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