Standard Start-up PF525
Section 1:
It is the responsibility of the engineer / end user to use proper safety precautions when working with any
equipment required for this Start-up.
Before applying power
Check for Ungrounded Distribution System – if it is, remove the MOV’ S Jumper and check for
High KVA of utility – if it is, you may need an ac line reactor or an isolation transformer. Check for
High Resistance Grounding – if it is, remove the MOV’ S Jumper.
Before applying power check the following for proper wiring: (check all Grounding)
Drive (Get Catalog number ) & (FRN )
(FRN=Firmware) (Once power is applied the FRN can be found in b29)
Check wiring for Digital Inputs Start, Stop etc...
(PowerFlex 525/25B)
Terminal # 1 controlled by P45
Terminal # 2 T62
Terminal # 3 T63
Terminal # 4 digital in common
Terminal # 5 T65
Terminal # 6 T66
Terminal # 7 T67
Terminal # 8 T68
Motor (Get Motor Name Plate Data) – you can enter the data on page 2
Check wiring at the Motor Connection Box, Check wring to an output contactor / bypass, if there is one
Check wiring for an output filter or harmonic filter, if there is one.
Encoder (Get Encoder Name Plate Data / Catalog number )
Drive Power / Source for encoder at encoder terminals +V and Cm (set Dip Switch +5 - +12VDC)
If encoder uses 24VDC Power then an external power source must be used.
_ _
Encoder channels A, A, B, B
The encoder Feedback channels auto select the Voltage coming in 5V, 12V or 24V DC.
Encoder settings on the Encoder Board for (+5 / +12V for source)
Encoder Placement on the Motor or on the Machine
Wiring to the PLC / SLC / Micrologix etc.
(Get Gear Box Ratio / Belt and Pulley Ratio )
1
Before Applying AC power, check that the Machine/Motor Area is clear and ready for use.
Then Apply AC power.
(Once power is applied the FRN can be found in b29)
AC power L1, L2, L3 and U, V, W Motor connections
Encoder Terminals
Section 2:
(P53 can give you a fresh start)
P53 = [Reset to Defaults] ((2) “Factory Rset”)
P30 = [Language] (1) English (Default)
Enter Motor Data
P31 = [Motor NP volts] = Volts
P32 = [Motor NP HZ] = HZ
P33 = [Motor OL Current] = Amps
P34 = [Motor NP FLA] = Amps
P36 = [Motor NP RPM] = RPM
P37 = [Motor NP Power] = KW
P35 = [Pairs of Poles] = 4 (3600RPM=2, 1800RPM=4, 1200RPM=6, 900RPM=8)@60HZ
(3000RPM=2, 1500RPM=4, 1000RPM=6, 750RPM=8)@50HZ
Use this formula for custom motors Poles = (120X f)/N Example: (120*140HZ)/4000RPM) =4Poles
P38 = [Voltage Class] = ONLY AVAILABLE WITH 600V DRIVES ((2) =480V and (3) = 600VDefault)
Enter Motor Control Mode
P39 = [Torque Perf Mode] (0) V/HZ, (1) SVC, (2) Economize, (3) Vector,
(Selecting a value of 1 SVC/ Sensrls Vect or 3 Vector requires that an Autotune be completed)
(Finish setting all the parameters in this document before running the Autotunes)
Vector = Better speed reg, and more parameters available
V/HZ does not require an autotune. Only A531 (Start Boost) and A530 (Boost Select) - with
Custom motors A532 [Break Voltage] and A533 [Break Frequency] may need to be adjusted as
well - to provide a Linear V/HZ curve. A531 start at 2V and slowly work your way up in increments
of 2Volts.
Whenever using multiple motors on one drive P39 must be set to V/HZ
2
Enter Speed Mode
A535= [Motor Fdbk Type] = (0) None (Default)
(0) None/Open Loop, (1) Pulse Train, (2) Single Chan, (3) Single Check, (4) Quadrature, (5) Quad Check
When A535 is set to 2,3,4,5 Encoder make sure you set the encoder PPR correctly.
A536 [Encoder PPR]
A538 [Ki Speed Loop] = 2.0 (Default)
A539 [Kp Speed Loop] = 5.0 (Default)
Enter Min and Max Speed (Default)
P43 = [Minimum Freq] = 0HZ
P44 = [Maximum Freq] = 60HZ
Note: Speed reference scaling over communications is (HZ times 100)
Enter Start Source 1 Keypad, (2) DigIn TrmBlk, (3) Serial/DSI, (4) Network Opt, (5) Ethernet/IP (Embedded)
P46 = [Start Source 1] = (1) Keypad (Default)
P48 = [Start Source 2] = (2) DigIn TrmBlk (Default)
P50 = [Start Source 3] = (3) Ethernet/IP (Default)
Enter Speed Reference
(Default)
P47 = [Speed Reference 1] = (1) Drive Pot (could be anything – it is application dependent)
P49 = [Speed Reference 2] = (5) 0-10V input (could be anything – it is application dependent)
P51 = [Speed Reference 3] = (15) Ethernet/IP (could be anything – it is application dependent)
(Default)
Set if needed T91&T92 [Analog In 0-10v Lo and Hi] = / 0% / 100%
Set if needed T95&T96 [Analog In 4-20ma Lo and Hi] = / 0% / 100%
Check b12 [Control Source], b2 [Commanded Freq HZ or RPM]
Check when using an Analog input d360 (0-10V) and d361 (4-20ma) for reading actual value
Note :> Selecting a preset speed through a digital input T65-T68 takes priority over other
speed references.
Enter Accel and Decel times
(Default)
P41 = [Accel Time 1] = Sec 20 Sec
P42 = [Decel Time 1] = Sec 20 Sec
Note:
It is possible to see Bus over voltage faults and current limit faults. If you get bus over voltage faults
you should install a Dynamic brake unit. If you are getting current limit faults you should check the
current limit setting and make sure the motor nameplate information is correct and if in SVC or Vector
make sure the correct auto-tunes were done.
(Many fan applications need to have a long Accel/Decel time like 120-180 Sec)
Enter Current Limit
(Default)
A484 = [Current Lmt 1] = “Rated Amps x 1.5” Based on Drive Rating
A493 = [Motor OL Select] (0) “No Derate” (Default), (1) “Min Derate” and (2) “Max Derate”
A495 = [Drive OL Mode] (0) “Disabled, (1)”Reduce CLim”, (2) “Reduce PWM” and (3) Both-PWM 1st (Default)
3
Enter Stop mode
(Default)
P45 = [Stop Mode] = (0) Ramp CF (CF = Clear Fault)
Note: If you are using an External Dynamic Brake P45 Must be set to 0, 4, 8, 9 or the Dynamic Brake will
never work. Also set A550 [Bus Reg Enable] to 0 Disabled, A437 [DB Resistor Sel] and
(A438 [DB threshold] (Rarely needed and you must read the warning before setting))
Enter Direction Mode
A544 = Reverse Disable = (0) Rev Enabled (Default), (1) Rev Disabled
Reverse Disable is used whenever you don’t want the drive/motor to go into reverse. (Set after Direction test)
T93 = [10V Bipolar Enbl] = (0) Uni-Polar (Default) (1) Bipolar is used when you are providing a +/- voltage a
positive voltage will be FWD and a Negative voltage will be REV. (+10Volts to -10Volts)
4
Enter Digital Input settings
(Default)
T65 = [DigIn TermBlk 05] = (7) = Preset Freq
T66 = [DigIn TermBlk 06] = (7) = Preset Freq
T67 = [DigIn TermBlk 07] = (5) = Spd+Strt2
T68 = [DigIn TermBlk 08] = (9) =Jog Forward
T62 = [DigIn TermBlk 02] = (48) = 2-Wire FWD
T63 = [DigIn TermBlk 03] = (50) = 2-Wire REV
Chart for selecting Preset speeds with DigIn TermBlk 05, 06, 07 and 08
Setup Relay Outputs:
(Default)
T76 [Relay Out 1 Sel] = 0 “Ready/Fault”
T81 [Relay Out 2 Sel] = 2 “Motor Running”
5
Section 3:
Typical wiring examples: (2 wire and 3 wire)
Note: (When the Dip Switch is set to SRC.)
If the jumper from 1 to 11 is not installed then you
Will never be able to start the drive.
2 Wire is using one switch to Start and Stop the drive.
3 Wire is using 2 switches one for Stop and one for Start.
Note:
For 3 wire you must also change Parameter T63 to a value of (51) “3-wire Dir” or to Zero “Not Used”.
If you do not change Parameter T63 to a value of (51), you will not be able to start the drive.
6
Motor Rotation/Encoder Direction Test The following setting will be (Just for the Rotation/Direction Test)
(Only follow the encoder instructions if you have an Encoder)
(You can use the start-up procedure in the HIM and select the Motor Rotation Test Or do it manually)
P39= Temporarily set to either (0) V/Hz or (1) SVC (Just for the Direction Test)
A535[Motor Fdbk Type] =(0) NONE / Open Loop
P47=7 Preset Freq 0 (Preset Freq 0 is A410) Set A410 to 20 HZ or less.
Start the drive. Check that the direction and Polarity match what you want - if not provide a stop command
and remove power from the drive then swap any 2 motor leads - reapply power to the drive.
With Encoder set The following:
A535 [Motor Fdbk Type] 5 Quad Check A536 [Encoder PPR] (1024 Default)
P47=7 Preset Freq 0 (Preset Freq 0 is A410) Set A410 to 20 HZ less.
If the drive faults on Encoder Loss then provide a stop command and power the drive off then swap A and
A Not. When using a Differential Dual channel.
When using a Single Ended Dual channel (A and B only) then swap A and B.
Motor Rotation/Encoder Direction test should now be complete
Make the necessary changes to put the parameters back to their settings prior to the test
*Note: If more than one Motor is connected to one drive then P39 should be set to Custom V/HZ.
7
Section 4: Begin Autotunes
Autotune No Load (P39 = 1 SVC Or 3 Vector)
P40 = [Autotune] 0 Ready/Idle (Default) (1) Static. (2) [Rotate (check if this can be done – It will run the
motor to 45HZ)]
*A496 = IR Volt drop
*A497 = Flux Current Ref
*General rule of thumb for A496 and A497
(The value is read @ zero speed) A496 for 5HP and less it can be between 8-70 volts
(The value is read @ zero speed) A496 for 7.5HP and Higher - it is typically 10V or less
(The value is read @45HZ) A497 for 5HP and less it should be around 1/2
Of the motors name plate FLA.
For 7.5HP and higher the value runs between 20-30% of the motor name plate FLA.-
(Typically Motor NP AMPS times .3)
For Custom motors get the manufacture Speed – Torque Curve Data Sheet.
A498 [Motor Rr] = (Rotor Resistance) A value is provided with Static and Rotate tune
A499 [Motor Lm] = (Motor Inductance) only Rotate tune plugs in a value
A500 [Motor Lx] = (Leakage Inductance) A value is provided with Static and Rotate tune
A509 [Speed Reg Sel] (0) Automatic (Default), (1) Manual (When P39 = 3 Vector ONLY)
A510 [Freq 1] = 8.33%, A512 [Freq 2] = 15% and A514 [Freq 3] = 20%
A511 [Freq 1 BW], A513 [Freq 2 BW] and A515 [Freq 3 BW] =10HZ (Default) (When P39 = 3 Vector ONLY)
A521 [Freq 1 KP], A523 [Freq 2 KP] and A525 [Freq 3 KP] = 100% (Default) (When P39 = 3 Vector ONLY)
8
Section 5:
Other useful parameters:
A556 [Text Scroll] = (0) off, (1) low speed, (2) Mid Speed, (3) High Speed
b1 [Output Freq]
b2 [Commanded Freq]
b3 [Output Current]
b4 [Output Voltage]
Check b6 [Drive Status] (Run, FWD, Accel, Decel, and Safety Active)
Check b7-b9 [Fault codes] 1-3,
Check b12 [Control Source]
Check b13 [Control In Status] (Drive terminals 1, 2, 3)
Check b14[ Dig In Status] (Drive terminals 5, 6, 7, 8)
Check b29 [Control SW Ver]
d360 (0-10V) and d361 (4-20ma) Analog In Value, Check b2 Commanded Freq
T94 [Anlg In V Loss]
A426 [Keypad Freq]
A431 [Jog Freq]
C121 [Comm Write Mode] (0) Save (Default), (1) RAM only
IP Address Subnet Mask Gateway Address
C129 = C133 = C137=
C130= C134 = C138=
C131= C135 = C139=
C132= C136 = C140=
C128 [EN Addr Sel] = (1) Parameters, (2) BootP (Default)
Note:
When commanding zero speed and the motor continues to creep at a very slow speed, set Parameter
P36 [Motor NP RPM] = to Synchronous speed (Example – when the motor NP RPM is 1750RPM
change it to 1800RPM). Then, the motor should not creep anymore.
If all went well the drive and motor should be working- save parameters into the HIM or connect with
(CCW) Connected Components Workbench and save the Parameters.
