PDL MICRODRIVE Series User manual

Microdrive Series Instruction Manual
4201-109 Rev I
MICRODRIVE SERIES
AC MOTOR SPEED CONTROLLER
INSTRUCTION MANUAL
4201-109 REV I
Leaders in AC Motor Controls
Head Office:
81 Austin Street
P.O. Box 741
Napier
New Zealand
Tel.: [phone]
Fax: [phone]
4201-003 Rev A Page 1 of 12

Microdrive Series Instruction Manual
4201-109 Rev I
4201-003 Rev A Page 2 of 12

Microdrive Series Instruction Manual
4201-109 Rev I
DEDICATION TO QUALITY
Speed controllers can dramatically improve your process control, productivity and energy
efficiency, but only if they are working correctly.
WhichiswhyweatPDLElectronicsgotogreatlengthsinourdesignandmanufacturing,toensure
that our products operate correctly first time, every time.
An extensive research and development investment ensures that this product is one of the most
technicallyadvancedinthe world, with built-in strength and robustness to suit your application and
environment.
Our NZS(ISO) 9001 certification gives you the confidence of our international, independently
certified Quality Assurance program. All staff are actively involved in continuous improvement
programs with a customer focus.
The components that go into our products are selected from the best in the world  and must
pass our rigorous and demanding test program.
And finally, every new drive design is run through a rigorous test program, including full load
operation at above rated temperature, under the most demanding load conditions.
Our dedication to quality makes the PDL Electronic's product, regardless of price, less expensive
than other controllers in the long run.
Extract from 4700-001, Issue 4
4201-003 Rev A Page 3 of 12

Microdrive Series Instruction Manual
4201-109 Rev I
COMPREHENSIVE SUPPORT PROGRAM
PDL Electronics customer support program demonstrates our confidence in our Quality Assur-
ance system. We have total faith in our products and their reliability, and so provide a
comprehensive three year warranty.
Fully trained engineers and technicians, with a wealth of experience and easy access to
information, can assist in solving any of your drive application projects.
Our service staff are available for commissioning, after sales service, and repairs, 24 hours a day,
seven days a week.
We select capable and highly qualified representatives to act as our distributors and service
agents. Only after passing our intensive training program are they accredited for repair or on-
selling of our products.
To further support our products and customers, we run a series of comprehensive training
programs focusing on self maintenance and application advice. These are available on-site and
at our Head Office.
Extract from 4700-001, Issue 4
4201-003 Rev A Page 4 of 12

Microdrive Series Instruction Manual
4201-109 Rev I
PLEASE HELP US TO IMPROVE!
To Our Valued Customer:
Your suggestions are important to us.
Please tell us of any ideas you have which can improve our products and service for you.
Comment:
Head Office:
81 Austin Street
Onekawa
P.O. Box 741
Napier
New Zealand
Tel.: [phone]
Fax: [phone]
FAX BACK TO
[phone]
Completing this section would be appreciated but is optional.
Name:
Company:
Address:
Phone: Fax:
May we contact you? Yes No
Date: Total Number of pages including cover sheet:
Attn: The Quality Manager, PDL Electronics Ltd
THANK YOU FOR TAKING THE TIME TO FILL OUT THIS QUESTIONNAIRE.
WE APPRECIATE YOUR INPUT.
4201-003 Rev A Page 5 of 12

Microdrive Series Instruction Manual
4201-109 Rev I
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Microdrive Series Instruction Manual
4201-109 Rev I
WARNING:
 The Microdrive operates from HIGH ENERGY ELECTRICAL SUPPLIES.
Stored charge is present after switch off.
 Due to the high leakage currents inherent to AC drives, earth connection
of both the motor and the Microdrive is essential before connection to the
supply.
 Service only by qualified personnel.
 Always isolate and allow to discharge before servicing.
 Always wear safety glasses if operating with the cover removed.
 Never work on live equipment alone.
 Observe all recommended practices.
 Ensure that the Microdrive is not mounted in an adverse environment.
 TheMicrodrive contains static sensitive printed circuit boards. Use static safe
procedures when handling these boards.
Understanding of the equipment is the key to safe and efficient use  please
read this manual thoroughly.
4201-003 Rev A Page 7 of 12
IMPORTANT NOTES

Microdrive Series Instruction Manual
4201-109 Rev I
REVISION HISTORY
Date: Revision: Description:
12.03.91 A Created and issued.
28.05.91 B Update.
09.09.92 C Update.
16.10.92 D Update.
10.03.93 E UD3/UDi combined documentation (CH93-021).
03.06.93 F Update.
10.11.93 G Update.
20.10.94 H Four new models added -
UD3-12, UD3-60, UDi-205 and UDi-300.
RS232 communications card option added.
Parallel drive models added.
Crane 3 Mode added to input modes (Screen 66).
04.03.99 I Large Frame-Size Motor Consideration added
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Microdrive Series Instruction Manual
4201-109 Rev I
4201-003 Rev A Page 9 of 12
Contents
MICRODRIVE-3 (UD3) SPECIFICATIONS 13
MICRODRIVE-I (UDI) SPECIFICATIONS 14
PART 1 THE STANDARD MICRODRIVE 20
1.1 APPLICATION RECOMMENDATIONS 20
1.2 INSTALLATION 20
1.2.1 Environmental Considerations 20
1.2.2 Mounting the Microdrive 21
1.2.3 Connecting the Microdrive 21
1.2.4 Large Frame-Size Motor Considerations 21
1.3 THE CONTROL PANEL 28
1.3.1 The LED Indicators 28
1.3.2 Use of the Control Panel 28
1.3.3 Screen Organisation 28
1.4 THE STANDARD CONFIGURATION 29
1.4.1 Standard control Terminal Configuration 29
1.4.2 Standard Screens (Short Menus) 29
1.5 COMMISSIONING THE MICRODRIVE 33
1.6 MAINTENANCE 35
1.7 SERVICE 35
1.7.2 RFI Filtering 35
1.7.3 Screen Fault Messages 36
1.7.4 Use Of The LED Indicators 37
1.7.5 Fuse Failure 38
1.7.6 Replacing The Control PCB 39
PART 2 THE FULL FEATURES OF THE MICRODRIVE 40
2.1 INTRODUCTION TO THE FULL FEATURES OF THE MICRODRIVE 40
2.2 CONTROL INPUT/OUTPUT FUNCTIONAL DESCRIPTION AND SPECIFICATION 40
2.2.1 Common Point Isolation 40
2.2.2 INPUTS 40
2.2.3 OUTPUTS 40
2.3 SUMMARY OF THE FULL SCREEN CONTROLS 47
2.4 Detail of the Full Screen Controls 47
APPENDIX 1A: COMMISSIONING CONFIGURATION RECORD  SHORT MENU 91
APPENDIX 1B: COMMISSIONING CONFIGURATION RECORD  FULL MENU 92
APPENDIX 1C: COMMISSIONING WIRING CONFIGURATION RECORD 93
APPENDIX 2: MICRODRIVE-3 (UD3) SPARES LISTS 94
APPENDIX 2: MICRODRIVE-I (UDI) SPARES LISTS 95

Microdrive Series Instruction Manual
4201-109 Rev I
4201-003 Rev A Page 10 of 12
Figure and Tables
Figure 1.1a The Microdrive-3 (UD3) 17
Figure 1.1b The Microdrive-i (UDi) 17
Figure 1.2a The Microdrive-3 (UD3) Block Diagram 18
Figure 1.2b The Microdrive-i (UDi) Block Diagram 19
Figure 1.3a Microdrive-3 (UD3) Mounting Details 22
Figure 1.3b Microdrive-i (UDi 90250) Cabinet Floor and Wall Mounting Details 23
Figure 1.3c Microdrive-i (UDi 300660) Cabinet Floor and Wall Mounting Details 24
Figure 1.3d Microdrive-i (UDi 90250) Baseplate Wall Mounting Details 25
Figure 1.4a Microdrive-3 (UD3) Recommended Power Wiring Instructions 26
Figure 1.4b Microdrive-i (UDi) Recommended Power Wiring Instructions 27
Figure 1.5 The Control Panel 28
Figure 1.6 Standard Configuration of the Control Terminals 30
Figure 1.7 Microdrive Problem Solving Chart 34
Figure 2.1 Block Diagram: Microdrive Programmable Configurations 41
Figure 2.2 The Microdrive Control Inputs and Outputs 42
Table 1.1 Display Screen Messages - Short Menus 31
Table 2.1.1 Display Screen Messages - Full Menus 43
Table 2.1.1 Display Screen Messages - Full Menus 44
Table 2.1.2 Display Screen Messages - Full Menu Modes 45
Table 2.1.2 Display Screen Messages - Full Menu Modes 46
APPENDIX 3: LOCAL KEYBOARD OPERATION 98
APPENDIX 4: USING THE MICRODRIVE AS A PROCESS CONTROLLER 99
4A: General Notes 99
4B: APPLICATION EXAMPLE - TACHO FEEDBACK 99
4C: APPLICATION EXAMPLE -CONSTANT PRESSURE PUMPING 100
4D: APPLICATION EXAMPLE -CONSTANT PRESSURE PUMPING WITH AUTOMATIC
STOP/START CONTROL 102
APPENDIX 5: MICRODRIVE-3 OPERATION FROM NON-STANDARD SUPPLIES 105
5A: UD3 DC SUPPLY 105
5B: UD3 SINGLE PHASE AC SUPPLY 105
5C: UD3 220-480V, THREE PHASE SPECIAL OPTIONS 105
5D: UDi DC SUPPLY 106
5E: UDi SINGLE PHASE AC SUPPLY 106
APPENDIX 5: MICRODRIVE-I OPERATION FROM NON-STANDARD SUPPLIES 106
APPENDIX 6: TORQUE CONTROL USING THE MICRODRIVE CURRENT LIMIT 107
6A: GENERAL NOTES 107
6B: APPLICATION EXAMPLE -CONSTANT TENSION WINDER 108
INDEX 109

Microdrive Series Instruction Manual
4201-109 Rev I
ABOUT THE MANUAL
Like the Microdrive itself, we have constructed this manual
to be as user friendly as possible. Technical descriptions
are kept to a minimum and the use of drawings and tables
to present condensed information is maximised.
This instruction manual covers the complete Microdrive
range of models  from the smallest Microdrive-3 to the
largest Microdrive-i. When the manual is discussing
features common to both the Microdrive-3 (UD3) and the
Microdrive-i (UDi), the term Microdrive will be used. If a
feature is applicable only to the UD3 or the UDi, then the
appropriate term will be used.
The first section describes the standard configuration of
the Microdrive, as it is supplied from the factory. For the
majority of applications, this is all that you will need to
consult.
To maximise the usefulness of the Microdrive however,
you will need to access some of the many programmable
control features.
Section 2 of this manual provides detailed descriptions of
the full Microdrive functions and programmable
configurations.
Finally you will find additional useful information in the
Appendices.
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Microdrive Series Instruction Manual
4201-109 Rev I
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Microdrive Series Instruction Manual
4201-109 Rev I
13
MICRODRIVE-3 (UD3) SPECIFICATIONS
OUTPUT OUTPUT kVA OUTPUT POWER DIMENSIONS NETT
MODEL CURRENT 380Vac 415Vac460Vac 380Vac415Vac460Vac H W D WEIGHT
Amps kVA kVA kVA kW kW kW mm mm mm kg
UD32.5 2.5 1.6 1.8 2.0 .75 1.1 1.1 360 207 142 8.0
UD36.5 6.5 4.3 4.7 5.2 2.2 3.0 3.0 360 207 142 8.0
UD310.5 10.5 6.9 7.5 8.4 4.0 4.0 5.5 360 207 142 10.0
UD312 12.0 7.9 8.6 9.6 5.5 5.5 5.5 360 207 142 10.0
UD316 16.0 10.5 11.5 12.7 7.5 7.5 9.0 360 207 142 10.0
UD322.5 22.5 14.8 16.2 17.9 11.0 11.0 11.0 510 207 142 11.0
UD331 31.0 20.4 22.2 24.7 15.0 15.0 18.5 510 390 142 23.0
UD346 46.0 30.2 33.1 36.6 22.0 22.0 25.0 510 390 142 23.0
UD360 60.0 39.5 43.1 47.8 30.0 33.0 33.0 680 439 142 35.0
UD370 70.0 46.1 50.3 55.8 33.0 37.0 40.0 680 439 142 35.0
FREQUENCY CONTROL SOURCES
0 10Vdc 420mA
Greater of 010Vdc or 420mA
Keyboard Inch 1, Inch 2
Process follow Process control
Switch control - continuous Switch control - 7 preset
Motorised potentiometer RS232/RS485 (Options)
CONFIGURABLE SWITCH CONTROLS
Stop Start
Start/reset Stop/reset
Inch Inch latched
Direction invert Emergency stop
Latched start with direction Crane functions
RS232/RS485 control input (Options)
CONFIGURABLE RELAY OUTPUTS
3 relays; 230Vac/30Vdc/1A
1 x change over; 2 x normally open
Output selection:
Failsafe fault UD3 started
UD3 running UD3 started or running
UD3 overloaded Motor overloaded
Frequency sense point Current sense point
Direction At set frequency
Combined overload alarm Feedback sense
Power flow direction
RS232/RS485 controlled (Options)
CONFIGURABLE 010V ANALOGUE OUTPUT
Output selection:
0100Hz 0150% UD3 current
0200Hz 0500Vac output voltage
010V RS232/RS485 (Options)
0150% UD3 torque component of current
0150% motor power
DIGITAL FREQUENCY OUTPUT
26.25 times the UD3 output frequency
CURRENT LIMIT SOURCES
010Vdc 420mA
Keyboard
INPUT
Input supply voltage 380480Vac
Input supply tolerance -20% to +5%
Phase 3 phase, 3 wire,
earthed neutral supply
Input frequency range 4862 Hz
Power factor (fundamental) .95
Input current < output current
Power loss ride through > 2 seconds
May also be operated from 450700Vdc or 220480Vac
single phase supply - refer to Appendix 5
OUTPUT
Current overload capability 150% for 30 seconds
Efficiency (full load, 50Hz) >97%
Power on delay <1 sec
Suit motor rated voltages 10995Vac
Suit motor rated frequencies 10250 Hz
Output voltage - cannot be greater than input voltage
Voltage regulation <±3%
Frequency range 0 to ±200Hz
Frequency resolution 0.01Hz
Control method Space vector modulation
Carrier frequency 4kHz (2kHz selectable)
Dominant ripple frequency 8kHz (4kHz selectable)
Tacho speed regulation 0.01%
ENVIRONMENTAL
Protection standard IP21; Pollution degree 2
Operating temperature 050°C
Storage temperature -40°C to +80°C
Relative humidity <90%, noncondensing
Altitude 1000m
Altitude derating (>1000m) -1% per 100m; 3000m max
UD3 PROTECTION
Supply loss Input phase loss
Output current limit IGBT overload
Short circuited load Ground fault
Low DC bus voltage Regeneration limit
Excessive DC bus voltage Motor overtemperature
UD3 thermal model Control PCB failure
Dynamic brake thermal model Serial comms loss detection
MOTOR PROTECTION
Stall avoidance Stall protection
PTC thermistor input Phase current imbalance
Shear pin mode Combined overload alarm
Thermal model overtemperature trip

Microdrive Series Instruction Manual
4201-109 Rev I
14
MICRODRIVE-i (UDi) SPECIFICATIONS
OUTPUT OUTPUT kVA OUTPUT POWER DIMENSIONS NETT
MODEL CURRENT 380Vac 415Vac440Vac 380Vac415Vac440Vac H W D WEIGHT
Amps kVA kVA kVA kW kW kW mm mm mm kg
UDi90 90 59.2 64.7 68.6 45 51 55 1350 405 422 126
UDi110 110 72.4 79.1 83.8 55 59 63 1350 405 422 126
UDi140 140 92.1 101 107 75 80 80 1350 405 422 126
UDi170 170 112 122 130 90 90 100 1350 545 422 160
UDi205 205 135 147 156 110 110 110 1350 545 422 175
UDi250 250 165 180 190 132 140 150 1350 545 422 175
UDi300 300 198 216 229 160 170 185 1350 965 422 303
UDi340 340 224 244 259 180 200 200 1350 965 422 303
UDi480 480 316 345 366 257 280 300 1350 965 422 333
UDi660 660 434 474 503 355 400 425 1350 1385 422 456
UDi830P 830 547 598 634 445 485 520 Consists of two UDi480
UDi1140P 1140 752 821 871 614 693 736 Consists of two UDi660
INPUT
Input supply voltage 380440Vac
Input supply tolerance -20% to +10%
Phase 3 phase, 3 wire,
earthed neutral supply
Input frequency range 4862 Hz
Power factor (fundamental) .95
Input current < output current
Power loss ride through > 2 seconds
May also be operated from 450700Vdc or 380440Vac
single phase supply - refer to Appendix 5.
OUTPUT
Current overload capability 150% for 30 seconds
Efficiency (full load, 50Hz) >97%
Power on delay <1 sec
Suit motor rated voltages 10995Vac
Suit motor rated frequencies 10250 Hz
Output voltage - cannot be greater than input voltage
Voltage regulation <±3%
Frequency range 0 to ±200Hz
Frequency resolution 0.01Hz
Control method Space vector modulation
Carrier frequency 2kHz (4kHz selectable)
Dominant ripple frequency 4kHz (8kHz selectable)
Tacho speed regulation 0.01%
ENVIRONMENTAL
Protection standard:
Cabinet Dust and water splash
protected; Pollution degree 3
Baseplate IP00; Pollution degree 2
Operating temperature 050°C
Storage temperature -40°C to +80°C
Relative humidity <90%, noncondensing
Altitude 1000m
Altitude derating (>1000m) -1% per 100m; 3000m max
UDi PROTECTION
Supply loss Input phase loss
Output current limit IGBT overload
Short circuited load Ground fault
Low DC bus voltage Regeneration limit
Excessive DC bus voltage Motor over temperature
UDi thermal model Control PCB failure
Dynamic brake thermal model Serial comms loss detection
MOTOR PROTECTION
Stall avoidance Stall protection
PTC thermistor input Phase current imbalance
Shear pin mode Combined overload alarm
Thermal model overtemperature trip
FREQUENCY CONTROL SOURCES
010Vdc 420mA
Greater of 010Vdc or 420mA
Keyboard Inch 1, Inch 2
Process follow Process control
Switch control - continuous Switch control - 7 preset
Motorised potentiometer RS232/RS485 (Options)
CONFIGURABLE SWITCH CONTROLS
Stop Start
Start/reset Stop/reset
Inch Inch latched
Direction invert Emergency stop
Latched start with direction Crane functions
RS232/RS485 control input (Options)
CONFIGURABLE RELAY OUTPUTS
3 relays; 230Vac/30Vdc/1A
1 x change over; 2 x normally open
Output selection:
Failsafe fault UDi started
UDi running UDi started or running
UDi overloaded Motor overloaded
Frequency sense point Current sense point
Direction At set frequency
Combined overload alarm Feedback sense
Power flow direction RS232/485 controlled
(Options)
CONFIGURABLE 010V ANALOGUE OUTPUT
Output selection:
0100Hz 0150% UDi current
0200Hz 0500Vac output voltage
010V RS232/RS485 (Options)
0150% UDi torque component of current
0150% motor power
DIGITAL FREQUENCY OUTPUT
26.25 times the UDi output frequency
CURRENT LIMIT SOURCES
010Vdc 420mA
Keyboard

Microdrive Series Instruction Manual
4201-109 Rev I
15
UD3 Dynamic Brake Module - DB15 PDL Part No. 0331
7.5kW braking
Resistor included
Low duty cycle
Field fittable
UD3 processor controlled
Thermal model protection
Instruction Manual - PDL Part No. 4201-112
DB-300 Microdrive Dynamic Brake Switch Module
PDL Part No. 0353
Up to four units may be fitted
Compatible with the UD3 and the UDi
Up to 220kW braking using external resistors
Controlled from Microdrive
Thermal model protection
Instruction Manual - PDL Part No. 4201-144
RS485 Communications Card PDL Part No. 0332
Compatible with the UD3 and the UDi
Two wire, high noise immunity RS485 system
Up to 1km transmission
Totally isolated output
1200/4800/9600 baud
Industry standard Modbus protocol
240 addresses
Group addressing and broadcast modes
All Microdrive functions fully accessible
Serial communications loss detection
Control I/O monitoring (independent of Microdrive
operation) may be used for associated control
systems. The following monitoring and control
functions are available on each Microdrive:
- 420mA input
- 010V input
- Switch input
- 010V output
- Relay output
- Tacho signal
Instruction Manual - PDL Part No. 4201-117
RS232 Communications Card PDL Part No. 0396
Compatible with the UD3 and the UDi
Three wire, RS232 system
Up to 15m transmission
Totally isolated output
1200/4800/9600 baud
Industry standard Modbus protocol
All Microdrive functions fully accessible
Serial communications loss detection
Control I/O monitoring (independent of Microdrive
operation) may be used for associated control
systems. The following monitoring and control
functions are available on each Microdrive:
- 420mA input
- 010V input
- Switch input
- 010V output
- Relay output
- Tacho signal
Instruction Manual - PDL Part No. 4201-117
CONTROL PANEL
32 character alphanumeric LCD display
Microdrive status, current, frequency permanently displayed
Estimated motor temperature, reference frequency, DC bus
voltage, output voltage optionally displayed
Multi-language capability
Direct status/level display of input control terminals
3 key input system
Security system
In excess of 50 programmable parameters plus 40 options
Local control possible
LED status indication:
- power on
- run
- fault
CONTROL FEATURES
Wide speed range - to 200Hz
7 switch selectable speed presets
Switch controlled speed inputs
Two skip frequencies
Programmable offset, gain and inversion of analogue
reference signal
Reverse lock out
Two sets of acceleration and deceleration rates
Wide acceleration and deceleration range
- 500Hz/s to 0.02Hz/s
Separate fault trip deceleration rate
Programmable S-curve acceleration/deceleration
Programmable to suit almost any motor
Programmable thermal model of motor
Very low motor noise
- Whisperwave modulation
- fixed frequency (normal) modulation
Dynaflux optimising system
Anti-condensation motor heater
Spinning start mode
Spinning stop mode
DC injection braking
Dynamic braking option
Simple process control
Tacho follow mode
Tacho feedback mode (0.01% accuracy)
Configurable switch controls
Selectable active high or low digital inputs
Special crane modes
Programmable reaction to mains loss
Automatic restart
Smooth current or torque limit
Selectable fixed or adaptive torque limit
Shearpin mode
Showering arc noise immunity tested
Serial communication options
OPTIONS

Microdrive Series Instruction Manual
4201-109 Rev I
16
THE MICRODRIVE
The Microdrive is a third generation digital AC Motor Speed
Controller. The use of an extremely powerful 16-bit
microcontroller has allowed us to include many
programmable features into the Microdrive yet retain
simplicity of control and adjustment through three key
switches and a 32 character alphanumeric LCD display.
Digital control means absolute precision and repeatability in
settings with complete keyboard control. There are no
internal adjustments (or trimpots) of any sort in the
Microdrive. All information, including input terminal status
and levels, is available on the Microdrive display.
In comparison with other drives, the Microdrive is greatly
simplified and condensed, offering advantages of reduced
installation space and increased reliability.
The Microdrive is available in two product ranges  the
Microdrive-3 (UD3) model ranges from 2.5A to 70A, and the
Microdrive-i (UDi) model ranges from 90A to 660A. Using
PDLs Parallel Drives technology, the UDi may be extended
up to 2MW.
The Microdrive-3 (UD3) has a protection rating of IP21;
which coupled with its compact size allows it to be installed
easily  stand-alone or within a switchboard.
The Microdrive-i (UDi) is available in two protection ratings 
a cabinet version and a baseplate version (suitable for
switchboard mounting). Both versions are of rugged
industrial construction with an abundance of termination
room. The cabinet version of the Microdrive-i has a clean
air enclosure for all the power and control electronics.
Technically the Microdrive operates on the same principles
as earlier AC Motor Speed Controllers - it just does it better!
For those already familiar with AC Motor Speed Controllers,
there is little new to learn - except how the many new
features and the great configurability of the Microdrive can
solve your process problems. For those unfamiliar with AC
Motor Speed Controllers - this manual and the standard
configuration of the Microdrive are specifically targeted at
you. The standard configuration is a factory preset set-up
of the Microdrive - it contains all standard functions and, in
many cases, may have all functions necessary for general
use, without need to access the full configurability of the
Microdrive.
The Microdrive employs an entirely new low acoustic noise
technique of waveform generation - Whisperwave
Modulation. Whisperwave removes the annoying tone
normally associated with AC Motor Speed Controllers,
allowing the little remaining motor noise to be easily
masked. This feature is especially valuable in applications
requiring low noise - particularly for heating and ventilation.
The Microdrive also includes the Dynaflux Optimising
System. Dynaflux automatically optimises the flux in the
motor according to load conditions. This leads to even
quieter operation, particularly under reduced load
conditions.
The Microdrive is one of the most technologically advanced
industrial drives currently available. It is very simple, but
very powerful. It is up to you to choose how few or how
many of its features you use.

Microdrive Series Instruction Manual
4201-109 Rev I
17
16x2 LCD DISPLAY
STATUS LEDs
"+" KEY
"-" KEY
"SELECT" KEY
SERIAL No. LABEL
MODEL NUMBER
INPUT & OUTPUT SPECIFICATION
PRODUCTION SERIAL NUMBER
SUPPLY SPECIFICATION
NOMINAL AC VOLTAGE RANGE
4807-019 Rev C
MANUFACTURED BY
PDL ELECTRONICS LTD
PO BOX 741, NAPIER
NEW ZEALAND
WARNING
STORED CHARGE
PRESENT SERVICING
DISCHARGE BEFORE
ALLOW 1 MINUTE TO
QUALIFIED PERSONNEL
SERVICE ONLY BY
MODEL
SERIAL No
VOLTAGE
FREQUENCY
CURRENT : 48-62Hz
: 380-480 VAC -20 / +5% 3ph
Amps
XXX
XXXXX
XXX-XXX
:
:
:
Figure 1.1a The Microdrive-3 (UD3)
Figure 1.1b The Microdrive-i (UDi)

Microdrive Series Instruction Manual
4201-109 Rev I
18
RFI
FILTER
RECTIFIER
SERIAL
COMMUNICATIONS
DYNAMIC
BRAKE FOR EXTERNAL
BRAKING RESISTOR
CONNECTIONS
SERIAL
COMMUNICATIONS
INPUTS
SWITCH
PROGRAMMABLE
CONTROL
PULSE TACHO
(ENCODER)
INPUTS
VOLTAGE I/P
CURRENT I/P
CONTROL
PROCESSOR
+
-DC BUS
THERMISTOR
DIGITAL FREQUENCY OUTPUT
PROGRAMMABLE ANALOGUE
OUTPUT 0-10VDC
PROGRAMMABLE
RELAY OUTPUTS
SUPPLY
+
_
*
4807-022 Rev E
CONVERTER
INPUTS
PULSE TACHO
COMMUNICATIONS
+10V
0-10V
0V
4-20mA
+10V
DC/DC
PTC
MOTOR
INVERTER
ON RUN OK
230VAC/30VDC
1A
OPTION:
OPTION:
IP1
IP2
IP3
0V
IP5
IP4
+12V
I/P
0V
~__~
__
Figure 1.2a The Microdrive-3 (UD3) Block Diagram

Microdrive Series Instruction Manual
4201-109 Rev I
19
RFI
FILTER
RECTIFIER
SERIAL
COMMUNICATIONS
SERIAL
COMMUNICATIONS
INPUTS
SWITCH
PROGRAMMABLE
CONTROL
PULSE TACHO
(ENCODER)
INPUTS
VOLTAGE I/P
CURRENT I/P
CONTROL
PROCESSOR
DC BUS
THERMISTOR
DIGITAL FREQUENCY OUTPUT
PROGRAMMABLE ANALOGUE
OUTPUT 0-10VDC
PROGRAMMABLE
RELAY OUTPUTS
230VAC/30VDC
SUPPLY
1A
FUSE
DC BUSSCR CONTROLLED
CHOKE
LINEINPUT
FUSES
DC/DC
CONVERTER
OPTION:
INPUTS
BRAKE
CONTROL OF EXTERNAL
CONNECTIONS FOR
MOTOR
+
-
+10V ON RUN OK
PTC
MOTOR
INVERTER
*_+
0-10V
+10V
4-20mA
0V
IP1
IP2
IP3
0V
IP5
IP4
+12V
I/P
0V
4807-251 Rev F
_
_
_
~_~
Figure 1.2b The Microdrive-i (UDi) Block Diagram

Microdrive Series Instruction Manual
4201-109 Rev I
20
PART 1 THE STANDARD MICRODRIVE
Other useful techniques include:
 The use of a six pole motor in a four pole
application (Microdrive operates around 75Hz
instead of 50Hz)  this gives better motor cooling
(hence a wider useful speed range) and 50% better
starting torque at very little extra motor cost.
 Small motors may often be connected in 230V
(delta) connection. Using this connection on a
Microdrive (motor voltage set to 230V) on a 400V
supply allows the motor to be operated with full flux
up to 87Hz, thus providing a very wide constant
torque speed range. Note that the motor in fact
produces 1.7 times its rated power when operated
at 87Hz. The penalty is that the motor draws 1.7
times more current (because of the delta
connection), so a larger Microdrive may be required.
Other recommendations:
 Regardless of how good a thermal overload or
model is, a PTC thermistor in the motor windings
provides the ultimate thermal protection and is
recommended. The Microdrive accepts standard
PTCs directly.
 Always specify motors with high temperature
insulation  at least class F or better.
1.2 INSTALLATION
1.2.1 ENVIRONMENTAL CONSIDERATIONS
The Microdrive must be sited in a suitable environment. As
with all equipment, the cleaner, cooler and more vibration
free the environment, the longer and more trouble free will
be the life of the Microdrive.
The ambient temperature should not be below 0°C, and must
not exceed the Microdrive specification of 50°C; relative
humidity should be less than 90% and there must be no
condensation. Avoid mounting the Microdrive in direct
sunlight.
The UD3 has a protection rating of IP21 and must have a
clean environment (Pollution degree 2), free of electrically
conductive (wet or dry) dust (e.g.,carbon fibre, salt, etc.),
and free of spraying water.
The cabinet version of the UDi is protected against dust and
splashing water (Pollution degree 3). The UDi should not
be hosed down.
The baseplate version of the UDi must have a clean
environment (Pollution degree 2), free of electrically
conductive (wet or dry) dust (e.g.,carbon fibre, salt, etc.),
and free of spraying water. The baseplate version of the
UDi is designed for mounting in a switchboard.
If mounting the Microdrive in a switch board be sure to allow
for sufficient cooling. The switchboard interior air
temperature must not exceed the Microdrive specification of
50°C. Calculate the correct airflow by using the formula
below and also consulting Section 1.2.2 - Mounting the
Microdrive.
In some applications it may be desirable to improve the
conditions in which the Microdrive is to be fitted. The first
choice in this case is to fit the Microdrive remotely in a clean
location.
If remote location is not practical, a protective box may have
1.1 APPLICATION RECOMMENDATIONS
The Microdrive is suitable for controlling the speed of all
standard three phase induction motors. Choose a
Microdrive which is capable of supplying the full load current
of the motor(s) to be driven.
When the Microdrive is correctly adjusted, full torque can be
obtained from the motor at up to rated speed. A standard
motor may be operated above rated speed by using higher
than rated frequency, but the torque that is able to be
generated declines (1/f) as there is insufficient voltage to
provide correct stator flux.
Operation below rated speed must take account of the
reduced cooling efficiency of the motor. Because of thermal
limitations, the continuous capability of the motor reduces
from rated torque at rated speed, to the value defined by the
zero speed cooling value at zero speed. The Microdrive
thermal model (overload) takes these factors into account
and provides safe protection from inadvertent overload of
this type. More detail is provided in Part 2 - The Full
Features of the Microdrive.
The quality of the Microdrive current waveform is such that
no derating of the motor torque due to harmonic heating is
necessary.
In a safety situation motors may be switched on and off the
Microdrive while it is running but this is not good control
practice  it stresses the Microdrive and may lead to
occasional tripping due to arcing of the contact terminals. A
more elegant control solution is to use the Microdrive
control terminals.
Generally it is better practice to leave electronic equipment
(including the Microdrive) permanently connected to the
mains supply. Switching the mains on and off to control the
Microdrive is bad practice and should be avoided (use the
control terminals). If mains switching is insisted upon (!), it
must not occur more often than once every 5 minutes or the
Microdrive-3 (UD3) charging circuits may be damaged. The
Microdrive-i (UDi) has a SCR controlled soft-charge input
circuit and does not suffer from multiple charging cycle
limitations.
Several motors may be operated at once on the Microdrive,
but individual protection must be supplied. Be sure to
choose a Microdrive which is capable of supplying the total
current requirements of all of the motors. If you plan to
start motors independently direct-on-Microdrive then you
must also include the DOL starting current of the motors
(this generally leads to gross oversizing of the Microdrive 
a much better solution is to stop the Microdrive, connect the
extra motors, and restart the Microdrive).
An advantage of the Microdrive is that non-standard motors
(frequency, voltage) can be driven from standard mains.
The Microdrive may be set to drive any motor with a rated
voltage between 10 and 995Vac, and any rated frequency
between 10 and 250Hz.
When selecting the gearing of your system, be sure to
operate the motor as near to rated speed as possible.
Centring your speed range around rated speed (so that
maximum speed actually overspeeds your motor) gives
better motor cooling and utilisation.