Rockwell Automation PowerFlex series Manuale utente

USER MANUAL

Firmware Version 1.006 - 2.001

PowerFlex® Digital DC Drive

PowerFlex Digital DC Drive User Manual

Important User Information Solid state equipment has operational characteristics differing from those of

electromechanical equipment. Safety Guidelines for the Application,

Installation and Maintenance of Solid State Controls (Publication SGI-1.1

available from your local Rockwell Automation sales office or online at http://

www.rockwellautomation.com/literature) describes some important differences

between solid state equipment and hard-wired electromechanical devices.

Because of this difference, and also because of the wide variety of uses for solid

state equipment, all persons responsible for applying this equipment must

satisfy themselves that each intended application of this equipment is

acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect

or consequential damages resulting from the use or application of this

equipment.

The examples and diagrams in this manual are included solely for illustrative

purposes. Because of the many variables and requirements associated with any

particular installation, Rockwell Automation, Inc. cannot assume responsibility

or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use

of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without

written permission of Rockwell Automation, Inc. is prohibited.

Throughout this manual, when necessary we use notes to make you aware of

safety considerations.

Important: Identifies information that is critical for successful application and

understanding of the product.

PowerFlex, DriveExplorer, DriveTools SP, DPI, and SCANport are either trademarks or registered trademarks of Rockwell Automation, Inc.

Klixon®is a registered trademark of Sensata Technologies, Inc.

!WARNING: Identifies information about practices or

circumstances that can cause an explosion in a hazardous

environment, which may lead to personal injury or death, property

damage, or economic loss.

!ATTENTION: Identifies information about practices or

circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you identify a hazard,

avoid a hazard, and recognize the consequences.

Shock Hazard labels may be located on or inside the equipment

(e.g., drive or motor) to alert people that dangerous voltage may be

present.

Burn Hazard labels may be located on or inside the equipment

(e.g., drive or motor) to alert people that surfaces may be at

dangerous temperatures.

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Summary of Changes

Manual Updates The information below summarizes the changes to the PowerFlex Digital

DC Drive User Manual, publication 20-UM001… since the October 2007

release.

Change Page(s)

Updated the Using Contactors section to include new Contactor Control selections

for configuring AC versus DC contactors.

1-9

Added the “Cable and Wiring Recommendations” table. 1-14

Updated the “Typical Power Wiring Diagrams” to include terminal and parameter

designations.

1-17

Added “Sourcing Digital Outputs, 24V DC external supply” diagram to I/O Wiring

examples.

1-39

Added an illustration and instructions for routing I/O and control wiring. 1-42

Added a graphical indicator for parameters accessible only when parameter 211

[Param Access Lvl] = 1 “Advanced”.

3-1

Added parameter 1409 [Jog Off Delay], to allow you to specify the minimum delay

between removing the Jog input and commanding the main contactor to open.

This delay reduces the wear on the contactor when repeatedly opening and

closing the Jog input over a short period of time.

3-24

Added parameter 1410 [Jog Ramp Time], to allow you to set the rate of

acceleration and deceleration while the Jog function is active.

3-29

Changed option 3 "Quick Stop" to "Fast Stop" for parameters 354 [Aux Inp Flt Cfg]

and 365 [OverTemp Flt Cfg].

3-53

Changed option 35 “Fld Weak En” to “Force MinFld” for parameters 133-144

[Digital Inx Sel].

3-65

Added option 64 “Invert Flt” to parameters 133-144 [Digital Inx Sel], to allow a

digital input wired to an inverting fault device to issue an “Inverting Fault” (F37).

3-65

Updated the options for parameter 1391 [ContactorControl] to accommodate the

use of a AC or DC contactor with or without a dynamic brake resistor.

3-67

Added the new “Inverting Fault” (F37) fault to indicate that the associated inverting

fault device has opened.

4-5

Updated the following drive specifications:

•Maximum short circuit rating

•Control speed regulation

•Torque regulation

A-2

Updated the fuses identified in the “Drive Power Circuit Protection” tables. A-7

Updated the “Control Power Circuit Protection Fuses” tables and fuse location

illustrations.

A-15

Added the “Lug Kit Specifications” table. A-21

Added the instructions for operating the PowerFlex DC drive in field weakening

mode and using a DC contactor and/or an inverting fault device in the armature

circuit with firmware version 1.006.

C-5

Updated the “Fine Tuning the Speed Regulator” procedure. C-29

Updated the terminal numbers indicated in the Digital Inputs/Outputs block

diagram.

D-3

Updated the Ramp Reference block diagram to include the new parameter 1410

[Jog Ramp Time].

D-7

Removed the 20-COMM-L communication adapter from the compatible

Communication Adapter Kits table.

E-1

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

soc-ii

The information below summarizes the changes to the PowerFlex Digital

DC Drive User Manual, publication 20-UM001… since the initial release.

Change Page(s)

Removed erroneous derating information. 1-2, A-1

Updated AC Input Voltages tables. 1-15

Updated “AnalogCflct” Alarm description to include parameters 1323-1327 [DPI Px

Select].

4-7

Updated Agency Certification Information. A-1

Added notation regarding required installation in a Pollution Degree 2 environment. A-1

Updated the Maximum Short Circuit Ratings data. A-2

Added footnote regarding coil voltage to DC Loop Contactor table information. A-19

Updated block diagrams to correct parameter numbers and names. D-2

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Table of Contents

Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Summary of

Changes

Manual Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . soc-i

Preface Overview

Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1

What is in this Manual?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1

Drive Storage Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1

Drive Nameplate Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-2

Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-2

Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-2

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-3

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-3

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-4

Chapter 1 Installation and Wiring

Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Operating Conditions and Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Mounting Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Lifting PowerFlex DC Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Mounting Frame C Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Removing the Drive Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Frame A Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Frame B and C Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Line Reactors / Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Using Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

AC Input Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

DC Output Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Dynamic Brake Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Control Power Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

General Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Safety Ground (PE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Power Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Encoder Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Tachometer Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Power Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Cable and Wiring Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

AC Input Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

DC Output Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Typical Power Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Armature Converter Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Field Circuit Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Field Current Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Thermistors and Thermal Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Control Circuit Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

Frame C Heatsink Cooling Fans and Armature Fuse Signal Terminals . . . . . . . . . . . 1-31

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

DIP Switch and Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

I/O Signal and Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35

I/O Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

Digital Encoder Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40

DC Analog Tachometer Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

I/O and Control Wire Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

Chapter 2 Drive Start Up

Drive Start Up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Before Applying Power to the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Applying Power to the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Speed-Up Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Configuring the Speed Zero Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Adaptive Speed Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Chapter 3 Programming and Parameters

About Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

How Parameters are Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

File–Group–Parameter Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Numbered List View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Cross Reference Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Basic Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Advanced Parameter View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Monitor File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Motor Control File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Speed Command File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Dynamic Control File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Applications File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Utility File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Communications File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Input / Output File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

Parameter Cross Reference – by Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

Parameter Cross Reference – by Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77

Chapter 4 Troubleshooting

Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

HIM Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Manually Clearing Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Clearing Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Alarm Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Common Drive Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Drive will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Drive starts but motor does not turn and no armature current. . . . . . . . . . . . . . . . . . . 4-12

The motor does not reach commanded speed.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

The motor is turning in the wrong direction.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

The motor reaches maximum speed immediately.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Testpoint Codes and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Appendix A Supplemental Drive Information

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

IP20 (NEMA UL/Type Open) Watts Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Typical Programmable Controller Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Logic Command/Status Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Drive Power Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Frame A and B Fuse Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Frame C Fuse Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

Control Power Circuit Protection Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15

AC Input Line Reactors and AC Input Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17

DC Output Contactors and Dynamic Brake Resistor Kits . . . . . . . . . . . . . . . . . . . . . . . A-19

DC Contactor Crimp Lug Kit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21

Appendix B HIM Overview

External and Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

LCD Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

ALT Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Using the S.M.A.R.T. List Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Viewing and Editing Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

LCD HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Removing/Installing the HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Appendix C Application Notes

Analog Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Example 1:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Example 2:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Analog Input Signal Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Current / Speed Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Droop Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Field Weakening Mode Configuration (v1.006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Using a DC Contactor Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

Using a DC Contactor and a Dynamic Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

Using an Inverting Fault Device Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

Using a DC Contactor and an Inverting Fault Device. . . . . . . . . . . . . . . . . . . . . . . . . . C-7

Using a DC Contactor, a Dynamic Brake and an Inverting Fault Device . . . . . . . . . . . C-7

PID Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8

Configure a Line Speed Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9

Configure the Feedback Signal in the Follower Drive(s) . . . . . . . . . . . . . . . . . . . . . . C-10

Configure the Tension Set Point Signal in the Follower Drive(s). . . . . . . . . . . . . . . . C-12

Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13

“Auto” Speed Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13

“Manual” Speed Sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13

Changing Speed Sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13

Torque Reference Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14

Auto/Manual Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14

Speed Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-15

Scale Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16

Linking Parameters Via the Scale Block Parameters . . . . . . . . . . . . . . . . . . . . . . . . . C-17

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Speed Regulation Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-17

Adaptive Speed Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-17

Speed Up Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-20

Speed Threshold Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-20

Speed Zero Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-22

Speed Draw Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-23

Start At Powerup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-24

Fine Tuning the Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-25

Manually Adjusting the Current Regulator Tune Settings. . . . . . . . . . . . . . . . . . . . . . C-26

Fine Tuning the Field Current Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-26

Fine Tuning the Speed Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-29

Fine Tuning the Voltage Regulator in the Field Converter . . . . . . . . . . . . . . . . . . . . . C-31

Tuning the Field Current Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33

Appendix D Control Block Diagrams

Diagram Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Appendix E Installing a Communication Adapter

Communication Adapter Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

What The Communication Adapter Kit Includes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

Tools That You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Installing the Communication Adapter Module in the Drive . . . . . . . . . . . . . . . . . . . . . . E-2

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

What This Option Board Provides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

I/O Expansion Board Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

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

What This Option Board Provides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

I/O Converter Board Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2

Index

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

Preface

Overview

The purpose of this manual is to provide you with the basic information

needed to install, start-up and troubleshoot the PowerFlex DC drive.

Who Should Use this

Manual?

This manual is intended for qualified personnel. You must be able to

program and operate DC drives. In addition, you must have an

understanding of the parameter settings and functions detailed in this

manual.

What is in this Manual? The PowerFlex DC User Manual is designed to provide installation, basic

start-up information, and drive parameter definitions. For detailed drive

information, please refer to “Reference Materials” on page Preface-2 for a

list of additional publications.

Drive Storage Conditions If it is necessary to store the drive for any length of time before installation,

follow these storage guidelines in order to ensure satisfactory operation at

start up and to maintain warranty coverage:

•After receipt and inspection, repack the drive in its original shipping

container and store in a clean, dry place.

•Place where the ambient temperatures do not exceed -25°C (-13°F) or

+55°C (131°F)

•Place where the relative air humidity range does not exceed 5% - 95%.

•At an altitude of less than 3,000 meters (10,000 ft.) above sea level.

For information on . . . See page . . .

Who Should Use this Manual? Preface-1

What is in this Manual? Preface-1

Drive Storage Conditions Preface-1

Drive Nameplate Data Preface-2

Reference Materials Preface-2

Drive Frame Sizes Preface-2

Manual Conventions Preface-3

General Precautions Preface-3

Catalog Number Explanation Preface-4

PowerFlex Digital DC Drive User Manual - Publication 20P-UM001C-EN-P - July 2008

p-2 Overview

Drive Nameplate Data The PowerFlex DC drive contains a data nameplate located on the side of

each drive that identifies the specific model number design, applicable AC

input power and DC output power data. All communication with Rockwell

Automation personnel concerning this product should include this

information.

Drive Frame Sizes Similar PowerFlex DC drive sizes are grouped into frame sizes to simplify

spare parts ordering, dimensioning, etc. Refer to the Catalog Number

Explanation on page Preface-4 for a list of drive catalog numbers and their

respective frame sizes.

Reference Materials The following manuals are recommended for general drive information:

For Allen-Bradley Drives Technical Support:

EXAMPLE ONLY

20P41AD4P1RA0NNN

Made in Italy

Output: 500VDC 4.1A REGEN 1.0HP

1 Min Overload Amps

3 Sec Overload Amps

MFD. in 2XXX on MMM DD

Cat No.

Input: 460VAC 50/60 Hz 3.3A 3 Phase

UL Type OPEN/IP20

Original Firmware V. 1.001

Serial Number: A23E0042

Series: A

Frame: A

6.2

8.2

I/O: 24VDC (Standard)

Ind. Cont.

Listed

DC Field:

Input: 460VAC 50/60 Hz 10A max. 1 Phase

Output: 360VDC 10A max.

Regulator Power: 115/230VAC 50/60 Hz 1.0/0.5A 1 Phase

Eq. 31KF

N223

Note: Certification

Marks Location.

Refer to the data

nameplate label

on your drive for

actual agency

certifications.

Title Publication Available Online at . . .

Preventive Maintenance of Industrial Control and

Drive System Equipment

DRIVES-TD001…

www.rockwellautomation.

com/literature

Safety Guidelines for the Application, Installation

and Maintenance of Solid State Control

SGI-1.1

A Global Reference Guide for Reading Schematic

Diagrams

100-2.10

Guarding Against Electrostatic Damage 8000-4.5.2

Title Online at . . .

Allen-Bradley Drives Technical Support www.ab.com/support/abdrives

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