Professional Documents
Culture Documents
SW-Version 4.3
Instruction Manual
Table of Contents
1.0 General Notes
1.1 Safety Instructions....................................................................................................... 1-1
1.2 General Notes ............................................................................................................. 1-2
1.3 Manual Scope ..............................................................................................................1.2
1.4 Related Documentation................................................................................................1-2
Appendices
Appendix A
Glossary of Terms ................................................................................................................ A-1...A-2
Appendix B
FlexPak 3000 User Input Parameters ................................................................................. B-1..B-52
Appendix C
FlexPak 3000 User Output Parameters ............................................................................ C-1...C-12
Appendix D
Index Block Diagrams.................................................................................................................... D-I
Block Diagrams................................................................................................................... D-1..D-14
Appendix E
Program Error Messages and Fault and Alarm Codes ......................................................... E-1...E-8
Appendix F
OIM Parameter Menu Tree................................................................................................... F-1...F-8
Appendix G
User Quick Reference Table ............................................................................................... G-1...G-8
Appendix H
CE-Conformity ..................................................................................................................... H-1...H-4
Appendix J
Cross Reference Part Numbers Catalogue Numbers........................................................ J-1...J-2
List of Figures
Figure 2.1 - FlexPak 3000 Functional Block Diagram ............................................................... 2-7
Figure 2.2 - Operator Interface Module (OIM) ........................................................................... 2-9
Figure 3.1 - Mounting Dimensions for FlexPak 3000, 25 and 60 A ........................................ 3-2
Figure 3.2 - Mounting Dimensions for FlexPak 3000, 150 A .................................................... 3-3
Figure 3.3 - Mounting Dimensions for FlexPak 3000, 250 and 450 A ...................................... 3-4
Figure 3.4 - Mounting Dimensions for FlexPak 3000, 800 A .................................................... 3-5
Figure 3.5 - Mounting Dimensions for FlexPak 3000, 1200 and 1600 A .................................. 3-6
Figure 3.6 - Mounting Dimensions for FlexPak 3000, 2000 A .................................................. 3-7
Figure 3.8a - CTB Connection Diagram - Example ................................................................... 3-12
Figure 3.8b - Main Contactor Connection Diagram - Example .................................................. 3-13
Figure 3.9/10 - Principle Wiring Diagram, 150 A..................................................................... 3-14
Figure 3.11/12 - Principle Wiring Diagram, 1600 A.................................................................... 3-16
Figure 4.1 - Regulator Board Jumpers ...................................................................................... 4-3
Figure 4.2 - AUTO REF Jumpers .............................................................................................. 4-6
Figure 5.1 - Integer Value Entry Screen ................................................................................... 5-1
Figure 8.2 - AC-Line Choke Dimensions ................................................................................ 8-10
Figure 8.3 - HF Filter Dimensions........................................................................................... 8-11
Figure 8.4 to 8.12 - RFI-Filter Dimensions ................................................................................ 8-13
Figure D.1 - Drive Control Signals............................................................................................. D-1
Figure D.2 - Speed Reference Overview .................................................................................. D-2
Figure D.3 - Speed Reference Source Select ........................................................................... D-3
Figure D.4 - Speed Reference Ramp........................................................................................ D-4
Figure D.5 - Speed Reference Mode Select ............................................................................. D-5
Figure D.6 - Speed Loop ........................................................................................................... D-6
Figure D.7 - Digital and Analog Outputs.................................................................................... D-7
Figure D.8 - Meter Outputs........................................................................................................ D-8
Figure D.9 - Current Minor Loop Reference.............................................................................. D-9
Figure D.10 - Current Minor Loop ............................................................................................. D-10
Figure D.11 - Field Block........................................................................................................... D-11
Figure D.12 - Outer Control Loop.............................................................................................. D-12
Figure D.13 - I/O Expansion Board Inputs ................................................................................ D-13
Figure D.14 - Level Detectors ................................................................................................... D-14
Figure H.1 - Cabinet Configuration............................................................................................ H-3
Figure H.2 - Specification for screened cable ........................................................................... H-4
List of Tables
Table 1.1 - Related Documentation.......................................................................................... 1-2
Table 2.1 - Armature Voltage ................................................................................................... 2-3
Table 2.2 - Tachometer Speed Regulation .............................................................................. 2-4
Table 2.3 - Drive Specifications................................................................................................ 2-4
Table 2.4 - Drive Modification Kits............................................................................................ 2-8
Table 2.5 - OIM Drive Fault and Status Indicators ................................................................ 2-10
Table 2.6 - Drive Monitor Capabilities .................................................................................... 2-11
Table 3.6 - User Device Connections to the Control Terminal Board..................................... 3-13
Table 3.7 - Recommended Lugs for Grounding FlexPak Drives in UL / cUL Version. ........... 3-18
Table 4.1 - Jumper and Adjustment Settings. .......................................................................... 4-2
Table 6.1 - Quick Start Jumper Settings....................................................................................6-2
Table 6.2 - Quick Start Parameter Modification Sequence. ..................................................... 6-3
Table 8.1/2 - Replacement Parts for FlexPak 3000 25-150 A .................................................. 8-3
Table 8.3/4 - Replacement Parts for FlexPak 3000 250-800 A .................................................. 8-4
Table 8.5/6 - Replacement Parts for FlexPak 3000 1200-2000 A .............................................. 8-5
Table 8.7 to 8.10 - Accessories ..................................................................................................... 8-6
Table 8.10 - RFI Filter Selection............................................................................................... 8-12
Table E.1 - Fault Codes ........................................................................................................... E-2
Table E.2 - Alarm Codes.......................................................................................................... E-7
Table G.1 - Quick Reference.................................................................................................... G-1
Table J.1 - Cross Reference Part Numbers Catalogue Numbers ......................................... J-1
NOTE: The term converter is used throughout this manual for the FlexPak 3000 Power Module.
DANGER: Before installing and/or operating this device, this manual must be understood by the
qualified electrical maintenance person who is familiar with this type of equipment and
the hazards involved. Failure to observe this precaution could result in bodily injury.
WARNING: Earth fault detection devices must not be used on this converter as the sole protection
measure against unintentional touching. The DC-component in the earth fault current
may inhibit the correct function of the fault detector.
CAUTION: Electronic converters cause disturbances to the supply network. The basic version of
this converter does not include any harmonic filters and may not fulfil the limits of the
national recommendations. The harmonic voltage disturbances produced by the
converter are dependent on the supply network impedance.
Machinery Directive
CAUTION: This inverter device is a component intended for implementation in machines or
systems for the capital goods industry.
The start-up of the inverter in the European market is not permitted until it has been
confirmed that the machine into which the inverters are built is in conformance with the
regulations of the Council Directive Machinery 98/37/EWG.
WARNING: To inhibit uncontrolled machine operation in case of the malfunction of the drive, the
user must provide an external emergency stop circuit, which ensures disconnection of
the power source from the motor.
This circuit must be hardwired with electro-mechanic components and shall not depend
on electronic logic or software. The stopping device (e.g. mushroom head pushbutton
with lock) must be accessible to the operator.
Failure to observe this precaution could result in bodily injury or loss of life.
CAUTION : The operating of inverters in the European market is only permitted if the Council
Directive Electromagnetic Compatibility 89/336/EWG has been observed.
It is the responsibility of the manufacturer of the machine or system to observe the
immunity and emission limits, requested by the Council Directive EMC in the European
market. Guidelines for the installation according EMC-regulations - for shielding,
grounding, filter arrangement as well as wiring instructions - are summarized in
Appendix H, CE-Conformance of this Instruction manual.
2.1.1 Nameplate
The FlexPak 3000 drive has a name-
plate on the right side of the carrier that
identifies the drive by its specific
Hardware and Software Part Numbers P.N. -EQUIPMENT 848.11.73 A SER. No.
P.N. -VERSION 790.30.72 A EU I/M 491340
and applicable AC input power and DC TYPE FP3000-S6R-800-AN-FC
output power data. Refer to this S/W VERSION 4.3
nameplate example. US M/N 650FR8742 I/M US P.N. D2-3475
All communication concerning this INPUT 500 VAC 3PH 50/60 Hz, 700 A
product should refer to the appropriate OUTPUT 0 -520 VDC, 800 A
Part Number information. SHORT CIRCUIT SYM RMS RATING 30 kA
ENCLOSURE IP00 CHARACTER OF LOAD M
The technical power information should MADE IN SWITZERLAND BY ROCKWELL AUTOMATION AG, DIERIKON
be referenced to verify proper power
application. CE, UL, CUL
Iad = Maximum continuous current without overload capability (Iad = 1.2 x Ia nom)
Ia nom = Nominal continuous current with overload capability 50% during 1 minute
every 10 minutes
Ia max = Maximum current during 1 minute after 9 minutes operation with Ia nom
(Ia max = 1.5 x Ia nom)
IF = Field current without overload capability
* A maximum field current of 20 A is permitted, if the power unit blower is switched on
together with the motor field.
The logic input circuits can be powered either from the internal +24 V DC power supply or from
an external +24 V DC power source. The internal +24 V DC power supply is available at the
regulator board terminal strip (see Figure 3-8). If an external power source is used, only its
COMMON must be connected to 24V COM on the regulator board (terminal 15). 24V COM is
internally not grounded, but may be externally grounded if required by the users control wiring.
Electrical Specifications:
Input Voltage ......................................................................................................... +24 V DC
Turn On Voltage ............................................................................................................ 8 V
Turn Off Current ....................................................................................................... 0.5 mA
Common ............................................................. All input circuits have the same common.
The drive is a full-wave power converter without back rectifier, complete with a digital current
minor loop and a digital major loop for armature voltage or speed regulation by tachometer
feedback. Figure 2-1 shows a block diagram of the Drive.
The Drive employs a wireless construction and uses a keypad for drive setup, including
parameter adjustments and unit selection, monitoring and diagnostics. Multiple language
capability in English, French, German, Spanish, Italian and Code is available. Reference,
feedback, and metering signals can be interfaced to the drive. The drive can be controlled
locally by the Operator Interface Module (OIM) Keypad or remotely by using the terminals at the
regulator board terminal strip (see Section 3 for terminal connections). Based on the active
control source selected using the CONTROL SOURCE SELECT key, the OIM displays the
control source as "KEYPAD" or "TERMBLK" (regulator board terminal strip), or "NETWORK"
(if an optional network communication board is installed).
FIELD
Regulator Board DRIVE CONTROL SIGNALS AND SEQUENCING FIELD POWER
Terminal Strip CONTROL SUPPLY
I/O Expansion
Board
MOTOR FIELD
DIGITAL, SPEED
ANALOG, & REFERENCE CURRENT S6/S6R MOTOR ARMATURE
FREQUENCY SELECTION SPEED MINOR POWER
INPUTS/ AND LOOP LOOP UNIT
OUTPUTS SCALING (CML)
ANALOG OR PULSE
TACHOMETER
Current Feedback
Voltage Feedback
OUTER
CONTROL Tachometer Feedback
LOOP
(OCL)
Rockwell Automation offers modification kits that broaden the application range of the drive.
A summary of these kits is presented in the following Table 2-4.
Related Instruction Manuals are listed in Table 1-1, Section 1.4.
Table 2-4 - Drive Modification Kits
Name Description Part
Number
Pulse Tacho Allows for digital pulse tachometer speed feedback on high 762.70.00
Feedback Kit PTK performance regulation applications. (Kit includes cable).
Enhanced Field Provides electronic field voltage trim and field economy. It replaces 762.70.10
Supply kit FVR the standard field supply.
Field Current Provides field economy, as well as pre-weakening of the field using 762.70.50
Regulator kit a fixed reference or field weakening for above base speed 762.70.60
FCU4 operation. Tachometer feedback is required with this kit. 762.70.70
FCU10 This kit replaces the standard field supply. (4,10,15A)
FCU15
I/O Expansion Mounts on the FlexPak 3000 chassis and gives the FlexPak 3000 762.70.80
Board IOE additional analog, frequency, and digital I/O capability.
AutoMax Network Allows the FlexPak 3000 to communicate on the Reliance AutoMax 762.70.40
Communic. kit Distributed Control System (DCS). (Kit contains board & cable).
AMXF
Interbus Communi- Allows the FlexPak 3000 to communicate over the standardized 762.70.45
cation kit IBSF field bus system INTERBUS. (Kit contains board & cable).
Profibus Communi- Allows the FlexPak 3000 to communicate over the standardized 762.70.95
cation kit PDPF Profibus-DP system. (Kit contains board & cable)
ControlNet Allows a FlexPak to communicate over the open protocol 762.70.96
Communication ControlNet network. Mounts inside the FlexPak and includes
Board CONF terminals for network connections. The AMX Network Comm.
board cannot be used when using the ControlNet.
DeviceNet Allows a FlexPak to communicate over the open protocol 762.70.90
Communication DeviceNet network. Mounts inside the FlexPak and includes
Board DNC terminals for network connections. The AMX Network Comm.
board cannot be used when using the DeviceNet board.
Drive Control Windows-based software that allows the user to connect any 788.05.30
Configuration personal computer running Micro-soft Windows version 3.1 or later
Software to a FlexPak 3000 drive. Allows you to create, store, upload, and
CS3000-V6 download drive configurations. You can also monitor and change
parameters through the PC and read and reset the drives fault log.
Interface Cable for connecting the drive to PC (25-pin to 9-pin) 772.27.00
Keypad Drive Operator Interface that allows you to access and change drive 922.95.10
Configuration parameters, read and clear the drives alarm and fault log.
Module KDCM The DCM cannot control the drive.
Keypad Operator Allows you to control (e.g. Start, Stop, Jog) the drive. 922.95.00
Interface Module You can also monitor and change parameters, read and clear the
KOIM drive's alarm and fault log.
(M/N 317C160D)
OIM Remote Provides for remote mounting of the OIM up to 5 meters away from 762.70.30
Mounting kit DMK the drive. Contains also the cover plate (762.70.31) for the
(M/N 905FK0101) regulator unit.
2.5 Controls/Indicators
See Figure 2-2 for location of the controls and indicators for the Keypad OIM.
Drive fault and status indicators are listed in Table 2-5.
Fault
Alarm
Interlock OK
Drive Ready
Running
Current Limit
Control Key Torque Limit
LCD-Indicators PROGRAM KEYPAD MANUAL FORWARD
2.5.1 Indicators
LCD (Liquid Crystal Display) and LED (Light Emitted Diode) displays are used to indicate the
status of the drive. LCD indicators are located on the OIM to the left of the text for the indicator.
LED indicators are located on the regulator board which is located behind the OIM.
LCD Indicators
An LCD indicator is on when a field is present !! ; off when extinguished. In Figure 2-2, the
Interlocks OK and the Drive Ready indicators are on. Table 2-5 contains a list of drive and fault
status indicators with their associated description.
Indicators Description
Fault A condition or conditions exists in the drive which stopped it or prevents it from
running. When a fault occurs, the type of fault and further instructions are
displayed on the OIM display.
Alarm An alarm does not prevent the drive from running but alerts the user that a
condition exists that could cause a fault in the future. When an alarm occurs,
the type of alarm and further instructions are displayed (unless a subsequent
fault occurs which will overwrite the alarm text display).
Interlock OK This indicator is on when all customer interlocks (terminal 9) and the Coast/DB
contact (terminal 8) are closed. Off = 1 or more are open.
Drive Ready This indicator in on when all customer interlocks are closed, the Coast/DB
contact is closed and there are no drive faults present. Pressing the RUN or
JOG key will cause the drive to start if this indicator on. Off = not ready.
Running When on, this indicates that the contactor is closed and the motor armature is
energized. Off = contactor is open and drive is not running.
Current Limit This is a real time indication of the motor operating in current limit.
Torque Limit On = current limit
Off = not in current limit.
LED Indicators
Two LED indicators are located on the regulator board for status and service use: (LED1) CPU
OK and (LED2) OIM COMM OK. See Section 7 of this instruction manual for further details
regarding the use of these indicators for status and troubleshooting purposes.
2.5.2 Controls
The OIM keys can be categorized into two general functions:
1) OIM Programming Keys (program/monitor, fault, help, cancel, enter, and arrow keys)
2) Drive Control Keys (control source select, auto/manual, forward/reverse, jog, run, and
stop/reset.)
PROGRAM This key cycles the OIM display between Program screens and two Monitor
screens. The state of this key (PROGRAM or MONITOR) is shown on the LCD
---------------
MONITOR directly above the key. The active OIM display mode is retained through drive
power cycles. For example, if the OIM was in MONITOR mode and power was
removed, the OIM would power up in the MONITOR display mode.
See the following example for more information.
NOTE: The PROGRAM mode is used for menu and parameter selection.
This screen allows the user to change the drive's setpoint (KEYPAD REF) when the CONTROL
SOURCE SELECT is set to KEYPAD and the drive is in manual mode. Use the up/down arrow
keys to change the drive's setpoint. Pressing the ENTER key will save the setpoint to non-volatile
memory.
Pressing the PROGRAM/MONITOR key a second time will display motor speed (RPM) and
motor load (FLA):
0 RPM !!
0 %FLA
MONITOR KEYPAD MANUAL FORWARD
This screen does not allow the user to change the drive's setpoint (KEYPAD REF).
Pressing the PROGRAM/MONITOR key after the second time will re-display the previous
PROGRAM display (the first screen in this example).
Pressing the ENTER key will save the setpoint to non-volatile memory.
Pressing the CANCEL key when in monitor mode will return the OIM to the PROGRAM mode.
Table 2.6 lists drive parameters monitored and reported to the OIM.
Table 2.6 - Drive Monitor Capabilities
Monitor List Selectable Engineering Units
Motor Speed Percent, RPM, Units*
Arm Volts (Armature Voltage) Volts
Motor Load (Armature Current) Percent Full Load Amps (%FLA), Amps
TERMBLK REF, KEYPAD REF Percent, RPM, Units*
or TORQUE REF**, NETWORK REF***
* Units: Indicates the user's option to select an engineering unit (6 characters maximum) for readout to display. A number
from 1 to 10,000 full scale can be assigned a meaningful value (e.g. FPM, Feet Per Minute, etc.). See "Define User
Units" in Section 4.
** When the drive is configured as a current (torque) regulator (J15 Hardware Jumper = CURRENT), the Control Source
Select (CSS) can only be set to TERMBLK or NETWORK (if option is installed). In this case, TORQUE REF or
NETWORK REF is displayed. The units are the same as displayed for MOTOR LOAD.
** When the drive is configured as a speed or armature voltage regulator (J15 Hardware Jumper = SPEED),
the selected control source determines the reference source (TERMBLK REF or KEYPAD REF, or NETWORK REF).
*** Available with an optional Network Communication Board.
This key allows the operator to review and clear logs (fault and alarm), reset faults,
FAULT
clear the alarm indicator and display fault history and diagnostic information for
servicing the drive. The state of this key (FAULT, ALARM or DIAGS) is shown on
the LCD directly above the key.
Pressing the FAULT key once will display the fault menu:
Fault Menu
" Review Log
Reset Faults !!
Clear Fault Log and Reset Faults !!
Pressing the FAULT key a second time will display the alarm menu.
Pressing the CANCEL key will return the OIM to the previous display mode (PROGRAM or
MONITOR).
Alarm Menu
" Review Log
Reset Alarms !!
Clear Alarm Log and Reset Alarms !!
Pressing the FAULT key a third time will display the diagnostics menu.
Pressing the CANCEL key will return the OIM to the previous display mode (PROGRAM or
MONITOR).
Diagnostics Menu
" Why is the drive not ready?
Why did the drive stop? !!
!!
Pressing the FAULT key after the third time will re-display the fault menu.
To exit this mode, press PROGRAM/MONITOR. This returns the OIM display to the previous
display mode (PROGRAM or MONITOR).
See Section 7 of this instruction manual for further details on the FAULT, ALARM, and DIAGS
menus.
Menu and Parameter HELP are available. Access Menu or Parameter HELP by
HELP
pressing the HELP key when the cursor is at the particular menu or parameter of
?
interest. In the MONITOR mode, pressing HELP displays status indicators in the
selected language. Pressing CANCEL at anytime will return to the display
from the previous screen.
MENU HELP
Menu HELP provides the user with information regarding the general purpose of the menu and
some details of related parameter selections.
For example: If English is the selected Language, the following is displayed when HELP is
pressed when at the Main Menu.
2-12 FlexPak 3000 491340 e
INTRODUCTION TO THE DRIVE
MENU HELP
FlexPak 3000 Main Menu
!!
Select the appropriate menu item with the
!!
UP/DOWN arrow keys and the ENTER key.
You can use CANCEL at any time to return
to the previous menu level.
PROGRAM KEYPAD MANUAL FORWARD
A # displayed at the bottom left of the text indicates that more text is available. Press the down
! key to scroll up the remaining text for viewing. Similarly, if a $ is displayed at the upper left
of the text, use the " key to scroll down the previous text for viewing.
Press CANCEL to exit MENU HELP.
PARAMETER HELP
Parameter HELP displays the following information:
Parameter name
Code (parameter No.)
Input
Retentive or Non-retentive
Units
To obtain parameter help, the OIM must be at a value entry screen. See Section:5 "How to
Make Parameter Adjustments" for examples of value entry screens.
For example: The following is displayed when HELP is pressed while at the value entry screen
for the TOP SPEED parameter.
Moves the cursor left or right in parameter modification (value entry) screens
to allow digit selection for parameter value setting.
Left () accesses the Language Selection menu at any menu level but not
at parameter modification screens. See section 4.13 of this instruction
manual for further details on the Language Selection menu.
Right () accesses the Contrast Adjustment screen at any menu level but
not at parameter modification screens. See section 4.7 of this instruction
manual for further details on the Contrast Adjustment screen.
Selects where the control signals for the drive originate. "KEYPAD" (OIM
CONTROL control), "TERMBLK" (terminal strip control) or "NETWORK" (network
SOURCE communication board). The selection can only be changed when the drive is
SELECT not running. The state of this key (TERMBLK or KEYPAD, SERIAL or
NETWORK) is shown on the LCD directly above the key.
Keypad control uses the OIM buttons to control drive operations. The KEYPAD REF value
(displayed in MONITOR mode) is used as the drive reference.
Termblk control uses the reference at regulator board terminals (17-18 for Manual Reference
or 19-20 for Auto Reference) for the setpoint. It also uses the controls connected to the
terminal strip for control of drive operations. Reference Figure 3-8 for more details.
Network control can only be selected with a network communication board installed and when
the control signals and reference originate from the network board.
When the drive is configured as a current regulator (J15 = CURRENT), the control source can
only be set to TERMBLK.
AUTO The AUTO/MANUAL key determines which drive reference source will be
-------- used when the CONTROL SOURCE SELECT is set to KEYPAD. The state
MANUAL of this key (AUTO or MANUAL) is shown on the LCD directly above the key.
AUTO will use the signal at regulator board terminals 19 and 20 (see figure 3.8). The type of
signal accepted at these terminals is determined by the position of hardware jumpers J10
and J12 (see Figure 4-1).
MANUAL will use the KEYPAD REF from the OIM as the drive reference. When CONTROL
SOURCE SELECT is not set to KEYPAD REF, the preset state of the reference mode is
shown above the key (determined from the selected control source). When the drive is
configured as a current regulator (J15 = CURRENT), AUTO/MANUAL is fixed in the AUTO
mode.
Active only when in KEYPAD control mode. This key causes the drive reference
.JOG to ramp up at the JOG ACCEL/DECEL rate to jog speed. When this key is
--------- released, the drive reference ramps to zero at the same rate. If the drive status
indicators show that the drive is "not ready", this request will be ignored.
Active only when in KEYPAD control mode. This key allows the motor to
RUN accelerate to the speed reference setpoint.
STOP STOP is active at all times regardless of the CONTROL SOURCE SELECT
------ setting. Pressing the key with the drive running causes the drive to stop in the
RESET selected stop mode. RESET is active only if the drive is not running and
# CONTROL SOURCE SELECT is set to KEYPAD. When the RESET key is
pressed, drive faults and alarms will be reset (see section 7 for more
information.)
DANGER
The user is responsible for conforming to all other applicable standards.
Wiring practices, grounding, disconnects, and overcurrent protection are of particular importance.
Size and install all wiring in conformance with the applicable standards.
Failure to observe this precaution could result in severe bodily injury or loss of life.
DANGER
This equipment must be connected to a power source for which it was designed. Compare available
power with the requirements listed on the nameplate to insure that voltage, frequency, phase, current
capacity and interrupting capacity are adequate.
Failure to observe this precaution could result in severe bodily injury or loss of life.
3.1 General
This Section outlines the procedures that are to be followed to properly install the FlexPak 3000
Drive.
269
25 219 25
7.0
14.0
12
Power connections
Terminals for 25 A Unit
Motor 6 mm2
1D, 1C 1.4 Nm
AC-Line 6 mm2
1U, 1V, 1W 1.4 Nm
386
Prot. earth 6 mm2
400
PE 1.4 Nm
130
Power connections
Terminals for 60 A Unit
136 Motor 16 mm2
185
1D, 1C 2.5 Nm
107
AC-Line 16 mm2
7
1U, 1V, 1W 2.5 Nm
25 219 25 Prot. earth 16 mm2
PE 2.5 Nm
MAX. 250
287
Weight: 10 kg
Minimum clearances
for air circulation: 100 mm
200
269
25 25 69.5 32.5 32.5 32.5 32.5 69.5
219
8.5
7.0
12 14.0
1U 1C 1V 1D 1W
Power Connections on
1-Quadrant Units S-6
69.5 36 29 29 36 69.5
185 8.5
386 400
428
1C 1U 1V 1W 1D
130
Power Connections on
136
4-Quadrant Units S-6R
107
Power Connections
7
Motor Bus bars
25 219 25 1D, 1C 90 mm2
AC-Line Bus bars
MAX. 250
1U,1V,1W 60 mm2
Prot. Earth Terminals 35 mm2
PE Torque 2.5 Nm
93
36
287
Weight: 14 kg
Minimum clearances
200
for air circulation: 100 mm
Power connections
for 250 A Unit
Motor Bus bars 25 x 5,
1D, 1C Hole 11 mm
AC-Line Bus bars 20 x 5,
1U, 1V, 1W Hole 11 mm
Prot. earth Bolt M10,
PE Torque 15 Nm
Power connections
for 450 A Unit
Motor Bus bars 40 x 5,
1D, 1C Hole 14 mm
AC-Line Bus bars 30 x 5,
1U, 1V, 1W Hole 14 mm
Prot. earth Bolt M10
PE Torque 15 Nm
Weight: 40 kg
Minimum clearances
for air circulation: 100 mm
25 1)
Power connections
Motor Bus bars 50 x 10,
1D, 1C Hole 13.5 mm
AC-Line Bus bars 40 x 10,
1U, 1V, 1W Hole 13.5 mm
Protection earth Bolt M12
PE Torque 15 Nm
Weight: 83 kg
Minimum clearances
for air circulation: 100 mm
455 515
400 6
14
25 1)
240
21 190
49 50
=
40 100
=
DC OUTPUT M12
60 317
197 200
975 905 52 50 M12
100 40
=
185 DC OUTPUT
138
418
130
154
26
26
Power connections
Motor Bus bars 100 x 10,
1D, 1C Drilling 4 x M12
AC-Line Bus bars 60 x 10,
1U, 1V, 1W Drilling 2 x 13,5 mm
Prot. earth PE Bolt M12, Torque 25 Nm
Weight: 195 kg
Cooling air: 2000 m3/h
Air flow direction: from bottom to top
Minimum clearances
200 for free air circulation: 100 mm
Figure 3-5: Mounting Data for FlexPak 1200/1600 A, 500V and 1600A, 575/690V
25 1)
Power connections
Motor Bus bars 120 x 10,
1D, 1C Drilling 4 x M12
Torque 25 Nm
AC-Line Bus bars 96 x 10,
1U, 1V, 1W Drilling 4 x 14 mm
Prot. earth PE Bus bar 60 x 10,
Drilling 2 x 14 mm,
Weight: 196 kg
Cooling air: 2000 m3/h
Air flow direction: from bottom to top
200
Minimum clearances
for free air circulation: 100 mm
CAUTION
The star point of the external AC-line transformer must always be grounded (Zero potential)
and connected to the drive ground point (terminal PE or ground stud).
Connection of a drive to a transformer with a primary rating of 2300 VAC or more may require additional
input line conditioning. Contact your local Rockwell Automation sales/service office for assistance when
this is required. Failure to observe this precaution could result in damage to,
or destruction of, the equipment.
Input transformers step up or step down input voltage and can be either auto or isolation
transformer types. Users should consider using an isolation transformer instead of an auto
transformer for the following advantages:
AC power line disturbances and transients are minimized by an isolation transformer, thus
reducing or eliminating possible damage to solid state components.
An isolation transformer provides electrical isolation for the drive from plant power system
grounds. Damaging currents may be avoided in instances where the DC output is
accidentally grounded or where the DC motor circuits are grounded.
Rockwell Automation offers a series of isolation transformers suitable for use with the drive.
DANGER
The standard EN 60204-1 requires that an input disconnect must be provided in the incoming power
line and either be located within sight of the drive or have provisions for a padlock. Install an input
disconnect in the incoming power line that is located in sight of the drive or one that has provisions for
a padlock. Failure to observe this precaution could result in severe bodily injury or loss of life.
Any fused disconnect or circuit breaker in the incoming AC line must accommodate a maximum
symmetrical AC fault current as indicated in 2.2.1 of this instruction manual.Size the disconnect
to handle the transformer primary current as well as any additional loads the disconnect may
supply.
1. Install an input disconnect in the incoming power line according to the standard EN 60204-1
if not provided with the drive.
The disconnect switch should be within clear view of machine operator and maintenance
personnel for easy access and safety. An open-type switch with provisions for a padlock is
recommended.
2. Wire this disconnect in the primary circuit of the drive isolation transformer (if used).
DANGER
The user is responsible for conforming to all applicable standards. Wiring, grounding, disconnects and
overcurrent protection are of particular importance.
Size and install all wiring in conformance with all other applicable standards.
Failure to observe this precaution could result in severe bodily injury or loss of life.
The Drive is designed for AC entry and DC power exiting at the top and control and signal
wiring entering from the bottom.
Reference signal wiring should be run in a separate conduit isolated from all AC and DC power
and control. Signal wires should not be run in parallel with high voltage or electrically noisy
conductors. Always cross such conductors at 90.
All reference signals should be wired with either twisted double or twisted triple conductor wire,
40 twists per meter, stranded copper, 1.5 mm2 , or screened 4-stranded (3, PE) 0.5 mm2 (PN
380.35.01), 600 VAC rated insulation, with a temperature range of 40 - 105C.
Analog tachometer feedback should be run in a separate conduit isolated from all AC and DC
power and logic control. Wiring should be the same as for the reference signals but screened
per pair if stranded cable 0.5 mm2 (PN 380.33.00) is used.
Digital tachometer feedback (Encoder) wiring should be twisted per pair, not screened and be
run in a separate conduit isolated from all AC and DC power and logic control.
For mounting with external contacts and solenoids, coils should be suppressed
to reduce noise.
NOTE: The maximum recommended wire length from the drive to the motor is 300 meter.
WARNING
The drive requires a 3-phase power source of 200 - 500 (300 - 575/690 V), 50/60 Hz (see 2.2.2).
If the correct voltage is not available, a transformer must be installed between power source and drive.
Do not connect the drive to a power source with available short circuit capacity in excess of the max.
symmetrical fault current. Failure to observe these precautions could result in bodily injury.
1. Size the AC line supply conductors for the specific drive rating and according to all applicable
standards.
2. Connect the AC line supply via disconnect (if used) and line reactor or matched transformer
to the terminal strips or bus bars at the top of the Converter or to the disconnect.
3.8.4 Main contactor (Refer to connection diagram example Figures 3-8a and 3-8b)
A main contactor in the AC-line input or armature circuit is not built-in and must be externally
provided. It allows Coast-to-rest (Category 0) or Ramp-to-rest (Category 1, according to
EN60204-1, Chap. 9.2.2.) each with disconnection of the power source from the motor.
The sequencing of the M-contactor must be controlled by the drive MCR contact of the FlexPak
3000, which is wired to terminal strip X1:5 and X1:6 located at top of the power unit.
On drives, where the inrush current of the M-contactor coil exceeds the MCR contact rating
(330 VA at AC 230V, cos phi 0.5), a pilot relay is required between the MCR contact output and
the M-contactor coil.
A normally open auxiliary contact from the main contactor must be wired to terminals X1:3 and
X1:4 to provide contactor status feedback to the drive.
WARNING: To inhibit uncontrolled machine operation in case of the malfunction of the drive, the
user must provide an external emergency stop circuit, which ensures disconnection of
the power source from the motor.
This circuit must be hardwired with electro-mechanic components and shall not depend
on electronic logic or software. The stopping device (e.g. mushroom head pushbutton)
must be accessible to the operator.
Failure to observe this precaution could result in bodily injury or loss of life.
It is the responsibility of the user to decide, how the Emergency Stop Function is fulfilled, depending on
the requirements of the application and based on a risk assessment of the machine.
Disconnection of the power source from the motor may be reached e.g. by one of the following
measures:
a) Circuit breaker used as Emergency Stopping Device:
- easy accessible to the operator, hand operated or
- remote operated, e. g. undervoltage trip coil released by mushroom head pushbutton.
b) Circuit breaker not used as Emergency Stopping Device:
- Emergency Stopping Device (mushroom head pushbutton) interrupts control circuit and
releases Coast Stop according to Category 0.
A Connection Diagram - Example for case b) is shown in Figures 3-8a and 3-8b.
FUNCTION: Actuating of the Emergency Stop pushbutton during operation, causes immediate
drop out of relay K10, opening the n.o. contact at input terminal 8 and blocking of the regulator.
At zero current, opening of contact output MCR will drop out the main contactor via auxiliary
contactor K1. The time delayed normally open contact of timer relay K10T ensures, that in case
of malfunction of the internal control circuit (MCR does not open) the main contactor drops out
after 1 second.
1
+ 24 V
2
RUN METERING OUTPUTS
3 24 ANALOG OUT1
STOP
4 25 ANALOG OUT
JOG
COM
5 26 ANALOG OUT2
REV/FWD
6
AUTO/MAN
Reference select
7 27
+ 24 V
K10 RUNNING
8 28
COAST STOP
9
CUSTOMER
INTERLOCK 29
10
FAULT/ALARM RESET ALARM
30
11
+ 24 V
12 31
DIGITAL INPUT 0
13 FAULT
MOTOR 32
THERMOSTAT
14
+ 24 V
15 24 V COM
MANUAL REFERENCE 16
+ 10 V (ISOLATED)
5k 18
COM
17
+ MAN REF
19
+/-
AUTO REFERENCE
20
COM
21
HI RANGE
22 LO RANGE
23 COMMON
ANALOG TACH
Table 3.6 - User Device Connections to the Regulator Board Terminal Strip
K1M
K1
5 3 4
MCR
6 X1
K10 K10T
1C
PE
V4 V5 V6
K1 T1
1U
L1
1V
L2 M
T2
1W
L3
R1 V1 V2 V3
1D
MOV 2-4
C1
0
2U 2V 2W F1
J
230
115
1 3 5 X2 1 2 1 2 3 4 5 6 1 2 3 4 1 3 5 7 8 11 12
THY1
47G
THY4
THY5
THY2
THY3
382G
THY6
481G
483G
X5 X6 X4 X7 47 45
1 3 X3
X1:5
X3 9
FlexPak 3000
X1:6
MCR 11
POWER INTERFACE
~ K1
TID 813.40.00
X6
X1:3
~ 8
INSTALLATION AND WIRING
+ - X1:4
7 K1
X1
X3
5 7
J2 J6
OIM 604.42.00
POWER SUPPLY REGULATOR or
FPP 810.89.00 810.79.40
DCM 604.42.10
J1 J7 J9 J1
J1 J2 J3 J4 J8 J5
1 32
Figure 3-9: Principle wiring diagram of FlexPak 3000, single quadrant (example S-6 150 A)
491340 e
491340 e
1 2 3V 3C
~ M1 +
MAX. 415V MOV1
4 3 3W 3D
~ -
1C
PE
0
F1
230
J
115
1 3 5 X2 1 2 1 2 3 4 5 6 1 2 3 4 1 3 5 7 8 11 12
47 45
45G
THY1
47G
THY4
THY5
THY2
THY3
382G
THY6
481G
483G
THY15
THY12
THY16
THY13
THY11
THY14
X5 X6 X4 X7
1 3 X3
X1:5
X3 RC 9
FlexPak 3000
X1:6
MCR 11
POWER INTERFACE
~ K1
TIC 813.39.00
X6
X1:3
~ 8
INSTALLATION AND WIRING
+ -
X1:4 K1
X1 7
X3
5 7
J2 J6
OIM 604.42.01
POWER SUPPLY REGULATOR
or
FPP 810.89.00 810.79.40
DCM 604.42.10
J1 J7 J9 J1
J1 J2 J3 J4 J8 J5
1 32
Figure 3-10: Principle wiring diagram of FlexPak 3000, four quadrant (example S-6R 150 A)
3-15
INSTALLATION AND WIRING
810.79.40
Field Curr.
762.70.70
Regulator
37
35
J3
+
J6
~
MOV 2-4
583
582
2
3
1
230
115
0
460 V
Figure 3-11: Principle wiring diagram of FlexPak 3000, single quadrant S-6, 1600 A, 575 V
810.79.40
Field Curr.
762.70.70
Regulator
37
35
J3
+
J6
~
MOV 2-4
583
582
2
3
1
230
115
0
460 V
Figure 3-12: Principle wiring diagram of FlexPak 3000, four quadrant S-6R, 1600 A, 575 V
The following describes how to interpret Reliance USA lug model numbers used in grounding the
FlexPak 3000 drive.
The lugs are non-insulated screw type (solderless) for use with solid and stranded wire.
1LG 1 2 03
Basic Catalog Number
Number of Conductors
1 = one conductor
2 = two conductors
3 = three conductors
Mounting Hole and Lug Material
1 = one mounting hole, copper
2 = one mounting hole, aluminum
3 = two mounting holes, copper
4 = two mounting holes, aluminum
5 = four mounting holes, copper
6 = four mounting holes, aluminum
Lug Version Number
01 to 99
DANGER
Only qualified electrical personnel familiar with the construction and operation of this equipment and
the hazards involved should install, adjust, operate and/or service this equipment. Read and
understand this section in its entirety before proceeding. Failure to observe this precaution could result
in bodily injury or loss of life.
4.1 Introduction
This section details the setup and adjustment of the drive. Record final settings in Table 4.1.
CAUTION
Do not use a megohmmeter for continuity checks in the drive. The high voltage of the megohmmeter
can damage the drive's electronic circuits. Failure to observe this precaution could result in damage to,
or destruction of, the equipment.
CAUTION:
A megohmmeter can be used for this motor ground check, but all conductors between the motor and
the drive must be disconnected. The megohmmeters high voltage can damage the drive's electronic
circuits. Disconnect all conductors between the motor and the drive before using a megohmmeter for
this motor ground check. Failure to observe this precaution could result in damage to, or destruction
of, the equipment.
The DC Motor frame and conduit box should be connected to a good earth ground per the
motor instruction manual.
Verify that there is no path to ground in either the D-C Motor armature circuit, the shunt field
circuit or the thermostat circuit. Connect one lead of a standard ohm reading meter to the motor
frame and the other lead to the two armature leads, then to the two field leads and to the two
thermostat leads. If a reading of less than 100,000 ohms is observed, a ground condition exists
and MUST be corrected before power is applied.
DANGER
This equipment is at line voltage when A-C power is connected to the drive. Disconnect and lockout
incoming power to the drive before proceeding. After power is removed, verify with a voltmeter at
power terminals 1U, 1V and 1W that no voltage exists before touching any internal parts of the drive.
Failure to observe these precautions could result in severe bodily injury or loss of life.
CAUTION
Unless explicitly stated otherwise, power must be removed before changing any jumper connection.
Failure to observe this precaution could result in damage to, or destruction of, the equipment.
Jumpers are read only on power-up, so power must be cycled for a change to a jumper setting
to be recognized by the drive.
1. Remove power from the drive.
2. Remove the cover and the keypad
3. The jumpers are located on the regulator board. See Figure 4.1 for jumper locations
4. Change the jumper settings as described in the following paragraphs per the requirements of
your application. Record final settings in Table 4.1.
Table 4.1 - Jumper and Adjustment Settings
JUMPER/ADJUSTMENT DEFAULT SETTING FINAL SETTING
J10 (AUTO REF) VOLTS
J11 (TACH V SCALE) 16
J12 (AUTO REF) VOLTS
J14 (TACH V RANGE) 62
J15 (REGULATOR TYPE) SPEED
J16 (OIM PROGRAM) ENABLE
J18 (ARM I FB RB) Position 4
J19 (MANUAL REF) POT
J20 (FIELD LOSS DETECT) DISABLE
J21 (FIELD SUPPLY) NOT APPLICABLE 1)
J26 (TACH LOSS DETECT) ENABLE
J27, J29 for future selection needs
J28 (FILTER SELECT) (red) FLDFBK (do not change) FLDFBK
J30 (POWER INTERFACE) LOW
ANALOG TACH ZERO ADJ 0
ARM VOLTAGE ZERO ADJ 0
(1) Only applicable when the optional Enhanced Field Supply kit is installed.
J15 determines whether the drive uses Speed/Voltage (SPEED) or Torque/Current (CURRENT)
regulation.
When CURRENT is selected, only the terminal strip or the AutoMax Network Communication
Board can be used as the control source. and the reference selection is automatically set to
AUTO mode.
Also note that speed/voltage parameters must be set to provide overspeed protection for the
drive.
J17 J28 J22
F2
F1 ARM I GND IOGND2
GND1
J7
J18
EPROM
J3 790.30.70
J25
J4
J6
J5
J2
J15 J20 J26 0VI2
J16 J21
J14 J11
J30 J29 J27
4.5.3 Set Field Loss Enable/Disable (FIELD LOSS DETECT) - J20 Jumper
The FIELD LOSS DETECT jumper (J20) determines whether or not a fault is generated when a
field loss occurs.
NOTE: Jumper J20 is ignored if the Field Current Regulator kit is installed. Therefore, placing
J20 in the DISABLE position will not disable field loss detection. See I/M 491345 for more
information on the Field Current Regulator.
WARNING
The user must provide external field current loss detection and inhibit drive operation via one of the
drive interlocks when this jumper is positioned to disable. Misapplication of this jumper can cause the
motor to run at dangerously high speeds.
Failure to observe this precaution could result in bodily injury.
To detect complete loss of field current, place the jumper on pins 1 and 2 (ENABLE). When a
complete loss is sensed, a fault is generated and the drive is stopped.
To ignore field loss, place the jumper on pins 2 and 3 (DISABLE). Any loss of field current is
than ignored. Use the DISABLE option only when no field exists, such as with a permanent
magnet or when a separate field supply is used.
WARNING
When this jumper is removed and pins 1 and 3 connected, the user must provide external tacho loss
detection and inhibit drive operation via one of the drive interlocks. Misapplication of this jumper can
cause the motor to run at dangerously high speeds.
Failure to observe this precaution could result in bodily injury.
To detect tacho loss, place the jumper on pins 1 and 2 (ENABLE). When a loss is sensed,
a fault is generated and the drive is stopped. To ignore tacho loss or open armature, the jumper
must be removed and pins 1 and 3 connected (through wire-wrap connection).
4.5.6 Setting the Source for the Manual Mode Reference (MANUAL REF) - J19 Jumper
CAUTION: The drive will not run at the correct speed if this jumper is not set to the correct position.
Failure to observe this precaution could result in damage to, or destruction of, the equipment.
The MANUAL REF jumper (J19) determines whether the internal +10 V isolated power supply
or an external +10 V source is used for the manual mode reference.
To use the +10V power supply for the manual reference potentiometer, place the jumper on
pins 2 and 3 (POT). The supply at terminal 16 of the regulator board terminal strip is used.
To use an external +10 V source, place the jumper on pins 1 and 2 (EXT). The external
reference is connected at terminals 17 and 18 of the regulator board terminal strip.
NOTE: This input can be used as a trim on auto mode speed reference by setting the jumper on
pins 1 and 2 (EXT). In this case a 10 V reference can be used.
4.5.7 Setting the Tachometer Voltage Range (TACH V RANGE) - J14 Jumper / and
Tachometer Voltage Scale (TACH V SCALE) - J11 Jumper
The TACH V RANGE (J14) and TACH V SCALE (J11) jumpers set the voltage range and scale
of the analog tachometer.
NOTE: This jumper is ignored if an analog tachometer is not used and if FEEDBACK SELECT
is not set to DC TACH or AC TACH.
CAUTION: The drive will not run at the correct speed if these jumpers are not set to the correct
position. Failure to observe this precaution could result in damage to, or destruction of the equipment.
During "Quick Start", the drive calculates the value of the tachometer range based on the values
of TOP SPEED and ANLG TACH VOLTS/1000 and the setting of FEEDBACK SELECT. The
correct values are displayed on the Correct Scaling Jumper Positions screen.
Verify these settings prior to performing the Self Tuning procedure.
The expected analog tachometer voltage range can be set to a maximum of 250 or 62 VDC.
J11 selects the hardware circuitry to maximize the resolution over the entire speed range.
Jumper J14 Jumper J11
Top Speed Tach Volts < 16 volts LOW 16
Top Speed Tach Volts < 31 volts LOW 31/125
Top Speed Tach Volts < 62 volts LOW 62/250
Top Speed Tach Volts < 125 volts HIGH 31/125
Top Speed Tach Volts < 250 volts HIGH 62/250
NOTE: The output voltage of the tachometer must not exceed 250 V for DC tachometers or 275
RMS for AC tachometers when the motor is rotating at TOP SPEED. To calculate the output
voltage at top speed, multiply the two parameter values:
Tachometer Voltage at TOP SPEED = TOP SPEED x ANALOG TACH VOLTS
1000 1000
4.5.8 Analog Auto Reference (AUTO REF) - J12 and J10 Jumpers
The AUTOREF Jumpers J12 and J10 select the type of analog auto reference to be used when
the AUTO mode is selected. J12 selects the type of signal - VOLTS (Voltage) or MAMPS (milli-
amps). J10 selects the range.
+ / - 10 VOLTS MAX 4 - 20 mA 10 - 50 mA
J12 J10 J12 J10 J12 J10
! VOLTS 10 - 50 !! VOLTS ! VOLTS 10 - 50 ! ! VOLTS ! VOLTS 10 - 50 ! ! VOLTS
! (BOTH) !! 4 - 20 ! (BOTH) ! ! 4 - 20 ! (BOTH) ! ! 4 - 20
! MAMPS PARK !! ! MAMPS PARK ! ! ! MAMPS PARK ! !
The ARM I FB RB) Jumper J18 scales the armature current feedback signal. The drive
calculates the value of the burden resistor needed to scale the armature current feedback
signal. The calculations are based on the values of MOTOR RATED ARM AMPS and
MAXIMUM CURRENT.
The OIM displays the correct position of this jumper during the "Quick Start" procedure.
Verify this setting prior to performing the Self Tuning procedure.
CAUTION:
The drive will not operate at the correct speed if this jumper is not set to the correct position.
Failure to observe this precaution could result in damage to the equipment or in bodily injury.
Please wait.
Network Communications
Input/Output
Meter Outputs
Analog I/O*
Digital I/O*
Frequency I/O*
Level Detectors*
Drive Information*
Correct Scaling Jumper Positions*
Field*
Standard/enhanced Field Supply
Field Current Regulator
Field Loop Test Points
Field Loop Tuning
Field Loop Configure
Field Loop Feedback Scaling
Operator Interface*
Memory Operations
Memory Save
Memory Restore
Restore Defaults
Reset Clock
Define User Units
Define Speed Units
Define Load Units
Define Outer Control Loop Units
An asterisk (*) in these paths indicates that a parameter or a parameter list exists when ENTER is pressed at that
menu selection. The * is not actually displayed when the menu selection is displayed on the OIM.
Refer to Appendices B and C for information regarding the menu access path(s) for individual parameters.
Appendix B contains an alphabetized list of input parameters with their associated default values, code No.,
description and the menu path for access. Appendix C contains an alphabetized list of output parameters with a
description, code No. and the menu path for access.
WARNING
If tachometer and/or rotation is incorrect, sudden and rapid acceleration may result which can cause
overspeed of the drive. Failure to observe this precaution could result in bodily injury.
4.12 Adjustments
This section describes Zero adjustments to compensate for signal drift when tachometer or
armature feedback is used. These adjustments are available by accessing the Speed/Voltage
Loop (SPD) Feedback menu from the Speed/Voltage Loop (SPD) at the Main Menu.
Speed/Voltage Loop (SPD)
Speed/Voltage Loop (SPD) Feedback*
With the drive stopped, note the value of "ARMATURE VOLTAGE" (P.289). If the value is 0
then no further adjustments are required. If the value is other than 0 then adjust the ARM
VOLTAGE ZERO ADJ (P. 205) with a more positive number if the reading is a minus value,
or with a more negative value if the reading is positive. Note the value of ARMATURE
VOLTAGE (P.289) and continue to adjust the zero adjust parameter accordingly until the
feedback value reads 0. Record the final value in Table 4.1, section 4.5.
With the drive stopped, note the value of "ANALOG TACH FEEDBACK" (P.291). If the value is
0 then no further adjustments are required. If the value is other than 0 then adjust the "ANALOG
TACH ZERO ADJ" (P.202) with a more positive number if the reading is a minus value, or with a
more negative value if the reading is positive. Note the value of "ANALOG TACH FEEDBACK"
(P.291) and continue to adjust the zero adjust parameter accordingly until the feedback value
reads 0. Record the final value in Table 4.1, section 4.5.
2. Press CANCEL if the current selected language is the one of your choice. The display now
returns to the previous menu.
3. To choose another language other than the current selected language, move the cursor to
the language of your choice using the Up/Down " ! keys and then press ENTER.
The OIM responds in the new selected language with:
"Please wait."
The display now returns to the main menu using the newly selected language. All drive
information (software parameters, fault/alarm messages and drive status) will subsequently be
displayed in the selected language.
WARNING
It is the user's responsibility to distribute the security password. Reliance is not responsible for
unauthorized access violations within the user's organization. Failure to observe this precaution could
result in bodily injury.
Fault
PASSWORD Alarm
!! Interlock OK
+ 55
!! Drive Ready
-10000 <-> 10000
Running
Current Limit
Torque Limit
PROGRAM KEYPAD MANUAL FORWARD
This choice allows the user to define a 1 to 6 character string for the units of a parameter in the
speed parameter class. Thus, the user defines the units for a class and every parameter in that
class will appear in those units i.e., user units. Parameters not in the class are not affected by
the user unit definitions. Parameters for which user units may be defined will be subsequently
displayed in terms of those units and will require value entry in such terms.
For example, suppose the user wants to define speed related parameters in terms of inches per
second rather than the standard units of RPM. All parameters in the speed class (MAXIMUM
SPEED, MINIMUM SPEED, etc.) will use this single set of units (unit label: "INCH/S"; scaling
constant: 100 IN/SEC = 1750 RPM) defined for the speed class.
First, use the left and right arrow keys to select the column to be changed. Use the up arrow
and down arrow keys to define the characters in the label. The label may be from 1 to 6
alphabetic characters in length. For example: "INCH/S".
Define Speed Units Fault
Alarm
Define Units Tag. $$ Interlock OK
INCH/S $$ Drive Ready
Running
Current Limit
Torque Limit
PROGRAM KEYPAD MANUAL FORWARD
Second, enter the scaling constant at the following display which relates the user unit to the
standard unit. The OIM will use this constant to translate between user and standard units.
Define Speed Units Fault
Alarm
FULL SCALE VALUE 100
$$ Interlock OK
+ 100 $$ Drive Ready
1 <-> 10000 Running
Current Limit
Torque Limit
PROGRAM KEYPAD MANUAL FORWARD
In the previous example, the OIM would translate between user and standard units as follows:
user units standard units
100 INCH/S 1750 RPM
50 INCH/S 875 RPM
-20 INCH/S -350 RPM
0 INCH/S 0 RPM
The scaling constant may be in increments of 0.01 by entering the number of decimal places at
the following screen. NOTE: this screen will appear only if the full scale value is less than 4094.
Define Speed Units Fault
Alarm
Enter the number of decimal places:
$$ Interlock OK
NONE $$ Drive Ready
ONE Running
TWO Current Limit
Torque Limit
PROGRAM KEYPAD MANUAL FORWARD
The OIM returns to the Define User Units menu after the number of decimal places has been
entered.
5.1 Introduction
DANGER
Only qualified electrical personnel familiar with the construction and operation of this equipment
and the hazards involved should install, adjust, operate and/or service this equipment. Read and
understand this section in its entirety before proceeding. Failure to observe this precaution could result
in bodily injury or loss of life.
Value entry screens (Integer, Standard Choice Integer, Selector Switch or Boolean) allow the
user to modify a single parameter's value or selection. Value entry screens contain a cursor and
an entry field area. Note that the cursor for value entry fields is a blinking underscore.
Generally, pressing ENTER while in a value entry screen has the following effects:
1) The current value/selection is accepted and the entry field is reset to the new value.
2) The display remains in the value entry screen.
HELP
? + STOP
RUN RESET
CANCEL ENTER
CANCEL Restores the original value and the current value entry screen remains displayed
x if an entry is in progress,
i.e. the value has been altered but not yet accepted (using ENTER).
-OR-
The previous menu before entering the value entry screen is displayed if no entry
is in progress, i.e. the value has not yet been altered.
CANCEL Restores the original value and the current value entry screen remains displayed
x if an entry is in progress,
i.e. the value has been altered but not yet accepted (using ENTER).
-OR-
The previous menu before entering the value entry screen is displayed if no entry
is in progress, i.e. the value has not yet been altered.
ATTENTION:
Only qualified electrical personnel familiar with the construction and operation of this equipment and
the hazards involved should install, adjust, operate and/or service this equipment. Read and
understand this section in its entirety before proceeding. Failure to observe this precaution could result
in bodily injury or loss of life.
6.1 Introduction
The Quick Start function from the Main Menu will be used to start up and tune the drive.
NOTE: CONTROL SOURCE SELECT must be set to KEYPAD for complete OIM control during
the Quick Start procedure.
ATTENTION:
The drive will not operate at the correct speed if hardware jumpers J11, J14 and J18 are not set as
indicated on the OIM during Quick Start. Record and verify that these jumpers are set as indicated on
the OIM during Quick Start. Failure to observe this precaution could result in damage to, or destruction
of, the equipment.
Record the present values of J11, J14 and J18 in Table 6.1 before continuing with this
procedure. The correct position of these jumper settings will be displayed during the "Quick
Start" procedure. If the correct position of these jumpers are the same as the values recorded in
Table 6.1, Self Tuning can be started without leaving the Quick Start screens. If they are not the
same, refer to section 4.5, Jumper Settings.
NOTE: The values entered in the Quick Start procedure are not automatically saved to retentive
memory. To save these values, the user must perform a memory save. Reference section 4 of
this instruction manual for procedures regarding memory operations.
ATTENTION: Some of the parameters set in the quick start procedure can cause the drive to operate
improperly if the values are entered incorrectly. Incorrect values can cause the drive to operate
outside of the recommended operating conditions. Verify that the values of these parameters are
appropriate for your application before changing them. Failure to observe these precautions could
result in bodily injury.
The MOTOR BASE SPEED/TOP SPEED standard choice integer value entry screen is now
displayed.
ATTENTION:
The incorrect setting of the Quick Start parameters can cause an overspeed condition.
These parameters must be set by a qualified person who understands the significance of setting.
Verify that the value of these parameters is set accurately per your application requirements.
Failure to observe this precaution could result in bodily injury.
ATTENTION:
The parameter for the current transformer turns ratio (Tp/Tn) CT TURNS RATIO (P.010) is factory set
depending on the power unit size. Do not adjust/change the value of this parameter from its factory
default value unless you are replacing the regulator board without downloading of the parameter set. In
that case refer to Appendix B for setting the ratio (Tp/Tn).
Failure to observe this precaution could result in damage to, or destruction of, the equipment.
13 JOG ACCEL/ 013 3 SEC. The time it takes the Jog reference circuit to
DECEL RATE reach TOP SPEED (P.011) from zero. The S-
CURVE ROUNDING (P.014) parameter does not
affect the setting of this parameter.
15 POSITIVE 005 150% FLA Sets the highest amount of current (% full load
CURRENT amps) for the forward bridge. Used as a high
LIM limit for the speed loop PI block when POS
CURRENT LIM SEL (P.224) is set to REGISTER.
16 NEGATIVE 006 150% This parameter only needs to be set for
CURRENT FLA regenerative drives. Selects the highest
LIM amount of current (% full load amps) for the
reverse bridge.
Used as a low limit for the speed loop PI block
when NEG CURRENT LIM SEL (P.224) is set to
REGISTER.
The range is clamped to zero:
For non-regenerative drives.
If FEEDBACK SELECT is set to AC TACH.
IF FEEDBACK SELECT is set to PULSE TACH
and PULSE TACH QUADRATURE (P.208) is set
to OFF.
The range depends on the setting of NEG CUR
LIM INV EN (P.226).
17 IR COMPEN- 206 0% FLA Armature voltage loss compensation value
SATION used when the drive is configured as a voltage
regulator. This parameter is also used by the
field current regulator to set the field
weakened threshold.
IR COMPENSATION is normally determined from
the motor data sheet. It should be set to the
percent IR drop of the motor.
If this data is not available on the motor data
sheet, you can set this empirically so that the
no-load and full-load speeds are as close as
possible when operating as a voltage
regulator.
This parameter is not available for
current/torque regulated drives.
ATTENTION: Before starting self-tuning, it must be verified that no overhauling or hanging loads are
on the motor. self-tuning will not operate properly if overhauling loads exist. Failure to observe this
precaution could result in bodily injury.
ATTENTION: The motor will rotate during self-tuning. Stay clear of rotating machinery to avoid contact
with rotating machinery. Failure to observe this precaution could result in bodily injury.
ATTENTION: Self-tuning will not operate properly if prior adjustments in the Drive Setup and
Adjustment are not performed. Perform all prior adjustment procedures contained in the "Drive Setup
and Adjustment" section before proceeding. Failure to observe this precaution could result in damage
to, or destruction of, the equipment.
ATTENTION: Self-tuning must not be performed on drives operating in a process line which are
mechanically coupled to one another through the process material. However, the drive may be self-
tuned with load applied and with inertia connected. Failure to observe this precaution could result in
damage to, or destruction of, the equipment.
NOTE: Speed Loop self-tuning can only be performed on drives with tachometer feedback
(analog or digital). In armature voltage-controlled drives, only the Current Minor Loop (CML) can
be self-tuned.
If the self-tune setup parameter values are acceptable, then continue to the EXECUTE SELF
TUNING procedure to self-tune the drive.
The following screen shows how the display will look after self-tuning has completed
successfully for both the CML and the SPD/Voltage Loop.
NOTE: The gains are not automatically saved to retentive memory. If the gain values are
acceptable, the user must perform a memory save.
- Three-Phase AC Line*
7.0 Troubleshooting/Diagnostics
7.1 General
DANGER
Only qualified electrical personnel familiar with the construction and operation of this equipment and
the hazards involved should install, adjust, operate and/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.
This section details troubleshooting and diagnostics information for the FlexPak 3000 Drive.
DANGER
This equipment is at line voltage when AC power is connected. Disconnect and lockout all ungrounded
conductors of the AC power line before checking wiring. Failure to observe this precaution could result
in severe bodily injury or loss of life.
Wiring errors and loose or grounded wiring are common problems that can inhibit operation of a
drive. Verify the installation wiring has been correctly executed and that the drive is free of loose
terminations and grounded conductors.
DANGER
This equipment is at line voltage when AC power is connected. Exercise extreme care when checking
the AC line and power input. Failure to observe this precaution could result in bodily injury or loss of
life.
Verify that the applied AC power is correct for the specific drive (refer to 2.1.2 and 2.2.3). If an
isolation transformer has been installed on the incoming AC power, verify its output voltage and
that it has been properly connected. Verify that the AC line fuses are semiconductor protection
type and have been correctly sized per Table 8-7. The AC and DC power conductors should
have been sized per local standards.
7.4 DC Motor
CAUTION
A megohmmeter (megger) can be used for this motor ground check, but all conductors between the
motor and the drive must be disconnected. The megger's high voltage can damage the drive's
electronic circuits. Disconnect all conductors between the motor and the drive before using a megger
for this motor ground check. Failure to observe this precaution could result in damage to, or
destruction of, the equipment.
Recheck all motor connections for tightness and correct identification. Verify that there is no
path to ground in either the DC motor armature circuit, the shunt field circuit or the thermostat
circuit. Connect one lead of a standard ohm meter to the motor frame and the other lead to the
two armature leads. then connect to the two thermostat leads and then to the two field leads.
If a reading of less than 100,000 ohms is observed, a ground condition exists and MUST be
corrected before power is applied. Check that the field winding is not open or shorted.
Verify the continuity of the motor thermostat and its proper connection to regulator board
terminals 13 and 14. If a motor thermostat has been installed, verify that it's circuit maintains
continuity in the terminal 13 and 14 circuit.
Pressing ENTER will display details and possible causes of the specific fault log entry.
OPEN SCR SENSITIVITY - This parameter adjusts for load sharing differences due to
unbalanced A-C lines. Increase its value to open the SCR diagnostic tolerance of load sharing
differences.
OPEN SCR TRIP THRESH - This is the trip point for the SCR loss function. The default value
should not be changed unless nuisance trips occur due to extremely unusual load conditions or
severe instability in the CML. Raising this value will increase the diagnostic's tolerance of such
disturbances. OPEN SCR TRIP THRESH should only be increased if raising OPEN SCR
SENSITIVITY does not eliminate nuisance trips.
ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this
equipment and the hazards involved should perform this test. 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.
ATTENTION: This is an open loop test. To prevent excess motor speed and current, lock the motor
shaft or disconnect the motor armature leads from the drive and replace them with a
dummy load (e.g. bulbs in series).
Failure to observe this precaution could result in severe bodily injury or loss of life.
An armature phase fire test mode is available to verify the operation of the S6 or S6R rectifier
bridge. This test should only be performed by qualified personnel. Note that this test is not
available through the DCM.
To perform an armature phase fire test:
1. Turn off power to the drive. (Lockout and tag power as necessary).
2. Either lock the motor armature to prevent rotation or disconnect the motor armature leads
from the drive and replace with bulbs in series.
When locking the motor armature, the motor field winding can be disconnected to prevent
excessive torque. If the motor field winding is disconnected field current loss faults must be
inhibited by either setting jumper J20 to DISABLE on FlexPak with field rectifier or setting
Parameter FIELD LOSS THRESHOLD (P.512) to 0 on FlexPak with field current regulator.
3. Turn on power to the drive. The drive must be stopped and the Drive Ready Indicator must
be ON.
4. Set CONTROL SOURCE SELECT to KEYPAD.
5. On the OIM, select Current Minor Loop (CML) SCR Diagnostics Armature Phase Fire Test.
6. Set PHASE FIRE TST BRIDGE (P.310). This parameter must be set to the appropriate value
before activating the armature phase fire test mode.
7. Attach an oscilloscope to the armature current feedback test point (J17+, J22 on the
Regulator board). Note that the CS3000 software oscilloscope mode does not have
sufficient bandwidth for this test.
8. Press RUN. The armature phase fire test mode is now active. The OIM Running indicator will
be on.
9. Set PHASE FIRE TEST DELTA (P.309) to 55 degrees. Slowly increase PHASE FIRE TEST DELTA
until a steady pattern of bumps appears on the oscilloscope. If all thyristors in the selected
bridge are operating, there will be six bumps per AC line cycle. If any bumps are missing,
one or more thyristors are not conducting.
Note that conduction will not begin until the firing angle is sufficiently advanced (PHASE FIRE
TEST DELTA (P.309) more than 60 degrees). A rate limit block limits the rate of change of
firing angle advances to prevent sudden increases in current. To prevent the drive from
entering continuous conduction during this test, PHASE FIRE TEST DELTA (P.309) should not
exceed 89 degrees.
10. Press STOP to stop the armature phase fire test.
11. Turn off power to the drive (lockout and tag as necessary).
12. Either unlock the motor armature or remove the bulbs and reconnect the motor armature
leads.
If the motor field winding was disconnected, reconnect it and return jumper J20 to its original
position (typically ENABLE on FlexPak with field rectifier) or (on FlexPak with field current
regulator) set parameter FIELD LOSS THRESHOLD (P.512) to its original value.
The following table lists the power supply PC board test pins and their respective voltage levels.
Since it is a switching power supply, all checks need to be made while load is connected to the
power supply card.
Replacement of a thyristor
on power unit Type 1200 - 2000 A
NOTE /b
Table 8-2: Urgent recommended spare parts for 4-Quadrant units S-6R 25, 60 and 150 A
Table 8-3: Urgent recommended spare parts for 1-Quadrant units S-6 250 / 450 and 800 A
Table 8-4: Urgent recommended spare parts for 4-Quadrant units S-6R 250 / 450 and 800 A
Table 8-5: Urgently recommended spare parts for 1-Quadrant Units S-6 1200-2000 A
Table 8-6: Urgently recommended spare parts for 4-Quadrant Units S-6R 1200-2000 A
8.2 Accessories
Semiconductor protection fuses in the AC-line input of the converter and field circuit and in case of four-
quadrant operation in the motor armature circuit are to be selected from the following tables 8-7 and 8-8.
Chokes in the AC-line input of the converter and field circuit are to be selected from the table 8-9.
The fuses and chokes are externally mounted and not supplied with the power module.
Bus bars
Fuse
AC Line AC Line
L1 L2 L3 PE L2 L3 PE
U1 V1 W1 1 4
U2 V2 W2 2 3
1U 1V 1W 3V 3W
Converter Input Field Rectifier Input
W2 W1 V 2 V 1 U 2 U 1
U1 V1 W1
B
A A
B
U2 V2 W2
= F = F
E G E G
D D
H C H
(1) (2)
Protection earth connection stud
Figure 8-2: Line Reactor Dimensions (mm), Power Losses (W) and Weight (kg):
The radiated emissions in the frequency range 30 -1000 MHz will stay below the limits, if for the
installation the same EMC measures are taken into account as for the conducted HF emissions.
NOTE: On all FlexPak drives a line input reactor must be connected between filter output and converter
input. This line reactor should be rated for minimum 2% voltage drop on drives up to 500 V and 4% for
690 V drives (selection according to Table 8-9). The drives AC-line input semiconductor protection fuses
as per Table 8-7 must be mounted between filter output and line reactor. Otherwise the filter inrush
current may damage the fuses. For installation instructions refer to Appendix H
HF Filter
If this filter is used on FlexPak 3000 converters with AC line input currents above 100 A the HF emission
limits for class A, group 2* (EN 55011) in the 2nd environment (industrial supply network) according to
the product standard EN 61800-3 are met and the drive fulfills CE conformity.
The HF filter is connected in front of the AC line reactor between the three AC line input phases and the
protection earth conductor PE.
PE
The ambient temperature T is the max. temperature around the filter (typical 50C inside cabinets for a
standard max. cooling air temperature of 40C). Typical DC-current form factor FF = 1.05
For other ambient temperatures (T) and form factors (FF) the continuous current of the filter can be
calculated as follows:
45 C 2 45 C
I FILTER = I Line( rms) = FF I ad
85 C T 3 85 C T
RFI-Filter
Filter 380 - 440 V 460 - 500 V 690 V Application
Current Part No. see Page Part No. see Page Part No. see Page
25A 839.72.05 8-13 on request
according
36A 839.72.06 8-13 on request
to a)
50A 839.72.07 8-13 on request
80A 839.72.09 8-14 on request
100A 839.71.53 8-15 839.71.53 8-15
150A 839.70.20 8-16
according
180A 839.74.22 8-17 on request
to b)
250A 839.73.25 8-20 on request
270A 839.70.66 8-18 839.70.66 8-18
280A 839.72.67 8-17 839.72.67 8-17
340A 839.71.68 8-19 839.71.68 8-19
500A 839.73.31 8-20 on request
600A - - 839.73.92 8-21 839.73.92 8-21
1000A 839.73.35 8-21 839.73.95 8-21 839.73.95 8-21
1600A 839.73.38 8-20 839.73.98 8-21 839.73.98 8-21
M6 150 65
E L3 L2 L1
42.5
LINE
200
250
115
6.5
42.5
LOAD
E' L3' L2' L1'
21 20 20 17
120
135
M10
E L3 L2 L1
LINE
400
350
375
427
LOAD
E' L3' L2' L1'
15
30 30 30 6.5 70
130
30 215 30 80
22
4 x M6 22
4 x M8
E L1 L2 L3
LINE
LOAD
E' L1' L2' L3'
22 22
62 50 50 50 63 18 47 15
M8
17 160 17
25 55 55 25 45
M10
24
1L1 1L2 1L3
180
95
292
475
550
163.5
LOAD
PE 1L1 1L2 1L3
55
J E
M10 4
E L3 L2 L1
LINE
A F B P
LOAD
E' L3' L2' L1'
15
H G G 6.5
L C
I Filter Pv Terminal
2
[A] Part No. A B C E F G H J L P R [kg] [W] max. mm
180 839.74-22 537 360 88 132 470 25 28 180 156 510 77 13 49 95
280 839.72-67 742 530 103 153 660 31 59 260 220 700 82 28 70 150
Figure 8-8: 180 A, 440 V and 280 A, 500 V RFI-Filter Dimensions (mm)
350
M12
65
30
E L3 L2 L1
LINE
110
135
550
135
110
5.1
LOAD
E' L3' L2' L1'
30
65
335
50
160
40 80 80 80
320
797 797
873
12
24.5
360 62
PE L1/L3 L2
L3 L2 L1
LINE
T
A B F
=
P
Q M
H L
I Filter
[A] Part No. A B C D E F G H K L M
250 839.73-25 460 350 230 149 260 200 285 120 100 79.5 24
500 839.73-31 590 500 250 154 280 280 305 150 93 59.5 24
1000 839.73-35 840 650 400 204 440 320 465 262 127 79 34
1600 839.73-38 870 680 400 204 440 340 465 262 127 79 34
I Ground W Pv
[A] P Q R S T Bolt [kg] [W]
250 - 24 30 10.5 10.5 M10 18 18
500 15 30 30 11 12 M12 49 45
1000 20 50 40 14 12 M12 90 90
1600 20 50 40 2x 14 12 M12 130 144
Figure 8-11 250, 500, 1000 and 1600 A, 440 V RFI-Filter Dimensions (mm)
PE L1/L3 L2
L3 L2 L1
LINE
T
A B F
=
P
Q M
H L
I Filter
[A] Part No. A B C D E F G H K L M
600 839.73-92 590 500 250 154 280 280 305 150 94.5 61.5 26
1000 839.73-95 610 500 250 198 280 280 305 172 90 51 26
1600 839.73-98 844 650 400 210 440 320 465 192 92 56 28
I Ground W Pv
[A] P Q R S T Bolt [kg] [W]
600 15 30 30 11 12 M10 49 45
1000 20 40 30 11 12 M10 65 120
1600 20 40 40 2x 14 12 M12 180 220
Figure 8-12 600, 1000 and 1600 A, 500/690 V RFI-Filter Dimensions (mm)
Glossary of Terms
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.
Constant Speed: Used to describe a motor which changes speed only slightly from a no-load to a full-
load condition.
Default Value: Parameter values which are stored in the drive's Read Only Memory (ROM).
Direct Current: A current that flows only in one direction in an electrical circuit. It may be continuous or
discontinuous and it may be constant or varying.
Efficiency: The ratio of mechanical output to electrical input. It represents the effectiveness with which the
motor converts electrical energy to mechanical energy.
Field: A term commonly used to describe the stationary (stator) member of a DC motor. The field provides the
magnetic field with which the mechanically rotating (armature or rotor) member interacts.
Power P in kW: The measure of the rate of work. The kW rating of a motor is expressed as a function of
torque and RPM.
For motors, the following approximate formula may be used:
P = M x RPM / 9550
where,
M = Torque in Nm and
RPM = revolutions per minute.
Inertial Load: A load (flywheel, fan, etc.) which tends to cause the motor shaft to continue to rotate after the
power has been removed (stored kinetic energy). If this continued rotation cannot be tolerated, some
mechanical or electrical braking means must be applied. This application may require a special motor due
to the energy required to accelerate the inertia. Inertia is measured in kg m2.
2
load RPM
Inertia reflected to the shaft of the motor = load Inertia
motor RPM
Motor: A device that converts electrical energy to mechanical energy to turn a shaft.
Motor Electrical Time Constant: The ratio of electrical inductance to armature resistance.
Electrical time constant in seconds defined as electrical:
Motor Identification:
Motor Nameplate: The plate on the outside of a motor which describes the motor, kW, voltage, RPM,
efficiency, design, enclosure, etc.
Motor Thermostat: Unit applied directly to the motor's windings which senses winding temperature and may
automatically break the circuit in an overheating situation.
Non-Retentive: Information and/or data not retained while power to the drive is OFF.
Retentive: Information and/or Data retained while power to the drive is OFF.
RPM: Revolutions per Minute - The number of times per minute the shaft of the motor (machine) rotates.
Service Factor (SF): When used on a motor nameplate, a number which indicates how much above the
nameplate rating a motor can be loaded without causing serious degradation, (i.e. a 1.15 SF can produce
15% greater torque than a 1.0 SF rating of the same motor).
Tachometer: Normally used as a rotational sensing device. Tachometers are typically attached to the output
shaft of a motor requiring close speed regulation. The tachometer feeds its signal to a control which adjusts its
input to the motor accordingly (called "closed loop feedback" control).
Top Speed: The highest speed a drive can achieve. Top Speed equals Base Speed when there is no field
weakening.
Torque: Turning force delivered by a motor or gear motor shaft, usually expressed in Nm:
WARNING
The incorrect setting of this parameter can cause an overspeed condition. This parameter must be set
by a qualified person who understands the significance of setting it. Set the value of this parameter
accurately per your application requirements. Failure to observe this precaution could result in bodily
injury.
WARNING
The incorrect setting of this parameter can cause an overspeed condition. This parameter must be set
by a qualified person who understands the significance of setting it. Set the value of this parameter
accurately per your application requirements. Failure to observe this precaution could result in bodily
injury.
*Note: The high limit might be less than 200.0 to prevent the tach voltage from exceeding 250V.
WARNING
The incorrect setting of this parameter can cause an overspeed condition. This parameter must be set
by a qualified person who understands the significance of setting it. Set the value of this parameter
accurately per your application requirements. Failure to observe this precaution could result in bodily
injury.
WARNING
The incorrect setting of this parameter can cause an overspeed condition. This parameter must be set
by a qualified person who understands the significance of setting it. Set the value of this parameter
accurately per your application requirements. Failure to observe this precaution could result in bodily
injury.
WARNING
The incorrect setting of this parameter can cause an overspeed condition. This parameter must be set
by a qualified person who understands the significance of setting it. Set the value of this parameter
accurately per your application requirements. Failure to observe this precaution could result in bodily
injury.
DANGER
This drive can operate at and maintain zero speed when this parameter is set to on. The user is
responsible for assuring safe conditions for operating personnel by providing suitable guards, audible
or visual alarms, or other devices to indicate that the drive is operating at or near zero speed. Failure
to observe this precaution could result in severe bodily injury or loss of life.
When the reference source is set to ANALOG, the analog auto input (terminals 19 and 20 on the
regulator board) is used. When the source is set to FREQUENCY IN, the frequency input (terminals 39,
40, and 41 on the I/O Expansion board) is used.
P.100 P.102 P.101 P.011
ANLG AUTO ANLG AUTO ANLG AUTO TOP SPEED P.103
SIGNAL TYPE ZERO ADJ P.188 AUTO
GAIN ADJ
(ANALOG AUTO REFERENCE
REFERENCE) HI
Analog Auto Reference SELECT
(+) terminal 19 LIMIT *ANALOG
A/D SOFTWARE SCALING To Speed Reference
(-) terminal 20
FREQUENCY IN Source Select Block Diagram
P.100 LO
P.011 *+/-10 V ANLG AUTO
- TOP SPEED SIGNAL TYPE
0 0 - 10 V
4-20 mA
10-50 mA
P.423 P.424 P.011
FREQ IN FREQ IN TOP SPEED
ZERO FULL SCALE P.491
I/O Expansion Board
(FREQ IN) HI
Frequency Input
(A) terminal 39 F/D SOFTWARE SCALING LIMIT
(A) terminal 40
(COM) terminal 41 LO
P.223
*REGISTER POS CURRENT
P.005 POSITIVE CURRENT LIM LIM SEL P.311
(A) ANALOG IN 1 CML REF LIMIT SELECT
From I/O Expansion
Inputs Block Diagram { (B)
ANALOG IN 2
POS CURRENT LIM
* SPD LOOP CUR LIM
REGISTER
NETW IN REG 1, 2, 3
From Network P.005
P.299
INIT KP HI (SPD LOOP OUTPUT) HI
PI LIMIT
P.224
P.006 NEGATIVE NEG CURRENT P.311
CURRENT LIM *REGISTER CML REF LIMIT
LIM SEL
(A) ANALOG IN 1 SELECT
From I/O Expansion
Inputs Block Diagram { (B) ANALOG IN 2 EN
P.226
* SPD LOOP CUR LIM
REGISTER
NETW IN REG 1, 2, 3
From Network NEG CURRENT LIM INV EN 3)
P.006
NEG CURRENT LIM EN
Important: When switching the control source from NETWORK to any other option, the internal multiplexer
selection parameters that use NETW IN REG 1, 2, and 3, are not affected. Therefore, any
selection that was set to NETW IN REG# will remain, and the data in NETW IN REG 1, 2, 3 will be
the value used in the control path. (Note that these parameters contain the last data received
from the network before the control source was switched and will no longer be updated from
the network.) To change this, you must reconfigure any affected selection parameters.
CAUTION:
This parameter is also used in the calculation of the burden resistor value. Do not adjust/change the
value of this parameter from its factory default value unless you are replacing the regulator board.
Failure to observe this precaution could result in damage to, or destruction of, the equipment.
DANGER
On a power cycle or reset, the contact is held at normally open until the drive software is initialized.
Make sure that this condition does not result in a dangerous situation for your application. Failure to
observe this precaution can result in severe bodily injury or loss of life.
DANGER
This output is intended for use as an indication. If it is used as a control source, a dangerous condition
can result. Failure to observe this precaution can result in severe bodily injury or loss of life.
DANGER
On a power cycle or reset, the contact is held at normally open until the drive software is initialized.
Make sure that this condition does not result in a dangerous situation for your application. Failure to
observe this precaution can result in severe bodily injury or loss of life.
DANGER
This output is intended for use as an indication. If it is used as a control source, a dangerous condition
can result. Failure to observe this precaution can result in severe bodily injury or loss of life.
WARNING
The incorrect setting of this parameter can cause an overspeed condition. This parameter must be set
by a qualified person who understands the significance of setting it. Set the value of this parameter
accurately per your application requirements. Failure to observe this precaution could result in bodily
injury.
P.514
FIELD PI PROP GAIN P.515
FIELD PI LEAD FREQ
KP WLD P.588
(FIELD DELTA)
FIELD
FROM FIELD BLOCK DIAGRAM FIELD
PHASE
PI FIRING
REGULATOR
SUPPLY
LOGIC
LO HI
0
P.587
FIELD DELTA HI LIM
LO HI
P.517
FIELD AUTO WEAKEN
FROM FIELD BLOCK DIAGRAM ENABLED
PI
DISABLED
FIELD DELTA HI LIM
KP WLD
P.520
P.519 FLD WEAKEN LEAD FREQ
FLD WEAKEN PROP GAIN
WARNING
The incorrect setting of this parameter can cause a motor overvoltage condition.
Set MOTOR HOT FLD AMPS to the motor's nameplate value. Make sure FIELD ECONOMY REF
and/or FIELD REF REGISTER (P.513) is above FIELD LOSS THRESHOLD (P.512).
Failure to observe this precaution can result in bodily injury and damage to the equipment.
P.510
MOTOR HOT FLD AMPS
P.599
HI (FIELD ECONOMY ACTIVE) P.590
(FIELD REFERENCE)
P.513 OFF
FIELD REF REGISTER
LO ON
P.510
MOTOR HOT FLD AMPS GAIN
MUL DIV
WARNING
The incorrect setting of this parameter can cause a motor overvoltage condition.
Set MOTOR HOT FLD AMPS to the motor's nameplate value. Make sure FIELD ECONOMY REF
and/or FIELD REF REGISTER (P.513) is above FIELD LOSS THRESHOLD (P.512).
Failure to observe this precaution can result in bodily injury and damage to the equipment.
KP WLD P.588
FIELD REFERENCE
(FIELD DELTA)
TO FIELD CURRENT REGULATOR FIELD
FIELD
PHASE
BLOCK DIAGRAM
+ PI FIRING
REGULATOR
SUPPLY
- LOGIC
LO HI
FIELD FEEDBACK
P.587
(FIELD DELTA HI LIM)
0
Refer to the table on the next page for initiated actions depending on parameter settings.
Parameter Range: 1 = DISABLED,
2 = FAULT IMMEDIATELY,
3 = DELAY BEFORE FAULT
Default Setting: DISABLED
Parameter Type: configurable
OIM Menu Path(s): Additional parameters
ATTENTION: When activated, inverting fault avoidance takes control of the Current Minor Loop either
by forcing the current reference to zero (if the drive is regenerating) or by disabling the
regenerative bridge (if the drive is not regenerating). You must analyze your
application to determine whether or not inverting fault avoidance should be used.
ATTENTION: Enabling the inverting fault avoidance logic does not guarantee that an inverting fault is
prevented in all instances. Therefore on regenerating drives super fast armature fuses
(according to chapter 8) must be provided.
INV FAULT AVOID SEL (P.312) settings and action taken when drive detects conditions that could lead to
an inverting fault.
Is Drive
Regenerating or
Attempting to
Parameter Setting Regenerate? Drive Action
DISABLED n/a None
FAULT Yes immediately stops (coast/DB)
IMMEDIATELY generates the fault F00015 (INVERTING FAULT AVOIDED).
FAULT No (drive is generates the alarm A00005 (INVERTING FAULT AVOIDED).
IMMEDIATELY motoring)
continues normal operation on the motoring bridge until a
request to regenerate is detected.
When a request to regenerate is detected, the drive immediately
stops (coast/DB) and generates the fault F00015 (INVERTING
FAULT AVOIDED)
DELAY BEFORE Yes Immediately forces the Current Minor Loop reference to zero
FAULT Logs the alarm A0005 (INVERTING FAULT AVOIDED)
Continues to operate normally for up to two seconds. The drive
can generate a motoring current as needed but will coast while a
demand for regenerative current exists.
If the demand for regenerative current persists for more than
two seconds, the drive:
- stops (coast/DB) and
- generates the fault F00015 (INVERTING FAULT AVOIDED).
If the conditions that caused the alarm return to normal within
two seconds, the drive returns to normal operation (the
regenerative bridge will be re-enabled) without stopping.
DELAY BEFORE No (drive is Logs the alarm A0005 (INVERTING FAULT AVOIDED).
FAULT motoring)
Continues normal operation on the motoring bridge until a
request to regenerate is detected.
When a request to regenerate is detected, the drive continues to
operate normally for up to two seconds. The drive can generate
a motoring current as needed but will coast while a demand for
regenerative current exists.
If the demand for regenerative current persists for approximately
two seconds, the drive:
- stops (coast/DB)
- generates the fault F00015 (INVERTING FAULT AVOIDED).
If the conditions that caused the alarm return to normal within
two seconds, the drive returns to normal operation (the
regenerative bridge will be re-enabled) without stopping.
IR COMPENSATION (P.206)
Sets the armature voltage loss compensation value used when the drive is configured as a voltage
regulator. This parameter is also used by the field current regulator to set the field weakened threshold.
Parameter Range: 0 to 50% of MOTOR RATED ARM AMPS (P.008)
Default Setting: 0%
Parameter Type: Tuneable
OIM Menu Path(s): Speed/Voltage Loop (SPD) - Spd/Volt Loop (SPD) Tuning - Quick Start
Field - Field Current Regulator - Field Loop Tuning
WARNING
The incorrect setting of this parameter can cause an overspeed condition. This parameter must be set
by a qualified person who understands the significance of setting it. Set the value of this parameter
accurately per your application requirements. Failure to observe this precaution could result in bodily
injury.
WARNING
When performing this adjustment, do not allow the motor to exceed the maximum safe speed of the
driven equipment as determined by the equipment manufacturer. Failure to observe this precaution
could result in bodily injury.
NOTE: Testpoint METER OUT FULL SCALE must source METER OUT 1 SELECT for an accurate
adjustment. See Appendix D, figure D.8, for further details.
DANGER
This drive can operate at and maintain zero speed when this parameter is set to on. The user is
responsible for assuring safe conditions for operating personnel by providing suitable guards, audible
or visual alarms, or other devices to indicate that the drive is operating at or near zero speed. Failure
to observe this precaution could result in severe bodily injury or loss of life.
WARNING:
The incorrect setting of this parameter can cause a motor overvoltage condition.
Set MOTOR HOT FLD AMPS to the motor's nameplate value. Make sure FIELD ECONOMY REF
and/or FIELD REF REGISTER (P.513) is above FIELD LOSS THRESHOLD (P.512).
Failure to observe this precaution can result in bodily injury and damage to the equipment.
P.510
MOTOR HOT FLD AMPS
P.599 P.590
HI (FIELD ECONOMY ACTIVE) (FIELD REFERENCE)
P.513 OFF
FIELD REF REGISTER + To Field Current Regulator
LO ON - Control Loop
0
P.510 GAIN
MOTOR HOT FLD AMPS MUL DIV
100 P.589
P.511
FIELD ECONOMY REF (FIELD FEEDBACK)
P.510 P.516
FLD FEEDBACK
MOTOR HOT FLD AMPS
GAIN ADJ
CAUTION:
The drive will not operate properly if this parameter value is entered incorrectly. This parameter must
be equal to the rated armature amps found on the motor nameplate. Overcurrent or excess heating of
the motor could result. Failure to observe this precaution could result in damage to, or destruction of,
the equipment.
This value is used by the internal I2t motor thermal overload function. This function allows for continuous
operation at 100% current and 60 seconds of operation at 150% of rated MOTOR RATED ARM AMPS
(P.008) following an inverse time overload curve.
WARNING
The incorrect setting of this parameter can cause an overspeed condition. This parameter must be set
by a qualified person who understands the significance of setting it. Set the value of this parameter
accurately per your application requirements. Failure to observe this precaution could result in bodily
injury.
WARNING:
When analog inputs or network registers are used to control current limits, bipolar values are permitted
for the positive and negative current limits of the current and speed loops. Extreme care must be
exercised when setting the current limit values in this case. If the negative current limit is set to a non-
zero value, the current loop reference will be clamped to this minimum value, possibly causing
unexpected motor or machine operation, including rapid acceleration or overspeed.
Failure to observe this precaution could result in bodily injury.
If you change NEG CUR LIM INV EN (P.226), POS CURRENT LIM SEL (P.223) and NEG CURRENT LIM SEL
(P.224) are automatically set to REGISTER. When this occurs, an alarm (A00052) is generated to notify
you of a possible change in the current limits. Make sure the settings of POS CURRENT LIM SEL (P.223),
NEG CURRENT LIM SEL (P.224), POSITIVE CURRENT LIM (P.005), and NEGATIVE CURRENT LIM (P.006) are
correct for your application before operating the drive.
Typically the state of the inverter should only change state during drive setup. Therefore, this should be
an infrequent event.
The positive limit register will always remain in the range 0 to MAXIMUM CURRENT.
The absolute value of the negative limit register would be constrained to the range 0 to MAXIMUM
CURRENT. The sign of the negative current limit value will be automatically adjusted according to the
state of the negative current limit inverter. For example, if the inverter is enabled and the negative
current limit is 10.0 A, then the negative current limit will be changed to -10.0 A when the inverter is
disabled. The negative limit register value will be clamped to zero for non-regenerative drives.
DRIVE TYPE
REGEN NON-REGEN
low limit high limit. low limit high limit
Positive 0 Maximum 0 Maximum
ENABLE Current Lim Current Current
Inverter Negative 0 Maximum 0 0
State Current Lim Current
Positive 0 Maximum 0 Maximum
DISABLE Current Lim Current Current
Negative -Maximum 0 0 0
Current Lim Current'
P.223
*REGISTER POS CURRENT
P.005 POSITIVE CURRENT LIM LIM SEL P.311
(A) ANALOG IN 1 CML REF LIMIT SELECT
From I/O Expansion
Inputs Block Diagram { (B)
ANALOG IN 2
POS CURRENT LIM
* SPD LOOP CUR LIM
REGISTER
NETW IN REG 1, 2, 3
From Network P.005
P.299
INIT KP HI (SPD LOOP OUTPUT) HI
PI LIMIT
P.224
P.006 NEGATIVE NEG CURRENT P.311
CURRENT LIM *REGISTER CML REF LIMIT
LIM SEL
(A) ANALOG IN 1 SELECT
From I/O Expansion
Inputs Block Diagram { (B) ANALOG IN 2 EN
P.226
* SPD LOOP CUR LIM
REGISTER
NETW IN REG 1, 2, 3
From Network NEG CURRENT LIM INV EN 3)
P.006
NEG CURRENT LIM EN
DANGER
The user must provide an external operator accessible coast/stop pushbutton at terminals 7 and 8 on
the regulator board (see figure 3.12) to disable the machine in case of improper operation.
Uncontrolled machine operation might result if this is not done. Failure to observe this precaution
could result in severe bodily injury or loss of life.
NOTE: Setting NETW COMM LOSS SELECT to HOLD LAST REF or USE TRMBLK REF will cause an
alarm to be generated when network communication is lost. Since alarms do not cause the drive to stop,
some form of hardwired stop must be available since stopping the drive via the network may not always
be possible. Once the drive is stopped, it cannot be restarted until network communication is re-
established or CONTROL SOURCE SELECT is changed to something other than NETWORK.
Lead/lag low break frequency of the outer control loop. Sets the lead break frequency if OCL LEADLAG
SELECT (P.807) is set to LEAD/LAG. Sets the lag break frequency if P.807 is set to LAG/LEAD.
Parameter Range: 0.01 to 34.90 RAD/S
Default Setting: 1.00 RAD/S
Parameter Type: Tuneable
OIM Menu Path(s): Outer Control Loop (OCL) - OCL Tuning
Refer also to Parameters: OCL LEADLAG RATIO (P.807)
OCL LEADLAG SELECT (P.805)
The OCL lead/lag high break frequency is determined by the settings of this parameter and the OCL
LEADLAG RATIO. For example, if the low break frequency is 0.50 rad/s and the ratio is 10, the high
break frequency is 5.00 rad/s.
*NONE OCL
FEEDBACK * BYPASS
(CML FEEDBACK) CML FEEDBACK SELECT
8 sample average INITV LEAD/LAG To Outer Control Loop
(A) ANALOG IN 1 Block Diagram
From I/O Expansion L/L LAG/LEAD
{
Inputs Block Diagram (B) ANALOG IN 2 (OCL FEEDBACK)
P.847
WLD RST\ RATIO OCL
LEADLAG
SPD LOOP OUTPUT
SPD LOOP OUTPUT 3) OCL SELECT
AUTO REF. P.806 OCL
LEADLAG LEADLAG P.805
ANALOG AUTO REFERENCE 3)
D.3 LOW FREQ RATIO P.807
NETW IN REG 1, 2, 3
From Network output of OCL
enable logic
P.808 P.810
OCL PI OCL PI
PROP POSITIVE
GAIN LIMIT
P.812
OCL TRIM RANGE
KP HI P.848
(OCL RAMP OUTPUT) INITV
MUL
(OCL OUTPUT)
* DISABLED To Speed Reference
+ PI GAIN
- output of OCL ENABLED Mode Select
RST\ P.011 Block Diagram
enable logic TOP SPEED
WLD LO
P.813
P.809 P.811 DIV OCL PROP
OCL PI OCL PI TRIM SELECT
LEAD NEGATIVE GAIN
FREQ LIMIT MUL
WARNING
The armature phase fire test is unregulated. To prevent excess motor speed, either disconnect the
armature leads from the drive and replace with a similar load or disconnect the field leads from the
drive. Lock the motor armature shaft securely to prevent rotation in either direction prior to selecting
this test. Failure to observe these precautions could result in bodily injury.
WARNING
The incorrect setting of this parameter can cause an overspeed condition. This parameter must be set
by a qualified person who understands the significance of setting it. Set the value of this parameter
accurately per your application requirements. Failure to observe this precaution could result in bodily
injury.
ATTENTION: When CONTROL SOURCE SELECT is changed from NETWORK to another value, the
speed feedback multiplier block is bypassed. This can cause the motor to rotate faster than it did when
under network control. The active speed reference should be set to zero before starting the drive from
the new control source. The active speed reference is based on the new control source and the
auto/manual setting.
SPD LOOP PI INIT SEL (Alternate network map, Drop_2, register 32)
Only available if the AutoMax Network Communication board is installed.
Selects the Speed Loop PI block initial value source when CONTROL SOURCE SELECT = Network.
NOTE: SPD LOOP PI INIT VAL is forced to ZERO when CONTROL SOURCE SELECT Network.
Parameter Range: 0= ZERO
1= SPD LOOP PI INIT VAL
2= ANALOG MAN TRIM REF
Default Setting: 0
Parameter Type: Configurable
OIM Menu Path(s): N/A, network only
Refer also to Parameters: CONTROL SOURCE SELECT (P.000)
ANALOG MAN TRIM REF (P.194)
SPD LOOP PI INIT VAL (Alternate network map, Drop_1, register 39)
SPD LOOP PI INIT SEL (Alternate network map, Drop_2, register 32)
SPD LOOP PI INIT VAL (Alternate network map, Drop_1, register 39)
Only available if the AutoMax Network Communication board is installed.
Network initial value for the Speed Loop PI block.
Parameter Range: -32768 - 32767
Default Setting: 0
Parameter Type: Tuneable
OIM Menu Path(s): N/A, network only
Refer also to Parameters: CONTROL SOURCE SELECT (P.000)
SPD LOOP PI RESET (Alternate network map, Drop_1, register 32, Bit 6)
SPD LOOP PI RESET (Alternate network map, Drop_1, register 32, Bit 6)
Only available if the AutoMax Network Communication board is installed. When asserted, the Speed
Loop PI block is held in Reset with the initial value appearing at the PI block output.
Parameter Range: 0 = ENABLE
1 = RESET
Default Setting: 1
Parameter Type: Tuneable
OIM Menu Path(s): N/A, network only
Refer also to Parameters: CONTROL SOURCE SELECT (P.000)
SPD LOOP PI INIT SEL (Alternate network map, Drop_2, register 32)
SPD LOOP PI INIT VAL (Alternate network map, Drop_1, register 39)
IV DEC ACC
P.110
P.018 TRIM MODE SELECT
RAMP STOP DECEL TIME * NO TRIM Ramp Stop
Command
INCREMENTAL Off
RAMP STOP DECEL TIME
RAMP STOP DEC. T. PROPORTIONAL On
---------------------------- * DECELERATION TIME
1 + DRAW PERCENT
STOP DECEL
SELECT
P.122
P.002
DECELERATION TIME * NO TRIM
INCREMENTAL
DECEL TIME PROPORTIONAL
---------------------------- P.110
1 + DRAW PERCENT
TRIM MODE SELECT
Sets the threshold speed below which the main contactor will automatically open after a ramp stop or
current limit stop is asserted. This value should be less than or equal to MINIMUM SPEED.
Parameter Range: 0 to MAXIMUM SPEED (RPM or user-defined units)
Default Setting: 0 (RPM or user-defined units)
Parameter Type: Tuneable
OIM Menu Path(s): Drive Reference - Drive Reference Configure
The open armature detection algorithm also uses this parameter. An open armature is detected when
the armature current is zero, motor speed feedback is <5% of TOP SPEED, and the SCR firing angle is
equal to TACH LOSS SCR ANGLE.
Use the following steps to adjust this parameter if a tach loss occurs.
Step 1. Check tach lead connections and polarity,
Step 2. Increment TACH LOSS SCR ANGLE by 1.
Step 3. Restart the drive.
Step 4. If tach loss occurs and the angle is less than 127, return to step 2.
WARNING
The incorrect setting of this parameter can cause an overspeed condition.
Set the value of this parameter only as high as necessary to stop incorrect tach loss faults.
Failure to observe this precaution could result in bodily injury.
TOP SPEED (P.011)
Warning
The incorrect setting of this parameter can cause an overspeed condition. This parameter must be set
by a qualified person who understands the significance of setting it. Set the value accurately per your
application requirements. Failure to observe this precaution could result in bodily injury.
ATTENTION: If CONTROL SOURCE is changed from NETWORK to any other control source, the
UNDERWIND ENABLE bit is forced to the default if DISABLED. If the setting was ENABLED and CONTROL
SOURCE is changed from NETWORK, the motor rotates in the opposite direction when the drive is
restarted. The active speed reference should be set to zero before starting the drive from the new
control source. Slowly increase the speed reference until the proper rotation direction can be
determined. If it is incorrect, change the setting of the FORWARD/REVERSE input. The active speed
reference is based on the new control source and the AUTO/MANUAL setting.
P.215
SPD LOOP LAG FREQ
INIT KP HI
P.217
(SPD LOOP ERROR) SPD LOOP
P.295 (SPD LOOP REFERENCE)
D.5(E) P.297 WLG LAG BYPASS
From Speed Reference + OFF
PI LAG
Mode Select Block Diagram To CML Reference
*ON
UNDERWIND ENABLE 1) RST Block Diagram
WLD LO P.298
Netw. Drop 1, Reg. 32, Bit 5 (SPD LOOP
LAG OUTPUT)
P.299
(SPD LOOP OUTPUT)
SPEED FEEDBACK GAIN 1)
Netw. Drop 1, Reg. 38 MUL A * B EN
1000 OUT
IN
KEYPAD,
TERMBLK
or SERIAL P.000 CSS
NETWORK
ANLG IN 1 (P.492)
Only available if the I/O Expansion kit is installed.
The value representing analog input 1 (terminals 50 and 51 on the I/O Expansion board) after gain and
zero have been applied. See ANLG IN 1 GAIN ADJ for block diagram.
OIM Menu Path(s): Input/Output - Analog I/O
Refer also to Parameters: ANLG IN 1 SIG TYPE (P.413),
ANLG IN 1 ZERO ADJ (P.414)
ANLG IN 1 GAIN ADJ (P.415)
ANLG IN 2 (P.493)
Only available if the I/O Expansion kit is installed.
The value representing analog input 2 (terminals 52 and 53 on the I/O Expansion board) after gain and
zero have been applied.
OIM Menu Path(s): Input/Output - Analog I/O
Refer also to Parameters: ANLG IN 2 GAIN ADJ (P.417),
ANLG IN 2 ZERO ADJ (P.416)
The amplitude and rate limited value of the selected CML reference.
OIM Menu Path(s): Current Minor Loop (CML) - CML Test Points
DIG IN 0 (P.490)
Only available if the CS3000 Software or the AMX Network communication card is installed.
Indicates the state of digital input 0 based on the voltage applied.
Parameter Range: ON
OFF
Default Setting: N/A
Refer also to Parameters: JOG SPEED 1 (P.012)
JOG SPEED 2 (P.017)
All digital inputs are normally open, thus will be OFF when open or connected to 24V COM (TB-15) and
ON when +24V (TB-14) is applied.
Conditions Indicated by DIG IN 0 (P.490)
DIG IN 0 SELECT (P.428) Condition if DIG IN 0 (P.490) Reads:
Setting ON OFF
1 = BRUSH WEAR INPUT Brushes OK Brushes Worn
2 = JOG SPEED SELECT JOG SPEED 2 selected JOG SPEED 1 selected
3 = OCL ENABLE OCL enabled OCL disabled
DIG IN 1 (P.495)
Only available if the I/O Expansion kit is installed.
Shows the state of digital input 1 (terminal 59 on the I/O Expansion board).
The input is ON when +24 VDC is applied for more than 20 ms. It is OFF when 0 VDC is applied.
Digital inputs 1 and 2 (terminals 59 and 60) are used to select which, if any, PRESET SPEED is used as
the speed reference for the speed/voltage control loop. See PRESET SPEED 1, 2, and 3 for more
information.
Parameter Range: ON,
OFF
OIM Menu Path(s): Input/Output - Digital I/O
Refer also to Parameters: PRESET SPEED 1 (P.117),
PRESET SPEED 2 (P.118)
PRESET SPEED 3 (P.119)
DIG IN 2 (P.496)
Only available if the I/O Expansion kit is installed.
Shows the state of digital input 2 (terminal 60 on the I/O Expansion board).
The input is ON when +24 VDC is applied for more than 20 ms. It is OFF when 0 VDC is applied.
Digital inputs 1 and 2 (terminals 59 and 60) are used to select which, if any, preset speed is used as the
speed reference for the speed/voltage control loop. See PRESET SPEED 1, 2, and 3 for more
information.
Parameter Range: ON, OFF
OIM Menu Path(s): Input/Output - Digital I/O
Refer also to Parameters: PRESET SPEED 1 (P.117),
PRESET SPEED 2 (P.118)
PRESET SPEED 3 (P.119)
DIG IN 3 (P.497)
Only available if the I/O Expansion kit is installed.
State of digital input 3 (terminal 62 on the I/O Expansion board), which is the MOP decrement input. The
input is ON when +24 VDC is applied for more than 20 ms. It is OFF when 0 VDC is applied.
See MOP ACCEL TIME for discussion and block diagram.
Parameter Range: ON, OFF
OIM Menu Path(s): Input/Output - Digital I/O
Refer also to Parameters: DIG IN 4 (P.498),
MOP ACCEL TIME (P.115)
DIG IN 4 (P.498)
Only available if the I/O Expansion Kit is installed.
State of digital input 4 (terminal 63 on the I/O Expansion board), which is the MOP increment input.
The input is ON when +24 VDC is applied for more than 20 ms. It is OFF when 0 VDC is applied.
See MOP ACCEL TIME for discussion and block diagram.
Parameter Range: ON, OFF
OIM Menu Path(s): Input/Output - Digital I/O
Refer also to Parameters: DIG IN 3 (P.497),
MOP ACCEL TIME (P.115)
DIG IN 5 (P.499)
Only available if the I/O Expansion Kit is installed.
State of Outer Control Loop enable input (terminal 64 on the I/O Expansion board).
The input is ON when +24 VDC is applied for more than 20 ms. It is OFF when 0 VDC is applied.
Parameter Range: ON, OFF
OIM Menu Path(s): Input/Output - Digital I/O
FREQ IN (P.491)
Only available if the I/O Expansion kit is installed.
The digital value of the frequency input (terminals 39, 40, and 41 on the I/O Expansion board).
FREQ IN is scaled between FREQ IN ZERO and FREQ IN FULL SCALE.
Parameter Range: 0 to 4095
OIM Menu Path(s): Input/Output - Frequency I/O
Refer also to Parameters: FREQ IN FULL SCALE (P.424), FREQ IN ZERO (P.423)
FREQ IN is zero when the frequency at the input is less than or equal to FREQ IN ZERO.
It is 4095 when the frequency equals FREQ IN FULL SCALE.
IR COMPENSATION TP (P.290)
An output testpoint that represents the level of IR COMPENSATION being used by the drive.
This parameter only has meaning if the selected drive feedback is set to armature voltage.
OIM Menu Path(s): Speed/Voltage Loop (SPD) - Speed/Voltage Loop (SPD) Test Points
The following block diagrams for the speed loop and current minor loop (CML) are provided to assist the
more experienced user in using the parameters associated with the signal flow of these loops.
A brief explanation of each diagram follows.
Figure D.1 shows the drive control signals as they relate to the OIM keypad and terminal strip control
sources.
Figures D.3, D.4, and D.5 provide further detail on the Speed Reference Source Select, Speed
Reference Ramp, and the Speed Reference Mode Select blocks presented in figure D.2.
Figure D.6 shows the relationship of the speed reference to the speed feedback selection and its output
to the CML.
Figures D.7 and D.8 list all the drive test points that could source the digital, analog, frequency, and
metering outputs. It also shows software scaling (gain and zero adjustments).
Figure D.9 shows the CML reference (speed or torque) routed from the speed loop. It also shows the
regulator selection (speed/voltage or current/torque), current limits (positive and negative) and a RATE
function acting on the CML reference.
Figure D.10 shows the relationship of the CML reference to the CML feedback selection in motor control.
It also shows associated gain functions and test parameters.
Figure D.13 shows the inputs on the optional I/O expansion board.
491340 e
KEYPAD P.000 Control Source Select Ramp Stop Command To Speed Reference Ramp
Keypad Stop Signal
*TERMBLK Stop Request and Mode Select Block Diagrams
Terminal Block Stop Signal
Network Stop Signal NETWORK
Serial Stop Signal SERIAL Current Limit Stop Command
Serial (HOST) Stop Request S To Speed Reference Mode
E Select Block Diagram
KEYPAD Q
OIM Run Signal P.000 Control Source Select
*TERMBLK U
Terminal Strip Run Signal Run Request
NETWORK E
Network Run Signal Jog Command
N To CML Reference
FlexPak 3000
Keypad Forward/Reverse Signal KEYPAD P.015
P.000 Control Source Select REVERSE DISABLE
Terminal Block Forward/Reverse Signal *TERMBLK
*OFF To Speed Reference
Network Forward/Reverse Signal NETWORK Forward/Reverse Command Ramp and Mode Select
SERIAL ON
Serial Forward/Reverse Signal Block Diagrams
Fixed Forward Direction Signal
P.799
Keypad Auto/Manual Signal KEYPAD (J15 REGULATOR TYPE)
P.000 Control Source Select *SPD Hardware Jumper REG TYPE
Terminal Block Auto/Manual Signal *TERMBLK (speed/voltage regulator)
Auto/Manual Command To Speed Reference Souce
Network Auto Mode Signal NETWORK
Select and Mode Select
Serial Port Auto/Manual Signal SERIAL Block Diagrams
CUR
Fixed Auto Mode Signal (current/torque regulator)
* = Default Selection
D-1
D-2
Torque Reference (current regulator) To CML
Reference
Block Diagram
(Fig.D.9)
OCL Reference
Signals
OUTER
CONTROL OCL Output
LOOP
Auto Speed
Reference Signal
Speed Reference
Manual Speed
APPENDIX D
FlexPak 3000
SPEED SPEED Ramped Speed SPEED Speed Loop
Reference Signal REFERENCE REFERENCE Reference Reference
REFERENCE To Speed Loop
Trim Reference SOURCE RAMP MODE Block Diagram
Signals SELECT Trim Reference SELECT (Fig.D.6)
MOP Increment/ (Fig.D.3) (Fig.D.4) (Fig.D.5)
Decrement Signals
491340 e
P.100 P.102 P.101 P.011 AUTO REF
ANLG AUTO ANLG AUTO ANLG AUTO TOP SPEED P.103 To OCL Feedback D.12 1)
SIGNAL TYPE ZERO ADJ P.188 AUTO P.000
GAIN ADJ
(ANALOG AUTO REFERENCE CONTROL
REFERENCE) HI
Analog Auto Reference SELECT SOURCE
491340 e
(+) terminal 19 LIMIT *ANALOG SELECT D.9(A)
A/D SOFTWARE SCALING *TERMBLK
(-) terminal 20 FREQUENCY IN INV To CML Reference
P.100 LO EN NETWORK Block Diagram
P.011 ANLG AUTO (TORQUE
*+/-10 V Forward/Reverse
- TOP SPEED SIGNAL TYPE REFERENCE)
0 - 10 V Command P.189
0
4-20 mA
Network Reference
D.13 10-50 mA
From I/O Expansion (C)
Input Block Diagram
FlexPak 3000
P.118 PRESET SPEED 2
P.115 MOP ACCEL TIME MOP DECEL TIME A=ON, B=ON
P.119 PRESET SPEED 3 Note
P.120 P.192
(ANALOG MAN 1) When configured as a current regulator
P.105 P.004 P.003 REFERENCE) (J15), Auto/Manual command is fixed at Auto
ANLG MAN MAXIMUM MINIMUM
REF ZERO ADJ
and CCS can only be set to TERMBL or NETWORK.
SPEED SPEED
Analog Manual Reference 2) MOP RESET ENABLE also affects the OIM Keypad
(+) terminal 17 SOFTWARE MAX/MIN SPEED Reference.
A/D SCALING SCALING
(-) terminal 18
3) (10V) terminal 16 3) J19 must be set to POT (2-3) to use the internal 10 V
P.104 To Field Loop power supply.
ANLG MAN REF
GAIN ADJ P.194 (ANALOG MAN TRIM REF) P.011
ANALOG MANUAL 1 P.108 TOP SPEED P.109
TRIM REFERENCE TRIM RANGE P.196
*REGISTER 0 HI
P.107 TRIM REF REGISTER SELECT (DRAW PERCENTAGE OUT) D.4(C)
D.13 2 MUL
(A) ANALOG IN 1 To Speed Reference
From I/O Expansion LIMIT
(B) GAIN Ramp Block Diagram
Inputs Block Diagram { ANALOG IN 2
6 LO
NETW IN REG 1, 2, 3
From Network 3,4,5
- TOP SPEED
* = Default Selection
D-3
D-4
Note 1:
"AUTO MODE MIN BYPASS" and "AUTO MODE RAMP BYPASS"
are valid only when the drive is in Auto Mode.
During a Ramp Stop Command, the S-curve ramp will P.198 (SPEED RAMP INPUT TP)
NOT be bypassed, regardless of the drive mode
(Auto/Manual) or the state of the "AUTO MODE RAMP
BYPASS" parameter.
P.004 S-CURVE ROUNDING
MAXIMUM SPEED Forward/Reverse
Command P.014 P.112
P.193
(SPD SOURCE SELECT OUT) AUTO MODE RAMP BYPASS
SUM MAX (see Note 1)
D3(B) LIMIT (w/hysteresis)
Ramp Stop SMOOTHING D5(D)
From Speed Command ON To Speed
EN
Off
Reference IN OUT
+ * OFF Reference
Source Select On SCURVE
Block Diagram + Mode Select
MIN MIN BYPASS REV DISABLE INV 0 RST RATE P.199 Block Diagram
P.110 (SPEED RAMP OUTPUT)
PROPORTIONAL TRIM MODE SELECT IV DEC ACC
FlexPak 3000
RAMP STOP DEC. T. PROPORTIONAL On
---------------------------- * DECELERATION TIME
1 + DRAW PERCENT
STOP DECEL
SELECT
P.196
(DRAW PERCENTAGE OUT) P.122
P.002
DECELERATION TIME * NO TRIM
INCREMENTAL
D3(C)
From Speed DECEL TIME PROPORTIONAL
----------------------------
Reference 1 + DRAW PERCENT P.110
Source Select TRIM MODE SELECT
Block Diagram
P.001
P.110
ACCELERATION TIME * NO TRIM TRIM MODE SELECT
INCREMENTAL
ACCEL TIME PROPORTIONAL
----------------------------
1 + DRAW PERCENT * = Default Selection
491340 e
P.848
491340 e
D12(A) From Outer Control Loop (OCL OUTPUT)
Block Diagram
P.295
(SPD LOOP REFERENCE)
P.011
P.199 TOP SPEED
(SPEED RAMP OUTPUT)
D.4(D) HI Jogging Active Current Limit
From Speed + Off Stop Command
+ + I O Off D.6(E)
Reference Ramp
-- - LO On To Speed Loop
Block Diagram On
Block Diagram
P.293 0
(CURRENT COMPOUND TP)
(CML FEEDBACK) SW
8 sample average SCALE
P.209
CURRENT COMPOUNDING
FlexPak 3000
P.490
P.017 DIG IN 0
ON
JOG SPEED 2 JOG SPEED SELECT DIG IN 0 SELECT Debounced
OFF Jog Request INV
JOG SPEED 1 * BRUSH WEAR ON
P.012 P.294
OCL ENABLE OFF EN RATELIM
0 (JOG RAMP OUTPUT)
ACC DEC
Forward/Reverse Command
P.013
JOG ACCEL/DECEL TIME
* = Default Selection
D-5
D-6
P.223
*REGISTER POS CURRENT
NOTE 1) Network only register. CSS must be set to NETWORK P.005 POSITIVE CURRENT LIM LIM SEL
and NETW REGISTER MAP SEL = ALTERNATE (A) ANALOG IN 1
D.13 From I/O Expansion SPD LOOP CUR LIM To CML Reference
NOTE 3) Also enables/disables on inverter CML ref. block diagram. Inputs Block Diagram ANALOG IN 2
{(B) Block Diagram
From Network NETW IN REG 1, 2, 3 D.9(B)
NETWORK P.224
P.006 NEGATIVE NEG CURRENT
P.009 P.204 P.205 CURRENT LIM *REGISTER
MOTOR RATED LIM SEL
ARM VOLTAGE ARM VOLTAGE D.13 (A) ANALOG IN 1
ARM VOLTS GAIN ADJ ZERO ADJ From I/O Expansion To CML Reference
P.289 EN
Inputs Block Diagram (B) ANALOG IN 2 Block Diagram
APPENDIX D
FlexPak 3000
(ARMATURE VOLTAGE)
{
Armature NETW IN REG 1, 2, 3 P.226 D.9(C)
From Network
Voltage A/D SOFTWARE SCALING + NEG CURRENT LIM INV EN 3)
(internal) -
* = Default Selection
PULSE TACH PPR PULSE TACH QUADRATURE
P.207 P.208
491340 e
Digital Outputs 1 and 2
491340 e
P.410/412
From Level Detector Block Diagram * n=2 LEVEL DETECT 2 OUTPUT DIG OUT 1 or 2
{ DIG OUT 1 or 2
SELECT
CONTACT TYP
IN CURRENT LIMIT * NORMAL OPEN
Digital Output 1: (+) terminal 66
DRIVE READY NORMAL CLOSED (-) terminal 67
From internal drive signals INV Digital Output 2: (+) terminal 68
{ NETW COMM STATUS (-) terminal 69
bit (n=1) of NETW IN REG 1, 2, 3
From Network
ANLG OUT 2
FlexPak 3000
D.3
D.11
{ FIELD REFERENCE
From Field Control Loop Block Diagram { FIELD FEEDBACK
NETW IN REG 1, 2, 3
From Network
D-7
D-8
Meter Outputs (n = 1, 2)
* n=1 CML FEEDBACK
FlexPak 3000
FULL SCALE 100 ms
4095
POWER OUTPUT
From Engineering Units Outputs Block Diagram
OCL REFERENCE
D.11
{ FIELD REFERENCE
From Field Control Loop Block Diagram { FIELD FEEDBACK
NETW IN REG 1, 2, 3
From Network
491340 e
491340 e
P.311
Positive current limit from CML REF LIMIT SELECT
Speed Loop Block Diagram * SPD LOOP CUR LIM
REGISTER
POS CURRENT LIM
P.005
Forward/Reverse
Command P.814
P.848 (OCL Output) OCL Type3
From OCL ENABLED POS REG EN 3)
D12(A) EN
Block Diagram
J15
P.189 CURRENT/TORQUE REGULATOR
(TORQUE REFERENCE) TYPE P.396
D3(A) From Speed Ref Source *DISABLED HI
Select Block Diagram (CML REFERENCE)
FlexPak 3000
From I/O Expansion
Inputs Block Diagram (B)
{ ANALOG IN 2
D13 NETW IN REG 1, 2, 3
From Network
P.311
CML REF LIMIT SELECT
Negative current limit from * SPD LOOP CUR LIM
D.6(C) Speed Loop Block Diagram
REGISTER
EN * = Default Selection
P.226
NEG CURRENT LIM INV EN 2) NOTE 1) Network only register. CSS must be set to NETWORK
and NETW REGISTER MAP SEL = ALTERNATE
NOTE 2) Also enables/disables on inverter speed loop block diagram.
D-9
D-10
P.396 P.398
(CML REFERENCE) (CML ERROR) P.301
CML PI PROP GAIN
D.9(C) From Current P.394
Minor Loop (ARMATURE BRIDGE POL)
KP
Reference
Block Diagram Drive Test Mode
+ IN PI OUT *
Phase
-
FlexPak 3000
Software
Scaling P.010
CT TURNS RATIO MOTOR
Analog to
Digital Rectifier
Converter 20K ohm
Current Feedback
Test Point 1 2 3 4
P.395
jumper J17, ARM I J18 "ARM I FB RB"
Hardware scaling jumper
(J18 ARM I FB RESISTOR)
* = Default Selection
Ground jumper
15 ohm 39 ohm
J22, GROUND
20 ohm 30 ohm
491340 e
P.514
FIELD PI PROP GAIN
P.510 FIELD PI LEAD FREQ
491340 e
MOTOR HOT FLD AMPS P.515
P.513 *REGISTER P.521 P.590
FIELD REF REGISTER FLD REF SELECT HI KP WLD P.588
(A) ANALOG IN 1 (FIELD REFERENCE) (FIELD DELTA)
D.13 From I/O Expansion OFF
FIELD FIELD
Inputs Block Diagram (B)
{ ANALOG IN 2 PI PHASE REGULATOR
LO ON
+ FIRING
ANALOG MAN TRIM REF - LOGIC SUPPLY
ANALOG MAN TRIM REF
P.194
(FIELD ECONOMY ACTIVE) LO HI
100
P.511
FIELD ECONOMY REF
P.510 P.516
MOTOR HOT FLD AMPS FLD FEEDBACK
GAIN ADJ 0
P.587
FIELD DELTA HI LIM
APPENDIX D
FlexPak 3000
LO HI P.517
FIELD AUTO
P.518 WEAKEN 1)
ENABLED
FLD WEAKEN + + PI
THRESHOLD - - DISABLED
FIELD DELTA
P.008 HI LIM
SOFTWARE KP WLD
MOTOR RATED
SCALING
ARM AMPS
P.520
P.206 P.519 FLD WEAKEN
IR COMPENSATION FLD WEAKEN LEAD FREQ
PROP GAIN
P.289 (note 1)
(ARMATURE VOLTAGE) + ABS
-
P.397 SOFTWARE
(CML FEEDBACK) SCALING Note 1: FIELD AUTO WEAKEN is clamped to DISABLED
8 Sample Average when FEEDBACK SELECT = ARMATURE VOLT
P.206
IR COMPENSATION
D-11
D-12
P.808 P.810
P.803 OCL PI OCL PI
OCL REF PROP POSITIVE
P.800 ROUNDING GAIN LIMIT
OCL P.812
P.801 *REGISTER REFERENCE OCL TRIM RANGE
OCL REF REGISTER JERK KP HI
(A) SELECT P.845 P.846 P.848
ANALOG IN 1
(OCL REFERENCE) (OCL RAMP OUTPUT) INITV (OCL OUTPUT)
MUL
From I/O Expansion (B) ANALOG IN 2 * DISABLED
Inputs Block Diagram S-CURVE + PI GAIN To Speed
D.13
{ (C) FREQUENCY IN output of OCL - output of OCL ENABLED Reference
RST\ INITV RST\ P.011
P.849 enable logic enable logic TOP SPEED Mode Select
NETW IN REG 1, 2, 3 ACC DCC WLD LO Block Diagram
From Network (from below) P.813
P.809 P.811 DIV OCL PROP
P.802 OCL PI OCL PI TRIM SELECT
OCL REF RAMP TIME 2) LEAD NEGATIVE GAIN
FREQ LIMIT MUL
P.804
*NONE OCL
FEEDBACK * BYPASS
(CML FEEDBACK) CML FEEDBACK SELECT
8 sample average INITV LEAD/LAG P.199
(A) ANALOG IN 1 SPEED RAMP
ABS
L/L LAG/LEAD
D.13 From I/O Expansion OUTPUT (RPM)
Inputs Block Diagram (B) ANALOG IN 2 WLD RST\ RATIO OCL
{ (OCL FEEDBACK)
D.6 SPD LOOP OUTPUT P.847 LEADLAG
SPD LOOP OUTPUT 3) OCL SELECT
AUTO REF. P.806 OCL NOTES
P.805
enable logic
FlexPak 3000
PI-blocks are held in reset causing the initial value (INITV)
to be copied to each block's output.
2) The 'OCL reference ramp blockcan be bypassed by
setting OCL REF RAMP TIME to 0.0.
Outer Control Loop Enable Logic
3) Only available through network registers
Network OCL Enable P.000 or the CS3000 software.
CONTROL
I/O Expansion
NETWORK SOURCE
Digital Inputs (terminal 64)
SELECT Drive P.849
TERMBLK Status
Installed Running (OCL ENABLE)
(DIG IN 5) 1)
*KEYPAD OCL enable output
Digital Input (term. 12) P.499 Not Installed Not Running
SERIAL OFF (to above)
OCL ENABLE
(DIG IN 0) I/O Expansion Kit
P.490 * BRUSH WEAR
491340 e
Digital Inputs (n = 1 through 5)
n=1: terminal 59 (Preset Speed Select)
n=2: terminal 60 (Preset Speed Select) P.495....99
491340 e
n=3: terminal 62 (MOP Decrement) (DIG IN n)
n=4: terminal 63 (MOP Increment) To function specified
n=5: terminal 64 (OCL Enable) by digital input n
+24 VDC available at terminal 14 on regulator board and
at terminal 58 or 61 on I/O Expansion board
P.416 P.417
APPENDIX D
FlexPak 3000
ANLG IN 2 ANLG IN 2
ZERO ADJ GAIN ADJ
P.493
Analog Input 2 (ANLG IN 2)
(+) terminal 52 A/D To any switch selection
SOFTWARE SCALING
(-) terminal 53 labeled ANALOG IN 2
D.3, 6, 9, 12
P.423 P.424
FREQ IN FREQ IN
Frequency Input ZERO FULL SCALE P.491
(FREQ IN) HI
Frequency Input
(A) terminal 39 To any switch selection
F/D SOFTWARE SCALING LIMIT labeled FREQUENCY IN
(A) terminal 40
(COM) terminal 41 LO
D.3, D12
* = Default Selection
D-13
D-14
Figure D.14 - Level Detectors
Level Detectors 1 and 2
P.602, P.605
CML FEEDBACK LEVEL DETECT
(CML FEEDBACK) 8 Sample Average
* n=1 SPD LOOP FEEDBACK 1 or 2 SELECT
From Speed Loop Block Diagram
SPD RAMP OUTPUT P.648, P.649
From Speed Reference ABS A (LEVEL DETECT
Ramp Block Diagram { *n=2 SPD RAMP INPUT TP A >B 1 or 2 OUTPUT)
COMPARE Start/Stop
From Speed Reference Source SPD SOURCE SEL OUT LEVEL DETECT To Digital Outputs
APPENDIX D
FlexPak 3000
B TIMER
Select Block Diagram 1 or 2 THRESH Block Diagram .D7
LEVEL DETECT
P.603, P.606 Delay Time
1 or 2 DELAY
P.604, P.607
491340 e
APPENDIX E
This appendix lists all possible OIM error messages generated by the drive and fault/alarm codes.
The error messages appear on the OIM display when certain drive conditions exist. Table E-1 lists fault
codes and Table E-2 lists alarm codes. Tables E-1 and E-2 list fault and alarm codes by number (Fxxxxx
= Fault; Axxxxx = Alarm), associated message visible at the OIM display and a description along with
possible causes.
1) When after stop command, the auxiliary contactor does not indicate that the main contactor opened,
this fault indication is 1000 msec time delayed.
A00052 NEG CUR LIM INV The parameter NEG CUR LIM INV EN (P.226) has changed state, either
ENABLE CHANGED enabling or disabling the negative current limit inverters. The
parameters POS CURRENT LIMIT SEL (P.223) and NEG CURRENT LIMIT
SEL (P.224) have been automatically set to REGISTER- The user should
carefully examine the current limit scheme to avoid unintended
operation by the drive.
A00700 RETENTIVE An attempt to save information (parameter values, fault log data or the
MEMORY SAVE keypad reverence value) to retentive memory failed. The drive may
ERROR continue to be operated.
Possible cause: Regulator board failure.
This appendix shows the FlexPak 3000 menu structures as they are displayed on the OIM. Parameter
names are in upper case, sub-menu names and menu items which cause an action to occur (such as
resetting faults) are in lower case.
The Fault Menu, Alarm Menu and Diagnostics Menu are accessed by repeated pressing of the OIM
FAULT key. The text "FAULT", "ALARM" or "DIAGS" will appear above the FAULT key.
Fault Menu
Review Log
Reset Faults
Clear Fault Log and Reset Faults
Alarm Menu
Review Log
Reset Alarm Indicator
Clear Alarm Log & Reset Alarms
Diagnostics Menu
Why is the drive not ready?
Why did the drive stop?
To access the Main Menu, press CANCEL until FlexPak 3000 Main Menu is displayed at the top of the
screen. Each menu shown below is expanded on the pages that follow.
If older versions of the OIM are used with newer versions of the regulator board, the menu item
Additional Parameters might also be available.
Drive Reference
Drive Reference Test Points
ANALOG AUTO REFERENCE (P.188)
ANALOG MAN REFERENCE (P.192)
ANALOG MAN TRIM REF (P.194)
SPD SOURCE SELECT OUT (P.193)
DRAW PERCENTAGE OUT (P.196)
TRIM OUTPUT (P.197)
SPEED RAMP INPUT TP (P.198)
SPEED RAMP OUTPUT (P.199)
JOG RAMP OUTPUT (P.294)
SPD LOOP REFERENCE (P.295)
MOP OUTPUT (P.191)
Drive Reference Trim
TRIM REF REGISTER (P.107)
TRIM REFERENCE SELECT (P.108)
TRIM RANGE (P.109)
TRIM MODE SELECT (P.110)
Drive Reference Limits
TOP SPEED (P.011)
MAXIMUM SPEED (P.004)
MINIMUM SPEED (P.003)
REVERSE DISABLE (P.015)
AUTO MODE MIN BYPASS (P.111)
Drive Reference Ramp
ACCELERATION TIME (P.001)
DECELERATION TIME (P.002)
S-CURVE ROUNDING (P.014)
JOG ACCEL/DECEL TIME (P.013)
AUTO MODE RAMP BYPASS (P.112)
MOP ACCEL TIME (P.115)
MOP DECEL TIME (P.120)
~
Speed/Voltage Loop (SPD) Feedback
FEEDBACK SELECT (P.200)
MOTOR RATED ARM VOLTS (P.009)
ARM VOLTAGE ZERO ADJ (P.205)
ARM VOLTAGE GAIN ADJ (P.204)
ARMATURE VOLTAGE (P.289)
ANALOG TACH ZERO ADJ (P.202)
ANALOG TACH GAIN ADJ (P.201)
ANALOG TACH FEEDBACK (P.291)
ANLG TACH VOLTS/1000 (P.203)
J11 ANLG TACH VLT SCL (P.792)
J14 ANLG TACH VLT RNG (P.793)
PULSE TACH PPR (P.207)
PULSE TACH QUADRATURE (P.208)
Current Minor Loop (CML)
CML Test Points
CML REFERENCE (P.396)
CML FEEDBACK (P.397)
CML ERROR (P.398)
SPD LOOP OUTPUT (P.299)
ARMATURE BRIDGE POL (P.394)
ARMATURE DELTA (P.399)
TORQUE REFERENCE (P.189)
J15 REGULATOR TYPE (P.799)
CML Tuning
CML PI PROP GAIN (P.301)
CML PI LEAD FREQUENCY (P.302)
CML REF RATE LIMIT (P.303)
POSITIVE CURRENT LIM (P.005)
NEGATIVE CURRENT LIM (P.006)
Self Tuning Setup
SELF TUNE BRIDGE (P.220)
SELF TUNE FIELD RANGE (P.218)
SELF TUNE STABILITY (P.219)
Self Tuning
POS CURRENT LIM SEL (P.223)
NEG CURRENT LIM SEL (P.224)
CML Feedback Scaling
MAXIMUM CURRENT (P.007)
MOTOR RATED ARM AMPS (P.008)
CML FEEDBACK GAIN ADJ (P.300)
J18 ARM I FB RESISTOR (P.395)
CT TURNS RATIO (P.010)
CML FEEDBACK (P.397)
~
Three Phase AC Line
NOMINAL AC LINE FREQ (P.306)
NOMINAL AC LINE VOLTS (P.307)
AC LINE PERIOD (P.393)
AC LINE VOLTAGE (P.392)
PLL MAXIMUM ERROR (P.308)
SCR Diagnostics
OPEN SCR SENSITIVITY (P.600)
OPEN SCR TRIP THRESH (P.601)
Armature Phase Fire Test
PHASE FIRE TEST DELTA (P.309)
PHASE FIRE TST BRIDGE (P.310)
ARMATURE DELTA (P.399)
CML FEEDBACK (P.397)
ARMATURE VOLTAGE (P.289)
Outer Control Loop (OCL)
OCL Test Points
OCL ENABLE (P.849)
OCL REFERENCE (P.845)
OCL RAMP OUTPUT (P.846)
OCL FEEDBACK (P.847)
OCL OUTPUT (P.848)
OCL Tuning
OCL PI PROP GAIN (P.808)
OCL PI LEAD FREQ (P.809)
OCL PI POSITIVE LIMIT (P.810)
OCL PI NEGATIVE LIMIT (P.811)
OCL LEADLAG LOW FREQ (P.806)
OCL LEADLAG RATIO (P.807)
OCL TRIM RANGE (P.812)
OCL REF RAMP TIME (P.802)
OCL REF ROUNDING (P.803)
OCL Configure
OCL REFERENCE SELECT (P.800)
OCL REF REGISTER (P.801)
OCL FEEDBACK SELECT (P.804)
OCL LEADLAG SELECT (P.805)
Field
Standard/enhanced Field Supply
J20 FIELD LOSS DETECT (P.597)
FIELD ECONOMY ACTIVE (P.599)
FIELD ECONOMY DELAY (P.501)
ENHANCED FLD VOLT ADJ (P.500)
J21 FLD SUPPLY JUMPER (P.598)
Field Current Regulator
FLD CURRENT REGULATOR (P.586)
Field Loop Test Points
FIELD REFERENCE (P.590)
FIELD FEEDBACK (P.589)
FIELD ECONOMY ACTIVE (P.599)
FIELD DELTA (P.588)
Field Loop Tuning
FIELD REF REGISTER (P.513)
FIELD PI PROP GAIN (P.514)
FIELD PI LEAD FREQ (P.515)
FLD WEAKEN THRESHOLD (P.518)
IR COMPENSATION (P.206)
IFLD WEAKEN PROP GAIN (P.519)
IFLD WEAKEN LEAD FREQ (P.520)
Field Loop Configure
FIELD ECONOMY REF (P.511)
FIELD ECONOMY DELAY (P.501)
FIELD LOSS THRESHOLD (P.512)
FIELD AUTO WEAKEN (P.517)
FIELD DELTA HIGH LIM (P.587)
Field Loop Feedback Scaling
MOTOR HOT FLD AMPS (P.510)
FLD FEEDBACK GAIN ADJ (P.516)
FIELD FEEDBACK (P.589)
~
Drive Information
Correct Scaling Jumper Positions
J11 ANLG TACH VLT SCL (P.792)
J14 ANLG TACH VLT RNG (P.793)
J18 ARM I FB RESISTOR (P.395)
PULSE TACHOMETER KIT (P.798)
NETWORK KIT (P.796)
I/O EXPANSION KIT (P.797)
FLD CURRENT REGULATOR (P.586)
POWER UNIT TYPE (P.795)
J15 REGULATOR TYPE (P.799)
J20 FIELD LOSS DETECT (P.597)
J21 FLD SUPPLY JUMPER (P.598)
REGULATOR SW VERSION (P.794)
Operator Interface
PASSWORD
Memory Operations
Memory Save
Memory Restore
Restore Defaults
Reset Clock
Define User Units
Define Speed Units
Define Load Units
Define Outer Control Loop Units
Additional Parameters
P.311 (CML REF LIMIT SELECT)
P.312 (INV FAULT AVOID SEL SEL)
P.226 (NEG CUR LIM INV EN)
P.017 (JOG SPEED 2)
P.122 (STOP DECEL SELECT)
P.608 (TACH LOSS SCR ANGLE)
P.018 (RAMP STOP DECEL TIME)
P.914 (NETW REGISTER MAP SEL)
P.813 (OCL PROP TRIM SELECT)
P.521 (FIELD REF SELECT)
P.490 (DIG IN 0)
P.428 (DIG IN 0 SELECT)
P.227 (TACH LEAD FLT THRESH)
P.228 (TACH LEAD FLT DELAY)
P.609 (PHASE LOSS DETECT EN
P.814 (OCL TYPE3 POSN REG EN
P.915 (CNI PROG/RUN MODE)
P.019 (SPD LOOP SCAN TIME)
Table G.1 - User Quick Reference Table for Input Parameters (continued)
Par. Parameter Parameter Selection / Pg Initial Factory User Data
No. Adjustment Range B- Setting Date Setting
105 ANLG MAN REF ZERO ADJ -200 - +200 4 0
106 MANUAL REF SELECT ANALOG 25 ANALOG
MOP
107 TRIM REF REGISTER + 100.0% 52 0%
108 TRIM REFERENCE SELECT ANALOG MANUAL 51 REGISTER
ANALOG IN 1
NETW IN REG 1
NETW IN REG 2
NETW IN REG 3
ANALOG IN 2
REGISTER
109 TRIM RANGE 0 - +100.0% 51 0.0%
110 TRIM MODE SELECT NO TRIM 51 NO TRIM
INCREMENTAL
PROPORTIONAL (DRAW)
111 AUTO MODE MIN BYPASS OFF 8 OFF
ON
112 AUTO MODE RAMP BYPASS OFF 8 OFF
ON
113 STOP SPEED THRESHOLD 0 - MAXIMUM SPEED (P.004) 50 0 (*RPM)
in *RPM
114 STOP MODE SELECT RAMP 49 RAMP
(3) COAST/DB
CURRENT LIMIT
115 MOP ACCEL TIME ACCELERATION TIME (P.001) - 29 5.0 seconds
300.0 seconds
116 MOP RESET ENABLE OFF 30 OFF
ON
117 PRESET SPEED 1 MINIMUM SPEED- MAX SPEED 43 250 *RPM
118 PRESET SPEED 2 MINIMUM SPEED- MAX SPEED 43 250 *RPM
119 PRESET SPEED 3 MINIMUM SPEED- MAX SPEED 43 250 *RPM
120 MOP DECEL TIME DECEL.. TIME (P.002)- 300 sec 30 5.0 seconds
121 JOG OFF DELAY TIME 0.0 to 10.0 seconds 23 1.0 seconds
122 STOP DECEL SELECT 1 = DECELERATION TIME 48 1
2 = RAMP STOP DECEL TIME
Feedback Selection
200 FEEDBACK SELECT ARMATURE VOLT 14 ARM VOLT for
DC TACH S-6
PULSE TACH DC TACH for
AC TACH S-6R
201 ANALOG TACH GAIN ADJ 0.750 - 1.250 1 1.000
202 ANALOG TACH ZERO ADJ -200 - +200 2 0
203 ANLG TACH VOLTS/1000 18.0 - 200.0 V/1000 RPM 6 60V/1000 RPM
204 ARM VOLTAGE GAIN ADJ 0.750 - 1.250 7 1.000
205 ARM VOLTAGE ZERO ADJ -200 - +200 V 8 0V
206 IR COMPENSATION 0 - 50 %FLA 22 0% FLA
(*) Or user defined unit.
(3) If drive is configured as a current regulator,
only COAST/DB can be selected.
G-2 FlexPak 3000 491340 e
APPENDIX G
Table G.1 - User Quick Reference Table for Input Parameters (continued)
Par. Parameter Parameter Selection / Pg Initial Factory User Data
No. Adjustment Range B- Setting Date Setting
207 PULSE TACH PPR 18 - 2500 PPR 43 18 PPR
208 PULSE TACH QUADRATURE OFF 44 ON
ON
209 CURRENT COMPOUNDING -50% - +50% 11 0%
Speed Regulator Adjustm.
211 SPD LOOP PI PROP GAIN 0.10 - 128.00 48 4.40
212 SPD LOOP PI LEAD FREQ 0.00 to 282.74 rad/s if P.200 = 47 3.00 rad/s
ARMATURE VOLT, P.019 = 10 ms
0.00 to 327.67 rad/s if P.200
ARMATURE VOLT, P.019 = 5 ms
213 SPD LEADLAG RATIO 2 - 20 46 2
214 SPD LEADLAG LOW FREQ 0.01 to 69.81 rad/s if P.200 = 46 1.00 rad/s
ARMATURE VOLT, P.019 = 10 ms
0.01 to 139.62 rad/s if P.200
ARMATURE VOLT, P.019 = 5 ms
215 SPD LOOP LAG FREQ 0.01 to 139.62 rad/s if P.200 = 47 1.00 rad/s
ARMATURE VOLT, P.019 = 10 ms
0.01 to 279.25 rad/s if P.200
ARMATURE VOLT, P.019 = 5 ms
216 SPD LEADLAG SELECT LEAD/LAG 46 BYPASS
BYPASS
LAG/LEAD
217 SPD LOOP LAG BYPASS OFF 47 ON
ON
Self Tuning Set-up
218 SELF TUNE FIELD RANGE 0.90 - 5.00 45 1.00
219 SELF TUNE STABILITY 10 - 100 45 25
220 SELF TUNE BRIDGE FORWARD 45 FORWARD
REVERSE
221 INERTIA COMP SELECT NONE 21 NONE
INTERNAL
ANALOG IN 1
ANALOG IN 2
NETW IN REG 1
NETW IN REG 2
NETW IN REG 3
222 NORMALIZED INERTIA 0.05 - 65.20 sec 36 1.00 sec
223 POS CURRENT LIM SEL REGISTER 42 REGISTER
ANALOG IN 1, ANALOG IN 2
NETW IN REG 1
NETW IN REG 2
NETW IN REG 3
224 NEG CURRENT LIM SEL REGISTER 32 REGISTER
ANALOG IN 1, ANALOG IN 2
NETW IN REG 1
NETW IN REG 2
NETW IN REG 3
226 NEG CUR LIM INV EN 1 = DISABLE 32 2
2 = ENABLE
227 TACH LEAD FLT THRESH 0.0 to 250 % (of TOP SPEED) 50 200.0
228 TACH LEAD FLT DELAY 0 to 32767 (msec) 50 10 000
Table G.1 - User Quick Reference Table for Input Parameters (continued)
Par. Parameter Parameter Selection / Pg Initial Factory User Data
No. Adjustment Range B- Setting Date Setting
Current Regulator Set-up
300 CML FEEDBACK GAIN ADJ 0.900 - 1.100 9 1.000
301 CML PI PROP GAIN 0.000 - 4.000 9 0.250
302 CML PI LEAD FREQ 10 - 500 rad/s 9 100 rad/s
303 CML REF RATE LIMIT 1 - 1000 msec 10 40 msec
306 NOMINAL AC LINE FREQ 48 - 62 Hz 36 50 Hz
307 NOMINAL AC LINE VOLTS 200 - 575 VAC or 36 400 VAC
300 - 850 VAC (types 575/690 V)
308 PLL MAXIMUM ERROR 2 - 1000 sec 42 2 sec
309 PHASE FIRE TEST DELTA 0 - 180 degrees 41 0 degrees
310 PHASE FIRE TST BRIDGE OFF 42 OFF
ON
311 CML REF LIMIT SELECT 1 = SPD LOOP PI LIMITS 10 1
2 = REGISTER
312 INV FAULT AVOID SEL 1 = DISABLED 21 DISABLED
2 = FAULT IMMEDIATELY
3 = DELAY BEFORE FAULT
Meter Outputs Set-up
400 METER OUT 1 GAIN ADJ 0.100 - 1.900 26 1.000
401 METER OUT 2 GAIN ADJ 0.100 - 1.900 28 1.000
402 METER OUT 1 ZERO ADJ -200 - +200 27 0
403 METER OUT 2 ZERO ADJ -200 - +200 28 0
404 METER OUT 1 SELECT CML FEEDBACK 27 CML
CML REFERENCE FEEDBACK
CML ERROR
SPD LOOP FEEDBACK
SPD LOOP REFERENCE
SPD LOOP ERROR
SPD LOOP OUTPUT
SPEED RAMP OUTPUT
SPEED RAMP INPUT TP
SPD SOURCE SELECT OUT
TRIM OUTPUT
ARMATURE VOLTAGE
ANALOG TACH FEEDBACK
PULSE TACH FEEDBACK
ZERO
FULL SCALE
POWER OUTPUT
OCL REFERENCE
OCL RAMP OUTPUT
OCL FEEDBACK
OCL OUTPUT
FIELD REFERENCE
FIELD FEEDBACK
NETW IN REG 1
NETW IN REG 2
NETW IN REG 3
405 METER OUT 2 SELECT same as above for P.404 28 SPD LOOP
FEEDBACK
Table G.1 - User Quick Reference Table for Input Parameters (continued)
Par. Parameter Parameter Selection / Pg Initial Factory User Data
No. Adjustment Range B- Setting Date Setting
Digital Outputs Set-up (on I/O card)
409 DIG OUT 1 SELECT LEVEL DETECT 1 OUTPUT 13 LEVEL
LEVEL DETECT 2 OUTPUT DETECT 1
IN CURRENT LIMIT OUTPUT
DRIVE READY
NETW COMM STATUS
NETW IN REG 1
NETW IN REG 2
NETW IN REG 3
410 DIG OUT 1 CONTACT TYP NORMAL OPEN 13 NORMAL
NORMAL CLOSED OPEN
411 DIG OUT 2 SELECT LEVEL DETECT 1 OUTPUT 14 LEVEL
LEVEL DETECT 2 OUTPUT DETECT 2
IN CURRENT LIMIT OUTPUT
DRIVE READY
NETW COMM STATUS
NETW IN REG 1
NETW IN REG 2
NETW IN REG 3
412 DIG OUT 2 CONTACT TYP NORMAL OPEN 13 NORMAL
NORMAL CLOSED OPEN
Analog Inputs / Outputs (on I/O card)
413 ANLG IN 1 SIG TYPE 0-10V, 10V 3 10 V
4-20 mA, 10-50 mA
414 ANLG IN 1 ZERO ADJ -200 - 200 3 0
415 ANLG IN 1 GAIN ADJ 0.750 - 2.250 3 1.000
416 ANLG IN 2 ZERO ADJ -200 - 200 4 0
417 ANLG IN 2 GAIN ADJ 0.750 - 2.250 4 1.000
418 ANLG OUT 1 SELECT CML FEEDBACK 5 ZERO
CML REFERENCE
CML ERROR
SPD LOOP FEEDBACK
SPD LOOP REFERENCE
SPD LOOP ERROR
SPD LOOP OUTPUT
SPEED RAMP OUTPUT
SPEED RAMP INPUT TP
SPD SOURCE SELECT OUT
TRIM OUTPUT
ARMATURE VOLTAGE
ANALOG TACH FEEDBACK
PULSE TACH FEEDBACK
ZERO
FULL SCALE
POWER OUTPUT
OCL REFERENCE
OCL RAMP OUTPUT
OCL FEEDBACK
OCL OUTPUT
FIELD REFERENCE
FIELD FEEDBACK
NETW IN REG 1
NETW IN REG 2
NETW IN REG 3
491340 e FlexPak 3000 G-5
APPENDIX G
Table G.1 - User Quick Reference Table for Input Parameters (continued)
Par. Parameter Parameter Selection / Pg Initial Factory User Data
No. Adjustment Range B- Setting Date Setting
419 ANLG OUT 1 SIG TYPE 0-10 V, 10 V, 4-20 mA 6 10 V
420 ANLG OUT 1 GAIN ADJ 0.500 - 1.300 5 1.000
421 ANLG OUT 2 SELECT same as above for P.418 7 ZERO
422 ANLG OUT 2 GAIN ADJ 0.500 - 1.300 6 1.000
Frequency Inputs/Outputs (on I/O card)
423 FREQ IN ZERO 2.0 - FREQ IN FULL SCALE kHz 19 2.0 kHz
424 FREQ IN FULL SCALE 2.0 - 250.0 kHz 19 250.0 kHz
425 FREQ OUT SELECT same as above for P.418 20 ZERO
426 FREQ OUT ZERO 2.0 - FREQ OUT FULL SCALE kHz 21 2.0 kHz
427 FREQ OUT FULL SCALE 2.0 - 250.0 kHz 20 250.0 kHz
428 DIG IN 0 SELECT 1 = BRUSH WEAR 12 1
2 = JOG SPEED SELECT
3 = OCL ENABLE
Field Regulator Set-up
500 ENHANCED FLD VOLT ADJ 0 - 180 (J21 = B-C) 14 84
501 FIELD ECONOMY DELAY 0 - 27 minutes 16 5 minutes
510 MOTOR HOT FLD AMPS 0.11 - installed supply rating 30 0.1 A
(4.00, 10.00, or 15.00 A)
511 FIELD ECONOMY REF 0 - 100% 16 0%
512 FIELD LOSS THRESHOLD Armature voltage regulators: 17 60% of
50 - 100% of MOTOR HOT
MOTOR HOT FLD AMPS (P.510) FLD AMPS
Speed regulators: 0 - 100% of
MOTOR HOT FLD AMPS (P.510)
513 FIELD REF REGISTER 0 to MOTOR HOT FLD AMPS 18 MOTOR HOT
(P.510) FLD AMPS
514 FIELD PI PROP GAIN 0.01 - 128.00 17 0.50
515 FIELD PI LEAD FREQ 0.01 - 56.50 rad/s 17 1.50 rad/s
516 FLD FEEDBACK GAIN ADJ 0.900 - 1.100 18 1.000
517 FIELD AUTO WEAKEN DISABLED 17 DISABLED
ENABLED
518 FLD WEAKEN THRESHOLD 0 to 120% of 19 95% of
MOTOR RATED ARM VOLTS MOTOR
(P.009) RATED ARM
VOLTS
519 FLD WEAKEN PROP GAIN 0.01 - 128.00 19 1.60
520 FLD WEAKEN LEAD FREQ 0.01 - 56.50 rad/s 18 0.50 rad/s
521 FIELD REF SELECT 1 = REGISTER 18 1
2 = ANALOG MAN TRIM REF
3 = ANALOG IN 1
4 = ANALOG IN 2.
587 FIELD DELTA HIGH LIM 0 - 180 degree 16 130 degree
Thyristor Firing check
600 OPEN SCR SENSITIVITY 0 - 100% 41 50%
601 OPEN SCR TRIP THRESH 800 - 4000 41 1600
Table G.1 - User Quick Reference Table for Input Parameters (continued)
Par. Parameter Parameter Selection / Pg Initial Factory User Data
No. Adjustment Range B- Setting Date Setting
Level Detectors
602 LEVEL DETECT 1 SELECT SPD SOURCE SELECT OUT 24 SPD LOOP
SPEED RAMP INPUT TP FEEDBACK
SPEED RAMP OUTPUT
SPD LOOP FEEDBACK
CML FEEDBACK
603 LEVEL DETECT 1 THRESH 0.1 to 100.0% if LEVEL 24 10.0%
DETECT 1 SELECT is not set
to CML FEEDBACK
0.1 to MAXIMUM CURRENT%
if LEVEL DETECT 1 SELECT
is set to CML FEEDBACK
604 LEVEL DETECT 1 DELAY 0.0 - 300.0 sec 24 10.0 sec
605 LEVEL DETECT 2 SELECT SPD SOURCE SELECT OUT 25 SPEED RAMP
SPEED RAMP INPUT TP INPUT TP
SPEED RAMP OUTPUT
SPD LOOP FEEDBACK
CML FEEDBACK
606 LEVEL DETECT 2 THRESH 0.1 - 100.0% if LEVEL 25 10.0%
DETECT 2 SELECT is not set
to CML FEEDBACK
0.1 to MAXIMUM CURRENT%
if LEVEL DETECT 2 SELECT
is set to CML FEEDBACK
607 LEVEL DETECT 2 DELAY 0.0 - 300.0 sec 24 10.0 sec
608 TACH LOSS SCR ANGLE 0 to 127 (degrees) 50 109
609 PHASE LOSS DETECT EN DISABLE, ENABLE 42 ENABLE
Outer Current Loop
800 OCL REFERENCE SELECT REGISTER 40 REGISTER
ANALOG IN 1
ANALOG IN 2
FREQUENCY IN
NETW IN REG 1
NETW IN REG 2
NETW IN REG 3
801 OCL REF REGISTER -4095 - 4095 40 0
802 OCL REF RAMP TIME 0.0 - 300.0 sec 39 10.0 sec
803 OCL REF ROUNDING 0 - 50% 40 0%
804 OCL FEEDBACK SELECT NONE 37 CML
CML FEEDBACK FEEDBACK
ANALOG IN 1
ANALOG IN 2
5=SPEED LOOP OUTPUT
6=ANALOG AUTO REF
7= NETW IN REG 1
8= NETW IN REG 2
9= NETW IN REG 3
805 OCL LEADLAG SELECT LEAD/LAG 38 BYPASS
BYPASS
LAG/LEAD
806 OCL LEADLAG LOW FREQ 0.01 - 34.90 rad/s 37 1.00 rad/s
807 OCL LEADLAG RATIO 2 - 20 37 10
Table G.1 - User Quick Reference Table for Input Parameters (continued)
Par. Parameter Parameter Selection / Pg Initial Factory User Data
No. Adjustment Range B- Setting Date Setting
808 OCL PI PROP GAIN 0.10 - 128.00 39 2.00
809 OCL PI LEAD FREQ 0.00 - 141.37 rad/s 38 1.00 rad/s
810 OCL PI POSITIVE LIMIT 0 - 100% of TOP SPEED 39 100%
811 OCL PI NEGATIVE LIMIT 0 - 100% of TOP SPEED 38 100%
812 OCL TRIM RANGE -100 - 100.0% 40 0.0%
813 OCL PROP TRIM SELECT 1 = DISABLED 39 1
2 = ENABLED
814 OCL TYPE3 POSN REG EN 1 = DISABLED 41 DISABLED
2 = ENABLED
Network Communication
900 NETW DROP NUMBER 1 - 55 if 35 1
(1) NETW CONNECT TYPE=BASIC
1 - 52 if
NETW CONNECT TYPE = FULL
901 NETW COMM LOSS SELECT FAULT 35 FAULT
(1) HOLD LAST REF
USE TRMBLK REF
902 NETW OUT REG 1 SELECT -32768 - 32767 35 0
903 NETW OUT REG 2 SELECT -32768 - 32767 35 0
904 NETW OUT REG 3 -32768 - 32767 36 0
910 NETWORK CONNECT TYPE BASIC 35 BASIC
(1) FULL
911 AMX NETW REF SELECT DIRECT 1 DIRECT
(1) BROADCAST n (n=1-8)
912 NETWORK BAUD RATE 0.0 Kbaud 34 0.0 Kbaud
(1) 125.0 Kbaud
250.0 Kbaud
500.0 Kbaud
913 DEVICENET POLL MSG CONTROL ONLY 11 CONTROL
(1) CONTROL + CONFIG ONLY
914 NETW REGISTER MAP SEL 1 = ORIGINAL 36 1
2 = ALTERNATE
915 CNI PROG/RUN MODE 1 = STOP 10 STOP
2 = NOT STOP
SPEED FEEDBACK GAIN 1000 32 000 46 1000
(Alternate network map,
Drop_1, reg. 38)
SPD LOOP PI INIT SEL 0 = ZERO 47 0
(Alternate network map, 1 = SPD LOOP PI INIT VAL
Drop_2, reg. 32) 2 = ANALOG MAN TRIM REF
SPD LOOP PI INIT VAL -32768 - 32767 48 0
(Alternate network map,
Drop_1, reg. 39)
SPD LOOP PI RESET 0 = OFF 48 0
(Alternate network map, 1 = ON
Drop_1, reg. 32, bit 6)
UNDERWIND ENABLE 0 = DISABLED (overwind) 52 1
(Alternate network map, 1 = ENABLED (underwind)
Drop_1, reg. 32, bit 5)
(1) Parameter is only available or displayed on the OIM if an optional Network Communications board is installed.
G-8 FlexPak 3000 491340 e
H - CE-CONFORMITY
EMC Directive
This converter device is a component intended for implementation in machines or systems for the capital
goods industry. They have been tested to meet Council Directive 89/336 Electromagnetic Compatibility
(EMC) and all applicable standards (listed in the technical construction file).
With the specified EMC filters and the measures as described in this guidelines the FlexPak 3000 can be
operated CE-conform according to product standard EN 61800-3.
CAUTION: The conformity of the drive and filter to any standard does not guarantee that the entire
installation will conform. Many other factors can influence the total installation and only
direct measurements can verify total conformity. It is therefore the responsibility of the
machine manufacturer, to ensure, that the EC-conformity is met.
Disturbances
Conducted, High Frequency Disturbances (0,15 - 30 MHz)
Depending on location - first environment (residential or public low voltage supply network), second
environment (industrial supply network) - and converter rating different limits are permitted, whereas the
practical limit for the first environment is 100 A. For converters with AC line input current below 100 A,
which are located in the first, as well as in the second environment, lower limits are required than for
converters above 100 A in the second environment.
Immunity
Immunity against Conducted and Radiated, High Frequency Disturbances
The FlexPak DC-converters have been tested to fulfill the Immunity requirement in the first, as well as in
the second environment.
Mounting Instructions
(Refer to Figure H-1)
The filters must be screwed directly to the panel with the largest possible contact area.
The support panel for the converters and filters must be a conducting steel sheet, with a common
ground busbar at the bottom. This ground busbar, mounted in front of the terminals, must be
solidly connected to the panel, ensuring good conductivity.
All cable screens, entering the cabinet, must be connected to the control cabinets ground busbar.
To ensure that the screen of the individual cable is connected solidly and with good conductivity to
the ground busbar, galvanised cable brackets as shown in Figure H-1 are recommended.
This applies also for coaxial cable, at which only the outer insulation should be removed.
Cable Glands
Use suitable EMC-tested cable glands only
The conductivity of the screen ground connection is ensured by laying the braid over a plastic cone
which will press it to the inner side of the gland when mounted. It is important that the connection
area is 360 degree around the cone. The cable glands provide pull-relief through the cable jacket.
Configuration
Cabinet
1U, 1V, 1W
Panel
AC-reactor
Converter
K1 AC-Input contactor
SCR-protecting fuses
1C, 1D 3C, 3D
RFI Filter
or
HF Filter
Circuit breaker
2
Cable bracket
3 Screen
4 Screened 3-wire
motor armature cable
5
Shielded 2-wire
6 motor field cable
PE Shielded signal
G conductor cable
M (feedback, reference)
EMC-tested armoured
- cable gland at terminal box
Wiring Instruction
Motor Cable
The cables between cabinet / armature output and DC-motor armature shall be 3-wire screened cable
(+, - and earth conductor green/yellow) as specified in Figure H-2.
The cables between field supply output and DC-motor field shall be 2-wire screened cable.
The screen must be tinned copper braid or tinned steel braid. It must be solidly connected to the
control cabinet ground busbar or ground stud of the converter with large connection area and good
conductivity.
The screen on the motor side must be solidly connected to the motor housing providing large
connection area with good conductivity.
If screened cables are not available (limited by the obtainable cross sections) the individual
conductors and protective conductors must be run in steel conduits or enclosed metal cable ducts
also connected to ground at both ends.
All leads shall have the same cross section
(earth conductors with cross section. >162 : min. 162 or 50% of armature lead)
The connections between filter and converter should be as short as possible!!
These conductors must be bound together (with tie wrap) forming a triangle in cross section.
Plastic insulation
Corporate Headquarters
Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, 53202-5302 USA, Tel: (1) 414.212.5200, Fax: (1) 414.212.5201
Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing Solutions
Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444
Europe/Middle East/Africa: Rockwell Automation SA/NV, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640
Asia Pacific: Rockwell Automation, 27/F Citicorp Centre, 18 Whitfield Road, Causeway Bay, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846