Programming the Motor Controller

The Synphase system is designed to control motor speed by sending a precise (12 bit) 0-10 Volt DC signal to the motor controller’s speed input. The 10-volt span represents a 0-2500 RPM range. This signal from the Synphase card is updated approximately 40 times per second. Each of these 3 features typically requires parameter value changes when installing a new motor controller.

1. The controller’s factory default settings typically reference a front panel input for speed control. The parameter setting(s) must be changed to reference the 0-10 Volt DC input.

2. The controller will typically run the attached motor between 0 and 1800 RPM. For a variable frequency inverter, this corresponds to 0-60 Hz output. Adjust the parameter setting(s) to change the range to 0-90 Hz.

Note: Failure to do this will exchange some dynamic range for resolution. If the production requirements do not require operating above 1700 RPM, the only problem will be that the diagnostic screen will calculate and display the motor slippage as approximately 30%.

3. Most controllers’ factory defaults for full-scale acceleration and deceleration times are preset to 5 seconds. This may cause unstable oscillations between full speed and stopped. Adjust these parameter setting(s) to 2 seconds or less. TCD Systems usually uses 0.5 seconds.

Starting and stopping the motor is the responsibility of the motor controller and its associated wiring. TCD Systems recommends a standard 3-wire connection to momentary start and stop switches remotely located near the motor. Synphase has absolutely no control of the motor start/stop function.

4. Most controllers are factory default set to use the front panel membrane switches for starting and stopping the motor. Adjust the parameter settings of the software to latch the start command and prevent automatic restarts after power failure recovery. Wire the switches using local codes and the controller manufacturer’s wiring diagrams. Make sure to change the controller’s parameter settings.


Step-by Step Instruction for a
Mitusbishi FR-S500 Series Inverter

The Mitsubishi FR-S500 series inverter is used when TCD Systems provides the inverters for the system. The following list is provided as a convenience when using these inverters. If you are using a different model/brand inverter, read the manual supplied by the inverter manufacturer and adjust the corresponding settings.

How to Adjust Parameter Settings:

Refer to pages 16 – 30 of the basic instruction manual provided with the drive for examples on how to change the settings. Remember, the inverter must be stopped and the front panel must be active (PU indicator LED active).

  1. Press MODE to enter the parameter list.
  2. Use the dial to display the parameter number you wish to change.
  3. Press SET to see the present value stored for that parameter.
  4. Use the dial to make any adjustments.
  5. Press SET again to save the new value.
  6. Exit the list by pressing the MODE button twice.
Setting to be Changed:
Maximum frequency is factory set at 60 Hz. Change this to 90 Hz for both DIN standard and NEMA standard motors. This will allow the signal from the Synphase control card to run a standard 4 pole motor at 2500 RPM. Also see P_38.
Minimum frequency is factory set at 0 Hz. Change this to 1-5 Hz to force the motor to rotate at least 30 RPM. This is necessary to insure proper operation of the tachometer but is still lower than any production set point.
Base frequency is factory set at 60 Hz for NEMA type motors. If you are using DIN type motors (50 Hz nameplate rating) change this to 50 Hz. Also refer to P-19.
Acceleration time is factory set at 5 seconds. Change it to ½ (0.5) seconds. Check this setting, as too high a setting will cause unstable control loop gain. (The motor will oscillate between minimum and maximum RPM.)
Deceleration time is factory set at 5 seconds. Change it to ½ (0.5) seconds. Check this setting, as too high a setting will cause unstable control loop gain. (The motor will oscillate between minimum and maximum RPM.)
Electronic thermal O/L relay is set to the rated output current of the inverter. If the motor is significantly smaller than the inverter, see details on page 78 of the detailed instruction manual for precautions and possible requirement of external thermal overload protection. (Page 78 of the detailed instruction manual may be found on page 87 of 257 in the Adobe PDF version on this CD-ROM.) Also review information about the related parameter P_71 located on page 105 of the detailed manual (found on 114 of 257 in PDF format).
Extended display (all functions) is default set to 0 which prohibits viewing or changing the following parameter. Change it to 1.
Rotation direction is set at clockwise. Normally you do not have to concern yourself with this. If, after wiring a motor, it runs in the wrong direction, you can either reverse 2 wires or change this setting to correct the direction.
Base frequency voltage is factory set at the mains voltage. If you are using a motor with a different requirement on its nameplate, enter that voltage here. Also refer to P_3.
Maximum frequency at 10 volt reference input is factory set to 60 Hz. Change it to 90 Hz. Also see P_1.
Enabling the Self-Holding Start/Stop
RL terminal function is factory set at 0 for multiple low speed operation command. Change it to 5 for the STOP button connection of an external 3-wire configuration (start self-holding). The START button should be connected to either terminal STR or terminal STF and the common to terminal SD.
Operation mode selection is factory set at 0. See page 33 of the basic manual or page 113 of the detailed manual (pg 122 of 257 in PDF format on this CD-ROM) for other options.
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