OMNIPULSE

DSD

Instruction Manual

Part Number: 140-10322 R5

August 2013
© Copyright 2013 Magnetek Material Handling
©2013 MAGNETEK

All rights reserved. This notice applies to all copyrighted material, included with this product, including,
but not limited, to this manual and software embodied within the product. This manual is intended for the
sole use of the persons to whom it was provided, and any unauthorized distribution of the manual or
dispersal of its contents is strictly forbidden. This manual may not be reproduced in whole or in part by
any means whatsoever without the expressed written permission of Magnetek

PRODUCT MANUAL SAFETY INFORMATION

Magnetek, Inc. (Magnetek) offers a broad range of radio remote control products, control
products and adjustable frequency drives, and industrial braking systems for material handling
applications. This manual has been prepared by Magnetek to provide information and recommendations
for the installation, use, operation and service of Magnetek’s material handling products and systems
(Magnetek Products). Anyone who uses, operates, maintains, services, installs or owns Magnetek
Products should know, understand and follow the instructions and safety recommendations in this manual
for Magnetek Products.

The recommendations in this manual do not take precedence over any of the following
requirements relating to cranes, hoists lifting devices or other material handling equipment which use or
include Magnetek Products:

 Instructions, manuals, and safety warnings of the manufacturers of the equipment where the
radio system is used,

 Plant safety rules and procedures of the employers and the owners of facilities where the
Magnetek Products are being used,

 Regulations issued by the Occupational Health and Safety Administration (OSHA),

 Applicable local, state or federal codes, ordinances, standards and requirements, or

 Safety standards and practices for the industries in which Magnetek Products are used.

This manual does not include or address the specific instructions and safety warnings of these
manufacturers or any of the other requirements listed above. It is the responsibility of the owners, users
and operators of the Magnetek Products to know, understand and follow all of these requirements. It is
the responsibility of the employer to make its employees aware of all of the above listed requirements and
to make certain that all operators are properly trained. No one should use Magnetek Products prior to
becoming familiar with and being trained in these requirements and the instructions and safety
recommendations in this manual.

WARRANTY INFORMATION

For information on Magnetek’s product warranties by product type, please visit the Material Handling site
at www.magnetek.com.

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TABLE OF CONTENTS

CHAPTER 1: INTRODUCTION ................................................................................................................... 4

Assessing the System Requirements ....................................................................................................... 4
Assessing the Drive Environment ............................................................................................................. 4
OmniPulse DSD General Specifications ................................................................................................... 5
AC Reactor Specifications ........................................................................................................................ 6
CHAPTER 2: INSTALLATION ..................................................................................................................... 7
Precautionary Statements......................................................................................................................... 7
OmniPulse DSD System Components and External Devices .................................................................. 9
Pre-Installation Considerations ............................................................................................................... 10
Installing the Drive .................................................................................................................................. 11
CHAPTER 3: WIRING ............................................................................................................................... 18
Suggested Circuit Protection Specifications and Wire Size ................................................................... 20
Power Circuit Wiring Procedures ............................................................................................................ 21
Control Circuit Terminals ........................................................................................................................ 23
Electrical Hook up ................................................................................................................................... 26
Pre-power Check .................................................................................................................................... 28
CHAPTER 4: PROGRAMMING FEATURES ............................................................................................ 30
Drive Description ..................................................................................................................................... 30
Software Operating Features .................................................................................................................. 36
Power Conversion Unit (PCU) ................................................................................................................ 37
Interface Specifications ........................................................................................................................... 40
Standard Control/Display Unit Operation................................................................................................ 40
Operating Mode Descriptions ................................................................................................................. 56
Parameter Function Descriptions............................................................................................................ 63
Modbus RTU Communications ............................................................................................................... 85
CHAPTER 5: TROUBLESHOOTING ........................................................................................................ 93

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CHAPTER 1: INTRODUCTION

Assessing the System Requirements

It is important to know how you’re going to use the drive before you start installation and wiring. You will
need to know your requirements for the following components:
 Speed control method(s)
 Braking method(s)
 Power source voltage, number of phases, and kVA rating
 Power source location
 Wire size
 Grounding location and method

Assessing the Drive Environment

When you choose a location for OmniPulse DSD, perform the following steps:
1. Ensure that three-phase power source is within (+10% to -10%) of nominal input voltage range of
150 to 525VAC. The drive is not sensitive to phase sequence. Input power specification is
contained on drive nameplate.
2. Ensure that control power is 115VAC (-10% to +10%), 1 phase.
3. Ensure the encoder is supplied with rated voltage.
4. If the amperage requirement is greater than 200 mA, provide an auxiliary power supply to the
encoder.
5. When connecting a drive (230V/460V, Transformer or Reactor 100AMP and smaller) a 3% line
reactor is required. Above 100AMPS a full rated Isolation Transformer is required. Transformer
kVA is to be equal to (output VDC multiplied by output current) divided by 884. kVA = VDC * ADC
/ 884
6. Ensure that the encoder wiring is less than 300 feet.
7. Ensure that the encoder wiring is isolated from the power wiring.
8. Ensure that the encoder wiring shield is grounded only at drive end.
9. Ensure that the drive circuit wiring is protected or isolated from:
 Ambient temperatures outside the range of +32° F to +113° F (-0° C to +45° C). (Consult
Magnetek if you must exceed this temperature range.)
 Rain or moisture
 Corrosive gases or liquids
 Direct sunlight
 Severe mechanical vibration
10. Ensure that the drive is housed in an appropriate NEMA-rated enclosure.
11. For severe-duty applications (for example—long lifts) or with 75-Hp-or-greater motors, ensure
that the drive control system is adequately cooled, even though the ambient temperature limit is
not exceeded. For more information, contact Magnetek.

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OmniPulse DSD General Specifications
Drive Ratings and Specifications
The OmniPulse DSD Drive is designed for connection to a three wire ungrounded power system, or a four
wire grounded or ungrounded power system.
230V Class

Specification Values and Information for Each 230V-Class Model

Specification
(C.F.= Consult Factory)
144-45195

144-45200

144-45205

144-45210

144-45215

144-45220

C.F.

C.F.

C.F.

C.F.
Rated current (A) 10 31 62 106 206 330 480 640 1100 1550
Capacity (kVA) 2.7 6.8 14 27 53 81 120 158 236 345

460V Class

Specification Values and Information for Each 460V-Class Model

Specification
(C.F.= Consult Factory)
144-45195

144-45200

144-45205

144-45210

144-45215

144-45220

C.F.

C.F.

C.F.

C.F.
Rated current (A) 10 31 62 106 206 330 480 640 1100 1550
Capacity (kVA) 5.7 14 28 57 110 120 249 328 492 718

230V and 460V Classes

Specification Specification Value and Information for All Models

Certification CSA
Rated input power Line 150 – 525 VAC, 3 phase; consult factory for 600 VAC
supply volts & freq Control 115VAC, Single phase
Allowable input voltage fluctuation +10% or –10% of nominal
Allowable input frequency fluctuation 48 to 62 Hz
Control method Full wave six pulse SCR control
Max output voltage 240VDC for 230VAC 3 phase input.
Maximum output voltage VDC
500VDC for 480VAC 3 phase.
Field weakening range Up to maximum nameplate RPM
Output speed control range 1000:1
Regulation 0.05% of set speed with digital encoder speed feed back
150% of rated load for 1 min. 200% full load current for 10
Overload capacity
seconds
Remote frequency reference sources 0-10VDC,±10VDC
0.5 to 15.0 sec both ramp parameters are independently
Accel/decel times
adjustable
Motor overload protection I²t motor overload protection
Overcurrent protection level (OC1) 200% of rated current for 10 seconds
Instantaneous over-current protection, blown-fuse protection,
Circuit protection
shorted SCR (test upon power-up)
The AC input power has dropped below 80% of the Nominal AC
Undervoltage protection level Line Voltage (F#10) for 3 consecutive cycles or lower than 50%
for one cycle.

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 Specification Value and Information for All
Specification
Models
Heatsink overtemperature Klixon trips at 125º C
Current Limit Maximum Armature Current Limit of 0-300%
Motor contractor, motor overload, overspeed,
Other protection features mechanical brake failure, open armature, E-stop
circuit fault, mechanical overload and field loss.
Indoors; requires protection from moisture,
Location
corrosive gases, and liquids
Ambient operating temperature 32º to 113ºF (0º to 45ºC) for open chassis
Storage temperature 32º to 113ºF (0º 45ºC)
Humidity 95% relative; noncondensing
Vibration 1 G less than 20 Hz; 0.2 G for 20-50Hz
Elevation 3300 Ft. (1000M) or less

Protective Features
Programmed memory protection Encoder monitoring and loss protection
Self-protected Control V power supply Input line monitoring
Fast phase-back of loop current Phase sequence insensitive
Contactor interlock for E-Stop dv/dt protection (snubbers)
I2t motor overload protection 1400 PRV Thyristors
AC line current limiting fuses Instantaneous over-current protection
Automatic power up test Phase loss protection
Control power supply loss detection DC bus fuse
Isolated and grounded electronics Field current economizer and loss protection

AC Reactor Specifications
Reactors, input (line) devices, protect direct current drives and other load devices against excessive
voltage and current.

The following guidelines may help determine input reactor requirements:

 100A and below a 3% line reactor is required
 Above 100A an isolation transformer is required KVA=(VDCxADC)/884

230V and 460V - Class

Model Number 230V and 460V Part Number Maximum Amps of Reactor
45195 REA460-7.5 12
45200 REA460-15 25
45205 REA460-30 45
45210 REA460-75 100

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CHAPTER 2: INSTALLATION

Precautionary Statements
IMPORTANT, WARNING, CAUTION, and Note statements are used throughout this manual to
emphasize important and critical information. These statements help ensure safety and prevent product
damage. The statements are defined below:

IMPORTANT

A statement of conditions that should be observed during drive setup or operation to ensure dependable
service.

CAUTION

A statement of conditions that must be observed to prevent undesired equipment faults or degraded drive
system performance

WARNING

A statement of conditions that MUST BE OBSERVED to prevent personal injury, death, or serious
equipment damage.

NOTE: A NOTE statement is used to notify installation, operation, programming, or maintenance

information that is important, but not hazard-related.

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 WARNING
 When preparing to mount the OmniPulse DSD drive, lift it by its base.
Never lift it by the front cover.

 Mount the drive on nonflammable material.

 The OmniPulse DSD drive generates heat. For the most effective
cooling possible, mount it vertically. For more details, refer to the
“OmniPulse DSD Dimensions/Heat Loss” in this chapter.

 When mounting units in an enclosure, install a fan or other cooling

device to keep the enclosure temperature below 113ºF (45ºC).

NOTE: Failure to observe these Warnings may result in equipment

damage.

This chapter explains the following:

1. Choosing a location
2. OmniPulse DSD components and external devices
3. Drive installation

In addition, this section will cover information on the components that interconnect with OmniPulse DSD.

Choosing a Location
Be sure that the drive is mounted in a location protected against the following conditions:
 Extreme cold and heat. Use only within the ambient temperature range:
Open Chassis: +32 to 113F (0 to 45C)
 Direct sunlight (not for use outdoors)
 Rain, moisture
 High humidity
 Oil sprays, splashes
 Salt spray
 Dust or metallic particles in the air
 Corrosive gases (e.g. sulfurized gas or liquids)
 Radioactive substances
 Combustibles (e.g. thinner, solvents, etc.)
 Physical shock, vibration
 Magnetic noise (e.g. welding machines, power devices, etc.)

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OmniPulse DSD System Components and External Devices
OmniPulse DSD Drive Components
 Logic input relays
 Logic output relays
 Motor contactor
 3 Phase input AC line reactor or 3 Phase input isolation transformer

Required External Devices

 Motor
 User input device (pendant, joystick, PC, PLC, radio, or infrared control)
 External circuit protection devices (fuses or circuit breakers).
 R-C surge suppressors on contactor coils

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Pre-Installation Considerations
Receipt of Shipment
All equipment is tested against defect at the factory. Any damages or shortages evident when the
equipment is received must be reported immediately to the commercial carrier who transported the
equipment. Assistance, if required, is available from your Magnetek representative. Always refer to the
order number, equipment description, and serial number when contacting Magnetek.
Unpacking Instructions
Remove the protective shipping material from around the equipment. Remove all packing material.
Unbolt the equipment from its crate. Inspect for loose wiring. Make sure that all contact wedges and
other shipping devices have been removed.
Packing Instructions for Reshipment or Storage
For long periods of storage, equipment should be covered to prevent corrosion and should be placed in a
clean, dry, location. If possible, equipment should be stored in its original crating. Periodic inspection
should be made to ensure that the equipment is dry and that no condensation has accumulated. The
equipment warranty does not cover damage due to improper storage.
The drive should be packed in its original shipping container if it is required that it be shipped.
Assistance, if required, is available from your Magnetek representative.
Physical Installation
The OmniPulse DSD Drive is air-cooled. The lowest HP rated units are cooled by convection; all other
units are equipped with a fan to ensure adequate airflow. Select a site for installing the drive that is clean
and well ventilated. Maintenance will be minimized if the drive is located in a clean atmosphere.
The standard drive is designed for vertical mounting. Attach the drive to a cabinet panel or other vertical
structure using the mounting holes provided at the back of the drive. Ensure that the unit is level.

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Installing the Drive
To install OmniPulse DSD:

1. Ensure the drive will be used in a proper environment (see Chapter 1: Introduction).

2. Review the “Control Circuit Terminals” table on page 23.

3. Determine the sizes and connection locations for the drive components and external devices that
need to be wired. Locate the ground.

4. Determine the position of the subpanel (reference the Wiring Size Chart in Chapter 3: Wiring).

5. Ensure that the drive is positioned vertically so that the heat can dissipate properly.

6. Ensure that the air can flow freely around the heatsink as shown in outline drive chassis drawings
(reference Figures 1 – 3).

Note:
 The recommended clearances at the top, bottom, and both sides of the OmniPulse DSD Drive
are the same for both open chassis and NEMA 1 enclosures.
 Allowable intake air temperature: 32ºF to 104ºF (-0ºC to +40ºC)
 If necessary, a heater or air conditioner must be used to maintain the temperature range listed
above.
7. Lay out the wire runs. Size the wire according to NEC Table 610-14(a). At a minimum, use #16
AWG for control wiring and #12 AWG for power wiring. When performing this step:

 Ensure that the drive control circuit and power circuit wires are perpendicular to each other at
any point they cross.

 Keep power and control festoon wiring in separate cables.

 Separate control drive circuit and power circuit wiring on the terminal block strip.

8. Obtain the appropriate hardware for mounting.

9. Mount the subpanel or surface to which you are mounting the drive (contact Magnetek if you
need advice on mounting, especially for larger drives).

10. Fasten the drive and components to the subpanel.

11. Remove the terminal cover.

12. Follow the wiring practices outlined in Chapter 3, “Wiring”.

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 OUTLINE DRAWING 106A

Figure 1: Drive Chassis Outline, OmniPulse DSD 10-106 Amp

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 OUTLINE DRAWING 206A

Figure 2: Drive Chassis Outline, OmniPulse DSD 206 Amp

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 OUTLINE DRAWING 330A

Figure 3: Drive Chassis Outline, OmniPulse DSD 330 Amp

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 OmniPulse DSD DC Drive Dimension / Heat Loss
Drive Heat Loss
Part Capacity (Watts)
Number (Amps) Height Width Depth Weight Total
21 in 13 in 10" 29lbs
144-45195 10 400
(540mm) (330mm) (260mm) (13KG)
21 in 13 in 10" 29lbs
144-45200 31 400
(540mm) (330mm) (260mm) (13KG)
22 in 13 in 10" 42lbs
144-45205 62 400
(560mm) (330mm) (260mm) (19KG)
22 in 13 in 10" 42lbs
144-45210 106 400
(560mm) (330mm) (260mm) (19KG)
22 in 13 in 14" 62lbs
144-45215 206 645
(560mm) (330mm) (360mm) (28KG)
24" 17" 13" 110lbs
144-45220 330 1082
(610mm) (430mm) (330mm) (50KG)
Consult 44" 32" 16" 225lbs
480 1497
Factory (1120mm) (810mm) (410mm) (102KG)
Consult 71" 45" 18" 660lbs Consult
1550
Factory (1800mm) (1140mm) (460mm) (300KG) Factory

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Selecting, Mounting and Wiring of the Digital Encoder
Encoder Selection
A quality encoder is recommended for use with the OMNIPULSE DSD controller for speed feedback. The
encoder should be a two-channel, quadrature, zero-speed type device with differential line drivers. The
OMNIPULSE DSD drive supplies +5V power for an encoder; however, the encoder and feedback signals
may operate from another source (up to 15 volts if desired). The Pulses per Revolution count must be
sufficient to provide an adequate frequency feedback at very low speeds, and yet not exceed 300 kHz
(per channel) at top speed. For most applications this target will be met when the feedback frequency
(per channel) is greater than 50KHz at contract speed. For geared machines with motors running at 1750
or 1150RPM, a 2500PPR encoder may be used. Direct mounted hollow shaft encoders, electrically
insulated from the motor shaft and motor frame, will yield the best results. The use of an analog AC or
DC tachometer is not supported by OMNIPULSE DSD drives software or hardware.
Mounting
Proper mounting and alignment of the digital encoder used for speed feedback is very critical for the
smooth operation of the OMNIPULSE DSD controller. Even the slightest wobble of the encoder shaft due
to misalignment can cause once-per-revolution torque pulsation that have the potential of exciting natural
rope resonance frequencies.

Non-concentric

Input Output

Angular Misalignment

End Float

Figure 4: Common Problems in Encoder Mounting

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Magnetek recommends mounting the encoder used for motor speed feedback directly to the motor shaft,
usually to the end opposite the drive end. Normally a stub shaft is mounted in the end of the motor shaft.
The stub shaft must be absolutely concentric (share the same center) with the motor shaft, and have no
angular misalignment. The encoder is normally face mounted to a bracket that is mounted on the motor.
A standard NEMA 56 “C” face adapter bracket may be used, or a special fabricated bracket may be
designed and used. The encoder should be mounted on the bracket and positioned so that the encoder
shaft and the stub shaft are concentric and have no angular misalignment or run-out. The coupling
should have electrical insulation to isolate the motor shaft from that of the encoder. The body of the
encoder should be electrically insulated from the motor frame.
Coupling

There is likely to be some small amount of misalignment, regardless of the care used in mounting the
encoder. A good quality coupling between the encoder shaft and the motor stub shaft can help avoid the
remaining problems due to shaft runout. A good coupling will also offer some protection for the encoder
against end float, a condition which exists in gearing on direction changes, and which can be transmitted
through the motor. Again, the coupling should provide electrical insulation between the motor and
encoder shafts.

Exceeding Operating Specification

Do not exceed the operating specification of the encoder/drive, in order to prevent the encoder from
providing incorrect data. All encoders have inherent mechanical and electronic limitations regarding
speed. The combination of several design factors including bearings, frequency response of the
electronics, and PPR of the encoder, etc. combine to determine "maximum operating speed". Exceeding
the maximum speed may result in incorrect data or premature failure. The encoder manufacturer can
provide both the electrical and mechanical encoder specifications.

To determine the encoder's maximum operating speed:

Step 1:
Determine maximum electronic operating speed in RPM.
Encoder freq. response (kHz) x 60
RPM 
Encoder PPR
Step 2:
A. If the RPM calculated in Step 1 is less than or equal to the encoder's maximum mechanical RPM
specification, then the RPM calculated in Step 1 is the maximum operating speed specification for this
particular encoder application.
B. If the RPM calculated in Step 1 is greater than the encoder's maximum mechanical RPM
specification, then the maximum mechanical RPM specification is the maximum operating speed for
this encoder application.
Step 3:
Compare the maximum operating speed as determined in Step 2 above with the application
requirements.
To determine if the application exceeds the operating specification of the OmniPulse DSD:
 Calculate the maximum pulses per revolution (PPR) for this application

300,000 Hz*60
PPR max 
max application RPM *1.2
Verify that the selected encoder’s PPR is below the calculated maximum PPR (PPRmax) for this
application.

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CHAPTER 3: WIRING

WARNING

Before you wire the drive, review the following practices to help ensure that your system is wired properly.

 Use hard contact inputs rather than solid-state inputs on external user input devices.
 OmniPulse DSD drives require input reactance. Ensure that there is at least 3 percent impedance
between the power source and the drive input. To accomplish this, you can install an isolation
transformer, or use an AC line reactor on the input of drives with 60HP or less output. If enough
impedance isn’t provided, excessive peak currents could damage the input power supply circuit.
 Comply with “Suggested Circuit Protection Specifications”.
 Use time delay fuses, which are sized at 150% of drive's continuous-rated current, for drive input
protection.
 Use appropriate R-C or MOV type surge absorbers across the coil of all contactors and relays in the
system. Failure to do so could result in noise-related, nuisance fault incidents.
 Do not ground the drive with any large-current machines.
 Before you use any welding or high-current machines near the crane, disconnect all line and ground
wiring.
 A two or three pole output contactor, with auxiliary contacts, should be installed between the drive
and motor.
 Do not let the wiring leads come in contact with the drive enclosure.
 Do not connect power factor correction capacitors to the drive input or output.
 Hard-wire the drive and motor (e.g., festoon cable). Do not use sliding collector bars.
 If you have a user input device, use shielded cable between the drive input terminals and the
interface output terminals or user input device(s).
 Before turning on the drive, check the output circuit for possible short circuits and ground faults.
 Increase the wire size by one size for every 250 ft. between the drive and motor; suggested for center
driven cranes, trolleys and bridges.
 When using more than one transformer for the drive's power, properly phase each transformer.
 To reverse the direction of rotation, interchange any two armature motor leads (A1 and A2).
(Changing L1, L2 or L3 will not affect the shaft rotation direction.)
 Use shielded cable for all low-level DC speed reference signals (0 to 10VDC, 4 to 20 mA). Ground
the shield only at the drive side.
 Please observe National Electrical Code (NEC) guidelines when wiring electrical devices.

Note: Failure to observe these warnings may result in equipment damage.

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 TYPICAL POWER WIRING

Figure 5: TYPICAL POWER WIRING

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Suggested Circuit Protection Specifications and Wire Size
In order to comply with most safety standards, some circuit protective devices should be used between
the incoming three-phase power supply and the OmniPulse DSD. These devices can be thermal,
magnetic, or molded-case breakers (MCCB); or “slow-blow” type fuses such as “CCMR” or “J.”

CAUTION

The following guidelines are only suggested values. Always conform to local electrical codes and wiring
practices.

Wiring Size
Time Power
Rated
Delay
Inverse Time Circuit
Control Ground
Model # Current(A) Molded/Case Wiring Copper (2)
Input Fuse Wiring (1)
Input Fuse Circuit Breaker (AWG) (AWG)
Class (AWG)

230/460V Class

144-45195 15 CC 20 12 16/14 12

144-45200 45 J 60 10 16/14 10

144-45205 70 J 110 4 16/14 8

144-45210 150 J 200 1/0 16/14 6

250
144-45215 300 J 350 16/14 4
2-2/0

400
144-45220 500 J 600 16/14 1
2-250
References:
1. NFPA 70 National Electrical Code 2011 Table 610-14(a) 90° C, 60-minute, copper, 45° C ambient.
2. NFPA 70 National Electrical Code 2011. Table 250-122.

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Power Circuit Wiring Procedures

To wire the power circuit for OmniPulse DSD:

1. Run the three-phase power supply wires through an appropriate enclosure hole.
2. Referring to “Suggested Circuit Protection Specifications and Wire Size,” the 230/460 Power V
Class Terminal Functions table on page 22, and the Control Circuit Terminals table on page 23,
connect the three-phase power supply wires to a circuit protection system.
3. Connect the three-phase power supply wires from the circuit protection to Terminals L1, L2 and
L3.
4. From Terminals A1 and A2, connect the power output wires to the motor armature leads A1 and
A2.
5. From drive Terminals F1 (proper current selection point) and F2 (-) connect motor field.

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230/460 Power V Class Terminal Functions

144-42195 144- Consult Consult

Model 144-45220
– 45210 45215 Factory Factory

10 to 106 206 640 to

Rated Current 330 Amps 480 Amps
Amps Amps 1550 Amps

L1

L2
Main circuit input power supply

L3

ARM (+) ARM(+) P P

ARM (-) ARM(-) N N

F1 (+)
F1(+) TB2(1) TB1(3)
Terminal

(Proper Amp Range)

F2(-) F2 (-) TB2(2) TB2(4)

Armature
Voltage (+) TB5 (2+) TB1(3) P
Feedback

Armature
Voltage (-) TB5 (1-) TB1(4) N
Feedback

Ground terminal (Ground resistance: 100 Ω or less)

TB3(7)
115 VAC (lo)
TB3(1) Control Power Supply
115 VAC (high)

TB1(AC1)
Field Power Supply
TB2(AC2)

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 Control Circuit Terminals

The table below outlines the functions of the control circuit terminals.
Classification TB1 - Signal Function Description Signal Level
Terminal
7 M Contactor Auxiliary M Contactor Energized when
closed
49 Forward run/stop Forward run when closed,
stop when open
8 Reverse run/stop Reverse run when closed,
stop when open
9 Speed 2 (default) Multi-Function contact input
Parameter 71
10 Speed 3 (default) Multi-Function contact input
Parameter 72
11 Speed 4 (default) Multi-Function contact input
Sequence Input Signal

Parameter 73
12 Speed 5 (default) Multi-Function contact input
Parameter 74 24VDC ± 10%

50 Speed 6 (default) Multi-Function contact input

Parameter 75
51 Fault Reset N/O (default) Multi-Function contact input
Parameter 76
52 Not used (default) Multi-Function contact input
Parameter 77
53 Not used (default) Multi-Function contact input
Parameter 78
54 Micro Speed Gain 1 (default) Multi-Function contact input
Parameter 79
48 Control +24 supply +24VDC for logic input

44 Control Signal Common Typically jumper to TB11 (1)

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Classification TB1 - Signal Function Description Signal Level
Terminal
28 +10V Power supply output For analog command +15V (Allowable
+10VDC power supply current 20 mA max.)
Analog Input Signal

29 -10V Power supply output For analog command -15V (Allowable current
–10VDC power supply 20 mA max.)
63(-) Differential analog speed -10 to +10V/-100% to 100% -10 to +10V (20k Ohm),
68(+) reference 0 to +10V/0 to 100% 0 to +10V/(20k Ohm)
71(-) Differential analog torque -10 to +10V/-100% to 100% -10 to +10V (20k Ohm),
76(+) reference 0 to 10V/0 to 100% 0 to +10V/(20k Ohm)
57 Common terminal for control 0V -
Input Signal
Analog

circuit
27, 47, 77 Connection to shield sheath - -
of signal lead
42 Drive Fault N.O. contact (K1) Multi-function output (K1)
41 Center of N.O./N.C. (K1) Drive Fault (default)
40 N.C. Contact (K1) Parameter #81 Dry contact
38 Multi-function output (K2) Contact capacity:
N.O. (K2) Contact
Parameter #82 Default (Brake 115VAC, 500 mA or
39 Brake release
Release) less

36 Multi-function output (K3) 30VDC, 2A or less

N.O. (K3) Contact
37 Parameter #83 Default (Brake
Brake release
Release)
Relay Output Signal

78 (K4) Open collector Multi-Function output (K4) Open collector Rated

UP or DOWN limit Parameter #84 Default (UP or 500mA @ 24VDC
DOWN limit)
79 (K5) Open collector Multi-Function output (K5)
Alarm-1 Parameter #85 Default
(Alarm-1)
80 Control Common
82 Control +24V Supply +24VDC for logic output
83 (K6) Open collector Multi-Function output (K6)
Drive running Parameter #86 Default (Drive
running) Open collector Rated
84 (K7) Open collector Multi-Function output (K7) 500mA @ 24VDC
Brake hold fault Parameter #87 Default (Brake
hold fault)

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Classification TB1 - Signal Description Signal Level
Terminal Function
45 Multi-Function Multi-Function analog 0 to ±10V Max. ±5%
0 to ± 10V
Analog Output

Analog Output 1 Parameter 60-62 2mA or less

Signal

80 Common
46 Multi-Function 0 to ± 10V Multi-Function analog 0 to ±10V Max. ±5%
Analog Output 2 monitor 2 Parameter 2mA or less
65-67
2 A
0 to 300 kHz ±5%
3 A- High level voltages
3.5 to 5
4 B Encoder Parameter Function #
Encoder

Low level voltages

Feedback 12, 15, 95, 96
5 B- 0.0 to 0.8
Duty cycle (on/off)
6 Shield 30% to 70%

1 +5VDC +5VDC ±5%

Encoder power supply
43 Common 350 mA
44 Common
Jumper 44 to 1
Ground

1 Ground
R- and S-
Modbus
Signal Common

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Electrical Hook up
Ensure that wire size and disconnect devices conform to the installation contractor’s drawings and to all
applicable codes.

Power Connections
The three phase input power to the drive is fuse protected internal to the Drive. However, it is
recommended to provide branch circuit protection by means of a circuit breaker in accordance with the
National Electrical Code, (USA) or as may be required by other local electrical codes.

Signal Connections
All low power, low voltage wiring to the OmniPulse DSD controller should be run separate from the
115VAC or higher power connections and the DC motor armature and field connections. These include:
 Encoder Wiring
 Speed Reference Wiring
 Pre-Torque Reference Wiring
 24 VDC Logic Inputs
 Analog Outputs
 Open Collector Logic Outputs
Rewiring these signals in shielded wire is recommended to avoid noise pickup.

Grounding
The OmniPulse DSD controller, the utility power system feeding it and all other connected power
equipment should be grounded as follows:
The facility power ground and grounding wire sizes should comply with NEC, UL, CSA and other
applicable codes for power distribution safety.
A common grounding stud or bus bar should be provided within the drive enclosure cabinet, electrically
bonded to the metal enclosure.
A grounding wire should be provided directly from the grounding terminal on the OmniPulse DSD drive
chassis to the common grounding stud.
A grounding wire should be provided directly from the electrical sub-panel on which the OmniPulse DSD
drive is mounted to the common grounding stud. Other electrical equipment, such as fans or relay
circuits may be grounded to the electrical sub-panel.
A grounding wire should be provided directly from the hoist motor frame to the common grounding stud.
A grounding wire should be provided directly from the power isolation transformer frame to the common
grounding stud.
A grounding wire should be provided directly from building steel to the common grounding stud.
If an armature circuit ripple filter is used, a grounding wire should be provided directly from the ripple filter
inductor frame to the common grounding stud. The sub-panel for capacitor mounting within the filter
should have a grounding wire to the inductor frame.

The secondary side of the power isolation transformer should remain un-grounded.

The low voltage circuit common should be grounded by connecting A1TB1-43 or A1TB1-44 to A1TB11.

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Connect terminal G to the common panel ground. Use ground wiring as specified in “Suggested Circuit
Protection and Wire Size” on page 20, and keep the length as short as possible.

 Ground Resistance: 230V class; 100Ω (ohms) or less, 460V or greater class; 10Ω (ohms) or less.
 Never run the OmniPulse drive ground wires in common with welding machines, or other high-current
electrical equipment.
 When more than one drive is used for the same system, ground each directly or daisy-chain to the
ground pole. Do not loop the ground wires.

M M

Not
Correct
Acceptable

Figure 6: Grounding of OmniPulse DSD Drive and DC Stabilized Shunt

Encoder Wiring
Wiring between the encoder and the OmniPulse DSD drive should be shielded cable with 3 twisted pairs.
The pairs should be made up of A and A-, B and B-, VDC, and common. The shield should be insulated
from the encoder case, and only connected at the drive end, to A1TB1 (6). This cable should be run in a
separate conduit between the encoder and the OmniPulse DSD drives.

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Pre-power Check

CAUTION

To prevent damage to the drive, the following checks MUST BE performed BEFORE applying 3-PHASE
INPUT POWER to the drive.

A. Inspect all equipment for signs of damage, loose connections, or other defects.
B. Ensure the three-phase line voltage is within +10% of the nominal input voltage range of 150 to 525
VAC. The drive is not sensitive to phase sequence. Input power specifications are contained on the
drive nameplate or the drive system Schematic Diagram.
C. Remove all shipping devices and relay wedges. Manually operate all contactors and relays to ensure
that they move freely.
D. Ensure that all electrical connections are secure.
E. Ensure that all transformers are connected for proper voltage according to the Drive system
Interconnection Diagram.

Drive Start up
Refer to the recommended connections shown in the connection diagrams. Attach a voltmeter across the
115VAC source for the control power supply, at A4TB3-1 & A4TB3-7.
Apply the control and three-phase power and verify that the control power is between 103 VAC and
126VAC. Then press the RESET push button on the front of the power cube, and observe the drive
power-up sequence as described below.

Drive power-up sequence

The power up sequence can be observed by monitoring the Standard Control/Display Unit (SCDU) on the
front of the power cube.
1. First, all of the segments on the digital LED display and all of the LEDs will light for about 1 second.
2. Then the LEDs and display should extinguish. The drive will perform internal checks. The SCDU will
display 'TEST' while a self-test is being performed.
3. If the drive passes the self-test, then the SCDU will display 'P-UP'. READY LED will light.

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Abnormal Display Conditions
Displays other than those mentioned above may occur. The following is a list of abnormal display
conditions that may occur, and the actions necessary to correct the situation:
4. If no digits or LEDs light up, then check for proper voltage between the 115 VAC control power lines,
or for blown 115 VAC control power fuses, or for a defective Control Voltage Power Supply in the
power cube.
5. If horizontal segment(s) of the SCDU display are lit, then one or more phases of the three-phase
power are missing. Measure and verify three phase power input at the drive terminals. Check the
three-phase power fuses. See page 40 for descriptions about the standard control/display unit
operation for more detailed information about this test.
6. If the FAULT LED lights and a fault code appears on the SCDU, then refer to the Fault/Error Codes
List to see what caused the fault and to find the correct solution. A fault code is the letter 'F' followed
by a number representing the fault. See section describing standard control/display unit operation for
more detailed information about fault reporting and clearing on page 40.
7. If the SCDU displays 'Prot', then the initial checks found that the protected non-volatile RAM
(NVRAM) has not been initialized. Move the NV RAM PROTECTION switch to "OFF" in order to
allow the microprocessor to initialize the NVRAM with preprogrammed default values. Notice that the
NV RAM UNPROTECTED LED is now lit to indicate the NV RAM PROTECTION switch position.
Next, press the RESET push button. The drive will go through its power up sequence again;
however, this time it will initialize the unprotected NVRAM and load in factory supplied default
parameter values.

Fan Check
On drives with a blower motor (power bridge fan), verify that the fans are working.

Verify Parameters
When the READY LED on the SCDU is lit, all the selectable parameter data should be checked and/or
verified to the proper values as follows:
8. VERIFY OR CHANGE EACH PARAMETER VALUE for the particular application and motor involved.
9. Perform PCU DIAGNOSTICS Function 998 should to verify armature and field circuitry.
10. Perform SELF-TUNE PARAMETER TEST Function # 997 to measure and verify various motor
parameters essential for proper operation.
11. STORE PARAMETERS, Function # 994, so that power can be removed and reapplied without losing
the entered parameters.
12. Set the NV RAM PROTECT switch to the protect position (UN PROT NV RAM light is off) to ensure
that set up data cannot be corrupted.
13. Operate drive, using external control signal inputs shown on the Interconnection Diagram.

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CHAPTER 4: PROGRAMMING FEATURES

Drive Description
The OmniPulse DSD Drive is a complete digital system drive that provides individual drive and system
control in one compact package. It is of 12SCR Regenerative configuration. The drive uses two
microprocessors: one for the Power Conversion Unit (PCU) circuitry, and one for the Drive Control Unit
(DCU) circuitry. Interface to other equipment is provided with Local I/O [Input/Output]. Extensive
diagnostics and setup capability are provided through two Control/Display Units. Depending on rating of
the unit, the power cube is in one of four chassis sizes. Refer to the outline dimension drawings. Each
power cube is designed for mounting inside a qualified electrical enclosure. Space allowances for air
circulation, additional components, outgoing terminals, and wire bends must be provided. Hinged door
swing-out clearance is the same as the width dimension.

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Figure 7: OmniPulse DSD Block Diagram A

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 F4 ME

SCR POWER BRIDGE

12 SCR REGEN
ME
MOTOR
CURRENT ARM.
SENSOR
SCR
RT1
GATE ME
SIGNALS
RIPPLE FILTER
DB
RESISTOR

ARMATURE
INTERFACE
PCB

+18888
STATUS UN PROT
POWER CONVERSION UNIT LEDS NV MEM
MICROPROCESSOR
RE-
SET
LOCAL CDU
RAM &
EPROMS DUAL PORT
MEM PROT
MEMORY
SWITCH

DRIVE CONTROL UNIT

MICROPROCESSOR

NV-RAM, RAM IN-OUT DRIVE CONTROL PCB

& EPROMS DRIVERS

RS-232 OR RS-422
SERIAL PORT TB1 LOCAL CONTROL I / O

CONTROL SIGNAL
WIRING
OR

OPTIONAL
SERIAL LINK
TO CAR
CONTROLLER

OPTIONAL
PCDU
PROGRAMMER

Figure 8: OmniPulse DSD Block Diagram A (continued)

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 GROUND INPUT
LUG POWER
LUGS

AC LINES
FUSES
F1-3

DC
ARMATURE
FUSE F4

ARMATURE SNUBBER
CURRENT PCB
TRANSDUCER

A2TB5
CUBE I.D.
PCB

BRIDGE SCR'S
THERMISTOR

Q7, FIELD
ARMATURE SCR
INTERFACE
PCB

DC OUTPUT AC INPUT
FIELD FOR FIELD
SUPPLY SUPPLY

Figure 9: OmniPulse DSD Component Layout Front View

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POWER
SUPPLY
COVER

A4 POWER
SUPPLY

A4 TB3
A1 MAIN
CONTROL
PCB

Figure 10: OmniPulse DSD Component Right Side View

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The Standard Control Display Unit (SCDU)
The SCDU is mounted on the Drive Control PCB and consists of a 4-1/2 digit numeric LED display, four
push buttons and READ/WRITE colored LEDs. The SCDU can be used for all setup functions and many
diagnostics.

The Portable Control Display Unit (PCDU)

The PCDU is an optional hand-held device that can be plugged into any OMNIPULSE DSD drive and
used for all the same functions as the SCDU plus some advanced diagnostics. The PCDU has two lines
of sixteen alphanumeric characters and a thirty-key keypad. Parameters are entered and displayed in
common understandable units. The drive can be completely set up prior to actual running and changes
can be made during operation. Keypad entry of changed parameters, protected memory, and factory
default values allow the operator to modify data with minimum risk to the process.

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Software Operating Features
The OmniPulse DSD DC motor drive is configured by software to operate various crane motions similar to
those available when using the Electromotive Systems Impulse AC motor drive. Motor armature power is
controlled through double way 6-SCR power conversion from 3-phase utility lines. OMNIPULSE DSD
drive hardware provides adjustable power control for the separately excited DC motor field by use of an
SCR-Diode component module and a closed loop current regulator. The following features are included
in the basic crane control software:

 Self-Tuning to match motor electrical characteristics

 Closed loop 4 quadrant armature current regulator
 Closed loop motor field current regulator with automatic field weakening
 Digital encoder speed feedback
 Run-Up, Run-Down logic control inputs (24 VDC)
 6 Pre-set operating speeds, plus separately adjustable jog speed
 Automatic Inching Run timer
 External analog speed follower input for PLC or joystick operation
 External analog torque command input for tension control or load sharing
 Adjustable acceleration and deceleration rates
 Adjustable current limit
 Programmable Start-Stop sequencing with or without machine brakes:
 Coast to stop
 Controlled Stop
 No-Load Brake - Automatic sequencing and verification of hoist brake
 Ultra-Lift for faster than normal speed operation at light loads
 Micro-Speed for slow speed positioning
 9 Programmable multi-function logic inputs (24 VDC) - feature selections include:
 Pre-set speed selects
 Slow-down and Stop limits
 Micro-speed enable
 Jog & Inch enable
 Ultra-Lift enable
 External Fault
 Fault Reset
 Brake answer-back
 7 Programmable multi-function logic outputs - feature selections include:
 Drive OK / Running / Fault indicators
 Brake activation
 Brake Fault Alarm
 Up / Down / Zero Motion indicators
 Slow / Stop / Current limit condition indicators
 Overtemperature / Overload / Low Line Alarms
 2 programmable analog output channels for data logging or diagnostics
 Diagnostic logic indicators for verification of input and output control signals
 Safety related features and fault traps with diagnostics, including:
 Blown fuse, Power loss, or Severe power line disturbance monitoring
 Motor over-load and over-current
 Motor field malfunction
 Contactor failure
 Encoder backwards, over speed, or loss
 115 VAC motor klixon input
 115 VAC contactor enable

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Power Conversion Unit (PCU)

Description
The Power Conversion Unit (PCU) circuitry has three major functions:

1. It converts three phase AC input power to variable DC voltage for application to a motor armature.
2. It converts motor generated DC power to three-phase power to feed back to the line.
3. It converts single phase AC input power to a variable DC voltage for application to a motor field.
Two sources of power are required. A three-phase power isolation transformer adjusts the utility mains
voltage to that required to operate OmniPulse DSD efficiently with the needs of the DC hoist motor.
115VAC control power from a separate source is used to power the low voltage power supply, cooling
fans, relay and contactor logic.
Three phase input power is applied through the AC line fuses to twin 6-SCR power bridges for forward
and reverse control. The PCU microprocessor controls armature current based on a reference received
from the Drive Control Unit (DCU) microprocessor. Output from the PCU microprocessor is sent to the
Armature Interface PCB, which produces the gating signals for power SCRs. The SCR bridge output is
an adjustable DC voltage, which is applied to the motor armature circuit. Power circuit AC and DC
measurement signals are routed to voltage dividers on the Armature Interface PCB, and scaled values
are sent to the PCU microprocessor. Armature current is also measured and the feedback signal is
routed through the Armature Interface PCB to the PCU microprocessor. An over current trip function
monitors this signal to initiate an instantaneous static trip (IST) in the event of excessive output current.
Single-phase power is also applied through the AC line fuses to the Field Rectifier Module. SCR gating
signals from the PCU microprocessor control the field rectifier SCRs. A separate current measuring
device is used to monitor the DC current flowing to the motor field. Additional connections allow for a
separate step-up or step-down transformer to be used to power the motor field rectifier from voltage
mains different from that for the motor armature.
If optional dynamic braking resistors (DBR) are present they are applied across the motor armature to
dissipate rotational energy whenever the motor contactor is dropped out. This helps to bring the motor to
a stop even when utility power is lost.
The largest component of the PCU is the SCR bridge (heatsink assembly). The heatsink is an extruded
aluminum structure that dissipates the heat generated by the SCRs mounted on the front surface (or
between heatsink sections, in large size power cubes). The SCRs control the current to the motor
armature and in turn are controlled by the Armature Interface PCB mounted in front of the SCRs. Three
input power line fuses are provided. A DC Bus fuse protects the motor armature circuit. A thermistor
(and klixon on some ratings) senses heatsink temperature and gives an over-temperature warning if an
over-temperature occurs.
Access to the SCR Bridge is obtained by opening the hinged door containing the Drive Control PCB A1.

WARNING

Opening the hinged door with power applied to the drive exposes dangerous voltage levels. The hinged
door should only be opened by a qualified service technician, and only when the power to the drive is
turned off.

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Hardware Description
OmniPulse DSD Power Supply PCB (A4)
Provides +5V, +15V, -15V, and +24V to the control circuits and has fold-back current limit protection. It
also provides 115VAC connections for the main contactor, motor klixon and fans.

Armature Interface PCB (A2)

Provides the interface circuitry between the digital firing pulses generated by the Drive Control PCB and
the high current SCR gating pulses controlling the armature current. It also provides feedback signals
from the power section to the Drive Control PCB. A small ‘cube ID’ circuit board is attached to the
Armature Interface PCB to identify the ampere capacity of the SCR power bridge to the PCU processor.

SCRs
The drive uses different selections of doubler packs or individual “hockey puck” SCRs according to the
horsepower ranges specified below:

MOTOR RMATURE SCR

CURRENT TYPE
25A - 195 A Doubler
300 - 1285 A "Hockey Puck"

Field Interface PCB (A3)

Provides the interface circuitry between the digital firing pulses generated by the Drive Control PCB and
transformer isolated SCR gating pulses controlling the field current. It also contains the field feedback
circuitry and the field SCR snubber circuit.

Cell snubber PCB (A5)

Provided for SCR protection. These are selected to work efficiently with utility line impedance between 2
and 8 percent, including that of the power input transformer.

Drive Control PCB (A1)

Mounted on the hinged door, this board provides the microprocessors, memory and support circuits
needed to control drive operation. Two control circuits are provided on this PCB: one for controlling the
Power Conversion Unit (PCU), and another for speed regulation and higher-level functions, called the
Drive Control Unit (DCU). These two circuits communicate primarily through a Dual-Port Random Access
Memory (DPRAM) IC (integrated circuit) device.

Drive Control Unit

The major element of the DCU is a 16/32-bit Motorola 68000 microprocessor. Random Access Memory
(RAM) provides memory space to store values that are maintained only while power is on. Non Volatile
Random Access Memory (NVRAM) maintains drive control parameters for the DCU when the power is
off. Two EPROM’s (Electrically Programmable Read Only Memory) devices, U39 & U40, contain the
specific drive program instructions for the DCU microprocessor.

Power Conversion Unit Control

The major element of the PCU control circuit is a 16-bit Intel 80C196 microprocessor. Again, RAM and
EPROM devices, U13 & U14, provide memory space and computer instructions for the PCU. Any PCU
parameters that need to be maintained while power is off are kept in NVRAM of the DCU and passed
through the DPRAM.

Local I/O
In a Material Handling application, the Local I/O [Input/Output] allow the drive to have inputs and outputs
(I/O) such as RUN, STOP, Encoder Feedback, Analog Reference Input, Fault condition relay logic output,
etc. connected directly to the drive.

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Front Panel Controls and Indicators
The upper right corner of the power cube cover contains the operator controls and indicators. Although
accessible with the cover in place, all of these components are part of the Drive Control PCB (A1).

DRIVE RESET Button (S1)

Pressing this button causes the drive to clear critical and non-critical faults and to restore drive operation
when faults are present. This button will have no affect when the drive is enabled.

Status LEDs
Located to the right of the RESET button is a vertical strip of six light emitting diodes (LEDs):

READY — Indicates that the drive is ready to run.

RUN — Motor contactor is closed and drive is controlling motor speed.

I LIMIT — Drive operation is demanding current limit armature current. This light will also blink at 2 Hz if
the drive is limiting speed due to excessive motor voltage or CEMF.

OVERLOAD — Motor armature current is in overload region. If lighted when the drive is stopped,
indicates that an over-load trip has occurred.

E-STOP — Drive contactor safety interlock is detected open. Drive will not run when this light is on.

FAULT — Indicates that a declared drive fault exists. The Fault/Error Code List defines what conditions
the drive will recognize as faults.

Standard Control Display Unit

The major part of the SCDU is a 4-1/2-digit numeric LED display. Each of its four full digits can display
the values of 0 to 9 plus limited alphabetic characters. The so-called half digit can display only the value
1 and a plus or minus sign. Underneath this display are a green LED (labeled DATA), a red LED (labeled
DATA PEND), and a row of four push buttons.

The DATA and DATA PEND LEDs are used to indicate the significance of the LED display data, and the
four push buttons (DATA/FCTN, › [UP], › [DOWN], and ENTER) are used to operate the SCDU.

Non-Volatile RAM Protection

To the left of the four push buttons of the SCDU there is a red LED labeled MEM UNPROT. This LED is
lit when the “protected” portion of the non-volatile random access memory (NVRAM) can be written to.
The switch labeled S3, which is located just under the MEM UNPROT LED, determines protection of the
NVRAM. When this switch is in the "ON" position, the NV RAM UNPROTECTED LED is off and the
protected portion of the NVRAM cannot be written to. This prevents setup parameters and other
important constants from being accidentally erased or changed. When these parameters need to be
changed the switch can be moved to the "OFF" position, removing the write protection and causing the
NV RAM UNPROTECTED LED to be lit. Refer to the section described as saving parameters.

The NV RAM PROTECTION switch should be left in THE "ON" position (UN-PROTECTED NV MEM LED
OFF) to protect the NVRAM during the critical power-up and power-down periods.

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Interface Specifications
OmniPulse DSD is designed to interface with isolation relays to input and output devices.

The drive has eleven logic programmable input terminals, which can be used to connect with the user
input device. Terminals 49 and 8 are always used for the directional run commands (Forward and
Reverse, Up and Down). The rest of nine terminals are multi-function terminals, and are used for speed
control and other characteristics. With multi-function terminals you can assign various functions and
performance characteristics without having to rewire the drive.

There are two preset function analog inputs: Each is selectable between 0-10 or ± 10VDC input. One is
speed reference and the other is torque reference.

The drive has programmable multi-function logic output. Three are 115VAC, 500mA relay contacts. Four
are open collector multi-function output terminals.

The drive has two programmable analog output channels for data logging and diagnostics.

Standard Control/Display Unit Operation

General
The Standard Control/Display Unit (SCDU) is used to change and/or monitor various drive dependent
operational set points and perform diagnostics for the Magnetek OmniPulse DSD Drive. The SCDU is
located in the upper right corner of the Drive Control PCB and is accessible through the power cube
cover. This Control/Display Unit is present on every Magnetek OmniPulse DSD Drive.

The SCDU consists of a 4-button keypad, a 4-1/2 digit numeric LED display, red and green colored LEDs,
an "NVRAM PROTECT" switch (marked NV RAM PROTECTION on the power cube cover), and a red
LED that shows the status of the "NVRAM PROTECT" switch.

Figure 11: OmniPulse DSD Standard Control/Display Unit

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Start-Up Operation
When power is first applied to the drive, all of the segments on the 4-1/2-digit display will turn on briefly in
order to show that all are functioning:

After this lamp test is completed, an internal check is made to determine if the NVRAM chips have ever
been used before, or if the EPROMs are the same as before power down. If not, the drive software will
attempt to load the defaults into the NVRAM chips. The SCDU displays the word ‘Prot’ if the NVRAM
PROTECTION switch is in the position that will not allow any updates of the NVRAM:

If the display shows ‘Prot’, it is necessary to move the NV RAM PROTECT switch to the "OFF" position
and press the CPU RESET button in order to load defaults into NVRAM and restart the drive. Then set
the NV RAM PROTECT switch back to "ON". This ‘Prot’ message will only happen when: the drive is
powered up for the very first time; if the software in the drive is changed; or the NVRAM chip (U56) is
changed.

After the LED lamp test has completed, the drive software will now perform a fuse test on each of the
three line fuses. If any power conversion fuse is open, the SCDU will indicate this on its display. The
SCDU display is arranged in a similar manner to the physical placement of the 3 line fuses in the power
cube. The middle segments of the three right-most digits are used to indicate blown fuses. For example,
if the left-most line fuse is bad, the SCDU will report it as follows:

If any two or more fuses are blown, the SCDU display will be:

The operator should then identify which fuses have failed.

The drive will not operate unless all three line fuses are functional. If the SCDU indicates a bad fuse,
power must be removed from the drive, the fuse replaced and power reapplied.

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After the drive has performed all three tests (lamp test, RAM test, and fuse test), the SCDU displays one
of two final messages. If there are any faults present at this time, the SCDU will display a Fault code.
The display will be similar to:

where the leading ‘F’ indicates a fault and the 3 digits following the ‘F’ indicate the fault number. If
however, there are no faults present, the SCDU displays the normal power-up message:

This ‘P-UP’ display will remain on the SCDU until a key is pressed or a fault occurs.

After Power-Up
After the drive has powered up and the SCDU display is showing ‘P-UP’ or a fault number, it can be used
to enter new parameters, monitor drive operation, and/or perform certain drive diagnostics. Every
operation that the SCDU can perform is called a ‘function’. There may be up to 1000 functions defined
within the DCU.

All SCDU functions have at least 2 levels, and some functions use 3 levels. The two colored LEDs below
the lower left corner of the 4-1/2-digit display are used to indicate which level of a particular function the
SCDU is currently at. The top level of the SCDU operation is called the "Function" level. The two colored
LEDs are off when the SCDU is in the "Function" level. The ▲ or ▼keys are used to select a function
number to be accessed while at this level. The ▲ key increments the function number in the display while
the ▼ key decrements it. The SCDU will ramp the displayed function number when the ▲ or ▼ key is
pressed and held for 1/2 second or longer.

The DATA/FCTN key is used to toggle between the “Data” level and the “Function” level. Press the
DATA/FCTN key when the desired function number is in the display. At this point, the SCDU leaves the
"Function" level and enters the "Data" level. Note that the green LED is now lit. This operation is
consistent for every function on the SCDU, although the data actually displayed while the LED is GREEN
is function-number specific. Examples of every type of SCDU function are given in subsequent sections.
All function numbers are shared between the SCDU and the PCDU (Portable Control/Display Unit).
There are some functions, however, that can only be performed with the PCDU. When such a function
number is selected on the SCDU and the DATA/FCTN key is pressed, the SCDU’s display will change to:

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Changing Parameter Functions
SCDU functions are used to modify and/or display setup points that the drive needs for operation. Items
that would typically fall into this category are functions such as Accel Times, Regulator Gains, Rated
Speed and any other parameters. The following steps show how to modify a given parameter via the
SCDU display.
1) Use the ▲ and ▼ keys to select the function number to be accessed. The two colored LEDs remain
off during this step. For example, if #040 is chosen:

2) Press the DATA/FCTN key to enter the "Data" level for this function number. The green LED is lit to
indicate that the number being shown is the current actual value for this parameter. For example, if
Function # 40 is currently set for a value of 10.6, it will be displayed as:

3) Use the ▲ and ▼ keys to ramp the number in the SCDU display to the desired value. Note that the
red LED is lit to indicate that the value being displayed is NOT the actual value, but rather is in the
process of being changed. Each parameter has an upper and lower limit. The following display will
occur when the lower limit is exceeded:

Similarly, if the upper limit is exceeded, the SCDU displays:

The SCDU display will increment from ‘10.6’ to ‘11.0’ if the ▲ key is pressed 4 times:

4) Press the ENTER key to transfer the value in the SCDU display to the actual value used by the drive.
Note that the green LED will now light to indicate that this value is now the actual value for this
parameter:

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If the ENTER key is pressed while the display is indicating that the upper or lower limit has been
exceeded, the display will change to the appropriate limit and the green LED will light.
5) Press the DATA/FCTN key to put the SCDU back into the "Function" level. As with the example
above, the SCDU display will be similar to:

All changes made become active values upon pressing the ENTER key. They remain active until the
next reset, or until the drive is powered down. When the drive is reset or powered up the value reverts to
the value stored in NVRAM. If changes are to be permanent, use Function # 994 to save the changed
value in NVRAM.

Due to programming considerations it may be possible to access a value that cannot be changed. In this
case the CDU function will proceed as described until the ENTER key is pressed to change the value. In
this case the value will simply ignore any requested changes and remain the same.

Viewing Monitor Functions

Items that would typically fall into this category are Speed Feedback, Armature Current and Armature
Voltage.

To view one of these values, it must have been previously programmed in the drive. The following steps
show how to display a given value on the SCDU display.

1) Use the ▲ and ▼ keys to select the function number (between 600 and 699) to be accessed.
The two colored LEDs remain off during this step. For example, if 600 is selected, the SCDU display
will be:

2) Press the DATA/FCTN key to enter the "Data" level for this function number. The green LED is lit to
indicate that actual data is currently being viewed. If the data for Function # 608 is currently at 20.94
for example, the SCDU display will change to:

The SCDU’s display is updated immediately if the value for the selected function changes.

NOTE: Values displayed with these function numbers cannot be modified.

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Error/Fault Reporting
The drive has two methods available to report errors and faults. Each error condition may utilize ONE,
BOTH OR NEITHER of the reporting methods.
The most conventional method is called ‘fault recording’. If this method is enabled for a particular fault,
the red FAULT LED and a unique fault code number will appear on the SCDU at the moment the fault
occurs. Each fault occurrence is recorded in a RAM location called the Fault List. The Fault List stores
the 16 OLDEST faults and stops recording faults as soon as the 16th fault occurs. This list is erased
when the drive is powered down or reset. Whether or not the drive stops or continues to run is dependent
on the way the particular fault is implemented. Most standard faults are set up so that the drive will stop if
a fault occurs. Faults stored on the Fault List will appear when viewing Function # 0.
The second method for error handling is called ‘error recording’. Error recording differs from fault
recording in three respects:
 The error condition will not be shown on the SCDU or the red Fault LED.
 The error list stores the 16 most recent errors and always overwrites the oldest error with the newest
error.
 This list is maintained in battery-backed-up RAM and is retained when the drive is powered down or
reset. Operation of the drive is totally independent of whether error recording is enabled or not.
 The Errors List may be viewed at Function # 800.

Function # 801
Used to display or alter the Fault & Error Disposition List. This list is consulted any time an error condition
occurs to determine whether it should be reported as an error, a fault, or both. The process for changing
the entry in the disposition list for a particular error using the SCDU is as follows:
1) Use the ▲ and ▼ keys to select function number # 801 from the function level. The two
colored LEDs remain off during this step.

2) Press the DATA/FCTN key to enter the "Data" level for Function #801. The green LED will light and
the error code last modified, with Function #801, will be in the SCDU display. The SCDU displays
error code #13 (illegal instruction) initially:

3) Use the ▲ and ▼ keys to select the error code entry in the Disposition List that is about to be
changed/viewed. For example, if the disposition for error code 102 (Numeric Underflow) is to be
modified, press the key until the SCDU display changes to:

4) Press the ENTER key when the desired error code is displayed on the SCDU. The red LED now
lights and the SCDU display changes as well to a format of ‘E.xF.y’.

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The ‘E’ and ‘F’ are abbreviations for Error and Fault respectively. The ‘x’ and ‘y’ will be either ‘1’ or ‘0’ to
indicate which list will record the error. For example, if the display is ‘E.1F.1’, the error is recorded in both
lists. If the display is ‘E.0F.1’, the error is recorded in the fault list, but not in the error list. If the display is
‘E.0F.0’, neither list records the error. In the example above, the factory set default disposition for a
numeric overflow F#102 is to record the error in the Error List, but not in the Fault List. In this case, the
SCDU display is:

5) Press either the ▲ or ▼ key repeatedly to change the numbers after the ‘E’ and ‘F’ from ‘1’ to ‘0’
and vice-versa. Starting from no declarations, the displays are: ‘E.0F.0’, ‘E.0F.1’, ‘E.1F.0’, and
‘E.1F.1’. For example, if the disposition for this error should be changed so that it is NOT recorded in
either the Fault or Error list, press the ▼ key once so the display changes to:

This display indicates that the Numeric Underflow error will now be recorded in the Fault List, but not in
the Error List.
Pressing the ▼ key once more will change the display to:

This is the desired status for the new disposition of the Numeric Underflow error, which is to not report it
to either the Fault or Error List.
6) Press the ENT key when the new disposition code is in the display. At this point, the green LED will
light, and the SCDU displays the error code again:

The ▲ and ▼ keys can now be used to select another error code to be modified, as in step 3.
7) When all changes in the Error Disposition List are finished, pressing ENTER key will exit back to the
function level:

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Fault Display/Clear
The drive stores the first 16 faults that have been reported to the Fault List, Function # 0. Once the Fault
List is filled with 16 faults, it will not accept any more entries. The data in this buffer is not retained when
the power is lost. Each time a fault condition occurs, and its entry in the Disposition List is set to also
record in the Fault List, the new fault is placed on the list (provided the list is not full).
Function # 0
Reserved for viewing the Fault List. The steps to view the Fault List are as follows:
1) Use the ▲ and ▼ keys to select Function # 0. The two colored LEDs remain off during this
step. Note that simply pressing the ▲ key once can access this function, if the SCDU display is ‘P-
UP’.
2) Press the DATA/FCTN key to enter the "Data" level for this function. The green LED is now lit to
indicate that the fault codes currently in the Fault List are being displayed. The very first display at
this point is the word 'ALL':

The SCDU display always displays the fault code that will be removed if the ENTER key is pressed. If the
ENTER key is pressed at this time, every fault currently in the Fault List will be removed from the list.
Each fault in the Fault List can be shown on the SCDU display and optionally cleared.

IMPORTANT

The process of clearing a fault from the Fault List DOES NOT actually clear the condition that caused the
fault.

To view the first fault on the list, press the ▲ key. If there is a Numeric Underflow fault 102 is on the
Fault List, for example, the SCDU display will change to:

The contents of the Fault List may be examined by using the ▲ and ▼ keys. The ▼ key moves
down the fault list while the ▲ key moves up the fault list. The first fault in the list is the first fault actually
declared. The SCDU displays the word 'End' after the last fault has been displayed:

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Error Display
The drive is able to store the most recent 16 errors that have been reported to the Error List. This list is
constantly updated, with the newest error overwriting the oldest in the list. This list is held in battery-
backed-up RAM (NVRAM), so it is retained when power is lost. Each time an error condition occurs, and
if its entry in the Disposition List is set to allow recording in the Error List, that new error is placed in the
list.

Function # 800
Reserved for viewing the Error List in NVRAM. The steps to view the Error List are as follows:
1) Use the ▲ and ▼ keys to select Function # 800. The two colored LEDs remain off during this
step.

2) Press the DATA/FCTN key to enter the "Data" level for the view error function. The green LED is
now lit to indicate that an error code is currently being viewed. If the error in this slot is a Numeric
Underflow fault 102 for example, the SCDU will display:

Other errors currently in the Error List can be viewed by pressing the ENTER key to display the Error
Code again, then use either the ▲ or ▼ key to move to the next slot in the list. The procedure
outlined above should be repeated as necessary to view the Error Code number for other errors in the
Error List.

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Non-Volatile Ram Access
Every parameter that the drive uses has three separate areas in memory associated with it. There is a
factory-set default value for each parameter which is stored in the “read only” EPROM chips. There is an
area in the active RAM which the drive uses while it is running. There is also an area in NVRAM reserved
for each parameter. The values in the NVRAM area are copied to the active RAM every time the drive is
powered up or the reset button is pressed. This split level approach makes it possible to return to the last
set of ‘stable’ parameters in NVRAM if some errors are made during fine-tuning of the active drive
parameters. The purpose of this function is to perform transfers between the NVRAM parameter list and
the active parameter list.
Function # 994 is used to perform the transfer of data between the NVRAM and active parameter lists.
The process for copying data to or from the NVRAM parameter list is as follows:
1) Use the ▲ and ▼ keys to select Function # 994 from the function level. The two colored LEDs
remain off during this step.

2) Press the DATA/FCTN key to enter the "Data" level for Function # 994. The green LED is now lit to
indicate that this function is currently being accessed. It is possible to SAVE the current active
parameters in RAM to the NVRAM parameter list, or to RESTORE the current parameters from the
NVRAM parameter list to ACTIVE RAM. Note that a RESTORE is the same operation that occurs
inherently every time the drive is powered up. Upon entering the data level for this function, the
SCDU displays:

The ▲ and ▼ keys can be used to toggle between the above display, which indicates a pending
RESTORE operation, and the following display, which indicates a pending SAVE:

Note that as soon as either the ▲ or ▼ key is pressed, the red LED will light.
3) Press the ENTER key to actually perform the transfer of data. If ENTER is pressed while 'SAVE' is
displayed, the SCDU display may change to:

This display means that the NV RAM PROTECTION switch is in the incorrect position preventing writes to
the NVRAM. Move the switch to the "OFF" position, press the DATA/FCTN key, and start over from step
2.

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If the SAVE or RESTORE operation was successful, the green LED will light. For example, if a SAVE
were performed, the display would be:

Load Default Function

Every parameter in the drive has a factory-set default value that is loaded when the drive is powered up
for the very first time. These default parameters may not be optimal values for the drive when actually
running, but they will generally allow the drive to function. It is possible to reload these default
parameters with Function # 995 of the SCDU. A re-load of the defaults would generally be done when
the drive is operating erratically and it is suspected that one or more parameters were improperly set.

CAUTION

Use of the LOAD DEFAULTS function will overwrite EVERY parameter currently being used by the drive
with the factory set default for each parameter. There is no way to restore parameters to their previous
value once this function is used.
Function # 995 is used to perform the transfer of data from the default parameter list to the ACTIVE RAM
parameter list. The process for accessing the Load Defaults Function is as follows:
1) Use the ▲ and ▼ keys to select Function # 995 from the function level. The two colored LEDs
remain off during this step.

2) Press the DATA/FCTN key to enter the "Data" level for Function # 995. The green LED is now lit to
indicate that this function is currently being accessed. The SCDU will now display:

3) Press the ENTER key to actually perform the Load Defaults transfer. After the transfer has
completed, the SCDU displays the word 'dOnE':

4) A cycling of control power is then necessary to implement the default settings onto the display.

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Self Tune Function
The OMNIPULSE OmniPulse DSD drive has a built-in current regulator SELF TUNING Function # 997.
When activated, this feature measures total motor armature circuit resistance, inductance including
wiring, and the field L/R time constant. After running the Self Tune Parameter Measurement function, the
values for armature resistance and armature inductance are stored in NVRAM. It is important to note that
it is possible to override the values that have been dynamically calculated for Armature Resistance,
Armature Inductance, and Field L/R Time Constant by the “USE SELF-TUNE” item in the parameter
menu (Function # 20). The dynamically calculated values are used if “USE SELF-TUNE” is set to “ON”
while the manually entered values (entered in parameters 4, 5, and 8) are used if this item is set to “OFF”.

NOTE: Armature current is circulated through the armature circuit during parts of the PCU Parameter
Measurement function. The PCU will reduce the field current to zero on motors with a shunt field in order
to minimize motor rotation. If the PCU detects significant motor voltage during the test, the PCU
parameter measurement function will abort

NOTE: Do not de-couple the motor or release the brake. Self Tune is non-rotational.
.

IMPORTANT

It is important to note that when applying a LRC output filter (Ripple Filter), the drive performance will be
affected. For this reason, it is necessary to run the SELF-TUNE test with the output configuration that will
be used. For example, if the filter is used with the capacitor fuse installed, then the SELF-TUNE test must
also be run with the filter fuse installed. If the capacitors are not needed, then the fuse should be pulled
and the SELF-TUNE test should be run with the fuse pulled.

The process for accessing the PCU PARAMETER MEASUREMENT function is as follows:
1) Use the ▲ and ▼ keys to select Function # 997 from the function level. The two colored LEDs
remain off during this step.

2) Press the DATA/FCTN key to enter the "Data" level for Function # 997. The green LED is now lit to
indicate that this function is currently being accessed. The SCDU displays the word 'Prot' if the NV
RAM PROTECTION switch is in the position that will not allow any updates to the NVRAM:

If the ‘Prot’ message appears, press the DATA/FCTN key to return to the "Function" level, move the
NVRAM PROTECTION switch to the "OFF" position, and press the DATA/FCTN key again. The SCDU
will jump to step #3 when the NVRAM PROTECTION switch is in the correct position upon entering this
function.

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3) The SCDU displays the word ‘Entr’ to prompt the user to press the ENTER key as further
confirmation that the PCU parameter measurement function is about to be performed:

4) Press the ENTER key to actually start the PCU Parameter Measurement function. The PCU will not
begin the measurement routine if a SEVERE PCU FAULT exists. The PCU will declare a SEVERE
FAULT under several conditions including an IST fault, power supply failure, line sync loss, low line,
or DCU failure. If a SEVERE FAULT exists when the PCU starts the parameter measurements, the
SCDU displays:

Severe faults can only be cleared by pressing the reset button on the Drive Control PCB, by cycling
power to the drive, or by replacing the bad component if applicable. The SCDU displays the word ‘tESt’
while it is performing the parameter measurements and there were no SEVERE FAULTS when the
ENTER key was pressed:

5) Press the DATA/FCTN key to exit the PCU parameter measurement routine and return to the
"Function" level. The SCDU displays:

6) After completion of SELF-TUNE, enable Function # 20 (unless using manual entry).

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Power Conversion Diagnostics
The drive has built-in diagnostic routines that can be performed via the SCDU. The PCU diagnostic
routines are able to test for four failure modes. The first test that the PCU performs is a test of the three
line fuses. Assuming the three line fuses are all OK, the PCU then performs a test for shorted
SCRs/doubler packs. If this test indicates no shorted SCRs/doublers, the PCU then verifies that less than
5% of the value entered for “Rated Field Current” is attainable. The PCU then tests for open SCRs by
passing current through the forward bridge followed by the reverse bridge, and finally checks polarity of
voltage feedback. The result of the test is displayed on the SCDU after the test completes. The SCDU
will light certain unique LED patterns on its display corresponding with the failure (see displays in the
procedure that follows). The Fault Codes F910 (Blown Fuse), F911 (Shorted SCR), F912 (Open SCR),
and F917 (Reverse Armature Feedback Wires) will not appear on the SCDU if the Error Disposition List is
programmed so that they are not reported to the Fault List.

WARNING

Armature current is circulated through the armature circuit during parts of the PCU Diagnostics Function.
The PCU will reduce the field current to zero on motors with a shunt field in order to minimize motor
rotation. However, a PERMANENT MAGNET motor must have its shaft locked mechanically prior to
running the PCU Diagnostics routine. If the PCU detects significant motor voltage during the test, the
PCU Diagnostics Function will abort.

The process for accessing the PCU Diagnostics Function is as follows:

1) Use the ▲ and ▼ keys to select Function # 998 from the function level. The two colored LEDs
remain off during this step.

2) Press the DATA/FCTN key to enter the "Data" level for Function # 998. The green LED is now lit to
indicate that this function is currently being accessed. The SCDU prompts the user to press the
ENTER key by displaying:

3) Press the ENTER key to actually start the PCU diagnostics. While the PCU is performing the
Function # 998 Diagnostics test, the SCDU displays:

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The PCU will not begin the diagnostic routines if a SEVERE PCU FAULT exists. The PCU will declare a
SEVERE FAULT under several conditions including an IST Fault, power supply failure, line sync loss, low
line, or DCU failure. If a SEVERE FAULT exists when the PCU starts the diagnostic tests, the SCDU
displays:

Severe faults can only be cleared by pressing the CPU reset button on the Drive Control PCB or by
cycling power to the drive.
If the display stays on 'tESt' and the contactor doesn't pick up, there is a fault in motor field connections or
settings.
If all tests indicate that there are no failed power components (SCRs and fuses), the SCDU displays:

Press the DATA/FCTN key to exit the PCU Diagnostics routine and return to the "Function" level. The
SCDU displays:

If the PCU detects one or more Open AC Fuses, it displays the fault code for a blown fuse (F910):

If the PCU detects one or more shorted SCR/doubler packs, the SCDU displays the fault code for a
shorted doubler (F911):

Remove power from the drive to replace the SCR(s) that are shorted, and repeat this test until the SCDU
displays the 'PASS' message.

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If the PCU detected one or more open SCR/doubler packs, the SCDU displays the fault code for an open
SCR/doubler pack (F912):

Remove power from the drive, consult Section 5, MAINTENANCE, to replace the SCR(s) that are open,
and repeat this test until the SCDU displays the 'PASS' message.
If the PCU detects Reversed Armature Feedback wires, it displays the fault code for a Reverse Armature
Fault (F917):

Remove power from the drive, reverse the Armature Feedback wires, and repeat this test until the SCDU
displays the 'PASS' message. This fault also occurs if the Armature FB wires are not connected.

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Operating Mode Descriptions
The following feature descriptions explain how each feature works and the necessary or interacting
adjustments. Specific adjustments are indicated by function name and/or the function number as (#xx).
For more details of any particular adjustment, please refer to the complete numeric listing in this manual.

Motor Field Current Control

Specific adjustments – (#6), (#7), (#8), (#9), (#11), (#17), (#18), (#90)
Related adjustments – (#3), (#10), (#13), (#20)

During normal operation motor field current is held at Stand-by Amps (#17) whenever the drive is idle.
When either the Up or Down (Forward or Reverse) logic inputs are energized, the motor field current
reference will switch to be Rated Field Current amps (#6). The closed loop current controls will adjust
motor field current to achieve that value. When measured field current reaches the magnitude set by Full
Field Detect (#90) the motor armature portion of the drive will be internally enabled to start. If motor field
current does not reach the magnitude of Full Field Detect (#90) motor armature control will not be
enabled. Measured motor field current may be displayed via function (#612).

Field weakening will automatically occur if the encoder speed passes beyond Rated Speed (#3) in Ultra-
Lift or other extended speed mode. As speed increases toward the Absolute Maximum RPM (#13), motor
field current will automatically follow a calculated profile to hold motor CEMF constant as speed increases
beyond Rated Speed. The setting of Weakened Field Current (#9) must be correct at Max Speed (#13)
for the motor voltage to be correct.

Motor field current will remain at Rated amps during all other low speed operations, including Load Float
and hoist Brake verification testing. If measured motor field current falls below 30% of Stand-by Field
Current (#17), a Field Loss fault will be declared (F905).

The motor field regulator needs to know the VAC magnitude of power connected to the SCR-Diode
module (#11), the electrical characteristics of the motor field, Rated VDC (#6), Rated amps (#7), L/R (#8),
and the desired Response (#18). These values should be correct before attempting to operate the drive.
In most cases, leaving the default settings of 0 for (#11) and 5 for (#18) will be adequate. During Self-
Tune, the motor field time constant will be measured and displayed at (#615). If Use Self-Tune (#20) is
OFF. the L/R value at (#8) will be used to tune the field current regulator. If (#20) is ON the measured
value at (#615) will be used.

Motor Armature Current Control

Specific adjustments – (#1), (#2), (#3), (#4), (#5), (#10), (#14), (#21), (#93), (#102)
Related Adjustments – (#19), (#20), (#40)

During normal operation the motor armature current will be proportional to the torque required to satisfy
the speed control regulator. When either the Up or Down (Forward or Reverse) logic inputs are
energized, and after motor field current has risen beyond the Full Field Detect threshold value set at
(#90), the motor armature motor contactor will be commanded to pull-in. Verification of the contactor
closure is via an auxiliary feedback contact through TB1(7). Motor armature current will then follow the
demands of the velocity regulator. If the Coast-to-Stop mode is selected (#40 = 1) motor armature
current will cease and the contactor will open immediately after the Up/Down inputs are released. This
will allow the motor to coast to a stop (or to dynamic brake if so equipped). If the selected Start-Stop
mode is other than Coast-to-Stop (#40 = 2, or 3), armature current will remain at the value necessary to
hold the load at zero speed after the speed regulator has reduced the speed to zero. When Load Float is
complete (if enabled) and the Brake has set (if enabled) motor armature current will ramp down to zero at
the rate set by Torque Decay Time (#93). When ramp down is complete, and Brake check is complete (if
enabled) the motor contactor will be opened.

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For proper operation of the armature current regulator, motor nameplate data should be entered at (#1),
(#2), (#3), and the drive input voltage at (#10). Enter maximum desired speed at (#13) even if it is the
same as (#3). Other important values required for current regulator stability are at (#4), (#5), (#14) and
(#21). If Use Self-Tune (#20) is OFF. the L and R values at (#4) and (#5) will be used to tune the
armature current regulator. If (#20) is ON the measured values at (#614, L) and (#613, R) will be used.
In most cases the default value for armature Current regulator Response (#21) should be used. If the
motor contactor fails to close or open as commanded, a Contactor Fault (F402) will be declared. For
large horsepower drives that use a slow acting contactor, set (#19) to be ON to allow for a 3 second delay
in contactor feedback action.

Motor armature current limit during regeneration (lowering or stopping a hoist load) will be as set by
Maximum Armature Current (#14). During motoring (accelerating or lifting a hoist load) the current limit
setting will be Maximum Armature Current (#14) divided by Regen Margin (#102). This ensures that the
hoist drive can always safely lower, stop or hold back what it can lift. Key motor armature variables may
be monitored at (#601), (#608), (#609), (#610), (#611).

Speed Control
Specific adjustments – (#12), (#15), (#16), (#22), (#23), (#24), (#26)
Related Adjustments – (#3), (#13), (#27), (#28), (#30), (#40), (#110)

The speed regulator used in the OMNIPULSE DSD is a Type 2 regulator. It will act to regulate encoder
pulse counts (position) and frequency rate (speed), or act to regulate motor armature voltage. During
normal operation drive speed will tightly track the commanded speed, including zero, with little or no
steady state speed or position error. If Coast-to-Stop or Ramp-to-Stop operating mode is selected (#40 =
1 or 4) the speed regulator will start with a zero armature current command. If either of the other speed
control modes are selected (#40 = 2 or 3), the speed error integrator may be pre-set with a specific pre-
torque armature current to prevent roll-back as the brake is released, and prevent releasing the brake
when pre-torque value is not achieved. Critical adjustments for good speed control, with Rated Speed
(#3), Encoder PPR (#12), and Armature Voltage @ Max Speed (#16) properly set to nameplate values,
are Bandwidth (#22), Per-Unit Inertia (#23) and Speed Stability (#24). Armature Voltage feedback is set
via Parameter #15 = OFF. It is only for applications that operate below base speed of the motor and
operate in the speed control modes of Coast-to-Stop, or Ramp-to-Stop. This is selected (#40 = 1 or 4).

Speed Reference Control

Specific adjustments – (#30 - #37), (#27), (#28)
Related Adjustments – (#3), (#13), (#92), (#110 - #113)

Speed Mode Select (#30) determines the source of speed reference commands. The status of logic input
commands at TB1(49 Up) and TB1(8 Down) will determine direction, and automatically select Speed Step
1 (#31). When other pre-set speeds are used, they must be selected in sequential order (1 --> 2 --> 3 --
>4 etc.) using external (programmable MFI) logic inputs, or the lowest numbered selection will prevail.
Not all speed steps need to be selected, and the actual speed setting values do not need to be in
progressive order. The actual speed step settings of (#31 – 37) are a percent of Rated RPM (#3). As
different speed steps are selected, the internal reference speed will ramp up or down at the pre-
programmed Accel (#27) or Decel (#28) rate.

If Speed Mode Select (#30) is set to 2, the speed reference will be from the analog input at TB1(68-63)
and internal speed steps will not be used (except for zero and Jog). The analog input will still be
conditioned by accel and decel rate controls. If Speed Mode Select (#30) is set to 3, the largest of either
the external analog or internal selected speed step will be used (except for zero and Jog).

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If Jog is enabled, Jog speed (#37) will be selected and will override any other selected speed step. If the
Inch mode is enabled, the selected speed step will become zero at the end of Inch Time (#92). Micro-
Speed and Ultra-Lift settings can also modify the internal speed reference. In all cases, the maximum
speed reference will be limited to the Absolute Maximum Speed setting (#13) or the calculated maximum
speed when Ultra-Lift is ON. The internal ramped speed reference can be monitored at (#600), with the
set target value at (#602).

Micro-Speed Operation
Specific adjustments – (#38), (#39)
Related Adjustments – (#30 - #37)

Micro-Speed may be engaged from an external logic (programmable MFI) input to cause the presently
selected speed reference to be multiplied by a fractional value Micro-Speed Gain 1 (#38) or Micro-Speed
Gain 2 (#39). This is useful to help position a load more precisely than can be accomplished at a higher
speed.

Ultra-Lift Operation
Specific adjustments – (#110), (#111), (#112), (#113), (#114)
Related Adjustments – (#13), (#14)

The Ultra-Lift operating mode allows a crane or hoist to move more quickly when lightly loaded. It does
so by weakening the motor field, which allows it to rotate faster without causing or requiring additional
motor voltage. Ultra-Lift is selectively enabled or disabled according to the value set in Ultra-Lift Mode
(#110). When enabled, and when the reference speed and measured speed are both greater than the
Ultra-Lift Threshold Speed (#111), and measured motor armature current (torque) is less than the Ultra-
Lift Maximum Current threshold (#113), a maximum safe operating speed will be calculated. The
calculation accounts for additional armature current that may be necessary to control the load with
weakened field strength and present settings for Current Limit (#14). The calculated speed may be less
than but never greater than Ultra-Lift Maximum Speed (#112) or Absolute Maximum Speed (#13). If the
qualification conditions continue to exist for Ultra-Lift Check Time (#114), Ultra-Lift will be engaged. The
internal reference speed will be switched to the pre-calculated Ultra-Lift speed. As motor speed
increases beyond Rated RPM (#3), automatic motor field weakening may take place as previously
described. When the selected speed is reduced below the Ultra-Lift Threshold Speed (#111) Ultra-Lift
Speed mode will be turned OFF and normal deceleration to a lower speed will begin. As rotational RPM
reduces toward Rated RPM (#3), motor field current will gradually increase to again be at Rated Field
Amps (#6).

Coast To Stop Operation

Related Adjustments – (#40), (#27)

The default drive Starting and Stopping mode is Coast To Stop. (Function #40 = 1) In this mode, the
drive acceleration rate will be controlled by (#27), but when Up and Down logic inputs are removed motor
torque will immediately cease. This will allow or cause the motor to coast to a stop. The motor contactor
will open as soon as current ramp-down is complete. The drive will then use dynamic braking, if so
equipped. Any machine Brake logic output will also be deactivated at this time. This mode is useful for
machine operations where no slow-down braking action is required.

If a multi-function input is programmed to be either an External Fault or External Stop function, the
activation of that input will cause the drive to perform a Coast To Stop.

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Ramp To Stop Operation
Related Adjustments- (#40), (#27), (#28)

Setting Start-Stop Mode control (#40) to a 4 programs the drive for a ramp to stop. In this mode the drive
acceleration rate will be controlled by (#27), and the deceleration rate will be controlled by (#28). When
Up and Down logic inputs are removed. The drive will decelerate to zero speed. The motor contactor will
open as soon as zero speed is reached. Any machine Brake logic output will also be deactivated at this
time. This mode is useful for applications that require the motor to be at zero speed prior to setting the
brake.

Automatic Brake Control and Load Float Sequencing

Specific adjustments – (#40 – #50), (#91)
Related Adjustments – (#27), (#28), (#71 - #79 Logic Input selects), (#81- #87, Logic Output selects),
(#93)

Setting Start-Stop Mode control (#40) to 2 or 3 turns automatic brake control sequencing ON. Mode =2 is
Brake sequencing. Mode =3 is for Brake sequencing with Brake switch answer-back.

The drive Start sequence will be:

1) A logic Up or Down command input will cause the drive field and armature circuits to start as
previously described. However, pre-torque will be activated to start with motor armature current at
the last known current, or at other minimum pre-set values (see “Starting Torque” explanation below).
2) The Brake output will be energized when 1) is satisfied and it is determined that motor field and motor
armature current are indeed at the expected current (Torque Proving) in IFBK OK Time (#50) or Pre-
Torque Fault, F413, will be declared.
3) When Brake Release Time (#41) expires, and/or Brake Answer-Back is received (if enabled) the
internal speed reference will be released to begin ramping toward speed 1 (or other speed if
enabled). If Answer-Back is turned ON, the Answer-Back signal must be received before Answer-
Back Time (#44) or an Answer-Back fault, F403, will be declared.
4) A Brake Release Timer (#47) will be started. During Brake Release Time (#47) seconds, encoder
motion will be measured to determine when the load actually moves, as proof that the brake has
indeed released. If encoder movement is less than Brake Release Movement (#48) before time (#47)
expires, a Brake Release Fault (F410) will be declared and the unit will shut down.
5) If all of the above occur in the proper sequence the drive will be accelerated toward the selected
speed. If a Brake Hold Fault (F401) exists, speed in the Up direction will be limited to Brake Fault
Speed (#49).

The drive Stop sequence will be:

1) The Up or Down logic input command is released. The drive will decelerate to zero speed.
2) With the speed reference at zero and when zero speed is detected by Threshold (#91), Load Float
time (#43) will begin. The drive will continue to hold the load at zero speed.
3) When Load Float time (#43) expires, the Brake coil output will be de-energized. Two timers will be
started and the drive will continue to hold the load during Brake Set time (#42) and Brake Slip Time
(#45). [A third timer, Brake Answer-back check, will also expect that the answer-back contact will be
correct within Answer-back Time (#44) seconds, or an F403 fault will be declared.]
4) After Brake Set timer (#42) expires, motor armature current (torque) will ramp to zero according to
torque Decay Time (#93). Any encoder movement will be recorded during Brake Slip Time (#45).
Encoder movement may be displayed at (#620).
5) If total encoder movement during Brake Slip Time (#45) is less than Max Brake Slip (#46) the Brake
will be considered to be holding the load correctly. The drive will continue to shut down by opening
the motor contactor and setting motor field current to Stand-By current (#17).

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6) If total encoder movement during time Brake Slip Time (#45) exceeds the setting of Max Brake Slip
(#46) the Brake will be considered faulty. A Brake Hold Fault (F401) will be declared. The Load Float
mode will be immediately re-started, with armature current at the torque previously established as
that necessary to hold the load. During the Load Float re-start process, a Brake Release fault (F410)
will be blocked from preventing the drive to re-start. The drive will remain indefinitely in Load Float
mode with F401 showing on the display until a new Up or Down logic input command is received.
Brake Hold Fault Relay outputs will be energized by F401 if so programmed (example: function #84
default setting for K7 relay = 14).
7) If a new Up or Down command is received when a Brake Hold Fault (F401) is active, the drive will
terminate Load Float and begin to accelerate, but speed will be limited to Brake Fault-Speed (#49) in
the Up direction. When the Up or Down command is release, a new Load Float cycle will be started.
The Brake Hold Fault (F401) will be cleared, de-energizing the Brake Hold Fault Relay output and
releasing the restriction of speed in the Up direction only if a new Brake Hold test is successful.

One can obtain Controlled Stop operation with or without a mechanical load brake by setting Load Float
Time (#43) to zero. Setting Brake Release, Set, Release Test, or Slip Test times (#41), (#42), (#47), or
(#45) also to zero, will simply eliminate any operating delay associated with either of those features.

Starting Torque
Specific adjustments – (#100), (#101), (#103)
Related Adjustments – (#14), (#30), (#102)
When Start-Stop Mode (#40) is set to 1, the drive will always start with zero armature current. When
Start-Stop Mode (#40) is set to 2 or 3, pre-torque is turned ON. Each time the drive is started the
minimum armature current at start-up will be largest of Initial Starting Torque (#100) or Minimum Starting
Torque (#101), or the last torque measured when the drive was in Load Float. If armature current does
not equal the pre-torque reference a Pre-torque Fault, F413 will be declared. The maximum starting
torque in the down direction is limited by, Down Start Current Limit (#103) until the Brake is confirmed to
be lifted. Motoring torque is always limited to less than the number defined by Maximum Armature
Current (#14) divided by Regen Margin (#102).

During acceleration or deceleration, bumping into either armature current limiting or calculated rated
motor CEMF will cause a temporary pause in speed reference ramping. This purposely slows down the
rate of acceleration in order to prevent regulator wind-up. Further acceleration will not continue unless
the maximum voltage or current conditions are relieved by this action.

Analog Input References

Specific adjustments – (#51), (#52), (#53), (#55), (#57), (#58)
Related Adjustments – (#30), (#104), (#668), (#676)

Two differential analog input channels are available: TB1(68-63) for a speed reference and TB1(76-71)
for armature current (torque). The drive hardware will accommodate +/-10V range on both channels.
However, the active range may be limited to be uni-polar only by setting Bi-polar Enable selects (#51) or
(#55) to zero. Separate Bias and Gain adjustments are provided at (#52), (#53), and (#57), (#58) for
each channel. One can read the resulting reference values at (#668) and (#676). Setting the gains of
(#53) or (#58) to zero will avoid any signal interference if these inputs are not used.

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Torque Follower Regulator
Specific adjustments – (#104)
Related Adjustments – (#55), (#57), (#58)

An analog signal input at terminals TB1(76 – 71) may be used as a torque command. The internal speed
reference will be trimmed to yield more (or less) motor armature current as requested by the external
signal. This feature is useful for load sharing between two or more units. Conditioning of the external
signal is via adjustments Bi-Polar Enable (#55), Bias (57) and Gain (#58). The resulting torque reference
may be viewed at (#676). Gain of the torque regulator [the amount of speed trim per torque error] is
adjusted at Torque Regulator Gain (#104).

Limit Switch Operations

Specific adjustments – Selections for (#71 – 79)

One or more multi-function inputs may be programmed to work with external Slow or Stop limit switches
in either the Up or Down direction.

When either an Up-Slow or Down-Slow logic input becomes active, the internal selected speed will be
that of Speed 1 (#31) for that particular direction. The drive will decelerate to that speed at the
Deceleration Time rate set at (#28). The drive will be allowed to move in the opposite direction at any
other selected speed.

An active Down Stop limit logic input will cause the drive to decelerate to zero speed at the Deceleration
Time rate set at (#28). The drive will be allowed to move Up at any other selected speed.

An active Up Stop limit logic input condition AND a valid UP command will cause the drive to immediately
call for zero speed with an internal Load Float time of zero. There will be no timed ramp-down of speed
during the deceleration. The brake will set when the drive comes to a halt if programmed to do so. This
will cause the hoist to stop moving Up as fast as possible. The drive torque may hit current limit (#14)
during the stopping process.

If a multi-function input is programmed to be either an External Fault or External Stop function, the
activation of that input will cause the drive to perform a Coast To Stop. An External Fault event will be
latched and will require an External Reset command to be cleared. An External Stop command is not
latched and will recover as soon as the External Stop input command is removed.

Diagnostic Indicators
The following status lights are visible on the front panel of the drive:

READY – Green. Indicates that the drive is ready to run when told to do so.
RUN – Green. Indicates that the drive is in the Run state with motor contactor closed.
TORQUE LIMIT – Yellow. Indicates that current reference is being limited. This light will also blink at 2
Hz if the drive is limiting speed due to excessive motor voltage or CEMF.
OVERLOAD – Yellow. Indicates that drive current reference is in the overload region or that the motor
overload has tripped.
E-STOP – Red. Indicates that the E-Stop control line is open such that the contactor cannot be closed.
FAULT – Red. Indicates that a drive Fault condition exists.

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Alarm Outputs
Related Adjustments –
Logic Output selects (#81 – #87)

Alarms indicate warnings of important impending malfunction conditions, but will not automatically shut
down the drive. Two separate alarm functions may be steered to activate any of the programmable logic
output lines. Alarm-1 is activated by Drive Thermistor/thermostat, Drive Over-Temperature, Motor Klixon,
or Motor Over-Load failure or fault conditions. Alarm-2 functions are individually selectable and TBD.

Drive Commissioning and Start-up Procedure

It is important to follow common sense procedures to install and commission OMNIPULSE DSD drives.
The following sequence should be followed to calibrate and initialize the equipment before attempting to
operate on a live crane. Failure to do so may result in safety risks for personnel and/or damage to
equipment. The basic procedure steps are:
1) If the motor is presently being used with an older controller or m-g set, measure and record the DC
volts and amps being supplied to the motor field as it is used with older controllers. Also record
typical armature volts and amps as it is being used. This will yield important set-up data that is not
likely to be available from the motor nameplate.
2) If the motor was previously used with an older controller or m-g set, inspect and service it before
attempting to operate it from the OMNIPULSE DSD controller. High-pot the motor field and armature
circuits to at least 600 VAC from motor leads to frame for 2 minutes to verify the quality of motor
insulation. Inspect and clean the motor commutator. Replace and adjust worn brushes. If there is
any question about the integrity of motor insulation, have the motor re-worked.
3) Ensure that the speed feedback encoder is mounted to be electrically isolated from the motor shaft
and frame. Ensure that the coupling is tight and correctly aligned.
4) Verify that motor field wires at TB4 on the drive are connected to the proper ampere range tap. Verify
that SW1 on PCB A3 is set to correspond to the ampere range tap being used.
5) Turn control power to the drive ON and enter in pertinent motor nameplate and site application data
for parameters #1 – 19. SAVE the data to NV-RAM. [See section 3.6]
6) Enter in other site set-up data corresponding to multi-function input and output use requirements and
necessary set point adjustments. Be sure to enable controlled stop at (#40) if it is expected to stop
the drive. Temporarily set Absolute Max RPM (#13) to Rated Motor RPM (#3). SAVE the data to NV-
RAM.
7) Turn control power OFF. Turn control and mains power ON. Verify that the READY light comes ON
after several seconds.
8) Use a separate DC clamp-on ammeter to verify that measured DC current to the motor field
corresponds to what the drive reports at #612. [Should be at Stand-by amps after power-up.]
9) Bypass the E-Stop circuit and perform Self-Diagnostics, F998. Should PASS. [See section 3.9]
Block motor armature or disable the mechanical brake so that it will not lift and perform Self-Tune,
F997. [See section 3.8. Only a small amount of torque will be produced, but the motor armature
should not be permitted to rotate during the test.] Review Self-Tune data at #613, #614, & #615. If
the data is reasonable set #20 ON. SAVE the data to NV-RAM. Remove the E-Stop jumper.
10) Enable the drive E-Stop circuit and Select UP. Verify that:
a) Measured motor field current at #612 goes to Rated Amps;
b) The drive contactor does pull in;
c) The motor does indeed rotate in the proper direction at pre-set speed 1.
d) Resolve any problems before continuing.
11) Verify Down direction and other speed selections using a procedure similar to step 10.
12) If there is noticeable overshoot or undershoot, adjust speed regulator tuning.
13) If equipped with machine Brake, verify and adjust automatic Brake controls.
14) If equipped with Ultra-Lift, adjust and verify operation. Set Max RPM (#13) to the desired maximum
operating speed or increase in incremental steps to verify proper operation. Read motor armature
CEMF (#609) and/or motor armature voltage (#610) at high speed. Adjust Motor Weak Field Current
(#9) to yield the same CEMF at all speeds above Rated RPM (#3).

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Parameter Function Descriptions

Rated Arm Volts Function #1

Units: VDC Range: 150. – 550.
Default: 240
This entry sets the motor nameplate full load, full speed voltage required by the motor used with
the drive. It should agree with the motor nameplate data.
Rated Arm Amps Function #2
Units: ADC Range: 2.0 - 1250.0
Default: 26.0
This entry is specified by the motor nameplate amps for the motor used with the drive.

Rated Motor RPM Function #3

Units: RPM Range: 50.0 – 1999.0
Default: 1750
This entry calibrates motor speed. The motor RPM X Encoder PPR is what will actually be speed
regulated. When a speed reference is set at 100%, the motor will rotate at this RPM.

Manual Armature Inductance Function #4

Units: HNY Range: 0.001 – 1.000
Default: 0.01
This is the value of the motor circuit inductance used to manually tune the armature current
regulator. The value to be entered is best measured by monitoring F614 - Measured Motor
Circuit Inductance, after the SELF-TUNE function has been completed. This value is used to
calculate armature current regulator gains.

Manual Armature Resistance Function #5

Units: OHM Range: 0.001 – 5.000
Default: 0.1
The total armature circuit resistance. The value to be entered is best measured by monitoring
F613, measured circuit resistance after the SELF-TUNE function has been completed. This
value is used to calculate armature current regulator gains and to calculate motor CEMF.

Rated Field Current Function #6

Units: ADC Range: 0.20 – 40.00
Default: 2.00
This is the motor field current amperes the drive should provide when starting and at low speed.
It should agree with Rated Motor Field Current according to the motor nameplate.

Rated Field Volts Function #7

Units: VDC Range: 50 – 525
Default: 240
This is the Rated Field Voltage necessary to produce Full field amps (#6) per the motor
nameplate. It is used to calculate motor field circuit resistance and determine motor field current
regulator gains. Improper adjustment can affect stability.

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Manual Field L/R Function #8
Units: SEC Range: 0.10 – 10.00
Default: 0.54
This is the Motor Field time constant, L/R. It is an important value to determine motor field
current regulator gains. The value to be entered is best measured by monitoring F615 -
Measured Field L/R Time Constant, after the SELF-TUNE function has been completed

Weak Field Current Function #9

Units: AMP Range: 0.1 – 40
Default: 30
This entry calibrates motor field weakening and CEMF at high motor speed. Set this value to the
motor field amperes required at maximum speed (#13). Read and verify CEMF at (#609) and
Armature Volts (#610) at maximum speed. Adjust (#9) accordingly to not exceed motor voltage
ratings. Weak field current (#9) may be set larger than Rated Field Current if field weakening is
not used as motor field current will never exceed (#6) amperes.

Nom AC Voltage Function #10

Units: VAC Range: 150. – 525.
Default: 480
This entry sets the nominal AC line to line voltage applied to the drive from the utility input or
secondary of the isolation transformer. This value should agree with the nominal utility value. It
sets the Low Line and Excessive CEMF detection thresholds.
Field Source Volts AC Function #11
Units: VAC Range 0. – 525.
Default: 0.
This is the single phase AC voltage used to power the Field Rectifier module. The factory default
value of zero will let the drive automatically select the same value as supplied for the motor
armature circuit as set by (#10). This conforms to factory supplied wiring. If an external
transformer is used to supply a different voltage to power the motor field circuit, set this value to
the nominal VAC provided.

Encoder Pulses/Rev. Function #12

Units: P/R Range: 600. – 19,999.
Default: 1024.
This entry sets the per channel pulses per revolution per the encoder nameplate.

Absolute Max RPM Function #13

Units: RPM Range: 50 – 3,000
Default: 1750
This defines the maximum allowable motor RPM. The internal reference speed will be limited to
not exceed this number in any operating mode.

Maximum Armature Current Function #14

Units: % Range: 0 – 300
Default: 250
This entry defines the maximum motor armature current as a percent of Rated Motor Amps (#2).
The current limit during regeneration will be set to this value. Armature current during motoring
will be limited as defined at (#102).

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Encoder Feedback On Function #15
Units: Logic Range: 0 (Off) – 1 (On)
Default: 0 (OFF)
This entry selects the source of speed feedback. When this Parameter is programmed to 1 (On)
the speed regulator will use the motor encoder pulses to regulate motor speed. When
programmed to 0 (Off) the OMNIPULSE DSD speed regulator will use armature voltage feedback
to regulate speed. Armature Voltage feedback is only for applications that operate below base
speed of the motor. It will operate only in the start stop modes of Coast-to-Stop, or Ramp-to-Stop.

Armature Voltage @ Max Speed Function #16

Units: VDC Range: 150 – 550
Default: 500
This entry is used to calibrate the drives speed regulator when controlling the OMNIPULSE DSD
in Armature Voltage feedback mode.

Standby Field Current Function #17

Units: % Range: 10 - 100
Default: 25
This is the field current in percent of (#6) amperes that the drive should provide when the system
is at rest (i.e. stopped with no Run command).
Field Regulator Response Function #18
Units: RAD Range: 1.0 – 10.0
Default: 5.0
This input defines the desired motor field current regulator bandwidth in radians per second.
3 Second Motor Contactor Fault Function #19
Units: Logic Range: 0 (Off) – 1 (On)
Default: 0 (Off)
This Parameter selects the detection time for motor contactor faults. These occur when the
contactor acknowledge feedback contact fails to open or close according to the commanded state
of the contactor coil driver. Small contactors should operate within 450 milliseconds and should
use the default value, 0, or OFF. If large contactors are used with large hp drives, set this value
to ON to yield a 3 second fault detection time.
Use Self Tune Function #20
Units: Logic Range: 0 (Off) – 1 (On)
Default: 0 (OFF)
This entry selects the source of critical numeric value adjustments for tuning the motor armature
current regulator. Values for motor resistance, R, motor inductance, L, and motor field time
constant L/R may come from either manually entered values or automatically determined by a
self-tune measurement. With (#20) set to 0, OFF, the settings of (#4), (#5), and (#8) will be used.
With (#20) set to 1, ON, the values determined by self-tuning and held at display locations (#613),
(#614), and (#615) will be automatically used.
Note: Setting this Parameter to a 1 will not change the values stored in (#4), (#5), or (#8).

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Arm Current Resp. Function #21
Units: RAD Range: 100. – 750.
Default: 250.
This entry sets the band width of the current regulator in radians. The nominal setting for this
entry for most cases would be 250 radians. The responsiveness of the armature current
regulator will increase as this number increases. If this number is too large, the motor current
may fluctuate. If this number is too small, the motor response may become sluggish.

Speed Reg Resp. Function #22

Units: RAD Range: 1.0 – 10.0
Default: 4.0
This entry sets the closed loop bandwidth response of the speed regulator. Increasing the value
of Parameter #22 will make the drive more responsive, but may also cause unwanted
amplification of mechanical vibration.

Sys PU Inertia Function #23

Units: SEC Range: 0.25 – 15.00
Default: 2.00
This value is the ratio of the effective inertia of the moving equipment mass to the rated torque
strength of the motor. The units, seconds, would be the time it would take to accelerate the
system inertia to rated speed using rated motor amps. This value affects the feed-forward gain of
the speed regulator and affects how well it will follow a changing reference speed and variations
in load.
Speed Stability Function #24
Units: — Range: 1.0 – 10.0
Default: 2.0
This setting affects the proportional gain and Phase Margin of the regulator. Decreasing this
setting will make the regulator more responsive to correct mechanical load speed variances, but
can cause it to amplify unwanted mechanical disturbances. Increasing the setting value will
provide smoother operation but at the expense of time-delayed reaction to speed errors.

Position Damping Function #26

Units: - Range: 0.5 – 10.00
Default: 2.00
This value adjusts damping of the second integrator that helps regulate position during Load
Float.

Acceleration Time Function #27

Units: SEC Range: 0.5 – 15.0
Default: 5.00
Total acceleration time in seconds for a change in speed from zero to Rated Speed (#3). All
changes to an increase in speed will be limited to this rate of change setting.

Deceleration Time Function #28

Units: SEC Range: 0.5 – 15.0
Default: 3.00
Total deceleration time in seconds for a change in speed from Rated Speed (#3) to zero. All
changes to a decrease in speed will be limited to this rate of change setting.

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Analog Source Select Function #29
Units: Number Range: 0 - 1
Default: 0
This Parameter allows the user to select the source of the analog reference signals.
Setting this value to 0 (default) enables the analog speed and torque command to follow the
corresponding analog input references.
Setting this value to 1 enables the analog speed and torque command to follow the
corresponding Modbus register references.

Speed Mode Select Function #30

Units: Number Range: 1 - 3
Default: 1
This Parameter allows the user to select the source of the speed reference signal.
 Multi-Step
Setting this value to 1 (default) enables the drive to follow only digital Pre-set Speeds defined
via Parameters #31 – #36 as selected by logic input commands. The direction of travel will be
supplied by the Up/Down logic input commands.
 Analog Only
Setting this value to 2 enables the drive to follow only the magnitude of the external analog
reference. The direction of travel will be supplied by the Up/Down logic input commands. A logic
command to Jog will temporarily override the analog reference selection.
 Higher Reference
Setting this value to 3 enables the drive to follow the either the selected pre-set speed value or
the analog reference input value, whichever is greater. A logic command to Jog will temporarily
override either the analog or pre-set speed reference selection.

Preset Speeds Functions #31 - 37

Units: % [of Rated RPM (#3)]
Range:
#31, speed 1: 0 – 50, Default: 10
#32, speed 2: 0 – 150, Default: 20
#33, speed 3: 0 – 150, Default: 30
#34, speed 4: 0 – 150, Default: 40
#35, speed 5: 0 – 150, Default: 50
#36, speed 6: 0 – 150, Default: 60
#37, Jog speed: 0 – 10, Default: 5
Seven digital pre-set speed settings are available. Pre-set speed 1 (#31) is automatically
selected when an Up or Down input command is active. Pre-set speeds 2 – 6 (#32-#36) are
selected in a progressive manner with the activation of additional logic input commands. Not all
of the pre-set speeds need to be used, but if selected out of sequence the lowest numbered
speed in sequence will be engaged. An external analog speed command or Ultra-Lift mode may
override any pre-set speed, when enabled. Pre-set speed #37 is used for Jog. Selecting Jog will
override any other speed selection.

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Micro-Speed 1 Gain Function #38
Units: PU Range: 0.00 – 1.00
Default: 1.00
Micro-Speed may be used to operate the drive at a slow speed for accurate load positioning.
When Micro-Speed 1 is activated by an external logic command, the internal speed reference will
be multiplied by this value.

Micro-Speed 2 Gain Function #39

Units: PU Range: 0.00 – 1.00
Default: 1.00
Micro-Speed may be used to operate the drive at a slow speed for accurate load positioning.
When Micro-Speed 2 is activated by an external logic command, the internal speed reference will
be multiplied by this value. Micro-Speed 2 will take priority over Micro-Speed 1.

Start-Stop Mode Function #40

Units: Numeric selectionRange: 1 – 4
Default: 1
This Parameter selects the operating mode for starting and stopping.
 Coast to Stop
Setting this value to 1 causes the drive to have controlled acceleration via (#27), but motor
torque will immediately cease when Up and Down logic inputs are disabled, allowing the motor to
coast to a stop. This mode is useful for machine operations where no slow-down braking action
is required. An external Brake may be controlled in this mode if programmed to a logic output.
Brake timing Parameters (#41), (#42), (#43) (#44), (#47) and (#48) are still active.
 NLB Hoist
Setting this value to 2 will activate a controlled stop mode of operation for no load brake hoists,
with or without coordinated brake control, as other variables are programmed. Acceleration will
be controlled on a start via (#27), after external brake release and confirmation according to
settings for (#41), (#47), and (#48). When Up and Down logic input commands are released, the
drive will decelerate to zero speed at the rate established by (#28). When zero speed is achieved
according to (#91), the control will go into Load Float for time (#43). At the end of Load Float time
the Brake control output will be de-energized (if used) and the brake will be checked according to
settings of (#42), (#45) and (#46). When Brake Slip check time (#45) is successfully completed,
the motor armature motor contactor will be de-energized.
If no Brake action is required, set (#41), (#42), (#43), (#45), and (#47) to zero.
 NLB Hoist with Answer Back
Setting this value to 3 will activate a controlled stop mode of operation as described above for
no load brake hoists, with coordinated brake control, AND the use of an answer-back contact on
the Brake. The correct answer-back response must be received by time (#44) when the brake is
energized or de-energized.
 Ramp to Stop
Setting this value to 4 causes the drive to have controlled acceleration via (#27), and the
deceleration rate will be controlled by (#28). When Up and Down logic inputs are removed, the
drive will decelerate to zero speed. The motor contactor will open as soon as zero speed is
reached. Any machine brake logic output will also be deactivated at this time. This mode is
useful for applications that require the motor to be at zero speed prior to setting the brake.

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Brake Release Timer Function #41
Units: SEC Range: 0.0 – 2.55 Seconds
Default: 0.7
Allows time for the Brake to physically release before allowing the internal speed reference to
move away from zero on a drive start. This reduces wear on brake pads during a start.

Brake Set Timer Function #42

Units: SEC Range: 0.0 – 2.55 Seconds
Default: 0.7
Allows time for the drive to continue to hold the load while the brake is being de-energized and
set.

Load Float Time Function #43

Units: SEC Range 0 – 255 Seconds
Default: 10
Programs the Load Float time. Load Float, where the drive holds the load at zero speed with
brake released, will start after the drive decelerates to zero speed according to the setting of
(#91). Re-energizing either the Up or Down logic command while in Load Float will cause the
drive to move the load and reset the Load Float timer. Load Float will NOT occur if (#40) is set to
1.

Answer-Back Time Function #44

Units: SEC Range 0.0 – 2.55 Seconds
Default: 0.7
Programs the maximum time allowed for the Brake Answer-back contact to confirm that the Brake
has indeed released or set as directed by the Brake actuation output. If the answer-back contact
does not agree with the status of the Brake control output for longer than (#44) seconds, a Brake
Answer-Back Fault, F403, will be declared. [Exception- Brake Answer-back will be ignored in the
event of a Brake Hold Fault, F401.]

Brake Slip Timer Function #45

Units: SEC Range 0.0 – 25.5 Seconds
Default: 5.0
Programs the time that brake slip will be checked after the brake has been told to set. This timer
is independent of and will run concurrently with Brake Set Time (#42). The Brake Slip timer is de-
activated in the Coast to Stop mode, (#40) set to 1.

Maximum Brake Slip Function #46

Units: encoder counts Range 0 – 16536
Default: 250
Programs the limit of brake slippage allowed during time (#45). If the measured accumulation of
encoder movement during time (#45) exceeds the setting of (#46), a Brake Hold Fault, F401 will
be declared. Load Float will then be turned back ON and held until a run Up or Down logic input
is received.

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Brake Release Check Time Function #47
Units: SEC Range 0 – 2.55 Seconds
Default: 0.5
Time that the encoder counts will be monitored to determine when the brake actually releases.
Status of the brake will be determined to be released after Brake Release Time (#41) has expired
AND if/when accumulated encoder movement exceeds (#48) counts. If the accumulated encoder
movement is less than (#48) counts at the end of (#47) seconds, a Brake Release Fault, F410,
will be declared. If brake answer-back is turned ON [(#40) set to 3] the Brake Release Check
Timer will not start until brake answer-back has also occurred.

Brake Release Movement Function #48

Units: encoder counts Range 0 – 16536
Default: 50
Programs the net movement, in encoder counts, to accumulate to determine when the brake
actually releases. Status of the brake will be determined to be released after Brake Release
Time (#41) has expired AND if/when accumulated encoder movement exceeds (#48) counts. If
the accumulated encoder movement is less than (#48) counts at the end of (#47) seconds, a
Brake Release Fault, F410, will be declared.
Brake Fault Speed Function #49
Units: % Range: 0 – 150
Default: 10.0
If a Brake Hold Fault (F401) occurs, the reference speed in the Up direction will be limited to this
value until the fault is reset.
IFBK OK Timer Function #50
Units: SEC Range 0.00 – 2.55 Seconds
Default: 1.5
Sets the amount of time to look for the Armature Current to be OK before posting a Pre-torque
Fault, F413. Enabled when Start-Stop Mode, F40 = 2 or 3 only. Setting this Parameter to 0.00 will
disable torque proving at start.

Bipolar Anlg Input T68 Function # 51

Units: Logic Range: 0 (OFF) – 1 (ON)
Default: 0 (OFF)
This enables or disables a bi-polar (+/-10V) analog input signal at terminals TB1(68-63) to be
used as an external analog speed reference.
If set to 0 (OFF), the external signal will be truncated to have an effective value between 0 and
+10V, AFTER the bias (#52) is added
If set to 1 (ON), the effective value will retain the polarity sign of the +/-10V input signal AFTER
the bias (#52) is added. This allows a bi-polar signal to control direction as well as speed.
Analog In T68 Bias Function # 52
Units: PU Range: +/-2.00
Default: 0.0
This entry is an offset bias to apply to the external analog signal from TB1(68-63).

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Analog In T68 Gain Function # 53
Units: PU Range: 0 – 2.00
Default: 1.0
This entry is a multiplier gain to apply to the analog signal from TB1(68-63) AFTER the offset bias
(#52). The resulting signal may be viewed at (#668). The resulting value may be used as a per
unit speed command from an external analog signal if enabled at (#30).

Bipolar Anlg Input T76 Function # 55

Units: Logic Range: 0 (OFF) – 1 (ON)
Default: 0 (OFF)
This enables or disables a bi-polar (+/-10V) analog input signal at terminals TB1(76-71) to be
used as an external analog torque reference.
If set to 0 (OFF), the external signal will be truncated to have an effective value between 0 and
+10V, AFTER the bias (#57) is added
If set to 1 (ON), the effective value will retain the polarity sign of the +/-10V input signal AFTER
the bias (#57) is added. This allows a bi-polar signal to control dictated torque direction as well
as magnitude.
Analog In T76 Bias Function # 57
Units: PU Range: +/-2.00
Default: 0.0
This entry is an offset bias to apply to the external analog signal from TB1(76-71).
Analog In T76 Gain Function # 58
Units: % Range: 0 – 2.00
Default: 1.0
This entry is a multiplier gain to apply to the analog signal from TB1(76-71) AFTER the offset bias
(#57). The resulting signal may be viewed at (#676). The resulting value may be used as a per
unit torque command from an external analog signal.
Analog Output 45 Function Function #60
Units: Numeric selection Range: 0 – 6
Default: 1 (Raw Speed Command)
This entry steers a specific internal signal toward the analog output at TB1(45). Selections are:
0 = Trace Buffer 0
1 = Raw Speed Command
2 = Ramped Speed command
3 = Encoder Feedback
4 = Armature Current Reference
5 = Measured Armature Current
6 = Measured Armature Voltage
7 = Field current Reference
8 = Measured Field Current
Analog Out 45 Bias Function # 61
Units: PU Range: +/-1.00
Default: 0.0
This entry is an offset bias to apply to the analog output signal selected by (#60) to be at TB1(45).

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Analog Out 45 Gain Function # 62
Units: PU Range: 0.0 – 10.0
Default: 0.80
This entry sets the specific multiplier value for the selected analog output signal to TB1(45)
AFTER offset (#62). The output channel is restricted between +/-10V. A value of 0.8 will set 8.0
volts of output for a 1 per unit signal, with some headroom to show over-scale conditions.
Analog Output 46 Function Function #65
Units: Numeric selection Range: 0 – 6
Default: 3 (Encoder Feedback)
This entry steers a specific internal signal toward the analog output at TB1(46). Selections are:
0 = Trace Buffer 1
1 = Raw Speed Command
2 = Ramped Speed command
3 = Encoder Feedback
4 = Armature Current Reference
5 = Measured Armature Current
6 = Measured Armature Voltage
7 = Field current Reference
8 = Measured Field Current
Analog Out 46 Bias Function # 66
Units: PU Range: +/-1.00
Default: 0.0
This entry is an offset bias to apply to the analog output signal selected by (#65) to be at TB1(46).

Analog Out 46 Gain Function # 67

Units: PU Range: 0.0 – 10.0
Default: 0.80
This entry sets the specific multiplier value for the selected analog output signal to TB1(46)
AFTER offset (#66). The output channel is restricted between +/-10V. A value of 0.8 will set 8.0
volts of output for a 1 per unit signal, with some headroom to show over-scale conditions.
Multi-Function Input Selects Functions #71 - 79
Units: Numeric Logic Selection
Range: 0 - 25
These entries program individual logic input terminals on TB1 to perform particular logical input
control functions. The correlation of parameter number to TB1 input terminal is as follows:
#71 – TB1(9), default = 1
#72 – TB1(10) default = 2
#73 – TB1(11) default = 3
#74 – TB1(12) default = 4
#75 – TB1(50) default = 5
#76 – TB1(51) default = 21
#77 – TB1(52) default = 0
#78 – TB1(53) default = 0
#79 – TB1(54) default = 14

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Any MFI logic terminal may be mapped to provide an input function as listed below. CAUTION -
More than one terminal may be mapped to the same function. If so, they will operate as if logical
OR’ed together. The logic selections are:
0 = None, Not Used
1 = Pre-Set Speed 2 Select
2 = Pre-Set Speed 3 Select
3 = Pre-Set Speed 4 Select
4 = Pre-Set Speed 5 Select
5 = Pre-Set Speed 6 Select
6 = Up Slow Limit Sw N/O
7 = Up Stop Limit Sw N/O
8 = Dn Slow Limit Sw N/O
9 = Dn Stop Limit Sw N/O
10 = Up Slow Limit Sw N/C
11 = Up Stop Limit Sw N/C
12 = Dn Slow Limit Sw N/C
13 = Dn Stop Limit Sw N/C
14 = Micro-Speed #1 Enable
15 = Micro-Speed #2 Enable
16 = Ultra-Lift Enable
17 = External Fault N/O
18 = External Fault N/C
19 = External Stop N/O
20 = External Stop N/C
21 = Fault Reset N/O
22 = Fault Reset N/C
23 = Brake answer-Back Sw
24 = Jog Enable
25 = Inch Enable

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Multi-Function Output Selects Functions #81 - 87
Units: Numeric Logic Selection Range: 1 – 14
Defaults: See listing below
These entries program individual logic output terminals on TB1 to perform particular output
control and status indicator functions. The Kxx label/name of the variable as displayed on the
PCDU display indicates the relay reference shown on the connection diagram. Any logic output
terminal may be mapped to provide any function as listed below. More than one terminal may be
mapped to the same function. The logic selections are:
1 = Brake Hold Fault
2 = Brake Release Control
3 = Drive READY
4 = Drive is RUNNING
5 = Drive in Torque Limit
6 = Moving Up/Fwd
7 = Moving Down/Rev
8 = At Zero Speed
9 = Ultra-Lift engaged
10 = Up Limit (Slow or Stop)
11 = Down Limit (Slow or Stop)
12 = Up or Down Limit
13 = Alarm-1 [Thermistor Fail, Over-Temp, Motor Thst, Motor Over-Load]
14 = Drive FAULT

Factory default settings are as shown below:

Param # Relay,TB1(term) Data, Function
#81 K1, (40-42) 14, Drive Fault
#82 K2, (38-39) 2, Brake Output
#83 K3, (36-37) 2, Brake Output
#84 K4, (78) 12, Up or Dn Limit
#85 K5, (79) 13, Alarm-1
#86 K6, (83) 4, Drive Running
#87 K7, (84) 1, Brake Hold Fault
Full Field Detect Function #90
Units: % Range: 50. – 95.
Default: 90.
Determines the threshold of sensing when motor field current has risen close to Rated amps to
ensure that the drive can produce required load torque. The motor field must be above (#90)
percent of (#6) amps for internal logic to recognize that the motor field current is nearly up to the
full field value. Motor field current must be above this value before the drive will be allowed to
start. The drive will wait for motor field to rise above this value before energizing the motor
contactor.
Zero Speed threshold Function #91
Units: % Range: 0.01 – 5.00 [of Rated speed (#3)]
Default: 0.1
Defines the zero speed threshold for detection of motion via encoder measurement. It controls
the Moving-Up/Down, & Zero Speed detector output signals, and determines when Load Float will
start. If set too close to zero, minor variations may prevent the speed from being detected as
zero, even though the load is observed as being held stationary. If set too far from zero, the
brake may set while the unit is still in motion.

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Inch Timer Function #92
Units: SEC Range: 0.0 – 15.0
Default: 2.0
Defines the drive running time when Inching is enabled via a selectable logic input. When Inching
is enabled, the drive will automatically stop at the end of time (#92) according to the Start-Stop
mode set by (#40). The Up or Down logic input command must be removed and re-applied to
begin another inching cycle. Inching may be engaged with any selectable speed command.
Torque Decay Time Function #93
Units: SEC Range: 0.01 – 2.50
Default: 0.20
This value controls the rate of decay of motor armature current during normal stops. This helps
to prevent brake ‘thumping’ or slipping when the drive is shut down and the brake is required to
hold the load. Armature current ramp-down will begin after the Run Up or Down command is
removed from the drive, and after the brake is supposedly set. Under all normal stopping
conditions, the motor armature contactor will be told to open AFTER current ramp-down is
complete to reduce wear on contactor contacts. With (#40) = 1, for Coast to Stop, current ramp-
down will begin whenever the Up or Down logic command is released. In Brake Control modes
(#40) set to 2 or 3 current ramp-down will begin at the end of Load Float time (#43), and after the
brake has been de-energized and supposedly set by time-out of (#42). In Ramp to Stop, current
ramp down will begin will begin at the end of the deceleration ramp time (#29).
NOTE: The 115 VAC E-Stop circuit must remain closed until after the contactor actually opens
for this feature to work properly.
Over-Speed Trip Function #94
Units: % [of maximum speed (#13)] Range: 0.0 – 150.0
Default: 110.0
This entry sets the positive and negative over speed trip point of the motor used on the drive. If
the motor speed exceeds this value, the drive will fault. This value is entered as a percent of
rated motor speed (RPM).
Encoder Sense V Function #95
Units: % Range: 0.0 – 100.0
Default: 25.0
This entry sets the armature voltage threshold where the encoder loss and reverse encoder fault
routines activate. This parameter prevents nuisance encoder faults at low speeds and high
torque loads. For example, if the rated motor armature voltage is 500 VDC and this input is set at
10%, the encoder loss function will become operative only when the armature voltage is above 50
VDC. This numeric input adjusts the encoder loss sensing function ability to ignore motor IR
drop.
Encoder Sense % Function #96
Units: % Range: 0.0 – 100.0
Default: 5.0
This entry sets the percentage of encoder feedback below which an encoder loss will be
declared. But this alone will not result in an encoder loss fault being declared. An encoder loss
will be declared when the per unit armature voltage is above the level that is Rated Volts (#1)
time the sum of Encoder Sense V (#95) and Encoder Sense % (#96), AND the percent encoder
feedback is less than the value entered for Encoder Sense (#96). For example, for default values
of 25% (#95) and 5% (#96)< an Encoder Loss will be declared when motor voltage is above 30%
(25+5) and the encoder speed feedback indicates less than 5% speed.

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Motor Over-Load Current Function #98
Units: PU [of Rated Current (#2)] Range: 0.50 – 2.00
Default: 1.15
This value sets the threshold level where the motor overload fault will begin to operate.
Sustained motor current above this value will eventually cause an overload trip according to the
time set in (#99). Motor current above this threshold value will also cause the Overload indicator
light to be ON. See (#99).
NOTE: An Over-Load trip in this version of software is an ALARM. It does NOT cause the drive
to automatically stop.
Motor Over-load Time Function #99
Units: SEC Range: 2.0 – 500.0
Default: 48.0
This value shapes the motor overload time-out curve. Motor armature current is sensed and
mathematically integrated over time to detect potential over heating caused by a dragging brake shoe or
other repeated abuse beyond ratings of the equipment. The calculation formula used for the electronic
motor overload is: t  T 2(i  Ko)
Where:
t = Calculated time to trip in seconds
i = Measured Per Unit motor current. Drive Param (#2) defines motor Per Unit current in amperes.
T = Time to trip setting (Param #99) at motor current of (Ko+0.5) per unit current.
Ko = Maximum Per Unit current that will not cause an Overload Trip (Param #98)

The USA National Electric Code (NEC) requires that the overload be adjusted to detect overheating of the
motor and motor wiring by using rated motor current as the comparison base. This is not the same as
rated current capability of the drive. The NEC requirement is that the overload must trip at 1.15 pu
current (no time specified), and after 60 seconds at 1.5 pu current, and after 10 seconds at 2 pu current.
It is recommended that the default values of Ko=1.1 and T=50 be used. This will provide no tripping with
average motor current of 1.1 pu or less, and a tripping time of 62 seconds at 1.5 pu. See the timing graph
below.

Overload Trip Time

Ko=1.1, To=50

200.0

150.0
Seconds

100.0

50.0

0.0
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8
Per Unit Current

Figure 12: MOTOR OVERLOAD, Ko=1.1, T=50

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Initial Starting Torque Function #100
Units: % [of Rated Current (#2)] Range: 0 – 100
Default: 100
This entry sets the pre-torque armature current value in Start-Stop Mode (#40) 2 or 3 if no other
pre-torque value has been retained in memory from the last stop. The effective minimum value
will be set by (#101). During normal stopping in (#40) mode 2 or 3 is to save the motor armature
current required to hold the load at the end of Load Float. This value is used to pre-torque the
speed regulator integrator when re-starting. If power is turned OFF or the drive is RESET, the
pre-torque information is lost. The values of (#100) or (#101) will then be used on the first drive
re-start.
Minimum Starting Torque Function #101
Units: % [of Rated Current (#2)] Range: 0 – 100
Default: 10
This entry sets a minimum value for initial starting torque (#100).
Regen Margin Function #102
Units: PU Range: 1.0 – 2.0
Default: 1.2
This parameter is the ratio of regen/motoring current limit settings. A ratio greater than 1
guarantees that the torque available during regeneration will be larger than that for motoring.
Down Start Current Limit Function #103
Units: % Range: 0 – 100
Default: 10
This entry restricts the initial current limit in the down direction before the brake has proven to be
released. This prevents the drive from forcing through the brake in the down direction if the brake
is indeed holding a heavy load.
Torque Regulator Gain Function #104
Units: PU Range: -10 to +10
Default: 0
This entry sets the amount of speed reference trim created when using the torque regulator
mode. Per Unit speed trim will be (TorqueRef – armCurentRef) X (#104). The maximum trim
allowed will always be internally limited to +/-10% of Rated Speed (#3).
Ultra-Lift Mode Function #110
Units:Numeric selection Range: 0 – 2
Default: 0 (OFF)
Defines if and how Ultra-Lift will be enabled.
If set to 0, Ultra-Lift is not enabled
If set to 1, Ultra-Lift will be automatically enabled each time speed and load conditions permit.
If set to 2, Ultra-Lift will be enabled when operating conditions permit AND an external logic
command is given. Removal of the external Ultra-Lift Enable logic signal will terminate Ultra-Lift,
causing the drive to decelerate to the previously established speed.
Ultra-Lift Threshold Speed Function #111
Units: % [of Rated Speed (#3)]
Range: 20 – 150 Default: 100
Ultra-Lift may be enabled when both the internal ramped reference speed and measured encoder
speed are above this set-point.

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Ultra-Lift Maximum Speed Function #112
Units: % [of Rated Speed (#3)]
Range: 20 – 150 Default: 100
This entry defines the maximum Ultra-Lift speed as a percent of Rated speed (#3). The actual
Ultra-Lift target speed will be calculated based on the measured load and field motor weakening
that may be necessary. This value represents an upper limit for those calculations.
Ultra-Lift Maximum Current Function #113
Units: % [of Rated current (#2)]
Range: 50 – 100 Default: 50
This entry sets the upper limit of load current to allow Ultra-Lift to be enabled. If average load
current is above this value during time (#114) Ultra-Lift will not be enabled.
Ultra-Lift Check Time Function #114
Units: SEC Range: 0.0 – 30
Default: 2.0
This entry is the dwell time necessary to verify steady state load torque and calculate the
maximum Ultra-Lift speed that could be accommodated by weakening the motor field and not
cause motor armature current to rise above Rated Current (#2). Time (#114) begins when all
other Ultra-Lift enabling conditions are met. If all enabling conditions continue to be met during
time (#114), the internal speed reference will be set at the calculated Ultra-Lift speed, but not
more than (#112).
Protocol Function #120
Units: Logic Range: 0 (Off) – 1 (On)
Default: 2.0
This entry enables or disables the Modbus communication options of drives with firmware
versions 409 build 10 and later. When disabled, port J2 communicates via a handheld keypad
protocol. When enabled, port J2 communicates via Modbus RTU.
Modbus Baud Function #121
Units: NUM Range: 0 – 2
Default: 1
This entry sets the drive’s port J2 baud rate when function #120 is On.
If set to 0, the baud rate is 4800 bps.
If set to 1, the baud rate is 9600 bps.
If set to 2, the baud rate is 19200 bps.
Modbus Address Function #122
Units: NUM Range: 1 – 31
Default: 1
This entry sets the drive’s Modbus slave address when function #120 is set to 1.
Modbus Parity Function #123
Units: NUM Range: 0 – 1
Default: 0
This entry sets the drive’s Modbus communication parity on port J2.
If set to 0, the parity is None.
If set to 1, the parity is Even.

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Modbus Run Time-out Function #124
Units: SEC Range: 0.0 – 30
Default: 2.0
This entry sets the time duration the drive will energize the motor without receiving a supported
Modbus communication packet while the Forward or Reverse Modbus control register bits are
set. A 414 fault will be set when these conditions are met.
Error List Reset Function # 199
Units:Logic Range: 0 (Off) – 1 (On)
Default: 0
This entry resets the F#800 error list, removing all faults and errors on the list. This may be used
to clear out old data to begin capturing a fresh record.

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MONITOR PARAMETER DESCRIPTIONS

Ramped Sped Ref Function # 600

Units: PU

This display is the ramped per unit speed reference AFTER accel-decel and limit controls.

Motor RPM Function # 601

Units: RPM

This display is the measured motor RPM.

Speed Reference Function # 602

Units:PU

This display is the raw speed reference before any limiting or accel-decel conditioning.

Armature Current Reference Function # 608

Units: PU

This is the Per Unit armature current reference.

CEMF Function # 609

Units: Volts DC

This display is the CEMF of the motor calculated from measured motor voltage, current and
armature circuit resistance.

Motor Armature V Function # 610

Units: Volts DC

This display is the measured voltage output to the motor armature circuit.

Motor Arm Current Function # 611

Units: Amps DC

This display is the measured drive output to the motor armature circuit.

Motor Field Current Function # 612

Units: Amps DC

This display is the measured motor field current.

Measured Motor Resistance Function # 613

Units: OHMS

This is the measured motor armature circuit resistance calculated during self-tune.

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Measured Motor Inductance Function # 614
Units: HENRIES

This is the measured motor armature circuit inductance calculated during self-tune.

Measured Field L/R Time Constant Function # 615

Units: Seconds

This is the motor field time-constant measured during self tune.

Speed Error Function # 616

Units: % of Rated Speed

This displays the difference between the speed reference and speed feedback.

AC Line Frequency Function # 617

Units: Hz

This display is the measured frequency of the 3 phase AC line.

Heatsink Temp Function # 618

Units: C°

This display is the measured heatsink temperature of the drive in C°.

AC Line Voltage Function # 619

Units: Volts rms Line-Line

This display is the measured 3 phase AC input line-line voltage.

Brake Slip Function # 620

Units: Encoder counts

This display is the net encoder movement counts accumulated during the brake slip test. It is a
live display during time (#45) testing. The total count accumulated during the last test will be held
until a new Up or Down command is given.

Analog Speed Command Function # 668

Units: %
This is the analog speed command applied to terminal # 68

Analog Torque Command Function # 676

Units: PU
This is the analog torque command applied to terminal # 76

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FUNCTION # DESCRIPTION REFERENCE PAGES

000 VIEW FAULT LIST Page 46-47

199 CLEAR ERRORS LIST Page 79

800 VIEW ERROR LIST Page 48

801 FAULT/ERROR ACTIONS See Error Reporting on page 45

980 TRACE MONITOR -

981 VERIFY I/O Page 104

993 CLEAR NVRAM -

See Non-Volatile RAM Access
994 SAVE/RECALL FUNCTION
on page 49
See Non-Volatile RAM Access
995 LOAD DEFAULTS
on page 50
996 HEX MONITOR -
See Self Tune Function on page
997 SELF TUNE
51
See Power Conversion
998 PCU DIAGNOSTICS
Diagnostics on page 53
999 DCU DIAGNOSTICS -

Diagnostic Function Descriptions

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Software IdentificationFunction # 688-699
The following read-only values identify the drive hardware set up and control software stored
in E-PROMs U13, U14, U39 & U40

FUNCTION # DESCRIPTION VALUE

688 SEE
CUBE I.D.
TABLE 1
689 SEE
FIELD RANGE
TABLE2
690 U13/U14
404
“97SAXXX”
691 PCU RELEASE -
692 DAY -
693 MONTH -
695 YEAR -
696 BETA “P” -
697 VERSION “SA” 409
698 RELEASE No. -
699 CUSTOMER ID -

Table 1: Function #688 CUBE I.D. CROSS-REFERENCE

CUBE Nameplate Max RUN Max Input

I.D. No. Amps amps VAC
1 9 10 525
6 28.6 31 525
9 61.6 62 525
12 111 106 525
15 209 206 525
21 348 330 525
28 513 480 525
31 679 640 525
37 1025 1100 525
43 1330 1550 525
44 111 106 600
46 348 330 600
47 513 480 600
48 679 640 600
49 1025 1100 600
50 1330 1550 600

Nameplate Amps is DC amps shown on drive nameplate. Maximum RUN amps is rated at
200% overcurrent.

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Table 2: Function #689 FIELD CURRENT RANGE

#689 SW1 Minimum Maximum

Read-Back* Rated Field Rated Field
Amps DC Amps DC
1 0.2 1.9
3 7.0 16.0
6 2.0 6.9
8 16.1 40.0
*Indicates actual SW1 setting

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Modbus RTU Communications
OmniPulse DSD drives with firmware versions 409 build 10 and later can be controlled from a PLC or
other master device via serial communications using the Modbus RTU protocol.

Modbus communications can be configured using the master and up to 31 slaves. The drive has slave
function only, and serial communication is normally initiated from the master and responded to by the
slave(s).

The master performs the serial communications with only one slave at a time. The address or node for
each slave must be set beforehand so the master can communicate with the slave at that address. A
slave that receives a command from the master will perform the specified function and then send a
response back to the master.

Communication Interface: RS-232 (RS-485 to RS-232 converter must be used for bus communication)
Format: 8 data bits, 1 stop bit

Serial Link Connections

Figure 13: Serial Link Connections

Communications Timing

To prevent overrun in the slave drive, the master should wait a minimum of 15 ms between sending
messages to the same drive.

Message Format
In Modbus communications, the master sends commands to the slave, and the slave responds. The
message format is configured for both sending and receiving as shown below, and the length of the
packets depends on the command content.

SLAVE ADDRESS
FUNCTION CODE
DATA
ERROR CHECK (CRC)

The slave address in the message defines the node the message is sent to. Use addresses between 1
and 31 (hex). The response from the slave will use an address 0 to the master.

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The OmniPulse DSD supports the three Modbus function codes shown below:

Function Function Name Data Length

Code Command Message Response Message
Minimum Maximum Minimum Maximum
03H Read Modbus registers 8 8 7 37
08H Loopback test 8 8 8 8
10H Write to multiple Modbus 11 41 8 8
registers

Command Registers

It is possible to both read and write control data to the control registers.
The following tables define the available OmniPulse DSD Modbus control registers:
Register Contents Access
No.
0002H Speed Reference (units 000.00 PU) RD/WR
0003H Torque Reference (units 00.000) Bipolar RD/WR
Save/Recall Function (#994) RD/WR
0 = No Action
0005H
1 = Save NVRAM
2 = Restore NVRAM

If parameter values are changed, the Save/Recall Function must be set to a 1 to save parameters to
NVRAM.

When Speed Mode Select (Parameter 30) is set to 4 or 5 a speed demand can be applied in one of two
manners:
1. Set either bit 0 or 1 of register 0001H to logic 1 to select the direction, and set a speed reference
in register 0002H.
2. Set either bit 0 or 1 of register 0001H to a 1 to select the direction; if Multi-Function Input Selects
(Parameters 71-79) are set to 1-5, set bits 4-9 of register 0001H to logic 1.

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I/O Registers

It is possible to read I/O data from the drive.

Register Contents Access

No.
Multi-function Digital Inputs RD
Bit 0 Forward Run (0 = Stop, 1 = Forward Run)
Bit 1 Reverse Run (0 = Stop, 1 = Reverse Run)
Bit 2 MFDI 1
Bit 3 MFDI 2
Bit 4 MFDI 3
Bit 5 MFDI 4
0010H Bit 6 MFDI 5
Bit 7 MFDI 6
Bit 8 MFDI 7
Bit 9 MFDI 8
Bit 10 MFDI 9
Bit 11 Reserved
Bit 12 Reserved
Bits 13-15 Reserved
Multi-function Digital Outputs RD
Bit 0 K1
Bit 1 K2
Bit 2 K3
0011H
Bit 3 K4
Bit 4 K5
Bit 5 K6
Bit 6 K7
0012H Multi-function Analog Input 1 RD
0013H Multi-function Analog Input 2 RD
0014H Multi-function Analog Output 1 RD
0015H Multi-function Analog Output 2 RD

Fault and Error Registers

It is possible to read Fault and Error data from the drive.

Register Contents Access

No.
0020H Fault 0 RD
0021H Fault 1 RD
0022H Fault 2 RD
0023H Fault 3 RD
0024H Fault 4 RD
0025H Fault 5 RD
0026H Fault 6 RD
0027H Fault 7 RD
0028H Fault 8 RD
0029H Fault 9 RD
002AH Fault 10 RD
002BH Fault 11 RD
002CH Fault 12 RD
002DH Fault 13 RD

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 Register Contents Access
No.
002EH Fault 14 RD
002FH Fault 15 RD
0030H Error 0 RD
0031H Error 1 RD
0032H Error 2 RD
0033H Error 3 RD
0034H Error 4 RD
0035H Error 5 RD
0036H Error 6 RD
0037H Error 7 RD
0038H Error 8 RD
0039H Error 9 RD
003AH Error 10 RD
003BH Error 11 RD
003CH Error 12 RD
003DH Error 13 RD
003EH Error 14 RD
003FH Error 15 RD

Parameter and Monitor Registers

It is possible to both read and write parameter data to parameter registers. It is possible to read monitor
data from monitor registers.

Function # Description Units Format Register #

1 Rated Armature Volts VDC 0 DP 0065H
2 Rated Armature Amps ADC 1 DP 0066H
3 Rated Motor RPM RPM 1 DP 0067H
4 Manual Armature Inductance HNY 4 DP 0068H
5 Manual Armature Resistance Ohm 3 DP 0069H
6 Rated Field Current ADC 2 DP 006AH
7 Rated Field Volts VDC 0 DP 006BH
8 Manual Field L/R Sec 2 DP 006CH
9 Weak Field Current ADC 2 DP 006DH
10 Nominal AC Voltage VAC 0 DP 006EH
11 Field Source Volts AC VAC 0 DP 006FH
12 Encoder Pulses/Rev. P/R 0 DP 0070H
13 Absolute Maximum RPM RPM 0 DP 0071H
14 Maximum Armature Current % 0 DP 0072H
15 Encoder Feedback On Logic Binary 0073H
16 Armature Voltage @ Maximum Speed VDC 0 DP 0074H
17 Standby Field Current % 0 DP 0075H
18 Field Regulator Response RAD 1 DP 0076H
19 3 Second Motor Contactor Fault Logic Binary 0077H
20 Use Self Tune Logic Binary 0078H
21 Armature Current Response RAD 0 DP 0079H
22 Speed Regulator Response RAD 1 DP 007AH
23 System PU Inertia SEC 2 DP 007BH
24 Speed Stability PU 1 DP 007CH

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Function # Description Units Format Register #
26 Position Damping PU 2 DP 007EH
27 Acceleration Time Sec 2 DP 007FH
28 Deceleration Time Sec 2 DP 0080H
29 Analog Source Select Logic Binary 0081H
30 Speed Mode Select # Select 0 DP 0082H
31 Preset Speed 1 % 1 DP 0083H
32 Preset Speed 2 % 1 DP 0084H
33 Preset Speed 3 % 1 DP 0085H
34 Preset Speed 4 % 1 DP 0086H
35 Preset Speed 5 % 1 DP 0087H
36 Preset Speed 6 % 1 DP 0088H
37 Preset Speed 7 % 1 DP 0089H
38 Micro –Speed 1 Gain PU 2 DP 008AH
39 Micro –Speed 2 Gain PU 2 DP 008BH
40 Start – Stop Mode # Select 0 DP 008CH
41 Brake Release Timer Sec 1 DP 008DH
42 Brake Set Timer Sec 1 DP 008EH
43 Load Float Time Sec 0 DP 008FH
44 Answer-Back Time Sec 2 DP 0090H
45 Brake Slip Timer Sec 1 DP 0091H
46 Maximum Brake Slip Pulses 0 DP 0092H
47 Brake Release Check Time Sec 2 DP 0093H
48 Brake Release Movement Pulses 0 DP 0094H
49 Brake Fault Speed % 1 DP 0095H
50 IFBK OK Timer Sec 2 DP 0096H
51 Bipolar Analog Input T68 Logic Binary 0097H
52 Analog Input T68 Bias PU 3 DP 0098H
53 Analog Input T68 Gain PU 3 DP 0099H
55 Bipolar Analog Input T76 Logic Binary 009BH
57 Analog Input T76 Bias PU 3 DP 009DH
58 Analog Input T76 Gain PU 3 DP 009EH
60 Analog Output T45 # Select 0 DP 00A0H
61 Analog Output T45 Bias PU 2 DP 00A1H
62 Analog Output T45 Gain PU 2 DP 00A2H
65 Analog Output T46 # Select 0 DP 00A5H
66 Analog Output T46 Bias PU 2 DP 00A6H
67 Analog Output T46 Gain PU 2 DP 00A7H
71 Multi-Function Input T_9_Select # Select 0 DP 00ABH
72 Multi-Function Input T_10_Select # Select 0 DP 00ACH
73 Multi-Function Input T_11_Select # Select 0 DP 00ADH
74 Multi-Function Input T_12_Select # Select 0 DP 00AEH
75 Multi-Function Input T_50_Select # Select 0 DP 00AFH
76 Multi-Function Input T_51_Select # Select 0 DP 00B0H
77 Multi-Function Input T_52_Select # Select 0 DP 00B1H
78 Multi-Function Input T_53_Select # Select 0 DP 00B2H
79 Multi-Function Input T_54_Select # Select 0 DP 00B3H
81 K1_Logic__Out_Select # Select 0 DP 00B5H

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Function # Description Units Format Register #
82 K2_Logic__Out_Select # Select 0 DP 00B6H
83 K3_Logic__Out_Select # Select 0 DP 00B7H
84 K4_Logic__Out_Select # Select 0 DP 00B8H
85 K5_Logic__Out_Select # Select 0 DP 00B9H
86 K6_Logic__Out_Select # Select 0 DP 00BAH
87 K7_Logic__Out_Select # Select 0 DP 00BBH
90 Full Field Detect % 0 DP 00BEH
91 Zero Speed Threshold % 2 DP 00BFH
92 Inch Timer Sec 1 DP 00C0H
93 Torque Decay Time Sec 2 DP 00C1H
94 Overspeed Trip % 1 DP 00C2H
95 Encoder Sense Voltage % 1 DP 00C3H
96 Encoder Sense Speed % 1 DP 00C4H
98 Motor Overload Current PU 2 DP 00C6H
99 Motor Overload Time Sec 1 DP 00C7H
100 Initial Starting Torque % 0 DP 00C8H
101 Minimum Starting Torque % 0 DP 00C9H
102 Regen Margin PU 2 DP 00CAH
103 Down Starting Current Limit % 0 DP 00CBH
104 Torque Regulator Gain PU 0 DP 00CCH
110 Ultra Lift Mode # Select 0 DP 00D2H
111 Ultra Lift Threshold Speed % 0 DP 00D3H
112 Ultra Lift Maximum Speed % 0 DP 00D4H
113 Ultra Lift Maximum Current % 0 DP 00D5H
114 Ultra Check Time Sec 1 DP 00D6H
120 Protocol Select # Select 0 DP 00DCH
121 Modbus Baud Rate # Select 0 DP 00DDH
122 Modbus Address NUM 0 DP 00DEH
123 Modbus Parity # Select 0 DP 00DFH
124 Modbus Communication Timeout Sec 3 DP 00E0H
600 Ramped Speed Reference PU 3 DP 02BCH
601 Motor RPM RPM 1 DP 02BDH
602 Speed Command Reference PU 3 DP 02BEH
608 Armature Current Reference PU 3 DP 02C4H
609 Motor CEMF VDC 1 DP 02C5H
610 Motor Armature Voltage VDC 1 DP 02C6H
611 Motor Armature Current ADC 1 DP 02C7H
612 Motor Field Current ADC 2 DP 02C8H
613 Measured R OHM 3 DP 02C9H
614 Measured L HNY 4 DP 02CAH
615 Measured Field L/R Sec 3 DP 02CBH
617 Line Frequency Hz 1 DP 02CDH
618 Heatsink Temperature C 0 DP 02CEH
619 AC Line Volts VAC 1 DP 02CFH
620 Brake Slip NUM 0 DP 02D0H
668 Analog Speed Command % 2 DP 0300H

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 Function # Description Units Format Register #
676 Analog Torque Reference PU 3 DP 0308H
688 Cube ID Number NUM 0 DP 0315H
689 Field ID Number NUM 0 DP 0316H
692 Day NUM 0 DP 0318H
693 Month NUM 0 DP 0319H
695 Year NUM 0 DP 031BH
696 Beta P NUM 0 DP 031CH
697 Version SA NUM 0 DP 031DH
698 Software Release NUM 0 DP 031EH
699 Customer ID NUM 0 DP 031FH

The numeric format is defined by the number of decimal point digits (DP). A number with a format 3 DP
would be represented as XX.XXX or have a scientific notation of XXXXX * 10-3.

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Drive Faults

The following Faults are custom to the OMNIPULSE DSD crane control software.

FUNCTION ERROR CODE LISTING

*** DCU ERRORS *** 406 = 10% LOW LINE ALARM

407 = EXCESSIVE CEMF ALARM
DISPLAY # - DESCRIPTION 408 = EXCESSIVE PCU CEMF FAULT
13 = ILLEGAL INSTRUCTION 409 = UNEXPECTED PCU RESET
14 = LINE 1010 EMULATOR 410 = BRAKE RELEASE FAULT
15 = LINE 1111 EMULATOR 411 = EXTERNAL FAULT
16 = PRIVELEGE VIOLATION 412 = TORQUE LIMIT FAULT
17 = DIVIDE BY ZERO 413 = PRE-TORQUE FAULT
21 = WATCHDOG TIMEOUT 414 = MODBUS COMM FAULT
22 = RESERVED INTERRUPT
23 = UNINITIALIZED INTERRUPT *** PCU ERRORS ***
24 = TRACE EXCEPTION
DISPLAY # - DESCRIPTION
26 = SPURIOUS EXCEPTION
97 = OVERSPEED TRIP 900 = PCU LOOP FAULT
98 = TACH/ENCODER LOSS 901 = PCU IST FAULT
99 = REVERSE TACH/ENCODER 902 = POWER SUPPLY FAULT
100 = NOT A NUMBER 903 = LINE SYNC FAILURE
101= MATH OVERFLOW 904 = LOW LINE FAULT
102 = MATH UNDERFLOW 905 = FIELD LOSS
103 = FLOATING POINT DIVIDE BY ZERO 906 = DCU FAILURE
104 = SIGN ERROR IN SPEED REG 907 = THERMISTOR FAULT
112 = BAD PCDU POINTER 908 = OVER TEMPERATURE
113 = MISSING PCU 909 = EXCESSIVE RIPPLE
114 = LOCKED UP QUEUES 910 = BLOWN FUSE
115 = MULTIPLEXER CONFIG. ERROR 911 = SHORTED SCR
220 = DCU ROM BUS ERROR 912 = OPEN SCR
221 = DCU RAM BUS ERROR 915 = PARAMETER SETUP FAULT
222 = DCU NVRAM BUS ERROR 916 = FORCING FAULT
223 = DCU DPRAM BUS ERROR 917 = REVERSE ARM. V. FEEDBACK
232 = UNKNOWN BUS ERROR 919 = RATED VAC. SETTING ERROR
240 = DCU ROM BUS ERROR 920 = RATED ARM. VOLT. SETTING
241 = DCU RAM ADDRESS ERROR 921 = BRIDGE RATING FAULT
242 = DCU NVRAM ADDRESS ERROR 923 = RATED ARM. I. SETTING ERROR
243 = DCU DPRAM ADDRESS ERROR 924 = RATED FIELD I. SETTING ERROR
252 = UNKNOWN ADDRESS ERROR 925 = FIELD PCB SENSE FAULT
926 = PCU WATCHDOG TIMEOUT FAULT
***DRIVE FAULTS/ERRORS*** 929 = FIELD CURR. WON’T GO TO ZERO
930 = FIELD CURR. WON’T GO TO
DISPLAY # - DESCRIPTION RATED
400 = MOTOR OVERLOAD 931 = OPEN CIRCUIT CEMF FAULT
401 = BRAKE HOLD FAULT 932 = CLOSED CIRCUIT CEMF FAULT
402 = CONTACTOR FAULT 933 = ARM CURRENT WON’T INCREASE
403 = BRAKE ANSWER-BACK FAULT 934 = LOW ARM INDUCTANCE
404 = ARMATURE CIRCUIT FAULT 935 = WRONG BUS VS ARM VOLTS FBK
405 = SAFETY CIRCUIT FAULT 936 = E-STOP OPENED DURING TEST
937 = LOW ARMATURE VOLTS FBK
938 = LOW BUS VOLTS FBK
Prot = CORRUPTED NV RAM DATA

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CHAPTER 5: TROUBLESHOOTING
The “Fault Code Descriptions & Diagnostics” table provides a description of drive faults and basic
troubleshooting steps to find and correct the problem.

FAULT CODE DESCRIPTIONS & DIAGNOSTICS

ERROR/FAULT PROBABLE CAUSE — CORRECTIVE ACTION
CODE
MOTOR OVER LOAD FAULT --- Indicates that the drive has delivered
400
excess motor amps for a significant period of time. Refer to parameters
#98 and #99 for proper set-up. Check for a dragging brake or overly
weakened motor field. A motor overload fault does not automatically
shut down the drive, but is annunciated via the ALARM logic output
when enabled. The yellow Over-Load LED will also be ON when an
Over-Load Fault has occurred.

BRAKE HOLD FAULT --- Indicates that the hoist brake has shown
401
excessive slip when expected to hold the load. – Causes:
1. Electrical problem. Start from the programmed output at TB1
(MFO: K2, K3 relay by factory default), ensure that power to the
Brake coil does indeed de-energize at the end of Load Float (#43).
2. Mechanical problem. Ensure that the Brake does indeed engage
when the coil is de-energized. Check Brake shoes for mechanical
problems, wear, dirt or grease contamination.
3. Brake Slip threshold adjustment (#46) is set too tight. Increase
(#46) slightly to avoid nuisance trips.
4. Brake Set time adjustment (#42) is too small. Drive starts torque
decay before brake is set. Increase (#42) to allow sufficient time for
brake to set.
5. Motor circuit interrupted while still holding the load. Verify that the
E-Stop and TB1(7) circuits remain energized until after the drive
has opened the contactor.
6. Over loaded hoist. Lower the load and remove/reduce load weight.

402 MOTOR CONTACTOR FAULT— The Motor Contactor auxiliary contact

does not pick up or drop out within the designated time as requested by
the drive. See Param. #19. – Causes:
1. Defective Motor Contactor Aux. Check for proper feedback at
TB1(7)
2. Defective Contactor. Check for open coil or mechanical binding.
3. Defective Motor Contactor Pilot Relay, if used. Verify proper
operation.
4. Interference from other noisy controls or power relay circuits. Verify
proper equipment grounding.

403 BRAKE ANSWER-BACK FAULT – Indicates that the brake answer-

back contact did/does not agree with the status of brake energization
within time set at (#44).
1. Verify that the Brake answer-back contact does indeed work and
that the MFI input is properly programmed.
2. If there is no answer-back contact set (#40) to 1 or 2.
3. Adjust the setting of (#44) to allow adequate time for answer-back.

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FAULT CODE DESCRIPTIONS & DIAGNOSTICS cont’d
ERROR/FAULT PROBABLE CAUSE — CORRECTIVE ACTION
CODE

404 OPEN ARMATURE CIRCUIT – A large current error existed for ½

second. Check the DC Armature Fuse F4 (reference Figure 9). Check
motor armature circuit wiring. Check power poles in the DC loop
contactor.

E-STOP CIRCUIT FAULT— The Safety Circuit is not closed. The Drive
405
has detected that the Safety Circuit wired between TB3-3 and TB3-6 on
the Power Supply A4 was not closed for 100 msec before an Up or
Down command was given, or that it opened unexpectedly while the
motor contactor was closed. Check for intermittent connections in the
E-Stop circuit. Verify that the E-Stop line remains closed until the drive
de-energizes the motor contactor. Verify that the motor klixon is closed
(if wired in the E-Stop circuit).

LOW LINE ALARM – Indicates that the input AC line voltage sagged
406
more than 10% below nominal line volts as set at Parameter #10. This
does not shut down the drive but may be an indication that work is
needed to avoid future Low Line shut down faults, F904.
407 CEMF ALARM - The CEMF of the motor exceeded 109% of measured
AC input voltage to the Drive. This is a warning only and does not
cause an automatic drive shut down. – Causes:
1. Insufficient VAC input (#10) as necessary to support motor voltage
(#1)
2. 3-phase input AC Line Voltage drooped under load or is too low.
3. Motor field current set too high. Verify motor field current set point
(#6) Vs desired motor voltage maximum speed (#13).
4. Check & correct speed regulator tuning to prevent speed and
CEMF overshoot. Review and verify settings for #22, #23, #24, &
#26.

PCU CEMF FAULT - The CEMF of the motor exceeded 118% of the
408
rated VAC input voltage to the Drive. This fault causes a drive shut
down to prevent fuse blowing. – Causes:
1. 3 Phase Input AC Line Voltage is low. Check and correct.
2. Incorrect motor field current setting or field regulator mis-operation
causing excessive CEMF. Check & correct.
3. Excessive drive speed overshoot. Correct with velocity regulator
adjustments (parameters #22-24).

PCU RESET — PCU processor was unexpectedly reset. Verify that

409
correct PCU software and revision level is being used. Possible
problem with main circuit card hardware. Look for external noise
interference. Ensure that equipment and signal grounding connections
are proper. Correct as necessary. If problem remains, replace main
PCB.

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FAULT CODE DESCRIPTIONS & DIAGNOSTICS cont’d
BRAKE RELEASE FAULT --- Indicates that the brake failed to release
410
within (#47) seconds when told to do so. Actual release is determined
by encoder movement of (#48) counts before time (#47).
1. Ensure that the brake does indeed release when told to do so.
Check electrical and mechanical components.
2. Ensure that the selected speed (#31 – 36) and acceleration rate
(#27) will cause the encoder to move within time (#47). Extend
measurement time (#47), increase the starting speed, or reduce the
acceleration time (#27).
3. Ensure that the encoder counts to determine brake release at (#48)
are realistic. Lower the setting of expected counts (#48).

EXTERNAL FAULT --- Indicates that the External Fault signal was
411
given. An external or internal fault RESET must be received after the
External Fault signal has been removed in order to clear this fault.

TORQUE LIMIT FAULT – This fault will occur if operating conditions

412
cause the drive to be in current limit for longer than 3 seconds. Verify
that:
1. Maximum Armature Current setting (#14) is correct.
2. Motor Field Current setting (#6) is correct.
3. The brake is not stuck or the machine jammed.

PRE-TORQUE FAULT- Before the brake is released, the drive’s

413 armature/field current did not reach a predetermined level within a
predetermined time.
MODBUS COMM FAULT-Communications were lost with Modbus
414 master while a Modbus control register applied a RUN command.
Verify that:
1. Modbus Time-out (#124) setting is correct.
2. Communication cable is properly connected.
POWER LOSS - Loss of 115VAC control power. — Check cable
" P.L. "
connection at TB3 of Power Supply Assembly A4. Ensure that control
power is always above 92 VAC.

BLOWN FUSES or loss of 3 phase input power. – Check for blown line
"– – –"
fuses. If fuses are not blown, verify that AC input voltage to drive is
present. Verify that power supply voltages are valid at TP1, 2, 3, & 4 on
the main PCB. Check connections to the Armature Interface PCB and
ribbon cable at J4.

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FAULT CODE DESCRIPTIONS & DIAGNOSTICS cont’d
ERROR/FAULT PROBABLE CAUSE — CORRECTIVE ACTION
CODE
13-17, 21-26, 100- MISC FAULTS - Problem with either hardware or software on the Drive
104, 112-114, 220- Control PCB. See list at Section 4.5.
234, 240-254, 926 1. Check and/or replace U13, U14, U39, and U40 (EPROMs).
2. Replace Drive Control PCB A1.
3. Call Magnetek Service at 866.MAG.SERV for assistance.

97 OVERSPEED FAULT - The motor speed has exceeded the trip level
set in Parameter #94, as measured by the encoder. Parameter #94 is a
percentage of the motor speed value set in Parameter #3. Possible
cause
1. Incorrect setting of Parameters #3, #12 or #94.
2. Poor speed regulator tuning - Check parameters #22, 23 & 24
3. Velocity reference set above rated speed.
4. Intermittent velocity encoder.

98 ENCODER LOSS FAULT - The drive does not see the encoder velocity
in proportion to armature voltage indication of speed. Refer to
Parameter explanations for #95 and #96.
1. Ensure that the encoder is working. Look for loose connections.
2. Raise the value for #95 if motor has high resistance.
3. Ensure that the contactor feedback circuit at TB1(7) does not close
before the armature power poles.

99 REVERSED ENCODER FAULT — The digital encoder and motor

voltage signals do not agree in direction of rotation. Probable cause:
Encoder leads are reversed. Reverse connections for A and ANOT.

900 MOTOR CONTACTOR FAULT - The contactor did not close or opened
unexpectedly. Or the motor voltage exceeded 30% of rated motor
voltage (F#7) during Self-Tune (F#997). When this occurs, the Severe
Fault flag is set and the OMNIPULSE DSD current reference is forced
to zero. This fault will shutdown the drive.
1. Check the contactor aux feedback circuit to TB1(7).
2. Check contactor and pilot relay coils (if used) for proper operation.
3. Check that power is being applied to MC contactor from the power
supply at TB3(5). (Will be momentary until F900 occurs.) If not
there, suspect an internal relay failure. Replace A4, Power Supply
PCB.

901 PCU IST FAULT – Current flow in excess of 300% of rated armature
current detected. Check for:
1. Ground fault or intermittent connection in motor armature circuit.
2. Faulty current measuring module.
3. Poor current regulator tuning.
4. Faulty drive.

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FAULT CODE DESCRIPTIONS & DIAGNOSTICS cont’d
ERROR/FAULT PROBABLE CAUSE — CORRECTIVE ACTION
CODE
POWER SUPPLY FAULT (CPU Reset Required)
902
The Low Voltage Power Supply (A4) output has dropped below 60% of
the rated voltage. This fault will shutdown the drive. Possible causes;
1. Loss of 115VAC power.
2. Short circuits in +5V, +/-15V, or +24V circuits, possibly external to
the drive.
3. Failed Power Supply
4. Blown fuse internal to power supply.

LINE SYNCRONIZATION FAULT (CPU Reset Required)

903
The Phase Locked Loop has lost synchronization with the 3 Phase AC
input power supply. When this occurs, the Severe Fault flag is set and
the current reference is forced to zero. Generally this is caused by AC
input power problems and is self correcting. This fault will shutdown the
Drive.
This fault will often occur with a F904 fault.

LOW LINE VOLTAGE FAULT

904
The AC input power has dropped below 80% of the Nominal AC Line
Voltage (F#10) for 3 consecutive cycles or lower than 50% for one
cycle. When this occurs, the Severe Fault flag is set and the
OMNIPULSE DSD current reference is forced to zero. This fault will
shutdown the Drive.

FIELD LOSS FAULT This fault will shutdown the Drive.

905
The field current feedback has dropped below 80% of the expected
current during the following conditions:
1. F#9 when Drive is in Field Weakening Mode (Top speed).
2. F#6 when Drive is in Full Field Mode (Accel or Decel).
3. F#17 when Drive is in Standing Field Mode (not running).
Probable causes are:
1. Open circuit failure of motor field or motor field wiring.
2. Hardware failure of motor field control circuitry.
3. Loss of power or incorrect phasing to Field Rectifier – check AC1
and AC2 connections.

DCU FAILURE FAULT (OMNIPULSE DSD Power down is required.)

906
The update of the Dual Port RAM from the Drive Control Unit (DCU) is
unreliable. This requires the replacement of the Drive Control PCB, A1.
This fault will shutdown the drive.
THERMISTOR FAULT --- The thermistor is found to be open or
907
shorted. Check and/or replace the thermistor. It should measure
between 2K – 10K ohms at 20C room temperature. A Thermistor Fault
will also occur if the ambient temperature is below 0C as the resistance
detected is too high to be measured. Check the thermistor connection
J29 of Armature PCB (reference Figure 9). This fault will not shutdown
the Drive.

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FAULT CODE DESCRIPTIONS & DIAGNOSTICS cont’d
ERROR/FAULT
PROBABLE CAUSE - CORRECTIVE ACTION
CODE(S)
OVER TEMPERATURE FAULT - The calculated SCR junction
908
temperature is above 125 degrees Centigrade. This is calculated from
the thermistor heatsink measurement and measured armature output
current heating effects of SCRs. Possible causes:
1. Ambient temperature too high. Check for cause.
2. Clogged air filter in cabinet. Clean or replace air filter.
3. Clogged heatsinks. Clean heatsink fins.
4. Cooling fan failure. Replace defective cooling fan(s) in power cube.
5. Defective thermistor (reference Figure 9).
Note: This fault will not shutdown the Drive.
RIPPLE FAULT - Repeated high peak to average motor armature
909
current. The cause of this condition may be defective hardware, which
can be discovered through the PCU Diagnostics function, #998. It may
also occur due to poor regulator tuning or other oscillatory operation
condition. See Magnetek Application Note OMNIPULSE DSD 412
(103) for a complete explanation of this fault.

BLOWN FUSE FAULT - One or more of the three AC line fuses is

910
open. This condition is checked on power-up and upon request through
the PCU Diagnostics function, #998. Detection is accomplished by
measurements via voltage dividers on the Armature Interface PCB, A2.
Possible causes are;
1. One or more of AC input fuses are blown.
2. Power wiring problem-check wiring.
3. Faulty DSPR power relay.

SHORTED SCRS/DOUBLER FAULT - (OMNIPULSE DSD Power

911
Down is required.)
One of the SCR/Doubler packs has a short circuit between the SCRS.
This condition is checked only upon request through the PCU
Diagnostics function, #998. The optional handheld PCDU will also
identify which SCR pair is bad.

OPEN SCR FAULT (OMNIPULSE DSD Power Down is required.)

912
One of the SCRs does not conduct current. This condition is checked
only upon request through the PCU Diagnostics function, #998. The
optional handheld PCDU will also identify which SCR pair is bad.
Check for faulty SCR gating leads.

PARAMETER SETUP FAULT (OMNIPULSE DSD powerdown is

915
required.)
One of the following parameters is not within the range of the chassis
hardware.
1. Rated Volts (F#7) or (F#10)
2. Rated Current (F#2) or (F#6)
Corrective action: Enter correct parameter data, save to NVRAM.
Reset the drive & re-start.

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FAULT CODE DESCRIPTIONS & DIAGNOSTICS cont’d
ERROR/FAULT
PROBABLE CAUSE - CORRECTIVE ACTION
CODE(S)
916 FORCING FAULT – The prohibit rotation bit was removed with the loop
picked-up. This fault can only occur when using the handheld PCDU.

REVERSE ARMATURE POLARITY - (Drive power down is required.)

917
This fault will show up when doing the F998 PCU Diagnostics Test. It
indicates that the polarity of the Armature Voltage Feedback wires are
reversed or missing. Check connections on TB5-1 and TB5-2 of the
Armature Interface PCB, A2. F909 faults and/or very poor drive/ride
performance may occur if not corrected.

LINE VOLTAGE SETTING FAULT (Drive power down is required.)

919
This fault is declared if a number is entered for the Nominal AC Input
Voltage (F#10) that is outside the acceptable range of 150 to 525 VAC. If
0 is entered, the rated line voltage defaults to 230 or 460 VAC depending
on the line voltage sensed.

920
LOAD VOLTAGE SETTING FAULT (Drive power down is required.)
Declared if the Rated Armature Voltage (F#1) value is outside the
acceptable range of 150 to 550 VDC.

BRIDGE RATING FAULT (Drive power down is required.)

921
The bridge type is determined by reading a sense resistor on the Cube ID
PCB plugged into the A2 Armature Interface PCB. The resistor value
identifies the ampere rating and current feedback scaling of the physical
hardware. This failure occurs if the computer cannot identify the drive size.
Possible causes:
1. J14 on Main Control PCB is not seated properly.
2. Missing or wrong Cube ID PCB.
3. Wrong PCU software in U13 & 14.
4. Faulty Armature Interface PCB – replace PCB.
5. Faulty Drive Control PCB – replace PCB.

LOAD CURRENT SETTING FAULT - (Drive power down is required.)

923
This fault is declared if a number is entered for Rated Armature Current,
F#2 that is outside the acceptable range of 0.125 to 2.0 times the bridge
current rating as determined by the bridge sense resistor on the Cube ID
PCB, on the Armature Interface PCB.

FIELD CURRENT SETTING FAULT (Drive power down is required.)

924
This fault is declared if a number is entered for Rated Field Current F#6
that is outside the acceptable range of the Field Interface board, A3 current
rating as determined by the field sense resistor selected by SW1 on the
Field Interface PCB.

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FAULT CODE DESCRIPTIONS & DIAGNOSTICS cont’d
ERROR/FAULT
PROBABLE CAUSE -CORRECTIVE ACTION
CODE(S)
FIELD SENSE FAULT - (Drive power down is required.)
925
The field bridge rating is determined by reading a sense resistor on the
Field Interface board selected by SW1. This resistance identifies the
motor field current feedback scaling for the A/D converter. If the resistance
value is not recognized a Field Sense Fault is declared. This indicates that
there is a hardware fault on the Field Interface PCB, Drive Control PCB, or
within the interconnecting cables and hardware. Check that J13 is seated
properly and that the cable is not defective.

PCU WATCHDOG - (Drive power down is required.)

926
This fault is declared when the PCU is reset via its own software watchdog
timer. It is an indication of a PCB hardware problem more so than a DCU
or PCU software problem. A likely cause is severe electrical interference.
Check for:
1. Faulty EPROMs or socket connections at U13, U14, U39 or U40.
2. Ensure that all panel relays have working R/C coil suppression.
Include relays that may be operating door opener equipment.
3. Look for relays where the +24V and 115VAC signals are being
switched in the same relay. There must be arc barriers between
contact poles to avoid “spark splash” from 115 VAC circuits into 24
VDC logic.
4. Check for intermittent grounds in the power circuit and in 24VDC signal
wiring.
5. Noise generated over the encoder feedback, power supply, or Drive
Control PCB can cause this fault. Verify all connections and verify that
the Drive Control PCB is properly grounded.
This fault is usually caused by electrical noise causing the Drive’s micro-
processor to malfunction.

CORRUPTED NVRAM DATA – The NVRAM has lost parameter set up

Prot
data. This fault will occur if the battery within NVRAM chip U56 is weak.
The drive display will show ‘Prot” if a loss of data is detected when power
has been re-applied, and the processor attempts to load in default values
while the NV-Protect switch is in the ‘safe’ ON position. MagneTek
recommends replacing U56 every 8 years.

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FAULT CODE DESCRIPTIONS & DIAGNOSTICS cont’d
OTHER CONDITIONS PROBABLE CAUSE - CORRECTIVE ACTION
No power at TB3 or failed power supply.
NO LED DISPLAY WITH 1. Verify 115 VAC control voltage at TB3(1 & 2)
POWER ON 2. Verify that cable J11 is seated properly.
3. Short circuit on external wiring dragging down the power
supply. Verify by temporary removal of wires at TB1(48,
82, & 1). If display operation is restored. fix external
problem.
4. Short circuit internal to current measuring transducer.
Verify by removal of J27. If display operation is restored,
replace the current transducer. DO NOT RUN THE
DRIVE WITH CURRENT TRANSDUCER
DISCONNECTED.

LOSS OF STORED Severe electrical disturbance with NV-Protect switch in OFF

PARAMETER DATA position, or failure to actually save the data, or weak battery
within U56.
1. Remember to SAVE the data when parameters are
changed. See Section 3.6
2. Return NV-Protect switch to ON when parameter data
changes are completed. See Section 3.6
Replace U56. MagneTek recommends replacing U56 every
8 years.

DRIVE DISPLAY INDICATES Control power applied before 3-phase armature supply.
BLOWN FUSES WHEN ALL Short circuit in +/-15 V wiring circuits prevents analog circuit
FUSES TEST GOOD WITH measurements from working.
OHMMETER 1. Verify that 3-phase power and control power are supplied
simultaneously. Or that drive faults will be RESET by
external circuits after 3-phase power is applied.
2. Read power supply voltages at test points near the top
front of PCB A1. TP8 is circuit common. TP1, 2, 3, & 4
(just below J11, to right of silver metal can U8) should be
+24V, +15V, -15V, +5V, +/-5% respectively.
3. If voltages in step 2 are low, unplug ribbon cables at J13
and J14 (A1 PCB, lower left). If power supply voltages
are restored, pursue cause of short circuit on those
cables. Suspect faulty current transducer or cable.
4. Remove power supply cover. Disconnect power supply
at J11. Re-measure voltages at marked test points on
power supply PCB. If voltages are OK with J11
disconnected and fault was not found in step 3, replace
main PCB.

REPEATED FALSE OVER- Leakage current between the thermistor on the heatsink and
TEMPERATURE INDICATIONS the thermistor leads can cause an elevated temperature to be
measured. Replace failing thermistor and/or klixon.

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FAULT CODE DESCRIPTIONS & DIAGNOSTICS cont’d
The following fault codes may occur during Self-Tune (Fctn #997) or Self-Diagnostic (Fctn #998).
ERROR/FAULT
PROBABLE CAUSE - CORRECTIVE ACTION
CODE(S)

F929 Motor field current does not reduce to near zero within 6 seconds. Verify
motor field current with an independent clamp-on DC ammeter.
Probable causes:
1. Incorrect phasing of VAC supply to field control module. Provide
correct single phase supply wiring.
2. Faulty SCR/Rectifier power module for motor field. Replace.

F930 Motor field current does not increase to near rated amperes within 6
seconds. Verify motor field current with an independent clamp-on DC
ammeter.
Probable causes:
1. Motor field not connected.
2. Not enough voltage available to achieve rated field current. Maximum
VDC output to motor field is 0.9 X VAC input at terminals A3TB1, AC1
& AC2. At –10% low line, the maximum VDC output is 0.8 x VAC. If
this voltage is not enough to produce rated field current through the
resistance of the motor field winding, reconnect the field windings for
lower voltage (and higher current) or provide a step-up transformer for
the motor field circuit.
3. Improper settings for the connected motor field. Insure that the proper
current tap at A3TB4 is used, and that calibration switch A3S1 is set
correctly, and that adjustments #6, #7, #9, and #11 are set correctly.
4. Faulty SCR/Rectifier power module for motor field. Replace.

F931 Excessive open circuit voltage to motor armature circuit. Measured

armature voltage is greater than 10% of rated volts (#1).
Probable Causes:
1. Motor is rotating, producing CEMF.
2. Unbalanced SCR leakage with low voltage setting of #1. Increase #1
for test.
3. Damaged SCR(s)

F932 Armature CEMF volts >20% of rated during test.

Probable causes:
1. Motor rotating during the test producing CEMF.
2. High motor armature resistance. Ensure that brush commutator is
clean. Temporarily increase Rated Armature Volts, #1 during the test.

F933 Motor armature current does not increase to near test amps within 6
seconds.
Probable causes:
1. Faulty motor armature circuit. Check wiring and motor for open circuit.
2. Open SCR or missing SCR gating. Perform Self-Diagnostics to verify.

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FAULT CODE DESCRIPTIONS & DIAGNOSTICS cont’d
ERROR/FAULT
PROBABLE CAUSE - CORRECTIVE ACTION
CODE(S)

F934 Calculated armature inductance is less than 0.00017 Henry. The drive will
not Self Tune with less than 170 micro-henries of load inductance. Verify
that inductance is really that low. Verify that VAC value at #10 is correct.
Manually enter the minimum value into #4. Parameter #20 must be set to
OFF.

F935 Calibration of bus voltage and armature voltage feedback circuits do not
match.
Probable causes:
1. Missing wire to bus or armature voltage feedback circuits.
2. Component problem - Feedback voltage divider ratios do not match.

F936 E-Stop contact was opened during test. Test data is not valid. Jumper E-
Stop circuit and re-test.

F937 Low read-back volts from motor armature circuit.

Probable Causes:
1. Missing wire to armature voltage feedback at TB5.
2. Component problem – Feedback voltage divider ratio does not match
that identified in Cube ID pcb.

F938 Low read-back volts from DC bus circuit.

Probable Causes:
1. Missing wire to bus voltage feedback. (Discrete wires on drives larger
than 300 amps DC.)
2. Component problem – Feedback voltage divider ratio does not match
that identified in Cube ID pcb.

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INPUT – OUTPUT SIGNAL VERIFICATION

The Control Display Unit (CDU) function #981 may be used to directly read and track the status of logic
input and output signals at OMNIPULSE DSD drive terminals. This is an easy way to verify the integrity
of input and output logic signals to the drive. Refer to specific connection diagrams for your application to
confirm the definition of how each signal is being used. The I/O indicator technique as described below
will work regardless of whether or not the particular terminals and signals are used by internal software
logic or actually wired into your application. Function #981 does not work with the Portable Control
display Unit.

Here’s how to use this valuable troubleshooting tool:

1. Press the Up ▲ or Down ▼ keys and go to F#981.

2. Press the DATA FCTN KEY. The green light should turn ON to indicate that data is being displayed.

3. Segments on the local Control Display Unit will light up to indicate active input and output logic
actions. Vertical segments represent input signals and horizontal segments represent output signals
as identified below.

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 OmniPulse DSD Complete Parameter List

Function # Description Units Range Default User Value

1 Rated Armature Volts VDC 0 - 550 240
2 Rated Armature Amps ADC 2.0 - 1250 26
3 Rated Motor RPM RPM 50 - 1999 1750
4 Manual Armature Inductance HNY 0.001 - 1.000 0.01
5 Manual Armature Resistance Ohm 0.001 - 5.000 0.1
6 Rated Field Current ADC 0.20 - 40.00 2
7 Rated Field Volts VDC 50 - 525 240
8 Manual Field L/R Sec 0.10 - 10.00 0.54
9 Weak Field Current ADC 0.1 - 40 30
10 Nominal AC Voltage VAC 150 - 525 480
11 Field Source Volts AC VAC 0 - 525 0
12 Encoder Pulses/Rev. P/R 600 - 19999 1024
13 Absolute Maximum RPM RPM 50 - 3000 1750
14 Maximum Armature Current % 0 - 300 250
15 Encoder Feedback On Logic 0 (OFF) - 1 (ON) 0 (OFF)
16 Armature Voltage @ Maximum Speed VDC 150 - 550 500
17 Standby Field Current % 10 - 100 25
18 Field Regulator Response RAD 1.0 - 10.0 5
19 3 Second Motor Contactor Fault Logic 0 (OFF) - 1 (ON) 0 (OFF)
20 Use Self Tune Logic 0 (OFF) - 1 (ON) 0 (OFF)
21 Armature Current Response RAD 100 - 750 250
22 Speed Regulator Response RAD 1.0 - 10.0 4
23 System PU Inertia SEC 0.25 - 15.00 2
24 Speed Stability PU 1.0 - 10.0 2
26 Position Damping PU 0.5 - 10.0 2
27 Acceleration Time Sec 0.5 - 15.0 5
28 Deceleration Time Sec 0.5 - 15.0 3
29 Analog Source Select Logic 0 (OFF) – 1 (ON) 0 (OFF)
30 Speed Mode Select # Select 1–3 1
31 Preset Speed 1 % 0 – 50 10
32 Preset Speed 2 % 0 – 150 20
33 Preset Speed 3 % 0 – 150 30
34 Preset Speed 4 % 0 – 150 40
35 Preset Speed 5 % 0 – 150 50
36 Preset Speed 6 % 0 – 150 60
37 Preset Speed 7 % 0 – 10 5
38 Micro –Speed 1 Gain PU 0.00 – 1.00 1
39 Micro –Speed 2 Gain PU 0.00 – 1.00 1
40 Start – Stop Mode # Select 1–4 1

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Function # Description Units Range Default User Value
41 Brake Release Timer Sec 0.0 – 2.55 0.7
42 Brake Set Timer Sec 0.0 – 2.55 0.7
43 Load Float Time Sec 0 – 255 10
44 Answer-Back Time Sec 0.0 – 2.55 0.7
45 Brake Slip Timer Sec 0.0 – 25.5 5
46 Maximum Brake Slip Pulses 0 – 16536 250
47 Brake Release Check Time Sec 0.0 – 2.55 0.5
48 Brake Release Movement Pulses 0 – 16536 50
49 Brake Fault Speed % 0 – 150 10
50 IFBK OK Timer Sec 0.0 – 2.55 0.5
51 Bipolar Analog Input T68 Logic 0 (OFF) – 1 (ON) 0 (OFF)
52 Analog Input T68 Bias PU +/ - 2.00 0
53 Analog Input T68 Gain PU 0.0 – 2.00 1
55 Bipolar Analog Input T76 Logic 0 (OFF) – 1 (ON) 0 (OFF)
57 Analog Input T76 Bias PU +/ - 2.00 0
58 Analog Input T76 Gain PU 0.0 – 2.00 1
60 Analog Output T45 # Select 0–6 1
61 Analog Output T45 Bias PU +/ - 1.00 0
62 Analog Output T45 Gain PU 0.0 – 10.00 0.8
65 Analog Output T46 # Select 0–8 1
66 Analog Output T46 Bias PU +/ - 1.00 0
67 Analog Output T46 Gain PU 0.0 – 10.00 0.8
71 Multi-Function Input T_9_Select # Select 0 – 25 1
72 Multi-Function Input T_10_Select # Select 0 – 25 2
73 Multi-Function Input T_11_Select # Select 0 – 25 3
74 Multi-Function Input T_12_Select # Select 0 – 25 4
75 Multi-Function Input T_50_Select # Select 0 – 25 5
76 Multi-Function Input T_51_Select # Select 0 – 25 21
77 Multi-Function Input T_52_Select # Select 0 – 25 0
78 Multi-Function Input T_53_Select # Select 0 – 25 0
79 Multi-Function Input T_54_Select # Select 0 – 25 14
81 K1_Logic__Out_Select # Select 0 – 14 14
82 K2_Logic__Out_Select # Select 0 – 14 2
83 K3_Logic__Out_Select # Select 0 – 14 2
84 K4_Logic__Out_Select # Select 0 – 14 12
85 K5_Logic__Out_Select # Select 0 – 14 13
86 K6_Logic__Out_Select # Select 0 – 14 4
87 K7_Logic__Out_Select # Select 0 – 14 1

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Function # Description Units Range Default User Value
90 Full Field Detect % 50 – 95 90
91 Zero Speed Threshold % .01 – 5 1
92 Inch Timer Sec 0 – 15 2
93 Torque Decay Time Sec 0.01 – 2.5 0.2
94 Overspeed Trip % 0 – 150 110
95 Encoder Sense Voltage % 0 – 100 25
96 Encoder Sense Speed % 0 – 100 5
98 Motor Overload Current PU 0.5 – 2 1.15
99 Motor Overload Time Sec 2 – 500 48
100 Initial Starting Torque % 0 – 100 100
101 Minimum Starting Torque % 0 – 100 10
102 Regen Margin PU 1.0 – 2.0 1.2
103 Down Starting Current Limit % 0 – 100 10
104 Torque Regulator Gain PU - 10 – 10 0
110 Ultra Lift Mode # Select 0–2 0
111 Ultra Lift Threshold Speed % 20 – 150 100
112 Ultra Lift Maximum Speed % 25 – 150 100
113 Ultra Lift Maximum Current % 50 – 100 50
114 Ultra Check Time Sec 0 – 30 2
120 Protocol Select # Select 0–1 0
121 Modbus Baud Rate # Select 0–2 1
122 Modbus Address NUM 1 – 31 1
123 Modbus Parity # Select 0–1 0
124 Modbus Communication Timeout Sec 0.005 – 10 0.250
199 Error List Reset Logic 0–1 0

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