Rockwell Automation Allen-Bradley PowerFlex 23PFC Owner's manual

PowerFlex DC Field Controller
Catalog Number 23PFC
Programming Manual
Original Instructions

Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are
required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may
be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Labels may also be on or inside the equipment to provide specific precautions.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017 3
Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Firmware Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 1
Startup Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools Required for Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Start up a PowerFlex DC Field Controller. . . . . . . . . . . . . . . . . . . . . . . 10
Startup Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Before You Apply Power to the Controller or Drive . . . . . . . . . . 10
Apply Power to the Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 2
Programming and Parameters About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
How Parameters are Organized. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Change the HIM Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Change the Parameter Access Level . . . . . . . . . . . . . . . . . . . . . . . . . 21
Basic Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Advanced Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Parameter Cross Reference – by Name . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Parameter Cross Reference – by Number. . . . . . . . . . . . . . . . . . . . . . . . 84
Chapter 3
Troubleshooting Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Field Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
HIM Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Manually Clear Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Clear an Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Alarm Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Common Field Controller Symptoms and Corrective Actions . . . 100
Field controller does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Field controller activates but there is no output current . . . . . 100
The field controller is unable to generate commanded
current or voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Testpoint Codes and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Appendix A
Control Block Diagrams Parameter Type Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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Appendix B
HIM Overview External and Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
LCD Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
ALT Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Using the S.M.A.R.T. List Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
View a Parameter Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Edit a Parameter Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Remove/Install the HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Appendix C
Application Notes Alpha Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Alpha Test Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Analog Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Example 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Example 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Analog-input Signal Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Logic Command/Status Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Reference Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
“Auto” Voltage Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
“Manual” Voltage Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Voltage Source Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Reference Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Auto/Manual Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Scale Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Link Parameters Via the Scale Block Parameters. . . . . . . . . . . . . 142
SCR Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Open SCR Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Shorted SCR Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
S-curve Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
S-curve Acceleration Ramp Example:. . . . . . . . . . . . . . . . . . . . . . . 146
Voltage Regulation Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Adaptive Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Voltage Threshold Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Voltage Zero Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Voltage Draw Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Voltage / Current Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Zero Current Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Voltage Regulation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Current Regulation Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Digital Current Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Start at Powerup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Fine Tune the Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Using the Test Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017 5
Table of Contents
Manually Adjust the Current Regulator Tune Settings. . . . . . . 153
Manually Adjust the Voltage Regulator. . . . . . . . . . . . . . . . . . . . . 155
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

6Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017
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Notes:

Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017 7
Preface
This manual provides information on how to startup, program, and
troubleshoot the PowerFlex® DC Field Controller. Startup procedures are
provided for a PowerFlex DC Field Controller that is used in standalone mode
and when a field controller is used with a PowerFlex DC drive or PowerFlex
DC Standalone Regulator. This manual excludes instructions for installation
and use of the PowerFlex DC Fiber-optic Interface option module (cat. no.
20P-S5H781), used for communication between the field controller and a
PowerFlex DC drive or PowerFlex DC Standalone Regulator. See the list of
Additional Resources on page 8for more information on related publications.
This manual is intended for qualified personnel. You must be able to program
and operate DC drives, DC field controllers, and associated equipment. In
addition, you must have an understanding of the parameter settings and
functions that are detailed in this manual.
Firmware Revision The contents of this manual pertain to PowerFlex DC Field Controller
firmware revision 1.001.
You can view the current firmware revision of the field controller on the HIM
(if installed) in parameter 331 [Software Version]. See the HIM Overview on
page 123, for details on how to use the HIM. If a HIM is not installed, the
firmware revision of the field controller is included on the data nameplate label.
See the PowerFlex DC Field Controller Installation Instructions, publication
23PFC-IN001, for details.
Product Downloads Download firmware, associated files (such as Add-on Profile, DTM, and EDS),
and access product release notes from the Product Compatibility and
Download Center at http://www.rockwellautomation.com/
rockwellautomation/support/pcdc.page.

8Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017
Preface
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at
http://www.rockwellautomation.com/global/literature-library/overview.page.
To order paper copies of technical documentation, contact your local
Allen-Bradley distributor or Rockwell Automation sales representative.
Resource Description
PowerFlex Digital DC Drive and Field Controller Technical Data, publication 20P-TD001 Provides detailed information on:
• Basic product selection
• Field controller specifications
• Option specifications
• Circuit protection
PowerFlex DC Field Controller Installation Instructions, publication 23PFC-IN001 Provides installation instructions for the PowerFlex DC Field Controller.
PowerFlex DC Fiber-optic Interface Option Module Installation Instructions, publication
20P-IN078
Provides installation instructions for the PowerFlex DC fiber-optic interface module.
PowerFlex Digital DC Drive - Frame A Hardware Service Manual, publication 20P-TG001 Provides hardware test procedures and spare parts replacement instructions for
Frame A PowerFlex DC drives and field controllers.
PowerFlex Digital DC Drive - Frame B Hardware Service Manual, publication 20P-TG002 Provides hardware test procedures and spare parts replacement instructions for
Frame B PowerFlex DC drives and field controllers.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, http://www.rockwellautomation.com/global/certification/
overview.page
Provides declarations of conformity, certificates, and other certification details.

Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017 9
Chapter 1
Startup
This chapter provides basic startup procedures for the PowerFlex® DC Field
Controller.
Qualified Personnel The procedures in this section are intended for qualified personnel.
• You must understand the hazards that are associated with
electromechanical equipment installations.
• You must understand and follow all applicable local, national, and/or
international electrical codes.
• You must be able to program and operate DC drives, field controllers,
and associated devices.
• You must have an understanding of the parameter settings and functions
for both DC drives and DC field controllers.
Tools Required for Startup You must use one of these tools to configure and start up the PowerFlex DC
Field Controller:
• LCD human interface module (HIM). If you use the HIM to
commission the field controller, read the HIM Overview on page 123
before performing the procedures in this chapter. If an operator interface
is not available, use a remote device to start up the field controller.
• DriveExecutive™ software - You must use DriveTools™ SP version 4.01 or
later, with the PowerFlex DC drive specific software patch installed. The
latest version of DriveTools SP software can be downloaded from the
Product Compatibility and Download Center at:
https://compatibility.rockwellautomation.com/Pages/home.aspx.
• Connected Components Workbench® software, version 10 or later.
ATTENTION: Power must be applied to the field controller to perform the
following startup procedures. Some of the voltages present are at incoming
line potential. To avoid electric shock hazard or damage to equipment, allow
only qualified service personnel to perform the following procedure.
Thoroughly read and understand the procedure before beginning. If an event
does not occur while performing this procedure, Do Not Proceed. Remove
Power including user-supplied control voltages. Correct the malfunction
before continuing.

10 Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017
Chapter 1 Startup
Start up a PowerFlex DC Field
Controller
Complete this startup procedure for a PowerFlex DC Field Controller that is
used in standalone mode or with a PowerFlex DC drive.
To complete the steps in these startup procedures, see the supporting
information in these publications:
• PowerFlex DC Field Controller Installation Instructions, publication
23PFC-IN001.
• PowerFlex DC Fiber-optic Interface Option Module Installation
Instructions, publication 20P-IN078
• PowerFlex Digital DC Drive User Manual, publication 20P-UM001.
Startup Sequence
This list contains the main procedures that are required to commission the
field controller.
Before You Apply Power to the Controller or Drive
Complete these procedures before you apply power to the field controller or
drive (if used).
Verify the Analog Input Configuration Settings
1. Remove the covers from the field controller and drive (if used).
2. Verify all switch settings for the analog inputs (S9, S10, and S11) on the
main control circuit board.
Description Page
Before You Apply Power to the Controller or Drive
Verify the Analog Input Configuration Settings 10
Verify the Power Wiring 11
Verify the Control and I/O Wiring 11
Apply Power to the Device
Apply Voltage to the Control Circuits 11
Verify the Control Voltages 12
Load the Default Settings 12
Configure the Most Commonly Used Parameters 12
Verify Field Controller Operation 15
Tune the Current Regulator 17

Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017 11
Startup Chapter 1
Verify the Power Wiring
• Verify that the AC line power at the disconnect device is within the
rated value of the device and that all power wiring is correct.
Verify the Control and I/O Wiring
1. Verify that control power and I/O wiring is correct.
• A digital input (1…8 only) must be wired and configured as an
enable.
• If the field controller is connected to a PowerFlex DC drive
(firmware revision 7.001 or later) by using I/O, verify that the analog
and digital I/O connections between the devices are correct.
2. If the field controller is used with a PowerFlex DC drive (firmware
revision 7.001 or later) and the Fiber-optic Interface option module is
installed in both devices, verify that the fiber-optic cable connections are
correct.
3. If you are using a PTC thermistor or thermal switch to help protect the
field controller from an overload condition, remove the 1 kΩresistor
between terminals 78 and 79.
Apply Power to the Device
The remainder of the startup procedures in this manual assumes the use of a
HIM to configure and autotune the device.
Apply Voltage to the Control Circuits
1. Apply power to the control circuits of the device (terminals U2 and V2).
2. If any of the digital inputs are configured to “Stop/CF” (CF = Clear
Fault), “Enable” or “Aux Fault,” verify that signals are present or
reconfigure parameter [Digital InxSel]. If a fault code displays, see Fault
Descriptions on page 93.
ATTENTION: Do not connect any external power to the DC output terminals,
personal injury and/or equipment damage can occur.
IMPORTANT When power is first applied, the HIM can require approximately 5 seconds
until commands are recognized (including the Stop key).

12 Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017
Chapter 1 Startup
3. If the STS light-emitting diode on the HIM assembly is not flashing
green, see Field Controller Status on page 91 for other indications.
Verify the Control Voltages
Verify that the following voltages are present at I/O terminal block 1 and 2:
Load the Default Settings
It is recommended that you reset the device to the default settings. By resetting
the device to the default settings, any previous parameter modifications you
have made are overwritten.
1. On the HIM, from the “Main” menu scroll to the “Memory Storage”
menu.
2. Press Enter.
3. Scroll to “Reset To Defaults” and press Enter.
4. A message displays to verify that you want to reset the device to the
factory settings.
5. Press Enter.
A “Params Defaulted” (F48) entry is made in the device Fault Queue to
indicate the change.
Configure the Most Commonly Used Parameters
If your standalone application only requires basic device parameter setup, you
can use the S.M.A.R.T. list screen available on the HIM to program the field
controller. See Using the S.M.A.R.T. List Screen on page 125 for more
information.
1. At the Main menu, scroll to the Parameter option.
2. Press ALT and then Sel.
3. Scroll to the Numbered List option.
4. Press Enter.
5. Type 211.
6. Press Enter.
Terminal Number… Voltage To Terminal Number…
7 +10V 9
8-10V 9
19 24…30V 18
IMPORTANT To access all parameters in the field controller, you must first set parameter
211 [Param Access Lvl] to 1 “Advanced” (as instructed in these steps).

Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017 13
Startup Chapter 1
7. Press Sel.
8. Type 1.
9. Press Enter.
10. Press Esc.
11. Press ALT and then Sel.
12. Scroll to the File-Group-Par option.
13. Press Enter.
14. Scroll to the “Load Control” file.
15. Press Enter.
16. Select the “Load Data” group, and press Enter.
17. Configure the following parameters:
• 175 [Load Rated Volt] - Enter the load nominal (rated) voltage for
the field controller.
• 179 [Load Rated Curr] - Enter the load nominal (rated) current.
18. Access the “Utility” file.
19. Press Enter.
20. Access the “Alarms” group.
21. Configure the following parameters:
• Par 481 [UnderVolt Thresh] - Enter the value at which the field
controller detects an AC under voltage condition. The default value
is 100V for a 200V AC configuration, and 400V for a 500V AC
configuration. Typically, this value is approximately 85% of the
nominal AC line voltage.
• Par 584 [OverCurrent Thr] - Enter the value at which an over
current condition is detected (default = 175%). Set the threshold
level at least 10% above the selected operating current limit (Par 7
[Current Limit]).
22. Par 585 [Overvolt Val] - Enter a value that is 10% above the maximum
rated voltage, as set in Par 175 [Load Rated Volt].
23. Complete the appropriate procedures for your application:
• For a PowerFlex DC Field Controller used in standalone mode, see
Configure a Standalone PowerFlex DC Field Controller on page 14.
• For a PowerFlex DC Field Controller connected to a PowerFlex DC
drive with analog and digital I/O, see Configure Analog and Digital
I/O Parameters for a PowerFlex DC Field Controller Connected to a
PowerFlex DC Drive on page 16.
• For a PowerFlex DC Field Controller connected to a PowerFlex DC
drive with a Fiber-optic Interface option module, see Configure
Parameters for a PowerFlex DC Field Controller Connected to a
PowerFlex DC Drive with a Fiber-optic Interface Option Module on
page 16.

14 Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017
Chapter 1 Startup
Configure a Standalone PowerFlex DC Field Controller
Complete these steps to configure a PowerFlex DC Field Controller that is
used in standalone mode.
1. Access the “Dynamic Control” file and press “Enter”.
2. Access the “Control Config” group.
3. “Set Par 241 [Vlt Cur Mode Sel] based on your application:
• Voltage regulation = 1 “Volt Reg”
• Current regulation = 2 “Curr Reg” (default)
4. Access the “Input / Output” file and press Enter.
5. Access the “Analog Inputs” group.
6. Configure the following:
• If you have connected a potentiometer to analog input 1 as a
reference:
• Verify that Par 70 [Anlg In1 Sel] is set to match the regulator
mode in Par 241 [Vlt Cur Mode Sel]. Par 70 = 5 “Current Ref ”
when Par 241 = 2 “Curr Reg”. Par 70 = 1 “Volt Ref A” when Par
241 = 1 “Volt Reg”.
• Verify that switch S9 and Par 71 [Anlg In1 Config] are
configured to match (voltage signal).
• Set Par 72 [Anlg In1 Scale] and Par 74 [Anlg In1 Offset]
appropriately.
• If you are using the HIM on the field controller cover (Port 1) for a
reference, set Par 70 [Anlg In1 Sel] to 0 “Off ” (No signal).
7. Access the “Digital Inputs” group.
8. Configure the following parameters:
• Par 1391 [ContactorControl] - If an AC contactor is used, select 1
“AC Cntcr”. In this case, an Auxiliary Status contactor must be wired
to a digital input (default setting for digital input 8).
• Par 140 [Digital In8 Sel] - If an AC contactor is NOT used, set to
other than 31 “Contactor” (for example, 0 “Not Used”).
• If an auxiliary status contactor is wired to a digital input other than
digital input 8, set the appropriate [Digital InxSel] parameter to 31
“Contactor”.
9. If you are using the HIM on the field controller cover (Port 1) for the
reference, complete the following steps:
• Access the “DPI Inputs” group.
• Set Par 1323 [DPI P1 Select] to match the regulator mode in Par 241
[Vlt Cur Mode Sel]. Par 1323 = 5 “Current Ref ” when Par 241 = 2
“Curr Reg”. Par 1323 = 1 “Volt Ref A” when Par 241 = 1 “Volt Reg”.

Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017 15
Startup Chapter 1
Verify Field Controller Operation
Verify that starting the field controller for the selected control mode (as set in
Par 241 [Vlt Cur Mode Sel]) and changing the reference, provides the
expected regulation.
For Voltage Regulation
For these steps, verify that the configured input voltage reference (value of Par
117 [Volt Reg In Pct]) is equal to the output voltage (value of Par 1009 [Volt
Reg Fdbk Pct]).
1. Set the voltage reference to “0” by using the assigned source (HIM,
digital input, or other source).
2. Press Start on the HIM and slowly increase the voltage reference until
full voltage (100%) is reached.
3. For four quadrant field controllers, press the Direction button on the
HIM and verify that the field voltage ramps down to “0” volts and then
to full voltage in the opposite polarity.
4. Press Stop on the HIM and verify that the field controller ramps to “0”
volts.
For Current Regulation
For these steps, verify that the configured input current reference (value of Par
39 [Current Ref ]) is equal to the output current (value of Par 199 [Out
Current Pct]).
1. Set the current reference to “0” by using the assigned source (HIM,
digital input, or other source).
2. Press Start on the HIM and slowly increase the current reference until
full load (100%) current is reached.
3. For four quadrant field controllers, change the polarity of Par 39
[Current Ref ] and verify that the field current ramps down to “0” amps
and then to full current in the opposite polarity.
4. Press Stop on the HIM and verify that the field controller ramps to “0”
amps.
If the default gain values are not adequate for your application, see Fine Tune
the Regulators on page 153.
You have completed the startup procedures for a standalone field controller.

16 Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017
Chapter 1 Startup
Configure Analog and Digital I/O Parameters for a PowerFlex DC Field Controller Connected
to a PowerFlex DC Drive
Complete these steps to complete the parameter configuration for a PowerFlex
DC Field Controller that is connected to a PowerFlex DC drive with analog
and digital I/O.
1. Access the “Dynamic Control” file and press “Enter”.
2. Access the “Control Config” group.
3. Verify that Par 241 [Vlt Cur Mode Sel] is set to 2 “Curr Reg”.
4. Access the “Input / Output” file.
5. Press Enter.
6. Access the “Analog Inputs” group.
7. Set an [Anlg InxSel] parameter (70, 75, or 80) to 5 “Current Ref ”. (A
corresponding analog output in the connected drive must be set to 36
“Field Curr Ref ”.)
8. Access the “Analog Outputs” group.
9. Set an [Anlg OutxSel] parameter (66…69) to 13 “Output Curr”
(default for [Anlg Out2 Sel]) or 29 “Filtered Curr”. (A corresponding
analog input in the connected drive must be set to 26 “FC Fdbk”.)
10. Access the “Digital Outputs” group.
11. Configure the following parameters:
• Set a [Digital OutxSel] parameter (145…152) to 32 “Wired FC En”
(A corresponding digital input in the connected drive must be set to
73 “Wired FC En”.)
•Seta[DigitalOutxSel] parameter (145…152) to 33 “Wired FC Inv”
(A corresponding digital input in the connected drive must be set to
74 “Wired FC Inv”.)
• Set a [Digital OutxSel] parameter (145…152) to 34 “Wired FC
Act” (A corresponding digital input in the connected drive must be
set to 75 “Wired FC Act”.)
12. Continue with Tune the Current Regulator on page 17.
Configure Parameters for a PowerFlex DC Field Controller Connected to a PowerFlex DC Drive
with a Fiber-optic Interface Option Module
Complete these steps to complete the parameter configuration for a PowerFlex
DC Field Controller that is connected to a PowerFlex DC drive with a Fiber-
optic Interface option module.
1. Access the “Dynamic Control” file.
2. Press Enter.
3. Access the “Control Config” group.

Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017 17
Startup Chapter 1
4. Set Par 241 [Vlt Cur Mode Sel] to 3 “Dig Curr Reg”.
5. Continue with Tune the Current Regulator on page 17.
Tune the Current Regulator
The auto tune procedure for the current regulator calculates the best gain
values for the PI regulator. The procedure can be used only when the field
controller is connected to a highly inductive load.
Follow these steps to tune the current regulator.
1. From the HIM, access Par 452 [CurrReg Autotune] in the “Autotune”
group, in the “Load Control” file, and select 1 “On.”
2. Press Enter.
3. The HIM displays “Ready for ST”.
4. Press the Start button on the HIM. While the auto tune procedure is in
progress, Par 451 [Autotune Status] displays 1 “In Progress”.
The current regulator auto-tuning test starts, which could take several minutes.
• If the auto tuning procedure completes with no errors, Par 451
[Autotune Status] displays 2 “Success”.
• If the auto tune does not complete due to any event other than a device
failure or user interruption, a “CurReg Tune Err” (F62) fault is
generated. See the description of parameter 451 [Autotune Status] on
page 34 for details on other auto tuning results.
The auto tune procedure attempts to calculate the best values of parameters
839 [CD Factor P], 840 [CD Factor I], 847 [DC Curr P], and 848 [DC Curr
I], which provide a compromise between fast current dynamics and limited
overshoots. Parameter 838 [CD Curr Thr] is set to 100. Parameters 849 [DC
Curr P Base] and 850 [DC Curr I Base] are not changed.
If the auto tune is interrupted or an error occurs during the auto tuning
procedure the PI parameters are reset to the values present before the auto tune
was started, otherwise they are overwritten with the new calculated values.
The gains calculated from the auto tune procedure can cause lengthy rise times
when these conditions exist:
• The nominal field current is less than half the value of the device size
rating
• The field controller is started from zero current and provided a reference
below 100%
If a lengthy rise time is unacceptable, make these adjustments:
• Increase the value of Par 848 [DC Curr I]
IMPORTANT The auto tuning procedure can be interrupted before it ends by stopping the
device operation or disabling the device.

18 Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017
Chapter 1 Startup
• Modify the value of Par 840 [CD Factor I] to keep the result of
Par 848 x Par 840 constant
If the default gain values are not adequate for your application, see Fine Tune
the Regulators on page 153.

Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017 19
Chapter 2
Programming and Parameters
This chapter provides a complete list of the PowerFlex® DC Field Controller
parameters. The list contains a description, default value, minimum and
maximum values, units, and data type for each parameter. The parameters can be
viewed and edited (programmed) using a Human Interface Module (HIM). See
the Enhanced PowerFlex 7-Class Human Interface Module (HIM) User Manual,
publication 20HIM-UM001, for information on using the HIM to view and edit
parameters.
As an alternative, programming can also be performed using Connected
Components Workbench™ software(1) and a personal computer. See Control
Block Diagrams on page 103 for visual diagrams of parameter interactions.
About Parameters To configure a field controller to operate in a specific way, certain parameters may
need to be changed from the default value. Three types of parameters exist:
•ENUM Parameters - ENUM parameters provide a selection of two or
more items. The LCD HIM will display a text message for each item.
•Bit Parameters - Bit parameters have individual bits associated with
features or conditions. If the bit is “0”, the feature is off or the condition is
false. If the bit is “1”, the feature is on or the condition is true.
•Numeric Parameters - These parameters have a single numerical value and
unit (for example, 0.1 Volts).
The example on the following page shows how each parameter type is presented
in this manual.
Topic Page
About Parameters 19
How Parameters are Organized 21
Monitor File 28
Load Control File 31
Volt Command File 37
Dynamic Control File 42
Applications File 47
Utility File 53
Communications File 66
Input / Output File 70
Parameter Cross Reference – by Name 80
Parameter Cross Reference – by Number 84
(1) You must use Connected Components Workbench software v10.00 or later. The software can be downloaded from
http://ab.rockwellautomation.com/Programmable-Controllers/Connected-Components-Workbench-Software

20 Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017
Chapter 2 Programming and Parameters
Table 1 - Parameters Table Example
123 4 5 6 7
File Group No.
Parameter Name & Description Values
Data Type Related
VOLT COMMAND
Volt Regulator
108 [Volt Zero Delay]
Amount of time that must elapse after the actual voltage goes below the value
set in Par 107 [Volt Zero Level] before Par 395 [At Zero Volt] changes state.
See Voltage Zero Function on page 150 for more information.
Default:
Min/Max:
Units:
100
0 / 65535
ms
16-bit
Int
107,
395
123 [Vlt Zero I En]
Enables/Disables the output of the integral section of the voltage regulator.
Used in the Zero Voltage function.
• “Enabled” = The output of the integral section of the voltage regulator is
set to zero when the voltage reference and the voltage feedback are equal
to zero. The I component is enabled when a reference value is entered to
restart acceleration.
• “Disabled” = The voltage regulator keeps its integral gain component when
the device is at zero voltage.
See Voltage Zero Function on page 150 for more information.
Default:
Options:
0 =
0 =
1 =
“Disable”
“Disable”
“Enable”
16-bit
Int
COMMUNICATIONS
Masks & Owners
591 [Logic Mask]
Determines which ports can control the device when Par 1377 [Write Mask Act], bit 15 is set to “1.” If the bit for a port is set to “0,” the port will
have no control functions except for stop. 0 = Control Masked, 1 = Control Permitted, x = Reserved.
1377
A
A
Options
Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved DPI Port 5 DPI Port 4 DPI Port 3 DPI Port 2 DPI Port 1 Digital In
Default xxxxxxxxxx000011
Bit 1514131211109 8 7 6 5 4 3 2 1 0
No. Description
1File– Lists the major parameter file category.
2Group– Lists the parameter group within a file.
3No.– Parameter number. = The parameter is only accessible when Par 211 [Param Access Lvl] = 1 “Advanced”.
= The parameter value cannot be changed until the device is stopped.
4 Parameter Name & Description – Parameter name, as it appears on an LCD HIM, and a description of the parameter function.
5Values– Defines the various operating characteristics of the parameter. Three types exist.
ENUM Default:
Options:
Lists the value assigned at the factory. “Read Only” indicates that the parameter is not configurable.
Displays the programming selections available.
Bit Options:
Default:
Bit:
Bit name.
Default setting.
Lists the bit place holder and definition for each bit.
Numeric Default:
Min/Max:
Units:
Lists the value assigned at the factory. “Read Only” indicates that the parameter is not configurable.
The range (lowest and highest setting) possible for the parameter.
Unit of measure and resolution as shown on the LCD HIM.
Important: Some parameters will have two unit values:
• For example: Analog inputs can be set for current or voltage as with Par 71 [Anlg InxConfig].
6DataType- Identifies the parameter data type (i.e. integer, real).
7 Related – Lists parameters (if any) that interact with the selected parameter.
A