Page 1 PowerFlex® Digital DC Drive USER MANUAL Firmware Version 1.006 - 2.001...
Page 2 Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures. PowerFlex, DriveExplorer, DriveTools SP, DPI, and SCANport are either trademarks or registered trademarks of Rockwell Automation, Inc. ® Klixon is a registered trademark of Sensata Technologies, Inc.
Page 3 Summary of Changes Manual Updates The information below summarizes the changes to the PowerFlex Digital DC Drive User Manual, publication 20-UM001… since the October 2007 release. Change Page(s) Updated the Using Contactors section to include new Contactor Control selections for configuring AC versus DC contactors. Added the “Cable and Wiring Recommendations”...
Page 4 soc-ii The information below summarizes the changes to the PowerFlex Digital DC Drive User Manual, publication 20-UM001… since the initial release. Change Page(s) Removed erroneous derating information. 1-2, Updated AC Input Voltages tables. 1-15 Updated “AnalogCflct” Alarm description to include parameters 1323-1327 [DPI Px Select].
Page 5: Table Of Contents
Table of Contents Important User Information ..........1-2 Summary of Manual Updates .
Page 6 I/O Wiring ............1-32 DIP Switch and Jumper Settings .
Page 7 Appendix A Supplemental Drive Information Specifications ............A-1 IP20 (NEMA UL/Type Open) Watts Loss .
Page 8 Speed Regulation Functions ..........C-17 Adaptive Speed Regulator .
Page 9: Preface
Preface Overview The purpose of this manual is to provide you with the basic information needed to install, start-up and troubleshoot the PowerFlex DC drive. For information on . . . See page . . . Who Should Use this Manual? Preface-1 What is in this Manual? Preface-1...
Page 10: Drive Nameplate Data
Overview Drive Nameplate Data The PowerFlex DC drive contains a data nameplate located on the side of each drive that identifies the specific model number design, applicable AC input power and DC output power data. All communication with Rockwell Automation personnel concerning this product should include this information.
Page 11: Manual Conventions
Overview • To help differentiate parameter names and LCD display text from other Manual Conventions text, the following conventions will be used: – Parameter Names will appear in [brackets]. For example: [Armature Voltage]. – Display Text will appear in “quotes.” For example: “Enabled.” •...
Page 12: Catalog Number Explanation
Overview Catalog Number Explanation Position 8-10 230V, 60 Hz Input Field Supply Drive Armature Field Code Type Code Type Code Frame Amps Amps Three-Phase Regulated PowerFlex DC Fixed Field w/Economy Single-Phase Regulated Motor Operation Code Type Packaging/Documentation Two Quadrant Operation Code Shipping Carton User Manual...
Page 13 Important: The PowerFlex DC drive is not designed for use with multiple motor applications. ATTENTION: The following information is merely a guide for proper installation. Rockwell Automation cannot assume responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this drive or associated equipment.
Page 14: Mounting Considerations
Installation and Wiring Mounting Considerations Operating Conditions and Temperatures PowerFlex DC drives are designed to operate at 0° to 50° C surrounding air temperature without derating. The drive must be mounted in a clean, dry location. Contaminants such as oils, corrosive vapors and abrasive debris must be kept out of the enclosure.
Page 15: Mounting Dimensions And Weights
Installation and Wiring Mounting Dimensions and The PowerFlex DC drive is available in a NEMA/UL Type Open, IP20 enclosure. Following all mounting instructions in order to ensure proper Weights operation. ATTENTION: Remove all loose packing materials, including the container(s) of desiccants (if any), from the drive enclosure before mounting and energizing the drive.
Page 16 Installation and Wiring Figure 1.3 Frame B Approximate Dimensions mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) 311 (12.2) 275 (10.8) 16.5 (0.65) 388 (15.3) 375 (14.8) 350 (13.8) PORT NET A NET B Table 1.B Frame B Weights Weight Drive w/ND Rating Code Drive...
Page 17: Lifting Powerflex Dc Drives
Installation and Wiring Figure 1.4 Frame C Approximate Dimensions mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) 521 (20.5) 499 (19.7) 511 (20.1) 400 (15.7) 200 (7.9) 55 (2.2) 56 (2.2) 416 (16.4) PORT NET A NET B...
Page 18: Mounting Frame C Drives
Installation and Wiring Mounting Frame C Drives All lifting equipment and lifting components (hooks, bolts, lifts, slings, chains, etc.) must have a minimum lifting capacity of 453.6 kg (1,000 lb.). Important: Verify that all mounting screws are properly tightened before and after drive operation.
Page 19: Removing The Drive Covers
Installation and Wiring Removing the Drive Covers The lower protective cover must be removed in order to access the drive’s power and I/O terminals. The upper cover only needs to be removed to install an optional communication adapter and service the drive. (Refer to Installing a Communication Adapter on page E-1 for information.) Frame A Drives...
Page 20: Frame B And C Drives
Installation and Wiring Remove the Lower Protective Cover Remove the two screws as shown below and, while gently lifting along the top edge, slide the cover down and off the chassis. Figure 1.7 Frame A Lower Cover Removal PORT NET A NET B Frame B and C Drives Loosen, but do not remove, the two screws that secure the bottom cover.
Page 21: Line Reactors / Filters
Installation and Wiring Line Reactors / Filters When connecting the drive directly to the main distribution system an AC line reactor must be used to guard against system disturbance. The type of line reactor used depends upon the following: • the current absorbed by the AC input •...
Page 22: Ac Input Contactors
1-10 Installation and Wiring • When a DC contactor and dynamic brake contactor are used: Set parameter 1391 [ContactorControl] to “DC Cntctr+DB” Set one [Relay Out x Sel] parameter (1392 [Relay Out 1 Sel] or [Relay Out 2 Sel]) to “Contactor” and the other relay output to “ContactorDB”...
Page 23: Control Power Protection
Installation and Wiring 1-11 Control Power Protection The 115V / 230V AC control circuit power input terminals U2 and V2 are required to be short circuit protected. This protection can be provided by using standard time delay fuses or a circuit breaker. The time delay fuses or circuit breaker must be selected to survive the short circuit available current of the feeder source for this circuit and the inrush current of the drive’s power supply.
Page 24: General Grounding Requirements
1-12 Installation and Wiring General Grounding The drive Safety Ground - PE must be connected to system ground. Ground impedance must conform to the requirements of national and local Requirements industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked.
Page 25: Power Feeder
Installation and Wiring 1-13 Power Feeder Each power feeder from the substation transformer to the drive must be provided with properly sized ground cables. The conduit or cable armor should be bonded to the substation ground at both ends. Each transformer enclosure and/or frame must be bonded to ground at a minimum of two locations.
Page 26: Cable And Wiring Recommendations
1-14 Installation and Wiring Cable and Wiring Use the following cable and spacing recommendations for all drives sizes: Recommendations Minimum Spacing Between Classes Steel Conduit/Tray See Spacing Wiring Notes, Category Class Signal Definition Signal Example Cable Type 2/3/4 9/10/11 page 1-15 Power AC Power (600V 2.3kV 3/ph AC Lines Per NEC &...
Page 27: Power Wiring
Installation and Wiring 1-15 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 601 volts. B.
Page 28: Dc Output Voltages
1-16 Installation and Wiring DC Output Voltages The output voltages below take into account an AC input undervoltage within the stated tolerance limits and a voltage drop of 4% due to an AC input line reactor. It is the same as the rated armature voltage suggested for the connected motor.
Page 29: Typical Power Wiring Diagrams
Installation and Wiring 1-17 Typical Power Wiring Diagrams Figure 1.10 Figure 1.13 represent recommended power wiring configurations. Figure 1.10 Power Wiring with AC Input Contactor (on I/O TB4) (N.O. Relay) M1 AC Contactor 19 (+24V - on I/O TB2) 3 Phase AC line PowerFlex DC Drive Control...
Page 30 1-18 Installation and Wiring Figure 1.11 Power Wiring with DC Output Contactor 34 (on I/O TB4) (N.O. Relay) M1 DC Contactor 19 (+24V on I/O TB2) 3 Phase AC line PowerFlex DC Drive Control Board P/S 460V 115V Control Power / Relay Terminal Block Field Power...
Page 31 Installation and Wiring 1-19 Figure 1.12 Power Wiring with DC Output Contactor and a Dynamic Brake 34 (on I/O TB4) (N.O. Relay) M1 DC Contactor 19 (+24V on I/O TB2) 3 Phase AC line PowerFlex DC Drive (N.C. Relay) DB Contactor Control Board P/S Resistor...
Page 32: Armature Converter Connections
1-20 Installation and Wiring Armature Converter Connections Terminals Description U, V, W Three phase AC input to the armature converter C, D DC output to the motor armature Safety ground Figure 1.14 Frame A Armature Converter Terminal Block Location Front View Note: Front view of drive shown with bottom protective and power terminal covers removed.
Page 33 Installation and Wiring 1-21 Figure 1.16 Frame C Armature Converter Terminal Block Location Front View Bottom View PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 34 1-22 Installation and Wiring Table 1.E Armature and Safety Ground (PE) Terminal Specifications Drive Current Rating Code Terminal Bolt Tightening Torque • • 230V 460V Terminals Wire Size and Type Size (mm) m / lbs A 7P0 – U, V, W, C, D, PE 6 / 53 –...
Page 35: Field Circuit Connections
Installation and Wiring 1-23 Field Circuit Connections Terminals Description U1, V1 Single phase AC input to the field circuit C1, D1 DC output to the motor field Figure 1.17 Frame A Field Circuit Terminal Block Location Bottom of Drive Figure 1.18 Frame B Field Circuit Terminal Block Location Top of drive PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 36: Field Current Resistors
1-24 Installation and Wiring Figure 1.19 Frame C Field Circuit Terminal Block Location Front of drive Table 1.F Field Circuit Wire Sizes and Terminal Specifications Drive Current Rating Code Tightening Torque • • Frame 230V 460V Terminals m / lbs Wire Size and Type U1, V1, C1, D1 0.5 - 0.8 / 4.4 - 7.1...
Page 37: Relay Outputs
Installation and Wiring 1-25 Compare the field current value of the motor to the rated value of the internal field converter of the drive (see Table 1.G below) and set switch S14 to the closest value. Note: The configuration of switch S14 is not required if the motor’s field control is provided via an external source, however, in this case it is recommended that the switch settings be completed as described above.
Page 38 1-26 Installation and Wiring between terminals 78 and 79 (installed at the factory). Follow the appropriate instructions below when installing a thermal sensor. Thermistors (PTC) PTC thermistors fitted in the motor can be connected directly to the drive via terminals 78 and 79. In this case the 1k ohm resistor is not required between terminals 78 and 79.
Page 39 Installation and Wiring 1-27 Figure 1.21 Frame B Relay and Thermistor/Thermal Switch Terminal Block Locations 78 79 35 36 75 76 Figure 1.22 Frame C Relay and Thermistor/Thermal Switch Terminal Block Locations 35 36 75 76 78 79 PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 40: Control Circuit Input Power
1-28 Installation and Wiring Control Circuit Input Power Terminals Description U2, V2 Single phase AC power for the control circuits The control circuit must be powered by an external 230V AC or 115V AC single phase power supply. For frame B and C drives only, a jumper is required between terminals SA and SB for 115V AC control input power.
Page 41 Installation and Wiring 1-29 Figure 1.25 Frame C Control Circuit Terminal Block Location Table 1.I Control Circuit Wire Sizes and Terminal Specifications Drive Current Rating Code Wire Size and Type Flexible Multi-core Tightening Torque • • 230V 460V Terminals m / lbs All All U2, V2 0.14 - 1.5...
Page 42 1-30 Installation and Wiring Figure 1.27 SA-SB Terminal Block Location on Frame C Drives The SA-SB terminal block is located on the Switching Power Supply circuit board on the back of the Control EMI Shield. Switching Power Supply board SA-SB terminals Back of Control EMI shield XSW connector To access the SA-SB terminal block:...
Page 43: Frame C Heatsink Cooling Fans And Armature Fuse Signal Terminals
Installation and Wiring 1-31 Frame C Heatsink Cooling Fans and Armature Fuse Signal Terminals Frame C drives require an external power supply for the heatsink cooling fans and include internal armature circuit protection fuses (drives rated 521A @ 230V AC and 495A and 667A @ 460V AC input only). The terminals for the internal armature circuit protection fuses can be connected to an external device to provide indication that the fuses have opened.
Page 44: I/O Wiring
1-32 Installation and Wiring I/O Wiring Observe the following points when installing I/O wiring: • Use copper wire only. • Wire with an insulation rating of 600V or greater is recommended? Important: I/O terminals labeled “(–)” or “Common” are not referenced to earth ground and are designed to greatly reduce common mode interference.
Page 45 Installation and Wiring 1-33 Table 1.L Control Circuit Board Jumper and DIP Switch Settings Jumper/ Factory Switch Function Default For factory boot flashing only. Leave set to the factory setting. Jumper Off Jumper On Firmware boot Jumper Off Normal function For factory boot flashing only.
Page 46 1-34 Installation and Wiring ATTENTION: The Drive can overspeed if DIP switch S4 is set incorrectly, or the tachometer is wired incorrectly. Failure to observe this precaution could result in damage to, or destruction of, the equipment. Figure 1.30 DC Analog Tachometer DIP Switch S4 Example Note: Illustration for example only.
Page 47: I/O Signal And Control Wiring
Installation and Wiring 1-35 Table 1.O Drives with 460V Input - DIP Switch S15 Configuration Drive Current Rating Code S15-1 S15-2 S15-3 S15-4 S15-5 S15-6 S15-7 S15-8 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.
Page 48 1-36 Installation and Wiring Figure 1.32 I/O Terminal Block Locations Terminal Block 3 Terminal Block 4 Terminal Block 1 Terminal Block 2 Table 1.Q I/O Terminal Block 1 Designations No. Signal Description Factory Default Config. Parameter Analog Input 1 (+) Isolated , bipolar, differential 1 “Speed Ref A”...
Page 49: I/O Wiring Examples
Installation and Wiring 1-37 Table 1.S I/O Terminal Block 3 Designations Factory No. Signal Description Default Config. Parameter Max. ±10V, 5 mA. Analog Output 1 (+) 12 “Motor Speed” 66 [Anlg Out1 Sel] Analog Output 1 (–) Analog Output 2 (+) 13 “Motor Curr”...
Page 50 1-38 Installation and Wiring Required Parameter Input/Output Connection Example Changes • Set Direction Mode: Analog Input Bipolar Speed 1322 [Direction Mode] Reference Common ±10V Input = 1 “Bipolar” • Adjust Scaling: 72 [Anlg In1 Scale] and 73 [Anlg1 Tune Scale] •...
Page 51 Installation and Wiring 1-39 Required Parameter Input/Output Connection Example Changes • Set Digital Input 1: 2-Wire Control 133 [Digital In1 Sel] Reversing Run Fwd. = 6 “Run Forward” 24V DC external supply • Set Digital Input 2: Run Rev. 134 [Digital In2 Sel] = 7 “Run Reverse”...
Page 52: Digital Encoder Terminal Block
1-40 Installation and Wiring Digital Encoder Terminal Block The encoder connection cables should always be connected directly to the terminals on the encoder terminal block. The encoder cable must be made up of twisted pairs with the shield connected to the shield ground on the drive side.
Page 53 Installation and Wiring 1-41 Figure 1.34 Sample Encoder Wiring Connection Example Encoder Power – Internal Drive Power +5/12-15V DC (200 mA) Internal (drive) +5/12-15V DC, 200mA Common to Shield Encoder Power –External Power Source Shield External Power Supply Encoder Signal – to Power Single-Ended, Dual Channel Supply Common...
Page 54: Dc Analog Tachometer Terminal Block
1-42 Installation and Wiring DC Analog Tachometer Terminal Block Figure 1.35 Analog Tachometer Terminal Block Location Analog Tachometer terminal block Refer to page A-3 for DC Analog Tachometer specifications. ATTENTION: The Drive can overspeed if DIP switch S4 is set incorrectly, or the tachometer is wired incorrectly.
Page 55: Drive Start Up
Chapter Drive Start Up This chapter describes how to start up the PowerFlex DC drive. The drive is configured at the factory for speed regulation with encoder feedback and independant motor field current regulation with constant current to control the motor from zero to base speed. If using the LCD HIM (Human Interface Module) to commission the drive, it is recommended that you read Appendix B...
Page 56: Drive Start Up Checklist
Drive Start Up Drive Start Up Checklist This checklist contains the major steps required to complete the drive commissioning procedure. 1. Verify all Drive Configuration Settings - page 2-2. 2. Verify the Power Wiring - page 2-2. 3. Verify the Control and I/O Wiring - page 2-3.
Page 57 Drive Start Up 3. Verify the Control and I/O Wiring: 1. Verify that control power and I/O wiring is correct. A digital input (1-8 only) must be wired and configured as a drive enable. Refer to Control Circuit Input Power on page 1-28 I/O Wiring on page 1-32 for further information.
Page 58: Applying Power To The Drive
Drive Start Up Applying Power to the Drive The remainder of the “Drive Start Up” procedure in this manual uses a HIM to configure and autotune the drive. If you prefer, you can use the DriveExplorer™ or DriveTools™ SP software to program drive parameters or use the drive “Start Up”...
Page 59 Drive Start Up Figure 2.1 Drive Status Indicators PORT NET A NET B Name Color State Description Green Flashing Drive ready, but not running and no faults are present. (Status) Steady Drive running, no faults are present. Yellow Flashing, A condition exists that is preventing the drive from Drive Stopped starting.
Page 60 Drive Start Up 6. Load the Default Settings: It is recommended that you reset the drive to the default settings. By resetting the drive to the default settings, any previous parameter modifications you have made will be overwritten. 1. On the HIM, from the “Main” menu scroll to the “Memory Storage”...
Page 61 Drive Start Up 10. With the “Motor Data” group selected, press Enter and configure the following parameters: 45 [Max Ref Speed] - Enter the motor nameplate base speed. If the application requires field weakening to operate above base speed, enter the maximum reference speed required. 162 [Max Feedback Spd] - Enter the motor nameplate base speed.
Page 62 Drive Start Up 11. Access the “Field Config” group and configure the following parameters: If the motor field power is supplied by an external source, set Par 497 [Field Reg Enable] = 0 “Disabled”. Otherwise, verify that this parameter is set to 1 “Enabled” (default). If you are utilizing field economy when the drive is stopped or at zero speed, set Par 1407 [Field Econ Delay] to the desired amount of time to elapse after the drive stops or reaches zero...
Page 63 Drive Start Up 12. Access the “Utility” file and press Enter. 13. Access the “Alarms” group and configure the following parameters: Par 481 [UnderVolt Thresh] - Enter the value at which a drive under voltage condition will be detected (default = 230V). Par 584 [OverCurrent Thr] - Enter the value at which a drive over current condition will be detected (default = 175%).
Page 64 2-10 Drive Start Up 17. Access the “Digital Outputs” group and configure the following parameters: If a contactor and a dynamic brake resistor is used: Par 629 [Relay Out 2 Sel] = 24 “ContactorDB”. If a neither a contactor and a dynamic brake resistor is used: Par 629 [Relay Out 2 Sel] = Set to other than 24 “ContactorDB”...
Page 65 Drive Start Up 2-11 2. Access the “Motor Control” file, the “Torq Attributes” group and set Par 7 [Current Limit] to the appropriate level for your application. This parameter defaults to 150%. The drive’s armature output current will correspond to Par 179 [Nom Mtr Arm Amps] x Par 7 [Current Limit].
Page 66 2-12 Drive Start Up 1. When checking motor polarity, the drive will have power applied and the motor will rotate. Verify that the motor is uncoupled from the load. If the motor cannot be uncoupled from the load, the following motor checks are recommended: All electrical connections are tight.
Page 67 Drive Start Up 2-13 9. Apply power to the drive. 10. Repeat steps 4 and 5 above and verify that the motor rotation is correct. 11. Complete the appropriate procedure based on the type of feedback device used for the application: For Armature Voltage feedback - Continue with Step 10 Configure the Speed Feedback Parameters: on page 2-14.
Page 68 2-14 Drive Start Up 10. Configure the Speed Feedback Parameters: 1. Access the “Speed Feedback” group and configure the following parameters: Par 414 [Fdbk Device Type] - Select the source for motor velocity feedback: 1 “Encoder”, 2 “DC Tach” or 3 “Armature” (default).
Page 69 Drive Start Up 2-15 4. Access the “Dynamic Control” file and press Enter. 5. Access the “Ramp Rates” group and configure the following parameters: Par 660 [Accel Time 1] - Set the desired acceleration ramp time. Par 662 [Decel Time 1] - Set the desired deceleration ramp time.
Page 70 2-16 Drive Start Up 3. Press the Start button on the HIM. This will start the speed regulator auto tuning test, which could take several minutes. When the test has been completed, the drive will automatically stop. During the test the following are completed: An acceleration test, with the torque limit value set in the Par 1048 [Autotune Cur Lim].
Page 71 Drive Start Up 2-17 1. Set the speed reference to “0” (zero) using the assigned source (HIM or analog potentiometer). Refer to Reference Control on page C-13 for more information on speed reference sources. 2. View Par 385 [Speed Ref Out] and verify that the value is “0”. 3.
Page 72: Speed-Up Function
2-18 Drive Start Up For additional regulator fine tuning procedures, refer to Fine Tuning the Regulators on page C-25. Speed-Up Function Oscillation may occur during a speed change with loads presenting a high moment of inertia. These oscillations can be reduced by enabling the “Speed Up”...
Page 73: Programming And Parameters
Chapter Programming and Parameters This chapter provides a complete listing and description of the PowerFlex DC drive parameters. The parameters can be programmed (viewed/edited) using a Human Interface Module (HIM). As an alternative, programming can also be performed using DriveExplorer™ or DriveTools™ SP software and a personal computer.
Page 74 Programming and Parameters Parameter Name & Description Values [Flying Start En] Default: “Disabled” Enables/Disables the ability of the drive to connect to a Options: “Disabled” spinning motor at actual RPM when a start command is “Enabled” issued. • “Enabled” = When the drive is turned on, the speed of the motor is measured and the ramp output is set accordingly.
Page 75: How Parameters Are Organized
Programming and Parameters How Parameters are 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, Organized 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...
Page 76: Basic Parameter View
Programming and Parameters Basic Parameter View Parameter 211 [Param Access Lvl] set to option 0 “Basic”. File Group Parameters Monitor Speed Meters [Speed Ref A] [Ramp In Pct] [Spd Feedback] [Speed Ref A Pct] [Ramp Out] [Spd Feedback Pct] 121 M o n it [Speed Ref B] [Ramp Out Pct]...
Page 77 Programming and Parameters File Group Parameters Utility Reference Config [Direction Mode] 1322 [Man Ref Preload] [MOP Select] 1375 [Save HIM Ref] [Save MOP Ref] U ti li ty Drive Memory [Param Access Lvl] 211 [Reset Defaults] Diagnostics [Drive Status 1] [Start Inhibits] 1403 [At Zero Speed]...
Page 78: Advanced Parameter View
Programming and Parameters Advanced Parameter View Parameter 211 [Param Access Lvl] set to option 1 “Advanced”. File Group Parameters Monitor Speed Meters [Speed Ref A] [Ramp In Pct] [Spd Feedback] [Speed Ref A Pct] [Ramp Out] [Spd Feedback Pct] 121 M o n it [Speed Ref B] [Ramp Out Pct]...
Page 79 Programming and Parameters File Group Parameters Dynamic Control Ramp Rates [Speed Ramp En] [MOP Decel Time] [Ramp Delay] [Ramp Type Select] 18 [Jog Ramp Time] 1410 [Zero Ramp Output] 344 [Accel Time 1] [S Curve Time] [Zero Ramp Input] D y n a m ic C o n tr o l [Decel Time 1]...
Page 80 Programming and Parameters File Group Parameters Applications PI Control [Enable PI] [PI Central v1] [PI Central vs1] [PI Steady Thrsh] [PI Central v2] [PI integr freeze] A p p li c a ti o n s [PI Integral Gain] [PI Central v3] [PI Upper Limit] [PI Prop Gain PID] [PI Central v sel]...
Page 81 Programming and Parameters File Group Parameters Utility Reference Config [Direction Mode] 1322 [Man Ref Preload] [MOP Select] 1375 [Save HIM Ref] [Save MOP Ref] U ti li ty Drive Memory [Param Access Lvl] 211 [Reset Defaults] Diagnostics [Drive Status 1] [Torque Positive] [Accel Status] 1188...
Page 82 3-10 Programming and Parameters File Group Parameters Input / Output Analog Inputs [Anlg In1 Sel] [Anlg2 Tune Scale] [Anlg In2 Target] [Anlg In1 Config] [Anlg In2 Offset] [Anlg In3 Target] In p u ts / O u tp u ts [Anlg In1 Scale] [Anlg In2 Tune] [Anlg In1 Cmp]...
Page 83: Monitor File
Programming and Parameters 3-11 Monitor File Parameter Name & Description Values page 3-2 for symbol descriptions [Speed Ref A] Default: Read Only First speed reference for the drive. Negative values apply to four Min/Max: –/+ Par 45 [Max Ref Speed] quadrant drives only.
Page 84 3-12 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [Actual Speed] Default: Read Only Filtered value of Par 122 [Spd Feedback]. Min/Max: –/+32766 Note: This parameter can be assigned to an analog output. Units: 1018 [Speed Draw Out] Default: Read Only...
Page 85 Programming and Parameters 3-13 Parameter Name & Description Values page 3-2 for symbol descriptions [FaultCode] Default: Read Only A code that represents the fault that tripped the drive. Refer to Min/Max: 0 / 65535 Fault Descriptions on page 4-4 for a list of fault codes and descriptions.
Page 86: Motor Control File
3-14 Programming and Parameters Motor Control File Parameter Name & Description Values page 3-2 for symbol descriptions [Max Ref Speed] Default: 1750 Maximum reference speed as determined by the application. If Min/Max: 1 / 16383 Field Weakening is not required, this value will be equal to the Units: Motor Nameplate Base Speed (RPM).
Page 87 Programming and Parameters 3-15 Parameter Name & Description Values page 3-2 for symbol descriptions [Fld Reg Ki Base] Default: 3277.00 Integral gain (K ) of the field current regulator in (base value). Min/Max: 0.10 / 32770.00 [Fld Weaken Ratio] Default: The ratio of Motor Nameplate Base Speed to Par 45 [Max Ref Min/Max: 0 / 100...
Page 88 3-16 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [Field Economy En] Default: “Enabled” 395, When this parameter is set to 1 = “Enabled” and the value in Par Options: “Disabled” 107 [Speed Zero Level] is reached, the minimum field current “Enabled”...
Page 89 Programming and Parameters 3-17 Parameter Name & Description Values page 3-2 for symbol descriptions [Current Lim Pos] Default: The drive current limit for the positive current direction Min/Max: 0 / 200 expressed as a percentage of the value in Par 179 [Nom Mtr Units: Arm Amps].
Page 90 3-18 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [TrqTpr_Enable] Default: “Disabled” 751, 752, Enables/Disables the current/speed function. The current/speed Options: “Disabled” 753, function allows you to change the current limits set in Pars 8 “Enabled”...
Page 91 Programming and Parameters 3-19 Parameter Name & Description Values page 3-2 for symbol descriptions [Filt Torq Cur] Default: 0.100 1193 First rate low-pass filter for Par 1193 [Torq Current Pct]. Min/Max: 0.001 / 0.250 Units: [Encoder PPR] Default: 1024.00 Number of pulses per revolution of the digital encoder. The Min/Max: 100.00 / 32770.00 value of Pars 169 [Encoder PPR] and 162 [Max Feedback Spd]...
Page 92 3-20 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [Encoder Err Chk] Default: “Disabled” Enables/Disables monitoring of the digital encoder connection Options: “Disabled” status. When an alarm is detected, the HIM displays the “Enabled” “Encoder Loss” (F91) fault. This parameter can be programmed on a digital output.
Page 93 Programming and Parameters 3-21 Parameter Name & Description Values page 3-2 for symbol descriptions 1014 [Inertia] Default: Based on drive current rating Motor inertia value. Min/Max: 0.001 / 999.999 1 Kg–m = 23.76 lb–ft Units: Kg–m 1015 [Friction] Default: Based on drive current rating Motor friction value.
Page 94 3-22 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [TstGen Output] Default: “NotConnected” Allows you to select a simulated parameter as the output for the Options: “NotConnected” test generator. The test generator is used to manually tune the “Reserved”...
Page 95: Speed Command File
Programming and Parameters 3-23 Speed Command File Parameter Name & Description Values page 3-2 for symbol descriptions [Minimum Speed] Default: Defines the minimum speed of the drive. This value applies to both Min/Max: 0 / Par 45 [Max Ref Speed] directions of motor rotation for four quadrant drives.
Page 96 3-24 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions 1409 [Jog Off Delay] Default: Specifies the amount of time that will elapse between removing the Min/Max: 0 - 10 Jog input and commanding the main contactor to open. The amount Units: of time specified in [Jog Off Delay] will not begin to elapse until the measured speed feedback is less than or equal to the value of...
Page 97 Programming and Parameters 3-25 Parameter Name & Description Values page 3-2 for symbol descriptions [Speed Thresh Pos] Default: 1000 Threshold speed for the drive above or below which the value of Par Min/Max: 1 / 32767 393 [Speed Threshold] changes. When the speed of the drive Units: exceeds the value of this parameter, Par 393 [Speed Threshold] displays “Above Thresh”...
Page 98 3-26 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [Spd Zero I En] Default: “Disable” Enables/Disables the output of the integral section of the speed Options: “Disable” regulator. Used in the Zero Speed function. “Enable” •...
Page 99 Programming and Parameters 3-27 Parameter Name & Description Values page 3-2 for symbol descriptions [Flying Start En] Default: “Disabled” Enables/Disables the ability of the drive to connect to a spinning Options: “Disabled” motor at actual RPM when a start command is issued. “Enabled”...
Page 100 3-28 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions 1016 [SpdFuncSelect] Default: “Speed Up” 444, 445, Selection of the “Speed Up” or “Inertia/Loss compensation” function. Options: “Speed Up” 447, Note that these two functions are mutually exclusive - if one is “Inertia/loss”...
Page 101: Dynamic Control File
Programming and Parameters 3-29 Dynamic Control File Parameter Name & Description Values page 3-2 for symbol descriptions [Ramp Type Select] Default: “Linear” Determines the type of ramp used. Options: “Linear” • 0 “Linear” = Linear ramp “S shaped” • 1 “S shaped” = S–shaped ramp [S Curve Time] Default: 1.00...
Page 102 3-30 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [Decel Time 2] Default: Sets the rate of deceleration for Ramp 2. Min/Max: 0 / 65535 Deceleration rate for Ramp 2 = Par 2 [Maximum Speed] / Par 30 Units: [Decel Time 2].
Page 103 Programming and Parameters 3-31 Parameter Name & Description Values page 3-2 for symbol descriptions [Torq Red CurLim] Default: The armature current limit, defined as a percentage of the value Min/Max: 0 / 200 defined in Par 179 [Nom Mtr Arm Amps] when Par 342 [Torque Units: Reduction] is set to 1 “Active”.
Page 104 3-32 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions 1262 [Closing Speed] Default: Motor speed at which the brake is closed. Used with External Brake Min/Max: 0 / 200 Control. Units: 1263 [Opening Delay] Default: Amount of time before the brake will open after the drive has been Min/Max: 0 / 30000...
Page 105 Programming and Parameters 3-33 Parameter Name & Description Values page 3-2 for symbol descriptions [Adaptive Joint 1] Default: 6.11 Defines a range above and below the value set in Par 184 [Adaptive Min/Max: 0.00 / 200.00 Spd 1] within which there is a linear change in gain from parameter Units: set 1 to parameter set 2 in order to prevent jumps in the adaptive speed regulator.
Page 106: Applications File
3-34 Programming and Parameters Applications File Parameter Name & Description Values page 3-2 for symbol descriptions [PI Steady Thrsh] Default: Feed–forward threshold for PI. Min/Max: 0 / 10000 • 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].
Page 107 Programming and Parameters 3-35 Parameter Name & Description Values page 3-2 for symbol descriptions [PI Central v sel] Default: 769, 776, Selects one of the four possible initial output values of the PID Min/Max: 0 / 3 777, regulator integral component (corresponding to the initial diameter) of 778, the PI block.
Page 108 3-36 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [PD Output PID] Default: Read Only Proportional / Derivative (PD) block output. Min/Max: –/+10000 [PD Deriv Gain 1] Default: 1.00 First derivative gain of the PD block. The value specified in this field Min/Max: 0.00 / 100.00 depends on the enabling and configuration of Par 181 [Adaptive Spd...
Page 109 Programming and Parameters 3-37 Parameter Name & Description Values page 3-2 for symbol descriptions [PID Clamp] Default: 10000 759, 763, The PID “clamp” allows a smooth tension setting of a controlled Min/Max: 0 / 10000 system winder/unwinder when the calculation of the initial diameter function cannot be used.
Page 110 3-38 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [PID Target] Default: “Not Used” Parameter number to which the PID Output value will be written. Options: 0 = “Not Used” 16 = “Reserved” 32 = “UsrDefined13” (Par 516) 1 = “Cur Lim Pos”...
Page 111 Programming and Parameters 3-39 Parameter Name & Description Values page 3-2 for symbol descriptions 1254 [PID Error Gain] Default: 1.005 Gain percentage of Par 759 [PID Error]. Min/Max: 0.000 / 32.010 Units: 1258 [Enable PID] Default: “Disabled” Enables/Disables both the PI and PD portions of the PID regulator. Options: “Disabled”...
Page 112 3-40 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [Scale1 In Off] Default: 0.00 [Scale2 In Off] Min/Max: – 2 / +2 – 1 1224 [Scale3 In Off] 1233 [Scale4 In Off] 1242 [Scale5 In Off] 1251 [Scale6 In Off] Offset to be added to the input quantity.
Page 113 Programming and Parameters 3-41 Parameter Name & Description Values page 3-2 for symbol descriptions 1153 [Max Diameter] Default: 1.00 Maximum roll diameter. Min/Max: 0.00 / 32.00 Units: 1154 [Roll Diameter] Default: Read Only Displays the calculated roll diameter. Note: This parameter can be Min/Max: 0.00 / 32.00 assigned to an analog output as a percentage of Par 1153 [Max...
Page 114 3-42 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions 1166 [Diam Preset 2] Default: 1.00 799, 1153 Third preset starting diameter. The value of this parameter must be Min/Max: 0.00 / 32.00 set between the value of Pars 799 [Minimum Diameter] and 1153 Units: [Max Diameter].
Page 115 Programming and Parameters 3-43 Parameter Name & Description Values page 3-2 for symbol descriptions 1176 [Taper Enable] Default: “Disabled” Enables/Disables the Taper function. Options: “Disabled” “Enabled” 1177 [Initial Diameter] Default: 0.10 Diameter that starts the taper tension reduction. Min/Max: 0.00 / 32.00 Units: 1178 [Final Diameter] Default:...
Page 116 3-44 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions 1196 [Spd Match Acc] Default: 83.88 Motor acceleration time during the launching phase. Min/Max: 0.30 / 300.00 Units: 1197 [Spd Match Dec] Default: 83.88 Motor deceleration time. If the motor decelerates during the launching Min/Max: 0.30 / 300.00 phase a stop command is issued.
Page 117 Programming and Parameters 3-45 Parameter Name & Description Values page 3-2 for symbol descriptions 1215 [Speed Demand En] Default: “Disabled” Enables/Disables the speed reference calculation for the Torque Options: “Disabled” Winder application. “Enabled” 1216 [Spd match torque] Default: Sets the torque current during the launching and change phase. Min/Max: 0 / 200 Units:...
Page 118: Utility File
3-46 Programming and Parameters Utility File Parameter Name & Description Values page 3-2 for symbol descriptions [Save HIM Ref] Enables a feature to save the present reference value issued by the HIM to drive memory when a power loss occurs. The value is restored to the HIM at power up.
Page 119 Programming and Parameters 3-47 Parameter Name & Description Values page 3-2 for symbol descriptions [Torque Positive] Default: Read Only Indicates whether the drive is operating with a positive torque Min/Max: 0 / 1 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.
Page 120 3-48 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [Drive Status 1] Read Only Present operating condition of the drive. Bit 0 “Ready” - When set (= “1”), the drive is ready Bit 1 “Active” - When set, the drive is active Bit 2 “Command Dir”...
Page 121 Programming and Parameters 3-49 Parameter Name & Description Values page 3-2 for symbol descriptions [Speed Threshold] Default: Read Only 101, 102, Indicates if the drive is above or below the threshold speed specified Min/Max: 0 / 1 in parameters 101 [Speed Thresh Pos] (clockwise rotation) and 102 [Speed Thresh Neg] (counter-clockwise rotation).
Page 122 3-50 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [Spd Select 1] Default: Read Only 400, Indicates the state of the assigned digital input, [Digital Inx Sel], set to Min/Max: 0 / 1 18 “Speed Sel 2”. Refer to Option Definitions for [Digital Inx Sel] on page 3-66 for instructions on how to set digital input speed selects to...
Page 123 Programming and Parameters 3-51 Parameter Name & Description Values page 3-2 for symbol descriptions 1328 [Drive Logic Rslt] The final logic command resulting from the combination of all DPI and discrete inputs. This parameter has the same structure as the product specific logic command received via DPI and is used in peer to peer communications. For each bit, 1=Condition true and 0=Condition false.
Page 124 3-52 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions 1402 [Last Stop Source] Default: Read Only Displays the source that initiated the most recent stop sequence. Options: “Pwr Removed” 1 - 5 = “DPI Port 1-5” “Reserved”...
Page 125 Programming and Parameters 3-53 Parameter Name & Description Values page 3-2 for symbol descriptions 1351 [Fault 1 Code] Default: Read Only 1352 [Fault 2 Code] Min/Max: 0 / 32768 1353 [Fault 3 Code] 1354 [Fault 4 Code] 1355 [Fault 5 Code] 1356 [Fault 6 Code] 1357...
Page 126 3-54 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [FldLoss Flt Cfg] Default: “Fault” Determines the response of the drive to a field loss condition (F6 “Fld Options: “Ignore” Current Loss”). If Par 497 [Field Reg Enable] is set to 0 “Disabled”, “Alarm”...
Page 127 Programming and Parameters 3-55 Parameter Name & Description Values page 3-2 for symbol descriptions [UsrValDiv1] Default: Denominator in the calculation for scaling the user-defined, drive Min/Max: 1 / 32767 speed display units. Note: This parameter is not used. [UserDefined0] Default: [UserDefined1] Min/Max: –32768/+32767...
Page 128 3-56 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [UsrDefBitWrdA0] Default: [UsrDefBitWrdA1] Min/Max: 0 / 1 [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.
Page 129 Programming and Parameters 3-57 Parameter Name & Description Values page 3-2 for symbol descriptions [UsrDefBitWrdB] Default: 537 - A bitmap of Pars 537 [UsrDefBitWrdB0] through 552 Min/Max: 0 / 65535 [UsrDefBitWrdB15]. With a parameter it is possible to read or write all of the bits inside a word.
Page 130: Communications File
3-58 Programming and Parameters Communications File Parameter Name & Description Values page 3-2 for symbol descriptions [DPI Baud Rate] Default: Read Only Shows the data transfer rate for attached drive peripherals. Min/Max: 1 / 1 “1” - 500 kbps [DPI Port Sel] Default: “DPI Port 1”...
Page 131 Programming and Parameters 3-59 Parameter Name & Description Values page 3-2 for symbol descriptions [Local Mask] [Logic Mask] Controls which adapters are allowed to take exclusive control of drive logic commands (except stop). Exclusive “local” control can only be taken while the drive is stopped. [Stop Owner] The adapters that are presently issuing a valid stop command.
Page 132 3-60 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [Data In A1] – Link A Word 1 Default: 0 (0 = “Disabled”) [Data In A2] – Link A Word 2 Min/Max: 0 / 1408 Parameter number whose value will be written from a communications device data table.
Page 133 Programming and Parameters 3-61 Parameter Name & Description Values page 3-2 for symbol descriptions 1377 [Write Mask Act] Read Only 1378 The status of write access for the DPI ports. When bit 15 is set, network security is controlling the write mask instead of Par 1378 [Write Mask Cfg]. 0 = Read Only, 1 = Write Permitted, x = Reserved.
Page 134: Input / Output File
3-62 Programming and Parameters Input / Output File Parameter Name & Description Values page 3-2 for symbol descriptions [Anlg In1 Sel] Default: “Speed Ref A” [Anlg In2 Sel] Default: “Off” [Anlg In3 Sel] Default: “Off” Selects the parameter to which a value will be written from the analog input.
Page 135 Programming and Parameters 3-63 Parameter Name & Description Values page 3-2 for symbol descriptions [Anlg In1 Offset] Default: [Anlg In2 Offset] Min/Max: –32768/+32767 [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.
Page 136 3-64 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions 1404 [Analog In1 Value] Default: Read Only Value of the signal at analog input 1. Units based on the value Min/Max: -/+20.00 set in Par 71 [Anlg In1 Config]. Units: V or mA 1405...
Page 137 Programming and Parameters 3-65 Parameter Name & Description Values page 3-2 for symbol descriptions [Digital In1 Sel] Default: “Stop/CF” [Digital In2 Sel] Default: “Start” [Digital In3 Sel] Default: 11 = “Jog” [Digital In4 Sel] Default: “Enable” [Digital In5 Sel] Default: 17 = “Speed Sel 1”...
Page 138 3-66 Programming and Parameters Parameter Name & Description Values page 3-2 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.
Page 139 Programming and Parameters 3-67 Parameter Name & Description Values page 3-2 for symbol descriptions [Dig In Status] Read Only Status of the digital inputs. Default 15 14 13 12 11 10 9 [Dig In Term 1] Default: Read Only [Dig In Term 2] Min/Max: 0 / 1 [Dig In Term 3]...
Page 140 3-68 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [Digital Out1 Sel] Default: “Ready” [Digital Out2 Sel] Default: “Fault” [Digital Out3 Sel] Default: “Spd Thresh” [Digital Out4 Sel] Default: “CurrentLimit” [Digital Out5 Sel]* Default: 26 = “Alarm”...
Page 141 Programming and Parameters 3-69 Parameter Name & Description Values page 3-2 for symbol descriptions Option Definitions for [Digital Outx Sel], [Relay Out 1 Sel] and [Relay Out 2 Sel] Option Description Spd Zero Thr “0” indicates that the drive is operating below the value set in Par 107 [Speed Zero Level] , “1” indicates that the drive is operating above Par 107 [Speed Zero Level].
Page 142 3-70 Programming and Parameters Parameter Name & Description Values page 3-2 for symbol descriptions [Dig Out Status] Read Only Status of the standard digital outputs and relay outputs on the drive and on the optional I/O Expansion circuit board (if present). Default 15 14 13 12 11 10 9 [Relay Out 2 Sel]...
Page 143 Programming and Parameters 3-71 Parameter Name & Description Values page 3-2 for symbol descriptions 1393 [Inversion Relay1] Default: “Disabled” Inverts the signal for Relay Output 1. Options: “Disabled” “Enabled” 1323 [DPI P1 Select] Default: “Off” Selects the destination of the reference value from DPI Port 1. Options: ”Off”...
Page 144: Parameter Cross Reference - By Name
3-72 Programming and Parameters Parameter Cross Reference Name Group Page Name Group Page Anlg3 Tune Scale Analog Inputs 3-62 – by Name AC Line Freq Drive Data 3-13 Arm Current Current Meters 3-12 AC Line Voltage Drive Data 3-13 Arm Current Pct Current Meters 3-12 Acc Dec Filter...
Page 145 Programming and Parameters 3-73 Name Group Page Name Group Page Diameter Calc St Diameter Calc 3-40 Enable PD PD Control 3-36 Diameter Filter 1162 Diameter Calc 3-41 Enable PI PI Control 3-34 Diameter Reached 1159 Diameter Calc 3-41 Enable PID 1258 PID Control 3-39...
Page 146 3-74 Programming and Parameters Name Group Page Name Group Page I Reg Error Autotune 3-20 Minimum Speed Limits 3-23 Inertia 1014 Autotune 3-21 MOP Accel Time Ramp Rates 3-29 Inertia C Filter 1012 Autotune 3-20 MOP Dec Active Diagnostics 3-49 InertiaCompAct 1191 Speed Regulator...
Page 147 Programming and Parameters 3-75 Name Group Page Name Group Page Preset Speed 6 Discrete Speeds 3-23 Scale4 Out Off 1234 Scale Blocks 3-40 Preset Speed 7 Discrete Speeds 3-23 Scale4 Output 1228 Scale Blocks 3-39 Ramp Delay Ramp Rates 3-29 Scale5 Div 1239 Scale Blocks...
Page 148 3-76 Programming and Parameters Name Group Page Name Group Page Speed Ref B Speed Meters 3-11 UnderVolt Thresh Alarms 3-54 Speed Ref B Pct Speed Meters 3-11 UserDefined0 User Defined 3-55 Speed Ref Out Speed Meters 3-11 UserDefined1 User Defined 3-55 Speed Reg En Speed Regulator...
Page 149: Parameter Cross Reference - By Number
Programming and Parameters 3-77 Name Group Page Z Captured Pos Speed Feedback 3-20 Z Capture Pos En Speed Feedback 3-20 Zero Ramp Input Ramp Rates 3-30 Zero Ramp Output Ramp Rates 3-30 Zero Torque Torque Attribute 3-17 Parameter Cross Reference Parameter Name Group Page...
Page 150 3-78 Programming and Parameters Parameter Name Group Page Parameter Name Group Page Digital Out8 Sel Digital Outputs 3-68 Drv Fld Brdg Cur Motor Data 3-14 Preset Speed 1 Discrete Speeds 3-23 Trim Ramp Pct Speed Reference 3-24 Preset Speed 2 Discrete Speeds 3-23 Trim Speed Pct...
Page 151 Programming and Parameters 3-79 Parameter Name Group Page Parameter Name Group Page UserDefined5 User Defined 3-55 Dig In Term 9 Digital Inputs 3-67 UserDefined6 User Defined 3-55 Dig In Term 10 Digital Inputs 3-67 UserDefined7 User Defined 3-55 Dig In Term 11 Digital Inputs 3-67 UserDefined8...
Page 152 3-80 Programming and Parameters Parameter Name Group Page Parameter Name Group Page PI Init Intgl Gn PID Control 3-36 1013 Torque Const Autotune 3-20 TrqTpr_Enable Torque Attribute 3-18 1014 Inertia Autotune 3-21 TrqTpr_Lim0 Torque Attribute 3-18 1015 Friction Autotune 3-21 TrqTpr_Lim1 Torque Attribute 3-18...
Page 153 Programming and Parameters 3-81 Parameter Name Group Page Parameter Name Group Page 1198 Offs Accel Time Winder Functions 3-44 1269 Inversion Out 3 Digital Outputs 3-70 1199 W Offset Winder Functions 3-44 1270 Inversion Out 4 Digital Outputs 3-70 1200 Spd Match Gain Winder Functions 3-44...
Page 154 3-82 Programming and Parameters Parameter Name Group Page 1380 Drive Alarm 1 Alarms 3-54 1381 TestPoint Sel Diagnostics 3-51 1382 TestPoint Data Diagnostics 3-51 1383 TaskLoad 32 ms Diagnostics 3-51 1384 TaskLoad 1 ms Diagnostics 3-51 1385 TaskLoad 2 ms Diagnostics 3-51 1386...
Page 155: Troubleshooting
Chapter Troubleshooting 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. For information on… page… Faults and Alarms Drive Status Manually Clearing Faults Fault Descriptions Clearing Alarms...
Page 156: Drive Status
Troubleshooting Drive Status The condition or state of your drive is constantly monitored. Any changes will be indicated through the LEDs and/or the HIM (if present). Figure 4.1 Drive Status Indicators PORT NET A NET B Name Color State Description Green Flashing Drive ready, but not running and no faults are present.
Page 157: Him Indication
Troubleshooting HIM Indication The LCD HIM also provides visual notification of a fault or alarm condition. Condition Display The drive is indicating a fault. The LCD HIM immediately reports the fault condition by F- > Faulted Auto displaying the following: •...
Page 158: Fault Descriptions
Troubleshooting Fault Descriptions Table 4.A Fault Types, Descriptions and Actions Fault Type Description Action AC Undervoltage There is an undervoltage on the power circuit. Possible causes include: • Par [UnderVolt Thresh] is set incorrectly Set Par [UnderVolt Thresh] correctly and then (possibly set to 400V when the drive is rated for reset the drive via Par 1347...
Page 159 Troubleshooting Fault Type Description Action Hardware Fault A non-resettable hardware error has occurred. Cycle power to the drive. If the problem persists, replace the Control board. Heatsink OvrTemp The heatsink temperature is too high Possible causes include: • The surrounding air temperature is too high. Lower the surrounding air temperature.
Page 160 Transformer or Transient Noise Filter circuit boards for Frame C size drives. Replace as necessary.* • If this fault occurs again, an internal fault may be present. Contact your Rockwell Automation sales office. *Note: Refer to Control Power Circuit Protection Fuses on page A-15 for fuse sizing information.
Page 161: Clearing Alarms
Troubleshooting Table 4.B Fault Cross Reference by Number Fault Fault Auxiliary Input Drive Overload Power Failure Sustained Curr AC Undervoltage 71 - Port 1 Adaptor Arm Overvoltage Port 2 Adaptor Fld Current Loss Port 3 Adaptor Heatsink OvrTemp Port 4 Adaptor Main Contactor Port 5 Adaptor Over Current...
Page 162 Troubleshooting Alarm Type Description CntactrCflct Contactor input functions are in conflict: • When Par 1391 [ContactorControl] is set to “None”, both relay outputs (Pars 1392 [Relay Out 1 Sel] and [Relay Out 2 Sel] and all digital inputs ([Digital Inx Sel]) cannot be set to “Contactor” or “ContactorDB”. •...
Page 163 Troubleshooting Alarm Type Description Fld Current The field current is too low. Refer to the “Fld Current Loss” fault description on Loss page 4-4 for more information. Motor Over The motor has exceeded its temperature rating (as signaled by the thermistor Temp connected to the drive terminals 78 and 79).
Page 164: Common Drive Symptoms And Corrective Actions
4-10 Troubleshooting Common Drive Symptoms Drive will not start and Corrective Actions Drive Symptom Action • Verify that no faults or alarms are displayed. If a An external “Start” command was issued, but the drive does not start. fault or alarm is displayed, follow the corrective action provided (refer to Fault Descriptions on page 4-4...
Page 165 Troubleshooting 4-11 Drive Symptom Action • Verify that the drive is "Ready", then verify that The external DB resistor contactor, if used, has not closed. the required coil voltage is present at terminals 75 and 76 (Relay Output 2). If the coil voltage is present at terminals 75 or 76, then verify that proper voltage is at the DB contactor coil.
Page 166: Drive Starts But Motor Does Not Turn And No Armature Current
4-12 Troubleshooting Drive starts but motor does not turn and no armature current. Drive Symptom Action • Verify the wiring to the analog input(s) The drive starts but there is no armature current and the motor does not respond to a speed signal. selected for speed reference (refer to Wiring Examples on page 1-37).
Page 167: The Motor Does Not Reach Commanded Speed
Troubleshooting 4-13 The motor does not reach commanded speed. Drive Symptom Action The drive starts and the motor turns but does The load may be too great for the motor and drive. • Remove the load from the motor and test for reach the commanded speed.
Page 168: The Motor Reaches Maximum Speed Immediately
4-14 Troubleshooting The motor reaches maximum speed immediately. Drive Symptom Action The motor accelerates to maximum speed and Check the analog input voltage and speed cannot be controlled. reference values: • Parameters 1404 [Analog In1 Value], 1405 [Analog In2 Value], 44 [Speed Ref A] and 48 [Speed Ref B] •...
Page 169: Appendix A Supplemental Drive Information
Appendix Supplemental Drive Information For information on . . See page . . Specifications IP20 (NEMA UL/Type Open) Watts Loss Communication Configurations Drive Power Circuit Protection Control Power Circuit Protection Fuses A-15 AC Input Line Reactors and AC Input Contactors A-17 DC Output Contactors and Dynamic Brake Resistor Kits A-19 DC Contactor Crimp Lug Kit Specifications...
Page 170 Supplemental Drive Information Category Specification Drive Type Full Wave Regen, 6 Pulse, Regulated Field Supply Electrical Input Voltages: 230 to 480V AC +/- 10%, 3 Phase Input Frequency: 50/60 Hz +/- 5% Armature Output Voltage: Two Quadrant Drives Four Quadrant Drives 260V DC @ 230V AC 240V DC @ 230V AC 470V DC @ 400V AC...
Page 171 Supplemental Drive Information Category Specification Feedback Encoder Type: Incremental, dual channel, two channel optional Devices (with jumper), differential (recommended) or single-ended Input Voltage: Configurable for +2.5V - 5.2V (switch S21 in ENC_5 position) or +5.4V - 15.2V (switch S21 in ENC_12 position) Input Current: 4.5 mA / 6.8 - 10.9 mA each channel Quadrature: 90°...
Page 172: Ip20 (Nema Ul/Type Open) Watts Loss
Supplemental Drive Information IP20 (NEMA UL/Type Open) Watts loss data shown below is based on the rated current of the drive. Watts Loss Important: For drives with 230V input, rated 150 HP / 521 A, the cooling fans must be powered by an external 230V 50/60 Hz power supply at terminals U3 &...
Page 173: Communication Configurations
Supplemental Drive Information Communication Typical Programmable Controller Configurations Configurations Important: If block transfers are programmed to continuously write information to the drive, care must be taken to properly format the block transfer. If attribute 10 is selected for the block transfer, values will be written only to RAM and will not be saved by the drive.
Page 174 Supplemental Drive Information Figure A.2 Logic Status Word Logic Bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Status Description x Ready 0 = Not Ready 1 = Ready Active 0 = Not Active 1 = Active Command 0 = Reverse...
Page 175: Drive Power Circuit Protection
Supplemental Drive Information Drive Power Circuit The tables on the following pages provide drive ratings and the recommended fuses for protecting the armature and field circuits. Protection Externally mounted fuses (as indicated in Figure A.3 on page A-7) must be sourced separately when installing the drive.
Page 176 Supplemental Drive Information Table A.B Recommended AC Input Line Fuses - 460V AC Input Frame A and B (Regenerative and Non-Regenerative Drives) Fuse Code FS1 (See Figure A.3 on page A-7) Bussmann Ferraz Shawmut (Gould Shawmut) Drive Current North Rating Line Ferrule FWP Ferrule...
Page 177 Supplemental Drive Information Table A.D Recommended Armature DC Output Fuses - 460V AC Input Frame A and B (Regenerative Drives Only) Fuse Code FS2 (See Figure A.3 on page A-7) Bussmann Ferraz Shawmut (Gould Shawmut) Drive Current North Rating Line Ferrule FWP Ferrule North American...
Page 178 A-10 Supplemental Drive Information Table A.F Recommended Field Circuit Fuses - 460V AC Input Frame A and B (Regenerative and Non-Regenerative Drives) Fuse Code FS3 (SeeFigure A.3 on page A-7, Figure A.4 below Drive Figure A.5 on page A-11 for location) Current Rating Field...
Page 179: Frame C Fuse Information
Supplemental Drive Information A-11 Figure A.5 Frame B Field Circuit Fuses Location Top View of Drive Field circuit fuses Frame C Fuse Information All AC input fuses for armature and field circuit protection are internally mounted and provided with frame C PowerFlex DC drives with 230V AC input and a current rating of 521A and 460V AC input and a current rating of 495A and 667A.
Page 180 A-12 Supplemental Drive Information Table A.G Recommended Field Circuit Fuses - 230V AC Input Frame C (Regenerative and Non-Regenerative Drives) Fuse Code FS3 (See Figure A.6 on page A-11 Figure A.7 Drive below for location) Current Rating Field Ferraz Shawmut Code Amps Type Bussmann...
Page 181 Supplemental Drive Information A-13 Table A.I Recommended Leg Fuses - 230V AC Input Frame C (Regenerative Drives Only) Drive Fuse Code FS4 (See Figure A.6 on page A-11 Figure A.8 below for location) Current Bussmann Ferraz Shawmut (Gould Shawmut) SIBA Rating Line Code...
Page 182 A-14 Supplemental Drive Information Table A.K Recommended AC Input Line Fuses - 230V AC Input Frame C (Non-Regenerative Drives Only) Drive Fuse Code FS4 (See Figure A.6 on page A-11 Figure A.8 below for location) Current Bussmann Ferraz Shawmut (Gould Shawmut) SIBA Rating Line...
Page 183: Control Power Circuit Protection Fuses
Supplemental Drive Information A-15 Control Power Circuit The following fuses are used to protect the Switching Power Supply circuit and the MOVs on the Pulse Transformer circuit board (frame B drives only) Protection Fuses or Transient Noise Filter circuit board (frame C drives only). Frame Mounted on Designation Fuse...
Page 184 A-16 Supplemental Drive Information Figure A.12 Frame C Switching Power Supply Fuse Location F1 = 3.15A fuse F2 = 2.5A fuse Fuses are located on the Switching Power Supply circuit board (SW-2) on the back of the Control EMI shield, which holds the Control board. PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 185: Ac Input Line Reactors And Ac Input Contactors
Supplemental Drive Information A-17 AC Input Line Reactors and If a DC Contactor is used, an AC Input contactor is not needed. AC Input Contactors Table A.M 230V AC Input, Regenerative Drives AC Line IP00 (Open Style) Line Reactor Drive Cat. No. DC Amps Amps Cat No.
Page 186 A-18 Supplemental Drive Information Table A.O 460V AC Input, Regenerative Drives AC Line IP00 (Open Style) Drive Cat. No. DC Amps Amps Line Reactor Cat No. Line Reactor kW (HP) AC Input Contactor Cat. No. 20P-41AD4P1 1321-3R4-A .55 (.75) 100-C12D10 20P-41AD6P0 1321-3R8-A .75 (1)
Page 187: Dc Output Contactors And Dynamic Brake Resistor Kits
Supplemental Drive Information A-19 ors and DC Output Contact Dynamic Brake Resistor Table A.Q 230V AC Input, Regenerative Drives Kits Dynamic Brake Armature Resistor Brake DC Loop DC Contactor AC Line Resistor Kit Voltage Resistor Size Amps Contactor Cat. Crimp Lugs Cat. Drive Cat.
Page 188 A-20 Supplemental Drive Information Table A.S 460V AC Input, Regenerative Drives Dynamic Brake Armature Brake DC Loop DC Contactor Drive Cat. Line Resistor Kit Voltage Resistor DB Resistor Amps Contactor Cat. Crimp Lugs Cat. Amps Amps Cat. No. (Volts) Size (ohms) Size (Watts) Required 20P-41AD4P1 4.1...
Page 189: Dc Contactor Crimp Lug Kit Specifications
Supplemental Drive Information A-21 Table A.T 460V AC Input, Non-Regenerative Drives Armature Resistor Brake DC Loop DC Contactor Line Dynamic Brake Voltage DB Resistor Size Amps Contactor Crimp Lugs Cat. Drive Cat. No. Amps Amps Resistor Kit Cat. No. (Volts) Size (ohms) (Watts) Required...
Page 190 A-22 Supplemental Drive Information Notes: PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 191: Him Overview
Appendix HIM Overview For information on . . See page For information on . . See page External and Internal Connections B-1 Menu Structure LCD Display Elements Viewing and Editing Parameters ALT Functions Removing/Installing the HIM External and Internal The PowerFlex DC drive provides a number of cable connection points for the HIM (Frame A shown).
Page 192: Using The S.m.a.r.t. List Screen
HIM Overview ALT Functions To use an ALT function, press the ALT key, release it, then press the programming key associated with the function printed on the HIM above the key: Table B.A ALT Key Functions Press the ALT Key and then …...
Page 193: Menu Structure
HIM Overview Menu Structure Figure B.1 HIM Menu Structure User Display (See Key below for button descriptions.) Faults Fault Info Diagnostics Status Info View Fault Queue Drive Status 1 Device Items Clear Faults Drive Status 2 Device Version Clr Fault Queue PowerFlex DC Drive Alarm 1 Reset Device...
Page 194 HIM Overview Diagnostics Menu When a fault trips the drive, use this menu to access detailed data about the drive. Option Description Faults View fault queue or fault information, clear faults or reset drive. Status Info View parameters that display status information about the drive.
Page 195: Viewing And Editing Parameters
HIM Overview Preferences Menu The HIM and drive have features that you can customize. Option Description Drive Identity Add text to identify the drive. User Dspy Lines Select the display, parameter, scale and text for the User Display. The User Display is two lines of user-defined data that appears when the HIM is not being used for programming.
Page 196: Removing/Installing The Him
HIM Overview Removing/Installing the HIM The HIM can be removed or installed while the drive is powered. Important: HIM removal is only permissible in Auto mode. If the HIM is removed while in Manual mode or the HIM is the only remaining control device, a fault will occur.
Page 197: Analog Input Configuration
Appendix Application Notes For information on . . See page For information on . . See page Analog Input Configuration Speed Feedback C-15 Current / Speed Curve Scale Blocks C-16 Droop Compensation Speed Regulation Functions C-17 Field Weakening Mode Configuration Start At Powerup C-24 (v1.006)
Page 198: Example 2
Application Notes Example 2: An external analog reference reaches a maximum value of 9.8V. Enter a scaling factor of 1.020 in [Anlg Inx Scale] to scale the maximum voltage from 9.8V to 10V. The same result could be obtained via parameter [Anlgx Tune Scale], by entering the values of the appropriate parameters via the HIM.
Page 199 Application Notes Configure the following: • Set Par 70 [Anlg In1 Sel] = “Speed Ref A” • Set [Digital Outx Sel] = “Input1 Cmp” (Par 1045 [Anlg In1 Cmp Eq]) • Set Par 1042 [Anlg In1 Cmp] = 4667 (700 x 10000 / 1500) •...
Page 200: Current / Speed Curve
Application Notes Current / Speed Curve The current/speed curve function allows you to establish a current limit lower than the standard current limits of the drive (specified in parameters 8 [Current Lim Pos] and 9 [Current Lim Neg]) and reduce the output current (torque) of the drive through a defined curve of five equally divided set points as the speed increases based on a threshold speed, effectively reducing torque.
Page 201: Droop Compensation
DC contactor and/or inverting fault device installed in the armature circuit. ATTENTION: The following information is merely a guide for proper installation. Rockwell Automation, Inc. cannot assume responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this drive or associated equipment.
Page 202: Using A Dc Contactor Only
Application Notes Using a DC Contactor 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]).
Page 203: Using A Dc Contactor And An Inverting Fault Device
Application Notes Using a DC Contactor and an Inverting Fault Device 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]).
Page 204: Pid Function
Application Notes Inverting Fault Device Configuration 1. Connect the inverting fault device contact to a digital input. 2. Set the corresponding [Digital Inx Sel] parameter (133-144) to 14 - "Aux Fault". 3. Set the corresponding [Inversion In x] parameter (1276-1283 or 1387-1390) to 1 - “Enabled”.
Page 205: Configure A Line Speed Signal
Application Notes Configure a Line Speed Signal The line speed signal is the main reference for the speed or current regulator in the follower drive(s). In the Master drive: • Configure an analog output for the main speed reference (1 “Spd Ref Out”) In the Follower drive: •...
Page 206: Configure The Feedback Signal In The Follower Drive(S
C-10 Application Notes In addition you can configure the following: • Enter the gain for the feed-forward signal in Par 787 [PID Source Gain] • Monitor the feed-forward signal after the gain is applied in Par 758 [Feed Fwd PID] P758 Feed Fwd PID P786...
Page 207 Application Notes C-11 In addition you can configure the following: • Par 763 [PID Feedback] contains the raw feedback counts from the analog input signal received from the transducer position (dancer) or tension (load cell) • Monitor the tension set point for a torque winder application in Par 1194 [Act Ten Ref Pct] •...
Page 208: Configure The Tension Set Point Signal In The Follower Drive(S
C-12 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 NIP-Roll Reverse Forward Load Cell...
Page 209: Reference Control
Application Notes C-13 Reference Control The drive speed command can be obtained from a number of different sources. The source is determined by drive programming and the condition of the digital inputs configured as speed selects, a digital input configured for “Auto/Manual”...
Page 210: Torque Reference Source
C-14 Application Notes Torque Reference Source The torque reference can only be supplied by an analog input, the HIM, or a network reference. Switching between available sources while the drive is running is not available. Digital inputs programmed as “Speed Sel 1, 2, 3” and the HIM Auto/Manual function (see above) do not affect the active torque reference.
Page 211: Speed Feedback
Application Notes C-15 Auto/Manual Notes 1. Manual control is exclusive. If a HIM or Terminal Block takes manual control, no other device can take manual control until the controlling device releases control. 2. If a HIM has manual control and power is removed from the drive, the drive will return to Auto mode when power is reapplied.
Page 212: Scale Blocks
C-16 Application Notes Scale Blocks The Scale Blocks function allows you to link or rescale dissimilar parameter types (e.g., 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.
Page 213: Linking Parameters Via The Scale Block Parameters
Application Notes C-17 Linking Parameters Via the Scale Block Parameters Most parameter values are entered directly by the user. However, certain parameters can be “linked,” via the Scale Block parameters, so the value of one parameter becomes the value of another. For example, the value of an analog input 1, parameter 70 [Anlg In1 Sel], can be linked to parameter 660 [Accel Time 1].
Page 214 C-18 Application Notes The adaptive speed regulator is enabled with parameter 181 [Adaptive Spd En] = “1 Enabled”. Normally the gain depends on the speed of the drive. It can, however, vary according to a variable defined in parameter 183 [Adap Ref].
Page 215 Application Notes C-19 Enter the step value in Par 60 [TstGen Amplitude], so that the speed remains inside the range to be tuned. The optimization is carried out separately for each range and the parameters of the regulator are set for each range with Pars [Adaptive P Gainx] and [Adaptive I Gainx].
Page 216: Speed Up Function
C-20 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.
Page 217 Application Notes C-21 the threshold speed for counter-clockwise rotation in Par 102 [Speed Thresh Neg]. You can specify a delay time before indication that the speed has fallen below the threshold values in Par 103 [Threshold Delay]. Par 393 [Speed Threshold] can be assigned to a digital output. A digital output so assigned will only change state at the clockwise (positive) speed threshold.
Page 218: Speed Zero Function
C-22 Application Notes Speed Zero Function The Speed Zero Logic determines the behavior of the drive when the motor is at zero speed. Refer to the Speed Adaptive and Speed Zero Logic block diagram on page D-12. 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.
Page 219: Speed Draw Function
Application Notes C-23 Speed Draw Function The Speed Draw function can be used to apply a configurable speed ratio (set in Par 1017 [Speed Ratio]) to the main speed reference of the drive. This function is useful in a multi-drive system where a proportional speed increase between the motors is required.
Page 220: Start At Powerup
C-24 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.
Page 221: Fine Tuning The Regulators
Application Notes C-25 Fine Tuning the Regulators The PowerFlex DC drive control regulators have predefined values meant to provide consistent drive performance without performing any further configuration, with the exception of the armature current regulator, which must always be tuned. When the armature current regulator has been tuned to meet the requirements of the application, the fine tuning procedures for the other regulators are not necessary.
Page 222: Manually Adjusting The Current Regulator Tune Settings
C-26 Application Notes Manually Adjusting the Current Regulator Tune Settings During the current regulator auto tuning test the value of Par 587 [I Reg Error] displays. This parameter is used to determine whether the current regulator is correctly tuned. The value should be as near to zero as possible, but values between -40 and +40 are acceptable.
Page 223 Application Notes C-27 3. Configure the following parameters: Set Par 497 [Field Reg Enable] = 1 “Enabled” (default) Set Par 469 [Field Mode Sel] = 1 “Field Weaken” Set Par 498 [Force Min Field] = 1 “Enabled” 4. Configure the following Test Generator parameters: Set Par 58 [TstGen Output] = 3 “Field Ref”...
Page 224 C-28 Application Notes Field Current Regulator Tuning Examples Figure C.5 Increase in the field current with oscillation Figure C.7 Increase in the field current without Non-optimal response of the regulator. oscillation Top: Par 500 [Field Ref Pct] This graph, as compared to the graph in Figure C.5, shows an Bottom: Par 234 [Fld Current Pct] increase in [Fld Reg Kp] from 2% to 10% with [Fld Reg Ki] = 5%.
Page 225: Fine Tuning The Speed Regulator
Application Notes C-29 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.
Page 226 C-30 Application Notes [Spd Reg Kp] and [Spd Reg Ki] curves Figure C.8 [Spd Reg Kp] too low Figure C.10 [Spd Reg Ki] too high Top: Par 122 [Spd Feedback] Top: Par 122 [Spd Feedback] Bottom: Par 199 [Arm Current Pct] Bottom: Par 199 [Arm Current Pct] 20.00 ms/DIV 20.00 ms/DIV...
Page 227: Fine Tuning The Voltage Regulator In The Field Converter
Application Notes C-31 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.
Page 228 C-32 Application Notes Field Voltage Regulator Tuning Examples Figure C.12 Field voltage oscillation Figure C.14 Optimal field regulation Oscillation after a speed change where [Arm Volt Kp] = 10% and After a short transient, the field current and armature voltage are [Arm Volt Ki] = 80%.
Page 229: Tuning The Field Current Curve
Application Notes C-33 Tuning the Field Current Curve The function of the field current curve is to control the actual motor flux and, subsequently, motor torque if the field goes into an overvoltage condition. Figure C.15 below illustrates the relationship between flux and flux current when the field current curve is defined versus not defined.
Page 230 C-34 Application Notes Field Current Curve Tuning Procedure: 1. Reset the field current curve by setting Par 920 [Reset Fld Curve] to “1”. 2. Configure the following parameters: Enter the percentage (100%) of the maximum motor nameplate rated armature voltage in Par 921 [Out Volt Level] Set Par 469 [Field Mode Sel] = 0 “Base Speed”...
Page 231: Diagram Conventions
Appendix Control Block Diagrams For information on . . See page . . PowerFlex DC Drive Overview Digital Inputs/Outputs & Mapping Standard and I/O Expansion Card Analog Inputs/Outputs and Mapping Speed Reference Selection Speed Reference Generation Ramp Reference Block Speed / Torque Regulator Droop Compensation - Inertia / Loss Compensation Speed Feedback D-10...
Page 232 Control Block Diagrams PowerFlex DC Drive Overview PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 233 Control Block Diagrams Digital Inputs/Outputs & Mapping Standard and I/O Expansion Card PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 234 Control Block Diagrams Analog Inputs/Outputs and Mapping PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 235 Control Block Diagrams Speed Reference Selection PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 236 Control Block Diagrams Speed Reference Generation PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 237 Control Block Diagrams Ramp Reference Block PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 238 Control Block Diagrams Speed / Torque Regulator PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 239 Control Block Diagrams Droop Compensation - Inertia / Loss Compensation PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 240 D-10 Control Block Diagrams Speed Feedback PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 241 Control Block Diagrams D-11 Speed Regulator PI Block PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 242 D-12 Control Block Diagrams Speed Adaptive and Speed Zero Logic > = PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 243 Control Block Diagrams D-13 Current Regulator PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 244 D-14 Control Block Diagrams Field Current Regulator PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 245 Control Block Diagrams D-15 Motor Parameters PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 246 D-16 Control Block Diagrams Speed Threshold / Speed Control PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 247 Control Block Diagrams D-17 PID Control PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 248 D-18 Control Block Diagrams Scale Blocks PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 249 Control Block Diagrams D-19 User Defined Variables PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 250 D-20 Control Block Diagrams Taper Current Limits PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 251 Control Block Diagrams D-21 Unit Scaling PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 252 D-22 Control Block Diagrams Test Generator Test Generator TstGen Output Generator output TstGen Amplitude TstGen Offset Time TstGen Frequency PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 253 Control Block Diagrams D-23 Speed Reference Selection Speed Reference Selection P402 P401 P400 Reference Spd Select 2 Spd Select 1 Spd Select 0 Speed Ref A Speed Ref B P155 Preset Speed 2 P156 Preset Speed 3 P157 Preset Speed 4 P158 Preset Speed 5 P159...
Page 254 D-24 Control Block Diagrams Fault / Alarm Mapping Fault/Alarm Mapping “Arm Overvoltage” (F5) “Fld Current Loss” (F6) P203 P473 OverVolt Flt Cfg FldLoss Flt Cfg 0 = “Ignore” 0 = “Ignore” 1 = “Alarm” 1 = “Alarm” 2 = “Fault” 2 = “Fault”...
Page 255: Appendix E Installing A Communication Adapter
Appendix Installing a Communication Adapter Communication Adapter The following Communication Adapter kits are available for use with the PowerFlex® DC drive: Kits Comm Option Catalog Number BACnet® MS/TP RS-485 Communication Adapter 20-COMM-B ControlNet™ Communication Adapter (Coax) 20-COMM-C DeviceNet™ Communication Adapter 20-COMM-D EtherNet/IP™...
Page 256: Safety Precautions
Installing a Communication Adapter Safety Precautions ATTENTION: Only qualified personnel familiar with drives, power products and associated machinery should plan or implement the installation, start-up, configuration and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. ATTENTION: To avoid an electric shock hazard, ensure that all power to the drive has been removed before performing the following.
Page 257 Installing a Communication Adapter 3. Remove the bottom cover from the drive: a. On frame A drives, remove the screws that secure the bottom cover to the drive, then slide the cover down and off the drive chassis. Frame A PORT NET A NET B...
Page 258 Installing a Communication Adapter 4. Remove the top cover from the drive: a. For frame A drives, press in on the sides at the bottom edge of the top cover and at the same time pull the cover toward you to pull it partially off the drive chassis.
Page 259 Installing a Communication Adapter b. On frame B and C drives, loosen, but do not remove, the screws that secure the top cover to the drive, then slide the cover up and off the drive chassis. Important:The HIM assembly is connected via a cable to the Control board and therefore will not pull free from the drive until disconnected.
Page 260 Installing a Communication Adapter 5. Disconnect the HIM Communication cable from the connector on the upper right corner of the Control board and set the cover aside. All Frames (Frame A shown) Pull tabs out to disconnect cable. 6. Secure and ground the Communication Adapter to the EMI Shield on the drive using the four captive screws.
Page 261 Installing a Communication Adapter 9. Install the HIM Communication cable in reverse order or removal. 10. Install the drive covers in reverse order of removal. PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 262 Installing a Communication Adapter Notes: PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 263: Appendix F Optional Analog And Digital I/O Expansion Circuit Board
Appendix Optional Analog and Digital I/O Expansion Circuit Board What This Option Board The optional I/O Expansion circuit board is mounted on the Control board of the drive and provides these additional I/O signals: Provides • Four (4) Digital Inputs •...
Page 264 Optional Analog and Digital I/O Expansion Circuit Board Table F.B I/O Expansion Board Terminal Block 1 Designations No. Signal Description ±10V, 5mA maximum Analog Output 3 (+) Analog Output 3 (–) ±10V, 5mA maximum Analog Output 4 (+) Analog Output 4 (–) Digital Output Common Digital Output 5 (+) Max volt.
Page 265: Appendix G Optional 115V Ac To 24V Dc I/O Converter Circuit Board
Appendix Optional 115V AC to 24V DC I/O Converter Circuit Board What This Option Board The 115V AC to 24V DC I/O Converter circuit board allows you to convert 115V AC digital input signals to 24V DC digital input signals in Provides order to interface with the standard digital I/O terminal blocks on the PowerFlex DC drive Control board.
Page 266: I/O Converter Board Wiring
Optional 115V AC to 24V DC I/O Converter Circuit Board I/O Converter Board Wiring Table G.A Recommended Signal Wire Size Wire Type and Size Tightening Torque • • Flexible (mm multi-core (mm m (lb 0.14 - 1.5 0.14 - 1.5 28-16 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...
Page 267 Optional 115V AC to 24V DC I/O Converter Circuit Board Figure G.2 I/O Converter Board with Internal Supply Wiring Diagram OPTO OPTO DC OUTPUT AC INPUT 24V 1 8 0V 8 COM M_OUT M_IN To Digital Inputs (Terminals 12-15, 31-34) on Control Board To Drive To Digital Input Common...
Page 268 Optional 115V AC to 24V DC I/O Converter Circuit Board Notes: PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 269 Index Numerics Agency Certification A-1 Alarms 115V AC to 24V DC I/O Converter circuit AnalogCflct 4-7 board G-1 Arm Voltage 4-7 2-Wire Control Non-Reversing, Wiring 1-38 Auxiliary Input 4-7 2-Wire Control Reversing, Wiring 1-39 BipolarCflct 4-7 3-Wire Control, Wiring 1-39 CntactrCflct 4-8 DigInCflcA 4-8 DigInCflctB 4-8...
Page 270 Index-2 Anlg In2 Target 3-63 Autotune Group 3-20, 3-21 Anlg In2 Tune 3-63 Aux Inp Flt Cfg 3-53 Anlg In3 Config 3-62 Auxiliary Input Alarm 4-7 Anlg In3 Offset 3-63 Auxiliary Input Fault 4-4 Anlg In3 Scale 3-62 Anlg In3 Sel 3-62 Anlg In3 Target 3-63 Base Omega 3-41 Anlg In3 Tune 3-63...
Page 271 Index-3 Control Block Diagrams D-1 Datalinks Group 3-60 Control Circuit DC Analog Tachometer Circuit Breaker 1-11 DIP Switch S4 Settings 1-34 Fuses 1-11 Terminal Block Location 1-42 Input Current 1-11 Terminal Designations 1-42 Protection 1-11 DC Contactor Crimp Lug Kit Specifications A-21 Control Wire Routing 1-42 DC Output Contactors 1-10, A-19...
Page 272 Index-4 Dig In Term 5 3-67 DIP Switch S12 Description of 1-33 Dig In Term 6 3-67 Location 1-32 Dig In Term 7 3-67 DIP Switch S14 Dig In Term 8 3-67 Description of 1-33 Dig In Term 9 3-67 Location 1-32 Dig Out Status 3-70 Settings 1-24...
Page 273 Index-5 Drive Data Group 3-13 Drive Dimensions Editing Parameters 3-1, B-5 Frame A 1-3 EEPROM Error Fault 4-4 Frame B 1-4 Elapsed Lifetime 3-13 Frame C 1-5 Electrostatic Discharge Precaution p-3 Drive Grounding Points 1-12 Enable Droop 3-31 Drive Logic Rslt 3-51 Enable Input, Wiring 1-38 Drive Memory Group 3-46 Enable PD 3-36...
Page 274 Index-6 Fault 7 Time 3-53 Faults AC Undervoltage 4-4 Fault 8 Code 3-53 Arm Overvoltage 4-4 Fault 8 Time 3-53 Auxiliary Input 4-4 Fault 9 Code 3-53 Descriptions 4-4 Fault 9 Time 3-53 Drive Overload 4-4 Fault Arm Amps 3-53 Dsp Error 4-4 Fault Clear 3-52 EEPROM Error 4-4...
Page 275 Index-7 Field Current Curve C-33 Tuning C-33 Gear Box Ratio 3-40 Field Current Loss Alarm 4-9 Grounding Field Current Loss Fault 4-4 Encoder 1-13 Field Current Pct 3-12 Power Feeder 1-13 Field Current Regulator Requirements 1-12 Fine Tuning C-26 Safety, PE 1-12 Tachometer 1-13 Field Current Resistors S14 1-24...
Page 276 Index-8 I/O Expansion Circuit Board F-1 Inversion Out 8 3-70 Mounting Location F-1 Inversion Relay1 3-71 Recommended Signal Wire Size F-1 Inversion Relay2 3-70 Terminal Block Designations F-2 Inverting Fault 4-5 Wiring Diagram F-2 I/O Wire Routning 1-42 I/O Wire Sizes 1-35 Jog Mask 3-58 I/O Wiring Examples 1-37 Jog Off Delay 3-24...
Page 277 Index-9 Load Limits Group 3-31 Motor Control File 3-14 Local Mask 3-59 Motor Data Group 3-14 Local Owner 3-59 Motor Over Temperature Alarm 4-9 Lock Speed Integ 3-26 Motor Over Temperature Fault 4-5 Logic Command Word A-5 Logic Mask 3-2, 3-58, 3-60 Logic Mask Act 3-60 NET A LED 4-2 Logic Status Word A-6...
Page 278 Index-10 Parameter Files Parameter Views Applications 3-34 Advanced 3-6 Communications 3-58 Basic 3-4 Dynamic Control 3-29 Input / Output File 3-62 Monitor 3-11 Motor Control 3-14 Speed Command 3-23 Utility 3-46 Parameter Groups Adaptv Regulator 3-32, 3-33 Alarms 3-53, 3-54 Analog Inputs 3-62, 3-63, 3-64 Analog Outputs 3-64 Autotune 3-20, 3-21...
Page 279 Index-11 Parameters Anlg In3 Target 3-63 AC Line Freq 3-13 Anlg In3 Tune 3-63 AC Line Voltage 3-13 Anlg Out1 Scale 3-64 Acc Dec Filter 3-30 Anlg Out1 Sel 3-64 Accel Mask 3-58 Anlg Out2 Scale 3-64 Accel Owner 3-59 Anlg Out2 Sel 3-64 Accel Status 3-50 Anlg Out3 Scale 3-64...
Page 280 Index-12 Data In C2 3-60 Digital In12 Sel 3-65 Data In D1 3-60 Digital In2 Sel 3-65 Data In D2 3-60 Digital In3 Sel 3-65 Data In SelData 3-60 Digital In4 Sel 3-65 Data In Val Sel 3-60 Digital In5 Sel 3-65 Data Out A1 3-60 Digital In6 Sel 3-65 Data Out A2 3-60...
Page 281 Index-13 Encoder Speed 3-11 Fld Reg Kp Base 3-14 Encoder State 3-50 Fld Weaken Ratio 3-15 Fast Stop Status 3-50 FldLoss Flt Cfg 3-54 Fast Stop Time 3-31 Flying Start En 3-27 Fault 1 Code 3-53 Force Min Field 3-15 Fault 1 Time 3-53 Freeze Ramp 3-30 Fault 10 Code 3-53...
Page 282 Index-14 Line Speed Pct 3-41 PI Central v3 3-34 Load Comp 3-31 PI Central vs0 3-35 Local Mask 3-59 PI Central vs1 3-35 Local Owner 3-59 PI Init Intgl Gn 3-36 Lock Speed Integ 3-26 PI Init Prop Gn 3-35 Logic Mask 3-2, 3-58, 3-60 PI integr freeze 3-35 Logic Mask Act 3-60...
Page 283 Index-15 Ref Zero Level 3-25 Scale5 Div 3-39 Reference Mask 3-58 Scale5 In Abs 3-40 Reference Owner 3-59 Scale5 In Max 3-39 Relay Out 1 Sel 3-70 Scale5 In Min 3-39 Relay Out 2 Sel 3-70 Scale5 In Off 3-40 Reset Defaults 3-46 Scale5 Input 3-39 Reset Fld Curve 3-16...
Page 284 Index-16 SpdReg Ki Bypass 3-27 Torq Current Pct 3-43 SpdReg Kp Bypass 3-27 Torq Limit Type 3-31 SpdTune Friction 3-21 Torq Red CurLim 3-31 Speed Demand En 3-45 Torque Const 3-20 Speed Draw Out 3-12 Torque Negative 3-47 Speed Feedback 3-11 Torque Positive 3-47 Speed Feedback Pct 3-11 Torque Reduction 3-17...
Page 285 Index-17 UsrDefBitWrdA2 3-56 PD Prop Gain 1 3-36 UsrDefBitWrdA3 3-56 PD Prop Gain 2 3-36 UsrDefBitWrdA4 3-56 PD Prop Gain 3 3-36 UsrDefBitWrdA5 3-56 PE Ground 1-12 UsrDefBitWrdA6 3-56 PE Ground Terminal UsrDefBitWrdA7 3-56 Location - Frame A 1-20 UsrDefBitWrdA8 3-56 Location - Frame B 1-20 UsrDefBitWrdA9 3-56 Location - Frame C 1-21...
Page 286 Index-18 PID Source Gain 3-38 Programmable Controller Configurations PID Steady Delay 3-36 Programming 3-1 PID Target 3-38 Port 1 Adapter Fault 4-5 Port 1 DPI Loss Fault 4-6 Port 2 Adapter Fault 4-5 Ramp Delay 3-29 Port 2 DPI Loss Fault 4-6 Ramp In 3-11 Port 3 Adapter Fault 4-5 Ramp In Pct 3-11...
Page 287 Index-19 Scale3 Output 3-39 Scale4 Div 3-39 S Curve Accel 1 3-30 Scale4 In Abs 3-40 S Curve Accel 2 3-30 Scale4 In Max 3-39 S Curve Decel 1 3-30 Scale4 In Min 3-39 S Curve Decel 2 3-30 Scale4 In Off 3-40 S Curve Time 3-29 Scale4 Input 3-39 S.M.A.R.T.
Page 288 Index-20 Spd Match Compl 3-44 Speed Ref A Pct 3-11 Spd Match Dec 3-44 Speed Ref B 3-11 Spd Match Gain 3-44 Speed Ref B Pct 3-11 Spd match torque 3-45 Speed Ref Out 3-11 Spd Ref Zero En 3-26 Speed Ref Out Pct 3-11 Spd Reg Autotune 3-21 Speed Reference Control C-13...
Page 289 Index-21 Start Mask 3-58 TestPoint Data 3-51 Start Owner 3-59 TestPoint Sel 3-51 Starting Up a Drive 2-1 Testpoints 4-14 Static F Zero 3-45 Thermal Switch Configuration 1-26 Static Friction 3-42 Thermistors (PTC) Status1 at Fault 3-52 Configuration 1-26 Status2 at Fault 3-52 Threshold Delay 3-25 Stop Modes Group 3-31, 3-32 Time AccDec Min 3-43...
Page 290 Index-22 UserDefined1 3-55 UsrDefBitWrdB15 3-57 UserDefined10 3-55 UsrDefBitWrdB2 3-57 UserDefined11 3-55 UsrDefBitWrdB3 3-57 UserDefined12 3-55 UsrDefBitWrdB4 3-57 UserDefined13 3-55 UsrDefBitWrdB5 3-57 UserDefined14 3-55 UsrDefBitWrdB6 3-57 UserDefined15 3-55 UsrDefBitWrdB7 3-57 UserDefined2 3-55 UsrDefBitWrdB8 3-57 UserDefined3 3-55 UsrDefBitWrdB9 3-57 UserDefined4 3-55 UsrDsplyDiv0 3-54 UserDefined5 3-55 UsrDsplyMult0 3-54 UserDefined6 3-55...
Page 291 Index-23 Wiring 1-1 2-Wire Control Non-Reversing 1-38 2-Wire Control Reversing 1-39 3-Wire Control 1-39 Analog Input Bipolar Speed Reference 1-38 Analog Input Unipolar Speed Reference 1-38 Analog Output Bipolar Signal 1-38 Enable Input 1-38 Encoder 1-41 Joystick 1-37 Potentiometer 1-37 Sourcing Digital Output 1-39 Write Mask Act 3-61 Write Mask Cfg 3-61...
Page 292 Index-24 PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008...
Page 294 Europe/Middle East/Africa: Rockwell Automation, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640 Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846...

Rockwell Automation PowerFlex series User Manual

Preface

Overview

Chapter 1 Installation and Wiring

Chapter 2 Drive Start up

Chapter 3 Programming and Parameters

Chapter 4 Troubleshooting

Appendix A Supplemental Drive Information

Appendix B HIM Overview

HIM Overview

Appendix C Application Notes

Appendix D Control Block Diagrams

Appendix E Installing a Communication Adapter

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

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

Quick Links

Related Manuals for Rockwell Automation PowerFlex series

Summary of Contents for Rockwell Automation PowerFlex series

Table of Contents