GE AV-300i Troubleshooting guide

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
GE Industrial Systems
AV - 30 0 i
AV - 30 0 i
Quick Start Up Guide
TM

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This book is referred to SW version 1.X00
This book replaces the Instruction Book Rev. 1.0c (09/98)
These instructions do not purport to cover all details or variations in equipment, nor to provide every possible contin-
gency to be met during installation, operation, and maintenance. If further information is desired or if particular prob-
lems arise that are not covered sufficiently for the purchaser’s purpose, the matter should be referred to GE Industrial
Systems.
This document contains proprietary information of General Electric Company, USA and is furnished to its customer
solely to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described.
This document shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without
the written approval of GE Industrial Systems.
© 1999 by General Electric Company, USA. All rights reserved.

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Table of Contents
1. Safety Precautions - Precautions de securité ......................................................................................................... 4
Functional connection diagram...................................................................................................7
2. Overview ......................................................................................................................................................................... 8
3. Control Terminals .......................................................................................................................................................... 9
3.1 Maximum cable cross section for regulator terminals ........................................................ 10
4. Power terminals .......................................................................................................................................................... 10
4.1 Maximum cable cross section for power terminals ............................................................ 10
5. Encoder terminals (XE connector)............................................................................................................................ 11
5.1 Encoder type connection .................................................................................................... 11
5.2 JUMPERS setting ............................................................................................................... 12
␣␣␣␣␣List of jumpers and dip-switch............................................................................................. 12
␣␣␣␣␣List of dip-switch .................................................................................................................. 13
5.3 Maximum cable length for encoder terminals..................................................................... 13
6. Keypad operation......................................................................................................................................................... 14
Keypads (on right the optional LED module) ............................................................................ 14
LEDs .......................................................................................................................................... 15
Moving inside a menu ............................................................................................................... 16
7. Pre Power Checks ....................................................................................................................................................... 17
8. Quick tuning ................................................................................................................................................................. 18
9. Options........................................................................................................................................................................... 22
10. Quick Tuning Guide for Factory Configured Drives............................................................................................... 22
11. Troubleshooting ........................................................................................................................................................... 23
Overflow list .............................................................................................................................. 23
List of Self-tuning Errpr Messages ............................................................................................ 24
Failure alarms in the keypad display ......................................................................................... 25
Other faults ................................................................................................................................ 27

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1. Safety Precautions - Precautions de securité
WARNING/ATTENTION!
According to the EEC standards the AV300i should be used
only after checking that the mechanical equipment uses
safety devices required by the 89/392/EEC set of rules.
Drive systems cause mechanical motion. It is the
responsibility of the user to insure that any such motion
does not result in an unsafe condition. Factory provided
interlocks and operating limits should not be bypassed or
modified.
Selon les normes EEC, les drives AV300i et leurs
accessoires doivent être employés seulement après avoir
verifié que la machine ait été produit avec les même
dispositifs de sécurité demandés par la réglementation 89/
392/EEC concernant le secteur de l’industrie.
Les systèmes provoquent des mouvements mécaniques.
L’utilisateur est responsable de la sécurité concernant les
mouvements mécaniques. Les dispositifs de sécurité
prévues par l’usine et les limitations operationelles ne
doivent être dépassés ou modifiés.
WARNING - ELECTRICAL SHOCK AND BURN
HAZARD / ATTENTION – DÉCHARGE ÉLECTRIQUE ET
RISQUE DE BRÚLURE :
When using instruments such as oscilloscopes to work
on live equipment, the oscilloscope’s chassis should be
grounded and a differential input amplifier should be used.
Care should be used in the selection of probes and leads
so that accurate readings may be made. See the
instrument manufacturer’s instruction book for proper
operation and adjustments of the oscilloscope.
Lors de l’utilisation d’instruments (par example
oscilloscope) sur des systémes en marche, le chassis de
l’oscilloscope doit être relié à la terre et un amplificateur
différentiel devrait être utilisé en entrée.
Les sondes et conducteurs doivent être choissis avec soin
pour effectuer les meilleures mesures à l’aide d’un
oscilloscope. Voir le manuel d’instruction pour une
utilisation correcte des instruments.
WARNING - FIRE AND EXPLOSION HAZARD /
ATTENTION – RISQUE D’INCENDIES ET
D’EXPLOSIONS:
Fires or explosions might result from mounting drives in
hazardous areas such as locations where flammable or
combustible vapors are present. Drives should be installed
away from hazardous areas, even if used with motors
suitable for use in these locations.
L’utilisation des drives dans des zônes à risques (présence
de vapeurs ou de poussières inflammables), peut provoquer
des incendies ou des explosions. Les drives doivent être
installés loin des zônes dangeureuses, et équipés de
moteurs appropriés.
WARNING - STRAIN HAZARD / ATTENTION À
L’ÉLÉVATION:
Improper lifting practices can cause serious or fatal injury.
Lift only with adequate equipment and trained personnel.
Une élévation inappropriée peut causer des dommages
sérieux ou fatals. Il doit être élevé seulement avec des
moyens appropriés et par du personnel qualifié.
WARNING - ELECTRICAL SHOCK / ATTENTION – CAS
DE DECHARGE ELECTRIQUE:
Drives and motors must be grounded according to NEC.
Tous les moteurs et les drives doivent être mis à la terre
selon le Code Electrique National ou équivalent.
WARNING / ATTENTION:
Replace all covers before applying power to the drive.
Failure to do so may result in death or serious injury.
Remettre tous les capots avant de mettre sous tension le
drive. Des erreurs peuvent provoquer de sérieux accidents
ou même la mort.
WARNING / ATTENTION:
Adjustable frequency drives are electrical apparatus for
use in industrial installations. Parts of the drives are
energized during operation. The electrical installation, tune-
up and troubleshooting should therefore only be carried
out by qualified personnel. Improper installation of motors
or drives may cause the failure of the drive as well as
serious injury to persons or equipment. The drive is not
equipped with motor overspeed protection logic.
Follow the instructions given in this manual and observe
the local and national safety regulations applicable.
Les drives à fréquence variable sont des dispositifs
électriques utilisés dans des installations industriels. Une
partie des drives sont sous tension pendant l’operation.
L’installation électrique et l’ouverture des drives devrait être
executé uniquement par du personel qualifié. De mauvaises
installations de moteurs ou de drives peuvent provoquer
des dommages materiels ou blesser des personnes.
Le convertisseur n’est pas pourvu de protection contre
vitesse de fuite du moteur. On doit suivir les instructions
donneés dans ce manuel et observer les régles nationales
de sécurité.
CAUTION / PRECAUTION:
Do not connect power supply voltages that exceeds the
standard specification. If excessive voltage is applied to
the drive, damage to the internal components will result.
Ne pas raccorder de tension d’alimentation dépassant la
fluctuation de tension permise par les normes. Dans le cas
d’ une alimentation en tension excessive, des composants
internes peuvent être endommagés.

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CAUTION / PRECAUTION:
Do not operate the drive without a ground wire being
connected. The motor chassis should be grounded to
earth through a ground lead separate from all other
equipment ground leads to prevent noise coupling.
The grounding connector shall be sized in accordance with
the NEC or Canadian Electrical Code. The connection shall
be made by a UL listed or CSA certified closed-loop
terminal connector sized for the wire gauge involved. The
connector must be attched to the wire using the crimp
tool specified by the terminal manufacturer.
Ne pas faire fonctionner le drive sans prise de terre. Le
chassis du moteur doit être mis à la terre à l’aide d’un
connecteur de terre separé des autres pour éviter le
couplage des perturbations. Le connecteur de terre devrait
être dimensionné selon la norme NEC ou le Canadian
Electrical code. Le raccordement devrait être fait par un
connecteur certifié et mentionné à boucle fermé par les
normes CSA et UL et dimensionné pour l’épaisseur du
cable correspondant. Le connecteur doit être fixé a l’aide
d’un instrument de serrage specifié par le producteur du
connecteur.
CAUTION / PRECAUTION:
Do not perform a megger test between the drive terminals
or the control circuit terminals.
Ne pas exécuter un test megger entre les bornes du drive
ou entre les bornes du circuit de contrôle.
CAUTION / PRECAUTION:
Because the ambient temperature greatly effects drive life
and reliability, do not install the drive in any location that
exceeds the allowable temperature. Leave the ventilation
cover attached for temperatures of 104° F (40° C) or below.
Étant donné que la température ambiante influe sur la vie
et la fiabilité du drive, on ne devrait pas installer le drive
dans des places ou la temperature permise est dépassée.
Laisser le capot de ventilation en place pour températures
de 104°F (40°C) ou inférieures.
CAUTION / PRECAUTION:
If the drive’s Fault Alarm is activated, consult the
TROUBLESHOOTING section of this instruction book.
Correct the problem before resuming operation, automatic
reset of faults is not recommended.
Si la Fault Alarm du drive est activée, consulter la section
du manuel concernant les défauts et après avoir corrigé
l’erreur, reprendre l’opération. Ne pas réiniliatiser l’alarme
automatiquement par une séquence externe, etc….
CAUTION / PRECAUTION:
Be sure to remove the desicant dryer packet(s) when
unpacking the drive. (If not removed these packets may
become lodged in the fan or air passages and cause the
drive to overheat).
Lors du déballage du drive, retirer le sachet déshydraté.
(Si celui-ci n’est pas retiré, il empêche la ventilation et
provoque une surchauffe du drive).
CAUTION / PRECAUTION:
The drive must be mounted on a wall that is constructed
of heat resistant material. While the drive is operating, the
temperature of the drive's cooling fins can rise to a
temperature of 194° F (90°C).
Le drive doit être monté sur un mur construit avec des
matériaux résistants à la chaleur. Pendant le
fonctionnement du drive, la température des ailettes du
dissipateur thermique peut arriver à 194°F (90°).
Note:
The terms “inverter”, “controller” and “drive” are sometimes
used interchangably throughout the industry. We will use
the term “drive” in this document
Les mots “inverter”, “controller” et “drive” sont
interchangeables dans le domaine industriel. Nous
utiliserons dans ce manuel seulement le mot “drive”.
1. Never open the device or covers while the AC Input power supply
is switched on. Minimum time to wait before working on the
terminals or inside the drive is listed in section 4.11 in the Instruction
manual .
Ne jamais ouvrir l’appareil lorsqu’il est suns tension. Le temps
minimum d’attente avant de pouvoir travailler sur les bornes ou bien
à l’intérieur de l’appareil est indiqué dans la section 4.11 (Instruction
manual).
2. Be careful not to the damage any components when handling the
drive. Changing of the isolation gaps or removing the insulation or
covers is not permissible. If the front cover has to be removed
because of a room temperature, higher than 40°C, the user has to
ensure that no occasional contact with live parts may occur.
Manipuler l’appareil de façon à ne pas toucher ou endommager
des parties. Il n’est pas permis de changer les distances d’isolement
ou bien d’enlever des matériaux isolants ou des capots. Si la plaque
frontale doit être enlevée pour un fonctionnement avec la
température de l’environnement plus haute que 40°C, l’utilisateur
doit s’assurer, par des moyens opportuns, qu’aucun contact
occasionnel ne puisse arriver avec les parties sous tension.
3. Protect the drive from extreme environmental conditions
(temperature, humidity, shock etc.)
Protéger l’appareil contre des effets extérieurs non permis
(température, humidité, chocs etc.).
4. No voltage should be connected to the output of the frequency
inverter (terminals U2, V2 W2). The parallel connection of several
drives via outputs nor the direct connection of inputs and outputs
(bypass) are not permissible.
Aucune tension ne doit être appliquée sur la sortie du convertisseur
(bornes U2, V2 et W2). Il n’est pas permis de raccorder la sortie de
plusieurs convertisseurs en parallèle, ni d’effectuer une connexion
directe de l’entrée avec la sortie du convertisseur (Bypass).
5. When engaging a running motor, the Auto capture function (Auto
capture in the ADD SPEED FUNCT menu) must be activated (not
applicable to Regulation mode=sensorless vect).
Pour reprendre des moteurs en rotation, la fonction suivante doit
être activée : “Auto capture” dans le menu ADD SPEED FUNCT.

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6. A capacitative load (e.g. variable power factor capacitors) should
not be connected to the output of the drive (terminals U2, V2, W2).
Aucune charge capacitive ne doit être connectée à la sortie du
convertisseur (bornes U2, V2 et W2) (par exemple des condensateurs
de mise en phase).
7. Always connect the drive to the protective ground (PE) via the
marked connection terminals (PE2) and the housing (PE1).
Adjustable Frequency Drives and AC Input filters have ground
discharge currents greater then 3.5 mA. EN 50178 specifies that
with discharge currents greater than 3.5 mA the protective conductor
ground connection (PE1) must be a fixed type and doubled for
redundancy.
Effectuer toujours des connexions de terre (PE) par le biais des
bornes (PE2) et du chassis (PE1). Le courant de dispersion vers la
terre est supérieur à 3,5 mA. Selon EN 50178 il faut prévoir dans
ces cas une double connexion à terre.
8. The electrical commissioning should only be carried out by quali-
fied personnel, who are also responsible for a suitable ground
connection. The power supply feeder must be in accordance with
the local and national regulations. The motor must be protected
against overloads.
La mise en service électrique doit être effectuée par un personnel
qualifié. Ce dernier est responsable de l’existence d’une connexion
de terre adéquate et d’une protection des câbles d’alimentation
selon les prescriptions locales et nationales. Le moteur doit être
protégé contre la surcharge
9. No dielectric tests should be carried out on parts of the drive. A
suitable measuring instrument (internal resistance of at least 10
kΩ/V) should be used for measuring the signal voltages.
Il ne faut pas éxécuter de tests de rigidité diélectrique sur des
parties du convertisseurs. Pour mesurer les tensions, des signaux,
il faut utiliser des instruments de mesure appropriés (résistance
interne minimale 10 k Ω /V).
10. If the drives have been stored for longer than three years, the
operation of the DC link capacitors may be impaired. Therefore,
before commissioning, connect them to a power supply for two
hours with no load connected in order to regenerate the capacitors
(the input voltage has to be applied without enabling the drive).
En cas de stockage des convertisseurs pendant plus de trois ans, il
faut tenir compte du fait que les condensateurs du circuit
intermédiaire gardent leurs caractéristiques d’origine seulement s’ils
sont alimentés avant trois ans, à partir de leur date de fabrication.
Avant la mise en service des appareils, qui sont restés stockés aussi
longtemps, il est conseillé d’alimenter les convertisseurs pendant
au moins deux heures, pour récupérer les caractéristiques d’origine
des condensateurs : appliquer une tension d’entrée sans activer le
convertisseur (Disable).
11. The drive may start accidentally because of a failure, even if
disabled, unless it has been disconnected from the AC input feeder.
L’appaeil peut rédémarrer de façon accidentel en cas d’anomalie,
sauf s’il a été déconnecté du reseau.

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Functional connection diagram
AC
Power
Supply
Cabinet Mountingpanel ACDrive
AC
Line
Reactor
Ground
Bus
Motor
cable
terminals
ACMotor
Encodercable
EMIfilter
U1V1W1 U2V2W2PE2 PE1
ACVoltage
Contactor
ACfuses
Note:
PE1 is the drive safety ground. If PE2 is used to connect the motor ground, EMC filter ground must connected to PE1.

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Underline: When words are underlined, they refer to a
key on the keypad.
Quotes: Quote marks are put around words which will be
seen in the display window of the keypad.
Menu Navigation: In the instructions, you will be directed
to press keys to get to certain menu items. In many cases,
the same key will have to be pressed more than once to
get to a value. Note that the display has two lines, the top
line always shows the next HIGHER level of the menu. All
of the menu items referred to in this start up will be shown
in the SECOND LINE of the display. The display on the top
line is for information only and has nothing to do with
entering data. If the instructions say to press the [Down
arrow] to “Regulation Mode” it means keep pushing the
[Down arrow] until the “Regulation Mode” is displayed in
the second line. If you get confused, refer to the manual
as it shows the complete menu structure.
I/O Connections: the drive WILL NOT OPERATE unless
the hardware enable (I/O terminal 12) and the other
interlocks are made. It is suggested to make things simple,
to temporarily connect the terminal board inputs as follows:
Jumper 16 to 18, jumper 19 to 15, jumper 15 to 14, jumper
12 to 13, and connect a simple switch between 13 and 14.
Turning the switch on and off will now enable and disable
the drive (and start and stop it at the same time). If you
have control over the I/O with the connected logic and
can make the same connections with pushbuttons/
contacts, the drive can be enabled with those.
2. Overview
This guide assumes a standard start up using the keypad
for a drive and motor that is to be run in either sensorless
vector or flux vector (with digital or sinusoidal encoder)
mode. It is also assumed that a standard scheme is to be
used for control. In other words, that the drive will be run
from pushbuttons (or contacts) and the speed will be set
from a pot input (or a 0 to 10 VDC source). While the drive
has more modes of operation, this guide will cover most
applications. The manual can be used to help adjust more
complicated configurations.
Standard Wiring: see the manual for the standard wiring
configuration. Note that if this is a system designed and
wired by our factory, the set up of the drive (aside from
minor tuning) has already been done.
NOTE:
Memory: There are two memories for set-up parameters.
One is the active memory which is always the one currently
in use by the drive. The other is the permanent memory
which is the one the drive will use if power is lost and then
restored. Note: power up is the ONLY time when the drive
looks at permanent memory. All file uploads and
downloads, all changes, etc. are made only to the active
memory and read from the active memory. The only time
permanent memory is used in any way is when it is booted
into active memory on power up, and when it is changed
to new values by the “Save Parameters” command. When
parameters are changed during set-up, the drive will use
those parameters but unless the “SAVE
PARAMETERS”command is used these changes will not
be permanent. This is an advantage if you are “trying”
something to see how it works and don’t intend to change
your permanent set-up.

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3. Control Terminals
1
2
3
4
5
6
7
8
9
12
13
14
15
16
18
19
BU-
Externalbraking
unit(optional)
StripX1 Function max
Programmable/configurableanalogdifferentialinput.Signal:terminal1.
Referencepoint:terminal2.Defaultsetting:Rampref1 ±10V
Programmable/configurableanalogdifferentialinput.Signal:terminal3. @0.25mA
Referencepoint:terminal4.Defaultsetting:none (20mAwhen
Programmable/configurableanalogdifferentialinput.Signal:terminal5. currentref
input)
Referencepoint:terminal6.Defaultsetting:none.(1)
+10VDC Referencevoltage+10V;Referencepoint:terminal9 +10V/10mA
-10VDC Referencevoltage-10V;Referencepoint:terminal9 -10V/10mA
0V Internal0Vandreferencepointfor±10V -
Enabledrive Driveenable:0Voropen;drivedisabled;+15…+30V:Driveenabled +30V
Start Drivestartcommand:0Voropen:Nostart;+15…+30V:Start 3.2mA@15V
Faststop OVoropen:Faststop.+15…+30V;NoFaststop. 5mA@24V
Externalfault OVoropen:Externalfault.+15…+30V;NoExternalfault 6.4mA@30V
COMDI/O Referencepointfordigitalinputsandoutputs, term.12...15,36...39,41...42 -
0V24 Referencepointfor+24VOUTsupply,terminal19 -
+24VDC +24Vsupplyoutput.Referencepoints:terminals18or27or28 +22…28V
120mA@24V
Analoginput1
Analoginput2
Analoginput3
Analogoutput
1Program.analogoutput;def.setting:Motorspeed.Ref.point:term.22 ±10V/5mA
0V Internal0Vandreferencepointforterminals21and23 -
Analogoutput
2Program.analogoutput;def.setting:Motorcurrent.Ref.point:term.22 ±10V/5mA
BUcomm.
output VeConcontrolledBU-...brakingunitscommand.Ref.point:term.27. +28V/15mA
0V24 ReferencepointforBU-...command,terminal26 -
RESERVED -
Digitalinput1 +30V
Digitalinput2 3.2mA@15V
Digitalinput3 5mA@24V
Digitalinput4 6.4mA@30V
Digitaloutput
1+30V/40mA
Digitaloutput
2
SupplyDO Supplyinputfordigitaloutputsonterminals41/42.Ref.point:term.16. +30V/80mA
MotorPTC 1.5mA
Programmabledigitaloutput;defaultsetting:none
MotorPTCsensingforovertemperature(cutoffR1kifused)
Programmabledigitalinput;defaultsetting:none
21
22
23
26
27
28
29
36
37
38
39
41
42
46
78
79
R1K
StripX2 Function maxcurr.
250VAC
1A,AC11
250VAC
1A,AC11
OKrelay
contact
Potential-relaycontactconfigurable(relay2).
Default:open0drivestopped
Relay2
contact
Potential-relaycontactOKrelay(closed=OK)
80
82
83
85
RESERVED

10
3.1 Maximum cable cross section for regulator terminals
MaximumPermissibleCableCross-Section Tightening
[mm
2
]torque
flexible multi-core [Nm]
1...79 0.14...1.5 0.14...1.5 28...16 0.4
80...85 0.14...1.5 0.14...1.5 28...16 0.4
Ai4090
AWG
Terminals
NOTE:
Terminal board points are intended for 1 wire/point.
Daisy chains and multiple wires/point are better done with a panel mounted terminal board.
4. power terminals
Function maxvolts/curr.
Motorgroundconnection
Brakingunitresistorcommand(brakingresistor
mustbeconnectedbetweenBR1andC)
DCBuscircuitconnection 770VDC/1.65X
outputcurrent
AClinevoltage 480VAC
+10%3Ph
Seetable2.4.2.1
Motorconnection AClinevolt3Ph
1.36Xoutput
current
Brakingresistor(optional)
M
3Ph~
PE1/
Grounding(protectiveearth)conductor
U1/L1
V1/L2
W1/L3
BR1
U2/T1
V2/T2
W2/T3
C
D
PE2/
4.1 Maximum cable cross section for power terminals
Hp 3/4 1 2 3 5 7.5 10 15 20 25 30
AWG
12 8 4
[mm2]
8 101625
Tighteningtorque
[Nm]
23
AWG
12 8 6
[mm2]
8 101616
Tighteningtorque
[Nm]
23
Hp 40 50 60 75 100 125 150 200
AWG
1/0 2/0 4/0 300* 350* 4xAWG2 *=kcmils
[mm2]
50 70 95 150 185 4x35
Tighteningtorque
[Nm]
AWG
[mm2]
Tighteningtorque
[Nm]
3
ai4040
35
6
16
14
210 4
0.5to0.6 6 1.2x1.5
14
2610
U1,V1,W1,U2,V2,W2,C,D
terminals
PE1,PE2terminals
U1,V1,W1,U2,V2,W2,C,D
terminals
PE1,PE2terminals
4
1.2x1.50.5to0.6
4
2
2
50
4 12 10-30

11
5. Encoder terminals (XE connector)
Designation Function I/O max.voltage max.current
ChannelB - 5Vdigitalor 10mAdigitalor
For B-digitalor B-COSincrementalsignal 1Vppanalog 8.3mAanalog
PIN2 -
ChannelC+ 5Vdigitalor 10mAdigitalor
ForC+digitaloranalog zeropulseorindex 1Vppanalog 8.3mAanalog
ChannelC- 5Vdigitalor 10mAdigitalor
ForC-digitaloranalogzeropulseorindex 1Vppanalog 8.3mAanalog
ChannelA+ 5Vdigitalor 10mAdigitalor
ForA+digitalorA+SINincrementalsignal 1Vppanalog 8.3mAanalog
ChannelA - 5Vdigitalor 10mAdigitalor
ForA+digitalorA+SINincrementalsignal 1Vppanalog 8.3mAanalog
PIN7 Referencepointfor+5Vencodersupplyvoltage O––
ChannelB+ 5Vdigitalor 10mAdigitalor
ForB+digitalorB+COSincrementalsignal 1Vppanalog 8.3mAanalog
PIN9 +5Vencodersupplyvoltage O+5V 200mA
ChannelE+ 5Vdigitalor 10mAdigitalor
ForE+digitalcommutationorSIN+absolutepositionsignal 1Vppanalog 8.3mAanalog
ChannelE- 5Vdigitalor 10mAdigitalor
ForE-digitalcommutationorSIN-absolutepositionsignal 1Vppanalog 8.3mAanalog
ChannelF+ 5Vdigitalor 10mAdigitalor
ForF+digitalcommutationorCOS+absolutepositionsignal 1Vppanalog 8.3mAanalog
ChannelF- 5Vdigitalor 10mAdigitalor
ForF-digitalcommutationorCOS-absolutepositionsignal 1Vppanalog 8.3mAanalog
ChannelG+ 5Vdigitalor
ForG+digitalcommutationsignal 1Vppanalog
ChannelG- 5Vdigitalor
ForG-digitalcommutationsignal 1Vppanalog
ai3140
PIN1
PIN3
PIN4
PIN5
I
I
PIN10
PIN11
I
I
PIN6
PIN8
I
I
I
I
10mAdigital
10mAdigitalPIN14
I
I
I
PIN15 I
PIN12
PIN13
5.1 Encoder type connection
123456789101112131415
B- C+ C- A+ A- 0V B+ +5V E+ E- F+ F- G+ G-
DE 8pole
• •••••••
SE 8pole
• •••••••
SESC 12pole
• •••••••••••
DEHS 14pole
• •••••••••••••
ai3160
XECONNECTORPIN
Encoder type Shielded
cable
-DE: 5V digital incremental encoder with A /A, B / B, C / C
-SE: 5V sinusoidal incremental encoder with A /A, B / B, C / C
-DEHS: 5V digital incremental encoder with A /A, B / B, C / C and three Hall sensor digital position signals
(for AC Brushless motors)
-SESC: 5V sinusoidal incremental encoder with A /A, B / B, C / C and and two sin/cos traces for absolute
position (for AC Brushless motors or positioning)

12
5.2 JUMPERS setting
Encoder/Jumperssetting S11 S12 S13 S14 S15 S16 S17 S18 S19 S20 S21 S22 S23
DE OFF OFF OFF OFF OFF OFF ON(*)
----
--
SE ON ON ON ON ON ON
- ----
BB
SESC ON ON ON ON ON ON
-
AAAAAA
DEHS OFF OFF OFF OFF OFF OFF ON(*) BBBBBB
ai3150
-DE: 5V digital incremental encoder with A /A, B / B, C / C
-SE: 5V sinusoidal incremental encoder with A /A, B / B, C / C
-DEHS: 5V digital incremental encoder with A /A, B / B, C / C and three Hall sensor digital position signals (for AC
Brushless motors)
-SESC: 5V sinusoidal incremental encoder with A /A, B / B, C / C and and two sin/cos traces for absolute position
(for AC Brushless motors or positioning)
(*) If the encoder is not provided with the zero channel, S17=OFF
List of jumpers and dip-switch
Designation Function Factorysetting
S0 Thesettingmustnotbechanged OFF
S1 Thesettingmustnotbechanged OFF
S5-S6 TerminatingresistorfortheserialinterfaceRS485 ON
ON=TerminationresistorIN
OFF=Noterminationresistor
S8 Adaptationoftheinputsignalofanaloginput1(terminals1and2) OFF
ON=0...20mA/4...20mA
OFF=0...10V/-10...+10V
S9 Adaptationoftheinputsignalofanaloginput2(terminals3and4) OFF
ON=0...20mA/4...20mA
OFF=0...10V/-10...+10V
S10 Adaptationoftheinputsignalofanaloginput3(terminals5and6) OFF
ON=0...20mA/4...20mA
OFF=0...10V/-10...+10V
S11-S12-S13 Encodersetting OFF
S14-S15-S16 ON=SinusoidalSEorSESCencoder(seeabove)
OFF=DigitalDEorDEHSencoder(seeabove)
S17 MonitoringoftheC-channelofthedigitalencoder OFF
ON=C-Channelmonitored
OFF=C-Channelnotmonitored(requiredforsingle-endedchannels)
S18-S19 Encodersetting B
S20-S21 Pos.A=digitalDEHSencoder(seeabove)
Pos.B=sinusoidalSESCencoder(seeabove)
S22-S23 Analoginput3enabling(alternativewithSESCencoder) A
Pos.A=enabled
Pos.B=disabled
S24 Jumpertodisconnect0V(of24V)fromground ON
ON=0Vconnectedtoground
OFF=0Vdisconnectedfromground
S25 Jumpertodisconnect0V(regulationsection)fromground ON
ON=0Vconnectedtoground
OFF=0Vdisconnectedfromground
ai4060

13
List of dip-switch S3
Hp 3/4 1 2 3 5 7.5 10 15 20
S1
ON OFF ON OFF OFF ON OFF ON OFF
S2
OFF ON ON OFF OFF OFF ON ON OFF
S3
OFF OFF OFF OFF ON OFF OFF OFF ON
S4
OFF OFF OFF OFF OFF OFF OFF OFF OFF
S5
ON ON ON OFF ON OFF OFF OFF OFF
S6
OFF OFF OFF OFF OFF OFF OFF OFF OFF
S7
OFF OFF OFF OFF OFF OFF OFF OFF OFF
S8
OFF OFF OFF OFF OFF OFF OFF OFF OFF
Hp 25 30 40 50 60 75 100 125 150 200
S1
ON OFF ON OFF ON OFF ON OFF ON OFF
S2
OFF ON ON OFF OFF ON ON OFF OFF ON
S3
ON ON ON OFF OFF OFF OFF ON ON ON
S4
OFF OFF OFF ON ON ON ON ON ON ON
S5
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
S6
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
S7
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
S8
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
ai4080
The drives are factory set, but when installing a space regulator card, remember to set dip-switch S3 according to the
above table.
5.3 Maximum cable length for encoder terminals
Cablesection[mm
2
]0.22 0.5 0.75 1 1.5
MaxLengthfeet[m] 88[27] 203[62] 305[93] 410[125] 492[150]
ai3130

14
6. Keypad operation
The keypad is made of a LCD display with two 16-digit lines, seven LEDs and nine function keys.
Keypad LED Module
Shift
Jog
Help Alarm
Escape Home
Enter
Speed
DriveControls
-Torque+TorqueAlarmEnableZeroSpeedLimit
Navigation
-Torque+TorqueAlarmEnableZeroSpeedLimit
-Torque Negativetorquecurrent
+Torque Positive
Alarm Alarmcondition
Enable Driveenablestatus
ZeroSpeedSpeed<=zerospeedthreshold
Limit Actualcurrent>=currentlimit
torquecurrent
Thismonitoringmodulecanbeupgradedwiththekeypadwith
alphanumericLCDdisplay
Keypad is used :
- To control the drive, when keypad use has been programmed (Main commands=DIGITAL.)
- To display the speed, voltage, diagnostics etc. during operation.
- To set parameters.
LEDs
The LEDs present on the keypad and LED module are used to quickly diagnose the operating state of the drive.
Designation Color Function
-Torque yellow the LED is lit, when the drive operates with a negative torque
+Torque yellow the LED is lit, when the drive operates with a positive torque
ALARM red the LED is lit; it signals a trip
ENABLE green the LED is lit, when the drive is enabled
Zero speed yellow the LED is lit; it signals zero speed
Limit yellow the LED is lit, when the drive operates at a current limit
Shift yellow the LED is lit, when the second keypad functions are enabled
ai5010

15
Keypad buttons
Jog
Help
Alarm
Escape
Home
Enter
Shift
Text reference
[START]
[STOP]
[Increase] / [Jog]
[Decrease] / [Rotation control]
[Down arrow] / [Help]
[Up arrow] / [Alarm]
[Left arrow] / [Escape]
[Enter] / [Home]
[Shift]
Function
START button controls the Enable and Run modes of the
drive if Main commands = DIGITAL and the Stop Mode is
on. This is the default setting.
When Main commands is set as TERMINALS the button is
not active
STOP button sets the main reference to zero when Main
commands is set as DIGITAL
(Pressing this button for 2 sec will cause the drive to be
disabled, this will also cause the drive to coast stop).
When Main commands is set as TERMINALS the button is
not active.
Plus button increases the speed reference for the Motor
pot function.
It is also the JOG command, when the shift button is
selected.
Minus button decreases the speed reference for the Motor
pot function.
Rotation control changes the direction in Jog mode and
Motor pot mode when the shift button is selected.
Down arrow - Used to change menu or parameter
selection. In parameter and reference setting modes, it
changes the value of the parameter or reference.
Help – Function Not available (“Help not found” displayed
when pressed with the shift button)
Up arrow - Used to change menu or parameter selection.
In parameter and reference setting modes, it changes the
value of the parameter or the reference.
Alarm - Failure register displayed ( shift selected). Use the
UP/DOWN Arrows to scroll through the last 10 alarms.
Left arrow-in edit mode selects the digit of the parameter
to modify. At other times it is used to exit from the setting
mode.
Escape - Used to exit from setting and Alarm displaying
mode (when shift button is pressed)
[Enter] - Used to [Enter] a new value for a parameter in the
parameter setting mode.
Home - Used to go directly to BASIC MENU (when shift
button is pressed)
Shift button enables the second keypad functions
(Rotation control, Jog, Help, Alarm, Escape, Home)

16
Moving inside a menu

17
7. Pre Power Checks
The following should be checked before switching ON the Drive:
Grounds / Grounding
• Verify ground connections between the drive and motor
• Verify AC Input, AC Output and control wiring aren’t grounded
Connections
• Verify AC Input (U1/L1, V1/L2, W1/L3), AC Output (U2/T1, V2/T2, W2/T3), DC link connection (C,D), Motor thermistor
(78, 79), OK Relay (80, 82), Relay 2 (83,85) and regulation board points (1.....46, XS, XE) connections.
Regulator Terminal Board Inputs:
12 ENABLE DRIVE (close to activate)
13 START (close to activate)
14 FAST STOP (open to cause a stop)
15 EXTERNAL FAULT (open to cause a stop)
16 Common for terminal board inputs
18 + 24V Common
19 +24VDC (internal power supply)
Set inputs on the regulator terminal board as follows:
• Enable drive (terminal 12) and Start (terminal 13) OPEN
• Fast stop (terminal 14) and External fault (terminal 15) CLOSED
• Record motor name plate data, encoder information, gearbox data.
MOTOR DATA

18
8. Quick tuning
1. After a complete check of wiring, turn the power on:
• The following voltages must be present:
Terminal 7, +10V to terminal 9 (on regulation board)
Terminal 8, -10V to terminal 9 (on regulation board)
Terminal 19, +24…30V to terminal 18 (on regulation
board)
• Check DC link voltage by pressing [Down arrow] to
get “Monitor”, then [Enter], then [Down arrow]
to“measurements”, then [Enter], then [Down arrow]
to “DC link voltage”, then [Enter].
The value should be:
275-357 VDC for 230 VAC input
480-650 VDC for 400 VAC input
550-715 VDC for 460 VAC input
If the DC Bus is not within these limits, check the AC
line voltage.
2. Default to Factory Values: If you are not certain of the
drive configuration, it will be necessary to default to factory
values or copy in a file from a PC. It is important to be
certain you are starting from a known configuration. To
default to factory values:
•Default to working memory: Push [Left arrow] to
get back to “Monitor”, then [Down arrow] to “Spec
Functions” and then [Enter]. Push [Down arrow] to
“Load Default” and [Enter]. The factory values will
now be loaded into the working memory, the original
values are still in permanent memory.
Note:
Step 2 can be skipped if you know that the drive is loaded
with factory defaults (as it comes out of the shipping
carton).
3. Set Line Voltage:
• Press [Left arrow] to “Spec functions” then [Up
arrow] to “BASIC MENU”, then [Enter], then [Down
arrow] to “Drive type”, then [Enter] to “Mains voltage”
and [Enter]. Now using the [Up arrow] / [Down
arrow] keys, change the voltage to your nominal AC
input rating. Then [Enter] to set the value.
4. Adaption to maximum ambient temperature:
• Press [Down arrow] to “Ambient temp” then [Enter].
Now using the [Up arrow] / [Down arrow] keys, set
the maximum ambient temperature value: 40°C or
50°C, then [Enter].
5. Load Default Motor Values:
• Press [Left arrow] until you are back to “BASIC MENU”
and then [Down arrow] to Drive Parameter, then
[Enter], then [Down arrow] to Motor Parameter,
[Enter], then [Down arrow] to “Load Motor Par” and
[Enter]. Use the [Up arrow]/[Down arrow] keys until
the display is the correct motor voltage, then [Enter].
For 460 VAC motors, select 460, and for 380/400 VAC
motors select 400.
6. Set Actual Motor Data:
• Press [Left arrow] until back to “Drive parameter”,
then [Enter] to get “Mot plate data” and [Enter] to
“Nominal Voltage” then [Enter] again to see the value.
Using the [Up arrow]/[Down arrow] keys to change
the value and the [Left arrow] to move the character
position. When correct press [Enter].
• Press [Down arrow] to “Nominal speed”, [Enter], then
use the [Up arrow] / [Down arrow] keys to get the
nominal speed on the motor nameplate. Press [Enter]
to set data. Note, some manufacturers of vector
motors put the synchronous speed (600, 900, 1500,
1800, 3600 RPM), rather than the slip speed at 60 Hz
on the nameplate. If this is done, you MUST estimate
slip speed. Figure 20 rpm less than the synchronous
speed for these cases.
• Press [Down arrow] to “Nom frequency” and [Enter]
and set to the nominal frequency on the nameplate
(50 or 60 Hz) Press [Enter] to set data.
• Press [Down arrow] to “Nominal current” and [Enter]
and set to the nominal current on the nameplate (rated
current) by using the [Up arrow] / [Down arrow] keys.
Press [Enter] to set data.
If the drive will “not accept” the value entered, the
most common cause is trying to [Enter] a value for
“Nominal Current” that is less than 30% of the drive
rating. This is not allowed due to parameter problems
encountered with a small motor and a large drive. Go
back to step 6 and repeat the entries. If this doesn’t
work, see the Overflow List in the troubleshooting
section of this book.
• Press [Down arrow] to “Cos phi” and [Enter] and set
the nominal power factor on the nameplate by using
the [Up arrow] / [Down arrow] keys (accept the
default if you don’t know). Press [Enter] to set data.
Press [Down arrow] to “Base Voltage” and [Enter]
and set the base voltage by using the [Up arrow] /
[Down arrow] keys (usually rated voltage). Press
[Enter] to set data. Look in the manual for both Base
Voltage and Base Frequency when operating the motor
above normal synchronous speed.
• Press [Down arrow] to “Base Frequency” and [Enter],
set to the base frequency by using the [Up arrow] /
[Down arrow] keys (usually rated frequency). Press
[Enter] to set data.
• Press [Down arrow] to “Take motor par” and [Enter]
and set all the motor parameters. If, when you do
this, a message saying “Over-range error XXX”
appears, there is something wrong with the data
you have entered. The drive has NOT ACCEPTED
the values you have entered. The most common cause

19
of this is trying to [Enter] a value for “Nominal Current
that is less than 30% of the drive rating. This is not
allowed due to problems encountered with a small
motor and a large drive. Try to go back to the
beginning of step 6 and repeat the entries. If this
doesn’t work, see Overflow list in troubleshooting
section or contact your service office.
7. Set Drive Base Values:
• Press [Left arrow] until back to “drive parameter” then
[Down arrow] to “configuration”, then [Enter].
• Press [Down arrow] to “Speed Base Value” then
[Enter] and set the nameplate rated full load speed
on the motor nameplate, press [Enter]. This bases all
speed related calibrations on top motor speed.
• Press [Down arrow] to “full load current” then [Enter]
and set the DRIVE (not motor) rated full load current
on the drive nameplate by using the [Up arrow] /
[Down arrow] keys, then press [Enter] to set. This
bases all current related calibraitons on motor “Full
Load Amps” (FLA).
8. Set Regulation Mode: (Sensorless vect, V/f or Field
oriented mode )
• Press [Up arrow] to “Regulation mode”, then [Enter]
and use [Up arrow] / [Down arrow] keys to select
“V/f”, “sensorless vect” or “Field oriented” then
[Enter].
• If “Field oriented” mode is selected:
• Press [Down arrow] until to “Motor spd fbk”, then
press
[Enter], [Down arrow] to “Encoder 1 type”, then
[Enter]. Use the [Up arrow]/[Down arrow] keys to
select sinusoidal encoder or digital encoder, then
[Enter].
• Press [Down arrow] to “Encoder 1 pulses”, then
[Enter] and set the value using the [Up arrow]/[Down
arrow] keys to the PPR (pulses per revolution) of your
encoder, [Enter].
• Press [Down arrow] four times to “Refresh Enc 1”
then
[Enter], “Enable” [Enter], this enables the Speed
fdbk Loss Alarm.
9. Speed Limit:
• Press [Left arrow] until “Basic Menu”, then [Down
arrow] to “Limits”, then [Enter] for “Speed Limits”,
then [Enter] for “Speed Amount”, then [Enter] to
“Speed Min Amount”. Press [Down arrow] to “Speed
Max Amount”, and [Enter]. Change the value from
5000 RPM to the maximum speed of the motor use
the
[Up arrow]/[Down arrow] keys as before (for now
set it to 105% of the rated motor speed). Press
[Enter].
10. Prepare for Self Tune:
• The keypad will be used for this purpose but the
I/O needs to be connected properly to the enable/
disable functions.
11. Save Parameters:
• Press [Left arrow] to “limits”, then [Up arrow] until
“Basic Menu” then [Enter], then [Down arrow] to
“save parameters”, then [Enter].
The display will read “wait” until the values are
permanently stored.
12. Self Tune:
Make sure power is on and drive not enabled.
Close the switch on terminal 12 (hardware enable has
24 Vdc on it).
• When the enable switch is made, Press [Left arrow]
until “Basic Menu” then [Down arrow] to “Drive
Parameter”, then [Enter], then [Down arrow] to
“motor parameters” and [Enter]. Press “[Down
arrow] to “Self Tuning” and [Enter] to “self tune 1”.
Press [Enter] to “start part 1” and [Enter], “start part
1 ?” and [Enter] again. The keypad should show the
“enable” led illuminated, if not, make sure that you
have the jumpers (or external switches) set so that 24
VDC exists on terminal boards 12, 13, 14, 15, with
respect to 16 or 18.
• You should now see “measuring Rs” (stator
resistance). Wait until the display says “end”, then
disable the drive (open the switch to 12) and push
[Left arrow] twice to see “self tune 1”, press [Enter],
then [Down arrow] all the way to “take val part 1”
and [Enter]. The display will read “wait” until the
values are stored. The motor shaft must not move
during the procedure. If necessary, the motor shaft
must be locked.
NOTE:
“xxx range error” or “timeout” messages may also occur in
some extreme parameter ranges. Repeat the tune in this
case. If error messages are persistent see troubleshooting
section.
13. Self Tune part 2:
The initial part of self tuning that can be done without
the motor rotating has been accomplished. Now, to
get the best possible tuning, the motor needs to turn
with no load attached to the shaft. For this we use
Self tune mode 2a. If, for any reason, the motor cannot
be made to rotate with no load, then a “close” level of
tuning can still be accomplished by selecting Self tune
mode 2b.
• Now press [Left arrow] to see “self tune 1” then
[Down arrow] to “self tune 2a or 2b and press [Enter].
Enable the drive using the switch to terminal 12. Press
[Enter], “start part 2a ?” or “start part 2b ?” then
[Enter] and see “measure sat 2a (or b)” will appear
and the motor shaft will turn (if “self tune 2a” is select).
Wait until the display says “end”, press [Left arrow]
to see “self tune 2a (or b)” then [Enter] and press
[Down arrow] to see “take val part 2a (or b)”. Disable
the drive (switch off terminal 12), then [Enter].

20
NOTE:
“xxx range error” or “timeout” messages may also occur in
some extreme parameter ranges. Repeat the tune in this
case. If error messages are persistent see troubleshooting
section.
If there was some reason you did not want to keep these
values permanently, but only wanted to try to run the drive
with them, there is no need to save them to permanent
memory. If power is cycled however, these values will be
lost unless the “Save Parameter” function is used.
14. Self tune part 3:
The third part of self tuning (Speed regulator tuning)
identifies the total inertia at the motor shaft, the friction
value and computes the proportional and integral gains
of the speed regulator. The motor needs to be free to
turn with load attached to the shaft.
NOTE:
When regulation mode = field-oriented, the encoder needs
to be verified before running Self Tune 3. Refer to page 22
“Encoder Verification”. After this verification procedure, put
the regulation mode back to field oriented.
WARNING !
This procedure requires free rotation of the motor shaft
coupled to the load. The Start/Stop command is
ignored, therefore it can not be used on drives with
limited travel, or when free rotation presen ts a safety
problem.
CAUTION !
The test is performed using the torque limit value set
in Test T curr lim parameter. The torque is applied in a
step fashion, with no ramp profile. Therefore, the
mechanical transmission must not have significant
backlash, and it must be compatible with operation at
the torque limit set in the Test T curr lim parameter.
The user can reduce the torque limit to a suitable value
via the Test T curr lim parameter.
Note !
• Application where the system inertia coupled to the
motor shaft is much higher than the motor inertia value
, increase the Test T curr lim parameter to avoid “Time
out” error.
• This procedure is not suitable for use with “hoist”
or “elevator” drives.
• Encoder feedback is required when Field oriented mode
is selected.
• Set the current limit (BASIC MENU\ T Current lim +/-)
to a value compatible with the motor size and load.
(Example when motor is 1/3 of the Drive power, the
limit should be reduced compared to the default value).
• Select the torque current value to be used during the
test via the Test T curr lim parameter
• Now press [Left arrow] to see “self tune 2a or 2b”
then
[Down arrow] to “self tune 3” and press [Enter]
to Fwd-Rev spd tune, then [Enter]. Set the motor shaft
direction for this test: Forward or Reverse by using
[Up arrow] / [Down arrow] keys. Press [Enter] to
set the selection.
• Enable the drive using a switch on terminal 12 [and
close terminal 13 to terminal 19 if Speed control
function is enabled (default)]. Press [Down arrow]
to “Start part 3” then press [Enter], “start part 3 ?”
then
[Enter] and see “measure speed” will appear and
the motor will turn. Wait until the display says “end”,
press [Left arrow] to see “self tune 3” then [Enter]
and press [Down arrow] to see “take val part 3”.
Disable the drive, then [Enter]. You are now finished
with the initial set up and tuning with values stored in
only in the “working memory”.
NOTE:
“xxx range error” or “timeout” messages may also occur
in some extreme parameter ranges. Repeat the tune in
this case. If error messages are persistent see
troubleshooting section.
NOTE:
If there was some reason you did not want to keep these
values permanently, but only wanted to try to run the drive
with them, there is no need to save to permanent memory.
If power is cycled however, these values will be lost unless
the next step is taken.
To save all values to permanent memory, select Save
parameters and press [Enter] .
15.Set up for Running:
First, before saving, let’s put the drive into the
configuration you want to run it in.
The drive is factory setting to run through the Increase
[+] and Decrease [-] keys (Enable motor pot
parameter = Enabled), see the following instruction to
run.