Rockwell Automation Reliance electric FlexPak 3000 User manual

Instruction Manual
Pulse Encoder Interface Kit
For Use With FlexPak™3000
and WebPak™3000 DC Drives
M/N 907FK0101
D2-3302-3

©2001 Rockwell International Corporation
The information in this manual is subject to change without notice.
Throughout this manual, the following notes are used to alert you to safety considerations:
Important: Identifies information that is critical for successful application and understanding of the product.
The thick black bar shown on the outside margin of this page will be used throughout this instruction manual to
signify new or revised text or figures.
!ATTENTION:Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss.
FlexPak, WebPak, and Reliance are trademarks of Rockwell Automation.
!ATTENTION:Only qualified electrical personnel familiar with the construction and operation of
thisequipmentandthehazardsinvolvedshouldinstall,adjust,operate,orservicethisequipment.
Read and understand this manual and other applicable manuals in their entirety before
proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
ATTENTION:Donotinstallorremovemodificationkitswithpowerappliedtothedrive.Disconnect
and lock out incoming power before attempting such installation or removal. Failure to observe
this precaution could result in severe bodily injury or loss of life.
ATTENTION:The user is responsible for conforming with all applicable local, national, and
international codes. Failure to observe this precaution could result in damage to, or destruction
of, the equipment.
Trademarks not belonging to Rockwell Automation are property of their
respective companies.

Contents I
CONTENTS
Chapter 1 Introduction
1.1 Related Publications........................................................................................1-1
1.2 Getting Assistance from Reliance Electric.......................................................1-1
Chapter 2 Installing the Pulse Encoder Interface Kit
2.1 Opening the Drive and Carrier.........................................................................2-1
2.2 Mounting the Pulse Encoder Interface Board..................................................2-2
2.3 Wiring the Pulse Encoder Interface Board ......................................................2-4
2.4 Checking Motor and Drive Wiring....................................................................2-5
2.5 Closing the Carrier and Drive ..........................................................................2-5
2.6 Verifying and Adjusting Drive Parameters.......................................................2-6
Chapter 3 Adjusting Drive Parameters
3.1 Adjusting FlexPak 3000 Parameters ...............................................................3-1
3.1.1 Parameter 200 (FEEDBACK SELECT).................................................3-1
3.1.2 Parameter 207 (PULSE TACH PPR)....................................................3-2
3.1.3 Parameter 208 (PULSE TACH QUADRATURE) ..................................3-2
3.1.4 Parameter 798 (PULSE TACH KIT)......................................................3-3
3.2 Adjusting WebPak 3000 Parameters...............................................................3-3
3.2.1 Parameter 200 (FEEDBACK SELECT).................................................3-4
3.2.2 Parameter 207 (ENCODER PPR).........................................................3-4
3.2.3 Parameter 798 (ENCODER KIT)...........................................................3-4
Chapter 4 Determining Pulse Encoder Feedback Polarity...................................................4-1
Appendix A Technical Specifications and Application Data...................................................A-1

II Pulse Encoder Interface Kit

Contents III
List of Figures
Figure 2.1 – Removing the OIM Carrier Shield.........................................................2-1
Figure 2.2 – Installing the Mounting Screws and Washers on the Pulse Encoder
Interface Board.....................................................................................2-2
Figure 2.3 – Mounting the Pulse Encoder Interface Board on the Carrier................2-3
Figure 2.4 – Mounting the Pulse Encoder Interface Board on an I/O Expansion
Board....................................................................................................2-3
Figure 2.5 – Wiring the Pulse Encoder Interface Board ...........................................2-5

IV Pulse Encoder Interface Kit

Contents V
List of Tables
Table 1.1 – Pulse Encoder Interface Kit Contents....................................................1-1
Table 2.1 – Twisted Pair Lead Numbering ...............................................................2-4
Table 3.1 – Pulse Encoder Parameter Ranges for Different Firmware Versions .....3-2
Table 3.2 – Parameter 798 Status Descriptions.......................................................3-3
Table 3.3 – Parameter 798 Status Descriptions.......................................................3-3

VI Pulse Encoder Interface Kit

Introduction 1-1
CHAPTER 1
Introduction
This instruction manual describes how to install and configure the optional Pulse
Encoder Interface kit used by FlexPak3000 and WebPak3000 Digital DC Drives.
These instructions assume that either a single-channel or quadrature differential
output Pulse Encoder has been properly installed on the drive’s motor. (Follow all
procedures from the manufacturer to properly install the Pulse Encoder on the motor.)
Each M/N 907FK0101 Pulse Encoder Interface kit includes a Pulse Encoder Interface
board (with captive screws), nylon washers, and an extension ribbon cable. See table
1.1.
1.1 Related Publications
This manual describes the Pulse Encoder Interface kit and its associated software
parameters. You will also need the following instruction manuals, which describe the
drive hardware and software.
•D2-3404 FlexPak 3000 Hardware Reference
•D2-3405-1 FlexPak 3000 Software Reference
•D2-3443 WebPak 3000 Hardware Reference
•D2-3444 WebPak 3000 Software Reference
1.2 Getting Assistance from Reliance Electric
If you have any questions or problems with the products described in this instruction
manual, contact your local Reliance Electric sales office. For technical assistance, call
1-800-726-8112.
Table 1.1 – Pulse Encoder Interface Kit Contents
Description Qty Reliance Part Number
M3 x 10 Screw 4 419062-1PEG
Nylon Washer 4 419064-4E
Pulse Encoder Interface Board 1 O-58775
60-pin Ribbon Cable 1 610273-38S

1-2 Pulse Encloder Interface Kit

Installing the Pulse Encoder Interface Kit 2-1
CHAPTER 2
Installing the Pulse Encoder Interface Kit
Installing the Pulse Encoder Interface kit requires completing the following steps.
When you have finished installing the kit, adjust the required drive parameters as
described in chapter 3 before using the drive.
•Opening the drive and carrier
•Mounting the Pulse Encoder Interface board
•Wiring the Pulse Encoder Interface board
•Checking motor and drive wiring
•Closing the carrier and drive
•Verifying and adjusting drive parameters
These steps are described in detail below.
2.1 Opening the Drive and Carrier
Step 1. Turn off, lockout, and tag power to the drive.
Step 2. If necessary, loosen the captive screws and remove the cover from the drive.
Step 3. Loosen the captive screw securing the Operator Interface Module (OIM)
carrier, and then swing open the carrier.
Step 4. Loosen and remove the four screws that attach the shield to the back of the
OIM carrier. See figure 2.1.
!ATTENTION:Do not install modification kits with power applied to the
drive. Disconnect and lock out incoming power before attempting such
installation.Failuretoobservethisprecautioncouldresultinseverebodily
injury or loss of life.
Figure 2.1 – Removing the OIM Carrier Shield
Captive Screw Remove
Screws
(Qty 4)
Carrier
Shield
J17
Power
Supply
Board
Side view with carrier open
(Drive cover has
been removed)

2-2 Pulse Encoder Interface Kit
Step 5. Remove the connector that attaches the shield’s ground wire to J17 on the
drive’s power supply. Set the shield aside.
2.2 Mounting the Pulse Encoder Interface Board
The Pulse Encoder Interface board is mounted on the back of the OIM carrier in one of
two ways: directly on the carrier or on an optional I/O (Input/Output) Expansion board.
If no I/O Expansion board is mounted on the carrier, perform the following steps (refer
to figures 2.2 and 2.3). If an I/O Expansion board is mounted on the carrier, skip
to step 6.
Step 1. Insert a mounting screw in each of the Pulse Encoder Interface board’s four
mounting holes.
Step 2. Slide a nylon washer over the end of each mounting screw. When the Pulse
Encoder Interface board is mounted, the washers are between the board and
the OIM carrier’s standoffs (see figure 2.2).
Step 3. Lift the option board ribbon cable out of the way, then position the Pulse
Encoder Interface board over the OIM carrier’s molded standoffs.
Step 4. Secure the Pulse Encoder Interface board to the carrier using the board’s
attached screws.
Step 5. Plug the option board ribbon cable into the Pulse Encoder Interface board.
Figure 2.2 – Installing the Mounting Screws and Washers on the Pulse Encoder Interface Board

Installing the Pulse Encoder Interface Kit 2-3
If an I/O Expansion Board is mounted on the carrier, perform the following steps
(refer to figures 2.2 and 2.4).
Step 6. Insert a mounting screw in each of the Pulse Encoder Interface board’s four
mounting holes.
Step 7. Slide a nylon washer over the end of each mounting screw. When the Pulse
Encoder Interface board is mounted, the washers are between the board and
the I/O Expansion board’s standoffs (see figure 2.2).
Step 8. Position the Pulse Encoder Interface board over the I/O Expansion board’s
standoffs.
Step 9. Secure the Pulse Encoder Interface board to the I/O Expansion board using
the attached screws.
Step 10. Connect the extension ribbon cable to the Pulse Encoder Interface board and
to the I/O Expansion board as shown in figure 2.4.
Figure 2.3 – Mounting the Pulse Encoder Interface Board on the Carrier
Figure 2.4 – Mounting the Pulse Encoder Interface Board on an I/O Expansion Board

2-4 Pulse Encoder Interface Kit
2.3 Wiring the Pulse Encoder Interface Board
Read and follow the recommendations listed below before wiring the Pulse Encoder
Interface board.
•Install all wiring in conformance with the NEC/CEC and all other applicable local
codes.
•Refer to the manufacturer’s wiring diagram (included with the tachometer) for all
pulse encoder connections.
•Use twisted pair wire having two or three twists per inch. (Reliance twisted pair,
12 to 18 AWG, is recommended for optimum long distance noise immunity.)
•The maximum cable length must insure the minimum specified supply voltage to the
pulse encoder and the minimum specified input voltage to the Pulse Encoder
Interface board.
•Route all tachometer wiring in its own separate conduit.
Refer to figure 2.5 when making wiring connections.
Step 1. Run the twisted pair wire from the motor to the FlexPak drive’s enclosure.
Place a lead number on each wire. For example:
Step 2. Swing the drive’s OIM carrier open.
Step 3. Continue routing the twisted pairs to the drive as follows:
Drives without a NEMA 1 enclosure
Route the twisted pairs to the OIM carrier’s pivot point and then along the
bottom of the carrier to the Pulse Encoder Interface board. Secure the
twisted pairs to the OIM carrier’s tie bar.
!ATTENTION:Do not route pulse encoder wiring with power (AC and DC
power) or logic control wiring in the same conduit. This may cause
interferencewithdriveoperation.Failuretoobservethisprecautioncould
result in damage to, or destruction of, the equipment.
ATTENTION:Do not ground any pulse encoder wiring connection.
Failure to observe this precaution could result in damage to, or
destruction of, the equipment.
Table 2.1 – Twisted Pair Lead Numbering
Pair No. Function Wire Lead No.
1 +15 VDC 71
15 VDC common 72
2A 73
A not 74
3B 75
B not 76

Installing the Pulse Encoder Interface Kit 2-5
Drives mounted in a NEMA 1 enclosure
Route the twisted pairs through the bottom of the drive chassis to the OIM
carrier’s pivot point and then along the bottom of the carrier to the Pulse
Encoder Interface board. Secure the twisted pairs to the OIM carrier’s tie bar.
Step 4. Make sure that the twisted pair wires reach the Pulse Encoder Interface
board’s terminal strip, then cut off any excess wire.
Step 5. Strip about 1/4 inch (6.35 mm) of the insulation from the end of each wire.
Step 6. Refer to figure 2.5. Connect each lead to the corresponding position on the
Pulse Encoder Interface board’s terminal strip. Tighten the terminal strip
connectors to no more than 7 in-lbs (.79 Nm).
Step 7. Refer to your Pulse Encoder’s installation instructions. Connect the twisted
pair wires to the Pulse Encoder in accordance with its manufacturer’s
installation instructions.
2.4 Checking Motor and Drive Wiring
Refer to your FlexPak 3000 drive’s installation manual. Check all motor and drive
wiring to make sure it is correct.
2.5 Closing the Carrier and Drive
Step 1. Close the carrier and secure it in place by tightening the captive screw.
Step 2. If necessary, replace the cover on the drive and secure it in place with its
captive screws.
Figure 2.5 – Wiring the Pulse Encoder Interface Board

2-6 Pulse Encoder Interface Kit
2.6 Verifying and Adjusting Drive Parameters
Perform system parameter adjustments and determine Pulse Encoder feedback
polarity according to the instructions in the following section and your drive’s
installation manual.

Adjusting Drive Parameters 3-1
CHAPTER 3
Adjusting Drive Parameters
Proper operation of the Pulse Encoder Interface kit requires verifying and adjusting
several drive parameters.
If you are using a FlexPak 3000 drive, use the procedures in sections 3.1 through
3.1.4.
If you are using a WebPak 3000 drive, use the procedures in sections 3.2 through
3.2.3.
3.1 Adjusting FlexPak 3000 Parameters
The following parameters must be verified and adjusted for FlexPak 3000 drives.
•Parameter 200 (FEEDBACK SELECT),
•Parameter 207 (PULSE TACH PPR),
•Parameter 208 (PULSE TACH QUADRATURE), and
•Parameter 798 (PULSE TACHOMETER KIT).
These parameters are accessed through the SPEED/VOLTAGE LOOP and DRIVE
INFORMATION menus on the OIM.
3.1.1 Parameter 200 (FEEDBACK SELECT)
The value of this input parameter determines the type of feedback signal used for the
drive’s major control loop.
Step 1. Access the Speed/Voltage Loop (SPD) Feedback menu.
Step 2. Verify and/or change (if necessary) the selection to PULSE TACH.
RANGE: Refer to the following table for ranges relating to the software
version of the drive.
!ATTENTION:The incorrect setting of parameters 207 (PULSE TACH
PPR) and 208 (PULSE TACH QUADRATURE) can cause an overspeed
condition. These parameters must be set by a qualified person who
understands the significance of setting them accurately. Set the values
of these parameters per your application requirements. Failure to
observe this precaution could result in bodily injury.

3-2 Pulse Encoder Interface Kit
DEFAULT: ARMATURE VOLT
Important: If the FEEDBACK SELECT has been previously set to PULSE TACH and
the Pulse Encoder Interface board either fails power-up diagnostics or is
removed, the drive will automatically change FEEDBACK SELECT to
ARMATURE VOLT.
3.1.2 Parameter 207 (PULSE TACH PPR)
This parameter’s value must contain the selected Pulse Encoder’s nameplate PPR
(Pulses Per Revolution). Refer to Appendix A for how to select a pulse encoder.
Step 1. Access the SPEED/VOLTAGE LOOP menu.
Step 2. Verify and/or adjust the parameter value to match the Pulse Encoder’s PPR
nameplate value.
RANGE: 18 - 2500 PPR
DEFAULT: 120 PPR
3.1.3 Parameter 208 (PULSE TACH QUADRATURE)
Unlike single-channel pulse encoders, a quadrature (dual-channel) pulse encoder
indicates both motor speed and rotation direction. A quadrature pulse encoder must
be used in applications which change rotation directions. Regenerative drive (S6R)
applications must use a quadrature pulse encoder because regenerative current from
the drive could result in reverse motor rotation.
When parameter 200 (FEEDBACK SELECT) is set to PULSE TACH, parameter 208
(PULSE TACH QUADRATURE) must be enabled (ON) for all regenerative (S6R) drive
applications. Parameter 208 may be disabled (OFF) when using non-regenerative
drive applications.
When parameter 208 is disabled (OFF), the drive automatically:
•clamps parameter 006 (NEGATIVE CURRENT LIM) to zero (0) to prevent
regenerative current
•clamps parameter 015 (REVERSE DISABLE) to ON to prevent reverse rotation
Step 1. Access the SPEED/VOLTAGE LOOP menu.
Table 3.1 – Pulse Encoder Parameter Ranges for Different Firmware Versions
FlexPak 3000 Firmware Version Range
Earlier than Version 2 ARMATURE VOLT
ANALOG TACHOMETER
PULSE TACH
Version 2 & later ARMATURE VOLT
DC TACHOMETER
PULSE TACH
AC TACHOMETER

Adjusting Drive Parameters 3-3
Step 2. Verify and/or adjust the parameter value to match your selected Pulse
Encoder type.
RANGE: ON (Enabled)
OFF (Disabled)
DEFAULT: ON (Enabled)
Important: A quadrature pulse tachometer can also be used in single-quadrant
(non-regenerative, nonreversing) motor applications.
3.1.4 Parameter 798 (PULSE TACHOMETER KIT)
This output parameter’s value simply indicates the status of the Pulse Encoder
Interface board. See the following table for status values and descriptions:
Important: If parameter 200 (FEEDBACK SELECT) has been previously set to
PULSE TACH and the Pulse Encoder Interface board is either removed or
fails power-up diagnostics, the drive will automatically change parameter
200 to ARMATURE VOLT.
3.2 Adjusting WebPak 3000 Parameters
The following parameters must be verified and adjusted for WebPak 3000 drives.
•Parameter 200 (FEEDBACK SELECT),
•Parameter 207 (PULSE ENCODER PPR),
•Parameter 798 (PULSE ENCODER KIT).
These parameters are accessed through the SPEED/VOLTAGE LOOP and DRIVE
INFORMATION menus on the OIM.
Table 3.2 – Parameter 798 Status Descriptions
Status Value Description
NOT INSTALLED A Pulse Encoder Interface board is not installed in the drive.
The drive’s processing will also prevent parameter 200
(FEEDBACK SELECT) from being set to PULSE ENCODER.
INSTALLED A Pulse Encoder Interface board is installed in the drive and it
passes power-up diagnostics.
FAILEDDIAGS A Pulse Encoder Interface board is installed in the drive and it
fails power-up diagnostics. The drive’s processing will also
prevent parameter 200 (FEEDBACK SELECT) from being set to
PULSE ENCODER. Using the OIM’s DRIVE INFORMATION
menu, verify the status of the Pulse Encoder Interface board.
!ATTENTION:The incorrect setting of parameter 207 (PULSE
ENCODER PPR) can cause an overspeed condition. This parameter
must be set by a qualified person who understands the significance of
setting them accurately. Set the values of this parameter per your
application requirements. Failure to observe this precaution could result
in bodily injury.

3-4 Pulse Encoder Interface Kit
3.2.1 Parameter 200 (FEEDBACK SELECT)
The value of this input parameter determines the type of feedback signal used for the
drive’s major control loop.
Step 1. Access the Speed/Voltage Loop (SPD) Feedback menu.
Step 2. Verify and/or change (if necessary) the selection to ENCODER.
RANGE: ARMATURE VOLT
DC TACHOMETER
ENCODER
DEFAULT: ARMATURE VOLT
Important: If the FEEDBACK SELECT has been previously set to ENCODER and
the Pulse Encoder Interface board either fails power-up diagnostics or is
removed, the drive will automatically change FEEDBACK SELECT to
ARMATURE VOLT.
3.2.2 Parameter 207 (ENCODER PPR)
This parameter's value must contain the selected Pulse Encoder's nameplate PPR
(Pulses Per Revolution). Refer to Appendix A for how to select a pulse encoder.
Step 1. Access the SPEED/VOLTAGE LOOP menu.
Step 2. Verify and/or adjust the parameter value to match the Pulse Encoder's PPR
nameplate value.
RANGE: 18 - 2500 PPR
DEFAULT: 120 PPR
3.2.3 Parameter 798 (ENCODER KIT)
This output parameter's value simply indicates the status of the Pulse Encoder
Interface board. See the following table for status values and descriptions:
Important: If parameter 200 (FEEDBACK SELECT) has been previously set to
ENCODER and the Pulse Encoder Interface board is either removed or
fails power-up diagnostics, the drive will automatically change parameter
200 to ARMATURE VOLT.
Table 3.3 – Parameter 798 Status Descriptions
Status Value Description
NOT INSTALLED A Pulse Encoder Interface board is not installed in the drive.
The drive’s processing will also prevent parameter 200
(FEEDBACK SELECT) from being set to ENCODER.
INSTALLED A Pulse Encoder Interface board is installed in the drive and it
passes power-up diagnostics.
FAILEDDIAGS A Pulse Encoder Interface board is installed in the drive and it fails
power-up diagnostics. The drive’s processing will also prevent
parameter 200 (FEEDBACK SELECT) from being set to
ENCODER. Using the OIM’s DRIVE INFORMATION menu, verify
the status of the Pulse Encoder Interface board.