soc-iiThe information below summarizes the changes to the PowerFlex DigitalDC Drive User Manual,publication 20-UM001...since the initial release.ChangePage(s)Removed erroneous derating information12A1Updated "AnalogCflct"Alarm description to include parameters 1323-1327 [DPI Px4-7Select].Updated Agency Certification Information.A-1Updated the Maximum Short Circuit Ratings data.Added footnote regarding coil voltage to DC Loop Contactor table information.A-19Updated block diagrams to correct parameter numbers and names.D-2Table of ContentsImportant User Information1-2Summary ofManual Updates...........Soc-iChangesPrefaceOverviewWho Should Use this Manual?.............................................p-1What is in this Manual?...................................................p-lDrive Storage Conditions ................................................p-1Drive Nameplate Data....................................................Reference Materials ....................................................p-2Manual Conventions.…p-3General Precautions…p-3Catalog Number Explanation ...........p-4Chapter 1Installation and WiringMounting Considerations.................................................1-2Operating Conditions and Temperatures.........................1-2Minimum Mounting Clearances......··1-2Mounting Dimensions and Weights1-3Lifting PowerFlex DC Drives..............................................1-5Mounting Frame C Drives................1-6Removing the Drive Covers........................................1-71-7Frame B and C Drives..................................................1-8Line Reactors /Filters..........1-9Using Contactors..…1-9AC Input Contactors.………1-101-10Dynamic Brake Resistors....................1-10Control Power Protection................................................1-11General Grounding Requirements...............1-12Safety Ground (PE)...................................................1-12Power Feeder.…1-131-13Tachometer Ground Connections........................................1-131-13Cable and Wiring Remendations ......................................1-14Power Wiring.……1-151-151-16Typical Power Wiring Diagrams...............................1-17Armature Converter Connections...............................1-20Field Circuit Connections...............1-23Field Current Resistors.................1-241-25Thermistors and Thermal Switches.......................................1-25Control Circuit Input Power............................................1-28Frame C Heatsink Cooling Fans and Armature Fuse Signal Terminals...........1-3121-32DIP Switch and Jumper Settings.........................................1-32I/O Signal and Control Wiring...........................................1-351-37Digital Encoder Terminal Block .......1-40DC Analog Tachometer Terminal Block..................................1-42I/O and Control Wire Routing...........................................1-42Chapter 2Drive Start UpDrive Start Up Checklist .................................................2-2Before Applying Power to the Drive.........................................2-2Applying Power to the Drive.……2-42-18Configuring the Speed Zero Logic.......................................2-18Adaptive Speed Regulation...........2-18Chapter 3Programming and ParametersAbout Parameters.…3-1How Parameters are Organized.............................................3-3File-Group-Parameter Order............................................3-3Numbered List View...................................................3-3Cross Reference Tables.................................................3-3Basic Parameter View...................................................3-4Advanced Parameter View...............................................3-6Monitor File ........................................................3-11Motor Control File ...................................................3-14Speed Command File.................................................3-23Dynamic Control File.................................................3-293-46Communications File3-58nput/Output File……3-62Parameter Cross Reference-by Name......................................3-72Parameter Cross Reference-by Number.............................3-77Chapter 4TroubleshootingFaults and Alarms…4-1Drive Status……4-24-3Manually Clearing Faults...................4-34-44-7Alarm Descriptions ...........47Common Drive Symptoms and Corrective Actions............................4-10Drive will not start....................................................4-10Drive starts but motor does not turn and no armature current...................4-12The motor does not reach manded speed................................4-13The motor is turning in the wrong direction.................................4-13The motor reaches maximum speed immediately.............................4-14Testpoint Codes and Functions............................................4-14Appendix ASupplemental Drive InformationSpecifications .........................................................A-1IP20 (NEMA UL/Type Open)Watts Loss....................................A-4Communication Configurations ...........................................A-5Typical Programmable Controller Configurations............................A-5Logic Command/Status Words...........................................A-5Drive Power Circuit Protection.............................................A-7Frame A and B Fuse Information ........................................A-7Frame C Fuse Information ............................................A-11Control Power Circuit Protection Fuses.....................................A-15AC Input Line Reactors and AC Input Contactors.............................A-17DC Output Contactors and Dynamic Brake Resistor Kits.................A-19DC Contactor Crimp Lug Kit Specifications.................................A-21Appendix BHIM OverviewExternal and Internal Connections..........................................B-1LCD Display Elements...................................................B-1ALT Functions.…B-2Using the S.M.A.R.T.List Screen.........................................B-2Menu Structure.........................................................B-3Viewing and Editing Parameters...............................B-5B-5Removing/Installing the HIM.................................B-6Appendix CApplication NotesAnalog Input Configuration ..............................................C-1Example 1:.…C-1Example2............................................................C-2Analog Input Signal Comparison.........................................C-2Droop Compensation....................................................C-5Field Weakening Mode Configuration (v1.006)................................C-5Usinga DC Contactor Only.............................................C-6Using a DC Contactor and a Dynamic Brake................................C-6Using an Inverting Fault Device Only......................................C-6Usinga DC Contactor and an Inverting Fault Device..........................C-7Using a DC Contactor,a Dynamic Brake and an Inverting Fault Device...........C-7PIDFuction...........................................................C-8Configure a Line Speed Signal...........................................C-9Configure the Feedback Signal in the Follower Drive(s)......................C-10Configure the Tension Set Point Signal in the Follower Drive(s)................C-12Reference Control.…C-13“Auto”Speed Sources.C-13Manual”Speed Sources.C-13Changing Speed Sources.........................................C-13Torque Reference Source ...................................C-14Auto/Manual Examples......................................C-14C-15Scale Blocks..…C-16Linking Parameters Via the Scale Block Parameters ........................C-174C-17Adaptive Speed Regulator..............................................C-17Speed Up Function..……C-20Speed Threshold Indicators.............................................C-20Speed Zero Function............................................C-22Fine Tuning the Regulators...............................................C-25Manually Adjusting the Current Regulator Tune Settings......................C-26Fine Tuning the Field Current Regulator...................................C-26Fine Tuning the Speed Regulator.........................................C-29Fine Tuning the Voltage Regulator in the Field Converter.....................C-31Tuning the Field Current Curve..........................................C-33Appendix DControl Block DiagramsDiagram Conventions......D-1Appendix EInstalling a Communication AdapterCommunication Adapter Kits.................E-1What The Communication Adapter Kit Includes...............................E-1Tools That You Need.....................................................E-ISafety Precautions........................................................E-2Installing the Communication Adapter Module in the Drive......................E-2Appendix FOptional Analog and Digital l/O Expansion Circuit BoardWhat This Option Board Provides...........................................F-1I/O Expansion Board Wiring...............................................F-IAppendix GOptional 115V AC to 24V DC I/O Converter Circuit BoardWhat This Option Board Provides...........................................G-1I/OConverter Board Wiring...............................................G-2IndexPrefaceOverviewThe purpose of this manual is to provide you with the basic informationneeded to install,start-up and troubleshoot the PowerFlex DC drive.For information on...See page...Who Should Use this Manual?Preface-1What is in this Manual?Preface-1Drive Storage ConditionsPreface-1Drive Nameplate DataPreface-2Reference MaterialsPreface-2Drive Frame SizesPreface-2Manual ConventionsPreface-3General PrecautionsPreface-3Catalog Number ExplanationPreface-4Who Should Use thisThis manual is intended for qualified personnel.You must be able toManual?program and operate DC drives.In addition,you must have anunderstanding of the parameter settings and functions detailed in thismanual.What is in this Manual?The PowerFlex DC User Manual is designed to provide installation,basicstart-up information,and drive parameter definitions.For detailed driveinformation,please refer to "Reference Materials"on page Preface-2 for alist of additional publications.Drive Storage ConditionsIf it is necessary to store the drive for any length of time before installation,follow these storage guidelines in order to ensure satisfactory operation atstart up and to maintain warranty coverage:After receipt and inspection,repack the drive in its original shippingcontainer and store in a clean,dry place.Place where the ambient temperatures do not exceed-25C(-13F)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.OverviewDrive Nameplate DataThe PowerFlex DC drive contains a data nameplate located on the side ofeach drive that identifies the specific model number design,applicable ACinput power and DC output power data.All munication with RockwellAutomation personnel concerning this product should include thisinformation.Series:ANote:CertificationMarks Location.Refer to the datanameplate labelon your drive forcertifications.ANen-BradeyDrive Frame SizesSimilar PowerFlex DC drive sizes are grouped into frame sizes to simplifyspare parts ordering,dimensioning,etc.Refer to the Catalog NumberExplanation on page Preface-4 for a list of drive catalog numbers and theirrespective frame sizes.Reference MaterialsThe following manuals are remended for general drive information:TitlePublicationAvailable Online at...Preventive Maintenance of Industrial Control andDRIVES-TD001...Drive System EquipmentSafety Guidelines for the Application.InstallationSGI-1.1and Maintenance of Solid State Controlwww.rockwellautomation./literatureA Global Reference Guide for Reading Schematic100-2.10DiagramsGuarding Against Electrostatic Damage80004.5.2For Allen-Bradley Drives Technical Support:TitleOnline at...Allen-Bradley Drives Technical Support www.ab./support/abdrivesOverviewManual ConventionsTo help differentiate parameter names and LCD display text from othertext,the following conventions will be used:Parameter Names will appear in [brackets].For example:[Armature Voltage].-Display Text will appear in“quotes.”For example:“Enabled.”The following words are used throughout the manual to describe anaction:WordMeaningCanPossible,able to do somethingCannotNot possible,not able to dosomethingMayMustUnavoidable,you must do thisShallRequired and necessaryShouldRemendedShould Not Not remendedGeneral PrecautionsATTENTION:This drive contains ESD(ElectrostaticDischarge)sensitive parts and assemblies.Static controlprecautions are required when installing,testing,servicing orrepairing this assembly.Component damage may result if ESDcontrol procedures are not followed.If you are not familiar withstatic control procedures,reference A-B publication 8000-4.5.2,"Guarding Against Electrostatic Damage"or any other applicableESD protection handbook.ATTENTION:An incorrectly applied or installed drive canresult in ponent damage or a reduction in product life.Wiringor application errors,such as,undersizing the motor,incorrect orinadequate AC supply,or excessive surrounding air temperaturesmay result in malfunction of the system.ATTENTION:Only qualified personnel familiar with DC drivesand associated machinery should plan or implement theinstallation,start-up and subsequent maintenance of the system.Failure to ply may result in personal injury and/or equipmentdamage.ATTENTION:An incorrectly applied or installed bypass systemcan result in ponent damage or reduction in product life.Themost mon causes are:Wiring AC line to drive output or control terminals.Improper bypass or output circuits not approved byAllen-Bradley.Output circuits which do not connect directly to the motor.Contact Allen-Bradley for assistance with application or wiring.OverviewCatalog NumberExplanationPosition1-38101113151620P41AD4P1RN0Na6egaf1gDriveField SupplyCodeTypeCodeArmatureCodeHpAmpsFrameTypePowerFlex DCAmpsAThee-Phase Regulated7P0157A10F29A10Single-Phase Regulated6012312A10Motor Operation020520100297529A10hCodeType2Two Quadrant Operation0381038A10Packaging/Documentation4User ManualFour Quadrant Operation0551555A10Code Shipping Carton0732073A140NoNo0932593A14AYesYes11030110A14NNoInput Type14640146B20No色CodeType1805018020121860218B20212 Pulse26575265B20360100360B20HIM434125434B20CodeOperator Interfaced521150521200*Standard -for additional selections refer to thePowerFlex Digital DC Drive Technical Data,CodeEndosure RatingConform.publication 20P-TD001...Coatf2AIP20,NEMA/UL Type OpenNo460W60H位InputIP43,NEMA/UL Type 1-NoCodeFrameFieldFilterHpAmpsAmpsGIP54,NEMA/UL Type 12No4P124.1A10CodeControlIP54,NEMA/UL Type 12-No6P036A10010510A10ANNo0147514A10Outputs)0191019A1115V ac Conversion Card (8 Digital1510Inputs &Outputs)02727Ae0352035A10ConversionInput Voltage0452545A10None (8-24V dc Digital InputsCodeVoltage0523052A10Outputs,3 Analog Outputs and 2B073407314Analog Inputs are Standard)5086A1410060100A14E12975129A14690V acCommunication Options167100167B20CodeDescription207125207B20NNone*250150250B20*Standard -for additional selections refer to the330200330B20PowerFlex Digital DC Drive Technical Data,412250412B20publication 20P-TD001...4953004952066740066720Cabi OptionsCodeTypeNNone