Instruction/ maintenance manual of the product DFS-1 PowerTec
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DFS-1 DFS-1 INST ALLA TION AND OPERA TION INSTR UCTION MANU AL P RODUCTION R ELEASE A UGUST , 1994 MICROPR OCESSOR B ASED BRUSHLESS D .C . MOTOR CONTROLLER SOFTWARE RELEASE 1.
A subsidiary of POWER TEC Industrial Corporation Mailing Address: P .O.Box 2650 • Rock Hill, South Carolina USA 29732 • PHONE: 803-328-1888 Shipping Addre ss: 2606 Eden T errace • Rock Hill, Sou.
[ST2] - 7 6 5 4 3 2 1 0 Local/Remote (0,1) Master/slave (0,1) At Speed (1) Fwd. Dir . Set Fault Detected (1) Drive Enabled (1) Microprocessor Fault Zero Speed [ST1] - 7 6 5 4 3 2 1 0 Bus not charged (.
Additional Info DFS Softwar e Modification For Dynamic Braking or Output Contactor Operation 25 October , 1994 Functional Description A new function for Contactor Aux has been added to the digital input choices. When configured as described in the example, 24VDC must be present at this input for the drive to run.
Page 1 Figur e 2: The Model 1000 chassis Figur e 1: The DFS-1 replaces two boar ds. If the board is being installed to replace the boards on a standard control, unplug the strips on TB1 and TB2, but do not disconnect any wires from them yet.
C ONTENTS Introduct ion ............................................................................................................................... 1 Summary of W arrant y and Disclaimer ............................................................
23. ANALOG INPUT #2 LOW ENGINEERING UNITS (EGU) .............................................................. 22 24. ANALOG INPUT #2 HIGH ENGINEERING UNITS (EGU) ............................................................. 22 25. ANALOG OUTPUT #1 MODE SELECT .
5.0 DFS-1 ERROR CODES .................................................................................................. 39 6.0 COMMUNICA TION PROTOCOL .................................................................................. 41 COMMAND LIST .
Page 4 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© T HIS PA G E WAS INTENTIONALL Y LEFT BLANK ..
Page 5 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© Programmable analog inputs and analog outputs allow many possibilities for control through external voltages, currents, and frequencies.
Page 6 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© S UMMAR Y OF W ARRANTY AND D ISCLAIMER POWER TEC Industrial Corporation warrants the DFS-1 to be free from defects in materials and work- manship.
Page 7 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© T1 T2 T3 1 2 3 4 5 6 7 8 9 10 Motor +24V Digital Out 1A Digital Out 1B Digital Out 2A Digital Out 2B Digital Out 3A Digital Out 3B Digital Out 4A.
Page 8 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© MOTOR ENCODER CABLE: The motor encoder cable is connected to plug-in t erminal strip TB1:A on the DFS-1 PC board. A shielded cable must be used for the motor encoder cable. The recommended cable is a 9-conductor shielded cable (Belden Cable part # 9539 or equiva- lent).
Page 9 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© The default speed reference input is Analog Input #1, located on TB1:B. The default input is for a 0 to +10VDC for zero to full speed of the motor . T erminal 3 is the positive side of the input and terminal 4 is the negative side.
Page 10 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© FREQUENCY OUTPUT : There are two outputs available to supply a frequency for external use. The first is located at TB2:B terminal 10 (+) and 1 1 (-). This is an output which is intended to provide a reference frequency input for another DFS-1, BCDMAX or CRM-1 .
Page 11 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© The programmable inputs (TB2-A4 through TB2-A10) may be programmed for jog, thread, or other preset speeds. The inputs may also be used to change torque levels, trim values, or ramp rates. Any value which can be affected by a parameter can be changed by a digital input.
Page 12 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© T HIS PA G E WAS INTENTIONALL Y LEFT BLANK ..
Page 13 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© D EF A UL T S ETUP The concept behind the DFS-1 calls for fully programmable inputs and outputs. The ability to change analog and digital inputs and outputs at will lends a whole new meaning to the word "flexibility".
Page 14 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© T HIS PA G E WAS INTENTIONALL Y LEFT BLANK ..
Page 15 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© 5.0 Each of the two inputs may be set up one of six ways: 1. -10 to +10 VDC 2. 0 to +10 VDC 3. 0 to 5 VDC 4. 1 to 5 VDC 5. 0 to 20 mADC 6. 4 to 20 mADC 6.0 Setup is by parameter selection (#18 for Analog Input #1 and parameter #22 for Analog Input #2).
Page 16 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© FREQUENCY INPUTS AND OUTPUTS There is one frequency input and there are two frequency outputs available. INPUT #1 REFERENCE FREQUENCY INPUT TB2:A T erminals 1 1 (+) and 12 (-). • This is a line receiver type input which must be driven by a differential line driver output.
Page 17 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© COMMUNICA TIONS Standard: RS-485 Data Rates: 300, 600, 1200, 2400, 4800, 9600, 19.2K, and 38.4K baud Addresses: 1 to 255 Protocols: POWER TEC Bi.
Page 18 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© T HIS PA G E WAS INTENTIONALL Y LEFT BLANK ..
Page 19 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© DFS-1 parameters are stored as DOUBLE WORD values (32 bits), regardless of the actual size of the data. This method is used to simplify the entire system at a cost of a little extra data storage.
Page 20 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© 0001b) , the Run FUNCTION cannot be controlled from the terminal strip, but can only be controlled t hrough the external communications link or the local comm link (keypad display unit). If VL1 has a value of 73 (01 1 1 001 1b), all functions except UP and DOWN are controlled remotely .
Page 21 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© 0000h Normal current limits (motor current not limited at a lower level) 0001h Motoring torque setpoint (motoring current to be limited at a low.
Page 22 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© 8 . MASTER RAMP UP TIME USE P ARAMETER #8 TO SET THE TIME T O RAMP FROM ZERO TO FULL SPEED. RANGE OF V ALUES: 0000 0001h to 0003 E418h 1 TO 255,000 (decimal) Default V alue: 0000 2710h 10,000 (decimal) This is the acceleration time from zero speed to full speed in the MASTER mode.
Page 23 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© tionship between motor speed and EGU is defined in parameter #14, which sets the value of EGU’ s at full motor speed. This parameter is used to determine the relationship between units of commanded speed and RPM.
Page 24 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© are implied. Therefore, the maximum ratio setpoint is 9.999. 1 7 . ANALOG INPUT #1 MODE SELECT USE P ARAMETER #17 TO SELECT THE PUR- POSE OF A SIGNAL A T ANALOG INPUT #1.
Page 25 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© As a Speed Reference input ( ...01h), Analog input #1 sets the speed of the controlled motor directly if the DFS-1 is set up in Master Mode (parameter #5 - VL2 VL1). If the DFS-1 is in SLA VE mode, Analog Input #1, when set to .
Page 26 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© 2 0 . ANALOG INPUT #1 HIGH ENGINEERING UNITS (EGU) USE P ARAMETER #18 TO SELECT THE MAXI- MUM ANALOG INPUT #1 EFFECT .
Page 27 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© 25 . ANALOG OUTPUT #1 MODE SELECT USE P ARAMETER #25 TO SELECT THE SOURCE OF A SIGNAL A T ANALOG OUTPUT #1. RANGE OF V ALUES: 0000 0000h to 0000 0003h 0 to 4 (decimal) Default V alue: 0000 0001h 1 (decimal) Analog Output #1 may be programmed for several modes of operation.
Page 28 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© 29. ANALOG OUTPUT #2 LO W ENGINEERING UNITS (EGU) USE P ARAMETER #29 TO SELECT THE THRESHOLD OF ANALOG OUTPUT #2 EFFECT .
Page 29 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© 3 1 . DIGIT AL INPUT #1 FUNCTION USE P ARAMETER #31 TO SELECT THE #1 DIGIT AL INPUT FUNCTION. RANGE OF V ALUES: 0000 0000h to 0001 000Fh no decimal significance Default V alue: 0001 0001h no decimal significance VL4 and VL2 are always 00.
Page 30 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© 3 5 . DIGIT AL INPUT #5 FUNCTION USE P ARAMETER #35 TO SELECT THE #5 DIGIT AL INPUT FUNCTION. RANGE OF V ALUES: 0000 0000h to 0001 000Fh no decimal significance Default V alue: 0001 0005h no decimal significance The setting options are the same as parameter #31.
Page 31 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© 39 . DIGIT AL OUTPUT #2 FUNCTION USE P ARAMETER #39 TO SELECT THE #2 DIGIT AL OUTPUT FUNCTION. RANGE OF V ALUES: 0000 0000h to 0001 000Fh no decimal significance Default V alue: 0000 0001h no decimal significance The setting options are the same as parameter #38.
Page 32 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© limit the output DRIVE current to 150%. This parameter CANNOT OVERRIDE that limit, but this parameter may be set for an ultimate current limit on drives which are built with more capability than the mot ors they run.
Page 33 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© When parameter #48 is set to 0000 0000h, the DFS-1 is in the JUMP mode. In MASTER mode (set by parameter #5), when the UP input function is activated, the speed will increase by the amount set in parameter #49.
Page 34 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© 5 3. INPUT DEBOUNCE V ALUE USE P ARAMETER #53 TO SET THE LENGTH OF TIME AN INPUT MUST BE ACTIVE TO BE ACTED UPON. RANGE OF V ALUES: 0000 0000h to 0000 00FFh 0 to 256 (decimal) Default V alue: 0000 0001h 1 (decimal) Parameter #53 is the length of time, in 10 milliseconds (1 millisecond =.
Page 35 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© 58 . SLA VE JOG RA TIO USE P ARAMETER #58 TO SET A JOG SPEED WHICH CAN BE T OGGLED IN AND OUT .
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Page 37 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© 4.0 DFS - 1 S ETUP Making parameter changes requires the optional keypad display unit or a computer with serial communications capability . This section covers the basic steps necessary to set up the DFS-1 beyond the needs of the default parameters.
Page 38 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© 6. SET P ARAMETER #42 FOR THE DRIVE GAIN. This value is defaulted to 50% of the range and therefore set to 128.
Page 39 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© 1. SET P ARAMETER #5 FOR THE MASTER MODE. Set the basic operation in this parameter to MASTER. This parameter also has options for current control (see page 16).
Page 40 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© 1. SET P ARAMETER #5 FOR THE SLA VE MODE. Set basic operation in this parameter to 1 for SLA VE mode. For INVERSE SLA VE mode enter 2. INVERSE SLA VE mode affects the way a setpoint is entered. This parameter also has options for current control (see page 16).
Page 41 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© 4 . 4 INPUTS AND OUTPUTS SETUP 1. SET P ARAMETERS #17, #18, #19, AND #20 TO SET UP ANALOG INPUT #1. If Analog Input #1 is to be used for speed reference, which is the default mode, and the reference is to be 0 to +10VDC, no action is necessary to change from the defaults.
Page 42 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© 3. SET P ARAMETER #3 TO SELECT WHICH FUNCTIONS ARE REMOTE. This parameter may be used to include or exclude control functions from local control and assign them to the remote link.
Page 43 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© ERROR CODES FOR ON-BO ARD DISPLA Y The DFS-1 has a single-digit alphanumeric display to show error codes when something is wrong. Following is a list of the meanings of the numbers in that display: 0 All conditions nominal 1 Undervoltage trip .
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Page 45 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© 6.0 COMMUNICA TIONS PRO T OCOL G ENERAL D EFINITIONS : [STX] - 02h - Start of data [ETX] - 03h - End of data [ACK] - 06h - Acknowledge [NAK] - 1.
Page 46 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© COMMAND LIST Following is a list of commands to the unit. Det ailed descriptions of each command are shown in att achment A beginning on page 55.
Page 47 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© P ARAMETER LIST : Following is a list of the parameters used in DFS-1. For a detailed description of each parameter see the list in attachment B beginning on page 57.
Page 48 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© A TT ACHMENT A: D E T AILED C OMMANDS Read Speed/Status (81) Command: Read Speed/Status Description: This command tells the unit to respond with it’ s current commanded speed, actual speed, load value, & status.
Page 49 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© Message: [DLE][STX][UID][CMD][DLE][ETX][CSM] Response: If no errors and unit i.d. does not equal 0 [DLE][STX][UID][ACK][DLE][ETX][CSM] If unit i.d. = 0 (global command) then no response at all but all DIGIMAXes will execute simultaneously .
Page 50 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© [ERR] - Reported error [80] - Unit not in remote mode [84] - Illegal channel number [86] - Illegal Command number Read Analog Output (88) Command: Read Analog Output Description: This command tells the unit to return the value of one of the analog outputs.
Page 51 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© Response: If no errors [DLE][STX][UID][ACK][VL4][VL3] [VL2][VL1][DLE][ETX][CSM] else [DLE][STX][UID][NAK][ERR][DLE][ETX][CSM] Definitions: [DIG].
Page 52 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© Definitions: [DIG] - Digital output number 01 to 04 [VL4] - Always 00 [VL3] - Always 00 [VL2] - Always 00 [VL1] - Status of output 00 = off 01 =.
Page 53 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© Message: [DLE][STX][UID][CMD][00][00] [SMH][SML][DLE][ETX][CSM] Response: If no errors [DLE][STX][UID][ACK][DLE][ETX][CSM] else [DLE][STX][UID][NAK][ERR][DLE][ETX][CSM] Definitions: [ERR] - Reported Error [80] - Unit not in remote.
Page 54 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© Application Mode (8F) Command: Application Mode Command Description: This command reads/sets the operating setpoint by communications rather than using an analog input for the setpoint when a special application mode is act ive (see parameter 5).
Page 55 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© Additional Info DFS S OFTWARE M ODIFICA TION F OR D YN AMIC B RAKING OR O UTPUT C ONT ACT OR O PERA TION Functional Description A new function for Contactor Aux has been added to the digital input choices.
Page 56 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp.© +24V D igit al Out 1A D igit al Out 1B D igit al Out 2A D igit al Out 2B D igit al Out 3A D igit al Out 3B D igit al Out 4A D igit al Out 4B FR .
Page 57 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© +24V D igit al Out 1A D igit al Out 1B D igit al Out 2A D igit al Out 2B D igit al Out 3A D igit al Out 3B D igit al Out 4A D igit al Out 4B FR .
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Page 59 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© A PPENDIX A R ETROFITTING THE M ODEL 1000, 1000A, OR 1000AR The DFS-1 Model 1000 series retro-fit kit consists of: Quantity 1 DFS-1 Printed Circ.
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Page 61 Revised 7/95 DFS-1 Manual POWERTEC Ind. Corp.© A PPENDIX B M ENU AND K EYP AD H IERARCHY When the DFS-1 is shipped, the factory presets the unit’ s parameters according to the motor and drive’ s specifications.
Page 63 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp. C F IGURE 1 Fig. 2 Fig. 30 *Parameters Enter History Enter Status Menu Enb/Dsb Bklt Enter Contrast Enter Time Enter Date Enter *Local/Remote Enter Select Figure 1.
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Page 65 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp. C Analog In Enter F IGURES 2 - 4 Fig. 2 Fig. 2 Fig. 4 Select Analog Out Enter Digital In Enter Digital Out Enter Unit ID Enter Fig. 3 Select Delay Enter Communications Enter Select Input/Output Enter Parameters Enter Select Communication Enter Select Fig.
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Page 67 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp. C Minimum Ratio Enter Preset Ratio 1 Enter F IGURES 5 - Fig. 5 Slave Enter Enter Fig. 2 Select Select Preset 2 Enter Accel Rate Enter Decel Rate Enter Jump up Delta Enter Jump Down Delta Enter Base Ratio Enter Maximum Ratio Enter Fig.
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Page 69 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp. C Fig. 13 Fig. 13 Fig. 4 Analog In Enter Channel # 1 Enter Select Select . Fig. 9 Channel # 2 Enter Fig. 10 Fig. 4 Fig. 16 Fig. 16 Fig. 11 Fig. 4 Fig. 18 F IGU R Fi g .1 2 Digital O u Channel # Select Select .
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Page 71 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp. C F IGUR E Fig. 14 Fig. 9 Low EGU Enter Ente r AI Channel #1o r2 Mode Enter Select Select . High EGU Enter Fig. 13 Fig. 13 Fig. 14 Fig. 13 Fig. 15 Fig. 10 Fig. 16 Fig. 15 Signal Condition Enter Calibration Enter Enter AI Sig.
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Page 73 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp. C F IGUR E Fig. 17 Fig. 18 Fig. 16 Fig. 20 Fig. 19 Fig. 11 Fig. 19 Fig. 18 Fi g DI Mode Enter General Purpose Enter Select Select Modes 15-11 Enter Fig.
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Page 75 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp. C F IGUR E Fig. 23 Fig. 22 Fig. 12 Fig. 21 Fig. 21 Fig. 22 Fig. 23 Fig. 21 Fig. 7 DO Channel #1o r2 Enter Mode Enter Select Select Polarity Enter .
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Page 77 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp. C F IGURE S Fig. 7 Regen I Limit Enter Horsepower Enter Fig. 25 Fig. 26 Pulse Multiplier Enter X1 Enter Select Select Fig. 7 X2 Enter X4 Enter Commutation Mode Enter Fig. 27 F Up J Select Sele c Fig.
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Page 79 DFS-1 Manual Revised 7/95 POWERTEC Ind. Corp. C F IGURES 29 - 30 Fig. 29 Fig. 7 Fig. 30 Fig. 1 Setpoint Control Enter Freeze Enter Select Select Float Enter History Enter KDU-1 Version Enter S.
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An important point after buying a device PowerTec DFS-1 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought PowerTec DFS-1 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data PowerTec DFS-1 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, PowerTec DFS-1 you will learn all the available features of the product, as well as information on its operation. The information that you get PowerTec DFS-1 will certainly help you make a decision on the purchase.
If you already are a holder of PowerTec DFS-1, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime PowerTec DFS-1.
However, one of the most important roles played by the user manual is to help in solving problems with PowerTec DFS-1. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device PowerTec DFS-1 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
