Bardac PLX User manual

1
Part 1
PL / PLX
DigitalDC Drive
Part 2
Application Blocks
Part 3
High PowerModules
PL / PLX DigitalDC Drive
Part 1
HG 102 633 v5.1 5i

2 Contents

Contents 3
NOTE. These instructions do not purport to cover all details or variations in equipment, or to provide for every
possible contingency to be met in connection with installation, operation, or maintenance. Should further
information be desired or should particular problems arise which are not covered sufficiently for the
purchaser's purposes, the matter should be referred to the localSupplier sales office. The contents of this
instruction manualshall not become part of or modify any prior or existing agreement, commitment, or
relationship. The sales contract contains the entire obligation of Sprint Electric Ltd. The warranty contained
in the contract bet w een the parties is the sole warranty of Sprint Electric Ltd. Any statements contained
herein do not create ne w w arranties or modify the existing warranty.
IMPORT A NT MESS A GE This is a version 5.15 manual. Version 5. 17 and above soft w are has all the
functions described. See 5.1.7 Finding the softw are version number of the unit.
DO YOU NEED HELP?See 14.13 What to do in the event of a problem.
Other PL/X manuals. Part 2 APPLIC A TION BLO CKS, Part 3 PL/X 275-98 0 (from 650 A to 2250 A), SERIAL
C O MMS and ST A C K DRIV ER. All also available to download from the internet at w w w.sprint-electric.com
1 Tableof contents
1Tableof contents...............................................................................................3
2Warnings ........................................................................................................13
2.1 GeneralWarnings ............................................................................................................... 13
2.2 Warnings and Instructions ................................................................................................... 14
2.3 GeneralRisks..................................................................................................................... 15
2.4 Summary of further WARNINGS ........................................................................................... 16
3Introduction and TechnicalData........................................................................19
3.1 Introduction....................................................................................................................... 20
3.2 How do they work? ............................................................................................................ 20
3.2.1 Usefulthings to know about the PL/X................................................................................ 21
3.2.2 Tips for using the manual................................................................................................. 21
3.3 GeneralTechnicalData........................................................................................................ 22
3.3.1 Regenerative stopping with PL models ............................................................................... 22
3.3.2 Supply voltages required for all models .............................................................................. 22
3.3.3 Controlterminals electricalspecification............................................................................ 24
3.4 Controlterminals overview. ................................................................................................. 25
3.4.1 Generalrequirements....................................................................................................... 25
3.4.2 Digitalinputs and outputs ................................................................................................ 25
3.4.2.1 Encoder inputs........................................................................................................ 26
3.4.2.2 Digitaloutputs ........................................................................................................ 26
3.4.3 Analogue inputs.............................................................................................................. 26
3.4.4 Analogue tachogenerator input ......................................................................................... 27
3.4.5 Signaltest pins............................................................................................................... 27
3.5 Controlterminaldefault functions ......................................................................................... 27
3.5.1 Run, Jog, Start, Cstop..................................................................................................... 29
3.5.2 Summary of default terminalfunctions............................................................................... 31
3.6 Supply loss shutdown ......................................................................................................... 32
4Basicapplication..............................................................................................33
4.1 Basic speed or torque control............................................................................................... 34
4.2 Main Contactor operation .................................................................................................... 35
4.2.1 Contactor controlquestions and answers ........................................................................... 35
4.3 Main contactor wiring options .............................................................................................. 37
4.3.1 Main contactor isolating AC stack supply ........................................................................... 37

4 Contents
4.3.2 Main contactor isolating AC stack and auxiliary supplies .......................................................37
4.3.3 Main contactor isolating DC armature.................................................................................38
4.3.4 Using pushbuttons for simple ST OP / S T ART (Coast to stop)................................................. 39
4.3.5 Using pushbuttons for ST OP / S T ART (With ramp to stop, jog and slack take up)..................... 40
4.4 ESSENTIAL pre-start checks.................................................................................................41
4.4.1 POWER ENGINEERING .....................................................................................................41
4.4.2 MECHANICAL ENGINEERING ............................................................................................41
4.5 C ON TROL ENGINEERIN G C O MMISSIONIN G PRO CED URES ....................................................... 4 2
4.5.1 Quick start calibration ......................................................................................................42
4.5.2 Quick start calibration step by step ....................................................................................43
4.5.3 Quick start current loop AUTOTUNE ..................................................................................43
4.5.4 PASSIVE MO TOR defaults / Using passive motor menu for small test motors........................... 44
5Menu tree structure......................................................................................... 45
5.1 Key functions .....................................................................................................................46
5.1.1 Incrementing and decrementing parameter values. ...............................................................47
5.1.2 PARAMETER SAVE..........................................................................................................47
5.1.3 Restoring the drive parameters to the default condition.........................................................47
5.1.4 Branch hopping bet w een monitor windows .........................................................................47
5.1.5 Po wer up windows ..........................................................................................................47
5.1.6 Default % DIA GN O STIC summary windows ........................................................................48
5.1.7 Finding the soft w are version number of the unit. .................................................................48
5.2 ENTRY MENU..................................................................................................................... 48
5.2.1 Full menu diagram (Change parameters)..............................................................................49
5.2.2 Full menu diagram (Change parameters continued)...............................................................50
5.2.3 Full menu diagram (Diagnostics) ........................................................................................51
5.2.4 Full menu diagram (Motor drive alarms, seriallinks and display functions)................................52
5.2.5 Full menu diagram (Application blocks and configuration)......................................................53
5.2.6 Full menu diagram (Configuration continued) .......................................................................54
5.2.7 Full menu diagram (Block OP and Fieldbus configs, Drive personality and Conflict Help) ............ 55
5.3 Archiving PL/X recipes......................................................................................................... 56
6CHANGE PARAMETERS................................................................................... 57
6.1 CHANGE PARAMETERS / CALIBRATION ................................................................................59
6.1.1 C ALIBRA TIO N / Block diagram ..........................................................................................60
6.1.2 C ALIBRA TIO N / Rated armature amps PIN 2 Q UIC K S T ART ............................................... 6 0
6.1.3 C ALIBR A TIO N / Current limit (%) PIN 3 Q UIC K S T ART ..................................................... 6 1
6.1.4 C ALIBR A TIO N / Rated field amps PIN 4 Q UIC K S T ART ..................................................... 61
6.1.5 C ALIBR A TIO N / Base rated motor rpm PIN 5 Q UIC K ST ART .............................................. 6 2
6.1.6 C ALIBR A TIO N / Desired max rpm PIN 6 Q UIC K ST ART ..................................................... 6 2
6.1.7 C ALIBRA TIO N / Zero speed offset PIN 7 ........................................................................... 6 2
6.1.8 C ALIBRA TIO N / Max tacho volts PIN 8 .............................................................................63
6.1.9 C ALIBRA TION / Speed feedback type PIN 9 Q UIC K S T ART ............................................... 64
6.1.10 C ALIBRA TIO N / EN CO DER S C ALIN G ................................................................................ 65
6.1.10.1 ENC ODER SC ALIN G / Quadrature enable PIN 10 ......................................................66
6.1.10.2 ENC ODER SC ALING / Encoder lines PIN 11 .............................................................67
6.1.10.3 ENC ODER SC ALING / Motor / encoder speed ratio PIN 12 ......................................... 67
6.1.10.4 ENC ODER SC ALIN G / Encoder sign PIN 13 ..............................................................67
6.1.11 C ALIBRA TIO N / IR compensation PIN 14.........................................................................68
6.1.12 C ALIBRA TIO N / Field current feedback trim PIN 15 ..........................................................68
6.1.13 C ALIBRA TIO N / Armature volts trim PIN 16.....................................................................68
6.1.14 C ALIBRA TIO N / Analog tacho trim PIN 17.......................................................................69
6.1.15 C ALIBRA TIO N / Rated armature volts PIN 18 Q UIC K ST ART ........................................... 69
6.1.16 C ALIBRA TIO N / EL1/2/3 rated A C volts PIN 19 Q UIC K S T ART ........................................ 6 9
6.1.17 C ALIBRA TIO N / Motor 1 or 2 select PIN 20.....................................................................70
6.2 C H A NGE PAR A METERS / RUN M ODE RA MPS ........................................................................ 71
6.2.1 RU N M ODE R A MPS / Block diagram including JOG ..............................................................72
6.2.2 RU N M ODE R A MPS / Ramp output monitor PIN 21 ............................................................73
6.2.3 RU N M ODE R A MPS / Forw ard up time PIN 22 ...................................................................73

Contents 5
6.2.4 RU N M ODE R A MPS / Forw ard do w n time PIN 23 .............................................................. 73
6.2.5 RU N M ODE R A MPS / Reverse up time PIN 24................................................................... 73
6.2.6 RU N M ODE R A MPS / Reverse do w n time PIN 25 .............................................................. 73
6.2.7 RU N M ODE R A MPS / Ramp input PIN 26 ......................................................................... 74
6.2.8 RU N M ODE R A MPS / For w ard minimum speed PIN 27 ....................................................... 74
6.2.9 RU N M ODE R A MPS / Reverse minimum speed PIN 28 ....................................................... 74
6.2.10 RUN M ODE RA MPS / Ramp automatic preset PIN 29 ....................................................... 75
6.2.11 RUN M ODE RA MPS / Ramp externalpreset PIN 30.......................................................... 75
6.2.12 RUN M ODE RA MPS / Ramp preset value PIN 31.............................................................. 75
6.2.13 RUN M ODE RA MPS / Ramp S-profile % PIN 32............................................................... 75
6.2.14 RUN M ODE RA MPS / Ramp hold enable PIN 33............................................................... 75
6.2.15 RUN M ODE RA MPS / Ramping threshold PIN 34 ............................................................. 76
6.2.16 RUN M ODE RA MPS / Ramping flag PIN 35 ..................................................................... 76
6.3 CH A NGE PARA METERS / JO G CRA WL SLA C K ...................................................................... 77
6.3.1 JOG CRA WL SLA CK / Block diagram including RUN M ODE RA MPS ....................................... 78
6.3.2 JOG CRA WL SLA CK / Jog speed 1 / 2 PINs 37 / 38 .......................................................... 79
6.3.3 JOG CRA WL SLA CK / Slack speed 1 / 2 PINs 39 / 40 ....................................................... 79
6.3.4 JO G CRA WL SLA CK / Cra wlspeed PIN 41....................................................................... 79
6.3.5 JOG CRA WL SLA CK / Jog mode select PIN 42 ................................................................. 80
6.3.6 JOG CRA WL SLA CK / Jog/Slack ramp PIN 43 .................................................................. 80
6.4 CH A NGE PARA METERS / MO TORISED PO T RA MP ................................................................. 8 1
6.4.1 M OT ORISED PO T RA MP / Block diagram............................................................................ 82
6.4.2 M OT ORISED PO T RA MP / MP output monitor PIN 45 ........................................................ 82
6.4.3 M OT ORISED PO T RA MP / MP Up / Do wn time PINs 46 / 47 ............................................... 82
6.4.4 M OT ORISED PO T RA MP / MP Up / Do wn command PINs 48 / 4 9 ....................................... 8 3
6.4.5 M OT ORISED PO T RA MP / MP Maximum / minimum clamps PINs 50 / 51 ............................. 83
6.4.6 M OT ORISED PO T RA MP / MP preset PIN 52..................................................................... 83
6.4.7 M OT ORISED PO T RA MP / MP Preset value PIN 53 ............................................................ 84
6.4.8 M OT ORISED PO T RA MP / MP memory boot up PIN 54 ...................................................... 8 4
6.5 CH A NGE PARA METERS / S TOP MO DE RA MP ........................................................................ 8 5
6.5.1 ST OP MODE RA MP / Block diagram .................................................................................. 85
6.5.1.1 Block diagram of contactor control............................................................................ 86
6.5.1.2 Speed profile when stopping..................................................................................... 87
6.5.1.3 Contactor drop out .................................................................................................. 87
6.5.1.4 Precise stopping...................................................................................................... 88
6.5.2 ST OP MODE RA MP / Stop ramp time PIN 56 .................................................................... 88
6.5.3 ST OP MODE RA MP / Stop time limit PIN 57 ..................................................................... 88
6.5.4 ST OP MODE RA MP / Live delay mode PIN 58 ................................................................... 89
6.5.5 ST OP MODE RA MP / Drop-out speed PIN 5 9 .................................................................... 8 9
6.5.6 ST OP MODE RA MP / Drop-out delay PIN 60 ..................................................................... 89
6.6 CH A NGE PARA METERS / SPEED REF SU MMER...................................................................... 9 0
6.6.1 SPEED REF SUMMER / Block diagram ................................................................................ 90
6.6.2 SPEED REF SUMMER / Internalspeed reference 1 PIN 62 ................................................... 91
6.6.3 SPEED REF SUMMER / Auxiliary speed reference 2 PIN 63 ................................................. 91
6.6.4 SPEED REF SUMMER / Speed reference 3 monitor PIN 64 .................................................. 91
6.6.5 SPEED REF SUMMER / Ramped speed reference 4 PIN 65 .................................................. 91
6.6.6 SPEED REF SUMMER / Speed/Current Reference 3 sign PIN 66 ........................................... 91
6.6.7 SPEED REF SUMMER / Speed/Current Reference 3 ratio PIN 67 .......................................... 92
6.7 CH A NGE PARA METERS / SPEED C ONTROL ........................................................................... 92
6.7.1 SPEED C O N TROL / Block diagram ..................................................................................... 93
6.7.2 SPEED C O N TROL / Max positive speed reference PIN 69 .................................................... 9 3
6.7.3 SPEED C O N TROL / Max negative speed reference PIN 7 0 ................................................... 9 3
6.7.4 SPEED C ON TROL / Speed proportionalgain PIN 71............................................................ 93
6.7.5 SPEED C O N TROL / Speed integraltime constant PIN 72 .................................................... 94
6.7.6 SPEED C O N TROL / Speed integralreset enable PIN 73....................................................... 94
6.7.7 SPEED C ON TROL / SPEED PI AD APTIO N ........................................................................... 9 4
6.7.7.1 SPEED PI AD APTIO N / Lo w break point PIN 74 ......................................................... 95
6.7.7.2 SPEED PI AD APTIO N / High break point PIN 75 ......................................................... 95

6 Contents
6.7.7.3 SPEED PI AD APTIO N / Lo w breakpoint proportionalgain PIN 76 ................................... 95
6.7.7.4 SPEED PI AD APTIO N / Lo w breakpoint integraltime constant PIN 77 ............................ 95
6.7.7.5 SPEED PI AD APTIO N / Integral% during ramp PIN 78................................................. 95
6.7.7.6 SPEED PI AD APTIO N / Speed loop adaption enable PIN 79 ..........................................96
6.7.7.7 SPEED PI AD APTIO N / Using small speed inputs ..........................................................96
6.8 CH A NGE PARA METERS / CURREN T C ON TROL ....................................................................... 97
6.8.1 CURRENT C ONTROL / Block diagram .................................................................................98
6.8.2 CURRENT C ONTROL / Current clamp scaler PIN 81............................................................98
6.8.3 C URRENT C ON TROL / C URREN T O V ERLO A D ...................................................................... 9 8
6.8.3.1 CURREN T O VERLO A D / Overload % target PIN 82 ..................................................... 99
6.8.3.1.1 Diagram sho wing O/LO A D % T ARGET set to 1 05 % ............................................... 99
6.8.3.1.2 How to get overloads greater than 150% using 8 2)O/LO A D % T ARGET .................. 1 00
6.8.3.1.3 Maximum overload table ................................................................................... 100
6.8.3.2 CURREN T O VERLO A D / Overload ramp time PIN 83 ................................................. 100
6.8.4 C URRENT C ON TROL / I DY N A MIC PRO FILE ...................................................................... 1 01
6.8.4.1 I D YN A MIC PRO FILE / Profile enable PIN 84 ............................................................ 101
6.8.4.2 I D YN A MIC PRO FILE / Speed break point for high current limit PIN 85.......................... 102
6.8.4.3 I D YN A MIC PRO FILE / Speed break point for low current limit PIN 86 .......................... 102
6.8.4.4 I DY N A MIC PRO FILE / Profile current for lo w current limit PIN 87 ............................... 102
6.8.5 CURRENT C ONTROL / Dualcurrent clamps enable PIN 88................................................. 102
6.8.6 CURRENT C ONTROL / Upper current clamp PIN 89 .......................................................... 103
6.8.7 CURRENT C ONTROL / Low er current clamp PIN 90.......................................................... 103
6.8.8 CURRENT C ONTROL / Extra current reference PIN 91 ...................................................... 103
6.8.9 CURRENT C ONTROL / Autotune enable PIN 92 ............................................................... 103
6.8.10 CURRENT CONTROL / Current amp proportionalgain PIN 93 ........................................... 104
6.8.11 CURRENT CONTROL / Current amp integralgain PIN 94 ................................................. 104
6.8.12 CURRENT CONTROL / Discontinuous current point PIN 95 .............................................. 105
6.8.12.1 Setting the current loop controlterms manually........................................................ 105
6.8.13 CURRENT CONTROL / 4 quadrant mode enable PIN 96 ................................................... 105
6.8.14 CURRENT CONTROL / Speed bypass current reference enable PIN 97............................... 105
6.9 CH A NGE PARA METERS / FIELD C ONTROL........................................................................... 10 6
6.9.1 FIELD C O N TROL / Block diagram ..................................................................................... 107
6.9.2 FIELD C O N TROL / Field enable PIN 99............................................................................ 108
6.9.3 FIELD C O N TROL / Voltage output % PIN 100 .................................................................. 108
6.9.4 FIELD C O N TROL / Field proportionalgain PIN 101 ............................................................ 108
6.9.5 FIELD C O N TROL / Field integralgain PIN 102 .................................................................. 108
6.9.6 FIELD C O N TROL / FLD WE A KENING MENU....................................................................... 109
6.9.6.1 FLD W E A KENIN G MENU / Field w eakening enable PIN 1 03 ........................................ 11 0
6.9.6.2 FLD W E A KENIN G MENU / Field w eakening proportionalgain PIN 104 ......................... 110
6.9.6.3 FLD W E A KENIN G MENU / Field w eakening integraltime constant PIN 105 .................. 110
6.9.6.4 FLD W E A KENIN G MENU / Field w eakening derivative time constant PIN 106 ............... 110
6.9.6.5 FLD W EA KENIN G MEN U / Field weakening feedback derivative time constant PIN 107 .. 111
6.9.6.6 FLD W E A KENIN G MENU / Field w eakening feedback integraltime constant PIN 108 ..... 111
6.9.6.7 FLD WEA KENING MENU / Spillover armature voltage % PIN 109................................ 111
6.9.6.8 FLD W E A KENING MEN U / Minimum field current % PIN 110 ..................................... 111
6.9.7 FIELD C O N TROL / Standby field enable PIN 111 .............................................................. 112
6.9.8 FIELD C O N TROL / Standby field current PIN 112 ............................................................. 112
6.9.9 FIELD C O N TROL / Quench delay PIN 113 ....................................................................... 112
6.9.10 FIELD CONTROL / Field reference input PIN 114 ............................................................ 112
6.10 CH A NGE PAR A METERS / ZERO IN TERLO C KS ...................................................................... 1 13
6.10.1 ZERO IN TERLO C KS / Block diagram ............................................................................... 114
6.10.2 ZERO INTERLO CKS / Standstill enable PIN 115 .............................................................. 114
6.10.3 ZERO IN TERLO C KS / Zero reference start enable PIN 116 ............................................... 114
6.10.4 ZERO IN TERLO C KS / Zero interlocks speed levelPIN 1 17 ................................................ 11 4
6.10.5 ZERO IN TERLO C KS / Zero interlocks current levelPIN 118 .............................................. 115
6.10.6 ZERO IN TERLO C KS / A t zero reference flag PIN 119 ...................................................... 115
6.10.7 ZERO IN TERLO C KS / A t zero speed flag PIN 120 ........................................................... 115
6.10.8 ZERO INTERLOCKS / At standstill flag PIN 121.............................................................. 115

Contents 7
6.10.8.1 Low speed performance ........................................................................................115
6.10.9 ZERO IN TERLO C KS / SPINDLE ORIEN T A TE ..................................................................... 116
6.10.9.1 SPIN DLE ORIEN T A TE / Block diagram......................................................................117
6.10.9.1.1 Spindle orientate operation................................................................................117
6.10.9.2 SPIN DLE ORIEN T A TE / Zero speed lock PIN 122 .....................................................118
6.10.9.3 SPIN DLE ORIEN T A TE / Marker enable PIN 240 .......................................................118
6.10.9.3.1 Marker specification.........................................................................................118
6.10.9.4 SPIN DLE ORIEN T A TE / Marker offset PIN 2 41 ........................................................1 19
6.10.9.5 SPIN DLE ORIEN T A TE / Position reference PIN 242 ..................................................120
6.10.9.6 SPIN DLE ORIEN T A TE / Marker frequency monitor PIN 24 3 .......................................120
6.10.9.7 SPIN DLE ORIEN T A TE / In position flag PIN 244 ......................................................120
7DIAGNOSTICS...............................................................................................121
7.1 DIA G NO STIC S / SPEED LO OP M O NIT OR ..............................................................................12 2
7.1.1 SPEED LO OP M O NIT OR / Totalspeed reference monitor PIN 123 .......................................122
7.1.2 SPEED LO OP M O NIT OR / Speed demand monitor PIN 1 2 4 ................................................. 12 3
7.1.3 SPEED LO OP M O NIT OR / Speed error monitor PIN 125 .....................................................123
7.1.4 SPEED LO OP M O NIT OR / Armature volts monitor PIN 126.................................................123
7.1.5 SPEED LO OP M O NIT OR / Armature volts % monitor PIN 127.............................................123
7.1.6 SPEED LO OP M O NIT OR / Back emf % monitor PIN 128 ....................................................123
7.1.7 SPEED LO OP M O NIT OR / Tachogenerator volts monitor PIN 129 ........................................124
7.1.8 SPEED LO OP M O NIT OR / Motor RPM monitor PIN 130 .....................................................124
7.1.9 SPEED LO OP M O NIT OR / Encoder RPM monitor PIN 13 2 ...................................................1 24
7.1.10 SPEED LO OP M O NIT OR / Speed feedback % monitor PIN 13 1 .........................................124
7.2 DIA G NO STIC S / ARM I LO OP M O NIT OR ...............................................................................1 25
7.2.1 ARM I LO OP M O NIT OR / Armature current demand monitor PIN 133 ..................................126
7.2.2 ARM I LO OP M O NIT OR / Armature current % monitor PIN 134 ..........................................126
7.2.3 ARM I LO OP M O NIT OR / Armature current amps monitor PIN 135......................................126
7.2.4 ARM I LO OP M O NIT OR / Upper current limit monitor PIN 136 ............................................126
7.2.5 ARM I LO OP M O NIT OR / Lo w er current limit monitor PIN 137............................................126
7.2.6 ARM I LO OP M O NIT OR / Actualprevailing upper/ lo w er current limits PINs 138 / 1 3 9...........12 7
7.2.7 ARM I LO OP M O NIT OR / O verload limit monitor PIN 140...................................................127
7.2.8 ARM I LO OP M O NIT OR / A t current limit flag PIN 141 ......................................................127
7.3 DIA G NO STIC S / FLD I LO OP M O NIT OR ................................................................................1 28
7.3.1 FLD I LO OP MO NITOR / Field demand monitor PIN 143 .....................................................128
7.3.2 FLD I LO OP MO NIT OR / Field current % monitor PIN 144 ..................................................128
7.3.3 FLD I LO OP MO NIT OR / Field current amps monitor PIN 145..............................................128
7.3.4 FLD I LO OP MO NITOR / Field firing angle of advance monitor PIN 146 ................................129
7.3.5 FLD I LO OP MO NITOR / Field active monitor PIN 147 .......................................................129
7.4 DIA GNOS TICS / A N ALO G IO M ONITOR ...............................................................................13 0
7.4.1 AN ALOG IO M O NITOR / UIP2 to 9 analogue input monitor PINs 150 to 157 .........................130
7.4.2 A N ALO G IO M ONIT OR / A OP1/2/3 analogue output monitor PINs 159, 160, 1 61 .................130
7.5 DIA G NO STICS / DIGIT AL IO M ONIT OR ................................................................................ 131
7.5.1 DIGIT AL IO M ONIT OR / UIP2 to 9 digitalinput monitor PIN 162 .........................................131
7.5.2 DIGIT AL IO MONITOR / DIP1 to 4 and DIO 1 to 4 digitalinput monitor PIN 163 ....................131
7.5.3 DIGIT AL IO M O NIT OR / D OP1 to 3 + ControlIPs digitalmonitor PIN 164 ...........................132
7.5.4 DIGIT AL IO M ONIT OR / + Armature bridge flag PIN 165....................................................132
7.5.5 DIGIT AL IO M ONIT OR / Drive start flag PIN 166 ..............................................................132
7.5.6 DIGIT AL IO M ONIT OR / Drive run flag PIN 167 ................................................................132
7.5.7 DIGIT AL IO M ONIT OR / Internalrunning mode monitor PIN 168 .........................................132
7.6 DIA G NO STIC S / BLO C K OP M ONIT OR .................................................................................1 33
7.6.1 BLO C K OP MO NIT OR / Generaldescription........................................................................134
7.7 DIA GNOS TICS / EL1/2/3 RMS M ON PIN 16 9 .....................................................................1 34
7.8 DIA GNOS TIC S / DC KILO W A T TS M ON PIN 1 70 .................................................................1 34
8MOTORDRIVE ALARMS ................................................................................135
8.1 MOTOR DRIVE ALARMS menu............................................................................................136
8.1.1 MOT OR DRIVE ALARMS / Speed feedback mismatch trip enable PIN 171............................137
8.1.2 MOT OR DRIVE ALARMS / Speed feedback mismatch tolerance PIN 172 .............................139

8 Contents
8.1.3 MOT OR DRIVE ALARMS / Field loss trip enable PIN 173 ................................................... 139
8.1.4 MOT OR DRIVE ALARMS / DigitalOP short circuit trip enable PIN 174 ................................ 139
8.1.5 MOT OR DRIVE ALARMS / Missing pulse trip enable PIN 175 ............................................. 140
8.1.6 MOT OR DRIVE ALARMS / Reference exchange trip enable PIN 1 76 .................................... 1 40
8.1.7 MOT OR DRIVE ALARMS / Overspeed delay time PIN 177 ................................................. 140
8.1.8 M OT OR DRIV E AL ARMS / ST ALL TRIP MENU ................................................................... 1 41
8.1.8.1 ST ALL TRIP MENU / Stall trip enable PIN 178 .......................................................... 141
8.1.8.2 ST ALL TRIP MENU / Stall current levelPIN 179 ....................................................... 141
8.1.8.3 ST ALL TRIP MENU / Stall time PIN 180 .................................................................. 141
8.1.9 MO T OR DRIVE ALARMS / A ctive and stored trip monitors PINS 18 1 / 18 2 ......................... 142
8.1.10 MOT OR DRIVE ALARMS / Externaltrip reset enable PIN 183 ........................................... 143
8.1.11 M OT OR DRIV E AL ARMS / DRIV E TRIP MESS A GE ............................................................ 1 43
8.1.11.1 DRIV E TRIP MESS A GE / Armature overcurrent ......................................................... 14 3
8.1.11.2 DRIV E TRIP MESS A GE / Armature overvolts ............................................................ 143
8.1.11.3 DRIV E TRIP MESS A GE / Field overcurrent................................................................ 143
8.1.11.4 DRIV E TRIP MESS A GE / Field loss .......................................................................... 144
8.1.11.5 DRIV E TRIP MESS A GE / User trip........................................................................... 144
8.1.11.6 DRIV E TRIP MESS A GE / Thermistor on T30 ............................................................. 144
8.1.11.7 DRIV E TRIP MESS A GE / O verspeed ........................................................................ 144
8.1.11.8 DRIV E TRIP MESS A GE / Speed feedback mismatch .................................................. 145
8.1.11.9 DRIV E TRIP MESS A GE / Stall trip ........................................................................... 145
8.1.11.10 DRIV E TRIP MESS A GE / Missing pulse.................................................................... 145
8.1.11.11 DRIV E TRIP MESS A GE / Supply phase loss ............................................................. 145
8.1.11.12 DRIV E TRIP MESS A GE / Synchronization loss.......................................................... 146
8.1.11.13 DRIV E TRIP MESS A GE / Heatsink overtemp ............................................................ 146
8.1.11.14 DRIV E TRIP MESS A GE / Short circuit digitaloutputs................................................. 146
8.1.11.15 DRIV E TRIP MESS A GE / Bad reference exchange ..................................................... 14 6
8.1.11.16 DRIV E TRIP MESS A GE / Cannot autotune ............................................................... 14 7
8.1.11.17 DRIV E TRIP MESS A GE / Autotune quit ................................................................... 147
8.1.11.18 DRIV E TRIP MESS A GE / Contactor lock out ............................................................ 147
8.1.11.19 DRIV E TRIP MESS A GE / Warning flags ................................................................... 147
9SELF TEST MESSAGE.................................................................................... 148
9.1.1 SELF TEST MESS A GE / Data corruption............................................................................ 148
9.1.2 SELF TEST MESS A GE / Disable GOTO, GETFROM ............................................................. 148
9.1.3 SELF TEST MESS A GE / Self caltolerance ......................................................................... 148
9.1.4 SELF TEST MESS A GE / Proportionalarmature current calfail .............................................. 148
9.1.5 SELF TEST MESS A GE / Integralarmature current calfail..................................................... 148
9.1.6 SELF TEST MESS A GE / Stop drive to adjust parameter....................................................... 149
9.1.7 SELF TEST MESSAGE / Enter password............................................................................ 149
9.1.8 SELF TEST MESS A GE / Enable GOTO, GETFROM .............................................................. 149
9.1.9 SELF TEST MESS A GE / G OT O C O NFLIC T ......................................................................... 1 49
9.1.10 SELF TEST MESS A GE / Internalerror code...................................................................... 149
9.1.11 SELF TEST MESS A GE / A uthorisation needed.................................................................. 149
9.1.12 SELF TEST MESS A GE / Memory w rite error .................................................................... 150
9.1.13 SELF TEST MESS A GE / Memory version error.................................................................. 150
9.1.13.1 Transferring files using PL PILOT ............................................................................ 150
10 SERIALLINKS, RS232 and FIELDBUS.............................................................. 151
10.1 SERIAL LINKS / RS232 PORT1........................................................................................... 152
10.1.1 RS232 PORT1 / Connection pinouts ............................................................................... 15 3
10.1.2 RS232 PORT 1 / Port1 Baud rate PIN 187...................................................................... 15 3
10.1.3 RS232 PORT 1 / Port1 function PIN 188 ....................................................................... 153
10.1.4 How to use USB ports.................................................................................................. 153
10.2 RS232 PORT 1 / PARA METER E X CH A NGE ........................................................................... 15 4
10.2.1 PAR A METER EX C H A NGE / Drive transmit ....................................................................... 154
10.2.1.1 PA RA ME TER EX C H A NGE w ith a locked recipe page 3. ............................................. 155
10.2.1.2 Transmitting parameter data file to a PC. Windo ws 95 up wards. ................................ 155
10.2.2 PAR A METER EX C H A NGE / Drive receive ........................................................................ 156

Contents 9
10.2.2.1 Receiving parameter data file from a PC. Windo ws 95 upwards. .................................156
10.2.3 PARA METER E X CH A NGE / menu list to host ...................................................................157
10.2.3.1 Transmitting a menu list to a PC. Windows 95 upwards. ...........................................157
10.2.3.2 PA RA ME TER EX C H A NGE / Drive to drive.................................................................158
10.2.3.3 PAR A METER E X CH A NGE / Eeprom transfer bet w een units.........................................159
10.2.4 Rules of parameter exchange relating to soft w are version..................................................159
10.2.5 Parameter exchange using ASCII COMMS .......................................................................160
10.2.5.1 PL PILO T and SC A D A (System ControlAnd Data A cquisition) package ........................160
10.3 RS232 PORT 1 / PORT1 REF EX C H AN GE .............................................................................1 61
10.3.1 REFEREN CE EX CH A NGE / Reference exchange slave ratio PIN 189 ...................................162
10.3.2 REFEREN CE EX CH A NGE/ Reference exchange slave sign PIN 190 ....................................162
10.3.3 REFEREN CE EX CH A NGE / Reference exchange slave monitor PIN 191 ..............................162
10.3.4 REFEREN CE EX CH A NGE / Reference exchange master monitor PIN 192 ............................162
10.3.5 REFEREN CE EX CH A N GE / Reference exchange master GET FRO M......................................162
11 DISPLAY FUNCTIONS ....................................................................................163
11.1 DISPLA Y F UN CTIO NS / Reduced menu enable......................................................................163
11.2 DISPLA Y F UN CTIO NS / P ASS W ORD C ON TROL ....................................................................1 63
11.2.1 PA SS W ORD C O NTROL / Enter pass w ord ........................................................................ 164
11.2.2 PA SS W ORD C O NTROL / Alter password.........................................................................164
11.3 DISPLA Y F UN CTIO NS / Language select..............................................................................164
11.4 DISPLA Y F UN CTIO NS / Soft w are version.............................................................................164
11.5 Remotely mounted display unit...........................................................................................164
12 APPLICATION BLOCKS ..................................................................................165
12.1 Generalrules....................................................................................................................165
12.1.1 Sample times...............................................................................................................165
12.1.2 Order of processing......................................................................................................165
12.1.3 Logic levels .................................................................................................................166
12.1.4 Activating blocks .........................................................................................................166
12.1.4.1 Conflicting GOTO connections................................................................................166
12.1.4.2 Application blocks PIN table...................................................................................166
13 CONFIGURATION ..........................................................................................167
13.1 CONFIGURATION menu.....................................................................................................168
13.1.1 PL PILO T configuration tool..........................................................................................168
13.2 Configurable connections...................................................................................................169
13.2.1 Key features of GOTO window ......................................................................................170
13.2.2 Key features of GET FROM window................................................................................170
13.2.3 Summary of G OTO and GET FRO M windows...................................................................171
13.2.4 JUMPER connections....................................................................................................171
13.2.5 Block Disconnect PIN 400 ...........................................................................................171
13.2.6 Hidden parameters .......................................................................................................171
13.2.7 C ON FIGUR A TIO N / EN A BLE G OT O, GET FRO M ................................................................1 72
13.3 C ONFIGUR A TIO N / UNIVERS AL INPU TS ..............................................................................1 72
13.3.1 UNIVERS AL INPUTS / Block diagram ..............................................................................174
13.3.1.1 UIPX SET UP / UIP(2) to (9) Input range PIN 3(2)0 to 3(9)0 .......................................1 74
13.3.1.2 UIPX SETUP / UIP(2) to (9) Input offset PIN 3(2)1 to 3(9)1 ......................................174
13.3.1.2.1 4-20m A loop input SETUP ................................................................................175
13.3.1.3 UIPX SETUP / UIP(2) to (9) Linear scaling ratio PIN 3(2)2 to 3(9)2 ............................175
13.3.1.4 UIPX SETUP / UIP(2) to (9) Maximum clamp levelPIN 3(2)3 to 3(9)3 ........................175
13.3.1.5 UIPX SETUP / UIP(2) to (9) Minimum clamp levelPIN 3(2)4 to 3(9)4 .........................175
13.3.1.6 UIPX SETUP / UIP(2) to (9) Make analog GO T O destination connection........................176
13.3.1.7 UIPX SETUP / UIP(2) to (9) Make digitaloutput 1 GO T O destination connection............176
13.3.1.8 UIPX SETUP / UIP(2) to (9) Make digitaloutput 2 GO T O destination connection............176
13.3.1.9 UIPX SETUP / UIP(2) to (9) Digitalinput, high value for output 1 PIN 3(2)5 to 3(9)5 ....177
13.3.1.10 UIPX SETUP / UIP(2) to (9) Digitalinput, lo w value for output 1 PIN 3(2)6 to 3(9)6 ....177
13.3.1.11 UIPX SETUP / UIP(2) to (9) Digitalinput, high value for output 2 PIN 3(2)7 to 3(9)7 ...177
13.3.1.12 UIPX SETUP / UIP(2) to (9) Digitalinput, lo w value for output 2 PIN 3(2)8 to 3(9)8 ....177
13.3.1.13 UIPX SETUP / UIP(2) to (9) Threshold PIN 3(2)9 to 3(9)9 ........................................177

10 Contents
13.4 C ON FIGUR A TIO N / A N AL OG O UTPUT S .............................................................................. 17 8
13.4.1 A N ALO G O UTPUTS / A OP4 Iarm output rectify enable PIN 250 ....................................... 178
13.4.2 A N ALO G O UTPUTS / A OP1/2/3/4 SETUP ....................................................................... 17 8
13.4.2.1 A OPX SETUP / A OP1/2/3 Dividing factor PINs 2 5 1 / 2 5 4 / 2 5 7 ............................. 179
13.4.2.2 A OPX SET UP / A OP1/2/3 O ffset PINs 2 52 / 2 55 / 258 ......................................... 17 9
13.4.2.3 A OPX SETUP / A OP1/2/3 Rectify mode enable PINs 253 / 256 / 259 ..................... 179
13.4.2.4 A OPX SETUP / A OP1/2/3 Make output GET FRO M source connection ........................ 179
13.4.2.5 Default connections for AOP1/2/3 .......................................................................... 179
13.4.3 A N ALO G O UTPUTS / Scope output select PIN 260 ........................................................ 180
13.5 C ONFIGUR A TIO N / DIGIT AL INPU TS .................................................................................. 18 0
13.5.1 Using DIP inputs for encoder signals............................................................................... 180
13.5.2 DIGIT AL INPUT S / DIPX SET UP ..................................................................................... 1 81
13.5.2.1 DIPX SETUP / DIP1/2/3/4 Input high value PINs 31 0 / 31 2 / 3 1 4 / 3 16 .................... 181
13.5.2.2 DIPX SETUP / DIP1/2/3/4 Input lo w value PINs 311 / 31 3 / 3 1 5 / 3 1 7 ..................... 181
13.5.2.3 DIPX SETUP / DIP1/2/3/4 Make input value GO T O destination connection ................... 181
13.5.2.4 Default connections for DIP1/2/3/4......................................................................... 181
13.5.3 DIGIT AL INPUT S / RUN INPU T SETUP ............................................................................ 1 82
13.5.3.1 RUN INPUT SETUP / RUN input HI value PIN 318 ................................................... 182
13.5.3.2 RUN INPUT SETUP / RUN input LO value PIN 319 .................................................. 182
13.5.3.3 RUN INPUT SETUP / Make input value GO T O destination connection .......................... 182
13.6 C ONFIGUR A TIO N / DIGIT AL IN/OU TPUTS ........................................................................... 18 3
13.6.1 DIGIT AL IN/O UTPUTS / DIO X SET UP ............................................................................. 1 83
13.6.1.1 DIO X SETUP / DIO 1/2/3/4 Output mode enable PINs 271 / 27 7 / 283 / 2 89 .............. 184
13.6.1.2 DIO X SETUP / DIO 1/2/3/4 OP valrectify enable PINs 272/ 2 78 / 28 4 /290 ............... 184
13.6.1.3 DIO X SETUP / DIO 1/2/3/4 OP comp threshold PINs 273 / 279 / 285 / 290 ................ 184
13.6.1.4 DIO X SETUP / DIO 1/2/3/4 OP inversion PINs 274 / 2 80 / 28 6 / 29 1 ......................... 184
13.6.1.5 DIO X SETUP / DIO 1/2/3/4 Make output GET FRO M source connection........................ 185
13.6.1.6 DIO X SETUP / DIO 1/2/3/4 Make input GO T O destination connection .......................... 185
13.6.1.7 DIO X SETUP / DIO 1/2/3/4 Input high value PINs 275 / 28 1 / 2 87 / 2 93 ................... 185
13.6.1.8 DIO X SETUP / DIO 1/2/3/4 Input lo w value PINs 2 7 6 / 28 2 / 2 88 / 2 94 .................... 186
13.6.1.9 Default connections for DIO1/2/3/4 ........................................................................ 186
13.6.1.10 DIO1/2/3/4 Internaloutput result PINs 685/6/7/8..................................................... 186
13.7 C ONFIGUR A TIO N / DIGIT AL OU TPUTS ............................................................................... 18 6
13.7.1 DIGIT AL O UTPU TS / DOPX SET UP ................................................................................ 18 6
13.7.1.1 DOPX SETUP / D OP1/2/3 OP valrectifiy enable PINs 261 / 264 / 267 ...................... 187
13.7.1.2 DOPX SETUP / D OP1/2/3 OP comparator threshold PINs 262 / 265 / 268 ................. 187
13.7.1.3 DOPX SETUP / DOP1/2/3 Output inversion enable PINs 263 / 266 / 269 ................... 187
13.7.1.4 DOPX SETUP / DOP1/2/3 Make output GET FROM source connection......................... 187
13.7.1.5 Default connections for DOP1/2/3 .......................................................................... 188
13.7.1.6 DOP1/2/3 Internaloutput result PINs 682/3/4 .......................................................... 188
13.8 C ONFIGUR A TIO N / ST A GING POSTS .................................................................................. 1 88
13.8.1 Connecting PINs with different units .............................................................................. 189
13.8.1.1 Connecting linear values with different units............................................................ 189
13.8.1.2 Connecting logic values with different messages ...................................................... 189
13.8.1.3 Connecting to multi-state logic parameters .............................................................. 190
13.8.2 ST A GING POS TS / Digital/ analog 1/2/3/4 PINs 296 to 303 ........................................... 190
13.9 C ONFIGURA TIO N / S OF T W ARE TERMIN ALS ....................................................................... 19 1
13.9.1 SO FT W ARE TERMIN ALS / Anded run PIN 3 05 ............................................................... 19 1
13.9.2 SO FT W ARE TERMIN ALS / Anded jog PIN 306 ............................................................... 191
13.9.3 SO FT W ARE TERMIN ALS / Anded start PIN 3 07 ............................................................. 19 2
13.9.4 SO FT W ARE TERMIN ALS / Internalrun input PIN 308 ..................................................... 192
13.10 C ONFIGURA TIO N / JU MPER C ONNEC TIO NS ....................................................................... 1 93
13.10.1 JUMPER CONNECTIONS / Make jumper GET FRO M source connection ............................. 193
13.10.2 JUMPER CONNECTIONS / Make jumper GOTO destination connection.............................. 193
13.11 C ON FIGURA TIO N / BLO C K OP C ON FIG ............................................................................... 19 4
13.11.1 BLO C K OP C ON FIG / Block outputs GOTO .................................................................... 195
13.11.2 Other G O TO windows ................................................................................................ 195
13.12 C ONFIGURA TIO N / FIELDBUS C ONFIG ................................................................................ 19 5

Contents 11
13.13 C ON FIGURA TIO N / DRIV E PERS ON ALIT Y ............................................................................1 96
13.13.1 DRIV E PERSO N ALIT Y / P ASSIVE M O TOR SET ...............................................................1 96
13.13.2 DRIV E PERSO N ALIT Y / Recipe page PIN 677 ...............................................................197
13.13.2.1 Recipe page block diagram ....................................................................................197
13.13.3 DRIV E PERSO N ALIT Y / Maximum current response PIN 678 ..........................................198
13.13.4 DRIV E PERSO N ALIT Y / Armature current burden resistance PIN 680 ...............................198
13.13.4.1 50% / 1 00 % rating select.....................................................................................199
13.13.4.2 W ARNING about changing BURDEN OHMS .............................................................200
13.13.4.3 Changing controlor power cards............................................................................200
13.14 CONFLICT HELP MENU .....................................................................................................201
13.14.1 CONFLICT HELP MENU / Number of conflicts.................................................................201
13.14.2 CONFLICT HELP MENU / Multiple GO TO conflict PIN identifier .........................................201
14 Installation ....................................................................................................203
14.1 Product rating table...........................................................................................................204
14.2 Product rating labels .........................................................................................................204
14.3 Semiconductor fuse ratings................................................................................................204
14.3.1 Proprietary fuses..........................................................................................................205
14.3.2 European stock fuses....................................................................................................205
14.3.3 DC semi-conductor fuses ..............................................................................................206
14.4 PL/X family cover dimensions.............................................................................................207
14.5 Mechanicaldimensions PL/X 5 - 50.....................................................................................208
14.5.1.1 Mounting PL/X 5 - 50 ...........................................................................................208
14.6 Mechanicaldimensions PL/X 65 - 145 .................................................................................209
14.6.1.1 Mounting PL/X 65 - 145........................................................................................209
14.7 Mechanicaldimensions PL/X 185 - 265 ...............................................................................210
14.7.1.1 Mounting PL/X 185 - 2 6 5 ......................................................................................210
14.7.1.2 Venting models PL/X 185 - 265 using back panelaperture.........................................211
14.7.1.3 Venting models PL/X 185 - 265 using standoff pillars................................................211
14.8 Line reactors....................................................................................................................212
14.9 Wiring instructions............................................................................................................213
14.9.1 Wiring diagram for A C supply to L1/2/3 different to EL1/2/3. (E.g. Low voltage field)............213
14.10 Terminaltightening torques................................................................................................214
14.11 Installation guide for EMC ..................................................................................................215
14.11.1 3-phase po wer supply port ..........................................................................................215
14.11.2 Earthing and screening guidelines .................................................................................215
14.11.3 Earthing diagram for typicalinstallation .........................................................................216
14.11.4 Guidelines when using filters .......................................................................................217
14.12 Approvals UL, cUL, CE ......................................................................................................217
14.12.1 CE Immunity..............................................................................................................217
14.12.2 CE Emissions.............................................................................................................217
14.12.3 UL, cUL ....................................................................................................................217
14.13 What to do in the event of a problem ..................................................................................218
14.13.1 A simple clarification of a technicalissue.......................................................................218
14.13.2 A complete system failure ...........................................................................................218
15 PIN numbertables..........................................................................................219
15.1 Numeric tables .................................................................................................................219
15.1.1 Change parameters 2 - 121 .........................................................................................219
15.1.2 Diagnostics and alarms 123 - 1 83 ................................................................................221
15.1.3 Seriallinks 18 7 - 249 .................................................................................................2 2 2
15.1.4 Configuration 251 - 400 .............................................................................................222
15.1.5 Application blocks 401 - 6 80 .......................................................................................224
15.1.6 Hidden pins 680 - 720 ................................................................................................2 2 5
15.2 Menu list .........................................................................................................................226
16 Index............................................................................................................229
16.1 Record of modifications.....................................................................................................233
16.2 Record of bug fixes...........................................................................................................234
17 Changes to product since manualpublication....................................................234

12 Contents
There is a system block diagram at the back of the manualalso available for downloading from the w eb site
w w w .sprint-electric.com.
www.bardac.com

Warnings 13
2 Warnings
2.1 GeneralWarnings
READ AND UNDERSTAND THIS MANUALBEFORE APPLYING POWERTO THE PL/X DRIVE UNIT
The PL/X motor drive controller is an open chassis component for use in a suitable enclosure
Drives and process controlsystems are a very important part of creating better quality and value in the goods
for our society, but they must be designed, installed and used with great care to ensure everyone's S A FETY.
Remember that the equipment you will be using incorporates...
High voltage electricalequipment
Po werfulrotating machinery with large stored energy
Heavy components
Your process may involve...
Hazardous materials
Expensive equipment and facilities
Interactive components
Always use qualified personnelto design, construct and operate your systems and keep SAFETY as your
primary concern.
Thorough personneltraining is an important aid to SAFETY and productivity.
SAFETY a w areness not only reduces the risk of accidents and injuries in your plant, but also has a direct
impact on improving product quality and costs.
If you have any doubts about the SAFETY of your system or process, consult an expert immediately. Do not
proceed without doing so.
HEALTH AND SAFETY AT WORK
Electricaldevices can constitute a safety hazard. It is the responsibility of the user to ensure the compliance
of the installation with any acts or bylaws in force. Only skilled personnelshould install and maintain this
equipment after reading and understanding this instruction manual. If in doubt refer to the supplier.
Note. The contents of this manualare believed to be accurate at the time of printing. The manufacturers,
how ever, reserve the right to change the content and product specification without notice. No liability is
accepted for omissions or errors. No liability is accepted fortheinstallation orfitness forpurposeor
application of thePL/X motordriveunit.
DA NGER
ELECTRIC SHO C K RISK

14 Warnings
2.2 Warnings and Instructions
WARNING
Only qualified personnelwho thoroughly understand the operation of this
equipment and any associated machinery should install, start-up or attempt
maintenance of this equipment. Non compliance with this w arning may result in
personalinjury and/or equipment damage. Never work on any controlequipment
without first isolating all po w er supplies from the equipment. The drive and motor
must be connected to an appropriate safety earth. Failure to do so presents an
electricalshock hazard.
CAUTION
This equipment w as tested before it left our factory. Ho wever, before
installation and start-up, inspect all equipment for transit damage, loose
parts, packing materials etc. This product conforms to IPO O protection.
Due consideration should be given to environmentalconditions of
installation for safe and reliable operation. Never perform high voltage
resistance checks on the wiring without first disconnecting the product
from the circuit being tested.
STATIC SENSITIVE
This equipment contains electrostatic discharge (ESD) sensitive
parts. Observe static controlprecautions when handling,
installing and servicing this product.
THESE WARNINGS AND INSTRUCTIONS ARE INCLUDED TO ENABLE THE USERTO OBTAIN
MAXIMUM EFFECTIVENESS AND TO ALERT THE USERTO SAFETY ISSUES
APPLICATION AREA: Industrial(non-consumer) " Motor speed controlutilising DC motors " .
PRODUCT MANUAL: This manualis intended to provide a description of how the product works. It is not
intended to describe the apparatus into which the product is installed.
This manualis to be made available to all persons who are required to design an application, install, service
or come into direct contact with the product.
APPLICATIONS ADVICE: Applications advice and training is available from Sprint Electric.
Bardac.

Warnings 15
2.3 GeneralRisks
INSTALLATION: THIS PRODUCT IS CLASSIFIED AS A COMPONENT AND MUST BE USED IN A
SUITABLE ENCLOSURE
Ensure that mechanically secure fixings are used as recommended.
Ensure that cooling airflo w around the product is as recommended.
Ensure that cables and wire terminations are as recommended and clamped to
required torque.
Ensure that a competent person carries out the installation and commissioning of
this product.
Ensure that the product rating is not exceeded.
APPLICATION RISK: ELECTROMECHANICALSAFETY IS THE RESPONSIBILITY OF THE USER
The integration of this product into other apparatus or systems is not the
responsibility of the manufacturer or distributor of the product.
The applicability, effectiveness or safety of operation of this equipment, or that of
other apparatus or systems is not the responsibility of the manufacturer or
distributor of the product.
Where appropriate the user should consider some aspects of the follo wing risk assessment.
RISK ASSESSMENT: Under fault conditions or conditions not intended.
1. The motor speed may be incorrect. 2. The motor speed may be excessive.
3. The direction of rotation may be incorrect. 4. The motor may be energised.
In all situations the user should provide sufficient guarding and/or additionalredundant monitoring and safety
systems to prevent risk of injury. NO TE: During a pow er loss event the product will commence a
sequenced shut down procedure and the system designer must provide suitable protection for this case.
MAINTENANCE: Maintenance and repair should only beperformed by competent persons using only
therecommended spares (orreturn to factory forrepair). Useof unapproved parts may createahazard and
riskof injury.
WHEN REPLACING A PRODUCT IT IS ESSENTIALTHAT ALL USERDEFINED
PARAMETERS THAT DEFINE THE PRODUCT'S OPERATION ARE CORRECTLY
INSTALLED BEFORE RETURNING TO USE. FAILURE TO DO SO MAY CREATE A
HAZARD AND RISK OF INJURY.
PA C K A GIN G: The packaging is combustible and if disposed of incorrectly may lead
to the generation of toxic fumes, which are lethal.
WEIGHT: Consideration should be given to the weight of the product when handling.
REPAIRS: Repair reports can only be given if the user makes sufficient and accurate defect reporting.
Remember that the product without the required precautions can represent an electricalhazard and risk of
injury, and that rotating machinery is a mechanicalhazard.
PROTECTIVE INSULATION:
1. All exposed metalinsulation is protected by basic insulation and userbonding to earth i.e. Class 1.
2. Earth bonding is the responsibility of the installer.
3. All signalterminals are protected by basic insulation, and the userearth bonding. (Class 1). The purpose
of this protection is to allow safe connection to other lo w voltage equipment and is not designed to allow
these terminals to be connected to any un-isolated potential.

16 Warnings
It is essentialthat all thefollowing warnings areread and understood.
2.4 Summary of furtherWARNINGS
This summary is provided forconvenience only. Pleaseread theentiremanualpriorto first timeproduct use.
0V on T13 must beused forprotectiveclean earth connection.
Terminals T30 and T36 must belinked if externalover-temperaturesensors arenot used.
See 3.5 Controlterminaldefault functions.
WARNING. Do not rely on any drivefunction to prevent themotorfrom operating when personnelare
undertaking maintenance, orwhen machineguards areopen. Electroniccontrolis not accepted by safety
codes to bethesolemeans of inhibition of thecontroller. Always isolatethepowersource beforeworking on
thedriveorthemotororload. See 3.5 Controlterminaldefault functions.
TheCSTOPmust behigh forat least 50mS priorto START going high.
See 3.5 Controlterminaldefault functions.
Contactorcoils usually haveahigh inductance. When thecontactoris de-energised it can produce high
energy arcing on theinternalPL/X controlrelay. This may degradethelifeof therelay and/orproduce
excessiveEMC emissions. Ensurethat thecontactorcoil is snubbered. Referto contactorsupplierfordetails.
See 4.2 Main Contactor operation.
Theessentialelements of controlling thecontactorareas follows.
1)It must bepossibleto releasethecontactorwithout relying on electronics.
2)Thecontactormust not break current. To obey this rulethefollowing applies:-
a)ThePL/X must not attempt to deliverarmaturecurrent until afterthecontactorhas closed.
b)Thearmaturecurrent must bebrought to zero beforethecontactorhas opened.
3)Thecontactorcontrolcircuit must becompatiblewith all likely application requirements.
Follow theinstructions and all theaboverequirements areunderthecontrolof thePL/X automatically.
See 4.2 Main Contactor operation.
It may benecessary forinstallations to haveover-riding externalindependent systems forde-energising the
main contactor. In this caseit is recommended that theCSTOPterminalbeopened 100mS in advance of the
main contacts opening. Failureto achievethis may result in damageto theunit.
Note. If theusers main contactorhas aclosing timedelay of greaterthan 75mS, then it is essentialthat
steps aretaken to delay thereleaseof armaturecurrent until themain contact has closed.
1)Insert an auxiliary normally open contact on themain contactorin series with theRUN input on T31.
2)Alternatively usecontactorwiring method shown in 4.3.2. See 4.2 Main Contactor operation.
It is dangerous to utiliseaDC contactorwhen field weakening is employed without also connecting T41 and
T43 to themotorarmature. This ensures that thePL/X can measurethearmaturevoltageeven when the
contactoris open. See 4.3.3 Main contactor isolating DC armature.
This is asummary of theessentialparameters that should bechecked priorto allowing powerto themotor.
You must beableto put atick against every section. Failureto comply with theserequirements may cause
incorrect functioning ordamageto thedriveand/orinstallation and will invalidateany warranty.
See 4.4 ESSENTIAL pre-start checks.
All externalfuses must beof thecorrect rating and type. TheI2t rating must beless than therating specified
in therating tables. This includes main and auxiliary fuses.
See 4.4 ESSENTIAL pre-start checks.
Check the3 phaseauxiliary supply phasing on ELl/2/3 equates to thephasing of themain stack supply on
Ll/2/3, and the1 ph controlsupply on T52/53 is correct. See 4.4 ESSENTIAL pre-start checks.
Disconnect thedriveforwiring tests using amegger.
See 4.4 ESSENTIAL pre-start checks.

Warnings 17
If theload regenerates orregenerativebraking is employed, then aDC rated armaturefusewith thecorrect
I2t rating in series with themotorarmatureis highly recommended.
See 4.4 ESSENTIAL pre-start checks.
A protectiveclean earth connection must bemadeto thecontrol0V on T13 to ensurethat theinstallation
complies with protectiveclass1 requirements. See 4.4 ESSENTIAL pre-start checks.
Theemergency stopping and safety procedure, including localand remoteactuators must bechecked priorto
applying powerto themotor. See 4.4 ESSENTIAL pre-start checks.
If you wish to abandon changes madesince thelast save, simply removethecontrolsupply WITHOUT
having performed parametersave. See 5.1.2 PARA METER S A VE.
Sometimes it is usefulto return a unit to its default setup condition. E.g. a trialconfiguration may prove to be
unw orkable and it is easier to start again. If all 4 keys are held dow n during the application of the control
supply, then the drive will automatically display the default parameters and connections. (EXCEPTthosein
theCALIBRATION menu, and 100)FIELD VOLTS OP% forMOTOR1 and MOTOR2, and 680)Iarm BURDEN
OHMS). The defaults will only be permanently retained how ever if they are then saved using the
PAR A METER S A V E menu. To revert to the last saved set, simply turn the controlsupply off, without doing a
PARAMETER SA VE and on again.
Also thePASSWORD is reset to 0000. See 11.2 DISPLA Y F UN C TIO NS / PA SS W ORD C O NTROL.
See also 13.13.2 DRIVE PERSONALITY / Recipe page PIN 677, for details of 2 and 3 key reset operation
and pow er up messages. See 5.1.3 Restoring the drive parameters to the default condition.
If your DESIRED M A XIMU M RPM is higher than the B ASE R A TED RPM then you w ill need to implement field
weakening in the C H A NGE PAR A METERS / FIELD C O NTROL menu. You must howeververify that yourmotor
and load arerated forrotation abovebasespeed. Failureto do so may result in mechanicalfailurewith
disastrous consequences. If however your desired maximum rpm is lo w compared to the base rpm then you
need to be a w are of the heat dissipation in the motor at full torque. Use motor force venting if necessary.
See 6. 1.6 C A LIBRA TIO N / Desired max rpm PIN 6 Q UIC K ST ART.
WARNING. Do not useAVF feedback modewith field weakening systems. See 6.9.6 FIELD CONTROL / FLD
WE AKENING MENU for a note about A VF / field w eakening trip.
A VF feedback contains more ripple than tacho feedback. It may be necessary for smooth operation to reduce
the SPEED C ONTROL loop gain with A V F. See 6.7.4 SPEED C ONTROL / Speed proportionalgain PIN 71.
See 6 .1.9 C A LIBRA TIO N / Speed feedback type PIN 9 Q UIC K S T ART.
When the drive is first being commissioned it is recommended that the A VF mode be used initially. This
allows any other speed feedback transducers to be examined for correct outputs prior to relying on them for
controlsafety. Forsystems employing aDC contactoryou must useT41 and T43 forremoteAVF.
See 6 .1.9 C A LIBRA TIO N / Speed feedback type PIN 9 Q UIC K S T ART.
Current loop controlterms. If you changeyoursupply voltage, current calibration ormotortype, the3 values
forPINs 93/94/95 must beadjusted accordingly. (Eitherby using theAUTOTUNE function ormanually).
See 6.8.9 CURRENT CONTROL / Autotune enable PIN 92
See 6.8.12.1 Setting the current loop controlterms manually.
Warning. Field reversalordisconnection.
Due to the high inductance of motor fields it may take severalseconds for the field current to decay to zero
after the field output has been inhibited by the PL/X. Do not open circuit thefield unless thefield current has
reached zero. See 6.9 CH A NGE PARA METERS / FIELD C ONTROL.
WARNING. When using field weakening and aDC sidepowercontactor, themotorarmaturemust be
connected to theREMOTE AV sensing terminals T41 and T43. Failureto do this will causeflashoverof the
commutatorbecausetheAVF feedback is lost when thecontactoropens.
See 6.9.6 FIELD C ONTROL / FLD WEA KENING MENU.

18 Warnings
WARNING. All thesealarms aregenerated by semiconductorelectronics. Localsafety codes may mandate
electro-mechanicalalarm systems. All alarms must betested in thefinalapplication priorto use. The
suppliers and manufacturers of thePL/X arenot responsibleforsystem safety.
See 8.1 M O TOR DRIVE ALARMS menu.
WARNING. Thefeedback loss protection afforded in field weakening modeis limited to totalfeedback loss
only. This is becausethespeed / AVF relationship is not maintained in field weakening mode. If apartialloss
of feedback occurs themotormay run to excessivespeed. When thefield has been completely weakened
and is at its minimum level, thearmatureovervoltagetrip will comeinto operation. This may only occurat a
dangerous speed. It is thereforerecommended that amechanicaldevice and orback up system beutilised to
protect against this possibility. See 6.9.6.8 FLD WEA KENING MENU / Minimum field current % PIN 110.
And 8.1.1 MOTOR DRIVE ALARMS / Speed feedback mismatch trip enable PIN 17 1.
WARNING. Forrated field currents that areless than 25% of modelrating thealarm threshold may betoo
low to trigger. Thealarm must betested. To overcomethis problem, 4)RATED FIELD AMPS may beset to a
higherleveland 114)FIELD REFERENCE set lower. This has theeffect of raising thethreshold.
E.g. Set 4)RATED FIELD AMPS to twice motorrating and 114)FIELD REFERENCE to 50.00%.
See 8.1.3 MO T OR DRIVE ALARMS / Field loss trip enable PIN 173
WARNING. When using armaturevoltagefeedback theIRdrop may besufficient to provideasignalin excess
of 117)ZERO INTLK SPD % and hence thestall alarm will not operate. Set 14)IRCOMPENSATION as
accurately as possible, and then test thealarm with astalled motor. (Disablethefield)Progressively increase
current limit to abovethe179)STALL CURLEVEL, to check that theAV speed feedback remains below
117)ZERO INTLK SPD %. It may benecessary to increase117)ZERO INTLK SPD % to ensuretripping.
See 8.1.8.1 ST ALL TRIP MENU / Stall trip enable PIN 178.
AfteraDATA CORRUPTION message. Check that thecalibration parameters and drivepersonality
Iarm burden valuearecorrect. See 9.1.1 SELF TEST MESS A GE / Data corruption.
Warning the24V supply on pin 2 may damageyourPC orotherinstrument. If in doubt do not connect it. The
transmit must beconnected to thereceiveon each port. See 10.1.1 RS232 PORT1 / Connection pinouts.
Parameter exchange generalWARNING. Check theCALIBRATION parameters arecorrect afterany process of
PARAMETEREXCHANGE. See 10.2 RS2 32 PORT 1 / PARA METER E X CH A NGE.
And 10.2.3.3. PAR A METER E X CH A NGE / Eeprom transfer bet w een units.
WARNING about changing BURDEN OHMS. It is important that 680)Iarm BURDEN OHMS, is set as closely as
possibleto theactualresistance used on thepowerboard. DO NOT ALLOW THE MODELRATING TO
EXCEED THE VALUES IN THE RATING TABLE AND ON THE RATING LABELFOUND UNDERTHE UPPEREND
CAP. FAILURE TO HEED THIS WARNING WILL INVALIDATE ANY WARRANTY, AND VIOLATE APPROVAL
STANDARDS. NO LIABILITY IS ACCEPTED BY THE MANUFACTURERAND/ORDISTRIBUTORFORFAULTS
CAUSED BY RE-RATING OF THE PRODUCT.See 13.13.4.2 W ARNING about changing BURDEN OHMS.
WARNING. All units must beprotected by correctly rated semi-conductorfuses. Failureto do so will
invalidatewarranty.See 14.3 Semiconductor fuse ratings.
WIRING INSTRUCTIONS. VERY IMPORTANT. Read all warnings in section 14.9
WARNING Safety earthing always takes precedence overEMC earthing.
See 14.11.2 Earthing and screening guidelines.
See 14.11.4 Guidelines w hen using filters.
The A C supply filter contains high
voltage capacitors and should not be
touched for a period of 20 seconds after
the removalof the A C supply
The A C supply filters must
not be used on supplies that
are un-balanced or float with
respect to earth
The drive and A C filter must only be
used with a permanent earth
connection. No plugs/sockets are
allo w ed in the A C supply
IMPORT A NT S A FETY W ARNINGS

Introduction and TechnicalData 19
3 Introduction and TechnicalData
3Introduction and TechnicalData........................................................................19
3.1 Introduction....................................................................................................................... 20
3.2 How do they work? ............................................................................................................ 20
3.2.1 Usefulthings to know about the PL/X................................................................................ 21
3.2.2 Tips for using the manual................................................................................................. 21
3.3 GeneralTechnicalData........................................................................................................ 22
3.3.1 Regenerative stopping with PL models ............................................................................... 22
3.3.2 Supply voltages required for all models .............................................................................. 22
3.3.3 Controlterminals electricalspecification............................................................................ 24
3.4 Controlterminals overview. ................................................................................................. 25
3.4.1 Generalrequirements....................................................................................................... 25
3.4.2 Digitalinputs and outputs ................................................................................................ 25
3.4.3 Analogue inputs.............................................................................................................. 26
3.4.4 Analogue tachogenerator input ......................................................................................... 27
3.4.5 Signaltest pins............................................................................................................... 27
3.5 Controlterminaldefault functions ......................................................................................... 27
3.5.1 Run, Jog, Start, Cstop..................................................................................................... 29
3.5.2 Summary of default terminalfunctions............................................................................... 31
3.6 Supply loss shutdown ......................................................................................................... 32

20 Introduction and TechnicalData
3.1 Introduction
The PL/X DC motor controller uses closed loop controlof armature current and feedback voltage to
give precise controlof motor torque and speed. The unit also controls the motor excitation field. The closed
loop parameters are programmable by the user and a wealth of inputs and outputs are provided to allo w very
complex motion controlprocesses to be achieved. The series is comprised of 5 frame variants each with 2
and 4 quadrant models. Selected 2 quadrant models also offerauniqueregenerativestopping facility.
Pleasealso referto Part 3 PL/X 275-980 forextradetails of frame4 and 5 high powerdrives.
Programming the unit is designed to be simple. A large backlit alphanumeric display guides the user through a
friendly menu structure to select options and parameter changes. Built in application soft w are blocks are
provided to be connected up as desired. Comprehensive fault monitoring and serialcommunications allow off
site programming and remote diagnostics. All models are stock items. These units are very compact. The
savings made possible in panelspace and enclosure costs may be significant.
3.2 How do they work?
This sho ws the basic arrangement of the drive controlloops. The 3-phase thyristor bridge is a phase-
controlled rectifier, which delivers pow er to the motor armature. The armature current (and hence the motor
torque) is sensed to provide feedback to the inner current loop. After being scaled this is compared to the
current demand. The current error amplifier is able to detect any difference, and then act in such a way that
the current feedback remains identicalto the current demand during normaloperation. This inner loop
monitors the armature current and delivers more current or less current as required.
The outer speed loop works in the same w ay as the inner current loop but uses different parameters. In the
above example, the demand is provided by the user in the form of a speed reference, and the speed feedback
is derived from a shaft-mounted tachometer. Any difference is detected and translated into a ne w current
demand level. This levelprovides the right amount of current (and hence torque) to reduce the speed error to
zero. This ne w demand levelis presented to the inner current loop, which obeys as rapidly as possible.
The whole process is performed on a continuous basis giving superb speed accuracy and dynamic
performance. In typicalsystems, there are numerous house keeping tasks and interface requirements. For
these, the PL/X series has a w ealth of standard features to benefit the user.
A range of standard application blocks is included, with a user-friendly configuration facility that displays a
description of the selected connection points. The programming menu is designed for rapid travelto the
desired parameter using 4 keys and a large backlit alphanumeric display. A large number of monitoring
facilities is available to enable display of all points in the block diagram.
The unit is supplied with PL PILOT, a superb PC windo ws based configuration and monitoring tool.
(Note. Also available is the PLA, with applications blocks, I/O modules and comms facilities only)
Inner current loop
Speed
reference
from user
Current
error
amplifier
Speed
error
amplifier
Current
feedback
scaling
Speed
feedback
scaling
Firing circuit and
3-phase bridge.
A C in, DC out.
M
Tacho
The signalhere
represents armature
current demand.
Outer
speed loop