User Manual PowerFlex Digital DC Drive PowerFlex DC Drive V1.006…6.002, PowerFlex DC Standalone Regulator V1.006…6.
Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
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 the Maximum Surrounding Air Temperature Specifications. 18 Updated the frame B drive dimensions to include a different depth dimension for certain catalog numbers. 20 Updated the Typical Power Wiring Diagrams to illustrate connections for bother series A and series B frame D fans.
Summary of Changes 4 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014
Table of Contents Preface Drive Storage Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Nameplate Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Series Letter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Firmware Version . . . . . . . . . . . . . . . . .
Table of Contents Installation Requirements Related to EN 61800-3 and the EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pollution Degree Ratings According to EN 61800-5-1 . . . . . . . . . . Power Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Power Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable and Wiring Recommendations . . . .
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 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. . . . . . . . . . . . . . . . . Isolation Transformers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Lifting/Torque Proving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 Tuning The Motor For Torque Prove Applications . . . . . . . . . . . . 291 Crane Setup with Encoder/Resolver Feedback . . . . . . . . . . . . . . . . . 291 Crane Setup - Encoderless. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 Manually Tuning the Speed Regulator for Firmware Version 6.xxx . . 301 PID Function. . . . . . . . . . . . . . . . . . . . . .
Table of Contents Appendix D Control Block Diagrams Diagram Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343 Appendix E Installing a Communication Adapter Communication Adapter Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 What The Communication Adapter Kit Includes . . . . . . . . . . . . . . . . . . Tools That You Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preface Topic Drive Storage Conditions Drive Nameplate Data Drive Specifications Extra Resources Technical Support Conventions General Precautions Standard Drive Catalog Number Explanation Standalone-Alone Regulator Catalog Numbers Page 11 12 12 13 13 13 14 15 16 The purpose of this manual is to provide you with the basic information required 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 on the side of each drive. This nameplate identifies the specific model number, applicable AC input power, and DC output power data. Include this information when communicating with Rockwell Automation personnel about this product. Cat No. 20P41AD4P1RA0NNN UL Type OPEN/IP20 Series: A Input: 460VAC 50/60 Hz 3.3A 3 Phase I/O: 24VDC (Standard) Original Firmware V. 1.001 N223 EO Output: 500VDC 4.1A REGEN 2.0HP 1 Min Overload Amps 6.
Preface Extra Resources These documents contain more information on 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, 8000-4.5.2 Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.
Preface General Precautions ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when you install, test, service, or repair this assembly. If ESD control procedures are not followed, component damage can result. If you are not familiar with static control procedures, see 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 Communication Option Kits on page 10.
Chapter 1 Installation and Wiring Topic Page Topic Page Mount the Drive 18 CE Conformity 39 Approximate Drive Dimensions and Weights 19 Power Circuit Protection 42 Lifting PowerFlex DC Drives 25 Control Power Circuit Protection 42 Remove the Drive Covers 27 Cable and Wiring Recommendations 43 Isolation Transformers / Line Reactors 29 Power Wiring 44 Contactors 30 DIP Switch and Jumper Settings 75 General Grounding Requirements 32 I/O Wiring 80 This chapter provides informa
Chapter 1 Installation and Wiring Operating Conditions and Temperatures Mount the Drive 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 clearances to provide proper drive operation. ATTENTION: Remove all loose packing materials, including the containers of desiccants (if any), from the drive enclosure before you mount and energize the drive. Figure 2 - Frame A Drive Dimensions A B C A1 A2 B1 mm (in.) mm (in.) 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 C1 C2(1) mm (in.) 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) 380 (15.0) (1) Only frame B drive catalog numbers 20P21AD330, 20P21AD412, 20P21AE405, 20P41AB360, 20P41AB434, 20P41AD330, 20P41AD412, 20P41AE405. A A1 C1 C2 PORT MOD NET A NET B STS B1 B A3 A2 Terminal Details Dimensions in mm (in.
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) Ø 23 (0.9) 129 (5.1) 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) 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 and Packaging Drive Drive and 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 that are specified in Table 3 on page 21 and Table 4…Table 7 on page 24 must be considered when mounting the device. Use the proper equipment to 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 - Lift Frame C Drives Must be less than 45° angle Lifting flanges Figure 8 - Lift Frame D Drives Must be less than 45° angle 4. Lift the drive into place onto the bolts that are 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).
Installation and Wiring Remove the Drive Covers Chapter 1 Some protective covers must be removed to provide access to the power and I/O terminals on the drive. Remove the upper cover only to install an optional communication adapter or service the drive. See Installing a Communication Adapter on page 367 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.
Chapter 1 Installation and Wiring Remove the Lower Protective Cover • Remove the two screws as shown here 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 1. Loosen, but do not remove, the two screws that secure the bottom cover. 2. Slide the cover down until the screw heads align with the key holes and lift the cover off the chassis.
Installation and Wiring Chapter 1 Frame D 1. For any protective cover, loosen, but do not remove, the hexalobular head screws that secure the cover to the drive frame. 2. Slide the cover up until the screw heads align with the key holes and lift the cover off the chassis. The top and bottom most covers are also secured with screws at the top and bottom of the drive, respectively.
Chapter 1 Installation and Wiring Contactors When an AC input contactor is used, the IEC AC1 rating of the contactor must be equal to the rated thermal (RMS) current value at the main input of the drive.
Installation and Wiring Chapter 1 When operating a drive with firmware version 1.006 in field weakening mode with a DC contactor or inverting fault device that is installed in the armature circuit, see Field Weakening Mode Configuration (v1.006) on page 285. AC Input Contactors See AC Input Line Reactors and AC Input Contactors on page 254 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.
Chapter 1 Installation and Wiring General Grounding Requirements The drive Safety Ground (PE) must be connected to system ground. Ground impedance must conform to the requirements of national and local industrial safety regulations and electrical codes. Periodically check the integrity of all ground connections. For installations within a cabinet, use a safety ground point or ground bus bar connected directly to building steel.
Installation and Wiring Chapter 1 Safety Ground (PE) 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 Figure 9 on page 32). Ground points must comply with national and local industrial safety regulations and electrical codes. Power Feeder Each power feeder from the substation transformer to the drive must be provided with properly sized ground cables.
Chapter 1 Installation and Wiring Grounding for Installations in an Ungrounded or HighImpedance, Neutral Ground, or System 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 that is referenced to earth.
Installation and Wiring Chapter 1 Figure 12 - High-impedance Ground Grounding the Wye secondary neutral through a resistor is an acceptable method of grounding. In this case, in a short-circuited secondary condition, none of the output phases to ground will exceed the normal line to line voltage. The resistor is often used to detect ground current by monitoring the associated voltage drop.
Chapter 1 Installation and Wiring Figure 14 - Frame B Pulse Transformer Circuit Board S9 Jumper Location Note: Remove the front covers from the drive to access the pulse transformer circuit board. See page 28 for instructions.
Installation and Wiring Chapter 1 Figure 16 - Frame C Transient Noise Filter Circuit Board (FIL-31), 200V…500V AC Input Drives, Ground Wire Location Note: Remove the front covers from the drive to access the transient noise filter circuit board. See page 28 for instructions. The transient noise filter board is between terminals C and D below the control EMI shield.
Chapter 1 Installation and Wiring Figure 18 - Frame D Pulse Transformer Circuit Board S1 Jumper Location Note: The pulse transformer circuit board is behind the top and bottom control panel covers. See page 29 for instructions on removing the covers from the drive.
Installation and Wiring CE Conformity Chapter 1 Compliance with the Low Voltage Directive and Electromagnetic Compatibility Directive has been demonstrated by using harmonized European Norm (EN) standards, references to which have been published in the Official Journal of the European Communities. PowerFlex DC drives comply with the EN standards listed here when installed according to this User Manual. EU Declarations of Conformity are available online at: www.rockwellautomation.
Chapter 1 Installation and Wiring Installation Requirements Related to the Low Voltage Directive • PowerFlex DC drives are designed to be CE compliant only if they are NOT connected to “corner-earthed” supply systems where one of the three phases of the supply system has been earthed. • PowerFlex DC drives are compliant with the CE LV Directive when used at altitudes no greater than 2,000 m (6,562 ft).
Installation and Wiring IMPORTANT Chapter 1 Use of EMC filters other than those listed in Table 9 on page page 40 must be verified in the application. Additional filters are listed in Alternate EMC Filters on page 261. • 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.
Chapter 1 Installation and Wiring 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 236 for a list of replacement fuses and general fuse locations.
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.
Chapter 1 Installation and Wiring 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.
Installation and Wiring Chapter 1 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 47 on page 68 for terminal block location on frame B drives and Figure 48 on page 68 for terminal block location on frame C drives.
L3 3 Phase L2 AC line L1 Lockable Installation Disconnect EMC Filter (if used) Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 400...460V AC Input Source (12) 230V AC Input Source (12) 115V or 230V AC (1, 12) Input Source Safety Ground Isolation (2) Transformer See footnote (13) (13) See footnote (2) Line Reactor AC Input Voltage FU FU FU FU FU K1 (14) A2 A1 K1 T3 L3 (14) T2 T1 L1 L2 14 13 Aux (N.O. Relay) M1 AC Contactor K1 (14) 460 VAC Max.
L3 3 Phase L2 AC line L1 Lockable Installation Disconnect Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 400...460V AC Input Source (12) 230V AC Input Source (12) See footnote (13) (13) (2) Line Reactor See footnote EMC Filter (if used) 115V or 230V AC (1, 12) Input Source Safety Ground Isolation (2) Transformer FU FU FU FU FU K1 (14) AC Input Voltage FS1 (3) FS1 (3) (3) FS1 460 VAC Max. or 230 VAC (11) Min.
L3 3 Phase L2 AC line L1 Lockable Installation Disconnect EMC Filter (if used) Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 400...460V AC Input Source (12) 230V AC Input Source (12) (13) (13) See footnote See footnote 115V or 230V AC (1, 12) Input Source Safety Ground Isolation (2) Transformer (2) Line Reactor FU FU FU FU FU K1 (14) (3) (3) AC Input Voltage FS1 FS1 FS1 (3) 460 VAC Max. or 230 VAC (11) Min.
Installation and Wiring Chapter 1 Power Wiring Diagrams Notes 1. For frame B and C drives only, a jumper is required between terminals SA and SB for 115V AC control input power. See Control Circuit Input Power on page Control Circuit Input Power for more information. 2. An Isolation Transformer and/or 3…5% impedance Line Reactor is required. If the Isolation Transformer provides the required 3…5% impedance, a Line Reactor is not required.
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 11 - 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 24 - Frame B Armature Converter Terminal Locations PE U C V D W Figure 25 - Frame C Armature Converter Terminal Locations Front View PE U C V D W Bottom View Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 51
Chapter 1 Installation and Wiring Figure 26 - 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 264 for details.
Installation and Wiring Chapter 1 Armature Voltage Feedback Connections When a DC output contactor or inverting fault breaker or 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 27 - 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 28 - 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 29 - Frame C Armature Voltage Feedback Circuit Terminal Block Location Bottom of Drive Figure 30 - 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 and 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 15 - 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 32 - Frame B Field Circuit Terminal Block Location U1 V 1C 1 D1 Top of Drive Figure 33 - 230V/460V AC Input Frame C Field Circuit Terminal Block Location Front of Drive D1 C1 U1 V1 58 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014
Installation and Wiring Chapter 1 Figure 34 - 575V/690V AC Input Frame C Field Circuit Terminal Block Location Top, Left Side of Drive Figure 35 - Frame D Field Circuit Terminal Block Location Top of Drive Wire routing hole Cable clamp 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 75 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 16 - 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 Contactors on page 30 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 19 - Relay Outputs and Thermistor/Thermal Switch Wire Sizes and Specifications Signal Type Wire Size and Type(1) Terminals Relay Outputs 35 & 36, 75 & 76 Thermistor and Thermal Switches 78 & 79 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 43 for more information.
Chapter 1 Installation and Wiring Figure 39 - 230V/460C AC Input Frame C Relay and Thermistor/Thermal Switch Terminal Block Locations 35 36 75 76 78 79 Figure 40 - 575V/690C AC Input Frame C Relay and Thermistor/Thermal Switch Terminal Block Locations Lower, right side of the control pan.
Installation and Wiring Chapter 1 Figure 41 - Frame D Relay and Thermistor/Thermal Switch Terminal Block Locations 78 79 35 36 75 76 Control pan, to the left of the HIM cradle. Control Circuit Input Power The control circuit must be powered by a clean, 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 47 on page 68.
Chapter 1 Installation and Wiring Figure 42 - Frame A Control Circuit Terminal Block Location U2 V2 Figure 43 - Frame B Control Circuit Terminal Block Location U2 V2 Figure 44 - 230V/460V AC Input Frame C Control Circuit Terminal Block Location U2 66 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 V2 PE
Installation and Wiring Chapter 1 Figure 45 - 575V/690V AC Input Frame C Control Circuit Terminal Block Location Lower, right side of the control pan.
Chapter 1 Installation and Wiring Figure 47 - SA-SB Terminal Block Location on Frame B Drives Top, right side of drive. Front of Drive Figure 48 - SA-SB Terminal Block Location on Frame C Drives The SA-SB terminal block is 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. Remove the top protective cover from the drive. 3.
Installation and Wiring Chapter 1 Frame C Heatsink Cooling Fan Specifications Frame C drives require an external 230V AC power supply for the heatsink cooling fans. If sourced from the main 3 phase AC input, the power supply connections must be taken from the primary side of the installed Isolation Transformer or Line Reactor (clean power). In addition, 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 or fuses.
Chapter 1 Installation and Wiring Figure 49 - 230V/460V AC Input Frame C Heatsink Cooling Fan Terminal Block Location U3 V3 Figure 50 - 575V/690V AC Input Frame C Heatsink Cooling Fan Terminal Block Location Lower, right side of the control pan.
Installation and Wiring Chapter 1 Frame D, Series B Heatsink Cooling Fan Specifications The Frame D, series B drive cooling fan requires three phase (50/60 Hz), 400…460V AC input power. If sourced from the main 3 phase AC input, the power supply connections must be taken from the primary side of the installed isolation transformer or line reactor (clean power). IMPORTANT When connecting the fan power wiring, verify that the airflow exits through the top of the drive.
Chapter 1 Installation and Wiring Table 23 - Frame D, Series B Heatsink Cooling Fan Terminal Designations Terminal Block Terminal Description AC Voltage Max Current U3 Three-phase AC input power connections 400…460V AC (50/60 Hz) 1.
Installation and Wiring Chapter 1 Frame C and D Armature Fuse Signal Terminals Terminals 81 and 82 on frame C and D drives are connected to the indicating switch mounted on each of the internal armature circuit protection fuses. These terminals 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).
Chapter 1 Installation and Wiring Figure 53 - 575V/690V AC Input Frame C Internal Armature Fuse Signal Terminal Block Location Lower, right side of the control pan.
Installation and Wiring DIP Switch and Jumper Settings Chapter 1 DIP switches and jumpers on the control circuit board are used to configure the drive for flashing firmware to the control board EEPROM, the appropriate speed feedback device settings, analog input signals and minimum field current. Figure 55 - Control Circuit Board DIP Switch and Jumper Locations See Table 27 on page 76 for descriptions corresponding to the ID numbers shown here.
Chapter 1 Installation and Wiring Table 27 - 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.
Installation and Wiring Chapter 1 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.
Chapter 1 Installation and Wiring Table 29 - 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
Installation and Wiring Chapter 1 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
Chapter 1 Installation and Wiring Table 32 - 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
Installation and Wiring Chapter 1 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 89 for information on routing I/O signal and control wires.
Chapter 1 Installation and Wiring Table 35 - 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”.
Installation and Wiring Chapter 1 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 80 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 80 for important bipolar wiring information.
Chapter 1 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 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.
Installation and Wiring Input/Output Connection Example 3-Wire Control Stop 24V DC external supply Requires 3-wire functions only ([Digital In1 Sel]). configuring 2-wire selections will cause a type 2 Start alarm (see page 224).
Chapter 1 Installation and Wiring Digital Encoder Terminal Block Always connect the encoder connection cables 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.
Installation and Wiring Chapter 1 Figure 60 - 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 59 on page 86.
Chapter 1 Installation and Wiring DC Analog Tachometer Terminal Block Figure 62 - Analog Tachometer Terminal Block Location Analog Tachometer terminal block See the PowerFlex Digital DC Drive Technical Data, publication 20P-TD001, 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.
Installation and Wiring Chapter 1 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 1 Installation and Wiring Notes: 90 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014
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 Remove the Drive Covers on page 27), verify that DIP switch S14 is set correctly to be ≥ the rated field current specified on the motor nameplate. See Table 16 on page 61. 2. Verify all switch settings (S9, S10, and S11) for the analog inputs. See Table 27 on page 76. 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 63 - Drive Status Indicators PORT MOD NET A NET B 2 1 STS # Name 1 STS (Status) 2 PORT MOD NET A NET B 94 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 81: 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 279 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 63 on page 94 for more information.
Chapter 2 Drive Start Up Figure 64 - 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 103. 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 105. For all other motors, continue with Configure the Speed Feedback Parameters on page 106. 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 279 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 310 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 If upgrading a drive to version 6.xxx firmware (from version 5.xxx or earlier) and it is not possible to perform speed regulator autotuning, see Appendix C, Manually Tuning the Speed Regulator for Firmware Version 6.
Drive Start Up Chapter 2 3. Select Par 1027 [Spd Reg Autotune] and enter “1.” 4. Press Enter. 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].
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 331. Fault STune Overspeed No.
Chapter 2 Drive Start Up For additional regulator fine tuning procedures, see Fine Tuning the Regulators on page 331. 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 320 for more information. Configuring the Speed Zero Logic The speed zero logic is factory set to 0 “Disabled”. See Speed Zero Function on page 322 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 113 115 123 128 145 151 157 173 187 191 203 209 This chapter provides a complete listing of the PowerFlex DC drive parameters.
Chapter 3 Programming and Parameters No. 1 2 3 4 5 6 7 114 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] [MOP Ref Config] 210 249 [MOP Select] 1375 Drive Memory [Param Access Lvl] 211 [Reset Defaults] 258 [Language] 302 Diagnostics [Drive Status 1] [Drive Status 2] [Speed Ref Source] [Spd Ref Sel Sts] 381 382 1329 1330 [Last Stop Source] [Start Inhibits] [Drive Logic Rslt] [At Speed] 1402 1403 1328 394 [At Zero Speed] [CurrLimit Active] [Spd Limit Active]
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] [Spd Reg Kp] [Spd Reg Ki] [Total Inertia] [Spd Reg BW] [Act Spd Reg BW] [Spd Reg Damping] [Spd Reg Kp Outpt] [Spd Reg Ki Outpt] [Spd Reg Pos Lim] [Spd Reg Neg Lim] [SpdOut FiltGain] 1 5 266 1409 154 155 42 378 242 (1) 87 88
Chapter 3 Programming and Parameters File Applications Applic Group PI Control ations PD Control PID Control Init Diam Calc Diameter Calc Winder Functions Torque Prove Scale Blocks 120 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 Diame
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] [Speed Ref Source] [Spd Ref Sel Sts] [Last Stop Source] [Start Inhibits] [Drive Logic Rslt] [At Speed] [At Zero Speed] [CurrLimit Active] [Clear Fault Que] [Fault Clear] [Fault Clr Mode] [Sta
Chapter 3 Programming and Parameters File Input / Output Inputs / Group Analog Inputs Outpu ts Analog Outputs Digital Inputs Digital Outputs DPI Inputs 122 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 114 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 347 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 124 See page 114 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 Speed Meters 1011 1018 10 11 14 17 Current Meters Values Default: Read Only Min/Max: Units: –/+8192 rpm Default: Read Only Min/Max: Units: Default: –/+200.0 % Read Only [Speed Draw Out] Speed draw output value. Min/Max: Notes: This parameter can be assigned to an analog output. See Speed Draw Units: Function on page 323 for more information.
232 234 Current Meters 236 351 476 MONITOR 500 928 57 Drive Data 233 235 300 331 332 126 See page 114 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 465 466 588 1052 See page 114 for symbol descriptions [Drive Size] Armature current rating (as indicated by the configuration of DIP switch S15 on the control board). This value is used to determine the Drive Overload fault (F64). Note: S15 is set to the appropriate value at the factory. However, if the control board was supplied separate from the drive and installed as a replacement part, S15 must be manually set to the appropriate drive size.
Chapter 3 Programming and Parameters 45 [Max Ref Speed] Highest speed reference that can be commanded. The value of this parameter also scales external speed reference values (rpm) to internal units (counts), including analog inputs (10V = Par 45 rpm). Rated motor speed is determined via Par 456 [Fld Weaken Ratio] when field weakening is used. If field weakening is not used, set this parameter to the motor base speed.
333 [MtrOvrld Factor] Sets the derating factor for motor overload. The derating begins when the motor speed is below the value set in Par 334 [MtrOvrld Speed]. The motor overload level is determined by Par 376 [MtrOvrld Type] (“StandardDuty” is 150% of Par 179 [Nom Mtr Arm Amps] for 60 sec. or 200% for 3 sec., “HeavyDuty” is 200% for 60 sec.) and is linearly decreased from its maximum to the value of the motor overload factor at zero speed (zero speed is defined by Par 107 [Zero Speed Level]).
91 [Fld Reg Kp] Proportional gain (KP) of the flux regulator expressed as a percentage of Par 97 [Fld Reg Kp Base]. Leave set to the default value for permanent magnet motor applications. [Fld Reg Ki] Integral gain (KI) of the flux regulator expressed as a percentage of Par 98 [Fld Reg Ki Base]. Leave set to the default value for permanent magnet motor applications. [Fld Reg Kp Base] The proportional gain (KP0) of the field current regulator (base value).
468 See page 114 for symbol descriptions 30 0 / Par 467 [Max Fld Flux Pct] % Related Parameter Name & Description Values Default: [Min Fld Curr Pct] Minimum allowable field current. The value set in this parameter also Min/Max: influences the threshold at which the “Fld Current Loss” (F6) fault occurs. The Units: threshold is half of the value of Par 468 [Min Fld Curr Pct].
498 A Parameter Name & Description Values [Force Min Field] Default: Enables/Disables the minimum field current value. Leave set to the default Options: value for permanent magnet motor applications. • “Enabled” = The field current corresponds to the value set via Par 468 [Min Fld Curr Pct]. • “Disabled” = The field current is regulated based on the quadrant mode and situation in which the drive is operating. Note: This parameter can be assigned to a digital input (35 “Force MinFld”).
921 [Out Volt Level] The percentage of maximum output voltage based on the value in Par 175 [Rated Motor Volt]. In regenerative, field-weakened applications (hoist, elevator, unwinder, etc.) set the value of this parameter less than 100%, to allow operation when overcoming gravity. The value of this parameter also determines the voltage where the drive begins field de-fluxing while Field Weaken mode is active (Par 469 [Field Mode Sel] = “Field Weaken”).
342 [Torque Reduction] Selection for torque reduction. When the torque reduction function is active (1 “Active”), the current limit changes accordingly by the percentage defined in Par 13 [Torq Red CurLim]. When this parameter is set to 0 “Not Active”, torque reduction is not active.
Related Data Type Real 162 Reserved Move Avg b2 Move Avg b1 Move Avg b0 [Encoder Config] Configures the encoder moving average filter. • Bits 0 “Move Avg b0”, 1 “Move Avg b1”, and 2 “Move Avg b2” - Select the moving average speed filter period (see Table 170A: Moving Average below). Note: This parameter was added for firmware version 6.001. Reserved A Chapter 3 100.00 / 32770.00 Reserved 170 1024.
423 [Reslvr Type Sel] The type of resolver used. See Resolver Type Selection on page 310 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 455 A 138 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 114 for symbol descriptions [Resolver Status] 431 Indicates the status of the resolver module. • Bit 0 “CableBalSts” - Cable balance tuning process status.
457 [Spd Fdbk Control] Enables/Disables speed feedback control. The speed feedback control function is automatically disabled when armature voltage feedback is selected (Par 414 [Fdbk Device Type] = 3 “Armature”). See page 114 for symbol descriptions Values Default: Options: 1= “Enabled” 0= 1= “Disabled” “Enabled” Related Parameter Name & Description Chapter 3 Data Type No.
914 [Spd FB Filt Gain] First order lead/lag filter gain on the speed feedback signal. Note: This parameter was added for firmware version 3.001. A 915 A Speed Feedback 923 A 1021 A 1022 A 93 MOTOR CONTROL A 94 A Autotune 452 [Spd FB Filt BW] First order lead/lag filter bandwidth on the speed feedback signal. Note: This parameter was added for firmware version 3.001. [Act Spd Filter] First order low pass filter time constant for Par 924 [Actual Speed].
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 A 1014 A 1015 A Autotune MOTOR CONTROL 1027 See page 114 for symbol descriptions [Friction] Motor friction value. 1 N•m = 0.738 lb•ft Values Default: Based on motor current rating Min/Max: Units: 0.
1048 [Autotune Cur Lim] Value of the torque current limit applied during the speed regulator auto tuning procedure. 58 A See page 114 for symbol descriptions Values Default: 20 Min/Max: Units: Default: 0 / Based on drive current rating % 0= “NotConnected” [TstGen Output] 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.
166 A 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. Reading Alpha Test Mode on page 273 is required before completing this test.
215 A 216 A 217 A 218 A 144 SCR 12 SCR 11 SCR 6 SCR 5 SCR 4 SCR 3 SCR 2 SCR 1 SCR 14 SCR 15 SCR 16 Reserved OpenSCR Warn 0 0 0 x 0 0 0 15 14 13 12 11 10 9 SCR 13 Default Bit Test Generator MOTOR CONTROL Options 0 8 0 7 0 6 0 5 0 4 0 3 0 2 0 1 0 0 [OpenSCR WarnLvl] Sets the open SCR warning level. This value determines when Par 214 [SCR Diag Status], bit 13 “OpenSCR Warn” is set. This parameter is only active when Par 213 [SCR Diag Test En], bit 0 “OpenSCR Tst” is enabled.
Programming and Parameters Chapter 3 1 Limits 2 3 SPEED COMMAND 4 5 Discrete Speeds 6 154 155 156 157 158 159 160 266 See page 114 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 114 for symbol descriptions 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 307 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.
100 A 101 A 102 Speed Regulator SPEED COMMAND A 103 A 104 A 105 A 106 A See page 114 for symbol descriptions [Spd Reg Ki Outpt] Displays the active integral coefficient of the speed regulator as a percentage of the value defined in Par 94 [Spd Reg Ki Base]. Note: Units changed from “%” to “sec-1” for firmware version 6.001. [Speed Thresh Pos] Threshold speed for the drive above or below which the value of Par 393 [Speed Threshold] changes.
107 A 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 114 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 322 for more information. [SpdOut FiltGain] First order lead/lag filter gain on the speed regulator output signal.
435 A 436 A 444 A 445 A Speed Regulator SPEED COMMAND 446 Related See page 114 for symbol descriptions [Act Spd Reg BW] Displays the actual speed regulator bandwidth or crossover frequency. It represents the bandwidth in Par 434 [Spd Reg BW] after the maximum bandwidth limits have been applied. Note: This parameter was added for firmware version 6.001.
Programming and Parameters Chapter 3 15 A 16 A DYNAMIC CONTROL Control Config 241 Ramp Rates 18 19 See page 114 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. value setting example where Par 45 = 1750: 1750/5 = 350 rpm.
20 A See page 114 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”. Values Default: 100 Min/Max: Units: 0 / 65535 ms Default: 10 Min/Max: Units: 0 / 65535 s Default: 10 Min/Max: Units: Default: 0 / 65535 s 10 Related Parameter Name & Description Data Type Programming and Parameters No.
660 662 See page 114 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]. [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]. DYNAMIC CONTROL Ramp Rates 665 [S Curve Accel 1] Amount of time (approximately half at the start and half at the end) applied to the A S-curve during Accel 1 changes.
699 A 700 A DYNAMIC CONTROL Load Limits 715 A 38 A 627 Stop Modes A See page 114 for symbol descriptions [Enable Droop] Enables/Disables the Droop function. • “Enabled” = The Droop function is enabled. • “Disabled” = The Droop function is disabled. Note: This parameter can be assigned to a digital input. [Droop Limit] The speed reference correction range within which the droop function becomes active. Note: See Droop Compensation on page 285 for more information.
0= “Disabled” 0= 1= “Disabled” “Enabled” Related Parameter Name & Description Values See page 114 for symbol descriptions Default: 1344 [Start At Powerup] Enables/Disables the ability to issue a “Run” command and automatically resume Options: running at commanded speed after drive input power is restored and the time in Par 1345 [Powerup Delay] has elapsed. Requires a digital input configured for “Run” and a valid start condition. Note: See Start At Powerup on page 330 for more information.
187 A 188 A 189 Adaptv Regulator DYNAMIC CONTROL A 190 A 191 A 192 A 193 A 156 See page 114 for symbol descriptions [Adaptive Joint 2] Defines a range above and below the value set in Par 185 [Adaptive Spd 2] with in which there is a linear change in gain from parameter set 2 to parameter set 3 to prevent jumps in the adaptive speed regulator. The value in this parameter is defined as percentage of the value defined Par 45 [Max Ref Speed].
Programming and Parameters Chapter 3 695 A 731 A 734 A A PI Control APPLICATIONS 764 765 A 769 A 771 A 776 A 777 A 778 A See page 114 for symbol descriptions [PI Steady Thrsh] Feed–forward threshold for PI. • If the value if Par 758 [Feed Fwd PID] is less than the value of Par 695 [PI Steady Thrsh] the integral regulation will be locked and the proportional gain assumes the value set in Par 793 [PI Init Prop Gn].
779 A 780 A PI Control APPLICATIONS 781 A A 784 A 785 A 793 A 421 A PD Control 766 A 767 A Par 781 0 1 0 1 Values Default: 1 Min/Max: 0/3 Default: 0 Min/Max: 0/1 Related See page 114 for symbol descriptions [PI Central v sel] Selects one of the four possible initial output values of the PID regulator integral component (corresponding to the initial diameter) of the PI block.
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 [Enable PD] Enables/disables the PD portion of the PID regulator. Note: This parameter can be assigned to a digital input. 10.00 Real 0= “Disabled” Options: 0= 1= 10.0 “Disabled” “Enabled” 16-bit Int Real 181 Real 181 Real 181 Real 181 0.0 / 100.0 [PD Deriv Gain 2] Default: Second derivative gain of the PD block.
763 A 772 A 773 A 774 A 782 160 PID Control APPLICATIONS A See page 114 for symbol descriptions [PID Feedback] Analog input feedback value received from the transducer position (dancer) or tension (load cell). Values Default: 0 Min/Max: –/+10000 [PID Output Sign] Default: Determines whether the output of the PID regulator is bipolar or positive (clamp of Options: the negative side). 1= “Bipolar” “Positive” “Bipolar” [PID Output Scale] Scale factor for Par 774 [PID 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 Init Diam Calc 799 See page 114 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. Note: Also included in the Diameter Calc group in the Applications file. Related Parameter Name & Description Data Type Programming and Parameters No.
See page 114 for symbol descriptions 1162 [Diameter Filter] Diameter calculation filter. A Values Default: 100 Min/Max: Units: Default: 0 / 5000 ms 1500 1163 [Base Omega] Winder speed at the maximum line speed and minimum diameter of the winder/ Min/Max: A unwinder (motor shaft side). Units: 1164 [Diam Preset 0] Default: First preset starting diameter. The value of this parameter must be set between the Min/Max: A value of Pars 799 [Minimum Diameter] and 1153 [Max Diameter].
APPLICATIONS Values See page 114 for symbol descriptions 1204 [Line Spd Source] Default: Parameter number from which the line speed source for the winder function value will be read. Notes: Added options 0…47 for firmware version 4.001. Added option 48 A “Resolver Spd” for firmware version 5.002.
Values Default: See page 114 for symbol descriptions 1176 [Taper Enable] Enables/Disables the Taper function. 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]. A 1180 [Tension Ref] Tension reference. A Note: This parameter can be assigned to an analog input or output.
1193 [Torq Current Pct] Displays the amount of torque current required. A Note: This parameter can be assigned to an analog output. 1194 [Act Ten Ref Pct] Displays the percentage of tension reference less the Taper percentage set via Par A 1179 [Tension Reduct]. If the Taper function is not enabled, it corresponds to the value displayed in Par 1180 [Tension Ref]. 1195 [Speed Match] Coil “launching” phase command for automatic switching. A Note: This parameter can be assigned to a digital input or output.
See page 114 for symbol descriptions Winder Functions APPLICATIONS 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 “Reserved” for firmware version 5.002.
See page 114 for symbol descriptions Winder Functions APPLICATIONS 1284 [Ref Spd Source] Parameter number from which the line speed reference (used for inertia compensation and line speed reference) will be read. Notes: Added options 0…47 for firmware version 4.001. Added option 48 A “Resolver Spd” for firmware version 5.002.
Parameter Name & Description Values See page 114 for symbol descriptions 1100 [Torq Prove Cfg] Enables/Disables the torque/brake proving feature. When this feature is enabled, brake control comes from a digital output relay set to “Brake Set.” • Bit 0 “TP Enable” - When set to “1,” the torque/brake proving features are enabled (regenerative drives only, non-regen. drives results in a type 2 alarm). • Bit 1 “Encoderless” - When set to “1,” enables encoderless operation.
Reserved Encoderless RefLoadLmted LoadTestActv Brake Set BrkSlip1 Alm Micro Psn DecelLmtActv EndLimitActv Values See page 114 for symbol descriptions 1103 [Torq Prove Sts] Status of the Torque Proving functions. A Bit 0 “EndLimitActv” - When set to “1,” indicates that an end (forward or reverse) travel limit condition active. Bit 1 “DecelLmtActv” - When set to “1,” indicates that a deceleration (forward or reverse) travel limit condition active.
Scale Blocks A 487 556 1221 1230 1239 1248 A 488 557 1222 1231 1240 1249 A 489 558 1223 1232 1241 1250 A Related Real 1100 Real 1100 Values Default: 5.0 Min/Max: Units: 0.1 / 500.0 s Default: 50 Min/Max: Units: 0 / 150 % Default: 0 Min/Max: 0 / 1410 Default: 0 Min/Max: 0 / 1410 16-bit Int [Scale1 Mul] [Scale2 Mul] [Scale3 Mul] [Scale4 Mul] [Scale5 Mul] [Scale6 Mul] Multiplier of the input quantity (after a possible limitation). Resolution: 5 digits.
490 559 1224 1233 1242 1251 Scale Blocks APPLICATIONS A 491 560 1225 1234 1243 1252 A 492 561 1226 1235 1244 1253 A 172 Parameter Name & Description Values [Scale1 In Off] Default: [Scale2 In Off] Min/Max: [Scale3 In Off] [Scale4 In Off] [Scale5 In Off] [Scale6 In Off] Offset to be added to the input quantity. Resolution: 5 digits. See the Scale Blocks block diagram on page 361 for more information. See page 114 for symbol descriptions 0.
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 Reset At Flt Reset AtStop Save At Stop Save PwrDown [Man Ref Preload] Default: 1= Enables/disables a feature to automatically load the present “Auto” reference Options: 0= value into the HIM when “Manual” is selected.
346 A 347 Diagnostics UTILITY A 349 372 174 See page 114 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 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 At Speed Faulted Alarm Decelerating Accelerating Actual Dir Command Dir Active Ready Local ID 0 (1) 0 7 0 6 0 5 0 4 1 3 1 2 0 1 1 0 11 0 0 0 0 1 1 1 1 Bits Related Read
Values [Drive Status 2] Present operating condition of the drive.
Diagnostics UTILITY 397 See page 114 for symbol descriptions [MOP Dec Active] Indicates whether the drive is decelerating using the preselected ramp. A • 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] Indicates the state of the assigned digital input, [Digital Inx Sel], set to 17 “Speed A Sel 1”.
(1) 14 0 0 0 0 1 1 1 1 Bits MOP Inc Local Reverse Forward Clear Faults Jog Start Stop 0 0 0 0 0 0 0 15 14 13 12 11 10 9 Accel 1 Accel 2 Decel 1 Decel 2 Spd Ref ID 0 Spd Ref ID 1 Spd Ref ID 2 Diagnostics Default Bit MOP Dec Values See page 114 for symbol descriptions 1328 [Drive Logic Rslt] The final logic command resulting from the combination of all DPI and discrete inputs.
Preset Auto Trim Speed Trim Ramp MicroPsnMult Max Spd Lim Min Spd Lim Ref B Auto Ref A Auto x 0 0 0 0 0 0 15 14 13 12 11 10 9 Manual Ref Scale Ref Bipolar Ref Rev Disable Unipolar Ref Decel Lmt Sw Reserved Diagnostics Default Bit End Lim Sw Values See page 114 for symbol descriptions 1330 [Spd Ref Sel Sts] 16-bit Status of the speed reference selections.
263 Reserved Startup Actv Reserved Stop Assertd Reserved Enable Type 2 Alarm Fault x x x 0 0 0 0 15 14 13 12 11 10 9 Digital In DPI Port 1 DPI Port 2 DPI Port 3 DPI Port 4 Reserved Default Bit Reserved Options DPI Port 5 Values See page 114 for symbol descriptions 1403 [Start Inhibits] Displays the inputs currently preventing the drive from starting. For each bit, 1=Inhibit condition true and 0=Inhibit condition false.
1361 1362 1363 1364 1365 1366 1367 1368 1369 1370 Faults A See page 114 for symbol descriptions 1371 [Fault Arm Amps] Captures and displays the armature current (as a percentage of rated current) at the time of the last fault. 1372 [Fault Speed] Captures and displays the output speed (rpm) of the drive at the time of the last fault. 1373 [Fault Field Amps] Captures and displays the field current (as a percentage of rated current) at the time of the last fault.
470 A Parameter Name & Description Values See page 114 for symbol descriptions [UnderVlt Flt Dly] Default: Configures the length of time that an AC Line undervoltage condition can persist Min/Max: before an AC undervoltage fault (F4) is activated. The condition must persist for Units: the entire delay time or the delay timer is reset. Note: This parameter was added for firmware version 6.001. 10 Related Data Type Programming and Parameters 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 114 for symbol descriptions 1925 0 / 7800 rpm Related Chapter 3 Data Type No.
50 See page 114 for symbol descriptions [UsrDsplyMult0] Numerator in the calculation for user-defined, drive speed display units. Note: This parameter is not used. Values Default: 1 Min/Max: 1 / 1073741823 32-bit Int A User Defined UTILITY 51 Default: 1 Min/Max: 1 / 1073741823 Default: 1 Min/Max: 1 / 32767 Default: 1 Min/Max: 1 / 32767 32-bit Int A 53 A 54 A 184 [UsrDsplyDiv0] Denominator in the calculation for user-defined, drive speed display units.
503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 A 519 User Defined UTILITY A See page 114 for symbol descriptions [UserDefined0] [UserDefined1] [UserDefined2] [UserDefined3] [UserDefined4] [UserDefined5] [UserDefined6] [UserDefined7] [UserDefined8] [UserDefined9] [UserDefined10] [UserDefined11] [UserDefined12] [UserDefined13] [UserDefined14] [UserDefined15] General use signed 16 bit variables used for data exchange. Note: Pars 503…506 can be assigned to analog inputs.
520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 A 536 User Defined UTILITY A 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 Default: [UsrDefBitWrdB0] [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.
[Decel Mask] Controls which adapters can select the deceleration ramp rate (Pars 662 [Decel Time 1] and 32 [Decel Time 2]) of the drive. See [Logic Mask] 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. See your communications option manual for datalink information.
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 114 for symbol descriptions 1377 [Write Mask Act] Read Only The status of write access for the DPI ports. When bit 15 is set, network security is controlling A 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 114 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 276 for more information.
A 259 260 261 A 295 296 297 Analog Inputs INPUT / OUTPUT 792 A 801 A 802 A 1042 1043 1044 192 See page 114 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 114 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].
Analog Outputs INPUT / OUTPUT See page 114 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. Note: Option 9 “Torque Ref” was changed to “Sel Torq Ref” for firmware version 6.001. Options: No.
Digital Inputs INPUT / OUTPUT 133 134 135 136 137 138 139 140 141 142 143 144 See page 114 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 196 and 197.
Values See page 114 for symbol descriptions 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.
Values See page 114 for symbol descriptions Option Definitions for [Digital Inx Sel], Continued 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 Digital In7 Digital In6 Digital In5 Digital In4 Digital In3 Digital In2 Digital In1 x x x x 0 0 0 15 14 13 12 11 10 9 Digital In8 Digital In10 Digital In11 Digital In12 Reserved Reserved Read Only Digital In9 Default Bit Reserved Options 565 566 567 568 569 570 571 572 573 574 575 576 0 8 0 7 0 6 0 5 0 4 0 3 0 2 0 1 0 0 Default: Read Only Min/Max: 0/1 Default: 0 “Disabled” Options:
Digital Outputs INPUT / OUTPUT 145 146 147 148 149 150 151 152 See page 114 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 for [Digital Outx Sel], [Relay Out 1 Sel] and [Relay Out 2 Sel] on page 200.
See page 114 for symbol descriptions Values Option Definitions for [Digital Outx Sel], [Relay Out 1 Sel] and [Relay Out 2 Sel] Option Spd Zero Thr Spd Thresh At Speed CurrentLimit Ready Ramp Pos Ramp Neg Spd Limited Fault Power Loss UserDefinedA Digital Outputs INPUT / OUTPUT UserDefinedB Stop Control Field Loss Spd Fbk Loss Spd Fdbk Err Diam Calc Input1 Cmp Diam Reached Speed Match Accelerating Decelerating Brake Cmd ContactorDB Contactor Alarm Running Jogging Active Brake Slip TP Brake Cmd 200 Desc
1267 1268 1269 1270 1271 1272 1273 1274 Digital Out8 Digital Out7 Digital Out6 Digital Out5 Digital Out4 Digital Out3 Digital Out2 Digital Out1 0 6 0 5 0 4 0 3 0 2 0 1 0 0 “Not Used” (Off) “Spd Zero Thr” “Spd Thresh” “At Speed” “CurrentLimit” “Ready” “Ramp Pos” “Ramp Neg” 8= 9= 10 = 11 = 12 = 13 = 14 = 15 = “Spd Limited” “Fault” “Power Loss” “UserDefinedA” “UserDefinedB” “Stop Control” “Field Loss” “Spd Fbk Loss” 16 = 17 = 18 = 19 = 20 = 21 = 22 = 23 = Default: “Spd Fdbk Err” “Diam Calc
1392 Digital Outputs INPUT / OUTPUT [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 200. Notes: Option 16 “Encoder Err” was changed for firmware version v5.002. Options 30 and 31 were added for firmware version v6.001.
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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 215 216 217 218 224 224 227 229 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 65 - 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 2 216 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 40 - Fault Types, Descriptions and Actions Fault Name AC Undervoltage Number Type(1) 4 2 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 Fwd End Limit 95 2 Fwd Over Travel 97 2 Hardware Fault 130 2 218 Description/Possible Cause(s) Action(s) There is an undervoltage on the power circuit (can only occur while the drive is active, i.e.
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 Open SCR 90 1 Overcurrent 13 1 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 Overspeed Number Type(1) 25 2 Params Defaulted Port 1-5 Adapter 48 2 71…75 2 Description/Possible Cause(s) The encoder or tachometer feedback indicated a speed that is more than the value of Par 585 [Overspeed Val]. Note: Configurable with Par 585 [Overspeed Val]. User parameters have been reset to their default values. The communication card has a fault. Port 1-5 DPI Loss 81…85 2 The DPI port stopped communicating.
Troubleshooting Fault Name Spd Fdbk Loss Number Type(1) 91 1 STune Aborted 62 2 STune CurLimit 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) The speed feedback device selected by Par 414 [Fdbk Device Type] is indicating less than 5% of Par 162 [Max Feedback Spd] while the measured armature voltage is greater than the value of Par 455 [Spd FB Loss Lvl].
Chapter 4 Troubleshooting Fault Name TorqPrv Spd Band Number Type(1) 94 2 Travel Lim Cflct 99 2 Description/Possible Cause(s) Action(s) The difference between the commanded speed and the encoder/resolver speed has exceeded the level set in Par 1105 [Speed Dev Band] for a time period greater than that value specified in Par 1106 [Spd Band Intgrtr]. This fault is only enabled when Par 1100 [Torq Prove Cfg], bit 0 “TP Enable” is set and causes the drive to coast to a stop.
Troubleshooting Chapter 4 Table 41 - Fault Cross Reference by Number No.
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].
Troubleshooting Alarm DigInCflctB Type 2 Chapter 4 Description One of the following digital input conflicts exists: • A digital Start input has been configured without a Stop input • None of the digital inputs are configured for “Enable” • Other digital input functions are in conflict. Combinations that conflict are marked with a “ ” and will cause an alarm.
Chapter 4 Troubleshooting Alarm Type Start At PowerUp 1 226 Torq Prov Cflct 2 TP Encls Config 2 Description Par 1344 [Start At Powerup] is enabled. The drive may start at any time after drive power up and the time specified in Par 1345 [Powerup Delay] has elapsed.
Troubleshooting Common Drive Symptoms and Corrective Actions Chapter 4 The following tables contain descriptions of common drive symptoms and the possible solutions to correcting the problem.
Chapter 4 Troubleshooting 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 83). 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 75).
Troubleshooting Chapter 4 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].
Chapter 4 Troubleshooting Notes: 230 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014
Appendix A Supplemental Drive Information Topic Certifications and 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-UM001K-EN-P - July 2014 Pa
Appendix A Supplemental Drive Information Certifications and Specifications Please see the PowerFlex Digital DC Drive Technical Data, publication 20P-TD001, for certification and specification information. IP20 NEMA / UL Type Open Watts Loss Watts loss data shown below is based on the rated current of the drive.
Supplemental Drive Information Appendix A Table 45 - 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.
Appendix A Supplemental Drive Information Communication Configurations 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.
Supplemental Drive Information Appendix A Figure 67 - 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 Description 0 = Not Ready 1 = Ready 0 = Not Active 1 = Active 0 = Reverse 1 = Forward 0 = Reverse 1 = Forward 0 = Not Accelerating 1 = Accelerating 0 = Not Decelerating 1 = Decelerating 0 = No Alarm 1 = Alarm 0 = No Fault 1 =
Appendix A Supplemental Drive Information Drive Power Circuit Protection The tables on the following pages provide the fuses required for protecting the armature and field circuits of the drive. Externally mounted fuses (as indicated in Figure 68 below) must be sourced separately when installing the drive. Internally mounted fuses (as indicated in Figure 68 below and Figure 71 on page 242) are provided with the drive. See page 242 for frames C and D fuse information.
Supplemental Drive Information Appendix A Frame A and B 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 68 on page 236.
Appendix A Supplemental Drive Information Table 49 - 575V AC Input Drives Frame Drive Current DC Amps Rating Code AC Line Amps B 067 101 135 270 405 55.1 82.7 110.3 220.6 330.9 67.5 101.
Supplemental Drive Information Appendix A Table 51 - 460V AC Input Drives Frame Drive Current Rating Code A 4P1 6P0 010 014 019 027 035 045 052 073 086 100 129 B 167 207 250 330 412 DC Amps AC Line Bussmann Amps Ferrule FWP Type North American FWP Type Mersen Ferrule A70QS Type North American A70P / A70QS Type 4.1 6 10 14 19 27 35 45 52 73 86 100 129 167 207 250 330 412 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.
Appendix A Supplemental Drive Information Frame A and B Field Circuit Fuses Field circuit fuses are internally mounted and provided with the drive. See Fuse Code FS3 in Figure 68 on page 236. Also, see Figure 69 on page 241 and Figure 69 on page 241 for fuse locations. Frame Table 53 - 230V AC Input Drives A B Drive Current Rating Code 7P0 9P0 012 020 029 038 055 073 093 110 146 180 218 265 360 434 Field Amps Type Quantity Bussmann Mersen SIBA 6 x 32 mm 2 FWH-016A6F E085449 70 125 40.
Supplemental Drive Information Appendix A Frame Table 55 - 575V AC Input Drives B Drive Field Current Amps Rating Code 067 101 135 20 270 405 Quantity Type Bussmann Mersen SIBA 2 FWC-25A10F A60Q25-2 60 033 05.
Appendix A Supplemental Drive Information 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 71 - 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.
Supplemental Drive Information Appendix A Frame Table 58 - 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 Mersen SIBA FWC-25A10F A60Q25-2 A60Q25-8 6003305.25 FWP-50A22F A70QS50-22F 5014006.50 Mersen SIBA FWC-25A10F A60Q25-2 A60Q25-8 6003305.25 FWP-50A22F A70QS50-22F 5014006.50 FWP-100A22F A70QS100-22F 5014006.
Appendix A Supplemental Drive Information Figure 73 - Frame D Field Circuit Fuse Location Top, left side of drive control panel.
Supplemental Drive Information Appendix A 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 71 on page 242. Also, see Figure 74 on page 246 and Figure 75 on page 247 for fuse locations. Frame Table 60 - Leg Fuses - 230V AC Input Frame C Drives C Drive Current Rating Code 521 700 DC Amps AC Line Qty Bussmann Mersen Amps Square Body - Flush End Contact SIBA 521 700 426 571 20 671 32.
Appendix A Supplemental Drive Information Table 66 - Leg Fuses - 690V AC Input Frame C Drives Frame Drive Current Rating Code C 452 565 DC AC Qty Bussmann Mersen Amps Line Square Body - Flush End Contact Amps SIBA 452 565 20 771 32.500 + switch 28 001 04 20 771 32.
Supplemental Drive Information Appendix A Figure 75 - Frame D Regenerative Drive - Leg Fuse Location Leg fuses and switches are installed 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 71 on page 242. Also, see Figure 76 on page 249 for fuse locations.
Appendix A Supplemental Drive Information Frame Table 71 - Leg Fuses - 460V AC Input Frame D Drives D Drive Current Rating Code 830 996 1K1 1K3 1K4 DC AC Line Qty Bussmann Mersen 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.
Supplemental Drive Information Appendix A Figure 76 - Frame C Non-Regenerative Drive - AC Input Line Fuse Location AC Input fuses and switches are installed on the bus bars behind the control board EMI shield. Note: Drive shown with front covers removed and control board EMI shield lowered. Control Power Circuit Protection Fuses Switching Power Supply Circuit Board Fuses The following fuses are used to protect the switching power supply circuit.
Appendix A Supplemental Drive Information Figure 77 - Frame A Switching Power Supply Circuit Board Fuse Location Top View of Drive switching power supply circuit board fuse holder. Figure 78 - 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. 250 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 F2 = 2.5 A fuse Rev. “H” and below only.
Supplemental Drive Information Appendix A Figure 79 - 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. The switching power supply circuit board is on the back of the control board EMI shield. Figure 80 - Frame D Switching Power Supply Circuit Board Fuse Location switching power supply fuse holder The switching power supply circuit board is on the control panel.
Appendix A Supplemental Drive Information Figure 81 - Frame B Pulse Transformer Circuit Board Fuse Location Pulse transformer board fuse locations (shown with control board EMI shield lowered). Control board EMI shield 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 on the left side wall inside the drive enclosure, behind the control panel.
Appendix A Supplemental Drive Information If a DC contactor is used, an AC input contactor is not needed. AC Input Line Reactors and AC Input Contactors Table 76 - 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 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 330 330 269.6 200 1321-3RB320-B 149 (200) 100-D300ED11 412 412 336.6 250 1321-3RB400-B 186.
Appendix A Supplemental Drive Information 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 93 118 256 3.7 (5) 5.5 (7.5) 7.5 (10) 11 (15) 15 (20) 18.
Supplemental Drive Information Appendix A 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 175 220 275 330 440 550 660 770 880 112 (150) 145 (200) 187 (250) 224 (300) 298 (400) 373 (500) 448 (600) 522 (700) 597 (800) 575 1321-3TH145-CA 1321-3TH145-CB 1321-3TH145
Appendix A Supplemental Drive Information Dynamic Brake Resistor Kits and DC Output Contactors See Table 82 and Table 83 on page 260 for recommended alternate DC Output Contactors for 575V and 690V AC input drives, respectively. Frame Table 80 - 230V AC Input Drives Drive Current DC Rating Code Amps AC Line Hp Amps Dynamic Brake Armature Resistor Kit Cat. No.
Frame Supplemental Drive Information Drive Current DC Rating Code Amps AC Line Hp Amps Dynamic Brake Resistor Armature Total DB Kit Cat. No. Voltage Resistance (Volts) (ohms) 495 667 830 996 404.4 544.9 678.1 813.7 300 400 500 600 HUBBELL_Y101W595GB HUBBELL_Y109W542GB 1K1 1162 949.4 700 1K3 1328 1085.0 1K4 1494 1220.6 C 495 667 D 800 960 (1) (2) (3) (4) 500 500 500 500 0.8 0.625 0.463 0.322 (2) 500 0.322 800 (2) 500 0.255 900 (2) 500 0.255 (1) (2) DC Loop Contactor Cat.
Appendix A Supplemental Drive Information Alternate Dynamic Brake Resistor Kits and DC Output Contactors 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. Table 82 - 575V AC Input Drives Frame DC Loop Contactor Cat. No.
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 40. 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 must 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 86 - 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 265 266 266 268 270 271 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 84 - 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 Communication. View the firmware version and hardware series of components. Parameter Menu Use this menu to view and edit parameters for the drive.
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 Key(s) Example Displays 1.
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: 272 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014
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 (v1.006) Lifting/Torque Proving Manually Tuning the Speed Regulator for Firmware Version 6.
Appendix C Application Notes Alpha Test Setup and Operation ATTENTION: Allow only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved to 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 76 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-UM001K-EN-P - July 2014 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 Lifting/Torque Proving Appendix C TorqProve™ technology for PowerFlex DC drives is intended for applications where proper coordination between motor control and a mechanical brake is required. Prior to releasing a mechanical brake, the drive will check motor armature continuity and verify proper motor control (torque proving). The drive will also verify that the mechanical brake has control of the load prior to releasing drive control (brake proving).
Appendix C Application Notes Figure 86 - Torque Proving Flow Diagram Operator Commands Run Command Run Command Released Run can be initiated anytime Time Drive Running [Brk Release Time] Parameter 1107 Drive Actions Torque Prove Initiated [Brk Set Time] Parameter 1108 [ZeroSpdFloatTime] Parameter 1113 Brake Released Float Initiated Brake (1) Set Brake Slip Test All times between Drive Actions are programmable and can be made very small (i.e. Brake Release Time can be 0.
Application Notes Appendix C Tuning The Motor For Torque Prove Applications It is possible to use Autotune to tune the motor (see Tune the Current Regulator on page 101 and Tune the Speed Regulator on page 108). However, it is recommended that the motor be disconnected from the hoist/crane equipment during the routine. ATTENTION: To guard against personal injury and/or equipment damage caused by unexpected brake release, verify the digital output used for brake connections and/or programming.
Appendix C Application Notes Set Up the Drive Adjust parameter settings and enter nameplate data.
Application Notes Appendix C Speed Reference Setup 1. Set the minimum speed. Parameter 1 [Minimum Speed] Setting 0.00 2. Set the maximum speed limits. Parameter 2 [Maximum Speed] Setting Speed limit used during normal operation 3. Set the digital input functions.
Appendix C Application Notes Torque Prove Setup Carefully perform the following steps in the order presented. 1. Enter the Torque Prove parameter settings. Parameter 629 [Relay Out 2 Sel] 1100 [Torq Prove Cfg] Setting “TP Brake Cmd” (31) Bit 0 “TP Enable” = 1 Once Torque Prove is activated the drive is in alarm state. 2. Select the source of speed feedback. Parameter 414 [Fdbk Device Type] Setting “Encoder” (1) - Verify that P169 [Encoder PPR] is set correctly. 3.
Application Notes Appendix C 9. Set the brake slip definition. Parameter 1110 [Brk Slip Count] Setting 0.25 (Default) Sets the number of encoder or resolver revolutions to define a brake slippage condition. 10. Set the brake float tolerance. Parameter 1111 [Float Tolerance] Setting 52.50 RPM Sets the level at which the float timer will start counting. 11. Set the brake float time. Parameter 1113 [ZeroSpdFloatTime] Setting 5.
Appendix C Application Notes Troubleshooting Crane Setup with Encoder/Resolver Feedback The following faults commonly occur during drive commissioning. F4 “AC Undervoltage” • If the mains supply is still present, reduce the undervoltage level at P481 [UnderVolt Thresh]. F5 “Arm Overvoltage” • Verify the parameter settings as stated in Set Up the Drive on page 292. F94 “TrqProve Spd Band” (Speed deviation fault) • This fault is only active when TorqProve is enabled. • The speed loop tuning is incorrect.
Application Notes Appendix C Set Up the Drive Adjust the parameter settings and enter nameplate data.
Appendix C Application Notes Speed Reference Setup 1. Set the minimum speed. Parameter 1 [Minimum Speed] Setting 0.00 2. Set the maximum speed limits. Parameter 2 [Maximum Speed] Setting Speed limit used during normal operation 3. Set the digital input functions.
Application Notes Appendix C 3. Set the speed deviation. Parameter 1105 [Speed Dev Band] Setting 200 RPM This setting can be lowered once the system has been tuned. The lower this value, the faster the protection. 4. Set speed deviation level. Parameter 1106 [SpdBand Intgrtr] Setting 200 ms This setting can be lowered once the system has been tuned. The lower this value, the faster the protection. 5. Set brake float tolerance.
Appendix C Application Notes Troubleshooting Crane Setup - Encoderless The following faults commonly occur during drive commissioning. F4 “AC Undervoltage” • If the mains supply is still present, reduce the undervoltage level at P481 [UnderVolt Thresh]. F5 “Arm Overvoltage” • Verify the parameter settings as stated in Set Up the Drive on page 297. F94 “TrqProve Spd Band” (Speed deviation fault) • This fault is active only when TorqProve is enabled. • The speed loop tuning is not correct.
Application Notes Manually Tuning the Speed Regulator for Firmware Version 6.xxx Appendix C The calculation of Speed Loop gains was simplified in firmware version 6.xxx so that they are similar to other PowerFlex Architecture class drives. The Speed Regulator gains (Kp and Ki) are now automatically determined by the value of parameter 434 [Spd Reg BW]. The Speed Regulator gains can still be entered manually by setting P434 [Spd Reg BW] to 0.
Appendix C Application Notes PID Function The PID function is used to increase or reduce the reference signal output to the speed or current regulator of the drive. The PID function can be used for 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 360.
Application Notes Appendix C 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).
Appendix C Application Notes • 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”.
Application Notes Appendix C • 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
Appendix C Application Notes 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 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 that
Application Notes Reference Control Appendix C 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 234 for more information).
Appendix C Application Notes 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 communication 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.
Application Notes Resolver Cable Balance Tuning Test Appendix C 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.
Appendix C Application Notes 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).
Application Notes Appendix C 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.
Appendix C Application Notes Linking Parameters Via the Scale Block Parameters Most parameter values are entered directly by the user. However, certain parameters can be “linked” by using 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]. Follow these steps to link parameters. 1. Set parameter 70 [Anlg In1 Sel] to 12 “UserDefined0”. 2.
Application Notes Appendix C Open SCR Test Under normal drive operation, the load carried by each SCR is relatively equal, as shown in this image. If one or more SCRs fail to turn to on, a unique pattern of insufficient or missing current pulses results, as shown in this image. Open SCR diagnostics detects SCRs that are not conducting by analyzing the level of current produced by each SCR pair firing.
Appendix C Application Notes The Open SCR diagnostic test calculates the percentage deviation of current feedback for each pair of SCRs from the average current feedback. The percent deviation must exceed the value set for Par 216 [OpenSCR Threshold] before the test proceeds to the next part of the diagnostic. In the next part, deviations from the average current are accumulated over time to eliminate transient effects from the calculation.
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 Appendix C Time (s) Adding s-curve to the ramp will increase the total length of time to perform the speed change.
Appendix C Application Notes 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.
Application Notes Speed Regulation Functions Appendix C The PowerFlex DC Digital drive provides a flexible speed regulator circuit that can be adapted to the requirements of a variety of applications. The drive is set to PI regulation by default. Adaptive Speed Regulator The adaptive speed regulator function enables different gains of the speed regulator depending on the speed reference or another variable (adaptive reference).
Appendix C Application Notes first set of parameters is active until the speed specified in Par 184 [Adaptive Spd 1] or Par 183 [Adap Ref ] is reached. Parameters 186 [Adaptive Joint 1] and 187 [Adaptive Joint 2] provide a smooth transition between the different parameter sets. The fields must be defined so that [Adaptive Joint 1] and [Adaptive Joint 2] do not overlap.
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 355. 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, a speed reference that forces the speed regulator into saturation (the speed reference is slightly above the speed feedback) is typically configured. In this case the drive follows the torque reference until there is a breakage or slippage in the application. When the drive is following a torque reference (torque mode) in SLAT Min mode, either one of two conditions will force the drive into following the speed reference (speed mode): 1.
Application Notes Appendix C SLAT MAX Mode In SLAT Max mode, a speed reference that forces the speed regulator into saturation (the speed reference is slightly below the speed feedback) is typically configured. In this case the drive follows 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 so the speed regulator is saturated 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 specific 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 91 - Increase in the field current with oscillation Figure 93 - 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 94 - [Spd Reg Kp] too low Figure 96 - [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 95 - [Spd Reg Kp] too high Figure 97 - [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 98 - Field voltage oscillation Figure 100 - 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 101 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 356. 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-UM001K-EN-P - July 2014 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 P122
DG4- DG4+ DG3- DG3+ DG2- DG2+ DG1- DG1+ Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 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 Sel P
Ref_1- Ref_1+ Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 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 P73 An
Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 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 Refe
Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 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 Speed
P662 Decel Time 1 P32 Decel Time 2 P660 Accel Time 1 P24 Accel Time 2 P1410 Jog Ramp Time Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 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 Reference Bl
Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 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 P1006 Dr
Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 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-UM001K-EN-P - July 2014 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-UM001K-EN-P - July 2014 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 (F91)
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-UM001K-EN-P - July 2014 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 P11
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-UM001K-EN-P - July 2014 & T >= T Lock speed I P185 Adaptive Spd 2 P184 Adaptive Spd 1 P124 Spd Ref Zero En P18
Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 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 Command
P233 Output Voltage Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 Output Voltage Spd=0 Thr P107 Speed Zero Level Max field curr Min field curr P499 Field Economy En P498 Force Min Field Min field current Max field current P921 Out Volt Level Energy saving Field Economy P175 Rated Motor Volt P1210 W Target P782 PID Target P80 Anlg In3 Sel P75 Anlg In2 Sel P70 Anlg In1 Sel Σ P468 Min Fld Curr Pct _ + P374 Rated Field Curr P476 Field Curve Out P469 Field Mode Select T
Output Voltage / Torque 358 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 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-UM001K-EN-P - July 2014 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 359
Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 - 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 P789
Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 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-UM001K-EN-P - July 2014 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 Input Analog Output P80 Anlg In3 Sel P75 Anlg In2 Sel Analog Input P512 UserDefined9 P505 UserDefined2 Target Param Source Param P513 UserDefined10 P506 UserDefined3 P507 User
Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 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 363
User Defined Variable 364 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-UM001K-EN-P - July 2014
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: Allow only qualified personnel familiar with drives, power products and associated machinery to plan or implement the installation, startup, 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, verify 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 circuit 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 90 - 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 to provide an interface with the standard digital I/O terminal blocks on the PowerFlex DC drive control circuit board.
Appendix G Optional 115V AC to 24V DC I/O Converter Circuit Board I/O Converter Board Wiring Table 92 - 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 105 - 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 Boa
Appendix G Optional 115V AC to 24V DC I/O Converter Circuit Board Notes: 378 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014
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: 380 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014
I Appendix 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-UM001J-EN-P, February 2014 Topic Added the Drive Series Letter section to the Preface to provide additional drive identification information.
Appendix I History of Changes Topic Changed the units from “%” to “none” for parameters 87 [Spd Reg Kp], 99 [Spd Reg Kp Outpt], and 459 [SpdReg Kp Bypass]. Changed the units from “%” to “sec-1” for parameters 88 [Spd Reg Ki], 100 [Spd Reg Ki Outpt], and 460 [SpdReg Ki Bypass]. Changed the default value of [Droop Filter] from 0 to 100.
History of Changes Appendix I Topic Updated the drive armature overcurrent trip specifications. Added the noise level values for each drive frame fan. Updated the Bussmann North American Fuse Block part numbers for frame A and B drives. Added the new S-curve Configuration section. Updated the Ramp Reference Block Diagram to reflect the interaction of the linear and S-curve ramps. 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 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. “I” and above control power circuit boards.
Appendix I 386 History of Changes Rockwell Automation Publication 20P-UM001K-EN-P - July 2014
Index Numerics 115V AC to 24V DC I/O converter board catalog number 375 2-wire control non-reversing 84 reversing 84 3-wire control 84, 85 A AC input contactors configure 30 recommended 254 AC input line reactors recommended 254 AC input voltage 44 AC Line Freq (Par. No. 588) 127 AC Line Voltage (Par. No. 466) 127 AC Undervoltage fault 218 Acc Dec Filter (Par. No. 1212) 167 Accel Mask (Par. No. 596) 188 Accel Owner (Par. No. 605) 188 Accel Status (Par. No. 1188) 165 Accel Time 1 (Par. No.
Index Anlg In3 Config (Par. No. 81) 191 Anlg In3 Filter (Par. No. 802) 192 Anlg In3 Offset (Par. No. 84) 192 Anlg In3 Scale (Par. No. 82) 191 Anlg In3 Sel (Par. No. 80) 191 Anlg In3 Target (Par. No. 297) 192 Anlg In3 Tune (Par. No. 261) 192 Anlg Out1 Scale (Par. No. 62) 193 Anlg Out1 Sel (Par. No. 66) 194 Anlg Out2 Scale (Par. No. 63) 193 Anlg Out2 Sel (Par. No. 67) 194 Anlg Out3 Scale (Par. No. 64) 193 Anlg Out3 Sel (Par. No. 68) 194 Anlg Out4 Scale (Par. No. 65) 193 Anlg Out4 Sel (Par. No.
Index configure AC input contactor 30 analog inputs 276 DC output contactor 30 dynamic brake resistor 30 feedback signal 304 Klixon 62 line speed signal 303 programmable controller 234 PTC 62 start at powerup 330 tension set point signal 306 thermal switch 62 thermistor 62 Connected Components Workbench 93 Connected Components Workbench software 113 Constant J Comp (Par. No. 1172) 164 Contactor Conflict alarm 224 ContactorControl (Par. No.
Index Diameter Reset (Par. No. 1157) 162 Dig In Status (Par. No. 564) 198 Dig In Term 1 (Par. No. 565) 198 Dig In Term 10 (Par. No. 574) 198 Dig In Term 11 (Par. No. 575) 198 Dig In Term 12 (Par. No. 576) 198 Dig In Term 2 (Par. No. 566) 198 Dig In Term 3 (Par. No. 567) 198 Dig In Term 4 (Par. No. 568) 198 Dig In Term 5 (Par. No. 569) 198 Dig In Term 6 (Par. No. 570) 198 Dig In Term 7 (Par. No. 571) 198 Dig In Term 8 (Par. No. 572) 198 Dig In Term 9 (Par. No. 573) 198 Dig Out Status (Par. No.
Index drive starts, motor does not turn 228 Drive Status 1 (Par. No. 381) 175 Drive Status 2 (Par. No. 382) 176 Drive Type (Par. No. 300) 126 Drive Type Sel (Par. No. 201) 128 drive will not start 227 DriveExplorer 93 DriveExplorer software 113 DriveTools SP 93 DriveTools SP software 113 droop compensation 285 Droop Filter (Par. No. 697) 153 Droop Limit (Par. No. 700) 154 Droop Out (Par. No. 1006) 124 Droop Out Pct (Par. No. 1007) 124 Droop Percent (Par. No. 696) 153 Drv Fld Brdg Cur (Par. No.
Index faults AC Undervoltage 218 Arm Overvoltage 218 Auxiliary Input 218 clear 217 Drive Overload 218 Dsp Error 218 EEPROM Error 218 Encoder Error 218 Fld Current Loss 218 Fwd End Limit 218 Fwd Over Travel 218 Hardware Fault 218 Heatsink OvrTemp 219 Interrupt Error 219 Inverting Fault 219 Main Contactor 219 Motor Over Temp 219 Motor Overload 219 No Fault 219 Open SCR 219 Overcurrent 219 Overspeed 220 Params Defaulted 220 Port 1 Adapter 220 Port 1 DPI Loss 220 Port 2 Adapter 220 Port 2 DPI Loss 220 Port 3 A
Index frame B armature converter terminals 51 dimensions 20 PE ground terminal 51 weights 20 frame C armature converter terminals 51 dimensions 21 PE ground terminal 51 weights 21 frame D armature converter terminals 52 dimensions 22, 23 PE ground terminal 52 terminal adapter kits 264 weights 24 frame size 12 Freeze Ramp (Par. No. 373) 152 Friction (Par. No.
Index install communication adapter 367 HIM 271 I/O converter circuit board 375 I/O expansion circuit board 373 Int Acc Calc En (Par. No. 1183) 165 interference common mode 80 Interrupt Error fault 219 Inversion In 1 (Par. No. 1276) 198 Inversion In 10 (Par. No. 1388) 198 Inversion In 11 (Par. No. 1389) 198 Inversion In 12 (Par. No. 1390) 198 Inversion In 2 (Par. No. 1277) 198 Inversion In 3 (Par. No. 1278) 198 Inversion In 4 (Par. No. 1279) 198 Inversion In 5 (Par. No. 1280) 198 Inversion In 6 (Par. No.
Index Max Fld Curr Pct (Par. No. 467) 130 Max Ref Speed (Par. No. 45) 128 Max Speed Fwd (Par. No. 3) 145 Max Speed Rev (Par. No. 4) 145 Maximum Speed (Par. No. 2) 145 menu HIM 268, 269 MicroPsnScalePct (Par. No. 1112) 170 Min Fld Curr Pct (Par. No. 468) 131 Min Speed Fwd (Par. No. 5) 145 Min Speed Rev (Par. No. 6) 145 Minimum Diameter (Par. No. 799) 162 Minimum Speed (Par. No. 1) 145 MOD LED 216 Monitor file 123-127 MOP Accel Time (Par. No. 22) 152 MOP Dec Active (Par. No. 397) 177 MOP Decel Time (Par. No.
Index parameter groups Adaptv Regulator 155-156 Alarms 181-183 Analog Inputs 191-193 Analog Outputs 193-194 Autotune 140-142 Comm Control 187 Control Config 151 Current Meters 125-126 DataLinks 189 Diagnostics 174-180 Diameter Calc 162-164 Digital Inputs 195-198 Digital Outputs 199-202 Discrete Speeds 145-146 DPI Inputs 202 Drive Data 126-127 Drive Memory 173 Faults 180-181 Field Config 130-133 Init Diam Calc 161-162 Limits 145 Load Limits 153-154 Masks & Owners 187-189 Motor Data 128-129 PD Control 158-15
Index power feeder ground 33 power terminals armature converter 50 power wiring 44 AC input contactor 46 armature output terminals 50 armature voltage feedback terminals 53 contact terminals 62 DC output contactor 47 diagrams 45 dynamic brake 48 field input terminals 56 field output terminals 56 motor thermistor terminals 62 normally open contact terminals 62 PE (earth ground) terminal 50 Powerup Delay (Par. No. 1345) 155 preferences HIM 270 Preset Speed 1 (Par. No. 154) 145 Preset Speed 2 (Par. No.
Index Scale1 Out Off (Par. No. 491) 172 Scale1 Output (Par. No. 485) 171 Scale2 Div (Par. No. 556) 171 Scale2 In Abs (Par. No. 561) 172 Scale2 In Max (Par. No. 557) 171 Scale2 In Min (Par. No. 558) 171 Scale2 In Off (Par. No. 559) 172 Scale2 Input (Par. No. 553) 171 Scale2 Mul (Par. No. 555) 171 Scale2 Out Off (Par. No. 560) 172 Scale2 Output (Par. No. 554) 171 Scale3 Div (Par. No. 1221) 171 Scale3 In Abs (Par. No. 1226) 172 Scale3 In Max (Par. No. 1222) 171 Scale3 In Min (Par. No.
Index SpdOut FiltGain (Par. No. 238) 149 SpdReg AntiBckup (Par. No. 643) 150 SpdReg BW Bypass (Par. No. 448) 150 SpdReg FB Bypass (Par. No. 458) 139 SpdReg Ki Bypass (Par. No. 460) 150 SpdReg Ki Pct (Par. No. 1035) 141 SpdReg Kp Bypass (Par. No. 459) 150 SpdReg Kp Pct (Par. No. 1034) 141 SpdReg NegLmOut (Par. No. 90) 125 SpdReg PosLmOut (Par. No. 89) 125 SpdTune Friction (Par. No. 1031) 141 specifications DC contactor crimp lug kits 259 Speed Command file 145-150 Speed Demand En (Par. No.
Index T tachometer DIP switch 77 ground 33 terminal block 88 Tachometer Speed (Par. No. 1408) 125 Taper Enable (Par. No. 1176) 165 TaskLoad 1 ms (Par. No. 1384) 179 TaskLoad 2 ms (Par. No. 1385) 179 TaskLoad 8 ms (Par. No. 1386) 179 TB Manual Ref (Par. No. 267) 146 temperature drive 18 Tension Reduct (Par. No. 1179) 165 Tension Ref (Par. No. 1180) 165 Tension Scale (Par. No.
Index UserDefined11 (Par. No. 514) 185 UserDefined12 (Par. No. 515) 185 UserDefined13 (Par. No. 516) 185 UserDefined14 (Par. No. 517) 185 UserDefined15 (Par. No. 518) 185 UserDefined2 (Par. No. 505) 185 UserDefined3 (Par. No. 506) 185 UserDefined4 (Par. No. 507) 185 UserDefined5 (Par. No. 508) 185 UserDefined6 (Par. No. 509) 185 UserDefined7 (Par. No. 510) 185 UserDefined8 (Par. No. 511) 185 UserDefined9 (Par. No. 512) 185 UsrDefBitWrdA (Par. No. 519) 185 UsrDefBitWrdA0 (Par. No.
Index Z Zero Ramp Input (Par. No. 345) 152 Zero Ramp Output (Par. No. 344) 152 Zero Torque (Par. No. 353) 134 ZeroSpdFloatTime (Par. No.
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