Reference Manual PowerFlex 70/700 Adjustable Frequency AC Drives PowerFlex 70 Firmware Versions – Standard Control 2.001 and Below, Enhanced Control 2.xxx and Below PowerFlex 700 Firmware Versions – Standard Control 3.001 and Below, Vector Control 3.
Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Summary of Changes The information below summarizes the changes to the PowerFlex 70/700 Reference Manual, publication PFLEX-RM001 since the last release.
Summary of Changes Notes: 4 Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Table of Contents Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Summary of Changes New and Updated Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Chapter 1 Preface Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Flying Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Grounding, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 HIM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Start Inhibits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start Permissives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stop Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Notes: 8 Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Chapter 1 Preface The purpose of this manual is to provide detailed drive information including operation, parameter descriptions and programming. Manual Conventions To help differentiate parameter names and LCD display text from other text, the following conventions will be used: • Parameter Names will appear in [brackets]. For example: [DC Bus Voltage]. • Display Text will appear in “quotes.” For example: “Enabled.
Preface Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource Description PowerFlex 700 Standard Control User Manual, publication 20B-UM001 Provides detailed information on: • Parameters and programming • Faults, alarms, and troubleshooting PowerFlex 70 AC Drive Technical Data, publication 20A-TD001 This publication provides detailed drive specifications, option specifications and input protection device ratings.
Chapter 2 Detailed Drive Operation This chapter explains PowerFlex drive functions in detail. Explanations are organized alphabetically by topic. Refer to the Table of Contents for a listing of topics. [Accel Time 1, 2] The Accel Time parameters set the rate at which the drive ramps up its output frequency after a Start command or during an increase in command frequency (speed change).
Advanced Tuning Advanced Tuning Advanced Tuning Parameters – PF700 Vector Control Only ! ATTENTION: To guard against unstable or unpredictable operation, the following parameters must only be changed by qualified service personnel. Parameter Name & Description 500 [KI Current Limit] Values Default: Related No. File Group The following parameters can only be viewed when “2, Unused” is selected in parameter 196, [Param Access Lvl]. 1500 Min/Max: 0/10000 Current Limit Integral gain.
Parameter Name & Description 509 [Lo Freq Reg KpId] Values Default: Related No. File Group Advanced Tuning 64 This proportional gain adjusts the output voltage at very Min/Max: 0/32767 1 Units: low frequency in response to the reactive, or d-axis, motor current. A larger value increases the output voltage change. Default: 64 510 [Lo Freq Reg KpIq] The proportional gain adjusts the output voltage at very Min/Max: 0/32767 1 low frequency in response to the active, or q-axis, motor Units: current.
Related No. File Group Advanced Tuning Parameter Name & Description 525 [Torq Adapt Speed] Values Default: Selects the operating frequency/speed at which the adaptive torque control regulators become active as a percent of motor nameplate frequency. 526 [Torq Reg Enable] Min/Max: 0.0/100.0% 0.1% Units: Enables or disables the torque regulator 527 [Kp Torq Reg] Proportional gain for the torque regulator 528 [Ki Torq Reg] Integral gain for the torque regulator 529 [Torq Reg Trim] Default: 10.
Alarms Alarms Alarms are indications of situations that are occurring within the drive or application that should be annunciated to the user. These situations may affect the drive operation or application performance. Conditions such as Power Loss or Analog input signal loss can be detected and displayed to the user for drive or operator action. There are two types of alarms: • Type 1 Alarms are conditions that occur in the drive or application that may require alerting the operator.
Alarms The configuration bits act as a mask to block or pass through the alarm condition to the active condition. An active alarm will be indicated on the LCD HIM and will cause the drive alarm status bit to go high (“1”) in the Drive Status word (Bit 6, parameter 209). This bit can then be linked to a digital output for external annunciation. As default, all configuration bits are high (“1”).
Alarms By setting Speed Ref A Hi to 60 Hz and Speed ref A Lo to 0 Hz, the speed reference is scaled to the application needs. Because of the Input scaling and link to the speed reference, 4 mA represents minimum frequency (0 Hz.) and 20 mA represents Maximum Frequency (60 Hz.) Scale Block P322 20mA P323 4mA P091 60 Hz P092 0 HZ The input is configured to recognize a loss of signal and react accordingly to the programming.
Analog Inputs While the process is normal and running from the analog input, everything proceeds normally. However, if the wire for the analog input should be severed or the sensor malfunction so that the 4-20mA signal is lost, the following sequence occurs: 1. The drive will sense the signal loss. 2. An active Type 1 Alarm is created and the last signal value is maintained as the speed reference. 3. The alarm activates the digital output relay to light the alarm light for the operator. 4.
Analog Inputs Analog Input Configuration [Anlg In Config] [Current Lmt Sel] allows an analog input to control the set point while [DC Brk Levl Sel] allows an analog input to define the DC hold level used when Ramp-to-Stop, Ramp-to-Hold, or Brake-to-Stop is active. To provide local adjustment of a master command signal or to provide improved resolution the input to analog channel 1 or 2 can be defined as a trim input.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013 Hz Reference A + Ref A Scale/Limit Hz Trim Out Sel Reference B + Trim Hi Trim Lo Trim In Select Hz Trim Scale/Limit Speed Ref B Hi Ref B Scale/Limit Speed Ref A Hi Speed Ref B Lo Speed Ref B Sel Speed Ref A Lo Speed Ref A Sel TB Manual Hz TB Manual Scale/Limit TB Man Ref Sel Volts or mA PI Reference % PI Reference Scale/Limit PI Reference Sel Cal Analog 2 PI Feedback Sel Current Lmt Sel DC Brk Levl Sel Parame
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013 Analog 2 Current Analog 2 Bipolar Analog 2 Unipolar Analog 1 Current Analog 1 Voltage ADC ADC (current) (voltage) Anlg In Config Anlg In Config Selection/Control Processing Parameter Input/Output 0-20mA -10v - +10v 0-10v Analog In 2 Hi Analog In 2 Lo 0-20mA 0-10v Current Cal 2 Bipolar Cal 2 Unipolar Cal 2 Note: If either of these parameters is < 0, input will go into bipolar mode, otherwise unipolar.
Analog Inputs Analog Scaling [Analog In Hi] [Analog In Lo] A scaling operation is performed on the value read from an analog input in order to convert it to units usable for some particular purpose. The user controls the scaling by setting parameters that associate a low and high point in the input range (i.e. in volts or mA) with a low and high point in the target range (e.g. reference frequency). Two sets of numbers may be used to specify the analog input scaling.
Analog Inputs 12 10 Input Volts 8 6 4 2 0 6 12 18 24 30 36 42 48 54 60 Output Hertz Analog Scaling [Speed Reference A Sel] = “Analog In 1” [Analog In 1 Hi] [Speed Ref A Hi] 10V 60 Hz [Analog In 1 Lo] [Speed Ref A Lo] 0V 0 Hz Configuration #2: • • • • • • [Anlg In Config], bit 0 = “0” (Voltage) [Speed Ref A Sel] = “Analog In 1” [Speed Ref A Hi] = 30 Hz [Speed Ref A Lo] = 0 Hz [Analog In 1 Hi] = 10V [Analog In 1 Lo] = 0V This is an application that only requires 30 Hz as a maximum output fre
Analog Inputs Configuration #3: • • • • • • [Anlg In Config], bit 0 = “1” (Current) [Speed Ref A Sel] = “Analog In 1” [Speed Ref A Hi] = 60 Hz [Speed Ref A Lo] = 0 Hz [Analog In 1 Hi] = 20 mA [Analog In 1 Lo] = 4 mA This configuration is referred to as offset. In this case, a 4-20 mA input signal provides 0-60 Hz output, providing a 4 mA offset in the speed command.
Analog Inputs 10 Input Volts 8 6 4 2 0 6 12 18 24 30 36 42 48 54 60 Output Hertz Analog Scaling [Speed Reference A Sel] = “Analog In 1” [Analog In 1 Hi] [Speed Ref A Hi] 10V 0 Hz [Analog In 1 Lo] [Speed Ref A Lo] 0V 60 Hz Configuration #5: • • • • • • [Anlg In Config], bit 0 = “0” (Voltage) [Speed Ref A Sel] = “Analog In 1” [Speed Ref A Hi] = 60 Hz [Speed Ref A Lo] = 0 Hz [Analog In 1 Hi] = 5V [Analog In 1 Lo] = 0V This configuration is used when the input signal is 0-5 volts.
Analog Inputs FV Vector • • • • • Configuration #6 – Torque Ref: [Anlg In Config], bit 0 = “0” (Voltage) [Torque Ref A Sel] = “Analog In 1” [Torque Ref A Hi] = 200% [Torque Ref A Lo] = 0% [Torque Ref A Div] = 1 This configuration is used when the input signal is 0-10 volts. The minimum input of 0 volts represents a torque reference of 0% and maximum input of 10 volts represents a torque reference of 200%.
Analog Inputs Signal Loss [Analog In 1, 2 Loss] Signal loss detection can be enabled for each analog input. The [Analog In x Loss] parameters control whether signal loss detection is enabled for each input and defines what action the drive will take when loss of any analog input signal occurs. One of the selections for reaction to signal loss is a drive fault, which will stop the drive. All other choices make it possible for the input signal to return to a usable level while the drive is still running.
Analog Inputs No signal loss detection is possible while an input is in bipolar voltage mode. The signal loss condition will never occur even if signal loss detection is enabled. 2V 1.9V 1.6V Signal Loss Condition End Signal Loss Condition Trim An analog input can be used to trim the active speed reference (Speed Reference A/B). If analog is chosen as a trim input, two scale parameters are provide to scale the trim reference. The trim is a +/- value which is summed with the current speed reference.
Analog Inputs Terminal Designations & Wiring Examples Refer to the appropriate PowerFlex User Manual or “Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives,” publication DRIVES-IN001 for I/O terminal designations and wiring examples.
Analog Inputs 3. Multiply by the Volts/Hertz ratio 15 Hz x 0.16667 Volts/Hz = 2.5 Volts Therefore the command frequency from 0 to 2.5 volts on the analog input will be 15 Hz. After 2.5 volts, the frequency will increase at a rate of 0.16667 volts per hertz to 7.5 volts. After 7.5 volts on the analog input the frequency command will remain at 45 Hertz.
Analog Outputs Here, the deadband is “shifted” due to the 50 Hz limitation. The command frequency from 0 to 3 volts on the analog input will be 15 Hz. After 3 volts, the frequency will increase at a rate of 0.2 volts per hertz up to 9 volts. After 9 volts on the analog input the frequency command will remain at 45 Hz. Explanation Each drive has one or more analog outputs that can be used to annunciate a wide variety of drive operating conditions and values.
Analog Outputs Absolute (default) Certain quantities used to drive the analog output are signed, i.e. the quantity can be both positive and negative. The user has the option of having the absolute value (value without sign) of these quantities taken before the scaling occurs. Absolute value is enabled separately for each analog output via the bitmapped parameter [Anlg Out Absolut].
Analog Outputs 10V [Analog Out1 Lo] Output Current vs. Analog Output Voltage Analog Output Voltage Marker Lines [Analog Out1 Hi] 0V 0% 200% Output Current This example shows that you can have [Analog Out1 Lo] greater than [Analog Out1 Hi]. The result is a negative slope on the scaling from original quantity to analog output voltage. Negative slope could also be applied to any of the other examples in this section.
Analog Outputs Filtering Software filtering will be performed on the analog outputs for certain signal sources, as specified in Table 1. “Filter A” is one possible such filter, and it is described later in this section. Any software filtering is in addition to any hardware filtering and sampling delays.
Analog Outputs INPUTS & OUTPUTS Analog Outputs 354 355 Vector v3 Vector v3 [Anlg Out1 Scale] [Anlg Out2 Scale] Default: Sets the high value for the range of analog out scale. Entering 0.0 will disable this scale and max scale will be used. Example: If [Analog Out Sel] = “Commanded Trq,” a value of 150 = 150% scale in place of the default 800%. 0.0 Min/Max: [Analog Out1 Sel] 0.01 Units: Example Analog Output 1 set for 0-10V DC at 0-100% Commanded Torque.
Auto/Manual Parameter Controlled Analog Output Enables the analog outputs to be controlled by Datalinks to the drive. 377 378 Vector v3 Vector v3 [Anlg1 Out Setpt] [Anlg2 Out Setpt] Sets the analog output value from a communication device. Example: Set [Data In Ax] to “377” (value from communication device). Then set [Analog Outx Sel] to “Param Cntl.” Default: 20.000 mA, 10.000 Volts Min/Max: 0.000/20.000mA –/+10.000V Units: 0.001 mA 0.001 Volt Example Analog Output 1 controlled by DataLink C1.
Auto/Manual gain exclusive control (Manual) of the reference. If granted control of the reference, the specific source for the reference is determined by the parameter TB manual reference select. The TB manual reference is selected in [TB Man Ref Sel]. The choices for this parameter are: – Analog Input 1 – Analog Input 2 – MOP Level – Analog Input 3 (PF700 Only) – Pulse Input (PF700 Only) – Encoder input (PF700 Only) – Releasing this input sends the control back to the Auto source.
Auto Restart (Reset/Run) 7. If a terminal has Manual control and clears its DPI reference mask (disallows reference ownership), then Manual control will be released. By extension, if the drive is configured such that the HIM can not select the reference (via reference mask setting), then the drive will not allow the terminal to acquire Manual control. 8. If a terminal has Manual control and clears its DPI logic mask (allowing disconnect of the terminal), then Manual control will be released.
Auto Restart (Reset/Run) The auto-reset/run feature provides 2 status bits in [Drive Status 2] – an active status, and a countdown status. 210 [Drive Status 2] Read Only 209 DP I Mo at 50 to 0 Bu r Ov k s F er Cu req ld rr R Au Lim eg to it Au Rst to A DB Rst ct A C Au ctiv tdn to T e * DC u n B in Sto raki g p n Jo ping g gg Ru ing nn Ac ing tiv Re e ad y UTILITY Diagnostics Present operating condition of the drive.
Autotune Aborting an Auto-Reset/Run Cycle During an auto-reset/run cycle the following actions/conditions will abort the reset/run attempt process. • Issuing a stop command from any source. (Note: Removal of a 2-wire run-fwd or run-rev command is considered a stop assertion). • Issuing a fault reset command from any source. • Removal of the enable input signal. • Setting [Auto Rstrt Tries] to zero. • The occurrence of a fault which is not auto-resettable. • Removing power from the drive.
Autotune Vector FV Inertia Test [Total Inertia] is set by the inertia test. [Total Inertia] represents the time in seconds, for the motor coupled to a load to accelerate from zero to base speed at rated motor torque. During this test, the motor is accelerated to about 2/3 of base motor speed. This test is performed during the Start-up mode, but can be manually performed by setting [Inertia Autotune] to “Inertia Tune”.
Autotune • The second method calculates them from the user-entered motor nameplate data parameters. When [Autotune] is set to 3 “Calculate”, any changes made by the user to motor nameplate HP, Voltage, or Frequency activates a new calculation. This calculation is based on a typical motor with those nameplate values. • Finally, if the stator resistance and flux current of the motor are known, the user can calculate the voltage drop across the stator resistance.
Autotune Troubleshooting the Autotune Procedure If any errors are encountered during the Autotune process drive parameters are not changed, the appropriate fault code will be displayed in the fault queue, and the [Autotune] parameter is reset to 0. If the Autotune procedure is aborted by the user, the drive parameters are not changed and the [Autotune] parameter is reset to 0.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013 PI Regulator Logic 10 01 108 100 138 10 01 Logic PI Output Meter Limit Speed Ref Selection + + Jog Speed 2 Jog Speed 1 2 Logic 10 01 272 PI Excl Mode Linear Ramp & S Curve Drive Ref Rslt Commanded Freq Commanded Speed PI Speed Trim + 273 22 Kf Speed Loop Ki Speed Loop 161 162 Bus Reg Mode B Logic Bus Reg Mode A Torque Trim *, /, + 88 449 447 445 446 Notch Control Lead Lag Provides additional informat
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013 PI Regulator Logic 10 01 108 100 138 10 01 Logic PI Output Meter Limit Speed Ref Selection + + Jog Speed 2 Jog Speed 1 Logic 10 01 PI Excl Mode Linear Ramp & S Curve Drive Ref Rslt Commanded Freq 2 272 Commanded Speed 2 V/Hz Mode with Speed Control PI Feedback PI Reference Trim Spd Ref B Process Control (2ms) DPI Port 1-6 Presets 1-7 MOP Enc/Pulse Spd Ref A 93 Speed Ref B Sel S O U R C E S 90 Speed Ref A Sel
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013 DPI Port 6 DPI Port 6 (NVS) (0) DPI Port 5 DPI Port 5 Saved Not Saved 192 1 0 0 Save HIM Ref (At Powr Down) DPI Port 4 DPI Port 4 DPI Port 3 Power Up Preload Preset Spd7 DPI Port 3 107 Preset Speed 7 Preset Spd6 DPI Port 2 106 Preset Speed 6 Preset Spd5 DPI Port 2 105 Preset Speed 5 Preset Spd4 DPI Port 1 104 Preset Speed 4 Preset Spd3 Preset Spd2 Preset Spd1 MOP Level Encoder DPI Port 1 103 102 Prese
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013 85 86 87 Skip Frequency 2 Skip Frequency 3 Skip Freq Band 0 1 209 84 Unipol Rev (-1) (0) 2 Drive Status 1 (Command Dir) Skip Frequency 1 Unipol Fwd 0 1 (+1) Internal Autotune From Reference (3H2) Skip Bands Max 0 1 209 Max Speed 0 2 1 2 454 82 (0) X 1 0 210 4 Drive Status 2 (Stopping) (-1) Stopping or Not Active Not Stopping and Active Rev Speed Limit Drive Logic Rslt (Jog) X Unipolar Reverse Dis B
Fdbk Filter Sel 416 25 Speed Feedback from Speed Cntrl Ref [4H4] Lead Lag s +ω ks + ω 23 Speed Reference - + Kf Speed Loop ω2 s2 + 2 s + ω 2 FeedFwd 2 nd Order LPass Filter 447 kf - - + + Ki Speed Loop 445 ki s I Gain Kp Speed Loop 446 kp P Gain 121 152 Testpoint 621 Droop RPM @FLA 621 Slip RPM @ FLA + Droop Limit 620 416 Testpoint 620 Fdbk Filter Sel Lead Lag ks + ω s+ω To Torque Control Ref [6A1] Speed Control - Regulator (1.
431 434 Torque Ref B Torque Ref B Mult 5 Flux Current 41 42 43 44 45 49 62 63 64 529 Motor NP Amps Motor NP Hertz Motor NP RPM Motor NP Power Motor Poles IR Voltage Drop Flux Current Ref Ixo Voltage Drop Torque Ref Trim 235/7 234/6 Motor NP Volts Vqs Cmd 235/7 234/6 4 Torque Current Vds Cmd 1 Current Output Frequency Calc Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013 Motor NP Torque, Flux,Rs, Lo,Ls Calc X / >0 0 124 + 235/7 234/6 Torque Est.
From Feedback Selectable Source(s) From Reference Selectable Source(s) 462 463 PI Feedback Lo 128 Enable Scale PI Configuration (Feedback SqRt) SqRt 05 Scale Out - Lo Hi - Lo Out - Lo Hi - Lo 124 461 PI Feedback Sel 460 PI Reference Hi PI Reference Lo PI Feedback Hi Selector Selector 126 PI Reference Sel 0 PI Fdback Meter 136 135 PI Ref Meter 133 -1 1 0 1 0 124 02 PI Configuration (Preload Mode) PI Preload - + 0 00 PI Integral Time 134 PI Status (PI Enabled)
Block Diagrams Figure 8 PowerFlex 700VC Block Diagrams (8) Save MOP Ref (At Stop) Drive Logic Rslt (Stop) 271 194 0 0 Clear 1 0 (0) MOP Control (2.
24 VDC Common TB1-26 Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013 TB2-32 TB2-31 TB2-30 TB2-29 TB2-28 TB1-27 TB1-25 {Logic Common} 24 VDC TB1-24 Debounce Debounce Debounce Debounce Debounce Debounce 00 01 02 03 From Internal Selectable Source(s) Selector Selector 388 Digital Out3 Sel 384 Digital Out2 Sel Logic 10 01 Logic 10 01 05 Dig In Status (DigIn 6) 216 Digital In6 Sel 216 366 Selector Terminal Block Configuration Setting [11A1] Logic Termi
TB1-20 TB1-19 TB1-4 TB1-3 TB1-18 TB1-17 TB1-2 TB1-1 + - + - 00 Current Jumper ma/V Scale 320 01 Anlg In Config Current Jumper ma/V Scale 320 Anlg In Config A/D 12bit A/D 12bit 00 01 Anlg In Sqr Root 321 17 Analog In2 Value Anlg In Sqr Root 321 16 Analog In1 Value Enable SqRt Enable SqRt Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013 Analog In 1 Loss Speed Ref B Lo TB Man Ref Lo Trim Lo 98 120 Speed Ref A Lo Analog In 2 Loss Selector 95 92 324 TB
DPI Port 5 DPI Port 4 DPI Port 3 DPI Port 2 DPI Port 1 (HIM) Terminal Block Configuration Settings [9Dx] AND 276 Logic Mask 6 / Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013 Ref Owner Logic Dir Owner Logic 297 Local Owner Logic Single Owner Eval Single Owner Eval Local Owner Single Owner Eval Local Mask Evaluation Jog Owner Logic 285 AND AND AND AND AND AND AND AND Start Owner Logic Local Mask MOP Mask 284 Fault Clr Mask 283 Decel Mask 282 Accel Mask
148 Current Limit Value 162 3 Output Current 161 151 PWM Frequency Bus Reg Mode B 150 Drive OL Mode Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013 257 255 253 251 249 247 245 243 Active PWM Freq Active Cur Limit Heatsink Temp 257 253 257 257 255 253 251 249 247 245 (DB Resistance) 255 251 243 253 255 251 249 247 245 243 Fault x Code 249 Fault x Code (Inv OL Level 1) (Inv OL Level 2) 04 03 02 247 245 243 Alarm x Code 235/7 234/6 235/7 23
Bus Regulation Bus Regulation [Bus Reg Gain] [Bus Reg Mode A, B] Some applications, such as the hide tanning shown here, create an intermittent regeneration condition. When the hides are being lifted (on the left), motoring current exists. However, when the hides reach the top and fall onto a paddle, the motor regenerates power back to the drive, creating the potential for a nuisance overvoltage trip.
Bus Regulation The bus voltage regulation set point (Vreg) in the drive is fixed for each voltage class of drive. The bus voltage regulation set points are identical to the internal dynamic brake regulation set points VDB's. DB Bus Motor Speed Output Frequency To avoid over-voltage faults, a bus voltage regulator is incorporated as part of the acceleration/deceleration control.
Bus Regulation Figure 13 Bus Voltage Regulator, Current Limit and Frequency Ramp.
Bus Regulation ! ATTENTION: The “adjust freq” portion of the bus regulator function is extremely useful for preventing nuisance overvoltage faults resulting from aggressive decelerations, overhauling loads, and eccentric loads. It forces the output frequency to be greater than commanded frequency while the drive's bus voltage is increasing towards levels that would otherwise cause a fault; however, it can also cause either of the following two conditions to occur. 1.
Bus Regulation Table 3 Voltage Class 240 DC Bus Memory < 342V DC > 342V DC 480 < 685V DC > 685V DC 600 < 856V DC > 856V DC 600/690V < 983V DC PowerFlex 700 Frames > 983V DC 5 & 6 Only DB On Setpoint 375V DC Memory + 33V DC 750V DC Memory + 65V DC 937V DC Memory + 81V DC 1076V DC Memory + 93V DC DB Off Setpoint On – 4V DC On – 8V DC On – 10V DC On – 11V DC 880 815 DB Turn On 750 DC Volts DB Turn Off 685 1 e# urv 650 C eg sR Bu 2 e# urv C eg sR ory Bu em M us B 509 453 320 360 460 4
Cable, Control If [Bus Reg Mode A], parameter 161 is set to “Both-DB 1st” Both regulators are enabled, and the operating point of the Dynamic Brake Regulator is lower than that of the Bus Voltage Regulator. The Bus Voltage Regulator setpoint follows the “DB Turn On” curve (Table 3). The Dynamic Brake Regulator follows the “DB Turn On” and turn off curves (Table 3).
Carrier (PWM) Frequency Carrier (PWM) Frequency In general, the lowest possible switching frequency that is acceptable for any particular application is the one that should be used. There are several benefits to increasing the switching frequency. Refer to Figure 14 and Figure 15. Note the output current at 2 kHz and 4 kHz. The “smoothing” of the current waveform continues all the way to 10 kHz.
CE Conformity CE Conformity EMC Instructions CE Conformity Conformity with the Low Voltage (LV) Directive and Electromagnetic Compatibility (EMC) Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. PowerFlex Drives comply with the EN standards listed below when installed according to the User and Reference Manuals. CE Declarations of Conformity are available online at: http://www.ab.com/certification/ce/docs.
CE Conformity Frame Table 5 PowerFlex 70 – EN61800-3 EMC Compatibility A B C D E Drive Description Drive Only Drive with any Comm Option Drive with Remote I/O Drive Only Drive with any Comm Option Drive with Remote I/O Drive Only Drive with any Comm Option Drive with Remote I/O Drive Only Drive with any Comm Option Drive with Remote I/O Drive Only Drive with any Comm Option Drive with Remote I/O Second Environment Restrict Motor Cable to 40 m (131 ft.
Copy Cat Table 8 Recommended Filters (1) Manufacturer Deltron Drive Type PowerFlex 70 PowerFlex 700 Schaffner PowerFlex 70 PowerFlex 700 Frame A B w/o Filter B w/Filter C D D w/o DC CM Capacitor E 0 1 2 2 w/o DC CM Capacitor 3 3 w/o DC CM Capacitor A B w/o Filter B w/Filter C D D w/o DC CM Capacitor 0 1 2 2 w/o DC CM Capacitor 3 3 w/o DC CM Capacitor Manufacturer Part Number KMF306A KMF310A KMF306A KMF318A KMF336A KMF336A – KMF318A KMF325A KMF350A KMF350A KMF370A KMF370A FN3258-7-45 FN3258-7-45 FN3
Current Limit Current Limit [Current Lmt Sel] [Current Lmt Val] [Current Lmt Gain] There are 6 ways that the drive can protect itself from overcurrent or overload situations: • • • • • • Instantaneous Overcurrent trip Software Instantaneous Trip Software Current Limit Overload Protection IT Heatsink temperature protection Thermal Manager 1. Instantaneous Overcurrent - This is a feature that instantaneously trips or faults the drive if the output current exceeds this value.
Datalinks 4. Overload Protection I2T - This is a software feature that monitors the output current over time and integrates per IT. The base protection is 110% for 1 minute or the equivalent I2T value (i.e. 150% for 3 seconds, etc.). If the IT integrates to maximum, an F64 “Drive Overload” fault will occur. The approximate integrated value can be monitored via the [Drive OL Count] parameter. 5. Heatsink Temperature Protection - The drive constantly monitors the heatsink temperature.
Datalinks In the PLC data Table, the user enters Word 3 as a value of 100 (10.0 Secs) and word 4 as a value of 133 (13.3 seconds). On each I/O scan, the parameters in the PowerFlex drive are updated with the value from the data table: Accel Time P140 = 10.0 seconds (value from output image table Word 3) Decel Time P142 = 13.3 seconds (value from output image table Word 4).
DC Bus Voltage / Memory Even if non-consecutive Datalinks are used (in the next example, Datalinks A1 and B2 would not be used), data is still returned in the same way. Datalink A2 B1 Most/Least Significant Word MSW LSW Parameter 242 242 Data (decimal) 13 32573 32-bit data is stored in binary as follows: 231 through 216 215 through 20 MSW LSW Example Parameter 242 - [Power Up Marker] = 88.
(1 ) (1 ) MO P Sp Dec d Sp Ref I d D Sp Ref 2 d R ID De ef 1 ce ID De l 2 0 ce Ac l 1 ce Ac l 2 c Mo el 1 p Lo Inc ca Re l Co ve n Fo rse trl rw Cle ard a Jo r Fa g ult Sta r Sto t p (1 ) Digital Inputs 0 0 0 0 1 1 1 0 1 0 0 0 1 1 0 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Bit # 0 0 0 1 0 0 1 0 0 1 0 0 1 0 0 0 1 = Condition True 0 = Condition False x = Reserved Accel 1 Accel 2 Decel 1 Decel 2 The effectiveness of these bits or digital inputs can be affected by [Decel Mask].
Digital Inputs Digital Input Configuration Inputs are configured for the required function by setting a [Digital Inx Sel] parameter (one for each input). These parameters cannot be changed while the drive is running.
Digital Inputs PowerFlex 70 Digital Input Selection 361 [Digital In1 Sel] Default: 4 [Digital In2 Sel] 362 [Digital In3 Sel] 363 [Digital In4 Sel] [Digital In5 Sel] 364 [Digital In6 Sel] 365 Selects the function for the digital inputs.
Digital Inputs Accel 2 Decel 2 Accel 2 & Decel 2 Select acceleration rate 1 or 2. Select deceleration rate 1 or 2. Select acceleration rate 1 and deceleration rate 1 or acceleration rate 2 and deceleration rate 2. Increment MOP (Motor Operated Pot Function Speed ref) Decrement MOP (Motor Operated Pot Function Speed ref) Select Stop Mode A (open) or B (closed) Select which bus regulation mode to use Enable Process PI loop. Hold integrator for Process PI loop at current value.
Digital Inputs Open Closed Closed Closed Open Closed Drive runs in reverse direction, terminal block takes direction ownership. Drive runs in forward direction, terminal block takes direction ownership. Drive continues to run in current direction, but terminal block maintains direction ownership. If one of these input functions is configured and the other one isn’t, the above description still applies, but the unconfigured input function should be considered permanently open.
Digital Inputs causes a configuration alarm. See page 109 for typical 2 and 3-wire configurations. • Start An open to closed transition while the drive is stopped will cause the drive to run in the current direction, unless the “Stop – Clear Faults” input function is open. The terminal block bit must be set in the [Start Mask] and [Logic Mask] parameters in order for the terminal block to start or change the direction of the drive using these inputs.
Digital Inputs The drive will not jog while running or while the “Stop - Clear Faults” input is open. Start has precedence. ! ATTENTION: If a normal drive start command is received while the drive is jogging, the drive will switch from jog mode to run mode. The drive will not stop, but may change speed and/or change direction. The terminal block bit must be set in the [ Jog Mask] and [Logic Mask] parameters in order for the terminal block to cause the drive to jog using this input function.
Digital Inputs and [Logic Mask] parameters, the terminal block becomes direction owner as soon as one (or both) of the “Jog Forward” or “Jog Reverse” input functions is closed. • Speed select 1, 2, and 3 One, two, or three digital input functions can be used to select the speed reference used by the drive, and they are called the Speed Select input functions. The current open/closed state of all Speed Select input functions combine to select which source is the current speed reference.
Digital Inputs The table below describes the various reference sources that can be selected using all three of the Speed Select input functions.
Digital Inputs • Auto/Manual The Auto/Manual facility is essentially a higher priority reference select. It allows a single control device to assume exclusive control of reference select, irrespective of the reference select digital inputs, reference select DPI commands, the reference mask, and the reference owner.
Digital Inputs by using the terminal block digital inputs, and the Speed Select Inputs will have no effect on which reference the drive is currently using. Because any combination of open / closed conditions (or unwired condition) commands a reference source, the terminal block seeks accel ownership as soon as the “Accel 2” input function is configured, which may happen at power-up.
Digital Inputs • Stop Mode B This digital input function selects between two different drive stop modes. See also Stop Modes on page 197. If the input is open, then [Stop Mode A] selects which stop mode to use. If the input is closed, then [Stop Mode B] selects which stop mode to use. If this input function is not configured, then [Stop Mode A] always selects which stop mode to use. • Bus Regulation Mode B This digital input function selects how the drive will regulate excess voltage on the DC bus.
Digital Inputs • Local Control The “Local Control” input function allows exclusive control of all drive logic functions from the terminal block. If this input function is closed, the terminal block has exclusive control (disabling all the DPI devices) of drive logic, including start, reference selection, acceleration rate selection, etc. The exception is the stop condition, which can always be asserted from any connected control device.
Digital Inputs This choice is made when the user wishes to link the input to the output, but desires that no other functionality be assigned to the input. The state of any digital input can be “passed through” to a digital output by setting the value of a digital output configuration parameter ([Digital Outx Sel]) to “Input n Link”. The output will then be controlled by the state of the input, even if the input is being used for a second function.
Digital Inputs Examples of configurations that cause an alarm are: • User tries to configure both the “Start” input function and the “Run Forward” input function at the same time. “Start” is only used in “3-wire” start mode, and “Run Forward” is only used in “2-wire” run mode, so they should never be configured at the same time • User tries to assign a toggle input function (for instance “Forward/Reverse”) to more than one physical digital input simultaneously.
Digital Inputs Table 11 Input function combinations that produce “DigIn CflctB” alarm Start Stop–CF Run Run Fwd Run Rev Jog Jog Fwd Jog Rev Fwd/ Rev Start Stop–CF Run Run Fwd Run Rev Jog Jog Fwd Jog Rev Fwd / Rev “Digin CflctC” indicates that more than one physical input has been configured to the same input function, and this kind of multiple configuration isn’t allowed for that function. Multiple configuration is allowed for some input functions and not allowed for others.
Digital Inputs The “Bipolar Cflct” alarm will be asserted if both of the following are true: • One or more of the following digital input functions are configured: “Forward/Reverse”, “Run Forward”, “Run Reverse”, “Jog Forward”, “Jog Reverse”. • [Direction Mode] is set to “Bipolar” or “Reverse Dis”. Digital In Status This parameter represents the current state of the digital inputs. It contains one bit for each input. The bits are “1” when the input is closed and “0” when the input is open.
Digital Outputs Digital Outputs Each drive provides digital (relay) outputs for external annunciation of a variety of drive conditions. Each relay is a Form C (1 N.O. – 1 N.C. with shared common) device whose contacts and associated terminals are rated for a maximum of 250V AC or 220V DC. The table below shows specifications and limits for each relay/contact.
Digital Outputs PowerFlex 70 Digital Output Selection 380 [Digital Out1 Sel] 384 [Digital Out2 Sel] Selects the drive status that will energize a (CRx) output relay. are in drive powered state with condition not present. For functions such as “Fault” and “Alarm” the normal relay state is energized and N.O. / N.C. contact wiring may have to be reversed.
Digital Outputs 2. The relay changes state because a particular value in the drive has exceeded a preset limit. The following drive values can be selected to cause the relay activation: Condition At Speed Description The drive Output Frequency has equalled the commanded frequency The balance of these functions require that the user set a limit for the specified value. The limit is set into one of two parameters: [Dig Out1 Level] and [Dig Out2 Level] depending on the output being used.
Digital Outputs An Output can be “linked” directly to an Digital Input so that the output “tracks” the input. When the input is closed, the Output will be energized, and when the input is open, the output will be de-energized.
Direction Control PowerFlex 700 Firmware 3.001 (& later) Enhancements Certain digital output enhancements have been included in firmware version 3.001 (and later) for the PowerFlex 700 Vector Control drive. These include: • Digital output control via Datalink Parameter Controlled Digital Outputs Enables control of the digital outputs through the Data In parameters. Vector v3 380 [Dig Out Setpt] Sets the digital output value from a communication device. Example Set [Data In B1] to “379.
DPI DPI Drive Peripheral Interface (DPI) is an enhancement to SCANport that provides more functions and better performance. SCANport was a CAN based, Master-Slave protocol, created to provide a standard way of connecting motor control products and optional peripheral devices together. It allows multiple (up to 6) devices to communicate with a motor control product without requiring configuration of the peripheral.
DPI so support of message fragmentation is not required. The following types of messaging are covered: • • • • • Drive status (running, faulted, etc.) Drive commands (start, stop, etc.) Control logic parsing operations (e.g., mask and owner parameters) Entering Flash programming mode “Soft” login and logout of peripheral devices (enabling/disabling of peripheral control) Peer-to-Peer operation Peer-to-Peer messaging allows two devices to communicate directly rather than through the master or host (i.e.
Drive Overload Table 12 Timing specifications contained in DPI and SCANport DPI SCANport DPI SCANport DPI SCANport DPI SCANport DPI SCANport DPI SCANport DPI SCANport Host status messages only go out to peripherals once they log in and at least every 125ms (to all attached peripherals). Peripherals time out if >250ms. Actual time dependent on number of peripherals attached. Minimum time goal of 5ms (may have to be dependent on Port Baud Rate).
Drive Overload If the drive is operated in a low ambient condition the drive may exceed rated levels of current before the monitored temperature becomes critical. To guard against this situation the drive thermal overload also includes an inverse time algorithm. When this scheme detects operation beyond rated levels, current limit may be reduced or a fault may be generated.
Drive Overload The lower curve in Figure 19 shows the boundary of heavy duty operation. In heavy duty, the drive is rated to produce 150% of rated current for 60 seconds, 200% for three seconds, and 220% for 100 milliseconds. The maximum value for current limit is 200% so the limit of 220% for 100 milliseconds should never be crossed.
Drive Overload Thermal Manager Protection The thermal manager protection assures that the thermal ratings of the power module are not exceeded. The operation of the thermal manager can be thought of as a function block with the inputs and outputs as shown below.
Drive Overload Current Limit Current Limit as selected by the user can be reduced by the thermal manager. The resulting active current limit may be displayed as a test point parameter. The active current limit will always be less than or equal to the value selected by the user, and will not be less than flux current. When drive temperature reaches the level where current limit would be clamped, the Drv OL Lvl 2 Alarm is turned on. This alarm will be annunciated even if reduced current limit is not enabled.
Drive Ratings (kW, Amps, Volts) torque load reducing the output frequency does not lower the current (load). Lowering current limit on a CT load will push the drive down to a region where the thermal issue becomes worse. In this situation the thermal manager will increase the calculated losses in the power module to track the worst case IGBT.
Efficiency Efficiency The following chart shows typical efficiency for PWM variable frequency drives, regardless of size. Drives are most efficient at full load and full speed. 100 vs. Speed % Efficiency 95 vs. Load 90 85 80 75 10 Fan Curve 20 30 40 50 60 70 % Speed/% Load 80 90 100 When torque performance (see page 201) is set to Fan/Pump, the relationship between frequency and voltage is shown in the following figure.
Faults Faults Faults are events or conditions occurring within and/or outside of the drive. Theses events or conditions are (by default) considered to be of such significant magnitude that drive operation should or must be discontinued. Faults are annunciated to the user via the HIM, communications and/or contact outputs. The condition that caused the fault determines the user response.
Faults The fault queue will be a first-in, first-out (FIFO) queue. Fault queue entry #1 will always be the most-recent entry (newest). Entry 4 (8) will always be the oldest. As a new fault is logged, each existing entry will be shifted up by one (i.e. previous entry #1 will move to entry #2, previous entry #2 will move to entry #3, etc.). If the queue is full when a fault occurs, the oldest entry will be discarded.
Flux Braking Resetting faults will clear the faulted status indication. If any fault condition still exists, the fault will relatch and another entry made in the fault queue. Clearing the Fault Queue Performing a fault reset does not clear the fault queue. Clearing the fault queue is a separate action. Fault Configuration The drive can be configured such that some fault conditions do not trip the drive. Configurable faults include those that are user inputs.
Flux Up limits. In general, the flux current is not increased when the motor is at or above rated speed. At higher speeds, field weakening is active and the motor flux current cannot be increased. As the speed decreases below base speed, the flux current increases until there is enough voltage margin to run rated motor current. Because flux braking increases motor losses, the duty cycle used with this method must be limited. Check with the motor vendor for flux braking or DC braking application guidelines.
Flying Start Figure 22 Flux Up Current versus Flux Up Time Flux Up Current Flux Up Current = Maximum DC Current Rated Flux Current Rated Motor Flux Motor Flux T1 T2 T3 T4 Flux Up Time [Flux Up Time] Once rated flux is reached in the motor, normal operation begins and the desired acceleration profile is achieved.
Fuses and Circuit Breakers Since the motor is “picked up “smoothly at its rotating speed and ramped to the proper speed, little or no mechanical stress is present. Configuration Flying Start is activated by setting the [Flying Start En] parameter to “Enable” 169 [Flying Start En] Enables/disables the function which reconnects to a spinning motor at actual RPM when a start command is issued.
Grounding, General Grounding, General Refer to “Wiring and Grounding Guidelines for PWM AC Drives,” publication DRIVES-IN001. HIM Memory See Copy Cat on page 65. HIM Operations Selecting a Language See also Language on page 111. PowerFlex 700 drives support multiple languages. When you first apply drive power, a language screen appears on the HIM. Use the Up or Down Arrow to scroll through the available languages. Press Enter to select the desired language.
Input Devices The User Display The User Display is shown when module keys have been inactive for a predetermined amount of time. The display can be programmed to show pertinent information. Setting the User Display Step Key(s) Example Displays 1. Press the Up Arrow or Down Arrow to scroll to Operator Intrfc. Press Enter. Operator Intrfc: Change Password User Display Parameters 2. Press the Up Arrow or Down Arrow to scroll to User Display. Press Enter. 3. Select the desired user display. Press Enter.
Input Modes Input Modes The PowerFlex family of drives does not use a direct choice of 2-wire or 3-wire input modes, but allows full configuration of the digital I/O. As a means of defining the modes used, consider the following: 2-Wire Control This input mode is so named because it only utilizes one device and 2 wires to control both the Start (normally referred to as “RUN” in 2-wire) and Stop functions in an application.
Input Power Conditioning Input Power Conditioning Refer to Chapter 2 of “Wiring and Grounding Guidelines for PWM AC Drives,” publication DRIVES-IN001A-EN-P. Jog Also refer to Jog on page 75. When a JOG command is issued by any of the controlling devices (terminal block digital input, communications adapter or HIM), the drive outputs voltage and frequency to the motor as long as the command is present. When the command is released, the drive output stops.
Language Language PowerFlex drives are capable of communicating in 7 languages; English, Spanish, German, Italian, French, Portuguese and Dutch. All drive functions and information displayed on an LCD HIM are shown in the selected language. The desired language can be selected several different ways: • On initial drive power-up, a language choice screen appears. • The language choice screen can also be recalled at any time to change to a new language.
Linking Parameters Table 13 Linkable Parameters Number 54 56 57 58 59 62 63 69 70 71 72 84 85 86 87 91 92 94 95 97 98 100 101 102 103 104 105 106 107 119 120 121 122 123 127 129 130 131 132 133 140 141 142 143 146 148 149 151 152 153 154 158 159 112 Parameter Maximum Voltage Compensation Flux Up Mode Flux Up Time SV Boost Filter IR Voltage Drop Flux Current Ref Start/Acc Boost Run Boost Break Voltage Break Frequency Skip Frequency 1 Skip Frequency 2 Skip Frequency 3 Skip Freq Band Speed Ref A Hi Speed Re
Masks A mask is a parameter that contains one bit for each of the possible Adapters. Each bit acts like a valve for issued commands. Closing the valve (setting a bit's value to 0) stops the command from reaching the drive logic. Opening the valve (setting a bit's value to 1) allows the command to pass through the mask into the drive logic. 276 [Logic Mask] 288 thru 297 DP I DP Port IP 5 DP o r t 4 I DP Port IP 3 DP o r t 2 I Dig Port ita 1 l In Determines which adapters can control the drive.
MOP Direction Mask Adapter # 0 0 0 0 0 1 0 0 X 6 5 4 3 2 1 0 This “masks out” the reverse function from all adapters except Adapter 2, making the local HIM (Adapter 1) REV button inoperable. Also see Owners on page 125. MOP The Motor Operated Pot (MOP) function is one of the sources for the frequency reference. The MOP function uses digital inputs to increment or decrement the Speed reference at a programmed rate.
Motor Control If the value is “SAVE MOP Ref ” when the drive power returns, the MOP reference is reloaded with the value from the non-volatile memory. When the bit is set to 0, the MOP reference defaults to zero when power is restored. The MOP save reference parameter and the MOP rate parameter can be changed while the drive is running.
Motor Nameplate Motor Nameplate [Motor NP Volts] The motor nameplate base voltage defines the output voltage, when operating at rated current, rated speed, and rated temperature. [Motor NP FLA] The motor nameplate defines the output amps, when operating at rated voltage, rated speed, and rated temperature. It is used in the motor thermal overload, and in the calculation of slip.
Motor Overload Also see Motor Overload Protection on page 119. The motor thermal overload uses an IT algorithm to model the temperature of the motor. The curve is modeled after a Class 10 protection thermal overload relay that produces a theoretical trip at 600% motor current in ten (10) seconds and continuously operates at full motor current.
Motor Overload Changing Overload Factor 140 Continuous Rating 120 100 80 OL % = 1.20 OL % = 1.00 OL % = 0.80 60 40 20 0 10 20 30 40 50 60 70 80 90 100 % of Base Speed 3. [Motor OL Hertz] is used to further protect motors with limited speed ranges. Since some motors may not have sufficient cooling ability at lower speeds, the Overload feature can be programmed to increase protection in the lower speed areas.
Motor Overload Protection 1 Minute 1 Minute 150% 100% 20 Minutes The ratio of 1:20 is the same for all durations of 150%.
Motor Start/Stop Precautions Motor Start/Stop Precautions Input Contactor Precautions ! ! ATTENTION: A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor. If an input device is used, operation must not exceed one cycle per minute or drive damage will occur.
Notch Filter Notch Filter Vector FV The 700 Vector has a notch filter in the torque reference loop used to eliminate mechanical resonance created by a gear train. [Notch Filter Freq] sets the center frequency for the 2 pole notch filter, and [Notch Filter K] sets the gain. Figure 24 Notch Filter Frequency Gain Notch Filter K 0 db Notch Filter Frequency Hz Due to the fact that most mechanical frequencies are described in Hertz, [Notch Filter Freq] and [Notch Filter K] are in Hertz as well.
Notch Filter Figure 26 Resonance The insert shows the resonant frequency in detail. Figure 27 shows the same mechanical gear train as Figure 26. [Notch Filter Freq] is set to 10.
Output Current Output Current [Output Current] This parameter displays the total output current of the drive. The current value displayed here is the vector sum of both torque producing and flux producing current components. Output Devices Drive Output Contactor ! ATTENTION: To guard against drive damage when using output contactors, the following information must be read and understood.
Output Frequency resulting from high dv/dt. When using motor line reactors, it is recommended that the drive PWM frequency be set to its lowest value to minimize losses in the reactors. By using an output reactor the effective motor voltage will be lower because of the voltage drop across the reactor - this may also mean a reduction of motor torque. Output Frequency [Output Frequency] This parameter displays the actual output frequency of the drive.
Owners Figure 28 Typical V/Hz Curve for Full Custom (with Speed/Frequency Limits Allowable Output Frequency Range Bus Regulation or Current Limit Allowable Output Frequency Range - Normal Operation (lower limit on this range can be 0 depending on the value of Speed Adder) Allowable Speed Reference Range Maximum Voltage Output Voltage Motor NP Voltage Frequency Trim due to Speed Control Mode Overspeed Limit Break Voltage Start Boost Run Boost 0 Minimum Break Speed Frequency Motor NP Hz Frequency Ow
Owners Non Exclusive Multiple adapters can simultaneously issue the same command and multiple bits may be high. 288 [Stop Owner] Read Only DP I DP Port IP 5 DP o r t 4 I DP Port IP 3 DP o r t 2 I Dig Port ita 1 l In Adapters presently issuing a valid stop command.
Parameter Access Level The operator first views the Start owner to be certain that the Start button on the HIM is issuing a command. Start Owner Adapter # 0 0 0 0 0 0 0 0 X 6 5 4 3 2 1 0 When the local Start button is pressed, the display indicates that the command is coming from the HIM. Start Owner Adapter # 0 0 0 0 0 0 1 0 X 6 5 4 3 2 1 0 The [Start Owner] indicates that there is not any maintained Start commands causing the drive to run.
PET PET Pulse Elimination Technique – See Reflected Wave on page 149. Power Loss Some processes or applications cannot tolerate drive output interruptions caused by momentary power outages. When AC input line power is interrupted to the drive, user programming can determine the drive’s reaction. Terms The following is a definition of terms. Some of these values are drive parameters and some are not.
Power Loss Line Loss Mode = Decel 700 Recover Close Trigger Open 650 600 DC Bus Volts DC Bus Volts 650 Line Loss Mode = Coast 700 550 600 550 500 500 450 450 400 Recover Close Trigger Open 400 350 400 AC Input Volts 450 350 400 AC Input Volts 450 Table 15 PF700 Bus Levels Class Vslew Vrecover Vclose Vtrigger1,2 Vtrigger1,3 Vopen Vopen4 Vmin Voff 5 200/240V AC 1.2V DC Vmem – 30V Vmem – 60V Vmem – 60V Vmem – 90V Vmem – 90V 153V DC 153V DC – 400/480V AC 2.
Power Loss Restart after Power Restoration If a power loss causes the drive to coast and power recovers the drive will return to powering the motor if it is in a “run permit” state. The drive is in a “run permit” state if: 3 wire mode – it is not faulted and if all Enable and Not Stop inputs are energized. 2 wire mode – it is not faulted and if all Enable, Not Stop, and Run inputs are energized. Power Loss Actions The drive is designed to operate at a nominal bus voltage.
Power Loss If the bus voltage rises above Vrecover for 20mS, the drive determines the power loss is over. The power loss alarm is cleared. If the drive is in a “run permit” state, the reconnect algorithm is run to match the speed of the motor. The drive then accelerates at the programmed rate to the set speed. 680V 620V 560V 500V Bus Voltage 407V 305V Motor Speed Power Loss Output Enable Pre-Charge Drive Fault 480V example shown, see Table 15 for further information.
Power Loss The inverter output is disabled and the motor coasts if the output frequency drops to zero or if the bus voltage drops below Vopen or if any of the “run permit” inputs are de-energized. The pre-charge relay opens if the bus voltage drops below Vopen. The pre-charge relay closes if the bus voltage rises above Vclose If the bus voltage rises above Vrecover for 20mS, the drive determines the power loss is over. The power loss alarm is cleared.
Power Loss The pre-charge relay opens if the bus voltage drops below Vopen/Vmin and closes if the bus voltage rises above Vclose. The power loss alarm in [Drive Alarm 1] is set and the power loss timer starts. The Alarm bit in [Drive Status 1] is set if the Power Loss bit in [Alarm Config 1] is set. The drive faults with a F003 – Power Loss fault if the power loss timer exceeds [Power Loss Time] and the Power Loss bit in [Fault Config 1] is set.
Power Loss The drive faults with a F003 – Power Loss fault if the power loss timer exceeds [Power Loss Time] and the Power Loss bit in [Fault Config 1] is set. The drive faults with a F004 – UnderVoltage fault if the bus voltage falls below Vmin and the UnderVoltage bit in [Fault Config 1] is set. The pre-charge relay opens if the bus voltage drops below Vopen and closes if the bus voltage rises above Vclose.
Preset Frequency Preset Frequency There are 7 Preset Frequency parameters that are used to store a discrete frequency value. This value can be used for a speed reference or PI Reference. When used as a speed reference, they are accessed via manipulation of the digital inputs or the DPI reference command. Preset frequencies have a range of plus/ minus [Maximum Speed].
Process PI Loop The PI function can perform a combination of proportional and integral control. It does not perform derivative control, however, the accel / decel control of the drive can be considered as providing derivative control. There are two ways the PI Controller can be configured to modify the commanded speed. • Process Trim - The PI Output can be added to the master speed reference • Process Control - PI can have exclusive control of the commanded speed.
Process PI Loop When the PI is enabled, the output of the PI Controller is added to the ramped speed reference. Slip Comp + Slip Adder + Spd Ref PI Ref PI Fbk Open Loop Linear Ramp & S-Curve Spd Cmd + Process PI Controller PI Enabled + Process PI Speed Control Exclusive Control Process Control takes the output of PI regulator as the speed command. No master speed reference exists and the PI Output directly controls the drive output.
Process PI Loop Slip Comp + Slip Adder + Linear Ramp & S-Curve Spd Ref Open Loop Spd Cmd Process PI PI Ref PI Fbk Process PI Controller Speed Control PI Disabled When the PI is enabled, the speed reference is disconnected and PI Output has exclusive control of the commanded speed, passing through the linear ramp and s-curve.
Process PI Loop PI_Config .Invert + PI Ref Sel PI Fdbk Sel PI Error – PI_Config .Sqrt PI Fbk • Preload Integrator - This feature allows the PI Output to be stepped to a preload value for better dynamic response when the PI Output is enabled. Refer to diagram 2 below. If PI is not enabled the PI Integrator may be initialized to the PI Pre-load Value or the current value of the commanded speed. The operation of Preload is selected in the PI Configuration parameter. PI_Config .PreloadCmd PI_Status .
Process PI Loop PI Enabled Start at Spd Cmd PI Output Spd Cmd Pre-load to Command Speed • Ramp Ref - The PI Ramp Reference feature is used to provide a smooth transition when the PI is enabled and the PI output is used as a speed trim (not exclusive control),. When PI Ramp Reference is selected in the PI Configuration parameter, and PI is disabled, the value used for the PI reference will be the PI feedback. This will cause PI error to be zero.
Process PI Loop • Feedback Square Root - This feature uses the square root of the feedback signal as the PI feedback. This is useful in processes that control pressure, since centrifugal fans and pumps vary pressure with the square of speed. The PI has the option to take the square root of the selected feedback signal. This is used to linearize the feedback when the transducer produces the process variable squared.
Process PI Loop When a digital input is configured as “PI Enable,” the PI Enable bit of [PI Control] must be turned on for the PI loop to become enabled. If a digital input is not configured as “PI Enable” and the PI Enable bit in [PI Control] is turned on, then the PI loop may become enabled. If the PI Enable bit of [PI Control] is left continuously, then the PI may become enabled as soon as the drive goes into run. If analog input signal loss is detected, the PI loop is disabled.
Process PI Loop undesirable and sudden operation if the system were switched to manual operation and back. Resetting the integrator eliminates this windup. NOTE: In the PowerFlex 70, once the drive has reached the programmable positive and negative PI limits, the integrator stops integrating and no further “windup” is possible. 3. [PI Status] parameter is a set of bits that indicate the status of the process PI controller • Enabled – The loop is active and controlling the drive output.
Process PI Loop Configuration Example: The PI reference meter and PI feedback meter should be displayed as positive and negative values. Feedback from our dancer comes into Analog Input 2 as a 0-10V DC signal.
Process PI Loop The PI Integral Gain is entered in seconds. If the PI Integral Gain is set to 2.0 seconds and PI Error is 100.00% the PI output will integrate from 0 to 100.00% in 2.0 seconds. Positive and Negative Limits The PI has parameters to define the positive and negative limits of the output PI Positive Limit, and PI Negative Limit. The limits are used in two places; on the integrator and on the sum of the Kp + Ki terms.
Process PI Loop Figure 29 Process PI Block Diagram PI_Config .ZeroClamp PI_Config .Exclusive PI_Status .Enabled Linear Ramp & S-Curve Spd Ref + +32K + -32K Spd Cmd Spd Ramp PI Pos Limit +32K PI Neg Limit 0 0 PI Kp PI ExcessErr abs *(PI Ref Sel) PI Ref Linear Ramp PI Cmd + ≥ ≥0 PI XS Error - PI Output * - PI_Status .Enabled Zclamped + PI Error + + * + PI_Config .RampCmd In Limit -1 z 0 *(PI Fbk Sel) PI Fbk PI_Config .Sqrt PI_Config .Invert PI Ki PI_Status .
Process PI Loop Figure 30 Vector Control Option Process PI Loop Overview PI Ref Hi PI Reference Sel 126 PI Configuration 124 1 460 PI Ref 135 Hi/Lo Scale PI Configuration PI Feedback Select 128 3 124 461 PI Fdbk Hi 462 Linear Ramp PI Ref Lo PI Config 0 124 5 PI Cmd PI Error 137 Limit PI Status 134 4 Ki PI Integral Time PI Fdbk In Limit 124 PI Configuration 124 2 136 Limit Hold 129 PI Configuration 7 Anti-Windup Ramp Ref 132 Kp PI Status 134 1 Invert Enable Hi/Lo PI Upper L
Process PI Loop For example, winders using torque control rely on PD control not PI control. Also, [PI BW Filter] is useful in filtering out unwanted signal response in the PID loop. The filter is a Radians/Second low pass filter. Percent of Reference 124 [PI Configuration] 124 thru 138 % of To Ref rqu ** An e T ti rim Sto -Win * p d Fe Mo Up ed de Ze bak ro S Ra Cla qrt m m Pre p Re p lo f Inv ad M e o Ex rt Er de cl ror Mo de Sets configuration of the PI regulator.
Reflected Wave 118 [Trim Out Select] 117 119 120 Ad d Tri or % m * Tri Ref m B Re fA Specifies which speed references are to be trimmed. x x x x x x x x x x x x x 0 0 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 =Trimmed/% 0 =Not Trimmed/Add x =Reserved * Vector firmware 3.001 & later. Bit # Factory Default Bit Values For example, % selected, Max Frequency = 130, Speed Reference = 22 Hz, Trim Reference = 20%. 4.4 Hz will be added to the Speed Reference.
Reflected Wave The above figure shows the inverter line-to-line output voltage (top trace) and the motor line-to-line voltage (bottom trace) for a 10 HP, 460V AC inverter, and an unloaded 10 HP AC induction motor at 60 Hz operation. 500 ft. of #12 AWG cable connects the drive to the motor. Initially, the cable is in a fully charged condition. A transient disturbance occurs by discharging the cable for approximately 4ms.
Regen Power Limit Regen Power Limit Vector FV The [Regen Power Lim] is programmed as a percentage of the rated power. The mechanical energy that is transformed into electrical power during a deceleration or overhauling load condition is clamped at this level. Without the proper limit, a bus overvoltage may occur. When using the bus regulator [Regen Power Lim] can be left at factory default, – 50%.
S Curve 80.0 60.0 40.0 Hz 20.0 0.0 -20.0 -40.0 -60.0 -80.0 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 Seconds S-Curve Selection S-curve is enabled by defining the time to extend the acceleration and deceleration. The time is entered as a percentage of acceleration and deceleration time. In this case acceleration time is 2.0 seconds. The line on the left has s-curve set to 0%. The other lines show 25%, 50%, and 100% S-curve. At 25% S-curve acceleration time is extended by 0.5 seconds (2.0 * 25%).
S Curve Time to Max Speed Note that S-curve time is defined for accelerating from 0 to maximum speed. With maximum speed = 60 Hz, Ta = 2.0 sec, and S-curve = 25%, acceleration time is extended by 0.5 seconds (2.0 * 25%). When accelerating to only 30 Hz the acceleration time is still extended by the same amount of time. 70.0 60.0 50.0 Hz 40.0 30.0 20.0 10.0 0.0 0.0 0.5 1.0 1.5 Seconds 2.0 2.5 3.
Scale Blocks Scale Blocks See also Analog Scaling on page 22 and page 32. Vector Scale blocks are used to scale a parameter value. [Scalex In Value] is linked to the parameter that you wish to scale. [Scalex In Hi] determines the high value for the input to the scale block. [Scalex Out Hi] determines the corresponding high value for the output of the scale block. [Scalex In Lo] determines the low value for the input to the scale block.
Scale Blocks Parameter Settings Parameter [Trim In Select] [Scale1 In Hi] [Scale1 In Lo] [Scale1 Out Lo] [Scale2 In Hi] [Scale2 In Lo] [Scale2 Out Hi] [Scale2 Out Lo] Value 11, Preset 1 10.
Scale Blocks Parameter Links Destination Parameter [Scale1 In Value] Encoder Speed 415 Source Parameter [Encoder Speed] 477 Scale1 In Hi 476 Scale1 In Value 478 Scale1 In Lo Description We are scaling Encoder Speed Analog Out1 Hi 343 Scale1 Out Value 481 Analog Out1 Lo 344 = Link Analog Out1 Example Configuration #3 Scale1 In Value = Analog In2 Value (Volts) In this configuration Analog In 2 is a –10V to +10V signal which corresponds to –800% to +800% motor torque from another drive.
Shear Pin Fault This feature allows the user to select programming that will fault the drive if the drive output current exceeds the programmed current limit. As a default, exceeding the set current limit is not a fault condition. However, if the user wants to stop the process in the event of excess current, the Shear Pin feature can be activated.
Skip Frequency Skip Frequency Figure 31 Skip Frequency Frequency Command Frequency Drive Output Frequency (A) (A) Skip + 1/2 Band 35 Hz Skip Frequency 30 Hz Skip – 1/2 Band (B) 25 Hz (B) Time Some machinery may have a resonant operating frequency that must be avoided to minimize the risk of equipment damage. To assure that the motor cannot continuously operate at one or more of the points, skip frequencies are used.
Skip Frequency Skip Frequency Examples The skip frequency will have hysteresis so the output does not toggle between high and low values. Three distinct bands can be programmed. If none of the skip bands touch or overlap, each band has its own high/low limit. Max. Frequency Skip Frequency 1 Skip Band 1 Skip Frequency 2 Skip Band 2 0 Hz If skip bands overlap or touch, the center frequency is recalculated based on the highest and lowest band values. 400 Hz.
Sleep Mode Sleep Mode Operation The basic operation of the Sleep-Wake function is to Start (wake) the drive when an analog signal is greater than or equal to the user specified [Wake Level], and Stop (sleep) the drive when an analog signal is less than or equal to the user specified [Sleep Level]. Setting [Sleep-Wake Mode] to “Direct” enables the sleep wake function.
Sleep Mode Timers Timers will determine the length of time required for Sleep/Wake levels to produce true functions. These timers will start counting when the Sleep/Wake levels are satisfied and will count in the opposite direction whenever the respective level is dissatisfied. If the timer counts all the way to the user specified time, it creates an edge to toggle the Sleep/Wake function to the respective condition (sleep or wake).
Speed Control, Mode, Regulation & Vector Speed Feedback Figure 32 Sleep/Wake Function Drive Run Sleep-Wake Function Wake Up Go to Sleep Start Stop Sleep Timer Satisfied Sleep Level Satisfied Wake Timer Satisfied Wake Time Wake Level Satisfied Sleep Time Wake Time Sleep Time Wake Level Sleep Level Example Conditions Wake Time = 3 Seconds Sleep Time = 3 Seconds Analog Signal Speed Control, Mode, Regulation & Vector Speed Feedback The purpose of speed regulation is to allow the drive to adjust cer
Speed Control, Mode, Regulation & Vector Speed Feedback Open Loop As the load on an induction motor increases, the rotor speed or shaft speed of the motor decreases, creating additional slip (and therefore torque) to drive the larger load. This decrease in motor speed may have adverse effects on the process. If the [Speed Mode] parameter is set to “Open Loop,” no speed control will be exercised.
Speed Control, Mode, Regulation & Vector Speed Feedback original speed. Conversely, when the load is removed, the rotor speed increases momentarily until the slip compensation decays to zero. Motor nameplate data must be entered by the user in order for the drive to correctly calculate the proper amount of slip compensation. The motor nameplate reflects slip in the rated speed value at rated load.
Speed Control, Mode, Regulation & Vector Speed Feedback Application Example - Baking Line The diagram below shows a typical application for the Slip Compensation feature. The PLC controls the frequency reference for all four of the drives. Drive #1 and Drive #3 control the speed of the belt conveyor. Slip compensation will be used to maintain the RPM independent of load changes caused by the cutter or dough feed.
Speed Feedback Filter [Motor Fdbk Type] selects the type of encoder: • “Quadrature” – dual channel. • “Quad Check” – dual channel and detects loss of encoder signal when using differential inputs. • “Single Chan” – pulse type, single channel. • “Single Check” – pulse type, single channel and detects loss of encoder signal when using differential inputs. [Encoder PPR] sets the number of encoder pulses per revolution. [Enc Position Fdbk] displays the raw encoder count.
Speed Reference Speed Reference Operation The output frequency of the drive is controlled, in part, by the speed command or speed reference given to it.
Speed Reference DPI See the DPI on page 92 for a description of DPI. One of the DPI ports can be selected as the source of the speed reference. In the PowerFlex 70, 700, and 700VC the speed reference from DPI is scaled so that [Maximum Freq] = 32767. [Maximum Freq] is the largest output frequency that the drive will deliver to the motor. Additionally, the PowerFlex 70 and 700 drives have a parameter called [Maximum Speed].
Speed Reference Using the above formula, calculate the Speed Reference sent from a network using a DPI adapter. For example, to send out a command frequency of 60 Hz with [Maximum Freq] = 70 Hz, we would calculate the following: SpeedRef = 60 Hz 70 Hz x 32767 = 28086 Jog When the drive is not running, pressing the HIM Jog button or a programmed Jog digital input will cause the drive to jog at a separately programmed jog reference. This speed reference value is entered in [ Jog Speed], parameter 100.
Speed Reference For example, if the following parameters are set: [Analog In x Hi] = 10 V [Analog In x Lo] = 0 V [Speed Ref A Hi] = 45 Hz [Speed Ref x Lo] = 5 Hz then the speed command for the drive will be linearly scaled between 45 Hz at maximum analog signal and 5 Hz at minimum analog signal. See additional examples under Analog Inputs on page 22. Polarity The reference can be selected as either unipolar or bipolar. Unipolar is limited to positive values and supplies only the speed reference.
Speed Regulator through. This is due to the positive and negative minimum speeds. If the reference is positive and less than the positive minimum, it is set to the positive minimum. If the reference is negative and greater than negative minimum, it is set to the negative minimum. If the minimum is not 0, hysteresis is applied at 0 to prevent bouncing between positive and negative minimums. See below.
Speed/Torque Select value of zero. Units are (per unit torque) / (per unit speed). For example, when [Kp Speed Loop] is 20, the proportional gain block will output 20% motor rated torque for every 1% error of motor rated speed. Vector FV Feed Forward Gain The first section of the PI regulator is the feed forward block. [Kf Speed Loop] allows the speed regulator to be dampened during speed changes. To reduce speed overshoot, reduce the value of [Kf Speed Loop].
Speed/Torque Select As shown, [Speed/Torque Mod] (parameter 88) is used to select the mode of operation. Zero torque current is allowed when set to “0.” When set to a “1,” the drive/motor is operated in speed mode. The torque command changes as needed to maintain the desired speed. A value of “2” selects torque mode. In torque regulation mode, the drive controls the desired motor torque. The motor speed will be a result of the torque command and load present at the motor shaft.
Speed/Torque Select Figure 38 Scale 428 Ref A Hi 429 Ref A Lo Torque Ref A Sel 427 Torq Ref A Div 430 Torque Ref B Sel 431 Scale 432 Ref B Hi 433 Ref B Lo / x + Torq Ref B Mult 434 Torque Reference: [Torque Ref A Sel], parameter 427 is scaled by [Torque Ref A Hi] and [Torque Ref A Lo]. Then divided by [Torq Ref A Div]. [Torque Ref B Sel], parameter 431 is scaled by [Torque Ref B Hi] and [Torque Ref B Lo]. Then multiplied by [Torq Ref B Mult].
Speed/Torque Select Figure 39 Internal Torque Command At Speed Relay Load Step (Decrease) Speed Feedback 308 RPM Sum Mode Configuring the drive in this mode allows an external torque input to be summed with the torque command generated by the speed regulator. The drive requires both a speed reference and a torque reference to be linked. This mode can be used for applications that have precise speed changes with critical time constraints.
Speed Units Speed Units Vector [Speed Units] selects the units to be used for all speed related parameters. The options for [Speed Units] are: • “Hz” – converts status parameters only to Hz. • “RPM” – converts status parameters only to RPM. • “Convert Hz” - converts all speed based parameters to Hz, and changes the value proportionately (i.e. 1800 RPM = 60 Hz). • “Convert RPM” - converts all speed based parameters to RPM, and changes the value proportionately.
Start-Up Start-Up Start-Up Routines PowerFlex drives offer a variety of Start Up routines to help the user commission the drive in the easiest manner and the quickest possible time. PowerFlex 70 Drives have the S.M.A.R.T Start routine and a Basic assisted routine for more complex setups. PowerFlex 700 drives have both of the above plus an advanced startup routine. S.M.A.R.T. Start During a Start Up, the majority of applications require changes to only a few parameters.
Start-Up Figure 40 PowerFlex 70 & 700 Standard Control Option Startup HIM Basic Start Up (Top Level) Main Menu: Parameter Device Select Memory Storage StartUp Preferences Esc 0-2 Startup Drive active? Abort PowerFlex 70 StartUp . The drive must be stopped to proceed. Press Esc to cancel. Yes Any state 'Esc' key No Stop 0-3 Startup previously aborted? 7. Done /Exit Yes PowerFlex 70 StartUp .
Start-Up Figure 41 PowerFlex 70 & 700 Standard Control Option Startup (1) Basic Start Up (Input Voltage) 1-0 StartUp 1. Input Voltage This step should be done only when "alternate voltage" is needed (see user manual). It will reset all drive parameters with specific choice of Volts and Hz. Enter Backup Backup Rated Volts >300? Yes Backup No 1-2 1-1 StartUp 1. Input Voltage Enter choice for Input Supply 400V, 50 Hz <480V, 60 Hz> StartUp 1.
Start-Up Figure 42 PowerFlex 70 & 700 Standard Control Option Startup (2) 2-0 Basic Start Up (Motor Data/Ramp) StartUp 2. Motr Dat/Ramp Use motor nameplate data and required ramp times for the following steps. Enter 2-1 StartUp 2. Motr Dat/Ramp Enter choice for Mtr NP Pwr Units Enter 2-2 2-7 StartUp 2. Motr Dat/Ramp Enter value for Motor NP Power 123.4 kW xxx.x <> yyy.y StartUp 2. Motr Dat/Ramp Enter choice for Stop Mode A Backup Enter Enter 2-3 2-10 StartUp 2.
Start-Up Figure 43 PowerFlex 70 & 700 Standard Control Option Startup (3) 3-0 Basic Start Up (Motor Tests) Startup 3. Motor Tests This section optimizes torque performance and tests for proper direction. Enter 3-1 Startup 3. Motor Tests Complete these steps in order: B. Directn Test C. Done Go to 0-1 (4) Done Auto Tune 3-2 Startup A. AutoTune Rotate Tune only with no load and low friction. Static Tune when load or friction are present.
Start-Up Figure 44 PowerFlex 70 & 700 Standard Control Option Startup (4) 4-0 Basic Start Up (Speed Limits) StartUp 4. Speed Limits This section defines min/max speeds, and direction method Enter 4-1 4-2 StartUp 4. Speed Limits Disable reverse operation? Yes StartUp 4. Speed Limits Enter choice for Direction Method +/- Speed Ref No Yes Enter 4-3 Backup StartUp 4. Speed Limits Enter value for Maximum Speed +60.00 Hz xxx.xx <> yyy.
Start-Up Figure 45 PowerFlex 70 & 700 Standard Control Option Startup (5) Basic Start Up (Speed Control) 5-0 StartUp 5. Speed Control This section defines a source from which to control speed. Adapter 5-2 StartUp 5. Speed Control Enter choice for Input Signal Analog Input 1 Analog Input 2 5-1 StartUp 5. Speed Control Enter choice for Speed Control Comm Adapter Local HIM-Port 1 Remote HIM Preset Speeds MOP StartUp 5.
Start-Up Figure 46 PowerFlex 70 & 700 Standard Control Option Startup (6) 6-0 6-1 StartUp 6. Strt,Stop,I/O This section defines I/O functions including start and stop from digital ins StartUp 6. Strt,Stop,I/O Complete these steps in order: B. Dig Outputs C. Anlg Outputs D. Done Enter Basic Start Up (Start,Stop,I/O) D. Done Go to 6-24 C. Anlg Outputs A. Dig Inputs 6-2 Go to 0-1 (7) B. Dig Outputs 6-18 Enter/ Backup Go to 6-29 StartUp A.
Start-Up Figure 47 PowerFlex 70 & 700 Standard Control Option Startup (7) Basic Start Up (Start,Stop,I/O [2]) 6-24 Go to 6-1 (C) Done StartUp B . Dig Outputs Make a selection Digital Out 2 Done Digital Out 1 6-29 StartUp C. Anlg Outpts Enter choice for Analog Out 1 Sel Digital Out 2 Enter 6-25 6-30 6-27 StartUp B. Dig Outputs Enter choice for Digital Out 1 Sel StartUp B. Dig Outputs Enter choice for Digital Out 2 Sel StartUp C.
Start-Up Figure 48 PowerFlex 700 Vector Control Option Startup For first time powerup... HIM Select: Francais Espanol Deustch Italiano Main Menu: Parameter Device Select Memory Storage Start-Up Preferences Flux Vector Start Up (Top Level) Start-Up/Continue (disallow Start/Jog) Abort (allow Start/Jog) Esc (allow Start/Jog) Drive active? 0-0 PowerFlex 700 Start-Up . Startup consists of several steps to configure a drive for basic applications. 0-3 PowerFlex 700 Start-Up .
Start-Up Figure 49 PowerFlex 700 Vector Control Option Startup (1) Flux Vector Start Up (Motor Control Select) 1-31 1-1 B 1-0 Start-Up 1. Motor Control This section selects the type of Motor Control the drive will use. 1-2 B B = Basic mode Start-Up 1. Motor Control Make a selection <1.SVC> 2.V/Hz 3.Flux Vector 4.More info SVC- Set #53= 0 Flux Vector Start-Up SVC Enter choice of Speed Units RPM Frequency More info 1-18 1-17 Start-Up V/Hz Select a V/Hz control option: <1.V/Hz-Fan/Pump> 2.
Start-Up Figure 50 PowerFlex 700 Vector Control Option Startup (2) Flux Vector Start Up (Motor Dat/Ramp) 2-0 B Start-Up 2. Motr Dat/Ramp Use motor nameplate data and required ramp times for the following steps. 2-1 B Enter Enter Start-Up 2. Motr Dat/Ramp Enter value for Motor NP Volts 123.4 Volt xxx.x <> yyy.y Enter Start-Up 2. Motr Dat/Ramp Enter value for Motor NP Hertz 60.0 Hz x.x <> y.y 2-6 B Start-Up 2. Motr Dat/Ramp Enter Stop Mode: 1.Coast <2.Ramp> 3.Ramp to Hold 4.
Start-Up Figure 51 PowerFlex 700 Vector Control Option Startup (3) 3-0 3-22 Start-Up 3. Motor Tests This section optimizes motor performance and tests for proper direction. Flux Vector Start Up (Motor Tests) Start-Up 3. Motor Tests Select source of Start/Stop Local HIM-Port1 Remote HIM-Port2 3-21 If Digital Inputs:- Set #361/2 to START/STOP resp. If Local HIM:- Set #361/2 to Not Used & #90 to 18 3-1 Enter Start Inhibit param != 0 Note: - Fix Jog/Reference to 5 Hz.
Start-Up Figure 52 PowerFlex 700 Vector Control Option Startup (4) Flux Vector Start Up (Speed Limits) 4-0 Start-Up 4. Speed Limits This section defines min/max speeds and direction method B 4-1 Start-Up 4. Speed Limits Enter value for Maximum Speed +60.00 Hz xxx.xx <> yyy.yy B 4-2 Start-Up 4. Speed Limits Enter value for Minimum Speed +5.78 Hz xxx.xx <> yyy.yy B FOC Mode? Yes 4-3 No Go to 0-1 (5. Speed Control) 190 Start-Up 4. Speed Limits Enter value for Rev Speed Lim +5.78 Hz xxx.xx <> yyy.
Start-Up Figure 53 PowerFlex 700 Vector Control Option Startup (5) 5-0 Start-Up Flux Vector Mode? 5. Speed Control This section selects the speed/torque control source. Note: - Only Analog and Local HIM are displayed in 5-1 for Basic mode. Comm Adapter write to #90 (Ref A Sel) selection 5-2 Start-Up Comm Adapter Make a selection Port 2-common Port 3-external Port 4-external Go to 0-1 (6.Strt/ Stop/I/O) Yes No 5-1 Speed Start-Up 5. Speed Control Choose source of Reference: <1.
Start-Up Figure 54 PowerFlex 700 Vector Control Option Startup (6) Flux Vector Start Up (Strt,Stop,I/O) B 6-0 Start-Up 6. Strt,Stop,I/O This section defines I/O functions including Start and Stop. B = Basic mode 6-1 Start-Up 6. Strt,Stop,I/O Complete these steps in order: B.Dig Outputs C.Analog Outputs D.Done A. Dig Inputs 6-2 B. Dig Outputs Go to 6-27 C.Analog Output Go to 6-49 Enter/ Backup D. Done 6-19 More info Start-Up A.
Start-Up Figure 55 PowerFlex 700 Vector Control Option Startup (7) 6-27 Digital Out 1 6-28 Start-Up B. Dig Outputs Enter choice for Digital Out 1 Sel No Flux Vector Start Up (Start,Stop,I/O [2]) Start-Up B. Dig Outputs Make a selection Digital Out 2 Digital Out 3 Done Go to 6-1 (C.Anlg Inputs) Done 6-34 Digital Out 3 6-32 Start-Up C. Anlg Inputs Enter choice for Input Signal Analog Input 2 Start-Up B.
Start-Up Figure 56 PowerFlex 700 Vector Control Option Startup (8) 7-0 Start-Up Flux Vector Start Up (Application Functions) 7.Appl. Features This allows programming of additional drive features. 7-1 Start-Up 7.Appl Features Make a Selection Auto Restart Done 7-2 No Start-Up 7.Appl Features Enter choice for PI Reference 1 Analog In 1 7-3 Start-Up 7.Appl Features Enter choice for PI Feedback 1 Analog In 1 7-4 Start-Up 7.Appl Features Enter value for PI Setpoint 50.0% xx.x < yy.
Start-Up Figure 57 PowerFlex 700 Vector Control Option Startup (9) 8-0 Start-Up SMART Enter choice of Speed units: RPM Flux Vector Start Up (S.M.A.R.T.) 8-1 Start-Up SMART Enter value for Digital In 2 Sel 5 Start 8-2 Start-Up 2. Motr Dat/Ramp Enter choice for Stop Mode A Coast Ramp to Hold DC Brake 8-3 8-4 8-5 Start-Up SMART Enter value for Minimum Speed 0.0 Hz Start-Up SMART Enter value for Maximum Speed 60.0 Hz Start-Up SMART Enter value for Accel Time 1 10.
Start-Up Figure 58 PowerFlex 700 Vector Control Option Startup (10) 1-0 Flux Vector Start Up (Motor Control Select) 1-1 Start-Up 1. Motor Control This section selects the type of Motor Control the drive will use. Start-Up 1.
Stop Modes Stop Modes [Stop Mode A, B] [DC Brake Lvl Sel] [DC Brake Level] [DC Brake Time] 1. Coast to Stop - When in Coast to Stop, the drive acknowledges the Stop command by shutting off the output transistors and releasing control of the motor. The load/motor will coast or free spin until the mechanical energy is dissipated. Output Voltage Output Current Motor Speed Time Stop Command Coast Time is load dependent 2.
Stop Modes 4. Ramp To Stop is selected by setting [Stop Mode x]. The drive will ramp the frequency to zero based on the deceleration time programmed into [Decel Time 1/2]. The “normal” mode of machine operation can utilize [Decel Time 1]. If the “Machine Stop” mode requires a faster deceleration than desired for normal mode, the “Machine Stop” can activate [Decel Time 2] with a faster rate selected.
Stop Modes 5. Ramp To Hold is selected by setting [Stop Select x]. The drive will ramp the frequency to zero based on the deceleration time programmed into [Decel Time 1/2]. Once the drive reaches zero hertz, a DC Injection holding current is applied to the motor. The level of current is set in [DC Brake Level]. In this mode, the braking is applied Continuously. [DC Hold Time] has no effect in this mode. Braking will continue until one of the following events occur: – The Enable Input is opened, or . . .
Test Points Test Points Diagnostics UTILITY (File E) 234 [Testpoint 1 Sel] 236 [Testpoint 2 Sel] Default: Min/Max: Selects the function whose value is displayed value in Display: [Testpoint x Data]. These are internal values that are not accessible through parameters. See Testpoint Codes and Functions for a listing of available codes and functions. Default: 235 [Testpoint 1 Data] 237 [Testpoint 2 Data] Min/Max: 32 The present value of the function selected in [Testpoint Display: x Sel].
Torque Performance Modes Torque Performance Modes [Torque Perf Mode] or [Motor Cntl Sel] (Vector) selects the output mode of the drive. The choices are: • Custom Volts/Hertz Used in multi-motor or synchronous motor applications. • Fan/Pump Volts/Hertz Used for centrifugal fan/pump (variable torque) installations for additional energy savings. • Sensorless Vector Used for most general constant torque applications. Provides excellent starting, acceleration and running torque.
Torque Performance Modes were started across the line. As seen in the diagram below, the volts/hertz ratio can be changed to provide increased torque performance when required. The shaping takes place by programming 5 distinct points on the curve: – Start Boost - Used to create additional torque for breakaway from zero speed and acceleration of heavy loads at lower speeds – Run Boost - Used to create additional running torque at low speeds. The value is typically less than the required acceleration torque.
Torque Performance Modes The algorithms operate on the knowledge that motor current is the vector sum of the torque and flux producing components. Values can be entered to identify the motor values or an autotune routine can be run to interrogate and identify the motor values (see Autotune on page 40). Early versions required feedback, but today, performance is sensorless.
Torque Reference Figure 59 Flux Vector High Bandwidth Current Regulator CURRENT FEEDBACK Flux Reg. SPEED REF. V mag Current Reg. Speed Reg. TORQUE REF. Voltage Control Inverter Motor V ang Encoder SLIP Adaptive Controller AUTOTUNE PARAMETERS SPEED FEEDBACK Torque Reference Vector FV When the PowerFlex 700 Vector Control drive is operated in Torque mode, an external signal is used for a Torque reference. Refer to Figure 60.
Troubleshooting PowerFlex 700 Firmware 3.001 (& later) Enhancements Extra selections have been added to [Torque Ref A Sel] and [Torque Ref B Sel] in firmware version 3.001 (and later) for the PowerFlex 700 Vector Control drive: • Scale Block Output available as a selection • Torque Setpoint 2 is new and available as a selection Default: 1 1 Selects the source of the external torque reference to Options: the drive. How this reference is used is dependent FV upon [Speed/Torque Mod].
User Sets User Sets After a drive has been configured for a given application the user can store a copy of all of the parameter settings in a specific EEPROM area known as a “User Set.” Up to 3 User Sets can be stored in the drives memory to be used for backup, batch “switching” or other needs. All parameter information is stored. The user can then recall this data to the active drive operating memory as needed.
Voltage Class Voltage Class PowerFlex drives are sometimes referred to by voltage “class.” This class identifies the general input voltage to the drive. This general voltage includes a range of actual voltages. For example, a 400 Volt Class drive will have an input voltage range of 380-480VAC. While the hardware remains the same for each class, other variables, such as factory defaults, catalog number and power unit ratings will change.
Watts Loss Notes: 208 Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Index A Accel Mask 113 Accel Owner 126 Accel Time 11 Accel Time 1/2 11 Advanced Tuning 70 Alarm Queue 18 Alarm x Code 18 Alarms 15 Analog I/O 18 Analog I/O Cable Selection 28 Analog In Lo 22 Analog In1 Value 28 Analog In2 Value 28 Analog Inputs 18 Analog Out Scale 35 Analog Out1 Sel 31 Analog Out2 Sel 31 Analog Outputs 31 Analog Scaling 22 Anlg In 1, 2 Loss 26 Anlg In Config 16, 19 Anlg In Loss 17 Anlg In Sqr Root 26 Anlg Out Setpt 36 Auto / Manual 36, 167 Auto Restart 38 Auto Rstrt Delay 38 Auto Rstrt Trie
Index EMC Directive 63 EMC Instructions 63 Encoder 165 ESD, Static Discharge 10 Exclusive Ownership 125 F Fan Curve 100 Fault Clr Mask 113 Fault Configuration 103, 157 Fault Queue 101 Faults 101 Feedback Select 162 Flux Up 104 Flux Up Mode 104 Flying Start En 106 Flying Start Gain 106 Flying StartGain 106 Fuses 106 G General Precautions 10 Group Digital Inputs 71, 72 Digital Outputs 71, 88 Power Loss 130 Speed References 16 L Language 111 Language Parameter 111 Language Select, HIM 107 Linking Parameter
Index Parameters Accel Mask 113 Accel Owner 126 Alarm x Code 18 Analog In Hi 22 Analog In Lo 22 Analog In1 Value 28 Analog In2 Value 28 Analog Out Scale 35 Analog Out1 Sel 31 Analog Out2 Sel 31 Anlg In Config 16, 19 Anlg In Loss 17 Anlg In Sqr Root 26 Anlg Out Setpt 36 Auto Rstrt Delay 38 Auto Rstrt Tries 38 Bus Reg Gain 56 Bus Reg Mode A, B 56 Clear Fault Owner 126 Compensation 149 Current Lmt Sel 19, 157 Decel Mask 113 Decel Owner 126 Dig Out Setpt 91 Dig Outx Level 89 Dig Outx OffTime 90 Dig Outx OnTime
Index Speed Units 176 Speed/Torque Select 172 Start Inhibits 176 Start Mask 113 Start Owner 126 Start Permissives 176 Start/Stop, Repeated 120 Start-Up 177 Static Discharge, ESD 10 Stop Mode A, B 197 Stop Modes 197 Stop Owner 126 Sum Mode 175 T Terminal Designations 29 Test Points 200 Testpoint 1 Sel 200 Testpoint x Data 200 Thermal Manager Protection 97 Thermal Regulator 200 Torque Performance Modes 201 Torque Ref x Sel 205 Torque Reference 204 Torque Regulation Mode 173 Torque Setpoint2 205 Trim 28 Trim
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