Magnetek Elevator Axial Flux HPV900 2 Series Guide

Axial Flux Start Guide
Guide to set up 900S2 Axial Flux drive

Axial Flux Start Guide
This is a quick setup guide to commission the HPV900 Series 2 Axial Flux drive.
Step 1 –Mechanical Mounting
First the encoder, proximity switch, and rider wheel must be mounted as follows:
1. Fit the Rider wheel (05P00066-0622) to the encoder (Box 05P00057-0112) using the set screw
(05P00302-6208).

Axial Flux Start Guide
2. Connect Proximity sensor (46S04441-0010) to proximity bracket (43T02814-0030) with the two
M12 nuts on the sensor
3. Remove old tachometer or encoder from the machine, and attach the new bracket and encoder to
the motor as shown below. The proximity bracket can be rotated to align with target flag
4. The target flag (43T02814-00XX based on which flag best fits) should be positioned on the
sheave so that the short edge will face the proximity sensor. Use the alcohol wipe (05P00100-
0064) to clean the surface, then fix target using the adhesive pad (05P00531-0025)
Use the gap tool (43T02814-0020) to give correct distance

Axial Flux Start Guide
Position target flag:
Use gap tool to give correct distance between proximity sensor and target flag:

Axial Flux Start Guide
Step 2 –Electrical Connection
Connect the encoder and proximity sensor wires to the drive as follows:
The wires are labelled, and should be connected into the terminals with the matching numbers in the long green
terminal blocks.
Make sure the switches on the TerMag board are set correctly as follows:

Axial Flux Start Guide
Step 3 –Drive Parameters
The following drive parameters should be entered for the Axial Flux drive:
Menu
Parameter
Correct Setting
U9
Drive Mode
“PM”
C1
Encoder Select
“Axial-Flux”
Motor Rotation
See table below
A4
Input L-L Volts
Enter Line to Line Voltage
A5
Rated Motor Power
From Motor Dataplate
Rated Motor Voltage
From Motor Dataplate
Rated Motor Current
From Motor Dataplate
Motor Poles
From Motor Dataplate
Rated Motor Speed
From Motor Dataplate
A1
Encoder Pulses
See table below
Motor Rotation (C1)
Ensure the motor is wired to the drive with U to U, V to V and W to W
If the motor sheave will rotate in a Clockwise direction for the car to travel up, set Motor Rotation (C1) to
FORWARDS
If the motor sheave will rotate in an Anti-clockwise direction for the car to travel up, set Motor Rotation (C1) to
REVERSE
Encoder Pulses (A1)
The encoder pulses in the A1 menu should be picked from the table below:
PM Motor Frame Types
Encoder Pulse (A1)
MX05/10
14395 PPR
MX05/16
14452 PPR
MX06/05
17067 PPR
MX06/10
17067 PPR
MX06/16
17067 PPR
MX10/05
19819 PPR
MX10/08
19735 PPR
MX10/10
19819 PPR
MX10/15
19680 PPR
MX18
26050 PPR
MX20
12950 PPR (75mm Rider Wheel)
These values are simply a starting point. The final encoder PPR value will be entered once the motor can be run
at full speed as detailed in step 5.
If the motor does not conform to any of the types listed above, the PPR can be calculated using the diameter of
the sheave where the encoder rider wheel is running (This may differ from the sheave diameter on the motor
dataplate), and the diameter of the rider wheel supplied (37mm or 75mm).

Axial Flux Start Guide
Step 4 –Alignment and Autotune
HF Inject Procedure
The drive must determine an encoder offset value before it can turn the motor.
The drive will automatically perform a HF inject alignment when it is given a run command and all parameters are
entered with no active faults.
During Alignment, a slight buzzing noise should come from the motor for approximately half a second and the
RUN light will be lit for the duration of the procedure.
If the fault AT CONTACT FLT is displayed, verify the motor contactor closes during this process
If the fault BRAKE IS OPEN is displayed, the drive has detected motion - verify the brake does NOT lift. If
brake doesn’t lift and minimal movement has occurred, increase BRK FLT LEVEL (A4).
The drive should now be able to run the motor, however an autotune should also be performed as follows:
When the alignment is complete, move to the U12 menu and perform an Autotune. The Autotune procedure is
similar to the Alignment procedure:
1. Move to the (U12) menu.
2. Press Enter to display:
3. Press Enter, and change Autotune select to YES or ON RUN. (“Yes” will begin the alignment
immediately, and “On Run” will wait till the drive is asked to run)
If “On Run” was selected for Autotune select, you will have to press and hold test control buttons while autotune is
carried out.
10:00 May 4
U0 UTILITY
U12 AUTOTUNE SEL
READY
RUN
USER
TORQUE
LIMIT
FAULT
SUBMENU
DATA ENTRY
U10 10:00
Autotune Select
DISABLE
READY
RUN
USER
TORQUE
LIMIT
FAULT
SUBMENU
DATA ENTRY
U10 10:00
Autotune Select
ON RUN
READY
RUN
USER
TORQUE
LIMIT
FAULT
SUBMENU
DATA ENTRY

Axial Flux Start Guide
During Autotune, a slight buzzing noise should come from the motor for approximately half a second and the RUN
light will be lit for the duration of the procedure.
If the fault AT CONTACT FLT is displayed, verify the motor contactor closes during this process
If the fault BRAKE IS OPEN is displayed, the drive has detected motion, verify the brake does NOT lift. If
brake doesn’t lift and minimal movement has occurred, increase BRK FLT LEVEL (A4).
Step 5 –Running
When the above steps have been completed, the drive should be ready to run the motor.
If any faults are displayed whilst running, refer to the troubleshooting section at the end of this guide.
ELSE
If the motor turns, but is running in the wrong direction, change MOTOR ROTATION parameter in C1.
If the motor turns halfway, then stops, check encoder ENCODER PULSES in the A1 menu. This should
match the value in the table above (14,000 to 26,050PPR).
Finally, once running correctly and the installation is close to completion, you can perform full speed runs in both
directions, and check “MEASURED PPR” and “EST INERTIA” in the D1 menu. Monitor these values in both
directions, and take an average of each.
This average value for “MEASURED PPR” should be entered in “ENCODER PULSES”in the A1 menu.
The average value for “EST INERTIA” should be entered in “INERTIA” in the A1 menu.
U10 10:00
ALARM!
AUTOTUNE IS DONE
READY
RUN
USER
TORQUE
LIMIT
FAULT
SUBMENU
DATA ENTRY

Axial Flux Start Guide
Troubleshooting
If any issues are experienced which are not covered by this guide, please refer to the technical manual (TM354)
which is available on the Magnetek website.
Faults/Alarms/Difficulties
Description
Solutions
Encoder Flt
The drive is in a run condition
and the encoder is:
not functioning
or
not connected
or
phasing is not proper with
motor phasing
Incorrect Encoder Phasing
Verify that the encoder
phasing is correct
Swap encoder A and /A
channel on TB1-1 and TB1-2
Perform an Open-Loop
Alignment
Encoder Power Supply
Check that the encoder
power supply on TB1-17
and TB1-18 is 12VDC
Verify that SW2 is switched
to the 12V position (at
right). Verify that the
voltage between TB1-17
and TB1-18 is 12 volts DC
Parameter Settings
Verify that the Encoder
Connect (C1) is set to axial
flux
Verify that the Encoder
Pulses (A1) is set to a
reasonable number
Encoder Mechanical Setup
Verify that the rider wheel
is firmly on the rotor and
that the encoder spins as
the rotor is spinning

Axial Flux Start Guide
Faults/Alarms/Difficulties
Description
Solutions
HIT TORQUE LIMIT
(alarm)
The drive has reached its torque
limit as defined in the A1 menu.
Incorrect Encoder Phasing
Verify that the encoder
phasing is correct.
Swap the A and /A wires in
TB1-1 and TB1-2
Perform an Open-Loop
Alignment
Proximity Switch
Verify that the target
sensor is being seen by the
proximity switch every time
the target is lined up with
the proximity switch using
the Z Edge Count (D1)
Verify that there is no noise
on the proximity switch
channel by verifying that
the Z Edge Count (D1) isn’t
incrementing/decrementin
g more than once per
motor rotation
Check that the proximity
switch power supply on
TB1-17 and TB1-18 is 12VDC
Verify that SW2 is switched
to the 12V position (at
right). Verify that the
voltage between TB1-17
and TB1-18 is 12 volts DC
Parameter Settings
Verify that the Encoder
Connect (C1) is set to axial
flux incremental
Verify that the Encoder
Pulses (A1) is set to a
reasonable number
Rotor Alignment
Perform a rotor alignment
in the U10

Axial Flux Start Guide
Faults/Alarms/Difficulties
Description
Solutions
Once Per Revolution Bump
The motor would jerk every time
the target sensor goes pass the
proximity switch
NOTE: for MRL setup, use the Z
Edge Count (D1) to see when
the target is being seen by the
drive if you can’t see the motor
Parameter Setting
Verify that the Encoder
Pulses (A1) matches the
number for Measured PPR
(D1) while the motor is
rotating at high speed
If they don’t match, enter
measured PPR in Encoder
Pulses (A1).
RTR NOT ALIGN
Run command given before
aligning the rotor.
The drive does not have a good
fix on the motor’s magnets.
Alignment Failed
Perform a Rotor Align (U10)
Verify the motor is
connected properly
Verify that the motor isn’t
bad
Verify that the contactor is
picked while the drive is
performing the alignment

Axial Flux Start Guide
Faults/Alarms/Difficulties
Description
Solutions
Spd Dev Flt
or
Spd Dev Alm
The speed feedback is failing to
properly track the speed
reference
Encoder Cable not properly
grounded
Verify encoder cable is
properly grounded
Motor Runaway Condition –
(PM)
Verify that the rider wheel is
firmly connected to the rotor
and that the encoder spins as
the rotor is spinning
Drive and/or Motor is
Undersized
Usually drive’s “HIT
TORQUE LIMIT” alarm
message is displayed
(depending on setting of
TRQ LIM MSG DLY (A1)
parameter)
Verify drive and/or motor
sizing. May need a larger
capacity HPV 900 S2 and/or
motor.
Check Parameter Settings –
PM
Usually drive’s “HIT
TORQUE LIMIT” alarm
message is displayed
(depending on setting of
TRQ LIM MSG DLY (A1)
parameter)
Check speed regulator
parameters RESPONSE and
INERTIA (A1)
Fault/Alarm sensitivity –
SPD DEV FLT LVL or SPD
DEV ALM LVL (A1)
parameter is set too low for
required
acceleration/deceleration
rate.
NOTE: Setting SPD DEV FLT
LVL too high will reduce drive’s
sensitivity runaway conditions!

Axial Flux Start Guide
Faults/Alarms/Difficulties
Description
Solutions
Z Marker Loss
The drive is expecting a signal
back from the proximity switch
but doesn’t see any within the
expected window.
Proximity Switch
Verify that the target
sensor is being seen by the
proximity switch every time
the target is lined up with
the proximity switch using
the Z Edge Count (D1)
Verify that there is no noise
on the proximity switch
channel by verifying that
the Z Edge Count (D1) isn’t
incrementing/decrementin
g more than once per
motor rotation
Check that the proximity
switch power supply on
TB1-17 and TB1-18 is 12VDC
Verify that SW2 is switched
to the 12V position (at
right). Verify that the
voltage between TB1-17
and TB1-18 is 12 volts DC