Magnetek CPA HPV 900 Axial Flux PM Series User manual

HPV 900 Series 2
Axial Flux PM
Technical Manual
NOTE: This is a supplementary manual for the PM Axial Flux. If any detail about the HPV900 Series 2
is needed, please refer to the technical manual TM7333
TM7354 Rev 20
© 2017 Magnetek Elevator

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 IN NO EVENT SHALL MAGNETEK BE LIABLE FOR LOSS OF PROFIT,
OF LIABILITY INDIRECT, CONSEQUENTIAL OR INCIDENTAL DAMAGES WHETHER
ARISING OUT OF WARRANTY, BREACH OF CONTRACT OR TORT.
HPV 900 S2 and Series 2 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.
2017 Magnetek, Inc.

IMPORTANT
Grounding Considerations
It is very important to make proper ground connections to the drive. The drive has a
common ground bus terminal connection. All grounds need to land at this common
point including building, motor, transformer, and filter grounds. This will limit the
impedance between the grounds and noise will be channeled back to building
ground. This improves the performance of the drive.

Table of Contents
Start Up Guideline................................................................................................................................... 1
Drive Model Number............................................................................................................................... 2
HPV 900 Series 2 Drive Ratings ............................................................................................................... 2
HPV900 S2 Axial Flux Drive Application Kits............................................................................................ 3
Mechanical Mounting Instructions ......................................................................................................... 6
Encoder Electrical Connection................................................................................................................. 8
Proximity Sensor Electrical Connection................................................................................................... 8
PM Drive Setup Procedure ...................................................................................................................... 9
PM Alignment Procedure ...................................................................................................................... 11
HF Inject (preferred method) ............................................................................................................ 11
Open Loop Alignment........................................................................................................................ 12
Auto Alignment Procedure................................................................................................................ 13
Auto-Tune Procedure............................................................................................................................ 15
Setting Auto-Tune ............................................................................................................................. 15
Troubleshooting .................................................................................................................................... 16
Timing Diagram ..................................................................................................................................... 21
Spare Parts List for HPV900 Series 2 Axial Flux ..................................................................................... 22

Start-Up Guideline
1
Start Up Guideline
1. Mechanically mount all the parts as explained in Mechanical Mounting Instructions on page 6.
Connect the encoder and proximity sensor to the drive as explained in Encoder Electrical
Connection on page 8 and Proximity Sensor Electrical Connection on page 8.
2. Then if not already pre-loaded, set all the drive parameters to parameters that are
recommended by the car controller manufacturer so the drive and controller can interface with
each other correctly; this includes all parameters in the A1 –A5 submenu and C1 –C4
submenus.
3. Proceed to PM Drive Setup Procedure on page 9 to continue with setting of motor data,
Encoder Pulses, rotor alignment, and auto-tune.
4. Refer to Troubleshooting on page 16 if there are some initial start-up problems for Axial Flux
specific problems ONLY. For general faults on the HPV900 Series 2, refer to the HPV900
Series 2 Technical Manual TM7333
NOTE: All the parts needed to get the Axial Flux drive to run are outlined on page 3 (need drive
part number HPV900-_ _ _ _-2E1-02 and kit 46S04444-_ _ _ _ )
NOTE: If the motor has a shaft, use a shaft mounted encoder. If a shaft mounted encoder is to be
used, a standard HPV900 Series 2 is recommended.

Axial Flux Drive Models
2
Drive Model Number
HPV 900 Series 2 Drive Ratings
Rated
Input
Voltage
NA1
Rated
HP
EU1
Rated
HP
NA1
Rated
kW
EU1
Rated
kW
Overload
Selection2
Carrier
Frequency
(kHz)3
Continuous
Output Current
General
Purpose Rating
Continuous
Output Current
Elevator Duty
Cycle Rating
Maximum
Output
Current
for 5 Sec
Frame
Size
Model Number
7.5
--
5.5
--
250%
10
25
29
63
2
HPV900-2025-2E1-02
200%
8
31
33
10
--
7.5
--
250%
10
31
36
78
2
HPV900-2031-2E1-02
200%
8
39
41
2
15
--
11
--
250%
10
41
48
103
3.5
HPV900-2041-2E1-02
3
200%
8
51
55
0
20
--
15
--
250%
10
52
60
130
3.5
HPV900-2052-2E1-02
V
200%
8
65
70
25
--
19
--
250%
10
75
87
187.5
4
HPV900-2075-2E1-02
30
--
22
--
250%
10
88
102
220
4
HPV900-2088-2E1-02
40
--
30
--
250%
10
98
114
245
5
HPV900-2098-2E1-02
5
5
3.7
3.7
250%
10
8
9
20
1
HPV900-4008-2E1-02
200%
8
10
11
7.5
5.5
5.5
4
250%
10
12
14
30
2
HPV900-4012-2E1-02
200%
8
15
16
10
7.5
7.5
5.5
250%
10
16
19
40
2
HPV900-4016-2E1-02
200%
8
20
21
15
10
11
7.5
250%
10
21
24
53
3
HPV900-4021-2E1-02
200%
8
26
28
4
20
15
15
11
250%
10
27
31
68
3
HPV900-4027-2E1-02
6
200%
8
34
36
0
25
20
19
15
250%
10
34
39
85
4
HPV900-4034-2E1-02
V
200%
8
43
45
30
25
22
18.5
250%
10
41
48
103
4
HPV900-4041-2E1-02
200%
8
51
55
40
30
30
22
250%
10
52
60
130
4
HPV900-4052-2E1-02
200%
8
65
70
50
40
37
30
250%
10
65
75
162.5
5
HPV900-4065-2E1-02
60
50
45
37
250%
10
72
84
180
5
HPV900-4072-2E1-02
75
60
56
45
250%
10
96
111
240
5
HPV900-4096-2E1-02
Table 1: HPV900 Series 2 Drive Ratings
NOTE: all ratings at 60/50Hz bases on a geared elevator application
1. NA refers to drives sold in North America and ratings are based off of 460VAC input.
EU refers to drives sold in Europe and are based off of 400VAC input
2. Based on Overload Select (C1) parameter selection
3. Maximum Carrier Frequency before derating
HPV900
-
-
-
drive
input voltage
2 = 230 volt
4 = 460 volt
continuous
output current
operator style
E = Elevator
N = no operator
software program
1 = Standard Software
2 = PM Axial Flux
2
1
2
0

Axial Flux Drive Application Kits
3
HPV900 S2 Axial Flux Drive Application Kits
Application Description
Kits to Order for Axial
Flux Application
Items in the Kits
Drive /
Inverter
For all Axial Flux application. Based on
motor voltage, amperes, and incoming
volt
HPV900-_ _ _ _-2E1-02i
HPV900 Series 2 Axial Flux PM drive
Cable Lengths
kits with 37.3mm rider wheel for MX05, MX06, and MX10 frames
For hoists that require 5m (16.4ft) of
cable between the drive and motor.
46S04444-0005i
5m cable for encoder, 5m cable for proximity sensor,
encoder, 37.3mm rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
For hoists that require 10m (32.8ft) of
cable between the drive and motor.
46S04444-0010i
10m cable for encoder, 10m cable for proximity sensor,
encoder, 37.3mm rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
For hoists that require 15m (49.2ft) of
cable between the drive and motor.
46S04444-0015i
15m cable for encoder, 15m cable for proximity sensor,
encoder, 37.3mm rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
For hoists that require 20m (65.6ft) of
cable between the drive and motor.
46S04444-0020i
20m cable for encoder, 20m cable for proximity sensor,
encoder, 37.3mm rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
For hoists that require 30m (98.4ft) of
cable between the drive and motor.
46S04444-0030i
30m cable for encoder, 30m cable for proximity sensor,
encoder, 37.3mm rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
For hoists that require 40m (131.2ft) of
cable between the drive and motor.
46S04444-0040i
40m cable for encoder, 40m cable for proximity sensor,
encoder, 37.3mm rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
For hoists that require 60m (196.8ft) of
cable between the drive and motor.
46S04444-0060i
60m cable for encoder, 60m cable for proximity sensor,
encoder, 37.3mm rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
For hoists that require 100m (328ft) of
cable between the drive and motor.
46S04444-0100i
100m cable for encoder, 100m cable for proximity sensor,
encoder, 37.3mm rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
kits with 75mm rider wheel for MX20 frames
For hoists that require 5m (16.4ft) of
cable between the drive and motor.
46S04444-1005i
5m cable for encoder, 5m cable for proximity sensor,
encoder, 75mm rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
For hoists that require 10m (32.8ft) of
cable between the drive and motor.
46S04444-1010i
10m cable for encoder, 10m cable for proximity sensor,
encoder, 75mm rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
For hoists that require 15m (49.2ft) of
cable between the drive and motor.
46S04444-1015i
15m cable for encoder, 15m cable for proximity sensor,
encoder, 75mm rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
For hoists that require 20m (65.6ft) of
cable between the drive and motor.
46S04444-1020i
20m cable for encoder, 20m cable for proximity sensor,
encoder, 75mm rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
For hoists that require 30m (98.4ft) of
cable between the drive and motor.
46S04444-1030i
30m cable for encoder, 30m cable for proximity sensor,
encoder, 75mm rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
For hoists that require 40m (131.2ft) of
cable between the drive and motor.
46S04444-1040i
40m cable for encoder, 40m cable for proximity sensor,
encoder, 75mm rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
For hoists that require 60m (196.8ft) of
cable between the drive and motor.
46S04444-1060i
60m cable for encoder, 60m cable for proximity sensor,
encoder, 75mm rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
For hoists that require 100m (328ft) of
cable between the drive and motor.
46S04444-1100i
100m cable for encoder, 100m cable for proximity sensor,
75mm encoder, rider wheel, proximity sensor, sensor
bracket, target, and other misc. hardware parts
i
NOTE: materials needed for Axial Flux are 1x HPV900 S2 Axial Flux drive and 1x of the 46S04444-_ _ _ _ kit
(which comes with everything but the drive)

Axial Flux Specific Parameters
4
Parameters additional to standard HPV900 Series 2
C0 Menu
Submenu
Parameters
Units
Range
Default
Site Setting
C1
User Switches C1 Submenu
C1
Encoder
Select
None
-Axial Flux
-Axial Flux
U0 Utility
Submenu
Parameters
Units
Range
Default
Site
Setting
U6
Drive Info U6 Submenu
U6
Drive Version
None
-SA4810-030_ _ _._ _
-SA4810-030_ _ _._ _
D0 Display 1 or 2
Submenu
Parameters
Units
Range
Default
Site Setting
D1
Measured
PPR
PPR
0 - 40000
-0
D1
Z Edge Count
None
-32767 - 32767
-0
A1 Drive
Name
Description
Units
Recommended
Setting
Encoder
Pulses
(Encoder Pulses) This parameter sets the number
of pulses the drive should see coming back from
the encoder at high running speeds.
PPR
-Refer to step 4 on
page 9 in PM Drive
Setup Procedure.
Enc PPR
Low
(Encoder Pulses Per Revolution Low) This
parameter sets the number of pulses the drive
should see coming back from the encoder at low
running speeds.
PPR
-
D1 Elevator Data
Name
Description
Units
Recommendation
Measured
PPR
This is a setup/fine tuning parameter. This
parameter will show how many pulses the drive
counted for one full revolution of the rotor.
NOTE: the number displayed here when a motor is
running at high speed/contract speed is more
accurate than one running at slower speeds
Pulses Per
Revolution
(PPR)
Use the value in this
parameter to set the
Encoder PPR (A1) to
the correct number for
your particular motor.
This is outlined in step
4 on page 9 in PM
Drive Setup
Procedure.
Z Edge
Count
This parameter is used for troubleshooting
noise/functionality on the Proximity Sensor.
The function of this parameter is to tell the user
how many times has the drive seen the target
sensor (aka how many revolutions has the motor
made) since it was powered up. The drive will
increase the number if it is rotating in the up and
decrease the number in the down. (it will only
decrease the number if the drive receives a valid
run command in the down)
NONE
Use for
troubleshooting the
proximity sensor

Interconnections
5
Figure 1: Interconnection Diagram
13
14
15
16
12
TB2
TB1
TB1
6
7
8
9
10
11
24
25
26
21
22
23
logic input 1
logic input 2
logic input 3
logic input 4
logic input 5
logic input 6
logic input 7
logic input 8
logic input 9
+24VDC isolated
logic input common
+24VDC iso. common
commcommoncommon
logic output 1
logic output 2
logic output 3
logic output 4
logic output common
analog input 2 (+)
analog input 2 (-)
shield
analog output 1
2
3
4
5
6
Speed Cmd
10VDC
PreTorque Cmd
10VDC
1
7
analog output 2
analog common
27
28
29
30
31
32
relay 1
relay 2
HPV 900
Axial Flux
input
power
R
S
T
17
18
1
2
3
4
19
20
encoder +12 VDC
encoder common
A
/A
B
/Z
/B
Z
TB2
9
Tx (+)
common
Rx (+)
Tx (-)
Rx (-)
5
shield
shield
8
analog input 1 (-)
B1
Dynamic Braking
Resistor
B2
-
dc bus (-)
dc bus (+)
+2
+1
optional DC choke
analog input 1 (+)
10
11
12
13
14
G
ground
ac
motor
U
V
W
motor
connections
Serial
Communication
Port
USB (Mag Explorer)
Connection
Refer to
Encoder
Electrical
Connection
on page 8
Refer to
Proximity
Switch
Sensor
Electrical
Connection
on page 8

Installation
6
Mechanical Mounting Instructions
The following parts need to be mounted on to the motor: proximity sensor (red device with 3 wires
coming out of it as shown in Figure 3), incremental encoder, rider wheel, sensor bracket, target, sticky
pad, and hex nuts.
Figure 2: Axial Flux Assembly Kit
Figure 3: Picture of Proximity Sensor (PN
05P00217-0097)
1. The rider wheel should be tightly fitted on
the incremental encoder’s shaft as shown
in Figure 4 with 2mm allen key (or a
Philips head screw driver depending on
the wheel type). It should be positioned so
that the wheel will sit on the center of the
exposed edge of the rotor. NOTE: if the
encoder shaft has a keying slot, do NOT
place any of the set screws in the keying
slots.
Figure 4: Incremental Encoder with the rider
wheel fitted on shaft
encoder
rider wheel