Reference Manual PowerFlex 700S AC Drives Phase II Control Firmware Revisions 1.xxx...4.
Important User Information Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices.
Summary of Changes This manual contains new and updated information. New and Updated Information This table contains the changes made to this revision. Topic Page Removed content of previous Chapter 1 - Specifications and Dimensions. See the PowerFlex 700S AC Drives, Phase II Control Technical Data, publication 20D-TD002 for the most current specifications and drive dimension information.
Summary of Changes 4 Rockwell Automation Publication PFLEX-RM003E-EN-E - January 2011
Table of Contents Summary of Changes New and Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Chapter 1 Detailed Drive Operation Accel Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Input Status Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inertia Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Breakers/Fuses . . . . . . . . . . .
Table of Contents Noise Filtering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Virtual Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Electronic Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Output Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Point to Point Motion Planner . . . . . . . . .
Table of Contents Ride Through Timeout Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precharge Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precharge Timeout Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Precharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precharge Staging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Speed Reference Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Stop Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Accel/Decel Ramp and S-Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Speed Reference Bypass and Delayed Speed Reference. . . . . . . . . . . 149 Inertia Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Index Configuring the Start and Stop for 2-Wire Control (Maintained Start and Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Stop Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 SynchLink . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents 12 Rockwell Automation Publication PFLEX-RM003E-EN-E - January 2011
Chapter 1 Detailed Drive Operation This chapter explains PowerFlex 700S drive with Phase II control functions and application programming in detail. Explanations are organized alphabetically by topic. Refer to the Table of Contents for a listing of all topics in this chapter. ATTENTION: Only qualified personnel familiar with the PowerFlex 700S Drive and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system.
Chapter 1 Detailed Drive Operation Configuration Parameters 365 [Fdbk LsCnfg Pri] through 399 [Position ErrCnfg] program the response of the drive to various conditions. Responses include Ignore, Alarm, Fault Coast Stop, Fault Ramp Stop, and Fault Current Limit Stop. Parameters 326 [Alarm Status 1] through 328 [Alarm Status 3] identify any alarms that are active. Configuration Example Parameter 376 [Inv OL Pend Cnfg] is set to a value of 1 “Alarm”.
Detailed Drive Operation Chapter 1 Parameters 804, 810, and 816 [Al x Filt Gain] and parameters 805, 811, and 817 [Anlg Inx Filt BW] are used to filter the analog input data. Refer to Lead-Lag Filter on page 50 for detailed information.
Chapter 1 Detailed Drive Operation Analog Input Loss Detection Signal loss detection can be enabled for each analog input. Parameters 1093, 1094 and 1095 [Anlg InxLossCnfg] 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.
Detailed Drive Operation Analog Outputs Chapter 1 Analog Output Specifications There are two analog outputs, differential, configurable for +/-10V or 0…20 mA. The D/A (digital to analog) converter is 11 bits plus the sign bit. Analog Output Configuration Parameters 831 and 838 [Anlg Outx Sel] are use to specify the signal used on Analog Outputs 1 and 2, respectively.
Chapter 1 Detailed Drive Operation Anlg Out1 DInt 832 Anlg Out1 Real 833 + + Analog I/O Units (AO1 Current) Dflt = 18 Anlg Out1 Sel 831 Anlg Out1 Offset Anlg Out1 Scale 821 16 Selector X 834 835 + Limit + D/A 12bit + TB1-09 TB1-10 836 10 [x] Anlg Out1 Zero 837 Anlg Out1 Value 1 [x] Example Configuration 1: This configuration sends the motor torque current reference value to a 0…10V analog output signal.
Detailed Drive Operation Autotune Chapter 1 Auto-tuning is a procedure that involves running a group of tests on the motor/ drive combination. Some tests are checking the drive hardware while others configure the drive parameters to maximize the performance of the attached motor. The auto-tuning procedure can be done using the Start-Up menu on the HIM. Autotune - Start-Up Menu The Start-Up menu prompts the user for information and yes/no responses as required.
Chapter 1 Detailed Drive Operation Feedback Configuration The Feedback Configuration submenu asks you to select the feedback device type. Possible selections are “Encoder 0,” “Encoder 1,” “Aux Speed,” “Motor Sim,” or “Option Card.” Encoder 0 and Encoder 1 are for the encoders on the I/O board. When “Encoder 0” or “Encoder 1” are selected, you must also enter the encoder PPR. “Motor Sim” is to simulate a motor when there is no motor connected to the drive.
Detailed Drive Operation Chapter 1 For Field Oriented Control the following motor tests are performed: Autotune Slip Test The Slip Frequency test allows the drive to establish the slip frequency of the motor. This value is displayed in parameter 486 [Rated Slip Freq]. The test runs the motor at 85% for frames 1…6 drives and near 50% for frames 9 and up drives. The test repeats three times.
Chapter 1 Detailed Drive Operation Troubleshooting a “MC Commissn Fail” Fault during Autotune The “MC Commissn Fail” fault (23) occurs when either the Power Circuits diagnostics test fails or one of the Motor Tests fails. To find out specifically why the fault occurred, before clearing the fault, check the bits in the following parameters: 463 [MC Diag Error 1], 464 [MC Diag Error 2], or 465 [MC Diag Error 3].
Detailed Drive Operation Chapter 1 Dynamic braking uses a 7th insulated gate bipolar transistor (IGBT) and braking resistor to dissipate regenerative energy. The drive switches the 7th IGBT on and off to keep the DC bus voltage at or below the DC bus voltage reference. Parameters in the PowerFlex 700S drive specify whether the resistor is an internal or external resistor. When an external resistor is used, you can enter the resistance value in parameter 544 [External DB Res].
Chapter 1 Detailed Drive Operation Set parameter 414 [Brake/Bus Cnfg] for your configuration.
Detailed Drive Operation Chapter 1 resistor vendor as the energy rating (in Joules) or a 1 second power rating (in Watts) with typical values in the range of 30 to 100 times higher than the resistor’s continuous power rating. • Parameter 416 [Brake PulseWatts] = (Resistors peak energy in Joules)/1 s; where the resistor package’s peak energy rating is obtained from the resistor manufacturer.
Chapter 1 Detailed Drive Operation Parameter 418 [Brake TP Sel] selects a value to monitor for diagnostics of the dynamic brake protection. Parameter 419 [Brake TP Data] displays the data selected in parameter 418 [Brake TP Sel]. Possible selections for parameter 418 [Brake TP Sel] are: Par 418 [Brake TP Sel] Setting Description 0 - “Zero” Do not monitor any test point for the brake protection.
Detailed Drive Operation Chapter 1 Cable Trays and Conduit Refer to the Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives Installation Instructions, publication DRIVES-IN001, for detailed information. Carrier (PWM) Frequency See the PowerFlex 700S AC Drives, Phase II Control Technical Data, publication 20D-TD002, for derating guidelines as they travel to carrier frequency. Parameter 402 [PWM Frequency] sets the carrier frequency.
Chapter 1 Detailed Drive Operation undesirable effects of higher switching frequencies include derating ambient temperature vs. load characteristics of the drive, higher cable charging currents and higher potential for common mode noise. A very large majority of all drive applications will perform adequately at 2…4 kHz.
Detailed Drive Operation Chapter 1 Datalinks: In the ControlLogix system, Datalinks are transmitted as DInt. In order to send or receive Real (floating-point) parameters a COP (copy) instruction must be utilized. The copy instruction in ControlLogix performs a bitwise copy. Set the length of the copy instruction to a value appropriate for the destination data type. Example to write a floating point Datalink: Parameter 125 [Torque Pos Limit] sets the positive torque limit for the motor.
Chapter 1 Detailed Drive Operation 6. The tag “PF700S_P303_MotorTorqueRef ” contains the value of parameter 303. Explicit Messaging: When using explicit messaging on DeviceNet, ControlNet, or Ethernet in the ControlLogix system, the message type CIP Generic is used. The data is transferred over ControlNet in the same data type as the parameter in the PowerFlex 700S.
Detailed Drive Operation Chapter 1 to transmit references more than base motor speed and less than twice base motor speed. The feedback is also scaled so that base motor speed = 32767. The PLC can only handle 16-bit integers, so the feedback has to be handled differently to account for references above 32767 or below -32768. The following example shows how to read feedback values more than base motor speed and less than twice base motor speed.
Chapter 1 32 Detailed Drive Operation Rockwell Automation Publication PFLEX-RM003E-EN-E - January 2011
Detailed Drive Operation Chapter 1 Datalink Programming Datalinks are transmitted and received through messages on Ethernet, ControlNet or DeviceNet and through block transfers on RIO. The PLC and SLC are limited to 16-bit integers and floating point. In order to send or receive floating point Datalinks we have to swap the LSW and MSW and utilize the COP (copy) instruction. Because the PLC and SLC do not support 32-bit integers, 32-bit Datalinks remain split into (2) 16-bit integers.
Chapter 1 Detailed Drive Operation Figure 5 - Reading Floating Point Datalinks in an SLC or PLC 5. Figure 6 - Writing Floating Point Datalinks in an SLC or PLC 5. Copy Cat 34 This feature allows you to upload a complete set of parameters to the LCD HIM. This information can then be used as backup or can be transferred to another drive by downloading the memory in the HIM. Generally, the transfer process manages all conflicts.
Detailed Drive Operation Current Limit Chapter 1 The following methods are available for a drive to use to protect itself from an overcurrent or overload condition. • Instantaneous Over Current Trip - This is a feature that instantaneously trips or faults the drive if the output current exceeds this value. The value is fixed by hardware and is typically 250% of drive rated amps. This feature cannot be disabled. • Software Over Current Trip - This is a configurable trip function.
Chapter 1 Detailed Drive Operation “Data In” Parameters Parameters 651 [DPI Data In A1] through 658 [DPI Data In D2] are inputs to the drive from the controller and are used to write to parameters. To write to a parameter, that parameter must be linked to one of parameters 651 through 659. Then set the appropriate bit in parameter 650 [DPI In DataType] to indicate if that parameter is a DInt (double integer) or Real (floating point). Turn the bit off for DInt and turn the bit on for floating point.
Detailed Drive Operation Decel Time Chapter 1 Parameter 33 [Decel Time 1] sets the rate at which the drive ramps down its output during a ramp Stop command or during a decrease in commanded speed.
Chapter 1 Detailed Drive Operation Digital Input Configuration Parameter 825…830 [Dig Inx Sel] can be set to the following values: 0 1 2 3 4 5 6 7 8 9 10 11 12 13 “Not Used” “Enable” “Clear Faults” “Ext Fault” “Norm Stop-CF” “Start” “Reverse” “Run” “Reserved” “Reserved” “Jog 1” “Reserved” “Reserved” “Jog 2” 14 15 16 17 18 19 20 21 22 23 24 25 26 27 “Normal Stop” “Spd Ref Sel0” “Spd Ref Sel1” “Spd Ref Sel2” “CurLim Stop” “Coast Stop” “AccelDecel2” “Indx Step” “Indx StpRev” “MOP Inc” “MOP Dec” “MOP Reset
Detailed Drive Operation Chapter 1 High Speed Digital Inputs: Local I/O Status [DigIn 1] 824 01 SynchLink Prt0/1 RegisCnfg 08 09 10 11 Bit Filter 823 Debounce 01 02 Dig In1 Sel Selector 825 DigIn Debounce 03 04 05 Standard Digital Inputs: Local I /O Status 823 11 12 Debounce DigIn Debounce 13 14 824 03 Dig In3 Sel 827 Selector 15 Digital Input Status Bits Parameter 824 [Local I/O Status] bits 1 through 6 give the status of the digital inputs.
Chapter 1 Detailed Drive Operation Digital Output Configuration Parameters 845 and 850 [Digital Outx Sel] can be set to the following settings: 0 1 2 3 4 5 6 7 8 9 “User Select” “Not Fault” “Not Alarm” “Ready” “Running” “Reserved” “Reserved” “Enable On” “Active” “At Speed” 10 11 12 13 14 15 16 17 18 19 “At Setpt 1” “Above Setpt 2” “At ZeroSpeed” “Speed Limit” “CurrentLimit” “Torque Limit” “Power Limit” “Fault” “Alarm” “Command Dir” 20 21 22 23 24 25 26 27 28 “Actual Dir” “Jogging” “In Position” “Posi
Detailed Drive Operation Chapter 1 Digital Output On/Off Delay Timers Each digital output has two user-controlled timers associated with it. One timer (the On timer) defines the delay time between a False to True transition (condition appears) on the output condition and the corresponding change in state of the digital output.
Chapter 1 Detailed Drive Operation bits. The following chart explains the effect that the direction button on the HIM has based on the condition of the “Bipolar SRef ” bit: Bipolar SRef Reference Controlled by HIM? HIM Direction Button Action Enabled Yes Changes the motor direction due to a HIM supplied (+) or (-) command signal. Enabled No Has no effect on motor direction. Direction determined by sign of Par 40 [Selected SpdRef].
Detailed Drive Operation Chapter 1 Client/Server C/S messages operate in the background (relative to other message types) and are used for non-control purposes. The C/S messages are based on a 10 ms “ping” event that allows peripherals to perform a single transaction (in other words, one C/S transaction per peripheral per time period). Message fragmentation (because the message transaction is larger than the standard CAN message of eight data bytes) is automatically handled by C/S operation.
Chapter 1 Detailed Drive Operation All the timing requirements specified in the DPI system, Control, and Messaging specifications are supported. Peripheral devices will be scanned (“pinged”) at a 10 ms rate. Drive status messages will be produced at a 5 ms rate, while peripheral command messages will be accepted (by the drive) as they occur (i.e. change of state).
Detailed Drive Operation Chapter 1 • During Flash mode, host stops ping, but still supports status/command messages at a 1…5 second rate. drive will use 1 second rate. Data transfer occurs via explicit message as fast as possible (i.e. peripheral request, host response, peripheral request, etc.) but only between two devices. The MUT, is based on the message type only. A standard command and Datalink command could be transmitted from the same peripheral faster than the MUT and still be O.K.
Chapter 1 Detailed Drive Operation than the motor current limit. After a period of time (typically 1 to 3 minutes), the function returns the limit to the short term rating. Closed Loop IT Function The drive will also adjust the torque current limit level based on the values in Parameter 358 [Cur Ref TP Data], parameter 313 [Heatsink Temp] and the thermal characteristics of the drive contained in the power EE memory.
Detailed Drive Operation Droop Chapter 1 Droop is used to “shed” load and is usually used when a soft coupling of two motors is present in an application. The master drive speed regulates and the follower uses droop so it does not “fight” the master. The input to the droop block comes from the torque output of the speed regulator before limiting. The output of the droop block reduces the speed reference.
Chapter 1 Detailed Drive Operation Electronic Gearing See Position Loop - Follower (Electronic Gearing) on page 90 Faults Faults occur due to conditions within and/or outside the drive that could affect drive operation or application operation. These events or conditions are considered to be of significant magnitude that drive operation should or must be discontinued. Faults are reported to the user via the HIM, communications and/ or contact outputs.
Detailed Drive Operation Chapter 1 Nomenclature Symbol s ω ωco Description of Symbol Laplace Operator Frequency Cut-off Frequency Units radians/sec radians/sec Low Pass Filter A low pass filter is designed to pass low frequencies and attenuate high frequencies. The break point between high and low is called the cut off frequency.
Chapter 1 Detailed Drive Operation Figure 8 - Second Order Low Pass Filter Bode Diagram Magnitude (dB) 0 -10 System: sys Frequency (rad/sec): 9.85 Magnitude (dB): -5.91 -20 -30 -40 -50 Frequency Phase (deg) 0 -45 -90 -135 -180 0 10 1 10 2 10 Frequency (rad/sec) There is a second order low pass filter in the Speed Control-Regulator. This filter is located after the speed error signal. The break frequency is set by parameter 89 [Spd Err Filt BW].
Detailed Drive Operation Chapter 1 Figure 9 - Kn < 1 “Lag Filter” gain 1 “Lag” (kn <1) kn w (rad/sec) wn wn kn Figure 10 below shows the bode plot of the lag configuration. Kn is set to 0.7 and Wn is set to 35 radians/second. The time domain shows a 100 radians/second sinusoidal input. Notice that the phase shift between input and output are marginal. Figure 10 - Bode Plot and Time Domain of Lag The lag configuration is good for eliminating unwanted noise and disturbance such as backlash.
Chapter 1 Detailed Drive Operation Lead-Lag Filter “Lead” When Kn is greater than one (Kn>1), the lead-lag filter operates as lead filter. The original equation is re-written into a term that can be used to utilize the lead function. Wn is divided throughout the equation. Two new terms are developed. The lead term (Wld) is used to display the lead of the filter. The lag term (Wlg) is used to show the lag of the filter.
Detailed Drive Operation Chapter 1 Figure 12 - Lead Filter Added to System Figure 12 above shows the results of adding the lead-lag. The system had a response of 5 radians/second. By adding the lead-lag filter the system response was increased to 50 radians/second. There is lead-lag filter for the position loops speed reference. The parameters are Kn=Parameter 25 [STrim2 Filt Gain], Wn=Parameter 26 [SpdTrim2 Filt BW].
Chapter 1 Detailed Drive Operation The resonant frequency is defined by the following equation: resonance = ( Jm + Jload ) Kspring × --------------------------------Jm × Jload • Jm is the motor inertia (seconds). • Jload is the load inertia (seconds). • Kspring is the coupling spring constant (rad2/sec). Figure 14 below shows a two mass system with a resonant frequency of 62 radians/second. One Hertz is equal to 2π radians/second.
Detailed Drive Operation Chapter 1 Figure 15 - 10 Hz Notch Conclusion There are several filters used in the PowerFlex 700S for various applications. The process trim uses a simple low pass filter to eliminate undesirable noise in the feedback circuit. The cut off frequency of the low pass filter is set by parameter 184 [PI Lpass Filt BW]. Typical values would range from 15…20 radians/second. The speed loop uses a second order low pass filter after the speed error term is developed.
Chapter 1 Detailed Drive Operation To use the lead function: 1. Set Wld equal to the desired lead in radians/second 2. Set Wlg equal to 5x Wld 3. Wn=Wlg 4. Kn=Wlg/Wld The torque reference has a notch filter used to eliminate resonance signals. The notch frequency is set by parameter 118 [Notch Filt Freq]. This frequency is set to the mechanical resonance in hertz. Firmware Functions Parameter 147 [FW Functions En] allows the user to enable and display firmware functions in the drive.
Detailed Drive Operation Chapter 1 The flying start function works by using the voltage feedback from the motor to determine the speed of the motor. When the speed is determined, the drive provides flux up time for the motor. Then the drive begins ramping the motor to the commanded speed from the speed determined by the voltage feedback. This process will prevent an overcurrent trip and significantly reduce the time for the motor to reach its desired frequency.
Chapter 1 Detailed Drive Operation Example: [FricComp Setup] = 524 means: 5 time steps between stick and slip, each of 0.002 sec. duration, 2 counts of hysteresis or 0.001 pu_speed (each count is 0.0005 pu speed), and 4 counts or 0.002 pu_speed is the trigger threshold (each count is 0.0005 pu speed). Parameter 66 [FricComp Stick] sets the torque reference needed to break away from zero speed. Breakaway torque due to friction is always greater than running torque due to friction.
Detailed Drive Operation HIM Operations Chapter 1 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 1. Press the Up Arrow or Down Arrow to scroll to Operator Intrfc. Press Enter. Key(s) Operator Intrfc: Change Password User Display Parameters 2. Press the Up Arrow or Down Arrow to scroll to User Display. Press Enter. 3.
Chapter 1 Detailed Drive Operation Position Control (BscIndx Prst) 740 14 OR Power up (BscIndx Step) 740 12 (BscIndxStpRv) 740 15 (BscIndx Rev) 740 13 OR Position Control 740 OR 1 X -1 BasicIndx Step 797 BasicIndx Preset 798 11 (BscIndx Enbl) + + 799 BasicIndx Output Configuring the Indexer Parameter 797 [BasicIndx Step] sets the position units for each indexer step.
Detailed Drive Operation Chapter 1 Controlling the Indexer from a Network or DriveLogix: Toggle parameter 740 [Position Control] bit 12 “BscIndx Step” to index forward. Toggle 740 [Position Control] bit 15 “BscIndxStpRv” to index reverse. [Position Control] can be controlled by from a network by using a Datalink. Refer to Datalinks on page 35 for details. [Position Control] can be controlled from DriveLogix by linking it to one of the FromDriveLogix words (parameters 602 to 622).
Chapter 1 Detailed Drive Operation Configuration See Speed PI Regulator - Advanced Tuning for the Speed Regulator with Gearbox or Belt on page 160 for details on using inertia adaption.
Detailed Drive Operation Chapter 1 The inertia compensation outputs the calculated torque to the parameter 59 [Inertia Trq Add]. [Inertia Trq Add] is summed with the output of the friction compensation block and the torque generated by the speed reference loop. That summed torque enters the torque selection block (refer to Torque Reference on page 193 for more information). Parameter 55 [Speed Comp] contains the rate of acceleration or deceleration calculated in the inertia compensation block.
Chapter 1 Detailed Drive Operation IT Protection The drive’s IT protection dictates the amount of overload capacitors and duty cycle. Ratings are in the tables listed below. Figure 16 shows expected times. Figure 16 - IT Curve 10000000.0 1000000.0 100000.0 Time (sec) 10000.0 1000.0 100.0 10.0 0% 15 0% 14 0% 13 0% 12 11 4% 2% 11 0% 11 8% 10 6% 10 4% 10 10 2. 5% 1.0 Current (%) Current (%) 150 145 140 135 130 125 120 115 114 113 112 111 110 109 108 107 106 105 104 103 102.
Detailed Drive Operation Jog Chapter 1 A jog reference is usually used to run the motor at some preset, low speed. Two separate jog speeds can be used as a speed reference - parameter 29 [ Jog Speed 1] or parameter 39 [ Jog Speed 2]. A jog could be initiated by a Digital Input, by the Logic Command word from a DPI adapter such as a HIM, or by the Logic Command word from DriveLogix.
Chapter 1 Links Detailed Drive Operation Links are software connections between two parameters. This allows one parameter to receive information from another parameter. Parameter Type Source Description Provides information Destination Receives information Parameter Symbol Source Dest. Each destination parameter can only have one source parameter. However, source parameters may be linked to multiple destination parameters.
Detailed Drive Operation Chapter 1 Using DriveExecutive To link parameters using DriveExecutive, complete the following steps. 1. Double-click on the destination parameter in the parameter list. The parameter XX edit dialog box displays. 2. Click the Link Source tab. 3. Click the Parameter radio button and select the desired source parameter in the Selected Parameter field.
Chapter 1 Masks Detailed Drive Operation A mask is a parameter that contains one bit for each of the possible DPI ports and adapters. Each bit acts like a valve for issued commands. Closing the valve (setting a bit value to 0) stops the command from reaching the drive. Opening the valve (setting a bit value to 1) allows the command to pass through the mask into the drive. Table 1 - Mask Parameters and Functions Parameter Name [Write Mask] No.
Detailed Drive Operation Motor Control Mode Chapter 1 Parameter 485 [Motor Ctrl Mode] selects the type of motor control to use. This parameter is set during the HIM assisted startup when asked to select the motor control mode. The settings for Parameter 485 [Motor Ctrl Mode] are • 0 “FOC” selects field oriented control. Field oriented control is used with AC squirrel cage induction motors for high performance.
Chapter 1 Detailed Drive Operation Permanent Magnet Control Permanent magnet motor control is selected by setting parameter 485 [Motor Ctrl Mode] = 2 “Pmag Motor”. Permanent magnet motor control requires a HiResolution Stegmann encoder, Heidenhain encoder, or compatible resolver feedback on the motor. Refer to the PowerFlex 700S AC Drive Phase II Control Frames 1…6 Installation Instructions, publication 20D-IN024, for a list of compatible Hi-Resolution Stegmann encoders and resolvers.
Detailed Drive Operation Chapter 1 4. Parameters 1 [Motor NP Volts] and 3 [Motor NP Hertz] set the upper portion of the curve to match the motor design and mark the beginning of the constant horsepower region. 5. Parameters 531 [Maximum Voltage] and 532 [Maximum Freq] slope that portion of the curve used above base speed. Maximum Voltage Motor NP Volts Break Voltage Start/Acc Boost Run Boost Break Frequency Motor Nameplate Motor NP Hertz Maximum Freq Parameter Name [Motor NP Volts] No.
Chapter 1 Detailed Drive Operation Motor Overload The overload capability applies to the rated speed range. Normal Duty After continuous operation at the rated output current, overload may be 110% rated output current (IL) for 1 minute as long as it is followed by a period of load less than the rated current so that the output current over the duty cycle does not exceed the rated output current (IL).
Detailed Drive Operation Chapter 1 of 60 minutes, the remaining 59 minutes must be at approximately 98% rated current or less. Motor Overload Memory Retention Per 2005 NEC The PowerFlex 700S drive with Phase II control (firmware 3.01 and higher) has the ability to retain the motor overload count at power down per the 2005 NEC motor overtemperature requirement. • To enable motor overload memory retention, set bit 20 “Motor OL Ret” of parameter 153 [Control Options] to “1”.
Chapter 1 Detailed Drive Operation Motor Start and 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.
Detailed Drive Operation Output Devices Chapter 1 Drive Output Disconnection ATTENTION: Any disconnecting means wired to the drive output terminals U, V and W must be capable of disabling the drive if opened during drive operation. If opened during drive operation, the drive will continue to produce output voltage between U, V, and W. An auxiliary contact must be used to simultaneously disable the drive. PowerFlex 700S Phase II drives can be used with an output contactor between the drive and motor.
Chapter 1 Detailed Drive Operation Output Display Output Current (Parameter 308) This parameter displays the measured RMS drive output current. Parameter 297 [Output Curr Disp] is the integer equivalent of parameter 308 with a resolution of 1/10 amperes. Output Freq (Parameter 310) This parameter displays the actual output frequency of the drive.
Detailed Drive Operation Chapter 1 Example 2: The drive is configured as a torque follower. If the mechanical connection to the load is severed, the torque command to the drive will probably be greater than the motor unloaded will require to maintain the system speed. This will cause the motor speed to increase until the torque command is met.
Chapter 1 Detailed Drive Operation For example, the operator presses the Stop button on the Local HIM to stop the drive. When the operator attempts to restart the drive by pressing the HIM Start button, the drive does not restart. The operator needs to determine why the drive will not restart.
Detailed Drive Operation Peak Detect Chapter 1 There are two peak detectors that can be used to detect the peak for a parameter value. Configuration: • Link parameter 212 [PkDtct1 In DInt] or 213 [PkDtct1 In Real] to the parameter for which you want to detect a peak value, depending on the data type. • To detect positive peak values, set parameter 210 [PeakDtct Ctrl In], bit 2 “Peak1SelHigh” = 1. To detect negative peak values, set parameter 210 [PeakDtct Ctrl In], bit 2 “Peak1SelHigh” = 0.
Chapter 1 Detailed Drive Operation Example: • Link parameter 213 [PkDtct1 In Real] to parameter 300 [Motor Spd Fdbk]. • Verify that parameter 210 [PeakDtct Ctrl In], bit 0 “Peak 1 Set” and bit 1 “Peak 1 Hold” are set to 0. • For parameter 210 [PeakDtct Ctrl In], set bit 2 “Peak1SelHigh” = 1. • Parameter 215 [PeakDetect1 Out] will contain the positive peak value of [Motor Spd Fdbk]. • To reset the output of the peak detector, for parameter 210 [PeakDtct Ctrl In], toggle on and then off bit 0 “Peak 1 Set”.
Detailed Drive Operation Chapter 1 drives. The PLL is used in conjunction with SynchLink, the speed loop, and the position loop in order to synchronize drives together in an ELS system.
Chapter 1 Detailed Drive Operation Feed Forward Low Pass Filter Parameter 730 [PLL LPFilter BW] specifies the bandwidth of the speed feed forward low pass filter in units of radians/second. Setting this parameter to zero (0) bypasses filtering. One use of the filter is to better time the feed-forward and reference encoder signals when parameter 728 [PLL Ext Spd Ref ] is linked to the master drive’s speed reference (a master drive is one that controls the PLL encoder).
Detailed Drive Operation Chapter 1 Base RPM Scaling The PLL, in addition to providing position reference, provides a speed reference to the drive as a feed forward. This is normal operating practice to secure zero position error and optimal tracking of the follower drive. The RPM setting in parameter 727 [PLL VirtEncdrRPM] determines 1 per unit speed output from the PLL. The setting should be logical, i.e. represent either base line speed or base motor speed.
Chapter 1 Detailed Drive Operation the position reference of the follower drives. Parameter 735 [PLL SpeedOut Adv] provides a position reference that is advanced by one scan time of the drive’s control loop. [PLL SpeedOut Adv] should be sent over SynchLink to the follower drives and linked into the follower drives’ speed reference.
Detailed Drive Operation Chapter 1 Note: making parameter 727 [PLL VirtEncdrRPM] = 1200 will scale PLL speed to a pu system based on rated line speed. This makes sense because there is no common base RPM of the motors given their different ratios. Further analysis shows that a 2048 line encoder provides adequate resolution for unit to folder registration and it is easy to install. The line encoder will be wired to encoder 1.
Chapter 1 Detailed Drive Operation Synchlink. Refer to Position Loop - Follower (Electronic Gearing) on page 90 for details on setting up the speed and position loop. • Adjust parameter 730 [PLL LPFilter BW] for the best overall performance. Point to Point Motion Planner This function allows the drive to execute point to point position moves using a trapezoidal or S-curve profile. Adjustments can be made to the acceleration, deceleration and S-curve times.
Detailed Drive Operation Chapter 1 Table 4 - Parameter 1134 Bit 0 “Absolute” and Bit 1 “Incremental” Settings Bit 1 Incremental 0 Bit 0 Absolute 0 0 1 1 0 1 1 Description of Operation Default mode Bit 2 “Start” of parameter 1135 [PPMP Status] is not used in this mode. The commanded position from the scale block is noted, call it value X. The drive then takes the difference between any new commanded input and value X and then adds that difference to the exiting position. I.e.
Chapter 1 Detailed Drive Operation Figure 20 - Point to Point Motion Planner Block Diagram PPMP Control (Over Ride En) 1134 PPMP Control (Scaling En) 1134 8 5 1134 PPMP Over Ride PPMP Rev Spd Lim PPMP Fwd Spd Lim 1136 1137 PPMP Scaled Cmd PPMP Control (Pause) 1138 1133 4 0 1 PPMP Pos Command 1130 PPMP Pos Mul 1131 PPMP Pos Div 1132 X X X 1144 PPMP Pos To Go 1142 PPMP Spd Output 1143 PPMP Pos Output / Scale FW Functions En (MotinPlanner) 147 19 Logic Command (Position En) 1
Detailed Drive Operation Chapter 1 Position Output Example: A material handling application uses the PPMP to move the materials from one position to another.
Chapter 1 Detailed Drive Operation Position Loop - Follower (Electronic Gearing) General facts about using the Position Loop for follower applications: • Parameter 768 [PositReg P Gain] is used for tuning. • Parameter 770 [PositReg Integ] is normally not needed for position following applications and is disabled by factory default. • The number of position counts per revolution depends on the type of feedback device used: – When using an encoder for positioning, the drive uses quadrature counts, i.e.
Detailed Drive Operation Chapter 1 The following is a block diagram overview of the position follower mode: Spd Ref Bypass2 Spd Reg Droop Preset Speed 2 Preset Speed 3 Preset Speed 4 Preset Speed 5 Preset Speed 6 Preset Speed 7 Speed Reference Selection For the position following mode to work properly, there needs to be a feed forward speed reference for the speed loop of the drive to follow.
Chapter 1 Detailed Drive Operation Speed Reference Ramp The speed reference ramp should be disabled when using the drive as a position follower. To disable the speed reference ramp, set parameter 151 [Logic Command], bit 0 “SpdRamp Dsbl” = 1. Enabling the Position Loop The firmware function for the position loop must be turned on by setting parameter 147 [FW Functions En] bit 16 “PositionCtrl” = 1. To enable the position loop, set parameter 151 [Logic Command], bit 13 “Position En” = 1.
Detailed Drive Operation Chapter 1 Setting the Electronic Gear Ratio and Speed Reference Scaling The position reference can be scaled by using the Electronic Gear Ratio (EGR) scaling. Parameters 745 [PositRef EGR Mul] and 746 [PositRef EGR Div] are used to scale the position reference. 744 Selected Position Reference Δ [N] [D] Deriv PositRef EGR Out Geared Position Reference Gear Rat PositRef EGR Mul 745 PositRef EGR Div 746 Example: In this example the encoders are mounted on the motors.
Chapter 1 Detailed Drive Operation Parameter 13 [Spd Ref2 Multi] is calculated: [Spd Ref2 Multi] = Ratiof 4 = =4 Ratiom 1 Notice that the encoder PPRs should not be included in the calculation for [Spd Ref2 Multi]. [Spd Ref2 Multi] is rounded to the 4th decimal place. The position loop gear ratios will be exact, so that the follower tracks at 4 times the master's speed. Position Offset Offsets can be added to the position reference.
Detailed Drive Operation Chapter 1 Parameter 776 [XReg Spd HiLim] sets the positive speed limit at which the position regulator will output. The default is set to +10% of the base motor speed. In position follower, the position loop only needs to trim the speed a small amount because the drive is setup to follow the master speed reference. Therefore, [XReg Spd LoLim] and [XReg Spd HiLim] can be left at the defaults.
Chapter 1 Detailed Drive Operation Position Loop - In Position Detect The In Position Detection determines if parameter 769 [Position Error] is within a user defined value. Parameter 769 [Position Error] is the result of parameter 747 [Position Cmmd] - parameter 762 [Position Fdbk].
Detailed Drive Operation Chapter 1 loop can be scaled to different units other than feedback counts, for example, degrees or inches. Typical applications for the point to point function would be turn tables and storage retrieval machines.
Chapter 1 Detailed Drive Operation Position Reference Scaling Position reference can be entered in user units by using the EGR scaling. Parameters 745 [PositRef EGR Mul] and 746 [PositRef EGR Div] are used to scale the position reference.
Detailed Drive Operation Chapter 1 of feedback because it is added to the position reference after the EGR scaling. Offsets must be maintained to keep the position. For example, if you enter 300 in the offset, the position loop will move 300 counts extra. If you zero the offset command, the motor will return to the previous position. When it is necessary to zero the offset after a move without returning to the previous position, set parameter 740 [Position Control], bit 5 “X Off ReRef ” = 1.
Chapter 1 Detailed Drive Operation Typically parameter 768 [PositReg P Gain] should be set between 1/5th to 1/3rd of parameter 90 [Spd Reg BW]. Parameter 768 [PositReg P Gain] may be set higher using lead compensation on the Position Regulator output. Lead-Lag filtering of the position regulator output is accomplished via the Speed Trim 2 filter.
Detailed Drive Operation Chapter 1 Absolute Point to Point Positioning: The Point to Point positioning mode may be configured to operate in an absolute mode. The absolute mode allows the point to point position regulator to remain active at all times, even when the drive is stopped and restarted. An absolute feedback device such as a Stegmann Hi-Resolution encoder can also be used in absolute mode in order to retain position feedback during power loss.
Chapter 1 Detailed Drive Operation Bit Swap 1 BitSwap 1A Data 0= 860 0= 861 Bit Swap 2 BitSwap 2A Data BitSwap 1 Result Bit Swap 865 Link 864 1= BitSwap 1A Bit Local I/O Status 824 Local I/O Status 862 824 3= Link Bit Swap 3 874 BitSwap 3A Bit Local I/O Status 824 1022 01 02 03 04 Link SelSwtch In00 0 1029 SelSwtch In01 1 1030 BitSwap 3B Data Link Selector Switch Sel Swtch Ctrl BitSwap 3 Result Bit Swap 871 868 BitSwap 2B Bit BitSwap 3A Data 2= 872 5= Link 867 4= 863 870
Detailed Drive Operation Chapter 1 Bit Swap 2 Setup: • Link parameter 865 [BitSwap 2A Data] to parameter 864 [BitSwap 1 Result]. Parameter 865 [BitSwap 2A Data] sets up any data you would like to pass through to the result and is linked to the result from bit swap 1. • Set parameter 866 [BitSwap 2A Bit] = 1. Parameter 866 [BitSwap 2A Bit] sets the bit that you would like to turn on in the result and is set to bit 1 in order to use bit swap 2 to turn on bit 1 of parameter 1022 [Sel Switch Ctrl].
Chapter 1 Detailed Drive Operation Position Loop - Position Watch The position watch is used to determine when the position feedback reaches a user defined value. There are two (2) position watches in the PowerFlex 700S. Position Actual 763 Posit Detct1 In Link 784 Position Control (X Watch 1 En) (X Watch 1 Dir) 740 16 740 17 PositDetct1 Stpt 741 08 Position Status (Posit Watch1) Position Watch 1 780 Parameter 784 [Posit Detct1 In] sets the position feedback that you would like to watch.
Detailed Drive Operation Chapter 1 • When parameter 240 [Encdr1 Position] becomes greater than 100,000 counts, parameter 741 [Position Status], bit 8 “Posit Watch1” is set to 1. Note that the position must pass 100,000 counts. If the motor position is already past 100,000 counts when the position watch is enabled, the position watch status bit will not detect the position until 100,000 counts is passed again.
Chapter 1 Detailed Drive Operation Table 6 - Trigger Source Settings for Encoder 0 Bit 2 0 0 1 1 Bit 1 0 1 0 1 Description Encoder 0 Z-pulse AND Ext Trig A Ext Trig B (Digital Input 2) Ext Trig A (Digital Input 1) Encoder 0 (Primary Encoder) Z phase Note: When the Z-pulse is selected as a trigger source, registration latch port 0 is used for Encoder 0 regardless of the setting of bit 0 “RL0 Encoder1”.
Detailed Drive Operation Chapter 1 • Parameter 237 [RegisLtch0/1 Ctrl] configures the control for registration latch 0 and 1. – Set bit 0 “RL0 Arm Req” or 16 “RL1 Arm Req” to arm the registration logic for the next trigger event. The particular latch will be armed and ready to be strobed on the next occurrence of the trigger input. – Set bit 1 “RL0DisarmReq” or 17 “RL1DisarmReq” to disarm the registration logic for next trigger event.
Chapter 1 Detailed Drive Operation • To arm the registration again, set parameter 237 [RegisLtch0/1Ctrl], bit 0 “RL0 Arm Req” = 1 to arm the registration. Parameter 238 [RegisLtch0/ 1Stat], bit 0 “RL0 Armed” will be set to 1 again and bit 1 “RL0 Found” will be set back to 0 until digital input 1 turns on again. Note: To disarm the registration if it has not been found you can set parameter 237 [RegisLtch0/1Ctrl], bit 1 “RL0DisarmReq” = 1.
Detailed Drive Operation Chapter 1 • Parameter 255 [Opt0/1 RegisCtrl] configures the registration control on port 0 and port 1 of the feedback option card. – Set bit 0 “O0 Arm Req” or bit 16 “O1 Arm Req” to arm the registration logic for the next trigger event. The particular latch will be armed and ready to be strobed on the next occurrence of the trigger input. – Set bit 1 “O0 DisarmReq” or bit 17 “O1 DisarmReq” to disarm the registration logic for next trigger event.
Chapter 1 Detailed Drive Operation restart allows the drive to continue normal operation by applying power to the motor again. This operation is intended to protect the drive from excessive inrush currents in the presence of input AC line disturbances and allow the drive to continue normal operation without user intervention. However, there is also a concern for safe auto-restart operation.
Detailed Drive Operation Chapter 1 Ride Through Operation An incoming power loss to the drive is detected by a 22% drop in bus voltage or a bus voltage that drops below the undervoltage level (as determined in parameter 408 [Power Loss Level] - see table below). The return of incoming power is detected by an 11% rise in bus voltage and a bus voltage level greater than the undervoltage level set in parameter 409 [Line Undervolts].
Chapter 1 Detailed Drive Operation down occurs (extended power loss). If the power loss duration is very short or there is sufficient input impedance to limit the inrush current when power returns, the drive will continue normal operation after the disturbance passes. However, if the power returns causing a large inrush current (precharge device is still bypassed) drive damage is likely.
Detailed Drive Operation Chapter 1 1. A user-controlled precharge enable must be present. The precharge enable can be provided by a hardware input or parameter configuration. When one of the digital input selection parameters (825…830 [Dig Inx Sel]) is set to 30 “PreCharge En”, the hardware precharge control is selected and the digital input controls the user precharge enable.
Chapter 1 Detailed Drive Operation 5. The drive precharge delay must be completed. After conditions 1 through 4 above are met, the time delay set in parameter 472 [PreCharge Delay] must be completed before the precharge device bypass is commanded. If any of the above conditions become false during the precharge delay period, the delay timer is reset. If parameter 472 [PreCharge Delay] is set less than 200 ms, then an internal 200 ms delay is used.
Detailed Drive Operation Chapter 1 Settings for parameter 381 [PreChrg Err Cnfg]: 0 “Ignore”: This setting disables the precharge timeout fault. In this case the drive ignores condition three of the precharge operation (described on page 112) so that the drive does not check for an unstable bus voltage. Therefore, after the precharge timeout period the precharge control will complete precharge, providing all of the other conditions for precharge are met.
Chapter 1 Detailed Drive Operation Precharge Staging Parameter 472 [PreCharge Delay] can be used in conjunction with a precharge enable (see condition one in Precharge Operation on page 112) to coordinate the precharge operation of a group of drives. Typical uses may include common bus or shared bus applications.
Detailed Drive Operation Process PI Loop The drive has a process PI loop that can be used to trim speed, torque, or other functions.
Chapter 1 Detailed Drive Operation The output of the integrator is limited by parameters 188 [PI Integ HLim] and 189 [PI Integ LLim]. [PI Integ HLim] is in per unit and has a range from 0…8. A value of 1 for [PI Integ HLim] can represent base motor speed, rated motor torque, or 100% of some external function. The output of the integrator after the integrator limits can be viewed in parameter 190 [PI Integ Output]. Parameter 186 [PI Prop Gain] sets the proportional gain of the regulator.
Detailed Drive Operation Chapter 1 Pulse Elimination Technique (PET) See Reflected Wave below. Reflected Wave Parameter 510 [FVC Mode Config], bit 9 “ReflWaveComp” enables reflected wave compensation. The pulses from a PWM inverter using IGBTs are very short in duration (50 ns…1 ms). These short pulse times combined with the fast rise times (50…400 ns) of the IGBT, will result in excessive overvoltage transients at the motor.
Chapter 1 Detailed Drive Operation cable transient. Thus, the second pulse arrives at a point in the motor terminal voltage's natural response and excites a motor overvoltage transient greater than 2 p.u. The amplitude of the double-pulsed motor overvoltage is determined by a number of variables. These include the damping characteristics of the cable, bus voltage, and the time between pulses, the carrier frequency, modulation technique, and duty cycle.
Detailed Drive Operation Security Chapter 1 The security feature provides write access protection for individual communication ports in a drive. The PowerFlex 700S Phase II drive must be firmware version 3.003 or higher in order to support this feature. In addition, the following drive peripherals and software tools support the security feature: Communication Peripherals • • • • 20-COMM-E EtherNet/IP v2.002 (or higher) 20-COMM-C/-Q ControlNet v2.001 (or higher) 20-COMM-D DeviceNet v2.
Chapter 1 Detailed Drive Operation Sensorless Operation Sensorless mode is used when zero speed or more than a 120:1 speed range is not required. The drive is set for sensorless operation when parameter 485 [Motor Ctrl Mode] is set to 0 “FOC” and parameter 222 [Mtr Fdbk Sel Pri] = 2 “Sensorless”.
Detailed Drive Operation Chapter 1 Sensorless Operation in Frames 9 and Up Drives In some installations with frames 9 and up drives it may be necessary to increase parameter 501 [Torque En Dly] if faults occur when the drive is started. Parameter 501 [Torque En Dly] is used to delay the torque command to the motor until a preset time to flux up the motor has completed. Note: The actual delay is twice the value of parameter 501 in firmware prior to v3.001.
Chapter 1 Detailed Drive Operation If the commanded speed of the drive is greater than or equal to the skip (center) speed and less than or equal to the high value of the band (skip plus 1/2 band), the drive will set the output speed to the high value of the band. See example A in Table 14 on page 125. If the commanded speed is less than the skip (center) speed and greater than or equal to the low value of the band (skip minus 1/2 band), the drive will set the output speed to the low value of the band.
Detailed Drive Operation Chapter 1 Table 14 - Skip Speed Examples A The skip speed 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. Fwd Speed Limit Skip Speed 1 Skip Band 1 Skip Speed 2 Skip Band 2 0 RPM B If skip bands overlap or touch, the center speed is recalculated based on the highest and lowest band values.
Chapter 1 Detailed Drive Operation Slip Compensation Note: Slip compensation is only active when the motor feedback is set to sensorless mode or parameter 485 [Motor Ctrl Mode] = 3 “V/Hz.” 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.
Detailed Drive Operation Chapter 1 original speed. Conversely, when the load is removed, the rotor speed increases momentarily until slip compensation declines to zero. The amount of slip added to the speed command is displayed in parameter 107 [Slip RPM Meter]. Slip compensation also affects the dynamic speed accuracy (ability to maintain speed during “shock” loading). The effect of slip compensation during transient operation is illustrated in Figure 22 below.
Chapter 1 Detailed Drive Operation Speed/Position Feedback The speed feedback block selects the feedback device and scales the feedback signal. This section will describe in detail how each of these functions operates. Feedback Device Parameter 222 [Mtr Fdbk Sel Pri] selects the primary feedback device for motor speed and position feedback.
Detailed Drive Operation Chapter 1 Parameters 232 [Encoder0 PPR] and 242 [Encoder1 PPR] set the pulse per revolution rating of the encoders. These parameters have a range from 10 to 20000 PPR.
Chapter 1 Detailed Drive Operation • Bit 7 “Enc0 EdgTime” or bit 23 “Enc1 EdgTime” configures the method of sampling used by the Velocity Position Loop (VPL). Setting the bit chooses “Edge to Edge” sampling, while resetting the bit to zero chooses “Simple Difference” sampling. “Simple Difference” sampling calculates speed by examining the difference between pulse counts over a fixed sample time.
Detailed Drive Operation Chapter 1 Parameter 234 [Encdr 0/1 Error] indicates the status of the encoder when there is an error. The encoder blocks generate position feedback, seen in parameter 230 [Encdr0 Position] or parameter 240 [Encdr1 Position]. Encoder position is in quadrature counts (the drive counts 4x the encoder PPR per motor revolution). The encoder blocks generate speed feedback, seen in parameter 231 [Encdr0 Spd Fdbk] and parameter 241 [Encdr1 Spd Fdbk].
Chapter 1 Detailed Drive Operation FIR Filter The recommended setting for the FIR filter is eight taps when parameter 146 [FW TaskTime Sel] is set to 0 or 1 (0.5ms for task 1). When parameter 146 [FW TaskTime Sel] is set to 2 (0.25 ms for task 1) the recommended setting for the FIR filter is 16 taps. This sets the noise bandwidth for 120 radians/second.
Detailed Drive Operation Chapter 1 Motor Simulator The simulator mode allows the drive to be operated without a motor connected and is meant for demo purposes only. If a motor is connected with this mode selected, very erratic and unpredictable operation will occur. Parameter 228 [MtrSpd Simulated] contains the simulated speed feedback. Parameter 229 [MtrPosit Simulat] contains the simulated position feedback.
Chapter 1 Detailed Drive Operation Parameter 253 [FB Opt1 Spd Fdbk] contains the speed feedback from the linear sensor when the MDI option card is installed.
Detailed Drive Operation Chapter 1 • Bits 10…12 “SmplRate btx” configure the sample interval for measuring speed (see Table 18 below). Increasing the encoder sample interval improves speed measurement near zero speed. Decreasing allows the speed control regulator to perform with high gains at high speeds. • The remaining bits are reserved (not used).
Chapter 1 Detailed Drive Operation • Bits 10…12 “SmplRate btx”, configure the sample interval for measuring speed (see Table 22 below). Increasing the encoder sample interval improves speed measurement near zero speed. Decreasing allows the speed control regulator to perform with high gains at high speeds.
Detailed Drive Operation Chapter 1 The following are the possible resolver settings: Par 277 Par 272 [Reslvr0 Type Sel] [Reslvr0 SpdRatio] 0 - Disabled 1 1 -T2014/2087x1 1 2 -T2014/2087x2 2 3 -T2014/2087x5 5 4 - MPL 460v 5 - Reserved 6 - Siemens 1FT6 1 1 1 7 - PrkrHn ZX600 1 8 - Reserved 9 - 1326Ax 460v 10 - Reserved 11 - Reserved 12 - Reserved 13 - Reserved 14 - AmciR11XC107 15 - PowerTec R1 16 - PowerTec R1 1 1 1 1 1 1 1 – – Par 273 Par 274 Par 275 [Reslvr0 Carrier] [Reslvr0 In Volts] [Reslvr0
Chapter 1 Detailed Drive Operation • Bit 4 “Energized” indicates the resolver is energized. • Bit 8 “Open Wire” indicates a problem with the cable (open circuit). • Bit 9 “Power Supply” indicates problem with the option card's power supply. • Bit 10 “Diag Fail” indicates the option card has failed its power-up diagnostics. • Bit 11 “Select OK” Resolver Cable Tuning Tests Three tests are performed for resolver cable tuning.
Detailed Drive Operation Chapter 1 Virtual Encoder Output to the Heidenhain Option Card With firmware version 4.001 you can program the Heidenhain feedback option for a scalable virtual encoder output. The virtual encoder output can be taken from the speed reference section or linked to other feedback parameters and be scaled to the desired EPR. The following parameters provide this functionality.
Chapter 1 Detailed Drive Operation Examples: 1. A Quad B output of Heidenhain feedback 2048 PPR from each rotation of the virtual encoder. • Set parameter 61 [Virt Encoder EPR] = 1048576 • Link parameter 1155 [Heidn VM Pos Ref ] to parameter 1160 [VirtEncPositFast] • Set parameter 266 [Heidn Encdr Type], bit 6 “VrtlMasterEn” = 1 • Set parameter 1156 [Heidn VM Enc PPR] = 2048 2. A Quad B output of Heidenhain feedback 2048 PPR from each rotation of Encoder0 input.
Detailed Drive Operation Chapter 1 Parameter 72 [Scaled Spd Fdbk] provides a user scalable speed feedback. It is multiplied by the value in parameter 73 [Spd Fdbk Scale]. Motor Spd Fdbk to Speed Control 300 To HIM Display Scaled Spd Fdbk Filter X 72 LPass 73 Spd Fdbk Scale Position Feedback Parameter 777 [PositionFdbk Sel] selects the position feedback device for the position control loop.
Chapter 1 Detailed Drive Operation The drive determines that the encoder has faulted based on a combination of hardware detection and monitoring the rate of change of the motor speed. The hardware fault detection is based on illegal encoder states and improper encoder switching patterns. The rate of change of motor speed detection is determined by a rate of change greater than a user-defined speed change.
Detailed Drive Operation Chapter 1 Parameter 155 [Logic Status], bit 12 “Tach Loss Sw”, shows which speed feedback device is currently active. A value of “0” in bit 12 indicates that the primary speed feedback device selected in [Mtr Fdbk Sel Pri] is active. A value of “1” in bit 12 indicates that the alternate speed feedback device selected in [Mtr Fdbk Sel Alt] is active. Parameter 222 [Mtr Fdbk Sel Pri] selects the primary speed feedback device.
Chapter 1 Detailed Drive Operation Speed Feedback Loss Ride Through Configuration Setting up the feedback loss ride through function requires the following steps: 1. Enter a valid feedback device selection in parameter 222 [Mtr Fdbk Sel Pri]. 2. Enter a valid feedback device selection in parameter 223 [Mtr Fdbk Sel Alt]. Default value is 2 “Sensorless”. 3. Set parameter 365 [Fdbk LsCnfg Pri] to 1 “Alarm”. 4. Set parameter 366 [Fdbk LsCnfg Alt] to 2 “FltCoastStop” (recommended but not necessary). 5.
Detailed Drive Operation Chapter 1 Manual Speed Feedback Device Switching Parameter 151 [Logic Command], bit 2 “TackLoss Rst”, provides a manual switch between active and non-active primary or alternate speed feedback devices with a “0” to “1” bit transition. Resetting bit 2 from a “1” to a “0” causes no change in operation. The switch is from the active feedback device (either primary or alternate) to the non-active feedback device.
Chapter 1 Detailed Drive Operation Figure 23 - Selected Speed Reference Applied LogicCmd 152 Applied LogicCmd 28 29 30 152 18 152 23 Selected Speed Ref 0 Speed Reference A 1 Speed Reference B Preset Speed 2 15 Preset Speed 3 16 Preset Speed 4 17 Preset Speed 5 18 Preset Speed 6 19 Preset Speed 7 20 2 0 Jog Speed 1 29 Jog Speed 2 39 0 40 1 1 3 4 5 6 7 Parameter 27 [Speed Ref A Sel] and parameter 28 [Speed Ref B Sel] determine the source of Reference A and B.
Detailed Drive Operation Chapter 1 Parameter 11 [Spd Ref1 Divide] and parameter 13 [Spd Ref2 Multi] are linkable parameters. This allows speed reference 1 and 2 to be scaled “dynamically” with an input signal if desired. An example would be to have an analog input linked to the scale parameter. The speed reference and the scale would then affect the value sent to the reference select block.
Chapter 1 Detailed Drive Operation Stop Command When a stop command is issued, parameter 157 [Logic Ctrl State], bit 0 “Spd Ref En” is set to “0”, causing a zero speed to be selected. When [Logic Ctrl State], bit 0 is set to “1” the selected speed or jog reference is used. Accel/Decel Ramp and S-Curve Parameter 32 [Accel Time 1] sets the acceleration time in seconds from 0 speed to the speed in parameter 4 [Motor NP RPM].
Detailed Drive Operation Chapter 1 half to the end of the ramp (as shown in the example below). The result of the Scurve block can be seen in parameter 43 [Ramped Spd Ref ]. Speed Time in Seconds 0.5 sec. 0.5 sec. Accel Time = 5.0 seconds S Curve Time = 1.0 second Total Ramp Time = 6.0 seconds Speed Reference Bypass and Delayed Speed Reference By default, parameter 37 [Spd Ref Bypass] is linked to parameter 43 [Ramped Spd Ref ].
Chapter 1 Detailed Drive Operation Friction Compensation The friction compensation block is used to calculate breakaway torque and the torque required to keep the motor running at a constant speed due to friction. For more information on friction compensation, see Friction Compensation on page 57. Virtual Encoder The virtual encoder can be used as a position master for position follower applications (see Position Loop - Follower (Electronic Gearing) on page 90 for details on position control).
Detailed Drive Operation Chapter 1 Speed Reference Filter A lead-lag filter for the selected speed reference can be turned on by setting parameter 153 [Control Options] bit 1 “SRef LdLg En” = “1”. Parameter 35 [SpdRef Filt Gain] sets the gain for the filter and parameter 36 [SpdRef Filt BW] sets the bandwidth for the filter. For more information on lead/lag filters see Lead-Lag Filter on page 50.
Chapter 1 Detailed Drive Operation Speed PI Regulator The drive takes the speed reference specified by the speed reference control loop and compares it to the speed feedback. The speed regulator uses proportional and integral gains to adjust the torque reference sent to the motor. This torque reference attempts to operate the motor at the specified speed. This regulator also produces a high bandwidth response to speed command and load changes.
Detailed Drive Operation Chapter 1 The speed trim values are summed with the speed reference from the speed reference control loop. Autotune Speed Reference During the inertia test, the autotune speed reference is used instead of the output of the speed trim summation. Parameter 74 [Atune Spd Ref ] sets the speed for the inertia test.
Chapter 1 Detailed Drive Operation Current Limit Stop When a current limit stop is commanded, parameter 157 [Logic Ctrl State], bit 6 “CurrLim Stop” is set. Then a zero speed reference command is sent into the speed regulator, bypassing the ramp and speed trim. Logic Ctrl State (CurrLim Stop) 157 06 0 from Speed Limits 0 to Speed Error 1 Speed Error The summed speed reference becomes parameter 301 [Motor Speed Ref ].
Detailed Drive Operation Chapter 1 normally be set to less than 1/3 speed regulator bandwidth, or for the desired response. Set [Servo Lock Gain] to zero to disable servo lock. + from Speed Error Filter to Speed Gains + ks s ServoLck 85 Servo Lock Gain Speed Regulator Gains The speed regulator gains determine the response of the speed regulator. See Basic Tuning with a Gear Box or Belt on page 158 for speed regulator tuning guidelines.
Chapter 1 Detailed Drive Operation However, it will exhibit some over-shoot and under-shoot. Increasing the value of [SpdReg AntiBckup] decreases the over-shoot and under-shoot, which is desirable where back-up cannot be tolerated. However, this tends to increase the following error: This parameter has no affect on the drive's response to load changes. The recommended setting is 0.1 to 0.5. The following is an example of how the anti-backup affects the speed regulator’s response.
Detailed Drive Operation Chapter 1 Integral Gain The speed droop is subtracted from the filtered speed error (after the servo lock is added and the anti-backup is subtracted). This signal is then sent to the integral gain block. The integral gain block outputs a torque command relative to the error integrated over a period of time. Parameter 82 [Spd Reg I Gain] sets the integral gain of the speed regulator.
Chapter 1 Detailed Drive Operation Speed Regulator Output Filter Once the proportional and integrator blocks are summed, the torque reference goes through a lead/lag filter, tuned by parameters 95 [SRegOut FiltGain] and 96 [SReg Out Filt BW]. For more information on lead/lag filters refer to Lead-Lag Filter on page 50. Parameter 157 [Logic Ctrl State] bit 8 “Spd Reg En” indicates when the speed regulator is enabled.
Detailed Drive Operation Chapter 1 where Hp is the nameplate horsepower of the motor and RPM is the base motor speed of the motor. System Inertia (parameter 9) is determined by performing the inertia test with the load coupled, or the value (in seconds) can be calculated using the formulas above if WK2 is known for the system. 2. Set the desired bandwidth in parameter 90 [Spd Reg BW]. Do not exceed the bandwidth limit of curve 1 on page 160 (based on the ratio of motor inertia to system inertia). 3.
Chapter 1 Detailed Drive Operation Advanced Tuning for the Speed Regulator with Gearbox or Belt When using a system with a gearbox or belts, the backlash or lost motion can cause instability. However, a feature called inertia adaption can compensate for backlash or lost motion. Follow the steps below to use inertia adaption: 1. Identify motor and system inertia (in seconds).
Detailed Drive Operation Chapter 1 3. Set parameter 133 [Inert Adapt BW] = parameter 90 [Spd Reg BW]. 4. Verify that the Lead-Lag filters are off: parameter 93 [SRegFB Filt Gain] =1 and parameter 95 [SReg Out Filt Gain] =1 to disable the filters. 5. Enable inertia adaption, parameter 132 [Inert Adapt Sel] bit 0 “Inrtia Adapt” = 1. 6. Enable the drive and adjust the bandwidth (BW) for the application but do not exceed curve 2 shown below.
Chapter 1 Detailed Drive Operation Figure 25 - Firmware Flowchart 110 Spd/TorqueMode Spd Reg PI Out [5H4] Logic Ctrl State (Forced Spd ) from Speed Control 302 Inertia Trq Add [4H5] 0 + 59 + 157 10 1 0 2 1 + 69 FricComp Trq Add [4G4] 0 Min 3 1 Max Torque Ref 1 111 Torque Ref 1 Div 112 Torque Ref 2 113 Torque Ref 2 Mult 114 Torque Trim 115 Selected Trq Ref + 319 5 / + X 4 + + + + Abs Min + 6 Torque Step 116 7 Speed Error Slat Min 100 Filter 89 [5C4] 2nd Orde
Detailed Drive Operation Chapter 1 “Sum” mode is selected when [Speed/TorqueMode] is set to a value of “5”. This mode allows an external torque command to be added to the speed regulator output when desired. “Absolute Min” mode is selected when [Speed/Torque Mode] is set to a value of “6”. This mode selects the smallest absolute algebraic value to regulate to when the torque reference and torque generated from the speed regulator are compared.
Chapter 1 Detailed Drive Operation Torque Regulation Mode A torque regulated application can be described as any process requiring some tension control. An example is a winder or unwinder with material being “drawn” or pulled with a specific tension required. The process also requires that another element set the speed. Configuring the drive for torque regulation requires parameter 110 [Speed/TorqueMode] to be set to 2 “Torque Ref ”. In addition, a reference signal must be linked to the torque reference.
Detailed Drive Operation Chapter 1 minimum is to operate as a torque regulator. While operating in torque regulation, the load decreases and the motor speeds up. Notice the torque command has not changed. When the speed regulator comes out of saturation, it clamps the speed and now the drive operates as a speed regulator. The “At Speed” relay then closes.
Chapter 1 Detailed Drive Operation SLAT Minimum Mode In SLAT minimum mode, you would typically configure a speed reference that forces the speed regulator into saturation (the speed reference is slightly above the speed feedback). In this case the drive would follow the torque reference until there was a breakage or slippage in the application.
Detailed Drive Operation Chapter 1 P119 SLAT Error Setpoint Speed Error < 0 P120 SLAT Dwell Time Low Pass Filter Off On Forced Speed Mode (FSM) Speed Error > SLAT Setpoint for SLAT Time FSM State Controller FSM = On Application Dependant Speed Reference Bias + - Speed Error PI Regulator Speed Regulator Output (SRO) Min Select Internal Torque Reference (ITR) Off Motor Speed Feedback External Torque Reference (ETR) Rockwell Automation Publication PFLEX-RM003E-EN-E - January 2011 167
Chapter 1 Detailed Drive Operation Paper Winder Application Example: The drive is set for SLAT minimum mode, so that the drive normally runs in torque mode and follows parameter 111 [Torque Ref1]. Torque reference 1 comes from an external controller and is approximately 60% of motor torque during the snapshot (seen below). The speed reference, also from an external controller, is set just above the speed feedback in order to saturate the speed regulator while in torque mode.
Detailed Drive Operation Chapter 1 • The speed error becomes positive (the speed feedback becomes less than the speed reference). This is forced speed mode. By forcing the drive to enter speed mode, the transition occurs earlier than it would have in the maximum torque mode, resulting in less velocity overshoot. Parameter 119 [SLAT ErrorSetpnt] and parameter 120 [SLAT Dwell Time] allow you to set some hysteresis for turning off the forced speed mode.
Chapter 1 Detailed Drive Operation Standalone Drive Homing without DriveLogix Overview Many positioning applications require the ability to find the “Home” position of the positioning device when an absolute device is not present. The ability to use the Homing feature without a DriveLogix processor has been added in firmware version 3.003. The Homing feature will home to a switch or an encoder marker.
Detailed Drive Operation IMPORTANT Chapter 1 Do not set bit 24 in [Position Control] when a digital input is programmed for “Find Home”. 3. When the drive is started, it will run at the commanded value of [Home Speed]. 4. When the “Home Switch”, connected to a digital input, transition occurs capturing the position, the drive decelerates to zero speed. 5. The drive moves back to the position captured at the switch transition. 6.
Chapter 1 Detailed Drive Operation 6. When the move to the “Found” position is complete, the following occurs: • bit 15 “Homed” of parameter 741 [Position Status] is set, • bit 13 “HomeRequired” of [Position Status] is turned off, • For firmware version 4.001 only, the value stored in parameter 1123 [Home Position] is transferred to parameter 763 [Position Actual], setting the Actual Position to a desired value for absolute moves from home, and • the drive holds position and zero speed. 7.
Detailed Drive Operation Chapter 1 Configuration Homing Type Parameter 740 [Position Control] is used to configure the type of homing to be used. Parameter 740 is also used to command a “Find Home”. Table 24 - Parameter 740 [Position Control] Bits Bit Name 24 Find Home 26 Home Dir 28 29 Description When this bit is on and the drive is started, a homing sequence will be initiated. When this bit is set, the homing direction will be opposite of the Home Speed commanded in parameter 1122 [Home Speed].
Chapter 1 Detailed Drive Operation Home Switch Selection • Parameters 825 [Dig In1 Sel] and 826 [Dig In2 Sel] are available to be set as the Home Switch when using Encoder0, Encoder1, the Stegmann Feedback board, or the Resolver Feedback board. Only one may be set.
Detailed Drive Operation Chapter 1 Homing Status Parameter 741 [Position Status] contains the status bit for the homing sequence. Table 25 - Parameter 741 [Position Status] Bits Bit Name Description 13 HomeRequired This bit is set when bit 24 “Find Home” of parameter 740 [Position Control] is set and the drive is waiting for a Start command. 14 Homing Set when the drive is running the homing sequence. 15 Homed Set when the homing sequence has completed.
Chapter 1 Detailed Drive Operation Start Inhibits This section covers start inhibits, displayed in parameter 156 [Start Inhibits]. This parameter indicates the cause of no response to a start request.
Detailed Drive Operation Chapter 1 2. Ramp Stop - when in ramp stop, the drive acknowledges the stop command by ramping down the motor speed reference using the programmed parameter 33 [Decel Time 1], maintaining control of the motor until the drive output reaches zero. The output transistors are then shut off. 3.
Chapter 1 Detailed Drive Operation To control from a communication network (20-COMM module): 1. Toggle bit 1 “Start” in the logic command word on and then off to perform a start. 2. Toggle bit 9 “CoastStop” in the logic command word on and then off to perform a coast stop. To configure the drive for 3-wire control with a current limit stop: For parameter 153 [Control Options], set bit 8 “3WireControl” = 1. To control from digital inputs: 1.
Detailed Drive Operation Chapter 1 To configure the drive for 2-wire control with a coast stop: Set parameter 153 [Control Options] bit 8 “3WireControl” = 0. To control from digital inputs: • Set one of the parameters 825…830 [Dig Inx Sel] = 7 “Run” To control from a communication network (20-COMM module): 1. Turn on bit 1 “Start” in the logic command word to run. 2. Toggle bit 9 “CoastStop” in the logic command word on and then off to perform a coast stop.
Chapter 1 Detailed Drive Operation SynchLink This section contains information specific to PowerFlex 700S Phase II Control SynchLink™ parameters and gives an example of setting up SynchLink using DriveExecutive. Please refer to the SynchLink System Design Guide, publication 1756-TD008, for PowerFlex 700S SynchLink topologies, hardware, and wiring details. ATTENTION: You cannot redefine a position when using SynchLink to communicate from a ControlLogix 1756 synch module to a PowerFlex 700S Phase II drive.
Detailed Drive Operation Chapter 1 SynchLink Direct Data Direct Data Receive Parameters (Follower) Parameters 906 [SL Rx DirectSel0]…909 [SL Rx DirectSel3] select what you want to do with direct received data. The available settings for these parameters are: • 0 “No Data” - SynchLink received data is passed straight through. Parameters 929 [SL Dir Data Rx00]…932 [SL Dir Data Rx03] contain the values for direct data received from SynchLink.
Chapter 1 Detailed Drive Operation Figure 27 - Diagram of Direct Receive Data (Word 00) SL Rx Direct Sel0 Rx Dir Data Type (SLDir00 Real) Rx Word 00 from SL Hardware 928 SL Dir Data Rx00 0 1 SL Mult A In 906 00 929 Convert Dint-Real 0 924 Use P929 Directly 2 3 10 SL Mult Base 923 1 / SL Mult B In SL Mult Out X 926 925 917 SL Rx P0 Regis 918 SL Rx P1 Regis 915 SL Rcv Events Direct Data Transmit Parameters Parameters 911 [SL Tx DirectSel0]…914 [SL Tx DirectSel3] select what direct tr
Detailed Drive Operation Chapter 1 • 25 “Opt0 Accum” - Use this selection to transmit feedback option 0 counts directly through before they enter the feedback control loop. This eliminates the update delay of the feedback control loop. • 26 “Opt1 Accum” - Use this selection to transmit feedback option 1 counts directly through before they enter the feedback control loop. This eliminates the update delay of the feedback control loop.
Chapter 1 Detailed Drive Operation • Bit 0 “Local Ovflow” - The result of the multiply function is too large. • Bit 1 “Rx Ovflow” - The data received from SynchLink is too large. • Bit 3 “FtoI Ovflow” - In the master, the data converted from floating point to integer is too large. Multiply Block Receive Parameters (Follower) Select the direct word on which to use the multiply block by setting one of the parameters, 906 [SL Rx DirectSel0]…909 [SL Rx DirectSel3] to 1 “SL Multiply.
Detailed Drive Operation Chapter 1 • Parameter 922 [SL Real2DInt Out] contains the integer value sent over SynchLink. One of the SynchLink Transmit Direct Selects (parameter 911…914) must be set to 1 “SL Multiply” to send the value over SynchLink. For example, to use the multiply block to scale the ramped speed reference and send it over SynchLink, link parameter 921 [SL Real2DInt In] to parameter 43 [Ramped Spd Ref ]. Set parameter 923 [SL Mult Base] to 10,000.
Chapter 1 Detailed Drive Operation Parameter 895 [SL CRC Error] displays the number of CRC errors that occurred during the last test (last 8 ms). This data is visible on the SynchLink diagnostics tab of the Peer Communication window. Parameter 896 [SL BOF Err Accum] displays the total accumulated number of BOF (Beginning of Frame) errors. Clearing a fault resets this accumulator. This data is visible on the SynchLink diagnostics tab of the Peer Communication window.
Detailed Drive Operation Chapter 1 • Bit 5 “Comm Frmt Er” indicates the format of received data does not match the configuration of the receive port • Bit 6 “Sys Rev Err” indicates the system revision in the received data does not match the value of Par 900 [SynchLink Rev] • Bit 7 “Mult TimeKpr” indicates more than one node on the SynchLink system is configured as a time keeper.
Chapter 1 Detailed Drive Operation Master PowerFlex 700S Drive Setup (Transmitting Drive) 1. In the master, or transmitting drive, select the desired transmittal format in the Transmit Format field. For this example, select “4 Direct Words, 8 Buffered Words.” 2. Below the Transmit Format field, for Direct Word 0, do the following: a. Click the arrow next to the Type field and select “Parameter.” b. Click the button to the right of the Source field and select 43 “Ramped Spd Ref.
Detailed Drive Operation Chapter 1 3. Check the Time Keeper box. The master will be the time keeper for SynchLink. 4. Click OK to apply the settings and close the SynchLink dialog. 5. To synchronize the speed references, you must add a time delay to the Scurve speed reference of the master by linking parameter 37 [Spd Ref Bypass] to parameter 45 [Delayed Spd Ref ]. Follower PowerFlex 700S Setup (Receiving Drive) 1.
Chapter 1 Detailed Drive Operation b. Click the button to the right of the Used By field and select “12 [Speed Ref 2].” This means that parameter 12 will be linked to Direct Word 0 from SynchLink™. 3. Click OK to close the SynchLink Setup dialog box. 4. To set the follower to use speed reference 2, set parameter 27 [Speed Ref A Sel] = 2 “Speed Ref 2.” Note that speed reference 2 in the follower will contain the ramped speed from the master drive.
Detailed Drive Operation Chapter 1 Reset SynchLink After setting up the configuration SynchLink must be reset on both drives in one of the following ways: • Set parameter 904 [SL Node Cnfg], bit 3 “Reset SL” = 1 on the drives. This bit will automatically transition back to 0 after SynchLink is reset. OR • Perform a reset on the drives. This can be done via the HIM by navigating from the Main Menu to Diagnostics > Faults > Reset Device. OR • Cycle power on the drives.
Chapter 1 Detailed Drive Operation • Parameters 793 [Xsync In 3]…795 [Xsync Out 3 Dly] can be used to synchronize a floating point parameter and delay it one scan. • Parameter 787 [Xsync Gen Period] sets the scan time of the synch generator. The following options are available: 0= 1= 2= 3= 4= 0.5 ms 1 msec 2 msec 4 msec 8 msec The default setting is 1 = “1 ms.” Task Time Task times are adjustable for the 3 tasks in the drive.
Detailed Drive Operation Time Function Generator Chapter 1 The time function generator ramps the output of the function generator at the rate in parameter 202 [Time Axis Rate]. • When parameter 153 [Control Options], bit 24 “Time Axis En” or parameter 151 [Logic Command] bit 3 “Time Axis En” =1 the output ramps from 0.0000 to 1.0000 at the rate set in [Time Axis Rate].
Chapter 1 Detailed Drive Operation The torque reference can be utilized when a master/slave multi-drive system is configured. The torque reference into the “slave” can be scaled to create the proper torque output. Keep in mind that the motors may be different ratings and this function is used to help the “system” share the load. Parameter 115 [Torque Trim] can be used to trim the torque. For example, [Torque Trim] can be limited to an analog input or to the Process PI output.
Detailed Drive Operation Chapter 1 7. To play back the data, you can monitor parameters 572 [Trend Out1 DInt] or 573 [Trend Out1 Real], 576 [Trend Out2 DInt] or 577 [Trend Out2 Real], 580 [Trend Out3 DInt] or 581 [Trend Out3 Real], and 584 [Trend Out4 DInt] or 585 [Trend Out4 Real], depending on the data type. The output parameters can be monitored in DriveObserver, or you can link analog outputs to the output parameters and monitor the analog output with a chart recorder or oscilloscope.
Chapter 1 Detailed Drive Operation Trend Control: Trend TrigA DInt 560 Trend TrigA Real 561 Trend TrigB DInt 562 Trend TrigB Real 563 Trend Trig Data 564 Trend Trig Bit 565 Trend Control (Enbl Collect) 556 Σ > Σ OR S R Buffer Full S R 0 Trend Status (Triggered) 557 1 Trend Status (Complete) 557 2 Trend Data: Trend Control (In 1 Real) 556 Trend In1 DInt 1 570 Trend In1 Real Trend Control (In 2 Real) 571 0 1 0 1 Trend Mark DInt 567 Trend Mark Real 568 TrendBuffPointer 5
Detailed Drive Operation User Functions Chapter 1 There are several user functions available in the drive for custom control. • Parameter 1000 [UserFunct Enable] is used to enable or disable user functions in the drive. The drive does not require a drive reset for a change to take affect. – Bit 0 “User Params” - enables use of user DInt and floating point parameters 1002…1021. – Bit 1 “Sel Switches” - enables a 16 selection switch, a DInt switch and a Real switch.
Chapter 1 Detailed Drive Operation • Set parameter 861 [BitSwap 1A Bit] = 1. This parameter sets the bit that you would like to turn on in the result, and is set to bit 1 because we want to use bit swap 1 to turn on bit 1 “Spd S Crv En” of parameter 151 [Logic Command]. • Link parameter 862 [Bit Swap 1B Data] to parameter 824 [Local I/O Status]. Parameter 862 [Bit Swap 1B Data] sets the data that you would like to compare. • Set parameter 863 [BitSwap 1B Bit] = 3.
Detailed Drive Operation Chapter 1 MOP Configuration • Parameter 1086 [MOP Control] is use to configure and control the motor operated potentiometer. The bits are as follows: – Bit 0 “Increase” - if set, increments the MOP level (output) from parameter 1087 [MOP Rate] to parameter 1088 [MOP High Limit]. – Bit 1 “Decrease” - if set, decrements the MOP level (output) from parameter 1087 [MOP Rate] to parameter 1088 [MOP Low Limit].
Chapter 1 Detailed Drive Operation Controlling the MOP from Digital Inputs: Program one of the digital inputs, parameters 825 [Dig In1 Sel]…830 [Dig In6 Sel], to 23 “MOP Inc.” Turn on the digital input to increase the MOP level at the rate programmed. Program a second digital input, parameters 825 [Dig In1 Sel]…830 [Dig In6 Sel], to 24 “MOP Dec.” Turn on the digital input to decrease the MOP level at the rate programmed. A digital input can also be programmed to 25 “MOP Reset.
Detailed Drive Operation Chapter 1 16 Position Selector Switch: Sel Swtch Ctrl Sel Swtch Ctrl 1022 00 1022 01 02 03 04 SelSwtch RealOut SelSwtch In00 1029 SelSwtch In01 1030 SelSwtch In02 1031 SelSwtch In03 1032 SelSwtch In04 1033 SelSwtch In05 1034 SelSwtch In06 1035 SelSwtch In07 1036 SelSwtch In08 1037 SelSwtch In09 1038 SelSwtch In10 1039 SelSwtch In11 1040 SelSwtch In12 1041 SelSwtch In13 1042 SelSwtch In14 1043 SelSwtch In15 1044 0 1045 1 SelSwtch DIntOut 2 3 10
Chapter 1 Detailed Drive Operation • Parameters 1029 [Sel Swtch In00]…1044 [Sel Swtch In15] are the inputs to the selector switch. All inputs are entered as Real values. You may use the output of the selector switch as either Real or DInt. A conversion is done to create the DInt value. • Parameter 1045 [SelSwtch RealOut] is the result of the selector switch inputs. The output is loaded with the selected input based on parameter 1022 [Sel Switch Ctrl] bits 1…4 and bit 0.
Detailed Drive Operation Chapter 1 Using Digital Inputs and the Selector Switches to Configure Preset Speeds: The digital inputs can be used to configure up to 16 preset speeds using the Selector Switches function.
Chapter 1 Detailed Drive Operation • Link Par 1045 [SelSwtch RealOut] to Par 1053 [MulDiv 1 Input]. This multiply/divide function block must be used because Par 1045 and 1046 cannot be linked to Par 14 [Preset Speed 1]. See Multiply/Divide Blocks on page 1-210 for more information. • Set Par 1054 [MulDiv 1 Mul] = 1 • Set Par 1055 [MulDiv 1 Div] equal to the motor nameplate RPMs.
Detailed Drive Operation Chapter 1 • Parameter 1024 [Swtch Real 1 NO] is the Normally Open input to the Real switch. When parameter 1022 [Sel Switch Ctrl], bit 5 is high, this input is updated to parameter 1025 [Swtch Real 1 Out]. • Parameter 1025 [Swtch Real 1 Out] is the result of the switch. The output is loaded with the selected input based on parameter 1022 [Sel Switch Ctrl], bit 5. If this parameter does not update, check the setting of parameter 1000 [UserFunct Enable] bit 1.
Chapter 1 Detailed Drive Operation DInt to Real and Real to DInt Converters The DInt to Real converter is used to convert a double integer parameter to a floating point value. The resulting floating point value can then be linked to a floating point parameter. The Real to DInt converter is used to convert a floating point parameter to a double integer value. The resulting double integer value can then be linked to a floating point parameter.
Detailed Drive Operation Chapter 1 Logic Blocks The logic blocks are used to perform the logical operations AND, NAND, OR, NOR, XOR, and NXOR on user-specified bits of user-specified parameters. Description of Logic operations: AND - When all bits compared are on, the result will be true (1). When one of the bits compared is off, the result will be false (0). NAND - When all bits compared are off, the result will be false (0). When one of the bits compared is off, the result will be true (1).
Chapter 1 Detailed Drive Operation • Parameter 1062 [Logic/Cmpr State], bits 0 “Logic 1 Rslt”, 1 “Logic 2 Rslt” and 2 “Logic 3 Rslt” display the logical states of the Logic routine (parameters 1063…1070). A value of 0 = False and 1 = True. • Parameter 1063 [Logic 1A Data] selects the data word for the first input to Logic Block 1. See parameter 1061 [Logic Config]. • Parameter 1064 [Logic 1A Bit] selects the bit of Par 1063 for the first input to Logic Block 1.
Detailed Drive Operation Chapter 1 Compare Blocks The compare block are used to compare two floating point values and indicate which value is larger. It is possible to use the DInt to Real converter to convert one double integer parameter to a floating point value and use that value as an input to a compare block.
Chapter 1 Detailed Drive Operation Multiply/Divide Blocks The multiply/divide blocks are used to multiply and divide floating point parameters. It is possible to use the DInt to Real converter to convert one doubleinteger parameter to a floating point value and use that value as an input to a multiply/divide block.
Detailed Drive Operation Chapter 1 On-Off Delay Timers This feature provides the ability to set two delay timers. Each timer can be set for an On delay timer or Off delay timer. The On delay timer defines the delay time between a False to True transition (condition appears) on the output condition and the corresponding change in state of an input/output.
Chapter 1 Detailed Drive Operation Watts Loss 212 See the PowerFlex 700S AC Drives, Phase II Control Technical Data, publication 20D-TD002, for Watts Loss data and curves.
Index A absolute point to point positioning 101 acceleration time 13 add block 210 alarms configuration 14 configuration example 14 analog inputs configuration 14 specifications 14 analog outputs configuration 17 specifications 17 auto/manual function 18 autotune Direction Test 20 feedback configuration 20 Inertia test 21 MC Commissn Fail fault 22 motor control 19 motor data 19 motor tests 20 Power Circuit test 20 Start-Up menu 19 auxiliary power supply 22 B bipolar references 41 bus regulation braking des
Index firmware functions 56 flying start 56 configuration 57 friction compensation 57 fuses 58 G grounding 58 high resistive installations 196 H high resistive ground installations 196 HIM copy cat function 34 memory 58 operation 59 user display 59 I indexer funtion configuration 60 inertia adaption 61 configuration 62 inertia compensation 62 input devices circuit breakers 63 contactors 63 EMC filters 63 fuses 63 input power conditioning 63 instantaneous over current trip 35 IT protection 64 J jog 65
Index position output 89 profile generator 88 speed output (feed-forward) 88 point to point position control digital inputs 101 point to point position loop 96 acceleration and deceleration 99 enabling 97 jogging 100 output limits 99 position offset 98 position reference scaling 98 position reference selection 97 re-reference 100 speed reference selection 97 tuning tips 99 position feedback 128, 141 FIR filter 132 motor simulator 133 sensorless 132 position loop electronic gear ratio 93 enabling 92 encoder
Index jog reference 147 lead-lag filter 151 limits 147 scaling 146, 151 S-curve 148 selection 145 speed trim 1 151 stop command 148 virtual encoder 150 speed regulation 127 speed regulation mode 163 speed regulator advanced tuning with gearbox or belt 160 basic tuning with a gear box or belt 158 speed/torque mode select 161 start and stop modes 176 configuring for 2-wire control 178 configuring for 3-wire control 177 start-up drive 179 stop modes 179 subtract block 210 sum speed/torque mode 165 sync genera
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