PowerTec

Chapter 4 - Wiring Procedure

4.1 Accessing the Connectors
4.1.1 Removing the Covers

NOTE! Observe the safety instructions and warnings given in this manual. The devices can be
opened without the use of force. Only use the tools specified.

See figure 2.2.2 “Drive view & components” to identify single parts.

Figure 4.1.1: Removing the covers (sizes PX-3 to PX-30)

2 2
no. 2 for
20-40 ...30-60
size
1

Sizes PX-3 to PX-15:

The terminal cover and cable entry plate of the device must be removed in order to make the
electrical connections:
- unscrew the screw (1), and remove the device cover (2) by pressing on both sides as
shown in the above figure (3).
- unscrew the two screws (4) to remove the cable entry plate.
The top cover must be removed in order to mount option cards and change the internal
jumper settings:
- remove the keypad and disconnect the connector (5)
- lift the top cover on the bottom side (over the connector level) and push it to the top (6)

Sizes PX-20 to PX-30:

The terminal cover and cable entry plate of the device must be removed in order to make the
electrical connections:
- unscrew the two screws (1) and remove the device cover
- unscrew the two screws (4) to remove the cable entry plate.
The top cover must be removed in order to mount the option card and change the internal
jumper settings:
- remove the keypad and disconnect the connector (5)
- lift the top cover on the bottom side (over the connector level) and push it to the top (6)

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-27
 FlexMax

Figure 4.1.2: Removing the covers (sizes PX-40 to PX-300)

3
3

2 2

Sizes PX-40 to PX-300:

The terminal cover of the device must be removed in order to make the electrical connections:
- unscrew the two screws (2) and remove the cover (1)
The top cover must be removed in order to mount the option card and change the internal
jumper settings:
- unscrew the two screws (3) and remove the top cover by moving it as indicated in fig. (4)

In order to avoid damage to the drive it is not

allowed to transport it by holding the cards!
Caution

4.1.2. Wiring Suggestion

Shield
Omega connector

Grounding 360° of a shielded cable

on Omega plug

CAN connector
Regulation section strip
(17 to 32 terminals)

Regulation section strip

(1 to 16 terminals)

4-28 • Chapter 4 Wiring Procedure Flex

FlexMax User’s Guide
 PowerTec

4.2 Power Section

Please note that a wrong connection on motor phases can cause the motor to move without
Caution
control and can destroy the drive.
Please check that motor phases are connected in right sequence before enabling drive.

4.2.1 Terminal Assignment on Power Section / Cable Cross-Section

Power terminals layout sizes PX-3 to PX-30

The terminals of the devices are made accessible by removing the cover and the cable entry
plate (see section 4.1, “Accessing the connectors”).
On PX-3 up to PX-15 sizes it is also possible to extract the removable connector.
All the power terminals are located on the power card PV33-...

Table 4.2.1.1: Power Section Terminals from PX-3 to PX-30

Function max
U1/L1
230V -15% …
3Ph~ V1/L2 AC mains voltage 480V+10%, 3Ph

W1/L3
Braking unit resistor command (braking resistor
BR1 must be connected between BR1 and C)

C
Internal braking resistor Intermediate circuit connection 770V DC / 1.65
output current
D

U2/T1

M
AC line volt 3Ph
V2/T2 Motor connection 1.36 output
current
W2/T3

PE2/ Motor ground connection

PE1 / Grounding (protective earth) conductor

Power terminals layout sizes PX-40 to PX-300

The terminals of the devices are made accessible by removing the cover (see section 4.1,
“Accessing the connectors”).

Table 4.2.1.2: Power Section Terminals from PX-40 to PX-100

Function max
PE1/ Grounding (protective earth) conductor
U1/L1
230 V -15% …
3Ph~ V1/L2 AC mains voltage 480V +10%
3Ph
W1/L3

C (+) 770V DC / 1.65

Braking resistor (optional) Intermediate circuit connection
Output current
D (-)
Braking unit resistor command (braking resistor
BR1 must be connected between BR1 and C)
U2/T1

M
AC line volt 3Ph
V2/T2 Motor connection 1.36 output
current
W2/T3

PE2/ Motor ground connection

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-29
 FlexMax

Table 4.2.1.3: Power Section Terminals from PX-125 to PX-300

Function max
PE1/ Grounding (protective earth) conductor
U1/L1
230 V -15% …
3Ph~ V1/L2 AC mains voltage 480V +10%
3Ph
W1/L3

C (+) 770V DC / 1.65

Intermediate circuit connection
Output current
D (-)
U3 Cooling fans supply connection
2V3
1V3 See Section 3.2.1 for details
U2/T1

M
AC line volt 3Ph
V2/T2 Motor connection 1.36 output
current
W2/T3

PE2/ Motor ground connection

Maximum cable sizes for power terminals U1, V1, W1, U2, V2, W2, C, D, PE

Table 4.2.2.2: Maximum cable cross section for power terminals

Type PX- 3 5 7 10 15 20 30 40 55
AWG 14 10 8 6 4
U1,V1,W1,U2,V2,W2,C,D
[mm2 ] 2 4 8 10 16 25
terminals
[sq in] (0.003) (0.006) (0.012) (0.016) (0.025) (0.039)
[Nm] 0.5 to 0.6 1.2 to 1.5 2 3
Tightening torque
[lbf-in] (4.4) to (5.3) (10.6) to (13.2) (17.7) (26.5)
[mm2 ] 2 4 8 10 6 10
BRI terminals
[sq in] (0.003) (0.006) (0.012) (0.016) (0.009) (0.016)
Tightening torque [lbf-in] (4.4) to (5.3) (10.6) to (13.2) (7.9) (14.1)
AWG 14 10 8 6
PE1, PE2 terminals [mm2 ] 2 4 8 10 16
[sq in] (0.003) (0.006) (0.012) (0.016) (0.025) (0.025)
[Nm] 0.5 to 0.6 1.2 to 1.5 2 3
Tightening torque
[lbf-in] (4.4) to (5.3) (10.6) to (13.2) (17.7) (26.5)
Type PX- 70 80 100 125 160 190 230 300
U1,V1,W1,U2,V2,W2,C,D AWG 2 1/0 2/0 4/0 300* 350* 4x #2
terminals [mm2 ] 35 50 70 95 150 185 4x35
[sq in] (0.054) (0.078) (0.109) (0.147) (0.233) (0.287) (4x 0.054)
[Nm] 4 12 10-30
Tightening torque
[lbf-in] (0.006) (106.2) (88.5) - (265.5)
BRI terminals [sq in] (0.016) (0.025)
terminals not avaible
Tightening torque [lbf-in] (14.1) (26.5)
AWG 6 2
PE1, PE2 terminals [mm2 ] 16 50
[sq in] (0.025) (0.078)
Tightening torque [lbf-in] (26.5) (35.4)
* = kcmils txv0060

The grounding conductor of the motor cable may conduct up to twice the value of the rated
current if there is a ground fault at the output of the FlexMax drive.

NOTE! Use 75°C copper conductor only.

4-30 • Chapter 4 Wiring Procedure Flex

FlexMax User’s Guide
 PowerTec

4.3 Regulation Section

4.3.1 R-XVy Regulation Card

S35

XT
XY4
XISP
S45
XY5
S46

XP
S3 RST
S2 PWM
S1 RUN
S0 PWR

XO

XEXP1
S17
S18
S15
S16
S13
S14

XEXP
S11
S12
S21
S22
S23

S34
S8

S9

1 2 3 4 5 6 7 8 9 10 11 1213 14 1516

CAN F1

C5C4C3C2 C1
171819 20 212223242526 272829303132
V+ H SH L V-
AL OP XFL(OUT)
XFL(IN)
XE / XER
S5
S6

CAN
RS485 XS

LEDs & Test points on Regulation Card

Designation Color Function
RST red LED lit during the Hardware Reset
PWM green LED lit during IGBT modulation
RUN green CPU status
PWR green LED lit when the voltage +5V is present and at correct level
RS485 green LED is lit when RS485 interface is supplied
CAN green LED is lit when CAN interface is supplied
AL red LED is lit during the “Field bus failure” alarm or when the integrated
CanOpen interface is not ready to communicate with the master
OP green LED is lit when the connection reaches the “Operational” phase
XY4 (test point) Phase current signal (U)
XY5 (test point) Reference point

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-31
 FlexMax

Figure 4.3.1: Connectors Location

CAN (C1...C5 terminals ) X1 (1...16 terminals )

X1 (17...32 terminals )
XE XS
11 15
6 9
6 10
1 5 1 5

11
6 10
15
XFL (OUT)
1 5

XER
XFL (IN)

Table 4.3.1.1: Jumpers on Regulation Card

Designation Function Factory setting
S0 Service only ! (Test and software loading: bootstrap-loader) OFF
S1 Service only ! (Test and software loading: monitor mode) OFF

S2 Service only ! (Test and software loading: boot-sector protection) OFF

S3 Service only ! (Test and software loading: manual reset) OFF
Terminating resistor for the serial interface RS485 (1)
S5-S6 ON = Termination resistor IN ON
OFF = No termination resistor
Adaptation to the input signal of analog input 0 (terminals 1 and 2)
S8 ON = 0..20 mA / 4..20 mA OFF
OFF = 0..10V / -10..+10 V
Adaptation to the input signal of analog input 1 (terminals 3 and 4)
S9 ON = 0..20 mA / 4..20 mA OFF
OFF = 0..10V / -10..+10 V
S11-S12-S13 Encoder setting on XE connector
S14-S15-S16- A = Sin / Cos encoder B (2)
S17-S18 B = Resolver
S21-S22-S23 Hall sensor settings
ON = Hall sensors OFF
OFF = No Hall sensors
S45-S46 INTERNAL USE - Do not modify factory setting OFF
txv0070

(1) on multidrop connection the jumpers must be ON only for the last drop of a serial line
(2) standard feedback setting. See chapter 4.3.5, Feedback drive connection for more details on S11 ... S23 jumper settings .

The devices are factory set accordingly.

When fitting a regulation card as a spare, remember to set again the encoders
Caution
jumpers.

4-32 • Chapter 4 Wiring Procedure Flex

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 PowerTec

4.3.2 Terminal Assignments on Regulation Section

Table 4.3.2.1: Plug-in Terminal Strip Assignments on Regulation Card
Strip X1 Function max
1 Programmable/configurable analog differential input. Signal: terminal 1.
Analog input 0
Reference point: terminal 2. Default setting: "Speed ref 1". ±10V
2
0.20mA
3 Programmable/configurable analog differential input. Signal: terminal 3.
Reference point: terminal 4. Default setting: none
Analog input 1
4
5 COM-DI Reference point for Digital inputs, terminals 6, 7, 8 , 9, 22, 23, 24 and 25.

6 Digital input 0 Drive enable; 0V or open: inverter disabled; +15…+30V: Drive enabled
+30V
7 Digital input 1 Programmable digital input, default setting: “Start/stop” 3.2mA @ 15V
5mA @ 24V
8 Digital input 2 Programmable digital input, default setting: “Inverse” 6.4mA @ 30V

9 Digital input 3 Programmable digital input, default setting: “Jog +”

10 Supply-DO Supply input for digital outputs +30V/40mA

11 COM-DO Reference point for digital outputs, terminals: 12 and 13 -

12 Digital output 0 Programmable digital output, default setting: “Drive enabled”

+30V/25mA
13 Digital output 1 Programmable digital output, default setting: “Speed reached”
+24 V ±10%
14 +24V OUT +24V DC supply output. Reference point: terminal 16 120mA
+24 V ±10%
15 +24V IN +24V DC supply input
1A
16 0 V (+24V) Reference point for +24 VDC I/O -

17 Analog output 0 Programmable analog output, default setting: “Filtered Actual speed”
±10V/5mA
18 Analog output 1 Programmable analog output, default setting: “Filtered Motor current”

19 0V Analog output reference point -

20 +10V Reference voltage +10V, reference point: terminal 19 +10V/10mA

21 - 10V Reference voltage - 10V, reference point: terminal 19 -10V/10mA

22 Digital input 4 Programmable digital input, default setting: “Jog -”

+30V
23 Digital input 5 Programmable digital input, default setting: none 3.2mA @ 15V
5mA @ 24V
24 Digital input 6 Programmable digital input, default setting: none
6.4mA @ 30V
25 Digital input 7 Programmable digital input, default setting: “Drive reset”

26 Digital output 2

27 Digital output 3
Programmable digital output, default setting: none +30V/25mA
Digital output 4
28
Digital output 5
29
30 Relay-NO “Drive OK” N.O. contact
250 V AC
31 Relay-NC “Drive OK” N.C. contact 1A AC

32 Relay-COM “Drive OK” common contact

C5 V+ CAN external positive supply (dedicated for supply of transceiver and optocouplers)

C4 H CAN_H bus line (dominant high)

C3 SH CAN_H shield

C2 L CAN_L bus line (dominant low)

C1 V- External supply reference

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-33
 FlexMax

Maximum Cable Sizes for control terminals

Table 4.3.2.3: Maximum permissible cable cross-section on the plug-in terminals of the regulator section

Maximum Permissible Cable Cross-Section Tightening

2
Terminals [mm ] torque
AWG
flexible multi-core [Nm]
1 ... 29 0.14 ... 1.5 0.14 ... 1.5 28 ... 16 0.4
30 ... 32 0.14 ... 1.5 0.14 ... 1.5 28 ... 16 0.4
txv0065

The use of a 75 x 2.5 x 0.4 mm (3 x 0.1 x 0.02 inch) flat screwdriver is recommended.
Remove 6.5 mm (0.26 inch) of the insulation at the cable ends. Only one unprepared wire
(without ferrule) should be connected to each terminal point.

Maximum Cable Length

Table 4.3.2.4: Maximum Control Cable Lengths

Cable section [mm2] 0.22 0.5 0.75 1 1.5
Max Length m [feet] 27 [88] 62 [203] 93 [305] 125 [410] 150 [492]
avy3130

Potentials of the control section

The potentials of the regulation section are isolated and can be disconnected via jumpers
from ground. The connections between each potential are shown in Figure 4.3.2.1.
The analog inputs are designed as differential amplifiers.
The digital inputs are optocoupled with the control circuit. The digital inputs have terminal 5
as reference point.
The analog outputs are not designed as differential amplifiers and have a common reference
point (terminal 19).
The analog outputs and the ±10V reference point have same potential (terminal 19).
The digital outputs are optocoupled with the control circuit. Terminals 12 to 13 and 26 to 29
have terminal 11 as a common reference point and terminal 10 as common supply.

4-34 • Chapter 4 Wiring Procedure Flex

FlexMax User’s Guide
 PowerTec

Figure 4.3.2.1: Potentials of the control section

To Expansion Cards Analog output 0

1 17
Analog input 0 (Filtered Actual
2 (Speed ref 1) speed)
0V

3
Analog input 1 Analog output 1
4 (Filtered Motor 18
current) 0V
19

6 S35 +10V
20
Digital input 0
(Enable drive)

7
Digital input 1 (Start stop) - 10V
21

8
Digital input 2 (Inverse) COM
32
Relay
NC 31
9
Digital input 3 (Jog +) NO
30
DO-Supply +24V
22 10
Digital input 4 (Jog -) Digital output 0
(Drive enabled)
12
23
Digital input 5 Digital output 1
(Speed reached)
13
24
Digital input 6
Digital output 2
26
25
Digital input 7 (Drive reset)
Digital output 3
27

5 COM DI Internal power

supply from Digital output 4
Power Card 28
15
Digital output 5
0 (+24 V) 29
16
COM DO
11
Fuse
S34 14

16

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-35
 FlexMax

4.3.3 XE Encoder Connector Assignments

XE XS
11
6 10
15
6
The connection with the drive is through a 15 pole high density sub-D connector
9

(VGA type female). Please note that it is mandatory to use a shielded cable with at
1 5 1 5

11 15

least 80 % coverage. The shield should be connected to ground on both sides of the
6 10
1 5

XER
connector, but not grounded at the motor end.
Please note that for resolver feedback it is mandatory to use a twisted pair cable with an
overall shield. Shields on each pair is recommended.

Table 4.3.3.1: XE Connector Assignments

I=Input
Assignment Function
O=Output
1 B– Incremental Encoder B- I
2 PTC Motor temperature sensor I
3 Z+ Zero channel Z (+) I
4 Z– Zero channel Z (–) I
5 A+ Incremental Encoder A (+) I
6 A– Incremental Encoder A (–) I
7 0VE Encoder Supply 0V reference O
5 1
8 B+ Incremental Encoder B(+) I
9 +5VE Encoder Supply O
10 6
10 SIN+ / H1 Sin / resolver input (+) / Hall 1 input I
15 11 11 SIN– / H2 Sin / resolver (–) / Hall 2 input I
12 COS+ / H3 Cos / resolver (+) / Hall 3 input I
Back View of VGA 13 COS– Cos / resolver (–) I
D-sub connector (solder side)
14 EXC+ Resolver excitation (+) O
15 EXC– Resolver excitation (–) O
txv0090

4.3.4 XER Encoder Connector Assignments

The connection with the drive is through a 15 pole high density sub-D connector (VGA type
female).

Table 4.3.4.1: XER Connector Assignments

I=Input
Assignment Function
O=Output
1 B– Digital incremental channel B (–) Input / Repetition I/O
2
3 Z+ Zero pulse (+) channel Input / Repetition I/O
4 Z– Zero pulse (–) channel Input / Repetition I/O
5 A+ Digital incremental channel A (+) Input / Repetition I/O
6 A– Digital incremental channel A (–) Input / Repetition I/O
7 0VR Encoder Supply 0V reference O
8 B+ Incremental channel B(+) Input / Repetition I/O
9 +5VR Encoder supply O
10 … 15
txv0100

4.3.5 Feedback /Drive Connections

The FlexMax drive can handle several feedback devices (see paragraph 3.4.2) selectable through the
setting of jumpers on the regulation board. The jumper setting will be as follows:
Table 4.3.5.1: Resolver/Encoder jumpers settings
Jumpers settings
Encoder
S11 S12 S13 S14 S15 S16 S17 S18 S21 S22 S23
DE / DEHS OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON
SE / SEHS OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON
SESC/SC A A A A A A A A OFF OFF OFF
HS OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON
RES B B B B B B B B OFF OFF OFF
txv0110

4-36 • Chapter 4 Wiring Procedure Flex

FlexMax User’s Guide
 PowerTec

The following tables specify the connections between FlexMax and the different feedback
devices installed on standard motors by PowerTec. For cabling, use twisted pair shielded
cable. All the shields must be connected together to connector body on drive side.

4.3.5.1 Resolver Connections (RES)

Motor FlexMax drive
Resolver PT standard
term strip Function 15 Pole XE
Wires Resolver Cable
(10 pos) connector
Red 1 Resolver Cos- black(grn) 13
Black 2 Resolver Cos+ green 12
Yellow 3 Resolver Sin+ blue 10
Blue 4 Resolver Sin- black(blu) 11
- 5 nc - -
Red/Wht 6 Resolver Excitation+ red 14
Blk/Wht 7 Resolver Excitation- black(red) 15
(Violet) 8 Motor Temperature Sensor black(wht) 7
(White) 9 Motor Temperature Sensor white 2
- 10 Cable shield shield to connector body
txv0240

4.3.5.2 Digital Encoder with Hall Effect Sensors Connections (DEHS)

17-pin motor FlexMax drive
PT standard
connector Function 15-pin XE
Encoder Cable
MS3102E20-29P connector
A Case GND shield to connector body
B n/c -
C Hall 1 + red/wht 10
D Hall 2 + black 11
E Hall 3 + red/blk 12
F n/c -
G Incremental Encoder A+ grn/wht 5
H Incremental Encoder A- green 6
J Incremental Encoder B+ blk/wht 8
K Incremental Encoder B- blue 1
L Zero Channel Z+ org/blk 3
M Zero Channel Z- blu/wht 4
N Hall 1 - - n/c
P Hall 2 - - n/c
R Hall 3 - - n/c
S Encoder supply +5VDC orange 9
T Encoder supply 0VDC reference red 7
Motor term strip
(1)
(10 pos)
8 Motor Temperature Sensor violet 7
9 Motor Temperature Sensor white 2
(1) Motor temperature sensor leads are not included in encoder cable. Cable
includes 24" pigtail leads from drive-end connector to attach sensors.

4.3.5.3 Original Powertec Hall Effect Encoder (DEHS)

Consult factory for special adapter

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-37
 FlexMax

4.3.5.4 Encoder /Resolver Specifications (XE connector)

Sinusoidal encoders
max. frequency _______________ 200 kHz ( select the appropriate number of pulses depending on required max. speed )
Number of pulses per revolution ___ min 1, max 65535
Channels ____________________ three-channel, differential. An encoder loss detection is possible via firmware setting.
Power supply _________________ + 5 V (Internal supply) *
Load capacity _________________ > 8.3 mA pp per channel

Digital encoders
max. frequency _______________ 250 kHz ( select the appropriate number of pulses depending on required max. speed )
Number of pulses per revolution ___ min 1, max 65535
Channels ____________________ three-channel, differential. An encoder loss detection is possible via firmware setting.
Power supply _________________ + 5 V (Internal supply) *
Load capacity _________________ > 4.5 mA / 6.8 ... 10 mA per channel
* Via keypad (ENCODER PARAMETER menu) it is possible to select 4 different values of internal encoder supply voltage to compensate
the voltage reduction due to encoder cable length and load current. Selections available (via MAIN ENCODER SUPPLY or AUX
ENCODER SUPPLY parameters) are: 0=5.2V, 1=5.6V, 2=6.1V, 3=6.5V

Absolute Encoder
Absolute trace frequency _________ 500 kHz (on the EXP-ASE-XVy expansion card)
Incremental trace max. frequency __ 200 kHz
Max encoder resolution __________ 29 bit (17 bit/rev * 12 bit/rev)
Interface electrical level __________ differential RS-485
Interface signals _______________ clock and data (bidirectional)
Clock synchronous period _______ 2µs
Encoder supply _______________ +5V(TTL) /+15V(HTL) +5V / +15V...+24V with external supply
max absorption of encoder supply __ 250 mA max

Resolver (2-pole)
Resolver excitation _____________ sinusoidal
Resolver excitation voltage _______ 6V rms
Resolver excitation current _______ 50mA rms max
Resolver excitation frequency _____ 8kHz
Resolver input _________________ differential
Resolver input impedence ________ 4kΩ
Resolver transformation ratio ______ 1:1 - 1:2 - 1:3
Suggested cable _______________ Belden 9504, 4 twisted pair, for runs of less than 100'. For longer runs, recommend
special, low capacitance cable: PT p/n 3566-300002-XX. Contact factory.

4.3.5.5 Encoder Simulation / Repetition, Auxiliary Encoder Input (XER Connector)

Digital encoder input
max. frequency _______________ 400 kHz ( select the appropriate number of pulses depending on required max. speed )
Number of pulses per revolution ___ min 1, max 65535
Channels ____________________ three-channel, differential. Encoder loss detection is not possible.
Power supply _________________ + 5 V (Internal supply) *
Load capacity _________________ > 4.5 mA / 6.8 ... 10 mA per channel

* Via keypad (ENCODER PARAMETER menu) it is possible to select 4 different values of internal encoder supply voltage to compensate
the voltage reduction due to encoder cable length and load current. Selections available (via MAIN ENCODER SUPPLY or AUX
ENCODER SUPPLY parameters) are: 0=5.2V, 1=5.6V, 2=6.1V, 3=6.5V

4-38 • Chapter 4 Wiring Procedure Flex

FlexMax User’s Guide
 PowerTec

On the regulation board there is available an incremental encoder output, with TTL Line
Driver levels, that can be used as simulation of the servomotor feedback device. This
function is performed by the microprocessor and it is possible to merely repeat the signals of
the motor encoder, or to simulate an encoder output with a programmable number of pulses/
rev. The encoder output signals are available on the XER connector (see table 4.3.4.1).

Digital encoder simulation (XER Port)

Interface _____________________ opto-isolated
Simulation ____________________ differential digital incremental
Standard outputs _______________ A+, A-, B+, B-,I+, I-
Outputs levels _________________ Standard TTL
Voltage limits on the TTL high-state outputs (on the pins)
(Uhigh TTL) ___________________ > 2.5V
Voltage limits on the TTL low-state outputs (on the pins)
(Ulow TTL) ___________________ < 0,5V
TTL load capacity ______________ 20mA max. each
Parallel connection of standard FlexMax inputs
with a TTL outputs ______________ 3 inputs
Max. frequency _______________ 400kHz ( select the appropriate number of pulses depending on required max. speed )

Max absorption of the encoder simulation

power supply _________________ 150mA@5V
Mechanics ___________________ Male high density 15-pole D-sub connector (type VGA) for standard inputs and extractable
terminals to be connected to a 0,14..1,5 mm2 power supply section

4.3.5.6 Encoder Cable Length

The following figures show the maximum encoder frequency as function of the encoder
cable length. For these figures we have considered cables with distributed capacitance less
than 90pF/m.
CABLE LENGHT (Sinusoidal encoder)

200

150
Lenght [mt]

100

50

0
100 120 140 160 180 200
Encoder frequency [KHz]

CABLE LENGHT (Digital encoders)

200
180
160
140
Lenght [mt]

120
XER Port
100
XE Port
80
60
40
20
0
100 200 300 400 500 600
Encoder frequency [KHz]

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-39
 FlexMax

The following figure shows the voltage drop as function of the cable length and of the
current absorbtion:
2
VOLTAGE DROP (Cable Cross-section 0.2 mm )

200

150 20mA

Lenght [mt]
50mA
100
100mA
50 150mA

0
0 1 2 3 4 5
Voltage drop [V]

4.3.5.7 Checking Encoder / Drive Connections

It is strongly recommended to follow the following instructions (parameters to be checked
are only those for the feedback device used, see next table):
- manually rotate the motor shaft clockwise
- check “.._POSITION” parameters values increasing up to “360” and then back to “0”
- check “.._REVOLUTIONS” parameters values increasing on each turn.

XE conn. XER conn.

SC (SinCos) HS (Hall+Dig) RES (resolver) DE (Dig.Enc.)
menu: 300-Service / 351-AD encoder
SYS_AD_ POS (IPA 19002) X X
SYS_AD_REV (IPA 19003) X X
menu: 300-Service / 352-AN encoder
SYS_AN POS (IPA 19017) X X
SYS_AN_REV (IPA 19018) X X
menu: 300-Service / 353-DI encoder
SYS DI POS (IPA 19011) X
SYS DI REV (IPA 19012) X
menu: 300-Service / 354-HA encoder
SYS_HA_POS (IPA 19022) X
SYS_HA_REV (IPA 19026) X
txv0255

4.3.6 CANopen Connection

The FlexMax brushless drive can be connected in a CANopen network, the pins are:
Pin / Signal Description
V- External supply reference
L CAN_L bus line (dominant low)
L V- SH CAN_H shield
H SH
V+ H CAN_H bus line (dominant high)
CAN external positive supply +24V (*), dedicated for supply of
V+
transceiver and optocouplers
txv0245

(*) The supply size has to be according to the used bus specification (CANopen or DeviceNet). Card absorption is 30 mA@24V.

The Bus connection is provided via a shielded loop to be placed far from the power cables,
with a minimum distance of 20 cm. The cable shielding must be ground connected on both
ends.
If the cable shieldings are ground connected on different points of the system, use equipotential
connection cables to reduce the current flow between the drives and the CAN bus master.

NOTE ON TERMINATING RESISTOR:

THE FIRST AND LAST NETWORK COMPONENTS MUST HAVE A 120 OHM RESISTANCE BETWEEN PINS C2 AND C4.

4-40 • Chapter 4 Wiring Procedure Flex

FlexMax User’s Guide
 PowerTec

4.3.7 Fast Link Connections

A fast serial connection that is optimized to exchange I/O and regulation parameters between
different drives is available on the XFL connectors. This synchronous serial interface is
named FAST LINK, and can have two different connection architectures :

- Multi Point : one drive is configured as master (transmitting) and the others as slaves
(receiving).
- Peer-to-Peer: This software is not yet released, but is supported by the existing hardware.

Figure 4.3.7.1: XFL-OUT Connector (FAST LINK Output)

Pin Function Description
1 -
2 -
3 DT_OUT+ Data output Fast-Link (+)
4 DT_OUT- Data output Fast-Link (-)
5 CLK_OUT+ Clock ouput Fast-Link (+)
6 CLK_OUT- Clock ouput Fast-Link (-)
7 -
8 -
txv0200

Figure 4.3.7.2: XFL-IN Connector (FAST LINK Input)

Pin Function Description
1 -
2 -
3 DT_IN+ Data input Fast-Link (+)
4 DT_IN- Data input Fast-Link (-)
5 CLK_IN+ Clock input Fast-Link (+)
6 CLK_IN- Clock input Fast-Link (-)
7 -
8 -
txv0210

4.3.7.1 Fast Link Data

Max number of drops ___________ 8 (1 Master + 7 Slaves)
Max length ___________________ 1.5 meters (with conductor shielded cables), 40 meters (with plastic optical fiber)
Baud rate ____________________ 3 Mbit
Max Data Exchanged ___________ 15 words + 1 CRC / Info every 250 µS in synchronous way from master to slave
PWM _______________________ Drive Synchronization
8 conductors shielded cable (*) ____ L= 65 cm, L=115 cm
Plastic optical fiber cable _________ L=5 m, L=10 m, L=20 m, L=30 m
Optical fiber interface kit __________ Transmitter and receiver

(*) Ferrite on Slave side

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-41
 FlexMax

4.4 Serial Interface

4.4.1 Serial Interface Description
The RS 485 serial interface enables data transfer via a loop made of two symmetrical,
twisted conductors with a common shield. The maximum transmission distance is 1200 m
(3936 feet) with a transfer rate of up to 38,400 KBaud. The transmission is carried out via a
differential signal. RS 485 interfaces are bus-compatible in half-duplex mode, i.e. sending
and receiving take place in sequence. Up to 31 FlexMax devices (up to 128 address selectable)
can be networked together via the RS 485 interface. Address setting is carried out via the
SYS_SL3_ADDRESS parameter, IPA18031. Further information concerning the parameters
to be transferred, their type and value range is given in the table contained in section 10,
“Parameter lists”.

Figure 4.4.1.1: RS485 Serial Interface

XS

0VS
+5 V S
470 R

470 R
100 R

150 R
S5 S6
TxA/RxA
TxB/RxB
+5 V

PE
5 4 3 2 1
9 8 7 6

RS485

The RS 485 on the FlexMax series devices is located on the Regulation card in the form of
a 9-pole SUB-D socket connector (XS). The communication may be with or without galvanic
isolation. When using galvanic isolation an external power supply is necessary (+5V).
Communication without galvanic isolation is suggested only in case of temporary connec-
tions for setup with one drive connected.

The differential signal is transferred via PIN 3 (TxA/RxA) and PIN 7 (TxB/RxB). Bus
terminating resistors must be connected at the physical beginning and end of an RS 485 bus
in order to prevent signal reflection. The bus terminating resistors on FlexMax drives are
connected via jumpers S5 and S6. This enables a direct point-to-point connection with a
PLC or PC.

NOTE! Ensure that only the first and last drop of an RS 485 bus has a bus terminating resistor (S5 and S6 mounted). In all other
cases (within the line) jumpers S5 and S6 must not be mounted.

A point to point, RS232 connection, without jumper setting, can be done using the optional
“PCI-485” adapter interface. With the PCI-485 adapter, pins 6 and 8 are used as an internal
+5V supply.

4-42 • Chapter 4 Wiring Procedure Flex

FlexMax User’s Guide
 PowerTec

For a multidrop connection (two or more drives), an external power supply is necessary
(pin 5: 0V and pin 9: +5V).

When connecting the serial interface ensure that:

- only shielded cables are used
- power cables and control cables for contactors/relays are routed separately

NOTE! See the manual “SLINK3 Communication protocol” for more detail.

4.4.2 RS 485 Serial Interface Connector Description

Table 4.4.2.1: Assignment of the plug XS connector for the RS 485 serial interface

Designation Function I/O Elec. Interface

PIN 1 Internal use – –
PIN 2 Internal use – –
PIN 3 RxA/TxA I/O RS485
PIN 4 Internal use – –
PIN 5 0V (Ground for 5 V) – Power supply
PIN 6 Internal use – –
PIN 7 RxB/TxB I/O RS 485
PIN 8 Internal use – –
PIN 9 +5 V – Power supply
ai4110

I = Input O = Output

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-43
 FlexMax

4.5 Standard Connection Diagram

4.5.1 FlexMax Connections
Figure 4.5.1.1: Typical connection

10 12 13 26 27 28 29 11
The circuit diagram is for the COM DO
standard configuration of the Dig. Out.5
drive as delivered.
K0

14
EMC installation and wiring tech- Dig. Out.4
+ 24V
niques are not shown. Dig. Out.3
For this see appropriate chap- 0 V24

16
ter. The connection of option card Dig. Out.2
is also shown separately. Dig. Out.1
The automatic restart of the drive

5
COM DI
after a failure alarm is not Dig. Out.0
included. Dig. Inp.3
DO supply

9
(Jog +)

output 1 output 0
Analog Analog

18
Dig. Inp.2
8 (Inverse)
FWD
Dig. Inp.1 0

17
K2
7

(Start) REV

21
K1M Digital Inp. 0 - 10 V
6

(Enable drive)

20 19
0 V 10 R1 (2 ... 5
+ 10 V kOhm)
22 23 24 25

Dig. inp.7

2
Analog input 1Analog input 0

Dig. inp.6
-

Dig. inp.5
1
+

Dig. Inp.4
4
-
3
+
7 8 9 10 11 12 13 14 15

EXC-
EXC+
COS-
30 31 32

Ok relay

COS+/H3
SIN-/H2
SIN+/H1
XE

+5VE
RS 485 +B
0VE
A-
5 6
Alarm

A+
Down
Up
Limit

Keypad
Drive Ok

Z-
1 2 3 4
Mode

M
Enter

Z+
L1 L3 PE PTC
L2 N B
Note!
U3/2V3 and 1V3 only 1V3
from size PX-100. 2V3
SMPS

For more details see U3

chapter 4.2.1.
D

C Thermistor
PE1

PE2
F1 K1M L1
W1/L3 W2/T3
5

V1/L2 V2/T2 M
3

E
U1/L1 U2/T1 3~
1

G1 M1

4-44 • Chapter 4 Wiring Procedure Flex

FlexMax User’s Guide
 PowerTec

4.5.2 Parallel Connection on the AC (Input) and DC (Intermediate Circuit) Side of Several
Drives
Features and Limits:
1 The drives used have to be all the same size.
2 AC line chokes (see chapter 4.7.1) have to be the same (provided by the same supplier).
3 The mains power supply has to be simultaneous for all inverters, i.e. a single switch /line contactor has to be
used.
4 Such connection is suitable for a maximum of 6 drives.
5 If necessary to dissipate braking energy; a single internal braking unit (with external resistor) has to be used;
or one (or several) external braking units (“BU32-..”) configured with the drive, or as a BU as master (all the
other connected BUs are configured as slaves).
6 Fast fuses (F12...F62) have to be fitted on the dc-link side ( C and D terminals) of each drive (see chapter
4.6.2).

Figure 4.5.2.1: Parallel Connection on the AC and DC Side of Several Drives

F11 L1
U
U2
V2 M1
V DRIVE 1 W2 3
C
W
D
F12

F21 L2
U2
U
V2 M2
V DRIVE 2 W2 3
C
W
D
BR
F22
L1

L2 Caution
(*) (*) Do not connect if external
L3 RBR
braking units are used
K1
F.. L..
U2
U
V2 M..
V DRIVE .. W2 3
C
W
D
F..

F61 L6
U
U2
V2 M6
V DRIVE 6 W2 3
C
W
D
F62

F7
7 8 9 10
BR D
RBR BU-32-...
CR (BUy-...) C
(MASTER)

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-45
 FlexMax

4.6 Circuit Protection

4.6.1 External Fuses for the Power Section
The drive must be fused on the AC Input side. Fuses, circuit breakers and slow protective
switches can be used. Superfast semiconductor fuses provide a greater degree of protection.
NOTE! If the terminals of the DC Link circuit (C +and D -) are connected with external devices,
semiconductor fuses must always be fitted on the AC input side. This, for example, is the
case with:
- connected external braking units (BU...)
- coupled DC Link circuits of several inverters
- connected external capacitors

Connections with three-phase inductance on AC input are not essential but will improve the
DC link capacitors lifetime and drive reliability in unusual power events.

Table 4.6.1.1: External Fuse Types for AC input side

F1 - Fuses type
Connections without three-phase reactor Connections with three-phase reactor
on AC input on AC input
Drive
type Life time Life time
Europe USA Europe USA
[h] * [h] *

PX-3 GRD2/10 or Z14GR10 A70P10 FWP10 GRD2/10 or Z14GR10 A70P10 FWP10

25000
PX-5 GRD2/10 or Z14GR10 A70P10 FWP10
GRD2/16 or Z14GR16 A70P20 FWP20
PX-7 10000 GRD2/16 or Z14GR16 A70P20 FWP20
PX-10 25000 GRD2/25 or Z14GR25 A70P25 FWP25 50000 GRD2/20 or Z14GR20 A70P20 FWP20
PX-15 10000 GRD3/35 or Z22GR40 A70P35 FWP35 GRD2/25 or Z14GR25 A70P25 FWP25
PX-20 25000 GRD3/50 or Z22GR40 A70P40 FWP40 GRD3/35 or Z22GR40 A70P35 FWP35
PX-30 10000 GRD3/50 or Z22GR50 A70P40 FWP50 GRD3/50 or Z22GR50 A70P40 FWP40
PX-40 GRD3/50 or Z22GR50 A70P50 FWP50
S00üf1/80/80A/660V or
PX-55 A70P80 FWP80
Z22gR80
S00üf1/80/100A/660V or
PX-70 A70P100 FWP100
M00üf01/100A/660V
PX-80 For these types an external reactor is S00üf1/80/160A/660V or
A70P175 FWP175
PX-100 10000 mandatory if the AC input impedence is 25000 M00üf01/160A/660V
equal or less than 1%
PX-125 S1üf1/110/250A/660V or
A70P300 FWP300
PX-160 M1üf1/250A/660V
PX-190
S2üf1/110/400A/660V or
PX-230 A70P400 FWP400
M2üf1/400A/660V
PX-300
txv0150

* DC link capacitors life time [h]

Fuse manufacturers:
Type GRD2... (E27), GRD3... (E33), M... (blade fuses),
Z14... 14 x 51 mm, Z22... 22 x 58 mm, S.... Jean Müller, Eltville
A70P... Gould Shawmut
FWP... Bussmann

NOTE! The technical data of the fuses, e.g. dimensions, weights, heat dissipation, auxiliary contactors,
are found in the manufacturers data sheets.

4-46 • Chapter 4 Wiring Procedure Flex

FlexMax User’s Guide
 PowerTec

4.6.2 External Fuses for the Power Section DC Input Side

Use the following fuses when an external bus supply is used.

Table 4.6.2.1: External fuses type for DC input side

Fuses type
Drive type
Europe USA
PX-3
Z14GR10 A70P10 FWP10A14F
PX-5
PX-7 Z14GR16
A70P20-1 FWP20A14F
PX-10 Z14GR20
PX-15 Z14GR32 A70P30-1 FWP30A14F
PX-20 Z14GR40 A70P40-4 FWP40B
PX-30 Z22GR63 A70P60-4 FWP60B
PX-40 S00üF1/80/80A/660V A70P80 FWP80
PX-55 S00üF1/80/100A/660V A70P100 FWP100
PX-70 S00üF1/80/125A/660V A70P150 FWP150
PX-80 S00üF1/80/160A/660V A70P175 FWP175
PX-100 S00üF1/80/200A/660V A70P200 FWP200
PX-125 S1üF1/110/250A/660V A70P250 FWP250
PX-160 S1üF1/110/315A/660V A70P350 FWP350
PX-190 S2üF1/110/400A/660V A70P400 FWP400
PX-230
S1üF1/110/500A/660V A70P500 FWP500
PX-300
txv0160

Fuse manufacturers:
Type Z14..., Z22, S00 ..., S1..., S2... Jean Müller, Eltville
A70P... Gould Shawmut
FWP... Bussmann

NOTE! The technical data of the fuses, e.g. dimensions, weights, heat dissipation, auxiliary contactors,
are found in the manufacturers data sheets.

4.6.3 Internal Fuses

Table 4.6.3.1: Internal fuses

Drive type Designation Protection of Fuse (source) Fitted on:

2A fast 5 x 20 mm (Bussmann: Power card PV33-4-
PX-40
SF523220 or Schurter: "D" and higher
to F1 +24V
FSF0034.1519 Power card PV33-5-
PX-300
or Littlefuse: 217002) "B" and higher
PX-3 to Regulation card
F1 +24V Resettable fuse
PX-300 R-XVy
2.5A 6.3x32
PX-125 Bottom cover
Fans (Bussmann: MDL 2.5, Gould
to F3 (power terminals
transformer Shawmut: GDL1-1/2, Siba: 70 059
PX-230 side)
76.2,5 , Schurter: 0034.5233)
txv0170

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-47
 FlexMax

4.7 Chokes / Filters

NOTE! A three-phase inductance should be connected on the AC Input side in order to limit the
input RMS current of FlexMax series drives. The inductance can be provided by an AC
Input choke or an AC Input transformer. While the drive will work without the inductance,
capacitor life will be shortened and general reliability will be less.

NOTE! For the use of output sinusoidal filters, please contact the factory.

4.7.1 AC Input Chokes

Table 4.7.1.1: 3-Phase AC Input Chokes
Three-phase choke type
Drive size
460 Vac 230 Vac
PX-3 KDRA8L KDRA54L
PX-5 KDRA9L KDRA53L
PX-7 KDRA1L KDRA25L
PX-10 KDRA3L KDRA26L
PX-15 KDRA4L KDRA28L
PX-20 KDRB2L KDRB22L
PX-30 KDRB2L KDRB23L
PX-40 KDRB1L KDRD25L
PX-55 KDRD1L KDRD24L
PX-70 KDRD2L KDRD26L
PX-80 KDRC1L KDRC22L
PX-100 KDRF2L KDRC24L
PX-125 KDRF3L KDRF24L
PX-160 KDRF3L KDRF26L
PX-190 KDRH3L KDRF26L
PX-230 KDRH2L KDRF24L
PX-300 KDRG3L ---
txv0180

For all the sizes an input choke is strongly recommended in order to:
- prolong the life time of the DC link capacitors and the reliability of the input rectifier.
- reduce the AC mains harmonic distortion
- reduce the problems due to a low impedance AC mains ( < 1%).

NOTE! The current rating of these inductors (reactors) is based on the nominal current of standard
motors, listed in table 2.3.2.1 in section 2.3.2, “AC Input/Output Connection”.

4.7.2 Output Chokes

FlexMax drives are best used with motors specially designed for use with drives with IGBT
output. The insulation systems used in those motors have a higher isolation rating to better
withstand PWM voltage. Motors purchased new from Powertec do not require any specific
filtering of the voltage waveform from the drive. For older motors (older than 1993 with
original winding), especially with long cable runs (typically over 30 m [98.5 feet]), an output
choke is recommended to maintain the voltage waveform within the specified limits. Sug-
gested choke ratings and part numbers are listed in table 4.7.2.1. When using the FlexMax
to replace an older drive, check to be sure the motor insulation system is capable of IGBT
operation.
The rated current of the filters should be approx. 20% above the rated current of the drive in
order to take into account additional losses due to PWM waveform.

4-48 • Chapter 4 Wiring Procedure Flex

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 PowerTec

Table 4.7.2.1: Recommended values for output chokes

Drive type Three-phase choke type

PX-3 … PX-7 LU3-003
PX-10 LU3-005
PX-15 … PX-20 LU3-011
PX-30 LU3-015
PX-40 LU3-022
PX-55 LU3-030
PX-70 LU3-037
PX-80 … PX-100 LU3-055
PX-125 … PX-160 LU3-090
PX-190 … PX-300 LU3-160
txv0190

NOTE! When the drive is operated at the rated current and at 50 Hz, the output chokes cause a
voltage drop of approx. 2% of the output voltage. Slightly less drop will occur at 60Hz.

4.7.3 Interference Suppression Filters

FlexMax drives must be equipped with an external EMI filter in order to reduce the
radiofrequency emissions on the mains line as required for operation in Europe. The filter
selection depends on the drive size and the installation environment.

Contact the factory for indications how to install the drive in an enclosure (connection of
filter and mains reactors, cable shield, ground, etc.) in order to make it EMC compliant
according the EMC Directive 89/336/EEC.

Table 4.7.3.1: Recommended EMI filters

EMI filters
Drive type AC mains voltage :
230 - 400V ±15% 480 ±10%
PX-3 …PX-7 EMI-FFP-480-9 EMI-FFP-480-9
PX-10 EMI-FFP-480-24 EMI-FFP-480-24
PX-15 EMI-FFP-480-24 EMI-FFP-480-24
PX-20 EMI-FFP-480-30 EMI-FFP-480-30
PX-30 EMI-FFP-480-40 EMI-FFP-480-40
PX-40 EMI 480-45 EMI 480-45
PX-55 EMI 480-70 EMI 480-55
PX-70 EMI 480-70 EMI 480-70
PX-80 EMI 480-100 EMI 480-100
PX-100 EMI 480-100 EMI 480-100
PX-125 EMI 480-150 EMI 480-150
PX-160 EMI 480-180 EMI 480-150
PX-190 EMI-520-280 EMI 480-180
PX-300 EMI-520-450 EMI-520-280
txv0195

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-49
 FlexMax

4.8 Braking Units

In regenerative operation, the motor feeds energy back to the DC link circuit via the drive.
This creates an increase in the intermediate circuit voltage. Braking units (BU) are therefore
used in order to prevent the DC voltage from rising to a value causing the drive to trip. When
used, these activate a braking resistor that is modulated across the capacitors of the
intermediate circuit. The feedback energy is converted to heat via the braking resistor (RBR),
thus providing very short deceleration times and restricted four-quadrant operation.

Figure 4.8.1: Operation with Braking Unit (Principle)

E
_ R BR

M
BU

FlexMax drives through size PX-100 have internal braking units. All FlexMax drives can be
equipped with an external braking unit (BU-32.xx...) connected to terminals C (+Bus) and
D (-Bus).

NOTE! When the internal braking unit is present, or when circuit terminals C and D are connected
to external devices, the AC Input must be protected with superfast semiconductor fuses!
Observe the mounting instruction concerned.

The braking resistors can be subject to unforeseen overloads due to possible

failures. The resistors have to be protected using thermal protection devices. Such
devices do not have to interrupt the circuit where the resistor is inserted but their
Warning auxiliary contact must interrupt the power supply of the drive power section. In
case the resistor foresees the presence of a protection contact, such contact has to
be used together with the one belonging to the thermal protection device.

4.8.1 Internal Braking Unit

The Internal Braking Unit is included as standard up to size PX-100. An Internal Braking
Resistor is included as standard up to size PX-30, but it is still possible to use an external
resistor. An external braking resistor is required on sizes PX-40 and up. For braking unit
thresholds, see table 2.3.2.1.

4.8.2 Internal and External Braking Resistors

The FlexMax drives, up to size PX-30, are equipped with an Internal Braking Resistor
according to the following table:
Drive Resistor PNBR RBR EBR
Type Type [W] [Ohm] [kJ]

PX-3 …PX-7 CBR-100R 100 100 11

PX-10 … PX-15 CBR-67R 150 67 11
PX-20 RFI1300-36R 200 36 16
PX-30 RFI1300-26R 200 26 16
txv0225

4-50 • Chapter 4 Wiring Procedure Flex

FlexMax User’s Guide
 PowerTec

For bigger sizes, the braking resistor is optional and has to be mounted externally. For
parameter settings refer to the section 10 Parameter, “200-Braking Resistor” menu.

The figure below shows the configuration for internal brake unit operation.

Figure 4.8.1.1: Connection with internal Braking Unit and external braking resistor

Braking
Unit

W1/L3

W2/T3
U1/L1

U2/T1
V1/L2

V2/T2
BR1

PE1 /
D

PE2/
C
Braking
F1 resistor

3Ph~

If the application requires the use of an External Braking Resistor, it is necessary to follow
the recommended external resistors to be used with drives internal braking units (see Table
4.8.2.2). Following are the Powertec standard external resistor assemblies for 10% stopping
duty:

Table 4.8.2.1: Lists and technical data of the external standard resistors

Drive Resistor PNBR RBR EBR

Type Type [kW] [Ohm] [kJ]

PX-40 RRM-12-24 2.5 24 125

PX-55 RRM-24-12 5 12 250
PX-70 RRM-24-12 5 12 250
PX-80 RRM-24-12 5 12 250
PX-100 RRM-36-08 7.5 8 375
txv0250

When using an external resistor, remove the connections of the internal braking
resistor from terminals BR1 and C and connect the two wires together using the
Warning proper fast-on.

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-51
 FlexMax

Parameters description:
P NBR Nominal power of the braking resistor
R BR Braking resistor value
E BR Max surge energy which can be dissipated by the resistor
P PBR Peak power applied to the braking resistor
T BRL Maximum braking time in condition of limit operating cycle
(braking power = PPBR with typical triangular profile)

Figure 4.8.2.2: Limit operating braking cycle with typical triangular power profile

n,P

PPBR

EBR

TBRL t
TCL

T CL Minimum cycle time in condition of limit operating cycle

(braking power = PPBR with typical triangular profile)

The BU overload alarm occurs if the duty cycle exceeds the maximum data allowed in
order to prevent possible damage to the resistor.

NOTE! The suggested match of resistor-model and drive-size, allows a braking stop at nominal
torque with duty cycle TBR / TC >= 20%

Where: TBR = Braking time

TC = Cycle time

4-52 • Chapter 4 Wiring Procedure Flex

FlexMax User’s Guide
 PowerTec

Figure 4.8.2.3: Braking cycle with TBR / TC = 20%

P,n

TBR t
TC

The resistors whose technical data are reported in the table 4.8.2.1 have been sized to
tolerate an overload equal to 10 times their nominal power for 5 seconds. In any event they
can also tolerate an overload whose energy dissipation is the same of the maximum power
level defined by:

Where: VBR = braking unit threshold

With reference to the figure 4.8.2.2, where the power profile is the typical triangular one,
the following example can be taken into consideration.

Resistor model: RRM-24-12

Nominal power PNBR = 5000 [W]
Maximum energy EBR = 10 x 5000[W] x 5[s] = 250[kJ]
Inverter mains supply = 460V
Voltage threshold: VBR =780V

PPBR = VBR2 / RBR = 7802 / 12 = 50.7 [kW]

TBRL = 2 * EBR / PPBR = 2 * 250 / 50.7 = 4.9[s]

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-53
 FlexMax

It is necessary to consider the following relation:

A) If TBR < EBR / PNBR verify:

1) PMB < 2 * EBR / TBR Where: PMB is the average power of the cycle
(see.fig. 4.8.2.2)
x
2)
The average power of the cycle must not be higher than the nominal power
of the resistor.

B) If TBR > EBR / PNBR , that is to say in case of very long braking time, it must
be limited to PMB < PNBR

If one of the above mentioned rules is not respected, it is necessary to increase the nominal
power of the resistor, respecting the limit of the internal braking unit as stated in the following
table.
Table 4.8.2.2: Technical data of the internal braking units
Drive Minimum
type IRMS I PK T RBR
[A] [A] [s] [ohm]
PX-3 …PX-7 4.1 7.8 19 100
PX-10 … PX-15 6.6 12 16 67
PX-20 12 22 17 36
PX-30 17 31 16 26
PX-40 18 52 42 15
PX-55 37 78 23 10
PX-70 29 78 37 10
PX-80 … PX-100 50 104 22 7.5
PX-125 … PX-300 External braking unit (optional)
txv0260

I RMS Nominal current of the braking unit

IPK Peak current deliverable for 60 seconds max.
T Minimum cycle time for a working at IPK for 10 seconds

Generally the following condition must be satisfied

IRMS 1 PPBR T BR
2 RBR TC

4.8.3 Control of the External Braking Power

The braking resistance average power is defined by the following formula:

P = 0.2 · Jtot · w2 · f

where: P = Dissipated power

J tot = Total inertia ( Kgm2 )
w = Max speed ( rad/sec )
f = Cycle frequency in Herz (number of cycles per second).
f = 1/TBR (sec)

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4.8.4 External Resistance Interaction with the System Parameters

When the external braking resistance is installed it is always necessary to carry out some
modifications in the parameters. See chapter 10, 200 Braking Resistor menu for further
details.

4.8.5 Choice of the Thermal Relay for Brake Resistor

Here is a procedure aimed at stating the coordination of a thermal relay for the protection of
the resistor bank in case of a sudden component failure (not detected), when the DC bus
power supply is continuously connected to the braking resistance.

It is important to remember that the drives are supplied with a I2t function for the resistor
bank protection; such a function is in a position to avoid any possible overload but it cannot
protect against component failure that might render impossible the logical control of the
braking resistor current.

As stated in the dimensioning procedure for the bus braking system, the resistor bank has,
with a given ambient condition, a possible instantaneous overload defined as:

Emax BR in [Joule] or as a product given by

Pmax_BR x Tmax_BR [Joule]

supplied by the producer of the resistor. Such parameters are able to define the resistor
overload possibility in case of continuous maximum power peaks.

According to Emax BR , and to the peak power value which the resistor bank is subject to:
PPBR = V2BR / RBR (VBR= 780 V, always ), the maximum time for the peak power application
is calculated as:

Tmax BR = Emax BR / PPBR

Furthermore, the peak current on the resistors is:

IPK = VBR / RBR

Therefore, the time/current curves of the thermal relays must have an overload ratio requiring
a thermal relay intervention time lower than Tmax BR.

Given that K is the overload ratio obtained from the curves, the current value to which the
thermal relay has to be set is:

Iterm = I PK
/k

Now it is necessary to check that the product VBR x Iterm is higher than the average power
which can be dissipated on the resistor bank. That value is stated during the dimensioning
procedure of the braking system.

In case the above-mentioned conditions are not satisfied, it is necessary to use a thermal
relay with a time/current feature able to obtain a K factor lower than the one stated above.
The thermal relays to be used are those coordinated for the protection of three-phase motors.
In this case it is advisable to use all the three contacts which have to be connected in series
to be able to break the substantial DC voltage involved.

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-55
 FlexMax

4.9 Buffering the Regulator Supply

When no external power is provided on terminals 15 and 16 of the regulation card, the power
supply of the control section is provided by a switched mode power supply unit (SMPS) from
the DC Link circuit. The drive is disabled as soon as the voltage of the DC Link circuit is
below the threshold value (UBuff). The regulator supply is buffered by the energy of the DC
Link circuit until the limit value (Umin) is reached. The buffer time is determined by the
capacitance of the DC Link capacitors. The minimum values are shown in the table below.
The buffer time (tBuff) can be extended (only on PX-20 and higher) by connecting external
capacitors in parallel (on terminal C (+ bus) and D(- bus)).

Buffer time tBuff Maximum Maximum

Internal (minimum value) with the permissible power required
capacitance internal capacitance at : external by switched
Drive type
AC Input AC Input capacitance mode power
Cstd voltage =400V voltage =460V supply
[µF] [s] [s] Cext [µF] PSMPS [W]
PX-3 220 0.165 0.25 0 65
PX-5 330 0.24 0.37 0 65
PX-7 330 0.24 0.37 0 65
PX-10 830 0.62 0.95 0 65
PX-15 830 0.62 0.95 0 65
PX-20 1500 1:12 1.72 1500 65
PX-30 1500 1:12 1.72 1500 65
PX-40 1800 1.54 2.3 4500 70
PX-55 2200 1.88 2.8 4500 70
PX-70 3300 2.83 4.2 4500 70
PX-80 4950 4.24 6.3 4500 70
PX-100 4950 4.24 6.3 4500 70
PX-125 6600 5.6 8.1 0 70
PX-160 6600 5.6 8.1 0 70
PX-190 9900 8.4 12.1 0 70
PX-230 14100 12.8 17.2 0 70
PX-300 14100 12.8 17.2 0 70
txv0270

SMPS = Switched Mode Power Supply

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Table 4.9.1: DC Link Buffer Time

Figure 4.9.1: Buffering the Regulator Supply by Means of Additional Intermediate Circuit Capacitors

1 = 1 + 1

W1/L3

W2/T3
U1/L1

U2/T1
V1/L2

V2/T2
BR1
Cx C1x C2x

PE1 /
D

PE2/
C
F1
CX 900 VDC or

3Ph~

NOTE! When connecting the intermediate circuit terminals C and D, the AC Input side must be
protected with superfast semiconductor fuses!

Formula for calculating the size of the external capacitors:

2 P SMPS t Buff 10 6

Cext = - C std
U2 Buff - U2min

Cext, Cstd [µF]

P SMPS [W] UBuff = 400 V at ULN = 400 V
tBuff [s] UBuff = 460 V at ULN = 460 V
UBuff, Umin [V] Umin = 250 V

Calculation example
A PX-40 drive is operated with an AC Input supply ULN = 400 V. A voltage failure buffer is
required for max. 1.5 s.

P SMPS 70 W tBuff 1.5 s

UBuff 400 V U min 250 V
C std 1800 µF

2 . 70 W . 1.5 s . 106 µF / F
C ext = - 1800mF = 2154 mF - 1800 mF = 354mF
(400 V) 2 - (250 V) 2

Flex
FlexMax User’s Guide Chapter 4 Wiring Procedure • 4-57
 FlexMax

4.10 Discharge Time of the DC-Link

Table 4.10.1: DC Link Discharge Time

Type I2N Time (seconds)

PX-3 3.5 90
PX-5 4.9
150
PX-7 6.5
PX-10 11
205
PX-15 15.4
PX-20 21.6 220
PX-30 28.7
PX-40 42
60
PX-55 58
PX-70 76 90
PX-80 90
PX-100 110
PX-125 142
PX-160 180 120
PX-190 210
PX-230 250
PX-300 310
txv0280

This is the minimum time that must be elapsed when a FlexMax drive is disconnected from
the AC Input before an operator may service parts inside the drive to avoid electric shock
hazard.

CONDITION The value considers the time to turn-off for a drive supplied at 480Vac +10%, without any
options, (the loads on the switching supply are the regulation card, the keypad and the 24Vdc
fans “if mounted”). The drive is disconnected from the line. This represents the worst case
condition.

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