Magnetek DSD 412 User manual

DSD 412
DSD 412 DC Elevator Drive
Technical Manual
To properly use the product, read this manual thoroughly and retain for easy reference, inspection,
and maintenance. Ensure that the end user receives this manual.
CS00407 rev 11
© Magnetek Elevator 2016
U39 / U40 97SA407x-0010 Rv16
U13 / U14 97SA404x-0008 Rv08

Warranty
Standard products manufactured by the Company are warranted to be free from defects in
workmanship and material for a period of one year from the date of shipment, and any
products, which are defective in workmanship or material, will be repaired or replaced, at the
Company’s option, at no charge to the Buyer. Final determination as to whether a product is
actually defective rests with the Company. The obligation of the Company hereunder shall
be limited solely to repair or replace, at the Company’s discretion, products that fall within
the foregoing limitations, and shall be conditioned upon receipt by the Company of written
notice of any alleged defects or deficiency promptly after discovery and within the warranty
period, and in the case of components or units purchased by the Company, the obligation of
the Company shall not exceed the settlement that the Company is able to obtain from the
supplier thereof. No products shall be returned to the Company without its prior consent.
Products, which the company consents to have returned, shall be shipped prepaid f.o.b. the
Company factory. The Company cannot assume responsibility or accept invoices for
unauthorized repairs to its components, even though defective. The life of the products the
Company depends, to a large extent, upon type of usage thereof and THE COMPANY
MAKES NO WARRANTY AS TO FITNESS OF ITS PRODUCTS FOR THE SPECIFIC
APPLICATIONS BY THE BUYER NOR AS TO PERIOD OF SERVICE UNLESS THE
COMPANY SPECIFICALLY AGREES OTHERWISE IN WRITING AFTER PROPOSED
USAGE HAS BEEN MADE KNOWN TO IT.
This warranty does not apply to experimental products for which no warranty is made or
given and Buyer waives any claim thereto.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER
WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, BUT LIMITED TO, ANY
WARRANTY OF MECHANTIBILITY OR OF FITNESS FOR A PARTICULAR PURPOSE
AND BUYER HEREBY WAIVES ANY AND ALL CLAIMS THEREFORE.
Limitations Of Liability
IN NO EVENT SHALL MAGNETEK BE LIABLE FOR LOSS OF PROFIT, INDIRECT,
CONSEQUENTIAL OR INCIDENTAL DAMAGES WHETHER ARISING OUT OF
WARRANTY, BREACH OF CONTRACT OR TORT.
DSD 412 is a trademark of Magnetek, Inc.
All rights reserved. No part of this publication may be reproduced or used in any form or by any means - graphic, electronic, or
mechanical including photocopying, recording, taping, or information storage and retrieval systems - without written permission
of the publisher.
2016 Magnetek, Inc.

1
Table of Contents
Introduction.............................................................................................................11
Drive Description ............................................................................................................................. 11
The Standard Control Display Unit (SCDU).................................................................................... 11
The Portable Control Display Unit (PCDU) ..................................................................................... 11
Drive Ratings and Specifications................................................................................................... 11
Basic Drive Specifications............................................................................................................... 11
Service Conditions .......................................................................................................................... 11
Protective Features......................................................................................................................... 11
Software Operating Features.......................................................................................................... 12
Power Conversion Unit.................................................................................................................... 17
Description ...................................................................................................................................... 17
Hardware Descriptions.................................................................................................................... 17
DSD 412 Power Supply PCB (A4).................................................................................................. 17
Armature Interface PCB (A2) .......................................................................................................... 17
SCR's .............................................................................................................................................. 18
Field Interface PCB (A3) ................................................................................................................. 18
Cell snubber PCB (A5).................................................................................................................... 18
Drive Control PCB (A1)................................................................................................................... 18
Precautionary Statements............................................................................................................... 20
How To Contact Magnetek.............................................................................................................. 20
Pre-Installation Considerations...................................................................................................... 21
Receipt of Shipment........................................................................................................................ 21
Unpacking Instructions.................................................................................................................... 21
Packing Instructions for Reshipment or Storage ............................................................................ 21
Physical Installation ........................................................................................................................ 21
Selecting, Mounting and Wiring of the Digital Encoder............................................................... 21
Encoder Selection........................................................................................................................... 21
Mounting ......................................................................................................................................... 21
Coupling .......................................................................................................................................... 22
Exceeding Operating Specification................................................................................................. 22
Electrical Hook up ........................................................................................................................... 23
Power Connections......................................................................................................................... 23
Signal Connections ......................................................................................................................... 23
Grounding ....................................................................................................................................... 23
Pre-power Check ............................................................................................................................ 23
Drive Start up.................................................................................................................................... 24
Drive power-up sequence ............................................................................................................... 24
Abnormal Display Conditions.......................................................................................................... 24
Fan Check....................................................................................................................................... 24
Verify Parameters ........................................................................................................................... 24
Interconnect Drawings .................................................................................................................... 25
Standard Control/Display Unit Operation .............................................................31
General ........................................................................................................................................... 31
Start-Up Operation.......................................................................................................................... 31
After Power-Up................................................................................................................................ 32
Changing Parameter Functions ...................................................................................................... 32
Viewing Monitor Functions.............................................................................................................. 33
Error Reporting................................................................................................................................ 33
Fault Display/Clear.......................................................................................................................... 35
Error Display ................................................................................................................................... 35
Non-Volatile Ram Access ............................................................................................................... 36
Load Default Function..................................................................................................................... 37

2
Self Tune Function.......................................................................................................................... 37
Power Conversion Diagnostics ....................................................................................................... 39
Drive Setup & Adjustments....................................................................................41
Motor Field Current Control ............................................................................................................ 41
Analog Velocity Follower................................................................................................................. 41
Internal Preset Speed & Profile Generator ..................................................................................... 41
Serial Link Follower......................................................................................................................... 41
Armature Voltage Feedback ........................................................................................................... 41
Pre-Torque, Function #114 ............................................................................................................. 41
Current Ramp-Down, Function #85 ................................................................................................ 41
Electronic Motor Over-Load ............................................................................................................ 42
External/Auto Fault Reset, Function #101 ...................................................................................... 42
Over-Speed Test, Functions #80 and #81...................................................................................... 42
Brake Control Logic, Functions #186 and #183.............................................................................. 42
Speed Regulator Adjustment/E-Reg............................................................................................... 43
Field Regulator Set-Up ................................................................................................................... 45
AC Input Voltage Requirement & Adjustment................................................................................. 45
Adjustment Function Descriptions ................................................................................................ 59
Display Monitor Functions.............................................................................................................. 76
Miscellaneous Functions ................................................................................................................ 78
Drive Faults .............................................................................................................79
Function Error Code Listing ........................................................................................................... 79
Troubleshooting .............................................................................................................................. 80
Input – Output Signal Verification .........................................................................89
Maintenance ............................................................................................................91
Preventive Maintenance ................................................................................................................. 91
Repair and Replacement Procedures............................................................................................. 91
Printed Circuit Boards ..................................................................................................................... 91
Drive Control PCB Replacement .................................................................................................... 97
IC Replacement .............................................................................................................................. 97
Testing and Replacement of Power Components. ......................................................................... 97
Testing and Replacement of Power Semiconductors and Snubber Components. ........................ 98
Testing and Replacement of the Motor Field Control Module and PCB......................................... 98
Repair of the 195Amp Assembly .................................................................................................... 99
Repair of the 300Amp Assembly .................................................................................................. 100
Appendix................................................................................................................104
Drive Ratings for Elevator Applications...................................................................................... 104
Power Loss..................................................................................................................................... 105
Wire Terminal Specs...................................................................................................................... 106
Power Terminal Wire Sizes........................................................................................................... 106
Ground Wire Sizes........................................................................................................................ 106
Field Interface Board (TB1, TB4) .................................................................................................. 106
Spare Parts ..................................................................................................................................... 107
Packing Instructions...................................................................................................................... 110
Outline Drawings............................................................................................................................ 111
Index.......................................................................................................................117

Quick Reference for Setup Parameters
3
FNCT. # DESCRIPTION UNIT RANGE DEFAULT SITE SETTING
1 CURRENT LIMIT. % 0 - 300 250
2 USE SELF- TUNE
VALUES LOGIC 0 - 1 0=OFF
3 RTD. ARMATURE AMPS ADC 2.0 - 1250.0 50.0
4 ARMATURE OHMS OHMS 0.001 - 5.000 0.100
6 ARMATURE
INDUCTANCE HNY 0.0010 -1.000 0.0100
7 RTD. ARMATURE VOLTS VDC 150 - 550 240
8 I REG CROSSOVER RAD 100 - 1000 500
9 NOMINAL AC INPUT VAC 150 - 525 230
10 ENCODER PPR P/R 600 - 19999 1024
11 RATED MOTOR RPM RPM 50.0 - 1999.0 1150.0
12 OVERSPEED % % 0.0 - 150.0 110.0
14 V SENSE % % 0.0 - 100.0 25.0
15 T SENSE % % 0.0 - 100.0 5.0
16 ENCDR / MTR RATIO - 1.000 - 19.000 1.000
17 RATED CAR SPEED - 1.0 - 1900.0 400.0
21 EXT ACCEL LIMIT - 2.00 - 10.00 4.20
22 ERROR LIST RESET LOGIC 0 - 1 0=OFF
32 FULL FIELD DETECT % 30 - 90 80
38 ARM VLT RESPONSE RAD 1.0 - 4.0 2.0
39 HI SPEED BANDWIDTH RAD 1.0 – 15.0 6.0
40 LO SPEED BANDWIDTH RAD 1.0 – 15.0 6.0
41 PER-UNIT INERTIA SEC 0.10 - 9.99 2.00

Quick Reference for Setup Parameters
4
FNCT. # DESCRIPTION UNIT RANGE DEFAULT SITE SETTING
42 STIFFNESS - 0.2 - 9.9 1.0
49 WEAK FIELD CURRENT ADC 0.20 - 40.00 40.00
50 FULL FIELD CURRENT ADC 0.20 - 40.00 1.90
51 MOTOR FIELD L/R SEC 0.10 - 10.00 0.54
52 RTD. FIELD VOLTS DC VDC 50 - 525 240
53 STANDBY FIELD AMPS % 10 - 100 25
54 FIELD RESPONSE RAD 1.0 - 10.0 5.0
55 FIELD CONTROL AC
SOURCE VOLTS VAC 0 - 525 0
63 U/D PICK-UP % 0.01 - 100.00 0.10
64 LOW SPEED
THRESHOLD % 0.1 - 100.0 2.0
80 OVER SPEED TEST LOGIC 0 - 1 0=OFF
81 OVER SPEED MULT - 1.00 - 1.50 1.00
82 REFERENCE MULT - -2.000 - 2.000 1.000
83 MOTOR OVERLD TIME SEC 2.0 - 500.0 48.0
84 MOTOR OVERLD LEVEL PU 0.50 – 2.00 1.15
85 I DECAY RAMP SEC 0.01 - 2.50 0.20
86 ANALOG SPD REF ZERO PU -0.2000 - +0.2000 0.0000
87 PRE-TORQUE MULT - 0.25 - 2.00 1.00
88 DSPR DELAY TIME MIN 0 - 60 0 (OFF)
89 BRAKE PICK TIMER SEC 0.5 - 5.0 1.0
90 BRAKE DROP TIMER SEC 0.5 - 5.0 1.5
91 MUST STOP TIMER SEC 0.1 - 5.0 2.0

Quick Reference for Setup Parameters
5
FNCT. # DESCRIPTION UNIT RANGE DEFAULT SITE SETTING
92 BRAKE AUTO STOP ON LOGIC 0 - 1 0=OFF
93 ANALOG OUT 0 BIAS - -1.00 - +1.00 0.00
94 ANALOG OUT 1 BIAS - -1.00 - +1.00 0.00
95 ANALOG OUT 0 SELECT
TB1(45) NUM 0 - 8 1
96 ANALOG OUT 1 SELECT
TB1(46) NUM 0 - 8 3
97 ANALOG OUT 0 MULT - 00.10 - 10.00 0.80
98 ANALOG OUT 1 MULT - 00.10 - 10.00 0.80
99 SPEED ERROR TRIP
TIME SEC 0.20 - 5.00 5.00
100 SPEED ERROR TRIP
LEVEL % 0.0 - 100.0 100.0
101 AUTO FAULT RESET ON LOGIC 0 - 1 0=OFF
102 3S LOOP FLT LOGIC 0 - 1 0=OFF
104 SERIAL GAIN SWITCH LOGIC 0 - 1 0=OFF
105 GAIN SWITCH SPEED PU 0.00 - 1.10 1.10
107 TACH RATE GAIN % 0.0 - 30.0 0.0
110 REFERENCE MODE
SELECT NUM 1 – 5 2
111 ARCH TRAV DISABLE LOGIC 0 - 1 1=ON
112 FEEDBACK SELECT NUM 0 - 1 1 =
ENCODER
113 ARM VOLTS @ MAX
SPEED VDC 0.0 – 650.0 100.0
114 PRE-TORQUE ENABLE LOGIC 0 - 1 0=OFF
115 RNUP RNDN ENABLE LOGIC 0 - 1 0=OFF
116 DECEL RATE LATCH LOGIC 0 - 1 0=OFF
117 PRETORQUE BIAS PU 0.00 – 1.00 0.00

Quick Reference for Setup Parameters
6
FNCT. # DESCRIPTION UNIT RANGE DEFAULT SITE SETTING
120 SPEED ERROR DETECT
TIME SEC 0.0 – 5.0 0.5
121 SPEED ERROR
THRESHOLD % 0.0 – 15.0 2.0
130 ARB MODE NUM 0 – 2 0 (OFF)
131 ARB BANDWIDTH RAD 1.0 – 15.0 6.0
132 ARB DAMPING - 0.01 –20.00 2.00
133 ARB SPD THRESHOLD % 0.0 – 10.0 0.0
150 BINARY SELECT ON LOGIC 0 – 1 1=ON
151 PRESET SPEED #1 - 0.0 – 1900.0 0.0
152 PRESET SPEED #2 - 0.0 –1900.0 0.0
153 PRESET SPEED #3 - 0.0 – 1900.0 0.0
154 PRESET SPEED #4 - 0.0 – 1900.0 0.0
155 PRESET SPEED #5 - 0.0 – 1900.0 0.0
156 PRESET SPEED #6 - 0.0 – 1900.0 0.0
157 PRESET SPEED #7 - 0.0 – 1900.0 0.0
170 ACCEL #1 TIME SEC 1.00 – 15.00 5.00
171 ACCEL #2 TIME SEC 1.00 – 15.00 5.00
172 DECEL #1 TIME SEC 1.00 – 15.00 5.00
173 DECEL #2 TIME SEC 1.00 – 15.00 5.00
174 ACCEL #1 % S % 0.1 – 100.0 25.0
175 ACCEL #2 % S % 0.1 – 100.0 25.0
176 DECEL #1 % S % 0.1 – 100.0 25.0

Quick Reference for Setup Parameters
7
FNCT. # DESCRIPTION UNIT RANGE DEFAULT SITE SETTING
177 DECEL #2 % S % 0.1 – 100.0 25.0
178 ACCEL #3 TIME SEC 1.00 – 15.00 5.00
179 DECEL #3 TIME SEC 1.00 – 15.00 5.00
180 ACCEL #3 % S % 0.1 – 100.0 25.0
181 DECEL #3 % S % 0.1 – 100.0 25.0
182 INVERT ALARM RELAY LOGIC 0 – 1 0=OFF
183 K3 LGC OUT SELCT NUM 1 – 4 1
184 K4 LGC OUT SELCT NUM 1 – 4 1
185 K5 LGC OUT SELCT NUM 1 – 4 1
186 K6 LGC OUT SELCT NUM 1 – 4 1
187 K7 LGC OUT SELCT NUM 1 – 4 1
190 NOTCH DEPTH - 0 – 10 0
191 NOTCH PERIOD - 0 – 10 7
192 F413 DETECTION LVL PU 0.05 – 0.50 0.05
Table 1: Drive Parameters

Read-Out and Control Parameters
8
FNCT. # DESCRIPTION UNIT
600 CAR SPEED -
601 MOTOR RPM RPM
602 SPEED REF -
603 PRE-TORQ SIGNL %
609 CEMF VOLTS VDC
610 MOTOR ARM V VDC
611 MOTOR ARM I ADC
612 MOTOR FIELD I ADC
613 MEASURED R OHM
614 MEASURED L HNY
615 MEAS. FIELD L/R SEC
616 MEASURED SPEED
ERROR %
617 LINE FREQ HZ
618 HEAT SINK TEMP DEG C
619 MEASURED AC LINE
VOLTS VAC
620 FIELD TRACKING PU
621 SERIAL COMM ON LOGIC
688 CUBE I.D. -
689 FIELD RANGE -
FNCT. # DESCRIPTION UNIT
690 PCU - VERSION -
691 PCU - RELEASE -
692 DAY -
693 MONTH -
695 YEAR -
696 BETA “P” -
697 VERSION “SA” -
698 DCU -RELEASE -
699 CUSTOMER ID -
Table 2: Monitor Functions
FNCT. # DESCRIPTION
22 CLEAR ERRORS LIST
000 VIEW FAULT LIST
800 VIEW ERROR LIST
801 FAULT/ERROR ACTIONS
980 TRACE MONITOR
981 VERIFY I/O
993 CLEAR NV RAM
994 SAVE/RECALL FUNCTION
995 LOAD DEFAULTS
997 SELF TUNE
998 PCU DIAGNOSTICS
Table 3: Misc Commands