3 70 302 1 Language Drive Memory 3 51 145 Digital Out1 Se Digital Outputs 3 73 381 Software Version Configuration 3 14 146 Digital Out2 Se Digital Outputs 3 73 342 Torque Reduction Torque Attribute 3 19 147 Digital Out3 Se Digital Outputs 3 73 344 Zero Ramp Output Ramp Rates 3 34 148 Digital Out4 Se Digital Outputs 3 73 345 Zero Ramp Input Ramp Rates 3 34 149 Digital Out5 Se Digital Outputs 3 73 346 Torque Positive Diagnostics 3 51 150 Digital Out6 Sel Digital Outputs 3 73 347 1 Torque Negative Diagnostics 3 51 151 Digital Out7 Sel Digital Outputs 3 73 348 Lock Speed Integ Speed Regulator 3 30 152 Digital Out8 Se Digital Outputs 3 73 349 CurrLimit Active Diagnostics 3 51 154 Preset
359. nfigured 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 before performing these procedures ATTENTION Power must be applied to the drive to perform A the follovving 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 follovving procedure Thoroughly read and understand the procedure before beginning If an event does not occur vvhile performing this procedure Do Not Proceed Remove Power including user supplied control voltages Correct the malfunction before continuing Important It is recommended that you uncouple the motor from all loads at this time until otherwise directed This checklist contains the major steps required to complete the drive commissioning procedure Verify all Drive Configuration Settings page 2 2 Verify the Power Wiring page 2 2 Verify the Control and I O Wiring page 2 2 Appiy Voltage to the Control Circuits page 2 3 Verify the Control Voltages page 2 5 Load the Default Settings page 2 5 Configure the Most Commonly Used Parameters page 2 5 Tune the Current Regulator page 2 10 Verify Motor Rotation and Run F
360. nformation A 5 IP20 NEMA UL Type Open Watts loss data shown below is based on the rated current of the drive Watts Loss Important For drives with 230V input rated 150 HP 521 A the cooling fans must be powered by an external 230V 50 60 Hz power supply at terminals U3 amp V3 2 Drive Current Rating E Code Total Watts Fans u 230V 0 460V Loss W Voltage V Rated Current A Air Capacity m3 h A 7P0 4P1 9P0 6P0 012 010 131 m 020 014 019 029 027 186 038 035 055 045 254 80 052 073 073 408 160 093 086 110 S 476 160 100 129 s Internal power supply w B 146 167 180 781 320 218 207 939 320 265 250 1038 320 330 1248 320 360 412 434 m 1693 680 C 1521 495 2143 230 0 75 1050 m 667 2590 230 0 75 1050 4 Refer to Standard Drive Catalog Number Explanation on page Preface 4 positions 8 10 for corresponding drive HP rating armature amp rating and field amp rating PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 A 6 Supplemental Drive nformation Communication Typical Programmable Controller Configurations Configurations Important If block transfers are programmed to continuously write information to the drive care must be taken to properly format the block transfer If attribute 10 is selected for the block transfer values will be wr
361. ng and configuration of Par 181 Adaptive Spd En PD Deriv Gain 3 Third derivative gain of the PD block The value specified in this field depends on the enabling and configuration of Par 181 Adaptive Spd En Real FF PID Represents the feed forward value which has been recalculated according to the PI correction It will be calculated with the following formula Par 418 Real FF PID Par 758 Feed Fwd PID 1000 x Par 771 PI Output When either the negative or positive limit of this parameter has been reached further increases in the value of Par 771 PI Output will be blocked in order to avoid undesirable saturation of the PID regulator For example When Par 758 Feed Fwd PID 8000 the positive limit of Par 771 PI Output will be automatically set at 10000 8000 1000 1250 PID Steady Delay The amount of time for which the gains in Pars 793 PI Init Prop Gn and 734 PI Init Intgl Gn will remain enabled after feed forward has exceeded the threshold value defined in Par 695 PI Steady Thrsh PI Init Intgl Gn The initial value of the integral gain This parameter is active when feed forward is greater than the value defined in Par 695 PI Steady Thrshl or Par 769 Enable PI transitions from 0 low to 1 high and the amount of time defined in Par 731 PID Steady Delay has elapsed PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Values Default
362. nits Default Min Max Default Min Max Default Min Max Default Options Default Min Max Default Min Max Units Off Off On 0 0 1 83 88 0 30 300 00 S 83 88 0 30 300 00 S 83 88 0 30 300 00 S 0 0 1000 rpm 100 0 150 0 071 0 0 100 Read Only 0 32767 0 0 65535 Read Only 432767 Disabled Disabled Enabled 0 0 1 0 0 65535 Read Only 4200 Related 1921 lt e a a lt Group Winder Functions No 1214 1215 1216 1217 1255 1256 1284 1285 1286 1287 Parameter Name amp Description See page 3 2 for symbol descriptions Closed Loop En Enables Disables closed loop tension control used with a load cell Speed Demand En Enables Disables the speed reference calculation for the Torque Winder application Spd match torque Sets the torque current during the launching and change phase W Reference Angular speed reference Note This parameter can be assigned to an analog output 10V 100 of Par 45 Max Ref Speed Jog TW Speed Torque Winder jog reference The parameter is entered as a percentage of Par 1160 Line Speed Pct Jog TW Enable Enables Disables the Torque Winder jog function Note This parameter can be assigned to a digital input Ref Spd Source Number of the line speed refer
363. nlg In1 Sel 70 Anlg2 Tune Scale 78 Anlg In2 Target 296 Anlg In1 Config 71 Anlg In2 Offset 79 Anlg In3 Target 297 Anlg Int Scale 72 Anlg In2 Tune 260 Anlg In1 Cmp 1042 Anlgi Tune Scale 73 Anlg In3 Sel 80 Anlg In1 Cmp Err 1043 Anlg Int Offset 74 Anlg In3 Config 81 Anlg Inf Cmp Dly 1044 Anlg In1 Tune 259 Anlg In3 Scale 82 Anlg Int Cmp Eql 1045 Anlg In1 Filter 792 Anlg3 Tune Scale 83 Analog Int Value 1404 Anlg In2 Sel 75 Anlg In3 Offset 84 Analog In2 Value 1405 Anlg In2 Config 76 Anlg In3 Tune 261 Analog In3 Value 1406 Anlg In2 Scale 77 Anlg Int Target 295 Analog Outputs Anlg Out1 Sel 66 Anlg Out4 Sel 69 Analog Out3 Scale 64 Anlg Out Sel 67 Analog Out Scale 62 Analog Out4 Scale 65 Anlg Out3 Sel 68 Analog Out2 Scale 63 Digital Inputs ContactorControl 1391 Digital In12 Sel 144 Dig In Term 1 565 Dig In Status 564 Inversion In 1 1276 Dig In Term 2 566 Digital In1 Sel 133 Inversion In 2 1277 Dig In Term 3 567 Digital In2 Sel 134 Inversion In 3 1278 Dig In Term 4 568 Digital In3 Sel 135 Inversion In 4 1279 Dig In Term 5 569 Digital In4 Sel 136 Inversion In 5 1280 Dig In Term 6 570 Digital In5 Sel 137 Inversion In 6 1281 Dig In Term 7 571 Digital In6 Sel 138 Inversion In 7 1282 Dig In Term 8 572 Digital In7 Sel 139 Inversion In 8 1283 Dig In Term 9 573 Digital In8 Sel 140 Inversion In 9 1387 Dig In Term 10 574 Digital In9 Sel 1
364. nlg Out2 Sel Analog Outputs 3 69 18 Ramp Type Select Ramp Rates 3 32 68 Anlg Out3 Sel Analog Outputs 3 69 19 S Curve Time Ramp Rates 3 33 69 Anlg Out4 Sel Analog Outputs 3 69 20 Ramp Delay Ramp Rates 3 33 70 Anlg Ini Sel Analog Inputs 3 67 22 MOP Accel Time Ramp Rates 3 33 71 Anlg Int Config Analog Inputs 3 67 24 Accel Time 2 Ramp Rates 3 33 72 Anlg Int Scale Analog Inputs 3 67 30 MOP Decel Time Ramp Rates 3 33 78 Anlg1 Tune Scale Analog Inputs 3 67 32 Decel Time 2 Ramp Rates 3 33 74 Anlg Int Offset Analog Inputs 3 68 38 Fast Stop Time Stop Modes 3 35 75 Anlg In2 Sel Analog Inputs 3 67 39 Torque Ref Torque Attribute 3 19 76 Anlg In2 Config Analog Inputs 3 67 40 Trim Torque Torque Attribute 3 19 TT Anlg In2 Scale Analog Inputs 3 67 41 Current Reg In Current Meters 3 13 78 Anlg2 Tune Scale Analog Inputs 3 67 42 Trim Ramp Speed Reference 3 27 79 Anlg In2 Offset Analog Inputs 3 68 43 Trim Speed Speed Reference 3 27 80 Anlg In3 Sel Analog Inputs 3 67 44 Speed Ref A Speed Meters 3 11 81 Anlg In3 Config Analog Inputs 3 67 45 Max Ref Speed Motor Data 3 15 82 Anlg In3 Scale Analog Inputs 3 67 47 Speed Ref A Pct Speed Meters 3 11 83 Anlg3 Tune Scale Analog Inputs 3 67 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009
365. not accessible through any other parameters Typically these are internal drive variables and registers Refer to Testpoint Codes and Functions on page 4 15 for more The present value of the function selected in Par 1381 Testpoint Sel Displays the source that initiated the most recent stop sequence Values Default Min Max Default Min Max Default Min Max Default Min Max Default Min Max Default Min Max Default Options 566 566 574 Read Only 231 231 1 0 00 100 00 Read Only 0 00 100 00 Read Only 0 00 100 00 Read Only 0 00 100 00 Read Only Pwr Removed DPI Port 1 5 Reserved Digital In Fault Not Enabled Reserved Jog Selftune Reserved o Il ch ED 00 4 SDS y Displays the inputs currently preventing the drive from starting For each bit 1 Inhibit condition true and O Inhibit condition PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 false S E BIBIE IEE IS Ele BIZ 0829 z 2 S iS S S S le e SE jx z 2 in Og 0 S 15 E 16 Blo 8 a je 2 Sig 9 8 0219 Q O qn nq o o ju je Default x x x 0 0 0 0 0 x 008 x 0 0 0 Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 10 Clea
366. nput 6 7 Digital Input 7 8 Digital Input 8 Com Digital Input Common Table G C 1 0 Converter Board M_OUT Terminal Block Designations No Signal Description 24V 24VDC Supply 24V DC 10 40mA power supply Max load 120mA Supply power can be provided by the 24V DC supply on the Control board I O terminal 19 see Figure G 2 on page G 3 or an external source see Figure G 3 on page G 3 1 Digital Output 1 Output type Open collector PNP type 2 Digital Output 2 E 2 ini utput current 10mA max m Dub Deli time hw OFF to ON 5ms typ Delay time hw ON to OFF 50ms typ 5 Digital Output 5 6 Digital Output 6 7 Digital Output 7 8 Digital Output 8 OV 124V Common Common for the power supply f an internal supply is used this terminal must be wired to the digital input common terminal 16 or 35 on the Control board 1 0 See Figure G 2 on page G 3 e f an external supply is used this terminal must be wired to the external 24V DC supply common and the digital input common terminal 16 or 35 on the Control board 1 0 See Figure G 3 on page G 3 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Optional 115V AC to 24V DC 1 0 Converter Circuit Board G 3 Figure G 2 1 0 Converter Board with Internal Supply Wiring Diagram o m e S o
367. nputs for 0 10V set parameters Anlg Inx Config to 1 0 10V To configure the analog inputs for a current signal set parameters Anlg Inx Config to 2 0 20mA or 3 4 to 20mA In addition switches S9 S10 and S11 must be properly configured refer to Table 1 M on page 1 39 for more information From Digital Reference Setting Anlg In1 Config Analog Input 1 10V dui Tune Scale C Int Tune 1 0 Ref_1 1 e Anig int Sel Y Speed Ref A Volts Anlg In1 Target DEA HI Anlg In1 Er 0 Window comparator Anlg In1 Scale Anlg In 1 Filter 1 0ms mm i 0 Anlg 111 Cmp Eq Anlg In Cmp Diy Refer the Analog Inputs Outputs amp Mapping block diagram on page 4 for more information Example 1 The speed reference value of a drive is defined with an external voltage of SV With this value the drive should reach the maximum allowable speed set in Par 45 Max Ref Speed Enter a scaling factor of 2 in Anlg Inx Scale to scale the input voltage from SV to 10V Example 2 An external analog reference reaches a maximum value of 9 8V Enter a scaling factor of 1 020 in Anlg Inx Scale to scale the maximum voltage from 9 8V to 10V The same result could be obtained via parameter Anlgx Tune Scale by entering th
368. nt Par 753 TrqTpr_Lim2 Par 754 TrqTpr_Lim3 Par 755 TrqTpr Lim4 Par 162 Max Feedback Spd Par 756 TrqTpr_Spd Speed PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Drive Reference and Feedback Scaling Application Notes C 7 e Enable the current speed curve function by setting parameter 750 TrqTpr Enable to 1 Enabled e Setthe current limit for both directions of rotation in four quadrant drives in parameter 751 TrqTpr Lim0 The value specified in this parameter overrides the value of parameters 8 Current Lim Pos and 9 Current Lim Neg e Setthe threshold speed at which current torque reduction begins in parameter 756 TTrqTpr Spd e Set the first reduced current limit in parameter 752 TrqTpr_Lim1 The value defined in this parameter must be less than the value in parameter 751 TrqTpr Lim0 and greater than the values in parameters 753 TrqTpr_Lim2 754 TrqTpr Lim3 and 755 TrqTpr Lim4 e Setthe second third and final reduced current limits in parameters 753 TrqTpr Lim2 754 TrqTpr_Lim3 and 755 TrqTpr_Lim4 respectively The value of each subsequent parameter must be less than the previous parameter s value The drive will maintain the value specified in parameter 755 TrqTpr Lim4 up to the value set in parameter 162 Max Feedback Spd With firmware version 3 001 external reference and feedback speed values are each normalized to 25 000
369. o 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 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 for more information Important In order to access all parameters in this procedure you must set the Parameter View option to Advanced 1 Atthe Main menu scroll to the Parameter option and press the ALT and then Sel button Scroll to the Numbered List option and press Enter Type 211 and press Enter Press the Sel button Type 1 and press Enter Press the Esc button Press the ALT and then Sel button Scroll to the File Group Par option and press Enter SF d e gU ROG Sa Scroll to the Motor Control file and press Enter PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 2 6 Drive Start Up 10 With the Motor Data group selected press Enter and configure the following parameters Note Parameters 45 Max Ref Speed and 162 Max Feedback Spd are typically set to the motor nameplate base speed However if a speed feedback device is used encoder or tachometer refer to Drive Reference and Feedback Scaling on page C 7 for details on setting these param
370. oard G 2 UO expansion circuit board F 1 PE ground 1 25 standard 1 0 1 42 wiring 2 wire control non reversing 1 46 2 wire control reversing 1 46 3 wire control 1 46 1 47 bipolar signal 1 46 bipolar speed reference 1 45 enable input 1 46 encoder 1 49 expansion circuit board F 2 joystick 1 45 potentiometer 1 45 power 1 19 sourcing digital output 1 47 unipolar speed reference 1 45 wiring diagrams UO converter circuit board G 3 wiring examples standard 1 0 1 45 VVrite Mask Act 3 66 Write Mask Cfg 3 66 Z Z Capture Pos En 3 22 Z Captured Pos 3 22 Z Channel Enable 3 22 Zero Ramp Input 3 34 Zero Ramp Output 3 34 Zero Torque 3 19 Index 25 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Index 26 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 154A42 U S Allen Bradley Drives Technical Support Tel 1 262 512 8176 Fax 1 262 512 2222 Email support drives ra rockwell com Online www ab com support abdrives www tockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core E Cyberport 3 100 Cyberport Roa
371. of the motor shaft rotation Options 1 Forward seen from the motor shaft side for the speed regulator auto 2 Reverse tuning procedure e Forward Clockwise rotation e Reverse Counter clockwise rotation 1030 Spd Tune Inertia Default Read Only Motor inertia value identified during the speed regulator auto Min Max 0 00 1000 00 tuning procedure Units Kg x m 1031 SpdTune Friction Default Read Only Motor friction value identified during the speed regulator auto 1 Min Max 0 00 99 99 tuning procedure Units N m 1032 Speed Tune Kp Default Read Only Proportional gain value of the speed regulator identified during Min Max 0 00 100 00 the speed regulator auto tuning procedure 1033 Speed Tune Ki Default Read Only Integral gain value of the speed regulator identified during the Min Max 0 00 100 00 speed regulator auto tuning procedure 1048 Autotune Cur Lim Default 20 Value of the torque current limit applied during the speed Min Max 0 Based on drive current rating regulator auto tuning procedure Units 3 23 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 24 File MOTOR CONTROL Programming and Parameters z 58 59 60 61 Parameter Name amp Description See page 3 2 for symbol descriptions Values TstGen Output Default 0 NotConnected Allows you
372. ol descriptions Values 1377 Write Mask Act Read Only 1378 The status of write access for the DPI ports When bit 15 is set network security is controlling the write mask instead of Par 1378 Write Mask Cfg 0 Read Only 1 Write Permitted x Reserved oO N oo EE le o K iz no isr o DE EE JEJE JE JEJE D x JE JEJE E S e S S IS S IS IS S 1S F S 5 S 1S5 S Z sl D jo joa joa jO jo jJO 10 p ja O D 45 SIS 1515 515 5 1515 a aa 16 z a A ala a a Default x x x x x x x x x 1 4 1 0 Bit 15 14 13 12 11 109 8 7 6 5 4 3 2 1 0 1378 Write Mask Cfg 1377 O Enables Disables parameter write access for the DPI ports Masking of the Port that is writing to this parameter is o prohibited 6 0 Read Only 1 Write Permitted x Reserved EE O IN o o fe e f lo o mr Le LO im Je jw je zE 2 5 I5 5 E g 5 5 5 S I5 I5 BS IS 2 o o S A ja ja ja ja c ga m ja ja ja s o 5 5 55 5 5 1515 9 a a a fa fa o QC 1414 4 a A ala a a d Defaut 0 X x x x x x x x x 1 1 1 hh 0 Bit 15 14 13 12 11 109 8 7 6 5 4 3 2 1 1379 Port Mask Act Read Only Bits 0 5 indicate status for DPI port communication Bit 15 indicates when security software is controlling the parameter 0 Not Active 1 Active x Reserved oO C x z Se lz e ses E 6 6 6666 62156156151515 5 ja ja ja ja mx 0 5 A
373. ommended 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 1 Relay Outputs and Thermistor Thermal Switch Wire Sizes and Specifications Wire Size and Type Tightening Flexible Multi core Torque Signal Type Terminals mm mm Nem bein Relay Outputs 35 amp 36 75 amp 76 Thermistor and 78 amp 79 0 140 1 500 0 140 1 500 26 14 0 5 4 4 Thermal Switches See Cable and Wiring Recommendations on page 1 17 for more information PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 32 Installation and Wiring Figure 1 23 Frame A Relay and Thermistor Thermal Switch Terminal Block Locations TEE EEE EIEEEEEEEY 2 Note Terminals 78 and 79 shown with 1k ohm resistor in place of temperature sensor 78 79 35 36 75 76 Figure 1 24 Frame B Relay and Thermistor Thermal Switch Terminal Block Locations 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 78 79 35 36 75 76 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring 1 33 1 25 Frame C BE and Thermistor Thermal Switch Terminal Block Locations vz 4 m mum m DANGER RISK OF ELECTRIC Bowen DISCONNECT INPUT POWER BEFORE SERVICING EQUIPMENT n en 9 218 ERT 35 36 75 76 7 H U2 V2 PE
374. on Notes Spd Reg Kp and Spd Reg Ki curves Figure C 9 Spd Reg Kp too low Figure C 11 Spd Reg Ki too high Top Par 122 Spd Feedback Top Par 122 Spd Feedback Bottom Par 199 Arm Current Pct Bottom Par 199 Arm Current Pct 20 00 ms DIV 20 00 ms DIV Figure C 10 Spd Reg Kp too high Figure C 12 Spd Reg Ki correct Top Par 122 Spd Feedback Top Par 122 Spd Feedback Bottom Par 199 Arm Current Pct Bottom Par 199 Arm Current Pct 20 00 ms DIV 20 00 ms DIV PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 43 Fine Tuning the Voltage Regulator in the Field Converter Important In most cases DC motors with independent excitation work with a constant field Par 469 Field Mode Sel 0 Base Speed In this case it is not necessary to optimize the regulator of the field current and the regulator of the armature voltage When field weakening occurs the voltage regulator keeps the armature voltage at a constant level The critical point for this regulator is at the beginning of field weakening because with the saturation of the motor field the system requires more consistent changes in the field current in order to carry out
375. on two quadrant drives Table A E Recommended Field Circuit Fuses 230V AC Input Frame A and B Regenerative and Non Regenerative Drives Fuse Code FS3 See Figure A 3 on page A 8 Figure Drive Current Rating Code 7P0 Field Amps 10 9P0 012 020 029 038 055 Type 6x32mm 073 14 093 110 A 4 on page A 11 and Figure A 5 on page A 12 for location Quantity Bussmann 2 FWH 016A6F Ferraz Shawmut Gould Shawmut E085449 SIBA 70 125 40 16 146 20 180 218 265 360 0 434 10x38mm PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 2 FWC 25A10F Internal fuses provided with the drive A60Q25 2 60 033 05 25 Supplemental Drive Information A 11 Table A F Recommended Field Circuit Fuses 460V AC Input Frame A and B Regenerative and Non Regenerative Drives Drive Fuse Code 5317 See Figure A 3 on page A 8 Figure Current A 4 below and Figure A 5 on page A 12 for location Rating Field Ferraz Shawmut Code Amps Quantity Type Bussmann Gould Shawmut SIBA 4P1 10 2 6x32mm FWH 016A6F E085449 70 125 40 16 6P0 010 014 019 027 035 045 052 073 14 086 100 129 B 167 20 2 10 x 38 mm FWC 25A10F A60Q25 2 60 033 05 25 207 250 330 412 7 Frame Inte
376. 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 3 33 acceleration and deceleration while the Jog function is active Changed option 3 Quick Stop to Fast Stop for parameters 354 Aux Inp Fit Cfg 3 58 and 365 OverTemp Fit Cfg Changed option 35 Fld Weak En to Force MinFld for parameters 133 144 3 70 Digital Inx Sel Added option 64 Invert Fit to parameters 133 144 Digital Inx Sel to allow a 3 70 digital input wired to an inverting fault device to issue an Inverting Fault F37 Updated the options for parameter 1391 ContactorControl to accommodate the 3 72 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 4 5 fault device has opened Updated the following drive specifications A 3 e Maximum short circuit rating e Control speed regulation e Torque regulation Updated the fuses identified in the Drive Power Circuit Protection tables A 8 Updated the Control Power Circuit Protection Fuses tables and fuse location A 16 illustrations Added the Lug Kit Specifications table A 22 Added the instructions for operating the PowerFlex DC drive in field weakening C 10 mode and using a DC contactor and or an inverting fault device in the armature circuit with firmware version 1 006
377. or 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 1 Par 140 Digital In8 Sel If a contactor is NOT used set to other than 31 Contactor for example 0 Not Used D Ifan auxiliary status contactor is wired to a digital input set the appropriate Digital Inx Sel parameter to 31 Contactor 17 Access the Digital Outputs group and configure the following parameters 3 Ifa contactor and a dynamic brake resistor are used OPar 629 Relay Out 2 Sel 24 ContactorDB 3 Ifa neither a contactor nor a dynamic brake resistor are used OPar 629 Relay Out 2 Sel Set to other than 24 ContactorDB or 25 Contactor for example 0 Not Used OPar 1392 Relay Out 1 Sel Set to other than 24 ContactorDB or 25 Contactor for example 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 and access the Analog Inputs group
378. or Field power module in an open loop mode By commanding a SCR firing angle specified in Par 167 Arm Test Angle or Par 168 Fld Test Angle a voltage is produced at the output of the selected power module A load greater than 500 mA is required for proper SCR operation typically an incandescent bulb or inductive load never a motor is used The Alpha Test is started as soon as Par 166 Alpha Test is set to 1 Arm Fwd armature forward 2 Arm Rev armature reverse or 3 Fld Fwd field forward The HIM displays ArmAlphaTest or FldAlphaTest while active Start and Jog commands have no affect and a motor contactor is not closed when the test mode is initiated The Alpha Test ends when Par 166 Alpha Test is set to O Off Otherwise only a digital input Enable or a Fault will stop the test a HIM Stop has no affect Changing the Alpha Test Mode set in Par 166 Alpha Test resets both test angles to their minimum firing value 180 deg Note All current and voltage limit protections are active during these tests Also the Autotune function is disabled while Alpha test is enabled PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 C 2 Application Notes Alpha Test Setup and Operation the construction and operation of this equipment and the hazards involved should perform this test Failure to observe this precaution could result in equipment damage and or bodily injury ATTEN
379. otune 3 23 1212 Acc Dec Filter Ramp Rates 3 34 1042 Anlg 111 Cmp Analog Inputs 6 1213 1 Actual Comp Winder Functions 3 48 1043 Anlg 111 Cmp Err Analog Inputs 3 68 1214 Closed Loop En Winder Functions 3 49 1044 Anlg Int Cmp Diy Analog Inputs 3 68 1215 Speed Demand En Winder Functions 3 49 1045 Anlg 111 Cmp Eq Analog Inputs 3 68 1216 Spd match torque Winder Functions 49 1046 PID Accel Time PID Control 3 42 1217 W Reference Winder Functions 3 49 1047 Decel Time PID Control 3 42 1218 Scale3 Input Scale Blocks 3 43 1048 Autotune Cur Lim Auto T ne 3 23 1219 Scale3 Output Scale Blocks 3 43 1052 Output Power Drive Data 3 14 1220 Scale3 Mul Scale Blocks 3 43 1153 Max Diameter Diameter Calc 3 45 1221 Scale3 Div Scale Blocks 3 43 1154 1 Roll Diameter Diameter Calc 4 1222 Scale3 In Max Scale Blocks 3 43 1155 Une Spd Thresh Diameter Calc 3 45 1223 Scale3 In Min Scale Blocks 3 43 1156 Spd Gain Diameter Calc 3 45 1224 Scale3 In Off Scale Blocks 3 44 1157 1 Diameter Reset Diameter Calc 4 1225 Scale3 Out Off Scale Blocks 3 44 1158 Diam Threshold Diameter Calc 3 45 1226 Scale3 In Abs Scale Blocks 3 44 1159 Diameter Reached Diameter Calc 3 45 1227 Scale4 Input Scale Blocks 3 43 1160 Line Speed Pct Diameter Calc 3 45 1228 Scale4 Output Scale Blocks 3 43 1161 Diam Calc Dis Diameter Calc 3 45 1229 Scale4 Mul Scale Blocks 3 43 1162 Diameter Filter Diameter Calc 3 45 1230 Scale4 Div Scale Blocks 3 43 1163
380. ou J0yejnBay JoyejnBay anyoipaid ur n2 pig ed wng 6pig Aen eed paedg wano pig pmd mm pig pmd yenbior o o uononpeg nbior eed Urn pay bior ld mo Bay up ung Lld oueyonpul wuy Yrd Joyejnbey US Un ul Bay 1ueun uononpeg enbio wno pig Aen Vid 110 904 4111 C Old Sog WIT JUANG 8d qu em 14 SHUI JUSLING ug feig yoolg uonoejeg apoyy nbiol wo PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 D 15 104 06 1SU09 SAWY DU AIN WON 8162 a 0824 5 Jod 07 18009 en pld 18584 D 19d lin pi i 2164 0264 amp LO peed a Dd Op 1SU09 n DU 195 9164 616d m iz np PISE Paley 5 64 O 9jqeu3 De DS 5 1 4 Dei Do Sum Die 2674 Jod Jeu Jej o4002 DEU 00Sd 18197 0197 p d 1014 Sawy Pld AN WON 0824 aseg M NOA Wy DIRE FE g rd Haz eseg dy yo Wy dy bou Pg g rd Se aseg d Deu pial Lino prey eyy AWOU093 pjal4 Jod UND Pls UIN 89 d DENOA MANO 6624 Da UIN 99104 8674 HOA 1010 N pere 9114 sn Dat UN queuno Play xew eBeyoA ndino 8487 HOA INO 19d UND Pld XEN seg bi Deu Pld DH OA Wy v6rd 1264 1984 m Burnes Dau seg dy De Pld spur nn PIS 264 ay HOA Wy 6674
381. ove the value set in Par 101 Speed Thresh Pos 1 indicates that the drive is operating below Par 101 Speed Thresh Pos At Speed O indicates that the actual speed is within the range specified in Par 104 At Speed Error 1 indicates that the actual speed is outside the range specified in Par 104 At Speed Error CurrentLimit 0 indicates that the drive is not limiting output current 1 indicates that the drive is limiting the output current Ready 1 indicates that the drive is powered Enabled and no Start Inhibits exist The state of the assigned digital output matches the state of bit 2 Ready of Par 381 Drive Status 1 Ramp Pos 1 indicates that the actual speed of the drive is going positive Follows the state of Par 346 Torque Positive Not asserted until after the amount of time in Par 20 Ramp Delay has elapsed Ramp Neg 1 indicates that the actual speed of the drive is going negative Follows the state of Par 347 Torque Negative Not asserted until after the amount of time in Par 20 Ramp Delay has elapsed Spd Limited 1 indicates that the speed is being limited to the value of Par 3 Max Speed Fwd 0 indicates that the speed is not being limited Fault O indicates that a drive fault has occurred Refer to Par 57 Fault Code Power Loss 0 indicates that the drive has detected a loss of the internal power supply UserDefinedA Indicates the status of Par 519 UsrDe
382. overwritten by the state of the digital input Option Description Enable Removing the enable input causes the motor to coast to stop without generating a fault Stop CF Stops the drive if running or jogging or clears a fault if the drive is already stopped Start Issues a Start command removal does not Stop the drive 3 wire control Fwd Reverse Selects the operating direction of the drive Run Issues a Start command removal causes the drive to Stop 2 wire control Run Forward Issues a Run command in the Forward direction Run Reverse Issues a Run command in the Reverse direction Run Level Level sensitive Run command no off to on transition required RunFwd Level Run Level command in the Forward direction RunRev Level Run Level command in the Reverse direction dog Starts the drive and runs at the speed in Par 266 Log Speed removal causes the drive to Stop Jog Forward Issues a Jog command in the Forward direction Jog Reverse Issues a Jog command in the Reverse direction Aux Fault Asserting causes an Auxiliary Input fault F2 Clear Faults Issues a Clear Faults command Auto Manual Selects between Automatic and Manual speed reference values Speed Sel 1 3 Selects one of eight speed references Bit enumerations 000 Par 44 Speed Ref A 001 Par 48 Speed Ref B 010 Par 155 Preset Speed 2 011 Par 156 Preset Speed 3 100 Pa
383. p 1032 Arm Inductance 454 Speed Tune Ki 1033 Speed Command Limits Minimum Speed 1 Min Speed Rev 6 Max Speed Fwd 3 Min Speed Fwd 5 Maximum Speed 2 Max Speed Rev 4 Discrete Speeds Jog Speed 266 Preset Speed 3 156 Preset Speed 7 160 Jog Off Delay 1409 Preset Speed 4 157 TB Manual Ref 267 Preset Speed 1 154 Preset Speed 5 158 Preset Speed 2 155 Preset Speed 6 159 Speed Trim Ramp 42 Trim Speed 43 Speed Ratio 1017 References Trim Ramp Pct 378 Trim Speed Pct 379 Speed Regulator Speed Reg En 242 1 Arm Volt Ki 494 SpdOut FiltBW 239 Arm Volt Kp 493 Spd Reg Ki 88 Spd Reg Kp 87 SpdOut FiltGain 238 1 This parameter available for use with firmware version 2 005 and lower only Dynamic Control Control Config Spd Trq Mode Sel 241 Ramp Rates Sea Ramp En 245 Accel Time 2 24 Jog Ramp Time 1410 Ramp Type Select 18 Decel Time 2 32 S Curve Time 19 Accel Time 1 660 MOP Accel Time 22 Decel Time 1 662 MOP Decel Time 30 Restart Modes Start At Powerup 1344 Powerup Delay 1345 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Programming and Parameters 3 5 File Group Parameters Utility Reference Config Direction Mode 1322 Man Ref Preload 210 MOP Select 1375 Save HIM Ref 209 Save MOP Ref 249 Drive Memory Param Access Lvl 211 Reset Defaults 258 Language 302 Diagnostics Drive Sta
384. p Delay 20 Ramp Type Select 18 Jog Ramp Time 1410 Zero Ramp Output 344 Accel Time 1 660 S Curve Time 19 Zero Ramp Input 345 Decel Time 1 662 S Curve Accel 1 665 Freeze Ramp 373 Accel Time 2 24 S Curve Decel 1 666 Acc Dec Filter 1212 Decel Time 2 32 S Curve Accel 2 667 MOP Accel Time 22 S Curve Decel 2 668 Load Limits Enable Droop 699 Droop Limit 700 Torq Limit Type 715 Droop Percent 696 Load Comp 698 Droop Filter 697 Torq Red CurLim 13 Stop Modes Fast Stop Time 38 Closing Speed 1262 Ramp n Zero En 1265 Spd 0 Trip Delay 627 Opening Delay 1263 Actuator Delay 1266 Restart Modes Start At Powerup 1344 Powerup Delay 1345 Adaptv Regulator Adaptive Spd En 181 Adaptive Joint 1 186 Adaptive Gain2 191 Adaptive Reg Typl 182 Adaptive Joint 2 187 Adaptive P Gain3 192 Adaptive Ref 183 Adaptive P Gain 188 Adaptive Gain3 193 Adaptive Spd 1 184 Adaptive Gain 189 Adaptive Spd 2 185 Adaptive P Gain2 190 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 3 8 Programming and Parameters File Applications Et Group Parameters PI Control Enable PI 769 PI Central v1 776 PI Central vs1 781 PI Steady Thrsh 695 PI Central v2 777 PI integr freeze 783 PI Integral Gain 764 PI Central v3 778 PI Upper Limit 784 PI Prop Gain PID 765 PI Central v sel 779 PI Lower Limit 785 PI Output 771 PI C
385. pected when the drive is out of operation 3 Conductive pollution or dry non conductive pollution occurs which becomes conductive due to condensation which is to be expected 4 The pollution generates persistent conductivity caused for example by conductive dust or rain or snow PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 16 Installation and Wiring Power Circuit Protection Control Power 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 521 A and 460V 495 A and 667 A frame C PowerFlex DC drives Refer to Drive Power Circuit Protection on page A 8 for a list of replacement fuses and general fuse locations 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 nuis
386. peed Up Function on page C 25 for more information Configuring the Speed Zero Logic The speed zero logic is factory set to 0 Disabled Refer to Speed Zero Function on page C 27 for more information Adaptive Speed Regulation 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 22 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 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 M or DriveTools SP software and a personal computer Refer to Appendix B for a brief description of the LCD HIM Refer to Appendix D for drive control block diagrams For information on See page About Parameters 3 1 How Parameters are Organized 3 3 Monitor File 3 11 Motor Control File 3 15 Speed Command File 3 26 Dynamic Control File 3 32 Applications File 3 38 Utility File 3 50 Communications File 3 63 Input Output File 3 67 Parameter Cross Reference by Name 3 77 Parameter Cross Reference
387. peed when the dancer is positioned in its central Min Max 100 working position 796 Max Deviation Default 8000 A value expressed in counts of D A that corresponds to the position Min Max 10000 of maximum shift admitted by the dancer This value is considered the m starting measurement of the dancer movement during the initial 8 diameter calculation phase B 797 Gear Box Ratiol Default 1 000 E Ratio reduction between the motor and the roll lt 1 Min Max 0 000 1 000 s 798 Dancer Constant Default 1 The measurement corresponding to the total bunching of the material Min Max 1 10000 in the dancer Units mm 799 Minimum Diameter Default 100 Minimum value of the roll diameter Min Max 1 2000 Units mm 800 Diameter Calc St Default Read Only Status of the initial diameter calculation Min Max 0 1 0 The initial diameter calculation has not completed 1 The initial diameter calculation has completed Note This parameter can be assigned to a digital output PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 File APPLICATIONS Group Diameter Calc No 1153 1154 1155 1156 1157 1158 1159 1160 1161 1162 1163 1164 Parameter Name amp Description See page 3 2 for symbol descriptions Max Diameter Maximum roll diameter Roll Diameter Displays the calculated roll diamet
388. per wire only e 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 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 below ATTENTION Configuring an analog input for current operation 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 ATTENTION Hazard of personal injury or equipment damage 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 Figure 1 32 Control Circuit Board DIP Switch and Jumper Locations
389. portant Verify that the motor does not start rotating less than one half a full turn during the Current Regulator tuning test due to remnant magnetization series field etc If necessary mechanically block the motor shaft so it does not turn 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 15096 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 Autotunel in the Autotune group in the Motor Control file and select 1 On and press Enter PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Drive Start Up 2 11 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 Par 453 Arm Resistance and Par 454 Arm Inductance are updated The d
390. pressed as a percentage of the value in Par 179 Nom Mtr Arm Amps Note This parameter can be assigned to an analog output Arm Current Pct Armature current expressed as a percentage of the value in Par 179 Nom Mtr Arm Amps Note This parameter can be assigned to an analog output and is the default selection for Par 67 Anlg Out Sel Arm Current Armature current in Amperes Note This parameter can be assigned to an analog output 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 and is the default value for Par 68 Anlg Out3 Sel Spd Reg Out Pct Output value of the speed regulator as a percentage of Par 179 Nom Mtr Arm Amps used as the reference for the current regulator Field Current Present value of the field current Note This parameter can be assigned to an analog output Flux Ref Pct Field flux reference as a percentage of Par 280 Nom Mtr Fld Amps Notes This parameter can be assigned to an analog output This name of this parameter was changed from Field Ref Pct to Flux Ref Pct with firmware version 3 001 Filt TorqCur Pct Filtered value of Par 1193 Torq Current Pct The amount of filtering is set by Par 926 fTorq Cur Filter Values Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default
391. put OV Winder 24V Unwinder 1 Unvinder 1193 Torq Current Pct Default Read Only Displays the amount of torque current required Min Max 0 00 200 00 Note This parameter can be assigned to an analog output Units 1194 Act Ten Ref Pct Default Read Only 1179 Displays the percentage of tension reference less the Taper Min Max 0 00 199 99 1180 percentage set via Par 1179 Tension Reduct If the Taper function is Units Ki PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 48 Programming and Parameters File Group 1196 1197 1198 1199 1200 1201 1202 1203 APPLICATIONS Winder Functions 1204 1208 1209 1210 1213 Parameter Name amp Description See page 3 2 for symbol descriptions Speed Match Coil launching phase command for automatic switching Note This parameter can be assigned to a digital input Spd Match Acc Motor acceleration time during the launching phase Spd Match Dec Motor deceleration time If the motor decelerates during the launching phase a stop command is issued Offs Accel Time Ramp time for the initial phase when the machine is stopped t refers to Par 45 Max Ref Speed W Offset Speed reference offset for the initial phase of the winder unwinder when the line is stopped Spd Match Gain Speed reference gain during the launching phase 100 corresponds to a peripher
392. r 157 Preset Speed 4 101 Par 158 Preset Speed 5 110 Par 159 Preset Speed 6 111 Par 160 Preset Speed 7 PI Enable Enables disables the PI block of the PID regulator Par 769 Enable PI PI Hold Enables disables a hold on the PI output PI Reset Asserting causes a reset of the PI output PI Invert Asserting causes an inversion of the PI output Local Enables exclusive drive control via the I O Terminal Block only Acc2 amp Dec2 Switches between the Accel Decel 1 and Accel Decel 2 ramp rates Accel 2 Switches between the Accel 1 and Accel 2 ramp rates Decel 2 Switches between the Decel 1 and Decel 2 ramp rates MOP Inc Asserting causes the MOP reference to increment at the rate set in Par 22 MOP Accel Time MOP Dec Asserting causes the MOP reference to decrement at the rate set in Par 30 MOP Decel Timel ES Fast Stop Causes the drive to Stop at the rate set in Par 38 Fast Stop Time Contactor Indicates the status of the main contactor DB contactor Must be assigned and asserted in order to run drive when Par 1391 ContactorControl Se Contactor or Contactor DB MOP Reset Asserting resets the MOP reference to zero TorqueReduce Turns on off Torque Reduction using the reduced current limit set in Par 13 Torq Red CurLim Force MinFld When asserted the field current is set to the value specified in Par 498 Force Min Field Important See Attention statem
393. r Fault Que Default 0 Ready 0 Allows you to clear the fault queue Refer to Chapter 4 Options 0 Ready Troubleshooting on page 4 1 for information on clearing the fault 1 Clr Fit Que queue 1347 Fault Clear Default 0 Ready Allows you to reset drive faults and or clear the fault queue Options 0 Ready z 1 Clear Faults 2 Cir Fit Que 1348 Fault Clr Model Default 1 Enabled Enables Disables a fault reset clear faults attempt from any source Options 0 Disabled This does not apply to fault codes which are cleared indirectly via 1 Enabled other actions Related Programming and Parameters 3 57 5 a o 8 g Parameter Name 8 Description s Z See page 3 2 for symbol descriptions Values 1349 Status1 at Fault 381 Captures and displays Par 381 Drive Status 1 bit pattern at the time of the last fault 0 Condition False 1 Condition True CO oa c lim a anl Jol g l 5 5 5 oo e GERS Se 889 E le mana IS IS 2 3 is Is B Ig 5 618 a lo lo o S S S z LE le 16 e e S 2 x Default 0 0 0 0 1 4 11 0 1 0 00 1 0 0 Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 40 1350 Status2 at Fault 382 Captures and displays Par 382 Drive Status 2 bit pattern at the time of the last fault O2 Condition False 12 Condition T
394. r Slave Drive Set Drive Feedback N Z Line Speed Signal a Internal Ramp 10V Forward 10V Reverse Line Speed Reference In addition configure the following in the Follower drive s e Verify that Par 762 PID Setpoint Sel is set to 0 Setpoint 0 P760 P762 PID Setpoint 0 PID Setpoint Sel P761 PID Setpoint 1 P1254 P763 PID Error Gain PID Feedback P763 PID Feedback gt 7 P1194 Act Ten Ref Pct P757 P759 PID Clamp PID Error PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 C 18 Application Notes Reference Control The drive speed command can be obtained from a number of different sources The source is determined by drive programming and the condition of the digital inputs configured as speed selects a digital input configured for Auto Manual or Reference Select bits of a command word see Communication Configurations on page A 6 for more information Auto Speed Sources The default auto source for a command reference all speed select digital inputs open or not programmed is analog input 1 configured for Speed Ref A parameter 44 Speed Ref A If any of the speed select digital inputs are closed the drive will use other parameters as the auto speed command source Manual Speed Sources The manual source for speed command to the drive is either the HI
395. r digital output can be defined as ContactorDB e With ContactorControl set to AC Cntcr DB or DC Cntcr DB both relay outputs and one digital input must be set to Contactor ContactorDB and Contactor respectively Because any relay output can be configured as contactor or DB control and any digital input as contactor status care must be taken to correctly wire the terminal blocks to match the parameter selections Digital input functions are in conflict Combinations marked with a will cause an alarm Acc2 Dec2 Accel 2 Decel 2 Jog 1 2 Jog Fwd Jog Rev Fwd Rev Acc2 Dec2 H m Accel 2 Decel 2 dog 1 2 dog Fwd dog Rev Fwd Rev PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 4 10 Troubleshooting Alarm DiginCflctB DigInCflctC EncoderCflct Feedback Loss FldCfg Cfict Fld Current Loss Motor Overload Motor Over Temp Start At PowerUp Type PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Description One of the following digital input conflicts exists e A digital Start input has been configured without a Stop input e None of the digital inputs are configured for Enable e Other digital input functions are in conflict Combinations that conflict are CAN marked with a amp and wi
396. r time constant for the Droop function Load Comp The load compensation signal This value is typically equal to the master drive s current The load compensation signal is a Enable Droop Enables Disables the Droop function e Enabled The Droop function is enabled e Disabled The Droop function is disabled Note This parameter can be assigned to a digital input Droop Limit The speed reference correction range within which the droop function becomes active Torq Limit Type This parameter determines the response of the drive during a current limiting condition e Torq Lim Pos The active positive torque limit is set by the value defined in Par 7 Current Limit and the active negative torque limit is set by the value defined in Par 9 Current Lim Neg e Torq Lim Mtr With this option the following three conditions apply 1 If the motor speed is greater than 1 of Par 162 Max Feedback Spd the active positive torque limit is set by the value defined in Par 8 Current Lim Pos and the active negative torque limit is set by the value defined in Par 9 Current Lim Neg 2 f the motor speed is less than 1 of Par 162 Max Feedback Spd the active positive torque limit is set by the value defined in Par 9 Current Lim Neg and the active negative torque limit is set by the value defined in Par 8 Current Lim Pos 3 f the motor speed is greater than 196 of Par 162 Max Feedback Spd and less t
397. rallel Must be sourced separately from drive HUBBELL_Y139W322GB Must be sourced separately from drive 6 Coil voltage 115V AC 50 60Hz 4 ABB EHDB360C 1L 22 ABB Contactor for drives with a dynamic brake Must be sourcing separately from drive 6 ABB EHDB520C2P 1L ABB Contactor for drives with no Dynamic Brake ABB_EHDB520C 1L ABB Contactor for drives with Dynamic Brake Must be sourced separately from drive 6 See DC Contactor Crimp Lug Kit Specifications on page A 22 for more information U Wire and Lug size dependant on Cabinet dims and local codes PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Supplemental Drive Information A 21 Table A S 460V AC Input Regenerative Drives Dynamic AC Brake Armature DB Brake DC Loop DC Contactor Drive Cat DC Line Resistor Kit Voltage Resistor DB Resistor Amps Contactor Cat crimp Lugs Cat No Amps Amps HP Cat No Volts Size ohms Size Watts Required No 9 20P 41AD4P1 41 133 2 11370 DBH63 1500 81 255 6 17 1370 DC56 1370 LG40 20P 41AD6P0 6 4 9 3 11370 DBH64 1500 62 245 8 06 1370 DC56 1370 LG40 20P 41AD010 10 8 2 5 11370 DBH65 1500 45 245 11 11 1370 DC56 1370 LG40 20P 41AD014 114 1114 17 5 1370 DBH66 1500 27 350 18 52 1370 DC56 1370 LG40 20P 41AD019 119 115 5 10 1370 DBH67 1500 20 420 25 00 1370 DC56 1370 LG40 20P 41AD027 27 1221 115 1137
398. re set to Speed Ref A or Speed Ref B This alarm takes precedence over the EncoderCflct alarm when both are present Refer to Figure C 1 or Speed Reference Selection on page D 5 for a graphical representation of the drive s reference selections Arm Overvoltage There is a possible overvoltage on the armature circuit or Par 175 Rated Motor Volt is set too low for the application Refer to the Arm Overvoltage fault description on page 4 4 for more information Auxiliary Input An auxiliary input interlock is open or a voltage 15 30 V or reference signal is missing for the digital input set to 14 Aux Fault Refer to the Auxiliary Input fault description on page 4 4 for more information BipolarCflct Par 1322 Direction Mode is set to Bipolar or Reverse Dis and one or more of the following digital input functions is configured Fwd Reverse Run Forward Run Reverse Jog Forward or Jog Reverse CntactrCflct DigInCflctA Contactor input functions are in conflict e When Par 1391 ContactorControl is set to None both relay outputs Pars 1392 Relay Out 1 Sel and 629 Relay Out 2 Sel and all digital inputs Digital Inx Sel cannot be set to Contactor or ContactorDB With ContactorControl set to AC Cntcr or DC Cntcr one relay output and one digital input must be set to Contactor No relay o
399. re two fault types Type Description D User Configurable T is type of fault allows you to configure the drive s response to the condition that caused the error e When configured for a fault the drive will be stopped the error condition will be annunciated on the HIM or a via digital output if programmed and the drive will not be allowed to start until the fault condition is corrected e When configured for an alarm the error condition will be annunciated on the HIM or via a digital output if programmed and the drive will continue to run and or be allowed to start e When configured for ignore or disabled the error condition will not be recognized by the drive or be indicated on the HIM or via a programmed digital output 2 Non Configurable T is type of fault is always enabled and will cause the drive to stop running in order to protect the drive and or motor from damage In some cases drive or motor repair may be required The cause of the fault must be corrected before the fault can be cleared via a fault reset using the HIM or programmed digital input The fault will be reset on power up after repair An alarm indicates a drive error condition that does not stop the drive but may prevent it from starting There are two types of alarms Type Description D User Configurable T is type of alarm indicates a drive error condition but does not stop the drive from starting or running However i
400. rective and Electromagnetic Compatibility Directive has been demonstrated using harmonized European Norm EN standards published in the Official Journal of the European Communities PowerFlex DC drives comply with the EN standards listed below when installed according to this User Manual CE Declarations of Conformity are available online at www rockwellautomation com products certification ce Low Voltage Directive 2006 95 EC EN 50178 Electronic equipment for use in power installations EMC Directive 2004 108 EC e EN 61800 3 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods General Considerations For CEcompliance the drive installation must satisfy requirements related to both EN 50178 and EN 61800 3 provided in this document e PowerFlex DC drives comply with the EMC requirements of EN 61800 3 when installed according to good EMC practices and the instructions provided in this document However many factors can influence the EMC compliance of an entire machine or installation and compliance of the drive itself does not ensure compliance of all applications PowerFlex DC drives are not intended to be used on public low voltage networks which supply domestic premises Without additional mitigation radio frequency interference is expected if used on such a network The installer is responsible to take measures such as supplementary line filters and enclosu
401. res to prevent interference in addition to the installation requirements of this document e PowerFlex DC drives generate notching and harmonic current emissions on the AC supply system When operated on a public low voltage network it is the responsibility of the installer or user to ensure that applicable requirements of the distribution network operator have been met in the protective earthing conductor which can reduce the ability of RCD s residual current operated protective devices or RCM s residual current operated monitoring devices of type A or AC to provide protection for other equipment in the installation ATTENTION PowerFlex DC drives may produce DC current PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 14 Installation and Wiring Installation Requirements Related to the Low Voltage Directive PowerFlex DC drives are designed to be CE compliant only if they are NOT connected to corner earthed supply systems where one of the three phases of the supply system has been earthed PowerFlex DC drives are compliant with the CE LV Directive when used at altitudes no greater than 2000 m 6562 ft PowerFlex DC drives provided in the IP20 IP21 and open enclosure types must be installed in a pollution degree 1 or 2 environment to be compliant with the CE LV Directive Characteristics of the different pollution degree ratings are provided on page 1 15 PowerFlex DC drives m
402. ring PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 G 4 Optional 115V AC to 24V DC I O Converter Circuit Board Notes PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Numerics 2 wire control non reversing 1 46 reversing 1 46 3 wire control 1 46 1 47 A AC input contactors configure 1 9 recommended A 18 AC input line reactors recommended A 18 AC input voltage 1 19 AC Line Freq 3 14 AC Line Voltage 3 14 AC Undervoltage fault 4 4 Acc Dec Filter 3 34 Accel Mask 3 63 Accel Owner 3 64 Accel Status 3 55 Accel Time 1 3 34 Accel Time 2 3 33 access S M A R T screen B 2 Act Spd Filter 3 22 Act Ten Ref Pct 3 47 Actual Comp 3 48 Actual Speed 3 12 Actuator Delay 3 36 Adaptive Gain1 3 37 Adaptive Gain2 3 37 Adaptive Gain3 3 37 Adaptive Joint 1 3 36 Adaptive Joint 2 3 37 Adaptive P Gain1 3 37 Adaptive P Gain2 3 37 Adaptive P Gain3 3 37 Adaptive Ref 3 36 Adaptive Reg Typ 3 36 Adaptive Spd 1 3 36 Adaptive Spd 2 3 36 Adaptive Spd En 3 36 adaptive speed regulator function C 22 Index Adaptv Regulator group 3 36 3 37 adjust current regulator C 37 advanced parameters 3 6 agency certifications A 1 alarm type non configurable 4 1 user configurable 4 1 alarms AnalogCflct 4 9 Arm Voltage 4 9 Auxiliary Input 4 9 BipolarCflct 4 9 CntactrCflct 4 9 DigInCflcA 4 9 DigInCflctB 4 10 DiginCflctC 4 10 EncoderCflct 4 10 Feedba
403. rite Mask Cfg 1378 Security 3 66 Z Channel Enable 911 Speed Feedback 3 22 Z Captured Pos 913 Speed Feedback 3 22 Z Capture Pos En 912 Speed Feedback 3 22 Zero Ramp Input 345 Ramp Rates 3 34 Zero Ramp Output 344 Ramp Rates 94 Zero Torque 353 Torque Attribute 3 19 No Parameter Name Group Page No Parameter Name Group Page 48 Speed Ref B Speed Meters 3 11 1 Minimum Speed Limits 3 26 49 Speed Ref B Pct Speed Meters 3 11 2 Maximum Speed Limits 3 26 50 UsrDsplyMultO User Defined 3 59 3 Max Speed Fwd Limits 3 26 51 UsrDsplyDivO User Defined 3 59 4 Max Speed Rev Limits 3 26 53 UsrValMult1 User Defined 3 59 5 Min Speed Fwd Limits 3 26 54 UsrValDiv1 User Defined 3 59 6 Min Speed Rev Limits 3 26 57 FaultCode Drive Data 3 14 7 Current Limit Torque Attribute 3 19 58 TstGen Output Test Generator 3 24 8 Current Lim Pos Torque Attribute 3 19 59 TstGen Frequency Test Generator 3 24 9 Current Lim Neg Torque Attribute 3 19 60 TstGen Amplitude Test Generator 3 24 10 Cur Lim Pos Out Current Meters 3 13 61 TstGen Offset Test Generator 8 24 11 Cur Lim Neg Out Current Meters 3 13 62 Anlg Out1 Scale Analog Outputs 3 69 13 Torq Red CurLim Load Limits 3 34 63 Anlg Out2 Scale Analog Outputs 3 69 14 Selected TorqRef Current Meters 3 13 64 Anlg Out3 Scale Analog Outputs 3 69 15 SLAT Err Stpt Control Config 3 32 65 Anlg Out4 Scale Analog Outputs 3 69 16 SLAT Dwell Time Control Config 3 32 66 Anlg Out Sel Analog Outputs 3 69 17 Motor Trq Ref Current Meters 3 13 67 A
404. rive User Manual publication 20 UM001 since the November 2008 release Change Page s Added information on how to find your drive frame size and firmware revision level Preface 2 Updated the Catalog Number Explanation to reflect drive availability Preface 4 Added CE Conformity information 1 13 Updated the Typical Wiring Diagrams section to reflect the addition ofthe new 1 20 Armature Voltage Feedback terminal block Added the Armature Voltage Feedback Connections section 1 26 Updated the S14 DIP switch settings for the field current configuration 1 30 Updated Table 1 L to include examples of the jumper and switch settings 1 39 Updated relevant 1 0 Wiring Examples to include required DIP Switch settings 1 45 Updated the Drive Start Up procedures 2 1 Corrected a parameter reference in the definition for parameter 121 Spd 3 12 Feedback Pct Corrected a parameter reference in the definition for parameter 924 Actual 3 12 Speed Added parameter 14 Selected TorqRefl to the Monitor file Current Meters group 3 13 Added parameter 17 Motor Trq Ref to the Monitor file Current Meters group 3 13 Renamed parameter 500 from Field Ref Pct to Flux Ref Pct 3 13 Corrected a parameter reference in the definition for parameter 928 Filt TorqCur 13 13 Pct Updated the maximum value of Par 45 Max Ref Speed 3 15 Updated the maximum value for Par 162 Max Feedback Spd 3 15 Added parameter 376 MtrOvrld Type to the Motor Control fi
405. rive is automatically stopped and Par 452 CurrReg Autotune will be set to 0 Off It is also possible to manually tune the current regulator Refer to Manually Adjusting the Current Regulator Tune Settings on page C 37 for more information If a drive fault occurs during the tuning procedure refer to Fault Descriptions starting on page 4 4 for a list of fault descriptions and actions 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 4 for more information checks you must provide a hard vvired 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 ATTENTION Prior to running the motor direction and polarity 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
406. rive switches from torque mode to forced speed mode the speed regulator integral part is pre loaded with the InternalTorque Reference ITR or Par 14 Selected TorqRef to create a smooth transition PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 C 32 Application Notes In order for the drive to switch from speed mode to torque mode forced speed mode if active must first be turned off Forced speed mode will turn off when the speed error is less than the SLAT error setpoint for the SLAT Dvvell Time With default parameter settings this will occur when the speed error becomes negative When Forced Speed Mode is off the drive will switch back to torque mode when the speed regulator output becomes less than the torque reference Par 15 SLAT Err Stpt Spat Emir Par 16 SLAT Dwell Time Low Pass Filter Forced Speed Mode FSM for SLAT Time FSM State Controller l Speed Error SLAT Setpoint Internal Torque Speed Regulator Reference ITR Application Output SRO Dependant Speed Reference Bias Select Motor Speed Feedback External Torque Reference ETR PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 33 Example The application is a paper winder The drive is set for SLAT Min mode so that the drive normally runs in torque mode and follows Par 39 Torque Ref Torque Ref comes f
407. rnal fuses provided with the drive These fuses are labeled FU1 and FV1 on the drive Figure A 4 Frame A Field Circuit Fuses Location Bottom View of Drive with Fan Bottom View of Drive without Fan 9 ur Field circuit fuses PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 A 12 Supplemental Drive Information FS4 Internally mounted fuses for the armature converter on the AC input side Figure A 5 Frame B Field Circuit Fuses Location Top View of Drive NULLE ia mn mn dito Field circuit fuses Frame C Fuse Information All AC input fuses for armature and field circuit protection are internally mounted and provided with frame C PowerFlex DC drives with 230V AC input and a current rating of 521A and 460V AC input and a current rating of 495A and 667A Figure A 6 Frame C Fuse Table Designations FS3 Internally mounted fuses for the field circuit on the AC input side PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Supplemental Drive Information A 13 Table A G Recommended Field Circuit Fuses 230V AC Input Frame C Regenerative and Non Regenerative Drives Drive Fuse Code FS3 See Figure A 6 on page A 12 and Current Figure A 7 belov for location Rating 2 Ferraz Shawmut Code Amps Type Quantity Bussmann Gould Shawmut SIBA 60 033 05 25 1 Internal fuses provided with the drive These fus
408. ro En 3 29 Spd Zero P En 3 29 Spd Zero P Gain 3 29 SpdFuncSelect 3 31 SpdOut FiltBW 3 30 SpdOut FiltGain 3 29 SpdReg FB Bypass 3 21 SpdReg Ki Bypass 3 31 SpdReg Kp Bypass 3 31 SpdTune Friction 3 23 Speed Demand En 3 49 Speed Draw Out 3 12 Speed Feedback 3 12 Speed Feedback Pct 3 12 Speed Match 3 48 Speed Ramp En 3 33 Speed Ratio 3 27 Speed Ref A 3 11 Speed Ref A Pct 3 11 Speed Ref B 3 11 Speed Ref B Pct 3 11 Speed Ref Out 3 12 Speed Ref Out Pct 3 12 Speed Reg En 3 30 Speed Reg In 3 12 Speed Reg In Pct 3 12 Speed Thresh Neg 3 28 Speed Thresh Pos 3 28 Speed Threshold 3 53 Speed Tune Dir 3 23 Speed Tune Ki 3 23 Speed Tune Kp 3 23 Speed Up Base 3 30 Speed Up Filter 3 30 Speed Zero Delay 3 29 Speed Zero Level 3 29 Index 17 Start At Powerup 3 36 Start Inhibits 3 56 Start Mask 3 63 Start Owner 3 64 Static F Zero 3 49 Static Friction 3 46 Status1 at Fault 3 57 Status at Fault 3 57 Stop Owner 3 64 Taper Enable 3 47 TaskLoad 1 ms 3 56 TaskLoad 2 ms 3 56 TaskLoad 32 ms 3 56 TaskLoad 8 ms 3 56 TB Manual Ref 3 27 Tension Reduct 3 47 Tension Ref 3 47 Tension Scale 3 47 TestPoint Data 3 56 TestPoint Sel 3 56 Threshold Delay 3 28 Time AccDec Min 3 47 Torq Cur Filter 3 20 Torq Current Pct 3 47 Torq Limit Type 3 35 Torq Red CurLim 3 34 Torque Const 3 23 Torque Negative 3 51 Torque Positive 3 51 Torque Reduction 3 19 Torque Ref 3 19 Torque Winder En 3 48 Trim Ramp 3 27 Trim Ramp Pct 3 27 Trim Speed 3 27 Trim Spee
409. rom an external controller and is approximately 6046 of motor torque during the snapshot The speed reference also from an external controller is set just above the speed feedback in order to saturate the speed regulator while in torque mode The following snapshot captures what occurs in the drive during a break in the web 500 Small amount of overshoot during web break Motor Spd Fdbk RPM Speed Regulator Saturated Speed Reg Out Speed Regulator is preloaded with Motor Torque Ref Speed Error RPM Speed Error 47 becomes negative Web break occurs 16 Torque Mode sl a Speed Made 1 Sum Mode Sum mode is selected when Par 241 Spd Torq Mode Sel is set to 5 Sum In this mode the reference is derived from the sum of the speed regulator output Par 236 Spd Reg Out Pct and the torque reference Par 39 TTorque Ref This mode can be used for applications that have precise speed changes vvith critical time constraints PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 C 34 Application Notes Torque Mode Selection Status Bits Bits 7 Forced Spd 8 Speed Mode and 9 Torque Mode of parameter 382 Drive Status 2 display the current status of the speed torque mode for the drive Par 382 Drive Status 21 Par 241 Spd Trq Mode Sel Bit 7 Forced Spd 8 Speed Mode
410. rrent Meters 3 13 104 At Speed Error Speed Regulator 3 28 200 Arm Current Current Meters 3 13 105 At Speed Delay Speed Regulator 28 201 Drive Type Sel Motor Data 8 1 106 Ref Zero Level Speed Regulator 3 28 203 OverVolt Fit Cfg Alarms 3 58 107 Speed Zero Level Speed Regulator 3 29 209 Save HIM Ref HIM Ref Config 3 50 108 Speed Zero Delay Speed Regulator 29 210 Man Ref Preload HIM Ref Config 3 50 110 Ramp In Speed Meters 3 11 211 Param Access Lvl Drive Memory 3 50 111 Ramp In Pct Speed Meters 3 11 233 Output Voltage Drive Data 3 14 113 Ramp Out Speed Meters 3 11 234 Fld Current Pct Torque Attribute 13 114 Ramp Out Pct Speed Meters 3 11 235 Lifetime Drive Data 3 14 117 Speed Reg In Pct Speed Meters 3 12 236 Spd Reg Out Pct Speed Regulator 3 12 118 Speed Reg In Speed Meters 3 12 238 SpdOut FiltGain Speed Regulator 3 2 121 Spd Feedback Pct Speed Meters 3 12 239 SpdOut FiltBW Speed Regulator 3 30 122 Spd Feedback Speed Meters 3 12 241 Spd Trq Mode Sel Control Config 3 32 123 SpdZerolEn Speed Regulator 3 29 242 Speed Reg En Speed Regulator 3 30 124 Spd Ref Zero En Speed Regulator 3 29 245 Speed Ramp En Ramp Rates 3 33 125 SpdZeroP En Speed Regulator 3 29 249 Save MOP Ref Reference Config 3 50 126 SpdZeroP Gain Speed Regulator 3 29 258 Reset Defaults Drive Memory 8 50 133 Digital In1 Sel Digital nputs 3 70 259 Anlgini Tune Analog Inputs 3 68 134 Digital In2 Sel Digital nputs 3 70 260 Anig 112 Tu
411. rter Circuit Board Mounting Location Control Board IO Converter Board 1 0 Converter Board Terminal Blocks The 115V AC to 24V DC 1 0 Converter circuit board is not factory installed 2 if more than eight 115V AC digital input signals require conversion to 24V i e the optional PowerFlex DC drive UO Expansion circuit board is used see Appendix F a second Converter board is required and must be sourced and wired independently from the 115V AC to 24V DC 1 0 Converter board mounted on the Control board and be mounted in an appropriate enclosure external to the PowerFlex DC drive enclosure PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 G 2 Optional 115V AC to 24V DC I O Converter Circuit Board UO Converter Board Wiring Table GA Recommended Signal Wire Size Wire Type and Size Tightening Torque Flexible mm multi core mm AWG Nem Ibin 0 14 1 5 28 16 A 75 x 2 5 x 0 4 mm 3 0 x 0 1 x 0 02 in flathead screwdriver is recommended for connecting wire to the terminal block inputs Strip the ends of the cables to a length of 6 5 mm 0 26 in Table G B 1 0 Converter Board M IN Terminal Block Designations No Signal Description 1 Digital Input 1 Rated input voltage 115V AC 10 50 Seed ON input voltage 118V AC 210 ini input voltage 10 8 III OFF input volg 0 70V AC ON input current 4 5 5mA 5 Digital Input 5 6 Digital I
412. rue 2 BIS RRSP BPS SSE Sle 6 o 99 9 6102 Z 8 5 8 8 8 lg le 6 6 8 6 6 SiS 15 5 6 m m jc E x aq c x lt lt O 5 cm c Default x Xx x x x x x x x 0001115000 Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 40 1351 Fault 1 Code Default Read Only 1352 FUIL 2 Code Min Max 0 32768 1353 Fault 3 Code 1354 Fault 4 Code 1355 Fault 5 Code 1356 Fault 6 Code 1357 Fault 7 Code 1358 Fault 8 Code 1359 Fault 9 Code 1360 Fault 10 Code A code that represents the fault that tripped the drive The codes will appear in these parameters in the order they occur i e Fault 1 Code the most recent fault Refer to Fault Descriptions on page 4 4 for a list of possible codes Note Par 1351 Fault 1 Code is accessible via the Basic Parameter Faults view 1361 Fault 1 Time Default Read Only 1362 Fault 2 Time 1363 Fault 3 Time js 1364 Fault 4 Time 1365 Fault 5 Time 1366 Fault 6 Time 1367 Fault 7 Time 1368 Fault 8 Time 1369 Fault 9 Time 1370 Fault 10 Time The time between initial drive power up and the occurrence of the associated trip fault 1371 Fault Arm Amps Default Read Only Captures and displays the armature current as a percentage of rated Min Max 200 current at the time of the last fault Units 1372 Fault Speed Default Read Only Captures and displays the output speed rpm of the drive at the time
413. rve Accel 2 667 Ramp Rates 3 34 Spd 0 Trip Delay 627 Stop Modes 3 35 S Curve Decel 1 666 Ramp Rates 3 34 Spd Draw Out Pet 1019 Speed Meters 3 12 S Curve Decel 2 668 Ramp Rates 3 34 Spd FB Filt BW 915 1 Speed Feedback 3 22 S Curve Time 19 Ramp Rates 3 33 Spd FB Filt Gain 914 Speed Feedback 3 22 Save HIM Ref 209 HIM Ref Config 3 50 Spd Fdbk Control 457 Speed Feedback 3 21 Save MOP Ref 249 Reference Config 3 50 Spd Fdbk Error 455 1 Speed Feedback 3 21 Scale1 Div 487 Scale Blocks 3 43 Spd Fdbk Filter 444 Speed Regulator 3 30 Scale1 In Abs 492 Scale Blocks 3 44 Spd Fdbk Invert 461 Speed Feedback 3 21 Scale In 488 Scale Blocks 3 43 Spd Feedback 122 Speed Meters 3 12 Scale1 In Min 489 Scale Blocks 3 43 Spd Feedback Pct 121 Speed Meters 3 12 Scale In Off 490 Scale Blocks 3 44 Spd Limit Active 372 Diagnostics 3 51 Scale1 Input 484 Scale Blocks 3 43 Spd Loss Fit Cfg 478 Alarms 3 58 Scale1 Mul 486 Scale Blocks 3 43 Spd Match Acc 1196 Winder Functions 3 48 Scale1 Out Off 491 Scale Blocks 3 44 Spd Match Compl 1203 Winder Functions 3 48 Scale1 Output 485 Scale Blocks 3 43 Spd Match Dec 1197 Winder Functions 3 48 Scale2 Div 556 Scale Blocks 3 43 Spd Match Gain 1200 Winder Functions 3 48 Scale2 In Abs 561 Scale Blocks 3 44 Spd match torque 1216 Winder Functions 3 49 Scale2 In Max 557 Scale Blocks 3 43 Spd Ref Out Pct 384 Speed Meters 3 12 Scale2 In Min 558 Scale Blocks 3 43 Spd Ref Zero En 124 Speed Regulator 3 29 Scale2 In Off 559 Scal
414. s 587 l Reg Error Default Read Only 452 Current Regulator tuning status parameter that is used as part Min Max 480 of the manual tuning process See Fine Tuning the Units V Regulators on page C 36 for details 1012 Inertia C Filter Default 0 First order low pass filter used to reduce noise caused by the Min Max 0 1000 speed differentiation process in the Inertia Loss compensation Units ms block 1013 Torque Const Default Based on drive current rating The Motor torque constant used to calculate inertia and friction Min Max 0 01 99 99 compensation The value in this parameter is automatically Units N m A adapted in the field weakening mode This value is determined during speed auto tuning 1014 Inertia Default Based on drive current rating Motor inertia value Min Max 0 001 999 999 1 Kg m 23 76 lb ft Units Kg m 1015 Friction Default Based on drive current rating Motor friction value Min Max 0 000 99 990 1 N m 0 738 lb ft Units N m 1027 Spd Reg Autotune Default 0 Starts the auto tuning procedure for the speed regulator Setting Options 0 Off this parameter to 1 On and pressing Start on the HIM keypad 1 On ATTENTION The motor will rotate during the Speed Regulator tuning procedure A hazard of personal injury exists due to motor shaft rotation and or machinery motion 1029 Speed Tune Dir Default 1 Forvard O Choice of the rotation direction
415. s 230V AC Input Frame C e Table A H Recommended Field Circuit Fuses 460V AC Input Frame C Table A I Recommended Leg Fuses 230V AC Input Frame C Table A J Recommended Leg Fuses 460V AC Input Frame C Table A K Recommended AC Input Line Fuses 230V AC Input Frame C e Table A L Recommended AC Input Line Fuses 460V AC Input Frame C Added an Attention statement to recommend that the drive be stopped before BA performing a download to the drive The information below summarizes the changes to the PowerFlex Digital DC Drive User Manual publication 20 UMO01 since the October 2007 release Change Page s Updated the Using Contactors section to include new Contactor Control selections 1 9 for configuring AC versus DC contactors Added the Cable and Wiring Recommendations table 1 17 Updated the Typical Power Wiring Diagrams to include terminal and parameter 1 20 designations Added Sourcing Digital Outputs 24V DC external supply diagram to 1 0 Wiring 1 47 examples Added an illustration and instructions for routing 1 0 and control wiring 1 50 Added a graphical indicator for parameters accessible only when parameter 211 3 1 Param Access Lvl 1 Advanced Added parameter 1409 Jog Off Delay to allow you to specify the minimum delay 3 27 between removing the Jog input and commanding the main contactor to open This delay reduces the wear on the contactor when repeatedly
416. s 354 799 Minimum Diameter Diameter Calc 3 44 652 Encoder Err Chk Speed Feedback 3 22 800 Diameter Calc St Diameter Calc 34 660 Accel Time 1 Ramp Rates RH 911 Z Channel Enable Speed Feedback 3 22 662 Time 1 Ramp Rates 912 Z Capture Pos En Speed Feedback 3 22 665 18 Curve Accel 1 Ramp Rates Sog 913 Z Captured Pos Speed Feedback 13 22 666 SCurve Decel 1 Ramp Rates 334 914 SpdFBFil Gain Speed Feedback 3 22 667 19 Curve Accel 2 Ramp Rates 2 915 SpdFBFitBW Speed Feedback 13 22 668 5 Curve Decel 2 Hamp Rates 916 Fld Const 40 Pct Field Config 8 18 695 PISteady Thr PI Control 3 38 917 Fld Const 70 Pet Field Config 318 696 Percent Load Limits 388 918 Fld Const 90 Pct Field Config 8 18 697 Droop Filter Load Limits 335 919 Set Fld Curve Field Config 3 18 698 Load Comp Load Limits 335 920 Reset Fid Curve Field Config 318 699 Enable Droop Load Limits 35 921 Out Volt Level Field Config 3 18 700 Droop Limit Load Limits 335 923 Act Spd Filter Speed Feedback 13 22 715 _ Torq Limit Type Load Limits 335 924 Actual Speed Speed Meters 3 12 781 PID Steady Delay PID Control 926 Torq Cur Filter Torque Attribute 3 20 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 86 Programming and Parameters
417. s 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 UM001E EN P June 2009 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 lifting capacity of 453 6 kg 1 000 Ib 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 angle as illustrated below Figure 1 5 Lifting Angle Must be less than 45 angle Lifting flanges CL LL LL LL UNO gi U n
418. s preloaded with the value of Par 14 Selected Torque Ref When Par 241 Spd Trq Mode is changed to 5 Sum the speed regulator is preloaded with the value of Par 14 Selected Torq Ref Par 39 Torque Ref Par 14 Par 39 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Start At Powerup Application Notes C 35 The Start At Powerup function allows you to automatically resume running at commanded speed after drive input power is restored a run command is issued and all of the start permissive conditions indicated in the diagram below are met To enable this feature parameter 1344 Start At Povverupl must be set to 1 Enable result if this parameter is used in an inappropriate application Do not use this function vvithout considering applicable local national and international codes standards regulations or industry guidelines ATTENTION Equipment damage and or personal injury may In addition A delay time of up to 10800 seconds 3 hours can be programmed in parameter 1345 Powerup Delay An automatic drive restart is not possible before the delay time has expired If a Start Run or Stop command is asserted before the time in this parameter expires the Start At Powerup function will be aborted Start At PowerUp Powerup Delay Time Expired Yes Al Start Permissives Met 1 No fault conditions are present 2 No Type 2
419. s the cause is in the external I O wiring Action s Pull the plug in I O terminal blocks out of the control circuit board and reset the drive via 1347 Fault Clear If there are no other faults check the I O wiring for a short circuit including the cable shielding Check fuses F1 and F2 located on the Switching Power Supply circuit board frame A size drives only have one fuse F1 Replace as necessary Check varistor fuses F1 F2 and F3 on the Pulse Transformer or Transient Noise Filter circuit boards for Frame C size drives Replace as necessary If this fault occurs again an internal fault may be present Contact your Rockwell Automation sales office Note Refer to Control Power Circuit Protection Fuses on page A 16 for fuse sizing information blocks and or fuses AN ATTENTION Remove power from the drive before removing the I O terminal The speed regulator auto tuning procedure has been stopped by the user Informational only The value of Par 1048 Autotune Cur Lim for auto tuning the speed regulator is set too high Decrease the value of Par 1048 Autotune Cur Lim and repeat the auto tune procedure The friction value attained during the auto tuning procedure is zero or lower than the control precision limit Decrease the value of Par 1048 Autotune Cur Lim and repeat the auto tune procedure The loading torque value is too high at zero speed to complete the speed regula
420. s which adapters can clear a fault 598 Mask See Logic Mask d Controls which adapters can issue MOP commands to the drive PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 64 Programming and Parameters s E o g Parameter Name amp Description s ir o See page 3 2 for symbol descriptions Values 599 Local Mask See Logic Mask Zen Controls which adapters are allowed to take exclusive control of drive logic commands except stop Exclusive local control can only be taken while the drive is stopped 600 Stop Owner The adapters that are presently issuing a valid stop command 0 No Command 1 Issuing Command x Reserved silo lo io p lo fo lo PT 19 rile 2 2 2 2 2 2 2 5 B IE GS S oo S io o o o o o fo EE jc no g lo o lo lo lo lo lo lo o a a la la la 9 ie mc je je E O jaa a AO Defaut X X Xx X X X X x x x 0000 0 0 Bit 15 14 13 d2 11 10 9 8 7 6 5 4 B 2 1 0 601 Start Owner See Stop Owner The adapters that are presently issuing a valid start command 602 Log Owner See Stop Owner The adapters that are presently issuing a valid jog command 603 Direction Owner See Stop Owner The adapter that currently has exclusive control of direction changes 604 Reference Owner See Stop Owner The adapter that has the excl
421. sh 1155 Diameter Calc 3 45 PI Lower Limit 785 PI Control 3 39 Line Speed Pct 1160 Diameter Calc 3 45 PI Output 7 PI Control 3 38 Load Comp 698 Load Limits 3 35 PI Prop Gain PID 765 PI Control 3 38 Local Mask 599 Masks amp Owners 3 64 PI Steady Thr 695 PI Control 3 38 Local Owner 608 Masks amp Owners 3 64 PI Upper Limit 784 PI Control 3 39 Lock Speed Integ 348 Speed Regulator 3 30 PID Accel Time 1046 PID Control 3 42 Logic Mask 591 Masks amp Owners 3 63 PID Clamp 757 PID Contro 3 41 Security 265 PID Decel Time 1047 PID Control 342 Logic Mask Act 1376 Security 3 65 PID Error 759 PID Control 341 Man Ref Preload 210 HIM Ref Config 3 50 PID Error Gain 1254 PID Control 343 Materl Width Pct 1173 Winder Functions 3 46 PID Feedback 763 PID Control 341 Max Deviation 796 Diameter Calc 3 44 PID Output 774 PID Contro 341 Max Diameter 1153 Diameter Calc 3 45 PID Output Scale 773 PID Contro 341 Max Feedback Spd 162 Motor Data 8 15 PID Output Sign 772 P D Contro 341 Max Fld Curr Pct 467 Field Config 8 17 PID Setpoint 0 760 PID Control 341 Max Ref Speed 45 Motor Data 3 15 PID Setpoint 1 761 PID Control 341 Max Speed Fud 3 mits PID Setpoint Sel 762 PID Control 341 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 80 Programming and Parameters
422. sk 3 2 3 63 3 65 Logic Mask Act 3 65 Man Ref Preload 3 50 Materl Width Pct 3 46 Max Deviation 3 44 Max Diameter 3 45 Max Feedback Spd 3 15 Max Fld Curr Pct 3 17 Max Ref Speed 3 15 Max Speed Fwd 3 26 Max Speed Rev 3 26 Maximum Speed 3 26 Min Fld Curr Pct 3 17 Min Speed Fwd 3 26 Min Speed Rev 3 26 Minimum Diameter 3 44 Minimum Speed 3 26 MOP Accel Time 3 33 MOP Dec Active 3 54 MOP Decel Time 3 33 MOP Inc Active 3 53 MOP Mask 3 63 MOP Owner 3 64 MOP Select 3 50 Motor Trq Ref 3 13 MtrOvrid Cfg 3 58 MtrOvrid Status 3 55 MtrOvrid Type 3 16 Nom Mtr Arm Amps 3 15 Nom Mtr Fld Amps 3 15 Offs Accel Time 3 48 Opening Delay 3 35 Out Volt Level 3 18 Output Power 3 14 Output Voltage 3 14 OverCurrent Thr 3 58 Overspeed Val 3 59 OverTemp Fit Cfg 3 58 OverVolt Cfg 3 58 Param Access Lvl 3 50 Index 15 PD Deriv Filter 3 40 PD Deriv Gain 1 3 40 PD Deriv Gain 2 3 40 PD Deriv Gain 3 3 40 PD Output PID 3 40 PD Prop Gain 1 3 40 PD Prop Gain 2 3 40 PD Prop Gain 3 3 40 PI Central v sel 3 39 PI Central v1 3 38 PI Central v2 3 38 PI Central v3 3 38 PI Central vst 3 39 PI Central vs1 3 39 PI Init Intgl Gn 3 40 PI Init Prop Gn 3 39 PI integr freeze 3 39 PI Integral Gain 3 38 PI Lower Limit 3 39 PI Output 3 38 PI Prop Gain PID 3 38 PI Steady Thrsh 3 38 PI Upper Limit 3 39 PID Accel Time 3 42 PID Clamp 3 41 PID Decel Time 3 42 PID Error 3 41 PID Error Gain 3 43 PID Feedback 3 41 PID Output 3 41 PID Output Scale 3 41
423. ss 3 31 SpdReg Kp Bypass 3 31 SpdTune Friction 3 23 specifications agency certifications A 1 control A 3 DC contactor crimp lug kits A 22 electrical A 3 environment A 2 protection A 1 Speed Command file 3 26 Speed Demand En 3 49 speed draw function C 28 Speed Draw Out 3 12 Speed Feedback 3 12 Speed Feedback group 3 20 3 21 3 22 Speed Feedback Pct 3 12 Speed Match 3 48 Speed Meters group 3 11 3 12 speed pot 1 45 Speed Ramp En 3 33 Speed Ratio 3 27 Speed Ref A 3 11 Speed Ref A Pct 3 11 Speed Ref B 3 11 Speed Ref B Pct 3 11 Speed Ref Out 3 12 Speed Ref Out Pct 3 12 speed reference sources auto C 18 manual C 18 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Index 22 Speed References group 3 27 Speed Reg En 3 30 Speed Reg In 3 12 Speed Reg In Pct 3 12 speed regulation function C 22 C 25 C 27 C 28 speed regulator tune C 41 Speed Regulator group 3 27 3 28 Speed sources change C 18 Speed Thresh Neg 3 28 Speed Thresh Pos 3 28 Speed Threshold 3 53 speed threshold indicators function C 25 Speed Tune Aborted fault 4 7 Speed Tune Current Limit fault 4 7 Speed Tune Dir 3 23 Speed Tune Friction Low fault 4 7 Speed Tune Ki 3 23 Speed Tune Kp 3 23 Speed Tune Load High fault 4 7 speed up function C 25 Speed Up Base 3 30 Speed Up Filter 3 30 Speed zero function C 27 Speed Zero Delay 3 29 Speed Zero Level 3 29 standard I O terminal blocks 1 43 wire size 1
424. stor 1 31 relay output 1 31 SA SB 1 35 standard I O 1 43 test generator use C 36 Test Generator group 3 24 3 25 TestPoint Data 3 56 TestPoint Sel 3 56 testpoints 4 15 thermal switch configure 1 31 thermistor configure 1 31 Threshold Delay 3 28 Time AccDec Min 3 47 Torq Attributes group 3 19 3 20 Torq Cur Filter 3 20 Torq Current Pct 3 47 Torq Limit Type 3 35 Torq Red CurLim 3 34 Torque Const 3 23 Torque Negative 3 51 Torque Positive 3 51 Torque Reduction 3 19 Torque Ref 3 19 torque reference source C 18 Torque Winder En 3 48 Trim Ramp 3 27 Trim Ramp Pct 3 27 Trim Speed 3 27 Trim Speed Pct 3 27 ndex 23 Trim Torque 3 19 troubleshooting 4 1 TrqTpr Enable 3 20 TraTpr_LimO 3 20 TrqTpr_Lim1 3 20 TraTpr_Lim2 3 20 TrqTpr_Lim3 3 20 TrqTpr Lim4 3 20 TraTpr_Spd 3 20 TstGen Amplitude 3 24 TstGen Frequency 3 24 TstGen Offset 3 24 TstGen Output 3 24 tune current regulator C 37 field current curve C 45 field current regulator C 38 speed regulator C 41 voltage regulator C 43 U UnderVolt Thresh 3 58 unipolar speed reference analog input 1 45 User Defined group 3 59 3 60 3 61 3 62 user sets B 4 UserDefinedO 3 60 UserDefined1 3 60 UserDefined10 3 60 UserDefined11 3 60 UserDefined12 3 60 UserDefined13 3 60 UserDefined14 3 60 UserDefined15 3 60 UserDefined2 3 60 UserDefined3 3 60 UserDefined4 3 60 UserDefined5 3 60 UserDefined6 3 60 UserDefined7 3 60 UserDefined8 3 60 UserDefined9 3
425. t Security 3 65 1267 Inversion Out 1 Digital Outputs 3 75 1377 Write Mask Act Security 3 66 1268 Inversion Out 2 Digital Outputs 3 75 1378 Write Mask Cfg Security 3 66 1269 1 Inversion Out 3 Digital Outputs 3 75 1379 1 Port Mask Act Security 3 66 1270 Inversion Out 4 Digital Outputs 3 75 1380 1 Drive Alarm 1 Alarms 3 59 1271 Inversion Out 5 Digital Outputs 3 75 1381 TestPoint Sel Diagnostics 3 56 1272 Inversion Out 6 Digital Outputs 3 75 1382 1 TestPoint Data Diagnostics 3 56 1273 1 Inversion Out 7 Digital Outputs 3 75 1383 TaskLoad 32 ms Diagnostics 3 56 1274 Inversion Out 8 Digital Outputs 75 1384 TaskLoad 1 ms Diagnostics 3 56 1275 Inversion Relay2 Digital Outputs 3 75 1385 TaskLoad 2 ms Diagnostics 3 56 1276 1 Inversion In 1 Digital Inputs 3 72 1386 TaskLoad 8 ms Diagnostics 3 56 1277 1 Inversion In 2 Digital Inputs 3 72 1387 Inversion In 9 Digital Inputs 72 1278 1 Inversion In 3 Digital Inputs 3 72 1388 Inversion In 10 Digital Inputs 3 72 1279 Inversion n 4 Digital Inputs 3 72 1389 Inversion In 11 Digital Inputs 8 72 1280 Inversion In 5 Digital Inputs 3 72 1390 Inversion In 12 Digital Inputs 3 72 1281 1 Inversion In 6 Digital Inputs 3 72 1391 1 ContactorControl Digital Inputs 3 72 1282 Inversion In 7 Digital Inputs 3 72 1392 1 Relay Out 1 Sel Digital Outputs 3 75 1283 1 Inversion In 8 Digital Inputs 3 72 1393 Inversion Relay1 Digital Outputs 3 76 1284 1 Ref Spd Source VVinder Functions 3 49 1402 Last Stop Source
426. t Stop Notes Refer to Chapter 4 for a list of alarm and fault descriptions 4 Normal Stop Option 3 was changed from Quick Stop to Fast Stop with firmware 5 CurrLim Stop version 2 001 365 OverTemp Flt Cfg Default 2 qe Determines the response of the drive to a motor over temperature Options 0 Ignore condition F16 Motor Over Temp 1 Alarm Notes Refer to Chapter 4 for a list of alarm and fault descriptions 2 Fault Option 3 was changed from Quick Stop to Fast Stop with firmware 3 Fast Stop version 2 001 4 Normal Stop 5 CurrLim Stop 473 FldLoss Cfg Default 2 Fault 497 6 Determines the response of the drive to a field loss condition F6 Fld Options 0 Ignore Current Loss If Par 497 Field Reg Enable is set to 0 Disabled 1 Alarm this parameter should be set to 0 Ignore 2 Fault Note Refer to Chapter 4 for a list of alarm and fault descriptions 478 Spd Loss Fit Cfg Default 2 Fault 458 O Determines the response of the drive to a speed feedback loss Options 1 Alarm condition 2 Fault 376 1290 File 2 Group Alarms No 585 1380 54 Programming and Parameters Parameter Name amp Description See page 3 2 for symbol descriptions Values Overspeed Val Default 1925 Speed value rpm at which an Overspeed
427. t all power to the drive has been removed before performing the following 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 Follow these steps to install a communication adapter module AN ATTENTION Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by e sending an erroneous signal to your system s field devices causing unintended machine motion e causing an explosion in a hazardous environment Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts may create electrical resistance 1 Remove and lock out all incoming power to the drive 2 Disconnect the DPI cable from the HIM on the drive PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installing a Communication Adapter E 3 3 Remove the bottom cover from the drive a On frame A drives remove th
428. t terminals 35 and 36 Relay Output 1 If the coil voltage is present at terminals 35 or 36 then verify that the proper voltage is at the DC Output contactor coil e Inspect the contactor for mechanical problems e Verify that parameter 1391 ContactorControl is set properly Verify that the contactor and or auxiliary contact is properly wired to a digital input on the drive and that the appropriate digital input selection parameter 133 144 Digital Inx Sel is set to 31 Contactor e Verify that parameter 1392 Relay Out 1 Sel is set to 25 Contactor PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 4 12 Troubleshooting Drive Symptom The external DB resistor contactor if used has not closed Action e Verify that the drive is Ready then verify that the required coil voltage is present at terminals 75 and 76 Relay Output 2 If the coil voltage is present at terminals 75 or 76 then verify that proper voltage is at the DB contactor coil e nspect contactor for mechanical problems e Verify that parameter 1391 ContactorControl is set properly e Verify that the auxiliary contacts for the AC Input or DC Output contactor and DB contactor are properly wired in series to a digital input on the drive e Verify that the appropriate digital input selection parameter 133 144 Digital Inx Sel is set to 31 Contactor e Verify that parameter 629 Relay Out 2
429. t to 17 Speed Sel 1 asserted Note By default the state of this parameter is determined by digital input 5 Spd Select 1 Default 18 Speed Sel 2 Refer to Option Definitions for Digital Inx Sel on page 3 71 for instructions on how to set digital input speed selects to different speed references 0 Digital input Digital Inx Sel set to 18 Speed Sel 2 not asserted 1 Digital input Digital Inx Sel set to 18 Speed Sel 2 asserted Note By default the state of this parameter is determined by digital input 6 Spd Select 2 Default 19 Speed Sel 3 Refer to Option Definitions for Digital Inx Sel on page 3 71 for instructions on how to set digital input speed selects to different speed references e 0 Digital input Digital Inx Sel set to 19 Speed Sel 3 not asserted 1 Digital input Digital Inx Sel set to 19 Speed Sel 3 asserted Note By default the state of this parameter is determined by digital input 7 Ramp Select 0 Default 25 Acc2 8 Dec or 26 Accel 2 e 0 Accel 1 ramp rate is selected 1 Accel 2 ramp rate is selected Note This parameter can be assigned to indicate the state of a digital input Ramp Select 1 Default 25 Acc2 8 Dec or 27 Decel 2 0 Decel 1 ramp rate is selected 1 Decel 2 ramp rate is selected Note This parameter can be assigne
430. t with binary logic Diam Preset1 Diam Preset0 Selection 2 0 0 Par 1164 Diam Preset 0 0 1 Par 1165 Diam Preset 1 2 1 0 Par 1166 Diam Preset 2 1 1 Par 1167 Diam Preset 3 lt 1205 Diam Inc Dec En Default 1 Enabled This parameter t is used to improve system stability for winder Options 0 Disabled unwinder applications If this parameter is enabled and if applied to a 1 Enabled winder the calculated diameter can never decrease if applied to an unwinder the calculated diameter can never increase 1206 Diam init filter Default 100 Initial filter on the diameter calculation Min Max 0 5000 Units ms 1207 Diam stdy delay Default 0 1155 The amount of time during which the value of Par 1206 Diam init Min Max 0 60000 1206 filter is kept active after the value defined in Par 1155 Line Spd Units ms Thresh has been overcome 1171 Variable J Comp Default 0 00 Torque compensation due to the wound material as a percentage of Min Max 0 00 199 99 the drive rated current Units 1172 Constant J Comp Default 1 00 Compensation of the fixed section motor reducer pin as a Min Max 100 00 percentage of the drive rated current Units 1173 Materl Width Pct Default 100 00 22 Width of the wound material as a percentage of the maximum width Min Max 0 00 100 00 z Units 96 1174 Static Friction Default 0 00 Compensation for static friction as
431. tactor default value for parameter 140 Digital In8 Sel Connect the DC contactor auxiliary status contact to a second digital input Set the corresponding second Digital Inx Sel parameter 133 144 to Fld Weak En Set the corresponding Inversion In x parameter 1276 1283 or 1387 1390 for the second digital input to Enabled Inverting Fault Device Configuration 1 2 Connect the inverting fault device contact to a digital input Set the corresponding Digital Inx Sel parameter 133 144 to 14 Aux Fault Set the corresponding Inversion In x parameter 1276 1283 or 1387 1390 to 1 Enabled the configurations detailed above dynamic braking stop time ATTENTION If a dynamic brake resistor is used with one of will be extended when the digital input configured as 35 Fld Weak En is asserted Equipment damage and or personal injury may result if one of these configurations is used in an inappropriate application Do not use one of these configurations vvithout considering applicable local national and international codes standards regulations or industry guidelines PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 13 PID Function The PID function is used to increase or reduce the reference signal output to the speed or current regulator of the drive The PID function can be used for nip roll winder unwinder roll doctor salvag
432. talog Number Preface 4 Explanation 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 for a 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 e 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 4 55 C 131 F e Place where the relative air humidity range does not exceed 5 95 At an altitude of less than 3 000 meters 10 000 ft above sea level PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 p 2 Overview Drive Nameplate Data Drive Frame Sizes Drive Firmware Version Reference Materials The PowerFlex DC drive contains a data nameplate label 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
433. ted current for one minute 200 rated current for three seconds Max Short Circuit Rating 100 000 A Control Speed Regulation All operating modes Max speed 8000 rpm Digital reference resolution 0 25 rpm Analog reference resolution gt 0 25 rpm With Digital Incremental Encoder Speed feedback resolution 0 5 rpm Operating range better than 1000 1 rpm bi directional Performance Accuracy 0 02 typical 170 rad sec bandwidth with DC Analog Tachometer Speed feedback resolution better than 2000 1 rpm Operating range better than 1000 1 rpm bi directional Performance accuracy x0 196 170 rad sec bandwidth with Armature Voltage Feedback Voltage feedback resolution better than 2000 1 rpm Operating range better than 100 1 rpm bi directional Performance accuracy 2 0 typical 80 rad sec bandwidth Subject to motor specs current loop tuning Torque Regulation Current feedback resolution better than 2000 1 rpm Performance accuracy 1 0 typical 500 rad sec bandwidth PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 A 4 Supplemental Drive nformation Category Feedback Devices Specification Encoder Type Incremental dual channel two channel optional with jumper differential recommended or single ended Input Voltage Configurable for 2 5V 5 2V switch S21 in ENC 5 position or 5 4V 15 2V switch S21 in ENC 12 position
434. ter than the value of SLAT Err Stpt for the amount of time specified in Par 16 SLAT Dwell Time then the forced speed mode is turned off Note This parameter was added with firmware version 3 001 SLAT Dwell Time Amount of time that the speed error must be greater than the value of Par 15 SLAT Err Stpt in order to return to SLAT Min or SLAT Max mode Note This parameter was added with firmware version 3 001 Spd Trq Mode Sel Configures the drive for a Speed or Torque mode of operation e Zero Trq Ref The drive operates as a torque regulator with the torque reference Par 14 Selected TorqRef forced to zero e Speed Reg The drive operates as a speed regulator with the reference Par 236 Spd Reg Out Pct inertia compensation Torque Reg The drive operates as a torque regulator with the reference equal to the value of Par 39 Torque Ref SLAT Min The drive operates in Speed Limited Adjustable Torque SLAT Minimum mode The drive operates as a torque regulator when the value of Par 39 Torque Ref is algebraically smaller in value than the speed regulator s output The drive may automatically enter speed regulation mode based on conditions within the speed regulator and the magnitude of the speed regulator s output relative to the torque reference SLAT Max The drive operates in SLAT Maximum mode The drive operates as a torque regulator when the value of Par 39 Torque Ref
435. ternal Ramp D k 10V Forward L 10V Reverse Line Speed Reference PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 C 16 Application Notes In addition you can configure the following Par 763 PID Feedback contains the raw feedback counts from the analog input signal received from the transducer position dancer or tension load cell Monitor the tension set point for a torque winder application in Par 1194 Act Ten Ref Pct Configure the PID feedback gain in Par 1254 PID Error Gain Limit the PID correction error using Par 757 PID Clamp Monitor the actual error input to the PI and PD blocks in Par 759 PID Error P760 P762 PID Setpoint 0 PID Setpoint Sel P761 PID Setpoint 1 P763 PID Feedback P1254 P763 PID Error Gain PID Feedback Ba P1194 P757 P759 Act Ten Ref Pct PID Clamp PID Error PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 17 Configure the Tension Set Point Signal in the Follower Drive s Configure the initial tension for the application in the Follower drive s Set Par 75 Anlg In2 Sel to 17 PID Setpt 0 Line Speed Master NIP Roll Reverse Forward Load Cell 0 10V Tension Set 10V Maste
436. ternal power to the damage can occur Verify the Control and 1 0 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 33 and I O Wiring on page 1 38 for further information 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 31 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Drive Start Up 2 3 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 M or DriveToolsTM SP software l to program drive 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 1 Important When power is first applied the HIM may require approximately 5 seconds until commands are recognized including the Stop key 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 Fa
437. th AC contactor if Fuses with Trip Indicator are used and wired to Inverting Fault input See Figure 1 13 on page 1 23 If regular fuses are used armature voltage TB can be used for overvoltage fault PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 AT 3 Phase AC line L3 Installation and Wiring Figure 1 11 Power Wiring with DC Output Contactor 34 on VO TB4 1 21 N O Relay M1 DC Contactor Aux 19 424V on I O TB2 LER a FS2 1 rei R Lt TH il 1 L2 1T2 Fe D LA D oue PowerFlex DC At 2 At w i Drive FU FU Armature Volt 141 Fdbk Term A1 m 1A2 e Control j d NEL Board P S A2 460V 115V V2 360 Fg ml Control Power Relay 36 Terminal Block Field Power Terminal Block U1 C1 FU1 E FV1 vi 01 2 1 AC input fuses for the armature drives See Drive Power Circuit Protec ion on page A 8 for fuse recommendations 2 par 140 Digital In8 Sel set to 31 Contactor converter are customer supplied for frame A and B drives an
438. the drive Reverse the polarity of only one channel for example B and B NOT Refer to Table 1 V on page 1 48 for digital encoder terminal block designations Continue with Configure the Speed Feedback Parameters on page 2 14 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 2 14 Drive Start Up Configure the Speed Feedback Parameters 1 Access the Speed Feedback group and configure the following parameters Note If a speed feedback device is used encoder or tachometer refer to Drive Reference and Feedback Scaling on page C 7 for instructions on associated parameter settings 3 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 vveakening mode Par 414 Fdbk Device Type must be set to 1 Encoder or 2 DC Tach 3 Par 457 Spd Fdbk Control If you are using an encoder or tachometer set this parameter to 1 Enabled to activate speed feedback control L1 Ifthe 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 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 33 on
439. 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 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 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 Preset Speed 1 Preset Speed 2 Preset Speed 3 Preset Speed 4 Preset Speed 5 Preset Speed 6 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 Jog Speed Reference value for jog mode Note This parameter can be assigned to an analog input PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Values 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
440. the value obtained when the current regulator auto tuning is completed PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Values Default Options Default Options Default Min Max Default Min Max Default Min Max Default Min Max Units Default Min Max Units Default Options Default Min Max Default Options Default Min Max Units Default Min Max Units 0 Disabled 0 Disabled 1 Enabled 0 Disabled 0 Disabled 1 Enabled 0 0 6553 Read Only 0 291 0 010 0 010 1 000 0 0 2000 ms 0 100 0 001 1 000 S 0 E Off 0 Off 1 Trim Ramp 2 Speed 3 Speed Ref A 4 Speed Ref B Read Only 232 0 Off 0 Off 1 On 0 50 Based on drive current rating Ohm 4 00 Based on drive current rating mH Sil Related 4 915 914 924 452 452 File MOTOR CONTROL Group Autotune initiates the speed regulator auto tuning procedure When the auto tuning procedure is complete this parameter automatically resets to 0 Off This test should be run with inertia connected to the motor if present but without process load i e material ZN Programming and Parameters o 6 Parameter Name 8 Description s Z See page 3 2 for symbol descriptions Value
441. ting LI Par 66 Anlg Ou Sel 18 Fld Current LI Par 67 Anlg Ou Sel 24 Field Ref Configure the following parameters 11 Set Par 497 Field Reg Enable 1 Enabled default LI Set Par 469 Field Mode Sel 1 Field Weaken 1 Set Par 498 Force Min Field 1 Enabled Configure the following Test Generator parameters D Set Par 58 TstGen Output 3 Field Ref 1 Set Par 60 TstGen Amplitude 70 of the field rated current of the motor this setting allows the system overshoot Increase the value of the Par 91 Fld Reg Kp until the overshoot of the field current displayed in Par 234 Fld Current Pct is lower than 4 Increase the value of Par 92 Fld Reg Ki until the overshoot is higher than 4 Then decrease the value of this parameter until it becomes slightly lower than 4 Important Because of the relatively high field time constant the rising speed of the field current is limited The rising time with optimal tuning conditions could be up to 100 milliseconds PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 C 40 Application Notes 7 Set Par 58 TstGen Output 0 NotConnected 8 Set Par 498 Force Min Field 0 Disabled 9 Set Par 468 Min Fld Curr Pct to the desired value 10 Configure the analog outputs according to your application needs Field Current Regulator Tuning Examples Figure C 6 Increase in t
442. tion may dictate separate spacing All wires of class 7 through 11 MUST be shielded per the recommendations In cable trays steel separators are advisable between the class groupings If conduit is used it must be continuous and composed of magnetic steel Spacing of communication cables classes 2 6 is Through Air 115V 2 in 51 mm 230V 1 5 in 38 mm 230V 4 in 101 5 mm 380 575V 3 in 76 mm 380 575V 8 in 203 mm 575V proportional to 6 in 152 mm per 1000V 575V proportional to 12 in 305 mm per 1000V PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Power Wiring AC Input Voltages Installation and Wiring 1 19 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 230V 10 1Ph 115V 15 1 Ph 400V 10 3Ph 440V 10 3Ph 460V 10 3Ph 400V 10 1Ph 460V 10 1Ph 50 60 Hz x5 or 230V 15 1Ph 50 60 Hz 5 480V 10 3Ph 50 60 Hz 5 UT 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 29 on page 1 35 for terminal block location on frame B drives and Figure 1 30 on page 1 36 for terminal block location on frame C
443. tion for Ramp 2 Deceleration rate for Ramp 2 Par 2 Maximum Speed Par 30 Decel Time 2 Speed Ramp En Enables or disables the ramp function The Ramp Reference block is bypassed when this parameter is set to 0 Disabled Values 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 Options Programming and Parameters 1 00 0 10 60 00 S 100 0 65535 ms 10 0 65535 S 10 0 65535 S 10 0 65535 S 10 0 65535 S 10 0 65535 Enabled Disabled Enabled 3 33 Related 668 113 346 347 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 34 Programming and Parameters 2 g o S g Parameter Name amp Description s ip See page 3 2 for symbol descriptions Values ka 344 Zero Ramp Output Default 1 Not Active Activates either the ramp output 1 or the brake function 0 When Options 0 Active this parameter is set to 0 Active the drive brakes through the 1 Not Active maximum avallable torque and the motor vill perform a Current Limit Stop Two quadrant drives do not support a brake option e Active The ramp output is disabled and Pars 113 Ramp Out and 114 Ramp Out Pct are immediately set to zero
444. tion of torque and constant power armature and field regulation field weakening The maximum armature voltage is configured in Par 175 Rated Motor Volt e External The motor field power is supplied by an external rectifier converter the drive s field output is disabled Field Reg Enable Enables Disables the field regulator e Enabled The field regulator is enabled and controlling the field output Disabled The field regulator is disabled the field current is zero Force Min Field Enables Disables the minimum field current value Enabled The field current corresponds to the value set via Par 468 Min Fld Curr Pct e Disabled The field current is regulated based on the quadrant mode and situation in which the drive is operating Note This parameter can be assigned to a digital input 35 Force MinFld ZN Values Default Min Max Units Default Min Max Units Default Options Default Options Default Options Programming and Parameters 100 Par 468 Min Fld Curr Pct 100 o Vo ATTENTION Failure to set this parameter to a value appropriate for the intended application could result in excessive motor speed equipment damage and or bodily injury 30 0 Par 467 Max Fld Curr Pct 0 ATTENTION Failure to set this parameter to a value appropriate for the intended application could result in excessive motor spee
445. tion on page Preface 4 positions 8 9 and 10 for corresponding drive HP rating armature amp rating and field amp rating 2 See Cable and Wiring Recommendations on page 1 17 for more information Figure 1 29 SA SB Terminal Block Location on Frame B Drives The SA SB terminal block is located at the top of the drive Front of Drive Y PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring Figure 1 30 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 XSW connector To access the SA SB terminal block 1 Remove the top protective cover from the drive 2 Disconnect cables XFCD and XR 3 Loosen captive Screws 3 Loosen D captive Screws 4 Lower EMI shield and disconnect cable XSW from Switching Power Supply board see above PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring 1 37 Frame C Heatsink Cooling Fans and Armature Fuse Signal Terminals Frame C drives rated 521 A 230V AC and 495 A and 667 A 460V AC input only require an external power supply for the heatsink cooling fans and include internal armature circuit protection fuses The terminals for the internal armature
446. to select a simulated parameter as the output for the Options 0 NotConnected test generator The test generator is used to manually tune the 1 Reserved regulators It consists of a square wave generator whose 2 Cur Ref frequency offset and amplitude can be manipulated 3 Field Ref e NotConnected No internal parameters defined by the 4 Ramp Ref 5 Speed Ref generator e Reserved Not used e 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 these tests and may cause personal injury and or equipment damage Verify that the drive is not connected to a motor armature circuit before enabling these test modes A ATTENTION Uncontrolled machine operation could result with a motor connected during P58 TstGen Output Generator Output P60 TstGen Amplitud
447. to the motor terminals the jumpers must be installed Note that this terminal block is not present on drives shipped from the factory prior to those with v3 001 firmware installed However new Pulse Transformer boards shipped as replacement parts from the factory will contain this terminal block and can be used with any version of firmware Terminals Description 1A1 Jumpered to A1 when internal armature voltage feedback is used Not used when A1 is connected to motor terminal A1 Al Voltage feedback from motor terminal A1 1A2 Jumpered to A2 when internal armature voltage feedback is used Not used when A2 is connected to motor terminal A2 A2 Voltage feedback from motor terminal A2 Figure 1 17 Frame A Armature Voltage Feedback Circuit Terminal Block Location Bottom of View of Drives Drive with no fan Drive with fan q TATTAT TA2 PA Ta TAI AT 1A2 A2 e 2 E s 1M M 1 Shown with terminals jumpered for internal armature voltage feedback PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring 1 27 Figure 1 18 Frame B Armature Voltage Feedback Circuit Terminal Block Location Top of Drive Shown with terminals umpered for internal armature voltage feedback N lt e x amp Figure 1 19 Frame C Armature Voltage Feedback Circuit Terminal Block Location O
448. tor auto tuning procedure Decrease the load torque where applicable and repeat the auto tune procedure The measured motor speed is too high during the speed regulator auto tuning procedure Decrease the value of Par 1048 Autotune Cur Lim and repeat the auto tune procedure The drive stalled during the speed regulator auto tuning procedure Increase the value of Par 1048 Autotune Cur Lim and repeat the auto tune procedure The speed regulator auto tuning procedure did not complete within the available time 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 3396 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 Fault No Type Power Failure 3 2 STune Aborted 62 STune CurLimit 59 2 STune FrictionLo 60 STune LoadHi 58 2 STune Overspeed 56 2 STune Stalled 57 STune Timeout 61 Sustained Curr 70 The motor CEMF is too high or the line voltage is too low Check the line voltage and frequency e Check the motor brushes and connections e Check the Main and DB Contactor connections if present e Verify that there are no overhauling loads present See page 4 1 for a description of fault types PowerFlex Digital DC Drive User Manua
449. tr or DC Cntctr 1 relay digital output 1 digital input is used AC Cntctr DB or DC Cntctr DB 2 relay digital outputs 1 digital input is used Note Options 1 and 2 changed from Contactor and Contactor DB to AC Cntetr and AC Cntctr DB respectively and options 3 and 4 added with firmware version 2 001 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Default Min Max Default Options Default Options hOoOnM OoO Read Only 0 1 Disabled Disabled Enabled AC Cntctr None AC Cntctr AC Cntctr DB DC Cntctr DC Cntctr DB Related File Digital Outputs Parameter Name amp Description See page 3 2 for symbol descriptions Values Programming and Parameters Digital Out1 Sel Default 5 Ready Digital Out2 Sel Default 9 Fault Digital Out3 Sel Default 2 SpdThresh Digital Out4 Sel Default 4 OurrentLimit Digital Out5 Sel Default 26 Alarm Digital Out6 Sel Default 0 Not Used Digital Out7 Sel Default 0 Not Used Digital Out8 Sel Default 0 Not Used Selects the source of the value that drives the digital output Refer to Option Definitions on Option Definitions for Digital Ouix Sel Relay Out 1 Sel and Relay Out
450. trol 3 38 608 Local Owner Masks amp Owners 3 64 778 P Central v3 PI Contro 3 38 609 1 Decel Owner Masks amp Owners 3 64 779 P Central v sel PI Contro 33 610 Data In A1 Datalinks 3 65 780 PI Central vsO PI Control 3 39 611 Data In A2 Dafalinks 3 65 781 PI Central vs1 PI Control 3 39 612 Dalan Bi Datalinks 365 782 P D Target PID Control 3 42 613 Data n B2 Datalinks 3 65 783 PI integr freeze PI Control 3 39 614 D st Datalinks 784 P Upper Limit PI Control 3 39 Daa nee une 265 785 Pl Lower Limit PI Contro 3 39 616 Data In D1 Datalinks 3 65 786 PID Source PID Control 3 42 617 _ Data In 02 Datalinks 265 787 P D Source Gain PID Control 342 618 Data Out Al Datalinks 365 788 Prop Gain 2 PD Control 3 40 5 50 ma 789 Deriv Gain 2 PD Control 240 620 Out B1 Datalinks 365 790 Prop Gain 3 PD Control 3 40 621 Data Out B Datalinks Z 791 PD Derv Gain 3 PD Control 3 40 622 Data Out C1 Datalinks 3 65 792 Anlg In 1 Filter Analog Inputs 3 68 623 Data Out C2 Datalinks 355 793 P Init Prop Gn PI Control 3 39 624 Data Out D1 Datalinks 3 65 794 Diameter Calc Diameter Calc 3 44 625 Data Out D2 Datalinks 3 65 795 DnerPosSpd Diameter Calc 3 44 627 SpdO Tip Delay Stop Modes 335 796 Deviation Diameter Calc 3 44 629 Relay Out 2 Sel Digital Outputs 75 797 Gear Box Ratio Diameter Calc 3 44 631 Decel Mask Masks amp Owners 3 64 798 Dancer Constant Diameter Calc 3 44 651 Encoder State Diagnostic
451. trol board be in the Off 10 Off 80 Anlg In3 Sel 6 Analog Input 3 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 M on page 1 39 Max 410V Max 0 25 mA 7 10V Pot Reference 2 5k ohm load Max H OV 10 mA 8 10V Pot Reference 9 Pot Common For and CH 10V pot references 10 PE ground PE ground to drive chassis Ifferential Isolation External Source must be maintained at less than With respect to Input provides high common moae immunity Table 1 5 1 0 Terminal Block 2 Designations No Signal Description Factory Default Config Parameter 11 Internal OV Gnd 12 Digital Input 1 Max 30V 15V 3 2 mA 24V 5 mA 2 Stop CF 133 Digital Int Sel 13 Digital Input 2 and 30V 6 4 mA 3 Start 134 Digital In2 Sel 14 Digital Input 3 A digital input 1 8 must be configured for 11 109 135 Digital In3 Sel 15 Digital Input 4 Enable 1 Enable 136 Digital In4 Sel 16 Digital Input Common Important 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 17 Not Used m a 18 24V Supply Common Common for the internal power supply 19 24V DC Supply Drive supplied control input power Max 20 30V 200 mA Note The total current draw is the sum of encoder power digital outputs
452. tus 1 381 Start Inhibits 1403 At Zero Speed 395 Drive Status 2 382 Drive Logic Rslt 1328 CurrLimit Active 349 Last Stop Source 1402 At Speed 394 Spd Limit Active 372 Faults Clear Fault Que 263 Status2 at Fault 1350 Fault Voltage 1374 Fault Clear 1347 Fault Arm Amps 1371 Fault 1 Code 1351 Fault Clr Mode 1348 Fault Speed 1372 Status1 at Fault 1349 Fault Field Amps 1373 Alarms Drive Alarm 1 1380 Communications Comm Control DPI Baud Rate 589 DPI Fdbk Select 1321 DPI Port Value 1343 DPI Pon Sel 590 Masks amp Owners Logic Mask 591 MOP Mask 598 Reference Owner 604 Start Mask 592 Local Mask 599 Accel Owner 605 Jog Mask 593 Decel Mask 631 Fault Clr Owner 606 Direction Mask 594 Stop Owner 600 MOP Owner 607 Reference Mask 595 Start Owner 601 Local Owner 608 Accel Mask 596 Jog Owner 602 Decel Owner 609 Fault Clr Mask 597 Direction Owner 603 Datalinks Data In A1 610 Data In D1 616 Data Out C1 622 Data In A2 611 Data In D2 617 Data Out C1 623 Data In B1 612 Data Out A1 618 Data Out D1 624 Data In B2 613 Data Out A2 619 Data Out D2 625 Data In C1 614 Data Out B1 620 Data In Val Sel 1319 Data In C2 615 Data Out B2 621 Data In SelData 1320 Input Output Analog Inputs Anlg Int Sel 70 Anlg In1 Target 295 Anlg Int Cmp Eq 1045 Anlg Int Config 71 Anlg In2 Target 296 Analog In1 Value 1404 Anlg In2 Sel 75 Anlg In3 Target 297 Analog In2 Val
453. ue 1405 Anlg In2 Config 76 Anlg Int Cmp 1042 Analog In3 Value 1406 Anlg In3 Sel 80 Anlg Int Cmp Err 1043 Anlg In3 Config 81 Anlg Int Cmp Dly 1044 Analog Outputs Anlg Out Sel 66 Anlg Out4 Sel 69 Analog Out3 Scale 64 Anlg Out2 Sel 67 Analog Scale 62 Analog Out4 Scale 65 Anlg Out3 Sel 68 Analog Out Scale 63 Digital Inputs Dig In Status 564 Digital In9 Sel 141 Dig In Term 6 570 Digital In1 Sel 133 Digital In10 Sel 142 Dig In Term 7 571 Digital In2 Sel 134 Digital In11 Sel 143 Dig In Term 8 572 Digital In3 Sel 135 Digital In12 Sel 144 Dig In Term 9 573 Digital In4 Sel 136 Dig In Term 1 565 Dig In Term 10 574 Digital In5 Sel 137 Dig In Term 2 566 Dig In Term 11 575 Digital In6 Sel 138 Dig In Term 3 567 Dig In Term 12 576 Digital In7 Sel 139 Dig In Term 4 568 Digital In8 Sel 140 Dig In Term 5 569 Digital Outputs Dig Out Status 581 Digital Out4 Sel 148 Digital Out8 Sel 152 Digital Out1 Sel 145 Digital Out5 Sel 149 Relay Out 1 Sel 1392 Digital Out2 Sel 146 Digital Out6 Sel 150 Relay Out 2 Gell 629 Digital Out3 Sel 147 Digital Out7 Sel 151 DPI Inputs DPI P1 Select 1323 DPI P3 Select 1325 DPI P5 Select 1327 DPI P2 Select 1324 DPI P4 Select 1326 PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 3 6 Programming and Parameters Advanced Parameter View Parameter 211 Param Access Lvl set to option 1
454. ult Enable or Aux Fault verify that signals are present or reconfigure Digital Inx Sel If a fault code displays refer to Chapter 4 Troubleshooting on page 4 1 2 Ifthe STS LED is not flashing green at this point refer to Drive Status Indicators below II 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 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 2 4 Drive Start Up Figure 2 1 Drive Status Indicators e E um PORT O MOD O NETAO NETBO 0000 0 OOOOO OOOOO OOOOO mn O Allen Bradley Po werFlex Name Color State Description STS Green Hashing Drive ready but not running and no faults are present Status Steady Drive running no faults are present Yellow Flashing A condition exists that is preventing the drive from starting Drive Stopped Check parameters 1403 Start Inhibits and or 1380 Drive Alarm 1 Flashing An intermittent type 1 alarm condition is occurring Check Drive Running parameter 1380 Drive Alarm 1 Refer to Fault Descriptions on page 4 4 and or Alarm Descriptions on page 4 9 Steady A continuous type 1 alarm condition exists Check p
455. ulties 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 Important The PowerFlex DC drive is not designed for use with multiple motor applications 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 ATTENTION The following information is merely a guide for PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 1 2 Installation and Wiring Mounting Considerations Operating Conditions and Temperatures PowerFlex DC drives are designed to operate at 0 50 C 32 122 F surrounding air temperature vvithout 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 driv
456. umber to vvhich the signal from analog input 3 is sent Par 503 TUserDefined01 and 8192 is a drive internal fixed offset value Line Speed Master NIP Roll Reverse Forward Load Cell 10V Tension Set 10V Master S Slave Drive et Drive Feedback Line Speed Signal VAN Internal Ramp up 10V Forward I L 10V Reverse Line Speed Reference PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 15 In addition you can configure the following e Enter the gain for the feed forward signal in Par 787 PID Source Gain Monitor the feed forward signal after the gain is applied in Par 758 Feed Fwd PID P758 Feed Fwd PID P786 PID Source P787 PID Source Gain Configure the Feedback Signal in the Follower Drive s The feedback signal originates from a load cell or a closed loop dancer and is input to the drive via an analog input typically analog input 1 due to the ability to filter this signal Set Par 70 Anlg Inl Sel to 19 PID Feedback Line Speed Master NIP Roll Reverse Forvvard Load Cell 0 10V Tension Set 10V Slave Drive Master Drive Set Feedback Line Speed Signal In
457. une 2009 1 12 Installation and Wiring Satety 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 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 42 for shield clamp location PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Installation and Wiring 1 13 CE Conformity Conformity with the Low Voltage Di
458. ure circuit on the DC side Table A A AC Input Line Fuses 230V AC Input Frame A and B Regenerative and Non Regenerative Drives Fuse Code FS1 See Figure A 3 above Drive Bussmann Ferraz Shawmut Gould Shawmut Current AC North Rating DC Line Ferrule FWP Ferrule North American American Ferrule A70QS North American Code Amps Amps Type Fuse Block FWP Type Fuse Block Type A70QS Type 7P0 7 5 7 FWP 10A14F CH143D FWP 10B A70QS10 14F 1A70P10 4 9P0 9 7 4 FWP 15A14F FWP 15B A70QS16 14F 1A70P15 4 012 12 98 FWP 20A14F FWP 20B A70QS20 14F 1A70P20 4 020 20 16 FWP 25A14F FWP 25B A70QS25 14F A70QS25 4 029 29 24 FWP 40A22F CH223D FWP 40B A70QS40 22F A70QS40 4 038 38 31 FWP 63A22F FWP 60B A70QS63 22F 700560 4 055 55 45 FWP 80A22F FWP 80B A70QS80 22F 700580 4 073 73 60 FVVP 100A 9114 A70QS100 4K 093 93 76 m FWP 150A 7005150 4 110 110 190 FWP 175A 7005175 4 146 146 119 FWP 250A m 7005250 4 180 180 147 E FWP 300A 7005300 4 218 218 178 m FWP 350A 7005350 4 265 265 217 FWP 400A ST38 72612 A70QS400 4 360 360 294 FWP 600A A70QS600 4K 434 434 1355 l FWP 600A A70QS600 4 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Supplemental Drive Information A 9 Table A B Recommended AC Input L
459. ured motor field current using an in line current meter or DC clamp on meter equals the feedback value displayed in parameter 351 Field Current If the motor does not achieve commanded speed continue with following tests e Check the speed parameter limits parameters 2 Maximum Speed 3 Max Speed Fwd 4 Max Speed Rev and 122 Spd Feedback e Check the analog voltage input and speed reference values parameters 1404 Analog In1 Value 1405 Analog In2 Value 44 Speed Ref A 48 Speed Ref B e Check the setting of switch S9 and parameter 71 Anlg In1 Config S10 and 76 Anlg In2 Config or S11 and 81 Anlg In3 Config e Tune the analog input s using parameters 259 261 Anlg Inx Tune with the potentiometer set at max e The encoder pulse per revolution PPR parameter 169 Encoder PPR value is too high e The DC Tach Scaling is incorrect or the jumpers are not properly set Check parameter 562 Anlg Tach Gain and check the setting of the DC Analog Tachometer DIP Switch S4 see Figure 1 33 on page 1 40 The motor is turning in the wrong direction Drive Symptom The motor is rotating in the wrong direction The motor is incorrectly wired e Change the armature or field connections to the drive using an encoder or DC analog tachometer for feedback and the speed feedback is correct then the feedback wiring must be changed If using an encoder then two encoder connections must be reversed A with
460. urning off the forced speed mode They are set to 0 as default so that there is no hysteresis In SLAT Min mode Par 15 SLAT Err Stpt sets how much less the speed feedback should be than the speed reference before turning off the forced speed mode Par 16 SLAT Dwell Time sets how long the speed error must exceed the SLAT error set point before turning off the forced speed mode At the time the drive switches from torque mode to forced speed mode the speed regulator integral part is pre loaded with the Internal Torque Reference ITR or Par 14 Selected TorqRef to create a smooth transition PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Dependant Speed Reference Bias Motor Speed Feedback External Torque Application Notes C 31 In order for the drive to switch from speed mode to torque mode forced speed mode if active must first be turned off Forced speed mode will turn off when the speed error is greater than the SLAT error setpoint for the SLAT dwell time With default parameter settings this will occur when the speed error becomes positive When Forced Speed Mode is off the drive will switch back to torque mode when the speed regulator output becomes greater than the torque reference Par 15 SLAT Err Stpt Speed Error lt 0 Par 16 SLAT Dwell Time 34 Forced Speed Mode FSM Low Pass on 9 Set Filter 1 Speed Error SLAT
461. ury Par 374 Drv Fld Brdg Cur x 0 33 0 00 Drv Fld Brdg Cur A 3 15 o Related 162 169 469 481 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 16 Programming and Parameters File Group 374 376 Motor Data 92 97 MOTOR CONTROL Ol 456 Field Config 462 463 Parameter Name amp Description See page 3 2 for symbol descriptions Drv Fld Brdg Cur Drive rated field bridge current The value in this field must be set equal to the value chosen with DIP switch S14 on the Control board refer to Table 1 H on page 1 30 for DIP switch configuration MtrOvrid Type Allows selection of the type of motor overload calculation based on Par 179 Motor Arm Amps e StandardDuty 150 load for 1 minute or 200 load for 3 seconds before a motor overload condition is indicated HeavyDuty 200 load for 1 minute before a motor overload condition is indicated This selection requires that the drive be oversized relative to the motor in order to be able to provide the necessary current without faulting from a Drive Overload F 64 Note This parameter was added with firmware version 3 001 Fld Reg Kp Proportional gain Kp of the flux regulator expressed as a percentage of Par 97 Fld Reg Kp Base Fld Reg Ki Integral gain Kj of the flux regulator expressed as a percentage of Par 98 Fld Reg Ki Base Fld Reg
462. usive control of the reference source selection 605 Accel Owner See Stop Owner 24 The adapter that has exclusive control of the acceleration 660 ramp rate Pars 660 Accel Time 1 and 24 Accel Time 2 for COMMUNICATIONS Masks amp Owners the drive 606 Fault Clr Owner See Stop Owner Adapter that is presently clearing a fault 607 Owner See Stop Owner Adapters that are currently issuing increases or decreases in MOP referenced 608 Local Owner See Stop Owner Adapter that has requested exclusive control of all drive logic functions If an adapter is in local lockout all other functions except stop on all other adapters are locked out and non functional Local control can only be obtained when the drive is not running 609 Decel Owner See Stop Owner 32 The adapter that has exclusive control of the deceleration 662 ramp rate Pars 662 Decel Time 1 and 32 Decel Time 2 for the drive 631 Decel Mask See Logic Mask 32 Controls which adapters can select the deceleration ramp 662 rate Pars 662 Decel Time 1 and 32 Decel Time 2 of the drive PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 File COMMUNICATIONS Security 611 1376 Programming and Parameters 3 65
463. ut 3 43 Scale5 Div 3 43 Scale5 In Abs 3 44 Scale5 In Max 3 43 Scale5 In Min 3 43 Scale5 In Off 3 44 Scale5 Input 3 43 Scale5 Mul 3 43 Scale5 Out Off 3 44 Scale5 Output 3 43 Scale6 Div 3 43 Scale6 In Abs 3 44 Scale6 In Max 3 43 Scale6 In Min 3 43 Scale6 In Off 3 44 Scale6 Input 3 43 Scale6 Mul 3 43 Scale6 Out Off 3 44 Scale6 Output 3 43 Security group 3 65 3 66 Selected TorqRef 3 13 set DIP switch S14 1 30 DIP switch S15 1 40 DIP switch S4 1 40 Set Fld Curve 3 18 set preferences HIM B 5 SLAT Dwell Time 3 32 SLAT Err Stpt 3 32 Software Version 3 14 sourcing digital output wiring 1 47 Spd 0 Trip Delay 3 35 Spd Draw Out Pct 3 12 Spd FB Filt BW 3 22 Spd FB Filt Gain 3 22 Spd Fdbk Control 3 21 Spd Fdbk Error 3 21 Spd Fdbk Filter 3 30 Spd Fdbk Invert 3 21 Spd Limit Active 3 51 Spd Loss Fit Cfg 3 58 Spd Match Acc 3 48 Spd Match Compl 3 48 Spd Match Dec 3 48 Spd Match Gain 3 48 Spd match torque 3 49 Spd Ref Zero En 3 29 Spd Reg Autotune 3 23 Spd Reg Ki 3 27 Spd Reg Ki Base 3 27 Spd Reg Ki Outpt 3 28 Spd Reg Kp 3 27 Spd Reg Kp Base 3 27 Spd Reg Kp Outpt 3 28 Spd Reg Neg Lim 3 28 Spd Reg Out Pct 3 13 Spd Reg Pos Lim 3 27 Index 21 Spd Select 0 3 54 Spd Select 1 3 54 Spd Select 2 3 54 Spd Trq Mode Sel 3 32 Spd Tune Inertia 3 23 Spd Up Gain Pct 3 30 Spd Zero En 3 29 Spd Zero P En 3 29 Spd Zero P Gain 3 29 SpdFuncSelect 3 31 SpdOut FiltBW 3 30 SpdOut FiltGain 3 29 SpdReg FB Bypass 3 21 SpdReg Ki Bypa
464. ut 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 36 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 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Drive Start Up 2 17 Verify Speed Reference Settings and Drive Operation Verify the following speed and direction for four quadrant drives references of the drive under a load 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 1 Set the speed reference to 0 zero using the assigned source HIM or analog potentiometer Refer to Reference Control on page C 18 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 th
465. ute 3 20 UsrDefBitWrdB12 549 User Defined 3 62 forq Current Pct 1193 Winder Functions 3 47 UsrDefBitWrdB13 550 User Defined 3 62 org Limit Type 715 Load Limits 3 35 UsrDefBitWrdB14 551 User Defined 3 62 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 82 Programming and Parameters Parameter Cross Reference by Number Name No Group Page UsrDefBitWrdB15 552 User Defined 3 62 UsrDefBitWrdB2 539 User Defined 3 62 UsrDefBitWrdB3 540 User Defined 3 62 UsrDefBitWrdB4 541 User Defined 3 62 UsrDefBitWrdB5 542 User Defined 3 62 UsrDefBitWrdB6 543 User Defined 3 62 UsrDefBitWrdB7 544 User Defined 3 62 UsrDefBitWrdB8 545 User Defined 3 62 UsrDefBitWrdB9 546 User Defined 62 UsrDsplyDivO 51 User Defined 3 59 UsrDspiyMult0 50 User Defined 3 59 UsrValDiv1 54 User Defined 3 59 UsrValMult1 53 User Defined 3 59 Variable J Comp 1171 Winder Functions 3 46 W Gain 1202 Winder Functions 3 48 W Offset 1199 Winder Functions 3 48 W Reference 1217 Winder Functions 3 49 W Target 1210 Winder Functions 3 48 Winder Side 1201 Winder Functions 3 48 Winder Type 1187 Winder Functions 3 47 Write Mask Act 1377 Security 3 66 W
466. uto Manual function see above do not affect the active torque reference The HIM however cannot acquire Manual Reference control while it is configured to supply the torque reference PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 19 Auto Manual Examples PLC Auto HIM Manual A process is run by a PLC when in Auto mode and requires manual control from the HIM during set up The speed reference is issued by the PLC through a communications module installed in the drive Port 5 Therefore parameter 1327 DPI P5 Select is set to Speed Ref A with the drive running from the Auto source Acquire Manual Control e Press ALT then Auto Man on the HIM When the HIM acquires manual control the drive speed command comes from the HIM speed control keys Release to Auto Control e Press ALT then Auto Man on the HIM again When the HIM releases manual control the drive speed command returns to the PLC PLC Auto Terminal Block Manual A process is run by a PLC when in Auto mode and requires manual control from an analog potentiometer wired to the drive terminal block The auto speed reference is issued by the PLC through a communications module installed in the drive Port 5 Therefore parameter 1327 DPI P5 Select is set to Speed Ref A with the drive running from the Auto source Since the Manual speed reference is issued by analog input 2 parameter 75 Anlg in2
467. ve User Manual Publication 20P UM001E EN P June 2009 B 6 HIM Overview Removing Installing the HIM The HIM can be removed or installed while the drive is powered Important HIM removal is only permissible in Auto mode If the HIM is removed while in Manual mode or the HIM is the only remaining control device a fault will occur Step LOTO Example Displays To remove the HIM 1 Press ALT and then Enter Remove aLr Remove Op Intrfc The Remove HIM confirmation screen SC ee E w appears isconnect Op ntrfc Port 1 Control 2 Press Enter to confirm that you want to remove the HIM 3 Remove the HIM from the drive To install HIM 1 Insert into drive or connect cable PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Alpha Test Mode Appendix C Application Notes See See For information on page For information on page Alpha Test Mode C 1 Reference Control C 18 Analog Input Configuration C 4 Speed Feedback C 20 Current Speed Curve C 6 Scale Blocks C 21 Drive Reference and Feedback Scaling C 7 Speed Regulation Functions C 22 Droop Compensation C 9 Speed Torque Mode Selection C 29 Field Weakening Mode Configuration 10 Start At Powerup C 35 v1 006 PID Function C 13 Fine Tuning the Regulators C 36 The Alpha Test is a diagnostic function that allows you to activate the Armature
468. vercurrent will be Default Options Default Min Max Units Default Min Max Units Bypass is set to 0 Disabled Failure to observe this precaution could result in high motor ATTENTION Par 478 Spd Loss Flt Cfg must be set to 1 Fault if Par 458 SpdReg FB A speeds equipment damage and or bodily injury if an Feedback Loss alarm condition were 2 Fault 0 Ignore 1 Alarm 2 Fault motor and or equipment damage Ensure that the motor is properly sized for the application and ATTENTION Setting Par 479 MtrOvrld Fit Cfg to Ignore or 1 Alarm could result in A that a separate device is installed that monitors for and signals a motor overload condition 230 0 1000 Vac 0 250 5 g Parameter Name amp Description s Z See page 3 2 for symbol descriptions Values 203 OverVolt Fit Cfg Default 2 Fault O Determines the response of the drive to an overvoltage condition F5 Options 0 Ignore Arm Overvoltage 1 Alarm Note Refer to Chapter 4 for a list of alarm and fault descriptions 2 Fault 354 Aux Inp Cfg Default 2 Fault Determines the response of the drive to an external fault condition 1 Options 1 Alarm F2 Auxiliary Input i e no voltage at the digital input terminal 2 Fault assigned to Digital Inx Sel with a value of 14 Aux Fault 3 Fas
469. x Min Max 0 00 100 00 Units 919 Set Fld Curvel Default 1 916 fe q When set to 0 this parameter controls the motor field current Min Max 0 1 917 E 2 to field reference curve according to the values specified in the 918 amp Fld Const xx Pct parameters With this curve is defined the o D result of Max Fld Curr Pct Flux Ref Pct equals the 2 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 07 it will automatically return to 1 920 Reset Fld Curve Default 0 Geh when set to 1 resets the drive to use a linear field curve When Min Max 0 1 this parameter is set Par 280 Nom Mtr Fld Amps is linearly Units changed through Max Fld Curr Pct Flux 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 Default 100 0 469 The percentage of maximum output voltage based on the value Min Max 0 0 110 0 in Par 175 Rated Motor Volt In regenerative field weakened Units applications hoist elevator unwinder etc the value of this parameter should be set less than 100 to allow operation when overcoming gravity The value of this parameter also determines the voltage where the drive begins field de fluxing while Field Weaken mode is active Par 469 Field Mode Sel Field Weaken Notes This parameter can be
470. x Ref Speed cannot exceed 8192 rpm Default 0 Min Max Par 45 Max Ref Speed 1 Units rpm The value of Par 45 Max Ref Speed cannot exceed 8192 rpm Default 0 00 Min Max 100 00 Units Default 0 00 Min Max 100 00 Units Default 10000 Min Max 0 32767 Default 10 00 Min Max 0 00 100 00 Units Default 1 00 Min Max 0 00 100 00 Units Default 0 30 x Par 93 nay Min Max 0 01 Based on drive current rating Units A rpm Default 0 30 x Par 94max Min Max 0 01 Based on drive current rating Units AJ rpm x ms Default 200 00 Min Max 200 00 Units 3 27 Related 378 379 42 43 93 94 100 87 99 88 100 96 PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 3 28 Programming and Parameters File Group o 100 101 102 SPEED COMMAND Speed Regulator 103 104 105 106 Parameter Name amp Description See page 3 2 for symbol descriptions Spd Reg Neg Lim Negative Speed Regulator output limit When this limit is active the negative integrator portion of the PI regulator is held to prevent windup Note This parameter was added with firmware version 3 001 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 Spd Reg Ki Outpt Displays the active integral coeff
471. xiliary status contact to a second digital input 19 Set the corresponding second Digital Inx Sel parameter 133 144 to Fld Weak En 20 Set the corresponding Inversion In x parameter 1276 1283 or 1387 1390 for the second digital input to Enabled PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 Application Notes C 11 Using a DC Contactor and a Dynamic Brake 1 2 Set parameter 1391 ContactorControl to Contactor DB Set one relay output parameter 1392 Relay Out 1 Sel or 629 Relay Out 2 Sel to Contactor and the other relay output parameter to ContactorDB Set one Digital Inx Sel parameter to Contactor default value for parameter 140 Digital In8 Sel Connect the DC contactor auxiliary status contact to a second digital input Set the corresponding second Digital Inx Sel parameter 133 144 to Fld Weak En Set the corresponding Inversion In x parameter 1276 1283 or 1387 1390 for the second digital input to Enabled Using an Inverting Fault Device Only 1 Connect the inverting fault device contact to tvvo separate digital inputs If using tvvo inverting fault devices the device contacts must be vvired in series Set one corresponding Digital Inx Sel parameter 133 144 to 35 Fld Weak En Set the other corresponding Digital Inx Sel parameter 133 144 to 14 Aux Fault Set both of the corresponding Inversion
472. y lock the rotor Attach the oscilloscope to the appropriate leads of the drive based on test to be performed Reapply power to drive and motor Verify the no faults or alarms present If an alarm or fault code displays refer to Chapter 4 Troubleshooting on page 4 1 Open the Enable input on the drive Set Par 166 Alpha Test to the desired value 1 Arm Fwd 2 Arm Rev or 3 z Fld Fwd Close the Enable input Slowly decrease the appropriate angle parameter Par 167 Arm Test Angle or Par 168 Fld Test Angle until a steady pattern of voltage pulses display on the oscilloscope If all Thyristors in the selected bridge are operating there will be six pulses per AC line cycle If not all Thyristors in the selected bridge are operating one or more pulses will be missing Note that conduction or output voltage will not typically begin until the angle is below about 120 degrees Open the Enable input and set Par 166 Alpha Test to O Off Remove power from the drive and motor Remove the oscilloscope from the leads of the drive and unlock the rotor If necessary replace the defective firing board in the drive Reconnect the motor armature and field leads to the drive Reapply power to the motor and drive PowerFlex Digital DC Drive User Manual Publication 20 001 June 2009 C 4 Application Notes Analog Input Configuration The analog inputs default to 10V To configure the analog i
473. y of the Language selection B 2 Added new Alpha Test Mode section C 1 Added new Drive Reference and Feedback Scaling section C 7 Updated the Speed Feedback section C 20 Added the Speed Torque Mode Selection section C 29 Updated the Fine Tuning the Regulators section to include new Manually C 37 Adjusting the Current Regulator Tune Settings procedures Updated the Speed Regulator block diagram D 8 Added the Torque Mode Selection block diagram D 9 Updated the Droop Compensation Inertia Loss Compensation block diagram 10 Updated the Speed Feedback block diagram D 11 Updated the Field Current Regulator block diagram D 15 Updated the Fault Alarm Mapping block diagram D 25 Added the Factory Default and Config Parameter columns to Table FB and 2 EC The information below summarizes the changes to the PowerFlex Digital DC Drive User Manual publication 20 UMO01 since the July 2008 release Change Page s Updated the description for parameter 455 Spd Fdbk Error concerning the 3 21 configuration of a speed feedback loss using parameter 478 Spd Loss Fit Cfg Updated the description and Attention statement for parameter 457 Spd Fdbk 21 Control concerning the configuration of a speed feedback loss configured in Par 478 Spd Loss Flt Cfg when using a DC tachometer Updated the description for parameter 458 SpdReg FB Bypass concerning the 3 21 configuration of a speed fe
474. y s 1 Press Esc to acknowledge the fault The fault information will be removed Esc so that you can use the HIM 2 Address the condition that caused the fault The cause must be corrected before the fault can be cleared 3 After corrective action has been taken clear the fault by one of these methods Press Stop Cycle drive power Set parameter 1347 Fault Clear to 1 Clear Faults Clear Faults on the HIM Diagnostic menu PowerFlex Digital DC Drive User Manual Publication 20P UM001E EN P June 2009 4 4 Troubleshooting Fault Descriptions Table 4 A Fault Types Descriptions and Actions Fault No Type Description Possible Cause s Action s AC Undervoltage 4 o There is an undervoltage on the power circuit Arm Overvoltage Auxiliary Input Drive Overload Dsp Error EEPROM Error o Possible causes include e Par 481 UnderVolt Thresh is set incorrectly possibly set to 400V when the drive is rated for 230V input power Set Par 481 UnderVolt Thresh correctly and then reset the drive via Par 1347 Fault Clear e The incoming voltage to the power terminals U V W of the drive is too low due to e The AC input voltage is too low e There are poor cable connections for example terminals on contactor choke filter etc is not properly connected e Verify AC input power level e Check all connections e The incoming voltage to the control power terminals

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