User Manual PowerFlex Digital DC Drive PowerFlex DC Drive V1.006…5.006, PowerFlex DC Standalone Regulator V1.006…5.
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.
Summary of Changes This manual contains new and updated information. New and Updated Information This table contains the changes made to this revision. Topic Page Added a note to Figure 5 - Frame D Dimensions - Right Side and Front Views indicating which terminal sizes apply to which frame D drive ratings.
Summary of Changes Notes: 4 Rockwell Automation Publication 20P-UM001I-EN-P - February 2013
Table of Contents Preface Drive Storage Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Nameplate Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Firmware Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . .
Table of Contents Power Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Power Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable and Wiring Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Input Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Chapter 3 Programming and Parameters About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameters Table Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How Parameters are Organized. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . File–Group–Parameter Order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Numbered List View. . . . . . . . . . . . . . . . . . . . . .
Table of Contents Control Power Circuit Protection Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . Switching Power Supply Circuit Board Fuses . . . . . . . . . . . . . . . . . . Frame B Pulse Transformer Circuit Board Fuses . . . . . . . . . . . . . . . Frame C Transient Noise Filter Circuit Board Fuses. . . . . . . . . . . . Frame D Overvoltage Clipping Circuit Board Fuses . . . . . . . . . . . . AC Input Line Reactors and AC Input Contactors. . . . . . . . . . . . . . . . .
Table of Contents Using a DC Contactor, a Dynamic Brake and an Inverting Fault Device (Firmware v1.006 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PID Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure a Line Speed Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure the Feedback Signal in the Follower Drive(s) . . . . . . . .
Table of Contents Appendix E Installing a Communication Adapter Communication Adapter Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 What The Communication Adapter Kit Includes . . . . . . . . . . . . . . . . . . Tools That You Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preface Topic Drive Storage Conditions Drive Nameplate Data Additional Resources Drive Frame Sizes Conventions General Precautions Standard Drive Catalog Number Explanation Standalone Regulator Catalog Numbers Page Below 12 13 12 13 14 15 16 The purpose of this manual is to provide you with the basic information needed to install, start-up and troubleshoot the PowerFlex DC drive. This manual is intended for qualified personnel. You must be able to program and operate DC drives.
Preface 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 with Rockwell Automation personnel concerning this product should include this information. Cat No. 20P41AD4P1RA0NNN Series: A Input: 460VAC 50/60 Hz 3.3A 3 Phase I/O: 24VDC (Standard) Original Firmware V. 1.001 Output: 500VDC 4.1A REGEN 2.0HP 1 Min Overload Amps 6.
Preface Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource Preventive Maintenance of Industrial Control and Drive System Equipment, DRIVES-TD001 Safety Guidelines for the Application, Installation and Maintenance of Solid State Control, SGI-1.1 A Global Reference Guide for Reading Schematic Diagrams, 100-2.10 Guarding Against Electrostatic Damage, 8000-4.5.
Preface General Precautions 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.
Preface Standard Drive Catalog Number Explanation Position 1-3 4 5 6 20P 4 1 A a b c d 7 8-10 D 4P1 e 11 f 13 14 15 R A 0 N N g h i j k f1 a Code Type 20P PowerFlex DC N l Field Amps Code Hp kW Armature Amps Frame Field Amps 7 A 10 067 50 37 67.5 B 20 9 A 10 101 75 56 101.3 B 20 2.2 12 A 10 135 100 75 135 B 20 5 3.7 20 A 10 270 200 149 270 B 20 029 7.5 5.5 29 A 10 405 300 224 405 B 20 Hp kW 7P0 1.5 1.
Preface Standard Drive Catalog Number Explanation, Cont. Position 1-3 4 5 6 7 8-10 11 12 13 14 15 16 20P 4 1 A D 4P1 R A 0 N N N a b c d e f g h i j k l g i k Field Supply HIM Communication Options Code Type Code Operator Interface Code Description R Single-Phase Regulated 0 Blank Cover N None Standard - for user installed options, see Human Interface and Wireless Interface Modules on page 9.
Chapter 1 Installation and Wiring Topic Page Topic Page Mounting Considerations 18 CE Conformity 40 Approximate Drive Dimensions and Weights 19 Power Circuit Protection 43 Lifting PowerFlex DC Drives 25 Control Power Protection 43 Removing the Drive Covers 28 Cable and Wiring Recommendations 44 Isolation Transformers / Line Reactors 30 Power Wiring 45 Using Contactors 31 DIP Switch and Jumper Settings 72 General Grounding Requirements 33 I/O Wiring 77 This chapter provides
Chapter 1 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 without derating. The drive must be mounted in a clean, dry location. Contaminants such as oils, corrosive vapors and abrasive debris must be kept out of the enclosure. NEMA/UL Type Open, IP20 enclosures are intended for indoor use primarily to provide a degree of protection against contact with enclosed equipment.
Installation and Wiring Approximate Drive Dimensions and Weights Chapter 1 The PowerFlex DC drive is available in a NEMA/UL Type Open, IP20 enclosure only. Follow all mounting dimensions and instructions in order to ensure proper operation. ATTENTION: Remove all loose packing materials, including the container(s) of desiccants (if any), from the drive enclosure before mounting and energizing the drive. Figure 2 - Frame A Drive Dimensions A B C A1 A2 B1 mm (in.) mm (in.) mm (in.) mm (in.
Chapter 1 Installation and Wiring Figure 3 - Frame B Drive Dimensions A A1 A2 A3 B B1 C mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) 311 (12.2) 275 (10.8) 16.5 (0.65) 7 (0.3) 388 (15.3) 375 (14.8) 350 (13.8) A A1 C PORT MOD NET A NET B STS B1 B A3 A2 Terminal Details Dimensions in mm (in.) 45.2 (1.8) 53.1 (2.1) 98.5 (3.9) 48.5 (1.9) 147.0 (5.8) 53.1 (2.1) 200.1 (7.9) 48.5 (1.9) 248.6 (9.
Installation and Wiring Chapter 1 Figure 4 - Frame C Drive Dimensions A A1 B B1 B2 B3 B4 B5 C mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) 521 (20.5) 499 (19.7) 511 (20.1) 400 (15.7) 200 (7.9) 55 (2.2) 56 (2.2) 10.5 (0.4) 416 (16.4) A1 C B4 PORT MOD NET A NET B B1 STS B B5 B2 B3 A Terminal Details Dimensions in mm (in.) 28.0 (1.1) 35.5 (1.4) 28.0 (1.1) 28.0 (1.1) 113.0 (4.5) 155.0 (6.1) 310.0 (12.
Chapter 1 Installation and Wiring Figure 5 - Frame D Dimensions - Right Side and Front Views Dimensions are shown in mm and (in.) 704 (27.7) Dimensions of terminals U, V, and W are the same. Lifting flange 174 (6.9) 436.5 (17.2) 80.5 (3.2) 359 (14.1) 544 (21.4) 25 (1.0) 15 (0.6) 60 (2.4) 30 (1.2) 42 (1.7) 44.5 (1.8) 792 (31.2) 1250 (49.2) 208 (8.2) 144 (5.7) 157.5 (6.2) PE C 44.5 25 (1.8) (1.0) 15 (0.6) 146 (5.7) D 10.5 (0.4) 252.5 (10.0) 44.5 (1.8) 134 (5.3) 437.5 (17.2) 22.6 (0.
Installation and Wiring Chapter 1 Figure 6 - Frame D Dimensions - Left Side and Back Views Dimensions are shown in mm and (in.) 94 (3.7) 103.25 (4.1) Lifting flange 127 (5.0) 127 (5.0) 127 (5.0) 94 (3.7) 127 (5.0) 127 (5.0) 94 (3.7) 10.5 (0.4) Ø 23 (0.9) 129 (5.1) 127 (5.0) 16 (0.6) 227.5 (9.0) Mounting holes 1435 MAX (56.5) 1230 (48.4) Mounting holes 157.5 (6.2) 129 (5.1) 215.225 (8.5) 531 (21.0) 10 (0.4) 10.5 (0.4) 94 (3.7) 127 (5.0) 127 (5.0) 541 (21.
Chapter 1 Installation and Wiring Table 4 - Frame D - 230V AC Input Drive Weights Drive w/ND Rating Code 875 1K0 Weight - Regenerative Drives Weight - Non-regenerative Drives Drive Drive & Packaging Drive Drive & Packaging kg (lb) kg (lb) kg (lb) kg (lb) 203 (447.5) 281 (619.5) 152 (335.1) 230 (507.
Installation and Wiring Lifting PowerFlex DC Drives Chapter 1 The dimensions and weights specified above must be taken into consideration when mounting the device. Use the proper equipment to safely lift and hold the weight of the drive while mounting. ATTENTION: To guard against possible personal injury or equipment damage... • Inspect all lifting hardware for proper attachment before lifting the drive.
Chapter 1 Installation and Wiring Figure 7 - Lifting Frame C Drives Must be less than 45° angle Lifting flanges 26 Rockwell Automation Publication 20P-UM001I-EN-P - February 2013
Installation and Wiring Chapter 1 Figure 8 - Lifting Frame D Drives Must be less than 45° angle 4. Lift the drive into place onto the bolt(s) installed in the panel. 5. Install the remaining bolts into the panel. Tighten M8 bolts to a minimum torque of 15 N•m (132.7 lb•in) and M10 bolts to a minimum torque of 25 N•m (221.2 lb•in).
Chapter 1 Installation and Wiring Removing the Drive Covers The appropriate protective cover(s) must be removed in order to access the drive’s power and I/O terminals. The upper cover only needs to be removed to install an optional communication adapter and service the drive. (See Installing a Communication Adapter on page 337 for information.) Frame A Drives You must remove both the lower protective cover and the power terminal cover on frame A drives to access the power terminals.
Installation and Wiring Chapter 1 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. PORT MOD NET A NET B STS Frame B and C Drives Loosen, but do not remove, the two screws that secure the bottom cover. Then, slide the cover down until the screw heads line up with the key holes and lift the cover off the chassis.
Chapter 1 Installation and Wiring Frame D For any protective cover, loosen, but do not remove, the Hexalobular head screws that secure the cover to the drive frame. Then, slide the cover up until the screw heads line up with the key holes and lift the cover off the chassis. The top and bottom most covers are also secured by screws at the top and bottom of the drive, respectively.
Installation and Wiring Using Contactors Chapter 1 When using an AC input contactor, the IEC AC1 rating of the contactor must be equal to the rated thermal (RMS) current value at the main input of the drive.
Chapter 1 Installation and Wiring When operating a drive with firmware version 1.006 in field weakening mode with a DC contactor and/or inverting fault device installed in the armature circuit, see Field Weakening Mode Configuration (v1.006) on page 271. AC Input Contactors See AC Input Line Reactors and AC Input Contactors on page 238 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.
Installation and Wiring 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.
Chapter 1 Installation and Wiring Safety Ground (PE) This is the safety ground for the drive that is required by code. This point must be connected to adjacent building steel (girder, joist), a floor ground rod or bus bar (see above). Grounding points must comply with national and local industrial safety regulations and/or electrical codes. Power Feeder Each power feeder from the substation transformer to the drive must be provided with properly sized ground cables.
Installation and Wiring Grounding for Installations in an Ungrounded or HighImpedance Neutral Ground or System Chapter 1 The PowerFlex DC drive was designed to work in distribution systems where the isolation transformer Wye neutral is connected to earth ground. PowerFlex DC drives are not designed to work in distribution systems that have ungrounded or high impedance neutral connections or systems that have a phase referenced to earth. Symmetrical incoming power is required for correct drive operation.
Chapter 1 Installation and Wiring Figure 12 - High Resistance Ground Grounding the wye secondary neutral through a resistor is an acceptable method of grounding. Under a short circuit secondary condition, any of the output phases to ground will not exceed the normal line to line voltage. The resistor is often used to detect ground current by monitoring the associated voltage drop.
Installation and Wiring Chapter 1 Figure 13 - Frame A Pulse Transformer Circuit Board S9 Jumper Location X3 XSW XSW1 XP TR2 Note: Remove the front covers from the drive to access the pulse transformer circuit board. See page 28 for instructions.
Chapter 1 Installation and Wiring Figure 15 - Frame C Pulse Transformer Circuit Board S9 Jumper Location Note: The pulse transformer circuit board is located at the top of the drive behind the control EMI shield. See page 29 for instructions on removing the front covers from the drive and page 67 for instructions on moving the control EMI shield.
Installation and Wiring Chapter 1 Figure 17 - Frame D Pulse Transformer Circuit Board S1 Jumper Location Note: The pulse transformer circuit board is located behind the top and bottom control panel covers. See page 30 for instructions on removing the covers from the drive.
Chapter 1 Installation and Wiring CE Conformity Conformity with the Low Voltage Directive 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.
Installation and Wiring Chapter 1 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).
Chapter 1 Installation and Wiring IMPORTANT Use of other filters should be verified in the application. Additional filters are listed in Alternate EMC Filters on page 247. • 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 provided from the drive enclosure to the motor enclosure.
Installation and Wiring Chapter 1 Power Circuit Protection It is recommended that you install frame A and B PowerFlex DC drives 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 frame C and D PowerFlex DC drives. See Drive Power Circuit Protection on page 219 for a list of replacement fuses and general fuse locations.
Chapter 1 Installation and Wiring Use the following cable and spacing recommendations for all drives sizes: Cable and Wiring Recommendations Category Wiring Signal Definition Class Signal Example Cable Type Power Per NEC & Local Codes Control 1 AC Power (600V Or Greater) 2.3kV 3/ph AC Lines 2 AC Power (Less Than 600V) DC Power DC Power 115V AC/DC Logic 460V 3/ph AC Lines 3 4 5 115V AC Power Signal (Process) 6 7 8 Signal (Comm.
Installation and Wiring Chapter 1 Cable 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. a. Class 1; Equal to or above 601V. b. Classes 2, 3 and 4 may have their respective circuits pulled in the same conduit or layered in the same tray. c. Classes 5 and 6 may have their respective circuits pulled in the same conduit or layered in the same tray.
Chapter 1 Installation and Wiring Control Circuit (Terminals U2, V2) • 115V ±15% or 230V ±15%, 1Ph Note: 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. See Figure 43 on page 67 for terminal block location on frame B drives and Figure 44 on page 67 for terminal block location on frame C drives.
Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 FU AC Input Voltage FU FU AC Input Voltage 115V or (1) 230V FU 230V These connections must be taken from the primary side of the Isolation Transformer or Line Reactor (clean power). AC Input Voltage (2) Line Reactor Safety Ground Isolation (2) Transformer 14 T1 T2 T3 A2 L1 L2 L3 A1 Aux 13 460 VAC Max. or 230 VAC (10) Min.
Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 FU AC Input Voltage FU 115V or (1) 230V FU AC Input Voltage FU 230V These connections must be taken from the primary side of the Isolation Transformer or Line Reactor (clean power). (2) Line Reactor Safety Ground Isolation (2) Transformer (3) (3) (3) AC Input Voltage FS1 FS1 FS1 460 VAC Max. or 230 VAC (9) Min.
Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 FU AC Input Voltage FU 115V or (1) 230V FU AC Input Voltage FU 230V These connections must be taken from the primary side of the Isolation Transformer or Line Reactor (clean power). (2) Line Reactor Safety Ground Isolation (2) Transformer (3) (3) (3) AC Input Voltage FS1 FS1 FS1 460 VAC Max. or 230 VAC (10) Min.
Chapter 1 Installation and Wiring Armature Converter Connections Terminals Description U, V, W Three phase AC input to the armature converter C, D DC output to the motor armature PE Safety ground Table 10 - Armature and Safety Ground (PE) Terminal Specifications Frame Drive Current Rating Code(1) 230V Terminals 460V 575 690 A 7P0…055 4P1…052 – – 073…110 073…129 – – All All – B All Wire Size and Type U, V, W, C, D, PE U, V, W, C, D All D All All All All All All All Tigh
Installation and Wiring Chapter 1 Figure 23 - Frame B Armature Converter Terminal Locations PE U C V D W Figure 24 - Frame C Armature Converter Terminal Locations Front View PE U C V D W Bottom View Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 51
Chapter 1 Installation and Wiring Figure 25 - Frame D Armature Converter Terminal Locations Important: Certain frame D drives require the use of a terminal adapter kit(s) for terminals U, V, W, C and D. See Terminal Adapter Kits for Frame D Drives on page 250 for details.
Installation and Wiring Chapter 1 Armature Voltage Feedback Connections When a DC output contactor or inverting fault breaker/fuse is used with the drive the Armature Voltage Feedback terminals can be used to monitor the armature voltage at the motor regardless of the state of the contactor or inverting fault device.
Chapter 1 Installation and Wiring Figure 26 - Frame A Armature Voltage Feedback Circuit Terminal Block Location Bottom of View of Drives Drive with fan Drive with no fan Shown with terminals jumpered for internal armature voltage feedback. Figure 27 - Frame B Armature Voltage Feedback Circuit Terminal Block Location Top of Drive Shown with terminals jumpered for internal armature voltage feedback.
Installation and Wiring Chapter 1 1A1(C) A1 1A2 (D) A2 1A1(C) A1 1A2 (D) A2 1A1(C) A1 1A2 (D) A2 1A1(C) A1 1A2 (D) A2 Figure 28 - Frame C Armature Voltage Feedback Circuit Terminal Block Location Bottom of Drive Figure 29 - Frame D Armature Voltage Feedback Circuit Terminal Block Location Shown with terminals jumpered for internal armature voltage feedback.
Chapter 1 Installation and Wiring Field Converter Connections For 575V or 690V AC input drives only, a step down transformer with either a 230 VAC secondary, for a 150V motor field, or 460 VAC, for a 300V motor field, is required before the input to the field control circuit (terminals U1, V1). Also, If the rated voltage of the DC motor field is not compatible with the field DC output voltage of the drive, an external field control transformer must be used.
Installation and Wiring Chapter 1 Table 14 - Frame D Field Circuit Wire Sizes and Terminal Specifications Drive Current Rating Code(1) 230V 460V 575V 690V 875 830 810 678 1K0 996 1K0 791 – – 1K2 904 – – 1K3 1K0 – – 1K6 – – 1K1 – 1K1 – 1K3 – 1K2 – 1K4 – 1K4 – – – 1K5 Terminals Wire Size(2) Tightening Torque N•m (lb•in) 6 AWG U1, V1, C1, D1 4.0 (35.
Chapter 1 Installation and Wiring Figure 31 - Frame B Field Circuit Terminal Block Location U1 V 1C 1 D1 Top of Drive Figure 32 - Frame C Field Circuit Terminal Block Location Front of Drive D1 C1 U1 V1 58 Rockwell Automation Publication 20P-UM001I-EN-P - February 2013
Installation and Wiring Chapter 1 Figure 33 - Frame D Field Circuit Terminal Block Location Wire routing hole Cable clamp Top of Drive AC input for field is at top of fuse holder (marked FU1, FV1) Shown with control cover removed. Remove control cover to access terminals.
Chapter 1 Installation and Wiring Field Current Configuration DIP switch S14 on the drive’s control circuit board is factory set to the minimum field current rating based on the drive size (see DIP Switch and Jumper Settings on page 72 for S14 location). The configuration of this switch must be changed to be greater than or equal to the rated field current specified on the motor nameplate (unless a permanent magnet motor is being used) or possible motor damage may result.
Installation and Wiring Chapter 1 Table 15 - DIP Switch S14 Field Current Configuration Settings Frames A, B and C Drives Switch ohms > 168.5 333.3 182 36.4 845 1668 3333 – Equivalent Resistance Field Current Scale S14-1 S14-2 S14-3 S14-4 S14-5 S14-6 S14-7 S14-8 Ohms 1A OFF OFF OFF OFF OFF ON 1668 2A OFF OFF OFF OFF ON OFF 845 3A OFF OFF OFF OFF ON ON 560.9 5A OFF ON OFF OFF OFF OFF 10 A ON OFF OFF OFF OFF OFF 13 A ON OFF OFF OFF ON ON 129.
Chapter 1 Installation and Wiring Relay Outputs 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 31 for more information. Terminals Description 35, 36 Normally open contact. Configured with parameter 1392 [Relay Out 1 Sel] - set to 25 “Contactor” by default.
Installation and Wiring Chapter 1 Table 18 - Relay Outputs and Thermistor/Thermal Switch Wire Sizes and Specifications Signal Type Terminals Relay Outputs 35 & 36, 75 & 76 Thermistor and Thermal Switches 78 & 79 Wire Size and Type(1) Flexible (mm2) Multi-core (mm2) AWG Tightening Torque N•m (lb•in) 0.140…1.500 0.140…1.500 26…14 0.5 (4.4) (1) See Cable and Wiring Recommendations on page 44 for more information.
Chapter 1 Installation and Wiring Figure 37 - Frame C Relay and Thermistor/Thermal Switch Terminal Block Locations 35 36 75 76 78 79 Figure 38 - Frame D Relay and Thermistor/Thermal Switch Terminal Block Locations 78 79 35 36 75 76 64 Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 Located on control pan to the left of the HIM cradle.
Installation and Wiring Chapter 1 Control Circuit Input Power 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, see Figure 43 on page 67. For frame C drive SA-SB terminal block location, see Figure 43 on page 67.
Chapter 1 Installation and Wiring Figure 41 - Frame C Control Circuit Terminal Block Location U2 V2 Figure 42 - Frame D Control Circuit Terminal Block Location U2 V2 66 Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 PE
Installation and Wiring Chapter 1 Figure 43 - 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 Figure 44 - 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 board EMI Shield. Switching Power Supply board SA-SB terminals Back of control board EMI shield XSW connector To access the SA-SB terminal block: 1.
Chapter 1 Installation and Wiring Frame C Heatsink Cooling Fans Power Supply Terminals Frame C drives require an external 230V AC power supply for the heatsink cooling fans. The power supply connections must be taken from the primary side of the installed Isolation Transformer or Line Reactor (clean power). See Typical Power Wiring Diagrams on page 46. In addition, the fan power input terminals U3 and V3 are required to be short circuit protected.
Installation and Wiring Chapter 1 Frame D Heatsink Cooling Fan Power Supply Terminals Frame D drives require an external 230V AC power supply for the heatsink cooling fan. The power supply connections must be taken from the primary side of the installed Isolation Transformer or Line Reactor (clean power). See Typical Power Wiring Diagrams on page 46. The fan power input terminals U3 and V3 are required to be short circuit protected. This protection can be provided by using a circuit breaker.
Chapter 1 Installation and Wiring Frame C and D Armature Fuse Signal Terminals Terminals 81 and 82 on frame C and D drives are connected to the internal armature circuit protection fuses and can be connected to an external device to provide indication that the fuses have opened. Alternatively, terminals 81 and 82 can be wired to drive digital input terminals configured for 64 “Invert Flt” (via Pars 133…144).
Installation and Wiring Chapter 1 Figure 48 - Frame D Internal Armature Fuse Signal Terminal Block Location 81 82 Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 71
Chapter 1 Installation and Wiring 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. DIP Switch and Jumper Settings Figure 49 - Control Circuit Board DIP Switch and Jumper Locations See Table 26 on page 73 for descriptions corresponding to the ID numbers shown here.
Installation and Wiring Chapter 1 Table 26 - Control Circuit Board Jumper and DIP Switch Settings ID 1 Jumper/ Switch Function Factory Default S0 For factory boot flashing only. Leave set to the factory setting. Jumper Off S1 S2 S3 2 3 Jumper On Firmware boot Jumper Off Normal function For factory boot flashing only. Leave set to the factory setting. Jumper On Write firmware boot code Jumper Off Boot code on flash is protected = ON =OFF Jumper Off For factory boot flashing only.
Chapter 1 Installation and Wiring DIP Switch S4 Settings ATTENTION: The drive can overspeed if DIP switch S4 is set incorrectly or the tachometer is wired incorrectly. Failure to observe this precaution could result in damage to, or destruction of, the equipment. DIP switch S4 must be configured to be greater than or equal to the maximum DC input voltage. Maximum DC Input Voltage = (Tach Volts/1000 rpm) x Par 45 [Max Ref Speed] x 1.1.
Installation and Wiring Chapter 1 Table 28 - Drives with 230V Input - DIP Switch S15 Configuration Frame Drive Current Rating Code S15-1 S15-2 S15-3 S15-4 S15-5 S15-6 S15-7 S15-8 A 7P0 ON OFF OFF OFF OFF OFF OFF OFF 9P0 OFF ON OFF OFF OFF OFF OFF OFF 012 ON ON OFF OFF OFF OFF OFF OFF 020 OFF OFF ON OFF OFF OFF OFF OFF 029 ON OFF ON OFF OFF OFF OFF OFF 038 OFF ON ON OFF OFF OFF OFF OFF 055 ON ON ON OFF OFF OFF OFF OFF 073 OFF OFF
Chapter 1 Installation and Wiring Frame Drive Current Rating Code S15-1 S15-2 S15-3 S15-4 S15-5 S15-6 S15-7 S15-8 B 167 ON OFF ON ON OFF OFF ON OFF 207 OFF ON ON ON OFF OFF ON OFF 250 ON ON ON ON OFF OFF ON OFF 330 OFF OFF OFF OFF ON OFF ON OFF 412 ON OFF OFF OFF ON OFF ON OFF 495 OFF ON OFF OFF ON OFF ON OFF 667 ON ON OFF OFF ON OFF ON OFF 830 OFF OFF ON OFF ON OFF ON OFF 996 ON OFF ON OFF ON OFF ON OFF 1K1 OFF
Installation and Wiring Chapter 1 Table 31 - Drives with 690V Input - DIP Switch S15 Configuration Frame Drive Current Rating Code S15-1 S15-2 S15-3 S15-4 S15-5 S15-6 S15-7 S15-8 C 452 OFF OFF OFF OFF OFF OFF ON ON 565 ON OFF OFF OFF OFF OFF ON ON 678 OFF ON OFF OFF OFF OFF ON ON 791 ON ON OFF OFF OFF OFF ON ON 904 ON OFF ON OFF OFF OFF ON ON 1K0 OFF ON ON OFF OFF OFF ON ON 1K1 ON ON ON OFF OFF OFF ON ON 1K2 OFF OFF OFF ON OFF
Chapter 1 Installation and Wiring I/O Signal and Control Wiring Eight (8) digital inputs, four (4) digital outputs, three (3) analog inputs, and two (2) analog outputs are available on the standard I/O terminal blocks provided with the drive. One digital input (1…8) must be configured for “Enable” (digital input 4 by default = “Enable”). See I/O and Control Wire Routing on page 86 for information on routing I/O signal and control wires.
Installation and Wiring Chapter 1 Table 34 - I/O Terminal Block 2 Designations 11 12 13 14 15 16 17 18 19 20 No. 11 12 13 14 15 16 Signal Internal 0V (Gnd) Digital Input 1 Digital Input 2 Digital Input 3 Digital Input 4 Digital Input Common 17 18 19 Not Used 24V Supply Common Internal +24V DC Supply 20 PE ground Description Max +30V, 15V/3.2 mA, 24V/5 mA, and 30V/6.4 mA. A digital input (1…8) must be configured for “Enable”.
Chapter 1 Installation and Wiring I/O Wiring Examples Input/Output Potentiometer Unipolar Speed Reference 10kΩ Pot. Recommended (2kΩ Minimum) Connection Example 1 2 3 4 5 6 7 8 9 10 Joystick Bipolar Speed Reference ±10V Input 1 2 3 4 Important: See the Attention statement on page 77 for important bipolar wiring information. 5 6 7 8 9 10 Analog Input Bipolar Speed Reference ±10V Input + 1 Common 2 3 4 Important: See the Attention statement on page 77 for important bipolar wiring information.
Installation and Wiring Input/Output Connection Example Analog Output Bipolar Signal ±10V Bipolar (based on the signal of the assigned input source - for – + example Analog Input 1) or 0…10V Unipolar (shown) 21 22 Chapter 1 Required Parameter Changes • Select Source Value: 66 [Anlg Out1 Sel] • Adjust Scaling: 62 [Anlg Out1 Scale] 23 24 25 26 27 28 29 30 Enable Input 24V DC internal supply • No Changes Required.
Chapter 1 Installation and Wiring Input/Output Connection Example 3-Wire Control Stop 24V DC external supply Requires 3-wire functions only ([Digital In1 Sel]). Using 2-wire selections will cause a type 2 alarm Start (see page 206).
Installation and Wiring Chapter 1 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.
Chapter 1 Installation and Wiring Figure 54 - Sample Encoder Power Wiring Power Source Internal Drive Power (1) +5/12…15V DC, 200 mA Connection Example +V COM +5/12-15V DC (200 mA) Common ZZ+ to Shield (1) BB+ AA+ External Power Source +V Z+ Z+ B- Common COM to Shield (1) External Power Supply B+ AA+ (1) Shield connection is on drive control board EMI shield. See Figure 53 on page 83.
Installation and Wiring Chapter 1 DC Analog Tachometer Terminal Block Figure 56 - Analog Tachometer Terminal Block Location Analog Tachometer terminal block See page 214 for DC Analog Tachometer specifications. ATTENTION: The drive can overspeed if DIP switch S4 is set incorrectly, or the tachometer is wired incorrectly. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
Chapter 1 Installation and Wiring I/O and Control Wire Routing Frames A…C 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). Frame A Shown Frame D Route the field power input cables through the opening at the top left side of the control panel. Route control and I/O cables through the opening at the bottom left side of the control panel.
Chapter 2 Drive Start Up This chapter describes how to start up the PowerFlex DC drive. If using the LCD HIM (Human Interface Module) to commission the drive, it is recommended that you read Appendix B - HIM Overview before performing these procedures. ATTENTION: Power must be applied to the drive to perform the following startup procedure. Some of the voltages present are at incoming line potential.
Chapter 2 Drive Start Up Before Applying Power to the Verify all Drive Configuration Settings Drive 1. With the bottom cover removed from the drive (see Removing the Drive Covers on page 28), verify that DIP switch S14 is set correctly to be ≥ the rated field current specified on the motor nameplate. See Table 15 on page 61. 2. Verify all switch settings (S9, S10, and S11) for the analog inputs. See Table 26 on page 73. 3.
Drive Start Up Applying Power to the Drive Chapter 2 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™, DriveTools™ SP, or Connected Components Workbench™ software to program drive parameters or use the drive “Start Up” wizard (basic application configuration only) available with both software packages. You must use DriveExplorer v5.02 or higher or DriveTools SP v4.
Chapter 2 Drive Start Up Figure 57 - Drive Status Indicators PORT MOD NET A NET B 2 1 STS # Name 1 STS (Status) 2 PORT MOD NET A NET B 90 Color Green State Flashing Steady Flashing, Drive Stopped Flashing, Drive Running Description Drive ready, but not running and no faults are present. Drive running, no faults are present. Yellow A condition exists that is preventing the drive from starting. Check parameters 1403 [Start Inhibits] and/or 1380 [Drive Alarm 1].
Drive Start Up Chapter 2 Verify the Control Voltages • Verify that the following voltages are present at I/O terminal block 1 and 2. See I/O Signal and Control Wiring on page 78: Terminal Number… 7 8 19 Voltage to Terminal Number… +10V 9 -10V 9 +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.
Chapter 2 Drive Start Up 1. At the Main menu, scroll to the Parameter option. 2. Press ALT and then Sel. 3. Scroll to the Numbered List option. 4. Press Enter. 5. Type 211. 6. Press Enter. 7. Press Sel. 8. Type 1. 9. Press Enter. 10. Press Esc. 11. Press ALT and then Sel. 12. Scroll to the File-Group-Par option. 13. Press Enter. 14. Scroll to the “Motor Control” file. 15. Press Enter.
Drive Start Up Chapter 2 16. With the “Motor Data” group selected, press Enter. 17. 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), see Drive Reference and Feedback Scaling on page 265 for details on setting these parameters. ❏ 45 [Max Ref Speed] - Enter the motor nameplate base speed.
Chapter 2 Drive Start Up 18. Access the “Field Config” group. 19. Configure the following parameters: ❏ If the motor field power is supplied by an external source, set Par 497 [Field Reg Enable] = 0 “Disabled”. Otherwise, verify that this parameter is set to 1 “Enabled” (default). Leave set to the default value if using a permanent magnet motor.
Drive Start Up Chapter 2 20. Access the “Utility” file. 21. Press Enter. 22. Access the “Alarms” group. 23. Configure the following parameters: ❏ 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). Typically, this value is approximately 85% of the nominal AC line voltage.
Chapter 2 Drive Start Up 28. Access the “Digital Inputs” group. 29. Configure the following parameters: ❏ Par 1391 [ContactorControl] - Select the type of contactor(s) used with the drive: 1 “Contactor” (default, AC input or DC output contactor), 2 “Contactor+DB” (AC input or DC output contactor and dynamic brake contactor), or 0 “None”. Note: If you select 0 “None” for Par 1391 [ContactorControl], a “CntactrCflct” alarm will display.
Drive Start Up Chapter 2 32. If you are using the HIM on the drive cover (Port 1) for the speed reference, complete the following steps: ❏ Access the “DPI Inputs” group. ❏ Set Par 1323 [DPI P1 Select] to 1“Speed Ref A”. ❏ Access the “Analog Inputs” group. ❏ Set Par 70 [Anlg In1 Sel] to 0 “Not Used”. 33.
Chapter 2 Drive Start Up 1. If an external supply is used to power the motor field, disconnect the wires from the motor field terminals. If the drive supplies power to the motor field, the internal field circuit will automatically be disabled during this test. IMPORTANT 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.).
Drive Start Up Chapter 2 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/resolver operation. If the STS LED is not flashing green at this point, see Figure 57 on page 90 for more information.
Chapter 2 Drive Start Up Figure 58 - Motor Connections C1 (+) C (+) F1 (+) A1 C1 (+) (2) C (+) F1 (+) A1 (2) (2) D (-) D1 (-) PowerFlex DC (2) D (-) A2 D1 (-) F2 (-) Motor Straight Shunt Machine, CCW Rotation Facing Commutator End PowerFlex DC A2 F2 (-) Motor Straight Shunt Machine, CW Rotation Facing Commutator End 13. Apply power to the drive. 14. Repeat step 6… step 9 on page 99. When the motor rotation direction is correct, continue with step 15. 15.
Drive Start Up Chapter 2 16.For permanent magnet motors only, continue with Tune the Current Regulator for a Permanent Magnet Motor on page 101. For all other motors, continue with Configure the Speed Feedback Parameters on page 102. Tune the Current Regulator for a Permanent Magnet Motor Only complete this procedure when you are using a permanent magnet motor.
Chapter 2 Drive Start Up Configure the Speed Feedback Parameters 1. Access the “Speed Feedback” group. 2. Configure the following parameters: Note: If an encoder or tachometer is used, see Drive Reference and Feedback Scaling on page 265 for instructions on associated parameter settings.
Drive Start Up Chapter 2 ❏ If the speed feedback source is a resolver complete the following steps: a. Select the type of resolver used in Par 423 [Reslvr Type Sel]. See Resolver Type Selection on page 283 for details on compatible resolver types. b. Select the appropriate ratio of resolver electrical to mechanical turns in Par 424 [Reslvr Spd Ratio]. c. Configure the resolver to digital conversion resolution and moving average speed filter period in par 425 [Resolver Config]. d.
Chapter 2 Drive Start Up Tune the Speed Regulator The speed regulator auto tuning test detects the total inertia value of the motor shaft (in Kg•m2), the friction value (in N•m) and the calculation of the proportional (P) and integral (I) gains of the speed regulator. IMPORTANT This test requires the free rotation of the motor shaft combined with the load. The auto tuning test of the speed loop cannot be carried out on machines with a limited stroke.
Drive Start Up Chapter 2 5. Press the Start button on the HIM. This will start the speed regulator auto tuning test, which could take several minutes. When the test has been completed, the drive will automatically stop. During the test the following are completed: • • • An acceleration test, with the torque limit value set in the Par 1048 [Autotune Cur Lim]. A deceleration test, with a lower torque limit value applied, until zero speed has been reached.
Chapter 2 Drive Start Up 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).
Drive Start Up Chapter 2 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 301. Fault STune Overspeed No.
Chapter 2 Drive Start Up For additional regulator fine tuning procedures, see Fine Tuning the Regulators on page 301. 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. See Speed Up Function on page 290 for more information. Configuring the Speed Zero Logic The speed zero logic is factory set to 0 “Disabled”. See Speed Zero Function on page 292 for more information.
Chapter 3 Programming and Parameters Topic About Parameters How Parameters are Organized Monitor File Motor Control File Speed Command File Dynamic Control File Applications File Utility File Communications File Input / Output File Parameter Cross Reference – by Name Parameter Cross Reference – by Number Page 109 111 119 123 138 144 150 163 175 179 190 194 This chapter provides a complete listing of the PowerFlex DC drive parameters.
Chapter 3 Programming and Parameters No. 1 2 3 4 5 6 7 110 Values Default: 16-bit Int 0= “Disabled” Options: 0= 1= “Disabled” “Enabled” Default: 0.00 Min/Max: Units: 0.00 / 100.00 % Reserved Reserved DPI Port 5 DPI Port 4 DPI Port 3 DPI Port 2 DPI Port 1 Digital In x x x x x x x 15 14 13 12 11 10 9 Reserved Default Bit Reserved Options x 8 x 7 x 6 0 5 0 4 0 3 0 2 1 1 1 0 Description File – Lists the major parameter file category.
Programming and Parameters How Parameters are Organized Chapter 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).
Chapter 3 Programming and Parameters Basic Parameter View Parameter 211 [Param Access Lvl] set to option 0 “Basic”.
Programming and Parameters File Utility Group Parameters Reference Config [Direction Mode] [Save HIM Ref] 1322 209 [Man Ref Preload] [Save MOP Ref] 210 249 [MOP Select] 1375 Drive Memory [Param Access Lvl] 211 [Reset Defaults] 258 [Language] 302 Diagnostics [Drive Status 1] [Drive Status 2] [Last Stop Source] 381 382 1402 [Start Inhibits] [Drive Logic Rslt] [At Speed] 1403 1328 394 [At Zero Speed] [CurrLimit Active] [Spd Limit Active] 395 349 372 Faults [Clear Fault Que] [Fault Cle
Chapter 3 Programming and Parameters Advanced Parameter View Parameter 211 [Param Access Lvl] set to option 1 “Advanced”.
Programming and Parameters File Speed Command Speed Comm and Group Limits Discrete Speeds Speed References Speed Regulator Chapter 3 Parameters [Minimum Speed] [Min Speed Fwd] [Jog Speed] [Jog Off Delay] [Preset Speed 1] [Preset Speed 2] [Trim Ramp] [Trim Ramp Pct] [Speed Reg En] [Arm Volt Kp] [Arm Volt Ki] [Spd Reg Kp] [Spd Reg Ki] [Arm Volt Kp Base] [Arm Volt Ki Base] [Spd Reg Kp Base] [Spd Reg Ki Base] [Spd Reg Kp Outpt] [Spd Reg Ki Outpt] [Spd Reg Pos Lim] [Spd Reg Neg Lim] 1 5 266 1409 154 155 4
Chapter 3 Programming and Parameters File Applications Applic Group PI Control ations PD Control PID Control Init Diam Calc Diameter Calc Winder Functions Scale Blocks 116 Parameters [Enable PI] [PI Output] [PI Steady Thrsh] [PID Steady Delay] [PI Init Prop Gn] [PI Init Intgl Gn] [Enable PD] [PD Output PID] [PD Prop Gain 1] [Enable PI PD] [PID Output] [Feed Fwd PID] [Real FF PID] [PID Source] [PID Source Gain] [Diameter Calc] [DncrPosSpd] [Max Deviation] [Minimum Diameter] [Max Diameter] [Roll Dia
Programming and Parameters File Utility Group Reference Config Utility Drive Memory Diagnostics Faults Alarms User Defined Communications Comm unicat ion Comm Control Masks & Owners Datalinks Security Chapter 3 Parameters [Direction Mode] [Save HIM Ref] [Param Access Lvl] [Drive Status 1] [Drive Status 2] [Last Stop Source] [Start Inhibits] [Drive Logic Rslt] [At Speed] [At Zero Speed] [CurrLimit Active] [Spd Limit Active] [Clear Fault Que] [Fault Clear] [Fault Clr Mode] [Status1 at Fault] [Sta
Chapter 3 Programming and Parameters File Input / Output Inputs / Group Analog Inputs Outpu ts Analog Outputs Digital Inputs Digital Outputs DPI Inputs 118 Parameters [Anlg In1 Sel] [Anlg In1 Config] [Anlg In1 Scale] [Anlg1 Tune Scale] [Anlg In1 Offset] [Anlg In1 Tune] [Anlg In1 Filter] [Anlg In2 Sel] [Anlg In2 Config] [Anlg In2 Scale] [Anlg2 Tune Scale] [Anlg Out1 Sel] [Anlg Out2 Sel] [Anlg Out3 Sel] [ContactorControl] [Dig In Status] [Digital In1 Sel] [Digital In2 Sel] [Digital In3 Sel] [Digital
Programming and Parameters Chapter 3 44 47 48 Speed Meters MONITOR 49 110 111 113 114 117 See page 110 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 317 for possible source signals. Note: The maximum value of this parameter was changed from –/+ Par 45 for firmware version 3.001.
118 121 122 428 384 Speed Meters MONITOR 385 420 924 1006 1007 1008 1009 120 See page 110 for symbol descriptions [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 for firmware version 3.001 [Spd Feedback Pct] Actual speed as a percentage of the Par 162 [Max Feedback Spd].
1010 1011 Speed Meters 1018 1019 1408 10 MONITOR 11 14 Current Meters 17 41 89 90 199 200 See page 110 for symbol descriptions [Spd Reg Err] Speed Regulator Error signal, the difference between Par 118 [Speed Reg In] and 1008 [Spd Reg Fdbk]. Note: This parameter was added for firmware version 4.001. [Spd Reg Err Pct] Par 1010 [Spd Reg Err] shown as a percentage of Par 45 [Max Ref Speed]. Note: This parameter was added for firmware version 4.001. [Speed Draw Out] Speed draw output value.
232 234 Current Meters 236 351 476 MONITOR 500 928 57 233 Drive Data 235 300 331 465 122 See page 110 for symbol descriptions [Inertia Comp Out] Displays the output of the Inertia Compensation function. The [Inertia Comp Out] signal (if selected by Par 1016 [SpdFuncSelect]) is summed with Pars 14 [Selected TorqRef] and 40 [Trim Torque]. Inertia compensation provides a torque feed forward signal during changes in motor speed reference. Note: This parameter was added for firmware version 4.
Drive Data MONITOR 466 588 1052 See page 110 for symbol descriptions [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. Values Default: Read Only Min/Max: Units: Default: 0 / 960 Vac Read Only Min/Max: Units: Default: 0.00 / 70.00 Hz Read Only Min/Max: Units: 0.00 / 9999.99 kW Values Default: 1750 Min/Max: Units: 1 / 6000 rpm Default: 1750.00 Min/Max: Units: 1.
201 [Drive Type Sel] A Values Default: See page 110 for symbol descriptions Important: This parameter is only applicable to non-regenerative (2quadrant) drives. Options: 0= “Off” 0= 1= “Off” “On” Related Parameter Name & Description Data Type Programming and Parameters No. Group File Chapter 3 16-bit Int Allows non-regenerative drives to use an external 4-quadrant controller.
97 3276.70 Related Parameter Name & Description Values See page 110 for symbol descriptions [Fld Reg Kp Base] Default: The proportional gain (KP0) of the field current regulator (base value). Leave Min/Max: set to the default value for permanent magnet motor applications. Chapter 3 Data Type No. Group File Programming and Parameters Real 91 Real 92 0.10 / 32767.00 A 98 [Fld Reg Ki Base] Integral gain (KI0) of the field current regulator in (base value).
469 [Field Mode Sel] Operating mode of the field controller. • “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]).
919 [Set Fld Curve] When set to “0”, this parameter controls the motor field current to field reference curve according to the values specified in the [Fld Const xx Pct] parameters. With this curve is defined, the result of [Max Fld Curr Pct] / [Flux Ref Pct] equals the percentage of field current according to the characteristic of the curve. This field is Write Only. After the value of this field is set to “0”, it will automatically return to “1”.
12 [Current Rate Lim] Specifies the largest change in armature current reference that will be allowed per current loop scan (2.7 ms @ 60Hz, 3.3 ms @ 50Hz AC line frequency). A value of 100% indicates that the armature current reference will not be permitted to change by more than rated motor current in a given speed loop scan period. Note: This parameter was added for firmware version 5.002.
754 [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]. A Torq Attributes 755 A 756 Values Default: 0 Min/Max: Units: 0 / 200 % [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].
423 [Reslvr Type Sel] The type of resolver used. See Resolver Type Selection on page 283 for descriptions of the attributes associated with each resolver type. To use the resolver as a speed feedback device, Par 414 [Fdbk Device Type] must = 4 “Resolver”. Important: After changing this parameter power to the drive must be cycled to have the new value incorporated into the resolver feedback module's operation. Note: This parameter was added for firmware version 5.002.
425 A Parameter Name & Description Values [Resolver Config] Configures the attributes of the resolver feedback module. • Bits 2 “Resolution 0” and 3 “Resolution 1” - Select the resolver to digital conversion resolution. See Table 425A: Resolution Settings below for selections. The selection of resolver resolution affects the maximum speed that can be measured by the resolver. These numbers are theoretical and actual limits could be higher based the application of the drive.
A 429 A 430 A 431 A 132 Reserved Reserved Reserved Energize CableCompSts ReslvrMinSpd CableBalTest CableBalSts x x 0 0 0 0 0 15 14 13 12 11 10 9 Open Wire PwrSupplySts HardwareSts ParametersOK Reserved Reserved Speed Feedback MOTOR CONTROL Default Bit SSI Comm OK Values See page 110 for symbol descriptions [Resolver Status] 431 Indicates status of the resolver module. • Bit 0 “CableBalSts” - Cable balance tuning process status.
455 [Spd FB Loss Lvl] Maximum allowed value of armature voltage (as a percentage of Par 175 [Rated Motor Volt]) with less than 5% measured speed feedback (relative to Par 162 [Max Feedback Spd]) before a Speed Feedback Loss condition (fault or alarm) is reported. Note: The name of this parameter was changed from [Spd Fdbk Error], changed the default value from 22, and min./max. values from 10/100 for firmware version 5.002. [Spd Fdbk Control] Enables/Disables speed feedback control.
652 [Encoder Err Chk] Enables/Disables monitoring of the digital encoder connection status. This parameter should be set to “Enabled” when using an encoder with a Z channel and monitoring is on (S20 on control board is set to “OFF”) or a differential encoder. Set this parameter to “Disabled” when using a singleended encoder. When an alarm is detected, the HIM displays the “Spd Fdbk Loss” (F91) fault. This parameter can be programmed on a digital output.
1013 [Torque Const] The Motor torque constant used to calculate inertia and friction compensation. This value is determined during speed auto tuning. Torque Const = EMF/Sb. It should be the same as Motor Rated Torque / Motor Full Load Amps. [Inertia] Motor inertia value. 1 Kg•m2 = 23.76 lb•ft2 [Friction] Motor friction value. 1 N•m = 0.738 lb•ft [Spd Reg Autotune] Starts the auto tuning procedure for the speed regulator.
58 A Parameter Name & Description Values See page 110 for symbol descriptions [TstGen Output] Default: Allows you to select a simulated parameter as the output for the test Options: generator. The test generator is used to manually tune the regulators. It consists of a square wave generator whose frequency, offset and amplitude can be manipulated. • “NotConnected” - No internal parameters defined by the generator. • “Reserved” - Not used.
166 A See page 110 for symbol descriptions 0= “Off” 0= 1= 2= 3= “Off” “Armature Fwd” “Armature Rev” “Field Fwd” Related Parameter Name & Description Values Default: [Alpha Test] Diagnostic test mode that selects the SCR bridge to activate. The SCR firing Options: 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.
Chapter 3 Programming and Parameters 1 Limits 2 3 SPEED COMMAND 4 5 Discrete Speeds 6 154 155 156 157 158 159 160 266 138 See page 110 for symbol descriptions [Minimum Speed] Defines the minimum speed of the drive. This value applies to both directions of motor rotation for four quadrant drives. A speed below the value set in [Minimum Speed] is not possible, regardless of the set speed reference value.
See page 110 for symbol descriptions Speed References Speed Regulator SPEED COMMAND Discrete Speeds 267 [TB Manual Ref] Reference value for the drive when the Terminal Block asserts Manual reference control. Notes: This parameter can be assigned to an analog input. See Reference Control on page 280 for more information. 1409 [Jog Off Delay] Specifies the amount of time that will elapse between removing the Jog input and commanding the main contactor to open.
96 A 99 A 100 A 101 A A Speed Regulator SPEED COMMAND 102 103 A 104 A 105 A 106 A 140 See page 110 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 for firmware version 3.001.
107 A See page 110 for symbol descriptions 20 Related Parameter Name & Description Values [Speed Zero Level] Default: Speed below which the actual speed is considered equal to zero. When a Stop Min/Max: command is issued and actual speed goes below this value, drive output is Units: disabled. The value applies to both rotation directions for four quadrant drives. Notes: Setting the value of this parameter too low could prevent the proper functioning of field economy.
126 A 238 239 242 See page 110 for symbol descriptions [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. Note: See Speed Zero Function on page 292 for more information. [SpdOut FiltGain] First order lead/lag filter gain on the speed regulator output signal.
447 A 459 A 460 A 493 Speed Regulator SPEED COMMAND 494 495 See page 110 for symbol descriptions [Speed Up Filter] The time constant of the filter for the D (derivative) component of the Speed Up function. Note: See Speed Up Function on page 290 for more information.
Chapter 3 Programming and Parameters 15 A 16 A DYNAMIC CONTROL Control Config 241 Ramp Rates 18 144 19 See page 110 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 greater 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. Max.
20 A See page 110 for symbol descriptions [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”.
Load Limits DYNAMIC CONTROL Ramp Rates 660 146 See page 110 for symbol descriptions [Accel Time 1] Sets the rate of acceleration for linear ramp 1. Acceleration rate for ramp 1 = Par 2 [Maximum Speed] / Par 660 [Accel Time 1]. 662 [Decel Time 1] Sets the rate of deceleration for linear ramp 1. Deceleration rate for ramp 1 = Par 2 [Maximum Speed] / Par 662 [Decel Time 1].
See page 110 for symbol descriptions Restart Modes Stop Modes DYNAMIC CONTROL Load Limits 700 [Droop Limit] speed reference correction range within which the droop function becomes A The active. Note: See Droop Compensation on page 271 for more information. 715 [Torq Limit Type] This parameter determines the response of the drive during a current limiting condition.
See page 110 for symbol descriptions 1345 [Powerup Delay] Defines the programmed delay time, in seconds, before a start command is accepted after a power up. If a “Start”, “Run” or “Stop” command is asserted before the time in this parameter expires, the “Start At Powerup” function will be aborted. Note: See Start At Powerup on page 300 for more information. 181 [Adaptive Spd En] Enables/Disables adaptive speed regulation.
189 A 190 Adaptv Regulator DYNAMIC CONTROL A 191 A 192 A 193 A See page 110 for symbol descriptions [Adaptive I Gain1] Integral gain for the range from zero to Par 184 [Adaptive Spd 1]. The value in this parameter is defined as percentage of the value defined Par 94 [Spd Reg Ki Base]. Note: See Adaptive Speed Regulator on page 287 for more information.
Chapter 3 Programming and Parameters 695 A 731 A 734 A 764 PI Control APPLICATIONS A 765 A 769 A 771 A 776 A 777 A 778 A 150 Related Parameter Name & Description Data Type No. Group File Applications File Values Default: 0 Min/Max: 0 / 10000 Default: 0 Min/Max: Units: 0 / 60000 ms 16-bit 695, Int 734, 793 Default: 10.00 Real Min/Max: 0.00 / 100.00 Default: 10.00 Min/Max: 0.00 / 100.00 [PI Prop Gain PID] Proportional gain of the PI block. Default: 10.
779 A 780 A 781 A 783 A 784 A 785 A 793 A 421 A PD Control 1 Min/Max: 0/3 Default: 0 Min/Max: 0/1 [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 vs0] for binary selections.
768 A 770 A PD Control 788 A 789 A 790 A 791 A APPLICATIONS 418 757 PID Control A 758 A 759 A 760 A 761 A 762 A 152 Values Default: 10.00 Min/Max: 0.00 / 100.00 Default: 0= “Disabled” Options: “Disabled” “Enabled” Default: 0= 1= 10.0 Min/Max: 0.0 / 100.0 Default: 10.0 Min/Max: 0.0 / 100.0 Default: 10.0 Min/Max: 0.0 / 100.0 Default: 1.00 Min/Max: 0.00 / 100.
763 A 772 A 773 A 774 A 782 PID Control APPLICATIONS A See page 110 for symbol descriptions [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.
786 A [PID Source] Parameter number from which the PID source value will be read. Notes: Added option 47 “Encoder Spd” for firmware version 4.001. Added option 48 “Resolver Spd” for firmware version 5.002.
798 A 799 See page 110 for symbol descriptions [Dancer Constant] The measurement corresponding to the total bunching of the material in the dancer. [Minimum Diameter] Minimum value of the roll diameter. Related Parameter Name & Description Chapter 3 Data Type No. Group File Programming and Parameters Values Default: 1 Min/Max: Units: Default: 1 / 10000 mm 100 Min/Max: Units: 1 / 2000 mm Default: Read Only Min/Max: 0/1 Default: 100 Min/Max: Units: 1 / 2000 mm Default: 1.
See page 110 for symbol descriptions 1162 [Diameter Filter] Diameter calculation filter. Diameter Calc APPLICATIONS A 1163 [Base Omega] Winder speed at the maximum line speed and minimum diameter of the winder/ A unwinder (motor shaft side). 1164 [Diam Preset 0] preset starting diameter. The value of this parameter must be set between the A First value of Pars 799 [Minimum Diameter] and 1153 [Max Diameter]. 1165 [Diam Preset 1] preset starting diameter.
0= 1= 2= 3= 4= 5= 6= 7= 8= 9= 10 = 11 = 12 = 13 = 14 = 15 = 16 = “Not Used” “Cur Lim Pos” (Par 8) “Cur Lim Neg” (Par 9) “CurLimPosOut” (Par 10) “CurLimNegOut” (Par 11) “TrqRedCurLim” (Par 13) “Torque Ref” (Par 39) “Trim Torque” (Par 40) “TorqueReg In” (Par 41) “Trim Ramp” (Par 42) “Trim Speed” (Par 43) “Ramp In” (Par 110) “Ramp Out” (Par 113) “Speed Reg In” (Par 118) “Adaptive Ref” (Par 183) “Arm Cur Pct” (Par 199) “SpdRegOutPct” (Par 236) 17 = 18 = 19 = 20 = 21 = 22 = 23 = 24 = 25 = 26 = 27 = 28 = 29 = 3
See page 110 for symbol descriptions 1176 [Taper Enable] Enables/Disables the Taper function. A 1177 [Initial Diameter] Diameter that starts the taper tension reduction. A 1178 [Final Diameter] Diameter that ends the taper tension reduction. A 1179 [Tension Reduct] Taper tension reduction as a percentage of Par 1180 [Tension Ref]. Winder Functions APPLICATIONS A 1180 [Tension Ref] reference. A Tension Note: This parameter can be assigned to an analog input or output.
See page 110 for symbol descriptions 1191 [InertiaCompCnst] the active compensation of the fixed section as a percentage of the drive A Displays rated current. 1192 [InertiaCompVar] Displays the active compensation of the variable section as a percentage of the A drive rated current. 1193 [Torq Current Pct] the amount of torque current required. A Displays Note: This parameter can be assigned to an analog output.
See page 110 for symbol descriptions 1210 [W Target] Number of the parameter to which the winder speed reference is written. Notes: Added options 0…47 for firmware version 4.001. Added option 48 A “Reserved” for firmware version 5.002.
See page 110 for symbol descriptions 1284 [Ref Spd Source] Parameter number from which the line speed reference (used for inertia compensation and line speed reference) will be read. A Notes: Added options 0…47 for firmware version 4.001. Added option 48 “Resolver Spd” for firmware version 5.002.
486 555 1220 1229 1238 1247 A 487 556 1221 1230 1239 1248 A 488 557 1222 1231 1240 1249 Scale Blocks APPLICATIONS A 489 558 1223 1232 1241 1250 A 490 559 1224 1233 1242 1251 A 491 560 1225 1234 1243 1252 A 492 561 1226 1235 1244 1253 A 162 See page 110 for symbol descriptions [Scale1 Mul] [Scale2 Mul] [Scale3 Mul] [Scale4 Mul] [Scale5 Mul] [Scale6 Mul] Multiplier of the input quantity (after a possible limitation). Resolution: 5 digits.
Programming and Parameters Chapter 3 Reserved Reserved Reserved Reserved Reserved At Pwr Down x 8 x 7 x 6 x 5 x 4 x 3 x 2 x 1 1 0 Default Bit Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved At Stop At Pwr Down x 7 x 6 x 5 x 4 x 3 x 2 0 1 0 0 1322 [Direction Mode] Selects the method that will be used for changing direction. • “Unipolar” - Drive Logic determines the direction. • “Bipolar” - The sign of the reference determines the direction.
346 A 347 Diagnostics UTILITY A 349 372 164 See page 110 for symbol descriptions [Torque Positive] Indicates whether the drive is operating with a positive torque reference. • 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.
Diagnostics UTILITY Description 13 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 12 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 Spd Ref A Auto Spd Ref B Auto Preset Spd 2 Auto Preset Spd 3 Auto Preset Spd 4 Auto Preset Spd 5 Auto Preset Spd 6 Auto Preset Spd 7 Auto TB Manual DPI Port 1 Manual DPI Port 2 Manual DPI Port 3 Manual DPI Port 4 Manual DPI Port 5 Manual DPI Port 6 Manual Jog Ref Faulted Alarm Decelerating Accelerating Actual Dir Command Dir Active Ready 0 8 0 7 0 6 0 5 0 4 1 3 1 2 0 1 1 0 (1) 11 0 0
Values [Drive Status 2] Present operating condition of the drive.
Diagnostics UTILITY 397 See page 110 for symbol descriptions [MOP Dec Active] whether the drive is decelerating using the preselected ramp. A Indicates • 0 “No Decel” = The drive is not decelerating using a preselected ramp • 1 “Decel” = The drive is decelerating using a preselected ramp 400 [Spd Select 0] the state of the assigned digital input, [Digital Inx Sel], set to 17 “Speed A Indicates Sel 1”.
Diagnostics (1) 14 0 0 0 0 1 1 1 1 Bits Local Reverse Forward Clear Faults Jog Start Stop 0 8 0 7 0 6 0 5 0 4 0 3 0 2 0 1 1 0 Description 13 0 0 1 1 0 0 1 1 12 0 1 0 1 0 1 0 1 No Command - Manual Mode Spd Ref A Auto Spd Ref B Auto Preset Spd 3 Auto Preset Spd 4 Auto Preset Spd 5 Auto Preset Spd 6 Auto Preset Spd 7 Auto 1381 [TestPoint Sel] the function whose value is displayed in [TestPoint Val]. These are internal A Selects values that are not accessible through any other parameters.
Values Default: See page 110 for symbol descriptions Options: 0= 1-5= 6= 7= 8= 9= 10 = 11 = 12 = 13 = Reserved Startup Actv Reserved Stop Assertd Reserved Enable Type 2 Alarm Fault DPI Port 1 DPI Port 2 DPI Port 3 DPI Port 4 x x x 0 0 0 0 15 14 13 12 11 10 9 Digital In Default Bit Reserved Reserved Options 0 8 x 7 0 6 0 5 1 4 x 3 0 2 0 1 0 0 263 [Clear Fault Que] Allows you to clear the fault queue.
1351 1352 1353 1354 1355 1356 1357 1358 1359 1360 Faults A 1361 1362 1363 1364 1365 1366 1367 1368 1369 1370 A 1371 UTILITY 1372 1373 1374 203 A See page 110 for symbol descriptions [Fault 1 Code] [Fault 2 Code] [Fault 3 Code] [Fault 4 Code] [Fault 5 Code] [Fault 6 Code] [Fault 7 Code] [Fault 8 Code] [Fault 9 Code] [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.
365 A 2= “Fault” 0= 1= 2= 3= 4= 5= “Ignore” “Alarm” “Fault” “Fast Stop” “Normal Stop” “CurrLim Stop” Related Parameter Name & Description Values See page 110 for symbol descriptions [OverTemp Flt Cfg] Default: Determines the response of the drive to a motor over temperature condition (F16 Options: “Motor Over Temp”). Notes: See Chapter 4 for a list of alarm and fault descriptions. Option 3 was changed from “Quick Stop” for firmware version 2.001. Chapter 3 Data Type No.
585 A Parameter Name & Description Values [Overspeed Val] Default: Speed value (rpm) at which an “Overspeed” fault (F25) will occur. Min/Max: Notes: Typically set at 110% of Par 162 [Max Feedback Spd]. See Chapter 4 for a list Units: of fault and alarm descriptions. This parameter was added for firmware version 3.001. See page 110 for symbol descriptions 1925 0 / 7800 rpm Related Data Type Programming and Parameters No.
54 A 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 A 519 User Defined UTILITY A See page 110 for symbol descriptions [UsrValDiv1] Denominator in the calculation for scaling the user-defined, drive speed display units. Note: This parameter is not used.
520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 A 536 User Defined UTILITY A Parameter Name & Description Values [UsrDefBitWrdA0] Default: [UsrDefBitWrdA1] Min/Max: [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.
537 538 539 540 541 542 543 544 545 546 547 548 549 550 551 552 A Parameter Name & Description Values [UsrDefBitWrdB0] Default: [UsrDefBitWrdB1] Min/Max: [UsrDefBitWrdB2] [UsrDefBitWrdB3] [UsrDefBitWrdB4] [UsrDefBitWrdB5] [UsrDefBitWrdB6] [UsrDefBitWrdB7] [UsrDefBitWrdB8] [UsrDefBitWrdB9] [UsrDefBitWrdB10] [UsrDefBitWrdB11] [UsrDefBitWrdB12] [UsrDefBitWrdB13] [UsrDefBitWrdB14] [UsrDefBitWrdB15] Bit variables. The individual “User Defined” bits can be read or written to.
[Jog Mask] Controls which adapters can issue jog commands. See [Logic Mask] 594 [Direction Mask] Controls which adapters can issue forward/reverse direction commands. See [Logic Mask] 595 [Reference Mask] Controls which adapters can select a manual reference. See [Logic Mask] 596 [Accel Mask] Controls which adapters can select the acceleration ramp rates (Pars 660 [Accel Time 1] and 24 [Accel Time 2]) of the drive. [Fault Clr Mask] Controls which adapters can clear a fault.
Values See page 110 for symbol descriptions 631 [Decel Mask] Controls which adapters can select the deceleration ramp rate (Pars 662 [Decel Time 1] and 32 [Decel Time 2]) of the drive. 610 611 Default: 0 (0 = “Disabled”) Min/Max: 0 / 1410 612 613 [Data In A1] – Link A Word 1 [Data In A2] – Link A Word 2 Parameter number whose value will be written from a communications device data table. The number will not be updated until the drive is stopped.
Reserved Reserved Reserved DPI Port 5 DPI Port 4 DPI Port 3 DPI Port 2 DPI Port 1 Reserved Reserved Reserved Reserved Reserved 0 x x x x x x 15 14 13 12 11 10 9 Reserved Default Bit Reserved Options Security Values See page 110 for symbol descriptions 1377 [Write Mask Act] Read Only status of write access for the DPI ports. When bit 15 is set, network security is controlling A The the write mask instead of Par 1378 [Write Mask Cfg]. 0 = Read Only, 1 = Write Permitted, x = Reserved.
Programming and Parameters Chapter 3 70 75 80 See page 110 for symbol descriptions [Anlg In1 Sel] [Anlg In2 Sel] [Anlg In3 Sel] Selects the parameter to which a value will be written from the analog input. Note: See Analog Input Configuration on page 262 for more information.
A 259 260 261 A 792 Analog Inputs INPUT / OUTPUT 295 296 297 A 801 A 802 A 1042 1043 1044 180 See page 110 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.
Analog Inputs 1404 1405 1406 Analog Outputs INPUT / OUTPUT 1045 62 63 64 65 See page 110 for symbol descriptions [Anlg In1 Cmp Eq] Provides an indication, after the amount of time specified in Par 1044 [Anlg In1 Cmp Dly] 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 In1 Cmp Err]. • “1” = The value of analog input 1 is within the range set in Par 1043 [Anlg In1 Cmp Err].
See page 110 for symbol descriptions [Anlg Out1 Sel] [Anlg Out2 Sel] [Anlg Out3 Sel]* [Anlg Out4 Sel]* Selects the source of the value that drives the analog output. *This parameter is used to configure an analog output on the I/O Expansion circuit board. See Appendix F - Optional Analog and Digital I/O Expansion Circuit Board. Options: Analog Outputs INPUT / OUTPUT No. Option (Par) Values Default: Default: Default: Default: Scaling of Analog Output Value No.
Digital Inputs INPUT / OUTPUT 133 134 135 136 137 138 139 140 141 142 143 144 See page 110 for symbol descriptions [Digital In1 Sel] [Digital In2 Sel] [Digital In3 Sel] [Digital In4 Sel] [Digital In5 Sel] [Digital In6 Sel] [Digital In7 Sel] [Digital In8 Sel] [Digital In9 Sel]* [Digital In10 Sel]* [Digital In11 Sel]* [Digital In12 Sel]* Selects the function driven by the digital input. See Option Definitions for [Digital Inx Sel] on page 184.
See page 110 for symbol descriptions Values Related No. Parameter Name & Description Data Type Programming and Parameters Group File Chapter 3 Digital Inputs INPUT / OUTPUT Option Definitions for [Digital Inx Sel] Note: When assigning digital inputs to certain options that are associated with parameters, those parameter values may be overwritten by the state of the digital input.
Digital Inputs INPUT / OUTPUT 1276 1277 1278 1279 1280 1281 1282 1283 1387 1388 1389 1390 [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.
Digital Outputs INPUT / OUTPUT 145 146 147 148 149 150 151 152 See page 110 for symbol descriptions [Digital Out1 Sel] [Digital Out2 Sel] [Digital Out3 Sel] [Digital Out4 Sel] [Digital Out5 Sel]* [Digital Out6 Sel]* [Digital Out7 Sel]* [Digital Out8 Sel]* Selects the source of the value that drives the digital output. See “Option Definitions” on Option Definitions for [Digital Outx Sel], [Relay Out 1 Sel] and [Relay Out 2 Sel] on page 187.
See page 110 for symbol descriptions Values Related Parameter Name & Description Chapter 3 Data Type No.
1267 1268 1269 1270 1271 1272 1273 1274 Reserved Digital Out8 Digital Out7 Digital Out6 Digital Out5 Digital Out4 Digital Out3 Digital Out2 Digital Out1 x 8 0 7 0 6 0 5 0 4 0 3 0 2 0 1 0 0 Reserved Reserved Reserved Reserved 0 0 x x x x x 15 14 13 12 11 10 9 Reserved Default Bit Relay Out1 Options [Relay Out 2 Sel] Selects the source of the value that drives the N.O. relay between the terminals 75 and 76. See “Option Definitions” on page 187.
1392 Digital Outputs [Relay Out 1 Sel] Selects the source of the value that drives the N.O. relay between the terminals 35 and 36. See “Option Definitions” on page 187. Note: Option 16 “Encoder Err” was changed for firmware version v5.002.
Chapter 3 Programming and Parameters Parameter Cross Reference – by Name Name No.
Programming and Parameters Chapter 3 Name No. Group Page Name No. Group Page Name No.
Chapter 3 Programming and Parameters Name No. Group Page Name No. Group Page Name No.
Programming and Parameters Name No. Group Page Name No.
Chapter 3 Programming and Parameters Parameter Cross Reference – by Number No.
Programming and Parameters Chapter 3 No. Parameter Name Group Page No. Parameter Name Group Page No.
Chapter 3 Programming and Parameters No. Parameter Name Group Page No. Parameter Name Group Page No.
Programming and Parameters No. Parameter Name Group Page No.
Chapter 3 Programming and Parameters Notes: 198 Rockwell Automation Publication 20P-UM001I-EN-P - February 2013
Chapter 4 Troubleshooting Topic Faults and Alarms Drive Status Manually Clearing Faults Fault Descriptions Clearing Alarms Alarm Descriptions Common Drive Symptoms and Corrective Actions Testpoint Codes and Functions Page 199 200 201 202 206 206 208 210 This chapter provides information to guide you in troubleshooting the PowerFlex DC drive. Included is a listing and description of drive faults (with possible solutions, when applicable) and alarms.
Chapter 4 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 59 - Drive Status Indicators PORT MOD NET A NET B 1 2 STS # 1 Name STS (Status) Color Green Yellow State Flashing Steady Flashing, Drive Stopped Flashing, Drive Running Steady, Drive Running Red Flashing Steady 2 200 PORT MOD NET A NET B Refer to the Communication Adapter User Manual.
Troubleshooting Chapter 4 HIM Indicators 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 • Fault number • Fault name • Time that has passed since the fault occurred Press “Esc” to regain HIM control. The drive is indicating an alarm.
Chapter 4 Troubleshooting Fault Descriptions Table 39 - Fault Types, Descriptions and Actions Fault Name AC Undervoltage Number Type(1) 4 1 Arm Overvoltage 5 1 Auxiliary Input 2 1 Drive Overload 64 2 Dsp Error 132 2 EEPROM Error 100 2 Encoder Error 92 2 Fld Current Loss 6 1 Hardware Fault 130 2 202 Description/Possible Cause(s) Action(s) There is an undervoltage on the power circuit (can only occur while the drive is active, i.e., running or jogging).
Troubleshooting Fault Name Heatsink OvrTemp Number Type(1) 8 2 Interrupt Error 131 2 Inverting Fault 37 2 Main Contactor 10 2 Motor Overload 7 1 Motor Over Temp 16 1 No Fault 0 – 2 Overcurrent 13 1 Overspeed 25 2 Params Defaulted 48 2 Description/Possible Cause(s) The heatsink temperature is too high Possible causes include: • The surrounding air temperature is too high. • The drive’s cooling fans have failed (drives > 110 A). • The heatsink is dirty.
Chapter 4 Troubleshooting Fault Name Port 1-5 Adapter Number Type(1) 71…75 2 Description/Possible Cause(s) The communications card has a fault. Port 1-5 DPI Loss 81…85 2 The DPI port stopped communicating. Power Failure 3 Possible causes include: 2 IMPORTANT Resolver Error 93 2 Spd Fdbk Loss 91 1 STune Aborted 62 2 204 Action(s) Check the DPI device event queue and corresponding fault information for the device. 1. Check the HIM connection. 2.
Troubleshooting Fault Name STune CurLimit Number Type(1) 59 2 STune FrictionLo 60 2 STune LoadHi 58 2 STune Overspeed 56 2 STune Stalled 57 2 STune Timeout 61 2 Sustained Curr 70 2 Description/Possible Cause(s) One of the following has occurred: • The value of Par 1048 [Autotune Cur Lim] for auto tuning the speed regulator is set too high. • Par 107 [Speed Zero Level] and/or 108 [Speed Zero Delay] is set too high.
Chapter 4 Troubleshooting Clearing Alarms Alarms are automatically cleared when the condition that caused the alarm is no longer present. Alarm Descriptions The status of the alarms can be viewed in 1380 [Drive Alarm 1]. Table 41 - Alarm Descriptions and Actions Alarm Type Arm Overvoltage 1 Auxiliary Input 1 BipolarCflct 2 CntactrCflct 2 DigInCflctA 2 Description There is a possible overvoltage on the armature circuit or Par 175 [Rated Motor Volt] is set too low for the application.
Troubleshooting Alarm DigInCflctC Type 2 FB Cfg Cflct 2 FldCfg Cflct 2 Fld Current Loss 1 Motor Overload 1 Motor Over Temp 1 Ref Cflct 2 Spd Fdbk Err 1 Spd Fdbk Loss 1 Start At PowerUp 1 Chapter 4 Description More than one physical input has been configured to the same input function. Multiple configurations are not allowed for the following input functions.
Chapter 4 Troubleshooting Common Drive Symptoms and Corrective Actions The following tables contain descriptions of common drive symptoms and the possible solutions to correcting the problem.
Troubleshooting Chapter 4 Drive starts but motor does not turn and no armature current Drive Symptom Action The drive starts but there is no armature current and the motor • Verify the wiring to the analog input(s) selected for speed reference (see I/O Wiring Examples on page 80). does not respond to a speed signal. • Verify the setting(s) of switch S9 and Par 71 [Anlg In1 Config]; or S10 and Par 76 [Anlg In2 Config]; or S11 and Par 81 [Anlg In3 Config] (see DIP Switch and Jumper Settings on page 72).
Chapter 4 Troubleshooting 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: • Parameters 1404 [Analog In1 Value], 1405 [Analog In2 Value], 44 [Speed Ref A] and 48 [Speed Ref B] • 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].
Appendix A Supplemental Drive Information Topic Specifications IP20 NEMA/UL Type Open Watts Loss Communication Configurations Drive Power Circuit Protection Control Power Circuit Protection Fuses AC Input Line Reactors and AC Input Contactors Isolation Transformers Dynamic Brake Resistor Kits and DC Output Contactors DC Contactor Crimp Lug Kit Specifications Alternate EMC Filters Terminal Adapter Kits for Frame D Drives Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 Page 212 215 217 21
Appendix A Supplemental Drive Information Specifications Category Agency Certification Specification According to file E59272 for the series of the approved devices.
Supplemental Drive Information Category Electrical Specification Input Voltages: Input Frequency: Max. Rate of Change of Input Frequency: Armature Output Voltage: Output Horsepower (Cont.) Output Current: Overload Capability: Field Output Voltage Controller Current Overload: Control Max.
Appendix A Supplemental Drive Information Category Feedback Devices Specification Encoder Resolver DC Analog Tachometer Inputs Analog Inputs Digital Inputs Outputs Analog Outputs Digital Outputs Relay Outputs 214 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).
Supplemental Drive Information IP20 NEMA/UL Type Open Watts Loss Appendix A Watts loss data shown below is based on the rated current of the drive.
Appendix A Supplemental Drive Information Table 44 - Frame C Drives Watts Loss and Fan Capacity Drive Current Rating Code(1) 521 700 495 667 540 675 452 565 AC Input Voltage 230 460 575 690 Total Watts Loss 2143 2700 2143 2590 2300 2620 1700 2300 Fans (2) Input Voltage Rated Current (VAC) (A) 230 0.75 Max Air Flow Capacity Noise Level 1050 m3/h 62.
Supplemental Drive Information Communication Configurations Appendix A Typical Programmable Controller 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 written only to RAM and will not be saved by the drive. This is the preferred attribute for continuous transfers.
Appendix A Supplemental Drive Information Figure 61 - Logic Status Word Logic Bits Status 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 x Ready x x x x x x x x x x x x x x x Active Command Direction Actual Direction Accel Decel Alarm Fault At Speed Local Control (1) Reference Source (1) See Masks & Owners on page 175 for further information.
Supplemental Drive Information Drive Power Circuit Protection Appendix A The tables on the following pages provide the recommended fuses for protecting the armature and field circuits of the drive. Externally mounted fuses (as indicated in Figure 62 below) must be sourced separately when installing the drive. Internally mounted fuses (as indicated in Figure 62 below and Figure 65 on page 225) are provided with the drive. See page 225 for frames C and D fuse information.
Appendix A Supplemental Drive Information Frame A and B Recommended AC Input Line Fuses AC input line fuses are externally mounted for frame A and B drives and must be sourced separately. See Fuse Code FS1 in Figure 62 on page 219. Frame Table 46 - 230V AC Input Drives Drive Current Rating Code A 7P0 9P0 012 020 029 038 055 073 093 110 B 146 180 218 265 360 434 DC Amps AC Line Bussmann Amps Ferrule FWP Type 7 9 12 20 29 38 55 73 93 110 146 180 218 265 360 434 5.7 7.4 9.
Supplemental Drive Information Appendix A Table 48 - 575V AC Input Drives Frame B Drive DC Amps Current Rating Code 067 101 135 270 405 67.5 101.3 135 270 405 AC Line Bussmann Amps North American FWP Type 55.1 FWP-100A 82.7 FWP-175A 110.3 FWP-225A 220.6 FWP-450A 330.
Appendix A Supplemental Drive Information Frame Table 50 - 460V AC Input Drives Drive DC Current Amps Rating Code A 4P1 6P0 010 014 019 027 035 045 052 073 086 100 129 B 167 207 250 330 412 4.1 6 10 14 19 27 35 45 52 73 86 100 129 167 207 250 330 412 AC Line Bussmann Amps Ferrule FWP Type 3.3 4.9 8.2 11.4 15.5 22.1 28.6 36.8 42.5 59.6 70.3 81.7 105.4 136.4 169.1 204.3 269.6 336.
Supplemental Drive Information Appendix A Frame A and B Recommended Field Circuit Fuses Field circuit fuses are internally mounted and provided with the drive. See Fuse Code FS3 in Figure 62 on page 219. Also, see Figure 63 on page 224 and Figure 63 on page 224 for fuse locations.
Appendix A Supplemental Drive Information Frame Table 54 - 575V AC Input Drives B Drive Field Current Amps Rating Code 067 101 135 20 270 405 Quantity Type Bussmann Ferraz Shawmut (Gould Shawmut) SIBA 2 FWC-25A10F A60Q25-2 60 033 05.
Supplemental Drive Information Appendix A Frame C and D Fuse Information All fuses for armature and field circuit protection are internally mounted and provided with frame C and D drives. Figure 65 - Frame C and D Fuse Table Designations FS4 = Internally mounted fuses for the armature converter on the AC input side. U FS4 V C W U1 FS3 D C1 V1 FS3 = Internally mounted fuses for the field circuit on the AC input side.
Appendix A Supplemental Drive Information Frame Table 57 - 575V AC Input Drives C D Drive Current Rating Code 540 675 810 1K0 1K2 1K3 1K6 Field Amps Type Qty Bussmann 20 10 x 38 mm 40 22 x 58 mm Ferraz Shawmut (Gould Shawmut) SIBA FWC-25A10F A60Q25-2 A60Q25-8 6003305.25 FWP-50A22F A70QS50-22F 5014006.50 Ferraz Shawmut (Gould Shawmut) SIBA FWC-25A10F A60Q25-2 A60Q25-8 6003305.25 FWP-50A22F A70QS50-22F 5014006.50 FWP-100A22F A70QS100-22F 5014006.
Supplemental Drive Information Appendix A Figure 67 - Frame D Field Circuit Fuse Location Top, left side of drive control panel.
Appendix A Supplemental Drive Information Fuses for Regenerative Frame C and D Drives Leg fuses are internally mounted and provided with frames C and D drives. See Fuse Code FS4 in Figure 65 on page 225. Also, see Figure 68 on page 229 and Figure 69 on page 230 for fuse locations.
Supplemental Drive Information Appendix A Table 65 - Recommended Leg Fuses - 690V AC Input Frame C Drives Frame Drive Current Rating Code C 452 565 DC AC Qty Bussmann Ferraz Shawmut (Gould Shawmut) Amps Line Square Body - Flush End Contact Amps SIBA 452 565 20 771 32.500 + switch 28 001 04 20 771 32.
Appendix A Supplemental Drive Information Figure 69 - Frame D Regenerative Drive - Leg Fuse Location Leg fuses and switches are located on the bus bars behind the control panel, which holds the circuit boards. Fuses for Non-Regenerative Frame C and D Drives AC input line and/or leg fuses are internally mounted and provided with frames C and D drives. See Fuse Code FS4 in Figure 65 on page 225. Also, see Figure 70 on page 232 for fuse locations.
Supplemental Drive Information Appendix A Frame Table 70 - Recommended Leg Fuses - 460V AC Input Frame D Drives D Drive Current Rating Code 830 996 1K1 1K3 1K4 DC AC Line Qty Bussmann Ferraz Shawmut (Gould Shawmut) Amps Amps Square Body - DIN 43653 Stud-Mount SIBA 830 996 1162 1328 1494 20 635 32.800 + switch 28 001 04 20 635 32.1000 + switch 28 001 04 20 635 32.1100 + switch 28 001 04 20 635 32.1250 + switch 28 001 04 20 635 32.1400 + switch 28 001 04 678.1 813.7 949.4 1085.0 1220.
Appendix A Supplemental Drive Information Figure 70 - Frame C Non-Regenerative Drive - AC Input Line Fuse Location AC Input fuses and switches are located on the bus bars behind the control board EMI shield. Note: Drive shown with front covers removed and control board EMI shield lowered.
Supplemental Drive Information Control Power Circuit Protection Fuses Appendix A Switching Power Supply Circuit Board Fuses The following fuses are used to protect the Switching Power Supply circuit. IMPORTANT Frame A B Verify the circuit board revision prior to ordering and installing fuses.
Appendix A Supplemental Drive Information Figure 72 - Frame B Switching Power Supply Circuit Board Fuse Location Top View of Drive Switching Power Supply circuit board fuse holders. F1 = 3.15 A fuse Rev. “H” and below only. F2 = 2.5 A fuse Rev. “H” and below only. Figure 73 - Frame C Switching Power Supply Circuit Board Fuse Location F1 = 3.15 A fuse Rev. “H” and below only. F2 = 2.5 A fuse Rev. “H” and below only.
Supplemental Drive Information Appendix A Figure 74 - Frame D Switching Power Supply Circuit Board Fuse Location Switching Power Supply fuse holder The Switching Power Supply circuit board is located on the control panel. Frame B Pulse Transformer Circuit Board Fuses The following fuses are used to protect the MOVs on the Pulse Transformer circuit board on frame B drives only.
Appendix A Supplemental Drive Information Frame C Transient Noise Filter Circuit Board Fuses The following fuses are used to protect the MOVs on the Transient Noise Filter circuit board for frame C drives only.
Supplemental Drive Information Appendix A Frame D Overvoltage Clipping Circuit Board Fuses The following fuses are used to protect the resistors and capacitors on the Overvoltage Clipping circuit board for frame D drives only. The Overvoltage Clipping circuit board is located on the left side wall inside the drive enclosure, behind the control panel.
Appendix A Supplemental Drive Information AC Input Line Reactors and AC Input Contactors If a DC contactor is used, an AC input contactor is not needed. Table 75 - 230V AC Input Drives Frame Drive Current Rating Code DC Amps AC Line Amps Hp IP00 (Open Style) Line Reactor Cat No. Line Reactor kW (HP) AC Input Contactor Cat. No. A 7P0 7 5.7 1.5 1321-3R8-A 0.75 (1) 100-C12D10 9P0 9 7.4 2 1321-3R12-A 1.49 (2) 100-C12D10 012 12 9.8 3 1321-3R18-A 0.75…3.
Supplemental Drive Information Appendix A Frame Drive Current Rating Code DC Amps AC Line Amps Hp IP00 (Open Style) Line Reactor Cat No. Line Reactor kW (HP) AC Input Contactor Cat. No. B 129 129 105.4 75 1321-3R160-B 56…75 (75…100) 100-D110D11 167 167 136.4 100 1321-3R160-B 56…75 (75…100) 100-D140D11 207 207 169.1 125 1321-3RB250-B 93…112 (125…150) 100-D180D11 250 250 204.3 150 1321-3RB250-B 93…112 (125…150) 100-D210ED11 330 330 269.
Appendix A Supplemental Drive Information Table 78 - 690V AC Input Drives Frame Drive Current Rating Code DC Amps AC Line Amps Hp IP00 (Open Style) Line Reactor Cat No. Line Reactor kW (HP) AC Input Contactor Cat. No.
Supplemental Drive Information Appendix A Isolation Transformers Three Phase Primary Voltage Three Phase Secondary Voltage kVA kW (Hp) Voltage 230V AC Catalog Number 460V AC Catalog Number 575V AC Catalog Number 5 1.2 - 2.2 (1.5 - 3) 230 1321-3TW005-AA 1321-3TW005-AB N/A 460 1321-3TW005-BA 1321-3TW005-BB N/A 575 1321-3TW005-CA 1321-3TW005-CB N/A 7.5 11 14 20 27 34 40 51 63 75 93 118 3.7 (5) 5.5 (7.5) 7.5 (10) 11 (15) 15 (20) 18.
Appendix A Supplemental Drive Information Three Phase Primary Voltage Three Phase Secondary Voltage kVA kW (Hp) Voltage 230V AC Catalog Number 460V AC Catalog Number 575V AC Catalog Number 145 93 (125) 230 1321-3TH145-AA 1321-3TH145-AB 1321-3TH145-AC 460 1321-3TH145-BA 1321-3TH145-BB 1321-3TH145-BC 175 220 275 330 440 550 660 770 880 242 112 (150) 145 (200) 187 (250) 224 (300) 298 (400) 373 (500) 448 (600) 522 (700) 597 (800) 575 1321-3TH145-CA 1321-3TH145-CB 1321-3
Supplemental Drive Information Appendix A See Table 83 on page 246 and Table 84 on page 246 for recommended alternate DC Output Contactors for 575V and 690V AC input drives, respectively.
Frame Appendix A Supplemental Drive Information Drive Current Rating Code D 800 960 1K1 1K3 1K4 (1) (2) (3) (4) (5) DC Amps AC Line Amps Hp Dynamic Brake Resistor Kit Cat. No. 830 996 1162 1328 1494 678.1 813.7 949.4 1085.0 1220.6 500 600 700 800 900 (2) (2) (2) (2) (2) Armature Voltage (Volts) 500 500 500 500 500 DB Resistor Size (ohms) DB Resistor Size (Watts) 0.463 0.322 0.322 0.255 0.255 6338 6221 6221 5718 5718 Brake Amps DC Loop Required Contactor Cat. No.
Supplemental Drive Information Appendix A The following alternate dynamic brake resistor kits and/or DC output contactors may be used with the corresponding PowerFlex DC drives but must be sourced separately from the drive. Alternate Dynamic Brake Resistor Kits and DC Output Contactors Frame Table 81 - 230V AC Input Drives B Drive Current Rating Code 360 434 C 521 700 D 875 1K0 Brake Amps Required DC Loop Contactor Cat. No.
Appendix A Supplemental Drive Information Frame Table 83 - 575V AC Input Drives B C D (1) (2) (3) (4) Drive Current Rating Code 067 101 135 270 405 540 675 810 1K0 1K2 1K3 1K6 DC Amps AC Line Amps Hp 67.5 101 135 270 405 540 675 810 1080 1215 1350 1688 55.1 83 110 221 331 441 551 662 882 993 1103 1379 50 75 100 200 300 400 500 600 800 900 1000 1250 Dynamic Brake Resistor Kit Cat. No. Armature Voltage (Volts) DB Resistor Size (ohms) (1) 600 600 600 600 600 600 600 600 600 600 600 600 5.
Supplemental Drive Information Alternate EMC Filters Appendix A The following recommended filters can be used in place of the Rasmi filters listed in the table in the Installation Requirements Related to EN 61800-3 and the EMC Directive section on page 41. IMPORTANT Only the Rasmi RF 3xxx-MHU, Rasmi RF-3xxx-SIEI, and EPCOS B84143B Type S081 filters have been certified for use with the PowerFlex DC drive. All other filters should be verified in the application.
Appendix A Supplemental Drive Information Frame Drive Current Rating Code Voltage Class A 460V AC B C D 4P1 6P0 010 014 019 027 035 045 052 073 086 100 129 167 207 250 330 412 495 667 830 996 1K1 1K3 1K4 Rasmi Filters Part Number EMI-FFP-480-9, Code 8270 (was RF 3009-SIEI) EMI-FFP-480-9, Code 8270 (was RF 3009-SIEI) EMI-FFP-480-24, Code 8271 (was RF 3024-SIEI) EMI-FFP-480-24, Code 8271 (was RF 3024-SIEI) EMI-FFP-480-24, Code 8271 (was RF 3024-SIEI) EMI-FFP-480-30, Code 8272 (was RF 3030-SIEI) EMI-F
Supplemental Drive Information Frame Drive Current Rating Code Voltage Class A 460 B C D B C D C D 4P1 6P0 010 014 019 027 035 045 052 073 086 100 129 167 207 250 330 412 495 667 830 996 1K1 1K3 1K4 067 101 135 270 405 540 675 810 1K0 1K2 1K3 1K6 452 565 678 791 904 1K0 1K1 1K2 1K4 1K5 575 690 Schaffner Filters Part Number FN 258HV-7-29 FN 258HV-7-29 FN 258HV-16-29 FN 258HV-16-29 FN 258HV-30-33 FN 258HV-30-33 FN 258HV-42-33 FN 258HV-55-34 FN 258HV-55-34 FN 258HV-75-34 FN 258HV-100-35 FN 258HV-1
Appendix A Supplemental Drive Information Table 87 - EPCOS and EPCOS Alternative Filters Frame Drive Current Rating Code D 875 1K0 830 996 1K1 1K3 1K4 135 270 405 540 675 810 1K0 1K2 1K3 1K6 452 565 678 791 904 1K0 1K1 1K2 1K4 1K5 D B C D C D Terminal Adapter Kits for Frame D Drives EPCOS Alternative Type Filters Part Number Part Number B84143B1000S020 – B84143B1600S020 – B84143B1000S020 B84143B1000S021 B84143B1600S020 B84143B1600S021 B84143B1600S020 B84143B1600S021 B84143B1600S020 B84143B1600S02
Appendix B HIM Overview Topic External and Internal Connections LCD Display Elements ALT Functions Menu Structure Viewing and Editing Parameters Removing/Installing the HIM External and Internal Connections Page 251 252 252 254 256 257 The PowerFlex DC drive provides a number of cable connection points for the HIM (Frame A shown). PORT 1 MOD NET A 4 NET B STS View with front cover removed 2 2 3ro 1 3 No.
Appendix B HIM Overview LCD Display Elements Display Description F-> Power Loss Auto 0.0 rpm Main Menu: Diagnostics Parameter Device Select Direction⎥ Drive Status⎥ Alarm⎥ Auto/Man⎥ Information Commanded or Output Speed or Current Programming / Monitoring / Troubleshooting The top line of the HIM display can be configured with parameter 1321 [DPI Fdbk Select].
HIM Overview Appendix B Using the S.M.A.R.T. List Screen The LCD HIM provides the S.M.A.R.T. list screen which contains some of the most commonly changed parameters, including the following: Parameter Name / Number [Max Ref Speed] (45) [Rated Motor Volt] (175) [Nom Mtr Arm Amps] (179) [Nom Mtr Fld Amps] (280) [Anlg In1 Sel] (70) [Maximum Speed] (2) [Current Limit] (7) [Accel Time 1] (660) [Fdbk Device Type] (414) Description The nameplate base motor speed.
Appendix B HIM Overview Menu Structure Figure 78 - HIM Menu Structure User Display Esc Diagnostics Parameter (See Key below for button descriptions.
HIM Overview Appendix B Diagnostics Menu When a fault trips the drive, use this menu to access detailed data about the drive. Option Faults Status Info Device Items Device Version Description View fault queue or fault information, clear faults or reset drive. View parameters that display status information about the drive. View statistics associated with DPI Communications. View the firmware version and hardware series of components.
Appendix B HIM Overview Preferences Menu The HIM and drive have features that you can customize. Option Drive Identity User Dspy Lines Viewing and Editing Parameters Description Add text to identify the drive. Select the display, parameter, scale and text for the User Display. The User Display is two lines of user-defined data that appears when the HIM is not being used for programming. LCD HIM Step 1. In the Main Menu, press the Up Arrow or Down Arrow to scroll to “Parameter.
HIM Overview Removing/Installing the HIM Appendix B 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 To remove the HIM… 1. Press ALT and then Enter (Remove). The Remove HIM confirmation screen appears. Key(s) ALT + 2. Press Enter to confirm that you want to remove the HIM.
Appendix B HIM Overview Notes: 258 Rockwell Automation Publication 20P-UM001I-EN-P - February 2013
Appendix C Application Notes Topic Alpha Test Mode Analog Input Configuration Current / Speed Curve Drive Reference and Feedback Scaling Droop Compensation Field Weakening Mode Configuration (v1.
Appendix C Application Notes Alpha Test Setup and Operation 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.
Application Notes Appendix C 6. Open the Enable input on the drive. 7. Set Par 166 [Alpha Test] to the desired value (1 = “Arm Fwd”, 2 = “Arm Rev” or 3 = “Fld Fwd”). 8. Close the Enable input. 9. 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.
Appendix C Application Notes Analog Input Configuration The analog inputs default to ±10V. To configure the analog inputs 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 (see Control Circuit Board Jumper and DIP Switch Settings on page 73 for more information).
Application Notes Appendix C 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 In1 Cmp Err 0 Anlg In1 Cmp 0 Anlg In1 Cmp Eq Anlg In1 Cmp Dly 0 ms Calculations used to determine Pars1042 [Anlg In1 Cmp] and 1043 [Anlg In1 Cmp Err]: • [Anlg In1 Cmp] = (comparison value) x 10000 / (max. reference value) • [Anlg In1 Cmp Err] = (tolerance value) x 10000 / (max.
Appendix C Application Notes • Par 1045 [Anlg In1 Cmp Eq] = “1” (high) when the signal on Analog Input 1 is within the range specified in Par 1043 [Anlg In1 Cmp Err]. Par 1045 [Anlg In1 Cmp Eq] = “0” (low) when the signal on Analog Input 1 is outside the range specified in Par 1043 [Anlg In1 Cmp Err]. 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.
Application Notes Appendix C • Enable the current/speed curve function by setting parameter 750 [TrqTpr Enable] to 1 “Enabled”. • Set the 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]. • Set the threshold speed at which current (torque) reduction begins in parameter 756 [TrqTpr Spd].
Appendix C Application Notes Armature Voltage Feedback When armature voltage feedback is configured, Par 162 [Max Feedback Spd] must be set to the motor base speed (rpm) value associated with Par 175 [Rated Motor Volt].
Application Notes Appendix C Example 1: Armature Voltage (Overvoltage Fixed at 20%) Because armature voltage feedback is being used the maximum reference and feedback speeds must be equal and set to the rated speed of the motor (in other words, field weakening is not permitted). • Par 175 [Rated Motor Volt] = 500V (default) • Par 45 [Max Ref Speed] = 1750 rpm (default) • Par 162 [Max Feedback Spd] = 1750 rpm (default) • The reference and feedback resolution = 0.
Appendix C Application Notes Example 3: DC Tachometer with Feedback Bypass This example is similar to example 2 except that it compensates for the loss in feedback resolution by setting parameter 562 [Anlg Tach Gain]. • Par 175 [Rated Motor Volt] = 500V (default) • Par 45 [Max Ref Speed] = 1750 rpm (default) • Set Par 562 [Anlg Tach Gain] = 2.
Application Notes Appendix C Example 5: Encoder with Field Weakening This example is similar to example 4 except that an encoder is configured so there is no feedback scaling required. • Par 175 [Rated Motor Volt] = 500V (default) • Set Par 45 [Max Ref Speed] = 2500 rpm • Set Par 162 [Max Feedback Spd] = 2500 rpm • Set Par 169 [Encoder PPR] = 240 ppr • Set Par 585 [Overspeed Val] = 2750 rpm • The reference and feedback resolution = (7500 fpm/25000 counts) = 0.
Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 0 500 1000 1500 2000 3000 4000 5000 6000 0 100 200 500 600 Par 162 = 300 rpm Par 169 = 500 ppr Par 169 [Encoder PPR] 400 Par 162 = 1465 rpm Par 169 = 100 ppr (min.) Par 162 = 6000 rpm (max.) Par 169 = 100 ppr (min.) 800 Par 162 = 8 rpm Par 169 = 977 ppr 1000 1200 Par 162 = 300 rpm Par 169 = 976 ppr Allowed Area 1400 1600 1800 2000 When Par 175 = 700V or greater, Par 162 min.
Application Notes Droop Compensation Appendix C 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 drives 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.
Appendix C Application Notes Using a DC Contactor Only (Firmware v1.006 Only) 1. Set parameter 1391 [ContactorControl] to "Contactor" (default value). 2. 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]). 3. Connect the DC contactor auxiliary (status) contact to a second digital input. 4. Set the corresponding second [Digital Inx Sel] parameter (133-144) to "Fld Weak En". 5.
Application Notes Appendix C Using a DC Contactor and an Inverting Fault Device (Firmware v1.006 Only) DC Contactor Configuration 1. Set parameter 1391[ContactorControl] to "Contactor" (default value). 2. 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]). 3. Connect the DC contactor auxiliary (status) contact to a digital input. 4.
Appendix C Application Notes Using a DC Contactor, a Dynamic Brake and an Inverting Fault Device (Firmware v1.006 Only) DC Contactor and Dynamic Brake Configuration 1. Set parameter 1391[ContactorControl] to "Contactor+DB". 2. 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". 3. Set one [Digital Inx Sel] parameter to "Contactor" (default value for parameter 140 [Digital In8 Sel]). 4.
Application Notes PID Function Appendix C 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 niproll, winder/unwinder, roll doctor/salvage machine, pump and extruder pressure control and extruder temperature control applications. (See the complete “PID Control” block diagram on page 330.
Appendix C 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: • 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” • Set Par 786 [PID Source] to 19 “UsrDefined0” (Par 503).
Application Notes Appendix C • Monitor the feed-forward signal after the gain is applied in Par 758 [Feed Fwd PID] P758 Feed Fwd PID P786 PID Source Gain 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. • Set Par 70 [Anlg In1 Sel] to 19 “PID Feedback”.
Appendix C Application Notes • 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] P762 PID Setpoint Sel P760
Application Notes Appendix C 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 Reverse NIP-Roll Forward Load Cell 0 - +10V M E M E Tension Set -10V Master Drive Set Slave Drive Feedback Line Speed Signal (Internal Ramp) +10V Forward -10V Reverse Line Speed Reference In addition, configure the following in the Follower drive(s): • Verify th
Appendix C 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 217 for more information).
Application Notes Appendix C 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 • Press ALT then Auto/Man on the HIM.
Appendix C Application Notes Resolver Cable Balance Tuning Test At drive power-up the resolver feedback module automatically performs some tuning (cable length compensation, Par 426 [Resolver Status] bit 3 “CableCompSts” and cable resonance, Par 426 [Resolver Status], bit 10 “HardwareSts”) of the attached resolver and cable. The following optional cable balance tuning test can be performed to possibly enhance the performance of the resolver.
Application Notes Appendix C 10. Monitor Par 426 [Resolver Status], bits 0 “CableBalSts” and 1 “CableBalTest”. The initial test typically takes approximately 10 seconds to successfully complete (subsequent tests more quickly). However, if the cable balance algorithm is unable to adapt to the cable, the test could be active for up to 60 seconds. • For bit 0 “CableBalSts”: 1 = the cable is not balanced or the test is currently active, and 0 = the cable is balanced (tuned).
Appendix C Application Notes Setting Par 18 [Ramp Type Select] to 1 “S shaped,” enables S-shaped ramp (S-curve) operation in the drive. When S-curve operation is enabled, it allows for a smoother change in speed than a linear ramp. Speed (rpm) S-curve Configuration Time (s) Adding s-curve to the ramp will increase the total length of time to perform the speed change.
Application Notes Appendix C Approximately half of the value of parameter 19 [S Curve Time] is added to the initial “S” and half of the value is added to the final “S.” When the S-shaped ramp > Linear ramp, the linear portion becomes zero. To calculate the total ramp time when s-curve is enabled, the amount of time in each section of the profile needs to be determined; T1 = initial S and final S, and T2 = linear.
Appendix C Application Notes 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.
Application Notes Appendix C Linking Parameters Via the Scale Block Parameters Most parameter values are entered directly by the user. However, certain 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 In1 Sel], can be linked to parameter 660 [Accel Time 1]. In order to do so: • Set parameter 70 [Anlg In1 Sel] to 12 “UserDefined0”.
Appendix C Application Notes P186 Adaptive Joint 1 P188 Adaptive P Gain1 P189 Adaptive I Gain1 P190 Adaptive P Gain2 P191 Adaptive I Gain2 P192 Adaptive P Gain3 P193 Adaptive I Gain3 P187 Adaptive Joint 2 P183 Adaptive Ref P184 Adaptive Spd 1 P185 Adaptive Spd 2 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 ].
Application Notes Appendix C Configuring the Adaptive Speed Regulator • Set Par 181 [Adaptive Spd En] = “1 Enabled” • If the 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.
Appendix C Application Notes 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, which allows 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).
Application Notes Appendix C 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.
Appendix C Application Notes P118 Speed Reg In P104 At Speed Error [Digital Outx Sel] = 3 “At Speed” P122 Spd Feedback P394 At Speed P105 At Speed Delay 0 t Speed Zero Function The Speed Zero Logic determines the behavior of the drive when the motor is at zero speed. See the Speed Adaptive and Speed Zero Logic block diagram on page 325. Configuring the Speed Zero Logic It is possible to avoid drive creep when the motor is at zero speed by disabling the Integral section of the Speed regulator.
Application Notes Appendix C Set the P gain for zero speed: • If the P gain corresponds to the value set in Par 126 [Spd Zero P Gain], then set Par 125 [Spd Zero P En] = 1 “Enabled” • 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].
Appendix C Application Notes Speed Draw Example Configuration Drive A: • Set parameter 70 [Anlg In1 Sel] to 4 “Trim Speed” Drive B: • Set parameter 70 [Anlg In1 Sel] to 4 “Trim Speed” • Set parameter 75 [Anlg In2 Sel] to 22 “Speed Ratio” • Set parameter 1017 [Speed Ratio] to 10500 Drive C: • Set parameter 70 [Anlg In1 Sel] to 4 “Trim Speed” • Set parameter 75 [Anlg In2 Sel] to 22 “Speed Ratio” • Set parameter 1017 [Speed Ratio] to 11000 Speed / Torque Mode Selection Parameter 241 [Spd Trq Mode Sel] is u
Application Notes Appendix C 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 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.
Appendix C Application Notes 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.
Application Notes Appendix C 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.
Appendix C Application Notes 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 from an external controller and is approximately 60% 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.
Application Notes Appendix C 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 [Torque Ref ]). This mode can be used for applications that have precise speed changes with critical time constraints.
Appendix C Application Notes Start At Powerup 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 Powerup] must be set to 1 “Enable”. ATTENTION: Equipment damage and/or personal injury may result if this parameter is used in an inappropriate application.
Application Notes Fine Tuning the Regulators Appendix C 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.
Appendix C Application Notes 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.
Application Notes Appendix C 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, less than a revolution, is OK). 9. Stop the drive. Note: If a Speed Feedback Loss fault (F91) occurs, increase the value of Par 455 [Spd FB Loss Lvl] to its maximum value. a. If Par 587 [I Reg Err] is positive, increase the value of Par 454 [Arm Inductance].
Appendix C Application Notes 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. The procedure below is used for drives that use constant torque and power (mixed armature and field regulation).
Application Notes Appendix C 5. 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%. 6. 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.
Appendix C Application Notes Field Current Regulator Tuning Examples Figure 84 - Increase in the field current with oscillation Figure 86 - Increase in the field current without oscillation Non-optimal response of the regulator. Top: Par 500 [Flux Ref Pct] Bottom: Par 234 [Fld Current Pct] This graph, as compared to the graph in Figure C.5, shows an increase in [Fld Reg Kp] from 2% to 10% with [Fld Reg Ki] = 5%.
Application Notes Appendix C Fine Tuning the Speed Regulator Follow the procedure below to fine tune and optimize the speed regulator: 1. Configure the following Test Generator parameters: ❏ Set Par 58 [TstGen Output] = 4 “Ramp Ref ” ❏ Set Par 59 [TstGen Frequency] = 0.2 Hz ❏ Set Par 60 [TstGen Amplitude] = 10 % ❏ Set Par 61 [TstGen Offset] = 20 % 2. Measure the results on analog outputs 1 and 2 by setting: ❏ Par 66 [Anlg Out1 Sel] = 8 “Spd Reg Out” ❏ Par 67 [Anlg Out2 Sel] = 13 “Motor Curr”. 3.
Appendix C Application Notes [Spd Reg Kp] and [Spd Reg Ki] curves Figure 87 - [Spd Reg Kp] too low Figure 89 - [Spd Reg Ki] too high Top: Par 122 [Spd Feedback] Bottom: Par 199 [Arm Current Pct] Top: Par 122 [Spd Feedback] Bottom: Par 199 [Arm Current Pct] 20.00 ms/DIV 20.00 ms/DIV Figure 88 - [Spd Reg Kp] too high Figure 90 - [Spd Reg Ki] correct Top: Par 122 [Spd Feedback] Bottom: Par 199 [Arm Current Pct] Top: Par 122 [Spd Feedback] Bottom: Par 199 [Arm Current Pct] 20.
Application Notes Appendix C 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.
Appendix C Application Notes Field Voltage Regulator Tuning Examples Figure 91 - Field voltage oscillation Figure 93 - Optimal field regulation 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] After a short transient, the field current and armature voltage are constant. [Arm Volt Kp] = 40%, [Arm Volt Ki] = 5%.
Application Notes Appendix C 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 94 illustrates the relationship between flux and flux current when the field current curve is defined versus not defined. Complete the procedures in the order listed below when tuning the field current curve: • Field current regulator.
Appendix C Application Notes • 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. See the Current Regulator block diagram on page 326. Field Current Curve Tuning Procedure: 1. Reset the field current curve by setting Par 920 [Reset Fld Curve] to “1”. 2.
Appendix D Control Block Diagrams Topic PowerFlex DC Drive Overview Digital Inputs/Outputs (Standard and Expansion) Mapping Analog Inputs/Outputs Mapping Speed Reference Selection Speed Reference Generation Ramp Reference Block Speed Regulator Torque Mode Selection Droop Compensation - Inertia / Loss Compensation Speed Feedback Speed Regulator PI Block Speed Adaptive and Speed Zero Logic Current Regulator Field Current Regulator Motor Parameters Speed Threshold / Speed Control PID Control Scale Blocks Use
P1018 Speed Draw Out P385 Speed Ref Out P110 Ramp In Terminal Block 4 P569 Dig In Term 5 P570 Dig In Term 6 P571 Dig In Term 7 P572 Dig In Term 8 P565 Dig In Term 1 P566 Dig In Term 2 P567 Dig In Term 3 Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 P568 Dig In Term 4 P576 Dig In Term 12 P575 Dig In Term 11 P574 Dig In Term 10 P573 Dig In Term 9 Expansion I/O (8 ms) Error (0) OK (1) P651 Spd Fdbk State Above Threshold (0) Below Threshold (1) P393 Speed Threshold
DG4- DG4+ DG3- DG3+ DG2- DG2+ DG1- DG1+ Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 35 34 35 33 35 32 35 31 DG8- DG8+ DG7- DG7+ DG6- DG6+ DG5- DG5+ Terminal Block 4 16 15 16 14 16 13 16 12 Terminal Block 2 * * * * * * * F P1283 Inversion In 8 F P1282 Inversion In 7 F P1281 Inversion In 6 F P1280 Inversion In 5 F P1279 Inversion In 4 F P1278 Inversion In 3 F P1277 Inversion In 2 F P1276 Inversion In 1 Digital Inputs Digital In8 Se
Ref_1- Ref_1+ Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 6 5 P1406 Analog In3 Value Ref_3- Ref_3+ P1405 Analog In2 Value Ref_2- Ref_2+ Analog Input 3 4 3 Analog Input 2 P1404 Analog In1 Value 2 1 Analog Input 1 Terminal Block 1 Analog Inputs - + Σ HW input type P81 Anlg In3 Config HW input type - + Σ P84 Anlg In3 Offset - + Σ P82 Anlg In3 Scale Volts P83 Anlg3 Tune Scale P77 Anlg In2 Scale Volts P78 Anlg2 Tune Scale P72 Anlg In1 Scale Volts P7
Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 P80 Anlg In3 Sel P75 Anlg In2 Sel P70 Anlg In1 Sel P1375 MOP Select P80 Anlg In3 Sel P75 Anlg In2 Sel P70 Anlg In1 Sel P430 Resolver Spd Sel P1021 Encoder Out Sel P1375 MOP Select P1327 DPI P5 Select P1326 DPI P4 Select P1325 DPI P3 Select P1324 DPI P2 Select P48 Speed Ref B P49 Speed Ref B Pct P47 Speed Ref A Pct P44 Speed Ref A DPI Port 5 Reference DPI Port 4 Reference DPI Port 3 Reference DPI Port 2 Reference DPI Port 1
Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 From Speed Reference Selection Diagram P384 Spd Ref Out Pct P385 Spd Ref Out P42 Trim Ramp P378 Trim Ramp Pct Σ T P345 Zero Ramp Input Zero Speed t Ramp Reference (2 ms) T P344 Zero Ramp Output Zero Speed t P114 Ramp Out Pct P113 Ramp Out Speed Reference Generation P384 Spd Ref Out Pct P385 Spd Ref Out P111 Ramp In Pct P110 Ramp In Jog (P1328 Drive Logic Res, b2) Reverse Command (P381 Drive Status 1, b2) 0 On From Sp
P662 Decel Time 1 P32 Decel Time 2 P660 Accel Time 1 P24 Accel Time 2 P1410 Jog Ramp Time Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 P665 S Curve Accel 1 P667 S Curve Accel 2 Accel/Decel 1/2 Command (digital input) From Speed Reference Generation Diagram Ramp Reference Input P111 Ramp In Pct P110 Ramp In Σ P20 Ramp Delay 0 S-Shaped Linear t P666 S Curve Decel 1 P668 S Curve Decel 2 P18 Ramp Type Select P38 Fast Stop Time (2 ms) Fast Stop Ramping Function Ramp Referenc
Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 P447 Speed Up Filter P445 Spd Up Gain Pct Speed Feedback P430 Resolver Spd Sel P782 PID Target P1210 W Target P1021 Encoder Out Sel P1375 MOP Select P1327 DPI P5 Select P1326 DPI P4 Select P1325 DPI P3 Select P1324 DPI P2 Select P1323 DPI P1 Select P80 Anlg In3 Sel P75 Anlg In2 Sel P70 Anlg In1 Sel - Σ P923 Act Spd Filter Speed up 32 ms sampled average 0 0 P924 Actual Speed Inertia/Loss Off P1007 Droop Out Pct P100
Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 P1210 W Target P782 PID Target P1327 DPI P5 Select P1326 DPI P4 Select P1325 DPI P3 Select P1324 DPI P2 Select P1323 DPI P1 Select P80 Anlg In3 Sel P75 Anlg In2 Sel P70 Anlg In1 Sel From Speed Regulator Block Diagram From Speed Regulator Block Diagram Inertia Compensation Output P39 Torque Ref ++ MAX MIN 0.
P118 Speed Reg In P1210 W Target Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 P1014 Inertia P106 Ref Zero Level P236 Spd Reg Out Pct Speed P698 Load Comp P80 Anlg In3 Sel P782 PID Target From Digital Setting or Analog Input P75 Anlg In2 Sel P70 Anlg In1 Sel Σ P500 Flux Ref Pct P1015 Friction - + 1.
Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 P455 Spd FB Loss Lvl P175 Rated Motor Volt % Armature Voltage P121 Spd Feedback Pct 5% P478 Spd Loss Flt Cfg Resolver - + + Ref - + P162 Max Feedback Spd % Speed Speed Feedback Loss Alarm Enabled Digital Encoder P458 SpdReg FB Bypass (2 ms) AB+ 6 8 1 2 3 4 5 RefL 6 CosL CosH SinL Shld SinH Shld RefH +V COM Z- Z+ 7 8 2 7 4 3 B- A+ 5 1 + - Tach Motor DC Tachometer Speed Feedback Loss Fault (F9
P182 Adaptive Reg Type P181 Adaptive Spd En P117 Speed Reg In Pct P183 Adaptive Ref P1210 W Target P782 PID Target P80 Anlg In3 Sel P75 Anlg In2 Sel Speed Adaptive and Speed Zero Logic P460 SpdReg Ki Bypass P94 Spd Reg Ki Base P70 Anlg In1 Sel P459 SpdReg Kp Bypass P93 Spd Reg Kp Base Speed P / I Base Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 P189 Adaptive I Gain1 P191 Adaptive I Gain1 P193 Adaptive I Gain3 P88 Spd Reg Ki P1009 Spd Reg Fdbk Pct P1008 Spd Reg Fdbk
T Speed P123 Spd Zero I En Ramp Ref / Speed Ref Speed Zero Ref 0 level P106 Ref Zero Level P126 Spd Zero P Gain P193 Adaptive I Gain3 P192 Adaptive P Gain3 & t Lock speed I P108 Speed Zero Delay 0 > = & Speed Zero Logic P191 Adaptive I Gain2 P189 Adaptive I Gain1 P190 Adaptive P Gain2 P188 Adaptive P Gain1 P125 Spd Zero P En Gain & Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 & T >= T Lock speed I P185 Adaptive Spd 2 P184 Adaptive Spd 1 P124 Spd Ref Zero En
Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 T T Lim PosNeg Speed +1% of Max Feedback Spd Rev Brdg Cur Lim Fwd Brdg Cur Lim Torque Limit Mtr Gen -1% of Max Feedback Spd Fwd Brdg Cur Lim Rev Brdg Cur Lim To rq ue T Lim MtrGen P715 Torq Limit Type From Torque Mode Selection Block Diagram P1210 W Target P8 Current Lim Pos P782 PID Target To rq ue Rev Brdg Cur Lim Fwd Brdg Cur Lim Torque Reduction Speed dt di Σ T P342 Torque Reduction - + Torque Reduction Com
P233 Output Voltage P175 Rated Motor Volt P1210 W Target P782 PID Target P80 Anlg In3 Sel P75 Anlg In2 Sel P70 Anlg In1 Sel Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 P918 Fld Const 90 Pct P917 Fld Const 70 Pct I field curve P374 Rated Field Curr T _ + Σ P469 Field Mode Select Field Weaken P476 Field Curve Out P495 Arm Volt Kp Base P496 Arm Volt Ki Base Voltage Reg P / I Base P280 Nom Mtr Fld Amps Motor Base Speed / P45 Max Ref Speed x 100 P456 Fld Weaken Ratio P9
Output Voltage / Torque 328 Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 H (A2) P233 Output Voltage A (A1) P456 Fld Weaken Ratio P175 Rated Motor Volt P45 Max Ref Speed P453 Arm Resistance P199 Arm Current Pct P200 Arm Current P587 I Reg Error P454 Arm Inductance Note that P453 and P454 are gains for the current regulator and may not match the physical characteristics of the motor.
P118 Speed Reg In P122 Spd Feedback P122 Spd Feedback P102 Speed Thresh Neg P101 Speed Thresh Pos P105 At Speed Delay P103 Threshold Delay (2 ms) 0 0 t t Speed Threshold / Speed Control Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 P394 At Speed P104 At Speed Error P393 Speed Threshold [Digital Outx Sel] = 3 “At Speed” [Digital Outx Sel] = 2 “Spd Thresh” Control Block Diagrams Appendix D Speed Threshold / Speed Control 329
Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 - P429 Resolver Pos Sel P80 Anlg In3 Sel P75 Anlg In2 Sel P70 Anlg In1 Sel P763 PID Feedback P761 PID Setpoint 1 P760 PID Setpoint 0 P80 Anlg In3 Sel P75 Anlg In2 Sel P70 Anlg In1 Sel P786 PID Source Σ + P1254 PID Error Gain P762 PID Setpoint Sel P757 PID Clamp P763 PID Feedback P1047 PID Decel Time P1046 PID Accel Time P787 PID Source Gain Gain P759 PID Error Thr 2 Thr P695 PI Steady Thresh P766 PD Deriv Gain 1
Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 P561 Scale2 In Abs P492 Scale1 In Abs Σ Σ P559 Scale2 In Off + + P490 Scale1 In Off + + P558 Scale2 In Min P557 Scale2 In Max P489 Scale1 In Min P488 Scale1 In Max P555 Scale2 Mul P486 Scale1 Mul X X Note: Up to six scale blocks are available. Scale blocks 3-6 follow the same flow as scale blocks 1 and 2, shown here.
Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 P1284 Ref Spd Src P68 Anlg Out3 Sel P510 UserDefined7 General Parameters P511 UserDefined8 P1204 Line Spd Src P67 Anlg Out2 Sel P69 Anlg Out4 Sel P786 PID Source P66 Anlg Out1 Sel P504 UserDefined1 P503 UserDefined0 P1210 W Target P782 PID Target Analog Output Analog Input P80 Anlg In3 Sel P75 Anlg In2 Sel P70 Anlg In1 Sel Analog Input P512 UserDefined9 P505 UserDefined2 Target Param Source Param P513 UserDefined10 P506 U
Rockwell Automation Publication 20P-UM001I-EN-P - February 2013 P755 TrqTpr Lim4 P754 TrqTpr Lim3 P753 TrqTpr Lim2 P752 TrqTpr Lim1 P751 TrqTpr Lim0 P750 TrqTpr Enable Cur Lim Pos Out or Cur Lim Neg Out P756 TrqTpr Spd Taper Current Limits Motor Max Speed Control Block Diagrams Appendix D Taper Current Limits 333
User Defined Variable 334 X P51 UsrDsplyDiv0 P50 UsrDsplyMult0 Unit Scale Factor Unit Scaling X P53 UsrValMult1 P54 UsrValDiv1 User Value Factor Control Variable Appendix D Control Block Diagrams Unit Scaling Rockwell Automation Publication 20P-UM001I-EN-P - February 2013
Control Block Diagrams Appendix D Test Generator Speed Select Settings Test Generator P58 TstGen Output Generator Output P60 TstGen Amplitude P61 TstGen Offset Time P59 TstGen Frequency Speed Select Settings P402 Spd Select 2 P401 Spd Select 1 P400 Spd Select 0 Reference 0 0 0 P44 Speed Ref A 0 0 1 P48 Speed Ref B 0 1 0 P155 Preset Speed 2 0 1 1 P156 Preset Speed 3 1 0 0 P157 Preset Speed 4 1 0 1 P158 Preset Speed 5 1 1 0 P159 Preset Speed 6 1 1 1 P160 Preset Spee
Appendix D Control Block Diagrams Fault / Alarm Mapping “Arm Overvoltage” (F5) “Fld Current Loss” (F6) P203 OverVolt Flt Cfg P473 FldLoss Flt Cfg 0 = “Ignore” 1 = “Alarm” 2 = “Fault” “Auxiliary Input” (F2) 0 = “Ignore” 1 = “Alarm” 2 = “Fault” “Speed Fdbk Loss” (F91) P354 Aux Inp Flt Cfg P478 Spd Loss Flt Cfg 1 = “Alarm” 2 = “Fault” 3 = “Fast Stop” 4 = “Normal Stop” 5 = “CurrLim Stop” “Motor Over Temp” (F16) 1 = “Alarm” 2 = “Fault” “Motor Overload” (F7) P365 OverTemp Flt Cfg 0 = “Ignore” 1 =
Appendix E Installing a Communication Adapter Communication Adapter Kits The following Communication Adapter kits are available for use with the PowerFlex® DC drive: Comm Option BACnet® MS/TP RS-485 Communication Adapter ControlNet™ Communication Adapter (Coax) DeviceNet™ Communication Adapter EtherNet/IP™ Communication Adapter HVAC Communication Adapter PROFIBUS™ DP Communication Adapter ControlNet™ Communication Adapter (Fiber) Remote I/O Communication Adapter (1) RS-485 DF1 Communication Adapter Exte
Appendix E Installing a Communication Adapter Safety Precautions 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 that all power to the drive has been removed before performing the following.
Installing a Communication Adapter Appendix E 3. Remove the cover(s) from the drive: Frame A: a. Remove the screws that secure the bottom cover to the drive, then slide the cover down and off the drive chassis. = PORT MOD NET A NET B STS Disconnect DPI cable. b. 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.
Appendix E Installing a Communication Adapter Frames B and C a. 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. Frame B shown = Disconnect DPI cable. b. 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.
Installing a Communication Adapter Appendix E Frame D a. Loosen, but do not remove, the Hexalobular head screws that secure the cover, containing the HIM cradle, to the drive frame. Then, slide the cover up until the screw heads line up with the key holes and lift the cover off the chassis. IMPORTANT The HIM assembly is connected to the control board by a cable and therefore will not pull free from the drive until disconnected. See step 4 below for instructions. = Disconnect DPI cable. 4.
Appendix E Installing a Communication Adapter 5. 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 grounded through a screw to the EMI shield. Recommended tightening torque is 0.9 N•m (8 lb•in). 6. Connect the Internal Interface cable to the DPI connectors on the control board and the communication Adapter board. = Secure adapter to EMI Shield with four (4) screws.
Appendix F Optional Analog and Digital I/O Expansion Circuit Board What This Option Board Provides The optional I/O Expansion circuit board(1) is mounted on the control board of the drive and provides these additional I/O signals: • Four Digital Inputs • Four Digital Outputs • Two Analog Outputs This circuit board is catalog number 20P-S5V62.
Appendix F Optional Analog and Digital I/O Expansion Circuit Board Table 91 - I/O Expansion Board Terminal Block 1 Designations 1 2 3 4 5 6 7 8 9 No. 1 2 3 4 5 6 7 8 9 10 10 Signal Analog Output 3 (+) Analog Output 3 (–) Analog Output 4 (+) Analog Output 4 (–) Digital Output Common Digital Output 5 (+) Digital Output 6 (+) Digital Output 7 (+) Digital Output 8 (+) +24VDC Description ±10V, 5 mA maximum Factory Default 18 “Fld Current” Config.
Appendix G Optional 115V AC to 24V DC I/O Converter Circuit Board What This Option Board Provides The 115V AC to 24V DC I/O Converter circuit board(1) 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. This circuit board is catalog number 20P-S520L.
Appendix G Optional 115V AC to 24V DC I/O Converter Circuit Board I/O Converter Board Wiring Table 93 - Recommended Signal Wire Size Wire Type and Size Flexible (mm2) multi-core (mm2) 0.14…1.5 0.14…1.5 AWG 28…16 Tightening Torque N•m (lb•in) 0.4 (3.5) 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.).
Optional 115V AC to 24V DC I/O Converter Circuit Board Appendix G 115V AC to 24V DC I/O Board Main Control Board Figure 98 - I/O Converter Board with Internal Supply Wiring Diagram OPTO OPTO 15k 15k DC OUTPUT 24V 1 2 3 4 5 AC INPUT 6 7 8 0V 1 2 3 4 5 6 7 8 COM M_OUT M_IN To Digital Inputs (Terminals 12-15, 31-34) on Control Board To Drive Supplied +24V DC (Terminal 19) on Control Board To Digital Input Common (Terminal 16 or 35) and 24V Supply Common (Terminal 18) on Control Boar
Appendix G Optional 115V AC to 24V DC I/O Converter Circuit Board Notes: 348 Rockwell Automation Publication 20P-UM001I-EN-P - February 2013
Appendix H PowerFlex DC Standalone Regulator Installation This appendix contains installation information specific to the PowerFlex DC Standalone Regulator (SAR). The PowerFlex DC SAR and Gate Amplifier are currently sold through Rockwell Automation Drive Systems only. Consult the factory for availability. Installation and Wiring Instructions Complete the following for SAR installation and configuration: 1.
Appendix H PowerFlex DC Standalone Regulator Installation Notes: 350 Rockwell Automation Publication 20P-UM001I-EN-P - February 2013
Appendix I History of Changes This appendix summarizes the revisions to this manual. Reference this appendix if you need information to determine what changes have been made across multiple revisions. This may be especially useful if you are deciding to upgrade your hardware or firmware based on information added with previous revisions of this manual. 20P-UM001H-EN-P, April 2011 Change Add the kW ratings to the Standard Drive Catalog Number Explanation.
Appendix I History of Changes 20P-UM001G-EN-P, October 2010 Change Added the 575V AC input, frame B & C drives and 690V AC input, frame C drives to the Standard Drive Catalog Number Explanation. Added the Standalone Regulator catalog numbers. Added the 575V AC input drives to Table 2 “Frame B Weights”. Added the 690V AC input drives to Table 3 “Frame C Weights”. Updated the frame D dimensions. Updated installation information regarding use of isolation transformers and line reactors.
History of Changes 20P-UM001F-EN-P, June 2009 20P-UM001E-EN-P, November 2008 Appendix I Change Updated the Catalog Number Explanation to reflect new drive ratings. Added frame D dimensions and weights. Added lifting instructions for frame D drives. Added instructions for opening frame D drives. Added CE Conformity information for frame D drives and updated the emissions limits table. Added Control Power Protection information for frame D drives and updated information for rev.
Appendix I History of Changes Change Updated the maximum value of Par 45 [Max Ref Speed]. Updated the maximum value for Par 162 [Max Feedback Spd]. Added parameter 376 [MtrOvrld Type] to the Motor Control file, Motor Data group. Added parameter 462 [Flux Divide] to the Motor Control file, Field Config group. Added parameter 463 [Flux Filter BW] to the Motor Control file, Field Config group. Changed the name of parameter 926 from [Filt Torq Cur] to [Torq Cur Filter].
Index Numerics 115V AC to 24V DC I/O converter board catalog number 345 2-wire control non-reversing 81 reversing 81 3-wire control 81, 82 A AC input contactors configure 31 recommended 238 AC input line reactors recommended 238 AC input voltage 45 AC Line Freq 123 AC Line Voltage 123 AC Undervoltage fault 202 Acc Dec Filter 160 Accel Mask 176 Accel Owner 176 Accel Status 158 Accel Time 1 146 Accel Time 2 145 access S.M.A.R.T.
Index Anlg In3 Filter 180 Anlg In3 Offset 180 Anlg In3 Scale 179 Anlg In3 Sel 179 Anlg In3 Target 180 Anlg In3 Tune 180 Anlg Out1 Scale 181 Anlg Out1 Sel 182 Anlg Out2 Scale 181 Anlg Out2 Sel 182 Anlg Out3 Scale 181 Anlg Out3 Sel 182 Anlg Out4 Scale 181 Anlg Out4 Sel 182 Anlg Tach Gain 133 Anlg1 Tune Scale 179 Anlg2 Tune Scale 179 Anlg3 Tune Scale 179 Applications file 150 Arm Current 121 Arm Current Pct 121 Arm Inductance 134 Arm Resistance 134 Arm Test Angle 137 Arm Volt Ki 143 Arm Volt Ki Base 143 Arm V
Index configure AC input contactor 31 analog inputs 262 DC output contactor 31 dynamic brake resistor 31 feedback signal 277 Klixon 62 line speed signal 276 programmable controller 217 PTC 62 start at powerup 300 tension set point signal 279 thermal switch 62 thermistor 62 Connected Components Workbench 109 Constant J Comp 157 Contactor Conflict alarm 206 ContactorControl 185 contactors AC input 238 configure 31 DC output 243 control block diagrams 313 control circuit input power 65 Control Config group 14
Index Dig In Status 185 Dig In Term 1 185 Dig In Term 10 185 Dig In Term 11 185 Dig In Term 12 185 Dig In Term 2 185 Dig In Term 3 185 Dig In Term 4 185 Dig In Term 5 185 Dig In Term 6 185 Dig In Term 7 185 Dig In Term 8 185 Dig In Term 9 185 Dig Out Status 188 Digital In1 Sel 183 Digital In10 Sel 183 Digital In11 Sel 183 Digital In12 Sel 183 Digital In2 Sel 183 Digital In3 Sel 183 Digital In4 Sel 183 Digital In5 Sel 183 Digital In6 Sel 183 Digital In7 Sel 183 Digital In8 Sel 183 Digital In9 Sel 183 Digita
Index drive will not start 208 DriveExplorer 89, 109 DriveTools SP 89, 109 droop compensation 271 Droop Filter 146 Droop Limit 147 Droop Out 120 Droop Out Pct 120 Droop Percent 146 Drv Fld Brdg Cur 124 Dsp Error fault 202 dynamic brake resistor configure 31 recommended 243 using 32 Dynamic Control file 144 Dynamic Friction 157 E edit parameters 256 EEPROM Error fault 202 Elapsed Lifetime 122 electrostatic discharge precaution 14 EMC Directive Installation Requirements 41 EMC Filters Alternates 247 Alterna
Index faults AC Undervoltage 202 Arm Overvoltage 202 Auxiliary Input 202 clear 201 descriptions 202 Drive Overload 202 Dsp Error 202 EEPROM Error 202 Encoder Error 202 Fld Current Loss 202 Hardware Fault 202 Heatsink OvrTemp 203 Interrupt Error 203 Inverting Fault 203 Main Contactor 203 Motor Over Temp 203 Motor Overload 203 No Fault 203 Overcurrent 203 Overspeed 203 Params Defaulted 203 Port 1 Adapter 204 Port 1 DPI Loss 204 Port 2 Adapter 204 Port 2 DPI Loss 204 Port 3 Adapter 204 Port 3 DPI Loss 204 Por
Index functions adaptive speed regulator 287 ALT key 252 current/speed curve 264 droop 271 PID 279 scale blocks 286 speed draw 293 speed regulation 287 speed threshold indicators 291 speed up 290 speed zero 292 fuses control power circuit 43 frame A 219 frame B 219 frame C 225 frame D 225 input power circuit 43, 219 overvoltage clipping circuit board, frame D 237 pulse transformer circuit board, frame B 235 Switching Power Supply circuit board 233 transient noise filter circuit board, frame C 236 G Gear B
Index Inversion Out 2 188 Inversion Out 3 188 Inversion Out 4 188 Inversion Out 5 188 Inversion Out 6 188 Inversion Out 7 188 Inversion Out 8 188 Inversion Relay1 189 Inversion Relay2 188 Inverting Fault 203 isolation transformer configuration 30 using 30 Isolation Transformers 241 J Jog Mask 176 Jog Off Delay 139 Jog Owner 176 Jog Ramp Time 146 Jog Speed 138 Jog TW Enable 160 Jog TW Speed 160 joystick wiring 80 jumper SA-SB 65 K kits communication adapter 337 Klixon configure 62 L Language 163 Last Sto
Index MOP Select 163 Motor Control file 123 Motor Data group 123, 124 motor not reaching commanded speed 209 motor not turning 209 Motor Over Temperature alarm 207 Motor Over Temperature fault 203 Motor Overload alarm 207 Motor Overload fault 203 motor reaches maximum speed immediately 210 Motor Trq Ref 121 motor turning wrong direction 209 mounting dimensions 19 drive 18 lifting 25 weights 19 MtrOvrld Flt Cfg 171 MtrOvrld Status 167 MtrOvrld Type 124 N NET A LED 200 NET B LED 200 Nom Mtr Arm Amps 123 Nom
Index parameters AC Line Freq 123 AC Line Voltage 123 Acc Dec Filter 160 Accel Mask 176 Accel Owner 176 Accel Status 158 Accel Time 1 146 Accel Time 2 145 Act Spd Filter 134 Act Ten Ref Pct 159 Actual Comp 160 Actual Speed 120 Actuator Delay 147 Adaptive I Gain1 149 Adaptive I Gain2 149 Adaptive I Gain3 149 Adaptive Joint 1 148 Adaptive Joint 2 148 Adaptive P Gain1 148 Adaptive P Gain2 149 Adaptive P Gain3 149 Adaptive Ref 148 Adaptive Reg Typ 148 Adaptive Spd 1 148 Adaptive Spd 2 148 Adaptive Spd En 148 A
Index Diam Preset Sel 156 Diam Stdy Delay 157 Diam Threshold 155 Diameter Calc 154 Diameter Calc St 155 Diameter Filter 156 Diameter Reached 155 Diameter Reset 155 Dig In Status 185 Dig In Term 1 185 Dig In Term 10 185 Dig In Term 11 185 Dig In Term 12 185 Dig In Term 2 185 Dig In Term 3 185 Dig In Term 4 185 Dig In Term 5 185 Dig In Term 6 185 Dig In Term 7 185 Dig In Term 8 185 Dig In Term 9 185 Dig Out Status 188 Digital In1 Sel 183 Digital In10 Sel 183 Digital In11 Sel 183 Digital In12 Sel 183 Digital
Index FldLoss Flt Cfg 171 Flux Current Pct 122 Flux Divide 125 Flux Filter BW 125 Flying Start En 142 Force Min Field 126 Freeze Ramp 145 Friction 135 Gear Box Ratio 154 I Reg Error 134 Inertia 135 Inertia C Filter 134 Inertia Comp Out 122 InertiaCompCnst 159 InertiaCompVar 159 Initial Diameter 158 Int Acc Calc En 158 Inversion In 1 185 Inversion In 10 185 Inversion In 11 185 Inversion In 12 185 Inversion In 2 185 Inversion In 3 185 Inversion In 4 185 Inversion In 5 185 Inversion In 6 185 Inversion In 7 18
Index PID Setpoint 1 152 PID Setpoint Sel 152 PID Source 154 PID Source Gain 154 PID Steady Delay 150 PID Target 153 Port Mask Act 178 Powerup Delay 148 Preset Speed 1 138 Preset Speed 2 138 Preset Speed 3 138 Preset Speed 4 138 Preset Speed 5 138 Preset Speed 6 138 Preset Speed 7 138 Ramp Delay 145 Ramp In 119 Ramp In Pct 119 Ramp In Zero En 147 Ramp Out 119 Ramp Out Pct 119 Ramp Select 0 167 Ramp Select 1 167 Ramp Type Select 144 Rated Motor Volt 123 Real FF PID 152 Ref Line Spd 161 Ref Spd Source 161 Re
Index Spd Reg Ki Base 139 Spd Reg Ki Outpt 140 Spd Reg Kp 139 Spd Reg Kp Base 139 Spd Reg Kp Outpt 140 Spd Reg Neg Lim 140 Spd Reg Out Pct 122 Spd Reg P Fil 142 Spd Reg Pos Lim 139 Spd Select 0 167 Spd Select 1 167 Spd Select 2 167 Spd Trq Mode Sel 144 Spd Tune Inertia 135 Spd Up Gain Pct 142 Spd Zero I En 141 Spd Zero P En 141 Spd Zero P Gain 142 SpdFuncSelect 143 SpdOut FiltBW 142 SpdOut FiltGain 142 SpdReg AntiBckup 143 SpdReg FB Bypass 133 SpdReg Ki Bypass 143 SpdReg Kp Bypass 143 SpdReg NegLmOut 121 S
Index UsrDefBitWrdA7 174 UsrDefBitWrdA8 174 UsrDefBitWrdA9 174 UsrDefBitWrdB 174 UsrDefBitWrdB0 175 UsrDefBitWrdB1 175 UsrDefBitWrdB10 175 UsrDefBitWrdB11 175 UsrDefBitWrdB12 175 UsrDefBitWrdB13 175 UsrDefBitWrdB14 175 UsrDefBitWrdB15 175 UsrDefBitWrdB2 175 UsrDefBitWrdB3 175 UsrDefBitWrdB4 175 UsrDefBitWrdB5 175 UsrDefBitWrdB6 175 UsrDefBitWrdB7 175 UsrDefBitWrdB8 175 UsrDefBitWrdB9 175 UsrDsplyDiv0 172 UsrDsplyMult0 172 UsrValDiv1 173 UsrValMult1 172 Variable J Comp 157 view 256 W Offset 159 W Reference
Index power wiring 45 AC input contactor 47 armature output terminals 50 armature voltage feedback terminals 53 contact terminals 62 DC output contactor 48 diagrams 46 dynamic brake 49 field input terminals 56 field output terminals 56 motor thermistor terminals 62 normally open contact terminals 62 PE (earth ground) terminal 50 Powerup Delay 148 preferences set 256 Preset Speed 1 138 Preset Speed 2 138 Preset Speed 3 138 Preset Speed 4 138 Preset Speed 5 138 Preset Speed 6 138 Preset Speed 7 138 programma
Index Scale2 In Abs 162 Scale2 In Max 162 Scale2 In Min 162 Scale2 In Off 162 Scale2 Input 161 Scale2 Mul 162 Scale2 Out Off 162 Scale2 Output 161 Scale3 Div 162 Scale3 In Abs 162 Scale3 In Max 162 Scale3 In Min 162 Scale3 In Off 162 Scale3 Input 161 Scale3 Mul 162 Scale3 Out Off 162 Scale3 Output 161 Scale4 Div 162 Scale4 In Abs 162 Scale4 In Max 162 Scale4 In Min 162 Scale4 In Off 162 Scale4 Input 161 Scale4 Mul 162 Scale4 Out Off 162 Scale4 Output 161 Scale5 Div 162 Scale5 In Abs 162 Scale5 In Max 162 S
Index specifications agency certifications 212 control 213 DC contactor crimp lug kits 244 electrical 213 environment 212 protection 212 Speed Command file 138 Speed Demand En 160 speed draw function 293 Speed Draw Out 121 Speed Feedback 120 Speed Feedback Error alarm 207 Speed Feedback group 129, 130, 131, 132, 133, 134 Speed Feedback Loss alarm 207 Speed Feedback Pct 120 Speed Match 159 Speed Meters group 119, 120, 121 speed pot 80 Speed Ramp En 145 Speed Ratio 139 Speed Ref A 119 Speed Ref A Pct 119 Spe
Index temperature drive 18 Tension Reduct 158 Tension Ref 158 Tension Scale 158 tension set point signal configure 279 terminal adapter kits frame D 250 terminal blocks analog tachometer 85 armature converter, frame A 50 armature converter, frame B 51 armature converter, frame C 51 armature converter, frame D 52 armature voltage feedback, frame A 54 armature voltage feedback, frame B 54 armature voltage feedback, frame C 55 armature voltage feedback, frame D 55 control circuit power 65 encoder 83 field, fr
Index UsrDefBitWrdA4 174 UsrDefBitWrdA5 174 UsrDefBitWrdA6 174 UsrDefBitWrdA7 174 UsrDefBitWrdA8 174 UsrDefBitWrdA9 174 UsrDefBitWrdB 174 UsrDefBitWrdB0 175 UsrDefBitWrdB1 175 UsrDefBitWrdB10 175 UsrDefBitWrdB11 175 UsrDefBitWrdB12 175 UsrDefBitWrdB13 175 UsrDefBitWrdB14 175 UsrDefBitWrdB15 175 UsrDefBitWrdB2 175 UsrDefBitWrdB3 175 UsrDefBitWrdB4 175 UsrDefBitWrdB5 175 UsrDefBitWrdB6 175 UsrDefBitWrdB7 175 UsrDefBitWrdB8 175 UsrDefBitWrdB9 175 UsrDsplyDiv0 172 UsrDsplyMult0 172 UsrValDiv1 173 UsrValMult1 1
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