Smartrise Magnetek HPV900AF Installation and operation manual

DRIVE STARTUP MANUAL
Magnetek HPV900AF Drive
PM Motor Installation
www.smartrise.us | 2601 Fair Oaks Blvd., Sacramento, CA 95864 | 916.457.5129

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Magnetek HPV900AF Drive
EQUIPMENT/SETTINGS VERIFICATION
Verify that the Job Specification parameter table on the drawings
“Sheet 1: Getting Started” matches the actual equipment.
Below is a sample table showing the important values that will
affect operation.
MAGNETEK PARAMETER LOCATION REFERENCE
ADJUST A0
DRIVE A1
Encoder Pulses (Follow procedure in Axial Flux manual Pg. 9)
POWER CONVERT –A4
Input L-L Volts
MOTOR –A5
Rated Mtr Power (Kw)
Rated Mtr Volts (VAC)
Rated Exit Freq (60Hz)
Rated Motor Curr (FLA –Amps)
Motor Poles
Rated Mtr Speed (RPM)
CONFIGURE C0
USER SWITCHES –C1
Encoder Select
“Axial Flux”
Sample: Sheet 1: - Getting Started
Motor
Volts
Motor
Amps
Motor
RPM
Motor
Poles
Motor
HP
Brake Volts
Pick/Hold
Encoder
PPR
Main Line
Volts
Motor
Frequency

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CONTROLLER GROUNDING REQUIREMENTS
NOTE –For the controller to function properly it is very important to
provide proper building ground connections to the controller.
Examples of a proper building-to-controller ground connection is
to attach the ground cable to:
The street side of the incoming water main.
To a grounding rod that has been driven into the pit flooring.
The controller has a common ground bus terminal connection.
All grounds need to land at this common point including building,
motor, transformer, and filter grounds. This prevents ground loops,
and will limit the impedance between the grounds and noise will
be channeled back to building ground.
Providing a proper ground is mandatory and will improve the
performance of the controller.

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WIRING –(Check off box when complete)
** Refer to the Appendix for the following connections **
Power –(Sheet 3: Machine Room connections)
Connect main line power to terminal block L1/L2/L3.
Connect the ground wire to the yellow/green terminal block next
to L1-L3.
Brake –(Sheet 5: Brakes)
Connect the main brake wiring to terminals K1 / K2 and the
secondary brake wiring to terminals J1 / J2 located on the terminal
block between the M contactor and the L1~L3 terminal blocks.
Jump EB to the terminal listed in the Construction box located on
“Sheet 01 – Getting Started” and connect either the rope gripper
or sheave brake to EBR (if installed).
Motor Leads
Connect motor leads to the M contactor at T1/T2/T3.
Encoder Cable –(Sheet 4: Drive and Motor)
Connect the encoder cable to terminal block TB1 located under the
lower cover to terminals 1, 2, 3, 4, 5, 17, & 18 (see table below).
Proximity Sensor –(Sheet 4: Drive and Motor)
Install the proximity sensor per the instructions in the Axial Flux
manual TM7354 - (pp. 6-8).
Connect the proximity sensor to terminal block TB1 located under
the lower cover to terminals 5, 17, 18, & 19 (see table below).

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24VDC
connections to
SRU board IOs
120VAC
connections to
DIN Rail
terminals
Emergency
brake
power
Temporary Run Stop Switch
Enable
CONSTRUCTION –(Sheet 1: Construction)
The following instructions are from the job drawings: “Sheet 1 –
Construction”. Refer to the job’s specific drawings for connections.
Construction Box (Sample)
24v DC connections
Install jumpers between M24 and the IOs listed on “Sheet 1:
Getting Started –Construction”.
Install jumpers between M24 any additional IO’s (if required):
* Pre-Transfer * Emergency Power
* Governor
IMPORTANT! REMOVE FACTORY WIRES ON INPUTS 521/522
oInstall the Run Bug Up/Down Switch to IO’s 521/522
Install the Run Bug Up/Down Enable switch to M24
120v AC connections
Install the temporary run switch between 120 and terminal SF1
and 120 to THL/MHL/BHL terminals on the DIN rail.
Install a jumper between EB and the terminal listed on the
drawings on “Sheet 1: Getting Started – Construction”.

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POWERING UP
(Check off box when complete)
Apply external power by closing the main disconnect.
Close the L1/L2 breaker, the M24, PS, BR and EBR breakers.
Verify that the LCD on the Smartrise board and the Magnetek
Drive should come on.
FINAL SETUP
(Check off box when complete)
Toggle the Inspection/Normal switch to the “INSP” position.
Set BYPASS TERM LIMITS to YES:
oOn the Smartrise Machine Room controller board, press
the Left Arrow (ESC) button several times to get to the
MAIN SCREEN.
oPress the Right Arrow to go to MAIN MENU. Use the Up /
Down Arrow keys and move the asterix to SETUP and press
the enter key.
Green in Window
OFF
Red in Window
ON
Up = OFF
Down = ON
MAIN MENU
Status
Faults
*Setup

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oUse the Up / Down Arrow keys and move the asterix to
MISC and press the enter key.
oBYPASS TERM LIMITS should be the first item listed. If it’s
not there use the Up / Down Arrow keys and move the
asterix to BYPASS TERM LIMITS and press the enter key.
oUse the Up / Down Arrow keys to change the word “NO”
to “YES”.
oUse the RIGHT Arrow key and move the asterix under the
word “SAVE” and press enter.
oHit the LEFT Arrow (ESC) button several times to get to the
MAIN SCREEN.
Verify the LCD displays “Construction” Mode on the MAIN
SCREEN.
Verify that the Magnetek drive is not showing a “Setup Fault One”
on the display.
oGo to “Troubleshooting –Setup Fault One” for corrective
actions.
SETUP
Local Outputs
Security
*Misc
MISC
*Bypass Term Limits
Emergency Power
Monitor BPS
BYPASS TERM LIMITS
NO
*
BYPASS TERM LIMITS
YES Save
*

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AUTO TUNING
The auto tune function must be performed for a PM motor to
properly operate. The two functions are Encoder Alignment and
Motor Alignment.
** During the alignment process the Smartrise SRU board may
display several faults. These are normal and won’t affect the
alignment procedure. **
MOTOR ALIGNMENT
(Check off box when complete)
Use the Left|Right arrow buttons to select the “AUTOTUNE
SEL U12”menu and then use the Up|Down arrow buttons to
change AUTOTUNE SELECT to “YES” but DON’T PRESS THE
ENTER BUTTON YET!
Press and hold the M contactor button in.
Press the Enter button on the drive to start the alignment.
ENCODER ALIGNMENT (NON-ROTATIONAL)
(Check off box when complete)
On the drive: in the ROTOR ALIGN U10 menu change the following
parameters:
OALIGNMENT METHOD to either “HF Inject” or “AUTO ALIGN” and
press Enter.
OALIGNMENT from DISABLED to ENABLE.
OBEGIN ALIGNMENT to “YES” but DON’T PRESS THE ENTER
BUTTON yet!
Press in and hold the M contactor button.
Press the Enter Button on the drive to start the alignment.
If the drive displays the error message “CAN NOT CHANGE AT THIS
TIME” make sure U10 ROTOR ALIGN –ALIGNMENT is set to ENABLE.

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If there are other faults during this process, refer to the fault section
of the Magnetek technical manual for diagnostic information.
HPV900AF DRIVE MENU TABLE
BASICS U9
PARAMETER
DESCRIPTION
CHOICES
DRIVE MODE
DRIVE OPERATION
OPEN LOOP
CLOSED LOOP
PM
AUTOTUNE SEL U12
PARAMETER
DESCRIPTION
CHOICES
AUTOTUNE SELECT
ALLOW AUTOTUNE TO RUN
DISABLE
ON RUN
YES
ROTOR ALIGN U10
PARAMETER
DESCRIPTION
CHOICES
ALIGNMENT
ALLOW ALIGNMENT TO BE PERFORMED
ENABLE
DISABLE
BEGIN ALIGNMENT
DETERMINE WHEN TO PERFORM
ALIGNMENT
YES
ON RUN
NO
ALIGNMENT METHOD
HOW ALIGNMENT WILL BE PERFORMED
OPEN LOOP
AUTO ALIGN
HF INJECT [SEE NOTE]
DRIVE INFO U6
PARAMETER
DESCRIPTION
CHOICES
DRIVE VERSION
SHOWS THE SOFTWARE VERSION OF
THE DRIVE SOFTWARE
SA4810-030-xxx.xx

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OPERATION
(Check off box when complete)
Run the car and verify the following:
No Faults
Make sure the car is moving without triggering a fault either
on the Smartrise SRU or the drive. If the SRU board displays a
“Drive Fault” on the SRU, look at the drive to see what the
fault is. The most common fault is “Encoder Flt”.
oGo to “Troubleshooting –Drive Fault / Encoder Flt” for
corrective actions.
Proper Direction
Make sure the car is moving in the same direction as the
control switch on the Run Bug.
oGo to “Troubleshooting –Wrong Direction” for corrective
actions.
At Speed
Make sure that the car is moving at the proper inspection
speed (approx. 50 FPM).
oGo to “Troubleshooting –Car Moving Too Slow or Rough”
for corrective actions.
Under Control
Make sure that the car is moving under full control. The car
should stop when commanded from the Run Bug. Verify that
the car runs with no faults for 10 seconds or more.
oGo to “Troubleshooting –Brake Not Lifting” for corrective
actions.

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TROUBLESHOOTING
DRIVE FAULT / ENCODER FLT
1. The most common fault at startup with a Magnetek drive is the
Encoder fault. Perform the following checks to correct this fault:
a. Check for a solid shield-to-ground connection at the motor
and drive.
b. Check for correct colored encoder wires to the terminals.
c. Verify that “C1 - Encoder Select” is set to “Axial Flux”.
d. Swap A+ / A- on terminal TB2 –#1 (A) and #2 (/A).
i. After changing any encoder wiring the Encoder Alignment
must be ran again (See page 6).
BRAKE NOT LIFTING
1. If the brake is not picking make sure that it is wired according to
Sheet 5 –Brakes and verify that the EB terminal is jumped to the
terminal listed on “Sheet 01 – Getting Started”. If it has the proper
voltage check the following:
a. During a run command, check for DC voltage between points
K1 / K2 and J1 / J2. Verify the voltages are also at the Brake
Coil(s) when commanded to pick.
b. Verify that the voltages match the Brake Coil voltages shown
on “Sheet 1: Getting Started” table.
WRONG DIRECTION
1. If the car is moving in the wrong direction:
a. On the Smartrise controller board make sure that IO 521
comes on when commanding the UP direction and IO 522
comes on when commanding the DOWN direction.
b. Change the direction of the motor in the drive by going to “C1
–Motor Rotation”and toggling between FORWARD/
REVERSE.
c. Swap two of the motor leads (T1 with T2). After swapping the
motor wires it may be necessary to change C1 –Motor
Rotation again. Run the U12 Auto Tune again.

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CAR MOVING TOO SLOW OR ROUGH
1. Swap the encoder wires A+ and A- on drive TB2 (terminals 1 & 2).
2. Verify the brakes are lifting fully.
SETUP FAULT ONE
This is caused when the HPV is programmed with motor data (A5) that
conflicts with drive software.
1. Unplug the CAT5 cable from the DRIVE port on the machine room
SRU board. This will restore access to the HPV LCD screen.
2. Go to A5 –Motor Parameters –Motor Poles and verify that you
have the correct number of poles listed.
3. Next, go to A5 –Motor Parameters –Rated Motor Speed and lower
the RPM 15-20 rpms and save.
4. Plug the CAT5 cable back into the DRIVE port on the SRU.

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APPENDIX
Terminal Locations
Encoder
wiring
terminals
GND
terminals
Main Line
terminals
L1/L2/L3
Motor
terminals
T1/T2/T3
Brake terminal
block
J1/J2 –K1/K2
Terminal
TB1
J1
J2