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Application Note
Division of Nidec Motor Corporation
Commander SK
7078 Shady Oak Road AN0357
Eden Prairie, MN 55344-3505 USA
Rev.1.9, 5/22/17
T: +1 952 995-8000
www.controltechniques.com
This Application Note applies to the Commander SK Series
A method of Starting/Stopping a drive could involve Communications via a Fieldbus – this is not
covered in this App Note – please refer to AN0320 for a discussion on this topic.
Getting Started
This parameter sets the minimum fan or pump speed. For many systems, the fan or pump must
always be turning at some low speed.
A first step however, when starting up a Commander SK, would be to simply enter in basic setup data
which would include motor nameplate data – parameters 1-9. We would run the drive using the on-
board keypad Start/Stop keys and use the Up and Down arrows to change the speed. Once the drive
is verified able to run the motor with this basic method you can select the scenario you wish and set
the drive up for that case. Follow instructions on the next page.
In order for the drive to work at all, the drive will still need to be Enabled. Enable is accomplished with
a connection between B2 and B4. Enable is intended for any safety oriented devices such as
cover/guard switches, light curtains, safety gates etc. that would disable or prevent the drive from
going into Run if this connection is broken. This is discussed under System Safety in the rear of this
App Note.
As with any system design where mechanical motion is involved, personnel safety should be
of paramount importance. This application note is for basic guidance in providing various drive
functions and does not address these issues as it is the sole responsibility of the control panel
and machine designers to meet all applicable Machine Safety requirements.
Recommended
mushroom head
B2 pushbutton with twist / Drive
pull to reset
Enable
B4 Or Push In Latch Pull to Reset
Basic Run-Up
Enter in your motor nameplate information and in general the settings for parameter Pr 1 thru 9. Leave
Pr 5 as PAd (Keypad mode)
To enable the drive there will need to be a temporary connection between B2- B4
Once this connection is in place, the drive should now indicate rd (Ready)
Preliminary testing can be accomplished by depressing the Green button on the drive.
The drive should now indicate Fr (Frequency)
You should be able to depress and hold the Up arrow and the motor should increase in speed.
Run up to about 1/3 speed and depress Stop, then 2/3 and Stop then full speed.
The Red button should stop the drive. Should any problem be encountered you could always hit the
Enable button or “kill switch” to disable the drive.
• You must decide on the method that the Operator adjusts the required motor speed
• You must decide on the method that the Operator commands the drive to Run, Stop and other
command requirements.
How does the Operator adjust the Speed of the drive? (If that is necessary, in some cases the
speed is set as a constant and not changed by the Operator)
Analog
a) Speed Potentiometer – See also AN0274
b) 0 to +10 V Signal – See also AN0274
c) 4-20 mA signal (20, 20-0, 4-20, and 20-4 mA with signal loss detection)
Digital
a) Preset Speeds – via contact inputs
b) Using remote increase/decrease PB’s (Motor Operated Pot)
c) Drives own Kyepad using Up/Down arrows – See also AN0274
d) SM-Keypad Remote or SM-LCD Keypad Plus (Options) – AN0313
e) HMI (3rd Party Keypad/Display panels) – See AN0320
f) Industrial PC/PLC –via Modbus RTU, Profibus, DeciceNet, EtherNet – AN0320
*This application note will discuss the Analog methods a, b, c, and Digital methods a, b, c above.
Controlling a drive via a Speed Pot (potentiometer) is probably the most common method given to a
machine operator to allow adjustment of a motors speed/machine production rate. We recommend an
Industrial Grade 5kΩ, 2W with a linear taper-(2K is the minimum). For 0-10 V signals apply + to T2
and – to T1.
Commander SK
To Drive +10 V T3
To Drive Common T1
The Commander SK can follow a bi-polar analog voltage signal if one employs the SM-IO Lite module
(#7.10 will need to be re-assigned to 0).
In many control systems, 4-20 milliamp signals are quite often preferred for command reference and
feedback signals as there are sound reasons to do so.
The advantages of a 4-20 mA reference signal as compared to a 0-10 Vdc reference signal are:
1. It is not sensitive to supply voltage variations – relatively noise tolerant.
2. It I not sensitive to wiring resistance changes – tolerant to long wire runs.
3. It can be “looped” through multiple drives.
4. Signal Loss (wire break) is easily detected, i.e. signal < 3 mA is a signal loss.
Advantage 3 above permits the reference signal to be “daisy chained” or connected in series to two or
more drives off the same 4-20 mA source. In order to use this type signal successfully, one must
understand the characteristics of the drive’s 4-20 ma input and the configuration / type of 4-20 ma
transmitter circuitry. Consult AN0160 for details.
+ ie 4 mA =0
12 mA = 50%
20 mA = 100%
Drive Setup
Set Pr 5 = AI.Pr
Set Pr 16 based on
your mA mode
4-20 milliamp signals are often used as feedback from Pressure, Flow, Level and Temperature
transducers that are used in conjunction with the drives internal PID loop. The application note deals
only with 4-20 milliamp signals that are used a Speed Reference or command signals – not feedback.
Previous to this we have been dealing with Analog Speed commands. Next, we will discuss Digital
methods of controlling speed.
This is the easy case. You would merely set Pr 5 = PAd. The drive will Start
when the green button is depress and Stop when the red button is
depressed. The motor speed is controlled by the Up and Down arrows.
To achieve this, set Pr 71 = 8.23 and then Pr 61 = 6.33 and depress the Red Reset button. Terminal
B5 will command a Reverse direction when closed to terminal B2.
Sometimes customers desire Start/Stop control via the drives terminal strip based on either a 2 Wire or
3 Wire scenario (as previously discussed), but desire to control the speed using the Up and Down
Arrows. This is a scenario that is not exactly implemented but there are a couple compromise
solutions.
Solution 1
The Up and Down Arrows can be used to modify the drives speed but one must depress the M button
to display Pr 1 (which is Min Spd-Hz) then depress the M button again then use the Up and Down
arrows to adjust speed. Once done adjusting speed they could either depress M again 2 times to
revert back to the normal display or hold the M in for about 2 seconds or they could simply walk away.
The display will revert back to the normal display after 4 minutes of key inactivity. This speed setting is
automatically stored.
Solution 2
Use a pre-programmed solution within LS010.
Digital presets are handy for applications where one might need a slow, medium and high speed
where once these speed values are determined, don’t need adjusted daily by the machine Operator.
Pr 5 when set to “Pr” will allow up to 4 preset speeds to be assigned an commanded per the table
below.
If we only 3 presets (slow, medium and fast) as mentioned in the first sentence above, we could use 2
simple single pole single throw switches to command our 3 speeds as shown below. When both switch
are off, the drive would be set for Low speed. It will go Fast Speed whenever Fast is on regardless of
the Medium switch. If Medium is on and Fast is switched off, the speed will be Medium.
+24 Vdc
B2
Commander SK
Fast
T4
Medium
B7
Slow
Slow Speed (Hz) – Pr18
Med Speed (Hz) – Pr19
Fast Speed (Hz) – Pr20
Fast Speed (Hz) – Pr21
Fast
Medium
On occasion customers desire to use Increase and Decrease momentary pushbuttons to raise and
lower the motors speed. For this function, the Commander SK has a built-in MOP (simulation of a
Motor Operated Potentiometer). To set the drive for this function one would set Pr 5 to E.Pot.
B2 +24 Vdc
Increase B7
Commander SK
Decrease
T4
When Pr 05 is set to E.Pot, the following parameters are made available for adjustment:
• Pr 61: Motorized pot up/down rate (seconds to 100% speed)
• Pr 62: Motorized pot bipolar select (0 = unipolar, 1 = bipolar)
• Pr 63: Motorized pot mode:
0 = zero at power-up
1 = last value at power-up
2 = zero at power-up and only change when drive is running.
3 = last value at power-up and only change when drive is running.
It should be noted that Pr 71, 72 and 73 are also being used by this function but could be changed if
one is happy with the settings of 61-63.
**If it is desired that the MOP always start from 0 after a Drive Stop, consult the relevant Sypt-Lite
program: MOP start from Zero CTSL002.
Defintions
First we need to define some of the terms that will be used in this article so that there is no
misunderstanding of their meaning.
NO – Normally Open – a relay or pushbutton contact set that is normally open but closes upon a
condition.
Start
NC – Normally Closed – a relay or pushbutton contact set that is normally closed but opens upon a
condition.
PB – pushbutton. Stop
Start – typically a remote button that is a used to Start the drive. A Start button is typically a
Green momentary pushbutton. The remote Start button would have a normally open contact
set that would be wired to the drive terminal strip.
Stop – typically a remote button that is ued to Stop the drive. A stop button is typically a Red
momentary pushbutton. The remote Stop button would have a normally closed contact set
that would be wired to the drive terminal strip.
Jog – typically a remote button that is used to intermittently run the drive. A Jog button is typically a
black momentary pushbutton. The remote Jog button would have a normally open contact set that
would be wired to the drive terminal strip. Jog is used to cause slow incremental machine movements
by Operator intervention. The Jog speed is usually a low speed with crisp acceleration and
deceleration rates. Jogging can be unidirectional or bi-directional depending on the machine
requirements.
Run – typically a remote contact or switch that is used to Run the drive. A Run contact may come from
a SPST toggle switch (like a common light switch) which is considered by nature a maintained contact.
A Run contact may come from a PLC output or from a latching relay which is part of an existing relay
logic.
Run Run
Off Run
Enable – typically a remote button that is used to disable the drive and in many cases
keep the drive from running. A disable button is typically a Red mushroom head
pushbutton that may be momentary or maintained. The preference is a maintained
switch for Enable. This is a pushbutton switch when depressed locks in the pushed in or
OFF position until it is deliberately pulled out or twisted to allow the system to run. The
remote Enable button would have a normally closed contact set that would be wired to
the drive terminal strip.
Maintained – In our context this referes to a contact that is held on in order to keep a drive running.
Once the contact opens, the drive would go to stop mode.
Momentary – In our context this refers to a contact, typically originating from a Start pushbutton, that
when depressed for a moment causes the drive to go into Run. Internally the function will need to latch
so that when the Start button is released the drive will continue to run.
Latch – In our context, when a Start button is depressed, the drive with latch into Run and remain so
until un-latched with a depression of the Stop pushbutton.
Dry Contact – a contact that is free of connection to any other source other than the drive. A free
unused contact that is not used any where else in a system certainly not connected to a 115 Vac
circuit.
3 Wire Start/Stop Circuit – a Start/Stop circuit using a NO momentary Start PB and a NC momentary
Stop PB. Implies latching will need to be involved either in the relay logic or within the drive itself.
B2
In this case, the
PB’s should be
located close to the
drive – 20 ft of wire B4 Commander SK
or less and in a Stop
clean run away
from high power
wiring.
B5
Start
Note: 3 wires
coming to drive
2 Wire Run/Stop Circuit – a Run/Stop circuit using maintained Run/Stop Switch or normally open
contact from some other control element that provide a contact to the drive when requesting the drive
go into Run. When the drive is no longer required to run the motor, the Run contact is opened and the
drive goes into a Stop mode.
+24 Vdc
B2
Commander SK
Run
B5
It may be possible to extend the above wiring beyond 20ft if shielded wire were to be utilized.
If shielded wire is used, dress off the switch end of the shield neatly using heat shrink tubing
and connect the shield to terminal T1 on the Commander SK.
With definitions out of the way, we can start discussin Start/Stop scenarios.
Question number 1
How is it intended for the Operator to Start and Stop the Drive?
If the Start/Stop pushbuttons are on the front door of the drive enclosure then this should be fine. If the
pushbuttons are remote this could present problems.
If these contacts are far away, then what will be happening is, you will be taking the drives +24 V
supply out a distance from the drive to these contacts. If great care is not taken to keep these wires
segregated from wiring with higher electrical noise content (motor wires, power wires etc), they in
essence will become antenna leads inviting all kinds of nasty, noisy signals into the drive which can
cause erratic operation and potentially even damage drive inputs if a stray spurious signal of high
energy content be impressed on these long leads. To avoid such situations we would recommend
using 115 Vac for Remote Control Logic- See AN0346 for details.
It may be possible to extend the above wiring beyond 20ft if shielded wire were to be utilized.
If shielded wire is used, dress off the switch end of the shield neatly using heat shrink tubing
and connect the shield to terminal T1 on the Commander SK.
Does this switch control a relay and a contact from that relay goint to go to the drive?
This would imply a 2 Wire scenario
Do they control a latching relay circuit and a contact from that relay is going to go to the drive?
This would imply a 2 Wire scenario to the drive
If the answer to the questions above is Yes, to either of these questions, this implies a “Maintained
Run” input to the drive which is non-latched (as opposed to momentary – which would require latching)
– see 2 wire definition.
Run
Start
Stop Located remote Located in or near
on Operators Drive cabinet
Console
Run
The circuit above is a typical 3 Wire latching Start/Stop circuit that picks up the RUN relay and latches
in until the Stop button is depressed. This circuit may be implemented using 115 Vac components.
A dry contact from the Run relay would be used to command the drive to Run/Stop using a 2 wire
hook-up. In the circuit above, the Operator pushbuttons would be located in the Operators console or
remote pendant and the Run relay would be located in or near the Drive. In this manner, the RUN
contact will be a short run keeping electrical interference tendencies to a minimum.
3 – Wire Start/Stop
In the case where the Start/Stop buttons are local to the drive (generally less than 20ft from drive) and
there is no interposing relay logic, we would need to select an internal latching mode from Pr 11 per
the scenario we desire. Selections of 1,3 or 4 would be possibilities. As one can see, these are
basically all the same except for terminal B6 functionality. If you do not care about going Reverse or
having a Jog function, any of these 3 modes would suffice.
+24 Vdc
Push In Latch Pull to Reset
B2
B4 Commander SK
Stop
B5
Start
Note: 3 wires
coming to drive
It may be possible to extend the above wiring beyond 20ft if shielded wire were to be utilized. If shielded wire is
used, dress off the switch end of the shield neatly using heat shrink tubing and connect the shield to terminal T1
on the Commander SK.
B2 +24 Vdc
Push In Latch Pull to Reset
B4
Commander SK
Stop
Pr 11= 1
B5
Start Fwd
B6
*optional Start Rev
B2 +24 Vdc
Push In Latch Pull to Reset
B4
Commander SK
Stop
Pr 11= 3
B5
Start Determines run direction
*optional B6
Reverse
B2 +24 Vdc
Push In Latch Pull to Reset
Stop B4
Commander SK
*optional
Jog Jog Spd Pr15
B6
In the case where there are only 2 wires coming to the drive, either from a Run/Stop switch or froma
dry relay contact (see 2 Wire discussion), typically we want to select from the non-latching modes –
mode 0 and 2.
B2 +24 Vdc
Drive Enable
Commander SK
Run (Forward) B5
B5
Pr 11= 0
Run Reverse
*optional
B6
B2 +24 Vdc
Drive Enable
Commander SK
Run (Forward) B5
B5
Pr 11= 2
Reverse
*optional Determines run direction
B6
In the case where there are only 2 wires coming to the drive, perhaps from a PLC or remote dry relay
contact, the setup would be similar to the previous 2 Wire scenarios as shown below.
Drive Enable
B2 +24 Vdc
Push In Latch Pull to Reset
Commander SK
B4
Run (Forward) B5
B5
Pr 11= 2
Reverse
*optional Determines run direction
B6
Drive Enable
B2 +24 Vdc
Push In Latch Pull to Reset
Commander SK
B4
Run Forward B5
B5
Pr 11= 4
Note: This is a 2 Wire Scenario but Pr 11 = 4 is a latching scenario, but since B4 and B5 are
connected, the above scenario will still be valid as 2 Wire.
Drive Enable
Commander SK
B4
B5
Run (Forward)
Pr 11= 0
B5
Pr 71= 8.24
Jog Forward Pr 72= 8.25
B6 Pr 61= 6.31
Jog Reverse
Pr 62= 6.37
B7
Jog Spd Pr15
*If the above scenario is used, also set Pr 73 = 8.15 and ensure Pr 63 = Off.
When interfacing the Commander SK to external system logic, it sometimes become necessary to
change the function of relay contact available at terminal T5 and T6. See AN0359.
This application note (AN0359) will attempt to outline several common assignments in hopes to make
setup for your application a little easier to achieve.
Should you need to assign a function to the SM I/O Lite or SM-I/O Timer module, we recommend you
consult AN0371.
Typically, Emergency Stop methods DO NOT utilize or depend on the motor drive to stop the motor or
machine in Emergency situations. They usually employ external independent devices and/or methods
to bring the motor or machine to rest in expeditious and stable manner. Many levels of System Safety
mandate that power be removed from the motor entirely. You must check on the level of System
Safety and the meaning of E-Stop or Emergency Stop for your application.
These safeguards are the sole responsibility of the Installer. For these reasons, the Installer must
envision all, implement all and test or simulate all failure methods.The Installer is responsible for
his/her resulting implementation to insure safe and reliable operation of the installation.
In addition, the Installer should provide the End User of his Installed system with a System User’s
Manual and instruct the User/Operator on correct/safe operation. Instruction should include the
demonstration and purpose of safety features that you the Installer have included and the importance
of periodic testing to insure they do indeed operate as originally designed. The Installer should
instruct, inform and warn his End User customer against bypassing the safety permissives the
Installer has provided.
A fundamental basic system interface suggestion would be to always employ a method to supply a
“permissive” or System Enable to allow the drive system to work if all things on the machine are
alright. This interface would provide a method to keep the System disabled if certain key safety
permissives are not satisfied. The installer should instruct, inform and warn his End User customer
against bypassing the safety permissives the Installer has provided. The System Enable function
would also have the ability to disable the drive if it was in operation and some safety device were
tripped or if the Operator encountered a need to request an Emergency Stop for instance.
115 Vac
Machine Ok to Run
Emergency (Enable) Enable Machine
Stop SYSRDY
Keyswitch or similar
Motor Thermal Switch
Stays in when pressed to enable machine
Motor Blower Thermal SYSRDY
Pull to Reset or Air flow verification
(see Optional Items)
System Ready
All other safety interlocks such as but not limited to:
Drive
SYSRDY
From above, the Machine OK to Run, can be a composite of a wide range of safety interlocking
devices. Typically these devices provide a closed contact if the safety condition that they are
monitoring is ok or within limits. These may include but are not limited to:
Light Curtains – a light beam that when cut indicates a person has entered an area of safety concern.
Safety Ropes – a rope, that when tripped over, disturbed or moved, opens a switch.
Safety Gate/Guard Switch – a switch placed on a safety gate or guard that indicates a person has
removed a guard, cover or opened a gate and has entered an area of safety concern.
Over Travel Limit Switches – a switch placed at the ends of a machine that indicate the machine has
traveled erroneously beyond normal limits and must be shutdown or stopped quickly.
Kill Switches – a switch provided for the Operators, Maintenance or any other person who is near a
machine to shut it down. Typically these are placed throughout the machine for ease of access. Some
may be automatic in nature.
Over Speed Limit Switches – a switch that indicates the machine has exceeded a safe design speed
limit erroneously and deemed “out of control” and must be shutdown. Sometimes these are in the form
of a centrifugal switches mounted on the end shaft of a motor or piece of machine.
E-Stop Pushbuttons – (Emergency Stop) typically a large Red mushroom head button that opens a
Normally closed contact which would cause a system to shutdown. They are commonly placed
through the machine for ease of access. Typically, this E-Stop function, activates some form of rapid
shutdown mechanisms that will cause the machine to halt in a short period of time. These shutdown
mechanisms may include Friction Brakes, DB resistors on DC Drives or other combinations that would
bring the mechanical system to a Stop and place it in a more stable safe condition.
A safer E-Stop pushbutton type are those that when pushed in – stay in – and require to be pulled out
to reset them. Some E-Stop buttons have a key switch such that when pushed will remain pushed until
the holder of the key uses it to unlock and release this pushbutton.
This application note does intend to imply that these methods satisfy the industry
standard definition of EMERGENCY STOP. Please consult OSHA or other machine
safety standards concerning this topic and the required criteria for your application.