Power Tec Digimax Service manual

Repair Center for Powertec Drives and Motors
460 Milford Parkway
Milford, OH . 45150
www.motorsystems.com
513-576-1725

POWERTEC Publication # DGMAX4IM
ADVANCED
MICROPROCESSOR CONTROLLED
DIGITAL SPEED / RATIO CONTROLLER
MADE IN USA
INSTALLATION AND OPERATION
INSTRUCTION MANUAL
Revision 2A
October 6, 1993
This manual is fully implemented with software version (SFWVER)
93271 and later. See page 10 to find the software version of your
unit

Page ii © copyright 1992-1996 by Powertec Industrial Motors

Page iiiDIGIMAX®®
®®
®Manual
INTRODUCTION ....................................................................................................... 1
1.0 INSTALLATION ......................................................................................................... 3
1.1 CUSTOMER CONNECTIONS................................................................................... 3
2.0 ORIENTATION .......................................................................................................... 9
3.0 SET UP PARAMETERS .......................................................................................... 13
#1 Maximum Motor Speed............................................................................................ 15
#2 Maximum Display Value .......................................................................................... 15
#3 Decimal Places ........................................................................................................ 16
#4 Slave Ratio Setting .................................................................................................. 16
#5 Feedback PPR......................................................................................................... 16
#6 Acceleration Time.................................................................................................... 16
#7 Deceleration Time ................................................................................................... 17
#8 Master/Slave............................................................................................................ 17
#9 Preset Speed ........................................................................................................... 17
#10 Jump UP Change .................................................................................................... 17
#11 Jump Down Change ................................................................................................ 18
#12 Up-to-Speed Tolerance ........................................................................................... 18
#13 M.O.P./Jump ............................................................................................................ 18
#14 Freeze/Float ............................................................................................................ 18
#15 Display Sample Rate ............................................................................................... 18
#16 Setup During Run .................................................................................................... 18
#17 Unit I.D.....................................................................................................................19
#18 Baud Rate................................................................................................................ 19
#19 Local/Remote/Keylock............................................................................................. 19
#20 Speed/Ratio SETPOINT........................................................................................ 19
#21 Operator Security Code........................................................................................... 19
#22 A to D Low Engineering Units ................................................................................. 19
#23 A to D High Engineering Units ................................................................................ 20
#24 A to D Display Mode................................................................................................ 20
#25 A to D Sample Rate ................................................................................................. 20
#26 A to D Trim Enable .................................................................................................. 20
#27 Communications Protocol........................................................................................ 21
#28 D to A Source .......................................................................................................... 21
#29 D to A Low Engineering Units ................................................................................. 21
#30 D to A High Engineering Units ................................................................................ 21
#31 Maximum Ratio ........................................................................................................ 21
#32 PRESET Input Mode ............................................................................................... 21
#33 REVERSE Input mode............................................................................................. 22
#34 UP Input Mode......................................................................................................... 22
#35 DN Input Mode......................................................................................................... 22
#36 Installed Option Enable ........................................................................................... 22
#37 Command Ratio Setpoint......................................................................................... 22
#38 Maximum Command Ratio....................................................................................... 22
#39 Debounce Value ...................................................................................................... 22
#40 AT SPEED Source................................................................................................... 22
#41 Communications Turn Around Time........................................................................ 22
Revised 10/06/93
DIGIMAX®Manual
Table of Contents

Page iv © copyright 1992-1996 by Powertec Industrial Motors
TABLE OF CONTENTS (continued)
4.0 SETUP AND OPERATION ...................................................................................... 23
LOCAL OR REMOTE .............................................................................................. 23
COMMAND OR ACTUAL ........................................................................................ 25
SETUP OR NORMAL .............................................................................................. 25
ERROR CODES ...................................................................................................... 27
JUMP OR MOP........................................................................................................ 30
FREEZE OR FLOAT................................................................................................ 31
MASTER OR SLAVE ............................................................................................... 31
Basic Master Mode setup ................................................................................... 31
Basic Slave Mode setup ..................................................................................... 32
ADVANCED FUNCTIONS ....................................................................................... 33
List of Illustrations
1. Physical Dimensions ................................................................................................. 2
2. Rear Terminal Strip connections ............................................................................... 5
3. Connections to the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®...................................................................................................................... 8
4. Front panel Display. .................................................................................................. 9
5. Typical connections to Model 500........................................................................... 24
6. Typical connections to Non-regenerative control.................................................... 26
7. Standard connections to Regenerative control ....................................................... 28
8. Standard Connections to the MILLENNIUM®drive ................................................. 30
List of TABLES
1 Basic Parameters Table (1 to 21)............................................................................ 14
1A Extended Parameters Table (22 to 36) ................................................................... 20
2 Error Codes ............................................................................................................ 27

Page vDIGIMAX®®
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WARNING!
THE DIGIMAX®AS SHIPPED FROM THE FACTORY OPERATES ON
115VAC POWER INPUT ONLY AT TB1 TERMINALS 1 AND 3.
230 VAC UNITS MAY BE OBTAINED BY SPECIAL ORDER, IN WHICH
CASE IT WILL HAVE A 230VAC NAMEPLATE AND STICKER.
DO NOT APPLY 230 VAC TO THE DIGIMAX®UNLESS YOU HAVE
CHECKED FOR THE PROPER CONNECTIONS.
NOTICE!
If you are replacing a DIGIMAX III with a DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®, check TB2
terminals 1,2, and 3 to be sure that there are no connections to these
terminals! These terminals weren't used on the DIGIMAX III, but they
are used internally on the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®. There should be NO CONNEC-
TIONS on TB2 terminals 1,2, and 3 when the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®is used.

Page vi © copyright 1992-1996 by Powertec Industrial Motors
POWERTEC Industrial Motors, warrants the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®to be free from defects in materials and
workmanship for a period of one year from the date of shipment from the factory, or, if purchased from an
authorizeddistributororOriginalEquipmentManufacturer,notmorethan18monthsfromthedateofshipment
from the factory. Upon written notification to the factory of a possible defect in materials or workmanship,
POWERTECwill,atitssoleoption, repairorreplace,atthefactory,suchdefectivepartsasitdeemsnecessary
to restore the unit to its original specifications.
Thereisnootherwarranty,expressorimplied,includingfitnessofpurposefortheapplicationintended.
Thiswarranty does notcover accidental orintentional damage; physicalor electrical misuseor abuse;
defectiveorincorrectinstallation;effectsoftheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®onotherequipmentoreffectsontheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®
causedbyotherequipment;attempteduseoutsideofspecifiedranges;oranyothersituationwhichisdeemed
tobeoutsideofthecontrolofPOWERTEC.
Theuserisresponsiblefortheapplicationoftheproductand/orthe programming thereof.
Programswhichattempttousethecommunicationscapabilityofthe DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®aretheresponsibility
of the user.
Thiswarrantydoesnotencompassanyotherclaims,including,butnotlimitedto,special,incidental,or
consequentialdamages.
ThisinstructionmanualhasbeenassembledasaguidetotheuseofaPOWERTECproduct. Itrepresents
thebesteffortstocompileandpresenttheinformationherein.Sucherrorsasmayappearinnowayaffectthe
abovestated warranty. If mistakes of factare found orsuspected in thismanual, pleasenotify the factoryor
your distributor at once.
SUMMARY OF WARRANTY AND DISCLAIMER

Page viiDIGIMAX®®
®®
®Manual

Page 1DIGIMAX®®
®®
®Manual
The DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®is an advanced, micro-processor based, digital speed reference
designed for use with POWERTEC Brushless motors and controls. It is a reliable and
repeatablepulsetrainsourcewithfeaturesdesignedfortheneedsofcomputercontrolled
processlines. It may be used for master speed setting or asan extremely accurate ratio
setting device.
TheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®isan"openloop"typeofcontrol,i.e.,speedfeedbackinformation
to this speed setting device is not necessary to maintain the speed regulation of the
system.ThenatureofthepermanentmagnetbasedBrushlessmotorandcontrolsystem
isthatitwillmaintainzeropercentspeedregulationfromnoloadtofullloadoveritsentire
speed range. Closing the speed loop for speed regulation is unnecessary. Speeds
generatedbytheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®areaccuratewithin50partspermillionunderallspecified
operating conditions. The Brushless motorwill run at exactly the speed atwhich it is told
to run, and the next time that same speed is commanded, it will be repeated exactly.
The DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®is as much at home in the ratio mode as it is in the speed mode,
and it can switch between the two on the fly. This consistent speed control is invaluable
in setting up processes which vary from day to day, but must be duplicated from order
to order.
TheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®isalsoeasytoapplyanduse. Itcanbeinstalledinlocations where
it is easily accessible to operators, which may be remote from the location of the motor
control.Controlinputsandoutputsareisolated,forflexibilityandimmunitytointeractions
between units.
Speedorratiosetpointsandoperatingparametersareenteredviaa16-keykeypad
on the face of the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®. Speed or ratio setpoints and parameters may also be
entered by remote connection to an industry standard RS-422 or RS-485 communica-
tions link with a variety of protocols.
The five place digital readout may be set for motor RPM, process speed, or other
usefulengineering units,fromthemotororfromanothersourcebesidesthemotorbeing
controlled. Indicators show when the speed is attained and whether the unit's control is
local or remote.
TheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®hassixprogrammableoutputswitches(opencollectortransistors),
offering the possibility of operation completely through the communications link.
Thereisa position registrationfunction(temporary increaseordecrease inspeed)
which may be alternatively programmed as a motor operated potentiometer. There are
UP and DOWN controls are on the front panel, and there are remote inputs for these
functionsaswell.TheMOPfunctionmaybeprogrammedtostayatitsformerspeedafter
a stop, or to return to zero speed when stopped.
DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®represents a high level of sophistication for users of POWERTEC
Brushless motors and controls. It is very effective in operator controlled or computer
controlled systems when precision, repeatability, flexibility, and ease of interface to the
host unit are required.
DIGIMAX®is a registered trademark of POWERTEC Industrial Corporation
INTRODUCTIONINTRODUCTION
INTRODUCTIONINTRODUCTION
INTRODUCTION

Page 2 ©copyright1992-1996 by Powertec Industrial Motors
Figure 1: Physical dimensions of the DIGIMAX®.

Page 3DIGIMAX®®
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®Manual
TheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®maybeinstalledinanyorientationinaclean,drylocation.Careshould
beexercisedinmakingthecutoutinthemountingpanel,sincethepinchbarsmustbeplaced
firmly against the mounting panel just outside of the cutout section to hold the unit in place.
Thefrontpanelhassealedmembraneswitches,butthefrontpanelshouldbeprotected
against moisture falling directly onto it and seeping into the box around the faceplate.
The front panel should be protected against physical damage, but accidental casual
contact with the front panel is not likely to cause a problem.
Thecustomer connection terminalsat therear ofthe boxrequire at least2" (50mm)of
free space behind the box for installation, removal and wiring. It is advisable to not install
highenergyswitchesorelectro-magneticdevicesnexttotheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®,norisitadvisable
to run wires carrying high energy in the same groupings as the wires to and from it.
1.1 CUSTOMER CONNECTIONS1.1 CUSTOMER CONNECTIONS
1.1 CUSTOMER CONNECTIONS1.1 CUSTOMER CONNECTIONS
1.1 CUSTOMER CONNECTIONS
TheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®hastwoterminalstripsonthebackoftheunitforcustomerconnections
(see figure 2 on page 5). These terminal strips are removable for ease of wiring and to
facilitate the replacement of the unit, should that become necessary for any reason. The
terminal strips are keyed differently to prevent mix-ups.
All connections except the AC input power are low voltage, low current, DC circuits
which may be susceptible to system electrical noise interference. Directions for wiring and
shielding must be followed exactly for best results (see figure 3 on page 8).
Wires to and from the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®®
®®
®must be kept away from power wiring.
All relays used in conjunction with, or in the vicinity of, the DIGIMAX®must have arc
suppressors(iftheyhaveACcoils)orfreewheelingdiodes(iftheyareDC).Keephighpower
switching relays and contactors away from the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®and its wiring to prevent
interference from arcing and magnetic field fluxes.
BOTTOMTERMINALSTRIP TB1BOTTOMTERMINALSTRIP TB1
BOTTOMTERMINALSTRIP TB1BOTTOMTERMINALSTRIP TB1
BOTTOMTERMINALSTRIP TB1
1115 VAC HOT line
2 unconnected pin
3115 VAC NEUTRAL
4CASE GROUND
5 EARTH GROUND
The DIGIMAX®must be operated on 115VAC, single phase. Tolerance is +/- 10%.
Frequency range is 48 to 62 hertz. If one side of the supply is grounded, the hot side of the
supply should be connected to terminal 1. The other wire is connected to terminal 3.
230VACDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®unitsmaybeobtainedonspecialorderfromthefactory.Theuse
of 230VAC power is discouraged due to the noisy nature of this type of power.
Terminal 2 is not connected to anything. It is used for voltage separation on the
terminals. Do not make connections of low-voltage, noise sensitive signals on terminal 2.
Terminal4isusedforgroundingthemetalcaseoftheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®withoneofthecase
mounting screws, and terminal 5 should be solidly grounded to an earth ground. The earth
ground must be tied to a system ground which is tied into the system power ground at a
central location. Where long and (electrically) noisy runs are involved, an earth ground rod
in the vicinity of the drive cabinet is recommended.
The AC supply should not have excessive line noise. The input power to the unit is
filtered, but excessive line gaps or spikes could cause erratic power supplies.
1.0 INST1.0 INST
1.0 INST1.0 INST
1.0 INSTALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION

Page 4 ©copyright1992-1996 by Powertec Industrial Motors
6 10 -> 12 VDC output, unregulated, 100 mA
7 24 VDC output, unregulated, 100 mA
8NO CONNECTION
9NO CONNECTION
If you have an application where you wish to use DC power to power a DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®,
you must either use a UPS or contact POWERTEC for a special unit.
Terminal 6 may be used for small 12VDC loads up to 100 mA.
Terminal 7 can supply up to 50 mA at 20 to 24 VDC, unregulated. Terminal 7 is most
often used to turn on the DIGITAL mode in the Model 1000 series and larger drives (using
the 141-108 series Current Controller board), and this is, in fact, recommended.
The output level of these two terminals is dependent on the AC supply voltage.Other
loads on the unit and the load on each of these terminals will also affect the voltage level.
Ifeitheroftheseterminalsareoverloaded,theaccuracyofthe DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®willbedegraded.
Terminal 4 or 5 may be used as a common for these terminals.
Voltage levels on terminals 6 and 7 ARE NOT GUARANTEED. These outputs are
for convenience only for small loads associated with the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®. If stable and/or
regulated voltages are needed for external relays and devices used for system purposes,
the user should incorporate in the system a separate power supply for them.
10 - FREQUENCY OUTPUT
11 + FREQUENCY OUTPUT
This is the output frequency to the controlled drive or drives. It is capable of driving up
to ten inputs of motor controls or ten other DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®inputs or a combination of the two
adding up to ten inputs. Output from these terminals is a square wave from a "totem-pole"
driver with a +24 VDC peak and an off value less than 0.5 VDC. The duty cycle may vary.
12 - ANALOG OUTPUT
13 + ANALOG OUTPUT
The analog output at TB1 terminals 12 and 13 may be used to read a voltage signal
proportional to one of the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®speed sources, or from the RS-422 link, or from the
keypad.This output ranges from 0 to +10 VDC. The source andlevel of this output is set by
parameters#28 (source ofthe outputsignal), #29(the lowestvalue for theoutput), and#30
(the highest value for the output). See page 21.
14 EMITTERS OF AUXILIARY OUTPUTS
15 "AT SPEED" OUTPUT (open collector)
16 AUXILIARY OUTPUT #1 (open collector)
17 AUXILIARY OUTPUT #2 (open collector)
18 AUXILIARY OUTPUT #3 (open collector)
19 AUXILIARY OUTPUT #4 (open collector)
20 AUXILIARY OUTPUT #5 (open collector)
21 AUXILIARY OUTPUT #6 (open colllector)
22 OUTPUTS SUPPLY CONNECTION
An external power supply MUST be used to power any devices connected to
these outputs.These outputs are "open collector" outputs with all of the emitters brought
togetheratTB1terminal14(seefigure2).Thepositivesideofthesupplyhastobeconnected
toTB1terminal22(thissuppliesthedriversontheboard),andthenegativesideofthesupply
must be connectedto TB1 terminal 14. Allof these outputs areisolated from the DIGIMAX®

Page 5DIGIMAX®®
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common,but their emitters are all common to each other. The maximum allowablevoltage
betweenTB1terminals22(+)and14(-)is30VDC. Themaximumallowablecurrentoneach
of the TB1 terminals 15 thru 21 is 100 mA. Snubber diodes are built into the outputs. If the
wiring to the external relays is run more than a few feet, additional snubber diodes should
be used at the external relay coils.
Do not run any large solenoid valves or large contactors directly from these outputs.
Use interface relays connected to these outputs to run this other equipment.
The AT SPEED output operates with the AT SPEED indicator on the front panel. The
adjustment of the AT SPEED tolerance is controlled by parameter #12. The AT SPEED
outputandtheATSPEEDfrontpanelLEDworkonlyintheMASTERmode.InSLAVEmode,
theAT SPEEDLED andthe AT SPEED output areon allof thetime, exceptwhen changing
to a newly entered ratio..
Theothersixoutputs are controllablebyprotocolcommands throughtheRS-422link.
Theycan also be operatedfrom the keypad onthe front (see page 11). These outputs may
be used for run, stop, man/auto, fwd/rev, or for peripheral device control.
By connecting relays to these outputs and using the relays to control the drive, it is
possible torun the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®andmotor control entirely throughthecommunicationslink.
TOPTERMINALSTRIP TB2TOPTERMINALSTRIP TB2
TOPTERMINALSTRIP TB2TOPTERMINALSTRIP TB2
TOPTERMINALSTRIP TB2
1 HARDWARE RESET
2DO NOT USE!
3 DO NOT USE!
Terminal 1 on TB2 is used for a hardware reset. When terminal 1 is connected to a
ground (such as TB1 terminal 5), the DIGIMAX®resets just as if the power to the unit were
turned off and the power was then turned back on again. The parameters are NOT cleared
by this operation.
It is NOT recommended that wires be permanently attached to these terminals
because there is a possibility that a noise pulse or accidental activation of the switch may
cause an unintentional reset, interrupting normal operation. Such noise may come from
nearby power components or a difference in potential between the case or terminals of the
DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®andground.
DONOTMAKEANYCONNECTIONSTOTB2TERMINALS2and3!Theseterminals
are used for programming functions. Connecting anything to these inputs will result in
damage to the unit.
Figure2: Rearterminalstrip connectionsofthe DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®

Page 6 ©copyright1992-1996 by Powertec Industrial Motors
4 CATHODES OF CONTROL INPUTS (ground or common)
5 RUN INPUT (+24 VDC)
6 PRESET INPUT (+24 VDC)
7 EMERGENCY STOP INPUT (+24 VDC)
8 REVERSE INPUT (+24 VDC)
9 JUMP/MOP UP INPUT (+24 VDC)
10 JUMP/MOP DOWN INPUT (+24 VDC)
Power for the control inputs must be supplied from a separate source. Usually this
powercomesfrom the Brushlessdrivebeing controlled.Nominalsupply voltageis24 VDC,
which need not be regulated, but must be filtered. The tolerance is +/- 25%.
The control inputs do not control any functions on the controlled drive. Commands
given to the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®must also be given to the drive at the same time.
The EMERGENCY STOP input must be activate before the unit will respond to any
externalinputorkeyboardcommands.Thisinputnormallyparallels the E.STOPofthedrive.
Activating the RUN input starts the DIGIMAX®, and will it run until the RUN input is
removed. Usually, the run relay contact on the speed board of the drive is used for this. A
SETPOINT value should be entered prior to the first time a RUN command is entered after
powerisapplied;otherwisetheunitwillstartatzerospeed(orratio)andwaitforaSETPOINT
to be entered by the operator. If parameter #14 is set to 1 (see page 18), on all subsequent
RUN commands, the DIGIMAX®will start at the last speed or ratio entered.
ThePRESET commandchangesthe speedoutput togoto thevalue inparameter #9.
The REVERSE input causes the frequency output to decelerate, at the rate set into
parameter #7, to zero speed, and then to accelerate back to the setpoint at the rate set into
parameter #6. Giving a reverse command to the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®does NOT cause the drive to
reverse. Aseparate,simultaneouscommandmustbegiventothedrive.Ifthedriveisgiven
a reverse command, it will not reverse until the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®is given a reverse command,
because the drive input frequency must be at zero before the drive will reverse direction.
The JUMP/MOP UP and JUMP/MOP DOWN inputs duplicate the functions of the UP
and DN inputs on the front panel.
11 - TACHOMETER INPUT
12 + TACHOMETER INPUT
13 - FOLLOWER INPUT
14 + FOLLOWER INPUT
These two inputs are isolated from the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®electronics and from each other.
Bothinputsrequirea+24VDCnominalpeakinput and alowoflessthan1VDC. Bothinputs
will accept signals up to 50 kilohertz. Minimum pulse width for both inputs is 10 microsec-
onds. Widerpulsewidthsaredesireable. Risetimesarenotcritical,buttheyshouldbeless
than 5% of the duty cycle.
The tachometer input is for the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®display and it also supplies a zero speed
signal. It normally comes from the motor control, but it may come from any frequency
reflectingthedrivenprocess. Witha1750RPMsmallframemotor,astandardPOWERTEC
Brushless motor control supplies a 3500 Hertz pulsed waveform to this input, but larger
motors'controlssupplya7000hertzsignaltothetachometerinputandservoratedcontrols
may supply frequencies of up to 50 kilohertz.
The follower input is the frequency which the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®follows in SLAVE mode. A
standard 1750 RPM low horsepower Brushless motor control operates at 3500 Hertz input
frequency. Thisistheidealinputfrequencyforthefollowerinputifthefollowermotoris1750
RPM.TheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®canmultiply byafactorofuptoeight,butperformanceandresolution
at high multiples may be degraded.

Page 7DIGIMAX®®
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15 - AUXILIARY ANALOG INPUT
16 GROUND
17 + AUXILIARY ANALOG INPUT
Themaximum inputis +10VDC, butthe inputis adifferential typeinput, soa negative
voltagemaybeacceptedbyreversinginputleads.TB2TERMINAL17MUSTALWAYSBE
MOREPOSITIVE(ONANABSOLUTESCALE)THANTB2TERMINAL15.IfTB2terminal
15 is more positive than TB2 terminal 17, the effective input will be 0.
The auxiliary analog input is for transferring an analog voltage representing a system
value (such as motor current) through the RS-422 communications link. For this type of
operation, parameter #26 must be 0. #23 is set to read out a +10 VDC input in Engineering
Units (EGU). Parameter #22 is set to low EGU, which may be zero, but doesn't have to be.
The auxiliary analog input may also be used as an analog trim or dancer (see
parameters #20 on page 19, and #26 on page 21). The input leads should be connected to
TB2 terminals 15 and 17 (not ground) and TB2 terminal 16 should be used for the shield.
Ifparameter#26is 1,a5VDCinputiszeroeffect.Increasingvoltageincreasesthesetpoint.
Ifparameter#26is2,a0VDCinputisnoeffect.Increasingvoltageincreasesthesetpoint.
Ifparameter#26is3,a0VDCinputisnoeffect.Increasingvoltagedecreasesthesetpoint.
The maximum speed (parameter #1) may not be exceeded in speed mode.
The maximum ratio (parameter #31) may not be exceeded in slave mode.
18 RS-422 - RECEIVE
19 RS-422 + RECEIVE
20 RS-422 No connection
21 RS-422 - TRANSMIT
22 RS-422 + TRANSMIT
In order to ensure good communications, it is required that shielded cable be used in
the RS-422 communications link. The cable should have conductors no smaller than #24
AWG for distances up to 500 feet. Recommended cables are cables such as Belden®Wire
Company part #9829 or part #88102.
Connecting the link together consists of connecting all of the transmit terminals of the
DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®units in parallel (+ to +, and - to -). Then all receive terminals are connected in
parallel (+ to +, and - to -).
ANSI standards apply to RS-422 communications. The RS-422 standard stipulates
thatthenumberofstationsshallbeatleast10withoutrepeaters. (Repeatersare amplifiers
which strengthen the signal to feed more stations). The DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®communications may
operate up to 32 units on the link.
AfterconnectingalloftheRS-422terminalstogether,oneendofthechainistiedtothe
host (a PLC, a personal computer through an RS-422 output card or an RS-232 to RS-422
converter, or an industrial computer with an RS-422 port). Normally the "transmits" of the
DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®'s will tied to the "recieve" of the host, and the "receives" to the "transmits", but
checkthespecificationsofthehosttobeused.Theunitatthefarendoftheline,furthestfrom
the host, must have a resistor equal to the cable's impedance (120 ohms) installed across
itsreceiveterminals. Thisis"terminating"theline. Itpreventssignalreflectionsfromcausing
spurious signals on the line. The transmit line is terminated at the host.
TheRS-485Communicationsstandard maybe usedwiththe DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®bytyingthe
+Transmittothe+Receiveand the-Transmittothe-Receive. Terminal 20isfortheshields.
If you are putting together a large system, it is a good idea to consult someone who is
knowledgable and experienced in the art of serial communications.

Page 8 ©copyright1992-1996 by Powertec Industrial Motors
Figure 3: Connections to the DIGIMAX®speed controller.

Page 9DIGIMAX®®
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®Manual
TheproperoperationoftheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®requiresacompleteunderstandingofthefront
panel controls. Speeds, ratios, and parameters will be set by the operator with the keypad,
whichconsistsofnumericalandactionkeys.ThedisplayandtheLED'swillsupplyimportant
information during setup and while the process is in operation.
The numeric display of the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®is normally lit up
while power is applied. There are, however, times at which the
display will be blank. One condition under which the display
blankswhilepowerisoniswhenthePGM/CLRbuttonispressed
justpriortoenteringtheaccesscode.Theaccesscodemaythen
beentered.Anotheroccasionwhenthedisplaygoesblankisafter
the ALT key is pressed until one of the keys with a command in
small letters above it is pressed.
Thedisplayisafullfivedigits,allowingnumbersupto99999tobedisplayed. Adecimal
point may be placed between any two of the five digits, allowing numbers to be displayed
or set down to 0.0001.
The display has two levels of brightness to indicate the mode in which it is operating.
The COMMAND mode is a dimmer display. In COMMAND mode the display shows the
SETPOINT value. The ACTUAL mode is a much brighter display. In ACTUAL mode the
display shows the actual speed of the motor in whatever scale is set up by the parameters.
See the explanation of the COM/ACT button below.
TheATSPEEDindicatorchangesonlyintheMASTERmode,indicatingthattheactual
motor speed is withinthe programmed tolerance.In SLAVEmode the AT SPEED indicator
is on all of the time except when slewing to a newly entered ratio.
TheREMOTEindicatorisonwhenremoteoperationison. InoneREMOTEmode,the
keypadislockedout unlesstheunit's LOC/REMkeyispressed. In another mode,eventhe
LOC/REM key is locked out.
The number keys on the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®are used for :
1. entering speeds and ratios into the unit while the unit is in operation. Speeds and
ratios may range from one to five digits, from 0.0001 to 99999;
2. enteringthesecuritycodetogainaccesstotheparameters. Thesecuritycodemay
vary from 1 to 5 digits. It is not necessary to enter leading zeroes;
3. entering parameter values while in setup mode. The parameter values may range
from one to five digits.
The DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®will not accept more than five digits in a single number. When a
number is pressed, the microprocessor enters the number entry mode. As numbers are
entered,theyaredisplayedinthedisplay(exceptintheentryofsecuritycodes,whendashes
aredisplayed). Onthesixthconsecutivedigitanewfivedigitnumberisstarted.Thisfeature
may be used to advantage when an incorrect number is pressed during an entry. Simply
keep pressing numbers until the display is full, then enter the correct number sequence.
The ENTER button must be pressed before any numerical data is entered into the
DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®. Numbers may be pressed continuously, but nothing will happen until the
ENTERbuttonispressed.TheENTERbuttonmustbepressedafterthesecuritycode,after
speedorratiocommandentries,andafterparametervaluesareentered.TheENTERbutton
is not used for function keys such as UP, DN, SET, COM/ACT, or LOC/REM.
The ENTER key may also be used to clear error codes (see page 27).
Figure 4: Front panel display
2.0 ORIENT2.0 ORIENT
2.0 ORIENT2.0 ORIENT
2.0 ORIENTAA
AA
ATIONTION
TIONTION
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Page 10 ©copyright1992-1996 by Powertec Industrial Motors
The UP and DN buttons are used to make changes in the speed or ratio while the
DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®is in operation. There are two control inputs on the back terminals which
accomplish the same functions as the front panel buttons.
There are two modes of response to the UP and DN buttons (see page 31):
1. A"shaft position change"(JUMP) function. Whenthe UP orDN button ispressed,
theoutputfrequencytemporarilyincreasesordecreases(dependingwhichoneispressed)
andreturnstotheSETPOINTwhenthebuttonisreleased.TheeffectofthisontheBrushless
motor control is to move the motor shaft forward or backward in its rotation by an amount
proportional to the extra pulses. The amount of change is determined by parameters.
2. A "motor operated potentiometer" (MOP) function. When the UP or DN button is
pressed, speed will continue to increase or decrease as long as the appropriate button is
pressed. Whenthebuttonisreleased, speedwillremainatthe value whichexistswhenthe
buttonisreleased.Thisemulatestheactionofthetraditionalmotoroperatedpotentiometer.
The UP and DN buttons are also used during parameter entry (see page 13).
TheCMD/ACTbuttontogglestheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®betweendisplayingthespeed(orratio)
COMMAND value and the ACTUAL speed (or a derivative thereof). In ACTUAL mode (the
display is bright) the microprocessor displays the speed information returned by the motor.
InCOMMANDmode (thedisplay isdimmed) the displayis thecurrent SETPOINT (aspeed
command in MASTER mode and a ratio command in SLAVE mode). In SLAVE mode a
decimalpointappearsafterthefirstdigittoshowhowmanynumberstoenter(seepage34).
ThePGM/CLRkeyisusedtoenterandleavetheparametertableintheSETUPmode.
It must be pressed first, followed by a security code and then the ENTER button to access
theparameters. WhenthePGM/CLRkeyispressed,thedisplaywillblankandthenumbers
of the security code, as they are entered, will be acknowledged by a dash for each number
pressed. Afterthe ENTER buttonis pressed,if thecode iscorrect, the displaywill showthe
parameterwhichwasdisplayed whentheparameterswerelast accessed, orparameter#1
ifthisis the firstaccesssince thelastpower-up. The PGM/CLRkeymust be pressedtoexit
the SETUP mode. If the access code is incorrect, the display returns to the mode it was in
before the PGM/CLR key was depressed.
The PGM/CLR key may also be used as a CLEAR function during value entry.
TheALTkeyisusedforquickaccesstocommandfunctionswhichareassignedtothe
numberandcommand keys asALTernatefunctions. Thesearefunctions whichmaynot be
used as often as the dedicated keys, but to which quick access is desired. To use the
alternatefunctions, itis necessaryto pressthe ALTkey (thedisplay willgo blank),and then
thekey with the desired function printed above it. Insome cases, additional actions may be
necessary.
UID The UID function displays the Unit ID number (param #17) when the ALT key is
pressed,followed bythe "0"key. After10 seconds,the display returnsto itsprevious state.
COMSIM COMSIMmeansCOMmunicationsSIMulator.TheCOMSIMfunctionsends
out a continuous string of "A" characters (hex 41) on the RS-422 port for 10 seconds. This
function is used for testing. It is accessed by pressing the ALT key followed by the "1" key.
SFWVER ToaccommodatechangesinfunctionoftheDIGIMAX®,thesoftwareinthe
EEPROMmaybechanged.Sometimesitisnecessarytorefertothespecificsoftwareinthe
unit.PressingALTfollowedbythe"2"keymakestheversiondateappearinthedisplay.The
formatofthedateisafivedigitnumber.Thefirsttwonumbersaretheyearandthelastthree
numbersarethedayoftheyear.Forinstance,April10thisthe100thdayofanon-leapyear.

Page 11DIGIMAX®®
®®
®Manual
SERNUM PressingALTfollowedby the "3"keydisplaysthe serialnumberofthe unit.
DIAG The DIAGnostics function will display a set of diagnostic aids to help to determine
thestateoftheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®.Youmusthaveaknowledgeofhowtousehexadecimalnumbers
to use the diagnostic functions.
Pressing ALT followed by the "4" key causes an equals sign ("=") to appear in the left
lower corner of the display.
If the "1"button is thenpressed, a twodigit HEX numberappears in thedisplay which
represents the on/off states of the inputs on terminals 4 through 10 on TB2.
Thenumbermayrangefrom"00"(allinputsoff)to"3F"(allinputson).Thenumber"05"
in the display would tell the operator that the RUN and ESTOP inputs are on, and therefore
theDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®shouldberunning.
This number is structured as follows:
The first digit is bits 4-7 (7654 binary).
The second digit is bits 0-3 (3210).
bit 7 = Not used
bit 6 = Not used
bit 5 = Down input
bit 4 = Up input
bit 3 = Reverse input
bit 2 = EStop input
bit 1 = Preset input
bit 0 = Run input
If the "DOWN" input (not the front panel key) is activated while running, the number
displayed should be "23" (0010 0011).
ANAOUT Pressing the ALT key and the "5" key displays the current value of the
AnalogOutputatterminals13(+)and12(-)onTB1.Thedisplayshowstheletter"Ao"onthe
leftsideofthedisplayandthecurrentvalueoftheAnalogOutputinEngineeringunits,which
are controlled and scaled with parameters #28 through #30. (See parameters section).
Parameter#28determinesthesourceoftheAnalogOutputsignalandparameters#29
and#30 determinetheminimumandmaximumvalues,respectively.Ifparameter#28isset
to"3",the Analog outputvalueis setfromthe keypad.Simplykey in anewnumber between
parameter #29 (0 VDC out) and parameter #30 (10 VDC out) and press ENT. The Analog
Output will go a the new value which is proportionally between the two.
AUXOUT PressingtheALTkeyandthe"6"keybringsuptheAUXiliaryOUTputmenu.
The letters "Au" appear on the left side of the display. You can see the state of one of the
sixauxiliaryoutputsbypressingtheoutputnumber(1through6).Ifyouthenwishtochange
the state of the output, you can press either the ON (UP) key or the OFF (DN) key and then
the ENT key to change the state of the output.
LOAD/AI ThevalueinengineeringunitsoftheAnalogInput(TB2terminals15and17)
is displayed by pressing the ALT key followed by the "7" key. An "Lo" is displayed followed
by the value. Scaling is handled by parameters #22 and #23 (see parameters section).
PRESET The DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®maybeforced intoPRESETspeed modeby pressingthe
ALT key followed by the "8" key followed by the "UP" (ON) key. To turn the PRESET off,
press ALT, then the "8" key, then the "DN" (OFF) key.

Page 12 ©copyright1992-1996 by Powertec Industrial Motors
REM/LCL PresstheALTkey followedbythe"9"keytotogglebetweentheRemoteand
LocalmodesoftheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®.InLocalmode(REMOTELEDindicatorinthedisplayisoff)
all keypad functions are active. In Remote mode only the REM/LCL function and the COM/
ACTkeywilloperate.Ifparameter#19issetto"2"(KEYLOCK),youmustpresstheALTkey,
anaccesscode,theUPkeyandtheENTkeyinsequencebeforetheDIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®willswitch
back to the Local mode from the KEYLOCK mode.
ON The ON function (the "UP" key) will only work for the AUXOUT and the PRESET
functions. It is not necessary to press the ALT key between the PRESET key and the ON
key or after the AUXOUT number key before the ON key.
OFF The OFF function (the "UP" key) will only work for the AUXOUT and the PRESET
functions. It is not necessary to press the ALT key between the PRESET key and the OFF
key or after the AUXOUT number key before the ON key.
RESETTING PARAMETERS TO FACTORY DEFAULTS
The parameters may be reset to the factory default values by the following key
sequence (the DIGIMAXDIGIMAX
DIGIMAXDIGIMAX
DIGIMAX®must be in the stopped mode):
[ALT] [CMD] - The display will blank out.
[7] [9] [1] [3] [5] - A dash ("-") will appear for each number entered.
[ENT] - A "y" will appear in the display.
[UP] - the parameters should be reset to the defaults.