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The information in this manual is subject to change without notice. Throughout this manual, the following notes are used to alert you to safety considerations: ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Important: Identifies information that is critical for successful application and understanding of the product.
ONTENTS Chapter 1 Introduction to the FlexPak OIM Related Publications ..................1-1 Getting Assistance from Reliance Electric............1-1 Chapter 2 Description of the OIM Keypad, Display, and Indicators Keypad ......................2-1 The Display...................... 2-5 2.2.1 Drive Status Indicators ................2-6 2.2.2 Key Indicators ..................
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Chapter 6 Using the OIM to Monitor and Control the Drive Using the OIM to Monitor Drive Outputs ............6-1 6.1.1 Description of the Monitor Mode Outputs ..........6-1 6.1.2 Selecting the Outputs to Monitor ............6-2 6.1.3 Using Help in Monitor Mode ..............6-2 Control Source ....................6-2 6.2.1 About the Control Source ..............6-3 6.2.2 Setting the Control Source..............6-4...
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List of Figures Figure 2.1 – OIM Keypad, Display, and Indicators ........... 2-1 Figure 2.2 – OIM Display in Program Mode ............. 2-5 Figure 3.1 – OIM Power-Up Sequence..............3-1 Figure 3.2 – Contrast Adjustment Screen..............3-2 Figure 3.3 – Language Selection Screen ..............3-3 Figure 3.4 –...
HAPTER Introduction to the FlexPak OIM ® The FlexPak Operator Interface Module ( ) is a keypad and display that connects to FlexPak 3000 DC drives. It communicates serially to the drive Regulator board and allows you to change drive parameters, operate the drive, and monitor drive operation. Changing Drive Parameters Drive parameters set critical information about the drive, such as the motor rated amps and top speed.
HAPTER Description of the OIM Keypad, Display, and Indicators This chapter describes how to use the keypad, display, and indicators on the configure, monitor, and control the drive. Figure 2.1 shows the in program mode with keys, indicators, and screen information identified.
Table 2.1 – Programming Key Descriptions Mode Function Program or Switches between program mode and the two monitor mode screens. Monitor In fault, alarm, or diagnostics menus, returns you to the program or monitor screen you were in previously. See chapter 7 for information.
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Table 2.1 – Programming Key Descriptions Mode Function Program In a menu, selects the option at the cursor. In a parameter entry screen, allows you to change input parameter values. If a list is available for the parameter, selects the value at the cursor. When the parameter value has been changed, saves the new value.
Table 2.2 – Control Key Descriptions Mode Function Program or Allows you to select from a list of possible sources for drive control Monitor signals. is not active when the drive is running or jogging, and during Quick Start and self-tuning. See section 6.2 for information on selecting a control source.
Table 2.2 – Control Key Descriptions Mode Function Program or If the drive is running, stops the drive as selected by STOP Monitor (P.114). When the is connected and MODE SELECT communicating with the drive, is always active, regardless of the setting of If the drive is not running and is set to...
2.2.1 Drive Status Indicators The indicators on the right of the display allow you to check the status of the drive. In figure 2.2, the Interlock OK and Drive Ready indicators are shown on. The indicators are described in table 2.3. Table 2.3 –...
In figure 2.2, the keys are set to , and . Indicators PROGRAM KEYPAD MANUAL FORWARD are described in table 2.4. Table 2.4 – Key Indicators Possible Key Indicator Above Indications Description is in program mode. PROGRAM is in monitor mode. MONITOR (blank) is in a fault, alarm, or diagnostic menu.
2.2.3 Special Display Characters There are several special characters you might see on the display. They are described in table 2.5. Table 2.5 – Special Display Characters The cursor. Indicates the currently selected options. Use to move the cursor. Use move the cursor.
HAPTER Powering Up and Adjusting the OIM This chapter tells you what to expect on power-up and power-down and how to make adjustments for your application. 3.1 Powering Up the OIM is powered when the drive is powered. During power up, the establishes communication with the drive and reads drive information from the Regulator board.
3.2 Adjusting the Screen Contrast If the display is difficult to read, you can adjust the contrast. You can do this at any time except when you are in a parameter value entry screen or during self-tuning. You might need to change the display contrast periodically because of ambient temperature changes.
3.3 Changing the Language Displayed on the OIM can display text in English, German, French, Spanish, or Italian. In addition, you can select , which displays the parameter code numbers instead of names, CODE with all other text in English. (Parameter code numbers are provided in the software manual.) The default language setting is English.
3.4 Scaling Values Displayed on the OIM If needed, you can scale speed, load, and outer control loop units to match your application requirements. You can select from pre-defined units, or configure your own units through the option. ( is available only for speed and outer control OTHER OTHER loop units.) Scaling these units affects only the...
3.4.1 Changing the Scaling of Speed, Load, and Outer Control Loop Units Examples in this procedure are for speed unit scaling. The same basic steps are used to configure load and outer control loop units. To scale units: Step 1. Press until the key indicator reads .
3.4.2 Scaling Speed or Outer Control Loop Units to Custom Settings Complete the procedure in “Changing the Scaling of Speed, Load, and Outer Control Loop Units” on page 3-5 before proceeding. If you selected for the speed or outer control loop units, screens are displayed OTHER that allow you to customize your scaling units.
Step 3. Determine the full scale value for your display units. This is the value that will be displayed for the maximum value of the units. For example, if TOP SPEED (P.011) is set at 1750 and you want to display 100 inches/second when the speed is at 1750 , you will enter a full scale value of 100.
HAPTER Basics of Configuring the Drive Using the OIM Configuring the drive customizes it for your application. You can use the CS3000 software, or network to configure the drive. This chapter describes how to use the to configure the drive, including: •...
4.2 Accessing OIM Menus and Parameters menus and parameters are accessed in program mode. To select program mode, press until the key indicator reads PROGRAM If you exit from a menu or parameter list using , you return to monitor mode. When you return to program mode, the last menu or parameter that was displayed is displayed again.
4.2.2 Using Help in Program Mode In program mode, you can access help for menus and parameter entry screens. To get help, press when the menu or parameter entry screen is displayed. When you have read the help screen, press to return to the previous screen.
4.2.3 Accessing the Parameters Parameters are accessed through the menus. The menu paths to get to parameters are provided: • In appendix A of this manual. • As part of the parameter descriptions in the software manual. Some parameters and parameter options are only available if the appropriate option is installed.
Step 3. Make sure the cursor is pointing at Meter Outputs. Press . The Meter Outputs menu is displayed, as shown in figure 4.7. Figure 4.7 – Meter Outputs Menu At this point, you can view or change parameter values. See the next sections. 4.2.4 Viewing Parameter Values In the parameter lists, parameter values are shown to the right of the parameter name, as shown in figure 4.7.
Important: To exit a parameter entry screen without making changes, press To change a parameter value: Step 1. Go to the menu that contains the parameter you want to change by using the procedure in section 4.2.3, “Accessing the Parameters”. Step 2.
Step 6. Press to accept the changed value and go to step 7. Step 7. Press to return to the list of parameters. Step 8. To save the changes to the parameters, you must perform a memory save. See section 4.4, “Saving and Restoring Parameter Values”. Step 9.
parameter toggles the program protection setting. If program PASSWORD protection is enabled, this procedure disables it. If disabled, the procedure enables it. To enable or disable software program protection: Step 1. Press until the indicator reads and “FlexPak 3000 PROGRAM Main Menu”...
4.4 Saving and Restoring Parameter Values Through the , you can save parameter values, restore parameter values from a previous save, or restore default parameter values. Memory Save You must use Memory Save to save changes to parameter values and the language setting through a power cycle.
Step 4. Select the action you want to perform. Press . Depending on the action you select, you will see: • Memory Save:“The current parameter values will be saved to memory. Continue?” • Memory Restore: “The last saved values will be restored. Continue?” •...
HAPTER Using Quick Start Quick Start lets you configure the most commonly used parameters through one menu. This helps you set up the drive as quickly as possible. Brief descriptions of Quick Start parameters are provided in section 5.5 in the order they are displayed as you go through Quick Start.
The exit options are: • Return to previous step: Returns to the previous parameter. After you accept that parameter value, Quick Start resumes from that parameter. To go back several parameters, you can press and select “Return to previous step” as many times as needed.
Figure 5.2 – First Quick Start Parameter Entry Screen Step 5. Use the procedure described in section 4.2.5 to change the value. Press . Quick Start automatically takes you to the next parameter entry screen. Step 6. Continue going through the Quick Start parameters, changing values as needed.
5.4 Self-Tuning the Current Minor and Speed Loops ATTENTION: Before self-tuning, verify that no overhauling or hanging loads are on the motor. Self-tuning will not operate properly if these types of loads exist. Failure to observe this precaution could result in bodily injury. ATTENTION: The motor will rotate during self-tuning.
Step 4. Set . See section 6.2 for instructions. KEYPAD TERMBLK Step 5. Clear any faults from the fault log. See chapter 7 for information. If you do not do these steps, you will get an error message when you try to start self-tuning. 5.4.2 Performing the Self-Tuning Procedure Before self-tuning, complete the steps in section 5.4.1.
Figure 5.4 – Self-Tuning Screen Step 5. The message “Self Tuning is active” blinks on the screen during self-tuning. The current minor loop takes a few seconds to self-tune. The speed loop takes about two minutes. During self-tuning, you can go to monitor mode without disrupting self-tuning.
5.4.3 Exiting Before Self-Tuning is Complete If you have not yet pressed to start self-tuning, you can stop self-tuning (and Quick Start) by pressing . The Main Menu is displayed if you enabled self-tuning in Quick Start, or the Self Tune Parameters menu. If you have already pressed to start self-tuning, press or assert the stop...
(P.219) SELF TUNE STABILITY Determines the Parameter Range: 10 to 100 self-tune stability, Default Setting: which configures the performance of the Parameter Type: Tunable speed loop. Low values increase the speed loop response. High values decrease the speed response, but result in more stability. The typical value is 25. Applies to speed loop tuning only.
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(P.008) MOTOR RATED ARM AMPS Parameter Range: The rated armature 0 to 3000.0 amps current from the Default Setting: 8.0 amps motor nameplate. Parameter Type: Configurable ATTENTION: This parameter must be less than the motor rated armature amps or drive current rating listed on the motor nameplate. If this is configured incorrectly, overcurrent or excess heating of the motor could result.
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(P.200) FEEDBACK SELECT Selects the type of Parameter Range: ARMATURE VOLT feedback signal that DC TACH is used for the PULSE TACH speed/voltage loop. AC TACH Default Setting: ARMATURE VOLT Parameter Type: Configurable can only be selected if the appropriate kit is installed PULSE TACH AC TACH (Pulse Encoder (Tachometer) kit or AC Tachometer Feedback kit).
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(P.208) PULSE TACH QUADRATURE Only available if Parameter Range: FEEDBACK SELECT set to PULSE TACH Default Setting: Parameter Type: Configurable Enables or disables pulse encoder quadrature. A quadrature pulse encoder must be used on regenerative drives that use a pulse encoder.
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(P.003) MINIMUM SPEED Selects the minimum Parameter Range: 0 to or user-defined units) MAXIMUM SPEED speed of the drive Default Setting: without being stopped. It is typically Parameter Type: Tunable greater than zero. If it is less than 10% of , an alarm is generated.
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(P.012) JOG SPEED The operating speed Parameter Range: 0 to or user-defined units) MAXIMUM SPEED while the drive is Default Setting: jogging if DIG IN (P.428) is set SELECT Parameter Type: Tunable JOG SPEED SELECT and digital input 0 (terminal 12 on the Regulator board) is off.
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(P.206) IR COMPENSATION Sets the armature Parameter Range: 0 to 50% voltage loss Default Setting: compensation value used when the drive Parameter Type: Tunable is configured as a voltage regulator. This parameter is also used by the Field Current Regulator kit to set the field-weakened threshold.
HAPTER Using the OIM to Monitor and Control the Drive allows you to monitor the speed, armature voltage, load, and current keypad reference outputs to the motor. You can choose between two viewing options. also allows you to control the drive. Motor control options available through include starting, stopping, jogging, and setting the manual reference and control source.
6.1.2 Selecting the Outputs to Monitor You can view one of two monitor mode screens. The first monitor mode screen shows all four monitored outputs. The second monitor mode screen shows the motor speed and motor load without labels, but in larger text so the values can be read from a distance.
6.2.1 About the Control Source The possible control sources are: • : Control is through the keypad. KEYPAD • : Control is through Regulator board terminals 16 through 20. See the TERMBLK hardware manual for terminal descriptions and wiring instructions. •...
6.2.2 Setting the Control Source Important: The control source selection you make might change the setting of . See table 6.1. To select the control source: Step 1. Stop the drive if it is running. Step 2. Press . The screen shown in figure 6.3 is displayed. Figure 6.3 –...
6.4 Using the OIM to Control the Drive When is set to , you can use the to control the drive. This includes KEYPAD running, jogging, changing the direction of, and stopping the drive. ATTENTION: If the drive is ready and is set to , pressing KEYPAD...
6.4.3 Changing Drive Direction When is set to , you can change the direction of the motor by pressing KEYPAD . The direction can be changed when the drive is running or stopped. The direction is fixed to FORWARD • for non-regenerative drives •...
HAPTER Troubleshooting the Drive Using the OIM Using the , you can troubleshoot drive problems using one of these methods: • If a fault or alarm message is displayed, you can use the message and the Fault or Alarm Menu to identify the problem. •...
Figure 7.2 – Example of an Alarm Screen Press to clear the fault or alarm message. If multiple faults or alarms occurred, they are displayed after you press If the fault or alarm log is full, a message is displayed. To log future faults and alarms, you must clear the log (section 7.2.2).
7.2.1 Reviewing the Fault and Alarm Logs You can review the fault and alarm logs to help identify the problem and determine when it occurred. Step 1. Select Review Log from the Fault or Alarm Menu. The screen shown in figure 7.5 is displayed.
These screens show: • The fault or alarm number (on the first line). You can use this number to look up information about the fault or alarm in the software manual. • A one-line description of the fault or alarm. •...
To reset the faults or alarms and clear the log Important: You cannot clear individual faults or alarms. This procedure clears the entire log. Step 1. Depending on whether you are clearing faults or alarms, do one of the following: •...
7.4 Clearing a Programming Error Message Programming errors occur if you select an option that is not valid, such as attempting to set a read-only parameter. These errors do not affect drive operation and are not logged. To remove a programming error message, press 7.5 Determining Why the OIM is Not Communicating with the Drive can stop communicating with the drive if the communication link is faulty, if a...
7.6 Replacing the OIM ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this section in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
7.6.3 Replacing the OIM Circuit Board Only Follow this procedure if you are replacing only the circuit board. If you are replacing the entire assembly, see section 7.6.4, “Replacing the Entire OIM Assembly”. You must remove the assembly from the drive to replace the circuit board. See section 7.6.1, “Preparing to Replace the OIM”, and section 7.6.2, “Accessing the OIM and Disconnecting It from the Regulator Board”, for instructions.
7.7 Resetting the Clock The elapsed time clock on the drive displays the day and time since the last power cycle or clock reset. The time is based on an internal 248-day counter. The clock is primarily used to show when a fault or alarm occurred. It is reset by cycling power or by using the procedure described here.
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7-10 FlexPak 3000 DC Drive OIM User’s Guide...
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LOSSARY Altitude. The atmospheric altitude (height above sea level) at which the motor or drive will be operating. Armature. The portion of the DC motor that rotates. Armature Resistance. Measured in ohms at 25 degrees Celsius (cold). Base Speed. The speed that a DC motor develops at rated armature voltage and rated field current with rated load applied.
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Inertial Load. A load (such as flywheel or fan) that tends to cause the motor shaft to continue to rotate after power has been removed (stored kinetic energy). If this continued rotation cannot be tolerated, some mechanical or electrical braking means must be applied.
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Rated Full Load Current. Armature current in amperes. Retentive. Parameter value is stored in the drive even when power is off. To save changes to the values, a Memory Save must be performed before removing power. RPM. Revolutions per Minute. The number of times per minute the shaft of the motor (machine) rotates.
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Glossary-4 FlexPak 3000 DC Drive OIM User’s Guide...
PPENDIX OIM Menu Structure This appendix shows the menu structure and the parameters in the menus. In these lists, parameter names are shown in upper case and menus are shown in lower case. A.1 FlexPak 3000 Main Menu To access the Main Menu, press until FlexPak 3000 Main Menu is displayed at the top of the screen.
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(P.002) DECELERATION TIME (P.003) MINIMUM SPEED (P.004) MAXIMUM SPEED (P.013) JOG ACCEL DECEL TIME (P.012) JOG SPEED (P.005) POSITIVE CURRENT LIM (P.006) NEGATIVE CURRENT LIM (P.206) IR COMPENSATION (P.792) ANLG TACH VLT SCL (P.793) ANLG TACH VLT RNG (P.395) ARM I FB RESISTOR Self Tune Drive Reference Drive Reference Test Points...
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Drive Reference Limits (P.011) TOP SPEED (P.004) MAXIMUM SPEED (P.003) MINIMUM SPEED (P.015) REVERSE DISABLE (P.111) AUTO MODE MIN BYPASS Drive Reference Ramp (P.001) ACCELERATION TIME (P.002) DECELERATION TIME (P.014) CURVE ROUNDING (P.013) JOG ACCEL DECEL TIME (P.112) AUTO MODE RAMP BYPASS (P.115) MOP ACCEL TIME (P.120)
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(P.104) ANLG MAN REF GAIN ADJ (P.192) ANALOG MAN REFERENCE (P.194) ANALOG MAN TRIM REF Speed/Voltage Loop ( Speed/Voltage Loop ( ) Test Points (P.295) SPD LOOP REFERENCE (P.296) SPD LOOP FEEDBACK (P.297) SPD LOOP ERROR (P.298) SPD LOOP LAG OUTPUT (P.299) SPD LOOP OUTPUT (P.293)
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(P.206) IR COMPENSATION (P.221) INERTIA COMP SELECT (P.222) NORMALIZED INERTIA (P.223) POS CURRENT LIM SEL (P.224) NEG CURRENT LIM SEL Speed/Voltage Loop ( ) Feedback (P.200) FEEDBACK SELECT (P.009) MOTOR RATED ARM VOLTS (P.205) ARM VOLTAGE ZERO ADJ (P.204) ARM VOLTAGE GAIN ADJ (P.289) ARMATURE VOLTAGE (P.202)
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Tuning (P.301) CML PI PROP GAIN (P.302) CML PI LEAD FREQUENCY (P.303) CML REF RATE LIMIT (P.005) POSITIVE CURRENT LIM (P.006) NEGATIVE CURRENT LIM Self Tuning Setup (P.220) SELF TUNE BRIDGE (P.218) SELF TUNE FIELD RANGE (P.219) SELF TUNE STABILITY Self Tuning (P.223) POS CURRENT LIM SEL...
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Armature Phase Fire Test (P.309) PHASE FIRE TEST DELTA (P.310) PHASE FIRE TST BRIDGE (P.399) ARMATURE DELTA (P.397) CML FEEDBACK (P.289) ARMATURE VOLTAGE Outer Control Loop ( Test Points (P.849) OCL ENABLE (P.845) OCL REFERENCE (P.846) OCL RAMP OUTPUT (P.847) OCL FEEDBACK (P.848) OCL OUTPUT...
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Input/Output Meter Outputs (P.404) METER OUT SELECT (P.402) METER OUT ZERO ADJ (P.400) METER OUT GAIN ADJ (P.405) METER OUT SELECT (P.403) METER OUT ZERO ADJ (P.401) METER OUT GAIN ADJ Analog I/O (P.797) O EXPANSION KIT (P.413) ANLG IN SIG TYPE (P.414) ANLG IN...
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(P.411) DIG OUT SELECT (P.412) DIG OUT CONTACT TYP Frequency I/O (P.797) O EXPANSION KIT (P.423) FREQ IN ZERO (P.424) FREQ IN FULL SCALE (P.491) FREQ IN (P.425) FREQ OUT SELECT (P.426) FREQ OUT ZERO (P.427) FREQ OUT FULL SCALE Level Detectors (P.602) LEVEL DETECT...
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2 (P.906) NETW IN REG 3 (P.907) NETW IN REG (P.912) NETWORK BAUD RATE (P.913) DEVNET POLL MSG TYPE Field Standard/enhanced Field Supply (P.597) FIELD LOSS DETECT (P.599) FIELD ECONOMY ACTIVE (P.501) FIELD ECONOMY DELAY (P.500) ENHANCED FLD VOLT ADJ (P.598) FLD SUPPLY JUMPER Field Current Regulator...
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(P.517) FIELD AUTO WEAKEN (P.587) FIELD DELTA HIGH LIM Field Loop Feedback Scaling (P.510) MOTOR HOT FLD AMPS (P.516) FLD FEEDBACK GAIN ADJ (P.589) FIELD FEEDBACK Drive Information Correct Scaling Jumper Positions (P.792) ANLG TACH VLT SCL (P.793) ANLG TACH VLT RNG (P.395) ARM I FB RESISTOR (P.798)
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Additional Parameters 2 (P.017) JOG SPEED (P.018) RAMP STOP DECEL TIME (P.122) STOP DECEL SELECT (P.226) NEG CUR LIM INV EN (P.227) TACH LEAD FLT THRESH (P.228) TACH LEAD FLT DELAY (P.311) CML REF LIMIT SELECT (P.312) INV FAULT AVOID SEL (P.428) DIG IN SELECT...
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Index display, 2-5 characters, 2-8 alarm, 5-2 contrast, 3-2 AC LINE VOLTAGE HIGH alarm, 5-2 drive AC LINE VOLTAGE LOW (P.001), 5-11 changing direction, 6-6 ACCELERATION TIME alarms jogging, 6-5 identifying, 7-1 running, 6-5 resetting and clearing logs, 7-4 starting, 6-5 reviewing and resetting, 7-2 status indicators, 2-6 reviewing logs, 7-3...
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Main Menu, 4-2, A-1 indicators manual drive status, 2-6 hardware, 1-1 key, 2-6 software, 1-1 input (parameter type), 4-1 manual reference, changing, 6-4 (P.206), 5-14 IR COMPENSATION (P.004), 5-12 MAXIMUM SPEED memory operations, 4-9 restore, 4-9 (P.013), 5-12 JOG ACCEL DECEL TIME save, 4-9 key, 2-4, 6-5...
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