BI012088

FEBRUARY 2013

Special Instruction
Manual
MD6640 Blast Hole Drill
Serial Number DR612176 / 2U70A10

SAFETY.CAT.COM
Special Instruction Manual
MD6640 Blasthole Drill BI012088
 Special Instruction Manual
BI012088 MD6640 Blasthole Drill

MD6640 Blasthole Drill

Special Instruction Manual

sn: 2U70A10

— Table of Contents —

Section 1 - AB BULLETIN 162

Section 2 - AB EQUIPMENT SAFETY
Section 3 - ARMORED MOTORS
Section 4 - BREAK OUT WRENCH 11.75
Section 5 - CABLE REEL
Section 6 - FLOWMASTER PUMP
Section 7 - LOW VOLTAGE CONTROL CENTERS
Section 8 - MEDIUM VOLTAGE CONTROLLER
Section 9 - OIL COOLERS
Section 10 - POWERFLEX AF DRIVE
Section 11 - PUMP DRIVES
Section12 - REMOTE PROPEL
Section 13 - ROTARY GEAR PUMPS
Section 14 - SIEMAN DRIVE SCHEMATICS
Section 15 - SIEMAN DRIVE PANEL
Section 16 - SIGMA AIR CONDITIONER UNIT
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MD6640 Blasthole Drill BI012088
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BI012088 MD6640 Blasthole Drill

DANGER:

THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND
OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE
SERVICED BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO
WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES, AND/
OR WARD LEONARD LOOP DC DRIVES. FAILURE TO COMPLY COULD RESULT IN
PERSONAL INJURY OR DEATH.

DANGER:

DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE

WITHOUT A FULL UNDERSTANDING OF EACH COMPONENT’S OPERATION AND
FUNCTION. COMPONENTS UTILIZING ELECTRICAL POWER, AIR PRESSURE,
HYDRAULIC PRESSURE AND COMPRESSION OR TENSION SPRINGS FOR
OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY.

The FEEDER CABLE must contain a provision for a ground connection, especially whenever
2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on
ground circuits) to a suitable permanent ground. At the machine, the power line must securely
terminate through a bolted connection to the machine frame. This provides a constant ground for
the machine and its electrical equipment. Failure to provide this adequate ground endangers
employees and equipment.

THE NEED FOR A POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE
CANNOT BE OVEREMPHASIZED. Without a good grounding system, high voltages exist between
the machine and the ground. The portable trail cable and power lines supplying electric energy to
the machine must have a ground wire, ample in capacity, running parallel to the main wires over
the entire distance from the transformer to the machine. A suitable grounding system must be
used at the transformer. Consult your local electrical supplier for details.

DANGER:

DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE

ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM IS REQUIRED THAT
INCLUDES GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING
RESISTOR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY
CHECK SYSTEM IS ALSO RECOMMENDED.
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MD6640 Blasthole Drill BI012088
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BI012088 MD6640 BLAST HOLE DRILL

Bulletin 161
AC Drive
(Series B)
0.2-3.7 kW (0.3-5 HP)

Firmware 2.001

User Manual
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Important User Information

Solid State equipment has operational characteristics differing from those of electromechanical
equipment. “Safety Guidelines for the Application, Installation and Maintenance of Solid-State
Controls” (Publication SGI-1.1) describes some important differences between solid-state
equipment and hardwired electromechanical devices. Because of this difference, and also because
of the wide variety of uses for solid-state equipment, all persons responsible for applying this
equipment must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation be responsible or liable for indirect or consequential damages
resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of
the many variables and requirements associated with any particular installation, Rockwell
Automation cannot assume responsibility or liability for actual use based on the examples and
diagrams.
No patent liability is assumed by Rockwell Automation with respect to use of information, circuits,
equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of
Rockwell Automation is prohibited.
Throughout this manual we use notes to make you aware of safety considerations

ATTENTION: Identifies information about practices or circumstances that can lead to

personal injury or death, property damage or economic loss.

Attention statements help you to:

● Identify a hazard
● Avoid a hazard
● Recognize the consequences

IMPORTANT: Identifies information that is especially important for successful application and
understanding of the product.
Shock Hazard labels located on or inside the drive indicate that dangerous voltage may be
present.

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TOC

Table of Contents
1. Getting Started................................ ................................ ................................ ...............
Important Precautions p.1
Conventions used in this manual p.2
Catalog Number Explanation p.2
Receiving Your New Drive p.3
Nameplate Label p.3
Drive Features p.4
2. Installation & Wiring ................................ ................................ ................................ ......
Storage and operating Conditions p.5
CE Compliance p.5
Installation p.5
Clearances p.5
Terminal Blocks p.6
Power Wiring p.7
Power Terminal Block Wiring Specifications p.8
Branch Circuit Protection Devices p.8
Input Power Conditioning p.8
Grounding p.8
Control Wiring p.9
Control Terminal Descriptions p.10
Programmable Digital Inputs 1-5 functionalit p.12
3. Parameters & Programmin ................................ ................................ .........................
Programming Keypad p.15
Programming Guide p.15
Programming Examples p.16
Initial Power Up p.16
Scrolling through the parameter groups p.16
Restoring Factory Defaults p.16
Operation of the Drive via the Fixed Keypad p.17
Parameter Tree p.18
Parameter Descriptions p.20
D Group parameters p.20
F Group parameters p.21
Mode A Group parameters p.21
Mode b Group parameters p.27
C Group parameters p.31
4. Faults & Troubleshooting ................................ ................................ .............................
Fault Information p.33
Clearing Faults p.33
Bulletin 161 Fault Descriptions p.33
Problems and Corrective Actions p.34
Other Displays p.35
PID Loop Block Diagra p.36

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TOC

Table of Contents cont.

5. Specifications & Dimensions ................................ ................................ ........................
Technical Data p.37
Dimensions p.38
Accessories p.40

Appendix A- CE Conformit ................................ ................................ ..............................

CE Compliance p.41
General Notes p.41
Essential Requirements for a Conforming EMC Installation p.41
Motor Cable requirements p.41
Control Cable requirements p.41

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Chapter 1 – Getting Started

Important Precautions
In addition to the precautions listed throughout this manual, you must read and understand the following
statements which identify hazards associated with AC drives.

ATTENTION
The Bulletin 161 drive contains high voltage DC bus capacitors which take time to discharge after
removal of input power. Before working on the drive, wait five minutes for capacitors to discharge to
safe voltage levels.
Darkened display LEDs are not an indication that capacitors have discharged to safe voltage levels.
Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION
This Bulletin 161 drive generates dangerous electrical voltages and controls potentially dangerous
rotating mechanical parts. Disregarding the guidelines provided in this manual could result in severe
bodily injury or loss of life.

Only personnel familiar with the drive and associated machinery should plan or implement the
installation, start-up and subsequent maintenance of the system. Failure to comply could result in
bodily injury and/or damage to the equipment.

ATTENTION
This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing, servicing or repairing this assembly. Component
damage may result if ESD control procedures are not followed. Failure to observe this precaution could
result in damage to the equipment.

ATTENTION
The drive is intended to be installed with a fixed ground connection. The protective ground only offers
protection for the drive, not against personal injury. According to EN 50178 it is not recommended to use
the Bulletin 161 drives on protective fault current switches as, due to a possible DC component (rectifier
load), the sensitivity of the safety switch will be reduced in the event of a failure. If unavoidable, only type
B Residual Current Operated Protective Devices (RCD’s) should be used. As a precautionary measure,
the EN 50178 regulations should be observed. Failure to observe this precaution could result in severe
bodily injury or loss of life.

ATTENTION
An incorrectly applied or installed drive can result in component damage or reduction in product life.
Wiring or application errors such as undersizing the motor, supplying an incorrect or an inadequate AC
supply, or excessive ambient temperatures may result in system malfunction. Failure to observe this
precaution could result in damage to the equipment.

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Getting Started

ATTENTION
• To prevent any injuries or damage, do not touch any components located within the housing with
your hands or with any other objects while input voltage is applied or if the DC-bus capacitors are
not discharged. Do not carry out any work on the wiring or check any signals if input voltage is
applied.

ATTENTION
• Ensure that the input voltage corresponds to the voltage indicated on the product nameplate.
Environmental influences such as high temperatures and high relative humidity are to be avoided as
well as dust, dirt and corrosive gases. The mounting location should be well ventilated and not
exposed to direct sunlight. Install the device upright on a non-flammable, vertical wall. Failure to
observe this precaution could result in damage to the equipment.

ATTENTION
• The drive start/stop and enable control circuitry includes solid-state components. If hazards due to
accidental contact with moving machinery or unintentional flow of liquid, gas or solids exist, an
additional hardwired stop circuit is required to remove AC input power to the drive.

• All the pertinent safety regulations, e.g. accident prevention regulations, professional association
regulations, EN, VDE regulations etc. must be observed. As these regulations are implemented
differently in different countries, the user must observe the regulations that apply for his particular
country.
Failure to observe these precautions could result in severe bodily injury or loss of life.

General information
Conventions used in this manual
To help differentiate parameter names and parameter settings from other text
the following conventions will be used:
• Parameter numbers and names are shown in the following way: Pd01 - [Output Frequency]
• Parameter Settings for inputs and outputs are shown with the setting number followed by the alpha
description in {Braces} ex: 18{RS}
Catalog Number Explanation
Figure 1.1 below describes the 161 catalog numbering scheme. Please note that not all combinations
can be configured as a Drive, refer to Chapter 5 Specifications & Dimensions.

Figure 1.1 Catalog Number

161S - A A01 N P K

First Position Second Position Third Position Fourth Position Fifth Position Sixth Position

Bulletin Number Voltage Rating Current Rating Enclosure Type Programmer Default Setting

S = Standard A = 200-240V A 01 N = Open (IP20) P = Fixed Keypad K = 50 Hz default settings

D = DeviceNet D = 100-120V A02 U = 60 Hz default settings
A03
A04
A05
A07
A10
A15

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Getting Started

Receiving Your New Drive

It is your responsibility to thoroughly inspect the equipment before accepting shipment from the freight
company. Check the item(s) received against your purchase order. If any items are obviously damaged, do
not accept delivery until the freight agent notes the damage on the freight bill.

Unpacking
Remove all packing material, wedges, or braces from within and around the drive. Remove all packing material
from the heat sink. Leave the debris cover in place on the top of the drive.
If you find any concealed damage during unpacking, notify the freight agent. Also, leave the shipping container
intact and have the freight agent make a visual inspection of the equipment to verify damage.

Inspecting
After unpacking, check the item(s) nameplate catalog number against your purchase order. An explanation of
the catalog numbering system for the Bulletin 161 drive was provided in Figure 1.1 as an aide for nameplate
interpretation.
IMPORTANT: Before you install and start up your Bulletin 161, inspect for mechanical integrity. Look closely for
loose parts, wires and connections.

Nameplate Label
Figure 1.2 depicts a typical Bulletin 161 Nameplate Label.

Figure 1.2 Bulletin 161 Nameplate Label Series

Catalog Number Letter

161S-AA01NPK SERIES B
O FRN: 2.001
I V: 200-240 1Ø (3Ø) V: 200-230 3Ø
U POWER TERMINAL WIRE
N A: 3.1(1.8) A: 1.4
P T Use 75˚C Cu Wire
2.1- 0.75 mm2 (14-18 AWG)
U Hz: 50/60 P Hz: 0.5-360 Torque 0.9 Nm (8 in.-lbs.)
U
T Motor
VA: 500 T Rating: 0.2 kW / 0.3 HP
S/N: 82T T1362281161 Date: 9927 NE16452-2
IP20 MADE IN JAPAN

Serial Number Firmware Version

Enclosure Rating

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Getting Started

Drive Features

Fixed keypad

Control terminal block cover

Screw

RS422 serial interface

Enclosure

Heat sin

Front case

Screw Control terminal bloc

To wire the power terminals
and fault relay, loosen the
screw and open the front
case.
Note that for ratings AA01-
AA03 the screw is located
under the control terminal
block cover.

Protective earth ground

connection

Debris
cover
Fault relay terminals

RS422 serial interface

Terminal cover

Power terminal bloc

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Getting Started

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Chapter 2 – Installation & Wiring

Storage and operating conditions
Follow these recommendations to prolong drive life and performance:
• Store within an ambient temperature range of –25oC to 70oC.
• Store within a relative humidity range of 20 to 90%, non-condensing.
• Avoid storing or operating the drive where it could be exposed to a corrosive atmosphere.
• Protect from moisture and direct sunlight.
• Operate within an ambient temperature range of –10oC to 40oC.
IMPORTANT: To operate the drive between 40oC and 50oC, make the following adjustments:
¾ Reduce the carrier frequency to 2kH
¾ Reduce the output current to 80% of the drives rated current
¾ Remove the debris cover from the top of the drive

CE Compliance
Refer to Appendix A

Installation
Mount the drives on a flat, vertical and level surface. Drive orientation must be vertical (top up) for
proper heat dissipation.
• Install the drive with screws, recommended screw sizes are listed in the table below. Note that
ratings AA01-AA03 require screws at the upper left and lower right corners only.
Description Metric English
Mounting Torque 1.2 – 1.3 Nm 10.6 – 11.5 lb.in.
Mounting Base Screws M4 x 0.7 #8-32
• Ensure that debris cover is in place when installing the drive to prevent filings, cable insulation
and dust from entering the drive.

Clearances
• The drive should be installed using the minimum clearances shown in Figure 2.1
Fig. 2.1 Bulletin 161 Minimum Clearances and Airflo

100 mm
(3.94 in) Air
Circulation

30 mm Bulletin 161 30 mm
(1.18 in) (1.18 in)

100 mm
(3.94 in)

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Installation & Wiring

Terminal Blocks
Figure 2.2 Location of Power, Control, and Fault Relay Terminal Blocks

Protective earth ground connection Front cover opened

L 5 4 3 2 1 P24 * +1 + - * * AL0 AL1 AL2

L1 L2 N/L3 U/T1 V/T2 W/T3

Power terminal block, AA01 - AA03 ratings only
(/) +1 + - Fault relay
terminal block

H O 0I L FM CM2 12 11
L1 L2 N/L3 U/T1 V/T2 W/T3
Control terminal block Power terminal block, all ratings except AA01 -AA03
* Not Used

ATTENTION
• The installation, commissioning and maintenance of these drives may only be carried out by
experienced personnel who are thoroughly familiar with the functioning of the equipment and the
entire machine.
• The devices feature DC-bus capacitors that are energized even when the input supply is switched
off. For this reason wait at least 5 minutes after switching off the input supply before you open the
device and start working on it. Take care that you do not touch any live parts.
• Do not apply input voltage to the output terminals U/T1, V/T2 and W/T3 as drive damage could
occur.
• Contact the motor or machine manufacturers if standard motors with frequencies greater than 60
Hz will be used in your application.
• Failure to follow these precautions could result in severe bodily injury, loss of life or damage to the
equipment.

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Installation & Wiring

Power Wiring
Precautions:

ATTENTION
• Ensure that the input voltage corresponds to the voltage indicated on the product nameplate.
• In normal operation apply the START/STOP commands via the control terminals or the control
panel and not by disconnecting and reapplying input power to the drive or motor contactor. If it
is necessary to use this method for starting and stopping, or if frequent cycling of power is
unavoidable, make certain it does not occur more than once every 5 minutes. Do not install any
capacitors or suppressors to the drive output terminals.
• Exercise particular caution if automatic restart is activated. To prevent injuries caused by
automatic restarting of the drive following a power failure, install a switching component at the
input that is deactivated in the event of a power failure and that may only be manually switched
on again on return of the power supply (e.g. contactor etc.).
• Suitable for use on a circuit capable of delivering not more than 5,000 rms symetrical amperes,
240V maximum.

Figure 2.3 Power wiring block diagram

Input power supply
Disconnect
Optional
Device
Filter
Fuses
L1 U/T1
3
L2 V/T2
Motor
N/L3
W/T3

Bulletin 161
_
DC
+ Bus

+1

Figure 2.4 Power terminal block descriptions

* +1 + - * * (/) +1 + -

L1 L2 N/L3 U/T1 V/T2 W/T3

AA01 - AA03 Power terminal block L1 L2 N/L3 U/T1V/T2 W/T3
* Not Used All ratings except AA01 - AA03 Power terminal block

Terminal Description
L1, L2, N/L3 Connection to incoming power. For single phase input applications, connect the
AC input power to input terminals L1 and N/L3
U/T1, V/T2, W/T Motor connections
-/+ DC Bus connection
+1 Connection for DC bus reactor
+ These terminals are connected by a copper bridge. For applications requiring a
DC bus reactor, remove the bridge prior to installing the reactor.
Protective earth ground connection

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Installation & Wiring

Power terminal block wiring specifications

2
Model Screw Size Max/Min Wire Size mm (AWG) Max/Min Torque Nm (lbin)
AA01-AA02 M3.5 2.1 – .75 (14-18) 0.9-0.8 (8.0-7.0)
AA03 M3.5 2.1 – 1.3 (14-16) 0.9-0.8 (8.0-7.0)
AA04, DA01 M4 5.3 – 1.3 (10-16) 1.3-1.2 (11.5-10.6)
AA05-AA10, DA02-DA03 M4 5.3 – 2.1 (10-14) 1.3-1.2 (11.5-10.6)
AA15 M4 5.3 – 3.3 (10-12) 1.3-1.2 (11.5-10.6)
Power Terminal Connection
IMPORTANT:
• Bulletin 161 Drives feature an electronic overload protection to monitor the motor current. In the
case of multi-motor operation, thermal contacts or PTC resistors must be used for each motor.
• In the case of motor lead lengths greater than 50 meters (165 feet), motor reactors should be used.
Branch Circuit Protection Devices
The following table shows the minimum recommended values for the branch circuit protection devices:
Fuse Rating (Class J) Bulletin 140
Model 1 Ph 3 Ph 1 Ph 3 Ph
AA01 10 10 140M-D8N-C10 140M-D8N-B40
AA02-AA03 10 10 140M-D8N-C10 140M-D8N-B63
AA04-AA05 15 15 140M-D8N-C16 140M-D8N-C10
AA07 20 15 140M-D8N-C16 140M-D8N-C16
AA10 30 20 140M-D8N-C25 140M-D8N-C16
AA15 N/A 30 N/A 140M-D8N-C25
DA01 10 N/A 140M-D8N-C10 N/A
DA02 15 N/A 140M-D8N-C10 N/A
DA04 20 N/A 140M-D8N-C16 N/A

Input Power Conditioning

The drive is suitable for connection to input power within the rated voltage of the drive (see specifications).
The power factor of the input power supply must not exceed .99. Compensation systems must ensure that
over compensation does not occur at any time.
If the drive must be installed in any of the following conditions, an Input Line Reactor must be used:
Input Power Condition Corrective Action
Line has intermittent noise spikes in excess of 2000V Install 3% impedance Input Line Reactor
If frequent voltage dips occur Install 3% impedance Input Line Reactor
The drive is operated on a generator Install 3% impedance Input Line Reactor
Line has power factor correction capacitors Install 3% impedance Input Line Reactor
Several drives are linked via a short common power supply bus bar. Install 3% impedance Input Line Reactor
Grounding

ATTENTION
• The Bulletin 161 has a high leakage current and must be permanently (fixed) hard wired to ground.
Failure to observe this precaution could result in severe bodily injury or loss of life.

Ground the drive. Be sure to separate the drive’s grounding pole from those of other electrical machinery.
If multiple drives are used, make certain grounding connections do not create a loop as shown in Fig. 2.5.
Figure 2.5 Suggested 161 Grounding

Bulletin 161 Bulletin 161 Bulletin 161 Bulletin 161 Bulletin 161 Bulletin 161

Protective
Protective
Earth
Earth
Ground
Ground

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Installation & Wiring

Control Wiring
Requirements
• Run all signal wiring in either a shielded cable or separate metal conduit.
• Do not exceed control wiring length of 20 meters (65.6 feet).
2
• Use Belden 8760 (or equivalent ) –18 AWG (0.750mm ), twisted pair, shielded or 3 conductor.
• Avoid crossing the power lines or motor lines with the control wires. If they must cross, ensure that
they cross at right (90o) angles.
• If using transistor outputs 11 or 12, with an inductive load such as a relay, install a recovery diode
parallel to the relay as shown in Figure 2.6, to prevent damage to the output.

Control Terminal Block Wiring Specifications

2
Max/Min wire size mm (AW ) Max/Min Torque Nm (in lb)
0.750 – 0.14 (18-28) 0.25 - 0.2 (2.21 – 1.77)
2
Note: 0.75mm (18 AWG) wire must be used for the alarm relay. Torque the mounting screw
to: 0.5-0.6 Nm (4.4-5.3 in lb).
Figure 2.6 Control Wiring Block Diagram
24V External Internal
Power Power 24V
P24
P24 FM 0-10V
1 V
1 L
4.4k
2 680
2
11
3
3

4
=
CM2 – +
4 PTC
4.4k 5V 24V
5.1k
5
5 12
4.4k
L 680 680
L
=
CM2 – +
24V

IMPORTANT: Only one frequency

source may be connected at a time. Frequency Reference 10V
H Fault Relay
If more than one reference is 230V AC
connected at the same time, 1-2k Ohm Pot. AL0
an undetermined frequency 0-10V
O ~
reference will result. AL1
OI
To improve noise immunity, the
common (terminal L) must be 4-20mA
connected to ground terminal/ L
AL2
protective earth.

Figure 2.7 Control terminal block descriptions

L 5 4 3 2 1 P24

ATTENTION
A hazard of electrical shock, death or equipment
damage exists. Control terminals are isolated but
not tied to earth ground. If terminal (L) on the
control terminal block is not grounded, exposed
conductors, shields or metal conductors can be at
hazardous voltage levels. H O 0I L FM CM2 12 11
Failure to observe this precaution could result in Control Terminal Block
severe injury or loss of life.

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Installation & Wiring

Control Terminal Descriptions

ATTENTION
• DO NOT jumper or short circuit terminals H and L or P24 and L or drive damage could occur.
The following table gives a description of each of the terminals on the control terminal block as well as
the fault relay:
Control Function Description
Terminal
P24 24 V DC 24 V potential for digital inputs 1-5 max. load 30mA
1 Programmable Digital Digital inputs 1 – 5 are fully programmable level triggered inputs.
2 Inputs. An overview of the possible functions can be found in the digital
26V max, 5KΩ input input description table in Chapter 2.
3 impedance. The inputs are fully programmable with these exceptions:
1. No two inputs can have the same function
4 2. Only input 5 can be programmed as PTC.
3. With the exception of the reset setting which must be
NO (active high), all of the inputs can be set as NO
5 (active high) or NC (active open) via PC11-[Digital
Input 1 Logic] - PC15-[Digital Input 5 Logic].
Note: A signal must be applied to the digital inputs for at least 12 ms
L 0V 0 V potential for output FM
H 10 V Reference Voltage for Potentiometer 0-9.6 V 4-19.6 mA
1 to 2 kOhm nominal 0-10 V nominal 0-20 mA
Analog Frequency
Command H
+
H H

O Voltage Analog Input O O

Input impedanc +
O
Input impedanc
OI OI 10 kOhm OI 250 Oh
Frequency Command
L L L
(0-10V) -
PE PE PE
OI Current Analog Input Input OI for 4-20mA is activated when one of the digital inputs is
Frequency Command set to 16{AT} via PC01-[Digital Input 1] – PC05-[Digital Input 5]
(4-20 mA) The analog input reference can be adjusted using PA11-[Analog
L 0 V Reference Potential for Frequency Minimum] – PA16-[Analog Filter Select].
Frequency Command If no digital input is programmed as 16{AT}, the set values are the sum of O and
Inputs OI.
FM Programmable Analog This output can be used to monitor the output frequency of the
Output drive (either Analog or Pulse) or the motor current. This output is
programmable using PC23-[Output FM].
Analog or Pulse Output Analog Signal Pulse Signal (50% duty cycle)
Frequency or Motor Current Frequency or Current Frequency only

T=4ms (constant) T = (Variable)

Analog Signal: The relation t/T (duty cycle) changes

proportionally with the frequency or current. The maximum
voltage of 10V (100% duty cycle) is reached when the maximum
frequency or 200% of the rated current is reached. Pb81 -
[Output FM Factor] may be used as a scaling factor.
Accuracy: +/- 5% for frequency , +/- 20% for current
Pulse Signal: Frequency = output frequency x Pb86-[Process
Display Scale Factor], but the maximum frequency is 3.6 kHz (ex.
Freq = 60Hz x 60 = 3.6kHz).

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Installation & Wiring

Control Function Description

Terminal
CM2 Reference potential for Transistor output, max. 27 Vdc, 50 mA
outputs 11 and 12

The outputs can be programmed as either NO (active high) or

NC (active open) contacts using PC31-[Digital Output 11Logic]
12 Programmable Digital and PC32-[Digital Output 12 Logic].
Output
The following 6 settings may be programmed using PC21-
[Digital Output 11] and PC22-[Digital Output 12]:
00{RUN} = Motor Running (Signal if output frequency > 0.5 Hz)
01{FA1} = At frequency (Signal when the set frequency is
reached and that frequency is > 0.5Hz)
02{FA2} = Above frequency (Signal if output frequencies > the
frequencies set under PC42-[Above Frequency Accel
11 Programmable Digital Setting] or PC43-[Above Frequency Decel Setting] and >
Output 0.5 Hz).
03{OL} = Motor overload (Signal if the motor current exceeds
the value set under PC41-[Overload Alarm Setting]
04{OD} = PID-deviation (Signal if the deviation between the
set value and the actual value returned is greater than the
value set under PC44-[PID Deviation Setting]). Only available
if the PID control PA71 –[PID Enable] is active.
05{AL} = Fault (Signal if a fault is indicated)

AL0 Fault Relay 250 VAC, 2.5 A resistive

230VAC
AL0 0.2A inductive
∼
AL1 30 VDC, 3.0A resistive
0.7A inductive
AL1
AL2 min. 100 VAC, 10mA
5 VDC 100 mA
Faulted / De-energized State

PC33-[Fault Relay AL1 Logic] can be used to invert the

AL2 operation.

PC33 PC33 = 01 PC33 = 00

AL0 – AL1 Open when Faulted Closed when faulted
Open when Power Off Open when Power Off
AL0 – AL2 Closed when Faulted Open when Faulted
Closed when power off Closed when Power Off

The fault relay is set with a time delay of approximately 2s after

the power is switched on.

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Installation & Wiring

Programmable Digital Input (Control terminal block inputs 1 through 5) Functions

The function of the digital inputs 1 through 5 are programmed via the corresponding PC01 [Digital Input
1] through PC05 - [Digital Input 5]. The following programming guidelines must be followed:
• No two inputs can be programmed for the same function.
• The PTC input (setting 19) is only programmable on input terminal 5.

The digital inputs can be programmed to respond to NO (Active High) or NC (Active Open) inputs via
PC11 - [Digital Input 1 Logic] through PC15 - [Digital Input 5 Logic].

ATTENTION
• All digital inputs respond to level sensitive commands.
• Inputs do not require a voltage transition (cycle) after a fault condition is cleared, after input power cycling or after
programming the logic of the digital input.
• All digital inputs can be programmed as NO or NC. HOWEVER, THE START COMMAND SHOULD BE SET AS
NO (ACTIVE HIGH) AND THE STOP COMMAND SHOULD BE SET AS NC (ACTIVE OPEN). If set opposite of
this, an inadvertent start or failure to stop could occur should a discrete connection be lost or control wire come
loose. IF THE USER CHOOSES TO DISREGARD THIS SAFETY PRACTICE – THE RISK ASSUMED BY THE
USER CAN BE REDUCED BY ASSURING THAT OTHER SAFEGUARDS ARE USED TO INSURE PROPER
START AND STOP OPERATION. Depending on the application: This may include appropriate emergency
stops, redundant wiring, electronic guards and/or mechanical guards.
Failure to observe this precaution could result in severe bodily injury or loss of life.

Numeric Alpha Function Description

Setting Setting
00 {FW} Forward 2-Wire (maintained) Run Forward/Run Reverse settings.
01 {RV} Reverse
00{FW}(N.O.)

01{RV}(N.O.)

Motor Speed

02 {CF1} Preset The preset frequencies may be programmed in two ways:

frequency input 1.) By programming desired preset frequency values via PA21-
[Preset Frequency 1] through PA35-[Preset Frequency 15].
03 {CF2} Preset 2.) By selecting the corresponding digital input setting and
entering the desired frequency via PF01-[Frequency
frequency input
Command].
Setting Input Preset Speed
04 {CF3} Preset 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
frequency input 02 CF1 ON ON ON ON ON ON ON ON
03 CF2 ON ON ON ON ON ON ON ON
04 CF3 ON ON ON ON ON ON ON ON
05 {CF4} Preset 05 CF4 ON ON ON ON ON ON ON ON
frequency input
Note: If any preset frequency input is active, all other frequency commands
will be ignored.
06 {JG} Jog When this input is active, the 00{FW} or 01{RV} inputs will
respond to the frequency programmed via PA38-[Jog
Frequency]. The accel ramp is NOT active.
The stop command is determined by PA39-[Jog Stop Mode].
Note: The Jog command will not work with 3-wire control.

Input 06 {JG} (NO)

Run Cmd (NO)
Motor Speed
nd nd
09 {2CH} 2 Accel/Decel 2 Accel/Decel ramp times are activated via this input and
ramp programmed via PA92-[Accel Time 2] and PA93-[Decel Time 2].

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Input/ Alpha Function Description

Parameter Setting
11 {FRS} Coast to Stop The motor voltage will be switched off immediately and the
motor will coast. This function can be programmed to operate
in two different modes via Pb88-[FRS Select].

synchronization of
the
motor speed 0Hz start

R u n (N O )

In p u t 1 1 {F R S } (N O )

M o to r s p e e d
W a itin g tim e
Note: The drive will start when 11 {FRS} input is removed
without reissuing a start command even if in 3 wire (momentary)
control.
12 {EXT} External Fault When this input is active, an E12 fault indication will be issued
(e.g. an input received from thermal contacts). The fault
indication will be cleared with a reset 18{RS}.
Important: After a reset 18{RS} command, the drive will start
again if a start command is active (00{FW}, 01{RV},or 20
{STA}).

Run (NO)
Motor will
Input 12 {EXT} (NO) Coast

Motor Speed

Input 18 {RS} (NO)

Fault relay (AL0-Al2) (NO)

13 {USP} Unintentional This function is designed to guard against unintended starting

Start Protection when input power is removed and then restored. In this case,
on Power Up if a start/run command is issued immediately upon/after power
is restored an E13 fault will be issued. A new start command
or a reset 18{RS} command will clear the fault indication.

Power Supply
00{FW} or
01 {RV} (N.O.)
13 {USP}(N.C.)

Fault relay (N.O.)

Min. 3 Sec
Motor Speed
15 {SFT} Program Loc Protects stored parameter values from being overwritten. See
Pb31-[Program Lock Select] for the 4 different levels of
protection.
16 {AT} 4-20mA Select Activates input terminal OI for use as a 4-20mA input. If no
input terminal is programmed for this setting, the factory
default input is O (0-10V) and the output frequency will
correspond to the value of the inputs to the O and/or OI
control inputs.
Note: PA01-[Frequency Command Select] determines from
what source the output frequency is commanded.

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Input/ Alpha Function Description

Parameter Setting
18 {RS} Reset Used to clear a fault condition. If a 18{RS} command is given
during operation, the output IGBT’s are switched off and the
motor will coast.

18 {RS} (NO)

Fault indication
relay
19 {PTC} PTC Input This input can only be programmed to digital input
terminal 5 and the PTC should be referenced to terminal
L.
If the PTC resistance exceeds 3k Ohms the output voltage to
the motor will be switched off and an E35 fault code will be
issued.
5

20 {STA} 3 wire run 3-Wire (Momentary) control inputs. Both settings 20 {STA}
and 21 {STP} must be programmed as digital inputs for 3-wire
control to function. If 20 {STA} is programmed into any digital
input then 2-wire (maintained) control will not function.
21 {STP} 3 wire stop Note: 3-wire stop command (21 {STP}) cannot be used to
clear a fault.
20{STA} (NO)

21{STP} (NC)
22 {F/R} 3 wire Forward/
Reverse 22 {F/R (NO)

Motor Speed

27 {UP} Remote Control These settings allow digital inputs to increase and decrease
UP the commanded frequency for the drive. PA01-[Frequency
Command Select] must be set to 02 to activate this function.
These inputs will change the value of PF01-[Frequency
Command] in Hz/Sec as defined b PA04-[Maximum
Frequency] ÷ (Accel time or Decel time).
RUN (NO)
28 {DWN} Remote Control
27 {UP} (NO)
DOWN
28 {DWN} (NO)
PF01-
[Freq. Command]

Motor Speed

31 {OPE} Run This setting is used to determine the source of the Run
Command commands.
Source Select Inactive Start command will come from the control terminals only,
regardless of the setting of PA02 - [Start Command Select]
Active Start command will come from the start key on the keypad only
regardless of the setting of PA02 - [Start Command Select]

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Parameters & Programming

Chapter 3 –Parameters & Programming

ATTENTION
Wait at least 6 seconds after programming the Bulletin 161 before issuing a start, reset command, or switching
off the power supply. Failure to wait 6 seconds, could result in failure to recognize programming changes,
which could lead to bodily injury or damage to the equipment.

Programming Keypad
The keypad is located on the front panel of the drive. This is an integrated keypad that can be used to
monitor drive operation, program parameters, and operate the drive.
Features
Keypad Functions Other Functions
The SELect key is a dual purpose key. It is used to The PRG LED will be lit when a
view parameter groups and to switch between programmable parameter is displayed.
parameter numbers and values. The SELect key
also acts as an Escape key to exit the parameter
values without changing them.
The Up/Down Arrow key are used to scroll The Hz and A LEDs are used to inform you
through parameters, or to increase and decrease whether Hz or Amps are being displayed.
parameter values.
The ENTER key is used to enter the current value The RUN LED will be lit when the drive is in
into memory. operation.

The Start key can be activated using PA02-[Start The Start Ke and Speed Pot LED’s are
Command Select] or digital input setting 31{OPE}. green LED’s which will light when the item is
When active, the key will start the motor in the active.
direction of rotation defined in PF04-[Start Key
Direction].
The Speed Potentiometer can be used to set the
commanded frequency. This can be activated using ATTENTION: If the Stop Key is
Min Max PA01-[Frequency Command Select]. used to clear a fault and there is a valid run
The Stop key is used to stop the motor. If the drive command, the drive will start to run as soon
has stopped due to a fault, pressing this key will as the fault is cleared without cycling the run
clear the fault. input. Failure to observe this precaution
could result in severe bodily injury.

Figure 3.1 Programming Guide

d01 A01

d09
A98
Entry of
F01 parameters
b01
F04
b89 Saving entered
A ..
C01 parameters

B ..
C91
C ..

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Parameters & Programming

Programming Examples
In this section you will find four different programming examples to help you program the 161 drive.
Initial Power Up
This example shows you how to proceed from the power up parameter value to the actual parameter
number.
Action Description Display
1. Apply power to the Drive
Note: If you were viewing a display parameter when power was last removed from
the drive, the same display parameter value will reappear when the drive is re- 
powered. If you were viewing any other parameter value when power was removed,
the parameter group or parameter number will appear when the drive is re-powered.
2. Press the SELect Key to switch from the parameter value to the parameter G
number.
Scrolling through parameter groups
This example will show you how to check a parameter value without changing the value of the parameter.
For this example, the operation of PC21 - [Digital Output 11] will be verified.
Action Description Display
3. Press the Up/Down keys to scroll through the parameter groups, stopping
at the C group.
Note: All of the d and F group parameters, but the A, b, and C parameters are &
grouped and the group must be SELected to view the parameters within that
specified group. Figure 3.2 contains a hierarchy which details which parameters are
in each group.
4. Press the SELect Key to enter into the C group. PC01 - [Digital Input 1]
should appear on the display. &
Note: When parameter groups are entered, the number of the parameter that was
being viewed when you last exited the group will be displayed.
5. Press the Up Key to scroll through the parameters contained within the
group, continue pressing the Up Key until PC21 - [Digital Output 11] is &
displayed.
Note: When viewing parameters within the A, b and C groups the parameters will
wrap from A01 through C91 by pressing the Up/Down Keys. To view parameters
within the d and F groups the SELect Key must be pressed until the display shows
A - -, b - - or C- -. Once the group letter is displayed, the Up/Down Key will scroll to
the d and F parameters.
6. Press the SELect Key to view the parameter value stored in PC21 - [Digital 
Output 11].
7. Press the SELect Key again to exit from the parameter value back to the &
parameter number without changing the stored value.
8. Press the SELect Key again to exit from the parameter number to the &
parameter group display.
Restoring Factory Defaults
This example will show you how to reset the factory defaults of the drive.
Action Description Display
9. Press the Down Key to advance to the b parameter group. E
10. Press the SELect key to enter into the b parameter group. E

11. Press the Up Key to scroll through the parameters until Pb84 - [Reset E
Functions] is displayed.

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Parameters & Programming

12. Press the SELect Key to view the parameter value stored in Pb84 - [Reset 
Functions] and verify that it is set to 01. If it is not 01, use the UP key to
change the value to 01, then press the Enter key.
Note: The defaults will be reset to the values determined by Pb85 - [Factory
Default Select].
13. Press the SELect Key to exit the parameter value back to the parameter E
number without changing the stored value.
14. Press and hold the SELect, Up, Down and Stop Keys for 3 seconds. E
+

15. Release the Stop Key and continue to hold the SELect, Up and Down Keys  “Blinking”
+ until the display begins to blink. Release the remaining keys. When this is 
done, 0.0 will be displayed (this is Pd01 - [Output Frequency].

Operation of the Drive via the Fixed Keypad

This example will show you how to configure the drive for operation via the Fixed Keypad. You will need to
change two parameters to accomplish this. The first step is to switch the frequency reference command from
the control terminal block (factory default) to the frequency potentiometer on the Fixed Keypad by
programming PA01 – [Frequency Command Select]. The second step is to switch the source of the start
input from the control terminal block (factory default) to the start key on the fixed keypad by programming
PA02 – [Start Command Select].
Action Description Display
16. Press the SELect Key to switch from the parameter value to the parameter G
number.
17. Press the Up/Down Keys to scroll through the parameter groups stopping at $
the A group.
18. Press the SELect Key to enter into the A group. $

19. If a parameter other than PA01 - [Frequency Command Select] is displayed 

press the Down Key until PA01 - [Frequency Command Select] is
displayed.
20. Press the SELect key to view the parameter value. 

21. Use the Down Key to change the value of PA01 - [Frequency Command 
Select] from the default value of 01 to 00. This will switch the source of the
frequency command to the potentiometer on the fixed keypad.
22. When the desired value is displayed, press the Enter Key. This writes the $
new value to memory and the display will return to the parameter number.
23. Press the Up Key to display PA02 - [Start Command Select]. $
24. Press the SELect Key to view the parameter value stored in PA02 - [Start 
Command Select].
25. Use the Up Key to change the value of PA02 - [Start Command Select] fro 
the default value of 01 to 02. This will switch the source of the start input
from the control terminal block to the fixed keypad.
26. When the desired value is displayed, press the Enter Key. This writes the $
new value to memory and the display will return to the parameter number.

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Parameters & Programming

Figure 3.2 Parameter Groups

Parameter Tree
d group - Display and Diagnostic Parameters (Read Only)

Display & Diagnostic Functions

d01 Output Frequency
d02 Output Current
d03 Direction
d04 PID Process Display
d05 Digital Input Status
d06 Output Status
d07 Process Display
d08 Last Fault
d09 Fault Register
d16 Elapsed Run Time
F group - Basic Function Parameters

Basic Functions
F01 Frequency Command
F02 Accel Time 1
F03 Decel Time 1
F04 Start Key Direction
A group - Advanced Function Parameters

Basic Functions DC Brake

A01 Frequency Command Select A51 DC Brake Select
A02 Start Command Select A52 DC Brake Start Frequency
A03 Base Frequency A53 DC Wait Time
A04 Maximum Frequency A54 DC Hold Voltage
A55 DC Hold Time
Analog Input Reference Adjustment
A11 Analog Frequency Minimum Operating Frequency Range
A12 Analog Frequency Maximum A61 Upper Frequency Limit
A13 Analog Input Minimum A62 Minimum Frequency
A14 Analog Input Maximum A63 Skip Frequency 1
A15 Analog Start Select A64 Skip Frequency Band 1
A16 Analog Filter Select A65 Skip Frequency 2
Preset Frequencies A66 Skip Frequency Band 2
A67 Skip Frequency 3
A20 Internal Frequency
A68 Skip Frequency Band 3
A21 Preset Frequency 1
A22 Preset Frequency 2 PID Controller
A23 Preset Frequency 3 A71 PID Enable
A24 Preset Frequency 4 A72 PID Proportional Gain
A25 Preset Frequency 5 A73 PID Integral Gain
A26 Preset Frequency 6 A74 PID Differential Gain
A27 Preset Frequency 7 A75 Process Reference Scale Factor
A28 Preset Frequency 8 A76 Analog Feedback Select
A29 Preset Frequency 9
A30 Preset Frequency 10 Automatic Voltage Regulation
A31 Preset Frequency 11 A81 AVR Function Select
A32 Preset Frequency 12 A82 Base Voltage
A33 Preset Frequency 13
A34 Preset Frequency 14 Second Acceleration/Deceleration Ramp
A35 Preset Frequency 15 A92 Accel Time 2
A38 Jog Frequency A93 Decel Time 2
A39 Jog Stop Mode A94 Accel/Decel 2 Select
A95 Accel 2 Start Frequency
V/F Characteristics/Boost A96 Decel 2 Start Frequency
A41 Boost Select A97 Accel Curve
A42 Manual Boost Voltage A98 Decel Curve
A43 Manual Boost Frequency
A44 V/Hz Select
A45 Maximum Voltage

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Parameters & Programming

Parameter Tree cont.

b Group - Advanced Control and Protection Parameters

Automatic Start After a Fault

b01 Restart Mode Select
b02 Power Loss Time
b03 Restart Time

Electronic Motor Protection

b12 Motor Overload Current
b13 Motor Overload Select

Current Limit
b21 Current Limit Select
b22 Current Limit
b23 Current Limit Decel Time
Parameter Protection
b31 Program Lock Select
Current Feedback Tuning
b32 Reactive Current Setting
Initialization/Adjustment Function
b81 Output FM Adjustment
b82 Start Frequency
b83 PWM Frequency
b84 Reset Functions
b85 Factory Defaults Select
b86 Process Display Scale Factor
b87 STOP Key select
b88 FRS Select
b89 Keypad Display
b92 Reserved

C Group - Intelligent I/O and Communication Parameters

Digital Inputs 1-5

C01 Digital Input 1
C02 Digital Input 2
C03 Digital Input 3
C04 Digital Input 4
C05 Digital Input 5
C11 Digital Input 1 Logic
C12 Digital Input 2 Logic
C13 Digital Input 3 Logic
C14 Digital Input 4 Logic
C15 Digital Input 5 Logic
Outputs 11,12, FM, AL0 - AL1
C21 Digital Output 11
C22 Digital Output 12
C23 Output FM Select
C31 Digital Output 11 Logic
C32 Digital Output 12 Logic
C33 Fault Relay AL1 Logic
C41 Overload Alarm Threshold
C42 Above Frequency Accel Threshold
C43 Above Frequency Decel Threshold
C44 PID Deviation Threshold

Communications
C70 Communication Command Select
C71 Baud Rate
C72 Drive Address
C79 Communication Error Select
C91 Debug Mode

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Parameters & Programming

Parameter Descriptions
D Group - Display and Diagnostic Parameters (Read Only)
This group of parameters consists of commonly viewed drive operation conditions such as output
frequency. All parameters in this group are Read Only.
Parameter Parameter Name / Description Min./Max. Units
Number Range
Display and Diagnostic Functions
d01 [Output Frequency] 0.0/360.0 0.1 Hz
Displays the output frequency to the motor.
d02 [Output Current] 0.00/999.9 0.01A
Displays the output current to the motor.
d03 [Direction] Alpha Alpha
Displays the present direction of rotation. Numeric Numeric
F=Forward Value Value
r=Reverse
o=Stop
d04 [PID Process Display] 0/100.0 0.01%
Displays the scaled PID Process variable (feedback), this is
only available when the PID control is active. The scale factor
is set using PC15 - [Digital Input 5 Logic].
d05 [Digital Input Status] N/A N/A
Displays the status of the 5 digital inputs regardless of how
each input is programmed in PC11 - [Digital Input 1 Logic]
through PC15 - [Digital Input 5 Logic].
54 321
Active
Inactive
d06 [Output Status] N/A N/A
Displays the status of the digital outputs and the fault
indication relays.
AL12 11
Active
Inactive
d07 [Process Display 0.00/9999 0.01
Displays Pd01 - [Output Frequency ] scaled by the variable set
in Pb86 - [Process Display Scale Factor].
Note: If there are more than 4 digits, the LSB will be dropped.
d08 [Last Fault] N/A ---
Displays the last fault. The output frequency, motor current,
and DC-bus voltage at the time of the last fault can be viewed
by pressing the SELect key. If there has not been a fault or the
register has been cleared, then --- will be displayed.
d09 [Fault Register] N/A ---
nd rd
Displays the 2 and 3 fault, if there are no faults stored in
rd
this register, then --- will be displayed. To view the 3 fault,
press the SELect key.
d16 [Elapsed Run Time] 0/9999 10
Displays the elapsed running time of the drive. The elapsed hours
running time is the displayed value x 10.

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Parameters & Programming

F Group – Basic Function Parameters

Parameter Parameter Name / Description Min./ Max. Units Factor
Number Range Defaults
1 1
Basic Functions U K
F01 [Frequency Command] 0.0/360.0 0.1 Hz N/A N/A
When PA01- [Frequency Command Select] is set
to 00 or 01, this parameter will display the
commanded frequency. When PA01 - [Frequency
Command Select] is set to 02, this parameter can
be used to change the commanded frequency on
the fly and write the value into PA20 - [Internal
Frequency]. When a preset frequency is active,
this parameter can be used to program or change
the value of the preset input on the fly while writing
the value into the corresponding parameter (PA21 -
[Preset Frequency 1] – PA35 - [Preset Frequency
15]).
Note: The value Is changed in real time and written to memory
without using the Enter key.
This parameter can be changed while motor is running.
F02 [Accel Time 1] 0.1/3000 <1000, 0.1 s 10.0 10.0
Time for the drive to ramp from 0.0 Hz to PA04 - >1000, 1 s
[Maximum Frequency]
This parameter can be changed while motor is running.
F03 [Decel Time 1] 0.1/3000 <1000, 0.1 s 10.0 10.0
Time for the drive to ramp from PA04 - [Maximum >1000, 1 s
Frequency] to 0.0 Hz
This parameter can be changed while motor is running.
F04 [Start Key Direction] 00/02 Numeric 00 0.0
Sets the direction of motor rotation when the drive Value
is set to Start Key mode, which is controlled by
PA02 - [Start Command Select] and digital input
setting 31 {OPE}.
Settings: 00=Forward
01=Reverse
02=Control Terminal – Digital inputs
(C01-C05) settings 00 {FW} and 01 {RV}
determine direction of Start Key.

A Group – Advanced Function Parameters

Parameter Parameter Name/ Description Min./Max Units Factor
Number Range Default
1 1
Basic Functions U K
A01 [Frequency Command Select] 00/02 Numeric 01 01
Selects the source of the frequency command for Value
the drive. Note: If any preset frequency inputs are active, all
other frequency commands will be ignored.
Settings: 00=Frequency pot
01=Input O/OI (Analog reference)
02=Internal frequency (PF01 -
[Frequency Command]/ PA20 -
[Internal Frequency])
A02 [Start Command Select] 01 / 02 Numeric 01 01
Selects the source of the start command. Value
Settings:
01=Control terminal bloc
02=Start Key (Input from Start Key on drive
keypad)
1
U = 60 Hz default settings, K = 50 Hz default settings. Settable using Pb85 – [Factory Default Select]

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Parameters & Programming

Parameter Parameter Name/Description Min/Max Units Factor

Number Range Default
1 1
Basic Functions cont. U K
A03 [Base Frequency] 50/360 1 Hz 60 50
Set value to rated nameplate frequency of motor
Command Upper
Voltage Frequency Frequency Limit
100% A61

0 Frequency Hz
Start Base Maximum Minimum
Frequency Frequency Frequency Frequency
b82 A03 A04 A62

A04 [Maximum Frequency] 50/360 1Hz 60 50

Highest frequency the drive will output.
Note: If a maximum frequency less than PA03 – [Base
Frequency] is needed, use PA61 – [Upper Frequency Limit].
Refer to diagram in PA03 – [Base Frequency].
1 1
Analog input reference adjustment U K
A11 [Analog Frequency Minimum] 0.0/360.0 0.1 Hz 0.0 0.0
Sets the frequency that corresponds to a 0V or
4mA analog signal.
Frequency
A12

% Input
A11
Scale

0V A13 A14 10V

4mA 20mA
A12 [Analog Frequency Maximum] 0.0/360.0 0.1 Hz 0.0 0.0
Sets the frequency that corresponds to a 10V or
20mA analog signal. A value of 0.0 will disable this
function. Refer to diagram in PA11 – [Analog Frequency
Minimum].
A13 [Analog Input Minimum] 0/99 1% 0 0
Sets the starting point (offset) for the analog input
range. Refer to diagram in PA11 - [Analog Frequency
Minimum]
A14 [Analog Input Maximum] 0/100 1% 100 100
The ending point (offset) for the analog input
range. Refer to diagram in PA11 - [Analog Frequency
Minimum].
A15 [Analog Start Select] 00/01 Numeric 01 01
Sets the output frequency when frequency Value
reference is below value set in PA13 – [Analog
Input Minimum].
Settings: 00 = PA11 - [Analog Frequency Minimum]
01 = 0 Hz
Frequency
A12

A15=00

% Input
A11
A15=01 Scale

0V A13 A14 10V

4mA 20mA
A16 [Analog Filter Select] 1/8 Numeric 8 8
Sets the level of the Analog input smoothing filter Value
where:
1 = low. (Bandwidth = 200 Hz)
8 = high. (Bandwidth = 25 Hz)
1
U = 50Hz default settings, K = 50 Hz default settings. Settable using Pb85 – [Factory Default Select]

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Parameters & Programming

Parameter Parameter Name/Description Min/Max Units Factor

Number Range Default
1 1
Pre-Set Frequencies U K
A20 [Internal Frequency] 0.0/360.0 0.1 Hz 60.0 0.0
When PA01-[Frequency Command Select] is set to
02, this parameter will provide the drives frequency
command. This parameter will change the
frequency command only after the new frequency
is entered into memory.
This value can also be changed via PF01 -
[Frequency Command] if no preset frequency
inputs are active.
This Parameter can be changed while motor is running.
A21 [Preset Frequency 1] The programmed value 0.0/360.0 0.1 Hz 0.0 0.0
sets the frequency that
A22 [Preset Frequency 2] the drive outputs when 0.0/360.0 0.1 Hz 3.0 0.0
selected. (Refer to
A23 [Preset Frequency 3] digital input settings 0.0/360.0 0.1 Hz 5.0 0.0
table in Chapter.2). Note:
A24 [Preset Frequency 4] If a preset frequency input is 0.0/360.0 0.1 Hz 10.0 0.0
active, the keypad frequency
A25 [Preset Frequency 5] pot and analog frequency 0.0/360.0 0.1 Hz 15.0 0.0
commands will be ignored.
A26 [Preset Frequency 6] Note: The value of any 0.0/360.0 0.1 Hz 20.0 0.0
Preset Frequency can be
A27 [Preset Frequency 7] changed via PF01 - 0.0/360.0 0.1 Hz 25.0 0.0
[Frequency Command] when
A28 [Preset Frequency 8] the Preset Frequency is 0.0/360.0 0.1 Hz 30.0 0.0
activated via the digital
A29 [Preset Frequency 9] inputs. 0.0/360.0 0.1 Hz 35.0 0.0
These Parameters can be
A30 [Preset Frequency 10] changed while motor is 0.0/360.0 0.1 Hz 40.0 0.0
running.
A31 [Preset Frequency 11] 0.0/360.0 0.1 Hz 45.0 0.0

A32 [Preset Frequency 12] 0.0/360.0 0.1 Hz 50.0 0.0

A33 [Preset Frequency 13] 0.0/360.0 0.1 Hz 55.0 0.0

A34 [Preset Frequency 14] 0.0/360.0 0.1 Hz 60.0 0.0

A35 [Preset Frequency 15] 0.0/360.0 0.1 Hz 0.0 0.0

A38 [Jog Frequency] 0.5/9.9 0.1Hz 5.0 5.0

This parameter sets the frequency the drive will
output when it receives a valid jog command.
This Parameter can be changed while motor is running.

A39 [Jog Stop Mode] 00/02 Numeric 01 01

This parameter sets the stop method when the jog Value
input is removed.
Settings:
00=Coast
01=Ramp
02=DC Brake (See PA53 - [DC Wait
Time] – PA55 - [DC Hold Time])

1
U = 60 Hz default settings, K = 50 Hz default settings. Settable using Pb85 – [Factory Default Select]

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Parameters & Programming

Parameter Parameter Name/Description Min./Max Units Factor

Number Range Default
1 1
V/F Characteristics / Boost U K
A41 [Boost Select] 00/01 Numeric 00 00
Used to select auto or manual boost Value
Settings:
00=Manual Boost
01=Auto Boost

A42 [Manual Boost Voltage] 0/99 Numeric 25 11

Sets the boost level as a percent of PA82 - [Base Value
Voltage].
This Parameter can be changed while motor is running.
Voltage
100% 99 ~ 20%
of Base Voltage at 0Hz,
then linear scale down
e.g. 25 ~ 5%

A42

Frequency
A43 30Hz 60 Hz
1/2 Base Base frequency
frequency

A43 [Manual Boost Frequency] 0.0/50.0% 0.1% 2.0 10.0

Sets the boost frequency point as a percent of
PA03 - [Base Frequency]. Refer to diagram in PA42 –
[Manual Boost Voltage]
This Parameter can be changed while motor is running.

A44 [V/Hz Select] 00/01 Numeric 00 00

Used to select the V/Hz mode. Value
Settings: 00=Constant Torque
01=Variable Torque
Voltage
100%
A44 = 00
Constant
Torque A44 = 01
Variable
Torque

frequency
0 Base frequency

A45 [Maximum Voltage Gain] 50/100 1% 100 100

Sets the voltage gain of the V/Hz characteristic.
Value is a percent of PA82 - [Base Voltage].
This Parameter can be changed while motor is running.
Voltage

100%

A45
50%

frequency
0 Base frequency

1
U = 60 Hz default settings, K = 50 Hz default settings. Settable using Pb85 – [Factory Default Select]

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Parameters & Programming

Parameter Parameter Name/Description Min./Max Units Factor

Number Range Default
1 1
DC Brake U K
A51 [DC Brake Enable] 00/01 Numeric 00 00
Used to enable/disable DC injection braking Value
Settings: 00=Disabled
01=Enabled
A52 [DC Brake Start Frequency] 0.5/10.0 0.1Hz 10.0 10.0
Sets the frequency at which the DC brake will
become active.
A53 [DC Brake Wait Time] 0.0/5.0 0.1 0.0 0.0
Sets the time the drive will wait after PA52 - seconds
[DC Brake Start Frequency] before applying
PA54 - [DC Hold Voltage].
A54 [DC Hold Voltage] 0/100 1% of drive 0 0
Sets the level of DC braking voltage in percent rating
of PA82 - [Base Voltage].
A55 [DC Hold Time] 0.0/60.0 0.1 0.0 0.0
The time that PA54 -[DC Hold Voltage] is seconds
applied to the motor after PA53 - [DC Brak
Waiting Time] has expired.
1 1
Operating Frequency Range U K
A61 [Upper Frequency Limit] 0.5/360.0 0.1Hz 0.0 0.0
This is an upper frequency limit similar to PA04
-[Maximum Frequency] except that it can be
set lower than PA03 - [Base Frequency]. A
value of 0.0 will disable this parameter.
Output Frequency
A61

A62

Frequency Command

A62 [Minimum Frequency] 0.0/360.0 0.1Hz 0.0 0.0

Lowest frequency the drive will output
continuously.
Refer to diagram in PA61 – [Upper Frequency Limit].
A63 [Skip Frequency 1] 0.0/360.0 0.1Hz 0.0 0.0
Sets a frequency at which the drive will not
output continuously.
A64 [Skip Frequency Band 1] 0.0/10.0 0.1Hz 0.5 0.5
Sets the bandwidth around PA63 -[Skip
Frequency 1]. The bandwidth is 2x PA64 –
[Skip Frequency Band 1] with ½ the band
below and ½ the band above PA63 - [Skip
Frequency 1].
A65 [Skip Frequency 2] 0.0/360.0 0.1Hz 0.0 0.0
Sets a frequency at which the drive will not
output continuously.
A66 [Skip Frequency Band 2] 0.0/10.0 0.1Hz 0.5 0.5
Sets the bandwidth around PA65 -[Skip
Frequency 2]. The bandwidth is 2x PA66 -
[Skip Frequency Band 2] with ½ the band
below and ½ the band above PA65 - [Skip
Frequency 2].
1
U = 60 Hz default settings, K = 50 Hz default settings. Settable using Pb85 – [Factory Default Select]

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Parameters & Programming

Parameter Parameter Name/Description Min./Max Units Factor

Number Range Default
1 1
Operating Frequency Range cont. U K
A67 [Skip Frequency 3] 0.0/360.0 0.1Hz 0.0 0.0
Sets a frequency at which the drive will not
output continuously.

A68 [Skip Frequency Band 3] 0.0/10.0 0.1 Hz 0.5 0.5

Sets the bandwidth around PA67 - [Skip
Frequency 3]. The bandwidth is 2x PA68 -
[Skip Frequency Band 3] with ½ the band
below and ½ the band above PA67 - [Skip
Frequency 3].
1 1
PID Controller U K
A71 [PID Enable] 00/01 Numeric 00 00
Used to disable / enable the use of PID control. Value
Settings: 00=disable
01=enable
(See Figure 4.1 for PID block diagram)
A72 [PID Proportional Gain] 0.2/5.0 N/A 1.0 1.0
Sets the proportional gain for the PID control.
This Parameter can be changed while motor is running.
A73 [PID Integral Gain] 0.0/150.0 0.1 1.0 1.0
Sets the integral gain for the PID control. seconds
This Parameter can be changed while motor is running.
A74 [PID Differential Gain] 0.0/100.0 N/A 0.0 0.0
Sets the differential gain for the PID control.
This Parameter can be changed while motor is running.
A75 [Process Reference Scale Factor] 0.01/99.99 N/A 1.00 1.00
Used to scale the target value equivalent to the
PID feedback value.
A76 [Analog Feedback Select] 00/01 Numeric 00 00
Selects the source from which the PID Value
feedback originates
Settings: 00=Input OI
01=Input O
1 1
Automatic Voltage Regulation (AVR) U K
A81 [AVR Function Select] 00/02 Numeric 02 02
Used to select the Automatic Voltage Value
Regulation function.
Settings: 00=Active
01=Inactive
02=Inactive during deceleration
A82 [Base Voltage] 200/220/230 Volts 230 230
Set voltage to rated nameplate voltage of /240
motor.
1 1
Second Acceleration / Deceleration Ramp U K
A92 [Accel Time 2] 0.1/3000 <1000, 0.1 s 15.0 15.0
Time for the drive to ramp from 0.0 Hz to PA04 >1000, 1 s
- [Maximum Frequency]. PA94 - [Accel/Decel
2 Select] is used to determine when active.
This Parameter can be changed while motor is running
A93 [Decel Time 2] 0.1/3000 <1000, 0.1 s 15.0 15.0
Sets the time for the drive to ramp from PA04 - >1000, 1 s
[Maximum Frequency] to 0.0 Hz. PA94 -
[Accel/Decel2 Select] is used to determine
when active.
This Parameter can be changed while motor is running.
1
U = 60 Hz default settings, K = 50 Hz default settings. Settable using Pb85 – [Factory Default Select]

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Parameters & Programming

Parameter Parameter Name/Description Min./Max Units Factor

Number Range Default
1 1
Second Acceleration/Deceleration Ramp U K
A94 [Accel / Decel 2 Select] 00/01 Numeric 00 00
Used to determine when the PA92 – [Accel Value
Time 2] and PA93 - [Decel Time 2] are used.
Settings: 00=Digital inputs (C01-C05) set to
09{2CH}
01=Automatic if frequency
programmed in PA95 - [Accel 2
Start Frequency]/ PA96 - [Decel 2
Start Frequency] is reached.
A95 [Accel 2 Start Frequency] 0.0/360.0 0.1 Hz 30.0 0.0
Sets the frequency at which PA92 - [Accel Time
2] will take effect if PA94 - [Accel/Decel 2
Select] is set to 01.
A96 [Decel 2 Start Frequency] 0.0/360.0 0.1 Hz 30.0 0.0
Sets the frequency at which PA93 - [Decel Time
2] will take effect if PA94 - [Accel/Decel 2
Select] is set to 01.
A97 [Accel Curve] 00/01 Numeric 00 00
Selects the type of acceleration curve. Value
Settings: 00=Linear
01=S-curve
A98 [Decel Curve] 00/01 Numeric 00 00
Selects the type of deceleration curve. Value
Settings: 00=Linear
01=S-curve
b Group – Advanced Control and Protection Parameters
Parameter Parameter Name/ Description Min./Max Units Factor
Number Range Default
1 1
Automatic Start After a Fault U K
b01 [Restart Mode Select] 00/03 Numeric 00 00
Selects the restart mode for the drive Value
Settings: 00=Fault indication
01=0 Hz start
02=Synchronize.
03=Synchr. and stop
Note: If set to 01, 02 or 03 the drive will attempt to restart
the following number of times after the following events:
Overcurrent – 3 restarts
Overvoltage – 3 restarts
Undervoltage – 16 restarts (refer to Pb03 – [Restart Time]
for time between restart attempts)

ATTENTION: This parameter may only be used as

outlined in NFPA 79, “Under Voltage Protection.”
Equipment damage and/or personal injury may result if this
parameter is used in an inappropriate application.
b02 [Power Loss Time] 0.3/25.0 0.1 1.0 1.0
If undervoltage exists longer than the seconds
programmed time, the drive will fault even if
Pb01 - [Restart Mode Select] is active.
b03 [Restart Time] 0.3/100.0 0.1 1.0 1.0
Sets the time between restart attempts after an seconds
undervoltage fault or the removal of a digital
input set to 11 {FRS}.
1
U = 60 Hz default settings, K = 50 Hz default settings. Settable using Pb85 – [Factory Default Select]

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Parameters & Programming

Parameter Parameter Name/Description Min/Max Units Factor

Number Range Default
1 1
Electronic Thermal Motor Protection U K
b12 [Motor Overload Current] 5/120% of 0.01A 115% 115%
Set to motor nameplate full load amps. rated of of drive
current drive rating
rating
b13 [Motor Overload Select] 00/02 Numeric 01 01
Selects the characteristics of the electronic Value
thermal motor protection.
Settings: 00=Derating1
01=No Derating
02=Derating2
Torque
b13 = 01
100%

80% b13 = 02

60%
b13 = 00

5Hz 20Hz 60Hz 120Hz

Output frequency
1 1
Current Limit U K
b21 [Current Limit Select] 00/02 Numeric 01 01
Selects the mode for current limit. Value
Settings: 00=Inactive
01=Active
02=Inactive in acceleration

b22 [Current Limit] 50/150% 0.01 A 150% 150%

Sets the maximum output current allowed before of rated of of drive
current limiting occurs. Value set in percent of current drive rating
drive rated output current. rating
b23 [Current Limit Decel Time] 0.3/30.0 0.1 second 1.0 1.0
Sets the deceleration time when the current
limiting occurs.
1 1
Parameter Protection U K
b31 [Program Lock Select] 00/03 Numeric 01 01
Sets the mode of program lock used. Value
Settings: 00=All parameters locked when digital
input setting 15 {SFT} active.
01=All parameters locked except PF01
– [Frequency Command] when
digital input setting 15 {SFT} active.
02=All parameters locked
03=All parameters locked except PF01
– [Frequency Command].
1 1
Current Feedback Tuning U K
b32 [Reactive Current Setting] 0.00/100% 0.01A 40% of 40% of
Use to improve accuracy by calibrating drive drive drive
2
motor combination. For improved accuracy, rating rating
adjust this value during no load operation until
Pd02 - [Output Current] matches actual motor
current.
1
U = 60Hz default settings, K = 50Hz default settings. Settable using Pb85 – [Factory Default Select]
2
5hp (3.7 kW) ratings have a default value of 35%.

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Parameters & Programming

Parameter Parameter Name/Description Min./Max Units Factor

Number Range Default
1 1
Initialization / Adjustment Function U K
b81 [Output FM Adjustment] 0/255 N/A 80 80
Sets the multiplier applied to output duty cycle for
the FM analog signal.
This Parameter can be changed while motor is running.

b82 [Start Frequency] 0.5/9.9 0.1 Hz 0.5 0.5

Sets the frequency at which the drive will start.
Refer to diagram in PA03 – [Base Frequency]

b83 [PWM Frequency 0.5/16.0 0.1 kHz 5.0 5.0

Carrier frequency for the PWM output waveform.
Output current must be derated by twenty percent
when set above 12 kHz.

b84 [Reset Functions] 00/01 Numeric 01 00

Resets the factory defaults or clears fault history. Value
Settings: 00=Clear fault history
01=Reset defaults
Note: To activate this parameter, set the value and press the Enter
Key, then hold the SELect, Up, Down, and STOP Keys for 3
seconds, release only the STOP Key until display is blinking, then
release all of the keys.
Note: Defaults will reset to factory settings determined by Pb85 –
[Factory Defaults Select]

b85 [Factory Default Select] 06/07 Numeric 07 06

Determines the default settings of all parameters. Value
The drive will reset to these default values when a
“reset defaults” command is executed as
described in Parameter b84, setting 01 = reset
defaults.
Settings: 06=K (50 Hz default settings)
07=U (60 Hz default settings)
Note: Parameter default values for settings 00 - 05 are not
published in this manual and are not recommended. If using these
default settings Parameter b87 becomes active. Refer to the
Attention statement under Parameter b87.

b86 [Process Display Scale Factor] 0.1/99.9 N/A 30.0 1.0

Sets the frequency factor for Pd07 –[Process
Display].
Also sets the multiplier that is applied to the output
frequency for the FM pulse signal.
This Parameter can be changed while motor is running

b87 [STOP Key Select] 00/01 Numeric 00 00

This parameter is not active when Parameter b85 Value
is set to setting 06 or 07.

ATTENTION: If parameter b85 settings 00 through 05,

are activated, this parameter will control the operation of the
keypad STOP key. Setting 00 will enable the STOP key and
01 will disable the STOP key. Disabling the STOP key is not
recommended as it could result in personal injury, loss of life
or equipment damage.

1
U = 60 Hz default settings, K = 50 Hz default settings. Settable using Pb85 – [Factory Default Select]

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Parameters & Programming

Parameter Parameter Name/Description Min./Max Units Factor

Number Range Default
1 1
Initialization / Adjustment Function U K
b88 [FRS Select] 00/01 Numeric 00 00
Selects operation of the drive after a digital input Value
(C01 – C05) setting 11{FRS} input is removed.
Settings: 00=0 Hz start
01=Synchronization of motor speed
after waiting period programmed via
Pb03 – [Restart Time].

b89 [Keypad Display] 01/07 Numeric 01 01

Selects the display parameter that will be shown Value
on the fixed keypad when the remote keypad is
connected.
Settings: 01 = Pd01 - [Output Frequency]
02 = Pd02 - [Output Current]
03 = Pd03 - [Direction of Rotation]
04 = Pd04 - [PID Process Display
05 = Pd05 - [Digital Input Status]
06 = Pd06 - [Output Status]
07 = Pd07 - [Process Display]

b92 [Reserved] 00/01 00

Reserved for Future Use, DO NOT CHANGE
1
U = 60Hz default settings, K = 50 Hz default settings. Settable using Pb85 – [Factory Default Select]

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Parameters & Programming

C Group – Intelligent I/O and Communication Parameters

This parameter group is used to program the functions of the digital and analog I/O.

ATTENTION
• All digital inputs respond to level sensitive commands.
• Inputs do not require a voltage transition (cycle) after a fault condition is cleared, after input power cycling or
after programming the logic of the digital input.
• All digital inputs can be programmed as NO or NC. HOWEVER, The START COMMAND SHOULD BE SET AS
NO (ACTIVE HIGH) AND THE STOP COMMAND SHOULD BE SET AS NC (ACTIVE OPEN). If set opposite of
this, an inadvertent start or failure to stop could occur should a discrete connection be lost or control wire come
loose. IF THE USER CHOOSES TO DISREGARD THIS SAFETY PRACTICE – THE RISK ASSUMED BY THE
USER CAN BE REDUCED BY ASSURING THAT OTHER SAFEGUARDS ARE USED TO INSURE PROPER
START AND STOP OPERATION. Depending on the application: This may include appropriate emergency
stops, redundant wiring, electronic guards and/or mechanical guards.
Failure to observe this precaution could result in severe bodily injury or loss of life.

Parameter Parameter Name/ Description Min./Max Units Factor

Number Range Default
1 1
Digital Inputs 1 – 5 U K
C01 [Digital Inputs 1-5] 00/31 Numeric 22 00
Used to program the function of digital inputs 1 – 5. Value
Settings: 00={FW} (Forward)
01={RV} (Reverse)
02={CF1} (Preset Frequency Input)
C02 03={CF2} (Preset Frequency Input) 20 01
04={CF3} (Preset Frequency Input)
05={CF4} (Preset Frequency Input)
06={JG} (Jog)
09={2CH} (Accel/Decel 2 Select)
11={FRS} (Coast to Stop)
C03 12={EXT} (External Trip) 21 02
13={USP} (Unintentional Start Protection)
15={SFT} (Program Lock)
16={AT} (4-20mA Select)
18={RS} (Reset)
19={PTC} (PTC Input) input C05 only
C04 20={STA} (3 Wire Run) 18 03
21={STP} (3 Wire Stop)
22={F/R} (3 Wire Forward/Reverse)
27={UP} (Remote Control Up)
28={DWN} (Remote Control Down)
C05 31={OPE} (Run/Stop Command Source Select) 13 13
Refer to Chapter 2 for setting descriptions of the “Programmable
Digital Input Functions” listed above.
C11 [Digital Inputs 1-5 Logic] 00/01 Numeric 00 00
C12 Sets the digital inputs to be NO or NC contacts Value 00 00
C13 Settings: 00=NO contact (active high) 01 00
C14 01=NC contact (active open) 00 00
C15 01 01
1 1
Outputs 11, 12, FM, AL0-AL1 U K
C21 [Digital Outputs 11-12] Sets the operation of the 00/05 Numeric 01 01
digital outputs Value
Settings: 00={RUN} (Motor running above 0.5 Hz)
01={FA1} (At frequency and above 0.5 Hz)
02={FA2} (Above frequency)
C22 03={OL} (Overload alarm) 00 00
04={OD} (PID deviation)
05={AL} (Fault)
Refer to control terminal table in chapter 2 for setting descriptions.
1
U = 60 Hz default settings, K = 50 Hz default settings. Settable using Pb85 – [Factory Default Select]

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Parameters & Programming

Parameter Parameter Name/Description Min/Max Units Factor

Number Range Default
1 1
Outputs 11, 12, FM, AL0-Al1 U K
C23 [Output FM Select] 00/02 Numeric 00 00
Sets the operation of the output FM. Value
Settings: 00={A-F} (Analog Output Frequency)
01={A} (Motor Current)
02={D-F} (Digital Output Frequency)
Refer to control inputs table in chapter 2 for setting
descriptions..
C31 [Digital Output 11-12 Logic] 00/01 Numeric 00 00
Sets the digital outputs to be NO or NC contacts. Value
C32 Settings: 00=NO contact (Active high) 00 00
01=NC contact (Active open)
C33 [Fault Relay AL1 Logic] 00/01 Numeric 01 01
Sets the fault relay to be either NO or NC contacts. Value
Settings:
00 = NO contact (active high)
01 = NC contact (active open)
Refer to control inputs table in Chapter 2 for setting descriptions.
C41 [Overload Alarm Threshold] 0/200% of 0.01 A 100% 100%
Sets the allowable overload level before digital drive of drive of drive
outputs 11-12 change state when set to 03 {0L}. rating rating rating
C42 [Above Frequency Accel Threshold] 0.0/360.0 0.1 Hz 0.0 0.0
Sets the frequency at which digital outputs 11-12
change state when set to 02 {FA2} if the drive is
accelerating.
C43 [Above Frequency Decel Threshold] 0.0/360.0 0.1 Hz 0.0 0.0
Sets the frequency at which digital outputs 11-12
change state when set to 02 {FA2} if the drive is
decelerating.
C44 [PID Deviation Threshold] 0.0/100% +/- 0.1% +/-3.0 +/-3.0
Sets the allowable PID Loop error before digital
outputs 11-12 change state when set to 04 {OD}.
1 1
Communications U K
C70 [Communication Command Select] 02/03 Numeric 02 02
Selects the source of the communication command. Value
Settings: 02 = Remote Operator
03 = RS485
C71 [Baud Rate] 04/06 Numeric 04 04
Selects the Baud Rate for RS485 communication. Value
Settings: 04 = 4800 bps
05 = 9600 bps
06 = 19200 bps
C72 [Drive Address] 01/32 N/A 01 01
Sets the drive node address on the RS485 network.
C79 [Communication Error Select] 00/01 Numeric 00 00
Selects the drives operation when a communication Value
error (E60) occurs.
Settings: 00 = Fault
01 = No Fault and continue operation
C91 Debug Mode
Used by Rockwell Automation field service personnel.

ATTENTION If PC91-[Debug Mode] is set to 01

parameters PC92-PC95 are enabled. Changing parameters
PC92-PC95 can lead to personal injury, death, or equipment
damage. DO NOT CHANGE PARAMETERS PC91-PC95.
1
U = 60 Hz default settings, K = 50 Hz default settings. Settable using Pb85 – [Factory Default Select]

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Chapter 4 –Faults & Troubleshooting

Fault Information
This chapter provides information to guide you in troubleshooting the drive. Included is a list and description of
drive faults and problems that may occur.
How to Clear a Fault
When a fault occurs, the cause must be corrected before the fault can be cleared. After corrective action has
been taken, any of the following actions will clear the fault.
ƒ Press the stop button on the Keypad.
ƒ “Reset” the drive via a digital input that is programmed to setting 18 {RS}.
ƒ Cycle power to the drive.

ATTENTION
• A hazard of personal injury or equipment damage exists. If a fault is cleared while there is a valid
run command, the drive will run as soon as the fault is cleared without cycling the input.
Bulletin 161 Fault Descriptions
Fault Fault Name Fault Description Corrective Action
Number
Overcurrent An overcurrent has been detected Check for a short circuit at the drive output or for
E 01 While running in the hardware trip circuit while excessive load conditions at the motor.
the drive was running.
Overcurrent An overcurrent has been detected Check for a short circuit at the drive output or for
E 02 During in the hardware trip circuit while excessive load conditions at the motor.
Deceleration the drive was decelerating.
Overcurrent An overcurrent has been detected Chec for a short circuit at the drive output,
E 03 During in the hardware trip circuit while excessive load conditions at the motor, an
Acceleration the drive was accelerating. acceleration time that is too short, or for a manual
boost setting that is improperly set.
Overcurrent at a An overcurrent has been detected Check the output lines or the motor for a ground
E 04 Standstill in the hardware trip circuit while fault.
the drive was at a standstill.
Internal Motor The internal electronic motor Check the entry under Pb12 - [Motor Overload
E 05 Protection protection has been triggered due Current]. Reduce PA42 - [Manual Boost Voltage].
to overloading of the connected Check the motor and drive rating.
motor.
Overvoltage The maximum DC Bus Voltage Motor regeneration has caused a bus overvoltage.
E 07 has been exceeded due to Extend the decel time.
regenerative energy from motor.
EEPROM Error The EEPROM has invalid data. Reset EEPROM by resetting the defaults using
E 08 Pb84 - [Reset Functions].
Undervoltage The DC Bus voltage fell below the Monitor the incoming AC line for low voltage or
E 09 minimum rated voltage. line power interruptions.
Processor Error Check external wiring for a possible cause. If
E 11 There is a malfunction or problems persist have drive serviced by
Processor Error abnormality of the CPU authorized Rockwell-Automation service
E 22 personnel.
External Fault External fault 12 {EXT} indication Remove the cause of the fault in the external
E 12 has been received at one of the wiring and clear the fault.
digital inputs (C01-C05).
Unintentional An input (C01-C05) was set to 13 Check incoming line voltage for low voltage or line
E 13 Start Protection {USP} and power was restored power interruptions. Remove the run command
while a run input was active. before power-up.
Ground Fault There was a ground fault at the Check for a ground fault at the output terminals.
E 14 motor output terminals.
Excess Input The input voltage is higher than Check the incoming AC line.
E 15 Voltage permitted.
*For a description of the reset function see digital input description table in Chapter 2, and parameters PC01 [Digital Input 1] –
PC05 [Digital Input 5] in Chapter 3.

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Faults & Troubleshooting

Fault Fault Name Fault Description Corrective Action

Number
Overtemperature Excessive heat has been Clear blocked or dirty heat sink fins. Chec
E 21 fault detected inside the drive. ambient temperature. Check for proper clearance
distances. On models with a fan, check for fan
operation. Check for excessive motor load.
PTC circuit The resistance from the Check for an overload condition at the motor, or
E 35 triggered. external thermistor was too check for proper ventilation at the motor.
large. (Greater than 3 Ω)
Communication A loss of communication has Check communication connections.
E 60 Error occurred.

Possible Problems and Corrective Actions

Problem Corrective Action
The motor does not start. 1. Check the power circuit.
ƒ Check the supply voltage.
ƒ Check all fuses and disconnects.
2. Check the Motor.
ƒ Verify that the motor is connected properly.
ƒ Verify that no mechanical problems exist.
3. Check the control input signals.
ƒ Verify that the start signal is present.
ƒ Verify that either the Run Forward or Run Reverse signal
is active, but not both.
ƒ Verify wiring of H, O, and L terminals if a remote speed
pot is being used.
ƒ If using 3 wire start, ensure that a 3 wire stop is
programmed.
ƒ Verify that the reset command {RS} is not active.
4. Check the setting of PA01-[Frequency Command Select].
5. Check setting of PA02 - [Start Command Select].
ƒ If set to keypad start chec PF04-[Start Key Direction],
when set to 02, the 00 {FW} or 01 {RV} digital input must
be active before pressing start key.
The direction of motor rotation is incorrect. 1. Check the motor output connections, reverse two of the three
phases if necessary.
2. Check that the control inputs have been wired correctly.
3. If using 3 wire control ensure that the 3 wire forward/reverse
input is programmed.
4. Check setting of PF04 – [Start Key Direction].
The motor does not accelerate properly. 1. Check to see that a frequency has been commanded.
2. Check to see if a preset frequency has been selected.
3. Check to see if the motor load is too high.
4. Check to see if the acceleration time is too long.
5. Check to see if manual boost and current limit are set
properly.
The motor runs unstable. 1. If sudden high load changes occur, choose a drive and motor
with higher ratings or reduce the load changes.
2. If resonant frequencies occur in the motor, set up skip
frequency bands.
3. If the input voltage is not constant, change the PWM carrier
frequency.

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Faults & Troubleshooting

Problem Corrective Action

The speed of the motor does not match the 1. Check to see that the maximum frequency has been entered
frequency. correctly.
2. Check the rated speed of the motor and the reduction ratio of
the gear.
3. Check to see if manual boost and current limit are set
properly.
4. If PID control is used, check gain adjustments.
The parameters stored do not match the values 1. When the input voltage was switched off the entered values
entered. were transferred to the power-failure safe EEPROM.
Reprogram the values and wait at least 6 seconds before
powering down.
No entries can be made. 1. Check to see if the parameter protection is activated via a
digital input setting of 15 {SFT}.
The electronic motor protection (fault E05) is 1. Check the manual boost setting to see if it is too high.
triggered. 2. Check the electronic motor protection setting to make sure
that it is correct.

Other Display

Display Description
A reset signal has been issued.
The Bulletin 161 drive is in standby mode.
Note: If motor was running when the 18{RS} input was received, the motor will coast to a
stop.

- - -
The input voltage has been switched off.

The waiting time before automatic restart has expired (see Pb01-[Restart Mode Select] -
Pb03-[Restart time]).

The factory setting has been selected and the drive is in the initialization phase
06 (see Pb84-[Reset Functions], Pb85-[Factory Defaults Select]). If your drive is a K version,
parameters for the 50Hz version are loaded. If your drive is a U version, parameters for
the 60 Hz version are loaded.
___ No data present or the function is not active.

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Faults & Troubleshooting

Figure 4.1 PID Loop Block Diagram

Frequency Setpoint Process Reference

Frequency
Command (Target) Scale Factor Command
Setting Process Reference Frequency
Command PA75 PF01
PF01 Scale Factor Select
reciprocal
Preset PA01
Frequency 1/PA75
PID
Settings Proportional
Gain
PA20 to PA35
PA72
Potentiometer
on keypad Error Frequency
PID
SP Integral Setting
Ε Gain Ε
V/I input PV PA73
select
PID
[AT] Differential
Process Variable Gain
(Feedback)
Voltage PA74
[O]
Analog input reference adjustment
Process Reference PID
PA12 Scale Factor Process Display
A GND PA75 PD04
PA11
L
PA15 PA13 PA14

OI PA76
Current Analog
Feedback
select

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Chapter 5 –Specifications & Dimensions

Technical Data
Series Bulletin 161
Type A01 A02 A03 A04 A05 A07 A10 A15
Drive rating kW (HP) 0.2 (.3) 0.4 (0.5) .55 (.75) 0.75 (1) 1.1 (1.5) 1.5 (2) 2.2 (3) 3.7 (5)
115V Input rated current (A) 5.5 10.0 N/A 16.0 N/A N/A N/A N/A
230V 1Φ Input rated current (A) 3.1 5.8 6.7 9.0 11.2 16.0 22.5 N/A
Φ Input rated current (A)
230V 3Φ 1.8 3.4 3.9 5.2 6.5 9.3 13.0 20.0
Output rated current (A) 1.4 2.6 3.0 4.0 5.0 7.1 10.0 15.9
Power Dissipation (W) 17 29 33 41 53 70 101 169
Mass (kg) See dimension drawings on following page.
Input voltage (V) 200 V -10% to 240 V + 5%, 50/60 Hz +/- 5%; 100V -5% to 120V +5%
Output voltage 3 Φ adjustable from 0 to 230V
Type of protection IP20
PWM carrier frequency 0.5 - 16 kHz
V/Hz characteristics Programmable V/Hz ratio, V/Hz control (constant torque, variable torque)
Type of control Voltage-driven, PWM sine weighted, IGBT-Power module
Output frequency 0.5 - 360 Hz
Accuracy of frequency Digital: +/- 0.01% of max. frequency
command Analog: +/- 0.2% of max. frequency
Frequency resolution Digital: 0.1 Hz, analog: 0.01% of max. frequency
Overload capacity Software: 150% for 60 s (once in a period of 10 min.), Hardware: 220%
Starting torque min. 150% at frequencies >3 Hz
Inherent Braking Torque A01 ... A04: 100%
A05 ... A07: 70%
A10 …A15: 20% (Approximate, Actual values depend on motor characteristics)
DC brake Starting frequency, braking torque, running times are variable.
Analog inputs 0 -10 V, input impedance 10 kΩ
4 - 20 mA, input impedance 250 Ω PTC input
Digital inputs 5 programmable level triggered inputs, 24V PNP logic, NO or NC contacts
Analog outputs 1 programmable output. 0-10V, 1mA, Accuracy: +/- 5% for frequency, +20% for current.
Digital outputs 2 open collector outputs. 27VDC, 50mA
Relay output 1 fault indication relay (change-over contact)
Resistive rating: 2.5A at 250VAC – 3A at 30VDC
Inductive rating: 0.2A at 250VAC – .7A at 30VDC
Protection functions Over-current, over-voltage, under-voltage, electronic motor protection, over-temperature,
ground fault, overload etc. (see Chap.4).
Other functions 15 preset speeds, PID control, unintentional start protection, RS422 serial interface, skip frequencies etc.

Ambient temperature -10 - +40 °C (up to +50 °C by removing top cover, reducing carrier frequency to 2kHz, and
derating output current by 20%)
Relative humidity 20 - 90% relative humidity, no condensation
Vibration/Shock Vibration: 0.6G operational / Shock: 10.0G operational
Max. installation altitude 1000 m (3300 ft.) above sea level
Options Line filter modules

Standards EN 61800-3 EMC guidelines in connection with optional line filter modules
in line with installation guidelines, EN 50178 Low-Voltage guideline,
ED 966 D 5966
ST TE
X

X
LIS
LI

UL508C CSA 22.2

ND
®
ND
® N223 (pending)
Q

E E
I

CONT CONT

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Specifications & Dimensions

Figure 5.1 Bulletin 161 Dimensions

(All dimensions are in millimeters and (inches).
AA01 / AA02 / AA03 AA04 / AA05
7 7
(0.28) (0.28)
67 AA01 - 93 (3.66) 98 129
(2.64) AA02/AA03 - 107 (4.31) (3.86) (5.08)

130
120 (5.12)
110 (4.72) 118
(4.33) (4.65)

5 (0.20)
5 (0.20) 10 (0.39) 10 (0.39)

80 110 4 (0.16)
4 (0.16) (4.33)
(3.15)
Mass Kg (lb) Mass Kg (lb)
AA01 AA04/AA05
0.7 (1.54) 1.3 (2.87)
AA02/AA03
0.85 (1.87)

2.5 (0.10)
2.5 (0.10)

AA07 AA10/AA15
7
7 Air
(0.28)
128 153 128 (0.28)
(5.04) (6.02) (5.04) 164
(6.46)

180 180
(7.09) (7.09)
168 168
(6.61) (6.61)

5 (0.20) 5 (0.20)
10 (0.39) Air

Mass Kg (lb) Mass Kg (lb)

AA07 AA10 / AA15
2.2 (4.85) 2.8 (6.17)

3.5 6
(0.14) Fan (0.24)

140
(5.51) 140
(5.51)

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Specifications & Dimensions

DA01 / DA02 DA04

7 7
(0.28) (0.28)
119 110 119 110
(4.69) (4.33) (4.69) (4.33)

180
118 130 (7.09)
(4.65) (5.12)
168
(6.61)

10 (0.39) 5 (0.20)
10 (0.39)
10 (0.39) 5 (0.20)
10 (0.39)

Mass Kg (lb)
DA01 Mass Kg (lb)
1.1 (2.42) DA04
DA02 1.5 (3.31)
128 2.6 (.10) 1.2 (2.64) 128 2.6 (0.10)
(5.04) (5.04)

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Specifications & Dimensions

Accessories
Line Filter Module
Specifications
Nominal Nominal Leakage Test voltage Input wire Output cable Heat
Line Filter Voltage Current Current [VDC for 2s] max. cross cross section dissipation
Module at 40°C at 50 Hz ph. to ph; section 2 2
[mm (in )] [W]
[V]
2 2
[A] (mA) ph. to ground [mm (in )]
161S-RFA-6- 240 +5% 6A < 3.5 1400 / 2800 4 (.006) 1.5 (.002) 5
161S-RFA-9- 240 +5% 10 A < 3.5 1400 / 2800 4 (.006) 1.5 (.002) 6
161S-RFA-22-C 240 +5% 23 A < 10 1400 / 1400 4 (.006) 2.5 (.004) 9

Current: at 40°C ambient temperature Dependence of current on ambient temperature

Overload: 150% IN for 10 min IB 1,2
IN
1,0
Frequency: 50 / 60 Hz
0,8
Material: steel, surface finished
0,6
Humidity class: C 0,4
Operation height: < 1000 m (3200 ft.) without derating 0,2
> 1000 m, IN-2%, for each 1000 0
0 20 40 60 80 100
Temperature range: -25°C to +85°C T i °C
temperature in °C
Connections Input terminals IP 20 and PE-screw M5
Load side: cable, unshielded

Figure 5.2 Filter Dimensions [mm (in)]: Line Filter Selection Guide
Drive
Input Voltage Line Filter Module
Ratings
AA01 1~ 220V-10% -240V +5% 161S-RFA-6-
AA02 1~ 220V-10% -240V +5% 161S-RFA-6-
F
AA03 1~ 220V-10% -240V +5% 161S-RFA-9-
AA04 1~ 220V-10% -240V +5% 161S-RFA-9-
type 1 AA05 1~ 220V-10% -240V +5% 161S-RFA-22-C
AA07 1~ 220V-10% -240V +5% 161S-RFA-22-C
D A
AA10 1~ 220V-10% -240V +5% 161S-RFA-22-C

E
C
B

Line Filter Module A B C D E F

161S-RFA-6- 120 (4.7) 80 (3.15) 25 (.98) 110 (4.33) 67 (2.64) 6 (.24) 2 holes
161S-RFA-9- 130 (5.12) 110 (4.13) 27 (1.06) 118 (4.65) 98 (3.86) 6 (.24) 4 holes
161S-RFA-22-C 180 (7.7) 140 (5.51) 29 (1.14) 168 (6.61) 128 (5.04) 6 (.24) 4 holes

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Appendix

Appendix A –CE Conformity

CE Compliance
This drive is a component intended for implementation in machines or systems for the industrial environment.
It is CE marked for conformity to the Low Voltage (LV) directive 73/23/EEC when installed as described. It
also has been tested to meet the Council Directive 89/336 Electromagnetic Compatibility (EMC). The
standards used for this testing are, LV: EN50178, EN60204-1, EN60950, EMC: EN61800-3 (EN55011,
Group 1, Class B (Industrial Environment)).

General Notes and Instructions

• The motor cable should be kept as short as possible in order to avoid electromagnetic emission as well as
capacitive currents. The cable length increases the capacitive current and electromagnetic emission.
It is recommended that the motor cable length does not exceed 50m.
It is always recommended to install output reactors if the cable length exceeds 50m.
• The filters contain capacitors between the phases and the phases to ground as well as suitable
discharging resistors, but after switching off the line voltage wait a minimum of 60 seconds before
removing protective covers or touching terminals to avoid an electric shock.
• The use of ground fault monitoring devices (RCD’s) is not recommended. If unavoidable, only monitoring
devices which are suited for DC, AC and High Frequency ground currents (type B RCD’s) should be used.
It is recommended to use devices whose responsiveness and time characteristics are adjustable, to avoid
nuisance tripping during power up of the drive.
• The thermal capacity of the line filter is guaranteed up to a maximum motor cable length of 50m.
• The line filters have been developed for use in grounded systems. Use in ungrounded systems is not
recommended.

Essential Requirements for a Conforming EMC Installation

The following items are required for CE conformance.
1. An input filter module (See Chapter 5 Specifications and Dimensions) must be installed to reduce
conducted emissions.
Compliance of the Bulletin 161 drive to the conducted emissions levels with appropriate line filter module is
as follows:
PWM Carrier Frequenc Motor Cable Length Limit
</= 16kHz 10 Class B
</= 5kHz 20 Class B
</= 16kHz 50 Class A

2. Grounding of equipment and cable shields must be solid with low impedance connections.
3. All motor cables must use shielded cable, or be in grounded metal conduit.
4. All control and signal wiring must use shielded cable or be in grounded metal conduit.
5. Ensure that the protective earth ground terminal (PE) of the filter is properly connected with the protective
earth ground terminal of the drive. The filter must be solidly and permanently connected with the ground
potential to avoid electric shock.

General Instructions for an EMC Compliant Installation

Motor Cable
• The cable between the drive and motor must be 4-wire shielded cable (three phases and ground).
• Do not exceed the maximum motor cable length for the specific line filter module used.
Control Cable
• Control wiring must use shielded cable or grounded metal conduit.
• The shield must be connected to PE at both ends of the cable.

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Appendix

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Publication 0161-5.0ML – October, 1999 Copyright 1998 Rockwell International Corporation. All rights reserved NB 571
Supersedes 161-5.0ML-EN – April, 1999
 SPECIAL INSTRUCTION MANUAL
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ALLEN-BRADLEY

Safety Guidelines for the Application,

Installation and Maintenance of Solid State
Control

Table of Contents

Foreword...........................................................................................1
NEMA Standard Text .......................................................................1
Section 1 Definitions .......................................................................1
Section 2 General............................................................................. 2
2.1 Ambient Temperature ............................................................. 2
2.2 Electrical Noise ...................................................................... 2
2.3 Off-State Current.................................................................... 3
2.4 Polarity ................................................................................... 3
2.5 Rate of Rise-Voltage or Current (DV/DT or DI/DT)................. 4
2.6 Surge Current......................................................................... 4
2.7 Transient Overvoltage ............................................................ 5
Section 3 Application Guidelines ................................................... 5
3.1 General Application Precautions ............................................ 5
3.2 Circuit Isolation Requirements ............................................... 8
3.3 Special Application Considerations ........................................ 8
3.4 Planning Electrical Noise Rejection .....................................10
3.5 Countering the Effects of Off-State Current .........................12
3.6 Avoiding Adverse Environmental Conditions........................13
3.7 The Need for Education – Knowledge Leads to Safety........14
Section 4 Installation Guidelines..................................................15
4.1 Installation and Wiring Practice ............................................15
4.2 Enclosures (Cooling and Ventilating) ...................................16
4.3 Special Handling of Electrostatic Sensitive Devices.............16
4.4 Compatibility of Devices with Applied Voltages and
Frequencies .........................................................................16
4.5 Testing Precautions ..............................................................16
4.6 Startup Procedures ..............................................................17
Section 5 Preventive Maintenance and Repair Guidelines ........18
5.1 General ................................................................................18
5.2 Preventive Maintenance .......................................................18
5.3 Repair...................................................................................19
5.4 Safety Recommendations for Maintenance Personnel.........20
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Foreword
This Allen-Bradley publication is formatted to harmonize with NEMA Standards Publication No. ICS
1.1-1987, also titled Safety Guidelines for the Application, Installation and Maintenance of Solid State
Control. The text of the NEMA Standard has been reprinted verbatim, with NEMA’s permission, in the
left column, captioned “NEMA Standard Text”. The right column, captioned “Explanatory Information”,
contains Allen-Bradley comments. The comments provide supplementary information to the NEMA
Standard to help the reader better understand the characteristics of industrial equipment employing
solid state technology. The Allen-Bradley Company is solely responsible for the explanatory comments,
which are not part of the NEMA Standard.
NEMA Standards Publication No. ICS 1.1-1984, Rev. No. 1 – October 1987, is available from the
National Electrical Manufacturers Association, 2101 L Street, N.W., Washington, D.C. 20037.

NEMA Standard Text Explanatory Information

SCOPE – This Standards Publication is intended (Supplementary Comments – Not part of NEMA
to provide general guidelines for the application, STANDARDS PUBLICATION NO. ICS-1.1)
installation, and maintenance of solid state control
in the form of individual devices or packaged Scope
assemblies incorporating solid state components. The scope of this Allen-Bradley Publication
The emphasis of the guidelines is personnel (SGI-1.1) is identical to the scope of NEMA
safety. Applicable NEMA standards and product Standards Publication No. ICS 1.1, quoted in the
related instructions should be carefully followed. left column.
Section 1
Definitions
Electrical Noise – Unwanted electrical energy that
has the possibility of producing undesirable effects
in the control, its circuits and system. Electrical
noise includes Electromagnetic Interference (EMI)
and Radio Frequency Interference (RFI).
Electrical Noise Immunity – The extent to which
the control is protected from a stated electrical
noise.
Electromagnetic Interference (EMI) – Electro-
magnetic disturbance that manifests itself in
performance degradation, malfunction, or failure of
electronic equipment. (IEC)
Off-State Current – The current that flows in a solid
state device in the off-state condition.
Off-State Condition – The conditions of a solid
state device when no control signal is applied.
On-State Condition – The condition of a solid state
device when conducting.
Radio Frequency Interference (RFI) – RFI is used
interchangeably with EMI. EMI is a later definition
that includes the entire electromagnetic spectrum,
whereas RFI is more restricted to the radio-
frequency band, generally considered to be
between 10k and 10G Hz. (IEC)
Surge Current – A current exceeding the steady
state current for a short time duration, normally
described by its peak amplitude and time duration.
Transient Overvoltage – The peak voltage in
excess of steady state voltage for a short time
during the transient conditions (e.g., resulting from
the operations of a switching device).

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Section 2
General General Comments
(Sections 2 through 5 are classified as Authorized Solid state devices provide many advantages such
Engineering Information 11-15-1984.) as high speed, small size, and the ability to handle
Solid State and electro-mechanical controls can extremely complex functions. However, they differ
perform similar control functions, but there are from electromechanical devices in the basic
certain unique characteristics of solid state operating characteristics and sensitivity to
controls which must be understood. environmental influences. In addition, solid state
devices exhibit different failure mechanisms when
In the application, installation and maintenance of
overstressed.
solid state control, special consideration should be
given to the characteristics described in 2.1 The comments which follow are intended to
through 2.7. provide additional information to help the reader
better understand the operating characteristics,
environmental limitations, and failure modes of
industrial equipment that incorporates solid state
technology. Those who select, install, use, and
service such equipment should apply that
knowledge to make appropriate decisions that will
optimize the performance and safety of their
applications.
2.1 Ambient Temperature C.2.1 Ambient Temperature
Care should be taken not to exceed the ambient Temperature of the air immediately surrounding an
temperature range specified by the manufacturer. open solid state device is the ambient temperature
which must be considered. When equipment is
installed in an enclosure, the enclosure internal air
temperature is the ambient temperature which
must be considered. Solid state component
manufacturers usually publish the component
failure rate for an ambient temperature of 40
degrees Celsius. A useful rule of thumb is: The
failure rate of solid state components doubles for
every ten degrees Celsius rise in temperature.
This rule of exponential increases in failure rate is
a strong incentive for the user to keep the ambient
temperature as low as possible.
Also see sections 3.6.1, and 3.6.2.

2.2 Electrical Noise C.2.2 Electrical Noise

Performance of solid state controls can be affected Solid state devices are generally more susceptible
by electrical noise. In general, complete systems to electrical noise interference than their
are designed with a degree of noise immunity. electromechanical counterparts. The reasons are
Noise immunity can be determined through tests straightforward. The operating mechanism for
such as described in 3.4.2. Manufacturer electromechanical devices requires a deliberate
recommended installation practices for reducing input of electrical energy that can be converted
the effect of noise should be followed. into a sustained mechanical force that is strong
enough to close the hard contacts and maintain
the closure for the duration on the ON cycle. Most
random electrical noise signals lack the energy
content to produce that magnitude of mechanical
force.
The operating mechanism for solid state devices is
totally different. The deliberate electric energy
input is used to disturb the placement of the
electrically charged particles within the molecular
structure. This molecular displacement changes
the electrical characteristic from that of an
insulator to that of a conductor or vice versa.
(continued)

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C.2.2 (continued)
The required energy level is very low. In addition, a
sustained signal is not required for components
such as SCRs, triacs, and logic gates because
these types are self-latching. Most random
electrical noise signals are of the momentary low
energy type. Since it is difficult to separate
deliberate signals from random noise, the devices
are thereby more susceptible. This is cause for
special concern regarding the electrical
environment and possible need for noise rejection
measures.
All see sections 3.4, 3.4.1, 3.4.2, 3.4.3.
2.3 Off-State Current C.2.3 Off-State Current
Solid state controls generally exhibit a small Off-state current is also referred to as leakage
amount of current flow when in the off-state current in the literature. A solid state “contact” is a
condition. Precautions must be exercised to solid block of material which is switched from ON
ensure proper circuit performance and personnel to OFF by a change internally from a conductor to
safety. The value of this current is available from an insulator. Since a perfect insulator does not
the manufacturer. exist, there is always some leakage current
present as long as voltage is applied to the device.
The presence of leakage current indicates that
OFF does not mean OPEN. The reader is warned
that simply turning a solid state device OFF does
not remove the possibility of a shock hazard.
Solid state and electromechanical devices, used
as inputs to solid state controls, must be
compatible with the solid state equipment with
which they are used. Solid state devices have
inherent off-state current, as explained in the
preceding paragraph. Electromechanical devices
may also permit a small amount of current to flow
when the device is in the “open” position due to
poor insulation characteristics, which may be
subject to further deterioration with age and use.
An example is a switching device that employs a
carbon brush in contact with an insulating segment
of the switch in the off-state, such that a
conductive film may be deposited by the brush on
the insulating segment. Any input device that could
produce an erroneous signal of sufficient
magnitude to cause a malfunction of the solid state
equipment, such as unintended turn ON or inability
to turn OFF, should not be used with solid state
controls.
Also see section 3.5.2.

2.4 Polarity C.2.4 Polarity

Incorrect polarity of applied voltages may damage In some instances incorrect polarity can cause
solid state controls. The correct polarity of solid damage to controlled equipment or unintended
state controls should be observed. actuation of outputs. This could result in personal
injury due to an unexpected response of the
controlled equipment or process.
Also see section 3.3.2.

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2.5 Rate of Rise-Voltage or Current C.2.5 Rate of Rise-Voltage or Current

(DV/DT or DI/DT) (DV/DT or DI/DT)
Solid state controls can be affected by rapid The DV/DT rating specifies the maximum rate at
changes of voltage or current if the rate of rise which voltage may be applied to the power
(DV/DT and/or DI/DT) is greater than the maximum terminals of a solid state device. Voltage applied at
permissible value specified by the manufacturer. a rate exceeding the DV/DT rating can switch the
device ON without an input signal being applied.
Electrical noise with high frequency content is one
source of rapidly changing voltage.
Another common source of high DV/DT is an
inductive load that is switched off faster than the
stored energy can be dissipated. This fast
switching produces “inductive kick voltages” that
might exceed the DV/DT limit.
The DI/DT rating specifies the maximum rate at
which current flow may be increased when
switching from OFF to ON. Currents that increase
faster than the DI/DT rating cause localized hot
spots due to current crowding in a small area until
the entire cross section can become conductive.
This results in gradual degradation of the device.
Subsequent operations generally result in over
dissipation and short circuit failures even under
normal load conditions. The most common
situations for high DI/DT are low load impedance,
or capacitance loads.
Manufacturers of solid state equipment usually
include internal means to limit the rate of rise of
voltage and current. Nonetheless, the user should
be aware that additional external means may be
necessary to adjust to the specific conditions of
some installations.

2.6 Surge Current C.2.6 Surge Current

Current of a value greater than that specified by The manufacturer may specify allowable surge
the manufacturer can affect the solid state control. current. Common practice is to specify the peak
Current limiting means may be required. sinusoidal current that can be allowed for one-half
cycle at line frequency. The intent behind this
practice is to give the user information for selecting
an appropriate fuse or other current limiting
means.
Applications that require short term overcurrent
capability (e.g., motor starting) must observe the
manufacturers restrictions on the number of times
the device can be subjected to overcurrent in a
specified time interval. The user should be aware
that this specification may vary depending upon
whether the conditions call for hot starts or cold
starts. Hot start means that the solid state
component is at or near the normal operating
temperature due to previous operation history
when the overcurrent condition occurs. Cold start
means that the solid state component is at or
below 40 degrees Celsius when the overcurrent
condition occurs.

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2.7 Transient Overvoltage C.2.7 Transient Overvoltage

Solid state controls may be affected by transient Solid state devices are especially sensitive to
overvoltages which are in excess of those excessive voltage. When the peak voltage rating is
specified by the manufacturer. Voltage limiting exceeded, even for a fraction of a second,
means should be considered and may be required. permanent damage can occur. The crystalline
structure of the device may be irretrievably altered
and the device may no longer be able to turn OFF.
The external symptom of this situation is exactly
the same as that of an electromechanical device
with welded contacts.
Minimum Holding Current
Another characteristic of concern is the minimum
holding current requirement for triacs and SCRs.
When the load current falls below the minimum
value, typically 25 – 100 mA, the triac or SCR
ceases conduction and passes only off-state
current until again triggered. Thus, it may not be
possible for the circuit to turn-on or conduct full
load current for very light loads. In these instances,
a load resistor called a bleeder resistor may be
connected to the output to provide the minimum
load. In some equipment special circuitry is
provided to overcome this problem.

Section 3
Application Guidelines
3.1 General Application Precautions
3.1.1 Circuit Considerations C.3.1.1 Circuit Considerations
The consequences of some malfunctions such as The predominant failure mode of solid state
those caused by shorted output devices, devices is in the ON condition. This failure mode
alteration, loss of memory, or failure of isolation and the other types of failures mentioned in the
within components or logic devices, require that NEMA Standard are the reasons for the
the user be concerned with the safety of personnel precautions that are recommended for safety-
and the protection of the electronics. critical circuits on systems that control potentially
It is recommended that circuits which the user hazardous processes or machine operations.
considers to be critical to personnel safety, such as Alternatively, if solid-state is used for circuits
“end of travel” circuits and “emergency stop” designated as safety-critical, the circuits should be
circuits, should directly control their appropriate designed to provide safety equivalent to the
functions through an electromechanical device recommended “hard-wired” electromechanical
independent of the solid state logic. Such circuits circuits. In such cases consideration should be
should initiate the stop function through de- given to techniques such as: redundancy, feed-
energization rather than energization of the control back loops, diagnostics, interlocking and read-only
device. This provides a means of circuit control memory for critical parts of a program.
that is independent of system failure. De-energization rather than energization of the
control device should be specified for STOP
circuits so broken wires or corroded contacts do
not go undetected. E-stop push buttons or pull
cords should be installed at appropriate locations
on a machine to provide operators with a rapid and
convenient means for removing power from
devices which control machine motion.
(continued)

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C.3.1.1 (continued)
Alternate methods of stopping such as dynamic
braking and regenerative braking may be available.
In order to accomplish the dynamic braking and
regenerative braking function, the control circuit, or
part of it, in the equipment must remain energized
during the stopping mode. However, operator
interface components such as stop push buttons
or pull cords, must still be connected through
normally closed contacts so broken wires or
corroded contacts do not go undetected. Also, if
dynamic or regenerative braking is used for
emergency stopping, provision should be made to
interrupt the power circuit as soon as the machine
comes to a stop.

3.1.2 Power Up/Power Down Considerations C.3.1.2 Power Up/Power Down Considerations
Consideration should be given to system design Response of a system during power up/power
so that unsafe operation does not occur under down can create hazards not encountered during
these conditions since solid state outputs may normal operation. Erratic operation of solid state
operate erratically for a short period of time after outputs due to the changing voltage of DC power
applying or removing power. supplies during start up is one example. To avoid
unpredictable outputs, many power supplies
incorporate a power turn-on time delay circuit. This
allows power supply output voltage to reach its
specified value before being applied to solid state
logic and output circuits. If this protection is not
part of the DC supplies for a system, a timing
circuit external to the power supply can be added
to delay the application of power to output devices.
Removing all power or losing all power from a
system simultaneously usually does not result in a
hazard since the power for machine operation is
also being removed. However, when power other
than electrical power is being controlled, a power
interlock circuit may be required to protect against
unexpected machine motion. Power interlocks with
automatic shutdown should be included if erratic or
hazardous operation results due to loss of one
power supply in a system with multiple supplies.
Automatic power supply sequencing should be
employed in systems that require the application or
removal of power in a specific sequence. If the
STOP or E-STOP sequence normally employs
dynamic braking, alternative safeguards, such as
automatic mechanical braking upon loss of power,
should be provided if coasting stops are
hazardous.
If hazardous operation can result from unexpected
restoration of power during a power outage or a
system shutdown, the system should include a
feature which requires a deliberate operator action
before power is reapplied to the system.

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3.1.3 Redundancy and Monitoring C.3.1.3 Redundancy and Monitoring

When solid state devices are being used to control The normal operating mechanism for solid state
operations, which the user determines to be components depends upon a deliberate electrical
critical, it is strongly recommended that signal input altering the internal molecular
redundancy and some form of checking be structure of the semiconductor material.
included in the system. Monitoring circuits should Unfortunately, spurious input signals may also
check that actual machine or process operation is alter the internal molecular structure without any
identical to controller commands; and in the event means for external detection that this has
of failure in the machine, process, or the happened. Therefore, solid state devices are
monitoring system, the monitoring circuits should subject to malfunction due to random causes that
initiate a safe shutdown sequence. are undetectable. Because of this, redundancy
and monitoring are the most highly recommended
means for counteracting this situation.
When redundancy is used, dissimilar components
not susceptible to common cause failure should be
used for the redundant elements if a common
cause could produce simultaneous failure of those
elements in a dangerous mode.
A “safe shutdown sequence” can involve much
more than disconnecting electrical power for some
machinery and processes. Examples include
machines with high inertia and hazardous access
points; processes that become unstable at
shutdown unless a specific sequence is followed;
etc. The control system for such applications
should be configured to deal with the particular
hazard(s) through use of special features such as
automatic transfer of control functions to
redundant devices in the event of failure of primary
controls; alarm circuits and diagnostics to signal
and identify failures that require repair in order to
maintain redundancy; emergency power sources
with automatic transfer upon loss of primary power
source; or other appropriate features.

3.1.4 Overcurrent Protection C.3.1.4 Overcurrent Protection

To protect triacs and transistors from shorted Even a closely matched short circuit protective
loads, a closely matched short circuit protective device (SCPD) will generally protect a solid state
device (SCPD) is often incorporated. These device only against shorted loads, an accidental
SCPDs should be replaced only with devices short to ground or a phase to phase short.
recommended by the manufacturer. Depending upon the application, additional
protective measures may be needed to protect the
solid state devices against small to moderate
overcurrents. Consult with the manufacturer if
necessary.
3.1.5 Overvoltage Protection C.3.1.5 Overvoltage Protection
To protect triacs, SCRs and transistors from See section 2.7.
overvoltages, it may be advisable to consider
incorporating peak voltage clamping devices such
as varistors, zener diodes, or snubber networks in
circuits incorporating these devices.

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3.2 Circuit Isolation Requirements

3.2.1 Separating Voltages C.3.2.1 Separating Voltages
Solid state logic uses low level voltage (e.g., less For specifications of Class 2 circuitry, refer to
than 32 volts DC) circuits. In contrast, the inputs Article 725 of the National Electrical Code, NFPA
and outputs are often high level (e.g., 120 volts 70.
AC) voltages. Proper design of the interface
protects against an unwanted interaction between
the low level and high level circuits; such an
interaction can result in a failure of the low voltage
circuitry. This is potentially dangerous. An input
and output circuitry incorporating effective isolation
techniques (which may include limiting impedance
or Class 2 supplied circuitry) should be selected.
3.2.2 Isolation Techniques C.3.2.2. Isolation Techniques
The most important function of isolation In addition to utilizing the various components
components is to separate high level circuits from discussed in the left column, specific wiring
low level circuits in order to protect against the techniques should be applied to assure separation
transfer of a fault from one level to the other. of power circuit wires from logic circuit wires. If at
Isolation transformers, pulse transformers, reed all possible, logic wires should be run in a conduit
relays, or optical couplers are typical means to that is segregated for that purpose only. Multiple
transmit low level logic signals to power devices in conductors in a shielded cable is an appropriate
the high level circuit. Isolation impedance means substitute for separate conduits. Another common
also are used to transmit logic signals to power practice is to run the logic signals through twisted
devices. pairs of wire. Regardless of the circumstances,
wires carrying logic signals should never be
wrapped in the same bundle with wires that carry
power signals.
3.3 Special Application
Considerations
3.3.1 Converting Ladder Diagrams C.3.3.1 Converting Ladder Diagrams
Converting a ladder diagram originally designed The example cited in this section of the NEMA
for electromechanical systems to one using solid Standard illustrates only one of a number of
state control must account for the differences reasons for special care in converting an
between electromechanical and solid state electromechanical (relay) ladder diagram to a
devices. Simply replacing each contact in the programmable controller (PC) program. Some
ladder diagram with a corresponding solid state other basic considerations are:
“contact” will not always produce the desired logic • A PC program is an instruction to the PCs
functions or fault detection and response. For central processing unit to enable it to perform the
example, in electromechanical systems, a relay logic functions and sequences for a particular
having a mechanically linked normally open (NO)
application. Typically, the PCs logic level
and normally closed (NC) contact can be wired to
components are electrically isolated from the
check itself. Solid state components do not have a
actual input, sensor and actuator devices, as
mutually exclusive NO-NC arrangement. However,
external circuitry can be employed to sample the contrasted with electromechanical controls which
input and “contact” state and compare to usually include contacts and coils of the actual
determine if the system is functioning properly. plant floor devices in the control schematic.
Therefore a PC program normally functions as
open-loop control, unless feedback loops from the
plant floor devices to separate inputs of the PC are
provided and programmed to cause corrective
action if inconsistencies are detected.
Programmers of PC systems should evaluate
functional and safety implications of all control
paths and provide appropriate feedback
arrangements as needed.
(continued)

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C.3.3.1 (continued)
• In an electromechanical implementation of a
ladder diagram, power is available to every rung at
all times, so that the logic of the various rungs is
executed continually and simultaneously, limited of
course by the operating delays inherent in the
electromechanical devices. By contrast, a typical
PC examines the status of input devices (I/O
scan), then executes the user program in
sequence (program scan), then changes outputs
accordingly in the next I/O scan. Therefore, the
sequential order of a PC program can be of more
importance and significance than in its
electromechanical counterpart, particularly when
special instructions such as “immediate” inputs or
outputs are programmed as some PCs permit.
Also, differences in response characteristics of
components, differences in system architecture,
and the scan time associates with a PC system
can combine to change timing characteristics of a
circuit significantly. In particular, care must be
taken in handling momentary or rapidly changing
inputs to a PC system which might be missed
between scans. Simple transfer of a ladder
diagram without consideration of these
characteristics of PCs may produce unintended
and possibly hazardous results. Programmers
should consult the user’s manual in order to
understand the characteristics of the particular PC
being used, and provide appropriate features in
the program to accommodate them.
• Another concern is the operating mode of
devices connected to input terminals. Input signals
must be arranged so loss of signal due to a broken
wire or corroded contact does not go undetected
and create a hazardous condition. In particular,
stop functions should be initiated by opening a
normally closed external circuit rather than closing
a normally open circuit even though the system is
capable of being programmed to accept either
type of input.
The considerations described in this section apply
to the creation of “new” programs as well as
conversion of existing ladder diagrams.
3.3.2 Polarity and Phase Sequence C.3.3.2 Polarity and Phase Sequence
Input power and control signals should be applied Additionally, incorrect polarity or phase sequence
with polarity and phase sequence as specified by connection may cause erratic response by solid
the manufacturer. Solid state devices can be state controls, with potential hazards to personnel.
damaged by the application of reverse polarity or Frequently, such a system contains a detection
incorrect phase sequence. circuit that illuminates an indicator when incorrect
phase sequence is applied. Phase sequence may
be corrected by interchanging any two system
input power leads. It is advisable to check rotation
of motors whenever input power leads are
disconnected and reconnected in a system.

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3.4 Planning Electrical

Noise Rejection
The low energy levels of solid state controls may
cause them to be vulnerable to electrical noise.
This should be considered in the planning stages.
3.4.1 Assessing Electrical Environment C.3.4.1 Assessing Electrical Environment
Sources of noise are those pieces of equipment Noise can also occur in the form of
that have large, fast changing voltages or currents electromagnetic radiation, or due to improper
when they are energized or de-energized, such as grounding practices. Section C.3.4.3 explains
motor starters, welding equipment, SCR type, these forms of noise and precautionary measures
adjustable speed devices and other inductive that should be taken for protection against them.
devices. These devices, as well as the more In many instances a system may begin to
common control relays and their associated wiring, malfunction some time after it has been installed
all have the capability of inducing serious current and is working properly. This may be due to recent
and voltage transients on their respective power installation of new equipment capable of inducing
lines. It is these transients which nearby solid state noise into presently operating systems. Thus, it is
controls must withstand and for which noise not sufficient to merely evaluate a system at the
immunity should be provided. time of installation. Periodic rechecks should be
An examination of the proposed installation site of made, especially as other equipment is moved,
the solid state control should identify equipment modified, or newly installed. When installing a solid
that could contaminate power lines. All power lines state system, it is wise to assume various noise
that will be tapped by the proposed solid state sources exist and install the system to guard
control should be examined for the presence, against possible interference.
severity, and frequency of noise occurrences. If
found, system plans should provide for the control
of such noise.
3.4.2 Selecting Devices to Provide C.3.4.2 Selecting Devices to Provide
Noise Immunity Noise Immunity
Installation planning is not complete without Inductive devices are capable of generating high
examination of the noise immunity characteristics voltage transients when switched off. In addition to
of the system devices under consideration. possibly causing damage to solid state devices by
Results of tests to determine relative immunity to exceeding the semiconductor voltage rating, the
electrical noise may be requested from the high voltage transient can be coupled to other
manufacturer. Two such standardized tests are the portions of a system where it appears as noise.
ANSI (C37.90a-1974) Surge Withstand Capability Fortunately, it is fairly easy to limit the effects of
Test and the NEMA (ICS.1-1983) noise test this type of noise with some form of suppression
referred to as The Showering Arc Test. These are device. When necessary, in addition to
applied where direct connection of solid state suppression devices often provided in solid state
control to other electromechanical control circuits equipment, an external suppressor should be
is intended. Circuits involving analog regulating connected as close as possible to the source of
systems or high speed logic are generally more the transient for maximum attenuation.
sensitive to electrical noise; therefore, isolation NOTE: A surge suppressor increases drop-out
and separation of these circuits is more critical. time of an electromechanical device.
Further information on electrical noise and
evaluation of the severity of noise may be found in
ANSI/IEEE Publication No. 518-1982.
Where severe power line transients are anticipated
or noted, appropriate filters such as commercially
available line filter, isolation transformers, or
voltage limiting varistors, should be considered.
All inductive components associated with the
system should be examined for the need for noise
suppression.

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3.4.3 Design of Wiring for C.3.4.3 Design of Wiring for

Maximum Protection Maximum Protection
Once the installation site and power conductors Noise can also occur in the form of
have been examined, the system wiring plans that electromagnetic radiation. Examples include radio
will provide noise suppression should be frequency (RF) energy emanating from portable
considered. transceivers (walkie-talkie) and fixed station
Conducted noise enters solid state control at the transmitters of various types. Close coupling is not
points where the control is connected to input required; the various lines entering the system act
lines, output lines, and power supply wires. as receiving antennas. Tests described in 3.4.2
may not be sufficient to demonstrate noise
Input circuits are the circuits most vulnerable to
immunity to radio frequency signals. Variations in
noise. Noise may be introduced capacitatively
building construction and equipment installation
through wire to wire proximity, or magnetically from
make it impossible for equipment manufacturers to
nearby lines carrying large currents. In most
perform meaningful tests of radio frequency
installations, signal lines and power lines should
sources. RF fields are affected by concentrating
be separate. Further, signal lines should be
masses of metal such as steel beams, piping,
appropriately routed and shielded according to
conduit, metal enclosures, and equipment used in
manufacturer’s recommendations.
production such as fork lift trucks and products
When planning system layout, care must be given being transported on conveyors.
to appropriate grounding practice. Because design
If the installation site will be subjected to this type
differences may call for different grounding, the
of noise, thorough testing should be performed to
control manufacturer’s recommendations should
assure that the solid state system has sufficient
be followed.
noise immunity for the expected levels of radio
frequency energy. Corrective measures should be
taken if necessary. These include shielding of solid
state circuits and/or connected wiring and the
establishment of restrictions to provide safe
operating distances between the solid state
equipment and the RF sources.
Grounding practices in industry are frequently
misunderstood and often ignored. Poor grounding
can lead to many problems in solid state systems.
Intentionally grounding one circuit conductor of
any electrical supply system is widely accepted
and is generally required by electrical codes.
However, the non-current carrying parts of a
system which enclose equipment and conductors
must also be grounded. In addition to complying
with various codes and standards, proper
equipment grounding achieves several desirable
objectives:
1. It reduces the potential difference between
conductive surfaces to minimize electric shock
hazard exposure for personnel.
2. It provides a path for passage of fault current to
operate protective devices in the supply circuit.
3. It attenuates the electrical noise and transients
which can reach enclosed equipment and also
reduces the electrical noise which the
equipment can contribute to its surroundings.

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3.5 Countering the Effects of

Off-State Current
3.5.1 Off-State Current C.3.5.1 Off-State Current
Solid state components, such as triacs, transistors, See section 2.3.
and thyristors, inherently have in the off-state a
small current flow called “off-state current”.
Off-state current may also be contributed by
devices used to protect these components, such
as RC snubbers.
3.5.2 Off-State Current Precautions C.3.5.2 Off-State Current Precautions
Off-state currents in a device in the off-state may The off-state current of a power switching device
present a hazard of electrical shock and the device such as a solid state motor controller can be lethal.
should be disconnected from the power source Simply switching off power via a stop push button
before working on the circuit or load. in a control circuit is not a sufficient precaution,
since off-state current will continue to flow through
solid state devices which remain connected to the
supply. Good practice requires disconnection of all
power from equipment before working on or near
exposed circuit parts. (See NFPA 70E, Part II.)
It should not be assumed that a shock hazard
does not exist simply because a solid state circuit
operates at low voltage levels. Standing on a wet
floor or working in a damp location can lower a
person’s body impedance to the extent that off-
state current from low voltage also presents an
electrical shock hazard.
If it is necessary to work on energized equipment,
the guidelines detailed in section 5.2 for Preventive
Maintenance should be followed. In addition to the
specific procedures for personnel safety, care is
needed when making measurements in energized
systems. First, there is a possibility of damage to
delicate instruments due to off-state current.
Second, the off-state current can lead to false
conclusions when using sensitive instruments to
check for “contact continuity.”
Precautions should be taken to prevent the off- When a device (solid state or electromechanical)
state current of an output device which is in the off- that can produce a leakage current in the off-state
state from energizing an input device. is used to provide the input to a solid state control,
the precautions explained in section C.2.3 apply.

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3.6 Avoiding Adverse

Environmental Conditions
3.6.1 Temperature C.3.6.1 Temperature
Solid state devices should only be operated within Operation above the maximum rated temperature
the temperature ranges specified by the will usually result in many failures in a short time.
manufacturer. Because such devices generate Nuisance type malfunctions can also be
heat, care should be taken to see that the ambient encountered as a result of elevated ambient
temperature at the device does not exceed the temperature. These malfunctions, when they
temperature range specified by the manufacturer. occur, are usually temporary and normal operation
The main source of heat in a solid state system is resumes when temperatures are lowered.
the energy dissipated in the power devices. Since Some solid state devices temporarily cease to
the life of the equipment can be increased by function when ambient temperature is below their
reducing operating temperature, it is important to minimum rated operating temperature. Operation
observe the manufacturer’s “maximum/minimum in cold environments should be avoided or heaters
ambient temperature” guidelines, where ambient should be installed in the equipment enclosures to
refers to the temperature of the air providing the bring the system up to the minimum specified
cooling. The solid state equipment must be operating temperature before applying power to
allowed to stabilize to within the manufacturer’s the system.
recommended operating temperature range before Air circulating in a non-ventilated enclosure with
energizing control functions. equipment operating will be at a higher
When evaluating a system design, other sources temperature than the room in which it is installed.
of heat in the enclosure which might raise the A temperature differential of 10 to 20 degrees
ambient temperature should not be overlooked. Celsius can be expected in a typical industrial
For example, power supplies, transformers, installation.
radiated heat, sunlight, furnaces, incandescent Also see section 2.1.
lamps, and so forth should be evaluated.
In instances where a system will have to exist in a
very hot ambient environment, special cooling
methods may have to be employed. Techniques
that are employed include cooling fans (with
adequate filtering), vortex coolers, heat
exchanges, and air conditioned rooms.
Over-temperature sensors are recommended for
systems where special cooling is employed. Use of
air conditioning should include means for
prevention of condensing moisture.

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3.6.2 Contaminants C.3.6.2 Contaminants

Moisture, corrosive gases and liquids, and Modules for solid state systems usually consist of
conductive dust can all have adverse effects on a electronic devices mounted on printed circuit
system that is not adequately protected against boards with relatively close spacing between
atmospheric contaminants. conductors. Moisture in the form of humidity is one
If these contaminants are allowed to collect on of the atmospheric contaminants which can cause
printed circuit boards, bridging between the failure. If moisture is allowed to condense on a
conductors may result in malfunction of the circuit. printed circuit board, the board metallizations
This could lead to noisy, erratic control operation, could “electroplate” across the conductor spacings
or at worst, a permanent malfunction. A thick when voltage is applied. In low impedance circuits,
coating of dust could also prevent adequate this conductive path would immediately burn open,
cooling on the board or heat sink, causing then reform to be burned open again. This action
malfunction. A dust coating on heat sinks reduces can lead to erratic operation. In high impedance
their thermal efficiency. circuits, a short circuit may appear resulting in a
permanent malfunction. Specifications for
Preventive measures include a specially
equipment often include a relative humidity
conditioned room or a properly specified enclosure
exposure limit, but appropriate precautions should
for the system.
be taken to prevent condensation. Failures due to
moisture are often accelerated in the presence of
corrosive gases or vapors. These increase the
conductivity of the moisture layer allowing
electromigration to occur more rapidly and at lower
potentials.
3.6.3 Shock and Vibration C.3.6.3 Shock and Vibration
Excessive shock or vibration may cause damage Solid state systems usually have good resistance
to solid state equipment. Special mounting to shock and vibration since they contain no
provisions may be required to minimize damage. moving parts. However, at relatively high levels of
shock or vibration, circuit boards may disengage
from mating connectors if not restrained
sufficiently. Circuit boards can crack, components
can come out of sockets or component leads can
break loose from a solder connection to the board.
Mounting position is usually of little significance to
solid state devices except in instances where air
flow is required for cooling.

3.7 The Need for Education –

Knowledge Leads to Safety
Planning for an effective solid state circuit requires
enough knowledge to make basic decisions that
will render the system safe as well as effective.
Everyone who works with a solid state control
should be educated in its capabilities and
limitations. This includes in-plant installers,
operators, service personnel, and system
designers.

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Section 4
Installation Guidelines
4.1 Installation and Wiring Practice
4.1.1
Proper installation and field wiring practices are of
prime importance to the application of solid state
controls. Proper wiring practice will minimize the
influence of electrical noise, which may cause
malfunction of equipment.
User and installers should familiarize themselves
with the follow installation and wiring instructions in
addition to requirements of all applicable codes,
laws, and standards. The manufacturer of the
device or component in question should be
consulted whenever conditions arise that are not
covered by the manufacturer’s instructions.
4.1.2 C.4.1.2
Electrical noise is a very important consideration in A great deal of effort goes into the design of solid
any installation of solid state control. While wiring state equipment to achieve a reasonable degree of
practices may vary from situation to situation, the noise immunity. Filters, shielding, and circuit
following are basic to minimizing electrical noise: design are all used. It is, however, impossible to
1. Sufficient physical separation should be design equipment which is impervious to every
maintained between electrical noise sources form of noise found in the industrial setting.
and sensitive equipment to assure that the When installing a system using solid state
noise will not cause malfunctioning or technology it is wise to assume that electrical
unintended actuation of the control. noise exists and install the equipment in
accordance with the recommended guidelines to
2. Physical separation should be maintained
minimize problems.
between sensitive signal wires and electrical
power and control conductors. This separation Also see section 3.4.1.
can be accomplished by conduits, wiring trays,
or as otherwise recommended by the
manufacturer.
3. Twisted-pair wiring should be used in critical
signal circuits and noise producing circuits to
minimize magnetic interference.
4. Shielded wire should be used to reduce the
magnitude of the noise coupled into the low
level circuit by electrostatic or magnetic
coupling.
5. Provisions of the 1984 National Electrical
Code➀ with respect to grounding should be
followed. Additional grounding precautions may
be required to minimize electrical noise. These
precautions generally deal with ground loop
currents arising from multiple ground paths.
The manufacturer’s recommendations should
be followed.
➀ Available from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269

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4.2 Enclosures C.4.2 Enclosures

(Cooling and Ventilating) (Cooling and Ventilating)
Suitable enclosures and control of the maximum NEMA Standards Publication No. 250-1985,
operating temperature, both of which are Rev. 2, May 1988, classifies enclosures by type
environmental variables, may be needed to number and specifies their design test
prevent malfunctions of solid state control. requirements.
The manufacturer’s recommendations should be Also see section 2.1 and 3.6.1.
followed for the selection of enclosures, ventilation,
air filtering (if required), and ambient temperature.
These recommendations may vary from
installation to installation, even within the same
facility.
4.3 Special Handling of C.4.3 Special Handling of
Electrostatic Sensitive Devices Electrostatic Sensitive Devices
Some devises may be damaged by electrostatic Many problems due to electrostatic discharge
charges. These devices are identified and should (ESD) occur due to handling of modules during
be handled in the special manner specified by the installation or maintenance.
manufacturer. In addition to specific guidelines provided by an
NOTE: Plastic wrapping material used to ship equipment supplier, the following general
these devices may be conductive and should not guidelines can help reduce damage due to ESD.
be used as insulating material. 1. Use a grounding bracelet if possible to minimize
charge build-up on personnel.
2. Handle a module by the edges without touching
components or printed circuit paths.
3. Store modules with ESD sensitive components
in the conductive packaging used for shipping
the modules. Also, use conductive packaging
when returning static sensitive modules for
repair.
4.4 Compatibility of Devices with
Applied Voltages and Frequencies
Prior to energization, users and installers should
verify that the applied voltage and frequency agree
with the rated voltage and frequency specified by
the manufacturer.
NOTE: Incorrect voltage or frequency may cause a
malfunction of, or damage to, the control.
4.5 Testing Precautions C.4.5 Testing Precautions
When testing solid state control, the procedures Make-do test devices such as incandescent lamps
and recommendations set forth by the or neon lamps should not be used for checking
manufacturer should be followed. voltages in solid state systems. Incandescent
When applicable, instrumentation and test lamps have low impedance; the low impedance of
equipment should be electrically equivalent to that these devices can effectively change a voltage
recommended by the manufacturer for the test level from a logic “1” condition to a logic “0”
procedure. A low impedance voltage tester should condition when attempting to make a
not be used. measurement. Unexpected machine motion can
result if an output to a controlled device is
High voltage insulation tests and dielectric tests
energized as a result. Neon lamps do not respond
should never be used to test solid state devices. If
to voltages typically used in logic circuits (e.g., 32
high voltage insulation of field wiring is required,
volts DC or less). Use of a neon lamp tester could
solid state devices should be disconnected.
lead to false conclusions about the voltage level
Ohmmeters should only be used when and as
present in a circuit.
recommended by the equipment manufacturer.
(continued)
Testing equipment should be grounded; if it is not,
special precautions should be taken.

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C.4.5 (continued)
High input impedance meters are required to
obtain accurate voltage measurements in high
impedance circuits. Unless otherwise specified by
the manufacturer, a meter with an input impedance
of ten megohms or greater is recommended for
making voltage measurements. The meter must
also have sufficient sensitivity to measure logic
level voltages; some meters do not respond to low
voltages.

4.6 Startup Procedures C.4.6 Startup Procedures

Checks and tests prior to startup and startup Startup procedures can provide important benefits
procedures recommended by the manufacturer for safety with new installation, or after
should be followed. modifications or repairs. A “dry run” under
controlled conditions can verify proper installation
and functioning of the control system before it is
turned over to operating personnel.
Many programmable solid state systems have the
capability for simulating operation in a mode
known as “test” mode or “dry run” mode. These
modes allow a user to check a program and
correct obvious programming errors with outputs
disabled. Unexpected machine motion and
possible damage to workpieces and equipment is
thus avoided. These modes can also be used to
verify proper system operation after a repair.
Many programmable systems provide capability for
“force on” and “force off” of inputs and outputs.
Use of these functions can reduce troubleshooting
and maintenance time by enabling personnel to
bypass certain operations without physically
operating switches on a machine. Care must be
taken when using “force” functions to avoid
exposing personnel to hazardous machine
motions or process operations.
For controllers operating a machine tool or robot,
running a part program at a fraction of the
programmed operating speed with a workpiece of
soft material is considered “good practice”. This
allows an operator to observe possible
interference of tooling with the part and make
corrections to the program. A workpiece of soft
material such as wood, plastic, or machinable wax
will minimize risk of tool damage if there is a tool
crash with the workpiece.

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Section 5
Preventive Maintenance and
Repair Guidelines
5.1 General
A well-planned and executed maintenance
program is essential to the satisfactory operation
of solid state electrical equipment. The kind and
frequency of the maintenance operation will vary
with the kind and complexity of the equipment as
well as with the nature of the operating conditions.
Maintenance recommendations of the
manufacturer or appropriate product standards
should be followed.
Useful reference publications for setting up a
maintenance program are NFPA 70B-1983,
Maintenance of Electrical Equipment, and NFPA
70E-1983, Electrical Safety Requirements for
Employee Workplaces.
5.2 Preventive Maintenance C.5.2 Preventive Maintenance
The following factors should be considered when Lithium batteries are frequently used for memory
formulating a maintenance program: backup in solid state equipment due to their
1. Maintenance must be performed by qualified excellent shelf life and high energy to weight ratio.
personnel familiar with the construction, Lithium is a highly reactive metal that can cause
operation, and hazards involved with the burns if there is contact with skin. The batteries
control. are sealed so there is seldom a problem of contact
with lithium as long as reasonable care is
2. Maintenance should be performed with the exercised when handling them. They should only
control out of operation and disconnected from be used in their intended application and not
all sources of power. If maintenance must be subjected to rough handling. When batteries are
performed while the control is energized, the replaced in equipment, the batteries removed
safety related practices of NFPA 70E should be should be disposed of in accordance with
followed. supplier’s instructions.
3. Care should be taken when servicing The Department of Transportation has certain
electrostatic sensitive components. The regulations that prohibit shipment of equipment
manufacturer’s recommendations for these with batteries installed if the batteries contain 0.5
components should be followed. gram or greater of lithium. The batteries must be
4. Ventilation passages should be kept open. If removed from equipment and shipped separately
the equipment depends upon auxiliary cooling, in a container approved by the Department of
Transportation. Additional Department of
e.g., air, water, or oil, periodic inspection (with
Transportation restrictions apply to the shipment of
filter replacement when necessary) should be
lithium batteries.
made of these systems.
NEMA Standards Publication No. ICS 1.3 – 1986,
5. The means employed for grounding or Preventive Maintenance of Industrial Control and
insulating the equipment from ground should be System Equipment, is recommended for personnel
checked to assure its integrity (see 4.5). responsible for maintenance of equipment.
6. Accumulations of dust and dirt on all parts,
including on semiconductor heat sinks, should
be removed according to the manufacturer’s
instructions, if provided; otherwise, the
manufacturer should be consulted. Care must
be taken to avoid damaging any delicate
components and to avoid displacing dust, dirt,
or debris in a way that permits it to enter or
settle into parts of the control equipment.
(continued)

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5.2 Preventive Maintenance (continued)

7. Enclosures should be inspected for evidence of
deterioration. Accumulated dust and dirt should
be removed from the top of the enclosures
before opening doors or removing covers.
8. Certain hazardous materials removed as part
of maintenance or repair procedure (e.g.,
polychlorinated biphenyls (PCB) found in some
liquid filled capacitors) must be disposed of as
described in Federal regulations.
5.3 Repair C.5.3 Repair
If equipment condition indicates repair or Follow manufacturer’s instructions exactly when
replacement, the manufacturer’s instruction replacing power semiconductors mounted on
manual should be followed carefully. Diagnostic heatsinks since improper installation may become
information within such a manual should be used the source of further difficulties. Torque
to identify the probable source of the problem, and semiconductors or bolts retaining semiconductors
to formulate a repair plan. The level of field repair to the value specified using a torque wrench. Too
recommended by the manufacturer should be much pressure against a heatsink can damage a
followed. semiconductor while too little can restrict the
When solid state equipment is repaired, it is amount of heat transferred from the semiconductor
important that any replacement part be in to the heatsink and result in operation at higher
accordance with the recommendations of the temperature with decreased reliability.
equipment manufacturer. Care should be taken to Exercise care when removing modules from a
avoid the use of parts which are no longer system during maintenance. Failed modules are
compatible with other changes in the equipment. frequently returned to the manufacturer for repair.
Also, replacement parts should be inspected for Any physical damage sustained during removal
deterioration due to “shelf life” and for signs of may result in more expensive repair or render the
rework or wear which may involve factors critical to module unrepairable if damage is too great.
safety. Modules with electrostatic sensitive components
After repair, proper start-up procedures should be should be handled by the edges without touching
followed. Special precautions should be taken to components or printed circuit conductors. Use
protect personnel from hazards during start-up. packaging material supplied with the replacement
module when shipping the module to the
manufacturer for repair.
When the scope of repairs exceeds the
manufacturer’s recommendations for field repair,
the module(s) should be returned to the
manufacturer for repair. Doing so will help to
ensure that only properly selected components are
used, and that all necessary hardware and
firmware revisions are incorporated into the repair.
Failure to make necessary updates may result in
safety, compatibility or performance problems
which may not become apparent for some time
after the repaired module has been placed back in
service. When firmware is protected by copyright
law, updates can be provided legally only by the
manufacturer or licensee.
Also see section 4.3.

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5.4 Safety Recommendations for

Maintenance Personnel
All maintenance work should be done by qualified
personnel familiar with the construction, operation,
and hazards involved with the equipment. The
appropriate work practices of NFPA 70E should be
followed.

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Reach us now at www.rockwellautomation.com

Wherever you need us, Rockwell Automation brings together leading
brands in industrial automation including Allen-Bradley controls,
Reliance Electric power transmission products, Dodge mechanical power
transmission components, and Rockwell Software. Rockwell Automation's
unique, flexible approach to helping customers achieve a competitive
advantage is supported by thousands of authorized partners, distributors
and system integrators around the world.

Americas Headquarters, 1201 South Second Street, Milwaukee, WI 53204, USA, Tel: (1) 414 382-2000, Fax: (1) 414 382-4444
European Headquarters SA/NV, avenue Herrmann Debroux, 46, 1160 Brussels, Belgium, Tel: (32) 2 663 06 00, Fax: (32) 2 663 06 40
Asia Pacific Headquarters, 27/F Citicorp Centre, 18 Whitfield Road, Causeway Bay, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846

Publication SGI-1.1 – April, 1990

Supersedes SGI-1.1 August 1987 Copyright 1990 Allen-Bradley Company, Inc. Printed in USA.
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INGEMAQ
INGENIERIA Y MAQUINARIAS

DRILL STEM BREAKOUT WRENCH

FOR BE49RIII DIAMETER 11.75”
MODEL INGEMAQ IM9601CPF11.75HR
SERIAL Nº C096
U.S. PATENT NUMBER 6,012,360
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INDEX

1 GENERAL DRAWING

2 HYDRAULIC SCHEMATIC

3 MAINTENANCE

4 BREAKOUT WRENCH SETUP

5 DISASSEMBLY FOR CHANGING COMPONENTS

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1 GENERAL DRAWING

27
Grease 28 - 16.2
28 - 16.2
26
29

1-2-3-4
Grease

5
Grease
1-6-7
8-9
23 - 16.1 Grease

24 - 16.1
25
22.1
22

14-15-16.1 21

Grease 20

17 19
18
11
13
STEM AXIS
12 12.1
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2 HYDRAULIC SCHEMATIC 49RIII

RETRACT

CONSOLE
CONTROL VALVE

EXTEND
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3 MAINTENANCE

Make a careful inspection of the teeth and hydraulic components.

Check the cylinders, hoses and valves for any leaks or other visible
irregularities, such as worn or abraded hoses. If you find any leaks
or other abnormal conditions, repair them before you start the drill.

Lubricate with grease every six months in the indicated points in

the general drawing. Use EP-2 grease.

Any part that has to be replaced shuold be greased before

assembly.

TEETH REPLACEMENT

If it were necessary to change the teeth (17), remove the

cotter pin and then give soft knocks to slide it out.

In the setting of the teeth, you must be careful to position each

tooth according to the following sketch.

SET INSERT
137PS FOR
EXTREMELY
WORN STEMS

TEETH ORIENTATION
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INGENIERIA Y MAQUINARIAS

4 BREAKOUT WRENCH SETUP

To fix the position of the wrench pedestal inside the mast, the
following recommendations apply:

1. Introduce the Pedestal inside the mast.

2. Aligne the pedestal paralel to the mast main axis at 536mm (21-
1/8”) from it, according to the drawing.

3. The end of the mast has to be at 1,617mm (63-11/16”) from the

center of the stem.

4. Deposit some bead welds and install the wrench to check the
position over the stem.

5. The position of the pedestal wil be Ok when the teeth are at

equal distance of the stem, with the swing cylinder fully
extended and the wrench fully opened. Then make the final
welding of the pedestal base.

6. Make sure that the wrench does not interfere with the mast in
the parking position. If it does make contact, you must deposit
some field welds in the stop contact point shown in the drawing.

7. The sequence valve set has two flow regulating valves that can
be adjusted to get an adequate operating speed. They are fixed
by a 2mm Allen screw. The 2mm Allen wrench is included in this
catalogue.
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4.1 PARKING POSITION

STOP
1617

490

536
1175
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4.2 WORKING POSITION

662
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5 DISASSEMBLY FOR CHANGING COMPONENTS

1) Disconect the two feeding hydraulic hoses #5.6 (see Hyd. Schematic,
page 5) from the valves in the mast and install plugs in the valves
and in the hoses.

2) Support the wrench with the drill winch and remove the main pin
#24 and the swing cylinder rear pin #28. (Both are secured with
hairpin cotters).

3) The wrench is ready to be removed from the drill.

4) Unfasten the spring clevis #22.1, for taking out the spring #22.

5) Disassemble the torque cylinder #29, removing the pins #4 and

#23.

6) Remove the pin #9, for taking out the lever #11.

7) To dismount the jaw #19 from the arm #20, take out the pin #15
that attaches both of them to the passive cylinder #21.

With this last operation, the wrench is totally disassembled for changing
any damaged component.
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5.1 LEVER DRAWING

5.2 JAW DRAWING

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5.3 ARM DRAWING

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FlowMaster™ Rotary Driven Hydraulic Pump

Models: 85480, 85481, 85482, 85483,
Series “B”
Models: 85247, 85610, 85586
Series “A”

U.S. Patent No. 6,102,676

Foreign Patent Pending

This pump conforms to the European Directive for Product Safety

7.5A-18100-H01 April 2002 Form 403222 Section - C8 Page - 269J

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FlowMaster™ Rotary Driven Hydraulic Pump

Table of Contents Annual inspection by the factory authorized warranty and

Page service center nearest you is recommended.
Safety . ................................................................2
Description....................................................................................2 A list of factory authorized warranty and service centers is
Appropriate Use................................................................2 available upon request.
Pump Performance and Specifications..............................3
Installing the Pump.....................................................................4 Damaged Pumps
Operation.....................................................................................5 Any pump that appears to be damaged in any way, is badly
Maintenance and Repair...........................................................5 worn or operates abnormally, shall be removed from use
Pump Dimensions.............................................................7 until repairs are made. Contact the factory authorized
Repair Parts List................................................................................9 warranty and service center nearest to you for repairs.
Trouble Shooting.........................................................................10
Description
Safety 85480 - Pump for 120 pound drum (16 gallon)
Read and carefully observe these operating instructions 85481 - Pump for 60 pound drum
before unpacking and operating the pump! The pump must 85482 - Pump for 400 pound drum (55 gallon)
be operated, maintained and repaired exclusively by per- 85483 - Pump for 5 gallon pail
sons familiar with the operating instructions. Local safety 85247 - Similar to 85480, but with a manual override
regulations regarding installation, operation and 85610 - Low Temperature Pump for 400 lb. drum (55 gallon)
maintenance must be followed. 85586 - Heavy Duty pump for 400 lb. drum

Operate this pump only after safety instructions and this

General Description
service manual are fully understood.
The Lincoln Industrial rotary Hydraulic Pump is a fully
hydraulically operated grease pump. Grease output is
proportional to the hydraulic input flow. The pump is primari-
ly designed for centralized lubrication systems such as the
Single Line parallel, Single Line Progressive and Two Line
Indicates a potentially hazardous situation which, if not
systems. An integrated pump control manifold is incorporat-
avoided, could result in death or serious injury.
ed with the motor to control input flow and pressure. A 24
volt DC solenoid valve is also incorporated as a method to
turn the pump on and off. A 24 volt DC solenoid valve with a
manual override is standard on model 85247 and is an
Indicates a potentially hazardous situation which, if not
option on other models.
avoided, may result in minor or moderate injury.
The pump is driven by the rotary motion of the hydraulic
Safety Instructions motor. Rotary motion is converted to reciprocating motion
This equipment generates very high grease pressure. through an eccentric crank mechanism. The reciprocating
Extreme caution should be used when operating this action causes the pump cylinder to move up and down. The
equipment as material leaks from loose or ruptured unit is a positive displacement double acting pump as
components can inject fluid through the skin and into the grease output occurs during both the up and down stroke.
body causing serious bodily injury. Adequate protection is
recommended to prevent splashing of material onto the During the down stroke, the pump cylinder is extended into
skin or into the eyes. the grease. Through the combination of shovel action and
If any fluid appears to penetrate the skin, get emergency vacuum generated in the pump cylinder chamber, the grease
is forced into the pump cylinder. Simultaneously, grease is
discharged through the outlet of the pump. The volume of
grease during intake is twice the amount of grease output
during one cycle. During the upstroke, the inlet check
medical care immediately. Do not treat as a simple cut. closes, and one half of the grease taken in during the
Tell attending physical exactly what fluid was injected. previous stroke is transferred through the outlet check and
discharged to the outlet port. Typical output of the pump is
Inspection shown on page 4.
If overpressurizing of the equipment is believed to have
occurred, contact the factory authorized warranty and service Appropriate Use
center nearest you for inspection of the pump. • All pump models are exclusively designed to pump and
dispense lubricants using hydraulic power.
Specialized equipment and knowledge is required for repair • The maximum specification ratings should not be
of this pump. Contact the factory authorized warranty and exceeded.
service center nearest you for repair or adjustments other • Any other use not in accordance with instructions will
than maintenance specified in this manual. result in loss of claims for warranty and liability.

Page Number - 2 7.5A-18100-I01 Form 403222

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FlowMaster™ Rotary Driven Hydraulic Pump

Hydraulic Motor
Hydraulic Manifold
(Item 42)

Hydraulic Material
Fluid Return Outlet
to Tank

Hydraulic
Fluid Inlet

Flow Control
Valve (Item 39)
Solenoid Valve
(Items 34*© & 35)
Pressure Gauge
Pressure Reducing
Vent (Item 32)
Valve (Item 38)
Valve
Illustration 1

Pump Performance and Specification

Supply inlet hydraulic pressure, Operating Temperature, ºF (ºC)- -20 to +150 (-29© to 65)**
maximum, PSIG (bar) - 3,500 (241) Operating Voltage, VDC - 24
Operating working hydraulic Hydraulic Inlet Port, In - SAE 4
pressure , PSIG (bar) - 300 to 450 (20 to 32). Tank Return Port, In - SAE 6
Hydraulic Inlet Flow, Pump Outlets, In - 1/4 NPTF
GPM (l/min) - Up to 7 (28) Maximum Hydraulic
Pump Ratio with manifold - 9:1 at low inlet pressure Fluid Temperature, ºF, (ºC) - 250 (121)
(300 to 350 psi [20 to 25 Weight, Lbs (Kg) - 36 (16)
bar]) and low inlet flow
(below 2 gpm [7 lpm])
Pump ratio approaches
11.0:1 ratio at higher
inlet pressure and flow. Do not exceed 3,500 PSIG (241 bar) maximum supply inlet
hydraulic pressure. Exceeding the rated pressure may result
in damage to system components and personal injury.

HYDRAULIC PUMP PERFORMANCE SPECIFICATIONS

Test conducted with Alvania NLGI # 2 Grade Grease
Grease Output 1,000 psi Backpressure
Cubic inches/min. (cm³/min.) (70 bar)
Hydraulic Flow Input
Temperature F 1 gpm 2 gpm 3 gpm 4 gpm 5 gpm 6 gpm 7gpm
(Temperature C) (4 l/min) (8 l/min) (11 l/min) (15 l/min) (19 l/min) (23 l/min) (26 l/min)
80 7 14 21 28 34 40 45
(27) (115) (229) (344) (459) (557) (656) (737)
40 7 14 21 28 33 38 41
(4) (115) (229) (344) (459) (541) (623) (642)
20 6 13 17 22 28 32 36
(-7) (98) (213) (279) (361) (459) (594) (590)
0 6 11 15 19 23 27 30
(-18) (98) (180) (245) (310) (376) (442) (491)
-10 5 7 8 9 10 12 13
(-23) (82) (115) (131) (148) (164) (197) (213)
-20 4 6 8 10 12 14 15
(-29) (66) (98) (131) (164) (197) (229) (245)

*Solenoid valve with manual override standard on Model 85247,

optional on other models.

** 85610 Operating Temperature, ° F(°C) is -70 to 150 (-57 to 65)

Form 403222 7.5A-18100-I01 Page Number - 3

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NOTE: To install the pump Model 85481 as a replacement

pump for 84961 used on Model 84944, use adapter/spacer
kit with bolts, included in the pump package (see illustration #4).
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repair kit.
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8. For Models 85480, 85481, 85482, 85483 and 85247, fill

crankcase with SAE 10W30 motor oil up to pipe plug (45)
before fastening housing cover (30) and housing gasket
(31). If pump will be used in very cold environments, use
Mobil Arrow HFA Low Temperature Oil. This oil stays fluid
even at -70°F.

For Model 85610, fill crankcase with lightweight Mobil

Arrow HFA Hydraulic Oil up to pipe plug (45) before
fastening housing cover (30) and housing gasket (31).

9. On 85586, replace inlet strainer (63).

Form 403222 7.5A-18100-I01 Page Number - 7

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FlowMaster™ Rotary Driven Hydraulic Pump

11.46 9.08
(291) (231)
4.61
9.54
(117)
(242) 8
1.5
3.125 (38)
(79)

5.025
Fill with SAE 2 (128)
10W30 Motor Oil
for Pumps 85480,
85481, 85482,
85483 and
85247. Fill with 3
light weight Mobil
Arrow HFA 1
Hydraulic Oil for
Pump 85610.

1. 1/4 NPTF Pump Outlets

2. SAE 4 Inlet Port
3. SAE 6 Tank Port
A 4. 1/4 NPTF Orifice fitting for
Vent Valve Port
5. Solenoid Valve
6. Pressure Reducing Valve
7. Flow Control Valve
8. Pressure Gauge

ø 1.25
(32)

MODEL DIM "A" in (mm) DIM "B" in (mm) 5

85480 27.50 (699) 38.56 (980)
85481 19.00 (483) 30.06 (764)
4
85482 34.00 (864) 44.94 (1142)
85483 13.69 (348) 24.75(629)
85247© 27.50 (699) 38.56 (980) 2.25
85586© 34.18 (868) 45.12 (1146) (57)
85610© 34.00 (864) 45.06 (1145) 7

1/4-20 THD 2.25

(57)
Illustration #5

Page Number - 8 7.5A-18100-I01 Form 403222

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FlowMaster™ Rotary Driven Hydraulic Pump

2
1
4
29 5
62 6
7
32 30 8
6
31
34 33 4

2 9
58
35
1 10

36 60 11

37 12
59
45 13
38 14
39 46
61 15
40 41 47
48 16
42 49
17
43
50
44 51
52
53
54 18
19
20

55

21

56
57
22

63 23
24
25
26
27
28

Illustration #6

Form 403222 7.5A-18100-I01 Page Number - 9

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FlowMaster™ Rotary Driven Hydraulic Pump

Lincoln Industrial Lincoln GmbH Lincoln Industrial © Copyright 2002

One Lincoln Way 69190 Walldorf 25 International Business Park Printed in USA
St. Louis, MO 63120-1578 Heinrich-Hertz Strasse 2-8 #01-68 German Centre
(+1) 314 679 4200 (+49) 6227 33-0 Singapore 609916 Web site:
(+65) 562-7960 www.lincolnindustrial.com

Page Number - 12 7.5A-18100-I01 Form 403222

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Installation Instructions

CENTERLINE 2100 Low Voltage Motor Control

Centers
Catalog Number 2100
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Important User Information

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death,
property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the
consequence

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
surfaces may reach dangerous temperatures.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

Allen-Bradley, Rockwell Automation, CENTERLINE, CENTERLINE 2100, ArcShield, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.
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Summary of Changes

This manual contains new and updated information. Changes throughout this
revision are marked by change bars, as shown to the right of this paragraph.

New and Updated This table contains the changes made to this revision.
Information Topic Page
Added information about ArcShield rating Throughout
Added illustrated checklist for ArcShield components 81

Rockwell Automation Publication 2100-IN012D-EN-P - September 2010 3

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Summary of Changes

Notes:

4 Rockwell Automation Publication 2100-IN012D-EN-P - September 2010

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Table of Contents

Preface
About this Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Purchased Components and Additional Instruction Sheets . . . . . . . . . . . 8

Chapter 1
General Information General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Nameplate Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
MCC Sequence Numbering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
UL/CSA Marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Short-circuit Rating Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ArcShield Rating Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Series Number and Series ID as Manufactured in the United States. . . 14
Series Lettering - Units and Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Receiving, Handling, and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Chapter 2
Installation Procedures Location Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Height Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Securing an MCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Seismic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Joining and Splicing New MCCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Joining and Splicing Existing MCCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Joining and Splicing MCCs with ArcShield. . . . . . . . . . . . . . . . . . . . . . . . . 38
Installing and Joining Pull Boxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Joining and Splicing NEMA Type 12 MCCs . . . . . . . . . . . . . . . . . . . . . . . 38
Joining and Splicing NEMA Type 3R and Type 4 MCCs . . . . . . . . . . . . 38
Bus Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Chapter 3
Installing Conduit and Cable Installing Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Installing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chapter 4
Installing and Removing Plug-in Installing Plug-in Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Units Remove a Plug-in Unit with a Vertical Operating Handle
from a Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Remove a Plug-in Unit with a Horizontal Operating Handle
from a Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Remove the Support Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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Chapter 5
Arc Flash Protection Marking Flash Protection Marking Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
as Required by the National Arc Flash Marking Clarification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Rockwell Automation Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Electrical Code
Chapter 6
Operator Handle and Unit Defeating the Unit Door Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Interlock Defeating the Unit Interlock Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Locking Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Chapter 7
Final Checklist Before Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Energizing Pre-energizing Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Perform the Pre-energizing Check Procedure . . . . . . . . . . . . . . . . . . . . . . . 72
ArcShield Components Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Required Minimum Electrical Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Chapter 8
Energizing the Equipment Energize the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Chapter 9
Maintenance Maintain the MCC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Disconnect the Switch and Contact Lubrication . . . . . . . . . . . . . . . . . . . . 91
Use Thermal Infrared or Other Temperature Measurement
Techniques for Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Chapter 10
Maintenance After Fault Maintain the MCC After a Fault Condition. . . . . . . . . . . . . . . . . . . . . . . . 95
Condition

Chapter 12
Parts Illustrations Typical Section Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Typical Construction of a Unit with a Vertical Operating Handle . . . 100
Typical Construction of a Half Space Factor Unit with a Horizontal
Operating Handle and Door Mounted Pilot Devices . . . . . . . . . . . . . . . 101
Typical Construction of a Unit with a Horizontal Operating
Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Index

6 Rockwell Automation Publication 2100-IN012D-EN-P - September 2010

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Preface

About this Publication This manual provides detailed installation instructions for installing, using the
operator handle, energizing, and maintaining your CENTERLINE 2100 Motor
Control Center.

Who Should Use This This manual is intended for engineers or technicians directly involved in the
installation, connection, energizing, and maintenance of the
Manual CENTERLINE 2100 Motor Control Center.

If you do not have a basic understanding of the CENTERLINE 2100 Motor

Control Center, contact your local Rockwell Automation sales representative for
information on available training courses.

Additional Resources The following publications supplement this manual. For more information and
further reference, please use these available publications.

Publication Name Publication No.

Arc-Flash Resistant Low Voltage Motor Control Center Designs White 2100-AP003
Paper
Power Factor Correction Capacitors for Bulletin 2100 MCC Starter Units 2100-AT001
Application Techniques
CENTERLINE 2100 Motor Control Centers Joining and Splicing Vertical 2100-IN010
Sections Instructions
CENTERLINE 2100 Motor Control Centers (MCC) Units with Vertical 2100-IN014
Operating Handles Installation Instructions
CENTERLINE Motor Control Centers NEMA Type 12 Sealing Instructions 2100-IN037
Receiving, Handling, and Storing Motor Control Centers Instructions 2100-IN040
CENTERLINE 2100 MCC Instantaneous Trip Motor Circuit Protectors 2100-TD001
(MCP) in Combination NEMA Starter, Soft Starter (SMC), and Variable
Frequency AC Drive Units Technical Data
CENTERLINE 2100 MCC Inverse Time Circuit Breakers in Combination 2100-TD002
NEMA Starter, Soft Starter (SMC), and Variable Frequency AC Drive
Units Technical Data
CENTERLINE Motor Control Centers Power Fuses Product Data 2100-TD003
DeviceNet Motor Control Centers (MCC) Technical Data 2100-TD019
CENTERLINE 2100 Motor Control Center End Closing Plates Installation 2100-IN069
Instructions
CENTERLINE 2100 Motor Control Center (MCC) Units with Horizontal 2100-IN060
Operating Handles Installation Instructions
CENTERLINE Motor Control Centers Mains and Incoming Lines 2100-4.2
Dimensions Reference
CENTERLINE Motor Control Centers Mains and Incoming Lines 2100-4.2DU1
Dimensions Reference Document Update
CENTERLINE Motor Control Centers Installing a Pull Box on a Bulletin 2100-5.28
2100 Vertical Section Installation Instructions
Safety Guidelines for the Application, Installation, and Maintenance of SGI-1.1
Solid-state Control Installation Instructions

Rockwell Automation Publication 2100-IN012D-EN-P - September 2010 7

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Preface

You can view or download publications at

http://www.rockwellautomation.com/literature. To order paper copies of
technical documents, contact your local Rockwell Automation distributor or
sales representative.

The documents in the following table are referenced in this document and can be
obtained from their respective organizations.

Resource Website
National Electrical Manufacturer’s Association (NEMA) www.nema.org
• NEMA ICS 1-2000 Industrial Control and Systems: General
Requirements
• NEMA ICS 2.3-1995, Instructions for Handling, Operation and
Maintenance of Motor Control Centers Rated Not More Than 600V
National Fire Protection Association (NFPA) www.nfpa.org
• NFPA 70 - National Electrical Code
• NFPA 70A - Recommended Practice for Electrical Equipment
Maintenance
• NFPA 70E - Standard for Electrical Safety in the Workplace
Institute of Electrical and Electronic Engineers (IEEE) www.ieee.org
IEEE standard C37.20.7 - IEEE Guide for Testing Metal-Enclosed
Switchgear Rated Up to 38 kV for Internal Arcing Faults

Purchased Components and When equipment such as transformers, metering, programmable controllers, or
drives are supplied with the motor control center (MCC), specific manuals and
Additional Instruction data sheets are also supplied. These documents should be read and understood
Sheets before installing and operating the MCC. Refer to the unit locations of these
devices for their manuals or data sheets.

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Chapter 1

General Information

General Description Allen-Bradley CENTERLINE Motor Control Centers (MCCs) consist of one
or more vertical sections containing electromagnetic or solid state control devices
that are prewired and tested within modular (plug-in) or frame mounted (hard-
wired) units.

CENTERLINE MCCs are designed in standard widths of 20 in. (508 mm), 25

in. (635 mm), 30 in. (762 mm), 35 in. (789 mm), and 40 in. (1016 mm). The
standard front-mounted depths of an MCC are 15 in. (381 mm) and 20 in.
(508 mm), in addition back-to-back mounted depths of 30 in. (762 mm) and
40 in. (1016 mm) are also offered. The standard height of an MCC is 90 in.
(2286 mm). A 70.5 in. (1791 mm) high section is also available. All MCC
sections are supplied with top and bottom horizontal wireways. Sections that are
designed to accommodate plug-in units include a vertical wireway. Each 90 in.
(2286 mm) vertical section can accommodate up to 6.0 space factors or 78 in.
(1981 mm) for units.

Units (buckets) are designed in increments of 0.5 space factors. Each 0.5 space
factor is approximately 6.5 in. (165.1 mm) high. Units are designed as either
removable (plug-in) or frame-mounted (non-plug-in).

Individual units house a wide variety of power and logic devices. Plug-in units are
mounted on unit support pans within the section. Stab assemblies on the back of
the unit plug onto the vertical bus. A mechanical interlock prevents the unit door
from being opened when the disconnect is not in the OFF position. An
additional mechanical interlock prevents the unit from being plugged-in or
unplugged when the disconnect is not in the OFF position.

Line power is distributed throughout the MCC via an isolated bus work
structure. The main horizontal bus is in the center of each section. Standard,
center-fed, 300 A rated vertical bus supplies power to the individual units above
and below the horizontal bus for an effective 600 A capacity, allowing virtually
unrestricted unit arrangement. An optional 600 A vertical bus provides 1200 A
effective rating.

The CENTERLINE MCC is also available with an ArcShield rating. The

ArcShield rating includes arc-resistant features that are intended to help provide
enhanced protection to you during internal arcing faults (when compared to
MCCs that are only designed to meet UL 845 requirements). Arcing faults can
be caused, for example, by accidental touching, closing into faulted lines, or loose
connections. Depending on the application, MCCs with the ArcShield rating can
provide up to Type 2 accessibility per IEEE standard C37.20.7, which helps
protect you when you are at the front, sides, and rear of the enclosure in the
unlikely event of an arcing fault.

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Chapter 1 General Information

A label on the MCC with the ArcShield rating provides information in regard to
the accessibility level and arc fault ratings.

For more information about accessibility levels, performance, and testing

requirements, refer to IEEE standard C37.20.7, IEEE Guide for Testing Metal-
Enclosed Switchgear Rated up to 38 kV for Internal Arcing Faults.

MCCs with the ArcShield rating provide a reinforced structure and arc-
containment latches on all doors. To help protect you during an arc-fault, arc-
containment latches, when closed and latched properly, allow pressure relief and
help keep the doors from unlatching or detaching from the structure.

Nameplate Data Each MCC section has a nameplate on the enclosure or vertical wireway door.
The nameplate includes:
• catalog number/serial number.
• series letter of section.
• bus bar voltage and current rating.
• section number.
• UL and cUL certification marking.
• UL registration number.
• enclosure type.

Figure 1 - Section Nameplate

Series Letter of Section

Catalog Number/Serial Number Bus Bar Voltage

and Current Rating

UL and cUL Certification Marking

UL Registration Number

Section Number Enclosure Type

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General Information Chapter 1

Each plug-in and frame mounted unit also has an identification label. The unit
label is on the interior of the bottom plate of plug-in units or on the interior
right-hand side plate of the frame mounted units. The unit label for each plug-in
or frame mounted unit includes:
• catalog number/serial number.
• series letter of the unit.
• voltage rating.
• unit location.
• UL and cUL certification marking.
• device type and size.

Figure 2 - Unit Label

Catalog Number / Serial Number Series Letter of Unit Unit Location

Voltage Rating
cUL Certification Marking Device Type and Size

The catalog number or serial number and series letter are required to properly
identify the equipment to sales or factory personnel.

MCC Sequence Numbering CENTERLINE MCCs are designed so functionality is not affected by the
section installation order, for example, vertical section-numbering sequence
order.

All MCC sections carry a serial plate that identifies vertical section sequence
numbering. For example, MCC section 1 of 1, 1 of 5, and so on.

Figure 3 - Section Nameplate

Identifies Vertical Section

Sequence Numbering

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Chapter 1 General Information

Sections are numbered to match factory-supplied MCC elevation drawings.

Numbering each section helps installers and users easily identify MCCs, sections,
and units. If there are questions about section numbering during field installation,
inspection, or operation, the following information can provide guidance on
equipment acceptability, listing, and certification.

CENTERLINE MCC sections can be installed or added as follows:

• In non-sequential order
• Addition of a single section (add-on section)
• Addition of multiple sections (add-on lineup of sections)
• Addition of single section or multiple section between MCC sections

If sections are added to an existing lineup and not installed in sequential order,
the installation should not be considered a misapplication or in conflict with
Underwriter Laboratories (UL) listing and Canadian Standards Association
(CSA) certification.

The paramount criteria for additions of sections to existing MCCs is matching

the horizontal bus electrical and ingress protection (enclosure type) ratings for
the total MCC line up. For example, the voltage, current rating, short circuit
withstand, and NEMA enclosure type (IP rating) for all sections must match.

Non-sequential numbering may not create a functional or listing/certification

issue. However, MCCs should be installed in sequential order. Installing MCCs
in sequential order helps ensure proper installation and ensures that factory-
supplied documentation matches the equipment.

You can rearrange MCC sections. However, if a section that uses a right-hand side
sheet with integral, internal mounting flanges is on the outside of a lineup, an
additional closing kit plate is required. Refer to CENTERLINE 2100 Motor
Control Center End Closing Plates Installation Instructions,
publication 2100-IN069. MCCs that contain arc resistant features cannot use a
section with integral mounting flanges on the outside of a lineup.

UL/CSA Marking CENTERLINE MCCs are listed by Underwriter’s Laboratories, Inc. (UL),
Standard for Safety UL 845, and certified by the Canadian Standards Associate
(CSA), Standard C22-2, No. 14.

Due to standards harmonization, a MCC may also carry the cUL designation.
The cUL designation is comparable to CSA certification.

Vertical sections and units are labeled independently. It is possible to have

combinations of labeled and non-labeled sections and units in the same MCC.

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General Information Chapter 1

Vertical sections and structure options that are UL listed and CSA/cUL certified
are marked accordingly. All components in a UL or CSA listed section must be
UL listed and cUL/CSA certified. The UL and/or CSA/cUL designation is an
integral part of the section nameplate as shown on page 11.

Units and unit options that are UL listed and CSA/cUL certified are marked
accordingly. All options and components in a UL and/or cUL/CSA listed unit
must be UL listed or recognized and/or cUL/CSA certified. The UL designation
is on the interior of the bottom plate of plug-in units or on the interior right-hand
side plate of frame mounted units.

Figure 4 - UL Label Designation for Units

Short-circuit Rating Label MCC vertical sections that are UL listed and/or CSA/cUL certified will carry a
short-circuit rating label. The short-circuit rating label for a vertical section is on
the inside of the vertical wireway door of standard sections or on the interior
right-hand side plate of a section that contains a unit that occupies the full section
and does not contain a vertical wireway.

Figure 5 - Short Circuit Label for Sections

MCC units that are UL listed and/or CSA/cUL certified will carry a short-
circuit rating label on the bottom plate of plug-in units or on interior right-hand
side plate of frame mounted units.

Figure 6 - Short Circuit Label for Units

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Chapter 1 General Information

ArcShield Rating Labels MCC units that have the arc resistant rating will carry a rating label on the
vertical wireway door. This label serves as the arc resistant nameplate and provides
information on the arc resistant rating. There will also be labels on other parts
that need to be in place before operating an arc resistant MCC.

Figure 7 - ArcShield Labels

100 ms Arc Duration Device Limited Rating

ARC RESISTANT EQUIPMENT ARC RESISTANT EQUIPMENT

PER IEEE C37.20.7-2007 PER IEEE C37.20.7 2007

ACCESSIBILITY: TYPE 2 ACCESSIBILITY: TYPE 2

ARC SHORT CIRCUIT CURRENT: ≤ 65 kA
ARC SHORT CIRCUIT CURRENT: ≤ 65 kA ARC DURATION: DEVICE LIMITED
ARC DURATION: ≤ 100 ms PROTECTIVE DEVICE:
UL LISTED FUSES
OPERATIONAL VOLTAGE: ≤ 480 V CLASS L – FERRAZ-SHAWMUT A4BQ ≤ 1200 A
CLASS R – ANY FUSE ≤ 600 A
CLASS J – ANY FUSE ≤ 600 A

WARNING UL LISTED MOLDED CASE CIRCUIT BREAKERS

ALLEN-BRADLEY – BULLETIN 140U, FRAME I, JD, or K
CUTLER-HAMMER – SERIES C, FRAME F, J, K, L, M, or N

ARC FLASH HAZARD

DOORS AND COVERS MUST BE PROPERLY WARNING
CLOSED, LATCHED, AND SECURED.
ARC FLASH HAZARD
EQUIPMENT MUST BE INSTALLED PER THE ARC CONTAINMENT CAPABILITY OF THE MOTOR
MANUFACTURER’S INSTRUCTIONS. REFER TO CONTROL CENTER IS DEPENDENT UPON THE MAIN
PUBLICATION 2100-IN012. PROTECTIVE DEVICE. PROTECT ONLY WITH UL LISTED
PROTECTIVE DEVICE SPECIFIED ABOVE.
ONLY INSTALL ArcShield 100ms / 480V / 65kA
DOORS AND COVERS MUST BE PROPERLY CLOSED,
RATED UNITS IN THIS STRUCTURE. LATCHED, AND SECURED. EQUIPMENT MUST BE INSTALLED
PER MANUFACTURER’S INSTRUCTIONS.
EQUIPMENT WILL NOT FUNCTION AS REFER TO PUBLICATION 2100-IN012.
ARC RESISTANT IF ABOVE GUIDLINES
ARE NOT FOLLOWED. EQUIPMENT WILL NOT FUNCTION AS ARC RESISTANT IF
ABOVE GUIDELINES ARE NOT FOLLOWED.
FAILURE TO FOLLOW THESE GUIDELINES COULD
FAILURE TO FOLLOW THESE GUIDELINES COULD RESULT IN
RESULT IN SEVERE INJURY OR DEATH. SEVERE INJURY OR DEATH.
41006-401-01 (1)
41006-402-01 (1)

Series Number and Series ATTENTION: Read tables 1 through 4 before adding new sections or
ID as Manufactured in the units to an existing CENTERLINE MCC.
United States
Table 1 - Sections
Series Scope Description of Change Date Implemented
Letter in the U.S.
A (1) — Original design February 1971
B (1) All Changed terminal blocks November 1976
C(1) All Elimination of external mounting channels June 1979
D(1) All Reverse fed 2192 and 2193 April 1981
E(1) All Redesign gasketing October 1982
F (1) All Modified top horizontal wireway pan to accept units with handle interlock in topmost space factor October 1983
G (1) 42K 42 k bracing-incorporates new bus support and cover January 1985
G(1) 65K 65 k bracing-incorporates new bus support and cover July 1985
H All New hinge design January 1986
J All Changed handle, operating mechanism, and circuit breaker to Cutler-Hammer series C, 150 A, 250 A, 400 A October 1986
frame
K All Changed to new unit grounding system May 1990
L All Changed to new 600...1200 A circuit breaker operating mechanism February 1996
M All Changed to serpentine DeviceNet cabling system May 2001
N All New design for 100,000 A bus bracing and begin use of right-hand sidesheet with integral mounting May 2009
flanges.
(1) Replacement and renewal parts are no longer supported. For more information, contact Rockwell Automation LV MCC Technical Support at 1.440.646.5800 and follow the
prompts to Allen-Bradley>Low Voltage Motor Control Centers>Post Shipment Support.

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Table 2 - 2100 Units

Series Scope Description of Change Date Implemented in
Letter U.S.
A (1) — Original design February 1971
B (1) All sizes Changed terminal blocks November 1976
C (1) All sizes Changed handle mechanism to Cutler-Hammer MCPs June 1979
D(1) Size 5 Changed from ITE to A-B 400A disconnect April 1981
E (1) All sizes Changed from Bulletin 709 series K starters to Bulletin 500 line starters April 1981
F(1) All sizes Redesign of gasketing, wraparound and unit support pan for Bulletin 700 line October 1982
G(1) All sizes Redesign of gasketing, wraparound and unit support pan for Bulletin 500 line October 1982
H (1) All sizes Changed to new door, circuit breaker mechanism and control station April 1984
J (1) Size 5 Changed to Bulletin 500 series L October 1984
Size 3 Changed to new PCP 100A disconnect December 1988
Size 6 Changed to Bulletin 500 series B starters October 1988
K Size 1-5 CB units Changed handle, operating mechanism and circuit breaker to Cutler-Hammer series C, 150 A, October 1986
and size 1-2 disc 250 A, 400 A frame
units
L 21A through 54A Changed to Bulletin 100 line contactors in 21 A, 30 A, 45 A SMC units and original design 24 November 1989
A, 35 A, 54 A SMC units
M All sizes Changed to new unit grounding system and 600 A, 800 A, 1200 A bolted pressure switch May 1990
N All sizes Changed to PCP 200 A and 400 A disconnect, rerated vacuum Bulletin 2112 and 2113 and January 1993
new pilot device offerings
P 0.5 SF CB units External auxiliary on circuit breakers April 1994
2103L, 2113,
2193
Q All sizes and New disconnect external auxiliary contacts and new 600 A...1200 A circuit breaker operating May 1996
ratings mechanism
R SMC units Redesign and upgrade of ratings for 24 A...500 A SMC-2 and SMC-PLUS units. Original August 1997
design of SMC Dialog Plus units
1200A 2193 Redesign of 1200A, 2193F and 2193M units November 1997
800A 2193 Changed circuit breakers to MDL Frame November 1998
225A 2193F Changed circuit breakers from J Frame to F Frame October 1999
T 2000A 2193 Changed to flange mounted operating handle November 2000
All sizes Changed the Bulletin 800MR and Bulletin 800T-PS pilot devices to Bulletin 800Es November 2000
All 1.5 space Changed unit bottom plate November 2000
factor units
U All except 2100- Changed to new Bulletin 1497 control circuit transformer July 2001
SD1
2100-SD1 Changed smoke detector head and base components November 2001

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Chapter 1 General Information

Table 2 - 2100 Units

Series Scope Description of Change Date Implemented in
Letter U.S.
V 2162Q, 2163Q, Redesign of 240-480V PowerFlex 70 and release of 600V PowerFlex 70 April 2002
2164Q, 2165Q
2162R, 2163R, Original release of PowerFlex 700 July 2002
2164R, 2165R
2154H, 2155H Original release of SMC-3 November 2002
2154J, 2155J Original release of SMC Flex April 2004
2112, size 3, 4 Redesign to reduced space factor with Class J fuse clip April 2004
and 5
2162T, 2163T Original release of PowerFlex 40 September 2004
2107, 2113, size Reduced space factor April 2005
3
2162Q, 2163Q Reduced space factor, changed CCT with integral fuses April 2005
X
All sizes 800F pilot devices August 2005
2154J, 2155J, Redesign to change units from frame mounted to plug-in March 2006
108 A and 135 A
2164Q, 2164R, Redesign for change from SMP overload relay to E1Plus overload relay August 2006
2165Q, 2165R
Y (Drive with
manual bypass)
2107, 2113, size Redesign due to starter component series letter change December 2009
2 and 3
(1) Replacement and renewal parts are no longer supported. For more information contact Rockwell Automation LV MCC Technical Support at 1.440.646.5800 and follow the
prompts to Allen-Bradley>Low Voltage Motor Control Centers>Post Shipment Support.

Table 3 - 2400 Units

Series Scope Description of Change Date Implemented
Letter in U.S.
A — Original design June 1990
B 18A, 24A, 30A Changed to series B, Bulletin 194R, 30 A disconnect March 1992
C 18A, 24A, 30A Changed to three Bulletin 800E pilot devices on 0.5 space factor units July 1992
D All sizes New disconnect external auxiliary contacts and new 600 A...1200 A circuit breaker operating February 1996
mechanism
16A-85A Original design of units with a Bulletin 100-C contactor September 1999

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General Information Chapter 1

Series Lettering - Units and When using sections in conjunction with units of different series letters, consult
the table below.
Sections
Table 4 - MCC Modifications for Unit and Structure Compatibility
If Mounted in Plug-in Units No Requires Requires Requires Requires Requires Requires Requires
this Type of Additional Style 1 Style 3 Style 3 Unit Alternate Door Retrofit Ground
Section(1),(2) Parts Unit Unit Support Top Gasketing Kit (3) Bus Kit
Required Support Support Pan w/ Horizontal Kit
Pan Pan Bushing Wireway
Pan
Space Series — 2100H- 2100H- 2100H- 2100H- 2100-GJ10 2100H- 2100H-
Factor UAJ1 UA12100H USPA1 NA4A1 R1 GS1
-UJ1 2100H- 2100H- 2100H-
USPJ1 NA4J1 R2
2100H-
NA4A2
2100H-
NA4J2
NEMA Type 1 1.0 or A-E (4)  — — — — — — —
Series A...D (4) larger
F-L(4) —  — — (5) — — —
(5)
M or —  — —  — — 
later (6)
NEMA Type 1 0.5(2) N or later — — —  — —  
Series E...J(4)
1.0 or A-E(4) — —  — — — — (8)
larger
F-L(4)  — — — — — — —
M or — — — — — — — 
later(6)
NEMA Type 1 0.5(2) N or later  — — — — — — —
Series K or later
1.0 or A-L(4) — —  — — — — (8)
larger
M or later  — — — — — — —
NEMA Type 1 w/ 1.0 or A-E(4)  — — — — — — —
gasket or Type larger
12 F-L(4) —  — —  (5)  — —
Series A...D
M or later —  — — (5)  — 

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Chapter 1 General Information

Table 4 - MCC Modifications for Unit and Structure Compatibility

If Mounted in Plug-in Units No Requires Requires Requires Requires Requires Requires Requires
this Type of Additional Style 1 Style 3 Style 3 Unit Alternate Door Retrofit Ground
Section(1),(2) Parts Unit Unit Support Top Gasketing Kit (3) Bus Kit
Required Support Support Pan w/ Horizontal Kit
Pan Pan Bushing Wireway
Pan
Space Series — 2100H- 2100H- 2100H- 2100H- 2100-GJ10 2100H- 2100H-
Factor UAJ1 UA12100H USPA1 NA4A1 R1 GS1
-UJ1 2100H- 2100H- 2100H-
USPJ1 NA4J1 R2
2100H-
NA4A2
2100H-
NA4J2
NEMA Type 1 w/ 0.5(2) N or later — — —  — —  
gasket or Type
12 1.0 or A-E(4) — —  — — — — (8)

Series E...J (7) larger (4)

F-L  — — — — — — —
M or later — — — — — — — 
NEMA Type 1 w/ 0.5(2) N or later  — — — — — — —
gasket or Type
12 1.0 or A-L(4) — —  — — — — (8)

Series K or later larger

M or later  — — — — — — —
(1) When installing unit in topmost location in vertical sections, care must be taken to comply with the National Electric Code 6.7 ft (2000 mm) unit handle-to-floor height
limitation. A unit operating handle extender (catalog number 2100-NE1) that provides 3 in. (76.2 mm) added height flexibility is available.

(2) When CENTERLINE 2100, 0.5 space factor or Space Saving NEMA Starter plug-in units are ordered unassembled or ordered for existing sections, a centralized wiring
diagram holder kit (catalog number 2100H-WDH) should be ordered.

(3) Permits installation of 0.5 space factor or Space Saving NEMA Starter plug-in units in existing series E...J CENTERLINE 2100 vertical sections.

(4) Replacement and renewal parts are no longer supported. Contact Rockwell Automation LV MCC Technical Support at 1.440.646.5800 and follow the prompts to Allen-
Bradley>Low Voltage Motor Control Centers>Post Shipment Support.

(5) Required only if series F or later, 1.0 space factor or larger CENTERLINE 2100 unit is installed in topmost location of series A...E vertical sections.

(6) For more information regarding possible door hinge requirements, contact Rockwell Automation LV MCC Technical Support at 1.440.646.5800 and follow the prompts to
Allen-Bradley>Low Voltage Motor Control Centers>Post Shipment Support.
(7) Series E...J sections cannot accommodate 0.5 space factor or Space Saving NEMA Starter plug-in units in bottom-most unit location.

(8) A ground strap can be used to ground units rather than installing a ground bus. Refer to the CENTERLINE 2100 Motor Control Centers (MCC) Units with Vertical Operating
Handles Installation Instructions, publication 2100-IN014.

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General Information Chapter 1

Receiving, Handling, and Refer to the following sections for information on receiving, handling, and
storage of MCC units.
Storage

Receiving

As standard, CENTERLINE MCCs are shipped upright in shipping blocks of

one to three front-mounted sections or two to six back-to-back sections. Each
shipping block of an MCC is provided with a lifting angle. The lifting angle is
optional on NEMA Type 3R and Type 4 MCCs. Each vertical section in a
shipping block is bolted to the shipping skid and covered with clear plastic wrap.
Equipment that extends from the structures is also protected. Protection is for
upright shipping and is not waterproof or watertight. If necessary, other types of
packaging are available.

Refer to publication 2100-IN040 for receiving, handling, and storage

instructions. This publication is shipped with each MCC, attached to the outside
of the MCC within the layer of clear plastic wrap. For additional information
about the handling, installation, operation, and maintenance of MCCs rated
more than not 600V, consult NEMA ICS 2.3-1995.

Export Packaging

A maximum of three vertical sections standing upright can be shipped with

export packaging together in one block. The MCC is bolted to a skid and
wrapped in poly wrap suitable for occasional water-spray; a wooden frame and
chipboard surround the sections. Export packaging is not watertight, waterproof
or intended for long-term storage. Extended storage may require space heaters
and other considerations. Export packing adds extra weight and dimensions to
the shipping block.

Figure 8 - Handling and Receiving MCCs

Lifting Angle

Shipping Skid

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Chapter 1 General Information

Handling

Lifting with a forklift, overhead lifting, sling lifting, and pipe or rod rolling are
methods that can be used to handle vertical sections. See the following tables for
typical weights and dimensions for standard 20 in. (508 mm) wide and 15 in.
(381 mm) or 20 in. (508 mm) deep sections. For sizes not listed consult your local
Rockwell Automation Sales Office.
Table 5 - Shipping Weights and Dimensions - Standard Packaging
Standard Packing (1) Weight Height Depth Width
lb (kg), in. (cm), in. (cm), in. (cm),
approx. approx. approx. approx.
Front mounted 500 (227) 96 (244) 36 (91) 43 (109)
1-section block
Front mounted 1000 (454) 96 (244) 36 (91) 43 (109)
2-section block
Front mounted 1500 (680) 96 (244) 36 (91) 63 (160)
3-section block
Back-to-back 1000 (454) 96 (244) 42 (107) 43 (109)
2-section block
Back-to-back 1800 (816) 96 (244) 42 (107) 43 (109)
4-section block
Back-to-back 2200 (998) 96 (244) 42 (107) 63 (160)
6-section block
(1) Standard packing for shipments in the United States and Canada. The MCC shipping block is mounted
on a skid and covered in clear plastic wrap. This packaging is not watertight or waterproof.
Table 6 - Shipping Weights and Dimensions - Export Packaging
Export Packing Weight Height Depth Width
(below deck)(1) lb (kg), in. (cm), in. (cm), in. (cm),
approx. approx. approx. approx.
Front mounted 600 (295) 99 (252) 37 (94) 44 (112)
1-section block
Front mounted 1150 (522) 99 (252) 37 (94) 44 (112)
2-section block
Front mounted 1650 (748) 99 (252) 37 (94) 64 (163)
3-section block
Back-to-back 1200 (544) 99 (252) 43 (109) 44 (112)
2-section block
Back-to-back 2000 (907) 99 (252) 43 (109) 44 (112)
4-section block
Back-to-back 2450 (1111) 99 (252) 43 (109) 64 (163)
6-section block
(1) Export packing for below deck is required for all international shipments. The MCC shipping block is
mounted on a skid and covered in clear plastic wrap. This packaging is not watertight or waterproof.
Additional packing materials surround the shipping block. The export packing adds extra weight and
increases the dimension of the shipping block.

ATTENTION: MCCs are top and front heavy. To avoid personal injury or
structural damage, never attempt to lift or move the MCC by any means
other than the methods outlined in Receiving, Handling and Storing Motor
Control Centers, publication 2100-IN040.

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General Information Chapter 1

Storage and Operation

CENTERLINE MCCs conform to NEMA standard ICS 1-2000 for service and
storage conditions. All MCCs should operate in an ambient temperature above
0 oC (32 oF) but not exceeding 40 oC (104 oF) at 95% non-condensing humidity.
If the equipment is stored, the ambient temperature should remain above
-30 oC (-22 oF) but not exceed 65 oC (149 oF). In addition, MCCs have an
altitude class of 2 km (1 km for MCCs that contain variable frequency drives).
The altitude class of 2 km designates equipment for installation where the
altitude does not exceed 2000 m (6600 ft). For installation above
2000 m (6600 ft), contact Rockwell Automation LV MCC Technical Support at
1.440.646.5800 and follow the prompts to Allen-Bradley>Low Voltage Motor
Control Centers>Post Shipment Support.

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Chapter 1 General Information

Notes:

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Chapter 2

Installation Procedures

Location Planning When planning the location for your CENTERLINE MCC, consider the
following:
• Conduits
• Busways
• Overall height of installation area
• Alignment with other equipment
• Future needs
• Ambient temperature

The area must be level and the environment must be compatible with the NEMA
enclosure rating of the equipment

Documentation packages shipped with assembled MCCs include an MCC

elevation drawing and an MCC floor plan layout.

Height Considerations If the MCC is equipped with optional external mounting channels or is mounted
on a pad, the height from the floor to the center of the top handles must be
checked for compliance with NFPA 70 National Electrical Code (NEC) Article
404.8 and UL Standard 845. If the distance from the floor to the center of the
highest handle is greater than 6.7 ft (2042.16 mm) a unit operating handle
extender should be added (catalog number 2100H-NE1).

Figure 9 - Height Planning Dimensions

Height of Handle

6.7 ft (2042.16 mm)

Maximum
Cement Pad

Floor Line

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Chapter 2 Installation Procedures

ArcShield Clearance Height

The area above the MCC top plate must be unrestricted to allow for proper
operation of the pressure relief venting system.
• A minimum clearance above the top of the MCC of 12 in. (305 mm) must
be available to allow for pressure relief and/or venting should an internal
arcing fault occur.
• Conduit, cable, and wiring must be installed in such a way so that it does
not interfere with the opening of the top plate vent (no cable or conduit in
the top-rear of cabinet; cable trays must be a minimum of 12 in. (305 mm)
above the top plate).

IMPORTANT The lifting angle should not be removed from ArcShield sections with
100 ms arc resistant rating.

Figure 10 - ArcShield Planning Dimensions

ArcShield Sections with

100 ms Arc Rating Only

12 in. (305 mm)

Securing an MCC Anchor bolts [1/2 in. (13 mm)] may be embedded in the foundation prior to
installation. Two bolts per vertical section fasten the MCC through its internal
mounting angle to the foundation [corner sections require three bolts and 40 in.
(1016 mm) wide sections require four bolts]. See the following illustrations and
tables for general dimensions. Dimensions matching your equipment can be
found on the elevation drawings shipped with your MCC.

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Installation Procedures Chapter 2

Figure 11 - Mounting Dimensions for 15 in. and 20 in. Sections

IMPORTANT The external vertical support angle on MCC sections with 100 ms arc-
resistant rating add an additional 2 in. (50.8 mm) to each end of the
lineup.

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Chapter 2 Installation Procedures

Figure 12 - Mounting Dimensions for 15 in. and 20 in. Sections - continued

(2) Mounting Slots
0.56 in. x 1.13 in. Slots
(14 mm x 29 mm) Slots

D D Standard Ground Bus

Rear

0.25 in.
(6.35 mm)

B C

7.38 in.
(187 mm)

Front

E E

For seismic bolt-down applications: first For seismic bolt-down applications: last section of
section of the MCC lineup. the MCC lineup, extra bolt-down locations (2 bolts).

The optional external mounting channels add 1.5 in. (38.1 mm) to the height.

15 in. Deep 20 in. Deep

Dimensions
approx. 20 in. Wide 25 in. Wide 30 in. Wide 35 in. Wide 20 in. Wide 25 in. Wide 30 in. Wide 35 in. Wide
in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm)
A 20.00 (508) 25.00 (635) 30.00 (762) 35.00 (889) 20.00 (508) 25.00 (635) 30.00 (762) 35.00 (889)
B 15.00 (381) 15.00 (381) 15.00 (381) 15.00 (381) 20.00 (508) 20.00 (508) 20.00 (508) 20.00 (508)
C 11.56 (294) 11.56 (294) 11.56 (294) 11.56 (294) 16.56 (421) 16.56 (421) 16.56 (421) 16.56 (421)
D 10.00 (254) 12.50 (318) 15.00 (381) 17.50 (445) 10.00 (254) 12.50 (318) 15.00 (381) 17.50 (445)
E(1) 9.25 (235) 11.75 (299) 14.25 (362) 16.75 (426) 9.25 (235) 11.75 (299) 14.25 (362) 16.75 (426)
(1) Applies to first and last sections that require seismic ratings.

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Installation Procedures Chapter 2

Mounting Dimensions for 30 in. and 40 in. Deep Back-to-Back Section

A 1.69 in. (43 mm)

D D (4) Mounting Slots

0.56 in. x 1.13 in. in Slots
Front (14 mm x 29 mm) Slots
7.38 in. (187 mm)

0.25 in. (6 mm)

Rear
B 3.19 in. (81 mm)
Rear
0.25 in. (6 mm) Standard Ground Bus

7.38 in. (187 mm)

Front

20 in. Deep 40 in. Deep

Dimensions
approx. 20 in. Wide 25 in. Wide 30 in. Wide 35 in. Wide 20 in. Wide 25 in. Wide 30 in. Wide 35 in. Wide
in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm)
A 20.00 (508) 25.00 (635) 30.00 (762) 35.00 (889) 20.00 (508) 25.00 (635) 30.00 (762) 35.00 (889)
B 30.00 (762) 30.00 (762) 30.00 (762) 30.00 (762) 40.00 (1016) 40.00 (1016) 40.00 (1016) 40.00 (1016)
C 11.56 (294) 11.56 (294) 11.56 (294) 11.56 (294) 16.56 (421) 16.56 (421) 16.56 (421) 16.56 (421)
D 10.00 (254) 12.50 (318) 15.00 (381) 17.50 (445) 10.00 (254) 12.50 (318) 15.00 (381) 17.50 (445)

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Chapter 2 Installation Procedures

Figure 13 - Mounting Dimensions for 25 in. Wide Section with 9 in. (228.6 mm)
Wireway [90 in. (2286 mm) high]

The optional external mounting channels add 1.5 in. (38.1 mm) to the height.

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Installation Procedures Chapter 2

Figure 14 - Mounting Dimensions for 10 in. Wide Section with 10 in. (254 mm)
Incoming Line Section

A (L1)
A (L2)
A (L3)

7.5 in. (191 mm)

1.12 in. (28 mm)
1.25 in. (32 mm)
10 in. (254 mm)

A B
Power Wires

Section Depth
Dimension,
approx. 15 in. (381 mm) Deep 20 in. (508 mm) Deep
in. (mm in. (mm
A 12.75 (324) 17.75 (451)
B 14.75 (375) 19.75 (502)

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Chapter 2 Installation Procedures

Figure 15 - Mounting Dimensions for NEMA 3R and 4 Section [90 in. (2866 mm) high]

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Installation Procedures Chapter 2

Figure 16 - Mounting Dimensions for NEMA 3R and 4 Section

A
B C 2.87 in. (73 mm)
Ground Bus Rear

12.37 in.
(314 mm) 0.25 in.
(6 mm) Interior Section 16.56 in. (421 mm)

14.06 in. (337 mm)

Front (2) Mounting Holes

0.63 in. (16 mm) Diameter

If the optional non-removal lifting angle is supplied, add 3.63 in. (92.2 mm) to
height.
Exterior Section Width
Dimension, 20 in. (508 mm) 25 in. (635 mm) 30 in. (762 mm)
approx. Wide(1) Wide(1) Wide(1)
in. (mm) in. (mm) in. (mm)
A 25.00 (635) 30.00 (762) 35.00 (889)
B 13.75 (349) 16.25 (413) 18.75 (476)
C 11.25 (286) 13.75 (349) 16.25 (413)
(1) This measurement is the interior section width.

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Chapter 2 Installation Procedures

Figure 17 - Mounting Dimensions for 15 in. and 20 in. Deep Corner Section
[90 in. (2866 mm) high]

A 1.41 in. (36 mm)

B

D
B
(2) Mounting Slots
0.56 in. x 1.13 in. in Slots C
A (14 mm x 29 mm) Slots
0.25 in. (6 mm)

(2) Mounting Holes

0.63 in. (16 mm) Diameter
D
0.25 in. (6 mm) Ground Bus
1.41 in. (36 mm) C

The optional external mounting channels add 1.5 in. (38.1 mm) to the height.
Section Depth
Dimension,
approx. 15 in. (381 mm) Deep 20 in.(635 mm) Deep
in. (mm) in. (mm)
A 25.13 (638) 30.13 (765)
B 12.63 (321) 15.13 (384)
C 16.81 (427) 21.81 (554)
D 17.62 (448) 22.62 (575)

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Installation Procedures Chapter 2

Figure 18 - Mounting Dimensions for 15 in. and 20 in. Deep x 40 in. Wide
Front-mounted Section

The optional external mounting channels add 1.5 in. (38.1 mm) to the height.

Section Width(1)
Dimensions
approx. 20 in. Wide 25 in. Wide 30 in. Wide 35 in. Wide 40 in. Wide
in. (mm) in. (mm) in. (mm) in. (mm) in. (mm)
A 17.25 (438) 22.25 (565) 27.25 (692) 32.25 (819) 37.25 (946)
B 16.50 (419) 21.50 (546) 26.50 (673) 31.50 (800) 36.50 (927)
C 5.25 (133) 7.75 (197) 10.25 (260) 12.75 (324) 15.25 (387)
(1) When a horizontal bus or a disconnecting means (switch or circuit breaker) is specified, reduce
the ‘A’ dimension by 5 in. (127 mm).

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Chapter 2 Installation Procedures

Figure 19 - Mounting Dimensions for 15 in. and 20 in. Deep x 40 in. Wide
Front-mounted Section
40.00 in. (1016 mm)
10.00 in. (254 mm) 10.00 in. (254 mm)

1.69 in. (43 mm)

Rear
0.25 in. (6 mm)

B A

7.15 in. (102 mm)

Front
(4) Mounting Slots
20.00 in. (508 mm) 0.56 in. x 1.13 in. in Slots
Standard Ground Bus (14 mm x 29 mm) Slots

Section Depth
Dimension,
approx. 15 in. (381 mm) Deep 20 in. (508 mm) Deep
in. (mm) in. (mm)
A 15 (381) 20 (508)
B 11.56 (294) 16.56 (421)

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Installation Procedures Chapter 2

Figure 20 - Mounting Dimensions for 71 in. H (reduced height) MCC Sections

0.25 in. (6 mm) 20 in. 0.25 in. (6 mm) 20 in.

(508 mm) (508 mm)
A

70.48 in.
C (1790.19 mm) 70.48 in.
(1790.19 mm)

71 in. High Section

(1803.4 mm)

Section Depth
Dimension,
approx. 15 in. (381 mm) Deep 20 in.(635 mm) Deep
in. (mm) in. (mm)
A 15.00 (380) 20.00 (508)
B 14.75 (374) 19.75 (500)
C 5.12 (130) 10.12 (256)
D 4 (101) 8 (203)
E — 4.40 (112)

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Chapter 2 Installation Procedures

Seismic Requirements To demonstrate the seismic withstand of various CENTERLINE MCCs [20 in.
deep (508 mm), 30 in. deep (762 mm) back-to-back, and 40 in. deep (1016 mm)
back-to-back], the MCC design construction has been qualified by seismic
calculations per the Uniform Building Code (UBC). CENTERLINE 2100
MCC samples have been seismically qualified by dynamic (triaxial multi-
frequency testing) seismic tests per IEEE 344 Seismic Test Standards. The results
of the MCC seismic testing demonstrated compliance with the 100% g level of
Uniform Building Code 1997 (UBC) zone 4 (the maximum UBC zone) and
100% g level of The International Building Code 2006 (IBC), for example, the
MCC structure, the MCC units, and the MCC components or electrical
functions were not compromised when subjected to a UBC Zone 4 earthquake,
or the IBC seismic event. Per the IEEE 344 standard, the equipment was under
power and operated before, during, and after the seismic tests.

IMPORTANT Variable frequency drive units using ‘rollout’ drive configurations are not
seismically tested.

In order to obtain a UBC or IBC seismic withstandability, each individual

CENTERLINE 2100 MCC lineup (for example, both front and back MCCs in
‘back-to-back applications), must be mounted on an adequate seismic foundation
and installed per the seismic anchoring requirements as shown in the following
illustrations.

In seismic application dimensions ‘E’ applies to the first and last sections of the
MCC lineup. See Figure 11 -Mounting Dimensions for 15 in. and 20 in. Sections
for dimensions.

Figure 21 - Seismic Bolt Down Requirements

E Rear E

1 1 1

First Section Front Last Section

Second Section and
Additional Sections
MCC Lineup

1The hardware required is 1/2 in.-13 Grade 5 or HSL-3 M12 or better bolts embedded in the foundation.

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Installation Procedures Chapter 2

Figure 22 - Seismic Weld Down Requirements

0.25 in. (6 mm)
Rear

Second Section and

Additional Sections
First Section Last Section

Front
1.50 in. (38 mm) 1.50 in. (38 mm)
1.50 in. (38 mm)
1.50 in.
1.50 in. 1.50 in. (38 mm)
(38 mm)
(38 mm) MCC Lineup

Rear Optional Location Front

for Rear Welds

Floor Line
Left-hand Side View

Joining and Splicing New A main horizontal bus splice kit must be installed between shipping blocks of
new MCCs to connect the main horizontal bus. In addition, the neutral bus
MCCs splice kit (if required) and the ground bus splice kit must be installed between
shipping blocks. Refer to CENTERLINE 2100 Motor Control Centers Joining
and Splicing Vertical Sections Instructions, publication 2100-IN010.

Joining and Splicing A main horizontal bus, a neutral bus (if required), and a ground bus splice kit
must be installed when adding to existing CENTERLINE MCCs. When adding
Existing MCCs to existing MCCs, you must identify the series of the MCC that you will be
adding to. If the existing MCC is series A or B, you must consult MCC technical
support at 1.440.646.5800 and follow the prompts to Allen-Bradley>Low
Voltage Motor Control Centers>Post Shipment Support for joining and splicing
procedures. When the existing MCC is series C or later, refer to
CENTERLINE 2100 Motor Control Centers Joining and Splicing Vertical
Sections Instructions, publication 2100-IN010.

Be sure to also connect DeviceNet cables and other control cables as required.

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Chapter 2 Installation Procedures

Joining and Splicing MCCs In addition to the horizontal, neutral (if required), and ground bus splicing kits,
CENTERLINE MCCs with arc-resistant ratings have these additional
with ArcShield requirements:
• MCCs with the 100 ms arc-resistant rating have a back-corner baffle at the
end of each lineup and insulation on the side closing-plate at the end of the
lineup. They also have external vertical support angles at each end of the
lineup.
• MCCs with the device-limited rating have insulation on the horizontal bus
side closing-plates at each end of the lineup.

Installing and Joining Pull When pull boxes are supplied with your MCC, refer to Installing a Pull Box on a
Bulletin 2100 Vertical Section, publication 2100-IN029, for installing and
Boxes joining the pull box onto the vertical section.

Joining and Splicing NEMA NEMA Type 12 MCCs must be properly installed to prevent the ingress of dust
and dirt. Follow the caulking instructions in the NEMA Type 12 Sealing
Type 12 MCCs Instructions, publication 2100-IN037, supplied with the NEMA 12 MCC.
Using caulk, close any mounting holes in the bottom plates and bolt holes
between shipping splits.

It is necessary that all door latches and wireway doors be fully latched to prevent
dust and dirt from entering the enclosure and to meet NEMA Type 12
requirements.

Joining and Splicing NEMA A main horizontal bus, a neutral bus (if required) and a ground bus splice kit
must be installed between the internal sections for new and existing NEMA Type
Type 3R and Type 4 MCCs 3R and Type 4 MCCs. Refer to CENTERLINE 2100 Motor Control Centers
Joining and Splicing Vertical Sections Instructions, publication 2100-IN010, for
splicing Type 3R and Type 4 internal sections.

Figure 23 - Joining Instructions for NEMA Type 3R and 4 Sections

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Installation Procedures Chapter 2

(2) wireway extensions required for 15 in. (381 mm) deep.

(2) wireway extensions required for 20 in. (508 mm) deep.
Cabinet Spacer (1) 0.25 in. (6 mm) -20 x 0.70 in. (17.78 mm) taptite per wireway extension.
(2) 0.25 in. (6 mm) x 0.50 in. (12.7 mm) Taptites

Remove left-hand driphood angle and remount

MCC MCC MCC after the adjacent driphood has been drilled out.

Remove right-hand driphood angle and (2) 0.25 in. (6 mm) x 0.50 in. (12.7 mm) Taptite
discard. Drill out (5) 0.172 in. (4.36
Gasket
mm) diameter holes to 0.25 in. (6 mm)
diameter in driphood.

Gasket

Remove the right-hand and left-

hand side plates before joining Gasket
sections. The gasket is across the
top of the driphood and down the
backplate on one of the adjoining
Cabinet Spacer
sections. (2) 0.25 in. (6 mm) x
Cabinet Spacer Wireway Extensions 0.50 in. (12.7 mm)
(2) 0.25 in. (6 mm) x 0.50 in. (2) or (4) 0.25 in. (6 mm) x 0.50 in. Taptites
(12.7 mm) Taptites (12.7 mm) Taptites

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Chapter 2 Installation Procedures

Bus Torque Specifications Tighten all bus splice connections with a torque wrench and socket at intervals
established by your maintenance policy. See Chapter 9 for suggested
maintenance. If a torque wrench is not available, tighten until the conical spring
washer is flat.

Torque values can be found on the information label on the interior of the vertical
wireway door or on the interior right-hand side plate of frame mounted units.

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Chapter 3

Installing Conduit and Cable

Installing Conduit When installing conduit, make sure it is installed according to local codes - to
assure water and moisture cannot enter or accumulate in the MCC enclosure.
Conduit must be installed so they are compatible with the NEMA rating of the
MCC. The conduit should be placed away from the horizontal ground bus to
avoid damage. We recommend that the conduit be positioned to minimize cable
bending and maintain relative vertical alignment to incoming connections.

Bottom Entry Conduit

Follow this procedure if your conduit is entering from the bottom.

1. Prepare the installation site so the foundation is level.

2. Before the MCC is installed, place and stub up conduit approximately 2 in.
(51 mm) above floor level, making sure all incoming conduit is clear of the
horizontal ground bus.

For approximate section base dimensions and ground bus locations, refer
to Installation Procedures, Chapter 2, or elevation and floor plan drawings
shipped with MCC.

For approximate bottom entry locations and wiring schemes for main
fusible disconnects, main circuit breakers, and incoming line
compartments, refer to Mains and Incoming Lines Dimension Reference,
publication 2100-TD018.

Top Entry Conduit

ATTENTION: For ArcShield units with 100 ms arc duration rating,

conduit, cable, and wiring must be installed in such a way so that it does
not interfere with the opening of the top plate vent (no cable or conduit in
the top-rear of cabinet; cable trays must be a minimum of 12 in. (305 mm)
above the top plate).

Follow this procedure if your conduit is entering from the top.

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Chapter 3 Installing Conduit and Cable

1. After the MCC is in place, leveled, and the sections are joined and spliced,
bring conduit into the top of the incoming section.
For approximate top entry locations and wiring schemes for main fusible
disconnects, main circuit breakers and incoming line compartments, refer
to Mains and Incoming Lines Dimension Reference,
publication 2100-TD018.
2. Remove the lifting angle and top plate.
3. Modify the top plate for necessary conduit entries.
This method helps guard against metal chips falling into the MCC, which
can cause serious damage to the components.
4. Replace the top plate and lifting angle bolts to guard against dust or dirt
from entering the top horizontal wireway.
5. Make sure that all incoming conduit is clear of the horizontal ground bus.
For approximate location of the horizontal ground bus mounted in the top
horizontal wireway, refer to Mains and Incoming Lines Dimension
Reference, publication 2100-TD018.
For space availability for incoming cables, refer to the elevation drawings
shipped with assembled MCCs.

Installing Cable Install the cable when the temperature is above freezing 0 °C (32 °F), unless the
cable is suitable for installation at temperatures below freezing. This will help
prevent cable insulation from cracking or splitting.

MCCs are rated for use with 75 °C (167 °F) cable. Cable must be sized by using a
75 °C (167 °F) column in NEC Table 310–16 (NEC 2005 Edition). The
temperature rating of the lugs is not relevant.

ATTENTION: Properly connect all line and load cables to avoid a bolted
fault and equipment damage.

Lugs

Follow this procedure to install the lugs.

1. Verify the compatibility of wire size, type, and stranding versus the power
lugs furnished.
Use correct lugs in all applications.
2. Crimp compression lugs with manufacturer recommended tools.
3. Use the MCC electrical schematics to verify field wiring connection
points.

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Installing Conduit and Cable Chapter 3

Incoming Line Compartment

Top or bottom entry to the incoming line-section bus is straight through to the
connection terminals. The vertical bus provides pads for the incoming lugs. The
lug selection should be based on the size, number, and type of conductor.
• Use of mechanical screw-type lugs is acceptable only when the incoming
lines’ available short-circuit current is 42,000 A rms symmetrical or less.
• Use of crimp or compression type lugs is acceptable when the incoming
lines’ available short-circuit current does not exceed 100,000 A rms
symmetrical.

Main Disconnect

Top entry is straight through to the line side of the main fusible disconnect or
main circuit breaker. For bottom entry, the connection scheme varies depending
on the rating of the main device. In some cases, the bottom entry connects to the
top or line side of the main fusible disconnect or main circuit breaker. In other
cases the connection is reverse-fed, the bottom entry cables connect to the
bottom of the main fusible disconnect or main circuit breaker. For further
information refer to Mains and Incoming Lines Dimension Reference,
publication 2100-TD018.

Mechanical screw-type lugs are supplied as standard with all main fusible
disconnects or main circuit breakers. Crimp or compression lugs are optional.

Cable Bracing

The CENTERLINE MCC bus work system has been tested and is qualified to
withstand maximum short-circuit forces exceeding the short-circuit withstand
ratings for the MCC. Incoming line cables and outgoing feeder cables also need
to be supported to withstand the same short-circuit forces. Follow NEC and local
codes when bracing incoming and outgoing cables. There are many sizes and
types of cables, as well as different means by which the cables can be supported.
Acceptable methods are shown on the following pages.

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Chapter 3 Installing Conduit and Cable

Securing Cables with Glass Tape

In this example, glass fiber-reinforced tape or glass filament tape is used. The
taping should be continuous from the point the cables enter the MCC to the
point the cables are terminated. It is important that cables are wrapped several
times for additional strength. Cable slack should be drawn up during wrapping so
that individual cables are supported by the tape as a single mass.

Figure 24 - Securing Cables with Glass Tape

Securing Cables with Nylon Rope

In this example, cables are lashed in a ‘figure 8’-type configuration by using nylon
rope. The rope lashing should be continuous from the point the cables enter the
MCC to the point the cables are terminated. Other types of rope lashing may be
acceptable. Cable slack should be drawn up during wrapping so that individual
cables are supported by the rope as a single mass.

Figure 25 - Securing Cables with Nylon Rope

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Installing Conduit and Cable Chapter 3

Securing Cables with Hardwood

In this example, a hardwood brace (maple hardwood) made for the specific
application is used. Holes are bored approximately the size of the cable diameter.
Several bolt holes are also bored the breadth of the hardwood brace. The brace is
cut in two pieces and is used as a clamp to secure the cables. Through bolts are
inserted into the brace and tightened so that cables are held tightly in place.

Figure 26 - Securing Cables with Hardwood

A second form of hardwood brace (not shown) is a yolk type in which the cables
are passed through. Holes should be small enough to provide a snug fit for the
cables. The connectors or lugs are attached to the cables and cables are bolted to
the terminals.

When using the hardwood bracing method and the short circuit current is less
than 42,000 A, cables should be braced every 12 in. (305 mm). When the short
circuit current is 42,000 A or greater, cables should be braced every 6 in.
(153 mm).

Incoming Line Brace

Allen-Bradley manufactures an incoming line brace similar to the hardwood

clamping-type brace. To order an incoming line brace, contact your local Allen-
Bradley sales office and reference assembly number 40113–848.

IMPORTANT Lugs should be installed so they are in line with each other and proper
spacing is used between phases. Hardware must be torqued per the
torque tables found on the enclosure door.

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Chapter 3 Installing Conduit and Cable

Notes:

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Chapter 4

Installing and Removing Plug-in Units

ATTENTION: When installing or removing MCC units, when possible, de-

energize, lockout, and tag-out all sources of power to the MCC. If the
MCC units will be installed or removed with power applied to the main
power bus, follow established electrical safety work practices. Refer to
the NFPA 70E Standard for Electrical Safety in the Workplace publication.

ATTENTION: Review your company safety lockout and tag-out

procedure.
De-energize all units before installing or removing.

ATTENTION: All covers and doors must be in place before applying

power to the MCC. If units are removed, they must be replaced with the
appropriate items such as units, doors, and unit support pans.

ATTENTION: When installing units for CENTERLINE 2100 Motor Control

Centers with the ArcShield rating, you must make sure you are installing a
unit that has the same arc resistance rating as the MCC in which it is
being installed. The arc resistance rating can be found on the ArcShield
label on the vertical wireway door.
Units that are not rated for 100 ms arc duration must not be installed in a
section that is rated for 100 ms arc duration. The arc resistant rating will not
apply if that is done.

Installing Plug-in Units For unit installation, refer to CENTERLINE 2100 Motor Control Centers
(MCC) Units with Vertical Operating Handles Installation Instructions,
publication 2100-IN014, and CENTERLINE 2100 Motor Control Center
(MCC) Units with Horizontal Operating Handles Installation Instructions,
publication 2100-IN060.

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Chapter 4 Installing and Removing Plug-in Units

Remove a Plug-in Unit with

a Vertical Operating Handle
from a Section

1. Make sure the disconnect handle is in the OFF/O position.

2. For non-arc resistant units, turn the door latches 1/4 turn; for units that
are equipped with arc-resistant door latches, push in the latch and rotate
1/4 turn.

Arc Containment Latch

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3. Open the door completely.

4. .Remove the unit door, if necessary.

TIP It is not necessary to remove the unit door to remove a unit from a
section. However, these steps may still be necessary even when
the door is not removed.

a. Remove the door-mounted devices and wiring, if necessary.

b. Remove the hinge pins by sliding upward with a flathead screwdriver.

For Units With Follow This Step

A control station First slide the hinge pin out of the hinge and through the tab on
the control station wiring.
ArcShield units with Two hinges are required for each hinge leaf.
100 ms arc duration
rating 1. The upper hinge on each door must be removed from the
structure to remove the uppermost hinge pin.
2. Remove the hinge pin through the lower hinge, then through
the hinge leaf and upper hinge.

Hinge for ArcShield Units with 100 ms Arc Duration Rating

Only top hinge
must be removed
to install hinge
pin.

Hinge

Hinge Pin

Hinge Leaf

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The control station can be hung on the front of the unit by using square
holes adjacent to the top unit latch.
c. Swing the door to near closed position.
d. Lift the door outward to remove.

5. Disengage the captive latches at the front of the unit, one at the top and
one at the bottom of the unit.
Units that are 2.0 space factor and larger have two latches at the top. All
units with the 100 ms arc-resistant rating have two latches at the top.

Wiring
Tunnel

6. Detach the front portion of the pull-apart terminal blocks from the unit
base and place the wires and terminal blocks in line with the wiring
clearance tunnel.

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7. Remove other cables or devices that would prevent the unit from being
withdrawn.
TIP It is not necessary to place wires and terminal blocks into the
vertical wireway to remove a plug-in unit that includes the wiring
clearance tunnel.
.

8. Pull the unit forward (outward) approximately 3 in. (7.5 cm) out of the
MCC, using the handle provided at the lower left of the unit and the tab in
the upper right of the unit as finger holds.
You may need to reposition your hands as necessary to properly support
the unit while you are removing the unit from the MCC.

ATTENTION: Plug-in MCC units may be heavy or awkward to

handle. Use an assistant or a platform lift device if necessary to
help you handle the unit.

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For the CENTERLINE 2100 MCC units with arc-resistant door latches,
you may need to tilt the top of the unit slightly to the rear to avoid
interference with the top arc latch bracket before removing the unit. If you
do not have enough clearance, you will need to loosen the latch bracket
screw (approximately two turns) to remove the unit.

Latch Bracket

Latch Bracket

TIP For dual-mounted, fusible-feeder disconnect switch units, you

will need to remove the bottom arc latch bracket. You can do this
by first removing the unit below the dual disconnect unit.

9. Remove the unit from the MCC.

10. Carefully install protective caps or close manual shutters after the unit is
removed.
Automatic shutters will close as units are removed.

ATTENTION: All covers and doors must be in place before

applying power to the MCC. If units are removed, they must be
replaced with the appropriate items such as units, doors, and unit
support pans.
When installing units for CENTERLINE 2100 Motor Control Centers
with the ArcShield rating, you must make sure you are installing a
unit that has the same arc resistance rating as the MCC in which it is
being installed. The arc resistance rating can be found on the
ArcShield label on the vertical wireway door.
Units that are not rated for 100 ms arc duration must not be installed
in a section that is rated for 100 ms arc duration. The arc resistant
rating will not apply if that is done.

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Installing and Removing Plug-in Units Chapter 4

Remove a Plug-in Unit with

a Horizontal Operating
Handle from a Section

1. Make sure the disconnect handle is in the OFF/O position.

2. For non-arc resistant units, turn the door latch 1/4 turn; for units that are
equipped with arc-resistant door latches, push in the latch and rotate 1/4
turn.

Arc Containment Latch

3. Open the door completely.

4. Remove the unit door, if necessary.
TIP It is not necessary to remove the unit door to remove a unit from a
section. However, these steps may still be necessary even when
the door is not removed.

a. Remove the door-mounted devices and wiring, if necessary.

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Chapter 4 Installing and Removing Plug-in Units

b. Remove the hinge pins by sliding upward with a flathead screwdriver.

For Units With Follow This Step

A control station First slide the hinge pin out of the hinge and through the tab on
the control station wiring.
ArcShield units with Two hinges are required for each hinge leaf.
100 ms arc duration
rating 1. The upper hinge on each door must be removed from the
structure to remove the uppermost hinge pin.
2. Remove the hinge pin through the lower hinge, then through
the hinge leaf and upper hinge.

Hinge for ArcShield Units with 100 ms Arc Duration Rating

Only top hinge
must be removed
to install hinge
pin.

Hinge

Hinge Pin

Hinge Leaf

The control station can be hung on the front of the unit by using square
holes adjacent to the top unit latch.
c. Swing the door to near closed position.
d. Lift the door outward to remove.
.

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Installing and Removing Plug-in Units Chapter 4

5. Detach the wiring/terminal block from the unit.

6. Place the wiring/terminal block in the vertical wireway to the right of unit.

7. Push the latch mechanism to the left with your right hand.
8. Pull the unit forward (outward) approximately 3 in. (7.62 cm) out of the
MCC.
You may need to reposition your hands as necessary to properly support
the unit while you are removing the unit from the MCC.

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Chapter 4 Installing and Removing Plug-in Units

For the CENTERLINE 2100 MCC units with swing-out door latches,
you will need to rotate the latch bracket 90o clockwise to avoid interference
with the unit.

Swing-out
Latch
Bracket

ATTENTION: Plug-in MCC units may be heavy or awkward to handle. Use

an assistant or a platform lift device if necessary to help you handle the
unit.

9. Remove the unit from the MCC.

10. Carefully install protective caps or close the manual shutters after unit is
removed.

ATTENTION: All covers and doors must be in place before

applying power to the MCC. If units are removed, they must be
replaced with the appropriate items such as units, doors, and unit
support pans.

Automatic shutters will close as units are removed.

11. See the next section for additional information.

ATTENTION: All covers and doors must be in place before

applying power to the MCC. If units are removed, they must be
replaced with the appropriate items such as units, doors, and unit
support pans.
When installing units for CENTERLINE 2100 Motor Control Centers
with the ArcShield rating, you must make sure you are installing a
unit that has the same arc resistance rating as the MCC in which it is
being installed. The arc resistance rating can be found on the
ArcShield label on the vertical wireway door.
Units that are not rated for 100 ms arc duration must not be installed
in a section that is rated for 100 ms arc duration. The arc resistant
rating will not apply if that is done.

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Installing and Removing Plug-in Units Chapter 4

Remove the Support Pan 1. For ArcShield sections with 100 ms arc duration rating, remove the vertical
wireway baffle and set aside for installation later.

2. Pry the plastic retaining clip from the right-hand unit support by using a
screwdriver.
This is visible in the vertical wireway.

Plastic
Retaining
Clip

For CENTERLINE MCC units with arc resistant latches, the unit
support pan is secured to the right-hand unit support by the screw that
retains the arc latch bracket. In order to remove the unit support pan, you
must remove the arc latch bracket.

Arc Latch
Bracket

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Chapter 4 Installing and Removing Plug-in Units

For CENTERLINE MCC units with the 100 ms arc duration rating,
there is an additional screw that secures the unit support pan. This screw is
at the left-rear corner of the unit support pan.

Unit Support Pan

Unit Support
Pan Screw

3. Lift the right side of the support pan approximately 4 in. (102 mm).

4. Pull the right side of the support pan forward to release from the left rear
slot on the structure.
5. Push back on the left side of the support pan until the support pan is free
from the structure.
Vertical sections may be supplied with plug-in stab opening protective
caps, manual shutters, or automatic shutters. Refer to the next step if any of
these options are supplied.
6. Carefully install the protective caps or close the manual shutters after the
unit is removed.
Automatic shutters will close as the units are removed.

ATTENTION: All covers and doors must be in place before

applying power to the MCC. If units are removed, they must be
replaced with the appropriate items such as units, doors, and unit
support pans.

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Chapter 5

Arc Flash Protection Marking as Required by

the National Electrical Code

Flash Protection Marking The flash protection marking requirement was initially established in 2000 by
The National Fire Protection Association (NFPA 70E), Standard for Electrical
Requirement Safety Requirements for Employee Workplaces. NFPA 70E applies to workers
who install, maintain, or repair electrical systems.

In 2002, NFPA 70, The National Electrical Code (NEC) added the Article
110.16, and reinforced the flash protection marking of equipment. The 2002
version of the article is stated below.

110.16 Flash Protection

Switchboards, panelboards, industrial control panels, and MCCs that are

in other than dwelling occupancies and are likely to require examination,
adjustment, servicing, or maintenance while energized shall be field
marked to warn qualified persons of potential electric arc flash hazards.
The marking shall be located so as to be clearly visible to qualified persons
before examination, adjustment, servicing, or maintenance of the
equipment.

FPN No. 1: NFPA 70E-2000, Electrical Safety Requirements for

Employee Workplaces, provides assistance in determining severity of
potential exposure, planning safe work practices, and selecting personal
protective equipment.

FPN No. 2: ANSI Z535.4-1998, Product Safety Signs and Labels, provides
guidelines for the design of safety signs and labels for application to
products.

As Arc Flash Technology emerges, new developments have caused changes to arc
flash criteria. For example, in 2004, the NFPA 70E was reissued in a completely
new format along with changes reflecting new developments. The NEC is revised
every three years and the NFPA 70E is revised every four years. The latest editions
of the NEC and NFPA 70E should be used in establishing potential electric arc
flash hazards and arc flash marking.

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Chapter 5 Arc Flash Protection Marking as Required by the National Electrical Code

Arc Flash Marking The flash protection marking per NEC Article 110.16 is a field marking
requirement and is to be applied by the MCC end-user for each specific
Clarification application. The marking is similar to other NEC marking requirements, for
example, voltage, voltage hazard labels, and circuits. However, flash protection
markings must be based on application information and calculations from the
installation site. The intent of the marking is to identify the presence of a
potential flash hazard and to provide assistance in determining necessary
protective clothing and personal protective equipment (PPE) that should be
worn by qualified electrical persons when servicing electrical equipment. You
must establish field marking requirements based upon:
• the level of the on-site personnel safety training.
• the level of required clothing and required PPE.
• consistency for the level of marking of various equipment, for example,
switchboards, panelboards, industrial control panels, and MCCs.
• the available flash energy on each piece of equipment. This energy is
determined from available fault current, arc flash duration due to the type
and degree of short circuit protection equipment.

Rockwell Automation Rockwell Automation understands the importance of you fulfilling the field arc-
flash hazard marking requirements as defined by Article 116.10 in the NEC.
Services Rockwell Automation may assist you in determining the necessary arc flash
marking as required by NFPA 70E.

Rockwell Automation offers services that can provide assistance in the following
areas:
• Arc-flash hazard analysis
• Providing input on the specific Bulletin 2100 MCC design being used
• The zone determination for the NFPA 70E Hazard/Risk levels
• Your required NEC field marking

For information regarding arc-flash hazard analysis, contact your local Rockwell
Automation sales office or distributor.

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Chapter 6

Operator Handle and Unit Interlock

The operator handle is an integral part of each MCC unit. Adjustment of the
handle is not required. The operator handle is interlocked with each unit door as
outlined by UL 845.

Defeating the Unit Door Refer to the following information for defeating the unit door lock.
Interlock
Open the Door When the Operating Handle Is in the ON/I
Position
ATTENTION: When working on or near energized electrical equipment,
follow established electrical safety-related work practices. Refer to NFPA
70E Standard for Electrical Safety in the Workplace.

When the unit door is closed and the operator handle is in the ON/I position, a
defeater screw must be deliberately operated to open the unit door (for example,
opening the door of an energized unit).

The defeater screw is just below (on units with a vertically mounted operator
handle) or just to the right (on units with a horizontally mounted operator
handle) of the pivot point of the operator handle. To operate the defeater
mechanism and defeat the door interlock while the operator handle is in the
ON/I position, use a flat-head screwdriver to turn the defeater screw clockwise
one-eighth to one-quarter turn.

ATTENTION: Opening the door reduces arc flash safety.

ATTENTION: When working on or near energized electrical equipment,

follow established electrical safety-related work practices. Refer to NFPA
70E Standard for Electrical Safety in the Workplace.
Personal protective equipment (PPE) is not shown for clarity.

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Chapter 6 Operator Handle and Unit Interlock

Figure 27 - Operating Handle Defeater for Vertical Operator Handle

Figure 28 - Operating Handle Defeater for Horizontal Operator Handle

Defeating the Unit Interlock Refer to the following information for defeating the unit interlock lever.
Lever

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Operator Handle and Unit Interlock Chapter 6

Energize a Unit with the Unit Door Open

ATTENTION: When working on or near energized electrical equipment,

follow established electrical safety-related work practices. Refer to NFPA
70E Standard for Electrical Safety in the Workplace.
Personal protective equipment (PPE) is not shown for clarity.

When the unit door is open and the operator handle is in the OFF/O position,
the defeater lever must be deliberately lifted on the vertical handles or pushed to
the left for horizontal handles, to move the operator handle to the ON/I
position, and energize the unit.

Figure 29 - Defeater Lever for Vertical Operator Handle

ATTENTION: When working on or near energized electrical equipment,

follow established electrical safety-related work practices. Refer to NFPA
70E Standard for Electrical Safety in the Workplace.
Personal protective equipment (PPE) is not shown for clarity.

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Chapter 6 Operator Handle and Unit Interlock

Figure 30 - Defeater Lever for Horizontal Operating Handle

Locking Provisions Refer to the following sections for locking provisions.

Lock Vertical Operating Handles in the OFF/O Position

ATTENTION: When working on or near energized electrical equipment,

follow established electrical safety-related work practices. Refer to NFPA
70E Standard for Electrical Safety in the Workplace.

To lock the small, medium, and large operator handle in the OFF/O position, put
the shackle of the lock through the opening in the operator handle assembly. The
opening can accommodate up to three padlocks.

Figure 31 - Locking Vertical Handles in OFF/O Position

Small and Medium Vertical Handle Large Handle

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Operator Handle and Unit Interlock Chapter 6

Lock Horizontal Operating Handles in the OFF/O Position

Some units use a horizontal operating handle. The horizontal operating handle
can be locked in the OFF/O position by putting the shackle of the lock through
the open slotted area to the left of the operator handle.

Figure 32 - Locking a Horizontally Mounted Operating Handle in OFF/O Position

Lock Units with Operating Handles in the ON/I Position

ATTENTION: Locking an operating handle in the ON/I position may be in

conflict with local codes and emergency shut down requirements.

Follow this procedure to lock the operator handle in the ON/I position.

1. Drill out the hole to 3/8 in. (9.5 mm) diameter maximum.
2. Insert the shackle of the lock.

The following instructions assume that the handle is in the ON/I position:
• For units with small handles, the hole is in the upper portion of the
operator handle assembly.
• For units with medium and large operator handles, the hole is underneath
the operator handle on the handle assembly.
• For units with a horizontally mounted handle, the hole is on the left-hand
side of the handle assembly.

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Chapter 6 Operator Handle and Unit Interlock

Figure 33 - Locking Small Handle in ON/I POSITION, Vertical Operating Handle

Drill Out

Figure 34 - Locking the Medium Handle in ON/I Position

Drill Out

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Operator Handle and Unit Interlock Chapter 6

Figure 35 - Locking Large Handle in ON/I Position

Drill Out

Figure 36 - Locking Horizontal Handle in ON/I Position

Drill Out

Unit Interlocks

A unit interlock is provided with each plug-in unit. Unit interlocks prevent units
from being removed from or inserted into a vertical section when the operator
handle is in the ON/I position.

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Chapter 6 Operator Handle and Unit Interlock

Units can also be locked out with a padlock preventing installation of the unit
into a vertical section. The lockout feature of the unit interlock can be used with a
padlock to keep the interlock in an extended position, which will prevent the unit
from being inserted into an MCC section. The unit interlock can also be used
with the unit installed in the section, but partially removed from the section.

In this position, the unit is partially removed from the MCC and the slot in the
interlock plate is in line with the flange of the unit support pan above this unit.
When the unit is locked in this position, the unit power and ground stabs are
disengaged. This position can be used to prevent insertion of a unit into the
MCC.

Figure 37 - Unit Interlock to Prevent Insertion - Vertical Operating Handler

ATTENTION: When working on or near energized electrical equipment,

follow established electrical safety-related work practices. Refer to NFPA
70E Standard for Electrical Safety in the Workplace.
We recommend that maintenance performed on the MCC units be performed
away from the MCC in a suitable work area, when possible.

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Figure 38 - Unit Interlock to Prevent Insertion - Unit Completely Withdrawn

In this position, the unit is partially removed from the MCC and the
intermediate slot in the interlock plate is in line with the bushing in the unit
support pan. When the unit is locked in this position, the unit power and ground
stabs are disengaged. This position can be used to prevent insertion of a unit into
the MCC.

Figure 39 - Unit Interlock to Prevent Insertion - Horizontal Operating Handle

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Chapter 6 Operator Handle and Unit Interlock

ATTENTION: When working on or near energized electrical equipment,

follow established electrical safety-related work practices. Refer to NFPA
70E Standard for Electrical Safety in the Workplace.
We recommend that maintenance performed on the MCC units be performed
away from the MCC in a suitable work area, when possible.

Figure 40 - Unit Interlock to Prevent Insertion - Unit Completely Withdrawn

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Chapter 7

Final Checklist Before Energizing

Introduction This section provides guidance for the startup of a newly installed MCC.

We recommend making an itemized list including:

• serial number.
• number of sections.
• number of units and their corresponding voltage.
• current ratings.
• horsepower ratings
• types of circuits.
• fuse sizes.
• circuit breaker ratings and trip settings.
• heater elements requirements.
• arc resistant components.
• other important data.

The itemized list could be modeled after the MCC layout drawings supplied with
each MCC. This itemized list should be saved in a file along with other data for
the MCC such as, component manuals, heater element instructions, MCC
manuals, and wiring diagrams. Blank sample forms are provided at the end of this
chapter.

Pre-energizing Check The following procedures should be executed by a ‘qualified person’ as defined by
NEMA Standards Publication / No. ICS 2.3, Instructions for the Handling,
Procedure Installation, Operation and Maintenance of Motor Control Centers, Section 1 as
follows:

1.4 Qualified Person

For the purpose of this guide, a qualified person is one who is familiar with
the installation, construction and operation of the equipment and the
hazards involved. In addition, he or she has the following qualifications:

1.4.1 Is trained and authorized to energize, de-energize, clear, ground and

tag circuits and equipment in accordance with established safety practices.

1.4.2 Is trained in the proper care and usage of protective equipment such
as rubber gloves, hard hat, safety glasses or face shields, flash clothing, etc.,
in accordance with established safety practices.

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Chapter 7 Final Checklist Before Energizing

Perform the Pre-energizing

Check Procedure ATTENTION: To ensure the safety of personnel performing the pre-
energizing check, make sure the MCC remote power sources are
disconnected and locked in the OFF/O position.
Using a voltmeter, verify that the MCC remote power sources are
disconnected.

ATTENTION: Power factor correction capacitors (PFCCs) should be

applied correctly. For application instructions refer to Power Factor
Correction Capacitors for Bulletin 2100 MCC Starter Units Application
Techniques, publication 2100-AT001. When PFCCs are connected to the
motor circuit and the start-up procedure requires the respective motors to
be jogged, inched, or bumped (rotation direction check), temporarily
disconnect PFCCs. For more information contact, Rockwell Automation LV
MCC Technical Support at 1.440.646.5800 and follow the prompts to
Allen-Bradley>Low Voltage Motor Control Centers>Post Shipment
Support.

ATTENTION: Verify that motor acceleration times are within specific

application specifications.
Excessive starting currents and/or acceleration times may cause inverse time
circuit breakers, power fuses, overload relays, and other components to
overheat and/or shutdown equipment.

1. Remove all blocks or temporary holding means used for shipping all
component devices in the MCC.
2. Inspect the enclosure and units for damage.
If structural damage is present, contact MCC technical support at
1.440.646.5800 and follow the prompts to Allen-Bradley>Low Voltage
Motor Control Centers>Post Shipment Support. If no structural damage
is visible, the electrical spacings should be intact. Refer to the tables starting
on page 82 for the required minimum electrical spacings.
3. Check and verify that the MCC is properly installed, as described in
Chapter 2, and inspect and verify that it is level, supported, and anchored.
4. For MCCs with the 100 ms arc-resistant rating, check that clearance
height is at least 12 in. (305 mm).
5. Check the integrity of the bus splice connections.
Recommended torque values can be found on the information label on the
interior of the vertical wireway door or on the interior right-hand side plate
of frame mounted units. See Joining and Splicing Vertical Sections,
publication 2100-IN010, for splicing information.

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The factory-made power bus connections are tightened by a computer-

controlled torquing system. The following connections do not require re-
torquing:
• vertical to horizontal bus connections.
• power conductor to horizontal bus connections.
These factory-made horizontal to vertical bus connections do not
require servicing for the life of the MCC.
6. Check and verify that all ground connections are made properly, based on
local standards.
If ground bus is not provided or has been removed, check that the MCC
sections are connected to provide a continuous ground path. Verify that
100 ms units are connected to the vertical equipment load ground bus.
7. Check the field wiring.
a. Check the field wiring for proper conductor sizing.
MCC field conductors should be sized by using the National Electrical
Code (NEC) 75 °C (167 °F) wire tables.
b. Removal of barrier or barriers may have been required for field wiring.
Check that all barriers and parts that may have been removed during
installation have been reinstalled.
TIP We recommend that a barrier checklist is developed including
such items as, unit location, and barrier location. This checklist
should be saved for future reference.

c. Check that all incoming and outgoing power wiring is secure and
braced to withstand the effects of a fault current as detailed in
Chapter 3.
d. Check that conduit and cabling are well supported.
For incoming line compartments, 2.0 space factors, 26 in. (660.4 mm)
or less, the incoming cables should be firmly secured halfway between
the top of the section and the incoming line compartment terminals. In
a full section (6.0 space factor) incoming line compartments the cables
should be braced every 12 in. (305 mm); if the system’s available short
circuit current is above 42,000 A but less than 65,000 A rms
symmetrical. Above 65,000 A rms symmetrical available current bracing
should occur every 6.5 in. (165 mm). This bracing is in accordance with
the Underwriters Laboratories (UL) listing and is necessary to
withstand forces resulting from high fault currents. For information on
cable bracing methods, see Chapter 3 of this publication.
e. Check the integrity of all field connections.
Recommended torque values not found on individual devices can be
found on the unit wiring diagrams.
f. Check field wired connections made to the MCC for agreement with
wiring diagrams and verify that proper spacings between adjacent
phases and/or phases to ground are being used. Refer to page 82 for the
minimum electrical spacing requirements.

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8. Check that the voltage and horsepower ratings on the motor correspond
with the MCC unit ratings.
9. Check that the overload relays or heater elements are selected, installed
and/or adjusted to relative full load current shown on the motor rating
nameplate.
10. For applications requiring power fuses, install the fuses in the fusible
switches in accordance with the NEC application requirements.
Refer to CENTERLINE Motor Control Centers Power Fuses Product
Data, publication 2100-TD003 for fuse information. Do not apply grease
or NO-OX-ID to fuse ferrules. All fuses must be completely inserted in
the fuse clips. Recommended torque values for fuse clamp screws can be
found on the unit wiring diagram. Verify that all fuses fit each application.
11. For circuit breaker applications, verify that the circuit breakers are in
accordance with NEC application requirements, and have correct
ampacity and trip settings.
Refer to MCC Instantaneous Trip Motor Circuit Protectors (MCP) in
Combination NEMA Starter, Soft Starter (SMC), and Variable Frequency
AC Drive Units Technical Data, publication 2100-TD001, and MCC
Inverse Time Circuit Breakers in Combination NEMA Starter, Soft
Starter (SMC), and Variable Frequency AC Drive Units Technical Data,
2100-TD002 for circuit breaker information in MCC units.

IMPORTANT High efficiency motors may have higher locked rotor and
inrush currents, therefore, higher magnetic trip settings than
those required equivalent standard motors may be required.

12. Refer to the device instruction sheets or manuals supplied with the MCC
for specific start-up guidance. Component devices in MCC units such as
transfer switches, PFCCs, transducers, motor protectors, line monitors,
over and under-voltage relays, and motor windings heaters may require
unique start-up procedures. Set and verify adjustable current, voltage, and
other settings, according to device instructions or wiring diagrams.

Allen-Bradley AC drives and soft starter units are shipped with preset
factory settings such as ramp speed, current limits, switch positions, and
readouts. Preset factory settings may not be suitable for many applications.
Refer to instruction manuals, supplied with the MCC for specific startup
guidance.

ATTENTION: Verify that the parameters of configurable devices,

such as drives, soft starters, and overload relays, are suitable for
the specific application and change them as needed for the
specific application.

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13. Manually exercise all switches, control auxiliary switches, circuit breakers,
their respective operators, unit interlocks, trip mechanisms (test by
pushing the ‘Push to Trip’ button), and any other operating mechanisms to
verify proper operation.
14. Check timing relay settings as required.
15. Check the vents and fans.
a. Check all vents to ensure they are free from obstructions.
b. Check all fans, used for forced air cooling to ensure the shaft rotates
without obstructions.
c. Check that filters are in place and clean, and set up an in-house program
for scheduled cleaning or replacement.
If you have an MCC with arc-resistant design features, if a unit has been
provided with arc resistant baffles over door vents and fans, these baffles
must be fastened securely in place in order to maintain the arc resistant
capabilities of the MCC. Do not install any type of filter in place of, or
in addition to, the arc resistant baffles.

ATTENTION: Current transformer secondaries should not be

‘open’. To avoid possible injury and electrical shock to personnel,
do not energize a current transformer with its secondary open.

16. Check all current transformers for proper polarity and ensure their
secondaries are not ‘open’, but are either connected to their respective
devices or ‘shorted.’
17. Recheck that all barriers and parts that may have been removed during
installation have been reinstalled. Refer to your barrier checklist, see
step 7.
18. Before closing the enclosure and/or individual units, remove all tools,
metal chips, scrap wire and other debris from the MCC interior.
If there is an accumulation of dust or dirt, clean out the MCC using a
brush, vacuum cleaner or clean, lint-free rag. Do not use compressed
air - it will redistribute contaminates on other surfaces.

ATTENTION: When conducting an electrical insulation resistance

test, isolate equipment sensitive to high test voltages, such as
meters, solid state devices, motor winding heaters, and capacitor
units.

19. Conduct an electrical insulation resistance test to verify the MCC wiring
integrity.
Conduct this test using an insulation resistance tester (megger) with a
potential of 500...1000V. This megger test should be conducted phase-to-
phase, phase-to-ground, and when applicable, phase-to-neutral on the
MCC buswork. The test should be conducted with all of the switches or
circuit breakers in the open or OFF/O positions. Typical insulation
resistance values are 50 MΩ or greater.

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Next, check the field wiring; for example, motor cables and incoming line
cables. Insulation resistance values are affected by temperature, humidity,
or dampness, which may cause a considerably lower insulation resistance
reading. If the insulation resistance values are below 1 MΩ (for example,
affected by dampness, temperature, or humidity) or the MCC has been
stored in a damp or humid area, we recommend that the equipment be
dried out. Dry out the motor cables by injecting a low voltage current or by
using space heaters.
Once the equipment is dry, repeat the insulation resistance test. The
minimum value for insulation resistance on a new installation at startup or
energizing is 1 MΩ. These readings may be recorded in the Megger
Reading Recording Table. This table allows for additional megger readings
to be recorded during regular maintenance periods.
20. Check that all arc-resistant parts are installed.
See ArcShield Components for more information.
21. Check that all unit latches are secure.
See Door Latch Position Diagrams for more information.
22. Close and latch all doors, making certain that no wires are pinched.
23. Check that all section closing plates are in place.

Certain applications may have latch requirements different from those provided.
If you have questions regarding proper latching, contact Rockwell Automation
LV MCC Technical Support at 1.440.646.5800 and follow the prompts to Allen-
Bradley>Low Voltage Motor Control Centers>Post Shipment Support.

Refer to the following illustrations for various latch placements.

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Door Latch Position Diagrams

Figure 41 - Vertical Wireway Door

Standard Latches Arc Resistant Latches

Figure 42 - 0.5 Space Factor and Units with Horizontal Disconnect Handles

0.5 Space Factor

1 Space Factor or Larger

Standard Latches Arc Resistant Latches

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Figure 43 - 1.0 Space Factor and Units with Vertical Disconnect Handles

1 Space Factor to 2.5

Space Factor

An arc resistant latch is

used for the center latch
only for main incoming
power units and 100 ms
2.5 Space Factor or arc-resistant rating.
Larger

Standard Latches Arc Resistant Latches

For most units, the center latch is a standard quarter-turn latch. For
some units a multi-turn latch is used.
Torque the latch to 20 lb•in +/- 2 lb•in.

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Figure 44 - 6 Space Factor (full section) Units

An arc resistant latch is

used for the second and
fourth positions. Other
latches are standard
quarter turn.
All center latches are
arc-resistant latches for
units with 100 ms arc-
resistant rating.

Standard Latches Arc Resistant Latches

When properly latched, the slots on all arc resistant latches are vertical and the
latch springs are compressed. The spacing of the spring coils are decreased.

Figure 45 - Spring Compression

Uncompressed Spring Compressed Spring

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ArcShield Components
Checklist ATTENTION: Arc resistant CENTERLINE 2100 MCCs are provided with
certain components to achieve the arc-resistant rating. These components
must be in place prior to using the MCC in order to maintain the arc
resistant capabilities.

TIP Not all of the components and features necessary for the arc-resistant
rating are shown in these images.

Figure 46 - Arc-resistant MCC with Insulating Sheet (15 in. deep, right side visible)

Insulation Sheet

End Closing Plate

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Figure 47 - ArcShield Components

Pressure Relief Vent Vertical Support Angle
(100 ms ArcShield rating only) (end of lineup)

WARNING
HOT GASES MAY BE EXHAUSTED IF AN INTERNAL
ARCING FAULT OCCURS.
41006-404-01 (1)

ArcShield Rating Label

ArcShield Door Latches Device Limited
100 ms Rating Rating
ARC RESISTANT EQUIPMENT ARC RESISTANT EQUIPMENT
PER IEEE C37.20.7 2007
PER IEEE C37.20.7-2007

ACCESSIBILITY: TYPE 2 ACCESSIBILITY: TYPE 2

ARC SHORT CIRCUIT CURRENT: ≤ 65 kA
ARC SHORT CIRCUIT CURRENT: ≤ 65 kA ARC DURATION: DEVICE LIMITED
PROTECTIVE DEVICE:
ARC DURATION: ≤ 100 ms
UL LISTED FUSES
OPERATIONAL VOLTAGE: ≤ 480 V CLASS L – FERRAZ-SHAWMUT A4BQ ≤ 1200 A
CLASS R – ANY FUSE ≤ 600 A
CLASS J – ANY FUSE ≤ 600 A

WARNING UL LISTED MOLDED CASE CIRCUIT BREAKERS

ALLEN-BRADLEY – BULLETIN 140U, FRAME I, JD, or K
CUTLER-HAMMER – SERIES C, FRAME F, J, K, L, M, or N

ARC FLASH HAZARD

DOORS AND COVERS MUST BE PROPERLY WARNING
CLOSED, LATCHED, AND SECURED.
ARC FLASH HAZARD
EQUIPMENT MUST BE INSTALLED PER THE ARC CONTAINMENT CAPABILITY OF THE MOTOR
MANUFACTURER’S INSTRUCTIONS. REFER TO CONTROL CENTER IS DEPENDENT UPON THE MAIN
PUBLICATION 2100-IN012. PROTECTIVE DEVICE. PROTECT ONLY WITH UL LISTED
PROTECTIVE DEVICE SPECIFIED ABOVE.
ONLY INSTALL ArcShield 100ms / 480V / 65kA
RATED UNITS IN THIS STRUCTURE. DOORS AND COVERS MUST BE PROPERLY CLOSED,

Support Pan Screws

LATCHED, AND SECURED. EQUIPMENT MUST BE INSTALLED
EQUIPMENT WILL NOT FUNCTION AS PER MANUFACTURER’S INSTRUCTIONS.
REFER TO PUBLICATION 2100-IN012.
ARC RESISTANT IF ABOVE GUIDLINES
ARE NOT FOLLOWED. EQUIPMENT WILL NOT FUNCTION AS ARC RESISTANT IF
ABOVE GUIDELINES ARE NOT FOLLOWED.
FAILURE TO FOLLOW THESE GUIDELINES COULD
RESULT IN SEVERE INJURY OR DEATH. FAILURE TO FOLLOW THESE GUIDELINES COULD RESULT IN
SEVERE INJURY OR DEATH.
41006-402-01 (1) 41006-401-01 (1)

Vertical Wireway Baffle

Top and Bottom Horizontal

Wireway U-nuts

Back Corner Baffles

(end of lineup only)

Frame-mount Support
Support Brackets

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Chapter 7 Final Checklist Before Energizing

Required Minimum .
Electrical Spacing Table 7 - General Spacing Requirements for MCCs (1) (2) (3)
Min Spacing, in. (mm)
Between Live Parts of Opposite Polarity Between Live Parts and
Grounded Metal Parts,
Through Air and Over
Voltage Through Air Over Surface Surface
125 or less 1/2 in. (12.7 mm) 3/4 in. (19.1 mm) 1/2 in. (12.7 mm)
126...250 3/4 in. (19.1 mm) 1.25 in. (31.8 mm) 1/2 in. (12.7 mm)
251...600 1 in. (25.4 mm) 2 in. (50.8 mm) 1 in. (25.4 mm)(4)
(1) Reference Underwriters Laboratories, Inc. Standards for Motor Control Centers, UL 845, Tables 16.1 and 16.3.

(2) Spacings at all horizontal and vertical buses, at incoming terminals, at the plug-in portion of all units and at
feeder units consisting of fusible disconnect switches or circuit breakers only, having other than horsepower
ratings, shall be as specified above. (See 17.2.2 from UL 345.)

(3) An isolated dead metal part, such as a screw head or a washer, interposed between uninsulated live parts of
opposite polarity or between an uninsulated live part and grounded dead metal is considered to reduce the
spacing by an amount equal to the dimension of the interposed part along the path of measurement.

(4) A through-air spacing of not less than 1/2 in. (12.7 mm) is acceptable at a circuit breaker or fusible
disconnecting means and between grounded dead metal and the neutral of a 277/480V, three-phase, four-wire
MCC.

Table 8 - Spacing Requirements within MCC Units (1) (2) (3)

Min Spacing, in. (mm)
Between Uninsulated Live Parts of
Opposite Polarity and Between an Between Uninsulated Live
Uninsulated Live Part and an Exposed or Parts and the Walls of a Metal
Uninsulated Dead Metal Part other than Enclosure(3), Including Fittings
the Enclosure for Conduit or Armored Cable
Voltage Through Air Over Surface Shortest Distance
125 or less 1/8 in. (3.2 mm) (2) 1/4 in. (6.4 mm) 1/2 in. (12.7 mm)
126...250 1/4 in. (6.4 mm) 3.8 in. (9.5 mm) 1/2 in. (12.7 mm)
251...600 3.8 in. (9.5 mm) 1/2 in. (12.7 mm) 1/2 in. (12.7 mm)
(1) Reference Underwriters Laboratories, Inc. Standards for Motor Control Centers, UL 845, Tables 16.1 and 16.3.

(2) The spacing between wiring terminals of opposite polarity shall not be less than 1/4 in. (6.4 mm) if the terminals
are in the same plane.
(3) The enclosure refers to the section enclosure.

A metal piece attached to the enclosure is considered a part of the enclosure

for the purpose of this note if deformation of the enclosure is likely to
reduce the spacing between the metal piece and a live part.

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Final Checklist Before Energizing Chapter 7

Figure 48 - Sample MCC Layout Worksheet

Horizontal Wireway
1.0 S.F. 1A 2A
A
113 in.
(330 mm) B

E 1E Full
Width

Vertical Wireway
F Section
G 1G

M
Horizontal Wireway

Table 9 - Location of Sample Units within above MCC Layout

Unit Data

Circuit Breaker Trip Setting

Size or Amp Rating

Power Fuse Rating

Full Load Current

Heater Elements
Unit Location

Horsepower
Description

Overload or

Kilowatts

Cat. No. Wiring Diagram

1A 2113B-EDB-48CA CSXXXXXXXX 4 FVNR 77 60 W73 — C —
1E 2112A-BDBD-24J-38-7FEC1A Y-XXXXXX 1 FVNR 4.8 3 7FECIA — — 10
1G 2100-NJ30 N/A — Blank — — — — — —
2A 2113B-2PAB-56WT Y-XXXXXX 450A FVNR(V) 364 250 W43 — 6 —

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Chapter 7 Final Checklist Before Energizing

Table 10 - Unit Description

Unit Type Code Code Description

CN2DN ControlNet to DeviceNet
DNC DeviceNet Connector
DNPS DeviceNet Power Supply
EN2DN Ethernet to DeviceNet
FCBX Insert with Circuit Breaker
FDSX Insert with Fusible Disconnect
FVLC Full Voltage Lighting Contactor
FVR Full Voltage Reversing
FVNR (V) Full Voltage Non-Reversing (Vacuum)
INSRT Unit Insert
LPAN Lighting Panel
(M)BPS MAIN Bolted Pressure Switch
(M)CB MAIN Circuit Breaker
(M)FDS MAIN Fusible Disconnect Switch
(M)LUG MAIN Line Lugs
METER Metering Unit
NCP Neutral Connection Plate
NLD ControlNet to DeviceNet
PLC Programmable Logic Controller
RVAT Reduced Voltage Autotransformer
SMC Solid State Motor Controller
SPD Surge Protection Device
TERM Terminal Unit
TS1W (R) Two-Speed One Winding (Reversing)
TS2W (R) Two-Speed Two Winding (Reversing)
VFD (VT) Variable Frequency Drive (Variable Torque)
VFD (CT) Variable Frequency Drive (Constant Torque)
VFDR Variable Frequency Drive Supplemental Unit
XFMR Transformer

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Final Checklist Before Energizing Chapter 7

Table 11 - MCC Layout Worksheet

MCC Name / Number ___________________________________________________________

Unit Data

Overload or Heater Elements

Circuit Breaker Trip Setting

Size or Ampere Rating

Power Fuse Rating

Full Load Current
Unit Location

Horsepower
Description

Kilowatts
Cat. No. Wiring Diagram

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Chapter 7 Final Checklist Before Energizing

Table 12 - Megger Reading Recording Table

MCC Name / Number ___________________________________________________________

Phase-to-Phase Phase-to-Ground Phase-to-Neutral

Circuit / Unit
Date Name / Number A-B B-C C-A A - Grd. B - Grd. C - Grd. A - Neut. B - Neut. C - Neut.

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Chapter 8

Energizing the Equipment

ATTENTION: This procedure is provided as general guidance for

energizing a newly installed CENTERLINE MCC and should be used after
the Final Check procedure has been completed. See Final Checklist Before
Energizing for more information.

ATTENTION: Energizing a MCC for the first time is potentially dangerous.

Serious damage and or personal injury can result when power is applied.
Therefore, only qualified personnel should energize the equipment.

ATTENTION: When working on or near energized electrical equipment,

follow established electrical safety-related work practices. Refer to NFPA
70E Standard for Electrical Safety in the Workplace.

Energize the Equipment 1. Review any additional instructions supplied for the proper operation of
special units such as variable frequency drives and soft starters with
appropriate and qualified personnel.
2. Check that there is no load on the MCC when it is energized.
3. De-energize all main and unit disconnect devices.
4. Check to see if any associated remote devices are de-energized.
5. Energize the MCC remote power source.

ATTENTION: The disconnect-device handles should be operated

with a firm, direct motion. Handles should not be ‘teased’ into the
closed (ON/I) position.

6. Energize the main devices followed by the feeder devices and the branch
circuit devices.
Always energize from the source of the system, working towards the loads.
7. After all of the disconnects have been closed, loads such as lighting circuits,
motor starters, and contactors may be energized.

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Chapter 8 Energizing the Equipment

a. When power-factor correction capacitors are energized with the motor

windings and the start-up procedure requires that the respective motors
be jogged or inched, temporarily disconnect the power factor
correction capacitors.
For more information on power factor capacitors and MCC units, refer
to the Power Factor Correction Capacitors for Bulletin 2100 Motor
Control Center Starter Units Application Techniques, publication
2100-AT001.
b. Verify that any acceleration times are within application specifications.

Excessive starting currents and acceleration times may cause inverse time circuit
breakers, power fuses, overload relays, and other components to overheat and shut
down the equipment.

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Chapter 9

Maintenance

Establish a periodic maintenance program for MCCs to avoid unnecessary

downtime. The frequency of service to the MCC will depend upon the
equipment usage and the environment in which it operates. The following is a
suggested checklist and can be used to establish a maintenance program.

ATTENTION: De-energize the MCC before servicing.

Maintain the MCC 1. Inspect the MCCs once per year or per established maintenance program.
2. Carefully inspect doors and enclosure sides for evidence of excessive heat.
3. Check for moisture or any signs of dampness or drippings inside the
MCC.

IMPORTANT Condensation in conduit or dripping from an outside source is a

common cause of MCC failure. Eliminate any source of moisture.

a. Seal off conduit, cracks, and openings that have allowed and/or could
allow moisture to enter the MCC enclosure.
b. Dry or replace and clean insulating material that is damp or wet or
shows signs of moisture.
c. Check devices such as contactors, circuit breakers, disconnect switches,
relays, and push buttons for wetness or signs of moisture, corrosion, or
contamination.
d. Replace damaged or malfunctioning parts.
4. Check the integrity of bus splice connections.
Bus splices can be easily identified by the label on the interior of the vertical
wireway door or on the interior right-hand side plate of frame mounted
units. Recommended torque values can be found on the information label
on the interior of the vertical wireway door or on the interior right-hand
side plate of frame mounted units.
The factory-made power bus connections are tightened by a computer-
controlled torquing system. The following connections do not require re-
torquing, vertical to horizontal bus connections and power conductor to
horizontal bus connections. These factory-made connections do not
require servicing for the life of the MCC.

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Chapter 9 Maintenance

5. Periodically clean or replace the air filters depending on the environmental

conditions.
6. Check for the proper function and freedom of movement (no sticking or
binding) for the disconnect handle operating and defeater mechanisms.
7. Replace broken, deformed, malfunctioning, or badly worn parts or
assemblies.
8. Inspect unit bus-stab connections for wear or corrosion.
Wear and/or corrosion can increase resistance and cause an increased
temperature of the contact point, leading to failure. Replace bus stabs if
wear or corrosion is excessive. Lubricate bus stabs with NO-OX-ID grease
(catalog number 2100H-N18 or 2100H-N18T) before installing the unit
into the section.

ATTENTION:
When working on or near energized electrical equipment, follow
established electrical safety-related work practices. Refer to NFPA
70E Standard for Electrical Safety in the Workplace.
To prevent injury or death to personnel lubricating disconnect switch
contacts, make sure the MCC power source(s) is disconnected and
the respective disconnect(s) is locked in the OFF/O position. For plug-
in units, remove the unit from the MCC.
To prevent personal injury or damage to equipment, make sure that
the unit handle operator is in the OFF/O position before removing the
unit.

9. Inspect current carrying parts such as fuse clips, knife blades of

disconnects, and line and load terminals of devices for discoloration,
corrosion, or other signs of wear or possible failure.
10. Check locking or interlocking devices for proper working condition.
11. Adjust, repair, or replace any device if necessary.
12. Check power contacts for excessive wear and dirt accumulation and
vacuum or wipe contacts with a soft cloth to remove dirt as needed.
Contacts are not harmed by discoloration and slight pitting. Contacts
should never be filed, as this could reduce the life of the contacts. Contact
spray cleaners should not be used, as they cause sticking on magnetic pole
faces or in operating mechanisms, interfering with the electrical continuity
of the contacts. Contacts should be replaced only after the silver has
become badly worn. Always replace contacts in complete sets to avoid
misalignment and uneven contact pressure.
13. Check for loose wire connections on power and control circuit terminals.
Loose connections can cause overheating, hot spots, or arcing faults that
could lead to equipment malfunction or failure. Replace any damaged
parts or wiring.

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Maintenance Chapter 9

14. Check contactor and relay coils for evidence of overheating, such as
cracking, melting, or burning of insulation.
If there is evidence of overheating, the coil must be replaced. When
replacing a coil, check and correct the overvoltage or undervoltage
conditions that may have caused the coil failure. Be sure to clean any
residue of melted coil insulation from other parts of the device and replace
as necessary.
15. Check all pilot lights and replace lamps and damaged lenses as necessary.
16. Check all fuses.
If replacing fuses, install the same type and rated fuse that was originally
furnished with the MCC.
17. Remove accumulated dust and dirt from structure and individual units by
vacuuming.
Do not use compressed air, as it may contain moisture and blow debris
within the enclosure.
18. Refer to individual user policies, NFPA 70B, Recommended Practice for
Electrical Equipment Maintenance for MCC Servicing Guidelines.

Disconnect the Switch and

Contact Lubrication ATTENTION:
Follow NFPA 70E safety guidelines when working on energized equipment.
To prevent injury or death to personnel lubricating disconnect switch
contacts, make sure the MCC power source(s) is disconnected and the
respective disconnect(s) is locked in the OFF/O position. For plug-in units,
remove the unit from the MCC.
To prevent personal injury or damage to equipment, make sure that the unit
handle operator is in the OFF/O position before removing the unit.

If a switch that is used frequently becomes difficult to operate or is in a highly

corrosive or caustic environment, it may require lubrication. The lubricant to be
used is NO-OX-ID Compound (catalog number 2100H-N18 for a 1 pt can or
catalog number 2100H-N18T for a 1 oz tube). To obtain the lubricant, contact
your local Rockwell Automation Sales Office, distributor or Rockwell
Automation.

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Chapter 9 Maintenance

1. Determine your unit type.

Plug-in Units
If a disconnect switch requires lubrication and is housed in a plug-in unit,
remove the plug-in unit from the MCC (For removal of unit, refer to 4,
Installing and Removing Plug-in Units, before lubricating the switch).
Frame Mounted Units
If a disconnect switch requires lubrication and is housed in a frame
mounted unit, turn off the power sources to the MCC so the switch can be
lubricated.

ATTENTION: To prevent injury or death to personnel lubricating

disconnect switch contacts, make sure that the MCC remote
power sources are disconnected and the respective disconnects
are locked in the OFF/O position.

Save all parts for reinstallation.

2. Remove the line guard from the disconnect.
3. For access to the disconnect's stationary contacts, remove the arc hood.
4. Generously apply the NO-OX-ID compound (sufficient enough to cover
with a noticeable film) to both sides of the movable contact blades and to
the adjacent insides stationary contacts and the hinge.
5. Reinstall the arc hood that was removed in step 3.
6. Reinstall the line guard cover that was removed in step 2.
7. If the lubricated disconnect switch is housed in a plug-in unit, reinstall the
unit.
For installation of unit, refer to Installing Units with Vertical Operating
Handles, publication 2100-IN014.

If the unit requires lubrication because of corrosion (for example, a sulfuric

environment), replacing the unit disconnect may be required to avoid overheating
conditions. Lubrication may temporarily resolve overheating, however replacing
the disconnect switch would be the ideal, long-term solution.

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Maintenance Chapter 9

Use Thermal Infrared or

Other Temperature ATTENTION:
Measurement Techniques Temperature measuring techniques are often performed with the units fully
for Preventive Maintenance energized and the doors and covers open.
Use extreme caution when performing these measurements so that
energized parts are not shorted.
If care is not taken, electrical shock, severe injury or death will result.
When working on or near energized electrical equipment, follow established
electrical safety-related work practices. Refer to NFPA 70E Standard for
Electrical Safety in the Workplace.

Use the following procedure when using thermal infrared or other temperature
measurement techniques as part of a periodic preventative maintenance program
on CENTERLINE 2100 Low Voltage MCCs.

1. Use test equipment to determine the temperature differential and the

temperature rise of accessible components within the unit.
2. Determine the services and repair recommendations based on the
temperature category in the following guidance chart.

Table 13 - Temperature Guidance

Category Temperature Temperature Repair/Service
Differential(1) Rise (2)
°C °F °C °F Service Interval Recommended Action
1 < 10° < 18° < 70° < 126° No service or repair required. See step 1 below.
2 10°...25° 18°...45° 70°...100° 126°...180° Service or repair the unit at next maintenance schedule (not See step 2 below.
greater than six months but continue monitoring as a part of
preventive maintenance.)
3 25°...50° 45°...90° 100°...115° 180°...207° Service or repair the unit within the next two weeks and
monitor the unit at the next maintenance interval.
4 > 50° > 90° > 115° > 207° Shutdown the unit and repair. Verify that the temperature is
reduced after re-energization.
(1) Temperature (measured or rise) differential between adjacent phases or like elements. Load between phases must be balanced with a normal variation not exceeding
seven percent.

(2) Measured temperature less ambient.

Due to difficulty obtaining accurate infrared temperature measurements from highly reflective surfaces, we recommend using temperature differential readings in
determining the Service/Repair guidelines, for example, emissivity of tin or silver plated material.

Inspect the Units for Signs of Overheating

1. If there are no signs of overheating and thermal infrared tests indicate

service is not necessary, document the units as acceptable.
Use this information for reviewing the mean time to maintenance for
preventative maintenance for the specific facility.

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Chapter 9 Maintenance

ATTENTION:
To service the units, make sure that the MCC remote power sources
are disconnected and that the respective disconnects are locked in
the OFF/O position.
If servicing a plug-in unit, remove it from the MCC to facilitate
servicing. Refer to Chapter 2 of this publication for unit removal
guidelines.
When plugging units back in, refer to CENTERLINE 2100 Motor
Control Centers (MCC) Units with Vertical Operating Handles
Installation Instructions, publication 2100-IN014, and CENTERLINE
2100 Motor Control Center (MCC) Units with Horizontal Operating
Handles Installation Instructions, publication 2100-IN060.

2. If there are no signs of overheating, but thermal infrared tests indicate

service is required, check the power connections for proper torque.
a. On disconnect switches, service the knife blades with a Scotch-Brite
cleansing pad.
b. Remove all hardened grease.
Care should be taken not to distort the disconnect jaw (stationary
contact).
c. Lubricate with a fine film of NO-OX-ID (catalog number 2100H-N18
for a 0.47 L (1 pt) can, or catalog number 2100H-N18T for a 29.5 ml
(1 oz) tube).
Should the disconnect be subject to environmental conditions causing
chronic tarnishing, it may be necessary to determine if there is an
incompatibility in the plating material, for example, hydrogen sulfide
and silver plating.
On fuses and fuse clips, service by polishing with a Scotch-Brite
cleansing pad. Do not lubricate the fuses or the fuse clips.
3. If overheating has occurred as indicated by severe tarnishing, infrared test
results, crystallization of insulation on conductors, discoloration of the
components, darkening of the molding materials, brittle conductor
insulation, or deformation and melting of parts, replace the components
that are suspect.

For more information contact, Rockwell Automation LV MCC Technical

Support at 1.440.646.5800 and follow the prompts to Allen-Bradley>Low
Voltage Motor Control Centers>Post Shipment Support.

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Chapter 10

Maintenance After Fault Condition

Maintain the MCC After a

Fault Condition ATTENTION: Make sure that the MCC remote power sources are
disconnected and that the respective disconnects are locked in the OFF/O
position.

The opening of the short circuit protective device (such as fuses or circuit
breakers) in a properly coordinated motor branch circuit is an indication of a
fault condition in excess of operating overload and must be corrected.

Fault conditions can cause damage to control equipment. When a fault occurs,
follow this procedure.

1. De-energize the MCC.

2. Investigate the cause of the fault and inspect all equipment thoroughly per
NEMA Standards publication ICS 2.3-1995, Instructions for the handling
installation operator and maintenance of MCCs not rated more than
600V, Section 11, Maintenance after a Fault has Occurred.
3. Make necessary repairs to units, components and structures as required,
prior to reenergizing the equipment.

Be sure that replacement parts are suitably rated for the application.

An insulation resistance test (megger) may be required. Refer to Chapter 7.

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Chapter 11 Renewal Parts

Notes:

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Chapter 12

Parts Illustrations

Typical Section
Construction
Lifting Angle
Top Horizontal
Wireway Baffle
Removable Top Plate

Top Horizontal
Wireway Cover
Left Hand
Top End Closing Plate
Right Hand Unit Support
Vertical Wireway Assembly

Horizontal and Vertical

Bus Support Bus Splice Access Cover

Vertical Power Bus

Section Nameplate

Horizontal Power Bus

Vertical Wireway Door

Left Hand Vertical to Horizontal Bus

Center End Plate Connection Access Cover

Vertical Plug-in Vertical Bus Support Cover

Ground Bus

Unit Support Pan

Sealing Strap
Left Hand Side Plate Assembly
Top and Bottom
Bottom Support Angle
Horizontal Ground Bus
Top or Bottom Bottom Horizontal
Wireway Cover
Left Hand
Bottom End Closing Plate

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Chapter 12 Parts Illustrations

Typical Construction of a Unit with a Vertical Operating Handle

Captive Latch
Starter or Contactor Diagram Pocket

Unit Stab Assembly

Control Circuit Unit Handle Interlock

Fuses and
Circuit Breaker or Fusible
Fuse Block
Disconnect (shown)

Auxiliary
Contacts
Overload Disconnect Handle
Control Circuit
Transformer (not shown)
Control Transformer Defeater Mechanism
Fusing and Fuse Block
Power and Control
Terminal Blocks Short Circuit Rating Label

Unit Identification Nameplate Captive Latch

UL Label

Control Station
Unit Nameplate

Handle Cutout

Unit Door

Reset Button

Pilot Devices

Plastic Retaining Pin

Unit Support Pan

Bulletin 2112, Size 1, FVNR
with Transformer Shown

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Parts Illustrations Chapter 12

Typical Construction of a Half Space Factor Unit with a Horizontal Operating Handle
and Door Mounted Pilot Devices
Control Circuit Transformer Unit Stab Assembly
Contactor or Starter
Overload Relay

Circuit Breaker (shown) Control Circuit Fuse

or Fusible Disconnect block and Fuses

Handle Mechanism
Unit Latch/Interlock
Control Terminal Block
Starter

Unit Nameplate

Unit Door

Pilot Devices

Unit Support Pan

Unit Support Pan Bushing Plastic Retaining Pin

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Chapter 12 Parts Illustrations

Typical Construction of a Unit with a Horizontal Operating Handle

Control Circuit Transformer Unit Stab Assembly Contactor or Starter
Overload Relay

Circuit Breaker (shown)

or Fusible Disconnect
Control Circuit Fuse
block and Fuses

Control Terminal Block

Handle Mechanism
Unit Latch/Interlock

Pilot Devices Auxiliary Contacts

Unit Nameplate

Unit Door

Unit Support Pan

Unit Support Pan Bushing Plastic Retaining Pin

Bulletin 2413, IEC Style Shown

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Index

A conduit 41
adding sections 12 bottom entry 41
top entry 41
additional resources 7 contactor and relay coil check 91
air filter check 90 cUL designation 12
air filters 75
altitude class 21
arc flash 61 D
protection marking requirement 59 defeater lever 62
Rockwell Automation services 60 defeating unit door interlock 61
ArcShield 9, 14
dimensions 9, 20, 23, 24
components checklist 80
door hinge removal 49, 54 disconnect handle check 90
door latch positions 77 door latch positions 77
IEEE 10 door removal 49, 53
insulating sheet 80 dust and dirt 91
joining and splicing 38
opening door 48, 53
pressure relief plate 24 E
rating 52, 56
rating label 14 electrical insulation resistance test 75
section clearance 24 electrical spacing 82
support pan removal 57, 58 end closing plate 12
top entry conduit 41 energize the MCC 71, 87
unit removal 52
energize unit
door open 63
B
bottom entry conduit 41 F
bus splice check 89 flash protection 59
bus torque specifications 40
fuse check 91
bus-stab check 90

G
C
general description 9
cable
general spacing requirements 82
installing 42
lugs 42 grounding 73
rating 42
cable bracing 43
glass tape 44
H
hardwood 45 handle height 23
nylon rope 44 handling 20
check height considerations 23
air filters 75, 90 horizontal bus 9
bus splice 89
bus stabs 90 splicing 37
horizontal handle 47
cabling 73
circuit breakers 74 door interlock defeater screw 61
conduit 73 swing-out door latches 56
contactor and relay coils 91 horizontal handle removal 53
disconnect handle 90
fuses 91
interlocking devices 90 I
locking devices 90 incoming line brace 45
moisture 89
inspection timeline 89
pilot lights 91
power contacts 90 installation 12
wiring 73 cable 42
check list 71 conduit 41
circuit breaker 74 horizontal handle 47

Rockwell Automation Publication 2100-IN012D-EN-P - September 2010 103

 SPECIAL INSTRUCTION MANUAL
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Index

lugs 42 section installation 12

plug-in units 47 securing 24
vertical handle 47 seismic requirements 36
interlocking devices check 90 storage 21
weights 20
MCC receiving, handling, and storage 19
J measuring temperature 93
joining and splicing 37 moisture check 89
bus torque 40 mounting dimensions 23
joining and splicing NEMA Type 12 motor 10 in. wide 29
control centers 38 15 in. and 20 in. 25
joining and splicing NEMA Type 3R and Type 15 in. and 20 in. corner sections 32
15 in. and 20 in. deep 40 in. wide 33
4 units 38 25 in. 28
30 in. and 40 in. 27
9 in. wireway 28
L NEMA 3R 30
labels NEMA 4 30
ArcShield 14 mounting dimesions
short circuit rating 13 71 in. sections 35
UL 13
layout worksheet 83
lifting angle 24 N
lifting sections 20 nameplate 10
line compartment 43 NFPA 70E 59, 61, 87, 90
location planning 23
locking
horizontal handle 67
O
horizontal operating handle 65 operating handle
large vertical handle 67 locking the horizontal operating handle in the
medium vertical handle 66 OFF/O position 65
padlock 68 locking the units with the operating handle in
small vertical handle 66 the ON/I position 65
units 67 locking the veritical operating handle in the
vertical operating handle 64 OFF/O position 64
locking device check 90 opening the door when the handle is in the
ON/I position 61
operation 21
M order information 97
main disconnect 43
bottom entry connection 43
top entry connection 43 P
maintaining the MCC pilot light check 91
after a fault condition 95 plug-in unit 9
overview 89 plug-in unit removal
MCC horizontal operating handle 53
dimensions 20 vertical operating handle 48
energizing 71, 87 power contacts check 90
joining and splicing exisiting motor control power-factor correction capacitors 72, 88
centers 37
joining and splicing NEMA Type 12 motor pre-energizing check procedure 71
control centers 38 pre-energizing checklist 72
joining and splicing NEMA Type 3R and Type preparing MCC 72
4 units 38 product overview 9
joining and splicing new motor control publications 7
centers 37
maintenance 89 pull boxes 38
mounting 24
mounting dimensions 23
operation 21 Q
product construction 99

104 Rockwell Automation Publication 2100-IN012D-EN-P - September 2010

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Index

temperature
qualified persons 71 guidance 93
measurement 93
test
R electrical insulation resistance 75
rearranging sections 12 top entry conduit 41
receiving 19
removing large units 51, 56 U
UL label 13
S UL/CSA marking 12
sections unit
adding 12 construction 99
installation 12 description 84
lifting 20 door removal 49, 53
numbering 12 horizontal handle removal 53
rearranging 12 interlock 67, 69
seismic requirements 36 interlock lever 62
latches 50
bolt down 36 overheating 93
IEEE 344 36 partially removed and locked 68, 69
weld down 37 removal 51
sequence numbering 11 removed and locked 69, 70
series space factor 9
lettering 17 type 9
number and series ID 14 vertical handle removal 48
shipping weights 20 unit door interlock 61
export 20 unit interlock 69
standard 20 unit removal 55
short circuit rating label 13 using a padlock 68
sections 13
units 13
shutters 52, 56 V
space factor 9
vertical bus 9
spacing requirements within the MCC 82
vertical handle 47
storage 21
vertical handle unit removal 48
support 94
support pan removal 57
ArcShield 57 W
swing-out door latches 56
weights 20
switch lubrication 91
wiring 50, 51, 55, 75
integrity 75
T

Rockwell Automation Publication 2100-IN012D-EN-P - September 2010 105

 SPECIAL INSTRUCTION MANUAL
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Index

106 Rockwell Automation Publication 2100-IN012D-EN-P - September 2010

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products.
At http://www.rockwellautomation.com/support/, you can find technical manuals, a knowledge base of FAQs, technical and
application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the
best use of these tools.

For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer TechConnect
support programs. For more information, contact your local distributor or Rockwell Automation representative,
or visit http://www.rockwellautomation.com/support/.

Installation Assistance

If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual.
You can contact Customer Support for initial help in getting your product up and running.

United States or Canada 1.440.646.3434

Outside United States or Use the Worldwide Locator at http://www.rockwellautomation.com/support/americas/phone_en.html, or contact
Canada your local Rockwell Automation representative.

New Product Satisfaction Return

Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility.
However, if your product is not functioning and needs to be returned, follow these procedures.

United States Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain
one) to your distributor to complete the return process.
Outside United States Please contact your local Rockwell Automation representative for the return procedure.

Documentation Feedback

Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document,
complete this form, publication RA-DU002, available at http://www.rockwellautomation.com/literature/.

Rockwell Otomasyon Ticaret A.Ş., Kar Plaza İş Merkezi E Blok Kat:6 34752 İçerenköy, İstanbul, Tel: +90 (216) 5698400

Publication 2100-IN012D-EN-P - September 2010 108 PN-93799

Supersedes Publication 2100-IN012C-EN-P - April 2009 Copyright © 2010 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

User Manual
Medium Voltage Controller
Bulletin 1512
400A, Two-high Cabinet
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Important User Information This manual documents the operation, installation, set-up, and maintenance
procedures for the Allen-Bradley 1512 medium voltage starter. Refer to
Rockwell Automation for any problems relating to the installation or operation
of the controller that are not covered in this manual.

Knowledge of electrical procedures and terminology is required to use this

manual.

Because of the variety of uses for this equipment and the differences between
solid-state equipment and electromechanical equipment, the user, and those
responsible for applying the equipment, must satisfy themselves of the suitabil-
ity of each application and use of the equipment. In no event will Rockwell
Automation be responsible or liable for indirect or consequential damages
resulting from the improper use or application of this equipment.

The illustrations in this manual are solely intended to illustrate the text in the
manual. Because of the many variables and requirements associated with any
particular installation, Rockwell Automation cannot assume responsibility or
liability for actual use based on illustrative uses and applications.

No patent liability is assumed by Rockwell Automation with respect to use of

information, circuits, or equipment discribed in this text.

Reproduction of the contents of this manual, in whole or in part, without

written permission of Rockwell Automation, is prohibited.

The information in this manual is organized in numbered chapters. Read each

chapter in sequence and perform procedures when you are instructed to do so.
Do not proceed to the next chapter until you have completed all procedures.

Attention statements throughout this manual make you aware of safety consid-
erations:

ATTENTION: Identifies information about practices or

circumstances that can lead to personal injury, death, property
damage, or economic loss.

Attention statements help you to:

• identify a hazard
• avoid the hazard
• recognize the consequences of the hazard

Important: Identifies information that is critical for successful application and

understanding of the product.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Table of Contents

General Information Chapter 1

Starter Identification ............................................................................. 1-1

Prepared Space ..................................................................................... 1-2

Installation Chapter 2

Door Opening Procedure ...................................................................... 2-1

Opening the Low Voltage Doors ................................................ 2-1
Opening the Medium Voltage Doors ......................................... 2-2
Anchoring ............................................................................................. 2-3
Joining Sections .................................................................................... 2-4
Access to the Power Bus ...................................................................... 2-5
Rear Access ................................................................................ 2-5
Side Access ................................................................................. 2-5
Front Access - Top Exiting Load Cables ................................... 2-6
Front Access - Bottom Exiting Load Cables .............................. 2-10
Bus Splicing ......................................................................................... 2-11
Power Bus ................................................................................... 2-11
Insulated Power Bus ................................................................... 2-12
Ground Bus ................................................................................. 2-13
Incoming Line Cable Connections ....................................................... 2-14
Load Cable Connections ...................................................................... 2-15
Top Exiting Load Cables ............................................................ 2-16
Bottom Exiting Load Cables ...................................................... 2-17
Hi-Pot and Megger Test ....................................................................... 2-18
Startup Procedure ................................................................................. 2-18
Contactor Inspection ................................................................... 2-18
Preliminary Checks .................................................................... 2-19
Testing Contactor Operation....................................................... 2-19
Typical Wiring Diagram ....................................................................... 2-20

Maintenance Chapter 3

Tool Requirements ............................................................................... 3-1

Recommended Torque Values ............................................................. 3-1
Door Interlock Circumvention ............................................................. 3-2
Power Lock-out Procedure ................................................................... 3-3
Contactor Maintenance ........................................................................ 3-6
Removing the Contactor....................................................................... 3-6
Contactor Interlock Rod Adjustment ................................................... 3-8
Isolation Switch Mechanism Inspection and Lubrication .................... 3-10
Isolation Switch Mechanism Grounding Adjustment .......................... 3-12
Auxiliary Contacts Inspection and Replacement ................................. 3-13
Auxiliary Contacts Adjustment ............................................................ 3-14
Adjusting the Normally Closed (ISb) Contact ........................... 3-14
Adjusting the Normally Open (ISa) Contact .............................. 3-15
Adjusting the Change-of-state Point .......................................... 3-15
Emergency Circumvention Procedure for Power Cell Entry ............... 3-16
1500-5.5 — March 1999
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Specifications 1-1

Chapter 1

General Information

Starter Identification A nameplate is attached to the right-side flange of the structure (see Figure
1.1). Refer to the nameplate for information such as series number, section
number, EEMAC/NEMA enclosure type, unit ratings, and bus ratings.

Figure 1.1
Nameplate

A nameplate is also found in the low voltage compartment (see Figure 1.2)
with specific unit motor application information.

Figure 1.2
Nameplate

Refer to these nameplates whenever you contact Rockwell Automation for

assistance. Be prepared to provide such information as series number,
structure series, unit series, diagram schematic and catalog number.
1500-5.5 — March 1999
 SPECIAL INSTRUCTION MANUAL
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1-2 Specifications

Prepared Space When ordering a starter kit to complete a prepared space, provide the
following information to ensure the proper components are supplied.

Series Number

Provide the series number from the structure with the prepared space. The
number is stamped on a nameplate on the right-hand flange of the starter
(see Figure 1.1). The series number is also available from the dimension
drawings for the starter.

Motor Data

Provide the following motor data:

• Locked rotor current;
• Full load current;
• Maximum locked rotor time;
• Acceleration time;
• Motor service factor;
• Motor horsepower.

Starter Features

Provide information regarding any special features required for the starter
kit. Indicate if these features are different from the motor control features in
the existing, complete power cell.

1500-5.5 — March 1999

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Installation 2-1

Chapter 2
Installation

Important: For information on the installation site preparation, see Getting

Started, General Handling Procedures for MV Products,
Publication MVB-5.0.

Door Opening Procedure Opening the Low Voltage Doors

Low voltage doors are identified as LV in Figure 2.1.

1) To access the compartments, use a flat-head screwdriver and turn both

of the 1/4-turn fasteners 180 degrees in a counter-clockwise direction.
2) The door is now released and will swing open.
3) Reverse the procedure to secure the doors.

Figure 2.1
Access to Low Voltage Compartments

. .

1/4-turn Fasteners for LV MV

Upper Low VoltageDoor

. .
. .

1/4-turn Fasteners for LV MV

Lower Low VoltageDoor

. .

See Access to the Power Bus, page 2-5, for the procedure to open the
swing-out low voltage panel behind the low voltage door.

ATTENTION: Medium voltage components are located

behind the swing-out low voltage panel. Complete the power
lock-out procedure on page 3-3 before attempting to open the
swing-out low voltage panel. Failure to do so may result in
severe burns, injury or death.

1500-5.5 — March 1999

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

2-2 Installation

Door Opening Procedure Opening the Medium Voltage Doors

(Cont.)

Medium voltage doors are identified as MV in Figure 2.2.

Figure 2.2
Access to Medium Voltage Compartments

. .

LV MV D oor Locking B olts for

U pper M edium Voltage D oor
Isolation S w itch H andle
. .
. .

LV MV D oor Locking B olts for

Low er M edium Voltage D oor

. .

Important: Each medium voltage door has its own isolation switch handle
and interlocking safeguards. Upper and lower power cells are
separated by an isolation barrier.

1) Electrically open the contactor by pressing the STOP button on the

starter or at the remote control location.
2) Move the isolation switch handle to the OFF position.
3) Unscrew the door locking bolts for the medium voltage door. The door
is now released and will swing open.
4) Reverse the procedure to close the door.

Important: When closing the medium voltage door(s), ensure all door
locking bolts are in place and tightened until the door is flush
with the flange. Do not overtighten the bolts. If the door is
not securely fastened, it will not be possible to move the isola-
tion switch handle to the ON position.

ATTENTION: Complete the Power Lock-out procedure on

page 3-3 before beginning any service procedures to the unit.
Failure to do so may result in severe burns, injury or death.

1500-5.5 — March 1999

 SPECIAL INSTRUCTION MANUAL
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Installation 2-3

Anchoring Place the controller in the desired installation location.

Use ½ in. (M12) floor mounting bolts to securely fasten the controller to the
mounting surface. See Figure 2.3 for the location of the mounting holes in
the cabinet.

Important: This unit will withstand seismic zone 1,2,3 and 4 activity
without overturning or lateral movement provided it is securely
mounted according to local code and using the configuration
shown in Figure 2.3. Seismic qualification does not indicate that
the equipment will function properly after a seismic event.

Figure 2.3
Cabinet Floor Plan

All dimensions in inches [mm]

1500-5.5 — March 1999

 SPECIAL INSTRUCTION MANUAL
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2-4 Installation

Joining Sections Note: Joining hardware can be found in a package mounted to the front of
the shipping skid.

1) Position the left side section on a level surface and secure the section in
place with ½ in. (M12) floor mounting bolts (Refer to Anchoring, page 2-3).
2) When joining NEMA/EEMAC Type 12 sections, apply a continuous
1/8-in.- (3-mm-) wide bead of silicon sealer around the perimeter of one
section.
3) Position the right section against the left section. Ensure that the surface
is level.
4) Secure the sections together using the 1/4-20 self-tapping screws.
Thread the screw through the 0.281 in. clearance hole to the corre-
sponding 0.219 in. pilot hole. To access the front clearance holes of the
left-side cabinet, open the medium voltage doors. To access the rear
clearance holes remove the rear covers of the starter. If rear access is
not available, refer to Access to the Power Bus - Front Access, page 2-6.
5) Secure the right section to the floor using ½ in. (M12) floor mounting
bolts (refer to Anchoring, page 2-3).

Figure 2.4
Joining Sections

Side B us A ccess C over

Front Front

0.281 C learance H oles (Q TY. 3) 0.219 P ilot H oles (Q TY. 3)

0.219 P ilot H oles (Q TY. 5) 0.281 C learance H oles (Q TY. 5)

(All dimensions in inches)

1500-5.5 — March 1999

 SPECIAL INSTRUCTION MANUAL
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Installation 2-5

Access to the Power Bus ATTENTION: This procedure requires contact with medium
voltage components. To avoid shock hazards, lock out
incoming power before working on the equipment.
(See Power Lock-out Procedure, page 3-3). Verify with a hot
stick or appropriate voltage measuring device that all circuits
are voltage free. Failure to do so may result in severe burns,
injury or death.

Rear Access

1) Remove the self-tapping screws from the rear bus access cover.
2) Remove the rear bus access cover.

Figure 2.5
Access to Power Bus From Side and Rear of Cabinet

Side Bus
Rear Bus Access Cover
Access Cover

Side Access

A side bus access cover is located on each side of the controller.

1) Remove the self-tapping screws from the appropriate side bus access
cover.
2) Remove the side bus access cover.

1500-5.5 — March 1999

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

2-6 Installation

Access to the Power Bus Front Access - Top Exiting Load Cables
(Cont.)

ATTENTION: To avoid shock hazards, lock out incoming

power (see page 3-3) before working on the equipment.
Verify with a hot stick or appropriate voltage measuring device
that all circuits are voltage free. Failure to do so may result in
severe burns, injury or death.

1) Complete the Power Lock-out Procedure (see page 3-3) for both
medium voltage power cells and the power bus.
2) Remove the hinge pins from the medium voltage doors and remove the
doors.
3) Open the low voltage cell doors (see page 2-1).
4) Disconnect the control wiring harness from the wire plug at the lower
left side of each contactor.
5) Remove the two self-tapping screws from the center vertical channel.
6) Pull on the center vertical channel to swing out the low voltage panel.

Figure 2.6
Center Vertical Channel

Remove Self-tapping
Screws from
Center Vertical Channel

Control Wiring
Harness

7) Remove each glass-polyester barrier located in front of the current

transformers.
8) Remove the retaining screw from the cable duct barrier and remove the
barrier (see Figure 2.7).
9) Remove the two retaining screws from the cable duct boot and remove
the boot (see Figure 2.7).
1500-5.5 — March 1999
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Installation 2-7

Access to the Power Bus Figure 2.7

(Cont.) Removing Cable Duct Boot and Barrier

Current Transformers

Remove Retaining
Screws

Cable Duct Boot

Cable Duct Barrier

Remove Retaining
Screw

10) To access the left side of the power bus, locate the two bus access
covers at the rear, left side of the power cell. Remove the four self-
tapping screws from each cover and remove the covers (see Figure 2.8).

Figure 2.8
Removing Bus Access Covers

Remove the four

self-tapping screws from
each Bus Access Cover.

1500-5.5 — March 1999

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

2-8 Installation

Access to the Power Bus 11) If access to the right side of the power bus is required, remove the
(Cont.) vacuum contactor from the upper power cell (See Removing the Contac-
tor, page 3-6).
12) Remove the power fuses from the isolation switch.
13) Remove the inter-phase barriers from the trailer fuse block by raising
them vertically up and out of the mounting slots (see Figure 2.9).
14) Use a 9/16 in. socket to remove the contactor bus bars from the isolation
switch trailer fuse block.

Figure 2.9
Contactor Bus Bars (Trailer Fuse Block for Clip-on Fuses Shown)

Mounting Bolts

Trailer Fuse Block

Inter-phase Barriers

Contactor Bus Bars

15) Disconnect the secondary control wiring from the control power trans-
former (CPT) and remove the CPT mounting plate. Leave the CPT
attached to the plate.

ATTENTION: The CPT is heavy and assistance may be

required to safely remove and transport the unit. Use caution
when removing the CPT. Failure to do so may result in
personal injury and/or damage to the equipment.

1500-5.5 — March 1999

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Installation 2-9

Access to the Power Bus 16) To access the right side of the power bus, remove the self-tapping
(Cont.) screws from the lower glass-polyester bus access cover and remove the
cover (see Figure 2.10).
17) Reverse the procedure to reassemble the cabinet.

Figure 2.10
Access to Right Side of Power Bus

Remove Self-tapping Screws

ATTENTION: Ensure all barriers are replaced before

energizing the equipment. Failure to do so may result in
electrical faults and cause damage to equipment or serious
injury to personnel.

1500-5.5 — March 1999

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

2-10 Installation

Access to the Power Bus Front Access - Bottom Exiting Load Cables
(Cont.)
If the cables in your cabinet exit from the bottom, the procedure to access
the power bus is almost identical to the one above. Follow the procedure for
Front Access - Top Exiting Load Cables, but remove the cable duct barrier
and cable duct boot from the top of the lower power cell, rather than those
at the bottom (see Figure 2.11).

Figure 2.11
Bottom Cable Exit Configuration

Cable Duct Barrier

Cable Duct Boot

1500-5.5 — March 1999

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Installation 2-11

Bus Splicing Power Bus

ATTENTION: This procedure requires contact with

medium voltage components. To avoid shock hazards, lock
out incoming power before working on the equipment.
(See Power Lock-out Procedure, page 3-3). Verify with a hot
stick or appropriate voltage measuring device that all circuits
are voltage free. Failure to do so may result in severe burns,
injury or death.

1) The power and ground bus splice kit can be found in a package
mounted to the front of the shipping skid.

Important: Verify that the structure series numbers on the splice kit package
match the structure series number found on the cabinet name-
plate (see page 1-1 for details regarding the nameplate).

2) Refer to Access to the Power Bus, page 2-5.

3) For a 1200A power bus, assemble the splice bars as shown in Figure
2.12. Tighten the nuts to 48 ft·lb (65 N·m).
For a 2000A power bus, assemble the splice bars as shown in Figure
2.13. Tighten the nuts to 48 ft·lb (65 N·m).

Important: Attach the bus links to the cabinet on the left side first - as
viewed from the front of the unit.

Important: Always place the bus clamps on the rear side of the main
horizontal bus or splice bar, as viewed from the front of the unit.
(see Figure 2.12 or 2.13).

Figure 2.12
Typical 1200A Power Bus Splicing Configuration (Viewed from front of cabinet)

B us S upport

M ain H orizontal
P ow er B us

B us C lam p

P ow er B us
S plice B ar

Flat W asher
(Front View) Lockw asher
H ex N ut
1500-5.5 — March 1999
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

2-12 Installation

Bus Splicing (Cont.) Power Bus (Cont.)

Figure 2.13
Typical 2000A Power Bus Splicing Configuration (Viewed from front of cabinet)

B us S upport

M ain H orizontal
P ow er B us

B us C lam p

P ow er B us
S plice B ars
Flat W asher
(Front View) Lockw asher
H ex N ut

ATTENTION: Ensure all barriers are replaced before

energizing the equipment. Failure to do so may result in
electrical faults and cause damage to equipment or severe
injury to personnel.

Insulated Power Bus Splicing

If the starter is equipped with insulated power bus, then a splice kit with
insulated links, insulating boots and tape will be provided. Refer to the kit for
installation instructions.

1500-5.5 — March 1999

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Installation 2-13

Bus Splicing (Cont.) Ground Bus

1) See Figure 2.14 to determine the correct ground splice configuration and
assemble as shown.
2) Torque the hardware to 6 ft·lb ± 1 ft.·lb (8 N·m ± 1 N·m).
3) Check all hardware for correct tightness and replace all covers and
plates.

Figure 2.14
Typical Ground Bus Splicing Configuration

H ex N ut

Lockw asher

Flat W asher

G round B us
S plice B ar

M ain
G round B us

G round B us
S upport

(Front View)

ATTENTION: Ensure all barriers are replaced before

energizing the equipment. Failure to do so may result in
electrical faults and cause damage to equipment or severe
injury to personnel.

1500-5.5 — March 1999

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

2-14 Installation

Incoming Line Cable ATTENTION: To avoid shock hazards, lock out incoming
Connections power (see page 3-3) before working on the equipment.
Verify with a hot stick or appropriate voltage measuring device
that all circuits are voltage free. Failure to do so may result in
severe burns, injury or death.

Incoming cables are connected to the power bus in the last section on the left.

Important: Cable size should not exceed 1-750 MCM or 2-500 MCM per
phase. For larger cables, an incoming line module must be used.

1) Remove the center-back plate or side plate to access the power bus. If
access to the rear of the unit is not possible, refer to Accessing the
Power Bus, page 2-5.
2) Connect the incoming power lines to the power bus. Torque to specifica-
tions (see page 3-1).

Figure 2.15
Incoming Line Cable Connections

Power Cable Lugs

Ground Bus Lug

Important: If line cables require installation by front access, complete the

incoming line connection before installing load cables.

3) Connect the ground wire to the ground bus lug.

4) Connect any external control wires to the control panel terminal blocks
in the low voltage compartment. Refer to wiring diagram.
1500-5.5 — March 1999
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Installation 2-15

Load Cable Connections ATTENTION: To avoid shock hazards, lock out incoming
power (see page 3-3) before working on the equipment. Verify
with a hot stick or appropriate voltage measuring device that
all circuits are voltage free. Failure to do so may result in
severe burns, injury or death.

Important: The current transformers may be positioned for top or bottom

cable exit. Follow the appropriate procedure described for your
starter configuration.

Important: Cable size should not exceed 1-500 MCM or 2-350 MCM per
phase.

1) Complete the Power Lock-out procedure (see page 3-3).

2) Follow steps 2-6 from Access to the Power Bus - Front Access
(see page 2-6 ) for the procedure to swing out the low voltage panel.
3) Remove the cable duct boot at the top of the cabinet for top exiting load
cables, or remove the one at the bottom of the cabinet for bottom exiting
load cables (see Figure 2.16).

Figure 2.16
Access to Load Cable Conduit Openings (Top exit cable configuration shown)
(Some parts removed for clarity)

Remove Cable Duct Boot to access

Load Cable Conduit Opening for
cables exiting from bottom power cell.

Current Transformer
Mounting Plate

Connect Load Cables to

Current Transformers.

1500-5.5 — March 1999

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

2-16 Installation

Load Cable Connections (Cont.) 4) Remove the appropriate load cable conduit openings in the top or bottom
of the cabinet (see Figure 2.17 or 2.18).

Top Exiting Load Cables

5) Load cables for the bottom power cell should be routed first. Pull the
cables into the cabinet through the appropriate opening (see Figure 2.17).
Run the cables behind the current transformer mounting plate and into
the bottom power cell.

Figure 2.17
Load Cable Conduit Openings (Top Exit Shown)
Top of Cabinet

Load Cable Conduit Opening for

cables from top power cell.

Load Cable Conduit Opening for

cables from bottom power cell.

Ground Lug

6) For the top power cell, pull the cables into the cabinet through the
appropriate opening (see Figure 2.17).
7) Connect the cables to the current transformers and tighten the connec-
tions to 48 ft·lb (65 N·m).
8) Connect cable shields to the ground lug.
9) Reinstall the cable duct boot and reassemble the cabinet.

ATTENTION: Ensure all barriers are replaced before

energizing the equipment. Failure to do so may result in
electrical faults and cause damage to equipment or serious
injury to personnel.

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BI012088 MD6640 BLAST HOLE DRILL

Installation 2-17

Bottom Exiting Load Cables

5) Load cables for the top power cell should be routed first. Pull the cables
into the cabinet through the appropriate opening (see Figure 2.18). Run
the cables behind the current transformer mounting plate and into the top
power cell.

Figure 2.18
Load Cable Conduit Openings (Bottom Exit Shown)

Load Cable Conduit Opening for

cables from top power cell

Load Cable Conduit Opening for

cables from bottom power cell

Bottom of cabinet

Contactor

6) For the bottom power cell, pull the cables into the cabinet through the
appropriate opening (see Figure 2.18).
7) Connect the cables to the current transformers and tighten the connec-
tions to 48 ft·lb (65 N·m).
8) Connect cable shields to the ground lug.
9) Reinstall the cable duct boot and reassemble the cabinet.

ATTENTION: Ensure all barriers are replaced before

energizing the equipment. Failure to do so may result in
electrical faults and cause damage to equipment or serious
injury to personnel.

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2-18 Installation

Hi-Pot and Megger Test Insulation integrity should be checked before energizing medium voltage
electrical equipment. Use a high voltage AC insulation tester or a Megger for
this test. If a Megger is used, a 5000 volt type is recommended.

ATTENTION: Exercise caution when performing high

voltage tests on the equipment. Failure to do so may result in
electric shock causing severe burns, injury or death.

ATTENTION: Disconnect power factor correction capacitors

(if so equipped) before performing the Hi-Pot test. Failure to
do so may result in personal injury or damage to the
equipment. See Power Lock-out Procedure, page 3-3, for
information on dissipating any stored power in the capacitors.

ATTENTION: Remove the primary fuses for the control

power transformer and/or the potential transformer from the
contactor fuse clips. Failure to do so may cause damage to the
equipment during the Hi-pot test.

Insulation can be tested from phase to phase and from phase to ground.
The recommended level for AC Hi-Pot testing is (2 X VLL) volts, where
VLL is the rated line-to-line voltage of the power system. The leakage
current must be less than 20 mA. Record the result for future comparison
testing.

If a Megger is used, it should indicate 50000 megohms or greater if the unit

is isolated from the line and the motor. If the unit is connected to a motor,
the Megger should indicate 5000 megohms or greater (phase to ground).

Start-up Procedure Contactor Inspection

See Chapter 2 in Medium Voltage Contactor 400A, Publication 1502-5.0

for information on pre-energization inspection, vacuum bottle integrity test
and insulation resistance test.

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Installation 2-19

Start-up Procedure (Cont.) Preliminary Checks

Verify the following:

• Contactor rating is correct for the attached load;

• Control voltage is correct;
• Settings for protective relays;
• Heater elements (if provided) in overload relay are secure and undamaged;
• Equipment grounding;
• External power and control connections match electrical diagrams;
• All hardware is correctly reinstalled and torqued to specifications (see
page 3-1);
• All barriers are replaced to correct positions;
• All fuses are correct class, type and rating;
• Mechanical interlocks and isolation switch function properly;
• Ensure that any microprocessor-based protection relay is programmed:
• Interior of cabinet is free from dirt, loose bolts, tools or metal chips.
Vacuum clean if necessary;
• All tools are accounted for. If you can not locate a tool, do not energize
the unit until it is found.

Testing Contactor Operation

1) Connect the appropriate external power supply (120 or 230 V AC) to the
test receptacle in the control panel. Turn the selector switch to the TEST
position.

ATTENTION: Some control circuit configurations may

require control jumpers to let the contactor close during the
test procedure. Do not jumper any isolation switch contacts
such as ISa or ISb (see page 3-13, Figure 3.13 for the location
of these contacts). Using jumpers for these contacts may
result in equipment damage or injury to personnel.

2) Electrically operate the contactor several times. Inspect the armature

plate to verify that it fully contacts the magnetic cores.
3) Turn the selector switch to the OFF position and unplug the test voltage.
4) Remove any metal filings or loose hardware from around the magnetic
cores. The debris is attracted to the coil once it is energized and could
prevent the contactor from closing properly.

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BI012088 MD6640 BLAST HOLE DRILL

2-20 Installation

Figure 2.19
Typical Wiring Diagram

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BI012088 MD6640 BLAST HOLE DRILL

Maintenance 3-1

Chapter 3

Maintenance
Important: Establish a maintenance and inspection schedule for the equip-
ment. Annual servicing, or every 20,000 operations (whichever
comes sooner) is the minimum recommended. Extreme operat-
ing conditions may warrant additional attention.

Tool Requirements Important: Some components of this product incorporate Imperial hard-
ware. Rockwell Automation recommends the use of the appro-
priate tools to successfully complete the maintenance procedures
on these components. If you cannot obtain such tools, contact
your area Rockwell Automation sales office for assistance.

• Torque wrench: 0-48 ft·lb (0-65 N·m)

• Sockets: 3/8 in., 7/16 in., 9/16 in.
• Ratchet handle and extension
• Wrenches: 7/16 in., 1/2 in., 9/16 in.
• Feeler gauges: 0.050 in. (1.3mm) 0.080 in. (2 mm), 0.020 in. (0.5 mm)
• Flat-blade screwdriver
• Nyogel 759G Lubricant, Allen-Bradley part no. 80158-357-51

Recommended Torque Values When reinstalling components, or when reassembling the cabinet, tighten the
following bolt sizes to the specified torque values:

1/4 in. hardware 6 ft·lb (8 N·m)

5/16 in. hardware 12 ft·lb (15 N·m)

3/8 in. hardware 20 ft·lb (27 N·m)

1/2 in. hardware 48 ft·lb (65 N·m)

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3-2 Maintenance

Door Interlock Circumvention ATTENTION: The door interlock mechanism is designed to

prevent access to the medium voltage cell while the unit is
energized. When the unit is in operation, do not circumvent
this interlocking safety feature. Always disconnect and lock
out incoming power (see Power Lock-out Procedure, pg. 3-3)
before proceeding with any adjustments requiring the handle
to be moved to the ON (closed) position. Failure to do so
may result in electric shock causing severe burns, injury or
death.

Some of the following sections may require moving the isolation switch
handle to the ON position while the medium voltage door is open. The
interlocking safeguards in the mechanism are designed to prevent the
handle from moving to the ON position while the cabinet door is open.
• To circumvent this safety feature, use a screwdriver, or other tool, to
depress the door interlock lever in the switch.
• Hold the lever down while moving the handle to the ON (closed)
position.

Figure 3.1
Door Interlock Lever

D oor Interlock
Lever

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Maintenance 3-3

Power Lock-out Procedure ATTENTION: Always perform the power lock-out procedure
before servicing the equipment. Failure to do so may result in
severe burns, injury or death.

ATTENTION: The following procedure requires moving the

isolation switch handle to the ON position. To avoid shock
hazards, disconnect and lock out incoming power before
proceeding with servicing the equipment. Failure to lock out
incoming power will result in a live power cell once the
isolation switch handle is in the ON position and may cause
severe burns, injury or death. Rockwell Automation does not
assume any responsibility for injuries to personnel who have
not completed the following safety procedure prior to
servicing the equipment.

1) Disconnect and lock out all feeder power supplies to the starter.
2) Move the isolation switch handle to the OFF position.
3) If the unit is equipped with power factor correction capacitors, stored
energy must be dissipated before entering the power cell. Wait at least
five minutes before entering the power cell or dissipate the power using
the following procedure:
a) Verify that the isolation switch handle is in the OFF position.
b) Open the low voltage door.
c) Plug the appropriate power supply (120 or 230V) into the auxiliary
power receptacle on the control panel (see Figure 3.2).
d) Move the control switch to the TEST position.

Figure 3.2
Control Panel

Auxiliary Power Receptacle

Control Switch

e) Electrically operate the contactor by pushing the START button

on the unit or at a remote location.
f) Disengage the contactor and move the control switch to the
NORMAL position. Disconnect the external power supply.
g) Complete the Power Lock-out procedure
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3-4 Maintenance

Power Lock-out Procedure 3) Open the medium voltage door.

(Cont.) 4) Visually inspect that the isolation switch blades fully engage the ground
ing pins on the grounding bar. The isolation switch shutters should be
closed (see Figure 3.3).

Figure 3.3
Inspecting Isolation Switch in Open Position
Grounding Bar

Isolation Switch Blades must

fully engage Grounding Pins
of Grounding Bar.
(Verify for each phase)

Isolation Switch Shutters

must be closed.
(Verify for each phase)

5) Check the line and load sides of the contactor with a hot stick or appro-
priate voltage measuring device to verify that they are voltage free (see
Figure 3.4).
a) Check for line-side voltage at the top vacuum bottle terminals.
b) Check for load-side voltage at the bottom vacuum bottle terminals.

Figure 3.4
Contactor Voltage Checkpoints
Check line-side power here

Check load-side power here

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Maintenance 3-5

Power Lock-out Procedure 6) Use the Door Interlock Circumvention procedure described on page 3-2
(Cont.) to move the isolation switch handle to the ON position
7) Check the isolation switch blades with a hot stick or appropriate voltage
measuring device to verify that they are voltage free (see Figure 3.5).

Figure 3.5
Isolation Switch Voltage Check Points

Isolation Switch Blades

must fully engage
Incoming Line Stabs

Check incoming line voltage here

8) Once all power circuits are verified to be voltage free, move the isolation
switch handle back to the OFF position. The unit is now safe to service.

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3-6 Maintenance

Contactor Maintenance Refer to Medium Voltage Contactor-400A, Publication 1502-5.0 for

contactor maintenance instructions.

Removing the Contactor ATTENTION: To avoid shock hazards, lock out incoming
power (see page 3-3) before working on the equipment. Verify
with a hot stick or appropriate voltage measuring device that
all circuits are voltage free. Failure to do so may result in
severe burns, injury or death.

1) Complete the Power Lock-out Procedure (see page 3-3).

2) Disconnect the control wiring harness from the wire plug at the lower
left side of the contactor (See Figure 3.6)
3) Remove the control power transformer primary fuses from the top of
the contactor.
4) Disconnect the control power transformer primary leads from the fuse
terminals at the top of the contactor.
5) Use a 9/16 in. socket wrench to disconnect the power cables and bus
bars from the rear of the contactor.

Figure 3.6
Removing the Contactor

C ontactor Interlock R od

C ontactor P lug

C ontactor
O perating Lever
C ontactor
M ounting B olts

6) Remove the nylon contactor bushing retaining screw from the contactor
operating lever.

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Maintenance 3-7

Removing the Contactor (Cont.) 7) Slide the contactor interlock rod and the nylon contactor bushing out of
the groove in the contactor operating lever (see Figure 3.7).

Figure 3.7
Removing the Contactor

C ontactor
Interlock R od

N ylon C ontactor Bushing

R etaining Screw

N ylon C ontactor
Bushing

N ylock N ut

C ontactor
R etaining Tabs

C ontactor
O perating Lever

8) Remove the two contactor mounting bolts at the front of the contactor.
9) Slide the contactor forward slightly to disengage the retaining tabs at the
rear of the contactor from the mounting bracket inside the cabinet.
10) Carefully remove the contactor from the cabinet.

ATTENTION: The contactor weighs approximately 50 lbs.

(22kg) and assistance may be required to safely remove it
from the cabinet and transport it. Failure to use caution when
moving the contactor may result in equipment damage and/or
personal injury.

11) Reverse the procedure to reinstall the contactor. Ensure the mounting
bolts, power cable hardware and bus bar hardware is properly torqued.
See Torque Requirements, page 3-1.
12) Adjust the contactor interlock rod according to the Contactor Interlock
Rod Adjustment procedure on page 3-8.

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3-8 Maintenance

Contactor Interlock Rod ATTENTION: To avoid shock hazards, lock out incoming
Adjustment power (see page 3-3) before working on the equipment. Verify
with a hot stick or appropriate voltage measuring device that
all circuits are voltage free. Failure to do so may result in
severe burns, injury or death.

1) Complete the Power Lock-out Procedure (see Page 3-3).

2) Open the medium voltage door. Use the Door Interlock Circumvention
procedure described on page 3-2 to move the isolation switch handle
halfway between the OFF and ON position (see Figure 3.8). Keep the
handle in this position until the adjustment procedure is completed.
3) With the contactor in the OFF position, insert a 0.050 in. (1.3 mm) feeler
gauge in the gap between the interlock lever and the isolation switch operating
lever. The gap must be between 0.045 in. to 0.060 in. (1.1 mm to 1.5 mm).
4) To reduce the gap distance, follow steps 5-7.
To increase the gap distance follow steps 8-10.

Figure 3.8
Isolation Switch Handle Adjustments
Gap
(0.045 in. to 0.060 in.)
(1.1 mm to 1.5 mm) Isolation Switch
Operating Lever

Interlock Lever

Stop Bracket
Isolation Switch Handle
at Halfway Position

Contactor
Interlock Rod

Contactor
Operating Lever Nylock Nut

To Reduce the Gap Distance

5) Loosen the two screws in the stop bracket and move the stop bracket up
against the interlock lever.
6) With the feeler gauge positioned in the gap, move the interlock lever and
the stop bracket closer to the isolation switch operating lever to reduce
the gap space. Tighten the stop bracket screws.
7) Tighten the nylock nut until it is snug against the contactor operating
lever. Do not overtighten the nylock nut as it will move the interlock
lever and reduce the gap. Proceed to Step 11.
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BI012088 MD6640 BLAST HOLE DRILL

Maintenance 3-9

Contactor Interlock Rod To Increase the Gap Distance

Adjustment (Cont.) 8) Loosen the two screws in the stop bracket and move the stop bracket
away from the interlock lever.
9) Loosen the nylock nut until the gap reaches the desired size.
10) Move the stop bracket until it just touches the interlock lever and tighten
the screws.

11) Apply Loctite 290 (or equivalent adhesive) to the stop bracket screws
and torque the screws to 6 ft.-lb. (8 N•m).
12) Move the isolation switch handle to the ON position.
13) Manually close the contactor by attaching locking pliers to the contactor
operating lever and pushing down until the armature plate contacts the
magnetic cores (see Figure 3.9). Verify that the interlock lever overlaps
the isolation switch operating lever by at least 0.125 in. (3 mm) (see
Figure 3.10).

Figure 3.9
Closing Contactor Manually (Some parts not shown)

Armature Plate

Magnetic Core
Figure 3.10
Isolation Switch Operating Lever Overlap

Isolation Switch
Overlap 0.125 in. min. Operating Lever
(3 mm)

Interlock Lever

14) Open the contactor. Verify that the interlock lever and the rod move freely
and that the return springs move the assembly back to the starting position.
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3-10 Maintenance

Isolation Switch Mechanism

Inspection and Lubrication ATTENTION: To avoid shock hazards, lock out incoming
power (see page 3-3) before working on the equipment. Verify
with a hot stick or appropriate voltage measuring device that
all circuits are voltage free. Failure to do so may result in
severe burns, injury or death.

1) Complete the Power Lock-out Procedure (see Page 3-3).

2) Open the medium voltage door.
3) Inspect the condition of the clevis pin and cotter pins shown in Figure
3.11. Replace any worn parts.
4) If it is necessary to replace the isolation switch operating lever or the
interlock lever, apply Dow Corning 55 O-ring lubricant (or equivalent) to
the pivot points before installing the new components (See Figure 3.11)

Figure 3.11
Isolation Switch Handle Mechanism Lubrication Points

Threaded
Connecting Rod

Clevis Pins and Isolation Switch

Cotter Pins Operating Lever

Interlock Lever

Lubrication Points
(Only at replacement)

Contactor
Interlock Rod

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Maintenance 3-11

Isolation Switch Mechanism 5) Inspect the mounting hardware on the isolation switch operating lever
Inspection and Lubrication and contactor interlock rod (see Figure 3.11). Tighten any loose hardware.
(Cont.) 6) Inspect the isolation switch blades and the incoming line stabs (see
Figure 3.13). The mating surfaces must be clean and well lubricated.
7) Remove any dirt and dried grease.

Important: Do not scrape or file the parts. This may remove the plating and
expose the underlying copper to corrosion.

8) Lubricate the isolation switch blades and the isolation switch blade pivot
points with Nyogel 759G (see Figure 3.12).

Important: Lubricate the isolation switch blades a minimum of once per

year to avoid excessive wear to the components and to prevent
the isolation switch blades from overheating.

Figure 3.12
Isolation Switch Lubrication Points

Lubricate Isolation Switch Blades

Lubricate Pivot Points

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3-12 Maintenance

Isolation Switch Mechanism ATTENTION: To avoid shock hazards, lock out incoming
Grounding Adjustment power (see page 3-3) before working on the equipment. Verify
with a hot stick or other appropriate voltage measuring device
that all circuits are voltage free. Failure to do so may result in
severe burns, injury or death.

1) Complete the Power Lock-out Procedure (see page 3-3).

2) Inspect the grounding of the isolation switch blades. When the isolation
switch handle is in the OFF position, the isolation switch blades must fully
engage the grounding pins and be within 0.06 in. (1.5 mm) of the ground
bar (see Figure 3-13). When the isolation switch handle is in the ON
position, the blades must fully engage the incoming line stabs.

Figure 3.13
Isolation Switch Grounding Adjustment

Ground Bar
Maximum Gap 0.06 in. (1.5 mm) between Ground Bar
and Isolation Switch Blade in open position

Isolation Switch Blade

Incoming Line Stab

Auxiliary Contact

Isolation Switch (Cut-away view from right side)

3) To adjust the distance from the blades to the bar, disconnect the
threaded connecting rod at the handle operating lever.
4) Turn the threaded connecting rod to lengthen or shorten it. This will
adjust the position of the isolation switch blades in the ON and OFF
position.

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Maintenance 3-13

Auxiliary Contacts ATTENTION: To avoid shock hazard, lock out incoming

Inspection and Replacement power (see page 3-3) before working on the equipment. Verify
with a hot stick or appropriate voltage measuring device that
all circuits are voltage free. Failure to do so may result in
severe burns, injury or death.

1) Complete the Power Lock-out Procedure (see page 3-3).

2) Inspect the auxiliary contacts for wear, scorching or heat damage.
Replace any damaged contacts. The contacts have a mean time between
failure (MTBF) rating of 20 million operations if used within the operat-
ing specifications.
3) To remove the contact, turn both of the D-head fasteners until the flat
sections are aligned with the edge of the contact (See Figure 3.14).
4) Remove the contact from the housing.
5) Disconnect the wires from the auxiliary contact.
6) Reverse the procedure to replace the auxiliary contact.
7) Ensure the contact is correctly positioned into the contact carrier (See
Figure 3.14).

Figure 3.14
Auxiliary Contact Orientation

AMP
20

D-head
Fastener

Correct Positioning

20
AMP

Incorrect Positioning
Install as Shown Above

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BI012088 MD6640 BLAST HOLE DRILL

3-14 Maintenance

Auxiliary Contacts Adjustment The auxiliary contacts are mounted on the left side of the isolation switch,
slightly below the cams on the isolation switch shaft.
Normally open contacts (Isolation Switch a Contacts—ISa) are on the inside
of the isolation switch housing, and normally closed contacts (Isolation
Switch b Contacts—ISb) are on the outside of the housing.
ISa and ISb contacts are exactly the same. The cam controls the normally
open or normally closed status of the contacts.

Important: The Isolation Switch Mechanism Grounding Adjustment

procedure (page 3-11) must be completed before adjusting the
auxiliary contacts to ensure proper synchronization of the
assembly.

Adjusting the Normally Closed (ISb) Contact

ATTENTION: To avoid shock hazards, lock out incoming

power (see page 3-3) before working on the equipment. Verify
with a hot stick or appropriate voltage measuring device that
all circuits are voltage free. Failure to do so may result in
severe burns, injury or death.

1) Complete the Power Lock-out Procedure (see page 3-3).

2) Move the isolation switch handle to the ON (closed) position.
3) Loosen the bolt holding the outside cam to the shaft. Do not loosen the
bolt entirely. The cam should not be able to rotate freely on the shaft.
4) Insert a 0.25 in. (6.35 mm) diameter pin into the cam groove between
the cam follower and the end of the cam groove.

Figure 3.15
Adjusting Auxiliary Contacts (ISb Auxiliary Contact Shown)

Cam

Gap
Cam 0.25 in.
Follower (6.35 mm)
AMP
20

Auxiliary SER. A
700-CPM
CATAL OG NO.

Contact

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BI012088 MD6640 BLAST HOLE DRILL

Maintenance 3-15

Auxiliary Contacts Adjustment 5) Adjust the cam on the shaft so that the gap from the cam follower to
(Cont.) the end of the cam groove is the width of the pin — 0.25 in. (6.35 mm).
6) Move the isolation switch handle to the OFF (open) position and check
that nothing prevents the cam from rotating with the shaft.
7) Tighten the bolt holding the cam to the shaft. Move the isolation switch
handle to the ON position and recheck the gap using the pin.

Adjusting the Normally Open (ISa) Contact

1) Move the isolation switch handle to the OFF (open) position.

2) Loosen the bolt holding the inside cam to the shaft. Do not loosen the
bolt entirely. The cam should not be able to rotate freely on the shaft.
3) Insert a 0.25 in. (6.35 mm) diameter pin into the cam groove between
the cam follower and the end of the cam groove.
4) Adjust the cam on the shaft so that the gap from the cam follower to
the end of the cam groove is the width of the pin — 0.25 in. (6.35 mm).
5) Move the isolation switch handle to the ON (closed) position and check
that nothing prevents the cam from rotating with the shaft.
6) Tighten the bolt that holds the cam to the shaft. Move the isolation
switch handle to the OFF position and recheck the gap using the pin.
7) Operate the handle several times and recheck the 0.25 in. (6.35 mm)
clearance between the end of the cam groove and the follower pin for
both cams.

Adjusting the Change-of-State Point

This procedure sets the secondary electrical interlock. When properly

adjusted, the electrical interlock is designed to open the contactor before the
isolation switch opens as the handle is moved to the OFF position.

1) Once the auxiliaries have been adjusted, move the isolation switch
handle to the ON position.
2) Connect a device to indicate continuity across the closed auxiliary contacts.
3) Slowly move the isolation switch handle towards the OFF position and
observe the point at which the movable isolation switch blades separate
from the incoming line stabs.
4) If the auxiliaries do not change state before the isolation switch opens,
adjust the threaded connecting rod as described in the Isolation Switch
Mechanism Grounding Adjustment procedure (see page 3-12).

ATTENTION: The auxiliary contacts must change state from

the closed to open position before the isolation switch blades
lose contact with the incoming line stabs. This prevents the
isolation switch from being opened while the unit is energized
and under load conditions. Failure to correctly set the auxiliary
contacts may result in serious damage to the controller and/or
injury to personnel.

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3-16 Maintenance

Emergency The interlocking mechanism of the medium voltage starter is designed to

Circumvention Procedure prohibit access to the power cell while the isolation switch handle is in the
for Power Cell Entry ON position and the isolation switch is closed.

Important: The following procedure is intended to be used only when the

isolation switch cannot be opened as described in the Door
Opening Procedure (page 2-1).

ATTENTION: This procedure may expose personnel to

energized medium voltage components. Whenever possible,
lock out incoming power before beginning this procedure. If
you are unable to lock out incoming power, use the
appropriate protective equipment and work practices to avoid
shock hazards. Failure to do so may result in severe burns,
injury or death.

1) Remove the two 1/4-20 self-tapping screws from the Z-clip and remove
the Z-clip.

Figure 3.16
Z-clip Assembly

Handle Pin

Remove 1/4-20
Self-tapping Screws

Remove Z-clip

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BI012088 MD6640 BLAST HOLE DRILL

Maintenance 3-17

Emergency 2) Remove the two door locking bolts.

Circumvention Procedure 3) Use a flat-headed screwdriver to turn the defeater pin on the right side of
For Power Cell Entry (Cont.) the isolation switch handle.

Figure 3.17
Defeater Pin

Defeater Pin

4) Open the power cell door.

If it is possible to move the isolation switch handle to the OFF position for
reassembly, follow steps 5-10.

If it is not possible to move the isolation switch handle to the OFF position
for reassembly, follow steps 11-13.

ATTENTION: The Z-clip assembly must be reassembled to

ensure the interlocking mechanism functions properly. Failure
to do so will let personnel access live medium voltage parts
and may cause severe burns, injury or death.

Installing Z-clip with Isolation Switch Handle in the OFF Position

5) Reattach the Z-clip using the self-tapping screws, but do not completely
tighten them.
6) Move the isolation switch handle to the OFF position.
7) Swing the door closed and inspect the position of the Z-clip with respect
to the handle pin.
8) Set the Z-clip so that it is just above the handle pin. Do not set the Z-clip
more than 0.125 in. (3 mm) above the pin. Open the door and tighten
the screws.
9) Close the door and move the handle to the ON position. Verify that the
handle pin overlaps the Z-clip and prevents the door from opening.
10) Move the handle to the OFF position and tighten the door locking bolts.

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BI012088 MD6640 BLAST HOLE DRILL

3-18 Maintenance

Emergency Installing Z-clip with Isolation Switch Handle in the ON Position

Circumvention Procedure
For Power Cell Entry (Cont.) 11) Close the door and tighten the door locking bolts.
12) Position the Z-clip as shown in Figure 3.16. Ensure the handle pin
overlaps the top portion of the Z-clip.
13) Use the self-tapping screws to reattach the Z-clip.
14) Complete steps 5-10 at the earliest opportunity to confirm that the Z-clip
assembly is correctly installed.

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BI012088 MD6640 BLAST HOLE DRILL
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Medium Voltage Business, 135 Dundas Street, Cambridge, ON N1R 5X1 Canada, Tel: (1) 519 623-1810, Fax: (1) 519 623-8930
Web Site: www.ab.com/mvb

Publication 1500-5.5 – March 1999

Supersedes Publication 1500-5.5 - September 1990 © 1999 Rockwell International Corporation. All rights reserved. Printed in Canada.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

BI010130
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

BI010130
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

BI010130
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Adjustable
Frequency AC
Drive

User Manual

www.abpowerflex.com
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Important User Information

Solid state equipment has operational characteristics differing from those of
electromechanical equipment. “Safety Guidelines for the Application, Installation
and Maintenance of Solid State Controls” (Publication SGI-1.1 available from
your local Rockwell Automation Sales Office or online at http://www.ab.com/
manuals/gi) describes some important differences between solid state equipment
and hard-wired electromechanical devices. Because of this difference, and also
because of the wide variety of uses for solid state equipment, all persons
responsible for applying this equipment must satisfy themselves that each intended
application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of
information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written
permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual we use notes to make you aware of safety considerations.

ATTENTION: Identifies information about practices or circumstances

that can lead to personal injury or death, property damage, or economic
! loss.

Attentions help you:

• identify a hazard
• avoid the hazard
• recognize the consequences

Important: Identifies information that is especially important for successful

application and understanding of the product.

Shock Hazard labels may be located on or inside the drive to alert

people that dangerous voltage may be present.

DriveExplorer, DriveTools32, and SCANport are trademarks of Rockwell Automation.

PLC is a registered trademark of Rockwell Automation.
ControlNet is a trademark of ControlNet International, Ltd.
DeviceNet is a trademark of the Open DeviceNet Vendor Association.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Preface

Overview

The purpose of this manual is to provide you with the basic information
needed to install, start-up and troubleshoot the PowerFlex 40 Adjustable
Frequency AC Drive.

For information on… See page…

Who Should Use this Manual? P-1
Reference Materials P-1
Manual Conventions P-2
Drive Frame Sizes P-2
General Precautions P-3
Catalog Number Explanation P-4

Who Should Use this Manual?

This manual is intended for qualified personnel. You must be able to
program and operate Adjustable Frequency AC Drive devices. In
addition, you must have an understanding of the parameter settings and
functions.

Reference Materials
The following manuals are recommended for general drive information:

Title Publication Available Online at …

Industrial Automation Wiring 1770-4.1 www.ab.com/manuals/gi
and Grounding Guidelines
Preventive Maintenance of DRIVES-SB001A-EN-E www.ab.com/manuals/dr
Industrial Control and Drive
System Equipment
Safety Guidelines for the SGI-1.1 www.ab.com/manuals/gi
Application, Installation and
Maintenance of Solid State
Control
A Global Reference Guide for 0100-2.10 www.ab.com/manuals/ms
Reading Schematic Diagrams
Guarding Against Electrostatic 8000-4.5.2 www.ab.com/manuals/dr
Damage
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P-2 Overview

Manual Conventions
• In this manual we refer to the PowerFlex 40 Adjustable Frequency
AC Drive as; drive, PowerFlex 40 or PowerFlex 40 Drive.

• Parameter numbers and names are shown in this format:

P031 [Motor NP Volts]

Name
Number
Group
d = Display Group
P = Basic Program Group
A = Advanced Program Group

• The following words are used throughout the manual to describe an

action:

Word Meaning
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed
Shall Required and necessary
Should Recommended
Should Not Not Recommended

Drive Frame Sizes

Similar PowerFlex 40 drive sizes are grouped into frame sizes to
simplify spare parts ordering, dimensioning, etc. A cross reference of
drive catalog numbers and their respective frame sizes is provided in
Appendix B.
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Overview P-3

General Precautions

ATTENTION: The drive contains high voltage capacitors which take

time to discharge after removal of mains supply. Before working on
! drive, ensure isolation of mains supply from line inputs [R, S, T (L1,
L2, L3)]. Wait three minutes for capacitors to discharge to safe voltage
levels. Failure to do so may result in personal injury or death.

Darkened display LEDs is not an indication that capacitors have

discharged to safe voltage levels.
ATTENTION: Only qualified personnel familiar with adjustable
frequency AC drives and associated machinery should plan or
! implement the installation, start-up and subsequent maintenance of the
system. Failure to comply may result in personal injury and/or
equipment damage.
ATTENTION: This drive contains ESD (Electrostatic Discharge)
sensitive parts and assemblies. Static control precautions are required
! when installing, testing, servicing or repairing this assembly.
Component damage may result if ESD control procedures are not
followed. If you are not familiar with static control procedures,
reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic
Damage” or any other applicable ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can result in
component damage or a reduction in product life. Wiring or application
! errors, such as, undersizing the motor, incorrect or inadequate AC
supply, or excessive ambient temperatures may result in malfunction of
the system.
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Chapter 1

Installation/Wiring
This chapter provides information on mounting and wiring the
PowerFlex 40 Drive.

For information on… See page For information on… See page
Opening the Cover 1-1 Fuses and Circuit Breakers 1-6
Mounting Considerations 1-2 Power Wiring 1-8
AC Supply Source Considerations 1-3 I/O Wiring 1-12
Recommendations
General Grounding Requirements 1-4 EMC Instructions 1-22

Most start-up difficulties are the result of incorrect wiring. Every

precaution must be taken to assure that the wiring is done as instructed.
All items must be read and understood before the actual installation
begins.

ATTENTION: The following information is merely a guide for

proper installation. Rockwell Automation, Inc. cannot assume
! responsibility for the compliance or the noncompliance to any code,
national, local or otherwise for the proper installation of this drive or
associated equipment. A hazard of personal injury and/or equipment
damage exists if codes are ignored during installation.

Opening the Cover

1. Press and hold in the tabs on each side of the cover.
2. Pull the cover out and up to release.
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1-2 Installation/Wiring

Mounting Considerations
• Mount the drive upright on a flat, vertical and level surface.
Frame Screw Size Screw Torque DIN Rail
B M4 (#8-32) 1.56-1.96 N-m (14-17 lb.-in.) 35 mm
C M5 (#10-24) 2.45-2.94 N-m (22-26 lb.-in.) –
• Protect the cooling fan by avoiding dust or metallic particles.
• Do not expose to a corrosive atmosphere.
• Protect from moisture and direct sunlight.
Minimum Mounting Clearances
Refer to Appendix B for mounting dimensions.

25 mm
(1.0 in.)

120 mm 120 mm
(4.7 in.) (4.7 in.)
Mounting Option A
No clearance required
between drives.

Mounting Option B

120 mm 120 mm
(4.7 in.) (4.7 in.)

Ambient Operating Temperatures

Table 1.A Enclosure and Clearance Requirements
Ambient Temperature Enclosure Rating Minimum Mounting
Minimum Maximum Clearances

IP 20/Open Type Use Mounting Option A

40°C (104°F) (1)
-10°C (14°F) IP 30/NEMA 1/UL Type 1 Use Mounting Option B
50°C (122°F) IP 20/Open Type Use Mounting Option B
(1) Rating requires installation of the PowerFlex 40 IP 30/NEMA 1/UL Type 1 option kit.

Debris Protection
A plastic top panel is included with the drive. Install the panel to prevent
debris from falling through the vents of the drive housing during
installation. Remove the panel for IP 20/Open Type applications.

Storage
• Store within an ambient temperature range of -40° to +85°C.
• Store within a relative humidity range of 0% to 95%,
non-condensing.
• Do not expose to a corrosive atmosphere.
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Installation/Wiring 1-3

AC Supply Source Considerations

Ungrounded Distribution Systems

ATTENTION: PowerFlex 40 drives contain protective MOVs that are

referenced to ground. These devices should be disconnected if the drive
! is installed on an ungrounded distribution system.

Disconnecting MOVs
To prevent drive damage, the MOVs connected to ground shall be
disconnected if the drive is installed on an ungrounded distribution
system where the line-to-ground voltages on any phase could exceed
125% of the nominal line-to-line voltage. To disconnect these devices,
remove the jumper shown in the Figures 1.1 and 1.2.

1. Turn the screw counterclockwise to loosen.

2. Pull the jumper completely out of the drive chassis.
3. Tighten the screw to keep it in place.

Figure 1.1 Jumper Location (Typical)

Important:
Tighten screw after
jumper removal.

Figure 1.2 Phase to Ground MOV Removal

R/L1
Three-Phase
AC Input S/L2
T/L3

Jumper 1 2 3 4
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1-4 Installation/Wiring

Input Power Conditioning

The drive is suitable for direct connection to input power within the rated
voltage of the drive (see Appendix A). Listed in Table 1.B are certain
input power conditions which may cause component damage or
reduction in product life. If any of the conditions exist, as described in
Table 1.B, install one of the devices listed under the heading Corrective
Action on the line side of the drive.

Important: Only one device per branch circuit is required. It should be

mounted closest to the branch and sized to handle the total
current of the branch circuit.

Table 1.B Input Power Conditions

Input Power Condition Corrective Action

Low Line Impedance (less than 1% line reactance) • Install Line Reactor(1)
• or Isolation Transformer
Greater than 120 kVA supply transformer
• or Bus Inductor – 5.5 & 7.5 kW
(7.5 & 10 HP) drives only
Line has power factor correction capacitors • Install Line Reactor
Line has frequent power interruptions • or Isolation Transformer

Line has intermittent noise spikes in excess of

6000V (lightning)
Phase to ground voltage exceeds 125% of normal • Remove MOV jumper to ground.
line to line voltage • or Install Isolation Transformer
with grounded secondary if
Ungrounded distribution system
necessary.
(1)
Refer to Appendix B for accessory ordering information.

General Grounding Requirements

The drive Safety Ground - (PE) must be connected to system
ground. Ground impedance must conform to the requirements of
national and local industrial safety regulations and/or electrical codes.
The integrity of all ground connections should be periodically checked.

Figure 1.3 Typical Grounding

R/L1 U/T1
S/L2 V/T2
T/L3 W/T3

SHLD
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Installation/Wiring 1-5

Ground Fault Monitoring

If a system ground fault monitor (RCD) is to be used, only Type B
(adjustable) devices should be used to avoid nuisance tripping.

Safety Ground - (PE)

This is the safety ground for the drive that is required by code. One of
these points must be connected to adjacent building steel (girder, joist), a
floor ground rod or bus bar. Grounding points must comply with national
and local industrial safety regulations and/or electrical codes.

Motor Ground
The motor ground must be connected to one of the ground terminals on
the drive.

Shield Termination - SHLD

Either of the safety ground terminals located on the power terminal
block provides a grounding point for the motor cable shield. The motor
cable shield connected to one of these terminals (drive end) should also
be connected to the motor frame (motor end). Use a shield terminating or
EMI clamp to connect the shield to the safety ground terminal. The
conduit box option may be used with a cable clamp for a grounding
point for the cable shield.

When shielded cable is used for control and signal wiring, the shield
should be grounded at the source end only, not at the drive end.

RFI Filter Grounding

Using single phase drives with integral filter, or an external filter with
any drive rating, may result in relatively high ground leakage currents.
Therefore, the filter must only be used in installations with
grounded AC supply systems and be permanently installed and
solidly grounded (bonded) to the building power distribution ground.
Ensure that the incoming supply neutral is solidly connected (bonded) to
the same building power distribution ground. Grounding must not rely
on flexible cables and should not include any form of plug or socket that
would permit inadvertent disconnection. Some local codes may require
redundant ground connections. The integrity of all connections should
be periodically checked.
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1-6 Installation/Wiring

Fuses and Circuit Breakers

The PowerFlex 40 does not provide branch short circuit protection. This
product should be installed with either input fuses or an input circuit
breaker. National and local industrial safety regulations and/or electrical
codes may determine additional requirements for these installations.

ATTENTION: To guard against personal injury and/or equipment

damage caused by improper fusing or circuit breaker selection, use only
! the recommended line fuses/circuit breakers specified in this section.

Fusing
The PowerFlex 4 has been UL tested and approved for use with input
fuses. The ratings in the table that follows are the minimum
recommended values for use with each drive rating. The devices listed in
this table are provided to serve as a guide.

Bulletin 140M (Self-Protected Combination Controller)/UL489

Circuit Breakers
When using Bulletin 140M or UL489 rated circuit breakers, the
guidelines listed below must be followed in order to meet the NEC
requirements for branch circuit protection.

• Bulletin 140M can be used in single and group motor applications.

• Bulletin 140M can be used up stream from the drive without the
need for fuses.
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1-8 Installation/Wiring

Power Wiring

ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.)

and local codes outline provisions for safely installing electrical
! equipment. Installation must comply with specifications regarding wire
types, conductor sizes, branch circuit protection and disconnect
devices. Failure to do so may result in personal injury and/or equipment
damage.
ATTENTION: To avoid a possible shock hazard caused by induced
voltages, unused wires in the conduit must be grounded at both ends.
! For the same reason, if a drive sharing a conduit is being serviced or
installed, all drives using this conduit should be disabled. This will help
minimize the possible shock hazard from “cross coupled” power leads.

Motor Cable Types Acceptable for 200-600 Volt Installations

A variety of cable types are acceptable for drive installations. For many
installations, unshielded cable is adequate, provided it can be separated
from sensitive circuits. As an approximate guide, allow a spacing of 0.3
meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases,
long parallel runs must be avoided. Do not use cable with an insulation
thickness less than 15 mils (0.4 mm/0.015 in.). Do not route more than
three sets of motor leads in a single conduit to minimize “cross talk”. If
more than three drive/motor connections per conduit are required,
shielded cable must be used.
UL installations in 50°C ambient must use 600V, 75°C or 90°C wire.
UL installations in 40°C ambient should use 600V, 75°C or 90°C wire.
Use copper wire only. Wire gauge requirements and recommendations
are based on 75 degree C. Do not reduce wire gauge when using higher
temperature wire.

Unshielded
THHN, THWN or similar wire is acceptable for drive installation in dry
environments provided adequate free air space and/or conduit fill rates
limits are provided. Do not use THHN or similarly coated wire in wet
areas. Any wire chosen must have a minimum insulation thickness of 15
mils and should not have large variations in insulation concentricity.
Shielded/Armored Cable
Shielded cable contains all of the general benefits of multi-conductor
cable with the added benefit of a copper braided shield that can contain
much of the noise generated by a typical AC Drive. Strong consideration
for shielded cable should be given in installations with sensitive
equipment such as weigh scales, capacitive proximity switches and other
devices that may be affected by electrical noise in the distribution
system. Applications with large numbers of drives in a similar location,
imposed EMC regulations or a high degree of communications /
networking are also good candidates for shielded cable.
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Installation/Wiring 1-9

Shielded cable may also help reduce shaft voltage and induced bearing
currents for some applications. In addition, the increased impedance of
shielded cable may help extend the distance that the motor can be
located from the drive without the addition of motor protective devices
such as terminator networks. Refer to Reflected Wave in “Wiring and
Grounding Guidelines for PWM AC Drives,” publication
DRIVES-IN001A-EN-P.

Consideration should be given to all of the general specifications

dictated by the environment of the installation, including temperature,
flexibility, moisture characteristics and chemical resistance. In addition,
a braided shield should be included and be specified by the cable
manufacturer as having coverage of at least 75%. An additional foil
shield can greatly improve noise containment.

A good example of recommended cable is Belden® 295xx (xx

determines gauge). This cable has four (4) XLPE insulated conductors
with a 100% coverage foil and an 85% coverage copper braided shield
(with drain wire) surrounded by a PVC jacket.

Other types of shielded cable are available, but the selection of these
types may limit the allowable cable length. Particularly, some of the
newer cables twist 4 conductors of THHN wire and wrap them tightly
with a foil shield. This construction can greatly increase the cable
charging current required and reduce the overall drive performance.
Unless specified in the individual distance tables as tested with the drive,
these cables are not recommended and their performance against the
lead length limits supplied is not known.

Recommended Shielded Wire

Location Rating/Type Description

Standard 600V, 90°C (194°F) • Four tinned copper conductors with XLPE insulation.
(Option 1) XHHW2/RHW-2 • Copper braid/aluminum foil combination shield and tinned
Anixter copper drain wire.
B209500-B209507, • PVC jacket.
Belden 29501-29507,
or equivalent
Standard Tray rated 600V, 90°C • Three tinned copper conductors with XLPE insulation.
(Option 2) (194°F) RHH/RHW-2 • 5 mil single helical copper tape (25% overlap min.) with three
Anixter OLF-7xxxxx or bare copper grounds in contact with shield.
equivalent • PVC jacket.
Class I & II; Tray rated 600V, 90°C • Three bare copper conductors with XLPE insulation and
Division I & II (194°F) RHH/RHW-2 impervious corrugated continuously welded aluminum armor.
Anixter 7V-7xxxx-3G • Black sunlight resistant PVC jacket overall.
or equivalent • Three copper grounds on #10 AWG and smaller.
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1-10 Installation/Wiring

Reflected Wave Protection

The drive should be installed as close to the motor as possible.
Installations with long motor cables may require the addition of external
devices to limit voltage reflections at the motor (reflected wave
phenomena). See Table 1.D for recommendations.

The reflected wave data applies to all frequencies 2 to 16 kHz.

For 240V ratings, reflected wave effects do not need to be considered.

Table 1.D Maximum Cable Length Recommendations

Reflected Wave
380-480V Ratings Motor Insulation Rating Motor Cable Only(1)
1000 Vp-p 15 meters (49 feet)
1200 Vp-p 40 meters (131 feet)
1600 Vp-p 170 meters (558 feet)
(1)
Longer cable lengths can be achieved by installing devices on the output of the drive.
Consult factory for recommendations.

Output Disconnect
The drive is intended to be commanded by control input signals that will
start and stop the motor. A device that routinely disconnects then
reapplies output power to the motor for the purpose of starting and
stopping the motor should not be used. If it is necessary to disconnect
power to the motor with the drive outputting power, an auxiliary contact
should be used to simultaneously disable drive control run commands.
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Installation/Wiring 1-11

Power Terminal Block

The drive utilizes a finger guard over the power wiring terminals. To
remove:

1. Press in and hold the locking tab.

2. Slide finger guard down and out.
Replace the finger guard when wiring is complete.

Figure 1.4 Power Terminal Block (Typical)

B Frame C Frame
R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 P2 P1

DC- DC+ BR+ BR- DC- DC+ BR+ BR-

Terminal (1) Description

R/L1, S/L2 1-Phase Input
R/L1, S/L2, T/L3 3-Phase Input
U/T1 To Motor U/T1 Switch any two motor
V/T2 To Motor V/T2 = leads to change
W/T3 To Motor W/T3 forward direction.
DC Bus Inductor Connection (C Frame drives only.)
The C Frame drive is shipped with a jumper between
P2, P1 Terminals P2 and P1. Remove this jumper only when
a DC Bus Inductor will be connected. Drive will not power
up without a jumper or inductor connected.
DC+, DC- DC Bus Connection
BR+, BR- Dynamic Brake Resistor Connection
[0.75 kW (1 HP) ratings and higher]
Safety Ground - PE
(1) Important: Terminal screws may become loose during shipment. Ensure that all
terminal screws are tightened to the recommended torque before applying power to
the drive.
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1-12 Installation/Wiring

Table 1.E Power Terminal Block Specifications

Frame Maximum Wire Size (1) Minimum Wire Size (1) Torque
B 5.3 mm2 (10 AWG) 1.3 mm2 (16 AWG) 1.7-2.2 N-m (16-19 lb.-in.)
C 8.4 mm2 (8 AWG) 1.3 mm2 (16 AWG) 2.9-3.7 N-m (26-33 lb.-in.)
(1)
Maximum/minimum sizes that the terminal block will accept - these are not
recommendations.

I/O Wiring Recommendations

Motor Start/Stop Precautions

ATTENTION: A contactor or other device that routinely disconnects

and reapplies the AC line to the drive to start and stop the motor can
! cause drive hardware damage. The drive is designed to use control input
signals that will start and stop the motor. If used, the input device must
not exceed one operation per minute or drive damage can occur.
ATTENTION: The drive start/stop control circuitry includes
solid-state components. If hazards due to accidental contact with
! moving machinery or unintentional flow of liquid, gas or solids exist,
an additional hardwired stop circuit may be required to remove the AC
line to the drive. When the AC line is removed, there will be a loss of
any inherent regenerative braking effect that might be present - the
motor will coast to a stop. An auxiliary braking method may be
required.

Important points to remember about I/O wiring:

• Always use copper wire.

• Wire with an insulation rating of 600V or greater is recommended.
• Control and signal wires should be separated from power wires by at
least 0.3 meters (1 foot).

Important: I/O terminals labeled “Common” are not referenced to the

safety ground (PE) terminal and are designed to greatly
reduce common mode interference.

ATTENTION: Driving the 4-20mA analog input from a voltage

source could cause component damage. Verify proper configuration
! prior to applying input signals.
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Installation/Wiring 1-13

Control Wire Types

Table 1.F Recommended Control and Signal Wire(1)

Wire Type(s) Description Minimum

Insulation Rating
Belden 8760/9460 0.8 mm2 (18AWG), twisted pair, 100% 300V
(or equiv.) shield with drain. (1) 60 degrees C
(140 degrees F)
Belden 8770 0.8 mm2 (18AWG), 3 conductor, shielded for
(or equiv.) remote pot only.
(1) If the wires are short and contained within a cabinet which has no sensitive circuits,
the use of shielded wire may not be necessary, but is always recommended.

I/O Terminal Block

Table 1.G I/O Terminal Block Specifications

Frame Maximum Wire Size (2) Minimum Wire Size (2) Torque
B&C 1.3 mm2 (16 AWG) 0.13 mm2 (26 AWG) 0.5-0.8 N-m (4.4-7 lb.-in.)

(2) Maximum/minimum sizes that the terminal block will accept - these are not
recommendations.

Maximum Control Wire Recommendations

Do not exceed control wiring length of 30 meters (100 feet). Control
signal cable length is highly dependent on electrical environment and
installation practices. To improve noise immunity, the I/O terminal block
Common must be connected to ground terminal/protective earth. If using
the RS485 (DSI) port, I/O Terminal 16 should also be connected to
ground terminal/protective earth.
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1-14 Installation/Wiring
Figure 1.5 Control Wiring Block Diagram
(4)
Enable
Jumper Typical Typical
(1)(4) SRC Wiring SNK Wiring
Stop
01
(2)
Start/Run FWD
02
Direction/Run REV
03
SNK SRC Digital Common
04
Digital Input 1
05
Digital Input 2
06
Digital Input 3
07
Digital Input 4
08
Opto Common
09
+24V +24V DC
11
+10V +10V DC
12
0-10V (or ±10V) Input
13
Analog Common
14
Pot must be
4-20mA Input 1-10k ohm
Relay N.O. 15
R1 0-10V 2 Watt Min.
Relay Common Analog Output
R2 0/4-20mA 16 (3)
Common
Relay N.C. Opto Output 1
R3 17 24V
Opto Output 2
30V DC 18
50mA RS485 Shield
Non-inductive 19

0-10V Analog Output Select (4)

Enable
ENBL Jumper
01 02 03 04 05 06 07 08 09
0-20mA
R1 R2 R3
SNK
RS485
11 12 13 14 15 16 17 18 19 (DSI)
SRC
(1) 1
30V DC 125V AC 240V AC
Resistive 3.0A 3.0A 3.0A
Inductive 0.5A 0.5A 0.5A

(1) Important: I/O Terminal 01 is always a coast to stop P036 [Start Source] Stop I/O Terminal 01 Stop
input except when P036 [Start Source] is set to Keypad Per P037 Coast
“3-Wire” control. In three wire control, I/O Terminal 01 3-Wire Per P037 Per P037(4)
2-Wire Per P037 Coast
is controlled by P037 [Stop Mode]. All other stop
RS485 Port Per P037 Coast
sources are controlled by P037 [Stop Mode].
Important: The drive is shipped with a jumper installed
between I/O Terminals 01 and 11. Remove this jumper when using I/O Terminal 01 as a stop or
enable input.
(2) Two wire control shown. For three wire control use a momentary input on I/O Terminal 02 to
command a start. Use a maintained input for I/O Terminal 03 to change direction.
(3) When using an opto output with an inductive load such as a relay, install a recovery diode parallel
to the relay as shown, to prevent damage to the output.
(4) When the ENBL enable jumper is removed, I/O Terminal 01 will always act as a hardware enable,
causing a coast to stop without software interpretation.
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Installation/Wiring 1-15

Table 1.H Control I/O Terminal Designations

No. Signal Default Description Param.
R1 Relay N.O. Fault Normally open contact for output relay. A055
R2 Relay Common – Common for output relay.
R3 Relay N.C. Fault Normally closed contact for output relay. A055

Analog Output Select DIP 0-10V Sets analog output to either voltage or current. Setting must match
Switch A065 [Analog Out Sel].
Sink/Source DIP Switch Source (SRC) Inputs can be wired as Sink (SNK) or Source (SRC) via DIP Switch
setting.

01 Stop (1) Coast The factory installed jumper or a normally closed P036 (1)
input must be present for the drive to start.
02 Start/Run FWD Not Active Command comes from the integral keypad by default. P036, P037
03 Direction/Run REV Not Active To disable reverse operation, see A095 [Reverse P036, P037,
Disable]. A095
04 Digital Common – For digital inputs. Electronically isolated with digital
inputs from analog I/O and opto outputs.
05 Digital Input 1 Preset Freq Program with A051 [Digital In1 Sel]. A051
06 Digital Input 2 Preset Freq Program with A052 [Digital In2 Sel]. A052
07 Digital Input 3 Local Program with A053 [Digital In3 Sel]. A053
08 Digital Input 4 Jog Forward Program with A054 [Digital In4 Sel]. A054
09 Opto Common – For opto-coupled outputs. Electronically isolated with
opto outputs from analog I/O and digital inputs.
11 +24V DC – Referenced to Digital Common.
Drive supplied power for digital inputs.
Maximum output current is 100mA.
12 +10V DC – Referenced to Analog Common. P038
Drive supplied power for 0-10V external
potentiometer.
Maximum output current is 15mA.
13 ±10V In (2) Not Active For external 0-10V (unipolar) or ±10V (bipolar) input P038,
supply (input impedance = 100k ohm) or A051-A054,
potentiometer wiper. A123, A132
14 Analog Common – For 0-10V In or 4-20mA In. Electronically isolated
with analog inputs and outputs from digital I/O and
opto outputs.
15 4-20mA In (2) Not Active For external 4-20mA input supply P038,
(input impedance = 250 ohm). A051-A054,
A132
16 Analog Output OutFreq 0-10 The default analog output is 0-10V. To covert to a A065, A066
current value, change the Analog Output Select DIP
Switch to 0-20mA. Program with A065 [Analog Out
Sel]. Max analog value can be scaled with A066
[Analog Out High].
Maximum Load: 4-20mA = 525 ohm (10.5V)
0-10V = 1k ohm (10mA)
17 Opto Output 1 MotorRunning Program with A058 [Opto Out1 Sel] A058, A059,
A064
18 Opto Output 2 At Frequency Program with A061 [Opto Out2 Sel] A061, A062,
A064
19 RS485 (DSI) Shield – Terminal should be connected to safety ground - PE
when using the RS485 (DSI) communications port.
(1) See Footnotes (1) and (4) on page 1-14.
(2) 0-10V In and 4-20mA In are distinct input channels and may be connected simultaneously.
Inputs may be used independently for speed control or jointly when operating in PID mode.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL
1-16 Installation/Wiring

I/O Wiring Examples

Input/Output Connection Example
Potentiometer P038 [Speed Reference] = 2 “0-10V Input”
1-10k Ohm Pot.
Recommended
12
(2 Watt minimum) 13
14

Analog Input Bipolar Unipolar (Voltage) Unipolar (Current)

0 to +10V, 100k ohm P038 [Speed Reference] P038 [Speed Reference] P038 [Speed Reference]
impedance = 2 “0-10V Input” and = 2 “0-10V Input” = 3 “4-20mA Input”
4-20 mA, 100 ohm A123 [10V Bipolar Enbl]
impedance = 1 “Bi-Polar In”

-/+ 10V 13 + 13
Common 14 Common 14 Common 14
+ 15

2 Wire SRC Control - Internal Supply (SRC) External Supply (SRC)

Non-Reversing
P036 [Start Source] = 11 01 01
2, 3 or 4 02 02
Stop-Run
Input must be active for Stop-Run
04
the drive to run. When
input is opened, the
drive will stop as +24V Common
specified by P037
[Stop Mode].
If desired, a User
Supplied 24V DC Each digital input draws 6 mA.
power source can be
used. Refer to the
“External Supply
(SRC)” example.
2 Wire SNK Control - Internal Supply (SNK)
Non-Reversing
01
02
Stop-Run
04
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Installation/Wiring 1-17

Input/Output Connection Example

2 Wire SRC Control - Internal Supply (SRC) External Supply (SRC)
Run FWD/Run REV
P036 [Start Source] = 11 01 01
02 02
2, 3 or 4 Stop-Run
03 Forward 03
Input must be active for Stop-Run
04
Forward
the drive to run. When Stop-Run
input is opened, the Reverse
drive will stop as Stop-Run
Reverse
specified by P037 +24V Common
[Stop Mode].
If both Run Forward
and Run Reverse Each digital input draws 6 mA.
inputs are closed at the
same time, an
undetermined state
could occur.
2 Wire SNK Control - Internal Supply (SNK)
Run FWD/Run REV
01
02
Stop-Run
Forward 03
04
Stop-Run
Reverse

3 Wire SRC Control - Internal Supply (SRC) External Supply (SRC)

Non-Reversing
P036 [Start Source] = 1 Stop 11 01 Stop 01
A momentary input will 02 02
start the drive. A stop Start
Start
input to I/O Terminal 01 04
will stop the drive as
specified by P037 +24V Common
[Stop Mode].

Each digital input draws 6 mA.

3 Wire SNK Control - Internal Supply (SNK)
Non-Reversing
Stop 01
02
03
Start
04
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

1-18 Installation/Wiring

Input/Output Connection Example

3 Wire SRC Control - Internal Supply (SRC) External Supply (SRC)
Reversing
P036 [Start Source] = 1 Stop 11 01 Stop 01
A momentary input will 02 02
start the drive. A stop 03
Start
03
Start
input to I/O Terminal 01 04
will stop the drive as Direction Direction
specified by P037
[Stop Mode]. I/O +24V Common
Terminal 03
determines direction.
Each digital input draws 6 mA.

3 Wire SNK Control - Internal Supply (SNK)

Reversing
Stop 01
02
03
Start
04
Direction

Opto Output (1 & 2) Opto-Output 1

A058 [Opto Out1 Sel]
determines
Opto-Output 1 (I/O
Terminal 17) operation.
A061 [Opto Out2 Sel]
determines
Opto-Output 2 (I/O 17
Terminal 18) operation.
CR
When using 09
Opto-Output with an +24V Common
inductive load such as
a relay, install a Each Opto-Output is rated
recovery diode parallel 30 VDC 50 mA (Non-inductive).
to the relay as shown,
to prevent damage to
the output.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Installation/Wiring 1-19

Input/Output Connection Example

Analog Output A065 [Analog Out Sel] = 0 through 14
A065 [Analog Out Sel] The Analog Output Select DIP Switch must be set to match the analog output
determines analog signal mode set in A065 [Analog Out Sel].
output type and drive
conditions.
0-10V,
1k ohm minimum 14
Common

0-20mA/4-20mA, 16
+
525 ohm maximum

Typical Multiple Drive Connection Examples

Input/Output Connection Example
Multiple Digital 02 04 02 04 02 04
Input Connections
Customer Inputs can
be wired per
External Supply
(SRC) or Internal
Supply (SNK) Customer Inputs Optional Ground Connection
examples on
page 1-17. When connecting a single input such as Run, Stop, Reverse or Preset Speeds to
multiple drives, it is important to connect I/O Terminal 04 common together for all
drives. If they are to be tied into another common (such as earth ground or
separate apparatus ground) only one point of the daisy chain of I/O Terminal 04
should be connected.

Multiple Analog
Connections 12 13 14 13 14 13 14

Remote Potentiometer Optional Ground Connection

When connecting a single potentiometer to multiple drives it is important to

connect I/O Terminal 14 common together for all drives. I/O Terminal 14 common
and I/O Terminal 13 (potentiometer wiper) should be daisy-chained to each drive.
All drives must be powered up for the analog signal to be read correctly.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL
1-20 Installation/Wiring

Start and Speed Reference Control

The drive speed command can be obtained from a number of different sources. The source is
normally determined by P038 [Speed Reference]. However, when A051 - A054 [Digital Inx Sel] is
set to option 2, 4, 5, 6, 11, 12, 13, 14, 15 and the digital input is active, or if A132 is not set to
option 0, the speed reference commanded by P038 [Speed Reference] will be overridden. See the
chart below for the override priority.

Drive will Start and Run

Jog Input at Jog Speed.
Enabled and Active: Drive Stopped
Yes Yes Direction comes from
A051, A052, A053 (Not Running)
or A054 = 2, 11, 12 I/O Terminal 03 Dir/Run REV
or
Jog Forward/Jog Reverse command
No
No

Local/Remote Input Start, Speed and Direction commands

Yes
Enabled and Active: come from Integral Keypad.
[Digital Inx Sel] = 5

No

Comm Select Input Start, Speed and Direction commands

Yes
Enabled and Active: come from RS485 (DSI) port.
[Digital Inx Sel] = 6

No
Speed commands come from 0-10V.
0-10V Override
Enabled and Active: Yes Start and Direction
[Digital Inx Sel] = 13 follows P036 [Start Source]
or
Bi-Polar input when enabled.

No

4-20mA Override Speed commands come from 4-20mA.

Enabled and Active: Yes
[Digital Inx Sel] = 14 Start and Direction
follows P036 [Start Source].

No

Run as specified by
P038 [Speed Refernece].
P038 [Speed Reference] Yes
= 4 or 5 Start and Direction commands come
from P036 [Start Source].

No

Run as specified by
A071-A077 [Preset Freq 1-7].
A051/A052/A053 Yes
Preset Inputs Active Start and Direction commands come
from P036 [Start Source].

No

Run as specified by
PID Enabled: A132 [PID Ref Select].
A132 [PID Ref Select] Yes
≠0 Start and Direction commands come
from P036 [Start Source].

No
Run as specified by
P038 [Speed Reference].
Start and Direction commands come
from P036 [Start Source].
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Installation/Wiring 1-21

Accel/Decel Selection
The Accel/Decel rate can be obtained by a variety of methods. The
default rate is determined by P039 [Accel Time 1] and P040 [Decel Time
1]. Alternative Accel/Decel rates can be made through digital inputs,
RS485 (DSI) communications and/or parameters. See the chart below
for the override priority.

Jog Input Drive will Start and Run

Enabled and Active: Drive Stopped at Jog Speed.
Yes Yes
A051, A052, A053 (Not Running)
or A054 = 2, 11,12 Drive will use A079 [Jog Accel/Decel]

No
No
Either
P039 [Accel Time 1]/P040 [Decel Time 1]
RS485 (DSI) Port Yes or
Controls Speed A067 [Accel Time 2]/A068 [Decel Time 2]
can be selected when
RS485 (DSI) port is active.

No

Input is programmed A067 [Accel Time 2]/A068 [Decel Time 2]

Yes
as "Accel 2 & Decel 2" is active when input is active.
A051, A052, A053
or A054 = 1

No

P039 [Accel Time 1]/P040 [Decel Time 1];

A067 [Accel Time 2]/A068 [Decel Time 2]
Speed is controlled Yes determined by the active
by [Preset Freq x]
Preset Frequency.
See A070-A077 [Preset Freq 0-7]

No
Either
P039 [Accel Time 1]/P040 [Decel Time 1]
or
Speed is controlled Yes A067 [Accel Time 2]/A068 [Decel Time 2]
by Stp Logic
can be selected by the Digit 3 setting
of the Step Logic parameters.
See A140-A147 [Stp Logic 0-7]
No

P039 [Accel Time 1]/P040 [Decel Time 1]

are used.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

1-22 Installation/Wiring

EMC Instructions
CE Conformity
Conformity with the Low Voltage (LV) Directive and Electromagnetic
Compatibility (EMC) Directive has been demonstrated using
harmonized European Norm (EN) standards published in the Official
Journal of the European Communities. PowerFlex Drives comply with
the EN standards listed below when installed according to the User
Manual.

CE Declarations of Conformity are available online at:

http://www.ab.com/certification/ce/docs.

Low Voltage Directive (73/23/EEC)

• EN50178 Electronic equipment for use in power installations
EMC Directive (89/336/EEC)
• EN61800-3 Adjustable speed electrical power drive systems Part 3:
EMC product standard including specific test methods.
General Notes
• If the plastic top panel is removed or the optional conduit box is not
installed, the drive must be installed in an enclosure with side
openings less than 12.5 mm (0.5 in.) and top openings less than 1.0
mm (0.04 in.) to maintain compliance with the LV Directive.
• The motor cable should be kept as short as possible in order to avoid
electromagnetic emission as well as capacitive currents.
• Use of line filters in ungrounded systems is not recommended.
• Conformity of the drive with CE EMC requirements does not
guarantee an entire machine installation complies with CE EMC
requirements. Many factors can influence total machine/installation
compliance.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Installation/Wiring 1-23

Essential Requirements for CE Compliance

Conditions 1-3 listed below must be satisfied for PowerFlex drives to
meet the requirements of EN61800-3.

1. Grounding as described in Figure 1.6. Refer to page 1-5 for

additional grounding recommendations.
2. Output power, control (I/O) and signal wiring must be braided,
shielded cable with a coverage of 75% or better, metal conduit or
equivalent attenuation.
3. Allowable cable length in Table 1.I is not exceeded.
Table 1.I Allowable Cable Length

Filter Type EN61800-3 First Environment EN61800-3 First Environment

Restricted Distribution or Unrestricted Distribution (3)
Second Environment (2)
Integral 10 meters (33 feet) 1 meter (3 feet)
(1)
External - S Type 10 meters (33 feet) 1 meter (3 feet)
External - L Type(1) 100 meters (328 feet) 5 meters (16 feet)
(1) Refer to Appendix B for details on optional external filters.
(2) Equivalent to EN55011 Class A.
(3) Equivalent to EN55011 Class B.

Figure 1.6 Connections and Grounding

(1)
Shielded Enclosure

IP 30/NEMA 1/UL Type 1

Option Kit

(2)
EMI Fittings and Metal Conduit
EMI Filter
L1 L1' R/L1 U/T1
S/L2 V/T2
L2 L2'
T/L3 W/T3
L3 L3'

Enclosure Ground Connection Shielded Motor Cable

Building Structure Steel

(1) First Environment Unrestricted Distribution installations require a shielded enclosure.

Keep wire length as short as possible between the enclosure entry point and the EMI
filter.
(2) Integral EMI filters are available on 240V, 1-Phase drives.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

1-24 Installation/Wiring

EN61000-3-2
• 0.75 kW (1 HP) 240V 1-Phase and 3-Phase drives and 0.37 kW (0.5
HP) 240V 1-Phase drives are suitable for installation on a private low
voltage power network. Installations on a public low voltage power
network may require additional external harmonic mitigation.
• Other drive ratings meet the current harmonic requirements of
EN61000-3-2 without additional external mitigation.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Chapter 2

Start Up
This chapter describes how to start up the PowerFlex 40 Drive. To
simplify drive setup, the most commonly programmed parameters are
organized in a single Basic Program Group.

Important: Read the General Precautions section before proceeding.

ATTENTION: Power must be applied to the drive to perform the

following start-up procedures. Some of the voltages present are at
! incoming line potential. To avoid electric shock hazard or damage to
equipment, only qualified service personnel should perform the
following procedure. Thoroughly read and understand the procedure
before beginning. If an event does not occur while performing this
procedure, Do Not Proceed. Remove All Power including user
supplied control voltages. User supplied voltages may exist even when
main AC power is not applied to the drive. Correct the malfunction
before continuing.

Prepare For Drive Start-Up

Before Applying Power to the Drive
❏ 1. Confirm that all inputs are connected to the correct terminals and are
secure.

❏ 2. Verify that AC line power at the disconnect device is within the rated
value of the drive.

❏ 3. Verify that any digital control power is 24 volts.

❏ 4. Verify that the Sink (SNK)/Source (SRC) Setup DIP Switch is set to
match your control wiring scheme. See Table 1.H on page 1-15 for
location.

Important: The default control scheme is Source (SRC). The Stop

terminal is jumpered (I/O Terminals 01 and 11) to allow
starting from the keypad. If the control scheme is changed
to Sink (SNK), the jumper must be removed from I/O
Terminals 01 and 11 and installed between I/O Terminals
01 and 04.

❏ 5. Verify that the Stop input is present or the drive will not start.
Important: If I/O Terminal 01 is used as a stop input, the jumper
between I/O Terminals 01 and 11 must be removed.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

2-2 Start Up

Applying Power to the Drive

❏ 6. Apply AC power and control voltages to the drive.
❏ 7. Familiarize yourself with the integral keypad features (see page 2-3)
before setting any Program Group parameters.
Start, Stop, Direction and Speed Control
Factory default parameter values allow the drive to be controlled from
the integral keypad. No programming is required to start, stop, change
direction and control speed directly from the integral keypad.

Important: To disable reverse operation, see A095 [Reverse Disable].

If a fault appears on power up, refer to Fault Descriptions on page 4-3

for an explanation of the fault code.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Start Up 2-3

Integral Keypad

➋
➊
RUN
➌
VOLTS
Menu Description
FWD AMPS Display Group (View Only)
REV HERTZ
Consists of commonly viewed drive operating
PROGRAM FAULT conditions.
➍ ➎ Basic Program Group
Consists of most commonly used
programmable functions.
➏ ➐ ➑ Advanced Program Group
Consists of remaining programmable functions.

➒ Fault Designator
Consists of list of codes for specific fault
conditions. Displayed only when fault is present.

No. LED LED State Description

➊ Run/Direction
Status
Steady Red Indicates drive is running and commanded motor direction.
Flashing Red Drive has been commanded to change direction. Indicates
actual motor direction while decelerating to zero.
➋ Alphanumeric
Display
Steady Red Indicates parameter number, parameter value, or fault code.
Flashing Red Single digit flashing indicates that digit can be edited.
All digits flashing indicates a fault condition.
➌ Displayed Units Steady Red Indicates the units of the parameter value being displayed.

➍ Program Status Steady Red Indicates parameter value can be changed.

➎ Fault Status Flashing Red Indicates drive is faulted.

➏ Pot Status Steady Green Indicates potentiometer on Integral Keypad is active.

➐ Start Key Status Steady Green Indicates Start key on Integral Keypad is active.
The Reverse key is also active unless disabled by A095
[Reverse Disable].

No. Key Name Description

➑ Escape Back one step in programming menu.
Cancel a change to a parameter value and exit Program
Mode.
Select Advance one step in programming menu.
Select a digit when viewing parameter value.
Up Arrow Scroll through groups and parameters.
Down Arrow Increase/decrease the value of a flashing digit.
Enter Advance one step in programming menu.
Save a change to a parameter value.
➒ Potentiometer Used to control speed of drive. Default is active.
Controlled by parameter P038 [Speed Reference].

Start Used to start the drive. Default is active.

Controlled by parameter P036 [Start Source].
Reverse Used to reverse direction of the drive. Default is active.
Controlled by parameters P036 [Start Source] and A095
[Reverse Disable].
Stop Used to stop the drive or clear a fault.
This key is always active.
Controlled by parameter P037 [Stop Mode].
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL
2-4 Start Up

Viewing and Editing Parameters

The last user-selected Display Group parameter is saved when power is removed and is displayed by
default when power is reapplied.
The following is an example of basic integral keypad and display functions. This example provides basic
navigation instructions and illustrates how to program the first Program Group parameter.
Step Key(s) Example Displays
1. When power is applied, the last user-selected VOLTS
Display Group parameter number is briefly AMPS
HERTZ
displayed with flashing characters. The display PROGRAM FAULT
then defaults to that parameter’s current value.
(Example shows the value of d001 [Output
Freq] with the drive stopped.)
2. Press Esc once to display the Display Group VOLTS
AMPS
parameter number shown on power-up. The HERTZ

parameter number will flash. PROGRAM FAULT

3. Press Esc again to enter the group menu. The VOLTS

group menu letter will flash. AMPS
HERTZ

4. Press the Up Arrow or Down Arrow to scroll PROGRAM FAULT

through the group menu (d, P and A).

or
5. Press Enter or Sel to enter a group. The right or VOLTS
AMPS
digit of the last viewed parameter in that group HERTZ

will flash. PROGRAM FAULT

6. Press the Up Arrow or Down Arrow to scroll or

through the parameters that are in the group.
7. Press Enter or Sel to view the value of a
parameter. If you do not want to edit the value,
or VOLTS
AMPS
HERTZ
press Esc to return to the parameter number. PROGRAM FAULT

8. Press Enter or Sel to enter program mode to

edit the parameter value. The right digit will or VOLTS
AMPS
HERTZ
flash and the Program LED will illuminate if the PROGRAM FAULT
parameter can be edited.
9. Press the Up Arrow or Down Arrow to change
the parameter value. If desired, press Sel to
or
move from digit to digit or bit to bit. The digit or
bit that you can change will flash.
10. Press Esc to cancel a change. The digit will
stop flashing, the previous value is restored and
the Program LED will turn off.
Or
Press Enter to save a change. The digit will stop VOLTS
AMPS
flashing and the Program LED will turn off. HERTZ

PROGRAM FAULT

11. Press Esc to return to the parameter list. VOLTS

AMPS
Continue to press Esc to back out of the HERTZ
programming menu. PROGRAM FAULT

If pressing Esc does not change the display,

then d001 [Output Frequency] is displayed.
Press Enter or Sel to enter the group menu.
The Basic Program Group (page 3-9) contains the most commonly changed parameters.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Chapter 3

Programming and Parameters

Chapter 3 provides a complete listing and description of the PowerFlex

40 parameters. Parameters are programmed (viewed/edited) using the
integral keypad. As an alternative, programming can also be performed
using DriveExplorer™ or DriveExecutive™ software, a personal
computer and a serial converter module. Refer to Appendix B for catalog
numbers.

For information on… See page…

About Parameters 3-1
Parameter Organization 3-2
Basic Program Group 3-9
Advanced Program Group 3-14
Parameter Cross Reference – by Name 3-41

About Parameters
To configure a drive to operate in a specific way, drive parameters may
have to be set. Three types of parameters exist:

• ENUM
ENUM parameters allow a selection from 2 or more items. Each
item is represented by a number.
• Numeric Parameters
These parameters have a single numerical value (i.e. 0.1 Volts).
• Bit Parameters
Bit parameters have four individual bits associated with features or
conditions. If the bit is 0, the feature is off or the condition is false. If
the bit is 1, the feature is on or the condition is true.
Some parameters are marked as follows.

= Stop drive before changing this parameter.

32
= 32 bit parameter. Parameters marked 32 bit will have two
parameter numbers when using RS485 communications and
programming software.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-2 Programming and Parameters

Parameter Organization
Refer to page 3-41 for an alphabetical listing of parameters.
Displa Ad
y Gro
up Progrvanced
am G
roup

See page 3-3 See page 3-14 See page 3-14

Output Freq d001 Digital In1 Sel A051 Comm Data Rate A103
Commanded Freq d002 Digital In2 Sel A052 Comm Node Addr A104
Output Current d003 Digital In3 Sel A053 Comm Loss Action A105
Output Voltage d004 Digital In4 Sel A054 Comm Loss Time A106
DC Bus Voltage d005 Relay Out Sel A055 Comm Format A107
Drive Status d006 Relay Out Level A056 Language A108
Fault 1 Code d007 Opto Out1 Sel A058 Anlg In 0-10V Lo A110
Fault 2 Code d008 Opto Out1 Level A059 Anlg In 0-10V Hi A111
Fault 3 Code d009 Opto Out2 Sel A061 Anlg In4-20mA Lo A112
Process Display d010 Opto Out2 Level A062 Anlg In4-20mA Hi A113
Control Source d012 Opto Out Logic A064 Slip Hertz @ FLA A114
Contrl In Status d013 Analog Out Sel A065 Current Limit 2 A118
Dig In Status d014 Analog Out High A066 Skip Frequency A119
Comm Status d015 Accel Time 2 A067 Skip Freq Band A120
Control SW Ver d016 Decel Time 2 A068 Stall Fault Time A121
Drive Type d017 Internal Freq A069 Analog In Loss A122
Elapsed Run Time d018 Preset Freq 0 A070 10V Bipolar Enbl A123
Testpoint Data d019 Preset Freq 1 A071 Var PWM Disable A124
Analog In 0-10V d020 Preset Freq 2 A072 Torque Perf Mode A125
Analog In 4-20mA d021 Preset Freq 3 A073 Motor NP FLA A126
Output Power d022 Preset Freq 4 A074 Autotune A127
Output Power Fctr d023 Preset Freq 5 A075 IR Voltage Drop A128
Drive Temp d024 Preset Freq 6 A076 Flux Current Ref A129
Counter Status d025 Preset Freq 7 A077 PID Trim Hi A130
Timer Status d026 Jog Frequency A078 PID Trim Lo A131
Stp Logic Status d028 Jog Accel/Decel A079 PID Ref Sel A132
DC Brake Time A080 PID Feedback Sel A133
DC Brake Level A081 PID Prop Gain A134
B
Progr asic DB Resistor Sel A082 PID Integ Time A135
am G
rou p S Curve % A083 PID Diff Rate A136
Boost Select A084 PID Setpoint A137
Start Boost A085 PID Deadband A138
Break Voltage A086 PID Preload A139
Break Frequency A087 Stp Logic 0 A140
Maximum Voltage A088 Stp Logic 1 A141
Current Limit 1 A089 Stp Logic 2 A142
Motor OL Select A090 Stp Logic 3 A143
See page 3-9 PWM Frequency A091 Stp Logic 4 A144
Motor NP Volts P031 Auto Rstrt Tries A092 Stp Logic 5 A145
Motor NP Hertz P032 Auto Rstrt Delay A093 Stp Logic 6 A146
Motor OL Current P033 Start At PowerUp A094 Stp Logic 7 A147
Minimum Freq P034 Reverse Disable A095 Stp Logic Time 0 A150
Maximum Freq P035 Flying Start En A096 Stp Logic Time 1 A151
Start Source P036 Compensation A097 Stp Logic Time 2 A152
Stop Mode P037 SW Current Trip A098 Stp Logic Time 3 A153
Speed Reference P038 Process Factor A099 Stp Logic Time 4 A154
Accel Time 1 P039 Fault Clear A100 Stp Logic Time 5 A155
Decel Time 1 P040 Program Lock A101 Stp Logic Time 6 A156
Reset To Defalts P041 Testpoint Sel A102 Stp Logic Time 7 A157
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-3

Display Group
d001 [Output Freq] Related Parameter(s): d002, d010, P034, P035, P038
Output frequency present at T1, T2 & T3 (U, V & W).
Values Default Read Only
Min/Max: 0.0/P035 [Maximum Freq]
Display: 0.1 Hz

d002 [Commanded Freq] Related Parameter(s): d001, d013, P034, P035, P038
Value of the active frequency command. Displays the commanded frequency even if the drive is not
running.
Important: The frequency command can come from a number of sources. Refer to Start and Speed
Reference Control on page 1-20 for details.
Values Default Read Only
Min/Max: 0.0/P035 [Maximum Freq]
Display: 0.1 Hz

d003 [Output Current]

The output current present at T1, T2 & T3 (U, V & W).
Values Default Read Only
Min/Max: 0.00/(Drive Rated Amps × 2)
Display: 0.01 Amps

d004 [Output Voltage] Related Parameter(s): P031, A084, A088

Output voltage present at terminals T1, T2 & T3 (U, V & W).
Values Default Read Only
Min/Max: 0/Drive Rated Volts
Display: 1 VAC

d005 [DC Bus Voltage]

Present DC bus voltage level.
Values Default Read Only
Min/Max: Based on Drive Rating
Display: 1 VDC
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-4 Programming and Parameters

Display Group (continued)

d006 [Drive Status] Related Parameter(s): A095
Present operating condition of the drive.

1 = Condition True, 0 = Condition False

Running Bit 0
Forward Bit 1
Accelerating Bit 2
Decelerating Bit 3

Values Default Read Only

Min/Max: 0/1
Display: 1

d007 [Fault 1 Code]

d008 [Fault 2 Code]
d009 [Fault 3 Code]
A code that represents a drive fault. The codes will appear in these parameters in the order
they occur (d007 [Fault 1 Code] = the most recent fault). Repetitive faults will only be recorded once.
Refer to Chapter 4 for fault code descriptions.
Values Default Read Only
Min/Max: F2/F122
Display: F1

d010 [Process Display] Related Parameter(s): d001, A099

32 32 bit parameter.

The output frequency scaled by A099 [Process Factor].

Output Process Process
Freq x Factor = Display

Values Default Read Only

Min/Max: 0.00/9999
Display: 0.01 – 1
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-5

Display Group (continued)

d012 [Control Source] Related Parameter(s): P036, P038, A051-A054
Displays the active source of the Start Command and Speed Command which are normally defined
by the settings of P036 [Start Source] and P038 [Speed Reference] but may be overridden by digital
inputs. Refer to the flowcharts on pages 1-20 and 1-21 for details.

Start Command Digit 0

0 = Keypad
1 = 3-Wire
2 = 2-Wire
3 = 2-Wire Level Sensitive
4 = 2-Wire High Speed
5 = RS485 (DSI) Port
9 = Jog
Speed Command Digit 1
0 = Drive Potentiometer
1 = A069 [Internal Freq]
2 = 0-10V Input/Remote Potentiometer
3 = 4-20mA Input
4 = A070-A077 [Preset Freq x]
(A051 - A053 [Digital Inx Sel] must be set to 4)
5 = RS485 (DSI) Port
6 = Step Logic Control (Parameters A140 - A147)
9 = Jog Freq
Reserved Digit 2
Reserved Digit 3

Values Default Read Only

Min/Max: 0/9
Display: 1

d013 [Contrl In Status] Related Parameter(s): d002, P034, P035

Status of the control terminal block control inputs.
Important: Actual control commands may come from a source other than the control terminal block.

1 = Input Present, 0 = Input Not Present

Start / Run FWD Input (I/O Terminal 02) Bit 0
Direction / Run REV Input (I/O Terminal 03) Bit 1
Stop Input(1) (I/O Terminal 01) Bit 2
Dynamic Brake Transistor On Bit 3
(1)
The stop input must be present in order to start the drive.
When this bit is a 1 the drive can be started.
When this bit is a 0 the drive will stop.

Values Default Read Only

Min/Max: 0/1
Display: 1
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-6 Programming and Parameters

Display Group (continued)

d014 [Dig In Status] Related Parameter(s): A051-A054
Status of the control terminal block digital inputs.

1 = Input Present, 0 = Input Not Present

Digital In1 Sel (I/O Terminal 05) Bit 0
Digital In2 Sel (I/O Terminal 06) Bit 1
Digital In3 Sel (I/O Terminal 07) Bit 2
Digital In4 Sel (I/O Terminal 08) Bit 3

Values Default Read Only

Min/Max: 0/1
Display: 1

d015 [Comm Status] Related Parameter(s): A103-A107

Status of the communications ports.

1 = Condition True, 0 = Condition False

Receiving Data Bit 0
Transmitting Data Bit 1
RS485 (DSI) Based Option Connected Bit 2
(Allen-Bradley devices only.)
Communication Error Occurred Bit 3

Values Default Read Only

Min/Max: 0/1
Display: 1

d016 [Control SW Ver]

Main Control Board software version.
Values Default Read Only
Min/Max: 1.00/99.99
Display: 0.01

d017 [Drive Type]

Used by Rockwell Automation field service personnel.
Values Default Read Only
Min/Max: 1001/9999
Display: 1
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-7

Display Group (continued)

d018 [Elapsed Run Time]
Accumulated time drive is outputting power. Time is displayed in 10 hour increments.
Values Default Read Only
Min/Max: 0/9999 Hrs
Display: 1 = 10 Hrs

d019 [Testpoint Data] Related Parameter(s): A102

The present value of the function selected in A102 [Testpoint Sel].
Values Default Read Only
Min/Max: 0/FFFF
Display: 1 Hex

d020 [Analog In 0-10V] Related Parameter(s): A110, A111

The present value of the voltage at I/O Terminal 13 (100.0% = 10 volts).
Values Default Read Only
Min/Max: 0.0/100.0%
Display: 0.1%

d021 [Analog In 4-20mA] Related Parameter(s): A112, A113

The present value of the current at I/O Terminal 15 (0.0% = 4mA, 100.0% = 20mA).
Values Default Read Only
Min/Max: 0.0/100.0%
Display: 0.1%

d022 [Output Power]

Output power present at T1, T2 & T3 (U, V & W).
Values Default Read Only
Min/Max: 0.00/(Drive Rated Power × 2)
Display: 0.01 kW

d023 [Output Powr Fctr]

The angle in electrical degrees between motor voltage and motor current.
Values Default Read Only
Min/Max: 0.0/180.0 deg
Display: 0.1 deg
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-8 Programming and Parameters

Display Group (continued)

d024 [Drive Temp]
Present operating temperature of the drive power section.
Values Default Read Only
Min/Max: 0/120 degC
Display: 1 degC

d025 [Counter Status]

The current value of the counter when counter is enabled.
Values Default Read only
Min/Max: 0/9999
Display: 1

d026 [Timer Status]

32 32 bit parameter.
The current value of the timer when timer is enabled.
Values Default Read Only
Min/Max: 0.0/9999 Secs
Display: 0.1 Secs

d028 [Stp Logic Status]

When P038 [Speed Reference] is set to 6 “Stp Logic”, this parameter will display the current step of
the step logic profile as defined by parameters A140-A147 [Stp Logic x].
Values Default Read Only
Min/Max: 0/7
Display: 1
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-9

Basic Program Group

P031 [Motor NP Volts] Related Parameter(s): d004, A084, A085, A086, A087
Stop drive before changing this parameter.
Set to the motor nameplate rated volts.
Values Default Based on Drive Rating
Min/Max: 20/Drive Rated Volts
Display: 1 VAC

P032 [Motor NP Hertz] Related Parameter(s): A084, A085, A086, A087, A090
Stop drive before changing this parameter.
Set to the motor nameplate rated frequency.
Values Default 60 Hz
Min/Max: 15/400 Hz
Display: 1 Hz

P033 [Motor OL Current] Related Parameter(s): A055, A058, A061, A089, A090,
A098, A114, A118
Set to the maximum allowable motor current.
The drive will fault on an F7 Motor Overload if the value of this parameter is exceeded by 150% for 60
seconds.
Values Default Based on Drive Rating
Min/Max: 0.0/(Drive Rated Amps × 2)
Display: 0.1 Amps

P034 [Minimum Freq] Related Parameter(s): d001, d002, d013, P035, A085,
A086, A087, A110, A112
Sets the lowest frequency the drive will output continuously.
Values Default 0.0 Hz
Min/Max: 0.0/400.0 Hz
Display: 0.1 Hz

P035 [Maximum Freq] Related Parameter(s): d001, d002, d013, P034, A065,
A078, A085, A086, A087, A111, A113
Stop drive before changing this parameter.
Sets the highest frequency the drive will output.
Values Default 60 Hz
Min/Max: 0/400 Hz
Display: 1 Hz
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-10 Programming and Parameters

Basic Program Group (continued)

P036 [Start Source] Related Parameter(s): d012, P037
Stop drive before changing this parameter.
Sets the control scheme used to start the drive.
Refer to Start and Speed Reference Control on page 1-20 for details about how other drive settings
can override the setting of this parameter.
Important: For all settings except option 3, the drive must receive a leading edge from the start input
for the drive to start after a stop input, loss of power or fault condition.
Options 0 “Keypad” (Default) • Integral keypad controls drive operation.
• I/O Terminal 1 “Stop” = coast to stop.
• When active, the Reverse key is also active unless
disabled by A095 [Reverse Disable].
1 “3-Wire” I/O Terminal 1 “Stop” = stop according to the value set
in P037 [Stop Mode].
2 “2-Wire” I/O Terminal 1 “Stop” = coast to stop.
3 “2-W Lvl Sens” Drive will restart after a “Stop” command when:
• Stop is removed
and
• Start is held active

ATTENTION: Hazard of injury exists due to unintended operation. When

P036 [Start Source] is set to option 3, and the Run input is maintained, the
! Run inputs do not need to be toggled after a Stop input for the drive to run
again. A Stop function is provided only when the Stop input is active (open).

4 “2-W Hi Speed” Important: There is greater potential voltage on the output

terminals when using this option.
• Outputs are kept in a ready-to-run state. The drive will
respond to a “Start” command within 10 ms.
• I/O Terminal 1 “Stop” = coast to stop.
5 “Comm Port” • Remote communications. Refer to Appendix C for details.
• I/O Terminal 1 “Stop” = coast to stop.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-11

Basic Program Group (continued)

P037 [Stop Mode] Related Parameter(s): P036, A080, A081, A082, A105
Active stop mode for all stop sources [e.g. keypad, run forward (I/O Terminal 02), run reverse (I/O
Terminal 03), RS485 port] except as noted below.
Important: I/O Terminal 01 is always a coast to stop input except when P036 [Start Source] is set for
“3-Wire” control. When in three wire control, I/O Terminal 01 is controlled by P037 [Stop Mode].

Hardware Enable Circuitry

By default, I/O Terminal 01 is a coast to stop input. The status of the input is interpreted by drive
software. If the application requires the drive to be disabled without software interpretation, a “dedicat-
ed” hardware enable configuration can be utilized. This is accomplished by removing the ENBL
enable jumper on the control board. In this case, the drive will always coast to a stop regardless of the
settings of P036 [Start Source] and P037 [Stop Mode].

Options 0 “Ramp, CF”(1) (Default) Ramp to Stop. “Stop” command clears active fault.
1 “Coast, CF”(1) Coast to Stop. “Stop” command clears active fault.
2 “DC Brake, CF”(1) DC Injection Braking Stop. “Stop” command clears active
fault.
3 “DCBrkAuto,CF”(1) DC Injection Braking Stop with Auto Shutoff.
• Standard DC Injection Braking for value set in A080 [DC
Brake Time].
OR
• Drive shuts off if the drive detects that the motor is
stopped.
“Stop” command clears active fault.
4 “Ramp” Ramp to Stop.
5 “Coast” Coast to Stop.
6 “DC Brake” DC Injection Braking Stop.
7 “DC BrakeAuto” DC Injection Braking Stop with Auto Shutoff.
• Standard DC Injection Braking for value set in A080 [DC
Brake Time].
OR
• Drive shuts off if current limit is exceeded.
(1) Stop input also clears active fault.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-12 Programming and Parameters

Basic Program Group (continued)

P038 [Speed Reference] Related Parameter(s): d001, d002, d012, P039, P040, A051-A054,
A069, A070-A077, A110, A111, A112, A113, A123, A132, A140-A147, A150-A157
Sets the source of the speed reference to the drive.
The drive speed command can be obtained from a number of different sources. The source is
normally determined by P038 [Speed Reference]. However, when A051 - A054 [Digital Inx Sel] is set
to option 2, 4, 5, 6, 11, 12, 13, 14, 15 and the digital input is active, or if A132 [PID Ref Sel] is not set
to option 0, the speed reference commanded by P038 [Speed Reference] will be overridden. Refer to
the flowchart on page 1-20 for more information on speed reference control priority.
Options 0 “Drive Pot” (Default) Internal frequency command from the potentiometer on the
integral keypad.
1 “InternalFreq” Internal frequency command from A069 [Internal Freq]. Must
be set when using MOP function.
2 “0-10V Input” External frequency command from the 0-10V or ±10V analog
input or remote potentiometer.
3 “4-20mA Input” External frequency command from the 4-20mA analog input.
4 “Preset Freq” External frequency command as defined by A070 - A077
[Preset Freq x] when A051 - A054 [Digital Inx Sel] are
programmed as “Preset Frequencies” and the digital inputs
are active.
5 “Comm Port” External frequency command from the communications port.
Refer to Appendix C for details.
6 “Stp Logic” External frequency command as defined by A070 - A077
[Preset Freq x] and A140 - A147 [Stp Logic x].

P039 [Accel Time 1] Related Parameter(s): P038, P040, A051-A054,

A067, A070-A077, A140-A147
Sets the rate of acceleration for all speed increases.
Maximum Freq
= Accel Rate
Accel Time

Values Default 10.0 Secs

Min/Max: 0.0/600.0 Secs
Display: 0.1 Secs

P035 [Maximum Freq]

De
on

cel
rati

era

Speed
ele

tion
Acc

0
P039 or A067 Time P040 or A068
[Accel Time x] [Decel Time x]
0
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-13

Basic Program Group (continued)

P040 [Decel Time 1] Related Parameter(s): P038, P039, A051-A054,
A068, A070-A077, A140-A147
Sets the rate of deceleration for all speed decreases.
Maximum Freq
= Decel Rate
Decel Time

Values Default 10.0 Secs

Min/Max: 0.1/600.0 Secs
Display: 0.1 Secs

P035 [Maximum Freq]

De
on

cel
rati

era

Speed
ele

tion
Acc

0
P039 or A067 Time P040 or A068
[Accel Time x] [Decel Time x]
0

P041 [Reset To Defalts]

Stop drive before changing this parameter.
Resets all parameter values to factory defaults.
Options 0 “Ready/Idle” (Default)
1 “Factory Rset” • After the reset function is complete, this parameter will set
itself back to “0”.
• Causes an F48 Params Defaulted fault.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-14 Programming and Parameters

Advanced Program Group

A051 [Digital In1 Sel] Related Parameter(s): d012, d014, P038, P039, P040,
(I/O Terminal 05) A067, A068, A070-A077, A078, A079, A118, A140-A147
A052 [Digital In2 Sel]
(I/O Terminal 06)
Stop drive before changing this parameter.
A053 [Digital In3 Sel]
(I/O Terminal 07)
A054 [Digital In4 Sel]
(I/O Terminal 08)
Selects the function for the digital inputs. Refer to the flowchart on page 1-20 for more information on
speed reference control priority.
Options 0 “Not Used” Terminal has no function but can be read over network
communications via d014 [Dig In Status].
1 “Acc & Dec 2” • When active, A067 [Accel Time 2] and A068 [Decel Time
2] are used for all ramp rates except Jog.
• Can only be tied to one input.
Refer to the flowchart on page 1-21 for more information on
Accel/Decel selection.
2 “Jog” • When input is present, drive accelerates according to the
value set in A079 [Jog Accel/Decel] and ramps to the
value set in A078 [Jog Frequency].
• When input is removed, drive ramps to a stop according to
the value set in A079 [Jog Accel/Decel].
• A valid “Start” command will override this input.
3 “Aux Fault” When enabled, an F2 Auxiliary Input fault will occur when the
input is removed.
4 “Preset Freq” Refer to A070 - A077 [Preset Freq x].
(A051 & A052 Default) Important: Digital Inputs have priority for frequency control
when programmed as Preset Speed and are active. Refer to
the flowchart on page 1-20 for more information on speed
reference control priority.
5 “Local” When active, sets integral keypad as start source and
(A053 Default) potentiometer on the integral keypad as speed source.
6 “Comm Port” • When active, sets communications device as default start/
speed command source.
• Can only be tied to one input.
7 “Clear Fault” When active, clears an active fault.
8 “RampStop,CF” Causes drive to immediately ramp to a stop regardless
of how P037 [Stop Mode] is set.
9 “CoastStop,CF” Causes drive to immediately coast to a stop regardless of
how P037 [Stop Mode] is set.
10 “DCInjStop,CF” Causes drive to immediately begin a DC Injection stop
regardless of how P037 [Stop Mode] is set.
11 “Jog Forward” Drive accelerates to A078 [Jog Frequency] according to A079
(A054 Default) [Jog Accel/Decel] and ramps to stop when input becomes
inactive. A valid start will override this command.
12 “Jog Reverse” Drive accelerates to A078 [Jog Frequency] according to A079
[Jog Accel/Decel] and ramps to stop when input becomes
inactive. A valid start will override this command.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-15

A051 - 13 “10V In Ctrl” Selects 0-10V or ±10V control as the frequency reference.
A054 Start source is not changed.
Options 14 “20mA In Ctrl” Selects 4-20mA control as the frequency reference. Start
(Cont.) source is not changed.
15 “PID Disable” Disables PID function. Drive uses the next valid non-PID
speed reference.
16 “MOP Up” Increases the value of A069 [Internal Freq] at a rate of 2 Hz
per second. Default for A069 is 60 Hz.
17 “MOP Down” Decreases the value of A069 [Internal Freq] at a rate of 2 Hz
per second. Default for A069 is 60 Hz.
18 “Timer Start” Clears and starts the timer function. May be used to control
the relay or opto outputs.
19 “Counter In” Starts the counter function. May be used to control the relay
or opto outputs.
20 “Reset Timer” Clears the active timer.
21 “Reset Countr” Clears the active counter.
22 “Rset Tim&Cnt” Clears the active timer and counter.
23 “Logic In1” Logic function input number 1. May be used to control the
relay or opto outputs (see parameters A055, A058, A061
Options 11-14). May be used in conjunction with Step Logic
parameters A140 - A147 [Stp Logic x].
24 “Logic In2” Logic function input number 2. May be used to control the
relay or opto outputs (see parameters A055, A058, A061
Options 11-14). May be used in conjunction with Step Logic
parameters A140 - A147 [Stp Logic x].
25 “Current Lmt2” When active, A118 [Current Limit 2] determines the drive
current limit level.

A055 [Relay Out Sel] Related Parameter(s): P033, A056, A092, A140-A147, A150-A157
Sets the condition that changes the state of the output relay contacts.
Options 0 “Ready/Fault” Relay changes state when power is applied. This indicates
(Default) that the drive is ready for operation. Relay returns drive to
shelf state when power is removed or a fault occurs.
1 “At Frequency” Drive reaches commanded frequency.
2 “MotorRunning” Motor is receiving power from the drive.
3 “Reverse” Drive is commanded to run in reverse direction.
4 “Motor Overld” Motor overload condition exists.
5 “Ramp Reg” Ramp regulator is modifying the programmed accel/decel
times to avoid an overcurrent or overvoltage fault from
occurring.
6 “Above Freq” • Drive exceeds the frequency (Hz) value set in A056 [Relay
Out Level].
• Use A056 to set threshold.
7 “Above Cur” • Drive exceeds the current (% Amps) value set in A056
[Relay Out Level].
• Use A056 to set threshold.
Important: Value for A056 [Relay Out Level] must be entered
in percent of drive rated output current.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-16 Programming and Parameters

A055 8 “Above DCVolt” • Drive exceeds the DC bus voltage value set in A056
Options [Relay Out Level].
(Cont.) • Use A056 to set threshold.
9 “Retries Exst” Value set in A092 [Auto Rstrt Tries] is exceeded.
10 “Above Anlg V” • Analog input voltage (I/O Terminal 13) exceeds the value
set in A056 [Relay Out Level].
• Do not use if A123 [10V Bipolar Enbl] is set to 1 “Bi-Polar
In”.
• This parameter setting can also be used to indicate a PTC
trip point when the input (I/O Terminal 13) is wired to a
PTC and external resistor.
• Use A056 to set threshold.
11 “Logic In 1” An input is programmed as “Logic In 1” and is active.
12 “Logic In 2” An input is programmed as “Logic In 2” and is active.
13 “Logic 1 & 2” Both Logic inputs are programmed and active.
14 “Logic 1 or 2” One or both Logic inputs are programmed and one or both is
active.
15 “StpLogic Out” Drive enters Step Logic step with Digit 3 of Command Word
(A140 - A147) set to enable Step Logic output.
16 “Timer Out” • Timer has reached value set in A056 [Relay Out Level].
• Use A056 to set threshold.
17 “Counter Out” • Counter has reached value set in A056 [Relay Out Level].
• Use A056 to set threshold.
18 “Above PF Ang” • Power Factor angle has exceeded the value set in A056
[Relay Out Level].
• Use A056 to set threshold.
19 “Anlg In Loss” Analog input loss has occurred. Program A122 [Analog In
Loss] for desired action when input loss occurs.
20 “ParamControl” Enables the output to be controlled over network
communications by writing to A056 [Relay Out Level].
(0 = Off, 1 = On.)

A056 [Relay Out Level] Related Parameter(s): A055, A058, A061

32 32 bit parameter.
Sets the trip point for the digital output relay if the value of A055 [Relay Out Sel] is 6, 7, 8, 10, 16, 17,
18 or 20.

A055 Setting A056 Min/Max

6 0/400 Hz
7 0/180%
8 0/815 Volts
10 0/100%
16 0.1/9999 Secs
17 1/9999 Counts
18 1/180 degs
20 0/1

Values Default 0.0

Min/Max: 0.0/9999
Display: 0.1
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-17

Advanced Program Group (continued)

A058 [Opto Out1 Sel] Related Parameter(s): P033, A056, A092, A140-A147, A150-A157
A061 [Opto Out2 Sel]
Determines the operation of the programmable opto outputs.
Options 0 “Ready/Fault” Opto outputs are active when power is applied. This indicates
that the drive is ready for operation. Opto outputs are inactive
when power is removed or a fault occurs.
1 “At Frequency” Drive reaches commanded frequency.
(A061 Default)
2 “MotorRunning” Motor is receiving power from the drive.
(A058 Default)
3 “Reverse” Drive is commanded to run in reverse direction.
4 “Motor Overld” Motor overload condition exists.
5 “Ramp Reg” Ramp regulator is modifying the programmed accel/decel
times to avoid an overcurrent or overvoltage fault from
occurring.
6 “Above Freq” • Drive exceeds the frequency (Hz) value set in A059 or
A062 [Opto Outx Level].
• Use A059 or A062 to set threshold.
7 “Above Cur” • Drive exceeds the current (% Amps) value set in A059 or
A062 [Opto Outx Level].
• Use A059 or A062 to set threshold.
Important: Value for A059 or A062 [Opto Outx Level] must be
entered in percent of drive rated output current.
8 “Above DCVolt” • Drive exceeds the DC bus voltage value set in A059 or
A062 [Opto Outx Level].
• Use A059 or A062 to set threshold.
9 “Retries Exst” Value set in A092 [Auto Rstrt Tries] is exceeded.
10 “Above Anlg V” • Analog input voltage (I/O Terminal 13) exceeds the value
set in A059 or A062 [Opto Outx Level].
• Do not use if A123 [10V Bipolar Enbl] is set to 1 “Bi-Polar
In”.
• This parameter setting can also be used to indicate a PTC
trip point when the input (I/O Terminal 13) is wired to a
PTC and external resistor.
• Use A059 or A062 to set threshold.
11 “Logic In 1” An input is programmed as “Logic In 1” and is active.
12 “Logic In 2” An input is programmed as “Logic In 2” and is active.
13 “Logic 1 & 2” Both Logic inputs are programmed and active.
14 “Logic 1 or 2” One or both Logic inputs are programmed and one or both is
active.
15 “StpLogic Out” Drive enters Step Logic step with Digit 3 of Command Word
(A140 - A147) set to enable Step Logic output.
16 “Timer Out” • Timer has reached value set in A059 or A062 [Opto Outx
Level].
• Use A059 or A062 to set threshold.
17 “Counter Out” • Counter has reached value set in A059 or A062 [Opto
Outx Level].
• Use A059 or A062 to set threshold.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-18 Programming and Parameters

A058, 18 “Above PF Ang” • Power Factor angle has exceeded the value set in A059 or
A061 A062 [Opto Outx Level].
Options • Use A059 or A062 to set threshold.
(Cont.) 19 “Anlg In Loss” Analog input loss has occurred. Program A122 [Analog In
Loss] for desired action when input loss occurs.
20 “ParamControl” Enables the output to be controlled over network
communications by writing to A059 or A062 [Opto Outx
Level].
(0 = Off, 1 = On.)

A059 [Opto Out1 Level]

A062 [Opto Out2 Level]
32 32 bit parameter.
Determines the on/off point for the opto outputs when A058 or A061 [Opto Outx Sel] is set to option 6,
7, 8, 10, 16, 17, 18 or 20.

A058 & A061 Setting A059 & A062 Min/Max

6 0/400 Hz
7 0/180%
8 0/815 Volts
10 0/100%
16 0.1/9999 Secs
17 1/9999 Counts
18 1/180 degs
20 0/1

Values Default 0.0

Min/Max: 0.0/9999
Display: 0.1

A064 [Opto Out Logic]

Determines the logic (Normally Open/NO or Normally Closed/NC) of the opto outputs.

A064 Option Opto Out1 Logic Opto Out2 Logic

0 NO (Normally Open) NO (Normally Open)
1 NC (Normally Closed) NO (Normally Open)
2 NO (Normally Open) NC (Normally Closed)
3 NC (Normally Closed) NC (Normally Closed)

Values Default 0
Min/Max: 0/3
Display: 1
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-19

Advanced Program Group (continued)

A065 [Analog Out Sel] Related Parameter(s): P035, A066
Sets the analog output signal mode (0-10V, 0-20mA, or 4-20mA). The output is used to provide a
signal that is proportional to several drive conditions.

Output Minimum Output Maximum Output Value DIP Switch

Option Range Value A066 [Analog Out High] Position
0 “OutFreq 0-10” 0-10V 0V = 0 Hz P035 [Maximum Freq] 0-10V
1 “OutCurr 0-10” 0-10V 0V = 0 Amps 200% Drive Rated Output Current 0-10V
2 “OutVolt 0-10” 0-10V 0V = 0 Volts 120% Drive Rated Output Volts 0-10V
3 “OutPowr 0-10” 0-10V 0V = 0 kW 200% Drive Rated Power 0-10V
4 “TstData 0-10” 0-10V 0V = 0000 65535 (Hex FFFF) 0-10V
5 “OutFreq 0-20” 0-20mA 0 mA = 0 Hz P035 [Maximum Freq] 0-20mA
6 “OutCurr 0-20” 0-20mA 0 mA = 0 Amps 200% Drive Rated Output Current 0-20mA
7 “OutVolt 0-20” 0-20mA 0 mA = 0 Volts 120% Drive Rated Output Volts 0-20mA
8 “OutPowr 0-20” 0-20mA 0 mA = 0 kW 200% Drive Rated Power 0-20mA
9 “TstData 0-20” 0-20mA 0 mA = 0000 65535 (Hex FFFF) 0-20mA
10 “OutFreq 4-20” 4-20mA 4 mA = 0 Hz P035 [Maximum Freq] 0-20mA
11 “OutCurr 4-20” 4-20mA 4 mA = 0 Amps 200% Drive Rated Output Current 0-20mA
12 “OutVolt 4-20” 4-20mA 4 mA = 0 Volts 120% Drive Rated Output Volts 0-20mA
13 “OutPowr 4-20” 4-20mA 4 mA = 0 kW 200% Drive Rated Power 0-20mA
14 “TstData 4-20” 4-20mA 4 mA = 0000 65535 (Hex FFFF) 0-20mA

Values Default 0
Min/Max: 0/14
Display: 1

A066 [Analog Out High] Related Parameter(s): A065

Scales the Maximum Output Value for the A065 [Analog Out Sel] source setting.
Examples:

A066 Setting A065 Setting A065 Max. Output Value

50% 1 “OutCurr 0-10” 5V for 200% Drive Rated Output Current
90% 8 “OutPowr 0-20” 18mA for 200% Drive Rated Power

Values Default 100%

Min/Max: 0/800%
Display: 1%
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL
3-20 Programming and Parameters

Advanced Program Group (continued)

A067 [Accel Time 2] Related Parameter(s): P039, A051-A054, A070-A077, A140-A147
When active, sets the rate of acceleration for all speed increases except jog. Refer to the flowchart on
page 1-21 for details.
Maximum Freq
= Accel Rate
Accel Time

Values Default 20.0 Secs

Min/Max: 0.0/600.0 Secs
Display: 0.1 Secs

P035 [Maximum Freq]

De
on

cel
rati

era
Speed
ele

tion
Acc

0
P039 or A067 Time P040 or A068
[Accel Time x] [Decel Time x]
0

A068 [Decel Time 2] Related Parameter(s): P040, A051-A054, A070-A077, A140-A147

When active, sets the rate of deceleration for all speed decreases except jog. Refer to the flowchart
on page 1-21 for details.
Maximum Freq
= Decel Rate
Decel Time

Values Default 20.0 Secs

Min/Max: 0.1/600.0 Secs
Display: 0.1 Secs

P035 [Maximum Freq]

De
on

cel
rati

era

Speed
ele

ti
Acc

on

0
P039 or A067 Time P040 or A068
[Accel Time x] [Decel Time x]
0

A069 [Internal Freq] Related Parameter(s): P038

Provides the frequency command to the drive when P038 [Speed Reference] is set to 1 “Internal
Freq”. When enabled, this parameter will change the frequency command in “real time” using the
integral keypad Up Arrow or Down Arrow when in program mode.
Important: Once the desired command frequency is reached, the Enter key must be pressed to store
this value to EEPROM memory. If the ESC key is used before the Enter key, the frequency will return
to the original value following the normal accel/decel curve.
If A051 - A054 [Digital Inx Sel] is set to 16 “MOP Up” or 17 “MOP Down” this parameter acts as the
MOP frequency reference.
Values Default 60.0 Hz
Min/Max: 0.0/400.0 Hz
Display: 0.1 Hz
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL
Programming and Parameters 3-21

Advanced Program Group (continued)

A070 [Preset Freq 0](1) Related Parameter(s): P038, P039, P040, A051-A053,
A071 [Preset Freq 1] A067, A068, A140-A147, A150-A157
A072 [Preset Freq 2]
A073 [Preset Freq 3]
A074 [Preset Freq 4]
A075 [Preset Freq 5]
A076 [Preset Freq 6]
A077 [Preset Freq 7]
Values A070 Default(1) 0.0 Hz
A071 Default 5.0 Hz
A072 Default 10.0 Hz
A073 Default 20.0 Hz
A074 Default 30.0 Hz
A075 Default 40.0 Hz
A076 Default 50.0 Hz
A077 Default 60.0 Hz
Min/Max: 0.0/400.0 Hz
Display: 0.1 Hz
Provides a fixed frequency command value when A051 - A053 [Digital Inx Sel] is set to 4 “Preset
Frequencies”.
An active preset input will override speed command as shown in the flowchart on page 1-20.

(1) To activate A070 [Preset Freq 0] set P038 [Speed Reference] to option 4 “Preset Freq 0-3”.

Input State Input State Input State

of Digital In 1 of Digital In 2 of Digital In 3
(I/O Terminal 05 (I/O Terminal 06 (I/O Terminal 07
when A051 = 4) when A052 = 4) when A053 = 4) Frequency Source Accel / Decel Parameter Used(2)
0 0 0 A070 [Preset Freq 0] [Accel Time 1] / [Decel Time 1]
1 0 0 A071 [Preset Freq 1] [Accel Time 1] / [Decel Time 1]
0 1 0 A072 [Preset Freq 2] [Accel Time 2] / [Decel Time 2]
1 1 0 A073 [Preset Freq 3] [Accel Time 2] / [Decel Time 2]
0 0 1 A074 [Preset Freq 4] [Accel Time 1] / [Decel Time 1]
1 0 1 A075 [Preset Freq 5] [Accel Time 1] / [Decel Time 1]
0 1 1 A076 [Preset Freq 6] [Accel Time 2] / [Decel Time 2]
1 1 1 A077 [Preset Freq 7] [Accel Time 2] / [Decel Time 2]
(2)
When a Digital Input is set to “Accel 2 & Decel 2”, and the input is active, that input overrides the settings in this
table.

A078 [Jog Frequency] Related Parameter(s): P035, A051-A054, A079

Sets the output frequency when a jog command is issued.
Values Default 10.0 Hz
Min/Max: 0.0/[Maximum Freq]
Display: 0.1 Hz
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-22 Programming and Parameters

Advanced Program Group (continued)

A079 [Jog Accel/Decel] Related Parameter(s): A078, A051-A054
Sets the acceleration and deceleration time when a jog command is issued.
Values Default 10.0 Secs
Min/Max: 0.1/600.0 Secs
Display: 0.1 Secs

A080 [DC Brake Time] Related Parameter(s): P037, A081

Sets the length of time that DC brake current is “injected” into the motor. Refer to parameter A081 [DC
Brake Level].
Values Default 0.0 Secs
Min/Max: 0.0/99.9 Secs (A setting of 99.9 = Continuous)
Display: 0.1 Secs

A081 [DC Brake Level] Related Parameter(s): P037, A080

Defines the maximum DC brake current, in amps, applied to the motor when P037 [Stop Mode] is set
to either “Ramp” or “DC Brake”.
Values Default Drive Rated Amps × 0.05
Min/Max: 0.0/(Drive Rated Amps × 1.8)
Display: 0.1 Amps

Ramp-to-Stop Mode DC Injection Braking Mode

Voltage
Volts/Speed

Volts/Speed

Vo
lta Speed [DC Brake Time]
ge
Spe [DC Brake Time]
ed
[DC Brake Level] [DC Brake Level]

Time Time
Stop Command Stop Command

ATTENTION: If a hazard of injury due to movement of equipment or material exists,

an auxiliary mechanical braking device must be used.
!
ATTENTION: This feature should not be used with synchronous or permanent
magnet motors. Motors may be demagnetized during braking.
!
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-23

Advanced Program Group (continued)

A082 [DB Resistor Sel] Related Parameter(s): P037
Stop drive before changing this parameter.
Enables/disables external dynamic braking.

Setting Min/Max
0 “Disabled”
1 “Normal RA Res” (5% Duty Cycle) – Refer to Table B.C on page B-2.
2 “NoProtection” (100% Duty Cycle)
3-99 “x%Duty Cycle” Limited (3% – 99% of Duty Cycle)

Values Default 0
Min/Max: 0/99
Display: 1

A083 [S Curve %]
Sets the percentage of acceleration or deceleration time that is applied to the ramp as S Curve. Time
is added, 1/2 at the beginning and 1/2 at the end of the ramp.
Values Default 0% (Disabled)
Min/Max: 0/100%
Display: 1%
Example: 50% S Curve
Accel Time = 10 Seconds Target
S Curve Setting = 50%
S Curve Time = 10 × 0.5 = 5 Seconds
Total Time = 10 + 5 = 15 Seconds
Target/2

1/2 S Curve Time Accel Time 1/2 S Curve Time

2.5 Seconds 10 Seconds 2.5 Seconds
Total Time to Accelerate = Accel Time + S Curve Time
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-24 Programming and Parameters

Advanced Program Group (continued)

A084 [Boost Select] Related Parameter(s): d004, P031, P032, A085,
A086, A087, A125
Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the Volts per Hz curve.
Active when A125 [Torque Perf Mode] = 0 “V/Hz”.
Drive may add additional voltage unless Option 5 is selected.
Options 0 “Custom V/Hz”
1 “30.0, VT”
2 “35.0, VT”
Variable Torque (Typical fan/pump curves.)
3 “40.0, VT”
4 “45.0, VT”
5 “0.0 no IR”
6 “0.0”
7 “2.5, CT”
[Default for
4.0, 5.5 & 7.5 kW
(5.0, 7.5 & 10.0 HP)
Drives]
8 “5.0, CT” (Default) Constant Torque
9 “7.5, CT”
10 “10.0, CT”
11 “12.5, CT”
12 “15.0, CT”
13 “17.5, CT”
14 “20.0, CT”

100
% P031 [Motor NP Volts]

1/2 [Motor NP Volts]

50
4
3
2
1
[Motor NP Hertz]
1/2

Settings
5-14

0 50 100
% P032 [Motor NP Hertz]
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-25

Advanced Program Group (continued)

A085 [Start Boost] Related Parameter(s): P031, P032, P034, P035,
A084, A086, A087, A088, A125
Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the Volts per Hz curve when A084
[Boost Select] = 0 “Custom V/Hz” and A125 [Torque Perf Mode] = 0 “V/Hz”.

Drive may add additional voltage unless Option 5 is selected.

Values Default 2.5%
Min/Max: 0.0/25.0%
Display: 1.1%

A088 [Maximum Voltage]

P031 [Motor NP Volts]

Voltage
A086 [Break Voltage]

A085 [Start Boost]

A087 [Break Frequency] P032 [Motor NP Hertz]

A034 [Minimum Freq] Frequency P035 [Maximum Freq]

A086 [Break Voltage] Related Parameter(s): P031, P032, P034, P035,

A084, A085, A087, A088, A125
Sets the frequency where break voltage is applied when A084 [Boost Select] = 0 “Custom V/Hz” and
A125 [Torque Perf Mode] = 0 “V/Hz”
Values Default 25.0%
Min/Max: 0.0/100.0%
Display: 1.1%

A087 [Break Frequency] Related Parameter(s): P031, P032, P034, P035,

A084, A085, A086, A088, A125
Sets the frequency where break frequency is applied when A084 [Boost Select] = 0 “Custom V/Hz”
and A125 [Torque Perf Mode] = 0 “V/Hz”
Values Default 15.0 Hz
Min/Max: 0.0/400.0 Hz
Display: 0.1 Hz
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL
3-26 Programming and Parameters

Advanced Program Group (continued)

A088 [Maximum Voltage] Related Parameter(s): d004, A085, A086, A087
Sets the highest voltage the drive will output.
Values Default Drive Rated Volts
Min/Max: 20/Drive Rated Volts
Display: 1 VAC

A089 [Current Limit 1] Related Parameter(s): P033, A118

Maximum output current allowed before current limiting occurs.
Values Default Drive Rated Amps × 1.5
Min/Max: 0.1/Drive Rated Amps × 1.8
Display: 0.1 Amps

A090 [Motor OL Select] Related Parameter(s): P032, P033

Drive provides Class 10 motor overload protection. Settings 0-2 select the derating factor for the I2t
overload function.
Options 0 “No Derate” (Default)
1 “Min Derate”
2 “Max Derate”

No Derate Min Derate Max Derate

% of P033 [Motor OL Curent]

100 100 100

80 80 80
60 60 60
40 40 40
20 20 20
0 0 0
0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200

A091 [PWM Frequency] Related Parameter(s): A124

Sets the carrier frequency for the PWM output waveform. The chart below provides derating
guidelines based on the PWM frequency setting.
Important: Ignoring derating guidelines can cause reduced drive performance.
Values Default 4.0 kHz
Min/Max: 2.0/16.0 kHz
Display: 0.1 kHz

100
96
92
88
84
80
76
72
68
64
60
56
52
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-27

Advanced Program Group (continued)

A092 [Auto Rstrt Tries] Related Parameter(s): A055, A058, A061, A093
Sets the maximum number of times the drive attempts to reset a fault and restart.
Clear a Type 1 fault and restart the drive.
1. Set A092 [Auto Rstrt Tries] to a value other than “0”.
2. Set A093 [Auto Rstrt Delay] to a value other than “0”.

Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting the drive.
1. Set A092 [Auto Rstrt Tries] to a value other than “0”.
2. Set A093 [Auto Rstrt Delay] to “0”.

ATTENTION: Equipment damage and/or personal injury may result if this parameter
is used in an inappropriate application. Do not use this function without considering
! applicable local, national and international codes, standards, regulations or industry
guidelines.

Values Default 0
Min/Max: 0/9
Display: 1

A093 [Auto Rstrt Delay] Related Parameter(s): A092

Sets the time between restart attempts when A092 [Auto Rstrt Tries] is set to a value other than zero.
Values Default 1.0 Secs
Min/Max: 0.0/300.0 Secs
Display: 0.1 Secs

A094 [Start At PowerUp]

Stop drive before changing this parameter.
Enables/disables a feature that allows a Start or Run command to automatically cause the drive to
resume running at commanded speed after drive input power is restored. Requires a digital input
configured for Run or Start and a valid start contact.
This parameter will not function if parameter P036 [Start Source] is set to 4 “2-W High Speed”.

ATTENTION: Equipment damage and/or personal injury may result if this parameter
is used in an inappropriate application. Do not use this function without considering
! applicable local, national and international codes, standards, regulations or industry
guidelines.

Options 0 “Disabled” (Default)

1 “Enabled”
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-28 Programming and Parameters

Advanced Program Group (continued)

A095 [Reverse Disable] Related Parameter(s): d006
Stop drive before changing this parameter.
Enables/disables the function that allows the direction of motor rotation to be changed. The reverse
command may come from a digital command, the keypad or a serial command. All reverse inputs
including two-wire Run Reverse will be ignored with reverse disabled.
Options 0 “Rev Enabled”
(Default)
1 “Rev Disabled”

A096 [Flying Start En]

Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM.
Options 0 “Disabled” (Default)
1 “Enabled”

A097 [Compensation]
Enables/disables correction options that may improve problems with motor instability.
Options 0 “Disabled”
1 “Electrical” (Default) Some drive/motor combinations have inherent instabilities
which are exhibited as non-sinusodial motor currents. This
setting attempts to correct this condition.
2 “Mechanical” Some motor/load combinations have mechanical resonances
which can be excited by the drive current regulator. This
setting slows down the current regulator response and
attempts to correct this condition.
3 “Both”

A098 [SW Current Trip] Related Parameter(s): P033

Enables/disables a software instantaneous (within 100 ms) current trip.
Values Default 0.0 (Disabled)
Min/Max: 0.0/(Drive Rated Amps × 2)
Display: 0.1 Amps

A099 [Process Factor] Related Parameter(s): d010

Scales the output frequency value displayed by d010 [Process Display].
Output Process Process
Freq x Factor = Display

Values Default 30.0

Min/Max: 0.1/999.9
Display: 0.1
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-29

Advanced Program Group (continued)

A100 [Fault Clear]
Stop drive before changing this parameter.
Resets a fault and clears the fault queue. Used primarily to clear a fault over network communications.
Options 0 “Ready/Idle” (Default)
1 “Reset Fault”
2 “Clear Buffer” (Parameters d007-d009 [Fault x Code])

A101 [Program Lock]

Protects parameters against change by unauthorized personnel.
Options 0 “Unlocked” (Default)
1 “Locked”

A102 [Testpoint Sel] Related Parameter(s): d019

Used by Rockwell Automation field service personnel.
Values Default 400
Min/Max: 0/FFFF
Display: 1 Hex

A103 [Comm Data Rate] Related Parameter(s): d015

Sets the serial port rate for the RS485 (DSI) port.
Important: Power to drive must be cycled before any changes will affect drive operation.
Options 0 “1200”
1 “2400”
2 “4800”
3 “9600” (Default)
4 “19.2K”
5 “38.4K”

A104 [Comm Node Addr] Related Parameter(s): d015

Sets the drive node address for the RS485 (DSI) port if using a network connection.
Important: Power to drive must be cycled before any changes will affect drive operation.
Values Default 100
Min/Max: 1/247
Display: 1
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-30 Programming and Parameters

Advanced Program Group (continued)

A105 [Comm Loss Action] Related Parameter(s): d015, P037, A106
Selects the drive’s response to a loss of the communication connection or excessive communication
errors.
Options 0 “Fault” (Default) Drive will fault on an F81 Comm Loss and coast to stop.
1 “Coast Stop” Stops drive via coast to stop.
2 “Stop” Stops drive via P037 [Stop Mode] setting.
3 “Continu Last” Drive continues operating at communication commanded
speed saved in RAM.

A106 [Comm Loss Time] Related Parameter(s): d015, A105

Sets the time that the drive will remain in communication loss before implementing the option selected
in A105 [Comm Loss Action].
Values Default 5.0 Secs
Min/Max: 0.1/60.0 Secs
Display: 0.1 Secs

A107 [Comm Format] Related Parameter(s): d015

Selects the protocol (RTU only), data bits (8 data bits only), parity (None, Even, Odd), and stop bits (1
stop bit only) used by the RS485 port on the drive.
Refer to Appendix C for details on using the drive communication features.
Important: Power to drive must be cycled before any changes will affect drive operation.
Options 0 “RTU 8-N-1” (Default)
1 “RTU 8-E-1”
2 “RTU 8-O-1”

A108 [Language]
Selects the language displayed by the remote communications option.
Options 1 “English” (Default)
2 “Français”
3 “Español”
4 “Italiano”
5 “Deutsch”
6 “Reserved”
7 “Português”
8 “Reserved”
9 “Reserved”
10 “Nederlands”
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-31

Advanced Program Group (continued)

A110 [Anlg In 0-10V Lo] Related Parameter(s): d020, P034, P038, A122
Stop drive before changing this parameter.
Sets the analog input level that corresponds to P034 [Minimum Freq] if a 0-10V input is used by P038
[Speed Reference].
Analog inversion can be accomplished by setting this value larger than A111 [Anlg In 0-10V Hi].
Values Default 0.0%
Min/Max: 0.0/100.0%
Display: 0.1%

P035 [Maximum Freq]

e
nc
fe re
d Re
ee
Sp

P034 [Minimum Freq]

0
0
A110 [Anlg In 0-10V Lo] A111 [Anlg In 0-10V Hi]

A111 [Anlg In 0-10V Hi] Related Parameter(s): d020, P035, P038, A122, A123
Stop drive before changing this parameter.
Sets the analog input level that corresponds to P035 [Maximum Freq] if a 0-10V input is used by P038
[Speed Reference].
Analog inversion can be accomplished by setting this value smaller than A110 [Anlg In 0-10V Lo].
Values Default 100.0%
Min/Max: 0.0/100.0%
Display: 0.1%

A112 [Anlg In4-20mA Lo] Related Parameter(s): d021, P034, P038

Stop drive before changing this parameter.
Sets the analog input level that corresponds to P034 [Minimum Freq] if a 4-20mA input is
used by P038 [Speed Reference].
Analog inversion can be accomplished by setting this value larger than A113 [Anlg In4-20mA Hi].
Values Default 0.0%
Min/Max: 0.0/100.0%
Display: 0.1%
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-32 Programming and Parameters

Advanced Program Group (continued)

A113 [Anlg In4-20mA Hi] Related Parameter(s): d021, P035, P038
Stop drive before changing this parameter.
Sets the analog input level that corresponds to P035 [Maximum Freq] if a 4-20mA input is used by
P038 [Speed Reference].
Analog inversion can be accomplished by setting this value smaller than A112 [Anlg In4-20mA Lo].
Values Default 100.0%
Min/Max: 0.0/100.0%
Display: 0.1%

A114 [Slip Hertz @ FLA] Related Parameter(s): P033

Compensates for the inherent slip in an induction motor. This frequency is added to the commanded
output frequency based on motor current.
Values Default 2.0 Hz
Min/Max: 0.0/10.0 Hz
Display: 0.1 Hz

A118 [Current Limit 2] Related Parameter(s): P033, A051-A054, A089

Maximum output current allowed before current limiting occurs. This parameter is only active if
A051 - A054 [Digital Inx Sel] is set to 25 “Current Lmt2” and is active.
Values Default Drive Rated Amps × 1.5
Min/Max: 0.1/(Drive Rated Amps × 1.8)
Display: 0.1 Amps

A119 [Skip Frequency] Related Parameter(s): A120

Sets the frequency at which the drive will not operate.
A setting of 0 disables this parameter.
Values Default 0 Hz
Min/Max: 0/400 Hz
Display: 1 Hz
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL
Programming and Parameters 3-33

Advanced Program Group (continued)

A120 [Skip Freq Band] Related Parameter(s): A119
Determines the bandwidth around A119 [Skip Frequency]. A120 [Skip Frequency Band] is split
applying 1/2 above and 1/2 below the actual skip frequency.
A setting of 0.0 disables this parameter.
Values Default 0.0 Hz
Min/Max: 0.0/30.0 Hz
Display: 0.1 Hz

Frequency Command
Frequency

Drive Output
Frequency

2x Skip
Skip Frequency Frequency Band

Time

A121 [Stall Fault Time]

Sets the time that the drive will remain in stall mode before a fault is issued.
Options 0 “60 Seconds” (Default)
1 “120 Seconds”
2 “240 Seconds”
3 “360 Seconds”
4 “480 Seconds”
5 “Flt Disabled”

A122 [Analog In Loss] Related Parameter(s): A110, A111, A132

Selects drive action when an input signal loss is detected. Signal loss is defined as an analog signal
less than 1V or 2mA. The signal loss event ends and normal operation resumes when the input signal
level is greater than or equal to 1.5V or 3mA. If using a 0-10V analog input, set A110 [Anlg In 0-10V
Lo] to a minimum of 20% (i.e. 2 volts).
Options 0 “Disabled” (Default)
1 “Fault (F29)” F29 Analog Input Loss
2 “Stop” Uses P037 [Stop Mode]
3 “Zero Ref” Drive runs at zero speed reference.
4 “Min Freq Ref” Drive runs at minimum frequency.
5 “Max Freq Ref” Drive runs at maximum frequency.
6 “Int Freq Ref” Drive runs at internal frequency.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-34 Programming and Parameters

Advanced Program Group (continued)

A123 [10V Bipolar Enbl] Related Parameter(s): P038, A111
Enables/disables bipolar control. In bipolar mode direction is commanded by the sign of the reference.
Options 0 “Uni-Polar In” (Default) 0 to 10V only
1 “Bi-Polar In” ±10V

A124 [Var PWM Disable] Related Parameter(s): A091

Stop drive before changing this parameter.
Enables/disables a feature that varies the carrier frequency for the PWM output waveform defined by
A091 [PWM Frequency].
Disabling this feature when low frequency conditions exist may result in IGBT stress and nuisance
tripping.
Options 0 “Enabled” (Default)
1 “Disabled”

A125 [Torque Perf Mode] Related Parameter(s): A084, A085, A086, A087, A127
Stop drive before changing this parameter.
Enables/disables sensorless vector control operation.
Options 0 “V/Hz”
1 “Sensrls Vect” (Default)

A126 [Motor NP FLA] Related Parameter(s): A127

Set to the motor nameplate rated full load amps.
Values Default Drive Rated Amps
Min/Max: 0.1/(Drive Rated Amps × 2)
Display: 0.1 Amps
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-35

Advanced Program Group (continued)

A127 [Autotune] Related Parameter(s): A125, A126, A128, A129
Stop drive before changing this parameter.
Provides an automatic method for setting A128 [IR Voltage Drop] and A129 [Flux Current Ref], which
affect sensorless vector performance. Parameter A126 [Motor NP FLA] must be set to the motor
nameplate full load amps before running the Autotune procedure.
Options 0 “Ready/Idle” (Default)
1 “Static Tune”
2 “Rotate Tune”
“Ready” (0) = Parameter returns to this setting following a “Static Tune” or “Rotate Tune.”
“Static Tune” (1) = A temporary command that initiates a non-rotational motor stator resistance test for
the best possible automatic setting of A128 [IR Voltage Drop]. A start command is required following
initiation of this setting. The parameter returns to “Ready” (0) following the test, at which time another
start transition is required operate the drive in normal mode. Used when motor cannot be uncoupled
from the load.
“Rotate Tune” (2) = A temporary command that initiates a “Static Tune” followed by a rotational test for
the best possible automatic setting of A129 [Flux Current Ref]. A start command is required following
initiation of this setting. The parameter returns to “Ready” (0) following the test, at which time another
start transition is required to operate the drive in normal mode. Important: Used when motor is
uncoupled from the load. Results may not be valid if a load is coupled to the motor during this
procedure.

ATTENTION: Rotation of the motor in an undesired direction can occur during this
procedure. To guard against possible injury and/or equipment damage, it is
! recommended that the motor be disconnected from the load before proceeding.

If the Autotune routine fails, an F80 SVC Autotune fault is displayed.

A128 [IR Voltage Drop] Related Parameter(s): A127

Value of volts dropped across the resistance of the motor stator.
Values Default Based on Drive Rating
Min/Max: 0.0/230.0 VAC
Display: 0.1 VAC

A129 [Flux Current Ref] Related Parameter(s): A127

Value of amps for full motor flux.
Values Default Based on Drive Rating
Min/Max: 0.00/[Motor NP Volts]
Display: 0.01 Amps
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL
3-36 Programming and Parameters

Advanced Program Group (continued)

A130 [PID Trim Hi]
Sets the maximum positive value that is added to a PID reference when PID trim is used.
Values Default 60.0
Min/Max: 0.0/400.0
Display: 0.1

A131 [PID Trim Lo]

Sets the minimum positive value that is added to a PID reference when PID trim is used.
Values Default 0.1
Min/Max: 0.0/400.0
Display: 0.1

A132 [PID Ref Select] Related Parameter(s): P038, A122

Stop drive before changing this parameter.
Enables/disables PID mode and selects the source of the PID reference. Refer to Appendix F for
details.
Options 0 “PID Disabled”
(Default)
1 “PID Setpoint”
2 “0-10V Input”
3 “4-20mA Input”
4 “Comm Port”
5 “Setpnt, Trim”
6 “0-10V, Trim”
7 “4-20mA, Trim”
8 “Comm, Trim”

A133 [PID Feedback Sel]

Select the source of the PID feedback. Refer to Appendix F for details.
Options 0 “0-10V Input” (Default) The PID will not function with a bipolar input. Negative
voltages are treated as 0 volts.
1 “4-20mA Input”
2 “Comm Port”

A134 [PID Prop Gain]

Sets the value for the PID proportional component when the PID mode is enabled by A132 [PID Ref
Sel].
Values Default 0.01
Min/Max: 0.00/99.99
Display: 0.01
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-37

Advanced Program Group (continued)

A135 [PID Integ Time]
Sets the value for the PID integral component when the PID mode is enabled by A132 [PID Ref Sel].
Values Default 0.1 Secs
Min/Max: 0.0/999.9 Secs
Display: 0.1 Secs

A136 [PID Diff Rate]

Sets the value for the PID differential component when the PID mode is enabled by A132 [PID Ref
Sel].
Values Default 0.00 (1/Secs)
Min/Max: 0.00/99.99 (1/Secs)
Display: 0.01 (1/Secs)

A137 [PID Setpoint]

Provides an internal fixed value for process setpoint when the PID mode is enabled by A132 [PID Ref
Sel].
Values Default 0.0%
Min/Max: 0.0/100.0%
Display: 0.1%

A138 [PID Deadband]

Sets the lower limit of the PID output.
Values Default 0.0%
Min/Max: 0.0/10.0%
Display: 0.1%

A139 [PID Preload]

Sets the value used to preload the integral component on start or enable.
Values Default 0.0 Hz
Min/Max: 0.0/400.0 Hz
Display: 0.1 Hz
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL
3-38 Programming and Parameters

Advanced Program Group (continued)

A140 [Stp Logic 0] Related Parameter(s): P038, P039, P040, A051-A054,
A141 [Stp Logic 1] A055, A058, A061, A067, A068, A070-A077, A150-A157
A142 [Stp Logic 2]
A143 [Stp Logic 3] Stop drive before changing this parameter.
A144 [Stp Logic 4]
A145 [Stp Logic 5]
A146 [Stp Logic 6]
A147 [Stp Logic 7]
Values Default 00F1
Min/Max: 0001/bAFF
Display: 4 Digits
Parameters A140-A147 are only active if P038 [Speed Reference] is set to 6 “Stp Logic”.
These parameters can be used to create a custom profile of frequency commands. Each “step” can
be based on time, status of a Logic input or a combination of time and the status of a Logic input.
Digits 0-3 for each [Stp Logic x] parameter must be programmed according to the desired profile.
A Logic input is established by setting a digital input, parameters A051 - A054 [Digital Inx Sel], to 23
“Logic In1” and/or 24 “Logic In2”.
A time interval between steps can be programmed using parameters A150 - A157 [Stp Logic Time x].
See the table below for related parameters.
The speed for any step is programmed using parameters A070 - A077 [Preset Freq x].

Related Preset Frequency Parameter Related Step Logic Time Parameter

Step Logic Parameter (Can be activated independent of (Active when A140-A147 Digit 0 or 1
(Active when P038 = 6 “Stp Logic”) Step Logic Parameters) are set to 1, b, C, d or E)
A140 [Stp Logic 0] A070 [Preset Freq 0] A150 [Stp Logic Time 0]
A141 [Stp Logic 1] A071 [Preset Freq 1] A151 [Stp Logic Time 1]
A142 [Stp Logic 2] A072 [Preset Freq 2] A152 [Stp Logic Time 2]
A143 [Stp Logic 3] A073 [Preset Freq 3] A153 [Stp Logic Time 3]
A144 [Stp Logic 4] A074 [Preset Freq 4] A154 [Stp Logic Time 4]
A145 [Stp Logic 5] A075 [Preset Freq 5] A155 [Stp Logic Time 5]
A146 [Stp Logic 6] A076 [Preset Freq 6] A156 [Stp Logic Time 6]
A147 [Stp Logic 7] A077 [Preset Freq 7] A157 [Stp Logic Time 7]

How Step Logic Works

The step logic sequence begins with a valid start command. A normal sequence always begins with
A140 [Stp Logic 0].
Digit 0: Logic For Next Step
This digit defines the logic for the next step. When the condition is met the program advances to the
next step. Step 0 follows Step 7. Example: Digit 0 is set 3. When “Logic In2” becomes active, the
program advances to the next step.
Digit 1: Logic to Jump to a Different Step
For all settings other than F, when the condition is met, the program overrides Digit 0 and jumps to the
step defined by Digit 2.
Digit 2: Different Step to Jump
When the condition for Digit 1 is met, the Digit 2 setting determines the next step or to end the
program.
Digit 3: Step Settings
This digit defines what accel/decel profile the speed command will follow and the direction of the
command for the current step. In addition, if a relay or opto output (parameters A055, A058 and A061)
is set to 15 “StpLogic Out”, this parameter can control the status of that output.
Any Step Logic parameter can be programmed to control a relay or opto output, but you can not
control different outputs based on the condition of different Step Logic commands.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-39

Step Logic Settings

The logic for each function is determined by the four digits for each step logic parameter. The following
is a listing of the available settings for each digit.
Refer to Appendix E for details.

Logic For Next Step Digit 0

Logic to Jump to a Different Step Digit 1
Different Step to Jump Digit 2
Step Settings Digit 3

Digit 3 Settings
Required Accel/Decel Step Logic Commanded
Setting Param. Used Output State Direction
0 Accel/Decel 1 Off FWD
1 Accel/Decel 1 Off REV
2 Accel/Decel 1 Off No Output
3 Accel/Decel 1 On FWD
4 Accel/Decel 1 On REV
5 Accel/Decel 1 On No Output
6 Accel/Decel 2 Off FWD
7 Accel/Decel 2 Off REV
8 Accel/Decel 2 Off No Output
9 Accel/Decel 2 On FWD
A Accel/Decel 2 On REV
b Accel/Decel 2 On No Output

Digit 2 Settings Digit 1 and Digit 0 Settings

0 = Jump to Step 0 0 = Skip Step (Jump Immediately)
1 = Jump to Step 1 1 = Step Based on [Stp Logic Time x]
2 = Jump to Step 2 2 = Step if “Logic In1” is Active
3 = Jump to Step 3 3 = Step if “Logic In2” is Active
4 = Jump to Step 4 4 = Step if “Logic In1” is Not Active
5 = Jump to Step 5 5 = Step if “Logic In2” is Not Active
6 = Jump to Step 6 6 = Step if either “Logic In1” or “Logic In2” is Active
7 = Jump to Step 7 7 = Step if both “Logic In1” and “Logic In2” is Active
8 = End Program (Normal Stop) 8 = Step if neither “Logic In1” or “Logic In2” is Active
9 = End Program (Coast to Stop) 9 = Step if “Logic In1” is Active and “Logic In2” is Not Active
A = End Program and Fault (F2) A = Step if “Logic In2” is Active and “Logic In1” is Not Active
b = Step after [Stp Logic Time x] and “Logic In1” is Active
C = Step after [Stp Logic Time x] and “Logic In2” is Active
d = Step after [Stp Logic Time x] and “Logic In1” is Not Active
E = Step after [Stp Logic Time x] and “Logic In2” is Not Active
F = Do Not Step/Ignore Digit 2 Settings
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Programming and Parameters 3-40

Advanced Program Group (continued)

A150 [Stp Logic Time 0] Related Parameter(s): P038, A055, A058, A061,
A151 [Stp Logic Time 1] A070-A077, A140-A147
A152 [Stp Logic Time 2]
A153 [Stp Logic Time 3]
A154 [Stp Logic Time 4]
A155 [Stp Logic Time 5]
A156 [Stp Logic Time 6]
A157 [Stp Logic Time 7]
Sets the time to remain in each step if the corresponding StpLogic command word is set to “Step after
Time”.
Values Default 30.0 Secs
Min/Max: 0.0/999.9 Secs
Display: 0.1 Secs
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-41 Programming and Parameters

Parameter Cross Reference – by Name

Parameter Name No. Group Parameter Name No. Group

10V Bipolar Enbl A123 Advanced Program Language A108 Advanced Program
Accel Time 1 P039 Basic Program Maximum Freq P035 Basic Program
Accel Time 2 A067 Advanced Program Maximum Voltage A088 Advanced Program
Analog In 0-10V d020 Display Minimum Freq P034 Basic Program
Analog In 0-20mA d021 Display Motor NP FLA A126 Advanced Program
Analog In Loss A122 Advanced Program Motor NP Hertz P032 Basic Program
Analog Out High A066 Advanced Program Motor NP Volts P031 Basic Program
Anlg In 0-10V Hi A111 Advanced Program Motor OL Current P033 Basic Program
Anlg In 4-10V Lo A110 Advanced Program Motor OL Select A090 Advanced Program
Anlg In4-20mA Hi A113 Advanced Program Opto Out Logic A064 Advanced Program
Anlg In4-20mA Lo A112 Advanced Program Output Current d003 Display
Auto Rstrt Delay A093 Advanced Program Output Freq d001 Display
Auto Rstrt Tries A092 Advanced Program Output Power d022 Display
Autotune A127 Advanced Program Output Powr Fctr d023 Display
Boost Select A084 Advanced Program Output Voltage d004 Display
Break Frequency A087 Advanced Program PID Deadband A138 Advanced Program
Break Voltage A086 Advanced Program PID Diff Rate A136 Advanced Program
Comm Data Rate A103 Advanced Program PID Feedback Sel A133 Advanced Program
Comm Format A107 Advanced Program PID Integ Time A135 Advanced Program
Comm Loss Action A105 Advanced Program PID Preload A139 Advanced Program
Comm Loss Time A106 Advanced Program PID Prop Gain A134 Advanced Program
Comm Node Addr A104 Advanced Program PID Ref Sel A132 Advanced Program
Comm Status d015 Display PID Setpoint A137 Advanced Program
Commanded Freq d002 Display PID Trim Hi A130 Advanced Program
Compensation A097 Advanced Program PID Trim Lo A131 Advanced Program
Contrl In Status d013 Display Preset Freq x A070-A077 Advanced Program
Control Source d012 Display Process Display d010 Display
Control SW Ver d016 Display Process Factor A099 Advanced Program
Counter Status d025 Display Program Lock A101 Advanced Program
Current Limit 1 A089 Advanced Program PWM Frequency A091 Advanced Program
DB Resistor Sel A082 Advanced Program Relay Out Level A056 Advanced Program
DC Brake Level A081 Advanced Program Relay Out Sel A055 Advanced Program
DC Brake Time A080 Advanced Program Reset To Defalts P041 Basic Program
DC Bus Voltage d005 Display Reverse Disable A095 Advanced Program
Decel Time 1 P040 Basic Program S Curve % A083 Advanced Program
Decel Time 2 A068 Advanced Program Skip Freq Band A120 Advanced Program
Dig In Status d014 Display Skip Frequency A119 Advanced Program
Opto Out Logic A064 Advanced Program Slip Hertz @ FLA A114 Advanced Program
Opto Outx Level A059, A062 Advanced Program Stp Logic Step x A140-A147 Advanced Program
Digital Inx Sel A051-A054 Advanced Program Stp Logic Time x A150-A157 Advanced Program
Opto Outx Sel A058, A061 Advanced Program Speed Reference P038 Basic Program
Drive Status d006 Display Stall Fault Time A121 Advanced Program
Drive Temp d024 Display Start At PowerUp A094 Advanced Program
Drive Type d017 Display Start Boost A085 Advanced Program
Elapsed Run Time d018 Display Start Source P036 Basic Program
Fault Clear A100 Advanced Program Stop Mode P037 Basic Program
Fault x Code d007-d009 Display SW Current Trip A098 Advanced Program
Flux Current Ref A129 Advanced Program Testpoint Data d019 Display
Flying Start En A096 Advanced Program Testpoint Sel A102 Advanced Program
Internal Freq A069 Advanced Program Timer Status d026 Display
IR Voltage Drop A128 Advanced Program Torque Perf Mode A125 Advanced Program
Jog Accel/Decel A079 Advanced Program Var PWM Disable A124 Advanced Program
Jog Frequency A078 Advanced Program
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3-42 Programming and Parameters

Notes:
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Chapter 4

Troubleshooting
Chapter 4 provides information to guide you in troubleshooting the
PowerFlex 40 drive. Included is a listing and description of drive faults
(with possible solutions, when applicable).

For information on… See page… For information on… See page…
Drive Status 4-1 Fault Descriptions 4-3
Faults 4-1 Common Symptoms and 4-5
Corrective Actions

Drive Status
The condition or state of your drive is constantly monitored. Any
changes will be indicated through the integral keypad.

LED Indications
See page 2-3 for information on drive status indicators and controls.

Faults
A fault is a condition that stops the drive. There are two fault types.

Type Fault Description

➀ Auto-Reset/Run When this type of fault occurs, and A092 [Auto Rstrt Tries]
Related Parameter(s): A055, A058, A061, A093 is set to a
value greater than “0,” a user-configurable timer, A093 [Auto
Rstrt Delay] Related Parameter(s): A092, begins. When the
timer reaches zero, the drive attempts to automatically reset
the fault. If the condition that caused the fault is no longer
present, the fault will be reset and the drive will be restarted.
➁ Non-Resetable This type of fault may require drive or motor repair, or is
caused by wiring or programing errors. The cause of the fault
must be corrected before the fault can be cleared.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL
4-2 Troubleshooting

Fault Indication
Condition Display
Drive is indicating a fault.
RUN VOLTS
The integral keypad provides visual notification of a FWD
REV
AMPS
HERTZ

fault condition by displaying the following. PRGOGRAM FAULT

• Flashing fault number

• Flashing fault indicator
Press the Escape key to regain control of the
integral keypad.

Manually Clearing Faults

Step Key(s)
1. Press Esc to acknowledge the fault. The fault information will be
removed so that you can use the integral keypad.
Access d007 [Fault 1 Code] to view the most recent fault information.
2. Address the condition that caused the fault.
The cause must be corrected before the fault can be cleared.
See Table 4.A.
3. After corrective action has been taken, clear the fault by one of these
methods.
• Press Stop if P037 [Stop Mode] is set to a value between “0” and “3”.
• Cycle drive power.
• Set A100 [Fault Clear] to “1” or “2”.
• Cycle digital input if A051-A054 [Digital Inx Sel] is set to option 7
“Clear Fault”.

Automatically Clearing Faults

Option / Step
Clear a Type 1 fault and restart the drive.
1. Set A092 [Auto Rstrt Tries] to a value other than “0”.
2. Set A093 [Auto Rstrt Delay] to a value other than “0”.

Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault

without restarting the drive.
1. Set A092 [Auto Rstrt Tries] to a value other than “0”.
2. Set A093 [Auto Rstrt Delay] to “0”.

Auto Restart (Reset/Run)

The Auto Restart feature provides the ability for the drive to
automatically perform a fault reset followed by a start attempt without
user or application intervention. This allows remote or “unattended”
operation. Only certain faults are allowed to be reset. Certain faults
(Type 2) that indicate possible drive component malfunction are not
resettable.
Caution should be used when enabling this feature, since the drive will
attempt to issue its own start command based on user selected
programming.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL
Troubleshooting 4-3

Fault Descriptions
Table 4.A Fault Types, Descriptions and Actions

Type(1)
No. Fault Description Action
F2 Auxiliary Input ➀ Auxiliary input interlock is open. 1. Check remote wiring.
2. Verify communications
programming for intentional fault.
F3 Power Loss ➁ DC bus voltage remained below 1. Monitor the incoming AC line for
85% of nominal. low voltage or line power
interruption.
2. Check input fuses.
F4 UnderVoltage ➀ DC bus voltage fell below the Monitor the incoming AC line for low
minimum value. voltage or line power interruption.
F5 OverVoltage ➀ DC bus voltage exceeded Monitor the AC line for high line
maximum value. voltage or transient conditions. Bus
overvoltage can also be caused by
motor regeneration. Extend the
decel time or install dynamic brake
option.
F6 Motor Stalled ➀ Drive is unable to accelerate Increase P039 - A067 [Accel Time x]
motor. or reduce load so drive output
current does not exceed the current
set by parameter A089 [Current
Limit 1].
F7 Motor Overload ➀ Internal electronic overload trip. 1. An excessive motor load exists.
Reduce load so drive output
current does not exceed the
current set by parameter P033
[Motor OL Current].
2. Verify A084 [Boost Select]
setting
F8 Heatsink ➀ Heatsink temperature exceeds a 1. Check for blocked or dirty heat
OvrTmp predefined value. sink fins. Verify that ambient
temperature has not exceeded
40°C (104°F) for IP 30/NEMA 1/UL
Type 1 installations or 50°C (122°F)
for IP20/Open type installations.
2. Check fan.
F12 HW OverCurrent ➁ The drive output current has Check programming. Check for
exceeded the hardware current excess load, improper A084 [Boost
limit. Select] setting, DC brake volts set
too high or other causes of excess
current.
F13 Ground Fault ➁ A current path to earth ground Check the motor and external wiring
has been detected at one or to the drive output terminals for a
more of the drive output grounded condition.
terminals.
F29 Analog Input ➀ An analog input is configured to 1. Check parameters.
Loss fault on signal loss. A signal loss 2. Check for broken/loose
has occurred. connections at inputs.
Configure with A122 [Analog In
Loss].
(1) See page 4-1 for a description of fault types.
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BI012088 MD6640 BLAST HOLE DRILL

4-4 Troubleshooting

Type(1)
No. Fault Description Action
F33 Auto Rstrt Tries ➁ Drive unsuccessfully attempted Correct the cause of the fault and
to reset a fault and resume manually clear.
running for the programmed
number of A092 [Auto Rstrt
Tries].
F38 Phase U to Gnd ➁ A phase to ground fault has been 1. Check the wiring between the
F39 Phase V to Gnd detected between the drive and drive and motor.
F40 Phase W to Gnd motor in this phase. 2. Check motor for grounded
phase.
3. Replace drive if fault cannot be
cleared.
F41 Phase UV Short ➁ Excessive current has been 1. Check the motor and drive output
F42 Phase UW Short detected between these two terminal wiring for a shorted
F43 Phase VW Short output terminals. condition.
2. Replace drive if fault cannot be
cleared.
F48 Params The drive was commanded to 1. Clear the fault or cycle power to
Defaulted write default values to EEPROM. the drive.
2. Program the drive parameters as
needed.
F63 SW OverCurrent ➀ Programmed A098 [SW Current Check load requirements and A098
Trip] has been exceeded. [SW Current Trip] setting.
F64 Drive Overload ➁ Drive rating of 150% for 1 minute Reduce load or extend Accel Time.
or 200% for 3 seconds has been
exceeded.
F70 Power Unit ➁ Failure has been detected in the 1. Cycle power.
drive power section. 2. Replace drive if fault cannot be
cleared.
F80 SVC Autotune The autotune function was either Restart procedure.
cancelled by the user or failed.
F81 Comm Loss ➁ RS485 (DSI) port stopped 1. If adapter was not intentionally
communicating. disconnected, check wiring to the
port. Replace wiring, port
expander, adapters or complete
drive as required.
2. Check connection.
3. An adapter was intentionally
disconnected.
4. Turn off using A105 [Comm Loss
Action].
F100 Parameter ➁ The checksum read from the Set P041 [Reset To Defalts] to option
Checksum board does not match the 1 “Reset Defaults”.
checksum calculated.
F122 I/O Board Fail ➁ Failure has been detected in the 1. Cycle power.
drive control and I/O section. 2. Replace drive if fault cannot be
cleared.
(1) See page 4-1 for a description of fault types.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Troubleshooting 4-5

Common Symptoms and Corrective Actions

Motor does not Start.
Cause(s) Indication Corrective Action
No output voltage to the motor. None Check the power circuit.
• Check the supply voltage.
• Check all fuses and disconnects.
Check the motor.
• Verify that the motor is
connected properly.
Check the control input signals.
• Verify that a Start signal is
present. If 2-Wire control is used,
verify that either the Run
Forward or Run Reverse signal
is active, but not both.
• Verify that I/O Terminal 01 is
active.
• Verify that P036 [Start Source]
matches your configuration.
• Verify that A095 [Reverse
Disable] is not prohibiting
movement.
Drive is Faulted Flashing red status light Clear fault.
• Press Stop
• Cycle power
• Set A100 [Fault Clear] to option 1
“Clear Faults”.
• Cycle digital input if A051 - A054
[Digital Inx Sel] is set to option 7
“Clear Fault”.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

4-6 Troubleshooting

Drive does not Start from Start or Run Inputs wired to the terminal block.
Cause(s) Indication Corrective Action
Drive is Faulted Flashing red status light Clear fault.
• Press Stop
• Cycle power
• Set A100 [Fault Clear] to option 1
“Clear Faults”.
• Cycle digital input if A051 - A054
[Digital Inx Sel] is set to option 7
“Clear Fault”.
Incorrect programming. None Check parameter settings.
• P036 [Start Source] is set to
option 0 “Keypad” or option 5
“RS485 (DSI) Port”.
• A051 - A054 [Digital Inx Sel] is
set to option 5 “Local” and the
input is active.
Incorrect input wiring. None Wire inputs correctly and/or install
See 1-16 for wiring examples. jumper.
• 2 wire control requires Run
Forward, Run Reverse or Jog
input.
• 3 wire control requires Start and
Stop inputs
• Stop input is always required.
Incorrect Sink/Source DIP switch None Set switch to match wiring scheme.
setting.

Drive does not Start from Integral Keypad.

Cause(s) Indication Corrective Action
Integral keypad is not enabled. Green LED above Start key is • Set parameter P036 [Start
not illuminated. Source] to option 0 “Keypad”.
• Set parameter A051 - A054
[Digital Inx Sel] to option 5
“Local” and activate the input.
I/O Terminal 01 “Stop” input is None Wire inputs correctly and/or install
not present. jumper.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Troubleshooting 4-7

Drive does not respond to changes in speed command.

Cause(s) Indication Corrective Action
No value is coming from the The drive “Run” indicator is lit • Check d012 [Control Source] for
source of the command. and output is 0 Hz. correct source.
• If the source is an analog input,
check wiring and use a meter to
check for presence of signal.
• Check d002 [Commanded Freq]
to verify correct command.
Incorrect reference source is None • Check d012 [Control Source] for
being selected via remote correct source.
device or digital inputs. • Check d014 [Dig In Status] to
see if inputs are selecting an
alternate source. Verify settings
for A051 - A054 [Digital Inx Sel].
• Check P038 [Speed Reference]
for the source of the speed
reference. Reprogram as
necessary.
• Review the Speed Reference
Control chart on page 1-20.

Motor and/or drive will not accelerate to commanded speed.

Cause(s) Indication Corrective Action
Acceleration time is excessive. None Reprogram P039 [Accel Time 1] or
A067 [Accel Time 2].
Excess load or short None Compare d003 [Output Current] with
acceleration times force the A089 [Current Limit 1].
drive into current limit, slowing Remove excess load or reprogram
or stopping acceleration. P039 [Accel Time 1] or A067 [Accel
Time 2].
Check for improper A084 [Boost
Select] setting.
Speed command source or None Verify d002 [Commanded Freq].
value is not as expected. Check d012 [Control Source] for the
proper Speed Command.
Programming is preventing the None Check P035 [Maximum Freq] to
drive output from exceeding insure that speed is not limited by
limiting values. programming.
Torque performance does not None Set motor nameplate full load amps
match motor characteristics. in parameter A126 [Motor NP FLA].
Perform A127 [Autotune] “Static
Tune” or “Rotate Tune” procedure.
Set A125 [Torque Perf Mode] to
option 0 “V/Hz”.
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BI012088 MD6640 BLAST HOLE DRILL

4-8 Troubleshooting

Motor operation is unstable.

Cause(s) Indication Corrective Action
Motor data was incorrectly None 1. Correctly enter motor nameplate
entered. data into P031, P032 and P033.
2. Enable A097 [Compensation].
3. Use A084 [Boost Select] to
reduce boost level.

Drive will not reverse motor direction.

Cause(s) Indication Corrective Action
Digital input is not selected for None Check [Digital Inx Sel] (See
reversing control. page 3-14). Choose correct input
and program for reversing mode.
Digital input is incorrectly None Check input wiring. (See page 1-15)
wired.
Motor wiring is improperly None Switch two motor leads.
phased for reverse.
Reverse is disabled. None Check A095 [Reverse Disable].

Drive does not power up.

Cause(s) Indication Corrective Action
No input power to drive. None Check the power circuit.
• Check the supply voltage.
• Check all fuses and disconnects.
Jumper between I/O Terminals None Install jumper or connect DC Bus
P2 and P1 not installed and/or Inductor.
DC Bus Inductor not
connected.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Appendix A

Supplemental Drive Information

For information on… See page…
Drive, Fuse & Circuit Breaker Ratings A-1
Specifications A-2

Drive, Fuse & Circuit Breaker Ratings

The tables on the following pages provide drive ratings and
recommended AC line input fuse and circuit breaker information. Both
types of short circuit protection are acceptable for UL and IEC
requirements. Sizes listed are the recommended sizes based on 40 degree
C and the U.S. N.E.C. Other country, state or local codes may require
different ratings.
Fusing
If fuses are chosen as the desired protection method, refer to the
recommended types listed below. If available amp ratings do not match
the tables provided, the closest fuse rating that exceeds the drive rating
should be chosen.
• IEC – BS88 (British Standard) Parts 1 & 2 (1), EN60269-1, Parts 1 &
2, type gG or equivalent should be used.
• UL – UL Class CC, T or J must be used. (2)
Circuit Breakers
Refer to listings in the following tables for recommended circuit
breakers (inverse time or instantaneous trip) and 140M Self-Protecting
Motor Starters.

(1) Typical designations include, but may not be limited to the following; Parts 1 & 2: AC,
AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG, GH.
(2) Typical designations include; Type CC - KTK-R, FNQ-R
Type J - JKS, LPJ
Type T - JJS, JJN
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Supplemental Drive Information A-3

Category Specification
Environment Altitude: 1000 m (3300 ft) max. without derating
Ambient Operating Temperature
Open Type, IP20: –10 to 50 degrees C (14 to 122 degrees F)
NEMA Type 1, IP30,
UL Type 1: –10 to 40 degrees C (14 to 104 degrees F)
Cooling Method
Fan: All drive ratings.
Storage Temperature: –40 to 85 degrees C (–40 to 185 degrees F)
Atmosphere: Important: Drive must not be installed in an
area where the ambient atmosphere contains
volatile or corrosive gas, vapors or dust. If the
drive is not going to be installed for a period of
time, it must be stored in an area where it will not
be exposed to a corrosive atmosphere.
Relative Humidity: 0 to 95% non-condensing
Shock (operating): 15G peak for 11ms duration (±1.0ms)
Vibration (operating): 1G peak, 5 to 2000 Hz
Control Carrier Frequency 2-16 kHz. Drive rating based on 4 kHz.
Frequency Accuracy
Digital Input: Within ±0.05% of set output frequency.
Analog Input: Within 0.5% of maximum output frequency,
10-Bit resolution
Analog Output: ±2% of full scale, 10-Bit resolution
Speed Regulation - Open Loop ±1% of base speed across a 60:1 speed range.
with Slip Compensation:
Stop Modes: Multiple programmable stop modes including -
Ramp, Coast, DC-Brake, Ramp-to-Hold and
S Curve.
Accel/Decel: Two independently programmable accel and
decel times. Each time may be programmed from
0 - 600 seconds in 0.1 second increments.
Intermittent Overload: 150% Overload capability for up to 1 minute
200% Overload capability for up to 3 seconds
Electronic Motor Overload Class 10 protection with speed sensitive
Protection response.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

B-6 Accessories and Dimensions

Product Dimensions
Table B.J PowerFlex 40 Frames – Ratings are in kW and (HP)
Frame 120V AC – 1-Phase 240V AC – 1-Phase 240V AC – 3-Phase 480V AC – 3-Phase
B 0.4 (0.5) 0.4 (0.5) 0.4 (0.5) 2.2 (3.0) 0.4 (0.5) 2.2 (3.0)
0.75 (1.0) 0.75 (1.0) 0.75 (1.0) 3.7 (5.0) 0.75 (1.0) 4.0 (5.0)
1.1 (1.5) 1.5 (2.0) 1.5 (2.0) 1.5 (2.0)
C 2.2 (3.0) 5.5 (7.5) 5.5 (7.5)
7.5 (10.0) 7.5 (10.0)

Figure B.1 PowerFlex 40 AC Drive

A C Dimensions are in millimeters and (inches).
D Weights are in kilograms and (pounds).

Frame
F Ship
A B C D E F Weight
E B 100 180 136 87 168 87.4 2.2
B (3.94) (7.09) (5.35) (3.43) (6.61) (3.44) (4.9)
C 130 260 180 116 246 – 4.3
(5.1) (10.2) (7.1) (4.57) (9.7) (9.5)

5.5 (0.22)

Figure B.2 IP 30/NEMA 1/UL Type 1 Option Kit without Communication Option
79.1 (3.11)
64.1 (2.52)
40.6 (1.60)
25.6 (1.01) ∅ 22.2
(0.87)

109.9
(4.33)
74.3
(2.93)
33.0
(1.30)

Frame B - 22-JBAB

107.0 (4.21) ∅ 28.5

66.0 (2.60) (1.12)
24.0 (0.94)
∅ 22.2
(0.87)

152.2
(5.99)

111.2
(4.38)
60.0
(2.36)

Frame C - 22-JBAC
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Accessories and Dimensions B-7

Figure B.3 IP 30/NEMA 1/UL Type 1 Option Kit with Communication Option
25.0
(0.98)
77.5 (3.05)
50.0 (1.97)
22.5 (0.89)
∅ 22.2
(0.87)

134.3
(5.29)
105.3
(4.15)
76.3
64.0 (3.00)
(2.52)

Frame B - 22-JBCB

25.0
(0.98) 108.7 (4.28)
92.2 (3.63)
69.2 (2.72) ∅ 28.5
45.7 (1.80) (1.12)
22.2 (0.87) ∅ 22.2
(0.87)

179.8
(7.08)
144.8
(5.70)

109.8
(4.32)
60.0
(2.36)

Frame C- 22-JBCC
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

B-10 Accessories and Dimensions

Figure B.6 Frame B EMC Line Filters – Dimensions are in millimeters and (inches)
Catalog Numbers: 22-RF012-BS, -BL; 22-RF018-BS; 22-RF021-BS, -BL
50 100
(1.97) 78 (3.94)
29.8
(1.17) (3.07)

217 229
(8.54) (9.02)

216
(8.50)

17.8 5.5 (0.22)

(0.70) 24.0
(0.94)
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Accessories and Dimensions B-11

Figure B.7 Frame C EMC Line Filters – Dimensions are in millimeters and (inches)
Catalog Numbers: 22-RF021-BL (Series B); 22-RF025-CL; 22-RF018-CS, -CL;
22-RF034-CS, -CL
60 130
(2.36) 90 (5.12)
32
(1.26) (3.54)

297 309
(11.69) (12.17)

297
(11.69)

17 5.5 (0.22)
(0.67) 30
(1.18)
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

B-12 Accessories and Dimensions

Figure B.8 Remote (Panel Mount) HIM – Dimensions are in millimeters and (inches)
Catalog Number: 22-HIM-C2

17.6 104
(0.69) (4.09)

220
(8.66)

2.9m

78
(3.07)
66
(2.60)

194
(7.64)

125
(4.92)

60.5
(2.38)
38
19.1 (1.50)
(0.75)

4.8
(0.19)
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Accessories and Dimensions B-13

Figure B.9 NEMA Type 1 Bezel – Dimensions are in millimeters and (inches)
Catalog Number: 22-HIM-B1

11.1
93 (0.44)
25.2 (3.66)
(0.99)

180
(7.09)

2m

67
(2.64)
60
(2.36)

154
(6.06)

4.8
(0.19)
77
(3.03)

19.1
(0.75)
23.5
(0.93)
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Appendix C

RS485 (DSI) Protocol

PowerFlex 40 drives support the RS485 (DSI) protocol to allow efficient
operation with Rockwell Automation peripherals. In addition, some
Modbus functions are supported to allow simple networking. PowerFlex
40 drives can be multi-dropped on an RS485 network using Modbus
protocol in RTU mode.

Controller

For information regarding DeviceNet or other communication protocols,

refer to the appropriate user manual.

Network Wiring
Network wiring consists of a shielded 2-conductor cable that is
daisy-chained from node to node.

Figure C.1 Network Wiring Diagram

PowerFlex 4 PowerFlex 4 PowerFlex 4
Master Node 1 Node 2 Node "n" FRONT
TxRxD+ TxRxD+ 120 ohm resistor
TxRxD+ 4 4 4
120 ohm resistor
TxRxD- TxRxD-
TxRxD- 5 5 5 PIN 1
Shield Shield Shield PIN 8
X X X
NOTE: The shield is connected at ONLY ONE end of each cable segment.

Only pins 4 and 5 on the RJ45 plug should be wired. The other pins on
the PowerFlex 40 RJ45 socket contain power, etc. for other Rockwell
Automation peripheral devices and must not be connected.

Wiring terminations on the master controller will vary depending on the

master controller used and “TxRxD+” and “TxRxD-” are shown for
illustration purposes only. Refer to the master controller’s user manual
for network terminations. Note that there is no standard for the “+” and
“-” wires, and consequently Modbus device manufacturers interpret
them differently. If you have problems with initially establishing
communications, try swapping the two network wires at the master
controller.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

C-2 RS485 (DSI) Protocol

Standard RS485 wiring practices apply. Termination resistors need to be

applied at each end of the network cable. RS485 repeaters may need to
be used for long cable runs, or if greater than 32 nodes are needed on the
network.

Control Terminal 19 on the PowerFlex 40 must also be connected to PE

ground (there are two PE terminals on the drive). See Table 1.H for more
information.

Parameter Configuration
The following PowerFlex 40 parameters are used to configure the drive
to operate on a network.

Parameter Details Reference

P036 [Start Source] Set to 5 “RS485 (DSI) Port” if Start is controlled from Page 3-10
the network.
P038 [Speed Reference] Set to 5 “RS485 (DSI) Port” if the Speed Reference is Page 3-12
controlled from the network.
A103 [Comm Data Rate] Sets the data rate for the RS485 (DSI) Port. All nodes Page 3-29
on the network must be set to the same data rate.
A104 [Comm Node Addr] Sets the node address for the drive on the network. Page 3-29
Each device on the network requires a unique node
address.
A105 [Comm Loss Action] Selects the drive’s response to communication Page 3-30
problems.
A106 [Comm Loss Time] Sets the time that the drive will remain in Page 3-30
communication loss before the drive implements A105
[Comm Loss Action].
A107 [Comm Format] Sets the transmission mode, data bits, parity and stop Page 3-30
bits for the RS485 (DSI) Port. All nodes on the network
must be set to the same setting.

Supported Modbus Function Codes

The peripheral interface (DSI) used on PowerFlex 40 drives supports
some of the Modbus function codes.

Modbus Function Code Command

03 Read Holding Registers
06 Preset (Write) Single Register

Important: Modbus devices can be 0-based (registers are numbered

starting at 0) or 1-based (registers are numbered starting at
1). Depending on the Modbus Master used, the register
addresses listed on the following pages may need to be
offset by +1. For example, Logic Command may be register
address 8192 for some master devices (e.g. ProSoft
3150-MCM SLC Modbus scanner) and 8193 for others
(e.g. PanelViews).
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

RS485 (DSI) Protocol C-3

Writing (06) Logic Command Data

The PowerFlex 40 drive can be controlled via the network by sending
Function Code 06 writes to register address 8192 (Logic Command).
P036 [Start Source] must be set to 5 “RS485 (DSI) Port” in order to
accept the commands.

Logic Command
Address (Decimal) Bit(s) Description
0 1 = Stop, 0 = Not Stop
1 1 = Start, 0 = Not Start
2 1 = Jog, 0 = No Jog
3 1 = Clear Faults, 0 = Not Clear Faults
00 = No Command
01 = Forward Command
5,4
10 = Reverse Command
11 = Change Direction (Toggle)
6 Not Used
7 Not Used
00 = No Command
01 = Accel Rate 1 Enable
9,8
10 = Accel Rate 2 Enable
8192 11 = Hold Accel Rate Selected
00 = No Command
01 = Decel Rate 1 Enable
11,10
10 = Decel Rate 2 Enable
11 = Hold Decel Rate Selected
000 = No Command
001 = Freq. Source = P036 [Start Source]
010 = Freq. Source = A069 [Internal Freq]
011 = Freq. Source = Comms (Addr 8193)
14,13,12
100 = A070 [Preset Freq 0]
101 = A071 [Preset Freq 1]
110 = A072 [Preset Freq 2]
111 = A073 [Preset Freq 3]
15 Not Used

Writing (06) Reference

The Speed Reference to a PowerFlex 40 drive can be controlled via the
network by sending Function Code 06 writes to register address 8193
(Reference). P038 [Speed Reference] must be set to 5 “RS485 (DSI)
Port” in order to accept the Speed Reference.

Reference
Address (Decimal) Description

8193 A decimal value entered as xxx.x where the decimal point is fixed. For
example, a decimal “100” equals 10.0 Hz and “543” equals 54.3 Hz.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

C-4 RS485 (DSI) Protocol

Reading (03) Logic Status Data

The PowerFlex 40 Logic Status data can be read via the network by
sending Function Code 03 reads to register address 8448 (Logic Status).

Logic Status
Address (Decimal) Bit(s) Description
0 1 = Ready, 0 = Not Ready
1 1 = Active (Running), 0 = Not Active
2 1 = Cmd Forward, 0 = Cmd Reverse
3 1 = Rotating Forward, 0 = Rotating Reverse
4 1 = Accelerating, 0 = Not Accelerating
5 1 = Decelerating, 0 = Not Decelerating
6 1 = Alarm, 0 = No Alarm
7 1 = Faulted, 0 = Not Faulted
8448
8 1 = At Reference, 0 = Not At Reference
9 1 = Reference Controlled by Comm
10 1 = Operation Cmd Controlled by Comm
11 1 = Parameters have been locked
12 Digital Input 1 Status
13 Digital Input 2 Status
14 Not Used
15 Not Used

Reading (03) Feedback

The Feedback (Output Frequency) from the PowerFlex 40 drive can be
read via the network by sending Function Code 03 reads to register
address 8451 (Feedback).

Feedback(1)
Address (Decimal) Description

8451 A xxx.x decimal value where the decimal point is fixed. For example, a decimal
“123” equals 12.3 Hz and “300” equals 30.0 Hz.
(1) Returns the same data as Reading (03) Parameter d001 [Output Freq].
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

RS485 (DSI) Protocol C-5

Reading (03) Drive Error Codes

The PowerFlex 40 Error Code data can be read via the network by
sending Function Code 03 reads to register address 8449 (Drive Error
Codes).

Logic Status
Address (Decimal) Value (Decimal) Description
0 No Fault
2 Auxiliary Input
3 Power Loss
4 Undervoltage
5 Overvoltage
6 Motor Stalled
7 Motor Overload
8 Heatsink Overtemperature
12 HW Overcurrent (300%)
13 Ground Fault
29 Analog Input Loss
33 Auto Restart Tries
8449 38 Phase U to Ground Short
39 Phase V to Ground Short
40 Phase W to Ground Short
41 Phase UV Short
42 Phase UW Short
43 Phase VW Short
63 Software Overcurrent
64 Drive Overload
70 Power Unit Fail
80 AutoTune Fail
81 Communication Loss
100 Parameter Checksum Error
122 I/O Board Fail

Reading (03) and Writing (06) Drive Parameters

To access drive parameters, the Modbus register address equals the
parameter number. For example, a decimal “1” is used to address
Parameter d001 [Output Freq] and decimal “39” is used to address
Parameter P039 [Accel Time 1].

Additional Information
Refer to http://www.ab.com/drives/ for additional information.
 SPECIAL INSTRUCTION MANUAL
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Appendix D

RJ45 DSI Splitter Cable

The PowerFlex 40 drive provides a RJ45 port to allow the connection of

a single peripheral device. The RJ45 DSI Splitter Cable can be used to
connect a second DSI peripheral device to the drive.

Connectivity Guidelines

ATTENTION: Risk of injury or equipment damage exists. The

peripherals may not perform as intended if these Connectivity
! Guidelines are not followed. Precautions should be taken to follow
these Connectivity Guidelines.

• Two peripherals maximum can be attached to a drive.

• If a single peripheral is used, it must be connected to the Master port
(M) on the splitter and configured for “Auto” (default) or “Master.”
Parameter 9 [Device Type] on the DSI / MDI keypads and Parameter
1 [Adapter Cfg] on the Serial Converter are used to select the type
(Auto / Master / Slave).
• Do not use the RJ45 Splitter Cable with a drive that has an
internal network communication adapter installed. Since only
one additional peripheral can be added, the second peripheral can be
connected directly to the RJ45 port on the drive. The internal Comm
is always the Master, therefore the external peripheral must be
configured as “Auto” (for temporary connections) or “Slave” (for
permanent connections).
• If two peripherals will be powered up at the same time, one must be
configured as the “Master” and connected to the Master port (M) and
the other must be connected as the “Slave” and connected to the
Slave port (S).
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

D-2 RJ45 DSI Splitter Cable

DSI Cable Accessories

RJ45 Splitter Cable

S
Slave Port

Master Port

M
PIN 1 PIN 8

RJ45 Two-Position Terminal Block Adapter –

TB2
(PIN 5) PIN 8

TB1
(PIN 4) PIN 1

RJ45 Adapter with Integrated Termination Resistor –

PIN 8

PIN 1
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

RJ45 DSI Splitter Cable D-3

Connecting One Temporary Peripheral

DSI / MDI Drive

DSI / MDI
Esc Sel
Serial Converter Hand Held

DISP LANG REMOVE

or Esc

4
Sel

5
9

6
ALT

Jog

1 2 3

M . 0 +/-
DSI

Parameter 1 [Adapter Cfg] set to "Auto"

(default) or "Master" and connected to
Master port (M) on RJ45 Splitter Cable

Parameter 9 [Device Type] set to "Auto"

(default) or "Master" and connected to
Master port (M) on RJ45 Splitter Cable

Connecting One Temporary Peripheral and

One Permanent Peripheral
NEMA 1 Bezel
with DSI / MDI
NEMA 4 Hand Held
Panel Mount Unit
DSI / MDI Drive
DISP LANG REMOVE

Esc Sel

7 8 9 ALT

4 5 6 Jog

1 2 3

Esc Sel . 0 +/-

or
DISP REMOVE
DSI
Esc Sel
LANG

ALT

Jog

DSI

Parameter 9 [Device Type]

S
set to "Master" and
connected to Master port
Parameter 1 [Adapter Cfg] (M) on RJ45 Splitter Cable
set to "Auto" (default) or
"Slave" and connected to
Slave port (S) on Serial Converter
RJ45 Splitter Cable
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

D-4 RJ45 DSI Splitter Cable

Connecting Two Permanent Peripherals

NEMA 1 Bezel
with DSI / MDI
NEMA 4 Hand Held
Panel Mount Unit

DSI /MDI Drive Esc

7
DISP

Sel

8
LANG

9
REMOVE

ALT

4 5 6 Jog

1 2 3

DISP REMOVE . 0 +/-

Esc Sel

or
DSI

LANG

ALT
Esc Sel

Jog

DSI

M Parameter 9 [Device Type] set to

"Master" and connected to Master
port (M) on RJ45 Splitter Cable
S

DISP LANG REMOVE

Esc Sel

7 8 9 ALT

Parameter 9 [Device Type] 4

1
5

2
6

3
Jog

Esc
.

set to "Slave" and

0 +/-
DISP REMOVE

ALT

or
DSI
Sel
LANG

connected to Slave port (S) Jog

on RJ45 Splitter Cable |

DSI

Connecting an RS-485 Network

DSI / MDI Drives

Esc Sel Esc Sel

Two-position
Terminal Block

or or
Terminating Resistor
(end of network)
Customer supplied RJ45 male-to-RJ45 male
cables with wires connected at pins 4 and 5 only.

Both the Master (M) and Slave (S) ports on the RJ45 Splitter
Cable operate as standard RS-485 ports in this configuration.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Appendix E

Step Logic, Basic Logic and

Timer/Counter Functions

Four PowerFlex 40 logic functions provide the capability to program

simple logic functions without a separate controller.

• Step Logic Function

Steps through up to eight preset speeds based on programmed logic.
Programmed logic can include conditions that need to be met from
digital inputs programmed as “Logic In1” and “Logic In2” before
stepping from one preset speed to the next. A timer is available for
each of the eight steps and is used to program a time delay before
stepping from one preset speed to the next. The status of a digital
output can also be controlled based on the step being executed.

• Basic Logic Function

Up to two digital inputs can be programmed as “Logic In1” and/or
“Logic In2”. A digital output can be programmed to change state
based on the condition of one or both inputs based on basic logic
functions such as AND, OR, NOR. The basic logic functions can be
used with or without step logic.

• Timer Function
A digital input can be programmed for “Timer Start”. A digital
output can be programmed as a “Timer Out” with an output level
programmed to the desired time. When the timer reaches the time
programmed into the output level the output will change state. The
timer can be reset via a digital input programmed as “Reset Timer”.

• Counter Function
A digital input can be programmed for “Counter In”. A digital output
can be programmed as “Counter Out” with an output level
programmed to the desired number of counts. When the counter
reaches the count programmed into the output level the output will
change state. The counter can be reset via a digital input
programmed as “Reset Counter”.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

E-2 Step Logic, Basic Logic and Timer/Counter Functions

Step Logic Using Timed Steps

To activate this function, set parameter P038 [Speed Reference] to 6 “Stp
Logic”. Three parameters are used to configure the logic, speed
reference and time for each step.

• Logic is defined using parameters A140-A147 [Stp Logic x].

• Preset Speeds are set with parameters A070-A077 [Preset Freq x].
• Time of operation for each step is set with parameters A150-A157
[Stp Logic Time x].
The direction of motor rotation can be forward or reverse.

Figure E.1 Using Timed Steps

Step 0 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7

Forward
0
Reverse

Time

Step Logic Sequence

• Sequence begins with a valid start command.
• A normal sequence begins with Step 0 and transition to the next step
when the corresponding step logic time has expired.
• Step 7 is followed by Step 0
• Sequence repeats until a stop is issued or a fault condition occurs.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL
Step Logic, Basic Logic and Timer/Counter Functions E-3

Step Logic Using Basic Logic Functions

Digital input and digital output parameters can be configured to use logic
to transition to the next step. Logic In1 and Logic In2 are defined by
programming parameters A051-A054 [Digital Inx Sel] to option 23
“Logic In1” or option 24 “Logic In2”.

Example

• Run at Step 0.
• Transition to Step 1 when Logic In1 is true.
Logic senses the edge of Logic In1 when it transitions from off to on.
Logic In1 is not required to remain “on”.
• Transition to Step 2 when both Logic In1 and Logic In2 are true.
The drive senses the level of both Logic In1 and Logic In2 and
transitions to Step 2 when both are on.
• Transition to Step 3 when Logic In2 returns to a false or off state.
Inputs are not required to remain in the “on” condition except under
the logic conditions used for the transition from Step 2 to Step 3.
Start Step 0 Step 1 Step 2 Step 3

Frequency

Logic In1

Logic In2

Time
The step time value and the basic logic may be used together to satisfy
machine conditions. For instance, the step may need to run for a
minimum time period and then use the basic logic to trigger a transition
to the next step.
Start Step 0 Step 1

Frequency

Logic In1

Logic In2

Time
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

E-4 Step Logic, Basic Logic and Timer/Counter Functions

Timer Function
Digital inputs and outputs control the timer function and are configured
with parameters A051-A054 [Digital Inx Sel] set to 18 “Timer Start” and
20 “Reset Timer”.

Digital outputs (relay and opto type) define a preset level and indicate
when the level is reached. Level parameters A056 [Relay Out Level],
A059 [Opto Out1 Level] and A062 [Opto Out2 Level] are used to set the
desired time in seconds.

Parameters A055 [Relay Out Sel], A058 [Opto Out1 Sel] and A061
[Opto Out2 Sel] are set to option 16 “Timer Out” and causes the output
to change state when the preset level is reached.

Example

• Drive starts up and accelerates to 30 Hz.

• After 30Hz has been maintained for 20 seconds, a 4-20mA analog
input becomes the reference signal for speed control.
• The timer function is used to select a preset speed with a 20 second
run time that overrides the speed reference while the digital input is
active.
• Parameters are set to the following options:
– P038 [Speed Reference] = 3 “4-20mA Input”
– A051 [Digital In1 Sel] = 4 “Preset Freq”
– A052 [Digital In2 Sel] = 18 “Timer Start”
– A055 [Relay Out Sel] = 16 “Timer Out”
– A056 [Relay Out Level] = 20.0 Secs
– A071 [Preset Freq 1] = 30.0 Hz
• The control terminal block is wired such that a start command will
also trigger the timer start.
• The relay output is wired to I/O Terminal 05 (Digital Input 1) so that
it forces the input on when the timer starts.
• After the timer is complete, the output is turned off releasing the
preset speed command. The drive defaults to following the analog
input reference as programmed.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Step Logic, Basic Logic and Timer/Counter Functions E-5

Output
Frequency

Start

Relay Out

Photo Eye

Digital In1
Counter In
Digital In2
Reset Counter
Limit Switch

Note that a “Reset Timer” input is not required for this example since the
“Timer Start” input both clears and starts the timer.
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E-6 Step Logic, Basic Logic and Timer/Counter Functions

Counter Function
Digital inputs and outputs control the counter function and are
configured with parameters A051-A054 [Digital Inx Sel] set to 19
“Counter In” and 21 “Reset Counter”.

Digital outputs (relay and opto type) define a preset level and indicate
when the level is reached. Level parameters A056 [Relay Out Level],
A059 [Opto Out1 Level] and A062 [Opto Out2 Level] are used to set the
desired count value.

Parameters A055 [Relay Out Sel], A058 [Opto Out1 Sel] and A061
[Opto Out2 Sel] are set to 17 “Counter Out” which causes the output to
change state when the level is reached.

Example

• A photo eye is used to count packages on a conveyor line.

• An accumulator holds the packages until 5 are collected.
• A diverter arm redirects the group of 5 packages to a bundling area.
• The diverter arm returns to its original position and triggers a limit
switch that resets the counter.
• Parameters are set to the following options:
– A051 [Digital In1 Sel] set to 19 to select “Counter In”
– A052 [Digital In2 Sel] set to 21 to select “Reset Counter”
– A055 [Relay Out Sel] set to 17 to select “Counter Out”
– A056 [Relay Out Level] set to 5.0 (counts)
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Step Logic, Basic Logic and Timer/Counter Functions E-7

Step Logic Parameters

Table E.A Code Descriptions for Parameters A140-A147
Digit 3 Digit 2 Digit 1 Digit 0
0 0 F 1

Table E.B Digit 3 – Defines the action during the step currently executing.
Accel/Decel Step Logic Output
Setting Parameters Used State Commanded Direction
0 1 Off FWD
1 1 Off REV
2 1 Off No Output
3 1 On FWD
4 1 On REV
5 1 On No Output
6 2 Off FWD
7 2 Off REV
8 2 Off No Output
9 2 On FWD
A 2 On REV
b 2 On No Output

Table E.C Digit 2 – Defines what step to jump to or how to end program when the
logic conditions specified in Digit 1 are met.
Setting Logic
0 Jump to Step 0
1 Jump to Step 1
2 Jump to Step 2
3 Jump to Step 3
4 Jump to Step 4
5 Jump to Step 5
6 Jump to Step 6
7 Jump to Step 7
8 End Program (Normal Stop)
9 End Program (Coast to Stop)
A End Program and Fault (F2)
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E-8 Step Logic, Basic Logic and Timer/Counter Functions

Table E.D Digit 1 – Defines what logic must be met to jump to a step other than the
very next step.
Setting Description Logic
0 Skip Step (jump immediately) SKIP
1 Step based on the time programmed in the respective [Stp Logic Time x] TIMED
parameter.
2 Step if “Logic In1” is active (logically true) TRUE
3 Step if “Logic In2” is active (logically true) TRUE
4 Step if “Logic In1” is not active (logically false) FALSE
5 Step if “Logic In2” is not active (logically false) FALSE
6 Step if either “Logic In1” or “Logic In2” is active (logically true) OR
7 Step if both “Logic In1” and “Logic In2” is active (logically true) AND
8 Step if neither “Logic In1” or “Logic In2” is active (logically true) NOR
9 Step if “Logic In1” is active (logically true) and “Logic In2” is not active XOR
(logically false)
A Step if “Logic In2” is active (logically true) and “Logic In1” is not active XOR
(logically false)
b Step after [Stp Logic Time x] and “Logic In1” is active (logically true) TIMED AND
C Step after [Stp Logic Time x] and “Logic In2” is active (logically true) TIMED AND
d Step after [Stp Logic Time x] and “Logic In1” is not active (logically false) TIMED OR
E Step after [Stp Logic Time x] and “Logic In2” is not active (logically false) TIMED OR
F Do not step OR no “jump to”, so use Digit 0 logic IGNORE

Table E.E Digit 0 – Defines what logic must be met to jump to the very next step.
Setting Description Logic
0 Skip Step (jump immediately) SKIP
1 Step based on the time programmed in the respective [Stp Logic Time x] TIMED
parameter.
2 Step if “Logic In1” is active (logically true) TRUE
3 Step if “Logic In2” is active (logically true) TRUE
4 Step if “Logic In1” is not active (logically false) FALSE
5 Step if “Logic In2” is not active (logically false) FALSE
6 Step if either “Logic In1” or “Logic In2” is active (logically true) OR
7 Step if both “Logic In1” and “Logic In2” is active (logically true) AND
8 Step if neither “Logic In1” or “Logic In2” is active (logically true) NOR
9 Step if “Logic In1” is active (logically true) and “Logic In2” is not active XOR
(logically false)
A Step if “Logic In2” is active (logically true) and “Logic In1” is not active XOR
(logically false)
b Step after [Stp Logic Time x] and “Logic In1” is active (logically true) TIMED AND
C Step after [Stp Logic Time x] and “Logic In2” is active (logically true) TIMED AND
d Step after [Stp Logic Time x] and “Logic In1” is not active (logically false) TIMED OR
E Step after [Stp Logic Time x] and “Logic In2” is not active (logically false) TIMED OR
F Use logic programmed in Digit 1 IGNORE
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Appendix F

PID Set Up

PID Loop
The PowerFlex 40 has a built-in PID (proportional, integral, differential)
control loop. The PID loop is used to maintain a process feedback (such
as pressure, flow or tension) at a desired set point. The PID loop works
by subtracting the PID feedback from a reference and generating an
error value. The PID loop reacts to the error, based on the PID Gains,
and outputs a frequency to try to reduce the error value to 0. To enable
the PID loop, parameter A132 [PID Ref Sel] must be set to an option
other than 0 “PID Disabled”.

Exclusive Control and Trim Control are two basic configurations where
the PID loop may be used.
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F-2 PID Set Up

Exclusive Control
In Exclusive Control, the Speed Reference becomes 0, and the PID
Output becomes the entire Freq Command. Exclusive Control is used
when A132 [PID Ref Sel] is set to option 1, 2, 3 or 4. This configuration
does not require a master reference, only a desired set point, such as a
flow rate for a pump.

PID Loop
PID Ref PID Prop Gain
+ PID + PID
– Error + Output Accel/Decel Freq
PID Fdbk PID Integ Time Ramp Command
+
PID Diff Rate
PID Enabled

Example

• In a pumping application, the PID Reference equals the Desired

System Pressure set point.
• The Pressure Transducer signal provides PID Feedback to the drive.
Fluctuations in actual system pressure, due to changes in flow, result
in a PID Error value.
• The drive output frequency increases or decreases to vary motor
shaft speed to correct for the PID Error value.
• The Desired System Pressure set point is maintained as valves in the
system are opened and closed causing changes in flow.
• When the PID Control Loop is disabled, the Commanded Speed is
the Ramped Speed Reference.

PID Feedback =
Pressure Transducer Signal
Pump

PID Reference =
Desired System Pressure
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PID Set Up F-3

Trim Control
In Trim Control, the PID Output is added to the Speed Reference. In
Trim mode, the output of the PID loop bypasses the accel/decel ramp as
shown. Trim Control is used when A132 [PID Ref Sel] is set to option 5,
6, 7 or 8.
Speed Ref
PID Loop Accel/Decel
PID Ref Ramp
PID Prop Gain
+ PID + PID +
– Error + Output + Output
PID Fdbk PID Integ Time Freq
+
PID Diff Rate
PID Enabled

Example

• In a winder application, the PID Reference equals the Equilibrium

set point.
• The Dancer Pot signal provides PID Feedback to the drive.
Fluctuations in tension result in a PID Error value.
• The Master Speed Reference sets the wind/unwind speed.
• As tension increases or decreases during winding, the Speed
Reference is trimmed to compensate. Tension is maintained near the
Equilibrium set point.

0 Volts

PID Reference = PID Feedback =

Equilibrium Set Point Dancer Pot Signal

10 Volts

Speed Reference
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F-4 PID Set Up

PID Reference and Feedback

Parameter A132 [PID Ref Sel] is used to enable the PID mode (A132 ≠ 0
“PID Disabled”) and to select the source of the PID Reference. If A132
[PID Ref Sel] is not set to 0 “PID Disabled”, PID can still be disabled by
select programmable digital input options (parameters A051-A054) such
as “Jog”, “Local” or “PID Disable”.

Table F.A A132 [PID Ref Sel] Options

Option Description
0 “PID Disabled” Disables the PID loop (default setting)
1 “PID Setpoint“ Selects Exclusive Control. A137 [PID Setpoint] will be used to
set the value of the PID Reference
2 “0-10V Input” Selects Exclusive Control. Selects the 0-10V Input. Note that
the PID will not function with a bipolar analog input. It will
ignore any negative voltages and treat them like a zero.
3 “4-20mA Input” Selects Exclusive Control. Selects the 4-20mA Input.
4 “Comm Port” Selects Exclusive Control. The reference word from a
communication network (see Appendix C for details on the
reference word) such as Modbus RTU or DeviceNet becomes
the PID Reference. The value sent over the network is scaled
so that P035 [Maximum Freq] x 10 = 100% reference. For
example, with [Maximum Freq] = 60 Hz, a value of 600 sent
over the network would represent 100% reference.
5 “Setpnt, Trim” Selects Trim Control. A137 [PID Setpoint] will be used to set
the value of the PID Reference.
6 “0-10V, Trim” Selects Trim Control. Selects the 0-10V Input. Note that the
PID will not function with a bipolar analog input. It will ignore
any negative voltages and treat them like a zero.
7 “4-20mA, Trim” Selects Trim Control. Selects the 4-20mA Input.
8 “Comm, Trim” Selects Trim Control. The reference word from a
communication network (see Appendix C for details on the
reference word) such as Modbus RTU or DeviceNet becomes
the PID Reference. The value sent over the network is scaled
so that P035 [Maximum Freq] x 10 = 100% reference. For
example, with [Maximum Freq] = 60 Hz, a value of 600 sent
over the network would represent 100% reference.

A133 [PID Feedback Sel] is used to select the source of the PID
feedback.

Table F.B A133 [PID Feedback Sel] Options

Option Description
0 “0-10V Input” Selects the 0-10V Input (default setting). Note that the PID will
not function with a bipolar analog input. It will ignore any
negative voltages and treat them like a zero.
1 “4-20mA Input“ Selects the 4-20mA Input.
2 “Comm Port” The reference word from a communication network (see
Appendix C of the PowerFlex 40 User Manual for details on the
reference word) such as Modbus RTU or DeviceNet becomes
the PID Feedback. The value sent over the network is scaled
so that P035 [Maximum Freq] x 10 = 100% Feedback. For
example, with [Maximum Freq] = 60 Hz, a value of 600 sent
over the network would represent 100% Feedback.
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PID Set Up F-5

Analog PID Reference Signals

Parameters A110 [Anlg In 0-10V Lo] and A111 [Anlg In 0-10V Hi] are
used to scale or invert an analog PID Reference.

Important: Firmware version FRN 1.xx does not support PID

Feedback scaling from an analog input.

Examples

Scale Function
For a 0-5 volt signal, the following parameter settings are used so that a 0
volt signal = 100% PID Reference and a 5 volt signal = 0% PID
Reference.
• A110 [Anlg In 0-10V Lo] = 0.0%
• A111 [Anlg In 0-10V Hi] = 50.0%
• A132 [PID Ref Sel] = 0 “0-10V Input”
12

10

8
Input Volts

6
4

0 10 20 30 40 50 60 70 80 90 100
PID Reference (%)

Invert Function
For a 4-20mA signal, the following parameter settings are used so that a
20mA signal = 0% PID Reference and a 4mA signal = 100% PID
Reference.
• A112 [Anlg In 4-20mA Lo] = 100.0%
• A113 [Anlg In 4-20mA Hi] = 0.0%
• A132 [PID Ref Sel] = 3 “4-20mA Input”
24

20
4-20mA Input

16

12

8
4
0 10 20 30 40 50 60 70 80 90 100
PID Reference (%)
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F-6 PID Set Up

PID Deadband
Parameter A138 [PID Deadband] is used to set a range, in percent, of the
PID Reference that the drive will ignore.

Example

• [PID Deadband] is set to 5.0

• The PID Reference is 25.0%
• The PID Regulator will not act on a PID Error that falls between 20.0
and 30.0%

PID Preload
The value set in A139 [PID Preload], in Hertz, will be pre-loaded into
the integral component of the PID at any start or enable. This will cause
the drive’s frequency command to initially jump to that preload
frequency, and the PID loop starts regulating from there.

PID Enabled

PID Pre-load Value

PID Output

Freq Cmd

PID Pre-load Value > 0

PID Limits
A130 [PID Trim Hi] and A131 [PID Trim Lo] are used to limit the PID
output and are only used in trim mode. [PID Trim Hi] sets the maximum
frequency for the PID output in trim mode. [PID Trim Lo] sets the
reverse frequency limit for the PID output in trim mode. Note that when
the PID reaches the Hi or Lo limit, the PID regulator stops integrating so
that windup does not occur.
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PID Set Up F-7

PID Gains
The proportional, integral, and differential gains make up the PID
regulator.

• A134 [PID Prop Gain]

The proportional gain (unitless) affects how the regulator reacts to
the magnitude of the error. The proportional component of the PID
regulator outputs a speed command proportional to the PID error.
For example, a proportional gain of 1 would output 100% of max
frequency when the PID error is 100% of the analog input range. A
larger value for [PID Prop Gain] makes the proportional component
more responsive, and a smaller value makes it less responsive.
Setting [PID Prop Gain] to 0.00 disables the proportional component
of the PID loop.
• A135 [PID Integ Time]
The integral gain (units of seconds) affects how the regulator reacts
to error over time and is used to get rid of steady state error. For
example, with an integral gain of 2 seconds, the output of the integral
gain component would integrate up to 100% of max frequency when
the PID error is 100% for 2 seconds. A larger value for [PID Integ
Time] makes the integral component less responsive, and a smaller
value makes it more responsive. Setting [PID Integ Time] to 0
disables the integral component of the PID loop.
• A136 [PID Diff Rate]
The Differential gain (units of 1/seconds) affects the rate of change
of the PID output. The differential gain is multiplied by the
difference between the previous error and current error. Thus, with a
large error the D has a large effect and with a small error the D has
less of an effect. This parameter is scaled so that when it is set to
1.00, the process response is 0.1% of [Maximum Freq] when the
process error is changing at 1% / second. A larger value for [PID Diff
Rate] makes the differential term have more of an effect and a small
value makes it have less of an effect. In many applications, the D
gain is not needed. Setting [PID Diff Rate] to 0.00 (factory default)
disables the differential component of the PID loop.
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F-8 PID Set Up

Guidelines for Adjusting the PID Gains

1. Adjust the proportional gain. During this step it may be desirable to
disable the integral gain and differential gain by setting them to 0.
After a step change in the PID Feedback:
– If the response is too slow increase A134 [PID Prop Gain].
– If the response is too quick and/or unstable (see Figure F.1),
decrease A134 [PID Prop Gain].
– Typically, A134 [PID Prop Gain] is set to some value below the
point where the PID begins to go unstable.
2. Adjust the integral gain (leave the proportional gain set as in Step 1).
After a step change in the PID Feedback:
– If the response is too slow (see Figure F.2), or the PID Feedback
does not become equal to the PID Reference, decrease A135
[PID Integ Time].
– If there is a lot of oscillation in the PID Feedback before settling
out (see Figure F.3), increase A135 [PID Integ Time].
3. At this point, the differential gain may not be needed. However, if
after determining the values for A134 [PID Prop Gain] and A135
[PID Integ Time]:
– Response is still slow after a step change, increase A136 [PID
Diff Rate].
– Response is still unstable, decrease A136 [PID Diff Rate].
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PID Set Up F-9

The following figures show some typical responses of the PID loop at
different points during adjustment of the PID Gains.

Figure F.1 Unstable

PID Reference

PID Feedback

Time

Figure F.2 Slow Response – Over Damped

PID Reference

PID Feedback

Time

Figure F.3 Oscillation – Under Damped

PID Reference

PID Feedback

Time

Figure F.4 Good Response – Critically Damped

PID Reference

PID Feedback

Time
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www.rockwellautomation.com

Corporate Headquarters
Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, 53202-5302 USA, Tel: (1) 414.212.5200, Fax: (1) 414.212.5201

Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing Solutions
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Publication 22B-UM001B-EN-E – June 2003

Supersedes January 2003
Copyright © 2003 Rockwell Automation, Inc. All rights reserved.
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RADIO REMOTE PROPEL

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Table of Contents
Safety Precautions ....................................................................................................................................................... 3
System Overview ........................................................................................................................................................ 4
Features ....................................................................................................................................................................... 4
Dimensions and Controls.................................................................................................................................... 5
Installing the Receiver.................................................................................................................................................. 6
Receiver Dimensions ................................................................................................................................................... 6
Special Functions......................................................................................................................................................... 7
Installation Considerations........................................................................................................................................... 8
Power the Transmitter.................................................................................................................................................. 9
Test the Transmitter / Receiver Link ............................................................................................................................ 10
Download ID Code ....................................................................................................................................................... 10
Diagnostics— Transmitter ................................................................................................................................... 12
Diagnostics— Receiver ..................................................................................................................................... 13
Troubleshooting Guide................................................................................................................................................. 14

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Safety Precautions

NOTE: These instructions are intended only for installing and operating the remote control equipment described here. This is not a
complete Operator’s Manual. For complete operating instructions, please read the Operator’s Manual appropriate for your particular
machine.

READ ALL INSTRUCTIONS

CAUTION: Changes or modifications not expressly approved by the party responsible for compliance could void the
user's authority to operate the equipment.
Failure to follow the SAFETY PRECAUTIONS may result in radio equipment failure and serious personal injury

Installation
PROVIDE A SAFETY CUTOFF SWITCH. If maintenance is required, the radio must be disconnected from power
USE PROPER WIRING. Loose or frayed wires can cause system failure, intermittent operation, machine damage, etc.
DO NOT INSTALL IN HOT AREAS. This apparatus can be damaged by heat in excess of 158° F (70° C)

Personal Safety
MAKE SURE MACHINERY AND SURROUNDING AREA IS CLEAR BEFORE OPERATING. Do not activate the remote
system unless it is safe to do so.
TURN OFF THE RECEIVER POWER BEFORE WORKING ON MACHINERY. Always disconnect the remote system
before doing any maintenance to prevent accidental operation of the machine

Care
KEEP DRY. Do not clean the transmitter / receiver under high pressure. If water or other liquids get inside the transmit-
ter battery or receiver compartment, immediately dry the unit. Remove the case and let the unit air dry
CLEAN THE UNIT AFTER OPERATION. Remove any mud, dirt, concrete, etc. from the unit to prevent clogging of but-
tons, switches, etc. by using a damp cloth.

Maintenance / Welding
DISCONNECT THE RADIO RECEIVER BEFORE WELDING on the machine the receiver is connected to. Failure to
disconnect will result in the destruction of the radio receiver.

3
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The symbols used on the transmitter label are as follows:

Turn transmitter power off, on.

Battery, transmit, E-stop lamps – see below.

Joystick button

Track, winch brake release (joystick enable)

Track, winch mode

Left track, right track forward

Left track, right track reverse

Winch down, up

Propel speed fast, slow

Boarding stairs down, up

Horn

Auto leveling extend, retract

Dust curtain lower, raise

Cable reel in, out

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Installing the Receiver

Use the Wiring Diagram and the Connector Diagram below to connect the receiver pins directly to the appropriate
contacts of the machine electronics. Output Cables can be provided with every system to simplify the wiring
process. The Wire Color column below only applies to the Output Cable configuration. Tips on mounting,
power connections and filtering are also provided under Installation Considerations.

Wiring Diagram
Pin-Output Wire Colors Functions
B7 Factory Configurable Only
B8 Factory Configurable Only
B12 - 19 Black/Red AUTO LEVEL RETRACT OUTPUT
B11 - 18 White/Black AUTO LEVEL EXTEND OUTPUT
B10 - 17 Blue/White RIGHT TRACK OR WINCH REVERSE OUTPUT
A1 - 16 Blue/Black LEFT TRACK REVERSE OUTPUT
A2 - 15 Black/White RIGHT TRACK OR WINCH PROPORTIONAL OUTPUT
A4 - 14 Green/Black LEFT TRACK PROPORTIONAL OUTPUT
B9 - 13 Red/White E-STOP ACTIVE OUTPUT
B6 - 12 Orange HORN OUTPUT
B5 - 11 White JOYSTICK ACTIVE OUTPUT
B4 - 10 Green/Black/White TRANSMITTER ON OUTPUT
B3 - 9 Green REMOTE BASE UNIT ACTIVE OUTPUT
B2 - 8 Red/Black/White CONTROL MODE WINCH (OFF = TRACK) OUTPUT
B1 - 7 White/Red/Black PROPEL SPEED LOW (OFF = FAST) OUTPUT
A12 - 6 Orange/Red BOARD NG STAIRS DOWN OUTPUT
A10 - 5 Orange/Black BOARD NG STAIRS UP OUTPUT
A11 - 4 Blue/Red DUST CURTAIN LOWER OUTPUT
A9 - 3 White/Red DUST CURTAIN RAISE OUTPUT
A8 - 2 Red/Green CABLE REEL OUT OUTPUT
A7 - 1 Orange/Green CABLE REEL IN OUTPUT

A5 Black/White/Red Switches to Power with

Link
A6 Red Power Input
(+9V to 30VDC)
A3 Black Ground

Outputs: 19 solid state, high-side driver outputs, 5A max. per pin and 7A max per bank, total combined current 15A

Inputs: All output pins can be factory configured as inputs. Input pins should be connected to a current limiting (fused) source

Connector Pin Assignments

Connectors as seen from under the receiver

ES FA L STA

5.13”

A B
4.00”

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Special Functions

After power is applied to the receiver, the REMOTE BASE UNIT output will be on and E-STOP ACTIVE output will be off.
Once the Transmitter is switched on and the green lamp is on, the TRANSMITTER ON and E-STOP outputs will come
on. With the Transmitter on, the E-STOP ACTIVE output will be on when the E-STOP button is depressed (stop lamp on)
and off when released (stop lamp off). With the Transmitter off, the E-STOP ACTIVE output is always off. The remaining
outputs operate in the following manner.
The joysticks have two modes controlled by the WINCH/TRACK switch. With the switch in the TRACK position, the
CONTROL MODE output is off and the receiver is in Propel mode. While in Propel mode the JOYSTICK ACTIVE output
will come on if the BRAKE RELEASE or BRAKE/WINCH RELEASE is pressed. The JOYSTICK ACTIVE output will re-
main on for one second after both joysticks are returned to the center position and both BRAKE RELEASE and BRAKE/
WINCH RELEASE buttons are off. When in Propel mode the JOYSTICK ACTIVE output must be on for any output to
appear on the LEFT TRACK or RIGHT TRACK/WINCH outputs.
The WINCH/TRACK switch in the WINCH position causes the CONTROL MODE output to go on and the receiver to go
in to Winch mode. The BRAKE/WINCH RELEASE button must be pressed to operate the RIGHT TRACK/WINCH out-
put. While in Winch mode the LEFT TRACK and JOYSTICK ACTIVE outputs are disabled.
Changing the CONTROL MODE while operating a joystick will cause JOUSTICK ACTIVE output to immediately shut off
(if it was on) and the LEFT TRACK and RIGHT TRACK/WINCH outputs to be disabled. They will remain disabled until
the BRAKE/WINCH RELEASE buttons and both joysticks are returned to their neutral position.
The PROPEL SPEED output is off when the switch is in the NORMAL position and on in the SLOW position. All other
switches will produce an output on their corresponding function when activated.

7
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Installation Considerations
NOTE: The FCC and ISC require that the antenna be restricted to that supplied by the manufacturer and approved for use with this product. An op-
tional 0dB coax wire antenna may be supplied. For other antenna options, please contact Control Systems ULC.

The antenna(s) used for this transmitter must not be co-located or operating in conjunction with any other antenna or transmitter.

Mounting and Installation

The receiver can be mounted by fastening two ¼” bolts through the two mounting holes in the unit’s enclosure. When
mounting, ensure that the receiver is oriented so that the text is reading right and the connector is pointing “down”.

When selecting a mounting point for the receiver, it is recommended that the location require only a minimal length of wir-
ing to connect it to the control panel, that it will be in a visible area where it has good exposure to the operator and that it
is mounted on a surface that is protected from the weather and sustains minimal vibration. It is also recommended that
the receiver have the best possible line of sight with the transmitter for maximum operating range.

When installing the receiver, it is recommended that a “Drip Loop” is formed

with the output cables. By creating a Drip Loop, water from condensation, rain
or wet environments, will drip off of the cable instead of running along the wire
and into the receiver connections or running along the cables into the ma-
chine’s electronic controls.

Using approximately 1 foot (30 cm) of cable create a loop with an approximate
radius of 3-4 inches (8-10 cm). Ensure the loop bottom is lower than the re-
ceiver connectors. 3” - 4 “
If connecting an external antenna, a Drip Loop radius of approximately 2-3
inches (5—8 cm) can be formed from approximately 8 inches (20 cm) of cable.

Drip Loop

Power Connections and Wiring

Whenever a power connection is made to an electronic device, it is a good practice to make both the Power (+) and
Ground (-) connections directly to the battery and avoid connecting the power from the charging side of existing wiring or
making use of existing "ACC" or other peripheral connection points.

When proportional voltage outputs are used to operate critical equipment it is good practice to use a separate enable sig-
nal as part of the control circuit. In some cases an application can be designed using an independent enable output for
each proportional output (see wiring diagram). An alternative solution is to use the “Switches to Power with Link” line (see
wiring diagram) to explicitly enable each of the functions that are using proportional voltage control. This will ensure that
under all fault conditions the equipment will be disabled when the link is disabled (e.g. by hitting E-Stop). As well, follow-
ing any instance of a fault condition (e.g. output shorted) it is recommended practice to fully cycle the power to
the receiver before restarting the transmitter to ensure that the system is restarted from a known state.

Make sure that wire of sufficient gauge and insulator type is used when connecting the outputs of the receiver to the con-
trol panel. Observe any component manufacturer's instructions and recommendations for proper integration of their prod-
uct. This includes the power ratings and requirements of such components as relays, valves, solenoids, etc.

Be sure to test each of the outputs with a multi-meter prior to connecting the outputs to your end devices. This will ensure
that each output has been programmed to operate in the manner required by each end device.

Filtering and Noise Suppression

Whenever a solenoid or electromagnetic switch is controlled by the receiver, it is a good practice to install a diode across
its terminals to ensure that surges and spikes do not continue back into the circuit. Appropriate 36V Bi-directional Diodes
kits can be ordered under the part number “AKIT-2492-01”.

8
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BI012088 MD6640 BLAST HOLE DRILL

Troubleshooting Guide (continued) Chart #2

Test the Transmitter—

Turn off the receiver

Ensure there are good batteries in the transmitter
Turn on the transmitter

OK state:
Active light—steady for
What is the state of about 3 seconds then Toggle a switch,
the lights? goes to fast flash. paddle or joystick
Battery light—OFF
E-Stop light—OFF

YES Does the Active

Go to Chart 3
light go to solid
YELLOW?

NO
Complete the following steps in order:
1. Check battery orientation
No light comes on 2. Clean battery contacts Either the switch/paddle is
at any time 3. Check or Replace batteries defective or the switch/paddle
4. Call for service connection to the circuit board
is broken.
Call for service
Stuck switch/paddle:
Both the Active light 1. Return all paddles/switches to neutral
and the E-Stop light (OFF) position
flash at the same time 2. Toggle the switch/paddle a few times
3. Call for service

Both the Active light Power switch is stuck in UP position:

and the Battery light 1. Return switch to neutral position
flash at the same time 2. Toggle the switch a few times
3. Call for service

Low Battery—Change Batteries

Active light and Note: Low batteries will last approxi-
Battery light flashing mately 20 hours once the Low Battery
alternately light begins to flash.
Replace batteries by next shift.

Battery light alter- The transmitter is in Calibration mode

nates between RED 1. Turn unit OFF, then turn back ON
and GREEN. 2. If condition persists, call for service.

Battery light flashes Press and release E-Stop if the condition

for 10 seconds then persists, then either there is a faulty E-
all lights are OFF Stop or transmitter failure—call for ser-
vice

15
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BI012088 MD6640 BLAST HOLE DRILL
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BI012088 MD6640 BLAST HOLE DRILL

Troubleshooting Guide (continued) Chart #4

Considerations when Downloading the ID

Potential downloading issues

If testing of the receiver and transmitter both show the system as working (Chart 1 & 2), then the transmitter and receiver
will both go into Download/Configuration mode.

Possible issues could arise during Step 4, the download phase of reprogramming. In this case there are 2 symptoms to
look for:
1. The Link light on the receiver will not turn GREEN when the power switch is toggled on the transmitter to download
2. The receiver will “time out” indicating that it didn’t receive a signal from the transmitter within the 30 seconds from
the time the receiver was put into Setup Mode.

If all indications appear normal during the download phase, test the link by turning on the transmitter (note: the transmit-
ter shuts off after transmitting the ID code in Step 4)

1. If the Link light on the receiver doesn’t turn GREEN, the receiver didn’t receive all of the information that was sent
from the transmitter.

Possible Solutions

1. Try the Downloading steps again

2. If this doesn’t correct the problem, send both the transmitter and receiver in for service.

Note: you could try to determine whether the fault lies with the transmitter or receiver by completing the downloading
procedure with a different transmitter. If this step works, then the fault lies with the original transmitter. If not, the
fault may lie with the receiver.

!!Caution!!

Note: Before attempting downloading with another transmitter, understand that repro-
gramming the receiver with another transmitter, could result in two receivers on the job
site responding to the one transmitter. If the original transmitter was sent in for repair,
Disconnect the receiver (disconnect connector A) to continue using the machine with-
out remote capability and without fear of inadvertently operating the machine with the
other transmitter. Connector A

Reprogramming Tips:

1. Use a pointy instrument to depress the Setup button on the receiver (i.e. a pen) as the button is relatively small
2. Follow each step as laid out in the procedure
3. Never lay the receiver circuit board down on anything metallic (there are contact points on the back which could con-
tact the metal and damage the receiver)

17
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

TVXY OM−05450−04 _EXT

March 3, 2004
GORMAN-RUPP GHS2 Rev. D 06-16-06

FOR BUCYRUS INTERNATIONAL ASSEMBLIES

SO44557,SO45940,SO54
INSTALLATION, OPERATION,
914 MAINTENANCE MANUAL
AND

ROTARY GEAR PUMPS

MODELS

GHS SERIES FLEXIBLE SEAL

IRON AND STEEL PUMPS
G,J,N & R SIZES

THE GORMAN-RUPP COMPANY MANSFIELD, OHIO

www.grpumps.com
GORMAN-RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
Copyright by the Gorman-Rupp Company
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

TABLE OF CONTENTS
(continued)
PUMP MAINTENANCE AND REPAIR − SECTION E . . . . . . . . . . . . . . . . . PAGE E − 1
TYPICAL GHS G, J, N And R SIZE PUMP MODEL ILLUSTRATION . . . . . . . . . . . . . . . . . . . PAGE E−2
PARTS KEY: TYPICAL G, J, N & R SIZE GHS PUMP MODEL . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−3
PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−4
Preparing for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−4
Pressure Relief Valve (10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−5
Optional Head Jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−5
Rotor Adjusting Sleeve (07) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−5
Coverplate Kit (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−5
Head/Idler Kit (01 and 02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−6
Seal Removal (05) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−6
Rotor/Shaft Removal (03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−6
Foot Bracket Kit (08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−6
Backhead Kit Removal (06) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−6
Housing Assembly (04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−7
PUMP REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−7
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−7
Bushing Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−7
Housing Assembly (04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−8
Backhead Kit (06) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−8
Rotor/Shaft Assembly (03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−8
Seal Installation (05) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−8
Head/Idler Kit (01 and 02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−9
Optional Head Jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−9
Coverplate Kit (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−9
Foot Bracket Kit (08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−9
Rotor Adjusting Sleeve (07) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−9
SETTING END CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−10
RELIEF VALVE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−11
RELIEF VALVE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−12
Relief Valve Installation (10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E−14

SEAL APPENDIX − SECTION F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE F−1

Standard Friction Drive (And Optional 60A, 60B And 61J) Mechanical Seals . . . . . . . . . . . PAGE F−1
Positive Drive (Option 60D) Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE F−4
Double Friction Drive (Options 60J And 60K) Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE F−7
Optional 60M, 60N, 60P, And 61L Cartridge Seal (G-N" Sizes Only) . . . . . . . . . . . . . . . . . . PAGE F−10
Balanced Seal (Option 60Q And 60R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE F−12
Friction Drive Tandem Mechanical Seal (Option 60S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE F−15
Cartridge Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE F−18
Standard (And Optional 65Q) Packing Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE F−21
Minimum Leak Packing Seal (Option 65S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE F−24

O-RING APPENDIX − SECTION G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE G−1

O-ring Information Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE G−1

ii
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

INTRODUCTION
Thank You for purchasing a Gorman-Rupp Rotary on design and components. Some models are
Gear Pump. This manual is designed to help you not recommended for use with water; others
achieve the best performance and longest life from when fitted with specific options, may be used
your Gorman-Rupp Rotary Gear pump. Read this with water; consult the factory.
manual carefully to learn how to safely install, op-
erate and repair your pump. Failure to do so could If there are any questions regarding the pump or
result in personal injury or damage to the pump. drive unit which are not covered in this manual or
in other literature accompanying this unit, please
This manual will alert personnel to known proce- contact your Gorman-Rupp distributor or the Gor-
dures which require special attention, to those man-Rupp Company:
which could damage equipment, and to those
which could be dangerous to personnel. However, The Gorman-Rupp Company
this manual cannot possibly provide detailed in- P.O. Box 1217
structions and precautions for each specific ap- Mansfield, Ohio 44901−1217
plication or for every situation that might occur dur- Phone: (419) 755−1011
ing maintenance of the unit. Therefore, it is the re- or:
sponsibility of the owner, installer and/or mainte- Gorman-Rupp of Canada Limited
nance personnel to ensure that applications and/ 70 Burwell Road
or maintenance procedures not addressed in this St. Thomas, Ontario N5P 3R7
manual are performed only after establishing that Phone: (519) 631−2870
neither personal safety nor pump integrity are
compromised by such applications or procedures.
WARRANTY INFORMATION
In addition to this manual, a separate Parts List is
shipped with the pump. Refer to the Parts List when
The warranty provided with your pump is part of
ordering parts.
Gorman-Rupp’s support program for customers
If your pump is furnished with a drive unit, refer to who operate and maintain their equipment as de-
the drive unit manufacturer’s installation and oper- scribed in this and the other accompanying litera-
ation instructions in the literature accompanying ture. Please note that should the equipment be
the pump. abused or modified to change its performance be-
yond the original factory specifications, the war-
These pumps can transfer a wide range of light, ranty will become void and any claim will be de-
medium, and heavy viscosity liquids, depending nied.

INTRODUCTION PAGE I−1

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

SAFETY − SECTION A
This information is specific to Gorman-Rupp GHS covered in this manual could lead to de-
Series Rotary Gear Pumps. It applies throughout struction of equipment, injury, or death.
this manual and any manual or literature ac-
companying the pump.

For information on the power unit used to drive this

pump, consult the separate literature accompany-
Depending on design and components,
ing the power unit.
this pump will handle a wide range of
light, medium, and heavy viscosity liq-
uids at a variety of temperatures. Do not
apply at higher temperatures than the
seal will handle. Do not attempt to pump
Pumps and related equipment must be in- liquids which may damage the pump or
stalled and operated according to all na- endanger personnel as a result of pump
tional, local and industry standards. failure; consult the factory for chemical
compatibility.

This manual will alert personnel to

If the pump and motor are furnished
known procedures which require spe-
mounted on a base, make certain that all
cial attention, to those which could
lifting devices have adequate capacity.
damage equipment, and to those which
If chains or cables are used in lifting,
could be dangerous to personnel. How-
make certain that they are positioned so
ever, this manual cannot possibly pro-
as not to damage components, and so
vide detailed instructions and precau-
that the load will be balanced.
tions for each specific application or for
every situation that might occur during
maintenance of the unit. Therefore, it is
the responsibility of the owner, installer
and/or maintenance personnel to en-
sure that applications and/or mainte- After the pump has been installed, make
nance procedures not addressed in this certain that the pump and all piping or
manual are performed only after estab- hose connections are secure before op-
lishing that neither personal safety nor eration. Loose connections can result in
pump integrity are compromised by damage to the equipment and serious
such applications or procedures. injury to personnel.

Never operate the pump without a pres-

Before attempting to install, operate, or sure relief valve installed on the pump
service this pump, familiarize yourself or in the discharge piping. Make certain
with this manual, and with all other liter- that pump-mounted pressure relief
ature shipped with the pump. Unfamil- valves are installed with their adjusting
iarity with all aspects of pump operation ends toward the suction port. If bi-rota-

SAFETY PAGE A−1

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

tional operation is required, a pressure

relief device must be provided for both
directions of flow. Operation without a
pressure relief valve or with an improp-
An overheated pump can cause severe
erly installed relief valve could cause
burns and injury. If overheating occurs:
the pump to explode, resulting in seri-
ous injury or death to personnel. 1. Stop the pump immediately.
2. Allow the pump to completely cool.
3. Refer to the instructions in this
manual before restarting the
pump.

Do not operate this pump without

guards in place over the rotating parts.
Exposed rotating parts can catch cloth-
ing, fingers or tools, causing severe in- Do not remove plates, covers, gauges,
jury to personnel. pipe plugs or fittings from an over-
heated pump. Vapor pressure within the
pump can cause parts being disen-
gaged to be ejected with great force. Al-
low the pump to completely cool before
servicing.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man-
ual. This pump may be used to handle liq-
2. Lock out incoming power to the uids which may cause serious illness or
drive unit to ensure that the pump injury through direct exposure or
will remain inoperative. emitted fumes. Wear protective cloth-
3. Allow the pump to completely cool ing, such as rubber gloves, face mask
if overheated. and rubber apron, as necessary, before
4. Close the discharge and suction disconnecting or servicing the pump or
valve (if used). piping.

PAGE A−2 SAFETY

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

INSTALLATION − SECTION B

Review all SAFETY information in Section A. Typical Pump Model

GHS 1 1/2 GF 32

Design Port Hydraulic Construction

Pumps and related equipment must be in- Style Size Size Code
stalled and operated according to all na-
tional, local and industry standards. Design Style: Gorman-Rupp rotary gear pumps
are available in five basic designs:
Since pump installations are seldom identical, this
section is intended only to summarize general rec-  GMC − Medium Duty − Compact
ommendations and practices required to inspect,  GMS − Medium Duty
position, and arrange the pump and piping. If there
are any questions concerning your specific instal-  GHC − Heavy Duty − Compact
lation, contact your Gorman-Rupp distributor or
 GHS − Heavy Duty
the Gorman-Rupp Company.
 GHA − Abrasive Duty
Most of the information applies to a flooded suction Port Size: Gorman-Rupp rotary gear pumps are
installation where liquid is supplied under pres- available in port sizes from 1 to 6 inches, depend-
sure. ing on the design style. Consult your Gorman-
Rupp distributor or the factory for additional sizes.

If the pump is positioned above the liquid in a static Hydraulic Size: The first letter in the hydraulic size
lift installation, information such as mounting, pip- is a rotor diameter code. The second letter indi-
ing configuration and priming must be tailored to cates tooth length.
specific conditions.
Construction Code: Construction Codes for Gor-
man-Rupp rotary gear pumps are as follows:

Code Description
3 Iron w/Mechanical Seal(s)
These pumps are not recommended for 4 Iron w/Packing or Lip Seal(s)
use with water. Some models may be used 9 316 SST w/Mechanical Seal(s)
with water when fitted with specific options; 10 316 SST w/Packing or Lip Seal(s)
consult the factory. 32 Steel w/Mechanical Seal(s)
38 Steel w/Packing or Lip Seal(s)
Theoretical Displacement: Table B-1 indicates
theoretical displacement values for each hydraulic
PUMP MODEL DESIGNATION size.

NOTE
Following is a description of the model numbering Actual capacities and recommended shaft speeds
system for Gorman-Rupp rotary gear pumps. vary according to application. Consult your Gor-
Rotary gear pump model numbers include design man-Rupp distributor or the factory for addtional in-
style, port size, hydraulic size and construction formation.
code.

INSTALLATION PAGE B−1

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

Table B-1. Theoretical Displacement If the pump will not be immediately installed, follow
these procedures or damage to the pump will oc-
cur.
Theoretical Displacement
Hydraulic Per Revolution a. Do not flush the pump. Ensure that the port
Size plugs shipped with the pump remain in place
Gallons Centimeters3
until piping is installed to help prevent dust or
DC 0.00568 21.486
other foreign objects from entering the pump.
DE 0.00704 26.646
GC 0.00967 36.619 b. Pumps that will not be installed for an ex-
GF 0.01405 53.186
GH 0.01915 72.479 tended period should be stored indoors if
GJ 0.02317 87.700 possible. The factory-installed port plugs will
JG 0.03579 135.49 not ensure protection from excessive humid-
JJ 0.05159 195.28 ity, splash water or rain. In very humid or wet
JL 0.07078 267.94 conditions, install air-tight plugs in the ports
JP 0.10078 381.48
and fill the pump completely with a lubricating
NK 0.10665 403.71
NM 0.14173 536.51 preservative liquid that is compatible with the
NP 0.17681 669.31 liquid to be pumped.
RM 0.24030 909.65
RP 0.29979 1134.8 c. Pumps stored outdoors must be fully pre-
RR 0.35927 1360.0 served as described above, completely cov-
RS 0.41876 1585.1 ered with plastic or other water-tight material,
SR 0.65752 2489.0
and the covering anchored to ensure that it
SU 1.10240 4173.2
TU 1.91280 7240.7 will not be blown off.

PREINSTALLATION INSPECTION Flushing

The pump assembly was inspected and tested be-

fore shipment from the factory. Before installation,
check for damage which may have occurred dur-
ing shipment. Check as follows:
Clean piping is essential because of close-
a. Inspect the pump assembly for cracks, dents,
tolerance moving parts in this pump. Flush
damaged threads, and other obvious dam-
all dirt, grit, weld beads or scale from the
age.
suction piping before installing the pump.
b. Check for loose attaching hardware. Since Damage to the pump because of debris in
gaskets tend to shrink after drying, check for the suction line is not covered by the pump
loose hardware at the mating surfaces. warranty.
Before shipment, the pump may have been tested
c. Carefully read all tags, decals, and markings
using a petroleum-based preservative. If flushing is
on the pump assembly, and perform all duties
required, do not do so until just before installation;
indicated.
the test oil protects close-tolerance pump parts
from corrosion.
STORAGE

Most cleaning solvents are toxic and

Due to the extreme close machining toler- flammable. Use them only in a well ven-
ances within rotary gear pumps, proper tilated area free from flame, sparks, and
storage before installation is essential to excessive heat. Read and follow all pre-
prevent damage to the pump. cautions printed on solvent containers.

PAGE B−2 INSTALLATION

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

To flush the pump, use an approved solvent com- Lifting

patible with the liquid being pumped. Make cer-
Remove suction and discharge hose and piping
tain that the solvent will not attack pump com-
before attempting to lift the pump. Use lifting equip-
ponents, particularly seals and gaskets.
ment with a capacity of at least five times the total
weight of the equipment being lifted.
NOTE
Simple flushing of the wetted end of the pump to re- Positioning The Pump
move test liquid may not be sufficient to thoroughly
Locate the pump as close as possible to the liquid
clean the seal cavity. Pump design and the particu-
being pumped. Locating the pump below the liq-
lar seal assembly being used may require draining
uid source will help self-priming and reduce the
the seal area by removing the backhead plug and
possibility of cavitation.
then flushing through a separate line.
Mounting
PUMP INSTALLATION
The pump may be shipped alone, mounted on a
Pump dimensions are shown in the separate base, or with pump and motor mounted on a base.
Pump Specification Bulletin. Install the pump and motor on a base before
mounting the base on a foundation.

Mount the base on a foundation that will provide

permanent, rigid support for the pump, and will be
heavy enough to absorb any vibration, strain or
Never operate the pump without a pres- shock.
sure relief valve installed on the pump
or in the discharge piping. Make certain Piping
that pump-mounted pressure relief Before establishing suction and discharge lines,
valves are installed with their adjusting determine pump port positions and rotation. Fig-
ends toward the suction port. If bi-rota- ure B−1 shows typical port positions for the stan-
tional operation is required, a pressure dard 90 housing; if you have selected a 180
relief device must be provided for both housing port option, your port positions will be dif-
directions of flow. Operation without a ferent.
pressure relief valve or with an improp-
erly installed relief valve could cause Either hose or rigid pipe may be used to make con-
the pump to explode, resulting in seri- nections. If rigid piping is used, install expansion
ous injury or death to personnel. joints to protect the pump from vibration and ther-
mal expansion in the piping. Do not use expansion
Maximum Operating Parameters joints or flexible connectors to adjust misaligned
piping.
Rotary gear pumps are capable of different operat-
ing parameters depending on such things a specif- Begin piping layout at the pump, and work toward
ic materials of construction, pump options, liquid the source of supply and the point of discharge. If
being pumped, etc. In no case should the applica- an obstacle is in the way of a suction or discharge
tion exceed the parameters shown below. Consult line, run the piping around the obstruction, not
the factory for specific ratings. over it. Running piping over an obstruction will
create an air pocket which will make priming more
difficult.
* Maximum Operating Parameters
Pressure 400 psi (28 Bar) If possible, slope the piping toward the pump so no
Speed 1750 rpm air or liquid is trapped in the piping. If a long hori-
Temperature 675F (358C) zontal suction line is necessary, install the line be-
low the liquid level whenever possible in order to
* Consult Factory for Specific Ratings keep the piping full of liquid. This will make priming

INSTALLATION PAGE B−3

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

easier because the pump will not have to remove

as much air in the line.

Liquid used for temperature control

Housing Position For Std. 90 Pump must not exceed 600 _F (316 _C) or 150
(3-12 O’clock) Head Mounted Relief Valve
psi (1034 kPa) pressure. Higher temper-
OPT. Drive End Front End atures or pressures can result in dam-
Rotation Clockwise age to the equipment and/or serious in-
jury to personnel.
D D
Gauges
STD. S S
Install a vacuum gauge in the suction line and a dis-
charge pressure gauge in the discharge line (both
should be as close as possible to the pump) to
Rotation Counter-clockwise monitor operation and assist in troubleshooting.

S S Strainers

Because of the close-tolerance moving parts of

01A D D this pump, it is recommended that a strainer be in-
stalled in the suction line. The strainer should be
large enough to prevent excessive vacuum, and
capable of operating under high vacuum without
collapsing. The net open area of the strainer
Figure B-1. Typical Port Positions & Rotation screen depends on liquid viscosity and desired
flow rate; in any case, the sum of the area of all the
holes in the screen should be three to five times the
The discharge and suction lines must be inde-
area of the suction pipe.
pendently supported to avoid vibration and strain
on the pump. For maximum pumping capacity, Sealing
keep the lines as short and straight as possible. El-
bows and fittings used in the lines increase friction Even a slight leak will affect priming, head, and ca-
losses; minimize their use. Reducers used in suc- pacity, especially in a suction lift application. Seal
tion lines should be the eccentric type installed all piping joints, valves and gauges with pipe dope
with the flat part uppermost to avoid creating air or teflon tape. The sealing material should be com-
pockets. patible with the liquid being pumped.

Valves
Before tightening a connection or flange, align it
exactly with the pump port. Never pull a pipe line To avoid air pockets, install piping valves with the
into place by tightening the flange bolts and/or stem horizontal.
couplings.
To prevent leakage during shutdown, install a shut-
off valve in the discharge line, particularly on a
Temperature Control flooded suction application. Shutoff valves are not
recommended for suction lines.
If your pump is equipped with temperature control It is not recommended that a foot valve be installed
jacket(s), follow the same guidelines described for at the end of the suction line. If desired to install a
suction and discharge piping installation when foot valve, consult the factory.
installing the temperature control piping. Be sure
to install a shutoff valve in each supply line to the When handling very hot or cold liquids, install a
jacket(s) for serviceability. pressure relief valve in any part of the system that

PAGE B−4 INSTALLATION

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

can be valved off or isolated; this will protect piping that can be applied depends primarily on the maxi-
against damage from liquid thermal expansion or mum seal design pressure (consult the factory).
contraction from temperature changes during
Do not pressurize tandem seals. Pressurizing a
shutdown.
tandem seal will cause the seal faces to separate,
resulting in leakage and/or damage to the seal.
Barrier Liquids for 65E Cartridge Triple Lipseal
Refer to the appropriate section in Seal Appendix,
In general, a barrier liquid is always recommended Section F for your specific seal option for operating
for these seals. This requirement may be satisfied instructions for the barrier liquid reservoir kit.
by a simple grease zerk, or it may become more
complicated based on the application. The follow- ALIGNMENT
ing barrier liquid guidelines are offered for maxi-
mum performance;

1. Select a clean, lubricating liquid that is

compatible with the pump construction
(iron or 316 SST). Make certain that power to the drive unit
is disconnected before attempting to
2. Select a clean, lubricating liquid that is
connect the pump drive; otherwise, per-
compatible with the pumped product
sonal injury may result.
and with the pump construction (iron or
316 SST). NOTE
See ROTATION in Section C before mounting the
3. Depending upon pump shaft speed, a
pump on the base.
pressurized barrier liquid may not be re-
quired. Consult the factory for your spe-
cific application. Coupled Drives

Barrier Liquids for Dual Mechanical Seals When using couplings, the axis of the power
source must be aligned to the axis of the pump
Pumps equipped with dual (tandem) mechanical shaft in both the horizontal and vertical planes.
seals require a barrier liquid to prevent contamina- Most couplings require a specific gap or clearance
tion of the seal assembly by the liquid being between the driving and the driven shafts. Refer to
pumped. The barrier liquid must have the following the coupling manufacturer’s service literature.
characteristics: Align spider insert type couplings by using calipers
a. The barrier liquid must have sufficient lubricat- to measure the dimensions on the circumference
ing characteristics, including an optimum vis- of the outer ends of the coupling hub every 90.
cosity of 1 to 5 cSt at the temperature of the The coupling is in alignment when the hub ends
liquid being pumped. are the same distance apart at all points (see Fig-
ure B-2).
b. The barrier liquid must be compatible in all re-
spects with all pump and seal components to
which it will be exposed.

c. The barrier liquid must be compatible in all re-

spects with the liquid being pumped.

Pumps equipped with dual mechanical seals re-

quire the barrier liquid to be supplied at a continu-
Figure B-2. Spider-type Couplings
ous pressure equivalent to the maximum dis-
charge pressure in order to avoid inboard seal face Align non-spider type couplings by using a feeler
separation. The maximum barrier liquid pressure gauge or taper gauge between the coupling halves

INSTALLATION PAGE B−5

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

every 90. The coupling is in alignment when the

hubs are the same distance apart at all points (see
Figure B-3).

MISALIGNED: MISALIGNED: ALIGNED: SHAFTS

SHAFTS SHAFTS PARALLEL AND
NOT PARALLEL NOT IN LINE SHEAVES IN LINE
Figure B-4. V-belt Alignment

Tighten the belts in accordance with the belt man-

ufacturer’s instructions. If the belts are too loose
they will slip; if they are too tight, there will be ex-
cessive power loss and possible bearing failure.

Select pulleys to match the proper speed ratio;

Figure B-3. Aligning Non-Spider Type Coupling overspeeding the pump may damage both pump
and power source.

Check parallel adjustment by laying a straightedge

across both coupling rims at the top, bottom, and
side. When the straightedge rests evenly on both
Do not operate this pump without
halves of the coupling, the coupling is in horizontal
guards in place over the rotating parts.
parallel alignment. If the coupling is misaligned,
Exposed rotating parts can catch cloth-
use a feeler gauge between the coupling and the ing, fingers or tools, causing severe in-
straightedge to measure the amount of misalign- jury to personnel.
ment.
V-BELT TENSIONING
General Rules of Tensioning
V-Belt Drives
For new v-belts, check the tension after 5, 20 and
50 hours of operation and re-tension as required
(see the following procedure for measuring belt
tension). Thereafter, check and re-tension if re-
When using V-belt drives, the power source and
quired monthly or at 500 hour intervals, whichever
the pump must be parallel. Use a straightedge comes first.
along the sides of the pulleys to ensure that they
Ideal v-belt tension is the lowest tension at which
are properly aligned (see Figure B-4). In drive sys-
the belt will not slip under peak load conditions. Do
tems using two or more belts, make certain that the not over-tension v-belts. Over-tensioning will short-
belts are a matched set; unmatched sets will cause en both v-belt and bearing life. Under-tensioning
accelerated belt wear. will cause belt slippage. Always keep belts free

PAGE B−6 INSTALLATION

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

OPERATION − SECTION C

Review all SAFETY information in Section A. Open all valves in the suction and discharge lines,
and close all drain valves.
Follow the instructions on all tags, labels and
decals attached to the pump. If your pump is equipped with a packing seal, loos-
en the gland nuts before starting until the packing
PUMP OPERATION gland may be moved slightly. If leakage seems ex-
cessive after starting, wait until the pump has run
long enough to reach its normal operating temper-
ature to adjust the gland nuts. Packing pumps
must leak slightly to cool and lubricate the shaft
and to allow the shaft to turn freely.
Never use a pressure relief valve to reg-
ulate liquid flow. Pressure relief valves Consult the drive manufacturer’s operating manu-
are designed as safety devices only. At- al before attempting to start the drive.
tempting to regulate flow with a pres-
sure relief valve may cause the pump or
piping to explode, causing severe per-
sonal injury or death.
Pumps equipped with cartridge seals may
PRE-OPERATION require a barrier liquid, flushing or quench-
ing lines to ensure proper seal perfor-
Make certain that all instructions in INSTALLA- mance. Consult the cartridge seal
TION, Section B have been carried out. manufacturer or the factory for specific
startup instructions. Failure to do so could
result in premature seal failure and/or addi-
tional damage to the pump.
In a suction lift application, fill the pump housing
The standard version of the pump is de- with liquid to seal clearances and to lubricate the
signed to handle a wide range of light, me- pump.
dium, and heavy viscosity liquids, depend-
ing on design and components. Do not op-
Checking Pump Rotation
erate the pump with higher liquid tempera-
tures than what it was designed; otherwise, Correct rotation of your pump is shown on the
pump components and operation may be pump serial plate or direction arrow plate.
affected. For temperature range consult
The Gorman-Rupp Company.

Before Starting the Pump

In applications with a single direction of

flow and a single pump-mounted pressure
relief valve, make certain that the drive unit
turns the pump in the correct direction of
Never operate the pump against a rotation. Otherwise, the pump-mounted
closed suction or discharge valve. The pressure relief valve will not function.
pump will overheat, and may rupture or
explode, causing personal injury or Follow the drive unit manufacturer’s instructions,
death. jog the pump motor briefly, and check rotation.

OPERATION PAGE C−1

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

If the pump does not deliver liquid within two min-

utes, stop the pump; it may be necessary to vent
the discharge line until liquid begins to flow.

Gorman-Rupp rotary gear pumps are bi- If the pump still does not deliver after consulting
TROUBLESHOOTING and venting the discharge
directional; however, the pumps are
line, contact your local Gorman-Rupp Rotary Gear
manufactured to rotate in one specific di-
Distributor or the factory.
rection. If rotation is to be changed, the
pressure relief valve must be re-installed OPERATION
with the cap pointing toward the suction
port. Additionally, if the discharge presure NOTE
is greater than the shaft seal rating (consult If the pump malfunctions or does not meet operat-
your Gorman-Rupp distributor), the pres- ing specifications, refer to TROUBLESHOOTING
sure relief plugs in the back of the housing − Section D.
must be switched (see Housing Assem-
bly under PUMP REASSEMBLY, Section
E). A change in operating noise when liquid first enters
the pump is normal. After the pump is fully opera-
tional, monitor it for any unusual noises or vibra-
If a 3-phase motor is being used and rotation is in-
tion; if either occurs, shut the pump down immedi-
correct, have a qualified electrician interchange
ately.
any two of the 3-phase wires to change the direc-
tion of rotation. If a 1-phase motor is being used
Liquid Temperature
and rotation is incorrect, consult the motor man-
ufacturer’s literature. Do not install the pump in a service with higher liq-
uid temperatures than what it was designed. Intro-
ducing hot liquid into a cold pump will expand
STARTING parts unevenly, causing excessive wear, pump fail-
ure, and operation may be affected. This thermal
Start the drive unit as indicated in the manufactur- shock can be reduced by gradually heating the liq-
er’s instructions and observe the suction and dis- uid being introduced into the pump. If it is not pos-
charge gauges. If the pump does not deliver liquid sible to heat the liquid, use heat tape and/or insula-
within one minute, stop the drive unit. Do not oper- tion to heat the pump.
ate the pump more than one minute without liquid High temperature bushings as well as optional
in it; dry operation will damage or destroy the jackets which may be used to heat or cool the
pump. pump are available options for many models.

Overheating

Overheating can occur if the pump is operated with

valves in the suction or discharge lines closed. Op-
Although this pump is self-priming, never erating against closed valves could bring the liquid
operate it dry. Dry operation could cause to a boil, build pressure, and cause the pump to
galling, seizing, damage to the seal or ex- rupture or explode. If overheating occurs, stop the
cessive wear of rotating parts. pump and allow it to completely cool before servic-
ing.
Review the previous steps outlined in PRE-OP-
ERATION and review TROUBLESHOOTING,
Section D. If everything appears normal, add liquid
to the pump housing to assist priming and start the
driver again. Do not remove plates, covers, gauges,

PAGE C−2 OPERATION

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

pipe plugs or fittings from an overheated PRESSURE RELIEF VALVE

pump. Vapor pressure within the pump ADJUSTMENT
can cause parts being disengaged to be
ejected with great force. Allow the pump to Some pumps are not provided with a pressure re-
completely cool before cooling. lief valve. A pressure relief valve must be installed
on the pump or in the discharge piping to ensure
safe operation. Otherwise, the pump may be dam-
Checking Gauges
aged and personnel injured.

Monitor vacuum and pressure gauge readings to

ensure that the pump is operating within normal
range and delivering full flow.

If operating at high temperatures, allow the

Strainer Check pump to completely cool before attempt-
ing any adjustments.
If a strainer has been installed in the suction line,
monitor vacuum gauge readings to detect block- Cracking Pressure
age. Check the strainer if flow rate begins to drop.
Cracking pressure is the pressure at which the
pressure relief valve first begins to open and by-
pass fluid. The nominal cracking pressure of the re-
lief valve provided with this pump is set at the facto-
ry and is indicated on the tag attached to the relief
Never introduce air or steam pressure valve.
into the pump housing to remove a
If the nominal cracking pressure set at the factory
blockage. This could result in personal
must be changed, see Table E-2 and instructions in
injury or damage to the equipment. If
Section E - MAINTENANCE AND REPAIR.
backflushing is absolutely necessary,
limit liquid pressure input to 50% of the Complete By-pass Pressure
maximum permissible operating pres-
sure shown in the pump performance Complete by-pass pressure is the maximum pres-
data. sure the pump will see when all the pumped fluid is
being by-passed through the pressure relief valve.
Leakage This pressure will vary depending on the cracking
pressure setting, liquid viscosity, and pump speed
(pump capacity).
No leakage should be visible at pump mating sur-
faces or at pump connections or fittings. Keep all To determine the complete by-pass pressure, refer
line connections and fittings tight to maintain maxi- to the pump performance chart or consult the fac-
mum efficiency. tory.

If your pump is equipped with a packing seal, the

packing is lubricated by the liquid being pumped.
Some leakage around the packing seal is normal.
Packing pumps must leak slightly (2-3 drops per
minute) to cool and lubricate the shaft and to allow
Do not remove the adjusting screw jam
the shaft to turn freely.
nut; with the jam nut removed the relief
valve spring(s) can be compressed too
Wait until the pump has run long enough to reach far for the valve to open. If the valve
its normal operating temperature to adjust the does not open, excessive pressure can
gland nuts. Adjust the nuts only tight enough to re- develop, causing damage to the pump
duce excessive leakage. and possible injury to personnel.

OPERATION PAGE C−3

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

STOPPING pump and piping with an oil-based preservative to

protect close-tolerance pump parts.

When handling liquids that solidify when at rest

If the pump will be out of service for an extended (tar, glue, etc.), flush the pump and piping with an
length of time, particularly when handling non-lu- approved solvent compatible with the pump com-
bricating liquids, drain the system and flush the ponents and the liquids being pumped.

PAGE C−4 OPERATION

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

TROUBLESHOOTING − SECTION D

Review all SAFETY information in Section A.

Before attempting to open or service the

pump:
1. Familiarize yourself with this manual.
2. Allow the pump to completely cool if
overheated.
3. Check the temperature before open-
ing any covers, plates, or plugs.
4. Close the suction and discharge
valves.
5. Drain the pump.

TROUBLESHOOTING WITH GAUGES

Most pump or system malfunctions can be detected by installing vacuum suction and discharge pressure
gauges. Read the gauges and refer to the following information for interpretation of the gauge readings. For
additional troubleshooting procedures, see the TROUBLESHOOTING CHART.
Vacuum Gauges Pressure Gauges

HIGH READING HIGH READING

Suction valve closed, suction line blocked, Liquid too viscous.
foot valve jammed, strainer blocked. Discharge line undersized or too long.
Liquid too viscous. Discharge valve partially closed.
Lift too high. Strainer blocked.
Suction line undersized. Relief valve pressure set too high.
Thermal changes in liquid.
LOW READING
LOW READING
Air leak in suction line.
End of suction line not submerged. Relief valve pressure set too low.
Pump parts worn or defective. Internal valve not seating properly.
End clearance too great. Pump bypass partially open.
No liquid in pump housing. End clearance too great.
Pump parts worn or defective.
ERRATIC READING
ERRATIC READING
Liquid overheated, vaporizing.
Liquid entering intermittently, suction air leak, Cavitation.
end of suction line not submerged. Liquid entering intermittently, suction air leak,
Vibration from cavitation, misalignment, dam- end of suction line not submerged.
aged parts. Drive misalignment causing vibration.

TROUBLESHOOTING PAGE D−1

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

TROUBLESHOOTING CHART
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS Internal clearance too great. Check and readjust clearance if re-
TO PRIME OR quired; see SETTING END CLEAR-
LOSES PRIME ANCE in Maintenance and Repair, Sec-
tion E.

Air leak in suction line; end of suction Check and correct as required.
line not submerged; foot valve blocked
or jammed; insufficient liquid in sump or
tank.
Suction strainer clogged. Check strainer.
Shaft seal leaking; gaskets, O-rings Check vacuum gauge; disassemble
worn. pump and replace faulty parts.
Leaking relief valve. Disassemble and repair.
Suction lift too high. See INSTALLATION, SECTION B and
check piping.
Pump starving" or liquid vapor- Increase suction pipe size or reduce
izing in suction line. length; position pump below liquid level.
Pump rotation incorrect. See OPERATION, SECTION C and
check rotation.
Pump speed too slow. Check driver speed.
Housing dry. Add liquid to housing, see OPERATION,
SECTION C.
PUMP DOES Air leak in suction line; end of suction Check and correct as required.
NOT DELIVER line not submerged; foot valve blocked
RATED DIS- or jammed; insufficient liquid in sump or
CHARGE OR tank.
CAPACITY Shaft seal leaking; gaskets, O-rings Check vacuum gauge; disassemble
worn. pump and replace faulty parts.

Relief valve pressure set too low. Readjust.

Suction or discharge lines blocked; Check strainer, valves and piping.

suction or discharge valves closed.
Pump speed too slow. Check driver speed; check belts/coup-
lings.

Pump starving" or liquid vaporizing Increase suction pipe size or reduce

in suction line. length; position pump below liquid level.
Rotating parts worn or damaged; im- Replace defective parts; see SETTING
proper end clearance. END CLEARANCE in Maintenance And
Repair, Section E.
PUMP REQUIRES Insufficient end clearances. Readjust clearance; see SETTING END
TOO MUCH CLEARANCE in Maintenance and Re-
POWER pair, Section E.
Pump speed too high. Reduce driver output.
Internal parts worn. Disassemble pump and inspect.
Discharge line undersized and/or too Increase size, decrease length.
long.

PAGE D−2 TROUBLESHOOTING

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

TROUBLESHOOTING CHART (Cont.)

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP REQUIRES Pump and/or drive mounting not Tighten mounting hardware; realign
TOO MUCH secure; drive misaligned. drive.
POWER
(Cont.) Power source undersized. Check power requirements for applica-
tion; resize as required.
Lubrication required. Add lubricant, as needed.
Liquid in pump solidified. Clear or heat.
Insufficient internal clearances. Consult factory.

EXCESSIVE Pump and/or piping not secure; drive Anchor base or piping, realign drive.
NOISE OR misaligned.
VIBRATION
Pumping entrained air. Check liquid level.
Pump starving" or liquid vapor- Increase suction pipe size or reduce
izing in suction line. length; position pump below liquid level.

Relief valve chatter. Increase pressure setting.

Rotating parts worn or damaged; im- Replace defective parts; check end
proper end clearance. clearance.
Pump operating outside designed Check discharge head and flow; adjust as
operating range. required to meet performance specifica-
tions.
Lubrication required. Add lubricant, as needed.

EXCESSIVE Corrosive liquid. Check local distributor or factory for

WEAR parts compatibility with liquid; check liq-
uid for contamination.
Abrasive liquid. Consult factory.
Contaminated liquid. Check liquid source; install strainer.
Exceeding operating limits. Check performance data in Pump Speci-
fications Bulletin.
Insufficient end clearance. See SETTING END CLEARANCE in
Maintenance And Repair, Section E.
Pump running dry. Add liquid to prime (See Operation, Sec-
tion C); check liquid flow.
Pump and/or drive mounting not se- Tighten mounting hardware; realign
cure; drive misaligned; piping incor- drive; check piping.
rectly installed.
Insufficient lubrication. Add lubrication and maintain at proper lev-
el.

TROUBLESHOOTING PAGE D−3

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

PREVENTIVE MAINTENANCE Check the thrust washer (medium duty models),

idler bushing, idler pin, idler assembly, shaft bush-
ing and rotor/shaft assembly at each inspection.
Since pump applications are seldom identical, and Wear patterns should be uniform, without evi-
pump wear is directly affected by such things as dence of deep or irregular grooves.
the abrasive qualities, pressure and temperature
For packing pumps, periodic adjustment of the
of the liquid being pumped, this section is intended
packing is required to keep leakage to a minimum
only to provide general recommendations and
(see the adjustment procedure described under
practices for preventive maintenance. Regardless
Leakage in Operation, Section C). Do not over-
of the application however, following a routine pre-
tighten. Replace the packing if leakage cannot be
ventive maintenance schedule will help assure
reduced by a slight adjustment.
trouble-free performance and long life from your
Gorman-Rupp rotary gear pump. For specific If the pump is equipped with a backhead bearing
questions concerning your application, contact (heavy duty models), inspect for free rotation of the
your Gorman-Rupp distributor or the Gorman- shaft and rotor, and excessive endplay or radial
Rupp Company. movement of the shaft, which could indicate bear-
ing wear. Remove the rotor adjusting sleeve as-
Record keeping is an essential component of a sembly and inspect the bearing for damaged
good preventive maintenance program. The ap- seals. Replacing the bearing at the first indication
pearance of wearing parts should be documented of a problem can extend the life of the pump and
at each inspection for later comparison. Also, if re- save considerable expense later to replace major
cords indicate that a certain part (such as the seal) components that can be damaged if the bearing is
fails at the same duty cycle, this part can be allowed to fail.
checked and replaced before failure occurs.
After extended service, adjustment of the clear-
ance between the rotor and the head will normally
Because of the tight tolerances within your rotary
improve performance (see the adjustment proce-
gear pump, wear between rotating parts is normal
dure in Maintenance And Repair, Section E).
and expected. For new applications, a first inspec-
tion at 250 hours will give insight into the wear rate If the pump is to be removed from service for repair,
for your particular application. Subsequent inspec- be sure to protect the internal components from
tions should be performed at regular intervals of rusting while the pump is disassembled and after
2000 hours. Critical applications should be in- reassembly if not immediately placed back into
spected more frequently. service.

PAGE D−4 TROUBLESHOOTING

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

Preventive Maintenance Schedule

Service Interval*
Item Daily Weekly Monthly Semi- Annually
Annually
General Condition (Temperature, Unusual
Noises or Vibrations, Cracks, Leaks,
Loose Hardware, Etc.) I
Pump Performance (Gauges, Speed, Flow) I
Bearings I
Seal Lubrication (And Packing Adjustment,
If So Equipped) I R
V-Belts (If So Equipped) I
End Clearance I
Pressure Relief Valve (If So Equipped) C
Pump and Driver Alignment I
Shaft Deflection I
Piping I
Driver Lubrication − See Mfgr’s Literature

Legend:
I = Inspect, Clean, Adjust, Repair or Replace as Necessary
C = Clean
R = Replace
* Service interval based on an intermittent duty cycle equal to approximately 4000 hours annually.
Adjust schedule as required for lower or higher duty cycles or extreme operating conditions.

TROUBLESHOOTING PAGE D−5

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

MAINTENANCE AND REPAIR − SECTION E

MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL

MAINTAIN PEAK OPERATING PERFORMANCE.

Pump Model
NOTE
A separate Parts List is shipped with each pump.
Below the pump model number on the Parts List
is a grouping of several alpha-numeric codes.
This code identifies the optional components of
the pump. Contact the Gorman-Rupp Company to
verify performance and options.

The following illustrations cover disassembly and reassembly for the pump models shown
below. Refer to the Parts List for your specific pump model.

The Following Pumps Are Covered By This Manual.

GHS SERIES PUMPS

G,J,N & R SIZES

MAINTENANCE AND REPAIR PAGE E−1

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

46167302
Shown: Standard Model With 90 Ports, Head-Mounted Relief Valve and Optional Foot Bracket. Also Available With
180 Ports And/Or Jacketed Seal, Head Jacket, Housing-Mounted Relief Valve. A Coverplate Kit Replaces Either Relief
Valve When Not Used.
NOTE: Refer to Seal Appendix, Section F for details of the Seal Assembly and Related Components.

Figure E−1. Typical GHS G, J, N And R Size Pump Models

PAGE E−2 MAINTENANCE AND REPAIR

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

PARTS KEY FOR FIGURE E-1

Note: Item numbers cross reference to specific part numbers on the separate Parts List.

ITEM PART NAME ITEM PART NAME

NO. NO.
01 HEAD KIT 07AJ −BRG SPACER (IF REQUIRED)
01A −HEAD ASSEMBLY 07F −O-RING (IF REQUIRED)
01AA −HEAD 07H −RETAINER CLIP (IF REQUIRED)
01AB −IDLER PIN 07L −SEAT SLEEVE (IF REQUIRED)
P −PIPE PLUG 07S −SEAT SLEEVE (IF REQUIRED)
01B −GASKET 07V −O-RING (IF REQUIRED)
B −CAPSCREW
08 FOOT BRACKET KIT
02 IDLER ASSEMBLY 08A −FOOT BRACKET
02A −IDLER B −CAPSCREW
02B −BUSHING D −NUT

03 ROTOR/SHAFT KIT 10 RELIEF VALVE KIT

03A −ROTOR/SHAFT ASSEMBLY 10A −RELIEF VALVE ASSEMBLY
03B −BEARING LOCKWASHER 10AA −VALVE BODY
03C −BEARING LOCKNUT 10AB −WARNING PLATE
N −SHAFT KEY BM −DRIVE SCREW
B −CAPSCREW
04 HOUSING ASSEMBLY 10C −O-RING
04A −HOUSING 10C −GASKET (0PTIONAL)
P −PIPE PLUG
12 NAMEPLATE KIT
05 SEAL & RELATED COMPONENTS 12A −NAMEPLATE
(SEE SECTION F) BM −DRIVE SCREW

06 BACKHEAD KIT NOT SHOWN:

06A −BACKHEAD ASSEMBLY SECONDARY OR OPTIONAL SEAL
06AA −BACKHEAD (IF REQUIRED, SEE SECTION F)
06AE −SHAFT BUSHING
P −PIPE PLUG NOT SHOWN:
06B −GASKET 11 HEAD COVERPLATE KIT (IF REQUIRED)
B −SOCKET HD CAPSCREW 11A −COVERPLATE ASSEMBLY
11AA −COVERPLATE
07 ROTOR ADJUSTING SLEEVE KIT 11AC −WARNING PLATE
07A −ROTOR ADJUSTING SLEEVE ASSY BM −DRIVE SCREW
07AA −ROTOR ADJUSTING SLEEVE P −PIPE PLUG
07AC −BALL BEARING K −WASHER
07AD −BEARING RETAINING NUT B −CAPSCREW
GA −SOCKET HD SETSCREW 10C −O-RING OR GASKET

INDICATES PARTS RECOMMENDED FOR STOCK

NOTE: Refer to O-Ring Appendix, Section G

for O-ring identification and location.

MAINTENANCE AND REPAIR PAGE E−3

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

PUMP DISASSEMBLY AND pump integrity are compromised by

REASSEMBLY such applications or procedures.

Review all SAFETY information in Section A.

Follow the instructions on all tags, labels and

decals attached to the pump. Do not attempt to service the pump un-
less all power to the power source has
This pump requires little service due to its rugged, been disconnected; otherwise, serious
minimum-maintenance design. However, if it be- personal injury or death could result.
comes necessary to inspect or replace the wearing
parts, follow these instructions which, unless
PUMP DISASSEMBLY
otherwise specified, are keyed to the sectional
view (see Figure E-1) and the accompanying parts
key. Refer to the separate parts list accompanying
your pump for part numbers.

In the following text, minor headings are followed This pump may be used to handle liq-
by a number in parenthesis. This number repre- uids which may cause serious illness or
sents the assembly for the item being discussed as injury through direct exposure or
identified in Figure E-1. emitted fumes. Wear protective cloth-
ing, such as rubber gloves, face mask
Before attempting to service the pump, shutdown and rubber apron, as necessary, before
incomming power and lock it out or disconnect the disconnecting or servicing the pump or
power source to ensure that it will remain inopera- piping.
tive.
In the instructions which follow the FRONT is the
For power source disassembly and repair, consult head assembly end of the pump and the REAR is
the literature supplied with the power source, or the drive (or backhead) end of the pump.
contact your local power source representative.
NOTE
It is strongly recommended that gaskets and O-
rings be replaced whenever the pump is reas-
sembled.

This manual will alert personnel to Preparing for Disassembly

known procedures which require spe-
cial attention, to those which could The pump should be removed from the system pip-
damage equipment, and to those which ing and drained for servicing. Close all valves in the
could be dangerous to personnel. How- suction and discharge lines to isolate the pump.
Position drain pans and/or absorbant material un-
ever, this manual cannot possibly pro-
der and around the pump suction and discharge
vide detailed instructions and precau-
ports. Disconnect the suction and discharge hose/
tions for each specific application or for piping.
every situation that might occur during
maintenance of the unit. Therefore, it is Remove the hardware securing the pump to the
the responsibility of the owner, installer power source and separate the power source and
and/or maintenance personnel to en- pump assembly. Retain all connection parts such
as shaft keys, etc.
sure that applications and/or mainte-
nance procedures not addressed in this Use a hoist and sling with sufficient capacity to
manual are performed only after estab- position the pump in a suitably sized drain pan or
lishing that neither personal safety nor surround the pump with absorbant material. Some

PAGE E−4 MAINTENANCE AND REPAIR

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

pumps are equipped with drain plugs in the head pipe wrench or other suitable tool to turn the rotor
and backhead. Remove the plug(s) and drain the adjusting sleeve clockwise (as viewed from the
pump before proceeding with disassembly. drive end) until the rotor binds against the head.
This will prevent the rotor from turning as the lock-
Pressure Relief Valve (10) nut is unscrewed.

If the pump is equipped with a pressure relief valve Straighten the tab on the bearing lockwasher (03B)
(10A), it can be mounted on either the head assem- and use a hammer and drift pin to loosen the bear-
bly (01A) or the housing assembly (04). Some ing locknut until it can be unscrewed from the
models are equipped with one of each. Take note shaft. Remove the bearing lockwasher.
as to the direction in which the relief valve is
mounted. To remove either style, remove the caps- Unscrew the rotor adjusting sleeve kit from the
crews (B) securing the relief valve to the pump. The backhead.
O-rings (10C) may remain in the head (01A) or in
the housing (04A). Remove and discard the O- NOTE
rings. For relief valve maintenance, see RELIEF Part or all of the seal assembly (05) may be re-
VALVE DISASSEMBLY followed by RELIEF moved with the rotor adjusting sleeve. Check the
VALVE REASSEMBLY at the end of this section. Parts List furnished with your pump to identify the
seal, refer to Seal Appendix, Section F, for removal
Optional Head Jacket of the seal and related components, then proceed
as follows with rotor adjusting sleeve disassembly.
(Figure E-1 And E-2)

If your pump is equipped with an optional head

jacket, see Figure E-2 and remove the capscrews
(B) securing the head jacket (01G), gasket (01F)
and O-rings (01E) to the head assembly (01A, Fig-
ure E-1).
When removing or installing the bearing
(07AC), never hit or press against the inner
race. Press only against the outer race.

Secure the rotor adjusting sleeve (07AA) in a vice

with the drive side down. Position a suitably sized
screwdriver horizontally through the slots in the
bearing retaining nut and use the screwdriver to
unscrew the bearing retaining nut from the rotor
adjusting sleeve. The bearing (07AC) is a light
press fit into the rotor adjusting sleeve and can
usually be removed with thumb pressure only. If
the bearing does not come out easily, use a suit-
able sized sleeve and a mallet to lightly tap the
bearing from the bore.

Refer to Cleaning and Inspection in this section

before reassembling the rotor adjusting sleeve.

Figure E-2. Typical Head Jacket Assembly Coverplate Kit (11)

Rotor Adjusting Sleeve (07) (Figure E-1 And E-3)

Before attempting to remove the bearing locknut The coverplate kit may be mounted on either the
(03C), loosen the socket head setscrews (GA) se- head assembly or the housing assembly. Removal
curing the rotor adjusting sleeve (07) and use a is the same for either.

MAINTENANCE AND REPAIR PAGE E−5

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

01A parts have sharp edges which will grow

01AA
11AA sharper with use.
P
01B
K NOTE
The idler bushing (02B) may be damaged during
10C 01AB removal. Do not remove the idler bushing unless re-
B
placement is required.

Remove the assembled idler (02) from the head as-

sembly. Inspect the idler bushing (02B) for exces-
sive wear or scoring. If replacement is required,
use an arbor (or hydraulic) press to remove the
02A
02B idler bushing from the idler.

P
To remove the idler pin (01AB), lay the head as-
sembly (01A) on an arbor (or hydraulic) press with
Figure E-3. Head Coverplate Kit, Head Kit the idler pin facing down and press the idler pin
And Idler Disassembly from the head.

Seal Removal (05)

Remove the hardware (B and K) securing the cov-
erplate (11AA) to the head (01AA) or housing The seal assembly (05) is available in a variety of
(04A). The O-rings (10C) may remain in the head or configurations. Check the Parts List furnished with
housing. Remove and discard the O-rings. your pump to identify the seal, then refer to Seal
Appendix, Section F, for removal of the seal and
Head/Idler Kit (01 and 02) related components.

(Figure E-1 And E-3) Rotor/Shaft Removal (03)

With the seal removed, slide the rotor/shaft assem-

Remove the hardware (B) securing the head as- bly (03A) out of the housing (04A). Due to close
sembly (01A) to the housing (04A). Separate the machine tolerances and assembly practices, the
head jacket from the head assembly. Remove and rotor/shaft is available only as an assembly. Further
discard the gasket (01B). disassembly is not required.

Foot Bracket Kit (08)

Remove the hardware (B and D) securing the foot

bracket (08A) to the head (01A) and the backhead
Use caution to prevent the idler assembly (06A).
from dropping off the idler pin; the idler
may be damaged if it falls on a hard sur- Backhead Kit Removal (06)
face.
(Figures E-1 and E-4)
Pull the head assembly (01A) from the housing as- Remove the screws (B) securing the backhead
sembly (04A). Use caution not to let the idler as- (06A) to the housing assembly (04), and separate
sembly (02) slide off the idler pin (01AB). the assemblies. Remove and discard the gasket
(06B).

NOTE
The throttle bushing (06AE) may be damaged dur-
ing removal. Do not remove the throttle bushing un-
Use caution when handling the idler (02) less replacement is required.
and the rotor shaft assembly (03A). These

PAGE E−6 MAINTENANCE AND REPAIR

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

The throttle bushing (06AE) is a tight press fit in the Cleaning and Inspection
backhead. Use an arbor (or hydraulic) press to re-
move the bushing.

06A,06AA Most cleaning solvents are toxic and

06B P
flammable. Use them only in a well ven-
tilated area free from flame, sparks, and
excessive heat. Read and follow all pre-
cautions printed on solvent containers.
Clean and inspect the pump parts (except the
bearing and seal assembly) with a cloth soaked in
fresh cleaning solvent. Inspect all parts for exces-
sive wear or for any nicks or burrs. Remove nicks or
burrs using emery cloth or a fine file. Replace any
06AE parts that are badly worn or damaged.
B Rotate the bearing by hand to check for roughness
or binding. If rotation is rough or if there is any side-
to-side movement of the inner race, replace the
Figure E-4. Standard Flexible Backhead
bearing.

Housing Assembly (04)

NOTE
Seal cavity pressure relief is accomplished using The bearing is permanently sealed and re-
socket head pipe plugs (P) in the back side of the quires no additional lubrication except a
housing. Removal of the plugs is not required un- coating of light oil on external surfaces to
less the direction of pump rotation is to be ease reassembly. External surfaces must
changed. be kept free of all dirt and foreign material.
Failure to do so could damage the bearing
or its mating surfaces.
If pump rotation is to be changed, remove the
socket head pipe plugs (P) from the housing. The The bearing tolerance provides a light press fit into
hole adjacent to the discharge port will have a the rotor adjusting sleeve (07AA). Replace the ro-
small pipe plug under the larger, outer pipe plug. tor adjusting sleeve if the proper fit is not achieved.
This plug must be removed and relocated to the
Clean and inspect the seal assembly as indicated
suction side of the pump.
in the appropriate section of the Seal Appendix,
Section F.

PUMP REASSEMBLY Bushing Preparation

When replacing bushings, lightly oil the O.D. of the

replacement bushing before installation.

Use caution when handling the idler (02A)

and the rotor shaft assembly (03A). These Be very careful when installing graphite
parts have sharp edges which will grow bushings. Graphite is extremely brittle and
sharper with use. will crack if improperly installed. Use a

MAINTENANCE AND REPAIR PAGE E−7

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

press to install the bushing with one contin- Backhead Kit (06)
uous motion until the bushing is fully (Figures E-1 and E-5)
seated. Stopping in mid-stroke will cause
the bushing to crack. After installation, Position the backhead (06AA) on the bed of an ar-
check the bushing for cracks. bor (or hydraulic) press with the rotor end facing
up. Use an arbor (or hydraulic) press to install the
throttle bushing (06AE) in the backhead until fully
NOTE seated.
When installing high temperature graphite bush-
ings, heat the part that receives the bushing to Install a new gasket (06B) against the backhead
500F and place the bushing in a freezer for at least shoulder.
one hour. This will allow easier installation with less
chance of breakage.
12 O’CLOCK HOUSING
BALANCE HOLE
Housing Assembly (04) AT 12 O’CLOCK

Inspect and clean the housing (04A) with a cloth

soaked in fresh cleaning solvent. Replace it if badly
worn or damaged. 3 O’CLOCK

BACKHEAD

Most cleaning solvents are toxic and Figure E-5. Housing/Backhead

flammable. Use them only in a well ven- Alignment
tilated area free from flame, sparks, and
excessive heat. Read and follow all pre- Position the balance hole as shown in Figure E-5,
cautions printed on solvent containers. and secure the backhead (06A) to the housing
(04A) with the capscrews (B).

Secure the foot bracket (08A) to the backhead with

the previously removed hardware (B and D).

Rotor/Shaft Assembly (03)

If the socket head pipe plugs (P) in the
Inspect the rotor/shaft assembly (03A) for exces-
back side of the housing were removed in
sive wear, scoring or scratches along the shaft
order to change the direction of pump rota-
sealing surface. If replacement is required, the
tion, the smaller diameter plug must be shaft and rotor must be replaced as an assembly.
installed in the hole adjacent to the dis- Small scratches can be dressed with a fine file or
charge port of the housing. Otherwise, emery cloth. Replace the rotor/shaft assembly or
over-pressurization of the seal cavity could any other parts if wear or damage is extensive.
result in premature seal failure.
Slide the rotor/shaft assembly into the housing and
backhead. Use caution not to scratch the I.D. of
If the socket head pipe plugs (P) in the back side of the bushing (06AE).
the housing were removed, install the smaller di-
ameter plug in the hole adjacent to the discharge Seal Installation (05)
port, and install one of the larger diameter pipe
plugs over the smaller one. Install the second large The seal assembly (05) is available in a variety of
pipe plug in the other hole in the back of the hous- configurations. Check the Parts List furnished with
ing adjacent to the suction port. your pump to identify the seal, then refer to Seal

PAGE E−8 MAINTENANCE AND REPAIR

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

Appendix, Section F, for installation of the seal NOTE

and related components. The O-rings (01E) that are installed between the
head jacket (01G) and the head (Figure 1, 01A) are
Head/Idler Kit (01 and 02) coated with PTFE (DuPont Teflon or equivalent).

(Figure E-1 And E-3)

Install the head jacket gasket (01F) and secure the
If the idler pin (01AB) was removed, apply Loctite head jacket to the head with the capscrews (B).
PST No. 565" pipe sealant (or equivalent com-
pound) to the O.D. of the replacement idler pin and Coverplate Kit (11)
the I.D. of the idler pin bore in the head (01A). Posi- (Figures E-1 and E-3)
tion the pin in the head with the chamfered side to-
The coverplate kit may be mounted on either the
ward the head and the milled flat side facing the
head assembly or the housing assembly. Installa-
crescent. (If the pin is stepped, position it with the
tion is the same for either.
large chamfered end toward the head.) Use an ar-
bor (or hydraulic) press to install the pin in the head Lightly lubricate the O-rings (10C) with oil and in-
until fully seated. stall them in the housing (04A). Secure the cover-
plate (11AA) with the hardware (B). Be sure that the
NOTE warning plate (11AC) is attached to the coverplate.
When properly installed, the pin will be positioned
0.010 inch (0,25 mm) below the surface of the cres- Foot Bracket Kit (08)
cent. Secure the foot bracket (08A) to the head (01A)
and backhead (06A) with the hardware (B and D).
If removed, install the pipe plug (P) in the hole in the Rotor Adjusting Sleeve (07)
suction side of the head (01A).
Clean the rotor adjusting sleeve and all component
Lightly oil the I.D. of the idler (02A), and use an ar- parts as described in Cleaning and Inspection.
Inspect the parts for wear or damage and replace
bor (or hydraulic) press to install the idler bushing
as necessary.
(02B) in the idler. The bushing should be centered
at both ends of the idler.

Place the head (01A) on a flat surface. Lightly oil the

idler bushing (02B) and pin (01AB); install the idler
assembly (02) on the pin. Spin the idler to make When removing or installing the bearing
certain that it moves freely on the pin.
(07AC), never hit or press against the inner
Install the head gasket (01B) over the head. Care- race. Press only against the outer race.
fully position the head and idler against the hous- Use an arbor (or hydraulic) press to install the bear-
ing and engage the idler and rotor/shaft assembly ing in the rotor adjusting sleeve (07A) until fully
(03A). Turn the rotor/shaft until the idler and rotor seated against the shoulder in the I.D. of the rotor
teeth engage. Do not force. adjusting sleeve.
Slide the head into the housing assembly. Rotate Apply 1 to 2 drops of Loctite Thread Locker No.
the head until the groove in the head matches the 272" or equivalent compound to the threads of the
groove in the housing. Secure the head to the bearing retaining nut (07AD), and screw the nut
housing with the capscrews (B). into the rotor adjusting sleeve until fully seated
against the bearing.
Optional Head Jacket
NOTE
(Figure E-1 And E-2) Part or all of the seal assembly (05) must be in-
stalled with the rotor adjusting sleeve. Check the
If your pump is equipped with an optional head Parts List furnished with your pump to identify the
jacket, see Figure E-2 and install the O-rings (01E) seal, refer to Seal Appendix, Section F for installa-
in the grooves in the head (Figure 1, 01A). tion of the seal and related components, then pro-

MAINTENANCE AND REPAIR PAGE E−9

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

ceed as follows with rotor adjusting sleeve installa- on the pump Parts List. Determine the end clear-
tion. Use caution not to damage seal parts when ance for your pump from either of these tables.
installing the rotor adjusting sleeve.
Max. Visc. (SSU)
750 2500 25,000 250,000 750 2500 25,000 250,000
HYD. SIZE Max. Temp. (_F)
Loosen the socket head setscrews (GA). Slide the 225 225 225 225 400 400 400 400
rotor adjusting sleeve kit over the shaft. Use cau- GC,GF,GH,GJ .004 .006 .008 .006 .008 .010
tion not to damage installed seal components on JG,JJ,JL,JP .004 .006 .008 .010 .006 .008 .010 .012
the shaft. Screw the rotor adjusting sleeve into the NK,NM,NP .006 .006 .008 .010 .006 .008 .010 .012
backhead until the rotor bottoms against the head. RM,RP,RR,RS 006 .008 .010 .012 .008 .008 .010 .014

Max. Visc. (SSU)

750 2500 25,000 250,000 750 2500 25,000 250,000
HYD. SIZE
Max. Temp. (_F)
525 525 525 525 675 675 675 675

GC,GF,GH,GJ .006 .008 .010 .008 .010 .012

It is recommended that a new bearing lock- JG,JJ,JL,JP .006 .008 .010 .012 .008 .010 .012 .014
washer (03B) be installed any time the ro- NK,NM,NP .008 .008 .010 .012 .010 .010 .012 .014

tor adjusting sleeve is disassembled. Re- RM,RP,RR,RS 008 .010 .012 .014 .010 .010 .012 .016

use of an old lockwasher may create a pre-

load condition on the bearing, resulting in Notes:
Dimensions are shown in inches. For Viscosities Above
premature bearing failure. 250,000 SSU, or Other Special Applications, Consult Your
Local Gorman-Rupp Distributor or the Factory.

Table E-1. End Clearance Based on Hydraulic

Install the bearing lockwasher (03B) and screw the Size, Viscosity and Temperature
bearing locknut (03C) onto the shaft until tight.
Align one of the slots in the locknut with one of the Rotor Pump Hydraulic Code
Trim
tabs on the lockwasher, and bend the tab on the Code D G J N R
lockwasher into the slot on the locknut. V
i Std .005 .005 .006 .006 .008
s
c
Proceed with Setting End Clearance. o
s 35B .005 .005 .006 .006 .008
i
SETTING END CLEARANCE t
y
35C .005 .006 .008 .008 .010
T
The end clearance between the head (01AA) and r
the face of the rotor (03A) is pre-set from the factory i
m 35D .009 .009 .012 .012 .015
based on the liquid temperature, viscosity and oth- s
er characteristics provided at the time of the order.
T
This clearance is critical to achieve the optimum e 35E .005 .010 .014 .014 .016
performance and maximum service life from your m
p
pump. The end clearance should be checked and
T 35J .006 .012 .016 .016 .018
adjusted, as required, as part of a regular preven-
r
tive maintenance schedule, whenever perform- i
ance drops or when the pump is disassembled. m 35N .014 .014 .018 .018 .020
s
Notes:
Consult Pump Parts List For Rotor Trim Code.
The proper end clearance for your pump can be For Rotor Trim Codes Not Listed or for Special Applications,
determined by two methods. Table E-1 shows cor- Consult Your Local Gorman-Rupp Distributor or the Factory.
rect end clearance based on hydraulic size, viscos-
ity and temperature. Table E-2 shows correct end Table E-2. End Clearance Based on Rotor
clearance based on the rotor trim code indicated Trim Code

PAGE E−10 MAINTENANCE AND REPAIR

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

When the recommended clearance has been de- the backhead to obtain the recommended end
termined from Tables E-1 or E-2, adjust the end clearance.
clearance as follows.
Tighten the setscrews (GA) until they bottom
(Figures E-1 and E-6) against the backhead (06A). Rotate the pump
shaft to ensure free rotation. If the rotor binds or
Loosen the setscrews (GA) in the rotor adjusting scrapes against the head, back off the rotor adjust-
sleeve. Turn the rotor adjusting sleeve (07AA) ing sleeve until rotation is free.
clockwise until the rotor bottoms against the head
(zero clearance), and install the bearing lockwash- Rotate the pump shaft to ensure free rotation. If the
er (03B) and locknut (03C) as previously de- rotor binds or scrapes against the head, back off
scribed. See Figure E-6 and mark the rotor adjust- the rotor adjusting sleeve until rotation is free.
ing sleeve (07AA) at the beveled mark on the back-
head (06A).
RELIEF VALVE DISASSEMBLY
(Figure E-7)
BACKHEAD (06AA) BEVELED MARK
NOTCH NOTE
If the relief valve is low pressure, it will have one in-
ternal spring (10AE). If the relief valve is high pres-
sure, it will have two internal springs (10AE and
10AF).

Unscrew the cap (10AN) from the bonnet (10AK).

Remove the optional gasket (10AP, if so equipped).
Back off the adjustment capscrew (10AM) to re-
lieve pressure on the spring(s) (10AE and/or
10AF).
ROTOR ADJUSTING SLEEVE (07AA)
Figure E-6. End Clearance Adjustment Unscrew the bonnet from the valve body (10AA)
and remove the gasket (10AJ) or O-ring (10C). Re-
Each of the notches on the rotor adjusting sleeve move the valve (10AD) and spring(s) (10AE and/or
(07AA) represents approximately 0.002 inch (0,05 10AF). The spring guide (10AH) is an O-ring fit in
mm) of end clearance. Back off the rotor adjusting the bonnet. Remove and discard the O-rings.
sleeve approximately 1/2 turn, then turn the sleeve
back in until the mark is the appropriate number of If the warning plate (10AB) must be replaced, re-
notches counterclockwise of the beveled mark on move the drive screws (BM), and remove the plate.

MAINTENANCE AND REPAIR PAGE E−11

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

PARTS KEY
10AA VALVE BODY
10AB WARNING PLATE
10AD POPPET
10AE SPRING
10AF SPRING (OPTIONAL)
10AG O-RING
10AH SPRING GUIDE
10AJ O-RING OR GSKT
10C BONNET O-RING
10AK BONNET
10AM CAPSCREW
10AN CAP
10AP CAP GSKT (OPTIONAL)
10AR TAG (OPTIONAL)
D JAM NUT
BM DRIVE SCREW
DIMENSION A" INCHES
(SEE TABLE E-2)

ASSEMBLED VIEW

Figure E-7. Pressure Relief Valve Assembly

RELIEF VALVE REASSEMBLY Insert the valve (10AD), finned end first, into the
valve body (10AA). Install the spring(s) (10AE and/
(Figure E-7) or 10AF). Make certain that the spring (10AE) fits
over the spring guide (10AH), and the optional
spring (10AF) fits into the guide, and thread the
bonnet into the valve body.

Install the jam nut (D) on the adjustment capscrew

Do not return the pump to service with- (10AM) and thread the capscrew into the bonnet
out the warning plate (10AB) installed. until the desired height (A", Figure E−7) is
Failure to observe the warning on the reached. Refer to the separate Parts List accompa-
plate could result in destruction of the nying your pump and determine the hydraulic size
pump, and injury or death to personnel. (D,G,J,N, etc.) and spring option code (STD, 25D,
etc.) for your pump. See Table E−3 or E−4 and ad-
just the capscrew (10AM) to the proper A" dimen-
Inspect the components for wear, grooves, or
sion for the desired cracking pressure.
other damage that might cause leakage. If any
components are worn, replace the defective parts.

If removed, attach the warning plate (10AB) to the

valve body (10AA) using the drive screws (BM).
Never operate the pump without the ad-
justing screw jam nut in place. Other-
If used, lightly oil the O-ring or gasket (10AJ) and
install it in the groove on the bonnet (10AK). wise, the relief valve spring(s) can be
compressed too far for the valve to
Lightly oil the O-ring (10AG) and install it in the open. If the valve does not open, exces-
groove on the spring guide (10AH). Start the large sive pressure can develop, causing
end of the spring guide into the bonnet (10AK), and damage to the pump and possible injury
push the guide in until it bottoms out. to personnel.

PAGE E−12 MAINTENANCE AND REPAIR

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

PUMP SINGLE CRACKING DIMENSION DOUBLE CRACKING DIMENSION

HYDRAULIC SPRING PRESSURE A" (INCHES) SPRING PRESSURE A" (INCHES)
SIZE OPTION CODE (PSI) Fig. E-7) OPTION CODE (PSI) Fig. E-7)

STD 25A 100 MIN. .60 FULLY OUT

50 MIN. .60 FULLY OUT
25D 25E 125 .51
75 .47
GC, GF, 25G 25H 150 .42
100 .33
GH, GJ 25J 25K 175 .33
25S 130 MAX. .16 FULLY IN
25T
200 .23

225 MAX. .16 FULLY IN

50 MIN. 1.17 FULLY OUT

STD 25A 100 .93

30 MIN. 1.17 FULLY OUT
JG, JJ, 25D 25E 125 .83
50 .88
JL, JP, 25G 25H
150 .72
25J 75 .57 25K
NK, NM, 175 .61
25S 95 MAX. .31 FULLY IN 25T
NP 200 .50

240 MAX. .31 FULLY IN

STD 105 MIN. 1.23 FULLY OUT

55 MIN. 1.23 FULLY OUT 25A
25D 125 .90
25H
RM, RP, 25G 75 .89 150 .70
25K
RR, RS 25J 100 .51 175 .55
25T
25S 190 MAX. .37 FULLY IN
110 MAX. .37 FULLY IN

Table E-3. Cracking (Valve Opening) Settings ( Denotes Factory Setting)

MAINTENANCE AND REPAIR PAGE E−13

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

PUMP SINGLE CRACKING DIMENSION DOUBLE CRACKING DIMENSION

HYDRAULIC SPRING PRESSURE A" (INCHES) SPRING PRESSURE A" (INCHES)
SIZE OPTION CODE (PSI) Fig. E-7) OPTION CODE (PSI) Fig. E-7)

100 MIN. .60 FULLY OUT

45 MIN. .60 FULLY OUT
125 .51
50 .57
GC, GF, 150 .42
25U 75 .47 25V
GH, GJ 175 .34
100 .22
200 .26
130 MAX. .16 FULLY IN
230 MAX. .16 FULLY IN

35 MIN. 1.17 FULLY OUT

30 MIN. 1.17 FULLY OUT
JG, JJ, 75 .87
50 .88
JL, JP, 100 .68
25U 25V
70 MAX. .31 FULLY IN
NK, NM, 125 .51

NP 150 MAX. .31 FULLY IN

40 MIN. 1.23 FULLY OUT

40 MIN. 1.23 FULLY OUT 100 .93

RM, RP, 125 .74
25U 75 .71 25V
RR, RS 150 .51
90 MAX. .37 FULLY IN
170 MAX. .37 FULLY IN

Table E-4. Cracking (Valve Opening) Settings ( Denotes Factory Setting)

After adjustment, tighten the jam nut (D) flush

against the bonnet.

Place the optional warning tag (10AR) between the

bonnet and the cap (10AN). Install the cap, and Do not return the pump to service with-
tighten until fully seated against the bonnet. out the warning plate (10AB) installed.
Relief Valve (10) Installation
Failure to observe the warning on the
plate could result in destruction of the
Lubricate and install the gaskets or O-ring(s) (10C) pump, and injury or death to personnel.
on the housing assembly (04A) or the head assem-
bly (01A). Secure the relief valve (10A) with the If the warning plate (10AB) has been removed, se-
capscrews (B). cure it with the drive screws (BM).

PAGE E−14 MAINTENANCE AND REPAIR

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

SEAL APPENDIX − SECTION F

PARTS KEY
03A ROTOR/SHAFT ASSY
03B BRG LOCKWASHER
03C BEARING LOCKNUT
N SHAFT KEY
05 SEAL ASSY
06A BACKHEAD
P PIPE PLUG
07F SEAT SLEEVE O-RING
07H SHAFT CLIP
07L SEAT SLEEVE
07S SEAT SLEEVE
07V SEAT SLEEVE O-RING
07AA ROTOR ADJ SLEEVE
07AC BALL BEARING
07AD BEARING RET NUT
07AJ BRG SPACER (IF REQ’D)
GA SETSCREW
ASSEMBLED VIEW
S SPRING PIN

16282.2

Figure F-2. Positive Drive (Option 60D) Seal

PAGE F − 4 SEAL APPENDIX

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

Seal Removal excessive heat. Read and follow all pre-

cautions printed on solvent containers.
(Figures E-1 and F-2)
The seal is not normally reused because wear pat-
See PUMP DISASSEMBLY and disassemble the terns on the finished faces cannot be realigned
pump up to and including the Rotor Adjusting during reassembly. This could result in premature
Sleeve (07). As the rotor adjusting sleeve (07AA) failure. If necessary to reuse an old seal in an emer-
is unscrewed from the backhead (06A), the seal gency, carefully wash all metallic parts in fresh
stationary element will remain inside the seat cleaning solvent and allow to dry thoroughly.
sleeve (07S).

Remove the seal stationary element and O-ring

from the seat sleeve. Use caution not to damage
the stationary element sealing face. Seal components must be kept clean.
Handle seal parts with extreme caution to
If the seat sleeve (07S) requires replacement, pry
prevent damage. Use care not to contami-
the sleeve off the O.D. of the bearing retaining nut
nate the precision-finished faces; even fin-
(07AD).
gerprints on the faces can shorten seal life.
Remove the pipe plugs (P) from the seat sleeve If necessary to clean the faces, use a clean
(07L). Reach through the pipe plug hole with an al- cloth and wipe in a circular pattern.
len wrench and loosen the setscrews in the rotat- Inspect the seal components for wear, scoring,
ing portion of the seal assembly (05). grooves, and other damage that might cause leak-
age. If any components are worn, replace the com-
Reach through the backhead (06A) and pry the
plete seal; never mix old and new seal parts.
seat sleeve (07L) loose from the backhead. Pull the
seat sleeve and rotating portion of the seal out of If a replacement seal is being used, unwrap the
the backhead. Remove the O-rings (07F and 07V) mechanical seal components. Check that the seal
from the seat sleeve. faces are clean, undamaged and free of any for-
eign matter. Set aside and cover the seal stationary
Remove the shaft clip (07H) if replacement is nec- element and O-ring; it will not be used until the rotor
essary. adjusting sleeve (07AA) is installed.

Continue as required with PUMP DISASSEMBLY. If removed, install new O-rings (07F and 07V) in the
grooves in the seat sleeve (07L). Press the sleeve
Seal Installation into the backhead until fully seated against the
backhead.
(Figures E-1 and F-2) Position the pump on a flat surface with the drive
end facing up. If removed, install the clip (07H) in
See PUMP REASSEMBLY, and assemble the
the groove in the shaft.
housing assembly (04), backhead kit (06) and ro-
tor/shaft assembly (03). Lightly oil the shaft of the rotor/shaft assembly
(03A). Position the rotating portion of the seal on
Clean the seal cavity and shaft with a cloth soaked the shaft with the sealing face up. Place a clean tis-
in fresh cleaning solvent. sue over the sealing face of this rotating subas-
sembly and slide it onto the shaft until fully seated
against the shaft clip (07H).

Reach through the pipe plug hole in the seat sleeve

(07L) with an allen wrench and tighten the set-
Most cleaning solvents are toxic and screws securing the rotating portion of the seal as-
flammable. Use them only in a well ven- sembly (05) to the shaft. Reinstall the pipe plug (P)
tilated area free from flame, sparks, and in the seat sleeve (07L).

SEAL APPENDIX PAGE F − 5

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

OM−05450 GHS SERIES

Assemble the rotor adjusting sleeve (07) as de- Lubricate the stationary element O-ring and posi-
scribed in Pump Reassembly, Section E and po- tion the stationary element in the seat sleeve (07S)
sition it on a flat surface with the drive end down. with the sealing face up. Cover the sealing face
with a clean tissue and use thumb pressure to
press the stationary element into the seat sleeve
If removed, position the seat sleeve (07S) over the until fully seated.
shoulder on the bearing retaining nut (07AD) and
press the sleeve onto the nut until fully seated. Proceed with Pump Reassembly, Section E.

PAGE F − 6 SEAL APPENDIX

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

GHS SERIES OM−05450

O-RING APPENDIX − SECTION G

Ref. Description Hyd. Dash No. Ref. Description Hyd. Dash No.
No. Size No. Size
01C Head to G 152 10AG Spring G 028
Housing J 159 Guide to J 034
N 164 Bonnet N 034
R 172 R 042
01E Head Jacket G 029 10AJ Bonnet to G 033
to Head J 135 Valve Body J 040
N 135 N 040
R 145 R 045
06G Housing to G 152 10C Valve or G 029
Backhead J 159 Coverplate J 135
N 164 to Head N 135
R 172 R 145
07B Seat Sleeve to G 145
Backhead J 152 O-RING FAMILY NUMBERS
N 152
R 152 5-DIGIT FAMILY O-RING MATERIAL
07F Seat Sleeve G 133
to Flex Back- J 139 25151−*** NEOPRENE
head N 139
R 141 25152−*** BUNA-N
07V Seat Sleeve G 142
to Intermedi- J 150 25154−*** VITON
ate Sleeve N 150
25156−*** KALREZ
R 152
09C Shaft Sleeve G 020 25157−*** TEFLON-ENCAPSULATED
to Shaft J 123
N 123 25158−*** CHEMRAZ (OR EQUAL)
R 126
*** This number refers to the standard size.
NOTE: Neoprene, Kalrez, Teflon and Viton are Registered
Trademarks of the DuPont Corp.
Chemraz is a Registered Trademark of Green, Tweed
and Co.
Equivalent material may be substituted for all materials.

Table G-1. O-Ring Information Chart

O-RING APPENDIX PAGE G − 1

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

AV−05791 (02-07-06)

THE GORMAN-RUPP COMPANY AND

GORMAN-RUPP OF CANADA LIMITED
12 MONTH LIMITED WARRANTY
EXTENT AND DURATION OF WARRANTY
Coverage: The Gorman-Rupp Company or Gorman-Rupp of Canada Limited (herein individually referred to as GR")
each individually warrant that its products and parts shall be free from defects in material and workmanship for twelve (12)
months from the date of purchase by the original end user.

Exceptions: This Limited Warranty shall not apply to the following products and parts: engines, motors, trade accesso-
ries and other products, components or materials not manufactured by GR. With respect to submersible pumps, the
pump and motor are an integral unit and are therefore warranted as a unit. However, with respect to the electrical
components in submersible pumps, this warranty is valid only when electrical controls for the pump have been specified
and/or provided by GR. Wear and tear on any product resulting from normal use is not covered by this Limited Warranty.

LIMITATIONS
GR’S SOLE AND EXCLUSIVE WARRANTY WITH RESPECT TO ITS PRODUCTS AND
PARTS IS THIS LIMITED WARRANTY. THIS LIMITED WARRANTY IS IN LIEU OF
ALL OTHER EXPRESS AND/OR IMPLIED WARRANTIES, INCLUDING IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR
PURPOSE.
EXCLUSIVE REMEDY AND DAMAGES
The sole and exclusive remedy for breach of this Limited Warranty by GR, and the entire extent of its liability for such
breach or for damages arising and/or resulting from the use of the products and parts covered by this Limited Warranty
shall be as follows:

1. Repair or replacement: If inspection shows that any GR product or part covered under this LimitedWarranty is defec-
tive in materials or workmanship, GR shall repair or replace the defective product or part at its option, without charge.
You must have properly installed, maintained and used the product or part claimed to be defective in accordance with
the maintenance schedule and/or manual which comes with the product. No allowance will be made for labor, trans-
portation or other charges incurred by you in connection with such repair or replacement.

2. To obtain the above remedy:

a) Immediately notify GR at the address below of the claimed defect in materials or workmanship and provide the
serial number or date code of the product and/or part and provide a copy of the invoice or bill of sale referencing
the product and/or part by no later than the expiration date of the Limited Warranty period.

b) GR will advise whether inspection of the product and/or part will be necessary and whether and how repair or
replacement will be effected. If inspection by GR is necessary, the product or part must be sent freight prepaid to
GR at the address stated below. Return shipment of the repaired product or part will be F.O.B. the address stated
below.

3. Damages: GR’s liability for damages for breach of this Limited Warranty shall not exceed the amount of the purchase
price of the product or part in respect to which damages are claimed. IN NO EVENT SHALL GR BE
LIABLE FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES FOR
BREACH OF THIS LIMITED WARRANTY OTHER THAN AS STATED HEREIN.
Some states do not allow the exclusion or limitation of incidental or consequential damages. Accordingly, the above
may not apply to you. This Limited Warranty gives you specific legal rights, and you may also have other rights which
vary from state to state and province to province.
THE GORMAN-RUPP COMPANY GORMAN-RUPP OF CANADA LIMITED
P.O. BOX 1217 70 Burwell Road
MANSFIELD, OH 44901−1217 St. Thomas, Ontario N5P 3R7
Phone: (419) 755−1011 Phone: (519) 631−2870
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

   

   
  


    

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 SPECIAL INSTRUCTION MANUAL
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 SPECIAL INSTRUCTION MANUAL
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 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

SIMOREG DC Master
6RA70 Series Base Drive Instructions
Microprocessor-based converters from 15A to 1660A
for variable speed DC drives

Rev 4.0

dc drives
Global network of innovation
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Converter software version:

As these Operating Instructions went to print, SIMOREG 6RA70 DC Master converters were being delivered
from the factory with software version 2.0 installed.
These Operating Instructions also apply to other software versions.
Earlier software versions: Some parameters described in this document might not be available in the software
(i.e. the corresponding functionality is not available on the converter) or some
parameters will have a restricted setting range. SIMOREG 6RA70 Base Drive Panel
series requires software version 1.8 or later.
Later software versions: Additional parameters might be available on the SIMOREG DC Master (i.e. extra
functions might be available which are not described in these Operating Instructions)
or some parameters might have an extended setting range. In this case, leave the
relevant parameters at their factory setting, or do not set any parameter values which
are not described in these Instructions !
The latest software version of the SIMOREG DC Master can be read in parameters r060 and r065.

The latest software version is available at the following Internet site:

http://www4.ad.siemens.de/view/cs/en/8467834

The reproduction, transmission or use of this document or contents is

not permitted without express written authority. All rights, including
rights created by patent grant or registration of a utility model or design,
are reserved.

We have checked that the contents of this publication agree with the
hardware and software described herein. Nonetheless, differences
might exist and therefore we cannot guarantee that they are completely
identical. The information given in this publication is reviewed at regular
intervals and any corrections that might be necessary are made in the
subsequent printings. Suggestions for improvement are welcome at all
times. SIMOREG ® is a registered trademark of Siemens

© Siemens Energy & Automation 2001 All rights reserved

 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

0 Contents
Page

1 Safety information 1-1

2 Introduction
2.1 Base Drive Panel Description 2-1

2.2 General Information 2-1

2.3 Rated DC Current 2-2

2.4 Card Rack Assembly 2-2

3 Parts and Service

3.1 Base Drive Panel model numbers 3-1
3.2 Service 3-2
3.3 Option part numbers 3-3
3.4 Spare Parts 3-4
3.5 Standard Terms & Conditions 3-10

4 Receiving and Unpacking 4-1

5 Technical Data
5.1 15 to 100 ADC Base Drive Panels 5-1
5.2 140 to 850 ADC Base Drive Panels 5-2
5.3 1180 and 1660 ADC Base Drive Panels 5-3
5.4 Applicable Standards 5-5

6 Installation and Dimensions

6.1 Installation Information 6-1
6.2 Base Drive Panel Outlines 6-2

7 Base Drive Panel Connections

7.1 Base Drive Panel Schematics 7-2
7.2 Control Connections CUD1 7-14
7.3 Control Connections CUD2 7-16
7.4 Description of Power/Control Terminals 7-18

Siemens Energy & Automation 0-1

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

8 Start-up
8.1 General safety information 8-1
8.2 Operator control panels 8-2
8.3 Parameterization procedure 8-4
8.4 Typical connection diagrams 8-6
8.5 Reset to factory default values 8-8
8.6 Start-up procedure 8-9

9 Faults and Alarms

9.1 Fault messages 9-1
9.2 Alarm messages 9-26

10 Abbreviated Parameter List

10.1 Overview 10-1
10.2 Overview of Abbreviations 10-2
10.3 Operating Status Display 10-3
10.4 General Visualization Parameters 10-5
10.5 Access Authorization Levels 10-10
10.6 Definition of SIMOREG Converter 10-10
10.7 Setting Values for Converter Control 10-12
10.8 Definition of Motor 10-14
10.9 Definition of Speed Sensing Pulse Encoder 10-19
10.10 Armature Current Control, Reversing, Gating 10-21
10.11 Current/Torque Limitation 10-22
10.12 Speed Controller 10-23
10.13 Field Current Control, Gating 10-24
10.14 Closed Loop EMF Control 10-24
10.15 Ramp Function Generator 10-25
10.16 Setpoint Processing 10-25
10.17 Monitoring Functions and Limits 10-25
10.18 Limit-Value Monitors 10-26
10.19 Digital Setpoint Inputs 10-27
10.20 Torque Shell Input 10-29
10.21 Input Quantities for Signals 10-29
10.22 Configuring of Closed-Loop Control 10-30
10.23 Control and Status Word 10-31
10.24 Further Configuring Measures 10-34

0-2 Siemens Energy & Automation

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

10.25 Analog Inputs 10-35

10.26 Analog Outputs 10-36
10.27 Binary Outputs 10-36
10.28 Configuration of Serial Interfaces 10-36
10.29 Deactivation of Monitoring Functions 10-41
10.30 Thyristor Diagnostics 10-41
10.31 Parameters for DriveMonitor and OP1S 10-42
10.32 Profile Parameters 10-42
10.33 Resetting and Storing Parameters 10-43

11 Simplified Block Diagrams 11-1

Siemens Energy & Automation 0-3

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

1 Safety information

WARNING
Hazardous voltages and rotating parts are present in this electrical equipment during
operation. Non-observance of the safety instructions can result in death, severe
personal injury or substantial property damage.
Only qualified personnel should work on or around the equipment after first becoming
thoroughly familiar with all warning and safety notices and maintenance procedures contained
herein. The successful and safe operation of this equipment is dependent on proper handling,
installation, operation and maintenance.

Definitions:
• QUALIFIED PERSONNEL

For the purpose of this Instruction Manual and product labels, a "Qualified Person" is someone who
is familiar with the installation, construction and operation of the equipment and the hazards
involved. He or she must have the following qualifications:
1. Trained and authorized to energize, de-energize, clear, ground and tag circuits and equipment in
accordance with established safety procedures.
2. Trained in the proper care and use of protective equipment in accordance with established
safety procedures.
3. Trained in providing first aid.

• DANGER

For the purpose of this Instruction Manual and product labels, "Danger" indicates that death,
severe personal injury or substantial property damage will result if proper precautions are not
taken.

• WARNING

For the purpose of this Instruction Manual and product labels, "Warning" indicates that death,
severe personal injury or substantial property damage can result if proper precautions are not
taken.

• CAUTION
For the purpose of this Instruction Manual and product labels, "Caution" indicates that minor
personal injury or property damage can result if proper precautions are not taken.

• NOTE

For the purpose of this Instruction Manual, "Note" indicates information about the product or the
respective part of the Instruction Manual which requires particular attention.

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NOTE
These operating instructions do not purport to cover all details or variations in equipment, nor to
provide for every possible contingency to be met in connection with installation, operation or
maintenance.
Should further information be desired or should particular problems arise which are not covered
sufficiently for the purchaser's purposes, the matter should be referred to the local Siemens
Sales Office.
The contents of these operating instructions shall not become part or modify any prior or existing
agreement, commitment or relationship. The Sales Contract contains the entire obligations of
Siemens. The warranty contained in the contract between the parties is the sole warranty of
Siemens. Any statements contained herein do not create new warranties or modify the existing
warranty.

DANGER
Converters contain hazardous electrical voltages, Death, severe bodily injury or significant
material damage can occur if the safety measures are not followed.
1. Only qualified personnel, who are knowledgeable about the converters and the provided
information, can install, start up, operate, troubleshoot or repair the converters.
2. The converters must be installed in accordance with all relevant safety regulations (e.g.
NEC, DIN, VDE) as well as all other national or local regulations. Operational safety and
reliability must be ensured by correct grounding, cable sizing and appropriate short-circuit
protection.
3. All panels and doors must be kept closed during normal operation.
4. Before carrying out visual checks and maintenance work, ensure that the AC power supply
is disconnected and locked out. Before the AC supply is disconnected, both converters and
motors have hazardous voltage levels. Even when the converter contactor is open,
hazardous voltages are still present.
5. When making measurements with the power supply switched on, electrical connections
must not be touched under any circumstances. Remove all jewelry from wrists and fingers.
Ensure that the test equipment is in good conditions and operationally safe.
6. When working on units that are switched on, stand on an insulating surface, i.e. ensure that
you are not grounded.
7. Carefully follow the relevant instructions and observe all danger, warning and cautionary
instructions.
8. This does not represent a full listing of all the measures necessary for safe operation of the
equipment. If you require other information or if certain problems occur which are not
handled in enough detail in the information provided in the Instruction Manual, please
contact your local Siemens office.

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CAUTION

Electro-statically sensitive devices

The converter contains electro-statically sensitive devices. These can easily be destroyed if they are not
handled correctly. If, however, it is absolutely essential for you to work on electronic modules, please pay
careful attention to the following instructions:
• Electronic modules (PCBs) should not be touched unless work has to be carried out on them.
• Before touching a PCB, the person carrying out the work must himself be electro-statically discharged.
The simplest way of doing this is to touch an electrically conductive ground object, e.g. socket outlet
ground contact.
• PCBs must not be allowed to come into contact with electrically insulating materials − plastic foil,
insulating table tops or clothing made of synthetic fibers −
• PCBs may only be set down or stored on electrically conducting surfaces.
• When carrying out soldering jobs on PCBs, make sure that the soldering tip has been grounded.
• PCBs and electronic components should generally be packed in electrically conducting containers
(such as metallized-plastic boxes or metal cans) before being stored or shipped.
• If the use of non-conducting packing containers cannot be avoided, PCBs must be wrapped in a
conducting material before being put in them. Examples of such materials include electrically
conducting foam rubber or household aluminum foil.
For easy reference, the protective measures necessary when dealing with sensitive electronic components
are illustrated in the sketches below.
a = Conductive flooring d = Anti-static overall
b = Anti-static table e = Anti-static chain
c = Anti-static footwear f = Grounding connections of cabinets

d d d
b b
e e

f f f f f

c a c
a a

Seated workstation Standing workstation Standing/seated workstation

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NOTES:

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2 Description
2.1 Base Drive Panel Description
Series 6RA70 SIMOREG DC MASTER Base Drive Panels are complete drive assemblies ready to be
installed and operated. They include a 3-phase armature converter, single-phase field converter, main
contactor, protective semiconductor fuses, control power transformer, and power / control terminals.
Base Drive Panels are fully digital, compact units which supply the armature and field of variable-
speed DC drives with rated armature currents from 15A to 1660A. The motor field circuit can be
supplied with DC currents of up to 40A (current levels depend on the armature rated current).

2.2 General Information

Series 6RA70 SIMOREG DC MASTER converters are characterized by their compact, space-saving
construction. Their compact design makes them particularly easy to service and maintain since
individual components are readily accessible. The electronics box contains the basic electronic
circuitry as well as any supplementary option boards.
All SIMOREG DC MASTER units are equipped with a PMU simple operator panel mounted in the
converter door. The panel consists of a five-digit, seven-segment display, three LED’s as status
indicators and three parameterization keys. The PMU also features connector X300 with an USS
interface in accordance with the RS232 or RS485 standard. The panel provides all the facilities for
making adjustments or settings and displaying measured values required to start-up the converter.
The OP1S optional converter operator panel can be mounted directly in the converter door or
externally, e.g., in the cubicle door. When mounted remotely, the OP1S can be connected to the
converter with cables up to 5 meters (15 feet) length. Cable up to 200 meter (600 feet) in length can be
used if a separate 5 VDC power supply is available. The OP1S connects to the SIMOREG through
connector X300 using the RS485 interface. The OP1S can be installed as an economic alternative to
conventional door mounted metering devices (i.e., voltmeters, ammeters, and speed indicator).
The OP1S features a liquid crystal display with 4 x 16 characters for displaying parameter names in
plain text. English, German, French, Spanish and Italian can be selected as the display languages. In
addition the OP1S can store parameter sets for easy downloading to other drives.
The converter can also be parameterized on a standard PC with appropriate software connected to the
serial interface on the basic unit. This PC interface is used during start-up, for maintenance during
shutdown and for diagnosis in operation. Furthermore, converter software upgrades can be loaded
through this interface for storage in flash memory.
On single-quadrant converters, a fully controlled three-phase bridge supplies the armature. On four-
quadrant converters, two fully controlled three-phase bridges are connected in an inverse-parallel
connection to allow both positive and negative armature current. For the field converter, a single-
phase, half-controlled 2-pulse bridge supplies the motor shunt field.
The armature and field converters can operate with AC line frequencies from 45 to 65 Hz. If required
for a specific application, the frequency of the armature and field AC supplies can be different. The
armature converter 3 phase AC supply is phase insensitive however on base drives rated 1180 and
1660 amperes, the 3 phase cooling fan must be connected to get the proper direction of rotation. The
power section cooling system is monitored by means of temperature sensors.

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The power section for the armature and field converters is constructed of isolated thyristor modules for
converters rated from 15A to 850A at 460VAC-line voltage. The heat sink in this case is electrically
isolated and at ground potential. On converters rated 1180 and 1660 amperes at 460 VAC, the power
section for the armature circuit is constructed using disk thyristors and the heat sinks are at line voltage
potential. The housing and terminal covers on power connections provide protection against
accidental contact for operators working in the vicinity. All connecting terminals are accessible from the
front.
All open and closed-loop drive control and communication functions are performed by two powerful
microprocessors. Drive control functions are implemented in the software as program modules that can
be "wired up" and changed by parameters.

2.3 Rated DC Current:

The rating plate of the 6RA70 power module has 2 rated currents listed on it. The first output rating is a
IEC class I ratings and has no bearing on the base drive panel rating. The second rating is the US
(NEMA) rating which the Base Drive Panel rating is derived from.
The US (NEMA) rated current allows operation at this rated current followed by an overload of 150%
for 60 seconds in a 45°C ambient. The overload can be applied no sooner than every 10 minutes.
Base Drive Panels are designed using the US rating which means that fuses, contactors, and terminal
blocks are sized for the rated US (NEMA) current.
The IEC class I rating is the maximum current the power module can supply continuously with no
overload. Because an overload is not possible the class I rated current is higher than the US rating.
The IEC class I rating cannot be used with Base Drive Panels because the Base Drive Panel fuses,
contactors, and terminal blocks will be overloaded.
The microprocessor calculates the current I2t value of the power section cyclically to ensure that the
thyristors are not damaged in overload operation.

2.4 Card Rack Assembly

One of the many features of the 6RA70 is its ability to expand its functionality modularly through the
use of adding additional option cards inserted in the internal card rack of the power module. A
complete list of the option cards can be found in 6RA70 catalog available from your local Siemens
Sales office.
The card rack assembly contains the CUD1 microprocessor board and two additional slots for two full
size option cards or four half-size option cards. The back plane of the card rack assembly contains an
EEPROM allowing the CUD1 to be replaced without reprogramming of the parameters. Since
additional information specific to the individual unit is programmed into the back plane of the
card rack assembly (model #, serial #, PIN code, etc..) the card rack assembly should never be
interchanged with another unit. If ordering an additional back plane (part # 6RY1703-0GA01)
the model and serial number of the power module will be required.

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3 Parts and Service

3.1 Base Drive Panel Catalog Numbers

US RATING 1-QUAD TYPE 4-QUAD TYPE Horsepower Horsepower

(Amps DC) (Catalog No.) (Catalog No.) (240V DC 1) (500V DC)

15 6RA7013-2FS22-0 6RA7013-2FV62-0 3HP 7.5HP

30 6RA7018-2FS22-0 6RA7018-2FV62-0 7.5HP 15HP

60 6RA7025-2FS22-0 6RA7025-2FV62-0 15HP 30HP

100 6RA7030-2FS22-0 6RA7030-2FV62-0 25HP 60HP

140 6RA7072-2FS22-0 6RA7072-2FV62-0 40HP 75HP

210 6RA7075-2FS22-0 6RA7075-2FV62-0 60HP 125HP

255 6RA7077-2FS22-0 6RA7077-2FV62-0 75HP 150HP

430 6RA7082-2FS22-0 6RA7082-2FV62-0 125HP 250HP

510 6RA7083-2FS22-0 6RA7083-2FV62-0 150HP 300HP

850 6RA7087-2FS22-0 6RA7087-2FV62-0 250HP 500HP

1180 6RA7091-2FS22-0 6RA7091-2FV62-0 700HP

1660 6RA7094-2FS22-0 6RA7094-2FV62-0 1000HP

1) Standard voltage configuration

as shipped is 460V AC.
See Technical application note
for 230 V AC connection

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3.2 Service

Spare Parts
An excellent stock of drive products spare parts is maintained at the Alpharetta, Georgia factory. Same
day delivery and after hour shipments can be serviced from this stock, including on weekends and
holidays. To contact Customer Service, simply call our Customer Service Group general phone number:
1-800-333-PIC1 (7421)

Technical Assistance
Should you need technical assistance (other than ordering a part), a reliable answering service ensures
that your request is relayed immediately to one of our technical support engineers 24 hours a day. To
contact the Technical Support and Field Service groups simply call:

1-800-333-PIC1 (7421)

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3.3 Option Part Numbers

Options Order No.

Terminal expansion card (CUD2) 6RX1700-0AK00
User-friendly operator control panel (OP1S) 6SE7090-0XX84-2FK0
AOP1 adapter for mounting OP1A in cubicle door, including 6SX7010-0AA00
5 m connecting cable
PMU-OP1S connecting cable, 3m 6SX7010-0AB03
PMU-OP1S connecting cable, 5m 6SX7010-0AB05
LBA Local bus adapter for the electronics box 6SE7090-0XX84-4HA0
Note: LBA is needed to install any boards listed below
ADB Adapter board 6SX7010-0KA00
Note: ADB is always needed to install CBC, CBP2, CBD,
EB1, EB2, SBP and SLB boards
SBP Pulse encoder evaluation board 1) 2) 6SX7010-0FA00
EB1 Terminal expansion board 2) 6SX7010-0KB00
EB2 Terminal expansion board 2) 6SX7010-0KC00
SLB SIMOLINK board 2) 6SX7010-0FJ00
CBP2 Communications board interface for PROFIBUS 2) 6SX7010-0FF05
CBC Communications board interface for CAN protocol 2) 6SX7010-0FG00
CBD Communications board interface for DeviceNet protocol 2) 6SX7010-0FK00
T400 Technology board with SPW 420 Axial winder software 2) 6DD1-842-0AA0
T400 Technology board with SPW 440 Angular Synchr. Software 2) 6DD1-842-0ABO

1) A pulse encoder evaluation circuit is a standard component of the basic SIMOREG converter. The SBP only
needs to be ordered in configurations requiring evaluation of a second pulse encoder.
2) The LBA local bus adapter and ADB adapter board must be ordered as additional components for installing
supplementary boards in the SIMOREG converter.

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3.4 Spare Parts

Printed Circuit Boards
DESCRIPTION WHERE USED PART RECOM
US Rating 460V NUMBER SPARE
Microprocessor board CUD1 All Ratings 6RY1703-0AA00 1
(C98 043-A7001-L1)
Power Interface board 1Q (85 to 575 VAC) All 1Q Ratings 6RY1703-0DA01 1
(C98 043-A7002-L1)
Power Interface board 4Q (85 to 575 VAC) All 4Q Ratings 6RY1703-0DA02 1
(C98 043-A7002-L4)
PMU Operator Panel (C98 043-A7005-L1) All Ratings 6RY1704-0AA00 -
Field Supply board (C98 043-A7014- 30 to 100 Amp 6RY1703-0CA03 1
L1)
Field Supply board (C98 043-A7014- 140 to 510 Amp 6RY1703-0CA01 1
L2)
Field Supply board (C98 043-A7004- 850 to 1660 Amp 6RY1703-0EA01 1
L1)
Snubber board (C98 043-A7007-L4) 60 to 100 Amp 6RY1703-0FA04
Snubber board (C98 043-A7007-L6) 30, 140 to 210 Amp 6RY1703-0FA11 -
Snubber board (C98 043-A7011-L6) 255 – 430 Amp 6RY1703-0FA10 -
Snubber boards (C98 043-A7011-L1) 510 – 850 Amp 6RY1703-0FA06 -
Main Power Section Connector board 15 Amp (1Q, 4Q) 6RY1703-0CA04 1
(C98 043-A7010-L2)
Fuse for Power Supply, 1 amp F1, F2 15 – 1660 Amp 6RY1702-0BA00 2
Mounted on Power Interface board

Cables
DESCRIPTION WHERE USED PART RECOM
US Rating 460V NUMBER SPARE
Ribbon Cable 20 pole X102 15 amp 6RY1707-0AA00
Ribbon Cable 64 pole X101 15 to 430 amp 6RY1707-0AA01 -
Ribbon Cable 20 pole X102 30 to 210 amp 6RY1707-0AA02 -
Ribbon Cable 20 pole X102 255 & 430 amp 6RY1707-0AA03 -
Ribbon Cable 20 pole X102 510 amp 6RY1707-0AA12 -
Ribbon Cable 64 pole X101 510 amp 6RY1707-0AA05 -
Ribbon Cable 20 pole X102 850 to 1660 amp 6RY1707-0AA06 -
Ribbon Cable 64 pole X101 850 to 1660 amp 6RY1707-0AA07 -

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Fans/Blowers
DESCRIPTION WHERE USED PART NUMBER RECOM
US Rating 460V SPARE
FAN, 24 VDC 140 & 210 amp 6RY1701-0AA07 -
(C98130-A1256-C553)
FAN, 230 VAC, 1 Phase 255, 430 & 510 6RY1701-0AA11 -
amp
(C98130-A7004-B130)
FAN, 230 VAC, 1 Phase 850 amp 6RY1701-0AA12 -
(C98130-A7004-B330)
FAN, 460 VAC, 3 Phase 1180 & 1660 amp 6RY1701-0AA04 -
(C98 247-S1002-C25)

Thyristors & Diodes

Armature Converter Thyristor Modules, (for 1-Quad Drives)
DESCRIPTION WHERE USED PART NUMBER RECOM
US Rating 460V SPARE
Dual Thyristor Module 15 amp 1Q 6RY1700-0AA16 1
Dual Thyristor Module 30 amp 1Q 6RY1700-0AA17 1
Dual Thyristor Module 60 amp 1Q 6RY1700-0AA18 1
Dual Thyristor Module 100 amp 1Q 6RY1700-0AA11 1
Dual Thyristor Module 140 amp 1Q 6RY1700-0AA14 1
Dual Thyristor Module 210 amp 1Q 6SY7010-0AA02 1
Dual Thyristor Module 255 amp 1Q 6RY1700-0AA15 1
Dual Thyristor Module 430 amp 1Q 6SY7010-0AA05 1
Dual Thyristor Module 510 amp 1Q 6SY7010-0AA04 1
Dual Thyristor Module 850 amp 1Q 6RY1700-0AA04 1
Thyristor/Heatsink Assembly, Front 1180 amp 1Q 6RY1702-0CA15 1
(C98 130-A1255-B510)
Thyristor/Heatsink Assembly, Back 1180 amp 1Q 6RY1702-0CA16 1
(C98 130-A1255-B511)
Thyristor/Heatsink Assembly, Front 1660 amp 1Q 6RY1702-0CA17 1
(C98 130-A1255-B520)
Thyristor/Heatsink Assembly, Back 1660 amp 1Q 6RY1702-0CA18 1
(C98 130-A1255-B521)

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Armature Converter Thyristor Modules, (for 4-Quad Drives)

DESCRIPTION WHERE USED PART NUMBER RECOM
US Rating 460V SPARE
Dual Thyristor Module 15 amp 4Q 6RY1700-0AA16 1
Dual Thyristor Module 30 amp 4Q 6RY1700-0AA17 1
Dual Thyristor Module 60 & 100 amp 4Q 6RY1700-0AA11 1
Dual Thyristor Module 140 amp 4Q 6RY1700-0AA14 1
Dual Thyristor Module 210 amp 4Q 6SY7010-0AA02 1
Dual Thyristor Module 255 amp 4Q 6RY1700-0AA15 1
Dual Thyristor Module 430 amp 4Q 6SY7010-0AA05 1
Dual Thyristor Module 510 to 850 amp 4Q 6SY7010-0AA04 1
Thyristor/Heatsink Assembly 1180 amp 4Q 6RY1702-0CA02 1
C98 130-A1256-B510
Thyristor/Heatsink Assembly 1660 amp 4Q 6RY1702-0CA03 1
C98 130-A1256-B520

Field Converter Thyristor Modules

DESCRIPTION WHERE USED PART NUMBER RECOM
US Rating 460V SPARE
Dual Thyristor Module 15 to 430 amp 6RY1700-0AA12 1
Dual Thyristor Module 510 to 1660 amp 6RY1700-0AA17 1

Field Converter Diode Modules

DESCRIPTION WHERE USED PART NUMBER RECOM
US Rating 460V SPARE
Dual Diode Module 15 to 430 amp 6RY1700-0BA04 1
Dual Diode Module 510 to 1660 amp 6RY1700-0BA01 1

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Power Fuses
Armature Converter AC Line Fuses, (1PFU - 3 PFU)
DESCRIPTION WHERE USED PART NUMBER RECOM
US Rating 460V SPARE
25 amp, 700 volt 15 amp A1-FUF-END-C25 2
50 amp, 700 volt 30 amp A1-FUF-END-CDN 2
70 amp, 500 volt 60 amp A1-FUF-00D-014 2
125 amp, 500 volt 100 amp A1-FUF-00D-018 2
150 amp, 500 volt 140 amp A1-FUF-00D-019 2
200 amp, 500 volt 210 amp A1-FUF-00D-021 2
250 amp, 500 volt 255 amp A1-FUF-00D-023 2
400 amp, 500 volt 430 amp A1-FUF-00D-028 2
500 amp, 500 volt 510 amp A1-FUF-00D-030 2
800 amp, 800 volt (Leg Fuse) 850 amp 3NE3338-8 3
1000 amp, 660 volt (Leg Fuse) 1180 amp 6RY1702-0BA02 3
1250 amp, 660 volt (Leg Fuse) 1660 amp 6RY1702-0BA01 3

Armature Converter DC Fuses, 4-Quad Only, (4PFU)

DESCRIPTION WHERE USED PART NUMBER RECOM
US Rating 460V SPARE
25 amp, 700 volt 15 amp A1-FUF-END-C25 2
50 amp, 700 volt 30 amp A1-FUF-END-CDN 2
90 amp, 700 volt 60 amp A1-FUF-00E-016 2
150 amp, 700 volt 100 amp A1-FUF-00E-019 2
175 amp, 700 volt 140 amp A1-FUF-00E-020 2
250 amp, 700 volt 210 amp A1-FUF-00E-023 2
300 amp, 700 volt 255 amp A1-FUF-00E-025 2
500 amp, 700 volt 430 amp A1-FUF-00E-030 2
600 amp, 700 volt 510 amp A1-FUF-00E-031 2

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Field Converter AC Line Fuses (1 & 2FSFU)

DESCRIPTION WHERE USED PART NUMBER RECOM
US Rating 460V SPARE
20 amp, 700 volt 60 to 210 amp A1-FUF-END-C20 2
40 amp, 700 volt 255 to 850 amp A1-FUF-END-C40 2
50 amp, 700 volt 1180 to 1660 amp A1-FUF-END-C50 2

Control Transformer Primary Fuses (1CFU, 2CFU)

DESCRIPTION WHERE USED PART NUMBER RECOM
US Rating 460V SPARE
1.25 amp, 600 volt, Class "CC" 15 to 100 amp A1-FUF-AFA-006 2
2.5 amp, 600 volt, Class "CC" 140 & 210 amp A1-FUF-AFA-011 2
1180 & 1660 amp
3.5 amp, 600 volt, Class "CC" 255 to 510 amp A1-FUF-AFA-014 2
850 amp, (460
volt input only)
5 amp, 600 volt, Class "CC" 1180 to 1660 amp A1-FUF-AFA-016 4
(3CFU, 4CFU,
5CFU, 6CFU)

Control Transformer Secondary Fuse (3CFU)

DESCRIPTION WHERE USED PART NUMBER RECOM
US Rating 460V SPARE
0.75 amp, 250 volt, Type MDL 15 to 100 amp A1-FUF-DKA-GBF 2
1.5 amp, 250 volt, Type MDL 140 & 210 amp A1-FUF-DKA-GBP 2
1180 & 1660 amp
2 amp, 250 volt, Type MDL 255 to 510 amp A1-FUF-DKA-GBV 2
6.25 amp, 250 volt, Type MDL 850 amp A1-FUF-DKA-GCM 2

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Control Transformer (1CTR, 2CTR, 3CTR)

DESCRIPTION WHERE USED PART NUMBER RECOM
460 VAC Primary US Rating 460V SPARE
115 VA, 230 VAC secondary 15 to 100 amp A1-TRC-Q0C-285 -
250 VA, 230 VAC secondary 140 & 210 amp A1-TRC-Q0C-286 -
1180 & 1660 amp
350 VA, 230 VAC secondary 255 to 510 amp A1-TRC-Q0C-287 -
1000 VA, 230 VAC secondary 850 amp A1-TRC-Q0C-288 -
750 VA, 460 VAC secondary 1180 & 1660 amp A1-TRC-Q0C-289 -

Main Contactor (M)

DESCRIPTION WHERE USED PART NUMBER RECOM
US Rating 460V SPARE
3 Pole AC contactor, 240 VAC coil 15 amp 3RT1016-1AP61 -
3 Pole AC contactor, 240 VAC coil 30 amp 3RT1025-1AP60 -
3 Pole AC contactor, 240 VAC coil 60 amp 3RT1035-1AP60 -
3 Pole AC contactor, 240 VAC coil 100 amp 3RT1044-1AP60 -
3 Pole AC contactor, 240 VAC coil 140 amp 3RT1045-1AP60 -
3 Pole AC contactor, 240 VAC coil 210 amp 3TF5222-0AP6 -
3 Pole AC contactor, 240 VAC coil 255 amp 3TF5322-0AP6 -
1 Pole DC contactor, 250 VDC coil 430 to 1660 amp A1-CRD-CAC-010 -

Contactor Coil Suppressor (1SP, ENSP)

DESCRIPTION WHERE USED PART NUMBER RECOM
US Rating 460V SPARE
Suppressor, varistor type 127 – 240 V 15 amp 3RT1916-1BD00 -
430 to 1660 amp
Suppressor, varistor type 127 – 240 V 30 to 140 amp 3RT1926-1BD00 -
Suppressor, varistor type 127 – 240 V 210 & 255 amp 3TX7462-3J -

Auxiliary Relay, (EN), and Rectifier Bridge, (MREC)

DESCRIPTION WHERE USED PART NUMBER RECOM
US Rating 460V SPARE
Relay, 2-NO, 2-NC, 230 VAC coil 430 to 1660 amp 3RH1122-1AP60
Rectifier Bridge, 1 Phase, 5A, 800 V 430 to 1660 amp A1-116-002-001 -

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3.5 Standard Terms and Conditions of Sale

Siemens Energy & Automation, Inc. ("Seller")

1. WARRANTY - Seller warrants that on the date of shipment the goods are of the kind and quality described herein and are free of non-
conformities in workmanship and material. This warranty does not apply to goods delivered by Seller but manufactured by others.

(b) Buyer's exclusive remedy for a nonconformity in any item of the goods shall be the repair or the replacement (at Seller's option) of
the item and any affected part of the goods. Seller's obligation to repair or replace shall be in effect for a period of one (1) year from
initial operation of the goods but not more than eighteen (18) months from Seller's shipment of the goods, provided Buyer has sent
written notice within that period of time to Seller that the goods do not conform to the above warranty. Repaired and replacement parts
shall be warranted for the remainder of the original period of notification set forth above, but in no event less than 12 months from repair
or replacement. At its expense, Buyer shall remove and ship to Seller any such nonconforming items and shall reinstall the repaired or
replaced parts. Buyer shall grant Seller access to the goods at all reasonable times in order for Seller to determine any nonconformity in
the goods. Seller shall have the right of disposal of items replaced by it. If Seller is unable or unwilling to repair or replace, or if repair or
replacement does not remedy the nonconformity, Seller and Buyer shall negotiate an equitable adjustment in the contract price, which
may include a full refund of the contract price for the nonconforming goods.

(c) SELLER HEREBY DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, EXCEPT THAT OF TITLE. SPECIFICALLY,
IT DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, COURSE OF
DEALING AND USAGE OF TRADE.

(d) Buyer and successors of Buyer are limited to the remedies specified in this article and shall have no others for a nonconformity in
the goods. Buyer agrees that these remedies provide Buyer and its successors with a minimum adequate remedy and are their
exclusive remedies, whether Buyer's or its successors' remedies are based on contract, warranty, tort (including negligence), strict
liability, indemnity, or any other legal theory, and whether arising out of warranties, representations, instructions, installations, or non-
conformities from any cause.

Note: This article 1 does not apply to any software which may be furnished by Company. In such cases, the attached Software License
Addendum applies.

2. PATENTS - Seller shall pay costs and damages finally awarded in any suit against Buyer or its vendees to the extent based upon a
finding that the design or construction of the goods as furnished infringes a United States patent (except infringement occurring as a
result of incorporating a design or modification at Buyer's request), provided that Buyer promptly notifies Seller of any charge of
infringement, and Seller is given the right at its expense to settle such charge and to defend or control the defense of any suit based
upon such charge. Seller shall have no obligation hereunder with respect to claims, suits or proceedings, resulting from or related to, in
whole or in part, (i) the use of software or software documentation, (ii) compliance with Buyer's specifications, (iii) the combination with,
or modification of, the goods after delivery by Seller, or (iv) the use of the goods, or any part thereof, in the practice of a process. THIS
ARTICLE SETS FORTH SELLER'S ENTIRE LIABILITY WITH RESPECT TO PATENTS.

3. PERFORMANCE; DELAYS - TTimely performance by Seller is contingent upon Buyer's supplying to Seller, when needed, all
required technical information and data, including drawing approvals, and all required commercial documentation. If Seller suffers delay
in performance due to any cause beyond its reasonable control, the time of performance shall be extended a period of time equal to the
period of the delay and its consequences. Seller will give to Buyer notice within a reasonable time after Seller becomes aware of any
such delay.

4. SHIPMENT, TITLE AND RISK OF LOSS - (a) The term "shipment" means delivery to the initial carrier in accordance with the delivery
terms of this contract. Seller may make partial shipments. Seller shall select method of transportation and route, unless terms are f.o.b
point of shipment and Buyer specifies the method and route and is to pay the freight costs in addition to the price. When terms are f.o.b.
destination or freight allowed to destination, "destination" means common carrier delivery point (within the United States, excluding
Alaska and Hawaii) nearest the destination.

(b) Title to the goods and risk of loss or damage shall pass to Buyer at the f.o.b. point. Seller shall not be responsible for damage to the
goods after having received "in good order" receipts from the carrier.

5. TAXES - Any applicable duties or sales, use, excise, value-added or similar taxes will be added to the price and invoiced separately
(unless an acceptable exemption certificate is furnished).

6. TERMS OF PAYMENT - (a) Unless otherwise stated, all payments shall be in United States dollars, and a pro rata payment shall
become due as each shipment is made. If shipment is delayed by Buyer, date of notice of readiness for shipment shall be deemed to be
date of shipment for payment purposes.

(b) On late payments, the contract price shall, without prejudice to Seller's right to immediate payment, be increased by 1 1/2% per
month on the unpaid balance, but not to exceed the maximum permitted by law.

(c) If any time in Seller's judgment Buyer is unable or unwilling to meet the terms specified, Seller may require satisfactory assurance or
full or partial payment as a condition to commencing or continuing manufacture or making shipment, and may, if shipment has been
made, recover the goods from the carrier, pending receipt of such assurances.

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7. NONCANCELLATION - Buyer may not cancel or terminate for convenience, or direct suspension of manufacture, except with Seller's
written consent and then only upon terms that will compensate Seller for its engineering, fabrication and purchasing charges and any other
costs relating to such cancellation, termination or uspension, plus a reasonable amount for profit.

8. NUCLEAR - Buyer represents and warrants that the goods covered by this contract shall not be used in or in connection with a nuclear
facility or application. If Buyer is unable to make such representation and warranty, then Buyer agrees to indemnify and hold harmless Seller
and to waive and require its insurers to waive all right of recovery against Seller for any damage, loss, destruction, injury or death resulting
from a "nuclear incident", as that term is defined in the Atomic Energy Act of 1954, as amended, whether or not due to Seller's negligence.

9. LIMITATION OF LIABILITY - Neither Seller, nor its suppliers shall be liable, whether in contract, warranty, failure of a remedy to achieve
its intended or essential purposes, tort (including negligence), strict liability, indemnity or any other legal theory, for loss of use, revenue or
profit, or for costs of capital or of substitute use or performance, or for indirect, special, liquidated, incidental or consequential damages, or for
any other loss or cost of a similar type, or for claims by Buyer for damages of Buyer's customers. Seller's maximum liability under this
contract shall be the contract price. Buyer and Seller agree that the exclusions and limitations set forth in this article are separate and
independent from any remedies which Buyer may have hereunder and shall be given full force and effect whether or not any or all such
remedies shall be deemed to have failed of their essential purpose.

10. GOVERNING LAW AND ASSIGNMENT - The laws of the State of Georgia shall govern the validity, interpretation and enforcement of
this contract, without regard to its conflicts of law principles. The application of the United Nations Convention on Contracts for the
International Sale of Goods shall be excluded. Assignment may be made only with written consent of both parties; provided, however, Seller
may assign to its affiliate without Buyer's consent.

11. ATTORNEY FEES - Buyer shall be liable to Seller for any attorney fees and costs incurred by Seller in enforcing any of its rights
hereunder.

12. DISPUTES - Either party may give the other party written notice of any dispute arising out of or relating to this contract and not resolved
in the normal course of business. The parties shall attempt in good faith to resolve such dispute promptly by negotiations between executives
who have authority to settle the dispute. If the matter has not been resolved within 60 days of the notice, either party may initiate non-binding
mediation of the dispute.

13. STATUTE OF LIMITATIONS - To the extent permitted by applicable law, any lawsuit for breach of contract, including breach of warranty,
arising out of the transactions covered by this contract, must be commenced not later than twelve (12) months from the date the cause of
action accrued.

14. PRICES - In the event of a price increase or decrease, the price of goods on order will be adjusted to reflect such increase or decrease.
This does not apply to a shipment held by request of Buyer. Goods already shipped are not subject to price increase or decrease. Orders on
a bid or contract basis are not subject to this article. Orders amounting to less than $100.00 net will be invoiced at $100.00 plus
transportation charges for goods covered by discount schedules. Seller's prices include the costs of standard domestic packing only. Any
deviation from this standard packing (domestic or export), including U.S. Government sealed packing, will result in extra charges. To
determine such extra charges, consult Seller's sales offices.

15. ADDITIONAL TERMS OF PAYMENT - (a) Invoice payment terms are as shown on latest discount sheets as issued from time to time.
Cash discounts are not applicable to notes or trade acceptances, to prepaid transportation charges when added to Seller's invoices or to
discountable items if there are undisputed past due items on the account. Portions of an invoice in dispute should be deducted and the
balance remitted with a detailed explanation of the deduction. Cash discounts will only be allowed on that portion of the invoice paid within
the normal discount period.

(b) Freight will be allowed to any common-carrier free-delivery point within the United States, excluding Alaska and Hawaii, on shipments
exceeding $1,000 net or more providing Seller selects the carrier. On shipments to Alaska and Hawaii, freight will be allowed to dockside at
the listed port of debarkation nearest the destination point on shipments of $1,000 net or more. Buyer shall pay all special costs such as
cartage, stevedoring and insurance. Special freight allowances are as shown on latest discount sheets as issued from time to time.
Cataloged weights are estimated, not guaranteed. Seller assumes no responsibility for tariff classifications on carriers.

16. CHANGES IN LAWS AND REGULATIONS - Seller's prices and timely performance are based on all applicable laws, rules, regulations,
orders, codes, standards or requirements of governmental authorities effective on the date of Seller's proposal. Any change to any law, rule,
regulation, order, code, standard or requirement which requires any change hereunder shall entitle Seller to an equitable adjustment in the
prices and any time of performance.

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4 Receiving, unpacking

SIMOREG Base Drive Panels are packed at the manufacturing plant in protective containers suitable
for shipping. Avoid dropping and shocks during unloading and moving the SIMOREG during receiving.
Observe the instructions on the package for transport, storage, and correct handling.

If you discover that the Base Drive Panel has been damaged during shipment, please inform your
shipping agent immediately.

WARNING
If a SIMOREG Base Drive Panel was damaged during transport, it must not be connected up
without first being repaired and tested by a qualified repair person.
Non-observance of the safety instructions can result in death, severe personal injury or
substantial property damage.
Only qualified personnel should work on or around the equipment after first becoming
thoroughly familiar with all warning and safety notices and maintenance procedures contained
herein. The successful and safe operation of this equipment is dependent on proper handling,
installation, operation and maintenance.

Procedure for Shipping Damage

SIMOREG Base Drive Panels are normally shipped FOB factory making it the buyers responsibility to
make sure the equipment is received undamaged. Carefully examine the equipment before accepting
the shipment from the transport carrier. If you do not notify the carrier immediately of any damage you
may lose your right to file a damage claim. If required you can request support from the local Siemens
office.

• When received, examine the shipment to ensure that it is complete and not damaged.
• Damaged or missing items that are obviously visible should be specified in the shipping papers
and must be countersigned by personnel from the transport company.
• Immediately notify the transport company in writing of any damage or missing items

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5 Technical data:
5.1 15ADC to 100ADC Base Drive Panels, 3AC 460V, 1 & 4Q

Rated supply voltage V 3 Phase

armature 1) 460 (+10% / – 5%)
Rated input current A 17.3 34.6 59.2 92
armature + field 2)

Rated supply voltage field V 1 Phase 460 (+10%)

Rated frequency Hz 45 to 65 Hz self adapting (armature
and field are independent)
Rated DC voltage 3) V 500
Rated DC armature current A 15 30 60 100
Overload capability 60s 7) 150% of rated DC current
Rated output @ 500 VDC Hp 7½ 15 30 60
Rated output @ 240 VDC Hp 3 7½ 15 25
Power loss at rated DC current W 150 200 350 500
(approximate)
Rated DC voltage field V 300
Rated DC field current A 5 10
Operational ambient °C 0 to 45 at Irated
temperature self-cooled 4)
Storage and transport °C – 25 to +70
temperature
Installation altitude above sea ≤ 1000 m at rated DC current 5)

level
Control stability Δn = 0.006% of the rated motor
speed, valid for pulse encoder
operation and digital setpoint
Δn = 0.1% of the rated motor
speed, valid for analog tachometer
or analog setpoint 6)
Degree of protection Open Chassis (IP00)
Dimensions See dimension drawings in Section 6
Weights (approx.) Lbs. 35 55 60 70

x) Explanation at end of list of tables

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5.2 140ADC to 850ADC Base Drive Panels, 3AC 460V, 1 & 4Q

Rated supply voltage V 3 Phase

armature 1) 460 (+10% / – 5%)
Rated input current A 129.8 187.2 234.1 377.6 448.2 727
armature + field 2)

Fan type V Internal 24VDC 1 Phase

230V
Air flow rate ft3/min 100 570 1300
Fan noise level dBA 40 76 85
Rated supply voltage field V 1 Phase 460 (+10%)
Rated frequency Hz 45 to 65 Hz self adapting (armature and field are
independent)
Rated DC voltage 3) V 500
Rated DC armature current A 140 210 255 430 510 850
Overload capability 60s 7) 150% of rated DC current
Rated output @ 500 VDC Hp 75 125 150 250 300 500
Rated output @ 240 VDC Hp 40 60 75 125 150 250
Power loss at rated DC current W 725 1000 1290 1825 2125 3750
(approximately)
Rated DC voltage field V 300
Rated DC field current A 15 25 30
Operational ambient °C 0 to 45 at Irated
temperature fan-cooled 4)
Storage and transport °C – 25 to +70
temperature
Installation altitude above sea ≤ 1000 m at rated DC current 5)

level
Control stability Δn = 0.006% of the rated motor speed, valid for pulse
encoder operation and digital setpoint
Δn = 0.1% of the rated motor speed, valid for analog
tachometer or analog setpoint 6)
Degree of protection Open Chassis (IP00)
Dimensions Refer to dimension drawings in Section 6
Weights (approx.) Lbs. 90 95 145 160 210 400

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5.3 1180ADC & 1660ADC Base Drive Panels, 3AC 460V, 1 & 4Q

Rated supply voltage armature V 3 Phase

1)
460 (+10% / – 5%)
Rated input current armature A 1000 1401
2)

Fan type V 3 Phase

460V
Air flow rate ft3/min 824
Fan noise level dBA 88
Rated supply voltage field V 1 Phase 460 (+10%)
Rated frequency Hz 45 to 65 Hz self adapting
(armature and field are
independent)
Rated DC voltage 2) V 500
Rated DC armature current A 1180 1660
Overload capability 60s 7) 150% of rated DC current
Rated output @ 500 VDC Hp 700 1000
Rated output @ 240 VDC Hp 350 500
Power loss at rated DC current W 6115 7930
(approximately)
Rated DC voltage field V 300
Rated DC field current A 40
Operational ambient °C 0 to 45 at Irated
temperature fan-cooled 4)
Storage and transport °C – 25 to +70
temperature
Installation altitude above sea level ≤ 1000 m at rated DC current 5)
Control stability Δn = 0.006% of the rated motor
speed, valid for pulse encoder
operation and digital setpoint
Δn = 0.1% of the rated motor
speed, valid for analog tachometer
or analog setpoint 6)
Degree of protection Open Chassis (IP00)
Dimensions Refer to dimension drawings in
Section 6
Weights (approx.) Lbs. 725 755

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Notes:
1) Operation with reduced input voltage will result in reduced maximum output voltage accordingly.
2) Values apply for rated DC output current on both the armature and field circuits.
3) The specified output DC voltage can be guaranteed up to an undervoltage of 5% of rated line voltage.

4) The table below gives load values, (DC current), as a function of ambient temperature surrounding the
Base Drive Panel, (refer to P077). Note, Important: When Base Drive Panels are installed into
enclosures, make sure the temperature inside does not exceed 45oC, otherwise derate the DC current
rating per the table below.

Ambient temperature % reduction in base drive dc ampere rating

Self-cooled converters Fan-cooled converters
(15, 30, 60, 100 ADC) (140 - 1660 ADC)
+40ºC –0 % –0 %
+45ºC –0 % –0 %
+50ºC –6 % –5 % a)
+55ºC – 11 % –5 % a)

+60ºC – 18 % –5 % a)

a) Operation of fan cooled units at ambients above 50oC is not permitted

because of limitations on the allowable fan operating temperature.

5) Load values, (DC current), as a function of installation altitude (refer to P077)

b1
%
100
Percentage
load "b"
80

67%
60

40

20

0
1000 2000 3000 4000 5000 m
Installation altitude

Curve b1: Reduction factor of load values, (DC current),

at installation altitudes above 1000 m.
No derating of the supply voltages to any circuits is required
up to an installation altitude of 5000 m for basic insulation.

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6) Requirements to achieve control stability:

The control stability (closed-loop PI control) is referred to the rated motor speed and applies
when the SIMOREG converter is warm. The following conditions are applicable:
• Temperature changes of ±10 °C.
• Line voltage changes corresponding to +10% / – 5% of the rated input voltage.
• Temperature coefficient of temperature-compensated tachometer 0.15‰ per 10 °K,
(applies only to analog tachometer).
• Constant setpoint (14-bit resolution).
• Motor, load, and encoder are correctly aligned and the load is balanced.

7) Details of overload capability:

Following operation at rated load, base drive panels are capable of carrying 150% of rated load
for 1 minute, followed by a period of light load operation of such duration that the rms load does
not exceed rated continuous current. Base Drive Panels are designed for operation with
heatsink air inlet temperatures up to 45°C.

5.4 Applicable standards

UL508A
National Electrical Code 1999

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5-6 Siemens Energy & Automation

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6 Installation and Dimensions

6.1 Installation Information
SIMOREG Base Drive Panels are designed as chassis units intended to be mounted inside a
protective enclosure or inside a control room. The units are to be mounted vertically in cubicles
usually with the power connections at the top and the control connections at the bottom. A minimum
100-mm (4-inch) clearance must be kept above and below the converter in order to ensure
unrestricted cooling airflow. The minimum enclosure size to be used is 23.6 by 23.6 by 86.6 inch
high. The open chassis units are designed to operate in a 45°C ambient. When enclosed in a cubicle
the ambient temperature outside the cubicle should not exceed 40°C, which then allows for a 5°C-
temperature rise inside the cubicle. Care must be taken in the selection of the cubicle so that the
internal temperature rise does not exceed 5°C. Refer to section 5 for approximate power loss data.

Note, Important: This equipment is designed and package-protected to handle the normal shock
and vibration typically encountered in shipment. Do not install these Base Drive Panels on
equipment subject to shock or vibration. Select a reasonably clean location for installation,
free from corrosive or conductive materials or fumes.

CAUTION
Failure to lift the Base Drive Panel in the correct manner can result in bodily injury and/or
property damage.
The Base Drive Panel must be lifted using suitable equipment and under the instruction of
appropriately qualified personnel.
The user is responsible for installing the Base Drive Panel, motor, transformer as well as other
equipment according to safety regulations (e.g. NEC), as well as all other relevant national or
local regulations regarding cable sizing and protection, grounding, disconnects, overcurrent
protection, etc.

The Base Drive Panels must be installed in accordance with the relevant safety regulations
(e.g. NEC), as well as all other relevant national and local regulations. It must be ensured that
the grounding, cable sizing and appropriate short-circuit protection have been implemented to
guarantee operational safety and reliability.
Note, Important: Base Drive Panels have high-speed semiconductor fuses installed for
protection of the thyristors in the event high fault currents are encountered. These fuses are
“special purpose” fuses, and do not meet the requirements of the NEC for short-circuit
protection in motor branch circuits. It is necessary to provide other devices for short-circuit
protection. Typically molded case circuit breakers or NEC style fuses are used for this purpose.
Refer to applicable sections of the NEC for additional information.

NOTE
The fundamental principles of EMC in Section 6.1 of SIMOREG 6RA70 DC Master operating
instructions (Order # 6RX1700-0AD76) must be adhered to when installing any unit.

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6.2 Base Drive Panel Outlines:

Dimensions are mm (inches)

TERMINALS 80 - 92

MOUNTING HOLES FOR M8, POWER TERMINALS

(.312"), SCREWS, 4-PLACES L1, L2, L3, A1, A2, GND

FUSE NOT
SUPPLIED ON
1-QUAD UNITS

638
(2 5 .1 )
SIEMENS 6RA70

613
(24.1)

P X300

(1 5 A m p ) 9
2 6 5 (1 0 .4 ) (0 .4 )
15
2 3 8 (9 .4 )
(3 0 A m p ) (0 .6 )
3 3 9 ( 1 3 .4 ) 2 6 8 (1 0 .6 )

NOTE, IMPORTANT: ALLOW AT LEAST 100 MILLIMETERS, (4"), OF CLEARANCE ABOVE AND BELOW THE UNIT
TO ENSURE UNRESTRICTED AIR FLOW. ADDITIONAL CLEARANCE MAY BE REQUIRED TO ALLOW FOR WIRE
OR CABLE ENTRY/EXIT AND BENDING. REFER TO APPLICABLE CODES FOR FURTHER INFORMATION.

15 - 30 AMP BASE DRIVE PANELS, (1 & 4Q)

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Dimensions are mm (inches)

TERMINALS 80 - 92
POWER TERMINALS
MOUNTING HOLES FOR M8, L1, L2, L3, A1, A2, GND
(.312"), SCREWS, 4-PLACES

FUSE NOT
SUPPLIED ON
1-QUAD UNITS

734
( 2 8 .9 )

709
(27.9) SIEMENS 6RA70

P
X300

9
3 3 9 (1 3 .4 ) (0 .4 )
15
238 (9.4)
(0 .6 )
2 6 8 (1 0 .6 )

NOTE, IMPORTANT: ALLOW AT LEAST 100 MILLIMETERS, (4"), OF CLEARANCE ABOVE AND BELOW THE UNIT
TO ENSURE UNRESTRICTED AIR FLOW. ADDITIONAL CLEARANCE MAY BE REQUIRED TO ALLOW FOR WIRE
OR CABLE ENTRY/EXIT AND BENDING. REFER TO APPLICABLE CODES FOR FURTHER INFORMATION.

60 AMP BASE DRIVE PANEL, (1 & 4Q)

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Dimensions are mm (inches)

TERMINALS 80 - 92
POWER TERMINALS
MOUNTING HOLES FOR M8, L1, L2 , L3, A1, A2, GND
(.312"), SCREWS, 4-PLACES

FUSE NOT
SUPPLIED
ON 1-QUAD
UNITS

831
(32.7)

806
(31.7)

SIEMENS 6RA70

P
X300

15 2 3 8 (9 .4 )
3 3 9 (1 3 .4 ) (0 .6 )
2 6 8 (1 0 .6 )

NOTE, IMPORTANT: ALLOW AT LEAST 100 MILLIMETERS, (4"), OF CLEARANCE ABOVE AND BELOW THE UNIT
TO ENSURE UNRESTRICTED AIR FLOW. ADDITIONAL CLEARANCE MAY BE REQUIRED TO ALLOW FOR WIRE
OR CABLE ENTRY/EXIT AND BENDING. REFER TO APPLICABLE CODES FOR FURTHER INFORMATION.

100 AMP BASE DRIVE PANEL, (1 & 4Q)

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Dimensions are mm (inches)

MOUNTING HOLES FOR M8,

(.312"), SCREWS, 4-PLACES

GROUND
TERMINAL TERMINALS 80 - 92

L1 L2 L3 A1 A2

FUSE NOT
SUPPLIED
ON 1-QUAD
UNITS

980
(38.6)

960
(37.8)
SIEMENS 6RA70

P X300

10
326(12.8) (0.4) 12
266(10.5)
(0.45)
290(11.4)

NOTE, IMPORTANT: ALLOW AT LEAST 100 MILLIMETERS, (4"), OF CLEARANCE ABOVE AND BELOW THE UNIT
TO ENSURE UNRESTRICTED AIR FLOW. ADDITIONAL CLEARANCE MAY BE REQUIRED TO ALLOW FOR WIRE
OR CABLE ENTRY/EXIT AND BENDING. REFER TO APPLICABLE CODES FOR FURTHER INFORMATION.

140 AMP BASE DRIVE PANEL, (1 & 4Q)

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Dimensions are mm (inches)

MOUNTING HOLES FOR M8,

(.312"), SCREWS, 4-PLACES

TERMINALS 80 - 92
GROUND
TERMINAL

L1 L2 L3 A1 A2

FUSE NOT
SUPPLIED ON
1-QUAD UNITS

1120
(44.1)

1100
(43.3)

SIEMENS 6RA70

P
X300

10
326(12.8) (0.4) 12
266 (10.5)
(0.45)
290 (11.4)

NOTE, IMPORTANT: ALLOW AT LEAST 100 MILLIMETERS, (4"), OF CLEARANCE ABOVE AND BELOW THE UNIT
TO ENSURE UNRESTRICTED AIR FLOW. ADDITIONAL CLEARANCE MAY BE REQUIRED TO ALLOW FOR WIRE
OR CABLE ENTRY/EXIT AND BENDING. REFER TO APPLICABLE CODES FOR FURTHER INFORMATION.

210 AMP BASE DRIVE PANEL, (1 & 4Q)

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Dimensions are mm (inches)

MOUNTING HOLES FOR M8,

(.312"), SCREWS, 4-PLACES

GROUND TERMINALS 80 - 92
TERMINAL

L1 L2 L3 A1 A2

FUSE NOT
SUPPLIED ON
1-QUAD UNITS

SIEMENS 6RA70

1180
(46.5)

1160
(45.7)

10
331 (13.0) (0.4) 12
266 (10.5)
(0.45)
290 (11.4)

NOTE, IMPORTANT: ALLOW AT LEAST 100 MILLIMETERS, (4"), OF CLEARANCE ABOVE AND BELOW THE UNIT
TO ENSURE UNRESTRICTED AIR FLOW. ADDITIONAL CLEARANCE MAY BE REQUIRED TO ALLOW FOR WIRE
OR CABLE ENTRY/EXIT AND BENDING. REFER TO APPLICABLE CODES FOR FURTHER INFORMATION.

255 AMP BASE DRIVE PANEL, (1 & 4Q)

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Dimensions are mm (inches)

MOUNTING HOLES FOR M10, GROUND TERMINAL

(.375"), SCREWS, 6-PLACES

L1 L2 L3 A1 A2

FUSE NOT SUPPLIED

ON 1-QUAD UNITS

TERMINALS 80 - 94
280
(11.0)

ADDITIONAL CLEARANCE
REQ'D FROM CONTACTOR
ARC CHUTE TO ANY
GROUNDED METAL

35
(1.4)

SIEMENS 6RA70

1200
(47.2)

880
(34.6)

P
X300

15 334 (13.1)
20 520 (20.5)
(0.6)
(0.8)
550 (21.6)
348 (13.7)

430 AMP BASE DRIVE PANEL, (1 & 4Q)

6-8 Siemens Energy & Automation

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Dimensions are mm (inches)

MOUNTING HOLES FOR M10, GROUND TERMINAL

(.375"), SCREWS, 6-PLACES

L1 L2 L3 A1 A2

FUSE NOT SUPPLIED

ON 1-QUAD UNITS

280 TERMINALS 80 - 94
(11.0)

ADDITIONAL CLEARANCE
REQ'D FROM CONTACTOR
ARC CHUTE TO ANY
GROUNDED METAL

35
(1.4)

1200
(47.2)
SIEMENS 6RA70

880
(34.6)

P
X300

20 15
520 (20.5)
(0.8) (0.6) 348 (13.7)
550 (21.6)
376 (14.8)

NOTE, IMPORTANT: ALLOW AT LEAST 100 MILLIMETERS, (4"), OF CLEARANCE ABOVE AND BELOW THE UNIT
TO ENSURE UNRESTRICTED AIR FLOW. ADDITIONAL CLEARANCE MAY BE REQUIRED TO ALLOW FOR WIRE
OR CABLE ENTRY/EXIT AND BENDING. REFER TO APPLICABLE CODES FOR FURTHER INFORMATION.

510 AMP BASE DRIVE PANEL, (1 & 4Q)

Siemens Energy & Automation 6-9

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Dimensions are mm (inches)

MOUNTING HOLES FOR M10,

GROUND
(.375"), SCREWS, 6-PLACES
TERMINAL

A1 A2 L1 L2 L3

TERMINALS
740 80 - 94
(29.1)

SIEMENS 6RA70

1524
(60.0)
NOTE:
SEMICONDUCTOR
P X300 FUSES ARE
LOCATED INSIDE
THE 6RA70
POWER MODULE

740
(29.1)

CABLE CONNECTIONS
TO POWER MODULE
THIS AREA

425 (16.7) 22 22
768 (30.2)
(0.9) (0.9)
813 (32.0)

850 AMP BASE DRIVE PANEL, (1 & 4Q)

6-10 Siemens Energy & Automation

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Dimensions are mm (inches)

MOUNTING SLOTS, FOR M12

(0.50"), SCREWS, 6-PLACES GROUND
TERMINAL

L1 L2 L3

TERMINALS
CTB
80 - 102
80 81 82 83 84 85 90 91 92 93 94 95 96 97 98 99 100101102

L1-1 L2-1 L3-1

80 81 82 83 84 85 90 91 92 93 94 95 96 97 98 99 100101102

5CFU
4CFU

7CFU
6CFU
1 1

965 1 1 1 1

1FSFU

2FSFU
RATE D RATE D RATE D RATE D
600V3
, 0A 600V,30A 600V,30A 600V3
, 0A
T M TM TM TM

DO N OT OP E N U NDE R L O A D DO N O T OP E N U NDE R L O A D DO N OT OP E N U NDE R L O A D DO N O T OP E N U N D E R L OA D

(38.0)
2 2 2 2
2 2

1CTR
PM H1 H3 H2 H4

1CFU
L1 2.5 A, 60 0V

2CFU
L2
2.5 A, 60 0V

3CFU
1.5A, 250V

X2 XF X1

NOTE:
SEMICONDUCTOR FUSES
2CTR
ARE LOCATED INSIDE THE
P X300 H1 H3 H2 H4 POWER MODULE, (PM).

1981
(78.0)
X2 X1

3CTR
H1 H3 H2 H4

1C1 1D1 X2 X1

MSP
965 EN
MSPAUX

(38.0) MREC

A1 A2

767 (30.2) 23 (0.9)

25
(1.0)
813 (32.0)

NOTE: FROM THE BACK OF THE MOUNTING PANELTO THE TOP

OF THE POWER MODULE, (TALLEST COMPONENT) = 629 (24.8")

1180 AMP BASE DRIVE PANEL, (1 & 4Q)

Siemens Energy & Automation 6-11

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Dimensions are mm (inches)

MOUNTING SLOTS, FOR M12

(0.50"), SCREWS, 6-PLACES GROUND
TERMINAL

L1 L2 L3

TERMINALS
80 - 102
80 81 82 83 84 85 90 91 92 93 94 95 96 97 98 99 100101102

L1-1 L2-1 L3-1

80 81 82 83 84 85 90 91 92 93 94 95 96 97 98 99 100101102

5CFU
4CFU

7CFU
6CFU
1 1
965 1 1 1 1

1FSFU

2FSFU
RATE D RATE D RATE D RATE D
600V, 30
A 600V, 30
A 600V, 30
A 600V, 30
A
TM T M T M TM

DO NOTOPE NUNDER LOAD DO NOTOPE NUNDER LOAD DO NOTOPE NUNDER LOAD DO NOTOPE NUNDER LOAD

(38.0)
2 2 2 2
2 2

1CTR
PM H1 H3 H2 H4

1C FU
L1 2. 5A, 6 00V

2C FU
L2
2. 5A, 6 00V

3CFU
1.5A, 250 V

X2 XF X1

NOTE:
SEMICONDUCTOR FUSES
ARE LOCATED INSIDE THE
2CTR
P X300 H1 H3 H2 H4
POWER MODULE, (PM).

1981
(78.0)
X2 X1

3CTR
H1 H3 H2 H4

1C1 1D1 X2 X1

MSP
EN
965
MSPAUX

(38.0) MREC

M2 M1

A2
A1

767 (30.2) 23 (0.9)

25
(1.0) 813 (32.0)

NOTE: FROM THE BACK OF THE MOUNTING PANELTO THE TOP

OF THE POWER MODULE, (TALLEST COMPONENT) = 629 (24.8")

1660 AMP BASE DRIVE PANEL, (1 & 4Q)

6-12 Siemens Energy & Automation

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

7 Base Drive Panel Connections

WARNING
Base Drive Panels are operated at high voltages.
Disconnect the power supply before making any connections!
Only qualified personnel who are thoroughly familiar with all safety notices contained in the
operating instructions as well as erection, installation, operating and maintenance instructions
should be allowed to work on these devices.
Non-observance of the safety instructions can result in death, severe personal injury or
substantial property damage.
Failure to make the correct connections may result in irreparable damage to the unit.
Voltage may be present at the power and control terminals even when the motor is stopped.
The snubber capacitors may still carry a hazardous voltage for up to 2 minutes after
disconnection. For this reason, wait for at least 2 minutes before opening the converter.
When working on the open converter, remember that live parts are exposed. The unit must
always be operated with the standard front covers in place.
The user is responsible for ensuring that the motor, SIMOREG Base Drive Panel and other
devices are installed and connected up in accordance with the approved codes of practice of
the country concerned and any other regional or local codes that may apply. Special attention
must be paid to proper conductor sizing, fusing, grounding, isolation and disconnection
measures and to overcurrent protection.
These units contain hazardous rotating machinery (fans) and control rotating mechanical
components (motors). Death, serious bodily injury or substantial property damage may occur if
the instructions in the relevant operating manuals are not observed.
The successful and safe operation of this equipment is dependent on careful transportation,
proper storage and installation as well as correct operation and maintenance.

Siemens Energy & Automation 7-1

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

7.1 Base Drive Panel Schematics

460 VAC

MAIN DISCONNECT AND

BRANCH CIRCUIT
PROTECTION SIZED
PER N.E.C.

CUSTOMER SUPPLIED
IF APPLICABLE
#4 AWG,60 C
TORQUE TO
11 INCH- LBS
BASE DRIVE PANEL, 15 AMPS, 1 & 4 QUAD
L1 L2 L3

L1 L2
1CFU - 2CFU
1CTR
2CFU
1CFU

1.25A,600V
A1-FUF-AFA-006 CONTROL

1PFU

2PFU

3PFU
TRANSFORMER 25A,700V
H1 H2 H3 H4
3CFU 115VA A1-FUF-END-C25
0.75A,250V A1-TRC-Q0C-285
A1-FUF-DKA-GBF 3CFU
230 V
XF
X2
CTB
86 88 85 82

J3 J4 J2 J1
M
87 89 84 83

MAIN
M CONTACTOR
3RT1016-1AP61
1SP SUPPRESSOR
3RT1916-1BD00

XP XP XR XR XP XF1-2 XF1-1

5U1 5W1 109 110 5N1 3U1 3W1 1U1 1V1 1W1
PWR PWR FIELD ARMATURE
SUPPLY SUPPLY SUPPLY SUPPLY
K1
POWER MODULE
CATALOG NO. 6RA7018-6FS22-0Z+X01, (1-QUAD)
CATALOG NO. 6RA7018-6FV62-0Z+X01, (4-QUAD)
E-STOP
106 105 3C 3D 1C1 1D1
XS XS XF2-2 XF2-1

4Q UNITS
4PFU

ONLY
25A,700V
A1-FUF-END-C25
MAUX

F(+) F(-)

90 91 80 81 A1 A2
#4 AWG,60 C
#10 AWG, 60 C TORQUE TO
TORQUE TO 11 INCH- LBS
5 INCH- LBS
MOTOR = 500 VOLTS DC
F.L.A. = 15 AMPS DC

7-2 Siemens Energy & Automation

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

460 VAC

MAIN DISCONNECT AND

BRANCH CIRCUIT
PROTECTION SIZED
PER N.E.C.

CUSTOMER SUPPLIED
IF APPLICABLE
#4 AWG,60 C
TORQUE TO
11 INCH- LBS
BASE DRIVE PANEL, 30 AMPS, 1 & 4 QUAD
L1 L2 L3

L1 L2
1CFU - 2CFU
1CTR
2CFU
1CFU

1.25A,600V
A1-FUF-AFA-006 CONTROL

1PFU

2PFU

3PFU
TRANSFORMER 50A,700V
H1 H2 H3 H4
3CFU 115VA A1-FUF-END-CDN
0.75A,250V A1-TRC-Q0C-285
A1-FUF-DKA-GBF 3CFU
230 V
XF
X2
CTB
86 88 85 82

J3 J4 J2 J1
M
87 89 84 83

MAIN
M CONTACTOR
3RT1025-1AP60
1SP SUPPRESSOR
3RT1926-1BD00

XP XP XR XR XP XF1-2 XF1-1

5U1 5W1 109 110 5N1 3U1 3W1 1U1 1V1 1W1
PWR PWR FIELD ARMATURE
SUPPLY SUPPLY SUPPLY SUPPLY
K1
POWER MODULE
CATALOG NO. 6RA7025-6FS22-0Z+X01, (1-QUAD)
CATALOG NO. 6RA7025-6FV62-0Z+X01, (4-QUAD)
E-STOP
106 105 3C 3D 1C1 1D1
XS XS XF2-2 XF2-1

4Q UNITS
4PFU

ONLY
50A,700V
A1-FUF-END-CDN
MAUX

F(+) F(-)

90 91 80 81 A1 A2
#4 AWG,60 C
#10 AWG, 60 C TORQUE TO
TORQUE TO 11 INCH- LBS
5 INCH- LBS
MOTOR = 500 VOLTS DC
F.L.A. = 30 AMPS DC

Siemens Energy & Automation 7-3

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

460 VAC

MAIN DISCONNECT AND

BRANCH CIRCUIT
PROTECTION SIZED
PER N.E.C.

CUSTOMER SUPPLIED
IF APPLICABLE
#1 AWG,60 C
TORQUE TO
27 INCH- LBS
BASE DRIVE PANEL, 60 AMPS, 1 & 4 QUAD
L1 L2 L3

L1 L2
1CFU - 2CFU
1CTR
2CFU
1CFU

1.25A,600V
A1-FUF-AFA-006 CONTROL

1PFU

2PFU

3PFU
TRANSFORMER 70A,500V
H1 H2 H3 H4 A1-FUF-00D-014
3CFU 115VA
0.75A,250V A1-TRC-Q0C-285
A1-FUF-DKA-GBF 3CFU
230 V
XF
X2
CTB
86 88 85 82

J3 J4 J2 J1
M
87 89 84 83

MAIN
1FSFU

2FSFU

M CONTACTOR 20A,700V
3RT1035-1AP60 A1-FUF-END-C20
1SP SUPPRESSOR
3RT1926-1BD00

XP XP XR XR XP XF1-2 XF1-1

5U1 5W1 109 110 5N1 3U1 3W1 1U1 1V1 1W1
PWR PWR FIELD ARMATURE
SUPPLY SUPPLY SUPPLY SUPPLY
K1
POWER MODULE
CATALOG NO. 6RA7028-6FS22-0Z+X01, (1-QUAD)
CATALOG NO. 6RA7028-6FV62-0Z+X01, (4-QUAD)
E-STOP
106 105 3C 3D 1C1 1D1
XS XS XF2-2 XF2-1

4Q UNITS
4PFU

ONLY
90A,700V
A1-FUF-00E-016
MAUX

F(+) F(-)

90 91 80 81 A1 A2
#1 AWG,60 C
#10 AWG, 60 C TORQUE TO
TORQUE TO 27 INCH- LBS
5 INCH- LBS
MOTOR = 500 VOLTS DC
F.L.A. = 60 AMPS DC

7-4 Siemens Energy & Automation

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

460 VAC

MAIN DISCONNECT AND

BRANCH CIRCUIT
PROTECTION SIZED
PER N.E.C.

CUSTOMER SUPPLIED
IF APPLICABLE
#1 AWG,60 C
TORQUE TO
27 INCH- LBS
BASE DRIVE PANEL, 100 AMPS, 1 & 4 QUAD
L1 L2 L3

L1 L2
1CFU - 2CFU
1CTR
2CFU
1CFU

1.25A,600V
A1-FUF-AFA-006 CONTROL

1PFU

2PFU

3PFU
TRANSFORMER 125A,500V
H1 H2 H3 H4 A1-FUF-00D-018
3CFU 115VA
0.75A,250V A1-TRC-Q0C-285
A1-FUF-DKA-GBF 3CFU
230 V
XF
X2
CTB
86 88 85 82

J3 J4 J2 J1
M
87 89 84 83

MAIN
1FSFU

2FSFU

M CONTACTOR 20A,700V
3RT1044-1AP60 A1-FUF-END-C20
1SP SUPPRESSOR
3RT1926-1BD00

XP XP XR XR XP XF1-2 XF1-1

5U1 5W1 109 110 5N1 3U1 3W1 1U1 1V1 1W1
PWR PWR FIELD ARMATURE
SUPPLY SUPPLY SUPPLY SUPPLY
K1
POWER MODULE
CATALOG NO. 6RA7031-6FS22-0Z+X01, (1-QUAD)
CATALOG NO. 6RA7031-6FV62-0Z+X01, (4-QUAD)
E-STOP
106 105 3C 3D 1C1 1D1
XS XS XF2-2 XF2-1

4Q UNITS
4PFU

ONLY
150A,700V
A1-FUF-00E-019
MAUX

F(+) F(-)

90 91 80 81 A1 A2
#1 AWG,60 C
#10 AWG, 60 C TORQUE TO
TORQUE TO 27 INCH- LBS
5 INCH- LBS
MOTOR = 500 VOLTS DC
F.L.A. = 100 AMPS DC

Siemens Energy & Automation 7-5

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

460 VAC

MAIN DISCONNECT AND

BRANCH CIRCUIT
PROTECTION SIZED
PER N.E.C.

CUSTOMER SUPPLIED
IF APPLICABLE
2 - #250 MCM,75 C
TORQUE TO
275 INCH- LBS
BASE DRIVE PANEL, 140 AMPS, 1 & 4 QUAD
L1 L2 L3

L1 L2
1CFU - 2CFU
1CTR 2CFU
1CFU

2.5A,600V
A1-FUF-AFA-011 CONTROL

1PFU

2PFU

3PFU
TRANSFORMER 150A,500V
H1 H2 H3 H4 A1-FUF-00D-019
3CFU 250VA
1.5A,250V A1-TRC-Q0C-286
A1-FUF-DKA-GBP 3CFU
230 V
XF
X2
CTB
86 88 85 82

J3 J4 J2 J1
M
87 89 84 83

MAIN
1FSFU

2FSFU

M CONTACTOR 20A,700V
3RT1045-1AP60 A1-FUF-END-C20
1SP SUPPRESSOR
3RT1926-1BD00

XP XP XR XR XP XF1-2 XF1-1

5U1 5W1 109 110 5N1 3U1 3W1 1U1 1V1 1W1
PWR PWR FIELD ARMATURE
SUPPLY SUPPLY SUPPLY SUPPLY
K1
POWER MODULE
CATALOG NO. 6RA7075-6FS22-0Z+X01, (1-QUAD)
CATALOG NO. 6RA7075-6FV62-0Z+X01, (4-QUAD)
E-STOP
106 105 3C 3D 1C1 1D1
XS XS XF2-2 XF2-1

4Q UNITS
4PFU

ONLY
175A,700V
A1-FUF-00E-020
MAUX

F(+) F(-)

90 91 80 81 A1 A2
2 - #250 MCM, 75 C
#10 AWG, 60 C TORQUE TO
TORQUE TO 275 INCH- LBS
5 INCH- LBS
MOTOR = 500 VOLTS DC
F.L.A. = 140 AMPS DC

7-6 Siemens Energy & Automation

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

460 VAC

MAIN DISCONNECT AND

BRANCH CIRCUIT
PROTECTION SIZED
PER N.E.C.

CUSTOMER SUPPLIED
IF APPLICABLE
2 - #250 MCM,75 C
TORQUE TO
275 INCH- LBS
BASE DRIVE PANEL, 210 AMPS, 1 & 4 QUAD
L1 L2 L3

L1 L2
1CFU - 2CFU
1CTR
2CFU
1CFU

2.5A,600V
A1-FUF-AFA-011 CONTROL
TRANSFORMER

1PFU

2PFU

3PFU
200A,500V
H1 H2 H3 H4
3CFU 250VA A1-FUF-00D-021
1.5A,250V A1-TRC-Q0C-286
A1-FUF-DKA-GBP 3CFU
230 V
XF
X2
CTB
86 88 85 82

J3 J4 J2 J1
M
87 89 84 83

MAIN
1FSFU

2FSFU

M CONTACTOR 20A,700V
3TF5222-0AP6 A1-FUF-END-C20
1SP SUPPRESSOR
3TX7462-3J

XP XP XR XR XP XF1-2 XF1-1

5U1 5W1 109 110 5N1 3U1 3W1 1U1 1V1 1W1
PWR PWR FIELD ARMATURE
SUPPLY SUPPLY SUPPLY SUPPLY
K1
POWER MODULE
CATALOG NO. 6RA7078-6FS22-0Z+X01, (1-QUAD)
CATALOG NO. 6RA7078-6FV62-0Z+X01, (4-QUAD)
E-STOP
106 105 3C 3D 1C1 1D1
XS XS XF2-2 XF2-1

4Q UNITS
4PFU

ONLY
250A,700V
A1-FUF-00E-023
MAUX

F(+) F(-)

90 91 80 81 A1 A2
2 - #250 MCM, 75 C
#10 AWG, 60 C TORQUE TO
TORQUE TO 275 INCH- LBS
5 INCH- LBS
MOTOR = 500 VOLTS DC
F.L.A. = 210 AMPS DC

Siemens Energy & Automation 7-7

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

460 VAC

MAIN DISCONNECT AND

BRANCH CIRCUIT
PROTECTION SIZED
PER N.E.C.

CUSTOMER SUPPLIED
IF APPLICABLE
2 - #250 MCM,75 C
TORQUE TO
275 INCH- LBS
BASE DRIVE PANEL, 255 AMPS, 1 & 4 QUAD
L1 L2 L3

L1 L2
1CFU - 2CFU
1CTR
2CFU
1CFU

3.5A,600V
A1-FUF-AFA-014 CONTROL

1PFU

2PFU

3PFU
TRANSFORMER 250A,500V
H1 H2 H3 H4 A1-FUF-00D-023
3CFU 350VA
2A,250V A1-TRC-Q0C-287
A1-FUF-DKA-GBV 3CFU
230 V
XF
X2
CTB
86 88 85 82

J3 J4 J2 J1
M
87 89 84 83

MAIN
1FSFU

2FSFU

M CONTACTOR 40A,700V
3TF5322-0AP6 A1-FUF-END-C40
1SP SUPPRESSOR
3TX7462-3J

XP XP XR XR XP XF1-2 XF1-1

5U1 5W1 109 110 5N1 3U1 3W1 1U1 1V1 1W1
PWR PWR FIELD ARMATURE
SUPPLY SUPPLY SUPPLY SUPPLY
K1
POWER MODULE
CATALOG NO. 6RA7082-6FS22-0Z+X01, (1-QUAD)
CATALOG NO. 6RA7082-6FV62-0Z+X01, (4-QUAD)
E-STOP
106 105 3C 3D 1C1 1D1
XS XS XF2-2 XF2-1

4Q UNITS
4PFU

ONLY
300A,700V
A1-FUF-00E-025
MAUX

F(+) F(-)

90 91 80 81 A1 A2
2 - #250 MCM, 75 C
#10 AWG, 60 C TORQUE TO
TORQUE TO 275 INCH- LBS
5 INCH- LBS
MOTOR = 500 VOLTS DC
F.L.A. = 255 AMPS DC

7-8 Siemens Energy & Automation

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

460 VAC

MAIN DISCONNECT AND

BRANCH CIRCUIT
PROTECTION SIZED
PER N.E.C.

CUSTOMER SUPPLIED
IF APPLICABLE
2 - #250 MCM,75 C
TORQUE TO
275 INCH- LBS
BASE DRIVE PANEL, 430 AMPS, 1 & 4 QUAD
L1 L2 L3

L1 L2
1CFU-2CFU
1CTR
1CFU

2CFU

3.5A,600V
A1-FUF-AFA-014 CONTROL
TRANSFORMER
H1 H2 H3 H4 350VA
3CFU A1-TRC-Q0C-287
2A,250V

1PFU

2PFU

3PFU
400A,500V
A1-FUF-DKA-GBV 3CFU A1-FUF-00D-028
230 V
XF
X2
CTB
86 88 85 82

J3 J4 J2 J1
87 89 84 83

ENABLE RELAY
EN 3RH1122-1AP60
1FSFU

2FSFU

M AUX SUPPRESSOR 40A,700V

ENSP 3RT1916-1BD00 A1-FUF-END-C40
RECT. BR
MREC A1-116-002-001
DC CONTACTOR
M A1-CRD-CAC-010
XP XP XR XR XP XF1-2 XF1-1

5U1 5W1 109 110 5N1 4U1 4N1 3U1 3W1 1U1 1V1 1W1
PWR PWR FAN FIELD ARMATURE
SUPPLY SUPPLY SUPPLY SUPPLY SUPPLY
K1
POWER MODULE
CATALOG NO. 6RA7085-6FS22-0Z+X01, (1-QUAD)
CATALOG NO. 6RA7085-6FV62-0Z+X01, (4-QUAD)
ENABLE E-STOP
38 106 105 3C 3D 1C1 1D1
X171 XS XS XF2-2 XF2-1
EN 94 93
M
J5

CTB 4Q UNITS
4PFU

ONLY
EN 500A,700V
A1-FUF-00E-030
F(+) F(-)

90 91 80 81 A1 A2

2 - #500 MCM, 75 C
#8 AWG, 60 C
TORQUE TO
TORQUE TO
375 INCH- LBS
7 INCH- LBS
MOTOR = 500 VOLTS DC
F.L.A. = 430 AMPS DC

Siemens Energy & Automation 7-9

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

460 VAC

MAIN DISCONNECT AND

BRANCH CIRCUIT
PROTECTION SIZED
PER N.E.C.

CUSTOMER SUPPLIED
IF APPLICABLE
2 - #500 MCM,75 C
TORQUE TO
375 INCH- LBS
BASE DRIVE PANEL, 510 AMPS, 1 & 4 QUAD
L1 L2 L3

L1 L2
1CFU-2CFU
1CTR
1CFU

2CFU

3.5A,600V
A1-FUF-AFA-014 CONTROL
TRANSFORMER
H1 H2 H3 H4 350VA
3CFU A1-TRC-Q0C-287
2A,250V

1PFU

2PFU

3PFU
500A,500V
A1-FUF-DKA-GBV 3CFU A1-FUF-00D-030
230 V
XF
X2
CTB
86 88 85 82

J3 J4 J2 J1
87 89 84 83

ENABLE RELAY
EN 3RH1122-1AP60
1FSFU

2FSFU

M AUX SUPPRESSOR 40A,700V

ENSP 3RT1916-1BD00 A1-FUF-END-C40
RECT. BR
MREC A1-116-002-001
DC CONTACTOR
M A1-CRD-CAC-010
XP XP XR XR XP XF1-2 XF1-1

5U1 5W1 109 110 5N1 4U1 4N1 3U1 3W1 1U1 1V1 1W1
PWR PWR FAN FIELD ARMATURE
SUPPLY SUPPLY SUPPLY SUPPLY SUPPLY
K1
POWER MODULE
CATALOG NO. 6RA7087-6FS22-0Z+X01, (1-QUAD)
CATALOG NO. 6RA7087-6FV62-0Z+X01, (4-QUAD)
ENABLE E-STOP
38 106 105 3C 3D 1C1 1D1
X171 XS XS XF2-2 XF2-1
EN 94 93
M
J5

CTB 4Q UNITS
4PFU

ONLY
EN 600A,700V
A1-FUF-00E-031
F(+) F(-)

90 91 80 81 A1 A2

2 - #500 MCM, 75 C
#8 AWG, 60 C
TORQUE TO
TORQUE TO
375 INCH- LBS
7 INCH- LBS
MOTOR = 500 VOLTS DC
F.L.A. = 510 AMPS DC

7-10 Siemens Energy & Automation

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460 VAC

MAIN DISCONNECT AND

BRANCH CIRCUIT
PROTECTION SIZED
PER N.E.C.

CUSTOMER SUPPLIED
IF APPLICABLE
3 - #500 MCM,75 C
TORQUE TO
375 INCH- LBS
BASE DRIVE PANEL, 850 AMPS, 1 & 4 QUAD
L1 L2 L3

L1 L2
1CFU-2CFU
1CTR
1CFU

2CFU

3.5A,600V
A1-FUF-AFA-014 CONTROL
TRANSFORMER
H1 H2 H3 H4 1000VA
3CFU A1-TRC-Q0C-288
6.25A,250V
A1-FUF-DKA-GCM 3CFU
230 V
XF
X2
CTB
86 88 85 82

J3 J4 J2 J1
87 89 84 83

ENABLE RELAY
EN 3RH1122-1AP60
1FSFU

2FSFU

M AUX SUPPRESSOR 40A,700V

ENSP 3RT1916-1BD00 A1-FUF-END-C40
RECT. BR
MREC
A1-116-002-001
DC CONTACTOR
M A1-CRD-CAC-010
XP XP XR XR XP XF1-2 XF1-1

5U1 5W1 109 110 5N1 4U1 4N1 3U1 3W1 1U1 1V1 1W1
PWR PWR FAN FIELD ARMATURE
SUPPLY SUPPLY SUPPLY SUPPLY SUPPLY
K1
POWER MODULE
CATALOG NO. 6RA7091-6FS22-0Z+X01, (1-QUAD)
CATALOG NO. 6RA7091-6FV62-0Z+X01, (4-QUAD)
ENABLE E-STOP
38 106 105 3C 3D 1C1 1D1
X171 XS XS XF2-2 XF2-1
EN 94 93
M
J5

CTB
EN

F(+) F(-)

90 91 80 81 A1 A2

3 - #500 MCM, 75 C
#8 AWG, 60 C
TORQUE TO
TORQUE TO
375 INCH- LBS
7 INCH- LBS
MOTOR = 500 VOLTS DC
F.L.A. = 850 AMPS DC

Siemens Energy & Automation 7-11

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460 VAC

CUSTOMER SUPPLIED
IF APPLICABLE
4 - #500 MCM,75 C
TORQUE TO
375 INCH- LBS
BASE DRIVE PANEL, 1180 AMPS, 1 & 4 QUAD
J6 CTB J7 CTB J8
L1 L2 L3 96 97 98 99 100 101

5A,600V

4CFU

5CFU

6CFU

7CFU
L1 L2
1CFU-2CFU A1-FUF-AFA-016
CONTROL
2.5A,600V 1CTR
1CFU

2CFU

TRANSFORMER
A1-FUF-AFA-011
250VA H1 H2 H3 H4 H1 H2 H3 H4
H1 H2 H3 H4
3CFU A1-TRC-Q0C-286 CONTROL
1.5A,250V TRANSFORMERS
A1-FUF-DKA-GBP 3CFU

3CTR
750VA

2CTR
230 V
XF 85 82 A1-TRC-Q0C-289
X2
CTB J2 J1
84 83 460 V 460 V

X1 X2 X1 X2
ENABLE RELAY
EN 3RH1122-1AP60
M AUX MSP L1 L2 L3
ENSP SUPPRESSOR
1FSFU

2FSFU

3RT1916-1BD00 MSP
50A,700V 1.1-1.6A 3RV1011-1AA10
RECT.BR A1-FUF-END-C50 SET@1.50A
MREC A1-116-002-001
DC CONTACTOR T1 T2 T3
M A1-CRD-CAC-010
XP XP XR XR XP XF1-2 XF1-1
5U1 5W1 109 110 5N1 3U1 3W1 1U1 1V1 1W1 4U1 4V1 4W1
PWR SUPPLY PWR SUPPLY FIELD SUPPLY SEMICONDUCTOR FAN
K1 POWER MODULE FUSES ARE INTERNAL SUPPLY
TO POWER MODULE
CATALOG NO. 6RA7093-4GS22-0Z+X01, (1-QUAD)
Note:
CATALOG NO. 6RA7093-4GV62-0Z+X01, (4-QUAD) ARMATURE FAN MUST ROTATE COUNTER-CLOCKWISE
ENABLE E-STOP SUPPLY WHEN VIEWED FROM ABOVE
38 106 105 3C 3D 1C1 1D1
X171 XS XS XF2-2 XF2-1
EN 94 93

J5
M
EN CTB

F(+) F(-)

90 91 80 81 A1 A2
#4 AWG, 60 C 4 - #500 MCM, 75 C
TORQUE TO TORQUE TO
11 INCH- LBS 375 INCH- LBS

MOTOR = 500 VOLTS DC

F.L.A. = 1180 AMPS DC

7-12 Siemens Energy & Automation

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460 VAC

CUSTOMER SUPPLIED
IF APPLICABLE
6 - #500 MCM,75 C
TORQUE TO
375 INCH- LBS
BASE DRIVE PANEL, 1660 AMPS, 1 & 4 QUAD J6 J7 J8
CTB CTB
L1 L2 L3 96 97 98 99 100 101

5A,600V

4CFU

5CFU

6CFU

7CFU
L1 L2
1CFU-2CFU A1-FUF-AFA-016
CONTROL
2.5A,600V 1CTR
1CFU

2CFU

TRANSFORMER
A1-FUF-AFA-011
250VA H1 H2 H3 H4 H1 H2 H3 H4
H1 H2 H3 H4
3CFU A1-TRC-Q0C-286 CONTROL
1.5A,250V TRANSFORMERS
A1-FUF-DKA-GBP 3CFU

3CTR
750VA

2CTR
230 V
XF 85 82 A1-TRC-Q0C-289
X2
CTB J2 J1
84 83 460 V 460 V
ENABLE RELAY
EN 3RH1122-1AP60 X1 X2 X1 X2
M1 M2 MSP
ENSP SUPPRESSOR
3RT1916-1BD00
MREC RECT.BR L1 L2 L3
1FSFU

2FSFU

A1-116-002-001 MSP
50A,700V 1.1-1.6A
M1 DC CONTACTOR 3RV1011-1AA10
A1-FUF-END-C50 SET@1.50A
A1-CRD-CAC-010
M2 T1 T2 T3

XP XP XR XR XP XF1-2 XF1-1
5U1 5W1 109 110 5N1 3U1 3W1 1U1 1V1 1W1 4U1 4V1 4W1
PWR SUPPLY PWR SUPPLY FIELD SUPPLY SEMICONDUCTOR FAN
K1 POWER MODULE FUSES ARE INTERNAL SUPPLY
TO POWER MODULE
CATALOG NO. 6RA7095-4GS22-0Z+X01, (1-QUAD)
Note:
CATALOG NO. 6RA7095-4GV62-0Z+X01, (4-QUAD) ARMATURE FAN MUST ROTATE COUNTER-CLOCKWISE
ENABLE E-STOP SUPPLY WHEN VIEWED FROM ABOVE
38 106 105 3C 3D 1C1 1D1
X171 XS XS XF2-2 XF2-1
EN 94 93

J5
M1 M2
EN CTB

F(+) F(-)

90 91 80 81 A1 A2
#4 AWG, 60 C 6 - #500 MCM, 75 C
TORQUE TO TORQUE TO
11 INCH- LBS 375 INCH- LBS

MOTOR = 500 VOLTS DC

F.L.A. = 1660 AMPS DC

Siemens Energy & Automation 7-13

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7.2 Control Connections CUD1

TYPICAL CONTROL CONNECTIONS

Also see Start-up 8.4.1 and 8.4.2

INPUTS OUTPUTS
X171 BINARY INPUTS
CUD 1
+24VDC SUPPLY 100mA
34
COMMON
35 M

SERIAL INTERFACE #2 RS485 X172

SELECT INPUT BINARY 1
36
START TX+ RS485
POWER ON / SHUTDOWN 56
37
TX- RS485
ENABLE OPERATION 57
38
RX+/TX+ RS485
SELECT INPUT BINARY 2 58
39 RS485 RX-/TX- RS485
8.5ma @ 24 V 59
M 60
BA BA
GND X173 PULSE ENCODER INPUTS
M
+15VDC SUPPLY 200mA
26 + M
COMMON
27 M

A POSITIVE
28 BINARY OUTPUTS X171
A NEGATIVE
29 RELAY 1
SELECT OUTPUT 1
B POSITIVE 46
30
B NEGATIVE 47
31
SELECT OUTPUT 2 RELAY 2
POSITIVE CPU 48
32
ZERO MARKER
(OPTIONAL) NEGATIVE OUTPUT TYPICAL 54
33
24 VDC, 100 ma MAX
+24VDC M

X174 REFERENCE, ANALOG INPUTS, MOTOR TEMP

SPEED
POT GND COMMON
1 M ANALOG OUTPUTS X175
10K
2 P10
(10V = 200% converter amps) Iact 12 V
CW RESOULTION ADJUSTABLE
3 N10
+/- 11 BITS TO +/- 14 BITS M 13
ANALOG 1
A 14 V
MAIN SETPOINT +
4 D
150 K ohms M 15
MAIN SETPOINT -
5
ANALOG 2
ANALOG 1 + A 16 V
6
ANALOG 1 - 515 K ohms D
7 Analog Outputs: M 17
MOTOR TEMP + RESOULTION +/- 11 BITS
22 O to +/- 10 Volts, 2mA MAX
23 MOTOR TEMP -

24 COMMON
M
OPERATOR
PANEL
X107 X110 X111 X300

OPTIONAL OPTIONAL CUD2 OPTIONAL

COMMUNICATIONS AND TERMINAL EXPANSION OP1S
TECHNOLOGY BOARDS OPERATOR

7-14 Siemens Energy & Automation

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Terminal Locations CUD1

34
35
36
37
38
39
46
47 X107
48
54 X171

56
57
58
59
60 X172

26
27
28
29
30
31
32
33 X173

1
2
3
4
5
6
7
22 X109
23
24 X174

12
13
14
15
16
17 X175

C98130-A7001

Siemens Energy & Automation 7-15

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7.3 Control Connections CUD2

OPTIONAL CUD2 CONTROL CONNECTIONS

OUTPUTS

INPUTS CUD 2
X165
RX+/TX+

RX-/TX-
X161BINARY INPUTS
RX+/TX+
+24VDC SUPPLY 100mA
210 RX-/TX- PARALLEL
CONVERTER
SELECT INPUT BINARY RX+/TX+ INTERFACE
211 X166
SELECT INPUT BINARY RX-/TX-
212
SELECT INPUT BINARY
213
RX+/TX+
SELECT INPUT BINARY
214
RX-/TX-
RETURN
215
216
OPTICALLY SERIAL INTERFACE #2 RS485 X162
217 M ISOLATED

8.5ma @ 24 V TX+ RS485

61
TX- RS485
62
RX+/TX+ RS485
63
RS485 RX-/TX- RS485
64

65
X163 BINARY INPUTS BA BA
+24VDC SUPPLY 100mA M
44
+ M
45 M

SELECT INPUT BINARY 3

40
SELECT INPUT BINARY 4 BINARY OUTPUTS X163
41
SELECT INPUT BINARY 5 SELECT OUTPUT 3 RELAY 3
42
50
SELECT INPUT BINARY 6
43
51
8.5ma @ 24 V SELECT OUTPUT 4 RELAY 4
52
M
OUTPUT TYPICAL 53
24 VDC, 100 ma MAX
+24VDC M

ANALOG OUTPUTS X164

X164 ANALOG INPUTS RESOULTION +/- 10 BITS
ANALOG 3
A 18 V
ANALOG 2 + D
8 M 19
52 K ohms
9 M M ANALOG 4
ANALOG 3 + A 20 V
10 D
52 K ohms Analog Outputs: M 21
11 M M RESOULTION +/- 11 BITS
MOTOR TEMP + O to +/- 10 Volts, 2mA MAX
204

205 MOTOR TEMP -

X110 X111

CONNECTION TO CUD1

7-16 Siemens Energy & Automation

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Terminal Locations CUD2

210
211
212
213
214
215
216
217 X161

61
62
63
64
65 X162

44
45
40
41
42
43
50
51
52
53 X163

8
9
10
11
18
19
20
21
204
205 X164

C98130-A7006

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7.4 Description of Power/Control Terminals

WARNING
The Base Drive Panel might sustain serious or irreparable damage if connected incorrectly.
The power cables and/or busbars must be secured mechanically outside the converter in order
to provide proper stress relief at the terminals.

Base Drive Panels are complete drive assemblies that include all semiconductor type fuses, main contactor, and
a control transformer, ready to be connected and operated. All external connections to Base Drive Panels,
including power connections are made with compression type terminals on the drive.

The user is responsible for installation of the motor, SIMOREG Base Drive Panel, transformer, and other devices
in accordance with the National Electric Code and other applicable local codes that cover such items as wire
size, protective grounding, disconnects, and short circuit protection. Depending on the rating, base drives can
accommodate a range of cable sizes as indicated below.

Base Drive Panel Power Connections 15 to 100 Amp

RATING CABLE RANGE RECOMMENDED TORQUE

15 AMP #12 to #4 AWG 1.2 Nm (11 IN-LBS)

L1, L2, L3, A1, A2, GND

30 AMP #12 to #4 AWG 1.2 Nm (11 IN-LBS)

L1, L2, L3, A1, A2, GND

60 AMP #10 to #1 AWG 3 Nm (27 IN-LBS)

L1, L2, L3, A1, A2, GND

100 AMP #10 to #1 AWG 3 Nm (27 IN-LBS)

L1, L2, L3, A1, A2, GND

Base Drive Panel Power Connections 140 to 255 Amp

RATING CABLE RANGE RECOMMENDED TORQUE

140 AMP 2 CABLES PER CONNECTION 31 Nm (275 IN-LBS)

L1, L2, L3, A1, A2 #6 AWG to 250 MCM

210 AMP 2 CABLES PER CONNECTION 31 Nm (275 IN-LBS)

L1, L2, L3, A1, A2 #6 AWG to 250 MCM

255AMP 2 CABLES PER CONNECTION 31 Nm (275 IN-LBS)

L1, L2, L3, A1, A2 #6 AWG to 250 MCM

Ground Terminal #8 to #2 AWG 5 Nm (45 IN-LBS)

140, 210, 255 Amp

7-18 Siemens Energy & Automation

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Base Drive Panel Power Connections 430 to 1660 Amp

RATING CABLE RANGE RECOMMENDED TORQUE

430AMP 2 CABLES PER CONNECTION

L1, L2, L3 ---------------- #6 AWG to 250 MCM (L1, L2, L3) ----------- 31 Nm (275 IN-LBS)

A1, A2 --------------------- #6 AWG to 500 MCM (A1, A2) ---------------- 43 Nm (375 IN-LBS)

510 AMP 2 CABLES PER CONNECTION 43 Nm (375 IN-LBS)

L1, L2, L3, A1, A2 #6 AWG to 500 MCM

850 AMP 3 CABLES PER CONNECTION 43 Nm (375 IN-LBS)

L1, L2, L3, A1, A2 #1/0 AWG to 500 MCM

1180 AMP 4 CABLES PER CONNECTION 43 Nm (375 IN-LBS)

L1, L2, L3, A1, A2 #1/0 AWG to 500 MCM

1660 AMP 6 CABLES PER CONNECTION 43 Nm (375 IN-LBS)

L1, L2, L3, A1, A2 #1/0 AWG to 500 MCM

Ground Terminal

430 TO 850 Amp #2 to #4/0 AWG ---------------------------------- 17 Nm (150 IN-LBS)

1180 & 1660 Amp #1/0 to 350 MCM -------------------------------- 31 Nm (275 IN-LBS)

Base Drive Panel Control Connections, (CTB), 15 TO 1660 Amp

RATING WIRE RANGE RECOMMENDED TORQUE

15 TO 255 Amp

CTB-80…….CTB-92 #18 to #10 AWG 0.55 Nm (5 IN-LBS)

430 TO 850 Amp

CTB-80…….CTB-85 #14 to #8 AWG --------------------------------- 0.8 Nm (7 IN-LBS)

CTB-86…….CTB-95 #18 to #10 AWG --------------------------------- 0.55 Nm (5 IN-LBS)

1180 & 1660 Amp

CTB-80…….CTB-85 #12 to #4 AWG --------------------------------- 1.3 Nm (11 IN-LBS)

CTB-86…….CTB-95 #18 to #10 AWG --------------------------------- 0.55 Nm (5 IN-LBS)

Siemens Energy & Automation 7-19

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Motor Armature circuit

Function Terminal Connection values/Remarks Possible

settings
Armature supply AC input L1 P078
L2
L3
Ground PE conductor See technical data, section 5 for
actual maximum current values.
Armature circuit motor A1 P100
connection A2 P101

Motor Field circuit

Function Terminal Connection values/Remarks Possible
settings
AC Supply connection CTB 83 Single Phase 460 VAC P076
CTB 84 See section 5 for current rating P078
Motor Field connection CTB 80 + Rated DC voltage 300V P102
CTB 81 -

Electronics power supply, main contactor, fans (if used) 15 to 850 amp
Function Terminal Connection values/Remarks Possible
settings
Incoming AC supply 230V CTB 87 Single Phase, 230 VAC, (hot)
(supplied by internal CTB 89 (ground side)
control transformer)

Current Requirement for Terminals 87, 89 if supplied from a separate source

15 amp to 100 amp base drive panels: 0.55 amps
140 and 210 amp base drive panels: 1.2 amps
255 to 510 amp base drive panels: 1.6 amps
850 amp base drive panel: 4.6 amps

7-20 Siemens Energy & Automation

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Electronics power supply, main contactor, and fans 1180 to 1660 amps
Function Terminal Connection values/Remarks Possible
settings
Incoming AC supply CTB 97 Internally connected to incoming
460 VAC, 3 Phase CTB 99 460V supply
CTB 101

Current Requirement for Terminals if supplied from a separate source

1180 and 1660 amp base drives: 2.5 amps at 460 VAC 3 phase

Note: Phase sequence is important for the fan direction of rotation. The fan must rotate counter-
clockwise when viewed from above. If necessary, swap the L1 and L2 phase wiring at
incoming supply to change the fan direction of rotation.

Remote relay Enable terminals: 430 amp to 1660 amp base drive panels
Function Terminal Connection values/Remarks Possible
settings
External enable (if used) CTB 93 If a remote enable function is required
CTB 94 using a relay contact, then remove jumper
J5 and install a normally open low voltage
contact at terminals 93 – 94.

The 430 amp to 1660 amp Base Drive Panels use a DC contactor that is interlocked through the enable function
at regulator terminals 34 and 38. This circuit is brought out to CBT terminals 93 and 94 to allow an easy point to
add an external enable contact if required. A remote enable contact can be wired directly to terminals 34 and 38
of the regulator for Base Drive Panels rated 15 to 255 amps.

Siemens Energy & Automation 7-21

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NOTES:

7-22 Siemens Energy & Automation

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8 Start-Up
8.1 General safety information for start-up

NOTE
Before handling any boards (in particular, the A7001 electronics board), please make sure that your body
is electrostatically discharged to protect electronic components against high voltages caused by
electrostatic charges. The simplest way of doing this is to touch a conductive, grounded object (e.g. bare
metal cabinet component immediately beforehand).
PCBs must not be allowed to come into contact with highly insulating materials (e.g. plastic foil, insulating
tabletops or clothing made of synthetic fibers).
PCBs may only be set down on electrically conducting surfaces.

WARNING
Hazardous voltages and rotating parts (fans) are present in this electrical equipment during
operation. Non-observance of the safety instructions can result in death, severe personal injury
or substantial property damage.
Hazardous voltage may be present at the signaling relays in the customer’s installation.
The units must not be connected to an AC supply with an earth-leakage ground detector since,
in the event of a fault to ground, the fault current may contain a DC component that may either
prevent or hinder a higher-level ground fault detector from tripping. In this case, all loads
connected to this ground fault detector will not be protected.
Only qualified personnel who are thoroughly familiar with all safety notices contained in the
operating instructions as well as erection, installation, operating and maintenance instructions
should be allowed to work on these devices.
The successful and safe operation of this equipment is dependent on careful transportation,
proper storage and installation as well as correct operation and maintenance.
The unit is at a hazardous voltage level even when the line contactor is open. The gating board
(board mounted directly to lower part of housing) has many circuits at hazardous voltage
levels. Before carrying out any maintenance or repair work, all Base Drive Panel power
sources must be disconnected and locked out.
These instructions do not claim to list all of the measures required to ensure the safe and
reliable operation of the converter. For special applications, additional, supplementary
information or instructions might be required. If problems do occur and you feel in any way
uncertain, please contact your local Siemens office or representative.
The use of unauthorized parts in the repair of this unit and handling of the equipment by
unqualified personnel can give rise to hazardous conditions which may cause death, severe
personal injury or substantial property damage. All safety notices contained in this instruction
manual and attached to the converter itself must be carefully observed.
Please read the safety information given in Section 1 of this instruction manual.

SIEMENS Energy & Automation 8-1

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8.2 Operator control panels

The basic converter is equipped with a simple operator panel (PMU) as standard. A user-friendly panel with
plain text display (OP1S) can be connected as an option.

8.2.1 Simple operator control panel (PMU “Parameterization Unit“)

The simple operator control panel is mounted in the converter door and consists of a 5-digit, 7-segment
display with three status display LED’s and three parameterization keys.
All adjustments, settings and measurements that need to be undertaken for the purpose of start-up can be
made on the simple control panel.

8.8.8.8.8.
Run Ready Fault

X300

• P key
− Switches over between parameter number (parameter mode), parameter value (value mode)
and index number (index mode) on indexed parameters.
− Acknowledges active fault messages.
− P and RAISE keys to switch a fault message and alarm to the background to get access to the
parameter mode.
− P and LOWER key to switch a fault message and alarm from the background back to the
foreground display on the PMU.

• UP key ()
− Selects a higher parameter number in parameter mode. When the highest parameter number is
displayed, the key can be pressed again to roll over to the lowest parameter number.
− Increases the displayed parameter value in value mode.
− Increases the index number in index mode (for indexed parameters)
− If the DOWN key is pressed, then, also pressing the UP key will accelerate the DOWN adjustment
process.

• DOWN key ()

− Selects a lower parameter number in parameter mode. When the lowest parameter number is
displayed, the key can be pressed again to roll over to the highest parameter number.
− Decreases the displayed parameter value in value mode.
− Decreases the index number in index mode (for indexed parameters)
− If the UP key is pressed, then, also pressing the DOWN key will accelerate the UP adjustment
process.

8-2 SIEMENS Energy & Automation

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LED displays
Run green LED
LED illuminated  in “Torque direction active” state (MI, MII, M0).
(See parameter r000)
Ready yellow LED
LED illuminated  in “Ready” state (o1 .. o7).
(See parameter r000)
Fault red LED
LED illuminated  in “Fault signal present” state (o11)
(See parameter r000)
LED flashing  An alarm is active (see Faults and Alarms).

8.2.2 User-friendly operator control panel (OP1S)

The optional, user-friendly, operator control panel with plain text display (order no.: 6SE7090-0XX84-2FK0)
can be mounted in the special location provided in the converter door or remotely mounted on the enclosure
door. The OP1S connects to the basic converter interface SST1 at sub D connector X300.
Parameters can be selected directly through input of the parameter number by the keyboard of the OP1S.
The following interrelationships apply:

Displayed Number to be keyed in

number on OP1S

Basic converter rxxx, Pxxx (0)xxx

parameter Uxxx, nxxx 2xxx

Technology board Hxxx, dxxx 1xxx

parameter Lxxx, cxxx 3xxx
For more information on the operation of the OP1S, refer to the power module operating instructions and the
instructions that were provided with the OP1S.

SIEMENS Energy & Automation 8-3

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8.3 Parameterization procedure

Parameterization is the process of changing or setting parameter values, activating converter functions, or
displaying measured values with the operator panel.
Parameters for the basic converter are called P, r, U or n parameters.
Parameters for an optional supplementary board are called H, d, L or c parameters.
The basic unit parameters are displayed first on the PMU, followed by the technology board parameters (if
such a board is installed). It is important not to confuse the parameters of the S00 technology software of
the basic unit with the parameters of an optional supplementary board (T400).
Depending on how parameter P052 is set, only some parameter numbers are displayed.

8.3.1 Parameter types

Display parameters (r, n, d, and c), are used to display current quantities such as the main setpoint,
armature voltage, feedback signals, outputs of controller, etc. The values of display parameters are read-
only values and cannot be changed.
Setting parameters (P, U, H, L), are used to both display and change parameter quantities such as the
rated motor current, thermal motor time constant, speed controller P gain, etc.
Indexed parameters (P, U, H, L), are used to both display and change several parameter values which are
all assigned to the same parameter number but identified by the index number.

8.3.2 Parameterization on simple operator control panel

After the electronics supply voltage has been switched on, the PMU is either in the operational display state
and indicating the current operating status of the SIMOREG 6RA70 (e.g. o7.0), or in the fault/alarm display
state and indicating a fault or alarm (e.g. F021).
Drive operational states are described by parameter r000 whereas fault and alarm messages are described
in the power module operating instructions in Section 10.
1. To enter the parameter number level from the operational display state (e.g. o7.0), press the P key and
then the <Up> or <Down> key to select individual parameter numbers.
2. To enter the parameter index levels (for indexed parameters) from the parameter number level, press P
again and then the <Up> or <Down> key to select individual indices. If you press P when a non-indexed
parameter is displayed, you go directly to the parameter value level.
3. To reach the parameter value level from the parameter index level (for indexed parameters), press P
again and the parameter value will be displayed.
4. On the parameter value level, you can change the setting of a parameter value by pressing the <Up> or
<Down> key.

CAUTION!
Parameters can be altered only if the following conditions are fulfilled:
− The key code is set with P051 = 40.
− The converter is in the correct operational state. Some parameters are “off-line” and cannot be changed
when the converter is in the “Run” or on-line state.
− The values of display parameters can not be changed (read only).

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5. Manual shifting
If the 5 existing digits on the 7-segment display are not sufficient to display a parameter value, the display
first shows just 5 digits (see Fig. 8.1). To indicate that more digits are concealed to the right or left of this
“window”, the right-hand or left-hand digit flashes. By pressing the <P>+<Down> or <P>+<Up> key, you
can shift the window over the remaining digits of the parameter value. As an orientation guide, the position
of the right-hand digit within the overall parameter value is displayed briefly during manual shifting.

Example: Parameter value “208.173“

"208.17" is displayed when the parameter is selected. When the
P and LOWER keys are pressed, "1" appears briefly followed by
“08.173“, i.e. the right-hand digit 3 is the 1st position in the P
parameter value. +
When the P and RAISE keys are pressed, "2" appears briefly P
followed by “208.17“, i.e. the right-hand digit 7 is the 2nd position +
in the parameter value.

Fig. 8.1 Shifting the PMU display for parameter values with more than 4 digits

6. Press the P key to return to the parameter number level from the parameter value level.

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8.4 Typical Connection Diagrams

8.4.1 Configured with Analog Speed Setpoint and

Start/Stop Control by Contacts

460 VOLT
3 PHASE, 50 / 60 HZ.

X174 L1 L2 L3

2 P10
CW
SPEED
4 REF+
SETPOINT
(10K) 5 REF-
1 COM

X171
PMU
34 P24
START Run Ready Fault

37 RUN
X300
38 ENABLE

39 SELECT INPUT

36 SELECT INPUT

XS
E-STOP
106 ES/P24

105 E-STOP WHEN DE-ENERGIZED

X174

26 27 28 29 30 31 A1(+) A2(-) 80(+) 81(-)

P15 COM A A B B

MOTOR
FIELD

ENCODER

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8.4.2 Configured with Analog Speed Setpoint and

Push-Button Start/Stop Control

460 VOLT
3 PHASE, 50 / 60 HZ.

X174 L1 L2 L3
2 P10
CW
SPEED
4 REF+
SETPOINT
(10K) 5 REF-
1 COM

X171 PMU
34 P24
START
Run Ready Fault
37 RUN P445 = 1
(PUSH-BUTTON CONTROL)
38 ENABLE X300

STOP
39 SELECT INPUT P444 = 16
(OFF 1 WHEN DE-ENERGIZED)

36 SELECT INPUT

XS
E-STOP
106 ES/P24

105 E-STOP WHEN DE-ENERGIZED

X174

26 27 28 29 30 31 A1(+) A2(-) 80(+) 81(-)

P15 COM A A B B

MOTOR
FIELD

ENCODER

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8.5 Reset to factory default values and adjust offsets

In order to start from a predefined set of parameter values, it is highly recommended that the “Restore to
default” function be executed before a complete new start-up operation is begun.

NOTE
When the “Restore to default” function is activated, all parameters set for a specific installation
are overwritten (deleted). If the old settings are to be retained they should be recorded before
the default procedure is executed. The old settings can be read out and stored in a file using a
PC and either the Quick Start or DriveMonitor PC program.
“Restore to default” must be followed by a completely new start-up operation since none of the
application related parameters are set.

Execution of the default function:

1. Set parameter P051 = 21
2. When the “P” key is pressed the parameter values are reset to the factory value.
The parameter values are stored in non-volatile storage (EEPROM) so that they will still be available
when the converter is switched off. This operation takes at least 5 s (but may also last several minutes).
The number of the parameter currently being processed is displayed on the PMU during the process.
The electronics power supply must remain powered up while this operation is in progress.
3. Field offset adjustments
Parameter P825.ii is automatically set (takes approx. 10 s) to provide proper calibration of the field
converter rated current. The offset adjustment can also be activated as an individual function by means
of parameter P051 = 22.

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8.6 Start-up procedure

WARNING
The Base Drive Panel is at a hazardous voltage level even when the line contactor is open.
The gating board (board mounted directly to lower part of housing) has many circuits at
hazardous voltage levels.
Non-observance of the safety instructions given in this manual can result in death, severe
personal injury or substantial property damage.

The following steps summarize the start-up procedure.

Always begin by defaulting the parameters back to the factory value as outlined in paragraph 8.5
Step Procedure

1 Set P051 = 40 to gain access to change parameters

2 Set P067 = 5 for US rating. This parameter setting is mandatory on Base Drive
Panels.

3 Set the actual operating AC supply voltage for the armature and field converters (P078)

4 Input motor data (P100, P101, P102, P114)

5 Select speed feedback method (P083) [analog tach, encoder, EMF voltage, custom]

6 Select field control and weakening (P081, P082)

7 Set current limits and ramp generator time (P171, P172, P303, P304, P305, P306)

8 Perform self tuning (P051 = 25, 26, 27, 28)

9 Set application specific parameters

10 Documentation of final parameter values

The following details explain how to do each of the above steps.

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1 Access authorization
P051 . . . Key parameter
0 Parameter cannot be changed
40 Parameter can be changed

P052 . . . Selection of parameters to be displayed

0 Only parameters that are not set to default are visible
3 All parameters are visible

2 Adjustment of converter rated currents

Base Drive Panels are designed to continuously operate at the converter US rated current and then provide
150% overload current for 60 seconds. In order to meet this requirement it is mandatory that P067 be set to a
value of 5. The IEC Class 1 rating provides a higher continuous current but has no overload capability. The
fuses, contactor, power terminals, and power wiring used on base drives have been selected based on the US
rating. Failure to set P067 on Base Drive Panels to the US rating may cause damage to Base Drive Panel
components and void warranty.
Set parameter P067 = 5 “U.S. Rating“.
Set parameter P075 = 1 to allow dynamic overload capability.

3 Adjustment to actual converter supply voltage

P078.001 . . . Supply voltage for armature circuit (in volts)
P078.002 . . . Supply voltage for field circuit (in volts)

4 Input of motor data

The motor data as given on the motor rating plate must be entered in parameters P100, P101, P102 and P114.

P100 . . . Rated armature current (in amps)

P101 . . . Rated armature voltage (in volts)
P102 . . . Rated field current (in amps)
P114 . . . Thermal time constant of motor (in minutes). If not known use the default 10-minute value.

5 Actual speed sensing data

5.1 Operation with analog tachometer

P083 = 1: The actual speed is supplied from the “Main actual value” channel (K0013)
(terminals XT.103, XT.104)

P741 Tachometer voltage at maximum speed (– 270,00V to +270,00V)

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5.2 Operation with pulse encoder

P083 = 2: The actual speed is supplied by the pulse encoder (K0040)

P140 Selecting a pulse encoder type (pulse encoder types see below)
0 No encoder/"Speed sensing with pulse encoder" function not selected
1 Pulse encoder type 1 (Normal selection)
2 Pulse encoder type 1a (Special encoder)
3 Pulse encoder type 2 (Special encoder)
4 Pulse encoder type 3 (Special encoder)

1. Pulse encoder type 1

Encoder with two pulse tracks mutually displaced by 90° (with or without zero marker)

Track 1
X173 28, 29

Track 2
X173 30, 31

Zero marker Heidenhain ROD

X173 32, 33 Teldix Rotaswitch Serie 26

P141 Number of pulses of pulse encoder (in pulses/revolution)

P142 Matching to pulse encoder signal voltage

0 Pulse encoder outputs 5 V signals (requires separate 5V encoder supply voltage)
1 Pulse encoder outputs 15V signals (uses internal 15V encoder supply voltage)

CAUTION
Resetting parameter P142 to the alternative 5V setting does not switch over the supply
voltage for the pulse encoder (terminals X173.26 and 27).
Terminal X173.26 always supplies +15V. An external voltage supply must be provided for
pulse encoders requiring a 5V supply.

P143 Setting the maximum operating speed for pulse encoder operation (in revolutions/minute).
The speed set in this parameter corresponds to an actual speed (K0040) of 100%.

5.3 Operation without tachometer (EMF control)

P083 = 3: The actual speed is supplied from the “Actual EMF” channel (K0287),
but scaled with P115.

P115 EMF at maximum speed (Note: EMF = Terminal voltage – IxR)

1.00% to 140.00% of rated converter supply voltage at r071.

5.4 Freely wired actual value

P083 = 4: The actual value input is defined with P609.

P609 Number of connector to which actual speed controller value is connected.

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6 Field data

6.1 Field control

P082 = 0: Internal field is not used and field functions are not used.
(e.g. with permanent-field motors)

P082 = 1: The field is switched together with the line contactor

(field pulses are enabled/disabled when line contactor closes/opens)

P082 = 2: Automatic connection of standstill field set by P257 after a delay parameterized by P258,
after operating status o7 or higher has been reached

P082 = 3: Field current permanently connected

6.2 Field weakening

P081 = 0: No field weakening as a function of speed or EMF

P081 = 1: Field weakening operation as a function of internal EMF control so that, in the field
weakening range, i.e. at speeds above motor base speed, the motor EMF is maintained
constant. Note: Rated EMF = Rated Terminal voltage – IratedxRarmature
EMFsetpoint (K289) = P101 – P100 * P110.

7 Selection of basic technological functions

7.1 Current limits

P171 Motor current limit in torque direction I (in % of P100, default value = 100%)

US setting P171 = 150%

P172 Motor current limit in torque direction II (in % of P100, default value = -100%)
US setting P172 = -150%

7.2 Ramp-function generator

P303 Acceleration time 1 (in seconds, default value = 10)

P304 Deceleration time 1 (in seconds, default value = 10)
P305 Initial rounding 1 (in seconds, default value = 0)
P306 Final rounding 1 (in seconds, default value = 0)

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8 Execution of optimization runs

8.1 The unit must be in operating state o7.0 or o7.1 (enter SHUTDOWN!).

8.2 Select one of the following optimization runs in key parameter P051:
P051 = 25 Optimization run for precontrol and current controller for armature and field
P051 = 26 Speed controller optimization run
P051 = 27 Optimization run for field weakening
P051 = 28 Optimization run for compensation of friction moment and moment of inertia
Note: The optimization runs should be performed in the above order.

8.3 The SIMOREG converter switches to operating state o7.4 for several seconds and then to o7.0 or o7.1
and waits for the START command and ENABLE.

Enter the commands START and ENABLE.

The flashing of the decimal point in the operational status display on the PMU (simple operator control
panel) indicates that an optimization run will be performed after the Start command.

If the start command is not given within 30 s, this waiting status is terminated and fault message F052
displayed.

8.4 As soon as the converter reaches operating status <o1.0 (RUN), the optimization run is executed.
An activity display appears on the PMU, consisting of two 2-digit numbers, separated by a bar that moves
up and down. These two numbers indicate (for SIEMENS personnel) the current status of the
optimization run.

P051 = 25 Optimization run for precontrol and current controller for armature and field (process
lasts approximately 40s).
The following parameters are set automatically: P110, P111, P112, P155, P156, P255,
and P256.

NOTE
Permanent-field motors (and motors with an extremely high residual flux) must be
mechanically locked during this optimization run.

WARNING
The set current limits are not effective during the current controller
optimization run. 75% of the rated motor armature current flows for
approximately 0.7s. Furthermore, individual current spikes of
approximately 120% of the motor rated armature current are
generated.

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P051 = 26 Speed controller optimization run (process lasts approximately 6s).

The following parameters are set automatically: P225, P226 and P228.
Note:
The speed controller optimization run takes only the filtering of the actual speed controller
value parameterized in P200 into account and, if P083=1, filtering of the main actual value
parameterized in P745.
When P200 < 20ms, P225 (gain) is limited to a value of 30.00.

The speed controller optimization run sets P228 (speed setpoint filter) to the same value
as P226, speed controller integration time, for the purpose of achieving an optimum control
response to abrupt setpoint changes. In many process applications, it may be better to set
P228 = 0 so that the actual speed follows the process setpoint with less delay.

WARNING
During the speed controller optimization run, the motor is accelerated
at a maximum of 45% of its rated armature current. The motor may
reach speeds of up to approximately 20% of maximum speed.

If field weakening is selected (P081 = 1), or if closed-loop torque control (P170=1) or torque limiting
(P169=1) is selected or if a variable field current setpoint is applied the optimization run for field weakening
must be run:

P051 = 27 Optimization run for field weakening (process lasts approx. 1min).
The following parameters are set automatically: P117 to P139, P275 and P276.
Note:
In order to determine the magnetization characteristic, the field current setpoint is reduced
during the optimization run from 100% of the motor rated field current as set in P102 down
to a minimum of 8%. The field current setpoint is limited to a minimum according to P103 by
setting P103 to values < 50% of P102 for the duration of the run. This might be necessary in
the case of uncompensated motors with a very high armature reaction.
The magnetizing characteristic is approximated linearly to 0, starting from the measuring
point, at a minimum field current setpoint.
To execute this optimization run, the minimum motor field current, P103, must be
parameterized to less than 50% of the rated motor field current (P102).

WARNING
During this optimization run, the motor accelerates to approximately
80% of rated motor speed (the armature voltage corresponds to
maximum 80% of the rated motor armature voltage (P101)).

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P051 = 28 Optimization run for compensation of friction moment

and moment of inertia (if desired) (process lasts approx. 40s)

The following parameters are set automatically: P520 to P530, P540

WARNING

The motor accelerates up to maximum speed during this optimization

run.

On completion of this run, the friction and inertia moment compensation function must be
activated manually by setting P223=1.
When the operating mode is switched from current control to torque control with P170, the
optimization run for friction and inertia moment compensation must be repeated.
Note:
The speed controller may not be parameterized as a pure P controller or as a controller with
droop when this optimization run is executed.

8.5 At the end of the optimization run, P051 is displayed on the operator panel and the drive switches to
operating state o7.2.

NOTE
In the case of motors with a limited travel path, the optimization run for field weakening
(P051=27) may not be interrupted by the SHUTDOWN command until the 1st field weakening
measuring point has been plotted. Likewise, the optimization run for the friction moment and
moment of inertia compensation function (P051=28) may not be interrupted by SHUTDOWN until
the measuring point at 10% of maximum speed has been determined. Premature interruption in
both cases will lead to activation of fault message F052. When either of these optimization runs
is restarted (P051=27 or P051=28), it will be continued at a more advanced position. In this way,
the respective run can be completed in several stages, even if the travel path is limited.
Note:
The respective optimization run is executed completely after a restart if:
a) a fault message is activated during the optimization run
b) if the electronics supply is disconnected before the relevant optimization run is restarted
c) if another function data set than the one before is selected or
d) if another optimization run is started in-between.
The parameters of the function data set selected in each case are optimized.
While optimization runs are being executed, the function data set selection must not be changed
or else a fault message will be activated.

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NOTE
Optimization runs should be executed in the order listed above (precontrol and current controller,
speed controller, and field weakening control, friction moment and moment of inertial
compensation).
The determined parameters are dependent on the motor temperature. Values set automatically
when the motor is cold can be used as effective defaults.
For highly dynamic drives, the optimization runs P051=25 should be repeated after the drive has
been operated under load (i.e. when motor is warm).

Checking and possible fine adjustment of maximum speed

After the optimization runs have been executed, the maximum speed should be checked and if necessary
adjusted to its final value. If it is necessary to change the maximum speed setting by more than about 10%, the
control response of the speed control loop must be checked. It may be necessary to repeat the speed controller
optimization run or re-optimize the controller manually.

The optimization runs for field weakening and friction motor and moment of inertial compensation must be
repeated every time the maximum speed setting is changed.

9 Setting Application Functions

9.1 Starting the Drive

With factory defaults, the Base Drive Panel is automatically configured to enable the drive with terminal 38 at
X171 and to start the drive with terminal 37 also at connector X171. The function of these terminals is fixed.
With all other methods of starting the drive, terminals 37 and 38 act as permissive to start and must be
energized to allow the selected method to start the drive.

Alternatively, the drive can be configured to start from the CUD1 serial ports at connectors X300 or X172, and
from optional communication boards or serial port located on the optional CUD2 board.

If an alternative method of starting the drive is required, the source of the start command is selected with
parameter P654. The normal choices are:

Source of Start Command P654 =

Terminal 37 @ connector X171 (factory default setting) B0001

Serial Interface 1, X300, USS protocol, Word 1, Bit 0 B2100
Serial Interface 2, X172, USS protocol, Word 1, Bit 0 B6100
Technology Board or First Communication Board, Word 1, Bit 0 B3100
Second Communication Board, Word 1, Bit 0 B8100
Serial Interface 3, CUD2 X162, USS protocol, Word 1, Bit 0 B9100

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9.2 Speed Setpoint Selection

With factory defaults, the Base Drive Panel is automatically configured to get the speed reference from the main
setpoint analog input at terminals 4 and 5 on connector X174. The default scaling provides, +10 volts at
terminals 4 with respect to 5, equals 100% speed setpoint in the forward direction. If the input is -10 volts at
terminals 4 with respect to 5 then -100% speed setpoint in the reverse direction is provided.

Alternatively, the drive can be configured receive the speed setpoint from the CUD1 serial ports at connectors
X300 or X172, and from optional communication boards or serial port located on the optional CUD2 board.

If an alternative source of the speed setpoint is required, it can be set using parameter P433.
The normal choices are:

Source of Speed Setpoint P433 =

Main setpoint analog input (factory default setting) K0011

Serial Interface 1, X300, USS protocol, Word 2 K2002
Serial Interface 2, X172, USS protocol, Word 2 K6002
Technology Board or First Communication Board, Word 2 K3002
Second Communication Board, Word 2 K8002
Serial Interface 3, CUD2 X162, USS protocol, Word 2 K9002

The speed setpoint can come from many other sources such as other analog inputs, other words in the serial
protocols, MOP function, and other freely selectable function in the base drive software. The ultimate selection
of the setpoint source depends on the application requirements. To use any other source, locate the connector
number for the source and set P433 to that value.

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9.3 Jog (Inching) Configuration

If the unit is not already running, a JOG command can be given to the unit to cause it to start and run at a pre-
selected speed. When the JOG command is released the motor speed will come to zero and the unit will stop.
Up to 8 jog speeds can be configured. If positive reference values are used, the motor will jog forward while
negative reference values will jog the motor in reverse.

Sources for both the jog command and the jog setpoint need to be configured. The source of the Jog
commands is selected using parameter P435, however the first two, Jog1 and Jog2, can also be set from the
source selected with parameters P668 and P669 through the control word 1 bits 8 and 9.

The following tables show a few examples of how the Jog commands and setpoints can be configured. The
source of the command and setpoint are completely independent for maximum flexibility.

Source of Jog Command P435 = Value

Terminal 36 @ connector X171 = Jog 1 Index .01 B0010

Terminal 39 @ connector X171 = Jog 2 Index .02 B0016
Serial Interface 1, X300, USS protocol, Word 1, Bit 8 = Jog 3 Index .03 B2108
Serial Interface 2, X172, USS protocol, Word 1, Bit 9 = Jog 4 Index .04 B6109
Technology Board or First Communication Board, Word 1, Bit 4 = Jog 5 Index .05 B3104
Second Communication Board, Word 1, Bit 5 = Jog 6 Index .06 B8105
Serial Interface 3, CUD2 X162, USS protocol, Word 1, Bit 3 = Jog 7 Index .07 B9107

If more than one source is selected for the same command, then the command will be issued when either one
is issued. If more than one jog function is selected, then the selected jog setpoints are added together. This
feature allows the available jog speeds to be greatly expanded using various jog combinations.

Source of Jog Setpoint P436 = Value

Analog select Input 1, terminals 6 to 7 @ connector X174 = Jog 1 setpoint Index .01 K0015
Fixed Jog 2 setpoint from parameter P401 Index .02 K0401
Fixed Jog 3 setpoint from parameter P402 Index .03 K0402
Serial Interface 1, X300, USS protocol, Word 4 = Jog 4 Index .04 K2004
Serial Interface 2, X172, USS protocol, Word 5 = Jog 5 Index .05 K6005
Technology Board or First Communication Board, Word 3 = Jog 6 Index .06 K3003
Second Communication Board, Word 3 = Jog 7 Index .07 K8003
Serial Interface 3, CUD2 X162, USS protocol, Word 4 = Jog 8 Index .08 K9004

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10 Documentation of setting values

• Save the parameter values using either Quick Start or the DriveMonitor PC program
or
• Document parameters manually
If P052=0, only parameters that have been changed from the factory default are displayed. This makes it
relatively easy to record the changed parameters.

NOTE
In the factory setting several fault codes are masked out with P820 and must be enabled if required.

NOTE
The 1180 amp and 1660 units contain a three phase fan. Although the armature circuit is phase insensitive
a check must be made to insure that the airflow in these units is from bottom to top. If the fan direction is
incorrect, swap the L1 and L2 phase wiring at incoming supply once the unit has been de-energized. See
drawings on pages 7-12 and 7-13.

NOTE
If the fan unit on the 1180 amp and 1660 amp units become misaligned during shipment the fan housing
can be re-aligned by loosing the front two mounting screws and re-aligning.

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NOTES:

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9 Faults and alarms

When a fault or alarm message is activated, it is displayed both on the simple operator control panel
(PMU) and on the OP1S user-friendly operator control panel (see also Section 7.2, Operator control
panels).
An alarm stops being displayed immediately the cause of the alarm signal has been eliminated.
A fault message must be cancelled by pressing the P key on the PMU or Reset key on the OP1S
(panel must be in "Operational display" status) as soon as the cause has been eliminated.

NOTE
Setting parameters when fault or alarm message is active
On the PMU:
You can shift an active fault message or alarm "to the background" by pressing the P key and
Higher key simultaneously on the PMU.
If you do not press any key on the PMU within a 30 s period, the fault message or active alarm in
the background is automatically displayed again.
You can fetch a message back to the foreground earlier by pressing the P key and Lower key
simultaneously on the PMU when the parameter number level is selected.
On the OP1S:
You can set parameters normally even if a fault message or alarm is active.

9.1 Fault messages

9.1.1 General information about faults

Fault message display:
On the PMU: F (fault) and a three-digit number. The red LED (Fault) lights up.
On the OP1S: On bottom line of operational display: The red LED (Fault) lights up.
Only one current fault message can be displayed at a time, i.e. other simultaneously active faults are
ignored.
Many fault messages (see List of Fault Messages) can only be active in certain operating states.

The system responses to a fault are as follows:

• The armature current is reduced, the firing pulses are disabled and the SIMOREG unit switches to
operating state o11.0 (fault)
• Fault message is displayed on the operator panel (PMU, OP1S)
• B0106 ( = status word 1, bit 3) is set and B0107 cancelled (see also alarm bits for special faults
such as undervoltage, overtemperature, external faults, etc.)
• Parameters
r047 (fault diagnostic memory)
r049 (fault time)
r947 (fault memory, see also r947 in Section 11, Parameter List)
r949 (fault value)
P952 (number of faults)
are updated

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A text is also displayed for each individual fault in parameter r951 (fault text list). These texts can, for
example, be displayed on the OP1S.
If a fault is not acknowledged before the electronics supply voltage is switched off, then fault message
F040 will be displayed when the supply is next switched on.

9.1.2 List of fault messages

NOTE
Further information about the causes of fault messages
When a fault message is activated, values providing more information about the fault cause are
stored in parameter r047. Where the values can be interpreted by the user, they are included in
the following list of fault messages.
The value in r047.001 is referred to as the "fault value". This is also stored in r949 which also
contains the fault values belonging to older fault messages. The values in r047 are overwritten
when the next fault message occurs.
Values for r047 which are not included in the list below can help a SIEMENS specialist to locate a
fault cause. For this reason, all indices of parameter r047 should be read out whenever a fault
message occurs, even if the meaning of the individual indices of parameter r047 is not specified
for every fault message listed below.
Please note: Before you contact SIEMENS with any query regarding a fault message, please
make a note of the contents of all indices of parameter r047.

Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

9.1.2.1 Supply faults

F001 Failure of electronics power supply
(active in all operating states)

Failure of the electronics supply voltage (terminals 5U1, 5W1, 5N1) in “RUN” state for longer than the “restart” time set in
parameter P086 or the electronics are operating on undervoltage.

Possible fault causes:

• Line contactor has opened in “RUN” state
• Brief supply failure
• Supply voltage too low

Fault value: r047 Index 002 to 016:

1 Electronics supply voltage in “RUN” has been interrupted i002 Duration of actual supply failure in 1/10 seconds
for longer than setting in P086
2 Supply failure prewarning responds periodically -
3 Supply failure prewarning is active for longer than 1.28 s -

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

F004 Phase failure in armature supply

(active in operating states of ≤ o4)

The supply voltage RMS value, calculated from the area of each supply half-wave (rectified average value * peak factor), must be
greater than the response value for phase failure monitoring
P353
P078.001 ∗
100%
The distance between two identical supply zero passages of a phase must not exceed 450 degrees.
If one of these two conditions remains unfulfilled for longer than the “restart time” set in P086, a fault message is activated.
After switch-on, the converter waits in operating states o4 and o5 together for a period not exceeding the setting in P089 for
voltage to appear at the power terminals (and for field current) before activating the fault message.

Possible fault causes:

• Parameter P353 is incorrectly set
• Armature phase has failed
• Line contactor opened in operation
• Fuse has blown on three-phase side in armature circuit
• Fuse has blown in power section
• Interruption in a thyristor firing pulse cable (auxiliary cathodes at connectors X12, X14, X16 are voltage carriers).

Fault value:
1 Voltage failure has occurred in armature supply (1U1, 1V1, 1W1) (when P086=0)
2 Delay time set in parameter P089 has expired in operating state o4
3 Fuse has blown in power section
4 Voltage failure has lasted longer than period set in P086 (if this is >0)
6 The "Main contactor checkback" (control word 2 bit 31) [see also P691] did not switch to "1" before the time set in P095 ran
out, or switched back to "0" during operation [V1.8 and later].
F005 Fault in the field circuit
(active in operating states of ≤ o5)

The line voltage RMS value calculated from the area of each network half-wave (rectification average value * peak factor) must
be greater than the response value for phase failure monitoring
P353
P078.002 ∗
100%
The distance between two identical network zero passages of the voltage for the field converter must not exceed 450 degrees.
The actual field current K0265 equals < 50% of the required field current setpoint K0268 for more than 500ms. This monitoring
function is effective only if the field current setpoint corresponds to >2% of the converter rated field current.
[In SW 1.9 and later, the percentage (50%) and time (500ms) can be altered in P396 and P397 respectively]
If one of the fault conditions described persists in operation (or ≤ o4) for longer than the “restart” time set in P086, the fault
message is output.
After the converter is switched on, it waits in operating state o5 for a period not exceeding the setting in P089 for the field supply
voltage or sufficiently high field current before this fault message is activated.
Monitoring for timeout as the field decays or builds up after initiation of field reversal (fault values 6 and 7) is not implemented
until SW 1.7 and later.

Possible fault causes

• Threshold for phase failure (P353) set incorrectly
• Field phase failed
• Line contactor opened during operation
• Fuse blown in the field circuit
• Field current controller and/or field current precontrol not optimized or badly optimized (check P112, P253 to P256; possibly
execute current controller optimization)
• Check P396 (field current monitoring threshold) and P397 (field current monitoring time)
• If the fault value is 6: Offset fault in the actual field current value sensing, relevant parameter: P825.i01-i03 (Offset depends
on P076.i02) or P394, P395 (Threshold and hysteresis for message I_field < I_field_min) must be checked
• If the fault value is 7: Circuit for the "new" field direction is interrupted (e.g. because the contactor for "new" field direction
does not pick up), P398, P399 (Threshold and hysteresis for message I_field < I_field_x) must be checked

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

Fault value:
1 Voltage failure occurred in the field supply (terminals 3U1 and 3W1) (if P086 = 0)
2 Delay time according to P089 elapsed in state o5.1 (waiting for voltage at the field power section)
3 Delay time according to P089 elapsed in state o5.0
(waiting until Ifield act (K0265) is > 50% of the instantaneous field current setpoint K0268)
[threshold settable in P396 as of SW 1.9]
4 After P086 > 0 has elapsed (time for automatic restart) in operating state ≤ o4:
Voltage failure in the field supply or Ifield act (K0265) < 50% Ifield set (K0268) for longer than 500 ms
[settable via P396 and P397 as of SW 1.9]
5 When P086 = 0 (no automatic restart) in operating state ≤ o4:
Ifield act (K0265) < 50% Ifield set (K0268) for longer than 500 ms
[settable via P396 and P397 as of SW 1.9]
6 If field reduction before field reversal, I_field ≤ I_field_min (P394) is not reached within 30 s
7 If field build-up after field reversal, I_field > I_field_x (P398) is not reached within 30 s
F006 Undervoltage
(active in operating states of ≤ o4)

The voltage at terminals 1U1, 1V1 or 1W1 and 3U1, 3W1 is lower than the response threshold for longer than the “restart time”
set in P086.

Response threshold for armature supply voltage:

P351
P078.001 ∗ (1+ )
100%
Response threshold for field supply voltage:
P351
P078.002 ∗ (1+ )
100%
Possible fault causes
• Line undervoltage
• Monitoring values set too sensitively or incorrectly (P351, P078)

Fault value: r047 Index 002 to 016:

1 Undervoltage has occured i002 Number of phase that has activated fault message
0 ... Phase UV
1 ... Phase VW
2 ... Phase WU
3 ... Phase field
i003 Incorrect voltage value (normalized to 16384)
4 Undervoltage persists for longer than time set in -
parameter P086 (if this is set to >0)
F007 Overvoltage
(active in operating states of ≤ o4)

The voltage at terminals 1U1, 1V1 or 1W1 and 3U1, 3W1 is higher than the response threshold (for longer than the “restart time”
set in P086).

Response threshold for armature supply voltage:

P352
P078.001 ∗ (1+ )
100%
Response threshold for field supply voltage:
P352
P078.002 ∗ (1+ )
100%
Possible fault causes
• Line overvoltage
• Monitoring values set too sensitively or incorrectly (P352, P078)

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

NOTE
This monitoring function is deactivated in the delivery state. It can be activated via parameter P820.
Fault value: r047 Index 002 to 016:
1 Overvoltage has occurred 002 Number of phase that has activated fault message
0 ... Phase UV
1 ... Phase VW
2 ... Phase WU
3 ... Phase field
i003 Incorrect voltage value (normalized to 16384)
4 Undervoltage persists for longer than time set in -
parameter P086 (if this is >0)
F008 Line frequency less than the minimum line frequency acc. to parameter P363
(active in operating states of ≤ o5)

This fault message is activated if the line frequency is less than the minimum line frequency (for longer than the “restart time” set
in parameter P086).

Note: Up to software version 1.7 the threshold for activation of the fault message (minimum line frequency) is 45Hz.

Fault value:
1 Frequency of the armature supply < minimum line frequency
2 Frequency of the field supply < minimum line frequency
4 Line frequency less than the minimum line frequency for longer than set in parameter P086 (if >0)
F009 Line frequency greater than the maximum line frequency acc. to parameter P364
(active in operating states of ≤ o5)

This fault message is activated if the line frequency is greater than the maximum line frequency (for longer than the “restart time”
set in parameter P086).

Note: Up to software version 1.7 the threshold for activation of the fault message (maximum line frequency) is 65Hz

Fault value:
1 Frequency of the armature supply > maximum line frequency
2 Frequency of the field supply > maximum line frequency
4 Line frequency greater than the maximum line frequency for longer than set in parameter P086 (if >0)

9.1.2.2 Interface error

F011 Telegram failure at GSST1

when P780 = 2:
USS telegram failure at G-SST1
(active from the first receipt of a valid protocol in all operating states)

After the receipt of the first valid protocol, no further telegrams have been received within the time period set in parameter P787.

Possible fault causes

• Cable break
• Error in USS master

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

F012 Telegram failure at GSST2

when P790 = 2:
USS telegram failure at G-SST2
(active from the first receipt of a valid protocol in all operating states)

After the receipt of the first valid protocol, no further telegrams have been received within the time period set in parameter P797.

Possible fault causes

• Cable break
• Error in USS master

when P790 = 4 or 5 and P798 = 32 or 33:

Peer-to-peer telegram failure at G-SST2
(active in operating states of ≤ o6)

After the receipt of the first valid protocol, no further telegrams have been received within the time period set in parameter P797.

Possible fault causes

• Interruption in connecting cable
• EMC interference on connecting cable
• P797 is set too low
F013 Telegram failure at GSST3

when P800 = 2 and P808 = 32 or 33:

USS telegram failure to G-SST3
(active from the first receipt of a valid protocol in all operating states)

After the receipt of the first valid protocol, no further telegrams have been received within the time period set in parameter P807.

Possible fault causes

• Cable break
• Error in USS master

when P800 = 4 or 5:
Peer-to-peer telegram failure at G-SST3
(active in operating states of ≤ o6)

After the receipt of the first valid protocol, no further telegrams have been received within the time period set in parameter P807.

Possible fault causes

• Interruption in connecting cable
• EMC interference on connecting cable
• P807 is set too low
F014 Telegram failure at paralleling interface
(active when U800 = 1 or 2 from the first receipt of a valid protocol in all operating states)

After the receipt of the first valid protocol, no further telegrams have been received within the time period set in parameter U807.

Possible fault causes

• Interruption in connecting cable
• EMC interference on connecting cable
• U807 is set too low

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

F015 Telegram failure on one SIMOLINK board

(active when U741 > 0 as soon as the first valid telegram is received)

After receipt of one valid telegram, no further valid telegrams have arrived within the period set in parameter U741.

Possible fault causes

• Break in connecting cable
• Parameter setting change during telegram exchange (for parameters see Section 11 "Configuration of SIMOLINK board)
• U741 is set to low

Fault value:
st
1 Telegram failure on 1 SLB
2 Reserved
F016 Hardware fault on expansion board EB1

Fault value:
1 Fault on first EB1
2 Fault on second EB1
F017 Hardware fault on expansion board EB2

Fault value:
1 Fault on first EB2
2 Fault on second EB2
F018 Short circuit or overloading of binary outputs
(active in all operating states)

Possible fault causes

• Short circuit or overload at terminals 46, 48, 50 or 52 and 26 or 34

Fault value: r047 Index 002 to 016:

1 Short circuit or overload at binary outputs i002 Bit 8 = 1: Overload at terminal 46
Bit 9 = 1: Overload at terminal 48
Bit 10 = 1: Overload at terminal 50
Bit 11 = 1: Overload at terminal 52
Bit 12 = 1: Overload at terminal 26 (24 V output)
Bit 13 = 1: Overload at terminal 34, 44 and/or 210
(24 V output)

NOTICE
This monitoring function is deactivated in the delivery state. It can be activated via parameter P820.

9.1.2.3 External faults

F019 Fault message from free function block FB286
(active in all operating states)

Fault value:
1 the binector wired via parameter U100 Index.005 is in the state log.”1”
2 the binector wired via parameter U100 Index.006 is in the state log.”1”
3 the binector wired via parameter U100 Index.007 is in the state log.”1”
4 the binector wired via parameter U100 Index.008 is in the state log.”1”
F020 Fault message from free function block FB287
(active in all operating states)

Fault value:
1 the binector wired via parameter U101 Index.005 is in the state log.”1”
2 the binector wired via parameter U101 Index.006 is in the state log.”1”
3 the binector wired via parameter U101 Index.007 is in the state log.”1”
4 the binector wired via parameter U101 Index.008 is in the state log.”1”

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

F021 External fault 1

(active in all operating states)

Bit 15 in control word 1 was in the log. "0" state for longer than the time set in P360 index 001
F022 External fault 2
(active in all operating states)

Bit 26 in control word 2 was in the log. "0" state for longer than the time set in P360 index 002
F023 Fault message from free function block FB2
(active in all operating states)

Fault value:
1 the binector wired via parameter U100 Index.001 is in the state log.”1”
2 the binector wired via parameter U100 Index.002 is in the state log.”1”
3 the binector wired via parameter U100 Index.003 is in the state log.”1”
4 the binector wired via parameter U100 Index.004 is in the state log.”1”
F024 Fault message from free function block FB3
(active in all operating states)

Fault value:
1 the binector wired via parameter U101 Index.001 is in the state log.”1”
2 the binector wired via parameter U101 Index.002 is in the state log.”1”
3 the binector wired via parameter U101 Index.003 is in the state log.”1”
4 the binector wired via parameter U101 Index.004 is in the state log.”1”

9.1.2.4 Fault messages from motor sensors

F025 Brush length too short
(active in operating states of ≤ o3)

When parameter P495=2 (binary sensing of brush length), fault message at log.”0” signal (longer than 10s) at terminal 211

Possible fault causes

• Encoder for brush length has responded
• Open circuit in encoder cable
F026 Bearings in bad condition
(active in operating states of ≤ o6)

When parameter P496=2 (bearing condition sensing) fault message at log. “1” signal (longer than 2 s) at terminal 212

Possible fault causes

• Encoder for bearing condition has responded
F027 Air-flow monitoring of motor fan
(active in operating states of < o6)

When parameter P497=2 (air-flow monitoring), fault message at log ”0” signal (longer than 40s) at terminal 213

Possible fault causes

• Encoder for fan monitoring has responded
• Open circuit in encoder cable
F028 Motor overtemperature
(active in operating states of ≤ o6)

When parameter P498=2 (thermostat connected), fault message at log. “0” signal (longer than 10s) at terminal 214

Possible fault causes

• Thermostat for monitoring motor temperature has responded
• Open circuit in encoder cable

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

F029 Motor overtemperature

(active in all operating states)

Select via P493=2 or 3 (temperature sensor at terminals 22 / 23) or

P494=2 or 3 (temperature sensor at terminals 204 / 205)

When parameter P490.01=1 (KTY84 at terminals 22 / 23) or P490.02=1 (KTY84 at terminals 204 / 205):
The fault message is activated if the motor temperature reaches or exceeds the value set in parameter P492.

When parameter P490.01=2, 3, 4 or 5 (PTC thermistor at terminals 22 / 23) or P490.02=2, 3, 4 or 5 (PTC thermistor at terminals
204/ 205):
The fault message is activated if the motor temperature reaches or exceeds the response value of the selected PTC thermistor.
Fault value:
1 Fault activation through temperature sensor at terminals 22 / 23
2 Fault activation through temperature sensor at terminals 204 / 205

9.1.2.5 Drive faults

NOTICE
The monitoring functions F031, F035, F36 and F037 are deactivated in the delivery state.
They can be activated via parameter P820.
F031 Speed controller monitoring
(active in operating states of – –, I, II)

The monitor responds when the difference between the connectors selected in P590 and P591 (factory setting: Setpoint/actual
value difference of speed controller) exceeds the limit set in parameter P388 for longer than the time set in parameter P390.

Possible fault causes

• Open control loop
• Controller not optimized
• P590 or P591 is not correctly parameterized

9.1.2.6 External faults

F033 Fault message from free function block FB4
(active in all operating states)

Fault value:
1 the binector wired via parameter U102 Index.001 is in the state log.”1”
2 the binector wired via parameter U102 Index.002 is in the state log.”1”
3 the binector wired via parameter U102 Index.003 is in the state log.”1”
4 the binector wired via parameter U102 Index.004 is in the state log.”1”
F034 Fault message from free function block FB5
(active in all operating states)

Fault value:
1 the binector wired via parameter U103 Index.001 is in the state log.”1”
2 the binector wired via parameter U103 Index.002 is in the state log.”1”
3 the binector wired via parameter U103 Index.003 is in the state log.”1”
4 the binector wired via parameter U103 Index.004 is in the state log.”1”

9.1.2.7 Drive faults

F035 Drive is blocked
(active in operating states of – –, I, II)

This monitoring function responds if the following conditions are fulfilled for longer than the period set in parameter P355:
• Positive or negative torque or armature current limit
• The armature current is higher than 1% of the converter rated armature DC current
• The actual speed is less than 0.4% of maximum speed

Possible fault causes

• Drive is blocked

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

F036 No armature current is flowing

(active in operating states of – –, I, II)

This monitoring function responds if the armature firing angle is at the rectifier stability limit for more than 500 ms and the
armature current is less than 1% of the converter rated armature DC current.

Possible fault causes

• Armature circuit is open
(e.g. DC fuses have blown, open circuit, etc.)
• Rectifier stability limit αG (P150) is incorrectly set
• Drive is operating at αG limit (e.g. due to supply undervoltag)
• EMF is too high because maximum speed setting is too high,
refer to P083, P115, P143, P741)
• EMF is too high because field weakening is not selected (refer to P082)
• EMF is too high because field current is set too high (refer to P102)
• EMF is too high because transition speed for field weakening is set too high (refer to P101) ??
F037 I2t motor monitor has responded
(active in operating states of – –, I, II)

This monitoring function responds when an I2t value is reached which corresponds to the final temperature at 110% of the rated
motor armature current.

Possible fault causes

• Parameter P114 is incorrectly set
• Drive has been operating for too long at >110% of rated motor armature current
F038 Overspeed
(active in operating states of – –, I, II)

This fault message is activated if the actual speed value (selected in P595) exceeds the positive (P380) or negative (P381)
threshold by 0.5%.

Possible fault causes

• Lower current limit has been input
• Current-controlled operation
• P512, P513 are set too low
• Tachometer cable contact fault in operation close to maximum speed
F039 I2t power section monitor has responded
(active in operating states of – –, I, II)

This monitoring function responds if the calculated I2t value of the power section reaches the permissible value for the power
section concerned (see also P075).

Possible fault causes

• Drive has been operating at overload for too long
• Parameter P075 is incorrectly set
• Parameter P077 is incorrectly set

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

F040 Electronics supply disconnected in active fault status

(active in all operating states)

This fault message is activated if the electronics power supply has been disconnected, even though a fault was displayed and not
yet acknowledged.

Possible fault causes

• Not all fault messages have been acknowledged

Fault value:
Last active fault message
F041 Ambiguous selection of parameter set or ramp-function generator
(active in all operating states)

• While an optimization run is in progress, the funtion data set selection must not be changed. Fault F041 is displayed if
another, different function data set is selected while an optimization run is being executed.

• Check whether ramp-function generator parameter set 1 or 2 or 3 (parameters P303 to P314) is clearly selected. If parameter
sets 2 and 3 are selected simultaneously for more than 0.5s, then fault message F041 is displayed. While the parameter set
selection is ambiguous, the system continues to apply the last clearly identified ramp-function generator parameters.

Possible fault causes

• P676 or P677 (selection of binectors which determine the active function data set in control word 2, bits 16 and 17) is
incorrectly set
• P637 or P638 (selection of binectors which determine ramp-function generator setting) is incorrectly set

Fault value:
2 The selection of the function data set has been changed during an optimization run
3 Ambiguous selection of ramp-function generator parameter set

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

F042 Tachometer fault

(active in operating states of – –, I, II)

Actual speed (K0179)

A check is performed every 20ms to ensure that is > +5%
Actual EMF (K0287)

If the check result is incorrect for 4 times in succession, the fault message is activated.

The following rule applies:

100% actual speed = maximum speed
100% actual EMF = ideal average DC voltage at α ≥ 0, i.e. when the thyristor bridge is fully gated

3∗ 2
The ideal DC voltage average value at α = 0 is P078.001 ∗
π
3∗ 2
The monitoring function is effective only if the EMF > a % of P078.001 ∗
π
"a" is a percentage that can be set in parameter P357 (default setting 10%).
The monitoring function is effective only if the armature current is > 2% of the converter rated DC current set in r072.002.

Possible fault causes

• Open circuit in tachometer or pulse encoder cable.
• Tachometer of pulse encoder cable incorrectly connected.
• Pulse encoder supply has failed.
• Polarity for actual speed value (P743) is incorrectly set.
• Armature circuit data (P110 und P111) are incorrectly set (execute current controller optimization run).
• Tachometer or pulse encoder defective
• Pulse encoder supply voltage is incorrectly set (P140)
• The field polarity is not reversed by the external hardware when the field is reversed.

Fault value: r047 Index 002 to 016:

1 Open circuit in tachometer or pulse encoder cable i002 Actual speed value (K0179) in case of fault
2 Polarity of tachometer or pulse encoder is incorrect i003 Actual EMF value (K0287) in case of fault
F043 EMF too high for braking operation
(active in operating states of – –, I, II)

This fault message is activated if the following 5 conditions are fulfilled when a torque direction reversal is requested (selection of
MI or MII):
• P272=0 (fault message is parameterized and not alarm + field weakening)
• A parameterized, additional, torque-free interval (P160 ≠ 0) has expired
• Parallel drive is ready for engagement of the new torque direction
• The absolute value of the armature current (K0118) requested in the new torque direction is >0.5% of P072
• The calculated firing angle (K0101) for the armature current requested for the new torque direction is >165 degrees.

Possible fault causes

• No “speed-dependent field weakening" (P081=0) is parameterized even though operation in the field weakening range is
needed for the requested maximum speed
Note:
In motor operation, it is possible to reach EMF values corresponding to the peak of the phase-to-phase supply voltage at a
firing angle of αG=30° (rectifier stability limit P150) and low armature currents.
• Setpoint EMF for field weakening operation too high (parameter P101 is set too high)
• Supply voltage dip
• EMF controller or field current controller is not optimized, possibly resulting in excessive EMF on power-up.

Fault value: r047 Index 002 to 016:

Calculated firing angle (armature) before limitation (K0101) i002 Instantaneously measured actual EMF (K0287)
i003 Armature current controller setpoint (K0118)
F044 A slave connected to the paralleling interface is not operating
(active when U800 = 1 or 2 and U806>10 (master) after receipt of the first valid protocol in operating states – –, I, II)

Fault value:
1 A fault message is active on a slave
2 A slave is not in operation (e.g. because its enable input is set to "0")

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

F046 Analog select input for main setpoint (terminals 4 and 5) faulty
(active in operating states of ≤ o6)

This fault message is activated when P700=2 (current input 4 to 20 mA) and an input current of less than 2mA is flowing.

Possible fault causes

• Open circuit in supply cable
• P700 is incorrectly set
F047 Analog select input 1 (terminals 6 and 7) is faulty
(active in operating states of ≤ o6)

This fault message is activated when P710=2 (current input 4 to 20 mA) and an input current of less than 2mA is flowing.

Possible fault causes

• Open circuit in supply cable
• P710 is incorrectly set
F048 Fault in measuring channel for digital speed sensing using pulse encoder
(active in all operating states)

1. Disturbances on encoder cables:

Faults on the encoder cables (transitions to 0 with a 1 signal or to 1 with a 0 signal) are signalled as a rotational direction change
by the evaluation circuit. Frequent changes in rotational direction can occur only at speeds around 0.
The fault message is activated if 10 consecutive pulse encoder signal evaluations identify “direction of rotation change” at a
speed of ≥ 48 rev/min and an EMF > threshold (see below).

2. Pulse encoder defective:

The fault message is activated if, at an EMF > threshold (see below) 10 consecutive pulse encoder signal evaluations identify
“implausible charracteristics” of these signals (i.e. frequent rotational direction changes, edges too close together, failure of an
encoder cable or short circuit between two encoder cables).

Possible fault causes

• EMC-related interference on a pulse encoder signal (terminals 28 to 31)
• Pulse encoder defective
• Interruption in an encoder cable
• Short circuit between an encoder cable and the supply voltage or another encoder cable
• P110 or P111 is incorrectly set (resulting in incorrectly calculation of EMF)

Note:
When the speed encoder is operating correctly, signal sequences, which are characteristic of a faulty pulse encoder or
disturbances on the pulse encoder cables, may occur continuously at the input terminals (e.g. continuous changes in rotational
direction or short pulse intervals) at about 0 speed, e.g. as the result of slight oscillation around a bright/dark transition on the
speed encoder disk).
3∗ 2
For this reason, fault F048 is not activuated until the EMF > 10% of P078.001 ∗ .
π

Fault value:
1 Disturbances on encoder cables
2 Defective pulse encoder

9.1.2.8 Start-up faults

F050 Optimization run not possible
(active in all operating states)

A fault has occurred during an optimization run.

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

NOTE
The contents of r047, Index 002 to 016, can provide specialists with more detailed information about fault causes. For this
reason, please read out and document all the indices associated with this fault and pass them on when you contact Siemens for
help.
Fault value:
1 Armature current is too low when α=30° and EMF=0.
(average armature current <75% of IA, motor or <75% of IA, rated)
Possible cause:
• Armature circuit interrupted
• High-resistance load
• P150 (Alpha G limit) has been set to excessively high value

2 It was not possible to determine the armature circuit resistance (P110) because the armature current was ≥ 37.5 % of P100
in fewer than 20 of the 150 firing cycles of the measuring phase.
Possible cause:
•Armature current of 37.5% of P100 (I A, motor) is no longer possible (although a current of 75% of P100 was already
flowing, maybe a fuse has blown).

3 Armature current peaks are too small at α=30° and EMF=0

(armature current peak value <50% of IA, motor or <50% of IA,rated)
Possible cause:
• Armature circuit inductance is too high (field supply from armature terminals)
• P150 (Alpha G limit) has been set to excessively high value
Possible remedy:
• Reduce P100 (IA,motor) while this optimization run is in progress

4 The armature circuit inductance (P111) cannot be determined from the sampled values of the armature current and line
voltage of the armature current crest last generated
Possible cause:
•P100 (IA,motor) or r072.i002 (IA,rated) very much smaller than actual motor rated current of the armature
•LA >327.67mH (armature circuit inductance too large)
•P100 (IA,motor) very much smaller than r072.i002 (IA,rated)
•Armature circuit short-circuited

5 Offset adjustment of actual field current sensing is not possible

(value detected for P825 is outside permissible value range)
Possible cause:
• Fault in actual field current sensing circuit
(defective A7004 gating board or A7001 electronics board)

7 The field circuit resistance (P112) is indeterminable

(the actual field current does not reach the internally specified setpoint of 95% of P102 as a result of P112 variation)
Possible cause:
• RA >3276.7Ω
• Fault in actual field current sensing circuit (defective gating board or A7001 electronics board)
• The command “Inject standstill field” is applied
• P102 is set too high
• A thyristor in the field bridge is not firing

8 80% of rated EMF (K287=P101 – P100 * P110) cannot be reached within 15s (or maximum of the three set acceleration
times)
Possible cause:
• Acceleration time (P303, P307, P311) is set too low
• P101 does not match the set maximum speed (UA at nmax < P101) or setting for P102 is too low
• The command “Ramp-function generator enable”=0 or ”Ramp-function generator stop”=1

9 Field current control loop is not stable enough to record field characteristics
(30s after injection of internal field current setpoint, actual field current is deviating by more than (0.39% of P102 + 0.15 %
of r073.002) from the setpoint)
Possible cause:
• Field current controller or field current precontrol is not optimized or optimized badly (check P112, P253 to P256 or
execute a current controller optimization run (P051=25))

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

10 Field characteristic is not uniform

(i.e. in spite of field current setpoint reduction, the flux values of this measuring point calculated from EMF and actual speed
are rising)
Possible cause:
• High armature reaction and sharp load variations during recording of field characteristics
• Field current controller or field current precontrol is not optimized or optimized badly (check P112, P253 to P256 or
execute a current controller optimization run (P051=25))

11 A lower field current limit of ≥ 50% of P102 (IF,motor) is applied

(for this reason, it is not possible to plot a minimum of 9 field weakening measuring points)
Possible cause:
• P103 ≥ 50% of P102
Check P614 !

12 The drive has reached the positive torque limit even though the applied field current setpoint is still ≥ 50% of P102
(IF,motor)
Possible cause:
• Armature current is very “unsteady”, e.g. due to high speed controller P gain setting in P225 (on drive with high integral-
action time). In this case, setting a lower actual speed filtering value in P200 and execution of another speed controller
optimization run (P051=26) may help.
• Check torque limits

13 The drive has reached the positive armature current limit even through the applied field current setpoint is still ≥ 50% of
P102 (IF,motor)
Possible cause:
• Armature current is very “unsteady”, e.g. due to high speed controller P gain setting in P225 (on drive with high integral-
action time). In this case, setting a lower actual speed filtering value in P200 and execution of another speed controller
optimization run (P051=26) may help
• Check armature current limits

14 The speed has changed by more than 12.5% at a constant speed setpoint even through the applied field current setpoint is
still ≥ 50% of P102 (IF,motor)
Possible cause: as for fault value 12

15 The EMF setpoint is too small to plot a field characteristic

EMFset = UA – IA,motor * RA = P101 – P100 * P110 < 10% of 1.35 * P078.i001
(e.g. P078.i001 = 400 V . . . minimum EMFset = 54 V)

16 Field weakening operation is not allowed in operation without a tachometer (P083=3)

17 The field current controller cannot be optimized because the field circuit time constant cannot be determined (actual field
current does not decay after switch-off to below 0.95*initial value within approximately 1s or to below 0.8 * 0.95*initial
values within approximately 2 s)
Possible cause:
• Setting in P103 is too high
• Field circuit inductance is too high
• Fault in actual field current sensing circuit (gating board or A7001 electronics board defective)
• Ratio r073.02 / P102 is too high (change P076.02 if necessary)

18 Field weakening range is too wide, i.e. during power-up (at full field) to a speed setpoint of +10% nmax , the |EMK| is > 77%
of setpoint EMF (P101 – P100 * P110)
Possible cause:
• Maximum speed setting is incorrect
• Pulse encoder parameters are incorrect (P140 to P143)
• Parameters for tachometer adaptation are incorrect (P741)
• Setpoint EMF is not correct (P101, P100, P110)
• An excessively high load torque (in positive or negative direction, e.g. a suspended load) causes the drive to rotate, one
of the armature current or torque limits may be parameterized too low

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

19 A steady-state actual speed of +10%, +20%, +30% . . . or +100% of the maximum speed cannot be reached within 3
minutes (or maximum value of the three set acceleration times) in speed-controlled operation (the speed setpoint/actual
value difference averaged over 90 firing cycles must equal <0.1% nmax for a specific time period)
Possible cause:
• Acceleration time is set too low (P303, P307, P311)
• Drive is blocked
• An excessively high load torque (in positive or negative direction, e.g. a suspended load) causes the drive to rotate, one
of the armature current or torque limits may be parameterized too low
• Poor speed controller setting (P225, P226, P228) or speed controller is parameterized as pure P controller or with
droop
• A band elimination filter (P201, P202 or P203, P204) is active
• Command “Ramp-function generator enable” =0 or ”Ramp-function generator STOP” =1 is applied

20 Current limit is too low

(With speed controller optimization run: Less than 30% or 45% of P100 (IA,motor) + the armature current required for zero
speed,
With optimization run for friction moment and moment of inertia compensation: Less than 20% of P100 (IA, motor) + the
armature current required for a steady-state speed corresponding to 10% of maximum speed)

21 Field weakening range is too wide (nact < +7% nmax produces |EMF| > 54% setpoint EMF)
(setpoint EMF= K289= P101 – P100 * P110)
Possible cause:
• Maximum speed setting is incorrect
• Pulse encoder parameters are incorrect (P140 to P143)
• Parameters for tachometer adaptation are incorrect (P741)
• Setpoint EMF is not correct (P101, P100, P110)
• Caution:
Even a high absolute negative actual speed value can produce an | EMF | of > 54% setpoint EMF

22 With speed controller optimization run:

With an acceleration current equalling 20% or 30% of P100 (IA, motor) + armature current required for zero speed or
With optimization run for friction moment and moment of inertia compensation:
With an acceleration current equalling the current required to achieve a steady-state speed of 10% of maximum speed +
20% of P100 (IA, motor), the maximum speed cannot be reached within 45s +7%
Possible cause:
• Centrifugal mass is too large
• Drive is blocked, heavily speed-dependent or excessively high load torque
• “Active” load is attempting to maintain a certain speed
Possible remedy:
• Increase P100 while the optimization run is in progress in order to raise the applied acceleration current during
optimization (during the speed controller optimization run, a maximum of 45% of IA, motor (+ armature current for zero
speed) is applied as the armature current setpoint, IA,motor (P100) can thus be increased to 2.2 times the value at
maximum without exceeding 100% IA, motor during optimization)

23 With speed controller optimization run:

With an acceleration current equalling 20% or 30% of P100 (IA, motor) + armature current required for zero speed or
With optimization run for friction moment and moment of inertia compensation:
With an acceleration current equalling the current required to achieve a steady-state speed of 10% of maximum speed +
20% of P100 (IA, motor), the maximum speed or 100% of setpoint EMF cannot be reached within 90s +13%
Possible cause:
• Flywheel mass is too large
• Drive is blocked, heavily speed-dependent or excessively high load torque
• “Active” load is attempting to maintain a certain speed
Possible remedy:
• Increase P100 while the optimization run is in progress in order to raise the applied acceleration current during
optimization (during the speed controller optimization run, a maximum of 45% of IA, motor (+ armature current for zero
speed) is applied as the armature current setpoint, IA,motor (P100) can thus be increased to 2.2 times the value at
maximum without exceeding 100% IA, motor during optimization)

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

24 With speed controller optimization run:

The actual speed does not drop to below +2% of maximum speed or to below the speed threshold nmin set in P370 within 2
minutes
With optimization run for field weakening:
The actual speed does not drop to below +2% of maximum speed or to below the speed threshold nmin set in P370 within
10 minutes
With optimization run for friction moment and moment of inertia compensation:
The actual speed does not drop to below +2% of maximum speed or to below the speed threshold nmin set in P370 within
11 or 2 minutes
Possible cause:
• Single-quadrant drive coasts to a standstill too slowly

25 The average armature current required for the speed range from +7% to approximately +13% of maximum speed to cover
the friction and/or steady-state load torque cannot be calculated
Possible cause:
• Drive with very little friction or very small integral-action time and, as a result of the very short measuring time,
computational inaccuracies during evaluation
• Distorted or disturbed actual speed value
• Large flywheel mass that is coupled to the drive via long shaft with high torsion, possibly via a
coupling with large amount of play
Possible remedy:
• Reduce P100 for duration of the optimization run to decrease the acceleration current applied during optimization and
thus to lengthen the measuring time

26 Load torque too high (nset =0% nmax results in nict ≥ 40% nmax) (actual speed value is averaged over 90 firing cycles,
speed monitoring at ≥ 40% nmax does not start for 1s after application of speed setpoint of nset=0)
Possible cause:
• An excessively high load torque (in a positive or negative direction, e.g. suspended load) causes the drive to rotate (the
speed controller parameters are parameterized according to the factory setting during this run)
• One of the armature current or torque limits is parameterized too low (the motor field may not be reaching full field
strength fast enough with the result that the initial motor torque is too low)
• Maximum speed setting is incorrect
• Pulse encoder parameters are incorrect (P140 to P143)
• Parameters for tachometer adjustment are not correct (P741)

27 Load torque is too high (nset=0% nmax results in |EMF| >100% setpoint EMF) (EMF monitoring at ≥ (P101 – P100 * P110)
does not start for 1 s after application of speed setpoint of nset=0)
Possible cause:
• An excessively high load torque (in a positive or negative direction, e.g. suspended load) causes the drive to rotate (the
speed controller parameters are parameterized according to the factory setting during this run)
• One of the armature current or torque limits is parameterized too low (the motor field may not be reaching full field
strength fast enough with the result that the initial motor torque is too low)
• Maximum speed setting is incorrect
• Pulse encoder parameters are incorrect (P140 to P143)
• Parameters for tachometer adjustment are not correct (P741)
• Setpoint EMF settings are incorrect (P101, P100, P110)

28 A steady-state actual speed corresponding to 0% of maximum speed cannot be reached within 0 s in speed-controlled
operation (the speed setpoint/actual value difference averaged over 90 firing cycles must be <1.0% nmax for a total of 4s)
Possible cause: As for fault value 26

29 The calculated armature circuit inductance is greater than 327.67 mH, therefore P111 = 327,67 mH has been set. All other
parameters (the current controller parameters P155 and P156 too) have been set correctly despite that. (For the real
armature circuit inductance in mH, see r047.i010).
Possible cause:
•e.g. field supply from the armature terminals

30 The calculated armature circuit inductance is greater than 327.67 mH and the calculated armature circuit resistance is
greater than 32.767 Ω, therefore P111 = 327,67 mH and P110 = 32,767 Ω has been set. All other parameters have also
been set. However, the values of the current controller parameters P155 and P156 might differ from the optimum setting.
Possible cause:
•e.g. field supply from the armature terminals

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

31 The calculated armature circuit resistance is greater than 32.767 Ω, therefore P110 = 32,767 Ω has been set. All other
parameters have also been set. Possibly the calculated P111 and therefore also the current controller parameters P155
and P156 have been distorted by the limitation in P110 .
Possible cause:
•e.g. field supply from the armature terminals

r047 Index 002:

1 Fault has occurred during optimization run for current controller and precontrol for armature and field (selected by means of
P051=25)
2 Fault has occurred during optimization run for speed controller (selected through setting P051=26)
3 Fault has occurred during optimization run for field weakening (selected through setting P051=27)
4 Fault has occurred during internal offset adjustments (selected through P051=22)
5 Fault has occurred in optimization run for friction and moment of inertia compensation (selected through setting P051=28)
F052 Optimization run aborted as a result of external cause
(active in operating states of – –, I, II)

This fault message is activated when the converter ceases operating in the RUN state (state I, II or --) during an optimization run
(and thus in response to every FAULT) or if the EMERGENCY STOP or SHUTDOWN command is applied. The optimization run
is aborted. Only those parameters which had been fully optimized prior to activation of the fault message are altered.
When the STANDSTILL command is applied, this fault message is not activated if the optimization run for field weakening is
interrupted after the 1st field weakening measuring point has been recorded or, in the case of the optimization run for friction and
moment of inertia compensation, after the measuring point at 10% maximum speed has been determined. In these cases, the run
may be interrupted by STANDSTILL so as to be able to complete the run in several stages (by repeated restarts) for a limited
travel path.

Fault value: r047 Index 002 to 016:

1 Run was aborted because converter is no longer i002=1 Fault has occurred during optimization run for current
operating in RUN mode controller and precontrol for armature and field
2 Run was aborted because EMERGENCY STOP (selected by means of P051=25)
command was applied (speed controller setpoint =0) i002=2 Fault has occurred during optimization run for speed
3 Run was aborted because STANDSTILL command was controller (selected through setting P051=26)
applied (ramp-function generator setpoint=0) i002=3 Fault has occurred during optimization run for field
4 Operation has been aborted because P051 was changed weakening (selected through setting P051=27)
during the optimization run i002=5 Fault has occurred in optimization run for friction and
5 Run was aborted because SWITCH-ON command was moment of inertia compensation (selected through
not applied within 30 s of selection of optimization run setting P051=28)

6 Operation has been aborted because the OPERATING

ENABLE command was not entered within 1 minute of
selection of the optimization run.
7 Operation has been aborted because converter was not
in operating state < o7.2 15 s after selection of the
optimization run with P051 = 25, 26, 27 or 28 (input of
OFF1 command may have been forgotten)

9.1.2.9 External faults

F053 Fault message from free function block FB288
(active in all operating states)

Fault value:
1 the binector wired via parameter U102 Index.005 is in the state log.”1”
2 the binector wired via parameter U102 Index.006 is in the state log.”1”
3 the binector wired via parameter U102 Index.007 is in the state log.”1”
4 the binector wired via parameter U102 Index.008 is in the state log.”1”

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

F054 Fault message from free function block FB289

(active in all operating states)

Fault value:
1 the binector wired via parameter U103 Index.005 is in the state log.”1”
2 the binector wired via parameter U103 Index.006 is in the state log.”1”
3 the binector wired via parameter U103 Index.007 is in the state log.”1”
4 the binector wired via parameter U103 Index.008 is in the state log.”1”

9.1.2.10 Start-up faults

F055 No field characteristic recorded
(active in operating states of – –, I, II)

Possible fault causes

• The optimization run for field weakening (P051=27) has not yet been executed.

Fault value:
1 P170 = 1 (”torque control”) selected, but “no valid field characteristic has been recorded” (P117=0) yet
2 P081 = 1 (”speed-dependent field weakening”) selected, but “no valid field characteristic has been recorded” (P117=0) yet
(P117=0)
F056 Important parameter is not set
(active in operating states of ≤ o6)

This fault message is activated if certain parameters are still set to 0.

Fault value:
1 Speed controller actual value selection in P083 is still set to 0
2 Rated motor armature current in P100 is still set to 0.0
3 Rated motor field current in P102 is still set to 0.00 (fault message only when P082 ≠ 0)
4 Rated DC current of external field device is still set to 0.00 in U838 (error message if P082 >= 21 only)
F058 Parameter settings are not consistent
(active in operating states of ≤ o6)

Inconsistent values have been set in mutually dependent parameters.

Fault value:
2 The parameters for speed-dependent current limitation are not set correctly (the following applies: P105>P107 (I1>I2) and
P104 < P106 (n1<n2))
3 The field characteristic is not uniform
4 The first threshold for P gain adaptation of the speed controller set in parameter P556 is higher than the second threshold
setting in parameter P559
5 P557 is set to greater than P560
6 P558 is set to greater than P561
7 If P083=1 (analog tachometer), then P746 may not equal 0 (main actual value is not connected)
8 If P083=2 (pulse encoder), then P140 may not equal 0 (no pulse encoder installed)
9 If P083=3 (EMF control) then P081 may not equal 1 (field weakening operation)
10 P090 (stabilization time for supply voltage) >P086 (time for automatic restart)
11 P090 (stabilization time for supply voltage) >P089 (waiting time in state o4 or o5)
12 P445=1 is set (switch-on, shutdown and crawl act as a pushbutton) although no binector is parameterized as a shudown
button (P444=0)
13 If P067 > 1, then P075 must also be > 0

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

F059 Technology option S00 is disabled/will be disabled soon

(active in all operating statuses)

Fault value:
1 Time credit for S00 = 0 hrs
The technology option S00 for 500 operating hours no longer applies. The functions are now no longer available, but the
parameter settings have been retained.
If you wish to continue using technology option S00, please contact your nearest Siemens Sales Office to obtain the PIN
number you will require to permanently enable this option.
You will need to know the serial number of your SIMOREG DC Master. For further details, please refer to the description of
parameters U977 and n978 in Chapter 11 of the Parameter List.
2 Time credit S00 < 100 Std.
The remaining time period of temporary enabling of technology option S00 is now less than 100 operating hours. The
technology functions will not be available for much longer.
If you wish to continue using technology option S00, please contact your nearest Siemens Sales Office to obtain the PIN
number you will require to permanently enable this option.
for permanent enabling of technology option S00.
You will need to know the serial number of your SIMOREG DC Master. For further details, please refer to the description of
parameters U977 and n978 in Chapter 11 of the Parameter List.
3 S00 operation will not be possible if an SLB cycle time of < 1 ms is set
Owing to the available capacity of the electronics board, it is not possible to operate the S00 technology option at the same
time as a SIMOLINK bus with an extremely short cycle time (U746 < 1 ms).
See also parameter U746.

9.1.2.11 Hardware faults

F061 Fault message from thyristor check function
(active in operating state o3)

This fault message can be activated only if the thyristor check is activated via parameter P830.

If “Thyristor defective” or “Thyristor unable to block” is signalled, then the relevant thyristor module must be replaced.

Possible causes for irreparable damage to thyristors:

• Interruption in snubber circuit
• Current controller and precontrol are not optimized (excessive current peaks)
• Inadequate cooling (e.g. fan is not operating, ambient temperature is too high, fan is rotating in wrong direction (incorrect
phase sequence), inadequate air supply, heatsink is very dirty)
• Excessive voltage peaks in incoming supply system
• External short circuit or fault to ground (check armature circuit)

If “Thyristor unable to block” is signalled, the cause can generally be attributed to a firing circuit fault, rather than to a defective
thyristor.

Possible causes:
• Firing pulse cable to relevant thyristor is interrupted
• Ribbon cable X101 or X102 is incorrectly inserted or interrupted
• Defective electronics or gating board
• Internal interruption in gating cable in thyristor module

The designations of the firing cables and associated thyristors can be found in Section 6.4 (power connections).

Fault value:
1 Defective thyristor (short circuit in module V1, on 15A and 30 converters: V1 or V4)
2 Defective thyristor (short circuit in module V2, on 15A and 30 converters: V2 or V5)
3 Defective thyristor (short circuit in module V3, on 15A and 30 converters: V3 or V6)
4 Defective thyristor (short circuit in module V4, on 15A and 30 converters: V4 or V1)
5 Defective thyristor (short circuit in module V5, on 15A and 30 converters: V5 or V2)
6 Defective thyristor (short circuit in module V6, on 15A and 30 converters: V6 or V3)
8 Fault to ground in armature circuit
9 I=0 message defective
Possible fault cause
• Defective A7001 electronics board

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

11 Thyristor cannot be fired (X11)

12 Thyristor cannot be fired (X12)
13 Thyristor cannot be fired (X13)
14 Thyristor cannot be fired (X14)
15 Thyristor cannot be fired (X15)
16 Thyristor cannot be fired (X16)
17 2 or more thyristors (MI) cannot be fired
Possible fault cause
• Armature circuit interrupted
21 Thyristor cannot be fired (X21)
22 Thyristor cannot be fired (X22)
23 Thyristor cannot be fired (X23)
24 Thyristor cannot be fired (X24)
25 Thyristor cannot be fired (X25)
26 Thyristor cannot be fired (X26)
27 2 or more thyristors (MII) cannot be fired
31 Thyristor unable to block (X11 or X21)
32 Thyristor unable to block (X12 or X22)
33 Thyristor unable to block (X13 or X23)
34 Thyristor unable to block (X14 or X24)
35 Thyristor unable to block (X15 or X25)
36 Thyristor unable to block (X16 or X26)

9.1.2.12 Internal faults

F062 Fault in parameter memory
(active in all operating states)

Software monitoring of correct functioning of the EEPROM module (non-volatile memory) on the A7009 board.
The EEPROM values contains all data which must be protected in the case of a power failure (i.e. parameter values and process
data which must remain stored during power failures).

The following are monitored:

• Connection between the A7001 electronics board and the EEPROM on the A7009 backplane wiring assembly
• Whether the parameter values stored on the EEPROM are within the permissible value range
• Whether data are being correctly stored on the EEPROM. For this purpose, values are read and checked for correctness
after they are transferred to the module
• Whether the checksum of the non-volatile process data in the EEPROM is correct

Possible causes for all fault types:

Excessive EMC-related interference is present (e.g. due to unprotected contactors, unscreened cables, loose shield connections)

Fault value: r047 Index 002 to 016:

1 Connection to EEPROM is faulty
Possible fault causes
• A7001 electronics board is defective
• A7009 backplane wiring assembly is defective
• Plug-in connection X109 is defective
2 Parameter value is outside permissible value range i002 Number of faulty parameter
Possible fault causes i003 Index of faulty parameter
• “Restore to default value” has never been executed i004 Faulty parameter value
with this software (e.g. after software replacement)
• A7009 backplane wiring assembly is defective

Possible remedy:
• Acknowledge fault, execute “Restore to default value”
and start up the drive again

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

3 Parameter value cannot be stored on EEPROM i002 Address of fault memory location
Possible fault causes i003 Faulty value in EEPROM
• A7001 electronics board is defective i004 Correct parameter value
• A7009 backplane wiring assembly is defective
• Plug-in connection X109 is defective
11 Checksum of non-volatile data (part 1) i002 Calculate checksum
is not correct i003 Checksum found in EEPROM
12 Checksum of non-volatile data (part 2)
is not correct
13 Checksum of non-volatile data (part 3)
is not correct
20 Checksum of configuring table of parameter values is not
correct
Possible fault causes
• Defective EEPROM
• “Restore to default value” has never been executed
with this software (e.g. after software replacement)

Possible remedy:
• Acknowledge fault, execute “Restore to default value”
and start up the drive again! Check interference
suppression measures and improve if necessary.
F063 Errors in compensation data of analog inputs and outputs
(active in all operating states)

This function monitors whether the factory-set compensation data for the analog inputs and outputs are plausible

Possible fault cause:

• Defective A7001 or A7006 electronics board

Fault value: r047 Index 002 to 016:

11 Incorrect number of words in compensation values i002 Incorrect number of words
for analog inputs and outputs of A7001
12 Checksum error in compensation values for i002 Calculated checksum
analog inputs and outputs of A7001 i003 Errored checksum
13 Incorrect value among compensation values for i002 Incorrect value
analog inputs and outputs of A7001
23 Incorrect value among compensation values for i002 Incorrect value
analog inputs and outputs of A7006
F064 Watchdog timer has initiated a reset
(active in all operating states)

An internal microprocessor hardware counter monitors whether the program for calculating the firing pulses runs at least once
every 14 ms (program is executed on average every 2.7 to 3.3 ms). If this is not the case, the counter initiates a reset, Fo64 is
then displayed.

Possible fault causes

• A7001 electronics board is defective
• Excessive EMC-related interference is present (e.g. due to unprotected contactors, unscreened cables, loose shield
connections)
F065 Illegal microprocessor status
(active in all operating states)

An internal microprocessor hardware function monitors the microprocessor for illegal operating states.

Possible fault causes

• A7001 electronics board is defective
• Excessive EMC-related interference is present (e.g. due to unprotected contactors, unscreened cables, loose shield
connections)
F067 Converter cooling faulty
(active in operating states of ≤ o13)

The heatsink temperature monitoring function is activated 6s after connection of the electronics supply.
(The current heat sink temperature is indicated at parameter r013 and on connector K050)

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

Fault value: r047 Index 002 to 016:

1 Heatsink temperature > 95°C i002 Measured heatsink temperature (16384 .. 100°C)
2 Heatsink temperature sensor is defective i003 Measured ADC value
3 Converter fan is defective
F068 Analog measuring channel faulty (main setpoint, main actual value or analog select input)
(active in all operating states)

Hardware monitoring of measuring circuits

Possible fault causes

• A7001 module defective
• Measuring circuit saturated (input voltage at terminals 4 and 5 or 6 and 7 higher than approx. 11.3V)

Fault value:
1 Measuring channel for main setpoint / analog select input 1 faulty (terminals 4 and 5)
2 Measuring channel for main actual value faulty (terminals 103 and 104)
3 Measuring channel for analog select input 1 faulty (terminals 6 and 7)
F069 MLFB data are faulty
(active in all operating states)

Possible fault causes

• Excessive EMC-related interference is present
(e.g. due to unprotected contactors, unscreened cables, loose shield connections)
• A7009 backplane wiring assembly is defective

Fault value: r047 Index 002 to 016:

1 MLFB code number (r070) = MLFB code number (r070) i002 Incorrect MLFB code number
is illegal
2 MLFB data checksum error -
3 Works number checksum error -
4 Number of words of MLFB data is incorrect -

9.1.2.13 Communication errors with supplementary boards

F070 SCB1: Serious initialization error
(active in all operating states)
SCB1 and SCI cannot power up correctly (see diagnostic parameter n697 for details)

Fault value:
12 No connection to slave 1
22 No connection to slave 2
F073 SCB1: Current below 4mA minimum value at analog input1 of slave 1
(active in all operating states)
The cause of the fault may be a cable break
F074 SCB1: Current below 4mA minimum value at analog input2 of slave 1
(active in all operating states)
The cause of the fault may be a cable break
F075 SCB1: Current below 4mA minimum value at analog input3 of slave 1
(active in all operating states)
The cause of the fault may be a cable break
F076 SCB1: Current below 4mA minimum value at analog input1 of slave 2
(active in all operating states)
The cause of the fault may be a cable break
F077 SCB1: Current below 4mA minimum value at analog input2 of slave 2
(active in all operating states)
The cause of the fault may be a cable break
F078 SCB1: Current below 4mA minimum value at analog input3 of slave 2
(active in all operating states)
The cause of the fault may be a cable break
F079 SCB1: Telegram failure
(active in all operating states)
Check function of SCB1 (activity LEDs) and connection to SCI slaves (fiber optics)

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

F080 Error in initialization of a CB/TB board

Possible causes for fault values 1 and 6:

• CB/TB board is defective
• CB/TB board is not installed correctly
• CB/TB board is taking too long to run up (e.g. due to very complex TB configuration)
Fault value (r949 index 001): r047 index 002 to 016:
1 The "Heartbeat counter“ of the CB/TB has not started to i015 Code number of board:
st
count within 20 s 1 TB or 1 CB
nd
2 2 CB
2 The product version of the installed CT/TB board is not i002 Code number of slot containing incompatible board:
compatible with the SIMOREG 6RA70 converter 2 Slot D
3 Slot E
4 Slot F
5 Slot G
6 CB when configuration includes TB
5 Parameters P918, U711 to U721 are not correctly set or i015 Code number of board:
st
not accepted after a change by means of U710 = 0 1 TB or 1 CB
nd
setting. (The meanings of these parameters are defined 2 2 CB
in the manual for the relevant CB board, see also function
diagrams, Section 8, Sheets Z110 and Z111)
6 The initialization run for a CB/TB board has not been i015 Code number of board:
st
completed within 40 s 1 TB or 1 CB
nd
2 2 CB
F081 CB/TB heartbeat error i015 Code number of board:
st
CB/TB has not incremented the monitoring counter for a period 1 TB or 1 CB
nd
of 800 ms 2 2 CB
Possible causes of fault
• CB/TB board is defective
• CB/TB board is not correctly installed

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Fault Description

No. Cause as a function of fault value Further information (r047.002 to r047.016)

(r047.001, r949.001 or r949.009 with acknowledged error)

F082 CB/TB message timeout or error in data exchange

Possible causes of fault

• CB/TB PZD message timeout (with fault value 10)
• Excessive EMC-related interference
(e.g. due to unprotected contactors, unscreened cables, loose screen connections)
• CB/TB board is defective
• CB/TB board is not correctly inserted

Fault value (r949 index 001): r047 Index 002 to 016:

1 Fault in alarm channel from CB to basic unit i015 Code number of board:
st
1 TB or 1 CB
nd
2 2 CB
2 Fault in alarm channel from TB to basic unit
3 Fault in fault channel from TB to basic unit
5 Fault in parameter job channel from CB to basic unit i015 Code number of board:
st
1 TB or 1 CB
nd
2 2 CB
6 Fault in parameter response channel from basic unit to i015 Code number of board:
st st
CB 1 1 TB or 1 CB
nd
2 2 CB
7 Fault in parameter job channel from TB to basic unit
8 Fault in parameter response channel from basic unit to
TB
10 CB/TB process data failure (message timeout period set i015 Code number of board:
st
in U722) 1 TB or 1 CB
nd
2 2 CB
11 Fault in parameter job channel from PMU to TB
12 Fault in parameter response channel from TB to PMU
15 Fault in setpoint channel from CB/TB to basic unit i015 Code number of board:
st
1 TB or 1 CB
nd
2 2 CB
16 Fault in actual value channel from basic unit to CB/TB i015 Code number of board:
st
1 TB or 1 CB
nd
2 2 CB

9.1.2.14 Fault messages from supplementary boards

F101 This group of fault messages is activated by supplementary boards
to Please refer to the operating manual of the relevant supplementary board for explanation of the fault messages and fault values
F147

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9.2 Alarm messages

Alarm message display:
On the PMU: A (Alarm) and a three-digit number. The red LED (Fault) flashes.
On the OP1S: On the bottom line of the operational display. The red LED (Fault) flashes.
An alarm message cannot be acknowledged, but disappears automatically when the cause has been
eliminated.
Several alarm messages can be active at the same time, these are then displayed in succession.
Many alarms (see List of Alarm Messages) can only be active in certain operating states.

The system responses to an alarm are as follows:

• Alarm message is displayed on the operator panel (PMU, OP1S)
• B0114 ( = status word 1, bit 7) is set and B0115 is cancelled
(see also special alarm bits in status word 2, e.g. for an external alarm, overload, etc.)
• The corresponding bit in one of the alarm words r953 (K9801) to r960 (K9808) is set

Alarm Description

A015 Simolink start

(active in all operating states)

Although the board has been initialized, it cannot yet exchange telegrams (parameters have not yet been correctly configured on
all nodes or the boards have not yet been linked via fiber optics to form a closed ring).
A018 Short circuit at binary outputs
(active in all operating states)

Hardware monitoring function to check for short circuit at one of the binary select outputs (see also F018 and r011).
A019 Alarm message from free function block FB256
(active in all operating states)

The binector wired via parameter U104 Index.002 is in the state log.”1”
A020 Alarm message from free function block FB257
(active in all operating states)

The binector wired via parameter U105 Index.002 is in the state log.”1”
A021 External alarm 1
(active in all operating states)

Bit 28 in control word 2 was in the log. "0" state for longer than the time set in P360 index 003.
A022 External alarm 2
(active in all operating states)

Bit 29 in control word 2 was in the log. "0" state for longer than the time set in P360 index 004.
A023 Alarm message from free function block FB6
(active in all operating states)

The binector wired via parameter U104 Index.001 is in the state log.”1”
A024 Alarm message from free function block FB7
(active in all operating states)

The binector wired via parameter U105 Index.001 is in the state log.”1”

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Alarm Description

A025 Brush length too short

(active in all operating states)

When parameter P495=1 (binary sensing of brush length):

Alarm in response to log. “0” signal (longer than 10s) at terminal 211

Possible causes
• Encoder for brush length has responded
• Interruption in encoder cable
A026 Poor bearing condition
(active in all operating states)

When parameter P496=1 (bearing condition sensing):

Alarm in response to log. “0” signal (longer than 2s) at terminal 212

Possible causes
• Encoder for bearing condition has responded
A027 Air flow monitoring
(active in operating states of < o6)

When parameter P497=1 (air flow monitoring):

Alarm in response to log. “0” signal (longer than 40s) at terminal 213

Possible causes
• Encoder for fan monitoring has responded
• Interruption in encoder cable
A028 Motor overtemperature
(active in all operating states)

When parameter P498=1 (thermostat connected):

Alarm in response to log. “0” signal (longer than 10s) at terminal 214

Possible causes
• Thermostat for monitoring motor temperature has responded
• Interruption in encoder cable
A029 Motor overtemperature
(active in all operating states)

Selection via P493=1 or 3 (thermostat at terminals 22 / 23) or

P494=1 or 3 (thermostat at terminals 204 / 205)

When parameter P490.01=1 (KTY84 at terminals 22 / 23) or P490.02=1 (KTY84 at terminals 204 / 205):
The alarm is activated if the motor temperature reaches or exceeds the values set in parameter P492.

When parameter P490.01=2, 3, 4 or 5 (PTC thermistor at terminals 22 / 23) or P490.02=2, 3, 4 or 5 (PTC thermistor at terminals
204 / 205):
The alarm is activated if the motor temperature reaches or exceeds the trip value of the selected PTC.
A031 Speed controller monitoring
(active in operating states of – –, I, II)

The monitor responds when the difference between the connectors selected in P590 and P591 (factory setting: Setpoint/actual
value difference of speed controller) exceeds the limit set in parameter P388 for longer than the time set in parameter P390.

Possible causes
• Control loop interrupted
• Controller is not optimized
• P590 or P591 is not correctly parameterized
A033 Alarm message from free function block FB8
(active in all operating states)

The binector connected via parameter U106 Index.001 is in the log. "1" state
A034 Alarm message from free function block FB9
(active in all operating states)

The binector connected via parameter U107 Index.001 is in the log. "1" state

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Alarm Description

A035 Drive blocked

(active in operating states of – –, I, II)

The monitoring function responds if the following conditions are fulfilled for longer than the time set in parameter P355:
• Positive or negative torque or armature current limit reached
• Armature current is greater than 1% of converter rated armature DC current
• The actual speed value is less than 0.4% of maximum speed
A036 No armature current can flow
(active in operating states of – –, I, II)

This monitoring function responds if the armature firing angle is at the rectifier stability limit for more than 500 ms and the
armature current is less than 1% of the converter rated armature DC current.
A037 I2t motor monitor has responded
(active in operating states of – –, I, II)

The alarm is activated when the calculated I2t value of the motor reaches the value which corresponds to the final temperature
at 100% of permissible continuous motor current (= P113*P100).
A038 Overspeed
(active in operating states of – –, I, II)

The monitoring function responds if the actual speed value (selected in P595) exceeds the positive (P512) or negative (P513)
threshold by 0.5%.

Possible causes
• Lower current limit has been input
• Current-controlled operation
• P512, P513 are set too low
• Tachometer cable contact fault in operation close to maximum speed
A039 I2t value of power section too high
(active in all operating states)

This alarm is activated if the permissible I2t value for the relevant power section is reached. At the same time, the current limit is
set to P077 * 100% of the converter rated DC current. This limit is not cancelled again until the setpoint drops below 100% of the
converter rated DC current. See also Fault F039 and Parameter P075.
A043 Autometic field current reduction if EMF is too high in operation
(active in operating states of – –, I, II)

This alarm is active only when parameter P272=1 and activated if the following equation applies to firing angle α (armature)
before limitation (K101):
α > (αW (inverter stability limit acc. to P151) – 5 degrees) or , at a low (pulsating) current
α > (165 degrees – 5 degrees)
The field is reduced simultaneously with A043, implemented through control of the armature firing angle to (αW (or 165 degrees)
- 5 degrees) using a P controller whose output reduces the EMF controller setpoint. For this reason, “Field current setpoint input
through internal EMF control” (PO81=1) must be parameterized.
When a tchange in torque direction is requested, both torque directions are inhibited until the calculated control angle (K101) is
<165 degrees for the armature current requested in the new torque direction, i.e. until the field, and thus the EMF, have been
reduced accordingly.
See also parameter P082.
A044 An alarm is active on one slave connected to the paralleling interface
(active in all operating states)
A046 Analog select input for main setpoint (terminals 4 and 5) faulty
(active in operating states of ≤ o6)

This alarm is activated when P700=2 (current input 4 to 20 mA) and the input current is less than 3mA.
A047 Analog select input 1 (terminals 6 and 7) faulty
(active in operating states of ≤ o6)

This alarm is activated when P710=2 (current input 4 to 20 mA) and the input current is less than 3mA.
A049 SCB1: No SCI slave connected
(active in all operating states)

A050 SCB1: Not all required SCI slaves are available

(active in all operating states)

The SCI slave required to perform the parameterized functions is not available
A053 Alarm message from free function block FB258
(active in all operating states)

The binector connected via parameter U106 Index.002 is in the log. "1" state

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Alarm Description

A054 Alarm message from free function block FB259

(active in all operating states)

The binector connected via parameter U107 Index.002 is in the log. "1" state
A059 Remaining time for temporary enabling of the S00 technology option is now less than 100 operating hours
(active in all operating statuses)

Remaining time for temporary enabling of the S00 technology option is now less than 100 operating hours. The functions will
soon be unavailable.
If you wish to continue using technology option S00, please contact to your nearest Siemens Regional Office for a PIN number
for permanent enabling of technology option S00.
You will need to know the serial number of your SIMOREG DC Master. For further details, please refer to the description of
parameters U977 and n978 in Chapter 11 of the Parameter List.
A067 Converter cooling faulty
(active in all operating states)

The heatsink temperature is > 90 °C.

The monitoring function is activated 6s after the electronics supply is connected.
(The current heat sink temperature is indicated at parameter r013 and on connector K050)
st
A081 CB alarm of 1 CB
to (active in all operating states ≤ o11)
A088
The meaning of these alarms depends on the type of board used.
For further information, refer to Section 7.7, Start-Up of Optional Supplementary Boards, in the relevant board description.
nd
A089 CB alarm of 2 CB
to (active in all operating states ≤ o11)
A096
The meaning of these alarms depends on the type of board used.
For further information, refer to Section 7.7, Start-Up of Optional Supplementary Boards, in the relevant board description.
A097 TB alarms
to (active in operating states ≤ o11)
A128
For more information about TECH BOARD alarms, please refer to Operating Instructions or Configuring Guide of the relevant
board.

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10 Parameter list

10.1 Overview

The Base Drive Panel Operating Instructions does not contain information about all available parameters.
Only the parameters mentioned in this book are included. For a complete list of parameters please refer to
power module Operating Instructions 6RX1700-0AD76.

Range of parameter Function

numbers
r000 Operating display
r001 - P050 General visualisation parameters
P051- r059 Access authorisation levels and parameter output
r060 - r065 Definition of SIMOREG DC MASTER converter
r067 - P079 Definition of SIMOREG DC MASTER power section
P080 - P096 Setting values for converter control
P100 - P139 Definition of motor
P140 - P148 Definition of pulse encoder, speed sensing using pulse encoder
P150 - P165 Closed-loop armature current control, auto-reversing stage, armature gating unit
P169 - P191 Current limitation, torque limitation
P200 - P234 Speed controller (further parameters for the speed controller P550 - P567)
P250 - P265 Closed-loop field current control, field gating unit
P272 – P284 Closed-loop EMF control
P295 – P319 Ramp-function generator
P320 – P323 Setpoint processing
P351 – P364 Setting values for monitoring functions and limits
P370 – P399 Setting values for limit-value monitors
P401 – P416 Settable fixed values
P421 – P428 Fixed control bits
P430 – P445 Digital setpoint input (fixed setpoint, inching and crawling setpoints)
P450 – P453 Position sensing with pulse encoder
P490 – P498 Definition of “Motor interface”
P500 – P503 Configuring of torque shell input
P509 – P515 Speed limiting controller
P590 – P597 Input quantities for signals
P600 – P646 Configuring of closed-loop control
P648 – P691 Control word, status word
P692 – P698 Further configuring measures
P700 – P746 Analog inputs (main actual value, main setpoint, selectable inputs)
P749 – P769 Analog outputs
P770 – P778 Binary outputs
P780 – P819 Configuration of serial interfaces on basic converter
P820 – P821 Deactivation of monitoring functions
r824 – r829 Compensation diagnosis
P830 Thyristor diagnosis
P831 - P899 Parameters for DriveMonitor and OP1S
P918 - P927 Profile parameters
r947 - r952 Fault memory
r953 - r968 Visualization parameters: Alarms, control and status word
P970 - r999 Resetting and storing parameters, list of existing and modified P and r parameters
U710 - n739 Configuration of supplementary boards in board locations 2 and 3
n980 - n999 List of existing and modified U and n parameters

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10.2 Overview of abbreviations

Example:
PNU Description Value range No. indices See
* [Unit] Change
FDS
P520 Friction at 0% speed 0.0 to 100.0 Ind: 4 P052 = 3
* 1) [%] FS=0.0 5) P051 ≥ 20
Setting as % of converter rated DC current or converter rated torque
0.1%4) Type: O2 3) Online6)
FDS2)
8)
9)

1) An under the parameter number means that the parameter requires confirmation, i.e. the altered value does
*
not take effect until the P key is pressed.
2) Abbreviation indicating that the parameter belongs to a data set (refers only to indexed parameters)

FDS Parameter belongs to the function data set

BDS Parameter belongs to the BICO data set

3) Specification of parameter type

O2 Unsigned 16-bit value
I2 Signed 16-bit value
O4 Unsigned 32-bit value
I4 Signed 32-bit value
V2 Bit-coded quantity
L2 Nibble-coded quantity

4) Setting steps for access via PKW mechanism

5) Factory setting

6) Minimum setting required (P052) to allow display of the relevant parameter

Minimum access level required (P051) to allow modification of the relevant parameter
Online: The parameter can be changed in all converter operating states
Offline: The parameter can only be changed in converter operating states of ≥ o1.0
8)
S00 Parameter belongs to the S00 optional technology software

9) The "OP parameter number" (i.e. the number to be entered via the OP1S operator panel) is specified in brackets
in the "PNU" column for all parameters which are not "P parameters" or "r parameters": e.g. (2010) under n010
or (2100) under U100.

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PNU Description Value range No. indices See

[Unit] Change

10.3 Operating status display

r000 Operating status display Ind: None P052 = 3
Type: O2
Status display, fault and alarm messages
Torque direction M0, MI or MII (=RUN)
-- No torque direction active
I Torque direction I active (MI)
II Torque direction II active (MII)

o1 Waiting for operating enable (=READY)

o1.0 Brake release delay time running.
o1.1 Waiting for operating enable at terminal 38.
o1.2 Waiting for operating enable via binector (acc. to selection in
P661) or control word, bit 3 (acc. to selection in P648)
o1.3 Inching command cancellation delay time running.
o1.4 Waiting for field to be reversed.
o1.5 Waiting for operating enable from optimization run
(the optimization run does not output the operating enable signal
at the end until n<nmin has been reached and SHUTDOWN
input).
o1.6 Waiting for concellation of immediate pulse disable via binector
(acc. To selection with P177) [SW 1.8 and later]

o2 Reserved
o2.0 Reserved

o3 Test phase
o3.0 Waiting for completion of thyrsitor check (selectable function).
o3.1 Waiting for completion of line symmetry check.
o3.2 Waiting for a DC contactor to pick up
o3.3 Waiting for "Main contactor checkback"
(control word 2 bit 31, see P961) [as of SW 1.8]

o4 Waiting for voltage (armature)

o4.0 Waiting for voltage at power terminals 1U1, 1V1, 1W1 (the
threshold set in parameters P351 and P353 must be exceeded,
see also P078.001)
o4.1 Waiting for fuse monitoring to signal OK [SW 1.7 and later]

o5 Waiting for field current

o5.0 Waiting until actual field current (K0266) equals >50% of field
current setpoint (K0275) and for "I field extern > I f min".
o5.1 Waiting for voltage at power terminals 3U1, 3W1
(the threshold set in parameters P351 and P353 must be
exceeded, see also P078.002)

NOTE
The converter dwells in states o4 and o5 for a maximum total delay time
that is set in parameter P089. The appropriate fault message is output if
the corresponding conditions are still not fulfilled at the end of this period.

o6 Wait status before the line contactor is closed

o6.0 Waiting for auxiliaries to be switched on (delay in P093)
o6.1 Waiting for a setpoint ≤ P091 to be applied to the ramp-function
generator input (K0193)

o7 Waiting for switch-on command (=READY TO SWITCH ON)

o7.0 Waiting for switch-on command via terminal 37.
o7.1 Waiting for switch-on command via binector (acc. to selection in
P654) or control word, bit 0 (acc. to selection in P648).
o7.2 Waiting for cancellation of internal shutdown through input of an
internal shutdown command or
waiting for cancellation of command "Braking with field reversal"

SIEMENS Energy & Automation 10-3

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

[Unit] Change

o7.3 Waiting for completion of "Restore factory settings" operation.

o7.4 Waiting for switch-on command before execution of an
optimization run
o7.5 Wait for completion of "Read in parameter set" operation.
o7.6 Wait for completion of "Load MLFB" operation (performed at
factory)
o7.9 reserved for firmware download for optional supplementary
modules [SW 2.0 and later]

o8 Waiting for acknowledgement of starting lockout

o8.0 Waiting for acknowledgement of starting lockout through input of
SHUTDOWN command (OFF1).
o8.1 Simulation operation active (see under U840) [SW1.7 and later]

o9 Fast stop (OFF3)

o9.0 Fast stop has been input via binector (acc. to selection in P658) or
control word, bit 1 (acc. to selection in P648).
o9.1 Fast stop has been input via binector (acc. to selection in P659).
o9.2 Fast stop has been input via binector (acc. to selection in P660).
o9.3 Fast stop is stored internally (memory can be reset by cancelling
FAST STOP command and entering SHUTDOWN).

o10 Voltage disconnection (OFF2)

o10.0 Voltage disconnection has been input via binector (acc. to
selection in P655) or control word, bit 1 (acc. to selection in P648).
o10.1 Voltage disconnection has been input via binector (acc. to
selection in P656).
o10.2 Voltage disconnection has been input via binector (acc. to
selection in P657).
o10.3 E-Stop (safety shutdown) has been input via terminal 105 or 107
o10.4 Wait for receipt of a valid telegram on G-SST1 (only if telegram
failure time monitoring is set with P787 ≠ 0)
o10.5 Waiting for receipt of a valid telegram on G-SST2 (only if telegram
failure time monitoring is set with P797 ≠ 0)
o10.6 Waiting for receipt of a valid telegram on G-SST3 (only if telegram
failure time monitoring is set with P807 ≠ 0)

o11 Fault
o11.0 = Fxxx Fault message is displayed, red LED lights up.

o12 Electronics initialization in progress

o12.1 Basic converter electronics initialization in progress
o12.2 Initialization of supplementary board in location 2 in progress
o12.3 Initialization of supplementary board in location 3 in progress
o12.9 Restructuring of parameters in non-volatile storage after software
update (takes approx. 15s)

o13 Software update in progress

o13.0 Waiting for arrival of start command from HEXLOAD PC routine
(press the DOWN key to abort this status and start a RESET)
o13.1 Deletion of Flash EPROM in progress
xxxxx Display of address currently being programmed
o13.2 The Flash EPROM has been successfully programmed
(a RESET is performed automatically after approx. 1 second)
o13.3 Programming of the Flash EPROM has failed
(press UP key to return to operating state o13.0)

o14 Loading of boot sector in progress

(this operation is performed only in factory)

o15 Electronics not connected to voltage

Dark display: Waiting for voltage at terminals 5U1, 5W1
(electronics supply voltage).

10-4 SIEMENS Energy & Automation

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

[Unit] Change

10.4 General visualization parameters

r001 Display of terminals 4 and 5 (main setpoint) -200.0 to 199.99 Ind: None P052 = 3
[%] Type: I2
0.01%
r002 Analog input, terminals 103 and 104 (main actual value) -200.0 to 199.99 Ind: None P052 = 3
[%] Type: I2
0.01%
r003 Analog input, terminals 6 and 7 (selectable input 1) -200.0 to 199.99 Ind: None P052 = 3
[%] Type: I2
0.01%
r004 Analog input, terminals 8 and 9 (selectable input 2) -200.0 to 199.99 Ind: None P052 = 3
[%] Type: I2
0.01%
r005 Analog input, terminals 10 and 11 (selectable input 3) -200.0 to 199.99 Ind: None P052 = 3
[%] Type: I2
0.01%
r006 Analog output, terminals 14 and 15 -200.0 to 199.99 Ind: None P052 = 3
[%] Type: I2
Display of output value before normalization and offset 0.01%
r007 Analog output, terminals 16 and 17 -200.0 to 199.99 Ind: None P052 = 3
[%] Type: I2
Display of output value before normalization and offset 0.01%
r008 Analog output, terminals 18 and 19 -200.0 to 199.99 Ind: None P052 = 3
[%] Type: I2
Display of output value before normalization and offset 0.01%
r009 Analog output, terminals 20 and 21 -200.0 to 199.99 Ind: None P052 = 3
[%] Type: I2
Display of output value before normalization and offset 0.01%
r010 Display of status of binary inputs Ind: None P052 = 3
Type: V2
Representation on operator panel (PMU):
15 14 13 12 11 10 9 8

7 6 5 4 3 2 1 0

Segment On: Corresponding terminal is activated

Segment Off: Corresponding terminal is not activated

Segment or bit
0 ....... Terminal 36
1 ....... Terminal 37 (switch-on)
2 ....... Terminal 38 (operating enable)
3 ....... Terminal 39
4 ....... Terminal 40
5 ....... Terminal 41
6 ....... Terminal 42
7 ....... Terminal 43
8 ....... Terminal 211
9 ....... Terminal 212
10 ....... Terminal 213
11 ....... Terminal 214
12 ....... Safety shutdown (E-Stop is applied) 1)
13 to 15 ....... (not used)

1)The emergency stop (safety shutdown) command is applied (segment

dark) if
-terminal XS-105 is open
or
-terminal XS-107 (Stop pushbutton) is opened briefly and terminal XS-
108 (Reset pushbutton) is not yet activated (pushbutton operation)

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SIMOREG DC Master Base Drive Panel Operating Instructions
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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

[Unit] Change

r011 Display of status of binary outputs Ind: None P052 = 3

Type: V2
Representation on operator panel (PMU):

15 14 13 12 11 10 9 8

7 6 5 4 3 2 1 0

Segment alight: Corresponding terminal is activated

(HIGH level is applied) or overloaded or short-circuited
Segment dark: Corresponding terminal is not activated
(LOW level is applied) or not overloaded or not short-
circuited

Display of status of binary output terminals:

Segment or bit
0 ..... Terminal 46
1 ..... Terminal 48
2 ..... Terminal 50
3 ..... Terminal 52
7 ..... Terminal 109/110 (relay contact for line contactor)

Display of overloading of binary outputs:

Segment or bit
8 ..... Terminal 46
9 ..... Terminal 48
10 .... Terminal 50
11 .... Terminal 52
12 .... Terminal 26
13 .... Terminal 34

r012 Motor temperature -58 to +200 Ind: 2 P052 = 3

[°C] Type: I2
Display of motor temperature when a KTY 84 temperature sensor is 1°C
connected (P490.x=1).
A value of "0" is always output in r012 when a PTC thermistor or no
temperature sensor is installed.

i001: Motor temperature 1 (sensor at terminals 22 / 23)

i002: Motor temperature 2 (sensor at terminals 204 / 205)
r013 Heatsink temperature -47 to +200 Ind: None P052 = 3
[°C] Type: I2
Display of heatsink temperature 1°C
r014 Temperature rise 0.0 to 200.0 Ind: 2 P052 = 3
[%] Type: O2
i001: Calculated motor temperature rise (see P114) 0.1%
i002: Calculated thyristor temperature rise (see P075)
r015 Display of line voltage (armature) 0.0 to 1500.0 Ind: None P052 = 3
[V] Type: O2
(generated as arithmetic rectification average, RMS value display applies to 0.1V
sinusoidal voltage, average over 3 line-to-line voltages)
r016 Display of line voltage (field) 0.0 to 800.0 Ind: None P052 = 3
[V] Type: O2
(generated as arithmetic rectification average, RMS value display applies to 0.1V
sinusoidal voltage)
r017 Display of line frequency 0.00 to 100.00 Ind: None P052 = 3
[Hz] Type: O2
0.01Hz
r018 Display of firing angle (armature) 0.00 to 180.00 Ind: None P052 = 3
[degrees] Type: O2
0.01degrees
r019 Display of actual armature current -400.0 to 400.0 Ind: None P052 = 3
[% of P100] Type: I2
The internal actual armature current value is displayed (arithmetic average 0.1% of P100
between two gating pulses)
r020 Display of armature current setpoint -300.0 to 300.0 Ind: None P052 = 3
[% of P100] Type: I2
0.1% of P100

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SIMOREG DC Master Base Drive Panel Operating Instructions
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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

[Unit] Change

r021 Display of torque setpoint after torque limitation -400.0 to 400.0 Ind: None P052 = 3
[%] Type: I2
∧ 0.1% of rated motor torque (=rated motor armature current
Steps: 1 = 0.1% (see column on
(P100) * magnetic flux at rated motor field current (P102)) left)
r022 Display of torque setpoint before torque limitation -400.0 to 400.0 Ind: None P052 = 3
[%] Type: I2
∧ 0.1% of rated motor torque (=rated motor armature current
Steps: 1 = 0.1% (see column on
(P100) * magnetic flux at rated motor field current (P102)) left)
r023 Display of speed controller setpoint/actual value deviation -200.00 to 199.99 Ind: None P052 = 3
[%] Type: I2
0.01%
r024 Display of actual speed value from pulse encoder -200.00 to 199.99 Ind: None P052 = 3
[%] Type: I2
0.01%
r025 Display of actual speed controller value -200.0 to 199.99 Ind: None P052 = 3
[%] Type: I2
0.01%
r026 Display of speed controller setpoint -200.0 to 199.99 Ind: None P052 = 3
[%] Type: I2
0.01%
r027 Display of ramp-function generator output -200.00 to 199.99 Ind: None P052 = 3
[%] Type: I2
0.01%
r028 Display of ramp-function generator input -200.00 to 199.99 Ind: None P052 = 3
[%] Type: I2
0.01%
r029 Display of main setpoint before limitation -200.00 to 199.99 Ind: None P052 = 3
[%] Type: I2
0.01%
r034 Display of firing angle (field) 0.00 to 180.00 Ind: None P052 = 3
[degrees] Type: O2
0.01degrees
r035 Display of field current controller actual value 0.0 to 199.9 Ind: None P052 = 3
[% of P102] Type: O2
0.1% of P102
r036 Display of field current controller setpoint 0.0 to 199.9 Ind: None P052 = 3
[% of P102] Type: O2
0.1% of P102
r037 Display of actual EMF value -1500.0 to 1500.0 Ind: None P052 = 3
[V] Type: I2
0.1V
r038 Display of actual armature voltage value -1500.0 to 1500.0 Ind: None P052 = 3
[V] Type: I2
0.1V
r039 Display of EMF setpoint 0.0 to 1500.0 Ind: None P052 = 3
[V] Type: O2
This parameter displays the EMF setpoint which is applied as the control 0.1V
quantity in the field-weakening range.
This value is calculated from:
Umotorrated – Imotorrated * RA (= P101 – P100 * P110)

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SIMOREG DC Master Base Drive Panel Operating Instructions
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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

[Unit] Change

r040 Display of limitations: Ind: None P052 = 3

Type: V2
Representation on operator panel (PMU):

15 14 13 12 11 10 9 8

7 6 5 4 3 2 1 0

Segment alight: Corresponding limitation is reached

Segment dark: Corresponding limitation is not reached

Segment or bit
0 αW limit (field) reached (P251)
1 Negative current limit (field) reached (K0274)
2 αW limit (armature) reached (αW acc. to P151
for continuous current, 165° for discontinuous current)
3 ....... Negative current limit (armature) reached (K0132)
4 ....... Negative maximum speed reached (P513)
Speed limiting controller responds (B0201)
5 ....... Negative torque limit reached (B0203)
6 ....... Neg. limitation at ramp generator output reached (K0182)
7 ....... Neg. limitation at ramp generator input reached (K0197)
8 ....... αG limit (field) reached (P250)
9 ....... Positive current limit (field) reached (K0273)
10 ....... αG limit (armature) reached (P150)
11 ....... Positive current limit (armature) reached (K0131)
12 ....... Positive maximum speed reached (P512)
Speed limiting controller responds (B0201)
13 ....... Positive torque limit reached (B0202)
14 ....... Pos. limitation at ramp generator output reached (K0181)
15 ....... Pos. limitation at ramp generator input reached (K0196)

Connector and binector displays

r041 High-resolution connector display: -200.00 to 199.99 Ind: 2 P052 = 3
[%] Type: I2
i001: Display of connector selected in P042.01 0.01%
i002: Display of connector selected in P042.02
The display value is filtered with a time constant of 300ms
P042 High-resolution connector display: All connector Ind: 2 P052 = 3
* numbers FS=0 P051 = 40
i001: Selection of connector to be displayed in r041.01 1 Type: L2 Online
i002: Selection of connector to be displayed in r041.02
The display value is filtered with a time constant of 300ms
r043 Connector display: -200.0 to 199.9 Ind: 7 P052 = 3
[%] Type: I2
i001: Display of connector selected in P044.01 0.1%
i002: Display of connector selected in P044.02
i003: Display of connector selected in P044.03
i004: Display of connector selected in P044.04
i005: Display of connector selected in P044.05
i006: Display of connector selected in P044.06
i007: Display of connector selected in P044.07
P044 Connector display: All connector Ind: 7 P052 = 3
* numbers FS=0 P051 = 40
i001: Selection of connector displayed in r043.01 1 Type: L2 Online
i002: Selection of connector displayed in r043.02
i003: Selection of connector displayed in r043.03
i004: Selection of connector displayed in r043.04
i005: Selection of connector displayed in r043.05
i006: Selection of connector displayed in r043.06
i007: Selection of connector displayed in r043.07
r045 Binector display: 0 to 1 Ind: 4 P052 = 3
Type: O2
i001: Display of binector selected in P046.01
i002: Display of binector selected in P046.02
i003: Display of binector selected in P046.03
i004: Display of binector selected in P046.04

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SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

[Unit] Change

P046 Binector display: All binector numbers Ind: 4 P052 = 3

* 1 FS=0 P051 = 40
i001: Selection of binector displayed in r045.01 Type: L2 Online
i002: Selection of binector displayed in r045.02
i003: Selection of binector displayed in r045.03
i004: Selection of binector displayed in r045.04

r047 Display of fault diagnostic memory 0 to 65535 Ind: 16 P052 = 3

1 Type: O2
Provides more detailed information about the cause of a fault after activation
of a fault message.

i001 Word 1 (fault value)

i002 Word 2
...
i016 Word 16 (fault number)
r048 Hours run 0 to 65535 Ind: None P052 = 3
[hours] Type: O2
Display of time (hours) in which drive has been operating in states I, II or - -. 1 hour
All times of ≥ approx. 0.1 s are included in the count.
r049 Fault time 0 to 65535 Ind: 8 P052 = 3
[hours] Type: O2
Display of time at which the current fault, and the last 7 acknowledged 1 hour
faults, were activated.

i001: Current fault hours

st
i002: 1 acknowledged fault hours
nd
i003: 2 acknowledged fault hours
rd
i004: 3 acknowledged fault hours
th
i005: 4 acknowledged fault hours
th
i006: 5 acknowledged fault hours
th
i007: 6 acknowledged fault hours
th
i008: 7 acknowledged fault hours
P050 Language 0 to 4 Ind: None P052 = 3
* 1 FS=0 P051 ≥ 0
Language of plaintext display on optional OP1S operator panel and in Type: O2 Online
SIMOVIS PC service routine

0: German
1: English
2: Spanish
3: French
4: Italian
P051 Key parameters see column on left Ind: None P052 = 3
* FS=40 P051 ≥ 0
0 No access authorization Type: O2 Online
6 Do not set (for use by SIMOVIS)
7 Do not set (for use by SIMOVIS)
21 Restore factory settings
All parameters are reset to their defaults (factory settings).
Parameter P051 is then automatically reset to factory setting
"40".
22 Execute internal offset compensation
24 Forcing (see parameters P480 to P485)
25 Optimization run for precontrol and current controller (armature
and field)
26 Optimization run for speed controller
27 Optimization run for field weakening
28 Optimization run for compensation of friction and moment of
inertia
29 Optimization run for speed controller with oscillating
Mechanical system
40 Access authorization to parameter values for authorized service
personnel

SIEMENS Energy & Automation 10-9

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

[Unit] Change

10.5 Access authorization levels and parameter output

P052 Selection of display parameters 0, 3 Ind: None P052 = 3
* FS=3 P051 ≥ 0
0 Display only parameters that are not set to original factory settings Type: O2 Online
1 Display only parameters for simple application
3 Display all parameters used

10.6 Definition of SIMOREG DC MASTER converter

P067 Load class 1 to 5 Ind: None P052 = 3
* 1 FS=1 P051 = 40
1 Load class DC I Type: O2 Off-line
2 Load class DC II
3 Load class DC III
4 Load class DC IV
5 US (NEMA) rating
The US rating is the only permissible setting for base drive units.
r071 Converter rated supply voltage (armature) 10 to 830 Ind: None P052 = 3
[V] Type: O2
Converter rated supply voltage (armature) as specified on rating plate 1V
r072 Converter rated DC current (armature) 1.0 to 6553.5 Ind: 2 P052 = 3
[A] Type: O2
i001: Converter rated DC current (armature) as specified on rating 0.1A
plate (output DC current at power terminals 1C1 and 1D1)
i002: Actual converter rated DC current (armature) as set in
parameter P076.001
r073 Converter rated DC current (field) 1.00 to 100.00 Ind: 2 P052 = 3
[A] Type: O2
i001: Converter rated DC current (field) as specified on rating plate 0.01A
(output DC current at power terminals 3C and 3D)
i002: Actual converter rated DC current (field) as set in parameter
P076.002
r074 Converter rated supply voltage (field) 10 to 460 Ind: None P052 = 3
[V] Type: O2
Converter rated supply voltage (field) as specified on rating plate 1V
P075 Control word for power section 0 to 2 Ind: None P052 = 3
* 1 FS=1 P051 = 40
Selection of operating characteristics of thermal monitor (I2t monitoring) of Type: O2 Offline
power.
0 The I2t monitoring function for the power section is deactivated.
The armature current is limited to P077 *r072.001.
1 The armature current is limited to P077 * 1.8 * r072.001 as long
as the calculated thyristor temperature rise does not exceed the
permissible value. When the permissible value is violated, alarm
A039 is activated and the limit for the armature current setpoint
reduced automatically to P077 * converter rated DC current until
the absolute value of the armature current setpoint before
limitation has dropped to below converter rated DC current and
the calculated temperature rise is within the permissible
tolerance again. The armature current setpoint limit is then
raised again to equal P077 * 1.8 * r072.001 current and alarm
A039 is deactivated again.
2 The armature current is limited to P077 * 1.8 * r072.001 as long
as the calculated thyristor temperature rise does not exceed the
permissible value.
Fault message F039 is activated in response to violation of the
permissible limit.

10-10 SIEMENS Energy & Automation

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

[Unit] Change

P076 Reduction of converter rated DC current see column on left Ind: 2 P052 = 3
* FS=100.0 P051 = 40
i001: Reduction of converter rated DC current (armature) Type: O2 Offline
i002: Reduction of converter rated DC current (field)
For the purpose of achieving a close match between the converter and
motor, the converter rated DC current is reduced to the value entered here.
The following values can be set:
10.0%, 20.0%, 33.3%, 40.0%, 50.0%, 60.0%, 66.6% 70.0%, 80.0%, 90.0%
and 100.0%
P077 Total thermal reduction factor 0.50 to 1.00 Ind: None P052 = 3
0.01 FS=1.00 P051 = 40
The factor set in this parameter effects a reduction in the armature current Type: O2 Offline
limit (as defined by the setting in P075).
The converter must be derated in the following instances:
– Operation at high ambient temperatures:
If the ambient temperature is higher than 45°C (on naturally air-cooled
converters) or 35°C (on converters with forced air-cooling), the possible
load capability of the converter decreases as a consequence of the
maximum permissible thyristor junction temperature by percentage
reduction "a" as specified in the table in Section 5, resulting in a
temperature reduction factor of
ktemp = (100 - a) / 100
– Installation altitudes of over 1000m above sea level:
In this case, the lower air density and thus less effective cooling reduce
the possible load capability of the converter to the percentage load "b1"
specified in the table in Section 5, resulting in an installation altitude
reduction factor of
kaltitude = b1 / 100

P077 must be set as follows: P077 = ktemp * kaltitude

Note:
A general reduction in the converter rated DC current (through appropriate
setting of parameter P076.001) can be included in this calculation.
P078 Reduction of converter rated supply voltage 10 to r071 Ind: 2 P052 = 3
[V] FS=r071 P051 = 40
i001: Rated input voltage armature 1V Type: O2 Offline
i002: Rated input voltage field
The rated voltage value of the power system actually used to supply the
power section must be set in this parameter.
This setting acts as the reference for the undervoltage, overvoltage and
phase failure monitoring functions (see also P351, P352 and P353) as well
as for connectors K0285 to K0289, K0291, K0292, K0301 K0302, K0303
and K0305

NOTE
If a SIMOREG converter is operated at a rated input voltage that is
lower than its rated supply voltage, then the rated DC voltage specified
in the technical data (Section 5) cannot be reached!

SIEMENS Energy & Automation 10-11

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

[Unit] Change

10.7 Setting values for converter control

P081 EMF-dependent field weakening 0 to 1 Ind: None P052 = 3
* 1 FS=0 P051 = 40
0 No field-weakening operation as a function of speed or EMF Type: L2 Offline
(100% of rated motor field current is applied constantly as the
internal field current setpoint).
1 Field-weakening operation by internal closed-loop EMF control to
ensure that in field-weakening operation, i.e. at speeds above the
motor rated speed (="field-weakening activation limit speed”), the
motor EMF is maintained constantly at the setpoint
EMFset (K0289) = P101 – P100 * P110 (field current setpoint is
the product of the EMF controller output and the precontrol
component determined by the actual speed according to the field
characteristic).

NOTE
When P081=1, a valid field characteristic must be available (P117=1),
otherwise the optimization run for field weakening (P051=27) must be
executed.

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SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS
P082 Operating mode for field 0 to 24 Ind: None P052 = 3
* 1 FS=2 P051 = 40
0 Internal field is not used (e.g. for permanent-field motors), field Type: O2 Offline
gating pulses are disabled. Unlike all other cases, the motor flux
(K0290) is not calculated according to the field characteristic
(P120 to P139) as a function of the actual field current (K0265),
but set to the value for 100% rated flux.
1 The field is switched with the line contactor - this setting must be
selected if the mains supplies for the field and armature power
sections are connected or disconnected simultaneously (field
gating pulses are enabled/disabled at the same time as the line
contactor is closed/opened, the field current decays with the field
time constant).
2 Automatic injection of standstill field set in P257 after expiry of a
time period set in P258, after converter has reached operating
state o7 or higher.
3 Field ACTIVE continuously.
4 The field is switched with “Auxiliaries ON” (B0251) signal
External field power module (40.00A field)
11 Board C98043-A7044 (40A field power module) is inserted at
connector X102 on board C98043-A7002 or C98043-A7003.
The field is controlled as described in para. 1.
12 As described in para. 11, but
the field is controlled as described in para 2.
13 As described in para. 11, but
the field is controlled as described in para 3.
14 As described in para. 11, but
the field is controlled as described in para 4.
External field device
21 The external field device. The setpoint for the external
field device is supplied via connector K0268 (e.g. via analog
output or the peer-to-peer interface). The
rated DC current of the external field device is set in
parameter U838. This value is also displayed in parameter
r073.001. P076.002 is inoperative. If
the external field device supplies an “I field < I field min” signal ,
then this can be fed in at P265. The field is
controlled as described in para 1.
22 As described in para. 21, but
the field is controlled as described in para 2.
23 As described in para. 21, but
the field is controlled as described in para 3.
24 As described in para. 21, but
the field is controlled as described in para 4.

Note:
Even though changes to the parameter value from > 0 to = 0 are accepted in
operating states of ≥ o1.0, they do not take effect until the converter reaches
an operating state of ≥ o7.0.
[Values 11 to 24 can be set only in SW 1.9 or later]

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SIMOREG DC Master Base Drive Panel Operating Instructions
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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS
P083 Selection of actual speed value 0 to 4 Ind: 4 P052 = 3
* 1 FS=0 P051 = 40
0 Actual speed value is not yet selected (fixed value 0%) Type: O2 Offline
FDS
1 Actual speed value supplied by "Main actual value” channel
(K0013) (terminals XT.103, XT.104)
2 Actual speed value supplied by "Actual speed from pulse
encoder” channel (K0040)
3 Actual speed value supplied by "Actual EMF" channel (K0287),
but weighted with P115 (operation without tacho)
4 Actual speed value is wired up freely (selected in P609)
P085 Wait period after cancellation of inching command 0.0 to 60.0 Ind: None P052 = 3
[s] FS=10.0 P051 = 40
After an inching command has been cancelled, the drive dwells in operating 0.1s Type: O2 Online
state o1.3 for the time period set in this parameter with the controllers
disabled, but the line contactor closed. This wait period does not commence
until n<nmin (P370, P371) is reached. If a new inching command is input
within this period, then the drive switches to the next operating state (o1.2 or
lower). However, if the time runs out without a new inching command being
entered, then the line contactor drops out and the drive switches to operating
state o7.
P086 Voltage failure period for automatic restart 0.0 to 2.0 Ind: None P052 = 3
[s] FS=0.4 P051 = 40
If the voltage fails (F001, F004) at one of the terminals 1U1, 1V1, 1W1, 3U1, 0.1s Type: O2 Online
3W1, 5U1 or 5W1, or if it drops below a certain threshold (F006
undervoltage) or exceeds a certain threshold (F007 overvoltage), or its
frequency is too low (F008 frequency <45Hz) or too high (F009 frequency
>65Hz), or if the actual field current drops to below 50% of the field current
setpoint for more than 0.5s (F005), then the corresponding fault message is
activated only if the fault condition has not been eliminated within the
"Automatic restart" period set in this parameter.
The gating pulses and controllers are disabled while the fault conditions are
present. The converter dwells in operating state o4 (in the case of armature
line voltage fault) or o5 (in the case of field line voltage or field current fault)
or in o13.
Setting this parameter to 0.0s deactivates the "Automatic restart" function.
P095 Pick-up time for a contactor in the DC circuit 0.00 to 1.00 Ind: None P052 = 3
[s] FS=0.00 P051 = 40
If the DC output (terminals 1C1 and 1D1) is switched through to the motor 0.01s Type: O2 Online
via a contactor, and if this contactor is controlled by the "Relay for line
contactor" (terminals 109 and 110), then the gating pulses may not be
enabled until the contactor has safely picked up. For this purpose, it may be
necessary to parameterize an additional delay time for the pick-up operation.
The timer set in P095 commences during a pick-up operation when the
converter reaches operating state o5. If the timer has still not run down by
the time the converter exits state o4, then the converter dwells in state o3.2
until the timer has finished.
During the time period set in P095, the “Main contactor checkback” signal
must also switch to “1” if this function is activated (see P961). Ootherwise the
converter dwells in state o3.3 until timer has finished and fault message
F004 is then output with fault value 6.

10.8 Definition of motor

P100 Rated motor armature current (acc. to motor rating plate) 0.0 to 6553.0 Ind: 4 P052 = 3
* [A] FS=0.0 P051 = 40
0.0 Parameter not yet set 0.1A Type: O2 Offline
FDS
P101 Rated motor armature voltage (acc. to motor rating plate) 10 to 1000 Ind: 4 P052 = 3
* [V] FS=400 P051 = 40
Notes: 1V Type: O2 Offline
FDS One of the functions of this parameter is to determine the point at which field-
weakening operation commences.
If possible, the rated motor armature voltage + the voltage drop in the motor
feeder cable (for a current setting acc. to P100) should be set in P101.
P102 Rated motor field current (acc. to motor rating plate) 0.00 to 100.00 Ind: 4 P052 = 3
* [A] FS=0.00 P051 = 40
0.00 Parameter not yet set 0.01A Type: O2 Online
FDS

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SIMOREG DC Master Base Drive Panel Operating Instructions
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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS
P103 Minimum motor field current 0.00 to 100.00 Ind: 4 P052 = 3
* [A] FS=0.00 P051 = 40
Note: 0.01A Type: O2 Offline
FDS
P103 must be set to <50% of P102 to execute the optimization run for field
weakening (P051=27).
P110 Armature circuit resistance 0.000 to 32.767 Ind: 4 P052 = 3
[Ω] FS=0.000 P051 = 40
This parameter is set automatically during the optimization run for precontrol Type: O2 Online
FDS 0.001Ω
and current controller (armature and field) (P051=25).
P111 Armature circuit inductance 0.000 to 327.67 Ind: 4 P052 = 3
[mH] FS=0.00 P051 = 40
This parameter is set automatically during the optimization run for precontrol 0.01mH Type: O2 Online
FDS and current controller (armature and field) (P051=25).
P112 Field circuit resistance 0.0 to 3276.7 Ind: 4 P052 = 3
[Ω] FS=0.0 P051 = 40
This parameter is set automatically during the optimization run for precontrol Type: O2 Online
FDS 0.1Ω
and current controller (armature and field) (P051=25).
P114 Thermal time constant of motor 0.0 to 80.0 Ind: 4 P052 = 3
[min] FS=10.0 P051 = 40
FDS 0.1min Type: O2 Online
0.0 I2t monitoring deactivated
P115 EMF at maximum speed in operation without tachometer 1.00 to 140.00 Ind: 4 P052 = 3
[% of r071.002] FS=100.00 P051 = 40
This parameter is used to adjust the speed in cases where the internal actual 0.01% Type: O2 Online
FDS EMF value is applied as the actual speed value. P115 defines the EMF
which corresponds to maximum speed as a percentage of P078.001.
P118 Rated EMF value 0 to 1000 Ind: 4 P052 = 3
[V] FS=340 P051 = 40
EMF that is reached with a full field (according to parameter P102) and a 1V Type: O2 Offline
FDS speed as set in parameter P119.
The parameter is set automatically during the field-weakening optimization
run (P051=27) and specifies in this case the setpoint EMF in the field-
weakening range.

Note:
As regards the closed-loop field-weakening control, only the ratio between
P118 and P119 is relevant. The EMF setpoint in the field-weakening range is
determined by (P101 – P100 * P110). When the setting in P100, P101 or
P110 is changed subsequently, the field-weakening optimization run need
not be repeated. However, P118 then no longer defines the setpoint EMF in
the field-weakening range.
When the setting in parameter P102 is changed subsequently, the field-
weakening optimization run must be repeated, the same applies if the
maximum speed setting is subsequently re-adjusted.
P119 Rated speed 0.0 to 199.9 Ind: 4 P052 = 3
[%] FS=100.0 P051 = 40
Speed at which an actual EMF value as set in parameter P118 is reached at 0.1% Type: O2 Offline
FDS full field (according to parameter P102).
This parameter is set automatically during the optimization run for field
weakening (P051=27) and specifies in this case the field-weakening
activation limit speed.

Note:
As regards the closed-loop field-weakening control, only the ratio between
P118 and P119 is relevant. When the setting in P100, P101 or P110 is
changed subsequently, the field-weakening optimization run need not be
repeated. However, P119 then no longer defines the field-weakening
activation limit speed.
When the setting in parameter P102 is changed subsequently, the field-
weakening optimization run must be repeated, the same applies if the
maximum speed setting is subsequently re-adjusted.

SIEMENS Energy & Automation 10-15

SIMOREG DC Master Base Drive Panel Operating Instructions
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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS

Magnetization characteristic (field characteristic)

Parameters P120 to P139 determine the curve shape of the magnetization characteristic (field characteristic) in normalized representation
(see example field characteristic below for further details).

Note:
When the setting in parameter P102 is changed subsequently, the field-weakening optimization run must be repeated, because this alters
the degree of saturation and thus the shape of the magnetization characteristic. (When parameter P100, P101 or P110, or the maximum
speed adjustment, is subsequently altered, the settings in P120 to P139 remain the same, but the values in P118 and/or P119 are
changed).
r120 Field current for 0% motor flux (field characteristic, point no. 0) 0.0 Ind: 4 P052 = 3
[% of P102] Type: O2
FDS 0.1% of P102
P121 Field current for 5% motor flux (field characteristic, point no. 1) 0.0 to 100.0 Ind: 4 P052 = 3
[%] FS=3.7 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P122 Field current for 10% motor flux (field characteristic, point no. 2) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=7.3 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P123 Field current for 15% motor flux (field characteristic, point no. 3) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=11.0 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P124 Field current for 20% motor flux (field characteristic, point no. 4) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=14.7 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P125 Field current for 25% motor flux (field characteristic, point no. 5) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=18.4 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P126 Field current for 30% motor flux (field characteristic, point no. 6) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=22.0 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P127 Field current for 35% motor flux (field characteristic, point no. 7) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=25.7 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P128 Field current for 40% motor flux (field characteristic, point no. 8) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=29.4 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P129 Field current for 45% motor flux (field characteristic, point no. 9) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=33.1 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P130 Field current for 50% motor flux (field characteristic, point no. 10) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=36.8 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P131 Field current for 55% motor flux (field characteristic, point no. 11) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=40.6 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P132 Field current for 60% motor flux (field characteristic, point no. 12) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=44.6 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P133 Field current for 65% motor flux (field characteristic, point no. 13) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=48.9 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P134 Field current for 70% motor flux (field characteristic, point no. 14) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=53.6 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P135 Field current for 75% motor flux (field characteristic, point no. 15) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=58.9 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P136 Field current for 80% motor flux (field characteristic, point no. 16) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=64.9 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P137 Field current for 85% motor flux (field characteristic, point no. 17) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=71.8 P051 = 40
FDS 0.1% of P102 Type: O2 Offline

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SIMOREG DC Master Base Drive Panel Operating Instructions
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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS
P138 Field current for 90% motor flux (field characteristic, point no. 18) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=79.8 P051 = 40
FDS 0.1% of P102 Type: O2 Offline
P139 Field current for 95% motor flux (field characteristic, point no. 19) 0.0 to 100.0 Ind: 4 P052 = 3
[% of P102] FS=89.1 P051 = 40
FDS 0.1% of P102 Type: O2 Offline

SIEMENS Energy & Automation 10-17

SIMOREG DC Master Base Drive Panel Operating Instructions
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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS

Example of a field characteristic

The example characteristic exhibits a sharper curvature (i.e. a lower degree of saturation) than the field characteristic produced by the
factory setting.

Φ Motor flux in % of ratet flux

100 1)

95

90

85

80

75

70

65

60

55

50

45

40

35

30

25

20

15

10

P124 P129 P134 P139 100,0% If

P123 P128 P133 P138
P122 P127 P132 P137
Field current in % of P102
P121 P126 P131 P136

r120 P125 P130 P135

1) For actual field currents If of > 100% of P102, the characteristic is extended linearly for internal calculation of the motor flux.

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SIMOREG DC Master Base Drive Panel Operating Instructions
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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS

10.9 Definition of pulse encoder, speed sensing using pulse encoder

The following types of pulse encoder can be used (type selection in P140):

1. Pulse encoder type 1

Encoder with two pulse tracks mutually displaced by 90° (with/without zero marker)

Track 1
X173 28, 29

Track 2
X173 30, 31

Zero marker Heidenhain ROD

X173 32, 33 Teldix Rotaswitch Serie 26

Notes on selecting a pulse encoder (number of pulses):

The lowest speed which can be measured by a pulse encoder is calculated with the following equation:

1
n min [ rev / min] =21973∗ Formula applies with a nominal measuring time of 1 ms when P146=0 and P147=0
X ∗P141

The following applies:

X = 1 for 1x evaluation of pulse encoder signals (P144=0)
2 for 2x evaluation of pulse encoder signals (P144=1)
4 for 4x evaluation of pulse encoder signals (P144=2)

Lower speeds are interpreted as n=0.

The frequency of the pulse encoder signals at terminals 28 and 29 or 30 and 31 must not be higher than 300 kHz.
The highest speed which can be measured by a pulse encoder is calculated with the following equation:

18000000
n max [ rev / min] =
P141

When selecting a pulse encoder, therefore, it is important to ensure that the lowest possible speed ≠ 0 is significantly higher than nmin and
the highest possible speed does not exceed nmax.

21973
IM >> Equations for selection of pulses per revolution IM of pulse encoder
X ∗n min [ rev / min]
18000000
IM ≤
n max [ rev / min]

Single/multiple evaluation of encoder pulses:

The setting for single/multiple evaluation of encoder pulses is applicable for both the speed and position sensing functions.

1x evaluation: Only the rising edges of one pulse track are evaluated (applies to all encoder types).
2x evaluation: The rising and falling edges of one pulse track are evaluated (can be set for encoder types 1, 1a and 2).
4x evaluation: The rising and falling edges of both pulse tracks are evaluated (can be set for encoder types 1 and 1a)

SIEMENS Energy & Automation 10-19

SIMOREG DC Master Base Drive Panel Operating Instructions
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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS
P140 Selection of pulse encoder type 0 to 4 Ind: None P052 = 3
1 FS=0 P051 = 40
0 No encoder/"Speed sensing with pulse encoder" function not Type: O2 Offline
selected
1 Pulse encoder type 1 Normal encoder
2 (Pulse encoder type 1a Special encoder)
3 (Pulse encoder type 2 Special encoder)
4 (Pulse encoder type 3 Special encoder)
P141 Number of pulses of pulse encoder 1 to 32767 Ind: None P052 = 3
[pulses/rev] FS=500 P051 = 40
1 pulse/rev Type: O2 Offline
P142 Matching to pulse encoder signal voltage 0 to 1 Ind: None P052 = 3
1 FS=1 P051 = 40
0 Pulse encoder outputs 5 V signals Type: O2 Offline
1 Pulse encoder outputs 15V signals
Matching of internal operating points to signal voltage of incoming pulse
encoder signals.

CAUTION
Resetting parameter P142 to the alternative setting does not switch over
the supply voltage for the pulse encoder (terminals X173.26 and 27).
Terminal X173.26 always supplies +15V. An external voltage supply is
must be provided for pulse encoders requiring a 5V supply.

P143 Setting the maximum speed for pulse encoder operation 1 to 6500.0 Ind: 4 P052 = 3
[rev/min] FS=500.0 P051 = 40
FDS The speed set in this parameter corresponds to an actual speed (K0040) of 0.1rev/min Type: O4 Online
100%.

Control parameters for speed sensing with pulse encoder P144 to P147:
P144 and P147 determine the basic setting for actual speed sensing by means of pulse encoder (single or multiple evaluation of pulse
encoder signals and nominal measuring time) and thus also define the lowest possible measurable speed (minimum speed).
P145 and P146 can be used in special cases to extend the measurable speed range down to even lower speeds, on the basis of the
minimum speed defined by the settings in P144 and P147.
P144 Multiple evaluation of encoder signals 0 to 2 Ind: 4 P052 = 3
* 1 FS=2 P051 = 40
0 1x evaluation of pulse encoder signals Type: O2 Offline
FDS 1 2x evaluation of pulse encoder signals (for encoder types 1, 1a, 2)
2 4x evaluation of pulse encoder signals (for encoder types 1, 1a)
Note:
In contrast to the 1x evaluation method, 2x or 4x evaluation reduces the
minimum measurable speed by a factor of 2 or 4 respectively, but may
produce an "unsteady" actual speed value on encoders with unequal
pulse/pause ratio or without an exact 90° displacement between encoder
signals.
P145 Automatic measuring range switchover for measurement of low speeds 0 to 1 Ind: 4 P052 = 3
* - switchover of multiple evaluation 1 FS=0 P051 = 40
FDS Type: O2 Offline
0 Automatic switchover of multiple evaluation of pulse encoder
signals OFF (i.e. P144 is always active)
1 Automatic switchover of multiple evaluation of pulse encoder
signals ON (i.e. when P144 = 0, 2x evaluation is selected for low
speeds and 4x evaluation for very low speeds. When P144 = 1,
4x evaluation is selected for low speeds)
As opposed to P145 = 0, this setting reduces the minimum
measurable speed by up to a factor of 4.
Caution:
Switching over the multiple evaluation method for encoder pulses also
affects the position sensing function in the measuring channel. For this
reason, this setting may not be used in conjunction with positioning
operations. Connectors K0042 to K0044 are inoperative when P145 = 1.

10-20 SIEMENS Energy & Automation

SIMOREG DC Master Base Drive Panel Operating Instructions
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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS
P146 Automatic measuring range switchover for measurement of low speeds 0 to 1 Ind: 4 P052 = 3
* - switchover of measuring time 1 FS=0 P051 = 40
FDS Type: O2 Offline
0 Automatic switchover of measuring time OFF
(i.e. P147 is always active)
1 Automatic switchover of measuring time ON
This setting extends the measuring time for low speeds (based
on the measuring time set in P147, i.e. when P147 = 0, the
nominal measuring time is switched over to 2 ms for low speeds
and to 4 ms for very low speeds. When P147 = 1, the nominal
measuring time is switched over to 4 ms for low speeds)
Caution:
When P146=1, the minimum measurable speed can be reduced by up to a
factor of 4 as opposed to a 0 setting. However, this setting results in a longer
actual speed sensing delay in the extended minimum speed range.
P147 Nominal measuring time of pulse encoder signal evaluation 0 to 2 Ind: 4 P052 = 3
* 1 FS=0 P051 = 40
0 Nominal measuring time = 1 ms Type: O2 Offline
FDS
1 Nominal measuring time = 2 ms (produces "steadier" actual
speed value than with 0)
2 Nominal measuring time = 4 ms (for drives with high moment of
inertia, produces "steadier" actual speed value than with 0)
Caution:
When P147 = 1 or 2, the minimum measurable speed can be reduced by a
factor of 2 or 4 respectively as opposed to 0. However, these settings
increase the actual speed sensing delay. For this reason, P200 should be
parameterized to at least 5ms before the optimization run for the speed
controller is executed.
P148 Pulse encoder monitoring function 0 to 1 Ind: 4 P052 = 3
* 1 FS=1 P051 = 40
0 Pulse encoder monitoring OFF (activation of F048 in response to Type: O2 Offline
FDS a defective pulse encoder is disabled)
1 Pulse encoder monitoring ON (hardware monitoring of pulse
encoder signals for implausible behaviour (i.e. frequent speed
changes, distance between edges too short, encoder cable
defect or short between two encoder cables) may cause
activation of F048)

10.10 Closed-loop armature current control, auto-reversing stage, armature gating

unit
P150 Alpha G limit (armature) 0 to 165 Ind: 4 P052 = 3
[degrees] FS=5 / 30 P051 = 40
FDS Rectifier stability limit for firing angle of armature converter. 1 degrees (for 1Q / 4Q Online
converters)
Type: O2
P151 Alpha W limit (armature) 120 to 165 Ind: 4 P052 = 3
[degrees] FS=150 P051 = 40
FDS Inverter stability limit for firing angle of armature converter. 1 degrees Type: O2 Online
This firing angle limitation is active only when the armature current is
continuous. In the case of a discontinuous armature current, the firing angle
is limited to 165 degrees.
P153 Control word for armature precontrol 0 to 2 Ind: 4 P052 = 3
* 1 FS=1 P051 = 40
0 Armature precontrol disabled, precontrol output=165° Type: O2 Offline
FDS
1 Armature precontrol active
2 Armature precontrol active, but EMF effect is active only on
change in torque direction
(must be set in cases where the armature terminals are to supply
large inductances, e.g. lifting solenoids, field supply)
P155 Armature current controller P gain 0.01 to 200.00 Ind: 4 P052 = 3
0.01 FS=0.10 P051 = 40
FDS Proportional gain of armature current controller Type: O2 Online
This parameter is automatically set during the optimization run for precontrol
and current controller (armature and field) (P051=25).

SIEMENS Energy & Automation 10-21

SIMOREG DC Master Base Drive Panel Operating Instructions
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PNU Description Value range No. indices See

* [Unit] Change
FDS
P156 Armature current controller reset time 0.001 to 10.000 Ind: 4 P052 = 3
[s] FS=0,200 P051 = 40
FDS This parameter is automatically set during the optimization run for precontrol 0.001s Type: O2 Online
and current controller (armature and field) (P051=25).
P157 Control word for current setpoint integrator 0 to 1 Ind: 4 P052 = 3
* 1 FS=0 P051 = 40
0 Reduced gearbox stressing Type: O2 Offline
FDS The integrator is active only after a change in torque direction
(acts as ramp-function generator for armature current setpoint
only until the output reaches the setpoint at the integrator input
st
for the 1 time after a change in torque direction).
1 Current setpoint integrator
The integrator is always active (acts as ramp-function generator
for the armature current setpoint)
P158 Ramp-up time for current setpoint integrator (reduced gearbox 0.000 to 1.000 Ind: 4 P052 = 3
stressing) [s] FS=0.000 P051 = 40
FDS 0.001s Type: O2 Online
Period of an acceleration ramp with a setpoint step change from 0% to 100%
at r072.002.
P157=1, P158=0.040 must be set for older machines.
P160 Additional torque-free interval 0.000 to 2.000 Ind: 4 P052 = 3
[s] FS=0.000 P051 = 40
FDS Additional torque-free interval for torque direction change in 4Q operation. 0.001s Type: O2 Online
It is particularly important to set this parameter to values of > 0 for converter
armatures which supply large inductances (e.g. lifting solenoids).
P162 EMF calculation method for armature precontrol 0 to 1 Ind: 4 P052 = 3
* 1 FS=1 P051 = 40
0 The EMF derived from the measured armature voltage is applied Type: O2 Offline
FDS
1 The EMF derived from the calculated armature voltage is applied
(the purpose of this setting is to prevent the occurrence of any
low-frequency (< 15 Hz) armature current fluctuations)

10.11 Current limitation, torque limitation

P169 Select closed-loop torque / current control 0 to 1 Ind: 4 P052 = 3
* 1 FS=1 P051 = 40
See parameter P170 Type: O2 Offline
FDS
P170 Select closed-loop torque / current control 0 to 1 Ind: 4 P052 = 3
* 1 FS=0 P051 = 40
P169 P170 Type: O2 Offline
FDS
0 0 Closed-loop current control and current limitation
0 1 Closed-loop torque control with torque limitation (the torque
setpoint is converted to a current setpoint: Current setpoint
= torque setpoint / motor flux)
Current limitation is active additionally
1 0 Closed-loop current control with torque limitation (the
specified torque limit is converted to a current limit: Current
limit = torque limit / motor flux)
Current limitation is active additionally
1 1 Do not set!

Note:
A valid field characteristic (P117=1) must be available when P169 or
P170=1. If one is not, the optimization run for field weakening (P051=27)
must be executed.
P263 determines the input quantity for the motor flux calculation.
P171 System current limit in torque direction I 0.0 to 300.0 Ind: 4 P052 = 3
[% of P100] FS=100.0 P051 = 40
FDS 0.1% of P100 Type: O2 Online
P172 System current limit in torque direction II -300.0 to 0.0 Ind: 4 P052 = 3
[% of P100] FS=-100.0 P051 = 40
FDS 0.1% of P100 Type: I2 Online

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SIMOREG DC Master Base Drive Panel Operating Instructions
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PNU Description Value range No. indices See

* [Unit] Change
FDS
P180 Positive torque limit 1 -300.00 to 300.00 Ind: 4 P052 = 3
[%] FS=300.00 P051 = 40
FDS 0.01% of rated Type: I2 Online
motor torque
P181 Negative torque limit 1 -300.00 to 300.00 Ind: 4 P052 = 3
[%] FS=-300.00 P051 = 40
FDS 0.01% of rated Type: I2 Online
motor torque

10.12 Speed controller

Setting values for speed controller - actual value/setpoint processing

P200 Filter time for actual speed controller value 0 to 10000 Ind: 4 P052 = 3
[ms] FS=0 P051 = 40
FDS Filtering of the actual speed value by means of a PT1 element. 1ms Type: O2 Online
This filter setting is taken into account by the speed controller optimization
run (P051=26).
P222 Speed controller: PI / P controller switchover threshold 0.00 to 10.00 Ind: 4 P052 = 3
[%] FS=0.00 P051 = 40
FDS 0.00 Automatic switchover from PI to P controller deactivated. 0.01% of maximum Type: O2 Online
> 0.00 Depending on the actual speed (K0166), the PI controller speed
switches over to a P controller if the speed drops below the
threshold set in parameter P222. The integrator is not switched in
again (with value of 0) until the actual speed is > P222 +
2%nmax.
This function allows the drive to be stopped without overshoot
using a zero setpoint with the controllers enabled.
This function is active only if the binector selected in P698 is in
the log. "1" state.

Setting values for speed controller

P223 Control word for speed controller precontrol 0 to 1 Ind: 4 P052 = 3

* 1 FS=0 P051 = 40
0 Speed controller precontrol disabled Type: O2 Offline
FDS 1 Speed controller precontrol acts as torque setpoint (is added to n
controller output)
P225 Speed controller P gain 0.10 to 200.00 Ind: 4 P052 = 3
0.01 FS=3.00 P051 = 40
FDS See also setting values for "Speed controller adaptation" function (P550 to Type: O2 Online
P559).
This parameter is set automatically during the speed controller optimization
run (P051=26).
P226 Speed controller reset time 0.010 to 10.000 Ind: 4 P052 = 3
[s] FS=0,650 P051 = 40
FDS This parameter is set automatically during the speed controller optimization 0.001s Type: O2 Online
run (P051=26).
Speed controller droop
Function: A parameterizable feedback loop can be connected in parallel to the I and P components of the speed controller (acts on
summation point of setpoint and actual value).
P227 Speed controller droop 0.0 to 10.0 Ind: 4 P052 = 3
[%] FS=0.0 P051 = 40
FDS A 10% speed droop setting causes a 10% deviation in the speed from the 0.1% Type: O2 Online
setpoint at a 100% controller output (100% torque or armature current
setpoint) ("softening" of closed-loop control).
See also P562, P563, P630 and P684

P228 Filter time for speed setpoint 0 to 10000 Ind: 4 P052 = 3

[ms] FS=0 P051 = 40
FDS Filtering of setpoint by means of a PT1 element. 1ms Type: O2 Online
This parameter is automatically set to the same value as the speed controller
reset time during the speed controller optimization run (P051=26).
It may be useful to parameterize lower values when the ramp-function
generator is in use.

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SIMOREG DC Master Base Drive Panel Operating Instructions
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PNU Description Value range No. indices See

* [Unit] Change
FDS

10.13 Closed-loop field current control, field gating unit

P250 Alpha G limit (field) 0 to 180 Ind: 4 P052 = 3
[degrees] FS=0 P051 = 40
FDS Rectifier stability limit for firing angle of field converter 1 degree Type: O2 Online
P251 Alpha W limit (field) 0 to 180 Ind: 4 P052 = 3
[degrees] FS=180 P051 = 40
FDS Inverter stability limit for firing angle of field converter 1 degree Type: O2 Online
P253 Control word for field precontrol 0 to 1 Ind: 4 P052 = 3
* 1 FS=1 P051 = 40
0 Field precontrol disabled, precontrol output = 180° Type: O2 Offline
FDS
1 Field precontrol active, output is dependent on field current
setpoint, field line voltage, P112
P255 Field current controller P gain 0.01 to 100.00 Ind: 4 P052 = 3
0.01 FS=5.00 P051 = 40
FDS This parameter is set automatically during the optimization run for precontrol Type: O2 Online
and current controller (armature and field) (P051=25).
P256 Field current controller reset time 0.001 to 10.000 Ind: 4 P052 = 3
[s] FS=0,200 P051 = 40
FDS This parameter is set automatically during the optimization run for precontrol 0.001s Type: O2 Online
and current controller (armature and field) (P051=25).
P257 Standstill field 0.0 to 100.0 Ind: 4 P052 = 3
[%] FS=0.0 P051 = 40
FDS Value to which the field current is reduced when "Automatic field current 0.1% of P102 Type: O2 Online
reduction" function is parameterized (by means of P082=xx2) or with signal-
driven selection of "Standstill excitation" function (selected in P692).
P258 Delay time with automatic field current reduction 0.0 to 60.0 Ind: 4 P052 = 3
[s] FS=10.0 P051 = 40
FDS Delay after which the field current is reduced to the value set in parameter 0.1s Type: O2 Online
P257 with automatic or signal-driven "Field current reduction" function when
the drive is stopped after operating state o7.0 or higher is reached.
P265 Source for selection of external field current monitoring signal All binector Ind: 2 P052 = 3
[as of SW 1.9] numbers FS=1 P051 = 40
BDS Selection of the binector to supply the field monitoring signal when an 1 Type: L2 Off-line
external field device is used. (status “1”
= field current is ok., If > If-min)
.The converter waits for this signal in state o5.0 as part of the power On
routine. If the signal disappears during operation, the drive is shut down with
fault message F005, fault value 4.
0 = binector B0000
1 = binector Booo1
etc

10.14 Closed-loop EMF control

P273 Control word for EMF controller precontrol 0 to 1 Ind: 4 P052 = 3
* 1 FS=1 P051 = 40
0 EMF controller precontrol disabled, precontrol output = rated Type: O2 Offline
FDS motor field current (P102)
1 EMF controller precontrol is active
P275 EMF controller P gain 0.10 to 100.00 Ind: 4 P052 = 3
0.01 FS=0.60 P051 = 40
FDS This parameter is automatically set during the field weakening optimization Type: O2 Online
run (P051=27).
P276 EMF controller reset time 0.010 to 10.000 Ind: 4 P052 = 3
[s] FS=0.200 P051 = 40
FDS This parameter is automatically set during the field weakening optimization 0.001s Type: O2 Online
run (P051=27).
P277 EMF controller droop 0.0 to 10.0 Ind: 4 P052 = 3
[%] FS=0.0 P051 = 40
FDS 0.1% Type: O2 Online

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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS
P284 Set EMF controller P component to zero 0 to 1 Ind: 4 P052 = 3
* 1 FS=1 P051 = 40
0 Set controller P component to zero (i.e. to obtain pure I Type: O2 Offline
FDS controller)
1 Controller P component is active

10.15 Ramp-function generator

See P639 and P640 for ramp-function generator setting parameters
Limitation at ramp-function generator output (setpoint limiting))
The effective limitations are:
Upper limit: Minimum value of P300 and the four connectors selected with P632
Lower limit: Maximum value of P301 and the four connectors selected with P633
Note: The limiting values for both the positive and negative setpoint limits can have a positive or negative sign. The negative setpoint
limit, for example, can therefore be parameterized to a positive value and the positive setpoint limit to a negative value.
P300 Positive limitation at ramp-function generator output -200.00 to 199.99 Ind: 4 P052 = 3
[%] FS=100.00 P051 = 40
FDS 0.01% Type: I2 Online
P301 Negative limitation at ramp-function generator output -200.00 to 199.99 Ind: 4 P052 = 3
[%] FS=-100.00 P051 = 40
FDS 0.01% Type: I2 Online
Ramp-function generator parameter set 1

P303 Ramp-up time 1 0.00 to 650.00 Ind: 4 P052 = 3

[s] FS=10.00 P051 = 40
FDS 0.01s Type: O2 Online
P304 Ramp-down time 1 0.00 to 650.00 Ind: 4 P052 = 3
[s] FS=10.00 P051 = 40
FDS 0.01s Type: O2 Online
P305 Lower transition rounding 1 0.00 to 100.00 Ind: 4 P052 = 3
[s] FS=0.00 P051 = 40
FDS 0.01s Type: O2 Online
P306 Upper transition rounding 1 0.00 to 100.00 Ind: 4 P052 = 3
[s] FS=0.00 P051 = 40
FDS 0.01s Type: O2 Online

10.16 Setpoint processing

P320 Multiplier for main setpoint -300.00 to 300.00 Ind: 4 P052 = 3
[%] FS=100.00 P051 = 40
FDS 0.01% Type: I2 Online
P321 Multiplier for additional setpoint -300.00 to 300.00 Ind: 4 P052 = 3
[%] FS=100.00 P051 = 40
FDS 0.01% Type: I2 Online

10.17 Setting values for monitoring functions and limits

Setting values for monitoring functions

P360 Response delay for external faults and alarms 0 to 10000 Ind: 4 P052 = 3
The fault message or alarm is not activated on the converter until the [ms] FS=0 P051 = 40
appropriate input or corresponding control word bit (as selected in P675, 1ms Type: O2 Online
P686, P688 or P689) has been in the LOW state for at least the time period
set in this parameter
i001: Delay for external fault 1
i002: Delay for external fault 2
i003: Delay for external alarm 1
i004: Delay for external alarm 2

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SIMOREG DC Master Base Drive Panel Operating Instructions
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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS

10.18 Setting values for limit-value monitors

n < nmin signal

P370 Speed threshold nmin 0.00 to 199.99 Ind: 4 P052 = 3

[%] FS=0,50 P051 = 40
FDS Speed threshold for n < nmin limit-value monitor. 0.01% of maximum Type: O2 Online
speed
Note:
This threshold also affects the sequence of control operations for
"Shutdown", "Fast stop", cancellation of the "Inching" or "Crawling"
command, the "Braking with field reversal" function and the brake control
operation.
P371 Hysteresis for n < nmin signal 0.00 to 199.99 Ind: 4 P052 = 3
[%] FS=0,50 P051 = 40
FDS This value is added to the response threshold if n < nmin is active. 0.01% of maximum Type: O2 Online
speed

n < ncomp. signal

P373 Speed threshold ncomp. 0.00 to 199.99 Ind: 4 P052 = 3

[%] FS=100.00 P051 = 40
FDS Speed threshold for n < ncomp. signal 0.01% of maximum Type: O2 Online
speed
P374 Hysteresis for < ncomp. signal (n < ncomp. signal) 0.00 to 199.99 Ind: 4 P052 = 3
[%] FS=3.00 P051 = 40
FDS This value is added to the response threshold if n < ncomp. is active. 0.01% of maximum Type: O2 Online
speed
P375 OFF delay for n < ncomp. signal 0.0 to 100.0 Ind: 4 P052 = 3
[s] FS=3.0 P051 = 40
FDS 0.1s Type: O2 Online

Overspeed

P380 Maximum speed in positive direction of rotation 0.0 to 199.9 Ind: 4 P052 = 3
[%] FS=120.0 P051 = 40
FDS 0.1% of rated speed Type: O2 Online
P381 Maximum speed in negative direction of rotation -199.9 to 0.0 Ind: 4 P052 = 3
[%] FS=-120.0 P051 = 40
FDS 0.1% of rated speed Type: I2 Online

Setpoint/actual value deviation

P388 Permissible deviation between setpoint and actual value 0.00 to 199.99 Ind: 4 P052 = 3
[%] FS=3.00 P051 = 40
FDS 0.01% of maximum Type: O2 Online
speed
P389 Hysteresis for setpoint/actual value deviation signal 0.00 to 199.99 Ind: 4 P052 = 3
[%] FS=3.00 P051 = 40
FDS This value is added to the response threshold if a setpoint/actual value 0.01% of maximum Type: O2 Online
deviation signal is active speed
P390 Response delay for setpoint/actual value deviation signal 0.0 to 100.0 Ind: 4 P052 = 3
[s] FS=3.0 P051 = 40
FDS 0.1s Type: O2 Online

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SIMOREG DC Master Base Drive Panel Operating Instructions
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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS

10.19 Digital setpoint input (fixed setpoint, inching and crawling setpoints)

Fixed setpoint
Function: Up to 8 connectors can be selected in P431 indices .01 to .08. These can be applied as an additional fixed setpoint (K0204,
K0209) via the binectors selected in P430, indices .01 to .08 (setpoint is applied when binector switches to log. "1" state). P432
indices .01 to .08 can be set to define for each setpoint individually whether the ramp-function generator must be bypassed on
setpoint injection.

If fixed setpoint injection is not selected, the connector set in P433 is applied to K0209.

P430 Source for fixed-setpoint injection All binector Ind: 8 P052 = 3

* numbers FS=0 P051 = 40
Selection of binector to control injection of the fixed setpoint 1 Type: L2 Offline
("1" state = fixed setpoint injected).
0 = binector B0000
1 = binector B0001
etc.
P431 Source for fixed setpoint All connector Ind: 8 P052 = 3
* numbers FS=0 P051 = 40
Selection of connector to be injected as the fixed setpoint 1 Type: L2 Offline
0 = connector K0000
1 = connector K0001
etc.
P433 Source for standard setpoint All connector Ind: 4 P052 = 3
* numbers FS=11 P051 = 40
Selection of the connector to be applied if fixed-setpoint injection is not 1 Type: L2 Offline
FDS selected
0 = connector K0000
1 = connector K0001
etc.

Inching setpoint
Function: Up to 8 connectors can be selected in P436 indices .01 to .08. These can be applied as an inching setpoint (K0202, K0207) via
the binectors selected in P435, indices .01 to .08 (setpoint is applied when binector switches to log. "1" state). P437 indices .01
to .08 can be set to define for each setpoint individually whether the ramp-function generator must be bypassed on setpoint
injection. If more than one inching setpoint is injected, an output value corresponding to inching setpoint = 0% is applied.

If inching setpoint injection is not selected, the connector set in P438 is applied to K0207.

P435 Source for injection of inching setpoint All binector Ind: 8 P052 = 3
* numbers FS=0 P051 = 40
Selection of binector to control injection of the inching setpoint 1 Type: L2 Offline
("1" state = inching setpoint injected).
0 = binector B0000
1 = binector B0001
etc.
P436 Source for inching setpoint All connector Ind: 8 P052 = 3
* numbers FS=0 P051 = 40
Selection of connector to be injected as the inching setpoint 1 Type: L2 Offline
0 = connector K0000
1 = connector K0001
etc.

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SIMOREG DC Master Base Drive Panel Operating Instructions
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PNU Description Value range No. indices See

* [Unit] Change
FDS
Crawling setpoint
Function: Up to 8 connectors can be selected in P441 indices .01 to .08. These can be applied as an additional crawling setpoint (K0201,
K0206) via the binectors selected in P440, indices .01 to .08. P445 can be set to define whether the setpoint must be applied
when the selected binectors have reached the log. "1" state (when P445=0) or in response to a 0 → 1 transition (when
P445=1). When setpoint injection in response to a 0 → 1 transition is selected, the setpoint injection function is reset when the
binector selected in P444 switches to the log. "0" state. P442 indices .01 to .08 can be set to define for each setpoint
individually whether the ramp-function generator must be bypassed on setpoint injection.

If crawling setpoint injection is not selected, the connector set in P443 is applied to K0206.

P440 Source for injection of crawling setpoint All binector Ind: 8 P052 = 3
* numbers FS=0 P051 = 40
Selection of binector to control injection of the crawling setpoint. 1 Type: L2 Offline
0 = binector B0000
1 = binector B0001
etc.
P441 Source for crawling setpoint All connector Ind: 8 P052 = 3
* numbers FS=0 P051 = 40
Selection of connector to be injected as the crawling setpoint 1 Type: L2 Offline
0 = connector K0000
1 = connector K0001
etc.
P443 Source for standard setpoint All connector Ind: 4 P052 = 3
* numbers FS=207 P051 = 40
Selection of the connector to be applied if crawling-setpoint injection is not 1 Type: L2 Offline
FDS selected
0 = connector K0000
1 = connector K0001
etc.
P444 Source for standstill command All binector Ind: 2 P052 = 3
* numbers FS=0 P051 = 40
Selection of the binector to control the standstill operation (OFF1) or 1 Type: L2 Offline
BDS resetting of crawling setpoint injection when P445=1 (log. "0" state = reset).
0 = binector B0000
1 = binector B0001
etc.
P445 Selection of level/edge for switch-on/crawling 0 to 1 Ind: None P052 = 3
* 1 FS=0 P051 = 40
Selection to define whether ON command must be input via terminal 37 and Type: O2 Offline
the crawling setpoint injected in response to a log. "1" level or to a 0 → 1
transition

0 ON with log. "1" state at terminal 37 and

injection of crawling setpoint with binectors selected in P440 in
log. "1" state
1 ON in response to 0 → 1 transition at terminal 37 and
injection of crawling setpoint in response to 0 → 1 transition of
binectors selected in P440
With this setting, the ON command or injection command for the
crawling setpoint is stored. The memory is reset when the
binector selected in P444 switches to the log. "0" state.
P493 Motor temperature analog 1 (temperature sensor at terminals 22 / 23): 0 to 3 Ind: 4 P052 = 3
* Tripping of alarm or fault message 1 FS=0 P051 = 40
FDS Type: O2 Offline
Motor temperature grasped with PTC thermistor KTY84
0 Monitoring deactivated
1 Alarm message (A029) when operating point of PTC thermistor is
reached
2 Fault message (F029) when operating point of PTC thermistor is
reached
3 Illegal setting

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SIMOREG DC Master Base Drive Panel Operating Instructions
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PNU Description Value range No. indices See

* [Unit] Change
FDS

10.20 Configuring of torque shell input

P502 Source for value to be added to speed controller output All connector Ind: None P052 = 3
* numbers FS=0 P051 = 40
Selection of connector to be injected as the value to be added to the speed 1 Type: L2 Offline
controller output (in addition to friction and moment of inertia compensation)
0 = connector K0000
1 = connector K0001
etc.
P562 Positive speed droop limitation 0.00 to 199.99 Ind: 4 P052 = 3
[%] FS=100.00 P051 = 40
FDS 0.01% Type: O2 Online
P563 Negative speed droop limitation -199.99 to 0.00 Ind: 4 P052 = 3
[%] FS=-100.00 P051 = 40
FDS 0.01% Type: I2 Online

10.21 Input quantities for signals

P590 Source for setpoint of “nset = nact signal” All connector Ind: None P052 = 3
* numbers FS=170 P051 = 40
Setpoint/actual value deviation signal: 1 Type: L2 Offline
Selection of connector to be injected as input quantity "nset" for the
setpoint/actual value deviation signal.
0 = connector K0000
1 = connector K0001
etc.
P591 Source for actual value of "n-set = n-act signal" All connector Ind: None P052 = 3
* numbers FS=167 P051 = 40
Setpoint/actual value deviation signal: 1 Type: L2 Offline
Selection of connector to be injected as input quantity "nact" for the
setpoint/actual value deviation signal.
0 = connector K0000
1 = connector K0001
etc.
P592 Source for actual value of "n < ncomp. signal” All connector Ind: None P052 = 3
* numbers FS=167 P051 = 40
n < ncomp. signal: 1 Type: L2 Offline
Selection of connector to be injected as input quantity (n) for the n < ncomp.
signal.
0 = connector K0000
1 = connector K0001
etc.
P593 Source for actual value of “n < nmin signal” All connector Ind: None P052 = 3
* numbers FS=167 P051 = 40
n < nmin signal: 1 Type: L2 Offline
Selection of connector to be injected as input quantity (n) for the n < nmin
signal.
0 = connector K0000
1 = connector K0001
etc.
P594 Source for input quantity of "Polarity signal” All connector Ind: None P052 = 3
* numbers FS=170 P051 = 40
Polarity signal of speed setpoint: 1 Type: L2 Offline
Selection of connector to be injected as input quantity "nset" for the polarity
signal of the speed setpoint.
0 = connector K0000
1 = connector K0001
etc.

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SIMOREG DC Master Base Drive Panel Operating Instructions
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PNU Description Value range No. indices See

* [Unit] Change
FDS
P595 Source for actual value of "Overspeed signal” All connector Ind: None P052 = 3
* numbers FS=167 P051 = 40
Overspeed signal: 1 Type: L2 Offline
Selection of connector to be injected as input quantity "nact" for the
overspeed signal.
0 = connector K0000
1 = connector K0001
etc.

10.22 Configuring of closed-loop control

Setting values for configuring of torque shell

P601 Source for armature current controller setpoint All connector Ind: 4 P052 = 3
* numbers FS= P051 = 40
i001,i002 Speed limiting controller: 1 i001: 141 Offline
Selection of connectors to be injected as input quantities for i002: 0
the speed limiting controller. Both values are added. i003: 134
i003,i004 Current limitation: i005: 0
Selection of connectors to be injected as armature current Type: L2
controller setpoint (before current limitation). Both values are
added.

Settings:
0 = connector K0000
1 = connector K0001
etc.

Speed controller

P609 Source for actual speed controller value All connector Ind: None P052 = 3
* numbers FS=0 P051 = 40
Selection of connector to be injected as the actual speed controller value 1 Type: L2 Offline
when P083=4
0 = connector K0000
1 = connector K0001
etc.

Setting values for configuring of closed-loop field and EMF control

P611 Source for field current controller setpoint All connector Ind: 4 P052 = 3
* numbers FS= P051 = 40
Limitation at EMF controller output: 1 i001: 277 Offline
Selection of connectors to be injected as the field current controller i002: 0
setpoint. The connectors selected in the four indices are added. i003: 0
i004: 0
0 = connector K0000 Type: L2
1 = connector K0001
etc.
P612 Source for actual field current controller value All connector Ind: None P052 = 3
* numbers FS=266 P051 = 40
Selection of connector to be injected as the actual field current controller 1 Type: L2 Offline
value
0 = connector K0000
1 = connector K0001
etc.
P615 Source for EMF controller setpoint All connector Ind: 4 P052 = 3
* numbers FS= P051 = 40
Selection of connectors to be injected as the EMF controller setpoint. The 1 i001: 289 Offline
connectors selected in the four indices are added. i002: 0
0 = connector K0000 i003: 0
1 = connector K0001 i004: 0
etc. Type: L2

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SIMOREG DC Master Base Drive Panel Operating Instructions
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PNU Description Value range No. indices See

* [Unit] Change
FDS
P616 Source for actual EMF controller value All connector Ind: None P052 = 3
* numbers FS=286 P051 = 40
Selection of connector to be injected as the actual EMF controller value 1 Type: L2 Offline
0 = connector K0000
1 = connector K0001
etc.

Speed controller

Speed controller: Filtering of setpoint and actual value, band-stop filters

Setting the speed controller I component

Function: When the binector selected in P695 switches state from log. "0" to log. "1", the I component of the speed controller is set to the
value of the connector selected in P631.
With this function it is possible, for example, to use the same signal (binector) to control controller enabling commands and
setting of the I component.
P634 Source for limitation input at ramp-function generator output All connector Ind: 2 P052 = 3
* numbers FS= P051 = 40
Selection of connectors which must be added up to provide the limitation 1 i001: 190 Offline
input at the ramp-function generator output (setpoint limitation). i002: 0
0 = connector K0000 Type: L2
1 = connector K0001
etc.
P645 Source for additional setpoint All connector Ind: 4 P052 = 3
* numbers FS=0 P051 = 40
Selection of connector to be injected as an additional setpoint 1 Type: L2 Offline
FDS
0 = connector K0000
1 = connector K0001
etc.

10.23 Control word, status word

Selection of sources of control words 1 and 2

P648 Source for control word 1 All connector Ind: 2 P052 = 3

* numbers FS=9 P051 = 40
Selection of connector to act as the source for control word 1. 1 Type: L2 Offline
BDS
0 = connector K0000
...
8 = connector K0008
9 = parameters P654 to P675 are effective
(every individual bit of control word 1 is input by a binector)
10 = connector K0010
etc.
P649 Source for control word 2 All connector Ind: 2 P052 = 3
* numbers FS=9 P051 = 40
Selection of connector to act as the source for control word 2. 1 Type: L2 Offline
BDS
0 = connector K0000
...
8 = connector K0008
9 = parameters P676 to P691 are effective
(every individual bit of control word 2 is input by a binector)
10 = connector K0010
etc.

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SIMOREG DC Master Base Drive Panel Operating Instructions
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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS
Display of control words 1 and 2

r650 Display of control word 1 Ind: None P052 = 3

Type: V2
Mode of representation on operator panel (PMU):

15 14 13 12 11 10 9 8

7 6 5 4 3 2 1 0

Segments 0 to 15 correspond to bits 0 to 15 of the control word

Segment alight: Corresponding bit is in log. "1" state

Segment dark: Corresponding bit is in log. "0" state
r651 Display of control word 2 Ind: None P052 = 3
Type: V2
Mode of representation on operator panel (PMU):

15 14 13 12 11 10 9 8

7 6 5 4 3 2 1 0

Segments 0 to 15 correspond to bits 16 to 31 of the control word

Segment alight: Corresponding bit is in log. "1" state

Segment dark: Corresponding bit is in log. "0" state

Display of status words 1 and 2

r652 Display of status word 1 Ind: None P052 = 3

Type: V2
Mode of representation on operator panel (PMU):

15 14 13 12 11 10 9 8

7 6 5 4 3 2 1 0

Segments 0 to 15 correspond to bits 0 to 15 of the status word

Segment alight: Corresponding bit is in log. "1" state

Segment dark: Corresponding bit is in log. "0" state
r653 Display of status word 2 Ind: None P052 = 3
Type: V2
Mode of representation on operator panel (PMU):

15 14 13 12 11 10 9 8

7 6 5 4 3 2 1 0

Segments 0 to 15 correspond to bits 16 to 31 of the status word

Segment alight: Corresponding bit is in log. "1" state

Segment dark: Corresponding bit is in log. "0" state

The following parameters are used to select the binectors (some of which are gated with one another or with other signals) to be applied to
the individual bits of the control word.
The settings of all these parameters are as follows:
0 = binector B0000
1 = binector B0001
etc.

Control word 1

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SIMOREG DC Master Base Drive Panel Operating Instructions
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BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS
P654 Source for control word 1, bit0 All binector Ind: 2 P052 = 3
* numbers FS=1 P051 = 40
(0=OFF1, 1=ON; ANDed with terminal 37) 1 Type: L2 Offline
BDS
P655 1st source for control word 1, bit1 All binector Ind: 2 P052 = 3
* nd rd numbers FS=1 P051 = 40
(0=OFF2; ANDed with 2 and 3 sources for bit1) 1 Type: L2 Offline
BDS
P656 2nd source for control word 1, bit1 All binector Ind: 2 P052 = 3
* st rd numbers FS=1 P051 = 40
(0=OFF2; ANDed with 1 and 3 sources for bit1) 1 Type: L2 Offline
BDS
P657 3rd source for control word 1, bit1 All binector Ind: 2 P052 = 3
* st nd numbers FS=1 P051 = 40
(0=OFF2; ANDed with 1 and 2 sources for bit1) 1 Type: L2 Offline
BDS
P658 1st source for control word 1, bit2 All binector Ind: 2 P052 = 3
* nd rd numbers FS=1 P051 = 40
(0=OFF3=Fast stop; ANDed with 2 and 3 sources for bit2) 1 Type: L2 Offline
BDS
P659 2nd source for control word 1, bit2 All binector Ind: 2 P052 = 3
* st rd numbers FS=1 P051 = 40
(0=OFF3=Fast stop; ANDed with 1 and 3 sources for bit2) 1 Type: L2 Offline
BDS
P660 3rd source for control word 1, bit2 All binector Ind: 2 P052 = 3
* st nd numbers FS=1 P051 = 40
(0=OFF3=Fast stop; ANDed with 1 and 2 sources for bit2) 1 Type: L2 Offline
BDS
P661 Source for control word 1, bit3 All binector Ind: 2 P052 = 3
* numbers FS=1 P051 = 40
(0=pulse disable, 1=enable; ANDed with terminal 38) 1 Type: L2 Offline
BDS
P662 Source for control word 1, bit4 All binector Ind: 2 P052 = 3
* numbers FS=1 P051 = 40
(0=set ramp-function generator to zero, 1=enable ramp-function generator) 1 Type: L2 Offline
BDS
P663 Source for control word 1, bit5 All binector Ind: 2 P052 = 3
* numbers FS=1 P051 = 40
(0=ramp-function generator stop, 1=ramp-function generator start) 1 Type: L2 Offline
BDS
P664 Source for control word 1, bit6 All binector Ind: 2 P052 = 3
* numbers FS=1 P051 = 40
(0=enable setpoint, 1=disable setpoint) 1 Type: L2 Offline
BDS
P665 1st source for control word 1, bit7 All binector Ind: 2 P052 = 3
* numbers FS=0 P051 = 40
(0→1 transition=acknowledge; ORed with 2 and 3 sources for bit7)
nd rd
BDS 1 Type: L2 Offline
P666 2nd source for control word 1, bit7 All binector Ind: 2 P052 = 3
* numbers FS=0 P051 = 40
(0→1 transition=acknowledge; ORed with 1 and 3 sources for bit7)
st rd
BDS 1 Type: L2 Offline
P667 3rd source for control word 1, bit7 All binector Ind: 2 P052 = 3
* numbers FS=0 P051 = 40
(0→1 transition=acknowledge; ORed with 1 and 2 sources for bit7)
st nd
BDS 1 Type: L2 Offline
P668 Source for control word 1, bit8 All binector Ind: 2 P052 = 3
* numbers FS=0 P051 = 40
(1=inching bit0) 1 Type: L2 Offline
BDS
P669 Source for control word 1, bit9 All binector Ind: 2 P052 = 3
* numbers FS=0 P051 = 40
(1=inching bit1) 1 Type: L2 Offline
BDS
P671 Source for control word 1, bit11 All binector Ind: 2 P052 = 3
* numbers FS=1 P051 = 40
(0=pos. direction of rotation disabled, 1=pos. direction of rotation enabled) 1 Type: L2 Offline
BDS
P672 Source for control word 1, bit12 All binector Ind: 2 P052 = 3
* numbers FS=1 P051 = 40
(0= neg. direction of rotation disabled, 1= neg. direction of rotation enabled) 1 Type: L2 Offline
BDS
P673 Source for control word 1, bit13 All binector Ind: 2 P052 = 3
* numbers FS=0 P051 = 40
(1=raise motorized potentiometer) 1 Type: L2 Offline
BDS

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PNU Description Value range No. indices See

* [Unit] Change
FDS
P674 Source for control word 1, bit14 All binector Ind: 2 P052 = 3
* numbers

P675 Source for control word 1, bit15 All binector Ind: 2 P052 = 3
* numbers FS=1 P051 = 40
(0=external fault, 1=no external fault) 1 Type: L2 Offline
BDS

Control word 2

P676 Source for control word 2, bit16 All binector Ind: 2 P052 = 3
* numbers FS=0 P051 = 40
(select function data set bit 0) 1 Type: L2 Offline
BDS
P677 Source for control word 2, bit17 All binector Ind: 2 P052 = 3
* numbers FS=0 P051 = 40
(select function data set bit 1) 1 Type: L2 Offline
BDS
P680 Source for control word 2, bit20 All binector Ind: 2 P052 = 3
* numbers FS=0 P051 = 40
(select fixed setpoint 0) 1 Type: L2 Offline
BDS
P681 Source for control word 2, bit21 All binector Ind: 2 P052 = 3
* numbers FS=0 P051 = 40
(select fixed setpoint 1) 1 Type: L2 Offline
BDS
P684 Source for control word 2, bit24 All binector Ind: 2 P052 = 3
* numbers FS=1 P051 = 40
(0=n controller speed droop disabled, 1=enabled) 1 Type: L2 Offline
BDS
P685 Source for control word 2, bit25 All binector Ind: 2 P052 = 3
* numbers FS=1 P051 = 40
(0=n controller disabled, 1=n controller enabled) 1 Type: L2 Offline
BDS
P686 Source for control word 2, bit26 All binector Ind: 2 P052 = 3
* numbers FS=1 P051 = 40
(0=external fault 2, 1=no external fault 2) 1 Type: L2 Offline
BDS
P687 Source for control word 2, bit27 All binector Ind: 2 P052 = 3
* numbers FS=0 P051 = 40
(0=master drive, speed control, 1=slave drive, torque control) 1 Type: L2 Offline
BDS
P688 Source for control word 2, bit28 All binector Ind: 2 P052 = 3
* numbers FS=1 P051 = 40
(0=external alarm 1, 1=no external alarm 1) 1 Type: L2 Offline
BDS
P689 Source for control word 2, bit29 All binector Ind: 2 P052 = 3
* numbers FS=1 P051 = 40
(0=external alarm 2, 1=no external alarm 2) 1 Type: L2 Offline
BDS
P690 Source for control word 2, bit30 All binector Ind: None P052 = 3
* numbers FS=0 P051 = 40
(0=select Bico data set 1, 1=select Bico data set 2) 1 Type: L2 Offline
P691 Source for control word 2, bit31 All binector Ind: 2 P052 = 3
* numbers FS=1 P051 = 40
(main contactor checkback signal) 1 Type: L2 Offline
BDS

10.24 Further configuring measures

P692 Source for selection of injection of standstill field All binector Ind: 2 P052 = 3
* numbers FS=0 P051 = 40
Selection of binector to control injection of the standstill field ("0" state = 1 Type: L2 Offline
BDS inject standstill field)
Note: The delay time set in P258 is not effective when this function is
active.
0 = binector B0000
1 = binector B0001
etc.

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PNU Description Value range No. indices See

* [Unit] Change
FDS

10.25 Analog inputs (main actual value, main setpoint, selectable inputs)

Analog input terminals 4 / 5 (main setpoint)

P700 Signal type of "Main setpoint" analog input 0 to 2 Ind: None P052 = 3
* 1 FS=0 P051 = 40
0 = Voltage input 0 to ±10 V Type: O2 Offline
1 = Current input 0 to 20 mA
2 = Current input 4 to 20 mA
P704 Source for selection of sign reversal at "Main setpoint" analog input All binector Ind: None P052 = 3
* numbers FS=0 P051 = 40
Selection of binector to control sign reversal at the analog input ("1" state 1 Type: L2 Offline
= reverse sign)
0 = binector B0000
1 = binector B0001
etc.

Analog input terminals 6 / 7 (analog selectable input 1)

P710 Signal type of "Analog selectable input 1" 0 to 2 Ind: None P052 = 3
* 1 FS=0 P051 = 40
0 = Voltage input 0 to ±10 V Type: O2 Offline
1 = Current input 0 to 20 mA
2 = Current input 4 to 20 mA
P711 Normalization of "Analog selectable input 1" -1000.0 to 1000.0 Ind: 4 P052 = 3
[%] FS=100.0 P051 = 40
This parameter specifies the percentage value which is generated for an 0.1% Type: I2 Online
FDS input voltage of 10V (or an input current of 20mA) at the analog input.
The following generally applies:
For voltage input:
Y
P711 [%] = 10 V ∗ X .. Input voltage in volts
X
Y .. % value which is generated for input
voltage X
With current input:
Y
P711 [%] = 20 mA ∗ X .. Input current in mA
X
Y .. % value which is generated for input
current X
P714 Source for selection of sign reversal at "Analog selectable input 1" All binector Ind: None P052 = 3
* numbers FS=0 P051 = 40
Selection of binector to control sign reversal at the analog input ("1" state 1 Type: L2 Offline
= reverse sign)
0 = binector B0000
1 = binector B0001
etc.
P715 Filtering time for "Analog selectable input 1" 0 to 10000 Ind: None P052 = 3
[ms] FS=0 P051 = 40
Note: Hardware filtering of approximately 1 ms is applied as standard. 1ms Type: O2 Online
P716 Source for enabling of "Analog selectable input 1" All binector Ind: None P052 = 3
* numbers FS=1 P051 = 40
Selection of binector to control enabling of the analog input ("1" state = 1 Type: L2 Offline
enabled)
0 = binector B0000
1 = binector B0001
etc.

Analog input terminals 8 / 9 (analog selectable input 2)

Analog input terminals 10 / 11 (analog selectable input 3)

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PNU Description Value range No. indices See

* [Unit] Change
FDS
Analog input terminals 103 / 104 (main actual value)

P741 Normalization for "Main actual value” -270.00 to 270.00 Ind: 4 P052 = 3
[V] FS=60.00 P051 = 40
FDS Rated value of input voltage at nmax (=tachometer voltage at maximum 0.01V Type: I2 Online
speed)
This parameter defines the maximum speed when P083=1.
P745 Filtering time for "Main actual value" analog input 0 to 10000 Ind: None P052 = 3
[ms] FS=0 P051 = 40
Note: Hardware filtering of approximately 1 ms is applied as standard. 1ms Type: O2 Online

10.26 Analog outputs

P750 Source for output value at analog output 1 All connector Ind: None P052 = 3
* numbers FS=0 P051 = 40
Selection of connector whose value is to applied to the analog output 1 Type: L2 Online
0 = connector K0000
1 = connector K0001
etc.
Analog output terminals 16 / 17

P755 Source for output value at analog output 2 All connector Ind: None P052 = 3
* numbers FS=0 P051 = 40
Selection of connector whose value is to applied to the analog output 1 Type: L2 Online
0 = connector K0000
1 = connector K0001
etc.

10.27 Binary outputs

P771 Source for output value at binary output 1 All binector Ind: None P052 = 3
* numbers FS=0 P051 = 40
Selection of binector to be injected at binary selectable output, terminal 46 1 Type: L2 Online
0 = binector B0000
1 = binector B0001
etc.
P772 Source for output value at binary output 2 All binector Ind: None P052 = 3
* numbers FS=0 P051 = 40
Selection of binector to be injected at binary selectable output, terminal 48 1 Type: L2 Online
0 = binector B0000
1 = binector B0001
etc.

10.28 Configuration of serial interfaces on basic converter

G-SST 1 (RS485 / RS232 on X300)

P780 Selection of protocol for G-SST1 basic converter interface 0, 2, 9 Ind: None P052 = 3
* 1 FS=2 P051 = 40
0 Setting has no function Type: O2 Offline
2 USS protocol
9 Diagnostic monitor (for factory test purposes)

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PNU Description Value range No. indices See

* [Unit] Change
FDS
P781 Number of process data for G-SST1 0 to 16 Ind: None P052 = 3
* 1 FS=2 P051 = 40
When P780 = 0 or 9 is selected: Parameter is irrelevant Type: O2 Offline
When USS protocol (P780=2) is selected: Number of PZD elements

0 No process data are expected or sent in the USS protocol

1...16 Number of process data words in USS protocol (same number
applies to transmission and receipt)
The received PZD elements (1 to max. 16) are available at
connectors (K2001 to K2016) and, in some cases, bit-serially at
binectors for "internal wiring" purposes.
The PZD elements to be transmitted (1 to max. 16) are selected
in parameters P784.01 to P784.16.
P782 Length of parameter jobs for G-SST1 0, 3, 4, 127 Ind: None P052 = 3
* 1 FS=127 P051 = 40
This parameter is effective only when P780=2 (USS protocol). Type: O2 Offline

0 No PKW data are expected or sent in the USS protocol.

3, 4 3 or 4 PKW data words are expected in the USS protocol and 3
or 4 PKW data words are also sent (for transmission of
parameter values).
127 Number of PKWs is determined by the telegram length
P783 Baud rate for G-SST1 1 to 13 Ind: None P052 = 3
* 1 FS=6 P051 = 40
1 300 baud Type: O2 Offline
2 600 baud
3 1200 baud
4 2400 baud
5 4800 baud
6 9600 baud
7 19200 baud
8 38400 baud
9 56700 baud
11 93750 baud
13 187500 baud
P784 Source for transmit data for G-SST1 All connector Ind: 16 P052 = 3
* numbers FS= P051 = 40
Selection of connectors to be transferred as transmit data to the USS master 1 i001: 32 Offline
via USS interface 1. i002: 167
i003: 0
i001: Selection for word 1 i004: 33
i002: Selection for word 2 i005-i016: 0
... Type: L2
i016: Selection for word 16

Applicable settings:
0 = connector K0000
1 = connector K0001
etc.
P785 Bus terminator for G-SST1 0 to 1 Ind: None P052 = 3
1 FS=0 P051 = 40
0 = Bus terminator OFF Type: O2 Offline
1 = Bus terminator ON
P786 USS bus address for G-SST1 0 to 30 Ind: None P052 = 3
* 1 FS=0 P051 = 40
This parameter is functional only when P780=2 (USS protocol). Address via Type: O2 Offline
which the unit can be addressed in USS bus operation.

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PNU Description Value range No. indices See

* [Unit] Change
FDS
P787 Telegram failure time for G-SST1 0.000 to 65.000 Ind: None P052 = 3
[s] FS=0.000 P051 = 40
The failure time set in this parameter is valid when setting P780=2 (USS 0.001s Type: O2 Offline
protocol) is selected.

0.000 No time monitoring

0.001...65.000 Time which may elapse between the receipt of two
telegrams addressed to the unit before a fault message
is activated.

Fault message F011 is activated if no valid telegram is received within this

time period.

Note:
The telegram monitoring function is active
• from the receipt of the first error-free telegram after connection of the
electronics power supply
• from the receipt of the first error-free telegram after the telegram monitor
has responded (i.e. monitoring timeout).
P788 Source for activation of F011 2030, 2031 Ind: None P052 = 3
* FS=2030 P051 = 40
Selection of binector which will activate fault message F011 when it switches Type: L2 Offline
to log. "1"
2030 = binector B2030
2031 = binector B2031
r789 Diagnostic information for G-SST1 Ind: 10 P052 = 3
Type: O2
Free-running counter, overflow at 65535

i001: Number of error-free telegrams

i002: Number of errored telegrams:
Byte frame, parity, overrun or BCC error
i003: Number of byte frame errors
i004: Number of overrun errors
i005: Parity error
i006: STX error:
Start interval before STX not observed,
telegram residual transfer time not observed,
delay time of LGE character too long,
erroneous STX, i.e. ≠ 02
i007: Violation of telegram residual transfer time
i008: Block check error
i009: Incorrect telegram length:
With P782=3 or 4 only:
The length of the received telegram is ≠ P781 + P782
(Note: If the received values are correct, they will be processed
even when this error has been detected)
i010: Timeout error:
No valid telegram has been received for a period exceeding the
setting in P787. After the occurrence of a timeout error, this
counter is not activated again until the next valid telegram is
received.

G-SST 2 (RS485 on X172)

P790 Selection of protocol for G-SST2 basic converter interface 0, 2, 5, 9 Ind: None P052 = 3
* 1 FS=0 P051 = 40
0 Setting has no function Type: O2 Offline
2 USS protocol
5 ”Peer-to-peer” communication
9 Diagnostic monitor (4-wire operation) (for factory test purposes)
P791 Number of process data for G-SST2 0 to 16 Ind: None P052 = 3
* 1 FS=2 P051 = 40
When P790 = 0 or 9 is selected: Parameter is irrelevant Type: O2 Offline
When USS protocol (P790=2) is selected: Number of PZD elements

0 No process data are expected or sent in the USS protocol

1...16 Number of process data words in USS protocol (same number
applies to transmission and receipt)

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PNU Description Value range No. indices See

* [Unit] Change
FDS
The received PZD elements (1 to max. 16) are available at
connectors (K6001 to K6016) and, in some cases, bit-serially at
binectors for "internal wiring" purposes.
The PZD elements to be transmitted (1 to max. 16) are selected
in parameters P794.01 to P794.16.

When peer-to-peer (P790= 5) is selected: Number of transferred words

0 Illegal setting
1...5 Number of transferred words
6...16 Illegal setting
P792 Length of parameter jobs for G-SST2 0, 3, 4, 127 Ind: None P052 = 3
* 1 FS=127 P051 = 40
This parameter is effective only when P790=2 (USS protocol). Type: O2 Offline

0 No PKW data are expected or sent in the USS protocol.

3, 4 3 or 4 PKW data words are expected in the USS protocol and 3
or 4 PKW data words are also sent (for transmission of
parameter values).
127 Number of PKWs is determined by the telegram length
P793 Baud rate for G-SST2 1 to 13 Ind: None P052 = 3
* 1 FS=6 P051 = 40
1 300 baud Type: O2 Offline
2 600 baud
3 1200 baud
4 2400 baud
5 4800 baud
6 9600 baud
7 19200 baud
8 38400 baud
9 56700 baud
11 93750 baud
13 187500 baud
P794 Source for transmit data for G-SST2 All connector Ind: 16 P052 = 3
* numbers FS= P051 = 40
Selection of connectors to be transferred as transmit data via basic converter 1 i001: 32 Offline
interface 2 i002: 167
i003: 0
When USS protocol (P790=2) is selected: i004: 33
i005-i016: 0
i001: Selection for word 1 Type: L2
i002: Selection for word 2
...
i016: Selection for word 16

When peer-to-peer (P790=5) is selected:

i001: Selection for word 1

i002: Selection for word 2
...
i005: Selection for word 5

i006: Not used

...
i016: Not used

Applicable settings:
0 = connector K0000
1 = connector K0001
etc.
P795 Bus terminator for G-SST2 0 to 1 Ind: None P052 = 3
1 FS=0 P051 = 40
0 = Bus terminator OFF Type: O2 Offline
1 = Bus terminator ON
P796 USS bus address for G-SST2 0 to 30 Ind: None P052 = 3
* 1 FS=0 P051 = 40
This parameter is functional only when P790=2 (USS protocol). Address via Type: O2 Offline
which the unit can be addressed in USS bus operation.

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PNU Description Value range No. indices See

* [Unit] Change
FDS
P797 Telegram failure time for G-SST2 0.000 to 65.000 Ind: None P052 = 3
[s] FS=0.000 P051 = 40
The failure time set in this parameter is valid when setting P790=2 (USS 0.001s Type: O2 Offline
protocol) or P790=5 (peer-to-peer) is selected.

0.000 No time monitoring

0.001...65.000 Time which may elapse between the receipt of two
telegrams addressed to the unit before a fault message
is activated.

Fault message F012 is activated if no valid telegram is received within this

time period.

Note:
The telegram monitoring function is active
• from the receipt of the first error-free telegram after connection of the
electronics power supply
• from the receipt of the first error-free telegram after the telegram monitor
has responded (i.e. monitoring timeout).

Since the telegram transfer time is dependent on the set baud rate, the
following minimum setting values for P797 are recommended:

Baud rate as set in P793: Recommended minimum value for P797:

300 baud 0.520s
600 baud 0.260s
1200 baud 0.140s
2400 baud 0.080s
≥ 4800 baud 0.040s

Note:
If the "Automatic restart" function is selected (P086>0) on the peer-to-peer
communication partner, then only a parameter setting of P797>P086 (on the
communication partner) is meaningful.
P798 Source for activation of F012 6030, 6031 Ind: None P052 = 3
* FS=6030 P051 = 40
Selection of binector which will activate fault message F012 when it switches Type: L2 Offline
to log. "1"
6030 = binector B6030
6031 = binector B6031
r799 Diagnostic information for G-SST2 Ind: 10 P052 = 3
Type: O2
Free-running counter, overflow at 65535

i001: Number of error-free telegrams

i002: Number of errored telegrams:
Byte frame, parity, overrun or BCC error
i003: Number of byte frame errors
i004: Number of overrun errors
i005: Parity error
i006: STX error:
Start interval before STX not observed,
telegram residual transfer time not observed,
delay time of LGE character too long,
erroneous STX, i.e. ≠ 02
i007: Violation of telegram residual transfer time (USS prot. only)
i008: Block check error
i009: Incorrect telegram length:
With P792=3 or 4 only:
The length of the received telegram is ≠ P791 + P792
(Note: If the received values are correct, they will be processed
even when this error has been detected)
i010: Timeout error:
No valid telegram has been received for a period exceeding the
setting in P797. After the occurrence of a timeout error, this
counter is not activated again until the next valid telegram is
received.

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PNU Description Value range No. indices See

* [Unit] Change
FDS
Peer-to-peer interfaces: Enable transmission and receipt of telegrams:
If transmission on a peer-to-peer interface is disabled, the associated output drivers are connected to high impedance. If reception is
disabled on a peer-to-peer interface, then the telegram failure monitoring function is deactivated.
P816 Peer-to-peer 2: Source for data reception enabling command All binector Ind: None P052 = 3
numbers FS=1 P051 = 40
0 = binector B0000 1 Type: L2 Offline
1 = binector B0001
etc.
P817 Peer-to-peer 2: Source for data transmission enabling command All binector Ind: None P052 = 3
numbers FS=1 P051 = 40
0 = binector B0000 1 Type: L2 Offline
1 = binector B0001
etc.

10.29 Deactivation of monitoring functions

WARNING
If monitoring functions are deactivated, there may be a risk to the safety of operating personnel or of
substantial property damage if a fault or error actually occurs!

P820 Deactivation of fault messages 0 to 147 Ind: 99 P052 = 3

* 1 FS= P051 = 40
The numbers of all fault messages to be deactivated must be entered in this see column Online
parameter. Fault numbers can be entered in any order. 0 must be entered for on left
any unused indices of the parameter. Type: O2
Factory setting:
i001 = 7 (overvoltage)
i002 = 18 (short circuit at binary outputs)
i003 = 31 (monitoring of speed controller)
i004 = 35 (drive blocked)
i005 = 36 (armature current cannot flow)
i006 = 37 (I2t motor monitoring function has responded)
i007 to i099 = 0
P821 Deactivation of alarms 0 to 147 Ind: 99 P052 = 3
* 1 FS= 0 P051 = 40
The numbers of all alarm messages to be deactivated must be entered in Type: O2 Online
this parameter. Alarm numbers can be entered in any order. 0 must be
entered for any unused indices of the parameter.

10.30 Thyristor diagnosis

P830 Control word for thyristor diagnosis 0 to 3 Ind: None P052 = 3
* 1 FS=0 P051 = 40
0 Thyristor check function deactivated Type: O2 Offline
1 Thyristors are checked on initial SWITCH-ON or INCHING
command after connection of the electronics supply voltage.
2 Thyristors are checked on every SWITCH-ON or INCHING
command.
3 Thyristors will be checked on the next SWITCH-ON or INCHING
command. Parameter P830 is set to 0 if no fault is detected.
Note:
The thyristor check function may not be activated (setting P830=0 must be
selected)
− when the ”Enable a torque direction for torque direction change by
parallel drive” function is in use (see also parameter P165) or
− when the converter is used to supply large inductances (e.g. field supply
from armature terminals, supply of lifting solenoids, etc.).

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PNU Description Value range No. indices See

* [Unit] Change
FDS

10.31 Parameters for DriveMonitor and OP1S

P831 Parameters for the Trace function of DriveMonitor P052 = 3
to
r849 These parameters are settings for the data exchange between DriveMonitor
and the SIMOREG converter. They must not be changed!
r850 Parameters for the OP1S P052 = 3
to
P899 These parameters are settings for the data exchange between OP1S and the
SIMOREG converter. They must not be changed!

10.32 Profile parameters

P918 CB bus address 3 to 200 Ind: 2 P052 = 3
1 FS=3 P051 = 40
Protocol-dependent bus address for communication boards Type: O2 Offline
Note:
The validity of the bus address is monitored by the communication board.
(Bus addresses 0 to 2 are reserved for Master stations on PROFIBUS
boards and must not therefore be set for other purposes). If the value is not
accepted by the COM BOARD, fault F080 is displayed with fault value 5
P927 Parameterization enable 0 to 127 Ind: None P052 = 3
* 1 FS=6 P051 = 40
Enabling of interfaces for parameterization. A parameter value can only be Type: V2 Offline
altered via an enabled interface.

0: None
1: Communications board (CB)
2: Parameterizing unit (PMU)
4: G-SST1 serial interface and OP1S
8: Reserved
16: Technology board (TB)
32: G-SST2 serial interface
64: G-SST3 serial interface

Setting information:
Every interface has a numeric code.
The number for one specific interface, or the sum of various numbers
assigned to several interfaces, must be entered in this parameter in order to
enable the relevant interface(s) for use as a parameterization interface.
Example:
Factory setting value 6 (=4+2) means that the PMU and G-SST1 interfaces
are enabled for parameterization purposes.
r967 Display of control word 1 Ind: None P052 = 3
Type: V2
Visualization parameter for control word 1 (bits 0-15)
Identical to r650 (control word 1)
r968 Display of status word 1 Ind: None P052 = 3
Type: V2
Visualization parameter for status word 1 (bits 0 - 15)
Identical to r652 (status word 1)

10-42 SIEMENS Energy & Automation

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS

10.33 Resetting and storing parameters,

list of existing and modified P and r parameters
P970 Restore factory setting 0 to 1 Ind: None P052 = 3
* 1 FS=1 P051 = 40
Reset parameters to factory setting (default) Type: O2 Offline
0: Parameter reset: All parameters are reset to their original values
(factory setting). This parameter is then automatically reset to 1.
1: No parameter reset

Note: Function can also be selected by setting P051=21.

P971 EEPROM transfer 0 to 1 Ind: None P052 = 3
* 1 FS=0 P051 = 40
Transfer of parameter values from RAM to EERPROM on switchover from 0 Type: O2 Offline
to 1.
It takes approximately 15s to process all values. The PMU remains in value
mode for this period.
r980 List of existing parameter numbers, start Ind: 101 P052 = 3
Type: O2
Visualization parameter for displaying the first 100 parameter numbers in the
P or r parameter range (0 to 999). The parameter numbers are listed in
ascending sequence.
Repetition of a number over several indices means that there are no further
parameter numbers in the 0 to 999 range.
The list is continued at the parameter whose number is displayed under
index 101.
See also r989
r981 List of existing parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r980.
r982 List of existing parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r980.
r983 List of existing parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r980.
r984 List of existing parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r980.
r985 List of existing parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r980.
r986 List of existing parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r980.
r987 List of existing parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r980.
r988 List of existing parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r980.
r989 List of existing parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
Continuation of the list can be found under index 101. Please note:
860 = r860 (TECH BOARD installed)
2980 = n980
See also r980.

SIEMENS Energy & Automation 10-43

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

PNU Description Value range No. indices See

* [Unit] Change
FDS
r990 List of modified parameter numbers, start Ind: 101 P052 = 3
Type: O2
Visualization parameter for displaying the first 100 modified parameters in
the P or r parameter range (0 to 999). The parameter numbers are listed in
ascending sequence.
Repetition of a number over several indices means that there are no further
modified parameters in the 0 to 999 range.
The list is continued at the parameter whose number is displayed under
index 101.
See also r999.
r991 List of modified parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r990.
r992 List of modified parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r990.
r993 List of modified parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r990.
r994 List of modified parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r990.
r995 List of modified parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r990.
r996 List of modified parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r990.
r997 List of modified parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r990.
r998 List of modified parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
See r990.
r999 List of modified parameter numbers, continuation Ind: 101 P052 = 3
Type: O2
Continuation of the list can be found under index 101. Please note:
2990 = n990
See also r990.

10-44 SIEMENS Energy & Automation

SIMOREG DC Master Base Drive Panel Operating Instructions
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

11 Simplified block diagrams

Basic functions
Page
Sheet 1 Legend ............................................................................................................................ 11-2
Sheet 2 Speed Setpoint System ................................................................................................... 11-3
Sheet 3 Speed Control & Current Limit......................................................................................... 11-4
Sheet 4 Armature Current Control ................................................................................................ 11-5
Sheet 5 EMF & Field Current Control ........................................................................................... 11-6
Sheet 6 USS Interface 1 ( X300 ) ................................................................................................. 11-7
Sheet 7 USS Interface 2 ( X172 ) ................................................................................................. 11-8
Sheet 8 Peer to Peer Interface ( X172 )........................................................................................ 11-9
Sheet 9 Data Exchange CB / TB to Base (PZD) ........................................................................ 11-10
Sheet 10 Control Word 1............................................................................................................... 11-11
Sheet 11 Control Word 2............................................................................................................... 11-12
Sheet 12 Status Word 1 ................................................................................................................ 11-13
Sheet 13 Status Word 2 ................................................................................................................ 11-14
Sheet 14 Signals .......................................................................................................................... 11-15

NOTE
The simplified block diagrams do not show all details or functions. Please refer to
Operating Instructions 6RX1700-0AD76 if additional detail or functions are required
including S00 functions and accessory boards.

SIEMENS Energy & Automation 11-1

SIMOREG DC Master Base Drive Panel Operating Instructions
 11-2
BI012088

1 2 3 4 5 6 7 8
Sheet 1

6RA70 DC MASTER
SIMPLIFIED BLOCK DIAGRAM
LEGEND
PARAMETERS VALUE FUNCTIONS VALUE FUNCTIONS
Legend

Pxxx (0) BASIC SETTING PARAMETER (P or U)

TECH BOARD (H or L) ADDER SWITCH

CONNECTOR B% 0
FACTORY DEFAULT VALUE A%
SELECTOR OUTPUT = A% IF BINECTOR VALUE = 0
PARAMETER NUMBER 1
B% OUTPUT = B% IF BINECTOR VALUE = 1
Pxxx (0) A% +
r xxx BASIC DISPLAY PARAMETER (r or n) K OUTPUT = A% + B%
+
TECH BOARD (d or c)
Bxxx

PARAMETER NUMBER MULTIPLIER

B% RATE LIMITER
TIME
INDEX parameters are used to both display and change
Pxxx (0)
several parameter values which are all assigned to
the same parameter number A% x B%
A% OUTPUT =
100%
Pxxx.01 F/B IN OUT

PART OF FUNCTION OR BINARY PARAMETER SET FILTER

INDEX NUMBER FILTER TIME
Pxxx (0)
PARAMETER NUMBER BINARY LOGIC FUNCTIONS

BINECTOR
CONNECTORS AND BINECTORS SELECTORS AND
IN OUT
Kxxx CONNECTOR (SIGNAL VALUE) Pxxx (0) OUTPUT
BINECTOR
B
CONNECTOR NUMBER
LIMITER & Bxxx
Pxxx (0)
MIN MAX B
Pxxx Pxxx
Bxxx BINECTOR (LOGIC VALUE)
BINECTOR
BINECTOR NUMBER
SELECTORS OR
OUTPUT
IN OUT Pxxx (0)
BINECTOR
PRE-ASSIGNED CONNECTORS AND BINECTORS B
≥1 Bxxx
K0000 = 0%
Pxxx (0)
K0001 = 100%
ABSOLUTE VALUE B
K0002 = 200%
K0003 = -100%
K0004 = -200%
K0005 = 50% IN OUT PAGE REFERENCE
K0006 = 150%
K0007 = -50% [ 4.6 ]
K0008 = -150%
PAGE COLUMN NUMBER
B0000 = L0GIC "0" SIMPLIFIED BLOCK DIAGRAM DOES NOT SHOW ALL DETAILS PAGE NUMBER
B0001 = LOGIC "1" REFER TO OPERATING MANUAL 6RX1700-0AD76 FOR COMPLETE BLOCK DIAGRAM 1

SIMOREG DC Master Base Drive Panel Operating Instructions

SIEMENS Energy & Automation
MD6640 BLAST HOLE DRILL
SPECIAL INSTRUCTION MANUAL
 1 2 3 4 5 6 7 8
BI012088

X171 BINARY
INPUTS
6RA70 DC MASTER
34
Sheet 2

P24 (CUD1) BINARY

SIMPLIFIED BLOCK DIAGRAM OUTPUTS
39 X171
(ALL AVAILABLE FUNCTIONS ARE NOT SHOWN ON SIMPLIFIED BLOCK DIAGRAM) (CUD1)
B0016
ASSIGNABLE P771 (0)
36 BINARY INPUTS CRAWL SETPOINT 46
B0010 SOURCE B
P0441 (0) 47
8 M
B0012
37 K P772 (0)
48
Index .01 - .08 B
ON / OFF

SIEMENS Energy & Automation

P654 (1) & INCH SETPOINT 54
B Cntrl Word 1 SOURCE M
Bit 0 [ 10.1 ]
P0436 (0)
8
B0014 K
38
Index .01 - .08 SPEED SETPOINT SYSTEM ADDITIONAL SETPOINT
AFTER RAMP
& ENABLE
P661 (1) FIXED SETPOINT
35 Cntrl Word 1 SOURCE P634 (0)
M B Bit 3 [ 10.3 ] .02
P0431 (0) K
8
K
X174 SCALING UP DOWN
Speed Setpoint System

SCALING Index .01 - .08

RATE RATE MIN MAX
P320.F (100.00)
MAIN P701.F (100.00) P303.F P304.F P301 P300
SETPOINT
ANALOG INPUT REVERSE SPEED SETPOINT FIXED INCH CRAWL RAMP
4 POLARITY r001 SOURCE SETPOINT SETPOINT SETPOINT r029 OPERATE STOP r028 r027
+
1 P0433.F (11)

SIMOREG DC Master Base Drive Panel Operating Instructions

P700 -1 K209 K207 K206 K198 K194 1 Run 1 Run K170 SPEED
K SETPOINT
0 K0011 TO SPEED
0 0 RAMP K190
K192
Hold Stop CONTROLLER
K190 0% [ 3.1 ]
5 - FIXED COMMAND
P704 (0)
P0430 (0)
B 8
B P305.F P306.F
Index .01 - .08 START END
ON / OFF RND RND
Cntrl [ 10.7 ]
INCH COMMAND ENABLE
>1 Word 1 Control Word 1 Bit 4
P0435 (0) Bit 0
8
B Control Word 1 Bit 0 [ 10.7 ]
Index .01 - .08 ON / OFF AND
CRAWL COMMAND
Cntrl Control Word 1 Bit 6 [ 10.7 ]
>1 Word 1
P0440 (0) 8 Bit 0
Control Word 1 Bit 5 [ 10.7 ]
B
X175 ANALOG
Index .01 - .08
OUTPUTS
SELECTABLE SETPOINT SCALING
ARMATURE 12 (CUD1)
ANALOG 1 (CUD1) P322.F (1) CURRENT
SCALING K 13
FILTER TIME M
P711.F (100.00) P715 (0) SCALING
P321.F (100.00) P750 (0)
6 REVERSE ADDITIONAL SETPOINT 14
POLARITY ON / OFF r003 BEFORE RAMP K
+ 0 15
1 0% P645.F (0) M
P710 -1
1 K0015 K
0 P755 (0)
ADDITIONAL SETPOINT 16
7 K
- SCALING
P714 (0) P716 (1) 17
P323.F (1) M
B B
K
2

11-3
MD6640 BLAST HOLE DRILL
SPECIAL INSTRUCTION MANUAL
 BI012088

11-4
1 2 3 4 5 6 7 8
Sheet 3

6RA70 DC MASTER
SIMPLIFIED BLOCK DIAGRAM
(ALL AVAILABLE FUNCTIONS ARE NOT SHOWN ON SIMPLIFIED BLOCK DIAGRAM)

POSITIVE DROOP DROOP ENABLE

DROOP LIMIT SCALING CONTROL WORD 2
P562.F (100) BIT 24 [ 11.6 ]
P227.F (0.0)

P563.F (-100)
NEGATIVE P170 (0)
DROOP LIMIT [ 5.7 ]
SPEED
MOTOR FLUX
CONTROLLER
SETPOINT <1> K290 <1>
KP TN
FILTER TIME POSITIVE POSITIVE
P225.F (3.0) P226.F (0.65) TORQUE LIMIT CURRENT LIMIT
P228.F(0)
<1> P180 (300%) <1> 1 1 P171 (100%)
r026 r022 r021
K162 O TORQUE
SPEED
SETPOINT K170 0 CURRENT
K174 K165 K160 K145 K141 K140 0 K133 K120
FROM RAMP SETPOINT
1 TO CURRENT
GENERATOR 0% CURRENT
CONTROL
[ 2.8 ] [ 14.2 ]
[ 4.2 ]
Speed Controller and Current Limit

FAST STOP P181 (-300%) P172 (-100%)

[ 10.7 ] NEGATIVE NEGATIVE
ADDITIONAL TORQUE LIMIT ADDITIONAL ADDITIONAL CURRENT LIMIT
ENABLE TORQUE TORQUE CURRENT
[ 11.6 ] <1> <1>
P502 (0) P601 (0) P601 (0)
.02 .04
K K K

ACTUAL SPEED VOLTAGE AT

FILTER TIME TOP SPEED
P200.F (0) P741.F
P083.F
r025 r002 XT
0
ANALOG
K167 1 TACH K013 ANALOG 103 +
TACHOMETER ANALOG TACHOMETER
2 ENCODER SCALING 104-

3 EMF

4
[ 14.2 ] [ 14.4 ] MAX
TYPE PPR RPM X173
P609 (0) P140 P141 P143.F
26 (+15 VOLTS)
K r024 27 (COMMON)
SPEED CONTROL & CURRENT LIMIT 28 (SIGNAL A)
r037 PULSE ENCODER
PULSE 29 (SIGNAL NOT A)
ENCODER
MOTOR EMF K040 SCALING 30 (SIGNAL B)
K287 135.05
<1> 100% CORRESPONDS TO THE RATED MOTOR CURRENT (P100) [ 5.3 ] 31 (SIGNAL NOT B)
P115
P115 (100%)
MAX SPEED 3

SIMOREG DC Master Base Drive Panel Operating Instructions

SIEMENS Energy & Automation
MD6640 BLAST HOLE DRILL
SPECIAL INSTRUCTION MANUAL
 BI012088

1 2 3 4 5 6 7 8
Sheet 4

6RA70 DC MASTER
SIMPLIFIED BLOCK DIAGRAM AC LINE
(ALL AVAILABLE FUNCTIONS ARE NOT SHOWN ON SIMPLIFIED BLOCK DIAGRAM) VOLTAGE

SIEMENS Energy & Automation

<1>
r019

K117 ARMATURE CURRENT ACTUAL VALUE CURRENT

CT'S
RECTIFICATION

di/dt KP TN
ADVANCE FORWARD
TIME P155.F (.1) P156.F (.2) LIMIT
<1> 0
P158.F (0) P150.F (30 )
r020
Armature Current Control

r018

CURRENT K120 K119 K118 K113 K110 K102

SETPOINT K100
CURRENT

SIMOREG DC Master Base Drive Panel Operating Instructions

FROM SPEED
CONTROL CONTROLLER REVERSE

[ 3.8 ]
0
P157.F (0) P151.F (150 )
MODE RETARD
0 = ACTIVE ONLY DURING LIMIT
TORQUE DIRECTION ARMATURE ARMATURE
CHANGE RESISTANCE INDUCTANCE
1 = ALWAYS ACTIVE
P110.F (0) P111.F (0)

FEED FORWARD

K305 K121
LINE VOLTAGE

K123 0
MEASURED EMF
REVERSING
K124 1
CALCULATED EMF DEAD BAND
P160.F (0)

P162 (1) P153.F (1)

CONTROL

REVERSING
LOGIC
ARMATURE CURRENT = 0

ARMATURE CURRENT CONTROL TACH MOTOR

<1> 100% CORRESPONDS TO THE RATED MOTOR CURRENT (P100)

11-5
MD6640 BLAST HOLE DRILL
SPECIAL INSTRUCTION MANUAL
 1 2 3 4 5 6 7 8
BI012088

11-6
6RA70 DC MASTER
Sheet 5

SIMPLIFIED BLOCK DIAGRAM

(ALL AVAILABLE FUNCTIONS ARE NOT SHOWN ON SIMPLIFIED BLOCK DIAGRAM)

<1>
ACTUAL FIELD
ACTUAL EMF CURRENT
EMF r037 iax R a r038 FIELD
r035
ACTUAL VALUE ACTUAL VALUE
P616 (286) EMF P612 (266) INTERNAL
ARMATURE TERMINAL
K K286 K K266 FIELD ACTUAL
VOLTAGE
K265 CURRENT
EMF P120.F - P139.F
K285 di a x L FLUX
[ 3.3 ] K0287 dt a
K290 [ 3.6 ]

EMF CONTROLLER FIELD CURRENT CONTROLLER FIELD

LINE VOLTAGE
DROOP FIELD
P277.F (0) WEAKENING RATED MOTOR <1>
ACTIVE FIELD CURRENT TN
KP TN FIELD KP ADVANCE
EMF P081 (0) P256.F (.2)
P275.F (.6) P276.F (.2) CURRENT P255.F (5) LIMIT
SETPOINT P102.F (0 A) 0
SETPOINT P250.F (0 )
r039 100% FIELD
P100.F X P110.F r036 r034
ECONOMY
0 K277 K276 K0275
- K288 K283 0 K263 K260 K251
K268
EMF and Field Current Control

K280 K278 K250

P101.F CURRENT
EMF 1
CONTROLLER 1 CONTROLLER

P103.F (0 A ) P257.F (0 %) CURRENT SETPOINT IS SET 0

ADDITIONAL EMF P251.F (180 )
ADDITIONAL MINIMUM FIELD STANDSTILL TO ZERO WHEN FIELD GATE
SETPOINT FIELD CURRENT FIELD RETARD
CURRENT PULSES ARE DISABLED
P615 (0) SETPOINTS LIMIT
FIELD
K P611 (0)
ENABLE ≥1 RESISTANCE
Index .02 - .04 K P112.F (0)
P273 (1)
Index .02 - .04
P692.B (0) MOTOR
FEED FORWARD
FIELD FIELD
SETPOINT
B

K271
LINE CONTACTOR
K293 CLOSED
SPEED K166 K304
ABSOLUTE n FIELD
B0124
VALUE n LINE VOLTAGE
P082=2
& t
P118.F (340) P119.F (100) P120.F P253.F (1)
RATED BASE to ENABLE
EMF SPEED P139.F
P258.F (10s)
FIELD Delay time
CHARACTERISTICS

<1> 100% CORRESPONDS TO THE RATED MOTOR FIELDCURRENT (P102)

5

SIMOREG DC Master Base Drive Panel Operating Instructions

SIEMENS Energy & Automation
MD6640 BLAST HOLE DRILL
SPECIAL INSTRUCTION MANUAL
 1 2 3 4 5 6 7 8
BI012088

6RA70 DC MASTER
Sheet 6

SIMPLIFIED BLOCK DIAGRAM

(ALL AVAILABLE FUNCTIONS ARE NOT SHOWN ON SIMPLIFIED BLOCK DIAGRAM)

USS interface 1 Receive data Transmit data

r810.17 r810.18 r810.19 r810.20 r811.17 r811.18 r811.19 r811.20
USS parameter data USS parameter data

SIEMENS Energy & Automation

Word 1: Param.-ID Word 1: Param.-ID
(PKE) (PKE)
X300:
G-SST1 Word 2: Param.Index Parameter Word 2: Param.Index

Word 3: Param.Value processing Word 3: Param.Value

Low Word Low Word
6
+5V Word 4: Param.Value Word 4: Param.Value
1 1 High Word High Word
4
RS232
7 TxD r810.01 to .16 r811.01 to .16
Process data Process Data
from USS interface to USS interface
USS Interface 1 ( X300 )

2 RxD P784 WE .01

every 16 bits
Word 1 K2001 K 32 Word 1 1
.02
3 Rx+/Tx+ Word 2 K2002 K 167 Word 2
.03
Word 3 K2003 K 0 Word 3
8 Rx-/Tx- ≥1 .04
Word 4 K2004 K 33 Word 4

SIMOREG DC Master Base Drive Panel Operating Instructions

.05
5 M RS485 Word 5 K2005 K 0 Word 5
.06
9 M Word 6 K2006 K 0 Word 6
.07
Word 7 K2007 K 0 Word 7
Submin D P785 (0) .08
Word 8 K2008 K 0 Word 8
0 1 0 1 .09
Word 9 K2009 K 0 Word 9
Bus terminator .10
Word 10 K2010 K 0 Word 10
.11
Word 11 K2011 K 0 Word 11
.12
+ M Word 12 K2012 K 0 Word 12
.13
Word 13 K2013 K 0 Word 13
.14
Word 14 K2014 K 0 Word 14
.15
Word 15 K2015 K 0 Word 15
.16
Word 16 K2016 K 0 Word 16

Bit 0 ... Bit 15

B2100 B2115 U116 (0)
B2200 .01
B2215 B
Parameters for USS interface
1 = "Telegram B2300 B2315
P780 (2) USS On/Off monitoring
timeout" B2400 B2415
P787 (0,000s) Telegram monitoring time B2030
B2500 B2515
P786 (0) Slave address 1s
B2600 B2615 U116 (0)
B2031 .16
P783 (6) Baud rate B2700 B2715 B
P781 (2) Length of process data B2800 B2815
15 0
P782 (127) Length of parameter data B2900 B2915 Binector / Connector K2020
Fault message trigger
r789 USS diagnostic parameter P788 (2030) Converter
B 1 = "Fault F011"
P927 Enable parameterization
6

11-7
MD6640 BLAST HOLE DRILL
SPECIAL INSTRUCTION MANUAL
 11-8
BI012088

1 2 3 4 5 6 7 8
Sheet 7

6RA70 DC MASTER
SIMPLIFIED BLOCK DIAGRAM
(ALL AVAILABLE FUNCTIONS ARE NOT SHOWN ON SIMPLIFIED BLOCK DIAGRAM)

USS interface 2 Receive data Transmit data

r812.17 r812.18 r812.19 r812.20 r813.17 r813.18 r813.19 r813.20
USS parameter data USS parameter data
Word 1: Param.-ID Word 1: Param.-ID
(PKE) (PKE)

Word 2: Param.Index Parameter Word 2: Param.Index

Word 3: Param.Value processing Word 3: Param.Value

G-SST2 Low Word Low Word
Word 4: Param.Value Word 4: Param.Value
X172 High Word High Word
1
USS Interface 2 ( X172 )

Process data r812.01 to .16 r813.01 to .16 Process data

56 Tx+
from USS interface P794 to USS interface
WE
57 Tx- every 16 bits .01
Word 1 K6001 K 32 Word 1 1
.02
58 Rx+/Tx+ Word 2 K6002 K 167 Word 2
.03
Word 3 K6003 K 0 Word 3
59 Rx-/Tx- .04
Word 4 K6004 K 33 Word 4
60 RS485 .05
M Word 5 K6005 K 0 Word 5
.06
Word 6 K6006 K 0 Word 6
.07
Word 7 K6007 K 0 Word 7
P795 (0) .08
Word 8 K6008 K 0 Word 8
0 1 0 1 .09
Word 9 K6009 K 0 Word 9
Bus terminator .10
Word 10 K6010 K 0 Word 10
.11
Word 11 K6011 K 0 Word 11
.12
+ M Word 12 K6012 K 0 Word 12
.13
Word 13 K6013 K 0 Word 13
.14
Word 14 K6014 K 0 Word 14
.15
Word 15 K6015 K 0 Word 15
.16
Word 16 K6016 K 0 Word 16

Bit 0 ... Bit 15

B6100 B6115
U117 (0)
B6200 B6215 .01
Parameters for USS interface B
1 = "Telegram B6315
B6300
P790 (0) USS On/Off monitoring
timeout" B6400 B6415
P797 (0,000s) Telegram monitoring time B6030
B6500 B6515
P796 (0) Slave address 1s
B6600 B6615 U117 (0) .16
P793 (6) Baud rate B6031 B6715 B
B6700
P791 (2) Length of process data B6800 B6815
15 0
P792 (127) Length of parameter data B6900 B6915
Fault message trigger Binector / Connector K6020
r799 USS diagnostic parameter P798 (6030) Converter
B 1 = "Fault F012"
P927 Enable parameterization
7

SIMOREG DC Master Base Drive Panel Operating Instructions

SIEMENS Energy & Automation
MD6640 BLAST HOLE DRILL
SPECIAL INSTRUCTION MANUAL
 BI012088

1 2 3 4 5 6 7 8
6RA70 DC MASTER
Sheet 8

SIMPLIFIED BLOCK DIAGRAM

(ALL AVAILABLE FUNCTIONS ARE NOT SHOWN ON SIMPLIFIED BLOCK DIAGRAM)

Peer-to-peer interface 2

SIEMENS Energy & Automation

Enable data send
P817 (1)
B
<1>

G-SST2 1

X172 0

56 Tx+ r812.01 to .05 r813.01 to .05

57 Tx- Receive data Transmit data
every 16Bits P794 (0)
Rx+/Tx+ .01
58 Word 1 K6001 K Word 1
Word 2 .02
59 Rx-/Tx- 1 K6002 K Word 2
Peer to Peer Interface ( X172 )

SIMOREG DC Master Base Drive Panel Operating Instructions

Word 3 .03 Word 3
K6003 K
60 RS485 .04
M 0 Word 4 K6004 K Word 4
Word 5 .05
K6005 K Word 5

P816 (1) <2>

P795 (0) From preceding To following
0 1 0 1 B drive drive
Bit 0 ... Bit 15
Bus terminator Enable data receive B6100 B6115
B6200 B6215
B6300 B6315
+ M
<1> Binector = 0: B6400 B6415
Output drivers are high resistance B6515
B6500
<2> Binector = 0:
Telegram sign-of-life-monitorig is not active

U117 (0) .01

Parametes for peer-to-peer interface : B
1 = "Telegram
P790 (0) monitoring Fault signal trip
Peer-to-peer On/Off P798 (6030)
timeout"
P797 (0,000s) Telegram monitoring time B6030 B 1 = "Fault F012"
P793 (6) Baud rate 1s
U117 (0)
P791 (2) No. of words (1...5) B6031 .16
B
r799 Peer-to-peer diagnostic parameter
15 0
Binector / Connector K6020
Converter

11-9
MD6640 BLAST HOLE DRILL
SPECIAL INSTRUCTION MANUAL
 BI012088

1 2 3 4 5 6 7 8

11-10
Sheet 9

6RA70 DC MASTER
SIMPLIFIED BLOCK DIAGRAM
(ALL AVAILABLE FUNCTIONS ARE NOT SHOWN ON SIMPLIFIED BLOCK DIAGRAM)

Process data exchange with a communications board (CB) or technology board (TB)
Receive data Transmit data
n733.01 to .16 n735.01 to .16

every 16 bits U734 (0)

.01
Word 1 K3001 K Word 1
.02
Word 2 K3002 K Word 2
.03
Word 3 K3003 K Word 3
.04
Word 4 K3004 K Word 4
.05
Word 5 K3005 K Word 5
.06
Word 6 K3006 K Word 6
.07
Word 7 K3007 K Word 7
.08
Word 8 K3008 K Word 8
From supplementary board .09 To supplementary board
Word 9 K3009 K Word 9
.10
Word 10 K3010 K Word 10
.11
Word 11 K3011 K Word 11
.12
Word 12 K3012 K Word 12
.13
Word 13 K3013 K Word 13
.14
Word 14 K3014 K Word 14
.15
Word 15 K3015 K Word 15
.16
Word 16 K3016 K Word 16
Data Exchange CB / TB to Base (PZD)

Bit 0 ... Bit 15

B3100 B3115
B3200 B3215
B3300 B3315
B3400 B3415
B3500 B3515
B3600 B3615
Parameters for the first CB board
B3700 B3715
B3800 B3815
U710 Index.01 Initialize link to supplementary boards
B3900 B3915
U711-U720 Index.01 CB parameters 1 to 10
U721 Index.01-.05 CB parameter 11 1 = "Telegram monitoring timeout"
U722.1 (0 ms) Telegram receive monitoring time B3030
n732 Index.01-.32 CB or TB diagnosis 1s
n738 Index.01-.04 Display parameter job (PKW) from CB B3031
n738 Index.09-.12 Display parameter job (PKW) from TB
Fault message trigger
n739 Index.01-.04 Display parameter response (PKW) to CB
1 = "Fault F082"
n739 Index.09-.12 Display parameter response (PKW) to TB (fault value = 10)
P918 Index.01 Bus address
P927 Enable parameterization 9

SIMOREG DC Master Base Drive Panel Operating Instructions

SIEMENS Energy & Automation
MD6640 BLAST HOLE DRILL
SPECIAL INSTRUCTION MANUAL
 1 2 3 4 5 6 7 8
BI012088

6RA70 DC MASTER
SIMPLIFIED BLOCK DIAGRAM
(ALL AVAILABLE FUNCTIONS ARE NOT SHOWN ON SIMPLIFIED BLOCK DIAGRAM)

When P648 = 9, bit-serial input of control bits (P654 to P675 are effective)
Control word 1 When P648 <> 9, word-serial input of control bits (P654 to P675 are not effective) 15 14 13 12 11 10 9 Bit8
Terminals 37 and 38 are always active. They are ANDed to get bit 0 or bit 3. r650
7 6 5 4 3 2 1 Bit0
NORMAL START / STOP
P648.B (9) Control word 1
[ 2.2 ] TERMINAL 37 ON / OFF Bit No. Meaning K0030 Display of control word 1 (r650)
K

SIEMENS Energy & Automation

on 7-segment display
0=OFF1, shutdown via ramp-function generator followed by to sequencing control, [ 2.7 ]
INCHING ON / OFF ≥1 Bit 0 pulse disable to brake control
1=ON, operating condition (edge-controlled)
B0160
Sheet 10 Control Word 1

CRAWL ON / OFF Bit 1 0=OFF2, pulse disable, motor coasts to standstill to sequencing control
1=operating condition
1 B0161
COAST STOP Bit 2 0=OFF3, fast stop to sequencing control,
P655.B (1) 1=operating condition to brake control [ 3.2 ]
B
[ 2.2 ] ENABLE Bit 3 1=Enable, enable pulses to sequencing control
P656.B (1) 0=Pulse disable
B & P662.B (1)
B Bit 4 1=Enable ramp-function generator to "Ramp-function generator" [ 2.7 ]
P657.B (1) 0=Set ramp-function generator to 0
B P663.B (1)

SIMOREG DC Master Base Drive Panel Operating Instructions

B Bit 5 1=Ramp-function generator start to "Ramp-function generator" [ 2.7 ]
FAST STOP 0=Ramp-function generator stop
P658.B (1) P664.B (1)
B B Bit 6 1=Enable setpoint to "Ramp-function generator" [ 2.7 ]
0=Disable setpoint
P659.B (1)
B & Bit 7 0 =>1 edge Acknowledge to sequencing control
P660.B (1) P668.B (0)
B B Bit 8 1=Inching 1 "Inching setpoint 1" [ 2.3 ] OR'd WITH P435.01
P669.B (0)
FAULT ACK
B Bit 9 1=Inching 2 "Inching setpoint 2" [ 2.3 ] OR'd WITH P435.02
P665.B (0)
B
Bit 10 1=Control requested <1>
P666.B (0) 0=No control requested
B ≥1 P671.B (1)
B Bit 11 1=Enable positive direction of rotation
P667.B (0) 0=Positive direction of rotation disabled
B P672.B (1)
B Bit 12 1=Enable negative direction of rotation
Pulse generator 0=Negative direction of rotation disabled
P673.B (0)
<1> B Bit 13 1=Increase motorized potentiometer
P360.01 (0ms)
P674.B (0) (0...10000ms)
Note:
Bit 10 must be set in the first PZD word B Bit 14 1=Decrease motorized potentiometer
of the telegram received via the serial
External fault 1
interfaces to ensure that the process data P675.B (1)
will be accepted as valid (cf. USS, B Bit 15 0=External fault 1 1 = "Fault F021"
Profibus, etc.). 1=No external fault

10

11-11
MD6640 BLAST HOLE DRILL
SPECIAL INSTRUCTION MANUAL
 BI012088

1 2 3 4 5 6 7 8

11-12
6RA70 DC MASTER
SIMPLIFIED BLOCK DIAGRAM
(ALL AVAILABLE FUNCTIONS ARE NOT SHOWN ON SIMPLIFIED BLOCK DIAGRAM)

Control word 2
When P649 = 9, bit-serial input of control bits (P676 to P691 are effective)
When P649 <> 9, word-serial input of control bits (P676 to P691 are not effective) r651 31 30 29 28 27 26 25 Bit24
P649.B (9) Control word 2
23 22 21 20 19 18 17 Bit16
K Bit No. Meaning K0031

P676.B (0) Display of control word 2 (r651)

on 7-segment display
Sheet 11 Control Word 2

B Bit 16 Select function data set bit 0

P677.B (0)
B Bit 17 Select function data set bit 1

Bit 18 Spare

Bit 19 Spare

P680.B (0)
B Bit 20 Select fixed setpoint 1 to sheet "Fixed setpoint" [ 2.3 ] OR'd WITH P430.01
P681.B (0)
B Bit 21 Select fixed setpoint 2 to sheet "Fixed setpoint" [ 2.3 ] OR'd WITH P430.02

Bit 22 Spare

Bit 23 Spare
P360.02 (0ms)
P684.B (1)
(0...10000ms)
B Bit 24 1=Enable speed controller droop to sheet "Speed controller"
0=Speed controller droop disabled
[ 3.4 ]
P685.B (1) External fault 2
B Bit 25 1=Enable speed controller to sheet "Speed controller"
0=Speed controller disabled 1 = "Fault F022"
[ 3.4 ]
P686.B (1)
B Bit 26 0=External fault 2
1=No external fault 2 P360.03 (0ms)
P687.B (0) (0...10000ms)
B Bit 27 0=Master drive (speed control)
1=Slave drive (torque control)
P688.B (1) External alarm 1
B Bit 28 0=External alarm 1
1 = "Alarm A021"
1=No external alarm 1
P689.B (1)
B Bit 29 0=External alarm 2
1=No external alarm 2 P360.04 (0ms)
P690 (0) (0...10000ms)
B Bit 30 0=Select Bico data set 1
1=Select Bico data set 2
External alarm 2
P691.B (1)
B Bit 31 Main contactor check-back signal 1 = "Alarm A022"

11

SIMOREG DC Master Base Drive Panel Operating Instructions

SIEMENS Energy & Automation
MD6640 BLAST HOLE DRILL
SPECIAL INSTRUCTION MANUAL
 BI012088

1 2 3 4 5 6 7 8
6RA70 DC MASTER
SIMPLIFIED BLOCK DIAGRAM
(ALL AVAILABLE FUNCTIONS ARE NOT SHOWN ON SIMPLIFIED BLOCK DIAGRAM)

Status word 1
15 14 13 12 11 10 9 Bit8
r652
Status word 1 7 6 5 4 3 2 1 Bit0
Bit No. Meaning K0032
Display of status word 1 (r652)

SIEMENS Energy & Automation

on 7-segment display
Bit 0 1 = Ready to switch on
from sequencing control B0100
0 = Not ready to switch on
Sheet 12 Status Word 1

1 B0101
Bit 1 1 = Ready to operate (pulses disabled)
from sequencing control B0102
0 = Not ready to operate
1 B0103
Bit 2 1 = Run (output terminals energized)
from sequencing control B0104
0 = Pulses disabled
1 B0105
Bit 3 1 = Fault is active (pulses disabled)
from fault processing B0106
0 = No fault is active
1 B0107
Bit 4 0 = OFF2 applied
rom sequencing control B0108
1 = No OFF2 applied
1 B0109
Bit 5 0 = OFF3 applied

SIMOREG DC Master Base Drive Panel Operating Instructions

from sequencing control B0110
1 = No OFF3 applied
1 B0111
Bit 6 1 = Switch-on inhibit
from sequencing control 0 = No switch-on inhibit (converter can be switched on) B0112
1 B0113
Bit 7 1 = Alarm is active
from alarm processing B0114
0 = No alarm is active
1 B0115
Bit 8 0 = Setpoint/actual value deviation detected
from sheet "Signals" B0116
1 = No setpoint/actual value deviation detected
1 B0117
from sequencing control Bit 9 1 = PZD control requests (always 1)

Bit 10 1 = Comparison setpoint reached

from sheet "Signals" B0120
0 = Comparison setpoint not reached
1 B0121
Bit 11 1 = Undervoltage fault
from fault processing B0122
0 = No undervoltage fault is active
1 B0123
Bit 12 1 = Request to energize main contactor
from sequencing control B0124
0 = Request not to energize main contactor
1 B0125
from setpoint processing Bit 13 1 = Ramp-function generator active
B0126
(part 2) 0 = Ramp-function generator not active
1 B0127
Bit 14 1 = Positive speed setpoint
from sheet "Signals" B0128
0 = Negative speed setpoint
1 B0129
Bit 15 Spare

12

11-13
MD6640 BLAST HOLE DRILL
SPECIAL INSTRUCTION MANUAL
 BI012088

1 2 3 4 5 6 7 8

11-14
6RA70 DC MASTER
SIMPLIFIED BLOCK DIAGRAM
(ALL AVAILABLE FUNCTIONS ARE NOT SHOWN ON SIMPLIFIED BLOCK DIAGRAM)

Status word 2
31 30 29 28 27 26 25 Bit24
r653
Status word 2 23 22 21 20 19 18 17 Bit16
Bit No. Meaning K0033
Display of status word 2 (r653)
on 7-segment display
Bit 16 Spare
Sheet 13 Status Word 2

Bit 17 Spare

from sheet "Signals" Bit 18 0 = Overspeed

B0136
1 = No overspeed
1 B0137
from sequencing control Bit 19 1 = External fault 1 active
B0138
0 = No extern fault 1 active
1 B0139
from sequencing control Bit 20 1 = External fault 2 acrive
B0140
0 = No external fault 2 active
1 B0141
from sequencing control Bit 21 1 = External alarm active
B0142
0 = No external alarm active
1 B0143
from alarm processing Bit 22 1 = Power section overload alarm active B0144
0 = No overload alarm active
1 B0145
from fault processing Bit 23 1 = Power section overtemperature fault active B0146
0 = No overtemperature faultactive
1 B0147
from alarm processing Bit 24 1 = Power section overtemperature alarm active B0148
0 = No overtemperature alarm active
1 B0149
from alarm processing Bit 25 1 = Motor overtemperature alarm active
B0150
0 = No motor overtemperature alarm active
1 B0151
from alarm processing Bit 26 1 = Motor overtemperature fault active
B0152
0 = No motor overtemperature fault active
1 B0153
Bit 27 spare

from fault processing Bit 28 1 = Motor locked fault active B0156

0 = No motor locked fault active
1 B0157
Bit 29 spare

Bit 30 spare

Bit 31 spare

13

SIMOREG DC Master Base Drive Panel Operating Instructions

SIEMENS Energy & Automation
MD6640 BLAST HOLE DRILL
SPECIAL INSTRUCTION MANUAL
 1 2 3 4 5 6 7 8
BI012088

6RA70 DC MASTER
SIMPLIFIED BLOCK DIAGRAM
(ALL AVAILABLE FUNCTIONS ARE NOT SHOWN ON SIMPLIFIED BLOCK DIAGRAM)

P388.F (3.00)
(0.00...199.99%) P390.F (3.0)
Signals Setp./act.val. dev. (perm.) (0.0...100.0 s)
Setp./act.val. dev. (time)
Sheet 14 Signals

n(set)

SIEMENS Energy & Automation

P590 (170) 1 0 T
[ 3.1 ] Setpoint/act. value deviation
K to status word 1, bit 8
0
n(act) OFF delay
P591 (167) 1 = "Fault F031"
[ 3.3 ] K P389.F (3.00)
(0.00...199.99%) 1 = "Alarm A031"
Setp./act.val. hyst.

P373.F (100.00)
(0.00...199.99%) P375.F (3.0)
n(comp.) (0.0...100.0 s)
Comparison (time)
n(act)
P592 (167) 1 0 T
Comparison setpoint reached

SIMOREG DC Master Base Drive Panel Operating Instructions

[ 3.3 ] K
to status word 1, bit 10
0
OFF delay

P374.F (3.00)
(0.00...199.99%)
n(comp.hyst.)

P370.F (0.50)
(0.00...199.99%)
OFF shutdown speed P088.F (3.0)
(0.0...100.0 s)
Comparison (time)
n(act)
P593 (167) 1
[ 3.3 ] K 0 T
0 OFF1 or OFF3 from & Firing pulse disable
sequencing control
OFF delay

P371.F (0.50)
(0.00...199.99%)
OFF shutdown speed (hyst.)

P381.F (-120.0) P380.F (120.0) 1 = "Fault F038"

(-199.9...0.0%) (0.0...199.9%)
n(max. neg. rot.) n(max. pos. rot.)
1 = "Alarm A038"
n(set) n(act)
P594 (170) 1 P595 (167)
Positive speed setpoint 1 Overspeed to
[ 3.1 ] K K
to status word 1, bit14 status word 2, bit 18
0 0
[ 3.3 ]
14

11-15
MD6640 BLAST HOLE DRILL
SPECIAL INSTRUCTION MANUAL
 BI012088

11-16
1 2 3 4 5 6 7 8
Data sets 5 Fixed Values 5 Fixed Values 5 Fixed Control Bits
setting range setting range
-199.99 to +199.99% -32768 to +32767
Note: r056
Switchover between function parameters
The applicable parameters active function data set
are identified by the code ".F" P401.F (0,00) P412.F (0) P421.F (0)
Parameter
number Index 1 Index 2 Index 3 Index 4 K0401 K0412 B0421
Sheet 15 Miscellaneous

xxxx
Function data set bit 0 P402.F (0,00) P413.F (0) P422.F (0)
xxxx
from control word 2 xxxx
xxxx K0402 K0413 B0422
xxxx
Function data set bit 1 xxxx P403.F (0,00) P414.F (0) P423.F (0)
from control word 2 xxxx
... K0403 K0414 B0423

P055. (012) P404.F (0,00) P415.F (0) P424.F (0)

(011...244)
Copy function data set K0404 K0415 B0424

P405.F (0,00) P416.F (0) P425.F (0)

Target data set (1...4)
K0405 K0416 B0425
Source data set (1...4)

ALSO SEE P406 TO P411 ALSO SEE P426 TO P428

Switchover between binector

r058
and connector parameters
active Bico data set
Note:
The applicable parameters Parameter 7 Connector Displays
are identified by the code ".B" number Index 1 Index 2
r043.01 r043.03 r043.05 r043.07 4 Binector Displays
xxxx
Bico data set xxxx
from control word 2 P044 (0) r043.02 r043.04 r041.06
xxxx .01
xxxx K r045.01 r045.03
.02
xxxx K
.03 r045.02 r045.04
xxxx K P046 (0)
xxxx .04 .01
K B
... .05 .02
K B
.06 .03
K B
.07 .04
P057 (012) K B
011...222
Copy Bico data set

Target data set (1/2)

Source data set (1/2) 15

SIMOREG DC Master Base Drive Panel Operating Instructions

SIEMENS Energy & Automation
MD6640 BLAST HOLE DRILL
SPECIAL INSTRUCTION MANUAL
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

Siemens Energy & Automation, Inc. 6RA70 Base Drives

dc drives instructions • 2003
3333 Old Milton Parkway
Alpharetta, GA 30005

1-800-964-4114
seainfo@sea.siemens.com

www.sea.siemens.com/drives

© 2003 Siemens Energy & Automation, Inc.

The Siemens logo and SIMOREG are registered trademarks of Siemens AG. Product names mentioned may be trade-
marks or registered trademarks of their respective companies. Specifications are subject to change without notice.
Order Number DCOM-80011-0103 Supercedes DROM-8001 500-0103SSS Printed in USA.
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

MANUAL : M9-0298
MODEL : MPV9MX1C
TYPE : Package
APPLICATION : Mining Drills,
Shovels, Draglines
JOB NUMBER : 9071

SIGMA Manual Number : MPV9MX1C-0298

Date of Original Issue : February 1998
Date of This Issue : May 1998

1
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

CHAPTER 1

UNIT DESCRIPTION

AND

SPECIFICATIONS

3
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

1.0.0 DESCRIPTION OF UNIT

The MPV9 is a heavy duty system suitable for rooftop or walkway mounting on the
cabs and electrical enclosures of mining and industrial equipment. This includes
shovels, draglines, drills, shiploaders, track maintenance, crane cabs and control
rooms.

Evaporator: Air is drawn from under the unit, passes over the heat exchange
coil and heating elements into the double inlet wheel fan deck and
is discharged through the base into the conditioned space.

Facility is also available to have supply and return air out the front
face of the evaporator unit.

Refrigerant flow is metered by an externally equalized TX valve,

and is cut off by a liquid line solenoid valve.

Heat exchange coil is large, with heavy gauge tubing and coarse
fin pitch to reduce clogging.

Fan motor is single shaft and of totally enclosed, fan cooled

construction.

Drain pan is large and of "V" design for ease of cleaning and to
facilitate draining.

All pressure controls are in the evaporator section and are fully
sealed, preset and ‘O’ ring connected.

Condenser: The compressor is a heavy duty, fully sealed scroll device. The
assembly is mounted to heavy flexible mounts to reduce noise
transmission to the structure and provide some damping of shock.

Connections are either soldered, ‘O’ ring or rotalock.

A large filter drier is mounted in the liquid line to filter and remove
moisture from the refrigerant. Isolation valves are installed on
either side to enable refrigerant to be "pumped down" and thus
enabling core to be replaced without total loss of refrigerant.

Condenser fan is single speed.

4
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

1.0.0 DESCRIPTION OF UNIT (cont.)

Electrics: The main control panel is mounted on the side of the evaporator
for ease of service. Switchgear is Klockner Moeller, and motor
protection is by circuit breaker thermal overloads. Heaters and
transformer have circuit breakers.

The pilot controls, when supplied, have OFF-LOW-HIGH fan

switch and HEAT-VENT-COOL-DEMIST mode switch, plus a set
point adjuster for thermostat.

A transformer supplies the 115V for control purposes.

1.1.0 Specifications

Dimensions : T9071004

Installation : T9071006 (2 sheets)

Electrical
Schematic : AE9071001

Nominal
Cooling Capacity : 31,000 Btu/hr. @ 460V/60Hz
27,000 Btu/hr. @ 380V/50Hz

Heating Capacity : 12 kw @ 460V/60Hz

10 kw @ 380V/50Hz

Power Requirement: 380V/3ph/50Hz 415V/3ph/50Hz 460V/3ph/60Hz

17.5 Amps (Norm) 19.0 Amps (Norm) 21.0 Amps (Norm)

Refrigerant : HFC 134a environmentally friendly 24 lbs.

Oil : POE Variety Mobil Artic EAL22CC or

ICI Emcarate RL32CF

Compressor : Fully sealed scroll compressor.

Condenser Coil : 5 row, 3/8” inch copper tube with 8 aluminum fins per
inch.

Evaporator Coil : 4 row, 3/8” inch copper tube with 10 aluminum fins per
inch.

5
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

1.0.0 DESCRIPTION OF UNIT (cont.)

1.1.0 Specifications (cont.)

Condenser Fan : Multi-blade axial, 17¼” inch diameter, 35 o pitch to

provide in excess of 3000 cfm @ 60Hz.

Supply Air : One forward curve double inlet fan supplies a nominal
1300 cfm (610 l/s) @ 60Hz,
1100 cfm (490 l/s) @ 50Hz.

Pressure Controls : HIGH-228/325 psi high pressure cut out, manual reset.
LOW - 10 psi cut out
25 psi cut in

Pressurization : A large Donaldson filter with a single inlet blower wheel

provides pressurization. Motor is 1 phase, 2 pole and
mounted within the condenser.

Thermostat : 5 stage electronic 1.5°C within stage.

6
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

CHAPTER 2

INSTALLATION

AND

COMMISSIONING

7
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

2.0.0 INSTALLATION AND COMMISSIONING

Time spent ensuring the preparation for installation will pay dividends by reducing
service requirements during operation.

2.1.0 Installation

Ensure the following:

• Area is clean, flat and strong enough to support the system.

• Adequate space is provided around the unit for service and air
flow.
• There is nothing underneath which will obstruct airflow or
distribution.

Mark out supply and return cutouts either from the drawing or the roof
sealing frame (see drawing T9071006, sheet 2 of 2). Carefully cut out
apertures. Place sealing frame in position, and tack corners. Check that
supply and return air plenum support assemblies fit. Some grinding may
be required on the inside edge of the roof sealing frame assembly to
provide clearance.

The support assemblies return and supply (see drawing T9071006, sheet 1
of 2) should mount with the drilled angle level - or near to - the ceiling. The
supply and return air plenums bolt to these frames. The skirt of the
mounting assembly can then be cut to suit and welded in position.

The roof sealing frame should then be welded to the roof, well sealed, and
painted.

Lift the air conditioner into position making sure that the casing to cab seal
is firmly in position on the underside of the unit prior to final positioning.
Lower the unit down onto the sealing frame.

The mounting channels have holes on the bottom for mounting to studded
bar, thus enabling ready removal of unit.

8
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

2.0.0 INSTALLATION AND COMMISSIONING (cont.)

2.1.0 Installation (cont.)

Fit the supply and return air plenums, and mount the pilot controls at a
convenient location, e.g. near the operator or on the wall.

Run the electrical inter-connecting control wires and supply power cable to
the appropriate site standards.

Run the condensate drain to a point where condensate is not going to

create a problem. Install in such a way that a barometric leg or P-trap is
used.

NOTE: In some cases with an old, or thin roof, it is a good idea to

manufacture a separate roof plate out of minimum 1/4” steel to provide a
sound, flat mounting surface. Thin skins buckle when welded, seals are
often poor and there is a high degree of pre-stress which in industrial
applications could lead to fatigue failure, cracks, and leaks.

2.2.0 Commissioning

The system has been fully charged and commissioned at the factory, but
must be site checked.

With all cabling run, and system mounted, the system is ready for
commissioning.

• Turn selector switch ‘OFF’.

• Select and wire the primary side of the transformer to ensure
110-120V single phase control. This is VERY IMPORTANT as
the transformer is multi-tapped and correct control voltage will
aid reliability.
• Check control voltage is 115V.

Proceed to live test.

A. Select ‘VENT’ on Mode switch.

Select ‘LOW’ on FAN switch.

This should result in evaporator fan running on low speed and

pressurization unit only.

9
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

2.2.0 Commissioning (cont.)

Check correct phase rotation of evaporator fan. This can be done

by either switching ‘OFF’ and have an observer looking into the
evaporator cover; or by closing the Main Isolator at the unit if on
you own.

Please be aware that air will flow in the right circuit no matter what
direction the fan runs - but the wrong direction will only result in
approximately 30% of the flow.

Select ‘HIGH’ on Fan switch and check that speed and flow
increase.

B. Select ‘HEAT’ on Mode switch.

Rotate thermostat knob fully clockwise.

Under normal temperatures of 70°F nominal, both heater

contactors will close bringing on both heat stages.

In the event that ambients and the cab temperature are too high,
immerse the temperature probe (in return air section of evaporator)
in a glass of cold water.

Check the individual staging of heater contactors as the probe either

cools - or warms up.

Check HIGH & LOW fan operation. Fans will automatically switch to
HIGH in high heat.

C. Select ‘COOL’ on Mode switch.

Rotate thermostat adjustment fully counterclockwise.

As with heating, the ambient should be in the 70°F range for cooling
to operate.

In the event that it isn’t, warm the return air probe in you hand. The
compressor should start, along with the condenser fan.

If the compressor does not start, check phase rotation as a device is

installed to ensure correct rotation.

10
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

2.2.0 Commissioning (cont.)

Observe the charge as indicated in the liquid line sight glass

(located in the condenser). The air conditioner is fitted with a HEAD
PRESSURE CONTROL VALVE which maintains a minimum
pressure of 130 psi at all ambients. This works by backing
refrigerant up into the condenser. Charge in the air conditioner is
high for this reason, but it provides great flexibility of application.

System should be capable of operating in the COOLING mode down

to 10°F ambient.

Check fan speed operation.

D. Select DEMIST on Mode switch.

This mode assists in demisting inside the cab window surfaces by

operating one stage of heating continuously and either COOLING if
it is hot, or 2nd stage of HEAT if it is cold.

Heating the air dries it and by passing over a cool heat exchange
coil, moisture is condensed and removed from the air stream. This
greatly increases the speed of demisting.

Check fan speed operation, but again be aware that full heat will
result in HIGH fan.

OPERATION MATRIX
Evap. Fan Pressurizer Heat Cooling
Low High 1st 2nd
OFF
LOW X X
HIGH X X
HEAT X T T
VENT X
COOL X T
DEMIST X X T T

X = Operational
T = Thermostatically Controlled

11
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

CHAPTER 3

SERVICING

12
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

3.0.0 SERVICING

Recommended service schedule. Site conditions may alter this.

1st Week
„ Check charge and add if required.
„ Leak Test - with ultraviolet black lamp and 134a specific
detector, good for use with Ester lubricant system. Spectronics
Corp GS-2/E Glow-Stick Capsule recommended..
„ Tighten all mounting bolts, fasteners, terminals, etc.
„ Check drains.
„ Check operation.

Daily
„ Clean filter if in dusty conditions.
„ Clean pressurizer if in dusty conditions.
„ Observe charge.

Monthly
„ Daily checks.
„ Check for leaks.
„ Check fans for tightness on shafts.
„ Clean out coils.
„ Flush drains.

3 Months
„ All monthly phases.
„ Check structure.
„ Check hoses and fittings.

Annually
„ All previous phases.
„ Give system a good cleaning out.
„ Check motor bearings and replace if necessary.

13
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

CHAPTER 4

FAULT FINDING

14
 SPECIAL INSTRUCTION MANUAL
BI012088 MD6640 BLAST HOLE DRILL

4.0.0 FAULT FINDING

This section is written on the assumption that the service mechanic is a qualified
trades person in refrigeration and air conditioning. They must have a good
understanding of the operation prior to fault diagnosis and repair.

4.1.0 System Dead

• Check main supply and circuit breakers.

• Check control transformer.
• Check power lines to ascertain where power is lost.

4.2.0 No Fans

• Check power lines to find where the loss or break in supply occurs.
• Check motors.

4.3.0 No Cooling All fans OK, but compressor doesn’t run.

• Check “COOL” selected, and if there is 115V power to terminal 22.

• Check HP and LP control are closed by testing for 115V at 11 (re-
set HP anyway - in evaporator liquid line). If LP is open, system
may have lost charge. Find leak and repair.
• Check that pumpdown relay closes and 115V power is supplied to
compressor thermal overload.
• Check that liquid line solenoid valve operates.
• If power is supplied to the contactor, but no action, the coil will have
failed.
• Check contactor is closing.
• Check overloads, circuit breakers.
• Check phase rotation relay.
• If power is being supplied to the compressor, but still no action,
isolate the power, disconnect the terminals and check for open
circuit in the motor.
• If breaker keeps tripping, the compressor may be grounded.
• Check thermostat operation and stage 3 is closed between K3C and
K3NO.

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4.0.0 FAULT FINDING (cont.)

4.4.0 Inadequate Cooling

System may not be performing as well as it should be.

• Check pressures. A system would normally operate between 130-

200 psi on the high side and 25-45 psi on the low side.

High pressure could indicate air in the system, dirty condenser,

overcharge. Low high side pressure could indicate low charge or
failing scroll in compressor.

If the low side has a much higher than 45 psi pressure it could
indicate failing compressor, liquid floodback, and/or poor TX valve,
operation (is suction line very ‘sweaty’?).

• Check refrigerant charge in sight glass. It should be full at all times

when compressor is running. Low charge will first become evident
at low ambients.

• Check for restriction in the system. This can be done by feeling the
plumbing before and after a “device”. If it is noticeably cooler,
expansion has taken place from a drop in pressure. There is
restriction, and steps should be taken to clear it. Check for a:

„ Blocked return air filter.

„ An open lid admitting outside air.
„ Coil for cleanliness.
„ TX valve for correct operation.

4.5.0 Charge

Normal factory charge is 24 lbs. of 134a to cater for low ambient operation
as the condenser fills with refrigerant. If bubbles appear in the sight glass,
check for leaks, repair and either weigh in the full charge if system has
been evacuated or top up as conditions demand. The system is forgiving
for normal site practices.

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SERVICE NOTES:
4.7.0 HEAD PRESSURE CONTROL VALVE OPERATION

The Head Pressure Control Valve’s purpose is to hold back enough of the
condensed liquid refrigerant so that some of the condenser surface is rendered
inactive. This reduction of active condensing surface results in a rise in
condensing pressure and sufficient liquid line pressure for normal system
operation. Due to the presence of the Head Pressure Control Valve the refrigerant
charging procedure is as follows.

CHARGING PROCEDURE MPV9

The following procedure requires the unit to be void of all refrigerants
and in a vacuum.
The MPV9’s total system refrigerant charge is 24lbs

1. With the unit off, dump charge 4lbs of 134a at the receiver outlet valve (the filter dryer evacuation
port can also be used.)

2. Connect the low side gauge to the charging port provided at the TXV (Just above the distributors.)
CAUTION: DO NOT CHARGE FROM THE SUCTION PORT!

3. With the unit off, charge as much of the remaining refrigerant as the system will allow (this number
will vary depending on ambient temperature.)

4. Switch the unit into cooling.

5. Continue adding refrigerant until the full 24lbs have been added (depending on the ambient
temperature, the low pressure switch may need to be shorted to allow the system to continue to run
until a sufficient charge has been added.)

WARNING: The compressor is phase rotation sensitive, and will not function
if wired incorrectly. Equal pressure at the discharge valve and the Suction valve is
one symptom of the compressor running in the wrong direction. Do not allow the
system to run in this condition for any extended period of time. Damage may
occur! In the event of a compressor change, the phases must be checked at the
compressor. Correct rotation can be felt with discharge to condenser getting hot,
and suction back is cool.
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4.6.0 Heating

The system has 6 equal elements in star formation and as the system
operates in extremes of ambients, a high capacity system has been
provided. It is also 2 stage in operation for improved comfort.

If heating is inadequate, check:

• Circuit breakers. One breaker will knock out 1/3 of that stage
capacity.
• Elements for open circuit.
• Thermostat for correct switching of contactors.
• Over temperature sensor cutting out failed evaporator fan.

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CHAPTER 7

RECOVERY

OF

REFRIGERANT

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7.0.0 RECOVERY OF REFRIGERANT

Although HFC134a is environmentally friendly, the refrigerant must be recovered

prior to opening up the system. Devices are fitted to minimize the amount
required, but venting to atmosphere is illegal.

The lubricant is a POE style, and does not mix with other mineral oils.

A dedicated recovery unit should be used, as should a gauge set.

THEY SHOULD NOT BE MIXED WITH R12, R22, MP39, OR OTHER

REFRIGERANTS.

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CHAPTER 8

134a

SPECIFIC TOOLS

8.0.0 134a SPECIFIC TOOLS

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UV Lamp
Manifold Gauge Set with Isolation Valves at Hose Ends.

CHAPTER 9
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