PowerFlex DC Drive Setup Instructions
A four quadrant PowerFlex DC motor drive, produced by Allen-Bradley, is available in the A185
lab. This device is used during many lab experiments involving machines and power electronics.
Each student must know how to properly connect the DC drive to the DC motors available at the
A185 lab workbenches, and how to configure the DC drives control parameters to a control the
DC motors.
DC Drive and DC Motor Wiring
Figure 1 is a wiring diagram illustrating the connection of the PowerFlex DC drive to one of the
DC motors available at the workbenches in A185.
Armature
Field
120 V
Power In
Encoder In
DC Motor Drive
208 V / 120 V
4-wire
source
A1
A2
S1
F1
S2
MOTOR
A2
F2
Encoder
DC Motor
S2
S1
DRIVE
ARMATURE
(-)
Steering Diode Box
120 V
single-phase
source
Figure 1: wiring diagram for DC motor drive and DC motor
Note that the DC drive requires power from two sources, namely:
- a 120 V single-phase power source, and
- a 208 V / 120 V four-wire three-phase source.
A steering diode box is also required in this connection. The steering diodes ensure that additive
magnetic field compounding occurs in the motor regardless of its direction of rotation.
!!IMPORTANT!!
All connections illustrated in figure 1 must be made with wires terminated with spaded
connectors.
Control Setup for DC Motor Drive
Basic Control Configuration:
During your work in the A185 lab, it will be necessary for you to modify the basic operating mode
of the DC drive.
Specifically, some lab experiments will require that the DC drive be operating in speed
regulation mode, while others will require that the drive be operating in torque regulation
mode.
When regulating for speed, the DC drive causes the motor to turn at a constant, user-specified
rotational speed.
When regulating for torque, the DC drive controls the torque produced by the motor. Care must
be taken when operating the drive in torque regulation mode. If the motor is made to produce
more torque than the sum of all torques opposing its rotation, the motor can accelerate out of
control. To protect against this, safe speed limits must also be specified using appropriate DC
drive control parameters.
To change the operating mode of the DC drive, first activate the drives control menu by pressing
the Esc key on the keypad located on the front of the drive. Then, select the following menu
options:
Parameter Dynamic Control Control Config Spd Trq Mode Sel
Press the enter key to change the parameter, and enter the password if requested.
For the speed regulation mode, set the parameter to Speed Reg.
For the torque regulation mode, set the parameter to Torque Reg.
Control Setup for DC Motor Drive (Continued)
Configuration of Current Limits:
The DC drive also has a current limiting capability. Therefore, it can protect the DC motor from
overcurrent damage. Also, the DC drives current limits can be used to control the motors
operation.
Three different current limits can be specified using the DC drives control parameters, namely:
- the symmetrical current limit,
- the positive current limit, and
- the negative current limit.
The symmetrical current limit parameter is used to specify both the positive current limit and the
negative current limit at the same time. If a change is made to the symmetrical current limit
parameter, both the positive current limit and the negative current limit are changed to this
value. However, if the positive current limit or the negative current limit is changed individually,
there is no change to the value of the symmetrical current limit parameter.
A reasonable value for this parameter is 60%, which specifies that the current flowing to the
motor armature will be no greater than 60% of the rated armature current of the motor.
To access the symmetrical current limit parameter, first access the DC drives control menu by
pressing the Esc key on the keypad located on the front of the drive. Then, select the following
menu options:
Parameter Motor Control Torq Attributes Current Limit
Press the enter key to change the parameter, and enter the password if requested.
Enter the desired value for the parameter.
Control Setup for DC Motor Drive (Continued)
Configuration of Current Limits (Continued):
The positive current limit is the maximum value of current that can flow in the positive direction
from the DC drive. That is, it is the maximum current that can flow out of the drives positive
armature terminal. This current limit has no effect on the current that flows out of the drives
negative armature terminal.
A reasonable value for this parameter is 60%, which specifies that the positive current flowing to
the motor will be no greater than 60% of the rated armature current of the motor.
If this current limit is set to 0%, it will be impossible for the motor to produce torque in the
forward direction.
To access the positive current limit parameter, first access the DC drives control menu by
pressing the Esc key on the keypad located on the front of the drive. Then, select the following
menu options:
Parameter Motor Control Torq Attributes Current Lim Pos
Press the enter key to change the parameter, and enter the password if requested.
Enter the desired value for the parameter.
Control Setup for DC Motor Drive (Continued)
Configuration of Current Limits (Continued):
The negative current limit is the maximum value of current that can flow in the negative direction
from the DC drive. That is, it is the maximum current that can flow out of the drives negative
armature terminal. This current limit has no effect on the current that flows out of the drives
positive armature terminal.
A reasonable value for this parameter is 60%, which specifies that the negative current flowing
to the motor will be no greater than 60% of the rated armature current of the motor.
If this current limit is set to 0%, it will be impossible for the motor to produce torque in the reverse
direction.
To access the negative current limit parameter, first access the DC drives control menu by
pressing the Esc key on the keypad located on the front of the drive. Then, select the following
menu options:
Parameter Motor Control Torq Attributes Current Lim Neg
Press the enter key to change the parameter, and enter the password if requested.
Enter the desired value for the parameter.
