Bardac driVES basicPL-X Digital 3-Phase DC Drives User Guide

basicPL/X Quick Start

This Quick Start is a supplement to the standard product manuals intended for use as a guide to get your PL/X Drive up and running as a basic speed controller in a safe and efficient manner. For all other applications, refer to the PL/X Product and Applications Manuals.
Only qualified personnel who thoroughly understand the operation of the machine on which the PL/X is installed and who are familiar with electrical wiring and safety standards should attempt to commission this equipment.
With ALL Power OFF
A. Connect up the drive
Hook your drive up according to the following diagrams.
Ensure power and control wiring are routed in separate conduit/cable trays and wiring meets applicable national and local electrical codes.

Power Wiring Diagram

See Product Manual for fuse specifications.

Power Terminals

Control Wiring Diagram

Control Terminals

Contact Descriptions (All are maintained-type) CSO (Coast Stop Override): Must be closed prior to all other control signals for proper sequencing. When opened, the drive immediately stops generating armature current and the contactor drops out. Motor coasts to stop.
ENA (Enable): Electronic inhibit for all modes of operation.
When closed, the drive may generate current. If open, no armature current will generated. May be jumpered to Terminal 35 in most applications.
JOG: When closed, the drive’s contactor comes in and the motor will run at the Jog Speed 1 setting (Default 5% speed). When opened, the drive ramps to zero and contactor opens after a delay (Default = 2 secs).
STRT (Start): When closed, the drive’s contactor comes in and the motor will run at potentiometer speed setting. When opened, the drive ramps to zero and contactor
opens after a delay (Default = 2 secs).
As programmed from the factory, after removal of the control input, the motor field current will be present until the field quench delay is completed (Default = 10 secs).

Optional Feedback Devices

A. Get the supply and motor nameplate data

Navigating through the menus

The green keys are used to setup the drive. In this Quick Start, the required key sequences are displayed to the left of each parameter to  be modified. When executed correctly, the display on the drive should match the one shown.
Legend of abbreviations used for keystrokes:
L,R,U,D = Press the specified button EXACTLY once.
8xU = Press the Up button 8 times.
U/D = Use the Up button to increase the value, use the Down button to decrease the value.
Final Power OFF Checks
Recheck all your wiring, especially the drive’s chassis ground. Also, use your multimeter to check the L1, L2, L3, F+, F-, A+, and A- Terminals for short circuits to ground.
All readings should be greater than 1 MΩ. Correct any low resistances prior to applying power.
It is essential to perform all of the following steps in their entirety and in the proper sequence! If in doubt, call 1-888-667-7333 (International 410-604-3400).

Power ON Checks

1. Apply Control Power and Calibrate
   Apply 100-240 VAC control power to T53 (Line) and T52 (Neutral).

2. Calibrate the Drive to the Motor
   At power up, the Diagnostic Summary Screens are displayed. By pressing the Left key at least 5 times, you will return you to these screens from any menu level.
   
   When at the top level, the display toggles between the Diagnostic Summaries about every 5 seconds.
   Press the keys in the sequence below to set the rated armature current from the nameplate data you recorded.

Use the up and down keys to change the values.
Now, to move to the rated field current:
Repeat these steps for the following:
Also check the following to ensure they have not been modified from the factory default settings:

Although the drive regulates field current by default, set the field voltage clamp as a percentage of AC supply volts.

Feedback calibration If you do not have a DC tachometer or encoder, skip this section and go to Step 3.
DC Tachometer Calibration
For a tachometer, initially calibrate the drive for the expected DC voltage at base speed.
TVb = (BS ÷ 1000) x TV

Caution:
TVb must not exceed 200 VDC.

Encoder Calibration
Ensure quadrature is enabled and enter the PPR.

3. Save Parameters
   To save your work thus far, from the Diagnostic Screens:
   

4. Check Control Terminals
   The next few checks are to ensure the drive contactor is sequenced properly prior to applying three phase power.
   The value under the letters TRJSC in the display indicate the actual Control Input (CIP) terminal status.

From the Diagnostic Screens, go to the CIP Diagnostic.

Leaving the CSO contact of your control wiring open (a 0 under the C), close the other control contacts. Check to see if the digit under the appropriate letter changes as you cycle of the contact. Generally, 1 = ON while 0 = OFF (for the thermistor T, 0 = OK while 1 = Motor Overtemp).
Once satisfied with the operation of the T,R,J, and S control inputs, leave R,J, and S OFF and check the C control input for proper operation.

5. Apply Main Three Phase Power

6. Autotune the PL/X
   Prior to running the motor, the current loop of the drive must be tuned to the motor and cabling (PIN’s 93,94,& 95).
   a) Ensure the drive is in a normal stop condition. The CIP’s should match TRJSC below:
   
   The contactor will close and an autotune will be performed (takes 10 – 60 seconds). When complete, the drive’s contactor will open. Turn off the Start Input (T33).
   Now, SAVE PARAMETERS as described in Step 3.

7. Motor Rotational Checks
   Ideally, you would like to perform these running checks with the motor disconnected from the gear box and the machine.
   As an additional precaution, restrict the available current to the drive by reducing the Current Limit to just enough current to turn the motor (usually 5 to 10%).

Check operation of the speed potentiometer by monitoring the Ramp Input. Leave the reference at zero after checking for proper operation.

Start the drive by energizing the Start Input (T33). Check the field voltage at the F+ and F-. When the motor is cold, you will measure somewhat less than the rated field voltage (approximately 240 VDC for a 300 VDC rated field).
Confirm the field current matches the IFb nameplate data.

Increase the potentiometer setting until the motor is turning slowly. Check motor rotation. If backwards, stop, turn off ALL power to the drive, and swap the field leads (F+, F-). Recheck after changes.
Now, slowly bring the motor up to full speed while checking the voltage on the A+ and A- terminals.

If you have neither a tachometer nor encoder, skip to Step

8. If using a tachometer or encoder, check to ensure the speed reference is positive (+).

Then, check the sign of the feedback, as follows:
Tachometer Feedback

If positive (+), skip to Step 8. If negative (-), stop, power off the drive, then swap the tachometer leads on T25 and T26 and recheck.
Encoder Feedback

If positive (+), skip to Step 8. If negative (-), stop the drive and invert the encoder sign and recheck.

8. Switching Feedback Type
Now, stop the drive and select the appropriate feedback.
Tachometer Feedback

Encoder Feedback

Again, start the drive and ensure maximum speed can be obtained and the armature voltage does not exceed the nameplate VA.

9. Increase the Current Limit to Rated Value
   At this point, the Current Limit may be returned to 150%.
   
   Now, SAVE PARAMETERS as described in Step 3.

10. Adjusting the Speed Calibration at Base Speed
    Gradually, increase your potentiometer to the maximum position and then adjust the final speed of the motor.
    Depending on the final feedback type, different parameters (PIN’s 16, 17,& 6) are used for speed calibration.
    Do NOT exceed the base speed (BS) value while adjusting these parameters. These calibration parameters may be adjusted while the drive is running.
    Armature Voltage
    
    Increase this value to reduce the armature voltage. If this parameter does not provide enough adjustment , stop and readjust PIN 18 – Rated Arm Volts from Step 2.
    Tachometer Feedback
    
    Change this value to achieve the desired motor speed.
    Again, SAVE PARAMETERS.

11. Setting Up Field Weakening
    When using either tachometer or encoder feedback, field weakening may be enabled for a motor which supports an extended speed range.
    a) First, stop the drive and enable the field weakening mode.
    
    b) Next, set the minimum field expected (with a 10% safety margin).
    Min Field % = (Ifm ÷ Ifb) x 90
    

Finally, adjust the maximum speed as described in Step 10. Again, do NOT exceed the maximum speed (MS)
value noted on the motor nameplate.
Again, SAVE PARAMETERS as described in Step 3.
Congratulations, you have successfully commissioned your Bardac PL/X Digital DC Drive.
If you have any questions or do not understand a portion of this Quick Start Manual, please contact us:

Bardac Corporation
40 Log Canoe Circle
Stevensville MD 21666 USA
Phone: 888-ON-SPEED (888-667-7333)
International: 410-604-3400
FAX: 410-604-3500
bardac.com | driveweb.com | automationthings.com
Email: info@bardac.com
HG501504; Issue 4

References

• Automation Things - AC Drives, DC Drives & Automation Controllers
• AC Drives, DC Drives, Motors & Control Technology | Bardac Drives
• Internet-Accessible Distributed Control Technology | drive.web

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