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One Motion Tuning Example / Best Practices

1. Overview

One Motion Products are designed for tough washdown sanitary environments (IP69K-rated), like food processing plants handling meat, cheese, or baked goods. Mag-Drives are built for reliability, require zero maintenance under normal conditions, and come with a 3-year warranty. They’re rated to last longer than all other solutions on the market.

This guide helps your maintenance team manage current levels during setup and troubleshooting to keep the Mag-Drives running efficiently.

Example Product:

This is a relative guide based on example part
(OD69-60-135-610-11193).

Each One Motion product has its own technical data specs.

Contact Technical Support for your PN technical data information.

We’ll use an example Mag-Drive with these ratings (found on its One Motion product data sheet example):

Example Current Values

• Continuous Current: 1.19 A
• Maximum Current: 3.57 A

2. What Are Current Limits?

Current limits tell you how much electrical current your Mag-Drive can handle safely. Going over these limits can overheat the Mag-Drive, causing damage or early failure. Here’s what they mean:

Continuous Current

This is the normal operating current for steady, continuous use. For our example Mag-Drive, it’s 1.19 A (check your product data sheet for your Mag-Drive’s value).

Maximum Current

This is the highest current the Mag-Drive can handle during short bursts, like startup or sudden heavy loads. For our example Mag-Drive, it’s 3.57 A (again, check your product data sheet).

3. Best Practices for Use (PowerFlex 525 as Example)

In a washdown environment, Mag-Drives face wet conditions, high-pressure cleaning, and potential load spikes from slippery surfaces or product surges. Follow these best practices to keep your One Motion Mag-Drive safe and running well:

4. How to Set Up Your PowerFlex 525 Drive

The Allen-Bradley PowerFlex 525 drive helps control and protect your Mag-Drive. Use Connected Components Workbench (CCW) software to set it up with the following settings, updated to align with your Mag-Drive’s needs in a washdown environment:

Step 1: Enter Mag-Drive Data

Use the values from your One Motion product data sheet to set these parameters:

Parameter	Setting	What It Does
P033	60 Hz	Sets the Mag-Drive’s frequency
P034	1.19 A (use your data sheet value)	Sets the continuous current
P036	257 RPM	Sets the Mag-Drive’s speed
P484/485	3.22 A	Sets a safe overcurrent limit

Step 2: Set Up Safety Protections

These settings stop the Mag-Drive from running too hot or overloading:

Parameter	Setting	What It Does
A484	4.00 A	Set drive fault limit (absolute limit)
A486	2.38 A (1.19 × 2.0)	First overcurrent warning level
A487	10 sec	Waits 10 sec before stopping if overcurrent
A488	3.57 A (use your max current)	Final overcurrent limit
A489	5 sec	Stops if max current lasts over 5 sec

Step 3: Adjust Start and Stop Settings

These settings help avoid big current spikes when starting or stopping:

Parameter	Setting	What It Does
P041	10 sec	Mag-Drive speed to target Hz (application specific)
P042	10 sec	Mag-Drive speed to 0 Hz (application specific)

5. Troubleshooting in a Washdown Environment

Here’s how to handle common issues in a washdown sanitary environment, like after cleaning or during heavy loads, using the updated settings:

Scenario A: Normal Operation (Cheese Block Conveyor)

Situation: Conveyor moving cheese blocks (2 kg each) for packaging, running 8 hours a day.

Goal: Keep current at 1.0–1.1 A.

Steps:

• Check B003 on the drive to see live current (should be 1.0–1.1 A).
• If current goes over 1.19 A (e.g., from cheese residue buildup), clean the conveyor to reduce friction.
• Drive will stop if current stays above 2.38 A for 10 sec (A486/A487 settings).

Scenario B: Restart After Washdown (Wet Trays)

Situation: Conveyor restarts after a high-pressure washdown, moving wet trays of chicken.

Goal: Avoid max current (3.57 A) for more than 60 sec in a 5-min cycle.

Steps:

• Soft start (P041 at 10 sec) keeps startup current around 2.5 A.
• If current hits 3.57 A (e.g., trays stick due to suction), drive stops after 5 sec (A489 setting).
• After startup, ensure current settles to 1.0–1.1 A; dry trays if needed to reduce sticking.

Scenario C: Heavy Load Surge (Meat Packages)

Situation: Sudden surge of heavy meat packages (3 kg each) on the conveyor.

Goal: Limit max current (3.57 A) to under 120 sec in a 10-min cycle.

Steps:

• Drive stops if current hits 3.57 A for over 5 sec (A489 setting).
• If the conveyor slips, increase A533 (suggest 1 Hz increment) to improve grip.
• If speed stutters, increase A581 (suggest +2) to smooth it out.
• Spread out the packages to lower the current back to 1.0–1.1 A.

6. Quick Reference Summary

7. Request PN Technical Data:

Contact Technical Support for your specific part number's technical data information.

PowerFlex 525 Parameter Reference for One Motion PM Motors

This table provides a complete breakdown of essential parameters used to configure, monitor, and protect One Motion permanent magnet motors with the PowerFlex 525 VFD.